Honda CB500F/FA Manual
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Honda CB500F/FA Manual

Honda CB500F/FA Manual

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Contents
31MJWB10
CB500F/FA
MOM 15994 (1608)
P. 2
P. 16
P. 40
P. 89
P. 107
P. 129
P. 133

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Table of Contents
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Summary of Contents for Honda CB500F/FA

  • Page 1: Table Of Contents

    Contents Motorcycle Safety P. 2 Operation Guide P. 16 Maintenance P. 40 Troubleshooting P. 89 Information P. 107 Specifications P. 129 Index P. 133 MOM 15994 (1608) CB500F/FA 31MJWB10...
  • Page 2 When service is required, remember that Honda motorcycle. Your selection of a your Honda dealer knows your motorcycle Honda makes you part of a worldwide family best. If you have the required mechanical of satisfied customers who appreciate “know-how” and tools, you can purchase an...
  • 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 ..............

  • 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, positioning the basic course, and even experienced riders yourself so other drivers can see you, signaling will find the advanced course beneficial.
  • Page 7 Safety Guidelines and bolts, and check the handlebar, control Keep Your Honda in Safe Condition levers, brakes, and wheels. Ride slowly and It's important to keep your motorcycle properly cautiously. maintained and in safe riding condition. Your motorcycle may have suffered damage Inspect your motorcycle before every ride and that is not immediately apparent.
  • Page 8 Safety Guidelines WARNING Carbon Monoxide Hazard Exhaust contains poisonous carbon monoxide, a Running the engine of your motorcycle colorless, odorless gas. Breathing carbon while in an enclosed or even partially monoxide can cause loss of consciousness and enclosed area can cause a rapid build- may lead to death.

  • 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, contact your dealer for a replacement. motorcycle provide important safety 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 ● Look for a DOT (Department of handlebar and feet on the footpegs. Keep passenger's hands onto the seat strap Transportation) certification label on any helmet ●...

  • Page 12: Riding Precautions

    Riding Precautions Riding Precautions Boots or Riding Shoes Sturdy boots with non-slip soles and ankle protection. Break-in Period Jacket and Pants During the first 300 miles (500 km) of running, Protective, highly visible, long-sleeved jacket follow these guidelines to ensure your and durable long pants for riding (or a motorcycle's future reliability and performance.
  • Page 13 Riding Precautions Exercise caution on low traction surfaces. Anti-lock Brake System (ABS) ● The tires slip more easily on such CB500FA only surfaces and braking distances are This model is equipped with an Anti-lock Brake longer. System (ABS) designed to help prevent the Avoid continuous braking.
  • Page 14 Riding Precautions Engine Braking Parking Engine braking helps slow your motorcycle Park on a firm, level 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 Turn the handlebar fully to the left. Refueling and Fuel Guidelines Turning the handlebar to the right Follow these guidelines to protect the engine reduces stability and may cause the and catalytic converter: motorcycle to fall. Use only unleaded gasoline. ●...

  • Page 16: Accessories & Modifications

    We strongly advise that you do not add any seriously hurt or killed. accessories that were not specifically designed or approved for your motorcycle by Honda or Follow all instructions in this owner's make modifications to your motorcycle from its manual regarding accessories and original design.

  • Page 17: Loading

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

  • Page 18: Operation Guide

    Parts Location Tool kit (P.39) Document bag (P.39) Right side cover (P.64) Fuel fill cap (P.37) Front brake fluid reservoir (P.72) Front suspension spring preload adjuster (P.87) Front brake lever (P.86) Throttle grip (P.83) Engine oil fill cap (P.65) Engine oil level inspection window (P.65) Engine oil filter (P.67)
  • Page 19 Front suspension spring preload adjuster (P.87) Clutch lever (P.80) Air cleaner (P.69) Front seat (P.62) Battery (P.60) Fuse box (P.105) Rear seat (P.63) Drive chain (P.76) Rear suspension spring preload adjuster (P.88) Coolant reserve tank (P.70) Side stand (P.75) Shift lever (P.36) Crankcase breather (P.84)
  • Page 20 Instruments button button Display Check When the ignition switch is turned to the ON position, 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: (P.25) Fuel gauge Remaining fuel when only 1st (E) segment starts flashing: approximately 0.85 US gal (3.2 L) If the fuel gauge indicator flashes in a repeat pattern or turns off: (P.94)
  • 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. To reset the tripmeter: (P.22) Odometer Tripmeter A Tripmeter B...
  • 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) Then, the display returns to the last selected To reset the tripmeter, average fuel 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 meter • Flashes from “0.0” gal or L. When the 1st (E) segment of the fuel gauge When the amount of consumed fuel is starts flashing, the odometer & tripmeter & more than 0.26 US gal (1.0 L), the display fuel mileage meter &...
  • 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, Backlight brightness adjustment average fuel mileage and fuel consumption automatic reset mode •...
  • Page 27 The following moves the ordinary display at Press button. The minute digits start display setting. flashing. • The buttons is not pressed for about 30 seconds • Turn the ignition switch to the OFF Press button until the desired minute is position and then to the ON position displayed.
  • Page 28 Instruments (Continued) 2 Backlight brightness adjustment: Press button. The backlight is set, and You can adjust the brightness to one of five then the display moves to the activating/ deactivating of tripmeter A, average fuel levels. mileage and fuel consumption automatic Press button.
  • Page 29 3 Activating/deactivating of tripmeter To end the selection, press button. The A, average fuel mileage and fuel activation/deactivation of automatic reset mode is set, and then the display moves to consumption automatic reset mode: the changing of the speed and mileage unit. You can also activate or deactivate the automatic reset mode by refueling after 1st (E) segment of the fuel gauge starts flashing.
  • 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 the OFF position.
  • 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/100 km”. turning the ignition switch to the OFF position. 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. Low oil pressure indicator Comes on when the ignition switch ABS (Anti-lock Brake System) indicator is turned to the ON position. CB500FA only Goes off when the engine starts.
  • Page 33 Left turn signal indicator Right turn signal indicator High beam indicator Neutral indicator Comes on when the transmission is in Neutral. PGM-FI (Programmed Fuel Injection) malfunction indicator lamp (MIL) Comes on briefly when the ignition switch is turned to the ON position with the engine stop switch in the (Run) position.
  • Page 34 Switches Engine stop switch Should normally remain in the (Run) position. In an emergency, switch to the (Off) position (the starter motor will not operate) to stop the engine. Start button Hazard switch Horn button Switchable when the ignition switch is Turn signal switch in the ON position.
  • Page 35 Ignition Switch Switches the electrical system on/off, locks the steering. Key can be removed when in the OFF or LOCK position. Turns electrical system on for starting/riding. Turns engine off. LOCK Locks steering. Continued...
  • Page 36 Switches (Continued) Steering Lock Locking Turn the handlebar all the way to the left. Lock the steering when parking to help Push the key down, and turn the ignition prevent theft. switch to the LOCK position. A U-shaped wheel lock or similar device is Jiggle the handlebar if the lock is difficult also recommended.
  • Page 37 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. Turn the ignition switch to the ON position. is cold or warm. Shift the transmission to Neutral ( indicator comes on).
  • Page 38 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 39 Refueling Opening the Fuel Fill Cap Ignition key Level plate Open the lock cover, insert the 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 40 Storage Equipment Helmet Holder WARNING The helmet holder is located underside of the Riding with a helmet attached to the rear seat. 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 41 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 (P.62) Removing the Rear Seat (P.63)

  • Page 42: 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. 41 Drive Chain............P. 76 Maintenance Schedule........

  • Page 43: 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 44 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 ●...

  • Page 45: Maintenance Schedule

    Maintenance work should be performed in 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 46 : Intermediate. We recommend service by your dealer, unless Inspect (clean, adjust, lubricate, or replace, if necessary) you have the necessary tools and are mechanically skilled. Replace Procedures are provided in an official Honda Service Manual Lubricate (2 P. 123). Clean : Technical.
  • Page 47 Maintenance Schedule Frequency 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 48: Maintenance Fundamentals

    Maintenance Fundamentals Suspension is adjusted to suit load. P. 87, Pre-ride Inspection ● P. 88 To ensure safety, it is your responsibility to perform a pre-ride inspection and make sure Check the following items after you get on your that any problem you find is corrected. A pre- motorcycle: ride inspection is a must, not only for safety, but Throttle action moves smoothly without...
  • Page 49 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 50 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 51 Maintenance Fundamentals WARNING Battery 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 operation. electrolyte level or add distilled water. Clean the battery terminals if they become dirty or A spark or flame can cause the battery corroded.
  • Page 52 30 days using a charger designed specifically for If the terminals are heavily corroded, clean your Honda, which can be purchased from your and polish the terminals with a wire brush or dealer. Read the information that came with sandpaper.
  • Page 53 Bump starting is also not recommended. NOTICE Installing non-Honda electrical accessories can NOTICE overload the electrical system, discharging the Replacing a fuse with one that has a higher battery and possibly damaging the system.
  • Page 54 Selecting the Engine Oil circular API service symbol. For recommended engine oil, see “Specifications.” P. 130 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 : MA ●...
  • Page 55 Wipe up spills immediately and wash thoroughly. pins, has missing O-rings, or kinks, have the chain inspected by your dealer. Recommended brake fluid: Honda DOT 4 Brake Fluid or equivalent WARNING Clean filler cap before removing. Use only DOT 4 fluid from a sealed container.
  • Page 56 Use a soft brush if the chain is dirty. After cleaning, wipe dry and lubricate with the recommended lubricant. Normal Worn Damaged (GOOD) (REPLACE) (REPLACE) Recommended lubricant: Pro Honda HP Chain Lube or equivalent NOTICE Use of a new chain with worn sprockets will cause rapid chain wear.
  • Page 57 Recommended Coolant If the drain tube overflows, the air filter may Pro Honda HP Coolant is a pre-mixed solution become contaminated with engine oil causing of antifreeze and distilled water. poor engine performance.
  • Page 58 Maintenance Fundamentals Inspecting for Damage Tires (Inspecting/Replacing) Checking the Air Pressure Inspect the tires for Visually inspect your tires and use an air cuts, slits, or cracks that pressure gauge to measure the air pressure at exposes fabric or least once a month or any time you think the cords, or nails or other tires look low.
  • Page 59 Maintenance Fundamentals Inspecting Tread Depth WARNING Inspect the tread wear indicators. If they Riding on tires that are excessively worn become visible, replace the tires immediately. or improperly inflated can cause a crash For safe riding, you should replace the tires in which you can be seriously hurt or when the minimum tread depth is reached.
  • Page 60 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 ●...
  • Page 61 Maintenance Fundamentals Tire Identification Number (TIN) Air Cleaner The tire identification number (TIN) is a group This motorcycle is equipped with a viscous type of numbers and letters located on the sidewall air cleaner element which cannot be cleaned of the tire. with compressed air or otherwise without degrading its performance.

  • Page 62: Removing & Installing Body Components

    Removing & Installing Body Components Battery Removal Make sure the ignition switch is in the OFF Rubber strap Positive terminal position. Remove the front seat. P. 62 Unhook the rubber strap from rear side. Negative Disconnect the negative - terminal from terminal the battery.

  • Page 63: Clip

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

  • Page 64: Front Seat

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

  • Page 65: Rear Seat

    Removing & Installing Body Components Rear Seat Rear Seat Removal Move the seat strap forward. Rear seat Ignition key Insert the ignition key into the seat lock. Turn it clockwise, then pull the rear seat Seat lock forward and up. Installation Insert the tab into the recess.

  • Page 66: Right Side Cover

    Removing & Installing Body Components Right Side Cover Right Side Cover Removal Remove the front seat. P. 62 Grommets Clip Remove the bolt and clip. P. 61 Remove the prongs from the grommets, then remove the right side cover by releasing the hooks.

  • Page 67: Engine Oil

    Engine Oil Checking the Engine Oil Oil fill cap If the engine is cold, idle the engine for 3 to 5 minutes. Turn the ignition switch to the OFF position and wait for 2 to 3 minutes. Place your motorcycle in an upright Oil level inspection window position on a firm, level surface.
  • Page 68 Engine Oil Adding Engine Oil Adding Engine Oil Securely reinstall the oil fill cap. NOTICE If the engine oil is below or near the lower Overfilling with oil or operating with insufficient level mark, add the recommended engine oil. oil can cause damage to your engine. Do not mix P.
  • Page 69 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 Using the wrong oil filter can result in serious Sealing washer damage to the engine.
  • Page 70 Engine Oil Changing Engine Oil & Filter Install a new sealing washer onto the drain bolt. Tighten the drain bolt. Oil filter Torque: 22 lbf·ft (30 N·m, 3.1 kgf·m) Fill the crankcase with the recommended oil ( P. 52, P. 130) and install the oil fill cap.

  • Page 71: Air Cleaner

    Air Cleaner Changing Air Cleaner Element Screws A Air cleaner case 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 72: Coolant

    Coolant Checking the Coolant UPPER level Check the coolant level in the reserve tank while the engine is cold. Place your motorcycle on a firm, level surface. Hold your motorcycle in an upright position. Check that the coolant level is between the UPPER level and LOWER level marks in the reserve tank.
  • Page 73 Coolant Changing Coolant 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. Securely reinstall the reserve tank cap. WARNING Removing the radiator cap while the engine is hot can cause the coolant to...

  • Page 74: Brakes

    Brakes Checking Brake Fluid If the brake fluid level in either reservoir is below the LWR mark or LOWER level mark or the brake lever and pedal freeplay becomes Place your motorcycle in an upright excessive, inspect the brake pads for wear. position on a firm, level surface.
  • Page 75 Brakes Inspecting the Brake Pads Inspecting the Brake Pads Inspect the brake pads from below Front the brake caliper. Inspect the brake pads from the rear Check the condition of the brake pad wear Rear right of the motorcycle. indicators. If necessary have the pads replaced by your The pads need to be replaced if a brake pad dealer.
  • Page 76 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 77: Side Stand

    Side Stand Checking the Side Stand Sit on the motorcycle, put the transmission in Neutral, and raise the side stand. Start the engine, pull the clutch lever in, and shift the transmission into gear. Lower the side stand all the way. The engine should stop as you lower the side stand.

  • Page 78: 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. Shift the transmission to Neutral.
  • Page 79 Drive Chain Adjusting the Drive Chain Slack Adjusting the Drive Chain Slack Pulser ring Wheel speed sensor CB500FA only Adjusting the chain requires special tools. CB500FA only Have the drive chain slack adjusted by your Lock nut dealer. CB500FA only When adjusting the drive chain slack, be Rear axle careful not to damage the wheel speed...
  • Page 80 Drive Chain Adjusting the Drive Chain Slack Turn both adjusting nuts an equal Tighten the rear axle nut. number of turns until the correct drive Torque: 65 lbf·ft (88 N·m, 9.0 kgf·m) chain slack is obtained. Turn the adjusting nuts clockwise to tighten the chain. Turn Tighten the drive chain adjusting nuts the adjusting nuts counterclockwise to lightly, then hold the adjusting nuts and...
  • Page 81 Drive Chain Adjusting the Drive Chain Slack Checking the Drive Chain Wear Red zone 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 82: 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 83 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. Loosen the upper lock nut. ＋ Turn the upper clutch cable adjuster until the freeplay is 3/8 - 13/16 in (10 - 20 mm). Tighten the upper lock nut and check the Upper clutch cable adjuster freeplay again.
  • Page 84 Clutch Adjusting the Clutch Lever Freeplay Loosen the upper lock nut and turn the Lower lock nut upper clutch cable adjuster all the way in (to provide maximum freeplay). Tighten the upper lock nut. Loosen the lower lock nut. Turn the adjusting nut until the clutch lever freeplay is 3/8 - 13/16 in (10 - 20 mm).

  • Page 85: Throttle

    Throttle Checking the Throttle Adjusting the Throttle Freeplay With the engine off, check that the throttle Slide the cable boot. rotates smoothly from fully closed to fully Loosen the lock nut. open in all steering positions and throttle Turn the adjuster until the freeplay is freeplay is correct.

  • Page 86: Crankcase Breather

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

  • Page 87: Other Adjustments

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

  • Page 88: Adjusting The 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 89: Adjusting The 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 3rd groove (hard), or turn counterclockwise to decrease spring preload (soft).

  • Page 90: Adjusting The Rear Suspension

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

  • Page 91: Troubleshooting

    Troubleshooting Engine Will Not Start........P. 90 Blown Fuse............P. 105 Overheating (High coolant temperature indicator is on) ..........P. 91 Warning Indicators On or Flashing....P. 92 Low Oil Pressure Indicator ........ P. 92 PGM-FI (Programmed Fuel Injection) Malfunction Indicator Lamp (MIL)....P. 92 ABS (Anti-lock Brake System) Indicator ..

  • Page 92: 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 Check the correct engine starting ● ● sequence. P. 35 sequence.

  • Page 93: Overheating (High Coolant Temperature Indicator Is On)

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

  • Page 94: 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 serious problem. Have your motorcycle If the low oil pressure indicator comes on, inspected by your dealer. pull safely to the side of the road and stop the engine.

  • Page 95: 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. CB500FA 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 96: Other Warning Indications

    Other Warning Indications 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 97: Tire Puncture

    Tire Puncture Repairing a puncture or removing a wheel WARNING requires special tools and technical expertise. Riding your motorcycle with a We recommend you have this type of service temporary tire repair can be risky. If the performed by your dealer. temporary repair fails, you can crash After an emergency repair, always have the and be seriously injured or killed.
  • Page 98 Tire Puncture Removing Wheels Take care to prevent the brake caliper CB500FA only When removing and installing the wheel, be from scratching the wheel during careful not to damage the wheel speed removal. sensor and pulser ring. Tape or cloth Mounting bolts Front Wheel Removal...
  • Page 99 Tire Puncture Removing Wheels Loosen the axle pinch bolt and front axle Installation shaft. Attach the right and left side collars in Support your motorcycle securely and their original locations on the wheel. raise the front wheel off the ground using On the left side, place the wheel between a maintenance stand or a hoist.
  • Page 100 Tire Puncture Removing Wheels Install the brake caliper and tighten the 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) Uncover the protective tape or cloth.
  • Page 101 Tire Puncture Removing Wheels Rear Wheel Pulser ring Wheel speed sensor CB500FA only Removal CB500FA only Place your motorcycle on a firm, level Collar A surface. Lock nut Washer Support your motorcycle securely and raise the rear wheel off the ground using a maintenance stand or a hoist.
  • Page 102 Tire Puncture Removing Wheels Remove the rear axle shaft, washer, brake Installation caliper bracket, rear wheel and side To install the rear wheel, reverse the 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 103 Tire Puncture Removing Wheels Make sure that the slot on the brake Adjust the drive chain. P. 77 caliper bracket is positioned in the lug on Tighten the rear axle nut. the swingarm. Torque: 65 lbf·ft (88 N·m, 9.0 kgf·m) Brake caliper bracket Tighten the drive chain adjusting nuts lightly, then hold the adjusting nuts and...

  • Page 104: 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 105 Electrical Trouble Burned-out Light Bulb Headlight/Position Lights Brake Light/Taillight Position lights Brake Light/Taillight Headlight The brake and taillight uses several LEDs. If there is a LED which is not turned on, see The headlight/position lights use several your dealer for servicing. LEDs.
  • Page 106 Electrical Trouble Burned-out Light Bulb Front/Rear Turn Signal Bulb License Plate Light Bulb Remove the screw and collar. Remove the screws, license light cover Remove the turn signal lens. and license light cover packing. Slightly press the bulb and turn it Pull out the bulb without turning.

  • Page 107: Blown Fuse

    Electrical Trouble Blown Fuse Blown Fuse CB500F Fuse box covers Before handling fuses, see “Inspecting and Replacing Fuses.” P. 51 Fuse Box Fuses Remove the front seat. P. 62 Remove the fuse box covers. Pull the fuses out one by one with the Spare fuses fuse puller in the tool kit and check for a blown fuse.
  • Page 108 Electrical Trouble Blown Fuse Main Fuse Pull the main fuse out and check for a blown fuse. Always replace a blown fuse Wire connector Main fuse with a spare fuse of the same rating. Spare main fuse is provided in the starter magnetic switch.

  • Page 109: Information

    Vehicle Identification Number..... P. 115 Emission Control Systems ......P. 116 Catalytic Converter ......... P. 121 Oxygenated Fuels..........P. 122 Authorized Manuals ........P. 123 Warranty Coverage and Service ....P. 124 Honda Contacts ..........P. 126 Reporting Safety Defects ..... P. 128...

  • Page 110: Keys

    Keys Keys Ignition key Key tag Ignition Key This motorcycle has two ignition keys and a key tag with a key number and a 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 111: Instruments, Controls, & Other Features

    Instruments, Controls, & Other Features Instruments, Controls, & Tripmeter Other Features The tripmeter A and B return to 0.0 when each read-out exceeds 9,999.9. Ignition Switch Also average fuel mileage and fuel consumption are reset at the same time. Leaving the ignition switch in the ON position with the engine stopped will drain the battery.

  • Page 112: Caring For Your Motorcycle

    Thoroughly rinse your motorcycle with Frequent cleaning and polishing is important to plenty of clean water and dry with a soft, ensure the life of your Honda. A clean clean cloth. motorcycle makes it easier to spot potential After the motorcycle dries, lubricate any problems.
  • Page 113 Caring for Your Motorcycle Do not direct water at the air cleaner: Washing Precautions ● Water in the air cleaner can prevent the Follow these guidelines when washing: engine from starting. Do not use high-pressure washers: ● Do not direct water near the headlight: High-pressure water cleaners can ●...
  • Page 114 Caring for Your Motorcycle When the exhaust pipe and muffler are painted, Panels do not use a commercially available abrasive Follow these guidelines to prevent scratches kitchen cleaning compound. Use a neutral and blemishes: detergent to clean the painted surface on the Wash gently using a soft sponge and plenty ●...

  • Page 115: Storing Your Motorcycle

    ● surfaces (except matte painted surfaces). For more information about storage, Canada 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 “Honda Warranty” in ●...

  • Page 116: Transporting Your Motorcycle

    Transporting Your Motorcycle Transporting Your You & the Environment Motorcycle Owning and riding a motorcycle can be enjoyable, but you must do your part to protect If your motorcycle needs to be transported, it the environment. should be carried on a motorcycle trailer or a flatbed truck or trailer that has a loading ramp Choose Sensible Cleaners or lifting platform, and motorcycle tie-down...

  • Page 117: Vehicle Identification Number

    Vehicle Identification Number Vehicle Identification Recycle Wastes Number Put oil and other toxic wastes in approved containers and take them to a recycling center. The VIN and engine serial number uniquely Call your local or state office of public works or identify your motorcycle and are required in environmental services to find a recycling center order to register your motorcycle.

  • Page 118: Emission Control Systems

    Emission Control Systems Emission Control Systems Your motorcycle engine emits combustion byproducts, 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 environment.
  • Page 119 Noise Emission Requirements Compliance with the terms of the The EPA requires that motorcycles built after Distributor's Warranties for Honda Motorcycle January 1, 1983 comply with applicable noise Emission Control Systems is necessary in order emission standards for one year or 3,730 miles to maintain a valid emissions system warranty.
  • Page 120 Emission Control Systems Exhaust Emission Control System Secondary Air Injection 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. adjustment, although periodic inspection by your dealer is recommended.
  • Page 121 Emission Control Systems Crankcase Emissions Control System Noise Emission Control System The engine is equipped with a closed crankcase TAMPERING WITH THE NOISE CONTROL system to prevent discharging crankcase SYSTEM IS PROHIBITED: emissions into the atmosphere. Blow-by gas is U. S. federal law prohibits, and Canadian returned to the combustion chamber through provincial laws may prohibit, the following acts the crankcase breather hose, air cleaner...
  • 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 Removal of, or puncturing the muffler, ● by your dealer if you experience any of the baffles, header pipes or any other following symptoms: component 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

    Authorized Manuals Authorized Manuals These Honda manuals are written for the professional technician. However, if you possess The Service Manual used by your the proper tools, observe the safety standards, authorized dealer is available from your Honda and are mechanically capable, you should find dealer or Helm, Inc.

  • Page 126: Warranty Coverage And Service

    Service workmanship of your Honda. Your warranty coverage does not apply to the normal wear Coverage and deterioration associated with use of the Your new Honda is covered by the following motorcycle. warranties: Motorcycle Limited Warranty ● Your warranty coverage is not voided if you Emission Control System Warranty ●...
  • Page 127 If you believe you have a problem with your dealership or their designated representative. motorcycle, call the service department of your Honda dealer. Make an appointment for an inspection and diagnosis. You will be asked to authorize that inspection, and your dealer will return the results of the inspection.

  • Page 128: Honda Contacts

    Dealer name and address ● motorcycle or with your dealer, please send your comments to the following address: We will likely ask your Honda dealer to respond, Motorcycle Division, or possibly acknowledge your comments American Honda Motor Co., Inc., directly.
  • Page 129 The sales department offers the Honda Protection Plan to extend almost all of your warranty coverage. Your Honda dealer can also supply information about, riding events, and information about safety training available in your local area, and the Honda Rider's Club of America (USA only).

  • Page 130: Usa

    Highway Traffic Safety Administration 1200 New Jersey Avenue, SE., (NHTSA) in addition to notifying Washington, DC 20590. American Honda Motor Co., Inc. You can also obtain other information about motor vehicle safety from: If NHTSA receives similar complaints, it http://www.safercar.gov.

  • Page 131: Specifications

    Specifications Main Components ■ Displacement 28.7 cu-in (471 cm Overall length 81.9 in (2,080 mm) Bore x stroke 2.64 x 2.63 in (67.0 x 66.8 mm) Overall width 31.1 in (790 mm) Compression ratio 10.7:1 Overall height 41.7 in (1,060 mm) Unleaded gasoline Fuel Wheelbase...
  • Page 132 Standard sprocket resource conserving on the circular API Recommended size Driven sprocket service label, SAE 10W-30, JASO T 903 engine oil standard MA, Pro Honda GN4 4-stroke oil (USA & Canada) or Honda 4-stroke oil, or an equivalent motorcycle oil...
  • Page 133 Specifications Bulbs Torque Specifications ■ ■ Headlight Oil filter 19 lbf·ft (26 N·m, 2.7 kgf·m) Brake light/Taillight Engine oil drain bolt 22 lbf·ft (30 N·m, 3.1 kgf·m) Front turn signal light 12 V-21/5 W × 2 Rear wheel axle nut 65 lbf·ft (88 N·m, 9.0 kgf·m) Rear turn signal light 12 V-21 W ×...
  • Page 134 Information Record Engine No. Color Label & Code Owner's Name Address City/State Phone Dealer's Name Address City/State Phone Service Manager...

  • Page 135: Index

    Index ABS (Anti-lock Brake System)....... 11 Caring for Your Motorcycle ......110 ABS (Anti-lock Brake System) Catalytic Converter........121 Indicator ............ 30, 93 Clutch System ........... 80 Accessories ............14 Color label ............48 Air Cleaner............69 Coolant............55, 70 Authorized Manuals........
  • Page 136 Tool Kit..............39 Helmet Holder..........38 High Beam Indicator........31 High Coolant Temperature Indicator ... 30, 91 Flooded Engine ..........35 Honda Contacts ..........126 Front Seat ............62 Horn Button ............32 Front Suspension ..........87 Fuel Consumption Meter .......... 20 Ignition Cut-off System Gauge ..............
  • Page 137 Indicators............30 Information Record........132 Engine ............52, 65 Instruments ............18 Overheating ............91 Oxygenated Fuels.......... 122 Labels..............7 Load Limits ............15 Parking ............... 12 Loading Guidelines.......... 15 Parts Location........... 16 Low Oil Pressure Indicator ...... 30, 92 PGM-FI (Programmed Fuel Injection) Malfunction Indicator Lamp (MIL)..
  • Page 138 Removal Equipment ............38 Battery..............60 Owner’s Manual ........39, 109 Clip................. 61 Tool Kit..............39 Front Seat............. 62 Storing Your Motorcycle ......113 Rear Seat.............. 63 Switches ............. 32 Right Side Cover ..........64 Repair Kit ............95 Reporting Safety Defects (U.S.)....128 Tachometer ............
  • Page 139 Washing Your Motorcycle......110 Weight Limit..........15, 129 Wheels Front Removal ............ 96 Rear Removal............99...

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