This Haynes DIY repair and service manual covers 1978-1986 Honda CX500, Honda GL500, Honda CX650, and Honda GL650 motorcycle models, including:
Book Excerpt: 1978-1986 Honda CX500, GL500, CX650, GL650 Repair Manual
- Honda CX500, U.K. 1978-1982 | U.S. 1978-1979
- Honda CX500C Custom, U.K. 1981-1982 | U.S. 1979-1982
- Honda CX500D Deluxe, U.S. only 1979-1981
- Honda CX500E Sport, U.K. only 1982-1983
- Honda GL500 Silver Wing, U.S. only 1981-1982
- Honda GL500D Silver Wing, U.K. only 1982-1983
- Honda GL500I Silver Wing Interstate, U.S. only 1981-1982
- Honda CX650C Custom, U.S. only 1983
- Honda CX650E Sport, U.K. only 1983-1986
- Honda GL650 Silver Wing, U.S. only 1983
- Honda GL650D2 Silver Wing Deluxe, U.K. only 1984-1986
- Honda GL650I Silver Wing Interstate, U.S. only 1983
CHECK THE BRAKES | FLUID LEVEL CHECK
WHEELS, BRAKES AND TIRES
The hydraulic front brake requires no regular adjustments; pad wear is compensated for by the automatic entry of more fluid into the system from the handlebar reservoir. All that is necessary is to maintain a regular check on the fluid level and the degree of pad wear.
To check the fluid level, turn the handlebars until the reservoir is horizontal and check that the fluid level, as seen through the translucent reservoir body , or, where applicable, the sight glass in the front or rear face of the reservoir body, is not below the lower level mark on the body.
Remember that while the fluid level will fall steadily as the pad friction material is used up, if the level falls below the lower level mark there is a risk of air entering the system; it is therefore sufficient to maintain the fluid level above the lower level mark, by topping-up if necessary.
Do not top-up the higher level mark (formed by a cast line on the inside of the reservoir where it is not made of translucent plastic) unless this is necessary after new pads have been fitted. If topping-up is necessary, wipe any dirt off the reservoir, remove the retaining screws, where fitted, and lift away the reservoir cover and diaphragm.
Use only good quality brake fluid of the recommended type and ensure it comes from a freshly opened sealed container; brake fluid is hygroscopic, which means that it absorbs moisture from the air, therefore old fluid may have become contaminated to such an extent that its boiling point has been lowered to an unsafe level.
Remember also that brake fluid is an excellent paint stripper and will attack plastic components; wash away any spilled fluid immediately with copious quantities of water.
When the level is correct, clean and dry the diaphragm, fold it into it's compressed state and fit it to the reservoir. Refit the reservoir cover (and gasket where fitted) and tighten securely, but do not over tighten, the retaining screws (where fitted).
On CX500 E-C and CX650 E-D models remove carefully the right-hand side panel to expose the rear brake master cylinder, then check the level as described above.
BLEEDING THE HYDRAULIC BRAKE SYSTEM
The method of bleeding a brake system of air and the procedure described below apply equally to either a front brake or rear brake of the
hydraulically actuated type.
- If the brake action becomes spongy, or if any part of the hydraulic system is dismantled ( such as when a hose is replaced) it is necessary to bleed the system in order to remove all traces of air.
The procedure for bleeding the hydraulic system is best carried out by two people.
- Check the fluid level in the reservoir and top-up with new fluid of the specified type if required. Keep the reservoir at least half full during the bleeding procedure; if the level is allowed to fall too far air will enter the system requiring that the procedure be started again from scratch.
Refit the cap onto the reservoir to prevent the ingress of dust or the ejection of a spout of fluid.
- Remove the dust cap from the caliper bleed nipple and clean the area with a rag. Place a clean glass jar below the caliper and connect a pipe from the bleed nipple to the jar.
A clear plastic tube should be used so that air bubbles can be easily seen. Where two calipers are fitted a pipe should be fitted to each nipple, and the two nipples operated simultaneously.
Place some clean hydraulic fluid in the jar so that the pipe (s) are immersed below the fluid surface throughout this operation.
- If parts of the system have been replaced, and thus the system must be filled, open the bleed nipple about one turn and pump the brake lever until fluid starts to issue from the clear tube.
Tighten the bleed nipple and then continue the normal bleeding operation as described in the following paragraphs.
Keep close check on the reservoir level while the system is being filled.
Subject: 1978, 1979, 1980, 1981, 1982, 1983, 1984, 1985, 1986 Honda CX500, GL500, CX650, GL650, Silver Wing, Interstate service, maintenance, repair. ISBN-10: 1850101574 | ISBN-13: 9781850101574 | Haynes 442