Sign In
Upload
Download
Table of Contents
Contents
Add to my manuals
Delete from my manuals
Share
URL of this page:
HTML Link:
Bookmark this page
Add
Manual will be automatically added to "My Manuals"
Print this page
×
Bookmark added
×
Added to my manuals
Manuals
Brands
Honda Manuals
Motorcycle
XBR500
Shop manual
Honda XBR500 Shop Manual
Hide thumbs
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
Table Of Contents
222
page
of
222
Go
/
222
Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Contents
Important Safety Notice
General Information
General Safety
Service Rules
Model Identification
Specifications
Torque Values
Standard Torque Values
Tools: Special
Tools: Common
Tools: Valve Seat Cutters
Lubrication: Specifications
Lubrication: Torque Values
Lubrication: Troubleshooting
Engine Oil Level Check
Engine Oil Change
Engine Oil Filter
Oil Filter Screen (in the Right Crankcase)
Oil Strainer: Removal
Oil Strainer: Installation
Lubrication Points
Maintenance: Service Information
Maintenance: Specifications
Maintenance: Torque Values
Maintenance: Tools
Maintenance Schedule
Fuel Line
Fuel Strainer Screen
Throttle Operation
Carburetor Choke
Air Cleaner
Crankcase Breather
Spark Plug
Valve Clearance
Decompressor System
Carburetor Idle Speed
Drive Chain
Battery
Brake Fluid
Brake Shoe/Pad Wear
Brake System: Brake Pedal Height
Brake System: Brake Pedal Free Play
Brake Light Switch
Headlight Aim
Clutch System
Side Stand
Suspensions: Front
Suspensions: Rear
Suspensions: Rear Shock Absorber/Swing Arm
Wheels: Tire Pressure
Steering Head Bearings
Nuts, Bolts, Fasteners
Cylinder Compression
Fuel System Overview
Fuel System: Service Information
Fuel System: Specifications
Fuel System: Troubleshooting
Carburetor Removal
Carburetor Disassembly: Vacuum Chamber
Carburetor Disassembly: Air Cut-Off Valve
Carburetor Disassembly: Float Chamber
Carburetor Assembly: Vacuum Chamber
Carburetor Assembly: Float Chamber
Carburetor Assembly: Float Level Inspection
Carburetor Assembly: Air Cut-Off Valve
Carburetor Installation
Pilot Screw Adjustment
Fuel Tank: Removal
Fuel Tank: Installation
Air Cleaner Case: Removal
Air Cleaner Case: Installation
Engine Removal/Installation View
Engine Removal/Installation: Service Information
Engine Removal/Installation: Specifications
Engine Removal
Engine Installation
Cylinder Head/Valves Exploded View
Cylinder Head/Valves: Service Information
Cylinder Head/Valves: Specifications
Cylinder Head/Valves: Torque Values
Cylinder Head/Valves: Tools
Cylinder Head/Valves: Troubleshooting
Cylinder Head Cover Removal
Cylinder Head Cover Disassembly
Sub-Rocker Arm and Shaft Inspection
Rocker Arm and Shaft Inspection
Camshaft Removal
Camshaft Bearing Inspection
Cylinder Head Removal
Cylinder Head Disassembly
Cylinder Head Inspection
Valve Spring Inspection
Valve/Valve Guide Inspection
Valve Guide Replacement
Valve Seat Inspection and Refacing
Valve Seat Cutters
Valve Seat Grinding
Cylinder Head Assembly
Cylinder Head Installation
Camshaft Installation
Cylinder Head Cover Assembly
Cylinder Head Cover Installation
Cylinder/Piston Overview
Cylinder/Piston: Service Information
Cylinder/Piston: Specifications
Cylinder/Piston: Torque Values
Cylinder/Piston: Troubleshooting
Cylinder Removal
Cylinder Inspection
Piston Removal
Piston/Piston Ring Inspection
Piston Ring Installation
Piston Installation
Cylinder Installation
Clutch/Oil Pump/Kick Starter Overview
Clutch/Oil Pump/Kick Starter: Service Information
Clutch/Oil Pump/Kick Starter: Specifications
Clutch/Oil Pump/Kick Starter: Tools
Clutch/Oil Pump/Kick Starter: Troubleshooting
Clutch/Oil Pump/Kick Starter: Torque Values
Right Crankcase Cover Removal
Right Crankcase Cover: Disassembly/Assembly
Clutch Removal
Spring Inspection
Clutch Disc Inspection
Clutch Plate Inspection
Clutch Outer and Outer Guide Inspection
Oil Pump: Removal
Oil Pump: Disassembly
Oil Pump Inspection
Oil Pump: Assembly
Oil Pump: Installation
Kick Starter: Removal
Kick Starter: Disassembly
Kick Starter: Inspection
Kick Starter: Assembly
Kick Starter: Installation
Clutch Installation
Right Crankcase Cover Installation
Alternator Overview
Alternator: Service Information
Alternator: Torque Values
Left Crankcase Cover Removal
Clutch Lifter Arm Disassembly
Alternator Stator Removal
Flywheel Removal
Flywheel Installation
Left Crankcase Cover Installation: Clutch Lifter Arm Installation
Left Crankcase Cover Installation: Alternator Stator Installation
Shift Linkage/Transmission Exploded View
Shift Linkage/Transmission: Service Information
Shift Linkage/Transmission: Specifications
Shift Linkage/Transmission: Torque Values
Shift Linkage/Transmission: Tool
Shift Linkage/Transmission: Troubleshooting
Shift Linkage/Transmission: Crankcase Separation
Shift Linkage/Transmission: Transmission Removal
Shift Linkage/Transmission: Inspection
Shift Linkage/Transmission: Transmission Assembly
Crankcase Assembly
Crankshaft/Balancer Exploded View
Crankshaft/Balancer: Service Information
Crankshaft/Balancer: Specifications
Crankshaft/Balancer: Tools
Crankshaft/Balancer: Troubleshooting
Crankshaft/Balancer Removal
Crankshaft Inspection
Balancer Inspection
Crankshaft Bearing Replacement
Crankshaft/Balancer: Installation
Front Wheel/Suspension/Steering Overview
Front Wheel/Suspension/Steering: Service Information
Front Wheel/Suspension/Steering: Specifications
Front Wheel/Suspension/Steering: Torque Values
Front Wheel/Suspension/Steering: Tools
Front Wheel/Suspension/Steering: Troubleshooting
Right Handlebar Removal
Left Handlebar Removal
Right Handlebar Installation
Left Handlebar Installation
Front Wheel: Removal
Inspection: Axle
Inspection: Wheel Bearing
Inspection: Wheel
Inspection: Wheel Balance
Front Wheel: Disassembly
Front Wheel: Assembly
Front Wheel: Installation
Front Forks: Removal
Front Forks: Disassembly
Inspection: Front Spring Free Length
Inspection: Fork Tube/Fork Slider/Piston
Inspection: Bushing/Back-Up Ring
Front Forks: Assembly
Front Forks: Installation
Steering Stem: Removal
Steering Stem: Bearing Replacement
Steering Stem: Installation
Steering Head Bearing Preload
Rear Wheel/Brake/Suspension Overview
Rear Wheel/Brake/Suspension: Service Information
Rear Wheel/Brake/Suspension: Specifications
Rear Wheel/Brake/Suspension: Torque Values
Rear Wheel/Brake/Suspension: Tools
Rear Wheel/Brake/Suspension: Troubleshooting
Rear Wheel: Removal
Rear Wheel: Inspection: Axle
Rear Wheel: Inspection: Rear Wheel Rim Runout
Rear Wheel: Inspection: Wheel Bearing Play
Rear Wheel: Assembly
Rear Wheel: Installation
Rear Brake: Brake Panel Removal
Rear Brake: Inspection Rear Brake Drum I.D.
Rear Brake: Inspection Brake Lining
Rear Brake: Rear Brake Shoe Replacement
Rear Brake: Brake Panel Installation
Brake Pedal: Removal
Brake Pedal: Installation
Rear Shock Absorbers: Removal
Rear Shock Absorbers: Disassembly
Shock Absorber Spring Inspection
Rear Shock Absorbers: Assembly
Rear Shock Absorbers: Installation
Swing Arm: Removal
Swing Arm: Pivot Bushing Replacement
Swing Arm: Installation
Hydraulic Brake Overview
Hydraulic Brake: Service Information
Hydraulic Brake: Specifications
Hydraulic Brake: Torque Values
Hydraulic Brake: Tool
Hydraulic Brake: Troubleshooting
Hydraulic Brake: Brake Fluid Draining
Hydraulic Brake: Brake Fluid Filling
Hydraulic Brake: Air Bleeding
Brake Pad/Disc: Pad Replacement
Brake Disc Inspection: Disc Thickness
Brake Disc Inspection: Disc Warpage
Front Brake Master Cylinder: Disassembly
Front Brake Master Cylinder: Inspection Master Cylinder I.D.
Front Brake Master Cylinder: Inspection Master Piston O.D.
Front Brake Master Cylinder: Assembly
Front Brake Caliper: Disassembly
Front Brake Caliper: Inspection Caliper Piston O.D.
Front Brake Caliper: Inspection Caliper Cylinder I.D.
Front Brake Caliper: Assembly
Front Brake Caliper: Caliper Bracket Disassembly
Front Brake Caliper: Caliper Bracket Assembly/Installation
Rear Fender Overview
Exhaust Pipe
Ignition System Overview
Ignition System: Service Information
Ignition System: Specifications
Ignition System: Troubleshooting
Ignition Coil: Removal
Ignition Coil: Inspection
Ignition Coil: Installation
CDI Unit: Inspection
Alternator Exciter Coil
Pulse Generator: Inspection
Pulse Generator: Removal
Pulse Generator: Installation
Ignition Timing
Battery/Charging System Overview
Battery/Charging System: Troubleshooting
Battery/Charging System: Specifications
Battery: Removal
Battery: Specific Gravity Test
Battery Charging System: Leakage Inspection
Charging System Inspection
Alternator Output Test
Charging Output Specifications
Alternator: Stator Coil Inspection
Voltage Regulator/Rectifier
Electrical Starter System Overview
Electrical Starter System: Service Information
Electrical Starter System: Specifications
Electrical Starter System: Troubleshooting
Starter Idle Gears: Removal
Starter Idle Gears: Inspection
Starter Clutch/Driven Gear
Starter Clutch/Driven Gear: Inspection/Assembly
Starter Clutch/Driven Gear: Installation
Starter Motor: Removal/Disassembly
Starter Motor: Brush Inspection
Starter Motor: Commutator Inspection
Starter Motor: Assembly/Installation
Starter Relay Switch
Clutch Switch Diode
Light/Switches/Instrument: Service Information
Light/Switches/Instrument: Specifications
Light/Switches/Instrument: Troubleshooting
Brake and Taillight Warning System
Bulb Replacement: Headlight
Bulb Replacement: Instruments
Tail/Brake Light
Turn Signal
Instruments: Removal
Instruments: Assembly/Installation
Advertisement
Quick Links
Download this manual
Table of
Contents
Previous
Page
Next
Page
1
2
3
4
5
Advertisement
Table of Contents
Troubleshooting
Lubrication: Specifications
12
Fuel System: Troubleshooting
37
Cylinder Head/Valves: Troubleshooting
57
Cylinder/Piston: Troubleshooting
78
Clutch/Oil Pump/Kick Starter: Tools
88
Shift Linkage/Transmission: Torque Values
116
Crankshaft/Balancer: Service Information
128
Front Wheel/Suspension/Steering: Tools
136
Rear Wheel/Brake/Suspension: Troubleshooting
160
Hydraulic Brake: Troubleshooting
176
Ignition System: Service Information
190
Battery/Charging System: Troubleshooting
196
Electrical Starter System: Service Information
202
Light/Switches/Instrument: Service Information
209
Troubleshooting: Engine Does Not Start Or Is Hard To Start
218
Troubleshooting: Engine Lacks Power
219
Troubleshooting: Poor Performance At Low And Idle Speeds
220
Troubleshooting: Poor Performance At High Speed
221
Need help?
Do you have a question about the XBR500 and is the answer not in the manual?
Ask a question
Questions and answers
Related Manuals for Honda XBR500
Motorcycle HONDA XR250Y Owner's Manual
(85 pages)
Motorcycle HONDA XR650 Owner's Manual
2004 (135 pages)
Motorcycle HONDA XR650L Owner's Manual
5 (235 pages)
Motorcycle Honda XR650L Owner's Manual
Honda xr650l motorcycle owner's manual (232 pages)
Motorcycle Honda XR250R Service Manual
(281 pages)
Motorcycle Honda XR250R Owner's Manual
(88 pages)
Motorcycle Honda Transalp XL700V Manual
(598 pages)
Motorcycle Honda XL700V Owner's Manual
(167 pages)
Motorcycle Honda XR70R Service Manual
1997-2003 (219 pages)
Motorcycle Honda XR250 Tornado Owner's Manual
(162 pages)
Motorcycle Honda Tornado XR250 Owner's Manual
(52 pages)
Motorcycle Honda XR400 Manual
(76 pages)
Motorcycle Honda AFRICA TWIN XRV650 Owner's Manual
(112 pages)
Motorcycle Honda XL650V Owner's Manual
(59 pages)
Motorcycle Honda XR125L Owner's Manual
(119 pages)
Motorcycle Honda XR650L 2019 Owner's Manual
(126 pages)
Related Products for Honda XBR500
HONDA XL125LK
Honda XL1000V Varadero
Honda XL600V Transalp 1994
Honda XL600V Transalp 1996
Honda XRV750 Africa Twin 1995
Honda XRV750 Africa Twin 1997
Honda XR125L
Honda XR650L 2021
Honda XL750 IN 2023
Honda XL750 V 2023
Honda XL750 II FO 2023
Honda X-ADV 2024
Honda XR150L 2023
Honda XR150 2018
Honda XRV750 Africa Twin 2002
Honda XRV750 Africa Twin 1996
Table of Contents
Save PDF
Print
Rename the bookmark
Delete bookmark?
Delete from my manuals?
Login
Sign In
OR
Sign in with Facebook
Sign in with Google
Upload manual
Upload from disk
Upload from URL
Need help?
Do you have a question about the XBR500 and is the answer not in the manual?
Questions and answers