Honda Motor Co., Ltd. 1999

OWNER’S MANUAL

MANUEL DU CONDUCTEUR

FAHRER-HANDBUCH

CBR900RRFIRE BLADE

06/03/06 13:39:47 3CMCJ600_001

This motorcycle is designed to be used only on the road.

Pay special attention to statements preceded by the following words:

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

Gives helpful information.

This motorcycle is designed to carry the operator and one passenger. Never exceed themaximum weight capacity as shown on the loading and accessories label.

IMPORTANT NOTICE

ON-ROAD USE

READ THIS OWNER’S MANUAL CAREFULLY

Indicates a strong possibility of severe personal injury or death if instructions arenot followed.

Indicates a possibility of personal injury or equipment damage if instructions arenot followed.

OPERATOR AND PASSENGER

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All information in this publication is based on the latest production informationavailable at the time of approval for printing. Honda Motor Co.,Ltd. reserves theright to make changes at any time without notice and without incurring anyobligation.No part of this publication may be reproduced without written permission.

HONDA CBR900RRFIRE BLADE

OWNER’S MANUAL

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The motorcycle presents you a challenge to master the machine, a challenge to adventure.You ride through the wind, linked to the road by a vehicle that responds to your commandsas no other does. Unlike an automobile, there is no metal cage around you. Like an airplane, apre-ride inspection and regular maintenance are essential to your safety. Your reward isfreedom.To meet the challenges safely, and to enjoy the adventure fully, you should becomethoroughly familiar with this owner’s manual BEFORE YOU RIDE THE MOTORCYCLE.When service is required, remember that your Honda dealer knows your motorcycle best. Ifyou have the required mechanical ‘‘know-how’’ and tools, your dealer can supply you with anofficial Honda Service Manual to help you perform many maintenance and repair tasks.

Pleasant riding, and thank you for choosing a Honda !

Following codes in this manual indicate each country.

UK

France

Brazil

AustraliaBelgiumGreeceHollandItalyPortugalSpainSwitzerland

ED

MexicoNew Zealand

EGFU

MXBR

Northern Europe

GermanyAustria

The specifications may vary with each locale.

Europe

WELCOME

( )

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〈 〉

page1 MOTORCYCLE SAFETY1 Safe Riding Rules2 Protective Apparel2 Modifications3 Loading and Accessories6 PARTS LOCATION9 Instruments and Indicators

24 MAJOR COMPONENTS(Information you need toopetate this motorcycle)

24 Suspension30 Brakes34 Clutch36 Coolant38 Fuel41 Engine Oil42 Tubeless Tyres45 ESSENTIAL INDIVIDUAL

COMPONENTS45 Ignition Switch46 Keys48 Immobilizer System (HISS)

Except MX,BR

page49 Right Handlebar Controls50 Left Handlebar Controls52 FEATURES

(Not required for operation)52 Steering Lock53 Seat55 Helmet Holder56 Document Bag56 Storage Compartment57 Storage Compartment for

U-Shaped Anti-theft Lock58 Middle Fairing59 Lower Fairing60 Inner Panel61 Headlight Aim Vertical Adjustment62 OPERATION62 Pre-ride Inspection63 Starting the Engine65 Running-in66 Riding68 Braking69 Parking69 Anti-theft Tips

OPERATION

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〈 〉

〈 〉

〈 〉

page70 MAINTENANCE71 Maintenance Schedule74 Tool Kit75 Serial Numbers76 Colour Label77 Maintenance Precautions78 Engine Oil82 Spark Plugs86 Throttle Operation87 Idle Speed88 Drive Chain94 Drive Chain slider95 Front and Rear Suspension

Inspection96 Side Stand97 Wheel Removal

102 Brake Pad Wear104 Battery106 Fuse Replacement109 Stoplight Switch Adjustment110 Bulb Replacement

page115 CLEANING

118 STORAGE GUIDE118 Storage120 Removal from Storage

121 SPECIFICATIONS

125 RADIO TYPE APPROVALS OFIMMOBILIZER SYSTEM (HISS)Except MX,BR

126 CATALYTIC CONVERTERFor G only

127 NOISE CONTROL SYSTEMAUSTRALIA ONLY

MAINTENANCE

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Always make a pre-ride inspection (page) before you start the engine. You

may prevent an accident or equipmentdamage.Many accidents involve inexperiencedriders. Most countries require a specialmotorcycle riding test or license. Makesure you are qualified before you ride.NEVER lend your motorcycle to aninexperienced rider.Many automobile/motorcycle accidentshappen because the automobile driverdoes not ‘‘see’’ the motorcyclist.Make yourself conspicuous to help avoidthe accident that wasn’t your fault:

Obey all national and local laws andregulations.

Excessive speed is a factor in manyaccidents. Obey the speed limits, andNEVER travel faster than conditionswarrant.Signal before you make a turn or lanechange. Your size and maneuverabilitycan surprise other motorists.

Wear bright or reflective clothing.Don’t ride in another motorist’s ‘‘blindspot.’’

Don’t let other motorists surprise you.Use extra caution at intersections,parking lot entrances and exits, anddriveways.Keep both hands on the handlebars andboth feet on the footpegs while riding. Apassenger should hold on to themotorcycle or the operator with bothhands and keep both feet on thepassenger footpegs.

1.

2.

3.

4.

5.

6.

62

MOTORCYCLE SAFETY

Motorcycle riding requires specialefforts on your part to ensure yoursafety. Know these requirementsbefore you ride:

SAFE RIDING RULES

1

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Most motorcycle accident fatalities aredue to head injuries: ALWAYS wear anapproved motorcycle helmet. You shouldalso wear a face shield or goggles as wellas boots, gloves and protective clothing.A passenger needs the same protection.The exhaust system becomes hot duringoperation, and it remains hot for a whileafter stopping the engine. Be careful notto touch the exhaust system while it ishot. Wear clothing that fully covers yourlegs.Do not wear loose clothing which couldcatch on the control levers, footpegs,drive chain or wheels.

1.

2.

3.

PROTECTIVE APPAREL MODIFICATIONS

Modification of the motorcycle, orremoval of original equipment, mayrender the vehicle unsafe or illegal.Obey all national and local equipmentregulations.

2

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The combined weight of the rider,passenger, cargo and all accessories mustnot exceed the maximum weight capacity:

Adjust tyre pressure (page ), frontsuspension (page ) and rear suspen-sion (page ) to suit load weight andriding conditions.

Keep cargo and accessory weight low andclose to the center of the motorcycle.Load weight equally on both sides tominimize imbalance. As weight is locatedfurther from the motorcycle’s center ofgravity, handling is proportionallyaffected.

Cargo weight alone should not exceed:

2.

1.

4224

27

LOADING AND ACCESSORIES

To prevent an accident, use extremecare when adding and riding withaccessories and cargo. Addition ofaccessories and cargo can reduce amotorcycle’s stability, performanceand safe operating speed. Never ridean accessory-equipped motorcycle atspeeds above 130 km/h (80 mph).And remember that this 130 km/h(80mph) limit may be reduced byinstallation of non-Honda accessories,improper loading, worn tyres andoverall motorcycle condition, poorroad or weather conditions. Thesegeneral guidelines may help youdecide whether or how to equip yourmotorcycle and how to load it safely.

Loading

3

14 kg (30 lbs)

189 kg (417 lbs)160 kg (353 lbs) …MX

…Except MX

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Genuine Honda accessories have beenspecifically designed for and tested on thismotorcycle. Because the factory cannot testall other accessories, you are personallyresponsible for proper selection, installation,and use of non-Honda accessories. Alwaysfollow the guidelines under Loading, andthese:

L ar ge f ork -mounted f a i r ings orwindshields, or poorly designed orimproperly mounted fairings can produceaerodynamic forces that cause unstablehandling. Do not install fairings thatdecrease cooling air flow to the engine.

Carefully inspect the accessory to makesure it does not obscure any lights,reduce ground clearance and bankingangle, or limit suspension travel, steeringtravel or control operation.

The Honda fairing is designed for thismotorcycle only. Do not install it on anyother motorcycle.

Vehicle handling and stability can beadversely af fected by loose cargo.Recheck cargo security and accessorymounts frequently.

Do not attach large or heavy items (suchas a sleeping bag or tent) to thehandlebars, fork, or fender. Unstablehandling or slow steering response mayresult.

1.

3.

4.

5.

2.

Accessories

4

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Accessories which alter your ridingposition by moving hands or feet awayfrom controls may increase reaction timein an emergency.Do not add electrical equipment that willexceed the motorcycle’s electrical systemcapacity. A blown fuse could cause adangerous loss of lights or engine power.This motorcycle was not designed to pulla sidecar or trailer. Handling may beseriously impaired if so equipped.Any modification of the cooling systemmay cause overheating and seriousengine damage. Do not modify theradiator shrouds or install accessorieswhich block or deflect air away from theradiator.

3.

4.

5.

6.

5

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Indicators

Clutch lever

Headlight dimmerswitch

Turn signal switch

Horn button

Front brake lever

Throttle grip

Engine stop switch

Tachometer

Front brake fluidreservoir

Fuel fill cap

Rearview mirror Rearview mirror

Coolant temperaturemeter

Ignition switchMulti-functiondisplay

Starter button

Passing switch(Except U type)

Headlight switch(Except U type)

Front spring preload adjuster/Front rebound damping adjuster

PARTS LOCATION

6

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Rear brake fluid reservoir

Passenger footpeg

Rear brake pedalOil filler cap

Tool box

Front compressiondamping adjuster

Storagecompartment

Engine oil inspectionwindow

Footpeg

Storage compartment forU-shaped anti-theft lock

7

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Gearshift pedal

Front compressiondamping adjuster

Helmet holder

BatteryFuse

Passengerfootpeg

Footpeg Rear springpreload adjusterRear rebound

damping adjusterSide stand

Coolant reserve tank

Documentcompartment

Rear compressiondamping adjuster

8

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〈 〉

The indicators are contained in theinstrument panel. Their functions aredescribed in the tables on the followingpages.

(1)

(2)

(4)(5)

(3)

(11) (10) (9) (6)(7)(8)(12)

(13)(1) Tachometer(2) Tachometer red zone(3) Fuel indicator(4) Immobilizer system (HISS) indicator

(6) Right turn signal indicator(7) High beam indicator(8) Right control button(9) Neutral indicator

(10) Left control button(11) Information indicator(12) Left turn signal indicator(13) Multi - function display

Except MX, BR type(5) Coolant temperature meter

INSTRUMENTS ANDINDICATORS

9

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(1) Tachometer

(2) Tachometer red zone

(3) Fuel indicator

Shows engine rpm.

Never allow the tachometer needle to enter the redzone, even after the engine has been broken in.

Lights when there is only few fuel left in the tank.The amount of fuel left in the tank when lights andwith the vehicle set upright is approximately:

(Ref.No.) Description

Running the engine beyond recommendedmaximum engine speed (the beginning of thetachometer red zone) can damage the engine.

Function

10

3.5 (0.92 US gal , 0.77 Imp gal)

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This indicator lights for a few seconds when theignition switch is turned ON and the engine stopswitch is at (RUN). It will then go off if theproperly-coded key has been inserted. If animproperly-coded key has been inserted, theindicator will remains on and the engine will not start.(page 48)

Shows coolant temperature (page 19).

Flashes when the right turn signal operates.

Light when the headlight is on high beam.

(4) Immobilizer system(HISS) indicator

(5) Coolant temperaturemeter

(6) Right turn signal indicator(green)

(7) High beam indicator (blue)

Function(Ref. No.) Description

11

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－

(8) Right control button

(9) Neutral indicator (green)

(10) Left control button

(11) Information indicator(red)

(12) Left turn signal indicator(green)

This button is used to adjust the time.

This button is used to adjust the time or to changethe speed and mileage units for the speedometer/odometer/tripmeter.

Lights when the transmission is in neutral.

The button is used to adjust the time, to reset thetripmeter, or to select the tripmeter A or B.

The indicator lights or flashes when there is anyabnormality in the coolant temperature, engine oilpressure, and/or PGM-FI (Programmed FuelInjection) system.See page 16 19.

Flashes when the left turn signal operates.

(Ref. No.) Description FunctionExcept E type:

For E type:

12

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－

(13) Multi-function display

Speedometer

Odometer

Tripmeter A and B

Digital clock

Information display

The display includes the following functions;

Shows riding speed (page 20).

Shows accumulated mileage (page 20).

Shows mileage per trip (page 20).

Shows hour and minute (page 22).

Includes coolant temperature, low oil pressure, andPGM-FI indicators which light when there is eachabnormality.See page 16 19.

(Ref. No.) Description Function

13

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Multi-function display ( ) includes thefollowing functions:

(1)

(2)

(4)

(5)

(3)

(6)

(7)

(4) Tripmeter

SpeedometerOdometerTripmeterDigital clockInformation display

1

(5) Digital clock

(2) Speedometer

(7) Right control button(8) Left control button(9) Information indicator

(3) Odometer

(1) Multi-function display(8)

(9)

(6) Information display

Multi-function Display

14

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Both digital clock and tripmeter will reset ifthe battery is disconnected.

When the ignition switch is turned ON, thered information indicator lights, and boththe multi-function display and coolanttemperature meter will temporarily show allthe modes and digital segments so you canmake sure the liquid crystal display isfunctioning properly.

The unit ‘‘mph’’ ( ) will be displayed onlyfor E type.

(1)

(1) ‘‘mph’’

1

Initial DisplayMulti-function display

Coolant temperature meter

15

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The red information indicator ( ) lightswhen there is any abnormality in thecoolant temperature and/or engine oilpressure. As this happen, the coolanttemperature indicator ( ) and/or low oilpressure indicator ( ) contained in theinformation display ( ) will also go on.

The red information indicator lights orflashes when there is any abnormality in thePGM-FI (Programmed Fuel Injection)system regardless of abnormality of others.As this happen, the PGM-FI indicator ( )contained in the information display willalso go on.

(1)

(5)(3)1

53

2

(1) Information indicator(2) Coolant temperature indicator(3) Low oil pressure indicator(4) PGM-FI indicator(5) Information display

(4)(2)

4

Information Indicator and InformationDisplay

16

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The low oil pressure indicator ( ) goes onand the red information indicator ( ) lightswhen engine oil pressure is below thenormal operating range.

Both indicator should go on when ignitionswitch is ON and engine is not running.Both should go off when the engine starts,except for occasional flickering at or nearidling speed when the engine is warm.

(2)

12 (1)

(1) Low oil pressure indicator(2) Information indicator

Low Oil Pressure Information

Running the engine with insufficientoil pressure may cause serious enginedamage.

17

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The PGM-FI indicator ( ) goes on and thered information indicator ( ) lights orflashes when there is any abnormality in thePGM-FI (Programmed Fuel Injection)system.The PGM-FI indicator should also go on fora few seconds and then go off when theignition switch is turned ON and enginestop switch is at (RUN).

If the PGM-FI indicator goes on and redinformation indicator lights or flashes at anyother time, reduce speed and take themotorcycle to your Honda dealer as soon aspossible.

(1)

(2)

12

(1) PGM-FI indicator(2) Information indicator

PGM-FI Information

18

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－－

－

Coolant temperature meter ( ) showscoolant temperature digitally.

When the coolant temperature reaches122°C, the display begins to flash. At thesame time, the coolant temperatureindicator ( ) goes on and the redinformation indicator ( ) lights.If this occurs, stop the engine and check thereserve tank coolant level. Read pages

and to not ride the motorcycleuntil the problem has been corrected.

1Overheating message

(1)(2)

Temperature display

(3)

32

3637

Below 34°C

Between 35°Cand 132°C

Above 132°C

‘‘ ’’ is displayed.

Actual coolant tempera-ture is indicated.

The display will remain‘‘132°C’’

(1) Coolant temperature meter(3) Information indicator(2) Coolant temperature indicator

Coolant Temperature Meter

Exceed ing max imum runningtemperature may cause seriousengine damage.

19

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There are two tripmeters, tripmeter A ( )and tripmeter B ( ). Switch between the Aand B displays by pressing the left controlbutton ( ) repeatedly.To reset the tripmeter, push and hold theleft control button with the display in thetripmeter A or tripmeter B mode.

Shows mileage par trip.

Shows accumulated mileage.

Shows riding speed.(2)

(4)

(4)

(5)

(6)

(1)

(3)

56

4

(1) Speedometer(2) Odometer(3) Tripmeter

(4) Left control button(5) Tripmeter A(6) Tripmeter B

Speedometer/Odometer/Tripmeter

Tripmeter

Odometer

Speedometer

20

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The speedometer displays both ‘‘km/h’’ and‘‘mph’’.Push the right control button ( ) to select‘‘km/h’’ or ‘‘mph’’.

(7)

7

(7) Right control button

Speed Unit Change(E type only)

21

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

Turn the ignition switch ON.Press the left control button whilepressing the right control button. Theclock will be set in the adjust mode withthe minute display flashing.

Set hour and minute.The clock will alternate between thehour and minute adjust modes eachtime the left control button is pressed.

(1)

(2)

1.2.

3.

(3)

(4)

(5)

(1) Digital clock(2) Left control button(3) Right control button

(4) Minute adjust mode(Minute display flashing)

(5) Hour adjust mode(Hour display flashing)

Digital clock

22

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To set the hour, set the clock in thehour adjust mode and press the rightcontrol button until the desired hourand AM/PM are displayed.

Wait approximately seconds; thedisplay will stop flashing automatically.Adjustment will be cancelled when theignition switch is turned OFF while theclock is in the adjust mode.

To set the minute, set the clock in theminute adjust mode and press the rightcontrol button until the desired minuteis displayed. The minute display willreturn to ‘‘00’’ when ‘‘60’’ is reachedwithout affecting the hour display.

4. 10

23

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To reduce (SOFT) :Turn the adjuster counterclockwise towardSOFT for a light load and smooth roadcondition.To increase (HARD) :Turn the adjuster clockwise toward HARDfor a firmer ride and rough road condition.

Adjust the spring preload by turning thepreload adjuster (1) with the 22 mm wrenchprovided in the tool kit.

To return to the standard posision, turn theadjusters until the 4th groove from the topaligns with the top surface of the fork caps.

(1)

Spring preload:

Standard posision:

(1) Preload adjuster

MAJOR COMPONENTS(Information you need to operate this motorcycle)

If the Pre-ride Inspection (page ) isnot performed, severe personal injuryor vehicle damage may result.

SUSPENSIONFront Suspension

62

24

Standard position

06/03/06 13:42:26 3CMCJ600_030

To reduce (SOFT) :Turn the adjuster counterclockwise towardSOFT for a light load and smooth roadcondition.To increase (HARD) :Turn the adjuster clockwise toward HARDfor a firmer ride and rough road condition.

To adjust the adjuster to the standardposition, proceed as follows:

Turn the damping adjuster ( ) clockwiseuntil it will no longer turn (lightly seats).This is the full hard setting.The adjuster is set in the standardposition when the adjuster is turnedcounterclockwise approximately turnso that its punch mark ( ) aligns with thereference mark ( ).

(1)

(3)

1.

2.

1

32

(2)

1

Rebound damping:

(3) Reference mark(1) Damping adjuster(2) Punch mark

25

06/03/06 13:42:32 3CMCJ600_031

To reduce (SOFT) :Turn the adjuster counterclockwise towardSOFT for a light load and smooth roadcondition.To increase (HARD) :Turn the adjuster clockwise toward HARDfor a firmer ride and rough road condition.

To adjust the adjuster to the standardposition, proceed as follows:

Turn the damping adjuster ( ) clockwiseuntil it will no longer turn (lightly seats).This is the full hard setting.The adjuster is set in the standardposition when the adjuster is turnedcounterclockwise approximately turnso that its punch mark ( ) aligns with thereference punch mark ( ).

1

23

1.

2.

Compression damping:

1.5

(3)

(2)

(1)

(1) Damping adjuster(2) Punch mark(3) Reference punch mark

26

06/03/06 13:42:37 3CMCJ600_032

To reduce (SOFT) :Turn the adjuster counterclockwise towardSOFT for a light load and smooth roadcondition.To increase (HARD) :Turn the adjuster clockwise toward HARDfor a firmer ride and rough road condition.

To adjust the adjuster to the standardposition, proceed as follows:

Turn the damping adjuster ( ) clockwiseuntil it will no longer turn (lightly seats).This is the full hard setting.The adjuster is set in the standardposition when the adjuster is turnedcounterclockwise approximately turnso that its punch mark ( ) aligns with thereference punch mark ( ).

Rebound damping: (1)

(2)

1

23

2.

1.(3)

2(1) Damping adjuster(2) Punch mark

(3) Reference punchmark

Rear Suspension

27

06/03/06 13:42:43 3CMCJ600_033

To reduce (SOFT) :Turn the adjuster counterclockwise towardSOFT for a light load and smooth roadcondition.To increase (HARD) :Turn the adjuster clockwise toward HARDfor a firmer ride and rough road condition.

To adjust the adjuster to the standardposition, proceed as follows:

Turn the damping adjuster ( ) clockwiseuntil it will no longer turn (lightly seats).This is the full hard setting.The adjuster is set in the standardposition when the adjuster is turnedcounterclockwise approximately turnso that its punch mark ( ) aligns with thereference punch mark ( ).

Compression damping:(1)

(2)

(3)

1.

2.

1

23

1(1) Damping adjuster(2) Punch mark

(3) Reference punchmark

28

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The spring preload adjuster ( ) hasspring preload positions for different

load or riding conditions.Use the pin spanner ( ) and extension bar( ) to adjust the rear shock. Positions to

are for a light load and smooth roadconditions. Position is the standardposition. Positions to increase springpreload for a stiffer rear suspension and canbe used when the motorcycle is moreheavily loaded.

Spring preload:1

(3)

(2)(1)

23

9

13

45 9

(1) Spring adjuster(2) Pin spanner

(3) Extension bar

7

6

89

332211 44 55

The rear shock absorber assemblyincludes a damper unit that containshigh pressure nitrogen gas. Theinstructions found in this owner’smanual are limited to adjustment ofthe shock assembly only. Do notattempt to disassemble, disconnect orservice the damper unit; an explosioncausing serious injury may result.Puncture or exposure to flame mayalso result in an explosion, causingserious injury.Service or disposal should only bedone by your Honda dealer or aqualif ied mechanic, equipped withthe proper tools, safety equipmentand the official Honda Shop Manual.

29

06/03/06 13:42:56 3CMCJ600_035

Both the front and rear brakes are thehydraulic disc types.As the brake pads wear, the brake fluidlevel drops.There are no adjustments to perform, butfluid level and pad wear must be inspectedperiodically. The system must be inspectedfrequently to ensure there are no fluid leaks.If the control lever or pedal free travelbecomes excessive and the brake pads arenot worn beyond the recommended limit(page ), there is probably air in the brakesystem and it must be bled. See your Hondadealer for this service.

Front Brake Fluid Level:

102

BRAKES Front Brake

Brake fluid may cause irritation.Avoid contact with skin or eyes. Incase of contact, f lush thoroughly withwater and call a doctor if your eyeswere exposed.KEEP OUT OF REACH OF CHIL-DREN.

Handle brake fluid with care becauseit can damage plastic and paintedsurfaces.When adding brake f luid, be sure thereservoir is horizontal before the capis removed or brake fluid may spillout.Use only DOT 4 brake fluid from asealed container.Never allow contaminants such asdirt or water to enter the brake fluidreservoir.

30

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Check that the fluid level is above theLOWER level mark ( ) with the motorcyclein an upright position.Brake fluid must be added to the reservoirwhenever the fluid level begins to reach theLOWER level mark ( ). Remove thescrews ( ), reservoir cover ( ), diaphragmplate ( ), and diaphragm ( ). Fill thereservoir with DOT 4 BRAKE FLUID froma sealed container up to the UPPER levelmark ( ). Reinstall the diaphragm,diaphragm plate, and cover. Tighten thescrews securely.

Other Checks:Make sure there are no fluid leaks. Checkfor deterioration or cracks in the hoses andfittings.

1

24

35

6

1

(1)(6)

(3)

(4)

(5)

(2)

(1)

(1) LOWER level mark

(2) Screws(3) Reservoir cover(4) Diaphragm plate

(5) Diaphragm(6) UPPER level mark

31

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The distance between the tip of the brakelever ( ) and the grip can be adjusted byturning the adjuster dial ( ) while pushingthe lever forward.

Rear Brake Fluid Level:

(3)(1)

(2)

(4)

21

Front Brake Lever:

(1) Front brake lever(2) Adjuster dial

(3) Numbers(4) Index mark

Brake fluid may cause irritation.Avoid contact with skin or eyes. Incase of contact, f lush thoroughly withwater and call a doctor if your eyeswere exposed.KEEP OUT OF REACH OF CHIL-DREN.

Handle brake fluid with care becauseit can damage plastic and paintedsurfaces.When adding brake f luid, be sure thereservoir is horizontal before the capis removed or brake fluid may spillout.Use only DOT 4 brake fluid from asealed container.Never allow contaminants such asdirt or water to enter the brake fluidreservoir.

Rear Brake

Align the numbers ( ) on the adjusterdial with index mark ( ).4

3

32

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Check that the fluid level is above theLOWER level mark ( ) with the motorcyclein an upright position.Brake fluid must be added to the reservoirwhenever the fluid level begins to reach theLOWER level mark ( ). Remove the bolt( ).Remove the reservoir cap ( ), diaphragmplate ( ), and diaphragm ( ). Fill thereservoir with DOT 4 BRAKE FLUID froma sealed container up to the UPPER levelmark ( ). Reinstall the diaphragm,diaphragm plate, cap and bolt securely.

Other Checks:Make sure there are no fluid leaks. Checkfor deterioration or cracks in the hoses andfittings.

1

2

(1)

1 (4)

(5)(6)

(2)

(3)

34 5

6

(1) LOWER level mark

(2) Bolt(3) Reservoir cap(4) Diaphragm plate

(5) Diaphragm(6) UPPER level mark

33

06/03/06 13:43:23 3CMCJ600_039

－ －

Clutch adjustment may be required if themotorcycle stalls when shifting into gear ortends to creep; or if the clutch slips, causingacceleration to lag behind engine speed.Minor adjustments can be made with theclutch cable adjuster ( ) at the lever ( ).Normal clutch lever free play is:

Loosen the lock nut ( ) and turn theadjuster ( ). Tighten the lock nut ( )and check the adjustment.If the adjuster is threaded out near itslimit or if the correct free play cannot beobtained, loosen the lock nut ( ) and turnin the cable adjuster ( ) completely.Tighten the lock nut ( ).

21.3 2

2.

23 31

2

(2)

(1)

(3)

((BB))

((AA))

(A) Increase free play(B) Decrease free play

(2) Lock nut(3) Clutch cable adjuster

(1) Clutch lever

CLUTCH

34

10 20 mm (0.4 0.8 in)

06/03/06 13:43:30 3CMCJ600_040

Start the engine, pull in the clutch leverand shift into gear. Make sure the enginedoes not stall and the motorcycle doesnot creep. Gradually release the clutchlever and open the throttle. Themotorcycle should begin to movesmoothly and accelerate gradually.

Loosen the lock nut ( ) at the lower endof the cable. Turn the adjusting nut ( ) toobtain the specified free play. Tighten thelock nut ( ) and check the adjustment.

If proper adjustment cannot be obtainedor the clutch does not work correctly, seeyour Honda dealer.

Remove the right middle fairing (page58) .

Other Checks:Check the clutch cable for kinks or signs ofwear that could cause sticking or failure.Lubricate the clutch cable with acommercially available cable lubricant toprevent premature wear and corrosion.

Install the right middle fairing.

5

3.

4

5

4. (4)(5) ((AA))

5.6.

((BB))

(4) Adjusting nut(5) Lock nut

(A) Increase free play(B) Decrease free play

35

06/03/06 13:43:38 3CMCJ600_041

The owner must properly maintain thecoolant to prevent freezing, overheating,and corrosion. Use only high qualityethylene glycol antif reeze containingcorrosion protection inhibitors specificallyrecommended for use in aluminum engines.(SEE ANTIFREEZE CONTAINER LABEL).

The factory provides a 50/50 solution ofantifreeze and distilled water in thismotorcycle. This coolant solution isrecommended f or most operat ingtemperatures and provides good corrosionprotection. A higher concentration ofantifreeze decreases the cooling systemperformance and is recommended onlywhen additional protection against freezingis needed. A concentration of less than 40/60 (40% antifreeze) will not provide propercorrosion protection. During freezingtemperatures, check the cooling systemfrequently and add higher concentrations ofantifreeze (up to a maximum of 60%antifreeze) if required.

COOLANTCoolant Recommendation

Use only low-mineral drinking wateror distilled water as a part of theantifreeze solution. Water that is highin mineral content or salt may beharmful to the aluminum engine.Using coolant with silicate inhibitorsmay cause premature wear of waterpump seals or blockage of radiatorpassages.Using tap water may cause enginedamage.

36

06/03/06 13:43:43 3CMCJ600_042

If the reserve tank is empty, or if coolantloss is excessive, check for leaks and seeyour Honda dealer for repair.

Check the coolant level in the reserve tank( ) while the engine is at the normaloperating temperature with the motorcyclein an upright position. If the coolant level isbelow the LOWER level mark ( ), removethe reserve tank cap ( ) and add coolantmixture until it reaches the UPPER levelmark ( ). Always add coolant to the reservetank. Do not attempt to add coolant byremoving the radiator cap.

The reserve tank is located behind the leftside of fairing.

1

3

2

4

(1) (4)

(2)(3)

(1) Reserve tank(2) UPPER level mark

(3) LOWER level mark(4) Reserve tank cap

Keep hands and clothing away fromthe cool ing f an, as i t s t ar t sautomatically.

Inspection

Do not remove the radiator cap whenthe engine is hot. The coolant is underpressure and could scald you.

37

06/03/06 13:43:49 3CMCJ600_043

－

The fuel tank capacity including the reservesupply is:

Use unleaded or low-lead petrol with aresearch octane number of 91 or higher.We recommend that you use unleadedpetrol because it produces fewer engine andspark plug deposits and extends the life ofexhaust system components.

To open the fuel fill cap ( ), insert theignition key ( ) and turn it clockwise. Thefuel fill cap is hinged and will lift up.After refueling, to close the fuel fill cap,push the fuel fill cap into the filler neck untilit snaps closed and locks. Remove the key.

Use unleaded petrol with a research octanenumber of 91 or higher.The use of leaded petrol will causepremature damage to the catalyticconverter.

Use unleaded petrol with a research octanenumber of 91 or higher.

Use unleaded or low-lead petrol with aresearch octane number of 88 or higher.Recommend Extra petrol.

(1)

12

(2)

(2) Ignition key(1) Fuel fill cap

Fuel TankFUEL For E, F, ED:

For G:

For U, BR:

For MX:

38

18.0 (4.76 US gal , 3.96 Imp gal)

06/03/06 13:43:57 3CMCJ600_044

(3)

(3) Filler neck

Petrol is extremely flammable and isexplosive under certain conditions.Refuel in a well-ventilated area withthe engine stopped. Do not smoke orallow flames or sparks in the areawhere petrol is stored or where thefuel tank is refueled.Do not overfill the tank (there shouldbe no fuel in the filler neck ( )). Afterrefueling, make sure the fuel fill capis closed securely.Be careful not to spill fuel whenrefueling. Spilled fuel or fuel vapormay ignite. If any fuel is spilled, makesure the area is dry before startingthe engine.Avoid repeated or prolonged contactwith skin or breathing of vapor.K E E P O U T O F R E A C H O FCHILDREN.

If ‘‘spark knock’’ or ‘‘pinking’’ occursat a steady engine speed undernormal load, change brands of petrol.If spark knock or pinking persists,consult your Honda dealer. Failure todo so is considered misuse, and dam-age caused by misuse is not coveredby Honda’s Limited Warranty.

3

39

06/03/06 13:44:02 3CMCJ600_045

Fuel system damage or engine performa-nce problems resulting from the use offuels that contain alcohol is not coveredunder the warranty. Honda cannotendorse the use of fuels containingmethanol since evidence of theirsuitability is as yet incomplete.Before buying fuel from an unfamiliarstation, try to find out if the fuel containsalcohol. If it does, confirm the type andpercentage of alcohol used. If you noticeany undesirable operating symptomswhile using a petrol that contains alcohol,or one that you think contains alcohol,switch to a petrol that you know does notcontain alcohol.

If you decide to use a petrol containingalcohol (gasohol), be sure it’s octane ratingis at least as high as that recommended byHonda. There are two types of ‘‘gasohol’’:one containing ethanol, and the other con-taining methanol. Do not use petrol thatcontains more than 10 % ethanol. Do not usepetrol containing methanol (methyl or woodalcohol) that does not also containcosolvents and corrosion inhibitors formethanol. Never use petrol containing morethan 5 % methanol, even if it has cosolventsand corrosion inhibitors.

Petrol Containing Alcohol

40

06/03/06 13:44:06 3CMCJ600_046

Check the engine oil level each day beforeriding the motorcycle.The level must be maintained between theupper ( ) and lower ( ) level marks in theinspection window ( ).

Reinstall the oil filler cap. Check for oilleaks.

If required, remove the oil filler cap ( )and add the specified oil (see page ) upto the upper level mark. Do not overfill.

Start the engine and let it idle for a fewminutes. Make sure the red informationindicator and low oil pressure indicatorgoes off. If the light remains on, stop theengine immediately.Stop the engine and hold the motorcyclein an upright position on firm, levelground.After a few minutes, check that the oillevel is between the upper ( ) and lower( ) level marks in the inspection window( ).

1 23

1.

2.

3.

4.

123

4

5.

(2)

(1)

(3)

(4)

78(4) Filler cap(1) Upper level mark

(2) Lower level mark(3) Inspection window

ENGINE OILEngine Oil Level Check

Running the engine with insufficientoil pressure may cause serious enginedamage.

41

06/03/06 13:44:14 3CMCJ600_047

This motorcycle is equipped with tubelesstyres, valves, and wheel rims. Use only tyresmarked ‘‘TUBELESS’’ and tubeless valveson rims marked ‘‘TUBELESS TYREAPPLICABLE.’’Proper air pressure will provide maximumstability, riding comfort and tyre life.Check tyre pressure frequently and adjust ifnecessary.

Tyre pressure should be checked beforeyou ride while the tyres are ‘‘cold’’.Tubeless tyres have some degree ofselfsealing ability if they are punctured,and leakage is often very slow. Inspectvery closely for punctures, especially ifthe tyre is not fully inflated.

Tyre size

FrontRear

Driver onlyCold tyrepressures

kPa(kgf/ , psi)

FrontRear

Driver and one passengerFrontRear

BRIDGESTONEFrontRear

FrontRear

MICHELIN

Tyre brandTUBELESS

ONLY

TUBELESS TYRES

42

120/70 ZR17 (58W)190/50 ZR17 (73W)

250 (2.50 , 36)290 (2.90 , 42)

250 (2.50 , 36)290 (2.90 , 42)

Pilot SPORT EPilot SPORT E

BT010RBT010F

06/03/06 13:44:28 3CMCJ600_048

〈 〉

Check the tyres for cuts, embedded nailsor other sharp objects. Check the rims fordents or deformation. If there is anydamage, see your Honda dealer for repair,replacement, and balancing.

Replace tyres before tread depth at thecenter of the tyre reaches the followinglimit:

German law prohibits use of tyres whosetread depth is less than 1.6 mm.

Front :Rear :

Minimum tread depth

For GermanyImproper tyre inflation will causeabnormal tread wear and create asafety hazard. Underinflation mayresult in the tyre slipping on, orcoming off of the rim causing tyredeflation that may result in a loss ofvehicle control.Operation with excessively worntyres is hazardous and will adverselyaffect traction and handling.

43

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

06/03/06 13:44:33 3CMCJ600_049

See your Honda Dealer.Tyre Repair/Replacement:

Do not install tube-type tyres ontubeless rims. The beads may not seatand the tyres could slip on the rims,causing tyre deflation that may resultin a loss of vehicle control.

The use of tyres other than thoselisted on the tyre information labelmay adversely affect handling.

Proper wheel balance is necessary forsa f e , s t ab le handl ing o f t hemotorcycle. Do not remove or changeany wheel balance weights. Whenwheel balancing is required, see yourHonda dealer. Wheel balancing isrequired af t er t y re repair orreplacement.

To avoid possible repair failure andtyre deflation that may result in a lossof vehicle control, do not exceed 80km/h (50 mph) for the first 24 hours,or 130 km/h (80 mph) at any time,after tyre repair.

Do not install a tube inside a tubelesstyre. Excessive heat build-up maycause the tube to burst resulting inrapid tyre deflation that may result ina loss of vehicle control.Replace the tyre if the sidewall ispunctured or damaged. Sidewallf lexing may cause repair failure andtyre deflation that may result in a lossof vehicle control.

Do not try to remove tubeless tyreswithout special tools and rimprotectors. You may damage the rimsealing surface or disfigure the rim.

44

06/03/06 13:44:39 3CMCJ600_050

The ignition switch (1) is below theindicator panel.

LOCK(steering lock)OFF

ON

Steering is locked. Engine and lights cannot beoperated.Engine and lights cannot be operated.

Engine and lights can be operated.

Key can beremovedKey can beremovedKey cannot beremoved

(1)

(1) Ignition switch

ESSENTIAL INDIVIDUAL COMPONENTSIGNITION SWITCH

Key Position Function Key Removal

45

06/03/06 13:44:45 3CMCJ600_051

〈 〉 〈 〉

This motorcycle has two keys and a keynumber plate.

(2)

(1)

(2)

(1)

Except MX, BR type For MX, BR type

(1) Keys (2) Key number plate

KEYS

46

06/03/06 13:44:50 3CMCJ600_052

〈 〉

〈 〉You will need the key number if you everhave to replace a key. Store the plate in asafe place.

To reproduce keys, bring all keys, keynumber plate and motorcycle to your Hondadealer.

Up to four keys can be registered with theimmobilizer system (HISS), including theones in hand.

These keys contain electronic circuitsthat are activated by the immobilizersystem (HISS). They will not work tostart the engine if the circuits aredamaged.

Keep the keys away from magneticobjects.

Do not grind, drill or in any way alterthe original shape of the keys.

Do not drop the keys or set heavyobjects on them.

If all keys are lost, the PGM-FI unit/ignition control module must be replaced.To avoid this possibility we recommendthat if only one key is lef t, youimmediately have it reproduced to ensurethat a back-up is available.

Except MX, BR type

Except MX, BR type

47

06/03/06 13:44:56 3CMCJ600_053

〈 〉

The immobilizer system (HISS) protectsyour motorcycle from theft. A properly-coded key must be used in the ignitionswitch for the engine to start. If animproperly-coded key (or other device) isused the engine’s starting circuit is disabled.

HISS is the abbreviation of Honda IgnitionSecurity System.

When the ignition switch is turned ON andthe engine stop switch is at ‘‘ ’’ (RUN),the immobilizer system (HISS) indicatorlights for a few seconds, then go off. If theindicator remains on, it means the systemdoes not recognize the coding of the key.Turn the ignition switch to OFF, removethe key, reinsert and turn the switch ONagain.

If all keys are lost, the PGM-FI unit/ignition control module must be replaced.

Do not attempt to alter the immobilizersystem (HISS) or add other devices to it.Electrical problems could result, makingit impossible to start your motorcycle.

The system may not recognize the key’scoding if any other immobilizer key isnear the ignition switch. To make surethe system recognize the key code, keepeach immobilizer key on a separate ring.

If the system repeatedly does not recognizethe coding of your key, contact your Hondadealer.

IMMOBILIZER SYSTEM (HISS)Except MX, BR type

48

06/03/06 13:45:01 3CMCJ600_054

The starter button (2) is below the enginestop switch (1).The engine stop switch ( ) is next to the

throttle grip. When the switch is in the(RUN) position, the engine will operate.

When the switch is in the (OFF)position, the engine will not operate. Thisswitch is intended primarily as a safety or e-mergency switch and should normally re-main in the (RUN) position.

When the starter button is pressed, thestarter motor cranks the engine. If theengine stop switch is in the (OFF)position, the starter motor will not operate.See page for the starting procedure.

1

(1)

(2)

63

(1) Engine stop switch(2) Starter button

RIGHT HANDLEBAR CONTROLSEngine Stop Switch

Starter Button

49

06/03/06 13:45:07 3CMCJ600_055

〈 〉

Headlight, taillight, positionlight and meter lights on.Position light, taillight andmeter lights on.Headlight, taillight, positionlight and meter lights off.

Push the dimmer switch to (HI) toselect high beam or to (LO) to selectlow beam.

When this switch is pressed, the headlightflashes on to signal approaching cars orwhen passing.

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

signal off.

Press the button to sound the horn.:

:

OFF(dot):

The headlight switch ( ) has threepositions: , and OFF, marked by awhite dot under .

(1)

(3)

(5)

(4)

(2)

1

(1) Headlight switch(2) Headlight dimmer switch(3) Passing light control switch(4) Turn signal switch(5) Horn button

Turn Signal SwitchLEFT HANDLEBAR CONTROLS

Headlight Switch

Headlight Dimmer Switch

Passing Light Control Switch

Horn Button

(4)

(5)

(1)

(2)

(3)

Except U type

50

06/03/06 13:45:17 3CMCJ600_056

〈 〉

Push the dimmer switch to (HI) toselect high beam or to (LO) to selectlow beam.

Press the button to sound the horn.

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

signal off.

(1)

(2)

(3)

(1) Headlight dimmer switch(2) Turn signal switch(3) Horn button

Headlight Dimmer Switch

LEFT HANDLEBAR CONTROLS

Horn Button

Turn Signal Switch

(3)

(2)

(1)

U type only

51

06/03/06 13:45:24 3CMCJ600_057

To lock the steering, turn the handlebars allthe way to the left or right, turn the key ( )to LOCK while pushing in. Remove the key.To unlock the steering, turn the key to OFFwhile pushing in.

1

(A)

(1) Ignition key

((BB))

(A)(C)

(1)

(A) Push in(B) Turn to LOCK(C) Turn to OFF

STEERING LOCK

Do not turn the key to LOCK whileriding the motorcycle; loss of vehiclecontrol will result.

To lock

To unlock

FEATURES(Not required for operation)

52

06/03/06 13:45:29 3CMCJ600_058

To remove the front seat (1), pull up theseat end and remove the two mountingbolts (2), and then pull the seat back and up.To install the front seat, insert the tab (3)into the recess under the frame and tightenthe mount bolts securely.

(3)

(2)

(2)

(1)

(1) Front seat(2) Mounting bolts

(3) Tab

SEAT

Front seat

53

06/03/06 13:45:33 3CMCJ600_059

To open the rear seat (4), insert the ignitionkey (5) into the seat lock (6) and turn itclockwise.To close the rear seat , push down on therear of the seat.

(4)

(5)(6)

(4) Rear seat(5) Ignition key

(6) Seat lock

Be sure the seat is locked securely inposition after installation.

Rear seat

54

06/03/06 13:45:36 3CMCJ600_060

The helmet holder is on the back side of therear seat.Open the rear seat ( ). (see page ).Hang the helmets on the holder hook ( ).Close the rear seat and lock it securely.

(2)

(1)12

54

(1) Rear seat(2) Holder hook

HELMET HOLDER

The helmet holder is designed forhelmet security while parked. Do notride with a helmet attached to theholder; the helmet may interfere withsafe operation and result in loss ofcontrol.

55

06/03/06 13:45:40 3CMCJ600_061

This owner’s manual and other documentsshould be stored in the document bag.When washing your motorcycle, be carefulnot to flood this area with water.

The document bag (1) is in the documentcompartment (2) on the reverse side of therear seat (3).

The storage compartment (4) is under therear seat.This compartment is for light weight items.Do not carry more than inthis compartment.The tool kit (5) should be stored in thecompartment.When washing your motorcycle, be carefulnot to flood this area with water.

(2)

(1)(3)

(4)

(5)

(1) Document bag(2) Document compartment

(4) Storage compartment(3) Rear seat (5) Tool kit

DOCUMENT BAG STORAGE COMPARTMENT

56

2.0 kg (4.5 lbs)

06/03/06 13:45:46 3CMCJ600_062

Some U-shaped locks may not be storedin the compartment due to their size ordesign.

The rear fender has a storage compartmentto store a U-shaped anti-theft lock under therear seat. After storing, be sure to fastenthe lock with the rubber band ( ) securely.1

(1)(1) Rubber band

STORAGE COMPARTMENT FOR U-SHAPED ANTI-THEFT LOCK

57

06/03/06 13:45:49 3CMCJ600_063

Installation can be done in the reverseorder of removal.

The right and left middle fairings can beremoved in the same manner.

Pull the tab (1).Remove the bolt A (2).Remove the bolt B (3), then remove thebolt C (4).Pull out the hook (5) from the grommet(6).

2.1.

3.

(4)4.

(4)

(1)

(2)(6)(5)

(1)

(2) (6) (5)

(3)

(4)

(3)

(4)

(1) Tab (2) Bolt A(3) Bolts B(4) Bolts C

(5) Hook(6) Grommet

MIDDLE FAIRINGInstallation:

Removal:

58

06/03/06 13:45:56 3CMCJ600_064

Installation can be done in the reverseorder of removal.Run the tubes through the clip of thelower fairing.

Remove the middle fairing. ( page )Remove the bolts A (1).Remove the bolts B (2).

2.1.

3.

1.

(1)

(2)

(3)

58

(1) Bolts A(2) Bolts B

(3) Lower fairing

LOWER FAIRING

Removal:

Installation:

59

06/03/06 13:46:01 3CMCJ600_065

The right and left inner panels can beremoved in the same manner.

Remove the middle fairing (page 58).Remove the clips (1).Remove the bolt A (2).Remove the bolt B (3).Remove the inner panel (4) while liftingfront of the fuel tank (5).Install the bolts B.

Installation can be done in the reverseorder of removal.

3.2.1.

4.5.

6.

(2)

(1)

(4) (5)

(3)

(1) Clips(2) Bolt A(3) Bolt B

(4) Inner panel(5) Fuel tank

INNER PANEL

Installation:

Removal:

60

06/03/06 13:46:06 3CMCJ600_066

Vertical adjustment can be made by turningthe adjuster ( ) in or out as necessary.Obey local laws and regulations. (1)

1

((BB))

((AA))

(A) Up(B) Down

(1) Adjuster

H E A D L I G H T A I M V E R T I C A LADJUSTMENT

61

06/03/06 13:46:10 3CMCJ600_067

－

－

－

－

－

－

－

－

－

－

－

－

－

Inspect your motorcycle every day beforeyou ride it. The items listed here will onlytake a few minutes to inspect, and in thelong run they can save time, expense, andpossibly your life.

Engine oil level add engine oil ifrequired (page ). Check for leaksFuel level fill fuel tank when necessary(page ). Check for leaksCoolant level add coolant if required.Check for leaksFront and rear brakes check operation;make sure there is no brake fluid leakage

Tyres check condition and pressure

Drive chain check condition and slack(page ). Adjust and lubricate ifnecessary.Throttle check for smooth opening andfull closing in all steering positionsLights and horn check that headlight,tail/brake light, turn signals, indicatorsand horn function properly.Engine stop switch check for properfunction

Correct any discrepancy before you ride.Contact your Honda dealer for assistance ifyou cannot correct the problem.

Side stand ignition cut-off system checkfor proper function

6.

8.

7.

5.

9.

1.

3.

2.

4.

.

.

.

10.41

38

(pages 36 37).

(pages 30 33).

(pages 42 44).

(page 49 ).

88

(page 96 ).

OPERATIONPRE-RIDE INSPECTION

If the Pre-ride Inspection is notperformed, severe personal injury orvehicle damage may result.

62

06/03/06 13:46:22 3CMCJ600_068

Always follow the proper starting proceduredescribed below.

Do not use the electric starter for morethan 5 seconds at a time. Release thestarter button for approximately 10seconds before pressing it again.

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

This motorcycle is equipped with a sidestand ignition cut-off system. The enginecannot be started if the side stand is down,unless the transmission is in neutral. If theside stand is up, the engine can be started inneutral or in gear with the clutch leverpulled in. After starting with the side standdown, the engine will shut off if thetransmission is put in gear before raisingthe side stand.

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

The immobilizer system (HISS) indicatoris OFF.

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

STARTING THE ENGINE

Never run the engine in an enclosedarea. The exhaust contains poisonouscarbon monoxide gas that can causeloss of consciousness and lead todeath.

Preparation

For G type:

63

06/03/06 13:46:29 3CMCJ600_069

Any Air TemperaturePress the starter button with the throttlecompletely closed.

This motorcycle has an automatic choke.Follow the procedure indicated below.

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

Starting ProcedureThe red information indicator and lowoil pressure indicator should go off afew seconds after the engine starts. Ifboth indicators stays on, stop theengine immediately and check engineoil level. Operating the engine with in-sufficient oil pressure can cause seri-ous engine damage.

64

06/03/06 13:46:34 3CMCJ600_070

If the engine fails to start after repeatedattempts, it may be flooded engine.

Leave the engine stop switch set to(RUN).

Open throttle fully.Press the starter button for 5 seconds.Then f ollow the normal start ingprocedure.If the engine start, then open the throttleslightly if idling is unstable.If the engine does not start, wait for 10seconds, then follow steps 1-4 again.

Help assure your motorcycle’s futurereliability and performance by paying extraattention to how you ride during the first500 km (300 miles).During this period, avoid full-throttle startsand rapid acceleration.

1.

3.2.

4.

5.

Flooded engine RUNNING-IN

65

06/03/06 13:46:37 3CMCJ600_071

－

〈 〉

After the engine has been warmed up,the motorcycle is ready for riding.While the engine is idling, pull in theclutch lever and depress the gearshiftpedal to shift into 1st (low) gear.Slowly release the clutch lever and at thesame time gradually increase enginespeed by opening the throt t le .Coordination of the throttle and clutchlever will assure a smooth positive start.When the motorcycle attains a moderatespeed, close the throttle, pull in the clutchlever and shift to 2nd gear by raising thegearshift pedal.This sequence is repeated to progres-sively shift to 3rd, 4th, 5th and 6th(top)gear.

Make sure you understand the functionof the side stand mechanism. (See MAIN-TENANCE SCHEDULE on page andexplanation for SIDE STAND on page

)

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

1.

4.

3.

2.

72

96

RIDING

Review Motorcycle Safety (pages) before you ride.

15

For G type

66

06/03/06 13:46:42 3CMCJ600_072

Coordinate the throttle and brakes forsmooth deceleration.Both front and rear brakes should beused at the same time and should not beapplied strongly enough to lock the wheel,or braking effectiveness will be reducedand control of the motorcycle be difficult.

6.

5.

67

06/03/06 13:46:44 3CMCJ600_073

For normal braking, gradually apply boththe f ront and rear brakes whiledownshifting to suit your road speed.For maximum deceleration, close thethrottle and apply the front and rearbrakes firmly. Pull in the clutch leverbefore coming to a complete stop toprevent stalling the engine.

2.

1.BRAKING

When riding in wet or rainy condi-tions, or on loose surfaces, the abilityto maneuver and stop will be reduced.All of your actions should be smoothunder these conditions. Rapid accel-eration, braking or turning may causeloss of control. For your safety, exer-cise extreme caution when braking,accelerating or turning.

Independent use of only the front orrear brake reduces s t oppingperformance. Extreme braking maycause either wheel to lock, reducingcontrol of the motorcycle.When possible, reduce speed orbrake before entering a turn; closingthe throttle or braking in mid-turnmay cause wheel slip. Wheel slip willreduce control of the motorcycle.

When descending a long, steep grade,use engine compression braking bydownshifting, with intermittent use ofboth brakes. Continuous brakeapplication can overheat the brakesand reduce their effectiveness.Riding with your foot resting on thebrake pedal or your hands on thebrake lever may act uat e t hebrakelight, giving a false indication toother drivers. It may also overheatthe brake, reducing effectiveness.

68

06/03/06 13:46:50 3CMCJ600_074

〈 〉

Always lock the steering and never leavethe key in the ignition switch. Thissounds simple but people do forget.Be sure the registration information foryour motorcycle is accurate and current.Park your motorcycle in a locked garagewhenever possible.Use an additional anti-theft device ofgood quality.Put your name, address, and phonenumber in this Owner’s Manual and keepit on your motorcycles at all times.Many times stolen motorcycles areidentified by information in the Owner’sManuals that are still with them.

NAME:

ADDRESS:

PHONE NO:

After stopping the motorcycle, shift thetransmission into neutral, turn thehandlebar fully to the left, turn theignition switch OFF and remove the key.

Lock the steering to help prevent theft(page ).

Make sure flammable materials such asdry grass or leaves do not come in contactwith the exhaust system when parkingyour motorcycle.

Use the side stand to support themotorcycle while parked.

1.

2.

5.

4.

3.

1.

2.

3.52

ANTI-THEFT TIPSPARKING

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

For G type

69

06/03/06 13:46:58 3CMCJ600_075

The Required Maintenance Schedule specifies how often you should have your motorcycleserved, and what things need attention. It is essential that your motorcycle be served asscheduled to retain its high level of safety, dependability, and emission controlperformance.

These instructions are based on the assumption that the motorcycle will be usedexclusively for its designed purpose. Sustained high speed operation, or operation inunusually wet or dusty conditions, will require more frequent service than specified in theMAINTENANCE SCHEDULE. Consult your Honda dealer for recommendationsapplicable to your individual needs and use.

MAINTENANCE

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The following Maintenance Schedule specifies all maintenance required to keep your motorcycle in peak operatingcondition. Maintenance work should be performed in accordance with standards and specifications of Honda byproperly trained and equipped technicians. Your Honda dealer meets all of these requirements.

10.6

646

12812

181218

241624

302030

362436

Perform the Pre-ride Inspection (page ) at each scheduled maintenance period.I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARYC: CLEAN R: REPLACE A: ADJUST L: LUBRICATE

1,000 km1,000 mi

MONTHS

RRI I

II

RRIIII

R

I

II

IRRIIII

I

IIR

RRIRII

Referto

pages

86

82

78798736

NOTE

NOTE

NOTE

FUEL LINETHROTTLE OPERATIONAIR CLEANERSPARK PLUGS

VALVE CLEARANCEENGINE OILENGINE OIL FILTERENGINE IDLE SPEEDRADIATOR COOLANTCOOLING SYSTEMSECONDARY AIR SUPPLY SYSTEM

FREQUENCY

ITEMS

WHICHEVERCOMESFIRST

ODOMETER READING [NOTE (1)]

62

(2)

(3)

EVERY 12,000km (8,000mi) I ,EVERY 24,000km (16,000mi) R

MAINTENANCE SCHEDULE

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↓NOTE

NOTE

10.6

646

12812

181218

241624

302030

362436

II

I

RI

I

II

I

EVERY 1,000 km (600 mi) I, L

1,000 km1,000 mi

MONTHDRIVE CHAINDRIVE CHAIN SLIDERBRAKE FLUIDBRAKE PAD WEARBRAKE SYSTEMBRAKE LIGHT SWITCHHEADLIGHT AIMCLUTCH SYSTEMEXHAUST VALVE CONTROL CABLESIDE STANDSUSPENSIONNUTS, BOLTS, FASTENERSWHEELS/ TYRESSTEERING HEAD BEARINGS

I

I

I

I

IIIIIII

IIIII

IIIIIIIIIIIII

IRIIIII

IIIII

Referto

pages889430

10230, 102

34

9695

FREQUENCY

ITEMS

WHICHEVERCOMESFIRST

ODOMETER READING [NOTE (1)]

(3)

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

At higher odometer readings, repeat at the frequency interval established here.Service more frequently if the motorcycle is ridden in unusually wet or dusty areas.Replace every 2 years, or at indicated odometer interval, whichever comes first. Replacement requiresmechanical skill.

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

NOTES : 1.2.3.

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×

××

Some roadside repairs, minor adjustmentsand parts replacement can be performedwith the tools contained in the kit.

The tool kit (1) is under the rear seat.

Pin spannerSpark plug wrench10 12 mm box end wrench22 mm box end wrench32 mm box end wrench10 12 mm open end wrench12 14 mm open end wrench8 mm open end wrenchPliersNo.2 Phillips screwdriverNo.2 screwdriverScrewdriver gripExtension bar5 mm hex wrench8 mm box wrenchTool bag

(1)

(1) Tool kit

TOOL KIT

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06/03/06 13:47:36 3CMCJ600_080

The frame and engine serial numbers arerequired when registering your motorcycle.They may also be required by your dealerwhen ordering replacement parts.Record the numbers here for yourreference.

The frame number (1) is stamped on theright side of the steering head.

The engine number (2) is stamped on top ofthe crankcase.

FRAME NO. ENGINE NO.

(1) (2)

(1) Frame number (2) Engine number

SERIAL NUMBERS

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The colour label (1) is attached to thestorage compartment below the rear seat(See page ).It is helpful when ordering replacementparts. Record the colour and code here foryour reference.

(1)

COLOUR

CODE

54

(1) Colour label

COLOUR LABEL

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MAINTENANCE PRECAUTIONS

If your motorcycle is overturned orinvolved in a collision, inspect controllevers, cables, brake hoses, calipers,accessories, and other vital parts fordamage. Do not ride the motorcycle ifdamage impairs safe operation. Haveyour Honda dealer inspect the majorcomponent s, including f rame,suspension and steering parts, formisalignment and damage that youmay not be able to detect.

Stop the engine and support themotorcycle securely on a firm, levelsurf ace bef ore perf orming anymaintenance.

Use new, genuine Honda parts ortheir equivalent for maintenance andrepair. Parts which are not ofequivalent quality may impair thesafety of your motorcycle and theeffective operation of the emissioncontrol systems.

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06/03/06 13:47:51 3CMCJ600_083

(Refer to the maintenance precautions onpage ).

Good engine oil has many desirablequalities. Use only high detergent, qualitymotor oil certified on the container to meetor exceed requirements for API ServiceClassification SE, SF or SG.

Viscosity grade of engine oil should bebased on average atmospheric temperaturein your riding area. The following provides aguide to the selection of the proper grade orviscosity of oil to be used at variousatmospheric temperatures.

77

ENGINE OIL

Viscosity:

Engine Oil

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06/03/06 13:47:57 3CMCJ600_084

Engine oil quality is the chief factoraffecting engine service life. Change theengine oil as specified in the maintenanceschedule (page ).

Change the engine oil with the engine atnormal operating temperature and themotorcycle on its side stand to assurecomplete and rapid draining.

To drain the oil, remove the oil filler capand oil drain plug ( ) and sealing washer( ).

Changing the oil filter requires a special oilfilter tool and a torque wrench. If you do nothave these tools and the necessary skill, werecommend that you have your Hondadealer perform this service. If a torquewrench is not used for this installation, seeyour Honda dealer as soon as possible toverify proper assembly.

Remove the middle fairing (page ) andthe lower fairing (page ).

2.

1.

21

(1)

(2)

71

5859

(2) Sealing washer(1) Oil drain plug

Engine Oil and Filter

To prevent oil leaks and filter damage,never support the engine on the oilf ilter.

A warmed-up engine and the oil in itare hot; be careful not to burnyourself.

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Remove the oil filter ( ) with a filterwrench and let the remaining oil drain out.

Apply a thin coat of engine oil to the newoil filter rubber seal ( ).Use only the Honda genuine oil filter or afilter of equivalent quality specified foryour model. Using the wrong Honda filteror a non-Honda filter which is not ofequivalent quality may cause enginedamage.Using a special tool and a torque wrench,install the new oil filter and tighten to atorque of:

(3)

4.3.

(4)

34

5.

(4) Oil filter rubber seal(3) Oil filter80

26 N·m (2.7 kgf·m , 20 lbf·ft)

06/03/06 13:48:12 3CMCJ600_086

－

When running in very dusty conditions,oil changes should be performed moref requently than specif ied in themaintenance schedule.Please dispose of used engine oil in amanner that is compatible with theenvironment. We suggest you take it in asealed container to your local recyclingcenter or service station for reclamation.Do not throw it in the rubbish or pour iton the ground or down a drain.

Check that the sealing washer on thedrain plug is in good condition and installthe plug. Replace the sealing washerevery other time the oil is changed, oreach time if necessary.Oil Drain Plug Torque:

Fill the crankcase with the recommendedgrade oil; approximately:

Start the engine and let it idle for 2 3minutes.Several minutes after stopping the engine,check that the oil level is at the upperlevel mark in the inspection window withthe motorcycle upright on firm, levelground. Make sure there are no oil leaks.

Install the oil filler cap.Install the middle fairing and the lowerfairing.

8.9.

7.

6.

10.

11.

Used engine oil may cause skin can-cer if repeatedly left in contact withthe skin for prolonged periods.Although this is unlikely unless youhandle used oil on a daily basis, it isstill advisable to thoroughly washyour hands with soap and water assoon as possible after handling usedoil.

81

29 N·m (3.0 kgf·m , 22 lbf·ft)

3.7 (3.9 US qt , 3.3 Imp qt)

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(Refer to the maintenance precautions onpage ).

Do not adjust the spark plug gap. If thegap is out of specification, replace thespark plug with a new one.

Use only ‘‘wire-type feeler gauge’’ tocheck the spark plug gap to preventdamaging the iridium coating of thecenter electrodes. Never use ‘‘leaf-typefeeler gauge’’.

Do not clean the spark plug. If thee lec t r ode is cont a mina t ed w i t haccumulated objects or dirt, replace thespark plug with a new one.

This motorcycle uses the spark plugs thathave a iridium coated center electrode. Besure to observe the following whenservicing the spark plugs.

Recommended plugs:Standard:

For cold climate: (Below 5 °C, 41 °F)

Remove the middle fairing (page 58) andthe lower fairing (page 59).Disconnect the radiator fan connector (1).Disconnect the thermo switch connector(2).Remove the nut (3) and lower radiatormounting bolt (4).Remove the upper radiator mounting bolt(5).

1.

2.3.

4.

5.

(1) Radiator fan connector(2) Thermo switch connector(3) Nut(4) Lower radiator mounting bolt(5) Upper radiator mounting bolt

(2)(5) (1)

(3)

(4)

77

SPARK PLUGS

82

IUH27D (DENSO)

IUH24D (DENSO)

06/03/06 13:48:28 3CMCJ600_088

Move the radiator (6) out of the way andremove the grommet (7) from the hook(8).Pull the radiator toward the front.

Disconnect the ignition coil connectors(9).Disconnect the ignition coils (10) fromthe spark plugs.

6.

7.

8.

9.

(7)

(8) (6) (10) (9)

(6) Radiator(7) Grommet

(8) Hook (9) Ignition coil connectors(10) Ignition coils

Be careful not to damage the radiatorfins.

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Clean any dirt from around the spark plugbases. Remove the spark plugs using theplug wrench ( ) furnished in the tool kit.

Inspect the electrodes and centerporcelain for deposits, erosion or carbonfouling. If the erosion or deposit is heavy,replace the plug.Make sure that the 1.0 mm wire-typefeeler gauge does not insert between thespark plug gap (12). If the gauge isinserted into the gap, replace the plugwith a new one.

10. 11.

12.

11

(11)

(12)

(12) Spark plug gap(11) Spark plug wrench84

06/03/06 13:48:39 3CMCJ600_090

－

Make sure the plug washer is in goodcondition.With the plug washer attached, threadthe spark plug in by hand to preventcross-threading.Tighten a new spark plug 1/2 turn with aspark plug wrench to compress thewasher. If you are reusing a plug, itshould only take 1/8 1/4 turn after theplug seats.

Connect the ignition coil connectors tothe ignition coils as before removal.

Reinstall the ignition coils.

Connect the connector with blue tube(13) to the second ignition coil ascounted from the left side of the engine.

Install the remaining parts in the reverseorder of removal.

15.

16.

17.13.

14.

(13)

18.

(13) Blue tube

The spark plug must be securelytightened. An improperly tightenedplug can become very hot andpossibly damage the engine.Never use a spark plug with an im-proper heat range. Severe enginedamage could result.

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(Refer to the maintenance precautions onpage ).

Check for smooth rotation of the throttlegrip from the fully open to the fullyclosed position at both full steeringpositions.Measure the throttle grip free play at thethrottle grip flange.The standard free play should beapproximately:

To adjust the free play, loosen the locknut ( ) and turn the adjuster ( ).

1.

2.

(1) (2)

1 2

77

(1) Lock nut (2) Adjuster

THROTTLE OPERATION

86

2 6 mm (0.08 0.24 in)

06/03/06 13:48:53 3CMCJ600_092

±(Refer to the maintenance precautions onpage ).The engine must be at normal operatingtemperature for accurate idle speedadjustment. Ten minutes of stop-and-goriding is sufficient.

Adjust idle speed with the throttle stopscrew ( ).

Warm up the engine, shift to neutral, andplace the motorcycle on its side stand.

1.

2.1

(1)

Idle Speed:

((AA))

((BB))

77

(1) Throttle stop screw (A) Increase(B) Decrease

IDLE SPEED

87

1,200 100 min (rpm)(In neutral)

06/03/06 13:48:59 3CMCJ600_093

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(Refer to the maintenance precautions onpage ).The service life of the drive chain isdependent upon proper lubrication andadjustment. Poor maintenance can causepremature wear or damage to the drivechain and sprockets.The drive chain should be checked andlubricated as part of the Pre-ride Inspection(page ). Under severe usage, or whenthe motorcycle is ridden in unusually dustyo r m u d d y a r e a s , m o r e f r e q u e n tmaintenance will be necessary.

Check slack in the lower drive chain runmidway between the sprockets.Drive chain slack should be adjusted toallow the following vertical movement byhand:

Turn the engine off, place the motorcycleon its side stand and shif t thetransmission into neutral.

Roll the motorcycle forward. Stop. Checkdrive chain slack. Repeat this procedureseveral times. Drive chain slack shouldremain constant. If the chain is slack onlyin certain sections, some links are kinkedand binding. Binding and kinking canfrequently be eliminated by lubrication.

(1)

1.Inspection :

2.

3.

77

62

(1) Drive chain

DRIVE CHAIN

88

40 50 mm (1.6 2.0 in)

06/03/06 13:49:06 3CMCJ600_094

Roll the motorcycle forward. Stop andplace it on its side stand. Inspect the drivechain and sprockets for any of thefollowing conditions:

DRIVE CHAIN*Damaged Rollers*Loose Pins*Dry or Rusted Links*Kinked or Binding Links*Excessive Wear*Improper Adjustment*Damaged or Missing O-rings

SPROCKETS*Excessively Worn Teeth*Broken or Damaged Teeth

A drive chain with damaged rollers, loosepins, or missing O-rings must be replaced. Achain which appears dry, or shows signs ofrust, requires supplementary lubrication.Kinked or binding links should be thor-oughly lubricated and worked free. If linkscannot be freed, the chain must be replaced.

4.

REPLACE

Normal Sprocket TeethGOOD

REPLACE

Worn SprocketTeethTeeth

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Adjustment:Drive chain slack should be checked andadjusted, if necessary, every 1,000 km (600miles). When operated at sustained highspeeds or under conditions of frequentrapid acceleration, the chain may requiremore frequent adjustment.

If the drive chain requires adjustment, theprocedure is as follows:

Loosen the axle nut (1).Loosen the lock nuts (2) on bothadjustihg bolts (3).Turn both adjusting bolts ( ) an equalnumber of turns until the correct drivechain slack is obtained. Turn theadjusting bolts counterclockwise totighten the chain. Turn the adjustingbolts clockwise and push the rear wheeltoward the front to provide more slack.Adjust the chain slack at a point midwaybetween the drive sprocket and the rearwheel sprocket. Rotate the rear wheeland recheck slack at other sections of thechain.Chain slack should be:

Place the motorcycle on its side standwith the transmission in neutral and theignition switch off.

1.

2.3.

(2)

(3)

(1)(4)

4.(5) 3

(1) Axle nut(2) Lock nut(3) Adjusting bolt

(4) Index mark(5) Corresponding scale

90

40 50 mm (1.6 2.0 in)

06/03/06 13:49:17 3CMCJ600_096

Align the chain adjuster index marks ( )with the corresponding scale ( )graduations on both sides of theswingarm.Both left and right marks shouldcorrespond. If the axle is misaligned, turnthe left or right adjusting bolt until themarks correspond on the sca legraduation on the swingarm and recheckchain slack.

Tighten the adjusting bolts lightly byturning it counterclockwise, then tightenthe lock nuts by holding the adjustingbolts with a spanner.

Tighten and torque the rear axle nut.

Recheck drive chain slack.

Axle nut torque:

45

5.

6.

7.

8.

Damage to the bottom part of theframe may be caused by excessivedrive chain slack of more than:

If a torque wrench was not used forinstallation, see your Honda dealer assoon as possible to verify proper as-sembly.

91

50 mm (2.0 in)

113 N·m (11.5 kgf·m , 83 lbf·ft)

06/03/06 13:49:24 3CMCJ600_097

－ －

Wear inspection:Check the chain wear label when adjustingthe chain. If the red zone ( ) on the labelaligns with the long index mark ( ) on thechain adjuster plates after the chain hasbeen adjusted to the proper slack, the chainis excessively worn and must be replaced.The proper slack is:

This motorcycle has a staked master linkdrive chain which requires a special tool forcutting and staking. Do not use an ordinarymaster link with this chain. See your Hondadealer.

Replacement chain:

21 (1)

(2)

(1) Index mark (2) Red zone

92

DID 50VA8 C1

40 50 mm (1.6 2.0 in)

RK GB50HFOZ5or

06/03/06 13:49:29 3CMCJ600_098

Lubricate every 1,000 km (600 miles) orsooner if chain appears dry.The O-rings in this chain can be damagedby steam cleaning, high pressure washers,and certain solvents. Clean the side surfacesof the chain with a dry cloth. Do not brushthe rubber O-rings. Brushing will damagethem. Wipe dry and lubricate only with SAE80 or 90 gear oil. Commercial chain lubri-cants may contain solvents which coulddamage the rubber O-rings.

Lubrication and cleaning:

The drive chain on this motorcycle isequipped with small O-rings betweenthe link plates. These O-rings retaingrease inside the chain to improve itsserv ice lif e. However, specialprecautions must be taken whenadjusting, lubricating, washing, andreplacing the chain.

93

06/03/06 13:49:34 3CMCJ600_099

(Refer to the maintenance precautions onpage ).Check the chain slider (1) for wear.The chain slider must be replaced if it isworn to bottom of the wear indicator mark( ). For replacement, see your Hondadealer.2 (2)

(1)

77

(1) Chain slider(2) Wear indicator mark

DRIVE CHAIN SLIDER

94

06/03/06 13:49:39 3CMCJ600_100

Carefully inspect all front and rearsuspension fasteners for tightness.

Check the fork assembly by locking thefront brake and pumping the fork up anddown vigorously. Suspension actionshould be smooth and there must be nooil leakage.

(Refer to the maintenance precautions onpage ).

Swingarm bearings should be checked bypushing hard against the side of the rearwheel while the motorcycle is on asupport block. Free play indicates wornbearings.

3.

2.

1.77

F R ONT A ND R EA R SUSPENSIONINSPECTION

95

06/03/06 13:49:44 3CMCJ600_101

(Refer to the maintenance precautions onpage ).Perform the following maintenance inaccordance with the maintenance schedule.

If the side stand system does not operate asdescribed, see your Honda dealer forservice.

Check the spring ( ) for damage or lossof tension and the side stand assemblyfor freedom of movement.Check the side stand ignition cut-offsystem:

Sit astride the motorcycle; put the sidestand up and the transmission inneutral.Start the engine and with the clutchlever pulled in, shift the transmissioninto gear.Lower the side stand. The engineshould stop as you put the side standdown.

1

1.

2.

3.

(1)

Functional Check:

77

(1) Side stand spring

SIDE STAND

96

06/03/06 13:49:50 3CMCJ600_102

(Refer to the maintenance precautions onpage ).

Raise the front wheel off the ground byplacing a support block under the engine.Remove the right and left caliperassembly (1) from the fork leg byremoving the fixing bolts (2).

Do not depress the brake lever when thecaliper assembly is removed. The caliperpiston will be forced out of the cylinderwith subsequent loss of brake fluid. If thisoccurs, servicing of the brake system willbe necessary. See your Honda dealer forthis service.

This motorcycle is equipped with a sidestand only. Therefore, if front or rearwheel removal is required, it will benecessary to raise the center of themotorcycle with a jack or other firmsupport. If none is available, see yourHonda dealer for this service.

2.

1. (2)

(1)

77

(1) Brake caliper assembly(2) Fixing bolts

WHEEL REMOVAL

Front Wheel Removal

To avoid damage to the brake hose,support the caliper assembly so thatit doesn’t hang from the hose. Do nottwist the brake hose.

97

06/03/06 13:49:57 3CMCJ600_103

Loosen the right and left axle pinch bolts(3), and remove the axle bolt (5).Withdraw the front axle (4) and removethe front wheel.

4.

3.

(3)(4) (5) (3)

(3) Axle pinch bolts(4) Front axle

(5) Axle bolt

98

06/03/06 13:50:01 3CMCJ600_104

Position the wheel between the fork legsand insert the front axle shaft from theleft side, through the left fork leg andwheel hub.Align the end of axle (1) with the surfaceof fork leg (2).Tighten the axle pinch bolt on the leftfork leg to the specified torque:

Tighten the axle bolt to the specifiedtorque:

Install the right and left caliper assemblyto the fork legs and tighten the fixingbolts to the specified torque:

Tighten the axle pinch bolts on the rightfork leg to specified torque:

To avoid damaging the brake pads whileinstalling the caliper assembly, carefullyfit both brake disks between the pads.Operate the front brake and pump thefork several times. Check for free wheelrotation after the brake is released.Recheck the wheel if the brake drags orthe wheel does not rotate freely.

Installation:1.

2.

3.

4.

5.

6.

7.

(2)

(1)

(1) End of axle(2) Surface of fork leg

If a torque wrench was not used forinstallation, see your Honda dealer assoon as possible to verify proper as-sembly. Improper assembly may leadto loss of braking capacity.

99

78 N·m (8.0 kgf·m , 58 lbf·ft)

30 N·m (3.1 kgf·m , 22 lbf·ft)

22 N·m (2.2 kgf·m , 16 lbf·ft)

22 N·m (2.2 kgf·m , 16 lbf·ft)

06/03/06 13:50:09 3CMCJ600_105

Do not depress the brake pedal while thewheel is off the motorcycle. The caliperpistons will be forced out of the cylinderswith subsequent loss of brake fluid. If thisoccurs, servicing of the brake system willbe necessary. See your Honda dealer forthis service.

Raise the rear wheel off ground byplacing a support block under the engine.Loosen the rear axle nut (1).Loosen the lock nut (2) and adjusting bolt(3).Remove the rear axle nut and washer.Remove the drive chain (4) from thedriven sprocket by pushing the rearwheel forward.

Remove the axle shaft (5), rear wheel,left chain adjust plate (6), right chainadjut plate (7) and side collar from theswing arm.

(1)

(3)

6.

(4)

(2)

(2)

(3)

1.

2.3.

4.5.

(7)

(6)(5)(1) Rear axle nut(2) Lock nuts(3) Adjusting bolts(7) Right chain adjust plate

(4) Drive chain(5) Axle shaft(6) Left chain adjust plate

Rear Wheel Removal

100

06/03/06 13:50:16 3CMCJ600_106

Installation Note:

After installing the wheel, apply the brakeseveral times and then check if the wheelrotates freely. Recheck the wheel if thebrake drags or if the wheel does not rotatefreely.

To install the rear wheel, reverse theremoval procedure.Make sure that the slot (8) on theswingarm (9) is located in the lug (10) inthe brake caliper.Tighten the axle nut to:

Adjust the drive chain (10)

(9)

(8)

(page 88).

(8) Slot(9) Swingarm

(10)Lug

If a torque wrench was not used forinstallation, see your Honda dealer assoon as possible to verify proper as-sembly. Improper assembly may leadto loss of braking capacity.

When installing the wheel, carefullyfit the brake disc between the brakepads to avoid damaging the pads.

101

113 N·m (11.5 kgf·m , 83 lbf·ft)

06/03/06 13:50:22 3CMCJ600_107

〈 〉(Refer to the maintenance precautions onpage ).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 the pads at each regularmaintenance interval (page ).

Check the grooves ( ) in each pad.If either pad is worn to the bottom of thegrooves, replace both pads as a set. Seeyour Honda dealer for this service.

1(1)

(1)77

72

FRONT BRAKE

(1) Wear indicator grooves

BRAKE PAD WEAR

Front Brake

102

06/03/06 13:50:28 3CMCJ600_108

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

2

(2)

REAR BRAKE

(2) Cutouts

Rear Brake

103

06/03/06 13:50:31 3CMCJ600_109

－

－

－

(Refer to the maintenance precautions onpage ).It is not necessary to check the batteryelectrolyte level or add distilled water asthe battery is a maintenance-free (sealed)type. If your battery seems weak and/or isleaking electrolyte (causing hard startingor other electrical troubles), contact yourHonda dealer.

77

BATTERY

The battery gives off explosive gases;keep sparks, flames, and cigarettesaway. Provide adequate ventilationwhen charging or using the battery inan enclosed space.

Removing the battery cap strip candamage the cap strip and result inleaks and eventual battery damage.When the motorcycle is to be storedfor an extended period of time,remove the bat t ery f rom themotorcycle and charge it fully. Thenstore it in a cool, dry place. If thebattery is to be lef t in the motorcycle,disconnect the negative cable fromthe battery terminal.

The battery contains sulfuric acid(electrolyte). Contact with skin oreyes may cause severe burns. Wearprotective clothing and a face shield.

If electrolyte gets on your skin,flush with water.If electrolyte gets in your eyes,flush with water for at least 15minutes and call a physicianimmediately.

Electrolyte is poisonous.If swallowed, drink large quantitiesof water or milk and follow withmilk of magnesia or vegetable oiland call a physician.

KEEP OUT OF REACH OF CHIL-DREN.

104

06/03/06 13:50:40 3CMCJ600_110

－

＋

－＋

Remove the front seat (page 53).Release the rings and remove the rubberband (1).Disconnect the negative ( ) terminallead ( ) from the battery first, thendisconnect the positive ( ) terminal lead( ).Pull out the battery (4) from the batterybox.

1.2.

3.

4.

Battery removal:

(3)(4)

2

3

(1)

(2)

(1) Rubber band(2) Negative ( ) terminal lead(3) Positive ( ) terminal lead(4) Battery

105

06/03/06 13:50:45 3CMCJ600_111

(Refer to the maintenance precautions onpage ).When frequent fuse failure occurs, itusually indicates a short circuit or anoverload in the electrical system. See yourHonda dealer for repair.

77 Never use a fuse with a differentrating from that specified. Seriousdamage to the electrical system or afire may result, causing a dangerousloss of lights or engine power.

FUSE REPLACEMENT

Turn the ignition switch OFF beforechecking or replacing the fuses toprevent accidental short-circuiting.

Blown fuse

106

06/03/06 13:50:51 3CMCJ600_112

Fuse box:The fuse box is located under the front seat.The specified fuses are:

Remove the front seat (page 53).Open the fuse box cover (1).Pull out the old fuse and install a new fuse.The spare fuse (2) are located in the fusebox.Close the fuse box cover and install thefront seat.

4.

3.2.1.

(1)

(2)

(1) Fuse box cover(2) Spare fuses

107

10A , 20A

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Remove the front seat (page 53).Disconnect the wire connector (2) of thestarter magnetic switch.Pull out the old fuse and install a new fuse.The spare fuse (3) is located the startermagnetic switch holder.Reconnect the connector and install thefront seat.

Main fuse A:The main fuse A (1) is located under thefront seat.The specified fuse is:

Main fuse B:The main fuse B (4) is located under thefront seat.The specified fuse is:

Remove the front seat (page 53).Open the fuse box cover (5).Pull out the old fuse and install a new fuse.The spare fuse is located in the fuse box.Close the fuse box cover and install thefront seat.

4.

3.

1.2.

(1)

(2)

(3)

(4)(5)

4.

3.

1.2. (4) Main fuse B

(5) Fuse box cover(1) Main fuse A(2) Wire connector(3) Spare main fuse A

108

30A

20A

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(Refer to the maintenance precautions onpage ).Check the operation of the stoplight switch( ) at the right side behind the engine fromtime to time.Adjustment is done by turning the adjustingnut ( ). Turn the nut in the direction ( ) ifthe switch operates too late and in direction( ) if the switch operates too soon.

1

2

B

A ((BB))

((AA))

77(2)

(1)

(1) Stoplight switch(2) Adjusting nut

STOPLIGHT SWITCHADJUSTMENT

109

06/03/06 13:51:08 3CMCJ600_115

(Refer to the maintenance precautions onpage ).

Be sure to turn the ignition switch OFFwhen replacing the bulb.Do not use bulbs other than thosespecified.After installing a new bulb, check that thelight operates properly.

77

BULB REPLACEMENT

The light bulb becomes very hot whilethe light is ON, and remains hot for awhile after it is turned OFF. Be sureto let it cool down before servicing.

Do not put f inger prints on theheadlight bulb, as they may create hotspots on the bulb and cause it tobreak.Wear clean gloves while replacing thebulb.If you touch the bulb with your barehands, clean it with a cloth moistenedwith alcohol to prevent its earlyfailure.

110

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Pull off the socket (1) without turning.Remove the dust cover (2).Remove the bulb (4) while pressing downon the pin (3).Pull out the bulb (4) without turning.Install a new bulb in the reverse order ofremoval.

Install the dust cover with its ‘‘TOP’’ markfacing up.

5.4.

3.2.1.

(2)

(3)

(1)

(4)

(3) Pin(4) Bulb

(1) Socket(2) Dust cover

Headlight Bulb

111

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Remove the inner panel (page 60).Pull the position light socket (1) andremove it.Pull out the bulb (2) without turning.Install a new bulb in the reverse order ofremoval.

2.1.

3.

(1)(2)

4.

(1) Position light socket(2) Bulb

Position Light Bulb(Except U type)

112

06/03/06 13:51:23 3CMCJ600_118

Open the rear seat (page 54).Turn the socket (1) 90° counterclockwise,then pull it out toward you.Pull out the bulb (2) without turning.Install a new bulb in the reverse order ofremoval.

1.2.

3.4.

(2)(1)

(1) Socket(2) Bulb

Stop/Taillight Bulb

113

06/03/06 13:51:27 3CMCJ600_119

Remove the turn signal lens (1) from theturn signal by removing the screw (2).Slightly press in on the bulb (3) and turnin 90° counterclockwise. Remove thebulb.Install a new bulb in the reverse order ofremoval.

(2)

(3)

3.

2.

1.

(1)

(3) Bulb(1) Lens(2) Screw

Front/Rear Turn Signal Bulb

114

06/03/06 13:51:31 3CMCJ600_120

Clean your motorcycle regularly to protectthe surface finishes and inspect for damage,wear, and oil, coolant or brake fluid leakage.

After cleaning, rinse the motorcyclethoroughly with plenty of clean water.Strong detergent residue can corrodealloy parts.

The inside of the headlight lens may beclouded immediately after washing themotorcycle. Moisture condensation insidethe headlight lens will disappeargradually by lighting the headlight inhigh beam. Run the engine while keepingthe headlight on.

Avoid spraying high pressure water (typicalin coin-operated car washes) at thefollowing areas:

Wheel HubsIgnition Switch

Brake Master CylindersInstrumentsHandlebar SwitchesMuffler OutletUnder Fuel TankDrive ChainUnder SeatHeadlight

Clean the fairing, headlight lens, meterlens and other plastic parts using a clothor sponge dampened with a solution ofmild detergent and water. Rub the soiledarea gently rinsing it frequently withfresh water.

Throttle body

1.

High pressure water (or air) candamage cer t a in par t s of t hemotorcycle.

CLEANING

115

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

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

Apply touch-up paint to the wheels wheredamage has resulted.

Dry the motorcycle, start the engine, andlet it run for several minutes.

Test the brakes before riding themotorcycle. Several applications may benecessary to restore normal brakingperformance.Lubricate the drive chain immediatelyafter washing and drying the motorcycle.

The exhaust pipe is titanium and stainlesssteel, but may become stained by oil or mud.If necessary, remove heat stains with aliquid kitchen abrasive.

2.

4.

3.

Painted Aluminum Wheel Maintenance

Braking efficiency may be tempora-rily impaired immediately af terwashing the motorcycle. Anticipatelonger stopping distance to avoid apossible accident.

Exhaust Pipe Maintenance

116

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＃

＃

Aluminun corrodes when it comes incontact with dust, mud and road salt.To remove stains, use Scotch Brite HandPad 7447 (maroon) or equivalent.Wet the pad and polish using strokesfollowing the surface finish around themuffler.Clean the muffler using a wet sponge and amild detergent, then rinse well with cleanwater.Dry the muffler with a soft clean cloth,using strokes following the surface finisharound the muffler.

(1)

(1) Surface finish

Avoid using steel wool, polishingcompounds, or wax on an aluminummuffler. Steel wool may damage ordiscolour the surface. A polishingcompound or wax may discolour thesurface after its heated by engineoperation.Muffler Stain Remover (Scotch BriteHand Pad 7447) is for removingstains on the aluminum mufflers only.Protect the muffler before you applyany chemical detergent to clean yourrear wheel. Chemical productsaccidentally applied to the mufflermay damage the surface of it.

Aluminum Muffler Maintenance

117

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Extended storage, such as for winter,requires that you take certain steps toreduce the effects of deterioration fromnon-use of the motorcycle. In addition,necessary repairs should be made BEFOREstoring the motorcycle; otherwise, theserepairs may be forgotten by the time themotorcycle is removed from storage.

Change the engine oil and filter.Make sure the cooling system is filledwith a 50/50% antifreeze solution.Empty the fuel tank into an approvedpetrol container using a commerciallyavailable hand siphon or an equivalentmethod. Spray the inside of the tank withan aerosol rust-inhibiting oil.Reinstall the fuel fill cap on the tank.

3.

1.2.

Petrol is extremely flammable and isexplosive under certain conditions.Perform this operation in a well-ventilated area with the enginestopped. Do not smoke or allowflames or sparks in the area wherepetrol is drained or stored and wherethe fuel tank is refueled.STORAGE

STORAGE GUIDE

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－

Remove the battery. Store in an areaprotected from freezing temperaturesand direct sunlight.Slow charge the battery once a month.Wash and dry the motorcycle. Wax allpainted surfaces. Coat chrome withrustinhibiting oil.

Inflate the tyres to their recommendedpressures. Place the motorcycle on blocksto raise both tyres off the ground.Cover the motorcycle (don’t use plastic orother coated materials) and store in anunheated area, free of dampness with aminimum of daily temperature variation.Do not store the motorcycle in directsunlight.

To prevent rusting in the cylinders,perform the following:

Lubricate the drive chain (page ).

Remove the ignition coil connectorsand ignition coils from the spark plugs.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 to theignition coil connectors.Pour a tablespoon (15 20 cm ) ofclean engine oil into each cylinder andcover the spark plug holes with a pieceof cloth.Crank the engine several times todistribute the oil.Reinstall the spark plugs, ignition coilsand ignition coil connectors.

5.

6.

7.8.

9.

4.

93

3

119

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Uncover and clean the motorcycle.Change the engine oil if more than 4months have passed since the start ofstorage.Charge the battery as required. Install thebattery.Drain any excess aerosol rust-inhibitingoil from the fuel tank. Fill the fuel tankwith fresh petrol.Perform all Pre-ride Inspection checks(page ).Test ride the motorcycle at low speeds ina safe riding area away from traffic.

1.

2.

3.

4.62

REMOVAL FROM STORAGE

120

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Overall lengthOverall widthOverall heightWheelbase

Dry weight

Engine oil After drainingAfter draining andoil filter changeAfter disassembly

Fuel tankCooling system capacityPassenger capacityMaximum weight capacity

DIMENSIONS

WEIGHT

CAPACITIES

SPECIFICATIONS

121

2,065 mm (81.3 in)680 mm (26.8 in)1,125 mm (44.3 in)1,400 mm (55.1 in)

170 kg (375 lbs)

1,395 mm (54.9 in)

160 kg (353 lbs)189 kg (417 lbs)Operator and one passenger3.2 (3.4 US qt , 2.8 Imp qt)18.0 (4.76 US gal , 3.96 Imp gal)4.0 (4.2 US qt , 3.5 Imp qt)3.7 (3.9 US qt , 3.3 Imp qt)

3.5 (3.7 US qt , 3.1 Imp qt)

171 kg (377 lbs)

… Except MX… MX

… Except MX… MX

… Except G… G

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× ×

±

Bore and strokeCompression ratioDisplacementSpark plug

Standard

For cold climate(Below 5°C, 41°F)

Idle speed

Valve clearance (Cold)

ENGINE

122

74.0 54.0 mm (2.91 2.13 in)11.3 : 1929 cm (56.7 cu-in)

IUH27D (DENSO)

IUH24D (DENSO)

1,200 100 min (rpm)

0.16 mm (0.006 in)0.27 mm (0.011 in)

IntakeExhaust

06/03/06 13:52:26 3CMCJ600_128

CasterTrailTyre size, frontTyre size, rear

Primary reductionGear ratio, 1st

2nd3rd4th5th6th

Final reduction

CHASSIS AND SUSPENSION

POWER TRANSMISSION

123

23°45’97 mm (3.8 in)120/70 ZR17 (58W)190/50 ZR17 (73W)

1.5212.6921.9331.6001.4001.2861.1902.6252.687

… Except MX… MX

06/03/06 13:52:34 3CMCJ600_129

－

－－－－－

BatteryGenerator

HeadlightTail/brake lightTurn signal light Front

RearPosition light

Main fuse AMain fuse BOther fuses

ELECTRICAL

LIGHTS

FUSE

124

12V 8.6AH0.421 kW/5,000 min (rpm)

12V 55W12V 21/5W12V 21W12V 21W12V 5W

20A30A

10A , 20A

…Except U

06/03/06 13:52:43 3CMCJ600_130

Belgium RTT/D/X1659

Manufacturer : KANSEI CORPORATIONModel number : BSSEU10

The system is certif ied under theregulations on Telecommunications andElectromagnetic Compatibility by theappropriate National Competent Authorityshown in the below.

IRL TRA 24/5/129/1

UKAustriaGreeceHollandFrance

Italy

See labelSee labelSee labelSee labelSee label

DGPGF/4/2/04/339456/FO0002383 of 11-9-98

NorwayPortugal

Switzerland

NO98000398-RICP-046TC-98

BAKOM 98.0363.G.P

Ireland LuxembourgSpain

L 2431/10425-01IE 08 98 0608

Germany

The radio type approval label of immobilizersystem (HISS) ( ) is attached in front ofthe ignition switch( ).

12

(1)(2)

(1) Radio type approval label of immobilizersystem (HISS)

(2) Ignition switch

RA DIO T Y PE A PPROVA L S OFIMMOBILIZER SYSTEM (HISS)(Except MX, BR)

125

06/03/06 13:53:03 3CMCJ600_131

〈 〉 A defective catalytic converter contributesto air pollution, and can impair your engine’sperformance. Follow these guidelines toprotect your motorcycle’s catalyt icconverter.

Always use unleaded petrol. Even a smallamount of leaded petrol can contaminatethe catalyst metals, making the catalyticconverter ineffective.

Keep the engine tuned-up.

Have your motorcycle diagnosed andreplaced if it is misfiring, backfiring,stalling or otherwise not running properly.

This motorcycle is equipped with a catalyticconverter.The catalytic converter contains preciousmetals that serve as catalysts, promotingchemical reactions to convert the exhaustgasses without affecting the metals.The catalytic converter acts on HC, CO, andNOx. A replacement unit must be anoriginal Honda part or its equivalent.

The catalytic converter must operate at ahigh temperature for the chemical reactionsto take place. It can set on fire anycombustible materials that come near it.Park your motorcycle away from highgrasses, dry leaves, or other flammables.

CATALYTIC CONVERTERFor G

126

06/03/06 13:53:07 3CMCJ600_132

TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Owners arewarned that the law may prohibit : (a) The removal or rendering inoperative by any personother than for purposes of maintenance, repair, or replacement, of any device or element ofdesign incorporated into any new vehicle for the purpose of noise control prior to its sale ordelivery to the ultimate purchaser or while it is in use; and (b) the use of the vehicle aftersuch device or element of design has been removed or rendered inoperative by any person.

NOISE CONTROL SYSTEM (AUSTRALIA ONLY)

127

06/03/06 13:53:09 3CMCJ600_133