HOW TO USE THIS MANUAL ‘This service manual descrbes the ic procedures fr he C8300 Follow the Maintonance Schadule (Section 4) recommendations to Pertorming the fist scheduled maintenance le very_inprtan, ‘compensates forthe inl wear that occurs during the breaksn pared Sections 1,3 and 4 apply to the whola matoreyol, Sacton 9 states proceaures ior removauintalaion of companers that maybe fared 1 pororm servco doserbed the folowing sectons Seen '6 trough 20 dscibe pars the maocye, goud Find the section you want on his page, then turn ote tale of contents ‘onthe fst page o! he section Most secions start with an assent or sysion ikutaton, serves informaten and roublesheaing forthe secson. The subsequent pages (Que stated procedure, 1 yeu ar not familar with this motorcycle, read Techical Feat jn Section 2 IF you dont know the source of the touble, go to section 22 “rottleshootng, ‘Your culty, and to salty of obs, every important. Tohelp you ‘ake itormed dossons we have provided sally messages and ‘ther Iformation throughout this manual. O1 course, tf not Practical or posse fo war you abo al the hazards associated (wt serving is vr ou must use your awn goo judgement. ENGINE AND DRIVE TRAIN CONTENTS GENERAL INFORMATION ee ‘TECHNICAL FEATURE fait FRAME/BODY PANELS/EXHAUST SYSTEM, MAINTENANCE (ee FUEL SYSTEM, : Programmed Fuel Injection) _ COOLING SYSTEM a ENGINE REMOVAL/INSTALLATION ee CYLINDER HEAD/CYLINDER/PISTON | 3 CLUTCH/GEARSHIFT LINKAGE = EZ LUBRICATION SYSTEM ALTERNATORISTARTER CLUTCH Ep CRANKSHAFT/TRANSMISSION/BALANCER ay You wil fine important salely stration in a vaiety of forms + Saley Labels on the vehicie + Salety Messages - proceed by salty alert symbol 4. and ‘ne of te sgnal words, DANGER, WARNING, or CAUTION, ‘These signal words moan BELO eo SRN ASSIS. | cn FRONT WHEEL/SUSPENSION/ STEERING REAR WHEEL/SUSPENSION — HYDRAULIC BRAKE HURT I you dent flow instructons, PSOE Pct genous. woe OI You CAN be HURT If you dont flow + Instructions — how to serie this vehicle comocly and satay. BATTERY/CHARGING SYSTEM IGNITION SYSTEM a ‘As you road this manual, you wil ind information tats precedod by a NOMKE) symool. The purpose of tis message is Yo. hep prevent damage to your vehicle, her propery, or he ervronment ELECTRICAL ALL INFORMATION, ILLUSTRATIONS, DIREC- TIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LAT- EST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda Motor Co., Lid. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLI- GATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITH OUT WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTE- NANCE ON Honda MOTORCYCLES, MOTOR SCOOTERS OR ATVS. Honda Motor Co., Ltd. ‘SERVICE PUBLICATION OFFICE ELECTRIC STARTER ca LIGHTS/METERS/SWITCHES EK IMMOBILIZER SYSTEM (HISS) EZ WIRING DIAGRAMS Ep INDEX {ese TROUBLESHOOTING Date of fssve: Feoruary, 2002 (@Honda Motor Co., Ltd.1. GENERAL INFORMATION ‘SERVICE RULES --.. MODEL IDENTIFICATION: GENERAL SPECIFICATIONS. LUBRICATION SYSTEM SPECIFICATIONS - 1-6 FUEL SYSTEM (Programmed Fuel Injection) ‘SPECIFICATIONS-- 1-6 COOLING SYSTEM SPECIFICATIONS - CYLINDER HEAD/CYLINDER/PISTON SPECIFICATIONS: CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS- ALTERNATOR/STARTER CLUTCH SPECIFICATIONS... CRANKSHAFT/TRANSMISSION/BALANCER vee 1B ‘SPECIFICATIONS: FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS: REAR WHEEL/SUSPENSION SPECIFICATIONS: HYDRAULIC BRAKE SPECIFICATIONS -----1-10 BATTERY/CHARGING SYSTEM ‘SPECIFICATIONS. IGNITION SYSTEM SPECIFICATIONS ------1-10 ELECTRIC STARTER SPECIFICATIONS -- LIGHTS/METERS/SWITCHES ‘SPECIFICATIONS: STANDARD TORQUE VALUES -. ENGINE & FRAME TORQUE VALUES - LUBRICATION & SEAL POINTS CABLE & HARNESS ROUTING -- 1-28 EMISSION CONTROL SYSTEMS -. 1-33 1-1GENERAL INFORMATION SERVICE RULES 1 |. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that don't meet Honda's design specifications may cause damage to the motorcycle. Use the special tools designed for this product to avoid damage and incorrect assembly. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English fasteners. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified, Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly. ‘After reassembly, check all parts for proper installation and operation. Route all electrical wires as show in the Cable and Harness Routing (page 1-23). MODEL IDENTIFICATION 1-2GENERAL INFORMATION The frame serial number is stamped on the ht side of the steering head. The engine serial numbor is stamped on the front side of the lower Bi cncine SeRAU NUMER The throttle body identification number is stamped on the intake side of the throttle body as shown. THROTTLE BODY IDENTIFICATION NUMBER ‘The color label is attached as shown. When ordering color-coded parts, always specify the designated color code. COLOR LASEL 1-3GENERAL INFORMATION GENERAL SPECIFICATIONS TEM Overalllength Overall width Overall height ‘Wheelbase Seat height Footpeg height Ground clearance Dry weight Curb weight Maximum weight capacity Frame type Front suspension Front axle travel Rear suspension Rear axle travel . Front tire size Rear tire size | Front tire brand, | DIMENSIONS FRAME Rear tire brand Front brake Rear brake Caster angle Trail length Fuel tank capacity ENGINE Cylinder arrangement Bore and stroke Displacement Compression ratio Valve train Intake valve opens at 1 mm (0.04 in) lift closes at 1mm (0.04 in) Exhaust valve opens at 1mm (0.04) closes at 1mm (0.04 Lubrication system Oil pump type Cooling system Air filtration Engine dry weight _ | Firing order FUEL DELIVERY ‘Type SYSTEM Throttle bore Clutch system Clutch operation system Transmission | Primary reduction Final reduction Gear rati 1st | and 3rd 4th 5th pattern ‘SPECIFICATIONS 2,220 mm (874 in) 780 mm (31.1 in) 1,420 mm (44.1 in) 41,51 mm (59.6 in) 790 mm (31.1 in) 350 mm (13.8 in) 195 mm (6.3 in) 224 kg (494 Ibs) 252 kg (556 Ibs) 188 kg (414 Ibs) Double cradle Telescopic fork 108.0 mm (4.30.in) ‘Swingarm 116.0 mm (4.57 in) 120/70 2R 17 MIC (58W) 180/55 ZR 17 MIC (73W) D220FSTK (Dunlop) MACADAM 100XC (Michelin) 220STK (Dunlop) MACADAM 100XC (Michelin) Hydraulic double Hydraulic single disc 25° 99 mm (3.9 in) 21.0 liter (5.55 US gal, 4.62 Imp gal) 4 cylinders incline, inclined 13° from vertical — 78.0 X 672. mm (3.07 X 2.68 in} 41,284 cm? (783 cu-in) 96:1 Chain driven, DOHC o° BTDC 35° ABDC 40° BBDC 5° BTDC Forced pressure and wet sump Trochoid Liquid cooled Paper element 878 kg (193.6 Ibs) 1agaees PGM-Fi (Programmed Fuel Injection) 36 mm (1.4 in) Multi-plate, wet Hydraulic operating Constant mesh, 5-speeds 1.652 (76/46) 2.167 (39/18) 3.083 (37/12) 2.062 (33/16) 1.545 (34/22) 1.272 (28122) 4.130 (26/23) Left foot operated return system, 1-N-2-3-4-5ELECTRICAL i ~] Ignition system Starting system Charging system Regulatorirectifier Lighting system GENERAL INFORMATION Te SPECIFICATIONS Tomputer-controlled digital transistorized with electric advance, Electric starter motor TTiple phase output alternator SCR shoreedtriple phase, full wave rectifica tion Battery 1-5GENERAL INFORMATION LUBRICATION SYSTEM SPECIFICATIONS Unit: mm (in) TEM ‘STANDARD SERVICE LIMIT Engine oil capacity ‘After draining |= S.7iliter (3.9 US qt, 3.3 imp ath ‘After draining/filier 3.9 iter (4.1 US at. 3.4 Imp at) = change ae ‘After disassembly 48 liter (6.1 US at, 42 imp ath Recommended engine oit Honda 4-stroke oil or equivalent motor oil AP! service classic ee Viscosity: SAE 10W~ Oil pressure at oil pressure switch “490 - 588 kPa (6.0 - 6.0 Kgfiem, 771-85 : pail at ,000 min" (rpm)80°C/176°F) n SE, SF or SG il pump rotor Tip clea [0.15 (0.008) 0.20 (0.008) Body clearance 0.18 - 0.22 (0,006 - 0.009) 0.35 (0.014) Side clearance 0.02= 0.07 (0.001 ~ 0.003) 0.10 (0.004) FUEL SYSTEM (Programmed Fuel Injection) SPECIFICATIONS Starter valve vacuum difference Base throttle valve for synchronization idle sp “Throttle grip free play e air temperature sensor resistance (at gine coolent temperature sensor resistance (at 20°Ci68°F) > Fuel injection resistance (at 20°C763" PAIR solenoid valve resistance lat 20°CI63°F) — ‘Cam pulse generator peak voltage (at 20°CI68°F) ignition pulse generator peak voltage (at 20°C/68°F) 0.7 Vminimum Manifold absolute pressure at idle 150 - 250 mm Ho Fuel pressure at idle 343 KPa (3.5 kgflem?, 50 psi) Fuel pump flow (et 121 188 cm (6.4 US oz, 6.6 Imp oz) minimum/10 seconds 08 145.0 20-240 07 Vminimum [eee EM, Coolant capacity Radiator and engine __ SPECIFICATIONS _ fer (2.90 US qt, 2.41 Imp at Reserve tank 1 31 liter(0.33 US qt, 0.27 Imp at) Radiator cap relief pressure I 108 = 137 kPa (1.1 ~ 1.4 kaficm’, 16 - 20 psi [Thermostat Begin to open 80 - 84 °C (176 - 183 °F} Fully open : a ‘95°C (203 °F % Valve lift I ‘mm (0.3 in) minimum Recommended antifreeze High quality ethylene glycol antifreeze containing corrosion protection inhibitors idard coolant concentration 50% mixture with soft water