CBGSOSC ADDENDUM HONDA CBGSOSC WORKSHOP MANUAL CBGSOSC ADDENDUM INTRODUCTION CONTENTS This Addendum contains information I'Dr the CBGEOSC, I, GENERAL INFORMATION s 2372 Refer to the base shop manual and Its subsequent adden- 1, SPECIFICATIONS ...... , . 23.2 dum for service information not included In (his addendum 2. TORQUE VALUES .............. 23.4 The following abbreviations (model cede) are used to 3_ CABLE AND WIRE HARNESS Idemlfy each model Val iaIion, and wherever each model ROUTING ,,,,,,,,,,,,,,,, 23.4 ODde appears, information is for [hat model only; otherwise 4_ MAINTENANCE SCHEDULE ..... , 23‘s servlce mformallon applles to all varlatlons‘ II. LUBRICATION _____________ ‘ 23_7 C' UK, F France G(GI,G|I]: Germany ED: (European we“) III. INSPECTION AND ADJUSTMENT , 23.7 IV. FUELSYSTEM .............. 23711 WWWWW W WWW WWWWWW _ V. FRONT WHEEL/SUSPENSION ......... 2312 ALL INFORMATION ILLUSTRATIONS, DIREC» VL REAR SUSPENSION “‘21 TIONS AND SPECIFICATIONS INCLUDED IN VIII HVDRAULIC DISC BRAKE ........... 23.21 THIS PUBLICATION ARE BASED ON THE LATEST_PRODUCT INFORMATION AVAILABLE W" “ANDLEBARS/SW'TCHES """""" 2325 AT THE TIME OF APPROVAL FOR PRINTING, IX. HEADLIGHT/INSTRUMENTS/ HONDA MOTOR ca, LTD. RESERVES THE FUSE HOLDER ,,,,,,,,,,,,,, 23.29 RIGHT To MAKE CHANGES AT ANv TIME WITH OUT NOTICE AND WITHOUT INCURRING ANv X- W'R'NG D'AGRAM """"""""" ”'32 OBLIGATION WHATEVER. I I NO PART OF THIS PUBLICATION MAY BE RE- PRODUCED WITHOUT WRITTEN PERMISSION HONDA MOTOR (30., LTD. Servlce Publications Office , , IMPORTANT SAFETY NOTICE M, , ,, iWA R‘NINO Ina/mm a .TImn]: (Juvviblluy Olsen/{111' pmmml [many I» hm (lfIUr i/ ulsmlcl‘l'mu are not fallownd. lo; unfilfl Imhmlcs a pavsiluhly {1/ [animal III/my or l'qlupnzllm rln/Imgl‘ i/mm'ucrl’om my not 1011mm. NOTE: GIVES helmul IIWIOIma‘IOnI Dmmled descllmions ol sumdsra wolksholl procedures, ssIely princlnles and semen operaxions are no: incIuded. II is Imporlsn: Io note that II’IlS manual consains some warmngs and cannons agamslsome specificselvice methods which mould cause PERSONAL INJURY to sen/Ice pmmnnel or could damage a vehlcle Ol render Il unsaIe Please undersland that Ilmse warmngs cuuld not cover an Ooncelvable , ways In WthI'I serwce, wnelher or noI Iecammended by Honda Imgm he done or m Thu possihm hazardous consequences cl each OOnOewable way, nnr caule Hands Invesugale all such ways. Anyone uslng sen/Ice prucedmes or wok;,whether 01 um recommended by Honda mus: sun'sly lumsul/ Illal‘olwhly {hat neithei personal sarew nor vehicle saIetv will be Ieupaldized by me sBl'vIce melhods Or Iools selected, 23-1 LGENERAL INFORMATION HONDA CBGSOSC 1. SPECIFICATIONS ITEM AREA CODE DIMENSIONS Ovarall length 2 2E§§ ”mm [3342 ii?) E’IFGIEID Overall width mIao in) Overall height 1,170 mm (46.1 in) Wheelbase 1510 mm (59.4 in) Sea! height 785 mm (309 in) Feoipeg height 320 mm (12.6 in) Ground clearance (45 mm (5.7 in) Dry weight 205 kg (452.0 )0) Curb weight (Wet) 219 kg (4528 lb) FRAME Type Double cradle Front suspension, travel Teleseopic fork 160 mm (6.3 In) Rear suspension, travel Swingerm 105 mm (4.1 in) From tire size 3.50519-4PR Rear rrre size 130/9046 x 67$ Up to 90 kg From 200 kPE (2.0 kg/emi, 28 psi) Clad tire (200 lbs) load Rear 200 kPa (2.0 kg/cm1, 28 psi) ””55”“ Up (a vehicle Front 200 kPa (210 kg/em’, 28 psi) capacity load Real 225 kPa (2.25 kg/cm1,32 psi) Fvom. brake, lining swept alea Doubie disc brake, 920 cm2 (142.6 sq in) Rear brake, lining swept area Internal expanding shoes) 221 cm2 (343 sq in) Fuel capacity 13 5 liters (3 6 us qt) Fuel reserve capacity 2. 5 lltels l0. 7 US gal) Caster angle 29° Trail rengrh 106 mm (4.2 in) From. fork ollcapacitv (Dry) 320 cm3 (10.8 02) (After draining) 300 em’ (10.2 02) Front fork air pressure 70410 kPa (0.7—1.1 kg/cmz, 10—16 psi) ENGlNE Type A)r cooled 4-stroke OHC engine Cylinder configuration Verriea) inrline (our Bore and stroke 59.9 x 55.8 mm (2 354 x 2.197 in) Displacement 626 cm" (38 2 cu in) Compression ratio 9.0 : 1 Valve train Silent chain, eamshatt and locker arm Maximum horsepower 46 KW/9,000 min” (63 BHP/9,000 rpm] E, F, 6)) ED 37 KW/8,000 min“1 (50 BHP/8,000 rpm) on Maximum mi'que 53 him/8,000 mil)" E, F, (3|, ED (54 kg-m <39 1 It»lb>/8,0DO rpm) 49 Nrm/G,500min" G). (5.0 kg~m <36,2 WILD/6,500 rpm) Oil Capacity 3.5 liters (3.7 us all Lubrication svstem Forced pressure and wet sump Air filtration paper filter Cylinder complessian (176.8 1 196»? kpa (120 + 2. o kg/cm (70 + 28 psi) intake valve Opens :(BTDC) at 1 mm lift °(BTDC) at 0 m Closes 35“ (ABDC) at I mm lirr, 127° (ABDC) at 0 llft Exhaust valve Opens “ (BBDC) at 1 mm liir, 121° [BBDCJ ato lirr 23-2 HON DA CB650$C ITEM AREA CODE ENGINE Closes 5° iATDCl ati mm lift] 65° lATDCl ato lift Valve clearance (coldl IN: 0.05 mm [0.002 in) Ex 0.08 mm [0.003 ml Englne weight 71 kg (156.6 lb) CARBURE Carburetor tvpe VB TION Identification number VB 545 Pilot screw initial opening 2-1/8 Float level 15.5 mm (0.61 in) Main jet #95 Jet needle mark 125 Main airjet #150 Idle speed 1050: 100 min" lrpm) Fast idle 1000 — 2700 min" (rpm) DRlVE TRAIN Clutch Wei, mum-plate Transmission Espeed constantrmesh Primary reduction 2.737 : 1 Gear ratio | 2692; 1 Gear ratio ll 1,778 :1 Gear ratio Ill 1.333i1 Gear ratio 1V L042 : 1 Gear ratio V 0,885 : 1 Final reduction 2.235 (38/17l Gearshit pattern Left toot-operated return system (1-Nv273-475l Drive Chaln RKEOMO or DID 50V,106LE ELECTFHCAL lgnitlon Fully transistclized ignition Ignitlon timing “F71” mark 10° BTDC at 1,050 mm (rpml idle Full advance 28°30’ Esme/31600 min“ (rpm) Starting system Starter motor only Alternator Three phase AVCV generator mow/5,000 mm" [rpm] Batterv Capacltv 12V712AH Spark plug For cold climate below 5°C (41°F) X22ESRVU (ND), DR7ES iNGK) Standard X24ESR»U (ND), DRBES-L (NGK) For extended high speed riding X27ESR-U iNDll DR8ES (NGK) Spark plug gap 0.6707 mm (0132443028 inl Firing older 14—4—3 Fuse 16A, 30A LlGHTS Headlight (high/low beam) GD/BSW, H4 Phillips Tall/stoplight 5/21Wx 2 Turn signal ifront/rearl 21/21W X 2 Speedometer 3,4W X 2 Tachometer SAW x 2 Neutral indicator 3.4w Turn signal indicator 3,4w High beam indicator 3_4w Oil pressure indicator SAW Position light 4w 23-3 HONDA (2365080 CHASSIS ITEM O'TY THREAD DIAMETER TORQUE (mm) kg-m (fl-[b] Handlebar holder bolts 8 8 1B—23 (1.8—2.3, 13—17) Caliper mounting 1301! 2/1 8 113—23 (1 .8~2.3, 13—17) Caliper shah 2/1 10 30—36 (30—33, 22—26) Brake pad pin retainer bolt 2/1 5 5— 8 (0.5—0.8, 4— 6) Brake calmer bleeder 2/1 — 7—- 9 (0 7—0.9, 5— 7] 3. CABLE AND WIRE HARNESS ROUTING :fw t (1) THROTTLE CABLES \/ ». _ I (2) CHOKE CABLE (3) BRAKE , HOSES / f / W 1(3) TACHOMETER-v 'v CABLE ‘3' / .,/ in} ‘ ‘ T \ \; ‘141FENDER\ CABLEGUIDE -\_ >- (5) CABLE, GUIDE (61 SPEEDOMETER CABLE 23-4 HONDA CBG5OSC (1] FRONT BRAKE HOSE {2) CHOKE CABLE Q'\;"‘,.¢ __ .\ AVG ' (a) CLUTCH CABLE (11) THROTTLE , 4%}, H (4) CABLE GU'DE CABLES / \1‘ (5) SPEEDOMETER (10) BRAKE HOSE \ CABLE CABLEGUIDE I‘ ”a I N Is) TURNSIGNAL l\\\.n§(w$ WIRES (9) TACHOMETER CABLE I7) MAIN HARNESS \ (8] TURN SIGNAMK /7 (12) BATTERY W'RES (14] WIRE HARNESS (15) REGULATOR/ RECTIFIER 23-5 HONDA CB6505C Perform the PRE RIDE lNSPECTlON In the Owner 5 Manual at each scheduled maintenance perlod Inspect and Clean, Adjust, Luincate or Replace if necessaly. C: Clean R: Replace A: Adjust L: Lubricate -\ WHICHEVER [NOTE 3] \\_\ FREQUENCY EFRCSL'JFRS 9 ,, ‘ ‘. ,, f"; WE & *0“ ITEM EVERY Heferm m N Pages 22, ENGINE OIL , YEAR 211,237“ ENGINE OIL FILTER YEAR Page 22 T AIR CLEANER " NOTE I'“ c ' O “Pag’eizIT-f ” CRANK CASE BHEATHER NOTE ’ C' c ' 'C' ' c W c IPage * FUEL LINES I I I ' I I Page ' FUEL STRAINER c c c c "'c' T VC "65:23 7 Pages 3-3 SPARK PLUGS I , , I R I RH I 237 " VALVE CLEARANCE ‘9 CAM CHAINTENSION , 3~6 * THROTTLE OPERATION I Page 377 * CAHBURETORCHOKE I PKII'e" 23.8 * CARBURETOR‘SYNCHRONIZATION I $193 3'9 ‘ CARBURETOR IOLE_ SPEED , I 7 I I M I ’l’AageZ2-54 DRIVECHAIN Page 312 BATTERY ' MONTH I' Page 21~ , . M “MONTH ‘ ,. __ _ g , -I BRAKE FLUlD (FRONTI 2YEARS.R I I I R I I Page 313 BFlAKE PADS/SHOES WEAR I I I I BRAKE SYSTEM I I I I I * BRAKE LlGHTSWlTCH ' .. ' I I" I I ' I I I I Page 3115 * HEADLIGHT AIM V" ‘ ' I I I 'I""”TW I Page 3-I5 Page 346,“ CLUTCH I I I I I I 21' 7 SIDESTAND I I I "Page 3-17 ' SUSPENSION , I I Pageszsm I ‘ NUTS, BOLTS, FASTENERS "'I' 3m I I l 'I 'Page 349 I a Pay}; 349 H WHEELS *‘ STEERINGHEAOBEARING “ SHOULD BE SERVICED BY AN AUTHORlZED HONDA DEALER, UNLESS THE OWNER HAS PROPER TOOLS AND SERVICE DATA AND IS MECHANICALLY QUALIFIED. H N THE INTEREST OF SAFETY, WE RECOMMEND THESE lTEMS BE SERVICED ONLY BY AN AUTHORIZED HONDA DEALERI NOTES: 1. SERVlCE MORE FREQUENTLY IF OPERATED lN DUSTV AREAS. 2. SERVlCE MORE FREQUENTLY WHEN HIDDEN lN RAlN OR AT FULL THROTTLE. 3. FOR HIGHER ODOMETER READINGS, REPEAT AT THE FREQUENCY INTERVAL ESTABLISHED HERE. 23-6 HONDA 0365050 ll. LUBRIGATION ENGINE OIL RECOMMENDATION APl SERVICE CLASSIFICATION: SE or SF VISCOSITY: SAE low-40 Other vlscosities shown In the chem may be used when the average fempevamre in your I’ldil'lg area is wkhm (he lfldlcawd range ||I.INSPEGT|0N AND ADJUSTMENT < ENGINE > FUEL STRAINER Tum the fuel valve OFF Remove the fuel cup, O'ring and filler scream, dralnlllg (he gasoline into a suifable comamel, Gaxoline is flammable and is explosive under certain candin’ans, Do no! smoke or allow flames or war/cs near the equipment while draining fuel Wash the cup and mm screen in clean nan- flammable or high flash Dolnt solvem, Replace the Owing. Hemsfall the screen securely, aIlgHing the Index marks on the fuel valve body and filter screen. Install a new O-ring mm the fuel valve bodvl Reinxlall the luel cup, makifig sure lhe new 0 rmg lS In place Hand tighten the cup and then torque It to specificaliow TORQUE: 3M5 N-m (0370.5 l20 710 o 10 20 30 40“ C I2) FILTER SCREENw». (1) INDEX MARKS ©«I’l3lO-RING .Hml FUEL CUP -. 23-7 CARBURETOR CHOKE Operate the choke lever and check for smooth operatlon, The choke lever must move smoothly and stay where positioned. To adjust lhe lever operating frlctlon, turn the adjusting screw To Check the choke lunction, remove the fuel tank. Make sure that the choke lever of the carbu- retor is fully closed when the handlebar lever is pushed all the way (0 the left, Adjust by loosening the choke cable clamp and movmg the choke cable as required. He» ‘l’lghwn the clamp while holdlng lhe lever fully closed. 6 HONDA 6365080 l1) CHOKE LEVER 23-8 HONDA. CBGSOSC GRANKGASE BREATHER Remove the plug from the drain tube to empty any deposits. Install the drain plug. NOTE: Service more irequentiy when riding in ram m at full throttle, or if the deposit level can be seen in the transparent sec‘ion of the drain tube < CHASSIS > BRAKE PAD WEAR Check the brake pads for wear, Replace the brake pads if the wear line reaches the edge of the brake disc (Refer to page 2322). :Lw’iuaoy. Always repltz‘ce‘iha‘keEnd‘sfifgrz‘zgio assure even :11 pressura . ,, gr 2) FRONT BRAKE ' CALIPER 23-9 é HONDA (3365050 SUSPENSION Do not ride a vehicle with faulty suspension Loam worn or damaged suspension parts impair vehicle stability and natural. FRONT Check the action 0! the from forks by pompressing Ihem several times. Check me entire fork assembly lor leaks or damage. Replace damaged components which cannol be repalred. Tlghlen all nms and bolts, Place lhe motorcycle on ils center stand. Do not use the Slde stand or you wul gel fals? pressme leading: Remove the valve cap and measure the front fork all pressure, NOT Some pvessuve wlll 9 osx when removing the gauge from Ihe valve Determine me amoum of loss and compensale accovdlngly FRONT FORK AIR PRESSURE: 70—110 kPa(0.7—1.1kg/cm1,10716 psi) mm Do no! exceed 300 kPa (3.17 kg/cm‘, 42 psi} or Wilh the hon! brake applied. pump the from Vorks up and down several [lmes. Check the operation 01 from suspension 23-10 HON DB. (2865056 IV.FUEL SYSTEM IV.FUEL SYSTEM 8 LOW JETS Remove the carburetors (page 2232). Remove the float chamber bodies and \emove the slow jels, Biow the slow jets with compressed air and iw spent them for nicks, scratches or other dam- age Screw in each slow jet mth it seals lighdy‘ and men turn approxwmalely 3/4 mm more. \nstafl the float chamber bodies, \nsiall the carburetors. 11) smwmr“ ' ' Mr «W 5’3:ka m,- 23-11 V.FRONT WHEEL/SUSPENSION 033$? V.FRONT WHEEL/ SUSPENSION I (1.8723 kg»m, 13—17mm 55765 N-m (5.5—6.5 kgvm, 40#47 lt-lb) 15—25 N- (3.0—4‘0 kgAm, (1.54.5 L2H“, V ‘. 22—29 Mb) H~1B ft-lb) ' 23—12 HONDA. CBGSOSC SERVICE INFORMATION 0 The CBGBOSCC uses an equalized, air-assisted front fork system. Adjustment of air pressure changes preload to provide (he desired ride undervarlous rider/cargo weights and riding conditions. TORQUE VALUES ITEM QNTV THREA?m°r:“]‘METER TORQUE N-m (kgvm, mm Front fork alt valve 2 B 4—7 (0.4—0.7, 3—5) From fork cap bolt 2 32 15w30 (I. —3.0, I1 ‘22) Front fork socket bolt 2 B 15-25 (I 42 5, 11718) Alr hose connector, righf 1 8 477 (0 70 7, 375I Air hose connector, left 1 10 15—20 (1. —-2 0, 11-15) Handlebar attaching bolt 8 8 18»23 (I. .3, 13—17] Front axle 'I — 55—65 (5.5—6.5. 40—47] Pinch bolt nut 1 8 15725 (1572.5,II7181 Caliper holder bolt 4 10 30740 (3074.0. 22729I SPECIFICATIONS ITEMS STENDARD SERVICE LIMIT “m spring free length Front fork bottom case |.D, Front lork lube OD. From lork lube bushing 0.0. From fork guide bushing LD. Front lork oil capacity From fork air pressure 570 mm (22 44 in) 38040—38080 mm (1.498—1.4991nl 36350—36375 mm (i.4547~1.4557 in) 320 x 2.5 cm1 (10.8 t 0.08 025] after assembly 300 z 2.5 cm’ 110.0 x 0.08 015) at draining 70—110 kPaIO.7—I.1kg/cm2,’lO#16 psi) 553 mm (21 77 in) 38.20 mm (1.504 in) 36.90 mm (1.453 in} 37.87 mm (1.491 in) See 2346 See 23-16 SPECIAL TOOL Fork seal d1 iver TROUBLESHOOTING Soft Suspension 1. Weak fork springs. 2 Insufficient fluid in forks. 3, Low aII' pressure. Hard Suspension 1. Incorrect fluid weighi in forks. 2. Excessive air pressure In fork tube. 3. Excessive oil amount in forks. 0794773710101 23—13 HONDA 0365086 FRONT FORK FRONT FORK REMOVAL/INSTALLA» “)FORKCAPBOLT 2) FUSEHOLDER TiON ‘ ' 3) RiGHTAiH HOSE Remove the fuse holder cover and fuse holder. ‘ ' CC‘TNNECEE Release air pressure and disconnect the air hose ‘ from the right hose connector. Disconnect the air hose from the left front fork. NOTE Tiae ore removing the front tom},- loosen th ’ ' front fork cap bolts to ease front to dis . . ' ' \.-‘ assemb , , (4) FORK PlNCHING tandlebar attaching bolts. Move the handlebars out of the way to ease loosen- ing the cap bolts. (page 237287, Remove the front wheel (page 23719). Remove the brake caliper (page 23723). Remove the from fender. Loosen the tap and bottom fork pinching bolts. Pull the fork tubes down and out while rotating them by hand. Install in the reverse order of removal. FRONT FORK DISASSEMBLY (2) SNAP-RING PLIEHS iii SNAP-RlNG The fork tube cap; are under spring pressure. Ute care when removing the caps to avoid injury Wear face and eye protection. Remove the Fork cap bolt. Remember, the cap bolts are under spring pressure; wear face and eye protection. Remove the spring from inside the fork tube. Pour out the remaining fork fluid by pumping the fork up and down several times. Remove the piston and rebound spring. Remove the dust seal and snap-ring. Remove the bankrupt plate with a magnet. i3) BACK-UP PLATE Pull the fork tube out untli resistance is felt from the bottom case bushing. Then move the tube in and out, tapping the bushing lightly until the tube separates from the bottom case. The oil seal, back-up ring and bushing will come outwith the tube. Remove and discard the oil seal. Remove the backup ring and bushing from the fork tube. Remove the oil lock piece from inside the bottom case. 11) FORK BOTTOM CASE (2) FORK TUBE 23-14 HONDA CBGSOSC FRONT FORK 4_7Nm (4) DUSTSEAL {0.4—0.7 kg-m, 15—30 Nrm 3~5 ft~IbI (1. 5—3 0kg- m. 15—20 N‘m _ (5) BACK UP 11 22 ftlb) (1.5—2.0 kg m, 1144 It-Ib) PLATE \§\m (71 BACK up SNAP II) AIR HOSE RING \ x. RING§ 4— 7Nm \@ (0.4— —O.7kgm 3— 5mm ® Q ® (a) OIL g (9] SLIDER BUSHING (I / / (15] g \ PISTON_‘@ ”2, I2) OIL LOCK PIECE RING I3) BOTTOM FSRK CASE ‘(IUI FORK S RING TUBE Q (13) PISTON l\ I (11) FORK TUBE BUSHING 1.5—2.5 kg~m (II—18ftrIb)\® 23-15 HONDA CBGSOSC SPRING INSPECTION Measure the spring and replace it If the free length is shorter than the service limit. FORK TUBE/BOTTOM CASE/PISTON INSPECTION Check the fork tubes, bottom cases, bushings and pistons for score marks, scratches, or excessive or abnormal wear. Replace those parts which cannot be reused. Measure the outside diameter of the fork tube within the range of 160mm (6.3 In) from the bottom and up to 400 mm (15.7 in), and check the condition of the tube piston and ring. Front fork tube O.D. SERVICE LIMIT: 36.90 mm (1,453 in) BUSHING/BACKUP RING INSPECTION Visually Inspect the bottom case and fork tube bushings. Replace the bottom case and fork tube bushings if they are scored or worn enough, or if the tellon overlay is worn so that the copper layer shows over more than 3/4 01 the total surface. Replace Ihe backrup ring if there is any distortion at the points shown. (1) STANDARD: 570.0 mm (22.44 in) (2) SERVICE LIMIT: 553 mm (21,77 in) III—III I1) FORK TUBE BUSHING I2) BOTTOM CASE BUSHING (3) MORE THAN 160 mm (6.3 ml AND UP TO 400 mm (75.7 in) I3] BACK-UP RING l2) COPPER SUR FACES I4) CHECK POINTS 23—16 HONDA CBGSOSC é? FORK TUBE Set the fork tube in V blocks and read the runaut Take 1/2 the total indicator reading to determine the aciual runout. RUNOUT SERVICE LIMIT: 0.2 mm (0.008 in) ASSEMBLY Clean all disassembled pans. Install the rebound spring and piston into the fork lube. Place the oil lock piece over me piston end and insert Ihe fork tube inlo the bottom case. Install the fork spring with the narrow coils reward the rep. Loosely install the lurk tube cap bolt. Place the fork bottom case in a vise wim soft jaws or a shop rowel. Apply a locking agent to the socket bolt and thread it into the piston. Tighten with a hex wrench. TORQUE: 15—25 N‘m (1.5—2.5 kg-m, 11-13 ftrlbi CAUTION Do not avem'ghwn 37370;: Vbbnom case In a visa. l1) PISTON (4i OIL LOCK PIECE _ (/fl & WIS) REBOUND SPRING I2) PISTON RING (II SHOP TOWEL 0R SOFT JAWS (2I HEX WRENCH 6 mm 0791773230000 HONDA. CBSSOSC Place the bottom case bushing over the lurk tube and rest it on the bottom case. Put the back-up ring and an old bushing or equivalent tool on top Drlve the bushing into place wlth the seal driver. Remove the old bushing. Wrap a piece of tape around the snaprrlng groove at the top 0' the fork tube. This will prevent the oil seal from being damaged when installed. Coat a new oil seal with ATF and slide it over the lork tube with the seal marklngs facing up. Drive the seal ln place with the seal driver untll the snaprring groove appears NOTE lt additionareeal depth is needed, install tne backrup plate and repeat driving the seal ln, Install the backup plate, snaprring and dust cover. NOTE Install the snaprring with lts raolused edge facing down. Remove the fork tube cap bolt and fill the tube Wlth ATF, Do not overfill. OIL CAPACITY: 320 cm’ (10.8 018) install and loosely torque the fork lube cap boll, After installation, tighten the bolt to l5~30 N-m (1.573,!) kg»m, 11722 (Mb) (see page 2344), (2) UP l3) OIL SEAL (ll FORK SEAL DRIVER 0794773710101 (1| SNAP-HlNG FLIERS (2i DUST COVER (3) SNAP-RING l4) BACK-UP PLATE (5) 01L SEAL t6) BACKUP RING (1) CAP BOLT 23-18 ]E[()I\TI)IK $865080 “v - v mma - (1) SPE DOMETER CABLE (3) PINCH BO _ » ' ‘ _ ‘ FRONT WHEEL REMOVAL Place a support b‘ock under (he engine and raise the from wheel off the ground. Expand the sex Spring and diwonnecx the speedometer cable. Remove the left or rwghl calmer assembly Loosen the nut and remove the from ax‘e pinch bolt, Remove the axle and remove the wheel. NOTE Du’héf’yofi’eine'me from brake lever- § after removing the from whee]. To do ’ ll w - so will cause difficulty in refining the (2) SET SPRING brake disc between the brake pads‘ DIS/ASSEMBLY 55765 NW“ (5.5—6.6 kg-m, 40~47 ft-lb) (1) BEARING RETAINER _@ 27—33 N-m 3 (2.7-8.3 kg-m, 20—24 ftrl NOTE v The COMSTAR wheel has no rim band. The from wheel uses a tube|ess lira For ‘ube‘ess lire repair, refer to the TUBELESS TIRE MANUAL (Code No‘ 6141550). 23-19 HONDA 0365080 FRONT WH EEL INSTALLATION Insert the axle through the right fork leg and wheel hub and screw lt into the left fork leg‘ Make sure the speedometer gearbox is perpen- dlcular to the left fork leg. Tlghten the axle nut to the specified torque TORQUE: 55—65 N-m (5.54.5 kg~m, 40— 47 Mb) Install the pinch bolt and loosely tlghten the IWUL Flt the calipers ever the discs, taking care not to damage the brake pads. lnstall the caliper holder muuntlng bolts. TORQUE: 30740 Nvm (3.0—4‘0 kg-m, 22— 29 fella) Measure the clearance between the outside surface of the right brake disc and the right caliper holder with a 0 7 mm (01128 in) leeler gauge, If the gauge lnserts easily, tlghten the pinch bolt nut. TORQUE: 15—25 Nrm (1,5-2 5 kg‘m, ‘Ili let-lb) If the teelet gauge cannot be insened easily, pull \he right lork outward until the gauge can be inserted and nghten the pinch bolt nut wnh the gauge inserted. Remove the gauge. After installing the wheel, apply the brake sevA eral times then recheck both discs for caliper holder-to-disc clearance ealipel holder clearance any damage the brake discs and impair braking efliclen» cy. 12) SEEDOMETEH GEARBOX l2) CALIPER HOLDER (1) FEELE R GAUGE l2) CALIPER t r HOLDERBOLT. l‘l) CLEARANCE «w M—l3l DISC 23—20 HONDA CBGSOSC VI.REAR SUSPENSION SPECIFICATIONS VI. REAR SUSPENSION VII.HYDRAULIC DISC BRAKE ITEM STANDARD SERVICE LIMIT Rear shock absorber spring (Ice length 233.9 mm (9.21 in) 229 mm (9.0 in) VII.HYDRAUI.IG DISC BRAKE SERVICE INFORMATION TORQUE VALUES ITEM ONTY THREART‘DnL?METER TORQUE N-m Ikgm ft~IbI Caliper shafi nut 2 10 30—35 (3,045] 22—26) Caliper mounting bolt 2 8 18~23(1.B—2,3,13—17) Pad pin Ietainer be“ 2 6 5 — 8 (0.5418, 4 7 6) SPECIFICATIONS ITEM STANDARD SERVICE LIMIT Caliper cyiinder | D. Caliper piston O D. Disc IhIckness 27000727076 mm (1 .063071 .0660 in) 25320—26970 mm (105987710618 in) 4.8752 mm (0.79—0.20 in) 27.09 mm (1.067 in) 93 mm (1.060 in) mm (0.18 in) BRAKE CALIPER 18723 Nvm 1.8723 kg~m, 30—36 N‘m 30—40 N-m (3 041.0 kg-m, 22726 be) <_ 22—29 Ian " 13—17mm ,./‘”\ (3.0—3.6 kg-m, /, Rafi“ R 7—9 Nrm (0.74.9 kg-m, g 577 be) 4—6 fr Ib) 23-21 0,570.8 kgrm, C, 7} HONDA % c365osc BRAKE PAD REPLACEMENT Remove the pad pin retainer bolt and retainer. (1) PIN RETAINE 2) PIN RETAINER BOLT Push the ca‘iper toward the disc, pushing the pistons all the way in to al‘ow for instaHa» tion of new brake pads. Remove the caHper mounting bolt and turn the mapr assemb‘y up. Remove the two pad pins and remove the pads from the caliperv InstaH new btake pads and insert the pms. lnstaH the caliper mounting bolt. TORQUE: 15—23 N-m (18*23 kg-m, 13— 17 (Mb) 23—22 HONDA (2365036 BRAKE CALIPER REMOVAL Place a container under lhe caliper and dis- connect the brake hose boll. Remove the brake hosei Remove the brake pads (page 2322). mg brake flu on painted surfaces Remove Ihe calmer mounting bolts and calir per. D ISASSEMB LY Remove the boots and collar. Remove the brake pad springl Place a shop towel over (he piswns. Remove the pistons by applying a small amount of air pressure to the fluid inlet. Do rim use high pr ssu e an or bring the nozzle too close to the inle Examine the pistons and cylinders fm scor- ing nr scratches and replace if necessazy. (2) CAMPER MOU L ”I -u (1) BOOTS (3) PAD SPR | N G (2) COLLAR 23-23 HONDA CBBSOSC Remove the oil seal by first pushing it into the cylinder as shown. Clean the caliper grooves with brake fluid. PISTON O D. INSPECTION Check the piston for scoring or scratches, Measure the outside diameter of the piston With a micrometer. SERVICE LIMIT: 26.93 mm (1.050 in) Replace the piston it it is smaller than the service limit. CYLINDER l.D. INSPECTION Check the cylinder for scoring or scratches and measure the cylinder bore. SERVICE LIMIT: 27.09 mm {1.067 inl Replace the caliper if the cylinder is larger than the service limit. ASSEMBLY Assemble the Caliper in the reverse order of disassembly, The oil seals must be replaced whenever removedt Lubricate the pistons and seals with a medium grade highrtemperature SiliCone grease. Place the pistons in the call- pers With the concave end facing the pad. Be certain the boots are seated in the collar grow/es. INSTALLATION Lubricate the caliper shafts with silicone grease. Install the caliper and torque the mounting bolts, TORQUE: 18e23 N~m (LB-QB kg-m, 13- 17 rural install the brake pads. Connect the brake hose. Connect the brake fluid reservoir and bleed the brake system [page 153) (1) OIL SEALS , 23-24 gggye Vlll.HANDLEBARS/SWITCHES VIII. HANDLEBARS/ SWITCHES RIGHT HANDLEBAR SWITCH REPLACEMENT Remove the fuel tank Remove the screws holding the uppei and lower switch housings. Remove the throttle cables Disconnect the front brakeiight switch Wires from the swnch. Remove the headlight from the headlight case and disconnect the right handlebar switch wire coupleri Remove the switch Wires from the headlight case. NOTE Connect a string to the switch Wires and then remove the wires leaving the string through the headlight case, This string is used as a draw cord when routing the wiring of a new switch. Align the new switch With the hole in the handlebar and install the swmch. Tighten the forward screws first, then the rear screw. Connect the Witch wires in the haadliglit (2858, Connect the wires to the blakelight swttch. Connect the throttle cables and reinstall the fuel tank Check svvitch operation and adjust the throttle cable free play (Page 2279i LEFT HAN DLEBAR SWITCH REPLACEMENT Remove the screws holding the upper and lower switch housmgs, Loosen the clutch lever bracket bolt. Disconnect the clutch switch wire from the swnch. Remove the headlight and disconnect the left handlebar switch wire coupler. Remove the switch mm: from the headlight case NOTE: *7, W Connect a string to the switch wires and then remove the wires leaving the String through the headlight case. This string is used as a draw cord when routing the wiring of a new switch, (I) RIGHT HANDLEBAR SWITCH HOUSING (2) PIN (1) LEFT HANDLEEAR SWITCH HOUSiNG / HONDA CBGSOSC Align the new switch with the hole in the handlebar and install the switch. Tighten the forward screws first, then the rear screw. Connect the switch Wires in the headlight case. Connect the wires to the clutch switch. Check switch operation and clutch free play [page 3-l 6i. HANDLEBAR REMOVAL Remove the handlebar switch wires from the handlebar. Remove the right handlebar switch housing screws. Remove the brake master cylinder CA UT 1 ON: Secure the brake cylinder in an upright position to prevent the Fluid from leal<~ ing and damaging the paint and to pre vent air from entering the brake system. Avoid getting brake fluid on painted surfaces. NOTE: Do not loosen the brake hose unless necessary. Remove the left grip. Remove the left handlebar sztch assembly. (See page 23-25]. Loosen the clutch lever bracket bolt. Loosen the handlebar attaching) bolts and remove the handlebars. Remove the clutch level biacltel assembly from the left handlebar. Remove the throttle grip and switch housing from the right handlebar. (1) HOLE (2) PIN 23—26 HONDA 6365036 HANDLEBAR INSTALLATION Insert the handlebars into the holes in the fork top bridge, lnstall the handlebar holders With the high mating surface forward and temporarily tighten the handlebar attaching bolts. Coat the throttle grip area at the handlebar with grease. Install the throttle grip switch housing and throttle cables. Check throttle operation (page 22.9). install the master cylinder on the handlebar. Align the holder mating surface Wlth the punch mark on the handlebar and wire reliel facing down, Tighten the upper bolt first, then tighten the lower bolt. Install the clutch lever bracket assembly and left handlebar switch housing. Align the lever bracket and surface with the punch mark on the handlebar and its split Wllh the lett handlebar switch housing mating surface Attach the switch wires and check clutch free play (page 3-16), (ll PUNCH MARK 23-27 HONDA CBfiSOSC HANDLEBAR ADJUSTMENT Loosen the eight handlebar attaching bolts Rotate and silde the handlebars up and down to match the rider’s height and riding posi- tion, using the punch marks on the handler bar: and index marks on the folk tap bridge as a reference Torque the forward handlebar attaching bolts first, then (argue the rear ljolts TORQUE: 18~23 N-m (1,8#Z.3 kgm, 13... 17 farlb) m M W, 0 Check the security of the handlebars and bolts by turnan both handlebars all the way to the left and right, and pushing and pulling an the handle- bars with force. 0 Check to be sure that the wnes, hoses, and cables are not kinked or pulled taut, and that they are free to move in all steering positions, (1) PUNCH MARKS 23-28 ,, HEADUGHT/INSTRUMENTS 6 Egg?“ 'x-/H0LDER IX.HEADLIGHT/ INSTRUMENTS/ FUSE HOLDER HEADLlGHT \NSTRUMENTS DISASSEMBLV Remove the headhgm. Disconnect the insvumem wire commctors in the headlight case‘ stconnect the speedometer and tachometer cabms from the mstrumcms. Remove me instrument mounting nuts and lle\$t\uIWei1ts. 23-29 HONDA CBSSOSC Remove the four screws and llft off the instrur ment COVGY. Remove the lndlcator lamp bulbs. Remove the lower instrument case by (97 moving two cap nuts. CA UT] UN .' Do not leave the instruments upside down lol' an Extended period of time er damping fluid will leak onto the lens. Separate the speedometer and tachometer tram the mounting bracket by removlng the three nuts ASSEMBLY Assemble the instruments in the reverse order of disassemblvv NOTE: Lubricate the speedometer and tachoV meter cables befure reconnecting them. v r... a z: n E 1 var!» vuaaen 4 mm. (3) HlGH BEAM (1) NEUTRAL (2) OIL n." e a a 5 v m" uoaoem (4) LEFT HAND TURN (5) RIGHT HAND TURN 23-30 HONDA CBGSOSC FUSE HOLDER REPLACEMENT Remove the headlight and disconnect the fuse homer coupler in the head‘ight case, Remove the two screws and lift off the fuse ho‘der cover" Remove the (use ho‘der by removing ma two SCYCWSV Install the fuse holder in the reverse order of remova‘ H) FUSE HOLDERCOVER MW} , V» (1) FUSE H a. ,1 w; 2331 HONDA. 8865080 MEMO 7; HONDA x WIRING DIAGRAM caesosc IIII WIS URL‘ uoIIv Izvsaw rusfi I5AINLuIrIm-0II.) x‘ WIRING DIAGRAM II. deI .mIImuwI MW. mum Izmw mum ISAINuIIm'AchId DIAGRAMA DE ALAMBRADO / ~usn IsAI’NmDLInmI mm MAIFuroI NLIIIIIAI mum/Iron mm qusdw I»: Manama a: new“) IZVCS AWI I II mm SIGNAL INDICATOR IIsIIr \2V3AW HIGH uLAM wow/non mm \2v34w m mdmdm dc We” derecha 12v: 4w s: Iwruw SIGNAL I'IIUNI HI AII BRAKE «mm Nubia IsAISEIIIII II: waI. m mdnmdam cm hat 5qu )2v3 4w 1 I, / / 'Puroda dc, “Wu ,mmwswm III? army/IN) I) y , rump“ I / / / /‘ I ma. 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