This manual should be considered a permanent part ... - Hondaowners.honda.com/assets/OWNERLINK/model/own_man/... · Honda Motor Co., Ltd. 2005 This manual should be considered a permanent

Honda Motor Co., Ltd. 2005

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

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

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

The vehicle pictured on the front cover may not match your vehicle.

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FOR OFF-ROAD USE ONLY

2006Honda CRF50FOWNER’S MANUAL

This vehicle is designed and manufactured for off-road use only.USA only:It conforms to US EPA Noise Emission regulations, but does not conform to Federal Motor Vehicle SafetyStandards or US EPA On Highway Exhaust Emission regulations, and operation on public streets, roads, orhighways is illegal. The vehicle is equipped with a USDA qualified spark arrester. Obey local laws andregulations.It conforms to US EPA and California exhaust emission regulations for off-road motorcycle.

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Safety Messages

Safety Labels

Safety MessagesDANGER, WARNING, CAUTION.

A Few Words About Safety

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

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

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

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

These signal words mean:

–– on the motorcycle.

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

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

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

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

Safety Messages

Safety Headings

Safety Section

Instructions

A Few Words About Safety

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

–– such as Motorcycle Safety.

–– how to use this motorcycle correctly and safely.

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

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Contents

Contents

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

Introduction

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

.............................Servicing Your Honda .....................................Motorcycle Safety .

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

1

13

23

29

41

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

The location, function, and operation ofthe throttle, brakes, and other basiccontrols.

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

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

Important safety information, a specialmessage for parents, precautions aboutloading, accessories, and modifications,and the location of safety labels.

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

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Contents

Contents

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

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

............................................................Tips .

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

.....................................Table of Contents .

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

Quick Reference

111

121

129

145

154

158

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

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

ID numbers, technical specifications,and other technical facts.

Information on warranties and how toget Honda service manuals.

Sequential listing of topics in thisowner’s manual.

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

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－

Introduction

Introduction

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

Congratulations on choosing your Honda off-road motorcycle.

Your Honda was designed as a recreationalmotorcycle for off-road use by one rider only.It’s an ideal bike for younger, beginning riders.

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

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

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

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

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

149

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Introduction

Introduction

WARNING:Whenever you ride, tread lightly. By stayingon established trails and riding only inapproved areas, you help protect theenvironment and keep off-road riding areasopen for the future.

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

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

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

Happy riding!

California Proposition 65 WarningThis product contains or emits

chemicals known to the State of Californiato cause cancer and birth defects or otherreproductive harm.

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1

Motorcycle Safety

Motorcycle Safety

This section presents some of the mostimportant information and recommendations tohelp you ride your motorcycle safely. Pleasetake a few moments to read these pages. Thissection also includes a special message forparents and location information for the safetylabels on your motorcycle.

.........................Important Safety Information . 2

.........................Important Message to Parents . 5..........Loading, Accessories & Modifications . 8

.......................................................Loading . 8....................Accessories & Modifications . 10

.................................................Safety Labels . 12

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－

－

2

Always Wear a Helmet

Never Carry a Passenger

Important Safety Information

Motorcycle Safety

Important Message toParents Parents,Youngsters and Of f -Highway Motorcycles

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

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

This motorcycle has been designed for youngerriders. However, not all youngsters arephysically or emotionally ready to ride.Therefore, before parents allow any youngsterto ride this motorcycle, we urge them tocarefully read the

beginning on page and the

booklet that came with the motorcycle (USAonly).

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

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

5

24

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3

Ride Off-Road Only Be Alert for Off-Road Hazards

Ride within Your LimitsTake Time to Learn and Practice

Motorcycle Safety


Tips & Practice Guidef or the Of f -Highway Motorcyclist

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

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

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

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

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

Also be sure to read thebooklet that

came with your motorcycle (USA only).

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4

Don’t Drink and Ride

Keep Your Honda in Safe Condition


Motorcycle Safety

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

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

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5Motorcycle Safety

Riding Readiness

Important Message to Parents

Your child’s safety is very important to Honda.That’s why we urge you to read this messagebefore you let any young person ride thismotorcycle. Off-road riding can be fun. But, aswith riding a bicycle, bad judgment can resultin injury, and we don’t want that to happen! Asa parent, you can help prevent accidents bymaking good decisions about if, when, andhow your youngster rides this motorcycle.

The first decision you’ll need to make iswhether your youngster is ready to ride. Ridingreadiness varies widely from one person toanother, and age and size are not the onlyfactors.

PHYSICAL ABILITY is an importantconsideration. For example, riders must be bigenough to hold the motorcycle up, get on, andcomfortably sit on the seat with both feettouching the ground. They should also be ableto easily reach and work the brakes, throttle,and all other controls.

ATHLETIC ABILITY is necessary for riding amotorcycle. Generally speaking, youryoungster should be good at riding a bicyclebefore getting on a motorcycle. Can youryoungster judge speeds and distances whileriding a bicycle and react with proper hand andfoot actions? Anyone who does not have goodcoordination, balance, and agility is not readyto ride this motorcycle.

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6 Motorcycle Safety

Instruction and Supervision


MENTAL AND EMOTIONAL MATURITYare requirements for safe riding. Does youryoungster think through problems and come tological solutions? On a bicycle, does youryoungster obey safe riding rules? Be honest!Young people who take unnecessary risks,make bad judgments, and don’t obey rules arenot ready to ride this motorcycle.

If you decide that your youngster is ready tosafely operate this motorcycle, make sure bothof you carefully read and understand theowner’s manual before riding. Also be sure thatyour youngster has a helmet and otherappropriate riding equipment and always wearsit when operating the vehicle or sitting on it.

GOOD INSTRUCTION is an important part ofhands-on training. The teacher can either beyou or another responsible adult who hasexperience with off-road motorcycle riding.(For help in finding a qualified instructor, talkwith your Honda dealer.) Even if you’re not themain teacher, it’s up to you to ensure youryoungster’s safety. Remember, learning to ridea motorcycle is a gradual, step-by-step process.It takes time, patience, and practice manyhours over a period of weeks or months.

To help your youngster build confidence asthey’re learning to ride, this Honda wasdelivered with a speed restrictor that limits topspeed. We recommend that all beginning ridersstart off with the speed restrictor may beadjusted to gradually increase maximum speedas the beginner becomes more familiar withriding their Honda motorcycle. For adjustmentand removal instructions, see page .72

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－

7Motorcycle Safety


SUPERVISION is another important obligationof parents. Even after youngsters have becomeskilled off-road riders, they should always ridewith adult supervision. It helps to regularlyremind young riders of basic safety rules andprecautions. And remember, it’s yourresponsibility to see that the motorcycle isproperly maintained and kept in safe operatingcondition.

SAFE AND RESPONSIBLE RIDING must bean on-going commitment by you and youryoungster. When you both put safety first, youcan enjoy more peace of mind, and youryoungster can enjoy more hours of safe off-road riding.

For your convenience, this comeswith an ignition switch and key. Remove thekey when the motorcycle is parked to helpprevent unauthorized use.

CRF50F

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

Follow all load limits and other loadingguidelines in this manual.

8

Loading, Accessories & Modifications

Motorcycle Safety

Loading

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

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

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

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

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88 lbs (40 kg)

9

Load Limits

Maximum weight capacity=

Loading Guidelines


Motorcycle Safety

Following are the load limits for yourmotorcycle:

Includes the weight of the rider and anyaccessories.

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

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

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

8

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

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

10

Accessories


Motorcycle Safety

Accessories & Modifications

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

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

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

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

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11

Modifications


Motorcycle Safety

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

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

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12

Safety Labels

Motorcycle Safety

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

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

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13

Operating Controls

Operating Controls

When you ride off-road, you need to operatethe throttle, brakes, and other controls withoutstopping to look at them. Read this sectioncarefully before you ride. It describes thelocation, function, and operation of all thebasic controls on your motorcycle.

..................Operation Component Locations . 14........................................Operating Controls . 17

.................................................Fuel Valve . 17..............................................Choke Lever . 18

..........................................Ignition Switch . 19...................................Engine Stop Switch . 20

.....................................Front Brake Lever . 20......................................................Throttle . 20

................................................Shift Lever . 21.......................................Rear Brake Pedal . 21

.................................................Kickstarter . 21

.................................................Side Stand . 21

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front brake lever

engine stop switch

throttle grip

14 Operating Controls

Operation Component Locations

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rear brake pedal

ignition switch

kickstarter

15


Operating Controls

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shift lever

choke lever fuel valve

16


Operating Controls

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ON RESOFF

17

Operating Controls

Operating Controls

Fuel Valve

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

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

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

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

ON

OFF

RES

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○○

○○

○○

ＡＡ

ＢＢ

ＣＣ

0.24 US gal (0.9 )

(1) choke lever

LEFTSIDE

(1)

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

18

Operating Controls

Operating Controls

Choke Lever

The reserve fuel supply is:

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

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

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

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

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

ON

OFF

DETENT

32

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

Before riding, insert the key and turn it tothe right for the ON position.

1

Key

Position

Function Key Removal

OFF

ON

The engine cannot beoperated.With the engine stopswitch at RUN and thetransmission inneutral, the enginecan be started.

The key canbe removed.The keycannot beremoved.

(1)

ONOFF

(1) ignition switch

RIGHT SIDE (under fuel tank)

ONOFF

19

Operating Controls

Operating Controls

Ignition Switch

After parking the motorcycle, remove the key.

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20

Throttle

Front Brake Lever

Engine Stop Switch

Operating Controls

Operating Controls

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

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

The engine stop switch is used to turn theengine off during normal riding situations. Tooperate, turn the switch to either OFF position.The switch must be in the RUN position to startthe engine.

37

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21

Shift Lever

Rear Brake Pedal

Kickstarter

Side Stand

Operating Controls

Operating Controls

Starting Procedure,

Shif ting Gears,

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

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

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

The shift lever is used to select the next higheror lower gear in the transmission. To operate,raise the shift lever (after closing the throttle)to engage the next higher gear or depress theshift lever to engage the next lower gear. See

page .35

37

32

38

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22 Operating Controls

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？

？

23

Before Riding

Before Riding


Before each ride, you need to make sure youand your Honda are both ready to ride. To helpget you prepared, this section discusses how toevaluate your riding readiness, and how toperform the recommended pre-ride inspectionof your Honda. If you’re a parent, be sure youalso read the onpage .

.............................Are You Ready to Ride . 24....................................Protective Apparel . 24

...........Is Your Motorcycle Ready to Ride . 26....................................Pre-ride Inspection . 27

5

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24

Are You Ready to Ride?

Before Riding

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

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

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

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

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

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

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

25

Helmets and Eye Protection

Additional Riding Gear

Are You Ready to Ride?

Before Riding

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

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

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

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

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

Off-road motorcycle gloves to help protectyour hands.

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

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

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

26

Is Your Motorcycle Ready to Ride?

Before Riding

Note to Parents:If a youngster will be perf orming any of thef ollowing pre-ride inspection procedures, it’syour responsibility to provide caref ulsupervision and make sure they are perf ormedsaf ely.

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

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27


Before Riding

Pre-ride InspectionFuel

Tires

Spokes &Rims

Engine Oil

Leaks

Spark Plug& Cap

Nuts &Bolts

Cables

Drive Chain

Check the following items before you get onthe motorcycle:

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

Make sure the spokes are tight.Also check the rims for damage(page ).

Check the level and add oil ifneeded (page ).

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

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

Check for looseness (page ).

Use a wrench to make sure allaccessible nuts, bolts, andfasteners are tight.

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

Check the condition and slack.Adjust and lubricate if needed.Also check the chain slider forwear and replace if needed(page ).96

91

64

58

79

101

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28


Before Riding

Throttle

Brakes

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

Check these items after you get on themotorcycle:

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

Squeeze the front brake leverand step on the rear brake pedalto check that the controlsoperate normally (page , ).Adjust freeplay, if necessary.(pages , ).

70

86 88

86 88

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29

Basic Operation & Riding


Tips & PracticeGuide f or the Of f -Highway Motorcyclist

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

booklet that came with your Honda (USA only).

This section gives basic information on how tobegin riding your motorcycle. It includes howto start and stop your engine, how to use thethrottle and brakes, and what to do when you’rethrough riding.

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

................................Safe Riding Precautions . 30....................Starting & Stopping the Engine . 32

................................................Preparation . 32.....................................Starting Procedure . 32

.........................................Flooded Engine . 34............................How to Stop the Engine . 34

...............................................Shifting Gears . 35..........................................................Braking . 37..........................................................Parking . 38

......................................Post-ride Inspection . 39

137

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30

Safe Riding Precautions



Important Saf etyInf ormation

Bef ore Riding.

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

beginning on page and theprevious section, titled

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

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

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

2

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31

Speed Restrictor for New Riders



The motorcycle is equipped with a throttlelimiter to restrict top speed. The throttle limiterscrew in the lower throttle housing can beadjusted to limit throttle grip movement (page

).

Use the throttle limiter with the transmissionset in first gear until your youngster becomesfamiliar with operating the motorcycle.

Before each ride, check the throttle limiterscrew measurement and the restriction ofthrottle grip movement.

72

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－－

○○

○○

○○

ＡＡ

ＢＢ

ＣＣ

(1) choke lever

(1)

LEFTSIDE

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

32

Starting Procedure

Preparation


Starting & Stopping the Engine

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

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

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

Always follow the proper starting proceduredescribed below.

Make sure that the transmission is in neutraland the engine stop switch is at RUN. Turn thefuel valve ON.

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

1. 1A

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－

33Basic Operation & Riding


Normal Air Temperature.

Normal AirTemperature.

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

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

With the throttle slightly open, operate thekickstarter. Kick from the top of the strokethrough to the bottom with a rapid,continuous motion.

High Air Temperature35°C (95°F) or above

Do not use the choke.Start the engine following step under

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

Warm up the engine by opening and closingthe throttle slightly.Continue warming up the engine until it idlessmoothly and responds to the throttle withthe choke lever ( ) OFF ( ).

Immediately after the engine starts, push thechoke lever down to the detent position ( ).About a quarter-minute after the enginestarts, push the choke lever down all the wayto fully OFF ( ).If idling is unstable, open the throttle slightly.

2.

3.

4.

1.2.

5.

1.

2.

3.

2

1 2

1 C

B

C

05/03/16 09:33:59 31GEL660_042

34

Flooded Engine How to Stop the Engine



High Air Temperature

Open the throttle fully.

Push the choke lever down all the way toOFF.

Crank the engine several times with thekickstarter.

Follow the startingprocedure (page ).

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

Turn the engine stop switch OFF.

Turn the engine stop switch to RUN.

To stop the engine, shift into neutral, turn theengine stop switch to either OFF.

2.

3.

1.

4.

5.6.

33

05/03/16 09:34:13 31GEL660_043

35

Shifting Gears


Improper shif ting may damage the engine,transmission, and drive train.To start riding, after the engine has been

warmed and the side stand raised:

Close the throttle and pull the front brakelever in.

Your motorcycle has three forward gears.

Raise the shift lever from neutral up to firstgear.

Release the front brake. Gradually open thethrottle.When you attain a moderate speed, close thethrottle and raise the shift lever. Aftershifting, apply the throttle.To continue shifting up to each higher gear,repeat step .To shift down to a lower gear, close thethrottle and depress the shift lever. Aftershifting, apply the throttle.

Remember to close the throttle beforeshifting.

2.

3.

1.

4.

5.

6.4

05/03/16 09:34:23 31GEL660_044

36

Shifting Gears


Downshif ting can help slow your motorcycle,especially on downhills. However,downshif ting when engine rpm is too high cancause engine damage.

To prevent transmission damage, do not coastor tow the motorcycle f or long distances withthe engine of f .

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

05/03/16 09:34:28 31GEL660_045

37

Braking


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

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

To slow or stop, apply the front brake and rearbrake pedal smoothly, while downshifting tomatch your speed. Gradually increase brakingas you feel the brakes slowing your speed. Forsupport, put your left foot down first, then yourright foot when you are through using the rearbrake.

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

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

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

05/03/16 09:34:35 31GEL660_046

38

Parking


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

05/03/16 09:34:38 31GEL660_047

39

Post-ride Inspection


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

After cleaning, carefully inspect yourmotorcycle for leaks or damage.

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

105

05/03/15 17:49:21 31GEL660_048

40 Basic Operation & Riding

05/03/15 17:49:23 31GEL660_049

41

Servicing Your Honda


Maintenance, replacement or repair of the emissioncontrol devices and systems may be performed byany motorcycle repair establishment or individualusing parts that are ‘‘certified’’ to EPA standards.

Bef ore You Service Your Honda

Service Preparations

Keeping your motorcycle well maintained isabsolutely essential to your safety. It’s also agood way to protect your investment, getmaximum performance, avoid breakdowns, andhave more fun.

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

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

...................The Importance of Maintenance . 43.......................................Maintenance Safety . 45

....................Important Safety Precautions . 45..................................Maintenance Schedule . 47

.....................................Maintenance Record . 51

.............Maintenance Component Locations . 52..............................................................Tools . 55

................................................Seat Removal . 56......................Front Fork Protector Removal . 57

138

USA only

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42



Service ProceduresFluids & Filters

................................................................Fuel . 58.....................................................Engine Oil . 61....................................................Air Cleaner . 67

Engine..........................................................Throttle . 70

...............................................Clutch System . 73............................................Valve Clearance . 75

.........................................Engine Idle Speed . 78.....................................................Spark Plug . 79

...............................................Spark Arrester . 81

Chassis....................................................Suspension . 83

............................................................Brakes . 86...........................................................Wheels . 91

................................................Tires & Tubes . 96...................................................Side Stand . 100.................................................Drive Chain . 101

.........................................Appearance Care . 108

05/03/15 17:49:32 31GEL660_051

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

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

43

The Importance of Maintenance


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

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

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

More frequent service is needed if you subjectyour motorcycle to severe use (such ascompetition) or ride in unusually wet or dustyareas.

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

05/03/15 17:49:38 31GEL660_052

44

The Importance of Maintenance


Note to Parents:As a parent, it’s up to you to make sure thatthis motorcycle is properly maintained andkept in saf e operating condition. Foryoungsters, learning how to take care of amotorcycle and perf orm basic maintenancecan be an important part of their ridingexperience. However, if you allow a youngsterto perf orm or assist in any maintenance task,such as f illing the tank with gasoline, youshould provide close supervision to make surethat it is perf ormed saf ely.

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

05/03/15 17:49:43 31GEL660_053

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

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

45

Carbon monoxide poisoning from engineexhaust.

Burns from hot motorcycle parts.

Injury from moving parts.

Maintenance Safety

Important Safety Precautions


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

(cont’d)

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

Be sure there is adequateventilation whenever you operate the engine.

Let theengine and exhaust system cool beforetouching.

Do not run theengine unless instructed to do so.

05/03/15 17:49:48 31GEL660_054

－－

46

Maintenance Safety


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

05/03/15 17:49:52 31GEL660_055

47

Maintenance Schedule


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

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

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

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

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

146

05/03/15 17:49:58 31GEL660_056

＊＊＊

＊＊

＊

48



Summary of Maintenance Schedule Notes andProcedures:

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

Service more frequently when ridden in wetor dusty conditions.

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

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

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

1.NOTE:

I:

C:A:L:R:

27

146

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－

－－

＊

＊＊

49



Referto

page:1001501

6001,000

6

1,2002,000

12

1,8003,000

18

2,4004,000

24Items

FrequencyWhicheverComes First

InitialMaint.

Regular Maint. Interval

Note

mikm

Month

Note 1

IR

I

CIIR

I

IICIIRCCI

CIIR

I

IICIIRCCI

In the interest of safety, we recommend these items be serviced only by your Honda dealer.

Should be serviced by your Honda dealer, unless the owner has the proper tools and service data and is mechanically qualified.Refer to the official Honda Service Manual (page ).

7067797561

78

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

146

05/03/15 17:50:20 31GEL660_058

－

－

＊

＊＊

50



Referto

page:1001501

6001,000

6

1,2002,000

12

1,8003,000

18

2,4004,000

24Items

FrequencyWhicheverComes First

InitialMaint.

Regular Maint. Interval

NoteNote 1

mikm

MonthI, L

II

III

IIII

I

IIIIII

III

IIII

I

IIIIII

III

In the interest of safety, we recommend these items be serviced only by your Honda dealer.

Should be serviced by your Honda dealer, unless the owner has the proper tools and service data and is mechanically qualified.Refer to the official Honda Service Manual (page ).

1011028986731008381

91, 96

Drive ChainDrive Chain SliderBrake Shoe WearBrake SystemClutch SystemSide StandSuspensionSpark Arrester

Nuts, Bolts, FastenersWheels/TiresSteering Head Bearings

146

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

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

05/03/15 17:50:35 31GEL660_059

51

Maintenance Record

Date Performed By: NotesMiles(km)


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

600 (1,000)1,200 (2,000)1,800 (3,000)2,400 (4,000)3,000 (5,000)3,600 (6,000)4,200 (7,000)4,800 (8,000)5,200 (9,000)

05/03/15 17:50:40 31GEL660_060

front brake lever

throttle grip

fuel fill cap

52

Maintenance Component Locations


05/03/15 17:50:44 31GEL660_061

front brake lever

spark plug

spark arrester

engine oildrain bolt(under engine)

rear brakepedal

engine oil filler cap/dipstick

adjusting nut(drive chain)

rear brake rod

rear brake adjuster

clutch adjuster

53Servicing Your Honda


05/03/15 17:50:48 31GEL660_062

front suspension

rear suspensionair cleaner

front brake cable

adjusting nut(drive chain)

rear wheel axle

carburetor

front brakeadjuster

front wheel axle drive chain

54 Servicing Your Honda


05/03/15 17:50:53 31GEL660_063

(1)

(2)

(3)

(1) spark plug wrench(2) handle(3) tool bag

55

Tools


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

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

21453

05/03/15 17:50:58 31GEL660_064

(1)

(2)

(3)

(4)(5)

(4) seat(5) prongs

(1) clips(2) screws(3) bolts

56

Seat Removal


Saf ety PrecautionsRefer to on page . RemovalRemove the clips ( ) and screws ( ) on thefuel tank shroud.Remove the bolts ( ) under the rear fender.Slide the seat ( ) with fuel tank shroud andrear cowl back.

Installation

Install the bolts and screws and tighten them,then install the clips.

Position the prongs ( ) under the seat intothe spaces for them in the frame.

1.

1.

2.

2.

45

3. 43

21

5

05/03/15 17:51:06 31GEL660_065

(1)

LEFT FRONT RIGHT FRONT

(1)

(3)(2) (4)(4)

(1) bolts(2) front brake cable

(3) cable guide(4) front fork protector

57

Front Fork Protector Removal


Saf ety PrecautionsRefer to on page . Removal

InstallationAttach the fork protector on the front fork.Install the front brake cable to the cableguide.Install the securing bolts and tighten them.

Remove the two bolts ( ) securing the frontfork protector.Remove the front brake cable ( ) from thecable guide ( ).Remove the front fork protector ( ).

1.

1.2.

2.

3.

45

2

1

3

3.

4

05/03/15 17:51:15 31GEL660_066

unleaded86 (or higher)

TypePump Octane Number

58

Fuel Recommendation

Fuel


Saf ety PrecautionsRefer to on page . If pinging or spark knock occurs at a steadyengine speed under normal load, change brandsof gasoline. If pinging or spark knock persists,consult your Honda dealer.

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

Your engine is designed to use any gasolinethat has a pump octane number of 86 or higher.Gasoline pumps at service stations normallydisplay the pump octane number. Forinformation on the use of oxygenated fuels, seepage .

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

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

45

142

05/03/15 17:51:23 31GEL660_067

0.79 US gal (3.0 )

0.24 US gal (0.9 )

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

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

(1)

(2)

(1) fuel fill cap(2) breather tube

(3) front number plate(4) filler neck

(4) (3)

59

Refueling Procedure

Fuel


Fuel Tank Capacity, including reserve:

Reserve Capacity:

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

To open the fuel fill cap ( ), pull thebreather tube ( ) away from the frontnumber plate ( ). Turn the fuel fill capcounterclockwise and remove it.

1.

2.

23

1

4

05/03/15 17:51:31 31GEL660_068

60

Fuel


After refueling, turn the fuel fill capclockwise until it is secure.Check that the breather tube is properlyseated in the front number plate.

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

3.

4.

05/03/15 17:51:36 31GEL660_069

＊＊

＊

SG or higher exceptoils labeled asenergy conservingon the circular APIservice label

MAPro Honda GN4 orHP4 (withoutmolybdenumadditives) 4-strokeoil (USA & Canada),or Honda 4-stroke oil(Canada only), or anequivalentmotorcycle oil

SAE 10W-30

API classification

viscosity (weight)JASO T 903 standardsuggested oil

61

Oil Recommendation

Engine Oil


Saf ety PrecautionsRefer to on page .

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

45

05/03/15 17:51:44 31GEL660_070

＊＊

＊

OKNOT RECOMMENDED

62

Engine Oil


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

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

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

05/03/15 17:51:53 31GEL660_071

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

(1)

(2)

63

Engine Oil


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

JASO T 903 standardThe JASO T 903 standard is an index forengine oils for 4-stroke motorcycle engines.There are two classes: MA and MB.Oil conforming to the standard is labeled on theoil container. For example, the following labelshows the MA classification.

05/03/15 17:51:59 31GEL660_072

(2)

(1)RIGHT SIDE

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

(3)

64

Checking & Adding Oil

Engine Oil


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

Start the engine and let it idle for 3-5minutes. Stop the engine. Wait 2-3 minutes.Immediately unscrew and remove the oilfiller cap/dipstick. Wipe it clean.Hold the motorcycle upright.Insert the oil filler cap/dipstick until it seats,but do not screw it in.Remove the oil filler cap/dipstick and checkthe oil level.

Check for oil leaks.

Insert the oil filler cap/dipstick and screw itin tightly.

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

1.

2.

3.

4.

5.6.

7.

1

8.

9.

3

2

05/03/15 17:52:10 31GEL660_073

(1)

(1) oil drain bolt(2) sealing washer

RIGHT SIDE

(2)

65

Changing Engine Oil

Engine Oil


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

If the engine is cold, start it and let it idle for3-5 minutes. Turn the engine off. Wait 2-3minutes for the oil to settle.Park your motorcycle on a firm, levelsurface.Remove the oil filler cap/dipstick.Place a drain pan under the crankcase.Unscrew and remove the oil drain bolt.After most of the oil is drained, gently tiltthe motorcycle from side to side to drain theremaining oil.Pour the drained oil into a suitable containerand dispose of it in an approved manner(page ).

(cont’d)

1.

2.

3.4.5.6.

7.

119

05/03/15 17:52:20 31GEL660_074

18 lbf·ft (24 N·m , 2.5 kgf·m)

0.6 US qt (0.6 )

66

Engine Oil


Remove the old sealing washer ( ) andinstall a new sealing washer on the drain bolt.

Install the oil filler cap/dipstick securely.

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

Pour the recommended oil into the crankcase,approximately:

Install the oil drain bolt and tighten to thespecified torque:

Start the engine and let it idle for 3-5minutes. Stop the engine. Wait 2-3 minutes.

8.

9.

10.

11.12.

13.

14.

2

63

05/03/15 17:52:28 31GEL660_075

67

Air Cleaner


Saf ety Precautions

Using the wrong air cleaner can result inpremature engine damage.

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

Refer to on page .

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

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

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

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

45

05/03/15 17:52:35 31GEL660_076

－(2)

LEFT SIDE

(1)

(3)

(4)(5)

(3) air cleaner(4) projection (air cleaner housing cover)(5) projection (air cleaner housing)

(1) attaching screws(2) air cleaner housing cover

68

Cleaning

Air Cleaner


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

4.

5.

1.

2.3.

12

3

05/03/15 17:52:43 31GEL660_077

69

Air Cleaner


Pour clean Pro Honda Foam Filter Oil or anequivalent (Canada: Honda Foam Filter Oilor an equivalent) over the entire surface ofthe air cleaner. Use both hands to evenlyspread the oil into the air cleaner. Gentlysqueeze out any excess oil. (To keep yourhands dry, place the air cleaner in a cleanplastic bag before spreading the oil into theair cleaner.)Clean the inside of the air cleaner housing.Install the air cleaner.Install the air cleaner housing cover, aligningits projection ( ) with the projection ( ) onthe air cleaner housing.Install and tighten the two attaching screws.

6.

7.

8.

9.

4 5

05/03/15 17:52:49 31GEL660_078

－－1/16 3/16 in (2.0 4.0 mm)

RIGHT SIDE

(1) freeplay

(3)

(4)

(1)

(2) dust cover(3) lock nut

(4) adjuster

(2)

70

Throttle Freeplay

Throttle


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

If necessary, adjust to the specified range.

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

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

1.2.

3.

1

4.

5.

2

4

3

45

05/03/15 17:53:01 31GEL660_079

(2) (1)

(1) throttle(2) throttle cable

71

Throttle Inspection

Throttle


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

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

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

1.

2.

3.

4.

5.

1

2

05/03/15 17:53:08 31GEL660_080

(2)

(1)RIGHT HANDLEBAR

(3)

(1) lock nut(2) throttle limiter screw(3) throttle limiter screw measurement

72

Throttle Limiter Adjustment

Throttle


Loosen the lock nut ( ).Turn the throttle limiter screw ( ) clockwiseto reduce throttle grip movement orcounterclockwise to increase throttle gripmovement.

The throttle limiter screw measurement ( )is 13/16 in (21 mm) when the throttle is fullyopen; less than 13/16 in (21 mm) when thethrottle opening (and maximum enginespeed) is restricted.

To prevent moisture or debris (dirt, sand,pebbles, sticks, etc.) from entering the throttlehousing, do not remove the throttle limiterscrew.Moisture and debris may interfere with properthrottle operation.

Hold the screw in place and tighten the locknut.

1.2.

3.

12

3

05/03/15 17:53:16 31GEL660_081

(2)

(1)

(1) adjuster lock nut(2) clutch adjuster

73

Clutch System



InspectionThe engine should start easily with thekickstarter without the clutch slipping. Whenshifting gears, the clutch operation should besmooth and light, especially when shifting intoneutral.

Loosen the adjuster lock nut ( ).Turn the clutch adjuster ( ) clockwise oneturn; do not turn excessively.

Adjustment

(cont’d)

1.2.

1

45

2

05/03/15 17:53:23 31GEL660_082

74

Clutch System


Slowly turn the adjuster counterclockwiseuntil a slight resistance is felt.From this position, turn the adjusterclockwise 1/8 to 1/4 turn, and tighten thelock nut.After adjustment, test ride the motorcycle tobe certain the clutch operates properly.

If you can’t get proper adjustment, or theclutch does not work properly, see yourHonda dealer.

3.

4.

5.

05/03/15 17:53:28 31GEL660_083

(1)

(2)

LEFT SIDE

(3)

(4)

(4)

(1) left crankcase cover(2) bolts A(3) bolt B(4) adjusting hole caps

75

Valve Clearance


Saf ety Precautions

Excessive valve clearance will cause noise andeventual engine damage. Little or no clearancewill prevent the valve from closing and causevalve damage and power loss. Check valveclearance when the engine is cold at theintervals specified in the Maintenance Schedule.

The checking or adjusting of the clearanceshould be performed while the engine is cold.The clearance will change as enginetemperature rises.

Refer to on page .

Remove the left crankcase cover ( ) byremoving the bolts A ( ) and bolt B ( ).Remove the adjusting hole caps ( ).

(cont’d)

1.

2.

1

45

2 34

05/03/15 17:53:34 31GEL660_084

LEFT SIDE (6)

(5)

(5) T mark(6) index mark

76

Valve Clearance


The adjustment must be made when the pistonis at the top of the compression stroke whenboth the intake and exhaust valves are closed.This condition can be determined by movingthe rocker arms. If they are free, it is anindication that the valves are closed and that thepiston is on the compression stroke. If they aretight and the valves are open, rotate theflywheel 360° and realign the T mark to theindex mark.

Rotate the generator flywheelcounterclockwise until the T mark ( ) on theflywheel lines up with the index mark ( ) onthe crankcase. In this position, the pistonmay either be on the compression or exhauststroke.

3.5

6

05/03/15 17:53:40 31GEL660_085

0.002 in (0.05 mm)

LEFT SIDE (7)

(8)

(9)

(7) feeler gauge(8) adjusting screw(9) adjusting screw lock nut

77

Valve Clearance


Check the clearance of both valves byinserting a feeler gauge ( ) between theadjusting screw ( ) and the valve stem.Clearance should be:

If it is necessary to make an adjustment,loosen the adjusting screw lock nut ( ) andturn the adjusting screw so there is a slightresistance when the feeler gauge is inserted.

After completing the adjustment, tighten theadjusting screw lock nut while holding theadjusting screw to prevent it from turning.Finally, recheck the clearance to make surethat the adjustment has not been disturbed.

Install the left crankcase cover.Install and tighten the bolts A, bolt B andadjusting hole caps.

4.

5.

78

9

6.7.

05/03/15 17:53:47 31GEL660_086

±

＋－

＋＋

－－

1,700 100 rpm

( ) increase rpm( ) decrease rpm

(1)

(1) throttle stop screw

LEFT SIDE

(( ))

(( ))

78

Engine Idle Speed


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

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

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

1.

2.

3.1

Idle Speed:

45

05/03/15 17:53:55 31GEL660_087

U20FSR-U (DENSO)CR6HSA (NGK)

CR5HSA (NGK)U16FSR-U (DENSO)CR7HSA (NGK)U22FSR-U (DENSO)

or

or

or

Standard

For cold climate(below 5°C, 41°F)For extended highspeed riding

(1) center electrode(2) side electrode(3) spark plug gap

(2)(1)

(3)

79

Spark Plug Recommendation

Spark Plug


Saf ety Precautions

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

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

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

45

05/03/15 17:54:05 31GEL660_088

－－0.024 0.028 in (0.60 0.70 mm)

80 Servicing Your Honda

Spark Plug

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

Tighten the spark plug:

Disconnect the spark plug cap.

Clean any dirt from around the spark plugbase.

Remove the spark plug with a plug wrench.Inspect the spark plug electrodes for wear.The center electrode ( ) should have squareedges. The side electrode ( ) should not beeroded. The insulator should not be crackedor chipped.Check the spark plug gap ( ), using a wire-type feeler gauge. If adjustment is necessary,bend the side electrode carefully. The gapshould be:

Make sure the plug washer is in goodcondition.If you have to install a new plug, first checkthe gap.With the plug washer attached, thread thespark plug in by hand (to prevent cross-threading).

If the old plug is good:1/8 turn after it seats.If installing a new plug, tighten it twice toprevent loosening:

First, tighten the plug:NGK: turn after it seats.DENSO: turn after it seats.Then loosen the plug.Next, tighten the plug again:1/8 turn after it seats.

Connect the spark plug cap.

2.3.4.

5.

6.

7.

3

1

1.

2

8.

a)

c)b)

3/41

05/03/15 17:54:17 31GEL660_089

(4)

RIGHT REAR

(3) gasket(4) muffler

(3)

(1)(2)

(1) bolts(2) spark arrester

81

Spark Arrester



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

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

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

Allow the engine and muffler to cool.

(cont’d)

1.2.

43

45

21

05/03/15 17:54:25 31GEL660_090

82

Spark Arrester


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

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

3. 4.

05/03/15 17:54:29 31GEL660_091

(1) mounting bolts

(1)

(2)

(2) mounting nuts

83

Front Suspension Inspection

Suspension



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

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

(cont’d)

1.

45

05/03/15 17:54:36 31GEL660_092

(1)

(1)

LEFT SIDE

RIGHT SIDE(2)

(2)

(1) swingarm bushing(2) shock absorber attachment points

(1) swingarm bushing(2) shock absorber attachment points

84

Rear Suspension Inspection

Suspension


Check the security of all fork mounting bolts( ) and handle bar mounting nuts ( ). If anyfront suspension components appear worn ordamaged, see your Honda dealer for furtherinspection.

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

1.

2.1 2

1

05/03/15 17:54:43 31GEL660_093

85

Suspension


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

2.

3.2

05/03/15 17:54:47 31GEL660_094

－－3/8 13/16 in (10 20 mm)

(1)

RIGHT SIDE

(1) front brake lever

86

Front Brake Lever Freeplay

Brakes


Saf ety PrecautionsRefer to on page . InspectionCheck freeplay by pulling in slowly on thefront brake lever ( ) until the brake starts toengage.


Freeplay:

1

45

05/03/15 17:54:53 31GEL660_095

＋－

＋＋

－－

( ) increase freeplay( ) decrease freeplay

LEFT FRONT

(( ))

(( ))

(2)(3)

(2) adjusting nut(3) brake arm pin

87

Brakes


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

1.

2.

3.

3

2

05/03/15 17:55:00 31GEL660_096

－－3/8 13/16 in (10 20 mm)

(1) rear brake pedal

(1)

RIGHT SIDE

88

Rear Brake Pedal Freeplay

Brakes


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


1.2.

Freeplay:

1

05/03/15 17:55:07 31GEL660_097

＋－

－－

＋＋

(4)

(2)

(3)

(1)

(1) arrow(2) brake arm

(3) reference mark(4) brake panel

LEFT FRONT

RIGHT REAR

(2) adjusting nut(3) brake arm pin

( ) increase freeplay( ) decrease freeplay

(2)

(3)

(( ))

(( ))

89

Brake Shoe Wear

Brakes


The front and rear brakes are equipped withexternal brake wear indicators that let youcheck brake wear without disassembly.Application of the brake control (lever orpedal) causes the arrow on the brake arm tomove toward a reference mark on the brakepanel.

Check the freeplay. If you can’t adjust thefreeplay properly, see your Honda dealer.

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

Turn the rear brake adjusting nut ( ). Makesure the cut-out on the adjusting nut is seatedon the brake arm pin ( ).

Adjustment1.

2.

3.

2

3

05/03/15 17:55:16 31GEL660_098

(2)

(3)

(1)

(4)

(1) arrow(2) brake arm

(3) reference mark(4) brake panel

RIGHT REAR

90

Other Inspections & Lubrication

Brakes


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

Place your motorcycle on its side stand.

Check that the front lever and rear pedalassemblies are positioned properly and thesecuring bolts are tight.Check the front brake cable for kinks orsigns of wear that could cause sticking orfailure.Lubricate the front brake cable with acommercially-available cable lubricant toprevent premature wear and corrosion.Front: Make sure the brake arm, spring, andfasteners are in good condition.Rear: Make sure the brake rod, brake arm,spring, and fasteners are in good condition.

1.2.

1

32

4

05/03/15 17:55:24 31GEL660_099

(1)

REAR

(1) wheel rim(2) spoke

(2)

91

Wheel Rims & Spokes

Wheels



Inspect the wheel rims ( ) and spokes ( )for damage.Tighten any loose spokes.

Maintenance of spoke tension and wheeltrueness (roundness) is critical to safemotorcycle operation. During the first 100miles (150 km), spokes will loosen morerapidly due to the initial seating of the parts.Excessively loose spokes may result ininstability at high speeds and the possible lossof control. Loose spokes may also cause rim orspoke damage (not covered by warranty). It’salso important that the rim locks are secure toprevent tire slippage.

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

(cont’d)

11.

2.

2

45

05/03/15 17:55:31 31GEL660_100

(1)

(2)

(5)

(4)

(3)(4) front axle nut(5) lug(6) slot

(6)

(1) brake adjusting nut(2) brake cable(3) brake arm

92

Front Wheel Removal

Wheels


Rotate the wheel slowly to see if it appearsto ‘‘wobble.’’ If it does, the rim is out ofround or not ‘‘true.’’ If the wobble isnoticeable, see your Honda dealer forinspection.

RemovalRaise the front wheel off the ground byplacing a maintenance stand or support blockunder the engine. Secure the rear of themotorcycle with tie-down straps.Remove the front fork protector (page ).Unscrew the front brake adjusting nut ( ).Pull the front brake lever in and disconnectthe brake cable ( ) from the brake arm ( ).Remove the front axle nut ( ) and front axleshaft.

Pull the brake assembly out carefully.Remove the wheel.

1.

2.

3.

3.

4.

5.

1

6.

24

3

57

05/03/15 17:55:41 31GEL660_101

35 lbf·ft (46 N·m , 4.8 kgf·m)

93

Wheels


Take care to prevent getting grease, oil, or dirton the brake shoe surfaces. This can cause poorbrake performance or rapid brake shoe wearafter reassembly.

InstallationReverse the removal procedure. Make surethe lug ( ) on the fork leg is located in theslot ( ) in the brake panel.Torque the axle to:

Check front brake adjustment (page ).

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

2.

1.

3.

56

86

05/03/15 17:55:48 31GEL660_102

RIGHT REAR

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

(1) (2)

(4)(3) (5)

LEFT REAR

(4)(5)

(6)

(4) lock nut(5) adjusting nut(6) rear axle nut

94

Rear Wheel Removal

Wheels


RemovalRaise the rear wheel off the ground byplacing a maintenance stand or support blockunder the engine. Secure the front of themotorcycle with tie-down straps.Unscrew the rear brake adjuster ( ). Pressthe rear brake pedal and disconnect the brakerod ( ) from the brake arm ( ).Loosen the lock nut ( ) and adjusting nut( ) on the chain adjuster on both sides.

Take care to prevent getting grease, oil, ordirt on the brake shoe surfaces. This cancause poor brake performance or rapid brakeshoe wear after reassembly.

Unscrew the rear axle nut ( ). Pull the rearaxle shaft out. Push the wheel forward andderail the drive chain from the rear sprocket.Remove the wheel.

1.

2.

3.

4.

1

32

54

6

05/03/15 17:55:58 31GEL660_103

35 lbf·ft (46 N·m , 4.8 kgf·m)(7)

(8)

RIGHT REAR

(9)

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

95

Wheels


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

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

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

2.3.

4.

1.

5.

103

87

9

88

05/03/15 17:56:06 31GEL660_104

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

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

96

Air Pressure

Tires & Tubes


Saf ety Precautions

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

Refer to on page .

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

and our recommendations on tire repair andreplacement.

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

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

45

05/03/15 17:56:13 31GEL660_105

－－

15 psi (100 kPa , 1.0 kgf/cm )18 psi (125 kPa , 1.25 kgf/cm )

FrontRear

(1) (2)

(1) tire tread depth(2) spoke nut

97

Inspection

Tires & Tubes


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

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

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

124

05/03/15 17:56:20 31GEL660_106

98

Tube Replacement

Tires & Tubes


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

Use a replacement tube equivalent to theoriginal.

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

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

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

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

1 124

97

05/03/15 17:56:28 31GEL660_107

2.50-10 33J

bias-ply, tube type

2.50-10 33JCHENG SHIN

CHENG SHIN

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

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

Front

Rear

Type

99

Tire Replacement

Tires & Tubes


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

We recommend that tires be replaced byyour Honda dealer.

Have the wheel balanced after a new tire isinstalled.

Replace the tube any time you replace a tire.The old tube will probably be stretched and,if installed in a new tire, could fail.

Use a replacement tire equivalent to theoriginal.

05/03/15 17:56:36 31GEL660_108

(1)

LEFT SIDE

(2)

(1) side stand spring(2) side stand

100

Side Stand


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

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

1.

2.

145

05/03/15 17:56:41 31GEL660_109

－－9/16 1 in (15 25 mm)

(1)

(1) drive chain

LEFT SIDE

101

Inspection

Drive Chain



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

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

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

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

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

(cont’d)

1.

45

1

05/03/15 17:56:49 31GEL660_110

(2)

(2) chain slider

(3)

(3)

(3) ridge

LEFT SIDE

102

Drive Chain


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

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

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

links and work them free. Adjust chain slackif needed.

damaged rollersloose pinsdry or rusted linkskinked or binding linksexcessive wear

Inspect the drive chain for:

Check the chain slider ( ) for wear. If theridge ( ) in the center of the slider is worn,have your Honda dealer replace the chainslider.

2.

3.

4. 23

106

105

05/03/15 17:56:57 31GEL660_111

38.5 in (978 mm)39.3 in (997 mm)

Measure a span of 77 pins

103

Drive Chain


Replace the drive chain if chain slack isexcessive when the rear axle is moved to thefarthest limit of adjustment. Excessive slackindicates the chain is worn beyond its servicelimit.To check the chain’s service limit, removethe drive chain (page ). Then measurethe distance between a span of pins,from pin center to pin center. If the distanceexceeds the service limit, the drive chain isworn out and should be replaced.

(cont’d)

5.

New Chain:Service Limit:

77106

05/03/15 17:57:03 31GEL660_112

(3)

(4)

(1)

Damaged SprocketTeeth

Worn SprocketTeeth

REPLACE

Normal Sprocket TeethGOOD

REPLACE

LEFT SIDE

(2)

(5)

(1) rear axle nut(2) lock nut(3) adjusting nut

(4) adjuster index mark(5) graduated scale

104

Adjustment

Drive Chain


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

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

Loosen the lock nuts ( ) on both sides of theswingarm.

Loosen the rear axle nut ( ).1.2.

6.

21

05/03/15 17:57:12 31GEL660_113

35 lbf·ft (46 N·m , 4.8 kgf·m)

105

Lubrication


Drive Chain

Turn the rear wheel by hand. Saturate eachchain link joint so that the lubricant penetratesbetween the link plates, pins, bushings, androllers.

Lubricate every 300 miles (500 km) or soonerif chain appears dry.

Turn the adjusting nuts ( ) on the right andleft chain adjusters an equal number of turnsto increase or decrease chain slack.Align the chain adjuster index marks ( )with the graduated scales ( ) on both sidesof the swingarm.Torque the rear axle nut to:

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

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

Recheck drive chain slack.

Tighten the adjusting nuts lightly. Then,while holding the adjusting nuts with awrench, tighten the lock nuts.

3.

4.

5.

6.

7.8.

4

3

5

88

05/03/15 17:57:22 31GEL660_114

－－

(1)

(1) master link retaining clip

LEFT SIDE

106

Removal, Cleaning & Replacement

Drive Chain


When the drive chain becomes extremely dirty,it should be removed and cleaned prior tolubrication.

Remove the master link retaining clip ( )with pliers. Do not bend or twist the clip.Remove the master link. Remove the drivechain.

Inspect the drive chain for possible wear ordamage. Replace the drive chain if it hasdamaged rollers, loose fitting links, orotherwise appears unserviceable.

Clean the drive chain with a non-flammable(high flash point) solvent such as kerosenenot gasoline and allow it to dry.

2.

1.

3.

1

05/03/15 17:57:28 31GEL660_115

107

More About: Drive Chain

Drive Chain


The master link is the most critical elementof drive chain security. Master links arereusable, as long as they remain in excellentcondition. We recommend installing a newmaster link retaining clip when the drivechain is reassembled.You may find it easier to install a new chainby connecting it to the old chain with amaster link and pulling the old chain toposition the new chain on the sprockets.

Inspect the sprocket teeth for wear ordamage. We recommend replacing thesprocket whenever a new chain is installed.Lubricate the drive chain.Pass the chain over the sprockets and join theends of the chain with the master link. Forease of assembly, hold the chain ends againstadjacent rear sprocket teeth while insertingthe master link. Install the master linkretaining clip so that the closed end of theretaining clip will face the direction offorward wheel rotation.

4.

5.6.

05/03/15 17:57:34 31GEL660_116

－－－－

108

General Recommendations

Appearance Care



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

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

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

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

45

05/03/15 17:57:42 31GEL660_117

109

Washing Your Motorcycle with a MildDetergent

Appearance Care


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

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

wheel hubsmuffler outlet

under fuel tankdrive chaincarburetor

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

engine stop switcharea under seat

(cont’d)

1.

2.

3.

4.

5.

05/03/15 17:57:53 31GEL660_118

110

Appearance Care


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

6.7.

8.

05/03/15 17:57:58 31GEL660_119

111

Tips

Tips

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

....................................Preparing for a Ride . 112...........................Transporting Your Honda . 114

....................................Storing Your Honda . 116..............................You & the Environment . 119

05/03/15 17:58:02 31GEL660_120

112

What to Take to the Riding Area

Preparing for a Ride

Tips

TakingCare of the Unexpected,

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

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

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

which begins on page.

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

a tool kittire repair supplies and tools, tubes, and tiresextra parts, such as a drive chain and masterlinks, control levers, cables, and spark plugswire, duct tape, and ropeextra gasoline

121

05/03/15 17:58:09 31GEL660_121

113

What to Take on the Trail

Preparing for a Ride

Tips

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

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

If you decide to take some tools, spare parts, orother supplies on the trail, be sure you cancarry them safely and know how to use them.Also, be sure to follow the loading guidelinesand weight limit (page ).9

05/03/15 17:58:14 31GEL660_122

114

Transporting Your Honda

Tips

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

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

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

05/03/15 17:58:21 31GEL660_123

115

Transporting Your Honda

Tips

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

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

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

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

05/03/15 17:58:26 31GEL660_124

116

Storing Your Honda

Tips

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

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

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

05/03/15 17:58:30 31GEL660_125

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

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

117

Preparation for Storage

Storing Your Honda

Tips

Change the engine oil (page ).Fill the fuel tank. Make sure the fuel fill capis properly installed.Check that the fuel valve is OFF.

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

(cont’d)

1.2.

3.

4.

11965

05/03/15 17:58:38 31GEL660_126

－

－

118

Removal from Storage

Storing Your Honda

Tips

Uncover and clean your motorcycle.

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

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

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

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

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

Inflate the tires to their recommendedpressures (page ).

Lubricate the drive chain.Wash and dry your motorcycle.

6.7.

8.

9.

1.2.

3.

4.5.

5.

27

96

65

05/03/15 17:58:47 31GEL660_127

119

Tread Lightly.

Keep the Noise Down.

Choose Sensible Cleaners.

You & the Environment

Tips

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

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

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

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

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

(cont’d)

05/03/15 17:58:53 31GEL660_128

120

Recycle Wastes.

You & the Environment

Tips

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

05/03/15 17:58:57 31GEL660_129

121

Taking Care of the Unexpected


Preparing f ora Ride

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

(page ).

......................................General Guidelines . 122..........If Your Engine Quits or Won’t Start . 123

...............................If You Have a Flat Tire . 124................................................If You Crash . 125

................................If You Lose Your Key . 126..................................If a Component Fails . 127

112

05/03/15 17:59:01 31GEL660_130

－

－

122

General Guidelines



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

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

Whatever the problem, the most important rulesare:

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

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

Always put personal safety first.

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123

If Your Engine Quits or Won’t Start



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

Additional recommendations for specificproblems follow.

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

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

Make sure there is enough gas in the tankand the fuel valve is at the ON or RESposition.

05/03/15 17:59:15 31GEL660_132

124

If You Have a Flat Tire



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

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

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

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

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

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

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

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

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

05/03/15 17:59:23 31GEL660_133

125

If You Crash



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

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

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

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

99

92 94

05/03/15 17:59:28 31GEL660_134

126



If You Lose Your Key

QuickRef erence

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

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

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

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

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

05/03/15 17:59:33 31GEL660_135

127

If a Component Fails



If any component of the front brake systemis damaged, you may be able to ridecarefully back to your base using the rearbrake for slowing or stopping.If you damage a throttle cable or othercritical component, your motorcycle may beunsafe to ride. Carefully assess the damageand make any repairs that you can. But ifthere is any doubt, it’s best to beconservative and safe.

The drive chain, master link, brake lever orpedal, control cables, and other componentscan be damaged as you ride in dense brush orover rocky terrain. Making a trailside repairdepends on how serious the damage is andwhat tools and supplies you have with you.

If the drive chain comes off because themaster link clip gets knocked off, you maybe able to put the chain back on with a newmaster link. However, if the chain breaks ordoes other damage when it comes off, youmay not be able to make a trailside repair.

05/03/15 17:59:39 31GEL660_136

128 Taking Care of the Unexpected

05/03/15 17:59:41 31GEL660_137

129

Technical Information


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

.................................Vehicle Identification . 130..............................................Specifications . 132

....................................Break-in Guidelines . 137..........................Emission Control Systems . 138

........................................Oxygenated Fuels . 142

05/03/15 17:59:45 31GEL660_138

(2) engine number

(1)

(2)

(1) frame number

LEFT SIDE

LEFT SIDE

130

Vehicle Identification

Serial Numbers


Quick Ref erence

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

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

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

1

2

05/03/15 17:59:51 31GEL660_139

(1)

(1) color label

LEFT SIDE

131

Vehicle Identification

Color Label & Code


Quick Ref erence

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

The color label ( ) is attached to the left sideof the frame down tube.

1

05/03/15 17:59:56 31GEL660_140

0.79 US gal (3.0 )51.3 in (1,302 mm)22.9 in (581 mm)30.5 in (774 mm)35.9 in (911 mm)

including reserve0.24 US gal (0.9 )unleaded gasoline,pump octanenumber of 86 orhigherPro Honda (USAonly) or Honda(Canada only) FoamFilter Oil or anequivalentafter draining:0.6 US qt (0.6 )after disassembly:0.8 US qt (0.8 )

Overall lengthOverall widthOverall heightWheelbase

Fuel tank capacity

Fuel tank reserveFuelrecommendation

Air cleaner oil

Engine oil capacity

Dimensions Fuel & Lubricants

132

Specifications


05/03/15 18:00:06 31GEL660_141

××

10.0 : 1

1.54 1.63 in(39.0 41.4 mm)

3.01 cu-in (49.4 cm )

none

operator only;no passenger88 lbs (40 kg)

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

API ServiceClassification SG orhigher except oilslabeled as energyconserving on thecircular API servicelabel, SAE 10W-30,JASO T 903standard MA,Pro Honda GN4 orHP4 (withoutmolybdenumadditives) 4-strokeoil (USA & Canada)or Honda 4-stroke oil(Canada only), or anequivalentmotorcycle oil

DisplacementBore & stroke

Compression ratio

PassengercapacityMaximum weightcapacityCargo capacity

Engine oilrecommendation

Drive chainlubricant

Fuel & Lubricants

Engine Specifications

Capacities

Fuel & Lubricants

133

Specifications


05/03/15 18:00:17 31GEL660_142

－－±

CR6HSA (NGK)

4.0583.2721.6671.190

U20FSR-U (DENSO)2.642chain

0.002 in(0.05 mm)0.002 in(0.05 mm)

CR5HSA (NGK)U16FSR-U (DENSO)

CR7HSA (NGK)U22FSR-U (DENSO)

0.024 0.028 in(0.60 0.70 mm)1,700 100 rpm

or

or

Intake:

Exhaust:

or

Primary reductionGear ratio, 1st2nd3rdFinal reductionFinal drive

Valve clearance(cold)

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

Idle speed

Engine Specifications Power Transmission

134

Specifications


05/03/15 18:00:28 31GEL660_143

－－

25°00’

2.50-10 33J1.3 in (32 mm)

distance between aspan of 77 pins

distance between aspan of 77 pins

9/16 1 in(15 25 mm)38.5 in (978 mm)

39.3 in (997 mm)

2.8 in (70 mm)axle travel

axle travel3.4 in (87 mm)cushion stroke3.79 in (96.3 mm)

bias-ply, tube type

2.50-10 33J

15 psi(100 kPa , 1.0 kgf/cm )18 psi(125 kPa , 1.25 kgf/cm )

CHENG SHIN

CHENG SHIN

Drive chainfreeplayNew chain length

Used chain servicelimit length

CasterTrailTire size, front

Tire size, rear

Tire typeTire pressure, front(cold)Tire pressure, rear(cold)Suspension, front

Suspension, rear

Power Transmission Chassis & Suspension

135

Specifications


05/03/15 18:00:40 31GEL660_144

18 lbf·ft (24 N·m ,2.5 kgf·m)35 lbf·ft (46 N·m ,4.8 kgf·m)

Oil drain bolt

Wheel axles

Torque Specifications

136

Specifications


05/03/15 18:00:45 31GEL660_145

137Technical Information

Break-in Guidelines

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

05/03/15 18:00:48 31GEL660_146

(1)

(1) vehicle emission controlinformation label

LEFT SIDE

138

Noise Emission RequirementsExhaust Emission Requirements (USA only)

Emission Control Systems


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

The U.S. Environmental Protection Agency(EPA) and the California Air Resources Board(CARB) require that your motorcycle complywith applicable exhaust emission standardsduring its useful life, when operated andmaintained according to the instructionsprovided.

The Vehicle Emission Control InformationLabel ( ) is attached to the inside of the leftside cover.

1

05/03/15 18:00:54 31GEL660_147

139

Exhaust Emission Control System

Crankcase Emission Control System

Source of Emissions



The exhaust emission control system iscomposed of appropriate carburetor settings.No adjustments should be made except for anidle speed adjustment with the throttle stopscrew or carburetor adjustment for high altitudeoperation. The exhaust emission control systemis separate from the crankcase emission controlsystem.

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

The combustion process produces carbonmonoxide (CO), oxides of nitrogen (NOx), andhydrocarbons (HC). Control of hydrocarbonsand oxides of nitrogen is very importantbecause, under certain conditions, they react toform photochemical smog when subjected tosunlight. Carbon monoxide does not react inthe same way, but it is toxic.

Honda Motor Co., Ltd. utilizes various systemsto reduce carbon monoxide, oxides of nitrogenand hydrocarbons.

05/03/15 18:00:58 31GEL660_148

140

Noise Emission Control System



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

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

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

2.

3.4.

05/03/15 18:01:03 31GEL660_149

141

Problems that May Affect MotorcycleEmissions



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

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

Federal regulations prohibit removing ordisabling a device or element of design thatmay affect your engine’s emissionperformance unless your motorcycle will beused exclusively in competition. If you modifyyour engine for use in sanctioned competitionevents, you must deface or destroy theemission control information label.

1.2.3.4.5.

05/03/15 18:01:07 31GEL660_150

142

Oxygenated Fuels


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

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

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

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

The following are the EPA-approvedpercentages of oxygenates:

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

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

05/03/15 18:01:14 31GEL660_151

143

Oxygenated Fuels


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

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

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

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

05/03/15 18:01:19 31GEL660_152

144 Technical Information

05/03/15 18:01:21 31GEL660_153

145

Consumer Information


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

.....................................Authorized Manuals .146......................................Warranty Coverage .149

..........................................Warranty Service .150........................................Contacting Honda .151

..........The Honda Rider’s Club (USA only) .152......................................Your Honda Dealer .153

05/03/15 18:01:24 31GEL660_154

＊

＊

$38.00$48.00$16.00

61GEL5261CM00231GEL660

2006 CRF50F Service ManualCommon Service Manual2006 CRF50F Owner’s Manual

Price EachDescriptionPublication Item No.

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

146

Authorized Manuals


The Service Manual used by your authorized Honda dealer is available from Helm, Inc. (USA only,Canada: See your Honda dealer to order authorized manuals.)

Also available but not necessary to service your model is the Honda Common Service Manualwhich explains theory of operation and basic service information for various systems common to allHonda motorcycles, motor scooters and ATVs.

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

05/03/15 18:01:31 31GEL660_155

－－

＊

＊

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

Prices are subject to change without notice and without incurringobligation.

PublicationItem No.

Item Description

Handling ChargeGrand Total

Sub Total

$5.00

PriceEach

Qty.

Purchaser’s Sales TaxMich. Add 6 %Calif. Add 8.25 %

TotalPrice

147

Order On-Line: www.helminc.com

Order Toll Free: 1-888-CYCLE93

OR


(NOTE: For Credit Card Orders Only)

(1-888-292-5393)

Monday Friday 8:00 AM 6:00 PM EST

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

Canada: See your Honda dealer to order authorized manuals.

05/03/15 18:01:40 31GEL660_156

－

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

AttentionCustomer Name

Apartment NumberStreet Address - No P. O. Box Number

Zip CodeStateCity

Daytime Telephone Number

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

MasterCard

VISA

Discover

DateCustomer Signature

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

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

Expiration: Mo. Yr.Account Number

( )

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

SHIP

TO

PAYMENT

148 Consumer Information

05/03/15 18:01:53 31GEL660_157

149

Warranty Coverage


Your new Honda is covered by thesewarranties:

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

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

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

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

Motorcycle Limited WarrantyExhaust Emission Warranty (USA only)Noise Control Warranty (USA only)

05/03/15 18:01:59 31GEL660_158

150

Warranty Service


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

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

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

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

05/03/15 18:02:04 31GEL660_159

151

Contacting Honda


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

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

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

Motorcycle Division, American Honda MotorCo., Inc., P.O. Box 2220, Torrance, CA 90509-2220, mailstop: 100-4W-5B, telephone: (866)784-1870.

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

Please include the following information inyour letter:

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

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

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152

The Honda Rider’s Club (USA only)


Honda Red RiderHonda Red Rider ATV

One of the best ways to get the most enjoymentfrom owning and riding your Honda is throughthe Honda Rider’s Club of America. Yourpurchase of a new motorcycle, scooter, ATV orPWC from a participating U.S. Honda dealerentitles you to a complimentary one-yearmembership in the Club. There are hundreds ofHRCA Chapter sponsoring dealers across theUSA with events and activities almost everyweekend. Membership benefits include:

24 hour, toll-free roadside assistance foryour new Honda (includes roadsideassistance for your transport vehicle as longas your Honda is aboard or in tow).

An exclusive HRCA website complete withaccess to the official Honda CommonService Manual, contests, insiderinformation and more.

One full year of themagazine or (forATV purchasers).

Reimbursement (up to $75) for MotorcycleSafety Foundation training. Separate freetraining from the Specialty Vehicle Instituteof America for ATV owners.

Discounts from HRCA partners forexperienced rider courses.Discounted vehicle insurance from theHRCA’s insurance partner.Racing contingency programs and assistanceat selected dual-sport, off-road, andmotocross events.

Contact your Honda dealer for moreinformation or call:1-800-847-HRCA or log on towww.hrca.honda.com.

Vehicle transport to the nearest Honda dealeror service center, if necessary.

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153

Your Honda Dealer


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

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

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

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

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

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

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154

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

.......................OPERATING CONTROLS . 13

......................................BEFORE RIDING . 23

Table of Contents

Table of Contents

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

.........................Important Safety Information . 2

.........................Important Message to Parents . 5..........Loading, Accessories & Modifications . 8

.......................................................Loading . 8....................Accessories & Modifications . 10

.................................................Safety Labels . 12

..................Operation Component Locations . 14........................................Operating Controls . 14

.................................................Fuel Valve . 17..............................................Choke Lever . 18

..........................................Ignition Switch . 19...................................Engine Stop Switch . 20

.....................................Front Brake Lever . 20......................................................Throttle . 20

................................................Shift Lever . 21.......................................Rear Brake Pedal . 21

.................................................Kickstarter . 21

.................................................Side Stand . 21

.............................Are You Ready to Ride . 24....................................Protective Apparel . 24

...........Is Your Motorcycle Ready to Ride . 26....................................Pre-ride Inspection . 27

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155

.............BASIC OPERATION & RIDING . 29 ...................SERVICING YOUR HONDA . 41

Table of Contents

Table of Contents

Bef ore You Service Your Honda

Service Preparations

(cont’d)

................................Safe Riding Precautions . 30....................Starting & Stopping the Engine . 32

................................................Preparation . 32.....................................Starting Procedure . 32

.........................................Flooded Engine . 34............................How to Stop the Engine . 34

...............................................Shifting Gears . 35..........................................................Braking . 37..........................................................Parking . 38

......................................Post-ride Inspection . 39

...................The Importance of Maintenance . 43.......................................Maintenance Safety . 45

....................Important Safety Precautions . 45..................................Maintenance Schedule . 47

.....................................Maintenance Record . 51

.............Maintenance Component Locations . 52..............................................................Tools . 55

................................................Seat Removal . 56......................Front Fork Protector Removal . 57

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156

SERVICING YOUR HONDA (cont’d)

............................................................TIPS . 111

Table of Contents

Table of Contents

Service ProceduresFluids & Filters

................................................................Fuel . 58.....................................................Engine Oil . 61....................................................Air Cleaner . 67

Engine..........................................................Throttle . 70

...............................................Clutch System . 73............................................Valve Clearance . 75

.........................................Engine Idle Speed . 78.....................................................Spark Plug . 79

...............................................Spark Arrester . 81

Chassis....................................................Suspension . 83

............................................................Brakes . 86...........................................................Wheels . 91

................................................Tires & Tubes . 96...................................................Side Stand . 100.................................................Drive Chain . 101

.........................................Appearance Care . 108

....................................Preparing for a Ride . 112...........................Transporting Your Honda . 114

....................................Storing Your Honda . 116..............................You & the Environment . 119

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157

TAKING CARE OF THE.........................................UNEXPECTED . 121

.............TECHNICAL INFORMATION . 129

..............CONSUMER INFORMATION . 145

.........................TABLE OF CONTENTS . 154

........................................................INDEX . 158

QUICK REFERENCE

Table of Contents

Table of Contents

......................................General Guidelines . 122..........If Your Engine Quits or Won’t Start . 123

...............................If You Have a Flat Tire . 124................................................If You Crash . 125

................................If You Lose Your Key . 126..................................If a Component Fails . 127

.................................Vehicle Identification . 130..............................................Specifications . 132

....................................Break-in Guidelines . 137..........................Emission Control Systems . 138

........................................Oxygenated Fuels . 142

....................................Authorized Manuals . 146.....................................Warranty Coverage . 149

.........................................Warranty Service . 150.......................................Contacting Honda . 151

.........The Honda Rider’s Club (USA only) . 152.....................................Your Honda Dealer . 153

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158

Index

Index

A

B

C

.....................................................accessories . 10......................................................air cleaner . 67

...........................................air pressure, tires . 96...............................altering your motorcycle . 11

................................................arrester, spark . 81

brakes,......................cable inspection/lubrication . 90

.................................................lever, front . 20..................................................pedal, rear . 21...................................................shoe wear . 89

..........................................................braking . 37......................................break-in guidelines . 137

.................................................capacity, fuel . 59carburetor,

...................................................idle speed . 78....................................................choke lever . 18.....................................................cleaner, air . 67

...........................cleaning, appearance care . 108.............................................clearance, valve . 75

.............................clutch system, adjustment . 73....................................................color label . 131

.................................consumer information . 145.........................................controls, operating . 13

..........................................customer service . 151

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159

Index

Index

D

E

F

...................................................drive chain . 101

.......................................education, rider . 3, 153............................emission control systems . 138

.............................................engine number . 130engine,

......................................................flooded . 34...................................................idle speed . 78

......................................................pinging . 58.......................................................starting . 32

.................................................stop switch . 20.....................................................stopping . 34

...............................................won’t start . 123..............................environment, protecting . 119

.........................................................filter, air . 67.........................................................flat tire . 124

................................flooded engine, starting . 34................................................................fork . 83

..............................................frame number . 130front brake,

...........................................................lever . 20............................................lever freeplay . 86

........................front fork protector, removal . 57............................................front suspension . 83

......................................front wheel removal . 92fuel,

........................................recommendation . 58..............................................oxygenated . 142

.............................................tank capacity . 59..........................................................valve . 17

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160

Index

Index

G

H

I

K

L

.......................................................key, lost . 126......................................................kickstarter . 21

lever,.................................................front brake . 20

...........................................................shift . 21....................................................limit, weight . 9

.............................................................loading . 8

.......................................Honda, contacting . 151.................................Honda service manual . 146

..........................................idle speed, engine . 78inspection,

....................................................post-ride . 39......................................................pre-ride . 27

..............................................gap, spark plug . 79........................................................gasohol . 142.........................................................gasoline . 58

................................................gears, shifting . 35

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161

Index

Index

M

O

P

R

maintenance,.................................component locations . 52

........................................................record . 51.........................................................safety . 45

.....................................................schedule . 47............................................manual, service . 146

................................................modifications . 11

..........................................................parking . 38............................................pedal, rear brake . 21

..............................................pinging, engine . 58.....................................................plug, spark . 79

.......................................post-ride inspection . 39.........................................pre-ride inspection . 27

............................reserve capacity, fuel tank . 59............................................rider training . 3, 153

riding,..........................................basic operation . 29

........................................................before . 23......................................................clothing . 24

................................................precautions . 30...........................................................safety . 2

......................................................oil, engine . 61..........................................operating controls . 13

.....................operation component locations . 14..................................................over-revving . 35

.........................................oxygenated fuels . 142

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162

Index

Index

S

T

..................................schedule, maintenance . 47service,

..................................................customer . 151

..................................................warranty . 150...................................................manuals . 146

.................................................shifting gears . 35....................................................shoe, brake . 88

.................................................side stand . 21, 98.................................................spark arrester . 81

...................................................spark knock . 58......................................................spark plug . 79

..............................................specifications . 132..............................................stand, side . 21, 100

..............................................starting, engine . 32........................................stop switch, engine . 20

.............................................stopping engine . 34.........................................................storage . 116

suspension,...........................................................front . 83

.............................................................rear . 84

throttle.....................................................freeplay . 70

..................................................limiter . 31, 72....................................................operation . 20

tires,................................................air pressure . 96

...........................................................flat . 124....................................................replacing . 99

...............................................................tools . 55............................................................towing . 35

...........................................training, rider . 3, 153.................................................transporting . 114

.............................troubleshooting, starting . 123

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163

Index

Index

U

V

W

..................................unexpected problems . 121

......................................................valve, fuel . 17..................................vehicle identification . 130

warranty,..................................................coverage . 149..................................................extended . 149

.....................................................service . 150............................washing your motorcycle . 109

.....................................................weight limit . 9............................................................wheels . 91

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164 Memo

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165Memo

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Quick Reference

Quick Reference

How To Avoid Costly Repairs

The following is a brief, but importantcollection of information you need to knowabout your Honda. You’ll also find space torecord important notes.

Frequent causes of costly chassis repair are:

Your Honda engine can be the most expensivecomponent to repair. Proper maintenance,especially the use of the recommended fluidsand filters, prevents premature wear anddamage.

Frequent causes of costly engine repairs are:

Air cleaner: dirty, cleaned but not oiled,leaking because of improper installation(poor seal).

Engine oil: insufficient quantity, improperoil.

Spokes: Loose spoke may break and damagethe wheel hub or rim.

Chain: A loosely adjusted chain or a chainstretched because of lack of lubrication maycome off and damage an engine case orwheel hub.

Record important information on the followingpage:

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Quick Reference

Quick Reference

Record important information here:

Frame No.Engine No.Ignition Key No.Color LabelOwner’s:

NameAddressCity/StatePhone

Dealer’s:NameAddressCity/StatePhoneService Mgr.

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0.79 US gal (3.0 )0.24 US gal (0.9 )

88 lbs (40 kg)

2.50-10 33J

CR6HSA (NGK) U20FSR-U (DENSO)18 psi (125 kPa , 1.25 kgf/cm )15 psi (100 kPa , 1.0 kgf/cm )bias-ply, tube type

2.50-10 33J

or

CHENG SHIN CHENG SHIN

Quick Reference

Quick Reference

Initial Maintenance about 100 miles (150 km) or one month.RegularMaintenance

about every 600 miles (1,000 km) or six months.

Pre-ride Inspection Check the following items each time before you ride (page ): tires, spokes & rims,leaks, engine oil, fuel, drive chain, cables, nuts & bolts, spark plug & cap, throttle, andbrakes.

Fuel/Capacity unleaded gasoline, pump octane number of 86 or highertank:reserve:

Engine Oil

Maximum WeightCapacity rider only (no passenger or cargo) and any accessoriesTires

Spark Plug

Tire Pressure (cold)

API Service Classification SG or higher except oils labeled as energy conserving on thecircular API service label, SAE 10W-30, JASO T 903 standard MA,Pro Honda GN4 or HP4 (without molybdenum additives) 4-stroke oil or equivalent

Front:

Front:Rear:

, Rear:

27

Type:

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Documents

This manual should be considered a permanent part ... - Hondaowners.honda.com/assets/OWNERLINK/model/own_man/... · Honda Motor Co., Ltd. 2005 This manual should be considered a permanent