Honda CB500X Service Manual
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Honda CB500X Service Manual

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This manual should be considered a permanent part of the motorcycle
and should remain with the motorcycle when it is resold.
This publication includes the latest production information available
before printing. Honda Motor Co., Ltd. reserves the right to make
changes at any time without notice and without incurring any obligation.
No part of this publication may be reproduced without written
permission.
The vehicle pictured in this owner's manual may not match your actual
vehicle.
© 2013 Honda Motor Co., Ltd.
http://www.motorcycle.in.th

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Summary of Contents for Honda CB500X

  • Page 1 This publication includes the latest production information available before printing. Honda Motor Co., Ltd. reserves the right to make changes at any time without notice and without incurring any obligation.
  • Page 2 Honda motorcycle. Your selection of a ● The illustrations here in are based on the Honda makes you part of a worldwide family CB500XA ED type. of satisfied customers who appreciate Country Codes Honda’s reputation for building quality into...
  • Page 3 A Few Words About Safety Your safety, and the safety of others, is very DANGER important. Operating this motorcycle safely is You WILL be KILLED or SERIOUSLY an important responsibility. HURT if you don’t follow instructions. To help you make informed decisions about safety, we have provided operating WARNING procedures and other information on safety...

  • Page 4: Table Of Contents

    Contents Motorcycle Safety P. 2 Operation Guide P. 16 Maintenance P. 39 Troubleshooting P. 82 Information P. 102 Specifications P. 114 Index P. 117 http://www.motorcycle.in.th...

  • Page 5: Motorcycle Safety

    Motorcycle Safety This section contains important information for safe riding of your motorcycle. Please read this section carefully. Safety Guidelines .........P. 3 Image Labels..........P. 6 Safety Precautions ........P. 10 Riding Precautions ........P. 11 Accessories & Modifications......P. 14 Loading ............P. 15 http://www.motorcycle.in.th...

  • Page 6: Safety Guidelines

    Safety Guidelines Safety Guidelines that you and your passenger are both wearing an approved motorcycle helmet and protective Follow these guidelines to enhance your safety: apparel. Instruct your passenger on holding ● Perform all routine and regular inspections onto the grab rails or your waist, leaning with specified in this manual.
  • Page 7 Safety Guidelines Make Yourself Easy to See Keep Your Honda in Safe Condition It’s important to keep your motorcycle properly Make yourself more visible, especially at night, by wearing bright reflective clothing, maintained and in safe riding condition. positioning yourself so other drivers can see...
  • Page 8 Safety Guidelines check the tightness of critical nuts and bolts, WARNING and check the handlebar, control levers, brakes, and wheels. Ride slowly and cautiously. Carbon monoxide gas is toxic. Your motorcycle may have suffered damage Breathing it can cause that is not immediately apparent. Have your unconsciousness and even kill you.

  • Page 9: Image Labels

    Image Labels Image Labels Read instructions contained in Owner’s Manual carefully. Except KO type The following pages describe the label meanings. Some labels warn you of Read instructions contained in Shop Manual potential hazards that could cause serious carefully. In the interest of safety, take the motorcycle to be serviced only by your dealer.
  • Page 10 Image Labels BATTERY LABEL DANGER • Keep flame and spark away from the battery. Battery produce explosive gas that can cause explosion. • Wear the eye protection and rubber gloves when handling the battery, or you can get burned or lose your eyesight by the battery electrolyte.
  • Page 11 Image Labels RADIATOR CAP LABEL Except U type DANGER NEVER OPEN WHEN HOT. Hot coolant will scald you. Relief pressure valve begins to open at 1.1 kgf/cm ACCESSORIES AND LOADING WARNING LABEL Except U type WARNING ACCESSORIES AND LOADING • The safety stability and handling of this motorcycle may be affected by the addition of accessories and luggage.
  • Page 12 Image Labels TYRE INFORMATION LABEL Cold tyre pressure: [Driver only] Front 250 kPa (2.50 kgf/cm , 36 psi) Rear 290 kPa (2.90 kgf/cm , 42 psi) [Driver and passenger] Front 250 kPa (2.50 kgf/cm , 36 psi) Rear 290 kPa (2.90 kgf/cm , 42 psi) Tyre size: Front...

  • Page 13: Safety Precautions

    Safety Precautions Safety Precautions ● Face shield with unobstructed field of vision or other approved eye protection ● Ride cautiously and keep your hands on the WARNING handlebar and feet on the footpegs. ● Keep passenger’s hands onto the grab rails or Not wearing a helmet increases the your waist, passenger’s feet on the footpegs chance of serious injury or death in a...

  • Page 14: Riding Precautions

    Riding Precautions Riding Precautions Brakes Observe the following guidelines: ● Running-in Period For full braking effectiveness, operate both the front and rear brakes together. During the first 500 km (300 miles) of running, ● Avoid excessively hard braking and down- follow these guidelines to ensure your shifts.
  • Page 15 Riding Precautions ❙ ❙ Anti-lock Brake System (ABS) Engine Braking CB500XA only Engine braking helps slow your motorcycle This model is equipped with an Anti-lock Brake down when you release the throttle. For further System (ABS) designed to help prevent the slowing action, downshift to a lower gear.
  • Page 16 Riding Precautions 3. Slowly lean the motorcycle to the left until its Parking weight rests on the side stand. ● Park on a firm, level paved surface. 4. Turn the handlebar fully to the left. ● If you must park on a slight incline or loose Turning the handlebar to the right reduces surface, park so that the motorcycle cannot stability and may cause the motorcycle to...

  • Page 17: Accessories & Modifications

    Honda or make modifications to your motorcycle from its Follow all instructions in this owner’s original design. Doing so can make it unsafe.

  • Page 18: Loading

    Loading Loading WARNING ● Carrying extra weight affects your Overloading or improper loading can motorcycle’s handling, braking and stability. cause a crash and you can be seriously Always ride at a safe speed for the load you hurt or killed. are carrying.

  • Page 19: Operation Guide

    Parts Location Side cover (P57) (P36) Fuel fill cap (P66) Front brake fluid reservoir Front brake lever Throttle grip (P76) Engine oil fill cap (P60) Engine oil level inspection window (P60) (P63) Engine oil filter Engine oil drain bolt (P62) Rear brake pedal Main fuse (P101)
  • Page 20 Windscreen (P80) Bulb Lid (P58) Clutch lever (P73) (P56) Seat (P59) Battery (P100) Fuse box Side cover (P57) Drive chain (P69) Rear suspension spring preload (P78) adjuster (P64) Coolant reserve tank (P68) Side stand (P35) Shift lever Crankcase breather (P77) http://www.motorcycle.in.th...
  • Page 21 Instruments SET button SEL button Display Check When the ignition switch is turned on, all the mode and digital segments will show, and the tachometer segment progresses to maximum scale and then disappear. If any part of these displays does not come on when it should, have your dealer check for problems.
  • Page 22 Speedometer Tachometer NOTICE Do not operate the engine in the tachometer red zone. Excessive engine speed can adversely affect engine life. Tachometer red zone (excessive engine rpm range) Clock (12-hour display) To set the clock: (P25) Fuel gauge Remaining fuel when only 1st (E) segment starts flashing: approximately 2.8 litres (0.74 US gal, 0.62 Imp gal) If the fuel gauge indicators repeat flashing or turned off: (P87)
  • Page 23 Instruments Odometer [TOTAL] & Tripmeter [TRIP A/B] & Fuel mileage meter & Fuel consumption meter SEL button selects the odometer, tripmeter A, tripmeter B, current fuel mileage, average fuel mileage and fuel consumption. (P22) To reset the tripmeter: Odometer Tripmeter A Tripmeter B Current fuel Average fuel...
  • Page 24 The average fuel mileage and fuel consumption will be based on tripmeter A. • Current fuel mileage: Current instant fuel mileage. If your speed is less than 7 km/h (5 mph), “ ” is displayed. When “ ” is displayed at speeds above 7 km/h (5 mph), go to your dealer for service. •...
  • Page 25 Instruments ❙ To reset the tripmeter, average fuel Then, the display returns to the last selected indication. mileage and fuel consumption To reset tripmeter A, average fuel mileage, and fuel consumption together, press and hold SET button with tripmeter A, average fuel mileage, or fuel consumption displayed.
  • Page 26 Reserve fuel consumption display • Flashes from “0.0” L (litre) or gal (US gal). When the 1st (E) segment of the fuel gauge When the amount of consumed fuel is more than 1.0 litre (0.26 US gal, 0.22 Imp starts flashing, the odometer & tripmeter & gal) the display blinks faster.
  • Page 27 Instruments Display Setting Ordinary display Following items to change sequentially. • Clock setting • Backlight brightness adjustment Setting Mode • Activating/deactivating of tripmeter A, Clock setting average fuel mileage and fuel consumption automatic reset mode Backlight brightness adjustment • Setting of HISS indicator •...
  • Page 28 In addition, to return to the ordinary display Press SET button. The minute digits start flashing. at display setting. • The button is not pressed for about 30 seconds • Turn the ignition switch off and then on Press SEL button until the desired minute is displayed.
  • Page 29 Instruments 2 Backlight brightness adjustment: Press SET button. The backlight is set, and then the display moves to activating/ You can adjust the brightness to five levels. deactivating of tripmeter A, average fuel Press SEL button. The brightness is switched. mileage and fuel consumption automatic reset mode.
  • Page 30 3 To activate/deactivate of tripmeter A, To end the selection, press SET button. The average fuel mileage and fuel activation/deactivation of automatic reset consumption automatic reset mode: mode is set, and then the display moves to You can also activate or deactivate the the on/off of blinks of HISS indicator (HISS automatic reset mode by refuelling after 1st indicator comes on).
  • Page 31 4 HISS indicator setting: 5 Changing the speed and mileage unit: You can select the blink or off the HISS E type only indicator. Press SEL button to select either “km/h” and Press SEL button to select “ ” (blinks) or “km”...
  • Page 32 6 Changing the fuel mileage meter unit: To end the selection, press SET button. Press SEL button to select “km/L” or “L/100 The established setting can also be set by km.” turning the ignition switch to OFF. The control is automatically switched from the setting mode to the ordinary display if the button is not pressed for about 30 E type only...
  • Page 33 Indicators Low oil pressure indicator ABS (Anti-lock Brake System) indicator CB500XA only Comes on when the ignition Comes on when the ignition switch is turned on. switch is turned on. Goes off when your speed reaches approximately Goes off when the engine starts. 10 km/h (6 mph).
  • Page 34 Left turn signal indicator Neutral indicator Comes on when the transmission is in Neutral. HISS indicator (P83) (P104) • Comes on briefly when the ignition switch is turned on. Goes off if the ignition key has the correct coding. • Flashes every 2 seconds for 24 hours when the ignition switch is turned off.
  • Page 35 Switches Engine stop switch Should normally remain in the (Run) position. In an emergency, switch to (Off) position to stop the engine. Start button Hazard switch Switchable when the ignition switch is on. Can be turned to Horn button off regardless of the ignition Turn signal switch switch position.

  • Page 36: Steering Lock

    Ignition Switch Turns electrical system Switches the electrical system on/off, locks the on for starting/riding. steering. Key can be removed when in the OFF or LOCK Turns engine off. position. LOCK Locks steering. ❙ Steering Lock Locking Lock the steering when parking to help Turn the handlebar all the way to the left.

  • Page 37: Starting The Engine

    Starting the Engine Start your engine using the following Make sure the engine stop switch is in the (Run) position. procedure, regardless of whether the engine is cold or warm. Turn the ignition switch to the ON position. Shift the transmission to Neutral ( indicator comes on).

  • Page 38: Shifting Gears

    Shifting Gears Your motorcycle transmission has six forward gears in a one-down, five-up shift pattern. If you put the motorcycle in gear with the side stand down, the engine will shut off. http://www.motorcycle.in.th...
  • Page 39 Refuelling Opening the Fuel Fill Cap Ignition key Fuel filler opening Open the lock cover, insert the ignition key, and turn it clockwise to remove the cap. Closing the Fuel Fill Cap After refuelling, align the fuel fill cap latch with the slot in the filler neck.
  • Page 40 Storage Equipment Helmet holder WARNING The helmet holder is located under the seat. A helmet set wire is in the tool kit. Riding with a helmet attached to the holder can interfere with the rear Helmet set wire wheel or suspension and could cause a crash in which you can be seriously hurt or killed.
  • Page 41 Tool kit / U-shaped lock Document bag The tool kit is located under the seat. The document bag is located underside of There is also space to store a U-shaped lock. the seat. Document bag Rubber strap Tool kit Rubber strap ❙...

  • Page 42: Maintenance

    Maintenance Please read “Importance of Maintenance” and “Maintenance Fundamentals” carefully before attempting any maintenance. Refer to “Specifications” for service data. Importance of Maintenance ..... P. 40 Brakes ............P. 66 Maintenance Schedule ......P. 41 Side Stand...........P. 68 Maintenance Fundamentals ..... P. 44 Drive Chain ..........P.

  • Page 43: Importance Of Maintenance

    Importance of Maintenance Importance of Maintenance Maintenance Safety Keeping your motorcycle well-maintained is Always read the maintenance instructions absolutely essential to your safety and to before you begin each task, and make sure that protect your investment, obtain maximum you have the tools, parts, and skills required. performance, avoid breakdowns, and reduce air We cannot warn you of every conceivable pollution.

  • Page 44: Maintenance Schedule

    Maintenance work should be performed in motorcycle to the new owner. accordance with Honda’s standards and Honda recommends that your dealer should specifications by properly trained and equipped technicians. Your dealer meets all road test your motorcycle after each periodic of these requirements.
  • Page 45 : Inspect (clean, adjust, lubricate, or replace if necessary) you have the necessary tools and are mechanically skilled. : Lubricate Procedures are provided in an official Honda Shop Manual. : Replace : Technical. In the interest of safety, have your motorcycle : Clean serviced by your dealer.
  • Page 46 Maintenance Schedule Frequency Pre-ride Annual Regular Refer to Items Check × 1,000 km Check Replace page P. 44 × 1,000 mi Drive Chain Every 1,000 km (600 mi): Drive Chain Slider Brake Fluid 2 Years Brake Pads Wear Brake System Brakelight Switch Headlight Aim Lights/Horn...

  • Page 47: Maintenance Fundamentals

    Maintenance Fundamentals ● Drive chain − Check condition and slack, Pre-ride Inspection adjust and lubricate if necessary. P. 69 To ensure safety, it is your responsibility to ● Brakes − Check operation; perform a pre-ride inspection and make sure Front and Rear: check brake fluid level and that any problem you find is corrected.
  • Page 48 Maintenance Fundamentals Replacing Parts Colour label Always use Honda Genuine Parts or their equivalents to ensure reliability and safety. When ordering coloured components, specify the model name, colour, and code mentioned on the colour label. The colour label is attached to the rear fender under the seat.
  • Page 49 Maintenance Fundamentals Battery WARNING Your motorcycle has a maintenance-free type The battery gives off explosive battery. You do not have to check the battery hydrogen gas during normal electrolyte level or add distilled water. Clean the operation. battery terminals if they become dirty or corroded.
  • Page 50 Always replace the battery with another maintenance-free battery of the same type. NOTICE Installing non-Honda electrical accessories can overload NOTICE the electrical system, discharging the battery and possibly Replacing a fuse with one that has a higher rating greatly damaging the system.
  • Page 51 Conserving” or “Resource Conserving” on the For recommended engine oil, see circular API service symbol. “Specifications.” P. 115 If you use non-Honda engine oil, check the label to make sure that the oil satisfies all of the following standards: ● JASO T 903 standard...
  • Page 52 If either has worn or damaged teeth, NOTICE have the sprocket replaced by your dealer. Brake fluid can damage plastic and painted surfaces. Wipe up spills immediately and wash thoroughly. Recommended brake fluid: Honda DOT 4 Brake Fluid or equivalent Normal Worn Damaged (REPLACE) (GOOD)
  • Page 53 Recommended lubricant: Drive chain lubricant designed Recommended Coolant specifically for O-ring chains. Pro Honda HP coolant is a pre-mixed solution of If not available, use SAE 80 or 90 gear oil. antifreeze and distilled water. Concentration: 50% antifreeze and 50% distilled water...
  • Page 54 Maintenance Fundamentals ❙ A concentration of up to 60% will provide Inspecting for Damage better protection in colder climates. Inspect the tyres for cuts, slits, or cracks NOTICE that exposes fabric or Using coolant not specified for aluminium engines or cords, or nails or ordinary tap water or mineral can cause corrosion.
  • Page 55 Maintenance Fundamentals ❙ Inspecting Tread Depth WARNING Inspect the tread wear indicators. If they become visible, replace the tyres immediately. Riding on tyres that are excessively For safe riding, you should replace the tyres worn or improperly inflated can cause when the minimum tread depth is reached.
  • Page 56 Always use the size and type of tyres ● Have the wheel balanced with Honda recommended in this owner’s manual. Genuine balance weights or equivalents after the tyre is installed. ●...
  • Page 57 Maintenance Fundamentals Air Cleaner This motorcycle is equipped with a viscous type air cleaner element. Compressed air cleaning or any other cleaning can degrade the viscous element performance and cause the intake of dust. Do not perform the maintenance. Should be serviced by your dealer. http://www.motorcycle.in.th...

  • Page 58: Tool Kit

    Tool Kit The tool kit is stored under the seat. P. 56 U, KO type ● Pin spanner ● You can perform some roadside repairs, 8 × 12 mm Open end wrench minor adjustments and parts replacement ● 10 × 14 mm Open end wrench with the tools contained in the kit.

  • Page 59: Removing & Installing Body Components

    Removing & Installing Body Components ❙ Seat Removal 1. Insert the ignition key into the seat lock. 2. Turn it clockwise, then pull the seat back Ignition key Tab Recess and up. Front prong ❙ Installation Rear 1. Insert the front and rear prongs into the prongs Seat lock front and rear stays on the frame.

  • Page 60: Side Cover

    Removing & Installing Body Components Side Cover Side Cover The left side cover must be removed to access the coolant reserve tank cap. The right side cover must be removed to Prongs grommets grommets access the main fuse. The right and left side covers can be removed in the same manner.

  • Page 61: Bulb Lid

    Removing & Installing Body Components Bulb Lid Bulb Lid Clip The bulb lid must be removed to replace the The clip must be removed to remove the bulb headlight bulb and position light bulb. lid. ❙ Removal 1. Press down on the centre pin to release the lock.

  • Page 62: Battery

    Removing & Installing Body Components Battery ❙ Battery Removal Make sure the ignition switch is off. 1. Remove the seat. P. 56 Positive Rubber 2. Unhook the rubber strap from rear side. terminal strap 3. Disconnect the negative terminal from the battery.

  • Page 63: Engine Oil

    Engine Oil Checking the Engine Oil 1. If the engine is cold, idle the engine for 3 to 5 minutes. 2. Turn the ignition switch off, stop the engine and wait for 2 to 3 minutes. Oil level inspection 3. Place your motorcycle in an upright window position on a firm, level surface.

  • Page 64: Adding Engine Oil

    Engine Oil Adding Engine Oil Adding Engine Oil NOTICE Overfilling with oil or operating with insufficient oil can If the engine oil is below or near the lower cause damage to your engine. Do not mix different brands level mark, add the recommended engine oil. and grades of oil.

  • Page 65: Changing Engine Oil/Filter

    Changing Engine Oil & Filter Changing the oil and filter requires special tools. We recommend that you have your motorcycle serviced by your dealer. Use a new Honda Genuine oil filter or equivalent specified for your model. Drain bolt Sealing...
  • Page 66 Engine Oil Changing Engine Oil & Filter 9. Install a new sealing washer onto the drain bolt. Tighten the drain bolt. Torque: 30 N·m (3.1 kgf·m, 22 lbf·ft). 10. Fill the crankcase with the recommended oil ( P. 48) and install the oil fill cap. Required oil When changing oil &...

  • Page 67: Coolant

    Coolant Checking the Coolant If the coolant level is dropping noticeably or the reserve tank is empty, you likely have a 1. Place your motorcycle on a firm, level serious leak. Have your motorcycle inspected surface. by your dealer. 2. Hold your motorcycle in an upright position.

  • Page 68: Changing Coolant

    Coolant Changing Coolant 1. Remove the left side cover. P. 57 Reserve tank cap 2. Remove the reserve tank cap and add fluid while monitoring the coolant level. Do not overfill above the UPPER level mark. Make sure no foreign objects enter the reserve tank opening.

  • Page 69: Brakes

    Brakes Checking Brake Fluid If the brake fluid level in either reservoir is below the LWR or LOWER level mark or the 1. Place your motorcycle in an upright brake lever and pedal freeplay becomes position on a firm, level surface. excessive, inspect the brake pads for wear.
  • Page 70 Brakes Inspecting the Brake Pads Inspecting the Brake Pads If necessary have the pads replaced by your dealer. Check the condition of the brake pad groove Always replace both left and right brake pads wear indicators. at the same time. The pads need to be replaced if a brake pad is worn to the indicator.

  • Page 71: Side Stand

    Side Stand 4. Start the engine, pull the clutch lever in, and shift the transmission into gear. 5. Lower the side stand all the way. The engine should stop as you lower the side stand. If the engine doesn’t stop, have your motorcycle inspected by your dealer.

  • Page 72: Drive Chain

    Drive Chain Inspecting the Drive Chain Slack Check the drive chain slack at several points along the chain. If the slack is not constant at all points, some links may be kinked and binding. Have the chain inspected by your dealer. 1.

  • Page 73: Adjusting The Drive Chain Slack

    Drive Chain Adjusting the Drive Chain Slack Adjusting the Drive Chain Slack Lock nut Adjusting the chain requires special tools. Have the drive chain slack adjusted by your dealer. CB500XA only When adjusting the drive chain slack, be careful not to damage the wheel speed sensor and pulser ring.
  • Page 74 Drive Chain Adjusting the Drive Chain Slack 5. Turn both adjusting nuts an equal number 7. Tighten the rear axle nut. of turns until the correct drive chain slack Torque: 88 N·m (9.0 kgf·m, 65 lbf·ft). is obtained. Turn the adjusting nuts 8.
  • Page 75 Drive Chain Checking the Drive Chain Slider ❙ Checking the Drive Chain Slider C h ecking the Drive C h ain Wear Check the chain wear label when adjusting Check the condition of the drive chain slider. the drive chain. If the index mark on the The drive chain slider need to be replaced if it washer enters the red zone on the label after is worn to the wear limit line.

  • Page 76: Clutch

    Clutch Checking the Clutch Check the clutch cable for kinks or signs of wear. If necessary have it replaced by your ❙ C h ecking the C l utch Lever Freeplay dealer. Lubricate the clutch cable with a Check the clutch lever freeplay. commercially available cable lubricant to Freeplay at the clutch lever: prevent premature wear and corrosion.

  • Page 77: Adjusting The Clutch Lever

    Clutch Adjusting the Clutch Lever Freeplay Adjusting the Clutch Lever Upper lock nut Freeplay ❙ Upper Adjustment Attempt adjustment with the upper clutch – cable adjuster first. 1. Loosen the upper lock nut. 2. Turn the upper clutch cable adjuster until the freeplay is 10 to 20 mm (0.4 to 0.8 in).
  • Page 78 Clutch Adjusting the Clutch Lever Freeplay 1. Loosen the upper lock nut and turn the Lower adjusting nut upper clutch cable adjuster all the way in Lower lock nut (to provide maximum freeplay). Tighten the upper lock nut. 2. Loosen the lower lock nut. 3.

  • Page 79: Throttle

    Throttle Checking the Throttle With the engine off, check that the throttle rotates smoothly from fully closed to fully open in all steering positions and throttle freeplay is correct. If the throttle does not move smoothly, close automatically, or if the cable is damaged, have the motorcycle inspected by your dealer.

  • Page 80: Crankcase Breather

    Crankcase Breather Cleaning the Crankcase Breather 1. Remove the crankcase breather tube plug from the tube. 2. Drain deposits into a suitable container. 3. Install the crankcase breather tube plug. Crankcase breather tube plug http://www.motorcycle.in.th...

  • Page 81: Other Adjustments

    Other Adjustments Adjusting the Rear Suspension ❙ Index mark Spring Preload You can adjust the spring preload by the adjuster to suit the load or the road surface. Adjuster Turn the adjuster using the pin spanner and extension bar provided in the tool kit. Lower P.

  • Page 82: Headlight Aim

    Other Adjustments Adjusting the Headlight Aim Adjusting the Headlight Aim Adjusting the Brakelight Switch You can adjust vertical aim of the headlight for proper alignment. Turn the pinion using a Check the operation of the brakelight switch. Phillips screwdriver provided in the tool kit Hold the brakelight switch and turn the P.

  • Page 83: Windscreen Height

    Other Adjustments Adjusting the Windscreen Height Adjusting the Windscreen 2. Remove the windscreen by removing the screws, the washers A. Height Windscreen You can adjust the windscreen height 2 Screws positions. 1. Remove the upper side caps. Upper side caps Screws Washers A http://www.motorcycle.in.th...
  • Page 84 Other Adjustments Adjusting the Windscreen Height 3. Remove the nuts and the washers B. 5. Install the windscreen. 6. Install and tighten the washers A and Washers B Nuts screws. 7. Install the upper side caps. 8. Make sure the installation order is the following illustration.

  • Page 85: Troubleshooting

    Troubleshooting Engine Will Not Start (HISS indicator stays Tyre Puncture..........P. 88 on) ............P. 83 Electrical Trouble ........P. 95 Overheating (High coolant temperature Battery Goes Dead ........P. 95 indicator is on)..........P. 84 Burned-out Light Bulb....... P. 95 Warning Indicators On or Flashing ...P.

  • Page 86: Engine Will Not Start (Hiss Indicator Stays On)

    Engine Will Not Start (HISS indicator stays on) ❙ Starter Motor Operates But Engine Check if there are no any metallic seals Does Not Start or stickers on the key. If the HISS indicator still stays on, have Check the following items: your motorcycle inspected by your ●...

  • Page 87: Overheating (High Coolant Temperature Indicator Is On)

    Overheating (High coolant temperature indicator is on) The engine is overheating when the 2. Check that the radiator fan is operating, following occurs: and then turn the ignition switch to the ● High coolant temperature indicator comes OFF position. If the fan is not operating: ●...

  • Page 88: Warning Indicators On Or Flashing

    Warning Indicators On or Flashing Low Oil Pressure Indicator If the engine oil level goes down rapidly, your motorcycle may have a leak or another If the low oil pressure indicator comes on, serious problem. Have your motorcycle pull safely to the side of the road and stop inspected by your dealer.

  • Page 89: Abs (Anti-Lock Brake System) Indicator (Cb500Xa Only)

    Warning Indicators On or Flashing ABS (Anti-lock Brake System) Indicator (CB500XA only) ABS (Anti-lock Brake System) If the ABS indicator stays on, your brakes will continue to work as a conventional system, Indicator (CB500XA only) but without the anti-locking function. If the indicator operates in one of the The ABS indicator may flash if you turn the following ways, you may have a serious...

  • Page 90: Other Warning Indication

    Other Warning Indication Fuel Gauge Failure Indication If the fuel system has an error, all segments will blink or go off as shown in the illustration. If these occurs, see your dealer as soon as possible. http://www.motorcycle.in.th...

  • Page 91: Tyre Puncture

    Tyre Puncture Repairing a puncture or removing a wheel WARNING requires special tools and technical expertise. We recommend you have this type of service Riding your motorcycle with a performed by your dealer. temporary tyre repair can be risky. If After an emergency repair, always have the the temporary repair fails, you can tyre inspected/replaced by your dealer.
  • Page 92 Tyre Puncture Removing Wheels CB500XA only Take care to prevent the brake caliper When removing and installing the wheel, be from scratching the wheel during careful not to damage the wheel speed removal. sensor and pulser ring. Mounting bolts Tape or cloth ❙...
  • Page 93 Tyre Puncture Removing Wheels 4. Loosen the axle pinch bolt and front axle Installation shaft. 1. Attach the right and left side collars in 5. Support your motorcycle securely and their original locations on the wheel. raise the front wheel off the ground 2.
  • Page 94 Tyre Puncture Removing Wheels 4. Install the brake caliper and tighten the 8. Raise the front wheel off the ground mounting bolts. again, and check that the wheel rotates freely after you release the brake. Torque: 30 N·m (3.1 kgf·m, 22 lbf·ft). 9.
  • Page 95 Tyre Puncture Removing Wheels ❙ Rear Wheel Rear axle shaft Removal Washer 1. Support your motorcycle securely and Adjusting nut raise the rear wheel off the ground using a maintenance stand or a hoist. 2. Loosen the rear axle nut, lock nuts and turn the adjusting nuts so the rear wheel can be moved all the way forward for maximum drive chain slack.
  • Page 96 Tyre Puncture Removing Wheels 5. Remove the rear axle shaft, washer, Installation brake caliper bracket, rear wheel and 1. To install the rear wheel, reverse the side collars. removal procedure. Support the brake caliper assembly so Take care to prevent the brake caliper that it doesn’t hang from the brake from scratching the wheel during hose.
  • Page 97 Tyre Puncture Removing Wheels 2. Make sure that the slot on the brake 3. Adjust the drive chain. P. 70 caliper bracket is positioned in the lug on 4. Tighten the rear axle nut. the swingarm. Torque: 88 N·m (9.0 kgf·m, 65 lbf·ft). Brake caliper bracket 5.

  • Page 98: Electrical Trouble

    Electrical Trouble Battery Goes Dead Burned-out Light Bulb Charge the battery using a motorcycle Follow the procedure below to replace a battery charger. burned-out light bulb. Remove the battery from the motorcycle Turn the ignition switch to the OFF or LOCK while charging.
  • Page 99 Electrical Trouble Burned-out Light Bulb ❙ Headlight Bulb 1. Remove the bulb lid. P. 58 2. Pull off the socket without turning. 3. Remove the dust cover. Bulb 4. Unhook the bulb retainer and pull out the bulb without turning it. 5.
  • Page 100 Electrical Trouble Burned-out Light Bulb ❙ Position Light Bulb 1. Remove the bulb lid. P. 58 2. Pull off the socket without turning. Socket 3. Pull out the bulb without turning. 4. Install a new bulb and parts in the reverse order of removal.
  • Page 101 Electrical Trouble Burned-out Light Bulb ❙ Brake/Tail Light Bulb Bulb Socket Bolts Rear fender cover 2. Turn the socket counterclockwise, and remove it. 1. Remove the bolts and rear fender cover. 3. Slightly press the bulb and turn it counterclockwise. 4.
  • Page 102 Electrical Trouble Burned-out Light Bulb ❙ ❙ Front/Rear Turn Signal Bulb License Plate Light 1. Remove the screw and collar. 1. Remove the screws, license light cover 2. Remove the turn signal lens. and license light cover packing. 3. Slightly press the bulb and turn it 2.

  • Page 103: Blown Fuse

    Electrical Trouble Blown Fuse Blown Fuse CB500X Fuse box covers Before handling fuses, see “Inspecting and Replacing Fuses.” P. 47 ❙ Fuse Box Fuses 1. Remove the seat. P. 56 2. Remove the fuse box covers. 3. Pull the fuses out with the fuse puller in...

  • Page 104: Main Fuse

    Electrical Trouble Blown Fuse ❙ Main Fuse 3. Pull the main fuse out and check for a blown fuse. Always replace a blown fuse Wire connector with a spare of the same rating. Spare main fuse is provided in the starter magnetic switch.

  • Page 105: Information

    Information Keys............P. 103 P. 104 Instruments, Controls, & Other Features..Fuels Containing Alcohol......P. 106 Catalytic Converter ........P. 107 Caring for Your Motorcycle.....P. 108 Storing Your Motorcycle ......P. 110 Transporting Your Motorcycle ....P. 111 You & the Environment ......P. 112 Serial Numbers .........P. 113 http://www.motorcycle.in.th...

  • Page 106: Keys

    Keys Keys To make a duplicate key and register it with your HISS system, take the spare key, the key number plate, and the motorcycle to your Ignition key dealer. The ignition key contains a special coded chip that is recognized by the immobilizer system A metal key holder may cause damage to the (HISS) in order to start the engine.

  • Page 107: Instruments, Controls, & Other Features

    Ignition Switch HISS The headlight is always on when the ignition The Honda Ignition Security System (HISS) switch is on. Leaving the ignition switch on with immobilizes the engine’s ignition system if an the engine stopped will drain the battery.
  • Page 108 Instruments, Controls, & Other Features EC Directive Morocco only This immobilizer system complies with R & TTE (Radio and Telecommunications Terminal Equipment and the mutual recognition of their conformity) Directive. Document Bag The declaration of conformity to R & TTE The owner’s manual, registration, and Directive is provided to the owner at the time of insurance information can be stored in the...

  • Page 109: Fuels Containing Alcohol

    Fuels Containing Alcohol Fuels Containing Alcohol The use of petrol containing more than 10% ethanol (or more than 5% methanol) may: ● Some conventional fuels blended with alcohol Damage the painting of the fuel tank. ● are available in some locales to help reduce Damage the rubber tubes of the fuel line.

  • Page 110: Catalytic Converter

    A defective catalytic converter contributes to air pollution and can impair your engine’s performance. A replacement unit must be an original Honda part or equivalent. http://www.motorcycle.in.th...

  • Page 111: Caring For Your Motorcycle

    Frequent cleaning and polishing is important to 3. Thoroughly rinse your motorcycle with plenty ensure the long life of your Honda. A clean of clean water and dry with a soft, clean motorcycle makes it easier to spot potential cloth.
  • Page 112 Caring for Your Motorcycle ❙ Washing Precautions should dissipate after a few minutes of Follow these guidelines when washing: running the engine. ● ● Do not use high-pressure washers: Do not use waxes containing compounds at High-pressure water cleaners can damage the matte painted surface: moving parts and electrical parts, Using plenty of water, clean the matte...

  • Page 113: Storing Your Motorcycle

    Storing Your Motorcycle ● Storing Your Motorcycle Wash gently using a soft sponge and plenty of water. ● To remove stubborn stains, use diluted detergent If you store your motorcycle outdoors, you and rinse thoroughly with plenty of water. should consider using a full-body motorcycle ●...

  • Page 114: Transporting Your Motorcycle

    Transporting Your Motorcycle Transporting Your After removing your motorcycle from storage, inspect all maintenance items required by the Motorcycle Maintenance Schedule. If your motorcycle needs to be transported, it should be carried on a motorcycle trailer or a flatbed truck or trailer that has a loading ramp or lifting platform, and motorcycle tie-down straps.

  • Page 115: You & The Environment

    You & the Environment You & the Environment drain or on the ground. Used oil, petrol, coolant, and cleaning solvents contain poisons Owning and riding a motorcycle can be that can hurt refuse workers and contaminate enjoyable, but you must do your part to protect drinking water, lakes, rivers, and oceans.

  • Page 116: Serial Numbers

    Serial Numbers Serial Numbers The frame and engine serial numbers uniquely identify your motorcycle and are required in order to register your motorcycle. They may also be required when ordering replacement parts. The frame number is stamped on the right side of the steering head.

  • Page 117: Specifications

    KO type Imp gal) Trail 108 mm (4.3 in) FTZ10S Except KO type 12V-8.6 Ah (10 HR) / 9.1 Ah (20 HR) CB500X 192 kg (423 lb) Battery YTZ10S CB500XA 194 kg (428 lb) Curb weight 12V-8.6 Ah (10 HR) / 9.1 Ah (20 HR) KO type 3.285...

  • Page 118: Service Data

    Drive chain lubricant designed specifically for Idle speed 1,200 ± 100 rpm drive chain O-ring chains. If not available, use SAE 80 or 90 Honda 4-stroke motorcycle oil API Service lubricant gear oil. Classification SG or higher, excluding oils Drive chain Recommended 35 to 45 mm (1.4 to 1.8 in)

  • Page 119: Torque Specifications

    22 N·m (2.2 kgf·m, 16 lbf·ft) License plate light 12V-5W Rear wheel axle nut 88 N·m (9.0 kgf·m, 65 lbf·ft) ■ Fuses Drive chain adjusting lock nuts 21 N·m (2.1 kgf·m, 15 lbf·ft) Main fuse CB500X 15A, 7.5A Other fuses CB500XA 30A, 15A, 7.5A http://www.motorcycle.in.th...

  • Page 120: Index

    Index Index ABS (Anti-lock Brake System) Caring for Your Motorcycle....108 Indicator ..........30, 86 Catalytic Converter........107 Accessories..........14 Clutch System ..........73 Anti-lock Brake System (ABS)....12 Coolant ..........50, 64 Crankcase Breather ........77 Battery ..........46, 59 Brakelight Switch........
  • Page 121 Equipment Headlight Aim..........79 Owner’s Manual........105 Headlight Dimmer Switch ......32 Tool Kit ............ 55 Helmet Holder ...........37 High Beam Indicator........31 High Coolant Temperature Flooded Engine ......... 34 Indicator ..........30, 84 Frame Number......... 113 HISS Indicator........31, 83 Fuel Horn Button ..........32 Cunsumption Meter .........
  • Page 122 Low Oil Pressure Indicator....30, 85 Passing Light Control Switch ....32 Petrol............106 PGM-FI (Programmed Fuel Injection) Maintenance malfunction indicator lamp (MIL) ..30, 85 Fundamentals .......... 44 Protective Apparel ........10 Importance ..........40 Safety ............40 Schedule ..........41 Rear Suspension ........
  • Page 123 Throttle ............76 Safety Precautions........10 Tool Kit............55 Seat ............56 Transporting Your Motorcycle....111 Serial Numbers ........113 Tripmeter ...........20, 104 Shifting Gears ..........35 Troubleshooting ........82 Side Cover ..........57 Turn Signal Indicators........31 Side Stand ..........68 Tyres Side Stand Ignition Cut-off System ..68 Air Pressure..........51 Specifications...........

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