Honda cb500f Service Manual Download

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Maintenance Fundamentals

Maintenance

Always use Honda Genuine Parts or their
equivalents to ensure reliability and safety.

When ordering coloured components, specify
the model name, colour, and code mentioned
on the colour label. The colour label is attached
to the rear fender under the seat.

P. 56

Replacing Parts

WARNING

Installing non-Honda parts may make
your motorcycle unsafe and cause a
crash in which you can be seriously
hurt or killed.

Always use Honda Genuine Parts or
equivalents that have been designed
and approved for your motorcycle.

Colour label

http://www.motorcycle.in.th

Summary of Contents for cb500f

Page 1: ...oduction information available before printing Honda Motor Co Ltd reserves the right to make changes at any time without notice and without incurring any obligation No part of this publication may be reproduced without written permission The vehicle pictured in this owner s manual may not match your actual vehicle 2013 Honda Motor Co Ltd http www motorcycle in th ...

Page 2: ... all recommendations and procedures contained in this manual Pay close attention to safety messages contained in this manual and on the motorcycle The following codes in this manual indicate each country The illustrations here in are based on the CB500XA ED type Country Codes The specifications may vary with each locale Code Country CB500X E UK F France Belgium ED European direct sales KO Korea CB...

Page 3: ...torcycle You must use your own good judgement You will find important safety information in a variety of forms including Safety labels on the motorcycle Safety Messages preceded by a safety alert symbol and one of three signal words DANGER WARNING or CAUTION These signal words mean 3DANGER You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions 3WARNING You CAN be KILLED or SERIOUSLY...

Page 4: ...Contents Motorcycle Safety P 2 Operation Guide P 16 Maintenance P 39 Troubleshooting P 82 Information P 102 Specifications P 114 Index P 117 http www motorcycle in th ...

Page 5: ...ortant information for safe riding of your motorcycle Please read this section carefully Safety Guidelines P 3 Image Labels P 6 Safety Precautions P 10 Riding Precautions P 11 Accessories Modifications P 14 Loading P 15 http www motorcycle in th ...

Page 6: ...re physically fit mentally focused and free of alcohol and drugs Check that you and your passenger are both wearing an approved motorcycle helmet and protective apparel Instruct your passenger on holding onto the grab rails or your waist leaning with you in turns and keeping their feet on the footpegs even when the motorcycle is stopped Even if you have ridden other motorcycles practice riding in ...

Page 7: ...orcycle properly maintained and in safe riding condition Inspect your motorcycle before every ride and perform all recommended maintenance Never exceed load limits 2 P 15 and do not modify your motorcycle or install accessories that would make your motorcycle unsafe 2 P 14 Personal safety is your first priority If you or anyone else has been injured take time to assess the severity of the injuries...

Page 8: ...ontains poisonous carbon monoxide a colourless odorless gas Breathing carbon monoxide can cause loss of consciousness and may lead to death If you run the engine in confined or even partly enclosed area the air you breathe could contain a dangerous amount of carbon monoxide Never run your motorcycle inside a garage or other enclosure Carbon Monoxide Hazard 3WARNING Carbon monoxide gas is toxic Bre...

Page 9: ...mbol on each label The meanings of each symbol and label are as follows Except KO type Read instructions contained in Owner s Manual carefully Read instructions contained in Shop Manual carefully In the interest of safety take the motorcycle to be serviced only by your dealer DANGER with RED background You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions WARNING with ORANGE backgr...

Page 10: ...ouch a battery unless they understand proper handling and hazards of the battery very well Handle the battery electrolyte with extreme care as it contains dilute sulfuric acid Contact with your skin or eyes can burn you or cause loss of your eyesight Read this manual carefully and understand it before handling the battery Neglect of the instructions can cause personal injury and damage to the moto...

Page 11: ...ion of accessories and luggage Read carefully the instructions contained in user s manual and installation guide before installing any accessory The total weight of accessories and luggage added to rider s and passenger s weight should not exceed 185 kg 408 lb which is the maximum weight capacity The luggage weight must not exceed 11 kg 24 lb under any circumstances The fitting of large fork mount...

Page 12: ... kgf cm2 36 psi Rear 290 kPa 2 90 kgf cm2 42 psi Tyre size Front 120 70ZR17M C 58W Rear 160 60ZR17M C 69W Tyre brand PIRELLI Front SCORPION TRAIL E Rear SCORPION TRAIL SAFETY REMINDER LABEL For your protection always wear helmet protective apparel FUEL LABEL Unleaded petrol only DRIVE CHAIN LABEL Keep chain adjusted and lubricated 35 to 45 mm 1 4 to 1 8 in Freeplay http www motorcycle in th ...

Page 13: ...ditions Helmet Safety standard certified high visibility correct size for your head Must fit comfortably but securely with the chin strap fastened Face shield with unobstructed field of vision or other approved eye protection Gloves Full finger leather gloves with high abrasion resistance Boots or Riding Shoes Sturdy boots with non slip soles and ankle protection Jacket and Trousers Protective hig...

Page 14: ...nt and rear brakes together Avoid excessively hard braking and down shifts u Sudden braking can reduce the motorcycle s stability u Where possible reduce speed before turning otherwise you risk sliding out Exercise caution on low traction surfaces u The tyres slip more easily on such surfaces and braking distances are longer Avoid continuous braking u Repeated braking such as when descending long ...

Page 15: ... brakes This is normal Always use the recommended tyres to ensure correct ABS operation Engine Braking Engine braking helps slow your motorcycle down when you release the throttle For further slowing action downshift to a lower gear Use engine braking with intermittent use of the brakes to reduce speed when descending long steep slopes Wet or Rainy Conditions Road surfaces are slippery when wet an...

Page 16: ...p the engine 2 Push the side stand down 3 Slowly lean the motorcycle to the left until its weight rests on the side stand 4 Turn the handlebar fully to the left u Turning the handlebar to the right reduces stability and may cause the motorcycle to fall 5 Turn the ignition switch to the LOCK position and remove the key 2 P 33 Follow these guidelines to protect the engine and catalytic converter Use...

Page 17: ...ycle illegal to operate on public roads and highways Before deciding to install accessories on your motorcycle be certain the modification is safe and legal Do not pull a trailer with or attach a sidecar to your motorcycle Your motorcycle was not designed for these attachments and their use can seriously impair your motorcycle s handling 3WARNING Improper accessories or modifications can cause a c...

Page 18: ...eep within specified load limits 2 Maximum weight capacity Maximum luggage weight P 114 Tie all luggage securely evenly balanced and close to the centre of the motorcycle Do not place objects near the lights or the muffler 3WARNING Overloading or improper loading can cause a crash and you can be seriously hurt or killed Follow all load limits and other loading guidelines in this manual http www mo...

Page 19: ...Throttle grip P76 Engine oil fill cap P60 Engine oil drain bolt P62 Engine oil filter P63 Front brake lever Fuel fill cap P36 Side cover P57 Engine oil level inspection window P60 Rear brake fluid reservoir P66 Main fuse P101 Rear brake pedal http www motorcycle in th ...

Page 20: ...n P69 Fuse box P100 Crankcase breather P77 Battery P59 Clutch lever P73 Side stand P68 Coolant reserve tank P64 Rear suspension spring preload adjuster P78 Shift lever P35 Bulb Lid P58 Windscreen P80 Side cover P57 http www motorcycle in th ...

Page 21: ... turned on all the mode and digital segments will show and the tachometer segment progresses to maximum scale and then disappear If any part of these displays does not come on when it should have your dealer check for problems SET button SEL button http www motorcycle in th ...

Page 22: ...ersely affect engine life Clock 12 hour display To set the clock P25 Fuel gauge Remaining fuel when only 1st E segment starts flashing approximately 2 8 litres 0 74 US gal 0 62 Imp gal Speedometer If the fuel gauge indicators repeat flashing or turned off P87 Tachometer red zone excessive engine rpm range http www motorcycle in th ...

Page 23: ...ption meter SEL button selects the odometer tripmeter A tripmeter B current fuel mileage average fuel mileage and fuel consumption u To reset the tripmeter P22 Odometer Tripmeter A Tripmeter B Current fuel mileage Average fuel mileage Fuel consumption Reserve fuel consumption P23 http www motorcycle in th ...

Page 24: ...played When is displayed at speeds above 7 km h 5 mph go to your dealer for service Average fuel mileage Average fuel mileage since tripmeter A was reset When is displayed go to your dealer for service Fuel consumption Total fuel consumption since tripmeter A was reset When displayed go to your dealer for service u To reset the average fuel mileage and fuel consumption P22 http www motorcycle in t...

Page 25: ...yed at each indication c Then the display returns to the last selected indication d To reset tripmeter B press and hold SET button with tripmeter B displayed Also the tripmeter A average fuel mileage and fuel consumption will automatically reset by refuelling more than the reserve amount and riding your motorcycle for 0 1 km 0 06 mile You can activate or deactivate the automatic reset mode by refu...

Page 26: ...on as possible Reserve fuel consumption display Flashes from 0 0 L litre or gal US gal u When the amount of consumed fuel is more than 1 0 litre 0 26 US gal 0 22 Imp gal the display blinks faster u If you change the display to odometer tripmeter fuel mileage meter and fuel consumption meter and so on P20 it will automatically return to the reserve fuel consumption display if the buttons are not pr...

Page 27: ...ndicator Changing of speed and mileage unit Changing of fuel mileage meter unit E type only Press and hold SEL button and SET button Press SET button Ordinary display Clock setting Activating deactivating of tripmeter A average fuel mileage and fuel consumption automatic reset mode Setting of HISS indicator Changing of fuel mileage meter unit Backlight brightness adjustment Setting Mode Changing o...

Page 28: ...and hold SEL button and SET button the hour digits start flashing c Press SEL button until the desired hour is displayed u Press and hold to advance the hour fast d Press SET button The minute digits start flashing e Press SEL button until the desired minute is displayed u Press and hold to advance the minute fast f Press SET button The clock is set and then the display moves to the backlight brig...

Page 29: ...n adjust the brightness to five levels a Press SEL button The brightness is switched b Press SET button The backlight is set and then the display moves to activating deactivating of tripmeter A average fuel mileage and fuel consumption automatic reset mode http www motorcycle in th ...

Page 30: ...fuelling after 1st E segment of the fuel gauge starts flashing Deactivation is initially set a Press SEL button to select activate or deactivate in the automatic reset mode b To end the selection press SET button The activation deactivation of automatic reset mode is set and then the display moves to the on off of blinks of HISS indicator HISS indicator comes on http www motorcycle in th ...

Page 31: ... fuel mileage meter unit Press SET button The HISS indicator setting is set and then the display moves to the changing of the speed and mileage unit Except E type E type only 5 Changing the speed and mileage unit a Press SEL button to select either km h and km or mph and mile b Press SET button The speed and mileage unit is set and then the display moves to the changing of the fuel mileage meter u...

Page 32: ...age shown by mile L or mile gal E type only b To end the selection press SET button The established setting can also be set by turning the ignition switch to OFF The control is automatically switched from the setting mode to the ordinary display if the button is not pressed for about 30 seconds Even in this case established setting is maintained http www motorcycle in th ...

Page 33: ...on switch is turned on If it comes on while riding P84 Comes on briefly when the ignition switch is turned on with the engine stop switch in the Run position Comes on when the ignition switch is turned on with the engine stop switch in the Off position If it comes on while engine is running P85 ABS Anti lock Brake System indicator Comes on when the ignition switch is turned on Goes off when your s...

Page 34: ...Neutral indicator Comes on when the transmission is in Neutral HISS indicator P83 P104 Comes on briefly when the ignition switch is turned on Goes off if the ignition key has the correct coding Flashes every 2 seconds for 24 hours when the ignition switch is turned off http www motorcycle in th ...

Page 35: ...witch is on Can be turned to off regardless of the ignition switch position u The signals continue flashing with the ignition switch is OFF or LOCK after the hazard switch is on Start button Headlight dimmer switch High beam Low beam Horn button Turn signal switch u Pressing the switch turns the turn signal off Passing light control switch Flashes the high beam headlight http www motorcycle in th ...

Page 36: ...o the LOCK position u Jiggle the handlebar if the lock is difficult to engage c Remove the key Unlocking Insert the key push it in and turn the ignition switch to the OFF position Ignition Switch Switches the electrical system on off locks the steering u Key can be removed when in the OFF or LOCK position ON Turns electrical system on for starting riding OFF Turns engine off LOCK Locks steering Pu...

Page 37: ...ngine does not start a Open the throttle fully and press the start button for 5 seconds b Repeat the normal starting procedure c If the engine starts open the throttle slightly if idling is unstable d If the engine does not start wait 10 seconds before trying steps a b again If Engine Will Not Start P83 NOTICE If the engine does not start within 5 seconds turn the ignition off and wait 10 seconds ...

Page 38: ...ifting Gears Your motorcycle transmission has six forward gears in a one down five up shift pattern If you put the motorcycle in gear with the side stand down the engine will shut off N 1 2 3 4 5 6 http www motorcycle in th ...

Page 39: ...sing the Fuel Fill Cap a After refuelling align the fuel fill cap latch with the slot in the filler neck b Push the fuel fill cap into the filler neck until it snaps closed and locks c Remove the key and close the lock cover u The key cannot be removed if the cap is not locked Filler neck plate Fuel level max Fuel fill cap Fuel filler opening Ignition key Lock cover Except KO type KO type 3WARNING...

Page 40: ...rked Removing the Seat P56 Helmet set wire Helmet D ring Helmet set wire Helmet holder 3WARNING Riding with a helmet attached to the holder can interfere with the rear wheel or suspension and could cause a crash in which you can be seriously hurt or killed Use the helmet holder only while parked Do not ride with a helmet secured by the holder http www motorcycle in th ...

Page 41: ...haped lock u The U shaped lock is held in place under the seat u Some U shaped locks may not fit in the compartment due to their size or design Rubber strap Tool kit U shaped lock Document bag The document bag is located underside of the seat Removing the Seat P56 Document bag Rubber strap http www motorcycle in th ...

Page 42: ...le P 41 Maintenance Fundamentals P 44 Tool Kit P 55 Removing Installing Body Components P 56 Seat P 56 Side Cover P 57 Bulb Lid P 58 Clip P 58 Battery P 59 Engine Oil P 60 Coolant P 64 Brakes P 66 Side Stand P 68 Drive Chain P 69 Clutch P 73 Throttle P 76 Crankcase Breather P 77 Other Adjustments P 78 Rear Suspension P 78 Headlight Aim P 79 Brakelight Switch P 79 Windscreen Height P 80 http www mo...

Page 43: ...forming maintenance Only you can decide whether or not you should perform a given task Follow these guidelines when performing maintenance Stop the engine and remove the key Park your motorcycle on a firm level surface using the side stand or a maintenance stand to provide support Allow the engine muffler brakes and other high temperature parts to cool before servicing as you can get burned Run th...

Page 44: ...se requirements Keep an accurate record of maintenance to help ensure that your motorcycle is properly maintained Make sure that whomever performs the maintenance completes this record All scheduled maintenance is considered a normal owner operating cost and will be charged for by your dealer Retain all receipts If you sell the motorcycle these receipts should be transferred with the motorcycle to...

Page 45: ... or replace if necessary Lubricate Replace Clean Items Pre ride Check 2 P 44 Frequency 1 Annual Check Regular Replace Refer to page 1 000 km 1 12 24 36 48 1 000 mi 0 6 8 16 24 32 Fuel Line Fuel Level 36 Throttle Operation 76 Air Cleaner 2 54 Crankcase Breather 3 77 Spark Plug Valve Clearance Engine Oil 62 Engine Oil Filter 63 Engine Idle Speed Radiator Coolant 4 3 Years 64 Cooling System Secondary...

Page 46: ...l Check Regular Replace Refer to page 1 000 km 1 12 24 36 48 1 000 mi 0 6 8 16 24 32 Drive Chain Every 1 000 km 600 mi 69 Drive Chain Slider 72 Brake Fluid 4 2 Years 66 Brake Pads Wear 67 Brake System 66 Brakelight Switch 79 Headlight Aim 79 Lights Horn Engine Stop Switch Clutch System 73 Side Stand 68 Suspension Nuts Bolts Fasteners Wheels Tyres 51 Steering Head Bearings I I I I I I I I I I I I I...

Page 47: ...itions 2 P 76 Engine oil level Add engine oil if necessary Check for leaks 2 P 60 Coolant level Add coolant if required Check for leaks 2 P 64 Drive chain Check condition and slack adjust and lubricate if necessary 2 P 69 Brakes Check operation Front and Rear check brake fluid level and pads wear 2 P 66 67 Lights and horn Check that lights indicators and horn function properly Engine stop switch C...

Page 48: ... code mentioned on the colour label The colour label is attached to the rear fender under the seat 2 P 56 Replacing Parts 3WARNING Installing non Honda parts may make your motorcycle unsafe and cause a crash in which you can be seriously hurt or killed Always use Honda Genuine Parts or equivalents that have been designed and approved for your motorcycle Colour label http www motorcycle in th ...

Page 49: ...f the terminals are starting to corrode and are coated with a white substance wash with warm water and wipe clean Battery NOTICE Your battery is a maintenance free type and can be permanently damaged if the cap strip is removed NOTICE An improperly disposed of battery can be harmful to the environment and human health Always confirm local regulations for battery disposal 3WARNING The battery gives...

Page 50: ...cuits on your motorcycle If something electrical on your motorcycle stops working check for and replace any blown fuses 2 P 100 Inspecting and Replacing Fuses Turn off the ignition switch to remove and inspect fuses If a fuse is blown replace with a fuse of the same rating For fuse ratings see Specifications 2 P 116 NOTICE Installing non Honda electrical accessories can overload the electrical sys...

Page 51: ...ngine oil check the label to make sure that the oil satisfies all of the following standards JASO T 903 standard 1 MA SAE standard 2 10W 30 API classification 3 SG or higher 1 The JASO T 903 standard is an index for engine oils for 4 stroke motorcycle engines There are two classes MA and MB For example the following label shows the MA classification 2 The SAE standard grades oils by their viscosit...

Page 52: ... If the chain does not move smoothly makes strange noises has damaged rollers or loose pins or missing O rings or kinks have the chain inspected by your dealer Also inspect the engine sprocket and rear wheel sprocket If either has worn or damaged teeth have the sprocket replaced by your dealer Brake Fluid NOTICE Brake fluid can damage plastic and painted surfaces Wipe up spills immediately and was...

Page 53: ...l and benzene abrasive cleaner chain cleaner or lubricant NOT designed specifically for O ring chains as these can damage the rubber O ring seals Avoid getting lubricant on the brakes or tyres Avoid applying excess chain lubricant to prevent spray onto your clothes and the motorcycle Pro Honda HP coolant is a pre mixed solution of antifreeze and distilled water A concentration of antifreeze below ...

Page 54: ... at least once a month or any time you think the tyres look low Always check air pressure when your tyres are cold Inspecting for Damage Inspect the tyres for cuts slits or cracks that exposes fabric or cords or nails or other foreign objects embedded in the side of the tyre or the tread Also inspect for the bumps or bulges in the side walls of the tyres Inspecting for Abnormal Wear Inspect the ty...

Page 55: ...the minimum tread depth is reached German law prohibits use of tyres whose tread depth is less than 1 6 mm Wear indicator location mark or TWI 3WARNING Riding on tyres that are excessively worn or improperly inflated can cause a crash in which you can be seriously hurt or killed Follow all instructions in this owner s manual regarding tyre inflation and maintenance Germany http www motorcycle in t...

Page 56: ...e tyre is installed Do not install a tube inside a tubeless tyre on this motorcycle Excessive heat build up can cause the tube to burst Use only tubeless tyres on this motorcycle The rims are designed for tubeless tyres and during hard acceleration or braking a tube type tyre could slip on the rim and cause the tyre to rapidly deflate 3WARNING Installing improper tyres on your motorcycle can adver...

Page 57: ...ped with a viscous type air cleaner element Compressed air cleaning or any other cleaning can degrade the viscous element performance and cause the intake of dust Do not perform the maintenance Should be serviced by your dealer Air Cleaner http www motorcycle in th ...

Page 58: ...ner 10 14 mm Open end wrench Standard Phillips screwdriver Screwdriver handle Extension bar 5 mm Hex wrench Helmet set wire Fuse puller Pin spanner 8 12 mm Open end wrench 10 14 mm Open end wrench Standard Phillips screwdriver Screwdriver handle Extension bar 5 mm Hex wrench 19 mm Box end wrench 24 mm Box end wrench Helmet set wire Fuse puller E F ED type U KO type http www motorcycle in th ...

Page 59: ...nd rear stays on the frame 2 Insert the recess into the tab 3 Push forward and down on the rear of the seat until it locks in place Make sure that the seat is locked securely in position to pull it up lightly The seat locks automatically when closed Take care not to lock your key in the compartment under the seat Tab Recess Seat lock Ignition key Front prong Rear prongs Seat Front stay Rear stays ...

Page 60: ...ver must be removed to access the main fuse The right and left side covers can be removed in the same manner Removal 1 Remove the bolt A and bolt B 2 Remove the prongs from the grommets 3 Remove the side cover by releasing the tab Installation Install the parts in the reverse order of removal Prongs Bolt A Prongs grommets Tab Bolt B grommets http www motorcycle in th ...

Page 61: ...the bulb lid Installation 1 Install the bulb lid and the clips Clip The clip must be removed to remove the bulb lid Removal 1 Press down on the centre pin to release the lock 2 Pull the clip out of the hole Installation 1 Push the bottom of the centre pin 2 Insert the clip into the hole 3 Press down on the centre pin to lock the clip Bulb lid Clips Centre pin http www motorcycle in th ...

Page 62: ... drop the terminal nuts Installation Install the parts in the reverse order of removal Always connect the positive terminal first Make sure that bolts and nuts are tight Readjust the clock after the battery is reconnected since the clock goes wrong once the battery disconnected The tripmeter A and B will be reset if the battery is disconnected For proper handling of the battery see Maintenance Fun...

Page 63: ...gnition switch off stop the engine and wait for 2 to 3 minutes 3 Place your motorcycle in an upright position on a firm level surface 4 Check that the oil level is between the upper and lower level marks in the oil inspection window Oil fill cap Upper level Lower level Oil level inspection window http www motorcycle in th ...

Page 64: ...rface when checking the oil level uDo not overfill above the upper level mark uMake sure no foreign objects enter the oil filler opening uWipe up any spills immediately 2 Securely reinstall the oil fill cap For the recommended oil and oil selection guidelines see Maintenance Fundamentals 2 P 48 NOTICE Overfilling with oil or operating with insufficient oil can cause damage to your engine Do not mi...

Page 65: ...n switch off stop the engine and wait for 2 to 3 minutes 3 Park on a firm level surface and lower the side stand 4 Place a drain pan under the drain bolt 5 Remove the oil fill cap drain bolt and sealing washer to drain the oil 6 Remove the oil filter with a filter wrench and let the remaining oil drain out Make sure the prior seal is not stuck to the engine uDiscard the oil and oil filter at an ap...

Page 66: ...hten the drain bolt 10 Fill the crankcase with the recommended oil 2 P 48 and install the oil fill cap 11 Check the oil level 2 P 60 12 Check that there are no oil leaks Torque 26 N m 2 7 kgf m 19 lbf ft Rubber seal Oil filter Torque 30 N m 3 1 kgf m 22 lbf ft Required oil When changing oil engine oil filter 2 7 litres 2 9 US qt 2 4 Imp qt When changing oil only 2 5 litres 2 6 US qt 2 2 Imp qt htt...

Page 67: ...ank If the coolant level is dropping noticeably or the reserve tank is empty you likely have a serious leak Have your motorcycle inspected by your dealer Adding Coolant If the coolant level is below the LOWER level add the recommended coolant 2 P 50 until the level reaches the UPPER level mark Add fluid only from the reserve tank cap and do not remove radiator cap UPPER level LOWER level Reserve t...

Page 68: ...he reserve tank opening 3 Securely reinstall the cap 4 Install the left side cover Changing Coolant Have your dealer change the coolant unless you have the proper tools and are mechanically qualified 3WARNING Removing the radiator cap while the engine is hot can cause the coolant to spray out potentially scalding you Always let the engine and radiator cool down before removing the radiator cap Res...

Page 69: ...luid level is between the LOWER level and UPPER level marks If the brake fluid level in either reservoir is below the LWR or LOWER level mark or the brake lever and pedal freeplay becomes excessive inspect the brake pads for wear If the brake pads are not worn you most likely have a leak Have your motorcycle inspected by your dealer Front Rear Front Rear Front brake fluid reservoir LWR mark Rear b...

Page 70: ...s worn to the indicator 1 Inspect the brake pads from below the brake caliper 2 Inspect the brake pads from the rear right of the motorcycle If necessary have the pads replaced by your dealer Always replace both left and right brake pads at the same time Front Rear Front Rear Pads Wear indicator Disc Wear indicator Pads Wear indicator Disc Wear indicator http www motorcycle in th ...

Page 71: ...g for damage or loss of tension 3 Sit on the motorcycle put the transmission in Neutral and raise the side stand 4 Start the engine pull the clutch lever in and shift the transmission into gear 5 Lower the side stand all the way The engine should stop as you lower the side stand If the engine doesn t stop have your motorcycle inspected by your dealer Side stand spring http www motorcycle in th ...

Page 72: ...orcycle on the side stand on a level surface 2 Stop the engine Place the transmission in Neutral 3 Check the slack in the lower half of the drive chain midway between the sprockets uDo not ride your motorcycle if the slack exceeds 60 mm 2 4 in 4 Roll the motorcycle forward and check that the chain moves smoothly 5 Inspect the sprockets 2 P 49 6 Clean and lubricate the drive chain 2 P 50 Drive chai...

Page 73: ...n slack be careful not to damage the wheel speed sensor and pulser ring 1 Place your motorcycle on the side stand on a level surface 2 Stop the engine Place the transmission in Neutral 3 Loosen the rear axle nut 4 Loosen the lock nuts on both sides of the swingarm CB500XA only Rear axle nut Lock nut Adjusting nut Adjusting nut Rear edge of adjusting slot Chain adjuster index mark Lock nut http www...

Page 74: ...ng sure the chain adjuster index marks align with the rear edge of the adjusting slots Both marks should correspond If the axle is misaligned turn the right or left adjusting nuts until the marks are aligned and recheck chain slack 7 Tighten the rear axle nut 8 Tighten the drive chain adjusting nuts lightly then hold the adjusting nuts and tighten the lock nuts 9 Recheck drive chain slack If a tor...

Page 75: ...d to the proper slack the chain is excessively worn and must be replaced If necessary have the drive chain replaced by your dealer Checking the Drive Chain Slider Check the condition of the drive chain slider The drive chain slider need to be replaced if it is worn to the wear limit line If necessary have the drive chain slider replaced by your dealer Chain DID 520V0 Red zone Index mark Drive chai...

Page 76: ... Check the clutch cable for kinks or signs of wear If necessary have it replaced by your dealer Lubricate the clutch cable with a commercially available cable lubricant to prevent premature wear and corrosion Freeplay at the clutch lever 10 to 20 mm 0 4 to 0 8 in Clutch lever Freeplay http www motorcycle in th ...

Page 77: ...lock nut 2 Turn the upper clutch cable adjuster until the freeplay is 10 to 20 mm 0 4 to 0 8 in 3 Tighten the upper lock nut and check the freeplay again Lower Adjustment If the upper clutch cable adjuster is threaded out near its limit or the correct freeplay cannot be obtained attempt adjustment with the lower adjusting nut Upper clutch cable adjuster Upper lock nut http www motorcycle in th ...

Page 78: ... to 20 mm 0 4 to 0 8 in 4 Tighten the lower lock nut and check the clutch lever freeplay 5 Start the engine pull the clutch lever in and shift into gear Make sure the engine does not stall and the motorcycle does not creep Gradually release the clutch lever and open the throttle Your motorcycle should move smoothly and accelerate gradually If proper adjustment cannot be obtained or the clutch does...

Page 79: ...ly 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 motorcycle inspected by your dealer Freeplay at the throttle grip flange 2 to 6 mm 0 1 to 0 2 in Freeplay Flange http www motorcycle in th ...

Page 80: ...her Cleaning the Crankcase Breather 1 Remove the crankcase breather tube plug from the tube 2 Drain deposits into a suitable container 3 Install the crankcase breather tube plug Crankcase breather tube plug http www motorcycle in th ...

Page 81: ...s The standard position is 3 when the index mark on the adjuster is aligned with the left end of the rear shock absorber lower mounting bolt Turn the adjuster in the direction A to decrease spring preload soft position 1 to 2 or turn the adjuster in the direction B to increase spring preload hard position 4 to 9 Attempting to adjust directly from 1 to 9 or 9 to 1 may damage the shock absorber Pin ...

Page 82: ...ed in the tool kit 2 P 55 in or out as necessary Obey local laws and regulations Adjusting the Brakelight Switch Check the operation of the brakelight 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 Lower Pinion Raise A B Brakelight switch Adjusting nut http www motorc...

Page 83: ...aintenance Adjusting the Windscreen Height You can adjust the windscreen height 2 positions 1 Remove the upper side caps 2 Remove the windscreen by removing the screws the washers A Upper side caps Windscreen Washers A Screws Screws http www motorcycle in th ...

Page 84: ...e low position holes or high position holes 5 Install the windscreen 6 Install and tighten the washers A and screws 7 Install the upper side caps 8 Make sure the installation order is the following illustration Washers B Nuts Nuts Low position High position Washer A Screw Nut Stay Washer B Windscreen Cap Upper side only http www motorcycle in th ...

Page 85: ...P 85 Low Oil Pressure Indicator P 85 PGM FI Programmed Fuel Injection Malfunction Indicator Lamp MIL P 85 ABS Anti lock Brake System Indicator CB500XA only P 86 Other Warning Indication P 87 Fuel Gauge Failure Indication P 87 Tyre Puncture P 88 Electrical Trouble P 95 Battery Goes Dead P 95 Burned out Light Bulb P 95 Blown Fuse P 100 http www motorcycle in th ...

Page 86: ...d turn the ignition switch to the ON position If the indicator still stays on check the following Check if there is no another HISS key including spare key close to the ignition switch Check if there are no any metallic seals or stickers on the key If the HISS indicator still stays on have your motorcycle inspected by your dealer Starter Motor Does Not Operate Check the following items Make sure e...

Page 87: ...he ignition switch to the OFF position Suspect a fault Do not start the engine Transport your motorcycle to your dealer Allow the engine to cool with the ignition switch in the OFF position 3 After the engine has cooled inspect the radiator hose and check if there is a leak 2 P 64 Do not start the engine Transport your motorcycle to your dealer 4 Check the coolant level in the reserve tank and add...

Page 88: ...ar the low level If the low oil pressure indicator stays on when the oil level is at the proper level stop the engine and contact your dealer If the engine oil level goes down rapidly your motorcycle may have a leak or another serious problem Have your motorcycle inspected by your dealer PGM FI Programmed Fuel Injection Malfunction Indicator Lamp MIL If the indicator comes on while riding you may ...

Page 89: ...tor comes on or starts flashing while riding Indicator does not come on when the ignition switch is in the ON position Indicator does not go off at speeds above 10 km h 6 mph If the ABS indicator stays on your brakes will continue to work as a conventional system but without the anti locking function The ABS indicator may flash if you turn the rear wheel while your motorcycle is lifted off the gro...

Page 90: ...er Warning Indication Fuel Gauge Failure Indication If the fuel system has an error all segments will blink or go off as shown in the illustration If these occurs see your dealer as soon as possible http www motorcycle in th ...

Page 91: ...e instructions provided with the emergency tyre repair kit Riding your motorcycle with a temporary tyre repair is very risky Do not exceed 50 km h 30 mph Have the tyre replaced by your dealer as soon as possible Removing Wheels Follow these procedures if you need to remove a wheel in order to repair a puncture 3WARNING Riding your motorcycle with a temporary tyre repair can be risky If the tempora...

Page 92: ... side remove the mounting bolts and brake caliper uSupport the brake caliper assembly so that it doesn t hang from the brake hose Do not twist the brake hose uAvoid getting grease oil or dirt on the disc or pad surfaces uDo not pull the brake lever while the brake caliper is removed uTake care to prevent the brake caliper from scratching the wheel during removal CB500XA only Mounting bolts Brake c...

Page 93: ...ve the front axle shaft front wheel and side collars Installation 1 Attach the right and left side collars in their original locations on the wheel 2 On the left side place the wheel between the fork legs and insert the front axle shaft to the end through the left fork leg and wheel hub 3 Tighten the axle shaft Front axle shaft Axle pinch bolt Left side collar Torque 54 N m 5 5 kgf m 40 lbf ft htt...

Page 94: ...e axle pinch bolt 8 Raise the front wheel off the ground again and check that the wheel rotates freely after you release the brake 9 Uncover the protective tape or cloth 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 capacity Torque 30 N m 3 1 kgf m 22 lbf ft NOTICE When installing the bra...

Page 95: ... and turn the adjusting nuts so the rear wheel can be moved all the way forward for maximum drive chain slack 3 Remove the drive chain from the rear wheel sprocket by pushing the rear wheel forward 4 Remove the rear axle nut and washer Drive chain Rear axle shaft Lock nut Adjusting nut Washer Rear axle nut Lock nut Adjusting nut Washer Wheel speed sensor CB500XA only Pulser ring CB500XA only http ...

Page 96: ...brake hose uAvoid getting grease oil or dirt on the disc or pad surfaces uDo not push the brake pedal while the brake caliper is removed Installation 1 To install the rear wheel reverse the removal procedure uTake care to prevent the brake caliper from scratching the wheel during installation NOTICE When installing the brake caliper into position carefully fit the brake disc between the pads to av...

Page 97: ...en the lock nuts 6 After installing the wheel apply the brake pedal several times then check if the wheel rotates freely Recheck the wheel if the brake drags or if the wheel does not rotate freely 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 capacity Slot Lug Brake caliper bracket Swinga...

Page 98: ...fter recharging contact your dealer Burned out Light Bulb Follow the procedure below to replace a burned out light bulb Turn the ignition switch to the OFF or LOCK position Allow the bulb to cool before replacing it Do not use bulbs other than those specified Check the replacement bulb for correct operation before riding For the light bulb wattage see Specifications 2 P 116 NOTICE Jump starting us...

Page 99: ...move the dust cover 4 Unhook the bulb retainer and pull out the bulb without turning it 5 Install a new bulb and parts in the reverse order of removal Do not touch the glass surface with your fingers If you touch the bulb with your bare hands clean it with a cloth moistened with alcohol Bulb retainer Socket Bulb Dust cover http www motorcycle in th ...

Page 100: ...ontinued Troubleshooting Position Light Bulb 1 Remove the bulb lid 2 P 58 2 Pull off the socket without turning 3 Pull out the bulb without turning 4 Install a new bulb and parts in the reverse order of removal Socket Bulb http www motorcycle in th ...

Page 101: ...ht Bulb 1 Remove the bolts and rear fender cover 2 Turn the socket counterclockwise and remove it 3 Slightly press the bulb and turn it counterclockwise 4 Install a new bulb and parts in the reverse order of removal Bolts Rear fender cover Socket Bulb http www motorcycle in th ...

Page 102: ...rclockwise 4 Install a new bulb and parts in the reverse order of removal uUse only the amber bulb License Plate Light 1 Remove the screws license light cover and license light cover packing 2 Pull out the bulb without turning 3 Install a new bulb and parts in the reverse order of removal Bulb Turn signal lens Screw Collar Bulb License light cover Screws Cover packing http www motorcycle in th ...

Page 103: ...move the seat 2 P 56 2 Remove the fuse box covers 3 Pull the fuses out with the fuse puller in the tool kit one by one check for a blown fuse Always replace a blown fuse with a spare of the same rating 4 Install the fuse box covers 5 Install the seat CB500X Spare fuses Fuse box covers CB500XA Spare fuses Fuse box covers http www motorcycle in th ...

Page 104: ...k for a blown fuse Always replace a blown fuse with a spare of the same rating uSpare main fuse is provided in the starter magnetic switch 4 Reinstall parts in the reverse order of removal Wire connector Spare main fuse Main fuse Starter magnetic switch NOTICE If a fuse fails repeatedly you likely have an electrical problem Have your motorcycle inspected by your dealer http www motorcycle in th ...

Page 105: ...ther Features P 104 Fuels Containing Alcohol P 106 Catalytic Converter P 107 Caring for Your Motorcycle P 108 Storing Your Motorcycle P 110 Transporting Your Motorcycle P 111 You the Environment P 112 Serial Numbers P 113 http www motorcycle in th ...

Page 106: ...ill or in any way alter their shape Do not expose to strong magnetic objects If you lose all keys and the key number plate the PGM FI unit ignition control module must be replaced by your dealer To avoid this keep a duplicate key If you lose a key make another duplicate key immediately To make a duplicate key and register it with your HISS system take the spare key the key number plate and the mot...

Page 107: ...ipmeter A B returns to 0 0 when the read out exceeds 9999 9 The Honda Ignition Security System HISS immobilizes the engine s ignition system if an improperly coded key is used to try and start the engine When the ignition switch is turned off the HISS immobilizer system is always alert even if the HISS indicator is not flashing If the ignition switch is turned on with the engine stop switch in the...

Page 108: ...t a safe place When the declaration of conformity is lost or is not provided contact your dealer The owner s manual registration and insurance information can be stored in the plastic document bag underside of the seat 2 P 38 A banking lean angle sensor automatically stops the engine and fuel pump if the motorcycle falls over To reset the sensor you must turn the ignition switch to OFF and back to...

Page 109: ...the name Gasohol Methanol methyl alcohol 5 by volume max that contain cosolvents and corrosion inhibitors to protect the fuel system Never use a blend containing more than 5 The use of petrol containing more than 10 ethanol or more than 5 methanol may Damage the painting of the fuel tank Damage the rubber tubes of the fuel line Cause corrosion of the fuel tank Cause poor drivability If you notice ...

Page 110: ...compounds A defective catalytic converter contributes to air pollution and can impair your engine s performance A replacement unit must be an original Honda part or equivalent Follow these guidelines to protect your motorcycle s catalytic converter Always use unleaded petrol Leaded petrol will damage the catalytic converter Keep the engine in good running condition Have your motorcycle serviced if...

Page 111: ...r plastic components with extra care to avoid scratching them Avoid directing water into the air cleaner muffler and electrical parts 3 Thoroughly rinse your motorcycle with plenty of clean water and dry with a soft clean cloth 4 After the motorcycle dries lubricate any moving parts u Make sure that no lubricant spills onto the brakes or tyres Brake discs or pads contaminated with oil suffer great...

Page 112: ...t the air cleaner u Water in the air cleaner can prevent the engine from starting Do not direct water near the headlight u Any condensation inside the headlight should dissipate after a few minutes of running the engine Do not use waxes containing compounds at the matte painted surface u Using plenty of water clean the matte painted surface with a soft cloth or sponge Dry with a soft clean cloth u...

Page 113: ... If you store your motorcycle outdoors you should consider using a full body motorcycle cover If you won t be riding for an extended period follow these guidelines Wash your motorcycle and wax all painted surfaces except matte painted surfaces Coat chrome pieces with rust inhibiting oil Lubricate the drive chain 2 P 50 Place your motorcycle on a maintenance stand and position a block so that both ...

Page 114: ... Motorcycle If your motorcycle 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 motorcycle with a wheel or wheels on the ground NOTICE Towing your motorcycle can cause serious damage to the transmission http www motorcycle in th ...

Page 115: ...ther 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 down a drain or on the ground Used oil petrol coolant and cleaning solvents contain poiso...

Page 116: ...ed in order to register your motorcycle They may also be required when ordering replacement parts The frame number is stamped on the right side of the steering head The engine number is stamped on top of the crankcase You should record these numbers and keep them in a safe place Frame number Engine number http www motorcycle in th ...

Page 117: ... 190 kg 419 lb CB500XA 195 kg 430 lb Maximum weight capacity 1 Except KO type 185 kg 408 lb KO type 160 kg 353 lb Maximum luggage weight 2 Except KO type 11 kg 24 lb Passenger capacity Rider and 1 passenger Minimum turning radius 2 8 m 9 2 ft Displacement 471 cm3 28 7 cu in Bore stroke 67 0 66 8 mm 2 64 2 63 in Compression ratio 10 7 1 Fuel Unleaded petrol Recommended 91 RON or higher Tank capacit...

Page 118: ...cluding oils marked as Energy Conserving or Resource Conserving SAE 10W 30 JASO T 903 standard MA Engine oil capacity After draining 2 5 litres 2 6 US qt 2 2 Imp qt After draining engine oil filter change 2 7 litres 2 9 US qt 2 4 Imp qt After disassembly 3 2 litres 3 4 US qt 2 8 Imp qt Recommended brake fluid Honda DOT 4 Brake Fluid Cooling system capacity 1 40 litres 1 48 US qt 1 23 Imp qt Recomm...

Page 119: ... 30A Other fuses CB500X 15A 7 5A CB500XA 30A 15A 7 5A Engine oil drain bolt 30 N m 3 1 kgf m 22 lbf ft Oil filter 26 N m 2 7 kgf m 19 lbf ft Front wheel axle shaft 54 N m 5 5 kgf m 40 lbf ft Front wheel brake caliper mounting bolts 30 N m 3 1 kgf m 22 lbf ft Front wheel axle pinch bolt 22 N m 2 2 kgf m 16 lbf ft Rear wheel axle nut 88 N m 9 0 kgf m 65 lbf ft Drive chain adjusting lock nuts 21 N m ...

Page 120: ...Turn Signal 99 Headlight 96 License Plate Light 99 Position Light 97 Rear Turn Signal 99 Bulb Lid 58 C Caring for Your Motorcycle 108 Catalytic Converter 107 Clutch System 73 Coolant 50 64 Crankcase Breather 77 D Digital Clock Adjustment 25 Drive Chain 69 E Electrical Trouble 95 Engine Number 113 Oil 48 60 Oil Filter 62 Overheats 84 Starting 34 Stop Switch 32 34 104 Stopping 104 Environment 112 ht...

Page 121: ... 100 G Gasohol 106 Gasoline 36 H Hazard Switch 32 Headlight Aim 79 Headlight Dimmer Switch 32 Helmet Holder 37 High Beam Indicator 31 High Coolant Temperature Indicator 30 84 HISS Indicator 31 83 Horn Button 32 I Ignition Cut off System Banking Sensor 105 Side Stand 68 Ignition key 103 Ignition Switch 33 34 Image Labels 6 Indicators 30 Instruments 18 L Labels 6 Load Limits 15 Loading Guidelines 15...

Page 122: ...Oil Engine 48 60 Overheating 84 P Parking 13 Parts Location 16 Passing Light Control Switch 32 Petrol 106 PGM FI Programmed Fuel Injection malfunction indicator lamp MIL 30 85 Protective Apparel 10 R Rear Suspension 78 Recommended Coolant 50 Fuel 36 Oil 48 Refuelling 36 Removal Battery 59 Bulb Lid 58 Clip 58 Seat 56 Side Cover 57 Repair Kit 88 Riding Precautions 11 http www motorcycle in th ...

Page 123: ...ing Engine 104 Storage Equipment 37 Owner s Manual 38 105 Tool Kit 38 Storing Your Motorcycle 110 Switches 32 T Tachometer 19 Throttle 76 Tool Kit 55 Transporting Your Motorcycle 111 Tripmeter 20 104 Troubleshooting 82 Turn Signal Indicators 31 Tyres Air Pressure 51 Puncture 88 Replacing 51 88 W Warning Indicators On 85 Washing Your Motorcycle 108 Weight Limit 15 Wheels Front removal 89 Rear remov...

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Honda cb500f, Service Manual

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