Honda CX500 (1978), CX500 (1980), CX500 (1979), CX500 (1981), CX500 (1982) Shop Manual
HOW TO
This shop manual covers emission controlled
CX500's manufactured after December
1977.
units.
Some procedures may not apply to earlier
USE
THlS
MANUAL
31,
This shop manual uses the
basis for all service procedures and data. The
manual
dendum~ beginning with section
Follow the applicable Maintenance Schedule re-
commendations to ensure that the vehicle is
in peak
levels are within U.S. Environmental Protection
Agency standards. Performing the first scheduled maintenance is very important. It compen-
sates for the initial wear that occurs during
break-in.
Sections
motorcycle, while sections
describe parts of the motorcycle, grouped
according to location.
Find the section you want on this page, then
turn to the table of contents on page
section.
is
kept up-to-date with subsequent ad-
opera.fing condition and the emission
1
through 3 apply to the whole
1978
CX500 as the
21.
4
through
1
of that
18
Most sections
illustration and all the required specifications,
torque
materials required for the section. The
sequent pages give detailed procedures for the
section.
If
you are not familiar with this motorcycle,
read through the TECHNICAL FEATURES in
section
If you don't know the source of the trouble, go
to section 20 TROUBLESHOOTING.
ALL INFORMATION, ILLUSTRATIONS, DIREC.
TlONS AND SPECIFICATIONS INCLUDED IN
THlS PUBLICATION ARE BASED ON THE
LATEST PRODUCT INFORMATION AVAILABLE
AT THE
HONDA MOTOR CO., LTD. RESERVES THE
RIGHT TO MAKE CHANGES AT ANY
WITHOUT NOTICE AND WITHOUT INCURRING
ANY OBLIGATION WHATEVER.
NO PART OF THlS PUBLICATION MAY BE
REPRODUCED WITHOUT WRITTEN PERMISSION.
19.
Start
with an assembly or system
valuk, working practices, tools and
sub.
TlME OF APPROVAL FOR PRINTING.
TlME
:
BRAKE
Date
of
Issue: September 1981
@American
Honda
HONDA MOTOR CO., LTD.
Service Publications Office
Motor
Co.,
Inc. 1981 - All Rights Resewed
MODEL IDENTIFICATION
BEGINNING WITH FIN 2000001
The frame serial number is stamped on the right side of
the steering head.
HONDA
CX508
The legal vehicle identification number
of the steering head.
is
on the left side
81
The engine serial number is stamped on the lower left
side of the engine case.
3INE SERI
I
"
IER
-,,
The carburetor identification number is on the left side
of the carburetor body.
IDENTIFICATION NUMBER
Date of Issue: August,
OHONOA MOTOR CO.,
1979
LTD.
-,,
-7
-
GENERAL SAFETY
1-1 WIRING DIAGRAM
1-6
.-
SERVICE RULES
SPECIFICATIONS
TORQUE VALUES 1-4 EMISSION CONTROL INFORMATION
SPECIAL
TOOLSICOMMON TOOLS 1-5
1-1 CABLE & HARNESS ROUTING
1-2 EMISSION CONTROL SYSTEM 1-8
LABEL 1-9
MAINTENANCE SCHEDULE 1-10
GENERAL SAFETY
77112
I/
I~P
engine must he running to do some work, make
sure the area is well-ventilated. Never run the engine
in a closed area. The exhaust contains poisonous
carbon monoxide gas.
hulrery electrolyte contains sulfuric acid. Protect
your eyes, skin and clothing. In case of contact, flush
thoroughly with water and call a doctor
were exposed.
1-7
if
your eyes
1
-
-
-
mm
(r~\f~l~r~~
under certain conditions. Do not smoke or allow
flames or
is
extremely flammable and is explosive
sparks in your working area.
.
.
I%(,
boirery generates hydrogen gas which can be
highly explosive. Do not smoke or allow
sparks near the battery, especially while
chargingit.
flomes or
SERVICE RULES
1.
Use geniune HONDA or HONDA-recommended parts and lubricants or their equivalent. Parts that do not meet HONDA's
design specifications 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 reasserhbling.
4.
When torquing bolts or nuts, begin with larger-diameter or inner bolt first, and tighten to the specified torque diagonally,
unless a particular sequence is specified.
5.
Clean'parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.
6.
After reassembly, check all parts for proper installation and operation.
7.
Use only metric tools when servicing this motorcycle. Metric bolts, nuts, and screws are not interchangeable with English
fasteners. The use of incorrect tools and fasteners may damage the motorcycle.
Date of Issue: January.
OHONDA MOTOR CO.. LTD
1978
HONDA
SPECIFICATIONS
GENERAL
INFORMATION
CX500
I
1-2
Date
of
Issue: January,
OHONDA MOTOR CO.,
1978
LTD.
HONDA
DRIVE TRAIN
GENERAL INFORMATION
23123 watt 32132
3.4 watt
2
cp
SAE
cp
No.
SAE
57
No.
Date
of
Issue:
o
HoNDA MOTOR
January,
co..
1981
LTD.
1-3
HONDA
TORQUE VALUES
Item
Crankshaft cap
Connecting rod cap
Cylinder head
Valve adjusting nut
Flywheel
Clutch center
Primary drive gear
Starting clutch outer
Cooling fan
Cam sprocket boss
Cam sprocket
Change pedal
Radiator drain bolt
GENERAL
1
0.t~
INFORMATION
7
4
8
8
1
1
1
3
1
1
2
1
1
Thread Dia.
(mml
kg-m
2.0 - 2.4
2.8
-
3.2
-
5.5
5.0
1.5
-
1.8
8.0 -10.0
8.0 -10.0
8.0 - 9.5
1.8
-
2.5
-
2.5
2.0
8.0 -10.0
-
2.0
1.6
-
1.4
1.0
0.15- 0.30
CX500
Torque Values
14 - 17
20
36
11
58
58
58
13
14
58
12
it-lb
-
23
-
40
-
13
-
72
-
72
-
69
-
18
-
18
-
72
-
14
7
-
10
1.1- 2.2
ka-m
Torque Values
ft-lb
ltem
Steering stem nut
Handlebar top bridge
Handlebar lock
Handlebar holder
Front fork bottom bridge
Front and rear axles
Front axle holder
Engine hanger bolt
Engine hanger bolt
Final drive flange nut
Rear brake torque link
Rear shock absorber
Foot peg
Swing arm pivot nut
Front brake disc
Gear case rear fork
Swing arm pivot bolt
Front
caber
Torque specifications listed above are important tightening points. Others should be torqued to standard torques below.
Thread Dia.
1
immi
STANDARD TORQUE VALUES
Item
5
mm bolt and nut
6
mm bolt and nut
8
mm bolt and nut
10
mm bolt and nut
12
mm bolt and nut
Torque Values kg-m
1-4
(ft-lb)
0.45-0.6 ( 3- 4)
0.8 -1.2 1 6- 9)
1.8 -2.5 (13-18)
3.0 -4.0 (22-29)
5.0 -6.0 (36-43)
Item
5
mm screw
6
mm screw
6
mm flange bolt and nut
8
mm flange bolt and nut
10
mm flange bolt and nut
Torque Values kg-m
0.35-0.5 ( 3- 4)
0.7 -1.1 ( 5- 8)
1.0 -1.4 ( 7-10]
2.0 -3.0 (14-211
3.0 -4.0 (22-291
Date of Issue: January,
OHONDA
MOTOR
(ft-lb)
CO.,
..~-
-
1978
LTD.
HONDA
CXSOO
SPECIAL TOOLS/COMMON TOOLS
--
SPECIAL TOOLS
Tool Name
Piston slider
Socket wrench
Final retainer wrench
Retainer B wrench
Snap ring pliers
Hollow set wrench
Socket bit 110 mml
Clutch center holder
.
Gear holder
"
Crank cap puller
Bearing remover head 120
(8earing remover handle)
(Bearing remover weight)
Bearina remover head
~iot bkaring outer remover
"
Piston remover
Valve guide driver attachment
Ball race driver
Crank cap driver
Mechanical seal driver attachment
"
Mechanical seal pilot
Ball race driver
Steering stem driver
Ball race remover
Ring gear DislAssembly tool set
(Ring gear center guide1
(OisIAssembly tool A)
(OislAssembly tool Bl
(OislAssembly tool C)
"
Main bearing OislAssembly tool
Valve guide reamer
Preload inspection tool
Inspection plug
Special tool case
Vacuum gauge tester
(Vacuum
*
Tire lever set lfor comstar wheel1
[Tire lever1
[Rim ~rotectori
toolsesterisked ('1 are included in the "SPECIALTOOLSET B 07900-4150101" and theseare new for CX500.
The
The tools starred (*I are designed for comstar wheels.
127 x 17 mml
(6 mml
mml
(BOTTOM1
(TOPI
(6.6 mml
gauge attachment)
GENERAL
Tool No.
INFORMATION
Appropriation List
Local purchase item T40 torx bit or socket
Local purchase item ratchet type
Local purchase item
Local purchase item
Ball race
Ball racelcone driver
remover/installat
ICommon Tool - Special Tool)
COMMON TOOLS
Tool Name
Float level gauge
Pin spanner
Tappet adjusting wrench
Tappet adjusting (131
Retainer wrench B
Retainer wrench body
Lock nut wrench socket
Lock nut wrench socket (30 x 32 mml
Extension bar & handle
Flywheel
Rotor puller
Valve guide remover
Pin driver (3.5 mml
Bearing driver outer (42 x 47 mm)
Bearing driver outer 152 x 55 mml
Bearing driver pilot (15 mmi
Bearing driver pilot I20 mml
Bearing driver pilot (22 mml
Bearing driver pilot 125 mml
Bearing driver pilot (30 mml
Front fork oil seal driver body
Front fork oil seal attachment
Bearing driver handle (A)
Valve spring compressor
Rear shock absorber
&
rotor puller
The tools asterisked
Seethe "NEW MOTORCYCLE COMMON
(10 x 12 mml
(26 x 29 mm)
(6.6 mml
(Dl
comorerror
1.1
indicate those which are not found in special tools.
Tool No.
07401-0010000
07702-0010000
07708-0030200
07708-0030400
07710.0010200
07710~0010401
07716-0020201
07716-0020400
07716-0020500
07733-0010000
07733-0020000
07742-0010200
07744-0010300
07746.0010300
07746.0010400
07746.0040300
07746.0040500
07746-0041000
07746-0040600
07746.0040700
E:~:~:$~E$~
07750-3290001
TOOL LIST" at the back of this manual.
-
Tappet adjusting wrench set 07908-3640000
(Tappet adjusting wrench
-
Retainer wrench 07910-3230101
1
Rotor puller 07933-2000000
Valve guide driver
Pin driver (3.5
Bearing driver 07945-3330100
Bearing driver
]
Fork seal driver
Driver handle attachment
(Not to be used with common tools1 07949.61 10000
Valve spring compressor
Appropriation List ICommon Tool -Special Tool1
-
Pin spanner 146 mml 07902-2400000
ITappet adjusting IAl 07908-32901 001
Local purchase item
Local purchase item
Flywheel
puller 07933-0010000
Not applicable to speciaitool
Not applicable to special tool
Not applicable to special tool
Not applicable to special tool
Not applicable to special tool
-
(10 mml 07908-36401 001
07942.61 10000
mml 07944-6340100
07946-371 0200
07947-3330000
07957-3290001
of
Issue:
Date
@
HONDA MOTOR CO., LTD.
January.
1981
ENGINE STOP
STARTER SWITCH
-n
IRING DIAGRAM
IGINE STOP ST,
llTCH ARRANGEh
TURN SIGNAI
-
WIRING DIAGRAM
REAR
STOP
-SWITl
LIG
WIRE BAND
FRONT BRAKE HOSE
THROTTLE CABLES
CABLE
&
HARNESS
ROUT1
CLUTC
FRONT BRAKE
H CABLE-
'LE
FRONT BRAKEHOSE
W
\
SPEEDOMETER CABLE
CABLE & HARNESS ROUTING
WIRE BANDS
COUPLER (GREEN) COUPLER (BROWN)
t
HEADLIGHT RECEPTACLE
HONDA
CXSOO
GENERAL INFORMATION
EMISSION CONTROL SYSTEM
>.
-
The CX500 is equipped with two emission control systems.
EXHAUST EMISSION CONTROL SYSTEM
The exhaust emission control system
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
is
composed of a factory preset carburetor. No adjustment should be made except to
REATHERTUBE
SEPARATOR
AIR CLEANER CASE
Date of Issue: January,
OHONDA
MOTOR
CO.,
1978
LTD.
DRAIN PLUG
-FRESH
-
AIR
BLOW-BY GAS
1
-8
HONDA
GENERAL INFORMATION
EMISSION CONTROL INFORMATION LABEL
CXSOO's manufactured after December 31, 1977 have an Emission Control Information label on the frame as shown. It
contains basic tune-up specifications for
details.
CX500's manufactured after December 31, 1977. Refer to this Shop Manual for more
Date of Issue: January, 1975
OHONDA MOTOR CO.,
LTD
HONDA
CXSQO
GENERAL INFORMATION
MAINTENANCE SCHEDULE
Perform the PRE-RIDE INSPECTION in the Owner's Manual at every maintenance period.
I
:
INSPECT, CLEAN, ADJUST. LUBRICATE OR REPLACE IF NECESSARY.
C: CLEAN
R: REPLACE
A: ADJUST
L: LUBRICATE
MONTH
.
,
**
IN THE INTEREST OF SAFETY, WE RECOMMEND THESE ITEMS BE SERVICED
'SHOULD BE SERVICED BY AN AUTHORIZED HONDA DEALER. UNLESS THE OWNER HAS PROPER TOOLS AND IS
~
----
NICALLY QUALIFIED.
NOTES:
-
I1 I 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) For higher odometer readings, repeat at the frequency interval established here.
ONLY
BY AN AUTHORIZED HONDA DEALER.
MECHA-
Date
of
Issue:
January,
OHONDA MOTOR
CO.,
1978
LTD.
GENERAL INFORMATION
a
HONDA
LUBRICATION DIAGRAM
ROCKER ARM
,--.
OIL PRESSURE
SWITCH
I
r
2-0
CRANKSHAFT TRANSMISSION COUNTERSHAFT
1
I
Date
of
Issue: January,
OHONDA MOTOR CO., LTD.
1978
HONDA
@
-
I
I
cxsoo
SERVICE INFORMATION 2-1
TROUBLESHOOTING
ENGINE OIL LEVEL CHECK
ENGINE OIL & OIL FILTER CHANGE 2-2
FINAL GEAR OIL CHECKIREPLACEMENT 2-3
DRIVE SHAFT JOINT LUBRICANT 2-3
I
LUBRICATION POINTS
SERVICE INFORMATION
WORKING PRACTICE
Oil pump
Oil pressure relief valve
Oil strainer
Refer to Section
Refer to Section
Refer to Section
I
I
1
2-4
7.
7.
7.
SPECIFICATIONS
I
Oil capacity
Oil
Oil pump delivery
3.0 liters (3.2 U.S. qt.) at engine assembly;
HONDA
9.4
CSTROKE Oil or equivalent, rated SAE 10W-40, grade SE
f
I
literl3.000 rpmlmin.
2.5
liters
(2.6
U.S. qt.) at oil change
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-up screen
4. Oil pump worn
High Oil Pressure:
1. Pressure relief valve stuck closed
2.
Plugged oil filter, gallery, or metering orifice
3. Incorrect oil being used
No Oil Pressure
1.
Oil level too low
2. Oil pump drive chain broken
3. Faulty oil pump
Date of Issue: January,
OHONDA MOTOR CO., LTD.
1978
2-
1
HONDA
ENGINE 011 LEVEL CHECK
Place the motorcycle on
the oil level with the filler cap dipstick after
2-3 minutes. Do not screw in the cap when
making this check. If the level
lower level mark on the dipstick, fill to the
upper level mark with the recommended oil.
its
center stand. Check
is
below the
ENGINE 011 & 011 FILTER
CHANGE
engine at normal operating temperature
and vehicle on
Remove the oil filler cap.
Remove the drain plug to drain oil from the
enoine.
NOTE
Crank the engine for 2-3 seconds to
drain any residual oil.
its
center stand to ensure
LUBRICATION
I
IPPFF
-. . -.
LEVEI
MARK
.
,
*-
LOWE
LEVEI
MARK
"
:..;..:
....
BXX:~
..........
CX500
-
-
a
...&
re.,
Screw out the oil 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.
TORQUE:
Reinstall the drain plug.
Making sure the sealing washer
condition.
Fill the engine with 2.5 liters (2.6 U.S.
recommended oil.
RECOMMENDED OIL:
Use HONDA 4-STROKE OIL or equivalent.
API Service Classification
General, all temperatures
Above
0~~132~~
2.0-2.5
15'~/59'~ : SAE 30
-
15'C/59'~ : SAE 20 or 20W
kg-rn
~p
(14-18
:
:
ft-lb)
is
in good
SE
SAE 1OW-40
qt) of
O-RING
COVER
I
Stop the engine, make sure that the oil level is
at
the upper level mark, and there are no oil
leaks.
2-2
OIL
'ILTER BOLT
/
WASHER
Date of Issue: January,
OHONDA MOTOR CO., LTD.
1978
HONDA
CX500
LUBRICATION
FINAL DRIVE GEAR OIL CHECK/
-
REPLACEMENT
OIL LEVEL CHECK
Place the motorcycle on its center stand.
Remove the oil filler cap.
Check that the final gear case
lower edge of the oil filler cap hole.
fresh oil through the oil filler opening
until it reaches the lower 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.
is
filled up to the
OIL CAPACITY: 170
RECOMMENDED OIL: HYPOID GEAR OIL
SAE
90
SAE
80
~
~
DRIVE SHAFT JOINT
Pump multipurpose grease through the drive
shaft joint grease fitting LITHIUM-BASED
MULTIPURPOSE GREASE.
cc
(Above 5'~. 41°F)
(Below 5"~. 41°F)
(5.7 US 02)
Date
of
Issue: January,
O
HONDA MOTOR CO., LTD.
1981
2-3
HONDA
LUBRICATION
POINTS
LUBRICATION
CX500
2-4
SIDE
STAND
Date
of
Issue:
January,
OHONDA MOTOR
CO..
1978
LTD.
I
HONDA
CX500
ENGINE FRAME
SERVICE INFORMATION 3- 1 BATTERY 3-9
AIR CLEANER
CRANKCASE BREATHER 3-3 BRAKE FLUID 3-10
FUEL
SPARK PLUG
VALVE CLEARANCE 3-4 CLUTCH FREE PLAY 3-13
CAM CHAIN
THROTTLE OPERATION 3-5 SUSPENSION 3-14
IDLE SPEED
CARBURETOR CHOKE
CARBURETOR
COOLANT 3-8
COOLING SYSTEM HOSES 3-8
RADIATOR CORE 3-8
LINE
SYNCHRONIZATION 3-7
3-2 BRAKE FLUID LEVEL 3-9
3-3 BRAKE SYSTEM 3-1 1
3-3 HEADLIGHT AIM 3-13
3-5
3-6 WHEELS 3-15
3-6
SIDE STAND 3-14
STEERING HEAD BEARING 3-15
NUTS, BOLTS, FASTENERS 3-15
?
J
INSPECTION
ADJUSTMENT
AND
-
-
.--
SERVICE INFORMATION
WORKING PRACTICE
ENGINE OIL LEVEL
ENGINE
FINAL DRIVE LUBRICANT
DRIVE SHAFT JOINT
SPECIFICATIONS
ENGINE
Spark
. .
Spark plug type: USA model Canadian model
ENGINE CHASSIS
Ignition timing.
Ignition advance
Valve clearance IN
Throttle free play
Idle speed
Vacuum pressure difference
Fast idle speed
Compression
Clutch free play
OIL & OIL FILTER CHANGE
pluq gap:
"FL" mark
between carburetors
0.6-0.7 mm (0.024-0.028
1
For cold climate
below
I
er
,rl0
-
-
,
ND
.
EX
I
I
ri
. . .
,
I
1
NGK
I
:
15' BTDC at 1,100 rpm Tire pressures:
:
37" BTDC at 5,500-6,000 rpm Rider only:
:
0.08 mm (0.003 in.) Front
:
0.10 mm (0.004 in.) Rear
:
2-6 mm (0.08-0.24 in.)
:
1,100il00rpm
:
40 mm (1.6 in.) Hg
:
1,500-2.500 rpm
:
12 + 2 kg/cm2 (171 f 28 psi.)
:
10-20 mm (318-314 in.)
Refer to Page 2-2
Refer to Page 2-2
Refer to Page 2-3
Refer to Page 2-3
in.)
Standard
ND
I
I
F~~
I
high speed
I
NGK ND
]
ND X24ESR-U, NGK DR8ES-L
rirlinn
I
NGK
Rear brake pedal free play
Rider and passenger:
Front
Rear
:
20-30 mm (314-1-114 in.)
:
1.75 kg/cm2 (25 psi.)
:
2.00 kglcm2 (28 psi.)
:
1.75 kglcm2 (25 psi.)
:
2.50 kg/cm2
(36
psi.)
-
TORQUE VALUES
Front axle nut
Front axle nut holder
Rear axle nut
Date of Issue: January. 1981
O
HONDA MOTOR CO., LTD.
:
5.5-6.5 kg-m (40-47 ft-lbs)
:
1.8-2.5 kg-m (13-18 ft.lbs)
:
5.5-6.5 kg-m (40-47 ft-lbs)
a
HONDA
AIR
CLEANER
Remove the seat.
Remove the air cleaner
counterclockwise.
Remove the air cleaner element.
cover by turning
INSPECTION
it
AND
ADJUSTMENT
CX500
Clean the air cleaner element by tapping
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.
it
3-2
Date of Issue: January,
OHONDA MOTOR CO., LTD.
1978
HONDA
CX500
INSPECTION AND ADJUSTMENT
CRANKCASE BREATHER
Remove the two drain plugs from the tubes,
and drain deposits.
Install the two drain plugs.
rain, or full at throttle openings, dropped
or washed often. Service if the deposit
level can be seen in the transparent sec-
.-
-
Make sure that the fuel lines and connections
are not deteriorated, damaged or leaking.
Replace any parts which have deterioration,
damage or leakage.
SPARK PLUG
Disconnect the spark 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 bending the side
electrode.
SPARK PLUG GAP: 0.6-0.7
STANDARD SPARK PLUG:
USA
model
Canadian model
Check the sealing washer condition.
ND X24ES-U NGK D8EA
ND X24ESR-U
NGK DR8ES-L
mm
(0.024-0.028
in.)
!4-0.028
in)
Date of Issue: May,
@
HONDA MOTOR CO.,
1979
LTD.
3-3
INSPECTION AND ADJUSTMENT
VALVE CLEARANCE
NOTE
This adjustment must be performed while
the engine is cold (below
Remove the crankshaft hole cap from the transmission cover and the timing inspection hole
cap from the rear cover.
Remove the spark plug caps.
Remove the cylinder head covers.
Turn the crankshaft clockwise and align the
"TL" mark on the rotor with the pulser index
mark. The left cylinder must be at T.D.C. of
the compression stroke.
Check the intake and exhaust valve clearance of
the left cylinder by inserting a feeler gauge
between the clearance adjusting screw and valve
stem.
VALVE CLEARANCE
IN:
0.08
mm
(0.003
EX:
0.10
mm
(0.004
Adjust, by loosening the lock nut, and turning
the screw until there
feeler guage.
Hold the screw and tighten the lock nut.
Recheck the valve clearances. Turn the crankshaft clockwise and align the "TR" mark on the
rotor with the pulser index mark. The right
cylinder must be at the T.D.C. of the com-
pression stroke.
Check the intake and exhaust valve clearance
of the right cylinder
cvlinder.
35'~).
in.)
in.)
is
a
slight drag on the
as
described for the left
ECTION
HONDA
I4
NOTE
Coat the cylinder head cover bolt rubbers
with oil before tightening.
1
LEFTCYLINDER
1
RIGHT CYLINDER
I
Date of Issue: January,
OHONDA MOTOR CO.. LTD.
1978
HONDA
-
_
L
Cx500
Remove the left cylinder head cover.
Remove the crankshaft and timing hole caps
from the transmission and rear covers
respectively.
Slowly turn the crankshaft clockwise and align
the rotor "TL" mark with the pulser index
mark. Be sure the left piston
compression stroke.
Loosen the cam chain tensioner lock bolt.
When this bolt
tensioner will automatically position itself to
provide the correct cam chain tension.
Retighten the lock bolt.
is
loosened, the cam chain
is
at TDC of the
INSPECTION AND ADJUSTMENT
THROTTLE OPERATION
Check that there
kinks in the throttle cables, and that the
throttle grip free play is
the outer edge of the throttle grip flange.
Check for smooth throttle
fully closed to fully open positions at all
steering positions.
Check that the throttle grip automatically
returns from fully open to fully closed position
when released.
Adjust or replace, if necessary.
is
no deterioration, damage, or
2-6
mm
(118-114
qrip rotation from
-.
in) on
THROTTLE
2-6
mm
(118-114
GRIP
in.)
FREE
PLAY:
Throttle grip free play can be adjusted at either
end of the throttle PULL cable. Major
adjustments must be made at the lower
adjuster. Adjust by loosening the adjuster lock
nut and turning the adjuster. Tighten the
locknut. Minor adjustments must be made at
the upper adjuster.
Date of Issue: January,
OHONDA MOTOR CO., LTD.
1978
LOWER
ADJUSTER
3-5
HONDA
INSPECTION AND ADJUSTMENT
IDLE SPEED
idle adjustment. Ten minutes of stop and
go driving
temperature gauge needle is in the wide
Warm up the engine, place the transmission in
neutral and the motorcycle on
Adjust idle speed with the throttle stop screw.
IDLE SPEED:
is
sufficient, or when the
its
center stand.
1,100?
100
rpm
CARBURETOR CHOKE
Operate the choke knob and check for smooth
operation.
THROTT
I
LE
CX500
STOP
SCREW.
/--.
-
-
,
.
.
.
. . .
..
.
.
..
.:
.
,.
.
,..i
3-6
CHOKE
Date of Issue: January,
OHONDA MOTOR CO., LTD.
1978
I
a
HONDA
INSPECTION AND ADJUSTMENT
CARBURETOR SYNCHRONIZATION
NOTE
1
This adjustment is performed with engine
normal operating temperature,
transmission in neutral, and vehicle on
center stand.
Remove the plugs from the carburetor spacers
and install adapters.
Connect the vacuum gauges.
Start the engine and adjust the idle speed to
1.100t l00rpm.
The difference of vacuum between cylinders
should be within
40
mm
(1.6
in)
Hg.
1
MUST
BE
WITHIN 40mm
(1.6
in) Hg OF EACH OTHER
ADJUSTMENT
Prepare a longer fuel tube and connect
fuel tank and carburetor.
Position the tank higher than normal.
Loosen adjusting screw lock nut.
Balance the vacuum between cylinders to within
40
mm
(1.6
in)
Hg
of each other, by turning
the adjusting screw.
Hold adjusting screw, and tighten the lock nut.
Recheck the synchronization and idle speed.
Reinstall the fuel tank and seat.
Date of Issue: January,
OHONDA MOTOR CO.,
1978
LTD.
it
to the
JUSTING SCREW
3-7
INSPECTION
Check the coolant level of the reserve tank with
the engine running at normal operating temperature.
The level should be between the "FULL" and
"LOW" level lines.
If necessary, remove the reserve tank cap and
fill to the
"FULL"
level line.
COOLING SYSTEM HOSES
Inspect the hoses for cracks or deterioration,
and replace if necessary.
Check the hose clamps, and tighten if necessa-
ry.
AND
ADJUSTMENT
CX500
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 surface.
3-8
Date of
o
HONDA
Issue:
MOTOR
January,
CO.,
1981
LTD.
HONDA
INSPECTION AND ADJUSTMENT
BATTERY
Remove the left side cover.
Inspect the battery electrolyte level.
When the electrolyte level nears the lower level
mark, fill with distilled water to the upper level
mark.
If sulfation forms on the battery walls or
sediments (paste) accumulate on the bottom of
the battery, replace the battery.
NOTE
Add only distilled water. Tap water will
shorten the service life of the battery.
(
Never add more electrolyte.
BRAKE FLUID LEVEL
Check that the brake fluid reservoir
the level mark engraved inside the reservoir.
If the level
reservoir with DOT-3 BRAKE FLUID up to the
level mark.
Check the entire system for leaks, if the level
low.
Do
as they are not compatible.
Do
handlebar has been
that the reservoir is level.
Avoid operating the brake lever with
the cap removed. Brakefluid
out if the lever is pulled.
The
acid. Protect your eyes, skin and clothing.
-.
In case of contact, flush thoroughly with
wter and call a doctor if your eyes were
exposed.
is
lower than the mark, fill the
not mix differentbrands of fluid,
not remove the cap until the
turnedfull left so
ballery electrolyte contains sulfuric
is
filled to
willflow
g
is
j:.:
Date of Issue: January,
O
HONDA MOTOR CO., LTD.
1981
3-9
HONDA
INSPECTION
BRAKE
Check the fluid level with the fluid reservoir
parallel with the ground.
FLUID
REPLACEMENT
the reservoir by the system pressure
pumped up by the
operation
of
the brake
lever.
Avoid spilling fluid on painted surfaces.
Place a rag over the fuel tank whenever
the system is serviced.
BRAKE FLUID DRAINING
Remove the bleeder valve dust cap.
Connect a bleed hose and place one end in a
clean container.
Loosen the caliper bleeder valve and pump up
the system pressure by operating the brake
leverlpedal.
Stop operating the
flowing out of the bleeder valve.
leverlpedal when no fluid is
BRAKE FLUID FILLING
AND
ADJUSTMENT
CXSOO
BRAKE FLUID DOT-3
,,
--
BLEEDER VALVE
the brake, to prevent air from being
pumped into the system.
Do
not mix different brands
Close the bleeder valve, fill the reservoir, and
install the diaphragm.
To prevent piston overtravel and brake fluid
seepage, keep a
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).
20
mm space between the lever
of
fluid since
AIR BLEEDING
Pull the brake lever all the way back to the
handlebar grip. Screw out the bleeder valve
about
112
turn, and retighten.
NOTE
Do not release the lever until the bleeder
valve has been closed.
Release the lever gradually and wait for several
seconds after it reaches the end of its travel.
Repeat the above steps until there are no air
bubbles in the fluid flowing out of the bleeder
valve.
Fill the reservoir up to the UPPER FLUID
LEVEL.
Check the entire system for leaks by operating
the lever.
maim
1
I
rofrraminated brake disc or wds
reduces stopping power. Replace contaminated pads, and clean a contaminated
NEVER
REUSE
I
Date of Issue: January, 1978
OHONDA MOTOR CO.. LTD.
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