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03/06/03 12:48:31 32MCB600_001
Honda XL650V
OWNER’S MANUAL
Honda Motor Co., Ltd. 2003
03/06/03 12:48:36 32MCB600_002
IMPORTANT INFORMATION
OPERATOR AND PASSENGER
This motorcycle is designed to carry the operator and one passenger. Never exceed the
maximum weight capacity as shown on the accessories and loading label.
ON/OFF-ROAD USE
This motorcycle is designed for ‘‘dual purpose’’ use.
READ THIS OWNER’S MANUAL CAREFULLY
Pay special attention to the safety messages that appear throughout the manual. These
messages are fully explained in the ‘‘A Few Words About Safety’’ section which appears
before the Contents page.
This manual should be considered a permanent part of the motorcycle and should remain
with the motorcycle when resold.
03/06/03 12:48:40 32MCB600_003
Honda XL650V
OWNER’S MANUAL
All information in this publication is based on the latest production information
available at the time of approval for printing. Honda Motor Co.,Ltd. reserves the
right to make changes at any time without notice and without incurring any
obligation.
No part of this publication may be reproduced without written permission.
03/06/03 12:48:45 32MCB600_004
WELCOME
The motorcycle presents you a challenge to master the machine, a challenge to adventure.
You ride through the wind, linked to the road by a vehicle that responds to your commands
as no other does. Unlike an automobile, there is no metal cage around you. Like an airplane, a
pre-ride inspection and regular maintenance are essential to your safety. Your reward is
freedom.
To meet the challenges safely, and to enjoy the adventure fully, you should become
thoroughly familiar with this owner’s manual BEFORE YOU RIDE THE MOTORCYCLE.
As you read this manual, you will find information that is preceded by a
symbol. This
information is intended to help you avoid damage to your motorcycle, other property, or the
environment.
When service is required, remember that your Honda dealer knows your motorcycle best. If
you have the required mechanical ‘‘know-how’’ and tools, your dealer can supply you with an
official Honda Service Manual to help you perform many maintenance and repair tasks.
Pleasant riding, and thank you for choosing a Honda !
03/06/03 12:48:52 32MCB600_005
Following codes in this manual indicate each country.
E
UK
F
France
Ireland
ED
The specifications may vary with each locale.
ED
European direct sales
European direct sales (Type
)
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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.
Of course, it is not practical or possible to warn you about all hazards associated with
operating or maintaining a motorcycle. You must use your own good judgment.
You will find important safety information in a variety of forms, including:
Safety Labels –– on the motorcycle.
Safety Messages –– preceded by a safety alert symbol
DANGER, WARNING, or CAUTION.
These signal words mean:
and one of three signal words:
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You WILL be KILLED or SERIOUSLY HURT if you don’t follow
instructions.
You CAN be KILLED or SERIOUSLY HURT if you don’t follow
instructions.
You CAN be HURT if you don’t follow instructions.
Safety Headings –– such as Important Safety Reminders or Important Safety Precautions.
Safety Section –– such as Motorcycle Safety.
Instructions –– how to use this motorcycle correctly and safely.
This entire manual is filled with important safety information –– please read it carefully.
03/06/03 12:49:04 32MCB600_008
OPERATION
page
1 MOTORCYCLE SAFETY
1
Important Safety Inforamation
3
Protective Apparel
5
Load Limits and Guidelines
10
13
PARTS LOCATION
Instruments and Indicators
20 MAJOR COMPONENTS
(Information you need to
opetate this motorcycle)
20
Brakes
22
Clutch
24
Coolant
26
Fuel
29
Engine Oil
30
Tyres
page
35 ESSENTIAL INDIVIDUAL
COMPONENTS
35
Ignition Switch
36
Keys
38
Immobilizer System (HISS)
40
Right Handlebar Controls
41
Left Handlebar Controls
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page
42 FEATURES
(Not required for operation)
42
Steering Lock
43
Seat
44
Helmet Holder
45
Left Side Cover
46
Right Side Cover
47
Center Compartment
47
Document Compartment
48
Headlight Aim Vertical Adjustment
page
49 OPERATION
49
Pre-ride Inspection
51
Starting the Engine
54
Running-in
55
Riding
57
Braking
58
Parking
59
Anti-theft Tips
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MAINTENANCE
page
60 MAINTENANCE
60
The Importance of Maintenance
61
Maintenance Safety
62
Safety Precautions
63
Maintenance Schedule
66
Tool Kit
67
Serial Numbers
68
Colour Label
69
Engine Oil
73
Spark Plug
77
Crankcase Breather
78
Throttle Operation
79
Idle Speed
80
Coolant
81
Drive Chain
87
Drive Chain Slider
88
Front and Rear Suspension
Inspection
89
Side Stand
90
Wheel Removal
95
Brake Pad Wear
97
Battery
99
Fuse Replacement
page
102
103
109
Stoplight Switch Adjustment
Bulb Replacement
CLEANING
112 STORAGE GUIDE
112
Storage
114
Removal from Storage
115
SPECIFICATIONS
119
CATALYTIC CONVERTER
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MOTORCYCLE SAFETY
IMPORTANT SAFETY INFORMATION
Your motorcycle can provide many years of
service and pleasure − if you take
responsibility for your own safety and
understand the challenges that you can
meet on and off-road.
Don’t Drink and Ride
Alcohol and riding don’t mix. Even one
drink can reduce your ability to respond to
changing conditions, and your reaction time
gets worse with every additional drink. So
don’t drink and ride, and don’t let your
friends drink and ride either.
There is much that you can do to protect
yourself when you ride. You’ll find many
helpful recommendations throughout this
manual. Following are a few that we
consider most important.
Always Wear a Helmet
It’s a proven fact: helmets significantly
reduce the number and severity of head
injuries, so don’t ride without one. We also
recommend that you wear eye protection,
sturdy boots, gloves and other protective
gear (page 4 ).
1
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Make Yourself Easy to See On-Road
Some drivers do not see motorcycles
because they are not looking for them. To
make yourself more visible, wear bright
reflective clothing, position yourself so
other drivers can see you, signal before
turning or changing lanes, and use your
horn when it will help others notice you.
Ride Within Your Limits
Pushing the limits is another major cause of
motorcycle accident both on-road and off.
Never ride beyond your personal abilities or
faster than conditions warrant. Remember
that alcohol, drugs, fatigue and inattention
can significantly reduce your ability to make
good judgements and ride safely.
Be Alert for Off-Road Hazards
The terrain can present a variety of
challenges when you ride of f -road.
Cont inually ‘‘read’’ t he t errain f or
unexpected turns, drop-offs, rocks, ruts, and
other hazards. Always keep your speed low
enough to allow time to see and react to
hazards.
Keep Your Bike in Safe Condition
For safe riding, it’s important to keep your
motorcycle properly maintained. Having a
breakdown can be difficult, especially if you
are stranded off-road far from your base. To
help avoid problems, inspect your
motorcycle before every ride and perform
all recommended maintenance. Never
exceed load limits, and use only accessories
that have been approved by Honda for this
motorcycle. See page 5 for more details.
2
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PROTECTIVE APPAREL
For your safety, we strongly recommend
that you always wear an approved
motorcycle helmet, eye protection, boots,
gloves, long pants, and a long-sleeved shirt
or jacket whenever you ride. Although
complete protection is not possible, wearing
proper gear can reduce the chance of injury
when you ride.
Following are suggestions to help you
choose proper gear.
Helmets and Eye Protection
Your helmet is your most important piece of
riding gear because it offers the best
protection against head injuries. A helmet
should fit your head comfortably and
securely. A bright-coloured helmet can
make you more noticeable in traffic, as can
reflective strips.
An open-face helmet offers some protection,
but a full-face helmet offers more. Always
wear a face shield or goggles to protect
your eyes and help your vision.
Not wearing a helmet increases the
chance of serious injury or death in a
crash.
Be sure you always wear a helmet,
eye protection and other protective
apparel when you ride.
3
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Additional On-Road Gear
In addition to a helmet and eye protection,
we also recommend:
Sturdy boots with non-slip soles to help
protect your feet and ankles.
Leather gloves to keep your hands warm
and help prevent blisters, cuts, burns and
bruises.
A motorcycle riding suit or jacket for
comfort as well as protection. Brightcoloured and reflective clothing can help
make you more noticeable in traffic. Be
sure to avoid loose clothes that could get
caught on any part of your motorcycle.
4
Additional Off-Road Gear
On-road apparel may also be suitable for
casual off-road riding. But if you plan on any
serious off-road riding you will need more
serious off-road gear. In addition to your
helmet and eye protection, we recommend
off-road motorcycle boots and gloves, riding
pants with knee and hip pads, a jersey with
elbow pads, and a chest/shoulder protector.
03/06/03 12:49:39 32MCB600_015
LOAD LIMITS AND GUIDELINES
Your motorcycle has been designed to carry
you and one passenger. When you carry a
passenger, you may feel some difference
during acceleration and braking. But so long
as you keep your motorcycle wellmaintained, with good tyres and brakes, you
can safely carry loads within the given limits
and guidelines.
Loading
How much weight you put on your
motorcycle, and how you load it, are
important to your safety. Anytime you ride
with a passenger or cargo you should be
aware of the following information.
However, exceeding the weight limit or
carrying an unbalanced load can seriously
affect your motorcycle’s handling, braking
and stability. Non-Honda accessories,
im p r o p e r m od i f i c a t i on s , a n d p o or
maintenance can also reduce your safety
margin.
Overloading or improper loading can
cause a crash and you can be
seriously hurt or killed.
Follow all load limits and other loading
guidelines in this manual.
The following pages give more specific
information on loading, accessories and
modifications.
5
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Load Limits
Following are the load limits for your
motorcycle:
Maximum weight capacity:
180 kg (396 lbs)
Includes the weight of the rider,
passenger, all cargo and all accessories
Maximum rear carrier cargo weight:
9 kg (20 lbs)
Maximum center compartment cargo
weight:
2.0 kg (4.4 lbs)
The weight of added accessories will reduce
the maximum cargo weight you can carry.
6
Loading Guidelines
Your motorcycle is primarily intended for
transporting you and a passenger. You may
wish to secure a jacket or other small items
to the seat when you are not riding with a
passenger.
If you wish to carry more cargo, check with
your Honda dealer for advice, and be sure
to read the inf ormat ion regarding
accessories on page 7 .
Improperly loading your motorcycle can
affect its stability and handling. Even if your
motorcycle is properly loaded, you should
ride at reduced speeds and never exceed
130 km/h (80 mph) when carrying cargo.
03/06/03 12:49:54 32MCB600_017
Follow these guidelines whenever you carry
a passenger or cargo:
Keep cargo small and light. Make sure it
cannot easily be caught on brush or other
objects, and that it does not interfere with
your ability to shift position to maintain
balance and stability.
Place weight as close to the center of the
motorcycle as possible.
Do not attach large or heavy items (such
as a sleeping bag or tent) to the
handlebar, fork, or front fender.
Make sure that all cargo is tied down
securely.
Never exceed the maximum weight limit.
Check that both tyres are inflated
properly.
Accessories and Modifications
Modifying your motorcycle or using nonHonda accessories can make your
motorcycle unsafe. Before you consider
making any modifications or adding an
accessory, be sure to read the following
information.
Improper accessories or modifications
can cause a crash in which you can be
seriously hurt or killed.
Follow all instructions in this owner’s
manual regarding accessories and
modifications.
7
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Accessories
We strongly recommend that you use only
genuine Honda accessories that have been
specifically designed and tested for your
motorcycle. Because Honda cannot test all
other accessories, you must be personally
responsible for proper selection, installation
and use of non-Honda accessories. Check
with your dealer for assistance and always
follow these guidelines:
Make sure the accessory does not reduce
ground clearance and lean angle, limit
suspension travel or steering travel, alter
your riding position or interfere with
operating any controls.
Be sure electrical equipment does not
exceed the motorcycle’s electrical system
capacity (page 118 ). A blown fuse can
cause a loss of lights or engine power.
8
Do not pull a trailer or sidecar with your
motorcycle. This motorcycle was not
designed for these attachments, and their
use can seriously impair your motorcycle’s
handling.
Modifications
We strongly advise you not to remove any
original equipment or modif y 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.
Removing or modif ying your lights,
mufflers, emission control system or other
equipment can also make your motorcycle
illegal.
03/06/03 12:50:09 32MCB600_019
OFF-ROAD SAFETY
Learn to ride in an uncongested off-road
area free of obstacles before venturing onto
unfamiliar terrain.
Always obey local off-road riding laws and
regulations.
Obtain permission to ride on private
property. Avoid posted areas and obey
‘‘NO Trespassing’’ signs.
Ride with a friend on another motorcycle
so that you can assist each other in case
of trouble.
Familiarity with your motorcycle is
critically important should a problem
occur far from help.
Never ride beyond your ability and
experience or faster than conditions
warrant.
If you are not familiar with the terrain,
ride cautiously. Hidden rocks, holes, or
ravines could spell disaster.
Spark arresters and mufflers are required
in most off-road areas. Don’t modify your
exha ust syst em. R emember t hat
excessive noise bothers everyone and
creates a bad image for motorcycling.
9
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PARTS LOCATION
Indicators
Speedometer
Rearview
mirror
Headlight dimmer
switch
Tachometer
Rearview mirrors
Front brake fluid
reservoir
Choke lever
Passing
switch
Front brake
lever
Clutch lever
Hazard switch
Throttle grip
Turn signal switch
Engine stop switch
Starter button
Ignition switch
Horn button
Fuel fill cap
10
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Seat lock
Air cleaner
Helmet holder
Coolant reserve tank
Tool box
Passenger footpeg
Gearshift pedal
Foot peg
Side stand
11
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Battery
Passenger
footpeg
Oil filler cap/dipstick
12
Foot peg
Rear brake pedal
03/06/03 12:50:26 32MCB600_023
INSTRUMENTS AND
INDICATORS
The indicators are contained in the
instrument panel. Their functions are
described in the tables on the following
pages.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
Left turn signal indicator
Speedometer
Odometer
Low oil pressure indicator
Neutral indicator
Immobilizer system (HISS) indicator
Tachometer
Tachometer red zone
Right turn signal indicator
Coolant temperature gauge
Digital clock
High beam indicator
Tripmeter
Tripmeter reset knob
Fuel gauge
(2)
(5) (6)
(3) (4)
(7)
(1)
(15)
(8)
(9)
(14)
(13)
(12)
(11)
(10)
13
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(Ref.No.) Description
(1) Left turn signal indicator
Function
Flashes when the left turn signal operates.
(2) Speedometer
Shows riding speed in miles (For E type) or
kilometers (Except E type) per hour.
(3) Odometer
Shows accumulated mileage.
(4) Low oil pressure
indicator (red)
Lights when the engine oil pressure is below normal
operating range. Should light when ignition switch is
ON and engine is not running. Should go out when
the engine starts, except for occasional flickering at
or near idling speed when engine is warm.
Running the engine with insufficient oil pressure may
cause serious engine damage.
(5) Neutral indicator (green)
14
Lights when the transmission is in neutral.
03/06/03 12:50:47 32MCB600_025
(Ref.No.) Description
(6) Immobilizer system
(HISS) indicator
Function
This indicator lights for a few seconds when the
ignition switch is turned ON and the engine stop
switch is at
(RUN). It will then go off if the
properly-coded key has been inserted. If an
improperly-coded key has been inserted, the
indicator will remain on and the engine will not start
(page 38 ).
(7) Tachometer
Shows engine revolutions per minute.
(8) Tachometer red zone
Never allow the tachometer needle to enter the red
zone, even after the engine has been broken in.
Running the engine beyond recommended maximum
engine speed (the beginning of the tachometer red
zone) can damage the engine.
15
03/06/03 12:51:01 32MCB600_026
(Ref.No.) Description
(9) Right turn signal indicator
Function
Flashes when the left turn signal operates.
(10) Coolant T emperature
Gauge
Shows coolant temperature (page 17 ).
(11) Digital clock
Shows hour and minute (page 19 ).
(12) High beam indicator
Lights when the headlight is on high beam.
(13) Tripmeter
Shows mileage per trip.
(14) Tripmeter reset knob
Resets tripmeter to zero (0) by pushing the knob.
(15) Fuel gauge
Shows approximate fuel supply available (page 18 ).
16
03/06/03 12:51:07 32MCB600_027
Coolant Temperature Gauge
When the needle begins to move above the
C (Cold) mark, the engine is warm enough
for the motorcycle to be ridden. The normal
operating temperature range is within the
section between the H and C marks. If the
needle reaches the H (Hot) mark, stop the
engine and check the reserve tank coolant
level. Read pages 24 − 25 and do not ride
the motorcycle until the problem has been
corrected.
Exceeding maximum running temperature
may cause serious engine damage.
(1)
(1) Coolant temperature gauge
17
03/06/03 12:51:12 32MCB600_028
Fuel Gauge
When the gauge needle enters the red band,
fuel will be low and you should refill the
tank as soon as possible.
The amount of fuel left in the tank when the
needle enters the red band and with the
vehicle set upright is approximately:
3.6 (0.95 US gal , 0.79 Imp gal)
(1)
(2)
(1) Fuel gauge
(2) Red band
18
03/06/03 12:51:18 32MCB600_029
Digital clock
Shows hour and minute. To adjust the time,
proceed as follows:
1. Turn the ignition switch ON.
2. Press the ‘‘H’’ button ( 2 ). To advance
time, keep the button down until the
desired hour is displayed.
3. Press the ‘‘M’’ button ( 3 ). To advance,
hold the button down. The display will be
returned to ‘‘00’’ when ‘‘60’’ minutes are
reached without affecting the hour
display.
(2)
(3)
(1)
(1) Digital clock
(2) ‘‘H’’ button
(3) ‘‘M’’ button
19
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MAJOR COMPONENTS
(Information you need to operate this motorcycle)
BRAKES
Both the front and rear brakes are the
hydraulic disc types.
As the brake pads wear, the brake fluid
level drops.
There are no adjustments to perform, but
fluid level and pad wear must be inspected
periodically. The system must be inspected
frequently to ensure there are no fluid leaks.
If the control lever or pedal free travel
becomes excessive and the brake pads are
not worn beyond the recommended limit
(page 95 ), there is probably air in the
brake system and it must be bled. See your
Honda dealer for this service.
Front Brake Fluid Level:
With the motorcycle in an upright position,
check the fluid level. It should be above the
LOWER level mark ( 1 ). If the level is at or
below the LOWER level mark ( 1 ), check
the brake pads for wear (page 95 ).
20
Worn pads should be replaced. If the pads
are not worn, have your brake system
inspected for leaks.
The recommended brake fluid is DOT 4
brake fluid from a sealed container, or an
equivalent.
Front
(1)
(1) LOWER level mark
Other Checks:
Make sure there are no fluid leaks. Check
for deterioration or cracks in the hoses and
fittings.
03/06/03 12:51:32 32MCB600_031
Rear Brake Fluid Level:
With the motorcycle in an upright position,
check the fluid level. It should be between
the UPPER ( 1 ) and LOWER ( 2 ) level
marks. If the level is at or below the
LOWER level mark (2 ), check the brake
pads for wear (page 96 ).
Rear
(1)
(2)
Worn pads should be replaced. If the pads
are not worn, have your brake system
inspected for leaks.
The recommended brake fluid is DOT 4
brake fluid from a sealed container, or an
equivalent.
(1) UPPER level mark
(2) LOWER level mark
Other Checks:
Make sure there are no fluid leaks. Check
for deterioration or cracks in the hoses and
fittings.
21
03/06/03 12:51:40 32MCB600_032
CLUTCH
Clutch adjustment may be required if the
motorcycle stalls when shifting into gear or
tends to creep; or if the clutch slips, causing
acceleration to lag behind engine speed.
Minor adjustments can be made with the
clutch cable adjuster ( 4 ) at the lever ( 1 ).
Normal clutch lever free play is:
10−20 mm (0.4−0.8 in)
1. Pull back the rubber dust cover ( 2 ).
2. Loosen the lock nut ( 3 ) and turn the
adjuster ( 4 ). Tighten the lock nut ( 3 )
and check the adjustment.
3. If the adjuster is threaded out near its
limit or if the correct free play cannot be
obtained, loosen the lock nut ( 3 ) and turn
in the cable adjuster ( 4 ) completely.
Tighten the lock nut ( 3 ) and install the
dust cover.
(1)
(2)
(B)
(A )
(3)
(1) Clutch lever
22
(4)
(2) Dust cover
(A) Increase free play
(3) Lock nut
(B) Decrease free play
(4) Clutch cable adjuster
03/06/03 12:51:47 32MCB600_033
4. Loosen the lock nut ( 5 ) at the lower end
of the cable. Turn the adjusting nut ( 6 ) to
obtain the specified free play. Tighten the
lock nut ( 5 ) and check the adjustment.
5. Start the engine, pull in the clutch lever
and shift into gear. Make sure the engine
does not stall and the motorcycle does
not creep. Gradually release the clutch
lever and open the throttle. T he
motorcycle should begin to move
smoothly and accelerate gradually.
Other Checks:
Check the clutch cable for kinks or signs of
wear that could cause sticking or failure.
L ubricate the clutch cable w it h a
commercially available cable lubricant to
prevent premature wear and corrosion.
(5)
(6)
If proper adjustment cannot be obtained or
the clutch does not work correctly, see your
Honda dealer.
(A )
(B)
(5) Lock nut
(6) Adjusting nut
(A) Increase free play
(B) Decrease free play
23
03/06/03 12:51:53 32MCB600_034
COOLANT
Coolant Recommendation
The owner must properly maintain the
coolant to prevent freezing, overheating,
and corrosion. Use only high quality
ethylene glycol antif reeze containing
corrosion protection inhibitors specifically
recommended for use in aluminum engines.
(SEE ANTIFREEZE CONTAINER LABEL).
Use only low-mineral drinking water or
distilled water as a part of the antifreeze
solution. Water that is high in mineral
content or salt may be harmful to the
aluminum engine.
Using coolant with silicate inhibitors may
cause premature wear of water pump seals
or blockage of radiator passages.
Using tap water may cause engine damage.
24
The factory provides a 50/50 solution of
antifreeze and distilled water in this
motorcycle. T his coolant solution is
recommended f or most operating
temperatures and provides good corrosion
protection. A higher concentration of
antifreeze decreases the cooling system
performance and is recommended only
when additional protection against freezing
is needed. A concentration of less than 40/
60 (40% antifreeze) will not provide proper
corrosion protection. During freezing
temperatures, check the cooling system
frequently and add higher concentrations of
antifreeze (up to a maximum of 60%
antifreeze) if required.
03/06/03 12:51:59 32MCB600_035
Inspection
The reserve tank is located under the left
radiator.
Check the coolant level in the reserve tank
( 1 ) while the engine is at the normal
operating temperature with the motorcycle
in an upright position. If the coolant level is
below the LOWER level mark (2 ), remove
the reserve tank cap (3 ) and add coolant
mixture until it reaches the UPPER level
mark (4 ). Always add coolant to the reserve
tank.
Do not attempt to add coolant by removing
the radiator cap.
If the reserve tank is empty, or if coolant
loss is excessive, check for leaks and see
your Honda dealer for repair.
(3)
(1)
(4)
(2)
(1) Reserve tank
(2) LOWER level mark
(3) Reserve tank cap
(4) UPPER level mark
25
03/06/03 12:52:08 32MCB600_036
FUEL
Fuel Tank
The fuel tank capacity including the reserve
supply is:
19.6 (5.18 US gal , 4.31 Imp gal)
To open the fuel fill cap ( 1 ), insert the
ignition key (2 ) and turn it clockwise. The
fuel fill cap is hinged and will lift up.
Do not overfill the tank. There should be no
fuel in the filler neck ( 3 ).
After refueling, to close the fuel fill cap,
push the fuel fill cap into the filler neck until
it snaps closed and locks. Remove the key.
(3)
(2)
Petrol is highly flammable and
explosive. You can be burned or
seriously injured when handling fuel.
Stop the engine and keep heat,
sparks, and flame away.
Refuel only outdoors.
Wipe up spills immediately.
26
(1) Fuel fill cap
(2) Ignition key
(1)
(3) Filler neck
03/06/03 12:52:11 32MCB600_037
Use unleaded petrol with a research octane
number of 91 or higher.
The use of leaded petrol will cause
premature damage to the catalytic
converters.
If ‘‘spark knock’’ or ‘‘pinking’’ occurs at a
steady engine speed under normal load,
change brands of petrol. If spark knock or
pinking persists, consult your Honda dealer.
Failure to do so is considered misuse, and
damage caused by misuse is not covered by
Honda’s Limited Warranty.
27
03/06/03 12:52:15 32MCB600_038
Petrol Containing Alcohol
If you decide to use a petrol containing
alcohol (gasohol), be sure it’s octane rating
is at least as high as that recommended by
Honda. There are two types of ‘‘gasohol’’:
one containing ethanol, and the other
containing methanol. Do not use petrol that
contains more than 10 % ethanol. Do not use
petrol containing methanol (methyl or wood
alcohol) that does not also contain
cosolvents and corrosion inhibitors for
methanol. Never use petrol containing more
than 5 % methanol, even if it has cosolvents
and corrosion inhibitors.
28
Fuel system damage or engine performance
problems resulting from the use of fuels
that contain alcohol is not covered under
the warranty. Honda cannot endorse the
use of fuels containing methanol since
evidence of their suitability is as yet
incomplete.
Before buying fuel from an unfamiliar
station, try to find out if the fuel contains
alcohol. If it does, confirm the type and
percentage of alcohol used. If you notice
any undesirable operating symptoms while
using a petrol that contains alcohol, or one
that you think contains alcohol, switch to a
petrol that you know does not contain
alcohol.
03/06/03 12:52:23 32MCB600_039
ENGINE OIL
Engine Oil Level Check
Check the engine oil level each day before
riding the motorcycle.
The level must be maintained between the
upper ( 1 ) and lower ( 2 ) level marks on the
dipstick ( 3 ).
1. Start the engine and let it idle for a few
minutes. Make sure the low oil pressure
indicator goes off. If the light remains on,
stop the engine immediately.
2. Stop the engine and put the motorcycle
on its side stand on level ground.
3. After a few minutes, remove the oil filler
cap/dipstick, wipe it clean, and reinsert
the dipstick without screwing it in.
Remove the dipstick. The oil level should
be between the upper and lower marks
on the dipstick.
4. If required, add the specified oil (see
page 69 ) up to the upper level mark. Do
not overfill.
5. Reinstall the oil filler cap/dipstick. Check
for oil leaks.
Running the engine with insufficient oil
pressure may cause serious engine damage.
(3)
(1)
(2)
(1) Upper level mark
(2) Lower level mark
(3) Oil filler cap/dipstick
29
03/06/03 12:52:30 32MCB600_040
TYRES
To safely operate your motorcycle, the tyres
must be the proper type (off-road) and size,
in good condition with adequate tread, and
correctly inflated.
Using tyres that are excessively worn
or improperly inflated can cause a
crash in which you can be seriously
hurt or killed.
Follow all instructions in this owner’s
manual regarding tyre inflation and
maintenance.
30
Air Pressure
Properly inflated tyres provide the best
combination of handling, tread life, and
riding comfort. Generally, underinflated
tyres wear unevenly, adversely affect
handling, and are more likely to fail from
being overheated. Underinflated tyres can
also cause wheel damage in rocky terrain.
Overinflated tyres make your motorcycle
ride more harshly, are more prone to
damage from surface hazards, and wear
unevenly.
Make sure the valve stem caps are secure.
If necessary, install a new cap.
03/06/03 12:52:38 32MCB600_041
Always check air pressure when your tyres
are ‘‘cold’’ − when the motorcycle has been
parked for at least three hours. If you check
air pressure when your tyres are ‘‘warm’’ −
when the motorcycle has been ridden for
even a few miles − the readings will be
higher than if the tyres were ‘‘cold’’. This is
normal, so do not let air out of the tyres to
match the recommended cold air pressures
given below. If you do, the tyres will be
underinflated.
The recommended ‘‘cold’’ tyre pressures
are:
kPa (kgf/cm , psi)
Driver
only
Front
Rear
200 (2.00 , 29)
200 (2.00 , 29)
Driver and
one passenger
Front
Rear
200 (2.00 , 29)
225 (2.25 , 32)
Inspection
Whenever you check the tyre pressures,
you should also examine the tyre treads and
sidewalls for wear, damage, and foreign
objects:
Look for:
Bumps or bulges in the side of the tyre or
the tread. Replace the tyre if you find any
bumps or bulges.
Cuts, splits or cracks in the tyre. Replace
the tyre if you can see fabric or cord.
Excessive tread wear.
Also, if you hit a pothole or hard object, pull
to the side of the road as soon as you safely
can and carefully inspect the tyres for
damage.
31
03/06/03 12:52:43 32MCB600_042
Tread Wear
Replace tyres before tread depth at the
center of the tyre reaches the following
limit:
Minimum tread depth
Front:
Rear:
1.5 mm (0.06 in)
2.0 mm (0.08 in)
〈For Germany〉
German law prohibits use of tyres whose
tread depth is less than 1.6 mm.
(2)
(1)
(1) Wear indicator
(2) Wear indicator location mark
32
03/06/03 12:52:46 32MCB600_043
Tube Repair and Replacement
If a tube is punctured or damaged, you
should replace it as soon as possible. A tube
that is repaired may not have the same
reliability as a new one, and it may fail while
you are riding.
If you need to make a temporary repair by
patching a tube or using an aerosol sealant,
ride cautiously at reduced speed and have
the tube replaced before you ride again.
Any time a tube is replaced, the tyre should
be carefully inspected as described on page
31 .
33
03/06/03 12:52:55 32MCB600_044
Tyre Replacement
The tyres that came on your motorcycle
were designed to match the performance
capabilities of your motorcycle and provide
the best combination of handling, braking,
durability and comfort.
Installing improper tyres on your
motorcycle can affect handling and
stability. This can cause a crash in
which you can be seriously hurt or
killed.
Always use the size and type of tyres
recommended in this owner’s manual.
T he r ecommended t yres f or your
motorcycle are:
Front: 90/90−21M/C 54S
BRIDGESTONE
TW47G
PLRELLI
MT60
Rear: 120/90−17M/C 64S
BRIDGESTONE
TW48G
PLRELLI
MT60
Whenever you replace a tyre, use one that
is equivalent to the original and be sure the
wheel is balanced after the new tyre is
installed.
Also remember to replace the inner tube
whenever you replace a tyre. The old tube
will probably be stretched, and if installed in
a new tyre, it could fail.
34
03/06/03 12:53:02 32MCB600_045
ESSENTIAL INDIVIDUAL COMPONENTS
IGNITION SWITCH
The ignition switch ( 1 ) is below the
indicator panel.
The headlight and taillights will come on
whenever you turn the ignition switch
ON. If your motorcycle is stopped with
the ignition switch ON and the engine is
not running, the headlight and taillights
will still be on, resulting in battery
discharge.
(1)
(1) Ignition switch
Key Position
LOCK
(steering lock)
OFF
Function
Steering is locked. Engine and lights cannot be
operated.
Engine and lights cannot be operated.
ON
Engine and lights can be operated.
(hazard)
When the harzard switch is ON, both left and
right turn signals flash.
Engine and lights cannot be operated.
Key Removal
Key can be
removed
Key can be
removed
Key cannot be
removed
Key cannot be
removed
35
03/06/03 12:53:06 32MCB600_046
KEYS
This motorcycle has two keys and a key
number plate.
(2)
(1)
(1) Keys
36
(2) Key number plate
03/06/03 12:53:13 32MCB600_047
You will need the key number if you ever
have to replace a key. Store the plate in a
safe place.
To reproduce keys, bring all keys, key
number plate and motorcycle to your Honda
dealer.
Up to four keys can be registered with the
immobilizer system (HISS), including the
ones in hand.
If all keys are lost, the ignition control
module must be replaced. To avoid this
possibility we recommend that if only one
key is left, you immediately have it
reproduced to ensure that a back-up is
available.
These keys contain electronic circuits that
are activated by the immobilizer system
(HISS). They will not work to start the
engine if the circuits are damaged.
Do not drop the keys or set heavy objects
on them.
Do not grind, drill or in any way alter the
original shape of the keys.
Keep the keys away from magnetic
objects.
37
03/06/03 12:53:18 32MCB600_048
IMMOBILIZER SYSTEM (HISS)
HISS is the abbreviation of Honda Ignition
Security System.
The immobilizer system (HISS) protects
your motorcycle from theft. A properlycoded key must be used in the ignition
switch for the engine to start. If an
improperly-coded key (or other device) is
used the engine’s starting circuit is disabled.
When the ignition switch is turned ON and
the engine stop switch is at ‘‘
’’ (RUN),
the immobilizer system (HISS) indicator
( 1 ) lights for a few seconds, then go off. If
the indicator remains on, it means the
system does not recognize the coding of the
key. Turn the ignition switch to OFF,
remove the key, reinsert and turn the
switch ON again.
(1)
(1) Immobilizer system (HISS) indicator
38
03/06/03 12:53:25 32MCB600_049
If the system repeatedly does not recognize
the coding of your key, contact your Honda
dealer.
The system may not recognize the key’s
coding if any other immobilizer key is
near the ignition switch. To make sure
the system recognize the key code, keep
each immobilizer key on a separate ring.
Do not attempt to alter the immobilizer
system (HISS) or add other devices to it.
Electrical problems could result, making
it impossible to start your motorcycle.
If all keys are lost, the ignition control
module must be replaced.
EC Directives
This immobilizer system complies with the
R & TTE (Radio equipment and telecommunications terminal equipment and the
mutual recognition of their conformity)
Directive.
The declaration of conformity to R & TTE
Directive is provided to the owner at the
time of purchase. The declaration of
conformity should be kept at a safe place.
When the declaration of conformity is lost
or is not provided, contact your Honda
dealer.
39
03/06/03 12:53:32 32MCB600_050
RIGHT HANDLEBAR CONTROLS
Engine Stop Switch
The engine stop switch ( 1 ) is next to the
throttle grip. When the switch is in the
(RUN) position, the engine will operate.
When the switch is in the
(OFF)
position, the engine will not operate. This
switch is intended primarily as a safety or
emergency switch and should normally
remain in the
(RUN) position.
When the starter button is pressed, the
starter motor cranks the engine, the
headlight will automatically go out, but the
taillights will stay on. If the engine stop
switch is in the
(OFF) position, the
starter motor will not operate. See page
52 for the starting procedure.
(1)
If your motorcycle is stopped with the
ignition switch ON and the engine stop
switch
(OFF), the headlight and
taillights will still be on, resulting in battery
discharge.
(2)
Starter Button
The starter button ( 2 ) is below the engine
stop switch ( 1 ).
(1) Engine stop switch
(2) Starter button
40
03/06/03 12:53:42 32MCB600_051
LEFT HANDLEBAR CONTROLS
Headlight Dimmer Switch ( 1)
Push the dimmer switch to
(HI) to
select high beam or to
(LO) to select
low beam.
With the ignition switch is
position, the
signals continue flashing even the engine or
other lights are OFF.
Passing Light Control Switch (2 )
When this switch is pressed, the headlight
flashes on to signal approaching cars or
when passing.
(5)
(2)
(1)
Turn Signal Switch ( 3 )
Move to
(L ) to signal a lef t t urn,
(R) to signal a right turn. Press to turn
signal off.
(3)
Horn Button (4 )
Press the button to sound the horn.
Hazard Switch ( 5)
When the hazard switch is
(ON)
position, both left and right turn signals
start flashing.
(1)
(2)
(3)
(4)
(5)
(4)
Headlight dimmer switch
Passing light control switch
Turn signal switch
Horn button
Hazard switch
41
03/06/03 12:53:49 32MCB600_052
FEATURES
(Not required for operation)
STEERING LOCK
To lock the steering, turn the handlebar all
the way to the left, turn the key ( 1 ) to
LOCK while pushing in. Remove the key.
To unlock the steering, turn the key to OFF
while pushing in.
Do not turn the key to LOCK while riding
the motorcycle; loss of vehicle control will
result.
To lock
(1)
(A)
(B)
(C)
(A )
To unlock
(1) Ignition key
42
(A) Push in
(B) Turn to LOCK
(C) Turn to OFF
03/06/03 12:53:55 32MCB600_053
SEAT
To remove the seat ( 1 ), insert the ignition
key into the seat lock ( 2 ) and turn it
clockwise. Pull the seat back and up.
To install the seat, insert the prongs ( 3 )
into the recess ( 4 ) under the frame cross
member and then push down on the rear of
the seat.
(4)
(3)
(1)
(3)
(4)
Be sure the seat is locked securely in
position after installation.
(4)
(1) Seat
(2) Seat lock
(2)
(3) Prongs
(4) Recess
43
03/06/03 12:54:01 32MCB600_054
HELMET HOLDER
The helmet holders are located below the
seat.
Remove the seat (page 43 ).
Hang the helmets on the holder hook ( 1 ).
Install the seat and lock it securely.
(1)
Riding with a helmet attached to the
holder can interfere with the rear wheel
or suspension and could cause a
crash in which you can be seriously
hurt or killed.
Use the helmet holder only while
parked. Do not ride with a helmet
secured by the holder.
(1) Holder hook
44
03/06/03 12:54:09 32MCB600_055
LEFT SIDE COVER
The left side cover must be removed for
fuse maintenance.
(2)
(3)
Removal:
1. Remove the seat (page 43 ).
2. Remove the three bolts ( 1 ).
3. Remove the seat lock cable ( 2 ) from the
seat lock ( 3 ).
4. Remove the left side cover ( 4 )
Installation:
Installation can be done in the reverse
order of removal.
(1)
(4)
(1)
(2)
(3)
(4)
Bolts
Seat lock cable
Seat lock
Left side cover
45
03/06/03 12:54:17 32MCB600_056
RIGHT SIDE COVER
The right side cover must be removed for
battery and fuse maintenance.
Removal:
1. Remove the seat (page 43 ).
2. Remove the three bolts ( 1 ).
3. Remove the right side cover (2 )
Installation:
Installation can be done in the reverse
order of removal.
(1)
(1) Bolts
(2) Right side cover
46
(2)
03/06/04 14:42:17 32MCB600_057
CENTER COMPARTMENT
The center compartment ( 1 ) is under the
seat. Opening and closing:
See ‘‘SEAT LOCK’’ (page 43 ).
MAXIMUM WEIGHT LIMIT:
2.0 kg (4.4 lbs)
DOCUMENT COMPARTMENT
The document bag ( 1 ) is in the document
compartment ( 2 ) under the seat.
When washing your motorcycle, be careful
not to flood this area with water.
(1)
Never exceed the maximum weight limit;
handling and stability may be severely
affected.
(2)
Do not direct water under pressure against
the center compartment as water will be
forced into the compartment.
(1)
(1) Center compartment
(1) Document bag
(2) Document compartment
47
03/06/03 12:54:26 32MCB600_058
HEA DL IGHT AIM VERTICAL
ADJUSTMENT
Vertical adjustment can be made by turning
the knob ( 1 ) in or out as necessary.
Obey local laws and regulations.
(B)
(A )
(1)
(1) Knob
48
(A) Up
(B) Down
03/06/03 12:54:33 32MCB600_059
OPERATION
PRE-RIDE INSPECTION
For your safety, it is very important to take
a few moments before each ride to walk
around your motorcycle and check its
condition. If you detect any problem, be
sure you take care of it, or have it corrected
by your Honda dealer.
1. Engine oil level− add engine oil if
required (page 29 ). Check for leaks.
2. Fuel level−fill fuel tank when necessary
(page 26 ). Check for leaks.
3. Coolant level−add coolant if required.
Check for leaks (pages 24 − 25 ).
4. Front and rear brakes−check operation;
make sure there is no brake fluid leakage
(pages 20 − 21 ).
Improperly maintaining this motorcycle
or failing to correct a problem before
riding can cause a crash in which you
can be seriously hurt or killed.
Always perform a pre-ride inspection
before every ride and correct any
problems.
49
03/06/03 12:54:40 32MCB600_060
5. Tyres−check condition and pressure
(pages 30 − 34 ).
6. Drive chain−check condition and slack
(page 81 − 86 ). Adjust and lubricate
if necessary.
7. Chain guide slider and slipper−check
slider wear (page 87 ).
8. Throttle−check for smooth opening and
full closing in all steering positions.
9. Lights and horn−check that headlight,
tail/brake light, turn signals, indicators
and horn function properly.
10. Engine stop switch−check for proper
function (page 40 ).
11. Side stand ignition cut-off system−check
for proper function (page 89 ).
50
03/06/03 12:54:46 32MCB600_061
STARTING THE ENGINE
Always follow the proper starting procedure
described below.
This motorcycle is equipped with a side
stand ignition cut-off system. The engine
cannot be started if the side stand is down,
unless the transmission is in neutral. If the
side stand is up, the engine can be started in
neutral or in gear with the clutch lever
pulled in. After starting with the side stand
down, the engine will shut off if the
transmission is put in gear before raising
the side stand.
Y our motorcycle’s exhaust contains
poisonous carbon monoxide gas. High
levels of carbon monoxide can collect
rapidly in enclosed areas such as a garage.
Do not run the engine with the garage door
closed. Even with the door open, run the
engine only long enough to move your
motorcycle out of the garage.
Do not use the electric starter for more than
5 seconds at a time. Release the starter
button for approximately 10 seconds before
pressing it again.
To protect the catalytic converters in your
motorcycle’s exhaust system, avoid
extending idling and the use of leaded
petrol.
51
03/06/03 12:54:57 32MCB600_062
Preparation
Before starting, insert the key, turn the
ignition switch ON and confirm the
following:
The transmission is in NEUTRAL
(neutral indicator light ON).
The engine stop switch is at
(RUN).
The red low oil pressure indicator is ON.
The immobilizer system (HISS) indicator
is OFF.
The low oil pressure indicator should go off
a few seconds after the engine starts. If the
light stays on, stop the engine immediately
and check the engine oil level.
Starting Procedure
To restart a warm engine, follow the
procedure for ‘‘High Air Temperature’’.
Normal Air Temperature
10°−35°C (50°−95°F)
1. Pull the choke lever ( 1 ) back all the way
to Fully ON (A ), if the engine is cold.
2. Start the engine, leaving the throttle
closed.
(1)
(B)
(A )
Operating the engine with insufficient oil
pressure can cause serious engine damage.
(1) Choke lever
52
(A) Fully ON
(B) Fully OFF
03/06/03 12:55:06 32MCB600_063
Do not open the throttle when starting the
engine with the choke ON. This will lean
the mixture, resulting in hard starting.
High Air Temperature
35°C (95°F) or above
1. Do not use the choke.
2. Open the throttle slightly.
3. Start the engine.
Operating the engine with insufficient oil
pressure can cause serious engine damage.
Low Air Temperature
10°C (50°F) or below
1. Follow steps 1 − 2 under ‘‘Normal Air
Temperature.’’
2. When engine speed begins to pick up,
operate the choke lever to keep fast idle
at:
2,000−3,000 min (rpm)
3. Continue warming up the engine until it
runs smoothly and responds to the
throttle when the choke lever ( 1 ) is at
Fully OFF ( B).
3. Immediately after the engine starts,
operate the choke lever ( 1 ) to keep fast
idle at:
2,000−3,000 min (rpm)
4. About a half minute after the engine
starts, push the choke lever ( 1 ) forward
all the way to Fully OFF (B ).
5. If idling is unstable, open the throttle
slightly.
Extended use of the choke may impair
piston and cylinder wall lubrication and
damage the engine.
53
03/06/03 12:55:10 32MCB600_064
Flooded Engine
If the engine fails to start after repeated
attempts, it may be flooded with excess fuel.
To clear a flooded engine, leave the engine
stop switch on
(RUN) and push the
choke lever forward to Fully OFF (B ). Open
the throttle fully and crank the engine for 5
seconds. If the engine starts, quickly close
the throttle, then open it slightly if idling is
unstable. If the engine does not start, wait
10 seconds, then follow the Starting
Procedure.
54
RUNNING-IN
Help assure your motorcycle’s future
reliability and performance by paying extra
attention to how you ride during the first
500 km (300 miles).
During this period, avoid full-throttle starts
and rapid acceleration.
03/06/03 12:55:18 32MCB600_065
RIDING
Review Motorcycle Safety (pages 1 − 9 )
before you ride.
Make sure you understand the function of
the side stand mechanism. (See MAINTENANCE SCHEDULE on page 65 and
explanation for SIDE STAND on page 89 ).
4. When the motorcycle attains a moderate
speed, close the throttle, pull in the clutch
lever and shift to 2nd gear by raising the
gearshift pedal.
This sequence is repeated to progressively shift to 3rd, 4th and 5th (top) gears.
1. After the engine has been warmed up,
the motorcycle is ready for riding.
2. While the engine is idling, pull in the
clutch lever and depress the gearshift
pedal to shift into 1st (low) gear.
3. Slowly release the clutch lever and at the
same time gradually increase engine
speed by opening the throt tle.
Coordination of the throttle and clutch
lever will assure a smooth positive start.
55
03/06/03 12:55:24 32MCB600_066
5. Raise the pedal to shift to a higher gear
and depress the pedal to shift to a lower
gear. Each stroke of the pedal engages
the next gear in sequence. The pedal
automatically returns to the horizontal
position when released.
56
Do not downshift when traveling at a
speed that would force the engine to
overrev in the next lower gear; the rear
wheel may lose traction, resulting in a
possible loss of vehicle control.
Do not shift gears without disengaging
the clutch and closing the throttle. The
engine and drive train could be damaged
by overspeed and shock.
Do not tow the motorcycle or coast for
long distances while the engine is off.
The transmission will not be properly
lubricated and damage may result.
Do not run the engine at high rpm with
the transmission in neutral or the clutch
lever pulled in. Serious engine damage
may result.
03/06/03 12:55:31 32MCB600_067
BRAKING
For normal braking, gradually apply both
the f ront and rear brakes while
downshifting to suit your road speed.
For maximum deceleration, close the
throttle and apply the front and rear brakes
firmly. Pull in the clutch lever before
coming to a complete stop to prevent
stalling the engine.
Important Safety Reminders:
Independent operation of only the brake
lever or brake pedal reduces stopping
performance.
Extreme application of the brake controls
may cause wheel lock, reducing control of
the motorcycle.
When possible, reduce speed or brake
before entering a turn; closing the
throttle or braking in mid-turn may cause
wheel slip. Wheel slip will reduce control
of the motorcycle.
When riding in wet or rainy conditions, or
on loose surfaces, the ability to maneuver
and stop will be reduced. All of your
actions should be smooth under these
conditions. Rapid acceleration, braking or
turning may cause loss of control. For
your safety, exercise extreme caution
when braking, accelerating or turning.
When descending a long, steep grade,
use engine compression braking by downshifting, with intermittent use of both
brakes.
Continuous brake application can
overheat the brakes and reduce their
effectiveness.
Riding with your foot resting on the
brake pedal or your hand on the brake
lever may actuate the brakelight, giving a
false indication to other drivers. It may
also overheat the brakes, reducing
effectiveness.
57
03/06/03 12:55:36 32MCB600_068
PARKING
1. After stopping the motorcycle, shift the
transmission into neutral, turn the
handlebar fully to the left, turn the
ignition switch OFF and remove the key.
2. Use the side stand to support the
motorcycle while parked.
Park the motorcycle on firm, level ground to
prevent it from falling over.
If you must park on a slight incline, aim the
front of the motorcycle uphill to reduce the
possibility of rolling off the side stand or
overturning.
3. Lock the steering to help prevent theft
(page 42 ).
58
Make sure flammable materials such as dry
grass or leaves do not come in contact with
the exhaust system when parking your
motorcycle.
03/06/03 12:55:40 32MCB600_069
ANTI-THEFT TIPS
1. Always lock the steering and never leave
the key in the ignition switch. This
sounds simple but people do forget.
2. Be sure the registration information for
your motorcycle is accurate and current.
3. Park your motorcycle in a locked garage
whenever possible.
4. Use an additional anti-theft device of
good quality.
5. Put your name, address, and phone
number in this Owner’s Manual and keep
it on your motorcycles at all times.
Many times stolen motorcycles are
identified by information in the Owner’s
Manuals that are still with them.
NAME:
ADDRESS:
PHONE NO:
59
03/06/03 12:55:47 32MCB600_070
MAINTENANCE
THE IMPORTANCE OF
MAINTENANCE
A well-maintained motorcycle is essential
for safe, economical and trouble-free riding.
It will also help reduce air pollution.
Because this motorcycle is capable of being
ridden over rough off-road terrain as well as
on pavement, careful pre-ride inspections
and good maintenance are especially
important.
To help you properly care for your
motorcycle, the following pages include a
Maintenance Schedule and a Maintenance
R ecord f or regularly scheduled
maintenance.
These instructions are based on the
assumption that the motorcycle will be used
exclusively for its designed purpose.
Sustained high speed operation or operation
in unusually wet or dusty conditions will
require more f requent service than
specified in the Maintenance Schedule.
Consult your Honda dealer f or
60
recommendations applicable to your
individual needs and use.
If your motorcycle overturns or becomes
involved in a crash, be sure your Honda
dealer inspects all major parts, even if you
are able to make some repairs.
Improperly maintaining this motorcycle
or failing to correct a problem before
you ride can cause a crash in which
you can be seriously hurt or killed.
Always follow the inspection and
maintenance recommendations and
schedules in this owner’s manual.
03/06/03 12:55:51 32MCB600_071
MAINTENANCE SAFETY
This section includes instructions on some
important maintenance tasks. You can
perform some of these tasks with the tools
provided − if you have basic mechanical
skills.
Other tasks that are more difficult and
require special tools are best performed by
professionals. Wheel removal should
normally be handled only by a Honda
technician or other qualified mechanic;
instructions are included in this manual only
to assist in emergency service.
Failure to properly follow maintenance
instructions and precautions can
cause you to be seriously hurt or killed.
Always follow the procedures and
precautions in this owner’s manual.
Some of the most important saf ety
precautions follow. However, we cannot
warn you of every conceivable hazard that
can arise in performing maintenance. Only
you can decide whether or not you should
perform a given task.
61
03/06/03 12:55:58 32MCB600_072
SAFETY PRECAUTIONS
Make sure the engine is off before you
begin any maintenance or repairs. This
will help eliminate several potential
hazards:
Carbon monoxide poisoning from
engine exhaust.
Be sure there is adequate ventilation
whenever you operate the engine.
Burns from hot parts.
Let the engine and exhaust system cool
before touching.
Injury from moving parts.
Do not run the engine unless instructed
to do so.
Read the instructions before you begin,
and make sure you have the tools and
skills required.
To help prevent the motorcycle from
falling over, park it on a firm, level
surface, using the side stand or a
maintenance stand to provide support.
62
To reduce the possibility of a fire or
explosion, be careful when working
around petrol. Use only nonflammable
solvent, not petrol, to clean parts. Keep
cigarettes, sparks and flames away from
all fuel-related parts.
Remember that your Honda dealer knows
your motorcycle best and is fully equipped
to maintain and repair it.
To ensure the best quality and reliability,
use only new genuine Honda parts or their
equivalents for repair and replacement.
03/06/03 12:56:06 32MCB600_073
MAINTENANCE SCHEDULE
Perform the Pre-ride Inspection (page 49 ) at each scheduled maintenance period.
I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY
C: CLEAN R: REPLACE A: ADJUST L: LUBRICATE
The following Maintenance Schedule specifies all maintenance required to keep your motorcycle in peak operating
condition. Maintenance work should be performed in accordance with standards and specifications of Honda by
properly trained and equipped technicians. Your Honda dealer meets all of these requirements.
Should be serviced by your Honda dealer, unless the owner has proper tools and service data and is mechanically
qualified. Refer to the Official Honda Shop Manual.
In the interest of safety, we recommend these items be serviced only by your Honda dealer.
Honda recommends that your Honda dealer should road test your motorcycle after each periodic maintenance is
carried out.
NOTES: (1)
(2)
(3)
(4)
At higher odometer readings, repeat at the frequency interval established here.
Service more frequently if the motorcycle is ridden in unusually wet or dusty areas.
Service more frequently when riding in rain or at full throttle.
Replace every 2 years, or at indicated odometer interval, whichever comes first. Replacement requires
mechanical skill.
(5) Service more frequently when riding OFF-ROAD.
63
03/06/03 12:56:23 32MCB600_074
FREQUENCY
ITEM
FUEL LINE
FUEL STRAINER SCREEN
THROTTLE OPERATION
CARBURETOR CHOKE
AIR CLEANER
CRANKCASE BREATHER
SPARK PLUG
VALVE CLEARANCE
ENGINE OIL
ENGINE OIL FILTER
CARBURETOR SYNCHRONIZATION
ENGINE IDLE SPEED
RADIATOR COOLANT
COOLING SYSTEM
SECONDARY AIR SUPPLY SYSTEM
64
WHICHEVER →
ODOMETER READING [NOTE (1)]
COMES
× 1,000 km 1
6 12 18 24 30 36
Refer
FIRST
× 1,000 mi 0.6 4
8 12 16 20 24
↓
to
NOTE
6 12 18 24 30 36
MONTH
Page
−
I
I
I
−
C C C C C C
I
I
I
78
−
I
I
I
NOTE (2)
−
R
R
NOTE (3)
C C C C C C
77
I
R
I
R
I
R
73
I
−
I
I
I
R
R
R
R
69
R
R
R
R
70
I
−
I
I
I
I
I
I
I
I
I
I
79
NOTE (4)
I
I
R
25
−
I
I
I
−
I
I
I
03/06/03 12:56:40 32MCB600_075
FREQUENCY
ITEM
DRIVE CHAIN
DRIVE CHAIN SLIDER
BRAKE FLUID
BRAKE PAD WEAR
BRAKE SYSTEM
BRAKE LIGHT SWITCH
HEADLIGHT AIM
CLUTCH SYSTEM
SIDE STAND
SUSPENSION
NUTS, BOLTS, FASTENERS
WHEELS/TYRES
STEERING HEAD BEARINGS
WHICHEVER →
ODOMETER READING ［ NOTE (1) ］
COMES
× 1,000 km 1
6 12 18 24 30 36
Refer
FIRST
× 1,000 mi 0.6 4 8 12 16 20 24
↓
to
MONTH
NOTE
6 12 18 24 30 36
Page
I, L EVERY 1,000 km (600 mi)
NOTE (5)
81
I
I
I
I
I
I
87
NOTE (4)
I
I
R
I
I
R
20
I
I
I
I
I
I
95
I
I
I
I
20 , 95
I
I
I
102
I
I
I
48
I
I
I
I
I
I
I
22
I
I
I
89
I
I
I
88
−
NOTE (5)
I
I
I
I
−
NOTE (5)
I
I
I
I
I
I
I
−
I
I
I
I
65
03/06/03 12:56:55 32MCB600_076
TOOL KIT
The tool kit ( 1 ) is under the seat (page 43 ).
Some roadside repairs, minor adjustments
and parts replacement can be performed
with the tools contained in the kit.
Spark plug wrench
10 × 12 mm Box end wrench
17 mm Box end wrench
24 mm Box end wrench
14 × 17 mm Open end wrench
10 × 12 mm Open end wrench
8 × 12 mm Open end wrench
No. 2 phillips screwdriver
No. 3 phillips screwdriver
No. 2 screwdriver
Screwdriver T-handle
Pliers
Extension bar
5 mm Hex wrench
Tool bag
66
(1)
(1) Tool kit
03/06/03 12:57:01 32MCB600_077
SERIAL NUMBERS
The frame and engine serial numbers are
required when registering your motorcycle.
They may also be required by your dealer
when ordering replacement parts.
Record the numbers here f or your
reference.
The frame number ( 1 ) is stamped on the
right side of the steering head.
FRAME NO.
ENGINE NO.
The engine number (2 ) is stamped on the
right side of the cylinder.
(2)
(1)
(1) Frame number
(2) Engine number
67
03/06/03 12:57:07 32MCB600_078
COLOUR LABEL
The colour label ( 1 ) is attached to the right
frame rail below the seat.
It is helpful when ordering replacement
parts. Record the colour and code here for
your reference.
COLOUR
CODE
(1)
(1) Colour label
68
03/06/03 12:57:14 32MCB600_079
ENGINE OIL
Refer to the Safety Precautions on page 62 .
Engine Oil
Good engine oil has many desirable
qualities. Use only high detergent, quality
motor oil certified on the container to meet
or exceed requirements for API Service
Classification SE, SF or SG.
Viscosity:
Viscosity grade of engine oil should be
based on average atmospheric temperature
in your riding area. The following provides a
guide to the selection of the proper grade or
viscosity of oil to be used at various
atmospheric temperatures.
(1) Single grade
(2) Multi grade
69
03/06/03 12:57:19 32MCB600_080
Engine Oil and Filter
Engine oil quality is the chief factor
affecting engine service life. Change the
engine oil as specified in the maintenance
schedule (page 64 ).
When running in very dusty conditions, oil
changes should be perf ormed more
f requently than specif ied in the
maintenance schedule.
Changing the oil filter requires a special oil
filter tool and a torque wrench. If you do not
have these tools and the necessary skill, we
recommend that you have your Honda
dealer perform this service.
Please dispose of used engine oil in a
manner that is compatible with the
environment. We suggest you take it in a
sealed container to your local recycling
center or service station for reclamation. Do
not throw it in the trash or pour it on the
ground or down a drain.
Change the engine oil with the engine at
normal operating temperature and the
motorcycle on its side stand to assure
complete and rapid draining.
Used engine oil may cause skin cancer if
repeatedly left in contact with the skin for
prolonged periods. Although this is unlikely
unless you handle used oil on a daily basis,
it is still advisable to thoroughly wash your
hands with soap and water as soon as possible after handling used oil.
70
If a torque wrench is not used for this
installation, see your Honda dealer as soon
as possible to verify proper assembly.
03/06/03 12:57:25 32MCB600_081
1. To drain the oil, remove the oil filler cap/
dipstick and crankcase drain plug ( 1 ) and
sealing washer ( 2 ).
2. Remove the oil filter ( 3 ) with a filter
wrench and let the remaining oil drain out.
Discard the oil filter.
(1)
(3)
(2)
(1) Crankcase drain plug
(2) Sealing washer
(3) Oil filter
71
03/06/03 12:57:35 32MCB600_082
3. Apply a thin coat of engine oil to the new
oil filter rubber seal (4 ).
4. Using a special tool and a torque wrench,
install the new oil filter and tighten to a
torque of:
9.8 N·m (1.0 kgf·m , 7 lbf·ft)
Use only the Honda genuine oil filter or a
filter of equivalent quality specified for your
model. Using the wrong Honda filter or a
non-Honda filter which is not of equivalent
quality may cause engine damage.
(4)
(4) Oil filter rubber seal
72
5. Check that the sealing washer on the
drain plug is in good condition and install
the plug. Replace the sealing washer
every other time the oil is changed, or
each time if necessary.
Oil Drain Plug Torque:
30 N·m (3.1 kgf·m , 22 lbf·ft)
6. Fill the crankcase with the recommended
grade oil; approximately:
2.3 (2.4 US qt , 2.0 Imp qt)
7. Install the oil filler cap/dipstick.
8. Start the engine and let it idle for 3−5
minutes.
9. 2−3 minutes after stopping the engine,
check that the oil level is at the upper
level mark on the oil filler cap/dipstick
with the motorcycle upright on firm, level
ground. Make sure there are no oil leaks.
03/06/03 12:57:44 32MCB600_083
SPARK PLUGS
Refer to the Safety Precautions on page 62 .
Recommended plugs:
Standard:
DPR8EA-9 (NGK) or
X24EPR-U9 (DENSO)
For extended high speed riding:
DPR9EA-9 (NGK) or
X27EPR-U9 (DENSO)
For cold climate: (Below 5°C, 41°F)
DPR7EA-9 (NGK) or
X22EPR-U9 (DENSO)
Never use a spark plug with an improper
heat range. Severe engine damage could
result.
73
03/06/03 12:57:50 32MCB600_084
1. Remove the seat (page 43 ).
2. Remove the left and right front cover
bolts ( 1 ),and disconnect them from the
holders on the fuel tank.
3. Remove the fuel tank mounting bolt ( 2 )
and the bushing.
(2)
(1)
(1)
74
(1) Bolts
(2) Fuel tank mounting bolt
03/06/03 12:57:55 32MCB600_085
4. To remove the spark plug from the rear
cylinder, raise the fuel tank.
Rear cylinder
(1)
5. Disconnect the spark plug caps from the
spark plugs.
6. Clean any dirt from around the spark plug
bases.
Remove the spark plugs using the spark
plug wrench ( 1 ) furnished in the tool kit.
Front cylinder
(1)
(1) Spark plug wrench
(1) Spark plug wrench
75
03/06/03 12:58:04 32MCB600_086
7. Inspect the electrodes and center
porcelain for deposits, erosion or carbon
fouling. If the erosion or deposit is heavy,
replace the plug. Clean a carbon or wetfouled plug with a plug cleaner, otherwise
use a wire brush.
8. Check the spark plug gap ( 2 ) using a
wire-type feeler gauge. If adjustment is
necessary, bend the side electrode ( 3 )
carefully.
The gap should be:
0.8−0.9 mm (0.03−0.04 in)
(3)
(2)
9. Make sure the plug washer is in good
condition.
10. With the plug washer attached, thread
the spark plug in by hand to prevent
cross-threading.
11. Tighten a new spark plug 1/2 turn with a
spark plug wrench to compress the
washer. If you are reusing a plug, it
should only take 1/8−1/4 turn after the
plug seats.
The spark plug must be securely tightened.
An improperly tightened plug can become
very hot and possibly damage the engine.
12. Reinstall the spark plug caps.
(2) Spark plug gap
(3) Side electrode
76
03/06/03 12:58:09 32MCB600_087
CRANKCASE BREATHER
Refer to the Safety Precautions on page 62 .
1. Remove the crankcase breather tube plug
( 1 ) from the tube and drain deposits into
a suitable container.
2. Reinstall the crankcase breather tube
plug.
Service more frequently when riding in rain,
at full throttle, or after the motorcycle is
washed or overturned. Service if the deposit
level can be seen in the transparent section
of the drain tube.
(1)
(1) Crankcase breather tube plug
77
03/06/03 12:58:16 32MCB600_088
THROTTLE OPERATION
Refer to the Safety Precautions on page 62 .
1. Check for smooth rotation of the throttle
grip from the fully open to the fully
closed position at both full steering
positions.
2. Measure the throttle grip free play at the
throttle grip flange.
The standard free play should be
approximately:
2.0−6.0 mm (0.08−0.24 in)
To adjust the free play, loosen the lock nut
( 1 ) and turn the adjuster ( 2 ).
(2)
(1) Lock nut
78
(1)
(2) Adjuster
03/06/03 12:58:23 32MCB600_089
IDLE SPEED
Refer to the Safety Precautions on page 62 .
(1)
The engine must be at normal operating
temperature for accurate idle speed
adjustment. Ten minutes of stop-and-go
riding is sufficient.
1. Warm up the engine, and shift to neutral,
and place the motorcycle on its side stand.
2. Adjust idle speed with the throttle stop
screw ( 1 ).
Idle speed (In neutral):
1,200 ± 100 min (rpm)
(A )
(B)
(1) Throttle stop screw
(A) Increase
(B) Decrease
79
03/06/03 12:58:28 32MCB600_090
COOLANT
Refer to the Safety Precautions on page 62 .
Coolant Replacement
Coolant should be replaced by a Honda
dealer, unless the owner has proper tools
and service data and is mechanically
qualified. Refer to an official Honda Shop
Manual.
Always add coolant to the reserve tank. Do
not attempt to add coolant by removing the
radiator cap.
80
Removing the radiator cap while the
engine is hot can cause the coolant to
spray out, seriously scalding you.
Always let the engine and radiator cool
down before removing the radiator cap.
03/06/03 12:58:40 32MCB600_091
DRIVE CHAIN
Refer to the Safety Precautions on page 62 .
The service life of the drive chain is
dependent upon proper lubrication and
adjustment. Poor maintenance can cause
premature wear or damage to the drive
chain and sprockets.
The drive chain should be checked and
lubricated as part of the Pre-ride Inspection
(page 49 ). Under severe usage, or when
the motorcycle is ridden in unusually dusty
or muddy areas, more f requent
maintenance will be necessary.
Inspection:
1. Turn the engine off, raise the rear wheel
off the ground by placing a support under
the engine, and shift the transmission
into neutral.
2. Check slack in the lower drive chain run
midway between the sprockets.
Drive chain slack should be adjusted to
allow the following vertical movement by
hand:
35−45 mm (1.4−1.8 in)
3. Roll the motorcycle forward. Stop. Check
the drive chain slack. Repeat this
procedure several times. Drive chain
slack should remain constant. If the chain
is slack only in certain sections, some
links are kinked and binding. Binding and
kinking can frequently be eliminated by
lubrication.
Excessive chain slack may allow the drive
chain to damage the engine cases.
(1)
(1) Drive chain
81
03/06/03 12:58:46 32MCB600_092
4. Rotate the rear wheel slowly and inspect
the drive chain and sprockets for any of
the following conditions:
DRIVE CHAIN
*Damaged Rollers
*Loose Pins
*Dry or Rusted Links
*Kinked or Binding Links
*Excessive Wear
*Improper Adjustment
*Damaged or Missing O-rings
SPROCKETS
*Excessively Worn Teeth
*Broken or Damaged Teeth
A drive chain with damaged rollers, loose
pins, or missing O-rings must be replaced. A
chain which appears dry, or shows signs of
rust, requires supplementary lubrication.
Kinked or binding links should be thoroughly lubricated and worked free. If links
cannot be freed, the chain must be replaced.
82
Damaged sprocket
Teeth
Worn sprocket
Teeth
Replace
Replace
Normal sprocket Teeth
GOOD
03/06/03 12:58:55 32MCB600_093
Adjustment:
Drive chain slack should be checked and
adjusted, if necessary, every 1,000 km (600
miles). When operated at sustained high
speeds or under conditions of frequent
rapid acceleration, the chain may require
more frequent adjustment.
(1)
(3)
(2)
(1) Axle nut
(2) Lock nuts
(3) Adjusting nut
(5)
If the drive chain requires adjustment, the
procedure is as follows:
1. Place the motorcycle on its side stand
with the transmission in neutral and the
ignition switch off.
2. Loosen the axle nut ( 1 ).
3. Loosen the lock nuts ( 2 ) on both right
and left swingarm.
4. Turn both adjusting nuts ( 3 ) an equal
number of turns until the correct drive
chain slack is obtained. Turn the
adjusting nuts clockwise to tighten the
chain, or counterclockwise to provide
more slack. Adjust the chain slack at a
point midway between the drive sprocket
and the rear wheel sprocket. Rotate the
rear wheel and recheck slack at other
sections of the chain.
Chain slack should be:
35−45 mm (1.4−1.8 in)
(4)
(4) Index mark
(5) Rear edge of
adjusting slot
83
03/06/03 12:59:00 32MCB600_094
5. Check rear axle alignment by making
sure the chain adjuster index marks ( 4 )
align with the rear edge ( 5 ) of the
adjusting slots.
Both left and right marks should
correspond. If the axle is misaligned, turn
the left or right adjusting nut until the
marks correspond on the rear edge of the
adjusting slots and recheck chain slack.
6. Tighten the axle nut to specified torque.
Axle nut torque:
88 N·m (9.0 kgf·m , 65 lbf·ft)
If a torque wrench is not used for this
installation, see your Honda dealer as soon
as possible to verify proper assembly.
7. Tighten the adjusting nuts lightly, then
tighten the lock nuts by holding the
adjusting nuts with a spanner.
84
03/06/03 12:59:08 32MCB600_095
Wear Inspection:
Check the chain wear label when adjusting
the chain. If the red zone ( 6 ) on the label
aligns with the arrow mark ( 7 ) on the chain
adjuster plates after the chain has been
adjusted to the proper slack, the chain is
excessively worn and must be replaced. The
proper slack is:
35−45 mm (1.4−1.8 in)
Damage to the bottom part of the frame
may be caused by excessive drive chain
slack of more than:
60 mm (2.4 in)
(6)
Replacement chain:
D.I.D. 525 112−120L
or
RK525S 112−120L
(7)
(6) Red zone
(7) Arrow mark
85
03/06/03 12:59:14 32MCB600_096
Lubrication and Cleaning:
Lubricate every 1,000 km (600 miles) or
sooner if chain appears dry.
The drive chain on this motorcycle is
equipped with small O-rings between the
link plates. These O-rings retain grease
inside the chain to improve its service life.
The O-rings in this chain can be damaged
by steam cleaning, high pressure washers,
and certain solvents. Clean the side surfaces
of the chain with a dry cloth. Do not brush
the rubber O-rings. Brushing will damage
them. Wipe dry and lubricate only with SAE
80 or 90 gear oil. Commercial chain lubricants may contain solvents which could
damage the rubber O-rings.
86
03/06/03 12:59:20 32MCB600_097
DRIVE CHAIN SLIDER
Refer to the Safety Precautions on page 62 .
(1)
Check the chain slider ( 1 ) for wear.
When the thickness ( 2 ) of the chain slider
reaches the limit, the chain slider must be
replaced. Chain slipper depth limit:
2.0 mm(0.08 in)
(2)
(1) Chain slider
(2) Thickness
87
03/06/03 12:59:24 32MCB600_098
FRONT A ND R EA R SUSPENSION
INSPECTION
Refer to the Safety Precautions on page 62 .
1. Check the fork assembly by locking the
front brake and pumping the fork up and
down vigorously. Suspension action
should be smooth and there must be no
oil leakage.
2. Swingarm bearings should be checked by
pushing hard against the side of the rear
wheel while the motorcycle is on the
center stand. Free play indicates worn
bearings.
3. Carefully inspect all front and rear
suspension fasteners for tightness.
88
03/06/03 12:59:33 32MCB600_099
SIDE STAND
Refer to the Safety Precautions on page 62 .
Perform the following maintenance in
accordance with the maintenance schedule.
Functional Check:
Check the spring ( 1 ) for damage or loss
of tension and the side stand assembly
for freedom of movement.
Check the side stand ignition cut-off
system:
1. Sit astride the motorcycle; put the side
stand up and the transmission in
neutral.
2. Start the engine and with the clutch
lever pulled in, shift the transmission
into gear.
3. Lower the side stand. The engine
should stop as you put the side stand
down.
If the side stand system does not operate as
described, see your Honda dealer for
service.
(1)
(1) Side stand spring
89
03/06/03 12:59:41 32MCB600_100
WHEEL REMOVAL
Refer to the Safety Precautions on page 62 .
(1)
This motorcycle is equipped with a side
stand only. Therefore, if front or rear wheel
removal is required, it will be necessary to
raise the center of the motorcycle with a
jack or other firm support. If none is
available, see your Honda dealer for this
service.
(2)
Front Wheel Removal
1. Raise the front wheel off the ground by
placing a support block under the engine.
2. Remove the speedometer cable set screw
( 1 ) and disconnect the speedometer
cable ( 2 ).
(1) Screw
(2) Speedometer cable
90
03/06/03 12:59:48 32MCB600_101
3. Remove the caliper assembly from the
fork leg by removing the fixing bolts ( 6 ).
4. Remove the front axle holder nuts ( 3 )
and frontal axle holder ( 4 ).
To avoid damage to the brake hose, support
the caliper assembly so that it doesn’t hang
from the hose. Do not twist the brake hose.
(4)
(6)
Do not depress the brake lever when the
caliper assembly is removed. The caliper
piston will be forced out of the cylinder with
subsequent loss of brake fluid. If this occurs,
servicing of the brake system will be
necessary. See your Honda dealer for this
service.
5. Unscrew the front axle shaft ( 5 ).
Remove the wheel.
(3)
(6)
(5)
(3) Axle holder nuts
(4) Axle holder
(5) Front axle shaft
(6) Fixing bolts
91
03/06/03 12:59:59 32MCB600_102
Installation:
1. Reverse the removal procedure.
Insert the axle through the left fork leg
and wheel hub.
2. Make sure that leg lug ( 7 ) on the
speedometer gearbox is located behind
the lug ( 8 ) on the right front fork ( 9 ) leg.
3. Install the axle holder with the UP mark
(10 ) upward and approach the upper
holder nuts first, then the lower holder
nuts.
4. Tighten the front axle shaft to the
specified torque.
Front axle shaft torque :
64 N·m (6.5 kgf·m , 47 lbf·ft)
5. Tighten the axle holder nut to the
specified torque :
12 N·m (1.2 kgf·m , 9 lbf·ft)
Install the brake caliper and tighten to the
specified torque:
33 N·m (3.4 kgf·m , 25 lbf·ft)
6. After installing the wheel, apply the brake
several times and then check if the wheel
rotate freely. Recheck the wheel if the
brake drags or if the wheel does not
rotate freely.
92
If a torque wrench was not used for
installation, see your Honda dealer as soon
as possible to verify proper assembly.
Improper assembly may lead to loss of
braking capacity.
(8)
(7)
(10)
(9)
(7) Leg lug
(8) Lug
(9) Right front fork
(10) UP mark
03/06/03 13:00:09 32MCB600_103
Rear Wheel Removal
1. Raise the rear wheel off the ground by
placing a support block under the engine.
2. Loosen the drive chain adjusting nut lock
nuts ( 1 ) and adjusting nuts ( 2 ).
3. Remove the rear axle nut ( 3 ).
4. Remove the drive chain ( 4 ) from the
driven sprocket by pushing the rear
wheel forward.
5. Remove the rear axle shaft ( 5 ), rear
wheel from the swingarm.
Do not depress the brake pedal while the
wheel is off the motorcycle. The caliper
pistons will be forced out of the cylinders
with subsequent loss of brake fluid. If this
occurs, servicing of the brake system will be
necessary. See your Honda dealer for this
service.
(2)
(1)
(1)
(3)
(5)
(2)
(1) Lock nut
(2) Adjusting nuts
(3) Axle nut
(4)
(4) Drive chain
(5) Rear axle shaft
93
03/06/03 13:00:18 32MCB600_104
Installation Notes:
1. To install the rear wheel, reverse the
removal procedure.
2. Make sure the tang ( 6 ) on the swingarm
is located in the slot ( 7 ) in the brake
panel ( 8 ).
3. Install the rear axle shaft, side collar and
rear wheel to the swingarm.
4. Tighten the axle nut to the specified
torque:
88 N·m (9.0 kgf·m , 65 lbf·ft)
5. Adjust the drive chain.
If a torque wrench was not used for
installation, see your Honda dealer as soon
as possible to verify proper assembly.
Improper assembly may lead to loss of
braking capacity.
(8)
(6)
When installing the wheel, carefully fit the
brake disc between the brake pads to avoid
damaging the pads.
After installing the wheel, apply the brake
several times and then check if the wheel
rotates freely. Recheck the wheel if the
brake drags or if the wheel does not rotate
freely.
94
(7)
(6) Tang
(7) Slot
(8) Brake panel
03/06/03 13:00:24 32MCB600_105
BRAKE PAD WEAR
Refer to the Safety Precautions on page 62 .
Brake pad wear depends upon the severity
of usage, the type of riding, and road
conditions. (Generally, the pads will wear
faster on wet and dirty roads.)
Inspect t he pa ds a t each r egular
maintenance interval (page 65 ).
〈FRONT BRAKE〉
Illustration shows left side,
right side similar.
Front Brake
Always inspect each pad in both right and
left brake calipers.
Check the grooves ( 1 ) in each pad.
If either pad is worn to the bottom of the
grooves, replace both pads as a set. See
your Honda dealer for this service.
(1)
(1) Wear indicator grooves
95
03/06/03 13:00:29 32MCB600_106
Rear Brake
Check the cutout ( 2 ) in each pad.
If either pad is worn to the cutout, replace
both pads as a set. See your Honda dealer
for this service.
〈REAR BRAKE〉
(2)
(2) Cutouts
96
03/06/03 13:00:34 32MCB600_107
BATTERY
Refer to the Safety Precautions on page 62 .
It is not necessary to check the battery
electrolyte level or add distilled water as the
battery is a maintenance-free (sealed) type.
If your battery seems weak and/or is
leaking electrolyte (causing hard starting or
other electrical troubles), contact your
Honda dealer.
Your battery is a maintenance-free type and
can be permanently damaged if the cap strip
is removed.
The battery gives off explosive
hydrogen gas during normal operation.
A spark or flame can cause the battery
to explode with enough force to kill or
seriously hurt you.
Wear protective clothing and a face
shield, or have a skilled mechanic do
the battery maintenance.
97
03/06/03 13:00:41 32MCB600_108
Battery Removal
1. Remove the right side cover (page 46 ).
2. Remove the battery holder ( 1 ) by
removing the nut (2 ).
3. Disconnect the negative (−) terminal
lead ( 3 ) from the battery first, then
disconnect the positive (＋) terminal lead
( 4 ).
4. Pull out the battery ( 5 ) from the battery
box.
(4)
(2)
(3)
(1)
(5)
(1)
(2)
(3)
(4)
(5)
98
Battery holder
Nut
Negative (−) terminal lead
Positive (＋) terminal lead
Battery
03/06/03 13:00:48 32MCB600_109
FUSE REPLACEMENT
Refer to the Safety Precautions on page 62 .
When frequent fuse failure occurs, it
usually indicates a short circuit or an
overload in the electrical system. See your
Honda dealer for repair.
Blown fuse
Never use a fuse with a different rating
from that specified. Serious damage to the
electrical system or a fire may result,
causing a dangerous loss of lights or engine
power.
99
03/06/03 13:00:56 32MCB600_110
Fuse Box:
The fuse box is located behind the left side
cover.
The specified fuses are:
10, 15 A
1. Remove the left side cover (page 45 ).
2. Open the fuse box cover ( 1 ).
3. Pull out the old fuse and install a new fuse.
The spare fuses ( 2 ) are located in the
fuse box.
4. Close the fuse box cover and left side
cover.
(1)
(2)
(1) Fuse box cover
(2) Spare fuses
100
03/06/04 11:41:15 32MCB600_111
Main Fuse:
The main fuse ( 1) is located behind the
right side cover.
The specified fuse is:
30 A
1. Remove the right side cover (page 46 ).
2. Disconnect the wire connector ( 2 ) of
the starter magnetic switch.
3. Pull out the old fuse and install a new fuse.
The spare main fuse ( 3 ) is located under
the starter magnetic switch.
4. Reconnect the connector and right side
cover.
(2)
(3)
(1)
(1) Main fuse
(2) Wire connector
(3) Spare main fuse
101
03/06/03 13:01:10 32MCB600_112
STOPLIGHT SWITCH
ADJUSTMENT
Refer to the Safety Precautions on page 62 .
Check the operation of the stoplight switch
( 1 ) at the right side behind the engine from
time to time.
Adjustment is done by turning the adjusting
nut ( 2 ). Turn the nut in the direction (A ) if
the switch operates too late and in direction
( B) if the switch operates too soon.
(1)
(B)
(2)
(1) Stoplight switch
(2) Adjusting nut
102
(A )
03/06/03 13:01:19 32MCB600_113
BULB REPLACEMENT
Refer to the Safety Precautions on page 62 .
The light bulb becomes very hot while the
light is ON, and remain hot for a while after
it is turned OFF. Be sure to let it cool down
before servicing.
The lighting equipment is not legal for
highway use. Do not operate this
motorcycle on public streets, roads or
highways.
Be sure to turn the ignition switch OFF
when replacing the bulb.
Do not use bulbs other than that specified.
After installing a new bulb, check that the
light operates properly.
Do not put finger prints on the headlight
bulb, as they may create hot spots on the
bulb and cause it to break.
Wear clean gloves while replacing the bulb.
If you touch the bulb with your bare hands,
clean it with a cloth moistened with alcohol
to prevent its early failure.
103
03/06/03 13:01:30 32MCB600_114
Headlight Bulb
1. Remove the headlight lower cover ( 1 ) by
loosening the two fixing bolts..
2. Pull off the socket ( 2 ) without turning.
3. Remove the dust cover ( 3 ).
4. Remove the bulb ( 5 ) while pressing
down on the pin ( 4 ).
5. Pull out the bulb ( 5 ) without turning.
6. Install a new bulb in the reverse order of
removal.
Install the dust cover with its arrow
mark ( 6 ) facing up.
(4)
(6)
(5)
(3)
(1)
104
(1)
(2)
(3)
(4)
(5)
(6)
Headlight lower cover
Socket
Dust cover
Pin
Bulb
Arrow mark
(2)
03/06/03 13:01:39 32MCB600_115
Position Light Bulb
1. Remove the lower maintenance cover ( 1 )
by removing the two screws ( 2 ).
2. Pull the position light socket ( 3 ) and
remove it.
3. Pull out the bulb ( 4 ) without turning.
4. Install a new bulb in the reverse order of
removal.
(1)
(4)
(3)
(1)
(2)
(1) Lower maintenance cover
(2) Screws
(2)
(3) Socket
(4) Bulb
105
03/06/03 13:01:46 32MCB600_116
Stop/Taillight Bulb
1. Remove the rear handle ( 1 ) by removing
the four screws ( 2 ) and collars A ( 3 ),
collars B ( 4 ).
2. Remove the rear tail ( 5 ).
3. Turn the bulb holder ( 6 ) clockwise and
remove the bulb ( 7 ).
4. Install a new bulb in the reverse order of
removal.
(2)
(5)
(2)
(4)
(2)
(4)
(3)
(4)
(3)
(1)
(7)
(1)
(2)
(3)
(4)
106
(6)
Rear handle
Screws
Collars A
Collars B
(5) Rear tail
(6) Bulb holder
(7) Bulb
03/06/03 13:01:54 32MCB600_117
Front Turn Signal Bulb
1. Remove the instrument panel cover by
removing the screws A ( 1 ) and the
screws B ( 2 ).
2. T u r n t h e b u l b h o l d e r ( 3 )
counterclockwise and remove the bulb
( 4 ).
3. Install a new bulb in the reverse order of
removal.
(2)
(4)
(2)
(3)
(1)
(1)
(2)
(1) Screws A
(2) Screws B
(3) Bulb holder
(4) Bulb
107
03/06/03 13:02:00 32MCB600_118
Rear Turn Signal Bulb
1. Remove the screw ( 1 ).
2. Remove the turn signal lens ( 2 ).
3. Remove the bulb ( 3 ) by pressing in and
turning counterclockwise.
4. Install a new bulb and check that the light
operates properly.
(3)
(1)
(2)
(1) Screws
(2) Turn signal lens
108
(3) Bulb
03/06/04 11:41:25 32MCB600_119
CLEANING
Clean your motorcycle regularly to protect
the surface finishes and inspect for damage,
wear, and oil, coolant or brake fluid leakage.
Avoid cleaning products that are not
specifically designed for motorcycle or
automobile surfaces.
They may contain harsh detergents or
chemical solvents that could damage the
metal, paint, and plastic on your motorcycle.
If your motorcycle is still warm from recent
operation, give the engine and exhaust
system time to cool off.
We recommend avoiding the use of high
pressure water spray (typical in coinoperated car washes).
High pressure water (or air) can damage
certain parts of the motorcycle.
Washing the motorcycle
1. Rinse the motorcycle thoroughly with
cool water to remove loose dirt.
2. Clean the motorcycle with a sponge or
soft cloth using cool water.
Avoid directing water to muffler outlets
and electrical parts.
3. Clean the fairing, headlight lens and
other plastic parts using a cloth or sponge
dampened with a solution of mild
detergent and water. Rub the soiled area
gently rinsing it frequently with fresh
water.
Take care to keep brake fluid or chemical
solvents off the motorcycle.
They will damage the plastic and painted
surfaces.
The inside of the headlight lens may be
clouded immediately after washing the
motorcycle. Moisture condensation inside
the headlight lens will disappear gradually
by lighting the headlight in high beam. Run
the engine while keeping the headlight on.
109
03/06/04 11:41:33 32MCB600_120
4. After cleaning, rinse the motorcycle
thoroughly with plenty of clean water.
Strong detergent residue can corrode
alloy parts.
5. Dry the motorcycle, start the engine, and
let it run for several minutes.
6. Test the brakes before riding the
motorcycle. Several applications may be
necessary to restore normal braking
performance.
7. Lubricate the drive chain immediately
after washing and drying the motorcycle.
Braking efficiency may be temporarily
impaired immediately after washing the
motorcycle.
Anticipate longer stopping distance to avoid
a possible accident.
110
Finishing Touches
After washing your motorcycle, consider
using a comme r cia lly-a v a ilable spr a y
cleaner/polish or quality liquid or paste wax
to finish the job. Use only a non-abrasive
polish or wax made specifically for
motorcycles or automobiles. Apply the
polish or wax according to the instructions
on the container.
If a surface on your motorcycle is chipped
or scratched, your Honda dealer has touchup paint to match your motorcycle’s colour.
Be sure to use your motorcycle’s colour
code (page 68 ) when you buy touch-up
paint.
03/06/04 11:41:42 32MCB600_121
Removing Road Salt
The salt contained in the road surface
freezing prevention medicine which a road
was sprayed with in winter, and the
seawater becomes the cause which rust
occurs in.
Wash your motorcycle by the following
point after it runs through such a place.
Clean The Windshield
Using plenty of water, clean the windshield
with a soft cloth or sponge. (Avoid using
detergents or any kind of chemical cleaner
on the windshield.) Dry with a soft, clean
cloth.
1. Clean the motorcycle using cool water
(page 119 ).
To avoid possible scratching or other
damage, use only water and a soft cloth or
sponge to clean the windshield.
Do not use warm water.
This worsens the effect of the salt.
2. Dry the motorcycle and the surface of the
metal is protected with the wax.
For a dirtier windshield, use a diluted
neutral detergent with a sponge and plenty
of water. Make sure to wash off all the
detergent. (Detergent residue may cause
windshield cracks.)
Replace the windshield if scratches cannot
be removed and they obstruct clear vision.
Take care to keep battery electrolyte, brake
fluid or other chemical solvents off the
windshield and screen garnish. They will
damage the plastic.
111
03/06/03 13:02:26 32MCB600_122
STORAGE GUIDE
Extended storage, such as for winter,
requires that you take certain steps to
reduce the effects of deterioration from
non-use of the motorcycle. In addition,
necessary repairs should be made BEFORE
storing the motorcycle; otherwise, these
repairs may be forgotten by the time the
motorcycle is removed from storage.
STORAGE
1. Change the engine oil and filter.
2. Make sure the cooling system is filled
with a 50/50 % antifreeze solution.
3. Empty the fuel tank into an approved
petrol container using a commercially
available hand siphon or an equivalent
method. Spray the inside of the tank with
an aerosol rust-inhibiting oil.
Reinstall the fuel fill cap on the tank.
If storage will last more than one month,
carburetor draining is very important, to
assure proper performance after storage.
112
Petrol is highly flammable and
explosive. You can be burned or
seriously injured when handling fuel.
Stop the engine and keep heat,
sparks, and flame away.
Refuel only outdoors.
Wipe up spills immediately.
03/06/03 13:02:33 32MCB600_123
4. To prevent rusting in the cylinder,
perform the following:
Remove the spark plug cap from the
spark plug. Using tape or string, secure
the cap to any convenient plastic body
part so that it is positioned away from
the spark plug.
Remove the spark plug from the
engine and store it in a safe place. Do
not connect the spark plug to the spark
plug cap.
Pour a tablespoon (15−20 cm ) of
clean engine oil into the cylinder and
cover the spark plug hole with a piece
of cloth.
Crank the engine several times to
distribute the oil.
Reinstall the spark plug and spark plug
cap.
5. Remove the battery. Store in an area
protected from freezing temperatures
and direct sunlight.
Slow charge the battery once a month.
6. Wash and dry the motorcycle. Wax all
painted surfaces. Coat chrome with
rustinhibiting oil.
7. Lubricate the drive chain (page 86 ).
8. Inflate the tyres to their recommended
pressures. Place the motorcycle on blocks
to raise both tyres off the ground.
9. Cover the motorcycle (don’t use plastic or
other coated materials) and store in an
unheated area, free of dampness with a
minimum of daily temperature variation.
Do not store the motorcycle in direct
sunlight.
113
03/06/03 13:02:38 32MCB600_124
REMOVAL FROM STORAGE
1. Uncover and clean the motorcycle.
Change the engine oil if more than 4
months have passed since the start of
storage.
2. Charge the battery as required. Install the
battery.
3. Drain any excess aerosol rust-inhibiting
oil from the fuel tank. Fill the fuel tank
with fresh petrol.
4. Perform all Pre-ride Inspection checks
(page 49 ).
Test ride the motorcycle at low speeds in
a safe riding area away from traffic.
114
03/06/03 13:02:49 32MCB600_125
SPECIFICATIONS
DIMENSIONS
Overall length
Overall width
Overall height
Wheelbase
2,257 mm (88.9 in)
922 mm (36.3 in)
1,318 mm (51.9 in)
1,501 mm (59.1 in)
WEIGHT
Dry weight
192 kg (423 lbs)
CAPACITIES
Engine oil
After draining:
After draining and oil filter change:
After disassembly:
Fuel tank
Fuel reserve tank
Cooling system capacity
Passenger capacity
Maximum weight capacity
2.1 (2.2 US qt , 1.8 Imp qt)
2.3 (2.4 US qt , 2.0 Imp qt)
2.9 (3.1 US qt , 2.6 Imp qt)
19.6 (5.18 US gal , 4.31 Imp gal)
3.8 (1.00 US gal , 0.84 Imp gal)
2.0 (2.1 US qt , 1.8 Imp qt)
Operator and one passenger
180 kg (396 lbs)
115
03/06/03 13:02:58 32MCB600_126
ENGINE
Bore and stroke
Compression ratio
Displacement
Spark plug
Standard
For extended high speed riding
For cold climate: (Below 5°C, 41°F)
Spark plug gap
Valve clearance
Idle speed
116
Intake:
Exhaust:
79.0 × 66.0 mm (3.11 × 2.60 in)
9.2 : 1
647 cm (39.5 cu-in)
DPR8EA-9 (NGK) or
X24EPR-U9 (DENSO)
DPR9EA-9 (NGK) or
X27EPR-U9 (DENSO)
DPR7EA-9 (NGK) or
X22EPR-U9 (DENSO)
0.8−0.9 mm (0.03−0.04 in)
0.15 mm (0.006 in)
0.20 mm (0.008 in)
1,200 ± 100 min (rpm)
03/06/03 13:03:06 32MCB600_127
CHASSIS AND SUSPENSION
Caster
Trail
Tyre size:
front
rear
28°04’
120 mm (4.7 in)
90/90−21M/C 54S
120/90−17M/C 64S
POWER TRANSMISSION
Primary reduction
Final reduction
Gear ratio, 1st
2nd
3rd
4th
5th
1.763
3.200
2.500
1.722
1.333
1.111
0.961
117
03/06/03 13:03:15 32MCB600_128
ELECTRICAL
Alternator
12V−10Ah
0.368 kW/5,000 min (rpm)
LIGHTS
Headlight
Stop/Taillight
Speedometer light
High beam indicator
Turn signal indicator
Turn signal light
Neutral indicator
12V 60/55W
12V 21/5W
12V 1.7W
12V 1.7W
12V 3.4W
12V 21W × 2
12V 3.4W
FUSE
Main fuse
Other fuses
30 A
10, 15 A
118
03/06/03 13:03:21 32MCB600_129
CATALYTIC CONVERTERS
This motorcycle is equipped with catalytic
converters.
Each catalytic converter contains precious
metals that serve as catalysts, promoting
chemical reactions to convert the exhaust
gasses without affecting the metals.
The catalytic converters act on HC, CO, and
NOx. Replacement parts must be original
Honda parts or equivalents.
The catalytic converters must operate at a
high temperature for the chemical reactions
to take place. They can set on fire any
combustible materials that come near them.
Park your motorcycle away from high
grasses, dry leaves, or other flammables.
Defective catalytic converters contributes to
air pollution, and can impair your engine’s
performance. Follow these guidelines to
prot ect your motorcycle’s cat alyt ic
converters.
Always use unleaded petrol. Even a small
amount of leaded petrol can contaminate
the catalyst metals, making the catalytic
converters ineffective.
Keep the engine tuned-up.
Have your motorcycle diagnosed and
replaced if it is misfiring, backfiring,
stalling or otherwise not running properly.
119

XL 650 V Transalp — модель мотоцикла марки Honda

Модель эндуро-туристического мотоцикла Honda XL 650 V Transalp выпускалась с 2000 по 2007 гг. и заменила собой прошлое поколение «Трансальпа» — Honda XL600V Transalp. В отличие от предшественника, новая модель имела более современный внешний вид, новую приборную панель, новую выхлопную систему, 2-х дисковые передние тормоза, более мощный двигатель и менее внедорожные подвески.

Главной особенностью Honda XL650V Transalp является 2-цилиндровый V-образный 6-клапанный двигатель жидкостного охлаждения, выдающий 53 л.с. мощности и 55 Нм крутящего момента. Как и предыдущие поколения мотоцикла, мотор 650-кубового «Трансальпа» настроен на ровную тягу с низких и средних оборотов, показывая максимальные характеристики на 5500-7500 об/мин. Данный мотор не стал новой разработкой, а перекочевал с модели Honda Bros 650 и ставился также на турист Honda NT 650 Deauville.

Из других особенностей Honda XL650V Transalp следует выделить классическую стальную раму, 5-ступенчатую КПП, двухдисковый передний тормоз, цепной привод, простые подвески в виде обычной телескопической вилки и моноамортизатора, 191 кг сухой массы.

Модельный ряд серии Honda Transalp:

Honda XL400V Transalp

Honda XL600V Transalp

Honda XL650V Transalp

Honda XL700V Transalp

Рассматривая все поколения «Трансальпов», следует выделить, что из года в год новые версии Honda Transalp теряли часть своих оффроадных возможностей и делали все больший уклон в сторону дорожного использования.

Основные конкуренты Honda XL650V Transalp в классе:

Kawasaki KLE 500

Suzuki XF650 Freewind

Yamaha XTZ660 Tenere

Краткая история модели:

2000 г. — начало производства и продаж модели Honda XL650V Transalp.

2007 г. — последний год выпуска модели. С 2008 года Transalp 650 заменяется на Honda XL700V Transalp

Технические характеристики:

Модель Honda XL650V Transalp

Тип мотоцикла туристический эндуро

Год выпуска 2000-2007 гг.

Тип двигателя 2-цилиндровый, 4-тактный, V-twin, SOHC

Рабочий объем 647 куб. см.

Степень сжатия 9,2:1

Охлаждение жидкостное

Диаметр цилиндра / ход поршня 79 x 66 мм

Количество клапанов на цилиндр 3 клапана на цилиндр

Система подачи топлива карбюратор, 2х Keihin CV 34 mm

Тип зажигания цифровое транзисторное

Максимальная мощность 53 л.с. при 7500 об/мин

Максимальный крутящий момент 55 Нм при 5500 об/мин

Коробка передач 5-ступенчатая

Тип привода цепь

Рама стальная

Передняя подвеска 41 мм телескопическая вилка, ход — 200 мм

Задняя подвеска маятниковая с моноамортизатором Pro-Link (регулировка отбоя), ход — 175 мм

Размер передней шины 90/90-21

Размер задней шины 120/90-17

Передние тормоза 2 диска, 256 мм, 2-поршневой суппорт

Задние тормоза 1 диск, 240 мм, 1-поршневой суппорт

Максимальная скорость 170 км/ч

Габаритные размеры (ДхШхВ) 2260 x 920 x 1315 мм

Высота по седлу 843 мм

Емкость бензобака 19 л

Масса мотоцикла 191 кг — сухая

212 кг — снаряженная

Расход топлива

Официально заявленный расход топлива на Honda XL650V Transalp составляет 5,2 л на 100 км пути.

Мануал

Руководство пользователя (Owners Manual) Honda XL650V Transalp (на русском)

Сервисный мануал (Service Manual) Honda XL650V Transalp (на русском)

Руководство по ремонту (Haynes Service Manual) Honda XL600V/XL650V Transalp и Honda XRV750 Africa Twin (на русском)

Руководство пользователя (Owners Manual) Honda XL600V Transalp