Manual de Taller HONDA CBR500R MNAUL TALLER 2013

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HOW TO USE THIS MANUAL

A Few Words About Safety

Service Information

The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting

service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also damage the

vehicle or create an unsafe condition.

This manual describes the proper methods and procedures for performing service, maintenance and repairs. Some procedures

require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service

procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of

the vehicle.

If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend

that you do not use replacement parts of inferior quality.

For Your Customer’s Safety

Proper service and maintenance are essential to the customer’s safety and the reliability of the vehicle. Any error or oversight while

servicing a vehicle can result in faulty operation, damage to the vehicle, or injury to others.

For Your Safety

Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety

practices (e.g., Hot parts–wear gloves). If you have not received shop safety training or do not feel confident about your knowledge

of safe servicing practice, we recommended that you do not attempt to perform the procedures described in this manual.

Some of the most important general service safety precautions are given below. However, we cannot warn you of every

conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should

perform a given task.

Important Safety Precautions

Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and

using safety equipment. When performing any service task, be especially careful of the following:

• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills

required to perform the tasks safely and completely.

• Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around

pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection.

• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe

burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.

• Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack,

make sure that it is always securely supported. Use jack stands.

Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will

help eliminate several potential hazards:

• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine.

• Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas.

• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.

Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when

working around gasoline or batteries.

• Use only a nonflammable solvent, not gasoline, to clean parts.

• Never drain or store gasoline in an open container.

• Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts.

Improper service or repairs can create an unsafe

condition that can cause your customer or others to

be seriously hurt or killed.

Follow the procedures and precautions in this

manual and other service materials carefully.

Failure to properly follow instructions and

precautions can cause you to be seriously hurt or

killed.

Follow the procedures and precautions in this

manual carefully.

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HOW TO USE THIS MANUAL

How To Use This Manual

This manual describes the service procedures for the CBR500R/RA, CB500F/FA and CB500X/XA.

Sections 1 and 3 apply to the whole motorcycle. Section 2 illustrates procedures for removal/installation of components that may be

required to perform service described in the following sections.

Section 4 through 22 describe parts of the motorcycle, grouped according to location.

If you are not familiar with this motorcycle, read Technical Feature in Section 1.

Follow the Maintenance Schedule recommendations to ensure that the motorcycle is in peak operating condition.

Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in

period.

Find the section you want on this page, then turn to the table of contents on the first page of the section.

Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The subsequent

pages give detailed procedure.

Refer to the troubleshooting in each section according to the malfunction or symptom. In case of an engine trouble, refer to PGM-FI

section troubleshooting first.

As you read this manual, you will find information that is preceded by a symbol. The purpose of this message is to help

prevent damage to your vehicle, other property, or the environment.

SERVICE PUBLICATION OFFICE

Date of Issue: January, 2013

Your safety, and the safety of others, is very important. To help you make informed decisions we have provided safety

messages and other information throughout this manual. Of course, it is not practical or possible to warn you about all the

hazards associated with servicing this vehicle.

You must use your own good judgement.

You will find important safety information in a variety of forms including:

• Safety Labels – on the vehicle

• Safety Messages – preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION.

These signal words mean:

You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.

You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.

You CAN be HURT if you don’t follow instructions.

• Instructions – how to service this vehicle correctly and safely.

ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS 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 WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT

WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF

MAINTENANCE ON Honda MOTORCYCLES, MOTOR SCOOTERS OR ATVS.

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HOW TO USE THIS MANUAL

SYMBOLS

The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to

these symbols, it would be explained specifically in the text without the use of the symbols.

Replace the part(s) with new one(s) before assembly.

Use the recommend engine oil, unless otherwise specified.

Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1).

Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent).

Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or

equivalent).

Example:

• Molykote® BR-2 plus manufactured by Dow Corning U.S.A.

• Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan

Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or

equivalent).

Example:

• Molykote® G-n Paste manufactured by Dow Corning U.S.A.

• Honda Moly 60 (U.S.A. only)

• Rocol ASP manufactured by Rocol Limited, U.K.

• Rocol Paste manufactured by Sumico Lubricant, Japan

Use silicone grease.

Apply locking agent. Use a medium strength locking agent unless otherwise specified.

Apply sealant.

Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified.

Use fork or suspension fluid.

CONTENTS

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GENERAL INFORMATION

FRAME/BODY PANELS/EXHAUST SYSTEM

MAINTENANCE

PGM-FI SYSTEM

IGNITION SYSTEM

ELECTRIC STARTER

FUEL SYSTEM

COOLING SYSTEM

LUBRICATION SYSTEM

CYLINDER HEAD/VALVES

CLUTCH/GEARSHIFT LINKAGE

ALTERNATOR/STARTER CLUTCH

CRANKCASE/TRANSMISSION

CRANKSHAFT/PISTON/CYLINDER/BALANCER

ENGINE REMOVAL/INSTALLATION

FRONT WHEEL/SUSPENSION/STEERING

REAR WHEEL/SUSPENSION

HYDRAULIC BRAKE

ANTI-LOCK BRAKE SYSTEM (ABS; CBR500RA/CB500FA/XA)

BATTERY/CHARGING SYSTEM

LIGHTS/METERS/SWITCHES

IMMOBILIZER SYSTEM (HISS)

WIRING DIAGRAMS

INDEX

ENGINE/ENGINE ELECTRICALCHASSIS

FRAME

ELECTRICAL

MEMO

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1. GENERAL INFORMATION

SERVICE RULES ··········································1-2

MODEL IDENTIFICATION ····························1-3

SPECIFICATIONS·········································1-5

TORQUE VALUES ······································1-14

LUBRICATION & SEAL POINTS ···············1-20

CABLE & HARNESS ROUTING·················1-24

EMISSION CONTROL SYSTEMS ··············1-71

TECHNICAL FEATURE······························1-73

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GENERAL INFORMATION

SERVICE RULES

1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda's design

specifications may cause damage to the motorcycle.

2. Use the special tools designed for this product to avoid damage and incorrect assembly.

3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English

fasteners.

4. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling.

5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in

incremental steps unless a particular sequence is specified.

6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.

7. After reassembly, check all parts for proper installation and operation.

8. Route all electrical wires as shown in the Cable and Harness Routing (page 1-24).

9. Do not bend or twist control cables. Damaged control cables will not operate smoothly and may stick or bind.

ABBREVIATION

Throughout this manual, the following abbreviations are used to identify the respective parts or systems.

DESTINATION CODE

Throughout this manual, the following codes are used to identify individual types for each region.

Abbrev. term Full term

ABS Anti-lock Brake System

CKP sensor Crankshaft Position sensor

DLC Data Link Connector

DTC Diagnostic Trouble Code

ECM Engine Control Module

ECT sensor Engine Coolant Temperature sensor

EEPROM Electrically Erasable Programmable Read Only Memory

EOP switch Engine Oil Pressure switch

HISS Honda Ignition Security System

IACV Idle Air Control Valve

IAT sensor Intake Air Temperature sensor

MAP sensor Manifold Absolute Pressure sensor

MCS Motorcycle Communication System

MIL Malfunction Indicator Lamp

2 sensor Oxygen sensor

PAIR Pulse Secondary Air Injection

PGM-FI Programmed Fuel Injection

SCS connector Service Check Short connector

TP sensor Throttle Position sensor

VS sensor Vehicle Speed sensor

DESTINATION CODE REGION

EU.K.

II E U.K.: Type II

ED European direct sales

III ED European direct sales: Type III

FFrance

II F France: Type II

KO Korea

II KO Korea: Type II

RU Russia

II RU Russia: Type II

U Australia, New Zealand

II U Australia, New Zealand: Type II

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GENERAL INFORMATION

MODEL IDENTIFICATION

This manual covers following models:

– CBR500R (Conventional Brake)

– CBR500RA (ABS)

– CB500F (Conventional Brake)

– CB500FA (ABS)

– CB500X (Conventional Brake)

– CB500XA (ABS)

Be sure to refer to the procedure for the appropriate model.

SERIAL NUMBERS/LABELS

CBR500R/RA CB500F/FA

CB500X/XA

(ABS model shown)

The Vehicle Identification Number (V.I.N.) [1] is stamped on

the right side of the steering head.

The engine serial number [1] is stamped on the upper right

side of the crankcase.

[1]

CBR500RA shown:

[1]

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GENERAL INFORMATION

The throttle body identification number [1] is stamped on the

lower right side of the throttle body.

CBR500R/RA/CB500X/XA: The registered number plate (E,

II E, ED, III ED, F, II F, R, II R types) or compliance plate (U,

II U types) [1] is attached on the right front side of the frame.

CB500F/FA: The registered number plate (E, II E, ED, III ED,

F, II F types) or compliance plate (U type) [1] is attached on

the left side of the steering head.

The Safety Certification Label (KO, II KO types) [1] is located

on the left side of the swingarm.

The color label [1] is attached on the rear fender B under the

seat. When ordering color-coded parts, always specify the

designated color code.

The Emission Control Information Label (KO, II KO types) [1]

is attached on the left side of the swingarm.

[1]

CBR500RA shown:

[1]

CBR500R/RA shown:

[1]

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GENERAL INFORMATION

SPECIFICATIONS

GENERAL SPECIFICATIONS

CBR500R/RA

ITEM SPECIFICATION

DIMENSIONS Overall length 2,075 mm (81.7 in)

Overall width 740 mm (29.1 in)

Overall height 1,145 mm (45.1 in)

Wheelbase 1,410 mm (55.5 in)

Seat height 785 mm (30.9 in)

Footpeg height 312 mm (12.3 in)

Ground clearance 140 mm (5.5 in)

Curb

weight

CBR500R Except KO, II KO 192 kg (423 lbs)

KO, II KO types 190 kg (419 lbs)

CBR500RA Except KO, II KO 194 kg (428 lbs)

KO, II KO types 195 kg (430 lbs)

Maximum weight capacity Except KO, II KO 182 kg (401 lbs)

KO, II KO types 160 kg (353 lbs)

FRAME Frame type Diamond

Front suspension Telescopic fork

Front axle travel 108 mm (4.3 in)

Rear suspension Swingarm

Rear axle travel 119 mm (4.7 in)

Front tire size 120/70ZR17M/C (58W)

Rear tire size 160/60ZR17M/C (69W)

Front tire brand D222F (DUNLOP),

ROADTEC Z8 INTERACT E (METZELER)

Rear tire brand D222 (DUNLOP),

ROADTEC Z8 INTERACT (METZELER)

Front brake Hydraulic single disc

Rear brake Hydraulic single disc

Caster angle 25° 30’

Trail length 102 mm (4.0 in)

Fuel tank capacity 15.7 liters (4.15 US gal, 3.45 Imp gal)

ENGINE Cylinder arrangement 2 cylinders in-line, inclined 20° from vertical

Bore and stroke 67.0 x 66.8 mm (2.64 x 2.63 in)

Displacement 471 cm

(28.7 cu-in)

Compression ratio 10.7 : 1

Valve train Chain driven DOHC with rocker arm

Intake valve opens at 1 mm (0.04 in) lift – 5° BTDC

closes at 1 mm (0.04 in) lift 35° ABDC

Exhaust valve opens at 1 mm (0.04 in) lift 33° BBDC

closes at 1 mm (0.04 in) lift – 13° ATDC

Lubrication system Forced pressure and wet sump

Oil pump type Trochoid

Cooling system Liquid cooled

Air filtration Viscous paper element

Engine dry weight 52.7 kg (116.2 lbs)

Firing order 1 – 2

Cylinder number Left: 1, Right: 2

FUEL DELIVERY

SYSTEM

Type PGM-FI (Programmed Fuel Injection)

Throttle bore 34 mm (1.3 in)

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GENERAL INFORMATION

CB500F/FA

DRIVE TRAIN Clutch system Multi-plate, wet

Clutch operation system Cable operating

Transmission Constant mesh, 6 speeds

Primary reduction 2.029 (69/34)

Final reduction 2.733 (41/15)

Gear ratio 1st 3.285 (46/14)

2nd 2.105 (40/19)

3rd 1.600 (32/20)

4th 1.300 (26/20)

5th 1.150 (23/20)

6th 1.043 (24/23)

Gearshift pattern Left foot operated return system

1 - N - 2 - 3 - 4 - 5 - 6

ELECTRICAL Ignition system Full transistorized ignition

Starting system Electric starter motor

Charging system Triple phase output alternator

Regulator/rectifier FET shorted/triple phase full wave

rectification

Lighting system Battery

ITEM SPECIFICATION

DIMENSIONS Overall length 2,075 mm (81.7 in)

Overall width 780 mm (30.7 in)

Overall height 1,060 mm (41.7 in)

Wheelbase 1,410 mm (55.5 in)

Seat height 785 mm (30.9 in)

Footpeg height 312 mm (12.3 in)

Ground clearance 155 mm (6.1 in)

Curb weight CB500F 190 kg (419 lbs)

CB500FA 192 kg (423 lbs)

Maximum weight capacity 182 kg (401 lbs)

FRAME Frame type Diamond

Front suspension Telescopic fork

Front axle travel 108 mm (4.3 in)

Rear suspension Swingarm

Rear axle travel 119 mm (4.7 in)

Front tire size 120/70ZR17M/C (58W)

Rear tire size 160/60ZR17M/C (69W)

Front tire brand D222F (DUNLOP),

ROADTEC Z8 INTERACT E (METZELER)

Rear tire brand D222 (DUNLOP),

ROADTEC Z8 INTERACT (METZELER)

Front brake Hydraulic single disc

Rear brake Hydraulic single disc

Caster angle 25° 30’

Trail length 102 mm (4.0 in)

Fuel tank capacity 15.7 liters (4.15 US gal, 3.45 Imp gal)

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GENERAL INFORMATION

CB500X/XA

ENGINE Cylinder arrangement 2 cylinders in-line, inclined 20° from vertical

Bore and stroke 67.0 x 66.8 mm (2.64 x 2.63 in)

Displacement 471 cm

(28.7 cu-in)

Compression ratio 10.7 : 1

Valve train Chain driven DOHC with rocker arm

Intake valve opens at 1 mm (0.04 in) lift – 5° BTDC

closes at 1 mm (0.04 in) lift 35° ABDC

Exhaust valve opens at 1 mm (0.04 in) lift 33° BBDC

closes at 1 mm (0.04 in) lift – 13° ATDC

Lubrication system Forced pressure and wet sump

Oil pump type Trochoid

Cooling system Liquid cooled

Air filtration Viscous paper element

Engine dry weight 52.7 kg (116.2 lbs)

Firing order 1 – 2

Cylinder number Left: 1, Right: 2

FUEL DELIVERY

SYSTEM

Type PGM-FI (Programmed Fuel Injection)

Throttle bore 34 mm (1.3 in)

DRIVE TRAIN Clutch system Multi-plate, wet

Clutch operation system Cable operating

Transmission Constant mesh, 6 speeds

Primary reduction 2.029 (69/34)

Final reduction 2.733 (41/15)

Gear ratio 1st 3.285 (46/14)

2nd 2.105 (40/19)

3rd 1.600 (32/20)

4th 1.300 (26/20)

5th 1.150 (23/20)

6th 1.043 (24/23)

Gearshift pattern Left foot operated return system

1 - N - 2 - 3 - 4 - 5 - 6

ELECTRICAL Ignition system Full transistorized ignition

Starting system Electric starter motor

Charging system Triple phase output alternator

Regulator/rectifier FET shorted/triple phase full wave

rectification

Lighting system Battery

ITEM SPECIFICATION

DIMENSIONS Overall length 2,095 mm (82.5 in)

Overall width 830 mm (32.7 in)

Overall height 1,260 mm (49.6 in)

Wheelbase 1,420 mm (55.9 in)

Seat height 810 mm (31.9 in)

Footpeg height 320 mm (12.6 in)

Ground clearance 170 mm (6.7 in)

Curb

weight

CB500X Except KO, II KO 192 kg (423 lbs)

KO type 190 kg (419 lbs)

CB500XA Except KO, II KO 194 kg (428 lbs)

KO type 195 kg (430 lbs)

Maximum weight capacity E, ED, F, U types 185 kg (408 lbs)

KO type 160 kg (353 lbs)

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GENERAL INFORMATION

FRAME Frame type Diamond

Front suspension Telescopic fork

Front axle travel 125 mm (4.9 in)

Rear suspension Swingarm

Rear axle travel 118 mm (4.6 in)

Front tire size 120/70ZR17M/C (58W)

Rear tire size 160/60ZR17M/C (69W)

Front tire brand SCORPION TRAIL E (PIRELLI)

Rear tire brand SCORPION TRAIL (PIRELLI)

Front brake Hydraulic single disc

Rear brake Hydraulic single disc

Caster angle 26° 30’

Trail length 108 mm (4.3 in)

Fuel tank capacity 17.3 liters (4.57 US gal, 3.81 Imp gal)

ENGINE Cylinder arrangement 2 cylinders in-line, inclined 20° from vertical

Bore and stroke 67.0 x 66.8 mm (2.64 x 2.63 in)

Displacement 471 cm

(28.7 cu-in)

Compression ratio 10.7 : 1

Valve train Chain driven DOHC with rocker arm

Intake valve opens at 1 mm (0.04 in) lift – 5° BTDC

closes at 1 mm (0.04 in) lift 35° ABDC

Exhaust valve opens at 1 mm (0.04 in) lift 33° BBDC

closes at 1 mm (0.04 in) lift – 13° ATDC

Lubrication system Forced pressure and wet sump

Oil pump type Trochoid

Cooling system Liquid cooled

Air filtration Viscous paper element

Engine dry weight 52.7 kg (116.2 lbs)

Firing order 1 – 2

Cylinder number Left: 1, Right: 2

FUEL DELIVERY

SYSTEM

Type PGM-FI (Programmed Fuel Injection)

Throttle bore 34 mm (1.3 in)

DRIVE TRAIN Clutch system Multi-plate, wet

Clutch operation system Cable operating

Transmission Constant mesh, 6 speeds

Primary reduction 2.029 (69/34)

Final reduction 2.733 (41/15)

Gear ratio 1st 3.285 (46/14)

2nd 2.105 (40/19)

3rd 1.600 (32/20)

4th 1.300 (26/20)

5th 1.150 (23/20)

6th 1.043 (24/23)

Gearshift pattern Left foot operated return system

1 - N - 2 - 3 - 4 - 5 - 6

ELECTRICAL Ignition system Full transistorized ignition

Starting system Electric starter motor

Charging system Triple phase output alternator

Regulator/rectifier FET shorted/triple phase full wave

rectification

Lighting system Battery

ITEM SPECIFICATION

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GENERAL INFORMATION

PGM-FI SYSTEM SPECIFICATIONS

IGNITION SYSTEM SPECIFICATIONS

ELECTRIC STARTER SPECIFICATION

Unit: mm (in)

FUEL SYSTEM SPECIFICATIONS

COOLING SYSTEM SPECIFICATIONS

LUBRICATION SYSTEM SPECIFICATIONS

Unit: mm (in)

ITEM SPECIFICATIONS

Engine idle speed 1,200 ± 100 min

-1

(rpm)

ECT senor resistance (40°C/104°F) 1.0 – 1.3 k

IAT sensor resistance (20°C/68°F) 1 – 4 k

Fuel injector resistance (20°C/68°F) 11 – 13 

2 sensor heater resistance (20°C/68°F) 10 – 40 

IACV resistance (25°C/77°F) 110 – 150 

ITEM SPECIFICATION

Spark plug CPR8EA-9 (NGK)

Spark plug gap 0.80 – 0.90 mm (0.031 – 0.035 in)

Ignition coil peak voltage 100 V minimum

CKP sensor peak voltage 0.7 V minimum

Ignition timing ("F" mark) 6° BTDC at idle speed

ITEM STANDARD SERVICE LIMIT

Starter motor brush length 12.0 – 13.0 (0.47 – 0.51) 6.5 (0.26)

ITEM SPECIFICATIONS

Throttle body identification number GQBJA

Throttle grip freeplay 2 – 6 mm (0.1 – 0.2 in)

Fuel pressure at idle 343 kPa (3.5 kgf/cm

, 50 psi)

Fuel pump flow (at 12 V) 319 cm

(10.8 US oz, 11.2 Imp oz) minimum/10 seconds

PAIR control solenoid valve resistance (20°C/68°F) 24 – 28 

ITEM SPECIFICATIONS

Coolant capacity Radiator and engine 1.4 liters (1.5 US qt, 1.2 Imp qt)

Reserve tank (Upper level) 0.12 liter (0.13 US qt, 0.11 Imp qt)

Radiator cap relief pressure 108 – 137 kPa (1.1 – 1.4 kgf/cm

, 16 – 20 psi)

Thermostat Begin to open 80 – 84°C (176 – 183°F)

Fully open 95°C (203°F)

Valve lift 8 mm (0.3 in) minimum

Recommended antifreeze High quality ethylene glycol antifreeze containing silicate-free

corrosion inhibitors

Standard coolant concentration 1:1 mixture with distilled water

ITEM STANDARD SERVICE LIMIT

Engine oil capacity At draining 2.5 liters (2.6 US qt, 2.2 Imp qt) –

At oil filter change 2.7 liters (2.9 US qt, 2.4 Imp qt) –

At disassembly 3.2 liters (3.4 US qt, 2.8 Imp qt) –

Recommended engine oil Honda "4-stroke motorcycle oil" or an

equivalent motor oil

API service classification: SG or higher

(except oils labeled as energy

conserving on the circular API service

label)

JASO T903 standard: MA

Viscosity: SAE 10W-30

–

Oil pressure at EOP switch 93 kPa (0.9 kgf/cm

, 13 psi)

at 1,200 min

-1

(rpm)/80°C (176°F)

–

Oil pump rotor Tip clearance 0.15 (0.006) 0.20 (0.008)

Body clearance 0.15 – 0.21 (0.006 – 0.008) 0.35 (0.014)

Side clearance 0.02 – 0.09 (0.001 – 0.004) 0.12 (0.005)

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GENERAL INFORMATION

CYLINDER HEAD/VALVES SPECIFICATIONS

Unit: mm (in)

CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS

Unit: mm (in)

ALTERNATOR/STARTER CLUTCH SPECIFICATIONS

Unit: mm (in)

CRANKCASE/TRANSMISSION SPECIFICATIONS

Unit: mm (in)

ITEM STANDARD SERVICE LIMIT

Cylinder compression at 450 min

-1

(rpm) 1,372 kPa (14.0 kgf/cm

, 119 psi) –

Valve clearance IN 0.16 ± 0.03 (0.006 ± 0.001) –

EX 0.27 ± 0.03 (0.011 ± 0.001) –

Rocker arm,

rocker arm

shaft

Arm I.D. IN/EX 10.000 – 10.015 (0.3937 – 0.3943) 10.10 (0.398)

Shaft O.D. IN/EX 9.972 – 9.987 (0.3926 – 0.3932) 9.75 (0.384)

Arm-to-shaft

clearance

IN/EX 0.013 – 0.043 (0.0005 – 0.0017) 0.10 (0.004)

Camshaft Cam lobe height IN 30.3955 – 30.6355 (1.19667 – 1.20612) 30.376 (1.1959)

EX 30.1424 – 30.3824 (1.18671 – 1.19616) 30.122 (1.1859)

Oil clearance 0.020 – 0.062 (0.0008 – 0.0024) 0.10 (0.004)

Runout – 0.04 (0.002)

Valve, valve

guide

Valve stem O.D. IN 4.475 – 4.490 (0.1762 – 0.1768) 4.465 (0.1758)

EX 4.465 – 4.480 (0.1758 – 0.1764) 4.455 (0.1754)

Valve guide I.D. IN/EX 4.500 – 4.512 (0.1772 – 0.1776) 4.54 (0.179)

Stem-to-guide

clearance

IN 0.005 – 0.042 (0.0002 – 0.0017) 0.07 (0.003)

EX 0.015 – 0.052 (0.0006 – 0.0020) 0.08 (0.003)

Valve guide height IN/EX 14.10 – 14.30 (0.555 – 0.563) –

Valve seat width IN/EX 0.90 – 1.10 (0.035 – 0.043) 1.5 (0.06)

Valve spring free length Inner (IN/EX) 29.78 (1.172) 28.58 (1.125)

Outer (IN/EX) 39.98 (1.574) 38.78 (1.527)

Cylinder head warpage – 0.10 (0.004)

ITEM STANDARD SERVICE LIMIT

Clutch lever freeplay 10 – 20 (0.4 – 0.8) –

Clutch Spring free length 43.2 (1.70) 42.0 (1.65)

Disc thickness 2.30 – 2.50 (0.091 – 0.098) 2.27 (0.089)

Plate warpage – 0.30 (0.012)

Clutch outer guide I.D. 22.000 – 22.021 (0.8661 – 0.8670) 22.031 (0.8674)

O.D. 27.987 – 28.000 (1.1018 – 1.1024) 27.977 (1.1015)

Mainshaft O.D. at clutch outer guide 21.967 – 21.980 (0.8648 – 0.8654) 21.95 (0.864)

ITEM STANDARD SERVICE LIMIT

Starter driven gear boss O.D. 51.705 – 51.718 (2.356 – 2.0361) 51.685 (2.0348)

Starter clutch outer I.D. 68.362 – 68.392 (2.6914 – 2.6926) 68.402 (2.6930)

ITEM STANDARD SERVICE LIMIT

Transmission Gear I.D. M5 28.000 – 28.021 (1.1024 – 1.1032) 28.04 (1.104)

C1 24.007 – 24.028 (0.9452 – 0.9460) 24.04 (0.946)

C2 31.000 – 31.025 (1.2205 – 1.2215) 31.04 (1.222)

Bushing O.D. M5, M6 27.959 – 27.980 (1.1007 – 1.1016) 27.94 (1.100)

C2 30.970 – 30.995 (1.2193 – 1.2203) 30.94 (1.218)

C3, C4 30.950 – 30.975 (1.2185 – 1.2195) 30.93 (1.218)

Gear-to-bushing

clearance

M5 0.020 – 0.062 (0.0008 – 0.0024) 0.10 (0.004)

C2 0.005 – 0.055 (0.0002 – 0.0022) 0.07 (0.003)

Bushing I.D. M5 25.000 – 25.021 (0.9843 – 0.9851) 25.04 (0.986)

C2 28.000 – 28.021 (1.1024 – 1.1032) 28.04 (1.104)

Mainshaft O.D. at M5 bushing 24.967 – 24.980 (0.9830 – 0.9835) 24.96 (0.983)

at C2 bushing 27.967 – 27.980 (1.1011 – 1.1016) 27.95 (1.100)

Bushing-to-shaft

clearance

M5, C2 0.020 – 0.054 (0.0008 – 0.0021) 0.07 (0.003)

Shift fork,

fork shaft

Shift fork shaft O.D. 11.957 – 11.968 (0.4707 – 0.4712) 11.95 (0.470)

Shift fork I.D. 12.000 – 12.018 (0.4724 – 0.4731) 12.03 (0.474)

Shift fork claw thickness 5.93 – 6.00 (0.233 – 0.236) 5.9 (0.23)

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