Honda MB5 1982 - Shop Manual

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SHOP

MANUAL

MB5

Main Page

How to Use this Manual3
Model Identification4
General Information5
General Safety5
Service Rules5
Specifications6
Torque Values8
Tools9
Cable and Harness Routing10
Maintenance Schedule12
Oil Flow Diagram14
Lubrication Specifications15
Lubrication Troubleshooting16
Transmission Oil Level Change17
Transmission Oil Level Check17
Oil Strainer Cleaning18
Oil Pump Removal19
Oil Pump Inspection20
Oil Pump Installation20
Oil Pump Bleeding21
Oil Tank Level Indicator Removal and Installation22
Oil Tank Removal22
Chassis Lubrication Points23
Inspection and Adjustment25
Fuel Lines27
Throttle Operation27
Air Cleaner28
Carburetor Idle Speed29
Spark Plug29
Ignition Timing30
Oil Pump Control Cable30
Battery31
Cylinder Compression31
Front Brake Fluid Level31
Pad Wear32
Rear Brake Pedal Play32
Brake Light Switch33
Brake Shoe Inspection33
Headlight Aim33
Clutch34
Drive Chain Inspection34
Drive Chain Adjustment35
Drive Chain Cleaning/Lubrication35
Suspension36
Wheels36
Muffler Decarbonizing37
Nuts, Bolts, Fasteners37
Steering Head Bearings37
Fuel System Diagram38
Fuel System Specifications39
Fuel System Troubleshooting40
Carburetor Removal41
Throttle Valve Disassembly42
Float/Float Valve/Jet Disassembly43
Jets/Float Valve/Float Assembly44
Float Level Adjustment45
Throttle Valve/Cable Installation45
Carburetor Installation46
Fuel Tank Inspection47
Fuel Tank Removal47
Fuel Strainer Check48
Fuel Tank Installation48
Engine Removal/Installation50
Engine Removal/Installation - Specifications51
Engine Removal52
Engine Installation55
Cylinder Head/Cylinder/Piston Diagram56
Cylinder Head/Cylinder/Piston Specifications57
Cylinder Head Decarbonizing58
Cylinder Head Inspection58
Cylinder Head Removal58
Cylinder Head Installation59
Cylinder Removal59
Cylinder/Piston59
Piston Removal60
Piston Ring/Expander Removal60
Cylinder/Piston Inspection61
Piston Ring Inspection62
Connecting Rod Inspection63
Piston/Cylinder Installation63
Reed Valve Removal64
Reed Valve Inspection65
Reed Valve Installation65
Clutch/Kickstarter/Shift Linkage Diagram66
Clutch/Kickstarter/Shift Linkage Specifications67
Right Crankcase Cover Disassembly68
Right Crankcase Cover Removal68
Right Crankcase Cover Installation69
Clutch Removal70
Clutch/Idler Gear70
Clutch Disc Inspection71
Clutch Spring Inspection71
Balancer Idler Gear/Oil Pump Driven Gear Removal72
Clutch Outer Inspection72
Clutch Plate Inspection72
Balancer Idler Gear Inspection73
Primary Drive Gear Removal73
Balancer Idler Gear Installation74
Oil Pump Driven Gear Installation74
Primary Drive Gear Installation74
Balancer Timing/Clutch Installation75
Kickstarter76
Spindle Removal76
Idler Gear Inspection77
Idler Gear Removal77
Kickstarter Installation78
Shift Linkage Removal79
Shift Linkage Inspection80
Shift Linkage Installation81
Alternator Diagram82
Alternator - Service Information83
Alternator Removal84
Alternator Installation86
Crankshaft/Transmission Diagram88
Table of Contents89
Crankshaft/Transmission - Service Information89
Crankshaft/Transmission Specifications90
Crankshaft/Transmission Troubleshooting90
Crankcase Separation91
Gearshift Fork/Shift Drum91
Transmission Disassembly91
- Shift Fork/Shift Fork Shaft/Shift Drum Inspection92
- Transmission Inspection93
- Transmission Removal93
- Balancer Weight Removal94
- Bearing Replacement94
Crankshaft Removal95
Crankshaft Inspection96
Crankshaft Installation98
Transmission Assembly99
Crankcase Assembly100
Front Wheel/Suspension Diagram102
Attachment103
Common Driver a Attachment103
Front Wheel/Suspension - Service Information103
Pilot 12 MM 077 46- 0040200103
- Front Wheel/Suspension Specifications104
- Front Wheel/Suspension Troubleshooting104
- Headlight Installation105
- Headlight Removal105
- Indicator and Meter Bulb Replacement105
- Instruments105
- Handlebar Removal106
- Instrument Removal/Installation106
- Front Wheel Axle Inspection110
- Front Wheel Bearing Inspection110
- Front Wheel Removal110
- Front Wheel Disassembly111
- Front Wheel Rim Runout111
- Front Wheel Assembly112
- Front Wheel Installation113
- Front Fork Disassembly114
- Front Fork Removal114
- Front Fork Spring Inspection115
- Front Fork Tube Runout116
- Slider/Piston Inspection116
- Front Fork Assembly117
- Front Fork Installation119
- Steering Stem Removal119
- Steering Stem Installation121
- Rear Wheel/Brake/Suspension Diagram122
- Rear Wheel/Brake/Suspension Specifications123
- Rear Wheel/Brake/Suspension Troubleshooting124
- Rear Wheel Axle Inspection125
- Rear Wheel Bearing Play Inspection125
- Rear Wheel Removal125
- Rear Wheel Disassembly126
- Rear Wheel Rim Runout Inspection126
- Final Driven Sprocket Inspection127
- Final Driven Sprocket Installation127
- Rear Wheel Bearing Installation127
- Rear Brake Lining Thickness128
- Rear Wheel Installation128
- Brake Cam Inspection129
- Rear Brake Drum Inspection129
- Rear Brake Shoe Replacement129
- Brake Panel Installation130
- Brake Pedal131
- Rear Shock Absorber Disassembly132
- Rear Shock Absorber Removal132
- Rear Shock Absorber Assembly and Installation133
- Spring Free Length133
- Swingarm Inspection134
- Swingarm Installation134
- Swingarm Removal134
- Hydraulic Brake Diagram136
- Hydraulic Brake Specifications137
- Hydraulic Brake Troubleshooting137
- Brake Fluid/Air Bleeding138
- Brake Pad Inspection139
- Brake Pad Replacement139
- Brake Pad/Disc139
- Brake Disc Inspection140
- Brake Caliper Disassembly141
- Brake Caliper Removal141
- Brake Caliper Inspection142
- Brake Caliper Assembly143
- Brake Caliper Installation144
- Brake Master Cylinder Removal144
- Brake Master Cylinder Disassembly145
- Brake Master Cylinder Inspection145
- Brake Master Cylinder Assembly146
- Brake Master Cylinder Installation146
- Electrical System Diagrams148
- Electrical System Specifications149
- Electrical System Troubleshooting150
- Battery Removal151
- Testing Specific Gravity151
- Battery Charging152
- Charging System Performance Test152
- Alternator Inspection153
- Silicone Rectifier Inspection153
- CDI Unit Removal154
- Ignition Coil Continuity Test154
- Ignition Coil Removal154
- Alternator Excitor Coil/Pulse Generator Inspection155
- CDI Unit Inspection155
- Brake Switches156
- Neutral Switch156
- Handlebar Switches157
- Ignition Switch Replacement158
- Wiring Diagram159
- Engine Does Not Start or Is Hard to Start161
- Troubleshooting161
- Engine Lacks Power162
- Poor Performance at Low and Idle Speeds163
- Poor Handling164
- Poor Performance at High Speed164
- Balancer165

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