owners manual.xlsx
Contents
1. SHOULD BE SERVICED BY AN AUTHERIZED HONDA DEALER UNLESS THE OWNER HAS PROPER TOOLS AND SERVICE DATA AND IS MECHANICALLY QUALIFIED REFER TO THE OFFICIAL HONDA SERVICE MANUAL IN THE INTEREST OF SAFTY WE RECOMMEND THESE ITEMS BE SERVICED ONLY BY AN AUTHORIZED HONDA DEALER NOTES 1 Athigher odometer readings repeatatthe frequancy interval established here 2 Service more frquantly when riding in unusually wet or dusty areas 3 California type only 4 Replace every 2 years or atthe indicated odometer intervals whichever comes first Replacement requires mechanical skill 52 MAINTENANCE MILES PERFORMED BY ODOMETER DATE Make sure whoever performs the maintenance completes this record All scheduled maintenance including the 600 mile 1 000 km break in maintenance is considered a normal owner operating cost and will be charged for by your dealer Detailed receipts verifying the performance of required maintenance should be retained These receipts should be transfered with the motorcycle to the new owner if the motorcycle is sold 53 MAINTENANCE TOOL KIT The tool kit is in the trunk Someroadside repairs minor adjustments and parts replacement can be performed with the tools contained in the kit Spark plug wrench 10 x 12 mm Box end wrench 22 mm Box end wrench 27 mm Box end wrench 10 x 12 mm Open end wrench 14 x 17 mm open end wrench Fuse puller Phillips screwdriver Screwdrive2. Wear Indicator Location Mark Tire Repair Replacement See your authorized Honda Dealer The use of tires other than those listed on the tire information label may adversely affect handling Do not install tube type tires on tubeless rims The beads may not seat and the tires could slip on the rims causing tire deflation that may result in a loss of vehicle control Any attemp to mount passenger car tires on a motorcycle rim may cause the tire bead to separate from the rim with enough explosive force to cause serious injury or death 30 MAJ OR COMPONENTS Information you need to operate this motorcycle WARNING Do not install a tube inside a tubeless tire Excessive heat build up may cause the tube to burst resulting in rapid tire deflation that may result in a loss of vehicle control Proper wheel balance is necessary for safe stable handling of the motorcycle Do not remove or change any wheel balance weights When wheel balancing is required see your authorized Honda dealer Wheel balancing is required after tire repair or replacement Toavoid possible repair faliure and tire deflation that may result in a loss of vehicle control do not exceed 50 mph for the first 24 hours or 80 mph at any time after tire repair Replace the tire if the sidewall is punctured or damaged Sidewall flexing may cause repair faliure and tire deflation that may result in loss of vehicle control CAUTION Do nottr
3. CAUTION Extended use of choke may impair piston and cylinder wall lubrication Flooded Engine If the engine fails to start after repeated attempts it may be flooded with excess fuel To clear a flooded engine turn the engine stop switch OFF and push the choke lever down to Fully Off A Open the throttle fully and crank the engine for 5 seconds and follow the High Air Temperature Starting Procedure page 43 44 OPERATION BREAK IN During initial break in newly machined surfaces will be in contact with each other and these surfaces will wear inn quickly Break in maintenance at 1 000 km 600 mls is designed to compensate for this initial minor wear Timely performaance of break in maintenance will ensure optimum service life and performance from the engine The general rules are as follows 1 Never lug the engine wiithh full throttle at low engine speeds This rule is applicablenot only during reak in bbut at all times Maximum continous engine speed during the first 1 000 km 600 miles must not exceed 4 000 rpm Increase the maximum continuous engine speed by 1 000 rpm between odometer readings of 1 000 km 600 miles and 1 600 km 1 000 miles Drive briskly vary speeds frequantly and use full throttle for short bursts only Do not exceed 6 000 rpm Upon reaching an odometer reading of 1 600 km 1 000 miles you can subject the motorcycle to full throttle operation However do not exceed 7600 rpm atan tim
4. PACIFIC COAST OWNER S MANUAL HONDA PC800 e 1989 IMPORTANT NOTICE OPERATOR AND PASSENGER This motorcycle is designed to carry the operator and one passenger Never exceed the maximum weight capacity as shown on the tire information label ON ROAD USE This motocycle is not equiped wiith a spark arrester and is designed to be used only on the road Operation in forest brush or grass covered areas may be illegal Obey local laws and regulations READ THIS OWNER S MANUAL CAREFULLY Pay special attention to statements proceded by the following words Indicates severe personal injury or death will result if instructions are not followed WARNING Indicates a strong possibility of personal injury or death will result if instructions are not followed CAUTION Indicates a possibility of perssonal injury or equpment damage if instructions are not followed NOTE Gives helpful information This manual should be considered permanent part of the motorcycle and should remain with the motorcycle when resold HONDA PACIFIC COAST 1989 PC800 OWNER S MANUAL All infromation in this publication is based on the latest production information availiable at the time of approval for ptinting HONDA MOTOR CO LTD Reserves the right to make changes at any time without notice and without incurring any obligation No part of this publication may be reproduced without written permission Honda Motor Co Ltd 1989
5. Removal of the left side covers is essentially the same However itis necessary to remove an additional bolt the chamber cover bolt 1 to remove the lower cover 61 FILTERS LUBRICATION ENGINE OIL AND FILTER Refer to Maintenance Precautions on page 56 Engine oil quality is the chief factor affecting engine service life Change the engine oil as specified in the maintenance schedule on page 51 CAUTION 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 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 NOTE Please dispose of used engine oil in a manner that is compatible with the enviroment We suggest you take it in a sealed container to your local service station for reclamation Do not throw it in the trash or pour it on the ground Change the engine oil with the engine at normal operating temperature and the motorcycle on its center stand to assure complete and rapid draining To drain the oil 1 Remove the step holder cover pages 57 60 the oil filler cap and drain bolt Drain Bolt Oil Filler CapiDipstick Upper Lower 62 FILTERS LUBRICATION 2 Remove the oil filter with a filter wrench Discard the oil filter Oil Filter 3 Apply a thin coat of engine oil to the rubber seal on the new oil filte
6. motorcycle or operator with both hands and keep both feet on the passenger footpegs CAUTION Do not ride over curbs or rub the wheel against an obstacle as wheel damage may result MOTORCYCLE SAFETY PROTECTIVE APPAREL Most motorcycle accident fatalities are due to head injuries ALWAYS wear a helmet You should also wear a face shield or goggles as well as boots gloves and proective clothing A passenger needs the same protection 2 The exhaust system becomes hot during operation and it remains hot for a while after stopping the engine Be carefull not to touch the exhaust system while it is hot Wear clothing that fully covers your legs 3 Do not wear loose clothing which could catch on the control levers footpegs or wheels MODIFICATIONS WARNING Modifications of the motorcycle or removal of original equipment may render the vehicle unsafe or ilegal Obey all federal state and local equipment regulations MOTORCYCLE SAFETY LOADING AND ACCESSORIES WARNING To prevent an accident use extreme care when adding and riding with accessories and cargo Addition of accessories and cargo can reduce motorcycle s stabillity perfomance and safe operating speed Never ride an accessory equipped motorcycle at speeds above 80 mph And remember that this 80 mph limit may be reduced by installation of non Honda accessories improper loading worn tires and overall motorcycle condition poor road or wea
7. 1 Removal of or puncturing the muffler baffles header pipes or any other component which conducts exhaust gases 2 Removal of or punctuing of any part of the intake system 3 Lack of proper maintenance 4 Replacing any moving parts ofthe vehicle or parts of the exhaust or intake system with parts other than those specified by the manufacturer Evaporative Emision Control System California only This motorcycle complies with the California Air Resources Board CARB requirements for evaporative emission regulations Fuel vapor from the fuel tank and carburetor is directed into the charcoal canister and air cleaner where it is absobered and stored while the engine is stopped When the engine is running and the purge control diaphram valve is open fuel vapour in the charcaol canister and air cleaner is drawn into the engine through the carburetor Crankcase Emission Control System The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere Blow by gas is returned to the combustion chamber through the air cleaner and the carburetor Problem that may affect motorcycle emissions If you are aware of any ofthe following symptoms have the vehicle inspected and repaired by your local authorizes Honda Motorcyle Dealer l Hard starting or stalling after starting Rough idle Misfiring or backfiring during acceleration After burnung backfiring Poor performance drivabil
8. Bolt Lower Edge 69 FRAME WHEELS BRAKES FRONT WHEEL REMOVAL For related torque specifications see page 73 The numbers indicate the sequance of disassembly 70 FRAME WHEELS BRAKES Wheel removal requires mechanical skill and professional tools such as a floor jack and torque wrench We recommend it be done only by yout authorized Honda dealer or other qualified mecahnic NOTE Forsome temporary tubeless tire repairs wheel removal may not be necessary See pages 30 31 Refer to Maintenance Precautions page 56 1 Raise the front wheel off the ground by placing a support block under the engine 2 Remove the parts in sequence according to the order in the illustration CAUTION 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 Avoid getting grease oil or dirt on the disk or pad surfaces because such contamination can cause poor brake performance or rapid brake wear after reassembly NOTE notdepress the brake lever when the wheel is off the motorcycle The caliper pistons will be forced out of the cylinder with subsequant loss of brake fluid If this occurs servicing ofthe brake system will be necessary See your Honda dealer for this service 71 FRAME WHEELS BRAKES Installation 1 Reassemble removed parts in the reversr order of removal NOTE When installing the wheel position the speedometer ge
9. SPARK PLUGS Refer to Maintenance Precautions on page 56 1 Remove the air duct maintenance cover and side cover pages 57 58 Right side shown left side similar Front Right Side Rear Right Side 66 ENGINE Recomemded plugs Standard DPR7EA 9 NGK X22EPR U9 ND For cold climate Below 59C 419F DPR6EA 9 NGK X20EPR U9 ND For extended high speed riding DPR8EA 9 X24EPR U9 ND 2 Disconnectthe spark plug caps 3 Clean any dirt from around the spark plug base 4 Remove and discard the spark plugs 5 Make sure the new spark plug gap is 0 8 0 9 mm 0 031 0 035 in using the 0 8 mm feeler gauge If adjustment is necessary bend the electrode carefully 6 With the plug washers attached thread the new spark plugs in by hand to prevent cross threading 7 Tighten the spark plugs 1 2 turn with a spark plug wrench to compress the washer 8 Reinstall the spark plug caps CAUTION The spark plug must be securely tightened An improperly tightened plug can become very hot and possibly damage the engine Never use a spark plug with an improper heat range Severe engine damage could result When installing body parts do not pinch any cables or wires Side Electrode 0 8 0 9 mm 0 031 0 035 in Washer 67 ENGINE IDLE SPEED Refer to Maintenance Precautions page 56 The idle speed adjustment procedure given here should only be used when changes in altitude af
10. damage may result Do not exceed 7600 rpm when running the engine without a load Serious engine damage may result NOTE Be careful when revving the engine or accelerating in 1st or 2nd gear as the engine speed will easily enter the red bar 47 OPERATION BREAKING Your motorcycle is equipped with independent front and rear brakes Braking Safety Independent use of only the front or rear brake increases stopping distance If too much force is applied to the brake it will lock resulting in tire skid and possible loss of control When possible reduce speed or brake before entering a turn Closing the throttle or braking in mid turn may cause tire skid and loss of control When riding in wetor rainy conditions or on loose surfaces your ability to maneuver and stop will be reduced All of your actions should be smooth under these conditions Sudden throttle application braking or turning can cause a loss of control For your safety exercise extreme caution in adverse conditions When descending a long steep grade use engine braking by downshifting and using both brakes intermittently Continuous application can cause overheating and eventual brake faliure Riding with your foot resting on the brake pedal or your hand on the breke lever may activate the brake light giving a false indication to other drivers It may also overheat the brake reducing its effectiveness For normal braking gradually app
11. green Lights when the transmission is in neutral 13 PARTS LOCATION OIL Oil Pressure Warning Light red Lights when engine oil pressure is below the normal operating range Should also light when the ignition switch is ON and the engine Is not running Should go off when the engine starts except for occasional flickering at or near idle speed when the engine is warm CAUTION Running the engine with insufficient oil pressure may cause serious engine damage SIDE STAND Side Stand Indicator amber Lights when the side stand is put down Before parking check that the side stand is fully down the light only indicates the side stand ignition cut off system page 78 is activated m E aaa F Shows approximate fuel supply available Fuel Gauge page 15 a a Coolant Gauge page 15 Shows coolant temperature 14 PARTS LOCATION Fuel Gauge The fuel gauge shows the approximate fuel supply availiable AtF Full there are 16 0 litres 4 2 US gal including the reserve supply When the gauge needle enters the red band the fuel level is 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 is approximately 3 0 liters 0 8 US gal Needle Red Band Coolant Temperature Gauge The normal operating temperatutre gauge is the zone between the C cold and H 9hot0 marks Wait for the temperature gauge n
12. symptoms while using a gasoline that contains alcohol or one that you think contains alcohol switch to a gasoline that you know does not contain alcohol 25 MAJ OR COMPONENTS Information you need to operate this motorcycle ENGINE OIL Check engine oile level each day before operating the motorcycle To check the oil level 1 2 3 4 5 Place the motorcycle on its center stand on firm level ground and remove the stepholder cover page 60 Start the engine and let it idle for a few minutes Stop the engine After a few minutes remove the dipstick and wipe ir clean then reinsertthe dipstick without screwing itin The oil level should be between the upper and lower level marks on the dipstick If required remove the filler cap add the specified oil up to the upper level mark Do not overfill Reinstall the filler cap dipstick and step holder cover CAUTION Running the engine with insufficient oil can cause serious engine damage Dipstick 26 MAJ OR COMPONENTS Information you need to operate this motorcycle Engine Oil Recommendation USE HONDA 4 STROKE OIL OR AN EQUIVALENT Use only high detergent premium quality motor oil certified to meet US automobile manufacturer s requirements for Service Classification SE or SF Motor oils intended for Service SE or SF will show this designation on the container The use of special oil additives is unnecessary and will only increase opera
13. EAR VISION CAUTION DO NOT LET BATTERY FLUID OR OTHER ACID CHEMICALS GET ON WINDSHIELD THEY WILL DAMAGE THE PLASTIC MOTORCYCLE SAFETY SAFE RIDING RULES WARNING Motorcycle riding requires special efforts on your part to ensure your safety Know these requirements before you ride Always make a pre ride inspection page 41 before you ride the motorcycle You may prevent an accident or equipment damage Many accidents involve inexperienced riders Most states require a special motorcycle riding test or licence Make sure you are qualified before you ride NEVER lend your motorcycle to an inexperienced rider Many automobile motorcycle accidents happen because the automobile driver does not see the motorcyclist Make yourself conspicious to help avoid the accident that wasn t your fault Wear bright or reflective clothing Don t ride in another motorist s blind spot Obey all federal state and local laws and regulations Excessive speed is a factor in many accidents Obey the speed limits and NEVER travel faster than conditions warrant Signal before you make a turn or lane change Your size and maneuverability can surprise other motorists Don tletother motorists surprise you Use extra caution at intersections parking lot entrances and exits and driveways Keep both hands on the handlebars and both feet on the footpegs while riding A passenger should hold on to the
14. ITY LOAD WEIGHT EQUALLY ON BOTH SIDES TO MINIMIZE IMBALANCE ACCESSORIES AND CARGO CAN REDUCE A MOTORCYCLE S STABILITY PERFORMANCE AND SAFE OPERATING SPEED NEVER RIDE AN ACCESSORY EQUIPED MOTORCYCLE AT SPEEDS ABOVE 130 KM H 80 MPH THIS 130 KM H 80 MPH LIMIT MAY BE REDUCED BY IMPROPER LOADING WORN TIRES AND OVERALL MOTORCYCLE CONDITIONS POOR ROAD OR WEATHER CONDITIONS ETC READ LOADING AND ACCESSORIES AND TIRES SECTIONS OF THIS MANUAL CAUTION TO AVOID DAMAGE TO THE TRUNK BE SURE THE LID IS CLOSED AND LATCHED BEFORE RIDING HEAVY ITEMS PLACED ON THE LID CAN DAMAGE THE LID OR ITS CONTENTS MOTORCYCLE SAFETY WARNING WINDSHIELD CLEANING DO NOT STORE ARTICLES BETWEEN FAIRING AND MOTORCYCLE THEY MAY INTERFERE WITH STEERING CAUSING LOSS OF CONTROL e ACCESSORIES AND CARGO CAN REDUCE MOTORCYCLE S STABILITY PERFORMANCE AND SAFE OPERATING SPEED NEVER RIDE AN ACCESSORY EQUIPED MOTORCYCLE AT SPEEDS ABOVE 130 KM H 80 MPH THIS 130 KM H 80 MPH LIMIT MAY BE REDUCED BY IMPROPER LOADING WORN TIRES AND OVERALL MOTORCYCLE CONDITIONS POOR ROAD OR WEATHER CONDITIONS ETC READ LOADING AND ACCESSORIES AND TIRES SECTIONS OF THIS MANUAL CLEAN WINDSHIELD WITH SOFT CLOTH OR SPONGE AND PLENTY OF WATER DRY WITH SOFT CLEAN CLOTH REMOVE MINOR SCRATCHES WITH COMMERCIALLY AVAILABLE PLASTIC POLISHING COMPOUND REPLACE WINDSHIELD IF SCRAT CHES CANNOT BE REMOVED AND THEY OBSTRUCT CL
15. Indicators MAJOR COMPONENTS Information you need to operate this motorcycle Rear Suspension Brakes Clutch Coolant Fuel Engine Oil Final Drive Oil Tubeless Tires ESSENTIAL INDIVIDUAL COMPONENTS Ignition Switch Right Handlebar Controls Left Handlebar Controls FEATURES Not required for operation Steering Lock Page 35 37 38 39 1 41 45 46 48 49 Helmet Holder Trunk Fairing Pocket Rear View Mirror OPERATION Pre ride Inspection Starting the Engine Break in Riding Braking Parking Anti Theft Tips CONTENTS MAINTENANCE Page 50 MAINTENANCE 51 Maintenance Schedule 53 Maintenance Record 54 Tool Kit 54 Licence Plate 55 Serial Numbers 55 Color Label 56 Maintenance Precautions 57 Cover Removal 62 FILTERS LUBRICATION 62 Engine Oil And Filter 64 Air Cleaner 66 ENGINE 66 Spark Plugs 68 Idle Speeds 69 DRIVE TRAIN 69 Final Drive Oil Page 10 10 74 77 78 79 19 81 83 85 85 86 87 89 89 91 FRAME WHEELS BRAKES Front Wheel Removal Rear Wheel Removal Brake Wear Indicators Side Stand ELECTRICAL Battery Fuse Replacement CLEANING STORAGE GUIDE Storage Removal From Storage SPECIFICATIONS CONSUMER INFORMATION USA ONLY Emission Control System Warranty Service MOTORCYCLE SAFETY Read this WARNING INFORMATION before you ride WARNING BE ALWAYS WEAR HELMET ON ROAD USE ONLY FAILURE TO FOLLOW PROPER STARTING AND OPERATING INST
16. RUCTIONS MAY RESULT IN AN ACCIDENT READ THE OVFNER S CAREFULLY WARNING ACCESSORIES AND LOADING THE SAFETY STABILITY AND HANDLING OF THIS MOTORCYCLE MAY BE ADVERSELY AF FECTED BT THE ADDITION OF ACCESSORIES AND CARGO READ AND UNDERSTAND THE WARNINGS CONTAINED IN THE OWNER S MANUAL AND THE INSTRUCTIONS IN THE ACCESSORY HANDBOOK BEFORE INSTALLING ANT ACCESSORY THE WEIGHT OF ACCESSORIES AND CARGO MUST BE ADDED TO THE WEIGHT OF THE RIDER AND PASSENGER WHEN DETERMIN ING IF THE MAXIMUM WEIGHT CAPACITY HAS BEEN EXCEEDED THE CARGO LOAD MUST HOT EXCEED 20 KG 44 LBS UNDER ANY CIRCUMSTANCES THE FITTING OF LARGE FORK MOUNTED OR LARGE HANDLEBAR MOUNTED FAIRING IS HOT RECOMMENDED MOTORCYCLE SAFETY TIRE INFORMATION COLD TIRE PRESSURES UP TO MAXIMUM WEIGHT CAPACITY FRONT 225 kPa 2 25 kg cm 33 psi REAR 280 kPa 2 8 kg cm 41 psi UP TO 90kg 200 Ibs LOAD FRONT 225 kPa 2 25 kg cm 33 psi REAR 225 kPa 2 25 kg cm 33 psi MAXIMUM WEIGHT CAPACITY 167kg 369 Ibs TIRE SIZE FRONT 120 80 17 61H REAR 140 80 15 M C 67H TIRE BRAND FRONT REAR Read Owner s Manual DUNLOP K177F K177 DUNLOP K555F K555 THIS MOTORGYGLE MIN RECOMENDED CENTER TREAD DEPTH IS EQUIPED WITH FRONT 1 5 mm 0 06 in REAR 2 0 mm 0 08 in TUBELESS TIRES WARNING DO NOT EXCEED MAXIMUM WEIGHT LIMIT EACH SIDE OF TRUNK 9 kg 20 Ibs TOTAL WEIGHT OF RIDER PASSENGER AND CARGO MUST NOT EXCEED MAXIMUM WEIGHT CAPAC
17. WELCOME Your new motorcycle presents you with an invitation to adventure and challenge to master the machine Your safety depends not only on your alertness and familiarity with the motorcycle but also the motorcycle s mechanical condition A pre ride inspection before every outing and regular maintenance are essential To help meetthe challenges safely and enjoy the adventure fully become thoroughly familliar with this Owner s Manual BEFORE YOU RIDE THE MOTORCYCLE Also for your own and your Honda s sake please read all the writtern material which came with your new Honda These items include Honda Owners Identification Card Set up and Predelivery Checklist Honda Motorcycle Emission Control System Distributors Warranty Honda Motorcycle Distributor s Limited Warranty Honda Motorcycle Noise Control Systems Distributors Warranty x mx When service is required remember that your Honda dealer knows whatittakes to keep your Honda going strong If you have the required mechanical know how and tools your dealer can supply you with an official Honda Service Manual to help you perfom many maintenance tasks Pleasant riding and thank you for choosing a Honda CONTENTS OPERATION Page 1 MM UT UT o 16 16 17 20 21 23 26 28 29 32 32 33 34 35 35 MOTORCYCLE SAFTY Safe Riding Rules Protective Apparel Modifications Loading and Accessories PARTS LOCATION Instruments and
18. ank Cap Fuel Filler Compartment Trunk Lateh Lever et EE Fuel Tank Gap PARTS LOCATION Radiator Reserve Tank Main Fuse Battery Oil Filler Cap Rear Brake Cooling Front Brake Dipstick Pedal Fan Caliper PARTS LOCATION Fairing Pocket Fuse Box Spare Fuse Gear Shift Side Center Final Drive Oil Pedal Stand Stand Filler Cap PARTS LOCATION INSTRUMENTS AND INDICATORS The indicators and warning lights are incorperated in the instrument panel Their function are described on the following pages USA model Odometer reads in miles Canadian model Odometer reads in kilometers Speedometer Tachometer SIDE STAND NEUTRAL x1000rpm Trip Meter Reset Button 12 PARTS LOCATION Speedometer shows the riding speed Tachometer shows engine rpm Never allow the tachometer needle to enter the red zone even after the engine has been broken in CAUTION The red zone indicates the maximum limits of the engine speed and running the engine in the red zone may adversely affect its service life Turn Signal Indictors amber Flashes when the turn signal operates m m m w uw O Odometer Shows accumulated milage 5 o Tripometer Shows mileage per trip Tripmeter Reset Button Pushing the button resets the tripometer to zero 0 HIGH BEAM High beam Indicator blue Lights when the headlight is on high beam NEUTRAL Neutral Indicator
19. arbox so thatthe lug on the gearbox is againstthe rear of the stopper lug on the left fork CAUTION When installing the wheel fit both brake discs carefully between the brake pads to avoid damaging the pads 2 Measure the clearence between the outside surface of the left brake disc and the left caliper holder with a 0 7 mm 0 028 in feeler auge If the gauge inserts easily tighten the right and left axel pinch bolts to the specified torque 72 FRAME WHEELS BRAKES Specified torque Axel bolt 90 N m 9 0 kg m 65 ft lb Axel pinch bolt 27 N m 2 7 kg m 20 ft lb WARNING Ifatorque wrench was not used for installation see your authorized Honda dealer as soon as possible to verify proper assembly Improper assembly may lead to loss of braking capacity 3 Ifthe feeler gauge cannot be inserted easily pull the left fork outward or push inward until the gauge can be inserted and tighten the axel pinch bolt with the gauge inserted 4 After tightening remove the gauge After installing the wheel apply the brake several times then recheck both discs for caliper holder to disc clearence Do not operate the motorcycle without adequate clearence WARNING Faliure to provide adequate disc to caliper holder clearence may damage the brake disc and impair braking efficiency 73 FRAME WHEELS BRAKES BRAKE WHEEL REMOVAL For related torque specifications see page 76 The numbers indicate the sequance of disasse
20. braking performance WARNING Braking efficiency may be temporarily impaired immediately after washing the motorcycle Anticipate longer stopping distance to avoid a possible accident 03 CLEANING Aluminium Wheel Maintenance Aluminium corrodes when it comes in contact with dust mud road salt etc After riding clean the wheels with a wet sponge and mild detergent then rinse well with water and wipe dry with a clean cloth CAUTION Do notuse a steel wool or a cleaner containing abrasives or compounds to clean the wheels as they can cause damage 84 STORAGE GUIDE Extended storage such as for winter requires that you atke certain steps to reduce the effects of deterioation 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 5096 antifreeze solution 3 Drain the fuel tank and carburetors Spray the inside of the tank with an aerosol rust inhibiting oil NOTE e fstorage will last more than one month carburetor draining is very important to assure proper performance after storage WARNING Gasoline is extremely flammable and is explosive under certain conditions Perform this operation in a well ventilated area with the engine stopped Do not smoke or allo
21. d pulling it out toward you Remove the air duct by pulling it backward NOTE The exhaust becomes very hot during operation and remains hot after stopping the engine Do not bring the Cover into contact with the exhaust pipe when removing it 2 Side Cover Remove screw 1 Disconnect the side cover from the end 2 ofthe upper cowl by sliding it backward Pry the cover outtoward you to release the retaining tabs 3 from the top shelter and the two retaining tabs 4 from the lower cover 58 MAINTENANCE 3 Fairing Protector Remove the screw 1 then while squeezing the edge 2 pull the protector out and back toward you 4 FrontLower Cover Remove both screws 1 and release the tab do the same on the other side then slide the cover forward 59 MAINTENANCE 5 Step Holder Cover Unfold th passenger foot peg 1 Holding the opening edge 2 of the holder cover with your fingers pull the cover 3 out then slide it to the rear 6 Saddlebag Protector Simultaneously squeeze the edge 1 and pull the protector toward you 60 FILTERS LUBRICATION 1 Rear Lower Covers Open the trunk lid then remove the bolts 1 Release the retaining hook 2 atthe rear ofthe cover With the passenger footpeg unfolded pull the rear ofthe cover out toward you to clear the passenger footeg P ull the front ofthe cover out also toward you until it clears of the brake pedal 4 Left Side Cover Removal
22. ds and use 50 MAINTENANCE MAINTENANCE SCHEDULE Perform the Pre ride inspectiion page 41 at each scheduled maintenance period INSPECT AND CLEAN ADJUST LUBRICATE OR REPLACE IF NECESSARY C CLEAN R REPLACE A ADJUST L LUBRICATE The following items require some mechanical knowledge Certain items particularly marked and may require more technical information and tools Consult your authorized Honda dealer FREQUENGY FUEL LINE HEN THROTTLE OPERATION CARBURETOR CHOKE Zm SYNCHRONIZATION system EVAPORATIVE EMISSION CONTROL SYSTEM es azma OmAPrma x100km prem T EN p T E ME LEE E EET EX EN ODOMETER READING NOTE 1 91 MAINTENANCE FREQUENGY ODOMETER READING NOTE 2 meses s iex eter to page NOTE x100km 10 64 128 192 256 320 384 Refer to page FINAL DRIVE OIL PT ji fi R 2868 r f re TI X maeserum Qj v7 i pmxuersmc ng e fr DL pp J TOO 1 gt X jetucHrLtupb jworE4 frfr pr j I R 2 s peso _ l l lll ij susrensiow 1 TT amp urs Borts Fasteners p ee wegsmes Fi ji C STEERING HEAD BEARINGS i fif
23. ds the life of exhaust components Never use stale or contminated gasoline or an oil gasoline mixture Avoid getting dirt dust or water in the fuel tank Use of a lower octane gasoline can cause persistant pinging or heavy spark knock a metallic rapping noise which if severe can lead to engine damage CAUTION If spark plug knock or pinging occurs ata steady engine speed under normal load change brands of gasoline If spark knock or pining persists consult your authorised Honda dealer Failure to do so is considered misuse and damage caused by misuse is not covered by Honda s Limited Warranty Occasionally you may experiance light spark knock while operating under heavy loads This is no cause for concern it simply means your engine is operating efficiently 23 MAJ OR COMPONENTS Information you need to operate this motorcycle Install the fuel tank cap by turning it clockwise California model Be sure to properly route the hose attached to the top of the cap Close the fuel filler compartment Lid with the key inserted and turned clockwise then turn the key counterclockwise to lock the lid WARNING Gasoline is extremely flammable and is explosive under certain conditions Refuel in a well ventilated area with the engine stopped Do notsmoke or allow flames or sparks in the area where the engine is refueled or where gasoline is stored Do notoverfill the tank there should be no fuel in the
24. e tachometer RED BAR limit CAUTION The red bar indicates the maimum limit of engine speed and running the engine in the red bar will adversly affect its service life 45 OPERATION RIDING Review Motorcycle Safty pages 1 8 before you ride WARNING Riding with an unlocked trunk may result in loss of vehicle control Be sure the trunk lid is closed secuely before riding Proper shifting will provide better fuel economy When changing gears under normal conditions use these recommended shift points Shifting Up From 1stto 2nd From 2nd to 3rd From 3rd to 4th From 4th to 5th Shifting Down From 5th to 4th From 4th to 3rd Disengage the clutch when speed drops below 9 mph 15 km h when engine roughness is evident or when engine stalling is imminent and shift down to 1st gear for acceleration 46 6 mph 10 km h 12 mph 20 km h 19 mph 30 km h 25 mph 40 km h 22 mph 35 km h 16 mph 25 km h OPERATION Do not downshift when traveling at a speed that would force the engine to overrev in the next lower gear the rear wheel may loose traction resulting in possible loss of vehicle control CAUTION Do not shift gears without disengaging the clutch and closing the throttle The engine and drive chain 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
25. e Schedule Perform all Pre ride inspection checks page 41 Testride the motorcycle at low speeds in a safe riding area away from traffic 86 SPECIFICATIONS DIMENSIONS Overall length 2290 mm 90 2 in Overall width 820 mm 32 3 in Overall height 1370 mm 53 9 in Wheelbase 1555 mm 61 2 in Ground clearence 140 mm 5 5 in WEIGHT Dry weight 262 kg 578 Ibs 263 580 Ibs California type CAPACITIES Engine oil 3 0 Itrs 3 2 US qt After draining Final drive gear oil 150 cc 5 1 oz After draining Fuel tank 16 0 105 4 2 US gal Cooling system capacity 2 5 ltrs 2 7 US qt Passenger capacity Operator and one passenger Maximum weight capacity 167 kg 369 Ib ENGINE Bore and stroke 19 5 x 80 6 mm 3 13 x 3 17 in Compression ratio 9 0 1 Displacement 800 cc 48 8 cu in Spark plug Standard X22EPR U9 ND DPR7EA 9 NGK For cold climate X20EPR U9 ND Below 59C 419F DPR6EA 9 NGK For extended high X24EPR U9 ND speed riding DPR8EA 9 NGK Spark plug gap 0 8 0 9 MM 0 031 0 036 in Idle speed 1200 100 rpm SPECIFICATIONS POWER TRANSMISSION Primary reduction 1 811 Secondary reduction 0 934 Gear ratio Ist 2 600 2nd 1 700 3rd 1 250 Ath 0 964 5th 0 800 Final reduction 3 400 ELECTRICAL Battery 12V 10AH Generator 0 34kw 5000rpm LIGHTS Headlight 12V 60 55W Tail stoplight 12V 2 32cp x 2 Turn signal light 12V 32cp x 4 Position light 12V 3cp x 2 License light 12V 3cp FUSES 30A Main fuse 15A 10A Other fu
26. eedle to move above the C mark before riding If the needle reaches the H mark stop engine and check the reserve tank coolant level page 21 Do not ride the motorcycle until the problem has been corrected CAUTION Exceeding maximum running temperature may cause serious engine damage Needle 15 MAJ OR COMPONENTS Information you need to operate this motorcycle WARNING If the pre ride inspection page 41 is not performed severe personal injury or vehicle damage may result Rear Suspension The left shock absorber has four adjustment positions for different load or riding conditions The right shock is not adjustable Use a handle to adjust the left shock Position 2 is for light loads and smmooth road conditions Positions 3 and 4 increase spring preload for a stiffer rear suspension and can be used when the motorcycle is heavily loaded Shock Absorber Handle 16 MAJ OR COMPONENTS Information you need to operate this motorcycle BRAKES Front Brake This motorcycle has hydraulic disk front brake As the brake pads wear the brake fluid level will drop Therefore the brake 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 77 there is probebly air in the brake system and it m
27. fect normal idel speed as set by your dealer See your authorized Honda dealer for regularly scheduled carburetor adjustments including individual carburetor adjustment and synchronization NOTE 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 shift to neutral and place the motorcycle on its center stand 2 Open the fuel filler compartment 3 Adjustthe idle speed with the adjusting knob Idle speed 1200 100 rpm in neutral Adjusting Knob ed pe j uel Filter Compartment 68 DRIVE CHAIN FINAL DRIVE OIL Refer to Maintenance Precautions page 56 Change the oil as specified in the maintenance schedule page 52 NOTE 4 Change the oil with the final drive at normal operating temperature and the motorcycle upright on firm level ground to assure complete and rapid draining To drain the oil remove the oil filler cap and drain plug After th oil has completely drained check that the sealing washer on the drain plug 15 in good condition and install the drain plug Drain Plug Torque 12N m 1 2 kg m 9 ft Ib Fill the final drive with approximatley 150cc 5 1 oz of the recommended oil Make sure the final drive oil level is Slightly lower than the lower edge of the inspection hole Install the oil filler cap Recommended oil HYPOID GEAR OIL SAE 80 Oil Filler Cap Drain
28. filler neck After refueling make sure the tank cap is closed properly and securely Becarefull notto spill fuel when refueling Spilled fuel or fuel vapor may ignite If any fuel is spilled make sure the area is dry before starting the engine Avoid repeated or prolonged contact wit skin or breathing of vapor KEEP OUT OF THE REACH OF CHILDREN Filler Neck 24 MAJ OR COMPONENTS Information you need to operate this motorcycle Gasolines Containing Alcohol If you decide to use gasoline containing alcohol gasohol be sure its octane rating is atleastas high as that recommended by Honda There are two types of gasohol one containing ethanol and the other containing methanol Do not use gasohol that contains more than 1096 ethanol Do not use gasoline containing methanol methyl or wood alcohol that does notalso contain cosolvents and corrosion inhibitors for methanol Never use gasoline containing more than 5 methanol even if ithas consolvents ad corrosion inhbitors Note Fuell system damage or engine performance problems resulting from the use of fuels that contain alcohol are not covered under the warranty Honda cannot endorse the use of fuels containing methanol since evidence of their suitability is as yet complete Before buying fuel from an unfamiliar station try to find if the fuel contains alcohol If it does confirm the type and percentage of alcohol used If you notice any undesirable operating
29. freeze up to a maximum of 60 antifreeze if required 21 MAJ OR COMPONENTS Information you need to operate this motorcycle Inspection Check the coolant level in the reserve tank while the engine 15 at normal operating temperature Add coolant to the reserve tank as required to bring the coolant level to the UPPER level mark If the reserve tank is empty or if the coolantloss is excessive check for leaks and see your authorised Honda dealer for repair WARNING Do not remove the radiator cap When the engine is hot the coolant is under pressure and could scold you Keep hands and clothing away from the cooling fan as it starts automatically Reserve Tank 22 MAJ OR COMPONENTS Information you need to operate this motorcycle FUEL Automatic Fuel ON OFF Fuel will flow to the carburetors when the engine is started or is running Fuel Tank Fuel tank capacity is 16 0 Itrs 4 2 US gal Insertthe ignition key and turn it clockwise to open the fuel filler compartment Turn the fuel tank cap counterclockwise to remove it Fuel Filler Compartment Ignition Key Fuel Tank Cap Your engine is designed to use any gasoline that has a pump octane number M of 86 or higher or that has a research octane number of 91 or higher Gasoline pumps at service station normally displatthe octane number We recomend that you use unleaded fuel because it produces fewer engine and spark plug deposits and exten
30. g frame suspension and steering parts for misalignment and damage that you may not be abel to detect Stop the engine and support the motorcycle securely on a firm level surface before performing any maintenance Use new genuine Honda parts or their equivalent for maintenance or repair Parts which are not of equivalent quality may impair the safty of your motorcycleand the effective operation of the emission control system The Vehicle Emission Control Information label is attached to the right side of the frame under the right cover The Vacuum Hose Routing Diagram is attached to the fuel tank under the left side cover California only Vehicle Emission Control Information Label Vacuum Hose Routing Diagram Label 56 MAINTENANCE COVER REMOVAL Right side shown left side similar The numbers indicate the sequence of disassembly 1 Air Duct Maintenance Cover 2 Side Cover EFP SET b 4 6 Saddlebag Protector 5 Step Holder Cover 4 Front Lower Cover ENGINE OIL AND FILTER MAINTENANCE Remove 5 right side AIR CLEANER MAINTENANCE Remove 1 2 each side and 8 e SPARK PLUG MAINTENANCE Remove 1 and 2 each side 3 Faring Protector e BATTERY Remove 1 2 3 4 5 6 and 7 right side e FUSE BOX Remove 1 and 2 left side 57 MAINTENANCE 1 Air Duct Maintenance Cover Release the clips 2 by gripping the edge 1 of the air duct end an
31. he bolt Disconnect the negative terminal lead from the battery first Pull the battery out of the battery box Disconnect the positive terminal lead Positive terminal lead Bolt Battery Battery Holder Negative terminal lead 80 ELECTRICAL FUSE REPLACEMENT Refer to Maintenance Precautions on page 56 The main fuse is located on the starter magnetic switch under the seat is 30 A The spare main fuse is under the starter magnetic switch The fuse box is located under the left side cover The air duct maintenance cover must be removed before removing the left side cover The specified fuses are 10 A and 15 A When frequant fuse faliure occurs it usually indicates a short vircuit or an overload in the electrical system See your authorized Honda dealer for repair CAUTION Turn the ignition switch OFF before checking or replacing fuses to prevent accidental short circuiting To replace the main fuse open the trunk and remove the seat by removing bolts Disconnect the wire connector of the starter magnetic switch and pull outthe old fuse Install a new fuse and reconnectthe connector Main Fuse Spare Main Fuse 81 ELECTRICAL To replace the fuses in the fuse box remove the left side air duct maintenance cover and the side cover pages 57 58 The spare fuses are located in the trunk Pull the old fuses out the clips with the fuse remover Push a new fuse into the clips and insta
32. he brake starts to take hold Stopper Bolt Lock Nut 18 MAJ OR COMPONENTS Information you need to operate this motorcycle Free play should be 20 30 mm 3 4 1 1 4 in If adjustment is necessary turn the rear brake adjusting nut NOTE Make sure the cut out on the adjusting nut is seated on the brake arm pin after making the final free play adjustment If proper adjustment cannot be obtained by this method see your authorized Honda dealer 4 Apply the brake several times and check for free wheel rotation when released 5 Check the adjustment has not activated the rear brake light even though there is no pressure on the brake pedal Also check that pressure on the brake pedal Also check that pressing down on the brake pedal does activate the rear brake light Other Checks Make sure the brake rod brake arm spring and fasteners are in good condition Adjusting Nut 19 MAJ OR COMPONENTS Information you need to operate this motorcycle CLUTCH This motorcycle has hydraulically actuated clutch There are no adjustments to perform but the clutch system must be inspected periodically for fluid level and leakage If the control lever free play becomes excessive and the motorcycle creeps or stalls when shifting into gear or if the clutch slips causing acceleration to lag behind engine speed there is probably air in the clutch system and it must be bled out See your authorized Honda dealer f
33. ity and poor fuel economy 90 CONSUMER INFORMATION USA ONLY WARRENTY SERVICE Owner Satisfacture Your satisfaction and goodwill are important to your dealer and to us The details of all Honda warranties are explaned in the Distributor s Limote Warranty Normally any problems with the product will be handled by your dealer s service department Sometimes however in spite of the best interpretations of all concerned misunderstandings can occur If your problem had not been handled to your satisfaction we suggest you take the following actions Discuss your problem with a member of dealership management Often complaints can be quickly resolved at that level If the problem has already been reviewed with the Service Manager cotactthe owner ofthe dealership or the General Manager If your problem still has not been resolved to your satisfaction contactthe Motorcycle Customer Service Department of American Honda Motor Co Inc The address is P O Box 420 Gardana CA90247 0805 Telephone 310 532 9811 we will need the following information in order to assist you Your name address and telephone number Product model and serial number Date of purchase Dealer name and address Nature of the problem After reviewing all the facts involved you will be advised of what action can be taken Please bear in mind that your problem will likely be resolved at the dealership using the dealer s facilities equipment a
34. ll the fuse box cover Fuse Box WARNING Never use a fuse with 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 Fuse Blown Fuse Remover ott dL CLEANING Clean your motorcycle regularly to protect the surface finishes and inspect for damage wear and oil coolant or hydraulic fluid seepage 1 Clean the windshield with a soft cloth or sponge and plenty of water Dry with a soft clean cloth Remove minor scratches with commercially availiable plastic polishing compound Replace the windshield if scratches cannot be removed and they obstruct clear vision CAUTION Do notlet battery electrolyte brake fluid or other acid chemicals get on the windshield They will damage the plastic Avoid spraying high pressure water typical in coin operated car washes at the following areas Brake Master Cylinder Fairing Pocket or Accessories Clurch Master Cylinder Ignition Switch Radiator Fins Steering Lock Wheel Hubs Handlebar Switches Muffler Outlet Instrument Panel Under Seat 2 After cleaning rinse the motorcycle with plenty of clean water Strong detergent residue can corrode alloy parts 3 Dry the motorcycle start the engine and let it run for several minutes 4 Testthe brakes before riding the motorcycle in normal traffic Several applications may be necessary to restore normal
35. ly both front and rear brakes while downshifting to suit your road speed For maximum deceleration close the throttle and apply the front and rear brakes firmly Disengage the clutch before the motorcycle stops 48 OPERATION PARKING 1 After stopping the motorcycle shift the transmission into neutral turn the ignition switch OFF and remove the key 2 Use the side or center stand to support the motorcycle while parked CAUTION Parkthe motorcycle on firm level ground to prevent it from falling over 3 Lock the steering to help prevent theft page 35 NOTE When stopping for a short time near traffic at night the ignition switch may be turned to P and the key removed This will turn on the taillightto make the motorcycle more visible to traffic The battery will discharge if the ignition switch is left at P for too long a time ANTI THEFT TIPS 1 Always lock the steering and never leave the keys in the ignition switch This sounds simple but people do forget 2 Besure the registration information for your motocycle 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 Putyourname address and phone number in this Owner s Manual and keep it in your motorcycle at all times Many times stolen motorcycles are identified by information in the Owner s Manuals that are still with them 49 MAINTENANCE The U S Environme
36. mbly FRAME WHEELS BRAKES Wheel removal requires mechanical skill and professional tools such as a torque wrench We recommend it be done only by your authorized Honda dealer or other qualified mechanic NOTE Forsome temporary tubeless tire repairs wheel removal may not be necessary See pages 30 31 Refer to Maintenance Precautions on page 56 1 Place the motorcycle on its center stand 2 Remove the parts in sequance according to the order in the illustration Installation Notes Before installing the rear wheel check thatthe wheel hub and final drive gear splines are coated in grease Reverse the removal procedure Be sure the splines on the wheel hub fit into the final gear case Before tightening the axel holding bolt tighten the axel nut to prevent misalignment 75 FRAME WHEELS BRAKES Tighten and torque the following nuts and bolts Axel nut torque 110 N m 11 0 kg m 80 ft lb Axel holding bolt torque 27 N m 2 7 kg m 20 ft lb Brake stopper arm nut torque 22 N m 2 2 kg m 16 ft lb Apply the brake several times and check for free wheel rotation when released WARNING Ifa torque wrench was not used for installation see your authorized Honda dealer as soon as possible to verify proper assembly Improper assembly may lead to loss of braking capacity CAUTION Always replace used cotter pins with new ones 76 FRAME WHEELS BRAKES BRAKE WEAR INDICATORS Refer t
37. nd personnel so itis very im portant that your initial contact be with the dealer Your purchase of a Honda productis greatly appreciated by both the dealer and the American Honda Motor Co Inc We want to assist you in every way possible to assure you complete satisfaction with your purchase 91 HONDA MOTOR CO LTD 31MR5600 amp OG 5008901K 00X31 MR5 6000 PRINTED IN JAPAN
38. nk can force water into the trunk NOTE Items placed in the trunk may be subject to high temperatures under certain conditions Latch Lever 37 FEATURES Not required for operation The damper unit contains high pressure nitrogen gas Do not attempt to disassemble disconect or service the damper unit an explsion causing serious injury may result Puncture or exposure to flame may also result in an explosion causing serious injury Service or disposal should only be done by your authorized Honda dealer FAIRING POCKET To open the left fairing pocket lid slide the button forward and open the lid WARNING Thefairing pocket is for lightweight items Do not carry more than 0 5 kg 1 lbs Review Loading and Accessories before handling page 6 38 FEATURES Not required for operation REAR VIEW MIRRORS Both rear veiw mirrors use Special breakaway mount which allows controlled seperation fo the mirror from its base upon impact with an obstacle short steel cable keeps the mirror connected to the mirror bracket Installation 1 Remove the two bolts fastening the mirror base to the body Remove the base 2 Remove the three screws from the mirror bracket 3 Position the mirror base on the mirror bracket and install using the three screws removed in step 2 Mirror Base Bolts Mirror Base Screws 39 FEATURES Not required for operation 4 Insertthe retaining tabs
39. ntal Protection Agency and California Air Resources Board CARB require that your motorcycle comply with applicable exhaust emissions standards during its usefull life when operated and maintained according to the instructions provided and that motorcycles built after J anuary 1 1983 comply with applicable noise emission standards for one year or 6 000 km 3 730 miles after the time of sale to the ultimate purchaser when operated and maintained according to the instructions provided Compliance with the terms of the Distributor s Warrenties for Honda Motorcycle Emission Control Systems is Necessary in order to keep the emissions system warranty in effect USA only When service is required remember that your authorized Honda dealer knows your motorcycle best and is fully equipped to maintain and repair it The scheduled maintenance and the anticipated maintenance may also be performed by a qualified service facility that normally does this kind of work or you may perform most of the work yourself if you are mechanically qualified and have the proper tools and service data These instuctions are based on the assumption that motorcycle will be used exclusively for its designed purpose Sustained high speed operation or operation in unusually wet or dusty conditions will require more frequent service than specified in the MAINTENANCE SCHEDULE Consult your authorized Honda dealer for recommendations applicable to your individual nee
40. o Maintenance Precautions page 56 Brake Pad Wear Brake pad wear will depend upon the severity of usage type of riding and conditions of the roads The pads will wear faster on dirty and wet roads Inspect the pads visually from under the caliper during all regular service intervals to determin the pad wear If either pad wears to the wear line both pads must be replaced as a set Brake Shoe Wear The rear brake is equipped with brake wear indicator When the brake is applied an arrow attached to the brake arm moves forward toward a reference mark on the brake panel if the arrow aligns with the reference mark on full application of the brake the brake shoes must be replaced lt FRONT gt Caliper Brake Pads lt REAR gt 77 FRAME WHEELS BRAKES SIDE STAND Refer to Maintenance Precautions page 56 Check the side stand system for proper function Check the spring for damage or loss of tension and the side stand assembly for freedom of movement Check the side stand ignition cut off system 1 Sitastride the motorcycle putthe side stand up and the transmission in neutral 2 Startthe engine and with the clutch lever pulled in shift the transmission into gear 3 Move the side stand fully down 4 The engine should stop as you putthe side stand down If the side stand system does not operate as descibed see your authorized Honda dealer for service Spring 78 ELECTRICAL BATTERY It is not neces
41. of the body in the forward grooves of the mirror base Install the two bolts removed in step 1 5 After reinstalling check the mirror for correct angle and the front turn signals for proper operation CAUTION Riding with a mirror hanging by its retaining cable may damage the motorcycle s body NOTE For your safety be sure to immediatly reassemble any seperated mirror Otherwise the mirror and turn signal will not be availiable to you while riding If a mirror is damaged so badly that it cannot be reused or reinstall on its base remove it from the base and transport the motorcycle to an authorized Honda dealer 40 FEATURES Not required for operation PRE RIDE INSPECTION WARNING If the pre ride inspection is not performed severe personal injury or vehicle damage may result Inspect your motorcycle every day before you ride The items listed here will only take a few minutes to inspect and in the long run can save time expense and possibly your life 1 Engine oil level add engine oil if required page 26 Check for leaks 2 Fuellevel fill fuel tank when necessary page 23 Check for leaks 3 Coolantlevel add coolant if required Check for leaks pages 21 22 4 Frontand rear brakes check operation make sure there is no brake fluid leakage Adjust free play if necessary pages 17 19 77 5 Tires check condition page 29 31 and pressure page 2 6 Throttle check for
42. op switch is at RUN The red engine oil pressure warning light is ON CAUTION Thered oil pressure warning light should go off a few seconds after the engine starts If the light stays on stop the engine immediately and check engine oil level Operating the engine with insufficient oil pressure can cause serious engine damage 42 OPERATION Starting Procedure To restart warm engine follow the procedure for High Air Temperature Normal Air Temperature 10 35 C 50 95 F 1 Pull the choke lever up all the way to fully On B 2 Startthe engine leaving the throttle closed NOTE Do notopen the throttle when starting the engine with the choke on This will lean the mixture resulting in hard starting Choke Lever 3 Immediately after the engine starts operate the choke lever to keep fast idle at 1 500 2 500 rpm 4 Abouta half minute after the engine starts push the choke lever down all the way to Fully Off A 5 Ifidling is unstable open the throttle slightly High Air Temperature 35 C 95 F or above 1 Do notuse the choke 2 Open the throttle slightly 3 Startthe engine 43 OPERATION Low Air Temperature 10 509F or below 1 Follow steps 1 2 under Normal Air Temperature 2 Warm up the engine by opening and closing the throttle slightly 3 Continue warning up the engine until it runs smoothly and responds to the throttle when the chole lever is at Fully Off A
43. or this service Fluid Level Check that the fluid level is above the LOWER LEVEL LINE If the fluid level is near the LOWER LEVEL LINE it indicates fluid leakage See your authorized Honda dealer for this service Other Checks Make sure there are no fluid leaks Check for deterioration or cracks in the hose and fittings Lower Level 20 MAJ OR COMPONENTS Information you need to operate this motorcycle COOLANT Coolant Recommendation The owner must properly maintain the coolant to prevent freezing overheating and corrosion Use only high quality ethylene glycol antifreeze containing corrsion protection inhibitors specially recommended for use in aluminium engines SEE ANTIFREEZE CONTAINER LABEL CAUTION Useonly 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 harmfull to the aluminium engine The factory provides a 50 50 solution of antifreeze and water in this motorcycle This coolant solution is recommended for most operating temperatures and provides good corrosion protection A higher concentration of antifreeze decreases 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 frequantly and add higher concentrations of anti
44. r Oil Filter 4 Installthe new oil filter and tighten it to the specified torque 10 N m 1 0 kg m 7 ft lb 5 Check that the sealing washer on the drain plug is in good condition Install the drain plug and tighten to the specified torque 35 N m 3 5 kg m 25 ft lb 6 Fillthe crankcase with approximately 3 0 liters 3 2 US qt of the recommended oil 7 Install the oil filler cap 8 Startthe engine and let it idle for a few minutes 9 Stopthe engine Make sure the oil level is atthe upper level mark on the dipstick page 26 and there are no oil leaks NOTE When running in very dusty conditions oil changes should be performed more frequantly than specified in the 63 maintenance schedule FILTERS LUBRICATION AIR CLEANER The number indicates the sequance of disassembly CD Remove the air duct maintenance cover and side cover pages 57 58 S 64 FILTERS LUBRICATION Refer to Maintenance Precautions on page 56 The air cleaner should be serviced at regular intervals page 51 Service more frequantly when riding in unusually wet or dusty areas 1 Remove the parts in sequance according to the order in the illustration NOTE Becareful notto break any tabs 2 Remove the air cleaner element and discard it 3 Install a new air cleaner element 4 Install removed parts in the reverse order of removal NOTE Make sure to engage all tabs and to secure all fasteners 65 ENGINE
45. r handle Screwdriver Handle grip Handle 5 mm Hex wrench 6 mm Hex wrench 8 mm Hex wrench 10 mm Hex wrench Tool Kit 0 7 mm Feeler gauge Tool bag LICENSE PLATE To install a license plate remove the license plate bracket nuts install the license plate on the bracket and reinstall the bracket Licence Plate Bracket Licence Plate 54 MAINTENANCE SERIAL NUMBERS The frame and engine serial numbers are required when registering the motorcycle They may also be required by your dealer when oredering replacement parts Record the numbers here for your reference The VIN Vehicle Identification Number is on the Safety Certification Label attached to the frame near the steering head The frame number is stamped on the right side of the steering head The engine number in stamped on the right side of the crankcase under the side cover COLOR LABEL The color label is attached inside the fuel filler compartment lid Itis helpful when ordering replacement parts Record the color and code here for your reference VIN FRAME NO ENGINE NO COLOR CODE s Engine Number MAINTENANCE MAINTENANCE PRECAUTIONS WARNING If your motorcycle is overturned or involved in a collision inspect control levers cables brake hoses calipers accessories and other vital parts for damage Do not ride the motorcycle if damage impairs safe operation Have your authorized Honda dealer inspect the major components includin
46. s on a motorcycle rim WARNING Any attempt to mount passenger car tires on motorcycle rim may cause the tire bead to seperate from the rim with enough explosive force to cause serious innjury or death Proper air pressure will provide maximum stability riding comfort and tire life Check tire pressure frequantly and adjust if necessary page 2 NOTE Tire pressure should be checked before you ride while the tires are cold Tubeless tires have some degree of self sealing ability if they are puctured and leakage is often very slow Inspect very closely for punctures especially if the tire is not fully inflated Check the tires for cuts embedded nails or other sharp objects Check the rims for dents or deformation If there is any damage see your authorized Honda dealer for repair replacement and balancing WARNING Improper tire inflation will causeabnormal tread wear and create a safety hazard Underinflation may result in the tire slipping on or coming of the rim causing tire deflation that may result in a loss of vehicle control Operation with excessively worn tires is hazardous and will adversely affect traction and handling Replace tires before tread depth atthe center of the tire reaches the limit as shown on the tire information label page 2 or when the surface is flush with the wear indicators 29 MAJ OR COMPONENTS Information you need to operate this motorcycle Wear Indicator
47. sary to check the battery electrolyte level or add distilled water as the battery is a maintenance free sealed type If the battery loses electrolyte and or seems weak causing hard starting or other electrical troubles contact your authorized Honda dealer CAUTION Do notattempt to remove the sealing caps from the cells you may damage the battery When the motorcycle is to be stored for an extended period of time remove the battery and charge it fully Then store itin a cool dry place The battery gives of explosive gases keep sparks flames and cigarettes away Provide adequate ventilation when charging or using the batteries in an enclosed area The battery contains sulfuric acid electrolyte Contact with skin or eyes may cause severe burns Wear protective clothing and a face shield if electrolyte gets on your skin flush with water if electrolyte gets on your eyes flush with water for at least 15 minutes and call a physician immediately Electrolyte is poisonous If swallowed drink large quantities of water or milk and follow with milk of magnesia or vegtable oil and call a physician KEEP OUT OF THE REACH OF CHILDREN 79 ELECTRICAL Battery Removal The battery is located in the battery box below the rear seat 1 Remove the air duct maintenance cover side cover fairing protector step holder cover saddlebag protector and rear lower cover pages 57 61 Remove the battery holder by removing t
48. ses 88 CONSUMER INFORMATION USA ONLY EMISION CONTROL SYSTEM Source of emissions The combustion process produces carbon monoxide and hydrocarbons Control of hydrocarbons Is very important because under certain conditions they react to form photochemical smog when subjected to sunlight Carbon monoxide does not react in the same way but Is toxic Honda Motor Co Ltd Utilises a secondary air supply system to reduce carbon monoxide and hydrocarbons Exhaust Emission Control System The exhaust emission control system consists of a secondary air supply system which introduces filtered air into the exhaust gases in the exhaust port No adjustmentto this system should be made although periodic inspection of the components is recommended Noise Emission Control System TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintainence repair or replacement of any device or element of design incorperated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while the vehicle is in use or 2 the use ofthe vehicle after such device or element of design has been removed or rendered inoperative by any person 89 CONSUMER INFORMATION USA ONLY AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW
49. smooth opening and closing in all steering positions 7 Lights and horn check that headlight taillight stoplight turn signals indicators and horn function properly 8 Engine stop switch check for proper function page 33 9 Sige stand ignition cut off system check for proper function page 78 Correct any discrepancy before you ride Contact your authorized Honda dealer for assistance if you cannot correct the problem 41 OPERATION STARTING THE ENGINE This motorcycle is equipped with side stand ignition cut off system The engine cannot be started if the side stand is down unless the transmission 15 in neutral Ifthe side stand is up the engine can be started in neutral or gear with the clutch lever pulled in After starting with the side stand down the engine will stop if the transmission is put in gear WARNING Never run the engine in a closed area The exhaust contains poisonous carbon monoxide gas that can cause loss of consciouness and may lead to death Do notflood the engine by twisting the throttle repeatedly The carburetor has no accelerator pump NOTE Do not use the electric starter for more than 5 seconds ata time Release the starter button for approximatley 10 seconds before pressing it again Preperation Before starting insertthe ignition key turn the ignition switch ON and confirm the following The transmission is in NEUTRAL neutral indicator light ON The engine st
50. sories you are personally responsible for proper selection installation and use of non Honda accessories Always follow the guidelines under loading and these 1 Carefully inspectthe accessory to make sure it does not obscure any lights reduce ground clearance and banking angle or limit suspension travel steering travel or control operation 2 Large fork mounted fairings or windshields or poorly designed or improperly mounted fairings can produce aerodynamic forces that cause unstable handling Do not install fairings that decrease cooling air flow to the engine MOTORCYCLE SAFETY 3 Accessories which alter your riding position by moving hands or feet away from controls may increase reaction time in an emergancy 4 Do not add electrical equipment that will exceed the motorcycle s electrical system capacity A blown fuse could cause dangerous loss of lights or engine power 5 This motorcycle was not designed to pull sidecar or trailer Handling may be serious impaired if so equipped 6 Any modification of the cooling system may cause overheating and serious engine damage Do not modify the radiator shrouds or install accessories which block or deflect air away from the radiator PARTS LOCATION Instruments And Indicators Ignition Switch Clutch Fluid Front Brake Fluid Reservoir Reservoir Left Handlebar Right Handlebar Control Control Front Brake Lever Throttle Grip Radiator Reserve T
51. t attached to the holder the helmet may interfere with safe operation and result in loss of control To Set Combination 1 Pullthe cable end out of the lock end 2 Remove the cone by turning ita quarter turn 90 counterclockwise Remove the four lock wheels 3 You can now setthe combination Align the red marks with the guide point on the cone Replace the lock wheels one at a time Lining up your selected numbers with the guide point on the cone CAUTION Reversing the wheels will cause the lock to jam 4 After positioning all four lock wheels place the cone onto the lock housing and turnit a quarter turn 909 clockwise Lock End D Cable End 2 D 36 FEATURES Not required for operation TRUNK To open the trunk Insert the ignition key and turn it clockwise to open the fuel filler compartment Pull the latch lever to open the trunk To lock the trunk Close the trunk lid Make sure the trunk is locked WARNING The trunk is for lightweight items Do not carry more than 9 kg 20 lbs in each side Excessive weight may adversely affect vehicle handling and control Load weight equally in both sides to minimize an imbalance that may result in a loss of vehicle control Review Loading and Accessories page 6 before loading CAUTION Closing the trunk lid with items placed in the damper channel or behind the damper may damage the damper Directing water under pressure against the tru
52. tarting Procedure Engine Stop Switch Starter Button 33 ESSENTIAL INDIVIDUAL COMPONENTS LEFT HANDLEBAR CONTROLS The controls next to the left handlebar grip are Headlight Dimmer Switch Select HI for high beam LO for low beam Horn Button Press the button to sound the horn Turn Signal Switch Move the switch to L to signal a left turn to R to signal a right turn the appropriate turn signal and indicator will blink The switch returns to the center when it is released The indicator will automatically stop blinking upon completing the turn Headlight Dimmer Switch Horn Button Turn Signal Switch 34 FEATURES Not required for operation STEERING LOCK To lock the steering turn the handlebar all the way to the left or right turn the key to LOCK while pushing in Remove the key WARNING Do notturn the key to LOCK while riding the motorcycle loss of vehicle control may result HELMET HOLDER The helmet holder lock is stored in the trunk The lock s combination is preset to 0 0 0 0 you may use this combination or select your own To Use 1 open the trunk page 37 and remove the combination lock 2 Run the cable end through the D ring of the helmet s and both passenger side grips then insert itin the lock end Helmet Holder Wire Side Grip FEATURES Not required for operation The helmet holder is designed for helmet security while parked Do not ride with helme
53. ther conditions These general guidelines may help you decide wether or how to equip your motorcycle and how to load it safely Loading The combined weight of the rider passenger cargo and additional accessories must not exceed 67 kg 369 Ibs the maximum weight capacity Cargo weight alone should not exceed 20 kg 44 lbs l Keep cargo and accessory weight low and close to the center of the motorcycle Load weight equally on both sides to minimize imbalance As weight is located farther from the motorcycle s center of gravity handling is proportionally affected Adjust tire pressure page 2 to suit load weight and riding conditions All cargo and accessories must be secure for stable handling Recheck cargo security and accessory mounts frequantily MOTORCYCLE SAFETY 4 Do not attach large heavy items to the handlebars front forks or fender Unstable handling or slow steering response may result 5 Do not exceed the maximum weight capacity of Honda accessories Trunk 9 kg 20 Ibs Each side Fairing pocket 0 5 kg 1 Ibs 6 The Honda fairing and trunk are designed for this motorcycle only Do not install them on any other motorcycle 7 Do not store articles between fairing and motorcycle They may interfere with steering causing loss of control Accessories Genuine Honda accessories have been specifically designed for and tested on this motorcycle Because the factory cannot test all other acces
54. ting expenses CAUTION Engine oil is a major factor affecting the performance and service life of the engine Non detergent vegetable or castor based racing oils are not recommended Recommended Oil Viscosity SAE 10W 40 Other viscosities shown in the chart below may be used when the average temperature in your riding area is within the indicated range ET REINES ERIGI SAE 20W 50 L l SAE 20W 40 I T a SAE 10W 40 ee eee SAE 10W 30 0 20 40 60 80 100 F 20 10 0 10 20 30 40 C 27 MAJ OR COMPONENTS Information you need to operate this motorcycle FINAL DRIVE OIL Oil Level Check Check the final drive oil level when specified by the maintenance schedule 1 Place the motorcycle on its center stand on firm level ground 2 Remove the oil filler cap 3 The oil level should be flush with the lower edge of the oil filler hole NOTE ifthe level is low check for leaks Add the recommended oil through the oil filler hole until it reaches the lower edge of the opening Recommended Oil HYPOID GEAR OIL SAE 80 Oil Filler Cap Lower Edge 28 MAJ OR COMPONENTS Information you need to operate this motorcycle TUBELESS TIRES This motorcycle is equiped with tubeless tires valves and wheel rims Use only tires marked TUBELESS and tubeless valvea on rims marked TUBELESS TIRE APPLICABLE Never mount tires designed for use on automobile
55. ust be bled See your authorized Honda dealer for this service Brake Fluid Level Brake fluid may cause irritation Avoid contact with skin or eyes In case of contact flush thoroughly with water and call a doctor if you eyes were exposed Brake fluid must be added to the reservoir whenever the fluid level begins to reach the lower level mark Fill the reservoir with DOT 4 BRAKE FLUID from a sealed container up to the upper level mark Reinstall the removed parts in the reverse order of removal Tighten the screws securely Screws Upper Level Cap Diaphragm Plate Diaphragm 17 MAJ OR COMPONENTS Information you need to operate this motorcycle CAUTION Handle brake fluid with care because it can damage plastic and painted surfaces When adding brake fluid be sure the reservoir is horizontal before the cap is removed or brake fluid may spill out Use only DOT 4 brake fluid from sealed container Never allow contaminants such as dirt or water to enter the brake fluid reservoir Other Checks Make sure there are no fluid leaks Check for deterioration or cracks in the hoses and fittings Rear Brake Adjustment 1 2 Place the motorcycle on its center stand The stopper bolt is provided to allow adjustment of the pedal height To adjust the pedal height loosen the lock nut and turn the stopper bolt Tighten the lock nut Measure the distance the rear the brake pedal moves before t
56. w open flames or sparks in the area or where gasoline is stored 4 Remove the spark pllugs and pour a tablespoon 15 20 cc of clean engine oil into each cylinder Crank the engine several times to distribute the oil then reinstall the spark plugs NOTE When turning the engine over the Engine Stop Switch should be OFF and each spark plug placed in its cable cap and grounded to prevent damage to the ignition system 5 Remove the battery Store in an area protected from freezing temperatures and direct sunlight Slow charge the battery once a month 85 STORAGE GUIDE Wash and dry the motorcycle Wax all painted surfaces Coat all chrome with rust inhibiting oil Inflate the tires to their recommended pressure Place the motorcycle on blocks to raise both tires off the ground Cover the motorcycle don t use plastic or other coated materials and store in an unheated area free of dampness with a minimum daily temperature variation Do not store the motorcycle in direct sunlight 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 Charge the battery as required Install the battery Drain any excess aerosol rust inhibiting oil from the fuel tank Fill the fuel tank with fresh gasoline Check the final drive oil adding the recommended gear oil if necessary Change the final drive oil if necessary as specified by the Maintenanc
57. y to remove tubeless tires without special tools and rim protectors You may damage the rim sealing surface or disfigure the rim 31 ESSENTIAL INDIVIDUAL COMPONENTS IGNITION SWITCH The ignition switch is on the handlebar cover Key Position Function Key Removal 04 s Engine and lights can be operated removed cannot be started removed For parking the motorcycle near traffic The taillight licence light are Key can be P park parking on but the other lights are off The removed engine cannot be started FF LOCK steering Steering is locked Engine and Key can be lock lights cannot be operated removed 32 ESSENTIAL INDIVIDUAL COMPONENTS RIGHT HANDLEBAR CONTROLS Engine Stop Switch The two positions engine stop switch 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 emergancy switch and should normally remain in the RUN position NOTE f your motorcycle is stopped with the ignition switch ON and the engine stop switch OFF the headlight and taillight will still be on resulting in battery discharge Starter Button The starter button is below the engine stop switch When the starter button is pressed the starter will crank the engine and the headlight will automatically go off but the taillight will stay on See pages 42 44 for S
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