Table Of Contents - Honda CX650C 1983 Shop Manual

Table of Contents

Table Of Contents3
General Information5
General Safety5
Service Rules5
Model Identification6
Specifications7
Torque Values9
Standard Torque Values10
Tools11
Cable & Harness Routing13
Emission Control System16
Emission Control Information Label16
Lubrication19
Service Information19
Troubleshooting19
Oil Level Too Low19
Engine Oil Level Check20
Engine Oil & Filter Change20
Oil Strainer Cleaning21
Final Gear Oil Check/Replacement22
Oil Level Check22
Oil Replacement22
Control Cable Lubrication22
Lubrication Points23
Maintenance25
Maintenance Schedule27
Fuel Lines28
Fuel Strainer28
Throttle Operation28
Carburetor Choke29
Air Cleaner30
Crankcase Breather31
Spark Plugs31
Valve Clearance32
Carburetor-Synchronization33
Carburetor-Idle Speed34
Radiator Coolant34
Radiator Core34
Cooling System Hoses35
Battery35
Brake Fluid35
Brake Shoe/Pad Wear36
Brake Shoe Inspection36
Brake Pad Wear36
Brake System36
Brake Light Switch37
Brake Pedal Free Play37
Headlight Aim37
Clutch38
Side Stand38
Suspension39
Front39
Rear39
Nuts, Bolts, Fasteners40
Wheels40
Steering Head Bearings40
Fuel System43
Engine Crank But Won't Start43
Carburetor Removal44
Carburetor Separation44
Carburetor Assembly46
Vacuum Cylinder Disassembly/ Inspection47
Float Chamber Disassembly49
Air Cut-Off Valve Disassembly51
Accelerator Pump Disassembly51
Component Assembly52
Float Level53
Fast Idle Adjustment53
Accelerator Pump Adjustmemt54
Carburetor Installation54
Pilot Screw Adjustment55
Idle Drop Procedure55
High Altitude Adlustment56
Fuel Tank57
Fuel Tank Removal57
Fuel Valve Inspection57
Fuel Valve Disassembly58
Fuel Valve Assembly59
Fuel Tank Installation59
Air Cleaner Case60
Engine Removal/Installation63
Engine Removal64
Engine Installation69
Cylinder Head/Valve71
Low Compression Or Uneven Compression72
High Compression72
Excessive Noise72
Contaminated Engine Oil Or Coolant72
Rocker Aam/Cylinder Head Removal73
Rocker Arm Shaft Inspection76
Rocker Arm Inspection76
Cylinder Head Disassembly77
Cylinder Head Inspection77
Valve Spring Inspection78
Valve Inspection78
Stem-Tb-Guide Clearance Inspection78
Valve Guide Replacement79
Valve Seat Inspection/Grinding80
Valve Seat Cutters81
Valve Seat Refacing81
Cylinder Head Assembly83
Rocker Arm Assembly84
Cylinder Head/Rocker Arm Installation84
Clutch/Oil Pump89
Clutch Disassembly90
Clutch Lifter Removal90
Clutch Lifter Plate Removal90
Clutch Removal91
Clutch Disc92
Clutch Plate92
Clutch Outer And Outer Guide93
Clutch Spring Inspection93
Clutch Installation94
Oil Pump Removal98
Oil Pump Disassembly99
Oil Pump Inspection100
Relief Valve Inspection101
Oil Pump Assembly101
Oil Bump Installation102
Alternator/Flywheel/Rear Cover105
Engine Rear Cover Removal106
Water Pump Removal106
Pulse Generator Removal107
Rear Cover Removal107
Rear Cover Disassembly109
Flywheel Removal110
Reduction Gear Inspection111
Starter Drive Gear Inspection111
Starter Clutch Outer Removal112
Starter Clutch Outer Inspection112
Starter Clutch Outer Installation112
Flywheel Installatiom113
Engine Rear Cover Installation114
Spark Advancer115
Ignition Timing Adjustment116
Water Pump Installation117
Cooling System121
Cooling System Testing122
Coolant122
Radiator Cap Inspection122
Radiator Leakage Test122
Coolant Replacement123
Thermostat124
Temperature Sensor Inspection125
Thermostat Inspection125
Radiator/ Cooling Fan126
Radiator Inspection128
Water Pump Mechanical Seal Replacement131
Camshaft/Cam Chain135
Cam Chain Removal136
Camshaft Removal137
Camshaft Inspection137
Camshaft Holder Inspection138
Camshaft Bearing Inspection138
Rocker Arm Removal139
Rocker Arm Inspectibn139
Rocker Arm Installation140
Camshaft Installation141
Valve Timing Adiusmemt143
Transmission146
Transmission Service Information147
Transmission Specifications147
Transmission Torque Values148
Transmission Tools148
Transmission Troubleshooting148
Gearshift Linkage Removal149
Final Shaft Disassembly149
Final Shaft Assembly150
Transmission Disassembly151
Transmission I Nspectibn155
Transmission Assembly156
Gearshift Linkage Installation162
Crankshaft/Piston165
Connecting Rod Removal167
Piston Removal168
Piston Inspection168
Cylinder Inspection169
Crankshaft Removal170
Rod Side Clearance Inspection171
Crank Pin Bearing172
Bearing Selection173
Crank Pin Bearing Selection173
Crank Pin Bearing Sizes173
Main Journal Bearing Inspection/Selection174
Main Journal Bearing Replacement175
Crankshaft Installation178
Piston Installation181
Connecting Rod Installation182
Cylinder Compression183
Front Wheel/Suspension185
Headlight187
Case Removal187
Case Installation187
Bracket Removal/Installation189
Instruments189
Handlebar190
Front Forks201
Front Fork Installation208
Steering Stem Removal209
Steering Stem Bearing Inspection210
Bottom Cone Race Replacement210
Ball Race Replacement211
Ball Race Installation212
Rear Wheel/Suspension/Brake Service Information215
Rear Wheel/Suspension/Brake Specifications215
Rear Wheel/Suspension/Brake Torque Values215
Rear Wheel/Suspension/Brake Tools215
Rear Wheel/Suspension/Brake Troubleshooting216
Axle218
Wheel Bearings218
Wheel Tim Runout218
Brake Drum I.d.219
Rear Brake Panel222
Lining Thickness Inspection222
Rear Brake Pedal224
Shock Absorber226
Spring Free Length227
Swing Arm229
Pivot Bearing Replacement230
Hydraulic Brake234
Hydraulic Brake Service Information235
Hydraulic Brake Specifications235
Hydraulic Brake Torque Values235
Hydraulic Brake Tool235
Hydraulic Brake Troubleshooting236
Brake Lever Soft Or Spongy236
Brake Lever Too Hard236
Brakes Drag236
Brake Fluid Replacement/Air Bleeding237
Brake Fluid Draining237
Brake Fluid Filling237
Air Bleeding238
Brake Pad/Disc239
Master Cylinder242
Disc Thickness242
Brake Disc Warpage242
Brake Caliper245
Final Drive Service Information249
Final Drive Specifications249
Final Drive Torque Values249
Final Drive Troubleshooting250
Final Drive Tools250
Oil Leak250
Final Drive Removal251
Drive Shaft251
Universal Joint252
Final Drive Gear253
Ring Gear Removal253
Ring Gear Bearing Removal254
Pinion Gear Removal255
Pinion Bearing Removal256
Pinion Retainer Oil Seal Replacement256
Case Bearing And Oil Seal Replacement257
Breather Hole Cleaning258
Pinion Gear Assembly258
Ring Gear Assembly259
Gear Tooth Contact Pattern Check261
Backlash Inspection263
Pinion Joint Installation264
Final Drive Installation265
Battery/Charging System268
Battery/Charging System Service Information269
Battery/Charging System Troubleshooting269
Battery Removal270
Testing Specific Gravity270
Charging System271
Battery Charging271
Charging Output Test271
Stator Coil Continuity Test272
Voltage Regulator/Rectifier Test272
Voltage Regulator Performance Test273
Ignition System274
Ignition System Diagram274
Ignition System Service Information275
Ignition System Troubleshooting275
Ignition System Specifications275
Ignition System Tools275
Ignition Coil276
Primary Coil Inspection276
Secondary Coil Inspection276
Transistorized Ignition System277
Spark Unit Inspection278
Ignition Timing Check280
Pulse Generator Air Gap Adjustment280
Starter System282
Starter System Service Information283
Starter System Specifications283
Starter System Troubleshooting283
Starter Motor Removal284
Starter Motor Brush Inspection284
Starter Motor Commutator Inspection284
Field Coil Inspection285
Starter Relay Switch Inspection286
Clutch Switch Diode Removal287
Clutch Switch Diode Inspection287
Switches/Lights Service Information289
Oil Pressure Switch290
Neutral Switch291
Clutch Switch291
Handlebar Switches291
Turn Signal Switch292
Horn Button292
Starter Button292
Engine Stop Switch293
Ignition Switch293
Thermostatic Switch295
Temperature Gauge295
Brake And Tail Llght Sensor296
Bulb Replacement297
Indicator Light Bulb297
Meter Bulb298
Turn Signal Bulb298
License Plate299
Wiring Diagram301
Engine Does Not Start Or Is Hard To Start302
Engine Lacks Power303
Poor Performance At Low And Idle Speeds304
Poor Performance At High Speed305