1982-Onward Honda MB5 Service & Repair Manual

SHOP MANUAL MB5 Downloaded from www.Manualslib.com manuals search engine

.----- ------ -IMPORTANT SAFETY NOTICE -- -- - - ____, t\'UI;iil@i Indicates a strong possibility of severe personal injury or loss of life if instructions are not followed. CAUTION : Indicates a possibility of personal injury or equipment damage if instructions are not followed. NOTE: Gives helpful! information . Detailed description of standard workshop procedures, safety principles and service operations are not included. It is important to note that this manual contains some warnings and caution against some specific serv i ce methods which could cause PERSONAL I NJURY to service personal or could damage a vehicle or render it unsafe. Please understand that those warnings could not cover al l conceivable ways in which service, whether or not recommended by Honda might be done or of the possible ha zardous consequences of each conceivable way, nore could Honda investigate all such ways. Anyone using service procedures or tools, whether or not recommended by Honda must satisfy himself thoroughly that neither personal safety nor vehicle safety will be jeopardized by the service method or too ls selected . . -..__/ Downloaded from www.Manualslib.com manuals search engine

HONDA MB5 HOW TO USE THIS MANUAL This shop manual describes the technical features and servicing procedures for the HONDA MB5. Section 1 through 3 apply to the whole motorcycle, while section 4 through 13 describe parts of the motorcycle, grouped according to loca- tion. Find the section you want on this page, then turn to the table of contents on page 1 of that section. Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The subsequent pages give detail ed procedures. If you are not familiar with this motorcycle, read the TECHNICAL FEATURES in section 15. If you don't know the source of the trouble, go to section 14, TROUBLESHOOTING. ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS IN- CLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. HONDA MOTOR CO., L TO. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGA- TION WHATEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION. HONDA MOTOR CO., L TO. SERVICE PUBLICATIONS OFFICE Date of Issue: July, 1981 © HONDA MOTOR CO., LTD. GENERAL INFORMATION LUBRICATION INSPECTION AND ADJUSTMENT FUEL SYSTEM ENGINE REMOVAL/INSTALLATION ~ CYLINDER HEAD/CYLINDER/PISTON ~ ~==c=L=U=T=C=H=/K==IC=K=S=T=A=R=T=E=R=/============ w GEARSHIFT LINKAGE (I) ~ :r:: 0 ALTERNATOR CRANKSHAFT/TRANSMISSION FRONT WHEEL/SUSPENSION REAR WHEEL/SUSPENSION HYDRAULIC BRAKE ELECTRICAL SYSTEM TROUBLESHOOTING TECHNICAL FEATURES Downloaded from www.Manualslib.com manuals search engine

MODEL IDENTIFICATION ~HONDA ~ MBS BEGINNING WITH F No. AC010 * CK000011 r .,.. The frame serial number is stamped on the steering head right side. The engine serial number is stamped on the left crankcase. 2 The vehicle identification number (VIN) is near the steering head left side. The carburetor identification number is on the carburetor body left side. Date of Issue: July, 1981 © HONDA MOTOR CO., L TO. Downloaded from www.Manualslib.com manuals search engine

~H~15Al. GENERAL INFORMATION GENERAL SAFETY SERVICE RULES SPECIFICATIONS TORQUE VALUES GENERAL SAFETY 1-1 1-1 1-2 1-4 If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas. Gasoline is extremely flammable and is explosive under certain conditions. Do not smoke or allow flames or sparks in your working area. SERVICE RULES SPECIAL TOOLS/COMMON TOOLS CABLE & HARNESS ROUTING MAINTENANCE SCHEDULE 1-5 1-6 1-8 The battery electrolyte contains sulfuric acid. Protect your eyes, skin and clothing. In case of contact, flush thoroughly with water and call a doctor if your eyes were exposed. The battery generates hydrogen gas which can be highly explosive. Do not smoke or allow flames or sparks near the battery especially while charging it. 1. Use geniune HONDA or HONDA-recommended parts and lubricants or their equivalent. Parts that do not meet HONDA's design specifications may damage the motorcycle. 2. Use the special tools designed for this product. 3. Use only metric tools when servicing this motorcycle. Metric bolts, nuts, and screws are not interchangeable with English fasteners. The use of incorrect tools and fasteners may damage the motorcycle. 4. Install new gaskets, 0-rings, cotter pins, lock plates, etc. when reassembling. 5. When tightening bolts or nuts, begin with larger-diameter or inner bolts first, and tighten to the specified torque diagonally, unless a particular sequence is specified. 6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly. 7. After reassembly, check all parts for proper installation and operation. Date of Issue: July, 1981 © HONDA MOTOR CO., L TO. 3 1-1 Downloaded from www.Manualslib.com manuals search engine

GENERAL INFORMATION SPECIFICATIONS DIMENSIONS FRAME ENGINE . CARBURETION 1-2 ITEM Overall length Overall width Overall height Wheelbase Seat height Foot peg height Ground clearance Dry weight Curb weight Type Front suspension, travel Rear suspension, travel Gross vehicle weight rating Vehicle capacity load Front tire size Rear tire size Cold tire pressures Front Rear Front brake, lining swept area Rear brake, lining swept area Fuel capacity Fuel reserve capacity Caster angle Trail Front fork oil capacity Type Cylinder arrangement Bore and stroke Displacement Compression ratio Maximum horsepower Maximum torque Oil capacity Transmission Oil tank Lubrication system Air filtration Cylinder compression Engine weight Idle speed Carburetor type Identification number Air screw initial setting Float level 4 ~HONDA ~ MBS 1,880 mm (74.0 in) 705 mm (27.8 in) 1 ,025 mm (40.4 in) 1,215mm (47.8 in) 750 mm (29.5 in) 310 mm (12.2 in) 160 mm ( 6.3 in) 79 kg (1741b) 90 kg (1981b) Cross line backbone Telescopic fork, Swingarm/shock absorber 189 kg (416.71b) 100 kg (220.51b) 2.50-18-4PR Rib pattern 2.50-18-4PR Block pattern 175 kPa (1. 75 kg/cm 2 , 25 psi) 225 kPa (2.25 kg/cm 2 , 32 psi) 125 mm (4.9 in) · 90 mm (3.5 in) Single disc brake, 384 cm 2 (59.6 sq in) Internal expanding shoe, 86.4 cm 2 (13.4 sq in) 9.0 liters (2.4 US gal) 2.0 liters (0.5 US gal) 25° 70 mm (2.8 in) 75 cc (2.54 ozs) Air cooled 2·stroke, reed valve Single cylinder 40° incline ~9.0 x 41.4 mm (1.54 x 1.63 in) 49 cc (2.98 cu in) 7.6: 1 7.0 BHP/9,000 rpm 5.6 N·m (0.56 kg·m, 4.05 ft·lb) 1.0 liters (1 .1 US qt) 1.1 liters (1.2 US qt) Forced and wet sump Oiled polyurethane foam 1,275 kPa ( 13.0 kg/cm 2 , 185 psi) 17.5 kg (38.61b) 1.400 rpm PF 15, 16 mm (0.63 in) venturi bore PF 15A 1 3/8 turns out 13.5 mm (0.53 in) Date of Issue: July , 1981 © HONDA MOTOR CO., LTD. Downloaded from www.Manualslib.com manuals search engine

~HONDA ~ MBS ITEM DRIVE TRAIN Clutch Transmission Primary reduction Final reduction Gear ratio I Gear ratio II Gear ratio Ill Gear ratio IV Gear ratio V Gear shift pattern ELECTRICAL Ignition Ignition timing "F" mark Full retard Starting system Generator Battery capacity Spark plug Standard For extended high speed riding For cold climate below 5°C (41°F) Spark plug gap Fuse LIGHTS Headlight (high/low beam) Tail/stoplight Front turn signal Rear turn signal Speedometer light Tachometer light Neutral indicator Turn signal indicator High beam indicator Date of Issue: July, 1981 © HONDA MOTOR CO., LTD. 5 GENERAL INFORMATION Wet, multi-plate 5-speed constant-mesh 4.117 3.307 (43/13) 3.083 1.882 1.400 1.130 0.960 left foot operated return system, 1-N-2-3-4-5 C.D.I. 19° ± 3° BTDC at 3,000 rpm 10° ± 5° BTDC at 7,000 rpm Primary kickstarter AC generator 66W/5,000 rpm 12V- 2.5 AH NGK BR8HS, ND W24FSR NGK BR9HS, ND W27FSR NGK BR7HS, ND W22FSR 0.6 - 0. 7 mm (0.024 - 0.028 in) 7A 31.5/30 w 8/27W 3/32 cp SAE NO. 1157 23W 32 cp SAE NO. 1073 23W 32 cp SAE NO. 1073 3.4W 2 cp SAE NO. 158 3.4W 2 cp SAE NO. 158 3.4W 2 cp SAE NO. 158 3.4W 2 cp SAE NO. 158 1.7W 1 cp SAE NO. 53 1-3 Downloaded from www.Manualslib.com manuals search engine

GENERAL INFORMATION TORQUE VALUES • ENGINE ~HONDA ~ MBS Item O'ty Thread Dia (mm) Torque Remarks N-m (kg·m, ft-lb) Cylinder head 4 8 18-22 (1.8-2.2, 13-16) Alternator rotor 1 12 50-60 (5.0-6.6, 36-43) Primary drive gear 1 12 45-55 (4.5-5.5, 33-40) Drain plug 1 12 20-25 (2.0-2.5, 14-18) • CHASSIS Item O'ty Thread Dia (mm) Torque Remarks N·m (kg·m, ft-lb) Steering stem nut 1 22 60-90 (6.0-9.0, 43-65) Handleber holder 4 6 8-12 (0.8- 1.2, 6- 9) Fork pinch bolts (top) 2 7 9-13 (0.9-1.3, 7- 9) Fork pinch bolts (bottom) 2 8 20-30 (2.0-3.0, 15-22) Front fork bolt 2 20 60-70 (6.0-7 .0, 43-51) Front fork inner bolt 2 - 34-42 (3.4-4.2, 25-30) Front axle nut 1 12 55-65 (5.5-6.5, 40-48) Engine mounting bolts 3 10 30-40 (3.0-4.0, 22-29) Rear axle nut 1 12 55-65 (5.5-6.5, 40-48) Final driven sprocket 3 10 55-65 (5.5-6.5, 40-48) Rear brake torque link 2 8 18- 25 (1.8-2.5, 13-18) Rear shock absorber 4 10 30-40 (3.0-4.0, 22-29) Foot peg 2 10 25-35 (2.5-3.5, 18-25) Gearshift pedal 1 6 8-12 (0.8-1.2, 6- 9) Kickstarter pedal 1 6 8-12 (0.8-1.2, 6- 9) Swingarm pivot nut 1 12 55-65 (5.5- 6.5, 40-48) Self-locking nut Front brake disc 3 8 27- 33 (2.7-3.3, 20-24) Front brake master cylinder 2 6 10-14 (1.0-1.4, 7-10) Front brake master cylinder reservoir cap 4 4 1- 2 (0.1-0.2,0.7-1.5) Brake hose bolt 2 10 25-35 (2.5-3.5, 18-25) Brake caliper bracket 2 8 24-30 (2.4-3.0, 17-22) Brake caliper 1 8 20-25 (2.0-2 .5, 15-18) Brake caliper pin bolt 3 8 15-20 (1.5-2,0, 11-15) Torque specifications listed above are for important fasteners. Others should be tightened to standard torque values below. • STANDARD TORQUE VALUES Item Torque Item Torque N-m (kg-m, ft-lb) N-m (kg-m, ft·lb) 5 mm bolt and nut 4- 6 (0.4-0.6, 3- 4) 5 mm screw 3- 5 (0.3-0.5, 3- 4) 6 mm bolt and nut 8-12 (0.8- 1.2, 6- 9) 6 mm screw 7-11 (0.7-1.1, 5-8) 8 mm bolt and nut 18-25 (1.8-2.5, 13-18) 6 mm flange bolt and nut 10-14 (1.0-1.4, 7-10) 10 mm bolt and nut 30-40 (3.0-4.0, 22-29) 8 mm flange bolt and nut 20-30 (2.0-3.0, 14-22) 12 mm bolt and nut 50-60 (5.0-6.0, 36-43) 10 mm flange bolt and nut 30-40 (3.0-4.0, 22- 29) 1-4 6 Date of Issue: July, 1981 © HONDA MOTOR CO., LTO. Downloaded from www.Manualslib.com manuals search engine

~HONDA ~ MBS TOOLS SPECIAL Tool Name Tool No. Crankshaft assembly tool 07965-1660100 Balancer weight driver 07945- 1660000 Bearing remover set 07936- 1660000 (Spind le assembly) (07936-1660100) (Slid i ng weight) (07936-3710200) Bearing puller (commercially available) 07631-0010000 Bearing driver 28 x 30 mm 07946-1870100 Hex wrench 6 mm (commercially available) 07917- 3230000 Ball rece driver 07944- 1150001 Snap ring pliers 07914-3230001 COMMON Tool Name Part No. O'ty Float level gauge 07401-0010000 1 Universal holder 07725-0030000 1 Flywheel puller 07733-0010000 1 Driver A 077 49-001 0000 1 Attachment 42 x 47 mm 077 46-0010300 1 Attachment 37 x 40 mm 077 46-001 0200 1 Attachment 32 x 35 mm 07746-0010100 1 Pilot 12 mm 07746-0040200 1 Pilot 17 mm 07746-0040400 1 Pilot 20 mm 07746-0040500 1 Driver B 07746-0010600 1 Attachment 20 mm 1.0. 07746-0020400 1 Front fork oil seal driver 07747-0010100 1 body Fork seal driver attachment 07747-0010300 1 B Pin spanner 07702-0010000 1 Shock compressor 07959-3290001 1 Date of Issue: July, 1981 © HONDA MOTOR CO., LTO. GENERAL INFORMATION O'ty Remarks Ref. page 1 Crankshaft installation 9-11 1 Balancer installation 9-11 1 Removal of small balancer 9-6 bearing and mainshaft bearing (1) (1) 1 Main bearing removal 9-9 1 Small balancer bearing and mainshaft 9-7 bearing installation 1 10-13, 10-15 1 10-18, 10-19 1 12-10, 12-17 Alternate Tool Remarks Ref. page Float level 4-7 07725-0010101 J Flywheel removal 7-7' 8-2,8-4 07933-0010000 8-2 Used with driver 9-7,9-10,11-5, attachment 10-10 9-7,9-10,11-5 Installation of front 10-10 wheel bearing Installation of crank- 9-10 shaft oil seal }U•od w;th dd"' 9-7,10-10 9-7,11-5 attachment 9-10 ~ Installing crankshaft 9-10 bearing 9-10 r 7947 - 1180001 10-16 }ln.tamng fo'k "''' ;n slider M9361-412-099788 Steering head bearing 10-18, 10-19 adjustment Installing rear shock 11-10, 11-11 spring 7 1-5 Downloaded from www.Manualslib.com manuals search engine

GENERAL INFORMATION CABLE & HARNESS ROUTING 1-6 BRAKE HOSE TACHOMETER CABLE CLUTCH CABLE 8 ~HONDA ~ MBS SPEEDOMETER CABLE THROTTLE CABLE CLUTCH CABLE TACHOMETER CABLE Date of Issue: July, 1981 © HONDA MOTOR CO., LTD. Downloaded from www.Manualslib.com manuals search engine

1982-Onward Honda MB5 Service & Repair Manual

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