2003-2004 ae iC a wa) PNHOW TO USE THIS MANUAL ‘hie serve manual deectibes the serve procedures for the Follow the Maintenance Schedule (Section 3) recommendations to levels re within the standard tet by the Calforia At Revoutoos Board (CARB CONTENTS GENERAL INFORMATION gy FRAME/BODY PANELS/EXHAUST SYSTEM. | 2 MAINTENANCE BZ _ Dons rho inna wear cesredcrng bron nowrne,” [| LUBRICATION SYSTEM | 4 ‘sweeter ange sina treo z | FUEL SYSTEM Sistem hough deat pescrte wn rvnedsering | [ COOLING SYSTEM | 6 Find the section you want on this page, then turn to the table of con- S ENGINE REMOVAL/INSTALLATION tro et age tt econ z [enenme removavinsrauiarion IR Yost satan sar whan astm oF sate tnaraon. sree | @ | CYLINDER HEAD/VALVE Ei information and robleshooing forthe secon. Th subcaquantpagee | ‘pive detailed procedures. > CYLINDER/PISTON | 9 If you do not know the source of the trouble, go to Section 21, r Tetoctng § | CLUTCH/GEARSHIFT LINKAGE }10 “ 3 eee Your: satay. and the safety of others, is very importent. To help vou i | CRANKSHAFT/TRANSMISSION Sree eet ce atreae FINAL DRIVE _ Sess ow la ‘nase | [| FRONT WHEEL/SUSPENSION/STEERING [RY "Sate Label ~on the vehicle g + Stay wssoges = paced by a aay ala mba bons | | @ | REAR WHEEL/SUSPENSION qi era an ae a, 3 —— ee 5 BHU © | HYDRAULIC DISC BRAKE @ EXIGE itor esto nenctone J = ry fey You CAN be KILLED of SERIOUSLY _j [BATTERY/CHARGING SYSTEM HURT you don follow intuctons 3 YouCAN be HURT yu donate & | IGNITION SYSTEM + Instructions - how to service this vehicle correctly and safely 8 ELECTRIC STARTER/STARTER CLUTCH j18 Aevourona ean yu uatingoraten tr ieprncacty | ™ [LIGHTS/METERS/SWITCHES WIRING DIAGRAMS {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 IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON Honde MOTORCY- (CLES, MOTOR SCOOTERS, OF ATVS. Honda Motor Co,, Ltd SERVICE PUBLICATIONS OFFICE TROUBLESHOOTING El [INDEX [22 Date of Issue: April, 2002 (© Honda Motor Co,, Ltd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. | replace tne pari with new ont befor easembiy. 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). a a Kesey | Ute mutt-pupoce ores ate ithiurn based multi-purpose grease NLGI #2 or equivalent). Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or equivalent). Example: Molykote® BR-2 plus manufactured by Dow Corning, U.S.A. | ‘Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan Use molybdenum disulfide paste (containing more than 40% molybdenum disulfi equivalent) Example: Molykote® G-n paste, manufactured by Dow Corning, U.S.A. Honda Moly 60 (U.S.A. only) Rocol ASP manufactured by Rocol Limited, U.K. Rocol Paste manufactured by Sumico Lubricant, Japan », NLGI #2 oF Use silicone grea Apply sealant. Use DOT 3 or DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified. ae “Sa Pym | Avot locking agent. Use # medium strength locking agent unless otherwise specified sens Po] Use fork or suspension fivid.