Honda CX650E Shop Manual Download

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Summary of Contents for CX650E

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Page 4: ...mrn 3 25x 2 4 8in Displacement 673 cc 41 1 cu in Comprssion ratio 9 8 1 Cylinder compression 1 200 kPa 12 0 kg crn2 171 psi M k e train Chain driven camshaft and push rad Lubrication system Forcedpressure and wet sump Oil capacity 3 6 lit 3 8 US qt 3 2 Imp st after disassembly 3 0 lit 3 2US qt 2 6 Imp qt after draining Oil type SE or SF IIOW 401 Cooling system capacity 2 08 lit 2 2 US qt 1 8 Imp q...

Page 5: ...Headlight HighlLW TaillStoplight Turn signal light Meter light Neutral Indicator Turn signal indiwtur High beam indicator Oil pressure warning light m lYmd G1 G2 I ELECTHICAL DPR8EA 9 NGK D P R 9 W NW 6 3GZ WR4 W 1 0 8 Q 9 mm O fBl O W5 in 30 A tmain TEA mbL 12V 60 5WV 12V 2 5W t2V B 8W 12V 21W 12v 23W 12V 3 4W f2V 3 4W 12V 3 4W 12V 3 4W 12V 3 4W Gmr ratio 1st 1 _ Gear ratio 2nd Gear ratio 3rd Gea...

Page 6: ... 58 29 36 33 40 33 40 17 18 22 29 33 4a 7 71 7 10 12 15 65 87 14 22 22 25 18 25 f8 a2 14 18 22 28 25 33 14 17 6 10 13 20 2 2 2 9 4 7 7 14 a 29 Z 29 17 22 standards TYPe 5 mm bdt nut 6 mm M nut 8 mm bdt nut 1 0mm bolt nut 12 mm bdt nut Torque Thread Dia mm 1 2 1 0 1 0 1 2 8 2 4 7 1 0 8 15 10 10 10 8 1 0 1 0 6 6 30 30 8 8 1 0 1 2 1 0 1 0 1 0 8 8 8 1 0 6 tQ 1 0 10 8 points If a toque N m 20 24 47 45 ...

Page 7: ...4S BDO REMARKS DESCRlITlON Driver handle A Bearing driver attachment 42x 47 mm Driver pilot 30 mrn Wheel bearing remover head 17 mm Wheel beating mmover expander Bearing dtiver attachment 32x 35 rnm Bewing driver attachment S x 56 mm Driver Bearing driver attachment 25 mm REF PAGE 22 28 22 33 D 3 0 22 34 2235 2236 22 36 Z 38 NUMBER 0 7 7 1 0 0 0 0 07746allOXKl 0 7 7 0774600W500 07746 0050100 07746...

Page 8: ...GENERAL INFORMATION INFORMACIONGENERAL WIRING DIAGRAM DIAGRAMA DE CABLEADO ...

Page 9: ...apepr t b e if they are conwct a sharp edge or rr Clean the attaching surface thoroughly More applying tape DO WE wires o r b r m s with a broken rwul Bq airby wrapping t h with a protective tape o r replaw4btw Rwte wire h a l A mtd aWW3lTarpedges w corners Also avoid the proje rands of bdls a m screws Keep dire hwnesses away fr8m the exwusl pipes and d Whot parts Be sure grammets are seatd in th ...

Page 10: ...GENERAL INFQRMATlON THERMOSTATlC SWITCH CODE ...

Page 11: ...ses of the engine Reinstall the drain plug and fill the crank case with approximately 3 0 liters 3 2 US qtl of recommendedoil through the oilfiller opening 1 DRAIN BGLI OIL STRAINER CLEANING Drain the engine oil Remwe the oil pan by removing the sight bolts Remove the oil strainer 1 OILPAN A c 2 tl OIL STRAINER Cleanthe oilstrainer and oil panthroughly Make sure the O ring on the oil strainer outl...

Page 12: ... bk ttb b 0 k J ZNid thelug in sib pan 1 OIL PUMP Re dce tne dl pan W k e t R a mw one Install the oil pan on the engine case inwing theend of the strainbrinto the oil pump Enlet z2 10 ...

Page 13: ...B VB28C Float level 15 5 mm 0 61 in Pilot screw 2 3 8 turns wt Idle speed 1 100 min I Irpm Vacuum at idle speed 200 mmHg Throttle grip free play 2 6 mrn 1 8 1 4 in Bend the throttle joint bolt lmk washer tabs down Remove the throtds join bolt and h k washer Disconnect the balljoint of the throttle tink from the throttle joint pipe ...

Page 14: ...L SYSTEM Remove the rear stay holding each pair of carburetorstogether Rernwe the frunt stay pWe holding eat pair of carburetors together ISeparate the caqtihh fiukoirtd to prevent damge t d t hhint pipeSl ...

Page 15: ... cm hecthQsprings Install the thmtlie joint pipe lock washer and holt Tighten the joint bott andbend up the lock washer t a bagainst the bolt head 21O RING FIRST IDLE ADJUSTMENT FAST IDLE 1 500 2 m rpm 3 1ABOUT 0 a m m 1 If fast idleadjustment is newssay remove the carburetors Then unscrewthe throttle stop screw until the throttle valve is oomdete v closed ktween the choke link arm and throttle dr...

Page 16: ... inner 49 5 1 1 W 47 6 1 874 5 CLUTCH CLUTCH OUTER REMOVAL Remove the dutch cover page 7 2 Remove the lifter b t e and spins mne Remove the lock nut and lock washer page 7 31 Remove the pressure plate discs plates and clutch center as a unit Remove the clutch outer guide and clutch A outer 1 ...

Page 17: ...sure the I D of the clutch outer SERVICE L I M E B 1 0 9 mm 0 in Check the cluth outer needle bearing for damage or excessive phy Replacethe f t h new one VW PFI m 11 SLOT 2 NEEDLE BEARING sp4A z d 3 21 L43 d P 1 3 1O U E R GUIDE CLUTCH SPRING INSPECTION Measure the spring free length SERVlCE LIMIT 7 9 mm I1 48 in ...

Page 18: ...d engine Reserve tank Total system RADIATOR REMOVAL Standard 1 7 2 1 8 US qt 0 3 8P 0 4 US qt 2 m P 2 2US qt Remwe the side cwas seat and fuel tank Remowthe radiitorcover by removingthe side bolts Drain t b ant Lfrq wW tor page 9 31 L o the uppenandrlwer diator hose bands 11 RAalATOR COVER 2 BOLTS 1 UPPER HOSE BAND ...

Page 19: ...W 6 4 T j jqh ng bolts dd qr ah ds g rr ct the M i o r hoses 2 MOUNTING L RADIATOR DISASSEMBLY Bmd down tho therrntxaatir switch and fan motor wire darn and wmove the wires R m v e the four fan shroud mounting bolts and fan shroud from the radiator 1 6A N SHROUD ...

Page 20: ...or qklerfed joints and seams fpr 3 Blow dirt out from between core Rns with mrnpmsgd air If insects e are dogging the radiator wash them bffwith low prwure water Carefully straighien m y bent fins RADIATOR ASSEMBLY 111 F A N PMde the fan motor on the shroud wfth its TOP mark facing up and tibhtm the three mms ...

Page 21: ...e plain wfsbf bk WaSherand nut 1 3 FAN SHROUD I M i i f t q tWr8diatoa With he four bolts I Secur Xhq wires whht the damps on the qR6 7 8 4 1 1 FAN G a i MOTOR COUPLER I r P I A D I A T IWTAE Am dw _ I I lhstall the r W i snm the mmU and tighten the ddntidd h 6 8 8 2 1 MOUNTING NUT ...

Page 22: ...COOLING SYSTEM Ernn d Ema tiqm h dnd f ir motor wire c o w r to thb tmmess St A 3 x 2 LOWER HOSE ...

Page 23: ...4 ft lb 6 x 32 mm bolt 10 14 N m 1 O 1 4 kg m 7 10 ft lbl M4 and M5 gmr 0 0 I D Shift drum I D Bushing O D 30 985 31 010 1 2199 1 2209 27 500 n M 1 c l a X 2 7 1 lm51 I Drurn to transmission holder clearance C1 gear C1 gear bushing C2 gear 30 95 1 2191 27 5411 084 29 020 2 9 0 4 1 1 1425 1 I433 28 979 29 m 1 1409 I I4171 1 9 9 8 7 20 000 0 7869 0 7874 2 7 4 5 9 27 480 1 0811 1 0819 5 93 6 00 0 233...

Page 24: ...SERVICE UMITS A C11 19 98 mm 0 788 in 8 021 27 44 mm I in C tautar guide 2491 mm 0 m in 1 I I I I I A Ldg I 1 1 A s u r e ahd record the shift drum 0 0 and transmission holder I D calculgte t clearance h w e m the shift drum and t b transmission holder SERVICE W M T 0 A5 mm 1 0 min1 RAE TRANSMISSION ASSEMBLY Drive th bearing ...

Page 25: ...e i8uirthfmm shown W o w c MOTE ILubricate the Jiding faces of the nears with md e Bii I 41 COUNTERSHAFT 3 1 5 T I l GEAR Bl 10 5TH GEAR I 3 1 1 i h7 k I 814TH GEAR 28 47 MAINSHAFT LOW GEAR 16 I n Mt the mainshaft y m i l l MAINSHAFT 21 MAINSHAFT3RD E A R ...

Page 26: ...3rd gear and the splined bushing onto the countenhaft Install the countershaft and 3rd gear assembly through 4th and 1st gears srad Into the needle baring j A 3UNTERSHAF _ GEAR Slide We 5th ahd Z M W P s onW countershaftand Miri Check the engag of the gears on the eeuntershaft and maimhaft 1 ...

Page 27: ...s I NO Alignthe pmjectianon theshiftdrum with the cutout in t b engine as Pie tlie fransmkion holder into place while rotatingthe mainshaftand torque the hdder bolts TORQUE 6 x 2 0 mm b l g a 1 5 2 0 kg m 11 14 ft lhj I irstaH the oil separator and torque the bolts TORQUE 8 x rnm b o k 10 14 N rn 1 0 1 4 kg m 7 10 ft lb ...

Page 28: ...4 6 0 8 2 4 8 5 I3 2465 3 2474 Cmnbhaft Cylinder Piston ring Piston Service Limit 0 W 0 0033 0 50 O oeOl a g 0 3 352 0 80 0 024 0 60 0 M4 1 10 10 043 82 36613 2427 Ctankpin oil clearance Connecting rod side ckarance I D Item F m t cushion spring fres bn gth Ring end gap Standard 480 5 18 921 275 em3 7 7 imp 0x1 B O cm3 8 2 imp oz 0 40 kPa 0 0 4 k g l c d 0 6 psi Front fork oil capaciiy TOP Second ...

Page 29: ...mended oil Above 5 C 41 O F SAE 90 Below 5 C1410F SAE 80 WHEEL BEARING REMOVAL Remwe the rear wheel page 14 31 Remove the final driven flange and rear broke discs Remove the wheel bearings and distance collar witht he special tool REAR SHOCK ABSORBER OIL SEAL REMOVAL Remove the rear shock absorber page 14 91 Remove the boot band and boot To removethe stopper ring press down on the back up plate an...

Page 30: ...oil ATF or equivalent in a dmn container P I the shock a h a h in a hydraulic press with an OIL SEAR DRNER AITACHMENT pa joned as shown Place the air hose in the oil and press the shock absorber swmal times until the damper is filled with the oil NOTE This shock abywbefs store is 43 mrn 1 89 in AIR VALVE 1 DAMPER OIL CATF OR ...

Page 31: ...c r n p r n g tke shack absorber e q dk aibs bei fW another 70 m h d href any b hininSJ ATF d d n m OIL SEAL INSTALtATlON I NOTE J Turn the shock absorber upide down as sodn as a O the ATF has d a h d from the outer case RI the damper Gase with the specified amount of ATF SPECIFIED AMOUNT 270 cc 9 1 U S 02 7 6 Imp 02 1 y p h f i h t h e a w o r A F wilt flaw 4 the dampar oaw ...

Page 32: ...ll it on the damper CAUTION Be carefulnot t o damage fhe oil seal during ir sralk n PrSs the oil 1 into fhe shock a M r with a hydrgulic pre Dntil the oil seal driver and oil seal driver ring stops at the edge of the outer case 1 OIL SEAL 21TAPE Install the back up ring tns all the stop ring being certain that it is seated in the ring grouve inthe outer case Install the boot and boot clip ...

Page 33: ...karings for M e lay or da age Apply gwaw t o ihe sglinesp Inmll the univmdljoint md swingarm FINAL DRIVE REMOVAL P b the motorcycle on imcenter stand Drain the final gear oil page 23 Remove the reat wFfM pLe9 Remove the final gear case attaching nuts and remwe the gear case from the swingarm 1 RNAL DRIVE G AR CASE ...

Page 34: ...le tugging slightly DISASSEMBLY gear case a circular Remove the spring oil seal and stop ring from the drive skaft NOTE Repbce the oil seal with a new one if it is removed FINAL DRIVE GEAR RING GEAR RWOYAL Renxwe the digtanee collar Rdmow the dust guard plate hob Removethe dust guard ptate by turning it ctockwwe 1 OIL SEAL SPRING ...

Page 35: ...hecover do W b w i q g M thb mer inafiresswWfi the ringgear down Make sure the covet I s secrely SUw P m the rin R m v e the ring r m I ease 8 1 RemovetheO ringguide by b w P O m b R m v e ring g r dusting spacer REMOVAL wring and 11 CASE COVER drive from ...

Page 36: ...jJthe a1 4mm the cwsk cover p h l a m g o f l 1 4 I m I I i I I L I L Install the pinion pint holder onto the pinion joint and m o e t b ninion shaft nut R a m m the tool and pinion joint i hw tb g i6a w A A _ r ...

Page 37: ...ullt k p1d asi3emBly 8 M h the pinion puller PlNlOM BEARING REIVIOVAL Pull the baring ou ef and inner races M the shaft with the bearing puller Pull the other inner race off with the same tool Remove the pinion adjustment spacer I PINION BEARING 9 16 4yJ m r t 1 2 SEARING PULLER COMMERCIALLY AVAILABLE ...

Page 38: ...il seal into the retainer Coat a new O ring with oil and install it onto the retainer I CASE BEARING AND 01L SEAL REPLACEMENT H the gear caw W C 176 F Tap the gear case with a plastic hammer and remove the ring gear and pinion bmrings Always wear gloves when handling the gear case after it bas been heated NOTE Urn baring remover 35 mm W93837104a to remove ring gear I 12 BRNER ...

Page 39: ...4 A i I NOTE 1 PINION BEAR 12 PINION SPACER ...

Page 40: ...wirR2the cast3 threads Apply gear oil to the O ring and threads on the pinion retainer Instalithe O ring guide tool Screw in the pinion retainer to pr s the pinion bearing in place then tighten it to the specified toque TORQUE 100 laD N rn lo 12 kern 72 87 ft lb RING GEAR ASSEMBLY Install the original spacer onto the ring gear gwr b r i n g and ar gmr case is replaced install a 2 0 mm thick spacer...

Page 41: ...an tbring 1 BEARINGPULLER APJD R V E R BW d W Wn drW e hew baring n t o the h a f i d h the bearing pulbr and 07934 MB00000 L htall a w O ring oirto the O ring guide Apply grease t t a b Q ring and drke the ring guide onto the ring gear shaft 1 3 1 DRIVER ...

Page 42: ...ll the shim and drive the stop pin into t b case cover Clean all sealing material oh the mating surfaces 4 gear casead cover 5 NOTE Eb cbfeTu1 not to damage t mating sulfaze3 Apply liquidsealant to the mating s u m of t h gear case cover G W R TOOTH CONT T PATTERN CHECK Apply a thin m d Pmsaian Blue to the pinion gear teeth for a gsar toaahcontact pattern check Place the wave washer and ring g r i...

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Page 44: ...n PlNLONSPACER A 1 82 pm1 B 1 manam AP 0 4 in C 134 mm g O Bin D 2 M rnm POR lnfStandard IE 2 06 nini b os r fm F 2 12 mm 0 084 in G 218 mm I in I 11 TOO LOW 13 FLANK I 113 FLANK 4 DRIVE SIDE 5 COAST SIDE may p e did inN qr Tqm the ring f2tE and measurn W a s h m is pwdumonw more Compare ths diffqp 1 0o f the three measurements D FFEF EHCE OF MEASUREMENT SERVICE LtMW 0 d mm 0 Win ...

Page 45: ...hen W ness of the spacer is chan W 0 10 mrn 0 004 id RING GWW GAGER A 1 mrir O m l h B 1 8 hlij fam4 fi c l m n r O m i n i D 2 00 mm 10 099 in Standam E 2 W rnm 0 081 in iI F 2 12 mm 0 084 inl G 2 18 mm I in Apply gear iil to the oil seal lTg contact Mpce x o f tfte bi qnj W ang instaH the pmion ioiht Install the pinion joint holder tod and tighten pinion nut TORQUE la 120 Wrn 10 12 kg m 72 87 ft...

Page 46: ...re that the gear assembly rotates smoothly without binding by turning the pinionjoint GEAR ASSEMBLY PRELOAD 2 4 N m 0 2 0 4 kg m 1 7 3 5 in lb m p l l drive l srea shaft drive Be seto oil s the zal ligt not pinion FtMAL DRiVE INSTALLATI0 N spline gcoov8s ...

Page 47: ...ghl I ao 3 o kg fn 34 32 ft lbl P f a e zhe mutorcycle an its canter mand Make sure that ttie xbin bait is tightened Rernove the 03 fllter cap and p h r the specifkl amouht af m o i n oil up to hefiller neck RECOMMENDED 01L HYPO10 GEAR 91L 111 FINAL GEAR CASE ATTACHING NUTS Above SDC SAE90 Below 5T SAE W3 0 r r n s I I lrn l C c 143 5 4 p 4 o IT W lLU 8 1 ...

Page 48: ...tor do not start di nnect I btack blue and green lids fnwn the thermostatic switch and s h o e them tq her with a jumper wimas shswn Turn the ignition witch on The cooling h mqWr sbytdcq pniw If ifm r t s mplace the fan themnostatic switch and m If it does norLMrt ghk for battery voltage from t i w glead N w tothe green b d ne ativt of the fan motor m k I If is no m e qhedr for a blown lor fauw fu...

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Honda CX650E, Shop Manual

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