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

The shop manual supplies the service and repair procedures; the companion volume explains the RH B51A wastegate-controlled turbocharger, C.F.I. air and fuel circuits, dual-map computer strategy, and engine-speed/boost-controlled transistorized ignition.

Repair limits: The turbocharger is replaced as an assembly; internal turbo overhaul is outside the repair scope. Tubeless-tire removal, repair, and remounting are referred to a separate Tubeless Tire Manual, which is not included.

PDF Search, Diagram Detail, and File Contents

Search and diagram detail: Neither PDF supports text search or has embedded bookmarks. Small labels in the shop manual's main wiring diagram are faint and remain difficult to read in places when enlarged. The companion's C.F.I. schematic labels are readable with zoom.

The ZIP contains two printable PDFs totaling 411 pages. The totals include cover and front-matter pages, nine memo pages in the shop manual, diagrams spread across multiple PDF pages, and one correction sheet in the companion volume.

Turbo/C.F.I. Diagnosis and Mechanical Repair

These are selected coverage highlights, rather than a full table of contents. Other topics include fairing/instrument removal and operation of the automatic cam-chain tensioner.

• Engine repair: Step-by-step engine removal/installation, cylinder-head and valve repair, valve-guide replacement, seat grinding, clutch/oil-pump service, camshaft installation, and cam-chain timing.

• Transmission and shaft drive: Constant-mesh transmission overhaul, crankshaft/piston inspection, swingarm/driveshaft service, and final-drive backlash, preload, and gear-contact adjustment.

• Turbocharger service: Turbine inspection, wastegate testing, oil-control-orifice service, and removal/installation procedures with assembly-replacement criteria.

• C.F.I. systems: Intake-manifold, surge-tank, ECU, fuel-pump, pressure-sensor, and engine-speed-sensor procedures, supported by LED self-diagnosis and symptom charts.

• Suspension and brakes: TRAC front-fork repair, Pro-Link shock/linkage work, hydraulic-brake bleeding, and master-cylinder and caliper overhaul.

• Cooling system: Radiator-cap and system pressure tests, thermostat inspection, radiator/fan removal, water-pump mechanical-seal replacement, and coolant filling/air bleeding.

• Electrical troubleshooting: Charging-output and regulator/rectifier tests, ignition checks, starter-motor overhaul, relay/switch tests, and wiring and harness references.

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.

C.F.I. Fault Diagnosis

Section 24 provides quick-reference and symptom charts for no-start/hard-start conditions, power loss, low- and high-speed running faults, afterfire, backfire, knock, smoke, abnormal turbo noise, and warning-lamp complaints.

Fuel-pressure, pump-delivery, and injector checks sit alongside static and dynamic pressure-sensor tests, plus temperature-, throttle-, and engine-speed-sensor checks. These references help distinguish fuel-supply problems from sensor or control-circuit faults before replacement parts are selected.

Separate checks address spark advance, the fuel-pump stop sensor, boost indicator, air and reed valves, and left/right throttle-valve synchronization.

Honda treats the fuel circuit as pressurized and provides specific isolation and eye-protection cautions before fuel-system work.

Turbocharger and Control-System Detail

The companion explains the surge tank, resonance chamber, pressure regulator, injectors, pump-control logic, fuel maps, compensation strategies, and fail-safe substitutions. It distinguishes PB manifold-pressure, P1 atmospheric-pressure, P2 charging-pressure, and PIGN ignition-advance sensors; the included correction sheet clarifies the basic fuel-map input logic.

Honda warns that removing carbon from turbine vanes can disturb rotor balance; a bent wastegate actuator rod requires turbocharger-assembly replacement. The oil-control-orifice section cautions that cleaning with wire can enlarge the metering hole.

Bearings, Final Drive, and Suspension

For bottom-end repair of the liquid-cooled OHV V-twin, select-fit crankshaft main and connecting-rod bearings are handled through color-code tables and Plastigage checks. Final-drive instructions relate shim selection to measured preload, backlash, and drive/coast contact patterns.

The rear-shock chapter documents oil-seal replacement and refilling with a hydraulic press. Damaged COMSTAR wheel assemblies are treated as nonserviceable.

Diagrams, Tools, and Service Data

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

Tool references include sensor inspection adapter 07999-MC70000, fuel-pressure gauge set 07406-0040000, piston remover 07941-MC70000, and preload inspection tool 07998-MC70000. Component torque tables, capacities, pressure/vacuum specifications, electrical voltage/resistance checks, wear limits, clearances, bearing-selection data, and adjustment specifications accompany the procedures.

A Preview of Valve and Wastegate Test Data

The valve-clearance section specifies 0.10 mm intake and 0.12 mm exhaust clearance with the engine cold, below 35°C (95°F). The related illustrations identify the cylinder timing marks and checking points.

For wastegate-actuator inspection, the shop manual specifies 2.0 mm of rod movement at an applied pressure of 130–138 kPa. This is an actuator-test specification, separate from the engine's operating boost-pressure data.