Honda · Honda XL / XR / SL four-stroke single (1970-)

GB500 TT / GB400

Library entry covers 1985-1990

21 factory 45 guideline

Published source

Honda XBR500 Shop Manual (Honda Motor Co., 1985), Maintenance Schedule p.3-3

Factory workshop manual. Covers XBR500 shop manual (Honda, 1985); the XBR500 is the European sibling of the GB500 with the same RFVC single; chart in km with Honda's mile figures.

Open the source

66 items for a 1985 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Wet sump (oil in crankcase)
Oil filtration: Centrifugal (slinger / rotor) filter
Valve gear: Overhead cam, screw/locknut adjusters
Ignition: Magneto (incl. magdyno, flywheel magneto)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Single carburetor
Cooling: Air / oil cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Shares engine oil
Clutch control: Hand lever, cable
Final drive: Chain
Front suspension: Telescopic fork
Rear suspension: Swingarm, twin shocks
Front brake: Disc, hydraulic
Rear brake: Drum (or band / belt rim)
Wheels: Spoked, tubed
Sidecar: No sidecar

Maintenance schedule

1985 Honda GB500 TT / GB400

On the road: every 300 km

1 item

Check engine oil level

Pre-ride / on the road

Guideline

Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 500 km

3 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline
Lubricate drive chain

Pre-ride / on the road

Guideline

Lube warm, ideally at the end of the riding day so it soaks in overnight. Sooner after rain.

On the road: every 1,000 km

1 item

Check chain slack and rear wheel alignment

Pre-ride / on the road

Guideline

Every 1,000 km

1 item

Clean drive chain thoroughly (remove and soak, re-lube)

Final drive

Factory

Manual: Drive chain: inspect and lubricate. Factory: Maintenance schedule p.3-3

Every 1,600 km or 6 months

2 items

Adjust rear drum brake and rod / cable linkage

Brakes

Guideline
Inspect tire tread, sidewalls and date codes

Wheels and tires

Guideline

Every 3,000 km or 12 months

1 item

Change engine oil

Engine

Factory

Manual: Engine oil: replace. Factory: Maintenance schedule p.3-3: first at 600 mi

Every 5,000 km or 12 months

9 items

Clean / inspect air filter

Fuel and air

Guideline

Mesh or oiled foam: clean and re-oil. Paper: blow out or replace. Some very early machines have no filter at all.
Clean fuel tap filter / sediment bowl

Fuel and air

Guideline
Check / set ignition timing

Ignition and electrics

Guideline
Clean and gap contact breaker points, oil cam felt

Ignition and electrics

Guideline
Inspect chain and sprockets for wear (measure stretch)

Final drive

Guideline
Inspect fork seals, stanchions and fork boots

Front end

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Check brake pads and discs

Brakes

Guideline
Check wheel bearings for play

Wheels and tires

Guideline

Every 6,000 km or 1 month

1 item

Check battery electrolyte, top up with distilled water

Ignition and electrics

Factory

Manual: Battery: inspect. Factory: Maintenance schedule p.3-3

Every 6,000 km or 12 months

1 item

Replace oil filter

Engine

Factory

Manual: Engine oil filter: replace. Factory: Maintenance schedule p.3-3: first at 600 mi

Every 6,000 km

13 items

Walk-around: check nuts and bolts for vibration loosening

Pre-ride / on the road

Factory

Manual: Nuts, bolts, fasteners: inspect. Factory: Maintenance schedule p.3-3: first at 600 mi; dealer item
Check and adjust valve clearances

Engine

Factory

Manual: Valve clearance: inspect. Factory: Maintenance schedule p.3-3: first at 600 mi; decompressor system inspected at the same interval
Check engine breather and oil return

Engine

Factory

Manual: Crankcase breather: clean. Factory: Maintenance schedule p.3-3: more often in rain or at full throttle
Inspect, clean and gap spark plugs

Engine

Factory

Manual: Spark plug: inspect. Factory: Maintenance schedule p.3-3
Check throttle cable(s) free play and return

Fuel and air

Factory

Manual: Throttle operation and carburetor choke: inspect. Factory: Maintenance schedule p.3-3: dealer item
Replace fuel filter

Fuel and air

Factory

Manual: Fuel strainer screen: clean. Factory: Maintenance schedule p.3-3: dealer item
Replace fuel lines

Fuel and air

Factory

Manual: Fuel line: inspect. Factory: Maintenance schedule p.3-3: dealer item
Synchronize carburetors

Fuel and air

Factory

Manual: Carburetor idle speed: inspect. Factory: Maintenance schedule p.3-3: first at 600 mi; dealer item
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Factory

Manual: Clutch system: inspect. Factory: Maintenance schedule p.3-3: first at 600 mi
Grease and check center / side stand and springs

Rear suspension and frame

Factory

Manual: Side stand: inspect. Factory: Maintenance schedule p.3-3
Inspect rear shocks for leaks and damping

Rear suspension and frame

Factory

Manual: Suspension: inspect. Factory: Maintenance schedule p.3-3: dealer item
Adjust front drum brake

Brakes

Factory

Manual: Brake shoe and pad wear, brake system: inspect. Factory: Maintenance schedule p.3-3: brake system first at 600 mi; brake light switch and headlight aim at the same interval
Check spoke tension and wheel true

Wheels and tires

Factory

Manual: Wheels: inspect. Factory: Maintenance schedule p.3-3: Honda recommends dealer service

Every 6,500 km or 12 months

1 item

Lubricate brake cam spindles, check linings and drums

Brakes

Guideline

Every 9,500 km or 12 months

6 items

Clean oil strainers / mesh screens

Engine

Guideline

Often done with every oil change on old machines.
Clean carburetor float bowl(s), check float level and jets

Fuel and air

Guideline

Ethanol fuel varnishes old carbs quickly in storage.
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Lubricate control cables and lever pivots

Controls and cables

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 9,500 km or 2 years

3 items

Clean centrifugal oil filter (rotor / slinger)

Engine

Guideline
Lubricate and check automatic advance unit

Ignition and electrics

Guideline
Magneto: clean slip ring and pickup brush, check HT lead

Ignition and electrics

Guideline

Every 12,000 km

2 items

Replace spark plugs

Engine

Factory

Manual: Spark plug: replace. Factory: Maintenance schedule p.3-3
Check steering head bearing adjustment

Front end

Factory

Manual: Steering head bearings: inspect. Factory: Maintenance schedule p.3-3: first at 600 mi; Honda recommends dealer service

Every 16,000 km or 2 years

2 items

Compression test (or leak-down)

Engine

Guideline
Change fork oil

Front end

Guideline

Some early telescopic forks are grease filled or use very small oil quantities. Check your manual.

Every 18,000 km

1 item

Replace air filter element

Fuel and air

Factory

Manual: Air cleaner: replace. Factory: Maintenance schedule p.3-3: more often in dusty areas

Every 19,500 km or 2 years

1 item

Grease swingarm pivot

Rear suspension and frame

Guideline

Every 19,500 km or 3 years

1 item

Replace points and condenser

Ignition and electrics

Guideline

Every 24,000 km

1 item

Replace brake linings / skim drums (wear based)

Brakes

Guideline

Every 29,000 km

1 item

Replace chain and sprockets (wear based)

Final drive

Guideline

Every 32,000 km or 4 years

2 items

Repack / replace steering head bearings

Front end

Guideline

Many old machines use loose balls in cups and cones. Taper roller conversions are common.
Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 40,000 km or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 40,000 km or 10 years

1 item

Magneto overhaul / re-magnetize, replace capacitor

Ignition and electrics

Guideline

Weak spark when hot is the classic symptom. Old capacitors fail with age, not miles.

Every 48,500 km or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 12 months

1 item

Check speedometer / odometer against a known distance

Controls and cables

Guideline

Old speedos drift with tire size and drive wear. Use phone GPS over a measured 10 miles / km.

Every 2 years

3 items

Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline
Replace brake fluid

Brakes

Factory

Manual: Brake fluid: replace. Factory: Maintenance schedule p.3-3: inspected monthly and every 3,750 mi

Every 4 years

2 items

Inspect brake hoses; replace old rubber

Brakes

Guideline
Rebuild calipers and master cylinders (seals)

Brakes

Guideline

Every 6 years

2 items

Replace inner tubes and rim tape with tires

Wheels and tires

Guideline
Replace tires on age (regardless of tread)

Wheels and tires

Guideline

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.