mbx50 PDF

�HONDA
� MBX50· MBX80
MB B BO
WORKSHOP MANUAL
HOW TO USE THIS MANUAL

This shop manual describes the service procedures
GENERAL INFORMATION
for the HONDA MBX50 and MBXBO based on
the MBX50 Standard model.
LUBRICATION
Section 1 throughs 3 apply to the whole motor
INSPECTION AND AJUSTMENT
cycle, while section 4 through 17 describe parts
of the motorcycle, grouped according to loca
FUEL SYSTEM
tion.
ENGINE REMOVAL/INSTALLATION
Find the section you want on this page, then
turn to the table of contents on page 1 of that CYLINDER HEAD/CYLINDER/PISTON
section. LU
z CLUTCH/KICKSTARTER/
Most sections start with an assembly or system z
(!)
LU
i============================-�
GEARSHIFT LINKAGE
illustration, service information and trouble ALTERNATOR
shooting for the section. The subsequent pages
give detailed procedures. CRANKSHAFT/TRANSMISSION
If you don't know the source of the trouble, go COOLING SYSTEM

to section, 18, TROUBLESHOOTING.
FRONT WHEEL/SUSPENSION
ALL INFORMATION, ILLUSTRATIONS, DIREC
TIONS AND SPECIFICATIONS INCLUDED IN Cf)
HYDRAULIC BRAKE
Cf)
THIS PUBLICATION ARE BASED ON THE LATEST Cf)
PRODUCT INFORMATION AVAILABLE AT THE <(
I REAR WHEEL/BRAKE/SUSPENSION
TIME OF APPROVAL FOR PRINTING HONDA u
MOTOR CO., LTD. RESERVES THE RIGHT TO
MAKE CHANGES AT ANY TIME WITHOUT FAIRING/UNDER COWL
NOTICE AND WITHOUT INCURRING ANY
OBLIGATION WHATEVER. BATTERY/CHARGING SYSTEM
NO PART OF THIS PUBLICATION MAY

BE REPRODUCED WITHOUT WRITTEN
PERMISSION.
SWITCHES
HONDA MOTOR CO., LTD.
SERVICE PUBLICATIONS OFFICE TROUBLESHOOTING
Downloaded from www.Manualslib.com manuals search engine

�HONDA
� MBX50·MBX80
MODEL IDENTIFICATION
(1) BEGINNING WITH F No. AC03-5000001.
(2) The frame serial number is stamped on the (3) The engine serial number is stamped on the
steering head right side. left crankcase.
(4) The carburetor identification number is on

the carburetor body left side.

�HONDA
MBX50·MBX80 GE ERAL I FOR ATIO 1 ··--- ·
GENERAL SAFETY 1-1 SPECIAL TOOLS/COMMON TOOLS 1�5

SERVICE RULES
SPECIFICATIONS
1-1
1-2
WIRING DIAGRAM
CABLE & HARNESS ROUTING
1-6
1-7
I]
TORQUE VALUES 1-4 MAINTENANCE SCHEDULE 1-10
r-------lMPORTANT SAFETY NOTICE-------.

Indicates a possibility of personal injury or loss of life if instructions are not followed.
CAUTION: Indicates a possibility of equipment damage if instructions are not fallowed.
Detailed descriptions of standard workshop procedures, safety principles and service operations are not includ
ed. It is important to note that this manual contains some warnings and cautions against some specific service
methods which could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it un
safe. Please understand that those warnings could not cover all conceivable ways in which service, whether or
not recommended by Honda might be done or of the possible hazardous consequences of each conceivable
way, not 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 methods or tools selected.
GENERAL SAFETY
�� W%\R'NINX�I
, � '- J '" > �' I
If the engine must be running to do some work, make The battery electrolyte contains sulfuric acid. Protect
sure the area is well-ventilated. Never run the engine your eyes, skin and clothing. In case of contact, flush
in a closed area. The exhaust contains poisonous thoroughly with water and call a doctor if your eyes
carbon monoxide gas. were exposed.
,:VI,; ·,W,A'RNIN6 1
,, ' ' Y. • • )
Gasoline is extremely flammable and is explosive The battery generates hydrogen gas which can be
under certain conditions. Do not smoke or allow highly explosive. Do not smoke or allow flames or
flames or sparks in your working area. sparks near the battery especially while charging it.
SERVICE RULES
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. fnstall new gaskets, 0-rings, cotte� 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 dissassembly. Lubricate any sliding surfaces before reassembly.
7. After reassembly, check all parts for proper installation and operation.
1-1
c:ifJ\ HONDA
GENERAL INFORMATION � MBX50·MBX80
·SPECIFICATIONS
AREA
ITEM MBX50 MSX80
(Type)
DIMENSIONS
Overall length 1,970 mm (77.5 in) +-
Overall width 675 mm (26.6 in) +-
Overali height Standard 1,005 mm (39.6 in) +-
Deluxe 1,110 mm (43.7 in) +-
Wheelbase 1,250 mm (49.2 in) +-
Seat height 775 mm (30.5 in) 780 mm (30.7 in)
Ground clearance 170 mm ( 6.7 in) 150 mm ( 5.9 in)
Dry weight 89 kg (196 lb) 92 kg (203 lb)
Curb weight 98 kg (216 lb) 101 kg (223 lb)
Loa�ed weight 248 kg (547 lb) 251 kg (553 lb)
Permissible maximum weight 268 kg (591 lb) 271 kg (597 lb)
FRAME
Type Semi-double cradle +-
Front suspension, travel Telescopic, 115 mm (4.53 in) +-
Rear suspension, travel Swingarm/shock absorber, 85 mm +-
85 mm ,(3.35 in)
Front tire size 2.50-18-4PR 2.75-18-4PR
Rear tire size 2.75-18-6PR 3.00-18-6PR
Cold tire pressure Up to 90 kg Front 175 kPa (1.75 kg/cm2 , 25 psi) 200 kPa (;:W kg/cm2 , 28 psi)
( 198 lb) Rear 175 kPa (1.75 kg/cm2 , 25 psi) 200 kPa (2.0 kg/cm2 , 28 psi)
Up to capacity Front 175.kPa (1.75 kg/cm2 , 25 psi) 200 kPa (2.0 kg/cm2, 28 psi)
load Rear 280 kPa (2.80 kg/cm2 , 40 psi) 280 kPa (2.8 kg/cm2, 40 psi)
Front brake Single disc brake +-
Rear brake Internal expanding shoe +-
Fuel capacity 1.2 liters (3.2 US gal, 2.6 Imp gal) +-
Fuel reserve capacity 1.2 liters (0.3 US gal, 0.3 Imp gal) +-
°
Caster angle 26 30' +-
Trail 72 mm (2.8 in) +-
Front fork oil capacity 149.5-154.5 cm3 (5.3-5.5 oz)
ENGINE
Type Water cooled 2-stroke, reed valve +-
°
Cylinder arrangement Single cylinder 15 incline from +-
vertical
Bore and stroke 39.0 x 41.4 mm (1.54 x 1.63 in) 49.5 x 41.4 mm (1.95 x 1.63 in)
Displacement 49 cm3 (2.98 cu in) 79 cm3 (4.82 in)
Compression ratio 7.3: 1 +-
1-2
�HONDA
� MBXSO, MBX80 GENERAL INFORMATION
ITEM MBX50 MBXSO AREA

(Type)
ENGINE
Maximum horsepower 5.8 kw/7,000 min-1 7.0 kw/5,750 min-1
(7.9 ps/7,000 rpm) (9.6 ps/5,750 rpm)
Maximum torque ·8".3 N.m (0.85 kg-m, 6.1 ft-lb)/ 11.7 N.m (1.2 kg-m, 8.7 ft-lb)
6,500 min-1 (rpm) 5,500 min-1 (rpm)
Oil capacity Transmission 0.9 liters (1.0 US qt, 0.8 Imp qt) +-
Oil tank 1.2 liters (1.3 US qt, 1.1 Imp qt) +-
Coolant capacity 670 cm3 (40.9 cu in) +-
Lubrication system Forced and wet sump +-
Air filtri!tion Oiled polyurethane foam +-
Cylinder compression 1,275 kPa (13.0 kg/cm2 , 185 psi) +-
Idle speed 1,400 min-1 (rpm) +-
CARBURETION
Carburetor type PF16, 16 mm (0.63 in) venturi bore PF16, 18 mm (0.71 in) venturi
bore
Identification number PF16A PF26D
Air screw initial setting 1% turns out 1 turn out
Flo.at level 13.5 mm (0.53 in) +-
DRIVE TRAIN
Clutch Wet, multi-plate +-
Transmission 6-speed constant-mesh +-
Primary reducation 4.117 +-
Final reducation 2.866 (43/15) 2.533 (38/15)
Gear ratio I 3.545 +-
II 2.333 +-
111 1.722 +-
'tv 1.380 +-
V 1.173 +-
VI 1.041 +-
Gear shift pattern Left foot operated return system, +-
1-N-2-3-4-5-6
ELECTRICAL
Ignition C.D.I. +-
19 ±3 BTDC at 3,000 min-1 (rpm)
° °
Ignition timing "F" mark +-
10.5 ±3.5 BTDC at 9,000 min-1 3 ±3.5 BTDC at 9,000 min-1
° ° ° °
Full retard
(rpm) (rpm)
Starting system Kickstarter +-
Generator 90W/5,000 min-1 (rpm) +-
Battery capacity 12V 3AH +-
Spark plug Standard NGK BR8ES, ND W24ESR-U +-
Optional NGK BR9ES, ND W27ESR-U +-
NGK BR7ES, ND W22ESR-U +-
Standard NGI( BR9ES, ND W27ESR-l,J G
Optional NGK BR7ES, ND W22ESR-U G
NGK BR8ES, ND W24ESR-U
Spark plug gap 0.7-0.8 mm (0.028-0.031 in) +-
Fuse 7A +-
LIGHTS
Headlight (high/low beam) 35/35W +:
36/36W F
Tail/stoplight 5/21W +-
Front turn signal 10W +-
Rear turn signal 10W +-
Speedometer light 3.4W +-
Tachometer light 3.4W +-
Neutral indicator 3.4W +-
Turn signal indicator 3.4W +-
High beam indicator 1.7W +-
1 -3
r:::iJ\ HONDA
GENERAL INFORMATION
� MBXSO· MBX80
TORQUE VALUES
e ENGINE
Torque
Item O'ty Thread Dia (mm) 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 (5.0-6.0, 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)
e CHASSIS
Torque Remarks
Item O'ty Thread Dia (mm)
N,m (kg-m, ft-lb)
Steering stem nut 1 22 60-90 (6.0-9.0, 43-65)
Handlebar holder 4 6 10-14 (1.0-1.4, 7-10)
Fork pinch bolts 2 8 24-30 (2.4-3.0, 17-22)
Front fork bolt 2 12 40-50 (4.0-5.0, 29-36)
Front fork inner bolt 2 22 15-30 (1.5-3.0, 11-22)
Front axle nut 1 12 55-70 (5.5-7.0, 40-51) Self-looking nut
3 10 30-40 (3.0-4.0, 22-29)
Rear axle nut 1 12 55-70 (5.5-7.0, 40-51) Self-looking nut
Final driven sprocket 3 10 40-50 (4.0-5.0, 29-36)
Rear brake torqu.e link 2 8 18-25 (1.8-2.5, 13-18)
Rear shock absorber 2 10 27-33 (2.7-3.3, 20-24) Self-looking nut
Rear shock linkage 3 10 40-50 (4.0-5.0, 29-36)
Swingarm pivot nut 1 14 70-85 (7.0-8.5, 51-62) 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)
Brake bleeder valve 1 - 4- 7 (0.4-0.7, 2.9-5.1)
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 bracket pin nut 2 8 20-25 (2.0-2.5, 15-18)
Brake caliper pin bolt 3 6 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.
e STANDARD TORQUE VALUES

Torque Torque
item Item
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.i...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
�HONDA
� MBX50· MBXIO GENERAL INFORMATION
TOOLS
SPECIAL
Tool Name Tool No. O'ty Remarks
Crankshaft assembly tool 07965-1660100 1 Crankshaft installation
Balancer weight driver 07945-1660000 1 Balancer installation
Bearing remover set 12mm 07936-1660000 1 Removal of small balancer bearing, water
pump bearing and mainshaft bearing
(Spindle assembly) (07936-1660100) (1)
(Sliding weight) (07936-3710200) (1)
Bearing puller (commercially
available) 07631-0010000 1 Main bearing removal
Bearing driver 28 >< 30 mm 07964-1870100 1 Small balancer bearing and mainshaft
bearing installation
Hex wrench 6 mm
(commercially available) 07917-3230000 1
Ball rece driver 07944-1150001 1
Snap ring pliers 07914-3230001 1
Front fork oil seal
driver attachment 07747-0010700 1
Shock absorber
compressorr attachment 07967-GE20000 1
Mechanical seal driver 07945-4150400 1 Water pump mechanical seal installtion
COMMON
Tool Name Part No. Q'ty Remarks

Float level gauge 07401-0010000 1 Float level
Universal holder 07725:....0030000 1
} Flywheel removal
flywheel puller 07733-0010000 1
Driver A 07749-0010000 1 Used with driver �nltaclhment
Attachment !52 ,c 55 mm 07746-0010400 1
Attachment 42 x 47 mm 07746--0010300 1
Attachment 37 x 40 mm 07746-0010200 1 Installation of front wlheei bearing
Attachment 32 x 35 mm 07746-0010100 1 installation of crankshaft oil se;;ii
Pilot 12 mm
Pilot 17 mm
Pilot 25 mm
07746-0040200
07746-0040400
07746-0040000
,
0
1
) U,ed with drloer attachment
Pilot 24 mm 07746-0040600 1 )
Driver C 07746-0030100 1
} Installing crankshaft bearing
Attachment 25 mm l.D. 07746-0030200 1
Front fork oil seal driver 07747-0010100 1 lnstalli.ng fork sea! in slider
body
Pin spanner 07702-0010000 1 Steering head bearing adjustment

�HONDA
� MIX50· MBXIO
MEMO

HONDA
MBX50·MBX80 GENERAL INFORMATION
CABLE & HARNESS ROUTING

(1) RADIATOR OVERFLOW TUBE
(2) HIGH TENSION CORD
(4) TACHOMETER CABLE
(3) CLUTCH CABLE
('·
/ ( f!J.I \
(6) WIRE HARNESS
/,1,
;J ' �/; .· .
l .
(.· Ci,'c ;.:! (7) SPEEDOMETER CABLE
��]·

�HONDA
GENERAL INFORMATION � MBX50· MBX80
(5) AlTERNATOR/NEUTRAL SWITCH

WIRES
(4) WIRE HARNESS
1-8
�HONDA
� MBX5.0·MBX80 GENERAL INFORMATION
(1) CLUTCH CABLE
(3) THROTTLE CABLE (2) TURN SIGNAL SWITCH COUPLER
(5) BRAKE HOSE
(8) IGNITION COIL

(6) OIL LEVEL (7) (9) CDI UNIT
SENSOR (10)HIGH TENSION CORD
(15) FUSE HOLDER (12)TACHOMETER

CABLE
(14)REAR BRAKE LIGHT (1) CLUTCH CABLE

SWITCH
1-9
�HONDA
GENERAL INFORMATION � MBX50· MBXSO
MAINTENANCE SCHEDULE
Perfrom the Pre- ride Inspection at each sheculed maintenance period.
I: Inspect and Clean, Adjust, Lubricate or Replace if necessary.
�-0.,0.·0
C: Clean R: replace A: Adjust L: Lubricate
WHICHEVER I ODOMETER READING (NOTE 2)

COMES
FIRST ·, �-4:'
<f'°"'
C §>
�'°"'
<§> §>
�*�
<§> er::, Refer to
M c�<::,
�� c::s <oc::s �c::s
EVERY ,@ �· �·�· <o\�'
� Oj
TRANSMISSION OIL R R Page 2-3

SPARK PLUG A R R R Page 3-4
AIR FILTER ELEMENT NOTE1 C C C Page 3-3
* CARBURETOR I I Page 3-5 ,4- 7
RADIATOR COOLANT I Page 3-8
* RADIATOR CORE I Page 3-8
* COOLING SYSTEM I I Page 3-8
HOUSES & CONNECTIONS
* THROTTLE OPERATION I I I I Page3-2
. ** OIL PUMP I I I I Page 3-5
* FUEL LINES I Page 3-2
* PUEL STRAINER C C C C Page 3-2
CLUTCH I I Page 3-7
DRIVE CHAIN NOTE3 l,L l,L l,L 1,L Page 3-11
BRAKE SHOES/PADS I I Page 3-9,3-10
BRAKE CONTROL LINKAGE I I Page 3-13
** WHEELS I I
TIRES I I I I Page 3-13
* FRONT AND REAR SUSPENSION I I
** STEERING HEAD BEARINGS I
BATTERY I I I I Page 3-9
MONTH:1
BRAKE FLUID I I I I Page 3-9
2 YEARS: R
* BRAKE LIGHT SWITCH I I I I Page 3-10
* HEADLIGHT AIM I I I I
SIDE STAND I I I
* LIGHTING EQUIPMENT I I I I
* ALL NUTS, BOLTS AND OTHER
I I I I Page 3-13
FASTENERS
** CYLINDER PISTON DECARBON-
C
IZATION
** CYLINDER EX. PORT
C
DECARBONIZATION
** MUFFLER DECARBONIZATION C Page3-13
* SHOULD BE SERVICED BY AN AUTHORIZED HONDA DEALER' UNLESS THE OWNER HAS THE PROPER TOOI-S
AND SERVICE DATA AND IS MECHANICALLY QUALIFIED. REFER TO THE OFFICAL HONDA SHOP MANUAL.
*ii IN
THE INTEREST OF SA!=ETY, WE RECOMMEND THESE ITEMS BE SERVICED ONLY BY AN AUTHORIZED
HONDA DEALER.
NOTES: 1 . Service more frequently when riding in dusty areas.
2. For higher odometer readings, repeat at the frequency interval established here.
3. Every 300 miles (500 km)
1-10
�HONDA
� MBX50· MBXSO LUBRICATIO 2.
*:
I
(1) ENGINE OIL FLOW
(4) OIL PUMP
OIL TANK
CAPACITY: 1.2 lit.
(1.3 US qt, 1.1 Imp qt)
(7) OIL PUMP
Do not attempt to disassemble the oil pump.
(8) OIL PUMP BLEEDER BOLT
(9)
------ -----------r-
Apply locking agent to the threads of the
oil pump mounting bolt and screw.
2-0
�HONDA
LUBRICATION � MBXSO· MBXSO
OIL FLOW 2-0

SERVICE INFORMATION 2-2
TROUBLESHOOTING 2-2
TRANSMISSION 01 L 2-3
01 L STRAINER CLEANING 2-4
OIL PUMP REMOVAL 2-5
OIL PUMP INSPECTION 2-6
OIL PUMP INSTALLATION 2-6
01 L PUMP BLEEDING 2-7
OIL TANK 2-8
CHASSIS LUBRICATION POINTS 2-9
2-1
{;;jJ\ HONDA
� MBX50· MBXSO LUBRICATION_
SERVICE INFORMATION
GENERAL INSTRUCTIONS
• Use utmost care when remvoing and installing the oil pump to keep dust and dirt from entering the engine.
e Do not attempt to disassemble the oil pump.
e Bleed air from the oil pump if there is air in the oil pipe from the oil tank to the oil pump or if the oil pipe has been dis
connected.
e Bleed air from the oil pass tube (from the oil pump to the inlet pipe) if the tube has been disconnected.
SPECIFICATIONS
INJECTOR OIL
Oil capacity 1.2 lit. (1.3 US qt, 1.1 Imp qt)
Oil recommendation Honda 2 Stroke Injector Oil or its equivalent
TRANSMISSION OIL
Oil capacity 0.9 lit. (1.0 US qt, 0.8 Imp qt) at disassembly
0.8 lit. (0.8 US qt, 0.7 Imp qt) at change
Oil recommendation Use HONDA 4-STROKE OIL or OIL VISCOSITIES
equivalent.
API SERVICE CLASIFICATION:
SE or SF
VISCOSITY: SAE 10W-40
-JO � 10 -10 10 20 JO 40 �c
TORQUE VALUES
Oil pump mounting bolt 8-12 N.m (0.8-1.2 kg-m, 6-9 ft-lb)
Oil pump mounting screw 8-12 N.m (0.8-1.2 kg-m, 6-9 ft-lb)
TROUBLESHOOTING
Excessive smoke/excessive carbon buildup in plug Sized or burnt piston
1. Pump not properly synchronized (excessive oil) 1. No oil in tank or clogged oil pipe
2. Low quality of engine oil 2. Pumpt not properly synchronized (insufficient oil)
3. Air in oil pipe
Overheating 4. Defective oil pump
1. Oil pump not synchronized properly (!insufficient oil)
2. Low quality of engine oil Oil not flowing out from tank
1. Clogged oil tank cap breather hole
2. Clogged oil tank filter screen
2-2
�HONDA
LUBRICATION � MBX50· MBX.80
TRANSMISSION Oil
OIL LEVEL CHECK
Before checking the oil level run the engine and
·allow to idle for a few minutes.
Support the motorcylce upright on level ground.
Stop the engine and remove the oil level check bolt
from the right crankcase cover.
A small amount of oil should flow out of the oil

level bolt hole.
(1) OIL LEVEL CHECKBOLT
OIL CHANGE
Warm the engine to normal operating temperature.
Remove the oil filler cap.

Remove the oil drain plug and drain the oil.
Reinstall the drain plug.

TORQUE: 20-25 N.m (2.0-2.5 kg-m,
14-18 ft-lb)
CAUTION
Make sure that the sealing washer on the drain
plug is in good condition.
(1) OIL FILLER CAP
Refill the engine up to the proper level.

Oil CAPACffV: 0.8 lit. (0.8 US qt, 0.7 Imp qt)
SPECIFIED Oil: 10W-40 or equivalent
Start the engine and check for leaks. Stop. the

engine and recheck the oil level.
(1). OIL DRAIN PLUG

20-25 N.m (2.0-2.5 kg-m, 14-18 ft-lb)
2..,3
r;;;;;Jj\ HONDA
� MBX50· MBXSO LUBRICATION
Oil STRAINER CLEANING (1) OIL PUMP
Disconnect the oil tube at the oil pump and allow

the oil to drain into a clean container.
(2) OIL TUBE
Remove the right side cover.
Loosen the tube clip and disconnect the oil tube

joint under the oil tank. (1) OIL STRAINER-ml
SCREEN
�
t!//fe
Remove the oil strainer screen.
(2) 01 L TUBE ---111>-
....
CLIP
(3) OIL STRAINER--�

JOINT
�
(4) OIL TUBE

JOINT
Clean the oil strainer screen with compressed air. (1) OIL STRAINER SCREEN
AIR NOZZLE
Installation of the oil strainer is the reverse order of
removal.
Fill the oil tank with the recommended oil up to the

proper level.
Bleed air from the oil pump and oil pipe (Page 2-7)
CAUTION
a Connect the oil pipe securely.
e Check for leaks.
2-4
LUBRICATION
{1) OIL PUMP MOUNTING BOLT {2) SCREW
NOTE
Before removing the oil pump, clean the oil
pump and crankcase.
Remove the carburetor (Page 4-3).

Disconnect the oil pump control cable.
Remove the left crankcase cover. (Page 8-3).
Remove the bolt and screw attaching the oil pump.
(3) OIL PASS TUBE (4) OIL TUBE
Disconnect the oil tube from the oil pump, and

pinch the end of the oil tube to prevent oil from
flowing out. (1) OIL TUBE
(2) TUBE CLIP
Disconnect the oil pass tube from the inlet pipe.

(1) OIL PUMP
NOTE
Use care not to allow oil to flow out of the (2) INLET PIPE
oil pass tube.
Remove the oil pump from the crankcase.
(3) OIL PASS TUBE
2-5
�HONDA
� MBX50· MBXSO LUBRICATION
(1) MAT ING FACE (2) CONTROL LEVER
Remove the oil pump and inspect the following

items:
Damaded or weakened 0-rings.
Damage to crankcase mating face.
Damage to pump body.
Improper oil control lever.
CAUTION
Do not disassemble the oil pump.
(3) 0-RING
Install the oil pump by aligning the pin on the pump

drive shaft with the groove in the pump driven
gear.
NOTE
® Lubricate the 0-ring with clean grease
before installation.
"' Make sure that the oil pump is inserted
into the crankcase properlv.
(1) 01 L PUMP SET PLATE

Secure the oil pump using the oil pump set plate, I
bolt and screw. I
NOTE
Apply locking agent to the bolt and screw I
threads.
__J
Reconnect the oil pump control cable.
Reinstall the oil tube and oil pass tube.
Install the carburetor. (Page 4-9).
NOTE
Perform the following inspections and adjust
ments:
® Control cable adjustment (Page 3-5).
® Oil pump air bleeding (Page 2-7).
e, Oil pass tube air bleeding (Page 2-7).
® Oil leaks.
2-6
r:::ifJ\ HONDA
LUBRICATION
� MBXSO· MBX80
OIL PUMP BLEEDING (1) ENGINE OIL TANK (2) 01 L FILLER CAP
NOTE
• Bleed air from the oil lines as it will block
or restrict oil flow,' resulting in severe
engine damage.
0 Bleed air from the oil tube and oil pump
first, then bleed air from the oil pass tube.
OIL TUBE/OIL PUMP
NOTE
Bleed air from the oil fube and oil pump when
the oil tube has been disconnected or there is
air in the oil tube.
Stop the engine.

Fill the oil tank with engine oil.
Place a rag around the oil pump as shown.
Unscrew the bleeder bolt at the top of the oil pump.

Tighten the bleeder bolt when the oil is free of air (1) BLEEDER BOLT
bubbles.
01 L PASS TUBE (3) OIL TUBE

NOTE
Bleed air from the oil pass tube when the tube
is disconnected or there is air in the oil tube
and oil pump.
Made sure that there is fuel in the fuel tank (25-

50 parts fuel to 1 part lubricant).
Start the engine and run it for about 10 minutes

with the oil pump control lever in the fully open
position so as to force air out of the oil pass tube
with the oil.
CAUTION (3) OIL PASS TUBE

• Use the recommended engine oil.
• Do not race the engine. (4) Open control lever fully.
2-7
HONDA
MBX50°MBXSO LUBRICATION
OIL TANK (1) OIL TANK MOUNTING BOLT
REMOVAL/INSTALLATION
Remove the seat, right and left side covers.

Remove the fuel tank and air cleaner case (Page
4-10).
Remove the rear suspension linkage mudguard (Page
13-13).
Disconnecto the oil tube at the oil pump and drain
the oil.
Disconnect the oil level warning unit coupler.
Remove the oil tank attaching bolt and tank.
Install the oil tank in the reverse order of removal.
(2) OIL LEVEL WARNING UNIT COUPLER

�HONDA
LUBRICATION � MBX50· MBX80
(4) CLUTCH AND BRAKE (5) FRONT FORK

LEVER PIVOTS (A.T. F .)
�
(2)
(1) WHEEL BEARINGS (3) THROTTLE // (6) or CABLE LUBRICANT
/ SPEEDOMETER AND
GRIP TACHOMETER CABLES
�
STEERING HEAD
BEARINGS
I�
�j,,
(14) BRAKE CAM \
I
\�1
f
I I
\ I
I \ (8) SPEEDOMETER
I
\ DRIVE GEAR
(13) [CHAIN LUBRICANT j \
(11) FOOT PEG \
DRIVE CHAIN PIVOT \ (9) WHEEL BEARINGS
�
(12) BRAKE PEDAL \�
PIVOT (10) MULTIPURPOSE GREASE MLG1 No. 2
(MoS2 Additive)
REAR SUSPENSION
LINKAGE
2-9
SERVICE INFORMATION 3-1 COOLING SYSTEM HOSES 3- 8
<ENGINE> RADIATOR CORE 3- 8
FUEL STARiNER 3-2 < CHASSIS>
THROTTLE OPERATION 3-2 BATTERY 3- 9
AIR CLEANER 3-3 FRONT BRAKE 3- 9
SPARK PLUG 3-4 REAR BRAKE 3-10
CARBURETOR IDLE SPEED 3-5 BRAKE LIGHT SWITCH 3-10
01 L PUMP CONTROL CABLE 3-5 DRIVE CHAIN 3-11
IGNITION TIMING 3-6 WHEELS 3-13
CYLINDER COMPRESSION 3-7 NUTS,BOLTS,FASTENERS 3-13
CLUTCH 3-7 MUFFLER DECARBONIZING 3-13
RADIATOR COOLANT 3-8
SERVICE rnFORMAlrnN
@ · Transmission oil See page 2-3.
m Oil pump See page 2-4.
a Cylinder head and piston decarbonizing See page 6-4.
e Cylinder exhaust port decarbonizing See page 6-6.
SPECIFICARIONS MBX50 MBX80
E.F G
<Engine>
Spark plug: Standard NGI< BR8ES, ND W24ESR-U +- NGI< BR9ES, ND W2J.ESR-U
Optional NGI< BR9ES, ND W27ESR-U +- NGI< BR7ES, ND W22ESR-U
NGI< BR7ES, ND W22ESR-U +-- NGK BABES, ND W24ESR-U
Plug gap
Ignition timing 0.7-0.8 mm (0.028-0.031 in) +-
19 ± 3 BTDC at 3,000 min-1 (rpm)
° °
"F'.' mark +-
Retard start 4,400-5,600 min-1 (rpm) +--
10.5 ± 3.5 BTDC at 9,000 min-1 (rpm) 3 ± 3.5 BTDC at 9,000 min-1 (rpm)
° ° 0 °
Full ratard
Idle speed 1,400 min-1 (rpm) +--
Air screw opening 1-% turns out (SW, B, SA), rn turns out (E) turn out
Cylinder compresssion 130 kPa (13;0 kg/cm2 , 185 psi) +--
Throttle grip free play 2-6 mm (1/8-1/4 in) +--
Coolant capacity Approximately 670 cm3 (1.4 US pt, +--
(1.2 Imp pt.)
<CHASSIS>
Rear brake pedal free play 20-30 mm (3/4-;--1-1/4 in) +-
Clutch lever free paly 10-20 mm (3/8-3/4 in) +-
Drive chain slack 10-20 mm (3/8-3/4 in) +--
Tire
Tire size Front 2.50-18-4PR 2.75-18-4PR
Rear 2.75-18-6PR 3.00-18-6PR
Cold tire pressure Front 175 kPa (1.75 kg/cm2 , 25 psi) 200 kPa (2.0 kg/cm2 , 28 psi)
Rear 175 kPa (1.75 kg/cm2 , 25 psi) 200 kPa (2.0 kg/cm2 , 28 psi)
Minimum tread depth Front 0.8 mm (1/32 in) +-
Rear 0.8 mm (1/32 in) +--
3-1
HONDA
INSPECTION AND ADJUSTMENT MBX50·MBX80
FUEL UNE AND FUEL STRAINER (1) FUEL VALVE (2) FUEL LINE
Turn the fuel valve OFF and remove the strainer

cup, 0-ring and filter screen from the fuel valve
body.
(3) FUEL STRIANER CUP
Wash the strainer cup and filter screen in high flash

point solvent.
Install the filter screen and 0-ring and tighten the
strainer cup.
TORQUE: 3-5 N.m (0.3-0.5 kg-m, 2.2-3.6 ft-lb)
Do not overtighten the strainer cup,
After installing, turn the fuel valve ON and check

that there are no oil leaks.
---..e
(1) FILTER SCREEN-
(2) 0-RING ----<::>

(3) STRAINER CUP
THROTTLE OPERATION
Check for smooth throttle grip full opening and
automatic full closing in all steering positions.
Check the th rattle cables and replace if deteriorated,
kinked or damaged.
Lubricate the throttle cable (Page 2-9) if throttle

operation is not smooth.
Measure throttle grip free P,lay at the throttle grip

flange.
FREEPLAY: 2-6 mm (1/8-1/4 in)

HONDA
MBX50·MBX80 INSPECTION AND ADJUSTMENT
(1) ADJUSTER
Adjust by loosening the lock nut and turning the
adjuster.
Tighten the lock nut.
Recheck throttle operation.
(2) LOCK NUT

AIR CLEANER (1) AIR CLEANER COVER
Remove the left side cover.

Remove the three screws attaching the air cleaner
cover and cover.
Remove the element.
(1) ELEMENT
3-3
HONDA
INSPECTION AND ADJUSTMENT MBX50,MBX80
Wash the element in non-flammable or high flash
point solvent and allow to dry.
NOTE
D o not wash the element in gasoline or vege
table oil.
Soak the element in clean engine oil or gear oil

(SAE 80-90) and squeeze out any excess.
Install the element air cleaner cover.

Install the left side cover. (1) WASH IN (2) SQUEEZE OUT (3) GEAR (4) SOEEZE OUT
SOLVENT SOLVENT OIL EXCESS OIL
THOROUGHLY
SPARK PLUG
(1) SIDE ELECTRODE
RECOMMENDED SPARK PLUG
MBX50 MBX80 (2) CENTER

ELECTRODE
E,F G
ND W24 ESR-U +- W27 ESR-U
Standard
NGK BAB ES +- BR9 ES
Optional NGK BR7 ES +- BR7 ES
NGK BR9 ES +- BAB ES
Disconnect the spark plug cap.

Clean any dirt from around the spark plug base.
Remove and discard the spark plug.
Measure the new spark plug gap using a wire-type
feeler gauge.
SPARK PLUG GAP: 0.7-0.8 mm
(0.028-0.031 in)
Adjust by bending the side electrode carefully.

With the plug washer attached, thread the spark
plug in by hand to prevent crossthreading.
Tighten the spark plug another 1 /2 turn with a
spark plug wrench to compress the plug washer.
Connect the spark plug cap.
3 .. 4
�HONDA
� MBX50· MBX80 INSPECTION AND ADJUSTMENT
CARBURETOR mLE SPEED

NOTE
The engine must be warm for accurate idle
adjustment.
Attach an engine tachometer.

Turn the throttle stop screw to obtain the specified
idle speed.
IDLE SPEED: 1,400 min-1 (rpm)
When the engine misses or runs erratically, proceed

as follows:
(1) THROTTLE SOP SCREW
Screw in the air screw until it lightly seats, then turn

it out specified turns.
MBX50: 1% turns (E type: 1% turns)
MBX80: 1 turn
Reset idle speed with the throttle stop screw.
Turn the air screw to find the highest idle speed.
Reset idle speed with the throttle stop screw.
Make sure that the engine does not miss or run
erratically. If necessary, repeat the above steps.
NOTE
The oil pump control cable should be adjusted
after the throttle grip free play has been (1) AIR SCREW
adjusted.
Loosen the lock nut. With the throttle fully open,

align the index mark on the pump body with the (3) INDEX MARK
(1) ADJUSTING NUT
reference mark on the control lever by turning the
�------------11
adjusting nut.
Tighten the lock nut. (2) LOCK NUT
CAUTION (6) OPEN
The idex mark on the control lever must be
in line with the reference mark on the pump
body. Failure to do so reduces the pump (4) REFERENCE MARK
delivery, resulting in serious engine damage.
When adjusting the index mark, it may be (7) CLOSE
within 1 mm (O. 04 in} out of line with the
ref erenee mark toward the OPEN region.
Excessive white smoke or hard starting:

Pump control lever excessively open
Burnt piston: Pump control lever not opened (5) CONTROL LEVER
properly
3-5
�HONDA.
INSPECTION AND ADJUSTMENT � MBXSO· MBX80
After adjustment, make sure that there is no in
terference between the control cable and the ( 1)
outer cable. Loosen the bolts attaching the cable (2) OUTER CABLE
bracket and adjust it if necessary.
(3) CONTROL CABLE
Apply locking agent.
IGNITION TIMING (1) _LEFT CRANKCASE COVER
NOTE
The COi ignition timing is not adjustable.
If the ignition timing is incorrect, check the
COi unit and alternator and replace any faulty
parts.
On the Deluxe model, remove the under cowl

(Page 14-3)
Remove the left crankcase cover.
(1) INDEX MARK (2) TIMING LIGHT

Connect a stroboscopic timing light to the high
tension wire.
Start the engine and bring engine speed to 3,000
min-1 (rpm).
Aim the time light at the timing mark.
The "F" mark should align with the index mark.
Bring engine speed to 9,000 min-1 (rpm} and
check that the index mark is between the fulI retard
marks.
pi([))h
(3) "F" MARK (4) RETARD MARKS

�HONDA
� MBX50,MBX80 INSPECTION AND ADJUSTMENT
CYLINDER COMPRESSION (1) COMPRESSION GAUGE
Warm up the engine.

Stop the engine and remove the spark plug.
Insert a compression gauge.
Open the choke and throttle grip fully and operate

the starter pedal several times.
COMPRESSION: 130 kPa (13.0 kg/cm2
185 psi)
low compression can be caused by:

• Blown cylinder head gasket
• Worn piston rings
• Worn cylinder
High compression can be caused by:

e Carbon deposits in combustion chamber or on
piston head
CLUTCH
l
Inspect the clutch lever free play at the end of the
lever.
FREE PLAY: 10-20 mm (3/8-3/4 in)
10-20 mm
(3/8-3/4 in)
(1) ADJUSTING NUT (2) LOCI< NUT (3) CLUTCH CABLE

Adjust free play by loosening the lock nut and turn
ing the adjusting nut until the free play is 10-
20 mm (3/8-3/4 in).
3 .. 7
�HONDA
INSPECTION AND ADJUSTMENT � MBX50· MBXSO
RADIATOR COOLANT (1) RESERVE TANK
Check the coolant level of the reserve tank with

the engine running at normal operating tempera
ture.
The level should be between the "F" (FULL) and
"L" ( LOW) level lines.
If necessary, remove the radiator cap and fill to the
"F" level line.
Engine must be cool before removing the

radiator cap, or severe scalding may result.
(2) LOW (3) FULL
COOLING SYSTEM HOSES (1) HOSES

Inspect the hoses for cracks or deterioration,
and replace if necessary.
Check the hose clamps, and tighten if necessary.
RADIATOR CORE
Check the air passages for clogging or damage.
Straighten bent fins.
Remove insects, mud or any obstruction with
compressed air or low water pressure.
Replace the radiator if the air flow is restricted
over more than 20% of the radiating surface.
3-8
HONDA
MBX50,MBX80 INSPECTION AND ADJUSTMENT
<CHASSIS> (1) UPPER LEVEL
BATTERY
Inspect the battery fluid level.
When the fluid level nears the lower level, remove
the battery and refill with distilled water to the
upper level.
NOTE
Add only distilled water. Tap water will
shorted the service life of the battery.
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 electrolyte gets in your eyes. (2) LOWER LEVEL
Replace the battery, if sulfation forms or sedi (1) UPPER LEVEL

ments accumulate on the bottom.
FRONT BRAKE
FLUID LEVEL
Check front brak fluid reservoir level.
If the level nears the lower level mark, fill the
reservoir with SAE J1703 or DOT-3 BRAKE
FLUID to the upper level mark.
Check the entire system for leaks, if the level is
low.
CATUION
" Do not remove the cover until the hand
leber has been turned so that the reservoir
is level. · (2) LOWER LEVEL
" Avoid operating the brake lever with the
cap removed. Brake fluid will squirt out if
the lever is pulled.
(1) BRAKE DISC
PAD WEAR
Check the brake pads for wear.
Replace the brake pads if the wear line on the top
of the pads reaches the edge of the brake disc (Refer
to Section 12).
CATUION
Always replace the brake pads in pairs to
assure even disc pressure.
3-9
�HONDA
INSPECTION AND ADJUSTMENT � MBXSO· MBX80
REAR BRAKE (1) ADJUSTING NUT
REAR BRAKE PEDAL PLAY

Measure the brake pedal free play.
FREE PLAY: 20-30 mm (3/4-1-1/4 in)
If adjustment is necessary, turn the rear brake

adjusting nut.
(1) ARROW MARK

BRAKE SHOE INSPECTION
Replace the brake shoes if the arrow on the brake
arm aligns with the reference marl< "/',!' on full
application of the rear brake (Page 13-6).
(2) REFERENCE MARK
(1) ADJUSTING NUT

Adjust the brake I ight switch so that the brake I ight
will light when the brake pedal is depressed and the
brake begins engagement.
NOTE
* Do not turn the switch body.
€>The fron brake light switch does not
require adjustment.
Adjust by turning the switch adjusting nut as

shown.
(2) REAR BRAKE LIGHT SWITCH
3-10
�HONDA
� MBX50· MBXSO INSPECTION AND ADJUSTMENT
DRIVE CHAIN
INSPECTION
Shift the transmission into neutral.
Measure the drive chain slack between the sprock

ets.
CHAIN SLACK: 10-20 mm (3/8-3/4 in)
(1 )ADJUSTING NUT (2) GRADUATED SCALE (3) INDEX MARK

ADJUSTMENT
To adjust the drive chain tension, loosen the rear
axle nut.
Tighten both adjusting nuts.
Be sure that the index mark aligns with the

same graduation on the scale on both sides.
(4) CHAIN ADJUSTER (5) A)(LE NUT
Tighten the rear axle nut.

TORQUE: 55-70 N.m (5.5-7.0 kg-m,
40-51 ft-lb)
Retighten both adjusting nuts.
Check the rear brake pedal after the drive

chain tension has been adjusted.
3-11
INSPECTION AND ADJUSTMENT
(1) RETAINING CLIP

CLEANING/LUBRICATION
If the drive chain is excessively dirty, it should be
removed and cleaned prior to lubrication.
Remove the master link retaining clip with pliers.
NOTE
Do not bend or twist the clip.
Remove the master link and drive chain.

Clean the drive chain with non-flammable or high
flash point solvent and brush and allow to dry.
Inspect the drive ch�in for possible wear or damge. �
Replace any chain that is damaged or excessively (2) ROTATING
worn. DIRECTION
Inspect the sprocket teeth for excessive wear or
damage. Replace if necessary.
CAUTION
Never install a new drive chain on worn
sprockets or i:t worn chain on new sprockets.
Both chain and sprockets must be in good
condition, or the new replacement chain or
sprockets will wear rapidly.
NOTE
Commercial aerosol type drive chain lubri
cants are recommended.
Lubricate the drive chain, saturating each chain link

joint.
Install the drive chain and master link.
Install the master link retaining clip so that the
closed end faces the direction of forward wheel
rotation.
Master links are reusable if they remain in excellent
condition, but it is recommended that a new master
link be installed whenever the drive chain is re
assembled.
Adjust the drive chain, and check rear brake adjust
ment.

INSPECTION AND ADJUSTMENT
NOTE
Tire pressure should be checked when tires
are COLD.
Check the tires for cuts, imbedded nails, or other

sharp objects.
RECOMMENDED TIRE PRESSURE AND TIRE

SIZE:
Cold tire pressure kPa(kg/cm 2,psi)
Up to 90kg Up to capacity
Tire size
(1981b) load
MBX50 Front 2.50-18-4PR 175(1.75,25) 175(1.75,25)
Rear 2.75-18-6PR 175(1.75,25) 280(2.8,40)
MBXBO Front 2.75-18-4PR 200(2.0,28) 200(2.0,28)
Rear 3.00-18-6PR 200(2.0,28) 280(2.8,40)
Check the front and rear wheels for trueness.
Measure the tread depth at the center of the tires.

Replace the tires if the tread depth reaches the
folowing limit.
Minimum tread depth:

Front: 0.8 mm (1/32 in)
Rear: 0.8 mm (1/32 in)
(2) MUFFLER
Check that all chassis nuts and bolts are tightened
to correct torque values.
Check all cotter pins and safety clips. (3) DIFFUSER PIPE
Remove the muffler (Page 5-3). DIFFUSER PIPE

Remove the diffuser pipe attaching screw.
Remove the diffuser pipe from the muffler.
Clean the diffuser pipe with a bristle wire brush.

Remove carbon from inside the muffler.
CAUTION
Do not heat or clean with solvent in an at
tempt to remove, carbon from the muffer.
Install the diffuser pipe and screw.

�HONDA
� MBXSO, MBXSO
( 1) Align with frame pipe.
4-0
�HONDA
�.MBX50, MBXSO FUEL SYSTEM
SERVICE INFORMATION 4-2 FLOAT LEVEL ADJUSTMENT 4-7

TROUBLESHOOTING 4-2 THROTTLE VALVE/CABLE 4-8
INSTALLATION
CARBURETOR REMOVAL 4-3
CARBURETOR INSTALLATION 4-9
THROTTLE VALVE DISASSEMBLY 4-4
FUEL TANK 4-9
FLOAT/FLOAT VALVE/JET 4-5
DISASSEMBLY AIR CLEANER 4-10
J ETS/FLOAT VALVE/FLOAT 4-6
ASSEMBLY
4-1
i-UEL SYSTEM
o Use caution when working with gasoline. Always work in a well-ventilated area and away from sparks or flames.
0 The float bowl has a drain plug that can be loosened to drain residual fuel.
0 When disassembling fuel system parts, note the locations of the 0-rings. Replace them during assembly.
TOOL
Common
Float Level Gauge 07401-0010000
MBX50 I MBX80 I
-
SPECIFICATIONS
SW,B,SA(Free) SW,B(Limited) E G F E
Venturi dia. � 13mm(0.51in) 1 8mm(O.71 in)
16mm(0.63in) <----
Setting mark
-
PF16A PF16E PF06D PF26D PF26F PF26G
Main jet
- -
#125 #60 #130 #90 #140
Main air jet
- -
#210 #210 #210 <------
Jet needle
-
- - - -
37V-2nd groove 37 F-2 nd groove 37Y-2nd groove
Slow jet
-
#45 #42 #40
Float level
- -- - -
Air screw opening 13.5mm(0.53in)
�
- - -
Idle speed 1 -1 /2turns out 1 · 1 '4turns out 1turn out
Throttle grip free play 1,400min-1(rpm)
-·
<------
2-6mm[t .'8-1 /4in)
Engine cranks but won't start Lean mi)(ture

1. No fuel in tank 1. Carburetor fuel jets clogged
2. No fuel to carburetor 2. Fuel cap vent clogged or blocked
3. Too juch fuel getting to cylinder 3. Fuel filter clogged
4. No spark at plug (ignition malfunction) 4. Fuel line kinked or restricted
5. Air cleaner clogged 5. Float valve faulty
6. Float level too low
Engine Idles roughly, staiis, or runs poorly 7. Air vent tube clogged
1. Idle speed incorrect
2. lgniton malfunction Rich mi)(turn
3. Low compression 1. Choke stuck closed
4. Rich mi)(ture 2. Faulty float valve
5. lean mixture 3. Float level too high
6. Air cleaner clogged 4. Carburetor air jets clogged
7. Air leaking into inlet pipe
8. Fuel contaminated

HONDA
MBX50 ° Ml!UU&O FUEL SYSTEM
(1) FUEL VALVE
Clean the carburetor and its surrounding area

thoroughly.
Turn the fuel valve to OFF and drain fuel from the
tank through the drain tube.
Disconnect the fuel line.

Disconnect the drain tube.
(2) FUEL TUBE
(1) TUBE BAND

Loosen the tube band.
Remove the nuts attaching the carburetor to the
engine inlet pipe.
(2) DRAIN TUBE

(1) AIR VENT TUBE
Disconnect the air vent tube.
Remove the carburetor from the engine.
NOTE
Keep dust and dirt from entering the carbu
retor and cylinder.
----------------- -------------'

HONDA
FUEL SYSTEM MBX50,MBX80
THROTTLE VALVE DISASSEMBLY (1) CARBURETOR TOP
Remove the carburetor top and pull out the throttle

valve.
(1) THROTTLE VALVE

Disconnect the throttle cable from the throttle
valve.
(1) SEALING CAP

Remove the return spring, carburetor top and
sealing cap.
(2) CARBURETOR TOP (3) RETURN SPRING
4-4
�HONDA
� MBXSO· MBX80 FUEL SYSTEM
Pry off the cable clip and remove the jet needle.
Check the jet needle and throttle valve for wear to

damage.
�(1) CABLECLIP
NEEDLE CLIP
Standard position: 2nd groove
(3) JET NEEDLE
(4), THROTTLE
VALVE
(1) FLOAT PIN

FLOAT/FLOAT VALVE/JET
DISASSEMBLY
Remove the float chamber and pull the float pin off
the chamber.
CAUTION
Remove the float pin in the arrow direction.
Remove the carburetor float and float valve.
FLOAT/FLOAT VALVE INSPECTION

(2) VALVE SEAT
Check the valve seat for wear or damage. CONTACTING FACE
Check the float for deformation or presence of fuel.
(1) FLOAT
4 .. 5
�HONDA
FUEL SYSTEM � MBXSO· M!SX80
Remove the main jet, needle jet holder and needle

(1) STOP SCREW �(2) MAIN JET
jet.
I '
r��4frr..
Remove the stop screw and air screw.
l-(3) NEEDLE JET HOLDER
NOTE
Before removing either screw, record the num '� �� (4) NEEDLE JET
�
ber of turns until the screw lightly rests 0�
(bottoms). This allows the screw to be rest to

l its original position. :ff _>)--15) BODY
\\�
(6) AIRSCREW Jj
Remove the choke (starter) valve. '� ... fl
(7) CHOKE (STARTER VALVE)�
- �
Blow open all jets and body openings with corn·

pressed air.
CAUTiON
Never use compressed air to clean the body
when the float assembly is installed. This
could damage the floats.
(1) THREADS
Check each part for wear or damage.
Inspect the choke (starter) valve.
The knob should be held securely when pulled out

fully.
(2) !<NOB

�HONDA
� MBX50· MBX80 FUEL SYSTEM
JETS/FLOAT VAlV[/flOAT ASSEMBLY (1) SLOW JET (2) MAIN JET
Install the needle jet, needle jet holder and main jet.
Install the air and stop screws by turning them into
their original positions.
(3) STOP SCREW (4) AIR SCREW
(1) FLOAT PIN (2) FLOAT VALVE (3) FLOAT

Install the choke (starter) valve.
Install the float valve, float and float pin.
CAUTION
I Insert the float pin in the arrow direction.
Check the float for operation. Install the float
chamber.
(4) CHOKE
(STARTER VALVE)
FLOAT lEVEl ADJUSTMENT (1) FLOAT GAUGE
Measure the float level with the float tip just con
tacting the float valve.
FLOAT LEVEL: 13.5 mm (0.53 in) ±1.0 mm
Replace the float assembly if not within specifica

tion.
4-7
�HONDA
FUEL SYSTEM � MBXSO· MBXSO
THROTTLE VALVE/CABLE (5) SEALING CAP

INSTALLATION
Install the jet needle on the throttle valve and secure (1) CABLE
with the cable clip. CLIP
Install the sealing cap, carburetor top and return (4) NEEDL
spring. (2) JET CLIP
NEEDLE
Standard
position:
2nd groove
(3)
THROTTLE
VALVE
(6) RETURN
SPRING
(1) THROTTLE CABLE
Connect the throttle cable to the throttle valve.
(1) GROOVE (2) CARBURETOR TOP

Slide the throttle valve into the carburetor body.
NOTE
Align the groove in the valve with guide
pin on the carburetor body.
Tighten the carburetor top.
CAUTION
Hand-tighten the carburetor top. Do not use
tools to forcefully tighten the top. This could
cause distortion and malfunction.
(3) THROTTLE VALVE GUIDE PIN
4-8
W\HONDA
� MBX50· MBXSO FUEL SYSTEM
CARBURETOR l�STAHATiON
Carburetor installation is essentially the reverse
order of removal.
Perform the following after installing the carbu
retor:
Carburetor adjustment (page 3-5).
Oil pump control cable adjustment (page 3-5).
(1) FUEL TANK

MOUNTING BOLT
Do not allow flames or sparks near gasoline.

Wipe up spilled gasoline at once.
REMOVAL
Remove the right and left side covers.
Remove the fuel tank mounting bolt.
Turn the fuel cock to OFF and disconnect the fuel
line.
Remove the fuel tank.
INSPECTI.ON
Check the vent hole of the filler cap for blockage.
FUEL STRAINER
(1) FUEL STRAINER �

Keep gasoline away from flames or sparks. SCREEN �
Wipe up spilled gasoline at once.
®
Check that fuel is flowing out of the fuel valve
freely.
If fuel flow is restricted, clean the fuel strainer. (2) LOCK NUT
4(l,
NOTE
(3) FUEL VALVE
Do not overtighten the fuel valve Jock nut.
(4) FUEL UBE
\
Make sure there are no fuel leaks
Q�
4.;.9
�HONDA
FUEL SYSTEM � MBX50·MBXS0
AIR CLEANER
AIR CLEANER CASE REMOVAL
Remove the seat and fuel tank.
Loosen the air cleaner tube band.
Remove the bolts tightening the battery holder
and radiator reserve tank.
(1) BOLTS
(1) BOLTS
Remove the bolts attaching the air cleaner case and
case.
NOTE
Do not attempt to remove the air inlet tube
from the case.
AIR CLEANER CASE INSTALLATION

Clean the air cleaner element (Page 3-3).
Install the air cleaner case in the reverse order of
removal.
NOTE
• Apply adhessive (Cemedain No. 540 or its
equivalent to the air cleaner tubes if they
are disconnected. (2) AIR CLEANER CASE
• Align the air inlet tube with the frame tube
when installing the air cleaner case.
( 1) (2) RETAINER
(5) Apply adhessive.
(5) Apply adhessive.
(6) Al R CLEANER TUBE
4-10
:g:�t:o ENGINE REMOVAL/INSTALLATION 5.
(1) DRIVE CHAIN MASTER

LINI<
, (2) RETAII\IING CLIP

Note the installation

(;it/\ HONDA
ENGINE REMOVAL/INSTALLATION � MBX50· MBX80

ENGINE REMOVAL 5-3
ENGINE INSTALLATION 5-7
5-1
{:;jj\ HONDA
� MBX50· MBXSO ENGINE REMOVAL/INSTALLATION
SERVICE INFORMATION
GENERAL INSTRUCTION
The following parts or components can be serviced with the engine installed in the frame:
• Clutch • Alternator
• Gearshift linkage • Carburetor
, Kickstarter • Coo}ing system
SPECIFICATIONS
Engine dry weight MBX50: Approximately 17.5 kg (38.6 lb)
MBX80: Approximately 18.9 kg (41.7 lb)
Transmission oil capacity 0.9 lit. (1.0 US qt, 0.8 Imp qt) at engine assembly
0.8 lit. (0.8 US qt, 0.7 Imp qt) at change
5-2
�HONDA
ENGINE REMOVAL/INSTALLATION � MBXSO, MBXSO
ENGINE REMOVAL (1) EXHAUST PIPE FLANGE NUTS
On the Deluxe model, remove the under cowl (Page

14-3)
Drain the transmission oil (Page 2-3).
Remove the two exhaus� pipe flange nuts.
(1) MUFFLER
Remove the muffler mounting nut and remove the
muffler.
(1) FUEL TANK MOUNTING BOLT

Remove the seat and both side covers.
Turn the fuel valve OFF and disconnect the fuel
tube at the fuel valve.
Remove the fuel tank mounting bolt and tank.
5-3
�HONDA
� MBX50· MBX80 ENGINE REMOVAL/INSTALLATION
Remove the radiator cap.
it21i/&i;i;j�ji(fij��
�-----,
Remove the drain bolt and drain the coolant.
(2) DRAIN BOLT

(1) SPARK PLUG CAP (2) RADIATOR HOSE
Disconnect the radiator hose at the cylinder head.
Remove the radiator (Page 10-4).
Remove the spark plug cap.
Disconnect the temperature sensor wire connector.
(3) TEMPERATURES SENSOR CONNECTOR

(1) OIL PUMP CONTROL CABLE
Disconnect the oil pump control cable.
Disconnect the oil tube at the oil pump (Page 2-4).

�HONDA
ENGINE REMOVAL/INSTALLATION � MBXSO, MBX80
(1) ALTERNATOR/NEUTRAL SWITCH WIRE CONNECTORS

Disconnect the alternator and neutral switch wire
connectors.
(1) AIR CLEANER TUBE BAND

Loosen the air" cleaner tube band.
Remove the two carburetor mounting nuts, carbure
tor and insulator.
(2) CARBURETOR INSULATOR

(1) LEFT CRANKCASE COVER
Remove the four bolts attaching the left crankcase
cover and cover.
5 ... 5
{;iJ\ HONDA.
� MBX50· MBXSO ENGINE REMOVAL/INSTALLATION
(1) MASTER LINK (2) RETAINING CLIP

Loosen the drive chain adjusting nuts and rear axle
nut.
Move the rear wheel forward, carefully remove the
drive chain master link retaining clip and remove
the drive chain.
(1) GEARSHIFT PEDAL

Remove the gearshift pedal pinch bolt and gearshift
pedal.
(1) CLUTCH CABLE (2) TACHOMETER CABLE

Disconnect the clutch and techometer cables.
5 .. 5
�HONDA
ENGINE REMOVAL/INSTALLATION � MBXSO· MBXSO
Place a jack under the engine.

Remove the engine mounting bolts and remove the
engine.
ENGINE INSTALLATION (1) SPACER
Install the engine in the reverse order of removal.
NOTE
e Fill the transmission with the recommend
ed oil (Page 2-3).
• Fill the cooling system with the recom
mended coolant (Page 10-3).
0 Check the locations of the cables and pipes
(Page 1-7).
e Bleed air from the oil pump (Page 2-7).
• Adjust the oil pump control cable (Page
3-5).
• Adjust the clutch lever free play (Page
3-7).
o Install the drive chain master link properly
(Page 3-12).
• Adjust the drive chain tension (Page 3-11). (2) ENGINE MOUNTING BOLTS
REAR AXLE NUT TORQUE:

55-65 N.m (5.5-6.5 kg-m, 40-48 ft-lb)
5-7
'
HONDA
MBX50·MBX80
CYLINDER HEAD/CYLINDER/
PISTON
6.
8-12 N.m (0.8-1.2 kg-m,
I
6-9 ft-lb)
6-0
�HONDA
CYLINDER HEAD/CYLINDER/PISTON � MBX50· MBXSO

TROUBLESHOOTING 6-2
CYLINDER HEAD 6-3
CYLINDE A/PISTON 6-5
REED VALVE 6-10
6-1
�HONDA
� MBX50,MBX80 CYLINDER HEAD /CYLINDER/PISTON
SERVICE INFORMATION
e All cylinder head maintenance and inspection can be accomplished with the engine installed.
8 Before disassembling the engine, clean the engine thoroughly to prevent dirt and dust to fall into the cylinder and crank-
case.
@ Remove all traces of gasket material from the mating surfaces of the cylinder head, cylinder and crankcase.
e Use caution when servicing the cylinder and piston to prevent damage to them.
111 Before assembling, apply clean engine oil to all sliding surfaces of parts.
TORQUE VALUE
Cylinder head nut 18-22 N.m (1.8-2.2 kg-m, 13-16 ft-lb)
Intake pipe bolt 8-12 N.m (0.8-1.2 kg-m, 6-9 ft-lb)
SPECIFICATIONS
ITEM STANDARD mm (in) SERVICE LIMIT mm (in)
Cylinder head warpage 0.10 (0.004)
Cylinder bore MBX50 38.998-39.013 mm
(1.5354-1.5359 in) 39.062 mm ( 1.5379 in)
MBX80 49.407-49.523 mm
(1.9452-1.9497 in) 49.572 mm (1.9516 in)
Piston 0.0. (10 mm (3/8 in) MBX50 38.955-38.970 mm
from piston skart) (1.5337-1.5343 in) 38.920 mm (1.5323 in)
MBX80 49.455-49.470 mm
(1.9470-1.9476 in) 49.420 mm (1.9457 in)
Cylinder-to-piston 0.035-0.050 mm
clearance (0.0014-0.0020 in) 0.090 mm (0.0035 in)
Piston pin bore 12.002-12.008 (0.4725-0.4 728) 12.030 (0.4736)
Piston pin 0.0. 11.994-12.000 (0.4722-0.4724) 11.980 (0.4717)
Piston-to-piston pin clearance 0.002-0.014 (0.0001-0.0006) 0.040 (0.0016)
Piston ring end gap (top/second) 0.10-0.25 (0.004-0.010) 0.35 (0.014)
Connecting rod small end 1.0. 17.005-17.017 (0.6695-0.6700) 17.030 (0.6705)
Compression too low, hard starting or poor Abnormal noise-piston

performance at low speed 1. Worn cylinder and piston
1. Blown cylinder head gasket 2. Worn piston pin or piston pin hole
2. Loose spark plug 3. Worn connecting rod small end bearing
3. Worn, stuck or broken piston rings
4. Worn or dmaged cylinder and piston Abnormal noise-piston rings
5. Faulty reed valve 1. Worn, stuck or broken piston
rings
Compression too high, overheating or knocking 2. Worn or damaged cylinder
1. Excessive carbon build up in cylinder head or on
piston top
6-2
�HONDA
CYLINDER HEAD/CYLINDER/PISTON � Ml!lXSO, MBXSO
(1) RADIATOR CAP
REMOVAL
(Page 5-3).
Remove the seat, both side covers and fuef. tank.

Remove the coolant drain bolt and drain the
coolant.
(2) DRAIN BOLT

(1) HIGH TENSION CORD (2) RADIATOR HOSE
Disconnect the radiator hose from the cylinder
head.
Remove the spark plug cap.
Disconnect the temperature sensor wire connector.
(3) TEMPERATURE SENSOR WIRE

(1) NUTS
Remove the four flange nuts attaching the cylinder
head to the cylinder.
6-3
W\HONDA
� MBX50· MBX80 CYLINDER HEAD/CYLINDER/PISTON
INSPECTION
Check the cylinder head for warpage with a straight
edge and freeler gauge in the directions shown.
SERVICE LIMIT: 0.10 mm (0.004 in)
DE CAR BONIZING
Remove the carbon deposits from the combustion
chamber.
Clean the head gasket surface of any gasket mate

rial.
NOTE
Avoid damaging the gasket surfaces.
INSTALLATION
Install the cylinder head using a new cylinder head
gasket.
Install the four flange nuts and tighten to the
specified torque in the sequence shown.
TORQUE: 18-22 N.m (1.8-2.2 kg-m,
13-16 ft-lb)
Fill the cooling system with the recommended

coolant (Page 10-3).
6-4
�HONDA
CYLINDER HEAD/CYLINDER/PISTON � MBXSO· MBXSO
CYLINDER/PISTON
CYLINDER REMOVAL
Remove the exhaust pipe (Page 5 - 3 ).
Remove the cylinder head (Page 6-3).
MUFFLER
(1) INTAl<E PIPE (2) OIL PUMP
Remove the carburetor (Page 4-3).
Remove the four flange bolts attaching the intake
pipe to the cylinder and remove the intake pipe.
NOTE
Do not remove the oil pass tube or locate the
end of the tube lower than the oil pump.
Bleed air from the oil pass tube when' it has
been disconnected or the end has been located
lower than the oil pump.
(3) 01 L PASS TUBE
Remove the radiator (Page 10-4).

Disconnect the radiator hose from the cylinder.
Remove the cylinder.
CAUTION
Do not pry strike the cylinder or cooling
fins.
Place a clean shop towel into the crankcase to keep

debris from falling in.
(1) RAD1ATOR HOSE
6-5
�HONDA
(1) PISTON
PISTON REMOVAL
Remove the piston pin clip using a pair of Jong-nose
pliers.
Press the piston pin free of the piston.
NOTE
Do not damage or scratch the piston.
(!)
"' Do not apply force in the piston pin direc

tion.
'° Do not let the clip fall into the crankcase.
Do not re-use the piston pin clips.
<!)
(2) PISTON PIN CLIP
PISTON RING/EXPANDER REMOVAL

(3) TOP RING
Spread each piston ring and remove by lifting it up (2) SECOND RING
at a point just opposite the gap.
Remove the expander.
CYLINDER/PISTON INSPECTION
Check the cylinder and piston for wear or damage.
Clean carbon deposits from the exhaust port area.
CAUTION
Do not damage the cylinder.

{:;;ijj\ HONDA
CYLINDER HEAD/CYLINDER/PISTON � MBX50· MBXSO
Inspect the cylinder bores for wear at three levels

in X and Y directions. Take the minimum figure
measured to determine the cylinder wear. Avoid the
port area.
SERVICE LIMIT:
MBX50 39.062 mm (1.5379 in)
MBX80 49.572 mm (1.9516 in)
y
Measure the 0.D. of the piston at a point 10 mm

(3/8 in) from the end of the skirt.
SERVICE LIMIT:
MBX50 38.920 mm (1.5323 in)
MBX80 · 49.420 mm (1.9457 in)
Calculated the piston-to-cylinder clearance.

Measure the 1.0. of the piston pin bore.

SERVICE LIMIT: 12.030 mm (0.4736 in) (1) PISTON PIN BORE 1.D.
Measure the 0.0. of the piston pin.

(2) PISTON PIN 0.0.
Calculate the piston pin-to-piston clearance.
SERVICE UMIT: 0.040 mm (0.0016 in)
6-7
�HONDA
� M!BXSO, MBXSO CYLINDER HEAD/CYLINDER/PISTON
(1) PISTON RING

PISTON RING INSPECTION
Set each piston ring squarely into the cylinder
from the bottom using the piston and measure the
end gap.
SERVICE UM!TS:
TOP: 0.35 mm (0.014 in)
SECOND: 0.35 mm (0.014 in)
Install the expander in the second groove of the

piston. Install the top and second rings (Page
6-9). (1) PISTON
NOTE
Press each piston ring into place at several
points to make sure that it is flush with the
piston surface.
If not, clean carbon deposits from the ring
groove. They should be free engough to be
rotated in the ring lands.
(3) SECOND RING

(4) EXPANDER
CONNECTING ROD INSPECTION

Install the bearing and piston pin in the connecting
rod small end and check for excessive play.
Measure the connecting rod small end I.D.

SERVICE LIMIT: 17.030 mm ( 0.6705 in)
(1) PLAY (2) I.D.
6-8
�HONDA
CYLINDER HEAD/CYLINDER/PISTON � MBX50· MBX80
PISTON/CYLINDER INSTALLATION
Install the expander and piston rings.
NOTE
e Install the rings with the marking facing
up.
"' The top and second rings are interchange
able with each other.
• Do not mix different brands of rings in an
engine. Do not replace one without replac
ing another.
(4) PISTON RING MAF.IK
Install the connecting rod small end bearing, piston

and piston pin.
NOTE (1) IN MARK

• Install the piston with the "IN" marking
facing the inlet side.
e Dip the small end bearing and piston pin in
clean oil before installation.
--(2) RAG
Install new piston pin clips.
NOTE
Do not let the clip fall into the crankcase.
(1) DOWEL PINS

Align each ring end gap with the dowel pin in the
ring land.
6-9
�HONDA
Place the cylinder gasket on the crankcase.
Lubricate the piston with engine oil and install the

cylinder over the piston while compressing the
piston rings.
NOTE
/ Do not damage the piston.
(1) CYLINDER GASKET
Install the cylinder head and new cylinder head

gasket (Page 6-4).
Install thereed valve and intake pipe.
Install the e)(haust muffler.
Install thecarburetor (Page 4-9).
Install the radiator (Page 10-5).

Perform the following inspections and operation:
Cylinder compression (Page 3-7); compression leaks.

Engine noise.
Secondary air leaks.
Air bleeding from oil pass tube (Page 2-7).
(1) INTAKE PIPE
REMOVAL
Remove the craburetor (Page 4-9).
Remove the intake pipe (Page 6-5).
NOTE
Do not remove the oil pass tube or locate the
end of the tube lower than the oil pump.
Bleed air from the oil pass tube when it has
been disconnected or the end has been located
lower than the oil pump.
(2) OIL PASS TUBE

�HONDA
. CYLINDER HEAD/CYLINDER/PISTON � MBX50· MBX80
(1) REED VALVE
Remove the reed valve.
(1) REED STOPPERS (2) REEDS

INSPECTION
Check the reeds for damage of fatigue and replace if
necessary. Replace the valve with a new one if the
seat rubber is cracked or damaged, or if there is
clearance between the reed and seat.
CAUTION
Do not disassemble or bend the reed stopper
as this may cause improper engine perfor
mance. The reed valve must not be disas
sembled. If the �tapper, reed or seat is defec
tive, replace all as a unit..
(3) REED VALVE SEAT

(1) CARBURETOR INSULATOR
INSTALLATION
Installation of the reed valve is essentially the
reverse order of removal.
CAUTION
I Bleed air from the oil pass tube (Page 2-7).
After installation, check for secondary air leaks.
6-11
CLUTCH/KICKSTARTER/
�HONDA
� MBX50· MBX80 GEARSHIFT LINKAGE J
(3) Align the balancer timing when
installing the clutch outer.
(2) Thickness.: 0.5 mm)

(0.02 in)
( 1) Thickness: 1.0 mm
(0.04 in)
Three plates and

four discs
(5) App ly
!
(4) WATER PUMP SHAFT
locking
agent.
45-55 N.m (4.5-5.5 kg-m, 33-40 ft-lb)
(5) Appl y
locking
agent.
7-0
�HONDA
CLUTCH/KICKSTARTER/GEARSHI FT LINKAGE � MBX50, MBX80
S ERVICE INFORMATION 7-2 CLUTCH INSTALLATION/ 7-10

BALANCER TIMING
TROUBLJ;SHOOTING 7-2 KICKSTARTER 7-11
RIGHT CRANKCASE COVER 7-3 SHIFT LINKAGE 7-14
CLUTCH/IDLER GEAR 7-5
7-1
HONDA
MBX50·MBX80 CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE
SERVICE INFORMATION
a All clutch and kickstarter maintenance and inspections can be accomplished with the engine installed.
e Make balancer timing adjustment when the clutch outer and primary drive gear are removed.
e Use the UNIVERSAL HOLDER to remove and install the primary drive gear.
e Remove all gasket materials from the mating faces of the cases.
m Do not allow dust and dirt to enter into the cylinder and crankcase.
• Avoid damaging or scratching the case mating surfaces.
e Before inspecting, clean all removed parts in solvent; dip the parts in clean transmission oil before installation.
TOOL
Common
Universal Holder 07725-0030000
TORQUE VALUE
Primary drive gear 45-55 N.m (4.5-5.5 kg-m, 33-40 ft-lb)
SPECIFICATIONS
ITEM STANDARD mm (in) SERVICE UMIT mm (in)
Clutch spring free length/preload 30.2/19-21 kg ( 1.19/41.9-4.3 lb) 28.5/17 kg (1.12/37.5 lb)
Clutch disc thickness 2.9-3.0 (0.114-0.118) 2.5 (0.098)
Clutch plate warpage -- 0.2 (0.008)
Clutch outer I.D. 17.000-17.018 (0.6693-0.6700) 17.060 (0.6717)
Kickstarter spindle 0.0. 11.966-11.984 (0.4711-0.4718) 11.950 (0.4704)
Kickstarter pinion 1.0. 12.016-12.034 (0.4731-0.4738) 12.070 (0.4752)
Kickstarter idle gear Contershaft 0.0. 15.000-15.018 (0.5906-0.5913) 14.940 (0.5882)
Gear I.D. 15.032-15.050 (0.5918-0.5925) 15.100 (0.5945)
Balancer idle gear shaft O.D. 9.972-9.987 (0.3926-0.3932) 9.930 (0.3909)
TROUBLESHOOTING
Clutch slips when accelerating Motorcycle creeps with clutch disengaged
1. No free play 1. Too much free play
2. Discs worn 2. Plates warped
3. Springs weak
Excessive lever pressure
Clutch operation feels rough 1. Clutch cable kinked, damaged or dirty
1. Outer drum slots rough 2. Lifter mechanism damaged
3. Clutch cable not routed properly
Abnormal engine vibration
1. Balancer out of time
7-2
�HONDA
CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE � MBX50·MBX80
RIGHT CRANKCASE COVER (1) CLUTCH CABLE (2) TACHOMETER CABLE
REMOVAL
(Page 14-3).
Drain the coolant (Page 10-3).
Drain oil from the transmission.

Remove the kickstarter pedal.
Disconnect the clutch cable from the clutch arm.
Disconnect the tachometer cable.
Disconnect the repiator hoses at the right crankcase
cover.
KICKSTARTER PEDAL (4) HOSES
Remove the ·bolts attaching the right crankcase

cover, and remove the right crankcase cover.
(1) RIGHT CRANKCASE COVER
(1) CLUTCH ARM

DISASSEMBLY
Remove the clutch lifter rod, then remove the
clutch arm.
Check the 0-ring for damage, fatigue or other
faults. Check the clutch arm for bending.
(3) CLUTCH LIFTER (2) 0-RING

ROD
7-3
�HONDA.
� MBXSO· MBXSO CLUTCH/KICKSTARTER/Gl;8RSHI FT LINKAGE
Remove the tachometer gear.
NOTE � (1) OIL SEA L

j Do not forget to install the washer. @ (2) WASHERS
(3) TACHOMETER
GEAR
INSTALLATION
(1) CLUTCH ARM
Install the clutch arm and clutch lifter rod.
Instal I the tachometer gear on the right crankcase
cover. �(2) TACHOMETER
GEAR
(1) GASKET
Install the dowel pins and gasket on the cr.ankcase.
(2) DOWEL PINS
7 ... 4
�HONDA
CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE � MBX50· MBXSO
Install the right crankcase cover on the crankcase.

Install the clutch cable bracket and tighten with the
flange bolt.
NOTE
Tighten the bolts in a crisscross pattern and in
two or three steps.
Install the kickstarter pedal.
(1) KICKSTARTER PEDAL (2) RIGHT CRANKCASE COVER

(1) CLUTCH CABLE (2) TACHOMETER CABLE
Connect the tachometer and clutch cables.
Connect the radiator hoses to the water pump.
Fill the transmission with recommended oil (Page
2-3).
Fill the cooling system with recommended cciolant
(Page 10-3).
Adjust the clutch lever free play (Page 3-7).
(3) RADIATOR HOSES
CLUTCH/IDLER GEAR (1) CLUTCH SPRINGS
CLUTCH REMOVAL
Remove the right crankcase cover (Page 7-3).
Remove the clutch lifter plate and clutch springs
by removing the bolts.
(2) LIFTER PLATE
7 ... 5
�HONDA
� MBX50· MBX80 CLUTCH/KICKSTARTER/GEARSHI FT LINKAGE
Remove the circlip. (1) CLUTCH DISCS

Remove the clutch center, clutch discs, clutch (2) PRESSURE (3) CLUTCH
(MBX80: 4 discs)
plates, and clutch pressure plate. PLATE OUTER
Remove the spline washer and remove the clutch
outer.
(7) SPLINE
(6) CLUTCH PLATES
CENTER (MBX80: 3 plates) WASHER
CLUTCH SPRING INSPECTION

Measure each clutch spring free length.
SERVICE LIMIT: 28.5 m_m (1.12 in)
CLUTCH DISC INSPECTION

Replace the clutch discs if they show signs of scor
ing or discoloration.
Measure each clutch disc thickness.

7-6
�HONDA
CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE � MBXSO· MBX80
CLUTCH PLATE INSPECTION
Check for plate warpage on a surface plate, using
a feeler gauge.
CLUTCH OUTER INSPECTION

Check the slots in the outer drum for nicks, cuts or
indentations made by the friction discs.
Measure the clutch outer 1.0.

BALANCER IDLER GEAR/OIL PUMP

DRIVEN GEAR REMOVAL
Remove the clutch, then remove the balncer idler
gear and oil pump driven gear.
7-7
�HONDA
� MBXSO· MBX80 CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE
(1) PRIMARY DRIVE GEAR

PRIMARY DRIVE GEAR REMOVAL
Remove the left crankcase cover.
Hold the flyweel with the UNIVERSAL HOLDER

and remove the 12 mm nut, drive gear, and collar.
NOTE
Use the UNIVERSAL HOLDER to prevent
the crankshaft from being turned during oper
ation.
(2) UNIVERSAL HOLDER (3) NUT
BALANCER IDLER GEAR INSPECTION

Check the balancer idler gear for wear or damage.
Check the idler gear shaft for bending, wear or

damage.
Measure the balancer idler gear shaft O.D. at two

places as shown.
Check the oil pump driven gear for wear or damage.
Check the oil pump driven gear shaft for cracks or

other defects.
Replace the shaft and gear with new ones if cracked.
7-8
�HONDA
CLUTCH/ KICKSTARTER/GEARSHIFT LINKAGE � MBXSO· MBX80
(1) SLOT (2) OIL PUMP DRIVE SHAFT

OIL PUMP DRIVEN GEAR INSTALLA
TION
Install the oil pump driven gear aligning the slot in
the gear with the pin on the drive shaft.
(3) 01 L PUMP DRIVEN GEAR
(1) BALANCER IDLER GEAR (2) SUB GEAR

BALANCER IDLER GEAR INSTALLA
TION
Install the balancer idle gear in the crankcase.
CAUTION
Install the idler gear while rotating the gear
by hand until the sub gear engages the bal
ancer gear.
(3) BALANCER GEAR
(1) PRIMARY DRIVE GEAR

PRIMARY DRIVE GEAR INSTALLATION
Install the collar on the crankshaft, then install the
primary drive gear.
NOTE
Align the punch mark on the end of the
crankshaft with the punch mark on the gear.
InstalI the washer and 12 mm nut on the end of the

crankshaft. Hord the flywheel with the UNIVER
SAL HOLDER and tighten the 12 mm nut to the
specified otrque.
TORQUE: 45-55 N.m (4.5-5.5 kg-m,
33-40 ft-lb)
(2) NUT
7 ... 9
�HONDA
� MBX50· MBX80 CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE
BALANCER TIMING/ ( 1) (2) INDEX MARK

CLUTCH INSTALLATION BALANCER IDLER
GEAR
( 1) Align the punch mark on the primary drive
gear with the index mark on the crankcase.
(4) INDEX
(2) Align the line on the balancer gear with the MARK
index mark on the crankcase.
PUNCH
MARK
(6) PRIMARY
DRIVE GEAR
(1) CLUTCH OUTER

CAUTION
Make sure that the aligning line on the balanc
er gear is in line with the mating line on the
shaft.
! nstall the clutch outer without disturbing the

setups in steps (1) and (2).
Rotate the clutch outer right or left until the gear

engages the sub gear, then push it in the crankcase.
(1) SUB GEAR (2) BALANCER IDLER GEAR

Make sure that the sub gear engages the clutch outer
gear properly.
(3) CLUTCH OUTER
7-10
�HONDA.
CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE � MBXSO, MBX80
Install the following parts in the clutch outer:,

Spline washer
Pressure plate
Clutch discs and clutch plates
Clutch center
Circlip
Clutch springs
Clutch lifter plate
6 mm bolts
After assembling, install the right crankcase cover

(Page 7-4).
Pour in the recommended transmission oil (Page

2-3).
(6) CLUTCH DISCS
(MBX80: 4 discs)
!
(1) 6 mm BOLT (3) CLUTCH SPRING (10) CLUTCH CENTER
(2) LIFTER PLATE (7) (9) SPLINE WASHER

(5) CLUTCH OUTER
KICKSTARTER (1) RATCHET GUIDE PLATE (2) KICK RETURN SPRING
SPINDLE REMOVAL
Remove the clutch assembly (Page 7-5).
NOTE
It is not necessary to remove the clutch to
remove the kickstarter spindle.
Remove the kick return spring from the ratchet

guide plate, then remove the kickstarter spindle.
(3) KICK STAR-VER SPINDLE
7-11
�HONDA
� MBX50· MBXSO CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE
Dissemble the kickstarter. (1) 15 mm THRUST (3) RETURN SPRING

WASHER
(4) COLLAR
(2)
(5) SPRING (6) RATCHET (7) PINION GEAR
(1) KICK STARTER IDLER GEAR

IDLER GEAR REMOVAL
Remove the two attaching bolts and remove the
ratchet guide plate.
Remove the kickstarter idler gear and 15 mm thrust

washer.
(2) RATCHET GUIDE PLATE

(1) KICK STARTER PINION GEAR
INSPECTION
Measure the kickstarter spindle O.D.
Measure the kick pinion gear I.D.

(2) KICKSTARTER SPINDLE
7-12
�HONDA
CLUTCH/Kl CKSTARTER/GEARSHI FT LINKAGE � MBXSO· MBX80
Measure the kick idler gear I.D.

Measure the countershaft 0.D.

Calculate the clearance between the gear and shaft.

SERVICE LIMITE: 0.100 mm (0.0039 in)
(1) COUNTERSHAFT
KICKSTARTER INSTALLATION
Install the 15 mm thrust washer and kickstarter
idler gear and ratchet guide plate.
(3) 15mm THRUST WASHER
Tighten the ratchet guide plate with the two bolts. (0.5mm)
Tighten to the specified torque.
TORQUE: 8-12 N.m (0.8-1.2 kg-m, 6-9 ft-lb)
CAUTION
Do not mix the 15 mm thrust washer (0.5
mm thick and kick spindle 15 mm thrust
washer (1.0 mm thick).
(4) KICKSTARTER IDLER GEAR
Install the kickstarter in the reverse order of dis

(1) 15mm THRUST WASER
assembly.
(1.0 mm)
CAUTION (2) SPRING H O LE
(3) PUNCH MARK
• Slide the ratchet over the kickstarter
spindle with the punch mark on the ratchet
aligned with the spring hole in the spindle.
• Do not confuse the 15 mm washer (1.0
mm thick) with the 0.5 mm thickness
washer.
7-13
�HONDA
� MBX50· MBX80 CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE

Install the kickstarter in the crankcase with the
drive ratchet resting against the guide plate stopper
as shown.
(2) DRIVE RATCHET

Install the kick return spring.
With the balancer properly timed, install the clutch
(Page 7-10).
Install the right crankcase cover (Page 7-4).
Check the operation of the kickstarter.
(2) KICKSTARTER RETURN SPRING
SHIFT LINKAGE (1) STOPPER ARM

,�---
MBX80
- ------,
REMOVAL
Remove the clutch (Page 7-5).
Remove the kickstarter idler gear (Page 7-11).
Remove the bolt attaching the clutch stopper arfn
and remove the stopper arm and spring.
(2) RETURN SPRING
7-14
CLUTCH/KlCKSTARTER/GEARSHIFT LINKAGE
DRUM CAIVl PLATE

Remove the bolt attaching the drum cam plate and
remove the plate and roller pins.
(2) BOLT
Remove the change pedal and withdraw the shift

spindle
INSPECTION (3) SHIFT RETURN

(1) SHIFT ARM
Perform the following operations: SPRING SPRING
/·
e Check the shift arm spring for weakness.
e Check the shift return spring for weakness. (2) SHIFT SPINDLE
e Check the stopper spring for weakness.
e Check the shift spindle for wear or bending.
(4) STOPPER
SPRING
0-
�
�
7-15
CLUTCH/KICKSTARTER/GEARSHI FT LINKAGE
INSTALLATION
Installation of the shift linkage is the reverse order
of removal.
Install the shift spindle and change pedal.

Tighten the change pedal bolt to the specified
torque.
(1) SHIFT SPINDLE (2) CHANGE PEDAL
(1) ROLLER PIN

Insert the roller pins into holes in the shift drum.
Position the drum cam plate on the pins with the
concaves in the plate with the higher pins.
Apply locking agent to the bolt threads and under
sides of the bolt and install the plate with the bolt.
Tighten the bolt to the specified torque.
(1) STOPPER ARM

Install the stopper arm and stopper spring in the
crankcase a_11d_Aighten the attaching bolt to the
specified torn_ue.
Check the operation of the shift linkage.

With the balancer properly timed, install the clutch
(Page 7-9).
(2) STOPPER (3) BOLT

SPRING
7 ... 15
�HONDA
� MBXSO, MBX80
( 1) Align the scribed 1.ine on the stator Vl!ith

the index mark on the crankcase.
(2) NEUTRAL SWITCH
oj
�
(3) WOODRUFF KEY
50-60 N.m (5.0-6.0 kg-m, 36-43 ft-lb)
8-0
�HONDA
� MBX50·MBX80
ALTERNATOR

ALTERNATOR REMOVAL 8-2
ALTERNATOR INSTALLATION 8-4
8-1
�HONDA
ALTERNATOR � MBX50· MBXSO
SERVICE INFORMATION
., The alternator can be serviced without removing it from the motorcycle. Do not remove the pulse generator from the stator
base
., For alternator inspection, refer to Section 15.
TOOLS
Common
Universal Holder 07 725-0030000
Flywheel Puller 07733-0010000
TORQUE VALUE
Alternator rotor nut 50-60 n.m (5,0-6.0 kg-m, 36-43 ft-lb)
8-2
ALTERNATOR
AUER R REMOVAL ('I) LEFT CRANKCASE COVER

(Page 14-3).
Remove the flange bolts and remove the left c rank
case cover.
(1) UNIVERSAL HOLDER

Remove the 12 mm nut attaching the flywheel.
(1) ROTOR PULLER (2) ALTERNATIOR ROTOR (FLYWHEEL)

Remove the flywheel.
NOTE
Keep the woodruff key in a parts rack so it is
not Jost.
8-3
�HONDA.
ALTERNATOR � MBXSO· MBX80
(1) CONNECTORS
Disconnect the alternator wire connectors anc;l
neutral switch wire.
(1) NEUTRAL SWITCH WIRE

Disconnect the netural switch wire from the switch.
NOTE
Do not remove the netural switch.
Oil will flow out when the switch is removed.
Remove the alternator.
CATUION
• Do not separate the pulse generator from
the stator base.
• Keep the coils in a parts rack to prevent
damaging the coil.
For alternator inspection, refer to page 15-6 and

16-4.
(2) STATOR (3) NEUTRAL SWITCH
8-4
r:;;;Jf\ HONDA
� MBX50· MBXSO ALTERNATOR
ALTERNATOR INSTALLATION (1) INDEX MARK

Install the stator.
NOTE
Install the stator with the line aligned with the
index mark on the crankcase.
(2) STATOR (3) ALIGNMENT LINE

(1) CONNECTORS
Connect the alternator and neutral switch wires.
NOTE
Secure the alternator wires to the frame. Press
down on the neutral switch terminal to install
the wire.
(4) NEUTRAL SWITCH

(1) FLYWHEEL
Install the woodruff key in the crankshaft l<eyway,
then install the flywheel on the crankshaft.
NOTE
e Check that there are no foreign materials
inside the flywheel before installation.
e Clean the taper hole in the flywheel of
burrs and other damage and repair if neces
sary.
TORQUE: 50-60 N.m

(5.0-6.0 kg-m, 36-43 ft-lb)
(2) UNIVERSAL HOLDER
8-5
�HONDA.
ALTERNATOR � MBXSO· MBX:80
After installing the flywheel, start the engine and

inspect the ignition timing (Page 3-6).
(1) LEFT CRANKCASE COVER

Install the left crankcase cover.
NOTE
<1> Make sure that the alternator and neutral
switch wires are not interfering with the
flywheel.
<1> Do not pinch the wires between the left
crankcase cover and case.
8-6
CRANKSHAFT/
�HONDA
� MBX50•MBX80
TRANSMISSION 9.
M4 t
M3
�
r2
'.@�
9-0
W\HON'DA
CRANKSHAFT/TRANSMISSION � MBX50· MBX80

TROUBLESHOOTING 9-3
CRANKCASE SEPARATION 9-4
TRANSMISSION DISASSEMBLY 9-4
CRANKSHAFT REMOVAL 9-8
CRANKSHAFT INSTALLATION 9-11
GRANSMISSION ASSEMBLY 9-12
CRANKCASE ASSEMBLY 9-13
9-1
HON'D.A
MBX50·MBX80 CRAN KS HAFT /TRANSMISSION
SERVICE INFORMATION
• This section includes transmission and crankshaft repairs which require crankcase separation.
• The following parts must be removed before disassembling the crankcase.
• Oil pump See section 2

• Cylinder head/cylinder/piston See section 6
• Clutch/kickstarter/gearshift linkage See section 7
• Alternator See section 8
TOOLS
Special
Crankshaft Assembly Tool 07965-1660100
Balancer Weight Driver 07945-1660000
Bearing Remover Set 12 mm 07936-1660000
Bearing Puller 07631-0010000 (Commercially available)
Attachment 28 x 30 mm 07746-1870100
Common
Driver A 07794-0010000
Attachment 32 x 35 mm 07746-0010100
Attachment 42 x 47 mm 07746-0010300
Attachment 52 x 55 mm 07746-0010400
Pilot 12 mm 07746-0040200
Pilot 17 mm 07746-0040400
Pilot 25 mm 07746-0040600
Driver C 07746-0030100
Attachment 25 mm 07746-0030200
SPECIFICATIONS
Shift fork I.D. 10.00-10.018 (0.3937-03944) 10.05 (0.396)
Shift fork end thickness 4.93-5.00 (0.194-0.197) 4.50 (0.177)
Shift fork shaft O.D. 9.972-9.987 (0.3926-0.3932) 9.95 (0.392)
Gasrshift drum 0.D. At 13 mm 12.934-12.984 (0.5092-0.5112) 12.85 (0.506)
At 36 mm 35.950-35.975 (1.4154-1.4163) 35.90 (1.413)
Gear I.D. M5 gear 17.016-17.034 (0.6699-0.6706) 17.10 (0.673)
M6 gear 17.016-17.034 (0.6699-0.6706) 17.10 (0.673)
C1 gear 16.516-16.534 (0.6502-0.6509) 16.60 (0.654)
C2 gear 20.020-20.041 (0.7882-0.7890) 20.10 (0.791)
C3, C4 gear 19.020-19.041 (0.7488-0.7496) 19.10 (0.752)
C2 gear bushing I.D. 17.016-17.034 (0.6699-0.6706) 17.10 (0.673)
O.D 19.995-19.984 (0.7872-0.7868) 19.90 (0.783)
Mainshaft 0.D. 16.966-16.984 (0.6680-0.6687) 16.93 (0.667)
Countershaft 0.D. At 16.5 mm 16.466-16.484 (0.6483-0.6490) 16.44 (0.647)
At 19 mm 18.959-18.980 (0.7464-0.7472) 18.93 (0.745)
At 17 mm 16.978-16.989 (0.6684-0.6689) 16.94 (0.667)
Connecting rod big end side clearance 0.15-0.55 (0.006-0.022) 0.85 (0.033)
Connecting rod big end radial play - 0.05 (0.002)
Crankshaft runout at journals - 0.10 (0.004)
9-2
�HONDA
TROUBLESHOOTING
Engine noise Hard shifting
1. Main journal bearing worn 1. Incorrect clutch adjustment
2. Crankpin bearing worn 2. Shift forks bent
3. Transmission bearing worn 3. Shift shaft bent
4. Shift spindle pawl bent or damged
Jumps out of gear 5. Shift drum cam slot damaged
1. Gear dogs worn
2. Shih fork bent
3. Shih shaft bent
4. Shift drum stopper damaged
9 .. 3
{:;;jj\ HONDA
�) MBXSO· MBX80 CRANKSHAFT/TRANSMISSION
CRANKCASE SEPARATION (1) DRIVE SPROCKET
Remove the drive sprocket.

Remove the crankcase bolts.
:1) LEFT CRANKCASE

Separate the left crankcase from the right crankcase.
CAUTION
I Do not pry between the right and left cases.
(2) RIGHT CRANKCASE
TRANSMISSION DISASSEMBLY (1) SHIFT FORK SHAFT
GEARSHIFT FORK/SHIFT DRUM

Remove the shift fork shaft from the right crank
case. Remove the shift drum and shift forks.
(2) SHIFT DRUM (3) SHIFT FORKS
9-4
W\HONDA.
CRANKSHAFT/TRANSMISSION � MBXSO· MBX80
SHIFT FORK/SHIFT FORK SHAFT/ SHIFT

DRUM INSPECTION
Check each shift fork for wear, bending or any
other faults. Measure the 1.0. and shift claw thick
ness.
SERVICE LIMITS:
Claw thickness: 4.50 mm (0.177 in)
I.D.: 10.50 mm (0.396 in)
Check the shift fork shaft for wear, damage or

bending.
Measure the O.D.

Inspect the shift drum grooves and replace the drum

if they are damged or show excessive wear.
Measure the shift drum 0.0.

SERIVCE LIMITS:
A: 12.85 mm (0.506 in)
B: 35.90 mm (1.413 in)
9-5
W\HONDA.
� MBX50· MBXSO CRANKSHAFT/TRANSMISSION
(1) MAINSHAFT (2) COUNTERSHAFT

TRANSMISSION REMOVAL
Remove the mainshaft and countershaft.
TRANSMISSION INSPECTION
Check gear dogs, dog holes and teeth for excessive
or abnormal wear, or evidence of insufficient lubri
cation. (1) COUNTERSHAFT
C3
(2) MAINSHAFT
@��
M5 �
M4 //
M3
M6rr@
��
M2
(3) C2 BUSHING
Measure the I.D. of each gear and I.D. and O.D

of the C2 bushing.
SERVICE LIMITS:
M5, M6 gears: 17.10 mm (0.673 in)
C1 gear 16.60 mm (0.654 in)
C2 gear : 20.10 mm (0.791 in)
C3 gear : 19.10 mm (0.752 in)
C4 gear : 19.10 mm (0.752 in)
C2 bushing O.D. : 19.90 mm (0.783 in)
I.D. : 17.10 mm (0.673 in)
9-6
�HONDA
(1) COUNTERSHAFT
Measure the O.D. of the mainshaft and counter
shaft.
SERVICE LIMITS:
A: 16.93 mm (0.667 in)
B: 16.44 mm (0.647 in)
C: 18.93 mm (0.745 in)
D: 19.43 mm (0.765 in)
(2) MAINSHAFT
(1) BALANCER WEIGHT
BALANCER WEIGHT REMOVAL
Drive the balancer wight out from the right crank
case.
(1) BALANCER WEIGHT BEARING

BEARING REPLACEMENT
Remove the balancer weight left bearing and main
shaft left bearing from the left crankcase with the
special tools as shown.
Remove the countershaft left bearing from the left
crankcase.
Remove the mainshaft right bearing from the right
crankcase.
(2) BEARING REMOVER SET 12 mm
9-7
�HONDA
� MBXSO· MBXSO CRANKSHAFT/TRANSMISSION
Drive in the bearings with the following common

and special tools.
Balancer weight left bearing:
e Driver A
e Attachment 32 x 35 mm
e Pilot 12 mm
Mainshaft right and countershaft left bearings:

• Driver A
e Attachment 42 x 47 mm
• Pilot 17 mm
Mainshaft left bearing:

• Driver A
• Attachment 28 x 30 mm (07746-1870100)
CRANKSHAFT REMOVAL (1) CRANKSHAFT
Remove the crankshaft from the right crankcase.

Drive the crankshaft out of the right crankcase
if it is difficult to remove by hands.
NOTE
.. Use a plastic or brass hammer.
• Screw a nut onto the crankshaft end to
prevent damage.
• Protect the crankcase mating surface by
resting it on a wooden block.
9-8
�HONDA
CRANKSHAFT/TRANSM ISSION � MBX50· MBX80
CRANKSHAFT INSPECTION
Measure the connecting rod big end side clearance
with a feeler gauge.
8
Measure the connecting rod big end radial clearance
at two points in the X and Y directions.
X
Set the crankshaft on a stand or V-blocks and read
8
runout using a dial gauge.
9-9
�HONDA
� MBXSO· MBX80 CRANKS HAFT/TRAN SMISSI ON
CRANKSHAFT BEARING INSPECTION

Spin the crankshaft bearing by hand and check for
play.
The bearing must be replaced if it is noisy or has
excessive play.
,----•! r PLAY
-l ---
AXIAL RADIAL
(.1) UNIVERSAL BEARING PULLER

(07631-0010000)
CRANKSHAFT BEARING REPLACEMENT
Remove the left crankshaft bearing with the UNI
VERSAL BEARING PULLER.
(2) LEFT CRANKSHAFT BEAR ING

(1) OIL SEAL
Remove the oil seal from the right crankcase.
Remove the right crankshaft bearing.
(2) RIGHT CRANKSHAFT BEARING
9-10
�HONDA
CRANKSHAFT/TRANSMISSION � MBXSO· MBX80
(1) DRIVER A
Drive new right crankshaft bearing and oil seal
with the following common tools.
Right crankshaft bearing:

• Drive A
• Attachment 52 x 55 mm
• Pilot 25 mm
Right crankshaft oil seal

• Driver A
• Attachment 32 x 35 mm
(2) ATTACHMENT 32 x 35 mm (3) ATTACHMENT 52 x 55 mm
Drive a new left crankshaft bearing over the crank

shaft.
CAUTION
Hold the left crank weight when driving the
bearing.
(1) ATTACHMENT 25 mm (2) DRIVER C
CRANKSHAFT INSTALLATION
Clean the crankcase mating surfaces before assembl
ing and check for wear or damage.
NOTE
• If there is minor roughness or irregularities
on the crankcase mating surfaces, dress
them with an oil stone.
• After cleaning, lubricate the crankshaft
bearings and other contacting surfaces with
clean 2-§_troke oil.
9-11
�HONDA
� MBX50· MBXSO CRAN l<SHAFT/TRANSMISSION
(1) CRANKSHAFT
Install the crankshaft in the right crankcase.
Use a special tool "CRANKSHAFT ASSEMBLY
TOOL (07965-1660100)" if it is hard to install
the crankshaft to the right crankcase.
NOTE
@Apply clean 2-cycle engine oil to the
journal and crankpin bearings.
o Coat the sealing I ips of each oil seal with
grease.
(1) BALANCER WEIGHT

TRANSMISSION ASSEMBLY DRIVER 07945-1660000
Drive the balancer weight in the right crankcase

while rotating the driver tool to prevent tilting the
balancer bearing.
(2) BALANCER WEIGHT
Apply oil to the gears before installing the mainshaft

and countershaft.
Make sure the gears rotate freely.
9-12
r::;;;/f\ HONDA
(1) MAINSHAFT (2) COUNTERSHAFT

Install the mainshaft and countershaft in the right
crankcase.
(1) SHIFT FORK SHAFT

Install the shift drum, shift froks and shift fork
shaft.
Position the shift drum in neutral as shown.
Make sure that the mainshaft and countershaft

rotate freely.
(2) SHIFT DRUM (3) SHIFT FORKS
CRANKCASE ASSEMBLY DOWEL PINS
Install a new gasket and two dowel pins.
(2) GASKET
9-13
�HONDA
� MBXSO· MBX80 CRAN KS HAFT/TRANSMISSION
(1) LEFT CRANKCASE

Place the left crankcase onto the right crankcase.
(2) RIGHT CRANKCASE
Tighten the crankcase bolts in a crisscross pattern.

Install the drive sprocket.
(3) DRIVE SPROCKET
9-14

�HONDA
� MBXSO· MBX80
8-12 N.m
(0.8-1.2 kg-m, 6_9 ft-lb)
(1) WATER PUMP SHAFT BUSHING
10-0
�HONDA
� MBX50·MBX80 COOLING SYSTEM

TROUBLESHOOTING 10-2
RADIATOR COOLANT 10-3
RADIATOR 10-4
WATER PUMP 10-6
THERMOSTAT/TEMPERATURE SENSOR 10-9
10-1

(;;;;J}\ HONDA
COOLING SYSTEM � MBX50· MBXSO
SERVICE INFORMATION
e To service the master pump mechanical seal, remove the left crankcase cover.
e All cooling system services can be done with the engine in the frame.
e Do not remove the radiator cap when the engine is hot. The coolant is under pressure and it could result in scaling. The
engine must be cool before sevicing the cooling sytem.
e Avodi spilling coolant on painted surfaces. After servicing the system, check for leaks.
TOOLS
Special
Bearing Remover Set 12 mm 07936-1660000
Mechanical Seal Driver Attachment 07954-4150400
Attachment 28 x 30 mm 07946-1870100
Common
Driver A 07749-0010000
Pilot 12 mm 07746-0040200
SPECIFICATIONS
-�- --
ITEM STANDARD mm (in) I SERVICE LIMIT mm (in)
Radiator cap reliefe pressure 75-105 kPa (0.75-1.05 kg/cm2 , 10.7-14.9 psi)
Recommended coolant Use only a high quality ethylene glycol based anti-freeze containing corro-
sion protection inhibitors specifically recommended for use in aluminum
engines. A 50/50 mixture of anti-freeze and water is recommended for
most operating conditions. (See anti-freeze container label for other
mixutre ratios).
Coolant capacity:
Radiator and engine 520 cm3 (31.7 cu in)
Reserve tank 150 cm3 ( 9.2 cu in)
Total system 670 cm3 (40.9 cu in)
°
Thermostat Begins to open: 60-64 -C (140-147 ° F)
° °
Fully open: 70 C (158 F)
Valve lift: 3-4 mm (0.12-0.16 in)
I
Water pump shaft O.D. 6.972-6.987 mm (0.2745-0.2751 in) 6.90 mm (0.272 in)
I
TORQUE VALUES
Right crankcase cover bolt 8-12 N.m (0.8-1.2 kg-m, 6-9 ft-lb)
TROUBLESHOOTING
Engine Temperature Too High Engine Temperature Too Low
1. Thermostat stuck closed 1. Thermostat stuck open
2. Faulty radiator cap
3. Insufficient coolant Coolant Leaks
4. Passages blocked in radiator, hoses, or water 1. Fulty pump mechanical seal
jacket 2. Deteriorated 0-ring
10-2
�HONDA
� MBXSO· MBX80 COOLING SYSTEM
RADIATOR COOLANT (1) RADIATOR CAP
COOLANT CHANGE
Engi,ne must be cool before servzczng the

cooling system, or severe scalding may result.

(Page 14-3).
Remove the seat, side covers and fuel tank.
Remove the coolant drain bolt and drain the coolant.
Lean the machine right to drain the coolant, trapp
ed in the engine.
Remove the reserve tank mounting bolt and reserve
tank.
Drain the coolant from the reserve tank.
Check that the drain bolt sealing washer 1s in (2) DRAIN BOLT
good condition, then install the drain bolt and (1) RADIATOR FILLER NECK
reserve tank.
Fill the system with the recommended coolant up
(Page 9-2) to the radiator filler neck.
Install the radiator cap.
Fill the reserve tank with the coolnant up to the "F"
mark .
CAPACITY:
RADIATOR AND ENGINE:
520 cm 3 (31.7 cu in)
RESERVE TANK: 150 cm 3 (9.2 cu in)
Bleed air from the radiator.

" Start the engine and n,m until there are no air
bubbles in the coolant, and the level stabilizes.
e Stop the engine and add coolant up to the filler
neck if necesssary.
0 Check the level of coolant in the reserve tank
and fill to the correct level if the level is low.
(1) COOLANT FILLER OPENING (2) MOUNTING BOLT
Install the radiator cap securely.
(2) RESERVE TANK

�HONDA.
COOLING SYSTEM � MBXSO· MBX80
RADIATOR (1) FUEL TANK
REMOVAL
(Page 14-3).

Remove the coolant drain bolt and rain the coolant.
(1) COOLANT DRAIN BOLT

(1) OVERFLOW TUBE RADIATOR
Disconnect the radiator hoses and overflow tube
at the radiator.
Remove the screw attaching the radiator cowl and
cowl.
Remove the radiator mounting bolts and radiator.
NOTE
Take care not to damage the radiator fins.
(3) RADIATOR COWL (4) RADIATOR FINS
10-4
HONDA
MBX50•MBX80 COOLING SYSTEM
INSPECTION
Inspect the radiator soldered joints and seams
for leaks.
Blow diret out from between core fins with com
pressed air. If insects, etc., are clogged the radiator,
wash them off with low pressure water.
(1) RADIATOR CAP

Pressure test the radiator cap. Replace the radiator
cap if it does not hold pressure, or if relief pressure
is too high or too low. It must hold specified
pressure for at least six seconds.
NOTE
Before installing the cap on the tester��
[ water to sealing surfaces.
�
RADIATOR CAP REUFT PRESSURE:
0.9 ± 0.15 kg/cm 2 (12.8 ± 2.1 psi)
INSTALLATION
Install the radiator in the reverse order of re
movl.
After installation, check the radiator and radiator
hoses for leaks.
10-5
�HONDA.
COOLING SYSTEM � MBX50· MBX80
WATER PUMP
1 (1) WATER PUMP COVER
REMOVAL
Drain the radiator coolant (Page 10-3).
Remove the water pump cover bolts and cover.
(1) IMPELLER (2) RADIATOR HOSES

Remove the cap nut, copper washer, impeller and
plain washer from the water pump shaft.
Disconnect the r.adiator hoses from the water pump.
(1) WATER PUMP SHAFT

Remove the water pump shaft from the right
crankcase cover.
10-6
�HONDA.
� MBX50·MBX80 COOLING SYSTEM
INSPECTION (1) IMPELLER (2) SEALING PLATE

Check the mechanical seal for damage or deteriora
tion.
Check the water pump shaft bearing in the right
crankcase cover for excessive play or damage.
(3) MECHANICAL SEAL
Check the water pump shaft for bent or other

damage.
Measure the shaft O.D.
SERVICE LIMIT: 6.90 mm (0.272 in}"
(1) BEARING REMOVER SET 12 mm

07936-1660000
BEARING/MECHANICAL SEAL
REPLACEMENT
Remove the water pump shaft bearing with the
special tool.
Remove the oil seal and mechanical seal from the
right crankcase cover.
(2) WATER PUMP SHAFT BEARING
10-7
HONDA
COOLING SYSTEM MBX50,MBX80
(1) DRIVER A
Drive a new mechanical seal with the following
special and common tools.
e Driver A
e Mechanical seal driver 07945-4150400
InstalI a new oiI seal.
Drive a new bearing into the right crankcase cover
with the following special and common tools.
e Driver A
e Attachment 28 x 30 mm 07946-1870100
• Pilot 12 mm
Replace the imeller seal plate with a new one.
(2) MECHANICAL SEAL (3) ATTACHMENT

DRIVER 28 x 30 mm
INSTALLATION 07945-4150400 (1) IMPELLER 07946-1870100
Install the water pump shaft in the right crankcase
cover.
Install the plain washer and imeller over the pump
shaft.
Install the copper washer and cap nut and tighten
the cap nut.
Connect the radiator hoses to the water pump.
(2) CAP NUT
(1) DOWEL PINS

Install the two dowel pins and new gasket.
(2) GASKET
10-8
HONDA
MBX50·MBX80 COOLING SYSTEM
(1) WATER PUMP COVER

Install the water pump cover with the three bolts.
Pour the recommeded coolant mixture up to the

correct lever (Page 10-3).
After installation, start the engine and check for

leaks.
THERMOSTAT/TEMPERATURE SENSOR (1) THERMOSTAT COVER
REMOVAL
Drain the coolant (Page 10-3).
Disconnect the radiator hose at the cylinder head.
Remove the thermostat cover and thermostat.
Remove the temperature sensor from the cylinder
head.
(2) TEMPERATURE SENSOR

TEMPRETURE SENSOR INSPECTION
Suspend the temperature sensor in heated water to (1) TEMPERATURE SENSOR
check its resistance.
Do not let the temperature sensor touch the pan or
false readings will result.
Replace the temperature sensor if its resistance
does not meet the specifications.
TEMPERATURE SENSOR RESISTANCE:

Temperature "C('F) 50( 122) 80(176) 100(212) 1 20(250)
Resistance Ohm 154 52 27 16
(2) THERMOMETER
10-9
�HONDA 1
COOLING SYSTEM � MBXSO,MBX80
THERMOSTAT INSPECTION
Inspect the thermostat visually for damage. (1) THERMOSTAT
Suspend the thermostat in heated water to chech: its
operation.
Do not let the thermostat or thermometer touch
(2) THERMOMETER
the pan or false readings will result.
Replace thermostat if valve stays open at room
temperature, or if it responds at temperatures other
than those specified.
TECHNICAL DATA:
° °
Start to open 60-64 C ( 140-14 7 F)
Valve lift 3 mm (0.12 in) mimimum
° °
when heated to 70 C ( 158 F)
for five minutes.
INSTALLATION
Install the temperature sensor and thermostat in
the reverse order of removal.
NOTE
Apply liquid sealant to the threads of the
temperature sensor before installation.

(1) TEMPERATURE SENSOR
10-10
11.
HONDA
MIX50•MBX80
FRONT WHEEL/SUSPENSION
24-30 N.m
(2.4-3.0 kg·m, 17-22 ft·lb)
24-30 N.m (2.4-3.0 kg-m,

17-22 ft-lb)
11-0
r::i!f\ HONDA
FRONT WHEEL/SUSPENSION � MBX50· MBX80
SERVICE INFORMAT ION 11-2

GROUBLESHOOTING 11-3
HEADLIGHT 11-4
INSTRUMENT S 11-5
HEADLE BAR 11-7
FRONT WHEEL 11-9
FRONT FORK 11-13
STEERING STE M 11-19
11-1
�HONDA
� MBXSO· MBX80 FRONT WHEEL/SUSPENSION
SERVICE INFORMATION
e A jack or other support is required to support the motorcycle.
e Never ride on the rim or try to bend the wheel.
TOOLS
Special
HEX Wrench 6 mm 07917-3230000
Ball Race Driver 07944-1150001
Front Fork Oil Seal Driver Attachment 07747-0010700
Snap Ring Pliers 07914-3230001
Common
Driver A 07749-0010000
Attachment 32 x 35 mm 07746-0010100
Pilot 12 mm 07746-0040200
Front Fork Oil Seal Driver Body 07747-0010100
Pin Spanner 07702-0010000
TORQUE VALUES
Handlebar upper holder bolts 8-12 N.m (0.8-1.2 kg-m, 6- 9 ft-lb)
Steering stem nut 60-90 N.m (6.0-9.0 kg-m, 43-65 ft-lb)
Front fork bolt 40-50 N.m (4.0-5.0 kg-m, 29-36 ft-lb)
Front fork inner bolt 15-30 N.m (1.5-3.0 kg-m, 11-22 ft-lb)
Bottom bridge pinch bolts 24-30 N.m (2.4-3.0 kg-m, 17-22 ft-lb)
Front axle nut 55-70 N.m (5.5-7.0 kg-m, 40-51 ft-lb)
Front brake caliper bracket 24-30 N.m (2.4-3.0 kg-m, 17-22 ft-lb)
SPECIFICATIONS
Front fork oiI capacity: 131.5-136.5 cm3 (4.7-4.9 oz)

Front axle shaft ben - 0.20 (0.008)
Front wheel rim runout Rdial - 2.0 (0.08)
Axial - 2.0 (0.08)
Front shock absorber spring free length 497.3 (19.58) 482.5 (19.00)
Front fork pipe bend - 0.20 (0.008)
11-2
�HONDA.
TROUBLESHOOTING
Hard steering Hard suspension
1. Insufficient tire pressure 1. Incorrect fluid weight in front forks
2. Steering adjustment nut too tight Front suspension noise
3. Damaged steering stem bearings 1. Slider binding
4. Damaged steering ball races or cone races 2. Loose fron fork fasteners
3. Insufficient fluid in forks
Steers to one side or does not track straight
1. Univenly adjusted right and left shock absorbers
2. Bent fron forks
3. Bent front axle; wheel installed incorrectly
Front wheel wobbling

1. Axle not tightened properly
2. Distorted rim
3. Worn front wheel bearing
4. Distorted spoke
5. Faulty tire
Soft suspension
1. Weak fork spring
2. Insufficient fluid in front forks
11-3
�HONDA.
� MBX50·MBX80 FRONT WHEEL/SUSPENSION
HEADLIGHT
REMOVAL
On the Deluxe model, remove the fairing (Page
14-2).
On the Standard model, remove the four headlight
case mounting bolts and headlight case.
Remove the headlight mounting bolts and headlight .
Disconnect the headlight coupler and position

I ight connectors.
(1) HEADLIGHT BULB SOCKET (2) POSITION LIGHT

BULB SOCKET
11-4
�HONDA
INSTALLATION
Align the alignment marks on the headlight with
the index marks on the bracket.
(1) Align
(1) BULB HOLDERS
INSTRUMENTS
INDICATOR AND METER BULB RE
PLACEMENT
Remove the headlight.
REMOVAL/INSTALLATION
Remove the headlight (Page 11-4).
Disconnect the instrument wire coupler.
Remove the instrument mounting nuts and remove
the instruments.
Install the instruments in the reverse order of
removal.
(1) TACHOMETER CABLE (2) SPEEDOMETER CABLE
11-5
�HONDA
DISASSEMBLY
Remove the two instrument cover screws.
Remove the four instrument lower cover scrws and

separate the instruments.
(3) TEMPERATURE
(1) TACHOMETER (2) SPEEDOMETER GAUGE
Remove the screws attaching each instrument and
remove the tachometer, speedometer and tempera
ture gauge.
11-6
�HONDA
FRONT WHEEL/SUSPENSION � MBX50· MBXSO
HANDLEBAR
REMOVAL
Disconnect the handlebar switch wires.
Remove the left handlebar switch.

Disconnect the clutch cable.
Remove the brake master cylinder.
Remove the throttle grip.
Remove the handlebar upper holders and hand

lebar.
11- 7
HONDA
MBXSO,MBX80 FRONT WHEEL/SUSPENSION
INSTALLATION (1) PUNCH MARK

Place the handlebar onto the lower holder by
aligning the punch mark with the upper face of the
lower holder.
Place the upper holders on the hndlebar with the
punch marks facing the front.
Tighten the forward bolts first, then tighten the rear
bolts.
(2) PUNCH MARK (3) UPPER HOLDER

(1) LOCATING PIN
Install the front master cylinder with the "N'
mark facing up.
Align the end of the holder with the handlebar
puch mark.
Tighten the upper bolt first, then the lower.

Apply grease to the throttle grip sliding surface.

Align the locating pin on the throttle grip housing
with the hole in the handlebar and install the
throttle grip.
(2) PUNCH (3) "N' MARK (4) HOLE

MARK
Connect the clutch cable.
Align the locating pin on the left handlebar switch
with the hole in the handlebar and install the
switch.
Tighten the upper nut first, then tighten the lower

nut.
Route the switch wires (Page 1-7).

Connect the switch wires.
Install the head I ight (Page 11-5).
(1) HOLE
11-8
�HONDA
FRONT WHEEL/SUSPENSION � MBXSO· MBXSO
FRONT WHEEL
REMOVAL
Remove the axle nut.
Raise the front wheel off the ground by placing a
block or safety stand under the engine.
(1) AXLE NUT
Disconnect the speedometer cable.

Remove the axle shaft and front wheel.
NOTE
Do not operate the front brake lever after
removing the front wheel. To do so will cause
difficulty in fitting the brake disc between the
brake pads.
(1) SPEEDOMET ER
CABLE
AXLE INSPECTION
Set the axle in V blocks, rotate and measure the
runout.
Actual runout is 1 /2 of the total indicator reading.

11-9
r:;;;)\ HONDA
� MBXSO· MBXSO FRONT WHEEL/SUSPENSION
WHEEL BEARING INSPECTION

(1) RADIAL
Check the wheel bearing by placing the wheel on
a truing stand and spinning the wheel by hand. (2)
---11-------"--
P LAY
Replace the bearing with a new one if it is noisy or
shows excessive play.
WHEEL RIM RUNOUT

Check the wheel rim for runout by placing the
wheel in a truing stand. Spin the wheel by hand and
read the rim runout using a dial indicator gauge.
SERVICE LIMIT:
Radial: 2.0 mm (0.08 in)
Axial: 2.0 mm (0.08 in)
NOTE
The COMSTAR TM WHEEL cannot be
repaired and must be replaced with a new one
if the service limits are exceeded.
DISASSSMBL Y ( 1) (3) DISTANCE

Remove the dust steal, bearing and distance collar. COLLAR
NOTE
Do not forget to install the rim band when
replacing the tire or tube.
�-----------�
(4) OIL SEAL
�@�I
t��
(5) SPEEDOMETER
GEARBOX RETAINER
11-10
r::ifJ\ HONDA
FRONT WHEEL/SUSPENSION � MBXSO, MBX80
ASSEMBLY (1) DRIVER A
Pack all bearing cavities with grease.
Drive in the right bearing.
Install the distance collar.
Drive in the left bearing.
NOTE
• Do not allow the bearing to tilt while
driving it in.
• Install the bearing with the sealed end fac
ing the outside.
(2) ATTADHMENT 32 x 35 mm
PILOT 12 mm
Install the brake disc.

TORQUE: 27-33 N.m (2.7-3.3 kg-m,
20-24 ft-lb)
Apply grease to the inside of the dust seal.

Install the dust seal and distance collar in the right
side of the wheel hub.
Wipe off the excess grease. Grease on the disc

will cause reduced braking efficiency and may
lead to an accident.
(1) DUST SEAL (2) COLLAR
( 1) (2) Align
Install the speedometer gearbox retainer, aligning
the tabs with the grooves in the hub.
Apply grease to the inside of the dust seal and
install.
Apply grease to the speedometer gearoox and hub
retainer.
Install the speedometer gearbox, aligning the tabs
on the gearbox with the grooves in the retainer.
(3) GEARBOX RETAINER (4) DUST SEAL
11-11
�HONDA
FRONT WHEEL INSTALLATION

Position the front wheel between the fork legs and
insert the axle from the right side.
Position the speedometer gearbox as shown.

Connect the speedometer cable to the speedo
meter gearbox.
(1) SPEEDOMETER (2) SPEEDOMETER

GEARBOX CABLE
Install the axle nut and tighten to the specified
torque.
TORQUE: 55-70 N.m (5.5-7.0 kg-m,
40-51 ft-lb)
NOTE
----------------:--,
P-ump the brake lever after the front wheel is
installed to ensure full braking efficiency.
(1) AXLE NUT
11-12
�HONDA.
FRONT WHEEL/SUSPENSION � MBXSO· MBXSO
FRONT FORK
REMOVAL
Remove the front wheel (Page 11-9).
Remove the brake caliper.
Remove the fron fender.
NOTE
Do not loosen the brake hose unless it is
absolutely necessary. If the hose is loosened
or disconnected, the brake system must be
bled.
(1) BRAKE CALIPER

(1) UPPER HOLDER BOLTS
Loosen the handlebar upper holder bolts.
Loosen the fork bolts and remove them by shift
ing the handlebar right and left.
(2) FORI< BOLTS
Loosen the fork pinch bolts.

Remove the front forks.
11-13
�HONDA.
� MBX50· MBX80 FRONT WHEEL/SUSPENSION
DISASSEMBLY (1) FORK INNER BOLT

Remove the inner bolt.
NOTE
• Hold the fork tube in a vise with rag or
soft jaws avoiding the sliding surface as
shown.
CAUTION
The inner bolt is under spring pressure. Cover
the inner bolt and wrench during removal
to prevent injury caused by the bolt, wrench,
or spring flying upwards.
Drain the ATF (Automatic Transmission Fluid)

from the fork by pumping it up and down slowly.
FORK SPRING INSPECTION

Measure the fork spring free length.
SERVICE LIMITS: 482.5 mm (19.00 in)
11 ..14
�HONDA
Remove the socket bolt.

Remove the fork tube, piston, rebound spring
and oiI lock piece.
CAUTION
Do not distort the slider in a vise.
(1) 6 mm HEX WRENCH

07917-3230000
FORK TUBE RUNOUT

Place the fork tube in V blocks and read the runout.
Take 1/2 of the total indicator reading to determine

the actual wear.
(1) OIL SEAL

Remove the dust seal.
Remove the set ring with the snap ring pliers.
Remove the oil seal using the dull end of a screw
driver as shown.
NOTE
Avoid damaging the inner and outer surfaces
of the fork slider when removing the set
ring and oil seal.
(2) SNAP RING (3) RAG

PLIERS
11-15
�HONDA
� MBX50· MBX80 FRONT WHEEL/SUSPENSION
SLIDER/PISTON INSPECTION (1)

Check the slider for score marks, scratches or
abnormal wear.
r
(2) PISTON
ASSEMBLY
NOTE
Wash all removed parts in solvent and wipe
them off thoroughly before assembly.
(1) FORK
/ BOLT (9) DUST
/
a
FORK
tj
(2)
...a-(4) PISTON
(10)
I
�
SET RING...._�
(11)
SEAL
I
3=,1NNER RING (12) / .,,,.,,...- OIL SEAL
BOLT BACK-UP -._
I
�. RING
4--(5) PISTON
FORK
TUBE
f!ifi, (6) REBOUND

SPRING
&!JI�
/
rJ �___,
(8) OIL
LOCK PIECE
11-16
�HONDA
Install the piston ring on the piston.

Install the frok tube rebound spring and piston.
Install the oil lock piece.
Apply locking agent to the socket bolt threads and

underside on the bolt.
NOTE
"' To tighten the socket bolt, it may be neces
sary to install the fork spring and tighten
the fork bolt provisionally.
e Do not distort the slider in a vise.
(1) 6mm HEX WRENCH

07917-3230000
(1) FORKSEAL DRIVER BODY
Install the back-up ring.
(2) (3)
Install the oil seal into the top of the fork slider. OILSEAL DUSTSEAL
NOTE
Apply ATF to the oil seal and drive it in
with the fork seal driver.
The oil seal is seated when the groove in the
slider is seen at top of the seal.
Install the set ring and dust seal.
(4) DRIVER ATTACHMENT (5) BACK-UP (6) SET RING

07747-0010700 RING
Fill the forks with the specified amount of ATF.

SPECIFIED FLUID: ATF
CAPACITIES: 149.5-154.5 cm 2 (5.3-5.5 oz)
Install the fork spring.
NOTE
t
InstalI the spring with the narrow pitch end
facing up.
11-17
{:;jj\ HONDA
� MBX50· MBXSO FRONT WHEEL/SUSPENSION
(1) FORK INNER BOLT

Install and torque the fork inner bolt.
TORQUE: 15-30 N.m (1.5-3.0 kg-m,
11-22 ft-lb)
NOTE
Hold the fork tube in a vise, avoiding the
sliding surface.
INSTALLATION
Install the front forks.
Install and torque the fork bolts.

TORQUE: 40-50 N.m (4.0-5.0 kg-m,
29-36 ft-lb)
Tighten the fork pinch bolts.

TORQUE: 24-30 N.m (2.4-3.0 kg-m,
17-22 ft-lb)
Install the handlebar upper holders (Page 11-8).

lnstall the fronwheel (Page 11-12).
Install the brake caliper (Page 12-9).
11-18
�HONDA
STEERING STEM (1) HEADLIGHT BRACKET
REMOVAL
Remove the instruments (Page 11-5).
Remove the front wheel (Page 11-9).
Remove the headlight case bracket.
Remove the handlebar (Page 11 · 7).
Remove the steering stem nut.
Remove the front forks (Page ·11-13).

Remove the fork bridge.
(2) STEM NUT (3) FORK TOP BRIDGE

(1) BEARING ADJUSTMENT NUT
Remove the bearing adjustment nut.
Remove the steering stem, top cone race, steel balls
and bottom cone race.
(2) PIN SPANNER
Remove the ball races with the special tool.
NOTE
If the motorcycle has been involved in an
I accident, examine the area around the steer
ing head for cracks.
(1) BALL RACE REMOVER

07944-1150001
11-19
�HONDA
� MBX50· MBXSO FRONT WHEEL/SUSPENSION
STEERING STEM INSTALLATION
(1) STEELBALLS(21)�
(2) BOTTOM CONE RACE�
(3) DUST SEAL�
(4) DUST WASHER�
�(6) BEARING ADJUSTMENT NUT

�(7) TOP CONE RACE
�(8) STEEL BALLS (21)
(9) TOP BALL RACE
�- (10) BOTTOM BALL RACE
Drive the top and bootom ball races into the head
pipe with the same tool.
(1) BALL RACE REMOVER

07944-1150001 (1) BEARING ADJUSTMENT
NUT
Instal I the washer and dust seal.
Grease the ball race, steel balls and cone race.
Install the steering stem.
Install the bearing adjustment nut in the frame neck
and tighten it until snug against the top cone race,
then back it out 1 /8 turn.
Check that the stem rotates freely.
(2) PIN SPANNER
11-20
�HONDA
FRONT WHEEL/SUSPENSION � MBXSO· MBX80
Install the top bridge.

Install the fron forks (Page 11-18).
Tighten the stem nut.
TORQUE: 60-90 N.m (6.0-9.0 kg-m,
43-65 ft-lb)
Install the removed parts in the reverse order of

removal.
(1) STEM NUT
11-21
�HONDA.
� MBX50•MBX80
HYDRAULIC BRAKE 12.
10-14 N.m
(1.0-1.4 kg-m, 7-10 ft-lb)
25-35 N.m (2.5-3.5kg-m,

18-25 ft-lb)
15-20 N.m (1.5-2.0 kg-m, 24-30 N.m (2.4-3.0 kg-m, 17-22 ft-lb)
11-14 ft-lb)
12-0
�HONDA
HYDRAU UC BRAKE � MBXSO· MBX80

GROUBLESHOOTING 12-2
BRAKE FLUID/AIR BLEEDING 12-3
BRAKE PAD/DISC 12-4
BRAKE CALIPER 12-6
BRAKE MASTER CYLINDER 12-9
12-1
�HONDA
� MBXSO· MBXSO HYDRAULIC BRAKE
SERVICE INFORMATION
• The front brake pads can be replaced without disconnecting the brake hose .. Once the hydraulic system has been opened, or
if the brake feels sraongy, the system must be bled.
• The brake caliper should be disassembled before the master cylinder is disassembled.
• Do not allow foreign material to enter the system when filling the reservoir.
• Avoid spilling brake fluid on painted surfaces or instrument lenses, as severe damage will result.
TOOL
Special
Snap Ring Pliers 07914-3230001
TORQUE VALUES
Master cylinder mounting bolts 10-14 N.m (1.0-1.4 kg-m, 7-10 ft-lb)
Brake hose bolts 25-35 N.m (2.5-3.5 kg-m, 18-25 ft-lb)
Bleeder valve 4- 7 N.m (0.4-0.7 kg-m, 2.9-5.1 ft-lb)
Brake pad pin bolts 15-20 N.m ( 1.5-2.0 kg-m, 11-14 ft-lb)
Brake caliper bracket bolts 24-30 N.m (2.4-3.0 kg-m, 17-22 ft-lb)
SPECIFICATIONS

Disc thickness 3.80-4.20 (0.15-0.165) 3.0 (0.12)
Dis runout 0-0.15 (0-0.006) 0.3 (0.01)
Master cylinder I.D. 12.700-12.743 (0.5000-0.5017) 12.755 (0.5022)
Master piston 0.D. 12.657-12.684 (0.4983-0.4994) 12.640 (0.4976)
Caliper cylinder I.D. 25.400-25.405 (1.0000-1.0002) 25.450 (1.0020)
Caliper piston O.D. 25.318-25.368 (0.9968-0.9987) 25.300 (0.9961)
TROUBLESHOOTING
Brake lever soft or spongy Brake drag
1. Air bubbles in hydraulic system 1. Hydraulic system sticking
2. Low fluid level 2. Sticking piston (s)
3. Hydraulic system leaking
Brake chatter or squeal
Brake lever too hard 1. Pads contaminated
1. Sticking piston (s) 2. Excessive disc runout
2. Clogged liydraulic system 3. Caliper installed incorrectly
3. Pads glazed or worn excessively 4. Disc or wheel misaligned
12-2
�HONDA
HYDRAULIC BRAKE � MBXSO· MBX80
BRAKE FLUID/AIR BLEEDING (1) UPPER LEVEL

Check the front brake lever free play. I f the paly is
excessive, check the brake pad for wear and bleed
air from the brake hydraulic system.
Remove the cap from the reservoir by remvoing

the attaching screws. Remove the diaphragm.
CAUTION
A void spilling fluid on painted surfaces,
plastic lenses or rubber parts as it can cause
damage to them.
Fill the brake fluid reservoir up to the UPPER

LEVEL mark.
CAUTION
Do not mix different brands of fluid since (2) RESERVOIR
they are not compatible.
SPECIFIED BRAKE FLUID:
DISC BRAKE FLUID DOT 3
Connect an extension tube to the bleeder valve

with the open end submerged in a glass jar.
With the brake lever pulled all the way back to the
handlebar grip, turn the bleeder valve about 1 /2
rotation out, then retighten.
NOTE
D o not release the brake lever until the
bleeder valve has been closed.
Release the brake lever gradually and wait several

seconds after it reaches the end ot its travel.
Repeat the above steps until there are no air bubbles
in the fluid flowing out of the bleeder valve.
NOTE (1) BLEEDER VALVE

• Keep the reservoir filled while bleeding the (1) BLEEDER VALVE CAP
system.
• D o not reuse brake fluid.
Close the bleeder valve.

TORQUE: 4-7 N.m (0.4-0.7 kg-m,
2.9-5.1 ft-lb)
Fill the reservoir up to the UPPER FLUID LEVEL.
Check the entire system for leaks by operating the

lever.
� WARNING
A contaminated brake disc or pads reduces
stopping power. Replace contaminated pads,
and clean a contaminated disc with a good
\
quality degreasing agent.
12-3
�HONDA
�MBX50·MBX80 HYDRAULIC BRAKE
BRAKE PAD/DISC (1) GROOVE
BRAKE PAD INSPECTION

The front brake pads require replacement if the
groove in the sides of the pads reaches the edges of
the brake disc.
(2) GROOVE (3) BRAKE PADS
BRAKE PAD REPLACEMENT

NOTE
Do not disconnect the brake hose when re
placing the brake pads.
Remove the pin bolt caps and loosen the pin bolts.
Remove the caliper bracket bolts and remove the
caliper from the fork leg.
(1) PIN BOLTS
Push the pistons all the way in to allow installation

of new brake pads.
Remove the two pin bolts, then the brake pads.
12-4
�HONDA
HYDRAULIC BRAKE � MBXSO, MBXSO
(3) PIN BOOTS
Clean the brake caliper.
Apply silicone grease to the pin bolts and pins on
the caliper bracket.
Install new brake pads and pad spring and loosely
install the pin bolts.
CAUTION
Replace both pads as a set. Do not replace
one without replacing another.
Ensure that the pin bolts are inserted through the

holes in the brake pads.
Assemble the caliper bracket and caliper and install

the caliper on the fork leg.
TORQUE: 24-30 N.m (2.4-3.0 kg-m,
17-22 ft-lb)
(4) PADS (5) PAD SPRING (6) CALIPER
Tighten the pin bolts to the specified torque and BRACKET
bend the tabs of the lock washer against the side
of each bolt.
TORQUE: 15-20 N.m (1.5-2.0 kg-m,
11-14 ft-lb)
Install the pin bolt caps.
BRAKE DISC INSPECTION

Measure the brake disc thickness.
Measure the brake disc warpage.

12-5
�HONDA
� MBX50· MBX80 HYDRAULIC BRAKE
BRAKE CALIPER
REMOVAL
Remove the pin bolt cap and loosen the pin bolts.
Remove the two bolts attaching the caliper and
remove the caliper from the fork leg.
Remove the bracket from the cliper.
DISASSEMBLY
Remove the pads, and spring by removing the pin
bolts.
Operate the brake lever to force the piston out of

the cylinder.
NOTE (1) PIN BOLTS

• Place an oil pan under the caliper to receive
brake fluid drained. (1) CALIPER BRACKET
• Avoid spilling brake fluid on painted
surfaces, plastic lenses or rubber parts.
Disconnect the brake hose from the caliper.

If the piston is seized in the caliper, observe the
following steps.
(2) CALIPER
Place a shop towel or rag over the pistons to prevent

the pistons and brake fluid from coming out, and
apply a small amount of air pressure to the fluid
inlet.
� WARNING'
I Do not use high pressure air or bring the
L_�ozz1e too close to the inlet.
12-6
�HONDA
HYDRAULIC BRAKE � MBX50· MBX80
(1) PISTON SEALS (2)
Remove the pin boots.
Lift out the p iston and dust seals by first pushing

them into the cylinder.
Clean the caliper grooves with brake fluid.

Replace the piston and dust seals with new ones.
(3) DUST SEALS (4) PIN BOOT
INSPECTION
Check the caliper cylinders for scoring, scratches or
other dama ge.
Measure the caliper cylinder I.D.

Check the pistons for scoring, scratches or other

defects.
Measure the caliper piston 0.D.

SERVICE LIMIT: 25.300 mm (0.9961)
12-7
�HONDA
� MBX50· MBXSO HYDRAULIC BRAKE
ASSEMBLY
Wash all the removed parts. Coat the piston and
dust seals with silicone grease.
Lubricate the inside diameter of the caliper cylinders

with brake fluid and install the pistons with the
concave end on the brake pad side.
NOTE
Install the pistons with the end 3-5 mm
(1/8-1/5 in) projecting above the caliper.
Wipe excess brake fluid off the caliper with a clean

cloth.
(1) PISTONS
(1) PIN BOOTS
Lubricate the inside of the pin boots with silicone
grease and install them in the caliper.
Install the pad spring and pads with the pin bolts.
NOTE
If the brake pad is dirty, clean with sand
paper.
Loosely tighten the pin bolts.
Make sure that the pin bolts are inserted through

the holes in the brake pad.
(1) PADS
12 ... a
�HONDA
HYDRAULIC BRAKE � MBXSO· MBXSO
INSTALLATION
Install the brake hose and seal washer.
TORQUE: 25-35 N.m (2.5-3.5 kg-m,
18-25 ft-lb)
Install the bracket to the caliper.

Install and tighten the caliper bracket to the front
fork to the specified torque.
TORQUE: 24-30 N.m (2.4-3.0 kg-m,
17-22 ft-lb)
Tighten the pin bolts arid install the pin bolt caps.
TORQUE: 15-20 N.m (1.5-2.0 kg-m,
11-14 ft-lb)
After the front brake has been installed, bleed air
from the system (Page 12-3).
(1) PIN BOLTS
(1) MASTER CYLINDER
BRAKE MASTER CYLINDER
REMOVAL
Drain brake fluid from the bleeder valve by operat
ing the brake lever.
Remove the brake lever, front stoplight switch, rear

view mirror and brake hose.
Remove the master cylinder from the handlebar.
(2) SNAP RING PLIERS

(1) BOOT 07914-3230001
'
DISASSEMBLY
Remove the reservoir cap and diaphragm.
Remove the boot.
Remove the snap ring.
Remove the master cylinder piston and spring.
12-9
{:;;jjj\ HONDA
� MBX50· MBXSO HYDRAU-LIC BR_AKE
(1) S PRING (2) DIAPHRAGM

Remove the reservoir from the master cylinder.
Clean the master cylinder and reservoir in brake
fluid.
(3) SNAP RING (4) MASTER PISTON
INSPECTION
Check the master cylinder for score marks, scratches
or other defects.
Measure the master cylinder I.D.

Check the master piston for score marks, scratches

or other damage.
Measure the master piston O.D.

12-10
�HONDA
HYDRAU UC BRAKE � MBXSO, MBX80
ASSEMBLY ..., � (1) SILICONE (2)

Apply silicone grease to the piston cup and pour a
small amount of brake fluid into the cylinder.
NOTE
"' Replace the master piston and spring as a
set. Do not replace one without replacing
the other.
• Check that the snap ring is seated in the
groove properly.
Install the front stoplight switch.
(1) SEAL WASHERS

INSTALLATION
Install the master cylinder on the handlebar
(Page 11-8).
TORQUE: 10-14 N.m (1.0-1.4 kg-m,
· 7-10 ft-lb)
Install the brake hose and seal washer.

TORQUE: 25-35 N.m (2.5-3.5 kg-m,
18-25 ft-lb)
After the front brake has been installed, bleed air

from the brake hydraulic system (Page 12-3).
(2) BRAKE HOSE
12-11
�HONDA
� MBX50· MBX80
REAR WHEEL/BRAKE/
SUSPENSION 13.
27-33 N.m (2.7-3.3 kg-m'
20-24 ft-lb)
70-85 N.m (7.0-8.5 kg-m '

51-62 ft-lb)
27-33 N.m (2.7-3.3 kg-m, 40-50 N.m
I
20-24 ft-lb) (4.0-5.0 kg-m,
18-25 N.m 9-36 ft-lb)
( 1.8-2.5 kg-m,
13-18 ft-lb)
IJ
13-0
�HONDA
REAR WHEEL/BRAKE/SUSPENSION � MBX50· MBX80
SERVICE INFOR MATION 13-2

REAR WHEEL 13-3
REAR BRAKE 13-6
REAR SHOCK ABSORBER 13-9
REAR SHOCK ABSORBER LINKAGE 13-11
L__
_ sw__ N G AR
1 _ _ _ _M
_______________ ____
13 13
_ _ ___ __J
13-1
(:;;jf\ HONDA
� MBXSO, MBX80 REAR WHEEL/BRAKE/SUSPENSION
SERVICE INFORMATION
• Do not remove rivets, nuts and pins from the rim, spoke plate and hub.
• Never ridte on the rim or try to bend wheel.
TOOLS
Special
Shock Compressor Attachment 07967-GE20000
Common
Shock Compressor 07959-3290001
Attachment 37 x 40 mm 07746-0010200
Driver A 07749-0010000
Pilot 12 mm 07746-0040200
TORQUE VALUES
Final driven sprocket nuts 40-50 N.m (4.0-5.0 kg-m, 29-36 ft-lb)
Rear brake torque link nuts 18-25 N.m (1.8-2.5 kg-m, 13-18 ft-lb)
Rear axle nut 55-70 N.m (5.5-7.0 kg-m, 40-51 ft-lb)
Rear brake arm bolt 8-12 N.m (0.8-1.2 kg-m, 6- 9 ft-lb)
Rear shock absorber mounting bolts and nuts 27-33 N.m (2.7-3.3 kg-m, 20-24 ft-lb)
Swingarm pivot bolt 70-85 N.m (7.0-8.5 kg-m, 51-62 ft-lb)
Rear shock absorber linkage pivot bolt 40-50 N.m (4.0-5.0 kg-m, 29-36 ft-lb)
SPECIFICATIONS
Axle runout - 0.20 {0.008)
Rear wheel rim runout Radial - 2.0 {0.08)
Axial - 2.0 {0.08)
Rear brake drum I.D. 110.0 {4.33) 111.0 {4.37)
Rear brake lining thickness 4.0 (0.16) 2.0 (0.08)
Rear shock absorber spring free length 137.5 (5.41) 135 {5.3)
TROUBLESHOOTING
Wobble or vibration Suspension noise
1. Distorted rim 1. Shock case binding
2. Loose wheel bearing 2. Loose fasteners
3. Distorted spoke
4. Faulty tire Poor brake performance
5. Loose axle 1. Brake not adjusted properly
6. Worn swingarm bushing 2. Worn brake linings
7. Loose swingarm pivot bolt 3. Contaminated brake linings
4. Worn brake cam
Soft suspension 5. Worn brake drum
1. Weak spring 6. Brake arm not properly installed
2. Shock absorbers fluid leaks 7. Worn brake shoes at cam contacting faces
Hard suspension
1. Bent shock absorber
13-2
�HONDA
REAR WHEEL/BRAKE/SUSPENSION � MBX50· MBXSO
REAR WHEEL (1), CHAIN ADJUSTING NUT (2) AXLE NUT
REMOVAL
Remove the brake rod.
Remove the cotter pin and disconnect the torque
link.
Remove the axle nut.

Loosen the lock nut and chain adjusting nut.
Withdraw the axle and remove the rear wheel.
(3) BRAKE ROD (4) BRAKE'TOROUE LINK

AXLE INSPECTION
Set the axle in V blocks and read the axle bend.
The actual axle bend is 1 /2 of the total indicator
reading.
SERVICE LIMITE: 0.20 mm (0.008 in)
REAR WHEEL BEARING PLAY INSPEC

TION
Check the wheel bearing play by rotating the wheel
by hand. Replace the bearings with new ones if
they are noisy or have excessive play.
! - (1)PLAY
SERVICE LIMIT: 0.027 mm (0.0010 in) t
RADIAL
13-3
aHONDA
� MBX50· MBX80 REAR WHEELIBRAKE/SUSPENSION
REAR WHEEL RIM RUNOUT INSPEC

TION
Check the rim for runout by placing the wheel in a
truing stand. Spin the wheel by hand and read the
runout using a dial indicator gauge.
SERVICE LIMITS:
Radial: 2.0 mm (0.08 in)
Axial: 2.0 mm (0.08 in)
NOTE
I Do not attempt to repair the spokes.
FINAL DRIVEN SPROCKET INSPECTION

Check the final driven sprocket for worn or dam
aged gear teeth.
NOTE
The drive chain and drive sprocket must also (1) GOOD (2)- REPLACE
be inspected if the driven sprocket is worn.
REAR WHEEL DISASSEMBLY

Remove the dust seal, bearings and distance collar. ( 1)
NOTE
Do not forget to install the rim band when the
tire and tube are replaced.
13-4
�HONDA
REAR WHEEL BEARING INSTALLATION (1) DRIVER A

Pack all bearing cavities with grease.
Drive in the right bearing.
Insert the distance collar.
Drive in the left bearing.
Coat the inside of the dust seal with grease and
install.
NOTE
• Drive in the bearings squarely.
• Install the bearings with the sealed end
facing outside.
(2) ATTACHMENT 37 x 40 mm
PILOT 12 mm
FINAL DRIVEN SPROCKET INSTALLA
TION
Install the final driven sprocket with the protector
ring end outside.
TORQUE: 40-50 N.m (4.0-5.0 kg-m,
29-36 ft-lb)
(1) PROTECTOR RING
\
REAR WHEEL INSTALLATION (1) RETAINING CLIP
Install the rear wheel and axle shaft.

Install the driven chain.
CAUTION
Note the direction of the drive chain master
link retaining clip.
DIRECTION OF,
ROTATION
13-5
W'\HONDA
� MBX50, MBX80 REAR WHEEL/BRAKE/SUSPENSION
(1) CHAIN (2) GRADUATED (3) INDEX
ADJUSTER SCALE MARK
Install the brake rod and brake torque link.
TORQUE: 18-25 N.m (1.8-2.5 kg-m,
40-51 ft-lb)
Adjust the drive chain tension (Page 3-11).
CHAIN SLACK: 10-20 mm (3/8-3/4 in)
CAUTION
Rotate the adjusters so that thte index marks
are aligned with the same scale number on
both sides.
Torque the axle nut.
TORQUE: 55-70 N.m (5.5-7.0 kg-m,
40-51 ft-lb)
Lubricate the drive chain (Page 3-12).

(4) BRAKE TORQUE
REAR BRAKE LINK
REAR BRAKE LINING THICKNESS

Measure the brake lining thickness.
REAR BRAKE DRUM INSPECTION

Measure the rear brake drum I.D.
13-6
2HONDA.
REAR WHEEL/BRAKE/SUSPENSION � MBXSO· MBX80
REAR BRAKE SHOE REPLACEMENT
Remove the brake shoes.
Replace the brake shoes with new ones.
BRAKE CAM DISASSEMBLY

Remove the brake arm.
Remove the indicator plate.
Remove the brake cam.
Remove the felt ring.
Clean the shoe contacting faces of the brake cam.
( 1)
BRAKE PANEL ASSEMBLY

Install the felt ring and wear indicator plate.
NOTE
Align the flat on the cam with the flat on the
wear indicator plate. (4) BRAKE SHOE
Instal I the brake arm.
NOTE
Align the punch mark on the brake cam with
'I
,
the punch mark on the brake arm.
Tighten the brake arm bolt to the specified torque. I

TORQUE: 8-12 N.m (0.8-1.2 kg-m, I
6-9 ft-lb)
( 1)
Install the brake panel on the rear wheel. (3) BRAKE CAM
4) PUNCH MARl<S
(2) FLATS (
BRAKE CAM
(6) BRAKE
ARM I
�� I ."- I
c_____ '
_____ --�--_J
13-7
HONDA
MBX50·MBX80 REAR WHEEL/BRAKE/SUSPENSION
BRAKE PEDAL (1) BRAKE ARM (2) BRAKE ROD

Remove the exhaust pipe.
Remove the brake rod.
(3) ADJU.STING NUT

(1) RETURN
SPRING
Remove the brakelight switch spring.
Remove the return spring.
Remove the c otter pin, plain washer, then remove
the brake pedal.
Assembly of the brake pedal is essentially the

reverse order of removal.
CAUTION
Before installing the brake pedal, apply grease
to the sliding surface.
Adjust the brake pedal free play (Page 3-10).
13-8
�HONDA
REAR WHEEL/BRAKE/SUSPENSION � MBXSO· MBXSO
REAR SHOCK ABSORBER (1) UPPER MOUNTING BOLT
REMOVAL
Raise the wheel off the ground by placing a block
under the engine.
Remove the shock absorber upper and lower mount
ing bolts and remove the shock absorber from the
frame.
(2) LOWER MOUNTING

BOLT
DISASSEMBLY
Install the special tool over the shock absorber
spring as shown and tighten the nuts securely.
(1) SHOCK ABSqRBER COMPRESSOR ATTACHMENT

07967-G E20000
Place the shcok absorber in a press and compress (1) DAMPER ROD (2) SPRING SEAT
the shock absorber spring.
Pull the damper rod up and remove the upper spring
seat.
Release the press and remove the special tool and
spring from the shock absorber.
13-9
HONDA.
MBX50·MBX80 REAR WHEEL/BRAKE/SUSPENSION
REAR DAMPER INSPECTION

Check the rear damper for damage or fluid leaks.
(1) REAR DAMPER
SPRING FREE LENGTH

Measure the spring free lenght.
SERVICE LIMIT: 135 mm (5.3 in)
....___ (1) FREE LENGTH ---i
(1) SPRING SEAT (2) UPPER JOINT

ASSEMBLY
Install the special tool over the spring and tighten
the tool nuts securely.
Compress the spring with the press, pull the damper
rod up and place the upper spring seat on the spring.
Release the press while aligning the spring seat and
upper joint.
Remove the special tool from the shock absorber.
(3) REAR SHOCK ABSORBER COMPRESSOR ATTACHMENT

07967-GE20000
13-10
�HONDA
REAR WHEEL/BRAKE/SUSPENSION � MBXSO· MBXSO
(1) UPPER MOUNTING
INSTALLATION BOLT
Install the shock absorber I ower mount on the
shock absorber linkage.
Align the shock absorber upper mount with the
frame while moving the rear wheel up and down and
install the upper monting bolt.
TORQUE: 27-33 N.m (2.7-3.3 kg-m,
20-24 ft-lb)
(2) LOWER MOUNTING BOLT

REAR SHOCK ABSORBER UNKAGE
REMOVAL
Remove the air cleaner case (Page 4-10).
(1) AIR CLEANER CASE

(1) CHAIN COVER
Remove the drive chain cover.
13-11
{:;;jjj\ HONDA.
� MBXSO, MBX80 REAR WHEEL/BRAKE/SUSPENSION
Raise the rear wheel off the ground by placing a

block under the engine.
Remove the rear shock absorber lingage pivot bolts
and nuts and remove the linkage.
Check the linkage bushings and collar for wear or
damge.
INSTALLATION
Apply paste grease (containing more than 45% of
molyodenum) to each bushings and install the
linkage.
27-33 N.m (2.7-3.3 kg-m,

20-24 ft-lb)
13 .. 12
�HONDA
SWINGARM (1) SHOCK LINKAGE MUD GUARD
REMOVAL
Remove the rear wheel (Page 13-3).
Remove the drive chain cover.
Remove the shock linkage mud guard from the
linkage.
Remove the swingarm-to-shock absorber linkage
bolt.
Remove the swingarm pivot bolt and the swingarm.
(3) SWINGARM PIVOT BOLT

INSPECTION
Check the seingarm for cracks or damage.
Check the bushings for damage or other defects.
Check the chain slider for wear or damage.
... CHAIN
SLIDER
INSTALLATION
Install the torque link and chain slider on the
swingarm.
Install the swingarm.
TORQUE: 70-85 N.m (7.0-8.5 kg-m,
51-62 ft-lb)
Install and torque the swingarm-to-shock linkage

bolt.
TORQUE: 40-50 N.m (4.0-5.0 kg-m,
:29-36 ft-lb)
Install the shock link mud guard.

Install the rear wheel (Page 13-5).
13-13
14-0
�HONDA.
FAIRING/UNDER COWL � MBX50· MBX80
FAIRING 14-2
UNDER COWL 14-3
14-1
2HON'DA
� MBXSO· MBX80 FAIRING/UNDER COWL
FAIRING (1) FAIRING

Remove the three fairing mounting screws and the
fairing.
(2) SCREWS
Remove the four bolts attaching the fairing bracket

and bracket.
(1) FAIRING BRACKET
Install the fairing in the reverse order of removal.
14-2
�HONDA
FAIRING/UNDER COWL � MBXSO· MBX80
UNDER COWL (1) SCREWS

Remove the four screws mounting the under cowl
and the under cowl.
(2) UNDER COWL
Remove the bolts attaching the under cowl brackets.

and brackets.
(1) UNDER COWL BRACKETS
Install the under cowl in the reverse order of re

moval.
14-3
�:g:M�:O BATTERY /CHARGINGSYSTEM 15.
(3) BATTERY
(1) RESISTOR
� I
(4) ALTERNATOR
15-0
�HONDA.
BATTERY/CHARGING SYSTEM � MBX50· MBXSO

BATTERY 15-3
CHARGING SYSTEM 15-5
15-1
�HONDA
� MBXSO· MBX80 BATTERY/CHARGING SYSTEM
SERVICE INFORMATION
• Battery fluid level should be checked regularly. Fill with distilled water when necessary.
• Do not quick charge a battery, except in an emergency. Slow-charging is preferred.
,a Remove the battery from the motorcycle for charging. If the battery must be charged on the motorcycle, disconnect the
battery cables.
� WARNING
Do not smoke, and keep flames away from a charging battery. The gas produced by a battery will explode if a flame
or spark is brought near.
• All chargi.ng system components can be tested on the motorcycle.

• Alternator removal, see secti0A--R
SPECIFICATIONS
Capacity 12V 3AH
° °
Battery Specific gravity 1.280/20 C (68 F)
Charging rate 0.3 amperes maximum
Alternator MBX50: Charging speed 2,000 min-1 (rpm) maximum
Capacity 4,000 min -1 (rpm) 8,000 min - 1 (rpm)
Lighting switch OFF O.BA min. (17.7V) 2.5A max. (18.2V)
Lighting switch ON 0.5A min. (17.7V) 2.5A max. (18.2V)
MBXBO: Charging speed 2,000 min-1 (rpm) maximum
4,000 min-1 (rpm) 8,000 min-1 (rpm)
-·
Capacity
Lighting switch OFF 0.8A min. (17.7V) --- 2.5A max. (18.2V)
Lighting switch ON 0.5A min. (17.7V) 2.5A max. (18.2V)
Regulator Transistorized non-adjustable
TROUBLESHOOTING
No power-key turned on: Low power-engine running:
1. Dead battery 1. Battery undercharged
- Low fluid level - Low fluid level
- Low specific gravity - One or more dead cells
2. Disconnected battery cable 2. Charging system failure
3. Fuse burned out
4. Faulty ignition switch Intermittent power:
1. Loose battery connection
Low power-key turned on: 2. Loose charging system connection
1. Weak battery
- Low fluid level Charging system failure:
- Low specific gravity 1. Loose, broken, or shorted wire or connection
- Charging system failure 2. Faulty rectifier
2. Loose battery connection 3. Faulty regulator
4. Faulty alternator
15-2
�HONDA
BATTERY/CHARGING SYSTEM � MBXSO· MBXSO
(1) NEGATIVE
BATTERY WIRE (2) POSTIVE WIRE
REMOVAL
Open the battery holder.
Disconnect the negative and positive wires at the
connectors.
Remove the battery.
(3) BATTERY HOLDER

TESTING SPECIFIC GRAVITY
Test each cell with a hydrometer.
SPECIFIC GRAVITY: 1.270-1.290
° °
(20 C, 68 F)
1.210-1.290 I Fully charged

Below 1.260 ) Undercharged
NOTE (1)
HYDROMETER
• The battery must be charged if the specific
gravity is qelow 1.260.
• The specific gravity Varies with the tem ',
perature as shown in the accompanying (2) ELECTROLYTE --
table. \
• Replace the battery if sulfation is evident
or·if the space below the cell plates is filled
with sediment.
� WARNING
The battery contains sulfun'c acid.
Avoid contact with skin, eyes, or clothing. I. 31 (3) BATTERY TEMPERATURE vs
1 ·304
Antidote: Flush with water and get prompt SPECIFIC GRAVITY
I. 30
medical attention.
>-
1-- 1. 29
> 1.284
<1'.
er. 1. 28
(.9
u I. 27
LL.
w
u
1.26
a..
en
1.256
::!, 1. 25
1. 24
0" 5" 1 O" 15" 20" 25" 30" 35" 40"

(5) ELECTROLYTE TEMPERATURE
°
(6) Specific gravity changes by 0.007 for every 10 C.
15-3
HONDA
MBX50,MBX80 BATTERY/CHARGING SYSTEM
CHARGING
Connect the charger positive (+) cable to the battery
positive (+) terminal.
Connect the carger negative (-) cable to the bat
tery nagative (-) terminal.
Charging current:
1.4 amperes max.
Charging:
Charge the battery until specific gravity is 1.270-
° °
1.290 at 20 C (68 F).
t; WARNING
" Before charging a battery, remove the cap
from each cell.
" Keep flames and sparks away from a charg-
ing battery.
" Turn power ON/OFF at the charger, not at
the battery terminals.
" Discontinue charging if the electrolyte
°
temperature exceeds 45°C (113 F).
(1) CHARGING TIME vs SPECIFIC GRAVITY
CAUTION 1. 300
1 .290
0
Quick-charging should only be done in an 0 1.270
emergency; slow-charging is preferred. 1. 260
>-
1-
> 1. 220
<(
�,
a:
1. 180
1. 140
1. 100
N
1.060 �-�-� ��-�
- ��
-
0 2 4 6 8 10 12 14 16
(3) CHARGING TIME (Hr)
CAUTION
Route the hreatlzer tuhc as shown m1 the
hatter_)' caution label.
(4) TUBE CL!E,..,//
(5) INSERT THE BATTERY

BREATHER TUBE
SECURELY
15-4
r:;;;JJ'\ HONDA
BATTERY/CHARGING SYSTEM � MBXSO· MBX80
(1) REGULATOR/RECTIFIER (2) IGNITION
CHARGING SYSTEM SWITCH
(4) DIMMER
SWITCH
(5) LIGHTING
SWITCH
(7)
RESISTOR -=- BATTER
(6)
Y
JI _ JJ -
4.0 Ohm
I
:
30W
(8) ALTERNATOR (9) HIGH BEAM (10) HEADLIGHT (13) LICENCE LIGHT 12V 5W
INDICATOR 12V 35/35W (12) METER LIGHT 12V 3.4W x 2
12V 1.7W (F type: 36/36W) (11) TAILLIGHT 12V 5W
PERFORMANCE TEST
NOTE
Be .sure the battery is in good condition and (1) VOLTMETER (2) AMMETER
fully charged before performing this test.
Warm up the engine.

Remove the frame right side cover.
Disconnect the black wire at the regulator/ rectifier
coupler.
Connect an ammeter and voltmeter as shown.

Start the engine.
LIGHTING 8,000 min-1 (rpm)

MODEL SWITCH CHARGEING RPM 4,00 min -1 (rpm)
--
MBX5u OFF 2,000 min-1 (rpm) max. (14.2V) 0.8A min. (17.7V) 2.5A max. (18.2V) I
ON 2,000 min-1 (rpm) max. (14.2V) 0.5A min. (17.7V) 2.5A max. (18.2V)
MBX80 OFF 2,000 min-1 (rpm) max. (14.2V) 0.8A min. (17.7V) 2.5A max. (18.2V)
--�
ON 2,000 min-1 (rpm) max. (14.2V) 0.5A min. (17.7V)-� _l 2.5A max. (18.2V)
15-5
�HONDA
� MBXSO· MBXSO BATTERY/CHARGING SYSTEM
ALTERNATOR INSEPCTION
Warm up the engine.
Stop the engine.
Disconnect the alternator connectors.
Check the resistances betweeen the connectors.
Yellow - Green: 0.1-1.0 Ohms
White - Green: 0.3-1.5 Ohms
Replace the stator and flywheel as a set if not

within the specifications.
(1) ALTERNATOR CONNECTORS

( 1) REGULATOR/
REGULATOR/RECTIFIER INSPECTION RECTIFIER C
Disconnect the regulator/rectifier coupler.
Measure the resistance between the terminals.
Replace the regulator/rectifier with a new one if the
readings do not fall within the limits shown in the
table.
NOTE
" The regulator/rectifier is fully transistoriz
ed.
" For accurate testing, it is necessary to use a
specified electric tester. Use of an im
proper tester or measurement in improper
range may give a false reading.
" U se SANWA ELECTRIC TESTER (P/N
07308-0020000) or KOWA ELECTRIC
TESTER (TH-5H).
A B D
Measuring ranges:
SANWA: x kS1
KOWA: x 100S1
Unit: KS1
------- ---
I\.,+' probe
A B C D
,�,probe�
A 1-5
�
00 00
f--.-
B 1-5 00 00
C 00 00
� 00
--
D 00 00 0.5-1.0 �
15-6
�HONDA
BATTERY/CHARGING SYSTEM � MBX50· MBX80
RESISTOR INSPECTION (1) RESISTOR

Disconnect the resistor connectors.
Measure the resistance between the connectors.
Pink - Green: 4 ohms
Green/White - Green: 6.7 ohms
15-7
HONDA
MBXSO·MBX80 SYSTE 16.
(2) IGNITION
COIL (3) CDI
UNIT
(1) SPARKPLUG
·\
/�
---
,1.-: ---
:1/
(4) ALTERNATOR
(7) IGNITION SWITCH

ON
OFF
( 4) ALTERNATOR --- -- ---1 (2) IGNITION COIL
(8) DIODE \
_
/ /� � Bk/R -+--+----IM------t Bk/Y 1--i
�
(5 ) f D (10) IGNITION 1 SPARK
EXCITER COIL 8/Y CONDENSER PLUG
(6) SCR
PULSE (9) GATE I
\ GENERATOR
_J
CURCUIT
I
..___�G--�----��
-··------
(3) CDI UNIT
16-0
�HONDA
IGNITION SYSTEM � MBX50· MBX80

IGNITION COi L 16-3
CID UNIT 16-4
ALTERNATOR EXCITOR COIL/PULSE GENERATOR 16-4
16-1
r:iJ\HONDA
� MBX50· MBXSO IGNITION SYSTEM
SERVICE INFORMATION
GENERAL
• A CDI IGNITIO N SYSTEM is used and no adjustments are to be made. If the timing is incorrect, inspect the CDI unit and
alternator and replace any defective parts.
• For spark plug information, see page 3-5.
SPECIFICATIONS
ND NGK
Spark plug Standard W24ESR-U (W27ESR-U) BRSES (BR9ES)
Optional W22ESR-U (W22ESR-U) BR7ES (BR7ES)
W27ESR-U (W24ESR-U) BR9ES (BRSES)
Spark plug gap 0.7-0.8 mm (0.028-0.030 in)
19 ± 3 BTDC at 3,00 min- 1 (rpm)
° °
Ignition timing "F" mark
Retard start MBX50 4,400-5,600 min-1 (rpm)
MBX80 3,200-4,900 min-1 (rpm)
10 ± 3.5 BTDC at 9,000 min-1 (rpm)
° °
Full retard MBX50
3 ± 3.5 BTDC at 9,000 min-1 (rpm)
° °
MBX80
( ): MBX80 - Gtype
TROUBLESHOOTING
No spark at plug Engine starts but runs poorly
1. Faulty spark plug 1. Ignition primary circuit
2. Poorly connected, broken or shorted wires - Faulty ignition coil
- Between alternator and CDI unit - Loose or bare wire or connector
- Between CDI unit and ignition coil - Poor contact in ignition switch
- Between CDI unit and ignition switch 2. Ignition secondary circuit
- Between CDI unit and spark plug - Faulty ignition coil
3. Faulty ignition switch - Faulty spark plug
4. Faulty ignition coil - Faulty high tension cord
5. Faulty CDI unit - Faulty plug cap
6. Faulty alternator 3. Improper ignition timing
- Faulty alternator
- Stator not installed properly
- Faulty CDI unit
16-2
�HONDA.
IGNITION SYSTEM � MBX.50· MBX.80
(2) IGNITON
IGNITION COil (1) PRIMARY COIL
REMOVAL
Remove the seat and fuel tank.
Disconnect the wire leads.
Remove the coil by removing the attaching bolts.

Remove the spark plug cap by rotating it by hand.
CONTINUITY TE.ST
Measure the resistances of the primary and secon
dary coils.
Resistances:
Primary coil: 0.2-0.3 Ohms
Secondary coil: 3.4-4.2 Ohms
(1) SECONDARY
16-3
HONDA
MBX50,MBX80 IGNITION SYSTEM
CDI UNIT IGN EXT SW
REMOVAL
Remove the COi unit from the coupler.
INSPECTION
Measure the resistances between the terminals.
Replace the COi unit with a new one if the read
ings do not fall within the limits shown in the table.
NOTE
• The CDI is fully transistorized.
• For accurate testing, it is necessary to use
a specified electric tester. Use of an im
proper tester or measurements in improper PC E
range may give a false reading.
• Use SANWA ELECTRIC TESTER (P/N Unit: kQ
07308-0020000) or KOWA ELECTRIC
Tester positive
TESTER (TH-5H). ( +}probe
• In the table, "Needle swings the returns"
indicates that tht:re is a charging current in SW EXT PC E IGN
the condenser for the first time. The Tester �
needle will then remain fixed unless the ,
negative( -)probe
condenser is discharged.
SW CX) CX) CX) CX)
Measuring ranges:
Needle swings,
SANWA: x K.Q EXT 0.1-20 CX) CX)
then returns
KOWA: x 100.Q
PC 0.5-200 0.5-100 0.5-30 CX)
E 0.2-60 0.1-20 CX) CX)
IGN CX) CX) CX) CX)
(1) ALTERNATOR CONNECTORS
ALTERNATOR EXCITOR COIL/

PULSE GENERATOR
INSPECTION
Warm up the engine.
Stop the engine.
Disconnect the alternator connectors.
Measure the exciter coil and pulse generator resist
ances.
Black/Red - Green (Exciter coil):
50 - 300 Ohms
Blue/Yellow -Green (Pulse generator):
10 -100 Ohms
Replace the stator and flywheel as a set if not
within the specifications.
16-4
17. SWITCHES �HONDA
� MBXSO· MBX80

IGNITION SWITCH 17-3
HANDLEBAR SWITCHES 17-3
BRAKE LIGHT SWITCHES 17-4
NEUTRAL SWITCH 17-4
01 L LEVEL SENSOR 17-5
DJ
17-1
(:;i!J\ HONDA
� MBX50· MBX80 SWITCHES
SERVICE INFORMATION
GENERAL
• Some wires nave different colored bands around them near the connector. These are connected to other wires which
respond with the band color.
• All plastic plugs have locking tabs that must be released before disconnecting, and must be aligned when reconnecting.
• The following color codes used are indicated throughout this section and on the wiring diagram.
B = Blue G = Green Lg = Light Green R = Red

Bk=Black Gr =Grey 0 = Orange W =White
Br = Brown Lb = Light Blue P = Pink Y =Yellow
• To isolate an electrical failure, check the continuity of the electrical path through the part. A continuity check can usually
be made without removing the part from the motorcycle. Simply disconnect the wires and connect a continuity tester or
volt-ohmmeter to the terminals or connections�
• A continuity tester is useful when checking to find out whether or not there is an electrical connection between the two
points. An ohmmeter is needed to measure the resistance of a circuit, such as when there is a specific coil resistance involv
ed, or when checking for high resistance caused by corroded connections.
17-2
HONDA
SWITCHES MBX50·MBX80
IGNITION SWITCH (1) IGNITION SWITCH

Disconnect the ignition switch connectors.
Check continuity of_ terminals on the coupler in
each switch position.
SWITCH POSTION
OFF: B/W to G
ON: RtoB
I\ Terminal IG E Ho BAT
\
-
Postions
-
-
OFF
ON
Color code Bk/W G Bk R
HANDLEBAR SWITCHES (1) DIMMER SWITCH (2) LIGHTING SWITCH

The handlebar cluster switches (lights, dimmer, turn
signals, horn) must be replaced as assemblies.
Continuity tests for the components of the hand
lebar cluster switches follow:
Continuity snould exist between the color coded
wires on each chart.
LIGHTING SWITCH
Terminal
(HL)
Position
•
N
p
N
H
Colar colde
DIMMER SWITCH
"'
(3) HORN BUTTON (4) TURN SIGNAL SWITCH
I\Terminal
Hi (HL) Lo
Position
Hi 0-'-0
(N) -
Lo 0-'-0
Colar code B - w
"
TRUN SIGNAL SWITCH
'\Terminal
R w L
Position
R 0-'-0
N
L 0- '-0
Colar code Lb Gr 0
HORN BUTTON
I\Terminal
HO B
Po.sition \
Free
Push 0-f-o
Color code Lg Bk
(1) HANDLEBAR SWITCH COUPLER
17-3
�HONDA
� MBXSO· MBX80 SWITCHES
BRAKE SWITCHES Bk
FRONT BRAKE
Disconnect the front brakelight switchf wires at the
connectors.
Check the brakelight switch for continuity with the
fron brake applied.
Replace the seitch if necessary.
G/Y
(1) REAR BRAKELIGHT SWITCH
REAR BRAKE
Disconnect the brakelight switch wire leads at the
connectors.
Check the switch for continuity with the rear brake
applied.
Replace the switch if necessary.
Bk G/Y
G
NEUTRAL SWITCH
Disconnect the nuetral switch wire (Light Green/
Red) and ground wire (Green) at the connector.
Check the switch for continuity between the wires
with the transmission in neutral and with the
transmission in any gear.
Replace the neutral switch if necessary.
LG/R
17-4
HONDA
SWITCHES MBX50,MBX80
Oil LEVEL SENSOR
INSPECTION
Disconnect the oil level sensor coupler and remove
the sensor from the oil tank.
Measure the oil level sensor resistance with empty
float position.
RESISTANCE: G/R to Bk: 5-15 ohm
G to Bk: 00
Measure the resistance· between the green/red and

the black wire terminals with full float position.
RESISTANCE: G/R to Bk Approximately 340 ohm
(2) FLOAT
(1) OIL WARNING LIGHT

Turn the ignition switch ON.
Connect the oil level sensor coupler to the- wire
harness. Move the float from full to empty and
check that the oil warning light comes on.
If the light does not go on, check for blown fuse or
bulb, loose connection or open circuit in the wire
harness. Replace the sensor if all of these para
meters check out good.
(1) FLOAT
17-5
C2f\ HONDA
� MBXSO· MBX80 TROUBLESHOOTI 18.
ENGINE DOES NOT START OR IS HARD TO START 14-1
ENGINE LACKS POWER 14-2
POOR PERFORMANCE AT LOW AND IDLE SPEEDS 14-3
POOR PERFORMANCE AT HIGH SPEED 14-4
POOR HANDLING 14-4
18-1
�HONDA
TROUBLESHOOTING � MBXSO· MBX80
ENGINE DOES NOT START OR IS HARD TO START

CHECK PROBABLE CAUSE
1. Check if fuel is reaching carburetor NOT REACHING---------a-(1) No fuel. in fuel tank
l
CARBURETOR (2) Clogged fuel pipe from tank to
REACHING CARBURETOR carburetor
(3) Clogged float valve in carbu
retor
(4) Breather hole in fuel tank cap
clogged
2. Remove spark plug and try spark SPARKS ARE WEAK OR D0-----1-(1) Faulty spark plug
test NOT JUMP AT ALL (2) Fouled spark plug
(3) Faulty COi unit
SPARK JUMPS (4) Broken or shorted high
tension cord
(5) Broken or shorted ignition coil
(6) Faulty ignition switch
3. TJ eyl;nde, eomprns,;on by LOSS OF COMPRESSION------(1) Piston rings stuck in ring lands

operating kick pedal (2) Flaw in casting
(3) Compression leak past crankcase
COMPRESSION IS NORMAL (4) Faulty or clogged reed valve
(5) Worn cylinder and piston rings
s,J
(6) Blown cylinder head gasket
4. by follow;ng no,mal Excessively open choke

ENGINE FIRES BUT---------1.,.(1)
starting procedure STOPS SOON Choke stuck closed
(2)
Air leaking past manifold
(3)
ENGINE DOES NOT FIRE (4)
Ignition timing out of proper
t
5. Remove spark plug
adjustment
WET--------------(1) Carburetor flooded
(2) Carburetor choke excessively
DRY closed
(3) Throttle valve excessively
RJ,,.
opened
6. with choke appl;ed
18-2
HONDA
MBX50,MBX80 TROUBLESHOOTING
ENGINE LACKS POWER

1. Raise wheel off ground WHEEL DOES NOT SPIN------ (1) Brake dragging
FREELY (2) Worn or damaged wheel bearing
WHEEL SPINS FREELY (3) Wheel bearing not lubricated
properly
(4) Drive chain too tight
2. Check tire pressure with tire TIRE PRESSURE IS T00------(1) Punctured tire
gauge LOW (2) Faulty tire valve
TIRE PRESSURE IS NORMAL
3. Try ratid acceleration from low ENGINE SPEED NOT CHANGED----(1) Clutch slipping
to high WHEN CLUTCH IS RELEASED (2) Worn clutch disc
(3) Clutch disc warped
ENGINE SPEED LOWERED
WHEN CLUTCH IS RELEASED
4. Lightlt accelerate engine ENGINE SPEED DOES NOT-------(1) Carburetor choke closed
INCREASE SUFFICIENTLY (2) Restricted fuel flow
ENGINE SPEED INCREASES (3) Air cleaner clogged
(4) Clogged fuel tank breather.
(5) Clogged muffler
5. Check ignition timing using IGNITION TIMING IS INCOR------(1) Improper ignition timing
timing light RECT
IGNITION TIMINGS IS CORRECT
6. Test ctlinder compression by COMPRESSION IS LOW-------(1) Worn cylinder and piston rings
operating kick pedal using (2) Blown cylinder head gasket
compression gauge (3) Flaws in compression parts
(4) Faulty or deteriorated reed
COMPRESSION IS NORMAL valve
•
7. Check for clogged carburetor CARBURETOR IS CLOGGED- ----(1) Damaged fuel strainer
(2) Caburetor not serviced
CARBURETOR IS NOT frequently enough
CLOGGED
t
8. Remove spark plug PLUG IS FOULED OR-------1-(1) Plug fouled
DISCOLORED (2) Use of plug with improper
PLUG IS NOT FOULED OR heat range
DISCOLORED
18-3
�HONDA
TROUBLESHOOTING � MBX50· MBX80
9. Ch}ck oil level. Also check LEVEL IS TOO LOW OR T00-----(1) Transmissio oil level too high,
oil for contamination HIGH resulting in lack of power
(2) Transmission oil level too low
CRAl\!KCASE IS FILLED TO (3) No engine oil in oil tank
PROPER LEVEL (4) Oil deteriorated or contami
nated
10. ChJck if engine overheats ENGINE OVERHEATS-------(1) Improperly adjusted oil pump
(2) Excessive carbon build-up in
ENGINE IS NOT OVERHEATED combustion chamber
(3) Use of improper quality fuel
j
11. Accelerate or run at high speed
(4)
(5)
Mixture too lean
Clutch slipping
ENGINE KNOCKS---------(1) Worn piston rings and cylinder

(2) Fuel air mixture too lean
ENGINE DOES NOT KNOCK (3) Excessive carbon build-up in
combustion chamber
(4) Ignition timing too early
(advanced)
POOR PERFORMANCE AT LOW AND IDLE SPEEDS

1. Check ignition timing INCORRECT (1) Faulty COi unit

(2) Faulty alternator
NORMAL
Ch}ck carburetor air screw (1) Fuel air mixture too lean
adjustment (To correct, screw in)
2. INCORRECT
(2) Fuel air mixture too rich

NORMAL (To correct, screw out)
3. Air is leaking past carburetor (1) Deteriorated insulator

packing 0-ring
LEAKING
(2) Loose carburetor

NOT LEAKING (3) Deteriorated carburetor
packing
4.
j
Remove spark plug and try
spark test
WEAK OR INTERMIITENT ( 1) Defective, or carbon or wet
fouled spark plug
(2) Faulty alternator
SPARK
GOOD SPARKS (3) Faulty ignition coil

(4) Faulty COi unit
18-4
�HONDA
� MBX50, MBX80 TROUBLESHOOTING
POOR PERFORMANCE AT HIGH SPEED

1. Check ignition timing IMPROPER-------------(1) Faulty alternator

{2) Faulty CDI
PROPER
2. oJonriect fuel tube at carburetor FUEL FLOW IS RESTRICTED-----(1) Lack of fuel in tank
(2) Clogged fuel tank cap breather
FUEL FLOWS OUT FREELY hole
(3). Clogged fuel line
(4) Clogged fuel valve
J
3. Remove carburetor and check CLOGGED-------------1...(1) Damaged fuel strainer
NOT CLOGGED
POOR HANDLING------------- Check tire pressure

PROBABLE CAUSE
1. Steering heavy--------------------------(1) Steering cone races excessively

tightened
(2) Damaged steering steel balls
2. F rant or rear wheel is excessively wobbling----------------(1) Excessive play in wheel bearing

(2) Distorted rim
(3) Improperly installed wheel hub
(4) Rear fork pivot bushing exces-
sively worn
( 5) Distorted frame
(6) Improper drive chain adjust
ment
3. Pulls to one side ------------------------(1) Unbalanced shock absorbers

(right and left/front and rear)
(2) Front and rear wheels not
aligned
(3) Bent front fork
(4) Bent rear fork

�HONDA
� MBX50•MBX80,
MEMO

�HONDA
� MBX50· MBXBO GENERAL INFORMATION
WIRING DIAGRAM MBX50

SCHEMA DE CABLAGE
SCHALTPLAN I
DIAGRAMA DE CONEXIONES
FRONT STOP UGHT SWITCH
Conlacteur de stop du frein a,·anl
VOROEREA BREMSLICHTSCHALTEA
R. FRONT TURN SIGNAL 12VIOW
Feu signal de riragt arant droile 12VIOW (r-r--B1 IGNITION SWITCH
BI/V
AECHTES �OADERES BLINKuCo-;--;- 12VIOW Contac-teur principal REGULATOR/RECTIFIER
\.___)-r:.__B1 -@J-B1 - ZUNDSCHALTEA � Rfgulateur/Rectificateur
r:�: ! ·1
4---i-+-tJ
�
G/Bu R. REAR TURN SIGNAL 12VIOW
CONTAIN TEMP METER
Contient l'ih:l.icateur de tem�rature �G - Lb-tube ) Feu signal de virage arritre droite I2VIOW
Q�
TEMPEAATURMESSUHR TURN SIGNAL RELAY
"'"'�""
RECHTES. HINTERES BLINKLICHT 12VIOW
::=dJ
Bl
Relais. des clignolanls
BLINKRELAIS
CD=
�
� W BI R G/W
TACHOMETER LIGHT 12V3.4W �
&lairage du tachomelre I2V3.4W G
OREHZAHLMESSER·BELEUCHTUNG 11Vl.4W B
r
BI G
,-- --· G/Bu
G/R BI G
�,w 1 1 �-f--+-...1
·cG/Bu � 1-G/Bu - '-+ Gr BI G
-G· �G
""'f+-t--+--1--t---+--�/w-----------------...
R. TURN SIGNAL INDICATOR 12V3.4W
Feu signal de rirage derecha I2V3.4W
RECHTES BLINKLICHT·KDNTRDLLEUCHTE �,b· ----H Lb Lbd
-Bro �Br-1.-t-+-,
1 R ---+-l-li---f----t--f--+-----+-+-+-.+---1,-11-..
Bl---+""'l-ll---t----t-----+-----+-+-+--+---11-1
12V3.4W CD= -+-
OIL PRESSURE LIGHT 12V3.lW I
Temoin de pres.sion d'huile 12V3.4W
"-----BI �Bl-11-1-+- -++-i-_.
CD=. ---.<!·1
OLDRUCK·KONTRDLLEUCHTE 11VUW G A-----Lb---+--+--11-----+---+------+-+-+-1-11---+-+-11----Lb,-t---CJ<::J--Cf,.I
CD=G
L TURN SIGNAL INDICATOR 12V3.4W /R- ..__G/V---+-+-+----+---+-----t--1-11-t-+---+-+-I---
Feu signal de \·irage gauche 12V3.4W g·---+t-1-41-0 0
LINKER. BLINKLICHT-KDNTROLLEUCHTE I._____,
12Vl.4W
�
NEUTRAL INDICATOR 12V3.4W
e
Temoin du point mort I2V3.4W
CD=
(D::�R--if,1-C::J.<r l.UR"l------i-,I 1
LEERLAUF·KONTROLLEUCHTE 11V3.4W '-+-+--+++.!----
m -�
·*
�G/R I BI G·lube �.
ube
G
HIGH BEAM INDICATOR 12Vl.7W Bu
Temoin des feLU de route 12Vl.7W
FERNLICHT·KONTROLLEUCHTE 11VI.TW [
G� � LICENS LIGHT 12V5W
._f+-----G- �____,. Eclair �aqre 12V5W
L+-+-le-+.....II---G/Bu,----+----1,-...---- - --, NU MME RNSCHILDBELEUCHTUNG
11VSW
l T / W Bu,- -- 11----(,:�:i::_;__,- -++ ::.::..-t-+ ++-+-i,-- ,-----...+--+-------,
�e,�L a� 35)l�il Jl Bu - - 1
SCHEINWERFER I S/JSW '---------,.--:1::o:)
M : -4-+ + +..i,..,t.++J ..-----.....
; -- - + G G/W
R G L. REAR TURN SIGNAL 12VIOW
p Feu signal de virage arrihe gauche 12VIOW
�
G/V�G/V LINKES HINTERES BLINKLICHT 11VIOW
G :::r:
f
1 mi
Bl�Bl--l_j
''�
POSITION LIGHT 12V4W -
Br/W'---f+--C,C:J--
Feu de position 12V4W - 1-Br/W----, REAR STOP LIGHT SWITCH
CQ: , � tt
I
@.·
STANDLICHT 11V4W G tube Contacteur de atop du !rein arriere
G HINTEREA BREMSLICHTSCHALTEA
G tube -i J P·tube •
SPEEDOMETER LIGHT 1 2V3.4W Br
Eclairage du compteur de \·ilesse 12V3.4W CD=G
I0 BJ BI BI
I
GESCHWINDIGKEITSMESSER·BELEUCHTUNG 1
12V3.4W
l
B ---@--B1------
[ill] BATTERY 12V3AH
It I I
L. FRONT TURN SIGNAL 12VIOW . O·tube
� -
c&B l Ballerie 12V3AH
Feu signal de rirage a\'ant gauche 12VIOW �Br W Bu V Br G HORN BATTERIE 11V3AH
LINKER. VOROERER BLINKLICHT 12v1ow
W BI l l rlg
f Amtisseur sonore NEUTRAL SWITCH
Contacteur de point mort
Il J HUPE
thHHxil
lfl(30W) 6.7Q(30W) LEEALAUFSCHALTER
ii� :l�:f:.�:
WIDERSTAND
ALTERNATOR
Alternateur
WECHSELSTRDM·LICHTMA SCHINE
LIGHTING • DIMMER • TURN SIGNAL • HORN SWITCH .
Contacleur de l'avertisseur sonore, du rMucteur d'iclairal{e
du signal de \·irage et d'�clairage
HUPEN ·ABBLEND·BLINKLICHT·BELEUCHTUNGSSCHALTEA
I BI
I
BI BLAGK Br .. · BROWN Nojr ,Br ·· Brun BI SCHWARZ Br · BRAUN
V YELLOW 0 ORANGE y Jaune 0 Orange GELB ORANGE
Bo .. BLUE Lb .. LIGHT BLUE Bu Bleu Lb ... Bien clair ,, au .... BLAU Lb·· HELLBLAU
SWITCH CONTINUITY
Raccordement des contacteurs G GREEN Lg ... LIGHT GREEN :: 'G Vert Lg Vert clair
,, GRUN Lg .. HELLGRU�
I II
ANORDNUNG CEA SCHAL TEA R RED p PINK R Rouge p Rose ROT ROSA
W · WHITE Gr· GRAV W· Blanc Gr ...... ... Gris w WEIB Gr · •· GRAU
LIGHTING SWITCH DIMMER SWITCH TURN SIGNAL SWITCH HORN SWITCH IGNITION SWITCH
'"'
Contadeur d'fdairage 1Ududeur d'tclairage Conladeur de clignotant &uton d'arertisseur Contacteur principal
BELEUCHTUNGSSCHALTEA ABBLENDSCHAL TEA BLINKLICHTSCHALTER HUPENSCHALTEA zur.icsc�:...... .,.E.f.
•
(HL) Cl RE TL p
� Hi (HL) Lo R w L
� HO B
/0 rO Hi
--
O f-0
- R 0 :.0 FREE
IN)
p
-- -- -
0 rO (N)
Lo
-
0 fO
N
-L 0l-0
PUSH 0k)
(N)
H
-- -- --
0 fO
0030Z-GE2-0100

�HONDA
� MBXSO· MBX80
MBXSO
SPARK PLUG
Bougie
ZUNDKERZE
FRONT STOPUGHT SWITCH

Contacteur de stop du frein annt
VOADERER BREMSUCHT SC HALTER
_r
R FRONT TURN SIGNAL 12VIOW �
i 12 � Bl IGNITION SWITCH OIL PRESSURE SWITCH
�;��;;' '.�;�;�;;-;:
1
/:: '.·'__ 1;�� BI BI
Contacteur prindpal
ZUNDSCHAL TEA
� C 0ntacttur de l'indit:ateur REGULATOR/RECTIFIER
RfguJateur/Reclificateur
lrr�.r1,
de pression
': � l r
1
0
OL DRUCKSCHALTER
--@J-
G/Bu R. REAR TURN SIGNAL 12YJOW
Q
TEMP METER UGHT Feu signal d e vir&ge arriere droite l2VJOW
Tfmoin de l'iooiuteur de temj)erature� BI G Y
Lb·lube ) RECHTES. HINTERES BLINKLICHT 11VIOW
TE VPERATUAMESSUHA LIGHT
1 BI - BI
"'"'�""" ::=OJ
TACHOMETER LIGHT 12YJ. CW
Edairage du lachometre 12V3.4W
DREHZAHLMESSER·BELEllCHTUNG 12V3.4W CD= �
BI
.J= n
\I G �
G
- w �
Bu
B� I Lb Gy
i I' :
�
[G/Bu � -G/ Bu -
R. TURN SIGNAL INDICATOR 12Y3 CW

Feu signal de rirage derecha 12V3.H\
.,_G-
-a,-
,-G-
-s, � ,1
IECHTES BLINKLICHT-KON.TROLLEUCHTE
01---+-+-+--1-----11---+--+-----1....-1-+---+---+--+-•
...
11VJ.4W -Lb- Lb.I
[
OIL PRESSURE LIGHT 12Yl.CW Lb---+--+--tl----·--+----+------+--+--+-,
i--e1- -01
Temoin de pression d'huile I2V3.4W Br---+--+---1-----1-----+------t---t--+-t--1----+-+--+-----+--
OLDRUCK·KONTROLLEUCeT[ 11VJ.4W --·--,-
R- -
----G/Y--1--1--+----1---1---·--+-+-+-+-+---+-1-1---1--1-
L. TURN SIGNAL INDICATOR 12Y3.CW
Feu signal de rirage gauche 12V3.H\'
�INKER BLINKLICHT·KONTROLLEUCHTE
--·- I
o-� .. o 0,---+--+---1-----1,-.---+--- --t--t--1-1--t----1--1--11---1---+---------
w
11Vl.4W
NEUTRAL INDICATOR 12Y3.CW I
Temoin du point mor! 12\'3,4W R - Lg/R
--
0---1--11--------1-------- --+-+-+--+-+-----+-!-+-+--+-..
LEERLAUF·KONTROLLEvCHT[ 11VJ."4W WR----+---1------------t----------�----1--1,..i,--.-1-�
-
i
- -G/R
HIGH BEAM INDICATOR 12VUW G·tube- -,]
I G/R
Ttmoin des (eux de route 12\'I.7W G
Gr- ----+--'
i
FEANLICHT-KONTROLL[UCHT[ 11Vl.7W LICENS LIGHT 12V5W

�G &lair plaqre 12VSW
G/Bu-----1---+--------. NUMMERNSCHILDBELEUCHTUNG IIVSW
HEADLIGHT 12Y36/36W Bu Bu�
,___________::=OJ
G-----+--1------.
Phm 12\'36/36W
SCHE,NWERFER 11V36/l6W
Bu
w w-c::J<J---w
- L. REAR TURN SIGNAL 12YIOW
12V35/35W , ONLY FOR GERMAN MODEL G ,-G G Feu signal de virage arritre gauche 12VIOW
(12VJS/35� , Seulement pour le modele allemandV P G GW FUSE 7A G/Y-c>CJ-G/Y-f--i LINKES. HINTERES BLINKLICHT 11VIOW
Bu
11VJS/35W NUR FUR DAS DEUTSCHE MODELL

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POSITION LIGHT 12V4W r/ w Br/W Lt G REAR STOPUGHT SWITCH
Feu de position 12V4W CQ: I Contadeur de stop du (rein arrihe
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STANOLICHT 11V4W G HINTERER BREMSLICHTSCHALTEA
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BATTERY 12V3AH
Batterie 12V3AH
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Feu signal de 1·irage a1·ant gauche J2VI0W BI NEUTRAL SWITCH
LINKER. VORDERER BLINKLICHT IIVIOW I HUPE Contatteur de point mort
4n(JOW) 6.ln(JOW) LEERLAUFSCHAL TEA
,U!J1Ull,UI RESISTOR ALTERNATOR
Rfsistance .\lternateur
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WIDERSTANO
LIGHTING • DIMMER • TURN SIGNAL • HORN SWITCH
Contacteur de l'avertiBStur sonore, du r�dudeur d'lclairag-e
du signal de 1·irage et d',dairage
HUPEN ·ABBLEND·BLINKLICHT·BELEUCHTUNGSSCHAL TEA
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11
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ANORDNUNG DER SCHALTEA
REC p R · ,
w .. WHifE Gr GRAY W· Blanc Gr .. Gns w WEIB Gr ··•· GRAU
LIGHTING SWITCH DIMMER SWITCH TURN SIGNAL SWITCH HORN SWITCH IGNITION SWITCH
Contacteur d'fc/airage RMucteur d'fdairage Contacteur de dignolant Bouton d'anrtisseur Contacleur principal
"" "'
BELEUCHTUNGSSCHALTEI ABBLENDSCHAL TEA BLINKLICHTSCHALTEA HUPENSCHALTER I ZUNDSCI-IAL TEfl
(HL) Cl RE TL Hi (HL) Lo R w L I"" HO B
•
p
--
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-
0 -0
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�HONDA

HOW TO USE THIS MANUAL

If you don't know the source of the trouble, go COOLING SYSTEM

NO PART OF THIS PUBLICATION MAY

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(1) BEGINNING WITH F No. AC03-5000001.

(4) The carburetor identification number is on

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GENERAL SAFETY 1-1 SPECIAL TOOLS/COMMON TOOLS 1�5

r-------lMPORTANT SAFETY NOTICE-------.

ITEM MBX50 MBXSO AREA

e STANDARD TORQUE VALUES

Tool Name Part No. Q'ty Remarks

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CABLE & HARNESS ROUTING

(2) HIGH TENSION CORD

(4) TACHOMETER CABLE

(3) CLUTCH CABLE

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(5) AlTERNATOR/NEUTRAL SWITCH

(4) WIRE HARNESS

(1) CLUTCH CABLE

(3) THROTTLE CABLE (2) TURN SIGNAL SWITCH COUPLER

(5) BRAKE HOSE

(8) IGNITION COIL

(15) FUSE HOLDER (12)TACHOMETER

(14)REAR BRAKE LIGHT (1) CLUTCH CABLE

WHICHEVER I ODOMETER READING (NOTE 2)

TRANSMISSION OIL R R Page 2-3

(4) OIL PUMP

(8) OIL PUMP BLEEDER BOLT

OIL FLOW 2-0

Oil capacity 1.2 lit. (1.3 US qt, 1.1 Imp qt)

Oil recommendation Honda 2 Stroke Injector Oil or its equivalent

VISCOSITY: SAE 10W-40

A small amount of oil should flow out of the oil

(1) OIL LEVEL CHECKBOLT

Remove the oil filler cap.

Reinstall the drain plug.

(1) OIL FILLER CAP

Refill the engine up to the proper level.

Start the engine and check for leaks. Stop. the

(1). OIL DRAIN PLUG

Oil STRAINER CLEANING (1) OIL PUMP

Disconnect the oil tube at the oil pump and allow

(2) OIL TUBE

Remove the right side cover.

Loosen the tube clip and disconnect the oil tube

(3) OIL STRAINER--�

(4) OIL TUBE

Fill the oil tank with the recommended oil up to the

{1) OIL PUMP MOUNTING BOLT {2) SCREW

Remove the carburetor (Page 4-3).

(3) OIL PASS TUBE (4) OIL TUBE

Disconnect the oil tube from the oil pump, and

(2) TUBE CLIP

Disconnect the oil pass tube from the inlet pipe.

Remove the oil pump from the crankcase.

Replace the battery, if sulfation forms or sedi (1) UPPER LEVEL

Measure the drive chain slack between the sprock