Honda CX650C 1983 Manuals

Manuals and User Guides for Honda CX650C 1983. We have 1 Honda CX650C 1983 manual available for free PDF download: Shop Manual

Honda CX650C 1983 Shop Manual (306 pages)

Brand: Honda | Category: Motorcycle | Size: 47.79 MB

Table of Contents
3
General Information
5
General Safety
5
Service Rules
5
Model Identification
6
Specifications
7
Torque Values
9
Standard Torque Values
10
Tools
11
Cable & Harness Routing
13
Emission Control System
16
Emission Control Information Label
16
Lubrication
19
Service Information
19
Troubleshooting
19
Oil Level too Low
19
Engine Oil Level Check
20
Engine Oil & Filter Change
20
Oil Strainer Cleaning
21
Final Gear Oil Check/Replacement
22
Oil Level Check
22
Oil Replacement
22
Control Cable Lubrication
22
Lubrication Points
23
Maintenance
25
Maintenance Schedule
27
Fuel Lines
28
Fuel Strainer
28
Throttle Operation
28
Carburetor Choke
29
Air Cleaner
30
Crankcase Breather
31
Spark Plugs
31
Valve Clearance
32
Carburetor-Synchronization
33
Carburetor-Idle Speed
34
Radiator Coolant
34
Radiator Core
34
Cooling System Hoses
35
Battery
35
Brake Fluid
35
Brake Shoe/Pad Wear
36
Brake Shoe Inspection
36
Brake Pad Wear
36
Brake System
36
Brake Light Switch
37
Brake Pedal Free Play
37
Headlight Aim
37
Clutch
38
Side Stand
38
Suspension
39
Front
39
Rear
39
Nuts, Bolts, Fasteners
40
Wheels
40
Steering Head Bearings
40
Fuel System
43
Engine Crank but Won't Start
43
Carburetor Removal
44
Carburetor Separation
44
Carburetor Assembly
46
Vacuum Cylinder Disassembly/ Inspection
47
Float Chamber Disassembly
49
Air Cut-Off Valve Disassembly
51
Accelerator Pump Disassembly
51
Component Assembly
52
Float Level
53
Fast Idle Adjustment
53
Accelerator Pump Adjustmemt
54
Carburetor Installation
54
Pilot Screw Adjustment
55
Idle Drop Procedure
55
HIGH ALTITUDE Adlustment
56
Fuel Tank
57
Fuel Tank Removal
57
Fuel Valve Inspection
57
Fuel Valve Disassembly
58
Fuel Valve Assembly
59
Fuel Tank Installation
59
Air Cleaner Case
60
Engine Removal/Installation
63
Engine Removal
64
Engine Installation
69
Cylinder Head/Valve
71
Low Compression or Uneven Compression
72
High Compression
72
Excessive Noise
72
Contaminated Engine Oil or Coolant
72
Rocker Aam/Cylinder Head Removal
73
Rocker Arm Shaft Inspection
76
Rocker Arm Inspection
76
Cylinder Head Disassembly
77
Cylinder Head Inspection
77
Valve Spring Inspection
78
Valve Inspection
78
Stem-Tb-Guide Clearance Inspection
78
Valve Guide Replacement
79
Valve Seat Inspection/Grinding
80
Valve Seat Cutters
81
Valve Seat Refacing
81
Cylinder Head Assembly
83
Rocker Arm Assembly
84
Cylinder Head/Rocker Arm Installation
84
Clutch/Oil Pump
89
Clutch Disassembly
90
Clutch Lifter Removal
90
Clutch Lifter Plate Removal
90
Clutch Removal
91
Clutch Disc
92
Clutch Plate
92
Clutch Outer and Outer Guide
93
Clutch Spring Inspection
93
Clutch Installation
94
Oil Pump Removal
98
Oil Pump Disassembly
99
Oil Pump Inspection
100
Relief Valve Inspection
101
Oil Pump Assembly
101
Oil Bump Installation
102
Alternator/Flywheel/Rear Cover
105
Engine Rear Cover Removal
106
Water Pump Removal
106
Pulse Generator Removal
107
Rear Cover Removal
107
Rear Cover Disassembly
109
Flywheel Removal
110
Reduction Gear Inspection
111
Starter Drive Gear Inspection
111
Starter Clutch Outer Removal
112
Starter Clutch Outer Inspection
112
Starter Clutch Outer Installation
112
Flywheel Installatiom
113
Engine Rear Cover Installation
114
Spark Advancer
115
Ignition Timing Adjustment
116
Water Pump Installation
117
Cooling System
121
Cooling System Testing
122
Coolant
122
Radiator Cap Inspection
122
Radiator Leakage Test
122
Coolant Replacement
123
Thermostat
124
Temperature Sensor Inspection
125
Thermostat Inspection
125
Radiator/ Cooling Fan
126
Radiator Inspection
128
Water Pump Mechanical Seal Replacement
131
Camshaft/Cam Chain
135
Cam Chain Removal
136
Camshaft Removal
137
Camshaft Inspection
137
Camshaft Holder Inspection
138
Camshaft Bearing Inspection
138
Rocker Arm Removal
139
Rocker Arm Inspectibn
139
Rocker Arm Installation
140
Camshaft Installation
141
Valve Timing Adiusmemt
143
Transmission
146
Transmission Service Information
147
Transmission Specifications
147
Transmission Torque Values
148
Transmission Tools
148
Transmission Troubleshooting
148
Gearshift Linkage Removal
149
Final Shaft Disassembly
149
Final Shaft Assembly
150
Transmission Disassembly
151
Transmission I Nspectibn
155
Transmission Assembly
156
Gearshift Linkage Installation
162
Crankshaft/Piston
165
Connecting Rod Removal
167
Piston Removal
168
Piston Inspection
168
Cylinder Inspection
169
Crankshaft Removal
170
Rod Side Clearance Inspection
171
Crank Pin Bearing
172
Bearing Selection
173
Crank Pin Bearing Selection
173
Crank Pin Bearing Sizes
173
Main Journal Bearing Inspection/Selection
174
Main Journal Bearing Replacement
175
Crankshaft Installation
178
Piston Installation
181
Connecting Rod Installation
182
Cylinder Compression
183
Front Wheel/Suspension
185
Headlight
187
Case Removal
187
Case Installation
187
Bracket Removal/Installation
189
Instruments
189
Handlebar
190
Front Forks
201
Front Fork Installation
208
Steering Stem Removal
209
Steering Stem Bearing Inspection
210
Bottom Cone Race Replacement
210
Ball Race Replacement
211
Ball Race Installation
212
Rear Wheel/Suspension/Brake Service Information
215
Rear Wheel/Suspension/Brake Specifications
215
Rear Wheel/Suspension/Brake Torque Values
215
Rear Wheel/Suspension/Brake Tools
215
Rear Wheel/Suspension/Brake Troubleshooting
216
Axle
218
Wheel Bearings
218
Wheel Tim Runout
218
Brake Drum I.D.
219
Rear Brake Panel
222
Lining Thickness Inspection
222
Rear Brake Pedal
224
Shock Absorber
226
Spring Free Length
227
Swing Arm
229
Pivot Bearing Replacement
230
Hydraulic Brake
234
Hydraulic Brake Service Information
235
Hydraulic Brake Specifications
235
Hydraulic Brake Torque Values
235
Hydraulic Brake Tool
235
Hydraulic Brake Troubleshooting
236
Brake Lever Soft or Spongy
236
Brake Lever too Hard
236
Brakes Drag
236
Brake Fluid Replacement/Air Bleeding
237
Brake Fluid Draining
237
Brake Fluid Filling
237
Air Bleeding
238
Brake Pad/Disc
239
Master Cylinder
242
Disc Thickness
242
Brake Disc Warpage
242
Brake Caliper
245
Final Drive Service Information
249
Final Drive Specifications
249
Final Drive Torque Values
249
Final Drive Troubleshooting
250
Final Drive Tools
250
Oil Leak
250
Final Drive Removal
251
Drive Shaft
251
Universal Joint
252
Final Drive Gear
253
Ring Gear Removal
253
Ring Gear Bearing Removal
254
Pinion Gear Removal
255
Pinion Bearing Removal
256
Pinion Retainer Oil Seal Replacement
256
Case Bearing and Oil Seal Replacement
257
Breather Hole Cleaning
258
Pinion Gear Assembly
258
Ring Gear Assembly
259
Gear Tooth Contact Pattern Check
261
Backlash Inspection
263
Pinion Joint Installation
264
Final Drive Installation
265
Battery/Charging System
268
Battery/Charging System Service Information
269
Battery/Charging System Troubleshooting
269
Battery Removal
270
Testing Specific Gravity
270
Charging System
271
Battery Charging
271
Charging Output Test
271
Stator Coil Continuity Test
272
Voltage Regulator/Rectifier Test
272
Voltage Regulator Performance Test
273
Ignition System
274
Ignition System Diagram
274
Ignition System Service Information
275
Ignition System Troubleshooting
275
Ignition System Specifications
275
Ignition System Tools
275
Ignition Coil
276
Primary Coil Inspection
276
Secondary Coil Inspection
276
Transistorized Ignition System
277
Spark Unit Inspection
278
Ignition Timing Check
280
Pulse Generator Air Gap Adjustment
280
Starter System
282
Starter System Service Information
283
Starter System Specifications
283
Starter System Troubleshooting
283
Starter Motor Removal
284
Starter Motor Brush Inspection
284
Starter Motor Commutator Inspection
284
Field Coil Inspection
285
Starter Relay Switch Inspection
286
Clutch Switch Diode Removal
287
Clutch Switch Diode Inspection
287
Switches/Lights Service Information
289
Table of Contents
289
Oil Pressure Switch
290
Brake Light Switch
290
Neutral Switch
291
Clutch Switch
291
Handlebar Switches
291
Turn Signal Switch
292
Horn Button
292
Starter Button
292
Engine Stop Switch
293
Ignition Switch
293
Thermostatic Switch
295
Temperature Gauge
295
BRAKE and TAIL Llght SENSOR
296
Bulb Replacement
297
Indicator Light Bulb
297
Meter Bulb
298
Turn Signal Bulb
298
License Plate
299
Wiring Diagram
301
Engine Does Not Start or Is Hard to Start
302
Engine Lacks Power
303
Poor Performance at Low and Idle Speeds
304
Poor Performance at High Speed
305

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Honda CX650C 1983 Shop Manual (306 pages)

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