CB500X Valve Checking/Adjustment Guide Before starting · CB500X Valve Checking/Adjustment Guide...
Transcript of CB500X Valve Checking/Adjustment Guide Before starting · CB500X Valve Checking/Adjustment Guide...
CB500X Valve Checking/Adjustment Guide
Before starting:
Removing the tank is much easier when it doesn’t have much fuel in it. Consider running the
tank to a low petrol level before starting the job.
Forum members in both the UK & USA have struggled with availability of new shims from
Honda, with them often being on back order for a week or more. Consider; if you can have
your bike in the workshop for a week plus, if you are happy to dismantle the bike twice (once
to measure and once to fit new shims) or if you can find a source of non-OEM shims (e.g.
Hot Cams kit)
Tools required:
2mm/3mm Allen key (for removing plastic clips and hooking rockers into place)
5mm Allen key
6mm Allen key
10mm spanner
8mm socket
10mm socket
13mm socket
17mm socket for crank cover plate
M6 bolt
Cross head (Phillips) screwdriver
Large flat head screwdriver
Feeler gauges
Micrometer or Vernier Calipers accurate to +/- 0.01mm
Magnetic pickup tool (recommended!)
Remove Seat
Remove Side Panels
Remove 2x 5mm allen bolts:
CB500X Valve Checking/Adjustment Guide
and pull panel out of rubber grommets, starting at the rear, to release:
Remove Front Fairing Side Panels
Remove inner fairing panel by pushing in the centre of the plastic clip, using a small allen
key, or similar, and removing allen bolt (5mm) from top of tank
Remove remaining 5mm allen bolts holding panel and plastic Phillips screw clip (also see
second photo). First photo shows bolt locations once panel is removed:
CB500X Valve Checking/Adjustment Guide
Location of plastic Phillips screw fastener on inside front of the panel
Pull the panel away from the bike at the rear to release the velcro patch and then pull
forwards to release plastic lugs from slots in the centre fairing panel. Slots on centre panel:
CB500X Valve Checking/Adjustment Guide
Lugs on inside of fairing side panel:
Remove Tank
Unscrew 2x 8mm bolts securing front of tank to bike
CB500X Valve Checking/Adjustment Guide
Pull up the front of the tank so that it pivots on the rear mounting bolt. Remove the 2x rubber
drain pipes to the bottom front of the tank
the electrical plug midway down the left-hand side of the tank (pinch to release) and the fuel
pipe from the pump (pinch white connector clip to release). A small amount of fuel will
escape, but this will be minimized if the end of the pipe is kept on the airbox.
Once the pipes and electrical connector are released, the rear bolt (10mm) can be removed to
release the tank.
CB500X Valve Checking/Adjustment Guide
Remove Hazard Relay and ECU
The ECU and Hazard Relay are located just behind the headstock on the under-tank tray. Pull
the Hazard Relay up off its mount and release the electrical connector in the base. Remove
the Relay and push the connector back through the under-tray.
Disconnect the multiplug from the base of the ECU and remove the ECU by pulling it
forwards and up through the rubber mounting band.
CB500X Valve Checking/Adjustment Guide
Release the rubber mounting band from the under-tank tray.
Disconnect feed wires (x4) to coils
CB500X Valve Checking/Adjustment Guide
Release the wiring loom securing clips so that the loom can be lifted away from the tray
Removing the under-tank tray
Remove the 10mm nut and bolt securing the PAIR valve to the under-tank tray and slide off
the spigot, so that it is no longer attached to the tray
CB500X Valve Checking/Adjustment Guide
Unclip the electrical connector secured to the outside left of the tray
Carefully lever the clutch and throttle
cables out of the retaining clip on the
right side of the tray.
Remove the 10mm bolt securing the front of
the tray to the frame
CB500X Valve Checking/Adjustment Guide
Carefully lift and maneuver the tray up and out of the frame. Release the right side first and
pull off the plug caps to allow the caps and leads to come away with the tray. Then lift the
front of the tray up and maneuver the tray away from the wiring on the left side, taking care
not to damage the connector mounting clips
Removing the PAIR valve
Release the clips from the ends of the pipes and disconnect the PAIR valve pipes from the
cam cover and airbox. Unclip the fuel hose from the PAIR hose and the electrical connector
to the valve. Then remove the PAIR valve complete with hoses
CB500X Valve Checking/Adjustment Guide
Disconnect Throttle and Clutch cables
To keep the throttle free-play, loosen the locknut on the rear throttle cable and count the
number of turns up to the top of the adjuster. Make a note of this for use in reassembly.
Unscrew the adjuster to release the cable from the bracket and then free the cable from the
throttle pulley
CB500X Valve Checking/Adjustment Guide
Unscrew the front cable to release this too
(Optional, but makes life easier on ABS bikes) Unscrew the 5mm allen bolt on the top of
the clutch cover, securing the clutch cable bracket. Release the bracket and unhook the cable
Pull the cables up through the frame and lay them out to side, so they are out of the way.
CB500X Valve Checking/Adjustment Guide
Remove the rubber heat shield
The heat shield stretches from the radiator at the front back to the frame above the cam cover.
It is installed under the top radiator hose, so can only be swiveled out of the way to the right.
To do this, unloop the ends of the shield from around the frame. Next remove the radiator top
mounting bolt (10mm) and pivot the radiator forwards enough for the shield to be stretched
over the top of the mount:
Release the shield from the left and right radiator lugs to enable it to be swiveled out to the
right side of the bike.
Release brake pipes (ABS models only)
Unscrew the 10mm brake pipe mounting
bolt to the right of the radiator top mount
and the bracket just inside the front of the
frame to give the brake pipes some slack.
Unclip the 2 white brake line securing clips
on the inside of the right frame member and
remove the clips. This enables the brake
pipes to move slightly up and out giving
more room to remove the cam cover
CB500X Valve Checking/Adjustment Guide
Remove cam cover
Unclip and remove the breather hose
from the back of the cam cover
Unbolt the 4x 10mm bolts securing the cam
cover in place. The cam cover should now be
free to lift upwards, although it might need
some persuasion to move. Once loose,
maneuver the cover backwards out through
the frame, tilting it up on the right, so clear
the cam sprockets. It will be necessary to
push the radiator top hose forwards and left
and, on ABS models, the brake pipes up and
right to enable the cover to come out.
CB500X Valve Checking/Adjustment Guide
Check valve clearances
Remove the crankcase cover using a 17mm socket
CB500X Valve Checking/Adjustment Guide
Using a 14mm socket on the crankshaft end nut, rotate the engine until the T mark lines up
with the nick at the front of the casing. The IN and EX marking on the rear cam sprocket
should line up with the top of the head
With these marks lined up, it is now possible to check the Exhaust valves (front camshaft).
The gap should be 0.27mm +/-0.03mm
If the gap needs adjusting, then it is necessary to remove the rocker shaft so that the shims
can be removed and measured. Unscrew the 6mm allen retaining bolt from the left of the
engine
and screw an M6 bolt a few turns into the end of the rocker shaft
CB500X Valve Checking/Adjustment Guide
Pull the rocker shaft out of the head to release the rocker arms.
CB500X Valve Checking/Adjustment Guide
With the rocket shaft removed, the rockers can be pushed away from the valves and the shims
removed. I used a magnetic pickup tool to get the shims out and remove them from the
engine without danger of them dropping into it.
Once the shim is removed, use a micrometer or Vernier caliper to measure its thickness. It is
then possible to work out the size of the new shim required:
New shim = Old shim – (0.27 – Actual gap)
e.g. If the gap was 0.21 and the old shim was 2.12 the calculation would be
New shim = 2.12 – (0.27 – 0.21)
= 2.12 – 0.06
= 2.06
Install the new shim in the top of the valves and re-install the rocker shaft, moving the
rockers back into position so the shaft can pass through.
CB500X Valve Checking/Adjustment Guide
Turn the crank bolt 1/2 a turn clockwise, so that the marks on the camshaft sprockets look
like this:
Repeat the clearance checking and shim measurement/replacement (as necessary) on the Inlet
valves (rear camshaft). The gap should be 0.16mm +/-0.03mm
To calculate the new shim size on the inlet valves, use the following formula:
New shim = Old shim – (0.16 – Actual gap)
Reassembly
Reassembly is the reverse of dismantling. The only thing to watch for is ensuring the front of
the fairing side panels are correctly aligned as this has to be done as the panel is slid into
place, before any fixings are put in.