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Honda CRF70F 2004 Owner's Manual

2004 honda crf70f.
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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 CRF70F 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 CRF70F 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, a special maintenance, what you need to know message for parents, precautions about before servicing your Honda, a maintenance schedule, and instructions loading, accessories, and modifications, and the location of safety labels.

  • Page 6

    Technical Information ......ID numbers, technical specifications, and other technical facts. Consumer Information ......Information on warranties and how to get Honda service manuals. Table of Contents ........Sequential listing of topics in this owner’s manual. Index ............Contents...

  • Page 7

    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 Important Message to Parents ......help you ride your motorcycle safely. Please Loading, Accessories & Modifications ... take a few moments to read these pages. This Loading ............

  • Page 11: Motorcycle Safety

    Important Safety Information Your motorcycle can provide many years of Always Wear a Helmet service and pleasure if you take responsibility It’s a proven fact: helmets significantly reduce for your own safety and understand the the number and severity of head injuries. So challenges you can meet while riding.

  • Page 12: Important Safety Information

    Important Safety Information Ride Off-Road Only Be Alert for Off-Road Hazards Your motorcycle is designed and manufactured The terrain can present a variety of challenges for off-road use only. The tires are not made when you ride off-road. Continually ‘‘read’’ for pavement, and the motorcycle does not the terrain for unexpected turns, drop-offs, have turn signals and other features required...

  • 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: Important Message To Parents

    Important Message to Parents Your child’s safety is very important to Honda. PHYSICAL ABILITY is an important That’s why we urge you to read this message consideration. For example, riders must be big before you let any young person ride this enough to hold the motorcycle up, get on, and motorcycle.

  • Page 15: Important Message To Parents

    (For help in finding a qualified instructor, talk Young people who take unnecessary risks, with your Honda dealer.) Even if you’re not the make bad judgments, and don’t obey rules are main teacher, it’s up to you to ensure your not ready to ride this motorcycle.

  • Page 16

    Important Message to Parents SUPERVISION is another important obligation of parents. Even after youngsters have become skilled off-road riders, they should always ride with adult supervision. It helps to regularly remind young riders of basic safety rules and precautions. And remember, it’s your responsibility to see that the motorcycle is properly maintained and kept in safe operating condition.

  • Page 17: 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 18: Loading, Accessories & Modifications

    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 19: 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 20: Accessories & Modifications

    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 21: 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 22

    Operating Controls When you ride off-road, you need to operate Component Locations ........the throttle, brakes, and other controls without Fuel Valve ............stopping to look at them. Read this section Choke Lever ........... carefully before you ride. It describes the Ignition Switch ..........

  • Page 23: Component Locations

    Component Locations front brake lever throttle engine stop switch Operating Controls...

  • Page 24: Component Locations

    Component Locations fuel valve choke lever shift lever side stand Operating Controls...

  • Page 25: Controls

    Component Locations kickstarter ignition switch rear brake pedal Operating Controls...

  • Page 26: 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 27: Choke Lever

    Operating Controls The reserve fuel supply is: The choke lever is used for starting the engine 0.29 US gal (1.1 ) (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 28: Ignition Switch

    Operating Controls RIGHT SIDE (under fuel tank) Ignition Switch The ignition switch is used to prevent unauthorized use of the motorcycle. Before riding, insert the key and turn it to the right for the ON position. Function Key Removal Position The engine cannot be The key can (1) ignition switch...

  • Page 29: Engine Stop Switch

    Operating Controls Engine Stop Switch Throttle The engine stop switch is used to turn the The throttle controls engine rpm (speed). To engine off during normal riding situations. To increase engine rpm, rotate the grip toward you. operate, turn the switch to the OFF ( To reduce engine rpm, rotate the grip away position.

  • Page 30: Shift Lever

    Operating Controls Shift Lever Kickstarter The shift lever is used to select the next higher The kickstarter is used to start the engine. To or lower gear in the transmission. To operate, operate, swing the kickstarter out from its raise the shift lever (after closing the throttle) stored position and depress it through its entire to engage the next higher gear or depress the stroke.

  • Page 31: Controls

    Operating Controls...

  • Page 32: Before Riding

    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 33: 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 34: Ready To Ride

    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 35: Is Your Motorcycle Ready To Ride

    Is Your Motorcycle Ready to Ride? Before each ride, it’s important to inspect your Note to Parents: motorcycle and make sure any problem you If a youngster will be perf orming any of the find is corrected. A pre-ride inspection is a f ollowing pre-ride inspection procedures, it’s must because off-road riding can be tough on a your responsibility to provide caref ul...

  • Page 36: Ready To Ride

    Is Your Motorcycle Ready to Ride? Fuel Check the level and add fuel Pre-ride Inspection (page ) if needed. Also make sure the fuel fill cap is securely Check the following items before you get on fastened. the motorcycle: Drive Chain Check the condition and slack.

  • Page 37: Ready To Ride

    Is Your Motorcycle Ready to Ride? Check these items after you get on the Remember, be sure to take care of any problem motorcycle: you find or have your Honda dealer correct it before you ride. Throttle Check the freeplay and adjust if needed.

  • Page 38: Basic Operation & Riding

    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 39: Safe Riding Precautions

    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 40: Starting & Stopping The Engine

    Starting & Stopping the Engine Always follow the proper starting procedure described below. Starting Procedure To restart a warm engine, follow the procedure Preparation High Air Temperature. Before starting, insert the key and turn the Normal Air Temperature ignition switch ON. 10°...

  • Page 41

    Starting & Stopping the Engine With the throttle slightly open, operate the High Air Temperature kickstarter. Kick from the top of the stroke 35°C (95°F) or above through to the bottom with a rapid, continuous motion. Do not use the choke. Start the engine (see step under Normal...

  • Page 42: Flooded Engine

    Starting & Stopping the Engine Flooded Engine How to Stop the Engine If the engine fails to start after repeated To stop the engine, shift into neutral, turn the attempts, it may be flooded with excess fuel. engine stop switch to OFF ( To clear a flooded engine: Turn the engine stop switch to OFF ( Push the choke lever down all the way to...

  • Page 43: Shifting Gears

    Shifting Gears Release the front brake. Gradually open the throttle. When you attain a moderate speed, close the throttle and raise the shift lever. After shifting, apply the throttle. To continue shifting up to each higher gear, repeat step . To shift down to a lower gear, close the throttle and depress the shift lever.

  • Page 44

    Shifting Gears Learning when to shift gears comes with experience. Upshift to a higher gear or reduce throttle before engine rpm (speed) gets too high. Downshift to a lower gear before you feel the engine laboring (lugging) at low rpm. Downshifting can help slow your motorcycle, especially on downhills.

  • Page 45: Braking

    Braking To slow or stop, apply the front brake and rear Generally, reduce your speed or complete brake pedal smoothly, while downshifting to braking before beginning a turn. Avoid braking match your speed. Gradually increase braking or closing the throttle quickly while turning. as you feel the brakes slowing your speed.

  • 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 Procedures Chassis Suspension ............. Fluids & Filters Brakes ............. Fuel ..............Wheels ............Engine Oil ............Tires & Tubes ..........Air Cleaner ............. Side Stand ............Drive Chain ............ Engine Throttle ............Appearance Care .......... .104 Clutch System ..........

  • 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

    However, if you allow a youngster to perf orm or assist in any maintenance task, such as f illing the tank with gasoline, you should provide close supervision to make sure that it is perf ormed saf ely. 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 lubricate (page replace In the interest of safety, we recommend these items be serviced only by your Honda dealer. Servicing Your Honda...

  • Page 56

    Engine Oil Centrifugal Filter 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

    87, 92 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

    Of course, if you find any problem while servicing your motorcycle, be sure it is corrected as soon as possible. Miles Date Performed By: Notes (km) 600 (1,000) 1,200 (2,000) 1,800 (3,000) 2,400 (4,000) 3,000 (5,000) 3,600 (6,000) 4,200 (7,000) 4,800 (8,000) 5,200 (9,000) Servicing Your Honda...

  • Page 59: Component Locations

    Component Locations carburetor front brake cable fuel tank air cleaner steering head rear suspension front suspension left side cover adjusting nut (drive chain) chain slider front axle shaft rear axle shaft side stand drive chain Servicing Your Honda...

  • Page 60: Front Brake Lever

    Component Locations throttle engine oil filler cap/dipstick front brake lever clutch adjuster spark plug spark arrester adjusting nut (drive chain) rear brake adjuster engine oil rear brake rod rear brake drain bolt pedal (under engine) Servicing Your Honda...

  • Page 61: Tools

    ( ) 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 (3) tool bag Servicing Your Honda...

  • Page 62: Seat Removal

    Align the side cover prongs with the rubber grommets. Press the side cover into position. (1) bolts A (5) slot Install the bolts and tighten them. (2) bolts B (6) fuel tank bolt (3) side cover prongs (7) seat prongs (4) rubber grommets Servicing Your Honda...

  • Page 63: Side Cover Removal

    Align the side cover prong with the rubber grommet. Press the side cover into position. Install the securing bolt and tighten it. Use the same procedure to remove and install the right side cover. (1) bolt (2) prong (3) rubber grommet Servicing Your Honda...

  • Page 64: 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 65

    Stop the engine and keep heat, sparks and flame away. Handle fuel only outdoors. Wipe up spills immediately. (1) fuel fill cap (3) front number plate (2) breather tube (4) filler neck Servicing Your Honda...

  • Page 66

    After refueling, turn the fuel fill cap clockwise until it is secure. Check that the breather tube is properly seated in the front number plate. If you replace the fuel fill cap, use only a genuine Honda replacement part. Servicing Your Honda...

  • Page 67: Engine Oil

    Running the engine with insufficient oil can viscosity (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 68

    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. (cont’d) Servicing Your Honda...

  • Page 69

    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 70

    Insert the dipstick and screw it in tightly. (2) upper level mark (3) lower level mark Check for oil leaks. Park your motorcycle on a firm, level surface. Clean around the oil filler cap/dipstick ( ) and nearby surfaces. Servicing Your Honda...

  • Page 71

    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 (1) oil drain bolt to the environment. (2) sealing washer (cont’d) Servicing Your Honda...

  • Page 72

    18 lbf·ft (25 N·m , 2.5 kgf·m) Check for oil leaks. Pour the recommended oil into the crankcase, approximately: 0.6 US qt (0.6 ) Install the oil filler cap/dipstick securely. Start the engine. Let it idle 3-5 minutes, then turn it off. Servicing Your Honda...

  • Page 73: 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 74

    Allow the air cleaner to dry thoroughly before applying oil. A wet air cleaner will not fully absorb the oil. (3) air cleaner (4) projection (air cleaner housing cover) (cont’d) (5) projection (air cleaner housing) Servicing Your Honda...

  • Page 75

    Air Cleaner Pour clean Pro Honda Foam Filter Oil or an equivalent (Canada: Honda Foam Filter Oil or an equivalent) over the entire surface of the air cleaner. Use both hands to evenly spread the oil into the air cleaner. Gently squeeze out any excess oil.

  • Page 76: Throttle

    After adjustment, check for smooth rotation of the throttle grip from fully closed to fully open in all steering positions. If you can’t get the freeplay within the specified range, contact your Honda dealer. (2) dust cover (4) adjuster (3) lock nut...

  • Page 77

    Check the cable for tension or stress in all steering positions. Lubricate the cable with a commercially- available cable lubricant to prevent premature rust and corrosion. (1) throttle (2) throttle cable Check that the throttle assembly is positioned properly and the securing bolts are tight. Servicing Your Honda...

  • Page 78: Clutch System

    (1) adjuster lock nut (2) clutch adjuster Loosen the adjuster lock nut ( ). Turn the clutch adjuster ( ) clockwise one turn; do not turn excessively. (cont’d) Servicing Your Honda...

  • Page 79

    1/8 to 1/4 turn, and tighten the lock nut. After adjustment, test ride the motorcycle to be certain the clutch operates properly. If you can’t get proper adjustment, or the clutch does not work properly, see your Honda dealer. Servicing Your Honda...

  • Page 80: Valve Clearance

    The clearance will change as engine (1) left crankcase cover temperature rises. (2) bolts (3) adjusting hole caps Remove the left crankcase cover ( ) by removing the bolts ( ). Remove the adjusting hole caps ( ). (cont’d) Servicing Your Honda...

  • Page 81

    Rotate the generator flywheel counterclockwise until the T mark ( ) on the flywheel lines up with the index mark ( ) on the crankcase. In this position, the piston may either be on the compression or exhaust stroke. Servicing Your Honda...

  • Page 82

    (7) adjusting screw (8) adjusting screw lock nut Check the clearance of both valves by inserting a feeler gauge ( ) between the adjusting screw ( ) and the valve stem. Clearance should be: 0.002 in (0.05 mm) Servicing Your Honda...

  • Page 83: Engine Idle Speed

    Ten minutes of stop-and-go riding is sufficient. Do not attempt to compensate for faults in other systems by adjusting idle speed. See your Honda dealer for regularly scheduled carburetor adjustments. Warm up the engine, shift to neutral and place the motorcycle on its stand.

  • Page 84: Spark Plug

    Standard CR6HSA (NGK) or U20FSR-U (DENSO) For cold climate CR5HSA (NGK) (below 5°C, 41°F) U16FSR-U (DENSO) For extended high CR7HSA (NGK) speed riding U22FSR-U (DENSO) (1) center electrode (2) side electrode (3) spark plug gap (cont’d) Servicing Your Honda...

  • Page 85

    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 86: 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 ( ). (cont’d) Servicing Your Honda...

  • Page 87

    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 88: Suspension

    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 89

    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 bushing (2) shock absorber attachment points Place the motorcycle on a maintenance stand.

  • Page 90

    Check that the fasteners for the shock absorber 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 91: Brakes

    SIDE Apply the brake, release it, then spin the wheel and check that it rotates freely. Repeat this procedure several times. (3) lock nut ( ) increase freeplay (4) front brake cable adjuster ( ) decrease freeplay Servicing Your Honda...

  • Page 92

    ( ). Turn the lower adjusting nut ( ) to obtain the specified freeplay. Tighten the lower lock nut. LEFT FRONT (5) cable guide bolt (6) lower lock nut ( ) increase freeplay (7) lower adjusting nut ( ) decrease freeplay (cont’d) Servicing Your Honda...

  • Page 93

    ( ) until the brake starts to Check the freeplay. If you cannot adjust the engage. 13/16 1 3/16 in (20 30 mm) freeplay properly, see your Honda dealer. Freeplay: If necessary, adjust to the specified range. Rear Brake Pedal Freeplay...

  • Page 94

    Check the freeplay. If you can’t adjust the Application of the brake control (lever or freeplay properly, see your Honda dealer. pedal) causes the arrow on the brake arm to move toward a reference mark on the brake panel.

  • Page 95

    ( ). Replace the brake shoes if the arrow aligns with the reference mark ( ) on the brake panel ( ) upon full application of the brake. If replacement is necessary, see your Honda dealer. Servicing Your Honda...

  • Page 96: Wheels

    (2) spoke Maintenance Schedule. However, information for wheel removal is provided for emergency situations. Inspect the wheel rims ( ) and spokes ( ) for damage. Tighten any loose spokes. (cont’d) Servicing Your Honda...

  • Page 97

    Raise the front wheel off the ground by round or not ‘‘true.’’ If the wobble is placing a maintenance stand or support block noticeable, see your Honda dealer for under the engine. Secure the rear of the inspection. motorcycle with tie-down straps.

  • Page 98

    43 lbf·ft (59 N·m , 6.0 kgf·m) Check front brake adjustment (page If a torque wrench was not used to install the wheel, see your Honda dealer as soon as possible to verify proper assembly. Improper assembly may lead to loss of braking capacity.

  • Page 99

    Remove the wheel. Take care to prevent getting grease, oil, or dirt on the brake shoe surfaces. This can cause poor brake performance or rapid brake shoe wear after reassembly. (6) lug (7) slot (8) brake panel Servicing Your Honda...

  • Page 100

    Repeat this procedure several times. If a torque wrench was not used to install the wheel, see your Honda dealer as soon as possible to verify proper assembly. Improper assembly may lead to loss of braking capacity.

  • Page 101: 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 102

    15 psi (100 kPa , 1.00 kgf/cm ) Rear 15 psi (100 kPa , 1.00 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 (cont’d) Servicing Your Honda...

  • Page 103

    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 104

    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 105: Side Stand

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

  • Page 106: Drive Chain

    Maintenance Schedule. Check slack in the lower drive chain ( ) run midway between the sprockets. Drive chain slack should allow the following vertical movement by hand: 3/8 13/16 in (10 20 mm) (cont’d) Servicing Your Honda...

  • Page 107

    Check the chain slider ( ) for wear. If the kinked and binding. Lubricating the chain ridge ( ) in the center of the slider is worn, will often eliminate binding and kinking. have your Honda dealer replace the chain slider. LEFT Excessive chain slack may allow the drive SIDE chain to damage the engine cases.

  • Page 108

    New Chain: 43.3 in (1,101 mm) from pin center to pin center. If the distance Service Limit: exceeds the service limit, the drive chain is worn out and should be replaced. (cont’d) Servicing Your Honda...

  • Page 109

    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 SIDE Damaged Sprocket Worn Sprocket Teeth Teeth REPLACE REPLACE Normal Sprocket Teeth (1) rear axle nut...

  • Page 110

    Torque the rear axle nut to: 43 lbf·ft (59 N·m , 6.0 kgf·m) If a torque wrench is not used for this installation, see your Honda dealer as soon as possible to verify proper assembly. Recheck drive chain slack. Check rear brake pedal freeplay and adjust as necessary (page ).

  • Page 111

    Inspect the drive chain for possible wear or damage. Replace the drive chain if it has damaged rollers, loose fitting links, or otherwise appears unserviceable. (1) master link retaining clip Servicing Your Honda...

  • Page 112

    Servicing Your Honda...

  • Page 113: Appearance Care

    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 values your motorcycle. A clean motorcycle is a mild, neutral detergent and water also easier to inspect and service.

  • Page 114

    After washing, rinse your motorcycle thoroughly with plenty of clean water to High pressure water (or air) can damage remove any residue. certain parts of your motorcycle. Dry your motorcycle with a chamois or a soft towel. (cont’d) Servicing Your Honda...

  • Page 115

    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 116: Tips

    Preparing for a Ride ........108 off-road adventure, how to transport and store Transporting Your Honda ......110 your Honda, and how to be an environmentally Storing Your Honda ........112 responsible motorcycle owner. You & the Environment ....... .115...

  • Page 117: 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 118

    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 119: 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 120

    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. Use another tie-down strap to keep the rear of the motorcycle from moving.

  • Page 121: 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 122

    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 123

    Storing Your Honda Wash and dry your motorcycle. Lubricate the drive chain. Removal from Storage Inflate the tires to their recommended pressures (page Uncover and clean your motorcycle. Store your motorcycle in an unheated area, If your motorcycle has been stored for more...

  • Page 124: 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 125

    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 126: Taking Care Of The Unexpected

    Taking Care of the Unexpected With all the challenges you can encounter off- General Guidelines ........118 road, there’s a chance that sometime something If Your Engine Quits or Won’t Start ... .119 may go wrong. This section gives practical If You Have a Flat Tire ........

  • Page 127: 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 128: If Your Engine Quits Or Won't Start

    Taking Care of the Unexpected If the problem is relatively minor and you The next area to check is the fuel system: have the tools, supplies, and skills to make a temporary repair, be sure to have permanent Make sure there is enough gas in the tank repairs made as soon as possible.

  • Page 129: If You Have A Flat Tire

    Taking Care of the Unexpected If the fuel system appears to be okay, check the ignition system (this requires a spark plug If You Have a Flat Tire wrench): How you handle a flat tire on the trail depends Check that the spark plug cap isn’t loose or on how serious the tube or tire damage is, and disconnected.

  • Page 130: If You Crash

    Taking Care of the Unexpected If the leak is more serious, or a temporary repair doesn’t hold, the tube must be replaced. If You Crash The tire will also need to be replaced if it is damaged (page ). Replacing a tube or tire Personal safety is your first priority after an involves removing and re-installing the wheel accident.

  • Page 131: If You Lose Your Key

    Also, be sure to have If you lose your key and aren’t carrying a your Honda dealer check the frame and duplicate, either get your spare or have one suspension after any serious crash.

  • Page 132: 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, master link, brake lever or brake for slowing or stopping.

  • Page 133

    Taking Care of the Unexpected...

  • Page 134: Technical Information

    Technical Information This section contains dimensions, capacities, Vehicle Identification ........126 and other technical data, plus information on Specifications ..........128 government requirements and how to break-in Break-in Guidelines ........133 your motorcycle. High Altitude Carburetor Adjustment ..134 Emission Control Systems ......

  • Page 135: Vehicle Identification

    Vehicle Identification LEFT 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 136

    Vehicle Identification LEFT SIDE Color Label & Code The color label ( ) is attached to the left side of the frame down tube. 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 137: Specifications

    130 lbs (59 kg) pump octane Dry weight recommendation number of 86 or higher Air cleaner oil Pro Honda (USA only) or Honda (Canada only) Foam Filter Oil or an equivalent Engine oil capacity after draining: 0.6 US qt (0.6 ) after disassembly: 0.8 US qt (0.8 )

  • Page 138

    SAE 10W-40, operator only; Passenger JASO T 903 no passenger capacity standard MA, Maximum weight 132 lbs (60 kg) Pro Honda GN4 or capacity HP4 (without Cargo capacity none molybdenum additives) 4-stroke Engine Specifications oil (USA & Canada) Displacement 4.38 cu-in (71.8 cm )

  • Page 139

    Specifications Engine Specifications Power Transmission Valve clearance Intake: 0.002 in Primary reduction 3.722 (cold) (0.05 mm) Gear ratio, 1st 3.272 Exhaust: 0.002 in 1.666 (0.05 mm) 1.190 Spark plug CR6HSA (NGK) Final reduction 2.400 (standard) U20FSR-U (DENSO) Final drive chain Spark plug CR5HSA (NGK) (cold climate;...

  • Page 140

    Specifications Power Transmission Chassis & Suspension Drive chain 3/8 13/16 in Caster 26°12’ freeplay (10 20 mm) Trail 2.42 in (61.5 mm) New chain length 42.5 in (1,080 mm) Tire size, front 2.50-14 4PR distance between a Tire size, rear 3.00-12 4PR span of 85 pins Tire pressure, front...

  • Page 141

    Specifications Torque Specifications Oil drain bolt 18 lbf·ft (25 N·m , 2.5 kgf·m) Rear wheel axle 43 lbf·ft (59 N·m , 6.0 kgf·m) Front wheel axle 43 lbf·ft (59 N·m , 6.0 kgf·m) Technical Information...

  • Page 142: 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 143: 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 144: 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 145

    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 146

    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 147

    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 148: 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 149

    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 150: Consumer Information

    Consumer Information This section contains information on your Authorized Manuals ........142 warranty and how to get an official Honda Warranty Coverage ........145 service manual. Warranty Service .......... .146 Contacting Honda .........147 The Honda Rider’s Club (USA only) ..

  • Page 151: Consumer Information

    61GCF07 ) 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 152

    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 153

    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 154: 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 155: 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 156: 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 157: 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 158: 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 159: Table Of Contents

    Table of Contents The following presents the contents of each Shift Lever ..........section of your owner’s manual. Rear Brake Pedal ........Kickstarter ..........MOTORCYCLE SAFETY ......Side Stand ..........Important Safety Information ......Important Message to Parents ......BEFORE RIDING ........

  • Page 160

    Table of Contents BASIC OPERATION & RIDING ....SERVICING YOUR HONDA ....Safe Riding Precautions ......... Bef ore You Service Your Honda Starting & Stopping the Engine ..... The Importance of Maintenance ....Preparation ..........Maintenance Safety ........Starting Procedure ........

  • Page 161

    Table of Contents SERVICING YOUR HONDA (cont’d) Chassis Service Procedures Suspension ............. Brakes ............. Fluids & Filters Wheels ............Fuel ..............Tires & Tubes ..........Engine Oil ............Side Stand ............Air Cleaner ............. Drive Chain ............ Engine Appearance Care ..........

  • Page 162

    If You Have a Flat Tire ........ .120 Contacting Honda .........147 If You Crash ..........121 The Honda Rider’s Club (USA only) ...148 If You Lose Your Key ........122 Your Honda Dealer ........149 If a Component Fails ........

  • Page 163: Index

    Index accessories ............capacity, fuel ..........air cleaner ............carburetor, air pressure, tires ..........idle speed ............ altering your motorcycle ........ choke lever ............. arrester, spark ..........cleaner, air ............cleaning, appearance care ......104 clearance, valve ..........clutch system, adjustment ......

  • Page 164: Index

    Index drive chain ............filter, air ............flat tire ............120 flooded engine, starting ......... fork ..............frame number ..........126 education, rider .........3, 149 front brake, emission control systems ......135 lever ............engine number ..........126 lever freeplay ..........

  • Page 165

    ............gears, shifting ..........lever, front brake ..........high altitude carburetor adjustment ....134 shift ............Honda, contacting .........147 limit, weight ............. Honda service manual ........142 loading .............. idle speed, engine ........... inspection, post-ride ............. pre-ride ............Index...

  • Page 166

    Index maintenance, parking ............record ............pedal, rear brake ..........safety ............pinging, engine ..........schedule ............plug, spark ............manual, service ..........142 post-ride inspection ........modifications ..........pre-ride inspection .......... oil, engine ............reserve capacity, fuel tank ......operating controls ...........

  • Page 167

    Index suspension, front ............rear .............. schedule, maintenance ........service, customer ........... .147 warranty ........... .146 manuals ............ .142 throttle shifting gears ..........freeplay ............shoe, brake ............. operation ............. side cover, removal ........tires, side stand ...........21, 96 air pressure ..........

  • Page 168

    Index unexpected problems ........117 valve, fuel ............vehicle identification ........126 warranty, coverage ........... .145 extended ........... .145 service ............146 washing your motorcycle ......105 weight limit ............wheels ............. Index...

  • Page 169

    Memo...

  • Page 170

    Memo...

  • Page 171: Quick Reference

    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 172

    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 173

    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 132 lbs (60 kg)

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