CBX Eng 1

SHOP MANUAL
[t1;~I
.---------IMPORTANT SAfETY NOTlCE - -- - -- ---,
Indicates a strong possibility of severe personal injury or loss of life if instructions are not followed.
CAUTION: Indicates a possibility of personal injury or equipment damage if instructions are not followed
NOTE: Gives helpful information.
Detailed descriptions ot standard workshop procedures, safety principles and service operations are not included. It is
important to note that this manual contains some warnings and cautions against some specific service methods which
could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe. Please understand
that those warnings could not cover all conceivable ways in which service, whether or not recommended by Honda might
be done or of the possible hazardous consequences of each conceivable way, nor could Honda investigate all such ways.
Anyone using service procedures or tools, whether or not recommended by Honda must satisfy himself thoroughly that
neither personal safety nor vehicle safety will be jeopardized by the service method or tools selected.
HOW TO USE THIS MANUAL CONTENTS
Follow the Maintenance Schedule recommenda-
GENERAL INFORMATION
tions to ensure that the vehicle is in peak operat-
ing condition and the emission levels are within
the U.S. Environmental Protection Agency LUBRICATION
standards. Performing the first scheduled main-
tenance is very important. It compensates for MAINTENANCE
the initial wear that occurs during the break-in
period. FUEL SYSTEM
Sections 1 through 3 apply to the whole motor- ENGINE REMOVAl/INSTALLATION

cycle, while sections 4 through 19 describe parts
of the motorcycle, grouped according to loca- CYLINDER HEAD/VALVE
tion.
CYLINDER/PISTON
Find the section you want on this page, then
turn to the table of contents on page 1 of that ~ ~=================================
CLUTCH (Includes removal of pulse generator)
section. "~ ~==============================~
Most sections start with an assembly or system GEAR SHIFT LINKAGE
illustration, service information and trouble-
shooting for the section. The subsequent pages CRANKCASE
give detailed procedures.
TRANSMISSION/OIL PUMP
If you are not familiar with this motorcycle,
read the TECHNICAL FEATURES in section CRANKSHAFT/PRIMARY SHAFT
20.
FRONT WHEEl/SUSPENSION
If you don't know the source of the trouble, go en
en
to section 21, TROUBLESHOOTING. en
«
~
REAR WHEEl/SUSPENSION
This Shop Manual is based on the 1981 model. u
HYDRAULIC BRAKE
Refer to Section 22 for 1982 service informa-
tion.
BATTERY/CHARGING SYSTEM
ALL INFORMATION, ILLUSTRATIONS, ~ ~================================
U IGNITION SYSTEM
DIRECTIONS AND SPECIFICATIONS IN-
CLUDED IN THIS PUBLICATION ARE ~ ~=================================
U ELECTRIC STARTER
BASED ON THE LATEST PRODUCT IN- w
FORMATION AVAILABLE AT THE TIME ~ ~=================================
w
OF APPROVAL FOR PRINTING. HONDA SWITCHES
MOTOR CO., LTD. RESERVES THE RIGHT
TO MAKE CHANGES AT ANY TIME WITH- TECHNICAL FEATURES
OUT NOTICE AND WITHOUT INCURRING
ANY OBLIGATION WHATEVER. TROUBLESHOOTING
NO PART OF THIS PUBLICATION MAY '82 CBX ADDENDUM

BE REPRODUCED WITHOUT WRITTEN
PERMISSION.
HONDA MOTOR CO., LTD.

SERVICE PUBLICATIONS OFFICE
Date of Issue: May, 1981

© HONDA MOTOR CO., LTD.
~ HONDA
2 GENERAL INFORMATION ~ CIJ ;p3
MODEL IDENTIFICATION
The frame serial number is stamped on tile right side of The vehicle identification number (VIN) is on the left
the steering head. side of the steering head.
8422-08
The engine serial number is stamped on the top of the The carburetor identification number is on the left of
crankcase. the carburetor body.

1-0 © HONDA MOTOR CO. , LTD .
HONDA
u/;E 1. GENERAL INFORMATION 3
GENERAL SAFETY 1-1 TOOLS 1-5

SERVICE RULES 1-1 WIRING DIAGRAM 1-7
SPECI FICATIONS 1-2 CABLE & HARNESS ROUTING 1-8
TORQUE VALUES 1-4 EMISSION CONTROL SYSTEM 1-10
GENERAL SAFETY
If the engine must be running to do some work, make • The battery electrolyte contains sUlfuric acid. Protect
sure the area is well-ventilated. Never run the engine your eyes, skin and clothing. In case of contact, flush
in a closed area. The exhaust contains poisonous thoroughly with water and call a doctor if your eyes
carbon monoxide gas. were exposed.
• The battery generates hydrogen gas which can be
highly explosive. Do not smoke or allow flames or
Gasoline is extremely frammable and is explosive sparks near the battery, especially while charging it.
under certain conditions. Do not smoke or allow
flames or sparks in your working area.
SERVICE RULES
1. Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalent. Parts that do not meet HONDA's
design specifications may damage the motorcycle.
2. Use the special tools designed for this product.
3. Install new gaskets, a-rings, cotter pins, lock plates, etc. when reassembling.
4. When torquing bolts or nuts, begin with larger-diameter or inner bolt first, and tighten to the specified torque diagonally,
unless a particular sequence is specified.
5. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.
6. When installing a new oil seal, make sure that the sealing lip is lubricated with grease. If an oil seal and related parts have
been washed, apply proper grease to the lip of the oil seal.
7. After reassembly, check all parts for proper installation and operation.
8. Use only metric tools when servicing this motorcycle. Metric bolts, nuts, and screws are not interchangeable with English
fasteners. The use of incorrect tools and fasteners may damage the motorcycle.

© HONDA MOTOR CO., LTD . 1-1
~ HONDA
4 GENERAL INFORMATION ~ CfJ iP-:1
SPECIFICATIONS
ITEM
DIMENSIONS Overall length 2365 mm (93.1 in)
Overall width 780 mm (30.7 in)
Overall height 1360 mm (53.5 in)
Wheelbase 1535 mm (60.4 in)
Seat height 810mm (31.9in)
Foot peg height 335 mm (13.2 in)
Ground clearance 155 mm ( 6.1 in)
Dry weight 287 kg (633 Ib)
FRAME Type Diamond
Front suspension, travel Telescopic air forks 160 mm (6.3 in)
Rear suspensi on, travel Swingarm 105 mm (4.1 in)
Front ti re size 3.50V19 (4PR)
Rear tire size 130/90V18
Up to 90 kg Front : 250 kPa (2.5 kg/cm 2 ,36 psi)
Cold tire (200 Ibs) load Rear 250 kPa (2.5 kg/cm 2 , 36 psi)
pressures Up to vehicle Front : 250 kPa (2.5 kg/cm 2 , 36 psi)
capacity load Rear 290 kPa (2.9 kg/cm 2 , 41 psi)
F. brake, I ining swept area Double disc brake, 22 cm 2 x 4 (3.4 sqin x 4)
R. brake, lining swept area Single disc brake, 22 cm 2 x 2 (3.4 sqin x 2)
Fuel capacity 22.0 liters (5.8 US gal)
Fuel reserve capacity 3.0 liters (0.8 US gal)
Caster angle 62°30 ,
Trail 120 mm (4.7 in)
Front fork oil capacity 345 cc (11.7 ozs)
Front fork ai r pressure 70 ± 20 kPa (0.7 ± 0.2 kg/cm 2 , 10 ± 3 psi)
Rear suspension oil capacity 618 cc (20.9 ozs) at disassembly
Rear suspension air pressure 200-400 kPa (2.0-4.0 kg/cm 2 , 28-57 psi)
ENGINE Type Air cooled 4-stroke

Cylinder arrangement Vertical parallel six
Bore and stroke 64.5 x 53.4 mm (2.54 x 2.10 in)
Displacement 1047 cc (63.89 cu in)
Compression ratio 9.3: 1
Valve train Chain driven DOHC 4 valve/cylinder
Maximum horsepower 100 BHP/9,OOO rpm
Maximum torque 8.5 kg-m (60.8 ft-lb)17,500 rpm
Oil capacity 5.5 liters (5.8 US qt) a'fter disassembly
4.0 liters (4.2 US qt) after draining
Lu bricati on system Wet sump dual pump with oil cooler
Air filtration Paper
Cylinder compression 12.0± 1.0 kg/cm 2 (170± 14 psi)
Intake valve Opens 5° (BTDC) at 1 mm lift, 78° (BTDC) at 0 lift
Closes 35° (ABDC) at 1 mm lift, 110° (ABDC) at 0 lift
Exhaust valve Opens 40° (BBDC) at 1 mm lift, 94° (BBDC) at 0 lift
Closes 5° (AT DC) at 1 mm lift, 71° (ATDC) at 0 lift
Valve overlap 149°
~~:}
Valve clearance (Cold)
0.06-0.13 mm (0.002-0.005 in)
Engine weight 108kg(238.1Ib)

Idle speed 900 ± 100 rpm

1-2 © HONDA MOTOR CO., LTD .
~ HONDA
~ UJi'£5. GENERAL INFORMATION 5
ITEM
CARBURETION Carburetor type VB 28 mm (1.1 in) venturi bore
Identification number VB64A
Pilot screw Refer to page 4-28
Float level 15.5 mm (0.61 in)
DRIVE TRAIN Clutch Wet, multi-plate
Transm issi on 5·speed constant-mesh
Primary reduction 2.269
Gear ratio I 2.438
Gear ratio II 1.750
Gear ratio III 1.391
Gear rati 0 I V 1.200
Gear ratio V 1.037
Final reduction 2.333 (18/42)
Gear shift pattern Left foot operated return system 1-N-2-3-4-5
ELECTRICAL Ignition Transistorized
0
Ignition timing "F" mark 10 BTDC static
0
Full advance 41 BTDC at 8,000 rpm
Firing order 1-5-3-6-2-4
Starting system Electric starter
Alternator Three phase Alternator 350 W/5,000 rpm
Battery capacity 12V -18AH
Spark plug For cold climate For extended
( ): Canada Model below Standard high speed
USA Model with radio installed. SOC,41°F riding
NO NGK NO NGK NO NGK
X22ES-U 07EA X24ES·U 08E'A X27ES-U 09EA

X22ESR· (OR7ES) (X24ESR (DR8ES (X27ESR (OR8ES)
U) ·U) -l) -U)
Spark plug gap 0.6-0 .7 mm (0.024-0.028 in);

LIGHTS Headlight (high/low beam) 60/55W H4 BULB (Philips 12342/99, or equivalent)
Tail/stopl ight 8/27W, 3/32 cp SAE NO. 1157
Turn signal Front 8/23W, 3/32 cp SAE NO.1 034
Rear 23W, 32 cp SAE NO. 1073
Speedometer light 3.4W, 2 cp SAE NO. 57
Tachometer light 3.4W, 2 cp SAE NO. 57
Neutral indicator 3.4W, 2 cp SAE NO. 57
Turn signal indicator 3.4W, 2 cp SAE NO. 57
High beam indicator 3.4W, 2 cp SAE NO. 57
Rear suspension air pressure warning light 3AW, 2~p SAE NO. 57
Running light 8W, 3 cp SAE NO. 1034
Date of Issue : May, 1981

© HONDA MOTOR CO ., LTD. 1-3
~ HONDA
6 GENERAL INFORMATION ~~ U1 i§3
TORQUE VALUES
• ENGINE
Item Q'ty Thread Dia (mm) Torque N.m (kg-m, ft-Ib) Remarks
Cylinder head cover 8 6 8-12 (0.8-1.2, 6- 9)

Cam holder 32 6 12-16 (1.2-1.6, 9-12)
Cylinder head 12 10 33-35 (3.3-3.5, 24-25)
Cylinder head 4 8 19-21 (1.9-2.1,14-15)
Cam sprocket 4 7 14-18 (1.4-1.8,10-13)
Spark plug 6 - 12-16 (1.2-1.6, 9-12) { Apply molybd,num d;,ul-
Crankcase - 8 23-27 (2.3-2.7, 17-20) fide base grease to threads
A.C. generator 1 14 36-44 (3.6-4.4, 26-32) and bottom of bolts
Primary shaft 1 22 40-50 (4.0-5.0, 29-36)
Mainshaft 1 25 45-55 (4.5-5.5,33-40)
Drive sprocket 1 10 50-54 (5.0-5.4,36-39)
Connecting rod nut 12 8 30-34 (3.0-3.4, 22-25)
Oil filter center bolt 1 20 27-33 (2.7-3.3, 20-24)
Oil pressure switch 1 - 15-20 (1.5-2.0,11-14) Apply THREE-BOND
Neutral switch 1 10 11-15 (1.1-1.5, 8-11)
Oil drain bolt 1 12 28-32 (2.8-3.2, 20-23)
Oil pipe 1 8 18-22 (1.8-2.2,13-16)
Oil pipe 1 10 20-24 (2.0-2.4, 14-17)
• CHASSIS
Item Q'ty Thread Dia (mm) Torque N.m (kg-m ft·lb) Remarks
Steering stem nut 1 24 80-120 (8.0-12.0, 58-87)

Steering handlebar 2 8 28-32 (2.8-3.2, 20-23)
Front fork bridge 2 7 9-13 (0.9-1.3, 7- 9)
Front fork cap bolt 2 34 15-30 (1.5-3.0,11-22)
Front axle nut 1 12 55-65 (5.5-6.5, 40-47)
Front/rear brake disc 10 8 27-33 (2.7-3.3, 20-24) UBS
Brake hose bolt 5 10 25-35 (2.5-3.5, 1B-25)
Rear axle 1 18 85-105 (8.5-10.5, 62-76) "U" nut
Final driven sprocket 5 12 80-100 (8.0-10.0, 58-72) UBS
Swingarm pivot nut 1 16 80-110 (8.0-11.0, 58-80) "U" nut
Seat strap 2 6 8-9.5 (0.8-0.95, 6- 7)
Engine hanger nut 3 14 90-100 (9.0-10.0, 65-72) "U" nut
Air cleaner inlet duct 2 5 3- 6(0.3-0.6, 2- 4)
Steering stem adjusting nut 1 26 11-13 (1.1-1.3, 8- 9)
Rear suspension link bolt
and nut - 10 40-50 (4.0-5.0, 29-36)
Torque specifications Iisted above are for important fasteners.

Others should be tightened to the standard torque values below.
STANDARD TORQUE VALUES
Type Torque N.m (kg-m ft·lb) Type Torque N.m (kg-m, ft-Ib)
5 mm bolt, nut 4.5-6.0 (0.45-0.6, 3.5-4.5) 5 mm screw 3.5-5.0 (0.35-0.5, 2.5-3.6)

6 mm bolt, nut 8-12 (0.8-1.2, 6- 9) 6 mm screw 7-11 (0.7-1.1, 5- 8)
8 mm bolt, nut 18-25 (1.8-2.5, 13-18) 6 mm flange bolt, nut 10-14 (1.0-1.4, 7-10)
10 mm bolt, nut 30-40 (3.0-4.0, 22-29) 8 mm flange bolt, nut 24-30 (2.4-3.0, 17-22)
12 mm bolt, nut 50-60 (5.0-6.0,36-43) 10 mm flange bolt, nut 30-40 (3.0-4.0, 22-29)
14 mm bolt, nut 90-100 (9.0-10.0, 65-72)

GENERAL INFORMATION 7
TOOLS
• SPECIAL
Tool Name Part No. O'ty Ref. page
Oil seal driver 07965-MA10100 1 14-13

Oil seal driver attachment 07965-MA 10200 1 14-13
Seal driver 07947-4630100 1 13-33
Vacuum gauge set 07504-0020000 1
(H/C No.4 7978) 1 } 3-8
or M937B-021-XXXXX
Oil pressure gauge 07506-3000000 1 2-3
Snap ring pliers 07914-3230001 1 15-1,14-14
Steering stem socket 07916-3710100 1 13-38
6 mm hollow set wrench 07917-3230000 1 13-30
Race bearing remover 07946-3710500 1 13-37
Steering stem driver 07946-3710600 1 13-37
Bearing driver attachment 07946-3710700 1 13-38
Piston base 07958-2500000 1 7- 8
Valve guide reamer (5.5 mm) 07984-2000000 1 6-14,6-16
Oil pressure gauge attachment 07510-4220100 1 2-3
Carburetor throttle wrench 07908-4220100 1 3-9,4-14
07908-4600000 1 3-9
Carburetor pilot screw wrench 07908-4220200 or 1
07908-4220201 1 } 4-29
Lock nut wrench 07916-4220000 1 8-4
Primary gear holder 07924-4250000 1 8-7
Piston ring compressor 07954-4220000 1 7-8
Valve lifter holder 07964-4220002 or 1 l 3-11,3-12
M9501-277-94752 (USA only) 1 j
Degree wheel 07974-4220000 or 1
07974-4220002 } 3-5
Lifter hole protector 07999-4220000 1 6-12,6-18
Lock nut wrench 07908-4690001 1 14-22
Retainer wrench 07910-4690100 or 1
KS·HBA-08-469 (USA only) 1 14-20
Bearing driver (needle bearing) 07946-4690100 or 1
07946-3710300 1 14-19
Bearing driver (angular bearing) 07946-4690200 1 14-20
Dust seal driver 07948-4690100 1 14-20
Driver handle 07949-3710000 1 14-18,14-19
Pin spanner, 55 mm 07902-4220000 1 12-18
Primary shaft holder 07924-6340300 1 12-18
Steering race remover 07953-4250002 1 13-38

~ HONDA
8 GENERAL INFORMATION ~ [JJ;[1
• COMMON
Alternate Tools
Tool Name Part No. O'ty Ref. Page
(Common tool--)o Special tool)
Float level gauge 07401-0010000 1 4-11

Retainer wrench attachment 07710-0010100 1 07910-2830000&07910-3600000 14-5,14-8
Retainer wrench attachment 07710-0010300 1 Bearing retainer wrench
07910-3230101 13-23, 13-26
Retainer wrench body 07710-0010400 1 13-23, 13-26
Lock nut wrench socket 07716-0020202 1 13-26

(26 x 30 mm)
Extension bar 07716-0020500 1 Commercially available 13-26
Universal holder 07725-0010101 1 Flywheel holder 07923-0400000 8-3
Valve guide remover (5.5 mm) 07742- 0010100 1 Valve guide driver 07942-3290100 6-15,6-16
Attachment (32 x 35 mm) 07746-0010100 1 Bearing driver 0794 5-4150200 16-8,16-9
Attachment (37 x 40 mm) 07746-0010200 1 Bearing driver 07946-2860200 12-15,16-9
Attachment (42 x 47 mm) 07746-0010300 1 Bearing driver 07946-9350200 13-25
Attachment (52 x 55 mm) 07746-0010400 1 Bearing driver 07946-9370100
}12-15,14-7
Bearing driver 07946-3710200
Attachment (62 x 68 mm) 07746-0010500 1 Bearing driver 07946-3600000 14-7
Driver 07746-0030100 1 11-3,12-15
Attachment (25 mm) 07746-0030200 1 12-15
Attachment (30 mm) 07746-0030300 1 11-3
Pilot (15 mm) 07746-0040300 1 13-25
Pilot (20 mm) 07746-0040500 1 14-7
Pilot (25 mm) 07746-0040600 1 12-14,12-15,
14-7
Driver (A) 07749-0010000 1 Dri ver 07949-6110000 12-14,13-25,
14-7, 14- 20,
16-8,16- 9
Valve spring compressor 07757-0010000 1 Valve spring compressor
07957-3290001 6-12,6-18
Date of Issu e: May , 1981

1-6 © HONDA MOTOR CO ., LTD .
~ HONDA
~ [J1 :t""3 GENERAL INFORMATION 11
DETAIL IGNITION COIL

PLUG
NO.2
L. OIL R.OIL
HOSE HOSE
CDI CONTROL UNIT
TURN SIGNAL PULSE GENERATOR

RELAY (MINI 6P WHT)
ALTERNATOR
(6P RED)
STARTER CABLE
REGULATOR/RECTIFIER

© HONDA MOTOR CO., LTD. 1-9
~ HONDA
12 GENERAL INFORMATION ~ [}1 ;p3
EMISSION CONTROL SYSTEM
The CBX is equipped with two Emission Control Systems.
EXHAUST EMISSION CONTROL SYSTEM
The exhaust emission control system is composed of a factory pre-set carburetor.

No. adjustment should be made except to the idle speed with the throttle stop screw.
CRANKCASE EMISSION CONTROL SYSTEM
The engine is equipped with a "Closed Crankcase System" to prevent crankcase emissions entering the atmosphere.
Blow-by gas is returned to the combustion chamber through the air cleaner and carburetor. Liquids are collected in the drain
tube.
Drain tube
Drain Plug
¢ = FRESH AIR
- BLOW-BY GAS
EMISSION CONTROL INFORMATION LAVEL
An Emission Control Information Label is located on the frame as shown. It contains basic tune-up specifications.
EMISSION CONTROL INFORMATION LABEL

HONDA
aJ :Q~ 13
MEMO
Date of Issue: May. 1981

© HONDA MOTOR CO ., LTD .
14 LUBRICATION
ENGINE LUBRICATION DIAGRAM
EXHAUST CAMSHAFT
PRIMARY
CHAIN
TENSIONER OIL FILTER
TRANSMI
MAINSHAFT
ON i~~~~
I~
~lIr=~........!. 01 L PUMP
OIL COOLER

2. LUBRICATION 15
SERVICE INFORMATION 2-1 OIL PRESSURE 2-3
TROUBLESHOOTING 2-1 OIL COOLER INSPECTION 2-3
ENGINE OIL LEVEL 2-2 OIL HOSE AND BOLT INSPECTION 2-4
ENGINE OIL & FILTER CHANGE 2-2 LUBRICATION POINTS 2-5
OIL STRAINER SCREEN CLEANING 2-3 DRIVE CHAIN 2-5
SERVICE INFORMATION
GENERAL INSTRUCTIONS
Oil pump: See Section 11
Oil pressure relief valve: See Section 11
SPECIFICATIONS
Oil capacity Approximately 4.0 liter (4.2 US qt) at change
5.5 liter (5.8 U.S. qt) at engine assembly
Recommended oil HONDA 4-stroke oil or equivalent API service classification-SE
General, all temperature SAE 10W-40
-20°C to +35°C (68°F to 95°F) SAE 10W-30
above -20°C (68°F) SAE 10W-40
above _10°C (50°F) SAE 20W-40, 20W-50
Oil pump delivery Right 36.5Iiters/min/4,000 rpm (38.6 qt/min/4,000 rpm)
Left 27.0 liters/min/4,000 rpm (28.5 qt/min/4,000 rpm)
Oil pressure (at oil pressure switch) 400-500 kPa
(4.5-5.0 kg/cm 2 , 64-71 psi)/4,000 rpm SO°C (176°F)
TOOLS
Special
Oil pressu re Gauge 07506-3000000
Oil Pressure Gauge Attachment 07510-4220100
TORQUE VALUES
Oil drain plug 28-32 N'm (2.8-3.2 kg-m, 20-23 ft-Ib) Pressure switch 15-20 N'm (1.5-2.0 kg-m, 11-14 ft-Ibl
Oil filter bolt 28-32 N' m (2.8-3.2 kg-m, 20-23 ft-Ib) Oil bolt (Cylinder head) 18-22 N-m (1.S-2.2 kg-m, 13-16 ft-Ib)
Oil pan bolt 8-12 N'm (0.8-1.2 kg-m, 6- 9 ft-Ib) Oil bolt (Crankcase) 20-24 N·m (2.0-2.4 kg-m, 14-17 ft-Ib)
TROUBLESHOOTING
Oil Level Too Low High Oil Pressure
1. External oil leaks 1. Pressure relief valve stuck closed
2. Worn piston rings 2. Plugged oil filter, gallery, or metering orifice
3. Worn valve guide or seal 3. Incorrect oil being used
Oil Contamination No Oil Pressure
1. Oil or filter not changed often enough 1. Oil level low
2. Head gasket faulty 2. Oil pump drive chain broken
3. Worn piston rings 3. Oil pump faulty
Low 0 il Pressure 4. Internal oil leakage
1. Oil level low
2. Pressure relief valve stuck open
3. Plugged oil pick-up screen
4. Oil pump worn
5. External oil leaks

© HONDA MOTOR CO ., LTD . 2-1
~HONDA
16 LUBRICATION ~- U!i §3
ENGINE OIL LEVEL

Run the engine and allow to idle for a few minutes.
Stop the engine and place the motorcycle on its
center stand. Check the oil level with the filler
cap/dipstick after a few minutes. Do not screw in
the cap when making this check. If the level is
below the lower level mark on the dipstick, fill to
the upper level mark.
Check the oil pressure warning light. This light

should go off when the engine starts.
If it does not, check the oil pump operation and/
or oil circuit .
ENGINE OIL & FILTER CHANGE

Warm the engine to normal operating temperature.
Stop the engine.

Place the motorcycle on its center stand.
Remove the oil filler cap. drain plug and oil filter
bolt and drain the oil.
Make sure that the sealing washer on the drain plug
and the a-rings on the oil filter bolt and oil filter
case are in good condition.
Replace the oil filter and install the oil filter bolt
and drain plug.
CAUTION
OIL FILTER BOLT DRAIN
Do not interchange the oil filter with those PLUG
for other models as it has a greater rate of
oil flow.
Fill the crankcase with 4. 0 lit (4.2 US qt) of the

recommended oil.
Reinstall the oil filler cap.

Start the engine and idle it for a few minutes.
Stop the engine.
Add the recommended oil to the upper level on

the dipstick.
Make sure that there are no oil leaks.
a-RINGS

LUBRICATION 17
OIL STRAINER CLEANING

NOTE
Perform this maintenance before filling the
engine with oil.
Remove the oil filler cap, drain plug and oil filter
bolt.
Remove the oil pan bolts and oil pan.
Remove and clean the oil strainer.
Install a new oil pan gasket and install the oil
strainer and oil pan.
Fill the crankcase with the recommended oil (Page
2-2).
OIL PRESSURE GAUGE PIN 07506-3000000
Connect the oil pressure gauge.

Check the oil level.
Warm the engine up to normal operating tempera·
ture (approximately 80° C= 176° Fl.
Check the pressure at 4,000 rpm.
STANDARD:
4S0-S00kPa (4.S-S.0 kg/cm 2 , 64-71 psi)
at 4,000 rpm and aooc (176°F)
NOTE
Before installing the pressure switch, apply a
liquid sealant to the thread.
ATTACHMENT PIN 07510-4220100

Check that the oil pressure warning light goes out.
If the oil pressure warning light stays on, stop the
engine immediately and determine the cause.
Also, touch the oil cooler.
OIL COOLER
It should be warm, indicating that oil is flowing
through it from the auxiliary oil pump.
OIL COOLER INSPECTION

Check for damage to the oil cooler core.
Clean the core if necessary.

~ HONDA
18 LUBRICATION ~ Ul:D
OIL HOSE AND BOLT INSPECTION TO CRANKCASE
Check for oil leaks at hose connections.

Check the oil hoses for deterioration. \
NOTE
• Install new sealing washers, if the hose
is removed.
• Install the oil with the oil orifice on the
crankcase side.
\
TO CYLINDER HEAD
Check that the oil orifice is not clogged.

2-4 © HONDA MOTOR CO., LTD.
~HONDA
~" at iQ3 LUBRICATION 19
LUBRICATION POINTS
-~
REAR SUSPENSION
MOUNTING BUSHING
_.unm
LE GRIP
....--.
_--Ull'IIi ----
CLUTCH, THROTTLE
AN CHOKE CABLES
CLUTCH AND BRAKE
LEVER PIVOT
SWINGARM
PI
SPEEDOMETER
AND TACHOMETER
CABLES
-~
STEERING
.,
HEAD BEARINGS
_ fiiHffi
SPEEDOMETER
DRIVE GEAR
WHEEL BEARINGS
DRIVE BRAKE REAR SIDE AND FOOT PEG
CHAIN PEDAL SUSPENSION CENTER STAND PIVOT
PIVOT LINKAGE PIVOT
DRIVE CHAIN
Clean the drive chain with kerosene and wipe dry .
CAUTION
Do not use a steam cleaner, high pressure
washers or solvents as these will damage
the O-rings.
Lubricate the drive chain with SAE 80 or 90 gear WIPE DRY

oil.
CAUTION
Do not use commercial aerosol chain lubri-
cants. They contain solvents which could SAE 80
damage the O-rings. OR SAE
90 GEAR 01 L
LUBRICATE
Date of Issue: May; 1981

~ HONDA
20 ~ [ij iP3
M EMO
Date of Issue: May, 198 1

© HONDA MOTOA CO ., LTD.
3. MAINTENANCE 21
SERVICE INFORMATION 3-1 ~CHASSIS~

MAINTENANCE SCHEDULE 3-2 DRIVE CHAIN 3-17
~ ENGINE ~ BATTERY 3-18
AIR CLEANER 3-3 BRAKE FLUID 3-18
CRANKCASE BREATHER 3-4 BRAKE PAD WEAR 3-19
FUEL LINES 3-4 BRAKE SYSTEM 3-19
SPARK PLUGS 3-4 BRAKE LIGHT SWITCH 3-20
IGNITION TIMING CHECK 3-5 HEADLIGHT AIM 3-20
SPARK ADVANCER 3-6 HEADLIGHT BULB REPLACEMENT 3-21
THROTTLE OPERATION 3-7 CLUTCH FREE PLAY 3-22
CARBURETOR SYNCHRONIZATION 3-8 SIDE STAND 3·23
CHOKE MECHANISM 3-10 SUSPENSION 3-24
IDLE SPEED 3·10 WHEELS 3·25
VALVE CLEARANCE 3·11 STEERING HEAD BEARINGS 3·25
CAM CHAIN 3-15 NUTS, BOLTS, FASTENERS 3·25
COMPRESSION TEST 3-16
SERVICE INFORMATION
GENERAL INSTRUCTIONS TOOLS
Engine oil level check See page 2-2 Special
Engine oil change See page 2-2 Valve lifter holder 07964-4220002 or
Oil strainer screen cleaning See page 2-3 M9501-277-94052 (USA only)
Carbo throttle wrench 07908-4220100
07908-4600000
Degree wheel 07974-4220001
Vacuum gauge 07404-0020000 or
SPECI F ICATI ON M937B-021-XXXXX (USA only)
< ENGINE> <CHASSIS>
Spark plug gap 0.6-0.7 mm (0.024-0.028 in) Drive chain free play 15-25 mm (5/8 in)
Spark plug type Clutch free play 10-20 mm (3/8-3/4 in)
Tire
U.S.A. model Cold tire
250 (2.5, 36)
Front
pressure
Rear 250 (2.5,36)
For cold climate For extending kPa
Standard At maximum load 290 (2.9,4.1)
below 5°C (41°F) high speed riding (kg/em', psi)
NO NGK NO NGK NO NGK Vehicle

capacity load 175 kg (385 Ibs)
X22ES-U D7EA X24ES-U D8EA X27ES-U D9EA limit
(X22ESR-U) (DR7ES) (X24ESR-U) (DR8ES-L) (X27ESR-U) (DRBES)
Tire size Front 350-V19 (4PR)
Rear 130/90V18
Type in parenthesis ( ) for Manufacturer
CANADA model or U.S. model ND: Nippondenso Co., Ltd. Tira brand Front GOLD SEAL F11 (DUNLOP)
with radio installed. NGK: NG K Spark Plug Co., Ltd. (Tubeless only) MAG. MOPUS.s706
(BR I DGESTON E)
Ignition timing Initial 10° BTDC (Static) GOLD SEAL K127 (DUNLOP)
Raar
Valve clearance: IN. and EX. 0.06-0.13 mm (0.0022-0.005 in) MAG. MOPUS-G5OB
Idle speed 900 ± 100 rpm (BRIDGESTONE)
Synchronization vacuum Difference between each
cylinder 40 mm Hg (1.6 in Hg) TORQUE VALUES
Compression 1200 ± 100 kPa Front axle holder nut 18-25 N·m (1.8-2.5 kg-m,
(12 ±1 kg/cm 2 , 170 ± 14 psi) 13-18 ft-Ib)
Firing order 1-5-3-6-2-4 Rear axle nut 85-105 N·m (8.5-10.5 kg-m,
62-76 ft-Ib)
~HOND.A
22 MAINTENANCE ~~ (]I if]
MAINTENANCE SCHEDULE
Perform the PR E-R I DE I NSPECTION in the Owner's Manual at each scheduled maintenance_
I : INSPECT AND CLEAN, ADJUST, LUBRICATE, OR REPLACE IF NECESSARY,
C: CLEAN A: ADJUST
R: REPLACE L: LUBRICATE
~
WHICHEVER
COMES
I ODOMETER READING (NOTE 3)
00~~~~
FIRST , ~ ?' ~ ?' . { ?' ~ l: ..{ l: ..{
ITEM ,f~'"
~.
~#.., Cb~
".~~
~l ....",~i<
~"
<i>{~ ~I".~
.... ~ ~
Refer to
EVERY
* FUEL LINES I I I I I Page 3-4
* TH ROTTLE OPE RATION I I I I I I Page 3-7
* CARBURETOR CHOKE I I I I I Page 3-10
en
:E AIR CLEANER NOTE 1 R R Page 3-3
w
I- CRANKCASE BREATHER NOTE 2 C C C C C Page 3-4
CI SPARK PLUGS R R R R R Page 3-4
w
I- * VALVE CLEARANCE I I I I I I Page 3-1 1
<{
...J
w * IGNITION TIMING I I I I I I Page 3-5
0:
Z
ENGINE OI L YEAR R R R R R R Pages 2-2
0 3-8
enen ENGINE OIL FILTER YEAR R R R R R R Page 2-2
:E * ENGINE OIL SCREEN C Page 2-3
w
* CAM CHAIN TENSION A A A
,
A A A Page 3-15
*
*
CARBURETOR-SYNCHRONIZE
CARBURETOR -IDLE SPEED
I
I
I
I
I
I I
I
I ,
I Page 3-8
Page 3-10
DR IVE CHAIN I, L EVERY 300 mi. (500 km) Pages 2-5,
3-17
en BATTERY MONTH I I I I I I Page 3-18
::2:
w MONTH I
I- BRAKE FLUID I I I *R I I Page 3-18
2 YEARS *R
CI
w BRAKE PAD WEAR I I I I I Page 3-19
~
...J
BRAKE SYSTEM 1 I I I I I Page 3-19
w * BRAKE LIGHT SWITCH I I I I I I Page 3-20
0:
Z * HEADLIGHT AIM I I I I I I Page 3-20
0
en CLUTCH I I I I I I Page 3-22
!!? SIDE STAND I I I I I Page 3-23
:E
~ * SUSPENSION I I I I I I Page 3-24
Z
0 * NUTS, BOLTS, FASTENERS I J I I I I Page 3-25
z
** WHEELS I I I I I I Page 3-25
** STEERING HEAD BEARING I I I Page 3-25
* SHOULD BE SERVICED BY AN AUTHORIZED HONDA DEALER, UNLESS THE OWNER HAS PROPER TOOLS AND
SERVICE DATA AND IS MECHANICALLY QUALIFIED,
** IN THE INIEREST OF SAFETY, WE RECOMMEND THESE ITEMS BE SERVICED ONLY BY AN AUTHORIZED
HONDA DEALER.
NOTES : 1. SERVICE MORE FREQUENTLY WHEN RIDING IN DUSTY AREAS.
2. SERVICE MORE FREQUENTLY WHEN RIDING IN RAIN OR AT FULL THROTTLE (USA ONLY).
3. FOR HIGHER ODOMETER READINGS, REPEAT AT THE FREQUENCY INTERVAL ESTABLISHED HERE.

MAINTENANCE 23
AIR CLEANER
Remove the seat by loosening the nuts on the sides
of the seat and lifting the seat to the rear.
Lift the air cleaner cover clip up.

Remove the two air cleaner cover screws and the
air cleaner cover.
SCREW COVER
ELEMENT SET SPRING

Remove the air cleaner set spring.
Replace the element with a new one according to
the maintenance schedule.
Install the holder, set spring and air cleaner cover.
When replacing the seat, align the grooves with
the lugs and push down firmly. Install the nuts
and tighten them to the recommended torque.
Torque specification: 3-4 N'm
(3.0-4.0 kg-m, 22-29 ft-Ibsl
Lift the seat to make sure the latches are secure.

~HONDA.
24 MAINTENANCE U!iP;]
CRANKCASE BREATHER
For U.S.A. model
Remove the plug from the drain tube to empty

any deposits.
Reinstall the drain plug.
NOTE
Service more frequently when ridden in rain
or at fully throttle, or if the deposit level can
be seen in the transparent section of the drain
tube.
For Canada model

<U.S.A. model>
Squeeze to open the lower end of the drain tube.
Remove any oil or water which may have accumu-
lated.
CAUTION
Check the drain tube for clogging and routing.
FUEL LINES
Check, the fuel lines for deterioration, damage,
or leakage. Replace any parts which show deteriora-
tion, damage or leakage.
SPARK PLUGS
Disconnect the spark plug caps. RECOMMENDED SPARK PLUG ) Canada model
Clean any dirt from around the spark plug bases. US. optional
Remove and discard the spark plugs. For cold climate For extending
Standard
below 50 C' (41 0 F) high speed riding
ND NGK ND NGK ND NGK
X22ES-U D7EA X24ES-U D8EA X27ES-U D9EA
(X22ESR-U) (DR7ES) (X24ESR-U) (DR8ES-L) (X27ESR-U) (DR8ES)

~HONDA
~ U1 iQ
3 MAINTENANCE 25
SIDE ELECTRODE
Measure the new spark plug gaps using a wire-type Check : Gap
feeler gauge. Deposit
SPARK PLUG GAP: 0.6-0.7 mm ~~~=nr Wear
0.6-0.7 mm (0.024-0.028 in) (0.024-0.028 inj
Adjust by bending the side electrode carefully.
With the plug washer attached, thread the new

spark plugs in by hand to prevent crossthreading.
Check: Sealing
Tighten the spark plugs another 1/2 turn with a Damage
spark plug wrench to compress the plug washer.
TORQUE:
12-14 N·m (1.2-1.4 kg-m, 9-12 ft-Ib)
Check: Cracks
Connect the spark plug caps.
NOTE
First tighten the spark plug finger tight, then
tighten 1/2 turn with a spark plug wrench.
IGNITION TIMING CHECK

• DYNAMIC
NOTE
Drain oil from engine for this inspection
method. Place an oil drain pan under the right
crankshaft end.
Remove all spark plug caps and either No . 6 spark

plug or No.1 spark plug.
Connect the removed plug with the spark plug cap
and ground the plug to the cylinder head.
Remove the right crankshaft cap.

Connect a stroboscopic timing light to the grounded
high tension wire.
Operate the starter motor while aiming the timing
light at the right crankshaft end.
The "F" mark should align with the front crankcase "T" MARK INDEX LINE
mating surfaces.
ADJUSTMENT
Remove the pulse generator cover.
Adjust by loosening the three pulse generator base
plate locking screws and rotating the plate.
Turn the base plate counterclockwise to advance
and turn it clockwise to retard the timing.
Tighten the base plate locking screws and recheck
the timing.
Install the removed parts in the reverse order of

disassembly. Add the correct amount of engine oil.
"F" MARK

~ HONDA.
26 MAINTENANCE ~ Uf;£{
ALTERNATIVE METHOD
• STATIC
NOTE
(ji©TO
R
1-6 PU LSE
This check can be done with oil in the engine .
Remove the right crankcase cap and pulse generator

cover .
Rotate the crankshaft clockwise and align the "F"

mark with the crankcase front upper and lower
mating surface .
Either No.6 or No.1 piston must be near TDC of

the compression stroke .
SCREW
The timing is correct if the narrow projection of the
1,6 pulse generator is aligned with the rotor tooth.
If the ign ition timing is incorrect, loosen the three

pulse generator base plate locking screws.
Rotating the base plate counterclockwise will
advance the ignition timing.
Rotating the base plate clockwise will retard the

ignition timing.
Tighten the base plate locking screws and recheck

the ignition timing.

disassembly.
SPARK ADVANCER
NOTE
• Check the spark advancer only if engine
performance difficulties occur.
• A high quality stroboscopic timing light
designed for transistorized ignition sys- I
tems must be used. It should also be DEGREE WHEEL
capable of accurate operation at 9,000 X~~'4!t"Irr--tt 07974-4220002
rpm. ROTO R TOOTH
Remove the pulse geQerator cover. INITIAL MARK

Remove the rotor bolt and install the special degree
I1
wheel. (07974-4220002). TIMING LIGHT
Align the initial mark on the degree wheel with the
rotor tooth and tighten the rotor bolt.
Connect a timing light to the NO. 6 high tension 2,300- 2,500 rpm FULL ADVANCE
wire. 5,600-7,000 rpm

MAINTENANCE 27
Start the engine. Vl

C1l
Check that the initial mark remains aligned with ~
C)
the rotor tooth at idle. C1l
Increase engine speed and check that the 23.5°

o 26.5° /2,300 rpm
mark aligns with the rotor tooth at 2,300-2,500 ~ \ 24.5° /5,200 rpm
C
r -- __\~
rpm. to
a:: 31°17,000 rpm
And then check that the 31° mark aligns with the C1l
rotor tooth at 5,600-7,000 rpm. ~

::J
U r'.- - -- - -i._- 21.5° /6,400 rpm
C1l
C,)
C
23.5° /2,500 rpm
CAUTION to
>
"0
Do not allow engine speed to exceed 8,000 <t
rpm or engine damage may result.
Replace the advancer assembly if it is not function -

ing properly.
1
Install the pulse generator cover. ----1.~ Engine rpm
THROTTLE OPERATION
Make sure that there is no deterioration, damage,
or kinks in the throttle cables, and that the throttle
2-6 mm (1/8-1/4 in)
grip free play is 2-6 mm (1/8-1/4) on the outer
edge of the throttle grip flange. Replace any dam-
aged parts.
Check for smooth throttle grip rotation from fully

closed to fully open in all steering positions and
that it automatically returns to "fully closed"
when released.
Adjust if necessary.
Major adjustments are made at the middle adjuster.

Remove the fuel tank.
To adjust, loosen the grip play adjuster lock nut and
turn the adjuster.
Tighten the lock nut.
Minor adjustments are performed at the upper

adjuster.
Recheck throttle operation .

HONDA
28 MAINTENANCE UJ ;p3
CARBURETOR SYNCHRONIZATION
NOTE
Perform carburetor synchronization with
engine at normal operating temperature,
transmission in neutral and motorcycle on the
center stand.
Remove the legshield.

Remove the seat and air cleaner inlet duct.
Turn the fuel valve OFF and remove the fuel tube
and fuel tank.
Prepare a longer fuel tube and reconnect it to the
fuel tank and carburetor.
Position the fuel tank higher than its normal posi-

tion.
Remove plugs from the carburetor intake parts
(except No.3 carburetor) and install long adapters
to inner carburetors and short adapters to outer
carburetors.
Connect vacuum gauges.
Start the engine and adjust the idle speed to 900

± 100 rpm. Clip the vacuum tube for the fuel auto
cock and disconnect the vacuum tube from the
plug.
Remove the plug from carburetor 3 and install the
long adapter, then connect the vacuum gauge.
Make sure that the maximum difference in vacuum
readings is 40 mmHg (1.6 inHg) or less.
VACUUM GAUGE 07404-0020000 or
M937B-021-XXXXX (USA only)

~ HONDA
~ Ul:E MAINTENANCE 29
TO NO.4 CARBURETOR
ADJUSTMENT
NOTE
The No.4 carburetor cannot be adjusted;
it is the base carburetor.
Start the engine and adjust the idle speed.

IDLE SPEED: 900 ± 100 rpm
Make sure that the maximum difference in vacuum
readings does not exceed 40 mm Hg (1.6 in Hg).
NO.1 ADJUSTING
SCREW
Adjust by loosening the locknuts and turning
the adjusting screws with the special tool Carburetor
Throttle Wrench. Adjust to a maximum difference
in vacuum readings between carburetors of less than
40 mm Hg (1.6 in Hg).
Adjust in the following order:
CARBURETOR
No. 5~No. 6~
No. 3~No. 2~No. 1
NOTE
Use carbo throttle wrench (07908-4600000)
to adjust the No.5 and No . 6 carbu retors.
Hold the adjusting screws and tighten the lock

nuts. LOCK NUT
CARB. THROTTLE WRENCH

00
Recheck the idle speed and synchronization .

disassembly.
Date of Issu e: May, 1981

HONDA
30 MAINTENANCE Ul iD3
CHOKE MECHANISM
Operate the choke lever and check for smooth
operation.
Pull the choke to "fully close" and make sure that
the choke lever fully closed at the carburetors.
Adjust by loosening the choke cable clamp and
moving the choke cable casing.
Retighten the clamp, holding the choke lever
fully closed.
Push the choke lever down all the way to fully
open. Make sure the choke valve is fully open by
checking for free play in the cable between the
lever and the cable casing.
IDLE SPEED ~_________T~

HmR_
OTTLESTOPSCREW____. .
NOTE
Adjust idle speed after synchronizing carbure-
tors. The engine must be warm for accurate
idle adjustment. Ten minutes of stop-and-go
riding is sufficient.
Warm up the engine, shift to NEUTRAL, and place

the motorcycle on its center stand.
Turn the throttle stop screw as required to obtain
the specified idle speed.
IDLE SPEED: 900 ± 100 rpm
NOTE
Pilot screws are factory pre-set. Do not adjust
the pilot screw unless the carburetors are
overhauled.

3-10 © HONDA MOTOR CO., LTD _
HONDA
[ij ;p3 MAINTENANCE 31
VALVE CLEARANCE
NOTE
• Inspect and adjust valve clearance while
the engine is cold. (Below 35°C. 95°F).
Lean the motorcycle right and left to drain
residual oil from the cylinder head.
Remove the seat and leg shield.

Turn the fuel valve OFF and remove the fuel tube
and fuel tank .
Remove the No.1 and No.6 spark plugs.
Remove the cylinder head brackets.
Remove the tachometer cable.
Remove the tachometer gear cap and tachometer

driven gear.
CAUTION
The tachometer driven gear must be removed
to prevent No. 4 camshaft holder breakage
when the camshafts are rotated. Camshaft
holder breakage necessitates cylinder head
assembly replacement.
Remove the four cylinder head side covers.

Remove the eight cylinder head cover mounting
bolts and cylinder head cover.
NOTE
• Do not allow engine oil to enter the
combustion chambers when the cylinder
head cover is removed.
• Make sure the torque of the camshaft
holder mounting bolts (32 bolts) is 12-14
N'm (1.2-1.4 kg-m, 104-122 in-Ib).
Remove the right crank cap.
INSPECTION
Measure intake and exhaust valve clearances by

inserting a feeler gauge between the camshaft and
valve lifter shim.
VALVE CLEARANCE:
0.06-0.13 mm (0.002-0.005 in)
Rotate the crankshaft clockwise and measure
the valve clearances in the following sequence:
Open No.2 Ex. Valves to maximum and Measure No.2 In., No.1 Ex., No. 3 ·Ex. clearance
Open No.4 Ex. Valves to maximum and Measure No.4 In., No.5 Ex., No.6 Ex. clearance
Open No.2 In. Valves to maximum and Measure No.1 In., No.3 In., No.5 In. clearance
Open No.5 Ex. Valves to maximum and Measure No.6 In., No.2 Ex., No.4 Ex. clearance
Record the valve clearances.

~ HONDA
32 MAINTENANCE ~ U1 ;D-:1
ADJUSTMENT
NOTE
Adjustment shims are available in 0.05 mm
increments, from 2.30 to 3.50 mm.
Select a replacement shim to achieve the specified

valve clearance, using the following procedures.
Turn the valve lifter notch toward the spark plug

hole.
Rotate the crankshaft so that the valve being

adjusted is at maximum lift.
Insert the special tool (Valve Lifter Holder) between

the camshaft and adjacent lifter.
CAUTION
INSTALL SPECIAL TOOL
Do not rotate the crankshaft too far or in the PROPERLY
wrong direction when the Valve Lifter Holder
is depressing a pair of Valves. To do so will
cause the intake and exhaust valves to strike
and damage each other.
VALVE LIFTER HOLDER

07964-4220002
VAL E LIFTER HOLDER

07964-4220002
VALVE LIFTER HOLDER

07964-4220002
Rotate the crankshaft clockwise until there is

enough clearance to remove the shim.

MAINTENANCE 33
Begin removal of the shim by prying it off with the

valve lifter.
VALVE LIFTER HOLDER

07964-4220002
Then remove the shim with tweezers.
SHIM TWE EZ ERS
Measure the thickness of the used shim with a

micrometer.
SHIM MICROMETER
Select a replacement shim using the chart on Page 3-
13.
Insert the replacement shim.
CAUTION
Make sure the opposite pair of valves does
not open. The valves could be bent or damaged
if the crankshaft is rotated incorrectly.
Rotate the crankshaft in the correct direction until

the valves being adjusted are at maximum lift.
Remove the special tool "Valve Lifter Holder".
Rotate the crankshaft 2-3 revolutions to fully seat
the -replacement shim.
Recheck the valve clearance.
disassembly.

w
CAlI .j>.
.... EXAMPLE: 1. Measure valve clearance = 0.16 mm

2. Measure present shim size = 2.50 mm
3. Refer to chart. (See shaded columns)
4. Replacement shim size = 2.55 mm
~ VALVE SHIM SELECTION CHART STANDARD VALVE CLEARANCE = 0.06 - 0.13 mm
EX
V PRESENT SHIM SIZE mm
SHIM
mm 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 13.45 13.50
VALVE
CLEARANCE
mm
0.01-0.05 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 13.40 13.45
0.06-0.13 SPECI FI ED CLEARANCE NO CHANGE REQUIRED
EX¢ 0.14-0.16 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 1 3 .5O V
0.17-0.21 2.40 2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3. 5O V
0.22-0.26 2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50
/'
0.27-0.31 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50
V s:
0.32-0.36 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50
V »
0.37-0.41 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 ./" z
-i
0.42-0.46 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 V m
Z
0.47-0.51 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50
/' »
z
0.52-0.56 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50
/' n
m
0.57-0.61 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50
/'
0.62-0.66 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50
A""~
0.67-0.71 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 ~",\'=> NOTE
(1) Measure the valve clearance while the
0.72-0.76 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 ~,'\'" engine is cold.
0.77-0.81 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 Vp.c.~ (2) For shim replacement, see page 3-12.
0.82-0.86 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 V~((;.'l"" (3) Measure old and new shims with a
micrometer.
V
~
0.87-0.91 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50
@o (4) The chart is for reference purpose only.
Icn'"
00
0.92-0.96 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 V After installing new shims, recheck the
Z..."
0",
0.97-1.01 3.20 3.25 3.30 3.35 3.40 3.45 3.50 / valve clearance.
V
=
}:>c 1.02-1.06 3.25 3.30 3.35 3.40 3.45 3.50 Before rechecking, rotate the camshafts
several times to seat the shims in the
::;'" 1.07-1.11 3.30 3.35 3.40 3.45 3.50 V
§~
0::; lifters.
-I",
0-<
1.12-1.16 3.35 3.40 3.45 3.50 /' (5) If the shim thickness required exceeds I
:0:"" 1.17-1.21 3.40 3.45 3.50 /' 3.5 mm, there is carbon build-up on
oco
I
.0 00
~
1.22-1.26 3.45 3.50 V the valve seat. Remove the carbon and
ref ace the seat.
r 1.27-1.31 3.50 /' I
~
-I
o
~HONDA
~ U1;Q3 MAINTENANCE 35
CAM CHAIN
Start the engine and allow it to idle.
Loosen the rear cam chain tensioner lock nut and
bolt at the rear of the cylinder head.
Tighten the bolt and lock nut.
Loosen. then tighten. the front cam chain tensioner

lock nut and bolt at the front of the cylinder.
NOTE
With engine running at idle. the tensioner
will automatically position itself to provide
the correct tension.
~A-_-t1 t,.\n LOCK NUT

P}.,.aIJjJJ,lf-I{f:rwt~

© HONDA MOTOR CO .• LTD. 3-15
HONDA
36 MAINTENANCE (Jl ;D
COMPRESSION TEST
NOTE
The battery must be fully charged for this
test.
Warm up the engine.

Remove all spark plugs.
Insert the compression gauge.
Open the choke and throttle valves fully .
Crank the engine with the starter motor ,
NOTE
Crank the engine until the gauge reading stops
rising. The maximum reading is usually
reached in several seconds.
COMPRESSION PRESSURE:
1200 ± 100 kPa (12 ±1 kg/cm 2 , 170 ± 14 psi)
If compression is low, check the following:

- Leaky valves
- Improper valve clearance
- Leaking cylinder head gasket
- Worn piston/rings/cylinder
If compression is high, it indicates that carbon
deposits have accumulated on the combustion
chamber wall or on the piston crown.

~ HONDA
~ {J1 ;p~ MAINTENANCE 37
DRIVE CHAIN
NOTE
Perform the following with the ignition
switch "OFF".
Place the vehicle on its center stand and shift the

transmission into neutral.
Inspect the drive chain midway between the sprock·
ets on the lower chain run.
FREE PLAY: 15-25 mm (5/8-1 in)

SERVICE LIMIT: 40 mm (1.5 in)
Adjust as follows:
Remove the rear axle ,c otter pin and loosen the nut.
Loosen the adjuster bolt lock nuts.
Turn the adjuster bolts an equal number of turns to
obtain the specified free play.
CAUTION
~
Be sure that the index mark aligns with the RED ZONE
same graduation of the scale on both sides. OF SWING ARM
Tighten the adjuster bolt lock nuts.

Tighten the axle nut securely.
Recheck free play and free wheel rotation.
Lubricate the drive chain (page 2·5).
AXLE NUT TORQUE:

85-105 N·m, (8.5·10.5 kg-m, 61-76 ft-Ib)
Replace the drive chain when the red zone on the

label aligns with the rear of the swing arm with a
chain free play of 20 mm (3/4 in).
Replacement chain: DID 50ZL, RK 50LO
Inspect the sprocket teeth for excessive wear or

damage.
Replace if necessary.
NOTE
Never install a new drive chain on worn
sprockets or a worn chain on new sprockets.
Both chain and sprockets must be in good
condition or the replacement chain or
sprockets will wear rapidly.

~ HONDA
38 MAINTENANCE ~ Q1;P::i
BATTERY
Remove the right and left side covers.
Disconnect the ground cable at the battery ter-
minal.
Disconnect the positive cable at the magnetic switch
terminal.
Remove the battery.
Inspect the battery fluid level.

When the fluid level nears the lower level, refill
with distilled water to the upper level.
NOTE
Add only distilled water. Tap water will
shorten the service life of the battery. LOWER LEVEL
The battery electrolyte contains sulfuric

acid. Protect your eyes, skin and clothing. UPPER LEVEL
In case of contact, flush thoroughly with
water and call a doctor if electrolyte gets
in your eyes.
Replace the battery, if sulfation forms or sediments

accumulate on the bottom.
CAUTION
• To prevent damage to the battery, do not
tap it with a hammer during installation.
• Do not grease the battery.
BRAKE FLUID
Check that the front and rear brake fluid reservoirs
are filled to the upper level mark.
If the level nears the lower level mark, fill the
reservoir with DOT -3 BRAKE FLUID to the upper
level mark.
Check the entire system for leaks, if the level is low.
CAUTION
• Do not mix different brands of fluid as
they may not be compatible.
• Do not remove the cap until the handlebar
has been turned full right so that the
reservoir is level.
• Avoid operating the brake lever with the
removed.
Brake fluid will squirt out if the lever is
pulled.
LOWER LEV E L

~ HON'DA
~ Ul ;Q3 MAINTENANCE 39
BRAKE PAD WEAR

Check for brake pad wear.
Replace the brake pads if the red line on the top
of the pads reaches the edge of the brake disc.
(Refer to Section 12).
CAUTION
Always replace the brake pads in pairs to
assure even disc pressure.
BRAKE SYSTEM
REAR BRAKE PEDAL HEIGHT
Adjust the pedal height so that the distance be·

tween the pedal and upper face of the footpeg
is 7 mm (0.27 in).
CAUTION
Improper brake pedal height adjustment
can cause brake drag.

HONDA
40 MAl NTENANCE at ;Q3
Adjust as follows:
Loosen the lock nut.
Turn the adjuster until the correct pedal height is
obtained.
Tighten the lock nut securely.
NOTE
After adjusting pedal height, adjust the
brakelight switch.
BRAKELIGHT SWITCH ADJUSTING NUT
Adjust the brakelight switch so that the brakelight

will light when the brake pedal is depressed and the
brake begins engagement.
Adjust by turning the switch adjusting nut as-

shown .
NOTE
• Do not turn the switch body.
• The front brakelight switch does not
require adjustment.
HEADLIGHT AIM
VERTICAL BEAM
The headlight beam can be raised or lowered by

turning the vertical beam adjusting knob.

~HONDA
~" CIl ;Q3 MAl NTENANCE 41
HORIZONTAL BEAM
Remove the headlight cover from the rubber seal

in the fairing.
Adjust horizontally by turning the adjusting screw
on the headlight rim.
Turn the adjusting screw clockwise to direct the
beam toward the right side of the rider.
NOTE
Adjust the headlight beam as specified by
local laws and regulations.
An improperly adjusted headlight may blind HORIZONTAL BEAM ADJUSTER

oncoming drivers, or it may fail to light the
road for a safe distance.
HEADLIGHT BULB REPLACEMENT CAP NUT
Loosen the screw attached to the headlight adjust-

ing knob.
Remove the adjusting knob, nut and washers.

Remove the crown nut.
ADJUSTING KNOB NUT HEX 12 mm
Remove the headlight cover from the fairing.

Pull out the headlight case and replace the bulb.
Reinstall the bulb clip.
CAUTION
• Do not touch the glass of a halogen bulb,
or early bulb failure will occur.
• If you do touch the bulb, wipe it clean
with a cloth moistened with alcohol.
HEADLIGHT CASE

© HONDA MOTOR CO:, LTD. 3-21
42 MAINTENANCE
CLUTCH FREE PLAY

Inspect the clutch lever free play at the end of the
lever.
FREE PLAY: 10-20 mm (3/8-3/4 in)
LOCK NUT ADJUSTING BOLT

ADJUSTMENT
Loosen the upper adjusting bolt's lock nut and

turn the adjusting bolt until the correct free play
is obtained .
Tighten the lock nut.
NOTE
Do not expose the adjusting bolt threads
more than 8 mm (3/4 in).
If adjustment cannot be made with the clutch

lever adjusting bolt, screw the adjusting bolt all the
way in. Adjustment must be made at the clutch
housing.
Loosen the lower clutch cable adjusting lock nut

and turn the adjusting nut all the way in.

3-22 © HONDA MOTOR CO. , LTD .
~HONDA
Gl :D MAINTENANCE 43
Remove the clutch lifter cap and loosen the clutch

lifter lock nut. Turn the adjusting screw in until a
slight resistance is felt. From this position, turn the
clutch adjusting screw counterclockwise 1 turn,
and tighten the lock nut.
Turn the clutch cable lower adjusting nut so that

there is 10-20 mm (3/8-3/4 in) of free play at the
end of the clutch lever. Tighten the lock nut.
Any minor adjustment can be obtained with the
adjusting bolt and lock nut at the clutch lever.
After adjustment, be sure all lock nuts are tightened

securely.
Check to see that the clutch is not slipping and is
properly disengaging.
SIDE STAND
Check the rubber pad for deterioration or wear.
Replace if any wear extends to the wear line as
shown.
Check the side stand spring for damage and loss
of tension, and the side stand assembly for freedom
of movement and bending.
SIDE STAND
NOTE
When replacing, use a rubber pad with the GOOD
mark "OVER 260 Ibs ON LY".
Spring tension is correct if the measurements
fall within 1.5-2.5 kg (3.3-5.5 Ib) when
pulling the side stand lower end with a spring
scale.
f'
J
j. WEAR LINE
.... ....
o x
44 MAINTENANCE
SUSPENSION
I'
Do not ride a vehicle with faulty suspension.
Loose, worn or damaged suspension parts
impair vehicle stability and rider control.
FRONT
With the front brake applied, pump the front
forks up and d()wn several times.
Place the motorcycle on the center stand.
Measure the air pressure.

STANDARD:
70 ± 20 kPa (0.7 ± 0.2 kg/cm 2 • 10 ± 3 psi)
CAUTION:
• Use only a hand operated air pump to
fill the fork tubes.
Do not use compressed air.
• Maximum pressure is 300 kPa (3 kg/cm 2 ,
43 psi). Do not exceed this or fork tube
component damage may occur.
Check the entire fork assembly for leaks or damage.

Replace any components which cannot be repaired.
Tighten all nuts and bolts.
REAR
Place the motorcycle on its center stand
Move the rear wheel sideways forcefully to see
if the swing arm bushings are worn .
Replace if excessively worn.
Check the entire suspension assembly to see if it is
securely mounted, and not damaged or distorted.
Tighten all nuts and bolts.
Lubricate the swing arm bushings.
Measure the air pressure.

STANDARD:
200-400 kPa (2.0-4.0 kg/cm 2 , 28-57 psi)
Adjust the rebound damping according to the fol-

lowing chart.
Recommended Rear Suspension Adjustment:
REBOUND RIDING
Rear Air Rider/
DAMPING CON·
Pressure Load
ADJUSTER DITIONS
200 kPa One General or
(2.0 kg/em' , around town
28 psi)
+
400 kPa
(4.0 kg/em'.
!
Up to
vehicle
2
riding .
Highway or
winding road
riding
57 psi) capacity
load Rough road Rebound damping adjuster
3
riding

~ HONDA
~ Gl;§3 MAINTENANCE 45
WHEELS
TI RE PRESSURE
NOTE
Tire pressure should be checked when tires
are COLD.
Check the tire for cuts, imbedded nails, or other

sharp objects.
Recommended tire pressure and tire size:
Cold tire
Front 250 (2.5, 36)
pressure
Rear 250 (2.5, 36)
kPa
Max load 290 (2.9, 41)
(kg/cm 2 ,psi)
Vehicle
capacity 175 kg (385 Ibs)
load limit
Tire size Front 3.50V19-4PR
Rear 130/90 V18
Tire brand Front GOLD SEAL F11
Tubeless (DUNLOP)
only MaG. MOPUS· 706
(BRIDGESTONE)
Rear GOLD SEAL K127
(DUNLOP)
MaG. MOPUS-G508
(BRIDGESTONE)
Check the front and rear wheels for trueness (page

14·5).
STEERING HEAD BEARINGS

NOTE
Check that the control cables do not interfere
with the handlebar rotation.
Raise the front wheel off the ground.

Check that the handlebar rotates freely.
If the handlebar moves unevenly, binds, or has
vertical movement, adjust the steering head bearing
by turning the steering head adjusting nut with a pin
spanner. (page 13-27).
NUTS, BOLTS, FASTENERS

Check that all chassis nuts and bolts are tightened
to correct torque values.
Check all cotter pins, safety clips and all other
fasteners.

~ HONDA
46 FUEL SYSTEM ~. (Jl:D
2.8-4.2 N'm (28-42 kg-em, 2-3 ft-Ib) ~
f'- --~
2.8-4.2 N'm (28-42 kg-cm, 2-3 ft-Ib)
0.6-1.2 N'm
16-12 kg-cm, 5-11 in-Ib)
(28 - 42 kg-em , 2-3 ft-Ib)
"
~~ !, ....
~.~ .
I~ , ! I
-:(1
1"
. , "C)
<> ,, ~
a
p~~ , \

~ HONDA
~ U1;E 4. FUEL SYSTEM 47
SERVICE INFORMATION 4-1 FLOAT LEVEL ADJUSTMENT 4-11

TROUBLESHOOTING 4-2 CARBURETOR SEPARATION 4-11
CARBURETOR REMOVAL 4-3 LINKAGE DISASSEMBLY 4-16
FUEL LINE DIAPHRAGM 4-5 CARBURETOR ASSEMBLY 4-17
VACUUM CYLINDER DISASSEMBLY 4-7 ACCELERATOR PUMP ADJUSTMENT 4-27
FLOAT CHAMBER DISASSEMBLY 4-8 PILOT SCREW ADJUSTMENT 4-28
AIR CUTOFF VALVE LIMITER CAP INSTALLATION 4-29
DISASSEMBLY 4-9 HIGH ALTITUDE ADJUSTMENT 4-30
ACCELERATOR PUMP DISASSEMBLY 4-10 FUEL TANK 4-31
COMPONENT ASSEMBLY 4-10 AIR CLEANER CASE 4-31
GENERAL INFORMATI ON
GENERAL INSTRUCTIONS
• Use caution when working with gasoline. Always work in a well-ventilated area and away from sparks or open flames.
• When disassembling fuel system parts, note the locations of the a-rings. Replace with new ones on re-assembly.
• The float bowls have drain plugs that can be loosened to drain residual gasoline.
• The carburetors are equipped with a fuel line diaphragm. After carburetor overhaul, it is necessary to crank the engine for
2-3 seconds, three times with the throttle fully closed to fill the float chambers.
• The pilot screw is factory pre-set and should not be removed unless the carburetor is overhauled.
TOOLS
Common
Float level gauge 07401-0010000
Special
Carburetor Throttle Wrench 07908-4220100
(for No.1, 2, 3 and 4)
07908-4600000
(for No.5 and 6)
Carburetor Pilot Screw Wrench 07908-4220200 or 07908-4220201
TORQUE VALUES
Front bracket 4-6 N'm (40-60 kg-cm, 35-52 in-Ib)

Rear bracket 2.8-4.2 N'm (28-42 kg-cm, 24-36 in-Ib)
Choke valve 0.6-1.2 N'm (6-12 kg-cm, 5-11 in-Ib)
Front and rear brackets between
three carburetors 2.8-4.2 N'm (28-42 kg-cm, 24-36 in-Ib)
Throttle joint holding nut 2.8-4.2 'N·m (28-42 kg-cm, 24-36 in-Ib)
SPECI FICATIONS
Venturi dia. 28 mm (1.1 in)

Setting mark VB64A
Float level 15.5 mm (0.61 in)
Main jet #105
Idle speed 900 ± 100 rpm
Throttle grip free play 2-6 mm (0.08-0.24 in)
Fast idle 2,000 ± 500 rpm after break-in
Pilot screw See page 4-28
Date of,lssue : May, 1981

~HONDA
48 FUEL SYSTEM ~. Gl iD-:]
TROUBLESHOOTING
Engine Cranks but Won't Start Lean Mixture
1. No fuel in tank 1. Clogged fuel jets
2. No fuel to carburetor 2. Piston stuck closed
• Fuel line diaphragm vent tube clogged 3. Faulty float valve
· Fuel line diaphragm vacuum tube clogged 4. Float level low
• Clogged fuel line diaphragm 5. Fuel cap vent blocked
• Clogged fuel line diaphragm check valve 6. Fuel strainer clogged
3. Engine flooded with fuel 7. Restricted fuel line
4. No spark at plug (ignition malfunction) 8. Air vent tube clogged
5. Air cleaner clogged 9 . Intake air leak
6. Intake air leak
7. Improper choke operation
8. Improper throttle operation Rich Mixture
1. Clogged air jets
Hard Starting or Stalling after Starting 2. Faulty float valve
1. Improper choke operation 3. Float valve too high
2. Ignition malfunction 4. Choke stuck closed
3. Fast idle speed incorrect 5. Stuck closed air cutoff valve
4. Carburetor malfunction 6. Clogged air cleaner
5. Fuel contaminated
6. Intake air leak
7. Idle speed incorrect
Rough Idle
1. Ignition malfunction
2. Idle speed incorrect
3. Incorrect carburetor synchronization
4. Carburetor malfunction
5. Fuel contaminated
Misfiring during Acceleration

2. Faulty air cutoff valve or accelerator pump
Backfiring
2. Carburetor malfunction
3. Faulty air cutoff valve or accelerator pump
Poor Performance (Driveability) and Poor Fuel Economy

1. Fuel system clogged
2. Ignition malfungtion
3. Faulty accelerator pump

~ HONDA
~" Ul :p3 FUEL SYSTEM 49
CARBURETOR REMOVAL THROTTLE CABLES
NOTE
To remove the carburetors, the engine must
be tilted.
Refer to Section 5 "ENGINE REMOVAL
AND INSTALLATION".
Remove the front fairing and leg shields.

Disconnect the throttle cables at the throttle
housing before tilting the engine.
Remove the choke cable at the left handlebar
switch housing.
AIR CLEANER CONNECTING BAND

Loosen the carburetor manifold bands.
Remove the carburetor assembly with the chamber .
NOTE
For easy removal, loosen the cylinder head
side bands.
CAUTION
IApply equal force to each carburetor.
BAND
Loosen the air cleaner connecting band.
(For more information, refer to Section 5) .
Tilt the engine.

HONDA
50 FUEL SYSTEM G1 ip"3
Remove the air chamber from the carburetor.
AIR CHAMBER
CHOKE CABLE THROTTLE CABLES

Disconnect the throttle and choke cables.
Drain the fuel by loosening each drain screw.
DRAIN SCREW

FUEL SYSTEM 51
FUEL LINE DIAPHRAGM AIR VENT TUBE FUEL TUBE FUEL LINE DIAPHRAGM
Disconnect the fuel tubes, vacuum tubes and

air vent tube.
Unscrew the screws attaching the fuel line dia-
phragm to the carburetors.
Remove the fuel line diaphragm.
VACUUM TUBE FUEL TUBES
INSPECTION
Remove the fuel line diaphragm (see above) .
Disconnect the inlet fuel tube from the diaphragm,

and connect a longer tube to the fuel tank.
Place a suitable drainage container under the outlet

fuel tubes.
Turn the fuel valve on. Fuel should not flow from
the outlet tubes.
Connect a vacuum gauge to the diaphragm vacuum

outlet. Fuel should flow out from the outlet tubes
when 10-20 mm Hg (0.4-0.8 in Hg) of vacuum is
applied.
If the flow is restricted, check the diaphragm for
clogged fuel or air passages and the diaphragm
itself for tears.
SCREWS
DISASSEMBLY
Disassemble the upper body, spacer, spring and

lower body by removing the screws shown.
Disassemble the spacer, being careful not to damage

the diaphragm.

52 FUEL SYSTEM
UPPER BODY DIAPHRAGM RETAINER SPACER

Check the upper and lower bodies for signs of
damage to the diaphragm contacting faces.
Check the diaphragms for damage, cracks or other

faults.
Check the bodies and spacer for clogged vent holes.
\ J,
Check the diaphragm seal for damage.
Check for clogged fuel or air passages. o
SPRING LOWER BODY DIAPHRAGM SPRING SEAT
DIAPHRAGM
ASSEMBLY
Clean all the disassembled parts in solvent and

allow to dry.
Install the spacer and diaphragm retainer.

Install the spring seat.
NOTE
Check that the diaphragm is installed in the
retainer properly.
SPACER RETAINER
UPPER BODY VENT

Install the spacer on the upper body.
NOTE
Align the air vent hole in the body with the
air passage in the spacer. fl f}
Install the diaphragm spring and lower body .

Install the bracket and tighten the screws.
VENT HOLE SPACER

~HON'DA
UJ;§3. FUEL SYSTEM 53
VACUUM CYLINDER DISASSEMBLY NEEDLE SET SCREW VACUUM PISTON
Remove the vacuum cylinders from the carburetor

bodies.
Carefully lift the vacuum piston out with the
needle and compression spring.
NOTE
Inspect the vacuum piston and cylinder for !; f
wear, nicks, scratches or other damage.
Make sure that the piston and jet needle move
up and down freely in the cylinder.
Remove the full open stopper.

Remove the needle set screw.
Separate the jet needle from the piston .
FULL OPEN STOPPER JET NEEDLE
NOTE
Inspect the needle and seat for deposits,
bending, grooves, or other damage.
SEAL RING AI R JET COVE R
Carefully lift the seal ring off the carburetor body.
Remove the air jet cover .
SLOW AIR JET PRIMARY MAIN AIR JETS

Blow open the primary main air Jet, secondary
main air jet and slow air jet with compressed air.
NOTE
Never clean carburetor jets with wire or drills.
This will enlarge the openings and result in
excessive fuel consumption.
SECONDARY MAIN AI R JETS

~HONDA
54 FUEL SYSTEM ~. miD
FLOAT CHAMBER DISASSEMBLY CLIP FLOAT
Remove the float chamber body ,

Remove the float arm pin.
Remove the float and float valve .
NOTE
Remember the direction of the clip to ensure
correct reassembly.
FLOAT ARM PIN
Inspect the float valve and seat for grooves, nicks

or deposits.
Inspect the float valve for operation.
VALVE SEAT
Remove the secondary main jet.

Remove the primary main jet.
Remove the slow jet plug.
NOTE
The slow jet is a press fit. It cannot be re-
moved.
MAIN JET

HONDA
UJ:Q:l FUEL SYSTEM 55
PILOTSCREW SlOW JET

Remove the needle jet holder.
Tilt the carburetor to remove the needle jet.
Blow all jets and body passages with compressed air.
NOTE
• If the needle jet is difficult to remove,
carefully press the needle jet from the
cylinder side with a wooden stick.
Before removing the pilot screw, record
the num ber of turns until it seats. Do not
damage the pilot screw threads when re-
moving the plain washer and O-ring.
NEEDLE JET HOLDER
AIR CUTOFF VALVE DISASSEMBLY AIR CUTOFF VALVE COVER
Remove the air cutoff valve cover and spring.
Remove the diaphragm and O-ring.

56 FUEL SYSTEM
RAGM
Inspect the diaphragm and valve for cracks and
brittleness.
/
O·RING
ACCELERATOR PUMP DISASSEMBLY

Remove the accelerator pump cover and spring.
Remove the diaphragm.

Inspect the diaphragm for cracks and brittleness.
NOTE
! Be sure the rod is not bent.
COMPONENT ASSEMBLY
To assemble the accelerator pump, air cutoff valve,
float chamber and vacuum cylinder, reverse the
disassembly procedure.
NOTE
When installing the air cutoff valve O-ring,
make sure the flat surface is toward the body .
DIAPHRAGM

FUEL SYSTEM 57
FLOAT LEVEL ADJUSTMENT

Adjust the float level by bending the float arm
carefully until the float tip just contacts the float
valve.
FLOAT LEVEL: 15.5 mm (0.61 in)
NOTE
Before adjusting, remove the adjacent cham-
bers.
CARBURETOR SEPARATION
Disconnect the overflow tubes from the float
chambers.
LEFT CARBURETOR ASS'Y RIGHT CARBURETOR ASS'Y

OVER FLOW TUBE OVER FLOW TUBE
SPRING COLLAR FUEL LINE DIAPHRAGM

Remove the cotter pin from the accelerator pump
rod.
Remove the plain washer, spring and spring collar .
Remove the fuel line diaphragm (page 4-5).
COTTER PIN

58 FUEL SYSTEM
THROTTLE STOP
SCREW HOLDER
Remove the throttle stop screw holder.
Turn the throttle stop screw out.
THROTTLE STOP SCREW
THROTTLE JOINT BOLT

Straighten the throttle joint bolt locking washer
tabs.
LOCKING WASHER
THROTTLE JOINT BOLT

LOCKING W ER
OD COMPRESSION SPRING
Loosen the throttle joint bolt.
Remove the locking washer and ball joint seat.
Disconnect the ball joint of the throttle link from
the throttle joint pipe.
Remove the rod.
Disconnect the throttle joint pipe from the No.3
carburetor throttle linkage.
Note each parts location to insure original assembly.
NOTE
For easy removal, hold the joint pipe and
turn the throttle link.
BALL JOINT SEAT SPRING SEAT JOINT PIPE

FUEL SYSTEM 59
Remove the rear bracket.
REAR BRACKET
Remove the front bracket.
1
FRONT BRACKET
Carefully separate the carburetors.
CAUTION
Separate the carburetor horizontally to
prevent damage to the fuel and air joint
pipes and choke link.' Then, tilt the right
carburetor assembly to clear the accelera-
tor pump rod.
Do not bend the accelerator pump rod.

~ HON'DA
60 FUEL SYSTEM ~ U1:Q3
Blow the air and fuel passages with compressed air.
SYNCHRONIZATION
ADJUSTING SCREW
NOTE
The separation of the No.1, 2 and 3 carbure-
tors is given here. The procedure is similar
for No.4, 5 and 6 carburetors.
Loosen the synchronization adjusting screw lock

nuts and adjusting screw with the carburetor throt-
tle wrench until there is no tension.
NOTE
Turn the synchronization screws in until
they seat and note the number of turns to
ensure correct repositioning.
Cut off the staked ends of the choke valve screws.

Remove the choke valves.
NOTE
I Do not allow filings to enter the carburetors.
CHOKE VALVES

~ HON'DA
~ [JJ;§3 FUEL SYSTEM 61
Remove the choke relief spring from the choke link

and pull the choke shaft out.
CAUTION
Do not reuse the choke shaft, choke valves
and screws.
RELIEF SPRING
FRONT BRACKET
Remove the rear and front brackets.
REAR BRACKET
Carefully separate the carburetors.

Blow the air and fuel joint pipes with compressed
air.

~ HOND.A
62 FUEL SYSTEM ~ Ul:D
LINKAGE DISASSEMBLY
Remove the right throttle joint, using the same
procedure as for the left throttle joint.
THROTTLE LINK
Remove the throttle link bolt.
Remove the throttle link.
Remove the fast idle adjusting arm cotter pin .

.
FAST IDLE ADJUSTING ARM
-
Remove the fast idle adjusting arm.

FUEL SYSTEM 63
CARBURETOR ASSEMBLY
NOTE
• Assemble one set of three carburetors at
a time .
No.1, 2 and 3 carburetor assembly is
shown here. The procedure is similar for
the No.4, 5 and 6 carburetors .
Install new a-rings on the air and fuel joint pipes

securely.
Install the air cutoff valve joint, fuel joint, accele-
rator pump joint and ai r vent pipes on the No.3
carburetor.
Install the choke dust tube.
NOTE
I Apply a thin coating of oil to the a-rings.
Loosen the synchronization adjusting screw until

there is no tension .
Insert the No.3 carburetor throttle link between SCREW
the plain washers.
Assemble the No.2 and No . 3 carburetors, pressing
them together carefully.
NOTE
The large washer should be positioned on the
spring side.
LOCK NUT
Attach the No. 1 carburetor to the No.2 carbure-

tor, pressing them together carefully.
NOTE
Check the condition of the a-rings and choke
dust tubes.

~ HONDA
64 FUEL SYSTEM ~ U1 ;P-:l
Install the front bracket loosely .

Place the carburetors on a flat surface with the
float chamber up.
Press the carburetors together equally and tighten
the screws in the sequence shown in two or more
steps to prevent carburetor misalignment.
TORQUE: 4-6 N·m (40-60 kg-em, 35-52
in-Ib)
NOTE
Insert the choke shaft to ensure correct
carburetor alignment before tightening screws.
Check that the choke shaft operation is
smooth. If it is not, recheck the carburetor
alignment.
Install the rear bracket using the same procedure as

for the front bracket.
TORQUE: 2.8-4.2 N·m (28-42 kg-em, 24-36
in-Ib)
NOTE
No.3 and No.4 carburetors require 5 x 16
mm screws. The other carburetors require
5 x 12 mm screws.
NOTE
Right carburetor screw tightening sequence is
shown here.

~HONDA
~. U1 i f] FUEL SYSTEM 65
THRUST SPRING
Install the thrust spring between the No. 1 and
No.2 carburetor throttle valve links.
Turn each synchronization adjusting screw to its

original position as noted during d isassembly.
NOTE
Make each distance between the by·pass hole
in the carburetor body and throttle valve
equal when assembling new carburetors.
Inspect throttle operation as described below:

• Open the throttle slightly by pressing the No.3
carburetor ball joint. Then release the throttle.
Make sure that it returns smoothly.
Make sure that there is no drag when opening
and closing the throttle.
Install a new choke shaft.
Check that choke shaft operation is smooth and it
does not bind during installation. If it binds, the
carburetors may not be properly aligned or the shaft
may be bent.
BALL JOINT

~ HONDA
66 FUEL SYSTEM ~ (jl:Q3
Slide the choke relief spring over the choke shaft.

Install the choke shaft.
Install the choke valve, but do not tighten the bolts.
Make sure that the clearance between the choke
shaft lever and carburetor body is approximately
1 mm (0.04 in).
Attach the choke relief spring to the choke link and

choke shaft lever.
Make sure that choke valve operation is smooth by

moving the choke link.
Close the choke valve by turning the choke link.

Hold the choke link.
Press the choke valve end to the fully opened posi·
tion.
Release the choke valve, then make sure that it
returns smoothly .

FUEL SYSTEM 67
Tighten the choke valve bolts.

TROUBLE: 0.6-1.2 N'm (6-12 kg·em, 5-11
in·lb)
Fold the tabs of the lock washer up.

Recheck the throttle and choke operation .
NOTE
The choke valve bolts and lock washer are for
rebuilding assembly only. The original as-
sembly uses staked screws.
tfA:'
V'"
BOLTS
Loosen the No.3 and No.4 carburetor rear bracket

screws. THROTTLE
JOINT BOLT
Connect the throttle joint to the throttle link.
CAUTION
Do not damage the ball joints and rubber LOCKING
grommets. BALL JOINT WASHER
Do not allow dust in the throttle joint SEAT
pipe.
Use a new locking washer.
~~~I----JOINT PIPE
ROD ---~~"II
COMPRESSION
SPRING
SP ING SEAT
Tighten the throttle joint bolt.

TORQUE: 2.8-4.2 N'm (28-42 kg-em, 24-36
in-Ib)
Secure the bolt by bending the tabs of the locking

washer.
NOTE
Bend the two small tabs up against the bolt
head.
Bend the center tab over the throttle joint
flat.
LOCKING WASHER
Date of Iss ue : May, 1981

© HONDA MOTOR CO. , LTD. 4-21
. HONDA
68 FUEL SYSTEM (J! ;§.3
FAST I DLE ADJUSTMENT
FAST IDLE: 2000 ± 500 rpm (after break-in)
Close the throttle valve and open the choke valve.

Measure the clearance between the throttle link and
fast idle adjusting arm pin.
SPECIFIED CLEARANCE:
0.7-1.0 mm (0.003-0.04 in)
FAST IDLE ADJUSTING ARM

Adjust by opening and closing the fork end of the
fast idle adjusting arm.
MARK
INSTALLATION
Install new O-rings on the air and fuel joint pipes.

Install the air cutoff valve joint pipe and accelerator
pump joint pipe on the No.4 carburetor.
NOTE
Apply a thin coating of oil to the O-rings.
Install the accelerator pump joint pipe with
the mark toward the No.4 carburetor.

~HON'DA
~. CIt ;'D FUEL SYSTEM 69
~~--~~~~--------~~~~~-------------~~~---------
Insert the accelerator pump rod.
Position the right and left carburetor assemblies
properly, aligning the pipes and choke link.
Press the assemblies together carefully .
Install the diaphragm bracket, front and rear

brackets loosely.
Connect the other throttle joint to the throttle

link.
Tighten the throttle joint bolt.
Secure the bolt by bending the tabs of the locking
washer as for the previous throttle joint.
TORQUE
2.8-4.2 N·m (28-42 kg-em, 24-36 in-Ib)
LOCKING WASHER

HONDA
70 FUEL SYSTEM rn;D,
Tighten the front and rear brackets in the sequence

shown.
TORQUE:
2.8-4.2 N'm (28-42 kg·em, 24-36 in-Ib)
Turn the synchronization adjusting screw on the

No.3 carburetor so that all throttle valve positions
are equal.
Move the throttle link to check throttle operation .
Move the choke link to check choke operation and

sy nch ron izati on.
Install the accelerator pump rod spring, washer,

collar and cotter pin.
Install the thrqttle stop screw.
Install the vacuum cylinder components.
Install the overflow tubes.
Remove the diaphragm bracket and assemble the
fuel line diaphragm .
.Reinstall the fuel line diaphragm.

~ HONDA
~ Gl:E FUEL SYSTEM 71
These photographs here and on the nex page show the details of the carburetor linkage.

72 FUEL SYSTEM

~HON'DA.
~. rn :k:i FUEL SYSTEM 73
TUBE ROUTING
Route the carburetor tubes as shown.
ACCELERATOR PUMP ADJUSTMENT

Measure the clearance between the accelerator
pump rod and adjusting arm with the throttle valve
close.
CLEARANCE: 0-0.04 mm (0-0.0016 in)
Adjust by bending the adjusting arm .
Measure the clearance between the adjusting arm

and stopper on the carburetor body.
CLEARANCE: 3.1-3.3 mm (0.12-0.13 in)
Adjust by bending the adjusting arm.

~ HOND.A
74 FUEL SYSTEM ~~ CIJ :[1
PILOT SCREW ADJUSTMENT
PILOT SCREW REMOVAL
NOTE
The pilot screws are factory pre-set and
should not be removed unless the carburetor
is overhauled.
Remove the carburetors. (Page 4-3) .
Remove the float chambers (Page 4-6) .
Turn the pilot screw in and carefully count the

number of turns before it seats lightly. Make a note
of this to use as a reference when reinstall ing the
pilot screw.
CAUTION
Damage to the pilot screw seat will occur if
the pilot screw is tightened against the seat.
Remove the pilot screw.
Inspect the pilot screw and replace if worn or

damaged.
Install the pilot screw and return it to its original

position as noted during removal. Perform pilot
screw adjustment if a new pilot screw is installed
(below).
NOTE
Do not install limiter caps on new pilot
screws until after adjustment has been made
(below).
PILOT SCREW WITH

LIMITER CAP
PILOT SCREW ADJUSTMENT
NOTE
• The pilot screws are factory pre-set and
no adjustment is necessary unless the pilot
screw is replaced (See removal above).
Use a tachometer with graduations of
50 rpm or smaller and that will accurately
indicate a 50 rpm change.
1. Turn each pilot screw clockwise until it seats

lightly and back it out to the specification
given. This is an initial setting prior to the final
pilot screw adjustment.
INITIAL OPENING: 1-1/4 turns out
Date of Issu e : May, 1981

4-28 © HONDA MOTOR CO " LTD .
FUEL SYSTEM 75
CAUTION
Damage to the pilot screw seat will occur if
the pilot screw is tightened against the seat.
2. Warm up the engine to operating temperature .

Stop and go driving for 10 minutes is sufficient.
3 . Attach a tachometer.
4 . Adjust the idle speed with the throttle stop
screw.
IDLE SPEED: 900 rpm
5. Turn each pilot screw in or out to obtain the

highest engine speed with a carburetor pilot
screw wrench.
6. Adjust the idle speed with the throttle stop
screw.
7. Turn the No. 1 carburetor pilot screw in until
it seats lightly and record the number of turns .
8. Turn the No.2 carburetor pilot screw in until
the engine speed drops 50 rpm.
9 . Turn the No. 2 carburetor pilot screw 1/2
turn out from the position obtained in Step 8.
10. Perform Steps 8 and 9 for the No . 3, 4 , 5 and
6 carburetor pilot screws.
11. Turn the No . 1 pilot screw the number of turns
recorded in step 7.
12. Turn the No.6 pilot screw in until it 5eats
lightly, recording the number of turns.
13. Perform Steps 8 and 9 for the No.1 carburetor
pilot screw.
14. Turn the No. 6 pilot screw out the number of
turns recorded in Step 12.
15. Adjust the idle speed with the throttle stop
screw.
PILOT SCREW
LIMITER CAP INSTALLATION

If the pilot screw is replaced, a new limiter cap must
be installed after pilot screw adjustment is com·
pleted.
After adjustment, cement the limiter cap over
the pilot screw, using LOCTITE ® 601 or equivalent.
The limiter cap should be placed against its stop,
preventing further adjustment that would enrich the
fuel mixture (limiter cap position permits clockwise
rotation and prevents counterclockwise rotationl .
NOTE
A pilot screw limiter cap must be installed.
It prevents misadjustment that could cause
poor performance and increase exhaust emis·
sions.

HONDA
76 FUEL SYSTEM moE
HIGH ALTITUDE ADJUSTMENT (USA only)
When the vehicle is to be operated continuously
above 2,000 m (6,500 feet) the carburetor must be
readjusted as follows to improve driveability.
Warm up the engine to operating temperature. Stop

and go driving for 10 minutes is sufficient.
Turn each pilot screw clockwise 1/2 turn.
Adjust the idle speed to 900 ± 100 rpm with the
throttle stop screw.
NOTE
These adjustment must be made at high alti-
tude to ensure proper high altitude operati on.
Attach the Vehicle Emission Control Information

Update label onto the left frame as shown (see
Service Letter No. 132).
NOTE
Do not attach the label to any part that can VEHICLE EMISSION CONTROL
be easily removed from the vehicle. INFORMATION UPDATE LABEL
~.~ .'
Operation at an altitllde lower tha", 1,500 m
(5,000 feet) with the carburetors adjusted for
high altitudes may cause the engine to idle
roughly and stall.
When the vehicle is to be operated conti-
nously below 1,500 m (5,000 feet), tum each
pilot screw counterclockwise to its stop and
adjust the idle speed to 900 ± 100 rpm. Be
sure to do these adjustments at low altitude.

HONDA
CIJ ;p3 FUEL SYSTEM 77
FUEL TANK
Do not allow flames or sparks near gasoline.
Wipe up spilled gasoline at once. SCREEN
Check the vent hole of the filler cap for blockage.
Check that fuel is flowing out of the fuel valve
freely.
If the fuel flow is restricted, clean the fuel strainer.
NOTE
I Do not overtighten the fuel valve lock nut.
Make sure there are no fuel leaks.
AIR CLEANER CASE

AI R CLEANER CASE/CHAMBER
Check the air cleaner case and chamber for cracking

or deterioration.
CRANKCASE VENTILATION SYSTEM
Check that the breather tube is not restricted.
BREATHER STORAGE TANK
AIR CHAMBER

78 ENGINE REMOVAL/INSTALLATION
18-25 N'm (1.8-2.5 kg-m, 13-18 ft-Ib)
~
90-100 N'm
(9.0- 10.0 kg-m, 65-72 ft-Ib) ~.,
30-40 N' m
13.0-4.0.,-m, 22-29 It-Ib) ~ (J
~
i;l ~ 'lib
• •
30-40 N' m
(3.0-4.0 kg-m, 22-29 ft-Ib)


CBX Eng 1

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SHOP MANUAL

NOTE: Gives helpful information.

Sections 1 through 3 apply to the whole motor- ENGINE REMOVAl/INSTALLATION

NO PART OF THIS PUBLICATION MAY '82 CBX ADDENDUM

HONDA MOTOR CO., LTD.

Date of Issue: May, 1981

Date of Issue: May, 1981

GENERAL SAFETY 1-1 TOOLS 1-5

Date of Issue: May, 1981

ENGINE Type Air cooled 4-stroke

Engine weight 108kg(238.1Ib)

Date of Issue: May, 1981

NO NGK NO NGK NO NGK

X22ES-U 07EA X24ES·U 08E'A X27ES-U 09EA

Spark plug gap 0.6-0 .7 mm (0.024-0.028 in);

Date of Issue : May, 1981

Cylinder head cover 8 6 8-12 (0.8-1.2, 6- 9)

Steering stem nut 1 24 80-120 (8.0-12.0, 58-87)

Torque specifications Iisted above are for important fasteners.

STANDARD TORQUE VALUES

5 mm bolt, nut 4.5-6.0 (0.45-0.6, 3.5-4.5) 5 mm screw 3.5-5.0 (0.35-0.5, 2.5-3.6)

Date of Issue: May, 1981

Tool Name Part No. O'ty Ref. page

Oil seal driver 07965-MA10100 1 14-13

Date of Issue: May, 1981

Float level gauge 07401-0010000 1 4-11

Lock nut wrench socket 07716-0020202 1 13-26

Date of Issu e: May , 1981

DETAIL IGNITION COIL

CDI CONTROL UNIT

TURN SIGNAL PULSE GENERATOR

Date of Issue: May, 1981

EXHAUST EMISSION CONTROL SYSTEM

The exhaust emission control system is composed of a factory pre-set carburetor.

CRANKCASE EMISSION CONTROL SYSTEM

EMISSION CONTROL INFORMATION LAVEL

EMISSION CONTROL INFORMATION LABEL

Date of Issue: May, 1981

Date of Issue: May. 1981

ENGINE LUBRICATION DIAGRAM

Date of Issue: May, 1981

SERVICE INFORMATION 2-1 OIL PRESSURE 2-3

TROUBLESHOOTING 2-1 OIL COOLER INSPECTION 2-3

ENGINE OIL & FILTER CHANGE 2-2 LUBRICATION POINTS 2-5

OIL STRAINER SCREEN CLEANING 2-3 DRIVE CHAIN 2-5

Date of Issue: May, 1981

ENGINE OIL LEVEL

Check the oil pressure warning light. This light

ENGINE OIL & FILTER CHANGE

Stop the engine.

Fill the crankcase with 4. 0 lit (4.2 US qt) of the

Reinstall the oil filler cap.

Add the recommended oil to the upper level on

Date of Issue: May, 1981

OIL STRAINER CLEANING

OIL PRESSURE GAUGE PIN 07506-3000000

Connect the oil pressure gauge.

ATTACHMENT PIN 07510-4220100

OIL COOLER INSPECTION