Honda CX500 Deluxe 1978 Manuals

Manuals and User Guides for Honda CX500 Deluxe 1978. We have 1 Honda CX500 Deluxe 1978 manual available for free PDF download: Shop Manual

Honda CX500 Deluxe 1978 Shop Manual (253 pages)

Brand: Honda | Category: Motorcycle | Size: 30.6 MB

General Information: Table of Contents
2
General Safety
2
Service Rules
2
Specifications
3
Table of Contents
4
Model Identification
5
Torque Values
7
Special Tools/Common Tools
8
Wiring Diagram
10
Cable and Harness Routing
12
Emission Control System
14
Information Label
15
Maintenance Schedule
16
Lubrication Diagram
17
Lubrication: Table of Contents
18
Lubrication: Troubleshooting
18
Engine Oil Level Check
19
Engine Oil and Oil Filter Change
19
Final Drive Gear Oil Check/Replacement
20
Drive Shaft Joint
20
Lubrication Points
21
Inspection and Adjustment: Table of Contents
22
Air Cleaner
23
Crankcase Breather
24
Fuel Line
24
Spark Plug
24
Valve Clearance
25
Cam Chain
26
Throttle Operation
26
Idle Speed
27
Carburetor Choke
27
Carburetor Synchronization
28
Coolant
29
Cooling System Hoses
29
Radiator Core
29
Battery
30
Brake Fluid Level
30
Brake Fluid Replacement
31
Brake System
32
Brake Pad Wear
32
Brake Shoe Inspection
32
Brake System Hose
32
Brake Pedal Height
33
Brake Pedal Free Play
33
Rear Brake Light Switch
33
Headlight Aim
34
Clutch Free Play
34
Side Stand
35
Front Suspension
35
Rear Suspension
35
Wheels
36
Tire Pressure
36
Steering Head Bearing
36
Nuts, Bolts, Fasteners
36
Fuel System Exploded View
37
Fuel System: Table of Contents
38
Fuel System: Troubleshooting
38
Carburetor Removal
39
Carburetor Separation
40
Carburetor Assembly
41
Vacuum Cylinder Disassembly/Inspection
42
Vacuum Piston Inspection
43
Float Chamber Disassembly
43
Air Cutoff Valve Disassembly
45
Component Assembly
45
Float Level Adjustment
46
Fast Idle Adjustment
46
Carburetor Installation
46
Pilot Screw Initial Setting
47
Fuel Tank
48
Air Cleaner Case
48
Crankcase Breather System
49
Engine Removal/Installation
51
Engine Removal/Installation: Table of Contents
52
Engine Removal
53
Engine Installation
58
Cylinder Head/Valve
59
Cylinder Head/Valve: Table of Contents
60
Cylinder Head/Valve: Specifications
61
Cylinder Head/Valve: Troubleshooting
61
Rocker Arm/Cylinder Head Removal
62
Rocker Arm Holder Disassembly
64
Rocker Arm Shaft Inspection
64
Rocker Arm Holder Inspection
65
Rocker Arm Inspection
65
Cylinder Head Disassembly
65
Cylinder Head Inspection
66
Valve Spring Inspection
66
Valve Inspection
67
Valve Guide Inspection
67
Stem to Guide Clearance Inspection
67
Valve Guide Replacement
68
Valve Seat Inspection and Grinding
69
Cylinder Head Assembly
72
Rocker Arm Assembly
73
Cylinder Head/Rocker Arm Installation
73
Clutch/Oil Pump: Overview
77
Clutch/Oil Pump: Troubleshooting
78
Clutch Removal
79
Clutch Lifter Removal
79
Clutch Lifter Plate Removal
79
Clutch Removal Procedure
80
Clutch Disc Inspection
81
Clutch Plate Inspection
81
Clutch Plate B Inspection
81
Clutch Outer and Outer Guide Inspection
82
Clutch Spring Inspection
82
Clutch Installation
82
Oil Pump Removal
85
Oil Pump Disassembly
86
Oil Pump Inspection
86
Relief Valve Inspection
87
Oil Pump Assembly
88
Oil Pump Installation
88
A.C. Generator/Flywheel/Rear Cover
91
A.C. Generator/Flywheel/Rear Cover: Table of Contents
92
Components Removal
93
Rear Cover Disassembly
93
Neutral Switch Inspection
94
Flywheel Removal
95
Reduction Gear Inspection
96
Starter Drive Gear Inspection
96
Starter Clutch Outer Removal
96
Starter Clutch Outer Inspection
97
Starter Clutch Outer Installation
97
Flywheel Installation
98
Components Assembly
99
Cooling System Overview
101
Cooling System Troubleshooting
102
Cooling System Specifications
102
Cooling System Testing
103
Radiator Cap Inspection
103
Coolant Replacement
104
Thermostat Removal
104
Temperature Unit Inspection
105
Thermostat Inspection
106
Cooling Fan Removal
106
Water Pump Assembly
107
Thermostat Installation
110
Cooling Fan Installation
110
Radiator Installation
111
Camshaft/Cam Chain Overview
113
Camshaft/Cam Chain Table of Contents
114
Camshaft/Cam Chain Specifications
114
Cam Chain Removal
115
Camshaft Removal
115
Camshaft Inspection
116
Camshaft Holder Inspection
117
Camshaft Bearing Inspection
117
Rocker Arm Removal/Inspection
118
Rocker Arm Shaft Inspection/Rocker Arm Installation
119
Camshaft Installation
120
Valve Timing Adjustment
122
Transmission Overview
125
Transmission Table of Contents
126
Transmission Service Information
126
Transmission Specifications
127
Transmission Troubleshooting
127
Gearshift Linkage Removal
128
Final Shaft Disassembly
128
Final Shaft Assembly
129
Transmission Disassembly
129
Transmission Assembly
135
Gearshift Linkage Installation
138
Crankshaft/Piston: Table of Contents
140
Crankshaft/Piston: Specifications
140
Crankshaft/Piston: Troubleshooting
141
Connecting Rod Removal
142
Piston Removal
143
Piston Inspection
143
Cylinder Inspection
144
Crankshaft Removal
146
Rod Side Clearance Inspection
147
Bearing Inspection/Selection
147
Crankpin
147
Main Journal
148
Rod Bearings
149
Rod Bearing and Selection
150
Main Journal Bearings
150
Main Bearing Selection
151
Journal Bearing Sizes
151
Main Journal Bearing Removal
152
Main Journal Bearing Installation
153
Crankshaft Holder Cap Bearing
153
Crankcase Main Journal Bearings
153
Crankshaft Installation
154
Piston Installation
156
Connecting Rod Installation
157
Front Wheel/Suspension
159
Front Wheel/Suspension: Table of Contents
160
Front Wheel/Suspension: Service Information
160
Front Wheel/Suspension: Specifications
160
Front Wheel/Suspension: Troubleshooting
160
Headlight Case Removal
161
Wiring Connection in Headlight Case
161
Headlight Installation
161
Cluster Disassembly
162
Indicator Lamp Replacement
162
Meter Disassembly
162
Meter Assembly
162
Handlebar Removal
163
Handlebar Installation
163
Front Wheel Removal
164
Axle Inspection
164
Wheel Bearing Inspection
165
Wheel Inspection
165
Wheel Disassembly
165
Front Wheel Assembly
166
Front Wheel Installation
167
Front Fork Removal
168
Front Fork Disassembly
169
Front Fork Spring Free Length Inspection
169
Oil Seal Removal
170
Fork Tube/Fork Slider/Piston Inspection
170
Fork Tube Inspection
170
Front Fork Assembly
171
Oil Seal Installation
172
Filling with Fork Oil
172
Front Fork Installation
173
Steering Stem Removal
174
Bottom Cone Race Replacement
175
Ball Race Replacement
176
Steering Stem Installation
176
Rear Wheel/Brake/Final Drive/Suspension
179
Rear Wheel/Brake/Final Drive/Suspension: Specifications
180
Rear Wheel/Brake/Final Drive/Suspension: Troubleshooting
181
Rear Wheel Removal
182
Axle Shaft Bend Inspection
183
Rear Wheel Bearing Play Inspection
183
Rear Wheel Rim Runout Inspection
184
Rear Wheel Disassembly
184
Rear Wheel Assembly
185
Rear Brake Lining Thickness
186
Rear Brake Shoe Replacement
186
Brake Drum I.D. Inspection
186
Rear Wheel Installation
187
Shock Absorber (Right Side) Removal
188
Shock Absorber (Left Side) Removal
188
Shock Absorber Disassembly Note
188
Shock Absorber Spring Free Length
189
Shock Absorber Assembly
189
Shock Absorber Installation
190
Final Gear Case Removal
191
Backlash Inspection
191
Ring Gear Removal
192
Bearing Retainer a Oil Seal Replacement
193
Ring Gear Bearing Replacement
193
Breather System Maintenance
194
Ring Gear Oil Seal Replacement (Gear Case Side)
194
Ring Gear Bearing Replacement (Gear Case Side)
194
Bearing Retainer B Removal
195
Bearing Retainer B Oil Seal, O-Ring Replacement
195
Bearing Retainer B Installation
196
Ring Gear Installation
197
Gear Tooth Contact Pattern Check
199
Final Gear Case Installation
200
Pinion Gear Lubrication
201
Filling Final Gear Case
201
Rear Fork/Propeller Shaft
202
Swing Arm/Propeller Shaft Removal
202
Propeller Shaft Inspection
203
Pivot Bearing Inspection (Left Side)
204
Pivot Bearing Replacement (Right Side)
205
Swing Arm/Propeller Shaft Installation
206
Hydraulic Disk Brake Overview
209
Hydraulic Disk Brake Table of Contents
210
Hydraulic Disk Brake Troubleshooting
210
Brake Pads/Disc Plate
211
Brake Pad Wear Check
211
Brake Pad Replacement
211
Brake Disc Thickness
212
Brake Disc Warpage
213
Brake Master Cylinder
213
Master Cylinder Disassembly
213
Master Cylinder I.D. Inspection
214
Master Piston O.D. Inspection
214
Master Cylinder Assembly
214
Brake Caliper
215
Caliper Removal
215
Caliper Disassembly
215
Caliper Cylinder I.D. Inspection
216
Caliper Piston O.D. Inspection
216
Brake Caliper Assembly
217
Caliper Bracket Disassembly
217
Caliper Bracket Assembly
218
Brake Caliper Installation
218
Battery Charging System: Table of Contents
220
Battery Charging System: Service Information
220
Battery Charging System: Specifications
220
Battery Charging System Schematic
221
Battery Charging System Troubleshooting
221
Battery Removal
222
Testing Specific Gravity
222
Battery Charging
223
Charging Output Test
223
Stator Coil Continuity Test
224
Voltage Regulator/Rectifier Test
224
Voltage Regulator Performance Test
225
Ignition System Table of Contents
226
Ignition System Specifications
226
Ignition System Overview
227
Ignition System Troubleshooting
227
Ignition Coil Removal/Installation
228
Ignition System Performance Test
228
C.D.I. Unit Inspection
229
A.C. Generator Inspection
230
Advance Pulser Inspection
230
Ignition Timing Check
230
Starter Motor: Table of Contents
232
Starter Motor: Service Information
232
Starter Motor: Specifications
232
Starter Motor: Troubleshooting
233
Instrument Removal
234
Custom: Rear Shock Absorber Removal
235
Custom: Rear Shock Absorber Installation
235
Custom: Oil Pressure/Stop Lamp Warning Indicator
236
'80 Addenium: Table of Contents
237
'80 Addenium: Specifications
238
Maintenance Schedule Deluxe and Custom
240
Deluxe and Custom Cable and Harness Routing
241
Deluxe and Custom: Lubrication
242
Deluxe and Custom: Engine Oil Recommendation
242
Deluxe and Custom: Spark Plug
242
Deluxe and Custom: Fuel System
243
Deluxe and Custom: Carburetor Specifications
243
Deluxe and Custom: Carburetor Separation
243
Deluxe and Custom: Carburetor Assembly
243
Deluxe and Custom: Accelerator Pump Inspection
244
Deluxe and Custom: Accelerator Pump Adjustment
244
Deluxe and Custom: Pilot Screw Removal/Installation
245
Deluxe and Custom: Pilot Screw Adjustment
245
Deluxe and Custom: Idle Limiter Installation
246
Wiring Diagram CX500 Deluxe
248
Wiring Diagram CX500 Custom
249

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Honda CX500 Deluxe 1978 Shop Manual (253 pages)

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