HONDA CB TWISTER OWNER’S MANUAL © Honda Motor Co., Ltd.
IMPORTANT INFORMATION • RIDER AND PASSENGER This vehicle is designed to carry the rider and one passenger. • ON-ROAD USE This vehicle is designed to be used only on the road. • READ THIS OWNER’S MANUAL CAREFULLY Pay special attention to the safety messages that appear throughout the manual. These messages are fully explained in the “A Few Words About Safety” section which appears before the Contents page.
HONDA CB TWISTER OWNER’S MANUAL All information in this publication is based on the latest production information available at the time of approval for printing. Honda Motor Co., Ltd. reserves the right to make changes at any time without notice and without incurring any obligation. No part of this publication may be reproduced without written permission.
WELCOME The vehicle 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 commands as no other does. Unlike an automobile, there is no metal cage around you. Like an aeroplane, a pre-ride inspection and regular maintenance are essential to your safety. Your reward is freedom.
A FEW WORDS ABOUT SAFETY Your safety, and the safety of others, is very important. And operating this vehicle safely is an important responsibility. To help you make informed decisions about safety, we have provided operating procedures and other information on labels in this manual. This information alerts you to potential hazards that could hurt you or others. Of course, it is not practical or possible to warn you about all hazards associated with operating or maintaining a vehicle.
! DANGER You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions. ! WARNING You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions. ! CAUTION You CAN be HURT if you don’t follow instructions. • Safety Headings – such as Important Safety Reminders or Important Safety Precautions. • Safety Section – such as vehicle Safety. • Instructions – how to use this vehicle correctly and safely. This entire manual is filled with important safety information–please read it carefully.
CONTENTS page 1 1 2 3 7 10 12 12 17 19 21 24 24 25 25 VEHICLE SAFETY Important Safety Information Protective Apparel Load Limits and Guidelines PARTS LOCATION Instruments and Indicators MAJOR COMPONENTS (Information you need to operate this vehicle) Brakes Fuel Engine Oil Tyres ESSENTIAL INDIVIDUAL COMPONENTS Ignition Switch Right Handlebar Controls Left Handlebar Controls Page 27 27 27 29 30 30 31 31 32 34 34 35 36 37 38 FEATURES (Not required for operation) Steering Lock Seat Storage Compartment Docum
Page 40 41 44 44 45 46 48 49 50 52 53 53 54 59 60 60 65 66 67 Safety Precautions Maintenance Schedule Tool Kit Serial Numbers Colour Code Engine Oil Crankcase Breather Spark Plug Valve Clearance Idle Speed Throttle Operation Air Cleaner Drive Chain Front and Rear Suspension Inspection Side Stand Wheel Removal Brake Pad Wear Brake Shoe Wear Battery Page 69 72 72 Fuse Replacement Brake Light Switch Adjustment Bulb Replacement 75 CLEANING 77 STORAGE GUIDE 77 Storage 78 Removal from Storage 79 SPEC
VEHICLE SAFETY Make Yourself Easy to be Visible IMPORTANT SAFETY INFORMATION Some drivers do not see vehicles because they are not looking for them. To make yourself more visible, wear bright reflective clothing, position yourself so other drivers can see you, signal before turning or changing lanes, and use your horn when required, it will help others notice you.
Keep Your Vehicle in Safe Condition PROTECTIVE APPAREL For safe riding, it is important to inspect your vehicle before every ride and perform all recommended maintenance. Never exceed load limits, and only use accessories that have been approved by Honda for this vehicle. See page 5 for more details. For your safety, we strongly recommend that you always wear an approved vehicle helmet, eye protection, boots, gloves, long pants and a long-sleeved shirt or jacket whenever you ride.
Helmets and Eye Protection • Your helmet is your most important piece of riding gear because it offers the best protection against head injuries. A helmet should fit your head comfortably and securely. A bright-colored helmet can make you more noticeable in traffic, as can reflective strips. LOAD LIMITS AND GUIDELINES An open-face helmet offers some protection, but a full-face helmet offers more. Always wear a face shield or goggles to protect your eyes and help your vision.
modifications, and poor maintenance can also reduce your safety margin. The following pages give more specific information on loading, accessories and modifications. Loading How much weight you put on your vehicle, and how you load it, are important to your safety. Anytime you ride with a passenger or cargo you should be aware of the following information. ! WARNING Overloading or improper loading can cause a crash and you can be seriously hurt or killed.
motorcycle is properly loaded, you should ride at reduced speeds whenever carrying cargo. Follow these guidelines whenever you carry a passenger or cargo: Accessories and Modifications Modifying your vehicle or using non-Honda accessories can make your vehicle unsafe. Before you consider making any modifications or adding an accessory, be sure to read the following information. • Check that both tyres are properly inflated (page 21).
Accessories • We strongly recommend that you use only genuine Honda accessories that have been specifically designed and tested for your vehicle. Because Honda cannot test all other accessories, you must be personally responsible for proper selection, installation and use of non-Honda accessories.
PARTS LOCATION/ iqtksZ Fuel meter dh fLFkfr Headlight dimmer switch Speedometer gSMykbV fMEej fLop LihMksehVj High beam indicator gkbZ che bafMdsVj ¶;wy ehVj Neutral indicator U;wVy ª bafMdsVj Front brake fluid reservoir ÝaV czd s ¶ywbM fjt+okZ;j Rearview mirror fj;j O;w fejj Rearview mirror fj;j O;w fejj Front brake lever Clutch lever ÝaV czd s yhoj Dyp yhoj Headlight switch gSM ykbV fLop Throttle grip Turn signal switch FkzkVS y fxzi VuZ flx~uy fLop Horn button gkWuZ cVu Signal I
Kickstarter Storage Compartment fddLVkVZj LVksjt s dEikVZeVa s Air Cleaner ,;j Dyhuj 8 Passenger Footpeg Footpeg ;k=h QqViSx QqViSx Rear brake pedal Oil filler cap/dipstick fj;j czd s iSMy vkW;y fQyj dSi@fMifLVd
Helmet holder Battery/Main fuse cSVjh/esu ¶;wt Choke knob gsYesV gksYMj Fuse ¶;wt pksd ukWc Seat lock lhV ykWd Fuel knob ¶;wy ukWc Engine oil drain plug baftu vkW;y Mªus Iyx Gear Shift lever fx;j f“k¶V yhoj Rider Footpeg pkyd QqViSx Side stand Centre stand lkbZM LVSMa Passenger Footpeg ;k=h QqViSx lSUVj LVSMa 9
INSTRUMENTS AND INDICATORS The indicators are contained in the instrument panel. Their functions are described in the tables on the following pages.
(Ref. No.) Description Function (1) Speedometer Shows riding speed. (2) Odometer Shows accumulated mileage. (3) Fuel meter Shows approximate fuel function available (page 12) (4) High beam indicator (blue) Indicate when the headlight is glowing on high beam. (5) Turn signal indicator (orange) Flashes when any of the turn signal operates. (6) Neutral indicator (green) Indicate when the transmission is in neutral.
FUEL METER MAJOR COMPONENTS When the gauge needle enters the red band (2), it shows the less fuel in the tank. Turn the fuel valve to the RES position and you should refill the tank as soon as possible. The amount of fuel left in the tank with the vehicle set upright when the needle enters the red band is approximately. (INFORMATION YOU NEED TO OPERATE THIS VEHICLE) BRAKES 1.6 L (0.42 US gal, 0.
Worn pads should be replaced. If the pads are not worn, have your brake system inspected for leaks. The recommended brake fluid is DOT 3 or DOT 4 brake fluid from a sealed container, or an equivalent. Front Brake (Drum type) Brakes are items of personal safety and should always be maintained in proper adjustment. The distance the front brake lever or rear brake pedal moves before the brake starts to engage is called freeplay.
Adjustment: 1. 2. Front brake adjustment should be made using the front brake-adjusting nut (2) at the front wheel. Adjust the brake lever free play with the front brake-adjusting nut. Turning the nut clockwise will decrease freeplay and turning the nut counterclockwise will increase freeplay. Make sure the cut-out on the adjusting nut is seated on the brake arm pin (3) after making final freeplay adjustment. Make sure the brake arm, spring and fasteners are in good condition.
REAR BRAKE Adjustment: 1. Place the vehicle on its center stand. 2. Measure the distance of rear brake pedal (1) moves before the brake starts to take hold. Freeplay should be: 20-30 mm (0.8-1.2 in) 3. If adjustment is necessary, turn the rear brake-adjusting nut (2). (1) (1) Rear brake pedal ¼fj;j czd s iSMy½ (2) Make sure the cut-out on the adjusting nut is seated on the brake arm pin (3) after making final free play adjustment. 4.
1. Other Checks: Make sure the brake rod, brake arm, spring and fasteners are in good condition. CLUTCH Clutch adjustment may be required if the vehicle stalls when shifting into gear or tends to creep; or if the clutch slips, causing acceleration to lag behind engine speed. Normal clutch lever freeplay is: 10-20 mm (0.4-0.8 in) (1) 2. Loosen the lock nut (2) at the lower end of the cable. Turn the adjusting nut (3) to obtain the specified freeplay. Tighten the lock nut and check the adjustment.
If proper adjustment cannot be obtained or the clutch does not work correctly, see your Honda dealer. Other Checks: Check the clutch cable for kinks or signs of wear that could cause sticking or failure. FUEL FUEL KNOB The three-way fuel knob (1) is on the left side below the fuel tank. ON With the fuel valve in the ON position, fuel will flow from the main fuel supply to the carburetor. RES With the fuel knob in the RES position, fuel will flow from the reserve fuel supply to the carburetor.
FUEL TANK The fuel tank capacity including the reserve supply is: 8.0 L (2.11 US gal, 1.76 Imp gal) To open the fuel fill cap (1), slide the fuel cap key shutter insert the ignition key (2) and turn it clockwise. The fuel fill cap will pop up and can be lifted off. Do not overfill the tank. There should be no fuel in the filler neck (3). ! WARNING Petrol is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Stop the engine and keep heat, sparks and flame away.
Use unleaded or low- lead petrol with a research octane number of 91 or higher. We recommend that you use unleaded petrol because it produces fewer engine and spark plug deposits and extends the life of exhaust system components. NOTICE If “spark knock” or “ pinking” occurs at a steady engine speed under normal load, change brands of petrol. If the spark knock or pinking persists, consult your Honda dealer.
The level must be maintained between the upper (1) and lower (2) level marks on the oil filler cap/dipstick (3). 1. Start the engine and let it idle for 3-5 minutes. 2. Stop the engine and put the vehicle on its center stand on level ground. 3. After 2-3 minutes, remove the oil filter cap/dipstick, wipe it clean, and reinsert the oil filler cap/dipstick without screwing it in. Remove the oil filler cap/ dipstick.
TYRES AIR PRESSURE To safely operate your vehicle, your tyres must be the proper type and size, in good condition with adequate tread, and correctly inflated for the load you are carrying. The following pages give more detailed information on how and when to check your air pressure, how to inspect your tyres for damage and what to do when your tyres need to be repaired or replaced. Keeping your tyres properly inflated provides the best combination of handling, tread life and riding comfort.
higher than of the tyres were “cold”. This is normal; so do not let air out of the tyres to match the recommended air pressures given below. If you do the tyres will be under inflated. The recommended “cold” tyre pressures are: kPa (kgf/cm², psi) Driver only Front Rear 175 (1.75, 25) 200 (2.00, 29) Driver and one passenger Front Rear 175 (1.75, 25) 280 (2.80, 41) HIGH NORMAL LOW NOTICE We recommend that always maintain correct air pressure in tyres.
TREAD WEAR TYRE REPLACEMENT Replace tyres when tread reach to the wear indicator arrow. The tyres that came on your vehicle were designed to match the performance capabilities of your vehicle and provide the best combination of handling, braking, durability and comfort.
ESSENTIAL INDIVIDUAL COMPONENTS IGNITION SWITCH The ignition switch (1) is below the speedometer. ON OFF (1) LOCK (1) Ignition switch Key Position LOCK (steering lock) OFF ON 24 ¼bXuh“ku fLop½ Function Key Removal Steering is Locked. Engine and lights Key can be removed cannot be operated. Engine and lights cannot be operated. Key can be removed Engine and lights can be operated Key cannot be removed Turn signal, passing light control switch and horn can be operated.
RIGHT HANDLEBAR CONTROL LEFT HANDLEBAR CONTROLS START BUTTON (IN CASE OF SELF START ONLY) HEADLIGHT SWITCH (1) The start button (1) is next to the throttle grip. When the start button is pressed, the starter motor cranks the engine. See page 33 for the starting procedure. The headlight switch (1) has two positions; and ( ) OFF ( ) : Headlight, taillight and meter lights on. : Headlight, taillight and meter lights off.
HEADLIGHT DIMMER SWITCH (2) HORN BUTTON (4) Push the dimmer switch to (HI) to select high beam or to (LO) to select low beam Press the button to sound the horn. TURN SIGNAL SWITCH (3) Move to (L) to signal a left turn, (R) to signal a right turn. Press to turn off the signal.
FEATURES SEAT (NOT REQUIRED FOR OPERATION) STEERING LOCK Removal For the seat removal, insert the ignition key into the seat lock and turn it clockwise. Pull the seat back and up. To lock the steering, turn the handlebar all the way to the left or right, turn the key (1) to LOCK position while pushing in. Remove the key. To unlock the steering, turn the key to OFF. Do not turn the key to LOCK while riding the vehicle which may result loss of vehicle control.
Installation For seat installation, insert the prongs into the recess under the frame cross member and then push down on the rear of the seat. Be sure the seat is locked securely in position after installation. HELMET HOLDER The helmet holder is located below the seat. Remove the seat. Hang the helmet on the holder hook (1). Install the seat and lock it securely.
LEFT SIDE COVER STORAGE COMPARTMENT The Left sidecover must be removed for battery and fuse maintenance. Removal: 1. Remove the seat (page 27). 2. Remove the screws (1). 3. Carefully pull the side cover (2) out from the grommet (3). Installation: • Installation can be done in the reverse (3) order of removal The storage compartment (1) is located under the seat (page 27). This compartment is for light weight items. Tool kit and first aid kit should be stored in this light weight compartment.
DOCUMENT BAG The document bag (1) is in the document compartment (2) on the reverse side of the seat (3). This owner’s manual and other documents should be stored in the document bag. When washing your vehicle, be careful not to flood this area with water. HEADLIGHT AIM VERTICAL ADJUSTMENT ADJUSTMENT Vertical adjustment can be made by moving the headlight assy, as necessary. To move the headlight assy, loosen the bolt (1). Tighten the bolt after adjustment. Obey local laws and regulations.
OPERATION PRE-RIDE INSPECTION For your safety, it is very important to take a few moments before each ride to walk around your vehicle and check its condition. If you detect any problem, be sure you take care of it, or have it corrected by your Honda dealer. ! 1. Engine oil level- add engine oil if required (page 19). Check for leaks. 2. Fuel Level- fill fuel tank when necessary (page 18). Check for leaks. 3. (For Drum type) Front and rear brakes.
8. Lights and horn – check these turn signals, indicators and horn function properly. STARTING THE ENGINE Always follow the proper starting procedure described below. The vehicle can also be started with the transmission in gear by disengaging the clutch before operating the self starter. Your vehicle’s exhaust contains poisonous carbon monoxide gas. High level of carbon monoxide can collect rapidly in enclosed areas such as a garage.
STARTING PROCEDURE Cold Engine: 1. Pull the choke lever (1) outward to fully ON (A). 2. With the throttle closed, press the start button. (or use the kickstarter) Lightly depress the kick-starter until resistance is left. Then let the kick-starter return to top of its stroke. With the throttle closed, operate the kick starter. 3. When engine speed begins to pick up, slowly press the choke lever to off position.
FLOODED ENGINE RUNNING- IN (Use the start button) Assure your vehicle’s future reliability and performance by paying extra attention to how you ride during the first 500 km (300 miles). If the engine fails to start after repeated attempts, it may be flooded with excess fuel. To clear a flooded engine, turn the ignition switch to ON, and move the choke lever to fully OFF (B). Open the throttle fully and crank the engine for 5 seconds.
3. Slowly release the clutch lever and at the same time gradually increase engine speed by opening the throttle. Coordination of the throttle and clutch lever will assure a smooth positive start. 4. When the vehicle attains a moderate speed, close the throttle, pull in the clutch Lever and shift to 2nd gear by raising the gearshift pedal. This sequence is repeated to progressively shift to 3rd and 4th (top) gears. 5. Coordinate the throttle and brakes for smooth deceleration. 6.
DOWNSHIFTING More higher downshifting speeds may over load the engine and can cause damage to the engine and transmission. BRAKING (Drum Type) Your vehicle is equipped with mechanicallyactivated drum brakes. Operating the brake lever applies the front drum brake. Depressing the brake pedal applies the rear drum brake. (Disc Type) Your vehicle is equipped with a hydraulically activated disc brake in front and a mechanically- activated drum brake at the rear.
• • • When riding in wet or rainy condition, on loose surfaces, the ability to maneuver and stop will be reduced. All of your conditions, Rapid acceleration, braking or turning may cause loss of control. For your safety, exercise extreme caution when braking, accelerating or turning. When descending a long, steep grade, use engine compression braking by down- shifting with intermittent use of both brakes. Continuous brake application can overheat the brakes and reduce their effectiveness.
ANTI THEFT TIPS 1. 2. Always lock the steering and never leave the key in the ignition switch. This sounds simple but people do forget. NAME: _______________________ ADDRESS: ____________________ ____________________________ Be sure the registration information for your motorcycle is accurate and current. PHONE NO: ____________________ 3. Park your vehicle in a locked garage whenever possible. MAINTENANCE 4. Use an additional anti-theft device of good quality. 5.
These instructions are based on the assumption that the vehicle will be used exclusively for its designed purpose. Sustained high speed operation or operation in unusually wet or dusty conditions will require more frequent service than specified in the Maintenance Schedule. Consult your Honda dealer for recommendations applicable to your individual needs and use.
! WARNING Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or killed. • Read the instructions before you begin, and make sure you have the tools and skills required. • To help prevent the vehicle from falling over, park it on a firm, level surface, using the center stand to provide support. • To reduce the possibility of a fire or explosion be careful when working around petrol or batteries.
MAINTENANCE SCHEDULE Perform the pre-ride Inspection (Ref. page 31) at each scheduled maintenance period. I:INSPECT, CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY C:CLEAN R: REPLACE A:ADJUST L:LUBRICATE. The following items require some mechanical knowledge. Certain item (particularly those marked * and **) may require more technical information and tools. Consult your Honda dealer.
FREQUENCY WHICHEVER ODOMETER READING [NOTE (1)] PAID SERVICE COMES SERVICE 1st 2nd 3rd 4th (Subsequent days /Kms applicable from last service) FIRST DAYS 30 90 150 210 60 120 REMARK ITEM NOTE KMS 750 3000 6000 9000 3000 6000 * FUEL LINE I I * FUEL STRAINER SCREEN C C * THROTTLE OPERATION I I I I I I * CHOKE OPERATION I I I I I I Do not open the air cleaner element untill AIR CLEANER (NOTE 2) R Replace every 15000 kms 15000 kms.unless there is any drivability problem.
FREQUENCY ITEM BRAKE LIGHT SWITCH HEAD LIGHT AIM CLUTCH SYSTEM SIDE STAND * SUSPENSION * NUTS, BOLTS, FASTENERS ** WHEELS/TYRES ** STEERING MOVEMENT ALL OTHER ELECTRICAL SWITCHES WASHING & CLEANING TEST DRIVE WHICHEVER ODOMETER READING [NOTE (1)] SERVICE COMES SERVICE 1st 2nd 3rd 4th (Subsequent daysPAID /Kms applicable from last service) FIRST DAYS 30 90 150 210 60 120 REMARK NOTE KMS 750 3000 6000 9000 3000 6000 I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I
TOOL KIT SERIAL NUMBER The tool kit (1) is in the storage compartment (2) under the passenger seat. The frame and engine serial numbers are required when registering your vehicle. They may also be required by your dealer when ordering replacement parts. Some road side repairs, minor adjustments and parts replacement can be performed with the tools contained in the kit.
The frame number (1) is stamped on the right side of the frame body. The engine number (2) is stamped on the left side of the crankcase. ENGINE NO. COLOUR CODE The colour table is attached below. It is useful during ordering the replacement parts. S.No. 1. 2. 3. 4. 5.
ENGINE OIL Refer to the Safety Precautions on page 40. Engine Oil Good engine oil has many desirable qualities. Use only high detergent, quality motor oil certified on the container to meet or exceed requirements for API Service Classification SJ. Viscosity: Viscosity grade of engine oil should be based on average atmospheric temperature in your riding area. The following provides a guide to the selection of the proper grade or viscosity of oil to be used at various atmospheric temperatures.
Please dispose of used engine oil in a manner that is compatible with the environment. We suggest you take it in a sealed container to your local recycling center or service station for reclamation. Do not throw it in the trash or pour it on the ground or down a drain. 1. 2. 3. Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, NOTICE Always use Honda genuine engine oil.
7. 2-3 minutes after stopping the engine, check oil level with dipstick. It should be on upper level mark of the dipstick with vehicle standing upright onfirm level ground. Make sure there are no oil leaks. CRANKCASE BREATHER Refer to the Safety Precautions on Page 40. 1. Remove the left side cover (page 29) 2. Remove the crankcase breather tube (1) from the air cleaner housing and drain deposits into a suitable container. 3. Reinstall the crankcase breather tube.
SPARK PLUG 3. Refer to the safety precautions on page 40. Recommended plugs: Standard: CPR7EA-9 (NGK) 4. NOTICE Never use a spark plug with an improper heat range. Severe engine damage could result. 1. Disconnect the spark plug cap (1) from the spark plug. 2. Clean any dirt from around the spark plug base. Remove the spark plug using a spark plug wrench (2) and spanner (3) furnished in the tool kit. Inspect the electrodes and center porcelain for deposits, erosion or carbon fouling.
5. Make sure the plug washer is in good condition. 6. Washer of the plug attached thread the spark plug in by hand prevent cross threading. (4) (3) NOTICE Improperly tightened spark plug: Too loose:- Can damage the engine or can burn a piston. Too tight:- Can damage the threads of cylinder head. 8. Reinstall the spark plug cap. Take care to avoid pinching any cables or wires. (3) Spark plug gap ¼LikdZ Iyx xSi½ (4) Side electrode ¼lkbZM bZyD S VªkM s ½ 7.
The clearance will change as the engine temperature rises. The adjustment must be made when the piston is at the top of the compression stroke when both the intake and exhaust valves are closed. (3) (2) Check the clearance of both valves by inserting a feeler gauge (5) between the adjusting screw (6) and the valve stem. Clearance should be: Intake: 0.10 mm (0.004 in) Exhaust: 0.10 mm (0.004 in) Finally, recheck the clearance to make sure that adjusting has not been disturbed.
IDLE SPEED 2. Refer to the safety precautions on page 40. The engine must be at normal operating temperature for accurate idle speed adjusting. 10 minutes of stop-and-go riding is sufficient. Do not attempt to compensate for faults in other systems by adjusting idle speed. See your Honda dealer for regularly scheduled carburetor adjustments. 1. Remove the right side cover. (A) (1) (B) (1) Throttle stop screw (A) Increase ¼c<+ k ,s a ½ (B) Decrease ¼?kVk,s a ½ 52 ¼FkzkWVy LVkWi LØw½ 3. 4.
THROTTLE OPERATION AIR CLEANER Refer to the safety Precautions on page 40. Refer to the Safety Precautions on page 42. 1. The air cleaner element should be replaced at regular intervals (Ref. page 42). Replace more frequently when riding in unusually wet or dusty areas. Check for smooth rotation of the throttle grip from the fully open to the fully closed position at both full steering positions. 2. Measure the throttle grip free play at the throttle grip flange.
4. Viscous type air filters should be replaced regularly. Do not reuse it by cleaning. 5. If the filter element is cleaned using pressured air or any solvent, viscous oil will be lost and as the base element is coarse paper, dust may enter along with air which will damage the engine. 6. Replace the air cleaner element if it is excessively dirty, torn or damage. Use Honda genuine air cleaner element specified for your model.
Inspection: 1. Turn the engine off, place the vehicle on its center stand, and shift the transmission into neutral. 2. Move the chain (1) up and down with your finger. Drive chain slack should be adjusted approximately to allow the following vertial movement by hand: 15-25 mm (0.59-0.98 in) 3. Rotate the rear wheel slightly and then stop to check the drive chain slackness again. Repeat this procedure several times. Drive chain slack should remain constant.
5. Inspect the sprocket teeth for possible wear or damage. Replace if necessary. Damaged sprocket Teeth Worn sprocket Teeth Replace Replace Normal sprocket Teeth GOOD If the drive chain or sprockets are excessively worn or damaged, they should be replaced. Never use a new chain with worn sprockets; rapid chain wear will result. 56 Adjustment: Drive chain slack should be checked and adjusted, if necessary, every 1,000 km (600 miles).
Align the chain adjuster index marks (5) with the rear edge (6) of the adjusting slot on both sides of the swingarm. 5. (2) (5) (6) (4) (5) (3) (4) (1) Rear axle nut ¼fj;j ,Dly uV½ Rear axle shaft ¼fj;j ,Dly ”kk¶V½ Drive chain lock nuts ¼Mªkbo psu ykWd uVl½ Drive chain adjusting nuts ¼Mªkbo psu ,MtfLVax uVl½ Index marks ¼ba M S D l ekDlZ ½ Rear edge of adjusting slot ¼,MtfLVax LykV dk fiNyk fdukjk½ Tighten the rear axle nut to: 54 N.m (5.5 kgf.m, 40lbf.
Lubrication Removal and cleaning: Lubricate every 1,000 km (600 miles) or sooner if chain appears dry. To clean and lubricate the chain visit your nearest Honda Dealer/Service Center. R 428HBS-118 When the drive chain becomes dirty, it should be removed and cleaned prior to lubrication. 1. With the engine off, and carefully remove the master link retaining clip (1) with a pair of pliers. Do not bend or twist the clip. Remove the master link. Remove the drive chain from the vehicle. 2.
sprockets must be in good condition, or the new replacement chain or sprocket will wear rapidly. 4. Lubricate the drive chain (page 58). 5. Pass the chain over the sprockets and join the ends of the chain with the master link.For ease of assembly, hold the chain ends against adjacent rear sprocket teeth while inserting the master link. The masterlink is the most critical part affecting the security of the drive chain.
2. 3. Swingarm bearings should be checked by pushing hard against the side of the rear wheel while the motorcycle is on the center stand. Freeplay indicates worn bearings. If the side stand is squeaky or stiff, clean the pivot area and lubricate the pivot bolt with clean engine oil. Carefully inspect all front and rear suspension fasteners for tightness. Front Wheel Removal SIDE STAND Refer to the safety precautions on page 40.
necessary. See your Honda dealer for this service (3) (2) (1) (2) Tab ¼LihMks e hVj ds c y½ • • Reverse the removal procedure. Position the wheel between the fork legs and insert the front axle from the right side, through the right fork leg and wheel hub. • Make sure that the lug (5) on the fork leg is contacting the lugs on the speedometer gear box. Tighten the front axle nut to the specified torque. Front axle nut torque: 54 N.m (55 kgf.m, 40 lbf.
If a torque wrench was not used for installation, see your Honda dealer as soon as possible to verify proper assembly. Improper assembly may lead to loss of braking capacity. 3. Remove the front brake adjusting nut (3) and remove the front brake cable (4) from the brake arm (5). Remove the front axle nut (6). Remove the front axle shaft (7) and the wheel. (6) 4. 5. (5) (5) (3) (5) Lug ¼yx½ Front wheel removal (Drum type) 1.
Installation Notes: • Reverse the removal procedure. • Position the wheel between the fork legs and insert the front axle from the right side, through the right fork leg and wheel hub. Tighten the front axle nut to specified torque. Front axle nut torque: 54 N.m (5.5 kgf.m, 40 lbf.ft) • • Make sure that the tang (8) on the left front fork leg is located in the slot (9) in the brake panel. • Adjust the brake (page 14-15).
REAR WHEEL REMOVAL 3. 1. Place the vehicle on its center stand. 2. Remove the rear brake adjusting nut (1). Disconnect the brake rod (2) from the brake arm (3). 4. 5. (3) (2) (7) (1) (6) Disconnect the brake stopper arm (4) from the brake panel by removing the cotter pin (5), stopper arm nut (6), washer and rubber grommet. Remove the rear axle nut (7). Remove the rear axle shaft (8), side collar and rear wheel from the swingarm.
Installation Notes: • Reverse the removal procedure. • Tighten the rear axle nut and brake stopper arm nut to specified torque. Rear axle nut torque: 54 N.m (5.5 kgf.m, 40 lbf.ft) Brake stopper arm nut torque: 22 N.m (5.5 kgf.m, 40 lbf.ft) • Adjust the brake (page 14-15) and drive chain (page 54). • After installing the wheel, apply the brake several times and then check if the wheel rotates freely. Recheck the wheel if the brake drags or if the wheel does not rotate freely.
Brake shoe wear Refer to the safety precautions on page 40. (Drum Type) The front and rear brakes are equipped with brake wear indicators. (Disc Type) The rear brake is equipped with a brake wear indication. When the brake is applied, an arrow (1) attached to the brake arm (2) moves toward a reference mark (3) on the brake panel (4). If the arrow aligns with the reference mark on full application of the brake, the brake shoes must be replaced.
BATTERY Refer to the safety precautions on page 40. It is not necessary to check the battery electrolyte level or add distilled water as the battery is a maintenance-free (sealed) type. If your battery seems weak and/or is leaking electrolyte (causing hard starting or other electrical troubles), contact your Honda dealer. NOTICE Your battery is maintenance-free type and can be permanently damaged if the cap strip is removed.
Removal 1. Make sure the ignition switch is OFF. 2. Remove the left side cover (page 29). 3. Remove the fuse holder (1). 4. Remove the bolt (2) and open the battery holder (3). 5. Disconnect the negative (-) terminal lead (4) from the battery, first. 6. Disconnect the positive (+) terminal lead (6). 7. Pull out the battery (5) from the battery box. Installation 1. 68 Reinstall in the reverse order of removal. Be sure to connect the positive (+) terminal first, then the negative (-) terminal.
FUSE REPLACEMENT Fuse holder Refer to the Safety Precautions on page 40. The fuse holder located near the battery. The specified fuse is: 10A-(Both kick and self) When frequent fuse failure occurs, it usually indicates a short circuit or an overload in the electrical system. See your Honda dealer for repair. NOTICE Never use a fuse with a different rating from that specified. Serious consequence to the electrical system or a fire may result, causing a dangerous loss of lights or engine power. 1.
2. 3. 4. Remove the left side cover (page 29). Open the fuse holder (1). Pull out the old fuse and install a new fuse. The spare fuse (2) is attached to the fuse holder. Install the fuse holders and left side cover. 5. Removal Do not try to open the clips, which prevent fuse from coming out; you could bend them and cause poor contact with the new fuse. A loose fuse could cause damage to the electrical system and even start a fire.
MAIN FUSE: 1. The main fuse (1) is located near the battery. The specified fuse is: 15A (Both kick and self) Turn the ignition switch OFF before checking or replacing the fuses to prevent an accident short-circuit. 2. Remove the left side cover (page 29). 3. Disconnect the wire connector (2) of the relay comp start (3). 4. Pull the fuse out. If the main fuse is blown, install a new main fuse. (2) (3) (4) The spare main fuse (4) is located under the relay comp start. 5.
BRAKELIGHT SWITCH ADJUSTMENT BULB REPLACEMENT Refer to the safety Precautions on page 40. Refer to the Safety Precautions on page 40. Check the operation of the brakelight switch (1) at the right side behind the engine from time to time. The light bulb becomes very hot while the light is ON, and remain hot for a while after it is tusrned OFF. Be sure to let it cool down before servicing. Adjustment is done by turning the adjusting nut (2).
HEADLIGHT BULB 1. Remove the front cowl (1) by removing the screws (2), (3). 2. Disconnect the connector (4). 3. 4. 5. (2) 6. (3) Remove the dust cover (1). Remove the bulb (2) while pressing down the locking pin (3). Install a new bulb in the reverse order of removal. Install the dust cover (1) with its “TOP” mark (4) facing up.
BRAKE/TAIL LIGHT BULB FRONT/REAR TURN SIGNAL BULB 1. 2. 1. Remove the turn signal lens (1) by removing the screws (2). 2. Slightly press the bulb (3) and turn it counterclockwise. 3. Install a new bulb in the reverse order of removal. (3) (1) 3. 4. 5. Open the seat . Remove the inspection cover plate by removing the screws (1). Remove the taillight holder by turning counterclockwise. Remove the bulb from bulb holder by pressing in & turning counterclockwise.
Avoid cleaning products that are not specifically designed for vehicle or automobile surfaces. They may contain harsh detergents or chemical solvents that could damage the metal, paint, and plastic on your vehicle. If your vehicle is still warm from recent operation, give the engine and exhaust system time to cool off. We do not recommend the use of high pressure water spray. NOTICE High pressure water (or air) can damage certain parts of the vehicles. Washing the vehicle 1.
4. After cleaning, rinse the vehicle thoroughly with plenty of clean water. strong detergent residue can corrode alloy parts. 5. Dry the vehicle start the engine, and let it run for several minutes. 6. Test the brakes before riding the vehicle. Several applications may be necessary to restore normal braking performance. 7. Lubricate the drive chain immediately after washing and drying the vehicle. Braking efficiency may be temporarily impaired immediately after washing the vehicle.
2. Dry the vehicle and to protect surface of metal, apply wax on it. STORAGE GUIDE To assure proper performance after storage lasting more than one month, it is important to drain the carburetor. ! Extended storage, such as for winter, requires that you take certain steps to reduce the effects of deterioration from nonuse of the vehicle. In addition necessary repairs should be made BEFORE storing the vehicle, otherwise, these repairs may be forgotten by the time the vehicle is removed from storage.
• • • • 4. 5. 6. 7. 78 Remove the spark plug from the engine and store it in a safe place. Do not connect the spark plug to the spark plug cap. Pour a tablespoon (15-20 cm³) of clean engine oil into the cylinder and cover the spark plug hole with a piece of cloth. Crank the engine several times to distribute the oil. Reinstall the spark plug and spark plug cap. Remove the battery. Store in an area protected from freezing temperatures and direct sunlight.
SPECIFICATIONS DIMENSIONS Overall length Overall width (Disc self) (Self drum) (Kick drum) Overall height Wheelbasse 1972 mm (77.6 in) 742 mm 742 mm 742 mm 1075 mm (42.3 in) 1262 mm (49.6 in) WEIGHT Dry weight (Kick drum) (Self drum) (Self Disc) 102 kg (224 lbs) 102 kg (224 lbs) 102 kg (224 lbs) After draining After disassembly Fuel tank Fuel reserve Passenger capacity 0.85 L (0.9 US qt, 0.8 Imp qt) 1.0 L (1.1 US qt, 0.7 Imp qt) 8.0 L (2.11 US gal, 1.76 Imp gal) 1.6 L (0.42 US gal, 0.
ENGINE Bore and stroke 50.0 x 55.6 mm (1.97 x 2.19 in) Compression ratio 9.0 : 1 Displacement 109.1 cm³ (6.66 cu-in) Spark Plug Standard CPR7EA-9 (NGK) Spark plug gap 0.8 - 0.9 mm (0.031 - 0.035 in) Idle speed 1,400 ± 100 min-1 (rpm) Valve clearance (Cold) Intake 0.10mm (0.004 in) Exhaust 0.10mm (0.004 in) CHASSIS AND SUSPENSION Caster 26° Trail 138 mm (5.
POWER TRANSMISSION Primary reduction 3.722 Gear ratio, 1st 3.182 2nd 1.706 3rd 1.238 4th 0.917 Final reduction 3.000 ELECTRICAL Battery 12V - 3Ah Generator 0.14kW/5,000 min-1 (rpm) LIGHT Headlight 12V-35/35W Brake/tail light Turn signal light Instrument lights 12V-5/21W Front 12V-10W Rear 12V-10W 12V-1.
Speedometer lamp 1.7W x 2 Neutral indicator 1.7W x 1 Turn signal indicator 1.7W High beam indicator 1.
CATALYTIC CONVERTER This motorcycle is equipped with a catalytic converter. The catalytic converter contains precious metals that serve as catalysts, promoting chemical reactions to convert the exhaust gases without affecting the metals. The catalytic converter acts on HC, CO and NOx. A replacement unit must be an original Honda part or its equivalent. • Always use unleaded petrol. Even a small amount of leaded petrol can contaminates the catalyst metals making the catalytic converter ineffective.
