1986 Honda Interceptor 500 Manual

The 1986 Honda Interceptor 500 is a sport motorcycle featuring a 498cc liquid-cooled V4 engine, 6-speed transmission, Pro-Link rear suspension, triple disc brakes, full fairing, and digital instrumentation. This manual covers maintenance procedures, specifications, troubleshooting, and repair guidelines for proper operation and longevity of your motorcycle.

1. Specifications 2. Maintenance Schedule 3. Engine Service 4. Chassis & Suspension 5. Electrical System 6. Brake System 7. Troubleshooting 8. Safety Information 9. Warranty & Support

Specifications

Technical specifications for the 1986 Honda Interceptor 500.

Component	Specification
Engine Type	498cc liquid-cooled 90° V4
Bore x Stroke	60.0 x 44.1 mm
Compression Ratio	11.0:1
Fuel System	Four 26mm constant velocity carburetors
Transmission	6-speed constant mesh
Final Drive	#530 O-ring chain
Suspension Front	37mm air-assisted fork
Suspension Rear	Pro-Link single shock
Brakes Front	Dual 276mm discs
Brakes Rear	Single 276mm disc
Tires Front	100/90-16
Tires Rear	120/80-16
Fuel Capacity	4.8 gallons
Wet Weight	474 lbs

Maintenance Schedule

Regular maintenance intervals for optimal performance.

Every 600 miles/1000 km: Check engine oil level, tire pressure, chain adjustment
Every 4,000 miles/6,400 km: Change engine oil and filter
Every 8,000 miles/12,800 km: Clean and sync carburetors, check valve clearance
Every 12,000 miles/19,200 km: Replace spark plugs, air filter
Every 16,000 miles/25,600 km: Replace brake fluid, check brake pads
Every 24,000 miles/38,400 km: Replace coolant, check wheel bearings

WARNING! Always perform maintenance with engine off and cool. Use proper safety equipment.

Engine Service

Engine maintenance and repair procedures.

Oil Change: Use 10W-40 motorcycle oil, capacity 3.7 quarts with filter change
Valve Adjustment: Intake: 0.004 in (0.10 mm), Exhaust: 0.005 in (0.12 mm)
Cooling System: Use 50/50 mix of antifreeze and distilled water
Carburetor Sync: Use vacuum gauges to balance all four carburetors
Spark Plugs: NGK CR8EH-9, gap 0.031-0.035 in (0.8-0.9 mm)

CAUTION! Engine components get extremely hot. Allow proper cooling time before service.

Chassis & Suspension

Frame, suspension, and steering maintenance.

Chain Adjustment: 1.0-1.2 inches (25-30 mm) free play at midpoint
Fork Oil: 10W fork oil, capacity 16.9 oz (500 ml) per leg
Steering Head Bearings: Check for play every 4,000 miles
Wheel Alignment: Ensure proper alignment using string method
Tire Pressure: Front: 28 psi, Rear: 32 psi (cold)

Electrical System

Battery, charging system, and electrical components.

Battery: 12V 10Ah, maintain fluid level, keep terminals clean
Charging System: Output: 280W at 5000 RPM
Fuses: Main fuse 30A, accessory fuses 10A
Bulbs: Headlight 60/55W, turn signals 21W, brake light 21/5W
Ignition System: Electronic CDI ignition, maintenance-free

Tip: Disconnect battery negative terminal first when working on electrical system.

Brake System

Brake maintenance and service procedures.

Brake Fluid: DOT 4, change every 2 years or 16,000 miles
Brake Pads: Replace when thickness reaches 1mm
Disc Inspection: Check for warping and minimum thickness (4.0mm)
Bleeding: Use proper bleeding sequence: rear, left front, right front
Caliper Service: Clean and lubricate slide pins annually

WARNING! Brake fluid is corrosive. Avoid contact with paint and skin.

Troubleshooting

Common issues and solutions for the Interceptor 500.

Symptom	Possible Cause	Corrective Action
Hard starting	Dirty carbs, weak battery	Clean carburetors, charge/replace battery
Poor idle	Vacuum leak, sync needed	Check vacuum lines, sync carburetors
Overheating	Low coolant, stuck thermostat	Check coolant level, replace thermostat
Electrical issues	Bad connections, regulator	Check grounds, test charging system
Brake pulsation	Warped discs	Replace brake discs
Chain noise	Poor lubrication, tight chain	Lubricate chain, adjust tension

Safety Information

Important safety precautions for operation and maintenance.

Always wear approved helmet and protective gear
Perform pre-ride inspection: tires, brakes, lights, chain
Never operate motorcycle under influence of alcohol/drugs
Follow all traffic laws and speed limits
Keep hands and feet away from moving parts during maintenance
Use proper jack stands when lifting motorcycle

CAUTION! Motorcycles offer less protection than cars. Ride defensively.

Warranty & Support

Original 1986 warranty information and current support options.

Original Warranty: 12 months unlimited mileage. Covered defects in materials and workmanship. Normal maintenance items and wear parts excluded.

Current Support: While original warranty has expired, Honda continues to provide parts support. Contact authorized Honda dealers for genuine parts and technical assistance.

Parts Availability: Many common maintenance parts remain available through Honda dealers and aftermarket suppliers.