2003-2004 ar a .HOW TO USE THIS MANUAL This service manual describes the service procedures for the Follow the Maintenance SanedulsISecton 3) recommendations to ‘nour thatthe vehicle isin peak orang condition anna emission levels re within the standard set by the Calfornia Ar Resour Board (CARBS fanaoea forthe inl we thet acca during te breakin bere Sections 1 and 3 apply to th whee vehicle. Section 2 striae pro ‘cedure for remvainstalstion of omypanants tt maybe ries to perfor sence dosed in he following sartone. Fin! he enction you wanton Ui page, then turn to he beet con tent on the rt page ofthe ection, Most seco Informa ve det rouble Wt you do not know the source of the vouble, go to Secon 21, CONTENTS GENERAL INFORMATION Hl FRAME/BODY PANELS/EXHAUST SYSTEM [IP MAINTENANCE Ei LUBRICATION SYSTEM FUEL SYSTEM COOLING SYSTEM _ ‘ake informed decane sv have provided ely {ea or penile ta warn you abou al the haar onccte wth, serena havi Yo mint as your on goo ogee Incline ‘ons ofthe signal words, BANGER, WARNING, or CAUTION That signa words mean Egret keaton See moe ENEMY "rss ENGINE AND DRIVE TRAIN CRANKSHAFT/TRANSMISSION CLUTCH/GEARSHIFT LINKAGE FINAL DRIVE FRONT WHEEL/SUSPENSION/STEERING EE] HYDRAULIC Co 15 BATTERY/CHARGING SYSTEM [16 [ELECTRIC sTaRTER/sTARTER CLUTCH RFE CHASSIS [ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND | SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAIL | ABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITH- ‘OUT INCURRING ANY OBLIGATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION. THIS MANUAL 15 WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON Honda MOTORCY: (CLES, MOTOR SCOOTERS, OR ATVS. Honda Motor Co,, Ltd SERVICE PUBLICATIONS OFFICE | ELECTRICAL LIGHTS/METERS/SWITCHES [19 WIRING DIAGRAMS [20 ‘TROUBLESHOOTING : El Ca 22 Date of Issue: April, 2002 © Honda Motor Co,, LidSYMBOLS ‘The symbols used throughout this manual show specific service procedures. If supplementary information is req) {taining to these symbols, it would be explained specifically in the text without the use of the symbols. | eviacete pari with new ont befor assembly. || Use the recommended engine oil, unless otherwise specified. Use molybdenum oil solution (mixture of the engine oll and molybdenum grease in a ratio of 1:1). Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent). Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or lent) amu RBH | Elample: Nolykoto® BR-2 plus manufactured by Dow Coming, U.S.A Be Ae | ‘Multi-purpose M-2 manufactured by Mitsubishi Qil, Japan | ayia boca ation ts 20% RaSobs a ie jai ce see Ceara Nthtoe® Go pat, rnutourd by Dow Coming, UA ena Fe sara 2 Real rid Te mantras Somes Noe ces Use silicone gr Apply a locking agent. Use a medium strength locking agent unless otherwise specified. An SE | ppiy seater << Use DOT 3 ar DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified. Use fork or suspension fivid.