ee HONDA cx500 FUEL SYSTEM Date of ue Tansey 1078 4-0 HONDA MOTOR 66. LTO>) HONDA (@) “cxs00 4. FUEL SYSTEM SERVICE INFORMATION TROUBLESHOOTING “1 CARBURETOR REMOVAL 42 CARBURETOR SEPARATION 43 CARBURETOR ASSEMBLY a4 VACUUM CYLINDER, DISASSEMBI V/INSPECTION 45 FLOAT CHAMBER DISASSEMBLY 4-6 AIR CUTOFF VALVE DISASSEMBLY +8 COMPONENT ASSEMBLY FLOAT LEVEL ADJUSTMENT FAST IDLE ADJUSTMENT (CARBURETOR INSTALLATION PILOT SCREW INITIAL SETTING FUEL TANK AIR CLEANER CASE GRANKCASE BREATHER SYSTEM 4-8 a9 49 49 4-10 au a" 412 | SERVICE INFORMATION © WORKING PRACTICE Use caution when working with gasoline, Always work in a well ventilated area and away from sparks or open flames. When disassembling fuel system parts, note the locations of the O-rings. Replace them with new ones on reassembly. ‘The float bowls have drain piugs that can be lonsened to drain residual gasoline. © SPECIAL TOOL FLOAT GAUGE 07401.0010000 * SPECIFICATIONS, Tem STANDARD. Venturi diamete ‘| __ 35mm (1.38 in). ‘See ~_vB26A [Float level 15.5 mm (0.61 in) Pilot serew ‘See Page 4-10 11002 100 rem Vacuum pressure difference _ |_ between carburetors ae Throttle arin free pla ao call (8-1/4 in.) TROUBLESHOOTING Engine Cranks But Won't Start 1. No fuel in tank 2, No fuel getting to eylinders 3. Too much fuel getting to cylinders 4. No spark at plugs ~ ignition malfunction 5, Aircleaner clogged Engine idles Roughly, Stalls, or Runs Poorly Idle speed incorrect Ignition malfunction Low compression Rich mixture Lean Mixture Air cleaner clogged ir leaking into manifold 8, Fuel contaminated 9, Carburetors not synchronized 10. Faulty vacuum piston Lean Mixture: 4. Carburetor fuel jets clogged 2. Vacuum piston stuck closed 3. Fuel cap vent blocked 4. Fue! filter clogged 5. Fu! lire blocked 6. Float valve faulty 7. Float level to0 low Rich Mixture: 1, Choke stuck closed 2. Float level set to0 high or float sticking 3, Carburetor air jet 4. Sticking float 5. Dirty air cleaner icaged Date of issue: January, 1978 HONDA MOTOR CO,, LTD.€ HONDA FUEL SYSTEM Ge/ CX500 CARBURETOR REMOVAL fuel valve off eat and fuel tank wire band, weather hose, bypass choke wire clamp, ‘carburetor band Remove the carburetor insulator hose, Remove Remove both carburetors from the air cleaner tube by pushing them down and forward, Pull the carburetors towards the lef. Loosen the lock nuts and disconnect the throt tle cables Disconnect the choke cable at the carburetors. Flomove the carburetors Date of Tsao: Janvary, 1078 4-2 @HONDA MOTOR CO, LTD.HONDA ¢xsooO FUEL SYSTEM CARBURETOR SEPARATION [cacTion} | Ihe carbusior& preset atthe factory | 207 except aft Hemove the synchronization adjustment screw. Remove the choke relief spring Remove the rear stay Date of lene: amuary, 1078 @HONDA MOTOR CO., LTO 4-3FUEL SYSTEM Remove the front stay plate, FRONT STAY PLATE Separate the carburetors SYNCHRONIZATION ADJUSTMENT SCREW SPRING CARBURETOR ASSEMBLY Slip an O-ring over each end of the fuel joint Pipe. ‘Assemble the right and left carburetors making sure the spring are properly posivioned. Install the synchronization adjustment screw. Date of lower January, 1078 4-4 HONDA MOTOR CO.,LTD,\ HONDA cx500 FUEL SYSTEM VACUUM CYLINDER VACUUM PISTON DISASSEMBLY /INSPECTION j Remove the vacuum cylinder from the cabe JET NEEDLE retor. _ NEEDLE SET SoREW Remove the vacuum piston and inspect for be aoa wear, nicks, or scratches. a, Make sure’ the piston’ moves freely in the cylinder and in the bore of the carburetor. FULLOPEN STOPPER ss VACUUM CYLINDER Remove the full open stopper. Remove thenesdle set screw and the jet needle. nore ee [spec nee and at Yor depo, | rooves, or other damage Carefully fft the seal ring off the carb | uretor body Remove the air jet cover Date of lesuer January, 1978 HONDA MOTOR CO.,LTD.€ HONDA Z FUEL SYSTEM =/ cx500 Blow open the primary main air jet, secondary air jet, and slow air jet, with compressed air. NOTE [Never clean carburetor Jet with wire or drills. This will enlarge the openings and -onsumotion * VACUUM PISTON INSPECTION Check the vacuum piston for free movement in the cylinder FLOAT CHAMBER DISASSEMBLY Romove the float chamber bedy. Remove the secondary main jet anc! jet needle holder. SLOW JET PLUG Remove the slow air jet plug. NOTE Do nat try to remove the slow air jet. Iisa press fit. Remove the primary main jt. Remove the pilot screw. ‘Date of ese: January, 1078 4-6 ©HONDA MOTOR CO.,LTD(2) HONDA (€) “cxs00 FUEL SYSTEM Remove the primary nozzle NOTE [Do not try to remove the siow air [itis press fit Remove the float arm pin using a needle nose plier Remove the float and float valve Inspect the float valve and esat for deposits, grooves or other damage. Date of lasie: January, 1978 @®HONUA MUIUK GO.,.1 TDFUEL SYSTEM AIR CUTOFF YALVE DISASSEMBLY Remove the dapbegm, Remove he Ost Inspect the air hoses and diophrogm and brittleness. Clean the passages and jets with compressed air COMPONENT ASSEMBLY ible the air cutott valve, float chamber .cuurn eylinder in the reverse order of dis: wembly. Make sure the O-rings seat in their 4-8 ‘Date of lesues January, 1078 7 HONDA MOTOR CO, 17FUEL SYSTEM FLOAT LEVEL ADJUSTMENT Measure the f Adjust th flost arm by bending the metal ose pliers. FLOAT LEVEL: 18.5 mm (0.61 in} Fast IDLE ADJUSTMENT f LE: 15092500 pm | | 0 cous ABOUT 08 mer THROTTLE DRUM er, and close the throttle valve By turning the throttle stop serew out Adjust by eoening oF clasing the fork end of the fast idle lever until the clearance between the fast idle lever sad throttle drum is about (08 mm (0.047 in} CARBURETOR INSTALLATION astallation is the reverse order of removal NOTE ‘Do. not Tate TURN throttle je the OPEN and RE] After instalation, p the following adjust- + Throttle Garbureto justment {Page 3-6). ow setting and adjustment (Page 4-10). Date of Issue: January, 1078 ‘HONDA MOTOR CO., LTD.FUEL SYSTEM PILOT SCREW INITIAL SETTING NOTE es caeeeesererireaes ‘The pilot screw is factory preset. Do not adjust unless the carburetor is overhauled. Turn the pilot screw clockwise until it seats lightly and back it out to the specification. This is & preliminary setting prior to the final pilot screw adjustment. PILOT SCREW INITIAL OPENING: 2 turns CAUTION] | Damage to the pilot serew seat will occur | | if the pitor screw is tightened, * PILOT SCREW ADJUSTMENT NOTE Use a tachometer with graduations of 100 rpm. farm up the engine to operating temper: Stop and 90 driving for approximately 10 ‘minutes is sufficient. 2, Attach a tachometer 3. Adjust the idle speed with the throttle stop IDLE SPEED: 1,100 100 rpm 4, Turn the pilot serew in or out to obtain the highest engine speed, 5 Readjust the idle speed with the throttle 6, Turn the pilot serew in gradually until the engine speed drops 100 rpm. nore » [tthe pilot serew seats before Towering ROTTLE STOP SCRE the engine speed 100 rpm, continue 10 _— . step 7. 7. Turn the pilot screw 1 turns open from the position obtained in step 6. 8, Readjust the idle speed with the throwe NOTE _ Perform stops 4 thru @ Yor the remaining carburetor. | a + HIGH ALTITUDE ADJUSTMENT The carburetor idle sed may have t0 bere adjusted for high altitude riding sbove 2.000 m. (63500 t IDLE SPEED: 1,100 2 100 pm_ WoTE [ Reaijast he plat eoew ihe naive ies rough mista or stall Date of ave Jenaary, TOTS 4-10 GHONDA MOTOR CO, LTOHONDA cxs500 FUEL SYSTEM FUEL TANK ‘eep gasoline away from open flames or | sparks | Wipe up spilled gasoline at once. | FUEL STRAINER SCREEN / f PACKING i NS Check that fuel is flowing out of the fuel valve If the fuel flow i restricted, clean he gqlOCK NUT Ab, | GBF 20-25 kami | BOL © (14-8 iste) * | =~ FUEL VALVE | AIR CLEANER CASE © AIR CLEANER CASE REMOVAL TAILLIGHT WIRES. Disconnect the taillight wires. Remove the hand rail, cowl and rear fender. Remove the battery Remove the starter magnetic switch and Remove the carburetor sparsr band Date of ane, donaary 1978 HONDA MOTOR C6, LTD 4-11FUEL SYSTEM Remove three bolts attaching the air cleaner plate, and pull the plate down. ‘Remove the C.D. unit. Remove the alt cleaner mounting bolt from under the ¢.0.1. unit Remove the air cleaner from the right. aa NOTE Installation of te air ek CRANKCASE BREATHER SYSTEM NOTE [ check “thatthe breather ‘whe is not] AIR CLEANER BREATHER SEPARATOR DRAIN PLUG <= FRESH AIR —— BLowsy cas ite of Ts Sy TOT 4-12 HONDA MOTOR CO.,LTD