Honda gl1500 2002 User Manual

GL1500C/GL1500CD

GL1500C1 GL1500C2 GL1500C3 GL1500CD1 GL1500CD2 GL1500CD3

3

13MZ01E3

© Honda Motor Co., Ltd. 2002

FOREWORD INDEX 1

	2
ENGINE GROUP

	3
FRAME GROUP

GL1500C

PART NUMBER INDEX 4

PART NAME INDEX 5

Instruction for use of parts catalogue

•This parts catalogue was prepared based on the latest information available as of June 20, 2002.

•See the parts catalogue news for any revision that is made after June 20, 2002.

•Always specify the part number when ordering a part.

•Check the model, type, serial numbers, color, maker, and the size as needed before ordering a part.

•Note that the illustrations (part drawings) can differ from the actual parts in shape.

They are given just to help you to refer to the parts.

•When modifications or additions to this parts catalogue are made, a revised edition will be issued at an appropriate time, with successively progressing revision numbers on the cover. We recommend obtaining such revisions in order to keep your parts catalogue up-to-date at all times. To check whether a parts catalogue revision has been issued, please contact your Honda distributor.

Initial version issue date

June 01, 2000

Honda Motor Co., Ltd.

		B 1
CONTENTS	Address
	Page	No.
• How to refer to the part information ............................	2	B	2	1	1
• Part catalogue structure .............................................	3	B	3
• When the parts were revised......................................	4	B 4
• Abbreviations used in the parts catalogue..................	4	B	4
• Part block and serial number check ...........................	5	B	5
• Color label attachment position check........................	5	B	5
• Models, parts catalogue codes and applicable
serial numbers ...........................................................	6	B	6
• Color label ..................................................................	8	B	8
• Color chart ..................................................................	9	B	9
• Fuel hose, general purpose hoses and vinyl
hose.........................................................................	15	B15
• How to use the flat rate time (F.R.T.) .......................	19	C	3
• Illustrated index ........................................................	22	C	6
• ENGINE GROUP.....................................................	30	D 1		2
• FRAME GROUP......................................................	66	G 1		3
• PART NO. INDEX...................................................	134	L 1		4
• PART NAME INDEX...............................................	141	M 1		5

1

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B 2

How to refer to the part information	Reference with “Illustrated index”

1

Reference with “Part number index”

Reference with “Part name index”

2

(

		B 3
Part catalogue structure	Address number
	• Address No. is provided (in place of the page No.) to help
	you refer to the part with the part No. or part name.		1
	Block title	Block number
	Service item/Flat rate time
	Reference number
	• Title number marked with the parenthesis or parentheses
	indicates that it continues from the previous page.
	Part number	Honda color code
	Description
	Assemblies
	• Sections framed with broken lines in the exploded view
	drawings are available as complete assemblies. (Their in-
	dividual parts can also be obtained.)
	Color description
	Note
	• Notes are shown with the parentheses in the part name
	column.
	Required quantity
	• Reqd. QTY shown in the parenthesis or parentheses indi-
	cates the optional part.
	• Reqd. QTY marked with “N” indicates the optional part that
	should be selected as needed.
	• Reqd. QTY indicates the number of the part used in the
	block.

Serial number

Parts catalogue code

• When the parts catalogue code column is blank, it indicates that the part is applicable to all codes.

• Parts enclosed within a dotted line			are covered in a
different block.
• A hollow arrow	indicates the block No. for the parts en-
closed within a dotted line		.
• A solid arrow	indicates the block No. the part in
question is connected to.				3

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When the parts were revised

1

Be sure to check the serial number!!

The number has been	When shown at the left side,	When shown at the right side,
used from the initial model	it is applicable to the models	it is applicable to the models
without revision.	of No.1008001 and the	up to No.1008000.
	subsequent numbers.

4

B 4

Abbreviations used in the parts catalogue

RIGHT is	“L.”stands
abbreviated
as “R.”	for LEFT

*“L.” or “R.” in the description of a part stands for the LEFT hand side or the RIGHT hand side. Determine the left or right as if you were in the motorcycle seat.

• The following abbreviations are used in this parts catalogue.

A ...........	Ampere
ABS .......	Anti-lock brake
	system
A.C. .......	Alternating current
A.M. ...... Attaching mark
ASSY. ....	Assembly
C.D.I. .....	Capacitive discharge
	ignition
COMP. ...	Complete
D.C. .......	Direct current
EX. ........	Exhaust
FR. ........	Front
G ...........	Gram
HEX. ..... Hexagonal
IN. .........	Inlet
KPH ......	Kilometers per hour

L. ............	Left
L (100L)	.Link (100 Links)
L.E.D. .....	Light emitted diode
MM .........	Millimeter
MPH .......	Miles per hour
R. ...........	Right
RR. .........	Rear
STD. .......	Standard
T (22T) ...	Tooth (22 Teeth)
TCS ........	Traction control
	system
T.M. ........	Transcript mark

V............Volt

W...........Watt

WL .........	With labelling
WOL .......	Without labelling

(

Part block and serial number check

	Part block	Engine parts	Carburetor parts	Frame parts
		E-1~	E-20~	F-1~

	Required			Engine serial	Carburetor serial	Frame serial
	serial
				number	number	number
	number
	Check
	point

DMZ0-A

DMZ0-B

B 5

Color label attachment position check

1

Colored parts

Color label

DMZ0-E

5

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1

6

B 6

Models, parts catalogue codes and applicable serial numbers

Models, parts catalogue codes and applicable serial Nos. given in this parts catalogue can be identified as follows. Parts with parts catalogue codes are exclusive for models destined for countries designated.

If no area codes are listed, parts are for common use.

	Model	Parts catarogue	Type	Applicable engine serial No.	Applicable frame serial No.	Applicable carburetor
		code				identification No.
		AR	Austria	SC34E-2400001~	1HFSC34A*1A400001~	VPK0P A
		CM	Canada	SC34E-2400001~	1HFSC342*1A400001~	VPK0J A
		E	England	SC34E-2400001~	1HFSC34A*1A400001~	VPK0S A
		ED	European	SC34E-2400001~	1HFSC34A*1A400001~
			direct sales
	GL1500C1
						VPK0P A
		F	France	SC34E-2400001~	1HFSC34A*1A400001~
		G	Germany	SC34E-2400001~	1HFSC34B*1A400001~
		SW	Switzerland	SC34E-2400001~	1HFSC34C*1A400001~	VPK0N A
		U	Australia	SC34E-2400001~	1HFSC34U*1A400001~	VPK0P A

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					B 7
Model	Parts catarogue	Type	Applicable engine serial No.	Applicable frame serial No.	Applicable carburetor
	code				identification No.
	AR	Austria	SC34E-2500001~	1HFSC34A*2A500001~	VPK0P A
	CM	Canada	SC34E-2500001~	1HFSC342*2A500001~	VPK0J A
	E	England	SC34E-2500001~	1HFSC34A*2A500001~	VPK0S A
	ED	European	SC34E-2500001~	1HFSC34A*2A500001~
		direct sales
GL1500C2
					VPK0P A
	F	France	SC34E-2500001~	1HFSC34A*2A500001~
	G	Germany	SC34E-2500001~	1HFSC34B*2A500001~
	SW	Switzerland	SC34E-2500001~	1HFSC34C*2A500001~	VPK0N A
	U	Australia	SC34E-2500001~	1HFSC34U*2A500001~	VPK0P A
	CM	Canada	SC34E-2600001~	1HFSC342*3A600001~	VPK0J A
GL1500C3
	U	Australia	SC34E-2600001~	1HFSC34U*3A600001~	VPK0P A
GL1500CD1	CM	Canada	SC34E-2400001~	1HFSC348*1A400001~
					VPK0J A
GL1500CD2	CM	Canada	SC34E-2500001~	1HFSC348*2A500001~
GL1500CD3	CM	Canada	SC34E-2600001~	1HFSC348*3A600001~

* Of carburetor/throttle body identification numbers, only the portions underlined in the example below are used for registration.

VPK0P KC

1

7

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B 8

	Color label
1	• When ordering parts, check the model name, main color, and code by observing the “COLOR LABEL” on the vehicle.
	• When ordering a colored part, use the color chart in the instruction for use of parts catalogue.

VFR800FIW

R-157

R157

8

(

B 9
Color chart
• When ordering a colored part, refer to the chart below and use a part number consisting of the relevant basic part number to which has been	1
added a part color code.

GL1500C (GL1500C1)
	MODEL					GL1500C1
	COLOR		Black	Black	Pearl
					coronado	Applicable model
					blue			Applicable	Ref.
	CODE		NH-1	NH-1	PB-255P			block
									No.
						Initial	Final	No.
No.	Name of colored parts	Basic part No.	NH1	NH1E	PB255X
						applicable	applicable
						model	model
1	COVER, CENTER	83700-MZ0-000	ZC	ZC	ZG			F-17	17
2	COVER, L. SIDE	83600-MZ0-000	ZC	ZC	ZG			F-18	9
3	COVER, R. SIDE	83500-MZ0-000	ZC	ZC	ZF			F-18	8
4	EMBLEM, L. FUEL TANK	17532-MZ0-610	ZA	-	-			F-37	4
5	EMBLEM, R. FUEL TANK	17531-MZ0-610	ZA	-	-			F-37	2
6	FENDER A SET, RR.	80110-MZ0-B00	ZA	ZB	ZC			F-26	8
7	FENDER A SET, RR.	80110-MZ0-U70	ZA	-	ZC			F-26	8
8	FENDER B SET, RR.	80210-MZ0-B00	ZA	ZB	ZC			F-26	9
9	FENDER SET, FR.	61110-MZ0-B00	ZA	ZB	ZC			F-8	5
10	LABEL, COLOR	87565-MZ0-B00	ZA	ZB	ZC			F-36	10
11	LABEL, FUEL	87586-MB6-870	-	-	ZF			F-36	11
12	LABEL, FUEL	87586-MR6-670	ZA	-	-			F-36	11
13	STRIPE, L. FR. FENDER	61112-MZ0-B00	-	ZA	ZB			F-37	8
14	STRIPE, L. FUEL TANK	17536-MZ0-B00	-	ZA	ZB			F-37	6
15	STRIPE, L. RR. FENDER A	80112-MZ0-B00	-	ZA	ZB			F-37	10
16	STRIPE, L. RR. FENDER B	80114-MZ0-B00	-	ZA	ZB			F-37	12
17	STRIPE, R. FR. FENDER	61111-MZ0-B00	-	ZA	ZB			F-37	7
18	STRIPE, R. FUEL TANK	17535-MZ0-B00	-	ZA	ZB			F-37	5
19	STRIPE, R. RR. FENDER A	80111-MZ0-B00	-	ZA	ZB			F-37	9
20	STRIPE, R. RR. FENDER B	80113-MZ0-B00	-	ZA	ZB			F-37	11
21	TANK SET, FUEL	17520-MZ0-B00	ZA	ZB	ZC			F-16	9
22	TANK SET, FUEL	17520-MZ0-G51	ZB	-	-			F-16	9
									9
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B10

1

GL1500CD (GL1500CD1)

	MODEL						GL1500CD1
	COLOR			Black	Black	Pearl
						coronado		Applicable model
						blue				Applicable	Ref.
	CODE			NH-1	NH-1	PB-255P				block
											No.
										No.
No.	Name of colored parts	Basic part No.		NH1	NH1E	PB255X		Initial	Final
								applicable	applicable
								model	model
1	COVER, CENTER	83700-MZ0-000		ZC	ZC	ZG				F-17	17
2	COVER, L. SIDE	83600-MZ0-000		ZC	ZC	ZG				F-18	9
3	COVER, R. SIDE	83500-MZ0-000		ZC	ZC	ZF				F-18	8
4	FENDER A SET, RR.	80110-MZ0-B00		ZA	ZB	ZC				F-26	8
5	FENDER B SET, RR.	80210-MZ0-B00		ZA	ZB	ZC				F-26	9
6	FENDER SET, FR.	61110-MZ0-B00		ZA	ZB	ZC				F-8	5
7	LABEL, COLOR	87565-MZ0-B00		ZA	ZB	ZC				F-36	10
8	STRIPE, L. FR. FENDER	61112-MZ0-B00		-	ZA	ZB				F-37	8
9	STRIPE, L. FUEL TANK	17536-MZ0-B00		-	ZA	ZB				F-37	6
10	STRIPE, L. RR. FENDER A	80112-MZ0-B00		-	ZA	ZB				F-37	10
11	STRIPE, L. RR. FENDER B	80114-MZ0-B00		-	ZA	ZB				F-37	12
12	STRIPE, R. FR. FENDER	61111-MZ0-B00		-	ZA	ZB				F-37	7
13	STRIPE, R. FUEL TANK	17535-MZ0-B00		-	ZA	ZB				F-37	5
14	STRIPE, R. RR. FENDER A	80111-MZ0-B00		-	ZA	ZB				F-37	9
15	STRIPE, R. RR. FENDER B	80113-MZ0-B00		-	ZA	ZB				F-37	11
16	TANK SET, FUEL	17520-MZ0-B00		ZA	ZB	ZC				F-16	9

10

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B11

1

GL1500C (GL1500C2)

	MODEL					GL1500C2
	COLOR			Black	Black	Applicable model
									Applicable	Ref.
	CODE			NH-1	NH-1				block
										No.
									No.
No.	Name of colored parts	Basic part No.		NH1	NH1K	Initial		Final
						applicable		applicable
						model		model
1	COVER, CENTER	83700-MZ0-000		ZC	ZC				F-17	17
2	COVER, L. SIDE	83600-MZ0-000		ZC	ZC				F-18	9
3	COVER, R. SIDE	83500-MZ0-000		ZC	ZC				F-18	8
4	EMBLEM, L. FUEL TANK	17532-MZ0-610		ZA	-				F-37	4
5	EMBLEM, R. FUEL TANK	17531-MZ0-610		ZA	-				F-37	2
6	FENDER A SET, RR.	80110-MZ0-B30		ZA	-				F-26	8
7	FENDER A SET, RR.	80110-MZ0-U90		ZA	ZB				F-26	8
8	FENDER B SET, RR.	80210-MZ0-B30		ZA	ZC				F-26	9
9	FENDER SET, FR.	61110-MZ0-B30		ZA	ZC				F-8	5
10	LABEL, COLOR	87565-MZ0-B30		ZA	ZC				F-36	10
11	LABEL, FUEL	87586-MB6-870		-	ZF				F-36	11
12	LABEL, FUEL	87586-MR6-670		ZA	-				F-36	11
13	STRIPE, L. FR. FENDER	61112-MZ0-B30		-	ZA				F-37	8
14	STRIPE, L. FUEL TANK	17536-MZ0-B30		-	ZA				F-37	6
15	STRIPE, L. RR. FENDER A	80112-MZ0-B30		-	ZA				F-37	10
16	STRIPE, L. RR. FENDER B	80114-MZ0-B30		-	ZA				F-37	12
17	STRIPE, R. FR. FENDER	61111-MZ0-B30		-	ZA				F-37	7
18	STRIPE, R. FUEL TANK	17535-MZ0-B30		-	ZA				F-37	5
19	STRIPE, R. RR. FENDER A	80111-MZ0-B30		-	ZA				F-37	9
20	STRIPE, R. RR. FENDER B	80113-MZ0-B30		-	ZA				F-37	11
21	TANK SET, FUEL	17520-MZ0-B30		ZA	ZC				F-16	9
22	TANK SET, FUEL	17520-MZ0-G51		ZB	-				F-16	9

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B12

1

GL1500CD (GL1500CD2)

	MODEL					GL1500CD2
	COLOR			Pearl
				coronado	Black	Applicable model
				blue				Applicable	Ref.
	CODE			PB-255P	NH-1			block
									No.
								No.
No.	Name of colored parts	Basic part No.		PB255X	NH1K	Initial	Final
						applicable	applicable
						model	model
1	COVER, CENTER	83700-MZ0-000		ZG	ZC			F-17	17
2	COVER, L. SIDE	83600-MZ0-000		ZG	ZC			F-18	9
3	COVER, R. SIDE	83500-MZ0-000		ZF	ZC			F-18	8
4	FENDER A SET, RR.	80110-MZ0-B30		ZB	ZC			F-26	8
5	FENDER B SET, RR.	80210-MZ0-B30		ZB	ZC			F-26	9
6	FENDER SET, FR.	61110-MZ0-B30		ZB	ZC			F-8	5
7	LABEL, COLOR	87565-MZ0-B30		ZB	ZC			F-36	10
8	STRIPE, L. FR. FENDER	61112-MZ0-B00		ZB	-			F-37	8
9	STRIPE, L. FR. FENDER	61112-MZ0-B30	-		ZA			F-37	8
10	STRIPE, L. FUEL TANK	17536-MZ0-B00		ZB	-			F-37	6
11	STRIPE, L. FUEL TANK	17536-MZ0-B30	-		ZA			F-37	6
12	STRIPE, L. RR. FENDER A	80112-MZ0-B00		ZB	-			F-37	10
13	STRIPE, L. RR. FENDER A	80112-MZ0-B30	-		ZA			F-37	10
14	STRIPE, L. RR. FENDER B	80114-MZ0-B00		ZB	-			F-37	12
15	STRIPE, L. RR. FENDER B	80114-MZ0-B30	-		ZA			F-37	12
16	STRIPE, R. FR. FENDER	61111-MZ0-B00		ZB	-			F-37	7
17	STRIPE, R. FR. FENDER	61111-MZ0-B30	-		ZA			F-37	7
18	STRIPE, R. FUEL TANK	17535-MZ0-B00		ZB	-			F-37	5
19	STRIPE, R. FUEL TANK	17535-MZ0-B30	-		ZA			F-37	5
20	STRIPE, R. RR. FENDER A	80111-MZ0-B00		ZB	-			F-37	9
21	STRIPE, R. RR. FENDER A	80111-MZ0-B30	-		ZA			F-37	9
22	STRIPE, R. RR. FENDER B	80113-MZ0-B00		ZB	-			F-37	11
23	STRIPE, R. RR. FENDER B	80113-MZ0-B30	-		ZA			F-37	11
24	TANK SET, FUEL	17520-MZ0-B30		ZB	ZC			F-16	9

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B13

1

GL1500C (GL1500C3)

	MODEL					GL1500C3
	COLOR			Black	Applicable model
								Applicable	Ref.
	CODE			NH-1				block
									No.
								No.
No.	Name of colored parts	Basic part No.		NH1	Initial		Final
					applicable		applicable
					model		model
1	COVER, CENTER	83700-MZ0-000		ZC				F-17	17
2	COVER, L. SIDE	83600-MZ0-000		ZC				F-18	9
3	COVER, R. SIDE	83500-MZ0-000		ZC				F-18	8
4	FENDER A SET, RR.	80110-MZ0-B30		ZA				F-26	8
5	FENDER A SET, RR.	80110-MZ0-U90		ZA				F-26	8
6	FENDER B SET, RR.	80210-MZ0-B30		ZA				F-26	9
7	FENDER SET, FR.	61110-MZ0-B30		ZA				F-8	5
8	LABEL, COLOR	87565-MZ0-B50		ZA				F-36	10
9	LABEL, FUEL	87586-MB6-870		ZF				F-36	11
10	TANK SET, FUEL	17520-MZ0-B30		ZA				F-16	9

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B14

1

GL1500CD (GL1500CD3)

	MODEL				GL1500CD3
	COLOR			Black	Applicable model
							Applicable	Ref.
	CODE			NH-1			block
								No.
							No.
					Initial	Final
No.	Name of colored parts	Basic part No.		NH1	applicable	applicable
					model	model
1	COVER, CENTER	83700-MZ0-000		ZC			F-17	17
2	COVER, L. SIDE	83600-MZ0-000		ZC			F-18	9
3	COVER, R. SIDE	83500-MZ0-000		ZC			F-18	8
4	FENDER A SET, RR.	80110-MZ0-B30		ZA			F-26	8
5	FENDER B SET, RR.	80210-MZ0-B30		ZA			F-26	9
6	FENDER SET, FR.	61110-MZ0-B30		ZA			F-8	5
7	LABEL, COLOR	87565-MZ0-B50		ZA			F-36	10
8	TANK SET, FUEL	17520-MZ0-B30		ZA			F-16	9

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B15

Fuel hose, general purpose hoses and vinyl hose

• The standard part fuel hose, general purpose hose and vinyl hose may be substituted by the coiled bulk part.

• When ordering the standard part fuel hose, general purpose hose and vinyl hose use the bulk part number written in the parts catalogue in brackets ( ) underneath the part name, or use the catalogue below.

(The bulk part standard length is 1 m, however, those displayed in the catalogue < > are available in 3 m and 8 m lengths.)

•When exchanging the hose, cut and use at the specified length as mentioned in the part name.

(For the method of cutting the bulk part, and method of filling out orders etc., please refer to the service manual and the instructions issued with the bulk part.)

•The list below is a catalogue of the standard part numbers and bulk part numbers. Note that those numbers are applicable to the listed replacement parts only.

Fuel hoses/Tubes

			Bulk part
	Standard part No.	Bulk part No.	Inner	Length
			diameter	(m)
			(mm)
	95001-30xxx-2x	95001-30001-20M	3.0	1
	95001-30xxx-3x	95001-30001-30M	3.0	1
	95001-30xxx-4x	95001-30001-40M	3.0	1
	95001-35xxx-2x	95001-35001-50M	3.5	1
		<95001-35003-50M>		3
	95001-35xxx-3x	95001-35001-60M	3.5	1
		<95001-35003-60M>		3
	95001-35xxx-4x	95001-35001-60M	3.5	1
		<95001-35003-60M>		3
	95001-35xxx-5x	95001-35001-50M	3.5	1
		<95001-35003-50M>		3
	95001-35xxx-6x	95001-35001-60M	3.5	1
		<95001-35003-60M>		3
	95001-45xxx-2x	95001-45001-50M	4.5	1
		<95001-45003-50M>		3
	95001-45xxx-3x	95001-45001-60M	4.5	1
		<95001-45003-60M>		3
		<95001-45008-60M>		8
	95001-45xxx-4x	95001-45001-60M	4.5	1
		<95001-45003-60M>		3
		<95001-45008-60M>		8
	95001-45xxx-5x	95001-45001-50M	4.5	1
		<95001-45003-50M>		3
	95001-45xxx-6x	95001-45001-60M	4.5	1
		<95001-45003-60M>		3
		<95001-45008-60M>		8
	95001-55xxx-2x	95001-55001-50M	5.5	1
		<95001-55003-50M>		3
		<95001-55008-50M>		8

Fuel hoses/Tubes

			Bulk part
	Standard part No.	Bulk part No.	Inner	Length
			diameter	(m)
			(mm)
	95001-55xxx-3x	95001-55001-60M	5.5	1
		<95001-55003-60M>		3
		<95001-55008-60M>		8
	95001-55xxx-4x	95001-55001-60M	5.5	1
		<95001-55003-60M>		3
		<95001-55008-60M>		8
	95001-55xxx-5x	95001-55001-50M	5.5	1
		<95001-55003-50M>		3
		<95001-55008-50M>		8
	95001-55xxx-6x	95001-55001-60M	5.5	1
		<95001-55003-60M>		3
		<95001-55008-60M>		8
	95001-75xxx-2x	95001-75001-50M	7.5	1
		<95001-75003-50M>		3
	95001-75xxx-3x	95001-75001-60M	7.5	1
		<95001-75003-60M>		3
		<95001-75008-60M>		8
	95001-75xxx-4x	95001-75001-60M	7.5	1
		<95001-75003-60M>		3
		<95001-75008-60M>		8
	95001-75xxx-5x	95001-75001-50M	7.5	1
		<95001-75003-50M>		3
	95001-75xxx-6x	95001-75001-60M	7.5	1
		<95001-75003-60M>		3
		<95001-75008-60M>		8
	95001-80xxx-2x	95001-80001-50M	8.0	1
	95001-80xxx-3x	95001-80001-60M	8.0	1
	95001-80xxx-4x	95001-80001-60M	8.0	1
	95001-80xxx-5x	95001-80001-50M	8.0	1
	95001-80xxx-6x	95001-80001-60M	8.0	1

1

15

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1

16

B16

Vinyl tube

			Bulk part
Standard part	Bulk part No.	Inner	Outer	Length
No.		diameter	dia-meter
		(mm)	(mm)	(m)
95003-01xxx-3x	95003-01001-60M	2.9	6.8	1
	<95003-01003-60M>			3
95003-01xxx-60	95003-01001-60M	2.9	6.8	1
	<95003-01003-60M>			3
95003-03xxx-3x	95003-03001-60M	3.0	6.0	1
	<95003-03003-60M>			3
95003-03xxx-60	95003-03001-60M	3.0	6.0	1
	<95003-03003-60M>			3
95003-05xxx-3x	95003-05001-60M	3.5	6.5	1
	<95003-05003-60M>			3
	<95003-05008-60M>			8
95003-05xxx-60	95003-05001-60M	3.5	6.5	1
	<95003-05003-60M>			3
	<95003-05008-60M>			8
95003-07xxx-1x	95003-07001-10M	4.0	7.0	1
	<95003-07003-10M>			3
	<95003-07008-10M>			8
95003-07xxx-20	95003-07001-10M	4.0	7.0	1
	<95003-07003-10M>			3
	<95003-07008-10M>			8
95003-07xxx-3x	95003-07001-60M	4.0	7.0	1
	<95003-07003-60M>			3
	<95003-07008-60M>			8
95003-07xxx-60	95003-07001-60M	4.0	7.0	1
	<95003-07003-60M>			3
	<95003-07008-60M>			8
95003-07xxx-7x	95003-07001-70M	4.0	7.0	1
	<95003-07003-70M>			3
	<95003-07008-70M>			8
95003-08xxx-1x	95003-08001-10M	4.5	6.5	1
	<95003-08003-10M>			3
	<95003-08008-10M>			8
95003-09xxx-3x	95003-09001-60M	4.5	8.0	1
	<95003-09003-60M>			3
95003-09xxx-60	95003-09001-60M	4.5	8.0	1
	<95003-09003-60M>			3
95003-10xxx-1x	95003-10001-10M	5.0	8.0	1
	<95003-10003-10M>			3
95003-10xxx-20	95003-10001-10M	5.0	8.0	1
	<95003-10003-10M>			3
95003-10xxx-3x	95003-10001-60M	5.0	8.0	1
	<95003-10003-60M>			3
95003-10xxx-60	95003-10001-60M	5.0	8.0	1
	<95003-10003-60M>			3
95003-11xxx-3x	95003-11001-60M	5.0	9.0	1
	<95003-11003-60M>			3
	<95003-11008-60M>			8
95003-11xxx-60	95003-11001-60M	5.0	9.0	1
	<95003-11003-60M>			3
	<95003-11008-60M>			8
95003-12xxx-1x	95003-12001-10M	5.0	7.0	1
	<95003-12003-10M>			3
	<95003-12008-10M>			8
95003-12xxx-20	95003-12001-10M	5.0	7.0	1
	<95003-12003-10M>			3
	<95003-12008-10M>			8

Vinyl tube

			Bulk part
Standard part	Bulk part No.	Inner	Outer	Length
No.		diameter	dia-meter
		(mm)	(mm)	(m)
95003-14xxx-1x	95003-14001-10M	6.0	9.0	1
	<95003-14003-10M>			3
95003-14xxx-20	95003-14001-10M	6.0	9.0	1
	<95003-14003-10M>			3
95003-14xxx-3x	95003-14001-60M	6.0	9.0	1
	<95003-14003-60M>			3
95003-17xxx-1x	95003-17001-10M	7.0	9.0	1
	<95003-17003-10M>			3
95003-19xxx-1x	95003-19001-10M	7.0	11.0	1
	<95003-19003-10M>			3
	<95003-19008-10M>			8
95003-19xxx-20	95003-19001-10M	7.0	11.0	1
	<95003-19003-10M>			3
	<95003-19008-10M>			8
95003-19xxx-3x	95003-19001-60M	7.0	11.0	1
	<95003-19003-60M>			3
	<95003-19008-60M>			8
95003-19xxx-60	95003-19001-60M	7.0	11.0	1
	<95003-19003-60M>			3
	<95003-19008-60M>			8
95003-21xxx-1x	95003-21001-10M	8.0	9.0	1
	<95003-21003-10M>			3
95003-21xxx-20	95003-21001-10M	8.0	9.0	1
	<95003-21003-10M>			3
95003-23xxx-1x	95003-23001-10M	8.0	12.0	1
	<95003-23003-10M>			3
95003-23xxx-20	95003-23001-10M	8.0	12.0	1
	<95003-23003-10M>			3
95003-23xxx-3x	95003-23001-60M	8.0	12.0	1
	<95003-23003-60M>			3
	<95003-23008-60M>			8
95003-23xxx-60	95003-23001-60M	8.0	12.0	1
	<95003-23003-60M>			3
	<95003-23008-60M>			8
95003-25xxx-1x	95003-25001-10M	9.0	11.0	1
	<95003-25003-10M>			3
95003-25xxx-20	95003-25001-10M	9.0	11.0	1
	<95003-25003-10M>			3
95003-25xxx-3x	95003-25001-60M	9.0	11.0	1
	<95003-25003-60M>			3
95003-25xxx-7x	95003-25001-70M	9.0	11.0	1
	<95003-25003-70M>			3
95003-27xxx-1x	95003-27001-10M	9.0	13.0	1
	<95003-27003-10M>			3
95003-27xxx-20	95003-27001-10M	9.0	13.0	1
	<95003-27003-10M>			3
95003-27xxx-3x	95003-27001-60M	9.0	13.0	1
	<95003-27003-60M>			3
95003-27xxx-60	95003-27001-60M	9.0	13.0	1
	<95003-27003-60M>			3
95003-33xxx-1x	95003-33001-10M	10.0	14.0	1
	<95003-33003-10M>			3
95003-33xxx-20	95003-33001-10M	10.0	14.0	1
	<95003-33003-10M>			3

Vinyl tube

			Bulk part
Standard part	Bulk part No.	Inner	Outer	Length
No.		diameter	dia-meter
		(mm)	(mm)	(m)
95003-36xxx-1x	95003-36001-10M	11.0	13.0	1
	<95003-36003-10M>			3
	<95003-36008-10M>			8
95003-36xxx-20	95003-36001-10M	11.0	13.0	1
	<95003-36003-10M>			3
	<95003-36008-10M>			8
95003-37xxx-3x	95003-37001-60M	11.0	15.0	1
	95003-37003-60M>			3
95003-37xxx-60	95003-37001-60M	11.0	15.0	1
	<95003-37003-60M>			3
95003-38xxx-1x	95003-38001-10M	12.0	13.0	1
	<95003-38003-10M>			3
95003-38xxx-20	95003-38001-10M	12.0	13.0	1
	<95003-38003-10M>			3
95003-39xxx-1x	95003-39001-10M	12.0	14.0	1
	<95003-39003-10M>			3
95003-39xxx-20	95003-39001-10M	12.0	14.0	1
	<95003-39003-10M>			3
95003-40xxx-20	95003-40001-10M	12.0	16.0	1
	<95003-40003-10M>			3
95003-40xxx-3x	95003-40001-60M	12.0	16.0	1
	<95003-40003-60M>			3
95003-40xxx-60	95003-40001-60M	12.0	16.0	1
	<95003-40003-60M>			3
95003-43xxx-1x	95003-43001-10M	13.0	15.0	1
	<95003-43003-10M>			3
	<95003-43008-10M>			8
95003-43xxx-20	95003-43001-10M	13.0	15.0	1
	<95003-43003-10M>			3
	<95003-43008-10M>			8
95003-45xxx-1x	95003-45001-10M	14.0	18.0	1
	<95003-45003-10M>			3
	<95003-45008-10M>			8
95003-45xxx-20	95003-45001-10M	14.0	18.0	1
	<95003-45003-10M>			3
	<95003-45008-10M>			8
95003-50xxx-1x	95003-50001-10M	16.0	19.0	1
	<95003-50003-10M>			3
95003-50xxx-20	95003-50001-10M	16.0	19.0	1
	<95003-50003-10M>			3
95003-50xxx-3x	95003-50001-60M	16.0	19.0	1
	<95003-50003-60M>			3
95003-55xxx-1x	95003-55001-10M	17.5	20.5	1
	<95003-55003-10M>			3
95003-55xxx-20	95003-55001-10M	17.5	20.5	1
	<95003-55003-10M>			3
95003-60xxx-1x	95003-60001-10M	22.0	27.0	1
	<95003-60003-10M>			3
95003-60xxx-20	95003-60001-10M	22.0	27.0	1
	<95003-60003-10M>			3
95003-60xxx-3x	95003-60001-60M	22.0	27.0	1
	<95003-60003-60M>			3
95003-60xxx-60	95003-60001-60M	22.0	27.0	1
	<95003-60003-60M>			3

(

General purpose hoses

			Bulk part
	Standard part No.	Bulk part No.	Inner	Length
			diameter	(m)
			(mm)
	95005-11xxx-3x	95005-11001-30M	11.0	1
	95005-11xxx-5x	95005-11001-50M	11.0	1
	95005-12xxx-1x	95005-12001-10M	12.0	1
		<95005-12003-10M>		3
	95005-12xxx-2x	95005-12001-20M	12.0	1
	95005-12xxx-3x	95005-12001-30M	12.0	1
	95005-12xxx-5x	95005-12001-50M	12.0	1
	95005-14xxx-1x	95005-14001-10M	14.0	1
	95005-14xxx-2x	95005-14001-20M	14.0	1
		<95005-14003-20M>		3
	95005-14xxx-3x	95005-14001-30M	14.0	1
	95005-14xxx-5x	95005-14001-50M	14.0	1
	95005-17xxx-1x	95005-17001-10M	17.0	1
	95005-17xxx-2x	95005-17001-20M	17.0	1
	95005-17xxx-3x	95005-17001-30M	17.0	1
	95005-17xxx-5x	95005-17001-50M	17.0	1
	95005-30xxx-3x	95005-30001-30M	3.0	1
	95005-30xxx-5x	95005-30001-50M	3.0	1
	95005-35xxx-1x	95005-35001-10M	3.5	1
		<95005-35003-10M>		3
		<95005-35008-10M>		8
	95005-35xxx-2x	95005-35001-20M	3.5	1
	95005-35xxx-3x	95005-35001-30M	3.5	1
	95005-35xxx-4x	95005-35001-10M	3.5	1
		<95005-35003-10M>		3
		<95005-35008-10M>		8
	95005-35xxx-5x	95005-35001-50M	3.5	1
	95005-45xxx-1x	95005-45001-10M	4.5	1
		<95005-45003-10M>		3
		<95005-45008-10M>		8
	95005-45xxx-2x	95005-45001-20M	4.5	1
	95005-45xxx-3x	95005-45001-30M	4.5	1

C 1

General purpose hoses

			Bulk part
	Standard part No.	Bulk part No.	Inner	Length
			diameter	(m)
			(mm)
	95005-45xxx-4x	95005-45001-10M	4.5	1
		<95005-45003-10M>		3
		<95005-45008-10M>		8
	95005-45xxx-5x	95005-45001-50M	4.5	1
	95005-50xxx-3x	95005-50001-30M	5.0	1
		<95005-50003-30M>		3
	95005-50xxx-5x	95005-50001-50M	5.0	1
	95005-55xxx-1x	95005-55001-10M	5.3	1
		<95005-55003-10M>		3
		<95005-55008-10M>		8
	95005-55xxx-2x	95005-55001-20M	5.3	1
		<95005-55003-20M>		3
	95005-55xxx-4x	95005-55001-10M	5.3	1
		<95005-55003-10M>		3
		<95005-55008-10M>		8
	95005-65xxx-1x	95005-65001-10M	6.5	1
		<95005-65003-10M>		3
	95005-65xxx-2x	95005-65001-20M	6.5	1
	95005-70xxx-3x	95005-70001-30M	7.0	1
		<95005-70003-30M>		3
	95005-70xxx-5x	95005-70001-50M	7.0	1
	95005-75xxx-1x	95005-75001-10M	7.3	1
		<95005-75003-10M>		3
	95005-75xxx-2x	95005-75001-20M	7.3	1
	95005-80xxx-1x	95005-80001-10M	8.0	1
		<95005-80003-10M>		3
	95005-80xxx-2x	95005-80001-20M	8.0	1
	95005-80xxx-3x	95005-80001-30M	8.0	1
	95005-80xxx-5x	95005-80001-50M	8.0	1
	95005-91xxx-3x	95005-91001-30M	12.0	1
	95005-91xxx-5x	95005-91001-50M	12.0	1
	95005-92xxx-3x	95005-92001-30M	12.0	1
	95005-92xxx-5x	95005-92001-50M	12.0	1

NOTE: X is displayed to represent the omitted numerals and letters of the roman alphabet.

CAUTION: It is DANGEROUS to confuse the fuel hose with the general purpose hose or vinyl hose.

Never use a general purpose hose or vinyl hose in place of a fuel hose or vice versa. Always use the correct bulk part in the parts catalogue, according to the service manual or the instructions issued with the bulk part.

1

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C 2

•Bulk part number of fuel hose, general purpose hose and vinyl hose.

1(Example)

9 5 0 0 1 - 7 5 0 0 1 - 5 0 M

Bulk part number: Refers to the bulk part.

Marking code (hose type): (fuel hose and general purpose hose)

Change code (for added hose): (Vinyl hose)

•Indicates number mark or change sequence, however, the code for the bulk part must be strictly 0 (zero).

Types of code:

Red outside braid

• Vinyl hose

1: Clear

• General hose 1: Ash gray

• Fuel hose

2:

(3 mm inside dia. only)

2: Black

2: Ash gray

5: Black inside braid

3: Light red

3: Black

3: Red (3 mm inside dia. only)

6: Light red

5: Black

4: Ash gray with red stripe

7: Pale black

(3 mm inside dia. only)

6: Black

Lengths:

001: 1 m (standard)

003: 3 m

008: 8 m

I.D code: (fuel hose and general purpose hose)

11 mm

30: 3.0 mm

11:

35: 3.5 mm

91: 12 mm (outside dia. 15) mm

45: 4.5 mm

92: 12 mm (outside dia. 16) mm

50: 5.0 mm

12: 12 mm (outside dia. 17) mm

55: 5.3 mm, 5.5 mm

14: 14 mm

65: 6.5 mm

17: 17 mm

70: 7.0 mm

75: 7.3 mm, 7.5 mm

80: 8.0 mm

ID./OD. code: (vinyl hose)

14: ID.

6.0,

OD.

9.0 mm

37: ID. 11.0,

OD. 15.0 mm

01: ID. 2.9,

OD. 6.8 mm

03: ID. 3.0,

OD. 6.0 mm

17: ID.

7.0,

OD.

9.0 mm

38: ID. 12.0,

OD. 13.0 mm

05: ID. 3.5,

OD. 6.5 mm

19: ID.

7.0,

OD. 11.0 mm

39: ID. 12.0,

OD. 14.0 mm

07: ID. 4.0,

OD. 7.0 mm

21: ID.

8.0,

OD.

9.0 mm

40: ID. 12.0,

OD. 16.0 mm

08: ID. 4.5,

OD. 6.5 mm

23: ID.

8.0,

OD. 12.0 mm

43: ID. 13.0,

OD. 15.0 mm

09: ID. 4.5,

OD. 8.0 mm

25: ID.

9.0,

OD. 11.0 mm

45: ID. 14.0,

OD. 18.0 mm

12: ID. 5.0,

OD. 7.0 mm

27: ID.

9.0,

OD. 13.0 mm

50: ID. 16.0,

OD. 19.0 mm

10: ID. 5.0,

OD. 8.0 mm

33: ID. 10.0,

OD. 14.0 mm

55: ID. 17.5,

OD. 20.5 mm

11: ID. 5.0,

OD. 9.0 mm

36: ID. 11.0,

OD. 13.0 mm

60: ID. 22.0,

OD. 27.0 mm

1: Fuel hose

Hose type:

3: Vinyl hose

5: General hose

18

(

How to use the flat rate time (F.R.T.)

This F.R.T. (Flat Rate Time) is used to determine the standard labor time allowed for replacement of parts covered by the warranty during the period the warranty is in effect. The F.R.T. for those parts which are not listed herein should be determined from the operation closely related to the replacement of that part.

1.The F.R.T. is based on the following servicing conditions

a.A liberal allowance is added to the net servicing time.

b.Standard times specified are based on the condition that the necessary servicing tools listed in the service manual (motorcycle) which describes the Honda service policy are available close at hand and the work performed by a mechanic with normal skill.

c.Time required for inspection and operational test following the servicing is included in the F.R.T.

C 3

2.Method of computing

The job times are listed in tenth of an hour to simplify computation.

(Example)	0.3	= 18 minutes
	5.6	= 5 hours and 36 minutes
		CONVERSION CHART
Hours		Minutes			Hours	Minutes
0.1		6			0.6	36
0.2		12			0.7	42
0.3		18			0.8	48
0.4		24			0.9	54
0.5		30			1.0	60

1

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(

1

20

3.Computing the F.R.T.

The following are only examples and do not reflect the actual F.R.T. for this product.

When several jobs are performed at the same time, make the calculation in the following manner.

a.Jobs of non duplicated nature

The F.R.T. for the job is obtained by totalling the F.R.T. for each part replaced.

(Example) Replacement of head cover gasket and oil filter.

Service item		F.R.T.
Packing, cylinder head cover		0.5
Cartridge, oil filter		0.5
	The F.R.T. for the job is: 0.5 + 0.5 = 1.0

b.Jobs of duplicated nature

Take the F.R.T. for the last part to be replaced.

(Example) Replacement of piston and cylinder head gasket.

Service item		F.R.T.
Gasket comp., cylinder head		3.0
Piston		*5.0
	The F.R.T. for the job is: 5.0

C 4

c.Jobs of partially related nature

Total up the F.R.T. for all of the parts replaced and then subtract the F.R.T. for the duplicated operation (i.e., cylinder head gasket service).

(Example) Replacement of valve and cylinder head.

Service item	F.R.T.
Valve	*3.0
Head assy., cylinder	*4.0
Gasket comp., cylinder head	*2.5

The F.R.T. for the job is: (3.0 + 4.0) - 2.5 = 4.5

•The F.R.T. shown with (*) includes engine removal and installation.

•The parts, having the same number of man-hour, are identified by a mark “•”, and classified under the title of their representative work.

(

4.Operations other than replacing parts a. Removal and installation

No.	Service item	F.R.T.
1	Engine	5.0
2	Cylinder head	1.7
3	Carburetor	2.1
4	Crankcase separation	*10.8
5	Radiator	0.6
6	Final Driven Gear	1.2

b.Adjustment, measurement and cleaning Engine

	No.	Service item	F.R.T.
	1	Spark plug adjustment and cleaning	0.4
	2	Carburetor idle adjustment	0.1
	3	Engine oil inspection	0.1
	4	Compression-pressure measurement	0.6
	5	Battery checking of electrolyte level and	0.2
		gravity
	6	Carburetor float level measurement	2.7
	7	Oil strainer cleaning	*11.0
	8	Throttle operation adjustment	0.1
	9	Carburetor synchronization adjustment	0.7
	10	Exterior radiator core cleaning	0.3
	11	Valve clearance adjustment	0.9

C 5

Frame

No.	Service item	F.R.T.
1	Front brake air bleeding	0.2
2	Rear brake air bleeding	0.2
3	Brake operation test	0.1
4	Headlight aiming	0.1
5	Front wheel balance	0.8
6	Rear wheel balance	1.1

c. Overhaul

No.	Service item	F.R.T.
1	Carburetor	3.6
2	Final driven gear	3.5

1

21

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	ENGINE GROUP		C 6
E-1	D 1 E-2	D 3 E-3	D 4
FRONT COVER/TIMING BELT	CYLINDER HEAD COVER		CYLINDER HEAD

2
	E-4	D 6	E-5	D 7	E-6	D 8
		CAMSHAFT/VALVE		WATER PUMP		TRANSMISSION COVER
	E-7	D 9	E-8	D10	E-9	D11
		CLUTCH COVER		CLUTCH		GENERATOR
22

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		ENGINE GROUP	C 7
E-10	D13 E-11	D14 E-12	D15
	STARTING MOTOR	REAR CASE	PRIMARY DRIVE GEAR

						2
E-13	E 1	E-14	E 2	E-15	E 4
	FINAL SHAFT		OIL PUMP		CYLINDER BLOCK
E-16	E 6	E-17	E 8	E-18	E10
	CRANKSHAFT/PISTON		TRANSMISSION		SHIFT DRUM/SHIFT FORK
						23

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	ENGINE GROUP		C 8
E-19	E12 E-20	E13 E-20-1	E15
WATER PIPE/THERMOSTAT	CARBURETOR(ASSY.)		CARBURETOR(TUBING)

2
	E-20-2	E16	E-21	F 2	EOP-1	F 3
	CARBURETOR (COMPONENT PARTS)			AIR INJECTION CONTROL VALVE		GASKET KIT A
	EOP-2	F 4
	GASKET KIT B
24

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			FRAME GROUP		C 9
F-1	G 1	F-1-1	G 3	F-2	G 5
HEADLIGHT(1)			HEADLIGHT(2)		METER
F-3	G 7	F-4	G 9	F-5	G11
SWITCH/CABLE			FR. BRAKE MASTER CYLINDER		CLUTCH MASTER CYLINDER
						3
F-6	G13	F-7	G14	F-8	G15
HANDLE PIPE/TOP BRIDGE			STEERING STEM		FRONT FENDER
						25

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				FRAME GROUP		C10
	F-9	G16	F-10	H 2	F-11	H 3
		FRONT FORK		FRONT BRAKE CALIPER		FRONT WHEEL
	F-12	H 5	F-13	H 7	F-14	H 8
		REAR BRAKE MASTER CYLINDER		REAR BRAKE CALIPER		REAR WHEEL
3
	F-15	H10	F-16	H13	F-17	H15
		FINAL DRIVEN GEAR		FUEL TANK		SEAT
26

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			FRAME GROUP		C11
F-18	I 1	F-19	I 2	F-20	I 4
SIDE COVER			AIR CLEANER		EXHAUST MUFFLER
F-21	I 6	F-22	I 7	F-23	I 9
PEDAL			STEP		SIDE STAND
						3
F-24	I10	F-25	I11	F-26	I12
SWING ARM			REAR CUSHION		REAR FENDER/GRAB RAIL
						27

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