HONDA MBX50- MBX80 MBX50°-MBX8O0 WORKSHOP MANUAL HOW TO USE THIS MANUAL This shop manual describes the service procedures for the HONDA MBX60 and MBX80 based on ‘the MBX50 Standard model. Section 1 throughs 3 apply to the whole motor- cycle, while section 4 through 17 describe parts of the motorcycle, grouped according to loca- tion, Find the section you want on this page, then turn to the table of contents on page 1 of that section, Most sections start with an assembly or system illustration, service information and trouble- shooting for the section, The subsequent pages give detailed procedures. If you don’t know the source of the trouble, go to section, 18, TROUBLESHOOTING. ALi WFORWATION, ILLUSTRATIONS, GREG] Tons" AND. SPECIEICATIONS. INCLUDED. Ik | THISPUBLICATION ARE BASSO ONTHE LATEST | PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL. FOR PRINTING HONDA | Moron cO, LvO. RESERVES THE RIGHT 70 MaKe CHANGES” AT. ANY TIME WITHOUT NOTIGE AND WITHOUT INCURRING ANY OBLIGATION WHATEVER NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION HONDA MOTOR CO., LTD. SERVICE PUBLICATIONS OFFICE ENGINE CHASSIS |ELECTRICAL GENERAL INFORMATION Ee LUBRICATION [2] INSPECTION AND AJUSTMENT Ei FUEL SYSTEM Ea ENGINE REMOVAL/INSTALLATION RG CYLINDER HEAD/CYLINDER/PISTON CLUTCH/KICKSTARTER/ GEA ALTERNATOR m3 | CRANKSHAFT/TRANSMISSION FRONT WHEEL/SUSPENSION COOLING SYSTEM HYDRAULIC BRAKE TROUBLESHOOTING@meret, MODEL IDENTIFICATION f aA (2) ‘The frame serial number is stamped on the steering head right side. (3) The engine serial number is stamped on the left crankcase. (4) The carburetor identification number is on the carburetor body left side.HONDA MBX50- MBX80 GENERAL INFORMATION 1. | GENERAL SAFETY 11 SPECIAL TOOLS/COMMON TOOLS 15 SERVICE RULES 1-1 WIRING DIAGRAM 16 iH SPECIFICATIONS 1-2 CABLE & HARNESS ROUTING V7 TORQUE VALUES 14 MAINTENANCE SCHEDULE 1-10 [> IMPORTANT SAFETY NOTICE - —— Indicates a possibility of personal injury or loss of life if instructions are not followed. Indicates a possibility of equipment damage if instructions are not followed. EI caution: Detaled descriptions of standord workshop procedures, safety principles and sorvice operation ae not ince 8 Its importat to note that this manual contains soma warning and cautions aguinet some spite sovce | methods which coud couse PERSONAL INJURY to service personel or could damage avohiclewerendon ten safe, Presse understand that those warings could not cover all concuvable waye in which servic, hate net recommended by Honda might bo dane or of the possible havardous consequences of tach conedivcblo way, not could Honda investigate al such ways, Anyone veingsorviee procedures or toes, whiter oy ret recommended by Honda must satisfy himself thoroughly tha ether parsonel etal nor vehicle safety wil bo inoporaiod by the service methods or tool selected | GENERAL SAFETY CRIS 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 gas, Gasoline is extremely flammable and is explosive under certain conditions, Do not smoke or allow lames or sparks in your working area, SERVICE RULES 1 The beter acolyte con seca Pret Pace dae aaa peer ie “car th ee sce ak were ‘The battery generates hydrogen gas which can be Ten enone Ds ne oe he ee sparks near the 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 motorcycle, 2. Use the special tools designed for this product. 3. Use only metric tools when servicing this motoreyele. Metric bolts, nuts, and seraws are not interchangeable with English fasteners, The use of incorrect tools and fasteners may damage the motorcycle. 4. Install new gaskets, O-rings, cotter pins, lock plates, etc. when reassembling 8. When tightening bolts or nuts, begin with largerdiameter or inner bolts frst, Unless a particular sequence is specified. . Clean parts in cleaning solvent upon dissassembly. Lubricate any sliding surfaces before reassembly. After reassembly, check all parts for proper installation and operation. , and tighten to the specified torque diagonally, 1-1HONDA. GENERAL INFORMATION MBX50- MBX80 SPECIFICATIONS f ~ : "AREA Tem MBXx50 - MBxe0 eal DIMENSIONS | Overai length 1,970 mm (77.5 in} « Overall width 675 mm (26.6 in) + Overall height Standard 1,005 mm (38.6 in) * Deluxe 1,110 mar (43.7 in) « Wheelbase 1.250 mm (49.2 in) + 778 mm (30.5 in) 780 mm (30.7 in) | Ground clesrance 170 mm 6.7 in) 160 mm ( 5.9 in) r £89 kg (196 tb) 92 kg (203 1b) 98 kg (216 Ib) 101 ka (223 tb) Loaded weight 248 kg (547 Ib) 251 ka (683 Ib) Perm 268 kg (591 Ib) 271 kg (697 Ib) FRAME Type ‘Semisdouble cradle + Front suspension, travel Telescopic, 11 mm (4,53 in) « Rear suspension, travel Swingarm/shock absorber, 8 mm |< 85 mm 43.35 in) Front tre size 2.50-18.4PR 2.75-18-4PR Rear tres 2.75-18-6PR 3.00-18-6PR Cold tire prassure Up to 90 kg Front | 175 kPa (1.75 ko/em?, 26 psi) 200 kPa (2.0 kg/em?, 28 psi) (198 ib) Rear | 175 kPa (1.78 ka/em?, 26 psi) 200 kPa (2.0 kalem?, 28 psi) Up to capacity Front] 175 kPa (1.75 ka/em?, 26 psi) 200 kPe (2.0 kglem?, 28 psi) oad Rear | 280 kPa (2,80 kg/em?, 40 psi) 280 kPa (2.8 ka/em?, 40 psi) Front brake Single disc brake « Rear brake Internal expanding shoe + Fuel capacity 1.2 liters (3.2 US gal, 2.6 Imp gal) |< Fuel reserve capacity 12ers (0.3 US gal, 0.3 Imp gal) |< | Caster angle 26°30" + Trail 72mm (2.8 in} « j__Front fork oil capacity 149.5-154.5 em? (6.3.5.5 02) ENGINE Type Water cooled 2stroke, reed valve |< Cylinder arrangement Single eylinder 1° incline from + vertical Bore and stroke 99.0 x 41.4 mm (1.64 x 1.63 in) | 49.5 x 41.4 mm (1.95 x 1.63 in) Displacement 49 cm? (2.98 eu in) 79-cm? (4.82 in} Compression ratio 73:1 + 1-2HONDA MBX50. MBX80 GENERAL INFORMATION ‘AREA | rem axso axe0 pal ENGINE Maximum horsepower 5.8 kw/7,000 min=* 7.0 kw/8,750 7 (7.9 ps/7,000 rpm) {9.6 ps/5,750 rpm) Maximum torque ‘8.3 N.m (0.86 kg-m, 6.1 ft-lb)/_ 11.7 N.m (1.2 kg-m, 8.7 ft-lb) 8,500 min! (rpm) 5,500 min™* (rpm) Oil capacity Transmission 0.9 liters (1.0 US gt, 0.8 Imp qt) aa 1.2 liters (1.3 US gt, 1.1 Imp qt) + 670 cm? (40.9 cu in) - Foreed and wet sump + Ar filtration Oiled polyurethane foam + Cylinder compression 1,275 kPa (13.0 kolem®, 185 psi) |< Idle speed 1,400 min~* (rpm) + E Identification number PFIGA PF26D Air sorew inital setting 1% turns out 1 tum out Float level 13.5 mm (0.63 in) « DRIVE TRAIN Cluteh Wot, multi-plate + Transmission 6-speed constant. mesh « Primary reducation anny - Final reducation 2.866 (43/15) 2.533 (38/15) Goarratio | 3.545 + " 2333 « i 1722 « Wv 1.380 . | v 173 « vi 10a © Geor shift pattern Left foot operated return system, | + 3456 ELECTRICAL Ignition + Ignition timing “F" mark 3° BTDC at 3,000 min“ (rpm) | + Full retard 10.5°+3.5° BTDC at 9,000 min-* 3°23.6° BTDC at 9,000 min™ (rom) (rom) | starting system Kickstarter + Generator 90W/5,000 min=" (rpm) + Battery capacity 12 3AH . Spark plug Standard NGK BReES, NO W24ESR-U + Optional NGK BROES, NO W27ESR-U ‘ NGK BR7ES, NO W22ESR-U ‘ Standard NGk BRES, NOW27EsRY | G Optional NGK BR7ES, NDW22ESR-U |G NGK BRAES,NDW24EsR-U |G Spark plug gap 0.7.0.8 rm (0.028.031 in) « Fuse 7A + LiGHTS Headlight (high/low beam) 35/35W . 36/36W F | taivstoptight srw « Front turn signal tow < } Rear turn signal row - | Speedometer ight aw « Tachometer light 3.4w « Baw « | Turn signal indicator 3.aw « igh beam indicator 1 « 1-3GENERAL INFORMATION TORQUE VALUES HONDA. MBX50- MBX80 © ENGINE ; ; Torque ( [ey [rion | nn =< Cylinder head 4 8 18-22 (1.8-22, 13-16) Alternator rotor 1 2 {50-60 (5.0-6.0, 36-43) Primary dri 1 2 45-55 (4.5-5.5, 33-40) Drain plug 1 12 20-25 (2.0-2.5, © CHASSIS, : ; Torque tem Q'ty | Thread Dia (mm) nage Remarks Steering stem nut 1 2 |" 60-90 16.0-9.0, 43-65) Handlebar holder 4 6 10-14 (1.0-1.4, 7-10) Fork pinch bolts 2 8 24-30 (2.4-3.0, 17-22) Front fork bolt } 2 12 40-60 (4.06.0, 29-36) Front fork inner bolt 2 2 18-30 (1.5-3.0, 11-22) Front axle nut 1 12 55-70 (5.5-7.0, 40-51) Self-looking nut 3 10 30-40 (3.04.0, 22-29) Rear axle nut 1 2 55-70 (6.5-7.0, 40-61) Selt-ooking nut Final driven sprocket 3 10 40-50 (4.0-5.0, 29-36) Rear brake torque link 2 8 18-25 (1.8-25, 13-18) | Rear shock absorber 2 10 27-33 (2.7-3.3, 20-24) Self-looking nut Rear shock linkage 3 10 40-50 (4.0-50, 29-36) Swingarm pivot nut 1 4 70-85 (7.0-8.5, 51-62) Seltocking nut | Front brake cise 3 8 27-33 (27-3.3, 20-24) Front brake master cylinder =| 2 6 10-14 (1.0-1.4, 7-10) Brake bleeder valve 4 - 4— 7(0.4-0.7,29-5.1) | Brake hose bolt 2 10 25-95 (2.6-3.6, 18-25) Brake caliper bracket 2 8 24-30 (2.4~-3.0, 17-22) Brake caliper bracket pin nut 2 8 20-25 (2.0-2.5, 16-18) Brake caliper pin bolt | 6 ‘Torque specifications listed above are for important fasteners, Others should be tightened to standard torque values belo, © STANDARD TORQUE VALUES 42mm bolt and nut 50-60 (5.0-6.0, 36-43) Torque Torque a Num (kgm, feb) a ‘um (kom, feb) ‘Simm bolt and nut 4 6104-06, 3-4 | Smmscrew 3- 5(03-05, 3-4) 6 mm bolt and nut 8-12 (0.8-1.2,. 6-9) | 6 mmscrew 7-11 (0.71.1, 5~ 8) Bmmboltand nut | 18-25 (1.8-25, 13-18) | Gmmflange bolt andnut_ | 10-14(1.0-1.4, 7-10) YOmmbolt and rut | 30-40(8.0-4.0, 22-29) | _gmmflange bolt and nut | 20-30 (20-80, 1422) 10mm flange bolt andnut | 30-40(3.0-4.0, 22-29) 1-4HONDA. MBXSO- MBX80 GENERAL INFORMATION TOOLS ‘SPECIAL Tool Name Tool No. oy Crankshaft assembly tool 07965~1660100 1 | Crankshaft installation Balancer weight driver 070481660000 1 | Balancer installation Bearing remover set 12mm (079361680000 1 | Removal of small balancer bearing, water pump bearing and mainshaft bearing {Spindle assembly) (07936—1660100) a) (sliding weight) (07936~3710200) a Bearing puller (commercially availble) 07631-0010000 1 | Main bearing removal Boaring driver 28 x 30 mm (07964~1870100 1 | Small belancar bearing and mainshatt bearing instalation Hex wrench 6 men | (commercially available) 07917—3230000 1 Ball rece driver 079441150001 1 Snap ring pliors 07914~3230001 1 | Front fork oil sea! | | driver attachment 07747-01070 1 ‘Shock absorber ‘comprestor attachment 07967-GE20000 1 ‘Mechanical seal driver 079484150400 1 | Weter pump mechanical seal instalition COMMON Tool Name Part No oy Remarks Float level gauge (074010010000 7 | lost tov | Universal holder 07726:-0030000 i yea per ovrgs-soroom |_|} Firm Driver A 0749-0010000 1 | Used with driver attachment ‘Attachmont 62 x 55 mm 07746-0010400 1 | ‘Attachment 42 x 47 mm 07748~-0010300 1 ‘Attachment 37 x 40 mm 07746-0010200 1 | Installation of front whos! bearing ‘Attachment 32 x 35 mm 07748-0010100 1 |_ Installation of crankshaft oll sel Pilot 12 mm 0746-0040200 1 Pilot 17 men 07746-0040400 1 | | Used with driver sttachment Pilot 25 mm 07746-04080 1 | Pilot 24 mm 07746~-0040809 1 0 | Driver C 0746-0030100 1h ‘ Attachment 26 mm 1.D. 07746—0030200 1 Le eee) Front fork ol seal driver 077470010100 1 | Installing fork: soa in slider body Pin spanner 07702~0010000 Steering head beering adjustment 1-5MEMO@) HONDA MBXSO- MBX80 GENERAL INFORMATION CABLE & HARNESS ROUTING (2) HIGH TENSION CORD (1) RADIATOR OVERFLOW TUBEHONDA GENERAL INFORMATION MBX50- MBX80 (4) WIRE HARNESS 1-8HONDA MBXS50- MBX80 GENERAL INFORMATION (1) CLUTCH CABLE or (3) THROTTLE CABLE yh (2) TURN SIGNAL SWITCH COUPLER (4) INSTRUMENT COUPLER (5) BRAKE HOSE {—~ ry (6) OIL LEVEL (7) NEGATIVE SENSOR WIRE (8) IGNITION con Svenrtow | )\\ TUBE \ \ sf f See eemomean ~ (12) TACHOMETER CABLE 1-9HONDA MBXS50- MBX80 GENERAL INFORMATION MAINTENANCE SCHEDULE Perfrom the Pre-ride Inspection at each sheculed maintenance period, Inspect and Clean, Adjust, Lubricate or Replace if necessary, C: Clean: replace ‘A: Adjust L: Lubricate —— WHICHEVER REQUENCY | COMES FIRST ITEM j EVERY ‘TRANSMISSION OIL, a ‘SPARK PLUG. AiR FILTER ELEMENT NOTET * | CARBURETOR RADIATOR COOLANT “RADIATOR CORE + COOLING SYSTEM |" | Houses & connections, [= [THROTTLE OPERATION **] OIL PUMP FUEL LINES FUEL STRAINER CLUTCH [DRIVE CHAIN NOTES BRAKE BRAKE WHEELS t TIRES FRONT AND REAR SUSPENSION ‘**] STEERING HEAD BEARINGS BATTERY _ a BRAKE FLUID ~ / MONTH: _| 2 YEARS: R_| > [BRAKE Lien swiTeH SIDE STAND =] LIGHTING EQUIPMENT + ALL NUTS, BOLTS AND OTHER FASTENERS | ‘+| CYLINDER PISTON DECARBON: IZATION ew | vs/ CYLINDER EX. PORT —>; BEGARBONIZATION MUFFLER DECARBONIZATION ¢ “SHOULD BE SERVICED BY AN AUTHORIZED HONDA DEALER’ UNLESS THE OWNER HAS THE PROPER TOOLS AND SERVICE DATA AND IS MECHANICALLY QUALIFIED, REFER TO THE OFFICAL HONDA SHOP MANUAL. “"IN THE INTEREST OF SAFETY, WE RECOMMEND THESE ITEMS BE SERVICED ONLY BY AN AUTHORIZED HONDA DEALER. NOTES: 1. Service more frequently when riding in dusty areas 2. For higher odometer readings, repeat at the frequency interval established here, 3. Every 300 miles (500 km) 1 Page 313 | ago 3-13 1-10OR LUBRICATION 2. ff (2) cansureTor >: (1) ENGINE OIL FLOW | (8) OIL TANK (6) OIL TANK CAPACITY: 1.2 lit. (1.3 US at, 1.1 Imp at) . 4 mf 5 aN 124m [ Ay locking aan othe tied aFthe Tg ae ‘agent [oil pump mounting bolt and screw. (0. 2-0HONDA. LUBRICATION MBX50- MBX80 OL FLOW 20 SERVICE INFORMATION 22 TROUBLESHOOTING 22 TRANSMISSION OIL 23 OIL STRAINER CLEANING 24 OIL PUMP REMOVAL 25 OIL PUMP INSPECTION 26 OIL PUMP INSTALLATION 26 OIL PUMP BLEEDING 27 OIL TANK 28 CHASSIS LUBRICATION POINTS 29 2-1HONDA MBXSO- MBX80 SERVICE INFORMATION GENERAL INSTRUCTIONS Use utmost care whan rem ‘© Do not attempt to disassemble the oil pump, LUBRICATION and installing the oi! pump to keep dust and dirt from entering the engine, Bleed alr from the oil pump if there is air in the oil pipe from the oil tank to the oil pump or if the oil pipe has been dis- connected. ‘Blood air from the oil pass tube (from the oil pump to the inlet pipo) if the tube has been disconnected. SPECIFICATIONS INJECTOR OIL [ot eapacty [___Sitrcomendstion TRANSMISSION OIL, | oncapcty i Oil recommendation equivalent. API SERVICE CLASIFICATION: | |e TORQUE VALUES il pump mounting bolt Oi! pump mounting serew TROUBLESHOOTING Excessive smoke/excossive carbon buildup in plug 1. Pump not properly synchronized (excessive oil) 2. Low quality of engine oil Overheating 1. Oil pump not synchronized properly (insufficient oil) 2. Low quality of engine oi! Honda 2 Stroke Injector Oil or its equivalent TO. it. (1.008 qt, 0.8 tmp at) at disassembly O38 lit. (0.8 US at, 0.7 Imp atl at change VISCOSITY: SAE 10W-40 it. (1.3 US at, 1.1 Imp at) 8-12 Num (0.8-1.2 kg-m, 6-9 ft-lb) 8-12 Num (0.8-1.2 kam, 6-9 ftlb) Sizad or burnt piston 1. No oil in tank or clogged oil pipe 2. Pumpt not properly synchronized (insufficient oi!) 3. Air in oll pipe 4. Defective oil pump Oil not flowing out from tank 41. Clogged oil tank cap breather hole 2. Clogged oil tank filter screen 2-2HONDA MBX50- MBX8O LUBRICATION TRANSMISSION OIL OIL LEVEL CHECK Before checking the oll level run the engine and allow to idle for a few minutes ‘Support the motorcylce upright on level ground, Stop the engine and remove the oil level check bolt ‘from the right crankcase cover. ‘A small amount of oil should flow out of the oil level bolt hole. OIL CHANGE Warm the engine to normal operating temperature Remove the oil filer cap. Remove the oil drain plug and drain the oil, Reinstall the drain plug TORQUE: 20-25 N.m (2.0.2.5 kg-m, 14~18 frlb) CAUTION ‘Make sure that the sealing was lug is in good condition. Refill the engine up to the proper level OIL CAPACITY: 0.8 lit. (0.8 US at, 0.7 Imp at) SPECIFIED OIL: 10W—40 or equivalent Start the engine and check for leaks. Stop the ‘engine and recheck the oil level. (1)- OIL DRAIN PLUG. 20-25 Nm (2.0-2.5 kgm, 14~18 ft-lb} 2-3HONDA @) MBX50- MBX80 OIL STRAINER CLEANING Disconnect the oil tube at the oi pump and allow the oll to drain into a clean container. Romove the right side cover. Loosen the tube clip and disconnect the oil tube Joint under the oil tank, Romove the oil strainer sereen, Clean the oil strainer seroon with compressed air. Installation of the oil strainer isthe reverse order of removal Fill the oll tank with the recommended oil up to the proper level Bleed ai rom the oil pump and oil pipe (Page 2-7) _ CAUTION * Connect the of pipe securely | # Check for leaks, J LUBRICATION (1) o1L puMP (2) OIL TUBE (1) OIL STRAINER» | SCREEN 2) CLIP =) | ce sug AF | Sone | (4) OL TUBE ——» JOINT (1) OIL STRAINER SCREEN (2) AIR NOZZLEHONDA. LUBRICATION PABXSO- MBX8O_ OIL PUMP REMOVAL (1) OIL PUMP MOUNTING BOLT (2) SCREW NOTE may ‘ - [Before ramoving the oil pump, clean the oil pump and crankcase. | Remove the carburetor (Page 4-3) Disconnect the oil pump control cable, Remove the left crankcase cover, (Page 2-2). Remove the bolt and screw attaching the oil pump. (4) OIL TUBE (3) OIL PASS TUBE Disconnect the oil tube from the of! pump, and hh the end of the oll tube to prevent oil from flowing out. (1) o1L TUBE (2) TUBE CLIP Disconnect the oll pass tube from the inlet pipe. (1) O1L PUMP. NOTE re not to allow oil to flow out of the oll pass tube, | Remove the oll pump from the crankcase, (2) INLET PIPE (3) OIL PASS TUBE 2-5HONDA MBX50- MBX80 LUBRICATION OIL PUMP INSPECTION (1) MATING FACE (2) CONTROL LEVER Remove the oil pump and inspect the following items: Damaded or weakened O-rings. Damage to crankcase mating face. Damage to pump body. Improper oil control lever. CAUTION ‘Do not disassemble the oll pump. OIL PUMP INSTALLATION Install the oil pump by aligning the pin on the purne drive shaft with the groove in the pump driven gear. NoTE © Lubricate the O-ring with clean grea before installation, © Moke sure that the ofl pump Is inserted into the orankease properly, (2) O-RING | Bod Secure the ol! pump using the off pump sat plate, bolt and serow. NOTE ee | Apply locking agent to the bolt and s | threat. Reconnect the oil purnp control cable. install the oil tube and oil pass tube. Install the carburatar. (Page 4-9). NOTE [Peron he fefowing rapetions and adhe rent Gomtol cable ajusiment (age 38). © Oil pump air bleeding (Page 2-7). © Oil pass tube air bleeding (Page 2-7). sciHONDA LUBRICATION MBX50- MBX80 OWL PUMP BLEEDING (1) ENGINE OIL TANK — (2) OIL FILLER CAP NOTE ‘© Bleed air from the ail lines as it will Block fr restrict il flow,’ resulting in severo } engine damage, © Bleed air from the oll tube and oll pump first, then bleed air from the oll OIL TUBE/OIL PUMP NOTE | Bleed air from the oll tube and oil purnp when ‘the oll tube has been disconnected or there Is. air in the oil tube, ‘Stop the engine. Fill the oil tank with engine ol Place a rag around the oil pump as shown, Unscrew the bleeder bolt at the top of the oil pump. Tighten the bleeder bolt when the oll is free of air bubbles. OIL PASS TUBE NOTE [ Bleed air from the oil pass tube when the tube] is disconnected or there is air in the oil tube and oil pump. Made sure that there is fuel in the fuel tank (25— {50 parts fuel to 1 part lubricant) Start the engine and run it for about 10 minutes with the oil pump control lever in the fully open osition so @s to force air out of the oil pass tube with the of Perform this operation in @ well ventilated area. CAUTION ‘© Use the recommended engine ofl. © Do not race the engine. 2-7 (1) FUEL-OIL MixTURE (25:50 : 1) Ms & oo (3) OIL Pass TUBE (3) OIL TUBE (2) OIL TANK faa (4) Open contro Fever fll.e HONDA \Y>/ MBX50- MBX80 LUBRICATION OIL TANK (1) O1L-TANK MOUNTING BOLT REMOVAL/INSTALLATION Remove the seat, right and left side covers Remove the fuel tank and air cleaner case (Page 4-10). Rlemove the rear suspension linkage mudguard (Page 13-13). Disconnecto the oil tube at the ofl pump and drain the oil Disconnect the all level warning unit coupler. Remove the oil tank attaching bolt and tank, Install the oil tank in the reverse order of removal. 2-8HONDA. LUBRICATION MBXSO- MBX80 CHASSIS LUBRICATION POINTS BP (4) CLUTCH AND BRAKE (5) FRONT FORK LEVER Pivots (ATF) Ss (2) suincan — ae eA a (1) WHEEL BEARINGS PIVOT (@) THROTTLE (718) oF CABLE LUBRICANT TACHOMETER CABLES — a (7) STEERING HEAD BEARINGS (14) BRAKE CAM (@) specoomeren (19) [GRAIN LUBRICANT] ot Drive GEAR DRIVE CHAIN my" PIVOT \ (9) WHEEL BEARINGS (12) BRAKE PEDAL Sa Pivor (10) MULTIPURPOSE GREASE MLG1 No.2 (Mos, Additive) REAR SusreNsion LINKAGE : 2-9INSPECTION AND ADJUSTMENT 3. COOLING SYSTEM HOSES SERVICE INFORMATION 34 38 | < ENGINE > RADIATOR CORE 28 FUEL STARINER 32 THROTTLE OPERATION 32 BATTERY 39 AIR CLEANER 33 FRONT BRAKE 39 SPARK PLUG 34 REAR BRAKE 310 CARBURETOR IDLE SPEED 35 BRAKE LIGHT SWITCH 310 OIL PUMP CONTROL CABLE 35 DRIVE CHAIN 311 | IGNITION TIMING 36 WHEELS 313 CYLINDER COMPRESSION 37 NUTS, BOLTS, FASTENERS 3413 CLUTCH 37 MUFFLER DECARBONIZING 313, | RADIATOR COOLANT 38 SERVICE INFORMATION GENERAL INSTRUCTIONS © Transmission oil Seo page 2-3, © Oil pump See page 2-4. © Cylinder head and piston decarbonizing Soo page 6-4. Cylinder exhaust port dacarbonizing Seo page 6-6, SPECIFICARIONS _MBxE0 Mexe0_ EF 6 < Engine > Spark plug: Standard NGK BRAES, ND W24ESR-U + | NGK BR9ES, ND W27eSR-U Optional NGK BROES, ND W27ESR-U «| NGKBR7ES, NO W22ESR-U NGK BR7ES, ND W22ESR-U + | NGKBRBES, ND W24eSR-U Plug gap Janition timing 0.7-0.8 mm (0.028-0.031 in) « “mare 49° £3° BTDC at 9,000 min-* (rom) + Retard start 4,400-5,600 min" (rpm) oe + Full ratard 10,5" £3.5° BTDC at 9,000 min" (rpm) | 3° #3.5°BTDC at 9,000 min-* (rom) Idle speed 4,400 min-* (rom) « Air screw opening 1% turns out (SW, B, SA), 1% turns out (E) 1 turn out Cylinder compresssion 130 kPa (13.0 kglem?, 185 psi) | + Throttle grip free play 2-6 mm (1/8—1/4 in) + Coolant capacity ‘Approximately 670 cm? (1.4 US pt, + (1.2 Imp pt.) < CHASSIS > Rear brake pedal free play 20-30 min (9/4=-1-1/4 in) + Clutch lever free paly 10-20 mm (3/8-3/4 in) + Drive chain slack 10-20 min (3/8-3/4 in) + Tire Tire size Front 2.60-18-4PR 2.76-18-4PR Rear 2.75-18.6°R 3.00-18.6PR Cold tire pressure Front 4176 kPa (1.75 kafem? 25 psi) | 200 kPa (2.0 ka/em?, 28 ps) Rear 176 kPa (1.75 kaem?, 26 psi) | 200 kPa (2.0 kgfom?, 28 psi) Minimum tread depth Front 0.8 mm (1/32 in) a Rear 0.8mm (1/32in) + 3-1© HONDA INSPECTION AND ADJUSTMENT MBX50- MBX80 FUEL LINE AND FUEL STRAINER Turn the fuel valve OFF and remove the strainer ‘cup, O-ring and filter sereon from the fuel valve body. (1) FUEL VALVE (2) FUEL LINE Wash the strainer cup and filter screen in high flash point solvent. Install the filter seroon and O-ring and tighten the strainer cup. TORQUE: 3-6 Num (0,3-0.5 kg-m, 2.2~3.6 fib) Do not overtighten the strainer cup, After installing, turn the fuel valve ON and check that there are no oil leaks, | womne | (3) STRAINER cup THROTTLE OPERATION Check for smooth throttle grip full opening and ‘automatic full closing in all steering positions. Check the throttle cables and replace if deteriorated, kinked or dameged. Lubricate the throttle cable (Page 2-9) if throttle ‘operation is not smooth, Measure throttle grip free play at the throttle grip flange. FREEPLAY: 2-6 mm (1/8—1/4 in)HONDA MBXS50- MBX80 INSPECTION AND ADJUSTMENT (1) ADJUSTER Adjust by loosening the lock nut and turning the adjuster. Tighton the lock nut. Recheck throttle operation. AIR CLEANER Romove the left side cover. Remove the three screws attaching the alr cleaner cover and cover. Remove the element (1) ELEMENTINSPECTION AND ADJUSTMENT HONDA. MBX50- MBX80 € Wash the element in non-flammable oF high flsh point solvent and allow to dy. note [Bo not wash the element in as | tabieoit Soak the element in clean engine oil or gear oll (SAE 80-90) and squeeze out any exces. Install the element air cleaner cover, Install the left side cover. SPARK PLUG RECOMMENDED SPARK PLUG mexso [ MBx80 | _ EFL 6 | : waa ESR-U| ~ |wa7 ESRU [amis Rox per = a )_|W22 ESA-U| + |W22 ESRU| Optional jar7es |< [er7es W27 ESR-U| = |W24ESI Lo [BROS | + lenges Disconnect the spark plug cap, Clean any dirt from around the spark plug base. Remove and discard the spark plug. Measure the new spark plug gap using a wire-type feoler gauge. ‘SPARK PLUG GAP: 0.7-0.8 mm (0.028-0.031 in) ‘Adjust by bending the side electrode carefully the plug washer attached, thread the spark plug in by hand to prevent crossthreading, Tighten the spark plug another 1/2 turn with a spark plug wrench to comprass the plug washer. Connect the spark plug cap, = & d (1) Wasi IN (2) SQUEEZEOUT (@) GEAR (4) SOEEZE OU souven” souvent oie” Reeason, THOROUGHLY L_ eee (i) SIDE ELECTRODE 07-0800 (0028-00 in) ta) cenren ELECTRODEHONDA © MBX50- MBX80 INSPECTION AND ADJUSTMENT CARBURETOR IDLE SPEED NOTE The engine must be warm for accurate idle adjustment. Attach an engine tachometer. ‘Turn the throttle stop screw to obtain the specified idle spoed, IDLE SPEED: 1,400 min-? (rpm) When the engine misses or runs erratically, proceed as follows: ‘Screw in the air screw until it lightly seats, then turn it out specified turns. MBXGO: 11% turns (E type: 1% turns) MBX@0: 1 turn’ Roset idle spood with the throttle stop screw. ‘Turn the air screw to find the highest idle speed, Reset idle speed with the throttle stop screw. Make sure that the engine does not miss or run erratically. H necessary, repeat the above steps. OIL PUMP CONTROL CABLE NOTE ‘The oll pump control cable should be adjusted aftor the throttle grip free play has been ___| LLooson the lock nut. With the throttle fully open, align the index mark on the pump body with the reference mark on the control lever by turning the adjusting nut. Tighten the lock nut, CAUTION The idex mark on the control lever must be in line with the reference mark on the pump body. Failure to do so reduces the pump delivery, resulting in serious engine damage. When adjusting the index mark, it may be within I mm (0,04 in) out of line with the [reference mark toward the OPEN region. Excessive white smoke or hard Pump control lever excessively ope Burnt piston: Pump control lever not opened properly (1) THROTTLE SOP SCREW (3) INDEX MARK (2) Lock NUT (6) OPEN (8) CONTROL LEVER@ HONDA \Ss/ MBX50- MBX80 wer Op INSPECTION AND ADJUSTMENT. After adjustment, make sure that there is no in: terference between the control cable and the (1) CABLE BRACKET ‘outer cable. Loosen the bolts attaching the cable bracket and adjust it if necessary. (2) OUTER CABLE | (3) CONTROL CABLE ar Apply locking agent, IGNITION TIMING Nore a [The CDI ignition timing ie not adjustable. | IF the ignition timing Is Incorrect, check the | D1 unitand aerator and replace any faulty L_ pare (1) LEFT CRANKCASE COVER On the Deluxe model, remove the under cowl (Page 14-3) Remove the left crankcase cover. Connect a stroboscopic timing light to the high tension wire Start the engine and bring engine speed to 3,000 min“? (rpm). ‘Aim the time light at the timing mark, ‘The “F” mark should align with the index mark, Bring engine speed to 9,000 min! (rpm) and ‘check that the index mark is between the full retard marks. (4) RETARD MARKS 3-6¢ HONDA = NBX5O- MBX80 CYLINDER COMPRESSION ___() COMPRESSION GaUGE ‘Warm up the engine, ‘Stop the engine and remove the spark plug. Insert a compression gauge. INSPECTION AND ADJUSTMENT Open the choke and throttle grip fully and operate ‘the starter pedal several times. COMPRESSION: 130 kPa (13.0 kg/em? 185 psi) ‘Low compression can be caused by: ‘© Blown cylinder head gasket ‘© Worn piston rings © Worn eylinder High compression can be caused by: © Carbon deposits in combustion chamber oF on piston head CLUTCH Inspect the clutch lever free play at the end of the lever. FREE PLA’ t- 10-20 mm (3/8 3/4 in) 10-20 mm (3/8-3/4 in) 4 ‘Adjust free play by foosaning the lock nut and turn: ing the adjusting nut until the free play is 10: 20 mm (3/8-3/4 in). fer CREASE, raya 3-7@ HONDA \S>/ MBX50- MBX8O INSPECTION AND ADJUSTMENT RADIATOR COOLANT (1) RESERVE TANK Check the coolant level of the reserve tank with the engine running at normal operating tempera ture, Tho level should be betwoen the “L" (LOW) level lines. necessary, remove the “E" level line. (FULL) and diator cap and fill to tho CAEN Engine must be cool before removing ine | radiator cap, or severe scalding may result (2) Low (3) FULL COOLING SYSTEM HOSES (1) Hoses Inspect the hoses for eracks or deterioration, and replace if necossary. Check the hose clamps, and tighten if necessary, RADIATOR CORE ‘Check the air passages for clogging or damage. Straighten bent fins. Remove insects, mud or any obstruction with compressed air or low water prossure Replace the radiator if the air flow Is restricted ‘over more than 20% of the radiating surface.@uere BATTERY Remove the right side cover. Inspect the battery fluid level. When the fluid level nears the lower level, remove the battery and refill with distilled water to the ‘upper level. NOTE ‘Add only distilled water. Tap water will shorted the service life of the battery, ‘The battery electrolyte contains sulfurie acid Protect your eyes, skin and clothing, In case of contact, lsh thoroughly with water and | cata doctor if electrolyte gets in your eyes. Replace the battery, if sulfation forms or se ‘ments accumulate on the bottom, FRONT BRAKE FLUID LEVEL CCheck front brak fluid reservoir level. if the level nears. the lower level’ mark, fil the reservoir with SAE J1703 or DOT-3' BRAKE FLUID to the upper level mark Check the entire system for leaks, if the level is low. CATUION © Do not remove the cover until the hand: leber has been turned so that the reservoir is level, ‘© Avoid operating the brake lever with the cap removed, Brake fluid will squirt out if the lever is pulled. PAD WEAR Check the brake pads for wear Replace the brake pads if the wear line on the top ‘of the pads reaches the edge of the brake dise (Refer to Section 12) CATUION Always replace the brake pads in pairs to [assure even dise pressure. | INSPECTION AND ADJUSTMENT (1) UPPER LEVEL (2) LOWER LEVEL (1) BRAKE DISC (2) WEAR LINES. 3-9Z\ HONDA (© nexso. waxed INSPECTION AND ADJUSTMENT REAR BRAKE (1) abuse Nut REAR BRAKE PEDAL PLAY ‘Measure the brake pedal free play. -1/4 in) If adjustment is necessary, turn the rear brake adjusting nut, BRAKE SHOE INSPECTION Replace the brake shoos if the arrow on the brake farm aligns with the reference mark “A” on full pplication of the rear brake (Page 13-6) (2) REFERENCE MARK BRAKE LIGHT SWITCH (1) ADJUSTING NUT A P Adjust the brake light switch so that the brake light, will light when the brake pedal is depressed and the brake begins engagement. NOTE © Do not turn the switch body. © The fron brake light switch does not [__ tei asta, | Adjust by turning the switch adjusting nut as shown, (2) REAR BRAKE LIGHT SWITCH 3-10HONDA MBX50- MBX80 INSPECTION AND ADJUSTMENT DRIVE CHAIN INSPECTION Shift the transmission into neutral, Measure the drive chain slack between the sprock- ts, CHAIN SLACK: 10-20 mm (3/8~3/4 in) (3) INDEX MARK, ADJUSTMENT To adjust the drive chain tension, loosen the rear axle nut. Tighten both adjusting nuts, Be sure that the index mark aligns with the same graduation on the sale 5 i) Tighton the rear axle nut. TORQUE: 55-70 N.m (6.5~7.0 kan, 40-51 feb) Retighten both adjusting nuts. Check the rer irae padal after the Ove | chain tension has Been usted.INSPECTION AND ADJUSTMENT CLEANING/LUBRICATION If the drive chain is excessively dirty, it should be removed and cleaned prior to lubrication, Remove the master link retaining clip with pliers, NOTE Do not bend or twist the cli Romove the master link and drive chain, Clean the drive chain with non-flammable or high flash point solvent and brush and allow to dry. Inspect the drive chain for possible wear or damge. Replace any chain that is damaged or excessively worn, Inspect the sprocket teeth for excessive wear or damage. Replace if necessary. CAUTION [Never install a new drive chain on wor sprockets or a worn chain on new sprockets. Both chain and sprockets must be in good condition, or the new replacement chain or sprockets will wear rapidly. NOTE Commercial aerosol type drive chain lubri- ‘ants are recommended, Lubrieste the drive chain, saturating each chain link joint, Install the drive chain and master fink, Install the master link retaining clip so that the closed end faces the direction of forward whee! rotation, ‘Master links are reusable if they remain in excellent ‘condition, but it is recommended that @ new master it stalled whenever the drive chain is re- Adjust the drive chain, and check rear brake adjust ‘ment, € HONDA MBXSO- MBX8O (1) RETAINING CLIP (2) ROTATING DIRECTION 3-12HONDA MBXSO- BX8O WHEELS Check the tires for cuts, imbedded nails, or othor sharp objects RECOMMENDED TIRE PRESSURE AND TIRE SIZE: Cold tee pressure KPatha/er ps reese | UR 90ke | Up fo eanecy These | (foamy | ie lwexso| ron] 260-18.0R| 7601.78.28) | 176(1.7828) Pose | 2-76-1899] 1757.75.26) | 2802040) ‘.18-4eR| 20012028) | 200(20.28) Rear] 2.00-18-6°m| 200(20.28) | 200(2.840) Check the front and rear wheels for trueness. Measure the tread depth at the center of the tres Replace the tires if the tread depth reaches the folowing limit. Minimum tread depth: Front: 0.8 mm (1/32 in) Rear: 0.8 mm (1/32 in) NUTS, BOLTS, FASTENERS Check that all chassis nuts and bolts are tightenad to correct torque values, Cheek all cotter pins and safety clipe. MUFFLER DECARBONIZING Remove the muffler (Page 3). Remove the diffuser pipe attaching screw, Remove the diffuser pipe from the muffler. Clean the diffuser pipe with a bristle wire brush, Remove caition from inside the muffler, CAUTION Do not heat or clean with solvent in an at. tempt fo remove carbon from the muffer. Install the diffuser pipe and screw, INSPECTION AND ADJUSTMENT (2) MUFFLER (3) DIFFUSER PIPE (1) DIFFUSER PIPE4. FUEL SYSTEM @menea, 4-0HONDA MBX50- MBX80 FUEL SYSTEM | Service INFORMATION 42 FLOAT LEVEL ADJUSTMENT 47 | TROUBLESHOOTING 42 THROTTLE VALVE/CABLE 48 INSTALLATION CARBURETOR REMOVAL 43 CARBURETOR INSTALLATION 49 THROTTLE VALVE DISASSEMBLY 44 FUEL TANK 49 FLOAT/FLOAT VALVE/JET 45 . DISASSEMBLY AIR CLEANER 410 JETS/FLOAT VALVE/FLOAT 46 ASSEMBLYFUEL SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS HONDA MBXS5O- MBX8O © Use caution when working with gasoline. Always work in a well-ventilated area and away from sparks or flames, ® The float bowl has a drain plug that can be loosened to drain residual fuel. ‘© When disassembling fuel system parts, note the locations of the O-rings. Replace them during assembly. TOOL Common Float Level Gauge SPECIFICATIONS Venturi Setting mark Main jet Main air jot Jot needie Slow jot Float level Air serew opening Idle speed Throttle grip free play TROUBLESHOOTING Engine cranks but won’t stort 1. No fuel in tank 2. No fuel to carburetor 3. Too juch fuel getting to oylindor 4, No spark at plug (ignition malfunction} 5. Air cloaner clogged Engine Ides roughly, stalls, or runs poorly 4. Idle speed incorrect 2. Igniton malfunetion 3. Low compression 4, Rich mixture 8. Lean micture 6. Al cleaner clogged 7. Air leaking into inlet pipe 8. Fuel contaminated 07401—0010000 [MBX6O) _ SW..SAraa = = ero. 65) TaeniOeT | Te = Prien, price | pros | eran Praec 26 #80 100 a0 #210 aro | ao | —— | 31V-2nd goose sTFandgoos [32a gee] —— | 15 a2 wo | —— | 13.50.5301 ee saan o | —— frritemat | tenon | —— | taoonirtiem | —— | —— | — | — | emit ervey | —— | —— | ——~ | —— | Lean mixture 1. Carburetor fuel jets clogged 2, Fuel cap vent clogged or blocked 3. Fuel filter clogged 4. Fu! line kinked or restricted 5, Flost valve faulty 6. Float level too low 7. Air vert tube clogged Rich mixture 1. Choke stuck closed 2. Faulty float valve 3, Float level too high 4, Carburetor air jets clogged 4-2FUEL SYSTEM @ HONDA ‘Ses / MBXSO- MBK8O CARBURETOR REMOVAL / MBX5O- MBX80 (1) ALTERNATOR/NEUTRAL SWITCH WIRE CONNECTORS (2) CARBURETOR INSULATOR (1) LEFT CRANKCASE COVER 5-5HONDA MBXSO- MBX80 ENGINE REMOVAL/INSTALLATION (1) MASTER LINK (2) RETAINING CLIP Loosen the drive chain adjusting nuts and rear axle f nut. Move the rear wheel forward, carefully remove the drive chain master link retaining clip and remove the drive chain, Remove the gearshift podal pinch bolt and gearshift pedal (1) CLUTCHCABLE (2) TACHOMETER CABLE Disconnect the clutch and techomotor cables.@ HONDA ENGINE REMOVAL/INSTALLATION MBX50- MBX80 Place @ jack under the engine, Remove the engine mounting bolts and ramove the engine. ENGINE INSTALLATION Install the engine in the reverse order of removal. NOTE transmission with the recommend: ed oil (Page 2:3) © Fill the cooling system with the recom: | mended coolant (Page 10-3). © Check the locations of the cables and pipes (Page 1-7). ‘© Bleed air from the oll pump (Page 2-7). | © Adjust the oil pump contro! cable (Page | ae es Pea . Adjust the drive chain tension (Page 9-11). | REAR AXLE NUT TORQUE: 55-65 N.m (6.5-6.5 kg-m, 40-48 ftb) 5-7© ONDA CYLINDER HEAD/CYLINDER/ = MBX50- MBX80 PISTON 6-0€ HONDA CYLINDER HEAD/CYLINDER/PISTON == / MBX50- MBX80 SERVICE INFORMATION a 62 TROUBLESHOOTING 62 CYLINDER HEAD 63 CYLINDER/PISTON 65 REED VALVE 6-10 6-1HONDA MBX50- MBX8O CYLINDER HEAD/CYLINDER/PISTON SERVICE INFORMATION GENERAL INSTRUCTIONS ® All cylinder head maintenance and inspection can be accomplished with the engine installed. ‘Before disassembling the engine, clean the engine thoroughly to prevent dirt and dust to fall into the eylinder and erank- Remove all traces of gasket material from the mating surfaces of the cylinder head, cylinder and erankease ‘© Use caution when servicing the cylinder and piston to prevent damage to them, © Before assembling, apply clean engine oil to all sliding surfaces of parts, TORQUE VALUE Cylinder head nut Intake pipe bolt SPECIFICATIONS Tem Cylinder head warpage Cylinder bore MBXEO | BX80 | stom 0.0. (10 mm (9/8 in ‘from piston skart) Mexeo crtnetpiton | rate pron one, Phonon in car Pioneers ee) [_ Somat nae ns TROUBLESHOOTING Compression too low, hard starting or poor performance at low speed 1. Blown cylinder head gasket 2. Loose spark plug 3. Worn, stuck or broken piston rings 4. Worn or dmaged eylinder and piston 5. Faulty reed valve Compression to0 high, overheating or knocking 1, Excessive carbon buildup in eylinder head or on piston top 18-22 N.m (1.82.2 kg-m, 19-16 ft-lb) 8-12 Num (0.8-1.2 kg-m, 6-9 ft-lb) STANDARD mm (in) [ SERVICE LIMIT mm fin) 0.10 (0.004) 38.998—30.013 mm (1,5354—1,5969 in) 49.407—49.523 mm (1,9452-1,9497 in) 38.955—38.970 mm (1.5337—1.5943 in) 39.062 mm (1.5379 in) 49.572 mm (1.9516 in} 38.920 mm (1.5323 in) 45,455 —49.470 mm (1,9870-1.9478 49.420 mm (1.9457 in) 0.035~0.060 mm (0.0014~0.0020 in 0.080 mm (0.0036 in) | 12002-12.008 "(0.4725-0.4728) 12030 (0.4736) t1.99812.000 (0.4722-0.4728) | 11.980 (0.717) | 002-0014 (0001-00008) | 680” focote) (0.004.010) 035 (0.014) 17090 (0.6705) _| ise-piston 1. Worn eylinder and piston 2. Worn piston pin or piston pin hole 3, Worn connecting rod small end bearing Abnormal noise—piston rings 1, Worn, stuck or broken piston rings 2, Worn or damaged cylinder 6-2CYLINDER HEAD/CYLINDER/PISTON CYLINDER HEAD REMOVAL ‘On the Delux model, remove the under cow! (Page 6:3). Remove the seat, both side covers and fuel. tank. Remove the radiator cap, ma ‘Engine must be cool before removing the reap, or severe scalding may result. | Remove the coolant drain bolt and drain the coolant, Disconnect the radiator hose from the cylinder heed, Remove the spark plug ca Disconnect the temperature :or wire connector. Remove the four flange nuts attaching the oylinder head to the cylinder. (1) RADIATOR CAP Se HONDA. MBXS0- MBX8O 6-3@) HONDA =2/ MBX5O- MBX80 CYLINDER HEAD/CYLINDER/PISTON INSPECTION Check the cylinder head for warpage with a straight ledge and freeler gauge in the directions shown, SERVICE LIMIT: 0,10 mm (0.004 in) DECARBONIZING Remove the carbon deposits from the combustion chamber, Clean the head gasket surface of any gasket mate- vial ceskotsurens———*d INSTALLATION Install the cylinder head using a new cylinder head gasket. Install the four flange nuts and tighten to the specified torque in the sequence shown, TORQUE: 18-22 N.m (1.8-2.2 ka-m, 13-16 feb) Fill the cooling system with the recommended coolant (Page 10-3). 6-4HONDA MBXSO: MBX80 CYLINDER HEAD/CYLINDER/PISTON CYLINDER/PISTON CYLINDER REMOVAL, Remove the exhaust pipe (Page 6 - 3 ). Remove the cylinder head (Page 6-3}, Remove the carburetor (Page 4-3). Remove the four flange bolts attaching the intake pipe to the cylinder and remove the Intake pipe, NOTE Do not remove the oll pass tube or locate the | fend of the tube lower than the oil pump, Bleed air from the oil pass tube when’ it has bbeen disconnected or the end has been located ower than the oll pump. Remove the radiator (Page 10-4). Disconnect the radiator hose from the eylinder. Remove the cylinder. ‘CAUTION not pry strike the cylinder or cooling fi Place a clean shop towel into the crankease to keep debris from falling in, (1) RADIATOR HOSE 6-5HONDA (1) PISTON, PISTON REMOVAL Remove the piston pin clip using a pair of long-nose pliers. Press the piston pin free of the piston. PISTON RING/EXPANDER REMOVAL Spreed each piston ring and remove by lifting it up (2) SECOND RING at point just opposite the gap, Remove the expander CYLINDER/PISTON INSPECTION ‘Check the eylinder and piston for wear ar damage, Clean carbon deposits from the exhaust port area, (3) TOP RING MBX50- MBX80 CYLINDER HEAD/CYLINDER/PISTON@ ) HONDA CYLINDER HEAD/CYLINDER/PISTON \Se/ MBX5O- MBX80 Inspect the cylinder bores for wear at three levels, in X and Y directions. Take the minimum figure ‘measured to determine the cylinder wear. Avoid the Port area, SERVICE LIMIT: MBXBO 39.062 mm (1.5379 in) MBX60 49.572 mm (1.9516 in) Measure the 0.0. of the piston at @ point 10 mm | (8/8 in) from the end of the skirt SERVICE LIMIT: MBX50 38.920 mm (1.5323 in) MBX80 . 49.420 mm (1.9457 in) Calculated the piston-to-cylinder clearance, SERVICE LIMIT: 0,090 mm (0.0035 in) Measure the I.D, of the piston pin bore, SERVICE LIMIT: 12,030 mm (0.4736 in) Measure the 0.D. of the piston pin, SERVICE LIMIT: 11,980 mm (0.4717 in) Calculate the piston pin-to-piston clearance. SERVICE LIMIT: 0.040 mm (0.0016 in)HONDA MBXSO: MBX80 PISTON RING INSPECTION Set each piston ring squarely into the cylinder from the bottom using the piston and measure the fend gap. SERVICE LIMITS: TOP: 0.35 mm (0.014 in) SECOND: 0.35 mm (0.014 in} Install the expander in the second groove of the piston, Install the top and second rings (Page 69), Press each piston points to make sure that itis flush with the piston surface, If not, clean carbon deposits from the ring groove. They should be free engough to be ‘rotated in the ring lands, CONNECTING ROD INSPECTION Install the bearing and piston pin in the connecting rod small end and check for excessive play. ‘Measure the connecting rod small end 1.0. SERVICE LIMIT: 17.030 mm (0.6708 in) CYLINDER HEAD/CYLINDER/PISTON (1) Piston (4) EXPANDER (1) PISTON RING 12) TOP RING (31 SECOND Ring (1) PLAY (2) 10. 6-8CYLINDER HEAD/CYLINDER/PISTON PISTON/CYLINDER INSTALLATION Install the expander and piston rings, NOTE | ‘© Install the rings with the markir up. © Tho top and second rings are interchange. able with each other. * Do not mix different brands of rings in an ne. Do not replace one without replac: ing {Install the connecting rod small end beering, piston {and piston pin, NOTE Install the piston with the “IN” marking facing the inlet side, Dip the small end bearing and piston pin in | Clean oil before installation, Install raw piston pin ali Note [not iat the lp flito the wankanm—] ‘Align each ring end gap with the dowel pin in the Fing land. Cie HONDA ee / MBX50- MBX80 (1) TOP RING (2) SECOND RING (4) PISTON RING MARKHONDA. @) MBXS0- MBX80 Pace the cylinder gasket on the crankcase, Lubricate the piston with engine oil and install the eylinder over the piston while compressing the piston rings. damage the piston. Install the eylinder head and new cylinder head gasket (Page 6-4), Install thereed valve and intake pipe, Install the exhaust muffler. Install thecarburetor (Page 4-9). Install the radiator (Page 10-5). Fill the cooling system with the recommended coolant (Page 10-3), Perform the following inspections and operation: Gylinder compression (Page 3-7); compression leaks, Engine noise. Secondary air leaks. Air bleeding from cil pass tube (Page 2-7) REED VALVE REMOVAL Remove the craburetor (Page 4-9). Remove the intake pipe (Page 6-5). Do not remove the oil pass tube or locate the fend of the tube lower than the oil pump. Bleed air from the oil pass tube when it has been disconnected or the end has been located lower than the oil pump. CYLINDER HEAD/CYLINDER/PISTON© HONDA CYLINDER HEAD/CYLINDER/PISTON MBXS50- MBX80 (1) REED VALVE Remove the reed valve (1) REED STOPPERS (2) REEDS INSPECTION Check the reeds for damago of fatigue and replace it necessary. Replace the valve with a now one if the seat rubber is cracked or damaged, or if there is clearance between the reed and seat, CAUTION Do not disassemble or bend the reed stopper 48 this may cause improper engine perfor ‘mance, The reed valve must not be disas sembled. If the stopper, reed vr seat is defec: tive, replace all asa uni. daa INSTALLATION Installation of the reed valve is essentially the reverse order of removal. CAUTION Bleed air from the oil pass tube (Page 2-7) i] After installation, check for secondary air leaks. 6-11a CLUTCH /KICKSTARTER / (© arso-maxao GEARSHIFT LINKAGE I. (3) Align the balancer timing when installing (0.02 in) | (1) Thicknoss: 1.0 mm (0.04 in ) (4) WATER PUMP SHAFT (5) Apply locking agent. 45-55 Num (4.5-5.5 kgm, 33~40 feb} (5) Apply locking 7-0CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE [SERVICE INFORMATION TROUBLESHOOTING RIGHT CRANKCASE COVER CLUTCH/IDLER GEAR 72 72 73 @) ©) CLUTCH INSTALLATION/ BALANCER TIMING KICKSTARTER SHIFT LINKAGE HONDA MBX50- MBX80 7-10 m1 m4 |@ HONDA =>/ MBX50- MBX80 CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE SERVICE INFORMATION GENERAL INSTRUCTIONS All clutch and kickstartor maintenance and inspections can be accomplished with the engine installed, Make balancer timing adjustment wien the clutch outer and primary drive gear are removed, Use the UNIVERSAL HOLDER to remove and install the primary drive gear. Remove all gasket materials from the mating faces of the cas Do not allow dust and dirt to enter into the eylinder and crankease, ‘Avoid damaging or scratching the case mating surfaces, Before inspecting, clean all removed parts in solvent; dip the parts in clean transmission oll before installation, TOOL Common Universal Holder 07725~0030000 TORQUE VALUE Primary drive gear 48-85 N.m (4.5~5.5 kgm, 33-40 feb) SPECIFICATIONS [ ITEM I STANDARD mm (i [SERVICE LIMIT mm (ny Clute Spring Tree length preload 302/19-21 kg (1.19/41.9-4.3 6) | 286/17 kg (1.12/87.8 Ib) Clutch dise thickness 28-30 (o1114~0.118) 25 (0.088) Clutch outer 1.0. 17,000-17.018 (0,6693-0,6700) 17.080 (0.6717) Kickstarter spindle 0.D. 11.966-11.984 (0.4711-0.4718) 11.950 (0.4704) Kiker pron | tote-izess fowrsr-osne) | Tame (047m Kiekstartor idle gear Contershaft 0 16.000-15.018 (0,5906-0.5913) 14.940 (0.5882) Gear 1. 16.032-15.050 (0.5918-0,5925) 18.100 (0.5945), Balancer idle gear shaft O.D. TROUBLESHOOTING .3926-0.3932) 9.930 (0.3909) Clutch slips when accelerating Motorcycle creeps with clutch disengaged 1. No free play 1, Too much free play 2. Discs worn 2. Plates warped 3. Springs weak Excessive lever pressure Clutch operation feols rough 1. Clutch cable kinked, damaged or dirty 1. Outér drum slots rough 2. Lifter mechanism damaged 3, Clutch cable not routed properly Abnormal engine vibration 1. Balancer out of time 7-2CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE (2) HONDA ‘© MBxso. mBx80 RIGHT CRANKCASE COVER (1) CLUTCH CABLE REMOVAL On the Deluxe model, remove the under cow! (Page 14-3) Drain the coolant (Page 10:3) Drain oil from the transmission. Remove the kickstarter pedal. Disconnect the clutch cable from the clutch arm, Disconnect the tachometer cable, Disconnect the repiator hoses at the right crankease (2) TACHOMETER CABLE (3) KICKSTARTER PEDAL (4) HOSES Remove the ‘bolts attaching the right crankease ‘cover, and remove the right crankcase cover. (1) RIGHT CRANKCASE COVER, DISASSEMBLY Remove the clutch lifter rod, then remove the clutch arm, Check the O-ring for damage, fatigue or other faults. Check the clutch arm for bending. (3) CLUTCH LIFTER ROD 7-3 (1) CLUTCH ARM (2) O-RINGC4 HONDA MBXSO- MBX80 Remove the tachometer gear. NOTE Do not forget to install the wash INSTALLATION Install the clutch arm and clutch lifter rod, Install the tachometer gear on the right crankcase Install the dowel pins and gasket on the cxankease CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE ——— (3) TACHOMETER, GEAR @-=— 1 on seat ®& (2) WASHERS f-—a TACHOMETER GEAR (2) DOWEL PINS. 7-4CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE Install the right crankcase cover on the trankease, Install the clutch cable bracket and tighten with the flange bolt NOTE [Tighten the bolts in a crisscross pattern and in ‘two or thrae steps, Install the kickstarter pedal (1) KICKSTARTER PEDAL (2) RIGHT CRANKCASE COVER, (1) CLUTCH CABLE Connect the tachometer and clutch cables. Connect the radiator hoses to the water pump. Fill the transmission with recommended oil (Page 23), Fill the cooling system with recommended edolant (Page 10:3) Adjust the clutch lever free play (Page 3-7). CLUTCH/IDLER GEAR (1) CLUTCH SPRINGS CLUTCH REMOVAL Remove the right crankcase cover (Page 7-3}. Remove the clutch lifter plate and clutch springs by removing the bolts, (2) LIFTER PLATE 7-5HONDA ‘> / MBX50: MBX80 Remove the circtip. Remove the clutch center, clutch discs, clutch plates, and clutch pressure plate. Remove the spline washer and remove the clutch outer, CLUTCH SPRING INSPECTION Measure each clutch spring free length, SERVICE LIMIT: 28.5 mm (1.12 in} CLUTCH DISC INSPECTION Replace the clutch discs if they show signs of scor ing or discoloration, Measure each clutch dise thickness. SERVICE LIMIT: 2.50 mm (0.098 in) CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE (2) PRESSURE (3) CLUTCH PLATE OUTER (i) CLUTCH DISGS (MB X80: 4 dises) (4) cIRCLIP (6) cuteH (7) SPLINE (6) clutcu pares CENTER (MBXE0: 3 plates) WASHER |