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Honda XL650V

OWNER’S MANUAL

Honda Motor Co., Ltd. 2003

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IMPORTANT INFORMATION
OPERATOR AND PASSENGER
This motorcycle is designed to carry the operator and one passenger. Never exceed the
maximum weight capacity as shown on the accessories and loading label.

ON/OFF-ROAD USE
This motorcycle is designed for ‘‘dual purpose’’ use.

READ THIS OWNER’S MANUAL CAREFULLY

Pay special attention to the safety messages that appear throughout the manual. These
messages are fully explained in the ‘‘A Few Words About Safety’’ section which appears
before the Contents page.

This manual should be considered a permanent part of the motorcycle and should remain
with the motorcycle when resold.
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Honda XL650V
OWNER’S MANUAL

All information in this publication is based on the latest production information

available at the time of approval for printing. Honda Motor Co.,Ltd. reserves the
right to make changes at any time without notice and without incurring any
obligation.
No part of this publication may be reproduced without written permission.
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WELCOME
The motorcycle presents you a challenge to master the machine, a challenge to adventure.
You ride through the wind, linked to the road by a vehicle that responds to your commands
as no other does. Unlike an automobile, there is no metal cage around you. Like an airplane, a
pre-ride inspection and regular maintenance are essential to your safety. Your reward is
freedom.

To meet the challenges safely, and to enjoy the adventure fully, you should become
thoroughly familiar with this owner’s manual BEFORE YOU RIDE THE MOTORCYCLE.

As you read this manual, you will find information that is preceded by a symbol. This
information is intended to help you avoid damage to your motorcycle, other property, or the
environment.

When service is required, remember that your Honda dealer knows your motorcycle best. If
you have the required mechanical ‘‘know-how’’ and tools, your dealer can supply you with an
official Honda Service Manual to help you perform many maintenance and repair tasks.

Pleasant riding, and thank you for choosing a Honda !

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Following codes in this manual indicate each country.

E UK Ireland ED European direct sales
F France ED European direct sales (Type )
The specifications may vary with each locale.
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A FEW WORDS ABOUT SAFETY

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

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

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

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

Safety Labels –– on the motorcycle.

Safety Messages –– preceded by a safety alert symbol and one of three signal words:
DANGER, WARNING, or CAUTION.

These signal words mean:

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

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

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

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

Safety Section –– such as Motorcycle Safety.

Instructions –– how to use this motorcycle correctly and safely.

This entire manual is filled with important safety information –– please read it carefully.
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OPERATION
page page
1 MOTORCYCLE SAFETY 35 ESSENTIAL INDIVIDUAL
1 Important Safety Inforamation COMPONENTS
3 Protective Apparel 35 Ignition Switch
5 Load Limits and Guidelines 36 Keys
38 Immobilizer System (HISS)
10 PARTS LOCATION 40 Right Handlebar Controls
13 Instruments and Indicators 41 Left Handlebar Controls

20 MAJOR COMPONENTS
(Information you need to
opetate this motorcycle)
20 Brakes
22 Clutch
24 Coolant
26 Fuel
29 Engine Oil
30 Tyres
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page page
42 FEATURES 49 OPERATION
(Not required for operation) 49 Pre-ride Inspection
42 Steering Lock 51 Starting the Engine
43 Seat 54 Running-in
44 Helmet Holder 55 Riding
45 Left Side Cover 57 Braking
46 Right Side Cover 58 Parking
47 Center Compartment 59 Anti-theft Tips
47 Document Compartment
48 Headlight Aim Vertical Adjustment
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MAINTENANCE
page page
60 MAINTENANCE 102 Stoplight Switch Adjustment
60 The Importance of Maintenance 103 Bulb Replacement
61 Maintenance Safety
62 Safety Precautions 109 CLEANING
63 Maintenance Schedule
66 Tool Kit 112 STORAGE GUIDE
67 Serial Numbers 112 Storage
68 Colour Label 114 Removal from Storage
69 Engine Oil
73 Spark Plug 115 SPECIFICATIONS
77 Crankcase Breather
78 Throttle Operation 119 CATALYTIC CONVERTER
79 Idle Speed
80 Coolant
81 Drive Chain
87 Drive Chain Slider
88 Front and Rear Suspension
Inspection
89 Side Stand
90 Wheel Removal
95 Brake Pad Wear
97 Battery
99 Fuse Replacement
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MOTORCYCLE SAFETY
IMPORTANT SAFETY INFORMATION Don’t Drink and Ride
Your motorcycle can provide many years of Alcohol and riding don’t mix. Even one
service and pleasure − if you take drink can reduce your ability to respond to
responsibility for your own safety and changing conditions, and your reaction time
understand the challenges that you can gets worse with every additional drink. So
meet on and off-road. don’t drink and ride, and don’t let your
friends drink and ride either.
There is much that you can do to protect
yourself when you ride. You’ll find many
helpful recommendations throughout this
manual. Following are a few that we
consider most important.

Always Wear a Helmet

It’s a proven fact: helmets significantly
reduce the number and severity of head
injuries, so don’t ride without one. We also
recommend that you wear eye protection,
sturdy boots, gloves and other protective
gear (page 4 ).

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Make Yourself Easy to See On-Road Ride Within Your Limits

Some drivers do not see motorcycles Pushing the limits is another major cause of
because they are not looking for them. To motorcycle accident both on-road and off.
make yourself more visible, wear bright Never ride beyond your personal abilities or
reflective clothing, position yourself so faster than conditions warrant. Remember
other drivers can see you, signal before that alcohol, drugs, fatigue and inattention
turning or changing lanes, and use your can significantly reduce your ability to make
horn when it will help others notice you. good judgements and ride safely.

Be Alert for Off-Road Hazards Keep Your Bike in Safe Condition

The terrain can present a variety of For safe riding, it’s important to keep your
challenges when you ride of f -road. motorcycle properly maintained. Having a
Cont inually ‘‘read’’ t he t errain f or breakdown can be difficult, especially if you
unexpected turns, drop-offs, rocks, ruts, and are stranded off-road far from your base. To
other hazards. Always keep your speed low help avoid problems, inspect your
enough to allow time to see and react to motorcycle before every ride and perform
hazards. all recommended maintenance. Never
exceed load limits, and use only accessories
that have been approved by Honda for this
motorcycle. See page 5 for more details.

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PROTECTIVE APPAREL Helmets and Eye Protection

For your safety, we strongly recommend Your helmet is your most important piece of
that you always wear an approved riding gear because it offers the best
motorcycle helmet, eye protection, boots, protection against head injuries. A helmet
gloves, long pants, and a long-sleeved shirt should fit your head comfortably and
or jacket whenever you ride. Although securely. A bright-coloured helmet can
complete protection is not possible, wearing make you more noticeable in traffic, as can
proper gear can reduce the chance of injury reflective strips.
when you ride.
Following are suggestions to help you An open-face helmet offers some protection,
choose proper gear. but a full-face helmet offers more. Always
wear a face shield or goggles to protect
your eyes and help your vision.

Not wearing a helmet increases the

chance of serious injury or death in a
crash.

Be sure you always wear a helmet,

eye protection and other protective
apparel when you ride.

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Additional On-Road Gear Additional Off-Road Gear

In addition to a helmet and eye protection, On-road apparel may also be suitable for
we also recommend: casual off-road riding. But if you plan on any
Sturdy boots with non-slip soles to help serious off-road riding you will need more
protect your feet and ankles. serious off-road gear. In addition to your
Leather gloves to keep your hands warm helmet and eye protection, we recommend
and help prevent blisters, cuts, burns and off-road motorcycle boots and gloves, riding
bruises. pants with knee and hip pads, a jersey with
A motorcycle riding suit or jacket for elbow pads, and a chest/shoulder protector.
comfort as well as protection. Bright-
coloured and reflective clothing can help
make you more noticeable in traffic. Be
sure to avoid loose clothes that could get
caught on any part of your motorcycle.

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LOAD LIMITS AND GUIDELINES Loading

Your motorcycle has been designed to carry How much weight you put on your
you and one passenger. When you carry a motorcycle, and how you load it, are
passenger, you may feel some difference important to your safety. Anytime you ride
during acceleration and braking. But so long with a passenger or cargo you should be
as you keep your motorcycle well- aware of the following information.
maintained, with good tyres and brakes, you
can safely carry loads within the given limits
and guidelines.

However, exceeding the weight limit or Overloading or improper loading can

carrying an unbalanced load can seriously cause a crash and you can be
affect your motorcycle’s handling, braking seriously hurt or killed.
and stability. Non-Honda accessories,
im p r o p e r m od i f i c a t i on s , a n d p o or Follow all load limits and other loading
maintenance can also reduce your safety guidelines in this manual.
margin.

The following pages give more specific

information on loading, accessories and
modifications.

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Load Limits Loading Guidelines

Following are the load limits for your Your motorcycle is primarily intended for
motorcycle: transporting you and a passenger. You may
Maximum weight capacity: wish to secure a jacket or other small items
180 kg (396 lbs) to the seat when you are not riding with a
Includes the weight of the rider, passenger.
passenger, all cargo and all accessories
Maximum rear carrier cargo weight: If you wish to carry more cargo, check with
9 kg (20 lbs) your Honda dealer for advice, and be sure
Maximum center compartment cargo to read the inf ormat ion regarding
weight: accessories on page 7 .
2.0 kg (4.4 lbs)
Improperly loading your motorcycle can
The weight of added accessories will reduce affect its stability and handling. Even if your
the maximum cargo weight you can carry. motorcycle is properly loaded, you should
ride at reduced speeds and never exceed
130 km/h (80 mph) when carrying cargo.

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Follow these guidelines whenever you carry Accessories and Modifications

a passenger or cargo: Modifying your motorcycle or using non-
Keep cargo small and light. Make sure it Honda accessories can make your
cannot easily be caught on brush or other motorcycle unsafe. Before you consider
objects, and that it does not interfere with making any modifications or adding an
your ability to shift position to maintain accessory, be sure to read the following
balance and stability. information.
Place weight as close to the center of the
motorcycle as possible.
Do not attach large or heavy items (such
as a sleeping bag or tent) to the
handlebar, fork, or front fender. Improper accessories or modifications
Make sure that all cargo is tied down can cause a crash in which you can be
securely. seriously hurt or killed.
Never exceed the maximum weight limit.
Check that both tyres are inflated Follow all instructions in this owner’s
properly. manual regarding accessories and
modifications.

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Accessories Do not pull a trailer or sidecar with your

We strongly recommend that you use only motorcycle. This motorcycle was not
genuine Honda accessories that have been designed for these attachments, and their
specifically designed and tested for your use can seriously impair your motorcycle’s
motorcycle. Because Honda cannot test all handling.
other accessories, you must be personally
responsible for proper selection, installation Modifications
and use of non-Honda accessories. Check We strongly advise you not to remove any
with your dealer for assistance and always original equipment or modif y your
follow these guidelines: motorcycle in any way that would change its
design or operation. Such changes could
Make sure the accessory does not reduce seriously impair your motorcycle’s handling,
ground clearance and lean angle, limit stability and braking, making it unsafe to
suspension travel or steering travel, alter ride.
your riding position or interfere with
operating any controls. Removing or modif ying your lights,
mufflers, emission control system or other
Be sure electrical equipment does not equipment can also make your motorcycle
exceed the motorcycle’s electrical system illegal.
capacity (page 118 ). A blown fuse can
cause a loss of lights or engine power.

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OFF-ROAD SAFETY Spark arresters and mufflers are required

Learn to ride in an uncongested off-road in most off-road areas. Don’t modify your
area free of obstacles before venturing onto exha ust syst em. R emember t hat
unfamiliar terrain. excessive noise bothers everyone and
Always obey local off-road riding laws and creates a bad image for motorcycling.
regulations.
Obtain permission to ride on private
property. Avoid posted areas and obey
‘‘NO Trespassing’’ signs.
Ride with a friend on another motorcycle
so that you can assist each other in case
of trouble.
Familiarity with your motorcycle is
critically important should a problem
occur far from help.
Never ride beyond your ability and
experience or faster than conditions
warrant.
If you are not familiar with the terrain,
ride cautiously. Hidden rocks, holes, or
ravines could spell disaster.

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PARTS LOCATION

Indicators
Speedometer
Tachometer Rearview mirrors
Rearview Headlight dimmer
mirror switch
Front brake fluid
Choke lever reservoir

Passing
switch
Front brake
Clutch lever lever

Hazard switch
Throttle grip
Turn signal switch
Engine stop switch

Starter button
Horn button
Ignition switch

Fuel fill cap

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Seat lock
Air cleaner

Helmet holder

Coolant reserve tank

Tool box

Passenger footpeg

Gearshift pedal Foot peg Side stand

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Battery

Passenger
footpeg

Oil filler cap/dipstick Foot peg Rear brake pedal

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INSTRUMENTS AND
INDICATORS
The indicators are contained in the (5) (6)
(3) (4) (7)
instrument panel. Their functions are (2) (8)
described in the tables on the following (1)
pages. (9)

(1) Left turn signal indicator

(2) Speedometer
(3) Odometer
(4) Low oil pressure indicator
(5) Neutral indicator
(6) Immobilizer system (HISS) indicator
(7) Tachometer
(8) Tachometer red zone
(9) Right turn signal indicator
(10) Coolant temperature gauge
(11) Digital clock
(12) High beam indicator (15) (14) (13) (12) (11) (10)
(13) Tripmeter
(14) Tripmeter reset knob
(15) Fuel gauge

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(Ref.No.) Description Function

(1) Left turn signal indicator Flashes when the left turn signal operates.

(2) Speedometer Shows riding speed in miles (For E type) or

kilometers (Except E type) per hour.

(3) Odometer Shows accumulated mileage.

(4) Low oil pressure Lights when the engine oil pressure is below normal
indicator (red) operating range. Should light when ignition switch is
ON and engine is not running. Should go out when
the engine starts, except for occasional flickering at
or near idling speed when engine is warm.

Running the engine with insufficient oil pressure may

cause serious engine damage.

(5) Neutral indicator (green) Lights when the transmission is in neutral.

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(Ref.No.) Description Function

(6) Immobilizer system This indicator lights for a few seconds when the
(HISS) indicator ignition switch is turned ON and the engine stop
switch is at (RUN). It will then go off if the
properly-coded key has been inserted. If an
improperly-coded key has been inserted, the
indicator will remain on and the engine will not start
(page 38 ).

(7) Tachometer Shows engine revolutions per minute.

(8) Tachometer red zone Never allow the tachometer needle to enter the red
zone, even after the engine has been broken in.

Running the engine beyond recommended maximum

engine speed (the beginning of the tachometer red
zone) can damage the engine.

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(Ref.No.) Description Function

(9) Right turn signal indicator Flashes when the left turn signal operates.

(10) Coolant T emperature Shows coolant temperature (page 17 ).

Gauge

(11) Digital clock Shows hour and minute (page 19 ).

(12) High beam indicator Lights when the headlight is on high beam.

(13) Tripmeter Shows mileage per trip.

(14) Tripmeter reset knob Resets tripmeter to zero (0) by pushing the knob.

(15) Fuel gauge Shows approximate fuel supply available (page 18 ).

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Coolant Temperature Gauge

When the needle begins to move above the
C (Cold) mark, the engine is warm enough
for the motorcycle to be ridden. The normal
operating temperature range is within the
section between the H and C marks. If the
needle reaches the H (Hot) mark, stop the
engine and check the reserve tank coolant
level. Read pages 24 − 25 and do not ride
the motorcycle until the problem has been
corrected.

Exceeding maximum running temperature

may cause serious engine damage.

(1)

(1) Coolant temperature gauge

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Fuel Gauge
When the gauge needle enters the red band,
fuel will be low and you should refill the (1)
tank as soon as possible. (2)
The amount of fuel left in the tank when the
needle enters the red band and with the
vehicle set upright is approximately:
3.6 (0.95 US gal , 0.79 Imp gal)

(1) Fuel gauge

(2) Red band

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Digital clock
Shows hour and minute. To adjust the time,
proceed as follows:

1. Turn the ignition switch ON.

2. Press the ‘‘H’’ button ( 2 ). To advance
time, keep the button down until the
desired hour is displayed.
3. Press the ‘‘M’’ button ( 3 ). To advance,
hold the button down. The display will be
returned to ‘‘00’’ when ‘‘60’’ minutes are
reached without affecting the hour
display. (2) (3)

(1)

(1) Digital clock

(2) ‘‘H’’ button
(3) ‘‘M’’ button

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MAJOR COMPONENTS
(Information you need to operate this motorcycle)
BRAKES Worn pads should be replaced. If the pads
Both the front and rear brakes are the are not worn, have your brake system
hydraulic disc types. inspected for leaks.
As the brake pads wear, the brake fluid
level drops. The recommended brake fluid is DOT 4
There are no adjustments to perform, but brake fluid from a sealed container, or an
fluid level and pad wear must be inspected equivalent.
periodically. The system must be inspected
frequently to ensure there are no fluid leaks. Front (1)
If the control lever or pedal free travel
becomes excessive and the brake pads are
not worn beyond the recommended limit
(page 95 ), there is probably air in the
brake system and it must be bled. See your
Honda dealer for this service.

Front Brake Fluid Level:

With the motorcycle in an upright position,
check the fluid level. It should be above the
LOWER level mark ( 1 ). If the level is at or (1) LOWER level mark
below the LOWER level mark ( 1 ), check
the brake pads for wear (page 95 ). Other Checks:
Make sure there are no fluid leaks. Check
for deterioration or cracks in the hoses and
fittings.
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Rear Brake Fluid Level: Rear

With the motorcycle in an upright position,
check the fluid level. It should be between
the UPPER ( 1 ) and LOWER ( 2 ) level
marks. If the level is at or below the
LOWER level mark (2 ), check the brake (1)
pads for wear (page 96 ).
(2)
Worn pads should be replaced. If the pads
are not worn, have your brake system
inspected for leaks.

The recommended brake fluid is DOT 4

brake fluid from a sealed container, or an (1) UPPER level mark
equivalent. (2) LOWER level mark

Other Checks:
Make sure there are no fluid leaks. Check
for deterioration or cracks in the hoses and
fittings.

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CLUTCH 1. Pull back the rubber dust cover ( 2 ).

Clutch adjustment may be required if the 2. Loosen the lock nut ( 3 ) and turn the
motorcycle stalls when shifting into gear or adjuster ( 4 ). Tighten the lock nut ( 3 )
tends to creep; or if the clutch slips, causing and check the adjustment.
acceleration to lag behind engine speed. 3. If the adjuster is threaded out near its
Minor adjustments can be made with the limit or if the correct free play cannot be
clutch cable adjuster ( 4 ) at the lever ( 1 ). obtained, loosen the lock nut ( 3 ) and turn
Normal clutch lever free play is: in the cable adjuster ( 4 ) completely.
10−20 mm (0.4−0.8 in) Tighten the lock nut ( 3 ) and install the
dust cover.
(1)
(2)

(B)

(A )

(3) (4)
(2) Dust cover (A) Increase free play
(1) Clutch lever (3) Lock nut (B) Decrease free play
(4) Clutch cable adjuster
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4. Loosen the lock nut ( 5 ) at the lower end Other Checks:

of the cable. Turn the adjusting nut ( 6 ) to Check the clutch cable for kinks or signs of
obtain the specified free play. Tighten the wear that could cause sticking or failure.
lock nut ( 5 ) and check the adjustment. L ubricate the clutch cable w it h a
5. Start the engine, pull in the clutch lever commercially available cable lubricant to
and shift into gear. Make sure the engine prevent premature wear and corrosion.
does not stall and the motorcycle does
not creep. Gradually release the clutch (5)
lever and open the throttle. T he
motorcycle should begin to move (6)
smoothly and accelerate gradually.

If proper adjustment cannot be obtained or

the clutch does not work correctly, see your (A )
Honda dealer.

(B)

(5) Lock nut (A) Increase free play

(6) Adjusting nut (B) Decrease free play

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COOLANT The factory provides a 50/50 solution of

Coolant Recommendation antifreeze and distilled water in this
The owner must properly maintain the motorcycle. T his coolant solution is
coolant to prevent freezing, overheating, recommended f or most operating
and corrosion. Use only high quality temperatures and provides good corrosion
ethylene glycol antif reeze containing protection. A higher concentration of
corrosion protection inhibitors specifically antifreeze decreases the cooling system
recommended for use in aluminum engines. performance and is recommended only
(SEE ANTIFREEZE CONTAINER LABEL). when additional protection against freezing
is needed. A concentration of less than 40/
Use only low-mineral drinking water or 60 (40% antifreeze) will not provide proper
distilled water as a part of the antifreeze corrosion protection. During freezing
solution. Water that is high in mineral temperatures, check the cooling system
content or salt may be harmful to the frequently and add higher concentrations of
aluminum engine. antifreeze (up to a maximum of 60%
antifreeze) if required.
Using coolant with silicate inhibitors may
cause premature wear of water pump seals
or blockage of radiator passages.
Using tap water may cause engine damage.

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Inspection If the reserve tank is empty, or if coolant

The reserve tank is located under the left loss is excessive, check for leaks and see
radiator. your Honda dealer for repair.
Check the coolant level in the reserve tank
(3) (1)
( 1 ) while the engine is at the normal
operating temperature with the motorcycle
in an upright position. If the coolant level is
below the LOWER level mark (2 ), remove
the reserve tank cap (3 ) and add coolant
(4)
mixture until it reaches the UPPER level
mark (4 ). Always add coolant to the reserve
tank.
Do not attempt to add coolant by removing
the radiator cap.

(2)

(1) Reserve tank (3) Reserve tank cap

(2) LOWER level mark (4) UPPER level mark

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FUEL
Fuel Tank (3)
The fuel tank capacity including the reserve
supply is:
19.6 (5.18 US gal , 4.31 Imp gal)
To open the fuel fill cap ( 1 ), insert the
ignition key (2 ) and turn it clockwise. The
fuel fill cap is hinged and will lift up.
Do not overfill the tank. There should be no
fuel in the filler neck ( 3 ).
After refueling, to close the fuel fill cap,
push the fuel fill cap into the filler neck until
it snaps closed and locks. Remove the key.

(2) (1)
Petrol is highly flammable and
explosive. You can be burned or
seriously injured when handling fuel. (1) Fuel fill cap (3) Filler neck
(2) Ignition key
Stop the engine and keep heat,
sparks, and flame away.
Refuel only outdoors.
Wipe up spills immediately.

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Use unleaded petrol with a research octane

number of 91 or higher.
The use of leaded petrol will cause If ‘‘spark knock’’ or ‘‘pinking’’ occurs at a
premature damage to the catalytic steady engine speed under normal load,
converters. change brands of petrol. If spark knock or
pinking persists, consult your Honda dealer.
Failure to do so is considered misuse, and
damage caused by misuse is not covered by
Honda’s Limited Warranty.

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Petrol Containing Alcohol Fuel system damage or engine performance

If you decide to use a petrol containing problems resulting from the use of fuels
alcohol (gasohol), be sure it’s octane rating that contain alcohol is not covered under
is at least as high as that recommended by the warranty. Honda cannot endorse the
Honda. There are two types of ‘‘gasohol’’: use of fuels containing methanol since
one containing ethanol, and the other evidence of their suitability is as yet
containing methanol. Do not use petrol that incomplete.
contains more than 10 % ethanol. Do not use Before buying fuel from an unfamiliar
petrol containing methanol (methyl or wood station, try to find out if the fuel contains
alcohol) that does not also contain alcohol. If it does, confirm the type and
cosolvents and corrosion inhibitors for percentage of alcohol used. If you notice
methanol. Never use petrol containing more any undesirable operating symptoms while
than 5 % methanol, even if it has cosolvents using a petrol that contains alcohol, or one
and corrosion inhibitors. that you think contains alcohol, switch to a
petrol that you know does not contain
alcohol.

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ENGINE OIL 5. Reinstall the oil filler cap/dipstick. Check

Engine Oil Level Check for oil leaks.
Check the engine oil level each day before
riding the motorcycle.
The level must be maintained between the
upper ( 1 ) and lower ( 2 ) level marks on the Running the engine with insufficient oil
dipstick ( 3 ). pressure may cause serious engine damage.
1. Start the engine and let it idle for a few
minutes. Make sure the low oil pressure (3)
indicator goes off. If the light remains on,
stop the engine immediately.
2. Stop the engine and put the motorcycle
on its side stand on level ground.
3. After a few minutes, remove the oil filler
cap/dipstick, wipe it clean, and reinsert
the dipstick without screwing it in. (1)
Remove the dipstick. The oil level should
be between the upper and lower marks
on the dipstick.
4. If required, add the specified oil (see (2)
page 69 ) up to the upper level mark. Do
not overfill. (1) Upper level mark
(2) Lower level mark
(3) Oil filler cap/dipstick
29
03/06/03 12:52:30 32MCB600_040

TYRES Air Pressure

To safely operate your motorcycle, the tyres Properly inflated tyres provide the best
must be the proper type (off-road) and size, combination of handling, tread life, and
in good condition with adequate tread, and riding comfort. Generally, underinflated
correctly inflated. tyres wear unevenly, adversely affect
handling, and are more likely to fail from
being overheated. Underinflated tyres can
also cause wheel damage in rocky terrain.
Overinflated tyres make your motorcycle
Using tyres that are excessively worn ride more harshly, are more prone to
or improperly inflated can cause a damage from surface hazards, and wear
crash in which you can be seriously unevenly.
hurt or killed.
Make sure the valve stem caps are secure.
Follow all instructions in this owner’s If necessary, install a new cap.
manual regarding tyre inflation and
maintenance.

30
03/06/03 12:52:38 32MCB600_041

Always check air pressure when your tyres Inspection

are ‘‘cold’’ − when the motorcycle has been Whenever you check the tyre pressures,
parked for at least three hours. If you check you should also examine the tyre treads and
air pressure when your tyres are ‘‘warm’’ − sidewalls for wear, damage, and foreign
when the motorcycle has been ridden for objects:
even a few miles − the readings will be
higher than if the tyres were ‘‘cold’’. This is Look for:
normal, so do not let air out of the tyres to Bumps or bulges in the side of the tyre or
match the recommended cold air pressures the tread. Replace the tyre if you find any
given below. If you do, the tyres will be bumps or bulges.
underinflated. Cuts, splits or cracks in the tyre. Replace
the tyre if you can see fabric or cord.
The recommended ‘‘cold’’ tyre pressures Excessive tread wear.
are:
Also, if you hit a pothole or hard object, pull
to the side of the road as soon as you safely
kPa (kgf/cm , psi) can and carefully inspect the tyres for
damage.
Driver Front 200 (2.00 , 29)
only Rear 200 (2.00 , 29)

Driver and Front 200 (2.00 , 29)

one passenger Rear 225 (2.25 , 32)

31
03/06/03 12:52:43 32MCB600_042

Tread Wear
Replace tyres before tread depth at the
center of the tyre reaches the following
limit:

Minimum tread depth

Front: 1.5 mm (0.06 in)
Rear: 2.0 mm (0.08 in)

〈For Germany〉
German law prohibits use of tyres whose
tread depth is less than 1.6 mm. (2)

(1)

(1) Wear indicator

(2) Wear indicator location mark

32
03/06/03 12:52:46 32MCB600_043

Tube Repair and Replacement

If a tube is punctured or damaged, you
should replace it as soon as possible. A tube
that is repaired may not have the same
reliability as a new one, and it may fail while
you are riding.

If you need to make a temporary repair by

patching a tube or using an aerosol sealant,
ride cautiously at reduced speed and have
the tube replaced before you ride again.
Any time a tube is replaced, the tyre should
be carefully inspected as described on page
31 .

33
03/06/03 12:52:55 32MCB600_044

Tyre Replacement T he r ecommended t yres f or your

The tyres that came on your motorcycle motorcycle are:
were designed to match the performance Front: 90/90−21M/C 54S
capabilities of your motorcycle and provide BRIDGESTONE
the best combination of handling, braking, TW47G
durability and comfort. PLRELLI
MT60

Rear: 120/90−17M/C 64S

BRIDGESTONE
Installing improper tyres on your TW48G
motorcycle can affect handling and PLRELLI
stability. This can cause a crash in MT60
which you can be seriously hurt or
killed. Whenever you replace a tyre, use one that
is equivalent to the original and be sure the
Always use the size and type of tyres wheel is balanced after the new tyre is
recommended in this owner’s manual. installed.

Also remember to replace the inner tube

whenever you replace a tyre. The old tube
will probably be stretched, and if installed in
a new tyre, it could fail.

34
03/06/03 12:53:02 32MCB600_045

ESSENTIAL INDIVIDUAL COMPONENTS

IGNITION SWITCH
The ignition switch ( 1 ) is below the
indicator panel.

The headlight and taillights will come on

whenever you turn the ignition switch
ON. If your motorcycle is stopped with
the ignition switch ON and the engine is
not running, the headlight and taillights
will still be on, resulting in battery
discharge.
(1)

(1) Ignition switch

Key Position Function Key Removal
LOCK Steering is locked. Engine and lights cannot be Key can be
(steering lock) operated. removed
OFF Engine and lights cannot be operated. Key can be
removed
ON Engine and lights can be operated. Key cannot be
removed
When the harzard switch is ON, both left and Key cannot be
(hazard) right turn signals flash. removed
Engine and lights cannot be operated.
35
03/06/03 12:53:06 32MCB600_046

KEYS
This motorcycle has two keys and a key
number plate.

(2)

(1)

(1) Keys (2) Key number plate

36
03/06/03 12:53:13 32MCB600_047

You will need the key number if you ever If all keys are lost, the ignition control
have to replace a key. Store the plate in a module must be replaced. To avoid this
safe place. possibility we recommend that if only one
key is left, you immediately have it
To reproduce keys, bring all keys, key reproduced to ensure that a back-up is
number plate and motorcycle to your Honda available.
dealer. These keys contain electronic circuits that
are activated by the immobilizer system
Up to four keys can be registered with the (HISS). They will not work to start the
immobilizer system (HISS), including the engine if the circuits are damaged.
ones in hand. Do not drop the keys or set heavy objects
on them.
Do not grind, drill or in any way alter the
original shape of the keys.
Keep the keys away from magnetic
objects.

37
03/06/03 12:53:18 32MCB600_048

IMMOBILIZER SYSTEM (HISS) When the ignition switch is turned ON and

HISS is the abbreviation of Honda Ignition the engine stop switch is at ‘‘ ’’ (RUN),
Security System. the immobilizer system (HISS) indicator
( 1 ) lights for a few seconds, then go off. If
The immobilizer system (HISS) protects the indicator remains on, it means the
your motorcycle from theft. A properly- system does not recognize the coding of the
coded key must be used in the ignition key. Turn the ignition switch to OFF,
switch for the engine to start. If an remove the key, reinsert and turn the
improperly-coded key (or other device) is switch ON again.
used the engine’s starting circuit is disabled.
(1)

(1) Immobilizer system (HISS) indicator

38
03/06/03 12:53:25 32MCB600_049

If the system repeatedly does not recognize EC Directives

the coding of your key, contact your Honda This immobilizer system complies with the
dealer. R & TTE (Radio equipment and telecommu-
The system may not recognize the key’s nications terminal equipment and the
coding if any other immobilizer key is mutual recognition of their conformity)
near the ignition switch. To make sure Directive.
the system recognize the key code, keep
each immobilizer key on a separate ring.
Do not attempt to alter the immobilizer
system (HISS) or add other devices to it.
Electrical problems could result, making The declaration of conformity to R & TTE
it impossible to start your motorcycle. Directive is provided to the owner at the
If all keys are lost, the ignition control time of purchase. The declaration of
module must be replaced. conformity should be kept at a safe place.
When the declaration of conformity is lost
or is not provided, contact your Honda
dealer.

39
03/06/03 12:53:32 32MCB600_050

RIGHT HANDLEBAR CONTROLS When the starter button is pressed, the

starter motor cranks the engine, the
Engine Stop Switch headlight will automatically go out, but the
The engine stop switch ( 1 ) is next to the taillights will stay on. If the engine stop
throttle grip. When the switch is in the switch is in the (OFF) position, the
(RUN) position, the engine will operate. starter motor will not operate. See page
When the switch is in the (OFF) 52 for the starting procedure.
position, the engine will not operate. This
switch is intended primarily as a safety or
emergency switch and should normally (1)
remain in the (RUN) position.

If your motorcycle is stopped with the

ignition switch ON and the engine stop
switch (OFF), the headlight and
taillights will still be on, resulting in battery
discharge.

Starter Button (2)

The starter button ( 2 ) is below the engine
stop switch ( 1 ).
(1) Engine stop switch
(2) Starter button

40
03/06/03 12:53:42 32MCB600_051

LEFT HANDLEBAR CONTROLS With the ignition switch is position, the

signals continue flashing even the engine or
Headlight Dimmer Switch ( 1) other lights are OFF.
Push the dimmer switch to (HI) to
select high beam or to (LO) to select
low beam.

Passing Light Control Switch (2 ) (2) (1)

(5)
When this switch is pressed, the headlight
flashes on to signal approaching cars or
when passing.

Turn Signal Switch ( 3 )

Move to (L ) to signal a lef t t urn,
(R) to signal a right turn. Press to turn
signal off.

Horn Button (4 ) (3)

(4)
Press the button to sound the horn.
(1) Headlight dimmer switch
Hazard Switch ( 5) (2) Passing light control switch
When the hazard switch is (ON) (3) Turn signal switch
position, both left and right turn signals (4) Horn button
start flashing. (5) Hazard switch
41
03/06/03 12:53:49 32MCB600_052

FEATURES
(Not required for operation)
STEERING LOCK (1)
To lock the steering, turn the handlebar all To lock
the way to the left, turn the key ( 1 ) to
LOCK while pushing in. Remove the key. (A)
To unlock the steering, turn the key to OFF
while pushing in.
(B)
Do not turn the key to LOCK while riding
the motorcycle; loss of vehicle control will
result. (C)

(A )

To unlock

(1) Ignition key (A) Push in

(B) Turn to LOCK
(C) Turn to OFF

42
03/06/03 12:53:55 32MCB600_053

SEAT
To remove the seat ( 1 ), insert the ignition (4) (3) (1) (3)
key into the seat lock ( 2 ) and turn it
clockwise. Pull the seat back and up.
To install the seat, insert the prongs ( 3 )
into the recess ( 4 ) under the frame cross
member and then push down on the rear of
the seat. (4)

Be sure the seat is locked securely in

position after installation.

(4) (2)

(1) Seat (3) Prongs

(2) Seat lock (4) Recess
43
03/06/03 12:54:01 32MCB600_054

HELMET HOLDER
The helmet holders are located below the
seat. (1)
Remove the seat (page 43 ).
Hang the helmets on the holder hook ( 1 ).
Install the seat and lock it securely.

Riding with a helmet attached to the

holder can interfere with the rear wheel
or suspension and could cause a
crash in which you can be seriously
hurt or killed.

Use the helmet holder only while

parked. Do not ride with a helmet
secured by the holder.

(1) Holder hook

44
03/06/03 12:54:09 32MCB600_055

LEFT SIDE COVER

The left side cover must be removed for (2) (3)
fuse maintenance.

Removal:
1. Remove the seat (page 43 ).
2. Remove the three bolts ( 1 ).
3. Remove the seat lock cable ( 2 ) from the
seat lock ( 3 ).
4. Remove the left side cover ( 4 )

Installation:
Installation can be done in the reverse (1)
order of removal.

(4)

(1) Bolts
(2) Seat lock cable
(3) Seat lock
(4) Left side cover
45
03/06/03 12:54:17 32MCB600_056

RIGHT SIDE COVER

The right side cover must be removed for
battery and fuse maintenance.

Removal:
1. Remove the seat (page 43 ).
2. Remove the three bolts ( 1 ).
3. Remove the right side cover (2 )

Installation:
Installation can be done in the reverse
order of removal.

(1) (2)

(1) Bolts
(2) Right side cover

46
03/06/04 14:42:17 32MCB600_057

CENTER COMPARTMENT DOCUMENT COMPARTMENT

The center compartment ( 1 ) is under the The document bag ( 1 ) is in the document
seat. Opening and closing: compartment ( 2 ) under the seat.
See ‘‘SEAT LOCK’’ (page 43 ).
When washing your motorcycle, be careful
MAXIMUM WEIGHT LIMIT: not to flood this area with water.
2.0 kg (4.4 lbs)
(1)
Never exceed the maximum weight limit;
handling and stability may be severely
(2)
affected.

Do not direct water under pressure against

the center compartment as water will be
forced into the compartment.

(1)

(1) Document bag

(1) Center compartment (2) Document compartment
47
03/06/03 12:54:26 32MCB600_058

HEA DL IGHT AIM VERTICAL

ADJUSTMENT
Vertical adjustment can be made by turning
the knob ( 1 ) in or out as necessary.
Obey local laws and regulations.

(A )
(B)

(1)

(1) Knob (A) Up

(B) Down

48
03/06/03 12:54:33 32MCB600_059

OPERATION
PRE-RIDE INSPECTION 1. Engine oil level− add engine oil if
For your safety, it is very important to take required (page 29 ). Check for leaks.
a few moments before each ride to walk 2. Fuel level−fill fuel tank when necessary
around your motorcycle and check its (page 26 ). Check for leaks.
condition. If you detect any problem, be 3. Coolant level−add coolant if required.
sure you take care of it, or have it corrected Check for leaks (pages 24 − 25 ).
by your Honda dealer. 4. Front and rear brakes−check operation;
make sure there is no brake fluid leakage
(pages 20 − 21 ).

Improperly maintaining this motorcycle

or failing to correct a problem before
riding can cause a crash in which you
can be seriously hurt or killed.

Always perform a pre-ride inspection

before every ride and correct any
problems.

49
03/06/03 12:54:40 32MCB600_060

5. Tyres−check condition and pressure

(pages 30 − 34 ).
6. Drive chain−check condition and slack
(page 81 − 86 ). Adjust and lubricate
if necessary.
7. Chain guide slider and slipper−check
slider wear (page 87 ).
8. Throttle−check for smooth opening and
full closing in all steering positions.
9. Lights and horn−check that headlight,
tail/brake light, turn signals, indicators
and horn function properly.
10. Engine stop switch−check for proper
function (page 40 ).
11. Side stand ignition cut-off system−check
for proper function (page 89 ).

50
03/06/03 12:54:46 32MCB600_061

STARTING THE ENGINE Y our motorcycle’s exhaust contains

Always follow the proper starting procedure poisonous carbon monoxide gas. High
described below. levels of carbon monoxide can collect
rapidly in enclosed areas such as a garage.
This motorcycle is equipped with a side Do not run the engine with the garage door
stand ignition cut-off system. The engine closed. Even with the door open, run the
cannot be started if the side stand is down, engine only long enough to move your
unless the transmission is in neutral. If the motorcycle out of the garage.
side stand is up, the engine can be started in
neutral or in gear with the clutch lever Do not use the electric starter for more than
pulled in. After starting with the side stand 5 seconds at a time. Release the starter
down, the engine will shut off if the button for approximately 10 seconds before
transmission is put in gear before raising pressing it again.
the side stand.

To protect the catalytic converters in your

motorcycle’s exhaust system, avoid
extending idling and the use of leaded
petrol.

51
03/06/03 12:54:57 32MCB600_062

Preparation Starting Procedure

Before starting, insert the key, turn the To restart a warm engine, follow the
ignition switch ON and confirm the procedure for ‘‘High Air Temperature’’.
following:
The transmission is in NEUTRAL Normal Air Temperature
(neutral indicator light ON). 10°−35°C (50°−95°F)
The engine stop switch is at (RUN). 1. Pull the choke lever ( 1 ) back all the way
The red low oil pressure indicator is ON. to Fully ON (A ), if the engine is cold.
The immobilizer system (HISS) indicator 2. Start the engine, leaving the throttle
is OFF. closed.
(1)
The low oil pressure indicator should go off
a few seconds after the engine starts. If the
light stays on, stop the engine immediately
and check the engine oil level. (B)

(A )
Operating the engine with insufficient oil
pressure can cause serious engine damage.

(1) Choke lever (A) Fully ON

(B) Fully OFF
52
03/06/03 12:55:06 32MCB600_063

Do not open the throttle when starting the High Air Temperature
engine with the choke ON. This will lean 35°C (95°F) or above
the mixture, resulting in hard starting. 1. Do not use the choke.
2. Open the throttle slightly.
3. Start the engine.

Operating the engine with insufficient oil Low Air Temperature

pressure can cause serious engine damage. 10°C (50°F) or below
1. Follow steps 1 − 2 under ‘‘Normal Air
3. Immediately after the engine starts, Temperature.’’
operate the choke lever ( 1 ) to keep fast 2. When engine speed begins to pick up,
idle at: operate the choke lever to keep fast idle
2,000−3,000 min (rpm) at:
4. About a half minute after the engine 2,000−3,000 min (rpm)
starts, push the choke lever ( 1 ) forward 3. Continue warming up the engine until it
all the way to Fully OFF (B ). runs smoothly and responds to the
5. If idling is unstable, open the throttle throttle when the choke lever ( 1 ) is at
slightly. Fully OFF ( B).

Extended use of the choke may impair

piston and cylinder wall lubrication and
damage the engine.
53
03/06/03 12:55:10 32MCB600_064

Flooded Engine RUNNING-IN

If the engine fails to start after repeated Help assure your motorcycle’s future
attempts, it may be flooded with excess fuel. reliability and performance by paying extra
To clear a flooded engine, leave the engine attention to how you ride during the first
stop switch on (RUN) and push the 500 km (300 miles).
choke lever forward to Fully OFF (B ). Open During this period, avoid full-throttle starts
the throttle fully and crank the engine for 5 and rapid acceleration.
seconds. If the engine starts, quickly close
the throttle, then open it slightly if idling is
unstable. If the engine does not start, wait
10 seconds, then follow the Starting
Procedure.

54
03/06/03 12:55:18 32MCB600_065

RIDING 4. When the motorcycle attains a moderate

Review Motorcycle Safety (pages 1 − 9 ) speed, close the throttle, pull in the clutch
before you ride. lever and shift to 2nd gear by raising the
gearshift pedal.
Make sure you understand the function of This sequence is repeated to progressive-
the side stand mechanism. (See MAIN- ly shift to 3rd, 4th and 5th (top) gears.
TENANCE SCHEDULE on page 65 and
explanation for SIDE STAND on page 89 ).

1. After the engine has been warmed up,

the motorcycle is ready for riding.
2. While the engine is idling, pull in the
clutch lever and depress the gearshift
pedal to shift into 1st (low) gear.
3. Slowly release the clutch lever and at the
same time gradually increase engine
speed by opening the throt tle.
Coordination of the throttle and clutch
lever will assure a smooth positive start.

55
03/06/03 12:55:24 32MCB600_066

5. Raise the pedal to shift to a higher gear Do not downshift when traveling at a
and depress the pedal to shift to a lower speed that would force the engine to
gear. Each stroke of the pedal engages overrev in the next lower gear; the rear
the next gear in sequence. The pedal wheel may lose traction, resulting in a
automatically returns to the horizontal possible loss of vehicle control.
position when released. Do not shift gears without disengaging
the clutch and closing the throttle. The
engine and drive train could be damaged
by overspeed and shock.
Do not tow the motorcycle or coast for
long distances while the engine is off.
The transmission will not be properly
lubricated and damage may result.
Do not run the engine at high rpm with
the transmission in neutral or the clutch
lever pulled in. Serious engine damage
may result.

56
03/06/03 12:55:31 32MCB600_067

BRAKING When riding in wet or rainy conditions, or

For normal braking, gradually apply both on loose surfaces, the ability to maneuver
the f ront and rear brakes while and stop will be reduced. All of your
downshifting to suit your road speed. actions should be smooth under these
For maximum deceleration, close the conditions. Rapid acceleration, braking or
throttle and apply the front and rear brakes turning may cause loss of control. For
firmly. Pull in the clutch lever before your safety, exercise extreme caution
coming to a complete stop to prevent when braking, accelerating or turning.
stalling the engine. When descending a long, steep grade,
use engine compression braking by down-
Important Safety Reminders: shifting, with intermittent use of both
Independent operation of only the brake brakes.
lever or brake pedal reduces stopping Continuous brake application can
performance. overheat the brakes and reduce their
Extreme application of the brake controls effectiveness.
may cause wheel lock, reducing control of Riding with your foot resting on the
the motorcycle. brake pedal or your hand on the brake
When possible, reduce speed or brake lever may actuate the brakelight, giving a
before entering a turn; closing the false indication to other drivers. It may
throttle or braking in mid-turn may cause also overheat the brakes, reducing
wheel slip. Wheel slip will reduce control effectiveness.
of the motorcycle.

57
03/06/03 12:55:36 32MCB600_068

PARKING Make sure flammable materials such as dry

1. After stopping the motorcycle, shift the grass or leaves do not come in contact with
transmission into neutral, turn the the exhaust system when parking your
handlebar fully to the left, turn the motorcycle.
ignition switch OFF and remove the key.
2. Use the side stand to support the
motorcycle while parked.

Park the motorcycle on firm, level ground to

prevent it from falling over.
If you must park on a slight incline, aim the
front of the motorcycle uphill to reduce the
possibility of rolling off the side stand or
overturning.

3. Lock the steering to help prevent theft

(page 42 ).

58
03/06/03 12:55:40 32MCB600_069

ANTI-THEFT TIPS NAME:

1. Always lock the steering and never leave
the key in the ignition switch. This ADDRESS:
sounds simple but people do forget.
2. Be sure the registration information for
your motorcycle is accurate and current.
3. Park your motorcycle in a locked garage
whenever possible.
4. Use an additional anti-theft device of PHONE NO:
good quality.
5. Put your name, address, and phone
number in this Owner’s Manual and keep
it on your motorcycles at all times.
Many times stolen motorcycles are
identified by information in the Owner’s
Manuals that are still with them.

59
03/06/03 12:55:47 32MCB600_070

MAINTENANCE
THE IMPORTANCE OF recommendations applicable to your
MAINTENANCE individual needs and use.
A well-maintained motorcycle is essential
for safe, economical and trouble-free riding. If your motorcycle overturns or becomes
It will also help reduce air pollution. involved in a crash, be sure your Honda
dealer inspects all major parts, even if you
Because this motorcycle is capable of being are able to make some repairs.
ridden over rough off-road terrain as well as
on pavement, careful pre-ride inspections
and good maintenance are especially
important.
Improperly maintaining this motorcycle
To help you properly care for your or failing to correct a problem before
motorcycle, the following pages include a you ride can cause a crash in which
Maintenance Schedule and a Maintenance you can be seriously hurt or killed.
R ecord f or regularly scheduled
maintenance. Always follow the inspection and
maintenance recommendations and
These instructions are based on the schedules in this owner’s manual.
assumption that the motorcycle will be used
exclusively for its designed purpose.
Sustained high speed operation or operation
in unusually wet or dusty conditions will
require more f requent service than
specified in the Maintenance Schedule.
Consult your Honda dealer f or
60
03/06/03 12:55:51 32MCB600_071

MAINTENANCE SAFETY
This section includes instructions on some
important maintenance tasks. You can
perform some of these tasks with the tools Failure to properly follow maintenance
provided − if you have basic mechanical instructions and precautions can
skills. cause you to be seriously hurt or killed.

Other tasks that are more difficult and Always follow the procedures and
require special tools are best performed by precautions in this owner’s manual.
professionals. Wheel removal should
normally be handled only by a Honda
technician or other qualified mechanic;
instructions are included in this manual only
to assist in emergency service.

Some of the most important saf ety

precautions follow. However, we cannot
warn you of every conceivable hazard that
can arise in performing maintenance. Only
you can decide whether or not you should
perform a given task.

61
03/06/03 12:55:58 32MCB600_072

SAFETY PRECAUTIONS To reduce the possibility of a fire or

Make sure the engine is off before you explosion, be careful when working
begin any maintenance or repairs. This around petrol. Use only nonflammable
will help eliminate several potential solvent, not petrol, to clean parts. Keep
hazards: cigarettes, sparks and flames away from
Carbon monoxide poisoning from all fuel-related parts.
engine exhaust.
Be sure there is adequate ventilation Remember that your Honda dealer knows
whenever you operate the engine. your motorcycle best and is fully equipped
Burns from hot parts. to maintain and repair it.
Let the engine and exhaust system cool
before touching. To ensure the best quality and reliability,
Injury from moving parts. use only new genuine Honda parts or their
Do not run the engine unless instructed equivalents for repair and replacement.
to do so.
Read the instructions before you begin,
and make sure you have the tools and
skills required.
To help prevent the motorcycle from
falling over, park it on a firm, level
surface, using the side stand or a
maintenance stand to provide support.

62
03/06/03 12:56:06 32MCB600_073

MAINTENANCE SCHEDULE
Perform the Pre-ride Inspection (page 49 ) at each scheduled maintenance period.
I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY
C: CLEAN R: REPLACE A: ADJUST L: LUBRICATE
The following Maintenance Schedule specifies all maintenance required to keep your motorcycle in peak operating
condition. Maintenance work should be performed in accordance with standards and specifications of Honda by
properly trained and equipped technicians. Your Honda dealer meets all of these requirements.

Should be serviced by your Honda dealer, unless the owner has proper tools and service data and is mechanically
qualified. Refer to the Official Honda Shop Manual.
In the interest of safety, we recommend these items be serviced only by your Honda dealer.

Honda recommends that your Honda dealer should road test your motorcycle after each periodic maintenance is
carried out.

NOTES: (1) At higher odometer readings, repeat at the frequency interval established here.
(2) Service more frequently if the motorcycle is ridden 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 interval, whichever comes first. Replacement requires
mechanical skill.
(5) Service more frequently when riding OFF-ROAD.

63
03/06/03 12:56:23 32MCB600_074

FREQUENCY WHICHEVER →
COMES ODOMETER READING [NOTE (1)]
FIRST × 1,000 km 1 6 12 18 24 30 36 Refer
↓ × 1,000 mi 0.6 4 8 12 16 20 24 to
ITEM NOTE MONTH 6 12 18 24 30 36 Page
FUEL LINE I I I −
FUEL STRAINER SCREEN C C C C C C −
THROTTLE OPERATION I I I 78
CARBURETOR CHOKE I I I −
AIR CLEANER NOTE (2) R R −
CRANKCASE BREATHER NOTE (3) C C C C C C 77
SPARK PLUG I R I R I R 73
VALVE CLEARANCE I I I I −
ENGINE OIL R R R R 69
ENGINE OIL FILTER R R R R 70
CARBURETOR SYNCHRONIZATION I I I I −
ENGINE IDLE SPEED I I I I I I I 79
RADIATOR COOLANT NOTE (4) I I R 25
COOLING SYSTEM I I I −
SECONDARY AIR SUPPLY SYSTEM I I I −

64
03/06/03 12:56:40 32MCB600_075

FREQUENCY WHICHEVER →
ODOMETER READING ［ NOTE (1) ］
COMES
FIRST × 1,000 km 1 6 12 18 24 30 36 Refer
↓ × 1,000 mi 0.6 4 8 12 16 20 24 to
ITEM NOTE MONTH 6 12 18 24 30 36 Page
DRIVE CHAIN NOTE (5) I, L EVERY 1,000 km (600 mi) 81
DRIVE CHAIN SLIDER I I I I I I 87
BRAKE FLUID NOTE (4) I I R I I R 20
BRAKE PAD WEAR I I I I I I 95
BRAKE SYSTEM I I I I 20 , 95
BRAKE LIGHT SWITCH I I I 102
HEADLIGHT AIM I I I 48
CLUTCH SYSTEM I I I I I I I 22
SIDE STAND I I I 89
SUSPENSION I I I 88
NUTS, BOLTS, FASTENERS NOTE (5) I I I I −
WHEELS/TYRES NOTE (5) I I I I I I I −
STEERING HEAD BEARINGS I I I I −

65
03/06/03 12:56:55 32MCB600_076

TOOL KIT
The tool kit ( 1 ) is under the seat (page 43 ).
Some roadside repairs, minor adjustments
and parts replacement can be performed (1)
with the tools contained in the kit.
Spark plug wrench
10 × 12 mm Box end wrench
17 mm Box end wrench
24 mm Box end wrench
14 × 17 mm Open end wrench
10 × 12 mm Open end wrench
8 × 12 mm Open end wrench
No. 2 phillips screwdriver
No. 3 phillips screwdriver
No. 2 screwdriver
Screwdriver T-handle
Pliers
Extension bar
5 mm Hex wrench
Tool bag (1) Tool kit

66
03/06/03 12:57:01 32MCB600_077

SERIAL NUMBERS The frame number ( 1 ) is stamped on the

The frame and engine serial numbers are right side of the steering head.
required when registering your motorcycle.
They may also be required by your dealer The engine number (2 ) is stamped on the
when ordering replacement parts. right side of the cylinder.
Record the numbers here f or your
reference.

FRAME NO. ENGINE NO.

(2)
(1)

(1) Frame number (2) Engine number

67
03/06/03 12:57:07 32MCB600_078

COLOUR LABEL
The colour label ( 1 ) is attached to the right
frame rail below the seat.
It is helpful when ordering replacement
parts. Record the colour and code here for
your reference.

COLOUR

CODE

(1)

(1) Colour label

68
03/06/03 12:57:14 32MCB600_079

ENGINE OIL
Refer to the Safety Precautions on page 62 .

Engine Oil
Good engine oil has many desirable
qualities. Use only high detergent, quality
motor oil certified on the container to meet
or exceed requirements for API Service
Classification SE, SF or SG.

Viscosity:
Viscosity grade of engine oil should be
based on average atmospheric temperature
in your riding area. The following provides a
guide to the selection of the proper grade or
viscosity of oil to be used at various
atmospheric temperatures.

(1) Single grade (2) Multi grade

69
03/06/03 12:57:19 32MCB600_080

Engine Oil and Filter Changing the oil filter requires a special oil
Engine oil quality is the chief factor filter tool and a torque wrench. If you do not
affecting engine service life. Change the have these tools and the necessary skill, we
engine oil as specified in the maintenance recommend that you have your Honda
schedule (page 64 ). dealer perform this service.
When running in very dusty conditions, oil
changes should be perf ormed more If a torque wrench is not used for this
f requently than specif ied in the installation, see your Honda dealer as soon
maintenance schedule. as possible to verify proper assembly.

Please dispose of used engine oil in a Change the engine oil with the engine at
manner that is compatible with the normal operating temperature and the
environment. We suggest you take it in a motorcycle on its side stand to assure
sealed container to your local recycling complete and rapid draining.
center or service station for reclamation. Do
not throw it in the trash or pour it on the
ground or down a drain.

Used engine oil may cause skin cancer if

repeatedly left in contact with the skin for
prolonged periods. Although this is unlikely
unless you handle used oil on a daily basis,
it is still advisable to thoroughly wash your
hands with soap and water as soon as possi-
ble after handling used oil.

70
03/06/03 12:57:25 32MCB600_081

1. To drain the oil, remove the oil filler cap/ 2. Remove the oil filter ( 3 ) with a filter
dipstick and crankcase drain plug ( 1 ) and wrench and let the remaining oil drain out.
sealing washer ( 2 ). Discard the oil filter.

(1) (3)

(2)

(1) Crankcase drain plug (2) Sealing washer (3) Oil filter
71
03/06/03 12:57:35 32MCB600_082

3. Apply a thin coat of engine oil to the new 5. Check that the sealing washer on the
oil filter rubber seal (4 ). drain plug is in good condition and install
4. Using a special tool and a torque wrench, the plug. Replace the sealing washer
install the new oil filter and tighten to a every other time the oil is changed, or
torque of: each time if necessary.
9.8 N·m (1.0 kgf·m , 7 lbf·ft) Oil Drain Plug Torque:
30 N·m (3.1 kgf·m , 22 lbf·ft)
Use only the Honda genuine oil filter or a 6. Fill the crankcase with the recommended
filter of equivalent quality specified for your grade oil; approximately:
model. Using the wrong Honda filter or a 2.3 (2.4 US qt , 2.0 Imp qt)
non-Honda filter which is not of equivalent 7. Install the oil filler cap/dipstick.
quality may cause engine damage. 8. Start the engine and let it idle for 3−5
minutes.
9. 2−3 minutes after stopping the engine,
(4) check that the oil level is at the upper
level mark on the oil filler cap/dipstick
with the motorcycle upright on firm, level
ground. Make sure there are no oil leaks.

(4) Oil filter rubber seal

72
03/06/03 12:57:44 32MCB600_083

SPARK PLUGS
Refer to the Safety Precautions on page 62 .
Recommended plugs:
Standard:
DPR8EA-9 (NGK) or
X24EPR-U9 (DENSO)
For extended high speed riding:
DPR9EA-9 (NGK) or
X27EPR-U9 (DENSO)
For cold climate: (Below 5°C, 41°F)
DPR7EA-9 (NGK) or
X22EPR-U9 (DENSO)

Never use a spark plug with an improper

heat range. Severe engine damage could
result.

73
03/06/03 12:57:50 32MCB600_084

1. Remove the seat (page 43 ). 3. Remove the fuel tank mounting bolt ( 2 )
2. Remove the left and right front cover and the bushing.
bolts ( 1 ),and disconnect them from the
holders on the fuel tank. (2)

(1)

(1)
(1) Bolts
(2) Fuel tank mounting bolt

74
03/06/03 12:57:55 32MCB600_085

4. To remove the spark plug from the rear 5. Disconnect the spark plug caps from the
cylinder, raise the fuel tank. spark plugs.
6. Clean any dirt from around the spark plug
bases.
Rear cylinder Remove the spark plugs using the spark
plug wrench ( 1 ) furnished in the tool kit.
(1)

Front cylinder

(1)

(1) Spark plug wrench

(1) Spark plug wrench

75
03/06/03 12:58:04 32MCB600_086

7. Inspect the electrodes and center 9. Make sure the plug washer is in good
porcelain for deposits, erosion or carbon condition.
fouling. If the erosion or deposit is heavy, 10. With the plug washer attached, thread
replace the plug. Clean a carbon or wet- the spark plug in by hand to prevent
fouled plug with a plug cleaner, otherwise cross-threading.
use a wire brush. 11. Tighten a new spark plug 1/2 turn with a
8. Check the spark plug gap ( 2 ) using a spark plug wrench to compress the
wire-type feeler gauge. If adjustment is washer. If you are reusing a plug, it
necessary, bend the side electrode ( 3 ) should only take 1/8−1/4 turn after the
carefully. plug seats.
The gap should be:
0.8−0.9 mm (0.03−0.04 in)

(3) The spark plug must be securely tightened.

An improperly tightened plug can become
(2) very hot and possibly damage the engine.

12. Reinstall the spark plug caps.

(2) Spark plug gap

(3) Side electrode
76
03/06/03 12:58:09 32MCB600_087

CRANKCASE BREATHER
Refer to the Safety Precautions on page 62 .

1. Remove the crankcase breather tube plug

( 1 ) from the tube and drain deposits into
a suitable container.
2. Reinstall the crankcase breather tube
plug.

Service more frequently when riding in rain,

at full throttle, or after the motorcycle is
washed or overturned. Service if the deposit
level can be seen in the transparent section
of the drain tube.

(1)

(1) Crankcase breather tube plug

77
03/06/03 12:58:16 32MCB600_088

THROTTLE OPERATION
Refer to the Safety Precautions on page 62 .

1. Check for smooth rotation of the throttle

grip from the fully open to the fully
closed position at both full steering
positions.
2. Measure the throttle grip free play at the
throttle grip flange.
The standard free play should be
approximately:
2.0−6.0 mm (0.08−0.24 in)

To adjust the free play, loosen the lock nut

( 1 ) and turn the adjuster ( 2 ).

(2) (1)

(1) Lock nut (2) Adjuster

78
03/06/03 12:58:23 32MCB600_089

IDLE SPEED
Refer to the Safety Precautions on page 62 .

The engine must be at normal operating (1)

temperature for accurate idle speed
adjustment. Ten minutes of stop-and-go
riding is sufficient.

1. Warm up the engine, and shift to neutral,

and place the motorcycle on its side stand.
2. Adjust idle speed with the throttle stop
screw ( 1 ).
Idle speed (In neutral): (A )
1,200 ± 100 min (rpm) (B)

(1) Throttle stop screw (A) Increase

(B) Decrease

79
03/06/03 12:58:28 32MCB600_090

COOLANT
Refer to the Safety Precautions on page 62 .

Coolant Replacement Removing the radiator cap while the

Coolant should be replaced by a Honda engine is hot can cause the coolant to
dealer, unless the owner has proper tools spray out, seriously scalding you.
and service data and is mechanically
qualified. Refer to an official Honda Shop Always let the engine and radiator cool
Manual. down before removing the radiator cap.

Always add coolant to the reserve tank. Do

not attempt to add coolant by removing the
radiator cap.

80
03/06/03 12:58:40 32MCB600_091

DRIVE CHAIN 3. Roll the motorcycle forward. Stop. Check

Refer to the Safety Precautions on page 62 . the drive chain slack. Repeat this
procedure several times. Drive chain
The service life of the drive chain is slack should remain constant. If the chain
dependent upon proper lubrication and is slack only in certain sections, some
adjustment. Poor maintenance can cause links are kinked and binding. Binding and
premature wear or damage to the drive kinking can frequently be eliminated by
chain and sprockets. lubrication.
The drive chain should be checked and
lubricated as part of the Pre-ride Inspection
(page 49 ). Under severe usage, or when
the motorcycle is ridden in unusually dusty Excessive chain slack may allow the drive
or muddy areas, more f requent chain to damage the engine cases.
maintenance will be necessary.

Inspection: (1)
1. Turn the engine off, raise the rear wheel
off the ground by placing a support under
the engine, and shift the transmission
into neutral.
2. Check slack in the lower drive chain run
midway between the sprockets.
Drive chain slack should be adjusted to
allow the following vertical movement by
hand:
35−45 mm (1.4−1.8 in) (1) Drive chain
81
03/06/03 12:58:46 32MCB600_092

4. Rotate the rear wheel slowly and inspect Damaged sprocket Worn sprocket
the drive chain and sprockets for any of Teeth Teeth
the following conditions:
DRIVE CHAIN Replace Replace
*Damaged Rollers
*Loose Pins
*Dry or Rusted Links
*Kinked or Binding Links
*Excessive Wear
*Improper Adjustment
*Damaged or Missing O-rings
SPROCKETS
*Excessively Worn Teeth
*Broken or Damaged Teeth
A drive chain with damaged rollers, loose Normal sprocket Teeth
pins, or missing O-rings must be replaced. A
chain which appears dry, or shows signs of GOOD
rust, requires supplementary lubrication.
Kinked or binding links should be thor-
oughly lubricated and worked free. If links
cannot be freed, the chain must be replaced.

82
03/06/03 12:58:55 32MCB600_093

Adjustment: If the drive chain requires adjustment, the

Drive chain slack should be checked and procedure is as follows:
adjusted, if necessary, every 1,000 km (600 1. Place the motorcycle on its side stand
miles). When operated at sustained high with the transmission in neutral and the
speeds or under conditions of frequent ignition switch off.
rapid acceleration, the chain may require 2. Loosen the axle nut ( 1 ).
more frequent adjustment. 3. Loosen the lock nuts ( 2 ) on both right
and left swingarm.
(3) (1) 4. Turn both adjusting nuts ( 3 ) an equal
number of turns until the correct drive
chain slack is obtained. Turn the
adjusting nuts clockwise to tighten the
chain, or counterclockwise to provide
more slack. Adjust the chain slack at a
point midway between the drive sprocket
and the rear wheel sprocket. Rotate the
rear wheel and recheck slack at other
sections of the chain.
Chain slack should be:
35−45 mm (1.4−1.8 in)

(2) (5) (4)

(1) Axle nut (4) Index mark

(2) Lock nuts (5) Rear edge of
(3) Adjusting nut adjusting slot
83
03/06/03 12:59:00 32MCB600_094

5. Check rear axle alignment by making

sure the chain adjuster index marks ( 4 )
align with the rear edge ( 5 ) of the
adjusting slots.
Both left and right marks should
correspond. If the axle is misaligned, turn
the left or right adjusting nut until the
marks correspond on the rear edge of the
adjusting slots and recheck chain slack.
6. Tighten the axle nut to specified torque.
Axle nut torque:
88 N·m (9.0 kgf·m , 65 lbf·ft)

If a torque wrench is not used for this

installation, see your Honda dealer as soon
as possible to verify proper assembly.

7. Tighten the adjusting nuts lightly, then

tighten the lock nuts by holding the
adjusting nuts with a spanner.

84
03/06/03 12:59:08 32MCB600_095

Wear Inspection:
Check the chain wear label when adjusting (6)
the chain. If the red zone ( 6 ) on the label
aligns with the arrow mark ( 7 ) on the chain
adjuster plates after the chain has been
adjusted to the proper slack, the chain is
excessively worn and must be replaced. The
proper slack is:
35−45 mm (1.4−1.8 in)
Damage to the bottom part of the frame
may be caused by excessive drive chain
slack of more than:
60 mm (2.4 in)

Replacement chain:
D.I.D. 525 112−120L
or
RK525S 112−120L (7)

(6) Red zone (7) Arrow mark

85
03/06/03 12:59:14 32MCB600_096

Lubrication and Cleaning:

Lubricate every 1,000 km (600 miles) or
sooner if chain appears dry.

The drive chain on this motorcycle is

equipped with small O-rings between the
link plates. These O-rings retain grease
inside the chain to improve its service life.
The O-rings in this chain can be damaged
by steam cleaning, high pressure washers,
and certain solvents. Clean the side surfaces
of the chain with a dry cloth. Do not brush
the rubber O-rings. Brushing will damage
them. Wipe dry and lubricate only with SAE
80 or 90 gear oil. Commercial chain lubri-
cants may contain solvents which could
damage the rubber O-rings.

86
03/06/03 12:59:20 32MCB600_097

DRIVE CHAIN SLIDER

Refer to the Safety Precautions on page 62 .
(1)
Check the chain slider ( 1 ) for wear.
When the thickness ( 2 ) of the chain slider
reaches the limit, the chain slider must be
replaced. Chain slipper depth limit:
2.0 mm(0.08 in)

(2)

(1) Chain slider (2) Thickness

87
03/06/03 12:59:24 32MCB600_098

FRONT A ND R EA R SUSPENSION
INSPECTION
Refer to the Safety Precautions on page 62 .

1. Check the fork assembly by locking the

front brake and pumping the fork up and
down vigorously. Suspension action
should be smooth and there must be no
oil leakage.
2. Swingarm bearings should be checked by
pushing hard against the side of the rear
wheel while the motorcycle is on the
center stand. Free play indicates worn
bearings.
3. Carefully inspect all front and rear
suspension fasteners for tightness.

88
03/06/03 12:59:33 32MCB600_099

SIDE STAND
Refer to the Safety Precautions on page 62 .

Perform the following maintenance in

accordance with the maintenance schedule.
Functional Check:
Check the spring ( 1 ) for damage or loss
of tension and the side stand assembly
for freedom of movement.
Check the side stand ignition cut-off
system:
1. Sit astride the motorcycle; put the side
stand up and the transmission in
neutral. (1)
2. Start the engine and with the clutch
lever pulled in, shift the transmission
into gear.
3. Lower the side stand. The engine
should stop as you put the side stand
down.
If the side stand system does not operate as (1) Side stand spring
described, see your Honda dealer for
service.

89
03/06/03 12:59:41 32MCB600_100

WHEEL REMOVAL
Refer to the Safety Precautions on page 62 .
(1)
This motorcycle is equipped with a side
stand only. Therefore, if front or rear wheel
removal is required, it will be necessary to
raise the center of the motorcycle with a
jack or other firm support. If none is
available, see your Honda dealer for this
(2)
service.

Front Wheel Removal

1. Raise the front wheel off the ground by
placing a support block under the engine.
2. Remove the speedometer cable set screw
( 1 ) and disconnect the speedometer
cable ( 2 ).

(1) Screw
(2) Speedometer cable

90
03/06/03 12:59:48 32MCB600_101

3. Remove the caliper assembly from the Do not depress the brake lever when the
fork leg by removing the fixing bolts ( 6 ). caliper assembly is removed. The caliper
4. Remove the front axle holder nuts ( 3 ) piston will be forced out of the cylinder with
and frontal axle holder ( 4 ). subsequent loss of brake fluid. If this occurs,
servicing of the brake system will be
To avoid damage to the brake hose, support necessary. See your Honda dealer for this
the caliper assembly so that it doesn’t hang service.
from the hose. Do not twist the brake hose.
5. Unscrew the front axle shaft ( 5 ).
(4) Remove the wheel.

(3)
(6)
(6)

(5)

(3) Axle holder nuts

(4) Axle holder (6) Fixing bolts
(5) Front axle shaft
91
03/06/03 12:59:59 32MCB600_102

Installation: If a torque wrench was not used for

1. Reverse the removal procedure. installation, see your Honda dealer as soon
Insert the axle through the left fork leg as possible to verify proper assembly.
and wheel hub. Improper assembly may lead to loss of
2. Make sure that leg lug ( 7 ) on the braking capacity.
speedometer gearbox is located behind
the lug ( 8 ) on the right front fork ( 9 ) leg.
3. Install the axle holder with the UP mark (8)
(10 ) upward and approach the upper
holder nuts first, then the lower holder (10) (7)
nuts.
4. Tighten the front axle shaft to the
specified torque.
Front axle shaft torque :
64 N·m (6.5 kgf·m , 47 lbf·ft)
5. Tighten the axle holder nut to the
specified torque :
12 N·m (1.2 kgf·m , 9 lbf·ft)
Install the brake caliper and tighten to the
specified torque: (9)
33 N·m (3.4 kgf·m , 25 lbf·ft)
6. After installing the wheel, apply the brake
several times and then check if the wheel
rotate freely. Recheck the wheel if the
brake drags or if the wheel does not (7) Leg lug (9) Right front fork
rotate freely. (8) Lug (10) UP mark
92
03/06/03 13:00:09 32MCB600_103

Rear Wheel Removal 5. Remove the rear axle shaft ( 5 ), rear

1. Raise the rear wheel off the ground by wheel from the swingarm.
placing a support block under the engine.
2. Loosen the drive chain adjusting nut lock Do not depress the brake pedal while the
nuts ( 1 ) and adjusting nuts ( 2 ). wheel is off the motorcycle. The caliper
3. Remove the rear axle nut ( 3 ). pistons will be forced out of the cylinders
4. Remove the drive chain ( 4 ) from the with subsequent loss of brake fluid. If this
driven sprocket by pushing the rear occurs, servicing of the brake system will be
wheel forward. necessary. See your Honda dealer for this
service.

(2)
(1)

(1)
(3)

(5)

(2) (4)

(1) Lock nut (3) Axle nut (4) Drive chain

(2) Adjusting nuts (5) Rear axle shaft
93
03/06/03 13:00:18 32MCB600_104

Installation Notes: If a torque wrench was not used for

1. To install the rear wheel, reverse the installation, see your Honda dealer as soon
removal procedure. as possible to verify proper assembly.
2. Make sure the tang ( 6 ) on the swingarm Improper assembly may lead to loss of
is located in the slot ( 7 ) in the brake braking capacity.
panel ( 8 ).
3. Install the rear axle shaft, side collar and
rear wheel to the swingarm.
4. Tighten the axle nut to the specified
torque: (8)
88 N·m (9.0 kgf·m , 65 lbf·ft)
5. Adjust the drive chain.
(6)
When installing the wheel, carefully fit the
brake disc between the brake pads to avoid
damaging the pads.

After installing the wheel, apply the brake

several times and then check if the wheel
rotates freely. Recheck the wheel if the (7)
brake drags or if the wheel does not rotate
freely. (6) Tang (8) Brake panel
(7) Slot

94
03/06/03 13:00:24 32MCB600_105

BRAKE PAD WEAR 〈FRONT BRAKE〉

Refer to the Safety Precautions on page 62 .
Illustration shows left side,
Brake pad wear depends upon the severity right side similar.
of usage, the type of riding, and road
conditions. (Generally, the pads will wear
faster on wet and dirty roads.)
Inspect t he pa ds a t each r egular
maintenance interval (page 65 ).

Front Brake
Always inspect each pad in both right and
left brake calipers.
Check the grooves ( 1 ) in each pad.
If either pad is worn to the bottom of the
grooves, replace both pads as a set. See
your Honda dealer for this service.

(1)

(1) Wear indicator grooves

95
03/06/03 13:00:29 32MCB600_106

Rear Brake 〈REAR BRAKE〉

Check the cutout ( 2 ) in each pad.
If either pad is worn to the cutout, replace
both pads as a set. See your Honda dealer
for this service.

(2)

(2) Cutouts

96
03/06/03 13:00:34 32MCB600_107

BATTERY
Refer to the Safety Precautions on page 62 .

It is not necessary to check the battery

electrolyte level or add distilled water as the The battery gives off explosive
battery is a maintenance-free (sealed) type. hydrogen gas during normal operation.
If your battery seems weak and/or is
leaking electrolyte (causing hard starting or A spark or flame can cause the battery
other electrical troubles), contact your to explode with enough force to kill or
Honda dealer. seriously hurt you.

Wear protective clothing and a face

shield, or have a skilled mechanic do
Your battery is a maintenance-free type and the battery maintenance.
can be permanently damaged if the cap strip
is removed.

97
03/06/03 13:00:41 32MCB600_108

Battery Removal
1. Remove the right side cover (page 46 ).
2. Remove the battery holder ( 1 ) by (4)
removing the nut (2 ).
3. Disconnect the negative (−) terminal
lead ( 3 ) from the battery first, then (2)
disconnect the positive (＋) terminal lead
( 4 ).
4. Pull out the battery ( 5 ) from the battery
box.

(3)

(1)

(5)

(1) Battery holder

(2) Nut
(3) Negative (−) terminal lead
(4) Positive (＋) terminal lead
(5) Battery
98
03/06/03 13:00:48 32MCB600_109

FUSE REPLACEMENT
Refer to the Safety Precautions on page 62 .

When frequent fuse failure occurs, it Blown fuse

usually indicates a short circuit or an
overload in the electrical system. See your
Honda dealer for repair.

Never use a fuse with a different rating

from that specified. Serious damage to the
electrical system or a fire may result,
causing a dangerous loss of lights or engine
power.

99
03/06/03 13:00:56 32MCB600_110

Fuse Box:
The fuse box is located behind the left side
cover. (1)
The specified fuses are:
10, 15 A
1. Remove the left side cover (page 45 ).
2. Open the fuse box cover ( 1 ).
3. Pull out the old fuse and install a new fuse.
The spare fuses ( 2 ) are located in the
fuse box.
4. Close the fuse box cover and left side
cover.

(2)

(1) Fuse box cover

(2) Spare fuses

100
03/06/04 11:41:15 32MCB600_111

Main Fuse:
The main fuse ( 1) is located behind the
right side cover. (2)
The specified fuse is:
30 A
1. Remove the right side cover (page 46 ).
2. Disconnect the wire connector ( 2 ) of
the starter magnetic switch.
3. Pull out the old fuse and install a new fuse.
The spare main fuse ( 3 ) is located under
the starter magnetic switch.
4. Reconnect the connector and right side
cover.

(3) (1)

(1) Main fuse

(2) Wire connector
(3) Spare main fuse

101
03/06/03 13:01:10 32MCB600_112

STOPLIGHT SWITCH
ADJUSTMENT
Refer to the Safety Precautions on page 62 .
(1)
Check the operation of the stoplight switch
( 1 ) at the right side behind the engine from
time to time.
Adjustment is done by turning the adjusting
nut ( 2 ). Turn the nut in the direction (A ) if
the switch operates too late and in direction
( B) if the switch operates too soon.
(B) (A )

(2)

(1) Stoplight switch

(2) Adjusting nut

102
03/06/03 13:01:19 32MCB600_113

BULB REPLACEMENT Be sure to turn the ignition switch OFF

Refer to the Safety Precautions on page 62 . when replacing the bulb.
Do not use bulbs other than that specified.
The light bulb becomes very hot while the After installing a new bulb, check that the
light is ON, and remain hot for a while after light operates properly.
it is turned OFF. Be sure to let it cool down
before servicing.
The lighting equipment is not legal for
highway use. Do not operate this
motorcycle on public streets, roads or
highways.

Do not put finger prints on the headlight

bulb, as they may create hot spots on the
bulb and cause it to break.
Wear clean gloves while replacing the bulb.
If you touch the bulb with your bare hands,
clean it with a cloth moistened with alcohol
to prevent its early failure.

103
03/06/03 13:01:30 32MCB600_114

Headlight Bulb
1. Remove the headlight lower cover ( 1 ) by (4)
loosening the two fixing bolts..
2. Pull off the socket ( 2 ) without turning.
3. Remove the dust cover ( 3 ).
4. Remove the bulb ( 5 ) while pressing
down on the pin ( 4 ). (6)
5. Pull out the bulb ( 5 ) without turning.
6. Install a new bulb in the reverse order of
removal.
Install the dust cover with its arrow
mark ( 6 ) facing up.

(5)

(3)
(2)

(1) Headlight lower cover

(2) Socket
(3) Dust cover
(4) Pin
(1) (5) Bulb
(6) Arrow mark
104
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Position Light Bulb

1. Remove the lower maintenance cover ( 1 )
by removing the two screws ( 2 ).
2. Pull the position light socket ( 3 ) and
remove it.
3. Pull out the bulb ( 4 ) without turning.
4. Install a new bulb in the reverse order of
removal.

(1)
(4)
(3)

(1)

(2)
(2)

(1) Lower maintenance cover (3) Socket

(2) Screws (4) Bulb
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Stop/Taillight Bulb (2)

1. Remove the rear handle ( 1 ) by removing
the four screws ( 2 ) and collars A ( 3 ), (5)
collars B ( 4 ). (2)
2. Remove the rear tail ( 5 ).
3. Turn the bulb holder ( 6 ) clockwise and (4)
remove the bulb ( 7 ).
4. Install a new bulb in the reverse order of (2)
removal. (4)
(3)
(4)
(3)

(1)
(7)
(6)

(1) Rear handle (5) Rear tail

(2) Screws (6) Bulb holder
(3) Collars A (7) Bulb
(4) Collars B
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Front Turn Signal Bulb

1. Remove the instrument panel cover by
removing the screws A ( 1 ) and the
screws B ( 2 ). (4)
2. T u r n t h e b u l b h o l d e r ( 3 )
counterclockwise and remove the bulb
( 4 ).
3. Install a new bulb in the reverse order of
removal.
(2) (2)

(3)

(1) (1)

(2)
(1) Screws A (2) Screws B (3) Bulb holder (4) Bulb
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Rear Turn Signal Bulb

1. Remove the screw ( 1 ).
2. Remove the turn signal lens ( 2 ).
3. Remove the bulb ( 3 ) by pressing in and
turning counterclockwise.
4. Install a new bulb and check that the light
operates properly.

(3)

(1)
(2)

(1) Screws (3) Bulb

(2) Turn signal lens
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CLEANING
Clean your motorcycle regularly to protect Washing the motorcycle
the surface finishes and inspect for damage, 1. Rinse the motorcycle thoroughly with
wear, and oil, coolant or brake fluid leakage. cool water to remove loose dirt.
2. Clean the motorcycle with a sponge or
Avoid cleaning products that are not soft cloth using cool water.
specifically designed for motorcycle or Avoid directing water to muffler outlets
automobile surfaces. and electrical parts.
They may contain harsh detergents or 3. Clean the fairing, headlight lens and
chemical solvents that could damage the other plastic parts using a cloth or sponge
metal, paint, and plastic on your motorcycle. dampened with a solution of mild
detergent and water. Rub the soiled area
If your motorcycle is still warm from recent gently rinsing it frequently with fresh
operation, give the engine and exhaust water.
system time to cool off. Take care to keep brake fluid or chemical
solvents off the motorcycle.
We recommend avoiding the use of high They will damage the plastic and painted
pressure water spray (typical in coin- surfaces.
operated car washes).
The inside of the headlight lens may be
clouded immediately after washing the
motorcycle. Moisture condensation inside
High pressure water (or air) can damage the headlight lens will disappear gradually
certain parts of the motorcycle. by lighting the headlight in high beam. Run
the engine while keeping the headlight on.

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4. After cleaning, rinse the motorcycle Finishing Touches

thoroughly with plenty of clean water. After washing your motorcycle, consider
Strong detergent residue can corrode using a comme r cia lly-a v a ilable spr a y
alloy parts. cleaner/polish or quality liquid or paste wax
5. Dry the motorcycle, start the engine, and to finish the job. Use only a non-abrasive
let it run for several minutes. polish or wax made specifically for
6. Test the brakes before riding the motorcycles or automobiles. Apply the
motorcycle. Several applications may be polish or wax according to the instructions
necessary to restore normal braking on the container.
performance.
7. Lubricate the drive chain immediately If a surface on your motorcycle is chipped
after washing and drying the motorcycle. or scratched, your Honda dealer has touch-
up paint to match your motorcycle’s colour.
Braking efficiency may be temporarily Be sure to use your motorcycle’s colour
impaired immediately after washing the code (page 68 ) when you buy touch-up
motorcycle. paint.
Anticipate longer stopping distance to avoid
a possible accident.

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03/06/04 11:41:42 32MCB600_121

Removing Road Salt Clean The Windshield

The salt contained in the road surface Using plenty of water, clean the windshield
freezing prevention medicine which a road with a soft cloth or sponge. (Avoid using
was sprayed with in winter, and the detergents or any kind of chemical cleaner
seawater becomes the cause which rust on the windshield.) Dry with a soft, clean
occurs in. cloth.
Wash your motorcycle by the following
point after it runs through such a place.

1. Clean the motorcycle using cool water To avoid possible scratching or other
(page 119 ). damage, use only water and a soft cloth or
sponge to clean the windshield.
Do not use warm water.
This worsens the effect of the salt. For a dirtier windshield, use a diluted
neutral detergent with a sponge and plenty
2. Dry the motorcycle and the surface of the of water. Make sure to wash off all the
metal is protected with the wax. detergent. (Detergent residue may cause
windshield cracks.)

Replace the windshield if scratches cannot

be removed and they obstruct clear vision.

Take care to keep battery electrolyte, brake

fluid or other chemical solvents off the
windshield and screen garnish. They will
damage the plastic.
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03/06/03 13:02:26 32MCB600_122

STORAGE GUIDE
Extended storage, such as for winter,
requires that you take certain steps to
reduce the effects of deterioration from
non-use of the motorcycle. In addition, Petrol is highly flammable and
necessary repairs should be made BEFORE explosive. You can be burned or
storing the motorcycle; otherwise, these seriously injured when handling fuel.
repairs may be forgotten by the time the
motorcycle is removed from storage. Stop the engine and keep heat,
sparks, and flame away.
STORAGE Refuel only outdoors.
1. Change the engine oil and filter. Wipe up spills immediately.
2. Make sure the cooling system is filled
with a 50/50 % antifreeze solution.
3. Empty the fuel tank into an approved
petrol container using a commercially
available hand siphon or an equivalent
method. Spray the inside of the tank with
an aerosol rust-inhibiting oil.
Reinstall the fuel fill cap on the tank.

If storage will last more than one month,

carburetor draining is very important, to
assure proper performance after storage.

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4. To prevent rusting in the cylinder, 5. Remove the battery. Store in an area

perform the following: protected from freezing temperatures
Remove the spark plug cap from the and direct sunlight.
spark plug. Using tape or string, secure Slow charge the battery once a month.
the cap to any convenient plastic body 6. Wash and dry the motorcycle. Wax all
part so that it is positioned away from painted surfaces. Coat chrome with
the spark plug. rustinhibiting oil.
Remove the spark plug from the 7. Lubricate the drive chain (page 86 ).
engine and store it in a safe place. Do 8. Inflate the tyres to their recommended
not connect the spark plug to the spark pressures. Place the motorcycle on blocks
plug cap. to raise both tyres off the ground.
Pour a tablespoon (15−20 cm ) of 9. Cover the motorcycle (don’t use plastic or
clean engine oil into the cylinder and other coated materials) and store in an
cover the spark plug hole with a piece unheated area, free of dampness with a
of cloth. minimum of daily temperature variation.
Crank the engine several times to Do not store the motorcycle in direct
distribute the oil. sunlight.
Reinstall the spark plug and spark plug
cap.

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REMOVAL FROM STORAGE

1. Uncover and clean the motorcycle.
Change the engine oil if more than 4
months have passed since the start of
storage.
2. Charge the battery as required. Install the
battery.
3. Drain any excess aerosol rust-inhibiting
oil from the fuel tank. Fill the fuel tank
with fresh petrol.
4. Perform all Pre-ride Inspection checks
(page 49 ).
Test ride the motorcycle at low speeds in
a safe riding area away from traffic.

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SPECIFICATIONS
DIMENSIONS
Overall length 2,257 mm (88.9 in)
Overall width 922 mm (36.3 in)
Overall height 1,318 mm (51.9 in)
Wheelbase 1,501 mm (59.1 in)

WEIGHT
Dry weight 192 kg (423 lbs)

CAPACITIES
Engine oil
After draining: 2.1 (2.2 US qt , 1.8 Imp qt)
After draining and oil filter change: 2.3 (2.4 US qt , 2.0 Imp qt)
After disassembly: 2.9 (3.1 US qt , 2.6 Imp qt)
Fuel tank 19.6 (5.18 US gal , 4.31 Imp gal)
Fuel reserve tank 3.8 (1.00 US gal , 0.84 Imp gal)
Cooling system capacity 2.0 (2.1 US qt , 1.8 Imp qt)
Passenger capacity Operator and one passenger
Maximum weight capacity 180 kg (396 lbs)

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03/06/03 13:02:58 32MCB600_126

ENGINE
Bore and stroke 79.0 × 66.0 mm (3.11 × 2.60 in)
Compression ratio 9.2 : 1
Displacement 647 cm (39.5 cu-in)
Spark plug
Standard DPR8EA-9 (NGK) or
X24EPR-U9 (DENSO)
For extended high speed riding DPR9EA-9 (NGK) or
X27EPR-U9 (DENSO)
For cold climate: (Below 5°C, 41°F) DPR7EA-9 (NGK) or
X22EPR-U9 (DENSO)
Spark plug gap 0.8−0.9 mm (0.03−0.04 in)
Valve clearance Intake: 0.15 mm (0.006 in)
Exhaust: 0.20 mm (0.008 in)
Idle speed 1,200 ± 100 min (rpm)

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CHASSIS AND SUSPENSION

Caster 28°04’
Trail 120 mm (4.7 in)
Tyre size: front 90/90−21M/C 54S
rear 120/90−17M/C 64S

POWER TRANSMISSION
Primary reduction 1.763
Final reduction 3.200
Gear ratio, 1st 2.500
2nd 1.722
3rd 1.333
4th 1.111
5th 0.961

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ELECTRICAL
Alternator 12V−10Ah
0.368 kW/5,000 min (rpm)

LIGHTS
Headlight 12V 60/55W
Stop/Taillight 12V 21/5W
Speedometer light 12V 1.7W
High beam indicator 12V 1.7W
Turn signal indicator 12V 3.4W
Turn signal light 12V 21W × 2
Neutral indicator 12V 3.4W

FUSE
Main fuse 30 A
Other fuses 10, 15 A

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CATALYTIC CONVERTERS
This motorcycle is equipped with catalytic Defective catalytic converters contributes to
converters. air pollution, and can impair your engine’s
Each catalytic converter contains precious performance. Follow these guidelines to
metals that serve as catalysts, promoting prot ect your motorcycle’s cat alyt ic
chemical reactions to convert the exhaust converters.
gasses without affecting the metals.
The catalytic converters act on HC, CO, and Always use unleaded petrol. Even a small
NOx. Replacement parts must be original amount of leaded petrol can contaminate
Honda parts or equivalents. the catalyst metals, making the catalytic
converters ineffective.
The catalytic converters must operate at a
high temperature for the chemical reactions Keep the engine tuned-up.
to take place. They can set on fire any
combustible materials that come near them. Have your motorcycle diagnosed and
Park your motorcycle away from high replaced if it is misfiring, backfiring,
grasses, dry leaves, or other flammables. stalling or otherwise not running properly.

119