this manual should be considered a permanent part of...

No part of this publication may be reproduced without written permission.

This publication includes the latest production information available before printing.Honda Motor Co., Ltd. reserves the right to make changes at any time without notice and withoutincurring any obligation.

This manual should be considered a permanent part of the motorcycle and should remain with themotorcycle when it is resold.

Honda Motor Co., Ltd. 2003

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2004Honda CRF150FOWNER’S MANUAL

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Safety Messages

A Few Words About Safety

Safety Labels

Safety MessagesDANGER, WARNING, CAUTION.

Your safety, and the safety of others, is very important. And operating this motorcycle safely is animportant responsibility.

To help you make informed decisions about safety, we have provided operating procedures andother information on labels and in this manual. This information alerts you to potential hazards thatcould hurt you or others.

Of course, it is not practical or possible to warn you about all hazards associated with operating ormaintaining a motorcycle. You must use your own good judgment.

You will find important safety information in a variety of forms, including:

–– on the motorcycle.

–– preceded by a safety alert symbol and one of three signal words:or

These signal words mean:

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You WILL be KILLED or SERIOUSLY HURT if you don’t followinstructions.

You CAN be KILLED or SERIOUSLY HURT if you don’t followinstructions.

You CAN be HURT if you don’t follow instructions.

Safety Messages

A Few Words About Safety

Safety Headings

Safety Section

Instructions

–– such as Important Safety Reminders or Important Safety Precautions.

–– such as Motorcycle Safety.

–– how to use this motorcycle correctly and safely.

This entire book is filled with important safety information –– please read it carefully.

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Contents

Contents

..................................Operating Controls .

...........................................Before Riding .

Introduction

....................................Motorcycle Safety .

.......................Basic Operation & Riding .

.............................Servicing Your Honda .

11

1

21

27

39

These pages give an overview of the contentsof your owner’s manual. The first page of eachsection lists the topics covered in that section.

Important safety information,precautions about loading, accessories,and modifications, and the location ofsafety labels.

The location, function, and operation ofthe throttle, brakes, clutch, and otherbasic controls.

The importance of wearing a helmetand other protective gear, plus how tomake sure you and your motorcycle areready to ride.

Why your motorcycle needs regularmaintenance, what you need to knowbefore servicing your Honda, amaintenance schedule, and instructionsfor specific maintenance items.

How to start and stop the engine, shiftgears, and brake. Also, ridingprecautions.

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Contents

Contents

..............Taking Care of the Unexpected .

.............................Technical Information .

...........................Consumer Information .

Quick Reference

..........................................................Index .

.....................................Table of Contents .............................................................Tips . 113

123

131

147

156

160

How to transport and store yourmotorcycle, and how to be anenvironmentally-responsible rider.

What to do if you have a flat tire, yourengine won’t start, etc.

ID numbers, technical specifications,and other technical facts.

Information on warranties and how toget Honda service manuals.

Handy facts about fuel, engine oil, tire sizes,and air pressures.

Sequential listing of topics in thisowner’s manual.

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－

Introduction

Introduction

Congratulations on choosing your Honda off-road motorcycle.

When you own a Honda, you’re part of aworldwide family of satisfied customerspeople who appreciate Honda’s reputation forbuilding quality into every product.

Your Honda was designed as a recreationalmotorcycle for off-road use by one rider only.

Before riding, take time to get acquainted withyour motorcycle and how it works. To protectyour investment, we urge you to takeresponsibility for keeping your motorcycle wellmaintained. Scheduled service is a must, ofcourse. But it’s just as important to observe thebreak-in guidelines, and perform all the pre-ride and other periodic checks detailed in thismanual.

We also recommend that you read the owner’smanual before you ride. It’s full of facts,instructions, safety information, and helpfultips. To make it easy to use, the manualcontains a table of contents, a detailed list oftopics at the beginning of each section, and anindex at the back of the book.

As you read this manual, you will findinformation that is preceded by a

symbol. This information is intendedto help you avoid damage to your Honda, otherproperty, or the environment.

Read the Warranties Booklet (page )thoroughly so you understand the coveragesthat protect your new Honda and are aware ofyour rights and responsibilities.

151

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Introduction

Introduction

Whenever you ride, tread lightly. By staying onestablished trails and riding only in approvedareas, you help protect the environment andkeep off-road riding areas open for the future.

If you have any questions, or if you ever need aspecial service or repairs, remember that yourHonda dealer knows your motorcycle best andis dedicated to your complete satisfaction.

Please report any change of address orownership to your Honda dealer so we will beable to contact you concerning importantproduction information.

You may also want to visit our website atwww.honda.com.

Happy riding!

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1

Motorcycle Safety

Motorcycle Safety

..........................Important Safety Information .2...........Loading, Accessories & Modifications .5

........................................................Loading .5.......................Accessories & Modifications .7

....................................................Safety Labels .9

This section presents some of the mostimportant information and recommendations tohelp you ride your motorcycle safely. Pleasetake a few moments to read these pages. Thissection also includes information about thelocation of safety labels on your motorcycle.

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－

－

2

Never Carry a Passenger

Ride Off-Road Only

Always Wear a Helmet

Important Safety Information

Motorcycle Safety

Your motorcycle can provide many years ofservice and pleasure if you take responsibilityfor your own safety and understand thechallenges you can meet while riding.

Your motorcycle is designed for one persononly. There are no handholds, footrests, or seatfor a second person so never carry apassenger. A passenger could interfere withyour ability to move around to maintain yourbalance and control of the motorcycle.

Your motorcycle is designed and manufacturedfor off-road use only. The tires are not madefor pavement, and the motorcycle does nothave turn signals and other features requiredfor use on public roads. If you need to cross apaved or public road, get off and walk yourmotorcycle across.

There is much that you can do to protectyourself when you ride. You’ll find manyhelpful recommendations throughout thismanual. The following are a few that weconsider most important.

It’s a proven fact: helmets significantly reducethe number and severity of head injuries. Soalways wear an approved motorcycle helmet.We also recommend that you wear eyeprotection, sturdy boots, gloves, and otherprotective gear (page ).22

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3

Take Time to Learn and Practice Be Alert for Off-Road Hazards

Ride within Your Limits

Motorcycle Safety


Tips & Practice Guidef or the Of f -Highway Motorcyclist

Developing off-road riding skills is a gradual,step-by-step process. Start by practicing at lowspeeds in a safe area and slowly build yourskills. Personal instruction from an experiencedrider can also be valuable.

If you need assistance, ask your dealer aboutriding groups in your area.

Also be sure to read thebooklet that

came with your motorcycle (USA only).

The terrain can present a variety of challengeswhen you ride off-road. Continually ‘‘read’’the terrain for unexpected turns, drop-offs,rocks, ruts, and other hazards. Always keepyour speed low enough to allow time to see andreact to hazards.

Pushing limits is another major cause ofmotorcycle accidents. Never ride beyond yourpersonal abilities or faster than conditionswarrant. Remember that alcohol, drugs, fatigue,and inattention can significantly reduce yourability to make good judgments and ride safely.

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4

Keep Your Honda in Safe Condition

Don’t Drink and Ride


Motorcycle Safety

It’s important to keep your motorcycle properlymaintained and in safe riding condition.Having a breakdown can be difficult,especially if you are stranded off-road far fromyour base. To help avoid problems, inspectyour motorcycle before every ride and performall recommended maintenance.

Alcohol and riding don’t mix. Even one drinkcan reduce your ability to respond to changingconditions, and your reaction time gets worsewith every additional drink. So don’t drink andride, and don’t let your friends drink and rideeither.

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Overloading or carrying a passengercan cause a crash and you can beseriously hurt or killed.

Follow all load limits and other loadingguidelines in this manual.

5

Loading, Accessories & Modifications

Motorcycle Safety

Loading

Your Honda was designed as a rider-onlymotorcycle. It was not designed to carry apassenger or cargo. A passenger or cargo couldinterfere with your ability to move around tomaintain your balance and control of themotorcycle.

More specific information on load limits,accessories, and modifications follows.

In addition, exceeding the weight limits orcarrying an unbalanced load can seriouslyaffect your motorcycle’s handling, braking,and stability. Adding accessories or makingmodifications that change this motorcycle’sdesign and performance can also make itunsafe. Also, the weight of any accessories willreduce the maximum load the motorcycle cancarry.

How much weight you put on your motorcycle,and how you load it, are important to yoursafety. If you decide to carry cargo, you shouldbe aware of the following information.

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220 lbs (100 kg)

6

Load Limits

Maximum weight capacity=

Loading Guidelines


Motorcycle Safety

Following are the load limits for yourmotorcycle:

Includes the weight of the rider and anyaccessories.

As discussed on page , we recommend thatyou do not carry any cargo on this motorcycle.However, if you decide to carry cargo, ride atreduced speeds and follow these common-sense guidelines:

Keep cargo small and light. Make sure itcannot easily be caught on brush or otherobjects, and that it does not interfere withyour ability to shift position to maintainbalance and stability.

Place weight as close to the center of themotorcycle as possible.Do not attach large or heavy items (such as asleeping bag or tent) to the handlebar, fork,or front fender.Make sure that all cargo is tied downsecurely.Never exceed the maximum weight limit.Check that both tires are inflated properly.

5

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Improper accessories or modificationscan cause a crash in which you can beseriously hurt or killed.

Follow all instructions in this owner’smanual regarding modifications andaccessories.

7

Accessories


Motorcycle Safety

Accessories & Modifications

Modifying your motorcycle or using non-Honda accessories can make your motorcycleunsafe.

Before you consider making any modificationsor adding an accessory, be sure to read thefollowing information.

We strongly recommend that you use onlygenuine Honda accessories that have beenspecifically designed and tested for yourmotorcycle. Because Honda cannot test allother accessories, you must be personallyresponsible for proper selection, installation,and use of non-Honda accessories. Check withyour dealer for assistance and always followthis guideline:

Make sure the accessory does not reduceground clearance and lean angle, limitsuspension travel or steering travel, alteryour riding position, or interfere withoperating any controls.

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8

Modifications


Motorcycle Safety

We strongly advise you not to remove anyoriginal equipment or modify your motorcyclein any way that would change its design oroperation. Such changes could seriously impairyour motorcycle’s handling, stability, andbraking, making it unsafe to ride.

We also advise you not to make anymodifications or remove any equipment (suchas the USDA qualified spark arrester oremission control system components) thatwould make the motorcycle illegal in your area.

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9Motorcycle Safety

Safety Labels

This page shows the locations of safety labels on your motorcycle. Some labels warn you ofpotential hazards that could cause serious injury. Others provide important safety information. Readthese labels carefully and don’t remove them.

If a label comes off or becomes hard to read, contact your Honda dealer for a replacement.

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10 Motorcycle Safety

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11

Operating Controls

Operating Controls

When you ride off-road, you need to operatethe throttle, clutch, brakes, and other controlswithout stopping to look at them. Read thissection carefully before you ride. It describesthe location, function, and operation of all thebasic controls on your motorcycle.

....................................Component Locations .12......................................................Fuel Valve .15

...................................................Choke Lever .16...............................................Ignition Switch .17

........................................Engine Stop Button .18..........................................Front Brake Lever .18

...........................................................Throttle .18...................................................Clutch Lever .18

.....................................................Shift Lever .19............................................Rear Brake Pedal .19

......................................................Kickstarter .19

......................................................Side Stand .19

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clutch lever front brake lever

engine stopbutton

throttle

ignition switch

12

Component Locations

Operating Controls

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choke lever

shift lever

fuel valve

side stand

13

Component Locations

Operating Controls

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rear brake pedal

kickstarter

14

Component Locations

Operating Controls

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ON RESOFF

15

Operating Controls

Operating Controls

Fuel Valve

The three-way fuel valve is used to control theflow of fuel from the fuel tank to thecarburetor.

Turning the fuel valve ON before attempting tostart the engine allows fuel to flow from thefuel tank to the carburetor.

Turning the fuel valve OFF after stopping theengine prevents the flow of fuel from the fueltank to the carburetor.

Turning the fuel valve to RES allows fuel toflow from the reserve fuel supply to thecarburetor.

(cont’d)

ON

OFF

RES

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○○

○○

○○

ＡＡ

ＢＢ

ＣＣ

0.40 US gal (1.5 )

(1) choke lever

(1)

LEFT SIDE

(A) fully ON(B) detent position(C) fully OFF

16

Operating Controls

Operating Controls

Choke Lever

The reserve fuel supply is:

The tank should be refilled as soon as possibleafter switching to reserve, and the fuel valveshould be returned to the ON position afterrefueling to avoid running out of fuel with noreserve.

The choke lever is used for starting the engine(page ). The choke increases the percentageof fuel in the fuel/air mixture delivered to theengine.

Used to start a cold engine with air temperaturebelow 35°C (95°F).

Used for normal operation, for restarting awarm engine, or starting a cold engine with airtemperature above 35°C (95°F).

Used to warm a cold engine immediately afterstarting with air temperature below 35°C(95°F).

ON

29

OFF

DETENT

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Key RemovalFunctionKey

Position

The key canbe removed.The keycannot beremoved.

The engine cannot beoperated.With the transmissionin neutral, the enginecan be started.

OFF

(ON)

(1)

ONOFF

(1) ignition switch

FRONT

ONOFF

17

Operating Controls

Operating Controls

Ignition Switch

The ignition switch is used to preventunauthorized use of the motorcycle.

Before riding, insert the key and turn it to theON position.

After parking the motorcycle, remove the key.

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18

Engine Stop Button

Front Brake Lever

Throttle

Clutch Lever

Operating Controls

Operating Controls

The engine stop button is used to turn theengine off during normal riding situations. Tooperate, push the button in and hold it in untilthe engine stops completely.

The throttle controls engine rpm (speed). Toincrease engine rpm, rotate the grip toward you.To reduce engine rpm, rotate the grip awayfrom you. The throttle will automatically returnto the closed position (engine idle) when youremove your hand.

The clutch lever is used to disengage the clutchwhenever you shift gears. To operate, pull theclutch lever in all the way before shifting, thenslowly release it after shifting.

The front brake lever is used to slow or stopyour motorcycle. To operate, pull the lever. Forinformation on braking techniques, seepage .35

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19

Shift Lever

Rear Brake Pedal

Kickstarter

Side Stand

Operating Controls

Operating Controls

Shif ting Gears,

Starting Procedure,

The shift lever is used to select the next higheror lower gear in the transmission. To operate,raise the shift lever (after pulling in the clutchlever) to engage the next higher gear or depressthe shift lever to engage the next lower gear.See page .

The rear brake pedal is used to slow or stopyour motorcycle. To operate, depress the pedal.For information on braking techniques, seepage .

The side stand is used to support yourmotorcycle while parked (page ). To operate,use your foot to lower the stand. Before riding,raise the stand.

The kickstarter is used to start the engine. Tooperate, swing the kickstarter out from itsstored position and depress it through its entirestroke. See page .

33

35

29

37

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20 Operating Controls

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21

Before Riding

Before Riding

Before each ride, you need to make sure youand your Honda are both ready to ride. To helpget you prepared, this section discusses how toevaluate your riding readiness, and how toperform the recommended pre-ride inspectionof your Honda.

................................Are You Ready to Ride? .22.....................................Protective Apparel .22

..............Is Your Motorcycle Ready to Ride? .24.....................................Pre-ride Inspection .24

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22 Before Riding

Protective Apparel

Are You Ready to Ride?

Before you ride your motorcycle for the firsttime, we strongly recommend that you:

For your safety, we strongly recommend thatyou always wear an approved motorcyclehelmet, eye protection, boots, gloves, longpants, and a long-sleeved jersey, shirt, or jacketwhenever you ride. Although completeprotection is not possible, wearing the propergear can reduce the chance of injury when youride. Following are suggestions to help youchoose the proper gear.

read this owner’s manualmake sure you understand all the safetymessagesknow how to operate all the controls

Before each ride, we also suggest that youmake sure you:

are in good physical and mental conditionare free of alcohol and drugsare wearing an approved motorcycle helmet(with chin strap tightened securely), eyeprotection, and other protective clothing

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Not wearing a helmet increases thechance of serious injury or death in acrash.

Be sure you always wear a helmet,eye protection and other protectiveapparel when you ride.

23

Helmets and Eye Protection

Additional Riding Gear

Before Riding

Are You Ready to Ride?

Your helmet is your most important piece ofriding gear because it offers the best protectionagainst head injuries. A helmet should fit yourhead comfortably and have a chin strap that canbe tightened securely.

An open-face helmet offers some protection,but a full-face helmet offers more. Regardlessof the style, look for a DOT (Department ofTransportation) sticker in any helmet you buy

(USA only). Always wear a face shield orgoggles to protect your eyes and help yourvision.

In addition to a helmet and eye protection, wealso recommend:

Riding pants with knee and hip pads, a ridingjersey with padded elbows, and a chest/shoulder protector.

Off-road motorcycle gloves to help protectyour hands.

Sturdy off-road motorcycle boots to helpprotect your feet, ankles, and lower legs.

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Improperly maintaining this motorcycleor failing to correct a problem beforeriding can cause a crash in which youcan be seriously hurt or killed.

Always perform a pre-ride inspectionbefore every ride and correct anyproblems.

24 Before Riding

Pre-ride Inspection

Is Your Motorcycle Ready to Ride?

Tires

Leaks

Spokes &Rims

Check the following items before you get onthe motorcycle:

Use a gauge to check the airpressure. Adjust if needed. Alsolook for signs of damage orexcessive wear (page ).

Make sure the spokes and rimlocks are tight. Also check therims for damage (page ).

Look under the motorcycle forsigns of leaking fluids (fuel,engine oil, brake fluid).

Before each ride, it’s important to inspect yourmotorcycle and make sure any problem youfind is corrected. A pre-ride inspection is amust because off-road riding can be tough on amotorcycle and you don’t want to have abreakdown far from help.

92

99

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25Before Riding


Engine Oil

Fuel

Spark Plug& Cap

Throttle

Brakes

Drive Chain

Cables

Nuts &Bolts

Check the level and add oil ifneeded (page ).

Check the level and add fuel(page ) if needed. Also makesure the fuel fill cap is securelyfastened.

Check for looseness (page ).

Check these items after you get on themotorcycle:

Check the freeplay and adjust ifneeded. Rotate the throttle tomake sure it moves smoothlywithout sticking, and snaps shutautomatically when it is released,in all steering positions(page ).

Check the condition and slack.Adjust and lubricate if needed.Also check the chain guideslider and slipper for wear andreplace if needed (page ).

Check the cable housings forwear. Check the fittings forlooseness. Replace or tighten asneeded.

Use a wrench to make sure allaccessible nuts, bolts, andfasteners are tight. (cont’d)

Squeeze the front brake leverand step on the rear brake pedalto check that the controlsoperate normally (pages ,

). Check for proper freeplay(pages , ). Adjustfreeplay, if necessary (pages

, ).

63

103

77

71

88

8884

84

58

88

84

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26 Before Riding


ClutchLever

Check for smooth operation andadjust if needed (page ).

Remember, be sure to take care of any problemyou find or have your Honda dealer correct itbefore you ride.

73

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－

27

Basic Operation & Riding


Tips & PracticeGuide f or the Of f -Highway Motorcyclist

This section gives basic information on how tobegin riding your motorcycle. It includes howto start and stop your engine, how to use thethrottle, clutch, and brakes, and what to dowhen you’re through riding.

For more advanced information how to maketurns, ride on hills, etc., see the

booklet that came with your Honda (USA only).

To protect your new engine and enjoy optimumperformance and service life, refer to Break-inGuidelines (page ).

.................................Safe Riding Precautions .28.....................Starting & Stopping the Engine .29

.................................................Preparation .29......................................Starting Procedure .29

..........................................Flooded Engine .31.............................How to Stop the Engine .32

................................................Shifting Gears .33...........................................................Braking .35...........................................................Parking .37

.......................................Post-ride Inspection .38

For information about carburetor adjustmentfor riding at high altitude, see page .

139

140

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28

Safe Riding Precautions



Important Saf etyInf ormation

Bef ore Riding.

Before riding your motorcycle for the first time,please review the

beginning on page and theprevious section, titled

Even if you have ridden other motorcycles,take time to become familiar with how thismotorcycle works and handles. Practice in asafe area until you build up your skills and getaccustomed to your motorcycle’s size andweight.

For your safety, avoid starting or operating theengine in an enclosed area such as a garage.Your motorcycle’s exhaust contains poisonouscarbon monoxide gas which can collect rapidlyin an enclosed area and cause illness or death.

Your motorcycle is not equipped with lights.Do not ride at night.

2

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－－

○○

○○○○

ＡＡ

ＢＢ

ＣＣ

(1) choke lever

LEFTSIDE

(1)

(A) fully ON(B) detent position(C) fully OFF

29

Starting Procedure

Preparation

Starting & Stopping the Engine


High Air Temperature.To restart a warm engine, follow the procedurefor

Normal Air Temperature10° 35°C (50° 95°F)

Your motorcycle can be kickstarted with thetransmission in gear by pulling in the clutchlever before operating the kickstarter.

Always follow the proper starting proceduredescribed below.

Before starting, insert the key and turn theignition switch ON.

Make sure that the transmission is in neutral.Turn the fuel valve ON.

(cont’d)

Pull the choke lever ( ) up all the way tofully ON ( ).

1. 1A

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30



Allowing the kickstarter to snap back f reelyagainst the pedal stop can damage the enginecase.

Lightly depress the kickstarter untilresistance is felt.Then let kickstarter return to the top of itsstroke.With the throttle closed, operate thekickstarter.Kick from the top of the stroke through tothe bottom with a rapid, continuous motion.

About a half-minute after the engine starts,push the choke lever down all the way tofully OFF ( ).If idling is unstable, open the throttle slightly.

Warm up the engine by opening and closingthe throttle slightly.

Immediately after the engine starts, push thechoke lever down to the detent position ( ).

2.

3.

4.

5.

6.

B

C

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－

31



Flooded Engine

Normal Air Temperature.

Normal AirTemperature.

Extended use of the choke may impair pistonand cylinder wall lubrication and damage theengine.

High Air Temperature

If the engine fails to start after repeatedattempts, it may be flooded with excess fuel.To clear a flooded engine:

Push the choke lever down all the way toOFF.Open the throttle fully.While pushing the engine stop button, crankthe engine several times with the kickstarter.Release the engine stop button.

High Air Temperature35°C (95°F) or aboveDo not use the choke.Start the engine following step under

Low Air Temperature10°C (50°F) or belowFollow steps under

Warm up the engine by opening and closingthe throttle slightly.Continue warming up the engine until it willidle smoothly with the choke lever ( )pushed down all the way to fully OFF ( ).

Follow the startingprocedure (this page).

2.3.

1.

4.5.

2.

1.

3.

1.2. 2

31

1C

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32



How to Stop the Engine

To stop the engine, shift into neutral, push theengine stop button in, and hold it in until theengine stops.

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2 3 4 5

1

33

Shifting Gears


When you attain a moderate speed, close thethrottle, pull the clutch lever in, and raise theshift lever. After shifting, release the clutchlever and apply the throttle.

If engine rpm (speed) is too low when yourelease the clutch lever, the engine will stall.If engine rpm is too high or you release theclutch lever too quickly, your motorcyclemay lurch forward.

Release the front brake. Gradually open thethrottle while you slowly release the clutchlever.

Depress the shift lever from neutral down tofirst gear.

Your motorcycle has five forward gears.

To start riding, after the engine has beenwarmed and the side stand raised:

Close the throttle and pull the front brakelever in.Pull the clutch lever all the way in.

(cont’d)2.

3.

1.

4.

5.

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34

Shifting Gears


Improper shif ting may damage the engine,transmission, and drive train.

To shift down to a lower gear, close thethrottle, pull the clutch lever in, and depressthe shift lever. After shifting, release theclutch lever and apply the throttle.

To continue shifting up to each higher gear,repeat step .

Remember to close the throttle and pull theclutch lever in completely before shifting.

Downshifting can help slow your motorcycle,especially on downhills. However,downshifting when engine rpm is too high cancause engine damage.

To prevent transmission damage, do not coastor tow the motorcycle for long distances withthe engine off.

Learning when to shift gears comes withexperience. Upshift to a higher gear or reducethrottle before engine rpm (speed) gets too high.Downshift to a lower gear before you feel theengine laboring (lugging) at low rpm.

6.

7.5

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35

Braking


To slow or stop, apply the front brake and rearbrake smoothly, while downshifting to matchyour speed. Gradually increase braking as youfeel the brakes slowing your speed. To preventstalling the engine, pull the clutch lever inbefore coming to a complete stop. For support,put your left foot down first, then your rightfoot when you are through using the rear brake.

Generally, reduce your speed or completebraking before beginning a turn. Avoid brakingor closing the throttle quickly while turning.Either action may cause one or both wheels toslip. Any wheel slip will reduce your control ofyour motorcycle.

(cont’d)

When riding in wet or raining conditions, or onloose surfaces, the ability to maneuver and stopwill be reduced. All of your actions should besmooth under these conditions. Rapidacceleration, braking, or turning may cause lossof control. For your safety, exercise extremecaution when braking, accelerating, or turning.

For maximum braking, close the throttle andfirmly apply the brake lever and pedal controls.

Applying the brakes too hard may cause thewheels to lock and slide, reducing control ofyour motorcycle. If this happens, release thebrake controls, steer straight ahead until youregain control, then reapply the brakes moregently.

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36

Braking


When descending a long, steep grade, useengine compression braking by downshifting,with intermittent use of both brakes.

When you brake to a stop, pull the clutch leverin before stopping completely to preventstalling the engine. For support, put your leftfoot on the ground first, then your right footwhen you’re through braking.

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37

Parking


Lower the side stand to support yourmotorcycle. Turn the ignition switch OFF andremove the key. If you’re through riding forthe day, also turn the fuel valve OFF. Alwayschoose a level place to park.

03/03/07 16:04:16 31KPT610_046

38

Post-ride Inspection


When you return home after riding, thoroughlyclean your motorcycle and remove any dirt,mud, brush, rocks or other objects you mayhave picked up along the way.

After cleaning, carefully inspect yourmotorcycle for leaks or damage.

Be sure to lubricate the drive chain (page )to prevent rusting.

107

03/03/07 16:04:21 31KPT610_047

39Servicing Your Honda

Servicing Your Honda

Bef ore You Service Your HondaKeeping your motorcycle well maintained isabsolutely essential to your safety. It’s also agood way to protect your investment, getmaximum performance, avoid breakdowns, andhave more fun.

To help keep your motorcycle in good shape,this section includes a Maintenance Schedulefor required servicing and step-by-stepinstructions for specific maintenance tasks.You’ll also find important safety precautions,information on oils, and tips for keeping yourHonda looking good.

(cont’d)

For information about the exhaust emission andnoise emission requirements of the U.S.Environmental Protection Agency (EPA) andthe California Air Resources Board (CARB),see page .

....................The Importance of Maintenance .41........................................Maintenance Safety .43

.....................Important Safety Precautions .43...................................Maintenance Schedule .45

......................................Maintenance Record .49..................................Competition Inspection .50

141

03/03/07 16:04:28 31KPT610_048

40



Service Preparations

Service Procedures

....................................Component Locations .53...............................................................Tools .55

......................................Side Cover Removal .56

Fluids & Filters.................................................................Fuel .57

......................................................Engine Oil .60.....................................................Air Cleaner .66

........................................Crankcase Breather .70

Engine...........................................................Throttle .71

................................................Clutch System .73..........................................Engine Idle Speed .76

......................................................Spark Plug .77................................................Spark Arrester .79

Chassis.....................................................Suspension .81

.............................................................Brakes .84............................................................Wheels .92

.................................................Tires & Tubes .98....................................................Side Stand .102..................................................Drive Chain .103

..........................................Appearance Care .110

03/03/07 16:04:32 31KPT610_049

Improperly maintaining this motorcycleor failing to correct a problem beforeyou ride can cause a crash in whichyou can be seriously hurt or killed.

Always follow the inspection andmaintenance recommendations andschedules in this owner’s manual.

41

The Importance of Maintenance


Frequent servicing of the air cleaner isespecially important to help you avoid apossible costly engine repair.

If your motorcycle overturns or is involved in acrash, be sure your Honda dealer inspects allmajor parts, even if you are able to make somerepairs.

(cont’d)

A well-maintained motorcycle is essential forsafe, economical, and trouble-free riding. Itwill also help reduce air pollution. Careful pre-ride inspections and good maintenance areespecially important because your motorcycleis designed to be ridden over rough off-roadterrain.

To help you properly care for your motorcycle,this section of the manual provides aMaintenance Schedule. The service intervals inthis schedule are based on average ridingconditions.

More frequent service is needed if you subjectyour motorcycle to severe use (see theCompetition Inspection checklist, page ) orride in unusually wet or dusty areas.

50

03/03/07 16:04:40 31KPT610_050

42

The Importance of Maintenance


Remember, proper maintenance is the owner’sresponsibility. Be sure to inspect yourmotorcycle before each ride and follow theMaintenance Schedule in this section.

03/03/07 16:04:44 31KPT610_051

Failure to properly follow maintenanceinstructions and precautions cancause you to be seriously hurt or killed.

Always follow the procedures andprecautions in this owner’s manual.

43

Carbon monoxide poisoning from engineexhaust.

Burns from hot motorcycle parts.

Injury from moving parts.

Maintenance Safety

Important Safety Precautions


The maintenance section includes instructionson how to perform some importantmaintenance tasks. Some of the most importantsafety precautions follow. However, we cannotwarn you of every conceivable hazard that canarise in performing maintenance. Only you candecide whether or not you should perform agiven task.

(cont’d)

Make sure the engine is off before you beginany maintenance or repairs.This will help eliminate several potentialhazards:

Be sure there is adequateventilation whenever you operate the engine.

Let theengine and exhaust system cool beforetouching.

Do not run theengine unless instructed to do so.

03/03/07 16:04:51 31KPT610_052

－－

44

Maintenance Safety


Read the instructions before you begin, andmake sure you have the tools and skillsrequired.To help prevent the motorcycle from fallingover, park it on a firm, level surface, usingthe side stand or a maintenance stand toprovide support.To reduce the possibility of a fire orexplosion, be careful when working aroundgasoline. Use only a non-flammable (highflash point) solvent such as kerosene notgasoline to clean parts. Keep cigarettes,sparks, and flames away from all fuel-related parts.

03/03/07 16:04:56 31KPT610_053

45

Maintenance Schedule


To maintain the safety and reliability of yourmotorcycle, regular inspection and service isrequired as shown in the Maintenance Schedulethat follows.

Because your motorcycle does not have anodometer, service intervals in the maintenanceschedules are expressed in terms of riding daysas well as miles. To avoid overlooking requiredservice, we urge you to develop a convenientway to record the number of days and/or milesyou ride.

The Maintenance Schedule lists items that canbe performed with basic mechanical skills andhand tools. Procedures for these items areprovided in this manual.

The Maintenance Schedule also includes itemsthat involve more extensive procedures andmay require special training, tools, andequipment. Therefore, we recommend that youhave your Honda dealer perform these tasksunless you have advanced mechanical skillsand the required tools. Procedures for items inthis schedule are provided in a service manualavailable for purchase from your dealer(page ).

If you do not feel capable of performing agiven task or need assistance, remember thatyour Honda dealer knows your motorcycle bestand is fully equipped to maintain and repair it.If you decide to do your own maintenance, useonly genuine Honda parts or their equivalentsfor repair or replacement to ensure the bestquality and reliability.

148

03/03/07 16:05:02 31KPT610_054

＊＊＊

＊＊

＊

46



Summary of Maintenance Schedule Notes andProcedures:

Perform the pre-ride inspection (page ) ateach scheduled maintenance period.

Service more frequently when ridden in wetor dusty conditions.

Each item on the maintenance schedulerequires some mechanical knowledge. Certainitems (particularly those marked and ) mayrequire more technical information and tools.Consult your Honda dealer.

Should be serviced by your Honda dealer,unless the owner has the proper tools andservice data and is mechanically qualified.Refer to the official Honda Service Manual(page ).In the interest of safety, we recommendthese items be serviced only by your Hondadealer.

Replace every 2 years. Replacement requiresmechanical skill.

Maintenance Procedures:inspect and clean, adjust, lubricate, orreplace, if necessarycleanadjustlubricatereplace

NOTES:1.

2.

24

I:

C:A:L:R:

148

03/03/07 16:05:12 31KPT610_055

－

－

－－

＊＊

＊

47



Referto

page:1001501

6001,000

6

1,2002,000

12

1,8003,000

18

2,4004,000

24Items

FrequencyWhicheverComes First

InitialMaint.

Regular Maint. Interval

Note

mikm

Month

Note 1

IR

I

CIIIR

I

IICIIIRCCI

CIIIR

I

IICIIIRCCI

71667077

60

76

Should be serviced by your Honda dealer, unless the owner has the proper tools and service data and is mechanically qualified. Referto the official Honda Service Manual (page ).In the interest of safety, we recommend these items be serviced only by your Honda dealer.

Fuel LineThrottle OperationAir CleanerCrankcase BreatherSpark PlugValve ClearanceEngine OilEngine Oil Strainer ScreenEngine Oil Centrifugal FilterEngine Idle Speed

148

EM

ISSION

RE

LA

TE

DIT

EM

S

03/03/07 16:05:29 31KPT610_056

－

－

＊＊

＊

－

48



Referto

page:1001501

6001,000

6

1,2002,000

12

1,8003,000

18

2,4004,000

24Items

FrequencyWhicheverComes First

InitialMaint.

Regular Maint. Interval

Note

mikm

MonthDrive ChainDrive Chain SliderBrake FluidBrake Shoes/Pads WearBrake SystemClutch SystemSide StandSuspensionSpark ArresterNuts, Bolts, FastenersWheels/TiresSteering Head Bearings

Note 1

Note 2

I, L

II

III

IIIII

I

IIIII

I

10310486

87, 8984731028179

92, 98

Should be serviced by your Honda dealer, unless the owner has the proper tools and service data and is mechanically qualified. Referto the official Honda Service Manual (page ).In the interest of safety, we recommend these items be serviced only by your Honda dealer.

IIIIIII

III

IIIIIII

III

148

I, L: every 300 mi (500 km) or 3 months

C: every 1,000 mi (1,600 km) or every 100 operating hours

NO

NE

MISSIO

NR

EL

AT

ED

ITE

MS

03/03/07 16:05:46 31KPT610_057

49

Date Performed By: NotesMiles (km) orMonths


Maintenance Record

Keeping an accurate maintenance record will help ensure that your motorcycle is properlymaintained. Use the space under Notes to record anything you want to remind yourself about ormention to your dealer. Of course, if you find any problem while servicing your motorcycle, be sureit is corrected as soon as possible.

600 (1,000) or 61,200 (2,000) or 121,800 (3,000) or 182,400 (4,000) or 243,000 (5,000) or 303,600 (6,000) or 364,200 (7,000) or 424,800 (8,000) or 485,400 (9,000) or 54

03/03/07 16:05:52 31KPT610_058

－

－－

－

50

Damage from competition use is not covered by the Distributor’s Limited Warranty on yourHonda.

No Item Inspect For: Action Refer toPage:


Competition Inspection

All items should be checked before each competition event. See your Honda dealer unless you aremechanically qualified and have the proper tools.

Refer to the Maintenance Schedule (page ) for regular service intervals.NOTE: 46

1

23456

all pre-ride inspectionitemsengine oilfuel linevalve clearanceengine idle speedcarburetor choke

contaminantsdeterioration, damage, or leakagecorrect clearancecorrect idle speedproper operation

changereplaceadjustadjust

24

60

76

03/03/07 16:06:03 31KPT610_059

－

－

51




(cont’d)

clutch discsair cleaner

spark plug

steering head bearings

front suspension

rear suspension

78

9

10

11

12

replaceclean orreplacetighten,replace orsecureadjust orretightenreplace oradjustreplace oradjust

66

77

81

82

proper operation, see NOTE 1contamination or tears

gap, tightness, proper heat range, high-tension terminal security

free rotation of handlebar and steeringstem nut tightnesssmooth operation, oil capacity, no oil leaks,good boot conditionsmooth operation, no oil leaks

Competition use may cause more rapid clutch disc wear. Refer to the official Honda ServiceManual, or see your Honda dealer for clutch disassembly and wear inspection.

NOTE 1:

03/03/07 16:06:14 31KPT610_060

－－

－

41 pins25.1 in (637 mm) /

52




smooth operationwear

wear beyond service limit

1314

1516

17

1819

20

swingarm bearingsrear suspension linkagebushingsbrake padsdrive chain:max. length/pinsprockets

seatcontrol cables

engine mounting bolts

wear and secure installation

securitysmooth operation, kinks and correctroutingtightness

replacereplace

replacereplace

replace ortightentightenlubricate orreplacetighten

8282

87105

106

03/03/07 16:06:25 31KPT610_061

steering head

front suspension

left side cover

rear wheelaxle

rear suspension

chainadjuster

clutch lever

front brake hose

carburetor

fuel tank

chain guide slider

engine oildrain bolt drive chain

side stand

chain slider

crankcasebreather

53Servicing Your Honda

Component Locations

03/03/07 16:06:30 31KPT610_062

front brake lever

front wheel axle

rear brake pedal

spark arrester

lower clutchadjusting nut

kickstarter

oil fillercap/dipstick

rim lock

throttlefuel fill cap

air cleaner

air cleanerhousing cover

rim lock

right side cover spark plug

54 Servicing Your Honda

Component Locations

03/03/07 16:06:35 31KPT610_063

(1) spark plug wrench(2) handle

(1)

(2)

55

Tools


Saf ety PrecautionsRefer to on page . The spark plug wrench ( ) and its handle ( )are stored in the tool bag delivered with yourmotorcycle.

You will need to provide your own tools toperform any owner maintenance other thanremoving the spark plug.

2143

03/03/07 16:06:40 31KPT610_064

(2)

(3)

LEFT SIDE

RIGHT SIDE

(1) screw(2) prongs

(3) rubber grommets

(1)

(2)

(3)

(1)

56

Side Cover Removal


Saf ety PrecautionsRefer to on page . RemovalUse a screwdriver to remove the screw ( ).Pull both side cover prongs ( ) out of therubber grommets ( ).

InstallationSlide the top of the side cover under thebottom edge of the seat.Align the side cover prongs with the rubbergrommets. Press the side cover into position.Install the securing screw and tighten it.

1.

1.

2.

2.

3.

431

23

03/03/07 16:06:49 31KPT610_065

unleaded92 (or higher)

TypePump OctaneNumber

57

Fuel Recommendation

Fuel


Saf ety PrecautionsRefer to on page .

Use of lower octane gasoline can causepersistent ‘‘pinging’’ or ‘‘spark knock’’ (alouder rapping noise) which, if severe, can leadto engine damage. (Light pinging experiencedwhile operating under a heavy load, such asclimbing a hill, is no cause for concern.)

If pinging or spark knock occurs at a steadyengine speed under normal load, change brandsof gasoline. If pinging or spark knock persists,consult your Honda dealer.

We recommend that you use unleaded fuelbecause it produces fewer engine deposits andextends the life of exhaust system components.

Never use stale or contaminated gasoline or anoil/gasoline mixture. Avoid getting dirt, dust,or water in the fuel tank.

Your engine is designed to use any gasolinethat has a pump octane number of 92 or higher.Gasoline pumps at service stations normallydisplay the pump octane number. Forinformation on the use of oxygenated fuels, seepage .

43

145

03/03/07 16:06:58 31KPT610_066

2.17 US gal (8.2 )

0.40 US gal (1.5 )

Gasoline is highly flammable andexplosive. You can be burned orseriously injured when handling fuel.

Stop the engine and keep heat,sparks and flame away.Handle fuel only outdoors.Wipe up spills immediately.

(1)(2)

(1) fuel fill cap(2) breather tube

(4)(3)

(3) steering stem nut(4) filler neck

58

Refueling Procedure

Fuel


Reserve Capacity:

Add fuel until the level reaches the bottomof the filler neck ( ). Avoid overfilling thetank. There should be no fuel in the fillerneck.

Fuel Tank Capacity, including reserve:

To open the fuel fill cap ( ), pull thebreather tube ( ) out of the steering stem nut( ). Turn the fuel fill cap counterclockwiseand remove it.

1.

2.

21

4

3

03/03/07 16:07:08 31KPT610_067

59

Fuel


After refueling, turn the fuel fill capclockwise until it is secure.

If you replace the fuel fill cap, use only agenuine Honda replacement part.

Insert the breather tube in the steering stemnut.

3.

4.

03/03/07 16:07:13 31KPT610_068

＊＊

＊

SG or higher exceptoils labeled asenergy conservingon the circular APIservice labelSAE 10W-40MAPro Honda GN4 orHP4 (withoutmolybdenumadditives) 4-strokeoil (USA & Canada),or Honda 4-stroke oil(Canada only), or anequivalentmotorcycle oil

API classification

viscosity (weight)JASO T 903 standardsuggested oil

60

Engine Oil


Oil RecommendationSaf ety PrecautionsRefer to on page .

Using the proper oil, and regularly checking,adding, and changing oil will help extend yourengine’s life. Even the best oil wears out.Changing oil helps get rid of dirt and depositsheld in the engine. Operating the engine withold or dirty oil can damage your engine.Running the engine with insufficient oil cancause serious damage to the engine andtransmission.

43

03/03/07 16:07:23 31KPT610_069

＊＊

＊

OKNOT RECOMMENDED

61

Engine Oil


For normal air temperatures. See next pagefor additional temperature/viscosityinformation.Suggested oils are equal in performance toSJ oils that are not labeled as energyconserving on the circular API service label.

Your motorcycle does not need oil additives.Use the recommended oil.Do not use oils with graphite ormolybdenum additives. They may adverselyaffect clutch operation.Do not use API SH or higher oils displayinga circular API ‘‘energy conserving’’ servicelabel on the container. They may affectlubrication and clutch performance.

Do not use non-detergent, vegetable, orcastor based racing oils.

03/03/07 16:07:32 31KPT610_070

(1) code number of the sales company of the oil(2) oil classification

(1)

(2)

62

Engine Oil


Other viscosities shown in the following chartmay be used when the average temperature inyour riding area is within the indicated range.

JASO T 903 standardThe JASO T 903 standard is an index to chooseengine oils for 4-stroke motorcycle engines.There are two classes: MA and MB.Oil conforming to the standard has thefollowing classification on the oil container.

03/03/07 16:07:41 31KPT610_071

(2)

(3)

(1)

(1) oil filler cap/dipstick(2) upper level mark(3) lower level mark

RIGHT SIDE

63

Checking & Adding Oil

Engine Oil


Park your motorcycle on a firm, levelsurface.Clean around the oil filler cap/dipstick ( )and nearby surfaces.

Start the engine and let it idle for 3-5minutes. Stop the engine. Wait 2-3 minutes.Immediately unscrew and remove the oilfiller cap/dipstick. Wipe it clean.Hold the motorcycle upright.Insert the dipstick until it seats, but do notscrew it in.Remove the dipstick and check the oil level.

If the oil is at or near the upper level mark( ), you do not have to add oil.If the oil is below or near the lower levelmark ( ), add the recommended oil untilit reaches the upper level mark. (Do notoverfill.)

Insert the dipstick and screw it in tightly.Check for oil leaks.

1.

2. 1

3.

4.

5.6.

7.

2

3

8.9.

03/03/07 16:07:53 31KPT610_072

UNDER

(2) (1)

(1) oil drain bolt(2) O-ring

(3) spring(4) oil strainer screen

(3)(4)

64

Engine Oil


Changing Engine Oil

Improper disposal of drained f luids is harmf ulto the environment.

If the engine is cold, start it and let it idle for3-5 minutes. Turn the engine off. Wait 2-3minutes for the oil to settle.

Remove the oil filler cap/dipstick.Place a drain pan under the crankcase.Remove the oil drain bolt ( ), O-ring ( ),spring ( ) and oil strainer screen ( ).Pour the drained oil into a suitable containerand dispose of it in an approved manner(page ).

Park your motorcycle on its side stand on afirm, level surface.

1.

2.

3.4.5.

6.

1 23 4

121

03/03/07 16:08:04 31KPT610_073

11 lbf·ft (15 N·m , 1.5 kgf·m)

1.1 US qt (1.0 )

65

Engine Oil


With the motorcycle held upright on levelground, check the oil level.If needed, add oil (page ) until it reachesthe upper level mark. (Do not overfill.)Check for oil leaks.

Clean the oil strainer screen.Check that the oil strainer screen, sealingrubber, and drain bolt O-ring are in goodcondition.

Install the oil strainer screen, spring, anddrain bolt.

Pour the recommended oil into the crankcase,approximately:

Install the oil filler cap/dipstick securely.Start the engine. Let it idle 3-5 minutes, thenturn it off.

Tighten the oil drain bolt to the specifiedtorque:

Install the O-ring to the oil drain bolt.

63

7.8.

9.10.

11.

12.

13.14.

15.

16.

03/03/07 16:08:16 31KPT610_074

66

Air Cleaner


Saf ety Precautions

Using the wrong air cleaner can result inpremature engine damage.

Improper or lack of proper air cleanermaintenance can cause poor perf ormance andpremature engine wear.

Refer to on page .

Proper air cleaner maintenance is veryimportant for off-road vehicles. A dirty, water-soaked, worn-out, or defective air cleaner willallow dirt, dust, mud, and other impurities topass into the engine.

Service the air cleaner more frequently if youride in unusually wet or dusty areas. YourHonda dealer can help you determine thecorrect service interval for your ridingconditions.

Your motorcycle’s air cleaner has very specificperformance requirements. Use a new genuineHonda air cleaner specified for your model oran air cleaner of equal quality.

Proper air cleaner maintenance can preventpremature engine wear or damage, expensiverepairs, low engine power, poor gas mileage,and spark plug fouling.

43

03/03/07 16:08:24 31KPT610_075

(2)

(1)

(1) screws(2) air cleaner housing cover

(3)

(1)

RIGHT SIDE

(3) set spring(4) set spring holder(5) air cleaner (4)

(5)

67

Cleaning

Air Cleaner


Remove the right side cover (page ).Remove the screws ( ) and air cleanerhousing cover ( ).

Remove the air cleaner ( ).

Unhook the set spring ( ), take care to avoidbending the set spring and set spring holder( ).

(cont’d)

4.

1.2.

3.

56

3

12

54

03/03/07 16:08:35 31KPT610_076

－

(5)(8)

(8)(6)

(7)

(5) air cleaner(6) air cleaner holder

(7) tabs(8) holes

68

Air Cleaner


Gently wash the air cleaner in clean, non-flammable (high flash point) solvent such askerosene not gasoline. After cleaning,gently squeeze out the remaining solvent.Avoid twisting or wringing the air cleaner.This can tear the foam.Inspect for tears or cracks in the foam orseams of the air cleaner. Replace the aircleaner if it is damaged.Allow the air cleaner to dry thoroughlybefore applying oil. A wet air cleaner willnot fully absorb the oil.

Remove the air cleaner holder ( ) from theair cleaner ( ).

7.

5.

6.

8.

65

03/03/07 16:08:43 31KPT610_077

(7) tabs

(7)

(7)

(9)

(10)

RIGHT SIDE

(9) upper hole(10) lower hole

69

Air Cleaner


Pour clean Pro Honda Foam Filter Oil or anequivalent (Canada: Honda Foam Filter Oilor an equivalent) over the entire surface ofthe air cleaner. Use both hands to evenlyspread the oil into the air cleaner. Gentlysqueeze out any excess oil. (To keep yourhands dry, place the air cleaner in a cleanplastic bag before spreading the oil into theair cleaner.)Assemble the air cleaner and holder.Insert the tabs ( ) in the air cleaner holes( ).

Apply a thin coat of grease to the sealingsurface of the air cleaner.

Clean the inside of the air cleaner housing.

Install the right side cover (page ).

Install the air cleaner housing cover andscrews.

Install the air cleaner assembly by insertingthe upper tab ( ) on the cleaner into theupper hole ( ) in the air cleaner housing,and the lower tab ( ) into the lower hole( ).Hook the set spring.Check that the air cleaner is properly seated.

9.

10.

11.12.

13.

14.

15.

78

56

79

710

03/03/07 16:08:53 31KPT610_078

LEFT SIDE

(1)

(1) plug

70 Servicing Your Honda

Crankcase Breather


Service more frequently if your motorcycle isridden in the rain or often at full throttle.Service the breather if you can see deposits inthe transparent section of the drain tube.

Drain the deposits by pinching the plug ( ).43 1

03/03/07 16:08:59 31KPT610_079

－－1/16 1/4 in (2 6 mm)

RIGHT SIDE

(1) freeplay

(2)

(3)

(4)

(1)

(2) rubber dust cover (4) adjuster(3) lock nut

71

Throttle Freeplay

Throttle


Saf ety PrecautionsRefer to on page . InspectionCheck freeplay ( ).Freeplay:

If necessary, adjust to the specified range.

AdjustmentPull the rubber dust cover ( ) back.Loosen the lock nut ( ) on the throttle cablemechanism.Turn the adjuster ( ).Tighten the lock nut. Return the dust coverto its normal position.After adjustment, check for smooth rotationof the throttle grip from fully closed to fullyopen in all steering positions.

If you can’t get the freeplay within thespecified range, contact your Honda dealer.

1.2.

3.

1

4.

5.

23

4

43

03/03/07 16:09:10 31KPT610_080

(2)

(1)

(1) throttle(2) throttle cable

72

Throttle Inspection

Throttle


Check for smooth rotation of the throttle ( )from fully open to fully closed in all steeringpositions. If there is a problem, see yourHonda dealer.

Check that the throttle assembly ispositioned properly and the securing boltsare tight.

Inspect the condition of the throttle cable ( )from the throttle grip down to the carburetor.If the cable is kinked or chafed, have itreplaced.Check the cable for tension or stress in allsteering positions.Lubricate the cable with a commercially-available cable lubricant to preventpremature rust and corrosion.

1.

2. 1

3.

4.

5.

2

03/03/07 16:09:19 31KPT610_081

－－

＋－

－－

＋＋

3/8 13/16 in (10 20 mm)

(2)

( ) increase freeplay( ) decrease freeplay

(1)(4)

(3)

LEFT SIDELEFT SIDE

(1) clutch lever

(( ))

(( ))

(2) rubber dust cover(3) upper lock nut(4) upper clutch cable adjuster

73

Clutch Freeplay

Clutch System


Saf ety Precautions

Upper clutch assembly adjuster:

Refer to on page . Upper AdjustmentMinor adjustments are generally made with theupper clutch cable adjuster.

Pull the rubber dust cover ( ) back.Loosen the upper lock nut ( ).Turn the upper clutch cable adjuster ( ) toobtain the specified freeplay.

InspectionCheck freeplay.Freeplay:


Improper freeplay adjustment can causepremature clutch wear. (cont’d)

1.2.3.

23

4

43

03/03/07 16:09:32 31KPT610_082

－

＋－

＋＋

－－ (5)

(6)RIGHT SIDE

(5) lower adjusting nut(6) lower lock nut


(( ))

(( ))

74

Clutch System


Hold the lower adjusting nut ( ) and loosenthe lower lock nut ( ) at the lower end of thecable.Turn the lower adjusting nut to obtain thespecified freeplay.Hold the lower adjusting nut and tighten thelower lock nut. Check the adjustment.

Tighten the lock nut and check the freeplayagain.

Lower AdjustmentThe lower clutch cable adjuster is used if theupper clutch cable adjuster is threaded out nearits limit or the correct freeplay cannot beobtained.

Loosen the upper lock nut ( ) and turn theupper clutch cable adjuster ( ) all the way in(to provide maximum freeplay).Tighten the upper lock nut and pull the dustcover ( ) back to its normal position.

1.

2.

3.

4.

5.

3

6

4.4

52

03/03/07 16:09:42 31KPT610_083

75

Other Inspections & Lubrication

Clutch System


Start the engine, pull the clutch lever in, andshift into gear. Make sure the engine doesnot stall and the motorcycle does not creep.Gradually release the clutch lever and openthe throttle. Your motorcycle should movesmoothly and accelerate gradually.

If you can’t get proper adjustment, or the clutchdoes not work properly, the cable may bekinked or worn, or the clutch discs may beworn. See your Honda dealer or refer to theofficial Honda Service Manual (page ).

Check that the clutch lever assembly ispositioned properly and the securing boltsare tight.

Lubricate the clutch cable with acommercially-available cable lubricant toprevent premature wear and corrosion.

Check the clutch cable for kinks or signs ofwear. If necessary, have it replaced.

6.

148

03/03/07 16:09:49 31KPT610_084

±

＋－

＋＋

－－

1,400 100 rpm

( ) increase rpm( ) decrease rpm

(( ))

(( ))

(1)

(1) throttle stop screw

RIGHT SIDE

76

Engine Idle Speed

Engine Idle Speed


Saf ety PrecautionsRefer to on page . The engine must be at normal operatingtemperature for accurate idle speed adjustment.Ten minutes of stop-and-go riding is sufficient.

Do not attempt to compensate for faults inother systems by adjusting idle speed. See yourHonda dealer for regularly scheduledcarburetor adjustments.

Warm up the engine, shift to neutral andplace the motorcycle on its stand.Connect a tachometer, following thetachometer manufacturer’s instructions.Adjust idle speed with the throttle stop screw( ).

1.

2.

3.1

Idle Speed:

43

03/03/07 16:09:59 31KPT610_085

X24EPR-U9 (DENSO)DPR8EA-9 (NGK)

DPR7EA-9 (NGK)X22EPR-U9 (DENSO)

or

or

Standard

For cold climate(below 5°C, 41°F)

(1)

(1) spark plug wrench(2) handle(3) center electrode

(4) side electrode(5) spark plug gap

(2)

(3)

(4)

(5)

RIGHT SIDE

77

Spark Plug Recommendation

Spark Plug


Saf ety Precautions

Using spark plugs with an improper heat rangecan cause engine damage.

Refer to on page . Use only the recommended type of spark plugsin the recommended heat range.

The recommended standard spark plug issatisfactory for most riding conditions.However, if you plan to ride for extendedperiods at high speeds or near maximum power(high engine rpm) in hot climates, or planextended riding in cold climates, a differentplug may be recommended.

(cont’d)

Clean any dirt from around the spark plugbase.

1.

43

03/03/07 16:10:11 31KPT610_086

－－0.031 0.035 in (0.80 0.90 mm)

78

Spark Plug


Improperly tightened spark plugs can damagethe engine. Too loose, you can burn a piston.Too tight, you can damage the threads.

Disconnect the spark plug cap. Tighten the spark plug:about 1/8-1/4 turn after it seats (if the oldplug is good).about 1/2 turn after it seats (if installing anew plug).

Remove the spark plug with a plug wrench( ) provided with your motorcycle.

With the plug washer attached, thread thespark plug in by hand (to prevent cross-threading).

If you have to install a new plug, first checkthe gap.

Make sure the plug washer is in goodcondition.

Check the spark plug gap ( ), using a wire-type feeler gauge. If adjustment is necessary,bend the side electrode carefully. The gapshould be:

Inspect the spark plug electrodes for wear.The center electrode ( ) should have squareedges. The side electrode ( ) should not beeroded. The insulator should not be crackedor chipped.

2.3.

4.

5.

6.

7.

34

5

1

03/03/07 16:10:23 31KPT610_087

(1)

(2)

(4)

RIGHT REAR

(1) spark arrester(2) bolts

(3) gasket(4) muffler

(3)

79

Spark Arrester



The spark arrester must be serviced every 100operating hours to maintain its efficiency.

Regular servicing prevents carbon buildup(which can diminish engine performance) andalso complies with USDA regulations forregular maintenance to assure proper function.The spark arrester prevents random sparksfrom the combustion process in your enginefrom reaching the environment.

Remove the three bolts ( ), the sparkarrester ( ), and the gasket ( ) from themuffler ( ).

Allow the engine and muffler to cool.

(cont’d)

1.2. 2

14

3

43

03/03/07 16:10:32 31KPT610_088

80

Spark Arrester


Use a brush to remove carbon deposits fromthe spark arrester screen. Be careful to avoiddamaging the spark arrester screen. Thespark arrester must be free of breaks andholes. Replace, if necessary. Check thegasket. Replace, if necessary.

Install the spark arrester and the gasket in themuffler and tighten the three bolts securely.

3. 4.

03/03/07 16:10:37 31KPT610_089

(1) mounting bolts

(1)

(1) (1)

FRONT

81

Front Suspension Inspection

Suspension



Loose, worn, or damaged suspensioncomponents may adversely affect the handlingand stability of your motorcycle. If anysuspension components appear worn ordamaged, see your Honda dealer for furtherinspection. Your dealer is qualified todetermine whether or not replacement parts orrepairs are needed.

Check fork operation. Pull the front brakelever in, to lock the brake. Then pump upand down on the fork legs several times. Thesuspension should function smoothly. Thereshould be no oil leakage.

(cont’d)

1.

43

03/03/07 16:10:45 31KPT610_090

(1)(1)

LEFT SIDE

RIGHT SIDE

(1) swingarm bearing(2) shock absorber attachment points(3) suspension linkage attachment points

(2)

(3)

(1) swingarm bearing

82

Rear Suspension Inspection

Suspension


Check the security of all handlebar and forkmounting bolts ( ). If any front suspensioncomponents appear worn or damaged, seeyour Honda dealer for further inspection.

Place the motorcycle on a maintenance stand.Push hard against the side of the rear wheeland feel for any freeplay which indicatesworn swingarm bearings ( ).

1.

12.

1

03/03/07 16:10:52 31KPT610_091

83

Suspension


Check that the fasteners for the shockabsorber attachment points ( ) and rearsuspension linkage attachment points ( ) aresecure.Check for oil leaks in the shock absorber. Ifany rear suspension components appearworn or damaged, see your Honda dealer forfurther inspection.

2.

3.

32

03/03/07 16:10:56 31KPT610_092

(1)(2)

(3)

RIGHT SIDE

(3) lock nut(4) adjuster

(4)(1) front brake lever(2) rubber dust cover

84

Front Brake Lever Adjustment

Brakes



Frequently inspect the system to ensure thereare no fluid leaks. Periodically inspect thebrake fluid level and the brake pads for wear.

Never use adjusters other than those designedfor this motorcycle. Install a new adjuster fromthe lever side with the lock nut under the headof the adjuster.

The front brake is the hydraulic disc type. Asthe brake pads wear, the brake fluid level willdrop. A leak in the system will also cause thelevel to drop.

If the front brake lever freeplay does not feelwithin the normal range while riding, check thebrake pads. If they are not worn beyond therecommended limit (page ), there isprobably air in the brake system. See yourHonda dealer to have the air bled from thesystem.

43

87

03/03/07 16:11:05 31KPT610_093

－－3/8 13/16 in (10 20 mm)

85

Brakes


Apply the brake, release it, then spin thewheel and check that it rotates freely. Repeatthis procedure several times.

Tighten the lock nut. Return the dust coverto its normal position.

To position the brake lever farther awayfrom the handgrip, turn the adjuster ( )clockwise.To position the brake lever closer to thehandgrip, turn the adjuster counterclockwise.

Loosen the lock nut ( ).Pull the rubber dust cover ( ) back. Check freeplay by pulling in slowly on the

front brake lever until the brake starts toengage.Freeplay:

If brake lever freeplay is not within thisrange, see your Honda dealer.

1.2.3.

4.

5.

6.23

4

03/03/07 16:11:13 31KPT610_094

(1)

(1) LOWER level mark

RIGHTHANDLEBAR

86

Brakes


Fluid Level Inspection

Front Brake Fluid Level

With the motorcycle in an upright position,check the fluid level.It should be above the LOWER level mark ( ).If the level is at or below the LOWER levelmark, check the brake pads for wear(page ).

Worn brake pads should be replaced. If thepads are not worn, have your brake systeminspected for leaks.

The recommended brake fluid is Honda DOT 4brake fluid from a sealed container, or anequivalent.

Other InspectionsMake sure there are no fluid leaks.Check for deterioration or cracks in thehoses and fittings.

1

87

03/03/07 16:11:22 31KPT610_095

(1)

(2)

LEFT FRONT

(1) front brake caliper(2) cutout

87

More About: Brake Fluid

Brake Pad Wear

Other Inspections

Brakes


Brake pad wear depends on the severity ofusage, the type of riding, and riding areaconditions. (Generally, the pads will wearfaster on wet and dirty riding terrain.) Inspectthe pads at each regular maintenance interval(page ).

Check the cutout ( ) in each pad. If either padis worn to the cutout, replace both pads as a set.See your Honda dealer for this service.

The recommended brake fluid is Honda DOT 4Brake Fluid, or any brake fluid of equalequality and performance. Use fresh brakefluid from a sealed container.

Brake fluid should be added and replaced byyour Honda dealer.

Check that the front lever assembly ispositioned properly and the securing bolts aretight.

48

2

03/03/07 16:11:32 31KPT610_096

－－

＋－

－－

＋＋

13/16 1 3/16 in (20 30 mm)

(1) rear brake pedal


(1)

(2)(3)

(4)

RIGHT SIDE

RIGHT REAR

(2) brake rod(3) adjusting nut(4) brake arm pin

(( ))

(( ))

88

Brakes


Rear Brake Pedal FreeplayInspection

Place your motorcycle on its side stand.Check freeplay by slowly depressing thebrake pedal ( ) until the brake starts toengage.


Adjustment

1.2.

Freeplay:

1

03/03/07 16:11:42 31KPT610_097

(4)

(2)

(3)

(1)

(1) arrow(2) brake arm

(3) reference mark(4) brake panel

RIGHTREAR

89

Brake Shoe Wear

Brakes


Turn the rear brake adjusting nut ( ). Makesure the cut-out on the adjusting nut is seatedon the brake arm pin ( ).Apply the brake, release it, and then spin thewheel and check that it rotates freely. Repeatthis procedure several times.Check the freeplay. If you can’t adjust thefreeplay properly, see your Honda dealer.

The rear brake is equipped with an externalbrake wear indicator that let you check brakewear without disassembly. Application of thebrake control (pedal) causes the arrow on thebrake arm to move toward a reference mark onthe brake panel.

(cont’d)

1.

2.

3.

3

4

03/03/07 16:11:52 31KPT610_098

90

Other Inspections & Lubrication

Brakes


Place your motorcycle on its side stand.

Check that the rear pedal assembly ispositioned properly and the securing boltsare tight.Rear: Make sure the brake rod, brake arm,spring, and fasteners are in good condition.

Apply the brake control (pedal) and checkthe movement of the arrow ( ) on the brakearm ( ). Replace the brake shoes if thearrow aligns with the reference mark ( ) onthe brake panel ( ) upon full application ofthe brake. If replacement is necessary, seeyour Honda dealer.

1.2.

43

12

03/03/07 16:11:59 31KPT610_099

RIGHTSIDE

(1) lock nut(2) stopper bolt

(1)

(2)

(3)

(3) rear brake pedal

91

Brakes


Rear Brake Pedal Height AdjustmentLoosen the lock nut ( ) and turn the stopperbolt ( ).Tighten the lock nut.Check the freeplay (page ).

1.

2.3.

12

88

03/03/07 16:12:06 31KPT610_100

92

Wheels



Maintenance of spoke tension and wheeltrueness (roundness) is critical to safemotorcycle operation. During the first 100miles (150 km), spokes will loosen morerapidly due to the initial seating of the parts.Excessively loose spokes may result ininstability at high speeds and the possible lossof control. It’s also important that the rim locksare secure to prevent tire slippage.

It is not necessary to remove the wheels toperform the recommended service in theMaintenance Schedule. However, informationfor wheel removal is provided for emergencysituations.

43

03/03/07 16:12:11 31KPT610_101

(1)

(2)

(3)

(1) wheel rim(2) spoke(3) rim lock

REAR

93

Wheel Rims & Spokes

Wheels


Inspect the wheel rims ( ) and spokes ( )for damage.Tighten any loose spokes or rim locks ( ).Rotate the wheel slowly to see if it appearsto ‘‘wobble.’’ If it does, the rim is out ofround or not ‘‘true.’’ If the wobble isnoticeable, see your Honda dealer forinspection.

11.

2.

2

33.

03/03/07 16:12:17 31KPT610_102

RIGHT FRONT(1)

(2)

(3)

(1) axle holder nuts(2) axle holder(3) front axle

(1)

94

Front Wheel Removal

Wheels


RemovalRaise the front wheel off the ground byplacing a maintenance stand or support blockunder the engine. Secure the rear of themotorcycle with tie-down straps.Remove the front axle holder nuts ( ) andthe front axle holder ( ).Unscrew and remove the axle ( ). Removethe wheel.Avoid depressing the brake lever when thewheel is off the motorcycle. This will forcethe caliper pistons out of the cylinders. Theresult will be loss of brake fluid. If thisoccurs, the brake system will require service.See your Honda dealer for this service.

1.

2.

3.

12

3

03/03/07 16:12:26 31KPT610_103

54 lbf·ft (74 N·m , 7.5 kgf·m)

9 lbf·ft (12 N·m , 1.2 kgf·m)

RIGHT FRONT

(4) UP mark

(4)

95

Wheels


Installation

Torque the axle to:

Reverse the removal procedure. Insert theaxle through the wheel hub and left fork leg.

Install the axle holder with the UP mark ( )upward and first tighten the upper holdernuts until lightly seated, then tighten thelower axle nuts until lightly seated.Operate the front brake and pump the forkseveral times.First tighten the upper holder nuts to thespecified torque, then tighten the lower axlenuts to the same torque:

After installing the wheel, apply the brakeseveral times and then check if the wheelrotates freely. Recheck the wheel if the brakedrags or if the wheel does not rotate freely.Check front brake adjustment (page ).

If a torque wrench was not used to install thewheel, see your Honda dealer as soon aspossible to verify proper assembly. Improperassembly may lead to loss of braking capacity.

1.

2.

3.

4.

5.

6.

4

84

03/03/07 16:12:37 31KPT610_104

RIGHT REAR

(1)

(5)

(3)

(2)

(4) (5)

(6)

LEFT REAR

(1) brake adjuster(2) brake rod(3) brake arm

(4) axle nut(5) chain adjusters(6) rear axle

96

Wheels


Rear Wheel RemovalRemoval

Raise the rear wheel off the ground byplacing a maintenance stand or support blockunder the engine. Secure the front of themotorcycle with tie-down straps.Unscrew the rear brake adjuster ( ). Pressthe rear brake pedal and disconnect the brakerod ( ) from the brake arm ( ).Loosen the rear axle nut ( ) while holdingthe axle.Turn both adjusters ( ) so the rear wheel canbe moved all the way forward for maximumdrive chain slack.Unscrew the axle nut ( ). Pull the axle out.Push the wheel forward and derail the drivechain from the rear sprocket. Remove thewheel.Take care to prevent getting grease, oil, ordirt on the brake shoe surfaces. This cancause poor brake performance or rapid brakeshoe wear after reassembly.

1.

2.

3.

4.

1

32

5.

5

4

4

03/03/07 16:12:48 31KPT610_105

80 lbf·ft (108 N·m , 11.0 kgf·m)

RIGHTREAR

(7) lug(8) slot(9) brake panel

(7)

(8)

(9)

97

Wheels


InstallationReverse the removal procedure. Make surethe lug ( ) on the swingarm is located in theslot ( ) in the brake panel ( ). Check thatthe chain adjusters are installed properly.Adjust the drive chain (page ).Torque the axle nut to:

Adjust the rear brake (page ).Apply the rear brake, release it, then spin thewheel and check that it rotates freely. Repeatthis procedure several times.

If a torque wrench was not used to install thewheel, see your Honda dealer as soon aspossible to verify proper assembly. Improperassembly may lead to loss of braking capacity.

2.3.

4.

1

5

78 9

106

88

03/03/07 16:12:58 31KPT610_106

Using tires that are excessively wornor improperly inflated can cause acrash in which you can be seriouslyhurt or killed.

Follow all instructions in this owner’smanual regarding tire inflation andmaintenance.

98

Air Pressure

Tires & Tubes


Saf ety Precautions

To safely operate your motorcycle, the tiresmust be the proper type (off-road) and size, ingood condition with adequate tread, andcorrectly inflated.

Refer to on page .

The following pages give detailed informationon how and when to check your air pressure,how to inspect your tires for wear and damage,

and our recommendations on tire repair andreplacement.

Make sure the valve stem caps are secure. Ifnecessary, install a new cap.

Properly inflated tires provide the bestcombination of handling, tread life, and ridingcomfort. Generally, underinflated tires wearunevenly, adversely affect handling, and aremore likely to fail from being overheated.Underinflated tires can also cause wheeldamage in rocky terrain. Overinflated tiresmake your motorcycle ride more harshly, aremore prone to damage from surface hazards,and wear unevenly.

43

03/03/07 16:13:06 31KPT610_107

－－

15 psi (100 kPa , 1.0 kgf/cm )15 psi (100 kPa , 1.0 kgf/cm )

FrontRear

(1)

(2)

(3)

(1) tire tread depth(2) spoke nut(3) rim lock nut

99

Inspection

Tires & Tubes


Always check air pressure when your tires are‘‘cold.’’ If you check air pressure when yourtires are ‘‘warm’’ even if your motorcyclehas only been ridden for a few miles thereadings will be higher. If you let air out ofwarm tires to match the recommended coldpressures, the tires will be underinflated.The correct ‘‘cold’’ tire pressures are:

A flat tire or blowout is inconvenient and mayeven cause an accident. Take time to inspectyour tires and wheels before you ride. For moreinformation about handling flat tires, seepage .

If you decide to adjust tire pressures for aparticular riding condition, make changes alittle at a time.

(cont’d)

126

03/03/07 16:13:15 31KPT610_108

100

Tube Replacement

Tires & Tubes


If a tube is punctured or damaged, you shouldreplace it as soon as possible. A repaired tubemay not have the same reliability as a new one,and it may fail while you are riding. Forinformation on making a temporary repair, seepage .

Use a replacement tube equivalent to theoriginal.

We recommend that tubes be replaced by yourHonda dealer. Replacing a tube requiresremoving and reinstalling the wheel. Any timea tube is replaced, carefully inspect the tire asdescribed on page .

Inspect carefully for bumps or bulges in theside of the tire or the tread. Replace any tirethat has a bump or bulge.Look closely for cuts, slits, or cracks in thetires. Replace a tire if you can see fabric orcord.Check for rocks or other objects embeddedin the tire or tread. Remove any objects.

Check the position of both valve stems. Atilted valve stem indicates the tube isslipping inside the tire or the tire is slippingon the rim. See your Honda dealer.

Measure tread depth ( ). Replace the tirebefore depth at the center reaches 0.12 in (3mm), or any time you notice a reduction intraction.

1 126

99

03/03/07 16:13:25 31KPT610_109

－－

70/100 19M/C 42M90/100 16M/C 51M

Installing improper tires on yourmotorcycle can affect handling andstability. This can cause a crash inwhich you can be seriously hurt orkilled.

Always use the size and type of tiresrecommended in this owner’s manual.

FrontRear

101

Tire Replacement

Tires & Tubes


The tires that came on your motorcycle weredesigned to provide a good combination ofhandling, braking, durability, and comfortacross a broad range of riding conditions.

Use a replacement tire equivalent to theoriginal.Replace the tube any time you replace a tire.The old tube will probably be stretched and,if installed in a new tire, could fail.Have the wheel balanced after a new tire isinstalled.We recommend that tires be replaced byyour Honda dealer.

03/03/07 16:13:34 31KPT610_110

(1)

LEFT SIDE

(2)

(1) side stand spring(2) side stand

102

Side Stand


Saf ety PrecautionsRefer to on page . Check the side stand spring ( ) for damageand loss of tension.Check the side stand assembly for freedomof movement.

If the side stand is stiff or squeaky, clean thepivot area and lubricate the pivot bolt withclean engine oil.

1.

2.

143

03/03/07 16:13:40 31KPT610_111

－－13/16 1 3/16 in (20 30 mm)

(1)

(1) drive chain

LEFT SIDE

103

Inspection

Drive Chain



The service life of the chain depends on properlubrication and adjustment. Poor maintenancecan cause premature wear or damage to thedrive chain or sprockets.

Under severe usage, or when the motorcycle isridden in unusually dusty or muddy areas, morefrequent maintenance will be necessary.

Before servicing your drive chain, turn theengine OFF, lower the side stand, and checkthat your transmission is in neutral.

It is not necessary to remove or replace thedrive chain to perform the recommendedservice in the Maintenance Schedule.

Check slack in the lower drive chain ( ) runmidway between the sprockets. Drive chainslack should allow the following verticalmovement by hand:

(cont’d)

1. 1

43

03/03/07 16:13:51 31KPT610_112

104

Drive Chain


Excessive chain slack may allow the drivechain to damage the engine cases.

Check drive chain slack at several pointsalong the chain. The slack should remainconstant. If it isn’t, some links may bekinked and binding. Lubricating the chainwill often eliminate binding and kinking.

Inspect the drive chain for:damaged rollersloose pinsdry or rusted linkskinked or binding linksexcessive weardamaged or missing O-rings

Replace the drive chain (page ) if it hasdamaged rollers, loose pins, or kinks thatcannot be freed. Lubricate the drive chain(page ) if it appears dry or shows signs

of rust. Lubricate any kinked or bindinglinks and work them free. Adjust chain slackif needed.Check the chain slider ( ), chain guide slider( ), chain roller ( ) and lower slider ( ) forwear. If the chain slider and lower slider areworn to the bottom of the cutouts ( ), haveyour Honda dealer replace the slider.Replace the chain guide slider if the chain isvisible through the wear inspection window( ).Replace the chain roller if it is smaller than0.7 in (18 mm).

2.

3.

4.

6

108

107

23 4 5

7

03/03/07 16:14:00 31KPT610_113

25.0 in (635 mm)25.1 in (637 mm)

LEFT SIDE

Measure a span of 41 pins(5)

(6)

(2) chain slider(3) chain guide slider(4) chain roller(5) lower slider

(6)

(3)

(4) (2)

(7)

(6) cutouts(7) wear inspection

window

105

Drive Chain


Replace the drive chain if chain slack isexcessive when the rear axle is moved to thefarthest limit of adjustment. Excessive slackindicates the chain is worn beyond its servicelimit. (cont’d)

To check the chain’s service limit, measurethe distance between a span of pins,from pin center to pin center. If the distanceexceeds the service limit, the drive chain isworn out and should be replaced.

This motorcycle has a staked master linkdrive chain which requires a special tool forcutting and staking. Do not use an ordinarymaster link with this chain.

5.

New Chain:Service Limit:

41

03/03/07 16:14:10 31KPT610_114

(3)

(4)Damaged SprocketTeeth

Worn SprocketTeeth

REPLACE

Normal Sprocket TeethGOOD

REPLACE

RIGHT REAR

LEFT REAR (1)

(5)

(4) (5)

(3) (2)

(1) axle(2) axle nut(3) chain adjusters(4) index marks(5) stopper pins

106

Adjustment

Drive Chain


Use of a new chain with worn sprockets willcause rapid chain wear.

Inspect the front and rear sprocket teeth forexcessive wear or damage. If necessary, haveyour Honda dealer replace a worn sprocket.

6.

03/03/07 16:14:19 31KPT610_115

80 lbf·ft (108 N·m , 11.0 kgf·m)

107

Lubrication

Drive Chain


Lubricate every 300 miles (500 km) or soonerif chain appears dry.The O-rings in this chain can be damaged bysteam cleaning, high pressure washers, andcertain solvents.

(cont’d)

Hold the axle ( ) and loosen the rear axlenut ( ).Turn both the right and left adjusters ( )equally to increase or decrease chain slack.After adjusting, be sure the same adjusterindex marks ( ) align with the stopper pins( ) on both sides of the swingarm.Torque the rear axle nut to:

Recheck drive chain slack.Check rear brake pedal freeplay and adjustas necessary (page ). Freeplay is affectedwhen repositioning the rear wheel to adjustdrive chain slack.

If a torque wrench is not used for thisinstallation, see your Honda dealer as soon aspossible to verify proper assembly.

3.

4.

5.6.

1.

2.

12

3

45

88

03/03/07 16:14:32 31KPT610_116

D.I.D. 520VD

108

Drive Chain


Removal, Cleaning & ReplacementLubricate only with SAE 80 or 90 gear oil.Commercial chain lubricants may containsolvents which could damage the rubberO-rings. Your motorcycle has an endless (riveted master

link) type chain. It should only be removed orreplaced by your Honda dealer.

When the drive chain becomes extremely dirty,it should be cleaned prior to lubrication.

Clean the side surfaces of the chain with adry cloth.Do not brush the rubber O-rings. Brushingwill damage them. Use of a solvent may alsodamage the O-rings.Inspect the drive chain for possible wear ordamage. Replace the drive chain if it hasdamaged rollers, loose fitting links, orotherwise appears unserviceable.Replacement chain:

2.

1.

03/03/07 16:14:40 31KPT610_117

109

Drive Chain


Inspect the sprocket teeth for wear ordamage. We recommend replacing thesprocket whenever a new chain is installed.Lubricate the drive chain.

3.

4.

03/03/07 16:14:44 31KPT610_118

－－－－

110

General Recommendations

Appearance Care



Frequent cleaning and polishing will keep yourHonda looking newer longer. Frequentcleaning also identifies you as an owner whovalues your motorcycle. A clean motorcycle isalso easier to inspect and service.

While you’re cleaning, be sure to look fordamage, wear, and gasoline or oil leaks.

To clean your motorcycle, you may use:watera mild, neutral detergent and watera mild spray and wipe cleaner/polishera mild spray and rinse cleaner/degreaserand water

Avoid products that contain harsh detergentsor chemical solvents that could damage themetal, paint, and plastic on your motorcycle.If your motorcycle is still warm from recentoperation, give the engine and exhaustsystem time to cool off.

43

03/03/07 16:14:52 31KPT610_119

111

Washing Your Motorcycle with a MildDetergent

Appearance Care


High pressure water (or air) can damagecertain parts of your motorcycle.

We recommend the use of a garden hose towash your motorcycle. High pressurewashers (like those at coin-operated carwashes) can damage certain parts of yourmotorcycle. If you use a high pressurewasher, avoid spraying the following areas:

wheel hubsmuffler outletarea under seatengine stop button

Rinse your motorcycle thoroughly with coolwater to remove loose dirt.Fill a bucket with cool water. Mix in a mild,neutral detergent, such as dish washingliquid or a product made especially forwashing motorcycles or automobiles.Wash your motorcycle with a sponge or asoft towel. As you wash, check for heavygrime. If necessary, use a mild cleaner/degreaser to remove the grime.After washing, rinse your motorcyclethoroughly with plenty of clean water toremove any residue.Dry your motorcycle with a chamois or asoft towel.

carburetordrive chainunder fuel tankbrake master cylinder

(cont’d)

1.

2.

3.

4.

5.

03/03/07 16:15:08 31KPT610_120

112

Appearance Care


Lubricate the drive chain to prevent rusting.Start the engine and let it idle for severalminutes. The engine heat will help dry moistareas.As a precaution, ride at a slow speed andapply the brakes several times. This will helpdry the brakes and restore normal brakingperformance.

6.7.

8.

03/03/07 16:15:13 31KPT610_121

113Tips

Tips

Here’s helpful advice on how to prepare for anoff-road adventure, how to transport and storeyour Honda, and how to be an environmentallyresponsible motorcycle owner.

.....................................Preparing for a Ride .114............................Transporting Your Honda .116

.....................................Storing Your Honda .118...............................You & the Environment .121

03/03/07 16:15:18 31KPT610_122

114

Preparing for a Ride

Tips

What to Take to the Riding Area

TakingCare of the Unexpected,

A safe and enjoyable ride begins with goodplanning and preparation. Always ride with atleast one other person in case you have trouble,and let someone know where you’re going andwhen you expect to return.

Before riding in an unfamiliar area, find out inadvance if you need special permits, get mapsso you can study the terrain, and talk to otherriders who know the area. The Forest Serviceand the Bureau of Land Management (USAonly), the Ministry of Natural Resources(Canada only), riding clubs, and off-roadmagazines are good sources of information.

We recommend that you always take water,food, a first aid kit, and your owner’s manual.Other items you should consider loading onyour truck or trailer include:

a tool kittire repair supplies and tools, tubes, and tires

wire, duct tape, and ropeextra gasoline

Along with your motorcycle and riding gear,you should take along some tools and suppliesin case you have a problem. For some of thedifficulties you might encounter, see

which begins on page.

extra parts, such as control levers, cables,and spark plugs

123

03/03/07 16:15:28 31KPT610_123

115

Preparing for a Ride

Tips

What to Take on the Trail

For safety, all refueling should be done at a gasstation on the way to the riding area or at yourbase camp.

What you take with you during a ride dependson the kind of terrain, how long you expect toride, how far you might go from your basecamp or help, and how experienced you or yourcompanions are in making repairs.

If you decide to take some tools, spare parts, orother supplies on the trail, be sure you cancarry them safely and know how to use them.Also, be sure to follow the loading guidelinesand weight limit (page ).6

03/03/07 16:15:33 31KPT610_124

116

Transporting Your Honda

Tips

If you use a truck or motorcycle trailer totransport your Honda, we recommend that youfollow these guidelines:

To secure your motorcycle, brace the frontwheel against the front of the truck bed ortrailer rail. Attach the lower ends of two strapsto the tie-down hooks on your vehicle. Attachthe upper ends of the straps to the handlebar(one on the right side, the other on the left),close to the fork.

Use a loading ramp.Make sure the fuel valve is off.Secure the motorcycle in an upright position,using motorcycle tie-down straps. Avoidusing rope, which can loosen and allow themotorcycle to fall over.

03/03/07 16:15:40 31KPT610_125

117

Transporting Your Honda

Tips

Check that the tie-down straps do not contactany control cables or electrical wiring.

Tighten both straps until the front suspension iscompressed about half-way. Too muchpressure is unnecessary and could damage thefork seals.

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

We recommend that you do not transport yourmotorcycle on its side. This can damage themotorcycle, and leaking gasoline could be ahazard.

03/03/07 16:15:46 31KPT610_126

118

Storing Your Honda

Tips

Honda Motorcycle Winter Storage Guide,If you won’t be riding for an extended period,such as during the winter, thoroughly inspectyour motorcycle and correct any problembefore storing it. That way, needed repairswon’t be forgotten and it will be easier to getyour motorcycle running again.

For more information about storage, refer totheavailable from your Honda dealer (USA only).

We suggest you perform the followingprocedures to keep your motorcycle in topcondition. These storage procedures will reducethe deterioration that can occur during storage.

03/03/07 16:15:51 31KPT610_127

Gasoline is highly flammable andexplosive. You can be burned orseriously injured when handling fuel.

Stop the engine and keep heat,sparks and flame away.Handle fuel only outdoors.Wipe up spills immediately.

119

Preparation for Storage

Storing Your Honda

Tips

Change the engine oil (page ).

Drain the carburetor into an approvedgasoline container and dispose of it in anapproved manner (page ). If storage willlast longer than one month, carburetordraining is important, to assure properperformance after storage.

Check that the fuel valve is OFF.

Fill the fuel tank. Make sure the fuel fill capis properly installed.

(cont’d)

1.2.

3.

4.

64121

03/03/07 16:15:58 31KPT610_128

－

－

120

Removal from Storage

Storing Your Honda

Tips

Uncover and clean your motorcycle.

If your motorcycle has been stored for morethan two months drain and replace the fuel.

If your motorcycle has been stored for morethan four months change the engine oil(page ).

Lubricate the drive chain.Perform a pre-ride inspection (page ),then test-ride your motorcycle at low speeds.

Cover your motorcycle with a porousmaterial. Avoid using plastic or similar non-breathing, coated materials that restrict airflow and allow heat and moisture toaccumulate.

Store your motorcycle in an unheated area,free of dampness, away from sunlight, witha minimum of daily temperature variation.

Inflate the tires to their recommendedpressures (page ).

Lubricate the drive chain.Wash and dry your motorcycle.

6.7.

8.

9.

1.2.

3.

4.5.

5.

98

64

24

03/03/07 16:16:09 31KPT610_129

121

Tread Lightly.

Keep the Noise Down.

Choose Sensible Cleaners.

You & the Environment

Tips

Owning and riding a motorcycle can beenjoyable, but you must do your part to protectnature. When you show respect for the land,wildlife, and other people, you also helppreserve the sport of off-road riding.

Following are tips on how you can be anenvironmentally-responsible motorcycle owner.

Stay on existing roads andtrails, avoid surfaces that are easily damaged,and ride only in areas approved for off-roadvehicles.

Loud motorcyclescan be offensive. Ride as quietly as possible,don’t remove your spark arrester, and don’tmodify the muffler or any other part of yourair intake and exhaust systems. Suchmodifications not only increase noise, theyalso reduce engine performance and may beillegal.

Use abiodegradeable detergent when you washyour motorcycle. Avoid aerosol spraycleaners that contain chloroflurocarbons(CFCs) which damage the atmosphere’sprotective ozone layer. Don’t throw cleaningsolvents away; see the following guidelinesfor proper disposal.

(cont’d)

03/03/07 16:16:16 31KPT610_130

122

Recycle Wastes.

You & the Environment

Tips

It’s illegal and thoughtlessto put used engine oil in the trash, down adrain, or on the ground. Used oil, gasoline,and cleaning solvents contain poisons thatcan hurt refuse workers and contaminate ourdrinking water, lakes, rivers, and oceans.Before changing your oil, make sure youhave the proper containers. Put oil and othertoxic wastes in separate sealed containersand take them to a recycling center. Callyour local or state office of public works orenvironmental services to find a recyclingcenter in your area and get instructions onhow to dispose of non-recyclable wastes.

03/03/07 16:16:20 31KPT610_131

123

Taking Care of the Unexpected


Preparing f ora Ride

With all the challenges you can encounter off-road, there’s a chance that sometime somethingmay go wrong. This section gives practicaladvice to help you deal with a wide range ofproblems. Take time to read this section beforeyou ride. Also review the tips in

(page ).

.......................................General Guidelines .124...........If Your Engine Quits or Won’t Start .125

................................If You Have a Flat Tire .126.................................................If You Crash .127

.................................If You Lose Your Key .128...................................If a Component Fails .129

114

03/03/07 16:16:24 31KPT610_132

－

－

124

General Guidelines



If something goes wrong during a ride, the firstthing to do is stop as soon as you safely can.Do not continue riding if you have a flat tire, oryou hear an unusual noise, or your motorcyclejust doesn’t feel right. If you continue riding,you could cause more damage and endangeryour own safety.

After a stop, take time to assess the situation.Carefully inspect your motorcycle to identifythe problem, then consider your options beforeyou decide what to do.

Whatever the problem, the most important rulesare:

If a problem is relatively minor and you havethe tools, supplies, and skills to make apermanent repair, you may be able to fix it onthe trail and continue riding. Or, you may beable to make a temporary repair that allows youto slowly ride back to your base where you canmake a permanent repair or get help.

When a problem is more serious or you don’thave the tools, supplies, experience, or time todeal with it you need to choose the safest wayto get yourself and your motorcycle back tobase. For example, if you are close enough,you (or you and another person) might be ableto push it back.

Always put personal safety first.

03/03/07 16:16:31 31KPT610_133

125

If Your Engine Quits or Won’t Start



The next area to check is the fuel system:If the problem is relatively minor and youhave the tools, supplies, and skills to make atemporary repair, be sure to have permanentrepairs made as soon as possible.Do not continue riding if you are hurt oryour motorcycle is not in safe ridingcondition.

Additional recommendations for specificproblems follow.

If the engine wasn’t making any unusual noisesbefore it quit running, and it feels normal whenyou operate the kickstarter, you can probablyrule out a major mechanical problem.

Make sure there is enough gas in the tankand the fuel valve is at the ON or RESERVEposition.Check the fuel fill cap vent tube to see if it ispinched or obstructed.Turn the fuel valve OFF, disconnect the fuelline that goes from the fuel valve to thecarburetor, then momentarily turn the fuelvalve ON. If fuel does not flow out, there isan obstruction in the fuel tank or the fuelvalve.

(cont’d)

03/03/07 16:16:41 31KPT610_134

126

If You Have a Flat Tire



How you handle a flat tire on the trail dependson how serious the tube or tire damage is, andwhat tools and supplies you have with you.

If you have a slow leak or a minor puncture,there are two ways to try making a temporaryrepair:

Use a tube patch kit to repair the puncture.(This requires removing the tire.)

Use an aerosol tire sealer to seal the punctureand inflate the tube. (This can be donewithout removing the tire or wheel.)

If the fuel system appears to be okay, check theignition system (this requires a spark plugwrench):

If you cannot identify or correct the problem,you will have to push your motorcycle back toyour base or get some help.

Operate the kickstarter while you watch thespark plug. If it sparks, the ignition system isprobably working. If there is no spark, installa new spark plug, if you have one with you.If there is still no spark, there is a problem inthe ignition system.

Disconnect the spark plug cap and removethe spark plug. Connect the spark plug cap tothe spark plug and ground the threadedportion of the spark plug on the cylinderhead.

Check that the spark plug cap isn’t loose ordisconnected.

03/03/07 16:16:50 31KPT610_135

127

If You Crash



If you are unable to repair a flat tire on the trail,you will need to push the motorcycle back toyour base or send for help. We stronglyrecommend that you do not try to ride with aflat tire. The motorcycle will be hard to handle,and if the tire comes off the rim, it may lock upthe wheel and cause you to crash.

Personal safety is your first priority after anaccident. If you or anyone else has been injured,take time to assess the severity of the injuriesand whether it is safe to continue riding. If youcannot ride safely, send someone for help. Donot ride if you will risk further injury.

If you decide you are capable of riding safely,carefully inspect your motorcycle for damageand determine if it is safe to ride. Check thetightness of critical nuts and bolts securingsuch parts as the handlebar, control levers,brakes, and wheels.

(cont’d)

If the leak is more serious, or a temporaryrepair doesn’t hold, the tube must be replaced.The tire will also need to be replaced if it isdamaged (page ). Replacing a tube or tireinvolves removing and re-installing the wheel(pages , ).94 96

101

03/03/07 16:16:57 31KPT610_136

128



If You Lose Your Key

QuickRef erence

If there is minor damage, or you are unsureabout possible damage but decide to try ridingthe motorcycle back to your base, ride slowlyand cautiously.

Sometimes, crash damage is hidden or notimmediately apparent. When you get home,thoroughly check your motorcycle and correctany problems you find. Also, be sure to haveyour Honda dealer check the frame andsuspension after any serious crash.

Be sure to record your key number in thesection at the rear of the manual.

You’ll need this number to have a duplicatekey made.

If you lose your key and aren’t carrying aduplicate, either get your spare or have onemade. If you don’t know your key number, callthe dealer you purchased your Honda from.They may have it listed in their records. If theydon’t, transport your motorcycle to them or thenearest Honda dealer. The dealer will probablyhave to remove the ignition switch assembly tofind the key number so they can make a key foryou.

03/03/07 16:17:04 31KPT610_137

129

If a Component Fails



If you damage a throttle cable or othercritical component, your motorcycle may beunsafe to ride. Carefully assess the damageand make any repairs that you can. But ifthere is any doubt, it’s best to beconservative and safe.

If the clutch lever breaks, you may be able totemporarily switch the front brake lever tothe clutch side, then ride carefully back tobase using the rear brake for slowing orstopping.

If any component of the front brake systemis damaged, you may be able to ridecarefully back to your base using the rearbrake for slowing or stopping.The drive chain, brake lever or pedal, control

cables, and other components can be damagedas you ride in dense brush or over rocky terrain.Making a trailside repair depends on howserious the damage is and what tools andsupplies you have with you.

If the chain breaks or does other damagewhen it comes off, you may not be able tomake a trailside repair.

03/03/07 16:17:11 31KPT610_138

130 Taking Care of the Unexpected

03/03/07 16:17:13 31KPT610_139

131

Technical Information


This section contains dimensions, capacities,and other technical data, plus information ongovernment requirements and how to break-inyour motorcycle.

..................................Vehicle Identification .132...............................................Specifications .134

.....................................Break-in Guidelines .139.........High Altitude Carburetor Adjustment .140

...........................Emission Control Systems .141.........................................Oxygenated Fuels .145

03/03/07 16:17:18 31KPT610_140

(2) engine number

(1)

(2)

(1) frame number

RIGHT SIDE

LEFT SIDE

132

Vehicle Identification

Serial Numbers


Quick Ref erence

The frame and engine serial numbers arerequired when you register your motorcycle.They may also be required when orderingreplacement parts. You may record thesenumbers in the section at therear of the manual.

The engine number ( ) is stamped on the leftside of the engine.

The frame number ( ) is stamped on the rightside of the steering head.

1

2

03/03/07 16:17:25 31KPT610_141

(1)(1) color label

LEFT SIDE

133

Vehicle Identification

Color Label & Code


Quick Ref erence

The color code is helpful when orderingreplacement parts. You may record the colorand code in the section at therear of the manual.

The color label ( ) is attached to the framebehind the left side cover (page ).

156

03/03/07 16:17:32 31KPT610_142

76.2 in (1,936 mm)31.5 in (799 mm)44.1 in (1,120 mm)52.1 in (1,323 mm)

214.3 lbs (97.2 kg)

2.17 US gal (8.2 )including reserve0.40 US gal (1.5 )unleaded gasoline,pump octanenumber of 92 orhigherafter draining:1.1 US qt (1.0 )after disassembly:1.3 US qt (1.2 )

Overall lengthOverall widthOverall heightWheelbase

Dry weight

Fuel tank capacity

Fuel tank reserveFuelrecommendation

Engine oil capacity

Dimensions

Weight

Fuel & Lubricants

134

Specifications


03/03/07 16:17:44 31KPT610_143

××

Pro Honda ChainLube or anequivalent, or SAE80 or 90 gear oil

9.0 : 1

none

220 lbs (100 kg)

operator only;no passenger

Pro Honda (USAonly) or Honda(Canada only) FoamFilter Oil or anequivalent

9.6 cu-in (157 cm )2.50 1.95 in(63.5 49.5 mm)

API ServiceClassification SG orhigher except oilslabeled as energyconserving on thecircular API servicelabel, SAE 10W-40,JASO T 903 standardMA,Pro Honda GN4 or HP4(without molybdenumadditives) 4-stroke oil(USA & Canada) orHonda 4-stroke oil(Canada only), or anequivalent motorcycleoil

Air cleaner oil

DisplacementBore & stroke

Compression ratio

PassengercapacityMaximum weightcapacityCargo capacity

Engine oilrecommendation

Drive chainlubricant

Fuel & Lubricants

Engine Specifications

Capacities

Fuel & Lubricants

135

Specifications


03/03/07 16:17:55 31KPT610_144

±

－－

DPR8EA-9 (NGK)

3.3332.7691.8821.4001.0950.9233.692

X24EPR-U9 (DENSO)

chain

0.004 in(0.10 mm)0.004 in(0.10 mm)

1,400 100 rpm

0.031 0.035 in(0.80 0.90 mm)

DPR7EA-9 (NGK)X22EPR-U9 (DENSO)

Intake:

Exhaust:

or

or

Primary reductionGear ratio, 1st2nd3rd4th5thFinal reductionFinal drive

Valve clearance(cold)

Spark plug(standard)Spark plug(cold climate;below 5°C, 41°F)Spark plug gap

Idle speed

Power TransmissionEngine Specifications

136

Specifications


03/03/07 16:18:05 31KPT610_145

－－

－－

25°45’

25.0 in (635 mm)

25.1 in (637 mm)

3.3 in (85 mm)

distance between aspan of 41 pins

distance between aspan of 41 pins

13/16 1 3/16 in(20 30 mm)

70/100 19M/C 42M90/100 16M/C 51M15 psi (100 kPa , 1.0kgf/cm )15 psi (100 kPa , 1.0kgf/cm )8.1 in (207 mm)axle travel8.8 in (223 mm)axle travel

Drive chainfreeplayNew chain length

Used chain servicelimit length

CasterTrailTire size, frontTire size, rearTire pressure, front(cold)Tire pressure, rear(cold)Suspension, front

Suspension, rear

Power Transmission Chassis & Suspension

137

Specifications


03/03/07 16:18:18 31KPT610_146

11 lbf·ft (15 N·m , 1.5kgf·m)

54 lbf·ft (74 N·m , 7.5kgf·m)

9 lbf·ft (12 N·m , 1.2kgf·m)

80 lbf·ft (108 N·m ,11.0 kgf·m)

Oil drain bolt

Front wheel axle

Axle holder nuts

Rear wheel axle

Torque Specifications

138

Specifications


03/03/07 16:18:23 31KPT610_147

139

Break-in Guidelines


Help assure your motorcycle’s future reliabilityand performance by paying extra attention tohow you ride during the first operating day or15 miles (25 km).During this period, avoid full-throttle starts andrapid acceleration.

03/03/07 16:18:28 31KPT610_148

140

High Altitude Carburetor Adjustment


Sustained operation at altitudes below 5,000f eet (1,500 m) with high altitude carburetormodif ications may cause engine overheatingand damage.

When operating this motorcycle at high altitude,the air-fuel mixture becomes overly rich.Above 6,500 feet (2,000 m), driveability andperformance may be reduced and fuelconsumption increased. The carburetor can bemodified to compensate for this high altituderichness.However, the carburetor must be returned tostandard factory specifications when loweraltitude riding is desired. See your Hondadealer for high altitude modification.

03/03/07 16:18:32 31KPT610_149

(1)

(1) vehicle emission controlinformation label

141

Exhaust Emission Requirements Noise Emission Requirements

Emission Control Systems


The California Air Resources Board (CARB)requires that your motorcycle comply withapplicable exhaust emissions standards duringits useful life, when operated and maintainedaccording to the instructions provided.(California only)

The Vehicle Emission Control InformationLabel ( ) is attached to the rear fender.

The EPA also requires that motorcycles builtafter January 1, 1983 comply with applicablenoise emission standards for one year or1,865 miles (3,000 km) after the time of sale tothe ultimate purchaser, when operated andmaintained according to the instructionsprovided. (USA only)

1

03/03/07 16:18:39 31KPT610_150

142

Exhaust Emission Control System

Crankcase Emission Control SystemSource of Emissions



The exhaust emission control system iscomposed of lean carburetor settings, and noadjustments should be made except idle speedadjustment with the throttle stop screw.The exhaust emission control system is separatefrom the crankcase emission control system.

The engine is equipped with a closed crankcasesystem to prevent discharging crankcaseemissions into the atmosphere.Blow-by gas is returned to the combustionchamber through the air cleaner and thecarburetor.

The combustion process produces carbonmonoxide (CO) and hydrocarbons (HC).Control of hydrocarbons is very importantbecause under certain conditions, they react toform photochemical smog when subjected tosunlight. Carbon monoxide does not react inthe same way, but it is toxic.Honda Motor Co., Ltd. utilizes lean carburetorsettings and other systems to reduce carbonmonoxide and hydrocarbons.

03/03/07 16:18:44 31KPT610_151

143

Noise Emission Control System



TAMPERING WITH THE NOISE CONTROLSYSTEM IS PROHIBITED: U. S. federal lawprohibits, or Canadian provincial laws mayprohibit the following acts or the causingthereof: (1) The removal or renderinginoperative by any person, other than forpurposes of maintenance, repair or replacement,of any device or element of designincorporated into any new vehicle for thepurpose of noise control prior to its sale ordelivery to the ultimate purchaser or while it isin use; or (2) the use of the vehicle after suchdevice or element of design has been removedor rendered inoperative by any person.

Removal of, or puncturing the muffler,baffles, header pipes, or any othercomponent which conducts exhaust gases.Removal of, or puncturing of any part of theintake system.Lack of proper maintenance.Replacing any moving parts of the vehicle,or parts of the exhaust or intake system, withparts other than those specified by themanufacturer.

AMONG THOSE ACTS PRESUMED TOCONSTITUTE TAMPERING ARE THEACTS LISTED BELOW:1.

2.

3.4.

03/03/07 16:18:50 31KPT610_152

144

Problems that May Affect MotorcycleEmissions



If you are aware of any of the followingsymptoms, have the vehicle inspected andrepaired by your Honda Motorcycle Dealer:

Hard starting or stalling after startingRough idleMisfiring or backfiring during accelerationAfter-burning (backfiring)Poor performance (driveability) and poorfuel economy

1.2.3.4.5.

03/03/07 16:18:54 31KPT610_153

145

Oxygenated Fuels


Some conventional gasolines are being blendedwith alcohol or an ether compound. Thesegasolines are collectively referred to asoxygenated fuels. To meet clean air standards,some areas of the United States and Canada useoxygenated fuels to help reduce emissions.

ETHANOL (ethyl or grain alcohol) 10% byVolumeYou may use gasoline containing up to 10%ethanol by volume. Gasoline containing ethanolmay be marketed under the name ‘‘Gasohol’’.

If you use an oxygenated fuel, be sure it isunleaded and meets the minimum octane ratingrequirement.

Before using an oxygenated fuel, try toconfirm the fuel’s contents. Some states/provinces require this information to be postedon the pump.

The following are the EPA-approvedpercentages of oxygenates:

MTBE (Methyl Tertiary Butyl Ether) 15% byVolumeYou may use gasoline containing up to 15%MTBE by volume.

METHANOL (methyl or wood alcohol) 5% byVolumeYou may use gasoline containing methanolcontaining up to 5% methanol by volume aslong as it contains cosolvents and corrosioninhibitors to protect the fuel system. Gasolinecontaining more than 5% methanol by volumemay cause starting and/or performanceproblems. It may also damage metal, rubber,and plastic parts of your fuel system.

(cont’d)

03/03/07 16:19:03 31KPT610_154

146

Oxygenated Fuels


Oxygenated f uels can damage paint andplastic. Damage caused by spilled f uel is notcovered under warranty.

If you notice any undesirable operatingsymptoms, try another service station or switchto another brand of gasoline.

Fuel system damage or performance problemsresulting from the use of an oxygenated fuelcontaining more than the percentages ofoxygenates mentioned above are not coveredunder warranty.

Oxygenated fuels can damage paint and plastic.Be careful not to spill fuel when filling the fueltank. Wipe up any spills immediately.

03/03/07 16:19:09 31KPT610_155

147

Consumer Information


This section contains information on yourwarranty and how to get an official Hondaservice manual.

.....................................Authorized Manuals .148......................................Warranty Coverage .151

..........................................Warranty Service .152........................................Contacting Honda .153

..........The Honda Rider’s Club (USA only) .154......................................Your Honda Dealer .155

03/03/07 16:19:14 31KPT610_156

＊

＊

$48.00$48.00$16.00

61KPT0161CM00131KPT610

2004 CRF150F Service ManualCommon Service Manual2004 CRF150F Owner’s Manual

Price EachDescriptionPublication Item No.

Prices are subject to change without notice and without incurr ing obligation.

148

Authorized Manuals


The Service Manual (Publication Item No. ) used by your authorized Honda dealer isavailable from Helm, Inc. (USA only, Canada: See your Honda dealer to order authorized manuals.)

Also available, but not necessary, to service your model is the Honda Common Service Manual(Publication No. ), which explains theory of operation and basic service information forvarious systems common to all Honda motorcycles, motor scooters and ATVs.

These Honda manuals are written for the professional technician, but most mechanically-capableowners should find them easy to use if they have the proper tools and observe proper safetystandards. Special Honda tools are necessary for some procedures.

61CM001

61KPT01

03/03/07 16:19:21 31KPT610_157

＊

＊

－－

Prices are subject to change without notice and without incurringobligation.

Orders are mailed within 10 days. Please allow adequate time fordelivery.

PublicationItem No.

Item Description Qty. PriceEach

TotalPrice

Sub TotalMich. PurchasersAdd 6 % Sales TaxHandling ChargeGrand Total

$4.00

149

Order On-Line: www.helminc.com

Order Toll Free: 1-888-CYCLE93

OR


(NOTE: For Credit Card Orders Only)

(1-888-292-5393)

Monday Friday 8:00 AM 6:00 PM EST

By completing this form you can order the materials desired. You can pay by check or money order,or charge to your credit card. Mail to Helm, Inc. at the address shown on the back of this order form(USA only).

Canada: See your Honda dealer to order authorized manuals.

03/03/07 16:19:32 31KPT610_158

－

NOTE: Dealers and Companies please provide dealer or company name, and also the name of the person towhose attention the shipment should be sent.

AttentionCustomer Name

Apartment NumberStreet Address - No P. O. Box Number

Zip CodeStateCity

Daytime Telephone Number

Check or money order enclosed payable to Helm Inc.U.S. funds only. Do not send cash.

MasterCard

VISA

Discover

DateCustomer Signature

These Publications cannot be returned for credit without receiving advance authorization within 14 days of delivery. Onreturns, a restocking fee may be applied against the original order.

Check here if your billing address is differentfrom the shipping address shown above.

Expiration: Mo. Yr.Account Number

( )

P.O. BOX 07280, DETROIT, MICHIGAN 48207HELM

SHIP

TO

PAYMENT

150 Consumer Information

03/03/10 10:17:41 31KPT610_159

151

Warranty Coverage


Your new Honda is covered by thesewarranties:

Your warranty coverage will not be voided ifyou choose to perform your own maintenance.However, you should have the proper tools andservice information and be mechanicallyqualified. Failures that occur due directly toimproper maintenance or lack of maintenanceare not covered.There are responsibilities, restrictions, and

exclusions which apply to these warranties.Please read the Honda Motorcycle WarrantiesBooklet given to you by your Honda dealer atthe time of purchase. Be sure to keep yourHonda owner’s card (USA only) with yourWarranties Booklet.

Motorcycle Limited WarrantyNoise Control Warranty (USA only)

It is important to realize that your warranty foryour Honda applies to defects in material orfactory workmanship. Your warranty coveragedoes not apply to normal wear or deteriorationassociated with using the motorcycle.

Almost all of your warranty coverage can beextended through the Honda Protection Plan(USA only). For more information, see yourHonda dealer.

03/03/07 16:19:55 31KPT610_160

152

Warranty Service


Please remember that recommendedmaintenance interval servicing is not includedin your warranty coverage. Additionally, yourwarranty does not apply to the normal wear ofitems (such as brakes, tires, etc.).

If you believe you have a problem with yourHonda, call the service department of yourHonda dealer. Make an appointment for aninspection and diagnosis. Remember, as theowner of the motorcycle, you will be asked toauthorize that inspection. Your dealer will giveyou the results of the inspection. If the problemis covered under warranty, your dealer willperform the warranty repairs for you.

If you have questions about warranty coverageor the nature of the repair, it is best to talk tothe service manager of your Honda dealer.

Sometimes, in spite of the best intentions of allconcerned, a misunderstanding may occur. Ifyou aren’t satisfied with your dealer’s handlingof the situation, we suggest you discuss yourproblem with the appropriate member of thedealership’s management team. If the problemhas already been reviewed with the ServiceManager, Parts Manager, Sales Manager, etc.,contact the Owner of the dealership or hisdesignated representative.

03/03/07 16:20:02 31KPT610_161

153

Contacting Honda


Your owner’s manual was written to covermost of the questions you might ask about yourHonda. Any questions not answered in theowner’s manual can be answered by yourHonda dealer. If he doesn’t have the answerright away, he will get it for you.

If you have a difference of opinion with yourdealer, please remember that each dealership isindependently owned and operated. That’s whyit’s important to work to resolve anydifferences at the dealership level.

If you wish to comment on your experienceswith your Honda or with your dealer, pleasesend your comments to the following address(USA only):

Motorcycle Division, American Honda MotorCo., Inc., P.O. Box 2220, Torrance, CA 90509-2220, mailstop: 100-4W-5B, telephone: (310)532-9811.

Canada: Refer to the warranty booklet that wassupplied with your vehicle.

Please include the following information inyour letter:

name, address, and telephone numberproduct model, year, and frame/VIN serialnumberdate of purchasedealer name and address

We will likely ask your Honda dealer torespond, or possibly acknowledge yourcomments directly.

03/03/07 16:20:10 31KPT610_162

154

The Honda Rider’s Club (USA only)


Honda Red Rider,

24-hr. emergency roadside assistance foryour Honda or transport vehicle.Transportation for your Honda or transportvehicle to the nearest Honda dealer orservice facility if roadside assistance can’tget you going again.Reimbursement (to $75) for motorcycle andscooter rider training from the MotorcycleSafety Foundation. Free ATV rider trainingis available from the Specialty VehicleInstitute of America with the purchase of anew Honda ATV.

A subscription to a bi-monthly insider’s magazine for all members.Special members-only HRCA website.Discounts from HRCA partners for both onand off-road riding schools and adventurepackages.Hospitality at national events.Optional insurance, club pin, patch, etc.Red Rider (MX) contingency and off-roadsupport at selected events.Computerized trip routing, color maps, andspecial travel packages.

Contact your Honda dealer for moreinformation or call: 1-800-847-HRCA. For acomplete list of all HRCA benefits and services,refer to your HRCA membership benefitsmanual or visit our website atwww.honda.com.

One of the best ways to get the most enjoymentfrom owning and riding your Honda is to jointhe Honda Rider’s Club of America (HRCA).Your purchase of a new motorcycle, scooter orATV from a participating Honda dealer entitlesyou to a complimentary one-year membership.The HRCA has hundreds of dealer-sponsoredchapters throughout the USA. Some of theHRCA membership benefits include:

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Your Honda Dealer


Once you purchase your new Honda, getfamiliar with the organization of your Hondadealer so you can utilize the full range ofservices available.

The service department is there to performregular maintenance and unexpected repairs. Ithas the latest available service informationfrom Honda. The service department will alsohandle warranty inspections and repairs.

The parts department offers Genuine Hondaparts, Pro Honda products, Hondalineaccessories (USA only), and Honda accessoriesand products (Canada only). The same qualitythat went into your Honda can be found inGenuine Honda replacement parts. You’ll alsofind comparable quality in the accessories andproducts available from the parts department.

We’re sure you’ll be as pleased with the serviceyour Honda dealer continues to provide afterthe sale as you are with the quality anddependability of your Honda.

The sales department offers the Honda CareProtection Plan to extend almost all of yourwarranty coverage (USA only).

Your dealer can inform you about competitionand other riding events in your area. You’ll alsofind that your dealer is a source of information(USA only) about American Honda’s RiderEducation Centers and the Honda Rider’s Clubof America.

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156

...........................MOTORCYCLE SAFETY .1

........................OPERATING CONTROLS .11

.......................................BEFORE RIDING .21

..............BASIC OPERATION & RIDING .27

Table of Contents

Table of Contents

The following presents the contents of eachsection of your owner’s manual.

..........................Important Safety Information .2...........Loading, Accessories & Modifications .5

........................................................Loading .5.......................Accessories & Modifications .7

....................................................Safety Labels .9

....................................Component Locations .12......................................................Fuel Valve .15

...................................................Choke Lever .16...............................................Ignition Switch .17

........................................Engine Stop Button .18..........................................Front Brake Lever .18

...........................................................Throttle .18...................................................Clutch Lever .18

.....................................................Shift Lever .19............................................Rear Brake Pedal .19

......................................................Kickstarter .19

......................................................Side Stand .19

..............................Are You Ready to Ride .22.....................................Protective Apparel .22

............Is Your Motorcycle Ready to Ride .24.....................................Pre-ride Inspection .24

.................................Safe Riding Precautions .28.....................Starting & Stopping the Engine .29

.................................................Preparation .29......................................Starting Procedure .29

..........................................Flooded Engine .31.............................How to Stop the Engine .32

................................................Shifting Gears .33...........................................................Braking .35...........................................................Parking .37

.......................................Post-ride Inspection .38

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....................SERVICING YOUR HONDA .39

Table of Contents

Table of Contents

Bef ore You Service Your Honda

Service Preparations

Service Procedures

....................The Importance of Maintenance .41........................................Maintenance Safety .43

.....................Important Safety Precautions .43...................................Maintenance Schedule .45

......................................Maintenance Record .49..................................Competition Inspection .50

....................................Component Locations .53...............................................................Tools .55

......................................Side Cover Removal .56

Fluids & Filters.................................................................Fuel .57

......................................................Engine Oil .60.....................................................Air Cleaner .66

........................................Crankcase Breather .70

Engine...........................................................Throttle .71

................................................Clutch System .73..........................................Engine Idle Speed .76

......................................................Spark Plug .77................................................Spark Arrester .79

Chassis.....................................................Suspension .81

.............................................................Brakes .84............................................................Wheels .92

.................................................Tires & Tubes .98....................................................Side Stand .102..................................................Drive Chain .103

..........................................Appearance Care .110

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.............................................................TIPS .113

TAKING CARE OF THE..........................................UNEXPECTED .123

..............TECHNICAL INFORMATION .131

Table of Contents

Table of Contents

.....................................Preparing for a Ride .114............................Transporting Your Honda .116

.....................................Storing Your Honda .118...............................You & the Environment .121

.......................................General Guidelines .124...........If Your Engine Quits or Won’t Start .125

................................If You Have a Flat Tire .126.................................................If You Crash .127

.................................If You Lose Your Key .128...................................If a Component Fails .129

..................................Vehicle Identification .132...............................................Specifications .134

.....................................Break-in Guidelines .139.........High Altitude Carburetor Adjustment .140

...........................Emission Control Systems .141.........................................Oxygenated Fuels .145

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...............CONSUMER INFORMATION .147 ..........................TABLE OF CONTENTS .156

.........................................................INDEX .160

QUICK REFERENCE

Table of Contents

Table of Contents

.....................................Authorized Manuals .148......................................Warranty Coverage .151

..........................................Warranty Service .152........................................Contacting Honda .153

..........The Honda Rider’s Club (USA only) .154......................................Your Honda Dealer .155

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Index

Index

A

B

C

........................................................accessories .7.......................................................air cleaner .66

............................................air pressure, tires .98..................................altering your motorcycle .8

.................................................arrester, spark .79

brakes,...................................................fluid level .86..................................................lever, front .18

...............................lever, front adjustment .84.....................................................pad wear .87...................................................pedal, rear .19....................................................shoe wear .89

...........................................................braking .35.......................................break-in guidelines .139.........................................button, engine stop .18

..................................................capacity, fuel .58carburetor,

...........................high altitude adjustment .140....................................................idle speed .76.....................................................choke lever .16......................................................cleaner, air .66

............................cleaning, appearance care .110clutch system,

..................................................adjustment .73............................................................lever .18

.....................................................color label .133...................................competition inspection .50

..................................consumer information .147..........................................controls, operating .11........................................cover removal, side .56

..........................................crankcase breather .70...........................................customer service .153

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Index

Index

D

E

F

....................................................drive chain .103

........................................education, rider .3, 155.............................emission control systems .141

.................................emission requirements .141..............................................engine number .132

engine,.......................................................flooded .31

....................................................idle speed .76.......................................................pinging .57........................................................starting .29

..................................................stop button .18......................................................stopping .32

................................................won’t start .125...............................environment, protecting .121

..........................................................filter, air .66..........................................................flat tire .126

.................................flooded engine, starting .31.................................................................fork .81

...............................................frame number .132front brake,

............................................................lever .18.............................................lever freeplay .84.............................................front suspension .81

.......................................front wheel removal .94fuel,

.........................................recommendation .57...............................................oxygenated .145

..............................................tank capacity .58...........................................................valve .15

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Index

Index

G

H

I

K

L

...............................................gap, spark plug .77.........................................................gasohol .145..........................................................gasoline .57

.................................................gears, shifting .33

...............................high altitude adjustment .140........................................Honda, contacting .153

..................................Honda service manual .148

...........................................idle speed, engine .76inspection,

................................................competition .50.....................................................post-ride .38

.......................................................pre-ride .24

.......................................................kickstarter .19

lever,..........................................................clutch .18

..................................................front brake .18............................................................shift .19

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Index

Index

M

O

P

R

.....................................................limit, weight .6..............................................................loading .5

maintenance,.........................................................record .49..........................................................safety .43

......................................................schedule .45.............................................manual, service .148

...................................................modifications .8

...........................................................parking .37.............................................pedal, rear brake .19

...............................................pinging, engine .57......................................................plug, spark .77

........................................post-ride inspection .38..........................................pre-ride inspection .24

.............................reserve capacity, fuel tank .58.............................................rider training .3, 155

riding,...........................................basic operation .27

.........................................................before .21.......................................................clothing .22

.................................................precautions .28............................................................safety .2..........................................................rim lock .93

.......................................................oil, engine .60...........................................operating controls .11

..........................................oxygenated fuels .145

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Index

Index

S

T

throttle......................................................freeplay .71.....................................................operation .18

tires,.................................................air pressure .98

............................................................flat .126...................................................replacing .101

................................................................tools .55.............................................................towing .34

............................................training, rider .3, 155..................................................transporting .116

..............................troubleshooting, starting .125

...................................schedule, maintenance .45service,

...................................................customer .153....................................................manuals .148...................................................warranty .152

..................................................shifting gears .33.....................................................shoe, brake .89

........................................side cover, removal .56................................................side stand .19, 102

..................................................spark arrester .79....................................................spark knock .57

.......................................................spark plug .77...............................................specifications .134

...............................................stand, side .19, 102...............................................starting, engine .29

.........................................stop button, engine .18..............................................stopping engine .32

..........................................................storage .118

suspension,............................................................front .81

..............................................................rear .82

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Index

Index

WV

.......................................................valve, fuel .15...................................vehicle identification .132

warranty,...................................................coverage .151...................................................extended .151

......................................................service .152.............................washing your motorcycle .110

......................................................weight limit .6.............................................................wheels .92

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Quick Reference

Quick Reference

How To Avoid Costly RepairsThe following is a brief, but importantcollection of information you need to knowabout your Honda. You’ll also find space torecord important notes. The engine of your Honda can be the most

expensive component to repair. Propermaintenance, especially the use of therecommended fluids and filters, preventspremature wear and damage.

Frequent causes of costly engine repairs are:

Engine oil: insufficient quantity, improperoil.Air cleaner: dirty, leaking because ofimproper installation (poor seal).

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Quick Reference

Quick Reference

Record important information here:

Frame No.Engine No.Ignition Key No.Color LabelOwner’s:

NameAddressCity/StatePhone

Dealer’s:NameAddressCity/StatePhoneService Mgr.

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－－

DPR8EA-9 (NGK) X24EPR-U9 (DENSO)15 psi (100 kPa , 1.0 kgf/cm )15 psi (100 kPa , 1.0 kgf/cm )90/100 16M/C 51M70/100 19M/C 42M

220 lbs (100 kg)

0.40 US gal (1.5 )2.17 US gal (8.2 )

or

Quick Reference

Quick Reference

Initial Maintenance about 100 miles (150 km) or one month.about every 600 miles (1,000 km) or six months.Regular

MaintenancePre-ride Inspection Check the following items each time before you ride (page ): tires, spokes & rims,

leaks, engine oil, fuel, drive chain, cables, nuts & bolts, spark plug and cap, throttle,brakes, and clutch lever.

rider only (no passenger or cargo) and any accessories

API Service Classification SG or higher except oils labeled as energy conserving on thecircular API service label, SAE 10W-40, JASO T 903 standard MA,Pro Honda GN4 or HP4 (without molybdenum additives) 4-stroke oil or equivalent

unleaded gasoline, pump octane number of 92 or highertank:reserve:

Spark Plug

Tire Pressure (cold)

Tires

Maximum WeightCapacity

Engine Oil

Fuel/Capacity

Front:

Front:Rear:

Rear:

24

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this manual should be considered a permanent part of...

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