0% found this document useful (0 votes)
257 views115 pages

CB 400

Uploaded by

Kim Kam
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
0% found this document useful (0 votes)
257 views115 pages

CB 400

Uploaded by

Kim Kam
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 115

This manual should be considered a permanent part of the motorcycle

and should remain with the motorcycle when it is resold.

This publication includes the latest production information available


before printing. Honda Motor Co., Ltd. reserves the right to make
changes at any time without notice and without incurring any obligation.

No part of this publication may be reproduced without written


permission.

The vehicle pictured in this owner’s manual may not match your actual
vehicle.

© 2010 Honda Motor Co., Ltd.

32MFM630.indb 2 2010/12/14 15:43:47

Downloaded from www.Manualslib.com manuals search engine


Welcome
Congratulations on your purchase of a new ●● The following codes in this manual
Honda motorcycle. Your selection of a indicate each country.
Honda makes you part of a worldwide ●● The illustrations here in are based on the
family of satisfied customers who appreciate CB400A type.
Honda’s reputation for building quality into Country Codes
every product. Code Country
CB400
To ensure your safety and riding pleasure: U, II U, V U, VI U Australia
●● Read this owner’s manual carefully. SI, II SI Singapore
●● Follow all recommendations and
CB400A
procedures contained in this manual.
●● Pay close attention to safety messages
U, II U Australia
II SI Singapore
contained in this manual and on the
motorcycle. * The specifications may vary with each locale.

32MFM630.indb 3 2010/12/14 15:43:47

Downloaded from www.Manualslib.com manuals search engine


A Few Words About Safety
Your safety, and the safety of others, is very
important. Operating this motorcycle safely DANGER
is an important responsibility. You WILL be KILLED or SERIOUSLY
To help you make informed decisions about HURT if you don’t follow instructions.
safety, we have provided operating
procedures and other information on safety WARNING
labels and in this manual. This information You CAN be KILLED or SERIOUSLY
alerts you to potential hazards that could HURT if you don’t follow instructions.
hurt you or others.
Of course, it is not practical or possible to CAUTION
warn you about all hazards associated with You CAN be HURT if you don’t follow
operating or maintaining a motorcycle. You instructions.
must use your own good judgement.
Other important information is
You will find important safety information in provided under the following titles:
a variety of forms, including: NOTICE Information to help you avoid
●● Safety labels on the motorcycle. damage to your motorcycle,
●● Safety Messages preceded by a safety other property, or the
alert symbol and one of three signal environment.
words: DANGER, WARNING, or CAUTION.
These signal words mean:

32MFM630.indb 4 2010/12/14 15:43:47

Downloaded from www.Manualslib.com manuals search engine


Contents

Motorcycle Safety P. 2

Operation Guide P. 12

Maintenance P. 29

Troubleshooting P. 72

Information P. 94

Specifications P. 106

Index P. 109

32MFM630.indb 1 2010/12/14 15:43:47

Downloaded from www.Manualslib.com manuals search engine


Motorcycle Safety

This section contains important information for safe riding of your motorcycle.
Please read this section carefully.

Safety Guidelines............................................................ P.3


Safety Precautions......................................................... P.6
Riding Precautions......................................................... P.7
Accessories & Modifications................................. P.10
Loading................................................................................. P.11

32MFM630.indb 2 2010/12/14 15:43:48

Downloaded from www.Manualslib.com manuals search engine


Safety Guidelines

Safety Guidelines that you and your passenger are both wearing
an approved motorcycle helmet and protective

Motorcycle Safety
Follow these guidelines to enhance your safety: apparel. Instruct your passenger on holding
●● Perform all routine and regular inspections onto the seat strap or your waist, leaning with
specified in this manual. you in turns, and keeping their feet on the
●● Stop the engine and keep sparks and flame footpegs, even when the motorcycle is
away before filling the fuel tank. stopped.
●● Do not run the engine in enclosed or partly
enclosed areas. Carbon monoxide in exhaust
gases is toxic and can kill you. Take Time to Learn & Practice
Even if you have ridden other motorcycles,
practice riding in a safe area to become
Always Wear a Helmet familiar with how this motorcycle works and
It’s a proven fact: helmets and protective handles, and to become accustomed to the
apparel significantly reduce the number and motorcycle’s size and weight.
severity of head and other injuries. So always
wear an approved motorcycle helmet and
protective apparel. P.6 Ride Defensively
Always pay attention to other vehicles around
you, and do not assume that other drivers see
Before Riding you. Be prepared to stop quickly or perform an
Make sure that you are physically fit, mentally evasive maneuver.
focused and free of alcohol and drugs. Check
3

32MFM630.indb 3 2010/12/14 15:43:49

Downloaded from www.Manualslib.com manuals search engine


Safety Guidelines

Make Yourself Easy to See Keep Your Honda in Safe Condition


Motorcycle Safety

Make yourself more visible, especially at night, It’s important to keep your motorcycle properly
by wearing bright reflective clothing, maintained and in safe riding condition.
positioning yourself so other drivers can see Inspect your motorcycle before every ride and
you, signaling before turning or changing perform all recommended maintenance. Never
lanes, and using your horn when necessary. exceed load limits ( P.11), and do not modify
your motorcycle or install accessories that
would make your motorcycle unsafe ( P.10).
Ride within Your Limits
Never ride beyond your personal abilities or
faster than conditions warrant. Fatigue and If You are Involved in a Crash
inattention can impair your ability to use good Personal safety is your first priority. If you or
judgement and ride safely. anyone else has been injured, take time to
assess the severity of the injuries and whether
it is safe to continue riding. Call for emergency
Don’t Drink and Ride assistance if needed. Also follow applicable
Alcohol and riding don’t mix. Even one laws and regulations if another person or
alcoholic drink can reduce your ability to vehicle is involved in the crash.
respond to changing conditions, and your
reaction time gets worse with every additional If you decide to continue riding, first evaluate
drink. Don’t drink and ride, and don’t let your the condition of your motorcycle. If the engine
friends drink and ride either. is still running, turn it off. Inspect for fluid
4

32MFM630.indb 4 2010/12/14 15:43:49

Downloaded from www.Manualslib.com manuals search engine


Safety Guidelines

leaks, check the tightness of critical nuts and


bolts, and check the handlebar, control levers, WARNING

Motorcycle Safety
brakes, and wheels. Ride slowly and cautiously.
Your motorcycle may have suffered damage Carbon monoxide gas is toxic.
that is not immediately apparent. Have your Breathing it can cause
motorcycle thoroughly checked at a qualified unconsciousness and even kill you.
service facility as soon as possible.
Avoid any areas or activities that
expose you to carbon monoxide.
Carbon Monoxide Hazard
Exhaust contains poisonous carbon monoxide,
a colourless, odorless gas. Breathing carbon
monoxide can cause loss of consciousness and
may lead to death.

If you run the engine in a confined or even


partly enclosed area, the air you breathe could
contain a dangerous amount of carbon
monoxide. Never run your motorcycle inside a
garage or other enclosure.

32MFM630.indb 5 2010/12/14 15:43:49

Downloaded from www.Manualslib.com manuals search engine


Safety Precautions

Safety Precautions ●● Faceshield with unobstructed field of vision


or other approved eye protection.
Motorcycle Safety

●● Ride cautiously and keep your hands on the


handlebars and feet on the footpegs. WARNING
●● Keep passenger’s hands onto the grab rail,
passenger’s feet on the footpegs while Not wearing a helmet increases the
riding. chance of serious injury or death in a
●● Always consider the safety of your crash.
passenger, as well as other drivers and
riders. Make sure that you and any
passenger always wear an approved
Protective Apparel
helmet and protective apparel.
Make sure that you and any passenger are
wearing an approved motorcycle helmet, eye ❙ Gloves
protection, and high-visibility protective Full-finger leather gloves with high abrasion
clothing. Ride defensively in response to resistance
weather and road conditions. ❙ Boots or Riding Shoes
Sturdy boots with non-slip soles and ankle
❙ Helmet protection
Safety-standard certified, high-visibility, correct ❙ Jacket and Pants
size for your head Protective, highly visible, long-sleeved jacket
●● Must fit comfortably but securely, with the and durable trousers for riding (or a protective
chin strap fastened. suit).
6

32MFM630.indb 6 2010/12/14 15:43:49

Downloaded from www.Manualslib.com manuals search engine


Riding Precautions

Riding Precautions Brakes

Motorcycle Safety
Observe the following guidelines:
Running-in Period ●● Avoid excessively hard braking and sudden
During the first 500 km (300 miles) of running, shifting to a lower gear.
follow these guidelines to ensure your a Sudden braking can reduce the
motorcycle’s future reliability and motorcycle’s stability.
performance. a Where possible, reduce speed before
●● Avoid full-throttle starts and rapid turning; otherwise you risk wheel
acceleration. slippage.
●● Avoid hard braking. ●● Exercise caution on low traction surfaces.
●● Ride conservatively. a The wheels lock more easily on such
surfaces, and braking distances are
longer.
●● Avoid continuous braking.
a Repeated braking can overheat the
brakes, reducing their effectiveness.

32MFM630.indb 7 2010/12/14 15:43:50

Downloaded from www.Manualslib.com manuals search engine


Riding Precautions

❙ Combined ABS (CB400A) ❙ Engine Braking


Your motorcycle is equipped with a brake Engine braking helps slow your motorcycle
Motorcycle Safety

system that distributes the braking force down when you release the throttle. For
between the front and rear brakes. further slowing action, downshift to a lower
The distribution of the braking force applied to gear. Use engine braking with intermittent use
the front and rear brakes is different when of the brakes to reduce speed when
operating the lever only and when operating descending long, steep slopes.
the pedal only.
For full braking effectiveness, operate both the ❙ Wet or Rainy Conditions
lever and pedal together. Road surfaces are slippery when wet, and wet
brakes further reduce braking efficiency.
This model is also equipped with an Anti-lock Exercise extra caution when braking in wet
Brake System (ABS) designed to help prevent conditions.
the brakes from locking up during hard If the brakes get wet, apply the brakes while
braking. Always use the recommended tyres riding at low speed to help them dry.
to ensure correct ABS operation.
●● ABS does not reduce braking distance. In
certain circumstances, ABS may result in a
longer stopping distance.
●● ABS does not function at speeds below
10 km/h (6 mph).
●● The brake lever and pedal may recoil slightly
when applying the brakes. This is normal.
8

32MFM630.indb 8 2010/12/14 15:43:50

Downloaded from www.Manualslib.com manuals search engine


Riding Precautions

4. Turn the handlebars fully to the left.


Parking a Turning the handlebars to the right

Motorcycle Safety
●● Park on a firm, level paved surface. reduces stability and may cause the
●● If you must park on a slight incline orloose motorcycle to fall.
surface, park so that the motorcycle cannot 5. Turn the ignition switch to the LOCK
move or fall over. position and remove the key. P.21
●● Make sure that high-temperature parts
cannot come into contact with flammable Refuelling and Fuel Guidelines
materials. Follow these guidelines to protect the engine
●● Do not touch the engine, muffler, brakes and catalytic converter:
and other high-temperature parts until they ●● Use only unleaded petrol.
cool down. ●● Use recommended octane number. Using
●● To reduce the likelihood of theft, always lower octane petrol will result in decreased
lock the handlebars and remove the key engine performance.
when leaving the motorcycle unattended. ●● Do not use fuels containing a high
Use of an anti-theft device is also concentration of alcohol. P.98
recommended. ●● Do not use stale or contaminated petrol or
an oil/petrol mixture.
❙ Parking with the Side Stand ●● Avoid getting dirt or water in the fuel tank.
1. Stop the engine.
2. Push the side stand down.
3. Slowly lean the motorcycle to the left until
its weight rests on the side stand.
9

32MFM630.indb 9 2010/12/14 15:43:50

Downloaded from www.Manualslib.com manuals search engine


Accessories & Modifications

Accessories &
Modifications WARNING
Motorcycle Safety

We strongly advise that you do not add any Improper accessories or modifications
accessories that were not specifically designed can cause a crash in which you can
for your motorcycle by Honda or make be seriously hurt or killed.
modifications to your motorcycle from its
original design. Doing so can make it unsafe. Follow all instructions in this owner’s
Modifying your motorcycle may also void your manual regarding accessories and
warranty and make your motorcycle illegal to modifications.
operate on public roads and highways. Before
deciding to install accessories on your Do not pull a trailer with, or attach a sidecar
motorcycle be certain the modification is safe to, your motorcycle. Your motorcycle was not
and legal. designed for these attachments, and their use
can seriously impair your motorcycle’s
handling.

10

32MFM630.indb 10 2010/12/14 15:43:50

Downloaded from www.Manualslib.com manuals search engine


Loading

Loading
WARNING

Motorcycle Safety
●● Carrying extra weight affects your
motorcycle’s handling, braking and stability. Overloading or improper loading can
Always ride at a safe speed for the load you cause a crash and you can be
are carrying. seriously hurt or killed.
●● Avoid carrying an excessive load and keep
within specified load limits. Follow all load limits and other
Maximum weight capacity P.106 loading guidelines in this manual.
●● Tie all luggage securely, evenly balanced and
close to the centre of the motorcycle.
●● Do not place objects near the lights or the
muffler.

11

32MFM630.indb 11 2010/12/14 15:43:50

Downloaded from www.Manualslib.com manuals search engine


Parts Location
Rear suspension spring preload adjuster P.70
Operation Guide

Coolant reserve tank P.53

Front brake fluid reservoir P.55

Front brake lever P.68


Front suspension spring
preload adjuster P.69

Throttle grip P.66


Engine oil fill cap P.49

Engine oil filter P.51

Engine oil level inspection


window P.49

Right side cover P.46

Rear brake fluid reservoir P.72


12

32MFM630.indb 12 2010/12/14 15:43:51

Downloaded from www.Manualslib.com manuals search engine


Front suspension spring preload adjuster P.69

Clutch lever P.63

Operation Guide
Fuel fill cap P.24
Battery P.47
Seat P.45
Fuse box P.91
(CB400A)

Left side cover P.46


Rear suspension spring
preload adjuster P.70

Fuse box P.90


Main fuse P.92
FI fuse P.73
Drive chain P.59
Shift lever P.23
Side stand P.58
Engine oil
drain bolt P.51 Crankcase breather P.67
13

32MFM630.indb 13 2010/12/14 15:43:52

Downloaded from www.Manualslib.com manuals search engine


Instruments
Speedometer
Operation Guide

Tachometer
NOTICE
Do not operate the engine in
the tachometer red zone.
Excessive engine speed can
adversely affect engine life.

Tachometer red zone


(excessive engine rpm range)

A button B button

14

32MFM630.indb 14 2010/12/14 15:43:52

Downloaded from www.Manualslib.com manuals search engine


Odometer [ODO] & Tripmeter
[TRIP 1/2]
A button switches between odometer &

Operation Guide
tripmeters.
•• Odometer: Total distance ridden.
•• Tripmeter: Distance ridden since tripmeter
was reset (press and hold A button to
reset to 0.0 km).

Display Check
When the ignition switch is turned ON, all the mode and digital segments will show. If any
part of these displays does not come on when it should, have your dealer check for problems.

continued 15

32MFM630.indb 15 2010/12/14 15:43:53

Downloaded from www.Manualslib.com manuals search engine


Instruments (Continued)

Clock (12-hour display)


Operation Guide

Fuel gauge
Remaining fuel when the display
lights as shown in the illustration:
approximately 4.0 litres (1.06 US
gal, 0.88 Imp gal)

A button B button

16

32MFM630.indb 16 2010/12/14 15:43:54

Downloaded from www.Manualslib.com manuals search engine


To set the clock: 5 Turn the ignition switch OFF.
1 Turn the ignition switch ON. a The adjustment will be cancelled if no
operation is performed for 30 seconds
2 Press and hold A and B buttons until

Operation Guide
during the time adjustment mode.
the hour digits start flashing.

3 Press A button until the desired hour and


AM/PM are displayed.
a Press and hold to advance the hour
fast.
4 Press B button until the desired minute
is displayed.
a Press and hold to advance the minute
fast.

17

32MFM630.indb 17 2010/12/14 15:43:55

Downloaded from www.Manualslib.com manuals search engine


Indicators
PGM-FI (Programmed Fuel Injection) Low oil pressure indicator
malfunction indicator lamp (MIL) Comes on when the ignition switch
Comes on briefly when the ignition switch is turned is turned ON. Goes off when the
Operation Guide

ON with the engine stop switch in the RUN engine starts.


position. If it comes ON while engine is
If it comes ON while engine is running: P.75 running: P.75

High coolant temperature


indicator
If it comes ON while engine is
running: P.74

ABS (Anti-lock Brake System)


indicator (CB400A only)
Comes on when the ignition switch is turned ON. Goes off when your speed reaches
approximately 10 km/h (6 mph).
If it comes ON while riding: P.76
18

32MFM630.indb 18 2010/12/14 15:43:57

Downloaded from www.Manualslib.com manuals search engine


Neutral indicator HISS indicator P.73
Comes ON when the •• Comes on briefly when the
transmission is in ignition switch is turned ON with

Operation Guide
Neutral. the engine stop switch in the
RUN position. Goes off if the
ignition key has the correct
coding.
•• Flashes every 2 seconds for 24
hours when the ignition switch is
turned OFF.

High beam indicator

Right turn signal indicator

Left turn signal indicator


19

32MFM630.indb 19 2010/12/14 15:43:59

Downloaded from www.Manualslib.com manuals search engine


Switches
Operation Guide

Engine stop switch


Should normally remain in the
RUN position.
a In an emergency, switch to
the OFF position to stop
the engine.

Horn button Hazard switch


Switchable when the ignition
Turn signal switch
switch is ON.
Headlight dimmer switch
•• : High beam
•• : Low beam
Start button
Passing light control switch Headlight turns off when
Flashes the high beam headlight. operating the starter motor.
20

32MFM630.indb 20 2010/12/14 15:44:02

Downloaded from www.Manualslib.com manuals search engine


Ignition Switch ON
Switches the electrical system on/off, locks Turns electrical system
the steering. on for starting/riding.

Operation Guide
a Key can be removed when in the OFF or OFF
LOCK position. Turns engine off.
LOCK
Steering Lock Locks steering.
Lock the steering when parking to help
prevent theft.
A U-shaped wheel lock or similar device is ❙ Locking
also recommended. 1 Turn the handlebars all the way to the left.
Ignition key 2 Push the key down, and turn the ignition
switch to the LOCK position.
Push a Jiggle the handlebars if the lock is
difficult to engage.
2
3 Remove the key.
Turn

❙ Unlocking
Insert the key, push it in, and turn the ignition
switch to the OFF position.
1

21

32MFM630.indb 21 2010/12/14 15:44:02

Downloaded from www.Manualslib.com manuals search engine


Starting the Engine
Start your engine using the following 1 Make sure the engine stop switch is in the
procedure, regardless of whether the RUN position.
engine is cold or warm. 2 Turn the ignition switch to the ON position.
Operation Guide

3 3 Shift the transmission to Neutral ( N


indicator comes ON). Alternatively, pull in
2 the clutch lever to start your motorcycle
with the transmission in gear so long as
1 the side stand is raised.
4 Press the start button with the throttle
completely closed.
4
If the engine does not start:
1 Open the throttle fully and press the start
NOTICE button for 5 seconds.
•• If the engine does not start within 5 seconds, turn
the ignition OFF and wait 10 seconds before trying to 2 Repeat the normal starting procedure.
start the engine again to recover battery voltage. 3 If the engine starts, open the throttle
•• Extended fast idling and revving the engine can slightly if idling is unstable.
damage the engine, and the exhaust system.
•• Snapping the throttle or fast idling for more than 4 If the engine does not start, wait 10
about 5 minutes may cause exhaust pipe seconds before trying steps & again.
discoloration. ❙ If Engine Will Not Start P.73
22

32MFM630.indb 22 2010/12/14 15:44:03

Downloaded from www.Manualslib.com manuals search engine


Shifting Gears
Your motorcycle transmission has six
forward gears in a one-down, five-up shift
pattern.

Operation Guide
If you put the motorcycle in gear with the
side stand down, the engine will shut off.

23

32MFM630.indb 23 2010/12/14 15:44:04

Downloaded from www.Manualslib.com manuals search engine


Refuelling
Opening the Fuel Fill Cap
Fuel fill cap Filler neck plate Open the lock cover, insert the ignition key,
Fuel level (max)
and turn it clockwise to open the cap.
Operation Guide

Fuel filler
opening
Closing the Fuel Fill Cap
1 After refuelling, push the fuel fill cap
Ignition key closed until it locks.
Lock cover 2 Remove the key and close the cover.
a The key cannot be removed if the cap is
Do not fill with fuel above the plate. not locked.
Fuel type: Unleaded petrol only
Fuel octane number: Your motorcycle is WARNING
designed to use Research Octane Number Petrol is highly flammable and
(RON) 91 or higher. explosive. You can be burned or
Tank capacity: 18.0 litres (4.76 US gal, seriously injured when handling fuel.
3.96 lmp gal)
•• Stop the engine, and keep heat,
❙ Refuelling and Fuel Guidelines sparks, and flame away.
P.9 •• Handle fuel only outdoors.
•• Wipe up spills immediately.

24

32MFM630.indb 24 2010/12/14 15:44:04

Downloaded from www.Manualslib.com manuals search engine


Storage Compartment
Helmet Holder ❙ Using the Helmet Holder
The helmet holder is located on the left 1 Insert the ignition key and turn it clockwise
side below the seat. to unlock.

Operation Guide
Holder 2 Hang your helmet on the holder hook.
Ignition key hook 3 Turn the key counterclockwise to lock the
holder hook and then remove the key.

WARNING
Riding with a helmet attached to
Turn the holder can interfere with the
rear wheel or suspension and could
cause a crash in which you can be
seriously hurt or killed.
Helmet
holder Use the helmet holder only while
a Use the helmet holder only when parked. parked. Do not ride with a helmet
a There is also another helmet holder located secured by the holder.
on under the seat. P.26

25

32MFM630.indb 25 2010/12/14 15:44:05

Downloaded from www.Manualslib.com manuals search engine


Storage Compartment (Continued)
Rear Compartment
The helmet holder, tool kit and document bag are located under the seat. There is also space
to store a U-shaped lock.
Operation Guide

Document bag

Rubber band
Helmet
holder
U-shaped lock

Tool kit WARNING


Riding with a helmet attached to
the holder can interfere with the
a The U-shaped lock is held in place above rear wheel or suspension and could
the rear fender by the rubber band. cause a crash in which you can be
a Use the helmet holder only when parked. seriously hurt or killed.
a Some U-shaped locks may not fit in the
compartment due to their size or design.
Use the helmet holder only while
parked. Do not ride with a helmet
❙ Removing the Seat P.45
secured by the holder.
26

32MFM630.indb 26 2010/12/14 15:44:06

Downloaded from www.Manualslib.com manuals search engine


Centre Compartment
The centre compartment is located under the seat.
Maximum Weight Limit: 3.0 kg (6.6 Ib)

Operation Guide
(CB400) (CB400A)
Centre compartment Centre compartment

a The centre compartment may become heated by the engine. Do not store any items that are
flammable or susceptible to heat damage.

❙ Removing the Seat P.45

27

32MFM630.indb 27 2010/12/14 15:44:06

Downloaded from www.Manualslib.com manuals search engine


Luggage Tie-down Hooks
This motorcycle is equipped with the
retractable luggage tie-down hooks below
Operation Guide

the seat of both sides.


Luggage tie-down hook

a Never use the tie-down hooks to tow or


lift the motorcycle.

28

32MFM630.indb 28 2010/12/14 15:44:07

Downloaded from www.Manualslib.com manuals search engine


Maintenance

Please read “Importance of Maintenance” and “Maintenance Fundamentals”


carefully before attempting any maintenance. Refer to “Specifications” for service
data.

Importance of Maintenance................................ P.30 Side Stand.......................................................................... P.58


Maintenance Schedule. ............................................P.31 Drive Chain.........................................................................P.59
Maintenance Fundamentals................................ P.34 Clutch..................................................................................... P.63
Tool kit.................................................................................. P.44 Throttle................................................................................ P.66
Removing & Installing Body Crankcase Breather ................................................... P.67
Components.................................................................... P.45 Other Adjustments..................................................... P.68
Seat. .................................................................................... P.45 Brake Lever...................................................................... P.68
Side Covers. .................................................................... P.46 Front Suspension......................................................... P.69
Battery................................................................................P.47 Rear Suspension............................................................ P.70
Engine Oil........................................................................... P.49 Headlight Aim................................................................ P.71
Coolant..................................................................................P.53 Brakelight Switch.......................................................... P.71
Brakes.....................................................................................P.55

32MFM630.indb 29 2010/12/14 15:44:07

Downloaded from www.Manualslib.com manuals search engine


Importance of Maintenance

Importance of Maintenance Maintenance Safety


Keeping your motorcycle well-maintained is Always read the maintenance instructions
absolutely essential to your safety and to before you begin each task, and make sure
protect your investment, obtain maximum that you have the tools, parts, and skills
Maintenance

performance, avoid breakdowns, and reduce required. We cannot warn you of every
air pollution. Maintenance is the owner’s conceivable hazard that can arise in
responsibility. Be sure to inspect your performing maintenance. Only you can decide
motorcycle before each ride, and perform the whether or not you should perform a given
periodic checks specified in the Maintenance task.
Schedule. P.31
Follow these guidelines when performing
WARNING maintenance.
Improperly maintaining your ●● Stop the engine and remove the key.
motorcycle or failing to correct a ●● Park your motorcycle on a firm, level surface
problem before you ride can cause a using the side stand or a maintenance stand
crash in which you can be seriously to provide support.
●● Allow the engine, muffler, brakes, and other
hurt or killed.
high-temperature parts to cool before
servicing as you can get burned.
Always follow the inspection and ●● Run the engine only when instructed, and
maintenance recommendations and do so in a well-ventilated area.
schedules in this owner’s manual.
30

32MFM630.indb 30 2010/12/14 15:44:08

Downloaded from www.Manualslib.com manuals search engine


Maintenance Schedule
The maintenance schedule specifies the All scheduled maintenance is considered a
maintenance requirements necessary to normal owner operating cost and will be
ensure safe, dependable performance, and charged for by your dealer. Retain all
proper emission control. receipts. If you sell the motorcycle, these
receipts should be transferred with the

Maintenance
Maintenance work should be performed in motorcycle to the new owner.
accordance with Honda’s standards and
specifications by properly trained and Honda recommends that your dealer should
equipped technicians. Your dealer meets all road test your motorcycle after each
of these requirements. Keep an accurate periodic maintenance is carried out.
record of maintenance to help ensure that
your motorcycle is properly maintained.
Make sure that whomever performs the
maintenance completes this record.

31

32MFM630.indb 31 2010/12/14 15:44:08

Downloaded from www.Manualslib.com manuals search engine


Maintenance Schedule

Odometer Reading *1
Frequency
× 1,000 km 1 6 12 18 24 30 36
Refer to
Items × 1,000 mi 0.6 4 8 12 16 20 24
page
Month 6 12 18 24 30 36
Fuel Line I I I –
Maintenance

Throttle Operation I I I 66
Air Cleaner *2 R R –
Crankcase Breather *3 C C C C C C 67
Spark Plug I R I –
Valve Clearance I –
Engine Oil R R R R 49
Engine Oil Filter R R R R 51
Radiator Coolant *4 I I R 53
Cooling System I I I –
Secondary Air Supply System I I I –
Maintenance Level Maintenance Legend
: Intermediate. We recommend service by your dealer, unless I : Inspect (clean, adjust, lubricate, or replace, if necessary)
you have the necessary tools and are mechanically skilled. C : Clean
Procedures are provided in an official Honda Shop Manual. L : Lubricate
R : Replace
: Technical. In the interest of safety, have your motorcycle
serviced by your dealer.

32

32MFM630.indb 32 2010/12/14 15:44:10

Downloaded from www.Manualslib.com manuals search engine


Maintenance Schedule

Odometer Reading *1
Frequency
× 1,000 km 1 6 12 18 24 30 36
Refer to
Items × 1,000 mi 0.6 4 8 12 16 20 24
page
Month 6 12 18 24 30 36
Drive Chain Every 1,000 km (600 mi): I L 59

Maintenance
Drive Chain Slider I I I 62
Brake Fluid *4 I I R I I R 55
Brake Pads Wear I I I I I I 56
Brake System I I I I 34
Brake Light Switch I I I 71
Headlight Aim I I I 71
Clutch System I I I I I I I 63
Side Stand I I I 58
Suspension I I I 69, 70
Nuts, Bolts, Fasteners I I I I –
Wheels/Tyres I I I 41
Steering Head Bearings I I I I –
Notes:
*1 : At higher odometer readings, repeat at the frequency interval established here.
*2 : Service more frequently when riding in unusually wet or dusty areas.
*3 : Service more frequently when riding in rain or at full throttle.
*4 : Replace every 2 years, or at indicated odometer intervals, whichever comes first. Replacement requires mechanical skill.

33

32MFM630.indb 33 2010/12/14 15:44:10

Downloaded from www.Manualslib.com manuals search engine


Maintenance Fundamentals
●● Combined weight is within load limits.
Pre-ride Inspection P.106
To ensure safety, it is your responsibility to ●● Cargo is secured properly.
perform a pre-ride inspection and make sure ●● Suspension spring preload is adjusted to suit
that any problem you find is corrected. A load. P.69, 70
Maintenance

pre-ride inspection is a must, not only for


safety, but because having a breakdown, or Check the following items after you get on
even a flat tyre, can be a major inconvenience. your motorcycle:
Check the following items before you get on ●● Throttle action moves smoothly without
your motorcycle: binding. P.66
●● Tyre tread wear and air pressures are within ●● Brake lever and pedal operate normally
limits. P.41 ●● Refuel when needed. P.9, 24
●● Lights, horn, and turn signals operate ●● Engine stop switch functions properly. P.20
normally.
●● Check the condition of the drive chain. Check the following items at regular intervals:
Adjust slack and lubricate as needed. ●● Oillevel is between the upper and lower
P.40, 59 marks. P.49
●● Brake fluid level is
Check the following items if you are carrying a Front: above the LOWER level mark.
passenger or cargo: Rear: between the UPPER and LOWER level
marks. P.55

34

32MFM630.indb 34 2010/12/14 15:44:11

Downloaded from www.Manualslib.com manuals search engine


Maintenance Fundamentals

●● Engine coolant level is between the UPPER


and LOWER level marks. P.53 Colour label
●● Side stand functions properly. P.23, 58

Replacing Parts

Maintenance
Always use Honda Genuine Parts or their
equivalents to ensure reliability and safety.
When ordering coloured components, specify
the model name, colour, and code mentioned
on the colour label. The colour label is
attached to the frame under the seat. P.45
WARNING
Installing non-Honda parts may
make your motorcycle unsafe and
cause a crash in which you can be
seriously hurt or killed.

Always use Honda Genuine Parts or


equivalents that have been designed
and approved for your motorcycle.

35

32MFM630.indb 35 2010/12/14 15:44:11

Downloaded from www.Manualslib.com manuals search engine


Maintenance Fundamentals

Battery WARNING
Your motorcycle has a maintenance-free type
battery. You do not have to check the battery The battery gives off explosive
electrolyte level or add distilled water. Clean hydrogen gas during normal
operation.
Maintenance

the battery terminals if they become dirty or


corroded.
Do not remove the battery cap seals. There is A spark or flame can cause the
no need to remove the cap when charging. battery to explode with enough
force to kill or seriously hurt you.
NOTICE
Your battery is a maintenance-free type and can be
permanently damaged if the cap strip is removed. Wear protective clothing and a face
shield, or have a skilled mechanic do
This symbol on the battery means
the battery servicing.
that this product must not be treated
as household waste.

NOTICE
❙ Cleaning the Battery Terminals
An improperly disposed of battery can be harmful to the
1. Remove the battery. P.47
environment and human health. 2. If the terminals are starting to corrode and
Always confirm local regulations for battery disposal. are coated with a white substance, wash
with warm water and wipe clean.

36

32MFM630.indb 36 2010/12/14 15:44:12

Downloaded from www.Manualslib.com manuals search engine


Maintenance Fundamentals

3. If the terminals are heavily corroded, clean


and polish the terminals with a wire brush Fuses
or sandpaper. Wear safety glasses. Fuses protect the electrical circuits on your
motorcycle. If something electrical on your
motorcycle stops working, check for and

Maintenance
replace any blown fuses. P.90

❙ Inspecting and Replacing Fuses


Turn off the ignition switch to remove and
inspect fuses. If a fuse is blown, replace with a
fuse of the same rating. For fuse ratings, see
4. After cleaning, reinstall the battery. “Specifications.” P.108
Blown fuse
The battery has a limited life span. Consult
your dealer about when you should replace
the battery. Always replace the battery with
another maintenance-free battery of the same
type.

NOTICE
NOTICE
Installing non-Honda electrical accessories can overload
Replacing a fuse with one that has a higher rating greatly
the electrical system, discharging the battery and possibly
increases the chance of damage to the electrical system.
damaging the system.

37

32MFM630.indb 37 2010/12/14 15:44:12

Downloaded from www.Manualslib.com manuals search engine


Maintenance Fundamentals

If a fuse fails repeatedly, you likely have an . The JASO T 903 standard is an index for engine
*1

electrical fault. Have your motorcycle inspected oils for 4-stroke motorcycle engines. There are
by your dealer. two classes: MA and MB. For example, the
following label shows the MA classification.
Engine Oil
Maintenance

Engine oil consumption varies and oil quality


deteriorates according to riding conditions and Oil code
time elapsed.
Check the engine oil level regularly, and add Oil classification
the recommended engine oil if necessary. Dirty
oil or old oil should be changed as soon as
possible. *2 . The SAE standard grades oils by their viscosity.
*3 . The API classification specifies the quality and
❙ Selecting the Engine Oil performance rating of engine oils. Use SG or
For recommended engine oil, see higher oils, excluding oils marked as “Energy
“Specifications.” P.107 Conserving” on the circular API service symbol.

If you use non-Honda engine oil, check the


label to make sure that the oil satisfies all of
the following standards:
●● JASO T 903 standard*1: MA
●● SAE standard*2: 10W-30
●● API classification*3: SG or higher Not recommended Recommended
38

32MFM630.indb 38 2010/12/14 15:44:13

Downloaded from www.Manualslib.com manuals search engine


Maintenance Fundamentals

If the chain does not move smoothly, makes


Brake Fluid strange noises, has damaged rollers or loose
Do not add or replace brake fluid, except in an pins or missing O-rings, or kinks, have the
emergency. Use only fresh brake fluid from a chain inspected by your dealer.
sealed container. If you do add fluid, have the

Maintenance
brake system serviced by your dealer as soon Also inspect the engine sprocket and rear
as possible. wheel sprocket. If either has worn or damaged
teeth, have the sprocket replaced by your
NOTICE dealer.
Brake fluid can damage plastic and painted surfaces.
Wipe up spills immediately and wash thoroughly.

Recommended brake fluid:


Honda DOT 4 Brake Fluid or equivalent

Drive Chain Normal Worn Damaged


(GOOD) (REPLACE) (REPLACE)
The drive chain must be inspected and
lubricated regularly. Inspect the chain more
frequently if you often ride on bad roads, ride NOTICE
at high speed, or ride with repeated fast Use of a new chain with worn sprockets will cause rapid
acceleration. chain wear.

39

32MFM630.indb 39 2010/12/14 15:44:14

Downloaded from www.Manualslib.com manuals search engine


Maintenance Fundamentals

❙ Cleaning and Lubricating Do not use a steam cleaner, a high pressure


After inspecting the slack, clean the chain and cleaner, a wire brush, volatile solvent such as
sprockets while rotating the rear wheel. Use gasoline and benzene, abrasive cleaner, chain
dry cloth with chain cleaner designed cleaner or lubricant NOT designed specifically
specifically for O-ring chains, or neutral for O-ring chains as these can damage the
Maintenance

detergent. Use a soft brush if the chain is dirty. rubber O-ring seals.
After cleaning, wipe dry and lubricate with Avoid getting lubricant on the brakes or tyres.
the recommended lubricant. If not available, Avoid applying excess chain lubricant to
use SAE 80 or 90 gear oil. prevent spray onto your clothes and the
Recommended lubricant: motorcycle.
Drive chain lubricant designed
specifically for O-ring chains Recommended Coolant
Pro Honda HP is a pre-mixed solution of
antifreeze and distilled water.
Concentration:
50 % antifreeze and 50 % distilled
water

40

32MFM630.indb 40 2010/12/14 15:44:14

Downloaded from www.Manualslib.com manuals search engine


Maintenance Fundamentals

A concentration of antifreeze below 40 % will ❙ Inspecting for Damage


not provide proper corrosion and cold Inspect the tyres for
temperature protection. A concentration of up cuts, slits, or cracks
to 60 % will provide better protection in that exposes fabric or
colder climates. cords, or nails or
other foreign objects

Maintenance
NOTICE embedded in the side
Using coolant not specified for aluminium engines or
of the tyre or the
using ordinary tap water can cause corrosion.
tread. Also inspect for
the bumps or bulges in the side walls of the
Crankcase Breather tyres.
Service more frequently when riding in rain, at
full throttle, or after the motorcycle is washed ❙ Inspecting for Abnormal Wear
or overturned. Service if the deposit level can Inspect the tyres for
be seen in the transparent section of the drain signs of abnormal
tube. wear on the contact
surface.
Tyres (Inspecting/Replacing)
❙ Checking the Air Pressure
Visually inspect your tyres and use an air
pressure gauge to measure the air pressure at
least once a month or any time you think the
tyres look low. Always check air pressure when
your tyres are cold.
41

32MFM630.indb 41 2010/12/14 15:44:15

Downloaded from www.Manualslib.com manuals search engine


Maintenance Fundamentals

❙ Inspecting Tread Depth


Inspect the tread wear indicators. If they WARNING
become visible, replace the tyres immediately.
For safe riding, you should replace the tyres Riding on tyres that are excessively
when the minimum tread depth is reached. worn or improperly inflated can
cause a crash in which you can be
Maintenance

seriously hurt or killed.

Follow all instructions in this owner’s


manual regarding tyre inflation and
maintenance.
Wear indicator
location mark

42

32MFM630.indb 42 2010/12/14 15:44:15

Downloaded from www.Manualslib.com manuals search engine


Maintenance Fundamentals

Have your tyres replaced by your dealer.


For recommended tyres, air pressure and WARNING
minimum tread depth, see “Specifications.”
P.107 Installing improper tyres on your
Follow these guidelines whenever you replace motorcycle can adversely affect
handling and stability, and can cause

Maintenance
tyres.
●● Use the recommended tyres or equivalents a crash in which you can be seriously
of the same size, construction, speed rating, hurt or killed.
and load range.
●● Have the wheel balanced with Honda Always use the size and type of tyres
Genuine balance weights or equivalents recommended in this owner’s
after the tyre is installed. manual.
●● Do not install a tube inside a tubeless tyre
on this motorcycle. Excessive heat build-up
can cause the tube to burst.
●● Use only tubeless tyres on this motorcycle.
The rims are designed for tubeless tyres, and
during hard acceleration or braking, a
tube-type tyre could slip on the rim and
cause the tyre to rapidly deflate.

43

32MFM630.indb 43 2010/12/14 15:44:16

Downloaded from www.Manualslib.com manuals search engine


Tool kit
The tool kit is stored under the seat. P.45

You can perform some roadside repairs,


minor adjustments and parts replacement
with the tools contained in the kit.
Maintenance

●● Pin spanner
●● 8 mm Open end wrench
●● 10 x 12 mm Open end wrench
●● 14 x 17 mm Open end wrench
●● Pliers
●● Standard/Phillips screwdriver
●● Screwdriver handle
●● Extension bar
●● 5 mm Hex wrench
●● 17 mm Box end wrench
●● 24 mm Box end wrench
●● Spark plug wrench

44

32MFM630.indb 44 2010/12/14 15:44:16

Downloaded from www.Manualslib.com manuals search engine


Removing & Installing Body Components

Seat ❙ Removal
1. Insert the ignition key into the seat lock
Front prong
and turn it clockwise.
Rear prongs
2. Pull the seat lock lever downward to

Maintenance
Seat unlock the seat.
3. Pull the seat back and up.

Seat lock ❙ Installation


Pull 1. Insert the front prong into the front stay
and the rear prongs into the rear stays on
the frame.
2. Push forward and then down on the rear
Ignition Lock of the seat.
key lever a Make sure that the seat is locked
securely in position to pull it up lightly.
Front stay Rear stay
a The seat locks automatically when
closed. Take care not to lock your key
under the seat.

45

32MFM630.indb 45 2010/12/14 15:44:16

Downloaded from www.Manualslib.com manuals search engine


Removing & Installing Body Components a Side Covers

Side Covers Right Grommets

The right side cover must be removed to


Bolt
access the coolant reserve tank.
The left side cover must be removed for fuse
Maintenance

maintenance.

The right and left side covers can be


removed in the same manner.
Prongs
❙ Removal
Left
1. Remove the seat. P.45
2. Remove the bolt.
3. Remove the prongs from the grommets.

❙ Installation
1. Insert the prongs into the grommets.
2. Install the bolt.
3. Install the seat properly.
Grommets Prongs Bolt

46

32MFM630.indb 46 2010/12/14 15:44:17

Downloaded from www.Manualslib.com manuals search engine


Removing & Installing Body Components a Battery

Battery ❙ Removal
(CB400) Make sure the ignition switch is OFF.
1. Remove the seat. P.45
Bolt 2. Open the battery cover by removing the

Maintenance
bolt.
Battery
cover

(CB400A)

Bolt

Battery
cover

47

32MFM630.indb 47 2010/12/14 15:44:18

Downloaded from www.Manualslib.com manuals search engine


Removing & Installing Body Components a Battery

(CB400) 3. Disconnect the negative terminal from


the battery.
Negative 4. Disconnect the positive terminal from
terminal the battery.
5. Remove the battery taking care not to
Maintenance

drop the terminal nuts.

❙ Installation
Positive Install the parts in the reverse order of
terminal
Battery removal. Always connect the positive
terminal first. Make sure that bolts and nuts
(CB400A)
are tight.
Negative
terminal The clock will be reset AM 1:00 if the
Battery battery is disconnected.
To set the clock, see “Operation Guide.”
P.17
Positive
terminal
For proper handling of the battery, see
“Maintenance Fundamentals.“ P.36
Battery Goes Dead P.86
48

32MFM630.indb 48 2010/12/14 15:44:19

Downloaded from www.Manualslib.com manuals search engine


Engine Oil

Checking the Engine Oil


1. If the engine is cold, idle the engine for 3
to 5 minutes.
2. Turn the ignition switch OFF, stop the

Maintenance
engine and wait 2 to 3 minutes. Oil level inspection
3. Place your motorcycle in an upright window
Upper level
position on a firm, level surface.
4. Check that the oil level is between the
upper and lower level marks in the oil Oil fill cap Lower level
inspection window.

49

32MFM630.indb 49 2010/12/14 15:44:19

Downloaded from www.Manualslib.com manuals search engine


Engine Oil a Adding Engine Oil

Adding Engine Oil NOTICE


Overfilling with oil or operating with insufficient oil can
If the engine oil is below or near the lower
cause damage to your engine. Do not mix different
level mark, add the recommended engine brands and grades of oil. They may affect lubrication and
oil. P.38 clutch operation.
Maintenance

1. Remove the oil fill cap. Add the


recommended oil until it reaches the For the recommended oil and oil selection
upper level mark. guidelines, see “Maintenance
a Place your motorcycle in an upright Fundamentals.” P.38
position on a firm, level surface when
checking the oil level.
a Do not overfill above the upper level
mark.
a Make sure no foreign objects enter the
oil filler opening.
a Wipe up any spills immediately.
2. Securely reinstall the oil fill cap.

50

32MFM630.indb 50 2010/12/14 15:44:20

Downloaded from www.Manualslib.com manuals search engine


Engine Oil a Changing Engine Oil & Filter

Changing Engine Oil & Filter 5. Remove the oil fill cap, drain bolt, and
sealing washer to drain the oil.
Changing the oil and filter requires special 6. Remove the oil filter with a filter wrench
tools. We recommend that you have your and let the remaining oil drain out. Make
motorcycle serviced by your dealer. sure the prior seal is not stuck to the

Maintenance
engine.
Use a new Honda Genuine oil filter or a Discard the oil and oil filter at an
equivalent specified for your model. approved recycling centre.

NOTICE
Using the wrong oil filter can result in serious damage to Rubber seal
the engine.

1. If the engine is cold, idle the engine for 3


to 5 minutes.
2. Turn the ignition switch OFF, stop the
engine and wait for 2 to 3 minutes.
3. Park on a firm, level surface and lower
the side stand. Oil filter Drain bolt Sealing washer
4. Place a drain pan under the drain bolt.

continued 51

32MFM630.indb 51 2010/12/14 15:44:20

Downloaded from www.Manualslib.com manuals search engine


Engine Oil a Changing Engine Oil & Filter

7. Apply a thin coat of engine oil to the 11. Check the oil level. P.49
rubber seal of a new oil filter. 12. Check that there are no oil leaks.
8. Install a new oil filter and tighten.
NOTICE
Torque: 26 N·m (2.7 kgf·m, 19 lbf·ft). Improper installation of the oil filter can result in serious

damage to the engine.
Maintenance

9. Replace the sealing washer. Install the


drain bolt and tighten.
Torque: 30 N·m (3.1 kgf·m, 22 lbf·ft).

10. Fill the crankcase with the recommended
oil ( P.38) and install the oil fill cap.
Required oil
When changing oil &
engine oil filter:
3.2 litres (3.4 US qt, 2.8 Imp qt)
When changing oil only:
3.0 litres (3.2 US qt, 2.6 Imp qt)

52

32MFM630.indb 52 2010/12/14 15:44:20

Downloaded from www.Manualslib.com manuals search engine


Coolant

Checking the Coolant If the coolant level is dropping noticeably or


the reserve tank is empty, you likely have a
The reserve tank is behind the right side serious leak. Have your motorcycle inspected
cover. by your dealer.
1. Place your motorcycle on a firm, level

Maintenance
surface.
2. Hold your motorcycle in an upright
position.
3. Check that the coolant level is between
the UPPER and LOWER level marks in the
reserve tank.
Reserve tank cap UPPER level

Reserve tank LOWER level

53

32MFM630.indb 53 2010/12/14 15:44:21

Downloaded from www.Manualslib.com manuals search engine


Coolant a Adding Coolant

Adding Coolant
WARNING
1. If the coolant level is below the LOWER
Removing the radiator cap while the
level, add the recommended coolant
engine is hot can cause the coolant
( P.40) until the level reaches the UPPER
to spray out, potentially scalding
Maintenance

level mark.
you.
Add fluid only from the reserve tank cap
and do not remove the radiator cap.
Always let the engine and radiator
2. Remove the right side cover. P.46
cool down before removing the
3. Remove the reserve tank cap and add
radiator cap.
fluid while monitoring the coolant level.
a Do not overfill above the UPPER level
mark. Changing Coolant
a Make sure no foreign objects enter the
reserve tank opening. Have your dealer change the coolant unless
4. Securely reinstall the cap. you have the proper tools and are
5. Install the right side cover. mechanically qualified.

54

32MFM630.indb 54 2010/12/14 15:44:21

Downloaded from www.Manualslib.com manuals search engine


Brakes

Checking Brake Fluid Front


Front brake fluid
reservoir
1. Place your motorcycle in an upright
LOWER level
position on a firm, level surface. mark
2. Check that the brake fluid reservoir is

Maintenance
horizontal and that the fluid level is:
Front above the LOWER level mark.
Rear between the LOWER level and
UPPER level marks.

If the brake fluid level in either reservoir is


below the lower level mark or the brake Rear Rear brake fluid
lever and pedal freeplay becomes excessive, reservoir
inspect the brake pads for wear. If the brake
pads are not worn, you most likely have a
UPPER level mark
leak. Have your motorcycle inspected by
your dealer.

LOWER level mark

55

32MFM630.indb 55 2010/12/14 15:44:22

Downloaded from www.Manualslib.com manuals search engine


Brakes a Inspecting the Brake Pads

1. Front Inspect the brake pads from in


Inspecting the Brake Pads front of the brake caliper.
Check the condition of the brake pad a Always inspect both left and right
groove wear indicators. calipers.
(CB400) 2. Rear Inspect the brake pads from the
Maintenance

Front The pads need to be replaced if a rear right of the motorcycle.


brake pad is worn to the bottom of the If necessary have the pads replaced by your
groove. dealer.
Rear The pads need to be replaced if a Always replace both left and right brake
brake pad is worn to the groove. pads at the same time.
Front Rear
Disc
Brake pads

Wear Wear
indicator indicator
Wear Wear Brake pads
indicator indicator Disc
Brake pads

56

32MFM630.indb 56 2010/12/14 15:44:22

Downloaded from www.Manualslib.com manuals search engine


Brakes a Inspecting the Brake Pads

(CB400A) 1. Front Inspect the brake pads from below


The pads need to be replaced if a brake pad the brake caliper.
is worn to the groove. a Always inspect both left and right
calipers.
2. Rear Inspect the brake pads from the

Maintenance
rear right of the motorcycle.
If necessary have the pads replaced by your
dealer.
Always replace both left and right brake
pads at the same time.
Front Rear

Brake pads

Wear Wear
Wear Wear indicator indicator
indicator indicator
Brake pads
Disc
Disc

57

32MFM630.indb 57 2010/12/14 15:44:23

Downloaded from www.Manualslib.com manuals search engine


Side Stand
4. Start the engine, pull the clutch lever in,
and shift the transmission into gear.
5. Lower the side stand all the way. The
engine should stop as you lower the side
stand. If the engine doesn’t stop, have
Maintenance

your motorcycle inspected by your dealer.

Side stand
spring

1. Check that the side stand operates


smoothly. If the side stand is stiff or
squeaky, clean the pivot area and
lubricate the pivot bolt with clean grease.
2. Check the spring for damage or loss of
tension.
3. Sit on the motorcycle, put the
transmission in Neutral, and raise the side
stand.

58

32MFM630.indb 58 2010/12/14 15:44:23

Downloaded from www.Manualslib.com manuals search engine


Drive Chain

Inspecting the Drive Chain 3. Check the slack in the lower half of the
drive chain midway between the
Slack sprockets.
Check the drive chain slack at several points Drive chain slack:
along the chain. If the slack is not constant 25 to 35 mm (1.0 to 1.4 in)

Maintenance
at all points, some links may be kinked and
binding. a Do not ride your motorcycle if the
Have the chain inspected by your dealer. slack exceeds 50 mm (2.0 in).

1. Place your motorcycle on the side stand


on a level surface.
2. Stop the engine place the gear in Neutral.

4. Roll the motorcycle forward and check


that the chain moves smoothly.
continued 59

32MFM630.indb 59 2010/12/14 15:44:24

Downloaded from www.Manualslib.com manuals search engine


Drive Chain a Adjusting the Drive Chain Slack

5. Inspect the sprockets. P.39


6. Clean and lubricate the drive chain. Index mark
P.40

Adjusting the Drive Chain Slack


Maintenance

Adjusting the chain requires special tools. Scales


Have the drive chain slack adjusted by your Adjusting bolt
dealer.
(CB400A only) Rear axle nut
When adjusting the drive chain slack, be
careful not to damage the wheel speed 4. Turn both adjusting bolts an equal
sensor and pulser ring. number of turns until the correct drive
chain slack is obtained. Turn the adjusting
1. Place your motorcycle on the side stand bolts counterclockwise to tighten the
on a level surface. chain. Turn the adjusting bolts clockwise
2. Stop the engine. Place the transmission in to provide more slack.
Neutral. Adjust the slack at a point midway
3. Loosen the rear axle nut. between the front sprocket and the rear
wheel sprocket.
Check the drive chain slack. P.59
60

32MFM630.indb 60 2010/12/14 15:44:24

Downloaded from www.Manualslib.com manuals search engine


Drive Chain a Adjusting the Drive Chain Slack

5. Check rear axle alignment by making 6. Tighten the rear axle nut.
sure the scales on the drive chain Torque: 88 N·m (9.0 kgf·m, 65 lbf·ft).
adjusters align with the index marks on
both sides of the swingarm. 7. Tighten the adjusting bolts lightly.
Both scales should correspond. If the axle 8. Recheck drive chain slack.

Maintenance
is misaligned, turn the right or left
adjusting bolt until the scales are aligned If a torque wrench was not used for
and recheck chain slack. installation, see your dealer as soon as
possible to verify proper assembly.
Improper assembly may lead to loss of
braking capacity.

61

32MFM630.indb 61 2010/12/14 15:44:24

Downloaded from www.Manualslib.com manuals search engine


Drive Chain a Checking the Drive Chain Slider

❙ Checking the Drive Chain Wear Checking the Drive Chain Slider
Check the chain wear label when adjusting Check the condition of the drive chain slider.
the drive chain. If the index mark on the The drive chain slider need to be replaced if
swingarm enters the red zone on the label it is worn to the wear limit line.
Maintenance

after the chain has been adjusted to the If necessary have the drive chain slider
proper slack, the chain is excessively worn replaced by your dealer.
and must be replaced.
Chain: Wear limit line
RK 525SMOZ5

If necessary have the drive chain replaced by


your dealer.

Index mark

Drive chain slider

Red zone

62

32MFM630.indb 62 2010/12/14 15:44:25

Downloaded from www.Manualslib.com manuals search engine


Clutch

Checking the Clutch Check the clutch cable for kinks or signs of
wear. If necessary have it replaced by your
dealer.
❙ Checking the Clutch Lever Freeplay Lubricate the clutch cable with a
Check the clutch lever freeplay. commercially available cable lubricant to

Maintenance
Freeplay at the clutch lever: prevent premature wear and corrosion.
10 to 20 mm (0.4 to 0.8 in)

Freeplay Clutch lever

63

32MFM630.indb 63 2010/12/14 15:44:26

Downloaded from www.Manualslib.com manuals search engine


Clutch a Adjusting the Clutch Lever Freeplay

Adjusting the Clutch Lever Upper clutch


Freeplay cable adjuster

❙ Upper Adjustment
Maintenance

Attempt adjustment with the upper clutch


cable adjuster first.

1. Loosen the upper lock nut.


2. Turn the upper clutch cable adjuster until Upper lock nut
the freeplay is 10 to 20 mm (0.4 to 0.8
in).
3. Tighten the upper lock nut and check the ❙ Lower Adjustment
freeplay again. If the upper clutch cable adjuster is threaded
out near its limit, or the correct freeplay
cannot be obtained, attempt adjustment
with the lower adjusting nut.

64

32MFM630.indb 64 2010/12/14 15:44:26

Downloaded from www.Manualslib.com manuals search engine


Clutch a Adjusting the Clutch Lever Freeplay

1. Loosen the upper lock nut and turn the Lower adjusting nut
upper clutch cable adjuster all the way in
(to provide maximum freeplay). Tighten
the upper lock nut.
2. Loosen the lower lock nut.

Maintenance
3. Turn the lower adjusting nut until the
clutch lever freeplay is 10 to 20 mm (0.4
to 0.8 in).
4. Tighten the lower lock nut and check the
clutch lever freeplay. Lower lock nut
5. Start the engine, pull the clutch lever in,
and shift into gear. Make sure the engine If proper adjustment cannot be obtained or
does not stall and the motorcycle does the clutch does not work correctly, see your
not creep. Gradually release the clutch dealer.
lever and open the throttle. Your
motorcycle should move smoothly and
accelerate gradually.

65

32MFM630.indb 65 2010/12/14 15:44:27

Downloaded from www.Manualslib.com manuals search engine


Throttle

Checking the Throttle Adjusting the Throttle Freeplay


With the engine off, check that the throttle 1. Loosen the lock nut.
rotates smoothly from fully closed to fully 2. Turn the adjuster until the freeplay is 2 to
open in all steering positions and throttle 6 mm (0.1 to 0.2 in).
Maintenance

freeplay is correct. If the throttle does not 3. Tighten the lock nut and inspect the
move smoothly, close automatically, or if the throttle action again.
cable is damaged, have the motorcycle
inspected by your dealer. Throttle
grip
Freeplay at the throttle grip flange:
2 to 6 mm (0.1 to 0.2 in).

Freeplay

Lock nut Adjuster

66

32MFM630.indb 66 2010/12/14 15:44:27

Downloaded from www.Manualslib.com manuals search engine


Crankcase Breather

Cleaning the Crankcase


Breather
1. Remove the crankcase breather tube plug
from the tube.

Maintenance
2. Drain deposits into a suitable container.
3. Install the crankcase breather tube plug.

Crankcase breather tube plug

67

32MFM630.indb 67 2010/12/14 15:44:28

Downloaded from www.Manualslib.com manuals search engine


Other Adjustments

Adjusting the Brake Lever After adjustment, check that the lever
operates correctly before riding.
You can adjust the distance between the tip
of the brake lever and handle grip. NOTICE
Do not turn the adjuster beyond its natural limit.
●●
Maintenance

❙ Adjustment method
Turn the adjuster until the index mark aligns
with the arrow while pushing the lever
forward in the desired position. Index mark

Adjuster
Arrow
Brake lever

68

32MFM630.indb 68 2010/12/14 15:44:28

Downloaded from www.Manualslib.com manuals search engine


Other Adjustments a Adjusting the Front Suspension

Adjusting the Front Suspension NOTICE


Do not turn the adjuster beyond its limits.
Adjust both left and right forks to the same spring
❙ Spring Preload preload.
You can adjust the spring preload by the

Maintenance
adjuster to suit the load or the road surface.
Turn clockwise to increase spring preload
(hard), or turn counterclockwise to decrease
spring preload (soft). The standard position
is the third groove from the top aligns with
the top surface of the fork cap.

Adjuster

Standard
position

69

32MFM630.indb 69 2010/12/14 15:44:29

Downloaded from www.Manualslib.com manuals search engine


Other Adjustments a Adjusting the Rear Suspension

Adjusting the Rear Suspension Attempting to adjust directly from 1 to 5 or


5 to 1 may damage the shock absorber.

❙ Spring Preload NOTICE


Adjust both left and right shock absorbers to the same
You can adjust the spring preload by the
spring preload.
Maintenance

adjuster to suit the load or the road surface.


Use the pin spanner and extension bar to
turn the adjuster. Position 1 to 2 are for a NOTICE
The rear shock absorber damper unit contains high
decrease spring preload (soft), or turn the
pressure nitrogen gas. Do not attempt to disassemble,
position 4 to 5 increase spring preload service, or improperly dispose of the damper. See your
(hard). The standard position is 3. dealer.
Pin spanner

54 3 21

Adjuster Extension bar

70

32MFM630.indb 70 2010/12/14 15:44:29

Downloaded from www.Manualslib.com manuals search engine


Other Adjustments a Adjusting the Headlight Aim

Adjusting the Headlight Aim Adjusting the Brakelight Switch


You can adjust vertical aim of the headlight Check the operation of the brakelight
for proper alignment. switch. Turn the adjusting nut in the
To move the headlight case, loosen the direction A if the switch operates too late,

Maintenance
bolts. or turn the nut in the direction B if the
Obey local laws and regulations. switch operates too soon.

Headlight case
Up
Bolts A

Down

Adjusting nut Brakelight switch

71

32MFM630.indb 71 2010/12/14 15:44:30

Downloaded from www.Manualslib.com manuals search engine


Troubleshooting

Engine Will Not Start Other Warning Indications....................................P.77


(HISS indicator stays ON). ....................................P.73 Fuel Gauge Failure Indication................................P.77
Overheating Tyre Puncture. ..................................................................P.78
(High coolant temperature Electrical Trouble.......................................................... P.86
indicator is ON)........................................................... P.74 Battery Goes Dead. .................................................... P.86
Warning Indicators ON or Flashing.................P.75 Burned-out Light Bulb.............................................. P.86
Low Oil Pressure Indicator.......................................P.75 Blown Fuse...................................................................... P.90
PGM-FI (Programmed Fuel Injection)
Malfunction Indicator Lamp (MIL)...................P.75
ABS Indicator (CB400A)........................................... P.76

32MFM630.indb 72 2010/12/14 15:44:31

Downloaded from www.Manualslib.com manuals search engine


Engine Will Not Start (HISS indicator stays ON)
Check if there are no any metallic seals
❙ Starter Motor Operates But Engine or stickers on the key.
Does Not Start the HISS indicator still stays ON, have
If
Check the following items: your motorcycle inspected by your
●● Check the correct engine starting dealer.
sequence. P.22
●● Check that there is petrol in the fuel tank. ❙ Starter Motor Does Not Operate

Troubleshooting
●● Check if the PGM-FI malfunction indicator Check the following items:
lamp (MIL) is ON. ●● Make sure engine stop switch is RUN
a If the indicator light is ON, contact position. P.20
your dealer as soon as possible. ●● Check for a blown fuse. P.90
●● Check if the HISS indicator stays ON. ●● Check for a loose battery connection or
a Turn the ignition switch to the OFF battery terminal corrosion. P.36
position and remove the key. Reinsert ●● Check the condition of the battery. P.86
the key and turn the ignition switch to If the problem continues, have your
the ON position. If the indicator still motorcycle inspected by your dealer.
stays ON, check the following:
Check if there is no another HISS key
(including spare key) close to the
ignition switch.

73

32MFM630.indb 73 2010/12/14 15:44:32

Downloaded from www.Manualslib.com manuals search engine


Overheating (High coolant temperature indicator is ON)
The engine is overheating when the 2. Check that the radiator fan is operating,
following occurs: and then turn the ignition switch to the
●● High coolant temperature indicator comes OFF position.
ON. If the fan is not operating:
●● Acceleration becomes sluggish. Suspect a fault. Do not start the engine.
●● If this occurs, pull safely to the side of the Transport your motorcycle to your dealer.
road and perform the following If the fan is operating:
Troubleshooting

procedure. Allow the engine to cool with the ignition


Extended fast idling may cause the high switch in the OFF position.
coolant temperature indicator comes ON. 3. After the engine has cooled, inspect the
radiator hose and check if there is a leak.
NOTICE P.53
Continuing to ride with an overheated engine can cause
If there is a leak:
serious damage to the engine.
Do not start the engine. Transport your
motorcycle to your dealer.
1. Stop the engine using the ignition switch, 4. Check the coolant level in the reserve
and then turn the ignition switch to the tank, and add coolant as necessary.
ON position. P.54
5. If 1-4 check normal, you may continue
riding, but closely monitor the high
coolant temperature indicator.
74

32MFM630.indb 74 2010/12/14 15:44:32

Downloaded from www.Manualslib.com manuals search engine


Warning Indicators ON or Flashing

Low Oil Pressure Indicator If the engine oil level goes down rapidly,
your motorcycle may have a leak or another
If the low oil pressure indicator comes ON, serious problem. Have your motorcycle
pull safely to the side of the road and stop inspected by your dealer.
the engine.

NOTICE
PGM-FI (Programmed Fuel

Troubleshooting
Continuing to ride with low oil pressure can cause Injection) Malfunction Indicator
serious damage to the engine.
Lamp (MIL)
1. Check the engine oil level, and add oil as
necessary. P.50 If the indicator comes ON while riding, you
2. Start the engine. may have a serious problem with the
a Only continue riding if the low oil PGM-FI system. Reduce speed and have
pressure indicator goes OFF. your motorcycle inspected by your dealer as
Rapid acceleration may momentarily cause soon as possible.
the low oil pressure indicator to come ON,
especially if the oil is at or near the low level.
If the low oil pressure indicator stays ON
when the oil level is at the proper level, stop
the engine and contact your dealer.

75

32MFM630.indb 75 2010/12/14 15:44:32

Downloaded from www.Manualslib.com manuals search engine


Warning Indicators ON or Flashing a ABS (Anti-lock Brake System) Indicator (CB400A)

ABS (Anti-lock Brake System) The ABS indicator may flash if you turn the
rear wheel while your motorcycle is lifted off
Indicator (CB400A) the ground. In this case, turn the ignition
If the indicator operates in one of the switch OFF and then ON again. The ABS
following ways, you may have a serious indicator will go OFF after your speed
problem with the brake system. Reduce your reaches 30 km/h (19 mph).
speed and have your motorcycle inspected
Troubleshooting

by your dealer as soon as possible.

●● Indicator comes ON or starts flashing


while riding.
●● Indicator does not come ON when the
ignition switch is in the ON position.
●● Indicator does not go OFF at speeds
above 10 km/h (6 mph).

If the ABS indicator stays ON, your brakes


will continue to work as a conventional
system, but without the anti-locking
function.

76

32MFM630.indb 76 2010/12/14 15:44:32

Downloaded from www.Manualslib.com manuals search engine


Other Warning Indications

Fuel Gauge Failure Indication


If the fuel system has an error, the fuel
gauge indicators will be displayed as shown
in the illustration.
If this occurs, see your dealer as soon as
possible.

Troubleshooting

77

32MFM630.indb 77 2010/12/14 15:44:33

Downloaded from www.Manualslib.com manuals search engine


Tyre Puncture
Repairing a puncture or removing a wheel
requires special tools and technical WARNING
expertise. We recommend you have this
Riding your motorcycle with a
type of service performed by your dealer.
temporary tyre repair can be risky. If
After an emergency repair, always have the
the temporary repair fails, you can
tyre inspected/replaced by your dealer.
crash and be seriously injured or
Troubleshooting

killed.
Emergency Repair Using a Tyre
Repair Kit If you must ride with a temporary
tyre repair, ride slowly and carefully
If your tyre has a minor puncture, you can
and do not exceed 50 km/h (30 mph)
make an emergency repair using a tubeless
until the tyre is replaced.
tyre repair kit.
Follow the instructions provided with the
emergency tyre repair kit. Removing Wheels
Riding your motorcycle with a temporary
tyre repair is very risky. Do not exceed Follow these procedures if you need to
50 km/h (30 mph). Have the tyre replaced remove the wheel in order to repair a
by your dealer as soon as possible. puncture.

78

32MFM630.indb 78 2010/12/14 15:44:33

Downloaded from www.Manualslib.com manuals search engine


Tyre Puncture a Removing Wheels

(CB400A only) 3. Remove the right and left caliper


When removing and installing the wheel, be assemblies from the fork leg by removing
careful not to damage the wheel speed the fixing bolts.
sensor and pulser ring. a Support the brake caliper assembly so
that it doesn’t hang from the brake
❙ Front Wheel hose. Do not twist the brake hose.
Removal a Avoid getting grease, oil, or dirt on the

Troubleshooting
1. Park on a firm, level surface. disc or pad surfaces.
2. Cover both sides of the front wheel and a Do not pull the brake lever while the
brake caliper with protective tape or brake caliper is removed.
cloth. a Take care to prevent the brake caliper
from scratching the wheel during
removal.
Brake caliper
assembly

Fixing bolts

79

32MFM630.indb 79 2010/12/14 15:44:33

Downloaded from www.Manualslib.com manuals search engine


Tyre Puncture a Removing Wheels

4. Loosen the right axle pinch bolts. 7. Loosen the left axle pinch bolts.
5. Remove the front axle bolt. 8. On the left side, withdraw the front axle
6. Support your motorcycle securely and shaft, and remove the side collars and
raise the front wheel off the ground wheel.
using a maintenance stand or a hoist.
Troubleshooting

Axle pinch bolts Front axle shaft


Front axle bolt Axle pinch bolts

80

32MFM630.indb 80 2010/12/14 15:44:34

Downloaded from www.Manualslib.com manuals search engine


Tyre Puncture a Removing Wheels

Installation 4. Tighten the left axle pinch bolts to hold


1. Attach the side collars to the wheel. the axle.
2. On the left side, place the wheel 5. Tighten the front axle bolt.
between the fork legs and insert the Torque: 59 N·m (6.0 kgf·m, 44 lbf·ft).
front axle shaft, through the left fork leg
and wheel hub. 6. Loosen the left axle pinch bolts.
3. Align the index line of the front axle shaft 7. Tighten the right axle pinch bolts.

Troubleshooting
with the surface of the fork leg. Torque: 23 N·m (2.3 kgf·m, 17 lbf·ft).

Index line 8. Install the right and left brake calipers
and tighten the fixing bolts.
Torque: 30 N·m (3.1 kgf·m, 22 lbf·ft).

a Take care to prevent the brake caliper
from scratching the wheel during
installation.
Surface of
NOTICE
the fork leg
When installing the brake calipers into position on the
fork legs, carefully fit the brake disc between the pads to
avoid scratching them.

81

32MFM630.indb 81 2010/12/14 15:44:35

Downloaded from www.Manualslib.com manuals search engine


Tyre Puncture a Removing Wheels

9. Lower the front wheel on the ground. If a torque wrench was not used for
10. Apply the brake lever several times. Then, installation, see your dealer as soon as
pump the fork several times. possible to verify proper assembly.
11. Retighten the left axle pinch bolts. Clearance
Torque: 23 N·m (2.3 kgf·m, 17 lbf·ft).

12. Raise the front wheel off the ground
Troubleshooting

again, and check that the wheel rotates


freely after you release the brake.
Brake caliper
13. Check the clearances between each body
surface of the brake disc and the brake
caliper body (not the brake pads) are
symmetrical.
If the clearances are not symmetrical, Brake disc
loosen the left axle pinch bolts and pull
the left fork outward or push inward to
adjust the clearance.
14. Lower the front wheel on the ground.
15. Remove the protective tape or cloth.

82

32MFM630.indb 82 2010/12/14 15:44:35

Downloaded from www.Manualslib.com manuals search engine


Tyre Puncture a Removing Wheels

4. Remove the drive chain from the rear


❙Rear Wheel wheel sprocket by pushing the rear wheel
Removal forward.
1. Support your motorcycle securely and 5. Remove the rear axle shaft.
raise the rear wheel off the ground using Drive chain
a maintenance stand or a hoist.
2. Loosen the rear axle nut and turn the

Troubleshooting
adjusting bolts so the rear wheel can be
moved all the way forward for maximum
drive chain slack.
3. Remove the rear axle nut/washer.

Rear axle nut Adjusting bolt

Adjusting bolt Rear axle nut

continued 83

32MFM630.indb 83 2010/12/14 15:44:36

Downloaded from www.Manualslib.com manuals search engine


Tyre Puncture a Removing Wheels

6. Remove the rear axle shaft, side collars


and rear wheel. NOTICE
When installing the brake caliper into position, carefully
a Support the brake caliper assembly so fit the brake disc between the pads to avoid scratching
that it doesn’t hang from the brake them.
hose. Do not twist the brake hose.
a Avoid getting grease, oil, or dirt on the 2. Make sure that the lug on the brake
disc or pad surfaces. caliper bracket is positioned in the slot on
Troubleshooting

a Do not push the brake pedal while the the swingarm.


brake caliper is removed.
Swingarm
Installation
1. To install the rear wheel, reverse the
Lug Slot
removal procedure.
a Take care to prevent the brake caliper
from scratching the wheel during
installation.

Brake caliper
bracket

84

32MFM630.indb 84 2010/12/14 15:44:37

Downloaded from www.Manualslib.com manuals search engine


Tyre Puncture a Removing Wheels

3. Adjust the drive chain. P.60


4. Install and tighten the rear axle nut.
Torque: 88 N·m (9.0 kgf·m, 65 lbf·ft).

5. After installing the wheel, apply the


brake pedal several times, then recheck
the disc for caliper holder to disc

Troubleshooting
clearance. Do not operate the motorcycle
without adequate clearance.

If a torque wrench was not used for


installation, see your dealer as soon as
possible to verify proper assembly.
Improper assembly may lead to loss of
braking capacity.

85

32MFM630.indb 85 2010/12/14 15:44:37

Downloaded from www.Manualslib.com manuals search engine


Electrical Trouble

Battery Goes Dead Burned-out Light Bulb


Charge the battery using a motorcycle Follow the procedure below to replace a
battery charger. burned-out light bulb.
Remove the battery from the motorcycle Turn the ignition switch to the OFF or LOCK
while charging. position.
Do not use an automobile-type battery Allow the bulb to cool before replacing it.
Troubleshooting

charger, as these can overheat a motorcycle Do not use bulbs other than those specified.
battery and cause permanent damage. Check the replacement bulb for correct
If the battery does not recover after operation before riding.
recharging, contact your dealer.
For the light bulb wattage, see
NOTICE “Specifications.“ P.108
Jump starting using an automobile battery is not
recommended, as this can damage your motorcycle’s
electrical system.

86

32MFM630.indb 86 2010/12/14 15:44:37

Downloaded from www.Manualslib.com manuals search engine


Electrical Trouble a Burned-out Light Bulb

4. Remove the dust cover.


❙ Headlight Bulb 5. Unhook the pin and remove the bulb.
1. Remove the screws from the headlight 6. Install a new bulb in the reverse order of
case. removal.
2. Gently pull the lower end of the a Install the dust cover with its“TOP”
headlight forward and remove the mark facing up.
headlight. Do not touch the glass surface of a new

Troubleshooting
3. Disconnect the connector by pressing headlight bulb with your fingers. If you
tabs. touch the bulb with your bare hands, clean
it with a cloth moistened with alcohol.
Screw Connector

“TOP”mark
Dust cover
Tabs Bulb

Pin

Headlight Screw

87

32MFM630.indb 87 2010/12/14 15:44:38

Downloaded from www.Manualslib.com manuals search engine


Electrical Trouble a Burned-out Light Bulb

❙ Front/Rear Turn Signal Bulb ❙ Brake/Tail light


1. Remove the screw.
Brake/Tail light
2. Remove the turn signal lens and lens
packing.
3. Slightly press the bulb and turn it
counterclockwise.
Troubleshooting

Screw

The brake and tail light uses several LEDs.


If there is a LED which is not turned on, see
Turn signal Lens packing Bulb your dealer for this service.
lens

4. Install a new bulb in the reverse order of


removal.

88

32MFM630.indb 88 2010/12/14 15:44:39

Downloaded from www.Manualslib.com manuals search engine


Electrical Trouble a Burned-out Light Bulb

❙ License Plate Light


1. Remove the screws.
2. Remove the license light cover.
3. Pull out the bulb without turning.
License light

Troubleshooting
cover

Screws Bulb

4. Install a new bulb in the reverse order of


removal.

89

32MFM630.indb 89 2010/12/14 15:44:39

Downloaded from www.Manualslib.com manuals search engine


Electrical Trouble a Blown Fuse

Blown Fuse 1. Remove the left side cover. P.46


2. Open the fuse box cover.
Before handling fuses, see “Inspecting and 3. Pull out the fuses one by one to check for
Replacing Fuses.” P.37 a blown fuse. Always replace a blown
fuse with a spare of the same rating.
❙ Fuse Box Fuses 4. Close the fuse box cover.
(CB400) 5. Install the left side cover.
Troubleshooting

Fuse box cover


Spare fuses

90

32MFM630.indb 90 2010/12/14 15:44:40

Downloaded from www.Manualslib.com manuals search engine


Electrical Trouble a Blown Fuse

(CB400A) Beside left rear suspension


Under seat 1. Remove the left side cover. P.46
1. Remove the seat. P.45 2. Open the fuse box covers.
2. Open the fuse box cover. 3. Pull out the fuses one by one to check for
3. Pull out the fuses one by one to check for a blown fuse. Always replace a blown
a blown fuse. Always replace a blown fuse with a spare of the same rating.
fuse with a spare of the same rating. 4. Close the fuse box covers.

Troubleshooting
4. Close the fuse box cover. 5. Install the left side cover.
5. Install the seat.

Under seat Beside left rear suspension

Fuse box
Fuse box cover
cover

Spare fuse Spare fuse

91

32MFM630.indb 91 2010/12/14 15:44:41

Downloaded from www.Manualslib.com manuals search engine


Electrical Trouble a Blown Fuse

4. Connect the wire connector of the starter


❙ Main Fuse magnetic switch.
1. Remove the left side cover. P.46 5. Install the left side cover.
2. Disconnect the wire connector of the
starter magnetic switch. NOTICE
If a fuse fails repeatedly, you likely have an electrical
3. Pull out the main fuse and check for a
problem. Have your motorcycle inspected by your dealer.
blown fuse. Always replace a blown fuse
Troubleshooting

with a spare of the same rating.


a Spare main fuse is provided under the
starter magnetic switch.
(CB400) (CB400A) Wire connector
Main fuse
Wire connector Starter magnetic
switch

Spare main fuse

Spare main fuse


Starter magnetic Main fuse
switch

92

32MFM630.indb 92 2010/12/14 15:44:42

Downloaded from www.Manualslib.com manuals search engine


Electrical Trouble a Blown Fuse

(CB400A)
❙ FI Fuse 1. Remove the left side cover. P.46
(CB400) 2. Open the fuse box cover located beside
1. Remove the left side cover. P.46 the left rear suspension.
2. Open the fuse holder. 3. Pull out the fuse and check for a blown
3. Pull out the FI fuse and check for a blown fuse. Always replace a blown fuse with a
fuse. Always replace a blown fuse with a spare of the same rating.

Troubleshooting
spare of the same rating. 4. Close the fuse box cover.
a Spare fuse is provided in the fuse box. 5. Install the left side cover.
P.90
(CB400A)
4. Close the fuse holder.
Fuse box cover
5. Install the left side cover.
(CB400)
FI fuse
Fuse holder

FI fuse Spare fuse

NOTICE
If a fuse fails repeatedly, you likely have an electrical
problem. Have your motorcycle inspected by your dealer.
93

32MFM630.indb 93 2010/12/14 15:44:43

Downloaded from www.Manualslib.com manuals search engine


Information

Keys..........................................................................................P.95
Instruments, Controls, &
Other Features............................................................. P.96
Fuels Containing Alcohol....................................... P.98
Catalytic Converter..................................................... P.99
Caring for Your Motorcycle................................ P.100
Storing Your Motorcycle. ..................................... P.102
Transporting Your Motorcycle......................... P.103
You & the Environment......................................... P.104
Serial Numbers............................................................. P.105

32MFM630.indb 94 2010/12/14 15:44:43

Downloaded from www.Manualslib.com manuals search engine


Keys

Keys To make a duplicate key and register it with


your HISS system, take the spare key, the key
number plate, and the motorcycle to your
Ignition key dealer.
The ignition key contains a special coded chip
that is recognized by the immobilizer system A metal key holder may cause damage to the
(HISS) in order to start the engine. Handle the area surrounding the ignition switch.
key carefully to prevent damaging the HISS
components.

Information
●● Do not bend keys or subject them to undue
stress.
●● Avoid prolonged exposure to sunlight or
high temperatures.
●● Do not grind, drill or in any way alter their
shape.
●● Do not expose to strong magnetic objects.

If you lose all keys and the key number plate,


the PGM-FI unit/ignition control module must
be replaced by your dealer. To avoid this, keep
a duplicate key.
If you lose a key, make another duplicate key
immediately.
95

32MFM630.indb 95 2010/12/14 15:44:43

Downloaded from www.Manualslib.com manuals search engine


Instruments, Controls, & Other Features

Instruments, Controls, & Tripmeter


Other Features The tripmeter returns to 0.0 when the read-
out exceeds 999.9.
Ignition Switch
The headlight is always ON when the ignition HISS
switch is ON. Leaving the ignition switch ON The Honda Ignition Security System (HISS)
with the engine stopped will drain the battery. immobilizes the engine’s ignition system if an
improperly-coded key is used to try and start
Information

Do not turn the key while riding. the engine. When the ignition switch is turned
OFF, the HISS immobilizer system is always
Engine Stop Switch alert, even if the HISS indicator is not flashing.
Do not use the engine stop switch except in an If the ignition switch is turned ON with the
emergency. Doing so when riding will cause engine stop switch in the RUN position, the
the engine to suddenly turn off, making riding HISS indicator turns ON and goes off after a
unsafe. few seconds to indicate it is OK to start the
If you stop the engine using the engine stop engine.
switch, turn the ignition switch OFF. Failing to HISS Indicator Does Not Turn OFF P.73
do so will drain the battery.
The HISS indicator starts flashing every 2
Odometer seconds for 24 hours after the ignition switch
The display locks at 999,999 when the read- is turned OFF. To prevent or to restore the HISS
out exceeds 999,999. indicator flashing:
96

32MFM630.indb 96 2010/12/14 15:44:44

Downloaded from www.Manualslib.com manuals search engine


Instruments, Controls, & Other Features

1. With the ignition switch ON, press and hold


the A button ( P.14) for 1 second or more Document Bag
when the display function mode is The owner’s manual, registration, and
odometer. insurance information can be stored in the
a The HISS indicator flashes once. plastic document bag located under the seat.
2. Turn the ignition switch OFF.
Ignition Cut-off System
EC Directive A banking (lean angle) sensor automatically
This immobilizer system complies with R & TTE stops the engine and fuel pump if the

Information
(Radio and Telecommunications Terminal motorcycle falls over. To reset the sensor, you
Equipment and the mutual recognition of their must turn the ignition switch to OFF and back
conformity) Directive. to the ON position before the engine can be
restarted.

The declaration of conformity to R & TTE


Directive is provided to the owner at the time
of purchase. The declaration of conformity
should be kept at a safe place. When the
declaration of conformity is lost or is not
provided, contact your dealer.

97

32MFM630.indb 97 2010/12/14 15:44:44

Downloaded from www.Manualslib.com manuals search engine


Fuels Containing Alcohol

Fuels Containing Alcohol The use of petrol containing more than 10 %


ethanol (or more than 5 % methanol) may:
Some conventional fuels blended with alcohol ●● Damage the painting of the fuel tank.
are available in some locales to help reduce ●● Damage the rubber tubes of the fuel line.
emissions to meet clean air standards. If you ●● Cause corrosion of the fuel tank.
plan to use blended fuel, check that it is ●● Cause poor drivability.
unleaded and meets the minimum octane
rating requirement. NOTICE
Use of blended fuels containing higher than approved
Information

The following fuel blends can be used in your percentages can damage metal, rubber, plastic parts of
your fuel system.
motorcycle:
●● Ethanol (ethyl alcohol) 10 % by volume If you notice any undesirable operating
(max). symptoms or performance problems, try a
●● Petrol containing ethanol may be marketed different brand of petrol.
under the name Gasohol.
●● Methanol (methyl alcohol) 5 % by volume
(max) that contain cosolvents and corrosion
inhibitors to protect the fuel system. Never
use a blend containing more than 5 %.

98

32MFM630.indb 98 2010/12/14 15:44:44

Downloaded from www.Manualslib.com manuals search engine


Catalytic Converter

Catalytic Converter Follow these guidelines to protect your


motorcycle’s catalytic converter.
This motorcycle is equipped with an oxidation ●● Always use unleaded petrol. Leaded petrol
catalytic converter. The catalytic converter will damage the catalytic converter.
contains precious metals that serve as catalysts ●● Keep the engine in good running condition.
in high temperature chemical reactions that ●● Have your motorcycle serviced if your engine
convert hydrocarbons (HC) and carbon is misfiring, backfiring, stalling, or otherwise
monoxide (CO) in the exhaust gasses into safe not running properly, stop riding and turn
compounds. off the engine.

Information
A defective catalytic converter contributes to
air pollution and can impair your engine’s
performance. A replacement unit must be an
original Honda part or equivalent.

99

32MFM630.indb 99 2010/12/14 15:44:44

Downloaded from www.Manualslib.com manuals search engine


Caring for Your Motorcycle

Caring for Your Motorcycle into the air cleaner, muffler, and electrical
parts.
Frequent cleaning and polishing is important 3. Thoroughly rinse your motorcycle with
to ensure the life of your Honda. A clean plenty of clean water.
motorcycle makes it easier to spot potential 4. After the motorcycle dries, lubricate any
problems. moving parts.
In particular, seawater and salts used to a Make sure that no lubricant spills onto
prevent ice on roads promote the formation of the brakes or tyres. Brake discs or pads
corrosion. Always wash your motorcycle contaminated with oil will suffer greatly
Information

thoroughly after riding on coastal or treated reduced braking effectiveness and can
roads. lead to a crash.
5. Lubricate the drive chain immediately after
Washing washing and drying the motorcycle.
Allow the engine, muffler, brakes, and other 6. Apply a coat of wax to prevent corrosion.
high-temperature parts to cool before a Avoid products that contain harsh
washing. detergents or chemical solvents. These
1. Rinse your motorcycle thoroughly using a can damage the metal, paint, and plastic
garden hose to remove loose dirt. on your motorcycle.
2. If necessary, use a sponge or a soft towel Keep the wax clear of the tyres and
with mild cleaner to remove road grime. brakes.
a Clean the headlight lens and other plastic a If your motorcycle has any matte painted
components with extra care to avoid parts, do not apply a coat of wax to the
scratching them. Avoid directing water matte painted surface.
100

32MFM630.indb 100 2010/12/14 15:44:44

Downloaded from www.Manualslib.com manuals search engine


Caring for Your Motorcycle

❙ Washing Precautions ●● Do not direct water at the air cleaner:


Follow these guidelines when washing: a Water in the air cleaner can prevent the
●● Do not use high-pressure washers: engine from starting.
a High-pressure water cleaners can damage ●● Do not direct water near the headlight:
moving parts and electrical parts, a Any condensation inside the headlight
rendering them inoperable. should dissipate after a few minutes of
●● Do not direct water at the muffler: running the engine.
a Water in the muffler can prevent starting
and causes rust in the muffler.

Information
●● Dry the brakes: Aluminium Components
a Water adversely affects braking Aluminium will corrode from contact with dirt,
effectiveness. After washing, apply the mud, or road salt. Clean aluminium parts
brakes intermittently at low speed to help regularly and follow these guidelines to avoid
dry them. scratches:
●● Do not direct water under the seat: ●● Do not use stiff brushes, steel wool, or
a Water in the underseat compartment can cleaners containing abrasives.
damage your documents and other ●● Avoid riding over or scraping against curbs.
belongings.

101

32MFM630.indb 101 2010/12/14 15:44:44

Downloaded from www.Manualslib.com manuals search engine


Storing Your Motorcycle

Exhaust Pipe and Muffler Storing Your Motorcycle


The exhaust is made of stainless steel, which If you store your motorcycle outdoors, you
can become tarnished with burn marks if should consider using a full-body motorcycle
splattered with oil or other substances when cover.
hot. To remove burn marks, use a mild abrasive If you won’t be riding for an extended period,
compound. To remove dirt and mud, use a follow these guidelines:
kitchen cleaning solution for stainless steel and ●● Wash your motorcycle and wax all painted
wash with a soft sponge. Rinse with plenty of surfaces (except matte painted surfaces).
Information

water to remove all residue. Coat chrome pieces with rust-inhibiting oil.
●● Lubricate the drive chain. P.40
NOTICE ●● Place your motorcycle on a maintenance
Even though the exhaust is made of stainless steel, it can stand and position a block so that both tyres
become stained. Remove all marks and blemishes as are off the ground.
soon as they are noticed. ●● After rain, remove the body cover and allow
the motorcycle to dry.
●● Remove the battery ( P.47) to prevent
discharge. Charge the battery in a shaded,
well-ventilated area.
a If you leave the battery in place,
disconnect the negative terminal to
prevent discharge.

102

32MFM630.indb 102 2010/12/14 15:44:45

Downloaded from www.Manualslib.com manuals search engine


Transporting Your Motorcycle

After removing your motorcycle from storage,


inspect all maintenance items required by the
Transporting Your
Maintenance Schedule. Motorcycle
If your motorcycle needs to be transported, it
should be carried on a motorcycle trailer or a
flatbed truck or trailer that has a loading ramp
or lifting platform, and motorcycle tie-down
straps. Never try to tow your motorcycle with
a wheel or wheels on the ground.

Information
NOTICE
Towing your motorcycle can cause serious damage to the
transmission.

103

32MFM630.indb 103 2010/12/14 15:44:45

Downloaded from www.Manualslib.com manuals search engine


You & the Environment

You & the Environment it down a drain or on the ground. Used oil,
petrol, coolant, and cleaning solvents contain
Owning and riding a motorcycle can be poisons that can hurt refuse workers and
enjoyable, but you must do your part to contaminate drinking water, lakes, rivers, and
protect the environment. oceans.

Choose Sensible Cleaners


Use a biodegradable detergent when you
Information

wash your motorcycle. Avoid aerosol spray


cleaners that contain chlorofluorocarbons
(CFCs) which damage the atmosphere’s
protective ozone layer.

Recycle Wastes
Put oil and other toxic wastes in approved
containers and take them to a recycling centre.
Call your local or state office of public works
or environmental services to find a recycling
centre in your area, and to get instructions on
how to dispose of non-recyclable wastes. Do
not place used engine oil in the trash, or pour
104

32MFM630.indb 104 2010/12/14 15:44:45

Downloaded from www.Manualslib.com manuals search engine


Serial Numbers

Serial Numbers
The frame and engine serial numbers uniquely
identify your motorcycle and are required in
order to register your motorcycle. They may
also be required when ordering replacement
parts.
The frame number is stamped on the right side
of the steering head.

Information
The engine number is stamped on the right
side of the crankcase.
You should record these numbers and keep Frame number
them in a safe place. Engine number

105

32MFM630.indb 105 2010/12/14 15:44:45

Downloaded from www.Manualslib.com manuals search engine


Specifications
■ Main Components Displacement 399 cm3 (24.3 cu-in)
Type NC42 Bore x stroke 55.0 x 42.0 mm (2.17 x 1.65 in)
Overall length 2,040 mm (80.3 in) Compression ratio 11.3:1
Overall width 725 mm (28.5 in) Unleaded petrol
Fuel
Overall height 1,070 mm (42.1 in) Recommended: 91 RON or higher
Wheelbase 1,410 mm (55.5 in) Tank capacity 18.0 litres (4.76 US gal, 3.96 Imp gal)
Minimum ground Battery 12V-8.6Ah (10 HR) / 9.1Ah (20 HR)
130 mm (5.1 in)
clearance 1st 3.307
Caster angle 25º 05´ 2nd 2.294
Trail 90 mm (3.5 in) 3rd 1.750
Gear ratios
CB400 195 kg (430 lb) 4th 1.421
Curb weight
CB400A 200 kg (441 lb) 5th 1.240
Specifications

Maximum weight 6th 1.130


179 kg (395 lb)
capacity*1 Reduction ratios
Passenger capacity Rider and 1 passenger 2.171 / 2.933
(primary / final)
Minimum turning
2.6 m (8.53 ft)
radius
*1 Including rider, passenger, all luggage, and accessories

106

32MFM630.indb 106 2010/12/14 15:44:45

Downloaded from www.Manualslib.com manuals search engine


Specifications

■ Service Data Honda 4-stroke motorcycle oil


Front 120/60ZR17M/C (55W) API Service Classification SG or higher,
Tyre size Recommended
Rear 160/60ZR17M/C (69W) excluding oils marked as
engine oil
Tyre type Radial, tubeless “Energy Conserving,”
DUNLOP D204FL SAE 10W-30, JASO T 903 standard MA
Front 3.0 litres (3.2 US qt,
Recommended BRIDGESTONE BT-50F After draining
Tyres 2.6 Imp qt)
DUNLOP D204J
Rear After draining &
BRIDGESTONE BT-50R Engine oil 3.2 litres (3.4 US qt,
engine oil filter
Tyre air pressure Front 225 kPa (2.25 kgf/cm2, 33 psi) capacity 2.8 Imp qt)
change
(Driver only) Rear 250 kPa (2.50 kgf/cm2, 36 psi)
3.8 litres (4.0 US qt,
Tyre air pressure Front 250 kPa (2.50 kgf/cm2, 36 psi) After disassembly
3.3 Imp qt)
(Driver and

Specifications
Rear 290 kPa (2.90 kgf/cm2, 42 psi) Recommended
passenger) Honda DOT 4 Brake Fluid
Front 1.5 mm (0.06 in) brake fluid
Minimum tread
depth Rear 2.0 mm (0.08 in) Cooling system
2.2 litres (2.3 US qt, 1.9 Imp qt)
capacity
CR8EH-9 (NGK) or
Spark plugs (standard) Recommended
U24FER9 (DENSO) Pro Honda HP Coolant
coolant
0.80 to 0.90 mm (0.031 to
Spark plug gap
0.035 in)
Idle speed 1,400 ± 100 rpm

107

32MFM630.indb 107 2010/12/14 15:44:45

Downloaded from www.Manualslib.com manuals search engine


Specifications

Recommended drive Drive chain lubricant designed ■ Fuses


chain lubricant specifically for O-ring chains Main fuse 30A
FI fuse 20A
Drive chain slack 25 to 35 mm (1.0 to 1.4 in)
CB400 20A, 10A
Other fuses
RK 525SMOZ5 CB400A 30A, 20A, 10A
Standard drive chain
No. of links 108
Engine sprocket 15T ■ Torque Specifications
Standard sprocket sizes
Rear wheel sprocket 44T Engine oil drain bolt 30 N·m (3.1 kgf·m, 22 lbf·ft)
Oil filter 26 N·m (2.7 kgf·m, 19 lbf·ft)
■ Bulbs Front axle bolt 59 N·m (6.0 kgf·m, 44 lbf·ft)
Headlight 12V-60/55W Front brake caliper fixing
30 N·m (3.1 kgf·m, 22 lbf·ft)
Brake/Tail light LED bolts
Specifications

SI type 12V-21/5W x 2 Front axle pinch bolts 23 N·m (2.3 kgf·m, 17 lbf·ft)
Front turn signal lights
U type 12V-21W x 2 Rear axle nut 88 N·m (9.0 kgf·m, 65 lbf·ft)
Rear turn signal lights 12V-21W x 2
License plate light 12V-5W

108

32MFM630.indb 108 2010/12/14 15:44:45

Downloaded from www.Manualslib.com manuals search engine


Index a A to E

A Compartment
ABS Indicator..............................................18 Centre.......................................................27
Accessories.................................................10 Luggage tie-down hooks..........................28
Owner’s Manual..................................26, 97
B Rear..........................................................26
Battery................................................. 36, 47 Tool Kit.............................................. 26, 44
Brakelight Switch.......................................71 Coolant................................................ 40, 53
Brakes Crankcase Breather................................... 67
Fluid....................................................39, 55
Pad Wear................................................. 56 D
Braking.........................................................7 Digital Clock Adjustment..........................17
Bulb Drive Chain.................................................59
Brake/Tail Light......................................... 88

Index
Front/Rear Turn Signal.............................. 88 E
Headlight..................................................87 Electrical Trouble...................................... 86
License Plate Light.................................... 89 Engine
Number...................................................105
C Oil...................................................... 38, 49
Caring for Your Motorcycle................... 100 Oil Filter....................................................51
Clutch System............................................ 63 Overheats.................................................74
Colour Label...............................................35 Starting.....................................................22
Combined ABS.............................................8 Stop Switch........................................ 20, 96
Stopping.................................................. 96
Environment............................................ 104
109

32MFM630.indb 109 2010/12/14 15:44:45

Downloaded from www.Manualslib.com manuals search engine


Index a F to L

F High Coolant Temperature


Flooded Engine......................................... 22 Indicator..............................................18, 74
Frame Number.........................................105 HISS Indicator.......................................19, 73
Front Brake Lever Adjustment................. 68 Horn Button.............................................. 20
Front Suspension.......................................69
Fuel I
Gauge.......................................................16 Ignition Cut-off System
Recommended..........................................24 Banking Sensor.........................................97
Remaining.................................................16 Side Stand................................................ 58
Tank Capacity............................................24 Ignition Key............................................... 95
Fuels Containing Alcohol......................... 98 Ignition Switch.....................................21, 96
Fuses......................................................37, 90 Indicators....................................................18
Index

Instruments................................................14
G
Gasohol...................................................... 98 L
Load Limits.................................................11
H Loading Guidelines....................................11
Hazard Switch........................................... 20 Low Oil Pressure Indicator..................18, 75
Headlight Aim............................................71 Luggage tie-down hooks......................... 28
Headlight Dimmer Switch........................ 20
Helmet Holder.................................... 25, 26
High Beam Indicator..................................19

110

32MFM630.indb 110 2010/12/14 15:44:46

Downloaded from www.Manualslib.com manuals search engine


Index a M to R

M Petrol................................................... 24, 98
Maintenance PGM-FI (Programmed Fuel Injection)
Fundamentals........................................... 34 malfunction indicator lamp (MIL).....18, 75
Importance.............................................. 30 Protective Apparel.......................................8
Safety....................................................... 30
Schedule...................................................31 R
Maximum Weight Limit.............................11 Recommended
Modifications.............................................10 Coolant.................................................... 40
Fuel...........................................................24
N Oil............................................................ 38
Neutral Indicator.......................................19 Refuelling...................................................24
Removal
O

Index
Battery......................................................47
Odometer............................................ 15, 96 Seat..........................................................45
Oil Side Covers.............................................. 46
Engine................................................ 38, 49 Repair Kit....................................................78
Other Warning Indications...................... 77 Riding Precautions.......................................7
Overheating...............................................74

P
Parking..........................................................9
Parts Location............................................12
Passing light control switch..................... 20
111

32MFM630.indb 111 2010/12/14 15:44:46

Downloaded from www.Manualslib.com manuals search engine


Index a S to W

S Tool Kit...................................................... 44
Safety Precautions.......................................6 Transporting Your Motorcycle................103
Seat............................................................ 45 Tripmeter............................................. 15, 96
Serial Numbers.........................................105 Troubleshooting........................................72
Shifting Gears........................................... 23 Turn signal indicators................................19
Side Covers................................................ 46 Tyres
Side Stand.................................................. 58 Air Pressure...............................................41
Side Stand Ignition Cut-off System......... 58 Puncture...................................................78
Specifications.......................................... 106 Replacing............................................ 41, 78
Speedometer..............................................14
Start Button.............................................. 20 W
Starting the Engine.................................. 22 Warning Indicators ON..............................75
Index

Steering Lock..............................................21 Washing Your Motorcycle...................... 100


Stopping Engine....................................... 96 Weight Limit...............................................11
Storage Wheels
Compartment...........................................25 Front removal............................................79
Owner’s Manual..................................25, 97 Rear removal............................................ 83
Storing Your Motorcycle.........................102
Switches..................................................... 20

T
Tachometer................................................14
Throttle...................................................... 66
112

32MFM630.indb 112 2010/12/14 15:44:46

Downloaded from www.Manualslib.com manuals search engine

You might also like