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Honda CX500 1978, Shop Manual

The Honda CX500 1978 Shop Manual is a comprehensive user guide for owners of this iconic motorcycle. Downloadable for free from our website, this manual offers detailed instructions on maintenance, repairs, and troubleshooting, making it an invaluable resource for CX500 enthusiasts seeking to maximize their riding experience.

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Summary of Contents for CX500 1978

Page 1: ......

Page 2: ...ion you want on this page then turn to the table of contents on page 1 of that section Most sections Start with an assembly or system illustration and all the required specifications torque valuk working practices tools and materials required for the section The sub sequent pages give detailed procedures for the section If you are not familiar with this motorcycle read through the TECHNICAL FEATUR...

Page 3: ...cle identification number is on the left side the steering head of the steering head The engine serial number is stamped on the lower left The carburetor identification number is on the left side side of the engine case of the carburetor body I 3INE SERI IER IDENTIFICATION NUMBER 7 Date of Issue August 1979 OHONOA MOTOR CO LTD 81 ...

Page 4: ...e highly explosive Do not smoke or allow flomes or sparks near the battery especially while chargingit SERVICE RULES 1 Use geniune HONDA or HONDA recommended parts and lubricants or their equivalent Parts that do not meet HONDA s designspecifications may damage the motorcycle 2 Use the special tools designed for this product 3 Install new gaskets O rings cotter pins lock plates etc when reasserhbl...

Page 5: ...HONDA GENERAL INFORMATION CX500 SPECIFICATIONS Date of Issue January 1978 1 2 OHONDA MOTOR CO LTD I ...

Page 6: ...HONDA GENERAL INFORMATION DRIVE TRAIN 23123 watt 32132 cp SAE No 3 4 watt 2 cp SAE No 57 Date of Issue January 1981 oHoNDA MOTOR co LTD 1 3 ...

Page 7: ...t caber Torque Values Thread Dia 1 immi kg m 2 0 2 4 2 8 3 2 5 0 5 5 1 5 1 8 8 0 10 0 8 0 10 0 8 0 9 5 1 8 2 5 2 0 2 5 8 0 10 0 1 6 2 0 1 0 1 4 0 15 0 30 it lb 14 17 20 23 36 40 11 13 58 72 58 72 58 69 13 18 14 18 58 72 12 14 7 10 1 1 2 2 Torque specifications listed above are important tightening points Others should be torqued to standard torques below STANDARD TORQUE VALUES Torque Values ka m D...

Page 8: ...l Name Float level gauge Pin spanner Tappet adjusting wrench 10 x 12 mml Tappet adjusting 131 Retainer wrench B Retainer wrench body Lock nut wrench socket 26 x 29 mm Lock nut wrench socket 30 x 32 mml Extension bar handle Flywheel rotor puller Rotor puller Valve guide remover 6 6 mml Pin driver 3 5 mml Bearingdriver outer 42 x 47 mm Bearingdriver outer 152 x 55 mml Bearingdriver pilot 15 mmi Bear...

Page 9: ...IGINE STOP ST llTCH ARRANGEh TURN SIGNAI IRING DIAGRAM ENGINE STOP STARTER SWITCH n ...

Page 10: ...WIRING DIAGRAM REAR STOP LIG SWITl ...

Page 11: ...CABLE HARNESS ROUT1 THROTTLE CABLES WIRE BAND CLUTCH CABLE FRONT BRAKE HOSE FRONT BRAKE LE FRONT BRAKEHOSE W SPEEDOMETER CABLE ...

Page 12: ...CABLE HARNESS ROUTING COUPLER GREEN COUPLER BROWN t HEADLIGHT RECEPTACLE WIRE BANDS ...

Page 13: ...e except to the idle speed with the throttle stop screw CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a Closed System to prevent crankcase emission from entering the atmosphere Blow by gas is returned to the combustion chamber through the breather tube separator and intake pipe CRANKCASE EMISSION CONTROL SYSTEM REATHERTUBE AIR CLEANER CASE SEPARATOR DRAIN PLUG FRESH AIR BLOW BY GAS...

Page 14: ...factured after December 31 1977 have an Emission Control Information label on the frame as shown It contains basic tune up specifications for CX500 s manufactured after December 31 1977 Refer to this Shop Manual for more details Date of Issue January 1975 OHONDA MOTOR CO LTD ...

Page 15: ...NDA DEALER SHOULD BE SERVICED BY AN AUTHORIZED HONDA DEALER UNLESS THE OWNER HAS PROPER TOOLS AND IS MECHA NICALLY QUALIFIED NOTES I1I More frequent service may be required when ridden in rain ridden at full throttle openings dropped or washed often Service if deposit level can be seen in the transparent section of drain tubes 121 More frequent service may be required when riding in dusty areas 13...

Page 16: ...GENERAL INFORMATION aHONDA LUBRICATION DIAGRAM OIL PRESSURE ROCKER ARM SWITCH I 1 I CRANKSHAFT TRANSMISSION COUNTERSHAFT 2 0 Date of Issue January 1978 OHONDA MOTOR CO LTD r ...

Page 17: ...CSTROKE Oil or equivalent rated SAE 10W 40 grade SE Oil pump delivery 9 4 f Iliterl3 000 rpmlmin TROUBLESHOOTING Oil Level Too Low 1 Normal oil consumption 2 External oil leaks 3 Worn piston rings Oil Contamination 1 Oil or filter not changed often enough 2 Defective head gasket L Low Oil Pressure 1 Faulty warning light switch 2 Pressure relief valve stuck open 3 Plugged oil pick upscreen 4 Oil pu...

Page 18: ...l filter bolt and remove the oil filter element from the oil filter case Check operation of the bypass valve in the oil filter bolt Install a new oil filter element and retighten the oil filter bolt bolt and the oil filter cover are not damaged and are in good condition Toraue the oil filter bolt p TORQUE 2 0 2 5 kg rn 14 18 ft lb Reinstall the drain plug Making sure the sealing washer is in good ...

Page 19: ...wer edge of the L OIL REPLACEMENT Remove the oil filler cap Remove the drain bolt to drain all oil from the final gear case Reinstall the drain bolt securely Fill the gear case with the recommended oil up to the correct level OIL CAPACITY 170 cc 5 7 US02 RECOMMENDED OIL HYPOID GEAR OIL SAE 90 Above 5 41 F SAE 80 Below 5 41 F DRIVE SHAFT JOINT Pump multipurpose grease through the drive shaft joint ...

Page 20: ...HONDA LUBRICATION CX500 LUBRICATION POINTS SIDE STAND 2 4 Date of Issue January 1978 OHONDA MOTOR CO LTD ...

Page 21: ... 6 0 7 mm 0 024 0 028 in Spark plug type USA model Canadian model 1 For cold climate I Standard I F ND X24ESR U NGK DR8ES L below I I er rl0 ri I high speed rirlinn I I ND 1 NGK I ND I NGK ND I NGK ENGINE CHASSIS Ignition timing Rear brake pedal free play 20 30 mm 314 1 114 in FL mark 15 BTDCat 1 100 rpm Tire pressures Ignition advance 37 BTDCat 5 500 6 000 rpm Rider only Valve clearance IN 0 08 m...

Page 22: ...ning it Remove the air cleaner element Clean the air cleaner element by tapping it lightly to loosen dust Remove the remaining dust with compressed air Replace if necessary NOTE Install the cover with the TOP mark facing the front Install element and cover Install seat 3 2 Date of Issue January 1978 OHONDA MOTOR CO LTD ...

Page 23: ...k plug cap and remove the spark plug Visually inspect the spark plug electrodes for wear The center electrode should have square edges and the side electrode should have a constant thickness Discard the spark plug if mere is apparent wear or if the insulator is cracked or chipped If the spark plug deposits can be removed by sandblasting the spark plug can be reused Adjust the spark plug gap by ben...

Page 24: ...g a feeler gauge between the clearance adjusting screw and valve stem VALVE CLEARANCE IN 0 08 mm 0 003 in ECTION I4 EX 0 10 mm 0 004 in Adjust by loosening the lock nut and turning the screw until there is a slight drag on the feeler guage Hold the screw and tighten the lock nut Recheck the valve clearances Turn the crank shaft clockwise and align the TR mark on the rotor with the pulser index mar...

Page 25: ...ositions Check that the throttle grip automatically returns from fully open to fully closed position when released Adjust or replace if necessary THROTTLE OPERATION Check that there is no deterioration damage or kinks in the throttle cables and that the throttle grip free play is 2 6 mm 118 114 in on the outer edge of the throttle grip flange Check for smooth throttle qrip rotation from Throttle g...

Page 26: ...e needle is in the wide Warm up the engine place the transmission in neutral and the motorcycle on its center stand Adjust idle speed with the throttle stop screw IDLE SPEED 1 100 100 rpm I THROTT L E STOP SCREW i CHOKE CARBURETOR CHOKE Operate the choke knob and check for smooth operation 3 6 Date of Issue January 1978 OHONDA MOTOR CO LTD I ...

Page 27: ...the idle speed to 1 100t l00rpm The difference of vacuum between cylinders should be within 40 mm 1 6 in Hg ADJUSTMENT Prepare a longer fuel tube and connect it to the fuel tank and carburetor Position the tank higher than normal Loosenadjusting screw lock nut Balance the vacuum between cylinders to with in 40 mm 1 6 in Hg of each other by turning the adjusting screw Hold adjusting screw and tight...

Page 28: ...vel line COOLING SYSTEM HOSES Inspect the hoses for cracks or deterioration and replace if necessary Check the hose clamps and tighten if necessa ry RADIATOR CORE Check the air passages for clogging or damage Straighten bent fins Remove insects mud or any obstruction with compressed air or low water pressure Replace the radiator if the air flow is restricted over more than 20 of the radiating surf...

Page 29: ... filled to the level mark engraved inside the reservoir If the level is lower than the mark fill the reservoir with DOT 3 BRAKE FLUID up to the level mark g Check the entire system for leaks if the level is low j Do not mix differentbrands of fluid as they are not compatible Do not remove the cap until the handlebar has been turnedfull left so that the reservoir is level Avoid operating the brake ...

Page 30: ...revent piston overtravel and brake fluid seepage keep a 20 mm space between the lever and the handlebar grip when bleeding the front brake system Pump up the system pressure with the lever until there are no air bubbles in the fluid flowing out of the reservoir small hole until lever resistance is felt AIR BLEEDING Pull the brake lever all the way back to the handlebar grip Screw out the bleeder v...

Page 31: ... brake disc Section 15 Always replace the brake pads in pairs to assure even disc pressure BRAKE SHOE INSPECTION WEAR INDICATOR Replace the brake shoes if the arrow on the brake arm aligns with the reference mark A on full application of the rear brake BRAKE SYSTEM HOSE Make sure that the brake hose is not deterio rated and check the entire brake system for leaks Date of Issue January 1981 O HONDA...

Page 32: ... 20 30 mm 314 1 114 in p If adjustment is necessary turn the rear brake adjusting nut REAR BRAKE LIGHT SWITCH Adjust the brake light switch so that the brake light will come on when the brake pedal is depressed 20 mm 314 in when the brake begins engagement Adjust by turning the switch adjusting nut NOTE 1 Perform brake light switch adiustment I after adjusting brake pedal play and pedal 1heioht 1 ...

Page 33: ...easure the clutch lever free play CLUTCH LEVER FREE PLAY 10 20mm 318 314 in 1 Major adjustments should be made using the adjuster located at the clutch housing Loosen the lock nut and turn the clutch cable adjusting nut Minor adjustments can be made with the clutch cable adjuster located on the clutch lever Loosen the lock nut and turn the adjuster NOTE Do not allow the threads at the adjuster to ...

Page 34: ...Replace if any wear extends to wear line as shown Check the side stand spring for damage and loss of tension and the side stand assembly for freedom of movement and bend the mark Over 260 Ibs ONLY Spring tension is correct if the measurements fall within 2 3kg When pulling the side stand lower end rear wheel Move the rear wheel sideways with force to see if the swing arm bushings are worn Replace ...

Page 35: ...03 TUBELESS ONLY Tire brand Rear YOKOHAMA Y 987 BRIDGESTONE S21 R2 TUBELESS ONLY Check the front and rear wheels for trueness Section 13 14 STEERING HEAD BEARING NOTE interfere with the rotation of the handle Raisethe front wheel off the ground Ciieck that the handlebar rotates freely If the handlebar moves unevenly binds or has vertical movement adjustment is necessary Adjust the steering head be...

Page 36: ...HONDA FUEL SYSTEM CX500 4 0 Date of Issue January 1978 OHONDA MOTOR CO LTD I ...

Page 37: ...HOOTING Engine Cranks But Won t Start 1 No fuel in tank 2 No fuel getting to cylinders 3 Too much fuel getting to cylinders 4 No spark at plugs ignition malfunction 5 Air cleaner clogged Engine Idles Roughly Stalls or Runs Poorly 1 ldle speed incorrect 2 Ignition malfunction 3 Low compression 4 Richmixture 5 Lean Mixture 6 Air cleaner clogged 7 Air leaking into manifold 8 Fuel contaminated 9 Carbu...

Page 38: ...tor band Remove the carburetor insulator hose bypass Remove both carburetors from the air cleaner tube by pushing them down and forward Pull the carburetors towards the left Loosen the lock nuts and disconnect the throt tle cables Disconnect the choke cable at the carburetors Remove the carburetors I R INSUL CHOKE Date of Issue January 1978 4 2 OHONDA MOTOR CO LTD ...

Page 39: ...r is pre set at the factory and pilor screw adjustment is not neces s n i y except after overhauling it Remove the synchronization adjustment screw Remove the choke relief spring Remove the rear stav I REARSTAY Date of Issue January 1978 OHONDA MOTOR CO LTD 4 3 ...

Page 40: ...ENT ATlON SCREW ADJ I SPRING I CARBURETOR ASSEMBLY MENT SCI Sl p an O ring over each end of the fuel joint pipe Assemble the right and left carburetors making PB sure the spring are properly positioned Install the svnchronization adiustment screw SPRING y JOINT i i Date of Issue January 1978 OHONDA MOTOR CO LTD ...

Page 41: ...ches Make sure the piston moves freely in the cylinder and in the bore of the carburetor Remove the full open stopper Remove the needle set screw and the jet needle JACUUM PICTnR1 grooves or other damage Carefully lift the seal ring off the carb Remove the air jet cover AIR UEEDLE REW PRlNG FULL OPI STOPPER hr ET COVEF Date of Issue January 1978 OHONDA MOTOR CO LTD 4 5 ...

Page 42: ...R JET VAC VACUUM PISTON INSPECTION Check the vacuum piston for free movement in the cylinder FLOAT CHAMBER DISASSEMBLY Remove the float chamber body Remove the secondary main jet and jet nt holder Remove the slow air jet plug NOTE Do not try to removethe slow air jet It is a press fit Remove the primary main jet Remove the pilot screw SLOW JE 4 6 Date of Issue January 1978 OHONDA MOTOR CO LTD I ...

Page 43: ...r Remove the float and float valve 26 Remove the primary nozzle 1 m a 3 7 r y f NOTE llMAIIY NC Inspect the float valve and seat for deposits grooves or other damage Do not try to removethe slow air jet It is a press fit Date of Issue January 1978 OHONDA MOTOR CO LTD 4 7 I ...

Page 44: ...iaphragm Removethe O ring RING COVER 8 s Clean the passages and jets with compressed air COMPONENT ASSEMBLY Assemble the air cutoff valve float chamber and vacuum cylinder in the reverse order of dis assembly Make sure the O rings seat in their 7 grooves 4 8 Date of Issue January 1978 OHONDA MOTOR CO LTD I ...

Page 45: ...he fork end of the fast idle lever until the clearance between the fast idle lever and throttle drum is about 0 8 mm 0 047 in CARBURETOR INSTALLATION Installation is the reverse order of removal NOTE I Do not interchanae the OPEN and RE I 1 TURN throttle cables After installation perform the following adjust ments Throttle grip free play Page3 5 Carburetor synchronization Page 3 7 Idle speed adjus...

Page 46: ...throttle stop screw IDLE SPEED 1 100i 100rpm 4 Turn the pilot screw in or out to obtain the highest engine speed 5 Readjust the idle speed with the throttle stop screw 6 Turn the pilot screw in gradually until the engine speed drops 100 rpm I 7 Turn the pilot screw 1 turns open from the position obtained in step 6 8 Readjust the idle speed with the throttle stop screw NOTE Perform steps 4 thru 8 f...

Page 47: ...t overtighten the fuel valve lock Make sure there are no fuel leaks AIR CLEANER CASE AIR CLEANER CASE REMOVAL FUEL STRAINER SCREEN PACKING glr LOCK NUT 14 18 Ibs ft FUEL VALVE HT WIRE Disconnect the taillight wires Remove the hand rail cowl and rear fender HAND RAIL Removethe battery Remove the starter regulatorlrectifier Removethe carbureto magnetic switch soacer band and Date of Issue January 19...

Page 48: ...the air cleaner mounting bolt from under the C D I unlt i i Remove the air cleaner from the right NOTE i Installation of the air cleaner is the reverse of removal CRANKCASE BREATHER SYSTEM NOTE Check that the breather tube is not clogged or collapsed FRESH AIR BLOW BY GAS 4 12 Date of Issue January 1978 OHONDA MOTOR CO LTD ...

Page 49: ... 4 HONDA CX500 MEMO Date of Issue January 1978 OHONDA MOTOR CO LTD ...

Page 50: ...HONDA ENGINE REMOVALIINSTALLATION CXSOO JD NU 5 0 Date of Issue January 1978 OHONDA MOTOR CO LTD ...

Page 51: ...NGINE REMOVAL 5 2 ENGINE INSTALLATION 5 7 Crankshaft Piston Connecting rods Camshafts Flywheel and starting clutch Gearshift spindle Transmission Water pump mechanical seal Remove and install the engine with a hydraulic jack to support its weight ENGINE WEIGHT 67 kg 148 Ibs Date of Issue January 1978 OHONDA MOTOR CO LTD ...

Page 52: ... the cable clear of the engine Disconnect the radiator bypass hose from the radiator Remove the breather hose Disconnect the clutch cable at the upper adjuster and remove it from the wire guide i Disconnect the thermostatic switch wire blue redl and oil pressure gauge wire green Remove the spark plug caps from the spark plugs Remove the 6 mm ignition coil mounting bolt at the rear Remove the engin...

Page 53: ...s and remove the exhaust mufflers Remove the exhaust pipeclamp nuts Loosen the exhaust pipe clamp bolts and re move the exhaust pipes Loosen the carburetor band Remove the rear brake adjusting nut Remove the rear brake pedal return spring M U t l MP BOLT Date of Issue January 1978 OHONDA MOTOR CO LTD 5 3 ...

Page 54: ...amber PLER WIRE BF 7 Remove the wire harnessbands Disconnect the C D I unit and A C generator cables at the couplers Disconnect the ignition coil cords Pull the wire harnesses clear of the frame Remove the drive shaft lock bolt 9 7 CK BOLT Date of Issue January 1978 OHONDA MOTOR CO LTD ...

Page 55: ...he engine front hanger bolts Disengage the final shaft from the U joint assembly by adjusting the jack height and moving the engine forward Remove the engine from the frame m Jack height must be continuously adjust ed during engine removal and installation to prevent damage to mounting bolt Date of Issue January 1978 OHONDA MOTOR CO LTD ...

Page 56: ...ap 1 Remove the radiator drain bolt and drain the my coolant Loosen the radiator upper and lower hose bands Remove the radiator mount bolts Remove the radiator while pulling off the RADIATOR upper hose Remove the front engine hanger Remove the clutch wire If the cylinder heads must be removed remove the cylinder drain bolts and drain the coolant J CLUTCH l RE 5 6 Date of Issue January 1978 OHONDA ...

Page 57: ... splines are I I exposed 5 6 mm from the end of the I U joint Toraue the loci bolt securelu TORQUE VALUE 1 8 2 5 kg m 13 18 ft lbs Align the mounting surfaces carefully to Perform the following adjustments prevent damage to mounting bolt threads Throttle cable free play Page3 51 dire harnessesand cables Clutch lever free play Page3 13 Route the wires and cables properly Page 1 81 Fill the engine w...

Page 58: ...CYLINDER HEADIVALVE HONDA CX500 Date of Issue January 1978 OHONDA MOTOR CO LTD ...

Page 59: ...ING PRACTICE All cylinder head maintenance and inspection can be accomplishedwith the engine installed Before removing the cylinder I I heads it is necessary to drain coolant from the cylinder water iackets by removingthe drain bolts I SPECIAL TOOLS Specialtools VALVE GUIDE DRIVER ATTACHMENT INIEX 07943 4150000 VALVE GUIDE REAMER INIEX 07984 61 10000 Common tools VALVE SPRING COMPRESSOR 07757 001 ...

Page 60: ...ct valve clearance Burned or bent valves Broken valve spring lncorrect valve timing Sticking valve 2 Cylinder head Leaking or damaged head gasket Warped or cracked cylinder head 3 Cylinder and piston Guide I D Stemto guide clearance High Compression 1 Excessive carbon build upon piston crown or combustion chamber Excessive Noise 1 lncorrect valve adjustment 2 Sticking valve or broken valve spring ...

Page 61: ... wires Remove the by passhose Removethe air spoiler Removethe spark plug caps Removethe cylinder head cover E WIRE L Removethe radiator cover Page 9 31 Remove the radiator drain bolt and drain the coolant Remove the cylinder drain bolts to drain the coolant Date of Issue January 1978 OHONDA MOTOR CO LTD 6 3 ...

Page 62: ...e must be cool before removin the cylinder heads Loosen the cylinder head hold dow bolts in a criss cross pattern in two or more stem Remove the rocker arm holder assembly Remove the exhaust pipe Remove the engine hanger bolts Loosen the carburetor insulator band Remove the breather hose Remove the push rods Remove the cylinder head Date of Issue January 1978 6 4 OHONDA MOTOR CO LTD ...

Page 63: ...the rocker arm shafts and remove the wave washers and rocker arms n u h c d ARM HO WAVE L Y L l l WASHER I nnc ER ARM s ROCKER ARM SHAFT INSPECTION VICE LlMl A Measure the O D of each rocker arm shaft Examinethe wave washers for damage Inspect each shaft for damage scoring or nicks Date of Issue January 1978 OHONDA MOTOR CO LTD ...

Page 64: ...ing screw or push rod contact faces inspect the push rods and stem contact faces for scoring scratches or evidence of insuffi cient lubrication i Inspect the push rods for wear damage and trueness Remove the valve spring cotters retainers springs and valve more than necessary to remove the cotters Mark all parts to ensure original assembly rnm 0 55 SEHVICE LIMIT 1 4 3 mm u 333 I 1n 1 CYLINDER HEAD...

Page 65: ...off easier if soaked with solvent 0 040 in Date of Issue January 1978 OHONDA MOTOR CO LTD CYLINDER HEAD INSPECTION l i iw Check the spark plug hole and valve areas care fully for cracks Check the cylinder head for warpage with a straight edge and a feeler gauge NOTE 1 Check for warpage in an X pattern VALVE SPRING INSPECTION Measure the free length of the inner and Outer valve springs SERVICE LIMI...

Page 66: ...CTION Ream the guides to remove any carbon build up before checking clearance STEM TO GUIDECLEARANCE INSPECTION Measure and record each valve guide I D using a ball gauge or inside micrometer Calculate the stem to guide clearance SERVICE LIMITS IN 0 10 mm 0 040 in EX 0 10 mm 0 040 in service limit determine if a new guide with standard dimensions would bring the clearance within tolerance If so re...

Page 67: ...cingvalve guides Support the cylinder head and drive out the guide from the valve port Place the ATTACHMENT on the VALVE GUIDE REMOVER Drive the guides into place from the top of the head Ream the new valve guides after installation this operation It is important that the reamer be rotated when it is inserted or removed Clean the head thoroughly of any Date of Issue January 1978 OHONDA MOTOR CO LT...

Page 68: ...ace Lap each valve and seat using a rubber hose or other hand lapp tool Remove the valve and inspect the face face is rough worn unevenly or contacts the seat improperly the valve must be I GRINDING ANGLES Inspecteach valve seat width STANDARD 1 1 1 3 mm 0 04 0 05 in SERVICE LIMIT 2 0 mm 0 08 in If the seat is too wide too narrow or has low spots the seat must be ground A power grinder is recommen...

Page 69: ... valve guide firmly and lubricate it lightely with thin oil I I J f rye injuries wear adequate eye protection when using a valve seat grind Us ng a 37 5 degree stone remove 114 of the exist ng valve seat material Remove the grinder and Inspect the area of the valve seat you have removed Date of Issue January 1978 OHONDA MOTOR CO LTD 6 1 1 VALVE SEAT GRINDER UP AND DOWN EX PILOT BAR B 6 6 mm 4 ...

Page 70: ...seat must be raised using a 63 5 degree stone Refinish the seat to 1 1 1 3 mm width using a 45 degree finishing stone If the contact area on the face of the valve is too high the seat must be lowered using a 37 5 degree cutting stone BOTTOM CUT iT OLD SEAT WIDTH TOP CUT CONTACT TOO HIGH OLD SEAT WIDTH 37 5 6 12 Date of Issue January 1978 OHONDA MOTOR CO LTD w ...

Page 71: ...em seals and spring seats Lubricate the valve stems with oil and insert the valves into the guides Install the valve springs and retainers NOTE 1 Install the valve springs with the I 1 tightly wound coils facing the head I Replace the stem seals with new ones whenever disassembled COTTERS ING TS SPR SEA TIGHTLY WOUND E Install the valve cotters 4 To prevent loss of tension do not com press the val...

Page 72: ...ER ARM ASSEMBLY I Assemble the rocker arms shafts and wave washers RM SHAF ARM EX NOTE Note the rocker arm shaft direction I Apply oil to each shaft before assembly CKER ARM WAVE WP I ad ROCKER ARM IN I y 3 CYLINDER HEADIROCKER ARM INSTALLATION b Clean the cylinder surfaces of any gasket material NOTE I Do not damage the gasket surfaces i I I Date of Issue January 1978 OHONDA MOTOR CO LTD ...

Page 73: ...heck the timing mark to be certain that the cylinder to be serviced is at TDC on the compression stroke NOTE Align the index mark with the TR I mark for the right cylinder Align the index mark with the TL mark for the left cylinder Install each cylinder head Install the dowel pins Insert the push rods into the rocker arm retain ers NOTE I Apply molybdenum disulfide grease to I 1 the end of each pu...

Page 74: ...ngine front hanger bolts TORQUE 3 0 4 0 kg rn 22 29 ft lbs Route the thermometer wire oil pressure gauge wire and thermostat by pass hose through the air spoiler and connect Tighten the air spoiler bolts Tighten the carburetor band Adjust the valve clearance Page 3 41 Torque the radiator drain bolt TORQUE 0 15 0 30 kpm 1 1 2 2 ft lbs 13 26 in lbs Connect the thermometer and oil pressure gauge wire...

Page 75: ...HONDA CX500 MEMO Date of Issue January 1978 OHONDA MOTOR CO LTD ...

Page 76: ...HONDA CLUTCHIOIL PUMP cxsoo TORQUE2 0 2 5 kg m 14 17 ft lbs 7 0 Date of Issue January 1978 OHONDA MOTOR CO LTD ...

Page 77: ... WRENCH 26 x 29 mm 07716 0020201 EXTENSION HANDLE 07716 0020500 SPECIFICATIONS 39 7 lbsl0 9252 in TROUBLESHOOTING Too much free play Plates warped Oil Pump Clutch Chatters or Rattles Refer to page 2 1 for oil pump trouble Worn clutch outer and disc splines shooting Motorcycle Creeps with Clutch Disengaged Clutch Too much free play Faulty clutch operation can usually be Plateswarped corrected by ad...

Page 78: ...LUTCH LIFTER REMOVAL Remove the lifter piece circlip spring clutch lever and 0 ring CLUTCH LIFT ER PIECE CLUTCH O I D R A COVER L t V t H UIL StAL CLUTCH LIFTER PLATE y REMOVAL Removethe bolts springs and lifter plate 4 NOTE Loosen the bolts in an X pattern in two or more steps 1 LIFTER P LATE 7 2 Date of Issue January 1978 OHONDA MCITOR CO LTD ...

Page 79: ...tiaht Removethe lock nut and lock washers ICAUTIONI IDamaze to the nressure date will occur I if theclutch ce ter holder is not attached with 4 bolts WRENCH Remove the pressure plate discs A and B disc plate and clutch center as a unit PLATE Remove the clutch outer Remove the clutch outer guide and thrust washer Date of Issue January 1978 OHONDA MOTOR CO LTD 7 3 ...

Page 80: ... discoloration in Measure the disc thickness C C V in SERVICE Disc LIMITS A 2 30 rn R 7 i n m CLUTCH PLATE INSPECTION Check for plate warpage on a surface plate using a feeler gauge CLUTCH PLATE B INSPECTION Check the wave spring for damage FEELE WAVE SPRING w 7 4 Date of Issue January 1978 OHONDAMOTOR CO LTD ...

Page 81: ...the grooves in its lining NDENTAT IONS CLUTCHOUTER ANDOUTER GUIDE INSPECTION Check the slots in the outer drum for nicks I cuts or indentations made by the friction discs Measure the I D of the clutch outer and the O D of the outer guide I in in SERVICE LIMIT 32 5 m m 1 2795 in CLUTCH DlSC PRESSUREPLATE SIDE LUTCH PLATE B CLUTCHCENTE CLUTCHDISCB 1 CLUTCH DlSC A I PRESSURE PLATE Date of Issue Janua...

Page 82: ...by rotating the clutch center Install the thrust washer and outer guide on the main shaft Install the clutch on the main shaft Install the lock washer and lock nut NOTE Be sure the washer and nut facing direc tions are correct 7 6 Date of Issue January 1978 OHONDA MOTOR CO LTD ...

Page 83: ...ing Torgue the lock nut Install the clutch springs lifter plate and lifter plate bolts NOTE Tighten the bolts evenly 2 3 steps using a crisscrosspattern Installthe oil seal in the clutch cover Installthe clutch lever Installthe spring and circlip CLUTC Date of Issue January 1978 OHONDAMOTOR CO LTD 7 7 ...

Page 84: ...tch cover Connect the clutch cable Adjust the clutch Page 3 13 TER PIECE 011 PUMP REMOVAL Drain the oil from the engine Disconnect the oil pressure switch Remove the transmission cover ed with the engine in the frame remove the radiator and clutch cable at the lower URE SWlT Remove the two 6 mm bolts shown and the oil pump drive chain 7 8 Date of Issue January 1978 OHONDA MOTOR CO LTD I ...

Page 85: ...ainer and clean with solvent Remove the sprocket Remove the pump cover thrust washer pump shaft and driving pin Removethe inner and outer rotors UIL Y H t S S U H t RELIEF VALVE I I OIL PUMP INSPECTION e 7 w Measure pumptip clearance CE LIMIT 0 1 mm 10 004 in Date of Issue January 1978 OHONDA MOTOR CO LTD 7 9 ...

Page 86: ...ht I14 in i RELIEF VALVE INSPECTION Remove the valve as an assembly and check its operation If the valve does not operate properly disas semble it and check for a stuck valve or weak spring Replace the relief valve as a unit if the spring or plunger is damaged 4 in SPRING SEAT Date of Issue January 1978 7 10 OHONDA MOTOR CO LTD ...

Page 87: ... this time IHHUbI WAbHtH PUMP COVER pump body Slide the drive pin into the pump shaft and install the shaft lnstall the thrust washer and drive pin lnstall the pump cover I PUMP SI ALVE 011 PUMP INSTALLATION lnstall the dowel pin lnstall the oil pump Do not tighten the mounting bolts a t this time Place the drive chain over the pump and drive 8 Date of Issue January 1978 OHONDA MOTOR CO LTD 7 1 1 ...

Page 88: ...he chain free play by rotating the pump right or left then torque the pump bolts FREE PLAY 2 0 3 5 mm 0 8 0 14 in Recheck the oil pump drive chain free play FREE PLAY 2 0 3 5 mm 0 08 0 14 in Install the dowel pins collars O rings and gasket Date of Issue January 1981 HONDA MOTOR CO LTD ...

Page 89: ... the oil pressure switch OIL PRESSURE SWlTCH Connect the clutcn cab e r r l lrrra frv Adj st tne c l t c n free play j l Instal tne radiator and fill to the proper leve with coolant CH CABLE OILDRAIN BOLT CLUTCHCOVER Date of Issue January 1978 OHONDA MOTOR CO LTD 7 13 ...

Page 90: ...aHONDA A C GENERATORIFLYWHEELIREAR COVER cxsoo 8 0 kg m Date of Issue January 1978 OHONDA MOTOR CO LTD ...

Page 91: ...eingdamaged when disassemblingand reassemblingthem When the C D I pulser stator is removed be sure to align the timing mark on the stator with the index mark on the case cover during reassembly The A C generator stator can be serviced without removingthe A C generator assembly SPECIAL TOOLS Special tools SOCKET WRENCH 17 x 27 mm GEARHOLDER TORX DRIVER BIT T40 Common tools EXTENSION BAR HANDLE ROTO...

Page 92: ...ISASSEMBLY Remove the water pump mechanical seal Page 1 9 61 9 Remove the starter motor Remove the C D I pulser cover and neutral switch Removethe neutral cord guide Remove the final shaft oil seal 3RD GUIDE SHIFTSPINDLE OILSEAL ITRAL SWITCH Disconnect the wires a t the pulser Remove the pulser stator TOR Remove the generator stator and right and left fixed pulsers 8 2 Date of Issue January 1978 Q...

Page 93: ...al switch for continuity be tween the top and bottom terminals The switch is normal if there is continuity Check for shorts between the top terminal and body ground Replace the switch if there is continuity Inspect the neutral switch wire NGER STARTER MOTOR INSPECTION Page 18 31 a C D I PULSER INSPECTION Page17 5 A C GENERATOR INSPECTION Page 17 51 Date of Issue January 1978 OHONDA MOTOR CO LTD 8 ...

Page 94: ...on 7 Attach the GEAR HOLDER to the driven gear Remove the C D I pulser rotor Removethe flywheel bolt Removethe flywheel the pulser pick up on the flywheel outer periphery Use the ROTOR PULLER to remove Remove the reduction gear shaft a ROTOR PULLER Date of Issue March 1979 8 4 OHONDA MOTOR CO LTD I ...

Page 95: ...D Calculate the gear to shaft clearance STARTER DRIVE GEAR INSPECTION sffl SERVICE LIMIT 0 2 mm 0 0079 i I D Check the drive gear for damage excessive wear indentations or other faults Measure the SERV C gear I D STARTER CLUTCH OUTER REMOVAL Remove the starter clutch rollen springs and plunger Remove the TORX bolts 7 BIT T40 I DRIVER Date of Issue January 1978 OHONDA MOTOR CO LTD 8 5 ...

Page 96: ...n or excessive wear ECT FOR WEAR ROLLE STARTER CLUTCH OUTER INSTALLATION Slide the clutch outer into the flywheel aligr ing the holes with the dowel pins in the fl wheel Installand torque the TORX bolts NOTE I Replaceused TORX bolts TORQUE 2 0 2 5 kgm 14 17 ft lbsl TORX bolts with a lockingagent prior to Position the roller into place while holding the plunger with ascrewdriver as shown PLUNGEH Sl...

Page 97: ...Install the starter drive gear on the clutch outer RIVE GE I NOTE Rotate the drive gear In the counterclock wise direct on to aid nstallat on IER Install the needle roller bearing in thedrivegear REDUCTION C THf Date of Issue March 1979 OHONDA MOTOR CO LTD 8 7 ...

Page 98: ...ing tab with the cutout in the flywheel NOTE I Replace the pulser rotor and stator as a I set COMPONENTS ASSEMBLY Install the final shah bearing lnstall the final shaft oil seal and gear shift spindle oil seal Install the neutral switch 8 8 Date of Issue January 1978 OHONDA MOTOR CO LTD I ...

Page 99: ...timing will be incorrect Route the wires and cables properly Replace the pulser rotor and stator as a set I Install the C D I pulser cover Connect the neutral switch wires and secure with the neutral cord guide Install the mechanical seal Page9 61 ASSEMBLY Install the following parts REAR COVER Page9 71 STARTER MOTOR Page9 71 TRANSMISSION COVER Page 7 13 ENGINE Section 5 ALIGN MARKS HERE C D I PUL...

Page 100: ...HONDA COOLING SYSTEM CX500 9 0 Date of Issue January 1978 OHONDA MOTOR CO LTD I ...

Page 101: ...DLE A 07749 0010000 COOLING SYSTEM TESTER M988X 525 XXXXX SPECIFICATIONS TROUBLESHOOTING Radiator cap relief pressure Freezingpoint Hydrometer test Coolant capacity Radiator and engine Reserve tank Total system Thermostat Boiling point with 50 50 mixture EngineTemperature Too High Engine Temperature Too Low Faulty temperature gauge or gauge sensor Faulty temperature gauge or gauge sensor Faulty vo...

Page 102: ... high or too low It must hold specified pressure for at least six seconds NOTE I Before installing the caD on the tester 1 apply water to the sealing surfaces RADIATOR CAP RELIEF PRESSURE 0 9 0 15 kglcm2 12 8 2 1 Psi Pressurize the radiator engine and hoses and check for leaks Excessive pressure can damage the radiator Repair or replace components if the system will not hold specified pressure for...

Page 103: ...liters To drain coolant from the cylinders remove the cylinder drain plugs about0 4 liters Replace the cylinder and radiator drain bolt p q Do not overtighten the radiator drain plug 4 Fill the system with a 50 50 mixture of dis tilled water and ethyleneglycol w TORQUE THERMOSTAT REMOVAL Remove the seat and fuel tank Remove the coolant drain plug coolant Disconnectthe bypass hose Disconnect the te...

Page 104: ...connectthe water pipe Remove the water temperature unit WATER TEMPERATURE UNIT TEMPERATURE UNIT INSPECTION Suspend the unit in oil and measure the resistance through the unit as the oil heats Tempera I 60 C I 8 5 11IO C 1120 C 1 Do not let the unit or thermometer touch the pan or false readings will result I Weargloves and eye protection J NOTE 1 oil must be used as the heated liquid to 1 1 I chec...

Page 105: ... or if it responds a t temperatures other than those specified Valve lift must be checked by applying FLYWHEEL Rl COOLING FAN REMOVAL Remove the seat and fuel tank Remove the radiator Page 5 61 Remove the crankshaft hole cap and hold the crankshaft Remove the fan bolts Remove the fan WATER PUMP DISASSEMBLY Remove the engine from the frame Page 5 2 Disconnect the water pipes L Remove the water pump...

Page 106: ...mage R MOTOF Drive the mechanical seal out from the in NOTE Avoid damaging the rear cover whe driving the seal out Inspect the mechanical seal for damag evidence of dererioration WATER PUMP ASSEMBLY Apply a thin coat liquid sealant to the outer periphery of the mechanicalseal NOTE Check that the water pump drain hole is clear 9 6 Date of Issue January 1978 OHONDA MOTOR CO LTD ...

Page 107: ... in place by screwing in the seal pilot See the illustration Drive in the seal squarely Remove the seal pilot after driving in Install the collars O rings dowel pins and rear cover gasket RING GASKET DOV Install the rear cover and torque the bolts s m TORQUES 6 mm bolts 0 8 1 2 kg m 6 9 ft lbs 6 8 mm bolts 1 8 2 5 kg m 13 18ft lbsl y 8 T r I Install the starter motor Engage the starter drive gear ...

Page 108: ...Slide the collar into the impeller and install the impeller Rotate thc pump turn the WASHER Install the copper washer and cap nut or camshaft and torque the cap nut TORQUE 0 8 1 2 kg m i 6 9 ft lbs 52 104 in lbs crankshaft to make sure that 1 sfreely without binding I Place a gasket on the watel install the cover pump cover and Date of Issue January 1978 OHONDA MOTOR CO LTD ...

Page 109: ...e and attach the thermostat cover and bracket lnstall the temperature unit slide new O rings onto the water pipes press the water pipes into the thermostat case and elbows NOTE 1Check that the 0 rinas are not dislodged 1 THEF rU1 HERMOSTAT COVER RUBBERGASKET Install the thermostat assembly lnstall the air spoiler Connect the water bypass hose COOLING FAN INSTALLATION lnstall the cooling fan Instal...

Page 110: ...he radiator Start the engine and run until there are no air bubbles in the coolant and the level stabilizes Stop the engine and add coolant up to the proper level if necessary Reinstall the radiator cap Check the level of coolant in the reserve tank and raise to the correct level if the level is low Pressurize the radiator engine and hoses and check for leaks Repair or replace components if the sy...

Page 111: ...he speedometer Check the ground connection between the green wire and its terminal Disconnect the yellow wire and measure volt age at the regulator terminal it should be 7 0 7 5VDC If voltage is too high or if a ground fault can t be corrected replace the voltage regulator Revised October 1981 American Honda Motor Co Inc 1981 All Rights Reserved MSV 3094 8110 9 11 ...

Page 112: ...HONDA CAMSHAFTICAM CHAIN 10 0 Date of Issue March 1979 I OHONDA MOTOR CO LTD ...

Page 113: ...re these orifices are not clogged and that the O rings and dowel pins are in place before assembling the engine Before assembling the camshaft lubricate the bearings with engine oil and pour 100 cc of engine oil into the engine block oil pockets to provide initial lubrication F SPECIALTOOLS GEARHOLDER 07924 41 50000 LOCK NUT SOCKET WRENCH 17 x 27 mm 07907 4150000 SPECIFICATIONS Rocker arms and TRO...

Page 114: ...sprocket with a GEAR HOLDER I to prevent it from turning I Loosen the 27 mm nut and remove the cam sprocket and cam sprocket boss c r c i J 2 L BOLT COLLA Remove the lock bolt and collar Remove the tensioner cam chain guide and chain guide set plate A C DOWE Remove the tensioner and cam chain guide Remove the 7 mm dowel bolts and remove the cam sprocket and cam chain Check the cam chain guide and ...

Page 115: ...AFT INSPECTION Measure the O D of each camshaft bearing journal Calculate the journal and bearing clearance SERVICE LIMIT 0 260 mm 0 0102 in Inspect the worn gear for wear or damage REAR OR I v v t n uR SERVICE LIM DAMAGE FRONT 2i REAR 2 ITS 1 910 mm i 910 mm 0 8526 in 1 0201 in Date of Issue January 1978 OHONDA MOTOR CO LTD 10 3 ...

Page 116: ...nspect the lobes for wear or damage SER VICE LlMl TS EX 36 0 CAMSHAFT HOLDER lNSPECTION Measure the camshaft holder I D as shown SERVICE L CAMSHAFT BEARING INSPECTION Measurethe bearing I D IMIT 22 i LIMIT 10 4 Date of Issue January 1978 OHONDA MOTOR CO LTD ...

Page 117: ... arm shaft Remove the rocker arm shaft Remove the rocker arm and wave washer 3M SHAFT 6 rnm B o l T ROCKER ARM INSPECTION Inspect the rocker arms for wear or damage to the camshaft contact surfaces or clogged oil holes Measure the I D of each rocker arm SERVICE LIMIT 30 in Date of Issue January 1978 OHONDA MOTOR CO LTD 10 5 ...

Page 118: ... LIMIT 0 08 mm 0 0031 in ROCKER ARM Install the rocker the inside INSTALLATION arms with the offset 1 5510 in toward Install the rocker arms and thrust springs in the cylinder block and then insert the rocker arm shafts NOTE engine oil before installation Install each rocker arm shaft with the threaded end facing the rear cam sprocket side 10 6 Date of Issue January 1978 OHONDA MOTOR CO LTD ...

Page 119: ...ock bolt hole Install the lock bolt R CAMSHAFT INSTALLATION Lubricate the camshaft journals with molybde num disulfide grease Install the camshaft thrust washer Insert the camshaft from the front Install the camshaft holder gasket O ring and collar GASKE Date of Issue January 1978 OHONDA MOTOR CO LTD ...

Page 120: ...and lock washer and tighten the nut temporarily lnstall the cam sprocket and finger tighten the bolts NOTE GEAR H lnstall the lock washer wlth the mark OUTSIDE fac ng out ET BOSS LULK M I J Hold the cam sprocket with the GEAR I HOLDER Torque the lock nut LULK tuu I U L K I vvntluLn I Ix LI r 07907 4 150000 Remove the cam sprocket d C IQUE 10 0 kg m 72 ft lbs Date of Issue January 1978 OHONDA MOTOR...

Page 121: ... valve timing by observing the follow ing Make sure the cam sprocket bolts are in line with the aligning marks on the cylinder block Check that the flywheel woodruff key aligns with the index mark on the crankshaft cap NOTE IWhen inspecting the valve timing push I the cam chain from the right side so the tensionerside of the chain is u l l e d taut Date of Issue January 1978 QHONDA MOTOR CO LTD 10...

Page 122: ...ll the chain guide set plate A cam chain guide and cam chain tensioner Install the tensioner spring Install the O ringon the lock nut Slide the collar into the tensioner arm and install the lock bolt Do not tighten the lock bolt at this time ENSIONE OCK Bi I i C r Date of Issue January 1981 O HONDA MOTOR CO LTD ...

Page 123: ...cc of engine oil into the oil pockets of the cylinder block Install the flywheel Page8 7 Install the cylinder head Page 6 14 Adjust the valve clearance Page 3 41 Install the engine Seesection 5 Date of Issue January 1978 OHONDA MOTOR CO LTD ...

Page 124: ...TRANSMISSION HONDA CX500 Date of Issue January 1978 11 0 OHONDA MOTOR CO LTD I ...

Page 125: ...n equivalent Apply engine oil to the other gears SPECIAL TOOLS Special tools CRANK CAP DRIVER for damper spring compressor BEARING REMOVER 20 mm BEARING REMOVER HANDLE BEARING REMOVER WEIGHT BEARING DRIVER ATTACHMENT BEARING DRIVER HANDLE BEARING DRIVER ATTACHMENT BEARING DRIVER ATTACHMENT BEARING DRIVER HANDLE BALL RACE REMOVERIDRIVER Common tools BEARING DRIVER 142 x 47 mm BEARING DRIVER PILOT 2...

Page 126: ... adjustment too much free play Shift forks bent Shift shaft bent Shift fork claw bent Shift drum cam grooves damaged Shift guide pin damaged Transmission Jumps Out of Gear Gear dogs worn Shift shaft bent Shift drum stopper broken Shift forks bent 11 2 Date of Issue January 1978 OHONDA MOTOR CO LTD ...

Page 127: ... the neutral switch plate shift drum stopper plate gearshift drum pin and collar NOTE Do not disassemble the shift drum plates I and pin except when replacement is necessary Check all removed parts for wear or damage RUM ST0 NG ANK CAP PPER ARR DRIVER JTRAL iPLATE FINAL SHAFT DISASSEMBLY Compress the spring with a press and CRANK CAP DRIVER and remove the spring cotters Remove the spring retainer ...

Page 128: ...de the lifter spring and retainer over the shaft Compress the spring in the CRANK CAP DRIVER and install the spring cotters NOTE Make sure that the cotters are properly seated SPRING COTTEF DAMPER SPRING TRANSMISSION DISASSEMBLY Remove the transmission cover and removethe clutch as an assembly Seesection 7 Remove the oil separater 11 4 Date of Issue January 1978 OHONDA MOTOR CO LTD I ...

Page 129: ...er bolls t P Removethe transmission as shown Drive the ends of the countershaft and shift i drum carefully and evenly with a soft hammer until the transmission holder is clear of the engine case 1 Date of Issue January 1978 OHONDA MOTOR CO LTD 11 5 ...

Page 130: ...00 K SHAFT Removethe shift fork shafts Removethe shift forks and the guide pins Removethe shift drum FOR Remove 2nd and 5th gears from the co shaft and mainshaft GEAR FORK GEAR Date of Issue January 1978 OHONDA MOTOR CO LTD ...

Page 131: ...prying off the snap ring xr 7 v Inspecteach holder bearing for wear or damage They should rotate smoothly and be free of play or rattle BEARING I 07936 371 Y U U L Remove the bearings from the transmission holder 2EMOVEF nrnn i HANDLE BEARING REMOVER 120 mm 07936 371 06 REMOVEF 0200 l WEIGHT Date of Issue January 1981 OHONDA MOTOR CO LTD ...

Page 132: ...6 37 10200 TRANSMISSION INSPECTION Check the gears for freedom of movement and rotation on the shaft Examine the gear dogs and slots for evidence of abnormal wear Measure each gears I D If any gear exceeds the limit the gear must be replaced SERVICE LIMITS M2 M3 M4 and M5 GEARS 25 10 mm 0 988 in C1 GEAR 24 10 mm 0 949 in C2 GEAR 27 60 mm 1 087 in C3 and C4 GEARS 25 10 mm 0 988 in C5 GEAR 32 10 mm ...

Page 133: ...alculate the clearance between the gear and gear shaft or bushing SERVICE LIMIT 0 15 mm 0 0059 in FT FORK VICE LIM WEAR MAINSP Measure the shift fork I D and claw thicknes Measurethe shift fork shaft O D i KNESS 0 217 n I CLAW T Measurethe transmission holder I D Inspect each holder bearing for wear or damage Spin the bearing by hand Bearings must be replaced if they are noisy or have excessive pl...

Page 134: ...VER HANDLE A Install the transmission holder bearing NOTE Support the transmission holder above the workbench to Drevent damaaina it TOOLS DRIVER HANDLE A 07949 001 0000 BEARING DRIVER ATTACHMENT 07946 3600000 BEARING DRIVER PILOT 25 mm BEARING DRIVER HANDLE 07949 61 10000 NEEDLE BEARING BALL RACE REMOVER DRIVER 07946 3290200 Assemble the mainshaft and countershaft NOTE BEARIN DRIVER I V U vnlVER ...

Page 135: ...gement of the gears on the countenhaft and mainshaft NOTE During installation hold the thrust washer to prevent it from falling Press the gear assembly into position by lightly tapping the mainshaft with a soft hammer NOTE 1 Hold the countershaft low gear to prevent 1 it from coming off I COUNTE LOW GE RSHAFT AR Date of Issue January 1978 OHONDA MOTOR CO LTD 11 1 1 ...

Page 136: ... theshift fork shafts we a I I F Placethe transmission in neutral Insert the transmission assembly into the engine case d V 8 L SHAFT Press the transmission holder into place while rotating the mainshaft Torque the holder bolts Install the oil separator Install the clutch Page7 61 Install the transmission cover Page7 13 11 12 Date of Issue January 1978 OHONDA MOTOR CO LTD I ...

Page 137: ...m Install the spring on the shift arm and shift spindle Install the spindle Rotate the shift drum to neutral lnstall the drum stopper cam plate Apply a locking agent and tighten the 6 mm bolt Attach the stopper spring ho a1 SHIFT ARM lnstall the final shatt lnstall the rear cover See section 9 r NDLE Date of Issue January 1978 OHONDA MOTOR CO LTD 11 13 ...

Page 138: ...TRANSMISSION HONDA CX500 TORQUE 2 0 2 4 kg rn 14 j7 ft lbs 12 0 Date of Issue January 1978 OHONDA MOTOR CO LTD ...

Page 139: ...sulfide grease to the journals crankpins and bearingsduring assembly SERVICE INFORMATION 12 1 MAIN JOURNAL BEARING 12 13 REMOVAL TROUBLESHOOTING 12 2 MAIN JOURNAL BEARING 12 14 CONNECTING ROB REMOVAL 12 3 INSTALLATION SPECIAL TOOLS Special tools GEARHOLDER 07924 4 150000 PISTON REMOVER 07941 4 150000 CRANK CAP PULLER 07935 41 50000 CRANK CAP DRIVER 07945 41 50100 MAlN BEARING DIS ASSEMBLY TOOL 079...

Page 140: ...en Compression 1 Worn cylinder or piston ring Excessive Smoke 1 Worn cylinder piston or piston rings 2 Improperly installed piston rings 3 Damaged piston or cylinder Overheating 1 Excessive carbon build up on piston head 2 Blocked or restricted flow of coolant 3 Sticking thermostat Knocking or Abnormal Noise 1 Worn pistons and cylinders 2 Excessive carbon build up on piston head Date of Issue Janu...

Page 141: ...piston to be removed is at B D C Bottom Dead Center Remove the bearingcap Mark the bearing caps and rods t o indicate cylinder position Remove the left side cap from the transmission side Work through the hole on the oil pump side to remove the right side cap Turn the crankshaft so that the piston is at T D C Place the PISTON REMOVER over the rod bolts and push the piston and rod assembly out i L ...

Page 142: ...rk the rings so they can be assembled in their original position Clean and inspect the piston crown Inspect the piston for damage and cracks ring grooves for excessive wear Insert each piston ring into the cylinder and measure the ring end gap SERVICE LIMIT C TOP SECOND NOTE To measure the gap use a piston and oush the rina souarelv into the cvlinder 12 4 Date of Issue January 1978 OHONDA MOTOR CO...

Page 143: ...the bottom of the ist ton and 90 to the piston pin hole CYLINDER INSPECTION CE LIMIT Measurethe cylinder I D Calculate the piston to cylinder clearance SERVICE LIMIT 0 10 mm 0 004 in Oversize pistons are available in standard and the following sizes 0 25 and 0 50 mm Measure each piston pin bore E LIMIT K BOTTOM Date of Issue January 1978 OHONDA MOTOR CO LTD ...

Page 144: ...it replace the rod Measure each piston p n O D SERVICE LIMIT 20 984 m m 0 8261 in Calculate the plston pln to pistonclearance SERVICE LIMIT 0 05 m m 0 002 in SERVICE LIMIT 2 SERVICE LIMIT 20 984 m m 0 8261 in 0 8294 in 7 12 6 Date of Issue January 1978 OHONDA MOTOR CO LTD A ...

Page 145: ...ary gear NOTE Mark the sub gear and side plate so that they will face the correct direction during reassemblv Remove the flywheel and cam chain Page 10 2 Remove the crankshaft cap bolts GEAF splines of the primary gear and timing sprocket with vinyl tape to prevent dam aqe to them Attach the CRANK of the engine CAP PULLER to the front Date of Issue January 1978 OHONDA MOTOR CO LTD 12 7 ...

Page 146: ...ns TORQUE VALUE 2 8 3 2 kg m 20 23ft lbsl steps Do not rotate the crankshaft during Measure the rod side clearance with a fj gauge SERVICE LIMIT 0 60mm 0 024in BEARING INSPECTION SELECTION Inspect each bearing insert for separation or other damage Put the connecting rod inserts in each rod cap Place a plastigauge strip across each rod crank pin avoiding the oil hole eeler Date of Issue January 198...

Page 147: ...l positions and torque to specifica tions steps Do not rotate the crankshaft during I L Remove the caps and measure the compressed plastigauge The widest thickness determines the oil clearance in MAIN J O U R N A L Measure each journal O D Date of Issue January 1978 OHONDA MOTOR CO LTD 12 9 ...

Page 148: ...p I D Calculate the journal to bearing cap clearance If rod bearing clearance is beyond tolerance select replacement bearings as follows ROD BEARINGS BtAHING CAP Determine and record each connecting rod I D code number I E NO 12 10 Date of Issue January 1978 OHONDA MOTOR CO LTD I ...

Page 149: ...9 982 mm 39 974 mm ROD I D COLOR IDENTIFICATION CODE UM I 1 43 000 43 008 YELLOW 11 6929 1 6932 in 2 43 008 43 016 REEN 1 6932 1 6935 in GREEN BROWN E 3 43 016 43 024 1 6935 1 6939in ROD BEARING SIZES NOTE After fitting new bearing inserts they should be rechecked with plastigauge v CRANKPIN O D CODE V COLOR MAlN JOURNAL BEARINGS Determine and record the main journal O D codes MAlN JOUF b INAL O D...

Page 150: ...rt I D and crank journal codes to determine the replace ment bearing color MAlN BEARING SELECTION BEARING IDENTIFI CRANKCASEICAP CATION COLOR 1 BEARING I I JOURNAL BEARING SIZES COLOR THICKNESS BROWN 1 989 1 999 mm 0 0783 0 0787 in BLACK 1 994 2 004 mrn 0 0785 0 0789 in BLUE 1 999 2 009 mm 0 0787 0 0791 in 7 Date of Issue January 1978 OHONDA MOTOR CO LTD ...

Page 151: ...ic press and bearing DISIASSEMBLY tool use a hydraulic press and bearing removal BEARING CHMENT IESS CRAl ATTA TO PF VK CAP Bl c I TOOL Press the bearings out of the crankshaft cap bearing support with a hydraulic press and bearingremoval tool Date of Issue January 1978 oHONDA MOTOR CO LTD 12 13 ...

Page 152: ...holder cap groove and press the bearings place p E K Do not damage the bearings when pre fitting them I CRANKCASE MAlN JOURNAL BEARINGS Lubricate the outer periphery of each bearing with engine oil or molybdenum disulfide grease Align the tab of each bearing insert with the crankcase bearing support groove and press the bearings into place ICAUTION I Do not damage the bearings when press fitting t...

Page 153: ...ng gear area with vinyl tape to orevent damaae Install the O ring and collar Install the crankshaft holder cap Install the guide bolts in the crankshaft holder cap as shown NOTE I Lubricate the bearing with molybde I num disulfide grease Screw in the guide bolts so that the I cap is not tilted Drive the crankshaft holder cap into place with a hammer and driver Date of Issue January 1978 OHONDA MOT...

Page 154: ...tall the dish spring with the pawls placed over the dowel pins to prevent them from coming out during oper ation Before assembling lubricate all parts with engine oil Note the primary sub gear and side plate directions by referring to the marks made during disassembly Install the DRIVE GEAR HOLDER to prevent the drive gear from turning Torque the primary gear 9 5 kg m 58 69 ft lbs 12 16 Date of Is...

Page 155: ...ing the piston pin and thrust sides Do not align the gap in the oil rings After installing the rings they should be free to rotate SIDE RAIL Coat rod small end with molybdenum disulfide grease Assemble the pistons and connecting rods with the piston pins and piston pin clips pins and connecting rods Make sure that the piston pin clips are properly seated Install the piston with the L mark on the l...

Page 156: ...NOTE 1 The rod assemblies should be installed I with the piston IN markings to the rear Lubricate the piston ring grooves and cvlinder walls with enqine oil Bring the piston to TDC Compress the piston rings with the PISTON SLIDER and insert the piston into the cylinder during assembly Insert the piston into the cylinder I OIL HOLE PISTON 07755 Date of Issue January 1978 12 18 OHONDA MOTOR CO LTD ...

Page 157: ...e connecting rod caps Torque the connecting rod cap bolts TORQUE 2 8 3 2 kg m 20 23 ft lbs in their correct location Turn the crankshaft to make sure the rods rotate freely without binding Date of Issue January 1978 OHONDA MOTOR CO LTD 12 19 ...

Page 158: ...HONBA FRONT WHEELISUSPENSION CX500 Date of Issue January 1978 OHONDA MOTOR CO LTD ...

Page 159: ...NG DRIVER OUTER 42 x 47 mm 07746 0010300 BEARING DRIVER PILOT 15 mm 07746 0040300 FRONT FORK OIL SEAL DRIVER BODY 07747 0010100 FRONT FORK OIL SEAL ATTACHMENT Dl 07747 0010500 SPECIFICATIONS ITEM I STANDARD I SERVICE LIMIT I t x l e shaft runout I 1 0 2 mm 10 008 in 1 TROUBLESHOOTING Front wheel rim runout Front cushion spring free length Hard Steering 1 Steering stem nut too tight 2 Faulty steeri...

Page 160: ...NNECTION IN HEADLIGHT CASE Route the wires into the headlight case through the headlight case hole Connect the wires color to color Set each coupler in its correct holder in the headlight case WIRING Section 1 HEADLIGHT INSTALLATION Place the headlight upper hook over the head light case and secure the headlight with two lower screws Check the headlight aim and adjust by screws A B if necessary NO...

Page 161: ...the above condition INDICATOR LAMP REPLACEMENT After installing a new bulb check for con tinuty If the bulb does not light inspect the wiring for open or short circuits METER DISASSEMBLY To replace a meter it is necessary to separate the cluster Remove the set plate and cable METER ASSEMBLY Connect the water temperature gauge wires as shown NOTE I Install the meter seal rubber properly ALL 12 V 3 ...

Page 162: ...TALLATION Installation of the handlebar is essentially the reverse order of removal NOTE Coat the throttle grip area of the han dlebar with grease Align the punch marks on the handlebar with the splits of the fuse box and switch housing Tighten the forward screw first then tighten the rear screws to the same torque TORQUE SPECIFICATION 2 5 3 0 kg m 18 22 ft lbs Connect the clutch switch wires Inst...

Page 163: ...edometer cable from the and loosen the axle nut Remove the axle holder from the fork end Withdraw the axle and remove the wheel removing the front wheel To do so will cause difficulty in refitting the brake disc AXLE INSPECTION Set the axle in V blocksand measurethe runout The actual runout is 112 of TIR Total Indicator Reading SERVICE LIMIT 0 2 mm 10 008in Date of Issue January 1978 OHONDA MOTOR ...

Page 164: ...re noisy or have excessive play WHEEL INSPECTION Check the rim runout by placing the wheel in a truing stand Then spin the wheel by hand and read the runout using a dial indicator gauge paired and must be replaced with a new one if the service limits are exceeded WHEEL DISASSEMBLY Remove the right bearing first T NOTE ITubeless tires are standard FWD 13 6 Date of Issue January 1978 OHONDA MOTOR CO...

Page 165: ...al and collar in the hub on the right side NOTE The spoke plate bolts and nuts require no retightening since they are secured with lock oins Do not remove these lock ins ICA ITION1 Remove all the grease arourld the outside of the oil seal Install the speedometer gear retainer in the hub from the left side Lubricate the oil seal lip and install Disassemble the speedometer gear box and lubricate the...

Page 166: ...rward nut to the specified torque first then tighten the rear bolt to the same torque TORQUE SPECIFICATION 1 8 2 5 kg rn 13 18 ft lbs NOTE Place a stand under the engine to remove load from the front fork Keep the front wheel forward Align the end of axle with the outside face of fork Connect the speedometer cable to the speedo meter gearbox while rotating the wheel by hand With the front brake ap...

Page 167: ... the brake hose clamp NOTE Do not loosen the brake hose unless nec essary Remove the front fender Remove the headlight case Page 14 31 Hold the headlight case with wire Loosenthe fork bridge bolts Loosen the front fork steering stem bolts Remove the fork tubes from the bottom bridge rotating them by hand if necessary Date of Issue January 1978 OHONDA MOTOR CO LTD ...

Page 168: ... bend the sliding sur face mna I U3r cur when loosen in the bolt or the 1 spring will pop out SHOP TOWEL OR SOFT JAWS FRONT FORK SPRING FREE LENGTH INSPECTION Measurethe front damper spring free length FREE LENGTH SERVICE LIMIT UPPER 90 1 mm 3 55 in LOWER 449 5 mm 17 70 in 13 10 Date of Issue January 1981 O HONDA MOTOR CO LTD ...

Page 169: ...he snap ring Carefully remove the oil seal with a screwdriver SCREWDRIVER faces of the slider when removing the seal OIL SEAL FORK TUBE FORK SLIDER PISTON INSPECTION Check the fork tubes fork sliders and pistons for score marks scratches or excessiveor abnor ma1wear replacing those which are damaged CASE FORK TUBE INSPECTION Set the fork tube in V blocks and read the runout Take 112 TIR to determi...

Page 170: ... Q t PISTON RING V a SOCKET BOLT APPLY LOCKING AGENT TO BOLT THREADS AN0 w 3 UNDERSIDE OF BOLT Install the piston and fork tube Apply a locking agent to the bolt threads and underside of the bolt then torque to specified tension NOTE Do not tighten the fork slider excessively n SHOPTOWELOR SOFT JAWS 9 HOLLOW SET WRENCH 16 r n r n 13 12 Date of Issue January 1981 O HONDA MOTOR CO LTD ...

Page 171: ... Fluid NOTE I Pour the s ecifiedamount of ATF Do1 not overfill Slide the front fork spring and spring seat into position and tighten the fork bolt FRONT FORK OIL SEAL ATTACHMENT D isi jLa NOTE 1 Place the fork tube in soft jaws avoid I ing the sliding surface Note the spring direction TORQUE SPECIFICATION 4 5 5 5 kg m 133 40 ft lbs TORQUE SPECIFICATION DOWN SHOPTOWELOR SOFT JAWS 1 I Date of Issue ...

Page 172: ... the fork bridge Torque the front fork bolt a t the steering stem Torque the front fork at the fork top bridge Install the headlight case Install the fender NOTE Note the fender guide direction Install the brake caliper Secure the brake hose Install the front wheel Page 13 8 3 0 4 0 kg m 22 29 ft lbs FEN 3 DER 13 14 Date of Issue January 1978 OHONDA MOTOR CO LTD ...

Page 173: ...he headlight case Page 13 21 Removethe handlebars Page 13 41 Unscrew the steering stem nut Loosen the fork bridge bolts and stem fixing bolt Remove the fork bridge Loosen the steering stem bolts Remove the front fork tubes BARi Date of Issue January 1978 OHONDA MOTOR CO LTD 13 15 ...

Page 174: ...ls to fall BOTTOM CONE RACE REPLACEMENT Inspect the bottom cone race for wear or damage and replace if necessary Remove the bottom cone race with a hammer and a drift Install a new washer and dust seal Drive a new bottom cone race into place STE 079 13 16 Date of Issue January 1978 1 OHONDA MOTOR CO LTD ...

Page 175: ...CE REMOVER 07953 3330000 STEERING STEM INSTALLATION NOTE Drive the ball races squarely Drive the ball races in until they seat Grease the top race and install 18 ball bearings Grease the lower cone race and install 19 ball bearings NOTE Do not allow the balls to fall BALL RACEDRIVER BALL RACE D RIVER 07945 3330300 07946 3290000 DRIVER HANDLE A DRIVER HANDLE A ADJUSTER TOP CONE e STEEL 5 STEEL BALL...

Page 176: ...angethe right and ieft fork I I legs PIN SPANNER Temporarily hold the fork tubes by tightening I 7 the steering stem bolts Install the fork top bridge Insert each fork into the front fork top bridge Torque the steering stem nut TORQUE SPECIFICATION 9 0 12 0 kg m 65 87 ft lbs Torque the stem fixing bolt TORQUE SPECIFICATION 1 8 2 5 kg m 13 18 ft lbsl LOCK NLI T WRENC H SOCKE O kg m 1 ft lbs QUE SPE...

Page 177: ...tem bolts TORQUE SPECIFICATION 1 8 2 5 kg m 13 18 ft lbs Tighten the fork bridge bolts TORQUE SPECIFICATION 0 9 1 3 kg m 7 9ft lbs with the too of Install the following HANDLEBAR Page 13 4 HEADLIGHT CASE Page 13 21 FRONT FENDER FRONT WHEEL Page 13 81 I Date of Issue January 1978 OHONDA MOTOR CO LTD 13 19 ...

Page 178: ...REAR WHEELIBRAKEI HONDA FINAL DRIVEISUSPENSION CXSOO Date of Issue January 1978 OHONDA MOTOR CO LTD ...

Page 179: ...WRENCH 07910 4150000 SOCKET BIT 10mm 07917 3710000 SLIDING WEIGHT 07936 3710200 PIVOT BEARING OUTER REMOVER 07936 4150000 MECHANICALSEAL DRIVER ATTACHMENT 07945 4150200 RING GEAR DIS ASSEMBLYTOOL SET 07965 4150000 CENTER SHAFT DISIASSEMBLYTOOL 07965 4150100 DlSlASSEMBLY TOOL A 07965 4150200 DISIASSEMBLYTOOL B 07965 3710200 DISIASSEMBLYTOOL C 07965 37I0300 PRELOAD INSPECTIONTOOL 07998 4150000 Commo...

Page 180: ...n 1 Shock absorbers improperly adjusted Suspension Noise 1 Shock case binding 2 Loose fasteners Poor Brake Performance 1 Improper brake adjustment 2 Fouled brake linings 3 Worn brake shoes 4 Worn brake shoe cam contacting faces 5 Worn brake drum 6 lmproper engagement between brake arm and shaft serrations Final drive gear noise 1 Oil level too low 2 Excessive backlash 3 Drive shaft splines damaged...

Page 181: ...HEEL REMOVAL Place the motorcycle on its center stand Remove the cotter pin and loosen the axle nut Loosenthe axle holder bolt Remove the cotter pin and remove the brake torque link Remove the brake adjusting nut and the brake rod Remove the rear axle Date of Issue January 1981 oHoNDA MOTOR CO LTD 14 3 ...

Page 182: ...FT BEND INSPECTION Set the axle shaft in V blocks and measure the axle shaft runout The actual axle bend is 112 of TIR Total Indicator Reading REAR WHEEL BEARING PLAY INSPECTION Rotate the rear wheel by hand Replace the wheel bearings with new ones if they are noisy or have excessive play SERVICE LIMIT 0 2 rnm 0 008 in PLAY RADIAL PLAY 1 AXIAL i Date of Issue January 1978 14 4 OHONDA MOTOR CO LTD ...

Page 183: ...in the wheel by hand and read the runout using a dial indicator gauge viced and must be replaced if the above limits are exceeded SERVICE LIMITS RADIAL RUNOUT 2 0 m m 0 08 in AXIAL RUNOUT 2 0 m m 0 08 in REAR WHEEL DISASSEMBLY Removethe bearing retainer NOTE I Tubeless tires are standard 1 I I Date of Issue January 1978 OHONDA MOTOR CO LTD 14 5 ...

Page 184: ...E 1Drive the bearings squarely Install the bearing retainer and punch it lnstall the distance collar and drive the right bearing into place BEARING DRIVER HANDLE A BEARING DRIVER OUTER 42 x 47 mm BEARING DRIVER PILOT 17 mm I R WRENC lnstall the O ring and lubricate the splines and O ring with lithium based multipurpose grease lnstall the final driven flange Date of Issue January 1978 OHONDA MOTOR ...

Page 185: ...ove the cotter pins Install new brake shoes Apply grease to the face of the brake cam I I I I I I I I I I I I I brake linings reduce stop I pirrg power Keep grease off the brake linings Wipe the excess grease offthe cam arm aligns with the punch mark on the brake camshaft o BRAKE DRUM I D INSPECTION Measure the brake drum I D SERVICE LIMIT 161 0 mm 6 34 in Date of Issue January 1978 OHONDA MOTOR C...

Page 186: ... in the direction shown Install the rear wheel and brake panel Insert the rear axle through the swing arm washer brake panel and rear wheel Connect the brake rod Install the brake torque link TORQUE SPECIFICATION 1 5 2 3 kg rn 11 17 ft lbs Torque the axle nut TORQUE SPECIFICATION 3 4 4 0 kg rn 22 29 ft bs e Tighten the axle fixing bolt TORQUE SPECIFICATION 2 0 3 0 kg rn 15 22 ft lbs f I Date of Is...

Page 187: ...ove the upper attaching nuts and the upper parts of both rear shock absorbers from the holders Loosen the left side lower bolt and pull out the bolt while lifting the rear wheel Remove the shock absorber SHOCK ABSORBER DISASSEMBLY NOTE Make sure that the shock absorber is in the softest position Set the rear cushion in the compressor as shown and compress the spring 30 mm by turning the compressor...

Page 188: ...own Remove the compressor I I t SHOCK ABSORBER SPRING FREE LENGTH Measure the rear shock absorber spring free length SHOCK ABSORBER ASSEMBLY Install the spring adjuster the spring under seat spring and stopper rubber on the damper NOTE Install the spring with the tightly wound end facing up b SERVICE LIMIT 245 5 rnrn 18 05 in SPRING UNDER SEAT JOINT UPPER Qt SPRING ADJUSTER 14 10 Date of Issue Jan...

Page 189: ...e rock nut securely NOTE 1 Check that the locknut is seated against I 1 the rod s bottom thread I Align the spring with the upper joint by loosening the holder nuts while releasing the compressor SHOCK ABSORBER INSTALLATION Lift the rear wheel and install the left absorber lower bolt with the right absorber removed TORQUE SPECIFICATION 3 0 4 0 kg m 22 29 ft lbs LOCKING j AGENT REAR SHOCK ABSORBER ...

Page 190: ...se excessively Set up a dial indicator on the ring gear teeth Install the preload inspection tool PIN 07998 4150000 to hold the pinion gear se curely Hold the pinion gear spline securely rotate the ring gear until gear slack is taken up Turn the ring gear back and forth to read backlash Measure 3 5 splines SERVICE LIMIT 0 25 m m 0 0098 in NOTE Ring gear control spacers are available in increments ...

Page 191: ...ove the eight left gear case cover bolts and left gear case cover with the ring gear and Separate the left case cover from the ring gear and bearing the ring gear and bearing tap it lightly with a soft hammer Avoid damaging the cover and bearing FINA GUARD bearing Remove the ring gear spacer from the case L RETAIN ocn 1 37 1OOOC ANDLE RlNG GI E F I GEAR CASE COVER Date of Issue January 1978 OHONDA...

Page 192: ...nstall a new O ring RING GEAR BEARING REPLACEMENT Inspect the bearing for smooth operation by t 1 spinning it by hand DISIASSEMBLY TOOC k 07965 41 50 Replace the bearing if it is noisy or has excessive play Install the ring gear bearing on the ring gear NOTE Drive the bearing in until it seats proper ly u a i A a a t v a I UUL A 07965 4150200 DISIASSEMBLY TC 37 10300 IOL C Date of Issue January 19...

Page 193: ...seal if the lip is damaged or if the spring band is distorted If replacement is necessary it is necessary to remove the ring gear bearing NOTE Drive the oil seal in squarely HANDLE TER 42 x 6 RlNG GEAR BEARING REPLACE MENT GEAR CASE SIDE BEARING DRIVER Inspect the bearing for smooth operation spin ning it by hand Replace the bearing with a new one if it is noisy or has excessive play NOTE RING DRl...

Page 194: ...her WASHER Remove the bearing retainer B in BEARING RETAINER B OIL SEAL O RING REPLACEMENT Inspect the bearing retainer B oil seal Replace the oil seal if the lip is worn or damaged or if the spring band is distorted Replace the O ring with a new one q r EAL HMENT 14 16 Date of Issue January 1978 OHONDA MOTOR CO LTD I ...

Page 195: ...er B rAlNER B WRENCH 17910 41 50000 Inspectthe pinion preload Run a string through a bolt hole in the pinion the groove i gear holder and wind it around the outside of Attach a spring scale to the string and measure the force needed to turn the holder a t one revo lution per second NOTE I Toraue reguired to begin pinion move I PINION PRELOAD 800 1 000g 1 76 2 2 Ibs 4 0 5 0 kg cm 3 48 4 32 in lbs I...

Page 196: ...e proper type lock tab RING GEAR INSTALLATION Clean all sealing material off the mating sur faces of the gear case and cover case Do not damage the mating faces of the Clean the cover mating surface of the gear case with an oil stone Apply liquid sealant to the mating surfaces of the gear case and cover Date of Issue January 1978 OHONDA MOTOR CO LTD ...

Page 197: ...specified tension in a cross pattern in two or more Steps TORQUE SPECIFICATION 8 mm bolt 2 3 2 8 kg m 17 20 ft lbs 10 mm bolt 3 5 4 5 kg m 25 33 ft lbs nm BOLT 1 1 Install the preload retainer A with the oil seal and O ring assembled in the retainer Before the retainer bottoms against the bearing measure the torque T to overcome the friction caused by the O ring Tighten the retainer to T t 4 0 kg ...

Page 198: ... the preload GEAR TOOTH CONTACT PATTERNCHECK Remove the oil filler cap from the final gear case Check the gear tooth contact pattern by rotat ing the ring gear several times in the normal direction of rotation The gear tooth contact pattern is indicated by Prussian Blue applied to the pinion before assembly Contact is normal if the Prussian Blue is transferred to the approximate center of each too...

Page 199: ...bs FINAL GEAR CASE INSTALLATION Lubricate the splines of the propeller shaft and pinion gear shaft with lithium based multi purposegrease and engage Temporarily install the gear case on the swing arm and rear shock absorber Apply lithium based multipurpose grease to the splinesof the rear wheel and ring gear shaft Insert the distance collar into the ring gear shaft in the direction shown Date of I...

Page 200: ...3 0 4 0 kg m 22 29 ft lbs Install the rear wheel Page 14 81 PINION GEAR LUBRICATION Pump lithium based multipurpose grease through the grease fitting GREASE QUANTITY 45 cc approx I kg m FILLING FINAL GEAR CASE Placethe motorcycle on its center stand Make sure that the drain bolt is tightened Remove the oil filler cap Pour the specified amount of recommended oil up to the filler neck RECOMMENDED OI...

Page 201: ...ller shaft joint bolt Remove the propeller shaft from the engine Remove the left shock absorber p z z q I Pump grease into the final gear case 1 through the grease nipple whenever the propeller shaft is removed from the en pine Remove the swing arm pivot bolt from the left Free the drain tube etc from the clamps Remove the right pivot Remove the swing arm and propeller shaft Date of Issue January ...

Page 202: ...ite direc tions If there is anv evidence of side l a v the shaft must be replaced IIV I and Drive out the spring pin Separate the drive shaft joint from the drive shaft LITHIUM BASED MULTIPURPOSE GREASE Inspect the drive shaft and drive shaft joint splines for wear and damage Lubricate the splines with lithium based multi purpose grease Assemble the drive shaft and drive shaft and drive in the spr...

Page 203: ...le to tilt when removingthe bearing outer Remove the remaining sealing plate and metal saw dust PIVOT BEARING OUTER REMOVER Install a new sealing plate g y X 8 r x ICAUTION Date of Issue January 1978 OHONDA MOTOR CO LTD L Install a new bear ng outer MECHANICAL SEAL U K l v t a p i i q ATTACHMENT Install the plate with the dished end fac ing up Install the bearingouter squarely n7345 4150 nn ...

Page 204: ...e it with a new one NOTE ICAL b t A L ATTACHMENT 41 50200 The bearing inner and outer must be replacedas a set Install the bearing holder so that the flange is seated against the frame body Pack all bearing cavities with grease apply grease to the oil seal lip Install the bearing and oil seal in the bearing holder Date of Issue January 1978 OHONDA MOTOR CO LTD Drive the bearing outer into the bear...

Page 205: ...rom the inside Install the right pivot in the bearing inner Install the brake torque link on the swing arm Insert the propeller shaft through the swing arm and install the boot NOTE Make sure that the right pivot oil seal is installed properly 1 5 2 3 kgm 11 17 ft lbs Date of Issue January 1978 OHONDA MOTOR CO LTD 14 27 ...

Page 206: ...ivot bearing Tighten the pivot bolt gradually NOTE Make sure that the end of the pivot bolt is inserted into the bearing inner Torque the swing arm pivot bolt TORQUE SPECIFICATION 0 8 1 2 kg m 6 9 ft lbs Tighten the lock nut TORQUE SPECIFICATION 8 0 12 0 kg m 58 87 ft lbs y l ue January 1978 OHONDA MOTOR CO LTD ...

Page 207: ...bsorber Lubricate the final shaft spline with lithium based multipurpose grease C c ck tho1 the final shaft does not appear rnore rhan 10 mm L Install the final drive gear case Page 14 21 Install the rear wheel Paae 14 8 p z q rivecase pump IAfter installinp the final a kg m 45 cc of lithium based multipurpose grease through the grease fitting Date of Issue January 1978 OHONDA MOTOR CO LTD ...

Page 208: ...HONDA HYDRAULIC DISC BRAKE CX500 2 5 3 5 kg m Date of Issue January 1978 OHONDA MOTOR CO LTD ...

Page 209: ... Pads fouled or glazed 4 Hydraulic system leaking SERVICE LIMIT 6 0 mm 0 24 in 0 3 mm 0 012 in 14 055 mm 0 5533 in 13 940 mm 0 5488 in 42 765 mm 1 6837 in 42 915 rnrn 1 6896 in Date of Issue January 1978 OHONDA MOTOR CO LTD STANDARDS 6 8 7 2 mm 0 27 0 28 in 14 000 14 043 mm 0 5512 0 5529 in 13 957 13 984 mm 0 5495 0 5506 in 42 772 42 822 mm 1 6839 1 6859 in 42 850 42 900 mm 1 6870 1 6890 in Disc t...

Page 210: ...h the arrow Q in the normal direc tion of disc rotation BRAKE PADSIDISC PLATE BRAKE PAD WEAR CHECK The front brake pads require replacement if the red line on the top of the pads reaches the edges of the brake disc BRAKE PAD REPLACEMENT Remove the two brake caliper bolts and remove the caliper 15 2 Date of Issue January 1978 OHONDA MOTOR CO LTD 1 ...

Page 211: ...ston boot for damage or brittle ness Insert the pin through the caliper bracket with the chamferred end facing as shown Inspect the condition of the dust covers Reinstall the brake caliper NOTE Tighten the bolts noting the mating faces i of the caliper and pin P c BRAKE DlSC THICKNESS Measure the brake disc thickness SERVICE LIMIT 6 0 mm 0 24 in Date of Issue January 1978 OHONDA MOTOR CO LTD ...

Page 212: ...he brake lever from the master cylin der Disconnect the brake hose 1CAUTION I IAvoid spilling brake fluid on painted sur I faces Place a rag over the fuel tank and instru ment whenever the brake system is serviced Remove the master cylinder Remove the snap ring Clean the interior of the master cylinder and reservoir with brake fluid SNAP RING PLIER 07914 3230001 15 4 Date of Issue January 1978 OHO...

Page 213: ...0 mm 0 5488 in MASTER CYLINDER ASSEMBLY JCAUTlON I Replace the master cylinder piston cylinder and spring as a set DIAPHRAGM MASTER CYLINDER BRAKE FLUID DOT 3 a Dip the piston cup in brake fluid or coat with silicon grease before assembly Install the master cylinder on the handlebar FRONT BRAKE STOPLIGHT Page 13 41 SWITCH Connect the brake hose and install the brake lever Bleed the front brake sys...

Page 214: ...ake caliper attaching bolts CALIPER DISASSEMBLY Remove the clip and piston boot from the caliper piston PIS TON BOO Place a shop towel or rag over the piston to pre pf B vent the piston from coming out and position a 2 the caliper with the piston down Apply a small amount of air pressure to the fluid inlet mm I Do NOI rr e h i h oressure air or brim the I PISTON I r u nozzle too close to the inlet...

Page 215: ...isassembled CALIPER CYLINDER I D INSPECTION Check the caliper cylinder for scoring scratches or other damage Measure the caliper cylinder bore I D SERVICE LIMIT 42 915 rnrn 1 6896 in CALIPER PISTON O D INSPECTION Check the piston for scoring scratches or other damage Measure the caliper piston diameter SERVICE LIMIT 42 765 mm 1 6837 in Dateof Issue January 1978 OHONDA MOTOR CO LTD 15 7 ...

Page 216: ...fluid Coat the O rings with silicon grease or brake fluid and install the piston with the dished end facing the brake pad Install the piston boot and clip on the piston PAD l NOTE Remove the pins and dust covers from the caliper bracket Make sure they are in good condition Make sure that the clip is installed securely DUST COVERS PINS Date of Issue January 1978 OHONDA MOTOR CO LTD Install the pad ...

Page 217: ...s in the caliper bracket NOTE b Make sure the dust covers are seated properly f v t a B R A K E CALIPER I N S T A L L A T I O N Connect the brake hose to the brake caliper and install the bleeder screw install the brake caliper NOTE Tighten the shafts carefully aligning the mating faces of the calipers Bleed the brake system Page 3 10 L b L Date of Issue January 1978 OHONDA MOTOR CO LTD 15 9 ...

Page 218: ...HONDA CX500 MEMO Date of Issue January 1978 OHONDA MOTOR CO LTD ...

Page 219: ...n an emergency slow charging is preferred Remove the battery from the motorcycle for charging Keep fire or sparks away from a charging battery because it produces hydrogen All charging system components can be tested on the motorcycle SPECIFICATIONS Date of Issue January 1981 oHONDA MOTOR CO LTD 16 1 12V 14 amperehours 1 28120 6 8 1 4 amperes maxlmum High beam 5 amperes minimum 5 000 rpm 114 5 vol...

Page 220: ...arging system failure 2 Loose battery connection Low Power Engine Running 1 Battery undercharged Low battery electrolyte level One or more dead cells 2 Charging system failure Intermittent Power 1 Loose battery connection 2 Loose charging system connection 3 Loose starting system connection 4 Loose connection or short circuit in igni tion system 5 Loose connection or short circuit in light ing sys...

Page 221: ...Botect your eyes skin and clothing In case of contact flush thoroughly with wter and call a doctor if your L E O L Y T E Specific gravity changes by 0 007 for every 1 0 The battery must be recharged if the specific gravity is below 1 23 The specific gravity varies with the temperature as shown in the accom panying table Replace the battery if sulfation is evident The battery must be replaced if pa...

Page 222: ...installing the battery apply an anti corrosive coating to the terminals piEq BATTERY BREATHER Route the breather tube as shown on the battery caution label SUB TANK CHARGING SYSTEM s CHARGING OUTPUT TEST Warm up the engine before taking readings Disconnect the black lead from the regulator1 rectifier to bypass the voltage regulator Connect a voltmeter and ammeter NOTE ruse a fully charged battery ...

Page 223: ...ge8 3 VOLTAGE REGULATOR1 RECTIFIER TEST Check the resistances between the leads with an ohmmeter GREE I hti lf a r ir sululionresistance tester since it may damage the rectifier and give you a shock b L YELLOW Q probe 0 probe GREEN REDIWHITE YELLOW NORMAL DIRECTION CONTINUITY REVERSE DIRECTION NO CONTINUITY REDIWHITE Q probe 0 probe YELLOW YELLOW REDWHITE The test results shown are for a positive ...

Page 224: ... V BLACK F b Testing with a variable resistor Connect a variable resistor 0 100 52 across the battery with a 50 resistance Check for continuity between green and each of three yellow terminals Test lamp must come on when voltage reads 14 to 15 V on the voltmeter by adjusting the variable resistor NECTED IN SERIES YELLOW GREEN A C GENERATOR REMOVAL INSTALLATION Removal and installation procedure Se...

Page 225: ... I Capacitive Discharge Ignition unit is non adjustable If ignition timing is incorrect check the C D I unit and AC generator and replace any defective part Date of Issue November 1980 o HONDA MOTOR CO LTD 17 1 SPECIFICATIONS X24ES U I 0 6 0 7 mm 0 024 0 028 in 15 37O 1 750 2 250 rpm 5 500 6 000 rpm 6 mm 0 24 in minimum Spark plug Spark plug gap Ignition timing Ignition coil Initial Full advance E...

Page 226: ...nit and engine stop switch Between C D I unit and ignition coil Between C D I unit and ignition switch Between ignition coil and plug 3 Faulty ignition switch 4 Faulty ignition coil 5 C D I Unit faulty 6 Faulty A C generator EngineStarts but Runs Poorly 1 lgnition primary circuit Faulty ignition coil Loose or bare wire Intermittent short circuit in a switch 2 Secondary circuit Faulty plug Faulty h...

Page 227: ...LIINSTALLATION Removethe fuel tank Disconnect the wire leads Remove the coil by removing the attaching bolts NOTE Connect the right and left cables pro perly PERFORMANCE TEST Perform a 3 point spark test with a coil tester Date of Issue January 1978 OHoNDA MOTOR CO LTD 17 3 SERVICE LIMIT 6 m m 10 24 in M NOTE SECONDARY Follow the instructions supplied with the ELECTRODE L coil tester SPARK THIRD E...

Page 228: ...pacitor before testing Needle swinging and going back to m in the table indicates that a capac itor is being charged with the tester The tester needle will stay at infinity in subsequent tests unless the capac itor is discharged Y 1 B m e r B K UPPER ROW MEASURING RANGE SANWA TESTER x k n LOWER ROW MEASURING RANGE KOWA TESTER 10012 The resistances shown in the table indicate those to be read on th...

Page 229: ... terminals WHITE BLUE GREEN WHITE 387 473 Ohms ORANGE GREEN LIGHT BLUE GREEN ORANGEIRED GREEN LIGHT BLUEIRED GREEN 81 99 Ohms NOTE TESTER MEASURING RANGE x i o n Use the HONDA SERVICE TESTER 07308 0020000 to perform this test The specifications in parentheses are applicable to the A C generator used on the following models CX500 E No CX500E 2049947 E No CX500E 2200013 CX500C E No PC01E 2002941 E N...

Page 230: ...gnition timing is incorrect check the 1 I r Remove the timing hole inspection cap from the engine case rear cover Connect a stroboscopic timing light to the right ADVANCE MAR cylinder Connect a tachometer Check that the flywheel FR mark and pulser index mark align at idle Check that the index mark is between the advance marks at 5 500 6 000 rpm Repeat for the left cylinder using the FLU reference ...

Page 231: ...ON WORKING PRACTICE The starter motor can be removed with the engine in the frame Starter clutch repairs Page 8 3 STARTER MOTOR SPECIFICATIONS SWITCH MAIN SWITCH SERVICE LIMIT 400 g 5 5 mm 0 21 in NEUTRAL FIELD MAGNET LAMP STANDARD 0 495 0 605 kg 11 0 12 5 mm 0 43 0 49 in Starter motor 1I BATTERY Brush spring tension Brush length Date of Issue January 1978 OHONDA MOTOR CO LTD 18 1 ...

Page 232: ...e open 8 Faulty clutch switch Starter Motor Turns Engine Slowly 1 Low battery 2 Excessiveresistance in circuit 3 Binding in starter motor Starter MotorTurns But Engine Does NotTurn 1 Faulty starter clutch 2 Faulty starter motor gears 3 Faulty starter motor or idle gear Starter Motor and Engine Turn But Engine Does Not Start 1 Faulty ignition system 2 Engine problems 3 Faulty engine stop switch Dat...

Page 233: ...RVICE LIMITS Brush length 5 5 mm 0 21 in Brush spring tension 400 g BOLTS Remove the starter mountingbolts and pull the motor out of the engine case Disconnect the starter cable L BRUSH INSPECTION 7 9 COMMUTATOR INSPECTION Remove the case NOTE Record the location and number of the thrust washers Inspect the commutator bars for discolora tion Bars discolored in pairs indicate grounded L armature co...

Page 234: ...ace the starter motor if the field coil is not continuous or if it is shorted to the motor case TERMINI COMMUTATOR CONTINUITY Fuur v m COMM ARMA N B eg c 7 CABLE 1 CABLE 1 UTATOR TURE SHI LJTINU Tz BARS I U U L U I U I l l U U l I Y IUIJHMAI ERMINAL LUNTlNUlTY NO BRUSH V RMAL CASE 2 MOTOR Ckot BRUSH WIRE ASSEMBLYIINSTALLATION Assemble the starter motor NOTE Align the punch mark on the case to the ...

Page 235: ...V battery to the switch cable terminals The switch is normal if there is continuity L DIODE INSPECTION Remove the fuse cover Connect an ohmmeter to the diode leads r I i NORMAL DIRECTION CONTINUITY probe Light greenlRed Oprobe GreenlRed 1 u REVFRSE DIRECTION NO CONTINUITY probe GreenIRed Qprobe Light greenlRed I NEUTRAL SWITCH INSPECTION Page 8 31 STARTER CLUTCH R E M O V A L Page 8 51 Date of Iss...

Page 236: ...HONDA TECHNICAL FEATURES CX500 WATER COOLED V TWIN ENGINE 4 valves per cylinder 80 degree water cooled engine rt stroke Drive shaft 1 Flywheel 19 0 Date of Issue January 1978 OHONDA MOTOR CO LTD I ...

Page 237: ...es the coolant to circulate only in the engine water jackets Only a small amount of coolant is returned through the by pass hose into the radiator causing the engine to warm up quickly As the coolant warms the bellow expands and the valve opens This allows the coolant to flow to the radiator where it is maintained at the desired operating temperature The radiator cap incorporates two valves the re...

Page 238: ...e silent chain drives the camshaft The rocker arm wave washers contribute to smooth quiet operation Four valves per cylinder high compression ratio short stroke crankshaft and other unique design features enable the CX500 to out perform other motorcycles of comparable size THRUST WASHER UPPER RC CKER ARM VALVE TWISTED CYLINDER HEAD The cylinder heads are twisted at 44 to each other This provides f...

Page 239: ...ar when the rear wheel moves up and down The final gear case is filled with hypoid gear oil and is equipped with a breather The pinion gear bearingretainer is packed with special grease L TUBELESS TIRE The front and rear wheels incorporate a tubeless tire It will carry nails and other puncturing objects for a considerable mileage without sudden puncture or blowout thus providing added safety Since...

Page 240: ...coil and charging coil are inside the stator FEATURES There are no contact points to require attention C D I can develop more voltage potential at the spark plugs than conventional systems and is more resistant to spark plug fouling Working on AC the secondary voltage is more stable regardlessof battery condition The timing advance will not be subject to errors and is virtually free from wear The ...

Page 241: ... pulser when the pick up reachesthe point where ignition must start This is due to changes in the flux The pulse is rectified by diode D2 and is applied to SCR L gate As this happens SCR L turns ON which in turn discharges the energy stored in the condenser through the primary coil Sufficient potential is then developed at the spark plug to ignite the air fuel mixture in the combustion chamber Sam...

Page 242: ...maximum advance is reached This limits timing advance ADVANCER OPERATION In C D I ignition timing advance depends on the build up time of voltage on the advance pulser which becomes faster as engine speed increases The SCR L acts like a switching device but there is a definite voltage at which it triggers The overall operation of the C D I system stems from these two facts The faster the voltage b...

Page 243: ...XED PULSER THROUGH D2 SIGNAL FROM FIXED PULSER THROUGH D3 PULSER WAVE FORMS DURING TIMING ADVANCE M SIGNAL FROM ADVANCE PULSER PULSER WAVE FORMS AT END OF ADVANCE With further increases in engine speed a transition The negative pulse from the fixed pulser balances the occurs in the wave form such as from A to B That is positive pulse from the advance pulser causing the SCR is triggered sooner to a...

Page 244: ...HONDA CXSOO MEMO Date of Issue January 1978 OHONDA MOTOR CO LTD ...

Page 245: ... 1 tension cord 5 Faulty A C generator 6 Broken or shorted ignition coil I Valve clearance too small I L141 lmoro er ignition timinq 1Test cylinder compression 7 Faulty main switch L J I Choke excessively open I Remove spark plugs I C O I unit or A C gene C J rator at fault Wet 1 Carburetor flooded C 2 1 Carburetor choke excessively 2 Valve stuck open 3 Worn cylinder and piston rings 4 Damaged cyl...

Page 246: ...lty A C generator I Check valve clearance I C 2 1 lmproper valve adjust 6 I ment 2 Worn valve seat Valve clearance is normal not correct uslng compression gauge T l 4 1 Valvestuckopen 2 Worn cylinder andlor Compression is low piston rings I 3 Leaking head gasket 1 4 4 lmproper valve timing Jchi k b G igi I n g I L 2 Carburetor is not clogged Carburetor is clogged 1 I Carburetor not serviced I 4 r ...

Page 247: ...se of improper quality of fuel 4 3 1 Clutch slipping 4 4 Fuel air mixture too lean 4 5 Insufficient coolant in radiator 6 Faulty thermostat 47 Clogged radiator fins a Clogged or restricted water jackets I Engine is not overheated r e o n a h i g 1 L L A 1 Faulty carbon or Weak or intermittent wet fouled spark plug soark 21 Faultv C D I unit I Liai A C denerator faulty I speed 1 L 1 1 4 lgnitibn co...

Page 248: ... I buretor I1 Lackof fuel in fuel tank DOOR HANDLING SYMPTOM PROBABLE CAUSE Both tire pressuresnormal Steering heavy 11 Steering cone racestoo tight 2 Damaged steering cones or steel balls 121 Clogged fuel line 3 Clogged fuel tank cap breather hole Fuel flows out freely Either wheel is 1 Excessivewheel bearing play wobbling 21 Distorted rim 31 Improperly installed wheel hub 4 Swing arm pivot bushi...

Page 249: ...orn rocker armslcamshaft 4 Bent push rods 1 Worn piston and cylinder 2 Worn piston pin and rod small end 3 Excessive carbon build up in combustion chamber If cam chain is noisy 1 Improper cam chain tension 2 Worn cam sprocket teeth 3 Worn camshaft bearing 4 Worn cam chain If clutch rattles or chatters 1 Excessivebacklash betweencluth outer and clutch plate 4 2 Excessive backlash betweenclutch cent...

Page 250: ......

Page 251: ...D RESERVES THE RIGHT TO MAKE CHANGES AT ANY TlME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHAT EVER NO PART OF THIS PUBLICATION MAY BE REPRO DUCED WITHOUT WRITTEN PERMISSION HONDA MOTOR CO LTD Service Publications Office TABLE OF CONTENTS 1 GENERAL INFORMATION 21 2 TORQUE VALUES 21 2 MAINTENANCE SCHEDULE 21 3 CABLE HARNESS ROUTING 21 4 2 INSPECTION AND ADJUSTMENT 21 5 BRAKE FLUID LEVEL ...

Page 252: ...6 40 11 13 58 72 58 72 58 69 13 18 14 18 58 72 12 14 7 10 1 1 2 2 Q ty Torque specifications listed above are for the most important tightening points If a torque specification is not listed follow the standards given below STANDARD TORQUE VALUES Thread Dia mml 24 7 6 8 8 14 8 10 12 10 8 10 10 23 8 10 23 10 Date of Issue Aug 1978 OHONDA MOTOR CO LTD Torque Values Item 5 mm bolt and nut 6 mm bolt a...

Page 253: ...ONOA DEALER UNLESSTHE OWNER HAS PROPER TOOLS AND SERVICE DATA AND IS MECHANICALLY OUALIFIED IN THE INTEREST OF SAFETY WE RECOMMED THESE INTEMS BE SERVICED ONLY BY AN AUTHORIZED HONOA DEALER NOTE 11 Service more frequently when riding in rain or at full throttle or after being washed or overturned 2 Service more frequently when riding in dusty areas 13 For higher odometer readings repeat at the fre...

Page 254: ...LE HARNESS ROUTING CLUTCH C A B L E L D 1 FRONT BRAKE HOSE CHOKE CABLE THROTTLE CABLES SPEEDOMETER CABLE CHOKE CABLE FRONT BRAKE HOSE THROTTLE CABLE RONT BRAKE HOSE EEDOMETER CABLE 21 4 Date of Issue Aug 1978 OHONDA MOTOR CO LTD ...

Page 255: ...TION AND ADJUSTMEN BRAKE FLUID LEVEL Check that the front brake fluid reservoir is filled to the upper level mark If the level is lower than the upper mark fill the reservoir with DOT 3 BRAKE FLUID up L to the upper level mark Check the entire system for leaks if the level is low handlebar has been turned full left so that the reservoir is level Avoid operating the brake lever with the cap removed...

Page 256: ...ront brake system Pump up the system pressure with the lever until there are no air bubbles in the fluid flowing out of the reservoir small hole and lever resistanceis felt AIR BLEEDING Pull the brake lever all the way back to the handlebar grip Open the bleeder valve about 112turn and close NOTE Do not release the lever until the bleeder valve has been closed Release the lever gradually and wait ...

Page 257: ...HONDA cxsoo 79 ADDENDUM 3 FRONT WHEEL SUSPENSION n Date of Issue Aug 1978 OHONDA MOTOR CO LTD 21 7 ...

Page 258: ...on O D Caliper cylinder I D Poor Brake Performance 1 Air bubbles in hydraulic system 2 Worn brake pads 3 Pads fouled or glazed 4 Hydraulic system leaking 21 8 Date of Issue Aug 1978 OHONDA MOTOR CO LTD STANDARDS 6 8 7 2 mm 0 27 0 28 in 14 000 14 043 mm 0 5512 0 5529 in 13 957 13 984 mm 0 5495 0 5506 in 42 772 42 822 mm 1 6839 1 6859 in 42 850 42 900 mm 1 6870 1 6890 in SERVICE LIMIT 6 0 mm 0 24 in...

Page 259: ... fuel tank whenever the brake system is serviced NOTE I Cover the end of the hose to prevent I contamination I Removethe master cylinder Removethe snap ring Clean the interior of the master cylinder and reservoir with brake fluid x 1 9 SNAP RING PL MASTER CYLINDER 1 D INSPECTION Measure the master cylinder I D Check the master cylinder for scores scratches or nicks SERVICE LIMIT 14 055 mm 0 5533 i...

Page 260: ...fore assembly Insert the spring into the master cylinder Dip the piston cup in brake fluid before assembly the lips to turn inside out Be certain the circlio is seated firrnlv in the eroove Install the boot washer and clip Install the reservoir on the master cylinder making sure that the O ring is in good condition PRIMARY CUP C MASTER CYLINDER PISTON SILICON GREASE OR BRAKE FUllD DOT 3 I 0 FRONTB...

Page 261: ...ILABLE AT THE TlME OF APPROVAL FOR PRINTING HONDA MOTOR CO LTD RESERVES THE RIGHT TO MAKE CHANGES AT ANY TlME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATIONWHATEVER NO PART OF THIS PUBLICATION MAY BE REPRO DUCED WITHOUT WRITTEN PERMISSION HONDA MOTOR CO LTD Service PublicationsOffice TABLE OF CONTENTS MODEL IDENTIFICATION 22 2 SPECIFICATIONS 22 3 WIRING DIAGRAM 22 5 CABLE HARNESS ROUTING 22 6...

Page 262: ...HONDA 79 DELUXE AND CUSTOMADDENDUM CXSOQ MODEL IDENTIFICATION DELUXE CUSTOM 22 2 Date of Issue January 1979 O HONDA MOTOR CO LTD I ...

Page 263: ...Compression ratio Valve train Oil capacity Lubrication system Cooling system capacity Air filtration Cylinder compression Intake valve Opens Closes Exhaust valve Opens Closes Valve clearance Front Rear Front Rear cold tire Pressures Internal expanding shoes 201 cm2 31 2 sq in 63 15 105 mm 4 1 in 135 cc 4 6 ozs After assembly Engine weight Idle speed Front brake lining swept area Up to 90 kg 200 Ib...

Page 264: ...tor light High beam indicator light Running light I 1 I See page 4 10 1 15 5 mm 0 61 in I Wet multi plate 5 speed constant mesh 2 242 2 733 1 850 1 416 1 148 0 931 3 091 11134 Left foot o erated return svstem 1 N 2 3 4 5 CDI 15 BTDC 37 i 3 BTOC 1 750 6 000 rpm Starting motor only Three phase A C generator 170w 5 000 rpm 12V 14AH USA model 1 ND NGK ND I NGK ND NGK I For cold climate below 5 C 41 F ...

Page 265: ...AND CUSTOMADDENDUI WIRING DIAGRAM CX500 DELUXE AND CUSTOM ER LIGHT 1 3 IW 11 I L METER L FRONT TURN SIGNALqRUNNINGLIGHT 12V3213cp 231BW GIB L B LGIR nlD I URE SWITCH2 NEUTRAL Date of Issue January 1979 O HONDA MOTOR CO LTD ...

Page 266: ... ELUXEAND CUSTOM ADDENDUM MAGNET SWIT J BATTERY I 4AH WITCH CONTINUITY Brown y Yc law Black B Blue W White GI Grey LG Lighl Green L B Lighl Blue R Red 0 Orange Green p pink ...

Page 267: ...UXE AND CUSTOM ADDENDU CABLE HARNESS ROUTING DELUXE CLUTCH CABLE BLES I LEFT HANDLEBAR RIGHT HANDLEBAh SWITCH WIRE HARNESS SWITCH WIRE HARNESS vy WlRE CLAMPS HOS SPEED CABLE I WlRE HARl GROUND CABLE WlRE BANDS ...

Page 268: ...f AND CUSTOM ADDENDUM HONDA CX500 SPEED OI CABLE HARN WIRE BANDS Date of Issue January 1981 O HONDA MOTOR CO LTD ...

Page 269: ... 79 DELUXE AND CUSTOM ADDENDUM CUSTOM HARNESS CLAMPS Date of Issue January 1979 o HONDA MOTOR CO LTD 22 7 ...

Page 270: ... 79 DELUXE AND CUSTOM ADDENDUM EA 22 8 Date of Issue January 1979 O HONDA MOTOR CO LTD ...

Page 271: ... covers Remove the radiator grill mounting screws CUSTOM SEAT AND FUEL TANK REMOVAL Remove seat the two seat mounting bolts and the Turn the fuel valve OFF and disconnect the fuel line at the fuel valve Remove the three fuel tank mounting bolts and the fuel tank Date of Issue January 1979 oHONDA MOTOR CO LTD 22 9 ...

Page 272: ...BLY Remove the retaining screws and horizontal adjusting screw from the rim Remove the two headlight unit retaining screws and headlight unit Assembly is the reverse of disassembly HEADLIGHT CASE INSTALLATION Align the punch marks on the headlight case and bracket Connect all wires at their couplers and connec tors NOTE Check each component for operation after assemblina Date of Issue January 1979...

Page 273: ...e right side of the rider NOTE Adjust the headlight beam asspecified by local and state laws ADJC SCRE An bnproperly adjusted headlight m y blind oncoming drivers or it may fail to light the road for a safe distance INSTRUMENTS INDICATOR BULB REPLACEMENT Remove the indicator light panel screws and panel Replace the bulb If the replacement bulb does not light check for loose connections a short or ...

Page 274: ...NT REMOVAL Remove the headlight Disconnect the instrument wire connectors and coupler Remove the speedometer and tachometer cables from the instruments Remove the instrument mounting bolts and instruments Date of Issue January 1979 O HONDA MOTOR CO LTD ...

Page 275: ...g bolts Remove the upper and lower shock absorber mountingbolts and nuts Remove the shock absorbers INSTALLATION Tighten the shock absorber bolts and nuts TORQUE 3 0 4 0 kg m 22 29 ft lb Installthe mufflers Adjust the right and left shock absorbers equally with a spanner wrench Check the shock absorber operation after instal lation GRAB D A l l Date of Issue January 1979 oHONDA MOTOR CO LTD 22 13 ...

Page 276: ... then reconnecting the Black1 Brown wire to positive terminal the test lamp does not go on Disconnect GreenIYellow wire from the Green wire The test lamp should go on Reconnect the GreenIYellow wire to the Green wire The test lamp should stay on Replace the unit if it does not pass the above test 2 Poor wire or socket connections 3 Open circuit Wire Harness 1 Poor wire connections 2 Open circuit 3...

Page 277: ...AND WITHOUT INCURRING ANY OBLIGATION WHATEVER NO PART OF THIS PUBLICATION MAY BE REPRO DUCED WITHOUT WRITTEN PERMISSION HONDA MOTOR CO LTD Service Publications Office 1 GENERAL INFORMATION 23 2 SPECIFICATIONS 23 2 MAINTENANCE SCHEDULE 23 4 CABLE HARNESS ROUTING 23 5 2 LUBRICATION 23 6 ENGINE OIL LUBRICATION 23 6 CABLE LUBRICATION 23 6 3 INSPECTION AND ADJUSTMENT 23 6 SPARK PLUG 23 6 4 FUELSYSTEM 2...

Page 278: ... 145 mm 5 7 in 202 kg 445 Ib Engine weight Idle speed 2 185 mm 86 0 in Front brake lining swept area Rear brake lining swept area Fuel capacity Up to 90 kg 200 Ibs load up to vehicle capacity load Liquid cooled 4 strokeOHV 2 cylinder transverse V 78 x 52 mm 3 07 x 2 04 in 496 cc 30 3 cu in 10 1 Silent chain driven camshaft and push rod 3 0 liters 3 2 US qt Forced pressure and wet sump 2 0 liters 0...

Page 279: ...lug gap Fuse Headlight highllow beam Taillstoplight Turn signal light fronthear Speedometer light Tachometer light Neutral indicator Turn signal indicator High beam indicator Running light CV 34 mm 1 3 in DR8ES 0 6 0 7 mm 0 024 0 028 in 20A main 10A sub 65 50W sealed beam 8 27W 3132 cp SAE NO 1157 23 23W 32132 cp SAE NO F 1034 R 1073 3 4W 2 cp SAE NO 57 3 4W 2 cp SAE NO 57 3 4W 2 cp SAE NO 57 3 4W...

Page 280: ... HONDA DEALER UNLESS THE OWNER HAS PROPER TOOLS AND SERVICE DATA AND IS MECHANICALLY QUALIFIED IN THE INTEREST OF SAFETY WE RECOMMEND THESE ITEMS BE SERVICED ONLY BY AN AUTHORIZED HONDA DEALER NOTE 1 Service more frequently when riding in dusty areas 2 Service more frequently when riding in rain or at full throttle or after being washed or overturned 3 For higher odometer readings repeat at the fr...

Page 281: ...HONDA CX500 80 ADDENDUM CABLE HARNESS ROUTING WIRE HARNESS I BATTERY NEGATIVE CABLE Date of Issue August 1979 OHONDA MOTOR CO LTD ...

Page 282: ...in your riding area is within the indicated range CABLE LUBRICATION Lubricate the clutch choke and throttle SPARK PLUG GAP 0 6 0 7 mm 0 024 0 028 in cables with a commercially available cable lubricant to prevent premature wear and corrosion 20 0 20 40 110 R O l0OoF 1 I 1 1 I 30 20 10 0 10 20 30 40 C With the plug Washers attached thread the new spark plugs in by hand to prevent crossthreading Tig...

Page 283: ...l Pilot screw Bore Main jet Removethe carburetors Page4 2 Separate the carburetors Page 4 3 noting that the accelerator pump joint pipe must be removed ASSEMBLY CX500 DELUXE VB28A 1 100i l00rpm 1 000 1 500 rpm 15 5 1 mm See page 23 9 34 mm Primary 78 Secondary I 15 Install a new O ring on each end of the accelerator pump and fuel joint pipes Assemble the right and left carburetors noting the compr...

Page 284: ...Be sure the accelerator rod is not bent 3 4 r r ACCELERATOR 4 PUMP COVER Assemble the accelerator pump in the reverse order of disassembly ACCELERATOR PUMP ADJUSTMENT Loosen the throttle stop screw so the throttle valve is closed Measure the clearance between the accelerator pump rod and the adjusting arm with the throttle valve closed CLEARANCE 0 1 0 3 mm 0 004 0 012 in Adjust by bendingthe adjus...

Page 285: ...ly count the number of turns before it seats lightly Make a note of this to use a s a reference when reinstallingthe pilot screws 1CAUTION 1 Damage to the pilot screw seat will occur if the pilot screw is tightened against the seat Remove the pilot screw Inspect the pilot screw for wear and replace if necessary Install the pilot screw and turn it to the original position as noted during removal Pe...

Page 286: ...ainst its stop preventing further adjust ment that would enrich the fuel mixture limiter cap position permits clockwise rota tion and prevents counterclockwise rotation NOTE installing the limiter caps Pilot screw limiter caps must be installed They prevent misadjust ment that could cause poor perfor mance and increase exhaust emis Date of Issue January 1981 O HONDA MOTOR CO LTD ...

Page 287: ... 80 ADDENDUM 5 WIRING DIAGRAM CX500 DELUXE FUSE 101 IHEAOLlGHTI STAR ENG FUSE P U T E Date of Issue August 1979 OHONDA MOTOR CO LTD ...

Page 288: ... 80 ADDENDUM B r Brwn Y Y s a B k Black B Blm W Whta Gr Gray LG L b l Grem L B L b lBlu R R d 0 0 rnge G Grwn P Rnk ...

Page 289: ...i23 BW TACHOMETER LIGHT R TURN SlWAL INDICATOR OIL PRESSURE INDICATOR LAMP I I I I I I I L FRONT TURN SIGNAL IIV32 3c lI3EN1 CLUTCH SIITCW TURN SIGNAL DIMMER HORN SWITCH IGNITION SWITCH CONTINUITY STARTER ENGINL STOP SWITCH CONTINUITY TURN SIGNAL OIMMER HORN SWITCH CONTINUITY ...

Page 290: ... 8 0 ADDENDUM n CONTINUITY I TURN SIGNAL SWITCH Date of Issue August 1979 OHONDA MOTOR CO LTD ...

Page 291: ...HONDA ADDENDUM ...

Page 292: ...KE CHANGES AT ANY TlME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATEVER NO PART OF THlS PUBLICATION MAY BE REPROD I UCED WITHOUT WRITTEN PERMISSION HONDA MOTOR CO LTD Service Publications Office TABLEOFCONTENTS 1 GENERAL INFORMATION 24 2 SPECIFICATIONS 24 2 MAINTENANCE SCHEDULE 24 4 CABLE HARNESS ROUTING 24 5 2 INSPECTION AND ADJUSTMENT 24 6 FUEL LlNE 24 6 CARBURETOR SYNCHRONIZATION 24...

Page 293: ...tio Valve train Oil capacity Front brake lining swept area Rear brake lining swept area Fuel capacity Lubrication system Cooling system capacity Air filtration Cylinder compression Intake valve Opens Closes Exhaust Opens Closes Valve clearance Front Rear Front Rear Engine weight Idle speed 2 0 kg cm2 28 psi 2 0 kg cm2 28 psi 2 0 kg cm2 28 psi 2 25 kg cm2 32 psi Liquid cooled 4 strokeOHV 2 cylinder...

Page 294: ...pm Startingmotor only Three phase A C generator 170W 5 000 rpm 12V 14AH Spark plug I I I Spark plug gap Fuse I I ND 1 NGK ND INGK 1 ND 1 NGK I USA model X22ES U D7EA X24ES U D8EA X27ES U D9EA For cold climate below 5 41DFI 0 6 0 7 mm 0 024 0 028 in 1 30A main 10 sub Standard Canadian model Headlight highllow beam Taillstoplight Turn signal light fronthear Speedometer light Tachometer light Neutral...

Page 295: ... HONDA DEALER UNLESS THE OWNER HAS PROPER TOOLS AND SERVICE DATA AND IS MECHANICALLY QUALIFIED IN THE INTEREST OF SAFETY WE RECOMMEND THESE ITEMS BE SERVICED ONLY BYAN AUTHORIZED HONDA DEALER NOTE 1 Service more frequently when riding in dusty areas 2 Service more frequently when riding in rain or at full throttle or after being washed or overturned 3 For higher odometer readings repeat at the fre...

Page 296: ...HONDA CX500 81 ADDENDUM CABLE AND HARNESS ROUTING Date of Issue January 1981 oHoNDA MOTORCO LTD 24 5 ...

Page 297: ... MUST BE WITHIN 40mm 1 6in Hg OF EACH OTHER ADJUSTMENT Stop the engine and remove the seat and fuel tank Prepare a longer fuel tube and connect it between the fuel tank and carburetor Position the tank higher than normal Start the engine and adjust the idle speed to 1 100 100 rpm Loosen the adjusting screw lock nut Balance the vacuum between cylinders to with in 40 mm 1 6 in Hg of each other by tu...

Page 298: ...erhauled TROUBLE SHOOTING Fuel Line Diaphragm Fuel not reaching carburetor 1 Fuel line diaphragm vent tube clogged L 2 Fuel line diaphragm vacuum tube clogged 3 Clogged fuel line diaphragm 4 Clogged fuel line diaphragm check valve SPECIFICATIONS I Canada Model Venturi diameter Idle speed Fast idle speed Float level Pilot screw opening Main jets I I Throttle grip free play CX5OO CUSTOM ITEM 34 mm 1...

Page 299: ...o ON If fuel comes out of the fuel line replace the fuel line diaphragm Connect a vacuum gauge to the diaphragm vacuum outlet Fuel should flow from the fuel line when 12 20 mm Hg 0 48 0 8 in Hg of vacuum is applied If flow is restricted replace the fuel line diaphragm INSTALLATION Installation of the fuel line diaphragm is the reverse order of removal NOTE vent tube connections are tight and not l...

Page 300: ...HONDA CX500 81 ADDENDUM Date of Issue January 1981 HONDA MOTOR CO LTD ...

Page 301: ...HONDA 81 ADDENDUM CX500 Date of Issue January 1981 HONDA MOTOR CO LTD ...

Page 302: ...1 Incorrect oil in front forks 2 Front fork air pressure incorrect STANDARD Fork spring free length Fork tube run out Fork fluid capacity Fork air pressure 5 5 6 5 kg m 40 47 ft lb 5 5 6 5 kg m 40 47 ft lb 1 8 2 5 kg m 13 18 ft lb 1 5 2 5 kg m 11 18 ft lb 0 9 1 3 kg m 7 9 ft lb 1 8 2 5 kg m 13 18ft lb 1 5 3 0 kg m 11 22 ft lb 0 6 0 9 kg m 4 7 ft lb 1 5 2 5 kg m 11 18 ft lb 1 5 2 0 kg m 11 14 ft lb...

Page 303: ...itting the brake INSTALLATION Install the front wheel by inserting the front axle through the right fork leg and wheel hub Screw the axle into the left fork leg NOTE Make sure the speedometer gearbox is perpendicular to the left fork leg Tighten the axle to the specified torque TORQUE 5 5 6 5 kg m 40 47 ft lb Install the axle holding bolt and tighten the nut to the specified torque TORQUE 1 5 2 5 ...

Page 304: ... fork and release the air in the fork tubes by pressing in on the valve stem Disconnect the air hose and remove the con nectors from the right and left forks 771e fork tube cans are under air and 1 spring pressure Front fork air pressure must be relieved and care used before removing the fork tube caps to prevent them from becoming projectiles Wear eye and face protection Date of Issue January 198...

Page 305: ...bolts and caliper Remove the front brake hose from the clip on the front fender Remove the front fender mounting bolts and fender Remove the front emblem by removing the mounting bolts Loosen the front fork tube pinch bolts F Pull each fork tube down and out while twisting them Date of Issue January 1981 O HONDA MOTOR CO LTD ...

Page 306: ...ork cap bolt should difficulty be en counterd in removing the socket bolt Date of Issue January 1981 O HONDA MOTOR CO LTD SHOP TOWEL OR SOFT JAWS HEX WRENCH 6 mm 07917 3230000 ALSO COMMERCIALLY AVAILABLE Remove the piston and rebound spring Remove the dust cover Remove the snapring and the back up plate Pull the fork tube out until resistance from the slider busing is felt SNAP HINCi Then move it ...

Page 307: ...HONDA 81 ADDENDUM CX500 CX500 DELUXE RIGHT FORK ASS Y LEFT FORK ASS Y CUSTOM CAP BOLT y DUSTCOVE SPRING B REBOUND 4 SPRING RIGHT FORKASS Y LEFTF O K ASS Y Date of Issue January 1981 O HONDA MOTOR CO LTD ...

Page 308: ... FORK TUBE O D SERVICE LIMIT DELUXE 32 90 mm 1 295 in CUSTOM 34 90 mm 1 374 in Check the back up ring at the points shown Replace if there is any distortion I BUSHING BUSHING COPPER SURFACES BUSHINGJBACK UP RING INSPECTION Visually inspect the slider and fork tube bush ings Replace if there is excessive scoring or scratches or if the teflon overlay is worn so that the copper surface appears on mor...

Page 309: ...0000 ALSO COMMERCIALLY AVAILABLE 1 I I Place the slider bushing over the fork tube and rest it on the slider Put the back up ring and on old bushing or equivalent tool on top of the bushing Drive the bushing into place with the seal driver PIN 07947 3290000 Remove the old bushing or equivalent tool Dip the new oil seal in ATF and install it over the fork tube with the marks facing up Drive the oil...

Page 310: ...e the spring direction NOTE Align the front fork alignment line with the top of the bridge Place the fork tube in a vise with a shop towel avoiding the sliding sur 0 Tighten the upper and lower fork pinch bolts TORQUE A1 GNMENT L UPPER 0 9 1 3 kgm 7 9ft lb i LOWER 1 8 2 5 kgm 13 18 ft lb Tighten the fork tube cap bolts TORQUE 1 5 3 0 kgm 11 22 ft lb Apply grease to the new O rings Place new O ring...

Page 311: ...o the recommendedair pressure AIR PRESSURE 0 7 1 1 kglcm2 10 16 psi CAUTION Use only a hand operated air pump to fillthefork tubes DO not usecompressed air Maximum pressure is 3 kg cmz 43 psi Do not exceed this or fork tube comuonent d a m e mav occur With the front brake applied pump the front forks up and d o w several times Place the i i I motorcycle on its center stand Check the air r 3 pressu...

Page 312: ...achometer cable nuts Remove the instrument cluster mounting bolts and the instrument cluster Remove the headlight case mounting headlightcase bolts and BOLT Remove the ignition switch mounting bolts and disconnect the ignition switch coupler Date of Issue January 1981 O HONDA MOTOR CO LTD ...

Page 313: ...ents Push the lugs from the slots and remove the se ASSEMBLY AND INSTALLATION Assembly and installation are the reverse order of disassembly and removal I When installing the headlight case align the punch marks on case with the punch j marks on the headlight case brackets i 1 ACKET Date of Issue January 1981 O HONDA MOTOR CO LTD ...

Page 314: ... TURN SIGNAL I1VII bllllY r LB W l LBt b I I L FRONT TURN SIWAL IIVI1IZI23 1Y TURN SIGNAL DIMMER HORN SWITCH SWITCH CONTINUITY IGNITION SWlTCii CONTlMllTY S1ARTER ENGINE STOP SWITCH CONTINUITY TURN SIGNAL DIMMER HORN SYlTCW CONTlNUlTY Date af Issue January 1981 O HONDA MOTOR CO LTD ...

Page 315: ... 81 ADDENDUM T BRAUE LIGHT SWIICY7 INUITY TURN SIGNAL SWITCH 1 Brown Y B11ii B WD8Ie Gr Lath Glen LB Lsghl Blur ...

Page 316: ...FRONT TURN SlGNhL 12V31 kpi23 1Wl R TURN SIGNAL INDICATOR OIL PRESSURE INDICATOR IGNITION COIL TURN SIGNIL DIMMER HORN SWITCH SWITCH CONTINUITY IGNITION SWITCH CONTINUITY STARTERaENGNE STOP SWITCH CONTINUITY TURN SIGNAL DIMMER HORN SWITCH CONTINUITY ...

Page 317: ...31 ADDENDUM HONDA cxsoo 101 IHEADLIGHll USE IOP IlAlLLiGHTl 1 FRONT BRAKE UGHT SWK4i7 I CONilNUlTY I TURN SIGNAL SWITCH I Date of Issue January 1981 HONDA MOTOR CO LTD ...

Page 318: ... INCURRING ANY OBLIGATION WHATEVER NO PART OF THlS PUBLICATION MAY BE REPRO DUCED WITHOUT WRITTEN PERMISSION HONDA MOTOR CO LTD Sewice Publications Office 1 GENERAL INFORMATION 25 2 SPECIFICATIONS 25 2 MAINTENANCE SCHEDULE 25 3 CABLE AND HARNESS ROUTING 25 4 2 LUBRICATION 25 5 3 INSPECTION AND ADJUSTMENT 25 5 FUEL VALVE STRAINER 25 5 BRAKE FLUID 25 6 BRAKE PAD WEAR 25 6 4 CARBURETOR 25 7 HIGH ALTI...

Page 319: ... l I 00 100 rpm 40 1 5 BTOC 2 780 rpm Three phase AC generator 252 Wl5 000 rpm DR8ES L NGK or X24ESR U ND DR8ES NGK or X27ESR U ND 3 4W 2 cp SAE No 158 3 4W 2 cp SAE No 158 3 4W 2 cp SAE No 158 3 4W 2 cp SAE No 158 3 4W 2 cp SAE No 158 ITEM DIMENSIONS FRAME DRIVE TRAIN ELECTRICAL LIGHTS Overall width Overall height Wheelbase Seat height Foot peq height Cold tire pressures Up to 90 kg 200 Ibs load ...

Page 320: ...DE STAND SUSPENSION z 0 z NUTS BOLTS FASTENERS WHEELS STEERING HEAD BEARING SHOULD BE SERVICED BY AN AUTHORIZED HONDA DEALER UNLESS THE OWNER HAS PROPER TOOLS ANDSERVICE DATA AND IS MECHANICALLY QUALIFIED REFER TO THE OFFICIAL HONDA SHOP MANUAL I N THE INTEREST OF SAFETY WE RECOMMEND THESE ITEMS BE SERVICED ONLY BY AN AUTHORIZED HONDA DEALER NOTE 1 Service more frequently when riding in dusty area...

Page 321: ...HONDA CX500 82 ADDENDUM CABLE AND HARNESS ROUTING FRONT FORK AIR HOSE FRONT BRAKE HOSE WlRE WlRE BANDS Date of Issue September 1981 American Honda Motor Co Inc 1981 All Rights Reserved ...

Page 322: ...container Wash the cup and filter screen in clean non flammable or high flash point solvent Reinstall the screen securely aligning the index marks on the fuel valve body and filter screen Install a new 0 ring Into the fuel valve body Re nstall the fuel cup making sure the new 0 ring is In place Hand tighten the fuel cup and then torque tto specification RECOMMENDED OIL VISCOSITIES 70 n 70 4n 811 1...

Page 323: ...reservoir is level Avoid operating the brake lever with the cap removed Brake fluid will squirt out if the lever ispulled Do not mix duerent types offluid as BRAKE PAD WEAR Check the brake pads for wear by looking through the slot indicated by the raised arrow cast on the caliper assembly Replace the brake pads if the wear line on the pads reaches the edge ofthe brake disc referto page 25 13 Alway...

Page 324: ...tude THROTTLE STOP operation 1 I Attach the Vehicle Emission Control Informa tion Update label as shown NOTE Instructionsfor obtaining Vehicle Emis sion Control Update labels are given in Service Newsletter No 132 Do not attach the label to any part that can be easilv removed from the vehicle Operation at an altitude lower than 5 000 feet 1 500 meters with the car buretors adjusted for high altitu...

Page 325: ...alled in the frame The swingarm must be removed first see page 14 23 Take care not to cut the AC generator and starter wires and wire harness when remov ing or installing parts ENGINE REAR COYER REAR COVER REMOVAL Drain engine oil Remove the engine from the frame or remove the swingarm Remove the water pipe gearshift pedal drive shaft dust cover and starter motor TARTER R w i I F T PEDAL rr 1 Remo...

Page 326: ...r and pump impeller L PULSE GENERATOR REMOVAL Remove the pulse generator cover Remove the pulse generator by removing the two mounting screws Remove the spark advancer bolt and spark advancer I Date of Issue September 1981 American Honda Motor Co Inc 1981 All Rights Resewed 25 9 ...

Page 327: ...bearing NOTE 1DOnot damage the stator coil I GENERATOR STATOR I REAR COVER lNSTALLATlON BEARING DRIVER OUTER Drive the final shaft bearing into the rear cover To installthe waterpump mechanicalseal refer to page 9 7 BEARING DRIVER HANDLE A Date of Issue September 1981 OAmerican Honda Motor Co Inc 1981 All Rights Resewed ...

Page 328: ...Install the starter motor and neutral switch Install spark advancer Align the lug on tht advancer with the cut out in the crankshaft Tighten the spark advancer attaching bolts TORQUE 0 8 1 2 kg m 6 9 ft lb Install the swingarm see page 14 27 IGNITION TIMING ADJUSTMENT Remove the timing inspection hole cap Rotate the crankshaft and align the F S mark on the TR right side with the index mark on the ...

Page 329: ...ear cover Check that the rotor tooth is aligned with the steel core on the lower coil case Check the air gap between the rotor tooth and the steel core AIR GAP 0 40 0 70 mm 0 016 0 028 in ALIGNING THE TriEL CORE WITH THE ROTOR TOOTH For air gap adjustment refer to page 25 22 Install the pump impeller water pump cover and water pipe Install the pulse generator cover 25 12 Date of Issue September 19...

Page 330: ...231 0 6243 in 30 148 30 149 mm 1 1869 1 1 889 in 30 230 30 280 mm 1 190 1 1921 in Slowly press the caliper against the disc to push the pistons back into their cylinders This is necessary to make room for the increased thickness of the new ads Remove the caliper mounting bolt Remove the caliper shaft and brake caliper SERVICE LIMIT 4 mm 0 16 in 0 3 mm 0 01 in 15 925 mm 0 6270 in 15 815 mm 0 6226 i...

Page 331: ...specified torque TORQUE CALIPER MOUNTING BOLT 2 0 2 5 kg m 14 18 ft lb CALIPER SHAFT 2 5 3 0 kg m 18 22 it lb Install the brake pad pin retainer BRAKE CALIPER DISASSEMBLY Place a container under the caliper and dis connect the brake hose bolt NOTE Avoid spilling brake fluid on painted surfaces Remove the brake pads Remove the caliper shaft and caliper mounting bolt Date of Issue September 1981 Ame...

Page 332: ...ying a small amount of air pressure to the fluid inlet Do not use highpressure air or bring the nozzle too close to the inlet Examine the pistons and cylinders for scoring or scratches and replace if necessaly Remove the oil seals from the cylinders as shown Clean the caliper grooves with brake fluid Date of Issue September 1981 American Honda Motor Co Inc 1981 All Rights Resewed ...

Page 333: ...IMIT 30 290 mm 1 1925 in ASSEMBLY reduces stopping power Replace con taminated pads and clean a contami nated discwithagoodqualitydegreasing Assemble the caliper in the reverse order of disassembly The oil seals must be replaced I whenever they are removed Lubricate the pistons and seals with a medium grade of high temperature silicon grease or brake fluid before assembly Make sure the piston seal...

Page 334: ...th Loctite 601 or an equivalent Cement CALIPER INSTALLATION Install the brake pads and the caliper Tighten the caliper mount boltand caliper shaft to the specified torque TORQUE CALIPER MOUNT BOLT 2 0 2 5 kg m 14 18 ft lb CALIPER SHAFT 2 5 3 0 kg m 18 22 ft lb Connect the brake hose Fill the brake fluid reservoir and bleed the front brake system see page 3 10 Date of Issue September 1981 American ...

Page 335: ...gnition coil 3 point spark test Engine cranks but will not start Engine stop switch OFF No spark at plugs Faulty transistorized spark unit Faulty pulse generator Standard For extended high speed riding F mark Full advance 6 mm 114 in minimum No spark at plug Engine stop switch OFF Poorly connected broken or shorted wires Between ignition switch and engine stop switch Between spark unit and engine ...

Page 336: ... with a coil tester SERVICE LIMIT 6 mm 114 in min NOTE Follow the coil tester manufacturer s instructions 6 m m 114 in MINIMUM iE G xE SPARK i7 THIRD ELECTRODE PRIMARY COlL INSPECTION Check the resistance of each ignition coil betweenthe leadswith an ohmmeterasshown RESISTANCE 2 3 n Replace the coil if the resistance exceeds the specified range b Date of Issue September 1981 American Honda Motor C...

Page 337: ...CE Replace the ignition coil if the resistances of tests 1 and 2 exceed the limits TRANSISTORIZED IGNITION SYSTEM INSPECTION Disconnect the spark plugs Hold each plug against any convenient engine ground Turn the ignition switch ON and run the engine with the starter motor Agood sparkto the plugmeans that the ignition system is in good condition If it is not inspect the pulse generator spark unit ...

Page 338: ... of the 4 pole coupler intermittently The transistor unit is normal if the voltage indicated by the voltmeterchangesfrom 12V to OV in each test SPARK ADVANCER Remove the pulse generator see page 25 9 Check the mechanical advancer cam for stick ing Lubricate the sliding surfaces and check the spring for loss of tension and the advancer pin for excessive wear SPARK ADVANCER ASSEMBLY When assembling ...

Page 339: ...ll Rights Resewed IGNITION TIMING CHECK Remove the timing hole cap Connect a timing light to the right cylinder and connect a tachometer Start the engine and check the ignition timing The index mark should be aligned with the FI for idle mark at 1 I 00 f 100 rpm Timing advance should start at 1 500f 100 rpm The index mark should be between the full advance marks at 2 780rpm Repeat for the left cyl...

Page 340: ...HONDA CX500 8 WIRING DIAGRAM l w t m SWITCH BAT1 IGI ICC TLI lL2 P ENGINE STOP S l l T M STARTER SWITCH Date of Issue September 1981 fin Unnrls hdntnr rn Inr 1QR1 A11 Rinhtc R a c r v e r l ...

Page 341: ... 82 ADDENDUM NEUTRAL SWITCH rOiL PRESSURE SWITCH G GREEN Y LIWT GRZEN R RED P PINK W WHITE G W A Y ...

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