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Honda FJ500 User Manual

Honda FJ500
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How to use this manual
How to use thi s manual
A Few Words About Safety
Service Information
The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting
service or repairs without the proper training, tools, and equipment could cause injury to you and/or others. It could also damage
this Honda product or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures
require the use special tools. Any person who intends to use a replacement part, service procedure, or a tool that is not
recommended by Honda must determine the risks to their personal safety and the safe operation of this product.
If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend
that you do not use replacement parts of inferior quality.
For Your Customer’s Safety
Proper service and maintenance are essential to the customer’s safety and the reliability of this product. Any error or oversight
while servicing this product can result in faulty operation, damage to the product, or injury to others.
For Your Safety
Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety
practices (e.g., Hot parts-wear gloves). If you have not received shop safety training or do not feel confident about your knowledge
of safe servicing practices, we recommend that you do not attempt to perform the procedures described in this manual.
Some of the most important general service safety precautions are given below. However, we cannot warn you of every
conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should
perform a given task.
Important Safety Precautions
Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
using safety equipment. When performing any service task, be especially careful of the following:
Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
required to perform the tasks safely and completely.
Protect your eyes by using proper safety glasses, goggles, or face shields anytime you hammer, drill, grind, or work around
pressurized air, pressurized liquids, springs, or other stored-energy components. If there is any doubt, put on eye protection.
Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
Protect yourself and others whenever you have equipment hoisted in the air. Anytime you lift this product with a hoist, make sure
that the hoist hook is securely attached to the product.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will
help eliminate several potential hazards:
Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine.
Burns from hot parts. Let the engine and exhaust system cool before working in those areas.
Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers, and clothing are out of the
way.
Gasoline vapors and hydrogen gasses from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries.
Use only a nonflammable solvent, not gasoline, to clean parts.
Never store gasoline in an open container.
Keep all cigarettes, sparks, and flames away from the battery and all fuel-related parts.
Improper service or repairs can create an unsafe
condition that can cause your customer or others to
be seriously hurt or killed.
Follow the procedures and precautions in this
manual and other service materials carefully.
Failure to properly follow instructions and
precautions can cause you to be seriously hurt or
killed.
Follow the procedures and precautions in this
manual carefully.
62V42000.book 1 ページ 2012年12月7日 金曜日 午前9時17分

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Questions and Answers:

Honda FJ500 Specifications

General IconGeneral
Engine ModelGX160
Displacement163 cc
ManufacturerHonda
EngineHonda GX160
Fuel TypeGasoline
Starting SystemRecoil
TransmissionGear

Summary

How to Use This Manual

A Few Words About Safety

General safety information and warnings for using the service manual.

Service Information

Information for qualified technicians about service procedures and parts.

For Your Customer’s Safety

Emphasizes the importance of proper service for customer safety and product reliability.

For Your Safety

Warns about shop safety practices and the need for training and judgment.

Important Safety Precautions

Lists essential safety precautions like understanding procedures, using eye protection, and handling hot parts.

Service Rules

Guidelines for using Honda parts, special tools, and proper reassembly.

Symbols

Explains symbols used in the manual for specific service procedures.

Abbreviations

Lists abbreviations used in the manual for parts and systems.

1. Specifications

Serial Number Location

Describes the location of engine and frame serial numbers for identification.

Specifications

Overview of technical specifications, including dimensions and engine details.

Dimensional Drawings

Visual representation of product dimensions for different models.

Wiring Diagram

Electrical wiring diagram for the ignition system.

Dimensions and Weights

Detailed dimensions and weights for different FJ500 models.

Engine

Technical specifications for the GX160H1 engine model.

Frame

Specifications related to the frame, including rotor type, handle height, and tillage width.

2. Service Information

Maintenance Standards

Standards and limits for various engine and frame parts.

Torque Values

Specified torque values for engine and frame bolts and nuts.

Lubrication & Seal Point

Locations for applying engine oil, grease, and sealants.

Tools

List of special tools required for service procedures.

Cable/Harness Routing

Correct routing for cables and harnesses to prevent damage.

Tube Routing

Proper routing for fuel and breather tubes.

Standard Torque Values

Standard torque values for various screws and bolts.

Frame

Lubrication points for the frame and transmission oil.

3. Maintenance

Maintenance Schedule

Schedule for regular maintenance tasks based on time or usage.

Engine Oil Level Check

Procedure to check and maintain the engine oil level.

Engine Oil Change

Steps for draining and refilling engine oil.

Air Cleaner Check/Cleaning/Replacement

How to inspect, clean, or replace the air cleaner element.

Bolts and Nuts Tightness

Verifying tightness of chassis bolts and nuts.

Clutch Lever Function

Checking smooth operation of the clutch lever and lock lever.

Transmission Oil Level Check

Procedure to check and maintain the transmission oil level.

Sediment Cup Cleaning

How to clean the fuel sediment cup.

Grease Application

Specifies parts requiring grease application.

Spark Plug Check/Adjustment/Replacement

Inspecting, adjusting, or replacing the spark plug.

Throttle Cable Check/Adjustment

Checking and adjusting the throttle cable.

Engine Idle Speed Check/Adjustment

Checking and adjusting the engine idle speed.

Clutch Cable Check/Adjustment

Checking and adjusting the clutch cable.

Belt Tension Check/Adjustment

How to check and adjust the belt tension.

Valve Clearance Check/Adjustment

Inspecting and adjusting valve clearance.

Combustion Chamber Cleaning

Cleaning carbon deposits from the combustion chamber.

Fuel Tank and Filter Cleaning

Cleaning the fuel tank and filter.

Fuel Tube Check

Inspecting the fuel tube for damage or leaks.

Belt Tension Adjustment

Detailed steps for adjusting belt tension.

Belt Stopper Adjustment

Adjusting belt stopper clearances.

4. Troubleshooting

Before Troubleshooting

Initial checks before starting troubleshooting.

General Symptoms and Possible Causes

Lists common problems and their potential causes.

Engine Troubleshooting

Troubleshooting steps for engine-related starting and power issues.

Frame Troubleshooting

Troubleshooting steps for clutch engagement and disengagement issues.

5. Fuel System

Tool

Lists tools used for fuel system maintenance.

Fuel Tank Removal/Installation

Procedures for removing and installing the fuel tank.

Air Cleaner Removal/Installation

Steps for removing and installing the air cleaner.

Carburetor Removal/Installation

Procedures for removing and installing the carburetor.

Carburetor Disassembly/Assembly

Detailed steps for disassembling and assembling the carburetor.

Governor Rod Removal/Installation

Steps for removing and installing the governor rod.

Valve Seal Installation

How to install the valve seal into the float chamber.

Lubrication

Lubrication points for fuel valve components.

Fuel Valve Lever Screw

Applying Loctite to the fuel valve lever screw threads.

Float Level Height Inspection

How to inspect and adjust the float chamber level.

Float Valve Inspection

Inspecting the float valve and its seat for wear or damage.

Carburetor Body Cleaning

Cleaning the carburetor body and float chamber passages.

6. Governor System

Control Base/Governor Arm Removal/Installation

Procedures for removing and installing the control base and governor arm.

Governor Adjustment

Steps to adjust the governor for proper engine speed control.

Governor Removal/Installation

Procedures for removing and installing the governor assembly.

7. Ignition System

Before Troubleshooting

Initial checks for ignition system issues.

Ignition System Troubleshooting

Troubleshooting steps for hard starting and ignition problems.

Fan Cover Removal/Installation

Procedures for removing and installing the fan cover.

Ignition Coil Removal/Installation

Steps for removing and installing the ignition coil.

Flywheel Removal/Installation

Procedures for removing and installing the flywheel.

Flywheel Removal

Steps for removing the flywheel.

Flywheel Installation

Procedures for installing the flywheel, cooling fan, and starter pulley.

Ignition Coil Air Gap Check/Adjustment

How to check and adjust the ignition coil air gap.

Ignition Coil Inspection

Inspecting the primary and secondary sides of the ignition coil.

Secondary Side

Measuring resistance of the ignition coil secondary side.

Spark Plug Cap Inspection

Measuring resistance of the spark plug cap.

Spark Test

Performing a spark test to check for spark presence.

Engine Stop Switch Removal/Installation

Procedures for removing and installing the engine stop switch.

Engine Stop Switch Inspection

Checking continuity of the engine stop switch.

8. Starting System

Recoil Starter Removal/Installation

Steps for removing and installing the recoil starter.

Recoil Starter Disassembly/Assembly

Detailed procedure for disassembling and assembling the recoil starter.

Recoil Starter Inspection

Inspecting the operation and parts of the recoil starter.

Assembly

Reassembly steps for the recoil starter, including rope and spring installation.

9. Muffler

Muffler Removal/Installation

Procedures for removing and installing the muffler.

10. Engine Removal/Installation

Engine Removal/Installation

General steps for engine removal and installation.

11. Clutch

Pulley/V-Belt Removal/Installation

Procedures for removing and installing the pulley and V-belt.

Drive Pulley Removal/Installation

Steps for removing and installing the drive pulley.

Driven Pulley Removal/Installation

Procedures for removing and installing the driven pulley.

12. Cylinder Head

Tools

Lists special tools required for cylinder head service.

Cylinder Head Removal/Installation

Procedures for removing and installing the cylinder head.

Cylinder Head Disassembly/Assembly

Detailed steps for disassembling and assembling the cylinder head.

Cylinder Head/Valves Inspection

Inspecting cylinder head, valves, compression, and warpage.

Valve Guide Replacement

Steps for replacing valve guides.

Valve Guide Reaming

Process for reaming valve guides.

Valve Seat Reconditioning

How to recondition worn valve seats.

Valve Spring Retainer Removal/Installation

How to remove and install valve spring retainers.

Valve Seat Width

Measuring valve seat width and reconditioning if needed.

Valve Guide I.D.

Measuring valve guide inside diameter.

Valve Face/Valve Stem O.D.

Measuring valve face and stem outer diameter.

Guide-to-Stem Clearance

Calculating and checking guide-to-stem clearance.

Valve Spring Free Length/ Perpendicularity

Measuring valve spring free length and perpendicularity.

Push Rod Runout

Checking push rod for wear and straightness.

13. Cylinder Block

Tools

Lists special tools for cylinder block service.

Crankcase Cover/Crankshaft/Camshaft/Piston Removal/Installation

Procedures for removing and installing major engine components.

Piston Disassembly/Assembly

Detailed steps for disassembling and assembling the piston.

Crankshaft Bearing/Oil Seal Replacement

Procedures for replacing crankshaft bearings and oil seals.

Camshaft Installation

Steps for installing the camshaft and valve lifters.

Piston-to-Cylinder Clearance

Measuring piston-to-cylinder clearance.

Piston Pin Bore I.D.

Measuring piston pin bore inside diameter.

Piston Pin O.D.

Measuring piston pin outer diameter.

Piston Pin-to-Piston Pin Bore Clearance

Measuring clearance between piston pin and bore.

Piston Ring Width

Measuring piston ring width.

Piston Ring Side Clearance

Measuring piston ring side clearance.

Piston Ring End Gap

Measuring piston ring end gap.

Connecting Rod Small End I.D.

Measuring connecting rod small end inside diameter.

Connecting Rod Big End I.D.

Measuring connecting rod big end inside diameter.

Connecting Rod Big End Side Clearance

Measuring connecting rod big end side clearance.

Connecting Rod Big End Oil Clearance

Measuring connecting rod big end oil clearance using Plastigauge.

Crankpin O.D.

Measuring crankpin outer diameter of the crankshaft.

Camshaft O.D.

Measuring camshaft outer diameter.

Camshaft Cam Height

Measuring camshaft cam height.

Decompressor Weight

Checking decompressor weight and spring for wear.

Crankshaft Bearing

Checking crankshaft bearing for play or noise.

14. Handle

Handle Column Assembly Removal/Installation

Procedures for removing and installing the handle column assembly.

Handle Column Disassembly/Assembly

Detailed steps for disassembling and assembling the handle column.

Clutch Lever Disassembly/Assembly

Procedures for disassembling and assembling the clutch lever.

Throttle Lever Disassembly/Assembly

Steps for disassembling and assembling the throttle lever.

Lock Lever Installation

Steps for installing the lock lever, washer, and cover.

15. Rotor/Transmission

Tools

Lists special tools for rotor and transmission service.

Rotor Removal/Installation (SER, DER Type)

Procedures for removing and installing rotors.

Rotor Disassembly/Assembly (SER, DER Type)

Detailed steps for disassembling and assembling rotors.

Rotor Assembly Check (SER, DER Type)

Checking proper assembly and symmetry of rotor tines.

Transmission Removal/Installation

Steps for removing and installing the transmission.

Transmission Disassembly/Assembly

Detailed procedures for transmission disassembly and assembly.

Fender Removal/Installation

Procedures for removing and installing fenders.

Front Wheel Removal/Installation (DER, DE Type)

Steps for removing and installing front wheels.

Final Shaft/Wheel Shaft

Removal and installation of final and wheel shafts.

Radial Ball Bearing Inspection

Inspecting radial ball bearings for play or noise.

Plug Seal/Oil Seal/Water Seal Installation

Installing plug, oil, and water seals using special tools.

Oil Seal (15 x 35 x 7 mm)

Installing a new oil seal.

Shift Fork Shaft Installation

Steps for installing the shift fork shaft.

Transmission Oil Filling

Filling the transmission with the recommended oil.

Sub Fender Removal/Installation

Procedures for removing and installing the sub fender.

Main Fender Removal/Installation

Steps for removing and installing the main fender.

16. Technical Feature

One Touch Drain System

Explanation of the one-touch drain system for fuel.

Function

Describes the function of the one-touch drain system in ON, OFF, and DRAIN positions.

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