Honda CBR500R 2016 Operation Manual
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Honda CBR500R 2016 Operation Manual

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Contents
31MJWA00
CBR500R/RA
MOM 15613 (1509)
P. 2
P. 16
P. 39
P. 88
P. 106
P. 128
P. 132

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Table of Contents
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Summary of Contents for Honda CBR500R 2016

  • Page 1: Table Of Contents

    Contents Motorcycle Safety P. 2 Operation Guide P. 16 Maintenance P. 39 Troubleshooting P. 88 Information P. 106 Specifications P. 128 Index P. 132 31MJWA00 CBR500R/RA MOM 15613 (1509)
  • Page 2 Honda dealer knows your motorcycle Honda motorcycle. Your selection of a best. If you have the required mechanical Honda makes you part of a worldwide family “know-how” and tools, you can purchase an of satisfied customers who appreciate official Honda Service Manual to help you 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: Motorcycle Safety

    Motorcycle Safety This section contains important information for safe riding of your motorcycle. Please read this section carefully. Safety Guidelines .........P. 3 Safety Labels ..........P. 7 Safety Precautions ........P. 9 Riding Precautions ........P. 10 Accessories & Modifications......P. 14 Loading ............P. 15...

  • Page 5: Safety Guidelines

    Safety Guidelines Safety Guidelines Before Riding Make sure that you are physically fit, mentally Follow these guidelines to enhance your safety: focused and free of alcohol and drugs. Check ● Perform all routine and regular inspections that you and your passenger are both wearing specified in this manual.
  • Page 6 Safety Guidelines We recommend that all riders take a certified Make Yourself Easy to See course approved by the Motorcycle Safety Make yourself more visible, especially at night, Foundation (MSF). New riders should start with by wearing bright reflective clothing, the basic course, and even experienced riders positioning yourself so other drivers can see will find the advanced course beneficial.
  • Page 7 Safety Guidelines check the tightness of critical nuts and bolts, Keep Your Honda in Safe Condition and check the handlebars, control levers, It’s important to keep your motorcycle properly brakes, and wheels. Ride slowly and cautiously. maintained and in safe riding condition.
  • Page 8 Safety Guidelines Carbon Monoxide Hazard WARNING Exhaust contains poisonous carbon monoxide, Carbon monoxide gas is toxic. a colorless, odorless gas. Breathing carbon Breathing it can cause monoxide can cause loss of consciousness and unconsciousness and even kill you. may lead to death. Avoid any areas or activities that If you run the engine in confined or even partly enclosed area, the air you breathe could contain...

  • Page 9: Safety Labels

    Safety Labels Safety Labels hazards that could cause serious injury. Read these labels carefully and don’t remove them. Safety and information labels on your If a label comes off or becomes hard to read, motorcycle provide important safety contact your dealer for a replacement. information and may warn you of potential continued...
  • Page 10 Safety Labels...

  • Page 11: 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 handlebars and feet on the footpegs. Look for a DOT (Department of ● Keep passenger’s hands on the seat strap or Transportation) certification label on any helmet your waist, passenger’s feet on the footpegs you buy.

  • Page 12: Riding Precautions

    Riding Precautions ❙ Riding Precautions Boots or Riding Shoes Sturdy boots with non-slip soles and ankle protection Break-in Period ❙ During the first 300 miles (500 km) of running, Jacket and Pants follow these guidelines to ensure your Protective, highly visible, long-sleeved jacket motorcycle’s future reliability and performance.
  • Page 13 Riding Precautions ❙ ● Exercise caution on low traction surfaces. Anti-lock Brake System (ABS) CBR500RA only The tires slip more easily on such surfaces and braking distances are longer. This model is equipped with an Anti-lock Brake ● Avoid continuous braking. System (ABS) designed to help prevent the Repeated braking, such as when brakes from locking up during hard braking.
  • Page 14 Riding Precautions ❙ Engine Braking Parking Engine braking helps slow your motorcycle ● Park on a firm, level paved surface. down when you release the throttle. For further ● If you must park on a slight incline or loose slowing action, downshift to a lower gear. Use surface, park so that the motorcycle cannot engine braking with intermittent use of the move or fall over.
  • Page 15 Riding Precautions ❙ Parking with the Side Stand Refueling and Fuel Guidelines 1. Stop the engine. Follow these guidelines to protect the engine 2. Push the side stand down. and catalytic converter: 3. Slowly lean the motorcycle to the left until its ●...

  • Page 16: Accessories & Modifications

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

  • Page 17: 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 18: Operation Guide

    Parts Location Tool kit (P38) (P38) Document bag Right side cover (P63) Front brake fluid reservoir (P71) Front suspension spring preload adjuster (P86) Front brake lever (P85) Throttle grip (P82) Engine oil fill cap (P64) Engine oil level inspection window (P64) (P67) Engine oil filter...
  • Page 19 Front suspension spring preload adjuster (P86) Clutch lever (P79) (P36) Fuel fill cap (P68) Air cleaner (P61) Front seat Battery (P59) Fuse box (P104) Rear seat (P62) Drive chain (P75) Rear suspension spring preload adjuster (P87) (P69) Coolant reserve tank (P74) Side stand (P35)
  • Page 20 Instruments button button Display Check When the ignition switch is turned on, all the mode and digital segments will show. If any part of these displays does not come on when it should, have your dealer check for problems.
  • Page 21 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 0.85 US gal (3.2 liters) If the fuel gauge indicators repeat flashing or turned off: (P93)
  • Page 22 Instruments (Continued) Odometer [TOTAL] & Tripmeter [TRIP A/B] & Current fuel mileage meter & Average fuel mileage meter [AVG] & Fuel consumption meter button selects the odometer, tripmeter A, tripmeter B, current fuel mileage, average fuel mileage and fuel consumption. (P22) To reset the tripmeter: Odometer...
  • Page 23 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 5 mph (7 km/h), “ ” is displayed. When “ ” is displayed at speeds above 5 mph (7 km/h), go to your dealer for service. •...
  • Page 24 Instruments (Continued) ❙ 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 button with tripmeter A, average fuel mileage, or fuel consumption displayed.
  • Page 25 Reserve fuel consumption display • Flashes from “0.0” gal or L. When the 1st (E) segment of the fuel gauge When the amount of consumed fuel is more than 0.26 US gal (1.0 liter), the starts flashing, the odometer & tripmeter & display blinks faster.
  • Page 26 Instruments (Continued) Display Setting Ordinary display Following items can be changed sequentially. • Clock setting Setting Mode • Backlight brightness adjustment Clock setting • Activating/deactivating of tripmeter A, average fuel mileage and fuel Backlight brightness adjustment consumption automatic reset mode •...
  • Page 27 The following moves the ordinary display at Press button. The minute digits start flashing. display setting. • The buttons are not pressed for about 30 seconds • Turn the ignition switch off and then on Press button until the desired minute is displayed.
  • Page 28 Instruments (Continued) 2 Backlight brightness adjustment: Press button. The backlight is set, and then the display moves to the activating/ You can adjust the brightness to one of five deactivating of tripmeter A, average fuel levels. mileage and fuel consumption automatic Press button.
  • Page 29 3 Activating/deactivating of tripmeter A, To end the selection, press button. The activation/deactivation of automatic average fuel mileage and fuel reset mode is set, and then the display consumption automatic reset mode: moves to the changing of the speed and You can also activate or deactivate the mileage unit.
  • Page 30 Instruments (Continued) 4 Changing of speed and mileage unit: When selecting the “mph” and “mile”. To end the selection, press button. Press button to select either “mph” and “mile” or “km/h” and “km”. The established setting can also be set by turning the ignition switch to OFF.
  • Page 31 5 Changing of fuel mileage meter unit: To end the selection, press button. Press button to select “km/L” or The established setting can also be set by “L/100km”. 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 seconds.
  • Page 32 Indicators If one of these indicators does not come on when it should, have your dealer check for problems. ABS (Anti-lock Brake System) indicator CBR500RA only Comes on when the ignition switch is turned on. Goes off when your speed reaches approximately 6 mph (10 km/h).
  • Page 33 Left turn signal indicator Neutral indicator Comes on when the transmission is in Neutral. Right turn signal indicator High beam indicator PGM-FI (Programmed Fuel Injection) malfunction indicator lamp (MIL) Comes on briefly when the ignition switch is turned on with the engine stop switch in (Run) position.
  • Page 34 Switches Engine stop switch Should normally remain in the (Run) position. In an emergency, switch to (Off) position (the starter motor will not operate) to stop the engine. Start button Hazard switch Switchable when the ignition Horn button switch is on. Can be turned to off regardless of the ignition Turn signal switch switch position.
  • Page 35 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 36 Starting the Engine Start your engine using the following Make sure the engine stop switch is in the procedure, regardless of whether the engine (Run) position. is cold or warm. Turn the ignition switch to the ON position. Shift the transmission to Neutral ( indicator comes on).
  • Page 37 Shifting Gears ❙ Your motorcycle transmission has 6 forward Recommended Shift Points gears in a one-down, five-up shift pattern. Shifting Up From 1st to 2nd 12 mph (20 km/h) From 2nd to 3rd 19 mph (30 km/h) From 3rd to 4th 25 mph (40 km/h) From 4th to 5th 31 mph (50 km/h)
  • Page 38 Refueling Opening the Fuel Fill Cap Level plate Open the lock cover, insert the ignition key, Ignition key and turn it clockwise to open the cap. Closing the Fuel Fill Cap After refueling, push the fuel fill cap closed until it locks. Remove the key and close the lock cover.
  • Page 39 Storage Equipment Helmet Holder WARNING The helmet holder is located underside of the rear seat. Riding with a helmet attached to the holder can interfere with your ability to safely operate the motorcycle and Helmet holder could lead to a crash in which you can be seriously hurt or killed.
  • Page 40 Storage Equipment (Continued) Tool Kit Document Bag The tool kit is located under the rear seat. The document bag is located underside of the front seat. Document bag Tool kit Rubber strap Rubber strap ❙ Removing the Front Seat (P61) ❙...

  • Page 41: Maintenance

    Please read “Importance of Maintenance” and “Maintenance Fundamentals” carefully before attempting any maintenance. Refer to “Specifications” for service data. An optional larger tool kit may be available. Check with your Honda dealer’s parts department. Importance of Maintenance ..... P. 40 Brakes ............P.

  • Page 42: Importance Of Maintenance

    Importance of Maintenance For information about the exhaust emission and Importance of Maintenance noise emission requirements of the U.S. Keeping your motorcycle well-maintained is Environmental Protection Agency (EPA), the absolutely essential to your safety and to California Air Resources Board (CARB), and the protect your investment, obtain maximum Environment Canada (EC).
  • Page 43 Importance of Maintenance Follow these guidelines when performing Maintenance Safety maintenance. Always read the maintenance instructions ● Stop the engine and remove the key. before you begin each task, and make sure that ● Place your motorcycle on a firm, level surface you have the tools, parts, and skills required.

  • Page 44: Maintenance Schedule

    If you sell the motorcycle, these receipts should be transferred with the Maintenance work should be performed in motorcycle to the new owner. accordance with Honda’s standards and specifications by properly trained and equipped technicians. Your dealer meets all of these requirements. Keep an accurate record of maintenance to help ensure that your motorcycle is properly maintained.
  • Page 45 : Intermediate. We recommend service by your dealer, unless Maintenance Legend you have the necessary tools and are mechanically skilled. : Inspect (clean, adjust, lubricate, or replace, if necessary) Procedures are provided in an official Honda Service Manual : Clean P. 123). : Lubricate : Technical.
  • Page 46 Maintenance Schedule Frequency*1 Items × 1,000 mi Regular Refer to Replace page × 1,000 km 12.8 19.2 25.6 32.0 38.4 Drive Chain Every 600 mi (1,000 km) Brake Fluid* 2 Years Brake Pads Wear Brake System Brake Light Switch Headlight Aim Clutch System Side Stand Suspension...

  • Page 47: Maintenance Fundamentals

    Maintenance Fundamentals ● Suspension is adjusted to suit load. Pre-ride Inspection P. 86, 87 To ensure safety, it is your responsibility to perform a pre-ride inspection and make sure Check the following items after you get on that any problem you find is corrected. A pre- your motorcycle: ride inspection is a must, not only for safety, ●...
  • Page 48 Maintenance Fundamentals Periodic Checks You should also perform other periodic maintenance checks at least once a month regardless of how often you ride, or more often if you ride frequently. Also, check the odometer reading against the Maintenance Schedule and perform all maintenance that is due.
  • Page 49 Maintenance Fundamentals Replacing Parts Always use Honda Genuine Parts or their Color label equivalents to ensure reliability and safety. When ordering colored components, specify the model name, color, and code mentioned on the color label. The color label is attached to the rear fender under the rear seat.
  • Page 50 Maintenance Fundamentals ● Electrolyte splashes into your mouth: Battery Rinse mouth thoroughly with water, and Your motorcycle has a maintenance-free type do not swallow. battery. You do not have to check the battery WARNING electrolyte level or add distilled water. Clean the battery terminals if they become dirty or The battery gives off explosive corroded.
  • Page 51 30 days using a charger designed specifically for 3. If the terminals are heavily corroded, clean your Honda, which can be purchased from your the terminals with a wire brush or sandpaper. dealer. Read the information that came with Wear safety glasses.
  • Page 52 Jump starting using an automobile battery can damage your motorcycle’s electrical system and is not recommended. Bump starting is also not recommended. NOTICE Installing non-Honda electrical accessories can overload the electrical system, discharging the battery and possibly NOTICE damaging the system.
  • Page 53 P. 129 higher oils, excluding oils marked as “Energy Conserving” or “Resource Conserving” on the If you use non-Honda engine oil, check the label circular API service symbol. to make sure that the oil satisfies all of the following standards: ●...
  • Page 54 Wipe up spills immediately and wash thoroughly. pins, has missing O-rings, or kinks, have the Recommended brake fluid: chain inspected by your dealer. Honda DOT 4 Brake Fluid or equivalent WARNING Clean filler cap before removing. Use only DOT 4 fluid from a sealed...
  • Page 55 After cleaning, wipe dry and lubricate with the recommended lubricant. Normal Worn Damaged Recommended lubricant: (GOOD) (REPLACE) (REPLACE) Pro Honda HP Chain Lube or equivalent NOTICE Use of a new chain with worn sprockets will cause rapid chain wear. continued...
  • Page 56 Service if the deposit level can be seen in the transparent section of the drain Recommended Coolant tube. Pro Honda HP coolant is a pre-mixed solution of If the drain tube overflows, the air filter may become contaminated with engine oil causing antifreeze and distilled water.
  • Page 57 Maintenance Fundamentals ❙ Inspecting for Damage Tires (Inspecting/Replacing) Inspect the tires for ❙ Checking the Air Pressure cuts, slits, or cracks Visually inspect your tires and use an air that exposes fabric or pressure gauge to measure the air pressure at cords, or nails or least once a month or any time you think the other foreign objects...
  • Page 58 Maintenance Fundamentals ❙ Inspecting Tread Depth WARNING Inspect the tread wear indicators. If they become visible, replace the tires immediately. Riding on tires that are excessively For safe riding, you should replace the tires worn or improperly inflated can cause when the minimum tread depth is reached.
  • Page 59 Maintenance Fundamentals ● Have the wheel balanced with Honda Tire Service Life Genuine balance weights or equivalent after The service life of your tires is dependent on the tire is installed. many factors, including, but not limited to, ● Do not install a tube inside a tubeless tire on riding habits, road conditions, vehicle loading, this motorcycle.
  • Page 60 Maintenance Fundamentals ❙ Tire Identification Number (TIN) Air Cleaner The tire identification number (TIN) is a group of This motorcycle is equipped with a viscous type numbers and letters located on the sidewall of air cleaner element which cannot be cleaned the tire.

  • Page 61: Removing & Installing Body Components

    Removing & Installing Body Components Battery Make sure the clock is set to the proper time after the battery is reconnected. P. 25 ❙ Removal For proper handling of the battery, see Make sure the ignition switch is off. “Maintenance Fundamentals.” P.

  • Page 62: Clip

    Removing & Installing Body Components Clip Clip ❙ Removal 1. Press down on the center pin to release the lock. 2. Pull the clip out of the hole. Center ❙ Installation 1. Push the bottom of the center pin. 2. Insert the clip into the hole. 3.

  • Page 63: Front Seat

    Removing & Installing Body Components Front Seat ❙ Front Seat Removal 1. Pull the rear corners of the front seat up, then remove the mounting bolts. 2. Pull the front seat back and up. ❙ Front Installation seat 1. Insert the tab into the recess. Mounting bolts 2.

  • Page 64: Rear Seat

    Removing & Installing Body Components Rear Seat ❙ Rear Seat Removal 1. Move the seat strap forward. 2. Insert the ignition key into the seat lock. Rear seat Ignition key 3. Turn the ignition key clockwise, then pull Seat lock the rear seat forward and up.

  • Page 65: Right Side Cover

    Removing & Installing Body Components Right Side Cover ❙ Right Side Cover Removal 1. Remove the front seat. P. 61 2. Remove the bolt and clip. P. 60 Grommets 3. Remove the prongs from the grommets, then remove the right side cover by Clip releasing the hooks.

  • Page 66: 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 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 67 Engine Oil Adding Engine Oil Adding Engine Oil 2. Securely reinstall the oil fill cap. NOTICE If the engine oil is below or near the lower Overfilling with oil or operating with insufficient oil can level mark, add the recommended engine oil. cause damage to your engine.
  • Page 68 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. NOTICE Drain bolt...
  • Page 69 Engine Oil Changing Engine Oil & Filter 9. Install a new sealing washer onto the drain bolt. Tighten the drain bolt. Torque: 22 lbf·ft (30 N·m, 3.1 kgf·m). 10. Fill the crankcase with the recommended oil ( P. 51, 129) and install the oil fill cap.

  • Page 70: Air Cleaner

    Air Cleaner Changing Air Cleaner Element Air cleaner case Screws A cover/element Use a new Honda Genuine air cleaner element or an equivalent specified for your motorcycle. NOTICE Using the wrong air cleaner element may cause premature engine wear or performance problems.

  • Page 71: Coolant

    Coolant Checking the Coolant Check the coolant level in the reserve tank while the engine is cold. UPPER level 1. Place your motorcycle on a firm, level LOWER level surface. 2. Hold your motorcycle in an upright position. Reserve tank 3.
  • Page 72 Coolant Changing Coolant 1. Remove the reserve tank cap and add Reserve tank cap fluid while monitoring the coolant level. Do not overfill above the UPPER level mark. Make sure no foreign objects enter the reserve tank opening. 2. Securely reinstall the cap. WARNING Removing the radiator cap while the engine is hot can cause the coolant to...

  • Page 73: Brakes

    Brakes Checking Brake Fluid If the brake fluid level in either reservoir is below the LWR mark or LOWER level mark or 1. Place your motorcycle in an upright the brake lever and pedal freeplay becomes position on a firm, level surface. excessive, inspect the brake pads for wear.
  • Page 74 Brakes Inspecting the Brake Pads Inspecting the Brake Pads Front Inspect the brake pads from below the brake caliper. Check the condition of the brake pad wear Inspect the brake pads from the Rear indicators. rear right of the motorcycle. The pads need to be replaced if a brake pad is worn to the indicator.
  • Page 75 Brakes Adjusting the Brake Light Switch Adjusting the Brake Light Switch Check the operation of the brake light switch. Hold the brake light switch and turn the adjusting nut in the direction A if the switch operates too late, or turn the nut in the direction B if the switch operates too soon.

  • Page 76: Side Stand

    Side Stand Checking the Side Stand 3. Sit on the motorcycle, put the transmission in Neutral, and raise the 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.

  • Page 77: 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 78 Drive Chain Adjusting the Drive Chain Slack Adjusting the Drive Chain Slack Wheel speed sensor Pulser ring CBR500RA only CBR500RA only Adjusting the chain requires special tools. Have the drive chain slack adjusted by your dealer. Lock nut CBR500RA only When adjusting the drive chain slack, be Rear axle Adjusting...
  • Page 79 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: 65 lbf·ft (88 N·m, 9.0 kgf·m). is obtained. Turn the adjusting nuts 8.
  • Page 80 Drive Chain Adjusting the Drive Chain Slack ❙ Checking the Drive Chain Wear Check the chain wear label when adjusting the drive chain. If the index mark on the washer enters the red zone on the label after the chain has been adjusted to the proper slack, the chain is excessively worn and must be replaced.

  • Page 81: Clutch

    Clutch Checking the Clutch Check the clutch cable for kinks or signs of wear. If necessary have it replaced by your ❙ Checking the Clutch 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 82 Clutch Adjusting the Clutch Lever Freeplay Adjusting the Clutch Lever Upper clutch cable adjuster Freeplay Upper lock nut – ❙ 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 3/8 to 13/16 in (10 to 20 mm).
  • Page 83 Clutch Adjusting the Clutch Lever Freeplay 1. Loosen the upper lock nut and turn the 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 84: Throttle

    Throttle Checking the Throttle Adjusting the Throttle Freeplay With the engine off, check that the throttle 1. Slide the cable boot. rotates smoothly from fully closed to fully 2. Loosen the lock nut. open in all steering positions and throttle 3.

  • Page 85: Crankcase Breather

    Crankcase Breather Cleaning the Crankcase Breather 1. Place a suitable container under the crankcase breather tube. 2. Remove the crankcase breather tube plug from the tube. 3. Drain deposits into a suitable container. 4. Install the crankcase breather tube plug. Crankcase breather tube Crankcase breather...

  • Page 86: Other Adjustments

    Other Adjustments Adjusting the Headlight Aim You can adjust vertical aim of the headlight for proper alignment. Turn the pinion in or out as necessary using a Phillips screwdriver. Obey local laws and regulations. Pinion Pinion Raise Lower Lower Raise Right side Left side...

  • Page 87: Brake Lever

    Other Adjustments Adjusting the Brake Lever Adjusting the Brake Lever Index mark Adjuster Forward You can adjust the distance between the tip of the brake lever and handle grip. ❙ Adjustment method Turn the adjuster until the numbers align with the index mark while pushing the lever forward in the desired position.

  • Page 88: Front Suspension

    Other Adjustments Adjusting the Front Suspension Adjusting the Front Suspension Fork bolt ❙ Spring Preload You can adjust the spring preload by the adjuster to suit the load or the road surface. Turn clockwise to increase spring preload (hard), or turn counterclockwise to decrease Adjusters 3rd groove spring preload (soft).

  • Page 89: Rear Suspension

    Other Adjustments Adjusting the Rear Suspension Adjusting the Rear Suspension Attempting to adjust directly from 1 to 9 or 9 to 1 may damage the shock absorber. Adjusting the suspension requires a pin Index mark spanner and extension bar. We recommend that you have your motorcycle serviced by your dealer.

  • Page 90: Troubleshooting

    Troubleshooting Engine Will Not Start .........P. 89 Other Warning Indication ......P. 93 Overheating (High coolant temperature Fuel Gauge Failure Indication ....P. 93 indicator is on)..........P. 90 Tire Puncture..........P. 94 Warning Indicators on or Flashing....P. 91 Electrical Trouble ........P. 101 Low Oil Pressure Indicator......P.

  • Page 91: Engine Will Not Start

    Engine Will Not Start Starter Motor Operates But Starter Motor Does Not Engine Does Not Start Operate Check the following items: Check the following items: ● ● Check the correct engine starting Make sure the engine stop switch is in sequence P.

  • Page 92: 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 93: 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 94: Abs (Anti-Lock Brake System) Indicator

    Warning Indicators on or Flashing ABS (Anti-lock Brake System) Indicator ABS (Anti-lock Brake System) If the ABS indicator stays on, your brakes will continue to work as a conventional system, Indicator but without the anti-locking function. CBR500RA only The ABS indicator may flash if you turn the If the indicator operates in one of the rear wheel while your motorcycle is lifted off following ways, you may have a serious...

  • Page 95: Other Warning Indication

    Other Warning Indication Fuel Gauge Failure Indication If the fuel system has an error, the fuel gauge indicators will be displayed as shown in the illustrations. If these occur, see your dealer as soon as possible.

  • Page 96: Tire Puncture

    Tire 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 tire repair can be risky. If After an emergency repair, always have the the temporary repair fails, you can tire inspected/replaced by your dealer.
  • Page 97 Tire Puncture Removing Wheels CBR500RA only Take care to prevent the brake caliper from scratching the wheel during When removing and installing the wheel, be removal. careful not to damage the wheel speed Tape or cloth sensor and pulser ring. ❙...
  • Page 98 Tire 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 99 Tire 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: 22 lbf·ft (30 N·m, 3.1 kgf·m). 9.
  • Page 100 Tire Puncture Removing Wheels ❙ Rear Wheel Wheel speed sensor Pulser ring CBR500RA only CBR500RA only Removal 1. Place on a firm, level surface. Collar A 2. Support your motorcycle securely and raise the rear wheel off the ground using Lock nut Washer a maintenance stand or a hoist.
  • Page 101 Tire Puncture Removing Wheels 6. 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 102 Tire Puncture Removing Wheels 2. Make sure that the slot on the brake 3. Adjust the drive chain. P. 76 caliper bracket is positioned in the lug on 4. Tighten the rear axle nut. the swingarm. Torque: 65 lbf·ft (88 N·m, 9.0 kgf·m). Brake caliper bracket 5.

  • Page 103: 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 before charging.
  • Page 104 Electrical Trouble Burned-out Light Bulb ❙ ❙ Headlights/Position Lights Brake/Tail Light Position lights Brake/Tail light Headlights The headlights/position lights use several The brake and tail light uses several LEDs. LEDs. If there is a LED which is not turned on, see If there is a LED which is not turned on, see your dealer for servicing.
  • Page 105 Electrical Trouble Burned-out Light Bulb ❙ ❙ Front/Rear Turn Signal Bulb License Plate Light Bulb 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 106: Blown Fuse

    Electrical Trouble Blown Fuse Blown Fuse CBR500R Fuse box covers Before handling fuses, see “Inspecting and Replacing Fuses.” P. 50 ❙ Fuse Box Fuses 1. Remove the front seat. P. 61 2. Remove the fuse box covers. 3. Pull the fuses out one by one with the fuse puller in the tool kit and check for a blown Spare fuses fuse.
  • Page 107 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 fuse of the same rating. Spare main fuse is provided in the Main fuse starter magnetic switch.

  • Page 108: Information

    Information Keys............P. 107 Honda Contacts ........P. 125 Instruments, Controls, & Other Features ...P. 108 Reporting Safety Defects....P. 127 Caring for Your Motorcycle.....P. 109 Storing Your Motorcycle ......P. 113 Transporting Your Motorcycle ....P. 114 You & the Environment ......P. 114 Vehicle Identification Number ....P.

  • Page 109: Keys

    Keys Keys Ignition key Key tag Ignition Key This motorcycle has two ignition keys and a key tag with a key number and bar code. Store the spare key and the key tag in a safe location. To make a duplicate key, take the spare key and the key tag to your dealer or a locksmith.

  • Page 110: Instruments, Controls, & Other Features

    Instruments, Controls, & Other Features Instruments, Controls, & Tripmeter Other Features The tripmeter A and B return to 0.0 when the read-out exceeds 9,999.9. Ignition Switch Document Bag Leaving the ignition switch ON with the engine stopped will drain the battery. The owner’s manual, registration, and insurance information can be stored in the Do not turn the key while riding.

  • Page 111: Caring For Your Motorcycle

    Frequent cleaning and polishing is important to 3. Thoroughly rinse your motorcycle with plenty ensure the 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 Do not direct water near the headlight: Follow these guidelines when washing: Any condensation inside the headlight ● Do not use high-pressure washers: should dissipate after a few minutes of High-pressure water cleaners can damage running the engine.
  • Page 113 Caring for Your Motorcycle Panels Windscreen Follow these guidelines to prevent scratches Using plenty of water, clean the windscreen and blemishes: with a soft cloth or sponge. (Avoid using ● Wash gently using a soft sponge and plenty detergents or any kind of chemical cleaner on of water.
  • Page 114 Caring for Your Motorcycle Replace the windscreen if scratches cannot be When the exhaust pipe and muffler are painted, removed and they obstruct clear vision. do not use a commercially available abrasive kitchen cleaning compound. Use a neutral Take care to keep battery electrolyte, brake detergent to clean the painted surface on the fluid, or other chemical solvents off the exhaust pipe and muffler.

  • Page 115: Storing Your Motorcycle

    Canada surfaces (except matte painted surfaces). For more information about storage, Coat chrome pieces with rust-inhibiting oil. visit our website at www.honda.ca and look up ● Lubricate the drive chain. P. 53 “Storage Tips” under the Parts & Service tab.

  • Page 116: Transporting Your Motorcycle

    Transporting Your Motorcycle Transporting Your Choose Sensible Cleaners Motorcycle Use a biodegradable detergent when you wash your motorcycle. Avoid aerosol spray cleaners If your motorcycle needs to be transported, it that contain chlorofluorocarbons (CFCs) which should be carried on a motorcycle trailer or a damage the atmosphere’s protective ozone flatbed truck or trailer that has a loading ramp layer.

  • Page 117: Vehicle Identification Number

    Vehicle Identification Number Vehicle Identification Number The VIN and engine serial number uniquely identify your motorcycle and are required in order to register your motorcycle. They may also be required when ordering replacement parts. The VIN is stamped on the right side of the steering head and also appears on the Safety Certification Label attached to the right side of the frame.

  • Page 118: Emission Control Systems

    Emission Control Systems Emission Control Systems Your motorcycle engine emits combustion by- products, including carbon monoxide (CO), oxides of nitrogen (NOx), and hydrocarbons (HC). Gasoline evaporation also emits hydrocarbons. Controlling the production of NOx, CO, and HC is important for the Engine number environment.
  • Page 119 Compliance with the terms of the Distributor’s The EPA requires that motorcycles built after Warranties for Honda Motorcycle Emission January 1, 1983 comply with applicable noise Control Systems is necessary in order to emission standards for one year or 3,730 miles...
  • Page 120 Emission Control Systems ❙ Secondary Air Injection System Exhaust Emission Control System The secondary air injection system adds filtered The exhaust emission control system includes air into the exhaust gas to help improve the following components that should not need emission control performance.
  • Page 121 Emission Control Systems Crankcase Emissions Control System Noise Emission Control System ❙ TAMPERING WITH THE NOISE CONTROL The engine is equipped with a closed crankcase system to prevent discharging crankcase SYSTEM IS PROHIBITED: emissions into the atmosphere. Blow-by gas is U.
  • Page 122 Emission Control Systems ❙ AMONG THOSE ACTS PRESUMED TO Problems Affecting Motorcycle Exhaust CONSTITUTE TAMPERING ARE THE Emissions FOLLOWING ACTS: Have your motorcycle inspected and repaired by ● Removal of, or puncturing the muffler, your dealer if you experience any of the baffles, header pipes or any other component following symptoms: which conducts exhaust gases.

  • Page 123: Catalytic Converter

    A defective catalytic converter contributes to air riding and turn off the engine. Have your pollution and can impair your engine’s motorcycle serviced as soon as possible. performance. A replacement unit must be an original Honda part or equivalent.

  • Page 124: Oxygenated Fuels

    Oxygenated Fuels Oxygenated Fuels If you accidentally fill your fuel tank with an oxygenated fuel containing higher percentages, Some conventional fuels blended with alcohol you may experience performance problems. To or an ether compound are available in some resolve the problem, have your dealer drain the locales to help reduce emissions to meet clean fuel tank and replace with the correct fuel.

  • Page 125: Authorized Manuals

    Honda dealer is available from your Honda scooter, ATV, and SxS for winter storage. dealer or Helm, Inc. (USA only, Canada: See your Honda dealer to These Honda manuals are written for the order authorized manuals.) professional technician. However, if you possess...

  • Page 126: Warranty Coverage And Service

    Honda. Your warranty coverage does not apply to the normal wear Coverage and deterioration associated with use of the motorcycle. Your new Honda is covered by the following warranties: Your warranty coverage is not voided if you ● Motorcycle Limited Warranty perform your own maintenance.

  • Page 127: Honda Contacts

    Maintenance Schedule is American Honda Motor Co., Inc. not included in your warranty coverage. If you wish to contact Honda directly to comment on your experiences with your If you believe you have a problem with your...
  • Page 128 Dealer name and address about, riding events, and information about safety training available in your local area, and We will likely ask your Honda dealer to respond, the Honda Rider’s Club of America (USA only). or possibly acknowledge your comments directly.

  • Page 129: Usa Reporting Safety Defects

    Highway Traffic Safety Administration Washington, DC 20590. (NHTSA) in addition to notifying You can also obtain other information American Honda Motor Co., Inc. about motor vehicle safety from: http://www.safercar.gov If NHTSA receives similar complaints, it may open an investigation, and if it finds...

  • Page 130: Specifications

    Specifications Specifications ■ Main Components Displacement 28.7 cu-in (471 cm Type PC44 Bore x stroke 2.64 × 2.63 in (67.0 × 66.8 mm) Compression Overall length 81.9 in (2,080 mm) 10.7:1 ratio Overall width 29.5 in (750 mm) Unleaded gasoline Overall height 45.1 in (1,145 mm) Fuel...
  • Page 131 API service label, SAE Standard Rear wheel engine oil 10W-30, JASO T 903 standard MA, Pro Honda sprocket sizes sprocket GN4 4-stroke oil (USA & Canada) or Honda 4- stroke oil, or an equivalent motorcycle oil...
  • Page 132 Specifications ■ ■ Bulbs Torque Specifications Headlight Oil filter 19 lbf·ft (26 N·m, 2.7 kgf·m) Brake/Tail light Engine oil drain bolt 22 lbf·ft (30 N·m, 3.1 kgf·m) Front turn signal lights 12V-21/5W x 2 Rear wheel axle nut 65 lbf·ft (88 N·m, 9.0 kgf·m) Rear turn signal lights 12V-21W x 2 Drive chain adjusting lock nuts 15 lbf·ft (21 N·m, 2.1 kgf·m)
  • Page 133 Information Record Engine No. Color Label & Code Owner’s Name Address City/State Phone Dealer’s Name Address City/State Phone Service Manager...

  • Page 134: Index

    Index Index Clutch System..........79 ABS (Anti-lock Brake System) Color Label ..........47 Indicator..........30, 92 Coolant..........54, 69 Accessories ..........14 Coolant Temperature Gauge ....90 Air Cleaner..........68 Crankcase Breather........83 Authorized Manuals ....... 123 Digital Clock Adjustment ......25 Battery ..........48, 59 Drive Chain...........52, 75 Brake Light Switch ........
  • Page 135 Hazard Switch ........... 32 Low Oil Pressure Indicator ....30, 91 Headlight Aim........... 84 Headlight Dimmer Switch ......32 Helmet Holder........... 37 Maintenance High Beam Indicator......... 31 Fundamentals........... 45 High Coolant Temperature Indicator ..30 Importance..........40 Honda Contacts........125 Safety............41...
  • Page 136 Schedule ..........42 Maximum Weight Limit ......15 Rear Seat ............62 Modifications..........14 Rear Suspension.........87 Recommended Coolant ............54 Neutral Indicator ........31 Fuel ............36 Oil ............51 Refueling............36 Odometer .......... 20, 108 Removal Battery............59 Engine..........51, 64 Clip............60 Other Warning Indications ....... 93 Front Seat ..........61 Overheating..........
  • Page 137 Side Stand..........74 Tripmeter ........... 20, 108 Side Stand Ignition Cut-off System..74 Troubleshooting........88 Specifications .......... 128 Turn Signal Indicators ....... 31 Speedometer..........19 Start Button..........32 Starting the Engine........34 Vehicle Identification Number ....115 Steering Lock..........33 Stopping Engine ........

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