@)Re™ HOW TO USE THIS MANUAL This shop manual covers emission controlled ‘CK500's manufactured after December 31, 1977. Some procedures may not apply to earlier units. This shop manual uses the 1978 CX500 as the basis for all service procedures and data, The manual is kept up-to-date with subsequent ad dendums beginning with section 21 Follow the applicable Maintenance Schedule re commendations to ensure that the vehicle is in peak operating condition and the emission levels are within U.S. Environmental Protection Agency standards. Performing the first sched uled maintenance is very important. It compen: sates for the initial wear that occurs during break-in. Sections 1 through 3 apply to the whole motorcycle, while sections 4 through 18 describe parts of the motorcycle, grouped according to location. Find the section you wart on this page, then tum to the table of conterts on page 1 of that section. Most sections start with an assembly or system itlustration and all the required specifications, ‘torque values, working practices, tools and materials required for the section. The sub: sequent pages give detailed procedures for the section If you are not tamiliar with this motorcycle, read throught the TECHNICAL FEATURES in section 19. If you don't know the source of the trouble, go +0 section 20 TROUBLESHOOTING. TABLE OF CONTENTS |_GENERAL INFORMATION 2{" AC. GENERATOR/FLYWHEEL/ 9| REAR cover 5 CHASSI HYDRAULIC DISC BRAKE i fe eee BATTERY/CHARGING SYSTEM L| LECTRICAL [el a a > a at m 3 a g a| = ‘ALL INFORMATION, ILLUSTRATIONS, DIREC. TIONS AND SPECIFICATIONS INCLUDED. iN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. HONDA MOTOR CO., LTD. RESERVES THE | RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PERMIS SION. HONDA MOTOR CO.,LTD. Service Publications Office 2 ig 5 ‘a 2 & at g 8 DELUXE/CUSTOM ADDENDUM "82 CUSTOM DUM ISTOM ADDEN| Date of Issue: October, 1981 SHONDA MOTOR CO., LTO.\ HONDA J €X500 MODEL IDENTIFICATION BEGINNING WITH F/N 2000001 ial number is stamped on the right side of The legal vebcle identification number is on the left side mber is stamped on the lower left The carburetor identification number i on the left side side of the engine case of the carburetor body. © & (DENTIFICATION NUMBER Date of Issue: October, 1981 © HONDA MOTOR CO,, LTD.“soo” |, GENERAL INFORMATION GENERAL SAFETY 1 | SERVICE RULES 1-1 SPECIFICATIONS 12 TORQUE VALUES 4 SPECIAL TOOLS/COMMON TOOLS 1-5 GENERAL SAFETY no If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in a closed area, The exhaust contains poisonous carbon monoxide gts. Gasoline is extremely flammable and is explosive under certain conditions. Do not smoke or allow flames ur sparks in your working area SERVICE RULES WIRING DIAGRAM 1-6 CABLE & HARNESS ROUTING 7 EMISSION CONTROL SYSTEM 18 EMISSION CONTROL INFORMATION LABEL 1-9 MAINTENANCE SCHEDULE 1-10 9 Tae ban ee coe cat mains fee ora tn cenia a oper ee eg we haat ae ot ouscerif reat cipro ‘The battery generates hydrogen gas which can be highly explosive. Do not smoke or allow flames or sparks near ihe battery, especially while charging it ‘Use geniune HONDA or HONDA-recommended parts and lubricants or their equivalent, Parts that do not meet HONDA’s design specifications may damage the matoreycle. Use the special tools designed for this product. Ao unless» particular sequence is specified. Install new gaskets, O-rings, cotter pins, lock plates ete. when reassernbling When torauing bolts or nuts, begin with larger-diameter or inner bol: frst, and tightan to the snecified torque diagonslly, Clear parts in caning solvent upon disassembly. Lubricate any siding surfaces before reatsembly. After reassembly, check all parts for proper installation and operation Use only metric toals when servicing this motorcycle, Metrie bolts, quts, und screws are not interchangeable with English fasteners. Tho use of incorrect tools and fasteners may damage the motorcycle. Date of Issue: January, 1978 HONDA MOTOR CO., LIU. 1-1GENERAL INFORMATION ¢X500 ‘SPECIFICATIONS im Metre - ‘vera eng 7185 mm Bem ‘Overall wie 1865 mm Balin ‘Overall eight 7175 mm, ‘6310 DIMENSIONS [__Wheet base 1.4855 me 57310 Seat height B10 mm 319m Foot peg height 35 mm 132m ‘Ground clearance 150mm 591 ‘Dry weiaht "200 ka ‘at be -— Tyee jamond surpension and al “Teescopi fork, 139.5 mam Sm TR wapenion and rave Saag arm, 85 ram (33 in) ir ain an a preseure BRESIOAPA 4 7S kalen® (26 pa) TR ie sige ans pressure PSSIOAPR 2.0725 nylon” (28/96 pa rane F brake Dise brake A brake Taternel expending heer Fuel capaci Tit 45 US p27 tae asl reserve capacity 35 09 US 98! 08 Imp al ‘Gastar sale a TFreienath Voom aa Front fork ot oOo T38 ce fo fav) ‘a7 on ra Ligui eooied @ stroke ORV engine ‘Gylindr aeranaement 2 evlindertranavere V Bore and stroke TexS2mm EXERC Diaploeement| 496.62 303 eu. in “Gompresion ato To Valve tain ‘Chain driven camahate ond push rod Ot capacity sou. [__32usq26imeqr ENGINE Lubrication ster Forced preste andl wet sump ‘Cooling system eapacity 20m. ‘08205 oo Gvlinder compression 2 kalem™ Tis a Opens ‘8 BTOC [ae mm ),_7S" GTDE la OUT { ‘loses FE" ABDC TOL rm Hf), 1159 ABDC lot Di ‘Schur vate ‘Opens 467 BBOC (ar mm if, 117 BBG aro eee ‘loses BEATDC (tT mmf, 719 ATDC lat Ot Valve cleranse am oo 2a, ex ‘0.10 mm 0.004 in Tale speed - 71002 100m Carburetornvee ‘GV vps. 36 me 1.36 in venti Bore ‘essing number = Va26A CARBURETION fe ae : ioe ~ 1-2 Date of issue: January, 1978 HONDA MOTOR CO., LTD.HONDA ) “cxs00 GENERAL INFORMATION [ in Mee Ea Gee War mule Trai Bred connant me rior eur a 2282 7499) Geert 2733 40/5) Gear 1.850 (3720) DRIVETRAIN Gear 146 (34720) Gearon V 1.148 13177 Gear atv 0931 729) Final rection 3.091 GANTT Gear anit oste Te oot cere ones : Fina ger cope Wor Wer | __ 6720308 ae - lition an can is e106 = Haima ence Say eros Ionsion mtanee waren ——— ELECTRICAL | Suing vt Sire motor Altersor Trespass ACG. 12 V 0.17 EDM Baneyeapty 1214 eae TSA mada We EST Noe DBE Canaan mode NO X24E5R-U_NGKORBEST. Soap 05 = 0 am 0028 00% Hesaiont owhigh beam 30/50 watt Talstop ight 3/27 wot 3159 ep SAE Wo. 1167 Turn ina ane | asrzswar 32/32 op sat No. FRONT $28 | ants Meter tight eee} awatt 2epSAE No. 67 asia inst taht Sa wait FpSAE No. BT urn ina instr ant SA watt? epSAEN0. 67 ih bea indo ht watt 2 epSAE No. &7 i presure raring i 3d vatt 2 epSAE No. 57 (ia eemnemee watt cp SAE No. 1054 Dote of Issue: January, 1981 HONDA MOTOR CO., LTD.GENERAL INFORMATION cxs500 TORQUE VALUES a ‘Torq Valor teen ee nm) em Rib ~ Crankahah ep 7 a 70-28 a=W Connecting ro ap 4 8 28-32 2 2 Cylinder head 3 2 5o 85 38 = 40 Valve ejuting nut 8 8 te 18 now Fie 1 2 80-100, se 7 Chatch eantr 1 20 80-100, & 7 Primary crv oor : 2 80-95 58 60 String dutch outer a 3 18-25 B18 Cooling fan ee a 20 - 25 4 - 8 Cam sro bot 1 20 80-100 se | camaprocket 2 | 7 16-20 12-14 | Change nee! 1 | 6 toi 7 = 10 Pedlator arin bolt 1 | | dite 030 1s 22 = ow | mom Torque Valow mm ra fb ie ‘Steering stem nut 1 4 9.0 -12.0 65 - 87 Hordlebor top Bdge 2 7 08-13, 729 Hanslabr lock 2 8 to 14 7710 Honelebar holder 4 8 28 — 30 1-2 Front fork bottom bridge 2 3 ts - 28 13-18 | Prontand rer axes, 1 ‘4 Bs — 68. wo - 47 Front axle holder 4 8 ta 28 nae Engine hanger bolt 4 10 as- 45, 3 | Engine hengr belt : 2 80-70, st Final ive flange nut 3 10 a8 — 48 2 33 Rear rake torque link 1 a | tea 28 "ow Fea hock stnorbr 4 wm | 40-40 2-2 Foot peo 2 to =6| 30-40 «| 2 - 20 | Swingarm pivot mut 1 | Bo -120 se - &7 | Front brake ase 5 3 | (an 33 nm & | Geo ese ear fork 3 10 as - 45 2 3 Sniogarm pivot bolt 1 2 os — 12 6-8 |__ Front atper 2 0 a0 - 40 2-2» “Torque sectcatins tated above are important tightening points. Others should be torqued to standard torques below + STANOARD TORQUE VALUES iy —]Torave Values tem eto) | tem Toraue Values km ib) [ Smm bolt and nut 0.45-0.6 ( 3— 4) ‘mm screw 0.35-0.5 ( 3— 4) mm belt and mat ag -12( 0-9) Om oon 07 111 5 8) @mmbolt and nut — | 1.8 -2.5 (13-18) 6 mm flange bolt and nut. 1.0 -1.4( 7-10) 10%mm bolt and mut 30 —4.0 (22-29) Simm lange bott and mat | 20 20 (14-21) 12mm bolt and mut 20 -60(36-43) | 10 mmTlangeboltand mat | 30 40 (22-20) SS. 1-4 ‘Date of Ise: January, 1078 @HONDA MOTOR CO., LTO.HONDA cx500 € GENERAL INFORMATION SPECIAL TOOLS /COMMON TOOLS @ SPECIAL TOOLS Tool Name Toot We. Torx diver bit ‘01703 0010100 Piston slider ‘57788 00%0000 |» Soetererancn (2717 am) ‘57909.4150000 | | Fina etainar rebch oraiea7r0100 + Retainer Branch '97910-4180000, Snap ring pee 7914 3730001 oltow et wrench (6 rem) ‘57917 3230000 Socket bit (10 mm) 7a17-2740000 | 5 ecm oer (07923-4150000, 2 Gen noir | 97928-41s0000 + Crank eap utter | 82935-4160000, Bearing remover eod (20 me) | 039363710600, (eorig *omower handle) (07036-37101001 | [Bearing remover weight (o7936-3710200) Bearing remover hea | ‘oxe363710600, | + Peo liearing outer remover yaa6-4150000, |S Patonremover veat-4160000, | + Valve acide diver sttachmant '87943-4150000 | 1 pallrace driver (8OTTOM! | o7aas-aa90s00 | + Stank cap arver Byeas-ars0100 ‘ Machanial sal diver attachment ‘roas-41 50200 | + Mechanieal set plot mnas-ayso01 | 7 Gatteace river (OP) 07546.3200000 | Staaring stem driver yea637r0800 | | Batlrace remover || 97989.3220000 | Fling gate Be Assombly toolset ‘7968-4180000 | (Bing gee comer guia (o7085-4188100) | + [Biefattambty toa Al || (o7968-4180200) | Gistassempiy toot (o7965-3710200) (irAssemly top! Ch (o79es-3710300) + Main tearing Die Assembly ‘001 1b7973-4750000, Valve guide tar (66 me) Dyeaastv0000 + Proloadinepaction too! || 2)008-41s0000, * Iaipection plug 7800-4150000, Sprcal tot cae 3707-2920300, aca gauge tester '97408.0020000, (Wer gauge attachment (o7et0-2000100) + Tire tver set (tor eomstar whe) '07772.0020000 (ire vel (07772.0020100) {rim protector) {07772.0020200) ‘Resropriaton L {Lal purchase item TAO torx bit or vorkat (Commen To0\~ Special Tool Local purchase tem teat purehore em 070462710400 Ball sercone ier r996-3710600 The tools atersked [7 ae included is the "SPEGIAL TOOL SET The tool seared 6) are detignad for comatar wheel ‘© COMMON TOOLS "FOTaDS ATEOTOT” and the are new Tor CXE00. Tosi ane Toot ne “Appropriation Lat (Gerrvan Fost = Special Toa oat evel gouae ‘00010000 — Pistoanne? (07702.0010000 | Pin spanner 146 mr .07802-2400000 "apoet suring oench st 09508 3640000 appet adjusting wrench (10 12 07708-9030200 |] [Tapper aja wrncr 110 mm ‘808 3840400) Srzogaotce |) Tan sant aN ‘7e08 3200100) eainec wrench 8 GI100010290 Detar wroncn 79163220101 Use rt wrench socket (28x 2 mm) : Uaeknot wreneh Socket (30 38mm) Loca! purchase tem Extension bar & hen CESS purehaee tm Fiyanen rote ule Fyne paler 107933.0010000 Fotor pute Aor pul ‘a3 2000000 Yate ui eover (6.8 mm) Wate guide iver Sonar 0000 Pin ceer {38 rn) Pin cver {8 om Drona sonora Searing ever ute (42x47 mv) Saving ever Graasseaoice ring erver outer (92x98 rm) rain er araseari000 Bearing ever pot Em Not applicable to seal too Bearing ever pot (2D? + Not appleale speci toot Sewing ver pilot (22 rh Not soplicavs to sci oot Bearing ever pilot 28 mm) Not applicabie to special tool Bring ver lo (20,0) 5 Notapptcabe te pec toot nt for ta rivet BOY Fork ve river o7e47.3330000 rent fork o seal athment (OF rere tery a ing driver Randle jor to be uted with common tools 10000 tre rng comresor 87987-0010000 | none cormeser : Sher 00001 fer shock etuovbercompreton 07780:2290001 —— “The tool asteriaked (*) indicate wove which are not found in special tool See the "NEW MOTORCYCLE COMMON TOOL LIST™” et the back of this manual (Date of Issue: January, 1981 HONDA MOTOR CO., LTO, 1-500302 —415—6700 1-6CABLE & HARNESS ROUTING COUPLER (sROHN)© HONDA *=/ CX500 GENERAL INFORMATION EMISSION CONTROL SYSTEM The CXBOO is equlpped with two emission control systents ‘* EXHAUST EMISSION CONTROL SYSTEM ‘The exhaust emission control system is Composed of a factory preset carburetor. No adjustment should be made except to the idle speed with the throttle stop screw © CRANKUASE EMISSION CONTROL SYSTEM The engine is equipped with 2 “Closed System” to prevent crankcase emission from entering the atmosphere. Blow by gas is returned to the combustion chamber through the breather tube, separator and intake pipe. CRANKCASE EMISSION CONTROL SYSTEM FROMANOTHER cYLinpen, BREATHER TUBE AIR CLEANER AIR CLEANER CASE BREATHER _SEPARATOR _ DRAIN PLUG / =e | ORAIN PLUS. << FRESH ALR —— sLow.sy sas Date of tise: Janwary, 1978 OHONDA MOTOR CO, LTD. 1-8HONDA cx500 © GENFRAL INFORMATION EMISSION CONTROL INFORMATION LABEL CXSUN'S manufactured after December 31, 1977 have ar ins basic tune-up specifications for CXSQ0's manufact mission Control Information label on the frame as shown. It fter December 31, 1977. Refer to this Shop Manual for more EMISSION CONTROL INFORMATION LABEL, Date of leave: January, 1978 1-9 HONDA MOTOR CO.,LTD.HONDA cx500 GENERAL INFORMATION MAINTENANCE SCHEDULE Pecterm the PRE-RIDE INSPECTION in the Owner's Manual ot every maintenance period. INSPECT, CLEAN, ADIIST. | LBRICATE OR REPLACC IF NECESSARY. CLEAN REPLACE ‘AousT CoBRICATE, reper ~ WhicHEVER =] ‘ODOMETER READING [NOTE (1 FREQUENCY ENGINE O| ENGINE O1L FILTER L (CRANKCASE BREATHER ‘EMISSION RELATED ITEMS, “CARBURETOR SYNCH ‘COOLANT ‘COOLING SYSTEM, HOSES FT RADIATOR CORE =) DRIVE SHAFT JOINT. FINAL DRIVE LUBRICANT. Page 2— BATTERY is @RAKE FLUID FRONT) Page 2 ‘GRAKE SHOE/PAD WEAR Page 3-11 ‘BRAKE SYSTEM Page 311 ‘BRAKE LIGHT SWITOH Page 3-12 HEADLIGHT AIM Page 3-13 CLUTCH FREE PLAY Poge 3-13 SIDE STAND Pooe 314 ‘SUSPENSION Page 314 NUTS, BOLTS, FASTENERS =| wHEeLs — == | STEERING HEAD BEARING NON EMISSION RELATEDITEMS Page 3-15, Page 3-15, Page 315, “+ Il THe INTEREST OF SAFETY, WE RECOMMEND THESE ITEMS BE SFRVICED ONLY OY AN AUTHORIZED HONDA DEALER. * SHOULD BE SERVICED BY AN AUTHORIZED HONDA DEALER, UNLESS THE OWNER HAS PROPER TOOLS AND IS MECHA- NICALLY QUALIFIED NOTES: (1) Mora Fraquant service may be required when ridden in ai, iden et ful throttle openings, dropoad or wma often Serves if depot oval can be sean inthe transparent section of dain tubes. (2) More frequene service mey be required han riding in Sut a (2) For hight odometer eadings,repet a the Trequency interval establishes here ‘Date of lauer January, 1978 HONDA MOTOR CO., LTD. 1-10