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Manuals and User Guides for Honda VTR250. We have 3 Honda VTR250 manuals available for free PDF download: Workshop Manual, Owner’s Manual

• Page 1
  09/01/30 17:37:31 32KFK600_001 Honda VTR250 OWNER’S MANUAL USO E MANUTENZIONE MANUAL DEL PROPIETARIO Honda Motor Co., Ltd. 2009…
• Page 2
  09/01/30 17:37:36 32KFK600_002 IMPORTANT INFORMATION OPERATOR AND PASSENGER (For ED, F type) 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. (For U type) This motorcycle is designed to carry the operator and one passenger.
• Page 3
  OWNER’S MANUAL All information in this publication is based on the latest production information available at the time of approval for printing. Honda Motor Co.,Ltd. reserves the right to make changes at any time without notice and without incurring any obligation.
• Page 4
  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 Shop Manual to help you perform many maintenance and repair tasks.
• Page 5
  09/01/30 17:37:50 32KFK600_005 The following codes in this manual indicate each country. The illustrations herein are based on the type. France European direct sales Australia New Zealand The specifications may vary with each locale.
• Page 6
  09/01/30 17:37:53 32KFK600_006 A FEW WORDS ABOUT SAFETY Your safety, and the safety of others, is very important. And operating this motorcycle safely is an important responsibility. To help you make informed decisions about safety, we have provided operating procedures and other information on labels and in this manual.
• Page 7
  09/01/30 17:37:58 32KFK600_007 You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be HURT if you don’t follow instructions. Safety Headings –– such as Important Safety Reminders or Important Safety Precautions. Safety Section ––…
• Page 8
  09/01/30 17:38:09 32KFK600_008 OPERATION page page MOTORCYCLE SAFETY ESSENTIAL INDIVIDUAL IMPOR T A NT SA F ET Y COMPONENTS INFORMATION IGNITION SWITCH PROTECTIVE APPAREL KEYS LOAD LIMITS AND GUIDELINES RIGHT HANDLEBAR CONTROLS LEFT HANDLEBAR CONTROLS PARTS LOCATION INSTRUMENTS AND INDICATORS MAJOR COMPONENTS (Information you need to operate this motorcycle)
• Page 9
  09/01/30 17:38:19 32KFK600_009 page page FEATURES OPERATION (Not required for operation) PRE-RIDE INSPECTION STEERING LOCK STARTING THE ENGINE SEAT RUNNING-IN HELMET HOLDER RIDING DOCUMENT BAG BRAKING CENTER COMPARTMENT PARKING HEA DL IGHT A IM V ER T ICAL ANTI-THEFT TIPS ADJUSTMENT…
• Page 10
  09/01/30 17:38:36 32KFK600_010 MAINTENANCE page page MAINTENANCE BRAKELIGHT SWITCH THE IMPORTANCE OF ADJUSTMENT MAINTENANCE BULB REPLACEMENT MAINTENANCE SAFETY SAFETY PRECAUTIONS CLEANING MAINTENANCE SCHEDULE TOOL KIT STORAGE GUIDE SERIAL NUMBERS STORAGE COLOUR LABEL REMOVAL FROM STORAGE ENGINE OIL THROTTLE OPERATION TAKING CARE OF COOLANT THE UNEXPECTED DRIVE CHAIN…
• Page 11
  09/01/30 17:38:44 32KFK600_011 MOTORCYCLE SAFETY IMPORTANT SAFETY INFORMATION Make Yourself Easy to See Your motorcycle can provide many years of Some drivers do not see motorcycles service and pleasure if you take because they are not looking for them. To responsibility for your own safety and make yourself more visible, wear bright understand the challenges that you can…
• Page 12
  Never exceed load limits, and only use accessories that have been approved by Honda for this motorcycle. See page more details. Not wearing a helmet increases the chance of serious injury or death in a crash.
• Page 13
  09/01/30 17:38:53 32KFK600_013 Helmets and Eye Protection Additional Riding Gear Your helmet is your most important piece of In addition to a helmet and eye protection, riding gear because it offers the best we also recommend: protection against head injuries. A helmet Sturdy boots with non-slip soles to help should fit your head comfortably and protect your feet and ankles.
• Page 14
  Non-Honda accessories, im p r o p e r m od i f i c a t i on s , a n d p o or Follow all load limits and other loading maintenance can also reduce your safety guidelines in this manual.
• Page 15
  If you wish to carry more cargo, check with Maximum cargo weight: your Honda dealer for advice, and be sure 14 kg (31 lbs) to read the inf ormat ion regarding The weight of added accessories will reduce accessories on page the maximum cargo weight you can carry.
• Page 16
  Accessories and Modifications a passenger or cargo: Modifying your motorcycle or using non- Check that both tyres are properly Honda accessories can make your inflated (page motorcycle unsafe. Before you consider To prevent loose items from creating a making any modifications or adding an…
• Page 17
  Do not pull a trailer or sidecar with your We strongly recommend that you use only motorcycle. This motorcycle was not Honda Genuine Accessories that have been designed for these attachments, and their specifically designed and tested for your use can seriously impair your motorcycle’s motorcycle.

• Page 18: Parts Location

  09/01/30 17:39:21 32KFK600_018 PARTS LOCATION Speedometer Tachometer Front brake fluid reservoir Indicators Rearview mirror Rearview mirror Passing light control switch Front brake lever Clutch lever Throttle grip Headlight dimmer Engine stop switch switch Turn signal switch Start button Horn button Ignition switch Fuel fill cap…

• Page 19
  09/01/30 17:39:25 32KFK600_019 Rear brake fluid reservoir Battery Fuse box Main fuse Tool kit Coolant reserve tank Passenger footpeg Oil filler cap Footpeg Rear brake pedal Engine oil inspection window…
• Page 20
  09/01/30 17:39:28 32KFK600_020 Center compartment Document compartment Seat lock/ Helmet holder Engine oil drain bolt Passenger Footpeg footpeg Shift lever Side stand…
• Page 21
  09/01/30 17:39:34 32KFK600_021 INSTRUMENTS AND INDICATORS The indicators are contained in the (10) (13) instrument panel. Their functions are (11) (14) described in the tables on the following (12) (15) pages. (1) Tachometer (2) Tachometer red zone (3) Digital clock (4) Right turn signal indicator (5) Right control button (6) Left control button…
• Page 22
  09/01/30 17:39:42 32KFK600_022 (Ref.No.) Description Function Tachometer Shows engine revolutions per minute. The tachometer needle will swing to the maximum scale on the dial once when the ignition switch is turned ON. Tachometer red zone Never allow the tachometer needle to enter the red zone, even after the engine has been broken in.
• Page 23
  09/01/30 17:39:51 32KFK600_023 (Ref.No.) Description Function Right turn signal indicator Flashes when the right turn signal operates. (green) Right control button Use this button for the following purpose. To adjust time Left control button Use this button for the following purposes. To adjust time To select display mode To reset tripmeter…
• Page 24
  09/01/30 17:39:59 32KFK600_024 (Ref.No.) Description Function Odometer/Tripmeter Shows odometer and tripmeter 1 and 2. display This display shows the initial display (page Odometer Shows accumulated mileage (page Tripmeter 1 and 2 Shows mileage per trip (page Speedometer Shows riding speed. The speedometer needle will swing to the maximum scale on the dial once when the ignition switch is turned ON.
• Page 25
  ON and engine stop switch is at (RUN). If it comes on at any other time, reduce speed and take the motorcycle to your Honda dealer as soon as possible. (11) H i g h c o o l a n t…
• Page 26
  09/01/30 17:40:12 32KFK600_026 (Ref.No.) Description Function (12) Neutral indicator (green) Lights when the transmission is in neutral. (13) Low oil pressure Lights when the engine oil pressure is below normal indicator (red) operating range. Should light when ignition switch is ON and engine is not running.
• Page 27
  09/01/30 17:40:16 32KFK600_027 (Ref.No.) Description Function (15) Low fuel indicator Lights when there is only few fuel left in the fuel tank. (amber) The amount of fuel left in the tank when lights and with the vehicle set upright is approximately: 1.5 (0.40 US gal , 0.33 Imp gal) Should also light for a few seconds and then go off when the ignition switch is turned ON.
• Page 28
  09/01/30 17:40:20 32KFK600_028 Initial Display When the ignition switch is turned ON, the display will temporarily show all the modes and digital segments so you can make sure the liquid crystal display is functioning properly. (Except digital clock) Digital clock and tripmeter will reset if the battery is disconnected.
• Page 29
  09/01/30 17:40:27 32KFK600_029 Odometer/Tripmeter Display The display ( ) has two functions, odometer and two tripmeter. Odometer Push the left control button ( ) to select ‘‘ODO’’, ‘‘TRIP 1’’ or ‘‘TRIP 2’’ mode. To reset the tripmeter, push and hold the Tripmeter 1 left control button when the display in the ‘‘TRIP 1’’…
• Page 30
  09/01/30 17:40:34 32KFK600_030 To set the hour, press the left control Digital Clock The digital clock will show hours and but t on u nt i l t h e de sir ed h our a nd minutes up to 11:59 with ‘‘AM’’ and ‘‘PM’’. AM/PM are displayed.
• Page 31
  09/01/30 17:40:40 32KFK600_031 To set the minute, press the right control button until the desired minute appears. The minute display will return to ‘‘00’’ when ‘‘60’’ is reached without affecting the hour display. The time advances by one minute, each time the button is pressed.
• Page 32
  As the brake pads wear, the brake fluid level drops. The recommended brake fluid is Honda There are no adjustments to perform, but DOT 4 brake fluid from a sealed container, fluid level and pad wear must be inspected or an equivalent.
• Page 33
  (page Worn pads should be replaced. If the pads are not worn, have your brake system inspected for leaks. The recommended brake fluid is Honda DOT 4 brake fluid from a sealed container, or an equivalent. (1) UPPER level mark…
• Page 34
  09/01/30 17:41:01 32KFK600_034 Loosen the lock nut ( ) and turn the CLUTCH Clutch adjustment may be required if the clutch cable adjuster. Tighten the lock motorcycle stalls when shifting into gear or nut and check the adjustment. tends to creep; or if the clutch slips, causing If the adjuster is threaded out near its acceleration to lag behind engine speed.
• Page 35
  Turn the adjusting nut ( ) to the clutch does not work correctly, see your obtain the specified freeplay. Tighten the Honda dealer. lock nut and check the adjustment. Start the engine, pull in the clutch lever Other Checks: and shift into gear.
• Page 36
  09/01/30 17:41:12 32KFK600_036 COOLANT The factory provides a 50/50 solution of Coolant Recommendation antifreeze and distilled water in this The owner must properly maintain the motorcycle. T his coolant solution is coolant to prevent freezing, overheating, r e c o m m e n d e d f o r m o s t o p e r a t i n g and corrosion.
• Page 37
  Do not attempt to add coolant by removing (2) Reserve tank cap the radiator cap. (3) Upper level mark (4) Lower level mark If the reserve tank is empty, or if coolant loss is excessive, check for leaks and see your Honda dealer for repair.
• Page 38
  09/01/30 17:41:30 32KFK600_038 FUEL Fuel Tank The fuel tank capacity including the reserve supply is: Petrol is highly flammable and 12.0 (3.17 US gal , 2.64 Imp gal) explosive. You can be burned or To open the fuel fill cap ( ), insert the seriously injured when handling fuel.
• Page 39
  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.
• Page 40
  Damage the painting of the fuel tank. is at least as high as that recommended by Damage the rubber tubes of the fuel line. Honda. There are two types of ‘‘gasohol’’: Cause corrosion of the fuel tank. one containing ethanol, and the other Cause poor drivability.
• Page 41
  09/01/30 17:41:45 32KFK600_041 ENGINE OIL Engine Oil Level Check Check the engine oil level each day before Running the engine with insufficient oil riding the motorcycle. pressure may cause serious engine damage. The level must be maintained between the upper ( ) and lower ( ) level marks in the inspection window ( ).
• Page 42
  09/01/30 17:41:50 32KFK600_042 TUBELESS TYRES Air Pressure To safely operate your motorcycle, your Keeping your tyres properly inflated tyres must be the proper type and size, in provides the best combination of handling, good condition with adequate tread, and tread life and riding comfort. Generally, correctly inflated for the load you are underinf lated tyres w ear unevenly, carrying.
• Page 43
  09/01/30 17:41:55 32KFK600_043 Always check air pressure when your tyres Inspection are ‘‘cold’’ when the motorcycle has been Whenever you check the tyre pressures, parked for at least three hours. If you check you should also examine the tyre treads and air pressure when your tyres are ‘‘warm’’…
• Page 44
  09/01/30 19:30:25 32KFK600_044 Tread Wear Replace tyres before tread depth at the center of the tyre reaches the following limit: Minimum tread depth Front: 1.5 mm (0.06 in) Rear: 2.0 mm (0.08 in) For Germany German law prohibits use of tyres whose tread depth is less than 1.6 mm.
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  09/01/30 17:42:04 32KFK600_045 Even if a tyre is professionally repaired with Tyre Repair If a tyre is punctured or damaged, you a permanent internal patch plug, it will not should replace it, not repair it. As discussed be as good as a new tyre. You should not below, a tyre that is repaired, either exceed 80 km/h (50 mph) for the first 24 temporarily or permanently, will have lower…
• Page 46
  09/01/30 17:42:10 32KFK600_046 T he r ecommended t yres f or your Tyre Replacement The tyres that came on your motorcycle motorcycle are: were designed to match the performance Front: 110/70-17M/C 54H capabilities of your motorcycle and provide BRIDGESTONE the best combination of handling, braking, G601F durability and comfort.
• Page 47
  09/01/30 17:42:14 32KFK600_047 Important Safety Reminders Do not install a tube inside a tubeless tyre on this motorcycle. Excessive heat build- up can cause the tube to burst. Use only tubeless t yres on this motorcycle. The rims are designed for t ubeless t y re s, a nd during hard acceleration or braking, a tube-type tyre could slip on the rim and cause the tyre to…
• Page 48
  09/01/30 17:42:23 32KFK600_048 ESSENTIAL INDIVIDUAL COMPONENTS IGNITION SWITCH The ignition switch ( ) is below the indicator panel. The headlight, position light (except U type), taillight and license light will come on whenever you turn the ignition switch ON. If your motorcycle is stopped with LOCK the ignition switch ON and the engine is not running, the headlight, position light…
• Page 49
  This motorcycle has two keys and a key have to replace a key. Store the plate in a number plate. safe place. To reproduce keys, bring all keys, key number plate and motorcycle to your Honda dealer. (1) Keys (2) Key number plate…
• Page 50
  09/01/30 17:42:35 32KFK600_050 RIGHT HANDLEBAR CONTROLS Start Button The start button ( ) is below the engine Engine Stop Switch stop switch. The engine stop switch ( ) is next to the When the start button is pressed, the throttle grip. When the switch is in the starter motor cranks the engine, the (RUN) position, the engine will operate.
• Page 51
  09/01/30 17:42:43 32KFK600_051 LEFT HANDLEBAR CONTROLS Headlight Dimmer Switch ( ) Push the headlight dimmer sw it ch to (HI) t o select high be am or t o (LO) to select low beam. Passing Light Control Switch ( ) When this switch is pressed, the headlight flashes on to signal approaching cars or when passing.
• Page 52
  09/01/30 17:42:49 32KFK600_052 FEATURES (Not required for operation) STEERING LOCK To lock the steering, turn the handlebar all the way to the left, turn the ignition key ( ) To lock to LOCK while pushing in. Remove the key. To unlock the steering, turn the key to OFF while pushing in.
• Page 53
  09/01/30 17:42:55 32KFK600_053 SEAT To remove the seat ( ), insert the ignition key into the seat lock ( ) and turn it clockwise. Pull the seat lock lever ( ) to unlock the seat. Pull the seat back and up. To install the seat, insert the front prong ( ) into the front stay ( ) of the frame.
• Page 54
  09/01/30 17:43:00 32KFK600_054 HELMET HOLDER The helmet holder ( ) is on the left side below the seat. Insert the ignition key ( ) and turn it clockwise to unlock. Hang your helmet on the holder hook ( ). Turn the key counterclockwise to lock the holder hook and then remove the key.
• Page 55
  09/01/30 17:43:05 32KFK600_055 DOCUMENT BAG The document bag ( ) is in the document compartment ( ) under the seat (page This owner’s manual and other documents should be stored in the document bag. When washing your motorcycle, be careful not to flood this area with water.
• Page 56
  09/01/30 17:43:11 32KFK600_056 CENTER COMPARTMENT The center compartment ( ) is below the seat (page This compartment is for light weight items. Do not ride with any luggage in the center compartment. The center compartment may become heated by the engine. Do not store food and other articles which are flammable or susceptible to heat damage in this compartment.
• Page 57
  09/01/30 17:43:15 32KFK600_057 H E A D L I G H T A I M V E R T I C A L ADJUSTMENT Vertical adjustment can be made by moving the headlight case ( ) as necessary. To move the headlight case, loosen the bolts ( ).
• Page 58
  If you detect any problem, be Coolant level add coolant if required. sure you take care of it, or have it corrected Check for leaks (pages by your Honda dealer. Front and rear brakes check operation; make sure there is no brake fluid leakage (pages…
• Page 59
  09/01/30 17:43:28 32KFK600_059 Tyres check condition and pressure (pages Drive chain check condition and slack (pages ). Adjust and lubricate if necessary. Throttle check for smooth opening and full closing in all steering positions. Lights and horn check that headlight, brake/tail light, position light (except U type), license light, turn signals, indicators and horn function properly.
• Page 60
  09/01/30 17:43:32 32KFK600_060 Y our motorcycle’s exhaust contains STARTING THE ENGINE Always follow the proper starting procedure poisonous carbon monoxide gas. High described below. levels of carbon monoxide can collect rapidly in enclosed areas such as a garage. This motorcycle is equipped with a side Do not run the engine with the garage door stand ignition cut-off system.
• Page 61
  09/01/30 17:43:39 32KFK600_061 Preparation Before starting, insert the key, turn the ignition switch ON and confirm the Operating the engine with insufficient oil following: pressure can cause serious engine damage. The transmission is in neutral (neutral indicator is ON). The engine stop switch is at (RUN).
• Page 62
  09/01/30 17:43:47 32KFK600_062 Starting Procedure Flooded Engine This motorcycle has a fuel-injected engine If the engine fails to start after repeated with an automatic choke. Follow the attempts, it may be flooded. procedure indicated below. L ea ve t he engine st op sw it ch set t o (RUN).
• Page 63
  09/01/30 17:43:49 32KFK600_063 RUNNING-IN Help assure your motorcycle’s future reliability and performance by paying extra attention to how you ride during the first 500 km (300 miles). During this period, avoid full-throttle starts and rapid acceleration.
• Page 64
  09/01/30 17:43:54 32KFK600_064 RIDING Slowly release the clutch lever and at the Review Motorcycle Safety (pages same time gradually increase engine before you ride. s p e e d b y o p e n i n g t h e t h r o t t l e . Coordination of the throttle and clutch Make sure you understand the function of lever will assure a smooth positive start.
• Page 65
  09/01/30 17:43:58 32KFK600_065 Coordinate the throttle and brakes for smooth deceleration. Both front and rear brakes should be used at the same time and should not be applied strongly enough to lock the wheel, or braking effectiveness will be reduced and control of the motorcycle be difficult.
• Page 66
  09/01/30 17:44:03 32KFK600_066 Important Safety Reminders: BRAKING For normal braking, apply both the brake Independent operation of only the brake pedal and lever while down-shifting to lever or brake pedal reduces stopping match your road speed. For maximum performance. braking, close the throttle and firmly apply Extreme application of the brake controls the pedal and lever;…
• Page 67
  09/01/30 17:44:05 32KFK600_067 When descending a long, steep grade, use engine compression braking by down- shifting, 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.
• Page 68
  09/01/30 17:44:10 32KFK600_068 Make sure flammable materials such as dry PARKING After stopping the motorcycle, shift the grass or leaves do not come in contact with transmission into neutral, turn the the exhaust system when parking your handlebar fully to the left, turn the motorcycle.
• Page 69
  09/01/30 17:44:14 32KFK600_069 NAME: ANTI-THEFT TIPS Always lock the steering and never leave the key in the ignition switch. This ADDRESS: sounds simple but people do forget. Be sure the registration information for your motorcycle is accurate and current. Park your motorcycle in a locked garage whenever possible.
• Page 70
  MAINTENANCE If your motorcycle overturns or becomes THE IMPORTANCE OF MAINTENANCE involved in a crash, be sure your Honda A well-maintained motorcycle is essential dealer inspects all major parts, even if you for safe, economical and trouble-free riding. are able to make some repairs.
• Page 71
  Wheel removal should normally be handled only by a Honda technician or other qualified mechanic; instructions are included in this manual only to assist in emergency service.
• Page 72
  To ensure the best quality and reliability, Injury from moving parts. Do not run the engine unless instructed use only new Honda Genuine Parts or their to do so. equivalents for repair and replacement. Read the instructions before you begin, and make sure you have the tools and skills required.

• Page 73: Maintenance Schedule

  ) may require more technical information and tools. Consult your Honda dealer. 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.

• Page 74
  09/01/30 17:44:47 32KFK600_074 FREQUENCY WHICHEVER ODOMETER READING [NOTE (1)] COMES FIRST 1,000 km Refer 1,000 mi ITEM NOTE MONTH Page FUEL LINE THROTTLE OPERATION AIR CLEANER NOTE (2) SPARK PLUG VALVE CLEARANCE ENGINE OIL ENGINE OIL FILTER RADIATOR COOLANT NOTE (3) 26, 75 COOLING SYSTEM SECONDARY AIR SUPPLY SYSTEM…
• Page 75
  09/01/30 17:45:00 32KFK600_075 FREQUENCY WHICHEVER ODOMETER READING [NOTE (1)] COMES FIRST 1,000 km Refer 1,000 mi ITEM NOTE MONTH Page DRIVE CHAIN I, L EVERY 1,000 km (600 mi) DRIVE CHAIN SLIDER BRAKE FLUID NOTE (3) 22, 23 BRAKE PADS WEAR 90, 91 BRAKE SYSTEM 22, 90…
• Page 76
  09/01/30 17:45:10 32KFK600_076 TOOL KIT The tool kit ( ) is in the tool box under the seat (page Some roadside repairs, minor adjustments and parts replacement can be performed with the tools contained in the kit. 8 mm Open end wrench 12 mm Open end wrench 17 mm Open end wrench Fuse remover…
• Page 77
  09/01/30 17:45:17 32KFK600_077 SERIAL NUMBERS The frame and engine serial numbers are The frame number ( ) is stamped on the required when registering your motorcycle. right side of the steering head. They may also be required by your dealer when ordering replacement parts.
• Page 78
  09/01/30 17:45:22 32KFK600_078 COLOUR LABEL The colour label ( ) is attached to the frame below the seat (page It is helpful when ordering replacement parts. Record the colour and code here for your reference. COLOUR CODE (1) Colour label…
• Page 79
  They may affect circular API service lubrication and clutch performance. label Viscosity SAE 10W-30 JASO T 903 standard Suggested Oil NOT RECOMMENDED Honda ‘‘4-STROKE MOTORCYCLE Do not use non-detergent, vegetable, or OIL’’ or equivalent. castor based racing oils.
• Page 80
  09/01/30 17:45:40 32KFK600_080 JASO T 903 standard Viscosity: Viscosity grade of engine oil should be The JASO T 903 standard is an index for based on average atmospheric temperature engine oils for 4-stroke motorcycle engines. in your riding area. The following provides a There are two classes: MA and MB.
• Page 81
  If a torque wrench is not used for this f r e q u e n t l y t h a n s p e c i f i e d i n t h e installation, see your Honda dealer as soon maintenance schedule.
• Page 82
  ( ). bolt. 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.
• Page 83
  09/01/30 17:45:59 32KFK600_083 Install the oil filler cap. Start the engine and let it idle for 3 5 Improper installation of the oil filter can minutes. cause serious engine damage. 2 3 minutes after stopping the engine, check that the oil level is at the upper Install the oil filter cover and tighten the level mark in the inspection window with oil filter center bolt.
• Page 84
  09/01/30 17:46:06 32KFK600_084 THROTTLE OPERATION Refer to the Safety Precautions on page Check for smooth rotation of the throttle grip from the fully open to the fully closed position at both full steering positions. Measure the throttle grip freeplay at the throttle grip flange.
• Page 85
  Refer to the Safety Precautions on page Coolant Replacement Removing the radiator cap while the Coolant should be replaced by a Honda engine is hot can cause the coolant to dealer, unless the owner has proper tools spray out, seriously scalding you.
• Page 86
  09/01/30 17:46:19 32KFK600_086 Roll the motorcycle forward. Stop. Check DRIVE CHAIN Refer to the Safety Precautions on page the drive chain slack. Repeat this procedure several times. Drive chain The service life of the drive chain ( ) is slack should remain constant. If the chain dependent upon proper lubrication and is slack only in certain sections, some adjustment.
• Page 87
  09/01/30 17:46:25 32KFK600_087 Roll the motorcycle forward. Stop and Damaged Sprocket Worn Sprocket place it on its side stand. Inspect the drive Teeth Teeth chain and sprockets for any of the following conditions: REPLACE REPLACE DRIVE CHAIN *Damaged Rollers *Loose Pins *Dry or Rusted Links *Kinked or Binding Links *Excessive Wear…
• Page 88
  09/01/30 17:46:32 32KFK600_088 Adjustment: If the drive chain requires adjustment, the Drive chain slack should be checked and procedure is as follows: adjusted, if necessary, every 1,000 km (600 Place the motorcycle on its side stand miles). When operated at sustained high with the transmission in neutral and the speeds or under conditions of frequent ignition switch off.
• Page 89
  Tighten the axle nut to: 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.
• Page 90
  RK 520MOZ6 This motorcycle has a staked master link drive chain which requires a special tool for cutting and staking. Do not use an ordinary master link with this chain. See your Honda (6) Red zone dealer. (7) Arrow mark…
• Page 91
  09/01/30 17:46:49 32KFK600_091 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.
• Page 92
  Refer to the Safety Precautions on page Check the chain slider ( ) for wear. The chain slider must be replaced if it is worn to the wear limit line ( ). For replacement, see your Honda dealer. (1) Chain slider (2) Wear limit line…
• Page 93
  09/01/30 17:46:58 32KFK600_093 FRONT AND REAR SUSPENSION INSPECTION Refer to the Safety Precautions on page Check the fork assembly by locking the front brake and pumping the fork up and down vigorously. Suspension action should be smooth and there must be no oil leakage.
• Page 94
  Lower the side stand. The engine should stop as you put the side stand down. If the side stand system does not operate as (1) Side stand spring described, see your Honda dealer for service.
• Page 95
  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.
• Page 96
  Remove the front axle nut ( ). occurs, servicing of the brake system will be Loosen the axle pinch bolt ( ). necessary. See your Honda dealer for this Remove the front axle shaft ( ), front service. wheel and side collars.
• Page 97
  If a torque wrench was not used for Front Wheel Installation Install the side collars into the left and right installation, see your Honda dealer as soon side wheel hub. as possible to verify proper assembly. Position the wheel between the fork legs…
• Page 98
  If this Remove the drive chain ( ) from the occurs, servicing of the brake system will be driven sprocket by pushing the rear necessary. See your Honda dealer for this wheel forward. service. (1) Rear axle nut…
• Page 99
  Rear Wheel Installation If a torque wrench was not used for To install the rear wheel, reverse the installation, see your Honda dealer as soon removal procedure. as possible to verify proper assembly. Install the side collars into the left and Improper assembly may lead to loss of right side wheel hub.
• Page 100
  Front Brake Check the wear indicator grooves ( ) 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) Wear indicator grooves…
• Page 101
  09/01/30 17:47:50 32KFK600_101 Rear Brake Check the wear indicator marks ( ) on each pad. If either pad is worn to the wear indicator mark, replace both pads as a set. See your Honda dealer for this service. (2) Wear indicator mark…
• Page 102
  If your battery seems weak and/or is disposal. leaking electrolyte (causing hard starting or other electrical troubles), contact your Honda dealer. The battery gives off explosive hydrogen gas during normal operation. Your battery is a maintenance-free type and can be permanently damaged if the cap strip A spark or flame can cause the battery is removed.
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  09/01/30 17:48:07 32KFK600_103 The battery ( ) is in the battery box below the seat. Removal: Make sure the ignition switch is OFF. Remove the seat (page Release the rings and remove the rubber band ( ). Disconnect the negative ( ) terminal lead ( ) from the battery first, then disconnect the positive ( ) terminal lead ( ).
• Page 104
  When frequent fuse failure occurs, it usually indicates a short circuit or an overload in the electrical system. See your Honda dealer for repair. 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.
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  09/01/30 17:48:20 32KFK600_105 Fuse Box: The fuse box ( ) is located under the seat. The specified fuse is: 10A, 20A Remove the seat (page Remove the fuse box cover ( ). Using the fuse remover, pull the old fuse out.
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  09/01/30 17:48:29 32KFK600_106 Main Fuse: The main fuse ( ) is located under the seat. The specified fuse is: Remove the seat (page Disconnect the wire connector ( ) of the starter magnetic switch ( ). Pull out the old fuse and install a new fuse. The spare main fuse ( ) is located under the starter magnetic switch.
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  09/01/30 17:48:34 32KFK600_107 BRAKELIGHT SWITCH ADJUSTMENT Refer to the Safety Precautions on page Check the operation of the brakelight switch ( ) at the right side behind the engine from time to time. Adjustment is done by turning the adjusting nut ( ).
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  09/01/30 17:48:40 32KFK600_108 BULB REPLACEMENT Refer to the Safety Precautions on page Be sure to turn the ignition switch OFF when replacing the bulb. The light bulb becomes very hot while the Do not use bulbs other than those light is ON, and remains hot for a while specified.
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  09/01/30 17:48:51 32KFK600_109 Position light bulb: Headlight/Position Light Bulb (except U type) Remove the screws ( ) from the Pull out the socket ( ). headlight case. Pull the position light bulb ( ) out. Gently pull the lower end of the headlight Install a new bulb in the reverse order of ( ) forward and remove the headlight.
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  09/01/30 17:48:57 32KFK600_110 Front/Rear Turn Signal Bulb The right and left turn signal bulbs replacement can be done in the same way. Remove the turn signal lens ( ) and the lens packing ( ) by removing the screw ( ). Slightly press the bulb ( ) and turn it counterclockwise.
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  09/01/30 17:49:04 32KFK600_111 Brake/Tail Light Bulb Remove the seat (page Turn the socket ( ) counterclockwise, then pull it out. Slightly press the bulb ( ) and turn it counterclockwise. Install a new bulb in the reverse order of removal. (1) Socket (2) Bulb…
• Page 112
  09/01/30 17:49:10 32KFK600_112 License Light Bulb Except U type Remove the screws ( ). Remove the license light cover ( ). Pull out the bulb ( ) without turning. Install a new bulb in the reverse order of removal. (1) Screws (2) License light cover (3) Bulb…
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  09/01/30 17:49:18 32KFK600_113 CLEANING Clean your motorcycle regularly to protect Washing the Motorcycle the surface finishes and inspect for damage, Rinse the motorcycle thoroughly with wear, and oil, coolant or brake fluid leakage. cool water to remove loose dirt. Clean the motorcycle with a sponge or Avoid cleaning products that are not soft cloth using cool water.
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  09/01/30 17:49:24 32KFK600_114 After cleaning, rinse the motorcycle Finishing Touches thoroughly with plenty of clean water. After washing your motorcycle, consider Strong detergent residue can corrode using a comme r cia lly-a v a ilable spr a y alloy parts. cleaner/polish or quality liquid or paste wax Dry the motorcycle, start the engine, and to finish the job.
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  09/01/30 17:49:30 32KFK600_115 Removing Road Salt Painted Aluminum Wheel Maintenance Road Salt used on roads during winter and Aluminum may corrode from contact with salt from seawater causes rust. dirt, mud, or road salt. Clean the wheels Wash your motorcycle as follows after it af ter riding through any of these has run through salty water or on roads substances.
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  09/01/30 17:49:33 32KFK600_116 Muffler Maintenance The muffler is stainless steel but may become stained by mud or dust. To remove mud or dust, use a wet sponge and a liquid kitchen abrasive, then rinse well with clean water. Dry with chamois or a soft towel.
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  09/01/30 17:49:39 32KFK600_117 STORAGE GUIDE Extended storage, such as for winter, requires that you take certain steps to reduce the effects of deterioration from non-use of the motorcycle. In addition, Petrol is highly flammable and necessary repairs should be made BEFORE explosive.
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  09/01/30 17:49:48 32KFK600_118 To prevent rusting in the cylinders, REMOVAL FROM STORAGE contact your Honda dealer. Uncover and clean the motorcycle. Remove the battery. Store in an area Change the engine oil if more than 4 protected from freezing temperatures months have passed since the start of and direct sunlight.
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  Also, be sure to have your vehicle is involved in the crash. Honda dealer check the frame and suspension after any serious crash. If you decide that you are capable of riding safely, first evaluate the condition of your motorcycle.
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  09/01/30 17:50:00 32KFK600_120 SPECIFICATIONS DIMENSIONS Overall length 2,070 mm (81.5 in) …Except U type 2,080 mm (81.9 in) …U type Overall width 725 mm (28.5 in) Overall height 1,055 mm (41.5 in) Wheelbase 1,405 mm (55.3 in) CAPACITIES Engine oil After draining 1.9 (2.0 US qt , 1.7 Imp qt) After draining and…
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  09/01/30 17:50:06 32KFK600_121 ENGINE Bore and stroke 60.0 44.2 mm (2.36 1.74 in) Compression ratio 11.0 : 1 Displacement 250 cm (15.3 cu-in) Spark plug Standard CR8EH-9 (NGK) U24FER9 (DENSO) Spark plug gap 0.80 0.90 mm (0.031 0.035 in) Idle speed 1,300 100 min (rpm) Valve clearance (Cold)
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  09/01/30 17:50:14 32KFK600_122 CHASSIS AND SUSPENSION Caster 25°30’ Trail 96 mm (3.8 in) Tyre size, front 110/70-17M/C 54H BRIDGESTONE G601F Tyre size, rear 140/70-17M/C 66H BRIDGESTONE G602 Tyre type bias-ply, tubeless POWER TRANSMISSION Primary reduction 2.821 Gear ratio, 1st 2.733 1.800 1.375 1.111…
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  09/01/30 17:50:23 32KFK600_123 ELECTRICAL Battery 12V 6Ah Generator 0.32 kW/5,000 min (rpm) LIGHTS Headlight 12V 60/55W Brake/Tail light 12V 21/5W Turn signal light Front 12V 21W Rear 12V 21W Position light 12V 5W …Except U type Instrument lights 12V 1.7W Turn signal indicator lights 12V 1.7W License light…
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  Always use unleaded petrol. Even a small NOx. A replacement unit must be an amount of leaded petrol can contaminate original Honda part or its equivalent. the catalyst metals, making the catalytic converter ineffective. The catalytic converter must operate at a…