Honda XL650V Owner's Manual
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Honda XL650V Owner's Manual

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03/06/03 12:48:31 32MCB600_001
Honda XL650V
OWNER'S MANUAL
Honda Motor Co., Ltd. 2003

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Summary of Contents for Honda XL650V

  • Page 1 03/06/03 12:48:31 32MCB600_001 Honda XL650V OWNER’S MANUAL Honda Motor Co., Ltd. 2003...
  • Page 2 03/06/03 12:48:36 32MCB600_002 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.
  • Page 3 OWNER’S MANUAL All information in this publication is based on the latest production information available at the time of approval for printing. Honda Motor Co.,Ltd. reserves the right to make changes at any time without notice and without incurring any obligation.
  • Page 4 When service is required, remember that your Honda dealer knows your motorcycle best. If you have the required mechanical ‘‘know-how’’ and tools, your dealer can supply you with an official Honda Service Manual to help you perform many maintenance and repair tasks.
  • Page 5 03/06/03 12:48:52 32MCB600_005 Following codes in this manual indicate each country. Ireland European direct sales France European direct sales (Type The specifications may vary with each locale.

  • Page 6: A Few Words About Safety

    03/06/03 12:48:57 32MCB600_006 A FEW WORDS ABOUT SAFETY Your safety, and the safety of others, is very important. And operating this motorcycle safely is an important responsibility. To help you make informed decisions about safety, we have provided operating procedures and other information on labels and in this manual.
  • Page 7 03/06/03 12:49:01 32MCB600_007 You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be HURT if you don’t follow instructions. Safety Headings –– such as Important Safety Reminders or Important Safety Precautions. Safety Section ––...

  • Page 8: Operation

    03/06/03 12:49:04 32MCB600_008 OPERATION page page 1 MOTORCYCLE SAFETY 35 ESSENTIAL INDIVIDUAL Important Safety Inforamation COMPONENTS Protective Apparel Ignition Switch Load Limits and Guidelines Keys Immobilizer System (HISS) 10 PARTS LOCATION Right Handlebar Controls Instruments and Indicators Left Handlebar Controls 20 MAJOR COMPONENTS (Information you need to opetate this motorcycle)
  • Page 9 03/06/04 11:40:46 32MCB600_009 page page 42 FEATURES 49 OPERATION (Not required for operation) Pre-ride Inspection Steering Lock Starting the Engine Seat Running-in Helmet Holder Riding Left Side Cover Braking Right Side Cover Parking Center Compartment Anti-theft Tips Document Compartment Headlight Aim Vertical Adjustment...

  • Page 10: Maintenance

    03/06/03 12:49:10 32MCB600_010 MAINTENANCE page page 60 MAINTENANCE Stoplight Switch Adjustment The Importance of Maintenance Bulb Replacement Maintenance Safety Safety Precautions 109 CLEANING Maintenance Schedule Tool Kit 112 STORAGE GUIDE Serial Numbers Storage Colour Label Removal from Storage Engine Oil Spark Plug 115 SPECIFICATIONS Crankcase Breather...
  • Page 11 03/06/03 12:49:16 32MCB600_011 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...
  • Page 12 Never exceed load limits, and use only accessories that have been approved by Honda for this motorcycle. See page for more details.

  • Page 13: Protective Apparel

    03/06/03 12:49:29 32MCB600_013 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.
  • Page 14 03/06/03 12:49:33 32MCB600_014 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.

  • Page 15: Load Limits And Guidelines

    Non-Honda accessories, im p r o p e r m od i f i c a t i on s , a n d p o or Follow all load limits and other loading maintenance can also reduce your safety guidelines in this manual.
  • Page 16 If you wish to carry more cargo, check with Maximum rear carrier cargo weight: your Honda dealer for advice, and be sure 9 kg (20 lbs) to read the inf ormat ion regarding Maximum center compartment cargo...
  • Page 17 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...
  • Page 18 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.

  • Page 19: Off-Road Safety

    03/06/03 12:50:09 32MCB600_019 Spark arresters and mufflers are required OFF-ROAD SAFETY 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.

  • Page 20: Parts Location

    03/06/03 12:50:13 32MCB600_020 PARTS LOCATION Indicators Speedometer Rearview mirrors Tachometer Rearview Headlight dimmer mirror switch Front brake fluid reservoir Choke lever P a s s i n g switch Front brake Clutch lever lever Hazard switch Throttle grip Turn signal switch Engine stop switch Starter button Horn button...
  • Page 21 03/06/03 12:50:17 32MCB600_021 Seat lock Air cleaner Helmet holder Coolant reserve tank Tool box Passenger footpeg Gearshift pedal Foot peg Side stand...
  • Page 22 03/06/03 12:50:20 32MCB600_022 Battery Passenger footpeg Foot peg Rear brake pedal Oil filler cap/dipstick...

  • Page 23: Instruments And Indicators

    03/06/03 12:50:26 32MCB600_023 INSTRUMENTS AND INDICATORS The indicators are contained in the instrument panel. Their functions are described in the tables on the following pages. (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...
  • Page 24 03/06/03 12:50:38 32MCB600_024 (Ref.No.) Description Function Left turn signal indicator Flashes when the left turn signal operates. Speedometer Shows riding speed in miles (For E type) or kilometers (Except E type) per hour. Odometer Shows accumulated mileage. Low oil pressure Lights when the engine oil pressure is below normal indicator (red) operating range.
  • Page 25 03/06/03 12:50:47 32MCB600_025 (Ref.No.) Description Function 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...
  • Page 26 03/06/03 12:51:01 32MCB600_026 (Ref.No.) Description Function Right turn signal indicator Flashes when the left turn signal operates. (10) Coolant T emperature Shows coolant temperature (page Gauge (11) Digital clock Shows hour and minute (page (12) High beam indicator Lights when the headlight is on high beam. (13) Tripmeter Shows mileage per trip.
  • Page 27 03/06/03 12:51:07 32MCB600_027 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.
  • Page 28 03/06/03 12:51:12 32MCB600_028 Fuel Gauge When the gauge needle enters the red band, fuel will be low and you should refill the tank as soon as possible. The amount of fuel left in the tank when the needle enters the red band and with the vehicle set upright is approximately: 3.6 (0.95 US gal , 0.79 Imp gal) (1) Fuel gauge...
  • Page 29 03/06/03 12:51:18 32MCB600_029 Digital clock Shows hour and minute. To adjust the time, proceed as follows: Turn the ignition switch ON. Press the ‘‘H’’ button ( ). To advance time, keep the button down until the desired hour is displayed. Press the ‘‘M’’...

  • Page 30: Major Components

    (page ), 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 (1) LOWER level mark LOWER level mark ( ).
  • Page 31 03/06/03 12:51:32 32MCB600_031 Rear Brake Fluid Level: Rear With the motorcycle in an upright position, check the fluid level. It should be between the UPPER ( ) and LOWER ( ) level marks. If the level is at or below the LOWER level mark ( ), check the brake pads for wear (page Worn pads should be replaced.
  • Page 32 03/06/03 12:51:40 32MCB600_032 Pull back the rubber dust cover ( ). CLUTCH Clutch adjustment may be required if the Loosen the lock nut ( ) and turn the motorcycle stalls when shifting into gear or adjuster ( ). Tighten the lock nut ( ) tends to creep;...
  • Page 33 If proper adjustment cannot be obtained or the clutch does not work correctly, see your Honda dealer. (5) Lock nut (A) Increase free play (6) Adjusting nut (B) Decrease free play...
  • Page 34 03/06/03 12:51:53 32MCB600_034 COOLANT The factory provides a 50/50 solution of Coolant Recommendation antifreeze and distilled water in this The owner must properly maintain the motorcycle. T his coolant solution is coolant to prevent freezing, overheating, r e c o m m e n d e d f o r m o s t o p e r a t i n g and corrosion.
  • Page 35 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 ( ) while the engine is at the normal operating temperature with the motorcycle in an upright position.
  • Page 36 03/06/03 12:52:08 32MCB600_036 FUEL Fuel Tank 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 ( ), insert the ignition key ( ) and turn it clockwise. The fuel fill cap is hinged and will lift up.
  • Page 37 If spark knock or pinking persists, consult your Honda dealer. Failure to do so is considered misuse, and damage caused by misuse is not covered by Honda’s Limited Warranty.
  • Page 38 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.

  • Page 39: Engine Oil

    03/06/03 12:52:23 32MCB600_039 ENGINE OIL 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 ( ) and lower ( ) level marks on the Running the engine with insufficient oil dipstick ( ).
  • Page 40 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.
  • Page 41 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’’...
  • Page 42 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.
  • Page 43 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.
  • Page 44 03/06/03 12:52:55 32MCB600_044 T he r ecommended t yres f or your Tyre Replacement The tyres that came on your motorcycle motorcycle are: were designed to match the performance Front: 90/90 21M/C 54S − capabilities of your motorcycle and provide BRIDGESTONE the best combination of handling, braking, TW47G...

  • Page 45: Essential Individual Components Ignition Switch

    03/06/03 12:53:02 32MCB600_045 ESSENTIAL INDIVIDUAL COMPONENTS IGNITION SWITCH The ignition switch ( ) 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.
  • Page 46 03/06/03 12:53:06 32MCB600_046 KEYS This motorcycle has two keys and a key number plate. (1) Keys (2) Key number plate...
  • Page 47 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...

  • Page 48: Immobilizer System (Hiss)

    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 ( ) lights for a few seconds, then go off. If...
  • Page 49 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...

  • Page 50: Right Handlebar Controls

    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 ( ) is next to the taillights will stay on. If the engine stop throttle grip.

  • Page 51: Left Handlebar Controls

    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 ( ) other lights are OFF. Push the dimmer switch to (HI) to select high beam or to (LO) to select low beam.

  • Page 52: Steering Lock

    03/06/03 12:53:49 32MCB600_052 FEATURES (Not required for operation) STEERING LOCK To lock the steering, turn the handlebar all To lock the way to the left, turn the key ( ) to LOCK while pushing in. Remove the key. To unlock the steering, turn the key to OFF while pushing in.
  • Page 53 03/06/03 12:53:55 32MCB600_053 SEAT To remove the seat ( ), insert the ignition key into the seat lock ( ) and turn it clockwise. Pull the seat back and up. To install the seat, insert the prongs ( ) into the recess ( ) under the frame cross member and then push down on the rear of the seat.

  • Page 54: Helmet Holder

    03/06/03 12:54:01 32MCB600_054 HELMET HOLDER The helmet holders are located below the seat. Remove the seat (page Hang the helmets on the holder hook ( ). 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...

  • Page 55: Left Side Cover

    03/06/03 12:54:09 32MCB600_055 LEFT SIDE COVER The left side cover must be removed for fuse maintenance. Removal: Remove the seat (page Remove the three bolts ( ). Remove the seat lock cable ( ) from the seat lock ( ). Remove the left side cover ( ) Installation: Installation can be done in the reverse...

  • Page 56: Right Side Cover

    03/06/03 12:54:17 32MCB600_056 RIGHT SIDE COVER The right side cover must be removed for battery and fuse maintenance. Removal: Remove the seat (page Remove the three bolts ( ). Remove the right side cover ( ) Installation: Installation can be done in the reverse order of removal.

  • Page 57: Center Compartment

    03/06/04 14:42:17 32MCB600_057 CENTER COMPARTMENT DOCUMENT COMPARTMENT The center compartment ( ) is under the The document bag ( ) is in the document seat. Opening and closing: compartment ( ) under the seat. See ‘‘SEAT LOCK’’ (page When washing your motorcycle, be careful not to flood this area with water.
  • Page 58 03/06/03 12:54:26 32MCB600_058 H E A D L I G H T A I M V E R T I C A L ADJUSTMENT Vertical adjustment can be made by turning the knob ( ) in or out as necessary. Obey local laws and regulations.
  • Page 59 Coolant level add coolant if required. − sure you take care of it, or have it corrected Check for leaks (pages − by your Honda dealer. Front and rear brakes check operation; − make sure there is no brake fluid leakage (pages −...
  • Page 60 03/06/03 12:54:40 32MCB600_060 Tyres check condition and pressure − (pages − Drive chain check condition and slack − (page ). Adjust and lubricate − if necessary. Chain guide slider and slipper check − slider wear (page Throttle check for smooth opening and −...

  • Page 61: Starting The Engine

    03/06/03 12:54:46 32MCB600_061 Y our motorcycle’s exhaust contains STARTING THE ENGINE Always follow the proper starting procedure poisonous carbon monoxide gas. High described below. levels of carbon monoxide can collect rapidly in enclosed areas such as a garage. This motorcycle is equipped with a side Do not run the engine with the garage door stand ignition cut-off system.
  • Page 62 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).
  • Page 63 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. Do not use the choke. Open the throttle slightly. Start the engine.
  • Page 64 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...
  • Page 65 03/06/03 12:55:18 32MCB600_065 RIDING When the motorcycle attains a moderate Review Motorcycle Safety (pages − 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.
  • Page 66 03/06/03 12:55:24 32MCB600_066 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;...
  • Page 67 03/06/03 12:55:31 32MCB600_067 When riding in wet or rainy conditions, or BRAKING For normal braking, gradually apply both on loose surfaces, the ability to maneuver t h e f r o n t a n d r e a r b r a k e s w h i l e and stop will be reduced.
  • Page 68 03/06/03 12:55:36 32MCB600_068 PARKING Make sure flammable materials such as dry After stopping the motorcycle, shift the grass or leaves do not come in contact with transmission into neutral, turn the the exhaust system when parking your handlebar fully to the left, turn the motorcycle.

  • Page 69: Anti-Theft Tips

    03/06/03 12:55:40 32MCB600_069 ANTI-THEFT TIPS NAME: Always lock the steering and never leave the key in the ignition switch. This ADDRESS: sounds simple but people do forget. Be sure the registration information for your motorcycle is accurate and current. Park your motorcycle in a locked garage whenever possible.
  • Page 70 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.

  • Page 71: Maintenance Safety

    Wheel removal should normally be handled only by a Honda technician or other qualified mechanic; instructions are included in this manual only to assist in emergency service.

  • Page 72: Safety Precautions

    Let the engine and exhaust system cool before touching. To ensure the best quality and reliability, use only new genuine Honda parts or their Injury from moving parts. Do not run the engine unless instructed equivalents for repair and replacement.

  • Page 73: Maintenance Schedule

    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.
  • Page 74 03/06/03 12:56:23 32MCB600_074 FREQUENCY WHICHEVER → ODOMETER READING [NOTE (1)] COMES FIRST 1,000 km Refer × ↓ × 1,000 mi ITEM NOTE MONTH Page FUEL LINE − FUEL STRAINER SCREEN − THROTTLE OPERATION CARBURETOR CHOKE − AIR CLEANER NOTE (2) −...
  • Page 75 03/06/03 12:56:40 32MCB600_075 FREQUENCY WHICHEVER → ODOMETER READING ［ NOTE (1) ］ COMES FIRST 1,000 km Refer × ↓ × 1,000 mi ITEM NOTE MONTH Page DRIVE CHAIN NOTE (5) I, L EVERY 1,000 km (600 mi) DRIVE CHAIN SLIDER BRAKE FLUID NOTE (4) BRAKE PAD WEAR...
  • Page 76 03/06/03 12:56:55 32MCB600_076 TOOL KIT The tool kit ( ) is under the seat (page Some roadside repairs, minor adjustments and parts replacement can be performed with the tools contained in the kit. Spark plug wrench 12 mm Box end wrench ×...

  • Page 77: Serial Numbers

    03/06/03 12:57:01 32MCB600_077 The frame number ( ) is stamped on the SERIAL NUMBERS 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 ( ) is stamped on the when ordering replacement parts.

  • Page 78: Colour Label

    03/06/03 12:57:07 32MCB600_078 COLOUR LABEL The colour label ( ) 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) Colour label...
  • Page 79 03/06/03 12:57:14 32MCB600_079 ENGINE OIL Refer to the Safety Precautions on page 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.
  • Page 80 If a torque wrench is not used for this f r e q u e n t l y t h a n s p e c i f i e d i n t h e installation, see your Honda dealer as soon maintenance schedule.
  • Page 81 03/06/03 12:57:25 32MCB600_081 To drain the oil, remove the oil filler cap/ Remove the oil filter ( ) with a filter dipstick and crankcase drain plug ( ) and wrench and let the remaining oil drain out. sealing washer ( ). Discard the oil filter.
  • Page 82 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 Fill the crankcase with the recommended filter of equivalent quality specified for your grade oil;...

  • Page 83: Spark Plugs

    03/06/03 12:57:44 32MCB600_083 SPARK PLUGS Refer to the Safety Precautions on page Recommended plugs: Standard: DPR8EA-9 (NGK) X24EPR-U9 (DENSO) For extended high speed riding: DPR9EA-9 (NGK) X27EPR-U9 (DENSO) For cold climate: (Below 5°C, 41°F) DPR7EA-9 (NGK) X22EPR-U9 (DENSO) Never use a spark plug with an improper heat range.
  • Page 84 03/06/03 12:57:50 32MCB600_084 Remove the seat (page Remove the fuel tank mounting bolt ( ) Remove the left and right front cover and the bushing. bolts ( ),and disconnect them from the holders on the fuel tank. (1) Bolts (2) Fuel tank mounting bolt...
  • Page 85 03/06/03 12:57:55 32MCB600_085 To remove the spark plug from the rear Disconnect the spark plug caps from the cylinder, raise the fuel tank. spark plugs. Clean any dirt from around the spark plug bases. Remove the spark plugs using the spark Rear cylinder plug wrench ( ) furnished in the tool kit.
  • Page 86 03/06/03 12:58:04 32MCB600_086 Inspect the electrodes and center Make sure the plug washer is in good porcelain for deposits, erosion or carbon condition. fouling. If the erosion or deposit is heavy, 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.

  • Page 87: Crankcase Breather

    03/06/03 12:58:09 32MCB600_087 CRANKCASE BREATHER Refer to the Safety Precautions on page Remove the crankcase breather tube plug ( ) from the tube and drain deposits into a suitable container. Reinstall the crankcase breather tube plug. Service more frequently when riding in rain, at full throttle, or after the motorcycle is washed or overturned.

  • Page 88: Throttle Operation

    03/06/03 12:58:16 32MCB600_088 THROTTLE OPERATION Refer to the Safety Precautions on page Check for smooth rotation of the throttle grip from the fully open to the fully closed position at both full steering positions. Measure the throttle grip free play at the throttle grip flange.

  • Page 89: Idle Speed

    03/06/03 12:58:23 32MCB600_089 IDLE SPEED Refer to the Safety Precautions on page The engine must be at normal operating temperature for accurate idle speed adjustment. Ten minutes of stop-and-go riding is sufficient. Warm up the engine, and shift to neutral, and place the motorcycle on its side stand.
  • Page 90 Refer to the Safety Precautions on page Coolant Replacement Removing the radiator cap while the Coolant should be replaced by a Honda engine is hot can cause the coolant to dealer, unless the owner has proper tools spray out, seriously scalding you.

  • Page 91: Drive Chain

    03/06/03 12:58:40 32MCB600_091 Roll the motorcycle forward. Stop. Check DRIVE CHAIN Refer to the Safety Precautions on page the drive chain slack. Repeat this procedure several times. Drive chain The service life of the drive chain is slack should remain constant. If the chain dependent upon proper lubrication and is slack only in certain sections, some adjustment.
  • Page 92 03/06/03 12:58:46 32MCB600_092 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...
  • Page 93 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 Place the motorcycle on its side stand miles). When operated at sustained high with the transmission in neutral and the speeds or under conditions of frequent ignition switch off.
  • Page 94 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. Tighten the adjusting nuts lightly, then tighten the lock nuts by holding the...
  • Page 95 03/06/03 12:59:08 32MCB600_095 Wear Inspection: Check the chain wear label when adjusting the chain. If the red zone ( ) on the label aligns with the arrow mark ( ) on the chain adjuster plates after the chain has been adjusted to the proper slack, the chain is excessively worn and must be replaced.
  • Page 96 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.

  • Page 97: Drive Chain Slider

    03/06/03 12:59:20 32MCB600_097 DRIVE CHAIN SLIDER Refer to the Safety Precautions on page Check the chain slider ( ) for wear. When the thickness ( ) of the chain slider reaches the limit, the chain slider must be replaced. Chain slipper depth limit: 2.0 mm(0.08 in) (1) Chain slider (2) Thickness...
  • Page 98 03/06/03 12:59:24 32MCB600_098 F R O N T A N D R E A R S U S P E N S I O N INSPECTION Refer to the Safety Precautions on page Check the fork assembly by locking the front brake and pumping the fork up and down vigorously.

  • Page 99: Side Stand

    Lower the side stand. The engine should stop as you put the side stand down. (1) Side stand spring If the side stand system does not operate as described, see your Honda dealer for service.

  • Page 100: Wheel Removal

    If none is available, see your Honda dealer for this service. Front Wheel Removal Raise the front wheel off the ground by placing a support block under the engine.
  • Page 101 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.
  • Page 102 03/06/03 12:59:59 32MCB600_102 Installation: If a torque wrench was not used for 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.
  • Page 103 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. (1) Lock nut (3) Axle nut (4) Drive chain...
  • Page 104 Installation Notes: If a torque wrench was not used for To install the rear wheel, reverse the installation, see your Honda dealer as soon removal procedure. as possible to verify proper assembly. Make sure the tang ( ) on the swingarm...

  • Page 105: Brake Pad Wear

    Always inspect each pad in both right and left brake calipers. Check the grooves ( ) in each pad. If either pad is worn to the bottom of the grooves, replace both pads as a set. See your Honda dealer for this service. (1) Wear indicator grooves...
  • Page 106 03/06/03 13:00:29 32MCB600_106 REAR BRAKE Rear Brake 〈 〉 Check the cutout ( ) 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) Cutouts...
  • Page 107 (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.
  • Page 108 03/06/03 13:00:41 32MCB600_108 Battery Removal Remove the right side cover (page Remove the battery holder ( ) by removing the nut ( ). Disconnect the negative ( ) terminal − lead ( ) from the battery first, then disconnect the positive ( ) terminal lead ＋...

  • Page 109: Fuse Replacement

    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.
  • Page 110 03/06/03 13:00:56 32MCB600_110 Fuse Box: The fuse box is located behind the left side cover. The specified fuses are: 10, 15 A Remove the left side cover (page Open the fuse box cover ( ). Pull out the old fuse and install a new fuse. The spare fuses ( ) are located in the fuse box.
  • Page 111 03/06/04 11:41:15 32MCB600_111 Main Fuse: The main fuse ( ) is located behind the right side cover. The specified fuse is: 30 A Remove the right side cover (page Disconnect the wire connector ( ) of the starter magnetic switch. Pull out the old fuse and install a new fuse.

  • Page 112: Stoplight Switch Adjustment

    03/06/03 13:01:10 32MCB600_112 STOPLIGHT SWITCH ADJUSTMENT Refer to the Safety Precautions on page Check the operation of the stoplight switch ( ) at the right side behind the engine from time to time. Adjustment is done by turning the adjusting nut ( ).

  • Page 113: Bulb Replacement

    03/06/03 13:01:19 32MCB600_113 Be sure to turn the ignition switch OFF BULB REPLACEMENT Refer to the Safety Precautions on page 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.
  • Page 114 03/06/03 13:01:30 32MCB600_114 Headlight Bulb Remove the headlight lower cover ( ) by loosening the two fixing bolts.. Pull off the socket ( ) without turning. Remove the dust cover ( ). Remove the bulb ( ) while pressing down on the pin ( ). Pull out the bulb ( ) without turning.
  • Page 115 03/06/03 13:01:39 32MCB600_115 Position Light Bulb Remove the lower maintenance cover ( ) by removing the two screws ( ). Pull the position light socket ( ) and remove it. Pull out the bulb ( ) without turning. Install a new bulb in the reverse order of removal.
  • Page 116 03/06/03 13:01:46 32MCB600_116 Stop/Taillight Bulb Remove the rear handle ( ) by removing the four screws ( ) and collars A ( ), collars B ( ). Remove the rear tail ( ). Turn the bulb holder ( ) clockwise and remove the bulb ( ).
  • Page 117 03/06/03 13:01:54 32MCB600_117 Front Turn Signal Bulb Remove the instrument panel cover by removing the screws A ( ) and the screws B ( ). T u r n t h e b u l b h o l d e r counterclockwise and remove the bulb ( ).
  • Page 118 03/06/03 13:02:00 32MCB600_118 Rear Turn Signal Bulb Remove the screw ( ). Remove the turn signal lens ( ). Remove the bulb ( ) by pressing in and turning counterclockwise. Install a new bulb and check that the light operates properly. (1) Screws (3) Bulb (2) Turn signal lens...
  • Page 119 03/06/04 11:41:25 32MCB600_119 CLEANING Clean your motorcycle regularly to protect Washing the motorcycle the surface finishes and inspect for damage, Rinse the motorcycle thoroughly with wear, and oil, coolant or brake fluid leakage. cool water to remove loose dirt. Clean the motorcycle with a sponge or Avoid cleaning products that are not soft cloth using cool water.
  • Page 120 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...
  • Page 121 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...

  • Page 122: Storage Guide

    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.
  • Page 123 03/06/03 13:02:33 32MCB600_123 To prevent rusting in the cylinder, 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.

  • Page 124: Removal From Storage

    03/06/03 13:02:38 32MCB600_124 REMOVAL FROM STORAGE Uncover and clean the motorcycle. Change the engine oil if more than 4 months have passed since the start of storage. Charge the battery as required. Install the battery. Drain any excess aerosol rust-inhibiting oil from the fuel tank.

  • Page 125: Specifications & Dimensions

    03/06/03 13:02:49 32MCB600_125 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)
  • Page 126 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) X24EPR-U9 (DENSO) For extended high speed riding DPR9EA-9 (NGK) X27EPR-U9 (DENSO) For cold climate: (Below 5°C, 41°F) DPR7EA-9 (NGK) X22EPR-U9 (DENSO)

  • Page 127: Chassis And Suspension

    03/06/03 13:03:06 32MCB600_127 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 1.722 1.333 1.111 0.961...
  • Page 128 03/06/03 13:03:15 32MCB600_128 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 × Neutral indicator 12V 3.4W FUSE Main fuse...

  • Page 129: Catalytic Converters

    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.

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