This Owner’s Manual covers the and models. You INTERCEPTOR ...owners.honda.com/assets/OWNERLINK/model/own_man/... · 04/07/02 14:09:05 31MCW630_004. A Few Words About Safety Safety

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

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

This Owner’s Manual covers the and models. Youmay find descriptions of equipment and features that are not on your particular model.All illustrations are based on the model.

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

2004 Honda Motor Co., Ltd.

INTERCEPTOR INTERCEPTOR ABS

INTERCEPTOR ABS

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2005Honda VFR800/AINTERCEPTOR/ABSOWNER’S MANUAL

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Introduction

Introduction

Congratulations on choosing your Hondamotorcycle.

When you own a Honda, you’re part of aworldwide family of satisfied customers

people who appreciate Honda’sreputation for building quality into everyproduct.

Before riding, take time to get acquaintedwith your motorcycle and how it works.To protect your investment, we urge youto take responsibility for keeping yourmotorcycle well maintained. Scheduledservice is a must, of course. But it’s just asimportant to observe the break-inguidelines, and perform all pre-ride andother periodic checks detailed in thismanual.

We also recommend that you read thisowner’s manual before you ride. It’s fullof facts, instructions, safety information,and helpful tips. To make it easy to use,the manual contains a detailed list oftopics at the beginning of each section,and both an in-depth table of contents andan index at the back of the book.

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

symbol. This information isintended to help you avoid damage to yourHonda, other property, or the environment.

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Introduction

Introduction

WARNING:

Read the Warranties Booklet (page )thoroughly so you understand thecoverages that protect your new Hondaand are aware of your rights andresponsibilities.

If you have any questions, or if you everneed special service or repairs, rememberthat your Honda dealer knows yourmotorcycle best and is dedicated to yourcomplete satisfaction.

Please report any change of address orownership to your Honda dealer so wewill be able to contact you concerningimportant production information.

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

Happy riding!

This product contains oremits chemicals known to the State ofCalifornia to cause cancer and birthdefects or other reproductive harm.

California Proposition 65 Warning

237

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A Few Words About Safety

Safety Messages

Safety Labels

Safety MessagesDANGER, WARNING, CAUTION

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

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

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

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

–– on the motorcycle.

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

These signal words mean:

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You WILL be KILLED or SERIOUSLY HURT if youdon’t follow instructions.

You CAN be KILLED or SERIOUSLY HURT if you don’tfollow instructions.

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

A Few Words About Safety

Safety Messages

Safety Headings

Safety Section

Instructions

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

–– such as Motorcycle Safety.

–– how to use this motorcycle correctly and safely.

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

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Contents

Contents

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

....................Instruments & Controls .

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

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

1

9

41

51

These pages give an overview of thecontents of your owner’s manual. The firstpage of each section lists the topicscovered in that section.

The importance of wearing a helmetand other protective gear, how to makesure you and your motorcycle are readyto ride, and important information aboutloading.

Important safety information youshould know, plus a look at the safety-related labels on your motorcycle.

The location and function of indicators,gauges, and controls on yourmotorcycle and operating instructionsfor various controls and features.

How to start and stop the engine, shiftgears, and brake. Also, ridingprecautions and important informationabout riding with a passenger or cargo.

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Contents

Contents

Quick Reference

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

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

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

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

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

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

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

........‘‘Reporting Safety Defects’’ .

69

175

181

211

233

242

244

248

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

How to store and transport 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.

Sequential listing of topics in thisowner’s manual.

Handy facts about fuel, engine oil, tiresizes, and air pressures.

Information on warranties, emissioncontrols, how to get Honda servicemanuals, and...

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1

Motorcycle Safety

Motorcycle Safety

This section presents some of the mostimportant information andrecommendations to help you ride yourmotorcycle safely. Please take a fewmoments to read these pages. This sectionalso includes information about thelocation of safety labels on yourmotorcycle.

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

...........................................Safety Labels . 7

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2

Important Safety Information

Motorcycle Safety

Always Wear a HelmetYour motorcycle can provide many yearsof service and pleasure if you takeresponsibility for your own safety andunderstand the challenges you can meetwhile 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.

It’s a proven fact: helmets significantlyreduce the number and severity of headinjuries. So always wear an approvedmotorcycle helmet and make sure yourpassenger does the same. We alsorecommend that you wear eye protection,sturdy boots, gloves, and other protectivegear (page ).42

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3


Motorcycle Safety

Make Yourself Easy to See

Take Time to Learn & Practice

Ride Defensively

You andYour Motorcycle: Riding Tips andPractice Guide,

Always pay attention to other vehiclesaround you, and do not assume that otherdrivers see you. Be prepared to stopquickly or make an evasive maneuver. Forother riding tips, see the booklet,

which came with yournew motorcycle (USA only).

Some drivers do not see motorcyclesbecause they are not looking for them. Tomake yourself more visible, wear brightreflective clothing, position yourself soother drivers can see you, signal beforeturning or changing lanes, and use yourhorn when it will help others notice you.

Even if you have ridden other motorcycles,take time to become familiar with howthis motorcycle works and handles.Practice in a safe area until you build yourskills and get accustomed to themotorcycle’s size and weight.

Because many accidents involveinexperienced or untrained riders, we urgeall riders to take a certified courseapproved by the Motorcycle SafetyFoundation (MSF). See page .

The most frequent motorcycle collisionhappens when a car turns left in front of amotorcycle. Another common situation isa car moving suddenly into your lane.

44

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4


Motorcycle Safety

Ride within Your Limits

Don’t Drink and Ride

Keep Your Honda in Safe ConditionPushing limits is another major cause ofmotorcycle accidents. Never ride beyondyour personal abilities or faster thanconditions warrant. Remember thatalcohol, drugs, fatigue, and inattention cansignificantly reduce your ability to makegood judgments and ride safely.

Alcohol and riding don’t mix. Even onedrink can reduce your ability to respond tochanging conditions, and your reactiontime gets worse with every additionaldrink. So don’t drink and ride, and don’tlet your friends drink and ride either.

It’s important to keep your motorcycleproperly maintained and in safe ridingcondition. To help avoid problems, inspectyour motorcycle before every ride andperform all recommended maintenance.Never exceed load limits (page ), anddo not modify your motorcycle (page )or install accessories that would makeyour motorcycle unsafe (page ).

6

5

49

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Improper accessories ormodifications can cause a crash inwhich you can be seriously hurt orkilled.

Follow all instructions in thisowner’s manual regardingaccessories and modifications.

5

Accessories

Accessories & Modifications

Motorcycle Safety

Modifying your motorcycle or using non-Honda accessories can make yourmotorcycle unsafe. Before you considermaking any modifications or adding anaccessory, be sure to read the followinginformation.

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-Hondaaccessories.Check with your Honda dealer forassistance and always follow theseguidelines:

Make sure the accessory does notobscure any lights, reduce groundclearance and lean angle, limitsuspension travel or steering travel, alteryour riding position, or interfere withoperating any controls. (cont’d)

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6

Modifications

Accessories & Modifications

Motorcycle Safety

Do not add any electrical equipmentthat will exceed the motorcycle’selectrical system capacity (page ).A blown fuse can cause a loss of lightsor engine power (page ).Do not pull a trailer or sidecar with yourmotorcycle. This motorcycle was notdesigned for these attachments, andtheir use can seriously impair yourmotorcycle’s handling.

We strongly advise you not to remove anyoriginal equipment or modify yourmotorcycle in any way that would changeits design or operation. Such changescould seriously impair your motorcycle’shandling, stability, and braking, making itunsafe to ride.

Removing or modifying your lights,exhaust system, emission control system,or other equipment can also make yourmotorcycle illegal.

219

202

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7

Safety Labels

Motorcycle Safety

Safety labels on your motorcycle either warn you of potential hazards that could causeserious injury or they provide important safety information. Read these labels carefully anddon’t remove them.

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

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〈〉

〈〉

For USA

For CANADA

8

Safety Labels

Motorcycle Safety

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9

Instruments & Controls


This section shows the location of allgauges, indicators, and controls you wouldnormally use before or while riding yourmotorcycle.

The items listed on this page are describedin this section. Instructions for othercomponents are presented in other sectionsof this manual where they will be mostuseful.

...........................Component Locations . 11..............Gauges, Indicators & Displays . 14

......................Multi-function Display . 24.........................................Fuel Gauge . 25

..............Coolant Temperature Meter . 26.....................Air Temperature Meter . 28

......................................Speedometer . 30..............Odometer/Tripmeter A & B . 31

Changing the Speed and Mileage....................................................Unit . 32

.....................................Digital Clock . 33

(cont’d)

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10



Controls & Features..................................Ignition Switch . 35

........................................Start Button . 36...........................Engine Stop Switch . 36

...................................Hazard Switch . 37................Headlight Dimmer Switch . 38

............................Turn Signal Switch . 38.......................................Horn Button . 39

................................SELECT Button . 39...................................RESET Button . 39

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rearview mirror

throttle grip

fuel fill cap

horn button

turn signal switch

clutch lever

headlight dimmerswitch

front brakelever

rearviewmirror

ignition switch

front brake fluidreservoir

engine stopswitch

tachometer

start button

clutch fluidreservoir

front spring pre-load adjuster

right multi-function displayleft multi-function display

hazard switch

11

Component Locations


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passenger footpeg

rear brake fluid reservoir

fuse box

helmet holder

rear spring pre-load adjuster knob(INTERCEPTOR ABS only)

tool kit compartment/storage compartment forU-shaped lock

footpeg

rear brake pedal oil inspection window

oil filler cap

12

Component Locations


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center stand

coolantreserve tank

owner’s manual storage

helmet holder

rear rebounddamping adjuster

battery

passenger footpeg

rear spring pre-load adjuster(INTERCEPTOR only)

fuse box(INTERCEPTOR ABS only)

side standfootpeg

shift lever

13

Component Locations


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(6)

(10) (8)

(11)

(7)

(3)(4)(5)(2)(1)

(9)

(14)(13)(12)

14

Gauges, Indicators & Displays


The gauges, indicators and displays onyour motorcycle keep you informed, alertyou to possible problems, and make yourriding safer and more enjoyable. Refer tothe gauges, indicators and displaysfrequently. Their functions are describedon the following pages.

(1) tachometer(2) tachometer red zone(3) anti-lock brake system (ABS)

indicator(INTERCEPTOR ABS only)

(4) high beam indicator(5) PGM-FI malfunction indicator lamp

(MIL)(6) right turn signal indicator(7) right multi-function display(8) RESET button(9) SELECT button

(10) left multi-function display(11) left turn signal indicator(12) low oil pressure indicator(13) coolant temperature indicator(14) neutral indicator

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15



LampCheck.

Lamp Check

The low oil pressure indicator comes onwhen you turn the ignition switch ON soyou can check that it is working. Theindicator remains on until after the engineis started.

When applicable, the high beam andneutral indicators come on when you turnthe ignition switch ON and remain on untilyou select the low beam or shift out ofneutral.

The anti-lock brake system (ABS)indicator comes on when you turn theignition switch ON. This indicator goesoff after you ride the motorcycle at aspeed above 6 mph (10 km/h).

These indicators are identified in the tableon pages with the words:

If one of these indicators does not comeon when it should, have your Honda dealercheck for burned-out bulbs or otherproblems.

The PGM-FI malfunction indicator lamplights for a few seconds and then goes offwhen you turn the ignition switch ON.

18

(INTERCEPTOR ABS only)

23

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16



DisplayCheck.

Display Check

When the ignition switch is turned ON, theleft multi-function display ( ) and rightmulti-function display ( ) willtemporarily show all the modes and digitalsegments so you can make sure the liquidcrystal display is functioning properly.

The displays are identified in the table onpages with the words:

If any part of these displays does not comeon when it should, have your Honda dealercheck for problems.

20

(Except digital clock)

22

12

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(1) left multi-function display(2) right multi-function display

(1)

(2)

17



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18



ABS IndicatorLamp

Check.

tachometertachometer red zone

Shows engine speed in revolutions per minute (rpm).Shows excessive engine rpm range (indicated fromthe beginning of the tachometer red zone) in whichoperation may damage the engine. Do not let thetachometer needle enter the red zone.

anti-lock brake system(ABS) indicator (red)

Lights when there is any abnormality in the anti-lockbrake system (ABS). Normally, this indicator comeson when the ignition switch is turned ON, and goesoff after you ride the motorcycle at a speed above 6mph (10 km/h). If the indicator comes on whileriding, stop the motorcycle in a safe place and turnoff the engine. Refer to , page .For information about ABS, see page .

high beam indicator(blue)

Lights when the headlight is on high beam.

12

3

4

(INTERCEPTOR ABS)

6162

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19



Lamp Check.

5

6

Flashes when there is any abnormality in the PGM-FI (Programmed Fuel Injection) system. Should alsolight for a few seconds and then go off when theignition switch is turned ON and the engine stopswitch is at RUN. If the indicator comes on at anyother time, reduce speed and take your motorcycle toa Honda dealer as soon as possible.

right turn signalindicator (amber)

Flashes when the right turn signal operates.

PGM-FI malfunctionindicator lamp (MIL)(red)

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5.81 US gal (22.0 )

0.92 US gal (3.5 )

20 Instruments & Controls


Display Check.right multi-functiondisplaytripmeter A & B

The display includes the following functions:

Shows the number of miles or kilometers riddensince you last reset the meter. The tripmeter has twosub modes, ‘‘A’’ and ‘‘B.’’ To zero (0) the tripmeter,press the RESET button (page ).

7

digital clock

fuel gauge

odometer Shows the total miles or kilometers ridden (page).

Shows approximate fuel supply available (page ).When segment F goes on, the fuel tank capacity is:

When segment E flashes while riding, fuel reservedin the tank is about:

Shows hour and minute (page ).

2531

31

33

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21



RESET button Selects odometer and tripmeter A or B and resets thetripmeter to zero (0) (page ).Also used to set the digital clock (page ).Selects coolant or air temperature meter (page )and changes speed and mileage units for thespeedometer/odometer/tripmeter (page ).Also used to set the digital clock (page ).

SELECT button

8

9

3233

3331

26

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Display Check.left multi-functiondisplay

The display includes the following functions:

speedometer

coolant temperaturemeter

air temperature meter Shows air (ambient) temperature (page ).USA : Fahrenheit (°F), Canada : Centigrade (°C).

10

Shows riding speed in miles or kilometers per hour(page ).Shows engine coolant temperature digitally (page

).USA: Fahrenheit (°F), Canada: Centigrade (°C).If the display begins to flash and a red bar appearson the display, pull safely to the side of the road. Seepage for instructions and cautions.

28

26

30

199

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23



Lamp Check

left turn signal indicator(amber)

Flashes when the left turn signal operates.

low oil pressure indicator(red)

Lights when engine oil pressure is low enough tocause engine damage. If the low oil pressureindicator lights during operation, pull safely to theside of the road. See page for instructions andcautions. .

Lights when the transmission is in neutral.

Lights when the coolant is over the specifiedtemperature. If the indicator comes on, pull safely tothe side of the road. See pages forinstructions and cautions.

coolant temperatureindicator (red)

neutral indicator (green)

11

12

13

14

201

199 200

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(1) left multi-function display(2) coolant/air temperature meter(3) speedometer(4) right multi-function display(5) odometer/tripmeter(6) fuel gauge(7) digital clock(8) SELECT button(9) RESET button

(1)

(9)(8)

(7)

(3)

(6)

(2) (4) (5)

24

Multi-function Display



The left multi-function display ( )includes the following functions:

The right multi-function display ( )includes the following functions:

Both the digital clock and tripmeter willreset if the battery is disconnected.

1

coolant/air temperature meterspeedometer

odometer/tripmeterfuel gaugedigital clock

4

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5.81 US gal (22.0 )

0.92 US gal (3.5 )

(1) fuel gauge display(2) segment F(3) segment E

(2)

(3)

(1)

25

Fuel Gauge



When segment E ( ) flashes, you shouldrefill the tank as soon as possible.The amount of fuel remaining when theflashing starts is approximately:

The fuel gauge liquid crystal display ( )shows the approximate fuel supplyavailable in a graduated display. Whensegment F ( ) goes on, the fuel tankcapacity is:

1

2

3

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〈〉

〈〉(1)

(2)

(1)

(2)

(1) coolant temperature meter(2) black bar

For Canada

For USA

26

Coolant Temperature Meter



The coolant temperature meter ( ) showsthe coolant temperature digitally.

Temperature Display

USA : Fahrenheit (°F),Canada : Centigrade (°C).

If the air temperature is displayed, pushthe SELECT button ( ) to display thecoolant temperature.

1

4

‘‘--’’ is displayed

Actual coolanttemperature isdisplayed.The display remains‘‘270 °F (132 °C)’’

Below94 °F (34 °C)Between95 °F 270 °F(35 °C 132 °C)Above270 °F (132 °C)

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〈〉

〈〉

(3)

(3)

(3) red bar(4) SELECT button(5) coolant temperature indicator

For USA

For Canada

(5)(4)

27



Continuing to ride with an overheatedengine can cause serious engine damage.

Overheating Message:When the coolant temperature reaches251°F (122°C), the numbers in thetemperature display start flashing and theblack bar ( ) under the numbers becomesa red bar ( ).At the same time, the coolant temperatureindicator ( ) lights.If this occurs, stop the engine and checkthe reserve tank coolant level. Read pages

and do not ride themotorcycle until the problem has beencorrected.

If the coolant temperature reaches 251°F(122°C) while the air temperature displayis selected, the display will automaticallyswitch to coolant temperature.

23

5

114 117

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28

Air Temperature Meter



The air temperature meter ( ) shows theair temperature digitally.

Temperature Display

USA : Fahrenheit (°F),Canada : Centigrade (°C).

The temperature sensor is located in theupper fairing. Therefore, the temperaturereading can be affected by heat reflectionfrom the road surface, engine heat, and theexhaust from the surrounding traffic. Thiscan cause on error in the temperaturereading when your speed is under 19 mph(30 km/h).

If the coolant temperature is displayed,push the SELECT button ( ) to displaythe air temperature.

1

2

Below14 °F ( 10 °C)Between15 °F 122 °F( 9 °C 50 °C)Above122 °F (50 °C)

‘‘--’’ is displayed

Actual airtemperature isindicated.The display willremain ‘‘122 °F(50 °C)’’

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〈〉

〈〉

For USA(1)

(1)

(2)

(1) air temperature meter(2) SELECT button

For Canada

29



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(1)

(1) speedometer

30

Speedometer



The speedometer ( ) shows riding speedin miles or kilometers per hour.

The speedometer will show ‘‘mph’’(USA) or ‘‘km/h’’ (Canada) when thebattery is reconnected.

1

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(3) tripmeter B(4) RESET button

(1) odometer(2) tripmeter A

(4)

(3)

(2)

(1)

31

Odometer/Tripmeter A & B



The odometer ( ) shows the total miles orkilometers ridden.

The tripmeter shows number of miles orkilometers ridden since you last reset themeter.

The tripmeter has two sub modes, A ( )and B ( ).

Push the RESET button ( ) to switchbetween the odometer ( ), tripmeter A( ) and tripmeter B ( ).

To reset the tripmeter, push and hold theRESET button ( ) with the display in thetripmeter A or B mode.

1

23

41

32

4

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(1) SELECT button

(1)

32

Changing the Speed andMileage Unit



The speedometer displays both ‘‘mph’’and ‘‘km/h.’’The odometer/tripmeter displays both‘‘mile’’ and ‘‘km.’’Press and hold the SELECT button ( ) toselect ‘‘mph’’/‘‘mile’’ and ‘‘km/h’’/‘‘km.’’

1

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(2)

(1)(3)

(1) digital clock(2) SELECT button(3) RESET button

33

Digital Clock



Turn the ignition switch ON.

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

Push and hold both the SELECT button( ) and RESET button ( ) for morethan 2 seconds. The digital clock ( )will be set in the adjust mode with thedisplay flashing.

1.2.

321

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34



Push the RESET button until thedesired time and AM/PM are displayed.

To end the adjustment, press theRESET button 5 seconds after the lastadjustment, or turn the ignition switchOFF.

The time is advanced by one minute,each time the button is pushed.The time is advanced by ten minutes,when the button is pushed and held.

3. 4.

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When the hazardswitch is ON, boththe left and rightturn signals flash.Engine and lightscannot beoperated.

(hazard)

Electrical circuits on.ONOFF No electrical

circuits function.LOCK(steeringlock)

No electrical circuitsfunction. Locks thesteering head.

FRONT

(1) ignition switch

(1)

LOCK

OFFON (hazard)

Key Position Function

35

Ignition Switch

Controls & Features


To unlock the steering lock, insert andpush down on the key and turn it to theright to the OFF position.

The ignition switch ( ) is used for startingand stopping the engine (page ) and tolock the steering for theft prevention (page

). Insert the key and turn it to the rightfor the ON position. Push down on the keyand turn it to the left to the LOCK(steering lock) position.

531

64

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(1)

RIGHT HANDLEBAR

OFFRUN

(2)

(1) start button(2) engine stop switch

36

Start Button Engine Stop Switch

Controls & Features


Starting Procedure,

When the start button is pushed, the startermotor will crank the engine; the headlightwill automatically go out, but the taillightwill stay on.

The start button ( ) is used for starting theengine. Pushing the button in starts theengine. See page .

The engine stop switch ( ) is used to stopthe engine in an emergency. To operate,push the switch to the OFF position. Theswitch must be in the RUN position tostart the engine, and it should normallyremain in the RUN position even when theengine is OFF.

The starter motor will not operate if theengine stop switch is in the OFF positionor the ignition switch is in the (hazard)position when the start button is pushed.

1

54

2

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(3) hazard switch

(3)

37

Hazard Switch

Controls & Features


If your motorcycle is stopped with theignition switch ON and the engine stopswitch OFF, the headlight and taillightwill remain on, resulting in batterydischarge.

The hazard switch ( ) should be used onlywhen the motorcycle is stopped underemergency or hazardous condition.

Be sure to turn the switch off when thehazard warning is no longer required, orthe turn signals will not work properly,and may confuse other drivers.

To operate, turn the ignition key to the ONor (hazard) position, and press thehazard switch. The front and rear turnsignals will blink simultaneously until youpress the switch again.

3

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HILO

LEFT HANDLEBAR

(1)

(2)

(3)(1) headlight dimmer switch

(2) turn signal switch(3) horn button

38

Headlight Dimmer Switch Turn Signal Switch

Controls & Features


The headlight dimmer switch ( ) is usedto change between the high and low beamsof the headlight. To operate, turn theswitch to HI for high beam, LO for lowbeam.

The turn signal switch ( ) is used to signala turn or a lane change. To operate, movethe switch all the way in the properdirection and release it. The appropriateturn signal lights will start blinking. Tocancel the light, push the switch in.

1 2

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39

Horn Button

SELECT Button

RESET Button

Controls & Features


The horn is used to alert other motorists.To operate, push the horn button ( ).

The SELECT button is used to switchbetween the coolant and air temperaturedisplays. To operate, press the button.

The SELECT button is also used tochange the speed and mileage units for thespeedometer/odometer/tripmeter. Tochange the unit, press and hold the button(page ).

The SELECT button is also used to set thedigital clock (page ).

The RESET button is used to switchbetween the odometer and the twotripmeter (A & B) displays. To operate,press the button.

To reset (zero) either tripmeter, press andhold the button for about 2 3 secondsuntil the display changes to zero.

The RESET button is also used to set thedigital clock (page ).

3

32

33

33

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？

？

41

Before Riding

Before Riding

Before each ride, you need to make sureyou and your Honda are both ready to ride.To help get you prepared, this sectiondiscusses how to evaluate your ridingreadiness, what items you should check onyour motorcycle, and adjustments to makefor your comfort, convenience, or safety.This section also includes importantinformation about loading.

For information about adjusting thesuspension on your Honda, see page .

.....................Are You Ready to Ride . 42.............................Protective Apparel . 42

...................................Rider Training . 44...Is Your Motorcycle Ready to Ride . 45

............................Pre-ride Inspection . 45.....................Load Limits & Guidelines . 48

..............................................Loading . 48.......................................Load Limits . 49

...........................Loading Guidelines . 49

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42

Protective Apparel

Are You Ready to Ride?

Before Riding

Before you ride your motorcycle for thefirst time, we urge you to:

Read this owner’s manual.Make sure you understand all the safetymessages.Know how to operate all the controls.

You feel well and are in good physicaland mental condition.

Before each ride, be sure: For your safety, we strongly recommendthat you always wear an approvedmotorcycle helmet, eye protection, boots,gloves, long pants, and a long-sleevedshirt or jacket whenever you ride.Although complete protection is notpossible, wearing proper gear can reducethe chance of injury when you ride.Following are suggestions to help youchoose the proper gear.

If you must carry an extra helmet whileriding, use a commercially-availableelastic cord, strap, or net to secure thehelmet to the seat.

You are wearing an approvedmotorcycle helmet (with chin straptightened securely), eye protection, andother protective clothing.You don’t have any alcohol or drugs inyour system.

Make sure your passenger is ready to ride,too, and is wearing proper gear including ahelmet.

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Not wearing a helmet increasesthe chance of serious injury ordeath in a crash.

Be sure you and your passengeralways wear a helmet, eyeprotection, and other protectiveapparel when you ride.

43


Before Riding

(cont’d)

Helmets and Eye ProtectionYour helmet is your most important pieceof riding gear because it offers the bestprotection against head injuries. A helmetshould fit your head comfortably andsecurely. A bright-colored helmet andreflective strips can make you morenoticeable in traffic.

An open-face helmet offers someprotection, but a full-face helmet offersmore. Regardless of the style, look for aDOT (Department of Transportation)sticker in any helmet you buy (USA only).Always wear a face shield or goggles toprotect your eyes and help your vision.

Leather gloves to help protect yourhands.

Sturdy boots with non-slip soles to helpprotect your feet and ankles.

In addition to a helmet and eye protection,we also recommend:

Additional Riding Gear

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44

Rider Training


Before Riding

Riding Tips

A motorcycle riding suit or jacket forcomfort as well as protection.Bright-colored and reflective clothingcan help make you more noticeable intraffic. Avoid loose clothes that couldget caught on any part of yourmotorcycle.

Developing your riding skills is an on-going process. Even if you have riddenother motorcycles, take time to becomefamiliar with how this motorcycle worksand handles. Practice riding themotorcycle in a safe area to build yourskills. Do not ride in traffic until you getaccustomed to the motorcycle’s controls,and feel comfortable with its size andweight.

We urge all riders to take a certifiedcourse approved by the Motorcycle SafetyFoundation (MSF). New riders shouldstart with the basic course, and evenexperienced riders will find the advancedcourse beneficial. For information aboutthe MSF training course nearest you, callthe national toll-free number: (800) 446-9227.

Other riding tips can be found in thebooklet that came with your

motorcycle (USA only).

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Improperly maintaining thismotorcycle or failing to correct aproblem before riding can cause acrash in which you can beseriously hurt or killed.

Always perform a pre-rideinspection before every ride andcorrect any problems.

45

Pre-ride Inspection

Before Riding

Is Your Motorcycle Ready to Ride?

Chain

Tires&

Wheels

Before each ride, it’s important to inspectyour motorcycle and make sure anyproblem you find is corrected. A pre-rideinspection is a must, not only for safety,but because having a breakdown, or evena flat tire, can be a major inconvenience.

Check the following items before you geton the motorcycle:

Look at the tires. If a tireappears low, use an airpressure gauge to check itspressure. Also look forsigns of excessive wear(page ) or damage tothe tires and wheels.

Check the condition of thechain. Adjust slack andlubricate as needed (page

).

(cont’d)

149

156

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46


Before Riding

Leaks,LooseParts

Lights

Load Limits

Cargo

Adjustments

Walk around yourmotorcycle and look foranything that appearsunusual, such as a leak orloose cable.

Make sure the headlight,brake light, taillight, andturn signals are workingproperly.

If you are carrying a passenger or cargo,also check the following:

Make sure you do notexceed the load limits(page ).

Check that all cargo issecure.

Adjust the suspension(pages , )according to your load.

49

135 137

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47


Before Riding

Periodic MaintenanceThrottle

Brakes

Indicators

If you haven’t ridden the motorcycle inover a week, you should also check otheritems, such as the oil level and other fluids.See (page ).Periodic maintenance should also be doneat least once a month, no matter how oftenyou ride.

Remember, be sure to take care of anyproblem you find, or have your Hondadealer correct it before you ride.

Check these items after you get on themotorcycle:

Rotate the throttle tocheck it moves smoothlywithout binding.

Pull the brake lever andpress on the brake pedalto check that theyoperate normally.

Turn the ignition on andcheck for normaloperation of theindicators (page ).14

76

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Overloading or improper loadingcan cause a crash and you can beseriously hurt or killed.

Follow all load limits and otherloading guidelines in this manual.

48

Loading

Load Limits & Guidelines

Before Riding

Your motorcycle has been designed tocarry you and one passenger. When youcarry a passenger, you may feel somedifference during acceleration and braking.But so long as you keep your motorcyclewell-maintained, with good tires andbrakes, you can safely carry loads withinthe given limits and guidelines.

However, exceeding the weight limit orcarrying an unbalanced load can seriouslyimpair your motorcycle’s handling,braking, and stability. Non-Hondaaccessories, improper modifications, andpoor maintenance can also reduce yoursafety margin.

How much weight you put on yourmotorcycle, and how you load it, areimportant to your safety. Anytime youride with a passenger or cargo, you shouldbe aware of the following information.

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399 lbs (181 kg)408 lbs (185 kg)

77 lbs (35 kg)

49

Loading GuidelinesLoad Limits


Before Riding

maximum weight capacity:

maximum cargo weight:

Your motorcycle is primarily intended fortransporting you and a passenger. Youmay wish to secure a jacket or other smallitems to the seat when you are not ridingwith a passenger.

If you wish to carry more cargo, checkwith your Honda dealer for advice, and besure to read the information regardingaccessories on page .

Following are the load limits for yourmotorcycle:

includes the weight of the rider,passenger, all cargo, and all accessories.

Improperly loading your motorcycle canaffect its stability and handling. Even ifyour motorcycle is properly loaded, youshould ride at reduced speeds and neverexceed 80 mph (130 km/h) when carryingcargo.

The weight of added accessories willreduce the maximum cargo weight youcan carry.

(Canada only)

5

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50


Before Riding

Follow these guidelines whenever youcarry a passenger or cargo:

To prevent loose items from creating ahazard, make sure that all cargo is tieddown securely before you ride.Place cargo weight as low and close tothe center of your motorcycle aspossible.Balance cargo weight evenly on bothsides.

Check that both tires are properlyinflated (page ).If you change your normal load, youmay need to adjust the front suspension(page ) and the rear suspension(page ).

147

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51

Basic Operation & Riding


This section gives basic riding instructions,including how to start and stop yourengine, and how to use the throttle, clutch,and brakes. It also provides importantinformation on riding with a passenger orcargo.

To protect your new engine and enjoyoptimum performance and service life,refer to Break-in Guidelines (page ).

To protect the catalytic converter in yourmotorcycle’s exhaust system, avoidextended idling and the use of leadedgasoline.

........................Safe Riding Precautions . 52............Starting & Stopping the Engine . 53

.........................................Preparation . 53.............................Starting Procedure . 54

..................................Flooded Engine . 55Bank Angle Sensor Ignition Cut-off

................................................System . 55....................How to Stop the Engine . 56

........................................Shifting Gears . 57..................................................Braking . 59

Anti-lock Brake System (ABS)....................(INTERCEPTOR ABS) . 61

ABS Indicator....................(INTERCEPTOR ABS) . 62

...................................................Parking . 63.........Riding with a Passenger or Cargo . 68

222

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52

Safe Riding Precautions


Motorcycle Saf ety

Bef ore Riding

Before riding your motorcycle for the firsttime, please review thesection beginning on page 1, and the

section beginning on page.

Even if you have ridden other motorcycles,take time to become familiar with howthis motorcycle works and handles.Practice in a safe area until you build yourskills and get accustomed to themotorcycle’s size and weight.

Make sure flammable materials such asdry grass or leaves do not come in contactwith the exhaust system when riding,idling, or parking your motorcycle.

41

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53

Preparation

Starting & Stopping the Engine


Always follow the proper startingprocedure described below.

For your safety, avoid starting or operatingthe engine in an enclosed area such as agarage. Your motorcycle’s exhaustcontains poisonous carbon monoxide gaswhich can collect rapidly in an enclosedarea and cause illness or death.

Your motorcycle can be started with thetransmission in gear by pulling in theclutch lever before operating the starter.

Your motorcycle is equipped with a sidestand ignition cut-off system. If the sidestand is down––the engine cannot bestarted unless the transmission is in neutral.If the side stand is up––the engine can bestarted in neutral, or in gear with the

clutch lever pulled in. After starting withthe side stand down, the engine will stop ifthe transmission is put in gear beforeraising the side stand.

Before starting, insert the key, turn theignition switch ON, and confirm thefollowing:

The transmission is in NEUTRAL(neutral indicator light ON).The engine stop switch is set to RUN.The low oil pressure indicator is ON.The PGM-FI indicator is OFF.

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54

Starting Procedure



The engine will not start if the throttle isfully open (because the electronic controlmodule cuts off the fuel supply).

Press the start button with the throttlecompletely closed.

Any Air Temperature

This motorcycle has a fuel-injected enginewith an automatic fast idle. Follow theprocedure indicated below.

The low oil pressure indicator should gooff a few seconds after the engine starts.If the low oil pressure indicator lightsduring operation, stop the engineimmediately and check the engine oil level.

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－

55

Flooded Engine Bank Angle Sensor IgnitionCut-off System



IfYour Engine Quits or Won’t Start,

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

Leave the engine stop switch set toRUN.Open the throttle fully.Press the start button for 5 seconds.Follow the normal starting procedure.If the engine starts, then open thethrottle slightly if idling is unstable.If the engine does not start, wait 10seconds, then follow steps again.

Your motorcycle’s banking (lean angle)sensor system is designed to automaticallystop the engine and fuel pump if themotorcycle is overturned.

Before restarting the engine, you mustturn the ignition switch to the OFFposition and then back to ON. The enginewill not restart until you perform thisprocedure.

If the engine still won’t start, refer topage

.

1.

4.5.

2.3.

41

183

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56

How to Stop the Engine



Normal Engine StopTo stop the engine, shift into neutral andturn the ignition switch OFF.

The engine stop switch should normallyremain in the RUN position even when theengine is OFF.

If your motorcycle is stopped with theengine stop switch OFF and the ignitionswitch ON, the headlight and taillightwill remain on, resulting in batterydischarge.

Emergency Engine StopTo stop the engine in an emergency, usethe engine stop switch. To operate, pressthe switch to the OFF position.

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shifting pattern

57

Shifting Gears


Learning when to shift gears comes withexperience. Keep the following tips inmind:

Close the throttle and pull the clutchlever in completely before shifting.Improper shifting may damage theengine, transmission, and drive train.Learn to recognize the engagementpoint as you release the clutch lever. Itis at this point the transmission ofpower to the rear wheel resumes.Upshift to a higher gear or reducethrottle before engine rpm (speed) getstoo high. Learn the relationship betweenengine sound and the normal shiftingpoints.

As a general rule, shift while moving ina straight line.

Downshift to a lower gear before youfeel the engine laboring (lugging) atlow rpm.

Your motorcycle has six forward gears ina one-down, five-up shift pattern which iscoordinated with a hydraulically actuatedclutch system.

(cont’d)

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58

Shifting Gears


Shif ting Up:

Shif ting Down:

Avoid downshifting to help slow yourmotorcycle when engine rpm is near itsallowable maximum (near thetachometer red zone). In this situation,the rev limiter in the engine ignitioncontrol module may not preventexcessive engine speed which coulddamage the engine.To prevent transmission damage, do notcoast or tow the motorcycle for longdistances with the engine off.

Recommended Shift PointsRide in the highest gear that lets theengine run and accelerate smoothly. Thiswill give you good fuel economy andeffective emissions control. Whenchanging gears under normal conditions,use these recommended shift points:

From 1st to 2nd:From 2nd to 3rd:From 3rd to 4th:From 4th to 5th:From 5th to 6th:

12 mph (20 km/h)19 mph (30 km/h)25 mph (40 km/h)31 mph (50 km/h)37 mph (60 km/h)

From 6th to 5th:From 5th to 4th:From 4th to 3rd:

28 mph (45 km/h)22 mph (35 km/h)16 mph (25 km/h)

Pull the clutch lever in when speed dropsbelow 9 mph (15 km/h), when engineroughness is evident, or when enginestalling is imminent; and shift down to 1stgear for acceleration.

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59

Braking


Model Not Equipped with ABS:

Your motorcycle is equipped with aLinked Braking System. Operating thefront brake lever applies the front brakeand a portion of the rear brake. Operatingthe rear brake pedal applies the rear brakeand a portion of the front brake. For fullbraking effectiveness, use both the leverand pedal simultaneously, as you wouldwith a conventional motorcycle brakingsystem.

As with a conventional motorcyclebraking system, excessively hardapplication of the brake controls maycause wheel lock, reducing control of themotorcycle.

To slow or stop, apply the brake lever andbrake pedal smoothly, while downshifting

to match your speed.

Gradually increase braking as you feel thebrakes slowing your speed. The increasein engine compression from downshiftingwill help slow your motorcycle.

To prevent stalling the engine, pull theclutch lever in before coming to acomplete stop. For support, put your leftfoot down first, then your right foot whenyou are through using the brake pedal.

Applying the brakes too hard may causethe wheels to lock and slide, reducingcontrol of your motorcycle. If this happens,release the brake controls, steer straightahead until you regain control, thenreapply the brakes more gently.

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60

Braking


When possible, reduce your speed orcomplete braking before entering a turn.Avoid braking or closing the throttlequickly while turning. Either action maycause one or both wheels to slip andreduce your control of your motorcycle.

Your ability to brake in a turn and to brakehard in an emergency situation areimportant riding skills. We suggestattending a Motorcycle Safety Foundationexperienced rider training course(page ) to retain these skills.

When riding in wet or rainy conditions, oron loose surfaces, the ability to maneuverand stop will be reduced. All of youractions should be smooth under theseconditions. Rapid acceleration, braking orturning may cause loss of control. For

your safety, exercise extreme cautionwhen braking, accelerating or turning.

When descending a long, steep grade,use engine compression braking bydownshifting, with intermittent use ofboth brakes. Continuous brakeapplication can overheat the brakes andreduce their effectiveness.

Riding with your foot resting on thebrake pedal or your hand on the brakelever may actuate the brakelight, givinga false indication to other drivers. Itmay also overheat the brakes, reducingeffectiveness.

44

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－

61

Anti-Lock Brake System (ABS)

Braking


This model is also equipped with an Anti-lock Brake System (ABS) designed to helpprevent wheel lock up during hard brakingon uneven or other poor surfaces whilerunning straight. Although the wheel maynot lock up if you are braking too hardin a turn the motorcycle can still losetraction, causing a loss of control.

In some situations, a motorcycle with ABSmay require a longer stopping distance tostop on loose or uneven surfaces than anequivalent motorcycle without ABS.

ABS cannot make up for road conditions,bad judgment, or improper operation of

the brakes. It is still your responsibility toride at reasonable speeds for weather, roadsurface, and traffic conditions, and toleave a margin of safety.

ABS is self-checking and always on.

ABS may be activated by riding over asharp drop or rise in the road level.It is important to follow the tirerecommendations (page ). The ABScomputer works by comparing wheelspeed. Non-recommended tires can affectwheel speed and may confuse the ABScomputer.ABS does not function at low speeds(approximately 6 mph (10 km/h) orbelow).ABS does not function if the battery isdischarged.

(INTERCEPTOR ABS)

152

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62

ABS Indicator

Braking


Normally, this indicator comes on whenthe ignition is turned ON, and goes offafter you ride the motorcycle at a speedabove 6 mph (10 km/h). If there is an ABSproblem, the indicator comes on andremains on. The ABS system does notoperate when the ABS indicator is on.

If the ABS indicator comes on whileriding, stop the motorcycle in a safe placeand turn off the engine.

Turn the ignition ON again. The indicatorshould come on, and go off after you ridethe motorcycle at speeds above 6 mph (10km/h). If it does not go off, ABS is not

functioning, but the brakes still work theLinked Braking System and providenormal stopping ability. However, youshould have the system checked by Hondadealer as soon as possible.

The ABS indicator may come on if youturn the rear wheel at high speed for morethan 30 seconds while the motorcycle isupright on the stand. This is normal. Turnthe ignition OFF, then turn it ON. Theindicator should come on, then go offafter you run the motorcycle above 6 mph(10 km/h).

(INTERCEPTOR ABS)

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63

Parking


Catalytic Converter

Look for a level parking area. If youcan’t park on a paved surface, makesure the ground surface is firm.

Use the side stand to support themotorcycle while parked.

To lower the side stand, use your footto guide it down. Remember thatlowering the side stand with thetransmission in gear will stop theengine, even if the clutch lever ispulled in. That is a function of theside stand ignition cut-off system.Check that the side stand is down allthe way so that the side stand ignitioncut-off system (page ) is activated.

If you must park on a hill, leave thetransmission in gear.

Make sure flammable materials such asdry grass or leaves do not come incontact with the exhaust system whenparking your motorcycle. Refer to

, page .

(cont’d)

1. 2.

53229

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(1) ignition key (A) push in(B) turn to LOCK(C) turn to UNLOCK

(1)((AA))

((BB))

((CC))

((AA))

FRONT CENTER

64

Parking


If you have to park on a soft surface,insert something solid under thecenter stand for support.

Use the steering lock, which locks thehandlebar in place. Turn the handlebarall the way to the left or right. Push inon the ignition key ( ) and turn it toLOCK. Remove the key.

To lower the center stand, stand onthe left side of the motorcycle. Holdthe left hand grip with your left handand, with your right hand, grasp theholder above the passenger footpeg.Press down on the tip of the standwith your right foot and,simultaneously, pull up and back onthe hand grip.

3.

1

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Riding with a helmet attached tothe holder can interfere with therear wheel or suspension andcould cause a crash in which youcan be seriously hurt or killed.

Use the helmet holder only whileparked. Do not ride with a helmetsecured by the holder.

(1) holder hooks

(1)

65Basic Operation & Riding

Parking

Use the helmet holder to secure yourhelmet with your motorcycle:

Remove the seat (page ).Hang your helmet on the holderhooks ( ).Install the seat.

4.

1

90

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66

Theft-Prevention Tips

Parking


Park your motorcycle in a lockedgarage whenever possible. If a garageisn’t available, park in a concealed areaor in a well-lit area with enoughpedestrian traffic to discourage a thief.Always take the ignition key with you.Always use the steering lock (page ),even if you’re parking for just a minuteor two. A thief can easily push anunlocked motorcycle to a waiting truck.

If you decide to use an anti-theft device,select one of good quality and be sure tofollow the manufacturer’s instructions.

In addition to the steering lock, use agood quality anti-theft device madespecifically to lock a motorcycle to asecure object.

The rear fender has a storagecompartment to store a U-shaped lockunder the seat. After storing, use therubber band ( ) to securely fasten thelock. Some U-shaped locks may not bestored in the compartment due to theirsize or design.

1

64

04/07/02 14:18:11 31MCW630_075

(1) rubber band

(1)UNDER SEAT

67

Parking


Keep your owner’s manual, currentregistration, and insurance informationwith your motorcycle. This will make iteasier for the authorities to find you ifyour motorcycle is stolen and recovered.

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68

Riding with a Passenger or Cargo


Load Limits,Loading

Guidelines,

Your motorcycle is a high-performancesport model designed to carry you and onepassenger. Whenever you add a passengeror cargo, you must be careful not toexceed the total load limits for this vehicle( page ). Make sure yourcargo is properly secured (

page ).

Also consider adjusting the suspension(page ) for the extra load.

Be aware that carrying a passenger orheavy cargo can affect acceleration,braking, and handling.

Tell your passenger to hold the grab rail oryour waist, lean with you in the turns, andkeep their feet on the passenger footpegsat all times, even when the motorcycle isstopped at a traffic light.

Before riding with a passenger, make sureyour passenger is wearing the properprotective apparel (page ). Also checkthat your passenger is not wearing anyloose apparel that might get caught in thedrive chain.49

49

42

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69Servicing Your Honda

Servicing Your Honda

Maintenance, replacement or repair ofthe emission control devices andsystems may be performed by anymotorcycle repair establishment orindividual using parts that are‘‘certified’’ to EPA standards.

Bef ore You Service Your Honda

To help keep your motorcycle in goodshape, this section includes a MaintenanceSchedule for required service, a list ofperiodic checks you should perform atleast once a month, and step-by-stepinstructions for specific maintenance tasks.You’ll also find important safetyprecautions, information on fuels and oils,and tips for keeping your Honda lookinggreat.

For information about the exhaustemission and noise emission requirementsof the U.S. Environmental ProtectionAgency (EPA) and the California AirResources Board (CARB), see page .

For information about replacing fuses, seepage .

(cont’d)

USA only

...........The Importance of Maintenance . 72...............................Maintenance Safety . 73

............Important Safety Precautions . 74............................Periodic Maintenance . 76..........................Maintenance Schedule . 78

..............................Maintenance Record . 83223

202

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70



Service Preparations

Service Procedures

Engine

Chassis

ElectricalFluids & Filters

...........................Component Locations . 85..................................................Tool Kit . 88

.......................Owner’s Manual Storage . 89.........................................Seat Removal . 90

.....................................Rear Seat Cover . 91........................Lower Fairing Removal . 93

..........................Inner Fairing Removal . 96.............................Inner panel Removal . 97...........................Raising the Fuel Tank . 98

......................................................Fuel . 100..............................Engine Oil & Filter . 104

.................................................Coolant . 114..........................................Air Cleaner . 118

................................................Throttle . 120......................................Clutch System . 122

................................Engine Idle Speed . 125..........................................Spark Plugs . 127

...........................................Suspension . 134..................................................Brakes . 141

.....................................................Tires . 147............................................Side Stand . 154..........................................Drive Chain . 155

..................................................Battery . 162

.................................Appearance Care . 167

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＊

＊＊

＊

＊＊

71



The following table summarizes the three types of inspections and servicingrecommendations for your motorcycle. Both the pre-ride inspection and the scheduledmaintenance at the recommended intervals are necessary to assure safe and dependableperformance. The periodic checks provide additional confidence in your motorcycle’sperformance.

more often if you ride frequently or long distances; or anytime you clean yourmotorcycleunless you have the proper tools and service data and are mechanically qualified

Type of Inspection/Service

Maintenance SchedulePeriodic MaintenancePre-ride Inspection

Refer to page:

interval on schedulemonthlybefore every ride

your Honda dealeryouyou

Who PerformsWhen Performed457678

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Improperly maintaining thismotorcycle or failing to correct aproblem before you ride cancause a crash in which you can beseriously hurt or killed.

Always follow the inspection andmaintenance recommendationsand schedules in this owner’smanual.

72

The Importance of Maintenance


Keeping your motorcycle well-maintainedis absolutely essential to your safety. It’salso a good way to protect yourinvestment, get maximum performance,avoid breakdowns, and have more fun. Aproperly maintained motorcycle will alsohelp to reduce air pollution.

Remember, proper maintenance is theowner’s responsibility. Be sure to inspectyour motorcycle before each ride, performthe periodic checks, and follow theMaintenance Schedule in this section.

If your motorcycle overturns or isinvolved in a crash, be sure your Hondadealer inspects all major parts, even if youare able to make some repairs.

04/07/02 14:19:02 31MCW630_081

Failure to properly followmaintenance instructions andprecautions can cause you to beseriously hurt or killed.

Always follow the procedures andprecautions in this owner’smanual.

73

Maintenance Safety


This section includes instructions on howto perform some important maintenancetasks. If you have basic mechanical skills,you can perform many of these tasks withthe tools provided with your motorcycle.

Other tasks that are more difficult andrequire special tools are best performed byprofessionals. Wheel removal shouldnormally be handled only by a Hondatechnician or other qualified mechanic.Instructions are included in this manualonly to assist in emergency service.

Some of the most important safetyprecautions follow. However, we cannotwarn you of every conceivable hazard thatcan arise in performing maintenance. Onlyyou can decide whether or not you shouldperform a given task.

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74

Important Safety Precautions

Maintenance Safety


Carbon monoxide poisoning fromengine exhaust.

Burns from hot motorcycle parts.

Injury from moving parts.

Read the instructions before you begin,and make sure you have the tools andskills required.

Make sure the engine is off before youbegin any maintenance or repairs. Thiswill help eliminate several potentialhazards:

Be sure there isadequate ventilation whenever youoperate the engine.

Letthe engine and exhaust system coolbefore touching.

Do not runthe engine unless instructed to do so.

To help prevent the motorcycle fromfalling over, park it on a firm, levelsurface, using the center stand.To reduce the possibility of a fire orexplosion, be careful when workingaround gasoline. Use onlynon-flammable solvent, not gasoline, toclean parts. Keep cigarettes, sparks, andflames away from all fuel-related parts.

04/07/02 14:19:15 31MCW630_083

75

Maintenance Safety


Remember that your Honda dealer knowsyour motorcycle best and is fully equippedto maintain and repair it. To ensure thebest quality and reliability, use only newgenuine Honda parts or their equivalentsfor repair and replacement. If you have thetools and skills required for additionalmaintenance jobs, you can purchase anofficial Honda Service Manual (page

).234

04/07/02 14:19:19 31MCW630_084

76

Periodic Maintenance


In addition to the regularly scheduledmaintenance (page ) and daily pre-rideinspection (page ), consider performingthe periodic checks on the following pageat least once a month, even if you haven’tridden your motorcycle, or as often asonce a week if you ride frequently or forlong distances. It’s a good idea to performthis maintenance any time you clean yourmotorcycle.

Check the odometer reading and performany scheduled maintenance checks that areneeded (page ). Remember, morefrequent checks may be needed for ridingin severe conditions.

4578

78

04/07/02 14:19:24 31MCW630_085

77

Periodic Maintenance


Fluids

Fuses

Make sure the headlight, brake light, taillight, and turn signals areworking properly.

Check condition, adjust slack, and lubricate as needed (page ).

Lights

Drive Chain

Freeplay

Make sure you have a full supply of spare fuses.Check the major fasteners and tighten as needed.Nuts & Bolts

Check the freeplay of the clutch lever (page ), throttle grip (page), and the front brake lever (page ) and rear brake pedal.

Check the levels of the engine oil (page ), coolant (page ),clutch fluid (page ) and brake fluid (page ). Add the correctfluid as necessary, and investigate the cause of any low fluid level.

Check the air pressure with a gauge and add air if needed (page ).Examine the tread for wear (page ).Look closely for nails, embedded objects, cuts, and other types ofdamage (page ). Roll your motorcycle so you can inspect theentire surface.Check the condition of the wheels.

Tires &Wheels

148149

149

108 115123 143

122120 141

155

04/07/02 14:19:38 31MCW630_086

78 Servicing Your Honda

Maintenance Schedule

The required Maintenance Schedule thatfollows specifies how often you shouldhave your motorcycle serviced, and whatthings need attention. It is essential to haveyour motorcycle serviced as scheduled tomaintain safe, dependable performanceand proper emission control.

The service intervals in this MaintenanceSchedule are based on average ridingconditions. Some items will need morefrequent service if you ride in unusuallywet or dusty areas or at full throttle.Consult your Honda dealer forrecommendations applicable to yourindividual needs and use.

Some items in the Maintenance Schedulecan be performed with basic mechanicalskills and hand tools. Procedures for theseitems are provided in this manual. Otheritems involve more extensive proceduresand may require special training, tools,and equipment. We recommend that youhave your Honda dealer perform thesetasks unless you have advancedmechanical skills and the required toolsand equipment. Procedures for such itemsin this schedule are provided in an officialHonda Service Manual available forpurchase (page ).234

04/07/02 14:19:43 31MCW630_087

＊＊＊

＊

＊＊

79



If you do not feel capable of performing agiven task or need assistance, rememberthat your Honda dealer knows yourmotorcycle best and is fully equipped tomaintain and repair it. If you decide to doyour own maintenance, use only genuineHonda parts or their equivalents for repairor replacement to ensure the best qualityand reliability.

Perform the pre-ride inspection (page )and owner maintenance (page ) at eachscheduled maintenance period.

Each item on the maintenance schedulerequires some mechanical knowledge.Certain items (particularly those marked

and ) may require more technicalinformation and tools. Consult yourHonda dealer.

In the interest of safety, we recommendthese items be serviced only by yourHonda dealer.

Should be serviced by your Hondadealer, unless you have the proper toolsand service data and are mechanicallyqualified. Refer to the official HondaService Manual (page ).

4580 234

04/07/02 14:19:49 31MCW630_088



Summary of Maintenance Schedule Notes& Procedures:

At higher odometer readings, repeat atthe frequency interval established here.Service more frequently if themotorcycle is ridden in unusually wet ordusty areas.

Maintenance Procedures:I: inspect and clean, adjust, lubricate,

or replace, if necessaryC: cleanA: adjustL: lubricateR: replace

Replace every 2 years, or at indicatedodometer interval, whichever comesfirst. Replacement requires mechanicalskill. Refer to the official Hondaservice manual.

NOTES:1.

2.

3.

04/07/02 14:19:56 31MCW630_089

××

－－

－

－－

－

＊＊

＊

＊

＊＊

＊

＊

＊＊

1,000 mi

1,000 km

8

12.8

I

I

R

R

I

I

I

I

4

6.4

I

0.6

1.0

R

R

I

12

19.2

R

I

I

16

25.6

I

I

I

R

R

I

I

I

I

20

32.0

I

24

38.4

I

I

R

R

R

I

R

I

I

I

FUEL LINE

THROTTLE OPERATION

AIR CLEANER

SPARK PLUGS

VALVE CLEARANCE

ENGINE OIL

ENGINE OIL FILTER

ENGINE IDLE SPEED

RADIATOR COOLANT

COOLING SYSTEM

SECONDARY AIR SUPPLY

SYSTEM

EVAPORATIVE EMISSION

CONTROL SYSTEM

NOTE

2

3

Refer to

page

119

127

108

109

125

115

ODOMETER READING (Note 1)

ITEM

FREQUENCYE

MIS

SIO

NR

ELA

TE

DIT

EM

S EVERY 16,000 mi (25,600 km) I,

EVERY 32,000 mi (51,200 km) R



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

Should be serviced by your Honda dealer, unless you have the proper tools and servicedata and are mechanically qualified. Refer to the official Honda Service Manual (page

).234

04/07/02 14:20:08 31MCW630_090

××

－－

－－－－

＊＊

＊＊＊＊＊＊

＊

＊＊

NOTE

3

3

DRIVE CHAIN

BRAKE FLUID

BRAKE PAD WEAR

BRAKE SYSTEM

BRAKE LIGHT SWITCH

HEADLIGHT AIM

CLUTCH SYSTEM

CLUTCH FLUID

SIDE STAND

SUSPENSION

NUTS, BOLTS, FASTENERS

WHEELS/TIRES

STEERING HEAD

BEARINGS

0.6

1.0

I

I

I

4

6.4

I

I

I

8

12.8

I

I

I

I

I

I

I

I

I

I

I

I

12

19.2

R

I

R

16

25.6

I

I

I

I

I

I

I

I

I

I

I

I

20

32.0

I

I

I

24

38.4

R

I

I

I

I

I

R

I

I

I

I

I

Refer to

page

160

143

145

146

122

123

154

ODOMETER READING (Note 1)

ITEM

FREQUENCYN

ON

-EM

ISS

ION

RE

LAT

ED

ITE

MS

EVERY 500 mi (800 km) I, L

1,000 mi

1,000 km

82



Should be serviced by your Honda dealer, unless you have the proper tools and servicedata and are mechanically qualified. Refer to the official Honda Service Manual (page

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

234

04/07/02 14:20:21 31MCW630_091

83

Maintenance Record


Miles (km) Odometer Date Performed By: Notes

Keeping an accurate maintenance record will help ensure that your motorcycle is properlymaintained. Retain detailed receipts to verify the maintenance was performed. If themotorcycle is sold, these receipts should be transferred with the motorcycle to the new owner.Make sure whoever performs the maintenance completes this record. All scheduledmaintenance, including the 600 mile (1,000 km) initial maintenance, is considered a normalowner operating cost and will be charged for by your dealer. Use the space under Notes torecord anything you want to remind yourself about or mention to your dealer.

600 (1,000)4,000 (6,400)8,000 (12,800)

12,000 (19,200)16,000 (25,600)20,000 (32,000)

04/07/02 14:20:29 31MCW630_092

84

Maintenance Record


Miles (km) Odometer Date NotesPerformed By:24,000 (38,400)28,000 (44,800)32,000 (51,200)36,000 (57,600)40,000 (64,000)44,000 (70,400)48,000 (76,800)52,000 (83,200)56,000 (89,600)60,000 (96,000)64,000 (102,400)68,000 (108,800)

04/07/02 14:20:37 31MCW630_093

throttle grip

front brake fluidreservoir

clutch fluidreservoir

fuel fill cap

front spring pre-load adjuster

85

Component Locations


04/07/02 14:20:42 31MCW630_094

front brakecaliper

spark plugs

rear brakefluid reservoir

seatspark plugs

oil filler cap oil inspection window

grab rails engine idle speedhelmetholder

tool kitcompartment

fuse box

rear spring pre-load adjuster knob(INTERCEPTOR ABS only)

rear brake caliper

86

Component Locations


04/07/02 14:20:46 31MCW630_095

owner’s manualstorage

drive chain

rear spring damping adjuster

center stand

inner fairing

lower fairing

side stand

coolantreserve tank

battery

helmet holder

inner panel

rear spring pre-load adjuster(INTERCEPTOR only)

fuse box(INTERCEPTORABS only)

shift lever

87

Component Locations


04/07/02 14:20:52 31MCW630_096

××

××

(1)(2)

(1) tool kit (2) extension bar

UNDER SEAT

88

Tool Kit


The tool kit ( ) is stored under the seat(page ). Some roadside repairs, minoradjustments, and parts replacement can beperformed with the tools contained in thekit.

tool bag10 12 mm box end wrench14 17 mm box end wrench

spark plug wrench5 mm hex wrench6 mm hex wrench8 12 mm open end wrench10 14 mm open end wrenchpliersno. 2 Phillips screwdriverno. 2 screwdriverscrewdriver handle8 mm box wrench0.7 mm feeler gaugepin spanner (for drive chain adjustment)

extension bar

The following tool is also provided withyour motorcycle.

pin spanner (for rear suspensionadjustment) (INTERCEPTOR)

190

04/07/02 14:21:09 31MCW630_097

(1)

(1) owner’s manual storage bag(2) owner’s manual storage

compartment

(2)

UNDER SEAT

89

Owner’s Manual Storage


Your motorcycle provides storage for theowner’s manual so you’ll have it with youfor easy reference. Store your owner’smanual (and other documents) in theplastic storage bag ( ) in the storagecompartment ( ) under the seat.

Be careful not to flood this area whenwashing your motorcycle.

12

04/07/02 14:21:16 31MCW630_098

(4)

(5)

(6)(1)

(3)

(2)(1) seat(2) ignition key(3) seat lock

(4) front prongs(5) front stays(6) rear prongs(7) rear stays

(7)

90

Seat Removal


Saf ety PrecautionsRefer to on page . RemovalInsert the ignition key ( ) into the seatlock ( ).Turn it clockwise and pull up on therear of the seat ( ).Pull the seat ( ) back and up.

InstallationInsert the front prongs ( ) into the frontstays ( ) and the rear prongs ( ) intothe rear stays ( ) on the frame.Push forward and then down on the rearof the seat.

Be sure to securely lock the seat afterreinstalling it.

The seat must be removed for battery,main fuse and rear brake reservoirmaintenance, to use the helmet holder, toaccess the tool kit and owner’s manual, orto lift the fuel tank.

1.

2.

2.

3.

1.

2

6

11

74

4

75

3

04/07/02 14:21:28 31MCW630_099

(1) (2)(3)

(3)

(4)

(6)

(5) (5)

(6) rear seat cover(7) stopper holes(8) pins

(3) washers(4) grab rails(5) grab rail covers

(1) caps(2) grab rail

mounting bolts

(2)

(4)

(8)

(7)

(2) (1)


Rear Seat Cover

Saf ety PrecautionsRefer to on page .

Installation

The grab rails must be returned to positionwhen riding in tandem.

Remove the seat (page 90).Remove the caps (1), grab rail mountingbolts (2) and washers (3).Remove the grab rails (4).Install the grab rail covers (5).

Turn the seat over.Install the rear seat cover (6) to the seat.Fit the stopper holes (7) of rear seatcover securely into the pins (8).Install the seat (page 90).

1.2.

3.

5.

4.

6.7.

8.

74

04/07/02 14:21:40 31MCW630_100

16 lbf·ft (22 N·m , 2.2 kgf·m)

92

Rear Seat Cover


RemovalRemoval can be done in the reverseorder of installation.The grab rails should be installed forriding with a passenger.Tighten the grab rail mounting bolts (2)to the specified torque:

Install the seat (page 90).

If a torque wrench was not used forinstallation, see your Honda dealer as soonas possible to verify proper assembly. Thegrab rails could come off easily and resultin serious injury if the assembly is notdone properly.

1.

2.

3.

04/07/02 14:21:47 31MCW630_101

RIGHT SIDE

(3) B bolts(4) C bolts

(4)

(1)

(1)

(2)

(3)

(1) A clips(2) A bolts

93

Lower Fairing Removal



The lower fairing must be removed toservice the coolant reserve tank or toremove the inner fairing.

74

04/07/02 14:21:54 31MCW630_102

LEFT SIDE

(3) B bolts(4) C bolts

(3)

(4)

(2)

(1)

(1)(1) A clips(2) A bolts

94



Removal

Installation

Remove the A clips (1).Remove the A bolts (2).Remove the B bolts (3).Remove the C bolts (4).

Installation can be done in the reverseorder of removal.

1.2.3.4.

04/07/02 14:22:02 31MCW630_103

95



A clip removal and installation:

Press down on the center pin to releasethe lock.Pull out the clip from the hole.

Slightly open the retaining pawls andthen push them out.Insert the clip into the hole.Lightly press down on the center pin tolock the clip.

Removal

Installation

04/07/02 14:22:11 31MCW630_104

(1)

(2)

(2) inner fairing(1) A clips

96

Inner Fairing Removal



The inner fairing must be removed toservice the engine oil filter.

Removal

Installation

Remove the lower fairing (page 93).Remove the A clips (1).


2.1.

74

04/07/02 14:22:19 31MCW630_105

(3)

(4)(1)

LEFT FRONT (right side similar)

(2)

(1) A bolt(2) B bolt

(3) A clip(4) inner panel

97

Inner Panel Removal



The inner panel must be removed toservice the fuses.

Removal


Installation

Remove the A bolt (1) and B bolt (2).Remove the A clip (3).Remove the inner panel (4).

1.2.3.

74

04/07/02 14:22:29 31MCW630_106

(2)

(3)

(1)

RIGHT SIDE

(1) bolts(2) washers(3) collars

98

Raising the Fuel Tank



The fuel tank must be raised to service theair cleaner or the rear cylinder spark plugs.The fuel tank does not require draining forthis procedure.

Place the motorcycle on its center standwith the transmission in neutral and theignition switch off.Check that the fuel fill cap is closed.Remove the seat (page 90).Remove the two bolts (1) with washers(2) and the collars (3).

1.

2.3.

74

04/07/02 14:22:36 31MCW630_107

RIGHT SIDE

(4)

(1)

(4) fuel tank(5) stopper cable(6) pin spanner(7) extension bar

(5)

(6)

(7)

99

Raising the Fuel Tank


When raising the fuel tank, be careful notto allow the collars fall down.

Raise the front of the fuel tank (4) andinstall the bolt (1) to frame body.

Do not raise the fuel tank higher than thestopper cable ( ) allows.

Insert a pin spanner (6) from the tool setin the extension bar (7).Place the base of the extension bar overthe installed bolt and position the pinspanner so that it supports the fuel tank.

4.

5.

6.

5

04/07/02 14:22:43 31MCW630_108

unleaded86 (or higher)

typepump octanenumber

100

Fuel Recommendation

Fuel



We recommend that you use unleaded fuelbecause it produces fewer engine depositsand extends the life of exhaust systemcomponents.

Your engine is designed to use anygasoline that has a pump octane number of86 or higher. Gasoline pumps at servicestations normally display the pump octanenumber. For information on the use ofoxygenated fuels, see page .

The use of leaded gas will damage thecatalytic converter.

74

230

04/07/02 14:22:53 31MCW630_109

101

Fuel


Use of lower octane gasoline can causepersistent ‘‘pinging’’ or ‘‘spark knock’’ (aloud rapping noise) which, if severe, canlead to engine damage. Light pingingexperienced while operating under a heavyload, such as climbing a hill, is no causefor concern.

If pinging or spark knock occurs at asteady engine speed under normal load,change brands of gasoline. If pinging orspark knock persists, consult your Hondadealer.

04/07/02 14:22:57 31MCW630_110

5.81 US gal (22.0 )

(3)

(1) ignition key(2) fuel fill cap

(3) filler neck

(2)(1)

102

Refueling Procedure

Fuel Capacity

Fuel


Saf ety Precautions

Never use stale or contaminated gasolineor an oil/gasoline mixture. Avoid gettingdirt, dust, or water in the fuel tank.

Refer to on page .

Insert the ignition key ( ) in the fuelfill cap ( ) and turn it clockwise.

Fuel tank capacity:

1. 12

74

04/07/02 14:23:07 31MCW630_111

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

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

103

Fuel


Open the cap.Add fuel until the level reaches thebottom of the filler neck ( ). Avoidoverfilling the tank. There should be nofuel in the filler neck.

After refueling, push the fuel fill capclosed until it snaps and locks.Remove the ignition key from the cap.

2.3.

5.

4.

3

04/07/02 14:23:14 31MCW630_112

104

Engine Oil & Filter


Engine oil quality is a major factor thataffects both the performance and theservice life of the engine.

When running in very dusty conditions, oilchanges should be performed morefrequently than specified in themaintenance schedule.

Change the engine oil as specified in themaintenance schedule on page .

Using the proper oil (page ) and filter,and regularly checking, adding, andchanging oil will help extend yourengine’s life. Even the best oil wears out.Changing oil helps get rid of dirt anddeposits in the engine. Operating theengine with old or dirty oil can damageyour engine. Running the engine withinsufficient oil can cause serious damageto the engine and transmission.

81

105

04/07/02 14:23:20 31MCW630_113

＊

＊

Pro Honda GN4 or HP4 (withoutmolybdenum additives) 4-strokeoil (USA & Canada), or Honda4-stroke oil (Canada only), or anequivalent motorcycle oil.

MA

SAE 10W-40

SG or higherexcept oilslabeled as energyconserving on thecircular APIservice label

APIclassification

JASO T 903standard

viscosity(weight)

suggested oil

105

Oil Recommendation

Engine Oil & Filter


Suggested oils are equal in performanceto SJ oils that are not labeled as energyconserving on the circular API servicelabel.

(cont’d)

04/07/02 14:23:31 31MCW630_114

OKNOT RECOMMENDED

106

Engine Oil & Filter


Do not use oils with graphite ormolybdenum additives. They mayadversely affect clutch operation.

Your motorcycle does not need oiladditives. Use the recommended oil.

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

Other viscosities shown in the followingchart may be used when the averagetemperature in your riding area is withinthe indicated range.

Do not use API SH or higher oilsdisplaying a circular API ‘‘energyconserving’’ service label on thecontainer. They may affect lubricationand clutch performance.

04/07/02 14:23:42 31MCW630_115

(1) code number of the sales companyof the oil

(2) oil classification

(1)

(2)

107

Engine Oil & Filter


JASO T 903 standardThe JASO T 903 standard is an index tochoose engine oils for 4-stroke motorcycleengines.There are two classes: MA and MB.Oil conforming to the standard has thefollowing classification on the oilcontainer.

04/07/02 14:23:48 31MCW630_116

－

－

RIGHT SIDE

(1) oil inspection window(2) upper level mark(3) lower level mark(4) oil filler cap

(4)

(1)

(3)(2)

108

Checking & Adding Oil

Engine Oil & Filter



Stop the engine and wait 2 3 minutes.

Start the engine and let it idle for 3 5minutes. Make sure the low oil pressureindicator goes off. If the indicatorremains on, stop the engineimmediately.

Park your motorcycle on its center standon a firm, level surface.

If the oil is at or near the upper levelmark ( ) –– you do not have to addoil.If the oil is below or near the lowerlevel mark ( ) –– remove the oilfiller cap ( ) and add therecommended oil until it reaches theupper level mark. (Do not overfill.)

Check that the oil level is between theupper ( ) and lower ( ) level marks inthe oil inspection window ( ).

2.

3.

1.

4.

74

32

2

34

1

04/07/02 14:23:59 31MCW630_117

109

Changing Engine Oil & Filter

Engine Oil & Filter


Saf ety Precautions

Using the wrong oil f ilter may result inleaks or premature engine damage.

Refer to on page .

Your motorcycle’s oil filter has veryspecific performance requirements. Use anew genuine Honda oil filter or a filter ofequal quality specified for your model.

Check for oil leaks.Reinstall the oil filler cap.5.

6.

74

04/07/02 14:24:07 31MCW630_118

－－

(2) sealing washer(1) crankcasedrain bolt

LEFT SIDE

(1) (2)

110

Engine Oil & Filter


Drain the Engine Oil:

This procedure requires mechanical skilland professional tools such as a torquewrench and oil filter wrench, as well as ameans for disposing of the drained fluid(page ). If you do not have the skillsor the tools, see your Honda dealer.

If the engine is cold, start it and let itidle for 3 5 minutes. Turn the engineoff. Wait 2 3 minutes for the oil tosettle.


Remove the lower fairing and the innerfairing (page ).

Place a drain pan under the crankcasedrain bolt ( ).To drain the oil, remove the oil fillercap, crankcase drain bolt, and sealingwasher ( ).

1.

2.

3.

4.

5.

2

1

96

180

04/07/02 14:24:18 31MCW630_119

(3) oil filter

LEFT SIDE

(3)

111

Engine Oil & Filter


Install a New Oil Filter:

Improper disposal of drained f luids isharmf ul to the environment.

Remove the oil filter ( ) with a filterwrench and let the remaining oil drainout. Discard the oil filter in an approvedmanner (page ).Pour the drained oil into a suitablecontainer and dispose of it in anapproved manner (page ).

(cont’d)

6.

7.

3

180

180

04/07/02 14:24:27 31MCW630_120

22 lbf·ft (29 N·m , 3.0 kgf·m)

3.3 US qt (3.1 )

20 lbf·ft (26 N·m , 2.7 kgf·m)

(4) oil filter rubber seal

(4)

112

Engine Oil & Filter


Add Engine Oil:

Apply a thin coat of engine oil to therubber seal ( ) of a new oil filter.

Install the new oil filter and tighten it byhand.

Check the condition of the sealingwasher on the drain bolt. Replace thewasher every other time the oil ischanged.Install the drain bolt and tighten it to thespecified torque:

Install the oil filler cap.

Using an oil filter wrench attachmentand a torque wrench, tighten the new oilfilter to the specified torque:

Fill the crankcase with therecommended oil (page ),approximately:

8.4

9. 13.

12.

11.

10.

105

04/07/02 14:24:38 31MCW630_121

113

Engine Oil & Filter


Start the engine and let it idle for a fewminutes.Stop the engine. Wait several minutes.

Check that there are no oil leaks.

Check that the oil level is at the upperlevel mark in the oil inspection window(page ).

Install the lower fairings and innerfairing.

If a torque wrench is not used forinstallation, see your Honda dealer as soonas possible to verify proper assembly.

14.

15.16.

17.18.

108

04/07/02 14:24:46 31MCW630_122

114

Coolant Recommendation

Coolant


Using coolant with silicate inhibitors maycause premature wear of water pumpseals or blockage of radiator passages.Using tap water may cause enginedamage.

Your motorcycle’s liquid cooling systemdissipates engine heat through the coolantjacket that surrounds the cylinder andcylinder head.

Maintaining the coolant will allow thecooling system to work properly andprevent freezing, overheating, andcorrosion.

Use Pro Honda HP coolant or anequivalent high quality ethylene glycolantifreeze containing corrosion protectioninhibitors specifically recommended foruse in aluminum engines. Check theantifreeze container label. Decreasing the concentration of antifreeze

to less than 40% will not provide propercorrosion protection.Use only distilled water as a part of the

coolant solution. Water that is high inmineral content or salt may be harmful tothe aluminum engine.

The factory provides a 50/50 solution ofantifreeze and water in this motorcycle.This coolant solution is recommended formost operating temperatures and providesgood corrosion protection.

04/07/02 14:24:54 31MCW630_123

(2)

(3)LEFT SIDE

(1)

(1) UPPER level mark(2) LOWER level mark(3) reserve tank cap

115

Checking & Adding Coolant

Coolant


Saf ety Precautions

Increasing the concentration of antifreezeis not recommended because it decreasescooling system performance. Higherconcentrations of antifreeze (up to 60%)should only be used to provide additionalprotection against freezing. Check thecooling system frequently during freezingweather.

Refer to on page .74

04/07/02 14:25:01 31MCW630_124

116

Coolant Replacement

Coolant



With the engine at normal operatingtemperature, check the coolant level inthe reserve tank. It should be betweenthe UPPER ( ) and LOWER ( ) levelmarks.

Remove the reserve tank cap ( ).Always add coolant to the reserve tank.Do not attempt to add coolant byremoving the radiator cap.Add coolant to the reserve tank asrequired to bring the coolant level to theUPPER level mark.

If the reserve tank is empty, or ifcoolant loss is excessive, check forleaks and see your Honda dealer forrepair.Remove the lower fairing (page ).

Coolant should be replaced by your Hondadealer, unless you have the proper toolsand service data and are mechanicallyqualified. Refer to the official HondaService Manual (page ).

1

3.

4.

1.

2.

2

933

74

234

04/07/02 14:25:11 31MCW630_125

Removing the radiator cap whilethe engine is hot can cause thecoolant to spray out, seriouslyscalding you.

Always let the engine and radiatorcool down before removing theradiator cap.

117

Coolant


You & the Environment,

Improper disposal of drained f luids isharmf ul to the environment.

To properly dispose of drained coolant,refer to page

.180

04/07/02 14:25:16 31MCW630_126

118

Air Cleaner


Saf ety Precautions

Using the wrong air cleaner may result inpremature engine damage.

Improper or lack of proper air cleanermaintenance can cause poor perf ormanceand premature engine wear.

Refer to on page .

Service the air cleaner more frequently ifyou ride in unusually wet or dusty areas.Your Honda dealer can help youdetermine the correct service interval foryour riding conditions.

Your motorcycle’s air cleaner has veryspecific performance requirements. Use anew genuine Honda air cleaner specifiedfor your model or an air cleaner ofequivalent quality.

Proper air cleaner maintenance canprevent premature engine wear or damage,expensive repairs, low engine power, poorgas mileage, and spark plug fouling.

74

04/07/02 14:25:23 31MCW630_127

(1) vacuum tube(2) screws

(3) air cleanerhousing cover

(2) (4) air cleaner

(4)

(2)

(1)(3)

119

Air Cleaner Replacement

Air Cleaner


Discard the air cleaner.Install a new air cleaner.Install the removed parts in reverseorder of removal.

Raise the fuel tank (page 98).Disconnect the vacuum tube (1).Remove the screws (2) that secure theair cleaner housing cover (3).Remove the cover.

Remove the air cleaner (4).

2.3.

4.

1.

5.6.7.8.

04/07/02 14:25:32 31MCW630_128

－－

＋－

＋＋

－－

1/16 1/4 in (2 6 mm)

RIGHT HANDLEBAR

(1) lock nut(2) adjuster

(2)(1)

( ) increase( ) decrease

(( ))

(( ))

120

Throttle Freeplay

Throttle



InspectionCheck freeplay at the throttle grip flange.Freeplay:

If necessary, adjust to the specified range.

AdjustmentLoosen the lock nut ( ).Turn the adjuster ( ).After adjustment, check for smoothrotation of the throttle grip from fullyclosed to fully open in all steeringpositions.

1.2.3.

1

74

2

04/07/02 14:25:43 31MCW630_129

121

Throttle Inspection

Throttle



Check that the throttle assembly ispositioned properly and the securingbolts are tight.Check for smooth rotation of thethrottle from fully open to fully closedin all steering positions. If there is aproblem, see your Honda dealer.

1.

2.

74

04/07/02 14:25:49 31MCW630_130

LEFT HANDLEBAR

(1)

(1) adjuster(2) arrow

(2)

(4)

(3) clutch lever(4) index mark

(3)

122

Clutch Lever Adjustment

Clutch System



Your motorcycle has a hydraulically-actuated clutch. There are no adjustmentsto perform, but the clutch system must beinspected periodically for fluid level andleakage.

If control lever freeplay becomesexcessive and the motorcycle creeps orstalls when shifted into gear, or if theclutch slips, causing acceleration to lagbehind engine speed, there is probably airin the clutch system. See your Hondadealer to have the air bled out of thesystem.

The distance between the tip of the clutchlever and the grip may be adjusted.

74

04/07/02 14:25:57 31MCW630_131

(1) LOWER level mark

(1)

LEFT FRONT

123

Fluid Level Inspection

Clutch System


Saf ety Precautions

Check that the fluid level is above theLOWER level mark. If the fluid level isbelow the LOWER level mark, it indicatesfluid leakage. See your Honda dealer forrepair.

Refer to on page .

Turn the adjuster ( ) while pushing theclutch lever forward.Align the arrow ( ) on the clutch lever( ) with the index mark ( ) on theadjuster.Start the engine, pull the clutch lever in,and shift into gear. Make sure theengine does not stall and the motorcycledoes not creep. Gradually release theclutch lever and open the throttle. Yourmotorcycle should move smoothly andaccelerate gradually.

2.

3.

1. 1

742

43

04/07/02 14:26:06 31MCW630_132

124

Other Inspections

Clutch System


Make sure there are no fluid leaks.Check for deterioration or cracks in thehose and fittings.Check that the clutch lever assembly ispositioned properly and the securingbolts are tight.

04/07/02 14:26:12 31MCW630_133

＋－

－－

＋＋

(1) throttle stopscrew

( ) increase( ) decrease

(1)(( ))

(( ))

RIGHT SIDE

125

Idle Speed Adjustment

Engine Idle Speed



Remember, idle speed adjustment is not a‘‘cure-all’’ for other problems in yourengine’s fuel-delivery system. Adjustingthe idle will not compensate for a faultelsewhere.

The engine must be at normal operatingtemperature for accurate idle speedadjustment.

If the engine is cold, start it and warm itup with ten minutes of stop-and-goriding. Stop the engine. (cont’d)

1.

74

04/07/02 14:26:20 31MCW630_134

±1,200 100 rpm

126

Engine Idle Speed


Adjust idle speed with the throttle stopscrew ( ).Idle speed (in neutral):

Shift into neutral. Start the engine.

Place your motorcycle on its centerstand on a firm, level surface.

3.4.

1

2.

04/07/02 14:26:27 31MCW630_135

－

－

IMR9B 9H (NGK)VNH27Z (DENSO)


or

or

standardspark plug

for coldclimate(below 5°C,41°F)

127

Spark Plug Recommendation

Spark Plugs


Using spark plugs with an improper heatrange can cause engine damage.

Use only the recommended type of sparkplugs in the recommended heat range.

This motorcycle uses spark plugs that havean iridium coated center electrode.Be sure to observe the following whenservicing the spark plugs.

Do not clean the spark plugs. If anelectrode is contaminated withaccumulated objects or dirt, replace thespark plug with a new one.Use only a ‘‘wire-type feeler gauge’’ tocheck the spark plug gap if necessary.To prevent damaging the iridiumcoating of the center electrode, neveruse a ‘‘leaf-type feeler gauge.’’Do not adjust the spark plug gap. If thegap is out of specification, replace thespark plug with a new one.

04/07/02 14:26:38 31MCW630_136

(1)

(1) bolts(2) ignition coil connectors(3) ignition coils

LEFT SIDE (right side similar)(rear cylinder)

(2)(3)

128

Spark Plug Replacement &Inspection

Spark Plugs



Spark Plug AccessTo access the rear cylinder spark plugs:

Raise the fuel tank (page ).Remove the bolts ( ).Disconnect the ignition coil connectors( ).Disconnect the ignition coils ( ) fromthe spark plugs.

3.

1.2.

4.

1

3

74

2

98

04/07/02 14:26:47 31MCW630_137

LEFT SIDE (right side similar)(rear cylinder)

(4)

(4) spark plug wrench

129

Spark Plugs


Clean any dirt from around the sparkplug bases.Using the spark plug wrench ( )provided in the tool kit, remove thespark plugs.

Be careful not to damage the hoses and thewire harness.

5.

6. 4

04/07/02 14:26:54 31MCW630_138

FRONT

(5) bolts(6) wire harness holder(7) ignition coil connectors(8) ignition coils

(7)

(5)(6)

(5) (8)

(front cylinder)

(7)

130

Spark Plugs


To access the front cylinder spark plugs:

Remove the bolts ( ) and wire harnessholder ( ).Disconnect the ignition coil connectors( ).Disconnect the ignition coils ( ) fromthe spark plugs.

9.

7.

8.6

8

5

7

04/07/02 14:27:03 31MCW630_139

FRONT

(9) spark plug gap

(4)

(4) spark plug wrench

(front cylinder)

(9)

131

Spark Plugs


Clean any dirt from around the sparkplug bases.Using the spark plug wrench ( )provided in the tool kit, remove thespark plugs.

Inspect the electrodes and centerporcelain for deposits, corrosion, orcarbon fouling. If the corrosion ordeposits are heavy, replace the plug.Make sure that a 1.0 mm wire-typefeeler gauge cannot be inserted betweenthe spark plug gap ( ). If the gaugefits in the gap, replace the plug with anew one.Make sure the plug washer is in goodcondition.

(cont’d)

9

4

10.

11.

12.

13.

14.

04/07/02 14:27:11 31MCW630_140

132

Spark Plugs


Improperly tightened spark plugs candamage the engine. If a plug is too loose,a piston may be damaged. If a plug is tootight, the threads may be damaged.

With the plug washers attached, threadthe spark plugs in by hand to preventcross-threading.Tighten each spark plug:

If the old plug is good:1/8 turn after it seats.

If installing a new plug, tighten ittwice to prevent 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.

Reinstall the ignition coils ( ).Connect the ignition coil connectors( ) to the ignition coils as beforeremoval.Install the wire harness holder ( ) tothe right side of front cylinder andinstall and tighten the bolts.Install the remaining parts in the reverseorder of removal.Hold the ignition coils wire harness( ) in the right side of front cylinderwith the wire harness holder ( ).

16.

10

15.

21.

20.

19.

18.17.

11

12

1312

a)

b)c)

1/21

04/07/02 14:27:22 31MCW630_141

RIGHT FRONT

(10)

(11)(13)

(12)

(front cylinder)

(12) wire harness holder(13) wire harness

(10) ignition coils(11) ignition coil connectors

133

Spark Plugs


04/07/02 14:27:27 31MCW630_142

134

Suspension


Your front and rear suspension systemsuse springs, hydraulic damping devices,and linkages (rear only) that suspend yourweight and most of the weight of yourmotorcycle.

The spring pre-loads for your front andrear suspension systems adjust the amountof force required to begin compression ofthe spring.

Consider adjusting your suspensionwhenever you change your normal load,by adding or subtracting a passenger,cargo, or accessories, or when the road orriding conditions change.

The way you ride your motorcycle and thetype of ride you want to experience canalso influence your suspension needs.

The oil damper systems hydraulicallycontrol the rebound of the suspensionsprings so that traction and comfort aremaintained as the wheels ride over roadsurfaces.

You may adjust the spring pre-load ofboth suspension systems. You may alsoadjust the rebound damping of the rearsuspension system.

04/07/02 14:27:34 31MCW630_143

135

Front Suspension Adjustment

Suspension


The front suspension can be adjusted forrider (and passenger) weight and ridingconditions by changing the spring pre-load.

Lower spring pre-load and softer dampingprovide a softer ride and are usuallypreferred for light loads and smooth roads.Higher spring pre-load and firmerdamping provide a firmer ride and arerecommended for heavy loads, rough roadconditions, and faster, more challengingriding.

04/07/02 14:27:39 31MCW630_144

FRONT

(1)

STANDARD POSITION

(1) pre-load adjuster

136

Front Suspension SpringPre-load

Suspension


Saf ety Precautions

To Reduce Spring Pre-load (SOFT):

To Increase Spring Pre-load (HARD):

Refer to on page .

Adjust the spring pre-load by turning thepre-load adjuster ( ) with the No. 2screwdriver provided in the tool kit.

For a light load and smooth roadconditions, turn the adjustercounterclockwise toward SOFT.

For a firmer ride and rough roadconditions, turn the adjuster clockwisetoward HARD.

Make sure that both fork legs areadjusted to the same position.

1

74

04/07/02 14:27:48 31MCW630_145

137

Rear Suspension Adjustment

Suspension


The rear shock absorber includes a damperunit that contains high pressure nitrogengas. Do not attempt to disassemble,service, or dispose of the damper; see yourHonda dealer. The instructions found inthis owner’s manual are limited toadjustments of the shock assembly only.

The rear suspension can be adjusted forrider (and passenger) weight and ridingconditions by changing the spring pre-loadand rebound damping.

04/07/02 14:27:54 31MCW630_146

(3) extension bar

LEFT SIDE

(1)

4

3

(2)(3)

5 6 7 2 1

(INTERCEPTOR)

(1) spring pre-load adjuster(2) pin spanner

138

Rear Suspension Spring Pre-load

Suspension


Saf ety PrecautionsRefer to on page . Use the pin spanner ( ) and extension bar( ) to adjust the rear shock spring pre-load.

Positions 3 to 7: for when the motorcycleis more heavily loaded. (Also increasespring pre-load for stiffer rear suspension.)

Position 2: standard position.

Position 1: for a light load and smoothroad conditions.

The spring pre-load adjuster ( ) haspositions for different load or riding

conditions.

Always adjust the shock absorber positionin sequence (1-2-3-4-5-6-7 or 7-6-5-4-3-2-1). Attempting to adjust directly from 1 to7 or 7 to 1 may damage the shock absorber.

7

74

1

23

04/07/02 14:28:05 31MCW630_147

(1) adjuster knob(2) end of the adjuster knob(3) indicator line

RIGHT SIDE

(3)

(2)

(1)

(INTERCEPTOR ABS)

139

Suspension


To Reduce Spring Pre-load (LOW):

To Increase Spring Pre-load (HIGH):

For a light load and smooth roadconditions, turn the adjustercounterclockwise toward LOW.

Turn the spring pre-load adjuster knob( ) counterclockwise until it will nolonger turn (lightly seats).This is the full LOW setting.Turn the adjuster clockwise by clicks.At that position, the end of the adjusterknob ( ) should be aligned with theindicator line ( ).

To adjust to the standard position:

To adjust the spring pre-load, turn theadjuster knob ( ).

The spring pre-load adjuster knob ( ) hasspring pre-load positions (clicks) or

more for different load or ridingconditions.

For a firmer ride and rough roadconditions, turn the adjuster clockwisetoward HIGH.

1.

2. 7

1

1

1

35

32

04/07/02 14:28:14 31MCW630_148

(1)(3)

(1) damping adjuster(2) punch mark(3) reference punch mark

LEFT UNDER

(2)

140

Rear Suspension Damping

Suspension


Saf ety Precautions

To Reduce Rebound Damping (SOFT):

To Increase Rebound Damping(HARD):

Refer to on page .

Rebound Damping

To adjust to the standard position:

Turn the damping adjuster ( )clockwise until it will no longer turn.This is the full hard setting.

For a light load and smooth roadconditions, turn the adjustercounterclockwise toward SOFT (S).

For a firmer ride and rough roadconditions, turn the adjuster clockwisetoward HARD (H).

Turn the adjuster counterclockwiseapproximately turns so that thepunch mark ( ) on the adjuster alignswith the reference punch mark ( ). Thisis the standard position.

1.

2.

1

23

1 ¼74

04/07/02 14:28:27 31MCW630_149

(1) adjuster(2) arrow

(3) brake lever(4) index mark

(4)

(2)(3)

(1)

RIGHT HANDLEBAR

141

Front Brake Lever Adjustment

Brakes


Saf ety Precautions

The hydraulic braking systems on yourmotorcycle dissipate the heat generated bythe friction of the brake pads on the brakediscs as the wheels are slowed.

As the brake pads wear, the brake fluidlevel will drop. A leak in the system willalso cause the level to drop.

Frequently inspect the system to ensurethere are no fluid leaks. Periodicallyinspect the brake fluid level and the brakepads for wear.

If the brake lever or brake pedal freeplaydoes not feel within the normal rangewhile riding, check the brake pads forwear (page ). Worn pads should bereplaced. If the pads are not worn beyondthe recommended limit, there is probably

air in the brake system. See your Hondadealer to have the air bled from the system.

Refer to on page .

The distance between the tip of the brakelever and the grip may be adjusted.

74

145

04/07/02 14:28:37 31MCW630_150

Honda DOT 4 BrakeFluid

brakefluid

142

Brake Fluid Recommendation

Brakes


The recommended brake fluid is HondaDOT 4 Brake Fluid, or any brake fluid ofequal quality and performance. Use freshbrake fluid from a sealed container. Besure to read the label before opening thesealed container. An opened containermay be contaminated or may haveabsorbed moisture from the air.

Align the arrow ( ) on the brake lever( ) with the index mark ( ) on theadjuster.

Turn the adjuster ( ) while pushing thelever forward.

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

2.

3.

1. 1

243

04/07/02 14:28:46 31MCW630_151

(1)

(1) LOWER level mark

RIGHT HANDLEBAR(front brake)

143

Fluid Level Inspection

Brakes


Saf ety Precautions

Brake f luid can damage plastic andpainted surf aces. Handle with care.

Refer to on page .

If your inspection indicates a low fluidlevel, have your Honda dealer add therecommended brake fluid.

Wipe up spills immediately. Avoid contactwith skin or eyes. In case of contact, washthoroughly and call a doctor immediatelyif it contacts your eyes.

Do not add or replace brake fluid, exceptin an emergency. If you do add fluid, haveyour Honda dealer check the system assoon as possible.

74

04/07/02 14:28:54 31MCW630_152

(1) UPPER level mark(2) LOWER level mark

(1)

(2)

UNDER SEAT(rear brake)

144

Brakes


Check the fluid level. It should bebetween the UPPER ( ) and LOWER( ) level marks. If the level is at orbelow the LOWER level mark, checkthe brake pads for wear (page ).

Worn pads should be replaced. If thepads are not worn beyond therecommended limit, have your brakesystem inspected for leaks.

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

Other Inspections

Remove the seat (page ).

Place your motorcycle on its centerstand on a firm, level surface.

1.

2.

13.

90

2

145

04/07/02 14:29:04 31MCW630_153

(1) cutouts

LEFT FRONT (right side similar)

(1)

(1)

REAR

145

Brake Pad Wear

Brakes



Brake pad wear depends upon the severityof usage, the type of riding, and roadconditions. Generally, the pads will wearfaster on wet and dirty roads. Inspect thepads at each regular maintenance interval(page ).

Check the cutouts ( ) in each pad. Ifeither pad is worn to the cutout, replaceboth pads as a set. See your Honda dealerfor this service.

Always inspect both pads in both the rightand left front brake calipers.

1

74

82

04/07/02 14:29:14 31MCW630_154

(1)

(1) left caliper assembly

LEFT FRONT

LEFT REAR

146

Brake System Inspection

Brakes



Place the motorcycle on its center stand,stop the engine, and place thetransmission in neutral.Move the left caliper assembly ( )upward while slowly rotating the rearwheel. The brake system is normal ifthe rear wheel stops. If the rear wheeldoes not stop, see your Honda dealer.

1.

2. 1

74

04/07/02 14:29:22 31MCW630_155

Using tires that are excessivelyworn or improperly inflated cancause a crash in which you can beseriously hurt or killed.

Follow all instructions in thisowner’s manual regarding tireinflation and maintenance.

147

Air Pressure

Tires


Saf ety Precautions

To safely operate your motorcycle, yourtires must be the proper type and size, ingood condition with adequate tread, andcorrectly inflated for the load you arecarrying.

The following pages give detailedinformation on how and when to check

your air pressure, how to inspect your tiresfor wear and damage, and ourrecommendations for tire repair andreplacement.

Properly inflated tires provide the bestcombination of handling, tread life, andriding comfort. Generally, underinflatedtires wear unevenly, adversely affecthandling, and are more likely to fail frombeing overheated. Overinflated tires makeyour motorcycle ride more harshly, aremore prone to damage from road hazards,and wear unevenly.

Refer to on page .74

04/07/02 14:29:30 31MCW630_156

42 psi (290 kPa ,2.90 kgf/cm )

36 psi (250 kPa ,2.50 kgf/cm )

rear

front

148

Tires


Tubeless tires have some degree of self-sealing ability if they are punctured.However, because leakage is often veryslow, you should look closely forpunctures whenever a tire is not fullyinflated.

Always check air pressure when your tiresare ‘‘cold’’ –– after the motorcycle hasbeen parked for at least three hours. If youcheck air pressure when your tires are

‘‘warm’’ –– even if your motorcycle hasonly been ridden for a few miles –– thereadings will be higher. If you let air outof warm tires to match the recommendedcold pressures, the tires will beunderinflated.

The recommended ‘‘cold’’ tire pressuresare:

We recommend that you visually checkyour tires before every ride and use an airpressure gauge to measure the air pressureat least once a month or any time youthink the tires might be low. Even tiresthat are in good condition may lose one totwo psi per month if not checked andadjusted regularly.

04/07/02 14:29:38 31MCW630_157

(1)

(2)

(1) wear indicator(2) wear indicator location mark

149

Inspection

Tires



Whenever you check the tire pressures,you should also look for:

Bumps or bulges in the side of the tireor the tread. Replace any tire that has abump or bulge.Cuts, slits, or cracks in the tires.Replace the tire if you can see fabric orcord.Nails or other foreign objects embeddedin the side of the tire or tread.Excessive tread wear.

Also, if you hit a pothole or hard objectwhile riding, pull to the side of the road assoon as you safely can and carefullyinspect the tires for damage.

Tread Wear

74

04/07/02 14:29:49 31MCW630_158

0.06 in (1.5 mm)0.08 in (2.0 mm)

frontrear

150

Tire Repair

Tires


Saf ety Precautions

If You Have a Flat Tire,

For the best performance, you shouldreplace a tire before the tread depth at thecenter reaches the following limits:

We strongly recommend that you replace,not repair, any tire that is punctured ordamaged. As discussed below, a tire that isrepaired, either temporarily orpermanently, will have lower speed andperformance limits than a new orundamaged tire.

If the wear indicators are visible, replacethe tire immediately as it is no longer safe.

Refer to on page .

A temporary repair can sometimes bemade in an emergency situation.However, since a temporary repair maynot hold, you must ride very slowly,preferably without any cargo or passenger,and have the tire replaced or permanentlyrepaired as soon as possible.(For more information on temporaryrepairs, see page

.)

74

188

04/07/02 14:29:58 31MCW630_159

151

Tire Replacement

Tires


Saf ety Precautions

A permanent repair, such as an internalplug patch, can be made if a tire has only asmall puncture in the tread area. With sucha repair, you should not exceed 50 mph(80 km/h) for the first 24 hours, or 80 mph(130 km/h) at any time thereafter. Inaddition, you may not be able to safelycarry as much weight. If you choose tohave a tire repaired, be sure the repairwork is performed by a professional andthat the wheel is balanced before you ride.

The tires that came on your motorcyclewere designed to match the performancecapabilities of your motorcycle andprovide the best combination of handling,braking, durability, and comfort.

Refer to on page .

If you have a tire professionally repairedat a non-Honda facility, we recommendthat you have the work checked by yourHonda dealer.

74

04/07/02 14:30:05 31MCW630_160

－

120/70ZR17M/C (58W)BRIDGESTONE

BT020F BB

METZELERMEZ4A FRONT

DUNLOP D204FK

180/55ZR17M/C (73W)BRIDGESTONE

BT020R BBDUNLOP D204KMETZELER MEZ4A

radial ply, tubeless

front

rear

type

Installing improper tires on yourmotorcycle can affect handlingand stability. This can cause acrash in which you can beseriously hurt or killed.

Always use the size and type oftires recommended in this owner’smanual.

152

Tires


The recommended tires for yourmotorcycle are:

You should replace the tires with tires ofthe same size, load range, and speed ratingas the originals.

Have the tire replaced by your Hondadealer if possible.

Have the wheel balanced after the tire isinstalled.

Whenever you replace a tire, remember:

04/07/02 14:30:17 31MCW630_161

153

Tires


If you have a tire professionally replacedat a non-Honda facility, we recommendthat you have the work checked by yourHonda dealer.

Important Safety RemindersDo not install a tube inside a tubelesstire on this motorcycle. Excessive heatbuild-up can cause the tube to burst.Use only tubeless tires on thismotorcycle. The rims are designed fortubeless tires, and during hardacceleration or braking, a tube-type tirecould slip on the rim and cause the tireto rapidly deflate.Do not install a bias-ply tire on thismotorcycle. Mixing bias-ply and radialtires can adversely affect handling andstability.

04/07/02 14:30:24 31MCW630_162

LEFT SIDE

(1) side stand spring

(1)

154

Side Stand


Saf ety PrecautionsRefer to on page . Check the spring for damage or loss oftension.Check the side stand ignition cut-offsystem:

Sit astride the motorcycle and put thetransmission in neutral.Raise the side stand.Start the engine.Pull the clutch lever in.Shift the transmission into gear.Lower the side stand all the way.

Check that the side stand assembly isworking properly. If the side stand isstiff or squeaky, clean the pivot areaand lubricate the pivot bolt with cleangrease.

The engine should stop as you lower theside stand. If the engine doesn’t stop,see your Honda dealer for service.

1.

2.3.4.5.6.

74

04/07/02 14:30:36 31MCW630_163

155

Drive Chain


An endless (riveted master link) chainconnects the countershaft and rear wheelsprockets. The O-ring chain uses rubberrings between the side plates of the pinand roller links to seal in themanufacturer-installed lubricating greaseand keep out moisture and dirt.

Under severe usage, or when themotorcycle is ridden in unusually dusty ormuddy areas, more frequent maintenancewill be necessary.

The service life of the chain depends onproper lubrication and adjustment. Poormaintenance can cause premature wear ordamage to the drive chain or sprockets.

The drive chain should be checked,adjusted, and lubricated as part of the pre-ride inspection (page ).

Before servicing your drive chain, turn theengine OFF, lower the center stand (page

), and check that your transmission isin neutral.

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

45

64

04/07/02 14:30:44 31MCW630_164

－－1 1 3/8 in (25 35 mm)

LEFT SIDE

(1) drive chain

(1)

156

Inspection

Drive Chain



Check slack in the lower drive chain( ) run midway between the sprockets.Drive chain slack should allow thefollowing vertical movement by hand:

Check drive chain slack at severalpoints along the chain. The slack shouldremain constant. If it isn’t, some linksmay be kinked and binding. Lubricatingthe chain will often eliminate bindingand kinking.Inspect the drive chain for:

damaged rollersdry or rusted linkskinked or binding linksexcessive wearimproper adjustmentdamaged or missing O-rings

1.

2.

3.1

74

04/07/02 14:30:54 31MCW630_165

wornsprocketteeth

REPLACE

damagedsprocketteeth

REPLACE

normal sprocket teethGOOD

157

Drive Chain


Use of a new chain with worn sprocketswill cause rapid chain wear.

Replace the drive chain (page ) if ithas damaged rollers, loose pins, orkinks that cannot be freed. Lubricate thedrive chain (page ) if it appears dryor shows signs of rust. Lubricate anykinked or binding links and work themfree. Adjust chain slack if needed.Inspect the front and rear sprocket teethfor excessive wear or damage. Ifnecessary, have your Honda dealerreplace a worn sprocket.

4.

161

160

04/07/02 14:31:02 31MCW630_166

－－

1 15/16 in (50 mm)

1 1 3/8 in (25 35 mm)

LEFT SIDE

(3) tip of driven sprocket teeth(2) red zone

(2)

(3)

158

Adjustment

Drive Chain


Saf ety Precautions

Wear Inspection The bottom part of the frame may bedamaged by excessive drive chain slack ofmore than:

Drive chain slack should be checked andadjusted, if necessary, every 500 miles(800 km). When operated at sustainedhigh speeds or under conditions offrequent rapid acceleration, the chain mayrequire more frequent adjustments.

Refer to on page .

Check the chain wear label when adjustingthe chain. If the red zone ( ) on the labelaligns with the tip of driven sprocket teeth( ) after the chain has been adjusted tothe proper slack, the chain is excessivelyworn and must be replaced. The properslack is:

2

3

74

04/07/02 14:31:11 31MCW630_167

－－

54 lbf·ft (74 N·m , 7.5 kgf·m)

1 1 3/8 in (25 35 mm)

(1)

(3)

(2)

LEFT SIDE

(1) bearing holder pinch bolt(2) bearing holder(3) pin spanner

159

Drive Chain


Place the motorcycle on its center standwith the transmission in neutral and theignition switch OFF.Loosen the bearing holder pinch bolt( ).Turn the bearing holder ( ) clockwiseor counterclockwise to obtain the properchain slack with the pin spanner ( ).Torque the bearing holder pinch bolt to:

If a torque wrench is not used for thisinstallation, see your Honda dealer as soonas possible to verify proper assembly.Improper assembly may lead to a loss ofbraking capacity.

Recheck chain slack.Chain slack should be:

1.

2.

3.

4.

5.

12

3

04/07/02 14:31:21 31MCW630_168

SAE 80 or 90 gear oil

160

Lubrication

Drive Chain



Lubricate every 500 miles (800 km) orsooner if chain appears dry. Lubricant:

Lubricate only with SAE 80 or 90 gear oil.Commercial chain lubricants may containsolvents which could damage the rubberO-rings.

74

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－

DID50VA8 RK50HFOZ5

161

Removal, Cleaning &Replacement

Drive Chain


Saf ety Precautions

Clean the side surfaces of the chainwith a dry cloth. Use a high flashpointsolvent such as kerosene notgasoline.Do not brush the rubber O-rings.Brushing will damage them. Use of asolvent may also damage the O-rings.Inspect the drive chain for possiblewear or damage.

Refer to on page .

Your motorcycle has an endless (rivetedmaster link) type chain. It should only beremoved or replaced by your Honda dealer.

The O-rings can be damaged by steamcleaning, high pressure washers, andcertain solvents.

Replacement Chain:

Replace the drive chain if it has damagedrollers, loose fitting links, damagedO-rings, or otherwise appearsunserviceable.

1.

2.

or

74

04/07/02 14:31:37 31MCW630_170

162

WARNING:

Wash hands afterhandling.

Battery


Your battery is a maintenance-f ree typeand can be permanently damaged if thecap strip is removed.

Battery Charging,

Battery Storage,

Your motorcycle has a maintenance-freetype battery. You do not have to check thebattery electrolyte level or add distilledwater as you would with a conventional-type battery.

If you do not expect to ride yourmotorcycle for at least two weeks, werecommend you remove the battery –– orat least disconnect the battery cables(negative cable first).

Electrical accessories use current from thebattery –– even when the ignition is OFF.Limited operation also allows the batteryto discharge. If you have electricalaccessories on your motorcycle –– or donot ride frequently, we recommend thatyou charge the battery frequently (see

page ).

If you plan to store your motorcycle, seepage .

If your battery seems weak and/or isleaking electrolyte (causing slow startingor other electrical problems), see yourHonda dealer.

Battery posts, terminalsand related accessories contain lead andlead compounds.

165

163

04/07/02 14:31:44 31MCW630_171

The battery gives off explosivehydrogen gas during normaloperation.

A spark or flame can cause thebattery to explode with enoughforce to kill or seriously hurt you.

Wear protective clothing and aface shield, or have a skilledmechanic do the batterymaintenance.

163

Battery Storage

Battery


Saf ety Precautions

BatteryCharging,

Refer to on page .

If you plan to store your motorcycle, werecommend you remove the battery andstore it where it can be charged at leastevery 30 days to maintain its service life.

If you do not remove the battery, werecommend disconnecting the batterycables (negative cable first).

You will get the best storage results fromremoving the battery and slow (trickle)charging it every 30 days (see

page ).

Before you remove the battery, be sure toread all the information that follows, aswell as the information on the batterylabel.74

165

04/07/02 14:31:53 31MCW630_172

－

＋

－＋

UNDER SEAT

(5)

(4) negative ( ) terminal lead(5) positive ( ) terminal lead(6) battery

(1)

(2)

(3) (4)(6)

(1) battery cover clips(2) battery cover(3) rubber band

164

Battery


The battery is located in the battery boxbelow the seat.

Remove the seat (page ).Remove the battery cover clips ( ),then remove the battery cover ( ).Release the rings and remove the rubberband ( ).Disconnect the negative ( ) terminallead ( ) from the battery first, thendisconnect the positive ( ) terminallead ( ).Pull the battery ( ) out of the batterybox.

1.2.

3.

4.

5.

190

2

3

4

65

04/07/02 14:32:02 31MCW630_173

(1) ‘‘trickle’’ charger

(1)

165

Battery Charging

Battery


Saf ety Precautions

Charge the battery (see followingsection), unless you have been ridingregularly.Store your battery in an easy-to-reachlocation off the floor, in an areaprotected from freezing temperaturesand direct sunlight.Clean the battery box after removingthe battery for storage. Dry the batterybox and, if paint is missing, re-paint thearea.Slow charge the battery (see followingsection) once every 30 days.

Refer to on page .

Be sure to read the information that camewith your battery charger and follow theinstructions on the battery. Impropercharging may damage the battery.

6.

7.

8.

9.

74

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166

Battery


We recommend using a ‘‘trickle’’ charger( ) for home charging. These units can beleft connected for long periods withoutrisking damage to the battery. However,do not intentionally leave the chargerconnected longer than the time periodrecommended in the charger’s instructions.

Avoid using an automotive-type batterycharger. An automotive charger canoverheat a motorcycle battery and causepermanent damage.

1

04/07/02 14:32:16 31MCW630_175

－－－

－

167

General Recommendations

Appearance Care


Saf ety Precautions

Frequent cleaning and polishing will keepyour Honda looking newer longer.Frequent cleaning also identifies you as anowner who values your motorcycle. Aclean motorcycle is also easier to inspectand service.

Refer to on page .

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

Avoid products that contain harshdetergents or chemical solvents thatcould damage the metal, paint, andplastic on your motorcycle.If your motorcycle is still warm fromrecent operation, give the engine andexhaust system time to cool off.Park in a shady area. Washing yourmotorcycle in bright sunlight may causethe finish to fade because water dropletsintensify the sun’s brightness. Spottingis also more likely because surfacewater can dry before you have time towipe it off.Clean your motorcycle regularly toprotect surface finishes.

(cont’d)

74

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168

Appearance Care


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

We recommend the use of a gardenhose to wash your motorcycle. Highpressure washers (like those at coin-operated car washes) can damagecertain parts of your motorcycle.

After cleaning, inspect for damage,wear, and leaks (fuel, oil, coolant, brake,and clutch fluid).

04/07/02 14:32:33 31MCW630_177

169

Washing Your Motorcycle with aMild Detergent

Appearance Care



Rinse your motorcycle thoroughly withcool water to remove loose dirt.Fill a bucket with cool water. Mix in amild, neutral detergent, such as dishwashing liquid or a product madeespecially for washing motorcycles orautomobiles.Wash your motorcycle with a sponge ora soft towel. As you wash, check forheavy grime. If necessary, use a mildcleaner/degreaser to remove the grime.Clean the windscreen with a soft clothor sponge and plenty of water. Dry witha soft clean cloth. Remove minor

scratches with a commercially-availableplastic polishing compound.Take care to keep brake fluid orchemical solvents off the fairing. Theywill damage the plastic.Clean the headlight, fairing, meter lensand other plastic parts using a cloth orsponge dampened with a solution ofmild detergent and water. Whencleaning the plastic headlight lens, usemore care because it will scratch easierthan a glass lens. Rub any soiled area,gently rinsing it frequently with freshwater.

If the inside of the headlight lensappears clouded immediately afterwashing, it should clear after a fewminutes of riding.

(cont’d)

1.

2.

3.

4.

5.74

04/07/02 14:32:43 31MCW630_178

170

Spray Cleaning Your Motorcycle

Appearance Care



Avoid using spray cleaner products on thetires or suspension components.

Suggestions for using spray cleaner(s)follow:

After washing, rinse your motorcyclethoroughly with plenty of clean water toremove any residue. Detergent residuecan corrode alloy parts.Dry your motorcycle with a chamois ora soft towel. Leaving water on thesurface to air dry can cause dulling andwater spots. As you dry, inspect forchips and scratches.

As a precaution, ride your motorcycle ata slow speed and apply the brakesseveral times. This will help dry thebrakes and restore normal brakingperformance.

Start the engine and let it idle forseveral minutes. The engine heat willhelp dry moist areas.

Lubricate the drive chain to preventrusting.

7.

8.

9.

6.

10.

74

04/07/02 14:32:52 31MCW630_179

Apply a spray cleaner/polish and wipe thepaint, chrome, glass, and clear plastic.

Dust and fingerprint smudges.

Light road grime. Spray any difficult-to-reach or very dirtyareas with a spray cleaner/degreaser.Rinse and dry.Apply a spray cleaner/polish and wipe witha non-abrasive cloth.

Apply a high quality chrome/aluminumpolish and wipe with a non-abrasive cloth.

Use a spray cleaner/degreaser.If necessary, rub with a sponge. Rinse anddry.Apply a spray cleaner/polish and wipe witha non-abrasive cloth.

Heavy grime. Oil leaks. Brakedust.

Dull, corroded chrome oraluminum.

Motorcycle Condition Recommended Cleaning

171

Appearance Care


04/07/02 14:33:03 31MCW630_180

172

Painted Aluminum WheelMaintenance

Appearance Care



Aluminum may corrode from contact withdirt, mud, or road salt. Clean the wheelsafter riding through any of thesesubstances. Use a wet sponge and milddetergent. Avoid stiff brushes, steel wool,or cleaners containing abrasives orchemical compounds.

After washing, rinse with plenty of waterand dry with a clean cloth.

If the paint is chipped, apply touch-uppaint.

74

04/07/02 14:33:09 31MCW630_181

173

Finishing Touches

Appearance Care



After washing your motorcycle, considerusing a commercially-available spraycleaner/polish or quality liquid or pastewax to finish the job. Use only a non-abrasive polish or wax made specificallyfor motorcycles or automobiles. Apply thepolish or wax according to the instructionson the container.

If a surface on your motorcycle is chippedor scratched, your Honda dealer has touch-up paint to match your motorcycle’s color.Be sure to use your motorcycle’s colorcode (page ) when you buy touch-uppaint.

If the frame has a chip that exposes themetal, first apply primer (to preventcorrosion) and then apply the touch-uppaint. Several thin layers of touch-up paintare better than one thick coat.

74

214

04/07/02 14:33:15 31MCW630_182


04/07/02 14:33:17 31MCW630_183

175

Tips

Tips

Here’s a few helpful tips on how to storeand transport your Honda, and how to bean environmentally responsiblemotorcycle owner.

............................Storing Your Honda . 176...........Transporting Your Motorcycle . 179

......................You & the Environment . 180

04/07/02 14:33:22 31MCW630_184

176

Preparation for Storage

Storing Your Honda

Tips

Saf ety Precautions

Honda Motorcycle Winter StorageGuide,

If you won’t be riding for an extendedperiod, such as during the winter,thoroughly inspect your motorcycle andcorrect any problem before storing it. Thatway, needed repairs won’t be forgottenand it will be easier to get your motorcyclerunning again.

Refer to on page .

We suggest you perform the followingprocedures to keep your motorcycle in topcondition. These storage procedures willreduce the deterioration that can occurduring storage.

For more information about storage, referto the

available from your Honda dealer(USA only).

Change the engine oil and filter (page).

Make sure the cooling system is filledwith a 50/50% antifreeze solution (page

).Fill the fuel tank. Make sure the fuel fillcap is properly installed.

1.

2.

3.

74

109

114

04/07/02 14:33:31 31MCW630_185

－

177

Storing Your Honda

Tips

To prevent rusting in the cylinders,perform the following:

Remove the battery and charge it fully.Store it in an area protected fromfreezing temperatures and directsunlight. Slow charge the battery (page

) once a month.Wash and dry your motorcycle. Wax allpainted surfaces. Apply rust-inhibitingoil to the chrome pieces.

Remove the ignition coil connectorsand ignition coils from the sparkplugs. Using tape or string, secure theconnectors to any convenient plasticbody part so that they are positionedaway from the spark plugs.Remove the spark plugs from theengine and store them in a safe place.Do not connect the ignition coils tothe ignition coil connectors.Pour a tablespoon (15 20 cc) ofclean engine oil into each cylinderand cover the spark plug holes with apiece of cloth.With the engine stop switch in theRUN position, press the start buttonseveral times to crank the engine anddistribute the oil.

Reinstall the spark plugs, ignitioncoils and ignition coil connectors.

(cont’d)

5.

6.

4.

165

04/07/02 14:33:41 31MCW630_186

178

Removal from Storage

Storing Your Honda

Tips

Saf ety Precautions

Inflate the tires to their recommendedpressures (page ).Store your motorcycle in an unheatedarea, free of dampness, away fromsunlight, with a minimum of dailytemperature variation.

Refer to on page .

Uncover and clean your motorcycle.If your motorcycle has been stored formore than four months –– change theengine oil (page ).If your motorcycle has been stored formore than two months –– ask yourHonda dealer to drain and replace thefuel.Charge the battery (page ) asrequired. Install the battery.

Perform a pre-ride inspection (page ),then test-ride your motorcycle at lowspeeds.

Lubricate the drive chain (page ).

Lubricate the drive chain (page ).

Place your motorcycle on its centerstand. Place a block under the exhaustpipes exposed under the lower fairing toraise the front tire off the floor.Cover your motorcycle with a porousmaterial. Avoid using plastic or similarnon-breathing, coated materials thatrestrict air flow and allow heat andmoisture to accumulate.

1.2.

3.

4.

5.6.

7.8.

9.

10.

11.

74

45

160

148

109

160

165

04/07/02 14:33:56 31MCW630_187

179

Transporting Your Motorcycle

Tips

If your motorcycle needs to be transported,it should be carried on a motorcycle trailer,or a truck or trailer with a flatbed area. Forinformation about 24-hour emergencyassistance, see page (USA only). Donot tow your motorcycle, as towing canseriously damage the transmission.

When contacting a towing or transportingservice, be sure to ask if they have aflatbed area, a loading ramp or powerramp to safely lift the motorcycle, andmotorcycle tie-down straps.

241

04/07/02 14:34:01 31MCW630_188

180

Choose Sensible Cleaners.

Recycle Wastes.

You & the Environment

Tips

Owning and riding a motorcycle can beenjoyable, but you must do your part toprotect nature.

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

Use abiodegradable detergent when you washyour motorcycle. Avoid aerosol spraycleaners that containchlorofluorocarbons (CFCs) whichdamage the atmosphere’s protectiveozone layer. Don’t throw cleaningsolvents away; see the followingguidelines for proper disposal.

It’s illegal andthoughtless to put used engine oil in thetrash, down a drain, or on the ground.Used oil, gasoline, coolant, andcleaning solvents contain poisons thatcan hurt refuse workers andcontaminate our drinking water, lakes,rivers, and oceans. Before changingyour oil, make sure you have the propercontainers. Put oil and other toxicwastes in separate sealed containers andtake them to a recycling center. Callyour local or state office of publicworks or environmental services to finda recycling center in your area, and toget instructions on how to dispose ofnon-recyclable wastes.

04/07/02 14:34:07 31MCW630_189

181

Taking Care of the Unexpected


This section discusses the more commonproblems that can occur with yourmotorcycle while you’re riding. It tellsyou how to evaluate each problem andwhat actions you can take to try to resumeriding. If the problem cannot be safelysolved, this section also gives instructionson the proper way to have yourmotorcycle transported.

For information about transporting yourmotorcycle, see page .

..............................General Guidelines . 182If Your Engine Quits or

..........................................Won’t Start . 183.......................If You Have a Flat Tire . 188

...................If Your Engine Overheats . 199If the Low Oil Pressure Indicator

...................................................Lights . 201....................................If a Fuse Blows . 202

........................................If You Crash . 207........................If You Lose Your Key . 208

.......If Your Battery is Low (or Dead) . 209179

04/07/02 14:34:12 31MCW630_190

182

General Guidelines



Remember to take along your owner’smanual, the tool kit that came with yourmotorcycle, and any other items (such astire repair supplies and additional tools)that might help you solve a problem onyour own.

Should you ever have a problem whileriding, please follow these guidelines:

Always put personal safety first.Take time to assess the situation andyour options before deciding what to do.If the problem is relatively minor andyou have the tools, supplies, and skillsto make a temporary repair, be sure tohave permanent repairs made as soon aspossible.Do not continue riding if you are hurt oryour motorcycle is not in safe ridingcondition.

Additional recommendations for specificproblems follow.

Keeping your motorcycle well-maintainedis the best way to reduce the possibility ofhaving a problem on the road. However,since problems can arise even with well-maintained machines, you may considersubscribing to an emergency roadsideservice plan. (USA only: For informationabout the Honda Rider’s Club of America,see page .)241

04/07/02 14:34:22 31MCW630_191

－－

183

If Your Engine Quits or Won’t Start


Starter motor doesn’t operate

Starter motor works,but the engine won’t start

Proper operation and maintenance canprevent starting and engine performanceproblems. In many cases, the cause of theproblem may be a simple operationaloversight.

If your motorcycle won’t start, listen asyou press the start button. If you don’thear the starter motor turning, refer to the

symptom. Ifyou can hear the starter motor workingnormally, refer to the

symptom.If you have a problem starting theengine or experience poor engineperformance the following informationmay help you. If you can’t correct theproblem, see your Honda dealer.

04/07/02 14:34:28 31MCW630_192

SYMPTOM:

ignition switch OFFengine stop switch OFFtransmission not in neutral

blown fuse

battery lead loose

side stand down (whentransmission not in neutral)

dead battery

faulty starter motor

Turn the ignition switch ON.Turn the engine stop switch to RUN.Shift into neutral.Put the transmission in neutral or raise the sidestand and pull the clutch lever in.

Replace with a new fuse of the same rating (page).

Tighten the battery lead.Charge the battery (page ). If charging doesn’thelp, see your Honda dealer.If all possible causes are negative, the startermotor may be faulty. See your Honda dealer.

POSSIBLE CAUSE WHAT TO DO

202

165

Starter motor doesn’t operate.

184



04/07/02 14:34:44 31MCW630_193

SYMPTOM:

out of fuelflooded engine

Fill the fuel tank.See (page ).


loose or unconnectedignition coil connectors andignition coils

weak batteryloose battery cables

Install the ignition coil connectors and ignition coilssecurely. If the engine still won’t start, see yourHonda dealer.

Charge the battery (page ). If charging doesn’thelp, see your Honda dealer.

Tighten the battery terminal bolts.

55

165

Starter motor works, but the engine won’t start.

Flooded Engine

185



04/07/02 14:34:57 31MCW630_194

SYMPTOM:

Raise the side stand. Start again.

SYMPTOM:

idles roughly, too fast, stalls

low oil pressure

overheating

Check the low oil pressure indicator. Refer topage

.

side stand down

See your Honda dealer.blubbers (rich fuel mixture)runs erratically, misfires See your Honda dealer.

Check engine idle adjustment (page ). If theproblem persists, see your Honda dealer.



Check the coolant temperature meter. Refer topage .

125

199

201

Engine starts, but stalls as you shift into gear.

Engine starts, but runs poorly.

Ifthe Low Oil Pressure Indicator Lights,

IfY our Engine Overheats,

186



04/07/02 14:35:14 31MCW630_195

SYMPTOM:

sooty exhaust (rich fuelmixture)

pre-ignition (runs on afterignition switched OFF)

detonates or pings underload

afterfires (backfires)

See your Honda dealer.

If applicable, switch to the recommended octanegasoline (page ) or change your brand ofgasoline. If the problem persists, see your Hondadealer.See your Honda dealer.See your Honda dealer.


100

Engine starts, but runs poorly. (cont’d)

187



04/07/02 14:35:26 31MCW630_196

188

If You Have a Flat Tire


A flat tire is always unwelcome,especially if you are far from help. If youthink you are losing air, or you hit apothole or hard object, pull safely to theside of the road so you can inspect thetires and assess the situation. (Be sure topark on a firm, level surface and use theside stand for support.) You shouldexamine the tire treads and sidewalls forforeign objects or damage. If you find atire that has been punctured or damaged,you have two options.

Option 1:Have Your Motorcycle TransportedIf a tire has a major puncture or a cut inthe tread or sidewall, or the bead has comeloose from the rim, there is probably notmuch you can do except have yourmotorcycle transported to a Honda dealer

or other qualified service facility. (USAonly: For information about 24-houremergency roadside assistance, see page

.) Even with a simple puncture, thismay be the safest and least troublesomesolution. For transporting instructions, seepage .

Option 2:Make a Temporary Roadside RepairIf a tire has only a minor nail puncture andis not completely flat, you may be able tomake an emergency repair that couldallow you to continue riding to where youcan get the tire replaced or permanentlyrepaired.

241

179

04/07/02 14:35:33 31MCW630_197

Riding your motorcycle with atemporary tire repair can be risky.If the temporary repair fails, youcan crash and be seriously injuredor killed.

If you must ride with a temporarytire repair, ride slowly andcarefully and do not exceed 30mph (50 km/h) until the tire ispermanently repaired or replaced.

189

Types of Temporary Repairs



Due to the uncertainty of any temporaryrepair, you should ride slowly (not over30 mph, 50 km/h) and carefully(preferably without a passenger or cargo)until the tire is replaced or permanently

repaired. Stop frequently and check the airpressure. If the tire is losing pressure, itmay be unsafe to continue riding. As thetire gets low, it will affect the handling ofyour motorcycle (especially with apassenger and cargo) and it may overheatand blow out.

The following types of temporary repairsgenerally require a source of air to inflatethe tire. Possible sources include COcartridges or cans of compressed airdesigned to inflate a tire.

2

04/07/02 14:35:39 31MCW630_198

190

Should You Repair or Replace aTire?



Inflate the tire:

Plug the hole:

Tubeless tires havesome self-sealing ability if they arepunctured and the result is usually just aslow leak. If this is the case, you can tryinflating the tire to see if it will hold airpressure. If you can see a nail or otherobject embedded in the tire tread, do notremove it at this time.

The idea here is to dosomething to temporarily stop the leak.If you have a tubeless tire repair kit,you can pull out the nail and tryinserting an external plug in thepuncture. Follow the instructions thatcame with the repair kit and be sure toinflate the tire to the correct pressure.

We strongly recommend that you replace,not permanently repair, any tire that ispunctured or damaged, even if the tire hasonly a minor puncture. For a fulldiscussion of repairs and replacement, seepage .150

04/07/02 14:35:45 31MCW630_199

(1)

LEFT SIDE

(1) protective tape

191

Emergency Front WheelRemoval/Installation




(cont’d)

We recommend wheel removal be doneonly by your Honda dealer or anotherqualified mechanic. Do not attempt toremove the wheel on your own. Wheelremoval requires mechanical skill andprofessional tools.

RemovalPark your motorcycle on its center standon a firm, level surface.Cover both sides of the front wheelwith protective tape ( ) or anequivalent.

Raise the front wheel off the ground bylowering the center stand (page ) andplacing a support block under theexhaust pipes exposed under the lowerfairing.

1.

2.1

3.64

74

04/07/02 14:35:56 31MCW630_200

LEFT SIDE

(3)

(2)

(4)

RIGHT SIDE(5)

(6)

(5) fixing bolts(6) right caliper assembly

(2) A socket bolt(3) B socket bolt(4) left caliper assembly

192



Remove the A ( ) and B ( ) socketbolts and remove the left caliperassembly ( ) from the fork leg.

4. 2 3

4

04/07/02 14:36:03 31MCW630_201

RIGHT FRONT

(8)(7)

(7) axle bolt(8) axle pinch bolt

193



(cont’d)

Remove the fixing bolts ( ) andremove the right caliper assembly ( ).

To avoid damage to the brake hoseduring removal, support the caliperassembly so that it doesn’t hang fromthe hose. Do not twist the brake hose.Avoid getting grease, oil, or dirt onthe disc or pad surfaces. Anycontamination can cause poor brakeperformance or rapid pad wear afterreassembly.

Remove the axle bolt ( ), and thenloosen the right and left axle pinch bolts( ).

6.5. 56

7

8

04/07/02 14:36:11 31MCW630_202

43 lbf·ft (59 N·m , 6.0 kgf·m)

LEFT FRONT

(9)

(7) axle pinch bolt

(7)

(9) front axle shaft

194



InstallationReassemble the removed parts in thereverse order of removal.

Remove the front axle shaft ( ), wheeland side collar.

Avoid depressing the brake leverwhen the wheel is off the motorcycle.This will force the caliper pistons outof the cylinders. The result will beloss of brake fluid. If this occurs, thebrake system will require service. Seeyour Honda dealer for this service.

Install the side collars and positionthe wheel between the fork legs.Insert the front axle shaft from theleft side, through the left fork leg andwheel hub.To avoid damaging the brake pads,carefully fit both brake discs betweenthe pads.

Tighten the axle bolt to the specifiedtorque:

Temporarily tighten the axle pinch boltson the left fork leg until lightly seated.

1.7.

2.

3.

9

04/07/02 14:36:22 31MCW630_203

16 lbf·ft (22 N·m , 2.2 kgf·m)

23 lbf·ft (31 N·m , 3.2 kgf·m)

23 lbf·ft (31 N·m , 3.2 kgf·m) LEFT FRONT

(13) feeler gauge

(10) clearance(11) brake disc

(12) caliper holder

(10)(12)

(11)

(13)

195



Measure the clearance ( ) between thebrake disc ( ) and the caliper holder( ) on each side with a 0.028 in(0.7 mm) feeler gauge ( ).

Operate the front brake and pump thefork several times.

Install the A and B left caliper socketbolts, and tighten to the specifiedtorque:

Install the right caliper fixing bolts andtighten to the specified torque:

Tighten the axle pinch bolt on the rightfork leg to the specified torque:

Fit the brake disc carefully between thebrake pads to avoid damaging the pads.

5.

6.

7.

8.

9.

4.

1011

1213

04/07/02 14:36:32 31MCW630_204

16 lbf·ft (22 N·m , 2.2 kgf·m)

196



If the feeler gauge inserts easily,remove it and tighten the left axle pinchbolt to the specified torque:

If the feeler gauge cannot be insertedeasily, loosen the left axle pinch boltand pull the left fork outward or pushinward to adjust the clearance. Thentighten the left axle pinch bolt to thespecified torque.

Failure to provide adequate disc-to-caliperholder clearance may damage the brakediscs and impair braking efficiency.

After installing the wheel, apply thebrake lever AND brake pedal severaltimes, then recheck both discs forcaliper holder to disc clearance. Do notoperate the motorcycle withoutadequate clearance.

Check for free wheel rotation afterthe brake lever and brake pedal arereleased. Recheck the wheel if thebrake drags or if the wheel does notrotate freely.After installing the wheel, operate thebrake lever AND brake pedal severaltimes until you feel pressure. Youmust restore pressure from BOTH thelever AND the pedal because thismotorcycle is equipped with a LinkedBraking System.Verify proper brake operation beforeriding.

Remove the protective tapes from thefront wheel.

10.11.

04/07/02 14:36:43 31MCW630_205

RIGHT REAR

(2)

(1) rear wheel nuts(2) rear wheel

(1)

197

Emergency Rear WheelRemoval/Installation




If a torque wrench was not used forinstallation, see your Honda dealer as soonas possible to verify proper assembly.Improper assembly may lead to loss ofbraking capability.

Removal

We recommend wheel removal be doneonly by your Honda dealer or anotherqualified mechanic. Do not attempt toremove the wheel on your own. Wheelremoval requires mechanical skill andprofessional tools.


Remove the four rear wheel nuts ( ).

Remove the rear wheel ( ) slowly.1.

2.

3.

74

1

2

04/07/02 14:36:54 31MCW630_206

80 lbf·ft (108 N·m , 11 kgf·m)

198



Installation If a torque wrench was not used forinstallation, see your Honda dealer as soonas possible to verify proper assembly.Improper assembly may lead to loss ofbraking capability.

Position the rear wheel and install therear wheel nuts.

Avoid getting grease, oil, or dirt onthe disc or pad surfaces. Anycontamination can cause poor brakeperformance or rapid pad wear afterreassembly.

Tighten the rear wheel nuts to thespecified torque:

After installing the wheel, apply thebrake several times and then check ifthe wheel rotates freely. Recheck thewheel if the brake drags or if the wheeldoes not rotate freely.Operate the brake pedal and check thebrake operation.Inspect the brake system (page ).

2.

3.

4.

1.

5. 146

04/07/02 14:37:05 31MCW630_207

199Taking Care of the Unexpected

If Your Engine Overheats

Continuing to ride with an overheatedengine can cause serious engine damage.

A steaming engine indicates a coolantleak. Shut the engine off and wait untilthe steaming stops. Look for a leak, butdon’t touch the engine or radiatorsystem. Let everything cool off first.

Normally, the coolant temperature on yourtemperature meter will rise and then leveloff. Hot weather may cause thetemperature to rise higher than normal. Sowill temporary stress such as climbing ahill. If you’re stuck in stop-and-go traffic,the temperature may climb some, but theradiator fan is designed to preventoverheating. Be aware of these variationsas you monitor the meter.

If there’s no obvious problem, leave theengine on so the fan and coolantcirculating system can continueworking. Monitor the temperature meter.The temperature may drop to thenormal range after a brief stop with noload on the engine.

If the coolant temperature display beginsto flash, a red bar appears on the displayand the coolant temperature indicator goeson for no apparent reason, pull safely tothe side of the road. If possible, park in ashady area.

(cont’d)

04/07/02 14:37:13 31MCW630_208

200

If Your Engine Overheats


Check the radiator fan.If the fan is not working, turn theengine off. Open the fuse box (page

) and check the radiator fan fuse.If the fuse is blown, replace it with theproper (same rating) spare fuse. Startthe engine. If the coolant temperatureindicator goes on, the coolanttemperature display begins to flash, anda red bar appears and stays on thedisplay, turn the engine off.If the radiator fan is working, visuallycheck the coolant level in the reservetank, located behind the left lowerfairing (page ). It isn’t necessary totouch the radiator system.If the reserve tank is low or empty, don’tride without adding coolant (page ).After adding coolant, turn the engine onand check the temperature meter.

If the temperature doesn’t drop, do notride. The engine needs repair. Transportyour motorcycle to a Honda dealer(page ).If the temperature drops to normal,check the coolant level. If it has gonedown, add more coolant.

If you are able to resume riding, continueto monitor the meter frequently.

If there’s a mild leak, you can ride forawhile, carefully watching the meter. Beprepared to stop and add more coolant orwater. If the leak is bad, transport yourmotorcycle to a Honda dealer (page ).

202

115

115

179

179

04/07/02 14:37:20 31MCW630_209

201Taking Care of the Unexpected

If the Low Oil Pressure Indicator Lights

Continuing to ride with low oil pressurecan cause serious engine damage.

If you check your engine oil levelregularly, you should never see the low oilpressure indicator while riding. Normally,it will only light momentarily when youturn the ignition switch ON. Occasionally,it may flicker at or near idling speed.

Low oil pressure may be caused by an oilleak, a low oil level, or some problem inthe engine’s lubrication system.

If the indicator comes on while you’reriding, don’t ignore it. Pull safely to theside of the road. If possible, pull the clutchlever in and coast to a stop. Stop theengine as soon as it’s safe to do so.

Check for an oil leak.Then check the oil level. If necessary,add the recommended oil (page ) tothe upper level mark. If you must leaveyour motorcycle to get oil, secure it asmuch as possible.After adding oil, start the engine, andcheck that the low oil pressure indicatorgoes off. Check for a possible leak.

If the indicator goes off and there is noleak –– resume riding. If there is aleak –– do not ride the motorcycle untilthe leak is repaired by a Honda dealer.

105

04/07/02 14:37:29 31MCW630_210

10A, 20A30A

30A30A

(INTERCEPTOR ABS ONLY)

other fusesmain fuse Bmain fuse A

202

If a Fuse Blows


All of the electrical circuits on yourmotorcycle have fuses to protect themfrom damage caused by excess currentflow (short circuit or overload).

If something electrical on your motorcyclestops working, the first thing you shouldcheck for is a blown fuse.Determine from the chart on the circuitfuse box cover which fuse or fuses controlthat component. Check those fuses first,but check all the fuses before lookingelsewhere for another possible cause ofthe problem. Replace any blown fuses andcheck component operation.

Main fuse A (and spare) are located onthe starter motor magnetic switch ( )under the seat.Main fuse B is located under the seat.

The circuit fuse box (including sparefuse) is located under the right innerpanel.

The circuit fuse boxes (including sparefuses) are located under the left andright inner panels.

Recommended Fuses

(INTERCEPTOR)

(INTERCEPTOR ABS)

3

04/07/02 14:37:41 31MCW630_211

UNDER SEAT(1) (6)

(3) (2)

(5)

(7)

(4)

(4) blown fuse

(1) main fuse A(2) wire connector(3) starter magnetic switch(5) spare main fuse A(6) main fuse B(7) main fuse B cover

MAIN FUSE A, B

203

If a Fuse Blows


Main Fuse Access:

(cont’d)

To access the main fuse A ( ),disconnect the wire connector ( ) ofthe starter magnetic switch ( ).Pull main fuse A out.If it is blown ( ), install spare mainfuse A ( ).

To prevent an accidental short circuit,turn the ignition switch OFF beforechecking or replacing the fuses.Remove the seat (page ).

3.

4.

12

3

45

1.

2. 90

04/07/02 14:37:52 31MCW630_212

RIGHT FRONT

(8)

(9)

(8) cover(9) spare fuses

204

If a Fuse Blows


Circuit Fuse Access:Reconnect the wire connector.To access main fuse B ( ), open themain fuse B cover ( ).

Remove the inner panel (page ).Open the fuse box cover ( ).

Pull main fuse B out.If it is blown, install a new main fuse B.Close the main fuse B cover.Install the seat.

5.6.

7.

8.9.

10.11.

687

97

04/07/02 14:38:04 31MCW630_213

LEFT FRONT

(8) cover(9) spare fuses

CIRCUIT FUSE

(10) blown fuse

(10)

(8)

(INTERCEPTOR ABS only)

(9)

205

If a Fuse Blows


Replacing a f use with one that has ahigher rating greatly increases the chanceof damage to the electrical system.

To check or replace a circuit fuse, pullthe old fuse out of its retaining clips.Look for a burned wire inside the fuse.If the fuse is blown ( ), replace it witha spare fuse ( ) of the same rating orlower.

Install the inner panel.Close the fuse box cover.

If you do not have a replacement fuse withthe proper rating for the circuit, install onewith a lower rating.

109

12.

13.14.

04/07/02 14:38:12 31MCW630_214

206

If a Fuse Blows


If you do not have a spare fuse and youcannot ride the motorcycle without fixingthe problem, take a fuse of the same ratingor a lower rating from one of the othercircuits that you can do withouttemporarily.

If you replace a blown fuse with a sparefuse that has a lower rating, replace thefuse with the correct rating as soon as youcan. Also remember to replace any sparefuses that were installed.

If the replacement fuse of the same ratingburns out in a short time, there is probablya serious electrical problem on yourmotorcycle. Leave the blown fuse in thatcircuit and have your motorcycle checkedby your Honda dealer.

04/07/02 14:38:17 31MCW630_215

207

If You Crash


Transporting Your Motorcycle,

Personal safety is your first priority afterany accident. If you or anyone else hasbeen injured, take time to assess theseverity of the injuries and whether it issafe to continue riding. Call foremergency assistance if needed. Alsofollow applicable laws and regulations ifanother person or vehicle is involved inthe accident.

If you decide you are capable of ridingsafely, carefully inspect your motorcyclefor damage and determine if it is safe toride. Check the tightness of critical nutsand bolts securing such parts as thehandlebar, control levers, brakes, andwheels.

If there is minor damage, or you areunsure about possible damage, ride slowlyand cautiously. Sometimes, crash damageis hidden or not immediately apparent, soyou should have your motorcyclethoroughly checked at a qualified servicefacility as soon as possible. Also, be sureto have your Honda dealer check theframe and suspension after any seriouscrash.

If your motorcycle cannot be ridden, seepage .179

04/07/02 14:38:24 31MCW630_216

208

If You Lose Your Key


Be sure to record your key number in theQuick Reference section at the rear of themanual. You’ll need this number to have aduplicate key made.

A lost key won’t be a problem if you takepreventative action. Store one duplicatekey in a safe place at home and carry asecond duplicate in your wallet.

If you lose your key and aren’t carrying aduplicate, either get your spare or haveone made. If you don’t know your keynumber, call the dealer you purchasedyour Honda from. They may have it listedin their records. If they don’t, transportyour motorcycle to them or the nearestHonda dealer. The dealer will probablyhave to remove the ignition switchassembly to find the key number so theycan make a key for you.

04/07/02 14:38:29 31MCW630_217

209

If Your Battery is Low (or Dead)


Jump starting is not recommended,especially if you use an automobile battery.The greater amperage of an automobilebattery when the car engine is running candamage your motorcycle’s electricalsystem.

Bump starting is also not recommended.

If you can’t charge the battery or itappears unable to hold a charge, contactyour Honda dealer.

04/07/02 14:38:34 31MCW630_218

210 Taking Care of the Unexpected

04/07/02 14:38:36 31MCW630_219

211

Technical Information


This section contains dimensions,capacities, and other technical data, plusinformation on government requirementsand how to break-in your motorcycle.

..........................Vehicle Identification . 212......................................Specifications . 215

.............................Break-in Guidelines . 222..................Emission Control Systems . 223

.............................Catalytic Converter . 229................................Oxygenated Fuels . 230

04/07/02 14:38:42 31MCW630_220

(1) VIN

(1)LEFT SIDE

212

Serial Numbers

Vehicle Identification


The frame, VIN, and engine serialnumbers are required when you registeryour motorcycle. They may also berequired when ordering replacement parts.You may record these numbers in theQuick Reference section at the rear of thismanual.

The VIN (vehicle identification number)appears on the Safety Certification Labelattached to the left side of the frame.

04/07/02 14:38:48 31MCW630_221

RIGHT SIDE

(2) frame number (3) engine number

(2)

LEFT SIDE

(3)

213



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

The engine number ( ) is stamped on thetop of the crankcase.

2 3

04/07/02 14:38:55 31MCW630_222

(1) color label

(1)UNDER SEAT

214

Color Label & Code



The color code is helpful when orderingreplacement parts. You may record thecolor and code in the Quick Referencesection at the rear of this manual.

The color label is attached to the frameunder the seat. Remove the seat (page )to check the label.

90

04/07/02 14:39:01 31MCW630_223

83.5 in (2,120 mm)28.9 in (735 mm)47.0 in (1,195 mm)57.5 in (1,460 mm)4.9 in (125 mm)

470 lbs (213 kg)472 lbs (214 kg)

483 lbs (219 kg)481 lbs (218 kg)

USACanada

USACanada

INTERCEPTOR ABS:

INTERCEPTOR:

overall lengthoverall widthoverall heightwheelbaseground clearance

dry weight

Dimensions

Weight

215

Specifications


04/07/02 14:39:13 31MCW630_224

unleaded gasoline, pump octane number of 86 or higher

SAE 80 or 90 gear oil

3.3 US qt (3.1 )3.1 US qt (2.9 )

4.0 US qt (3.8 )5.81 US gal (22.0 )

3.09 US qt (2.92 )

API Service Classification SG or higher except oilslabeled as energy conserving on the circular API servicelabel, SAE 10W-40, JASO T 903 standard MA,Pro Honda GN4 or HP4 (without molybdenum additives)4-stroke oil (USA & Canada) or Honda 4-stroke oil(Canada only), or an equivalent motorcycle oil

after disassembly:after draining:after draining & oil filter change:

engine oil capacity

engine oilrecommendation

cooling system,capacity

Pro Honda HP Coolant or an equivalent high qualityethylene glycol antifreeze containing corrosion protectioninhibitors specifically recommended for use in aluminumengines

cooling system,recommendation

drive chain lubricant

fuel tank capacity

fuelrecommendation

Fuel & Lubricants

216

Specifications


04/07/02 14:39:26 31MCW630_225

－

－－

－

±

Operator and one passenger

rider, passenger, all cargo and accessories

47.7 cu-in (782 cm )2.83 x 1.89 in (72.0 x 48.0 mm)11.6 : 1IMR9B 9H (NGK)VNH27Z (DENSO)

399 lbs (181 kg)408 lbs (185 kg)

0.031 0.035 in (0.80 0.90 mm)


1,200 100 rpm

USA:Canada:

or

or

no adjustment0.008 in (0.20 mm)0.014 in (0.35 mm)

passengercapacitymaximum weightcapacity

displacementbore & strokecompression ratiospark plug(standard)

spark plug gap

spark plug(cold climate)

idle speed

valve clearance(cold)

intakeexhaust

Capacities

Engine Specifications

217

Specifications


04/07/02 14:39:43 31MCW630_226

1.9392.8462.0621.5781.2911.1110.9652.687

1643

chainDID50VA8 RK50HFOZ5

drive (engine) sprocket:driven (rear wheel) sprocket:

or

primary reductiongear ratio, 1st2nd3rd4th5th6thfinal reductionstandardsprocket sizesfinal drive

Power Transmission

218

Specifications


04/07/02 14:39:57 31MCW630_227

－－

－

25°30’3.7 in (95 mm)120/70ZR17M/C (58W)180/55ZR17M/C (73W)

0.47kW/5,000rpm

12V 10AH12V 11AH

42 psi (290 kPa , 2.90 kgf/cm )

36 psi (250 kPa , 2.50 kgf/cm )radial ply, tubeless

or

castertrailtire size, fronttire size, rear

battery

generator

tire pressure, rear(cold)

tire pressure, front(cold)

tire type

Chassis & Suspension

Electrical

219

Specifications


04/07/02 14:40:11 31MCW630_228

－－－－－

12V 55W12V 21/5W12V 21W12V 21W12V 8W

(2 bulbs)

(rear)(front)

(4 bulbs)headlightbrake/tail lightturn signal lights

license light

Lights

220

Specifications


04/07/02 14:40:19 31MCW630_229

30A30A

80 lbf·ft (108 N·m , 11 kgf·m)

16 lbf·ft (22 N·m , 2.2 kgf·m)

23 lbf·ft (31 N·m , 3.2 kgf·m)

43 lbf·ft (59 N·m , 6.0 kgf·m)20 lbf·ft (26 N·m , 2.7 kgf·m)22 lbf·ft (29 N·m , 3.0 kgf·m)

23 lbf·ft (31 N·m , 3.2 kgf·m)

10A, 20A, 30A (INTERCEPTOR ABS ONLY)other fuses

main Amain B

front wheel calipersocket bolts

rear wheel nuts

front wheel axlepinch bolts

front wheel caliperfixing bolts

front wheel axlebolt

oil filteroil drain bolt

Fuses

Torque Specifications

221

Specifications


04/07/02 14:40:33 31MCW630_230

222

Break-in Guidelines


Help assure your motorcycle’s futurereliability and performance by payingextra attention to how you ride during thefirst 300 miles (500 km).

During this period, avoid full-throttlestarts and rapid acceleration.

04/07/02 14:40:38 31MCW630_231

(2)

(1)

(1) vehicle emission control informationlabel

(2) vehicle emission control informationlabel (Canada only)

223

Exhaust Emission Requirements

Noise Emission Requirements

Warranty Compliance

Emission Control Systems


The U.S. Environmental ProtectionAgency (EPA), the California AirResources Board (CARB), andEnvironment Canada require that yourmotorcycle comply with applicableexhaust emissions standards during itsuseful life, when operated and maintainedaccording to the instructions provided.

The EPA also requires that motorcyclesbuilt after January 1, 1983 comply withapplicable noise emission standards forone year or 3,730 miles (6,000 km) afterthe time of sale to the ultimate purchaser,when operated and maintained accordingto the instructions provided. (USA only)

Compliance with the terms of theDistributor’s Warranties for HondaMotorcycle Emission Control Systems isnecessary in order to keep the emissionssystem warranty in effect. (USA only)

04/07/02 14:40:44 31MCW630_232

224



Source of Exhaust EmissionsThe Vehicle Emission ControlInformation label ( ) ( ) is attached tothe air cleaner housing under the fuel tank.

The combustion process produces carbonmonoxide (CO), oxides of nitrogen (NOx)and hydrocarbons (HC). Control ofhydrocarbons and oxides of nitrogen isvery important because, under certainconditions, they react to formphotochemical smog when subjected tosunlight. Carbon monoxide does not reactin the same way, but it is toxic.

Honda Motor Co., Ltd. utilizes varioussystems to reduce carbon monoxide,oxides of nitrogen and hydrocarbons.

1 2

04/07/02 14:40:49 31MCW630_233

225



PGM-FI System

Ignition Timing Control System

Exhaust Emission Control SystemThe PGM-FI system uses sequentialmultiport fuel injection. It has foursubsystems: Air Intake, Engine Control,Fuel Control, and Exhaust Control.The Engine Control Module (ECM) usesvarious sensors to determine how much airis going into the engine. It then controlshow much fuel to inject under alloperating conditions.

The system constantly adjusts the ignitiontiming, reducing the amount of HC, COand NOx produced.

The exhaust emission control systemincludes a secondary air injection system,PGM-FI system, two three-way catalyticconverters, and two heated oxygen sensors.

No adjustment to these systems should bemade although periodic inspection of thecomponents is recommended.

04/07/02 14:40:54 31MCW630_234

226

Secondary Air Injection System Evaporative Emission Control System(USA only)

Three-Way Catalytic Converters



The secondary air injection systemintroduces filtered air into the exhaustgases in the exhaust port. The secondaryair injection system helps improveemission performance.

This motorcycle complies with therequirements of the California AirResources Board (CARB) evaporativeemission regulations. Fuel vapor from thefuel tank is directed into the charcoalcanister and air cleaner where it isadsorbed and stored while the engine isstopped. When the engine is running andthe purge control solenoid valve is open,fuel vapor in the charcoal canister and aircleaner is drawn into the engine throughthe throttle body.

The three-way catalytic converters are inthe exhaust system. Through chemicalreactions, they convert HC, CO, and NOxin the engine’s exhaust to carbon dioxide(CO ), dinitrogen (N ), and water vapor.2 2

04/07/02 14:40:59 31MCW630_235

227

Problems That May Affect MotorcycleExhaust Emissions

Crankcase Emission Control System



If you are aware of any of the followingsymptoms, have the vehicle inspected andrepaired by your authorized Hondamotorcycle dealer.

Symptoms:Hard starting or stalling after startingRough idleMisfiring or backfiring duringaccelerationAfter-burning (backfiring)Poor performance (driveability) andpoor fuel economy

The engine is equipped with a closedcrankcase system to prevent dischargingcrankcase emissions into the atmosphere.Blow-by gas is returned to the combustionchamber through the air cleaner and theintake manifold.

1.2.3.

4.5.

04/07/02 14:41:04 31MCW630_236

228

Noise Emission Control System



Removal of, or puncturing the muffler,baffles, header pipes or any othercomponent which conducts exhaustgases.Removal of, or puncturing of any partof the intake system.Lack of proper maintenance.Replacing any moving parts of thevehicle, or parts of the exhaust or intakesystem, with parts other than thosespecified by the manufacturer.

AMONG THOSE ACTS PRESUMEDTO CONSTITUTE TAMPERING ARETHE FOLLOWING ACTS:

TAMPERING WITH THE NOISECONTROL SYSTEM IS PROHIBITED:U. S. federal law prohibits, or Canadianprovincial laws may prohibit the followingacts or the causing thereof: ( ) Theremoval or rendering inoperative by anyperson, other than for purposes ofmaintenance, repair or replacement, of anydevice or element of design incorporatedinto any new vehicle for the purpose ofnoise control prior to its sale or delivery tothe ultimate purchaser or while it is in use;or ( ) the use of the vehicle after suchdevice or element of design has beenremoved or rendered inoperative by anyperson.

1.

2.

3.4.

1

2

04/07/02 14:41:10 31MCW630_237

229Technical Information

Catalytic Converter

A defective catalytic converter contributesto air pollution, and can impair yourengine’s performance. Follow theseguidelines to protect your motorcycle’scatalytic converter.

Always use unleaded gasoline. Even asmall amount of leaded gasoline cancontaminate the catalyst metals, makingthe catalytic converter ineffective.

Keep the engine tuned-up.

Have your motorcycle diagnosed andrepaired if it is misfiring, backfiring,stalling or otherwise not runningproperly.

This motorcycle is equipped with twothree-way catalytic converters.The catalytic converter contains preciousmetals that serve as catalysts, promotingchemical reactions to convert the exhaustgasses without affecting the metals.

The catalytic converters act on HC, CO,and NOx. A replacement unit must be anoriginal Honda part or its equivalent.

The catalytic converters must operate at ahigh temperature for the chemicalreactions to take place. They can set fire toany combustible materials that come nearthem. Park your motorcycle away fromhigh grasses, dry leaves, or otherflammables.

04/07/02 14:41:14 31MCW630_238

230

Oxygenated Fuels


Some conventional gasolines are beingblended with alcohol or an ethercompound. These gasolines arecollectively referred to as oxygenatedfuels. To meet clean air standards, someareas of the United States and Canada useoxygenated fuels to help reduce emissions.If you use an oxygenated fuel, be sure it isunleaded and meets the minimum octanerating requirement.Before using an oxygenated fuel, try toconfirm the fuel’s contents. Some states/provinces require this information to beposted on the pump.

The following are the EPA-approvedpercentages of oxygenates:

ETHANOL (ethyl or grain alcohol) 10%by Volume

You may use gasoline containing up to10% ethanol by volume. Gasolinecontaining ethanol may be marketedunder the name ‘‘Gasohol’’.

MTBE (Methyl Tertiary Butyl Ether) 15%by Volume

You may use gasoline containing up to15% MTBE by volume.

04/07/02 14:41:22 31MCW630_239

231

Oxygenated Fuels


Oxygenated f uels can damage paint andplastic. Damage caused by spilled f uel isnot covered by warranty.

Fuel system damage or performanceproblems resulting from the use of anoxygenated fuel containing more than thepercentages of oxygenates mentionedabove are not covered under warranty.

Oxygenated fuels can damage paint andplastic. Be careful not to spill fuel whenfilling the fuel tank. Wipe up any spillsimmediately.

If you notice any undesirable operatingsymptoms, try another service station orswitch to another brand of gasoline.

METHANOL (methyl or wood alcohol)5% by Volume

You may use gasoline containingmethanol containing up to 5% methanolby volume as long as it also containscosolvents and corrosion inhibitors toprotect the fuel system. Gasolinecontaining more than 5% methanol byvolume may cause starting and/orperformance problems. It may alsodamage metal, rubber, and plastic partsof your fuel system.

04/07/02 14:41:28 31MCW630_240

232 Technical Information

04/07/02 14:41:31 31MCW630_241

233

Consumer Information


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

............................Authorized Manuals . 234.............................Warranty Coverage . 237

.................................Warranty Service . 238................................Contacting Honda . 239

.............................Your Honda Dealer . 240The Honda Rider’s Club

..........................................(USA only) . 241Reporting Safety Defects

..........................................(USA only) . 242

04/07/02 14:41:36 31MCW630_242

＊

＊

$60.00

$48.00

$16.00

2005 VFR800/A INTERCEPTOR/ABS Service Manual

Common Service Manual

2005 VFR800/A INTERCEPTOR/ABS Owner’s Manual

61MCW03

61CM002

31MCW630

DescriptionPublication Item No. Price Each

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

234

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 ServiceManual which explains theory of operation and basic service information for various systemscommon to all Honda motorcycles, motor scooters and ATVs.

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

04/07/02 14:41:44 31MCW630_243

－－

＊

＊Prices are subject to change without notice and without incurring

obligation.

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

delivery.

Item DescriptionPublication

Item No.

Total

Price

Price

Each

Qty.

Handling Charge

Grand Total

$5.00

Sub Total

Purchaser’s Sales Tax

Mich. Add 6 %

Calif. Add 8.25 %

235

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 ormoney order, or charge to your credit card. Mail to Helm, Inc. at the address shown on theback of this order form (USA only).

Canada: See your Honda dealer to order authorized manuals.

04/07/02 14:41:56 31MCW630_244

－

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

Customer Name Attention

Zip CodeStateCity

Daytime Telephone Number

Check here if your billing address is different from theshipping address shown above.

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

MasterCard

VISA

Discover

Account Number

Date

Expiration: Mo. Yr.

Customer Signature

Apartment NumberStreet Address - No P. O. Box Number

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

( )

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

PAYMENT

SHIP

TO

236 Consumer Information

04/07/02 14:42:10 31MCW630_245

237

Warranty Coverage


Your new Honda is covered by thesewarranties:

Motorcycle Limited WarrantyExhaust Emission WarrantyNoise Control Warranty

There are responsibilities, restrictions, andexclusions which apply to these warranties.Please read the Warranties Booklet givento you by your Honda dealer at the time ofpurchase. Be sure to keep your Hondaowner’s card with your WarrantiesBooklet (USA only).

It is important to realize that yourwarranty applies to defects in material orworkmanship of your Honda. Yourwarranty coverage does not apply tonormal wear or deterioration associatedwith using the motorcycle.

Your warranty coverage will not bevoided if you choose to perform your ownmaintenance. However, you should havethe proper tools and service informationand be mechanically qualified. Failuresthat occur due directly to impropermaintenance are not covered.

Almost all of your warranty coverage canbe extended through the Honda ProtectionPlan (USA only). For more information,see your Honda dealer.

04/07/02 14:42:18 31MCW630_246

238

Warranty Service


Please remember that recommendedmaintenance interval servicing is notincluded in your warranty coverage.Additionally, your warranty does notapply to the normal wear of items (such asbrakes, tires, etc.).

If you believe you have a problem withyour motorcycle, call the servicedepartment of your Honda dealer. Makean appointment for an inspection anddiagnosis. Remember, as the owner of themotorcycle, you will be asked to authorizethat inspection. Your dealer will give youthe results of the inspection. If theproblem is covered under warranty, yourdealer will perform the warranty repairsfor you.

If you have questions about warrantycoverage or the nature of the repair, it isbest to talk to the service manager of yourHonda dealer.

Sometimes, in spite of the best intentionsof all concerned, a misunderstanding mayoccur. If you aren’t satisfied with yourdealer’s handling of the situation, wesuggest you discuss your problem with theappropriate member of the dealership’smanagement team. If the problem hasalready been reviewed with the ServiceManager, Parts Manager, Sales Manager,etc., contact the Owner of the dealershipor their designated representative.

04/07/02 14:42:24 31MCW630_247

239Consumer Information

Contacting Honda

Your owner’s manual was written to covermost of the questions you might ask aboutyour Honda. Any questions not answeredin the owner’s manual can be answered byyour Honda dealer. If your dealer doesn’thave the answer right away, they will getit for you.

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

Canada: Refer to the Warranties Bookletthat was supplied with your vehicle.

Please include the following informationin your letter:

name, address, and telephone numberproduct model, year, and frame/VINserial numberdate of purchasedealer name and address

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

If you have a difference of opinion withyour dealer, please remember that eachdealership is independently owned andoperated. That’s why it’s important towork to resolve any differences at thedealership level.

If you wish to comment on yourexperiences with your Honda or with yourdealer, please send your comments to thefollowing address (USA only):

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Your Honda Dealer

Once you purchase your new Honda, getfamiliar with the organization of yourHonda dealer so you can utilize the fullrange of services available.

The service department is there to performregular maintenance and unexpectedrepairs. It has the latest available serviceinformation from Honda. The servicedepartment will also handle warrantyinspections and repairs.

The parts department offers GenuineHonda parts, Pro Honda products,Hondaline accessories (USA only), andHonda accessories and products (Canadaonly). The same quality that went intoyour Honda can be found in GenuineHonda replacement parts. You’ll also findcomparable quality in the accessories and

products available from the partsdepartment.

The sales department offers the HondaProtection Plan to extend almost all ofyour warranty coverage (USA only).Your Honda dealer can inform you aboutcompetition and other riding events inyour area. You’ll also find that your dealeris a source of information about AmericanHonda’s Rider Education Centers and theHonda Rider’s Club of America (USAonly).

We’re sure you’ll be as pleased with theservice your Honda dealer continues toprovide after the sale as you are with thequality and dependability of your Honda.

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The Honda Rider’s Club (USA only)

Honda Red RiderHonda Red Rider ATV

One of the best ways to get the mostenjoyment from owning and riding yourHonda is through the Honda Rider’s Clubof America. Your purchase of a newmotorcycle, scooter, ATV or PWC from aparticipating U.S. Honda dealer entitlesyou to a complimentary one-yearmembership in the Club. There arehundreds of HRCA Chapter sponsoringdealers across the USA with events andactivities almost every weekend.Membership benefits include:

An exclusive HRCA website completewith access to the official Honda

Common Service Manual, contests,insider information and more.

Vehicle transport to the nearest Hondadealer or service center, if necessary.

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

Reimbursement (up to $75) forMotorcycle Safety Foundation training.Separate free training from theSpecialty Vehicle Institute of Americafor ATV owners.One full year of themagazine or (forATV purchasers).Discounts from HRCA partners forexperienced rider courses.Discounted vehicle insurance from theHRCA’s insurance partner.Racing contingency programs andassistance at selected dual-sport, off-road, and motocross events.

Contact your Honda dealer for moreinformation or call: 1 800-847-HRCA orlog on to www.hrca.honda.com.

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Reporting Safety Defects (USA only)

To contact NHTSA, you may either callthe Auto Safety Hotline toll-free at1-800-424-9393 (or 366-0123 inWashington, D.C. area) or write to:NHTSA, U.S. Department ofTransportation, Washington, D.C. 20590.

You can also obtain other informationabout motor vehicle safety from theHotline.

If you believe that your vehicle has adefect which could cause a crash or couldcause injury or death, you shouldimmediately inform the National HighwayTraffic Safety Administration (NHTSA)in addition to notifying American HondaMotor Co., Inc.

If NHTSA receives similar complaints, itmay open an investigation, and if it findsthat a safety defect exists in a group ofvehicles, it may order a recall and remedycampaign. However, NHTSA cannotbecome involved in individual problemsbetween you, your dealer, or AmericanHonda Motor Co., Inc.

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244

Table of Contents

Table of Contents

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

.......INSTRUMENTS & CONTROLS . 9

...............................BEFORE RIDING . 41

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

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

...........................................Safety Labels . 7

...........................Component Locations . 11..............Gauges, Indicators & Displays . 14

......................Multi-function Display . 24.........................................Fuel Gauge . 25

..............Coolant Temperature Meter . 26.....................Air Temperature Meter . 28

......................................Speedometer . 30..............Odometer/Tripmeter A & B . 31

Changing the Speed and Mileage....................................................Unit . 32

.....................................Digital Clock . 33

Controls & Features..................................Ignition Switch . 35

........................................Start Button . 36...........................Engine Stop Switch . 36

...................................Hazard Switch . 37................Headlight Dimmer Switch . 38

............................Turn Signal Switch . 38.......................................Horn Button . 39

................................SELECT Button . 39...................................RESET Button . 39

.....................Are You Ready to Ride . 42.............................Protective Apparel . 42

...................................Rider Training . 44...Is Your Motorcycle Ready to Ride . 45

............................Pre-ride Inspection . 45.....................Load Limits & Guidelines . 48

..............................................Loading . 48.......................................Load Limits . 49

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245

Table of Contents

Table of Contents

.....BASIC OPERATION & RIDING . 51

...........SERVICING YOUR HONDA . 69Bef ore You Service Your Honda

Service Preparations

(cont’d)

...........................Loading Guidelines . 49

........................Safe Riding Precautions . 52............Starting & Stopping the Engine . 53

.........................................Preparation . 53.............................Starting Procedure . 54

..................................Flooded Engine . 55Bank Angle Sensor Ignition Cut-off

................................................System . 55....................How to Stop the Engine . 56

........................................Shifting Gears . 57..................................................Braking . 59

Anti-lock Brake System (ABS)....................(INTERCEPTOR ABS) . 61

ABS Indicator....................(INTERCEPTOR ABS) . 62

...................................................Parking . 63.........Riding with a Passenger or Cargo . 68

...........The Importance of Maintenance . 72...............................Maintenance Safety . 73

............Important Safety Precautions . 74............................Periodic Maintenance . 76..........................Maintenance Schedule . 78

..............................Maintenance Record . 83

...........................Component Locations . 85..................................................Tool Kit . 88

.......................Owner’s Manual Storage . 89.........................................Seat Removal . 90

.....................................Rear Seat Cover . 91........................Lower Fairing Removal . 93

..........................Inner Fairing Removal . 96.............................Inner Panel Removal . 97...........................Raising the Fuel Tank . 98

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246

Table of Contents

Table of Contents

SERVICING YOUR HONDA (cont’d)

.....................................................TIPS . 175

Service Procedures

Fluids & Filters

Chassis

Engine

Electrical

......................................................Fuel . 100..............................Engine Oil & Filter . 104

.................................................Coolant . 114..........................................Air Cleaner . 118

................................................Throttle . 120......................................Clutch System . 122

................................Engine Idle Speed . 125..........................................Spark Plugs . 127

...........................................Suspension . 134..................................................Brakes . 141

.....................................................Tires . 147............................................Side Stand . 154

..........................................Drive Chain . 155

..................................................Battery . 162

.................................Appearance Care . 167

............................Storing Your Honda . 176...........Transporting Your Motorcycle . 179

......................You & the Environment . 180

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247

Table of Contents

Table of Contents

TAKING CARE OF THE.................................UNEXPECTED . 181

.....TECHNICAL INFORMATION . 211

......CONSUMER INFORMATION . 233

.................TABLE OF CONTENTS . 244

................................................INDEX . 248

QUICK REFERENCE

..............................General Guidelines . 182..If Your Engine Quits or Won’t Start . 183

.......................If You Have a Flat Tire . 188...................If Your Engine Overheats . 199

If the Low Oil Pressure Indicator...................................................Lights . 201

....................................If a Fuse Blows . 202........................................If You Crash . 207

........................If You Lose Your Key . 208.......If Your Battery is Low (or Dead) . 209

..........................Vehicle Identification . 212......................................Specifications . 215

.............................Break-in Guidelines . 222..................Emission Control Systems . 223

.............................Catalytic Converter . 229................................Oxygenated Fuels . 230

............................Authorized Manuals . 234.............................Warranty Coverage . 237

.................................Warranty Service . 238................................Contacting Honda . 239

.............................Your Honda Dealer . 240The Honda Rider’s Club

..........................................(USA only) . 241Reporting Safety Defects

..........................................(USA only) . 242

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248

Index

Index

A

C

B

ABS indicator........................(INTERCEPTOR ABS) . 62

...............................................accessories . 5..................................air pressure, tires . 147

.............................air temperature meter . 28...............American Honda, contacting . 239

anti-lock brake system (ABS)........................(INTERCEPTOR ABS) . 61

.................................apparel, protective . 42...................................appearance care . 167

..................................bank angle sensor . 55..................................................battery . 162

brakes,..................................................fluid . 142

.....................front lever adjustment . 141...........................................pad wear . 145

...................................................braking . 59..............................break-in guidelines . 222

button,...............................................RESET . 39

............................................SELECT . 39

.......................................capacity, fuel . 102..................................care, appearance . 167

...............................catalytic converter . 229..........................................chain, drive . 155

...................cleaning, appearance care . 167..........................................................clip . 95

...........................................clock, digital .33.......................................clutch system . 122

............................................color label . 214

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’

249

Index

Index

D

E

compartment,...............................owner s manual . 89

................................................tool kit . 88component locations,

......................indicators and controls . 11.......................................maintenance . 85

.........................consumer information . 233..................................................coolant . 114

.....................coolant temperature meter . 26cover,

..............................................rear seat . 91..................................customer service . 239

...................damping, suspension, rear . 140......................................defects, safety . 242

...........................................digital clock . 33display,

..................................................check . 16

....................................multi-function . 24...........................................drive chain . 155

.....................emission control systems . 223engine,

...............................................flooded . 55.........................................idle speed . 125

................................low oil pressure . 201.............................................number . 213

.....................................................oil . 104..........................................overheats . 199

.............................................pinging . 101

...............................................starting . 53.........................................stop switch . 36

..............................................stopping . 56........................................won’t start . 183.........................................environment . 180

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250

Index

Index

G

H

I

F

fairing removal,...................................................inner . 96..................................................lower . 94

..................................................flat tire . 188.......................................flooded engine . 55

......................................frame number . 213fuel,

..................................................gauge . 25.......................................oxygenated . 230

..............................recommendation . 100........................................tank raising . 98....................................tank capacity . 102

.....................................................fuses . 202

.....................................gap, spark plug . 131

.................................................gasohol . 230................................................gasoline . 100

................gauges, indicators & displays . 14

.........................................hazard switch . 37.......................headlight dimmer switch . 38

.........................................helmet holder . 65...............................high beam indicator . 18

Honda,........................................contacting . 239

.....................................Rider’s Club . 241................................................dealer . 240

.........................Honda service manual . 234.............................................horn button . 39

..........................identification, vehicle . 212

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251

Index

Index

M

K

L

............................................labels, safety . 7.............................................lamp check . 15...........................................limit, weight . 49

..............................................load limits . 49..................................loading guidelines . 49

location, components,.........................indicators & controls . 11

.......................................maintenance . 85..........................................lock, steering . 64

............................lower fairing removal . 93

................................idle speed, engine . 125ignition cutoff system,

..........................................bank angle . 55...........................................side stand . 53

.......................................ignition switch . 35................................................indicators . 14

.............................inner fairing removal . 96...............................inner panel removal . 97................................inspection, pre-ride . 45

................................................key, lost . 208...................................................kit, tool . 88

maintenance,.........................................importance . 72

..............................................periodic . 76.................................................record . 83..................................................safety . 73

.............................................schedule . 78....................................manual, service . 234

..........................maximum weight limit . 49...........................................modifications . 6

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252

Index

Index

R

P

O

N

.....................................numbers, serial . 212

..........................................odometer . 14, 31oil,

...............................................engine . 105.....................................low pressure . 201

..................................operating controls . 35...................................overheat, engine . 199

.........................owner’s manual storage . 89..................................oxygenated fuels . 230

...................................................parking . 63....................................pinging, engine . 101

..........................................plugs, spark . 127pre-load, suspension

.................................................front . 136...........................................rear . 138, 139

.................................pre-ride inspection . 45..........................problems, unexpected . 181

..................................protective apparel . 42

removal,.......................................inner fairing . 96

.........................................inner panel . 97......................................lower fairing . 93....................................rear seat cover . 91

.....................................................seat . 90.......................reporting safety defects . 242

........................................RESET button . 39......................................rider training . 2, 44

............................Rider’s Club, Honda . 241

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253

Index

Index

S

(cont’d)

riding,...................................basic operation . 51

..............................................clothing . 42.........................................precautions . 52

....................................................safety . 2..............................safety precautions . 52

.....................with passenger or cargo . 68

safety,........................important precautions . 74

....................................................labels . 7..............................reporting defects . 242..............................riding precautions . 52

...........................schedule, maintenance . 78...........................................seat removal . 90

.....................................SELECT button . 39.................................sensor, bank angle . 55

......................................serial numbers . 212

service,...........................................customer . 239............................................manuals . 234...........................................warranty . 238

.........................................shifting gears . 57.............................................side stand . 154

..........side stand ignition cutoff system . 53..........................................spark knock . 101...........................................spark plugs . 127

.......................................specifications . 215...........................................speedometer . 30

............................................stand, side . 154.............................................start button . 36

starting,.................................................engine . 53

................................troubleshooting . 183...........................................steering lock . 64

................................stop switch, engine . 36

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254

Index

Index

T......................................stopping engine . 56

storage,.......................................motorcycle . 176

.................................owner’s manual . 89suspension,

............front suspension adjustment . 135.....front suspension spring pre-load . 136

.............rear suspension adjustment . 137rear suspension spring

....................................pre-load . 138, 139.................rear suspension damping . 140

switch,.........................................engine stop . 36

.................................................hazard . 37...............................headlight dimmer . 38

...............................................ignition . 35..........................................turn signal . 38

.......................................tachometer . 14, 18temperature meter,

.......................................................air . 28................................................coolant . 26

...............................theft prevention tips . 66..................................................throttle . 120

tires,.......................................air pressure . 148

....................................................flat . 188..........................................replacing . 151

....................................................tool kit . 88.....................................training, rider . 2, 44

..............transporting your motorcycle . 179.................................................tripmeter . 31

.............................trouble, unexpected . 181......................troubleshooting, starting . 183

.......................turn signal indicators . 19, 23

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255

Index

Index

W

V

..........vehicle identification no. (VIN) . 212

warranty,...........................................coverage . 237...........................................extended . 237

..............................................service . 238....................washing your motorcycle . 169

............................................weight limit . 49wheels,

...................................front removal . 191.....................................rear removal . 197

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256 Memo

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Quick Reference

Quick Reference

How To Avoid Costly RepairsThe following is a brief, but importantcollection of information you need toknow about your Honda. You’ll also findspace to record important notes. The engine of your Honda can be the most

expensive component to repair. Propermaintenance, especially the use of therecommended fluids and filters, preventspremature wear and damage.

Frequent causes of costly repairs are:Engine oil: insufficient quantity,improper oil.Air cleaner: dirty, leaking because ofimproper installation (poor seal).

Record important information on thefollowing page:

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Quick Reference

Quick Reference

VIN/Frame No.Engine No.Frame No.Ignition Key No.Color LabelOwner’s Name

AddressCity/StatePhone

Dealer’s NameAddressCity/StatePhoneService Mgr.

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5.81 US gal (22.0 )

399 lbs (181 kg)408 lbs (185 kg) Canada

Quick Reference

Quick Reference

ScheduledMaintenancePre-rideInspectionPeriodicChecksFuel/Capacity

Initial: 600 miles (1,000 km)Regular: every 4,000 miles (6,400 km)Check the following items each time before you ride (page ): tires &wheels, chain, leaks, loose parts, throttle, brakes, indicators, lights.

unleaded gasoline, pump octane number 86 or higher

Engine Oil

Check the following items monthly (page ): tires & wheels, fluids,lights, freeplay, drive chain, fuses, nuts & bolts.

MaximumWeightCapacity rider, passenger, all cargo and accessories

API Service Classification SG or higher except oils labeled as energyconserving on the circular API service label,SAE 10W-40, JASO T 903 standard MA,Pro Honda GN4 or HP4 (without molybdenum additives) 4-stroke oilor equivalent

45

77

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－－

－

120/70ZR17M/C (58W)BRIDGESTONE BT020F BB

METZELER MEZ4A FRONT180/55ZR17M/C (73W)

BRIDGESTONE BT020R BBDUNLOP D204KMETZELER MEZ4A

10A, 20A, 30A30A30A

VNH24Z (DENSO)VNH27Z (DENSO)

IMR8B 9H (NGK)IMR9B 9H (NGK)

42 psi (290 kPa , 2.90 kgf/cm )36 psi (250 kPa , 2.50 kgf/cm )

DUNLOP D204FK

radial ply, tubeless

oror

oror

(INTERCEPTOR ABS ONLY)

Quick Reference

Quick Reference

Tires

Fuses

Coolant ethylene glycol antifreeze (silicate-free) for aluminum engines in 50/50solution with Pro Honda HP Coolant or an equivalent distilled water

Spark Plugs

Tire Pressure(cold)

Front:

Rear:

Front:Rear:standard:cold climate:

main A:main B:other:

oror

Type:

04/07/02 14:44:50 31MCW630_269

Documents

This Owner’s Manual covers the and models. You INTERCEPTOR ...owners.honda.com/assets/OWNERLINK/model/own_man/... · 04/07/02 14:09:05 31MCW630_004. A Few Words About Safety Safety