Honda CRF230F 2004 Owner's Manual
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Honda CRF230F 2004 Owner's Manual

Honda CRF230F 2004 Owner's Manual

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This manual should be considered a permanent part of the motorcycle and should remain with the
motorcycle when it is resold.
This publication includes the latest production information available before printing.
Honda Motor Co., Ltd. reserves the right to make changes at any time without notice and without
incurring any obligation.
No part of this publication may be reproduced without written permission.
Honda Motor Co., Ltd. 2003

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Summary of Contents for Honda CRF230F 2004

  • Page 1 This publication includes the latest production information available before printing. Honda Motor Co., Ltd. reserves the right to make changes at any time without notice and without incurring any obligation. No part of this publication may be reproduced without written permission.
  • Page 2 2004 Honda CRF230F OWNER’S MANUAL...
  • Page 3 A Few Words About Safety Your safety, and the safety of others, is very important. And operating this motorcycle safely is an important responsibility. To help you make informed decisions about safety, we have provided operating procedures and other information on labels and in this manual. This information alerts you to potential hazards that could hurt you or others.
  • Page 4 A Few Words About Safety You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be HURT if you don’t follow instructions. Safety Headings ––...
  • Page 5 ........Why your motorcycle needs regular Important safety information, maintenance, what you need to know precautions about loading, accessories, before servicing your Honda, a and modifications, and the location of maintenance schedule, and instructions safety labels. for specific maintenance items.
  • Page 6 Handy facts about fuel, engine oil, tire sizes, and air pressures. Technical Information ......ID numbers, technical specifications, and other technical facts. Consumer Information ......Information on warranties and how to get Honda service manuals. Contents...
  • Page 7 We also recommend that you read the owner’s road motorcycle. manual before you ride. It’s full of facts, instructions, safety information, and helpful When you own a Honda, you’re part of a tips. To make it easy to use, the manual − worldwide family of satisfied customers contains a table of contents, a detailed list of people who appreciate Honda’s reputation for...
  • Page 8 Honda dealer knows your motorcycle best and is dedicated to your complete satisfaction. Please report any change of address or ownership to your Honda dealer so we will be able to contact you concerning important production information. You may also want to visit our website at www.honda.com.

  • Page 10: Table Of Contents

    Motorcycle Safety This section presents some of the most Important Safety Information ......important information and recommendations to Loading, Accessories & Modifications ... help you ride your motorcycle safely. Please Loading ............take a few moments to read these pages. This Accessories &...

  • Page 11: Motorcycle Safety

    Important Safety Information Your motorcycle can provide many years of Never Carry a Passenger − service and pleasure if you take responsibility Your motorcycle is designed for one person for your own safety and understand the only. There are no handholds, footrests, or seat −...
  • Page 12 Important Safety Information Take Time to Learn and Practice Be Alert for Off-Road Hazards Developing off-road riding skills is a gradual, The terrain can present a variety of challenges step-by-step process. Start by practicing at low when you ride off-road. Continually ‘‘read’’ speeds in a safe area and slowly build your the terrain for unexpected turns, drop-offs, skills.
  • Page 13 So don’t drink and ride, and don’t let your friends drink and ride either. Keep Your Honda in Safe Condition It’s important to keep your motorcycle properly maintained and in safe riding condition. Having a breakdown can be difficult, especially if you are stranded off-road far from your base.

  • Page 14: Loading, Accessories & Modifications

    Loading, Accessories & Modifications Your Honda was designed as a rider-only More specific information on load limits, motorcycle. It was not designed to carry a accessories, and modifications follows. passenger or cargo. A passenger or cargo could interfere with your ability to move around to...
  • Page 15 Loading, Accessories & Modifications Load Limits Place weight as close to the center of the Following are the load limits for your motorcycle as possible. motorcycle: Do not attach large or heavy items (such as a sleeping bag or tent) to the handlebar, fork, Maximum weight capacity or front fender.

  • Page 16: Accessories & Modifications

    Before you consider making any modifications and use of non-Honda accessories. Check with or adding an accessory, be sure to read the your dealer for assistance and always follow following information.
  • Page 17 Loading, Accessories & Modifications Modifications We strongly advise you not to remove any original equipment or modify your motorcycle in any way that would change its design or operation. Such changes could seriously impair your motorcycle’s handling, stability, and braking, making it unsafe to ride. We also advise you not to make any modifications or remove any equipment (such as the USDA qualified spark arrester or...

  • Page 18: Safety Labels

    This page shows the locations of safety labels on your motorcycle. Some labels warn you of potential hazards that could cause serious injury. Others provide important safety information. Read these labels carefully and don’t remove them. If a label comes off or becomes hard to read, contact your Honda dealer for a replacement. Motorcycle Safety...
  • Page 19 Motorcycle Safety...
  • Page 20 Operating Controls When you ride off-road, you need to operate Component Locations ........the throttle, clutch, brakes, and other controls Fuel Valve ............without stopping to look at them. Read this Choke Lever ........... section carefully before you ride. It describes Ignition Switch ..........

  • Page 21: Operating Controls

    Component Locations ignition switch front brake lever clutch lever engine stop throttle button start button Operating Controls...
  • Page 22 Component Locations fuel valve choke lever side stand shift lever Operating Controls...
  • Page 23 Component Locations rear brake pedal Operating Controls...

  • Page 24: Fuel Valve

    Operating Controls Fuel Valve Turning the fuel valve ON before attempting to start the engine allows fuel to flow from the fuel tank to the carburetor. Turning the fuel valve OFF after stopping the engine prevents the flow of fuel from the fuel tank to the carburetor.

  • Page 25: Choke Lever

    Operating Controls The reserve fuel supply is: The choke lever is used for starting the engine 0.40 US gal (1.5 ) (page ). The choke increases the percentage of fuel in the fuel/air mixture delivered to the The tank should be refilled as soon as possible engine.

  • Page 26: Ignition Switch

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

  • Page 27: Start Button

    Operating Controls Start Button Front Brake Lever The start button is used for starting the engine. The front brake lever is used to slow or stop Pushing the button in starts the engine. See your motorcycle. To operate, pull the lever. For Starting Procedure, page information on braking techniques, see...

  • Page 28: Clutch Lever

    Operating Controls Clutch Lever Rear Brake Pedal The clutch lever is used to disengage the clutch The rear brake pedal is used to slow or stop whenever you shift gears. To operate, pull the your motorcycle. To operate, depress the pedal. clutch lever in all the way before shifting, then For information on braking techniques, see slowly release it after shifting.
  • Page 29 Operating Controls...
  • Page 30 Before Riding Before each ride, you need to make sure you Are You Ready to Ride? ........ and your Honda are both ready to ride. To help Protective Apparel ........get you prepared, this section discusses how to Is Your Motorcycle Ready to Ride? ....

  • Page 31: Before Riding

    Are You Ready to Ride? Before you ride your motorcycle for the first time, we strongly recommend that you: Protective Apparel read this owner’s manual make sure you understand all the safety For your safety, we strongly recommend that messages you always wear an approved motorcycle know how to operate all the controls helmet, eye protection, boots, gloves, long...
  • Page 32 Are You Ready to Ride? (USA only). Always wear a face shield or goggles to protect your eyes and help your Not wearing a helmet increases the vision. chance of serious injury or death in a crash. Additional Riding Gear In addition to a helmet and eye protection, we Be sure you always wear a helmet, also recommend:...

  • Page 33: Is Your Motorcycle Ready To Ride

    Is Your Motorcycle Ready to Ride? Before each ride, it’s important to inspect your motorcycle and make sure any problem you Pre-ride Inspection find is corrected. A pre-ride inspection is a must because off-road riding can be tough on a Check the following items before you get on motorcycle and you don’t want to have a the motorcycle:...
  • Page 34 Is Your Motorcycle Ready to Ride? Engine Oil Check the level and add oil if Cables Check the cable housings for needed (page wear. Check the fittings for looseness. Replace or tighten as Fuel Check the level and add fuel needed.
  • Page 35 Check the freeplay and adjust if Remember, be sure to take care of any problem needed. Rotate the throttle to you find or have your Honda dealer correct it make sure it moves smoothly before you ride. without sticking, and snaps shut...
  • Page 36 Braking ............Guide f or the Of f -Highway Motorcyclist Parking ............booklet that came with your Honda (USA only). Post-ride Inspection ........To protect your new engine and enjoy optimum performance and service life, refer to Break-in Guidelines (page...

  • Page 37: Basic Operation & Riding

    Basic Operation & Riding Your motorcycle is not equipped with lights. Safe Riding Precautions Do not ride at night. Before riding your motorcycle for the first time, please review the Important Saf ety Inf ormation beginning on page and the previous section, titled Bef ore Riding.

  • Page 38: Starting & Stopping The Engine

    Starting & Stopping the Engine Always follow the proper starting procedure described below. Starting Procedure Your motorcycle can be started with the To restart a warm engine, follow the procedure transmission in gear by pulling in the clutch High Air Temperature. lever before operating the starter.
  • Page 39 Starting & Stopping the Engine With the throttle closed, press the start High Air Temperature button. 35°C (95°F) or above Immediately after the engine starts, push the Do not use the choke. choke lever down to the detent position ( ). Start the engine following step under Warm up the engine by opening and closing Normal Air Temperature.

  • Page 40: Flooded Engine

    Starting & Stopping the Engine Flooded Engine If the engine fails to start after repeated attempts, it may be flooded with excess fuel. To clear a flooded engine: Push the choke lever down all the way to OFF. Open the throttle fully. While pushing the engine stop button, press the start button for 5 seconds.

  • Page 41: How To Stop The Engine

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

  • Page 42: Shifting Gears

    Shifting Gears Depress the shift lever from neutral down to first gear. Release the front brake. Gradually open the throttle while you slowly release the clutch lever. If engine rpm (speed) is too low when you release the clutch lever, the engine will stall. If engine rpm is too high or you release the clutch lever too quickly, your motorcycle may lurch forward.
  • Page 43 Shifting Gears To continue shifting up to each higher gear, Downshifting can help slow your motorcycle, repeat step . especially on downhills. However, To shift down to a lower gear, close the downshifting when engine rpm is too high can throttle, pull the clutch lever in, and depress cause engine damage.

  • Page 44: Braking

    Braking To slow or stop, apply the front brake and rear Generally, reduce your speed or complete brake smoothly, while downshifting to match braking before beginning a turn. Avoid braking your speed. Gradually increase braking as you or closing the throttle quickly while turning. feel the brakes slowing your speed.
  • Page 45 Braking When descending a long, steep grade, use engine compression braking by downshifting, with intermittent use of both brakes. When you brake to a stop, pull the clutch lever in before stopping completely to prevent stalling the engine. For support, put your left foot on the ground first, then your right foot when you’re through braking.

  • Page 46: Parking

    Parking Lower the side stand to support your motorcycle. Turn the ignition switch OFF and remove the key. If you’re through riding for the day, also turn the fuel valve OFF. Always choose a level place to park. Basic Operation & Riding...

  • Page 47: Post-Ride Inspection

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

  • Page 48: Servicing Your Honda

    Servicing Your Honda Keeping your motorcycle well maintained is Bef ore You Service Your Honda absolutely essential to your safety. It’s also a The Importance of Maintenance ....good way to protect your investment, get Maintenance Safety ........maximum performance, avoid breakdowns, and Important Safety Precautions .....
  • Page 49 Servicing Your Honda Service Preparations Engine Component Locations ........Throttle ............Tools ............... Clutch System ..........Side Cover Removal ........Engine Idle Speed .......... Spark Plug ............Service Procedures Spark Arrester ..........Fluids & Filters Chassis Fuel ..............Suspension .............

  • Page 50: The Importance Of Maintenance

    If your motorcycle overturns or is involved in a is designed to be ridden over rough off-road crash, be sure your Honda dealer inspects all terrain. major parts, even if you are able to make some repairs.
  • Page 51 The Importance of Maintenance Remember, proper maintenance is the owner’s responsibility. Be sure to inspect your motorcycle before each ride and follow the Maintenance Schedule in this section. Servicing Your Honda...

  • Page 52: Maintenance Safety

    Always follow the procedures and precautions in this owner’s manual. Injury from moving parts. Do not run the engine unless instructed to do so. (cont’d) Servicing Your Honda...
  • Page 53 To reduce the possibility of a fire or explosion, be careful when working around gasoline. Use only a non-flammable (high flash point) solvent such as kerosene not − gasoline to clean parts. Keep cigarettes, − sparks, and flames away from all fuel- related parts. Servicing Your Honda...

  • Page 54: Maintenance Schedule

    If you do not feel capable of performing a given task or need assistance, remember that The Maintenance Schedule also includes items your Honda dealer knows your motorcycle best that involve more extensive procedures and and is fully equipped to maintain and repair it.
  • Page 55 Refer to the official Honda Service Manual clean (page adjust ＊＊ In the interest of safety, we recommend lubricate these items be serviced only by your Honda replace dealer. Servicing Your Honda...
  • Page 56 − Engine Idle Speed ＊ Should be serviced by your Honda dealer, unless the owner has the proper tools and service data and is mechanically qualified. Refer to the official Honda Service Manual (page ＊＊ In the interest of safety, we recommend these items be serviced only by your Honda dealer.
  • Page 57 Steering Head Bearings − ＊ Should be serviced by your Honda dealer, unless the owner has the proper tools and service data and is mechanically qualified. Refer to the official Honda Service Manual (page ＊＊ In the interest of safety, we recommend these items be serviced only by your Honda dealer.

  • Page 58: Maintenance Record

    Months 600 (1,000) or 6 1,200 (2,000) or 12 1,800 (3,000) or 18 2,400 (4,000) or 24 3,000 (5,000) or 30 3,600 (6,000) or 36 4,200 (7,000) or 42 4,800 (8,000) or 48 5,400 (9,000) or 54 Servicing Your Honda...

  • Page 59: Competition Inspection

    Competition Inspection All items should be checked before each competition event. See your Honda dealer unless you are mechanically qualified and have the proper tools. Damage from competition use is not covered by the Distributor’s Limited Warranty on your Honda.
  • Page 60 NOTE 1: Competition use may cause more rapid clutch disc wear. Refer to the official Honda Service Manual, or see your Honda dealer for clutch disassembly and wear inspection. (cont’d) Servicing Your Honda...
  • Page 61 25.1 in (637 mm) / 41 pins replace max. length/pin sprockets wear and secure installation replace or tighten seat security tighten − control cables smooth operation, kinks and correct lubricate or − routing replace − engine mounting bolts tightness tighten Servicing Your Honda...

  • Page 62: Component Locations

    Servicing Your Honda...
  • Page 63 Servicing Your Honda...

  • Page 64: Tools

    The spark plug wrench ( ) and its handle ( ) are stored in the tool bag delivered with your motorcycle. You will need to provide your own tools to perform any owner maintenance other than removing the spark plug. (1) spark plug wrench (2) handle Servicing Your Honda...

  • Page 65: Side Cover Removal

    Align the side cover prongs with the rubber grommets. Press the side cover into position. Install the securing screw and bolts and tighten them. (1) screw (4) prongs (2) bolt A (5) rubber grommets (3) bolt B Servicing Your Honda...

  • Page 66: Fuel

    If pinging or spark knock occurs at a steady engine speed under normal load, change brands Fuel Recommendation of gasoline. If pinging or spark knock persists, consult your Honda dealer. Type unleaded We recommend that you use unleaded fuel Pump Octane...
  • Page 67 Stop the engine and keep heat, sparks and flame away. Handle fuel only outdoors. Wipe up spills immediately. (1) fuel fill cap (3) steering stem nut (2) breather tube (4) filler neck Servicing Your Honda...
  • Page 68 Fuel After refueling, turn the fuel fill cap clockwise until it is secure. Insert the breather tube in the steering stem nut. If you replace the fuel fill cap, use only a genuine Honda replacement part. Servicing Your Honda...

  • Page 69: Engine Oil

    (weight) SAE 10W-40 cause serious damage to the engine and JASO T 903 standard transmission. ＊＊ suggested oil Pro Honda GN4 or HP4 (without molybdenum additives) 4-stroke oil (USA & Canada), or Honda 4-stroke oil (Canada only), or an...
  • Page 70 Do not use API SH or higher oils displaying a circular API ‘‘energy conserving’’ service label on the container. They may affect lubrication and clutch performance. NOT RECOMMENDED Do not use non-detergent, vegetable, or castor based racing oils. Servicing Your Honda...
  • Page 71 4-stroke motorcycle engines. There are two classes: MA and MB. Oil conforming to the standard has the following classification on the oil container. (1) code number of the sales company of the oil (2) oil classification Servicing Your Honda...
  • Page 72 Insert the dipstick and screw it in tightly. (1) oil filler cap/dipstick Check for oil leaks. (2) upper level mark (3) lower level mark Park your motorcycle on a firm, level surface. Clean around the oil filler cap/dipstick ( ) and nearby surfaces. Servicing Your Honda...
  • Page 73 Pour the drained oil into a suitable container and dispose of it in an approved manner (page Improper disposal of drained f luids is harmf ul to the environment. (1) oil drain bolt (3) spring (2) O-ring (4) oil strainer screen Servicing Your Honda...
  • Page 74 11 lbf·ft (15 N·m , 1.5 kgf·m) Pour the recommended oil into the crankcase, approximately: 1.1 US qt (1.0 ) Install the oil filler cap/dipstick securely. Start the engine. Let it idle 3-5 minutes, then turn it off. Servicing Your Honda...

  • Page 75: Air Cleaner

    Your motorcycle’s air cleaner has very specific performance requirements. Use a new genuine Honda air cleaner specified for your model or an air cleaner of equal quality. Servicing Your Honda...
  • Page 76 Unhook the set spring ( ), take care to avoid bending the set spring and set spring holder ( ). Remove the air cleaner ( ). (1) screws (2) air cleaner housing cover (3) set spring (4) set spring holder (cont’d) (5) air cleaner Servicing Your Honda...
  • Page 77 Replace the air cleaner if it is damaged. Allow the air cleaner to dry thoroughly before applying oil. A wet air cleaner will not fully absorb the oil. (5) air cleaner (7) tabs (6) air cleaner holder (8) holes Servicing Your Honda...
  • Page 78 Air Cleaner Pour clean Pro Honda Foam Filter Oil or an Install the air cleaner housing cover and equivalent (Canada: Honda Foam Filter Oil screws. or an equivalent) over the entire surface of Install the right side cover (page the air cleaner. Use both hands to evenly RIGHT SIDE spread the oil into the air cleaner.

  • Page 79: Crankcase Breather

    Drain the deposits by pinching the plug ( ). Service more frequently if your motorcycle is ridden in the rain or often at full throttle. Service the breather if you can see deposits in the transparent section of the drain tube. LEFT SIDE (1) plug Servicing Your Honda...

  • Page 80: Throttle

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

  • Page 83: Clutch System

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

  • Page 86: Engine Idle Speed

    Ten minutes of stop-and-go riding is sufficient. Engine Idle Speed Do not attempt to compensate for faults in LEFT SIDE other systems by adjusting idle speed. See your Honda dealer for regularly scheduled carburetor adjustments. Warm up the engine, shift to neutral and ＋ ＋...

  • Page 87: Spark Plug

    X24EPR-U9 (DENSO) For cold climate DPR7EA-9 (NGK) (below 5°C, 41°F) X22EPR-U9 (DENSO) (1) spark plug wrench (4) side electrode (2) handle (5) spark plug gap (3) center electrode Clean any dirt from around the spark plug base. Servicing Your Honda...
  • Page 88 Make sure the plug washer is in good condition. If you have to install a new plug, first check the gap. With the plug washer attached, thread the spark plug in by hand (to prevent cross- threading). Servicing Your Honda...

  • Page 89: Spark Arrester

    (1) spark arrester (3) gasket (2) bolts (4) muffler Allow the engine and muffler to cool. Remove the three bolts ( ), the spark arrester ( ), and the gasket ( ) from the muffler ( ). Servicing Your Honda...
  • Page 90 Be careful to avoid muffler and tighten the three bolts securely. damaging the spark arrester screen. The spark arrester must be free of breaks and holes. Replace, if necessary. Check the gasket. Replace, if necessary. Servicing Your Honda...

  • Page 91: Suspension

    FRONT and stability of your motorcycle. If any suspension components appear worn or damaged, see your Honda dealer for further inspection. Your dealer is qualified to determine whether or not replacement parts or repairs are needed.
  • Page 92 RIGHT SIDE Check the security of all handlebar and fork mounting bolts ( ). If any front suspension components appear worn or damaged, see your Honda dealer for further inspection. Rear Suspension Inspection LEFT SIDE (1) swingarm bearing Place the motorcycle on a maintenance stand.
  • Page 93 ( ) and rear suspension linkage attachment points ( ) are secure. Check for oil leaks in the shock absorber. If any rear suspension components appear worn or damaged, see your Honda dealer for further inspection. Servicing Your Honda...

  • Page 94: Brakes

    (3) lock nut probably air in the brake system. See your (2) rubber dust cover (4) adjuster Honda dealer to have the air bled from the system. Never use adjusters other than those designed for this motorcycle. Install a new adjuster from the lever side with the lock nut under the head of the adjuster.
  • Page 95 To position the brake lever closer to the If brake lever freeplay is not within this handgrip, turn the adjuster counterclockwise. range, see your Honda dealer. Tighten the lock nut. Return the dust cover to its normal position. Apply the brake, release it, then spin the wheel and check that it rotates freely.
  • Page 96 Worn brake pads should be replaced. If the Fluid Level Inspection pads are not worn, have your brake system inspected for leaks. Front Brake Fluid Level The recommended brake fluid is Honda DOT 4 RIGHT brake fluid from a sealed container, or an HANDLEBAR equivalent.
  • Page 97 More About: Brake Fluid Brake fluid should be added and replaced by your Honda dealer. The recommended brake fluid is Honda DOT 4 Brake Fluid, or any brake fluid of equal equality and performance. Use fresh brake fluid from a sealed container.
  • Page 98 If necessary, adjust to the specified range. Adjustment RIGHT REAR − − (1) rear brake pedal ＋ ＋ (2) brake rod ( ) increase freeplay ＋ (3) adjusting nut ( ) decrease freeplay − (4) brake arm pin (cont’d) Servicing Your Honda...
  • Page 99 Application of the Check the freeplay. If you can’t adjust the brake control (pedal) causes the arrow on the freeplay properly, see your Honda dealer. brake arm to move toward a reference mark on the brake panel.
  • Page 100 ( ) upon full application of are tight. the brake. If replacement is necessary, see Rear: Make sure the brake rod, brake arm, your Honda dealer. spring, and fasteners are in good condition. Servicing Your Honda...
  • Page 101 Loosen the lock nut ( ) and turn the stopper Rear Brake Pedal Height Adjustment bolt ( ). Tighten the lock nut. RIGHT Check the freeplay (page SIDE (1) lock nut (3) rear brake pedal (2) stopper bolt Servicing Your Honda...

  • Page 102: Wheels

    Excessively loose spokes may result in instability at high speeds and the possible loss of control. It’s also important that the rim locks are secure to prevent tire slippage. Servicing Your Honda...
  • Page 103 REAR Rotate the wheel slowly to see if it appears to ‘‘wobble.’’ If it does, the rim is out of round or not ‘‘true.’’ If the wobble is noticeable, see your Honda dealer for inspection. (1) wheel rim (2) spoke...
  • Page 104 The result will be loss of brake fluid. If this occurs, the brake system will require service. See your Honda dealer for this service. (1) axle holder nuts (2) axle holder (3) front axle...
  • Page 105 Check front brake adjustment (page (4) UP mark If a torque wrench was not used to install the wheel, see your Honda dealer as soon as Reverse the removal procedure. Insert the possible to verify proper assembly. Improper axle through the wheel hub and left fork leg.
  • Page 106 (2) brake rod (5) chain adjusters Take care to prevent getting grease, oil, or (3) brake arm (6) rear axle dirt on the brake shoe surfaces. This can cause poor brake performance or rapid brake shoe wear after reassembly. Servicing Your Honda...
  • Page 107 Repeat this procedure several times. If a torque wrench was not used to install the wheel, see your Honda dealer as soon as (7) lug possible to verify proper assembly. Improper (8) slot assembly may lead to loss of braking capacity.

  • Page 108: Tires & Tubes

    Make sure the valve stem caps are secure. If necessary, install a new cap. The following pages give detailed information on how and when to check your air pressure, how to inspect your tires for wear and damage, Servicing Your Honda...
  • Page 109 15 psi (100 kPa , 1.0 kgf/cm ) If you decide to adjust tire pressures for a particular riding condition, make changes a little at a time. (1) tire tread depth (2) spoke nut (3) rim lock nut Servicing Your Honda...
  • Page 110 We recommend that tubes be replaced by your slipping inside the tire or the tire is slipping Honda dealer. Replacing a tube requires on the rim. See your Honda dealer. removing and reinstalling the wheel. Any time a tube is replaced, carefully inspect the tire as...
  • Page 111 Installing improper tires on your We recommend that tires be replaced by motorcycle can affect handling and your Honda dealer. stability. This can cause a crash in which you can be seriously hurt or killed. Always use the size and type of tires recommended in this owner’s manual.

  • Page 112: Side Stand

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

  • Page 113: Drive Chain

    Check slack in the lower drive chain ( ) run service in the Maintenance Schedule. midway between the sprockets. Drive chain slack should allow the following vertical movement by hand: 13/16 1 3/16 in (20 30 mm) − − Servicing Your Honda...
  • Page 114 If the chain slider and lower slider are worn to the bottom of the cutouts ( ), have Excessive chain slack may allow the drive your Honda dealer replace the slider. chain to damage the engine cases. Replace the chain guide slider if the chain is...
  • Page 115 Do not use an ordinary farthest limit of adjustment. Excessive slack master link with this chain. indicates the chain is worn beyond its service limit. Servicing Your Honda...
  • Page 116 Drive Chain Inspect the front and rear sprocket teeth for excessive wear or damage. If necessary, have Adjustment your Honda dealer replace a worn sprocket. LEFT REAR Damaged Sprocket Worn Sprocket Teeth Teeth REPLACE REPLACE RIGHT REAR Normal Sprocket Teeth...
  • Page 117 If a torque wrench is not used for this Lubricate every 300 miles (500 km) or sooner installation, see your Honda dealer as soon as if chain appears dry. possible to verify proper assembly. The O-rings in this chain can be damaged by steam cleaning, high pressure washers, and certain solvents.
  • Page 118 O-rings. Your motorcycle has an endless (riveted master link) type chain. It should only be removed or replaced by your Honda dealer. When the drive chain becomes extremely dirty, it should be cleaned prior to lubrication. Clean the side surfaces of the chain with a dry cloth.
  • Page 119 Drive Chain Inspect the sprocket teeth for wear or damage. We recommend replacing the sprocket whenever a new chain is installed. Lubricate the drive chain. Servicing Your Honda...

  • Page 120: Battery

    If your battery seems weak and/or is leaking electrolyte (causing slow starting or other Electrical accessories use current from the electrical problems), see your Honda dealer. battery –– even when the ignition is OFF. Limited operation also allows the battery to...
  • Page 121 Wear protective clothing and a face You will get the best storage results from shield, or have a skilled mechanic do removing the battery and slow (trickle) the battery maintenance. charging it every 30 days (see Battery Charging, page Servicing Your Honda...
  • Page 122 Remove the battery holder ( ). Pull the battery ( ) out of the battery compartment. LEFT SIDE (1) battery holder (2) negative ( ) terminal lead − (3) positive ( ) terminal lead ＋ (4) battery (cont’d) Servicing Your Honda...
  • Page 123 Slow charge the battery (see following section) once every 30 days. (1) ‘‘trickle’’ charger Be sure to read the information that came with your battery charger and follow the instructions on the battery. Improper charging may damage the battery. Servicing Your Honda...
  • Page 124 However, do not intentionally leave the charger connected longer than the time period recommended in the charger’s instructions. Avoid using an automotive-type battery charger. An automotive charger can overheat a motorcycle battery and cause permanent damage. Servicing Your Honda...

  • Page 125: Appearance Care

    Appearance Care Refer to Saf ety Precautions on page General Recommendations Frequent cleaning and polishing will keep your Honda looking newer longer. Frequent To clean your motorcycle, you may use: − cleaning also identifies you as an owner who water −...
  • Page 126 After washing, rinse your motorcycle thoroughly with plenty of clean water to remove any residue. High pressure water (or air) can damage Dry your motorcycle with a chamois or a certain parts of your motorcycle. soft towel. (cont’d) Servicing Your Honda...
  • Page 127 Start the engine and let it idle for several minutes. The engine heat will help dry moist areas. As a precaution, ride at a slow speed and apply the brakes several times. This will help dry the brakes and restore normal braking performance. Servicing Your Honda...

  • Page 128: Tips

    Preparing for a Ride ........120 off-road adventure, how to transport and store Transporting Your Honda ......122 your Honda, and how to be an environmentally Storing Your Honda ........124 responsible motorcycle owner. You & the Environment ....... .127...

  • Page 129: Preparing For A Ride

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

  • Page 131: Transporting Your Honda

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

  • Page 133: Storing Your Honda

    Honda Motorcycle Winter Storage Guide, your motorcycle and correct any problem available from your Honda dealer (USA only). before storing it. That way, needed repairs won’t be forgotten and it will be easier to get We suggest you perform the following your motorcycle running again.
  • Page 134 Storing Your Honda Drain the carburetor into an approved Preparation for Storage gasoline container and dispose of it in an approved manner (page ). If storage will Change the engine oil (page last longer than one month, carburetor Fill the fuel tank. Make sure the fuel fill cap draining is important, to assure proper is properly installed.
  • Page 135 Storing Your Honda Remove the battery and charge it fully. Store it in an area protected from freezing Removal from Storage temperatures and direct sunlight. Slow charge the battery (page ) once a month. Uncover and clean your motorcycle. Wash and dry your motorcycle.

  • Page 136: You & The Environment

    You & the Environment Owning and riding a motorcycle can be Choose Sensible Cleaners. Use a enjoyable, but you must do your part to protect biodegradeable detergent when you wash nature. When you show respect for the land, your motorcycle. Avoid aerosol spray wildlife, and other people, you also help cleaners that contain chloroflurocarbons preserve the sport of off-road riding.
  • Page 137 You & the Environment Recycle Wastes. It’s illegal and thoughtless to put used engine oil in the trash, down a drain, or on the ground. Used oil, gasoline, and cleaning solvents contain poisons that can hurt refuse workers and contaminate our drinking water, lakes, rivers, and oceans.

  • Page 138: Taking Care Of The Unexpected

    Taking Care of the Unexpected With all the challenges you can encounter off- General Guidelines ........130 road, there’s a chance that sometime something If Your Engine Quits or Won’t Start ... .131 may go wrong. This section gives practical If You Have a Flat Tire ........

  • Page 139: General Guidelines

    Taking Care of the Unexpected If a problem is relatively minor and you have General Guidelines the tools, supplies, and skills to make a permanent repair, you may be able to fix it on If something goes wrong during a ride, the first the trail and continue riding.

  • Page 140: If Your Engine Quits Or Won't Start

    If you repairs made as soon as possible. can’t correct the problem, see your Honda Do not continue riding if you are hurt or dealer. your motorcycle is not in safe riding condition.
  • Page 141 Tighten the battery lead. dead battery Charge the battery (page ). If charging doesn’t help, see your Honda dealer. faulty starter motor If all possible causes are negative, the starter motor may be faulty. See your Honda dealer. Taking Care of the Unexpected...
  • Page 142 F looded Engine (page loose or unconnected spark Install the spark plug caps securely. If the engine still plug caps won’t start, see your Honda dealer. loose battery cables Tighten the battery terminal bolts. weak battery Charge the battery (page ).
  • Page 143 If applicable, switch to the recommended octane gasoline load (page ) or change your brand of gasoline. If the problem persists, see your Honda dealer. afterfires (backfires) See your Honda dealer. pre-ignition (runs on after See your Honda dealer.

  • Page 144: If You Have A Flat Tire

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

  • Page 145: If A Fuse Blows

    Taking Care of the Unexpected If something electrical on your motorcycle If a Fuse Blows stops working, the first thing you should check for is a blown fuse. All of the electrical circuits on your motorcycle Check the fuse before looking elsewhere for have fuses to protect them from damage caused another possible cause of the problem.
  • Page 146 Taking Care of the Unexpected The fuse is located behind the left side cover. LEFT SIDE Recommended Fuse main fuse 7.5 A To prevent an accidental short circuit, turn the ignition switch OFF before checking or replacing the fuse. For access the main fuse ( ), remove the left side cover (page Remove the starter magnetic switch ( ) from the battery box ( ).

  • Page 147: If You Crash

    Also, be sure to have your Honda dealer check the frame and If you decide you are capable of riding safely, suspension after any serious crash.

  • Page 148: If You Lose Your Key

    If you don’t know your key number, call the dealer you purchased your Honda from. They may have it listed in their records. If they don’t, transport your motorcycle to them or the nearest Honda dealer.

  • Page 149: If A Component Fails

    Taking Care of the Unexpected If any component of the front brake system If a Component Fails is damaged, you may be able to ride carefully back to your base using the rear The drive chain, brake lever or pedal, control brake for slowing or stopping.

  • Page 150: If Your Battery Is Low (Or Dead)

    Bump starting is also not recommended. If you can’t charge the battery or it appears unable to hold a charge, contact your Honda dealer. Taking Care of the Unexpected...
  • Page 151 Taking Care of the Unexpected...

  • Page 152: Technical Information

    Technical Information This section contains dimensions, capacities, Vehicle Identification ........144 and other technical data, plus information on Specifications ..........146 government requirements and how to break-in Break-in Guidelines ........151 your motorcycle. High Altitude Carburetor Adjustment ..152 Emission Control Systems ......

  • Page 153: Vehicle Identification

    Vehicle Identification RIGHT SIDE Serial Numbers The frame and engine serial numbers are required when you register your motorcycle. They may also be required when ordering replacement parts. You may record these numbers in the Quick Ref erence section at the rear of the manual.
  • Page 154 Vehicle Identification LEFT SIDE Color Label & Code The color label ( ) is attached to the frame behind the left side cover (page The color code is helpful when ordering replacement parts. You may record the color and code in the Quick Ref erence section at the rear of the manual.

  • Page 155: Specifications

    Specifications Dimensions Fuel & Lubricants Overall length 81.1 in (2,059 mm) Fuel tank capacity 2.17 US gal (8.2 ) Overall width 32.0 in (812 mm) including reserve Overall height 45.6 in (1,159 mm) Fuel tank reserve 0.40 US gal (1.5 ) Wheelbase 54.0 in (1,372 mm) Fuel...
  • Page 156 API service label, SAE 10W-40, Capacities JASO T 903 standard Passenger operator only; capacity no passenger Pro Honda GN4 or HP4 Maximum weight 220 lbs (100 kg) (without molybdenum capacity additives) 4-stroke oil Cargo capacity none (USA & Canada) or...
  • Page 157 Specifications Engine Specifications Power Transmission Valve clearance Intake: 0.004 in Primary reduction 3.090 (cold) (0.10 mm) Gear ratio, 1st 2.769 Exhaust: 0.004 in 1.941 (0.10 mm) 1.450 Spark plug DPR8EA-9 (NGK) 1.148 (standard) X24EPR-U9 (DENSO) 0.960 Spark plug DPR7EA-9 (NGK) 0.812 (cold climate;...
  • Page 158 Specifications Power Transmission Chassis & Suspension Drive chain 13/16 1 3/16 in − Caster 26°45’ freeplay (20 30 mm) − Trail 4.4 in (111 mm) New chain length 25.0 in (635 mm) Tire size, front 80/100-21M/C distance between a Tire size, rear 100/100-18M/C span of 41 pins Tire pressure, front...
  • Page 159 Specifications Torque Specifications Oil drain bolt 11 lbf·ft (15 N·m , 1.5 kgf·m) Front wheel axle 55 lbf·ft (74 N·m , 7.5 kgf·m) Axle holder nuts 9 lbf·ft (12 N·m , 1.2 kgf·m) Rear wheel axle 80 lbf·ft (108 N·m , 11.0 kgf·m) Technical Information...

  • Page 160: Break-In Guidelines

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

  • Page 161: High Altitude Carburetor Adjustment

    However, the carburetor must be returned to standard factory specifications when lower altitude riding is desired. See your Honda dealer for high altitude modification. Sustained operation at altitudes below 5,000 f eet (1,500 m) with high altitude carburetor modif ications may cause engine overheating and damage.

  • Page 162: Emission Control Systems

    Emission Control Systems Exhaust Emission Requirements Noise Emission Requirements The California Air Resources Board (CARB) The EPA also requires that motorcycles built requires that your motorcycle comply with after January 1, 1983 comply with applicable applicable exhaust emissions standards during noise emission standards for one year or its useful life, when operated and maintained 1,865 miles (3,000 km) after the time of sale to...
  • Page 163 Carbon monoxide does not react in carburetor. the same way, but it is toxic. Honda Motor Co., Ltd. utilizes lean carburetor settings and other systems to reduce carbon monoxide and hydrocarbons. Exhaust Emission Control System...
  • Page 164 Emission Control Systems Noise Emission Control System AMONG THOSE ACTS PRESUMED TO TAMPERING WITH THE NOISE CONTROL CONSTITUTE TAMPERING ARE THE SYSTEM IS PROHIBITED: U. S. federal law ACTS LISTED BELOW: prohibits, or Canadian provincial laws may Removal of, or puncturing the muffler, prohibit the following acts or the causing baffles, header pipes, or any other thereof: (1) The removal or rendering...
  • Page 165 Problems that May Affect Motorcycle Emissions If you are aware of any of the following symptoms, have the vehicle inspected and repaired by your Honda Motorcycle Dealer: Hard starting or stalling after starting Rough idle Misfiring or backfiring during acceleration...

  • Page 166: Oxygenated Fuels

    Oxygenated Fuels Some conventional gasolines are being blended ETHANOL (ethyl or grain alcohol) 10% by with alcohol or an ether compound. These Volume gasolines are collectively referred to as You may use gasoline containing up to 10% oxygenated fuels. To meet clean air standards, ethanol by volume.
  • Page 167 Oxygenated Fuels If you notice any undesirable operating symptoms, try another service station or switch to another brand of gasoline. Oxygenated f uels can damage paint and plastic. Damage caused by spilled f uel is not Fuel system damage or performance problems covered under warranty.

  • Page 168: Consumer Information

    Consumer Information This section contains information on your Authorized Manuals ........160 warranty and how to get an official Honda Warranty Coverage ........163 service manual. Warranty Service .......... .164 Contacting Honda .........165 The Honda Rider’s Club (USA only) ..

  • Page 169: Authorized Manuals

    61KPS01 ) used by your authorized Honda dealer is available from Helm, Inc. (USA only, Canada: See your Honda dealer to order authorized manuals.) Also available, but not necessary, to service your model is the Honda Common Service Manual (Publication No.
  • Page 170 By completing this form you can order the materials desired. You can pay by check or money order, or charge to your credit card. Mail to Helm, Inc. at the address shown on the back of this order form (USA only). Canada: See your Honda dealer to order authorized manuals. Publication Item Description Qty.
  • Page 171 NOTE: Dealers and Companies please provide dealer or company name, and also the name of the person to whose attention the shipment should be sent. Customer Name Attention Street Address - No P. O. Box Number Apartment Number City State Zip Code Daytime Telephone Number Check or money order enclosed payable to Helm Inc.

  • Page 172: Warranty Coverage

    Please read the Honda Motorcycle Warranties Almost all of your warranty coverage can be Booklet given to you by your Honda dealer at extended through the Honda Protection Plan the time of purchase. Be sure to keep your (USA only).

  • Page 173: Warranty Service

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

  • Page 174: Contacting Honda

    2220, mailstop: 100-4W-5B, telephone: (310) owner’s manual can be answered by your 532-9811. Honda dealer. If he doesn’t have the answer right away, he will get it for you. Canada: Refer to the warranty booklet that was supplied with your vehicle.

  • Page 175: The Honda Rider's Club (Usa Only)

    One of the best ways to get the most enjoyment A subscription to Honda Red Rider, a bi- from owning and riding your Honda is to join monthly insider’s magazine for all members. the Honda Rider’s Club of America (HRCA). Special members-only HRCA website.

  • Page 176: Your Honda Dealer

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

  • Page 177: Table Of Contents

    Table of Contents The following presents the contents of each Side Stand ............section of your owner’s manual. BEFORE RIDING ........？ MOTORCYCLE SAFETY ......Are You Ready to Ride ......Important Safety Information ......Protective Apparel ........？ Loading, Accessories & Modifications ...
  • Page 178 Table of Contents SERVICING YOUR HONDA ....Engine Bef ore You Service Your Honda Throttle ............The Importance of Maintenance ....Clutch System ..........Maintenance Safety ........Engine Idle Speed .......... Important Safety Precautions ..... Spark Plug ............Maintenance Schedule ........
  • Page 179 Table of Contents TIPS ............. .119 TECHNICAL INFORMATION ....143 Preparing for a Ride ........120 Vehicle Identification ........144 Transporting Your Honda ......122 Specifications ..........146 Storing Your Honda ........124 Break-in Guidelines ........151 You & the Environment .......
  • Page 180 TABLE OF CONTENTS ......168 Authorized Manuals ........160 Warranty Coverage ........163 INDEX ............172 Warranty Service .......... .164 Contacting Honda .........165 QUICK REFERENCE The Honda Rider’s Club (USA only) ...166 Your Honda Dealer ........167 Table of Contents...

  • Page 181: Index

    Index button, engine stop ..........start ............. accessories ............air cleaner ............air pressure, tires ..........altering your motorcycle ........arrester, spark ..........capacity, fuel ..........carburetor, high altitude adjustment ......152 idle speed ............ choke lever ............. battery ............111 cleaner, air ............
  • Page 182 Index consumer information ........159 starting ............controls, operating .......... stop button ..........cover removal, side ........stopping ............crankcase breather .......... won’t start ..........131 customer service ..........165 environment, protecting ....... .127 drive chain ............ .104 filter, air ............
  • Page 183 ..........gasohol ............157 gasoline ............gears, shifting ..........lever, clutch ............front brake ..........shift ............limit, weight ............. high altitude adjustment ....... .152 loading .............. Honda, contacting .........165 Honda service manual ........160 Index...
  • Page 184 Index maintenance, parking ............record ............pedal, rear brake ..........safety ............pinging, engine ..........schedule ............plug, spark ............manual, service ..........160 post-ride inspection ........modifications ........... pre-ride inspection .......... oil, engine ............reserve capacity, fuel tank ......operating controls ...........
  • Page 185 Index suspension, front ............rear .............. schedule, maintenance ........service, customer ........... .165 manuals ............ .160 warranty ........... .164 throttle shifting gears ..........freeplay ............shoe, brake ............. operation ............. side cover, removal ........tires, side stand ..........19, 103 air pressure ..........
  • Page 186 Index valve, fuel ............warranty, vehicle identification ........144 coverage ........... .163 extended ........... .163 service ............164 washing your motorcycle ......117 weight limit ............wheels ............. Index...
  • Page 187 How To Avoid Costly Repairs about your Honda. You’ll also find space to record important notes. The engine of your Honda can be the most expensive component to repair. Proper maintenance, especially the use of the recommended fluids and filters, prevents premature wear and damage.
  • Page 188 Quick Reference Record important information here: Frame No. Engine No. Ignition Key No. Color Label Owner’s: Name Address City/State Phone Dealer’s: Name Address City/State Phone Service Mgr. Quick Reference...
  • Page 189 API Service Classification SG or higher except oils labeled as energy conserving on the circular API service label, SAE 10W-40, JASO T 903 standard MA, Pro Honda GN4 or HP4 (without molybdenum additives) 4-stroke oil or equivalent Maximum Weight 220 lbs (100 kg)

Table of Contents