Honda MBX80 Manuals

Manuals and User Guides for Honda MBX80. We have 1 Honda MBX80 manual available for free PDF download: Workshop Manual

Honda MBX80 Workshop Manual (195 pages)

Brand: Honda | Category: Motorcycle | Size: 24.59 MB

Contents
1
Workshop Manual
1
Model Identification
2
General Information
3
Important Safety Notice
3
General Safety
3
Service Rules
3
Specifications
4
Torque Values
6
Standard Torque Values
6
Tools
7
Cable & Harness Routing
9
Maintenance Schedule
12
Lubrication
13
Oil Flow
13
Lubrication Service Information
15
Lubrication Specifications
15
Transmission Oil
15
Excessive Smoke/Excessive Carbon Buildup in Plug
15
Oil Level Check
16
Oil Change
16
Transmission Oil
16
Oil Strainer Cleaning
17
Oil Tank
17
Oil Pump Removal
18
Oil Pump Mounting Bolt
18
Oil Pump Inspection
19
Oil Pump Installation
19
Oil Pump Bleeding
20
Oil Tube/Oil Pump
20
Oil Pass Tube
20
Oil Tank
21
Oil Tank Mounting Bolt
21
Oil Level Warning Unit Coupler
21
Chassis Lubrication Points
22
Inspection and Adjustments
23
General Instructions
23
Fuel Une and Fuel Strainer
24
Throttle Operation
24
Air Cleaner
25
Spark Plug
26
Recommended Spark Plug
26
Oil Pump Control Cable
27
Carburetor Idle Speed
27
Ignition Timing
28
Cylinder Compression
29
Clutch
29
Radiator Coolant
30
Cooling System Hoses
30
Radiator Core
30
Chassis
31
Battery
31
Front Brake
31
Fluid Level
31
Rear Brake
32
Rear Brake Pedal Play
32
Brake Shoe Inspection
32
Brake Light Switch
32
Drive Chain
33
Cleaning/Lubrication
34
Wheels
35
Nuts, Bolts, Fasteners
35
Muffler Decarbonizing
35
Recommended Tire Pressure and Tire Size
35
Inspection and Adjustment
35
Fuel System
36
Fuel System Service Information
38
Fuel System Tools
38
Fuel System Specifications
38
Fuel System Troubleshooting
38
Carburetor Removal
39
Throttle Valve Disassembly
40
Float/Float Valve/Jet Disassembly
41
Float/Float Valve Inspection
41
Float Level Adjustment
43
Throttle Valve/Cable Installation
44
Carburetor Installation
45
Fuel Tank Removal
45
Fuel Tank Inspection
45
Fuel Strainer
45
Air Cleaner Case Removal
46
Air Cleaner Case Installation
46
Engine Rmeoval/Installation
47
Engine Removal/Installation Service Information
49
Cylinder Head/Cylinder/Piston
55
Cylinder Head/Cylinder/Piston Service Information
57
Cylinder Head/Cylinder/Piston General Instructions
57
Cylinder Head/Cylinder/Piston Torque Value
57
Cylinder Head/Cylinder/Piston Specifications
57
Cylinder Head Removal
58
Cylinder Head Inspection
59
Cylinder Head Decarbonizing
59
Cylinder Head Installation
59
Cylinder/Piston
60
Cylinder Removal
60
Piston Removal
61
Piston Ring/Expander Removal
61
Cylinder/Piston Inspection
61
Piston Ring Inspection
63
Connecting Rod Inspection
63
Piston/Cylinder Installation
64
Reed Valve Removal
65
Gearshift Linkage
67
Table of Contents
68
Clutch/Kickstarter/Gearshift Linkage Service Information
69
Clutch/Kickstarter/Gearshift Linkage Tool
69
Clutch/Kickstarter/Gearshift Linkage Specifications
69
Clutch/Kickstarter/Gearshift Linkage Troubleshooting
69
Right Crankcase Cover
70
Honda � Mbx50, Mbx80
70
Clutch/Idler Gear
72
Clutch Removal
72
Clutch Disc Inspection
73
Clutch Plate Inspection
74
Clutch Outer Inspection
74
Balancer Idler Gear/Oil Pump
74
Driven Gear Removal
74
Primary Drive Gear Removal
75
Balancer Idler Gear Inspection
75
Oil Pump Driven Gear Installation
76
Balancer Idler Gear Installation
76
Primary Drive Gear Installation
76
Balancer Timing/Clutch Installation
77
Kickstarter
78
Spindle Removal
78
Idler Gear Removal
79
Idler Gear Inspection
79
Kickstarter Installation
80
Shift Linkage Removal
81
Alternator
84
Alternator Service Information
86
Alternator Tools
86
Alternator Torque Value
86
Alternator Removal
87
Alternator Installation
89
Crankshaft/Transmission
91
Crankshaft/Transmission Service
93
Crankshaft/Transmission Tools
93
Crankshaft/Transmission Specifications
93
Cylinder Head
93
Crankshaft/Transmission Troubleshooting
94
Engine Noise
94
Jumps out of Gear
94
Hard Shifting
94
Crankcase Separation
95
Transmission Disassembly
95
Gearshift Fork/Shift Drum
95
Shift Fork/Shift Fork Shaft/ Shift Drum Inspection
96
Transmission Removal
97
Transmission Inspection
97
Balancer Weight Removal
98
Bearing Replacement
98
Crankshaft Removal
99
Crankshaft Inspection
100
Crankshaft Bearing Inspection
101
Crankshaft Bearing Replacement
101
Crankshaft Installation
102
Transmission Assembly
103
Crankcase Assembly
104
Cooling System
106
Cooling System Service Information
108
Cooling System Tools
108
Cooling System Specifications
108
Cooling System Troubleshooting
108
Mbx50·Mbx80
108
Coolant Change
109
Bleed Air from the Radiator
109
Radiator Removal
110
Radiator Inspection
111
Radiator Installation
111
Water Pump Removal
112
Water Pump Inspection
113
Bearing/Mechanical Seal Replacement
113
Water Pump Installation
114
Thermostat/Temperature Sensor Removal
115
Temperature Sensor Inspection
115
Temperature Sensor Resistance
115
Thermostat Inspection
116
Technical Data
116
Front Wheel/Suspension
117
Front Wheel/Suspension Service Information
119
Front Wheel/Suspension Tools
119
Front Wheel/Suspension Torque Values
119
Front Wheel/Suspension Specifications
119
Front Wheel/Suspension Troubleshooting
120
Hard Steering
120
Steers to One Side or Does Not Track Straight
120
Front Wheel Wobbling
120
Mbx50· Mbx80
120
Headlight Removal
121
Headlight Installation
122
Instruments
122
Indicator and Meter Bulb Replacement
122
Handlebar Removal
124
Handlebar Installation
125
Front Wheel Removal
126
Axle Inspection
126
Wheel Bearing Inspection
127
Wheel Rim Runout
127
Front Wheel/Suspension Assembly
128
Front Wheel Installation
129
Front Fork Removal
130
Fork Tube Runout
132
Slider/Piston Inspection
133
Steering Stem
136
Steering Stem Installation
137
Hydraulic Brake
139
Hydraulic Brake Service Information
141
Hydraulic Brake Tool
141
Hydraulic Brake Specifications
141
Hydraulic Brake Troubleshooting
141
Brake Fluid/Air Bleeding
142
Brake Pad/Disc
143
Brake Pad Inspection
143
Brake Pad Replacement
143
Brake Disc Inspection
144
Brake Caliper Removal
145
Brake Caliper Disassembly
145
Brake Caliper Inspection
146
Brake Caliper Assembly
147
Brake Master Cylinder Removal
148
Brake Master Cylinder Disassembly
148
Brake Master Cylinder Inspection
149
Brake Master Cylinder Assembly
150
Brake Master Cylinder Installation
150
Rear Wheel/Brake/Suspension
151
Rear Wheel/Brake/Suspension Service
153
Rear Wheel/Brake/Suspension Tools
153
Rear Wheel/Brake/Suspension Torque Values
153
Rear Wheel/Brake/Suspension Troubleshooting
153
Rear Wheel Removal
154
Rear Wheel Bearing Play Inspection
154
Rear Wheel Rim Runout Inspection
155
Final Driven Sprocket Inspection
155
Rear Wheel Disassembly
155
Rear Wheel Bearing Installation
156
Final Driven Sprocket Installation
156
Rear Wheel Installation
156
Rear Brake Lining Thickness
157
Rear Brake Drum Inspection
157
Rear Brake Shoe Replacement
158
Brake Cam Disassembly
158
Brake Panel Assembly
158
Brake Pedal
159
Rear Shock Absorber
160
Rear Damper Inspection
161
Spring Free Length
161
Rear Shock Absorber Unkage
162
Swingarm Removal
164
Swingarm Inspection
164
Swingarm Installation
164
Fairing/Under Cowl
165
Battery/Charging System
169
Battery/Charging System Service Information
171
Battery/Charging System Specifications
171
Battery/Charging System Troubleshooting
171
No Power-Key Turned on
171
Battery Removal
172
Testing Specific Gravity
172
Battery Charging
173
Charging System
174
Performance Test
174
Alternator Inspection
175
Regulator / Rectifier Inspection
175
Resistor Inspection
176
Ignition System
177
Ignition System Service Information
179
Ignition System Specifications
179
Ignition System Troubleshooting
179
No Spark at Plug
179
Ignition Coil Removal
180
Ignition Coil Continuity Test
180
CDI Unit Removal
181
CDI Unit Inspection
181
Alternator Excitor Coil/Pulse Generator
181
Ignition System
181
Switches
182
Switches Service Information
183
Ignition Switch
184
Switch Postion
184
Handlebar Switches
184
Brake Switches
185
Neutral Switch
185
Oil Level Sensor
186
Troubleshooting
187
Engine Does Not Start or Is Hard to Start
188
Engine Lacks Power
189
Poor Performance at Low and Idle Speeds
190
Poor Performance at High Speed
191
Poor Handling
191
Wiring Diagram
193

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Honda MBX80 Workshop Manual (195 pages)

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