Honda CX500 Turbo 1982 OEM Service Manual (P/N 61MC700 )

• Covers the 1982 Honda CX500 Turbo from beginning frame number *JH2PC030CM000001**, with model-specific service information for the turbocharged engine, C.F.I. controls, driveline, suspension, brakes, and electrical system.
• Supplied as a 411-page PDF set: Honda Shop Manual 61MC700 - 373 pages, dated October 1981; Honda Turbocharger/C.F.I. Manual 62MC700 - 38 pages.
• Details turbocharger inspection, wastegate testing, oil-control-orifice service, and turbo removal/installation, together with intake-manifold, surge-tank, ECU, fuel-pump, pressure-sensor, engine-speed-sensor, air-valve, and reed-valve procedures.
• Engine chapters document removal and installation, cylinder-head and valve repair, valve-guide replacement and seat grinding, clutch and oil-pump work, camshaft and cam-chain timing, transmission overhaul, and crankshaft/piston bearing selection.
• Chassis sections cover TRAC front-fork repair, Pro-Link rear-shock and linkage work, swingarm/driveshaft service, final-drive backlash, preload, and contact-pattern adjustment, plus hydraulic-brake bleeding and master-cylinder and caliper overhaul.
• Diagnostic material combines C.F.I. LED self-diagnosis and fail-safe information with symptom charts, wiring and harness references, pressure/vacuum and electrical tests, torque tables, capacities, wear limits, and adjustment specifications.

Factory Repair Scope

These manuals are built around Honda's 497 cc, liquid-cooled, turbocharged 80-degree OHV V-twin, five-speed constant-mesh transmission, and shaft final drive. The main shop manual supplies the service and repair procedures; the companion volume explains how the RH B51A wastegate-controlled turbocharger, C.F.I. air and fuel circuits, dual-map computer strategy, and engine-speed/boost-controlled transistorized ignition work. This set is suited to professional technicians and mechanically qualified owners with the proper service tools; it assumes standard workshop knowledge rather than teaching basic shop methods.

Section 24 begins with quick-reference and symptom charts for no-start and hard-start conditions, power loss, low- and high-speed running faults, afterfire, backfire, knock, smoke, abnormal turbo noise, and turbo warning-lamp complaints. Component checks cover fuel pressure and pump delivery, injector operation, and static and dynamic testing of the pressure, temperature, throttle, and engine-speed sensors. Separate procedures address spark advance, the fuel-pump stop sensor, boost indicator, wastegate, air and reed valves, and left/right throttle-valve synchronization.

For bottom-end repair, select-fit crankshaft and connecting-rod bearings are handled through color-code tables and Plastigage checks. Final-drive work uses measured preload, backlash, shims, and gear-contact patterns rather than generic reassembly notes. The rear-shock chapter documents oil-seal replacement and refilling with a hydraulic press.

Turbocharger and C.F.I. Detail

The technical volume separates the air-intake, fuel, and electronic-control functions, explaining the surge tank, resonance chamber, pressure regulator, injectors, pump-control logic, fuel maps, compensation strategies, and fail-safe substitutions. It identifies the distinct jobs of the PB manifold-pressure, P1 atmospheric-pressure, P2 charging-pressure, and PIGN ignition-advance sensors. An included correction page clarifies the input logic used by the two basic fuel-injection maps.

The turbocharger is treated as a replace-as-an-assembly component; the set does not provide an internal turbo overhaul. Honda warns that removing carbon from the turbine vanes can disturb rotor balance, while a bent wastegate actuator rod requires replacement of the turbocharger assembly. The oil-control-orifice section cautions that cleaning it with wire can enlarge the metering hole.

Diagrams, Tools, and Service Data

Named visual references include the full Wiring Diagram, Cable & Harness Routing views, C.F.I. System Diagram, Turbocharger Diagram, Block Diagram of Computer Operation, and the LED-based Self-Diagnosis System chart. Assembly drawings and component views support the mechanical chapters.

Model-specific tools are identified by number, including sensor inspection adapter 07999-MC70000, fuel-pressure gauge set 07406-0040000, piston remover 07941-MC70000, and preload inspection tool 07998-MC70000. The specifications cover component torque, capacities, pressure and vacuum tests, electrical voltage and resistance checks, wear limits, clearances, bearing selection, and adjustment data.

The manual treats damaged COMSTAR wheel assemblies as nonserviceable; tubeless-tire removal, repair, and remounting are referred to a separate Tubeless Tire Manual. Honda also treats the fuel circuit as pressurized and provides specific isolation and eye-protection cautions before fuel-system work.