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Summary of Contents for CBR500R

Page 1: ...nformation 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...

Page 2: ...is 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 CBR5...

Page 3: ...ou 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...

Page 4: ...Contents Motorcycle Safety P 2 Operation Guide P 16 Maintenance P 39 Troubleshooting P 81 Information P 101 Specifications P 113 Index P 116 13 CBR500R 32MGZB000 book 4 http mototh com...

Page 5: ...tant information for safe riding of your motorcycle Please read this section carefully Safety Guidelines P 3 Safety Precautions P 10 Riding Precautions P 11 Accessories Modifications P 14 Loading P 15...

Page 6: ...lly 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 t...

Page 7: ...operly 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 in...

Page 8: ...isonous 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...

Page 9: ...label The meanings of each symbol and label are as follows Except KO II KO type Read instructions contained in Owner s Manual carefully Read instructions contained in Shop Manual carefully In the inte...

Page 10: ...tery 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...

Page 11: ...ies 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 passe...

Page 12: ...kPa 2 90 kgf cm2 42 psi Tyre size Front 120 70ZR17M C 58W Rear 160 60ZR17M C 69W Tyre brand DUNLOP METZELER Front D222F ROADTEC Z8 INTERACT E Rear D222 ROADTEC Z8 INTERACT SAFETY REMINDER LABEL For y...

Page 13: ...fety 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 pr...

Page 14: ...owing guidelines Avoid excessively hard braking and sudden shifting to a lower gear u Sudden braking can reduce the motorcycle s stability u Where possible reduce speed before turning otherwise you ri...

Page 15: ...s 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 down...

Page 16: ...e 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 handlebars fully to the left u Turning the handlebars to the right reduces sta...

Page 17: ...al 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 you...

Page 18: ...specified load limits 2 Maximum weight capacity Maximum luggage weight P 113 Tie all luggage securely evenly balanced and close to the centre of the motorcycle Do not place objects near the lights or...

Page 19: ...oil fill cap P61 Engine oil drain bolt P63 Engine oil filter P64 Front brake lever Fuel fill cap P36 Tool kit P38 Document bag P37 Side cover P58 Engine oil level inspection window P61 Rear brake flui...

Page 20: ...ve chain P70 Fuse box P99 Crankcase breather P78 Battery P60 Clutch lever P74 Side stand P69 Coolant reserve tank P65 Rear Seat P56 Rear suspension spring preload adjuster P79 Shift lever P35 13 CBR50...

Page 21: ...all the mode and digital segments will show and the tachometer segment progress to maximum scale and then disappear If any part of these displays does not come on when it should have your dealer chec...

Page 22: ...ct 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 ga...

Page 23: ...r 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 mile...

Page 24: ...n 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 con...

Page 25: ...turns 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 rese...

Page 26: ...e 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 fu...

Page 27: ...Changing of speed and mileage unit Changing of fuel mileage meter unit E II E type only Ordinary display Press and hold SEL button and SET button Press SET button Clock setting Activating deactivating...

Page 28: ...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 flashin...

Page 29: ...he 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 mil...

Page 30: ...ng 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...

Page 31: ...ileage 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 5 Changing the speed and mileage unit a Press SEL button t...

Page 32: ...mile L or mile gal E II 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...

Page 33: ...s turned on If it comes on while riding P83 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 t...

Page 34: ...indicator Comes on when the transmission is in Neutral HISS indicator P82 Comes on briefly when the ignition switch is turned on Goes off if the ignition key has the correct coding Flashes every 2 sec...

Page 35: ...n 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 sw...

Page 36: ...position u Jiggle the handlebars 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 e...

Page 37: ...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 eng...

Page 38: ...s 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 13 CBR500R 32...

Page 39: ...ll 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 lo...

Page 40: ...g the Rear Seat P56 Helmet holder Helmet set wire 3WARNING Riding with a helmet attached to the holder can interfere with your ability to safely operate the motorcycle and could lead to a crash in whi...

Page 41: ...ck u The U shaped lock is held in place under the front seat u Some U shaped locks may not fit in the compartment due to their size or design The document bag is located underside of the front seat Re...

Page 42: ...P 41 Maintenance Fundamentals P 44 Tool Kit P 55 Removing Installing Body Components P 56 Rear Seat P 56 Front Seat P 57 Side Cover P 58 Clip P 59 Battery P 60 Engine Oil P 61 Coolant P 65 Brakes P 6...

Page 43: ...enance 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 su...

Page 44: ...ents 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...

Page 45: ...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...

Page 46: ...egular 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 70 Drive Chain Slider 73 Brake Fluid 4 2 Years 67 Brake Pads Wear 68 Brake System 67 Brake...

Page 47: ...77 Engine oil level Add engine oil if necessary Check for leaks 2 P 61 Coolant level Add coolant if required Check for leaks 2 P 65 Drive chain Check condition and slack adjust and lubricate if necess...

Page 48: ...ed on the colour label The colour label is attached to the rear fender under the rear seat 2 P 56 Replacing Parts 3WARNING Installing non Honda parts may make your motorcycle unsafe and cause a crash...

Page 49: ...nals 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...

Page 50: ...our motorcycle If something electrical on your motorcycle stops working check for and replace any blown fuses 2 P 99 Inspecting and Replacing Fuses Turn off the ignition switch to remove and inspect f...

Page 51: ...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 inde...

Page 52: ...ain 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 sp...

Page 53: ...ch as petrol 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 ty...

Page 54: ...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 o...

Page 55: ...m 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 in...

Page 56: ...nstalled 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 tubele...

Page 57: ...h a viscous type air cleaner element Air blow 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...

Page 58: ...ch 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...

Page 59: ...on 1 Insert the prongs into the rear stays on the frame 2 Push down on the rear of the rear seat Make sure that the seat is locked securely in position to pull it up lightly The seat locks automatical...

Page 60: ...ollars and then pull the front seat back and up Installation 1 Insert the tab into the recess 2 Install the collars and mounting bolts 3 Tighten the mounting bolts securely Make sure that the seat is...

Page 61: ...access the coolant reserve tank cap The right and left side covers can be removed in the same manner Removal 1 Remove the bolt and clip 2 P 59 2 Remove the prongs from the grommets 3 Remove the side...

Page 62: ...ve the side covers 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 d...

Page 63: ...he 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...

Page 64: ...tch 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...

Page 65: ...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...

Page 66: ...tch 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 wa...

Page 67: ...rain 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 61 12 Check that there are no oil leaks Torque 26 N m 2 7 kgf m 19 lbf ft Rubber...

Page 68: ...f 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 LO...

Page 69: ...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 R...

Page 70: ...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...

Page 71: ...pad is 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 Al...

Page 72: ...ge 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...

Page 73: ...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...

Page 74: ...in 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 r...

Page 75: ...n 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 rech...

Page 76: ...per 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...

Page 77: ...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 Fr...

Page 78: ...ut 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...

Page 79: ...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 do...

Page 80: ...the cable is damaged have the motorcycle inspected by your dealer Adjusting the Throttle Freeplay 1 Slide the cable boot 2 Loosen the lock nut 3 Turn the adjuster until the freeplay is 2 to 6 mm 0 1...

Page 81: ...g 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 13 C...

Page 82: ...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 he direction A to decrease spring preload s...

Page 83: ...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 Turn the adjusting nut in the direction A if the switch...

Page 84: ...l Pressure Indicator P 84 PGM FI Programmed Fuel Injection Malfunction Indicator Lamp MIL P 84 ABS Anti lock Brake System Indicator CBR500RA only P 85 Other Warning Indication P 86 Fuel Gauge Failure...

Page 85: ...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...

Page 86: ...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 ha...

Page 87: ...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...

Page 88: ...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...

Page 89: ...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 13 CBR500R 3...

Page 90: ...ructions 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 pos...

Page 91: ...ght 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 th...

Page 92: ...or a hoist 6 Remove the front axle shaft front wheel and side collars Installation 1 Attach the side collars to the wheel 2 On the left side place the wheel between the fork legs and insert the front...

Page 93: ...lt 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 installat...

Page 94: ...rn 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...

Page 95: ...id 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 c...

Page 96: ...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 torq...

Page 97: ...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...

Page 98: ...ocket off the bulb without turning it 3 Unhook the bulb retainer and pull out the bulb without turning it 4 Install a new bulb and parts in the reverse order of removal uMake sure the arrow marks on t...

Page 99: ...ooting Position Light Bulb 1 Remove the screws 2 Remove the position light lens 3 Pull out the bulb without turning 4 Install a new bulb and parts in the reverse order of removal Position light lens S...

Page 100: ...lb 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...

Page 101: ...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...

Page 102: ...t seat 2 P 57 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 Ins...

Page 103: ...ck 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 conne...

Page 104: ...es P 103 Fuels Containing Alcohol P 105 Catalytic Converter P 106 Caring for Your Motorcycle P 107 Storing Your Motorcycle P 109 Transporting Your Motorcycle P 110 You the Environment P 111 Serial Num...

Page 105: ...ny 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 ke...

Page 106: ...er 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 W...

Page 107: ...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...

Page 108: ...sohol 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 tha...

Page 109: ...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...

Page 110: ...tic 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 wi...

Page 111: ...aner 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...

Page 112: ...u 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 s...

Page 113: ...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...

Page 114: ...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 instructi...

Page 115: ...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 cra...

Page 116: ...KO type 160 kg 353 lb Except KO II KO type 182 kg 401 lb Maximum luggage weight 2 ExceptKO IIKO U II U type 11 kg 24 lb Passenger capacity Rider and 1 passenger Minimum turning radius 2 7 m 8 9 ft Dis...

Page 117: ...lassification SG or higher excluding 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...

Page 118: ...uses CBR500R 15A 7 5A CBR500RA 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 c...

Page 119: ...eadlight 95 License Plate Light 98 Position Light 96 Rear Turn Signal 98 C Caring for Your Motorcycle 107 Clutch System 74 Colour label 45 Coolant 50 65 Crankcase Breather 78 D Digital Clock Adjustmen...

Page 120: ...Switch 32 Headlight Aim 80 Headlight Dimmer Switch 32 Helmet Holder 37 High Beam Indicator 31 High Coolant Temperature Indicator 30 83 HISS Indicator 31 82 Horn Button 32 I Ignition Cut off System Ban...

Page 121: ...P Parking 13 Parts Location 16 Passing Light Control Switch 32 Petrol 105 PGM FI Programmed Fuel Injection malfunction indicator lamp MIL 30 84 Protective Apparel 10 R Rear Seat 56 Rear Suspension 79...

Page 122: ...ne 103 Storage Equipment 37 Owner s Manual 104 Storing Your Motorcycle 109 Switches 32 T Tachometer 19 Throttle 77 Tool Kit 55 Transporting Your Motorcycle 110 Tripmeter 20 103 Troubleshooting 81 Turn...

Page 123: ...13 CBR500R 32MGZB000 book 120 http mototh com...

Page 124: ...13 CBR500R 32MGZB000 book 121 http mototh com...

Page 125: ...13 CBR500R 32MGZB000 book 122 http mototh com...

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