HONDA L500 INTERSTATE GL6SO INTERSTATE HOW TO USE THIS MANUAL low the Maintenance Schedule recommen: to ensure that the vehicle in peak operat ‘g condition and the emission levels are with fandards set by the U.S. Environmental tion Agency. Performing the first sched. ed maintenance is very important. it compen 5 for the initial weer that occurs during he break-in period view procedures are based on the standard text or a7 ss0ries'' covers torque speci airreinstatlation of accessories Section 20, Inter ications and .ctions 1 through 3 apply sections 4 ne motorcycle to the whole mot 19 desc grouped according to location, Fini ine section you want on this page, then © the table of contents on page 1 of that Most sections start with an assembly or system illustration, service information and trouble hooting for the section. The subsequent pa: detailed procedures. f you are not familiar with this motorcycte, read the TECHNICAL FEATURES in section 27 you don’t know the source of the trouble. 22 99 ‘0 section 22, TROUBLESHOOTING. ion 23 for 1982 service infor sction 24 for 983 GL INTERSTATE we saman tigen oa oa ace] | ot ema esse | [Psciueitecentcacsiatencapares | time of approval for printing, Honda Motor Co, | | sere at tae eg | | ine "nikon ‘etal md atte nae | | obtigetion whetever, No part of this put | | ri ean" | HONDA MOTOR CO., LTD. Service Publications Office pe = = 9 = = 8 g = a 2 2 @ & L OI | 112 2 - @ (REAR WHEEL /GRAKE/FINAL DRIVE = |__SUSPENSION BE sone HYDRAULIC DISC BRAKE iG nn 16 | "83 ADDENDUM CONTENTS ENGINE REMOVAL/INSTALLATION 2 g g 3 5 R 3 iz a > i = 5 2 a | “a2 Gtsoo;WTERSTATE ADDENDUM Date of tssua: Ocr., 1982 HONDA MOTOR CO., LTOMODEL IDENTIFICATION\ HONDA ) GLS00 GL500 INTERSTAVE GENERAL SAFETY 1 SERVICE RULES i SPECIFICATIONS 1 TORQUE VALUES 1 SPECIAL TOOLS/COMMON TOOLS 1 GENERAL SAFETY oom If the engine mast be running to do some work, moke Sure the area is wellwenulated, Never tun the engine ln © closed area, The exhaust contains poisonoss ram monavie gas oI ‘asoline is extremely flammable and is explosive tueder ceriain conditions, Do not smoke wr allow ns or sparks in your working area SERVICE RULES al oy HONDA-recommendas may damage the motor sia} tools designed for this, ic tools when servicing this motoreycte gaskets, 0-1 or sequence is specified leaning so check als ports fo proper installation nt upan disassembly. L CABLE & HARNESS ROUTING 1 1. GENERAL INFORMATION 1 EMISSION CONTROL SYSTEM 19 2 EMISSION CONTROL INFORMATION LABEL 1-9 4 CII The battery electrolyte contains sulfurie acid. Proveet vour eves, skin and clothing. In case of comtues, flash thoroughly wih water and call @ doctor it your eves were exposed. oom The battery generates hydrogen gas which can be ughty explosive. Da not smoke or allow flames or sparks near the bacterv, especially while charging it snd lubricants er their equivalent, Parts that do nat meet HONDA Metric bolts, nuts, and serews are r ed fasteners may damage the motorcycle 9 cotter pins, lack plates, ete. v begin with larger-iacreter or 210 any aiding surfaces be interchangeatte with Enalish bolts ani tighten to the specified torque diagonally of Ise: October, 1984 HONDA MOTOR CO.,LTD iliesGENERAL INFORMATION ) GiSoo \HONDA / GL500 INTERSTATE SPECIFICATIONS new Overait length vera ath sonal aight vy awcight nb wwwight (Wer) Faane Te F suspension, eravel suspension, savel F suspension air pressure A serbension air prossure Fre Up to 90 kg, £200 ts) lowe Up 10 vehie! F byake ae lining saat area Ro brakes an fining swept area Fut canacity Fuel reserve capacity Caster angle Trai tenath Front fork ail capacity Reon siunck bil capacity NGINE Type, evluader arrangement Gylinder compress: Latiseation system Air titration system Ceoling Faia cap relist pressure 2.207 mom (86.9 ini 2,308 mm 490 7 int 875 mm (34.4 io) B75 mm (34.4 in} 1178 mm (46.4 im} 1,505 mr (58.2 inh 1.405 mr (58.8 in} = = 288 mm (31.0 in} 778 me (30.5 in} 302 mem (12.7 int 218 nm 112.4 in 132 mm { 5.2 int 127 mm ( 5.0 in} 207 kg (456 Ibs} 230 kg (507 Host kg (404 ts} 207 kg (64? ibs} Diamond Telescopic, 450 mm (5.9 in) Swing arm, 120 mm (4.7 in} 190 KPa (08-12 kg/cm? 11-17 psi 400-600 ka - 800 KPa Hl 79 pst 1-88 kgiem?, Triboless 130/90-16 67S Tubeless Front 200 KPa {2.0 kaiom®, 28 psid Rea 200 KPa (2.0 ka’em®. 28 psi From 200 KPs (2.0 kgiem’, 28 pis) 250 HONDA MOTOR CO.,LTD.GLS00 / GLS5OO INTERSTATE rey ENGINE Camshaft (at # may Ft) Ttake valve Exhaust valve | Vaive clearance (coi Iie speed IN | Carburetor type Identification number | Pitor screw | Float level | cluten | Transmission I Primary reduction ratio Gear ratio 1st Gear ratio and | Gear ratio 3ra | Gear ratio 4th | Sear ratio Sth | Final reduction ratio | Gear shitt pattern | caraur RIVE TRAIN, Final gear oil capacity | tgnition | ignition timing “E" marie Full sdverce | Starting system Altornator [ Satry capcity ELECTRICAL, | Spark plug | Standard |_ For extendad high speed riding For optional radio Standart For extended high speed ring Spark plug gap Fuse | Headlight (High/Low | Tawstoptight | Turn signal tight | Moter tight Noutral incicator ‘Tare signal indicator | High bear indicator i | Oil pressure warning bab Opens Closes Opens Closes iN ex (Front) Bear) GENERAL INFORMATION e800 susgoinrensrare | 6° 8TOC (at mm tit, 79” BTDE (at Oi) 45° ABDC (at 1 mm ftt), 123° ABDC Jat O litt) 46° BBDC fat { mm lift, 114” BBD iat O litt) 6° ATOC [at t mm lifth, BS” ATC {at O lft) 0.08 men (0.093 in} 0.10 mm {0.004 in} 5,100 + 100 1pm VB type, 34 mm {1.3 in) venturi bore Ve29A Rotec to page 4:12 15.5 mm (0.81 in} J | Wet, multi-plate S-speed constant-mesh 2.242 (74/33) 2.793 (4115) 1,850 (37/20) 1.416 (34/24) 3.14a (31/274 9.935 (27/29) 3.091 (34/11) eft foot operated return system 1.N23-85 360-180 ce (6.4--8.1 02) Transistorizes 15" BTDC at idle 5° BTDG/3,000 rpm Starting motor AC generator, 12V-252W/5,000 rpm 12V ~ 14a 4g DBEA (NGK} or X24 ES-U {ND} DBA (NGK} or X27 ES.U IND! DABES.L (NGK} or X24ESR-U IND} DABES (NGK! or X27ESR-U IND) 06.-0.7 mm (0.024~-0.028 in} 1A, 30A {Main fuse) | 5A, 10A, 30A (Main fuse) a . : 12V-60/55W H4 bulb (Phillips 123424 12V-~3/32 ep No. 1187 ‘or equivalent) 12V-32 cp No. 1034 | 32V-32 cp No. 1073 12V2ep No. 87 12V-2cp No.8? | i2V-20p No 87 12V-2ep No, 87 12V-2ep No. 87 Date of tsue: July, 1981 2 HONDA MOTOR €O,, LTD.Bg HONDA GENERAL INFORMATION Gt300 evrenstare TORQUE VALUES ENGINE OY | Than ai tr teas ‘Srankahelt 7 a w0-34° P30 aa ing ad cap ut boa 8 22 pea had bot 3 a 50-80 50-60 majenter Tok suk a 6 iia | tS 3 wise ot : 2 9105 | go tas crt 20% ou 1 2 80-10 | BO 190 fy dv pest 1 © Boss | ao95 ng utero ate a é 1835 13-28 ; & mo | 2028 ut t % @-100 | Bo-100 2 ? ace 18-20 1 2 16-20 | 015-430 Ty T eo-s0 | i 238 erat 3 iba8 aoes a a i 13-98 eee ‘ So-i20 fg iach poe 2 138 enor 2 H 1-45 arneser at 3 2538 ; & j seo Bae 3 ie a8 088 2 10 45-55 | 48-85 ? é aes ‘ne Rappers bt ; 1838 seo al 2 j 13a ‘oct yg wo 3 | 085 | ese tore ont ! $843 a at och 1 : Soto Seg na ae i 3 i ieee ' cnt i 3 : 3038 : 3 j 4538 / er moun bal 3 2 as | ner past bet i 2 333 we caliper bo i : oes noe a : . aeia | en i 5 ie2e | Bre et ne ok ; é seas | cana pot ba : é 18038 ara Brno : 8 ret 1 ‘8 2038 : 2 ° aoa foie as i 3 ae-08 fom Sun bok 3 | 3 se can i bt ESS aru specitivations fisted above are for the most important tightening points. If a torque specification is not listed, follow he standards yiven alow TANDARD TORQUE VALUES ype i Torque Nm Sko-e. ft 4b) Type Sarton ame | 48-6 01045-06,33-45) | Simm iaew 1 35°$00038-05,25-30° | | Smmbcicne | gia Woartaeay Sr sew (Oloriea | Brombon nt 18-25 1825 13-18) Somtangebot mt | woot Nock) MERE! | GIB SGARS a GaN | Ae ae aha | [2mm por mr | 80-60 (60-60, 36-43} 18mm Marge boltjwwt | 80-80 (30-40, 22-29) | Bue of tue uy 108) 1-4 6 HONDA MOTOR CO.,LTDGisoo /GL500 INTERSTATE GENERAL INFORMATION SPECIAL TOOLS /COMMON TOOLS SPECIAL Asoishe (toy ate nt th 6500 al SCO Gescaierion sumer [| atrenware roo. | mumoca | ner pact Pinson guar rotamer wrench O7IO-MAIDIO || Pinion ger vetamar wench | 079104150000 14-89 Pinion gut ptr attachment o7934-4a0100 i 15-38 | rom 8 ule enter 7ena-tasozo0 | 14-34 | meter 7e65-84010500 Mazin | +t a sive atachrenn 07965-ma10200 waza | Oi al ue | ora7a-mataion | ee | +0 ving guide o7or3-mai200 “2 Sorat it #7 | 07703: on20800 Daan | | eesoeeerae Orman ocs0000 Even tolecoreercty | wos7a. om |g ut gauge attaches (07810-3000700) J) yee tn gue at “oe 3-8 | Tour te Bt 97903-00101 ci 6 } Seton vie 97765-ao10000 —F Euwsclet won commeresy rete i Senet woanch 17x77 em 2790 7-4180000 | 103 Privat eek wren 37908-4080001 || swing tocanut wrench JKS-“ANA-OB-a69} 14-17, 14-25 | Ping go! eine re avgro- 3720100 1428 Cet are 97614.-3250001 }4_| Eaten tools commercthy | 1141-6 | Aten vrench 6 sm | oroy sza0900 [17 sainbie wn U8 i 113 | Cutah cmt holder | o7923-4180000 || 23,7 Gea holaer co7e2s-a1so000 || a4. 19-3,12-6| rank cap pul co7e35-4190000 | Us hydauie en a7 sent eenover 20 xm o7a36-s750000 i reins Searing remnever attachvnent 20 mm | o7a36-a710600 | | Heat | Eeaing move ane 4 g19a6-a7t0100 || : ons een emover weight o7m36- 2740200 | \ meri | este bering emo 7036-2890300 | 1g | Pht moa | orastaiso000 | i wa ‘Vole guile driver ateachment | 07963-¢1s0000 | | s9 | froin ner aachinent | ovaes-asam200 | i 8-9, 13-75 Crank exp aver eet, 79452150109 | ! ya 19-18 fing ger cater ie | oraas—ats0100 | i215 chon sol dive ataehewet | 979454180400 |_| aver | ev0a8--s710200 Sent deer ataciment | 7045150200 | $20,421,142 208 ine attachment | 3200000 |r| sat race emswerineller ——-—g7846-740400 | 13-28 oun te dre | oroas-arioses || | 124 i Fork so! ier atachman | orsa7—teaznzen | | | nar \ Bat esee verve | o7a5a-1490000 |) | aux remover | o7e93-4280009 | 13-24 | ins gea) Gisiessembly toa! se | 97988. 4130007 14.29 | fing geo oiesembly nota | ovmes—arsnan | 429 | fing ew Sianeweiy soo | 47965-2710200 f 28 Mom dearng axcrsemby svol | 07973-a140000 || i Visayas | Valin guide seamen | 07034-6110000 |_| vata guide eames | omee-soror00 | 6-26-10 | | nS orpiont mipecion eel | oma-ataeaen || | [Nate teas | Garturetor syncanizng wren — | 07908~a600200 |_| ! a9 | a news ur J 8979-081 ae i | AK ' ! mun specton plug o7a99-4150000 || Lins ———— of Issue: October, 1981 9) HONDA MOTOR CO.. LTD. = aHONDA Gisoo GL500 INTERSTATE GENERAL INFORMATION COMMON aesemorion [Tnomecn” [7] 7 aCreaware toot wowace | 1 Foie soon F oxo1-coroai0 | mabe | cre corm || tcc peter | | / Valve ase wench 10 | ovmo8-2n20200 |-7-| Vane seater seeneh | erect | ' Valve aufiusting wrench 07708-0020800 1 | } fewingreraineroronen | o2rro-c010200 | etsy wrnch | orare-szoot01 | Senin retains wemchty | o7o-aovoaot | | i [rear toc mitwencraessonm | arneccorame || ' ee Sree ster scter 39% 521mm O7T8- 0020800. $4. | Eaves ons commercsy | taza enum | srrs-oozomo (4 ‘mniaoen os | rs \ Rotor puller | 97733-00100 | Retor putter | 079320010000 | 9-8 Fyne alley 97733-0020001 || Fivaea per | 070332050000 | 3s Yates ide emowar 8 wm 97742-0010200 | Vato ui ivr | o792-6410000 | 6-9 | on | 079426570100 | o7a4-6340100 | 1418 9748-0010300 || Pie ariver 35 mm 07746070100 ay} Artachimont / i i |store seaeneo | S136 | 1 atochmen 07905-92010 i ‘tach 79 40 mn o7rse-aovoroo || tachment 079464250100 | 14~20.14-21 | Asachment 42°47 ma (97746--0010300 || sasachment | 07098-3330100 11-10, 33-10 | : eal | 148 | fovachivent $2 » 88 am 07746-01040 || attschmant | 07046-71020 | 1110 | chr 6288 re orme-ovtosme || Atecina [orece_sonoo |e Sito $5 mm wrr45-0080300 || | | 13-10, “ot 20 na o7745-0040800 | ! | arto Pos 22 me | 07245-0081000 | | lane | Plot 75 am 07 746-0040600 | | rt0 | Pilot 9 | orras-oosare0 | i 130 \ oe |forree®acresont | ras | Fork oi sob river | e7ra7coroion || | a | |e ein creer [27er-oorotan | | vevesingompronar | orasr-szitoos | 6-76-19 | a E Date of sue: Jay, 1881 1-6 8 © HONDA MOTOR CO,, LTD.GENERAL INFORMATION GL500 CLUTCH caBLE ae REAR SHOCK. RADIATOR ABSORBER AIR SIPHON TUBE THROTTLE HOSE CABLES TACHOMETER CABLE CRANKCASE BREATHER DRAIN TUBE BREATHER TUBE ‘CARBURETOR DRAIN TUBES AND FUEL VALVE AIR VENT TUBE TURN SIGNAL WIRES STARTER MOTOR CABLE raiuicut \_/ wire uly, 1981 a }OTOR CO, LTD. 9 detHONDA GL500 GL500 INTERSTATE GENERAL INFORMATION GL500 INTERSTATE WIRING BRACKET ~ SPEEDOMETER CABLE FRONT BRAKE HOSE TACHOMETER CABLE CABLES CLUTCH CABLE INSTRUMENT WIRES REGULATOR WIRE accet \ | LEFT HANDLEBAR IGNITION SWITCH WIRE FUSE CASES SWITCH WIRE IGHT HANDLEBAR ‘SWITCH WIRE FAIRING HEADLIGHT WIRE WIRE HAR HARNESS re GROUND TERMINAL, FAIRING MAIN WIRE WIRE HARNESS HARNESS 1-8 (Date of Issue: July, 1981 10 © HONDA MOTOR CO., LTD.HONDA GL500 INTE(jp) HONDA Qh) sis LUBRICATION SiS00 wrensrare LUBRICATION DIAGRAM OL PRESSURE ROCKER ARMS SwiTCH A OW FILTER CAMSHAFT / \ TRANSMISSON Main | Snarr | \ ou oRiFice / PRESSURE RELIEF VaLvE 2? OL STRAINER f iy CRANKSHAFT ‘TRANSMISSION COUNTERSHAFT 2-0 Date of Issue: uly, 1987 e © HONDA MOTOR CO., LTD.w Bese 2. LUBRICATION SERVICE INFORMATION TROUBLESHOOTING ENGINE OIL LEVEL CHECK ENGINE OIL & OIL FILTER CHANGE FINAL GEAR Oft CHECK/REPLACEMENT DRIVE SHAFT JOINT CONTROL CABLE LUBRICATION LUBRICATION POINTS SERVICE INFORMATION GENERAL INSTRUCTIONS Refer to Section 7 Oil capacity 25 lit (2.6 US gt, 2:2 Imp adh at change | 3.0 lit (3.2 US qe, 2.8 Imp qt) at cisessers Bil recommendation OL VISCOSITIES Use HONDA 4:STROKE OIL or equivalent TION: SE Other viscosities shown in the chart may be ‘sed wen the average temperature in vour e aa __Sding area is within the incestedt range 3 9.3 ~ 9.5 tiimin at 3,000 rpm = : wpaciy ~~ 80 cc 154-50 Recommended ai Hiypoid gear oli Above S°Ci41F at - Below BCE TROUBLESHOOTING it Lovet Too Low 1 Nore! oil consumption P valve stuck closed s piston rings {being used c roination No Oit Pressure io filter nox changed often enough 1. Oit level toa low Tefective Nead gasket 2. Oi pump drive chain broken pump tuck ope Date of tssue> duty, 1981 © HONDA MOTOR CO.,LTD. 2-1HONDA Gis00 5 GL300 INTERSTATE LUBRICATION ENGINE O1L LEVEL CHECK OL, FILTER CAPO! ENGINE OIL & OIL FILTER CHANGE ML FHLTER 6OLT O-RING FILTER COVER 1818 1H NLPILTER BOLT SPRING —-WASHEF 2-2 1GL500 5 y RQNDA CONTROL CABLE LUBRICATIONUBRICATION © GLSOO INTERSTATE LUBRICATION POINTS ——— elf THROTTLE GR TT seeepomereR ano TACHOMETER CABLES am ENGINE BRAKE PEDAL PIVOT BRICANT]GLSOO INTERSTATE SERVICE INFORMATION MAINTENANCE SCHEDULE ENGINE > FUEL LINES THROTTLE OPERATION CARBURETOR CHOKE AIR CLEANER SRANKCASE @REATHER SPARK PLUGS VALVE CLEARANCE CAM CHAIN TENSION SARBURETOR-SYNCHRONIZATION CARBURETOR JOLE SPEED RADIATOR COOLANT RADIATOR CORE SERVICE INFORMATION SENERAL INSTRUCTIONS See page 22 gine on fitter Bee page 2-2 gee ol See page 23 ‘ut Ser page 23 vacanien gauge 7404 10.12 mm 6 adjuster B CIFICATIONS wed spark plage SL500, GLBQOL Pes 9.08 int 18° BTDG at 9.98 mm 10.002 in) es 0.10 mm 10.004 sn}, 2-6 mm (0.08 4,100 + 100 rpm pressive diMerence extended BYDE at 1,100 -p wwowemuwe SeUNanoee 3-10 310 3-10 07708. 0930200 a7?98-op30400 para xQ7esu 0.24 it betwean caeburetore 40 mm (4.6 in} Hg compressor 1,200 + 200 kPa (12 5 2 &glcm latch free play 18 20 mm (9/8 3/4 in 3. MAINTENANCE COOLING SYSTEM HOSES CHASSIS > BATTERY. BRAKE FLUID BRAKE SHOE/PAD WEAR BRAKE SYSTEM BRAKELIGHT SWITCH HEADLIGHT AIM CLUTCH SIDE STAND SUSPENSION NUTS, BOLTS, FASTENERS WHEELS. STEERING HEAD BEARINGS 10020000 oF M937B--021 -XXXXX (USA only} 7908-60020 07908 -3640000 For optional racte Stands riging DREESL X24ESR-U 714 28 psit xQ7ESRU at | 3-11 a1 | 3-12 3-13 3-14 3-14 3-16 3-16 3-17 [For extended high speed ages issu: October, 1981 HONDA MOTOR CO.,LTD