Honda VTR250 (2009) manual

Honda Motor Co., Lt d. 2009 OW NER ’S MA NUA L M AN U AL D E L P RO P I E TAR I O Honda V T R 250 USO E MANUTENZ IONE 09/01/30 17:37:31 32KFK600_001[...]

Pay special at tent ion t o t he saf ety message s tha t a ppear thr oughout the manual. T hese messages are f u lly explained in t he ‘‘A F ew Wor ds A bout Sa f et y’’ sect ion which appea rs be f ore the Co nte nts pa ge . T his manua l should be conside red a per manen t pa rt of t he mot orcy cle a nd should r emain wit h the mot orcyc[...]

A ll inf ormat i on in t his publicat ion is based on t he lat est product ion inf or mat i on av ailable at t he t ime of approv al f o r print ing . Honda Mot or Co.,L t d. r eserv es t h e right t o make changes at any t ime w it hout not ice and w it hout incurr ing any obligat i on. No part of t his publicat ion may be r eproduced w it hout w [...]

T he mot orcycle pr esent s you a challenge t o maste r the ma chine, a challenge t o adve nture . Y ou r ide t hr ough th e w ind, linked t o t h e r oad by a ve hicle th at re sponds to you r comma nds as no ot her does. Unlike an a utomobile, ther e is no me ta l cage a round you. L ike an airpla ne, a pre-r ide inspection a nd r egular ma inten[...]

A ustr alia T he f ollow ing codes in t his ma nual indicat e ea ch count ry. T he illustrat ions her ein are based on th e type . Fran ce European dire ct sales New Zealand T he spec if i cation s m ay vary with each lo cale. F ED U ED 09/01/30 17:37:50 32KFK600_005[...]

Y our saf ety, and th e s af ety of ot her s, is ver y import ant. A nd operat ing this motor cycle saf ely is an import ant responsibilit y. T o help you ma ke inf or med decisions about saf ety, we have pr ovided opera ting procedur es and ot her inf ormat ion on labels and in this manual. T his inf ormat ion ale rts you to potent ial hazards tha[...]

–– such a s Import ant Saf ety R e minders or Importa nt Sa f e ty Precaut ions. –– such as Motorcycle Saf ety. –– how to use this motorcycle correctly and saf ely. T his entire manual is f illed wit h impor ta nt sa f e ty inf ormat ion –– please r ead it caref ully. Saf et y Headings Saf et y Sect ion Inst r uct ions You WILL be K[...]

LO AD LIM I T S AN D GU I D ELI N E S PR OT ECT IVE APPA REL INST R UMENT S A ND INDICA T OR S IGNIT ION SW IT CH KE YS I MP O RTAN T S AFE TY INFOR MAT ION BR A K ES CL UT CH COOL A NT FUE L ENGINE OIL TU B EL ES S TYR E S R IGHT HA NDL EBAR CONT R OL S L EF T HA NDL E BA R CONT R OLS page page 1 2 4 11 22 24 26 28 31 32 38 39 40 41 OPER A T ION M[...]

ST EER ING L OCK PR E-R IDE INSPECT ION S TARTI N G TH E E N G I N E R UNNING-IN R IDING BR A K ING PA R K ING AN TI - TH E F T TI P S SEA T HEL MET HOL DER DOCUMENT BA G CENT ER COMPA R T MENT H EAD LI GH T AI M VE RTIC AL AD JU STM EN T page page 42 43 44 45 46 47 48 50 53 54 56 58 59 OPERA T ION FE A TURE S (N ot requi red f or ope rat io n) 42 [...]

MA INT ENA NCE SCHEDULE S AF ETY P RE C AU TI O N S MA INT E NA NCE SA F ET Y TH E I M P O RTAN C E O F MA INT E NA NCE T OOL K IT SER IA L NUMBER S C OLO U R LAB EL ENGINE OIL BUL B R EPL A CEMENT ST OR AGE BR A K EL IGHT SWIT CH AD JU STM EN T RE MO VAL F ROM S TORAG E TH RO TTLE O P ER ATI O N COOL A NT DR IV E CHA IN DR IV E CHA IN SLIDE R FR O[...]

− T h e r ei sm u c h t h a t y o uc a nd ot op r o t e c t yourself w hen you ride. Y ou’ll f ind many helpf ul recomme ndat ions t hrough out th is manual. Following are a f e w tha t w e consider t o be most importa nt. Y our moto rcycle can pro vide many year s of service and pleasur e if you take respons ibility f or your own sa f e ty and[...]

F o ry o u rs a f e t y ,w es t r o n g l yr e c o m m e n d that you always wear an a pproved motorcycle helmet, eye protect ion, boots, gloves, long pants, and a long-sleeved shirt or jacket whenever you ride. A lthough complete pr otect ion is not possible, we aring proper gear can reduce t he chance of injur y when you ride. Follow ing are sugg[...]

Y our h elmet is your most import ant piece of riding ge ar becaus e it of f er s t he best prot ection against he ad injuries. A helmet should f it your head comf orta bly and securely. A bright-coloured helmet can make you more noticeabl e in traf f ic, as can ref lective strips . A n open -f ace helmet of f ers some protection, but a f ull-f a c[...]

How much w eight you put o n your motorcycle, and how you load it , a re import ant t o y our sa f e t y. A ny time you ride wit h a passenge r or car go y ou sh ould be aw are of t he f ollowing inf ormat ion. Y our m otorcycle has been desig ned to c arry you and one passenger. W hen you carry a passenger , you may f e el some dif f erence during[...]

Follow ing are t he load limit s f or y our motorcyc le: Y our mot orcycle is pr imarily int ended f or tr anspor ting you and a pa ssenger . Y ou may wish t o secur e a jacket or ot her small items to the sea t when you are not rid ing with a passenger. If you w ish to carry more cargo, check with your Honda dealer f or advice, and be sure to read[...]

Modif ying your mot orcy cle or using non- Hon da accessori es can mak e your motorcycl e unsaf e. Bef ore y ou consider making any modif ications or adding an a c c e s s o r y ,b es u r et or e a dt h ef o l l o w i n g inf ormation. Follow t hese guidel ines whenever you carry a passe nger or ca rgo: Check tha t both tyres are properly inf lated[...]

R emoving or modif ying your lights, muf f lers, emission control syste m or ot her equipm ent can also make your motorcycl e illegal. We strongly advise you not to remove a ny original equipment or modif y your motorc ycle i n any way that would chang e its design or opera tion. Such cha nges could seriously impair your mot orcycle’s handling, s[...]

Clut ch l ev er Headlight dimmer swi tch T hrottle grip T urn signal swit ch Ho rn b utto n Engine stop swit ch Indicators T achometer Speedometer Rearv iew mirror Front brake f luid reserv oir Fro nt b rak e l ever Rearv iew mirror Ignition swit ch Passing ligh t cont ro l sw it ch Fuel f ill cap Start but ton PA RT S L OCA T ION 8 09/01/30 17:39:[...]

Ba ttery Passenger f ootpeg T ool kit Foot peg Engine oil inspection window Rear brake pedal Oil f iller cap Coolant reserve t ank Rear brake f luid reservoir Fus e b ox Main f u se 9 09/01/30 17:39:25 32KFK600_019[...]

Side stand Foot peg Shif t lev er Passenge r f ootpeg Engine oil drain bolt Center compartment Document compartment Seat lock/ Helmet holder 10 09/01/30 17:39:28 32KFK600_020[...]

T h ei n d i c a t o r sa r ec o n t a i n e di nt h e instr ument pa nel. T he ir f unctions ar e described in t he t ables on t he f ollowing pages. (1) Tachometer (2) Tachometer red zo ne (3) Digit al clock (4) R ight t urn signal indica tor (5) Right c ontrol button (6) Lef t c on trol bu tton (7) L ef t tur n signal indica tor (8) O dom et er/[...]

T a chomet er Shows engine rev olutions per minut e. R unning th e engine bey ond recomme nded maximum engine speed (t he beginning of the t achome te r red zone) can da mage the e ngine. Never allow the tachometer needle to enter t he red zone, ev en af ter the engine has be en broke n in. T achometer red zone T he t acho met er nee dle will sw in[...]

Fla shes w hen t he r ight t urn signa l opera tes. Righ t co ntr ol bu tton Us e this bu tton f o r the f oll owin g p urpo se. To a d j u s t ti m e R ight tur n signal indica tor (green) Lef t co ntrol b utto n Us e this bu tton f o r the f oll owin g p urpo ses. To a d j u s t ti m e T o select display mode T o reset tripmeter Flashes when the [...]

Odometer/T ripmeter display Shows odometer and t ripmet er 1 and 2. Odometer Show s accumulat ed mileage ( page ). Shows mileage per trip ( page ). Speedometer Shows riding speed. T he speedometer needle will swing to t he maximum scale on the dial onc e when the ignition switch is tur ned ON. T his display show s th e initia l display (pa ge ). Tr[...]

− PGM-FI ma lf unct ion indica t or la mp (MIL ) (amber) L ight s whe n th ere is any abnor malit y in t he PGM-F I (Pro gramme d Fue l Inje cti on) syst em. Should also l i g h t fo r a fe w s e c o n d s a n d th e n g o o ff w h e n th e ignition sw itch is tur ned ON and engine st op swit ch is at (R UN). If it comes on at a ny ot her t ime, [...]

Neut ral indica tor (gree n) L ight s wh en th e tr ansmission is in ne utr al. L ow oil pressur e indicat or ( red) L ight s w he n t he engin e oil p res sure is below normal opera ting ra nge. Should ligh t w hen ignition sw itch is ON and engine is not running. Should go out w hen the engine sta rt s, except f or occa sional f lickering at or n[...]

L ow f uel indi cat or (amber) L ig hts when there i s on ly f ew f u el left in the f uel tank. T he amount of f uel le f t in th e t ank w hen lights and wit h t he veh icle set upright is a pproximat ely: S h o u l d a l s o l i g h t fo r a fe w s e c o n d s a n d t h e n g o o ff when the i gni tion switc h is turn ed ON . (15) (R ef .No.) De[...]

When the ign itio n swi tch is turn ed ON, the display will t empor ar ily show a ll t he mode s and digit al segments so you can ma ke sur e the liquid cr ysta l displa y is f unctioning properly. ( Except digit al clock) Digi tal clock and tripmeter will reset if the bat ter y is disconnect ed. (1) (2) (1) Odometer/Tripmeter display (2) Digit al [...]

Th e d i sp l ay ( ) h as tw o fu n c ti on s, odometer a nd two t ripmet er. T o rese t the trip me ter, pus h an d hol d th e l e f t c o n t r o lb u t t o nw h e nt h e d i s p l a yi nt h e ‘‘T R IP 1’’ or ‘‘T R IP 2’’ mode. T he display w ill re tur n to odomete r if t he bat ter y is disconnect ed. Pu sh the le f t con trol b[...]

T ur n the ign itio n s witch ON . T he digit al clo ck will show hour s a nd minute s up t o 11 :59 w it h ‘‘A M’’ a nd ‘‘PM’’. T o adjust the time, proceed as f ollows: Pre ss an d ho ld the l ef t co ntr ol b utton ( ) a n dr i g h t c o n t r o lb u t t o n( )f o r m o r e tha n 2 seconds. T he clock w ill be set in the adjust m[...]

T o set the minute, pres s the right cont rol butt on unt il the desired minut e appe ars. T he minut e displa y will ret urn to ‘‘00’’ when ‘‘60’’ is reached without af f ecting the hour display. T he time advan ces by one mi nute, each tim e th e butto n i s p res sed. T he time advances f ast when the b u t t o ni sp r e s s e da[...]

Both the f ron t and rear brakes are the hydra ulic disc types. A s th e bra ke pads w e ar, t he br ake f luid level drops. T he re are no adjust ments t o per f orm, but f luid level and pad w ear must be inspected periodical ly. T he sys te m must be inspecte d f req uent ly t o e nsur e the re a re no f luid lea ks. If t he control lever or ped[...]

R ear Brak e Flui d L evel: T he recom mended br ake f luid is Honda DOT 4 bra ke f luid f r om a seale d conta iner , or an equival ent. Wit h the mot orcycle in a n upr ight position, check the f luid level. It should be between t h e U P P E R( )a n d L O W E R( ) l e v e l marks. If the level is at or below the L OWER level mark, check the rear[...]

−− Clutch adjust ment ma y be r equir ed if the motor cycle sta lls when sh if ting int o gear or tends t o cr eep; or if t he clutch slips, causing acceler at ion t o lag be hind engine spee d. Minor adjust ments ca n be ma de w it h t he clutch ca ble a djust er ( ) a t the clut ch lever () . Normal clut ch lev er f reepla y is: L oosen t he [...]

If proper a djustment cannot be obt ained or the c lutc h do es no t work c orrec tly, see y ou r Honda dea ler. Other Checks: Check t he clut ch cable f or kinks or signs of wear that cou ld cause sticki ng or f ailu re. L ubric ate th e clutch cable w ith a commercia lly a vaila ble cable lubricant to prevent prem at ure wear an d corros ion . L [...]

T he f actory pr ovides a 50/50 solut ion of antif reeze and distilled wat er in t his motorcycle. T his coolant solution is recomme nded f or most ope ra ting temperatures and provides go od corro sion protect ion. A higher concentrat ion o f antif reeze decreases the cooli ng system perf ormance and is recomme nded only when a dditional prot ecti[...]

If the r eserve t ank is empty, or if coolant loss is e xcessiv e, check f or leaks and see your Honda dealer f or repa ir. Check th e coolant lev el wh ile the engine is at the n orm al op era tin g te mper ature. Hold the motorcycle in an upright position on f irm, lev el ground. R emove the reserve t ank cap ( ), wipe it clean , and reinsert the[...]

T o open the f uel f ill ca p ( ), insert t he ignition key ( ) and t urn i t clockw ise . T he f uel f ill cap is hinged and w ill lif t up. T he f uel t an k c apacit y including th e reser ve supply is: Do not over f ill th e t ank. T here should be no f uel above the rear edge of hole ( ) of the stopper pla te ( ). A f ter ref ueling, to close [...]

If ‘‘spa rk knock’’ or ‘‘pinkin g’’ o ccurs at a stea dy engine speed under normal loa d, change bra nds of pet r ol. If spar k knock or pinking pe rsist s, consult your Honda deale r. Fa ilure to do so is considered misuse , and damage caused by misuse is not cover ed by Honda’s L i mited W a rra nty . Use unlea ded pet rol w ith[...]

If you decide to use a pet rol containing a l c o h o l( g a s o h o l ) ,b es u r ei t ’ so c t a n er a t i n g is at lea st a s h igh as th at r ecommended by Honda. T here a re t wo t ypes of ‘‘gasohol’’: o ne con tai ni ng e tha nol , and th e oth er conta ining me tha nol. Do not use pe tr ol t ha t con tains m ore than 10 % ethanol[...]

− − − Check t he engine oil level each day bef ore riding t he motor cycle. T he level must be maintained between the u p p e r( )a n dl o w e r( )l e v e lm a r k si nt h e inspection w indow ( ). Sta rt t he engine an d let it id le f or 3 5 minutes . Ma ke sure t he low oil pressur e indicat or goes of f . If the indicat or light rema ins [...]

T o saf ely operat e your mot orcycle, your tyr es must be the prope r type and size , in good condit ion w ith a dequat e t rea d, and corre ctl y inf late d f or t he l oad y ou ar e carr ying. T he f ollowing pages give mor e detailed inf ormation on how and when t o check your air pressure, how t o inspect your tyr es f or damage , and wha t to[...]

− − − T he r ecommended ‘‘cold’’ ty re pre ssures are: Whenever you check the tyre pressures, y o us h o u l da l s oe x a m i n et h et y r e t r e a d sa n d sidewa lls f or w ear , da mage , a nd f oreign objects: L ook f or : Bumps o r bulg es in the side of t he ty re o r t h et r e a d .R e p l a c et h et y r ei f y o uf i n da[...]

〈〉 R eplace tyres bef ore tr ead depth at t he center of the t yre reaches the f ollowing limit: German law prohibits use of t yres whose trea d dep th i s les s than 1.6 mm . (1) Minimum tr ead dept h (2) For Ge rm any Fro nt: Rea r: (1) W ear indicator ( 2 ) W e a ri n d i c a t o rl o c a t i o nm a r k T read W ear 34 1.5 mm (0.06 in) 2.0 m[...]

If a tyre is punc tured or damaged , you should repla ce it, not r epair it. A s discussed below, a tyre that is repaired, e ither tempor arily or perma nently , w ill hav e low er speed and perf ormance limits than a new tyre . A temporary r epair, such as an external tube less t yr e plug, ma y not be sa f e f or normal speeds and riding condit i[...]

T he tyres that came on your motorcycle were desig ned to match the performance capabilit ies o f y our motor cycle and provide the best combinat ion of handli ng, br aking, durabilit y a nd comf or t. T he reco mmend ed tyres f or your motorcyc le are: Whenever you replace a t yre, use one that is equival ent t o the origin al and be sure the whee[...]

Do not insta ll a tube inside a t ubeless tyr e on this motor cycle. Excessiv e heat build- up can cause the t ube t o burst . Use only tubele ss tyres on this motorc ycle. The rims are designed f or tub ele ss tyres , an d du ri ng hard acceler at ion or bra king, a tub e-t ype ty re could slip on t he r im and cau se th e t yre t o rapidly def la[...]

T he ignition swit ch ( ) is below t he indicat or pa nel. LO CK (steering loc k) OFF ON Ste ering is locked. Engine a nd ligh ts ca nnot be operat ed. Engine and ligh ts ca nnot be operat ed. Engine and ligh ts ca n be oper at ed. Ke y c an be removed Ke y c an be removed K ey ca nnot be removed T he hea dlight, positi on light ( except U type ), [...]

T his motor cycle has t w o ke ys and a key number p lat e. Y ou will need the key number if you ever have t o replace a key. Store the pl ate in a saf e place. T o reproduce keys, bri ng all keys, key number plate and mot orcycle to your Honda dealer. (2) (1) (2) K ey number plate (1) K eys KE YS 39 09/01/30 17:42:28 32KFK600_049[...]

T he e ngine stop sw itch ( ) is next t o the thr ottle gri p. Wh en the sw itc h is in the (R UN) posit ion, t he en gine w ill oper at e. When the swi tch is in th e (O FF) position, t he engine w ill not oper ate . T his swit ch is intended pri marily as a saf et y o r emerge ncy sw it ch a nd sh ould norma lly rema in in the (R UN) position. If[...]

Wh en t his swit ch is pressed, t he headligh t f lashes on to sign al approaching cars or when passing. Move t o (L ) to signal a lef t t urn , (R ) t o signal a r ight t urn. Pre ss to t urn signal of f . Press the but to n to sound t he h orn. Push the hea dlight dimmer swit ch to (HI) t o selec t high be am or t o (L O) t o select low be am. (1[...]

Do not t urn th e key t o L OCK w hile riding the motor cycle; loss of ve hicle cont rol will result. T o unlock t he st ee ring, turn t he key to OFF while pushing in. T o lo ck the stee ri ng , turn the ha nd leb ar all the wa y to the l eft, turn th e ign itio n key ( ) to L OCK w hile pushing in. R emove th e key. (1) ( ( A A ) ) ( ( A A ) ) 1 [...]

T o remove th e seat ( ), ins ert the igni tion key into the sea t lock ( ) and t urn it clockwise. Pull t he seat lock lever ( ) t o unlock the seat. Pull t he se at ba ck and up. T o install the sea t, insert t he f ront prong ( ) in to the f ron t stay ( ) of the f rame . Push f orw ard and th en down on t he r ear of the sea t. Be sure t he sea[...]

T he he lmet holde r ( ) is on th e le f t side below t he sea t. I n s e r t t h ei g n i t i o nk e y ( )a n dt u r ni t clockwise t o unlock. Hang y our helmet on the holde r hook ( ). T ur n the key counter clockwise t o lock t he holder hook and then rem ove the key. (1) (3) 2 1 3 (2) (1) Helmet holder (2) Ignit ion key (3) Holder hook HEL MET[...]

When w ashing y our motor cycle, be care f ul no t to f l ood this area with wa ter. T he document bag ( ) is in t he docum ent compart ment ( ) under the se at (page ). T his owner’s manual an d othe r document s should be stor ed in the document bag. 1 24 3 (1) (2) (1) Document bag (2) Document compartment DOCUMENT BA G 45 09/01/30 17:43:05 32K[...]

T he cent er compa rt ment ( ) is below the seat (pag e ). T his compartme nt is f or light weight items. Do not r ide w it h any lu ggage in t he cent er co mpar tmen t. T he cent er com part ment ma y become heat ed by t he engine. Do not st ore f ood and oth er a rt icle s whi ch ar e f lammabl e or susc eptible to h eat damage in this co mpar t[...]

V ert ical adjust ment c an be made by moving the hea dlight case ( ) as necessar y. T o move t he headlight case, loosen t he bolts ( ). T ight en t he bolt s af te r adjust ment . Obey local laws a nd regula tions. ( ( A A ) ) ( ( B B ) ) (1) (2) 1 2 (A) Up (B) Down (1) Headlight case (2) Bolts HEA DL IGHT A IM V ERT ICAL AD J US TME N T 47 09/01[...]

− − − − − − For your saf ety, it is very important to take a f ew momen ts bef ore each r ide t o walk around y our mot orcy cle and check it s condition. If you det ect any pro blem, be sure you take care of it, or have it corrected by your Honda dea ler. Engine oil leve l a dd e ngine oil if requir ed (page ). Check f or leaks. Fuel l[...]

− − − − − − − − T y res che ck condit io n and pr essur e (pages ). T hr ott le check f or smooth opening and f ull closing in all st eering posit ions. D r i v ec h a i n c h e c kc o n d i t i o na n ds l a c k (pages ). A djust and lub ricate if necessar y. Side st and ignit ion cut -of f syst em check f or proper f unction (page[...]

Your moto rcycl e’s exh aust con tain s poisono us carbo n mo noxide ga s. High levels of carbon monoxide can collec t rapid ly in enclo sed areas such as a garage. Do not run t he e ngine wit h t he gara ge door closed. Eve n wit h the door open, run t he engine only long enough to move your motorc ycle out of the garag e. Do no t us e the el ec[...]

Be f ore startin g, ins ert the key, turn the ignit io n s w it ch ON and con f irm th e f ollowing: T he tra nsmission is in neut ral (n eu tral ind ica tor is ON ). T he engine stop sw itch is at (R UN). Opera ting th e engine w it h insuf f icient oil pressur e can cause serious engine da mage. T he low oil pre ssure indicat or is ON. T he PGM-F[...]

− If the engine f ails t o start af ter repeated attem pts, it may be f loo ded . L ea ve the engine stop swit ch set t o (R UN) . Op en throttl e f ul ly. Press t he st art butt on f or 5 seconds. Follow the normal st art ing procedur e. If t he engi ne st art s w ith unsta ble idle, op en the th rottle sl ig htly . If t he engine doe s not st a[...]

Hel p as su re your moto rcycle ’s f utu re relia bility a nd perf ormance by paying e xtr a att ention to how you ride during t he f irst 500 km (300 miles). During t his per iod, avo id f ull-throt t le st art s and rapid accelerati on. R UNNING-IN 53 09/01/30 17:43:49 32KFK600_063[...]

− R eview Motorcycle Saf ety (pages ) bef ore you rid e. Make sure yo u unders tand the f unction of the si de s tan d me ch an i s m. ( Se e MAI N- T ENA NCE SCHEDUL E on pa ge a nd explan at ion f or SID E STA ND o n p age ). Make sur e f lammable mat erials such as dr y grass or leaves do not com e in contact with the exha ust syste m w hen ri[...]

Coordinat e t he thr ott le and brakes f or smooth deceleration. Both f ront a nd rea r br akes should be u s e da tt h es a m et i m ea n ds h o u l dn o t b e app lied st ro ngly enoug h t o lock the w hee l, or braking ef f e ctive ness will be reduced and contr ol of t he mot orcycle be dif f icult . 6. 5. 55 09/01/30 17:43:58 32KFK600_065[...]

For normal bra king, apply bot h th e brake pedal and lever whi le dow n-shif ting t o mat ch your r oad speed. F or ma ximum braking, close t he thr ot tle and f irmly apply the pedal and lever; pull in the clutch lever bef ore c oming t o a comp let e st op to pre vent sta lling the engine. Independent ope rat ion of only t he br ake lever or bra[...]

R iding wit h your f oot resting on t he brake pedal or your hand on t he br ake lever may act uat e t he b rake light , giving a f als e ind ica tio n to other dri ver s. It may also overh eat t he brakes, re ducing ef f ectiveness. Wh en descending a long, st ee p grade, u s ee n g i n ec o m p r e s s i o nb r a k i n gb yd o w n - sh ifting , w[...]

L ock the steer ing t o help prevent thef t (page ). A f ter stopping th e mot orcycle, shif t t he trans miss ion into neutral , turn the handlebar f u lly t o the lef t , turn the ignition sw itch OFF and remov e t he key. Use the side stand to support t he motor cycle w hile par ked. Park t he mot orcycle on f irm, level gr ound to prev ent it f[...]

A lways lock t he steering and never leave the ke y in the ig ni t io n swi tch. This sounds simple but people do f orget. Be sure the regi strati on in f o rm ati on f or your m otorcycle i s accurate an d c urrent. Park your motorcycle in a locked garage whenever possible. Use an addi t ional an ti-thef t devic e of good qualit y. Put you r name,[...]

A w ell-maint ained mot orcy cle is esse ntial f or saf e, economical and trouble-f ree riding . It w ill also he lp reduce air pollut ion. If your motorcycle overturns or becom es involve d in a cr ash , be s ure your Honda dealer inspects all major parts, even if you a r ea b l et om a k es o m er e p a i r s . T o help you prop erly care f or yo[...]

− T his section includes inst ruct ions on some imp ortant maintenanc e tasks. Y ou can perf orm some of th ese task s w ith th e t ools provided if you have basic mechanical skills. Other tasks that are more dif f icult and requi re special t ool s are best perf ormed by prof essiona ls. Whe el remov al should normally be handle d only by a Hond[...]

Make sur e t he e ngine is of f bef ore you begin any maintena nce or repair s. T his will help eliminat e sev era l potent ial hazards: Be su re there is adeq uate venti la tio n whenever you operate the engin e. L et t he engine and exha ust syst em cool bef ore t ouching. Do not run the engine unless instruct ed to do so. R ead t he instruct ion[...]

＊＊ ＊ Perf orm the Pre- ride Inspec tion ( page ) at each scheduled m ainte nance per iod. I: I NSPECT AND CLEA N, ADJUST , LUBRICAT E OR R EPL ACE IF NECESSARY C: CL EA N R: R E PL A CE A : A DJUST L: L UBR ICA T E T he f ollowing it em s r equire some m echanica l kn owledge. Cert ain it em s ( part icular ly t hose ma rked and ) may requir [...]

× × − − − − − − → ↓ FUEL LINE TH ROTTLE OP ERA TIO N MONT H AI R CLE ANER 6 4 6 12 8 12 I I I I R R I I I 18 12 18 R 24 16 24 I I R I R R I I I 30 20 30 Refer to Page 74 69 71 26, 75 NOT E NOT E (2) NOT E (3) SPAR K PL UG VALVE C L EARAN CE ENGINE OIL ENGINE OIL FIL T E R RA DIA T OR COOL A NT COOLING SY ST EM SECONDAR Y A IR SUPP[...]

× × − − − → ↓ DRIV E CHA IN DR IV E CHA IN SL ID ER MONT H 1 0.6 I I I I 6 4 6 I I I 12 8 12 I I I I I I I I I I I I 18 12 18 R I I 24 16 24 I I I I I I I I I I I I 30 20 30 I I I 36 24 36 I R I I I I I I I I I I Refer to Page 76 82 22, 23 90, 91 22, 90 97 47 24 84 83 NOT E NOT E (3) BR A K E FL UID B RAKE P ADS W EAR BR A K E SY ST E M[...]

× × T he tool kit ( ) is in t he t ool box unde r t he seat (pag e ). Some roa dside r epairs, minor a djustment s and parts replacem ent can be perf o rmed with the tool s c ontai ned in the k it. 10 12 m m Op en end wrench 14 17 m m Op en end wrench S p a r kp l u gw r e n c h 24 mm Box end wrench Screw driv er h andle Fus e r em ove r T ool ba[...]

T he f ram e and engine seri al numb ers are requi red when registerin g your motorcycle. T h e ym a ya l s ob er e q u i r e db yy o u rd e a l e r when orderi ng repl acemen t parts. R ecor d t he numbe rs her e f or y our ref erence. FR AME NO. ENGINE NO. T he f r ame number ( ) is stampe d on the right sid e of t he steering head . T he e ngine[...]

It is h elpf ul w hen or der ing rep laceme nt part s. R eco rd the colour a nd code here f or your ref erence. COL OUR CODE T he co lour la bel ( ) is attac hed to the f r a m eb e l o wt h es e a t( p a g e ) . 1 43 (1) (1) Colour label C O LO U R LAB E L 68 09/01/30 17:45:22 32KFK600_078[...]

Y our mot orcy cle does not need oil a dditive s. Use t he r ecommende d oil. Do not use oils w ith graphit e or molybdenum addit ive s. T hey ma y adv ersely af f ect clutch ope rat ion. Do not use A PI SH or h igher oils displaying a circular A PI ‘‘energy conse rving ’’ se rvice label on t he c onta iner . T hey ma y af f ect lubricat io[...]

JA SO T 90 3 sta ndard T he JA SO T 903 sta ndar d is an inde x f or engine oils f or 4-st roke mot orcycle engines. T here are tw o classes: MA and MB. Oil conf orming t o t he st anda rd is labeled on the oil cont ainer . F or exa mple, t he f ollow ing label sho ws t he MA cla ssif ica tion. V iscosit y grade of engine oi l should be based on av[...]

Engine oil qua lity is t he chie f f act or af f ect ing engine serv ice lif e. Change th e engi ne oil as specif ied in the maintenanc e schedule ( page ). Wh en r unning in very dust y condit ions, oil changes should be per f ormed more f requently than specif ied in t he maint enance schedule. Please dispo se of used en gine oil in a manne r th [...]

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− − Improper inst allat ion of t he o il f ilter can cause se rious e ngine dama ge. Insta ll the oil f iller cap. Sta rt t he engine an d let it id le f or 3 5 minute s. 2 3 minutes a f ter st opping the e ngine, check that t he oil level is at t he upper l e v e lm a r ki nt h e i n s p e c t i o nw i n d o ww i t h the motorcycle upright on [...]

−− Re fe r t o t h e S a fe ty P r e c a u ti o n s o n p ag e . Check f or smooth rot at ion of t he t hrot tle grip f rom the f ully open t o t he f ully close d position at both f ull steering positions. M e a s u r et h et h r o t t l eg r i pf r e e p l a ya tt h e thro ttle grip f l ang e. T h es t a n d a r df r e e p l a ys h o u l db e[...]

Re fe r t o t h e S a fe ty P r e c a u ti o n s o n p ag e . Coolant s hould be r eplace d by a Honda dealer, unless t he own er has proper t ools and service data and is mec hanically qualif ied. R ef er t o an of f icial Honda Shop Manual. A lways add cool ant to t he reserve tank. Do n o ta t t e m p tt oa d dc o o l a n tb yr e m o v i n gt h [...]

−− Re fe r t o t h e S a fe ty P r e c a u ti o n s o n p ag e . T he ser vice lif e of the dr ive chain ( ) is dependent upon proper lu bricat ion and adjust ment. Poor main te nance can cause premature wear or damage to the drive chain and spr ockets. T he drive chain should be checked, adju sted and lubri cated as part of t he Pre- ride Insp[...]

Damaged Sprocket T eeth Worn Sp rock et T eeth Normal Sprock et T eeth R oll t he mot orcy cle f orwa rd. St op and place it on its s ide st and. Inspect th e driv e chain and spr ocket s f or a ny of t he f ollowing conditions: DR IV E CHA IN *Damag ed R ollers *L oose Pins *Dry or Rust ed Links *K inked o r Binding L inks *Excess ive Wear *Improp[...]

−− Place t he motor cycle on its side sta nd wit h t he tra nsmission in neutr al a nd t he ignition sw itch of f . Drive chain slack should be checked and adjusted, if necessar y, ever y 1,000 km (600 miles). When oper at ed a t sust ained high speeds or under conditions of f requen t rapid accel erat ion , the chain may require more f requent[...]

If a t orque wr ench is not used f or t his insta llat ion, see your Hon da dealer a s soon as possible to v erif y proper assembly. Both le f t a nd righ t mar ks should corre spond. If the axl e is misaligned, tur n the lef t or righ t a djusting nut until t he marks correspond on t he rea r edge of th e adjus ting slots and recheck chain slack. [...]

−− Da ma ge to the botto m part of the f rame m a yb ec a u s e db ye x c e s s i v ed r i v ec h a i n slack of more than: Wear Inspection: Check the chain we ar label when adjusting the chain. If the red zone ( ) on the label al ig ns with the arrow mark ( ) on the c hai n adju ster plates af ter the chain has been ad ju sted to the pro per s[...]

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Re fe r t o t h e S a fe ty P r e c a u ti o n s o n p ag e . Check the chain slider ( ) f or wear. T he chai n slider must be repla ced if it is wor n t o t he w ear limit li ne ( ). F or replacemen t, see your Hon da dealer. (1) 1 (2) 2 62 (1) Chain slider (2) W ear limit line DR IV E C HA IN SL IDER 82 09/01/30 17:46:54 32KFK600_092[...]

Re fe r t o t h e S a fe ty P r e c a u ti o n s o n p ag e . Check t he f ork asse mbly by locking the f ront bra ke and pumping t he f ork up a nd down vigorously. Suspe nsion action should be smoot h and t here must be no oil leaka ge. Caref ully inspect all f ront a nd rear suspension f ast eners f or tight ness. Swinga rm bear ings should be c[...]

Re fe r t o t h e S a fe ty P r e c a u ti o n s o n p ag e . Perf orm the f o llowing maintenance in accord ance with the mai ntenance sc hedul e. Funct ional Ch eck: If t he side st and syste m doe s not opera te as described, see you r Honda dealer f or service. Check the side st and spr ing ( ) f or damage or loss of tensi on and t he side st a[...]

Re fe r t o t h e S a fe ty P r e c a u ti o n s o n p ag e . T his mot or cycle is equippe d w it h a side stand only. T heref ore, if f ront or rear w heel remov al is r equire d, i t will be nece ssary t o raise the cent er of t he mot orcycle wit h a jack or other f irm suppo rt. If non e is ava ilable, see your Honda de aler f or this service.[...]

Do not depress t he brake lever when the whe el is of f t he motor cycle. T he ca liper pistons w ill be f or ced out of t he cylinders wit h subsequent loss of brake f luid. If th is occurs, ser vicing of the brake syst em w ill be necessar y. See y our Honda de ale r f or t his service. R aise the f ront w hee l of f t he ground by placing a supp[...]

Po siti on the wheel betwee n the f o rk leg s and insert t he f ront axle sha f t f rom t he lef t side, through t he lef t f or k leg a nd wheel hub. T o a void da maging th e bra ke pads w hile insta lling the w heel, ca ref ully f it the brake d isc b et ween the pads. If a tor que w rench was not used f or insta llat ion, see your Hon da deale[...]

R aise th e rea r w he el of f t he ground by placing a suppor t block unde r t he engine. L oosen the r ear axle nut ( ). L oosen t he lock nut ( ) a nd t urn the adjust ing nut ( ). R e m o v et h er e a ra x l en u t . R emove the drive chain ( ) f rom the driven sprocket by pushing t he rear wheel f orward. R e m o v et h er e a ra x l es h a f[...]

T o install t he rear w heel, reverse t he remova l procedure. If a tor que w rench was not used f or insta llat ion, see your Hon da dealer a s soon as possibl e to verif y proper assembl y. Improper assembly may lead to loss of braki ng capacity. Af ter i ns tall in g the whe el, app ly the brak e several times and then check if the w heel rotat [...]

Re fe r t o t h e S a fe ty P r e c a u ti o n s o n p ag e . Brake pad wear depen ds upo n the severity of usa ge, the type of riding, and roa d conditions . (Gene ral ly, t he pad s will w ear f a ste r on wet and dirt y roa ds.) Inspect the pads at each r egular maint enance inter val (page ). Check the wear indic ator grooves ( ) in each pad. I[...]

Check t he w ea r indi cat or ma rks ( ) on each pad. If either pad is worn t o the w ear indicator mark, r eplace both p ads as a set. See your Honda dea ler f or t his se rvice . 2 (2) ( 2 ) W e a ri n d i c a t o rm a r k R ear Brak e 91 09/01/30 17:47:50 32KFK600_101[...]

Re fe r t o t h e S a fe ty P r e c a u ti o n s o n p ag e . It is no t n ec essary to che ck the battery electrolyte level or add distilled wa ter as the battery is a maintenance-f ree ( sealed) type. If your battery seems weak and/or is leaking elect rol yte ( causing har d star ting or other ele ctr ical t roubles), contact your Honda dea ler. [...]

− ＋ ＋ − − ＋ Disconnect t he ne gat ive ( ) ter minal le ad ( ) f rom th e b attery f ir st, the n disconnect t he positiv e ( ) t ermina l lea d () . R elea se t he r ings and r emove the rubber band ( ). Make sur e the ignition swit ch is OF F . R emo val: Pu ll out the batter y f r om the b attery box . Insta llation: R eins tall in t[...]

Re fe r t o t h e S a fe ty P r e c a u ti o n s o n p ag e . W h e n fr eq u e n t fu s e fa i l u r e o c c u r s , i t usually indicat es a shor t circuit or an over load in the elect rical syste m. See your Honda dea ler f or r epair . Never use a f use wit h a dif f er ent rat ing f rom t hat speci f ied. Serious damag e to the electrical syst[...]

Fuse Box: T he f use box ( ) is locat ed under the seat. Th e s p e c i fi e d fu s e i s : Re mo ve th e se a t (p ag e ) . R e m o v et h ef u s eb o xc o v e r( ) . Using t he f use r emov er, pull th e old f use o u t .I f t h ef u s ei sb l o w n ,i n s t a l lan e wf u s e . T he spare f us es ( ) are located in the f use box. Close the f use[...]

Main Fuse: T he main f use ( ) is locat ed under the se at. Th e s p e c i fi e d fu s e i s : Re mo ve th e se a t (p ag e ) . Disconnect t he w ire connect or ( ) of the star ter mag neti c switc h ( ) . Pull ou t t he old f use a nd in sta ll a new f use . T he spa re ma in f use ( ) is locat ed under the starte r ma gn etic swi tch. R econnect [...]

Re fe r t o t h e S a fe ty P r e c a u ti o n s o n p ag e . Check the operat ion of the brakelight swit ch ( ) a t th e r ight si de beh ind t he en gin e f rom time to time . A djustme nt is done by t urning t he adjust ing nut ( ). T urn t he nut i n th e dir ect ion ( ) if the swi tch ope rate s too la te and i n di recti on ( ) if the switch [...]

Re fe r t o t h e S a fe ty P r e c a u ti o n s o n p ag e . T he light bulb becomes ver y hot w hile th e light is ON, a nd re mains h ot f or a w hile a f t e ri ti st u r n e dO F F .B es u r et ol e ti tc o o l down bef ore se rvicing. Do not put f inger print s on t he headligh t bulb, as t hey may cr ea te hot spot s on th e bulb and cause i[...]

― ― Headlight bulb: R emove the seat rubber ( ). R emov e the h eadligh t bulb ( ) while pressing dow n on the pin ( ). Disconnect the connect ors ( ). Gently pull t h e low er end of t he headligh t ( ) f orward and remove the headli ght. Position light bulb: Pull ou t t he socket ( ). Pull the position light bulb ( ) out . Ins tall a new bulb[...]

Ins tall a new bulb in the reverse order of removal . Slightly pre ss the bulb ( ) a nd t urn it counter clockwise . R emov e th e t urn signa l lens ( ) a nd th e lens packing ( ) by removing t he scr ew () . T he r ight a nd lef t tur n s ignal bulbs replacem ent can be done in the sam e way. 1. 2. 3. (3) (4) (2) (1) 1 2 3 4 (1) T urn signal lens[...]

Re mo ve th e se a t (p ag e ) . T ur n the socket ( ) count erclockw ise, the n pull it out . Slightly pre ss the bulb ( ) a nd t urn it counter clockwise . Ins tall a new bulb in the reverse order of removal . 1. 2. 3. 4. 1 (1) (2) 2 43 (1) Sock et (2) Bulb Brak e/T ail L ig ht Bulb 101 09/01/30 17:49:04 32KFK600_111[...]

〈〉 Ins tall a new bulb in the reverse order of removal . Pull out t he bulb ( ) w itho ut t urning. R emove the license light cove r ( ). Re mo ve th e sc re ws ( ). 1. 2. 3. (1) 4. (2) (3) 1 3 2 (1) Screws (2) L icense light cover (3) Bul b Li c e n s e Li g h t B u l b Excep t U t y pe 102 09/01/30 17:49:10 32KFK600_112[...]

Clean your motor cycle regula rly t o pr otect the surf ace f inishes a nd inspect f or damage, wea r, a nd oil, coolant or bra ke f luid leakage. Avoid cleani ng produ cts that are not specif ically desig ned f or motorcycle or automo bil e surf aces. T hey may contain harsh detergents or chemi cal solven ts t hat could damag e the meta l, paint ,[...]

A f ter cleani ng, rinse the motorcycle thor oughly wit h plent y of clea n wat er. Str ong dete rgent r esidue ca n corrode alloy pa rts . Dry th e mot or cycle, st ar t th e e ngine, a nd let it run f o r several m inutes. Te s t t h e b ra k e s be f o re r id i n g th e motor cycle. Sev era l applica tions may be necessary to r estore normal br[...]

A luminum ma y cor rode f rom cont act w ith dirt , mud, or road salt . Clean the wheels af t er ridin g thr ough any of t hese substa nces. U se a w et sponge and mild de terge nt. Avoi d stiff bru sh es , steel wool , or cleaner s conta ining abrasiv es or chemica l compounds. A f ter w ash ing, r inse w ith plen ty of wat er and dry with a c lea[...]

T he muf f l er is stainless steel bu t may become st ained by mud or dust. T o re move mud o r dust, use a w et sponge a n da l i q u i dk i t c h e na b r a s i v e ,t h e nr i n s e wel l with cle an water. Dr y with c hamo is or a sof t tow el. If necessary, remove heat stains by using a commercially ava ilable f ine te xture compound. T hen ri[...]

Exten ded storage , such as f o r winter, requi re s that y ou take certain steps t o reduce t he ef f ects of deterioration f rom non-use of the mot orcycle . In addit ion, nece ssary repairs shou ld be made BEFORE storing the motorcycle; ot her wise, t hese rep airs may be f orgo tten by the tim e the motorc ycle is remo ved f rom storage. Change[...]

Remo ve the batte ry. Stor e in an are a protect ed f rom f reezing t emperatures and dire ct sunligh t. Sl ow c harg e the b attery on ce a mon th. Wa sh a nd dry the motorcycle. Wa x a ll painted surf aces. Coat chrome with rust inhibiting oil. L ubrica te the dr ive ch ain (pa ge ). T o pr ev ent rust ing in th e cylinde rs , conta ct y our Hond[...]

Person al saf ety is your f irst priority af t er a crash. If you or a nyone else has been injured, t ake t ime t o a ssess t he sever ity of the injuries and w het her it is saf e to continue riding. Call f or emerge ncy assist ance if nee ded. A lso f ollow a pplicable laws and regulations if another person or vehicle is invol ved in the crash. I[...]

Engine oil A f ter dr aining A f ter draining and oil f ilter cha nge A f ter disasse mbly Fue l ta nk Cooling syst em capa city Passe nger capaci ty Maxim um weight cap acity Overall length Over all w idth Overall height Wheelbase SPECIF ICA T IONS DIMENSIONS CA PA CIT IES 110 2,070 mm (81.5 in ) 1,405 mm (55.3 in ) 1.9 (2.0 US qt , 1.7 Imp qt) 2.[...]

×× ± −− Bore a nd stroke Com pressi on ratio Displacement Spark plug Sta ndard S p a r kp l u gg a p Idle speed V alve cleara nce (Cold) ENGINE 111 60.0 44.2 mm (2.36 1.74 in) 11.0 : 1 250 cm (15.3 cu-in) CR8EH- 9 (NGK) U24FER9 (DENSO) 1,300 100 min (rpm) 0.17 mm (0.007 in ) 0.22 mm (0.009 in ) 0.80 0.90 mm (0.031 0.035 in ) or Intake Exhaus[...]

Caste r Tr ai l T yr e size, f ront T yre size, rea r Ty re t yp e Primar y re duction Gear ratio, 1st 2nd 3rd 4th 5th Fina l reduct ion CHA SSIS A ND SUSPENSION POW ER T R A NSMISSION 112 25°30’ 96 mm (3.8 in ) 110/70-17M/C 54H G601F 140/70-17M/C 66H G602 bias -ply, tubel ess 2.821 2.733 1.800 1.375 1.111 0.965 2.928 BRIDGEST ONE BRIDGEST ONE 0[...]