Honda FT500 '83 service manual

(HONDA
© FT500

IMPORTANT SAFETY NOTICE

notes à strong ii of severe personal ini or loss of life If nsucions are nor
Fallo,

CAURON indicate e pos of personal ier or equipes damage I buiructonsare no fol

Dotes aeserigrione of standar workshop procura, safety principles and envios opartos re na {lue
iris Important Lo note thet this manuel contains sore vistring: and can sunt some ¿pci savin
matado mich could sauee PERSONAL INJURY to sais pine or could damsgo seca oF tender À
Urata lata undarnano that hoes mings end not cov all eonestain ways in wih sec, wether oF
tot recommend by Honda might bx done or of the poule azardos cosequenen of each conca y
mor ‘cold. Honda Inveigte all such ways. Anyana using service procedures or tos, wheter or nat
Focommendod by Honda rua sty hime! are that eter personal safety nor voice y vel be
Fons y the service meto too selected

IMPORTANT POUR LA SECURITE
Sigma un fort risque de blessure graves ou d'accident mor si es Instructions ne sont
Dar suivies.

PRECAUTION Signal un risque de blessures et de détérioration du véhicule es instructions ne sont pes
suivis

Ce manuel ne donne pas le dal des procédures standard «atelier, principes de scurit er opérations
«estreien. est Important de noter qu' contiene cetaies miss en garde (attention et précaution) conte
‘des méthodes d'entrelen spécifiques qui pouralent enralnr des DOMMAGES CORPORELS pour le
personnel enteten e porter attinte au vélicule qu à sa sécurité. Ces mies en garde ne peuvent, natur

ment, couvrir toutes le méthodes, recommandées ou non par Honds, coneevahle pout l'exbrion de
Féntreen, ni tous es risques entraine par ces méthodos, Honda agan pu ls explorer tous, Tout
personne ayant recours aux prooaiures où outils d'ntellen, recommandés où non par Honda, dolt sas
fare que alla sure personnel celle du vehleule West menacé par elle.

WICHTIGE INFORMATION ZUR SICHERHEN

Zaigt mögliche Verletzungs- oder Labensgofohr wa, als Anweisungen nicht befolgt
‘worden,

VORSICHT Zeit méglche Beschidigung dns Motors an, fale Anweisungen nicht befolgt worden.

Austanriche Boschrobungen allgemeiner Werksatt-Areitswesan. Sicherheits und Warturgsver
Iniven sid nich eingeschlossen. Es ist wichtig zu baschten, da dees ancbuch ange Warnungen und
Vorsichtsmatrageln fr evil Wertungsrmeinaden enthält, ch PERSONLICHE VERIETZUNG des Work
slattoersorais verursachen, das Fahrznug buschödien acer es fahrunsicher machen Können. erst
chanson dose Warnungen NIC! al absorbaven Vafahransweisen der Visrtung, 0a von nord
Smoforln ode nicht, oder e möglchen gefährlichen Folgen der einzelnen Verahranseresen essen
‘gine abgesshen davon, daß Honda nicht ale seiche Vrfehrensenesen erforschen kann Jeder, dr De
‘Simmte Warungswerfavan oder Werkzeuge benutzt, ab von Honda empfohinn des pic, muß sch seat
gründieh davon Ceerzougon, daß dur ie gewihllen Wartungsmetnagen oder Werkzeuge wider ie
Paradies 3 Ich de Sionerbrt des Fahrzeuge gefalwóa sd.

AVISO IMPORTANTE

RRMA indic I posibilidad de accidentes serios fatales si no se sixuen as instrucciones,

PRECAUCIÓN: Indica a posibilidad de accidentes o daños al equipo ino se siguen as instrucciones

¡No se incluyen las descripcionos de os procedimientos estándar del taller, principios de seguridad ni
funcionamiento de servicio, Es importante tener en cuenta que este manuel contene advertencs y
avisos contra cortos métodos espe fics de servicio que podrlan causar daños al personal de servicio y
podran dañar el vehleul o hacer de 6 un geligo. Tener en cuenta porfavor que todos ess arten.
is quis no puedan cubrir todas las formas concebibles en las cuales el servicio, ha sido recomen
onda o no, puedo efectuarse o de ls ponbles consecuencias peligrosas derivados de cade
iular Honda, por supuesto, tampoco podrá investigar todos nos casos, Cualquier persona
dimientos de servicio 0 herramientas, recomendadas 0 no por Honda, debe cer-

‘lorarse que éstos no causen accident alguno en la persona ni en el ventoso.

J

oe —

HOW TO USE THIS MANUAL

This manual is bated on the ED (Europian
Dior Sale) model, For other than ED model,
eriptions are precadd by any of the follow:
{np ebbrevitions whenever discrepancies ost:
ing éuneral export KM/H}, DM (General ex
Pore Meri, € (U, Ki, U (Australia, G (Germ
Pol France), B (Belgium), SA (South Africa)
‘GW (Switzerland) and $ (Sweden.

Sections 1 through 3 apply to the whole motor
Sel eile sections à through 21 deserve
Dur of the matoreyele, grouped according to
location.

Find the section you want on this page, then
Fin is table of contents on page 1 of thot
section.

Most sections start with an assembly or system
an and all the required specifications,
ue values, general, tools and troubleshooting

he ection, The subsequent pages Give

cried procedures for the section.

AE you are not familiar with this motoreyele ead
We TECHNICAL FEATURES, section 22
Mou don't know the soure of the trouble, 0
No tion 23, TROUBLESHOOTING.

ALL INFORMATION, ILLUSTRATION
AUCIVIONS AND. SPECIFICATIONS
REED IN THIS PUBLICATION ARE |
ON THE LATEST PRODUCT
ARMOR AVAILABLE, AT THE
MAP APPROVAL FOR PRINTING,
TOA. MOTOR co, LTD, RESERVES
HONDA dit TO. MAKE CHANGES AT
TRS RiGee wrmour NOTICE, AND
Aa QUIT INCURRING ANY OBLIGA
NER NATEVER.. NO PART OF THIS
TION CANON MAY BE REPRODUCED
E SUTIAITTEN PERMISSION

HONDA MOTOR CO., LTD.
‘Service Publications Office

CONTENTS

GENERAL INFORMATION

| [eee
[erunnennesonawes

vi LP CYLINDER/PISTON.
ye
| ST exuronmn ume
¡3 on
IED
| Transmission

1. GENERAL INFORMATION RR

SERVICE RULES
SPECIFICATIONS

| TORQUE VALUES
TOOLS

[ GENERAL SAFETY

| CABLE & WIRE HARNESS ROUTING

GENERAL SAFETY
arm

A the engine must e runing todo some work, make
ee the ven ts nelsentluted, Never un the eine
We dosed ar The etioust contains poborous
han monoxile go

The battery electrolyte conta fue acid rect
Jour eyes, sin and coins. If electabte get in
pe ah em thoroughly wh ware and ell
docto

SERVICE RULES

Us gmuine HONDA or HONDA romand parts and lubricants other eau

mentions may damage he mot,
Stn ant tots da for ths produc.

Be ten ica bs oiacyel. Mate Bok, rut, and ser or rhone

ca

Gasoline is extremely flammable and explosive
der certain conditions Do nor smoke or low
ames or sar your working ares

The battery generates hydrogen sas mich con be
Andy epa. Do not smoke ar allow mes or
‘pure ur ne battery, especia whe charging

len. Ports hat don't most HONDA!

with Engh

a e ns a Incorrect tol an estes may damage the motores
Fee ont Dim, cote in, lock lates, te. whe resembling

Trea ret nontlamgble o high Fas pont vent ue

om sey, Lite ay ding a

Geen ono ers, bg th e race ros Dl fc, and tn Lo ta sin ore eo

yin sep, umes partly mauence bei

2, Near comity, ehe parts Tor proper malston and operation.

$ HONDA
@ FT500

GENERAL INFORMATION

SPECIFICATIONS

en = AREA TYE)
DIMENSIONS | Over orate EEE

Overall with 1 “780 mm (302 in)
cera ihe | 1188 mm (46.7 in
clase 1438 mm (888 1)
Sachet 809 mm (315 io}
Foot pea height 350 mm (3181
Dry woah 159 (3808 0}

Tu Bianono

Frontanpenion, vol | Telescope 160mm (62 int
ar manon, ve! Swingarm 00 mm (35 in)
Front ir sia, murs 3SOS19-APA 175kPa (175 kom, 24 psd
Rear to size, pressure 428518_4PR 2001Ps (2 00 kom" 28 pb
Front brake, ing sept ares | Dike brake, S16em!
Reur baka ining oneptares | Dis brake, 476 em?
Fuel apa 13 (34 US gal 29 In ou)
Fun rnpssiy 211108 US qu, 4 Imo gall
Gente or
Tan 120 mm (in)
Fron ork ll pci 330 ce (1.808)
ENGINE Te Air cold tros ONE

idas rangement Vera single
Bore srt 89 x 80 mm (350 x 3 16)
lamen ABB ce (30.9 en)
Compson ato 8:1
Macinum horca $33 B4PIB.S00 rom

26. 4,7 p/,500 mit (rm)
uk 272 21/5500 mn (em)
Maximum torque 20 Km $8.09) 000i rom)

42.1 Nim (6.2 kg 78,000 mir (em
440.2 Nm 14.0 997.000 min (ram)
Où esse ZA 25 US 2 mp qu tar amy
ZA 122 US 1.85 Imp a a er orange
20 12.1 US ae 170 Imp a a o cane
Larson sam Forced pres and amp
vide mention 1228 kPa (125 kale, 175 pl
Intake vale Opens sBroc) e (8TOC})
Co REDE | ey gre 1082 x00 |
Exhausvalee Opane we 93 weoc
Com 65" arocı)
Va claros Intake 905 mn 10.002 in
LOT Bas | 010mm {0008 in)
‘CARBURETOR | Tier RS
10 number vert
Wainer pnmany | 478
SECONDARY | #128

stole

Pot sr à
Poste
tae sp

$ HONDA
©

FT500 GENERAL INFORMATION

ME AREA TT
DRIVETRAIN | Guten os DATENT
“ranean Spee content mesh
Primary ration 2.379 (00729)
Sara! 246 ra)
Gear 1 1507 Brin)
Gear ratio 1250 (25720)
Gear 1000 (20/29
Gear ato V as (21725)
Fit een 2668 (0/18)
| Geant pte La nt operates ratur ayer 112945)
Drie can 10 50V or RKSONO 100 Links
pain timing, nal IB 7 D € ar 1200 0m LE mar)
Fost rence | 35° 22° 8 TOC MALO pr
Arton 1700/5000 rm
Batey capacity ata
Spa las Standod: DRBES-L INGK or X24ESR UY IND)
For col.lmato (low 5°C. FI
DATES (NGK or X22E8R.U (NO)
Fos extend a ser ding
OnBeS INGKI or XA7ESA INO}
Spark ua geo 08-07 mm (0024-0020 in
Headlight COWIGH So
Talore Ge
Turn uaal ight FRONT/REAR
Speedomater ight
Torn na ndeaor

y HONDA
€ FT500

THREAD DIA mm)

TORE Wom Vom nr

Dive spot

Saavedra bering set

por rankean 6 mm boit
8 mm bat

Le erankene rom ha,
‘mm bolt

Bateos pode ack not

Cam chain tnsorer

Cinch cano

Cylinder bot

Ctr pad ut

(Cam roca bale

Cylinder had mener

finder ad cover 6 mm.

Rocker arm suse lock mut

Vale dur cover

Spark play

iar cover bot

$

10-14 (0-14, 2-10)

9-13 (09-13, 7-8)
19-14 (40-14, 7-101
22-28 (22-28, 16-20)
10-16 (10-14, 7-10)
27-33 027-33,20 20
52-30 (92-98, 23-201
22-28 22-28, 10.200
10-18 (10-14.7-10)
45-60 (45-60, 39-49)
8-50 (45-860, 39-491
100-120 4100120, 72-87)
10-14 (10-14, 7-10)
2-3 (22-238, 18-20)
22-28 02 28,16 20
1972311723, 12-17)
foots (10-14, 7-10)
14 (40-14, 7-10)
[ER HEBF AR]
1518 05-10, 11-191
10-14 (19-14.7-10)
18-20 (18-20, 1-14)
20-40 {2.0-40, 22-29),
13-15 1.2.18.0-10

Ten

ai sem nur

Hs ottorn aller
Fork baie

String stem

Fork ee

Front axle mot

Sponiorete cable com
Car brachen & bottom ese
Calpe clipe racer
Calpe aide pin te

Brake pr retainer pin holder
Sool

Caliper ba valve

Singur por bolt

esr ene nat

Pew cushion upper

Final driven rocket

2

Bauer

TTOROUE Rom teem, fe

1
90-120 9.0-120, 65-80),
20-20 20-30, 16-22)
9-13 (09-13,7-8)
5-55 (45-88, 33-20)
15-30 (15-30, 11-22)
20-25 (20-25, 14-18)
55-60 15-05, 40-47)
1528 1572, 11-18)
Posse
27533 (27-33, 20-24)
30-0 (30-40, 22-201,
20-25 (20-25, 14-18)
25-20 126-90, 18-22)
B73 (0.8-13,6-9)
25-25 (25-35, 18-151
©7104-07,9-5)

80-80 (0-60, 83-58)
70-100 (70-100, 61-72),
30-40 (30-40, 22-29),
30-40 (30-40, 22-29),
60-70(6.0-70, 43-50)
20-28 00-28. 1410

e

(HF HONDA
E)“ rr500

GENERAL INFORMATION

rem

THREAD DIA tar

TORQUE Rm Vom. |

Fear brake die
Fear brake beaches A

Brake hoe bolt
Rear cape bieder
‘eer master cylinder
naine Menger bat

(Rear upoen)
(ax onen)

TE

6 me sort
mn bolt nat
10 mn bot

Fear cala bracket 8 top
Calpe backen A exer

2.

am
mm
"am

STANDARD TORQUE VALUES

“ToRGUE

Torque sections lito above we for the most portant kahtning pois

10

ve

6 mm sre
men ane bol, nut
‘mm tang bot nu

= (27-33, 20-24),
20-25 (20-25, 14-18)
20-25 20-28, 14-18)
20-25 (20-25, 14-10),
26-30 (26-30, 18-22)
81308-13601
26-36 (25-35, 18-281
227 04-0730)

35-5 1035-05, 3-8)
5-19 08-13,6-0)
20-35 20-35, 14-25),
5-00 (48-60, 38-49),
120

TORQUE
km. TAB,
25-08 [25-36
ora | 5-8

10-14 | 710
530 | 17-22
50-40 | 22-20

GENERAL INFORMATION.

&

€ HONDA

FT500

TOOLS

SPECIAL

DESCRIPTION

HUNGER

REMAKE

Shan no ire

Hex rene, 6 mm
Chen holder
Foo holder
Bruning roman set

Race remover
Staring tom diver
Fotk ol ver
Node agrio remover

| vote guide reamar
oleate (Koma)

| ove25—a7s0000,

| 70041510000
rs

18-2200

rex7=sza0000
070234280000

(072082710000 [Brain remover,

eros arios |
Crau

Tarot
07048 KAG0000

20mm vase 3710600

Ééssrnahande … 07036-3710100

Lromosor ent 07926-3710200
singe Bering

‘or attachment 07846-3710300 and
‘ver 07749-0010000

ral muet (Kowa) 07211

19-21, 13-22
19-22
no
Kar

en
Bann

COMMON

DESCRIPTION

numsen |

REF. PAGE

oat evel ques
‘Wrench, 20x 32 mm
Extension bar

Roter puller

‘Attachment, 42x 47 mm

Pilot 15mm
Pilot, 17 mm
Pio, 20 mm
| Driver
| Drier
Attachment 36 mm LD.
| Wrench 10x 12mm
| Aajusing wrench A
Vales ring compresser
Shock compresor
aes guide deter 8.6 mm

| vate aude arr
in sane,
rise

Grao1-0010000
7716002040
07716 -0020500
(077330020001
77460010800

o7746-0040300
‘7746-0040400
‘40040509
077490010000
‘77460020100
77460020400,
‘7708000200,
(077080030200 |
077870010000 |
osé sra000t |
O2 -0010200

orr42-0020200
.0702-0010000,
(77460020100,

or 078222290001
1 07048 4200200, 07845-330100,
jose -2R40000

or 07929-110000.

070572290001

or 07942-6570100, 07002
79495520200, 07042

0: 07942-3700200,

or 07002-24000

3
13-20, 19-23,
13-20, 13-23 |
Des

fous

19
160
ue
19,148
SAS
118,128
+e

38
88,616
10

eu
sv

19-21, 19-29
120)

E HONDA

GENERAL INFORMATION 2) FT500

CABLE & WIRE HARNESS ROUTING

8) SPEEDOMETER CABLE

TACHOMETER CABLE

(meLutcn CABLE INSPEEDOVETER CABLE

(REAR BRAKE HOSE

1-7

GENERAL INFORMATION

HONDA
FT500

WIRE HARNESSES

CTA
DÉcOHPRESSOI
LEVER
(o ree

® HONDA
LUBRICATION FT500

11) CAMSHAFT

m
MAINSHAET

Ya

(MOL FILTER SCREEN ———

2. LUBRICATION

| SERVICE INFORMATION
‘TROUBLESHOOTING
ENGINE OIL LEVEL CHECK
ENGINE OIL
FILTER CHANGE
OIL STRAINER CLEANING
LUBRICATION POINTS

SERVICE INFORMATION

GENERAL

(© Tre tion derives inspection ant ralacamant of engine il and elaning of ol itr cran
Tre ai pum seeing procure e red in Scan.

SPECIFICATIONS

Où capaci 24 ter (25 U Sat 2.1 Imp a tar engine is
2.1 tar (22 U Sat 1.85 Imp q o tar change
20 thee 2.1 U Sat 176 Im al change

Recommended ci; HONDA ra ol or quiet
[AP seve clito SE or SF
Genera al temperature SAEIOTAO

Où pans daivery: Ste (BSW Sat 46 tmp qu 000 rem

TORQUE
Oran pls 30-40 Nm (30 40kpm, 22 — 29 Fb)

TROUBLESHOOTING

it Lee Too Lowe
Normal oi ennumps
3. Worn pin ine

Où Contamination
1 Gi nor cheng often enough
2: Faut head asker,

LUBRICATION

ENGINE OIL LEVEL CHECK

Paca the motoreyle on its center stand
ol ol withthe pack,

I te il era i low or ear he oie vel mark

fn the disk, FIL tothe upper level mark wi

Piel
l'a cowen Lever
RACE

ENGINE OIL

Remove the file ap and drain pu.
‘Aer te où Mas danas, cha tat the dain

(90-40 tm, 22-29 tb)

Fi he canoa with 20 Mes 121 US at. 176
Imp ay of he recommended i

IL SPECIFICATION:
HONDA Ara i or equivalent
AP Savon Cine

Install the oil ter eapsipstck, sar th engine
and lett ia for 2-8 minutes

Stop the engine and check that th ol lvl is. at
the upper Teel mark wih the motoreyle spi
{heck tat hare ar no less

MORAINPLUG

$ HONDA
K @) FT500

(2) SEALING WASHER

LUBRICATION

FILTER CHANGE

Drain the sone a (08 2-2.
Remove tool ite cover bol and er,

Replace the où ft, and inal the of Tier
one bol ar rain og
more
Make ae hatha Oo on e ol Wer
cover bolt and où Har cove ae i good
cordon,
+ a the oi filter cover by aligning te
slot of th cover wih te seme be,
Be suo the a Mer mul mark fear

FF am erankeen wits the recomendo i (ase
2

OIL STRAINER CLEANING

Drain the angine où 009 2-2,
emer te ol pon bot and où pan.
ara theo saine

the ai svoner

M te Her coe by afina te lt of
the cover uth ha entr 1 35 shown.
Fil the crankeace withthe recommended ol (age
pan

nore _
‘Make wie tet Se
| isingocd conso.

(HOILFILTER mORINGS

(OIL STRAINER.

15
Hast

$ HONDA
ee FT500

LUBRICATION

LUBRICATION POINTS

Us gneral purpose where specification ie
Apply oll oF grease to siding suraces and cables not

a
evsreet mus

Im FRONT FORK CONE Race
carr BALLRACE (a) THROTTLE GRIP PIPE

}
1
Hi

/ (6) siamuGaan PIVOT
/ BEARING

(o(CaBRCANT)
DRIVE CHAIN

Pi SPEEDOMETER GEAR (MENGINE (00) DRIVEN FLANGE
Perr BALL BEARING
MAIN STAND

3, MAINTENANCE

SERVICE INFORMATION 3-2 <CMASSIS»>

MAINTENANCE SCHEDULE 3-3 DRIVE CHAIN

ENGINE BATTERY

FUEL LINE BRAKE FLUID

FUEL STRAINER BRAKE PAD WEAR

THROTTLE OPERATION BRAKE SYSTEM

CARBURETOR CHOKE BRAKE LIGHT SWITCH

AIR CLEANER HEADLIGHT AIM

CRANKCASE BREATHER CLUTOH

SPARK PLUG SIDE STAND

VALVE CLEARANCE SUSPENSION

IGNITION TIMING TIRES

BALANCER CHAIN TENSION STEERING HEAD BEARINGS

‘CARBURETOR IDLE SPEED NUTS, BOLTS, FASTENERS
| CYANDER compression

querer

&

Lost

MAINTENANCE

SERVICE INFORMATION

GENERAL
Engine ol aa check
ote

SPECIFICATIONS

ENGINE
rion ting: Ia
Fu advance

Spukpug Pup wp
Pla yo

Page 2-2
Page 2-2
Pape 2-3

10% TD aise Fark)
352 7 BTOC 400m
06-07 mm 1024-0028 in)

“Far calma,
Below CA,

Far end ih

et ‘peed ing

RSR U

© nex | ag
EE ESO

pres

Vat crane eo:
INTAKE! 005 mm (0.002
EXHAUST; 0.10 mm (0.008 in)

“Throttle ip rs play:

Iai speed:

Cylinder compreson:

‘cHAssis
Drive coin sa

‘ute ve fae play
‘Side stand spring enon

Tia premures: Front
ear

Tina Front

TORQUE VALUES

Balancer holder oc bol

2-0 me (V/8-M4in}
12002 100 rpm
1228 kPa (126 gen? 1751

18-25 9m (6/01 ind
10-20 men (9/8 — 9/4 in
O

175409 (1.75 fe, 24 pd
200 KPa (2.00 kaon? 2B

35081940 (betes)
4.25818 APR (belo)

22-29Nmm122-28 kp, 16-20 0)
76-100 Nem (70-100 kg, 51-7

MAINTENANCE

$ HONDA
e &) FI500

MAINTENANCE SCHEDULE
Pator Preside Inspection a each schedule maintenance paño

1 — inept cles, nos or plc cosa
CAS
Chan

CT

Pa 316
[Paga 315,

Tran 19

Page 317
Page 319
Page 318
Page 519]

Pau 317]

11 VIMICHEVER COMES FIRST
21 ODOMETER READING
For higher domar ratings repeat atthe
trequenay intra eran here

3) ENGINE OIL

4) OW FILTER ELEMENT

5) AIR CLEANER

©) CRANKCASE BREATHER

7) FUEL LINES

8) FUEL STRAINER

9) SPARK PLUGS

10) VALVE CLEARANCE

11) BALANCER CHAIN TENSION

12) THROTTLE OPERATION

12) CARBURETORIDLE SPEED

14) CARBURETOR CHOKE

15) DRIVE CHAIN.

16) BATTERY

IM BRAKE FLUID

19) BRAKE PAD

19) BRAKE SYSTEM

20) BRAKE LIGHT switch

21) HEADLIGHT AIN
22) CLUTCH FREE PLAY
23) SIDE STAND
241 SUSPENSION
25) ALL NUTS, BOLTS, FASTENERS

25) WHEELS

27) STEERING HEAD BEARING

28) Serio more equity lopareod in duty

In THE INTEREST OF SAFETY, WE
RECOMMEND THESE ITEMS. BE
SERVICED ONLY BY AN AUTHO:
RIZE HONDA DEALER
SHOULD BE SERVICED BY AN
AUTHORIZED "HONDA DEALER,
UNLESS THE OWNER HAS PROPER
TOOLS AND IS. MECHANICALLY
‘QUALIFIED.

+ Eve

fe Every month

fe Every 2 yrs

Sa Eva 1.000 km (800 mi

Serene Sarin more frecuen, when cid

($ HONDA

MAINTENANCE Se FT500

FUEL LINE

plan ny aoe, damaged of king parts.

(0) FUEL LINE

FUEL STRAINER

“urn the fel vais OFF.
Remove the fue cup. Orting and filter sree,
dro the gula In à afable container, m

__ FUEL VALVE
‘Gasoline flammable and te explosive |
ions Be
tier certain con a ae

Do not smoke or allow flames or sparks (5) FILTER. ip —7
priests heen a sencen E

ah the (ul cp and itor seen in clan non
Hamble or ih sh point stent
Reinga he fer tren, aligning the Index ari
fn the ac van Dady and the ter cren. Isa
roe Oring into th fs wave bay
Feta the fue cup, making sve tre naw Oxiog
ein plc.
naar gite the cup, tan torque to specif

TORQUE: 9-5 Nm

(03-08 kgm, 2-4 lb)

Aster insaing, tun the fue ave ON and crec
thot tere are o fl aks,

THROTTLE OPERATION

Cck for smooth trots grip fal open and
tomate fal losing in all steering postions

Hake sur there I no deterioran, damage. or
tring inthe rte cables. pls any dares
pure Mako soe dat te trot gp feo pay Is
220 mm (BV in a he orde go noe,

MAINTENANCE

“aro rp tee play con bo adjusad at her
and of the tate cable

ine adfusnts ar made with the upper trate
be aster,

Major adermant ae made withthe ower jte

élus ro play by loaning the lek not) and
turning ma adjuster. Tighten the lok nate

ech throttlaeperaton. Replace any damagıd

CARBURETOR CHOKE

(Crack tor moon choke knots option.
Pull the choke up al he way o "uly clos”
Sd make sre te choke van fully load by
‘The ehake Iver on Ihe carburetor should nal be
able tobe med.

To dius the choke, remove the following parts

Lown the choke cable clump on We uber,
‘Then tiran the clon, holding the choke leer
ally coset

Pu the choke Kon down a the way o fully
ake ste th enok vas fly opan by checking
forte lay but the lover a abe ang,

echck the choke operation.
The evoke nab mu Move mostly and soy

Aust th choke operating triton by toning the
user
mat te fuel tank, mot and frame sa cones,

HONDA
e FT500

(2 INCREASE(SIDECAEASE
PLAY (6)LOCK NUT

SILOCK NUTS (DECREASE (INCREASE {MADNISTER.
PLAY PLAY

a
ADJUSTER

a. E
INGREASE Wa 7)

OSB gg

MAINTENANCE

$) HONDA
E FT500

AIR CLEANER

Turn the ar clean oper eauntecockwe and

Note a
Do not separate te or rar lament om

the a ean sve.

Can the clement by ping Hay o foxes
dase Blow may the remining dur by aopying
empre wi rom cutie to lament

Replace ds aleman axe iy, okas |

or domed

Remove the plug from the sir cane ease drain
Ten the cram pl,

MAINTENANCE

CRANKCASE BREATHER

Remove th plug fom the dran we wo empty
any Spot

Ina rain pl,

note 2
Serios mora Trquenty when rien In a
US a full re or Ifthe capos laa an |
be ian In the tramparent cion of the
ran tbe

SPARK PLUG a Sapere
Disconnect the spark plug cap and clean any dirt e
es

ind aia

etm ike pad e

nr

Mae 2 mn st oe wi cos

EE pe by br aer ce

SPARK PLUG GAP: 06.0.7 mm
1002-0028 in

RECOMMENDED SPARK PLUG:

oe | (2) Cue: Sos damage
CET

Nek | omes

mms [No | xeresreu

vs nok [ones |

Make sora the sealing ashe slo goad condition
td nal he spare pi

“Tighten it by nd, then shan wih mark pl
tre

TORQUE: 15-20 Nm (15-20 kom, 11-14 fb)
Connect the sark lug oo.

3-7

MAINTENANCE

VALVE CLEARANCE

nore

not and un vay laren wh
‘uel (Gaon 35° CS P)

Remove he fam sido covers and the st,

“Tur the fuel salve OFF, diconnsct sh (ul tne
nd remo te ta

Remove the create an sing mark hole cap
And e val join coves.

ots th Ayto! comterciociai to allan he

VALVE CLEARANCES:

INTAKE + 0.08 mm (0.002 in)
EXHAUST | 0.10 mm (0004 In)

jus: by looting the lock nut an turning the
cjstingseraceunt there i sig ing on the
fener gauge. Hold te austing ew and gen
thotock it

TORQUE: 15-18 Nm
(15-18 koe, 1191)
check se vale clan,

Inst the romand pars in the reverse onder of
dissem.

lao.
UVINDEXMARK (2

(Lock nur

me

(2 FEELER GAUGE (3) VALVE ADJUSTER

CI VALVE ADIUSTER

LOCK NUT

€ HONDA
MAINTENANCE FI500.

IGNITION TIMING ATT

Note
“The Csparino Dias Tann. aston ie
Facto presa and cannot be adios, To
ct te function of the CDI component,
ignition ming nspocton procoduros we
genre

Remove the timing ha cap and cones the
cometa and ining i,

Start the engine

“The ming core I ne Indx mak air with
00 “ES mare o (12002100 ep).

‘Alto ehack dut tho index marks between the

unit, pulse rotor and pu generator, und replace
ny fly part (Rate to acto 10)

BALANCER CHAIN TENSION A

Drain the engine ot Page 22
Romane the right Crees cou [Pago 8-3.
{ein th plan Rode ok Bt

whan te lock bol i oosned, tho spring wi pall
the almas older ote it
Rema the lack bot i Keep the holder fom
moëng
Move the holder tothe let one graduation fom
wher estopa and ren te oc Bot.

TORQUE: 22-28 Nm

(22-28 ham, 16-20 fsb)

A) BALANCER HOLDER (3) INDEX MARK
1f the homer holder reel cited by he Lock BOUT

Bole contacting the end of the dot, the

‘alancor holder mus Be reset ro provide the

required chai tenio. Ser blow

ll ah aft eae ofthe turer elder tet contacts
the Lock ai, et follows

Removes balancer Poe sping ight crio
pr

Remove te ver and the holder Mange srl.
‘Then ration the anes holder 9 ration
bras

(MAINTENANCE

Insaliion ithe reves rd o im

Nore _
‘Align Mo Bolas Weihe and aT” puna |

CARBURETOR IDLE SPEED

Mean,
Tie nine mu be war or escree le

and atmen. Ten nutes of
100 nd go viii sucio

tha mororeyele pri.

dit e ile ape withthe trot stop sro.
IDLE SPEED: 1,200 100 pm ln neue)

CYLINDER COMPRESSION

Wem up the eng,

Le engine and remove the spark pls. Remove
Tec tok cent
Inserts comprenion 15000 né uh she choke
knob in at te ways Tum the agin top su
or.
Open the conte gl fully. Crank tw engine wien
the whic var un the ange ope sng
Check the gauge ronge

nore \
|
COMPRESSION: 1226 hPa (125 halem?, 15 pil

Improper valve adjusumens
aking nds hesd sees
In pitos rigor older

High comprame canbe caused by

Carbon deport in e combustion chamber or on
a piton head

PURA MARKS)

(1 DECREASE SPEED,

2) THROTICE
sror
SCREW

iii GauGe

BALANCER
‘WEIGHT

TO INCREASE SPEED

MAINTENANCE

DRIVE CHAIN

“Turn the ignition nich of, lao the motreyle
‘ons canter and and nit he wanamien Into
Inspect drive chain fre play midway batween the
proche on the lower hal rn.

eme the amount of free pay by moving the

FREE PLAY: 15-26 mm (5/81 in)

Ade tom
‘Loosen the exe ut

Ubosen the tock nits and turn he shusing ute
both Su on equal number of urs.

‘Be sure the Index mark aligné withthe same
roda om the ee on both iden of
Ie ouster

Basics the ove onan when red Jona on te
in rr ofthe chain sera
25m (in

TORQUE: 70-110 0m
(7.0-11.0 km, 51-20 te)

Rostock fee pay and tree wheel rotation.

Tien he jun nut and lock uta

Leann:

whan the eva chin becomes extremely dit, it

shouts be removed 9nd cess prior 1 ubicar,

Remove the as whe! Page 14-3) aná tr ing.
‘dive sprocket cover and drive chain.

($ HONDA
MAINTENANCE &/ Fr500

Acer the driv chain dítencaberwosn pan of
AN pn from pin camer to pin center win the
‘hain Pad tut and ny Kid Joints ta gen

40 PITCHES STANDARD: 636 mm (26. in)
(@1PINS) SERVICE LIMIT: 048 mm (255 a)

Inept the dr en ad sprocket or any ofthe
following coins.
= Dare rotar
Dry or Rustad ks
Kirke or Binding inks
Improper Adustment
= Ming Die

damage. Replace ncaa.

nore
Never Toil now drive chin on worn
fprocket or à woen cin on now socks,
Both ensin and rocks mute be ln 900d
condition, or the ma place

rack var 9.

‘lean the dele cin with Ktrosns and wie dry

[Do not use à steam cleaner, high pressure

eur ar sobren as hese vil damage the
in

ZW KEROSENE

Lues the dre chan win SAE #90 or #90

canon (2) wire ORY

Do not use commercial aerosol chain lub =
‘ante They contain sobres eich could comas
amage the Oringe A

ea ar
teen ee ER
Ron ce oes |

3-12

MAINTENANCE

BATTERY
Remove the fame ight it cover.

Inept th battery fi ev.
Wien the fig level ears te lowe loa, aed
ed wate to ta upper lec.

Nore
‘Add hy did water, Top water wil
Shorten the Serve te of se bata

The erty ecole cone sulphrie
aci Prower your eye, skin, and clon
LY elecrotyte gets in your evs,

‘moroughly wire water and

BRAKE FLUID

Check the front and rar brake fu resol
Tol I te level ese the lower Joel make fi
the rene with DOT-S BRAKE FLUID to the
‘parle! mark

Check the onto system for leak, i the lool

caunon _
Do nor remove the Feen
the reenor are level.

+ De not operate the brake Iver withthe
‘ap removed. Broke Pid il squ ou
Home ever pled

(S)LOWER LEVEL

m
ges

A) LOWER LEVEL

MAINTENANCE

BRAKE PAD WEAR

Check the des ads for wor by loci Urach
tho sot pointed 1 by the er ron on a clip

agin te brake pad i tho waa’ line on te nad
res to sige of the brake di (Secvon 11
ways replace the brake pads ln pais to

ur von die pesar

BRAKE SYSTEM

REAR BRAKE PEDAL HEIGHT

cun the pada ng 0 nt ne distance bon
‘he paca end upper (ce of the foatay Is covet.

at brake dez

PEDAL HEIGHT: 15-20 mm (5/8-3/4 i)

MAINTENANCE

(@\HONDA
© FT500

Tinten the ook nut mure.
[After ati pol neigt, aut the brake ont
vie

BRAKE LIGHT SWITCH

a wh dt i]

HEADLIGHT AIM

Ads era aim by Iorcning both height ose
‘rovnting vota nd iting te adit a reed
aka Warzen am by turning he ads
ee sh an he Design

Dear demand te fe er

in impropery abated Hoi may bled |

Stee

RASE

12) LOWER (3) ADJUSTING {él LOCK NUT

(1) ADJUSTING nur

A
(2) ADJUSTING SCREW

MAINTENANCE

CLUTCH
are the lc fe play athe ver end

FREE PLAY: 10-20 mm (78-34 in)

Minar sustentar mado vi he upper sust

Pu the Ir cover bac, len th lack nut and
‘ur the dst o obtain he speed free ply.

‘Tighten th lock nut ental the ove

Check teh operation

Major ajustmens ae made with he tomer ur,

Turn the upper junte in a be way and buck

Loon ene loi lock rat and tun the Jo
unto abla the speed fe ply.

AS
mLocenur PLAY

Ai DECREASE
PLAY

Lee

en

‘SI DECREASE Ia) INCREASE
PLAY PLAY

MAINTENANCE

‘SIDE STAND

(Check the rubber ped for dtwrirtin or war
Replace if any wear extends to ie wen Inn ar
shown

hack the side sand spring for damage and 1 of
{orton and the sie stand smb for ludo
movemantund bing.

nore
mark above 288 1 ont
th side

SUSPENSION
FRONT

Check the ation af he front fr by compressing
them mer ties

Check the mir fork sembly fr wann of teks,
fe damage. Replace amy Components which are
‘Thon all ts and bol to he spect true

‘Do, not ride u vehicle with faulty suspension. |
Loue, warn, or damaged suspension ports
may effect aby and ier conto,

‘Check the front fa ar pressure whan the front

acs te ehe on its cents ad

Remove sho vale co and mesura the front fork
av pra

FRONT FORK AIR PRESSURE:
40-90 Kon (04-08 Kafe, 57-114 pa

ii
y
ES m
FEAR un

€ HONDA
5) FI500

(MAINTENANCE

REAR

Pac the viele on tecno tnd ori
‘ies

Move th rer we idee with free tose it
{the seins boring ara worm. Replace i excess

ine suspenso ately, Bing sue Tt
‘Surely mounted and nok damaged or estore

gen ait ruts ond bol tothe pei torquo

Grane the simgwm pot basting noo the
ing pens tig.

TIRES
TIRE PRESSURE

ore _ —
Ti presuré ald be end when He
tres are COLD.
PRESSURE
FRONT: 176 kPa (1.75 fem, 24 al
REAR: 200 KPa (200 fem 28 psi)
size:
FRONT: 250818—4PA
REAR: 25818 4PR
(Creek the tes for eut, med nal, oF other
orp bets.

18

MAINTENANCE

$) HONDA
€ FT500

STEERING HEAD BEARINGS

al off the ground and chee
thot te anidar rate rey.

It the handiber motos unernl, binds or hos
et movement, ad the eig he bearing
bby summing the steering head acusting nut with à
in ant.

NUTS, BOLTS, FASTENERS

“Then he bolt te ad atar to intel
hom in ıhe Maintentnce Schule (Page 3-3)
{hock tho ll chai ts and bots ae tg
18 thir comet torque saluos (Page 1-4 nd Bh
has al coter pnt and safety lips

STARTER DECOMPRESSOR (G ONLY)

(a mai be made forthe manual
Compresor.

nore

‘Adjust dre nage afer us|
inthe vale Gran, (es pags 33.

Remove the crankshaft and timing mar hole caps.

Rotate the flywheel countectockise Lo ag the T
rr wth oh inden ar

Naka ur the piston is St TDC (Top Dead Contr)
fn the comprsio stoke.

aura fr pin at de Up of the compresor
‘aie liter eve

FREE PLAY: 05-1 mm
To adjust feo play. Ionen lock nut on manual

acometer ein nd wm adjusting nut 35
Fried, Thun bock nt

Breese fet play cause bard art: |
fen free play may cause eure Ling
and ae dames

‘Opirte ne manual dacomprasior ever and check

(operation of be decomorccor mechs
echas th ray.

(m TMARK

MARA

FUEL SYSTEM
CIRCUIT D'ESSENCE
KRAFTSTOFFSYSTEM

| SISTEMA DEL COMBUSTIBLE

FUEL SYSTEM

2
ja,

4. FUEL SYSTEM

SERVICE INFORMATION
TROUBLESHOOTING

FUEL TANK

AIR CLEANER

CRANKCASE BREATHER
CARBURETOR REMOVAL

VACUUM CYLINDER DISASSEMBLY
FLOAT CHAMBER DISASSEMBLY
AIR CUT-OFF VALVE DISASSEMBLY
ACCELERATOR PUMP DISASSEMBLY
ACCELERATOR PUMP ADJUSTMENT
COMPONENT ASSEMBLY

FLOAT LEVEL ADJUSTMENT
CARBURETOR ASSEMBLY
‘CARBURETOR INSTALLATION
PILOT SCREW

FAST IDLE ADJUSTMENT

HIGH ALTITUDE ADJUSTMENT

SERVICE INFORMATION.
GENERAL

Gasoline 1 esremely flammable and à explosion under certain conditions. Work in a well entlted aes, Do not
smoke ar alow flames or parks in your work are

(© ion dissombling fl system pars, note the location ofthe Osings, nplac them with sw anes on res
1 Thecsrburstor ost Dow pa rin pag tha canbe loosened ta dats esis! gle

SPECIFICATIONS

Fuel one ae

ess casei

Carter

Teens number

tele spa

Man Primary
Sscondry

Fei rod
‘Ar eu va operating
Pres

Too

Host el ga

131 (8. US 9,29 Imp gl
Zn (05 US on,

Sm in)
ver
155mm (0

39m (in)
FH

228 mm (8-18
1.000.250,
008-016 caso

No. 0701-0910000

1

E

FUEL SYSTEM

‘TROUBLESHOOTING

Engine Cranks But Won't Start,
Sr No fuel nan,
2 No fuit evtinder
3. Too mush fuel ri o yr
4. No spark at plugs ron mala)
5. Ar anar closed

Engin es Roughly, Sls, or Runs Poorly
TL dle sped incorrect.
2. lion malunetion
3. Low compresión
4. ich mure
5. on mixture
Air came ey
7. Baking imo inte pipe
8, Fuel contsminted

1 Carburetor ful os logged
2. Ful cap vent blocked

3, ul ter closed

3. Furia kinked o oct
5. Float vate faulty

ich Maure
1. Choke tek closed
2. Flos vale ly
2 Flot evel too hh
A: Carburetor os longed
$ Seeking fost
6. Dry air laner

FUEL SYSTEM

$ HONDA
® = FTSOO

FUEL TANK

‘Keep sasoline away from flames or sparks
Mine up sped oline at once

REMOVAL

Remove the set and fume right and lft side
Brcomect the ful me, weuum tube and air

Remove the fue tank mount bol and remove the

FUEL VALVE INSPECTION {USA only}

Check thatthe ful nk fl and ur he fue
‘als ON,

tubo,

Fun! sould fw out from the un ott tube
en 12-20 mm 105-048 in M) of vacuum I
in om o ua

RES and enec that fu! Sow cut, fal slows
‘tof the for out. the od va dephragm is
‘amoged cr the fut or woeuum art i loa.
Ie the Hon of fl sil ect wih ye a
ave in RES, tis dicto Sat the fuel vale

aimer, Mn page or unl tank cap, breather

oles com

ai FUEL VALVE (3) SIDE ta) SEAT.
cover

FUEL SYSTEM

a $ HONDA
FT500

FUEL STRAINER DIASSEMBLY (USA only)
‘ain the fl rom th Su tne
Remove the fel va by loosening the ock rut

note

Wold the ful vane body while turing de |
| toc mate

Remove the fel sine sn,
rove a

‘Check the Oring for dotrration or damage and
race Isi a new one recy

Remove the iapte cover by removing te tour
ingre

Inspect he disphregm for deterioration or demag.
Choon the fl vals using compress a.

note
Blow open al panne with the valve MON
and RES postion.

(1) Lock nur

FUEL SYSTEM

FUEL VALVE ASSEMBLY (USA only)

‘Asay the ovr arr of dam.

Note.

* Moke tre tht the prog Bor pin
tdi the valve body.

+ Attar Italien, check the operation of |
th fue vale. Also make ae Bat fel |
ct sim.

Hild a fl vale ie ring he ful |
‘a tai not. |
+ Do nat var the us vale lock nut

LSTRAINER —_

SCREEN

(2)D1APHRAGM

crsprins

moni

a) FUEL VALVE
Dispacen

(@loouLar

(SISPRING SEAT

HONDA
E)“ Fr500

FUEL SYSTEM

AIR CLEANER

Ferma the fam right ar let side ever.

(MAIR CLEANER CASE COVER

IMAIR CLEANER CASE

In (AIR CLEANER ELEMENT

FUEL SYSTEM

CRANKCASE BREATHER
Route the oramkene bros be sho,
out the breother separator rain tbe as show,

Sie Page 3-7 for erankeate brsiher spa

sic measguneran

HONDA
e FT500

(AIA CLEANER

ee

FUEL SYSTEM

CARBURETOR REMOVAL

Turn the ue ate off nd remove he cs nd us
uk

al
(2) FUEL VALVE "OFF

(hornet the sete nd choke cable
oun the dain ssi nd drin rea gtc.

~~

(2) THROTTLE CABLE Es THROTTLE CABLE
Open SIDE) ¡CLOSE IDE)

(vacuum TUBE {21 AIR CLEANER CASE

Diacannet the fuel and vacuum tober
Loosen the srtws string th career Band

TE) CARBURETOR BANDS

FUEL SYSTEM

$ HONDA
® FT500

VACUUM CYLINDER DISASSEMBLY

Remove he vecu linde fem the exburetor
boa

‘Grea itt the scam piston out wit is nec
Shad eempresion ing

Nove

[inspect the vacaum piston and lado for
Mats sure that he pin moves up and down
teal ne et

Remove 108 fll opin stopper and the mode set
‘Separate the et acai rm the piston.

ref It the mal cng olf the carburetor body
nd rem o sr joo

low open she primary min sr jet, secondary main
A and slow nt ith coord al
Never sian carburetor Je with wie or
Ari This wil entre ho opening and
Fo exce ful coupe or.
+ Do nat to emove the a

2
VACUUMPISTON (1}JETNEFDLE (SIFULLOPENSTOMER

(OINEEDLE SET (a) COMPRESSION
‘SCREW

Sr E
FUEL SYSTEM »/ FT500

FLOAT CHAMBER DISASSEMBLY | per MAIN JET.

Remo the Hon chamber body.

Pa it arm pin e with par of

Remove tho toa roa vale,

Remove the slow jet ep.
Remove the econdary main jet and jet medi
Remove the primary man jet an nz.

Remove he low it.

‘Tit a carburetor to ree dhe na jt.

Cleon the pagas and jets wäh compres al

FUEL SYSTEM

Insert flot valve and sat fr groes nick,
Apart or ter ful.

AIR CUT-OFF VALVE DISASSEMBLY

Remove the sr cof valve cover and pull ou de
sing

Remove the dispo and take out the Oring.

Inspect te diaphragm and vale Tor cracks and
ii

In VALVE

FUEL SYSTEM

(AHONDA |
WE) Fr500 |

ACCELERATOR PUMP DISASSEMBLY

Remove tha seserator pump cor, pump rod and
‘pring. Check to dephragm for wars or pin ele.

wore
(Check th acer pump Tor Tandam of

Remove the boot and check it fr tar or pin han

ACCELERATOR PUMP: ADJUSTMENT

Losin the tote stop Siew, co the trots
sae dom

Mesure the clarnce between the sceeator
Purp rod and adjusting arm with she ori
ate on

‘CLEARANCE: 0-0.04 mm (00.0018 in)

don by ending teasing am,

esse the carence Denver the ating am
ted stoper on the carmurnar body,

‘CLEARANCE: 2:1-3.31mm 012-0131)

‘Auer by bending the ajuting am.

(neun? Rod

sy

(sicover

FUEL SYSTEM

COMPONENT ASSEMBLY

“To arb to ie ttt val, cclaor pump,
float chamber and vacuum cylinder, revere te
sembly procedure,

note
a ing the ir eutol! va Orig,
ake aur te a ures i werd the Boy.

FLOAT LEVEL

Remove he Hoa cham,

FLOAT LEVEL: 166 mm (0.511)

Replace cho Host I fhe Host le not within

CARBURETOR ASSEMBLY

NOTE _
* Ur or Ori whanavar te error
economia
+ Handi dl je and reis with oe
They can ely ba scored or srached.
+ Be ae to me dw top over re |
waters rig asembly |

Acme she carburetor in the ross order of
ces

CARBURETOR INSTALLATION

Carmen instalation ie mental the revere
order or remara.
Nore _
[Moke aaa the and of the erbarer ar
om prop sens fn the intake Pipe

just trot rite play and choke cable

DARE

2 FLOAT Gau
‘07401 -0010000

FUEL SYSTEM

PILOT SCREW
Ti tw dk vt ne ty
MAL OPENING: 277 um ut

canon

Damage to the pos sre weak vl car Hf
me por erre irene epi the seat.

FAST IDLE ADJUSTMENT
FAST IDEL: 1,000-2500 rpm

1 ajustment of he fs eis necessary, remove
the crburetor and clos the tote sale by tan
Ing the torte stop sere out

‘Adjust by opening or coin the fork en
os ink arm nt he craneo bi
‘choke ink sem and the tote du
18 mm (003 m.

A THROTILE (2) PILOT SCREW

STOP SCREW

(ay TROTTLE DRUM

\
DEN

/

(2)0HOKE LINK

a
OPEN OR CLOSE

FUEL SYSTEM

HIGH ALTITUDE ADJUSTMENT
(USA ONLY)

Nore en
Ths acfamantı must ba made at M
He to en proper high ade open

Vine the voile 5 10 be opera coniruouiy

shove 6/500 ft (2000 m} tha exbureor must be

sch. se Oncribed talon to improve dia

ity und decreas han emision.

1. Rasa the standar mein jet (#140) wth ih
ide sy min pt (TE)

2 Warn up the engine to operating temperature
‘Stop and go ding or 10 minutes i cent

3. Turm the pile tre cn 2 um

A, Adjust he ile sp to 1200 + 100 vom with

Arch the Vende Emision Control Informa
‘ion Update taba

nore
(Oo not sich the al To any part tha a
De eal removed lem the vehicle,

‘Operation ar an alnıde Tower than 5.000 fr]
(2.300 m} wih the carburetor ausied for |
high altres may cause the engine o il |
re an all |
When the vehlte ie 1o De opened cont
uty Bet 5.000 fe (1.500 m) replace the
ai fet ath 8140 main jet m he pot
ren comnterciocons o orinal pasion
agir e sop and adjust te le speed 1 |
7200 = 100 mm. Be re 10 de Mo |

ENGINE REMOVAL/INSTALLATION

|
]_70=10nm
: “Gal —(7.0-Ni kam, 61-80 tb)
{20-25 em x y)
EA) i N oe
— (70-100 koe, 81-72 to)

(45-80 to,
Bat

14550 kgm.
Sean)

RR

ENGINE REMOVAL/
» INSTALLATION

SERVICE INFORMATION
ENGINE REMOVAL
ENGINE INSTALLATION

SERVICE INFORMATION
GENERAL
+ During raova nd into uppor the motocoyco with table look olde stable

+ Pars eating engine mov for servicing
Cylinder hesd Section &
Grankese Section 10
Crane Seven 11
Botan on 1
Transicion Sein 12

SPECIFICATIONS

Engine weit 47 49 (10818)

Oitespacty 241025 US.at, 21 Imp ath alto dant
2318 122 US at, 1.85 mp mi at iter ere
201K (21 US at, 1.38 Imp at at où change

TORQUE VALUES

8 mm bots 20-36 Nm (20-36 kom, 1428 fib)
16 mm boit 43 2 60 Nm (48 = 60 am 23 — #3)
12 mm bolt (Upper) 70 = 100 Nom 7.0 - 100 vm, 51 —72 e)
12mm bot {Lowes} 120 140 Nim (120 = 18.0 kom, 7 — 101 fib)
Foot peg bo 702100 Nem (7.0 = 10.0 kom, 81 = 72 1b)
Matter tana 15-25 Km (1.8 - 2 Kam, 11 ~ 18 eb)
Exhaust pipe nut 8 120m 08 1259.6 91)
Res ae mat 70 HO Nam (70— 1103, 81 ~ 6038)

ENGINE REMOVAL/INSTALLATION

ENGINE REMOVAL

Drain the al from the engine and remove both
fama ai covers

Turn te ful ave OFF and donne the fel
Remove the seat and fuel tank.

Dizcoanet the battery negative weil

(GISIDE COVER

(STARTER SOLENOIO cOUPLER
Disconnect the tater oo, pue generator
and alero couple.

2 ALTERNATOR (MPULSE GENERATOR
‘COUPLERS COUPLER

amor their cnet (Pape 4-61 and the corto

ENGINE REMOVAL/INSTALLATION

Remove tro spark plug cap and drones the
tachometer cable

Diconneet the clutch cable at he clutch arm,
Remove tha brake pel ht foot pag and brake
Haye sre

(3) FOOT PEG

AN BREATHER TUBE
Diconnac the breather tbe from the rank. q
Remove de Geral peda and racket com

HA) BRAKE PEDAL

ENGINE REMOVAL/INSTALLATION

Loui the orale nu.
lor the chan ajuste lock nuts and adjusting

Fl te roe wheal onward

Laveen the muftr Ban eis,

Remove 20 deve sorecket with ma are ain,

12 AXLE Nur

AS) LOCK NUT

yo) HONDA
WR

ENGINE REMOVAL/INSTALLATION

[Pies a jose or padded Bak under th angie |
before fosening the front engine mounting

Remove te engine

ENGINE INSTALLATION

Ansa he angina inthe rover order of ror,
noting the fling

Anal the engine hanger Bots and sahen hem o
the act torque vale

section and ce
Engine oi (Page 2-2)
Togo fos play Page 3-8)
Ori chan rap
Poor ra {Pome 3-18)
Cut verte pay (Page 3-1
Check al lacie equipment,

Rout all wire amuses and cables prop (Paget
19.
he masas pi stat are not damaged

(0) 10mm BOLTS 45-60 Non (8 8 mm BOLTS 20-35 Nm
(45-00 kgm, 33-43 fb)

12) 22mm ours Sram 901s
EYES un ER
25 00wm] 20-s5hm,
ze ee

(9) 12mm BOLT 120-140 Nm (a) 10 mm BOLTS 45-00 Nim
(120-140 kom, 87-101 A (45-60 kom, 39-43

GQHONDA |

© FT500

CYLINDER HEAD /VALVE
CULASSES/SOUPAPES
ZYLINDERKOPF/ ,
VENTILE

CULATAS /VALVULAS

HONDA
FT500 CYLINDER HEAD/VALVES

EmmaLors
10-18 Nem
10-14 kom 7-10 6)

2mm BOUT
He Nm
| 31780 9-12 et

10 14K
(10-183,
Ton

10-14Nm

014 km

Er

10-14 8m
(10-14 kom, 710400)

SS

ag ae N

22- 200m

NG

16- 0um)

| SERVICE INFORMATION
TROUBLESHOOTING
| CYLINDER HEAD COVER REMOVAL

CYLINDER HEAD COVER DISASSEMBLY
‘CAMSHAFT REMOVAL

CYLINDER HEAD REMOVAL

CYLINDER HEAD DISASSEMBLY

VALVE SEAT INSPECTION AND REFACING
CYLINDER HEAD ASSEMBLY

CYLINDER HEAD INSTALLATION
CAMSHAFT INSTALLATION

CYLINDER HEAD COVER ASSEMBLY
CYLINDER HEAD COVER INSTALLATION

SERVICE INFORMATION

GENERAL

This econ covers malrtanancs of tho cylinder head, vases, camshaft and rocker arms: Al oso operarios canbe
accomplish with th engine inallo inte rama.

+ Compa luis ol a ed tothe cylinder Head rauch an ol conto rfc inthe engine cate, Bo ur ter ricas
Am not log and thatthe ring an dal pins ar in place before iealing the cylinder head

+ Before sembly, apply molydemum isla grease t the coma beings to prone il ubieaon.

2 Pooreleen engine a ito the pocket In the nds, head o rise tha cae efor isang he efindar Ness eve,

SPECIFICATIONS.

men STANDARD, SERVICE LT
Compresion EXT
Comte Ge "aT mm (14945 in) 2523 mn (420
30.06 mm 1.967 in) 2027 mm (1.4289)
Jura 0. | 23904-23378we (D9agr-op 6) | 239mm Isa)
19954-19.975mm (0/850-0./884in) | 109mm (0.28.0)
Runout ee (0.4m 10.002 in)
Sid crane
ocean 10. 12.000- 12.018 mm (0724-04791 I
Rocker arm shalt 0 | 1.966=11,984 mm (04711-0:47180)
Rocker rm sales clare Roi 0062 mm 10.0006-0.0020 in) 0.14 men 10006 1)
Vire Free length Inner | 38,3 mim (1500) 37 0 mm (AB 1
Outer | 2024 mm (1.430) 353 mm (139 in)
Pralsafeng inner | 7.0 = 08 Ka/26 mm (16.6 1.111020 |
18 20.0 men (29.1217 it)

CYLINDER HEAD/VALVES.

TROUBLESHOOTING

Engine topend problems ar uta performance lad and can usually be ago by «compression tet.
Engine notas can Uma Bo trees toa op and wit a sounting rod or stethoscope,

Uneven or Low Compresion
Taies
comet he sdument
Burns or bane values
I Income vale timing
Broken va pring,
2. Cylinder head
Ling or damaged and gasket
- Wars or erechad einer head
2. Glin: end Don (fer o Section 7)

High Comprosion
Y. Een eon Blip an piston crm or combustion chamber

Tingo vv usen

2, Sclng valo or broken vals sing

3. Damar or orn rocker rm o eal
5. Wom or damaged cam chi tensioner

A

2

Loos alar cin

Poor ling
Y. Compresion 00 low

CYLINDER HEAD/VALVES

CYLINDER HEAD COVER REMOVAL

sor dia gr rom the plier

move she cylinder hs cover bolt, noting the
oem of he 7m bot
Remove e inde heed cover

CYLINDER HEAD COVER
DISASSEMBLY

Qu à grogne in he ee pin in a rats cnr

CYLINDER HEAD/VALVES

move the cocker arm es by tapping te comer
witha pas hammer

V
ROCKER ARM SHAFTS.

(ievLINoER
HEAD COVER

Brant the rocker ams and wave washers rm the 2

te

(2)ROCKER ARM (3) WAVE WASHER (4) ROCKER ARM
‘SHAFT

ROCKER ARM INSPECTION

Inspect the rocker ars for damage, wer or log
cle,

Nore _ —
[any rar am requires king or esas

CYLINDER HEAD/VALVES

Mann the LD. of se rocker om.

SERVICE LIMIT: 1205 mm (0.474 io

ROCKER ARM SHAFT INSPECTION

Inypec rocker im sate for wur or damage und
mascara a D 0.

SERVICE LIT: 11,01 mm (0.450
kette te roger arts lene

SERVICE LIMIT: 0:14 mm 12.008 in)

CAMSHAFT REMOVAL

Measure the stone fom ha tp ofthe tensioner
to me top of the wedge 8, IL more han Om
1035 ie coches fs warn and mut e apa.
cad, Tho cars enin an be placa by remoxing te
snternkeser cover and teh (Scton 8.
Pall toe wed A up for enough to Inart à 2 mm
tr pin (per ep) in tha hole to look i
Gina wedge 8. This wil ree arson ost
the cam chai bythe automate emi

CYLINDER HEAD/VALVES

y HONDA
E) FT500

eme the create hole cap nd timing hole

Remove she cam sprocket
nore =.
Rt opt bole m He

sprocket cutouts re even with the top of die
inser hess show.

ul ee eam apar af the cama

Remove the com chain fom the cam sprocket

‘Super the cam chin with pion of wire to kop
At rom fling into te errar,

Pace to cam creer in torial potion.

Pall he comente up and remonte socket und
‘imate.

(a) cam SPROCKET BOLT

CYLINDER HEAD/VALVES

CAMSHAFT INSPECTION

‘heck the carafe journals for var or damage,
assure the 0.D. of esc outa

SERVICE LIMITS:
RIGHT: 23.9 mm (0.94 in)
LEFT: 199 rm 0.76 in}

hick sch cam toe or var or damage
Measure the eight lech ar lb

senvice Limits:
INTAKE: 36:23 mm 1.426 in)
EXHAUST: 36.27 mm (142810)

CAMSHAFT SEARING INSPECTION

‘Chace asen camshaft bering for wear 0
natal in lindern covet

TORQUE: Gm 10-16 Nm
{01 kom, 7-10 010)

7 mn FAT
113-17 kom, 9:12 tb)

sure the com bario LD.
SERVICE LIMIT:

RIGHT: 24.07 mm (0.969)
Leet: 2007 mm (0970)

6-8

¿Y HONDA
E FT500

A) INTAKE PIPE sracen

CYLINDER HEAD/VALVES

CYLINDER HEAD REMOVAL

ma the flloming pats:

inc had cover (Page 6).

an tenir ble and washer

(E) TENSIONER
eour

Remove the inde hd cap nats and washers in
rot pat in mo or mor sup

CRE

nore = a
avoit damas Be cylinder head m
tes.

CYLINDER HEAD DISASSEMBLY

Femme ne vale ring ot
Re va vane song com

To prevent los of tension do not compress |
the rae springs more than necessary o
remote the cono,

nove y
me veined]

| hee ana poston,

(1 VALVE sPntisG COMPRESSOR
(97757-0010900 OF 079573200001

CYLINDER HEAD/VALVES

Pme she carbon Anal from she combustion
Chamber and clan any gust material trem me
Slider a.

CYLINDER HEAD INSPECTION
“Chak the sk plug hole and valu ace fr esc.
Check the elinder Reed for ware with sigh
oe od ele num

SERVICE LIMIT: 0.0 mm (0.004 in)

VALVE SPRING INSPECTION

ensure the fee lang of he nner and outer valve
SERVICE LIMITS:

INNER: 220 mm (1.66)
OUTER: 26:3 mm 1139 m1

CYLINDER HEAD/VALVES

VALVE /VALVE GUIDE INSPECTION

Inepnet ac vv or unes, burning, erates or
erst stom ee

{ck ths ale movant in the quite

nro and ecard eh valo stim OD.

SERVICE LIMITS:
INTAKE: "6.565 mm (0.2686 i)
EXHAUST: 6.550 mm (02578 in)

am the guide 10 remove any carbon bul
befor checking he alv guid LD.

Menaue and second each vole guide LD, using à
Bil gauge o ni mromater

SEAVICE LIMITS:
INTAKE: 6.63 mm (0.26 in}
EXHAUST: 6.63 mm (0.26 in)

sut te sem to ui coran.

VALVE STEM-TO.GUIDE CLEARANCE
SERVICE LIMITS:
INTAKE: 0.065 mm (0.0028)
EXHAUST: 0.080 mm (0.0051 in]

nore _

1 the moque eewance Buck te
‘eves dm, determine 1 2 ew cule with
ana mens sould bring te clean
8 win tolerance, I o, reglas guides 63
necessary and rear oft

It somtoguideclerance sl! oxcees tho sr
iit wen new gues are ina, repo the

VALVE GUIDE REPLACEMENT
‘senor he end ad and divo out the guide
‘rom the wae port.

[Whey diving out te valve quid, be es]

‘et to damape she Han E

$ HONDA
® FT500

>)

() VALVE GUIDE DRIVER, Lamm
7742 -0010200 OR 07242-6570100

6-11

CYLINDER HEAD/VALVES

Insta ana va guia rom the cop of he head
Check the vae guide For image afer nro.

(N VALVE GUIDE DRIVER
107742-0020200 08
070423200200.
(nvatve Gus nEANER
74551000
eam the new va guides after insano

nore
‘Use cating ol on to rumor during th |

operation orto the reser hl marina
sod remoina it.

ele the vete set (ele.
Clan tie eyinde head thorculy to remove amy
men parte

VALVE SEAT INSPECTION
AND REFACING

Clan at otk and exa ata thoroughly to
remove carbon dos.

App à ight costing of Pu

‘other hard app toa

Remove the vie and nec he ae.
Far ma ae at

SERVICE LIMIT: 20 mm (0.08 in)

[re vt ronde Tj he ve fase
ds burned or badly worn ort conta he
| seuruneveny replace hera

6-12

CYLINDER HEAD/VALVES

Inipecc each valve sat
SERVICE LIMIT: 20 men (0.08 in)

A6 the satis too wide 100 nara, or hs low spot
tha war mur be seinlhed for good mal

Nove

VALVE SEAT CUTTERS

(nVALve SEAT CUTTER
VALVE SEAT GRINDING

Using a 45 degre cuter, somero any raum ar

CYLINDER HEAD/VALVES

Using a2 dere cuter, ramen 1/8 ofthe exiting
‘lv eat material

Use 260 dre cuter and remove the bottom 14
of the old at

Us à 45 dre fiin cuter and out th tothe

(m Lo SEAT wiora

Sa

OLD Sear unoTH

CYLINDER HEAD/VALVES

($|HOND.
Ca] F300

NOTE

{App a thin coating of Prion uo to the va
tee Prem the rave through the vals pide m
‘Oma the sa to mike a ler pattern,

more the valve wo ispecies
Nee contact aren 160 high oh als, the eat
mon be lowered using à 32 degree la cuter.

Lie contact aes i 00 low on the vl ne ent
must be ad using 960 degree imer cuter.
Refinien the vst to petitions ag AB gr
Amen eee

Alte cutting he sa, aplylaping compound to
the vale then, and ap tho vive using ght vai
Alter ping, va all residuo) compound of te

UI CONTACT TOO HIGH

Sa

OLD seat more

CYLINDER HEAD/VALVES

e HONDA

FT500

CYLINDER HEAD ASSEMBLY

Compress ha valio Just ecu to intl tha he

To prevent Tn of wale spring tenir, do or
compress he vale spring more han necesa.

apport he nde ad or i wg
Bench race lo. revert posiblo sab

Ta tha abe stem gay vi api mint
prets

i serING
(VALVE | SEAT

a

(Innen SPRING

“'GISTEMSEAL OUTER RETAINER COTTER

SPRING
‘a

(1 VALVE SPRING COMP?
'07767-0010000 OR.
079871290001

oe

RESSOR

PLASTIC HANMER

à HOND:
€ FT500 ti

CYLINDER HEAD/VALVES

CYLINDER HEAD INSTALLATION MORING

Romane any met mar rom te cylinder
Tall the Orion, dowel pine and a naw gate

Insta he eylindr hend and Gabon the cylinder
sd nuts in a css patin in uo oF more

TORQUE: 22-28Nm
(22-20 kom. 10-200)

Insulin Intake pio an poor

Q)INTAKE PIPE (SPACER

CYLINDER HEAD/VALVES

Install the cam halo tensioner bolt and sting

‘Tien the vnlöner bot 1 socie org.

TORQUE: 10-14 Nim
(19-14 tm, 7-10 ei)

(TENSIONER (ISEALING
sorr WASHER

CAMSHAFT INSTALLATION m cam pan

Cost he came Journals win malyhtenum
halte re.

Route tho camshaft dough the cam chain and
ina the cam sprocket orth eumeaft th he
‘ing mare acing he esd of the engine

Note

“Turn the canto and sign tho "7" mark onthe
wnat ror wit he ie mark on he fet
nena coer

(GP HONDA
E) FT500

CYLINDER HEAD/VALVES.

Alin the timing marke om ho cam sprocket with
‘tha top ofthe linger ead

(WEDGE A (2}2mmPIN (MCAMSPROCKET
Side te cin over the cum ¿proce without 7

rio the sprocket,

“gran th cam pret bolt

TORQUE: 17-23Nm
(1.7223 km, 12-17 fb)

Remove the? mm in holding ed A up

CYLINDER HEAD COVER
ASSEMBLY

Insta tho rociar ams, asker sm sa, Oring

jar
eurour

Insta! ds dei pins.

CYLINDER HEAD/VALVES

CYLINDER HEAD
COVER INSTALLATION

ty al ssln 1 the einer mang surfaces |
fh linger nad,

‘Keep aber vs frm the cama being |
arcs.

(1)00 NOT APPLY SEALANT

vn engine ol nto te ol pocket in the
that he com ober esmero.

aa

DOWEL PINS

AH) TACHOMETER GEAR CASE.
At ate 4 om On nd
‘An the tachometer gsr shot nd id the lab

ont the eine ead.

CYLINDER HEAD/VALVES

Loon the vales acting seres and thon ns
the Gin hand.

Tíghen the cylinder Need boite 40 the specified
‘torque in a Os ptr in two ar mor spa

TORQUE: Gmm: 10-14 Nm
(10-14 jm, 7-10 101

7 m0 18-17 Wan
(13-17 tom, 9-12 fb)

Note

[leo rose salon am ahead]

Ase he atv etarnce (Page 3-8) and iat
tha vale adhster covers making sure the Ovingt
Ar proper sated inthe groove

(A VALVE ADJUSTER
COVER

7. CYLINDER/PISTON "3°

SERVICE INFORMATION
‘TROUBLESHOOTING
CYLINDER REMOVAL
PISTON REMOVAL

PISTON INSTALLATION
CYLINDER INSTALLATION

SERVICE INFORMATION
GENERAL

+ Camihat beating oils fed t the elder heed through an orifice in he engine case
22 th ee no lage and tar the Oring and owe pins ae in place before installing te cylinder asa.

ET STANDARD. SERVICE LIMIT
Grier To, A fa) | 89.11 mm (2.508 i)
Taper — 05 mm 10002 0
Out of round = 0.95 mm (0002 in
Mars across top = 010 mm (0004 in)

SPECIFICATIONS

tan, piston ving and Bion |
OD. ss 8897-880 mm (2600-3.804 in) £8888 rm (3.99 in)
Pin pin bore 21002-21008 mm (08268-06271 ja} | 21.08 om (0.890 i)

ston in piston charme {1002-0014 men (.0001-0,0008 in) | 0:12 mm (0.008 ni

Pinon ng end pp
Topfeond | 030-050 mm 100118-0.0197 in) 085 a (0.026 in)
Où Sido Ra 02-09 mm (0007-0038 in)

etn ringto-roone crane
Top 0030-0086 mm (00012-0.0026 in) | 0:12 men [Mon is
Second 0015-0.048 mm (0.0005-0.0018 0.12 mm (0008 in

Opindartogiton Casan 1910-0040 mm (0.0004-0.001 à 3 mm (0.008 in

Pon pin 0.0, 20834-21000 mm (02266-02268 n)_| 2086 mm (0825 in |

TORQUE VALUES

Cylinder bolt 10 14NMILO=144gm,7 - ih)
Cri eut 22-28 Nm (22 — 28m 18 20 Fb)

os y) HONDA
CYLINDER/PISTON E) FI500

TROUBLESHOOTING

Low or Unstable Compro,
om erinder or pitos ie

Exsonve Smoke
Tivo ender, piston, or piston ras
2. Improper nallation of piston ring
3. Sand or sata piston or lada wat

cheating
Excess bon buildup on pisan ern or

Knocking or Abnorm Nose
‘Worn leon and ylnder
2, Beco cron Bio an piston erown or
‘combustion Chamber

CYLINDER/PISTON

CYLINDER REMOVAL Wore

Remove the ends had (Suction 6.
Remove the cylinder head geet, dowel pins and
vn

Rema the cam chin ge

(GIGASKET

Remove the com chain tensioner belt and sing
var

(UTENSIONER BOLT

maur

(A) DOWEL PINS

(2180118

CYLINDER /PISTON

Remove all gasket matic from the oyinder top

CYLINDER INSPECTION

(he cyinder tore for wenr or mag
Mesure the cylinder LO.

SERVICE LIMIT: 69.11 mm (2.508 in)
Callate the taper and ext of ound
SERVICE LIMITS:

‘OUT OF ROUND: 0.05 mm (0.9021)
TAPER. 005 mm (0.002 im)

Anspct he top of the cylinder for wars in an X
ar how.

SERVICE LIMIT: 0.0 mm (0.008 in

2) MIDDLE e

da sorron

HONDA
FT500

(@Q\HONDA —
eyLINOERVPISTON DO

Remove the bat quit, doe! pas aná ol control
oi

PISTON REMOVAL

Prac sap o shop tonel int to erro
men te ston pin lip with pier.

NOTE

(is re

Press ne ton pin ut of he piston.

PISTON/PISTON RING INSPECTION
Mesure de estan rng trame cleaner.

SERVICE LIMIT {TOP/SECOND):
10.12 men (0.006 in)

CYLINDER/PISTON

amore piston ings.
Inspect te ton fr damage and ing roots for

Insert each piston log win thw piston into the
Endara mabe th ing nd ao

SERVICE LIT:
(TOPISECOND): 0.68 mm (0.025 in)

Mesure the piston diameter 10 mm from the
and 90? to the piston pin hol.

SERVICE LIMIT: 88.88 mm (3.498)

SERVICE LIMIT: 0.10 mm (0.004 in)

CYLINDER/PISTON,

east mis piston pia hole LD.

SERVICE LIMIT: 21.08 mm (0.3300)

usure the piston pin OD,
SERVICE LIMIT: 20.96 mm 0.825 o)

otto e plcono-piston pin crane

SERVICE LIMIT: 0.12 mm (0.08 ot

PISTON RING INSTALLATION

(ia te pan tng groove car

Nove

Pre te For CT]

CYLINDER/PISTON

Clean the piston ringe and install nem with he
aa foi Up.

NOTE
Aval piñon und plan Hing damage during

11 TOP RING

|
|
|

Space the piston ring end gaps 190 grove apart
So "Do not align the oll ring fade rm) oo
ss

Aste nl, tha rines shoul rate rey in
‘he sens

y 18) SPACER

Ss) SIDE RAIL

CYLINDER/PISTON

PISTON INSTALLATION

Inet the pit, piston pin and new piston pin

Postion the pin “IN mak 00 Be
Inca atin ie
+ 0 not align the piston pin ip and gp

CYLINDER INSTALLATION

Inst the oyincer get, down pins and ei
conta re.

nore

ES at the Tre]

neck mar he Oring i in placeon teeing

(1) O-RING,

HONDA
FT500

curêur

ía
EnDGA? |

CYLINDER/PISTON.

7

HONDA
FT500

Cot the cylinder bore and piston inge wi engine
ai

Carefully tour the cylinder our the piston by
Smprasing the pito ring by and a sho,

‘ident vider bolts and ts
TORQUES:
Sind bot: 10-14 Nm
10-14 pe, 7-10 10)
tinder nut: 2-20 Nm
(22-28 tem, 18-2010)

Hold the cam chain tensioner up and insert the
tonsioner Halt and sing washer nt the cir
Foes Thea gh the bat.

cnn Sn gue nthe ovine
+ ui the aude in unt it bottoms in he

Inst the rng and dow ins ln he top of the
nina

iva anew cylinder head us

lan a epost rom ta einer ead and
Inv Papo 611

(2) TENSIONER SOT

urgasker

(2) CaM CHAIN
Sue

TE) DOWEL PINS

(}eYLINDER

FT500

e HONDA 7

CLUTCH/OIL PUMP

EMBRAYAGE/POMPE
A HILE

KUPPLUNG/OLPUMPE

EMBRAGUE/BOMBA
| DE ACEITE

CLUTCH/OIL PUMP.

8. CLUTCH/OIL PUMP

SERVICE INFORMATION

TROUBLESHOOTING

RIGHT CRANKGASE COVER REMOVAL

cLuTcH
OIL PUMP

DRIVE GEAR REMOVAL:
DRIVE GEAR INSTALLATION
RIGHT CRANKCASE COVER INSTALLATION

SERVICE INFORMATION

GENERAL

+, This seo costs removal end Instalan the cute and af pump, stating with the rt canas cove. Al these
parlons cn bs camp with te ani inne in Us rame.
a Pia te exi cute dls apap, ont new es with ana il lore assembly.

SPECIFICATIONS

ire

SERVICE LIN

omy Tr fs pia fat evo end)
Spring re length
Spring potosdength

Die thickets 1A}
Die min (0
Piste pone
Primary ev ur 1.0.
Outer guide OD.

10-30 mm (38-34 in)

an mm HE in
237-283 RT mm
13-016)
282-210 mm (0102-0109 in
292-306 mm (0115-0121 in)

25.5028 080 mm 11.0814 1.0622 in

3520-2990 mm 107-1311 m)

2:30 mm 10.090 in
[250 mn 0.102
[0.3mm (0.01 in

27.000-27 021 mm (0.08801. 1 27.08 mm (1.05 in

112031 m (1.050

22,600 22.035 mm 0.8001-0.678 1] 2208 mn (0.868 in)

$38.10 mm 11.203

‘imp ner ovario outer ror ceras | 0.18 mm (0.006 in max

Out rotor body dotan
Rotor cone lerne

0.15 -021 mm (0006-0008 a)
0192-08 mm (0010 009 in)

L 16.018 15,004 mm (0.912-0.581

2 mm (001 m)
25 mm 001 mi

1530 nm (0.8 m

[0.12 mm (0005 in

TORQUE VALUES

Outer tek mat

Dre er,
Fig annee comer

Où io oie te
TOOL

Special
‘Ciccone older

69 Nm (4.5 ~ G0 Kp, 9-49
To him (48 = 80cm. 38 — a3

B-12Nm 08-12 10m. 6 =D

10-14 Nim (1.014 Kam. 7-10 fb)

07923-42000

9.12mm (0005 m) _ |

CLUTCH/OIL PUMP

TROUBLESHOOTING

Faulty ut operation can uly be orestd by ajusta the ech lev e play

Clutch Sips When Accsorating
1. No frs play
2 Des mom

‘Chueh Wil Not Oisengge
"1 Toomich fe play
2, Prev

Motoroyee Crop With Cluch Disons

Exceso Laver Prasure
Y Cha bl Kn, damage or ity
2: Liter mechanism imaged

‘lush Operan esl Roush
1 Dura cum os ou

Y. Faut ol pump
2. Oum dre ear broken

CLUTCH/OIL PUMP.

($ HONDA
E os

RIGHT CRANKCASE COVER REMOVAL

Rome the sata us ak,
Den ai from the engine.

Remove the ih fot pag and mar brake pal
Disconnect ia cute ck.

Disconnect ma puts generator wes mth couple

Rem the bots holding the right ranks cove,

di CLUTCH CABLE.

(1 PULSE GENERATOR COUPLER

CLUTCH/OIL PUMP

CLUTCH LIFTER ARM DISASSEMBLY

ma ihe hitter od nd spring in.
emo tier rn an rum in

PULSE GENERATOR REPLACEMENT

Insta the pulse generator wire in the crankcase
ove estas ou

(1) PULSE GENERATOR

CLUTCH/OIL PUMP.

CLUTCH

(PRESSURE PLATE (syctuten oureR:

oise vA" (eh

ue
UODER SPRING

P - $8 OA eaanbensear
Y

Lotehaser A

A2CLUTÓA CENTER
\ do ‘aajeturee ot

SPRING

| wurbrrure
women

moor
CLUTCH REMOVAL

Remove the ifr pit xro

23 00

remove he cua ter plate and lu sings.

(CLUTCH SPRING (MLIFTER PLATE (4) BEARING

(HONDA
cLuTenron PUMP WE) FI500

‘CLUTCH SPRING INSPECTION
oven the cl pring frat
SERVICE LIMIT: 425 mn (1.87 in}

da dom.
omo cut cater holder or dutch spin

Remove the dutch center, uch dis and sae,
a pate, coh over, uch ie and cls

remove the ri, der spring. ter sat and
‘hu te 8 frm nen ent

/ 5
MELUTOH,GENTER HOLDER
O. a2a-4280000
CLUTCH DISC INSPECTION

place the euch dias they show sgn of cr

esr the de ticas

SERVICE Lis:
DISC A 230 mm (0.090)
Disen: 280 mm (0.102 in)

CLUTCH/OIL PUMP.

$) HONDA

PLATE INSPECTION

hack fr pita warpage on a surface plate, ung à
cr gage.

SERVICE LIMIT: 0:20 mm (0.012 in)

CLUTCH OUTER AND OUTER GUIDE
INSPECTION

(heck the dot inthe cuter dum for ls, ut or
nena one made by th eon des

Mange the LD, of ne primary driv gar and te
2B. D: and teng ofthe eter guide

service Liar

PRIMARY DRIVE GEAR 1.0.

27.08 mm (1.065 in)
OUTER GUIDE OD.

26:91 rom (1.059 in)
OUTER GUIDE D.

2208 mm (0.888 ta)
OUTER GUIDE LENGTH

39:10 mm (1.303 in)

CLUTCH INSTALLATION

Last one juger pc and sat, euch plata
And rip inthe cut entr
MOTE a
Nols Gestion of te wring wat rin
sea pice.

Ins the catch des, cut pitos end prose
fate on ho each enter
TE
‘S108 the dis and plates army a
Coat now |

a |

DEL
N reste je

N van
a NS Lou Bises à O
Surco

incuurcnoenten

CLUTCH/OIL PUMP.

Intl he eich enter into the dutch ser
ling the liner by rotating the len enter.

Sido the colar and ech outer guido ove the
rara and instal the etch

Ins dhe feck washer making suo the "OUTSIDE"
Mark o a

Ina the clutch cuter Roe oo! with so eve
bete or ara he cute ing ving four 8 im
ote and entes, hf the ramon nto 09
‘har late er broke pal

LOCK WASHER.

CLUTCH/OIL PUMP.

“Taian the lack it sail tongue.

TORQUE: 45-60 Nm
(05-00 Kam. 3-43 to)

emos the elta cante holier or late sprog
{ake the end ol lok nu into the grow ofthe
rai shaft ih à punch

TIMAINGHAFT—(9/CLUTCH LOCK NUT

(nstanıno_wLIFTER PLATE
Install he lc spins ter pt and titer late me

bolt, Tigo the bolts in a era patea ln

23s,

ta bring into the fr pat.

DIL PUMP
OIL PUMP REMOVAL,

Remove the durch (Page 8-6) and vomove où
pump set po

1 OIL PUMP SET PLATE

À HONDA
CLUTCH/ON PUMP e FT500

(u iDLE GEAR,

Remo the il ea and the ol pump,

Nove

E nat rmove a Tork gad sal rom e

on Pune o1sasseMBLY
RÉ let ecw pret creas soy SD
A en ivi

mona

body.
Rove the Oring rom tho pump body

router
ROTOR

(spuve-cover

CLUTCH/OIL PUMP.

HONDA
FT500

OIL PUMP INSPECTION
esse he pump parano

SERVICE LIMIT: 020 men (0.008 in)

eure to pmp body cleaner

SERVICE LIMIT: 0.25 mm (0.010 m)

Messe the pump nd clean

SERVICE LIMIT: 0.12 mm (0.005 in)

CLUTCH/OIL PUMP.

IDLER GEAR INSPECTION
Inspect the ir qu fr war and meso tha LO,

SERVICE LIMIT: 16.10 mm (0.506 in

OIL PUMP ASSEMBLY
Install he inner ec outer cote nthe pump body.
ans he O ing and dowel in in the pump body

Sido the pump ri gear sat through he pump
ie and inal he corr on ba body,

“rente cover rs

OIL PIPE INSPECTION,

Remove the ei pipe joint bolt and sting bolt
thon rove theo ip

pS

CLUTCH/OIL PUMP,

neck tat theo pipe ent restricted,
‘Gant racer.

OIL PUMP INSTALLATION

Inst m où pipe.
"inten the ll pipe ont bolt 0 pa trau

TORQUE: 8.

Nom
{08-12 kgm, 6-9 fib)

ake sure thet the O-ings and dome! pin ae in
acs and neal te le aa.
Ina a o ump.

Ansa theo pum set plate
“Alen the 08 pump es plate with the ext
ut of the shift fork guide shaft. Ifthe sift
ork guide shaft moves, the Iibrierion
esse may be Blocked eng mansion

‘Tien te ot pumo setting bolt.

($ HONDA.
CcLUTCH/ONL PUMP ® FT500

DRIVE GEAR REMOVAL (DRIVE GEAR

Remove th euch Pa
Rove the Jack nut, ont, ple rotor nd ets
oar

Remove the il pre pad stepper plo, pad end
un.

DRIVE GEAR INSTALLATION

Instalado pin no th cana
Install he primary dire ar win the es
ambien tel facing te race,

yore _ —
All the de la wih game of @

(MDOWELPIN (ZICRANKSHAFT

iNDOwEL PIN
Insti the put rotor, ging the dan pin and

CLUTCH/OIL PUMP,

$ HONDA
e FT500

ii sroprEn rin
Install theo preure pad, rng and topper pin. 10

NOTE
mos mae]
| Chace teal presure pad for acc mos

Install the weer and Hohen the lock ut 0 the
ec torque.

TORQUE: 45-60.
(45-60 kgm, 32-43 fsb)

Crack atan operation
BE
{2} SPRING TA OIL PRESSURE PAD

RIGHT CRANKCASE COVER
INSTALLATION

{nat dol ps and a,

Not

‘Apply Taxi ur 1o the canicas cover
| tin foe to hol he gk.

Ina he iran ever,

note
‘Check pscttion of the Gutch Tver ater

[sein ove

Tighten the right erankema cover bolts end starter
Joao rt pe bel

TORQUE: 2-12 m
(08-12 km. 6-8 fe)

(RIGHT CRANKGASE COVER

CLUTCH/OIL PUMP.

Connect tn teh cable

eat he brake ped and lg foot pm

(21 FOOT PEG (SIBRAKE PEDAL

(NPULSE GENERATOR COUPLER
Connect th pus generator wire couler
Aral the fl tank na 0

Fi the caia with the recommended ol up
to th propa vel (Page 2-2)

ist ha lute rs pliy Pago 3-1)
rl the brake one teh (Pape 9-17),

¿$ HOND. LÉ
® 500 à

ALTERNATOR/GEARSHIFT LINKAGE

ALTERNATEUR/
TRINGLERIE DE
CHANGEMENT
DE VITESSE

LICHTMASCHINE/
SCHALTGESTANGE

ALTERNADOR/ARTICULACION |
DE CAMBIO DE VELOCIDADES |

ALTERNATOR/GEARSHIFT LINKAGE

(2.0238 kom
7-10)

100 120 Nm
100-120 kom,
ma

(08-12 kee,
Got

ALTERNATOR/ 5
O. GEARSHIFT LINKAGE RER"

SERVICE INFORMATION
LEFT CRANKCASE COVER REMOVAL
ALTERNATOR ROTOR REMOVAL
GEARSHIFT LINKAGE DISASSEMBLY
GEARSHIFT LINKAGE ASSEMBLY
ALTERNATOR ROTOR INSTALLATION

| LEFT CRANKCASE COVER INSTALLATION

SERVICE INFORMATION

GENERAL

Tired witht engine I he ram fr remos
+ Far erster perio, refer 0 ne con 17.

TORQUE VALUES
Altrenato rotor bolt 100 120 Ne (10.0 — 12.0 kp, 72 87 fu)
10-16 Na LO- 1Aken, 7. 10 Ib)
3 12 Nm (081.2 kom, 6-3 fb)
Gehe topper am bolt 10- 14 Nm {KO = LA gm, 7- 10 He)
Gene topper plato bot 102 14 Nim (LD = LA gem, 7— 10 te

Tools
Special
ae olde 7924730000

Common
tor pl 07723-012000 or 07038-9290001

ALTERNATOR/GEARSHIFT LINKAGE

LEFT CRANKCASE COVER REMOVAL

‘Remove the fam ota vih sae covers
Remove the aot and fel anc ad the bane from
a almator and sone ite.

Disconnect the altrator and solnoid couples

Drain the ol rem the engine
Remove the gar sit ped.
none the ano picar cout.

Aemase the trar dee pinion co.

AN DRIVE SPROCKET COVER (2IGEARSHIFT PEDAL

_ cover

12) MOUNT BOLTS

ALTERNATOR/GEARSHIFT LINKAGE

‘lsconaer ho rer moto cable and remove the
Bares motor mount bol

pS

N pnEATHER TUBE
Diszonoct te crankcase breather tube 2 4
Rome in lt crakear cover mounting bot and

ant che As holder and remove the rotor

ALTERNATOR ROTOR REMOVAL . —

1 FLYWHEEL HOLDER
‘970251730000

ALTERNATOR/GEARSHIFT LINKAGE

Uw she Meet rotor aller to remove the rotor.

(077330020001 OR

(MROTOR PULLER
‘0703-32000,

GEARSHIFT LINKAGE DISASSEMBLY RESTES
Remove the stopper plat et bot und mural A >
men to

emacs the peri inde, sie sopor arm and

(U mar to dort the aa wc |
vor during disent

Remove ne rope ls

(2) SHIFT SPINDLE

ALTERNATOR/GEARSHIFT LINKAGE

GEARSHIFT LINKAGE ASSEMBLY

Inst he dow pin and topper plat,

(1) SPRING

Set the rameminion in uta,
Insta the topper am and spring,
e or stopper am opero.

Hoss ne peat sine

ALTERNATOR/GEARSHIFT LINKAGE

Ans dhe ute! uste rotor, fig the rotor
ntc point up and ening the tbs Wath the
‘owe i he sopor pita

Frnt the an wher” nd ites the bate
Per

ALTERNATOR ROTOR INSTALLATION

ion the inside of the rotor anita he rotor
foto th exo

Note
[lig te ran act Key with the ]

| rotorkeiwny

Install the Sota holder onto the cran.
Tien the roter Bol to the sped Lore.

TORQUE: 100-120 Nm
100-12. km, 72-87 140

LEFT CRANKCASE COVER ASSEMBLY
trata the star il onthe et eankeat cover as

en th wir mp sorely

MIRE CLAMP

PN
Er“

ow - o
Neu re w
mate helio terminal e ITRALSMIICHMNRE

AN

N

(SS NEÚTRAL STEH

(WISTARTER MOTOR GEAR HOUSING
Instat the Oxdog onto the starter motor gue Be
Housing tour

Insta the do pins and ger.

(1 DOWEL PINS TIGASKET

zo

ALTERNATOR/GEARSHIET LINKAGE

Ans the ef cana ever noting the sealing
och lato,

Teva te starter dw pinion cove.

‘Connect ne canes beater mb.

Route the bs and connect. te couples and
stead the wir bands.

Anse sive sprocket coves,

(or LEFT CRANKCASE COVER

‘opty gous to the gear dol plot hat,
{rl th gnc nage with he punch mark on
the arf ar facing uo.

2 Ye too the Lock ut and ur the acer
roman the ook at secar

(IIGEARSHIFT PEDAL. 12) LOCK (3) ADJUSTER

nur

(GSEALING.
WASHER AND BOLT

$

3) IN à
COMTE

CRANKCASE
CARTER MOTEUR
KURBELGEHAUSE

CARTER DEL CIGUENAL

Ge)HONDA
WW) Frsoo

CRANKCASE

mn Bour
mm BOUT
PRET
(22-2819,
16-20")

Hactatym
CE)

(22-2840,
te 20 te)

Ton) (27-33 kom,
20-24 fb)

10. CRANKCASE

| SERVICE INFORMATION

CRANKCASE SEPARATION
L CRANKCASE ASSEMBLY

SERVICE INFORMATION

GENERAL.

À oem must be mparat repair he eranksat, connecting rd, kick transmision und lan
mona the folowing ors efor oparting te crank

ENGINE RENOVAL section 8
CYLINDER HEAD Section 6
CYLINDERPISTON Section 7
GLUTCHOIL PUMP Secon 8
ALTERNATOR Section o

TORQUE VALUES
Unparcrnkesse — Smmbolt 1014 Nm (9 1A kom. 7 — 10)
Bm bot 22228 Nm 22 - 28km. 1620 fe)

Lower renkene Gen bolt 10 14 Nem (1.9 — 18 kom, 7 — 100)
5 mm bat 37-580. (27 = 23 kom, 20 28 fe)
10 mm bat 522 Nm 2-38 km, 23 27 eb)

alow ok lt 22-28Nm 22 -28k9m, 18-201)
Cam chain tnsioner 10 1610m(10— 15,7 ~ 104)

CRANKCASE

TACA CHAIN

CRANKCASE SEPARATION TENSIONER (1 ON PIPE

Remove she bla holder lock bolt and spin.
moss te com chan mène and of pp
mos he cam chi,

Rem the balancer in gui,

Tun ane engine upside down and remove dhe
Bottom canas ots

Remove th of pan by removing he ol pan mount
Inga say.

€)

HONDA
FT500

(Si ca CHAIN

|

($ HONDA
sE) FT500

CRANKCASE &

“urn the engine uprión up end remos the upper
cnica bal

Seperate 10 erankense sembly hates.

mes Le upper cas mu en Back from
toner coe

[2 ‘not pry Berween the upper and lower

‘Remove the balancer chin fom he rn alan

IE

12) REAR BALANCER (3) MAIN SHAFT

CRANKCASE

CRANKCASE ASSEMBLY

‘team any old mont tario! om the erankease

Apo liu sealer o he src.

‘djs ho balances
Amal the upper

tn the cam bolts in the sequence sow In po
more

TORQUE VALUES:
mm bot 10-18 Nm
(19-14 4907-1010)
22-28Nm
(22-28 tam, 16-20 fib)

mm bot

(9) Dowel. PINs

(1) 8m BOUT

(qo) HONDA
CRANKCASE E) FT500

“Turn te cercos upide down and pra the
Termin exe bots in to sequen shown and in.

(1 9mm BOLT

‘TORQUE VALUES:
mm boite 10-18 Nm
(10-14 kg, 7-10 tb)
Bmmbote 27-33Nm
(27-33 kgm, 20-28 fib)
10 mmbole: 22-33.
(2-38 kgm, 28-77 ten)

Insta he em han nd he ip.

Ant se cam chin trons nd tin the bot.
TORQUE 10-18 Nn
(10-14 Kg, 7-10 08)

TORQUE! 22-28Nm
(22-2. kam, 16-20 fib)
Ansa he focos
ier (Seton 0)
Chueh pump (Section
Eylinderpton Seti 7.
= Cylinder ea Seton 6)
= hain into the frame (Section 1.

GQ) HONDA 4
E) Fr500

CRANKSHAFT /BALANCER

VILEBREQUIN/
EQUILBREUR

KURBEL WELLE/
BALANCER

CIGUENAL/EQUILIBRADOR

¿$ HONDA
© FT500

CRANKSHAFT/BALANCER

44, CRANKSHAFT/
11. Batancer

SERVICE INFORMATION
‘TROUBLESHOOTING

FRONT BALANCER REMOVAL
REAR BALANCER REMOVAL
(CRANKSHAFT REMOVAL,

(CRANKSHAFT INSTALLATION
REAR BALANCER INSTALLATION
FRONT BALANCER INSTALLATION
BALANCER TIMING

BALANCER TIMING INSPECTION

CAMSHAFT TIMING SPROCKET REPLACEMENT
BALANCER TIMING SPROCKET REPLACEMENT

SERVICE INFORMATION
GENERAL

SPECIFICATIONS

== roo

© To serio th erankaft and rar baanr near o separate the crak
= Ale inating he liner check buenos timing and aust bale al ano

AECI |

‘adi are

Ganka ur

aa Connecting re big et aan | 0080-0660 mm (06020-60288 a)
Conneeing ro big end 0006-0018 mm (0.0002-0.0007 in)

Connecting rod smailend | 21020-21041 mm (08276-04784 in)

Game (003 in)
005 rm (0.002 ii
2107 mm (0590

01 mm (0.008)

Safe holder OD, 564-2008 mm 1 5734- 1.5740 in)
‘Shalt oder 10. 25.007-26.020 rm (1.0290- 1.0244 in)

‘39.91 mm nern
2605 mm (1.028)
26.05 mm {1.026 i

ranita play Fada
Asa

Res balance 10. 26.00726.028 mm (1.0239-1.0247 in}

10.10 mm (008)
OS mm (0.002

TOOLS

Common
Attachment 7746-ca20400
Drm 0746-c030100,

TROUBLESHOOTING

en
nia
on connecting od mal or ig end bring.
= Sant connecting ra
Worm eranahaf basin,

=" ImDropor ining austen.

— Improper chin anfutment.
= Damaged han

CRANKSHAFT/BALANCER

FRONT BALANCER REMOVAL

Separate the crncos sai (Pag 10-2)
Remove the Balancar chin ro ih eur blas
Remove in 20 mm cei andthe bon rocket
‘wi blanc: enn ino,

Remove the banane haft od sat ald.
Remove the clip.
Rama the sat olde fem he sat.

ensure he shaft older ole LD.
care te shat Bode OD.
SERVICE Lis:
SHAFT HOLE LD. : 26.05 mm (1.026 in)
SHAPTOD. à 2991 mm (157 in)

12) FRONT BALANCE
‘SPROCKET

@ HONDA
CRANKSHAFT/BALANCER E) FI500

REAR BALANCER REMOVAL

Remove the nee asia and Inst washer fam

Aho main,
Remove the rar lee, It mer and en

roller bestng

Mercure the balances LD.
SERVICE LIMIT: 28.05 mm (1.025 i)

CRANKSHAFT REMOVAL

Separaı the crane (age 10-2) and remove
‘raat

HONDA
CRANKSHAFT/BALANCER FT500

(CRANKSHAFT INSPECTION

st the eankhalt on a ting stand or Y blocks
Sia messe De uncut using a dl indicator

SERVICE LIMIT: 0.1 mm (0:04 in)

Us 1/2 the tote indicator ceding 0 devis
ets rout.

cee the connsrting rod big end sid lerne
in ane u

SERVICE LIMIT: 0.8mm (003%)

Meare he eomesting rod big end radi ce

SERVICE LIMIT: 0.05 mm (0.002 in)

CRANKSHAFT/BALANCER

? HOND.
© F300

raue the connecting rod el nd 10.
“SERVICE LIMIT: 21.07 mm (0.830 in)

Spin the crankshaft bearing by hand and check for

Te bearing must be aplico IR I nio or has
tome ay.

CAMSHAFT TIMING SPROCKET
REMOVAL/INSTALLATION

Remove the casa timing rocket.
Sire à ie cut from any tooth center of she

Install ehe spore, aligning the sited ne wih
the dowel pin alan the eramkaft ing Being
iver (07926-003010) snd dir atachment
mum LO. (07746 -0090400)

qn

(ARIAL (2) RADIA

in SPROCKET SCRIBE LINE
7

(DOWEL PIN HOLE

CRANKSHAFT/BALANCER

BALANCER TIMING SPROCKET
REPLACEMENT

Remove the balanar ving rocket from the
Graal

{fan new sort onthe sat eth te punch
Tou aged ith ma aft keyway using Bring
er (67748 -0090100) and iver arca
Se ri 1.0. 07748-0080400).

CRANKSHAFT INSTALLATION

ase te se rin nthe lor ricas
Trea he cena in he our rank

REAR BALANCER INSTALLATION

Anya the thrust water, needle bearing. colar
And ren Data oo the mans

vost washer and need bearing

(NEEDLE,
BEARING

ARENA

NONE] Gietaninc
0) THRUST WASHER

FINA
CRANKSHAFT/BALANCER 5) FI500

FRONT BALANCER INSTALLATION seu Sheu ana lnocKer soe

Set the tete in th “ler daft with their
Sharp eds toner ho outside

tesa th pal has and noel borings.

wore iat
"Alin Tie ware be withthe el
y gen to the ine sda of the
ie to hold in lace during install

GIBALANCER (4)NEEDLE BEARING
WEIGHT SIDE (20X26%20)

15) sl iho tus vr and he bares wel
al
eur welt

Ans the ciclo with ts sharp edge toward the
ute.

BAL
MEIGHT

0

(N BALANGER HOLDER
Ans he Hane on the fence older nd tere

(itn ne eli noting direction ofthe lang.

nore

‘Install the elvclip with the sharp edge towards.
ae 1

$, HON D.
e 300 >

BALANCER SHAFT HOLDER

CRANKSHAFT/BALANCER

“rsa the blancs safe Holder Inthe erankeoe.
Test the lance sh F ne

BALANCER TIMING

ta he balance chain a tree points a, hand
D lnc starting a any ak toward he ttt and
‘ng to e right wong he lower eng of he

MISTMARK [BIOTHLINK. (3) 25TH LINK
TRORFAONT |" (FORCRANKSHAFT] (FOR REAR
BALANCER) BALANCER)

STONE
ace the Bum chin over da font lanar
st aim de Te ink al e proc

o
$ HONDA
GRANKSHAFT/BALANCER @) Ft800

Inst th trust wir and baanca sprocket on
th lancer sat and secure wth th ico.

Nove
IE

ce the balancer cain on the rear baancer
rocken,

Note

Alan Bon mem |

the rer bance rockt.

rec tht the tt ine algs with he
Leon ee ont balancer acte |

€ HONDA
) " FT500

cy sr
Pense that th Bi nk is ln is wi

nan he rank balance rock

gn he par and ow exe bot.

Ans the lone cin guide and the balances
me.

ne balancer ange 2 the left one gration
Mowe Minera rest and tighten the lock bol

TORQUE: 22-28N-m
(22-238 kom. 16-20 6)

(2) INDEXMARK — SICRANKSMAFT

BALANCER TIMING INSPECTION (1) ALIGNMENT MARK

Rott the erankihat until Ue connecting rd is
kT 06.

oko soe tha he inde mats are lied font
tee tner.

veining à coat if he edge of the font ght
ue a lipid wien the lim mark at
shown,

nur tht he ad ofthe rar lanes sas in

\

i) ALIGNENT MARK (2)REAR BALANCER

€ HONDA : +

TRANSMISSION

BOITE DE VITESSES
GETRIEBE
TRANSMISION

TRANSMISSION

12. TRANSMISSION AREA

| SERVICE INFORMATION wt

TROUBLESHOOTING 2.
| TRANSMISION DISASSEMBLY 2a
L TRANSMISSION ASSEMBLY na

SERVICE INFORMATION
GENERAL

wv conca must be parte 1 serie te amant
The goal aoe déasembiy, refer 1 scion.

SPECIFICATIONS

Tre I ‘STANDARO SERVICE owt

Ge bia Tow 20d “GAO men 16.0017 0.0082 wy | 020 rom (0.008)
ponian | coHe=0.140 mm (0018~0.0055n) | 020mm main)

car side cinco Má 08-041 mm (0.002-0.016 in) (050 mm (01020 ia
Ton 008-058 mm (0.002-0.023 m) £0.65 mm (0.028 nb

C Lou 905-022 mm (0002-000 in} 990 mm (0.012 im

Car (008-041 mm (0002-0018 I) £950 mm (0020 in

ana 005.022 mn (0002-0.09 in) 020 mm 0012 I

rato ear cames M Do GE mm (00016-000821 | 0.5 mm (0.008)
Gad aoe pee mm none. | 015 mm 0006 m)

Sroero, Low ir buningcerance | 0020-0054 mm (00008-09021 io) | DO men Ds

Satine Long ares | 040-0082 mm (MO | Ahm Ar in
Bushings. Low ge clean 0910-0057 mm 109505-0.0022 mM | 0.10 um (0.004)
Busıng1oM.Top ar clearance Slosococae mm (060%8-0.0032 iM | 0.15 mm (0.008 I)
Bu Gerra DD OZ ma (00018-000821) | 2.15 mm (0.008 n)
Gur. cin 200-1511 mm {0860-09880 in) | _ 25.10 mm (0.988 i)
Gad Dar mm (1.0898—1.0646 in) | 27.10 mm (1067 0}

ces D pet mm (11091-110801) | 2.10 mm (1.106)

an o 25.04 mm (0850-09880 in) | 25.10 mm 388)

Msn 20-20. mm (1.1031-1.090i0) | 28.10 mm (1.108)

Top gs buitins OD, 23020-27080 mm (11007—1.1016in) | 2791 mm (1.0990)
Caesar bushing LD 22020-26081 mn (9050-0080 in) | 2510mm (0.988 i)
00. 23089-27080 mm (11007-11016 in) | 2701 mm (1.0980)

Co Low garbushing 1 PR pen mm (07882-07800 M | 2010mm 0701 in)
08. Boe 28018 mm [0904409819 m | 2495 mm (0982 i)

aint où FD 2000 mm 09820-090354) | 2491 mm (0081
Courant op. FSU 2.000 mm (07669-07874 10 | 19.95mm (0,768 in)
a 2490-24 900 mm (0982609605 m) | 2891 mm (0381 Il
rn a | Bonn
A | 1600016021 mm (9.5008-0.044 n) | 1608 mm SDS)

Foi cm deka 835.00 mm (0194-0197 in) Am 01810)

Generali | 11980-11984mm iartt-darıgin | 1181 mm (0408 0)
eat | 12006-14004 mm (6892=0.5600 m) | 1491 mm (058% i
11.91 mm (0.469)

Since bamos.
re Ga LD al nn are

"HONDA
E 2) FT500 TRANSMISSION

TORQUE VALUES

eur drum bering et ate 9 198m (091.9 Kem, 7-8 eb)

TOOL

common
rier 077460020100

‘TROUBLESHOOTING

Hard to Shit
1 Impeoper ech ciutiment
3. Shift shaft bent
4, Shit ork tae bons
5 Shite drum cam groove deagos

Transmision Jumps Out OF Gar
1 Gear dogs wor
2. Shit nate best
3. Shit dram stopper broken
3. Shit orks bone

TRANSMISSION

TRANSMISSION DISASSEMBLY
soporto cree sembly. (Section 10
Sere de Lale chain from the main,
ener

TRANSMISSION GEAR INSPECTION

Anson ah go or cio
SERVICE LIMIT: 020 mm (0.08 in)

pes the purs into neural and check cach ar
Te ie nor sooth, mpsct the ust washes,
ae foes and sie drum, replacing tre
Par en How once wer,

TRANSMISSION

remove the manent and count
Brenn ho mint and counter
grr doa for exces or nos wer

SERVICE LIMITS:
© TM ihe 28.10 mm (0.988 in)
Card 27:10 mm (106710)
ed, M St 28.10 mm (1.1060)

ease the LD a 0.0: ofthe oar bushings

SERVICE LIMITS:
20.10 mm (0791 in)
2495 mm (2.982 in)
27.9 mm (1.099 in)
25.10 mm (0.888 in)
2191 mm (1.009)

Calcula the dance denen ie ou and
bos

SERVICE LIMIT: 0:10 mm (0.004 in)

Mesure tha manhatt 02.

SERVICE LIMITS: 24.81 mm (0981 in)

Cult the imanos besser the mainhaft and
or

SERVICE LIMIT: 0.6 mm (0.008 in)

TRANSMISSION

Measure o countrsatt 0.0.
SERVICE LIMITS:

‘24.34 mm (02981 0)

49.8 mm (0.785 in)

Calle: the eesrance ber, the mar und
convert

SERVICE LIMIT: 0.18 mm 1.08 in)

Ramoca the shit fork hats and it tk
onthe fore fo eau correct ney

{GUIDE SHAFT

SHIFT FORK/GUIDE SHAFT.
INSPECTION

ensure te it fork 0.
SERVICE LINITS:

FT, RIGHT: 15.05 mm (0.582 in)

CENTER: 1205 mm (0474 in)

SHIFT FORK

TRANSMISSION

Are he shit or le thickness.

SERVICE LIMIT: 48 mim (0.18 in)

sur tho guide salt 0,
SERVICE Lines:

LEFT, RIGHT: 10:91 mm (0587 in)
CENTER: 1191 mm (0469 in)

SHIFT DRUM DISASSEMBLY

te basing so plate and remove she wi

AAA BEARING SET PLATE

EN

TRANSMISSION

Samar the beni rom tho sift rum.
rec ach prt fr went or damage and replace if
‘The bearing shoud be plc wih ne oe
Foie or ha axes pa.

GEARSHIFT DRUM INSPECTION

esse te itt deur OD.

SERVICE LIMIT: 11.91 mm (0460)

Inspect the drum groves and replace te rum iit
dame or shows exe war.

Measure se loner com LO.

+ 12:10 mm (0.478 in)

TRANSMISSION.

HONDA
FT500

€

TRANSMISSION ASSEMBLY
SHIFT DAUM INSTALLATION

Anal he being, sf drum and state

NOTE _ <a
‘Note the dieron af he st ate

I See dat me fe drum operates
snooty

(0) SET PLATE

(ser FonK.
Sue smart

Insta he it ad eit ork,

Ana th center e fork.

Grange te RE and
sie on

Fri nstling, cha that the forks
‘Spree moot

TPICENTER SHIFT FORK

(BEARING

_WRIGHT SHIFT FORK
ar

Er
FORK

e HONDA
TRANSMISSION,

TRANSMISSION GEAR ASSEMBLY
Coot each gar with engine ol

a a a a a
am thea) SRD GST} smhizın COUNTERSHAFT

pe bo é 4

0) woos 080 (LODO

ee ‘ol ee
“wlan anon E

oa
eee seni BatmceR

i ea
Maw ster
BEARING «sf

vive he_moioatt beading ing te diver
(7746002000

nore _
al I he BB pw ui
he aisha 1 (01 M5 BUSTING (3) MAIN SHAFT

(NCOUNTERSHAFT
nal the bearing se in and st rag the emer

Pin she counterhatt suambly into the Ion

nore u
an the wel pint ne rer anne]
2 Fl an att ring inthe Bl orig outer

Mike sur the il sl sid in ne

TRANSMISSION

©*

ONDA
FT500

Inst he mans
note

TS
Bern te at ring isn te bering outer
pac coc

me he rank haves [Pas 104 and 6.

($ HONDA .
(E) "Frsoo

FRONT WHEEL /SUSPENSION /
STEERING

ROUE SUSPENSION
AVANT/DIRECTION

VORDERRAP/FEDERUNG
LENKUNG

RUEDA DELANTERA/
SUSPENSION /DIRECCION

FRONT HEEL /SUSPENSION/STEERING

20-25Nm
120-254 14-2210

Samt
=9-10m
(09—13k9m,? =9 is)
20Nm

20
5565 Nm P2030 9m, 142260

(65-65 kgm, 40 #7 fe Ú
45 55 Nm
(68-55 hgm, 3340 0)

TRE
Y

8-18Nm
DB ak, 80 am

3 FRONT WHEEL/

SUSPENSION / STEERING

SERVICE INFORMATION
‘TROUBLESHOOTING
HEADLIGHT
INSTRUMENTS
HANDLEBAR

FRONT WHEEL

FRONT FORK
‘STEERING STEM

SERVICE INFORMATION

GENERAL

"aja or thar support regula 10 support he motor.

SPECIFICATIONS

Front wheel rr rara

ia han

20 mm (4

az mm TA in) |

[Front ok se run

AN

Fa ube 00.

BR ma

DI ren one er 10.

TORQUE VALUES
Sino sem
ort age pin bal
incitar upper older
Scie tom pin bolt
Front al older pinch bolt
Sesto ann ame

190-120 Nm 0-12. km, 05-07 fb)
ian (09-13 cae, 7-940)
Solas 20-253, 14-18 te)
Donne (45-88 kom, 840 eI
138-85 Nm (65-85 Kom. 0-37 Fb)
eN (1-25 kom, 1-10 se)
ME Nim (18-30 Kam, 11-22 o
VE Von (13228 om. 1118 fi
DS Nm IS a mb EE)
Jorden (20-25 kam, 14-18 010
3-35 Nin 0-20 ham, 14-22 a)

FRONT WHEEL/SUSPENSION/STEERING

Toot
Special
Serias
mo ring oles
fork mal ae
Elise amor rivar

common
Pin pane
Eoceno, 6 mm
Box wrench, 30 32 mm
Extension ar
onan 42x49 nm
Plan 15m

TROUBLESHOOTING

Hard storing
Smeg tem nat 100 th
2, uly saco sem boris
2 nd wenig om bal ras and/or one
Eolica tre pres

ter to One Side or Dos Nor Tock Stat
ane or arre
2. Bant rot fork
2 apt ad, wh sales Inorestiy

Front he! Mob
dentin
2, Worn ont whee sin
3, Fault tie
alent en proper

soft Suspension
{teak fork sng
3. Vraie li front forks

Hara Spanien
roared when font forks

Front Suspension Noise
1 Sicerbindie
3. Ian Bn forks
cs tone fork fasteners

orose-s710801
‘aror4—3720001
07982-371010
‘oyaug—a710400

7702-90000
troy -2230000,
G7r1e-0920400
orrie-0020400,
‘077480010000,
trae—0010300,
‘07746 -0040200,

($ HONDA

FRONT WHEEL/SUSPENSION/STEERING & FT500

HEADLIGHT (1) MOUNTING BOLT
HEADLIGHT CASE REMOVAL Se

Romane the agit and dironmet al wire at
thet coupes and connectors

“Fo remove the helos se, unscrew the cli
Sas mounting bots end semone the Meth 3,

WIRING CONNECTION IN HEADLIGHT
CASE

ou the wies nto th height as och
upper ho.

Route the vie humen ico ne ads cas
‘hough he loa hl

Connect the color code wien and the coupes
For wire armas ost, se page 1-8.

HEADLIGHT CASE INSTALLATION

‘nn tne punch mark on the await cas with
nc marks on the Pedi cae becker

‘creck al slain equipment functions

(1) PUNCH MARK,

STEERING

INSTRUMENTS
CLUSTER REMOVAL

Remove the heats.
Remove ot ane eos atthe couplers and comes
Tote get te epandometer cable and tahoe

among te bolts.

INDICATOR/METER LAMP
REPLACEMENT

move the eadlg ot.

Remove tho so sere Hang the cover on 110
(ove of the le

(BOLTS

2) 9oREWS

RONT WHEEL/SUSPENSION/STEERING.

Lu te scher out nd rep ve bulb
tte A
neck th mete wires Ta non Da

im.

Cr

FUSE HOLDER REPLACEMENT

Remove the fuse covte and rier the sre
ain he fe oes in ace
move ta heaton ext (Page 13-30

Disconnect the wit couple and romane e fuse
older
NOTE a
Talore connecting ow baler wes, de
FR Lo drum, The ang canbe und 0.
(See cet when og nm old

IGNITION SWITCH REPLACEMENT
remove ahead xi (Pane 13-31

remove the bolt holding the ion swith and
conse a ire hares couples

® HONDA
FRONT WHEEL/SUSPENSION/STEERING E)” FT500

HANDLEBAR ‘i (MIRE HARNESS BAND

REMOVAL,

Remove the at and eft wis humos bands
move se fant a oe sich ambi
Remove to front master ends.

Remove me handler uppar bols upper holders,
sea handle

| oe

(ONTURN SIGNAL. DIMMER UPPER ENGINE STOP THROTTLE

AND HORN SHTCH HOLDERS SWITCH
a a
INSTALLATION
NOTE

Pan oe punch mark ont
| theton of ne hare lower ole.

tbe and onthe ower her
Pe upper har on he Rande

ion the forward bote fs, then tighten the
tear older als,

TORQUE: 20-25 Nm
20-25kom, 16-104)

Ansa ii handle sunen asembi. ning
De of tne witch sembly weit the Punch
mo on se parda
‘Taam ne wo sere

FRONT WHEEL/SUSPENSION/STEERING

©

HONDA
FT500

‘Align the ph marc on the handlbar wi she
Split eft trot gripe housing.
Then tigen ne wo sce,

call he master ende on the handibar with
the bom of ts holder align wit he punch mark
Tone the tp bot ft, han ight the Bottom
bole

FRONT WHEEL
REMOVAL

Remove the socedamatar cable sat screw and the
one bla

Loose te axe sft aider ut and looen tr ae
aie

ie ae front wht pullout the ad hat and
au the fonte.

li
[os ei esmas
[tek de 4

ES

(2) FRONT AXLE

INSPECTION
AXLE

rt tho sx in Y loge and manu he run
ent runout e 1/2 of the tol indicator
Dites

SERVICE LIMIT: 02mm (01 in

WHEEL BEARING

‘creck the whl bearing pay by placing te whee
Chae stand and ning te whee bY and

Reg he bung ih a en eo
tomy or have cs i

WHEEL

Crec te ci runout plain the whe on à
De M en ain the wal by Nae nd od
trv ung a! indienor ur.

SERVICE LIMIT: 20 mm (0.08

©

HONDA
FT500

HONDA

E FT500

GEAR RETAINER
wi
SPEEDONETER GEAR

(Wr BRAKE DISK

MDRIVER 07748-0010000
PAG AMENT. 42 7 mm 07740-001000.
PILOT 18 mm 07746-040300

ASSEMBLY

riven the ihe beng
me nance ator and dive in et

bearing

a
instal dhe bearing with the maled end toward 1
== |

-RONT WHEEL/SUSPENSION/STEERING.

($ HONDA
ORAR

un) coLLAR
pty coe to the nid e dust a.

sa the dos sal and colar Inthe right ice of
ms

Hall the spssdomene gear retar in the ft
wea ab.

the inde of the ot sal and instal it
Biene te spesdemner gear and brin the
‘ng srtces with ges
Inui de spandemster gu in 108 wheel hub,
Iii the forge ith te notches inthe retainer

INSTALLATION

‘Align the boss on the spandomeser gor with the
Bou on the ron Tork hat.

(a oust SEAL

FRONT WHEEL/SUSPENSION/STEERING

tone ne ae trough he wheel hb fom hs rt
a

sn the eto hat

‘TORQUE: 5-65 Um
(65-65 kgm, 40-70 fib)

gant axe holder mt

TORQUE: 19-25Nm
(19-25 kgm, 12-18 eb)

estat vo speedometer cable 10 tw speedometer

nr
Wien ore front sde app, sumo the front forks
VD and dn sever ties to cheek the front fork
{or smooth operation.

nore
[fae te ont whl Hwy wo eos |
[emo T

(MSCREW (2) SPEEDOMET:

€ HONDA
FRONT WHEEL /SUSPENSION/STEERING FT500

FRONT FORK (1) CALIPER BRACKET MOUNT BOLTS.
REMOVAL,

Roma tho spendometee cable and front wes
(Page 13-7)

Remove the broke caliper bracket mount bolts and
te brake eae

a SPEEDOM:

(1) FRONT FENDER
Remove the four bols hang the font fer and
femora tho fant Ferd.

Remove the fur fork brace x bots and vero
the fork brace

¿HONDA
@)* F500

FRONT WHEEL/SUSPENSION/STEERING
An) FORK BRIDGE PINCH BOLT

Loom the fork bridge and terna sum bots

Remove the fork tube from te staring stm,
outing the for tube by Mand

DISASSEMBLY
Remove he font fork wb (Page 13-12.

apresta valve cor to aka ar pret fom

“The fork tbe cap are under ar ond serios |
rose, Front fork ar presse must de
Pl and ar aed when emorin ie fork

‘he cape to prevent them from becomins
[mice War ne nd foe proc

Dian the fork oil by removing the dain pos

Hola the fork ser in a io with of jun oF 0

Remove the socket bolt.

a dana to]

oid te ube ina vi, sic the aigue
drama he fork cap bo

areas]

Mg po ea
[eee spring pon set
mn clr, er nde fo PD

Pour out any remain fork fu by pumping te

a
SHOP TOMELOR
SOFT JAWS

FRONT WHEEL/SUSPENSION/STEERING

ose the ol sal dutt cone and up ing
Pathe fork tube gut untl rsizane rom the
Sher bushing i ee, Then more i in and ut 30.
uo in ight un [ok ba apart
PO acer. Te Aider thing wil be forced
tity th ok (bo bushing

rose We lt sa, back-up ng and er busing

INSPECTION

FORK SPRING

Messe the fork pring relat
SERVICE LIMITS: 442.1 mm (1241 ind

{ui ou seat,

(ai BACKUP RING

(4) FORK TUBE BUSHING

Vie
19 SLIDER BUSHING

FRONT WHEEL/SUSPENSION/STEERING

FORK TUBE/PISTON/BUSHING

ek the far bi, dr, uns and pin
Don mark, erates, exc of normal
ling om ve can not be mund.

ensure the outside amer ofthe fork tube and
M suing Vall spa he slider and fork

tube bushings.
Re thre ae noie wore marks ofr
ea ia lon cating worn so that copper
eo Dr mora tan ia of the total sure.

check the Backup ia athe points own
apace if there I any dro at the points

FORK TUBE 0.0. SERVICE LIMIT
26.3 mm (1.4839 ia)

Set the frk tube on Y Books od mature che

M of he ot! nieto rin to demrmine

SERVICE LIMIT: 0.20 mm (908 in)

IN FORK TUBE
a

Piston
RING

PISTON

meus

=

SURFACES
(6yBACK.UP RING
J

f +

| mronr FORK TUBE

(8
E HONDA

| ERONT WHEEL/SUSPENSION/STEERING. & FT500

ASSEMBLY

A
awe ana

u

Back uP o —— SS

(6) FORK SLIDER

tesoexer oS

(ork TUBE

e

= «va Fork car 2017
us coLLAn

wu

PISTON P

RING

If
an 1]
(16) SPRING

Pisron N

{ha} REBOUND SPRING
(a0lt Lock Piece

TH SLIDER BUSHING
(IFORK TUBE SUSHING

Clean sm parts with nonanmabe oF
‘igh sash pint oven.

testa ne bushing ono the ier tbe

nat the piston, it Took pies into the fork
any à toca agent tthe bolt heeds and un
A othe bat then itn he bot

TORQUE: 15-25 Nm
(15-25 mpm, 11-18 fb

[Donor rte fora |

MHEx WRENCH, ram
‘079172230000
COMMERCIALLY AVAILABLE

eS

STEERING

Pace the side bushing over he fark wb and est
Fon th or
Dane the buin into place with the fork mal

Ine ne backup rim

(Cost a new oft el with ATE and instal te
fou racking cinq.

Det te sn in th hes river un he took
bottoms seins th de.

tesa he aap ring ard ust cove,

Pour in the sci amount of ATE

SPECIFIED FLUID: ATE
CAPACITY: 320 ce (11.64 or)

mon SEAL,

fe anckur |

e HONDA

FRONT WHEEL/SUSPENSION/STEERING FT500

‘Check the Orina on the fork ubo ca an replace aa
Homo dame ES

Insta the fork tb spring wih the narrow wind
ings toward re op.

Ines the washer and he cl

Hold the tube in avis, vain he sing surface
uh the fo ca hol plato sping and rod
‘tint the fore ab

Torque the fork cep bot to the spcitietion
TORQUE: 16-30Nm
(15-20 pm, 122A)

(shop Towel on
SOFT JAWS

mat he fork tubes into a seeing stm and
‘ok ridge uri am by Nand

op ofeach tbe fh wth
the top ofthe fore ei,

Fork
TUE

Tighten the fork bridge and steering stem pinch
tots on one ie

TORQUE VALUES:
ork top bridge: 9-19 Nm
(09-13 kam, 7-9 ei)
Stern sum: 45-55 Nin
(65-55 kam, 33-40 tin)

Intl tve for roe hex bal oe

ihe the fork bridge a ron pinchboit
‘nthe other ió othe rei orga.

wore

Ina the fron fender and ake eli.
teal th ra wee
“Then the fork braco hee bolts 0 the space
TORQUE: 20-25 Nun
(20-25 kgm, 15-18 0)

13-19

FRONT WHEEL /SUSPENSION/STEERING

STEERING STEM
FORK BRIDGE REMOVAL

emos the handight (age 13-3)

connect he wire at dni eauplers and connec:
orn and remous the hesdight case (Page 13-9.

Remove the instrument cluster (Page 13-4) and
the anclas (age 12-0)

Remove the steering som cover and height
Becken,

more en cal andthe Fontes (398 13-7

Loose the fork bros bols and rame the fork
bea

Remove the (ont fender and fork bree

LOWER HOLDER REMOVAL/INSTALLA-
TION

temer te coto pins nd row the ts
tomer ol

tg the rubber cion, Replace them they
are damaged o terrae

na the lower holder In the reverse order of

Fee
01

"ron

FRONT WHEEL/SUSPENSION/STEERING

HONDA
FT500

STÉERING HEAD ADJUSTER REMOVAL

Remove the front fork tubos (Page 13-121 and
‘he st heed ester

NOTE

Fra

Remove tha suering stem and sted balls being
lu nette drop any

Remove the top all race aná then ta bottom bl

2ISTEERING HEAD

(Pin Pannen ADJUSTER

A bl se removal)

MY ff 3
Yj

fe
/eitor m
oP BORE

FRONT WHEEL/SUSPENSION/STEERING

€

HONDA
FT500

Inspec the Dal as, 1 they are om o droge,
{epics them ith nt ones.

‘STEERING STEM INSTALLATION
‘rive in th tp bl aca with the Bol race ier.

Pace à 17mm OD. cola, 10mm thik (or
lent) to the sc diver been the ing
Strachan and hand to provide caras forthe
{op rec. Than drive the bottom bal ace nto the
tte head

Intl the wacher and dst onthe tr stem,
Jrs the bottom race ato the suering stm wing
Gena the upper and boton ress and Intl the
ei ball on the res

‘Side he steering str through the torn hed
fram the Data

OTE ee
18 sta alse ur Yor upon roves and]
[19 sta bale forte oer rca

[TOP BALL RACE

(2)BoTTom BALL RACE

tp bal sensation) 7) (otom bal rn itl
TBALL RACE RENOVERDAIVER spot
Rd ¡SPOT IN
TOP BALL AACE

yO

ae

DRIVE IN
TOPBALL RACE

Lynn
BOTON RACE

ge 4

For
ru!
wn stect an sos
steeL atts.
epreces) 2
tor sare)
Race
aorrow Bat
S-race
ES merecia ns
Gorieces)
Se sorrom nace!
(01 oust SEAL
S

(10) MASHER

|
—

(HONDA
FRONT WHEEL/SUSPENSION/STEERING WE) 1500

(STEERING HEAD
ADJUSTER

Insta the autor onto the swing stem and GENE RS

tighten ie untl sup gains the upper cone rat

“Thon, bak I out 1/0 im, Make sre at ter

9 were! movement andthe stom rotates rs.

Ansa he font fon tube (Pape 13-19)

“Temporarily hold the front fork by tftening the
sterng stem pinch bolts,
Ira the top bridge nd Wohten tha stem ut

TORQUE: 90-120 Nm
(99-120 km, 88-87 fb)

ige the fork bridge and tering stm bos
And the fone fds, brake calar and font
el (age 13-10)
Inga fork race Pape 13-19)
Install the flowing pet
Harton rocket

Steering stem co

ondes (Page 13-0)

Hdi o (Page 13-31,

Install the Pla and jus (age 3-16

Connect the wire at the coupe and connsctrs

@ HONDA

uE) FT500

REAR WHEEL/SUSPENSION

ROUE/SUSPENSION
ARRIERE

HINTERRAD/AUFHANGUNG

RUEDA TRASERA/
SUSPENSION

20-25 nm
(20-25 kam,
ramo

20-25 Nm
(20-25 cpm,

(0-40 kgm,
22-2915)

20-26 Nm

ÉDITER
te D

REAR WHEEL
14. suspension

‘SERVICE INFORMATION ta
‘TROUBLESHOOTING 1-2
REAR WHEEL 13
‘SHOCK ABSORBERS 148
SWINGARM un

SERVICE INFORMATION
GENERAL

jack or block a required to sport the motorycle
“The shock svorbers ae mounted withthe qu led damper ontop. This reduce unspung wit. Do not try to di
samba he pe dampar.

ARA

SPECIFICATIONS

FORMS SAVE]
2269 mm (8.90 in) 2 Om (828 in)
— om Dos)
Bias 20 mm 1008)
Rear ace une = 02 nm (001)

Pear wheal rant

TORQUE VALUES
Seingarm pivot bolt 0-80 Nem (6.08.0 ko, 43-88 e)
Ros ate aut 70-100 Nem (70-100 kg, 51-72 11)
ar ¿nc abre upper) ‘Nem (3.040 kp, 22-29 ft)

dena Nm (80-40 kg-m, 22-29 tt)
Final riven socket 80-70 Nm (6.0-7.04gm, 43-61 it)
Sigma inner plate bolt 20-25 Nm 120-2, 4m. 14-18 fu)

TOOLS
Special
Bearing mow, Arm orsa8-3710600
fearing remove hand 7906-3710100
Bearing remover weht o75a8-s740200,

Nod earn rover (07046-KASO0DD or Attachment 07048-3710200

Common
“Attachment, 42 x 47 ron 07746-0010300,
Di 071182010000
Pot 17 mm (77460040400
Pot, 20 mn ‘72460020600,
Shock oberer compressor 078601290001

€ HONDA
REAR WHEEL/SUSPENSION FT500

TROUBLESHOOTING

1. Tre presure inoomaet
2. Foy te
À Bent

À. Laon whee! sing
5. Singen busting ween

Soft Suspension
2, Shook sbsotbersimoropetly ajuste

Hard Suspension
1. Shel absorber improperly au
2, Ben shock abro od

Suspension Noise
Loose
2. Won socks

REAR WHEEL/SUSPENSION,

REAR WHEEL 1 CHAIN COVER
REMOVAL

ale the ear whet ft te round by pling à

Ihe or block under the engine

Lowen the ive chain eck te and during rats.

Loom the alent

Puch the rear wheel forward und dera the drive
che,

nove

[Do nat oporto the ver bate paul ter
(ul in reiting the brake dhe betr

pad, }

INSPECTION
AXLE SHAFT

Set the axle on V blocks and mesure the runout
The acta! runou ls 12 of the tol idestor
racing

SERVICE LIMIT: 0.2mm (0.00)

DAR

a) Lock nur

REAR WHEEL/SUSPENSION

REAR WHEEL BEARING PLAY

{hack the whos esting play by placing the wine
in a ting wand and spinning the wha! By hand
Rapin the bearings wi new ones If they are
noi or have exceso lay.

REAR WHEEL RIM RUNOUT

(Check the rim runout by placing the wheal on a
ig stand. Turn the whee by hand and mesure
the runout using a dl naar

SERVICE LIMIT: 20mm (008 in)

FINAL DRIVEN SPROCKET

‘Check he condition of te final dren srockat
tem.
Reale ne srocke i wom or domage

gore =
“The dive chin and are rock maw ao
tbe speed ifthe dien sprocket sen,
dama

(RADIAL,

(2)REPLAce

($ HONDA

REAR WHEEL/SUSPENSION \@) FT500

DISASSEMBLY.

Disssembte the er whee at own,

IDRC pjousrsent

(8) 60-70%
O-TON. 3-51 tu)

/
(6) DAMPER RUBBER \

(SORIvEN FLANGE

Loos the driven sprocket mute and remove the
‘on Mange tom at hub,

REAR WHEEL/SUSPENSION

> HONDA
e FT500

Replace the damper rubber if thay are damaged or
etarra

ASSEMBLY

Drive the ight bearing in and Intl ho distance
Brive the at baring

esse on the brake linings reduces stopping
Power. Keep rase of the ing.

ack a eating exits with whe
{pd Tata being into the dri

Nort = =
Insta a bearing witht ssl end om
A usd.

Install the damper bers and the even ange

moRıveR
077480010000

(2) ATTACHMENT, 42 x 47 mm 07748 -0010200
PILOT, 17 mm (mel HUB)
PILOT, 20 mm (ORIVEN FLANGE}

bauren aussen

REAR WHEEL/SUSPENSION

Tionten he driven sprocket ruts.

TORQUE: 50-70 Mm
(6.0-7.0 kam, 43-51 feb)

poy res th ini o he dss

Ira e ut ssl and colar In ne whe! ha eft
sie.

Ay res to ne edo du a.

Install he dust ssl and cor ino ve whee! hub
ri sd,

INSTALLATION

Boon tv eer wa nto he sing,
Ita the die, chim on the diven rocket.
Insert tho rau aa hrauph the singe and the
tear whos! hub,

Tighten the dle mut Loos and aus the eve
ain ton lay (Pape 3-10)

REAR WHEEL/SUSPENSION

Tropen the axe rut

TORQUE: 70-100 Mam

(70-100 km, 51-721

Inst di chain cover.

SHOCK ABSORBERS
REMOVAL
mont mest ad et cov

Remove the upper and lower shock absrber mount
ina bolt and remove the sock sober

DISASSEMBLY

arm Lo NUT
& Do sroren
<F Dear

|

m UPPER JOINT

So ear

Se (1) SPRING ADJUSTER.

REAR WHEEL/SUSPENSION

Campress the spring with à sock compresor

Look th oc nt ad remove the upper joint

SHOCK ABSORBER SPRING.
INSPECTION

escroto ong fee Ion

Reotace the spin i is dote thn the service

SERVICE LIMIT: 222.0 mm 8.4 in)

ASSEMBLY
App Lock agent tthe rs tse

Inst he ack nut and the uope jo

REAR WHEEL/SUSPENSION.

HONDA
FT500

‘Tighten the ok mu.

TORQUE: 30-45 Nm
(0-05 kom, 22-35 10

INSTALLATION

Inst the ear shock sbrorbers withthe ajusta on
top and tien the upper and lover mounting
bats

Toraue:
UPPER: 30-40 m
(80-40 kgm, 22-20 fsb)
LOWER: 20-40 en
(30-40 km, 22-29 fsb)

Ansa de mutt
Incl rae ah and te sido cover

‘ADJUSTMENT

ins sh side covers.
{Chak te operan of th e supina.

a

Só

[aoJustER |
in

Wey

REAR WHEEL/SUSPENSION

HONDA
FT500

‘SWINGARM
REMOVAL

ais the roar whl off the round with a jek or
Block under de engine,

Remove tie foin pat:
otter
Rear whe! (Page 14-3)
= Shock absorbs (age 14-8)
minga Bot ele and singen

GEARING PLAY INSPECTION

‘hack ne swingin bring ey
piece the basing with à new one I I has ee
he pi

DISASSEMBLY

Remove Ue st ess an te cola
Remove the Dane and true bushings with the
‘ugar bering remos st.

luce the romoutr behind the suinarm being.
rie the bearing fom he owing wi a ul.
tor punch

SERES

1 SGA

N DUST COVER 13) BEARING
BUSHING
(dl

9 COLLAR.

(2) BEARING REMOVER, 20 mm 078362710800
REMOVER HANDLE 07036-3710100
07836-3710200

EAR WHEEL/SUSPENSION.

INSPECTION
Inne th alla and bearing.

Replace them if they have score marks, etches,
exce or sonora we

Replace ne chin sider Hf axcestoy worn,

| N
moRıven ®@ COLLAR (m THRUST BUSHING |OUST (5
[ATTACHMENT 07740-00000 cover
07046 -3710900 (4) CHAIN SLIDER

OR NEEDLE BEARING REMOVER

ASSEMBLY

Sn the bearings noraughty, then blest thom
win proce

Caral driv the beating nt the swingarm with
the special too, Drie the thrust busing Into int
minar with the same spel! oo.

note

io The barge with the marking ing

beats the bearing wih poso after instalo,

INSTALLATION

(Sram the inside ofthe pvt colar and aus seis.
Ina te singh and phen the pivot bolt

TORQUE: 60-90 Nm
160-30Kam,43-58 (10)

Ins folowing pate
sick absorbers Pape 14-10)
Rar nel (Page 14°71,

— o caler
Mutt
= Drive chain cover

(@ISWINGARM PIVOT BOLT ti SWINGARM

14-12

REAR WHEEL/SUSPENSION

Aste station, gas the swingarm piro using
‘trough te pres tng onthe ange

$) HONDA
COM

HYDRAULIC BRAKE |
FREIN HYDRAULIQUE
HYDRAULISCHE

SCHEIBENBREMSE
FRENO HIDRAULICO

HYDRAULIC BRAKES

N
(08- 13ksm, 8-9 feo)

4-7Nm

(0407 gen, Ste) donee
(68-13 kom, 80 eb)
25-20Nm
125-20kam, 18-2240)

18

2-00. }}

Tom, 1822 140 4-5Nm
128-301, 182214 aca

a» e

to N
20m o "
Eso. a Le P 20-2614

20-2549, 14-181)

(20-254, 14

20-2000 -
20-28 tam, 14—

120. 25km, 14 1880)

ES

en

15. HYORAULIC_BRAKES

SERVICE INFORMATION
‘TROUBLESHOOTING

BRAKE FLUID REPLACEMENT/
AIR BLEEDING

BRAKE PAD/DISC
FRONT MASTER CYLINDER,
FRONT BRAKE CALIPER
REAR MASTER CYLINDER
REAR BRAKE CALIPER,
BRAKE PEDAL SHAFT

SERVICE INFORMATION
GENERAL
= The front andre brakes can be removed without deconneetng te rai sem.
= Once te hydraule systems ha ban opened, o the brakes el spay, the system must be bled
: meer! o ter the system when filing te er
‘Avoid ing brake ui on painted surface or Instrument lab, vere damage wi rea
2 Ahunysehack baka operation ato riding the matreye,

SPECIFICATIONS

Dai SERVICE UNT
Fromäne meinen | a Sonn 6m)
Fron uno > - [0:29 mm 109€
From mar eyinder LO AE) 14055 nm (0353
1308712 06 me (05405-0 5805in) 13.940 mm (05499 er
SA | 20,6 mm 17)
Aroma nee 10 | 3223-3028 mn 19011021) | _ 902mm |
Fr mat inde 10. — 1009-1010 05612-06295) 14:58 nm (SER)
13957-18964 mn (0506-0 580516) 13.910 mm 105488 in)
Res elie end D 3028-3028 mm 1.1001-1.1021 in) 3028 100 1
ar ip iron 0. 108 3.100 nen 1,860 1.800 ET Brenn 07
Pau de tias TR TA
eu runout Sonn (0.012

Honda FT500 '83 service manual

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Honda FT500 '83 service manual