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Honda Motorcycle – Service Manual Download.Honda Motorcycle
Once you enter the portal below use the search box at the top of the page to find your service manual to download, here is an example in red of what you will type in the search box to find your model service manual:. Example 1. Example 2. Example 3. NOTE: This is a huge site and contains almost every Honda service manual ever produced, if you do not get results from the searh box you may have to try a different combination of words.
Sometimes it is best not to enter the year but only the make and model motorcycle, you should include service manual or owners manual like the examples above. Do-It-Yourself and fix your problems now, enjoy! The purpose of the clutch is to smoothly disengage and engage the engine from the rear wheel for starting, stopping and shifting gears. The clutch is a wet, multiple-disc clutch with steel plates and fiber friction plates stacked alternately in the clutch shell.
The pack consists of seven fiber plates, seven steel plates, one narrow fiber plate, one damper spring and one damper spring seat. The fiber plates clutch driving plates are keyed to the clutch shell, which is driven by the engine through the primary chain.
The steel plates clutch driven plates are keyed to the clutch hub, which drives the rear wheel through the transmission and secondary drive belt. When the clutch is engaged clutch lever released , the diaphragm spring applies strong force against the pressure plate.
The pressure plate then presses the clutch plates together causing the plates to turn as a single unit. The result is that the rotational force of the clutch shell is transmitted through the clutch plates to the clutch hub. As long as the transmission is set in a forward gear, power from the engine will be transmitted to the rear wheel. When the clutch is disengaged clutch lever pulled to left handlebar grip , the pressure plate is pulled outward by clutch cable action against the diaphragm spring, thereby compressing the diaphragm spring.
With the pressure plate retracted, strong inward force no longer squeezes the clutch plates together. The fiber plates are now free to rotate at a different relative speed than that of the steel plates i. Slippage between the clutch plates occurs. The result is that the rotational force of the clutch shell is no longer fully transmitted through the "unlocked" clutch plates to the clutch hub.
The engine is free to rotate at a different speed than the rear wheel. Satisfactory engine performance depends upon a mechanically sound engine. In many cases, unsatisfactory performance is caused by combustion chamber leakage.
A compression test can help determine the source of cylinder leakage. A proper compression test should be performed with the engine at normal operating temperature when possible. Disconnect spark plug wires. Clean around spark plug base and remove spark plugs. HD to front cylinder per manufacturer's instructions. Make sure transmission is in neutral. With throttle plate in wide open position, crank engine continuously through 5 to 7 full compression strokes.
Note gauge readings at the end of the first and last compression strokes. Record test results. Compression is normal if final readings are within the range specified in Table , and do not indicate more than a 10 psi 0. If compression is below psi 6. Readings that are considerably higher during the second test indicate worn piston rings. NOTE: After completing the compression test s and reinstalling the spark plugs, make sure the throttle plate is in the closed position before starting the engine.
Compression low on first stroke, tends to build up on the following strokes, but does not reach normal. Improves considerably when oil is added to cylinder. Compression low on first stroke, does not build up much on following strokes. Does not improve considerably with the addition of oil. Check for correct pushrod length. The cylinder leakage test pinpoints engine problems including leaking valves, worn, broken or stuck piston rings and blown head gaskets.
The cylinder leakage tester applies compressed air to the cylinder at a controlled pressure and volume and measures the percent of leakage from the cylinder. The following are some general instructions that apply to Honda motorcycle engines:. Run engine until it reaches normal operating temperature. Stop engine. Clean dirt from around spark plugs and remove the spark plugs. Remove the air cleaner and set the throttle in the wide open position. The piston in the cylinder being tested must be at top dead center of compression stroke both valves closed during the test.
To keep the engine from turning over when air pressure is applied to the cylinder, engage transmission in fifth gear and lock the rear brake. NOTE: Before performing the cylinder leakage test, verify that the tester itself is free from leakage to obtain the most accurate test results.
With a soap solution [applied around all tester fittings], connect the cylinder leakdown tester to the compressed air source and look for any bubbles that would indicate leakage from the tester. Following the manufacturer's instructions, perform a cylinder leakage test on the front cylinder. Make a note of the percent of leakage. Listen for air leaks at induction module intake, exhaust pipe and head gasket.
Air escaping through the induction module indicates a leaking intake valve. Air escaping through the exhaust pipe indicates a leaking exhaust valve. NOTE: If air is escaping through valves, check push rod length. NOTE: After completing the cylinder leakage test s and reinstalling the spark plugs, make sure the throttle plate is in the closed position before starting the engine.
Check Prior to Cylinder Head Removal. Oil tank overfilled. Oil carryover. Breather hose restricted. Restricted oil filter. Check After Cylinder Head Removal. Oil return passages for clogging. Valve guide seals. Valve guide to valve stem clearance. Gasket surface of both head and cylinder. Cylinder head casting's porosity allowing oil to drain into combustion chamber. When an engine needs repair, it is not always possible to determine definitely beforehand whether repair is possible with only cylinder heads, cylinders, and pistons disassembled, or whether complete engine disassembly is required for crankcase repair.
Most commonly, only cylinder head and cylinder repair is needed valves, rings, piston, etc. Malfunctioning or improperly installed check valve. Does not glow when ignition is turned on prior to operating engine.
The Troubleshooting section is a guide to diagnose problems. Read the appropriate sections of your Honda manual before performing any work. The following check list of possible operating troubles and their probable causes will be helpful in keeping a motorcycle in good operating condition.
More than one of these conditions may be causing the trouble and all should be carefully checked. Engine run switch in OFF position. Discharged battery, loose or corroded connections solenoid chatters. Starter control circuit, relay, or solenoid faulty.
Electric starter shaft pinion gear not engaging or overrunning clutch slipping. Security system activated. Motorcycle in gear and clutch not pulled in. Main fuse not in place. Jiffy stand down and transmission in gear. Fuel tank empty. Fuel filter clogged. Plugged fuel injectors. Discharged battery, loose or broken battery terminal connections.
Fouled spark plugs. Spark plug cables in bad condition and shorting, cable connections loose or cables connected to incorrect cylinders. Damaged wire or loose wire connection at ignition coil, battery or ECM connector. Sticking or damaged valve s or wrong length push rod s. Engine lubricant too heavy winter operation. NOTE: For cold weather starts, always disengage clutch. Spark plugs in bad condition, have improper gap or are partially fouled.
Spark plug cables in bad condition.
Honda Motorcycle User Manuals Download.Honda motorcycle manual download
Page 68 The battery will not be charged while the engine speed is near idle speed. Avoid idling for prolonged periods. Do not tow the motorcycle or coast for long distances while the engine is off. The transmission will not be properly lubricated Page 69 When possible, reduce speed or brake before entering a turn; closing the throttle or braking in mid-turn may cause wheel slip.
Wheel slip will reduce control of the motorcycle. When riding in wet or rainy conditions, or on loose surfaces, the ability to maneuver and stop will be reduced. Above 6, feet 2, m , driveability and performance may be reduced and fuel consumption increased. The carburetor can be modified to compensate for this high altitude richness. Page 71 OFF, turn the handlebar all the way to the left and remove the key. Use the center stand to support the motorcycle while parked.
Park the motorcycle on firm, level ground to prevent it from falling over. Page 72 This sounds simple but people do forget. Be sure the registration information for your motorcycle is accurate and current. Park your motorcycle in a locked garage whenever possible. Use an additional anti-theft device of good quality. When you park your motorcycle, we Page 73 A well-maintained motorcycle is essential for safe, economical and trouble-free riding.
It will also help reduce air pollution. To help you properly care for your motorcycle, the following pages include a Maintenance Schedule and a Maintenance Record for regularly scheduled maintenance. You can perform some of these tasks with the tools provided - if you have basic mechanical skills. Other tasks that are more difficult and require special tools are best performed by professionals. Page 75 Read the instructions before you begin, and make sure you have the tools and skills required.
To help prevent the motorcycle 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 gasoline or batteries. Environmental Protection Agency and California Air Resources Board CARB require that your motorcycle comply with applicable exhaust emissions standards during its useful life, when operated and maintained according to the instructions provided, and that Each item on the maintenance schedule requires some mechanical knowledge.
Consult your authorized Honda Dealer. Should be serviced by your authorized Honda dealer, unless the owner has proper tools, service data and is mechanically qualified. Page 80 mile 1, km break-in maintenance, is considered a normal owner operating cost and will be charged for by your dealer. Detailed receipts verifying the performance of required maintenance should be retained.
These receipts should be transferred with the motorcycle to the new owner if the motorcycle is sold. Odometer Date Page 81 No. Wheel wrench Extension bar They may also be required by your dealer when ordering replacement parts. Record the numbers here for your reference. Page 83 The engine number 3 is stamped on top of the crankcase. Remove the side cover. It is helpful when ordering replacement parts. Record the color and code here for your reference.
They may adversely affect clutch operation. Page 85 If a torque wrench is not used for this installation, see your authorized Honda dealer as soon as possible to verify proper assembly.
Change the engine oil with the engine at normal operating temperature and the motorcycle on its side stand to assure complete and rapid draining. Page 86 Remove the middle fairing page To drain the oil, remove the oil filler cap and crankcase drain plug 1 and sealing washer 2. Remove the oil filter 3 with a filter wrench and let the remaining oil drain out.
Discard the oil filter 3. Page 87 Start the engine and let it idle for minutes. Several minutes after stopping the engine, check that the oil level is at the upper level mark on the dipstick with the motorcycle upright on firm, level ground. Make sure there are no oil leaks. Page 89 Inspection Disconnect the spark plug caps from the spark Plugs.
Clean any dirt from around the spark plug bases. Remove the spark plugs using the spark plug wrench 5 furnished in the tool kit. Inspect the electrodes and center porcelain for deposits, corrosion or carbon fouling. Page 90 With the plug washer attached, thread the spark plug in by hand to prevent cross threading. Check for smooth rotation of the throttle grip from the fully open to the fully closed position at both full steering positions. Measure the throttle grip free play at the throttle grip flange.
Page 92 See your authorized Honda dealer for regularly scheduled carburetor adjustments. Warm up the engine, shift to neutral and place the motorcycle on its stand. Adjust idle speed with the throttle stop screw 1. Coolant Replacement Coolant should be replaced by an authorized Honda dealer, unless the owner has proper tools and service data and is mechanically qualified. Page 94 The drive chain should be checked, adjusted and lubricated as part of the Pre-ride Inspection page Under severe usage, or when the motorcycle is ridden in unusually dusty or muddy areas, more frequent maintenance will be necessary.
Page 95 Roll the motorcycle forward. Stop and place it on its side stand. Page 96 If the drive chain requires adjustment, the procedure is as follows: Turn the engine off, place the motorcycle on its center stand and shift the transmission into neutral.
Loosen the bearing holder pinch bolt 1. Page 97 Wear inspection Check the chain wear label when adjusting the chain. If the red zone 4 on the label aligns with the tip of driven sprocket teeth 5 after the chain has been adjusted to the proper slack, the chain is excessively worn and must be replaced.
Page 98 Lubrication and cleaning: Lubricate every miles 1, km or sooner if chain appears dry. The drive chain on this motorcycle is equipped with small O-rings between the link plates.
These O-rings retain grease inside the chain to improve its service life. Brake pad shoe wear depends upon the severity of usage, the type of riding, and road conditions. Page Rear Brake Check the cutout 2 in each pad. Starter control circuit, relay, or solenoid faulty. Electric starter shaft pinion gear not engaging or overrunning clutch slipping.
Security system activated. Motorcycle in gear and clutch not pulled in. Main fuse not in place. Jiffy stand down and transmission in gear. Fuel tank empty. Fuel filter clogged. Plugged fuel injectors.
Discharged battery, loose or broken battery terminal connections. Fouled spark plugs. Spark plug cables in bad condition and shorting, cable connections loose or cables connected to incorrect cylinders.
Damaged wire or loose wire connection at ignition coil, battery or ECM connector. Sticking or damaged valve s or wrong length push rod s. Engine lubricant too heavy winter operation. NOTE: For cold weather starts, always disengage clutch. Spark plugs in bad condition, have improper gap or are partially fouled. Spark plug cables in bad condition. Battery nearly discharged. Damaged wire or loose wire connection at battery terminal, ignition coil or ECM connector.
Ignition not functioning properly possible sensor failure. Faulty ignition coil. Fuel tank filler cap vent plugged or fuel line closed off restricting fuel flow.
Water or dirt in fuel system. Intake air leak. Partially plugged fuel injectors. Valves sticking. Air cleaner EVAP flapper if equipped stuck close or inoperative. Starts But Runs Irregularly or Misses. Spark plugs in bad condition or partially fouled. Spark plug cables in bad condition and shorting or leaking.
Spark plug gap too close or too wide. Damaged wire or loose connection at battery terminals, ignition coil or ECM connector.
Intermittent short circuit due to damaged wire insulation. Fuel tank vent system plugged. Air leak at intake manifold or air cleaner. Damaged intake or exhaust valve s. Weak or broken valve springs. Incorrect valve timing. Air cleaner EVAP flapper if equipped stuck closed or inoperative. Incorrect spark plug. Piston rings badly worn or broken. Fuel mixture too rich. Valve guides or seals badly worn or damaged. Pre-Ignition or Detonation Knocks or Pings.
Excessive carbon deposit on piston head or in combustion chamber. Incorrect heat range spark plug. Faulty spark plug s. Ignition timing advanced. Fuel octane rating too low. Intake manifold vacuum leak. Insufficient oil supply or oil not circulating. Insufficient air flow over engine. Leaking valve s. Heavy carbon deposits. Ignition timing retarded. Low oil pressure caused by oil feed pump not functioning properly or oil passages obstructed. Faulty hydraulic lifter s.
Bent push rod s. Incorrect push rod length. Cam s , cam gear s , or cam bushing s worn. Rocker arm binding on shaft. Valve sticking in guide. Honda CB Workshop Manual Honda CB Workshop Manual to Honda cbsc wiring diagrams. Honda cbf wiring diagrams. Honda CG Workshop Manual. Honda CT Shop Manual. Honda ct90 wiring diagrams. Honda Pantheon Dylan Service repair manual. Honda sl wiring diagrams. Honda sl70 wiring diagrams.
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