GL1500C/GL1500CD GL1500C1 GL1500C2 GL1500C3 GL1500CD1 GL1500CD2 GL1500CD3. 13MZ01E3 Honda Motor Co., Ltd. 2002

Transcription

1 GL500C/GL500CD GL500C GL500C2 GL500C GL500CD GL500CD2 GL500CD MZ0E Honda Motor Co., Ltd. 2002

2 FOREWORD INDEX ENGINE GROUP 2 FRAME GROUP GL500C PART NUMBER INDEX 4 PART NAME INDEX 5

3

4 B Instruction for use of parts catalogue CONTENTS Address Page This parts catalogue was prepared based on the latest information available as of June 20, See the parts catalogue news for any revision that is made after June 20, Always specify the part number when ordering a part. Check the model, type, serial numbers, color, maker, and the size as needed before ordering a part. Note that the illustrations (part drawings) can differ from the actual parts in shape. They are given just to help you to refer to the parts. When modifications or additions to this parts catalogue are made, a revised edition will be issued at an appropriate time, with successively progressing revision numbers on the cover. We recommend obtaining such revisions in order to keep your parts catalogue up-to-date at all times. To check whether a parts catalogue revision has been issued, please contact your Honda distributor. How to refer to the part information... 2 Part catalogue structure... When the parts were revised... 4 Abbreviations used in the parts catalogue... 4 Part block and serial number check... 5 Color label attachment position check... 5 Models, parts catalogue codes and applicable serial numbers... 6 Color label... 8 Color chart... 9 Fuel hose, general purpose hoses and vinyl hose... 5 How to use the flat rate time (F.R.T.)... 9 Illustrated index ENGINE GROUP... 0 FRAME GROUP PART NO. INDEX... 4 PART NAME INDEX... 4 B 2 B B 4 B 4 B 5 B 5 B 6 B 8 B 9 B5 C C 6 D G L M Initial version issue date June 0, 2000 Honda Motor Co., Ltd.

5 B 2 How to refer to the part information Reference with Illustrated index Reference with Part number index Reference with Part name index 2

6 B Part catalogue structure Address number Address is provided (in place of the page ) to help you refer to the part with the part or part name. Block title Block number Service item/flat rate time Reference number Title number marked with the parenthesis or parentheses indicates that it continues from the previous page. Part number Honda color code Assemblies Sections framed with broken lines in the exploded view drawings are available as complete assemblies. (Their individual parts can also be obtained.) Color description Note Notes are shown with the parentheses in the part name column. Required quantity shown in the parenthesis or parentheses indicates the optional part. marked with N indicates the optional part that should be selected as needed. indicates the number of the part used in the block. Serial number When the parts catalogue code column is blank, it indicates that the part is applicable to all codes. Parts enclosed within a dotted line are covered in a different block. A hollow arrow indicates the block for the parts enclosed within a dotted line. A solid arrow indicates the block the part in question is connected to.

7 B 4 When the parts were revised Be sure to check the serial number!! Abbreviations used in the parts catalogue RIGHT is abbreviated as R. L. stands for LEFT * L. or R. in the description of a part stands for the LEFT hand side or the RIGHT hand side. Determine the left or right as if you were in the motorcycle seat. The number has been used from the initial model without revision. When shown at the left side, it is applicable to the models of and the subsequent numbers. When shown at the right side, it is applicable to the models up to The following abbreviations are used in this parts catalogue. A... Ampere ABS... Anti-lock brake system A.C.... Alternating current A.M.... Attaching mark ASSY.... Assembly C.D.I.... Capacitive discharge ignition COMP.... Complete D.C.... Direct current EX.... Exhaust FR.... Front G... Gram HEX.... Hexagonal IN.... Inlet KPH... Kilometers per hour L....Left L (00L).Link (00 Links) L.E.D....Light emitted diode MM...Millimeter MPH...Miles per hour R....Right RR....Rear STD....Standard T (22T)...Tooth (22 Teeth) TCS...Traction control system T.M....Transcript mark V...Volt W...Watt WL...With labelling WOL...Without labelling 4

8 B 5 Part block Part block and serial number check Engine parts Carburetor parts Frame parts E-~ E-20~ F-~ Color label attachment position check Colored parts Required serial number Engine serial number Carburetor serial number Frame serial number Color label Check point DMZ0-A DMZ0-E DMZ0-B 5

9 B 6 Models, parts catalogue codes and applicable serial numbers Models, parts catalogue codes and applicable serial Nos. given in this parts catalogue can be identified as follows. Parts with parts catalogue codes are exclusive for models destined for countries designated. If no area codes are listed, parts are for common use. Model Parts catarogue code Type Applicable engine serial Applicable frame serial Applicable carburetor identification AR Austria SC4E ~ HFSC4A*A40000~ VPK0P A CM Canada SC4E ~ HFSC42*A40000~ VPK0J A E England SC4E ~ HFSC4A*A40000~ VPK0S A GL500C ED European direct sales SC4E ~ HFSC4A*A40000~ F France SC4E ~ HFSC4A*A40000~ VPK0P A G Germany SC4E ~ HFSC4B*A40000~ SW Switzerland SC4E ~ HFSC4C*A40000~ VPK0N A U Australia SC4E ~ HFSC4U*A40000~ VPK0P A 6

10 B 7 Model Parts catarogue code Type Applicable engine serial Applicable frame serial Applicable carburetor identification AR Austria SC4E ~ HFSC4A*2A50000~ VPK0P A CM Canada SC4E ~ HFSC42*2A50000~ VPK0J A E England SC4E ~ HFSC4A*2A50000~ VPK0S A GL500C2 ED European direct sales SC4E ~ HFSC4A*2A50000~ F France SC4E ~ HFSC4A*2A50000~ VPK0P A G Germany SC4E ~ HFSC4B*2A50000~ SW Switzerland SC4E ~ HFSC4C*2A50000~ VPK0N A U Australia SC4E ~ HFSC4U*2A50000~ VPK0P A GL500C CM Canada SC4E ~ HFSC42*A60000~ VPK0J A U Australia SC4E ~ HFSC4U*A60000~ VPK0P A GL500CD CM Canada SC4E ~ HFSC48*A40000~ GL500CD2 CM Canada SC4E ~ HFSC48*2A50000~ VPK0J A GL500CD CM Canada SC4E ~ HFSC48*A60000~ * Of carburetor/throttle body identification numbers, only the portions underlined in the example below are used for registration. VPK0P KC 7

11 B 8 Color label When ordering parts, check the model name, main color, and code by observing the COLOR LABEL on the vehicle. When ordering a colored part, use the color chart in the instruction for use of parts catalogue. VFR800FIW R-57 R57 8

12 B 9 Color chart When ordering a colored part, refer to the chart below and use a part number consisting of the relevant basic part number to which has been added a part color code. GL500C (GL500C) MODEL COLOR CODE Black Black Pearl coronado blue NH- NH- PB-255P GL500C Applicable model Applicable block Name of colored parts Basic part NH NHE PB255X Initial applicable model Final applicable model COVER, CENTER 8700-MZ0-000 ZC ZC ZG F COVER, L. SIDE 8600-MZ0-000 ZC ZC ZG F-8 9 COVER, R. SIDE 8500-MZ0-000 ZC ZC ZF F EMBLEM, L. FUEL TANK 752-MZ0-60 ZA - - F EMBLEM, R. FUEL TANK 75-MZ0-60 ZA - - F FENDER A SET, RR. 800-MZ0-B00 ZA ZB ZC F FENDER A SET, RR. 800-MZ0-U70 ZA - ZC F FENDER B SET, RR MZ0-B00 ZA ZB ZC F FENDER SET, FR. 60-MZ0-B00 ZA ZB ZC F LABEL, COLOR MZ0-B00 ZA ZB ZC F-6 0 LABEL, FUEL MB ZF F-6 2 LABEL, FUEL MR6-670 ZA - - F-6 STRIPE, L. FR. FENDER 62-MZ0-B00 - ZA ZB F STRIPE, L. FUEL TANK 756-MZ0-B00 - ZA ZB F STRIPE, L. RR. FENDER A 802-MZ0-B00 - ZA ZB F STRIPE, L. RR. FENDER B 804-MZ0-B00 - ZA ZB F STRIPE, R. FR. FENDER 6-MZ0-B00 - ZA ZB F STRIPE, R. FUEL TANK 755-MZ0-B00 - ZA ZB F STRIPE, R. RR. FENDER A 80-MZ0-B00 - ZA ZB F STRIPE, R. RR. FENDER B 80-MZ0-B00 - ZA ZB F-7 2 TANK SET, FUEL 7520-MZ0-B00 ZA ZB ZC F TANK SET, FUEL 7520-MZ0-G5 ZB - - F-6 9 9

13 B0 GL500CD (GL500CD) MODEL COLOR CODE Black Black Pearl coronado blue NH- NH- PB-255P GL500CD Applicable model Applicable block Name of colored parts Basic part NH NHE PB255X Initial applicable model Final applicable model COVER, CENTER 8700-MZ0-000 ZC ZC ZG F COVER, L. SIDE 8600-MZ0-000 ZC ZC ZG F-8 9 COVER, R. SIDE 8500-MZ0-000 ZC ZC ZF F FENDER A SET, RR. 800-MZ0-B00 ZA ZB ZC F FENDER B SET, RR MZ0-B00 ZA ZB ZC F FENDER SET, FR. 60-MZ0-B00 ZA ZB ZC F LABEL, COLOR MZ0-B00 ZA ZB ZC F STRIPE, L. FR. FENDER 62-MZ0-B00 - ZA ZB F STRIPE, L. FUEL TANK 756-MZ0-B00 - ZA ZB F STRIPE, L. RR. FENDER A 802-MZ0-B00 - ZA ZB F-7 0 STRIPE, L. RR. FENDER B 804-MZ0-B00 - ZA ZB F STRIPE, R. FR. FENDER 6-MZ0-B00 - ZA ZB F-7 7 STRIPE, R. FUEL TANK 755-MZ0-B00 - ZA ZB F STRIPE, R. RR. FENDER A 80-MZ0-B00 - ZA ZB F STRIPE, R. RR. FENDER B 80-MZ0-B00 - ZA ZB F-7 6 TANK SET, FUEL 7520-MZ0-B00 ZA ZB ZC F-6 9 0

14 B GL500C (GL500C2) MODEL GL500C2 COLOR CODE Name of colored parts Basic part NH NHK Initial applicable model Final applicable model COVER, CENTER 8700-MZ0-000 ZC ZC F COVER, L. SIDE 8600-MZ0-000 ZC ZC F-8 9 COVER, R. SIDE 8500-MZ0-000 ZC ZC F EMBLEM, L. FUEL TANK 752-MZ0-60 ZA - F EMBLEM, R. FUEL TANK 75-MZ0-60 ZA - F FENDER A SET, RR. 800-MZ0-B0 ZA - F FENDER A SET, RR. 800-MZ0-U90 ZA ZB F FENDER B SET, RR MZ0-B0 ZA ZC F FENDER SET, FR. 60-MZ0-B0 ZA ZC F LABEL, COLOR MZ0-B0 ZA ZC F-6 0 LABEL, FUEL MB ZF F-6 2 LABEL, FUEL MR6-670 ZA - F-6 STRIPE, L. FR. FENDER 62-MZ0-B0 - ZA F STRIPE, L. FUEL TANK 756-MZ0-B0 - ZA F STRIPE, L. RR. FENDER A 802-MZ0-B0 - ZA F STRIPE, L. RR. FENDER B 804-MZ0-B0 - ZA F STRIPE, R. FR. FENDER 6-MZ0-B0 - ZA F STRIPE, R. FUEL TANK 755-MZ0-B0 - ZA F STRIPE, R. RR. FENDER A 80-MZ0-B0 - ZA F STRIPE, R. RR. FENDER B 80-MZ0-B0 - ZA F-7 2 TANK SET, FUEL 7520-MZ0-B0 ZA ZC F TANK SET, FUEL 7520-MZ0-G5 ZB - F-6 9 Black NH- Black NH- Applicable model Applicable block

15 B2 2 GL500CD (GL500CD2) MODEL COLOR CODE Pearl coronado blue PB-255P Name of colored parts Basic part PB255X NHK Initial applicable model Final applicable model COVER, CENTER 8700-MZ0-000 ZG ZC F COVER, L. SIDE 8600-MZ0-000 ZG ZC F-8 9 COVER, R. SIDE 8500-MZ0-000 ZF ZC F FENDER A SET, RR. 800-MZ0-B0 ZB ZC F FENDER B SET, RR MZ0-B0 ZB ZC F FENDER SET, FR. 60-MZ0-B0 ZB ZC F LABEL, COLOR MZ0-B0 ZB ZC F STRIPE, L. FR. FENDER 62-MZ0-B00 ZB - F STRIPE, L. FR. FENDER 62-MZ0-B0 - ZA F STRIPE, L. FUEL TANK 756-MZ0-B00 ZB - F-7 6 STRIPE, L. FUEL TANK 756-MZ0-B0 - ZA F STRIPE, L. RR. FENDER A 802-MZ0-B00 ZB - F-7 0 STRIPE, L. RR. FENDER A 802-MZ0-B0 - ZA F STRIPE, L. RR. FENDER B 804-MZ0-B00 ZB - F STRIPE, L. RR. FENDER B 804-MZ0-B0 - ZA F STRIPE, R. FR. FENDER 6-MZ0-B00 ZB - F STRIPE, R. FR. FENDER 6-MZ0-B0 - ZA F STRIPE, R. FUEL TANK 755-MZ0-B00 ZB - F STRIPE, R. FUEL TANK 755-MZ0-B0 - ZA F STRIPE, R. RR. FENDER A 80-MZ0-B00 ZB - F STRIPE, R. RR. FENDER A 80-MZ0-B0 - ZA F STRIPE, R. RR. FENDER B 80-MZ0-B00 ZB - F-7 2 STRIPE, R. RR. FENDER B 80-MZ0-B0 - ZA F-7 24 TANK SET, FUEL 7520-MZ0-B0 ZB ZC F-6 9 Black NH- GL500CD2 Applicable model Applicable block

16 B GL500C (GL500C) MODEL GL500C COLOR CODE Name of colored parts Basic part NH Initial applicable model Final applicable model COVER, CENTER 8700-MZ0-000 ZC F COVER, L. SIDE 8600-MZ0-000 ZC F-8 9 COVER, R. SIDE 8500-MZ0-000 ZC F FENDER A SET, RR. 800-MZ0-B0 ZA F FENDER A SET, RR. 800-MZ0-U90 ZA F FENDER B SET, RR MZ0-B0 ZA F FENDER SET, FR. 60-MZ0-B0 ZA F LABEL, COLOR MZ0-B50 ZA F LABEL, FUEL MB6-870 ZF F-6 0 TANK SET, FUEL 7520-MZ0-B0 ZA F-6 9 Black NH- Applicable model Applicable block

17 B4 GL500CD (GL500CD) MODEL GL500CD COLOR CODE Name of colored parts Basic part NH Initial applicable model Final applicable model COVER, CENTER 8700-MZ0-000 ZC F COVER, L. SIDE 8600-MZ0-000 ZC F-8 9 COVER, R. SIDE 8500-MZ0-000 ZC F FENDER A SET, RR. 800-MZ0-B0 ZA F FENDER B SET, RR MZ0-B0 ZA F FENDER SET, FR. 60-MZ0-B0 ZA F LABEL, COLOR MZ0-B50 ZA F TANK SET, FUEL 7520-MZ0-B0 ZA F-6 9 Black NH- Applicable model Applicable block 4

18 B5 Fuel hose, general purpose hoses and vinyl hose The standard part fuel hose, general purpose hose and vinyl hose may be substituted by the coiled bulk part. When ordering the standard part fuel hose, general purpose hose and vinyl hose use the bulk part number written in the parts catalogue in brackets ( ) underneath the part name, or use the catalogue below. (The bulk part standard length is m, however, those displayed in the catalogue < > are available in m and 8 m lengths.) When exchanging the hose, cut and use at the specified length as mentioned in the part name. (For the method of cutting the bulk part, and method of filling out orders etc., please refer to the service manual and the instructions issued with the bulk part.) The list below is a catalogue of the standard part numbers and bulk part numbers. Note that those numbers are applicable to the listed replacement parts only. Standard part Fuel hoses/tubes Bulk part Bulk part Inner diameter (mm) Length (m) xxx-2x M xxx-x M xxx-4x M xxx-2x xxx-x xxx-4x xxx-5x xxx-6x xxx-2x xxx-x xxx-4x xxx-5x xxx-6x xxx-2x M < M> M < M> M < M> M < M> M < M> M < M> M < M> < M> M < M> < M> M < M> M < M> < M> M < M> < M> Standard part xxx-x xxx-4x xxx-5x xxx-6x xxx-2x xxx-x xxx-4x xxx-5x xxx-6x Fuel hoses/tubes Bulk part M < M> < M> M < M> < M> M < M> < M> M < M> < M> M < M> M < M> < M> M < M> < M> M < M> M < M> < M> Bulk part Inner diameter (mm) xxx-2x M xxx-x M xxx-4x M xxx-5x M xxx-6x M Length (m)

19 B6 Vinyl tube Vinyl tube Vinyl tube Standard part Bulk part Inner dia- meter (mm) Bulk part Outer dia-meter (mm) Length (m) Standard part Bulk part Inner dia- meter (mm) Bulk part Outer dia-meter (mm) Length (m) Standard part Bulk part Inner dia- meter (mm) Bulk part Outer dia-meter (mm) Length (m) xxx-x xxx xxx-x xxx xxx-x xxx xxx-x xxx xxx-x xxx xxx-7x xxx-x xxx-x xxx xxx-x xxx xxx-x xxx xxx-x 9500-xxx xxx-x xxx M < M> M < M> M < M> M < M> M < M> < M> M < M> < M> M < M> < M> M < M> < M> M < M> < M> M < M> < M> M < M> < M> M < M> < M> M < M> M < M> M < M> M < M> M < M> M < M> M < M> < M> M < M> < M> M < M> < M> M < M> < M> xxx-x xxx xxx-x xxx-x xxx-x xxx xxx-x xxx xxx-x xxx xxx-x xxx xxx-x xxx xxx-x xxx xxx-x xxx-7x xxx-x xxx xxx-x xxx xxx-x 9500-xxx M < M> M < M> M < M> M < M> M < M> < M> M < M> < M> M < M> < M> M < M> < M> M < M> M < M> M < M> M < M> M < M> < M> M < M> < M> M < M> M < M> M < M> M < M> M < M> M < M> M < M> M < M> M < M> M < M> xxx-x xxx xxx-x xxx xxx-x xxx xxx-x xxx xxx xxx-x xxx xxx-x xxx xxx-x xxx xxx-x xxx xxx-x xxx-x xxx xxx-x xxx xxx-x xxx M < M> < M> M < M> < M> M M> M < M> M < M> M < M> M < M> M < M> M < M> M < M> M < M> M < M> < M> M < M> < M> M < M> < M> M < M> < M> M < M> M < M> M < M> M < M> M < M> M < M> M < M> M < M> M < M>

20 C Standard part General purpose hoses Bulk part Bulk part Inner diameter (mm) Length (m) xxx-x M xxx-5x M xxx-x M < M> xxx-2x M xxx-x M xxx-5x M xxx-x M xxx-2x M < M> xxx-x M xxx-5x M xxx-x M xxx-2x M xxx-x M xxx-5x M xxx-x M xxx-5x M xxx-x M < M> < M> xxx-2x M xxx-x M xxx-4x M < M> < M> xxx-5x M xxx-x M < M> < M> xxx-2x M xxx-x M Standard part xxx-4x M < M> < M> xxx-5x M xxx-x M < M> xxx-5x M xxx-x xxx-2x xxx-4x xxx-x M < M> < M> M < M> M < M> < M> M < M> NOTE: X is displayed to represent the omitted numerals and letters of the roman alphabet xxx-2x M M xxx-x < M> xxx-5x M xxx-x General purpose hoses Bulk part M < M> xxx-2x M xxx-x M 8.0 < M> xxx-2x M xxx-x M xxx-5x M xxx-x M xxx-5x M xxx-x M xxx-5x M Bulk part Inner diameter (mm) Length (m) CAUTION: It is DANGEROUS to confuse the fuel hose with the general purpose hose or vinyl hose. Never use a general purpose hose or vinyl hose in place of a fuel hose or vice versa. Always use the correct bulk part in the parts catalogue, according to the service manual or the instructions issued with the bulk part. 7

21 C 2 Bulk part number of fuel hose, general purpose hose and vinyl hose. (Example) M Bulk part number: Refers to the bulk part. Marking code (hose type): (fuel hose and general purpose hose) Change code (for added hose): (Vinyl hose) Indicates number mark or change sequence, however, the code for the bulk part must be strictly 0 (zero). Types of code: Fuel hose 2: Red outside braid ( mm inside dia. only) 5: Black inside braid : Red ( mm inside dia. only) 4: Ash gray with red stripe ( mm inside dia. only) 6: Black Vinyl hose : Clear 2: Black : Light red 6: Light red 7: Pale black General hose : Ash gray 2: Ash gray : Black 5: Black Lengths: 00: m (standard) 00: m 008: 8 m I.D code: (fuel hose and general purpose hose) 0:.0 mm : mm 5:.5 mm 9: 2 mm (outside dia. 5) mm 45: 4.5 mm 92: 2 mm (outside dia. 6) mm 50: 5.0 mm 2: 2 mm (outside dia. 7) mm 55: 5. mm, 5.5 mm 4: 4 mm 65: 6.5 mm 7: 7 mm 70: 7.0 mm 75: 7. mm, 7.5 mm 80: 8.0 mm ID./OD. code: (vinyl hose) 0: ID. 2.9, OD. 6.8 mm 4: ID. 6.0, OD. 9.0 mm 7: ID..0, OD. 5.0 mm 0: ID..0, OD. 6.0 mm 7: ID. 7.0, OD. 9.0 mm 8: ID. 2.0, OD..0 mm 05: ID..5, OD. 6.5 mm 9: ID. 7.0, OD..0 mm 9: ID. 2.0, OD. 4.0 mm 07: ID. 4.0, OD. 7.0 mm 2: ID. 8.0, OD. 9.0 mm 40: ID. 2.0, OD. 6.0 mm 08: ID. 4.5, OD. 6.5 mm 2: ID. 8.0, OD. 2.0 mm 4: ID..0, OD. 5.0 mm 09: ID. 4.5, OD. 8.0 mm 25: ID. 9.0, OD..0 mm 45: ID. 4.0, OD. 8.0 mm 2: ID. 5.0, OD. 7.0 mm 27: ID. 9.0, OD..0 mm 50: ID. 6.0, OD. 9.0 mm 0: ID. 5.0, OD. 8.0 mm : ID. 0.0, OD. 4.0 mm 55: ID. 7.5, OD mm : ID. 5.0, OD. 9.0 mm 6: ID..0, OD..0 mm 60: ID. 22.0, OD mm Hose type: : Fuel hose : Vinyl hose 5: General hose 8

22 C How to use the flat rate time (F.R.T.) This F.R.T. (Flat Rate Time) is used to determine the standard labor time allowed for replacement of parts covered by the warranty during the period the warranty is in effect. The F.R.T. for those parts which are not listed herein should be determined from the operation closely related to the replacement of that part.. The F.R.T. is based on the following servicing conditions a. A liberal allowance is added to the net servicing time. b. Standard times specified are based on the condition that the necessary servicing tools listed in the service manual (motorcycle) which describes the Honda service policy are available close at hand and the work performed by a mechanic with normal skill. c. Time required for inspection and operational test following the servicing is included in the F.R.T. 2. Method of computing The job times are listed in tenth of an hour to simplify computation. (Example) 0. = 8 minutes 5.6 = 5 hours and 6 minutes CONVERSION CHART Hours Minutes Hours Minutes

23 C 4. Computing the F.R.T. The following are only examples and do not reflect the actual F.R.T. for this product. When several jobs are performed at the same time, make the calculation in the following manner. a. Jobs of non duplicated nature The F.R.T. for the job is obtained by totalling the F.R.T. for each part replaced. (Example) Replacement of head cover gasket and oil filter. Service item F.R.T. Packing, cylinder head cover 0.5 Cartridge, oil filter 0.5 The F.R.T. for the job is: =.0 b. Jobs of duplicated nature Take the F.R.T. for the last part to be replaced. (Example) Replacement of piston and cylinder head gasket. Service item F.R.T. Gasket comp., cylinder head.0 Piston *5.0 The F.R.T. for the job is: 5.0 c. Jobs of partially related nature Total up the F.R.T. for all of the parts replaced and then subtract the F.R.T. for the duplicated operation (i.e., cylinder head gasket service). (Example) Replacement of valve and cylinder head. Service item F.R.T. Valve *.0 Head assy., cylinder *4.0 Gasket comp., cylinder head *2.5 The F.R.T. for the job is: ( ) = 4.5 The F.R.T. shown with (*) includes engine removal and installation. The parts, having the same number of man-hour, are identified by a mark, and classified under the title of their representative work. 20

24 C 5 4. Operations other than replacing parts a. Removal and installation Service item F.R.T. Engine Cylinder head.7 Carburetor 2. 4 Crankcase separation *0.8 5 Radiator Final Driven Gear.2 b. Adjustment, measurement and cleaning Engine Service item F.R.T. Spark plug adjustment and cleaning Carburetor idle adjustment 0. Engine oil inspection 0. 4 Compression-pressure measurement Battery checking of electrolyte level and gravity Carburetor float level measurement Oil strainer cleaning *.0 8 Throttle operation adjustment 0. 9 Carburetor synchronization adjustment Exterior radiator core cleaning 0. Valve clearance adjustment 0.9 Frame Service item F.R.T. Front brake air bleeding Rear brake air bleeding 0.2 Brake operation test 0. 4 Headlight aiming 0. 5 Front wheel balance Rear wheel balance. c. Overhaul Service item F.R.T. Carburetor.6 2 Final driven gear.5 2

25 ENGINE GROUP C 6 E- FRONT COVER/TIMING BELT D E-2 CYLINDER HEAD COVER D E- CYLINDER HEAD D4 2 E-4 CAMSHAFT/VALVE D6 E-5 WATER PUMP D 7 E-6 TRANSMISSION COVER D8 E-7 CLUTCH COVER D9 E-8 CLUTCH D0 E-9 GENERATOR D 22

26 ENGINE GROUP C 7 E-0 STARTING MOTOR D E- REAR CASE D4 E-2 PRIMARY DRIVE GEAR D5 2 E- FINAL SHAFT E E-4 OIL PUMP E 2 E-5 CYLINDER BLOCK E4 E-6 CRANKSHAFT/PISTON E6 E-7 TRANSMISSION E 8 E-8 SHIFT DRUM/SHIFT FORK E0 2

27 ENGINE GROUP C 8 E-9 WATER PIPE/THERMOSTAT E2 E-20 CARBURETOR(ASSY.) E E-20- CARBURETOR(TUBING) E5 2 E-20-2 CARBURETOR (COMPONENT PARTS) E6 E-2 AIR INJECTION CONTROL VALVE F2 EOP- GASKET KIT A F EOP-2 GASKET KIT B F4 24

28 FRAME GROUP C 9 F- HEADLIGHT() G F-- HEADLIGHT(2) G F-2 METER G5 F- SWITCH/CABLE G 7 F-4 FR. BRAKE MASTER CYLINDER G 9 F-5 CLUTCH MASTER CYLINDER G F-6 HANDLE PIPE/TOP BRIDGE G F-7 STEERING STEM G4 F-8 FRONT FENDER G5 25

29 FRAME GROUP C0 F-9 FRONT FORK G6 F-0 FRONT BRAKE CALIPER H 2 F- FRONT WHEEL H F-2 REAR BRAKE MASTER CYLINDER H5 F- REAR BRAKE CALIPER H 7 F-4 REAR WHEEL H8 F-5 FINAL DRIVEN GEAR H0 F-6 FUEL TANK H F-7 SEAT H5 26

30 FRAME GROUP C F-8 SIDE COVER I F-9 AIR CLEANER I2 F-20 EXHAUST MUFFLER I 4 F-2 PEDAL I6 F-22 STEP I7 F-2 SIDE STAND I 9 F-24 SWING ARM I0 F-25 REAR CUSHION I F-26 REAR FENDER/GRAB RAIL I2 27

31 FRAME GROUP C2 F-27 WINKER I4 F-28 TAILLIGHT() I6 F-28- TAILLIGHT(2) J F-29 BATTERY J5 F-0 WIRE HARNESS J7 F- IGNITION COIL J9 F-2 RADIATOR J0 F- FRAME BODY J F-4 ENGINE GUARD J5 28

32 FRAME GROUP C F-5 TOOLS J6 F-6 CAUTION LABEL K F-7 STRIPE/MARK K 29

33 E- FRONT COVER/TIMING BELT D 2 Service item F.R.T. Part GL500C GL500CD 2 2 Serial 0

34 E- FRONT COVER/TIMING BELT D 2 2 Part GL500C GL500CD 2 2 Serial

35 E-2 CYLINDER HEAD COVER D Service item F.R.T. 2 Part GL500C GL500CD 2 2 Serial 2

36 E- CYLINDER HEAD D 4 Service item F.R.T. 2 Part GL500C GL500CD 2 2 Serial

37 E- CYLINDER HEAD D 5 2 Part GL500C GL500CD 2 2 Serial 4

38 E-4 CAMSHAFT/VALVE D 6 Service item F.R.T. 2 Part GL500C GL500CD 2 2 Serial 5

39 E-5 WATER PUMP D 7 Service item F.R.T. 2 Part GL500C GL500CD 2 2 Serial 6

40 E-6 TRANSMISSION COVER D 8 Service item F.R.T. 2 Part GL500C GL500CD 2 2 Serial 7

41 E-7 CLUTCH COVER D 9 Service item F.R.T. 2 Part GL500C GL500CD 2 2 Serial 8

42 E-8 CLUTCH D0 Service item F.R.T. 2 Part GL500C GL500CD 2 2 Serial 9

43 E-9 GENERATOR D Service item F.R.T Part GL500C GL500CD 2 2 Serial

44 E-9 GENERATOR D2 2 Part GL500C GL500CD 2 2 Serial 4

45 E-0 STARTING MOTOR D Service item F.R.T. 2 Part GL500C GL500CD 2 2 Serial 42

46 E- REAR CASE D4 Service item F.R.T. 2 Part GL500C GL500CD 2 2 Serial 4

47 E-2 PRIMARY DRIVE GEAR D5 Service item F.R.T. 2 Part GL500C GL500CD 2 2 Serial 44

48 E-2 PRIMARY DRIVE GEAR D6 2 Part GL500C GL500CD 2 2 Serial 45

49 E- FINAL SHAFT E Service item F.R.T. 2 Part GL500C GL500CD 2 2 Serial 46

50 E-4 OIL PUMP E 2 Service item F.R.T. 2 Part GL500C GL500CD 2 2 Serial 47

51 E-4 OIL PUMP E 2 Part GL500C GL500CD 2 2 Serial 48

52 E-5 CYLINDER BLOCK E 4 Service item F.R.T. 2 Part GL500C GL500CD 2 2 Serial 49

53 E-5 CYLINDER BLOCK E 5 2 Part GL500C GL500CD 2 2 Serial 50

54 E-6 CRANKSHAFT/PISTON E 6 Service item F.R.T. 2 Part GL500C GL500CD 2 2 Serial 5

55 E-6 CRANKSHAFT/PISTON E 7 2 Part GL500C GL500CD 2 2 Serial 52

56 E-7 TRANSMISSION E 8 Service item F.R.T. 2 Part GL500C GL500CD 2 2 Serial 5

57 E-7 TRANSMISSION E 9 2 Part GL500C GL500CD 2 2 Serial 54

58 E-8 SHIFT DRUM/SHIFT FORK E0 Service item F.R.T. 2 Part GL500C GL500CD 2 2 Serial 55

59 E-8 SHIFT DRUM/SHIFT FORK E 2 Part GL500C GL500CD 2 2 Serial 56

60 E-9 WATER PIPE/THERMOSTAT E2 Service item F.R.T. 2 Part GL500C GL500CD 2 2 Serial 57

61 E-20 CARBURETOR(ASSY.) E Service item F.R.T Part GL500C GL500CD 2 2 Serial

62 E-20 CARBURETOR(ASSY.) Part GL500C GL500CD 2 2 Serial E4 2 59

63 E-20- CARBURETOR(TUBING) E5 Service item F.R.T. 2 Part GL500C GL500CD 2 2 Serial 60

64 E-20-2 CARBURETOR (COMPONENT PARTS) E6 Service item F.R.T. 2 Part GL500C GL500CD 2 2 Serial 6

65 E-20-2 CARBURETOR (COMPONENT PARTS) F Service item F.R.T. 2 Part GL500C GL500CD 2 2 Serial 62

66 E-2 AIR INJECTION CONTROL VALVE F 2 Service item F.R.T. 2 Part GL500C GL500CD 2 2 Serial 6

67 EOP- GASKET KIT A F Service item F.R.T. 2 Part GL500C GL500CD 2 2 Serial 64

68 EOP-2 GASKET KIT B F 4 Service item F.R.T. 2 Part GL500C GL500CD 2 2 Serial 65

69 F- HEADLIGHT() G Service item F.R.T. Part GL500C GL500CD 2 2 Serial 66

70 F- HEADLIGHT() Part GL500C GL500CD 2 2 Serial G 2 67

71 F-- HEADLIGHT(2) Service item G F.R.T. 68 Part GL500C GL500CD Serial 2 2

72 F-- HEADLIGHT(2) G 4 Part GL500C GL500CD 2 2 Serial 69

73 F-2 METER G 5 Service item F.R.T. 70 Part GL500C GL500CD Serial 2 2

74 F-2 METER G 6 Part GL500C GL500CD 2 2 Serial 7

75 F- SWITCH/CABLE G 7 Service item F.R.T. 72 Part GL500C GL500CD 2 2 Serial

76 F- SWITCH/CABLE G 8 Part GL500C GL500CD 2 2 Serial 7

77 F-4 FR. BRAKE MASTER CYLINDER G 9 Service item F.R.T. Part GL500C GL500CD 2 2 Serial 74

78 F-4 FR. BRAKE MASTER CYLINDER G0 Part GL500C GL500CD 2 2 Serial 75

79 F-5 CLUTCH MASTER CYLINDER G Service item F.R.T. Part GL500C GL500CD 2 2 Serial 76

80 F-5 CLUTCH MASTER CYLINDER G2 Part GL500C GL500CD 2 2 Serial 77

81 F-6 HANDLE PIPE/TOP BRIDGE G Service item F.R.T. Part GL500C GL500CD 2 2 Serial 78

82 F-7 STEERING STEM G4 Service item F.R.T. Part GL500C GL500CD 2 2 Serial 79

83 F-8 FRONT FENDER G5 Service item F.R.T. Part GL500C GL500CD 2 2 Serial 80

84 F-9 FRONT FORK G6 Service item F.R.T. Part GL500C GL500CD 2 2 Serial 8

85 F-9 FRONT FORK H Part GL500C GL500CD 2 2 Serial 82

86 F-0 FRONT BRAKE CALIPER H 2 Service item F.R.T. Part GL500C GL500CD 2 2 Serial 8

87 F- FRONT WHEEL H Service item F.R.T. 84 Part GL500C GL500CD 2 2 Serial

88 F- FRONT WHEEL H 4 Part GL500C GL500CD 2 2 Serial 85

89 F-2 REAR BRAKE MASTER CYLINDER H 5 Service item F.R.T. Part GL500C GL500CD 2 2 Serial 86

90 F-2 REAR BRAKE MASTER CYLINDER H 6 Part GL500C GL500CD 2 2 Serial 87

91 F- REAR BRAKE CALIPER H 7 Service item F.R.T. Part GL500C GL500CD 2 2 Serial 88

92 F-4 REAR WHEEL H 8 Service item F.R.T. Part GL500C GL500CD 2 2 Serial 89

93 F-4 REAR WHEEL H 9 Part GL500C GL500CD 2 2 Serial 90

94 F-5 FINAL DRIVEN GEAR H0 Service item F.R.T. Part GL500C GL500CD 2 2 Serial 9

95 F-5 FINAL DRIVEN GEAR H Part GL500C GL500CD Serial

96 F-5 FINAL DRIVEN GEAR H2 Part GL500C GL500CD 2 2 Serial 9

97 F-6 FUEL TANK H Service item F.R.T. 94 Part GL500C GL500CD 2 2 Serial

98 F-6 FUEL TANK H4 Part GL500C GL500CD 2 2 Serial 95

99 F-7 SEAT H5 Service item F.R.T. 96 Part GL500C GL500CD 2 2 Serial

100 F-7 SEAT H6 Part GL500C GL500CD 2 2 Serial 97

101 F-8 SIDE COVER I Service item F.R.T. 98 Part GL500C GL500CD 2 2 Serial

102 F-9 AIR CLEANER I2 Service item F.R.T. Part GL500C GL500CD 2 2 Serial 99

103 F-9 AIR CLEANER I Part GL500C GL500CD 2 2 Serial 00

104 F-20 EXHAUST MUFFLER I4 Service item F.R.T. Part GL500C GL500CD 2 2 Serial 0

105 F-20 EXHAUST MUFFLER I5 Part GL500C GL500CD Serial

106 F-2 PEDAL I6 Service item F.R.T. Part GL500C GL500CD 2 2 Serial 0

107 F-22 STEP I7 Service item F.R.T. Part GL500C GL500CD 2 2 Serial 04

108 F-22 STEP I8 Part GL500C GL500CD 2 2 Serial 05

109 F-2 SIDE STAND I9 Service item F.R.T. Part GL500C GL500CD 2 2 Serial 06

110 F-24 SWING ARM I0 Service item F.R.T. Part GL500C GL500CD 2 2 Serial 07

111 F-25 REAR CUSHION I Service item F.R.T. Part GL500C GL500CD 2 2 Serial 08

112 F-26 REAR FENDER/GRAB RAIL I2 Service item F.R.T. Part GL500C GL500CD 2 2 Serial 09

113 F-26 REAR FENDER/GRAB RAIL I Part GL500C GL500CD Serial 0

114 F-27 WINKER I4 Service item F.R.T. Part GL500C GL500CD Serial 2 2

115 F-27 WINKER I5 Part GL500C GL500CD 2 2 Serial 2

116 F-28 TAILLIGHT() I6 Service item F.R.T. Part GL500C GL500CD 2 2 Serial

117 F-28 TAILLIGHT() J Part GL500C GL500CD Serial 2 2 4

118 F-28 TAILLIGHT() J2 Part GL500C GL500CD 2 2 Serial 5

119 F-28- TAILLIGHT(2) Service item J F.R.T. 6 Part GL500C GL500CD 2 2 Serial

120 F-28- TAILLIGHT(2) J4 Part GL500C GL500CD 2 2 Serial 7

121 F-29 BATTERY J5 Service item F.R.T. Part GL500C GL500CD 2 2 Serial 8

122 F-29 BATTERY J6 Part GL500C GL500CD 2 2 Serial 9

123 F-0 WIRE HARNESS J7 Service item F.R.T. 20 Part GL500C GL500CD 2 2 Serial

124 F-0 WIRE HARNESS J8 Part GL500C GL500CD 2 2 Serial 2

125 F- IGNITION COIL J9 Service item F.R.T. Part GL500C GL500CD 2 2 Serial 22

126 F-2 RADIATOR J0 Service item F.R.T. Part GL500C GL500CD 2 2 Serial 2

127 F-2 RADIATOR J Part GL500C GL500CD Serial

128 F-2 RADIATOR J2 Part GL500C GL500CD 2 2 Serial 25

129 F- FRAME BODY J Service item F.R.T. 26 Part GL500C GL500CD 2 2 Serial

130 F- FRAME BODY J4 Part GL500C GL500CD 2 2 Serial 27

131 F-4 ENGINE GUARD J5 Service item F.R.T. Part GL500C GL500CD 2 2 Serial 28

132 F-5 TOOLS J6 Service item F.R.T. Part GL500C GL500CD 2 2 Serial 29

133 F-6 CAUTION LABEL K Service item F.R.T. 0 Part GL500C GL500CD 2 2 Serial

134 F-6 CAUTION LABEL K 2 Part GL500C GL500CD 2 2 Serial

135 F-7 STRIPE/MARK K Service item F.R.T. 2 Part GL500C GL500CD 2 2 Serial

136 F-7 STRIPE/MARK K 4 Part GL500C GL500CD 2 2 Serial

137 PART NO. INDEX L 4 4 Part Number Address Page Part Number Address Page Part Number Address Page Part Number Address Page Part Number Address Page

138 PART NO. INDEX L 2 Part Number Address Page Part Number Address Page Part Number Address Page Part Number Address Page Part Number Address Page 5 4

139 PART NO. INDEX L 4 6 Part Number Address Page Part Number Address Page Part Number Address Page Part Number Address Page Part Number Address Page

140 PART NO. INDEX L 4 Part Number Address Page Part Number Address Page Part Number Address Page Part Number Address Page Part Number Address Page 7 4

141 PART NO. INDEX L Part Number Address Page Part Number Address Page Part Number Address Page Part Number Address Page Part Number Address Page

142 PART NO. INDEX L 6 Part Number Address Page Part Number Address Page Part Number Address Page Part Number Address Page Part Number Address Page 9 4

143 PART NO. INDEX L 7 Part Number Address Page Part Number Address Page Part Number Address Page Part Number Address Page Part Number Address Page 4 40

144 PART NAME INDEX M Part name Address Page Part name Address Page Part name Address Page 4 5

145 PART NAME INDEX M Part name Address Page Part name Address Page Part name Address Page

146 PART NAME INDEX M Part name Address Page Part name Address Page Part name Address Page 4 5

147 PART NAME INDEX M Part name Address Page Part name Address Page Part name Address Page

148 PART NAME INDEX M5 Part name Address Page Part name Address Page Part name Address Page 45 5

149 PART NAME INDEX M Part name Address Page Part name Address Page Part name Address Page

150 PART NAME INDEX M7 Part name Address Page Part name Address Page Part name Address Page 47 5

151 PART NAME INDEX M Part name Address Page Part name Address Page Part name Address Page

152 PART NAME INDEX M9 Part name Address Page Part name Address Page Part name Address Page 49 5

153 FOREWORD INDEX 2 ENGINE GROUP FRAME GROUP 4 PART NUMBER INDEX 5 PART NAME INDEX

154 E.O A Published by Honda Motor Co., Ltd. Printed in Japan

155 PARTS CATALOGUE NEWS Honda Motor Co., Ltd. Service Division PARTS CATALOGUE - CORRECTED CODE NO. PARTS CATALOGUE NEWS BOOKLET TYPE MICRO- FICHE MZ0E MZ0EC GL500C/GL500CD GL500C/C2/C GL500CD/CD2/CD Printed in Japan NEWS NO. 00

156 PARTS CATALOGUE NEWS Honda Motor Co., Ltd. Service Division PARTS CATALOGUE - CORRECTED CODE NO. PARTS CATALOGUE NEWS BOOKLET TYPE MICRO- FICHE MZ0E MZ0EC GL500C/GL500CD GL500C/C2/C GL500CD/CD2/CD Printed in Japan NEWS NO. 002

157

158

159 PARTS CATALOGUE NEWS Honda Motor Co., Ltd. Service Division PARTS CATALOGUE - CORRECTED CODE NO. PARTS CATALOGUE NEWS BOOKLET TYPE MICRO- FICHE MZ0E MZ0EC GL500C/GL500CD GL500C/C2/C GL500CD/CD2/CD Printed in Japan NEWS NO. 00