Honda XBR500 Manuals

Manuals and User Guides for Honda XBR500. We have 1 Honda XBR500 manual available for free PDF download: Shop Manual

Honda XBR500 Shop Manual (222 pages)

Brand: Honda | Category: Motorcycle | Size: 124.14 MB

Contents
2
Important Safety Notice
3
General Information
4
General Safety
4
Service Rules
4
Model Identification
5
Specifications
6
Torque Values
8
Standard Torque Values
9
Tools: Special
10
Tools: Common
11
Tools: Valve Seat Cutters
11
Lubrication: Specifications
12
Lubrication: Torque Values
12
Lubrication: Troubleshooting
12
Engine Oil Level Check
13
Engine Oil Change
13
Engine Oil Filter
14
Oil Filter Screen (in the Right Crankcase)
15
Oil Strainer: Removal
16
Oil Strainer: Installation
17
Lubrication Points
18
Maintenance: Service Information
19
Maintenance: Specifications
20
Maintenance: Torque Values
20
Maintenance: Tools
20
Maintenance Schedule
21
Fuel Line
22
Fuel Strainer Screen
22
Throttle Operation
22
Carburetor Choke
23
Air Cleaner
24
Crankcase Breather
24
Spark Plug
25
Valve Clearance
25
Decompressor System
26
Carburetor Idle Speed
26
Drive Chain
27
Battery
28
Brake Fluid
28
Brake Shoe/Pad Wear
29
Brake System: Brake Pedal Height
30
Brake System: Brake Pedal Free Play
30
Brake Light Switch
31
Headlight Aim
31
Clutch System
31
Side Stand
32
Suspensions: Front
32
Suspensions: Rear
32
Suspensions: Rear Shock Absorber/Swing Arm
33
Wheels: Tire Pressure
33
Steering Head Bearings
33
Nuts, Bolts, Fasteners
33
Cylinder Compression
34
Fuel System Overview
35
Fuel System: Service Information
36
Fuel System: Specifications
36
Fuel System: Troubleshooting
37
Carburetor Removal
38
Carburetor Disassembly: Vacuum Chamber
39
Carburetor Disassembly: Air Cut-Off Valve
39
Carburetor Disassembly: Float Chamber
40
Carburetor Assembly: Vacuum Chamber
41
Carburetor Assembly: Float Chamber
42
Carburetor Assembly: Float Level Inspection
42
Carburetor Assembly: Air Cut-Off Valve
43
Carburetor Installation
43
Pilot Screw Adjustment
44
Fuel Tank: Removal
45
Fuel Tank: Installation
45
Air Cleaner Case: Removal
46
Air Cleaner Case: Installation
47
Engine Removal/Installation View
48
Engine Removal/Installation: Service Information
49
Engine Removal/Installation: Specifications
49
Engine Removal
50
Engine Installation
52
Cylinder Head/Valves Exploded View
54
Cylinder Head/Valves: Service Information
55
Cylinder Head/Valves: Specifications
55
Cylinder Head/Valves: Torque Values
56
Cylinder Head/Valves: Tools
56
Cylinder Head/Valves: Troubleshooting
57
Cylinder Head Cover Removal
58
Cylinder Head Cover Disassembly
59
Sub-Rocker Arm and Shaft Inspection
60
Rocker Arm and Shaft Inspection
60
Camshaft Removal
60
Camshaft Bearing Inspection
61
Cylinder Head Removal
61
Cylinder Head Disassembly
62
Cylinder Head Inspection
64
Valve Spring Inspection
64
Valve/Valve Guide Inspection
65
Valve Guide Replacement
65
Valve Seat Inspection and Refacing
66
Valve Seat Cutters
67
Valve Seat Grinding
67
Cylinder Head Assembly
69
Cylinder Head Installation
70
Camshaft Installation
71
Cylinder Head Cover Assembly
72
Cylinder Head Cover Installation
73
Cylinder/Piston Overview
76
Cylinder/Piston: Service Information
77
Cylinder/Piston: Specifications
77
Cylinder/Piston: Torque Values
77
Cylinder/Piston: Troubleshooting
78
Cylinder Removal
79
Cylinder Inspection
80
Piston Removal
80
Piston/Piston Ring Inspection
81
Piston Ring Installation
82
Piston Installation
84
Cylinder Installation
84
Clutch/Oil Pump/Kick Starter Overview
86
Clutch/Oil Pump/Kick Starter: Service Information
87
Clutch/Oil Pump/Kick Starter: Specifications
87
Clutch/Oil Pump/Kick Starter: Tools
88
Clutch/Oil Pump/Kick Starter: Troubleshooting
88
Clutch/Oil Pump/Kick Starter: Torque Values
88
Right Crankcase Cover Removal
89
Right Crankcase Cover: Disassembly/Assembly
90
Clutch Removal
91
Spring Inspection
92
Clutch Disc Inspection
92
Clutch Plate Inspection
93
Clutch Outer and Outer Guide Inspection
93
Oil Pump: Removal
93
Oil Pump: Disassembly
94
Oil Pump Inspection
94
Oil Pump: Assembly
97
Oil Pump: Installation
98
Kick Starter: Removal
99
Kick Starter: Disassembly
100
Kick Starter: Inspection
100
Kick Starter: Assembly
101
Kick Starter: Installation
102
Clutch Installation
103
Right Crankcase Cover Installation
106
Alternator Overview
108
Alternator: Service Information
109
Alternator: Torque Values
109
Left Crankcase Cover Removal
110
Clutch Lifter Arm Disassembly
111
Alternator Stator Removal
111
Flywheel Removal
111
Flywheel Installation
112
Left Crankcase Cover Installation: Clutch Lifter Arm Installation
112
Left Crankcase Cover Installation: Alternator Stator Installation
112
Shift Linkage/Transmission Exploded View
114
Shift Linkage/Transmission: Service Information
115
Shift Linkage/Transmission: Specifications
115
Shift Linkage/Transmission: Torque Values
116
Shift Linkage/Transmission: Tool
116
Shift Linkage/Transmission: Troubleshooting
116
Shift Linkage/Transmission: Crankcase Separation
117
Shift Linkage/Transmission: Transmission Removal
119
Shift Linkage/Transmission: Inspection
120
Shift Linkage/Transmission: Transmission Assembly
122
Crankcase Assembly
124
Crankshaft/Balancer Exploded View
127
Crankshaft/Balancer: Service Information
128
Crankshaft/Balancer: Specifications
128
Crankshaft/Balancer: Tools
128
Crankshaft/Balancer: Troubleshooting
128
Crankshaft/Balancer Removal
129
Crankshaft Inspection
130
Balancer Inspection
131
Crankshaft Bearing Replacement
131
Crankshaft/Balancer: Installation
132
Front Wheel/Suspension/Steering Overview
134
Front Wheel/Suspension/Steering: Service Information
135
Front Wheel/Suspension/Steering: Specifications
135
Front Wheel/Suspension/Steering: Torque Values
135
Front Wheel/Suspension/Steering: Tools
136
Front Wheel/Suspension/Steering: Troubleshooting
136
Right Handlebar Removal
137
Left Handlebar Removal
138
Right Handlebar Installation
139
Left Handlebar Installation
139
Front Wheel: Removal
140
Inspection: Axle
141
Inspection: Wheel Bearing
141
Inspection: Wheel
141
Inspection: Wheel Balance
141
Front Wheel: Disassembly
142
Front Wheel: Assembly
142
Front Wheel: Installation
144
Front Forks: Removal
145
Front Forks: Disassembly
146
Inspection: Front Spring Free Length
148
Inspection: Fork Tube/Fork Slider/Piston
148
Inspection: Bushing/Back-Up Ring
148
Front Forks: Assembly
149
Front Forks: Installation
151
Steering Stem: Removal
152
Steering Stem: Bearing Replacement
154
Steering Stem: Installation
155
Steering Head Bearing Preload
157
Rear Wheel/Brake/Suspension Overview
158
Rear Wheel/Brake/Suspension: Service Information
159
Rear Wheel/Brake/Suspension: Specifications
159
Rear Wheel/Brake/Suspension: Torque Values
159
Rear Wheel/Brake/Suspension: Tools
159
Rear Wheel/Brake/Suspension: Troubleshooting
160
Rear Wheel: Removal
161
Rear Wheel: Inspection: Axle
161
Rear Wheel: Inspection: Rear Wheel Rim Runout
161
Rear Wheel: Inspection: Wheel Bearing Play
162
Rear Wheel: Assembly
163
Rear Wheel: Installation
165
Rear Brake: Brake Panel Removal
166
Rear Brake: Inspection Rear Brake Drum I.D.
166
Rear Brake: Inspection Brake Lining
166
Rear Brake: Rear Brake Shoe Replacement
166
Rear Brake: Brake Panel Installation
167
Brake Pedal: Removal
168
Brake Pedal: Installation
169
Rear Shock Absorbers: Removal
169
Rear Shock Absorbers: Disassembly
170
Shock Absorber Spring Inspection
170
Rear Shock Absorbers: Assembly
170
Rear Shock Absorbers: Installation
171
Swing Arm: Removal
171
Swing Arm: Pivot Bushing Replacement
172
Swing Arm: Installation
173
Hydraulic Brake Overview
174
Hydraulic Brake: Service Information
175
Hydraulic Brake: Specifications
175
Hydraulic Brake: Torque Values
175
Hydraulic Brake: Tool
175
Hydraulic Brake: Troubleshooting
176
Hydraulic Brake: Brake Fluid Draining
177
Hydraulic Brake: Brake Fluid Filling
177
Hydraulic Brake: Air Bleeding
178
Brake Pad/Disc: Pad Replacement
179
Brake Disc Inspection: Disc Thickness
181
Brake Disc Inspection: Disc Warpage
181
Front Brake Master Cylinder: Disassembly
181
Front Brake Master Cylinder: Inspection Master Cylinder I.D.
182
Front Brake Master Cylinder: Inspection Master Piston O.D.
183
Front Brake Master Cylinder: Assembly
183
Front Brake Caliper: Disassembly
184
Front Brake Caliper: Inspection Caliper Piston O.D.
185
Front Brake Caliper: Inspection Caliper Cylinder I.D.
185
Front Brake Caliper: Assembly
185
Front Brake Caliper: Caliper Bracket Disassembly
186
Front Brake Caliper: Caliper Bracket Assembly/Installation
186
Rear Fender Overview
187
Exhaust Pipe
188
Ignition System Overview
189
Ignition System: Service Information
190
Ignition System: Specifications
190
Ignition System: Troubleshooting
190
Ignition Coil: Removal
191
Ignition Coil: Inspection
191
Ignition Coil: Installation
192
CDI Unit: Inspection
192
Alternator Exciter Coil
193
Pulse Generator: Inspection
193
Pulse Generator: Removal
193
Pulse Generator: Installation
193
Ignition Timing
194
Battery/Charging System Overview
195
Battery/Charging System: Troubleshooting
196
Battery/Charging System: Specifications
196
Battery: Removal
197
Battery: Specific Gravity Test
197
Battery Charging System: Leakage Inspection
198
Charging System Inspection
199
Alternator Output Test
199
Charging Output Specifications
199
Alternator: Stator Coil Inspection
200
Voltage Regulator/Rectifier
200
Electrical Starter System Overview
201
Electrical Starter System: Service Information
202
Electrical Starter System: Specifications
202
Electrical Starter System: Troubleshooting
202
Starter Idle Gears: Removal
203
Starter Idle Gears: Inspection
203
Starter Clutch/Driven Gear
203
Starter Clutch/Driven Gear: Inspection/Assembly
204
Starter Clutch/Driven Gear: Installation
205
Starter Motor: Removal/Disassembly
206
Starter Motor: Brush Inspection
207
Starter Motor: Commutator Inspection
207
Starter Motor: Assembly/Installation
208
Starter Relay Switch
208
Clutch Switch Diode
208
Light/Switches/Instrument: Service Information
209
Light/Switches/Instrument: Specifications
209
Light/Switches/Instrument: Troubleshooting
209
Brake and Taillight Warning System
210
Bulb Replacement: Headlight
211
Bulb Replacement: Instruments
211
Tail/Brake Light
212
Turn Signal
212
Instruments: Removal
212
Instruments: Assembly/Installation
213
Ignition Switch: Inspection
213
Ignition Switch: Removal/Disassembly
214
Handlebar Switches
215
Brakelight Switches: Front
216
Brakelight Switches: Rear
216
Clutch Switch
217
Brake and Taillight Sensor: Inspection
217
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
Troubleshooting: Poor Handling
221

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Honda XBR500 Shop Manual (222 pages)

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