Unicorn - Service Manuval PDF

Spark Plug Checking Spark Plug Open end wrench Maintenance For the recommended spark plug, see “Specifications”. 2 P. 96 Use only the recommended type of spark plug in the recommended heat range. NOTICE Using a spark plug with an improper heat range can cause engine damage. 1. Disconnect the spark plug cap from the spark Spark plug wrench Spark plug cap plug. 4. Inspect the electrodes and centre porcelain 2. Clean any dirt from around the spark plug base. for deposits, erosion or carbon fouling. ► If the erosion or deposit is heavy, replace 3. Remove the spark plug using provided spark plug wrench. 2 P. 42 the plug. ► Clean a carbon or wet-fouled plug with a plug cleaner, otherwise use a wire brush. 48

Spark Plug ► Checking Spark Plug 5. Check the spark plug gap using a wire-type 8. Tighten the spark plug: Maintenance feeler gauge. z If the old plug is good: ► If adjustment is necessary, bend the side electrode carefully. 1/8 turn after it seats. z If installing a new plug, tighten it twice to The gap should be: 0.8 to 0.9 mm (0.03 to 0.04 in) prevent loosening: a) First, tighten the plug: Side electrode 1/2 turn after it seats. b) Then loosen the plug. c) Next, tighten the plug again: 1/8 turn after it seats. Spark plug gap NOTICE An improperly tightened spark plug can damage the Plug washer engine. If a plug is too loose, a piston may be damaged. If a plug is too tight, the threads may be 6. Make sure the plug washer is in good damaged. condition. 9. Install the parts in the reverse order of 7. Install the spark plug. With the plug washer removal. attached, thread the spark plug in by hand to ► When reinstalling the spark plug cap, take prevent cross-threading. care to avoid pinching any cables or wires. 49

Engine Oil Oil fill cap/dipstick Maintenance Checking the Engine Oil Upper level Lower level 1. If the engine is cold, idle the engine for 3 to 5 minutes. 2. Turn the ignition switch to the OFF position and wait 2 to 3 minutes. 3. Place your vehicle on its centre stand on a firm, level surface. 4. Remove the oil fill cap/dipstick and wipe it clean. 5. Insert the oil fill cap/dipstick until it seats, but don’t screw it in. 6. Check that the oil level is between the upper level and lower level marks on the oil fill cap/ dipstick. 7. Securely install the oil fill cap/dipstick. 50

Engine Oil ► Adding Engine Oil Adding Engine Oil For the recommended oil and oil selection Maintenance guidelines, see “Maintenance Fundamentals”. If the engine oil is below or near the lower level 2 P. 36 mark, add the recommended engine oil. Changing Engine Oil 2 P. 36, 96 Changing the oil requires special tools. We recommend that you have your vehicle serviced 1. Remove the oil fill cap/dipstick. Add the by your dealer. recommended oil until it reaches the upper 1. If the engine is cold, idle the engine for 3 to 5 level mark. ► Place your vehicle on its centre stand on a minutes. firm, level surface when checking the oil 2. Turn the ignition switch to the OFF position level. ► Do not overfill above the upper level and wait for 2 to 3 minutes. mark. 3. Place your vehicle on its centre stand on a ► Make sure no foreign objects enter the oil filler opening. firm, level surface. ► Wipe up any spills immediately. 4. Place a drain pan under the drain bolt. 2. Securely reinstall the oil fill cap/dipstick. NOTICE Overfilling with oil or operating with insufficient oil can cause damage to your engine. Do not mix different brands and grades of oil. The may affect lubrication and clutch operation. continued 51

Maintenance Engine Oil ► Changing Engine Oil 6. Install a new sealing washer onto the drain 5. Remove the oil fill cap/dipstick, drain bolt bolt. Tighten the drain bolt. and sealing washer to drain the oil. Torque: 30 N·m (3.1 kgf·m, 22 lbf·ft) ► Discard the oil at an approved recycling 7. Fill the crankcase with the recommended centre. oil (2 P. 36, 96) and install the oil fill cap/ Sealing washer dipstick. Oil drain bolt Required oil When changing oil: 1.0 litres (1.1 US qt, 0.9 Imp qt) 8. Check the oil level. 2 P. 50 9. Check that there are no oil leaks. 52

Brakes Front brake fluid reservoir Maintenance LWR mark Checking the Front Brake Fluid 1. Place your vehicle in an upright position on a firm, level surface. 2. Check that the brake fluid reservoir is horizontal and that the fluid level is above the LWR level mark. If the brake fluid level in the reservoir is below the LWR mark or the brake lever freeplay becomes excessive, inspect the brake pads for wear. If the brake pads are not worn, you most likely have a leak. Have your vehicle inspected by your dealer. 53

Brakes ► Inspecting the Front Brake Pads Brake pads Inspecting the Front Brake Pads Wear indicator Check the condition of the brake pad wear Maintenance indicator. The pads need to be replaced if a brake pad is worn to the bottom of the indicator. Wear indicator Disc 1. Inspect the brake pads from below the brake caliper. If necessary have the pads replaced by your dealer. Always replace both left and right brake pads at the same time. 54

Brakes ► Inspecting the Rear Brake Pedal Freeplay Inspecting the Rear Brake Adjusting the Rear Brake Maintenance Pedal Freeplay Pedal Freeplay 1. Place your vehicle on its centre stand on a Make sure the cut-out on the adjusting nut is firm, level surface. seated on the brake arm pin when adjusting the freeplay. 2. Measure the distance the rear brake pedal moves before the brake takes hold. Adjusting nut Brake arm pin Freeplay at the tip of the brake pedal: 20 to 30 mm (0.78 to 1.18 in) Freeplay If proper adjustment cannot be obtained by this method, see your dealer. Make sure the the brake rod, brake arm, spring and fastener are in good condition. continued 55

Brakes ► Adjusting the Rear Brake Pedal Freeplay 3. Push the brake arm to confirm that there is a gap between the rear brake adjusting nut and brake arm pin. Brake arm Maintenance Decrease Brake Push Freeplay arm pin Adjusting Increase Brake arm pin nut Freeplay Gap Adjusting nut 1. Adjust by turning the rear brake adjusting After adjustment, confirm the freeplay of the nut a half-turn at a time. brake pedal. 2. Apply the brake several times and check for Make sure the brake rod, brake arm, spring and free wheel rotation after the brake pedal is fastener are in good condition. released. NOTICE Do not turn the adjuster beyond its natural limits. 56

Brakes ► Inspecting the Rear Brake Shoe Wear Inspecting the Rear Brake When the brake is applied, an arrow attached to Maintenance Shoe Wear the brake arm moves toward a reference mark on the brake panel. If the arrow aligns with the The rear brake is equipped with a brake wear reference mark on full application of the brake, indicator. the brake shoes must be replaced. See your dealer for this service. Arrow When the brake service is necessary, see your Brake dealer. Use only Honda Genuine Parts or its panel equivalent. Reference mark Brake arm 57

Maintenance Brakes ► Adjusting the Brakelight Switch Brake light switch BA Adjusting the Brakelight Adjusting nut Switch Check the operation of the brake light switch. Hold the brakelight switch and turn the adjusting nut in the direction A if the switch operates too late, or turn the nut in the direction B if the switch operates too soon. 58

Side Stand 4. Start the engine, pull the clutch lever in, and Checking the Side Stand shift the transmission into gear. 5. Lower the side stand all the way. The engine Maintenance should stop as you lower the side stand. If the engine doesn’t stop, have your vehicle inspected by your dealer. Side stand spring 1. Check that the side stand operates smoothly. If the side stand is stiff or squeaky, clean the pivot area and lubricate the pivot bolt with clean grease. 2. Check the spring for damage or loss of tension. 3. Sit on the vehicle, shift the transmission to Neutral, and raise the side stand. 59

Drive Chain Drive chain slack: 30 to 40 mm (1.2 to 1.6 in) Inspecting the Drive Chain Slack ► Do not ride your vehicle if the slack exceeds 50 mm (2.0 in). Check the drive chain slack at several points Maintenance along the chain. If the slack is not constant at all points, some links may be kinked and binding. Have the chain inspected by your dealer. 1. Shift the transmission to Neutral. Stop the engine. 2. Place your vehicle on its centre stand on a firm, level surface. 3. Remove the inspection hole cap. 4. Move the drive chain up and down with your finger. Inspection 5. Rotate the rear wheel and check that the hole cap chain moves smoothly. 6. Remove the chain case. 2 P. 44 7. Inspect the sprockets. 2 P. 37 8. Clean and lubricate the drive chain. 2 P. 38 9. Install the parts in the reverse order of the removal. 60

Drive Chain ► Adjusting the Drive Chain Slack Adjusting the Drive Chain Scale Slack graduations Adjusting the chain requires special tools. Rear edge of Maintenance adjusting slot Have the drive chain slack adjusted by your Adjusting nut dealer. Lock nut 1. Shift the transmission to Neutral. Stop the 5. Turn both adjusting nuts an equal number of engine. turns until the correct drive chain slack is obtained. Turn the adjusting nuts clockwise 2. Place your vehicle on its centre stand on a to tighten the chain. Turn the adjusting nuts firm, level surface. counterclockwise and push the rear wheel toward the front to provide more slack. 3. Loosen the rear axle nut. Adjust the slack at a point midway between 4. Loosen the lock nuts on both adjusting bolts. the front sprocket and the rear sprocket. Check the drive chain slack. 2 P. 60 Lock nut Scale graduations 6. Check rear axle alignment by making sure the end of the chain adjuster aligns with the scale Adjusting nut Rear edge of graduations on both sides of the swingarm. adjusting slot continued 61 Axle nut

Drive Chain ► Adjusting the Drive Chain Slack Maintenance Both marks should correspond. If axle is # Checking the Drive Chain Wear misaligned, turn the right or left adjusting nut until the marks are aligned and recheck Check the chain wear label when adjusting the chain slack. drive chain. If the index mark of the adjusting 7. Tighten the rear axle nut. plate enters the red zone on the label after the chain has been adjusted to the proper slack, Torque: 88 N·m (9.0 kgf·m, 65 lbf·ft) the chain is excessively worn and must be replaced. 8. Tighten the drive chain adjusting nuts lightly, Drive chain must be replaced with new sprocket then hold the adjusting nuts and tighten the set. lock nuts. Chain: DID428VIX3 9. Recheck drive chain slack. LGB R428OR 10. Rear brake pedal freeplay is affected when If necessary have the drive chain replaced by repositioning the rear wheel to adjust the your dealer. drive chain slack. Check rear brake pedal freeplay and adjust as necessary. 2 P. 55 Chain wear label Red zone 11. Reinstall the inspection hole cap. If a torque wrench was not used for installation, see your dealer as soon as possible to verify proper assembly. Improper assembly may lead to loss of braking Adjusting plate Index mark capacity. 62

Clutch Check the clutch cable for kinks or signs of Maintenance wear. If necessary have it replaced by your Checking the Clutch dealer. # Checking the Clutch Lever Freeplay Lubricate the clutch cable with a commercially available cable lubricant to prevent premature Check the clutch lever freeplay. wear and corrosion. Freeplay at the clutch lever: NOTICE 10 to 20 mm (0.39 to 0.79 in) Improper freeplay adjustment can cause premature clutch wear. Freeplay Clutch lever 63

Clutch ► Adjusting the Clutch Lever Freeplay Maintenance Adjusting the Clutch Lever Adjusting nut Freeplay + - 1. Loosen the lock nut. 2. Turn the adjusting nut until the clutch lever Lock nut If proper adjustment cannot be obtained or the freeplay is 10 to 20 mm (0.39 to 0.79 in). clutch does not work correctly, see your dealer. 3. Tighten the locknut and check the clutch lever freeplay. 4. Start the engine, pull the clutch lever in and shift into gear. Make sure the engine does not stall and the vehicle does not creep. Gradually release the clutch lever and open the throttle. Your vehicle should move smoothly and accelerate gradually. 64

Throttle Maintenance Checking the Throttle With the engine off, check that the throttle rotates smoothly from fully closed to fully open in all steering positions and throttle freeplay is correct. If the throttle does not move smoothly, close automatically, or if the cable is damaged, have the vehicle inspected by your dealer. Freeplay at the throttle grip flange: 2 to 6 mm (0.1 to 0.2 in). Freeplay Flange 65

Maintenance Crankcase Breather Cleaning the Crankcase Breather 1. Remove the right side cover. 2 P. 47 2. Place a suitable container to receive deposits. 3. Remove the crankcase breather tube and drain deposits. 4. Reinstall the crankcase breather tube. Crankcase breather tube 66

Other Adjustments Headlight Adjusting bolt Adjusting the Headlight Up Maintenance Aim Down You can adjust vertical aim of the headlight for proper alignment. To move the headlight, loosen the bolt. Tighten the bolt after adjustment. Obey local laws and regulations. 67

Other Adjustments ► Adjusting the Rear Suspension Pin spanner Adjuster 12 3 Maintenance Adjusting the Rear Suspension Adjusting the suspension requires a pin spanner. We recommend that you have your vehicle serviced by your dealer. ▌ Spring Preload You can adjust the spring preload by the adjuster to suit the load or the road surface. Use the pin spanner to turn the adjuster. Position 1 is for a decrease spring preload (soft), or turn the position 2 to 3 to increase spring preload (hard). The standard position is 2. NOTICE Attempting to adjust directly from 1 to 3 or 3 to 1 may damage the shock absorber. NOTICE Do not turn the adjuster beyond its limits. 68

Troubleshooting Engine Will Not Start ............................................... P. 70 Warning Indicators On or Flashing ............... P. 71 PGM-FI (Programmed Fuel Injection) Malfunction Indicator Lamp (MIL)..........................P. 71 ABS (Anti-lock Brake System) Indicator................P. 71 Tyre Puncture................................................................... P. 72 Electrical Trouble.......................................................... P. 77 Battery Goes Dead...................................................................P. 77 Burned-out Light Bulb..........................................................P. 77 Blown Fuse.........................................................................................P. 80 Unstable Engine Operation Occur Intermittently................................................................ P. 82

Troubleshooting Engine Will Not Start Starter Motor Does Not Operate Starter Motor Operates But Engine Does Not Start Check the following items: z Check the correct engine starting Check the following items: z Check the correct engine starting sequence. 2 P. 20 z Make sure engine stop switch is in the sequence. 2 P. 20 z Check that there is petrol in the fuel tank. (Run) position. 2 P. 18 z Check if the PGM-FI malfunction indicator z Check for a blown fuse. 2 P. 80 z Check for a loose battery connection (2 P. 43) lamp (MIL) is on. u If the indicator lamp is on, contact your or battery terminal corrosion (2 P. 33). z Check the condition of the battery. 2 P. 33 dealer as soon as possible. If the problem continues, have your vehicle inspected by your dealer. 70

Warning Indicators On or Flashing PGM-FI (Programmed Fuel z Indicator comes on or starts flashing while Troubleshooting Injection) Malfunction riding. Indicator Lamp (MIL) z Indicator does not come on when the If the indicator comes on while riding, you ignition switch is in the ON position. may have a serious problem with the PGM-FI system. Reduce speed and have your vehicle z Indicator does not go off at speeds above inspected by your dealer as soon as possible. 5 km/h (3 mph). ABS (Anti-lock Brake If the ABS indicator stays on, your brakes will System) Indicator continue to work as a conventional system, but without the anti-locking function. If the indicator operates in one of the following ways, you may have a serious The ABS indicator may flash if you turn the problem with the ABS. Reduce your speed rear wheel while the rear wheel is lifted off and have your vehicle inspected by your the ground. In this case, turn the ignition dealer as soon as possible. switch to the OFF position, and then to the ON position again. The ABS indicator will go off after your speed reaches 5 km/h (3 mph). 71

Tyre Puncture Repairing a puncture or removing a wheel WARNING requires special tools and technical expertise. We recommend you have this type of service Riding your vehicle with a temporary performed by your dealer. tyre repair can be risky. If the After an emergency repair, always have the temporary repair fails, you can crash tyre inspected/replaced by your dealer. and be seriously injured or killed. Troubleshooting Emergency Repair Using a If you must ride with a temporary tyre Tyre Repair Kit repair, ride slowly and carefully and do not exceed 50 km/h (30 mph) until the If your tyre has a minor puncture, you can tyre is replaced. make an emergency repair using a tubeless tyre repair kit. Removing Wheels Follow the instructions provided with the emergency tyre repair kit. Follow these procedures if you need to Riding your vehicle with a temporary tyre remove a wheel in order to repair a repair is very risky. Do not exceed 50 km/h puncture. (30 mph). Have the tyre replaced by your dealer as soon as possible. 72

Tyre Puncture u Removing Wheels When removing and installing the wheel, be Speedometer Speedometer careful not to damage the wheel speed gear box cable sensor and pulser ring. Axle nut cap Tab Troubleshooting # Front Wheel Front axle nut Front axle shaft Removal Side collar 1. Place your vehicle on its centre stand on a continued 73 firm, level surface. 2. Support your vehicle securely and raise the front wheel off the ground using a maintenance stand or a hoist. 3. Remove the speedometer cable by pushing the tab. 4. Remove the axle nut cap and front axle nut. 5. Remove the front axle shaft, front wheel, side collar and speedometer gear box. u Avoid getting grease, oil, or dirt on the disc or pad surfaces. u Do not pull the brake lever while the front wheel is removed.

Tyre Puncture u Removing Wheels Troubleshooting Installation 5. After installing the wheel, apply the brake 1. Attach the side collar and speedometer lever several times, then check if the wheel rotates freely. Recheck the wheel if the gearbox to the wheel. brake drags or if the wheel does not 2. Position the wheel between the fork legs rotate freely. and insert the front axle shaft from the 6. Install the speedometer cable securely. right side, through the right fork leg and wheel hub. Lug Slot NOTICE When installing a wheel or caliper into original position, carefully fit the brake disc between the pads to avoid scratching them. 3. Make sure that the lug on the left fork leg Axle nut cap Speedometer is located in the slot of the speedometer gearbox gearbox. If a torque wrench was not used for 4. Install and tighten the axle nut and fix axle installation, see your dealer as soon as nut cap. possible to verify proper assembly. Torque: 59 N·m (6.0 kgf·m, 44 lbf·ft) Improper assembly may lead to loss of braking capacity. 74

Tyre Puncture u Removing Wheels # Rear Wheel Drive chain Lock nut case Adjusting nut Removal 1. Support your vehicle securely and raise Rear axle nut Brake rod the rear wheel off the ground using the centre stand or a hoist. Troubleshooting 2. Remove the rear brake adjusting nut, disconnect the brake rod from the brake Brake Brake arm by pushing down on the rear brake Brake adjusting Stopper Cotter stopper pedal. arm nut arm nut pin arm 3. Disconnect the brake stopper arm from the brake panel by removing the cotter 7. Remove the drive chain from the driven pin, stopper arm nut, washer and rubber sprocket by pushing the rear wheel grommet. forward. 4. Remove the drive chain case. 2 P. 44 5. loosen the drive chain lock nuts and drive 8. Remove the rear axle shaft, rear wheel chain adjuster nuts on both sides of the and side collar from the swingarm. swingarm. 6. Remove the rear axle nut while holding the rear axle shaft at the other end with a wrench. continued 75

Tyre Puncture u Removing Wheels Drive chain Adjusting nut 6. Connect the brake rod to the brake arm. 7. Adjust the drive chain. 2 P. 61 Troubleshooting Rear axle shaft Lock nut 8. Adjust the rear brake freeplay. 2 P. 55 9. Tighten the rear axle nut. Installation Torque: 88 N·m (9.0 kgf·m, 65 lbf·ft) 1. Install the side collar into rear wheel. 10. Reassemble the drive chain case. 2 P. 44 2. Place the rear wheel between the swingarm 11. After installing the wheel, apply the brake and install the drive chain over the driven sprocket. pedal several times, then check if the wheel rotates freely. Recheck the wheel if 3. Insert the rear axle shaft from the left side, the brake drags or if the wheel does not through the left swingarm, wheel hub and rotate freely. brake panel. If a torque wrench was not used for 4. Temporarily tighten the rear axle nut. installation, see your dealer as soon as possible to verify proper assembly. 5. Reassemble the brake stopper arm and Improper assembly may lead to loss of tighten the stopper arm nut. braking capacity. A used cotter pin may not effectively secure Torque: 22 N·m (2.2 kgf·m, 16 lbf·ft) a fastener. Always replace a used cotter pin with a new one. 76

Electrical Trouble Burned-out Light Bulb Troubleshooting Battery Goes Dead Follow the procedure below to replace a burned-out light bulb. Charge the battery using a motorcycle Turn the ignition switch to the OFF or LOCK battery charger. position. Remove the battery from the vehicle before Allow the bulb to cool before replacing it. charging. Do not use bulbs other than those specified. Do not use an automobile-type battery Check the replacement bulb for correct charger, as these can overheat a motorcycle operation before riding. battery and cause permanent damage. If the battery does not recover after For the light bulb wattage, see recharging, contact your dealer. “Specifications.“ 2 P. 97 NOTICE Jump starting using an automobile battery can damage your vehicle’s electrical system and is not recommended. 77

Electrical Trouble u Burned-out Light Bulb # Headlight bulb 4. Install a new bulb and parts in the reverse order of removal. “TOP” mark Pin u Install the dust cover with its “TOP” mark facing up. Troubleshooting Bulb Do not touch the glass surface with your Rubber dust cover fingers. If you touch the bulb with your bare hands, clean it with a cloth moistened with 1. Remove the headlight case. 2 P. 45 alcohol. 2. Remove the rubber dust cover. 3. Press the pin down and pull out the bulb without turning it. 78

Electrical Trouble u Burned-out Light Bulb # Brakelight/Taillight Bulb # Front/Rear Turn Signal Bulb Bulb Screw Bulb Stoplight lens Inner lens Socket Troubleshooting Screws Turn signal lens 1. Remove the stoplight lens and inner lens 1. Remove the turn signal lens by removing by removing the screws. the screw. 2. Slightly press the bulb and turn it 2. Turn the socket counterclockwise, and counterclockwise. remove it. 3. Install a new bulb and parts in reverse 3. Slightly press the bulb and turn it order of removal. counterclockwise. 4. Install a new bulb and parts in the reverse order of removal. u Use only the amber bulb. 79

Troubleshooting Electrical Trouble u Blown Fuse 1. Remove the left side cover. 2 P. 47 2. Open the fuse box cover. Blown Fuse 3. Pull out the fuses one by one with the fuse Before handling fuses, see “Inspecting and puller provided in the tool kit (2 P. 25) to Replacing Fuses.” 2 P. 35 check for a blown fuse. Always replace a # Fuse Box Fuses blown fuse with a spare of the same rating. u Spare fuses are provided in the fuse Fcouvseerbox box. 4. Reinstall parts in the reverse order of removal. NOTICE If a fuse fails repeatedly, you likely have an electrical problem. Have your vehicle inspected by your dealer. Spare fuses 80

Electrical Trouble u Blown Fuse # Main Fuse 1. Remove the left side cover. 2 P. 47 2. Disconnect the negative - terminal from Wire connector Troubleshooting Main fuse the battery. 2 P. 43 3. Pull out the starter magnetic switch. Spare 4. Disconnect the wire connector of the main fuse Starter magnetic switch starter magnetic switch.. 5. Pull the main fuse out and check for a blown fuse. Always replace a blown fuse with a spare fuse of the same rating. u Spare main fuse (20 A) is provided below the starter magnetic switch. 6. Reinstall parts in the reverse order of removal. NOTICE If a fuse fails repeatedly, you likely have an electrical problem. Have your vehicle inspected by your dealer. 81

Troubleshooting Unstable Engine Operation Occurs Intermittently If the fuel pump filter is clogged, unstable engine operation will occur intermittently while riding. Even if this symptom occurs, you can continue to ride your vehicle. If unstable engine operation occurs even if sufficient fuel is available, have your vehicle inspected by your dealer as soon as possible. 82

Information Keys........................................................................................... P. 84 Instruments, Controls, & Other Features................................................................. P. 85 Caring for Your Vehicle............................................ P. 86 Storing Your Vehicle................................................... P. 89 Transporting Your Vehicle..................................... P. 90 You & the Environment........................................... P. 91 Serial Numbers............................................................... P. 92 Fuels Containing Alcohol....................................... P. 93 Catalytic Converters................................................... P. 94

Information Keys Ignition key Key number plate Keys Ignition key Be sure to record the key number provided with the key number plate. Store the spare key and key number in a safe location. To make a duplicate, take the spare key or the key number to your dealer. If you lose all ignition keys and the key number, the ignition switch assembly will probably have to be removed by your dealer to determine the key number. A metal key holder may cause damage to the area surrounding the ignition switch. 84

Instruments, Controls, & Other Features Instruments, Controls, & Tripmeter Information Other Features The tripmeter returns to 0.0 when the read-out Ignition Switch exceeds 999.9. Leaving the ignition switch in the ON position Document Bag with the engine stopped will drain the battery. Do not turn the key while riding. The owner’s manual, registration, and insurance information can be stored in the plastic Engine Stop Switch document bag located under the seat. Do not use the engine stop switch except in an Ignition Cut-off System emergency. Doing so when riding will cause the engine to suddenly turn off, making riding A banking (lean angle) sensor automatically unsafe. stops the engine and fuel pump if the vehicle If you stop the engine using the engine stop falls over. To reset the sensor, you must turn the switch, turn the ignition switch to the OFF ignition switch to the OFF position and back to position. Failing to do so will drain the battery. the ON position before the engine can be restarted. Odometer The odometer returns to 0 when the read-out exceeds 999,99.9. 85

Caring for Your Vehicle Information Caring for Your Vehicle 3. Thoroughly rinse your vehicle with plenty of clean water and dry with a soft, clean cloth. Frequent cleaning and polishing is important to ensure the life of your Honda. A clean vehicle 4. After the vehicle dries, lubricate any moving makes it easier to spot potential problems. parts. In particular, seawater and salts used to prevent u Make sure that no lubricant spills onto the ice on roads promote the formation of brakes or tyres. Brake discs, pads, drum corrosion. Always wash your vehicle thoroughly or shoes contaminated with oil will suffer after riding on coastal or treated roads. greatly reduced braking effectiveness and can lead to a crash. Washing 5. Lubricate the drive chain immediately after Allow the engine, muffler, brakes, and other washing and drying the vehicle. high-temperature parts to cool before washing. 1. Rinse your vehicle thoroughly using a low 6. Apply a coat of wax to prevent corrosion. u Avoid products that contain harsh pressure garden hose to remove loose dirt. detergents or chemical solvents. These 2. If necessary, use a sponge or a soft towel can damage the metal, paint, and plastic on your vehicle. with mild cleaner to remove road grime. Keep the wax clear of the tyres and u Clean the headlight lens, panels, and brakes. u If your vehicle has any matte painted other plastic components with extra care parts, do not apply a coat of wax to the to avoid scratching them. Avoid directing matte painted surface. water into the air cleaner, muffler, and electrical parts. 86

# Washing Precautions Caring for Your Vehicle Information Follow these guidelines when washing: z Do not direct water at the air cleaner: z Do not use high-pressure washers: u Water in the air cleaner can prevent the engine from starting. u High-pressure water cleaners can damage moving parts and electrical parts, z Do not direct water near the headlight: rendering them inoperable. u The headlight’s inside lens may fog temporarily after washing or while riding u Water in the air intake can be drawn into in rain. This does not impact the headlight the throttle body and/or enter the air function. cleaner. u Any condensation inside the headlight should dissipate after a few minutes of z Do not direct water at the muffler: running the engine with the headlight u Water in the muffler can prevent starting on. and causes rust in the muffler. However, if you see a large amount of water or ice accumulated inside the z Dry the brakes: lens(es), have your vehicle inspected by u Water adversely affects braking your dealer. effectiveness. After washing, apply the brakes intermittently at low speed to help z Do not use wax or polishing compounds on dry them. matte painted surface: u Use a soft cloth or sponge, plenty of z Do not direct water under the seat: water, and a mild detergent to clean matte u Water under the seat can damage your painted surfaces. Dry with a soft clean documents and other belongings. cloth. continued 87

Information Caring for Your Vehicle Exhaust Pipe and Muffler Aluminium Components When the exhaust pipe and muffler are painted, do not use a commercially available abrasive Aluminium will corrode from contact with dirt, kitchen cleaning compound. Use a neutral mud, or road salt. Clean aluminium parts detergent to clean the painted surface on the regularly and follow these guidelines to avoid exhaust pipe and muffler. If you are not sure if scratches: your exhaust pipe and muffler are painted, z Do not use stiff brushes, steel wool, or contact your dealer. cleaners containing abrasives. z Avoid riding over or scraping against curbs. Panels Follow these guidelines to prevent scratches and blemishes: z Wash gently using a soft sponge and plenty of water. z To remove stubborn stains, use diluted detergent and rinse thoroughly with plenty of water. z Avoid getting petrol, brake fluid, or detergents on the instruments, panels or headlight. 88

Storing Your Vehicle Storing Your Vehicle After removing your vehicle from storage, inspect all maintenance items required by the If you store your vehicle outdoors, you should Maintenance Schedule. consider using a full-body vehicle cover. If you won’t be riding for an extended period, Information follow these guidelines: z Wash your vehicle and wax all painted surfaces (except matte painted surfaces). Coat chrome pieces with rust-inhibiting oil. z Lubricate the drive chain. 2 P. 38 z Place your vehicle on its centre stand and position a block so that both tyres are off the ground. z After rain, remove the body cover and allow the vehicle to dry. z Remove the battery (2 P. 43) to prevent discharge. Fully charge the battery and then place it in a shaded, well-ventilated area. u If you leave the battery in place, disconnect the negative terminal to prevent discharge. 89

Information Transporting Your Vehicle Transporting Your Vehicle If your vehicle needs to be transported, it should be carried on a motorcycle trailer or a flatbed truck or trailer that has a loading ramp or lifting platform, and motorcycle tie-down straps. Never try to tow your vehicle with a wheel or wheels on the ground. NOTICE Towing your vehicle can cause serious damage to the transmission. 90

You & the Environment You & the Environment down a drain or on the ground. Used oil, petrol, and cleaning solvents contain poisons that can Owning and riding a vehicle can be enjoyable, hurt refuse workers and contaminate drinking but you must do your part to protect the water, lakes, rivers, and oceans. environment. Information Choose Sensible Cleaners Use a biodegradable detergent when you wash your vehicle. Avoid aerosol spray cleaners that contain chlorofluorocarbons (CFCs) which damage the atmosphere’s protective ozone layer. Recycle Wastes Put oil and other toxic wastes in approved containers and take them to a recycling centre. Call your local or state office of public works or environmental services to find a recycling centre in your area, and to get instructions on how to dispose of non-recyclable wastes. Do not place used engine oil in the trash, or pour it 91

Serial Numbers Serial Numbers The frame and engine serial numbers uniquely identify your vehicle and are required in order to register your vehicle. They may also be required when ordering replacement parts. You should record these numbers and keep them in a safe place. Information Frame number Engine number 92

Fuels Containing Alcohol Fuels Containing Alcohol Information Some conventional fuels blended with alcohol The use of petrol containing more than 10% are available in some locales to help reduce ethanol may: emissions to meet clean air standards. If you z Damage the painting of the fuel tank. plan to use blended fuel, check that it is z Damage the rubber tubes of the fuel line. unleaded and meets the minimum octane z Cause corrosion of the fuel tank. rating requirement. z Cause poor drivability. The following fuel blends can be used in your NOTICE vehicle: Use of blended fuels containing higher than approved z Ethanol (ethyl alcohol) up to 10% by volume. percentages can damage metal, rubber, plastic parts of your fuel system. u Petrol containing ethanol may be marketed under the name Gasohol. If you notice any undesirable operating symptoms or performance problems, try a different brand of petrol. 93

Catalytic Converters Information Catalytic Converters Follow these guidelines to protect your vehicle’s catalytic converters. This vehicle is equipped with two three-way z Always use unleaded petrol. Leaded petrol catalytic converter. Each converter contains precious metals that serve as catalysts in high will damage the catalytic converters. temperature chemical reactions that convert z Keep the engine in good running condition. hydrocarbons (HC), carbon monoxide (CO), z Have your vehicle serviced if your engine is and oxides of nitrogen (NOx) in the exhaust gasses into safe compounds. misfiring, backfiring, stalling, or otherwise not running properly, stop riding and turn off the A defective catalytic converter contributes to air engine. pollution and can impair your engine’s performance. A replacement unit must be an original Honda part or equivalent. 94

Specifications J Main Components Displacement 162.71 cm3 (9.925 cu-in) Bore x stroke 57.300 x 63.096 mm (2.256 × 2.484 in) Overall length 2081 mm (81.9 in) Compression ratio 10.0:1 Fuel Unleaded petrol Overall width 756 mm (29.8 in) Fuel containing Recommended: 91 RON or higher alcohol Overall height 1103 mm (43.4 in) Tank capacity ETHANOL up to 10% by volume Battery Wheelbase 1335 mm (52.6 in) 13.0 litres (3.43 US gal, 2.86 Imp gal) Gear ratio ETZ5 Minimum ground clearance 187 mm (7.4 in) 12 V - 4 Ah (10 HR) Reduction ratio 1st 3.076 Caster angle 26º0’ (primary / final) 2nd 1.789 3rd 1.300 Trail 98 mm (3.9 in) 4th 1.066 5th 0.916 Curb weight 140 kg (309 lbs) 3.136/3.000 Maximum weight capacity*1 170 kg (375 lbs) Specifications Passenger capacity Rider and 1 passenger Minimum turning radius 2.16 m (7.09 ft) *1 Including rider, passenger, all luggage, and accessories 95

Specifications J Service Data Honda 4-stroke motorcycle oil API Service Classification SJ or higher, Tyre size Front 80/100-18M/C 47P Recommended excluding oils marked as “Energy Conserving,” Rear engine oil or “Resource Conserving” 100/90-18M/C 56P SAE 5W-30 or 10W-30, JASO T 903 standard Tyre type Engine oil MA Tubeless capacity Recommended Front After draining 1.0 litres Tyre Rear MRF NYLOGRIP ZAPPER-FS Recommended (1.1 US qt, 0.9 Imp qt) brake fluid TVS ATT 525M Recommended After disassembly 1.2 litres drive chain (1.3 US qt, 1.1 Imp qt) MRF ZAPPER-Yg lubricant Specifications Honda DOT3 or DOT4 Brake fluid TVS ATT 750KE Front Drive chain lubricant Tyre air pressure (Driver only) If not available, use SAE 80 or 90 gear oil. 175 kPa (1.75 kgf/cm2, 25 psi) Rear (Driver and passenger) Drive chain slack 30 to 40 mm (1.2 to 1.6 in) 175 kPa (1.75 kgf/cm2, 25 psi) Spark plug Standard drive DID428VIX3 or LGBR428OR 128 Spark plug gap (Driver only) chain 15T Idle speed 200 kPa (2.00 kgf/cm2, 29 psi) No. of links 45T (Driver and passenger) Standard 225 kPa (2.25 kgf/cm2, 33 psi) sprocket size Drive sprocket CPR8EA-9 (NGK) Driven sprocket 0.8 to 0.9 mm (0.03 to 0.04 in) 1400 ± 100 rpm 96

Specifications J Bulbs J Torque Specifications Headlight 12 V-35/35 W Engine oil drain bolt 30 N·m (3.1 kgf·m, 22 lbf·ft) Brakelight/Taillight 12 V-21 / 5 W Front turn signal 12 V- 10 W x 2 Rear axle nut 88 N·m (9.0 kgf·m, 65 lbf·ft) Rear turn signal 12 V- 10 W x 2 Front axle nut 59 N·m (6.0 kgf·m, 44 lbf·ft) J Fuses 20 A x 1 7.5 A x 3 Stopper arm nut 22 N·m (2.2 kgf·m, 16 lbf·ft) Main fuse 10 A x 2 Specifications Other fuses 97