Honda CB550 Manual Download Page 6

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Summary of Contents for CB550

Page 1: ...rihgs 33 5 Oil pump and oil filter 36 9 COMPARISON OF CB550 TO CB500 113 6 Clutch 40 7 Gear shift mechanism 43 10 ENGINE 121 8 Cam chain tensioner 46 1 Clutch 121 9 Crankshaft and connecting rod 47 2...

Page 2: ...Upper crankc ase bolt 8x 100 Flange hex bolt Upper crankcase bolt 8x 145 hex bolt Lower crankcase bolt 8x 100 hex bolt Connecting rod nut Oil pump screw 6x35 cross flat head screw Clutch filter fixing...

Page 3: ...40 8 x 50 hex bolt 3 1 8 2 3 13 0 16 6 _ 16 Front fork bolt 2 5 5 6 5 39 8 47 0 17 Steering stem nut 1 8 0 12 0 57 9 86 7 18 Steering stem bolt 10X 40 hex bolt 2 3 0 4 0 21 7 28 9 19 Rear wheel axle n...

Page 4: ...item No 17 07945 3000500 IWeight sliding hammer 1 07945 3330300 Bearing driver attachment X X 07945 3330200 Driver attachment I X x I07946 3600000 Driver attachment ___ _ o _ 1 I Transmission bearing...

Page 5: ...4 2 SPECIAL TOOLS G 4 D o ill I D LJ I o l l ID e II I o m J Next Page Contents Prev Page...

Page 6: ...q G t 1 12 _J I 2 SPECIAL TOOLS 5 G I I G 3Q iii ow DC O 3h Next Page Contents Prev Page...

Page 7: ...rances INLET 0 05 mm 0 002 in EXHAUST 0 08 mm 0 003 in 6 Next rotate the crankshaft one revolu tion and realign the T l 4 mark on the spark advancer to the timing mark in this position the No 4 piston...

Page 8: ...fuel tube 2 Adjust the throttle stop screw so that the throttle lever is 49 1 5mm 11 16 1 i in from the stay 3 Install the vacuum gauge in the inlet manifolds Remove the plugs from the inlet manifolds...

Page 9: ...carburetor the standard adjustment for the air screws is 1 3 8 turn open from the complete close position 8 Readjust the engine idle speed to 950 1 050rpm with the throttle stop screw Note Tighten the...

Page 10: ...position 3 BREAKER POINT GAP AND IGNI TION TIMING ADJUSTMENT Check the condition of the contact points point gap and ignition timing Adjust the ignition timing of the l 4 points first Breaker point g...

Page 11: ...th strobo scopic timing light The use of the stroboscopic timing light is recommended to obtain the most accurate timing 1 Plug the timing light cord into the timing light receptacle 2 Remove the spar...

Page 12: ...ster lock bolt 2 Turn the adjuster clockwise unti l a slight resistance is felt and then turn counter clockwise about 3 mm 1 8 in At that point tighten the lock bolt 3 Adjust play in the clutch cable...

Page 13: ...t is damaged Standard spark plugs D 7ES NGK X 22ES DENSO 7 ENGINE OIL INSPECTION AND CHANGE Oil Level Inspection Check the oil level with the dipstick gauge without screwing it into the case If the le...

Page 14: ...that there is a small clearance between the fixed friction pad and the brake disc 1 Raise the front whee l off the ground using a suitable prop 2 Loosen the caliper stopper bolt lock nut 3 Using a sui...

Page 15: ...rocedure until bubbles cease to appear in the fluid at the end of the hose 5 Remove the bleeder hose tighten the bleeder valve and install the bleeder valve dust cap 6 Do not allow the fluid reservoir...

Page 16: ...ake Adjustment 1 Normal play at the end of the brake pedal is 2 3 cm 3 4 l3 i6in 2 Perform the adjustment with the adjuster nut 10 AIR CLEANER ELEMENT SERVICING 1 Open the seat and remove the tool tra...

Page 17: ...is low open the seat and remove the tool tray to add distilled water to the battery 2 Remove six battery filler caps and fill the water to each cell up to the upper limit 13 FRONT FORK OIL REPLACEMENT...

Page 18: ...reading will increase with each kicking To obtain the true pressure reading per form the measurement after warming up the engine Low compression pressure W hen the compression pressure is below 10 kg...

Page 19: ...1 4 ENGINE i Next Page Contents Prev Page...

Page 20: ...nd dismount the fuel tank 2 Unscrew the oil drain bolt and the oil filter center bolt and drain the engine oil 3 Remove the exhaust pipe and the muffler 4 Disconnect the high tension cords at the spar...

Page 21: ...switch and then the gener ator wiring at the coupler 11 Remove the gear change pedal unscrew the starting motor cover bolts remove the starting motor cover and then remove the left crankcase cover Dis...

Page 22: ...ex bolt 10X50 hex bolt Rear upper hang er bolt 8x 100 hex bolt 8X40 hex bolt Rear lower hanger bolt z 10x80 hex holt 4 ENGINE 12 Remove the final driven sprocket and the drive chain 13 Disconnect the...

Page 23: ...lt Make sure that the generator cord and starting motor cord are not pinched when the left crankcase cover is installed Make sure that the two mufflers on each side are properly connected with the muf...

Page 24: ...nscrew six 6 mm screws and remove the breather cover 5 Remove the tappet hole caps left and right side covers unscrew twelve 6 mm screws and six bolts and remove the cylinder head cover Note Loosen th...

Page 25: ...cylinder by raising the cam chain guide slightly and rotate the guide 90 and removing it toward the top During this operation do not drop the cam chain 13 Unscrew the cam chain adjuster lock nut Fig 5...

Page 26: ...5 Remove the piston pin clip piston pm and the piston Note When removing the pin clip exercis e care not to drop the clip into the crankcase 16 Remove the piston rings 17 Screw a 6 mm bolt into the ro...

Page 27: ...t the top center and bottom in both the X and Y axes Rebore the cylinder if beyond the serviceable limit at any point When reboring the cylinder rebore it to fit one of the four standard oversize pist...

Page 28: ...a feeler gauge 9 Measure the piston pin hole using an inside micrometer or cylinder gauge 10 Inspect the piston for damage distortion and excessive wear C Reassembly 1 Install the rocker arm and the r...

Page 29: ...en installing the 011ring first place the spacer anc l then the rails in position b The spacer and rail gaps must be stag gered 2 3 cm 0 783 1 181in Note The gap of the oil rin g refer s to that of th...

Page 30: ...ve entered the cylinder remove the bases and piston ring compressors Next turn the crank shaft slightly and install the No 1 and 4 pistons being careful not to expose the rings of the No 2 and 3 pisto...

Page 31: ...ugh them from the right side and set it on the bearings in the cylinde r head Install the cam cha in on the cam sprocket 13 Adjustment of valve timing Remove the point cover rotate the crankshaft in t...

Page 32: ...justin g screw to check that they are properly meet ing the valves Use the six 6 mm copper washers as shown in Fi g 57 Install the head side cover set plate with washers mounted on both sides of the 6...

Page 33: ...Inspection l Measure valve stem clearance Insert the valve into the guide and measure the clearance in both the X and Y direc tions using a dial gauge Replace the valve and guide in set if clearance b...

Page 34: ...e seat grinder in accordance with the instruction manual 3 Measure valve runout Place the valve on V block and measure the runout of the valve with a dial gauge applied to the face of the valve while...

Page 35: ...valve guide Inlet valve guide Component parts of the ylinder head Valve spring outer seat Retainer Valve spring inner seat Cotter Valve stem seal Valve rocker arm shaft Inner valve spring Valve rocker...

Page 36: ...ngine 4 ENGINE Lubricating System Block Diagram Cam profile Rocker arm slipper f 4 Crank room Rocker arm shaft Valve stem Piston pin Piston Transmission counter shaft 1 Primary gear f 1 Crank room 1 l...

Page 37: ...ing Next remove three 6 mm screws and the oil pump 4 Remove the cap and disassemble the re lief valve and spring j Oil Screen Filter j 1 Drain the engine oil in accordance with section 2 A 2 Unscrew t...

Page 38: ...the clearance beyonds the serviceable limit replace the pump 2 Measure the clearance between the outer rotor and the pump body Use a feeler gauge to measure the clearance between the outer rotor and...

Page 39: ...ll the 47 mm 0 ring on the oil pump body and install the oil pump cover with three 6 mm screws 4 Install the relief valve and spring into the oil pump body and install the cap 5 Insta ll the two 0 rin...

Page 40: ...ing bolts and remove the clutch pressure plate and four clutch springs 5 Remove the clutch lifter joint piece 6 Remove the 25mm snap ring shims some engine may not have shims installed and the clutch...

Page 41: ...nting the clutch outer to the driven gear for looseness and replace the clutch outer if any of rivets are loose C Reassembly 1 Assemble the clutch lifter rod into the main shaft so that the spherical...

Page 42: ...mble them on the clutch center so that the oil g rooves are facing as per Fig 118 6 After assembling the friction discs and clutch plates set them with the snap ring Place a dial gauge against the end...

Page 43: ...ble the upper and lower crank case and disassemble the transm ission gears in accordance with the section 9 A 8 Remove the neutral stopper switch from the gear shift drum 9 Remove the shift drum guide...

Page 44: ...ace any part which exceeds the serviceable limit 2 Measure the width of the gear shift fork fingers with a micrometer Replace if beyond serviceable limit C Reassembly 1 Set the le t right and center g...

Page 45: ...thread lock cement Note The pin and the pin hole in the cam plate must be ali g ned 7 Attach the shift drum stopper spring to the drum stopper and to the drum neutral stopper as shown in Fig 132 then...

Page 46: ...l on which a layer of heat resistant rubber is vulcanized and a sheet of teflon cemented It applies pressure against the cam chain and absorbs the shocks produced by the chain The cam chain guide on t...

Page 47: ...head cylinder and piston in accordance with section 3 A 3 Remove the generator cover and remove the rotor using a generator rotor puller Tool No 07933 2160000 4 Remove the point cover and the special...

Page 48: ...model CB 550 use a primary shaft hammer Tool No 07936 3740100 and weight hammer Tool No 07945 3000500 Note Disassembly of the primary shaft trans mission and kick starter can be per formed without re...

Page 49: ...with a cylinder gauge and select out the corresponding alphabet from the table below C B A mm in 36 016 36 024 1 4179 1 4182 36 008 36 016 1 4176 1 4179 36 000 36 008 l 4173 1 4176 3 Measure the diam...

Page 50: ...Selection of The Bearing I 1 Measure crankshaft pin diameter with a micrometer and select out the corre sponding alphabet from the table below A 34 99 35 00 1 3775 1 3780 B 34 98 34 99 1 3771 1 3775...

Page 51: ...connecting rod small end Measure the diameter of the connect ing rod small end with an inside dial gauge Replace if beyond serviceable limit C Reassembl y 1 Install the primary chain and cam chain on...

Page 52: ...quence shown in Fig 151 to a torque of 2 3 2 5 kg m 16 63 18 08 lbs ft Nex t tighten thirteen 6 mm bolts Fig 152 Note Note position of the two 8mm bolts which are stamped on the bolt head with numeral...

Page 53: ...the frame in accordance with section 2 A 2 Remove the clutch in accorda nce with section 6 A 3 Separate the upper and lower crankcase in accordance with section 9 A 4 Remove the transmission and disa...

Page 54: ...9 A and remove the 20 mm snap ring and primary drive gear 8 Remove the side collar and pull out the 6205 ball bearing 9 Remove the 30 mm snap ring primary driven sprocket starting clutch and pull out...

Page 55: ...mary driven sprocket and install on the starting clutch with 30 mm set ring 3 Drive the 6205 ball bearing into the primary shaft 4 Mount the startin g clutch gear on the starting clutch insert the nee...

Page 56: ...starter spindle D 57 mm bearing set ring 25 mm snap ring 5205 special ball bearing 24 5 mm 0 ring Transmission counter shaft 33x57x7 oil seal I Drive sprocket 17T Drive sprocket fixing plate Gea r shi...

Page 57: ...ordance with 2 B 11 CARBURETOR A Disassembly 1 Remove the carburetor unit from the engine in accordance with section 2 A IStay Plate And Carburetor I 2 Unhook the throttle return spring off the link l...

Page 58: ...s from the stay plate and remove the carbu retor unit Throttle Valve And Jet Needle j 6 Unscrew the two carburetor top mount ing screws from each carburetor and re move the tops 7 Position the throttl...

Page 59: ...aft and remove the valve plate 11 Remove the jet needle from the throttle valve J A djusterllolder J 1 Remove the carburetor from the stay plate in accordance with section 1 5 2 Remove the adjusting s...

Page 60: ...the leaf spring and the main jet 3 Pull out the float arm pin and remove the float 4 Disengage the clip plate and remove the valve seat B Inspection 1 Fuel level adjustment Position the float so that...

Page 61: ...ith section 7 and 8 IThrottle Valve And Jet Needle I 1 Install the jet needle on the throttle valve 2 Place two each spring washers and 3 mm screws on the valve plate and then place the tab of the val...

Page 62: ...washer with the tongue positioned as shown in Fig 187 tighten the 6 mm bolt and then bend up the washer tongue against the bolt head 6 Install the carbu retor top with the two 5 mm screws 7 Combine th...

Page 63: ...the nuts 12 Connect the throttle return spring on the link lever being careful not to damage the hook 13 Install and route the two fuel tubes as shown in Fig 193 14 Mount the carburetor unit on the e...

Page 64: ...Front spoke A Front wheel rim 6302R ball bearing 22368 dust seal Front wheel bearing retainer Front wheel collar Front wheel axle nut 1 Place a suitable block under the engine to raise the front whee...

Page 65: ...ten the tongues on the tongued washers and unscrew the disc mounting nuts 7 Remove the speedometer gear box and retainer cover from the opposite side 8 Remove the front wheel bearing B Inspection 1 Ch...

Page 66: ...ve C Reasse mbly 1 Drive the 6302R wheel ball bearing into the hub using a bearing driver On the model CB 550 use driver attach ment Tool No 07946 935020 and driver handle Tool No 07949 6110000 2 Inst...

Page 67: ...rotating the wheel several times The balance weights are available in four different weight sizes 5 10 15 and 20 gr e The front wheel should be balanced with the brake disc installed The disc brake s...

Page 68: ...joint bolt and disconnect the brake hose 7 ID Piston Pad A 69 Fig 210 CD Oil joint Oil joint bolt Brake hose 3 Unscrew the three caliper mounting bolts and a caliper adjusting bolt and remove the cal...

Page 69: ...r cylinder unit from the hand le bar 9 Disassemble the master cylinder Master cylinder unit Brake hose Master cylinder mounting bols CDBrake lever cap Brake lever Stopper washer Boot s 18mm internal s...

Page 70: ...pad to 0 15 mm 0 006in with the caliper adjusting bolt Adjust by turning the caliper adjusting bolt until the pad drags slightly against the brake disc and from this position back off 1 2 turn and tig...

Page 71: ...well as water re pellent Do not apply grease on the pad friction surface 3 App ly a coat of brake fluid to the inside surface of the cylinder 4 Instail the check valve to the return spring and instal...

Page 72: ...n t finish rubber parts and meter components therefore exercise care in handling and immediately wipe in case of spillage To air bleeding the brake system refer page 15 Fig 222 73 5mm 0 08 0 2in Fig 2...

Page 73: ...the drive chain adjusting bolt on both sides remove the cotter pin and loosen the axle nut 5 Push the heel forward and lift the chain off the driven sprocket Remove the lock bolts chain adjusting sto...

Page 74: ...Check ball bearing wear 6 Check for loose spokes bending and da mage Tighten straighten or replace as necessary 7 Check tire on both inside and outside for cuts bruises and imbedded of nails Repair or...

Page 75: ...nd driver handle Tool No 07949 6110000 taking care not to allow the space collars to incline 4 Mount the brake panel on the hub and the drive chain on the sprocket Insert the wheel axle through the as...

Page 76: ...4 Remove the head light unit from the head light case and disconnect the wiring at the harness within the case 5 Unscrew four bolts remove the hand le bar holders and disconnect the wire harness Fig 2...

Page 77: ...them B Inspection 1 Check the handle bar for twist ing and damage 2 Check the steering stem for twisting and cracking 3 Check the steel balls for cracks and wear 4 Check the cone race for wear 5 Chec...

Page 78: ...20 0 mm 3 8 3 4 in at the end of the lever Brake lever 2 5 mm 5 64 13 64 in at the end of the lever 4 FRONT SUSPENSION Fig 244 CD Punch marks Fig 245 CD Clutch cable Wire harness Front brake hose Fork...

Page 79: ...fork 4 Unscrew the 8 x 56 mm and the 10x 35 mm bolts and pull the forks off the bottom 5 Unscrew the front fork bolt loose from the piston rod lock nut and remove the front fork spring and cushion spr...

Page 80: ...snap ring Replace the removed seal with a new one 4 App ly a coat of thread lock cement to the threaded part of the damper Making sure that the 8 mm lock nut is completely screwed on the threaded par...

Page 81: ...of tubular construction which provides gre iter rigidity A Disa sse mbly 1 Remove the mufflers 2 Remove the rear wheel 3 Remove the rear suspension mounting nut and bolt and then remove the suspension...

Page 82: ...k swing arm for bend ing twisting and cracks C Reassembly 1 Mount the rear brake arm stopper to the rear fork 2 Apply grease on the fork pivot bushing and install the rear fork on the frame with the p...

Page 83: ...B Disassembly 1 Position the fuel cock lever to STOP disconnect the fuel tube from the fuel cock and dismount the fuel tank from the frame 2 Remove the mufflers and dismount the engme 3 Remove the fr...

Page 84: ...the tank interior with clean gosoline 6 Remove dust from the air cleaner ele ment by blowing compressed air from the inside Check element for damage 7 Replace exhaust pipe gasket if damaged D Reassem...

Page 85: ...ad light switch Starter switch High beam pilot lamp Neutral lamp Oil warning lamp Winker pilot lamp Speed warning lamp except USA type Winker switch Horn button Ignition coil Speed warning system exce...

Page 86: ...current to spark plugs 1 and 4 the other breaker furnishes current to plugs 2 and 3 The contact breakers ignite the spark plugs in a firing sequence of 1 2 4 and 3 which is indicated on the high tens...

Page 87: ...wo ignition coil mounting bolts and separate the ignition coil from the frame B Inspection 1 Ignition coil continuity test Primary coils Check for continuity between the termi nals of the primary coil...

Page 88: ...onnect the opposite terminal ends to the primary terminals of the coil Con nect red test lead to the black terminal of the ignition coil and the white test lead to the yellow cord of the left coil to...

Page 89: ...e and if necessary adjust to the specified gap Standard gap 0 6 0 7 mm 0 023 0 027in 3 Replace the spark plug if the porcelain insulator is damaged or the gasket if it is damaged or distorted Standard...

Page 90: ...breaker point and ignition timing refer to the section Maintenance Operations Condenser Measure the capacitance of the condenser using the service tester Standard value 0 22 0 26 F Note The point s s...

Page 91: ...gh the upper contact and to the field coil The strength of the magnetic field is dependent upon the strength of the battery voltage When the battery terminal voltage is 12V the field coil current is 1...

Page 92: ...e voltmeter to the EBend of the battery cable and ground the 8 side of the voltmeter Fig 282 4 Start the engine operate the engine under both the NIGHT RIDING and DAY RIDING conditions and check to se...

Page 93: ...oil leads Wh ite Green using the Ser vice Tester OHMS function STANDARD RESISTANCE VALUE 4 90 10 NOTE Test may be performed without removin g field coil 2 Stator coil resistance test a Check resistanc...

Page 94: ...ent Regulating voltage adjustment 1 To adjust for low charge current or low battery voltage loosen the lock nut on the voltage adjusting screw and turn the adjusting screw clockwise When the regulator...

Page 95: ...shorten the lif e of the battery as well as causing a large current to flow through the electrica l syst em cau sing damage to the silicon rectifier and al so destroyin g the wire harne ss 3 Do not o...

Page 96: ...sed energizes the starter magnetic switch and closes the contacts of the starter circuit This permits approximately 120 A of current to flow from the battery to the starting motor which then rotates t...

Page 97: ...e 0 12 kg cm 11000 0 86 ft lb Revo lution 20000 rpm 3200 rpm A Disassembly 1 Disconnect the starting motor cable at the magnetic switch 2 Remove the starting motor cover le t crankcase cover and unscr...

Page 98: ...erformance Surface of the commutator should be polished with a fine grade emery paper and completely washed before reassembly 3 Stator coil inspection Check continuity between the brush wired to the s...

Page 99: ...ity test If there is no continuity the primary coil is open If a clicking noise is heard when a 12V battery is connected to the two leads of the coil the primary coil is satisfactory 2 After long use...

Page 100: ...evel mark 2 Whenever there is rapid lowering of the electrolyte level the charging system shou ld be inspected 3 Periodically measure the specific gravity After adding distilled water allow the batter...

Page 101: ...ke lever travels beyond the play in the lever 3 Rear stop switch inspection After making sure that the stop switch spring is disconnected apply tester lead probes to the switch terminals green yellow...

Page 102: ...cord terminal and orange cord terminal left winker and between the gray cord terminal and light blue cord terminal right winker respectively of the winker switch Con tinuity for the respective tests s...

Page 103: ...to various parts of engine When the oil pressure drops the oil supply becomes insufficient The oil system is designed so that when the oil pressure drops below 0 5 kg cm2 7 lbs in 2 the oil pressure...

Page 104: ...e left side of the upper crankcase When the transmission is in neutral the switch be comes grounded and the neutral pilot lamp comes on Position the transmission in neutral remove the left crankcase c...

Page 105: ...e play as measured at the tip of the clutch lever To adjust proceed as follows 1 Loosen the clutch adjuster lock nut CD and turn the adjuster to align the marks on the actuating arm and engine side co...

Page 106: ...the cylinder head is conducted into the element seal case through the breather tube The gas is then conducted into the element B through the openings on both sides in the seal plate and punching meta...

Page 107: ...into the air 2 STARTING MOTOR SAFETY UNIT Description The starting motor safety unit operates in the way that the starting motor functions only when the transmition is in neutral or while the clutch l...

Page 108: ...1 Clutch lever switch The clutch lever switch is designed to be turned on when the clutch lever is squeezed to cause the clutch to be disengaged only This switch has the same construction and function...

Page 109: ...nsion As the wheel has passed the bump or hole it moves down To eliminate excessive up and down motion of the spring and wheel there will be a restraint on the spring and wheel action In operation as...

Page 110: ...brake lining has worn the brake cam moves excessively Such a move ment of the cam is checked by the arrow on the periphery o the indicator Further the brake panel cam boss is provided with the wear l...

Page 111: ...Pis ton disp lacement 498cc or 30 4cu in Diameter 58 5mm 2 303in Piston displacement 544cc or 33 2cu in Fig 332 Exploded from left Fig 333 Exp loded from right Modified part Cylinder Pistons Piston ri...

Page 112: ...clutch springs to be compressed producing clearance between the friction discs and plates Now the face pressure on the frict ion surfaces of the power transmitting parts is reduced to zero resulting...

Page 113: ...9 COMPARISON OF CB550 TO CB500 115 Construction of CB500 clutch system Fig 334 Construction of CB550 clutch system Fig 335 Next Page Contents Prev Page...

Page 114: ...sembly is provided with the transmission oil pipe The oil comes up to the right side of the countershaft through the oil passage in the right side of the lower crankcase and is fed to the countershaft...

Page 115: ...PARISON OF CB550 TO CB500 _1 1 r r I I I Fig 339 DOil pump Trochoid pump Transmission oil_ pipe Oil to countershaft oooc Oil to cylinder head and crankshaft through oil pump 117 Next Page Contents Pre...

Page 116: ...um Fig 344 CD Groove for gear shift drum gide screw Fig 343 CD Gear shift fork shaft Gear shift drum Center gear shift fork Right and left gear shift forks The center fork is in stalled to the drum an...

Page 117: ...on with employ ment of the blow by gas scavenging device the air cleaner was changed in shape Jumber of teeth 37 Fig 349 1 Turn signal switch 2 Horn switch 3 Dimmer switch Fig 351 I Ignition switch 2...

Page 118: ...er rod 5 Remove the four clutch pressure plate mounting bolts 6 Remove the clutch lifter plate 7 Remove the 25mm snap ring and shim and remove the clutch assembly from the mainshaft 8 Remove the clutc...

Page 119: ...ction disk thickness Using a vernier caliper measure the thickness of each friction Re place a disk whose thickness is below the service limit Assembly standard 2 7 0 1063 C Assembly _I_ Unit mm in Se...

Page 120: ...e snap ring The washers are available in three thicknesses namely 0 1mm 0 0039in 0 3mm 0 0118in and 0 5 mm 0 0197in 6 Install the four clutch springs Install the lifter plate and tighten the four 6mm...

Page 121: ...ch See page 120 2 Remove the gear change pedal 3 While holding down the gearshift arm as shown pull out the gearshift spindle 4 Remove the shift drum stop bolt and neutral stop bolt and remove the shi...

Page 122: ...al separately issued C Assembly 1 Position the center gearshift fork on the drum as shown in Fig 48 2 Insert the guide pin into the center gear shift fork and secure with the guide pin clip NOTE Insta...

Page 123: ...crankcases securely 7 Install the bearing set plate on the drum side and secure with the two 6mm bolts 8 Install the drum gearsh ift center NOT E Properl y fit the Jug of the drum into the hole in th...

Page 124: ...shift drum and check each component for smooth movement 13 Install the gearshift arm and check to see if it moves smoothly and equally in booth directions 14 Install the clutch See page 121 Fig 374 12...

Page 125: ...nder and piston 7 Worn weak or broken piston ring 8 Loose spark plug 11 2 Heavy carbon deposit on chamber and piston head Lean fuel mixture Retarded ignition timing combustion I 5 Low oil level poor q...

Page 126: ...rped pressure plate Replace 4 Bent main shaft Replace Pedal does not 11 Faulty return spring Replace return 2 Unhook return spring IHook return spring Kick starter 1 Excessive wear of kick starter paw...

Page 127: ...fork stoppe r ru bber 4 Insufficient front fork oil Defe ctive brake 1 Front brake fluid Insufficent brake fluid Air in the brake system Worn brake pad Worn piston Worn or distorted front brake disc...

Page 128: ...air or rep lace 3 Poor contact of start ing motor carbon brush Repair or rep lace Horn inopera tive poor sound or too weak sound 1 Horn Cracked diaphragm 2 Horn button Poor grounding 3 Wiring Poor con...

Page 129: ...coil Open circuit in one of the stator coil Faulty or shorted silicon diode 3 Regulator Replace Replace Replace Replace Voltage below specified value at no load Readjust I Dirty of pitted points Poli...

Page 130: ...e battery 1 Shorted 2 Insufficient charging 3 Distilled water overfilled 4 Contaminated electrolyte 11 of overloading remove some of the excess load Check to assure proper charging rate 1 1 Check spec...

Page 131: ...RS Check and adjust if necessary 0 THROTTLE OPERATION 0 Inspect cables Check and adjust free play 1 FUEL FILTER SCREEN Clean 0 FUEL LINES Check 0 CLUTCH Check operation and adjust if necessary 0 DRIVE...

Page 132: ...50 18 4 PR Block tire tire air pressure 28 5 psi 2 0 kg cm 2 r i l s F Brake Lining Area Disc brake lining area 32 36 in2 x 2 288 8cm 2 X2 R Brake Lining Area Internal expanding shoe lining area 26 28...

Page 133: ...n sprocket 34 T Gear Shift Pattern Left foot return type Ignition Battery and ignition coil Starting System Electrical motor and kick pedal Alternator Three phase A C 12 V 0 2 KW 5 000 rpm Battery Cap...

Page 134: ...sk brake lining area 32 36 in2 x 2 288 8 cm2 x2 R Brake Lining Area Internal expanding shoe lining area 26 28 in2X 2 169 6cm 2x2 Fuel Capacity 3 7 U S gal 3 1 Imp gal 14 0lit Fuel Reserve Capacity 1 1...

Page 135: ...duction 2 176 drive sprocket 17 driven sproket 37 T Gear Shift Pattern Left foot return type Ignition Battery and ignition coil Starting System Electrical motor and kick pedal Alternator Three phase A...

Page 136: ...er Exhaust 5 430 5 445 0 2137 0 2142 Valve face I 0 05 runout 0 009 mm in Item IStandard value I Serviceable limit Cylinder head 1 f o 3 flatness 0 011 Item I Standard value Serviceable limit Valve Ou...

Page 137: ...on 1 13 957 13 984 l 0 5494 0 5505 13 940 0 549 Wheel J Standard value J Serviceable limit Rim runout TIR vertica l and side 0 5 0 02 2 0 0 08 Item ISt d d 1 e I Serviceab le an ar va u limit Disc tru...

Page 138: ...ameter Exhaust 5 430 5 445 0 2137 0 2142 Valve face 0 05 runount 0 009 mm in Item Cylinder head flatness Standard value I Ser ic able limit 0 3 0 011 I em Standard value ierviceable limit Valve Outer...

Page 139: ...5528 Piston 13 957 13 984 13 940 0 549 0 5494 0 5505 Whee l IStandard value IServiceable limit R7 im _ r _u _n _o _ u t J T IR vertical and O 5 O OZ I 2 0 0 08 side Item Standard value Disc trueness...

Page 140: ...CHLjl lRII CB500 f ChlTIJN COl l rt 1 1 JI J q LB TAIL STOP LAMP 12 1324c v c J r ffl rC Jo Sr _9 l REAR TURN SIG NALLAMP 12 132cp Br Sro fl w wh te 8 Bue LG lif t Gret11 G Y G ttn Yellow Q Qrange c...

Page 141: ...ACT BREAKER i A 1 E I URN SIGNAL LIGHT H I B r y y IBATfE LB CT I I 12Y12AH J fu Gl I y __ __ _ C B II j LB LB TAil STOP LIGHT REAR STOP SWITCH t I J _jl I Gy_ _G y I STA TER ETC c E SW T lf Y Y R _ R...

Page 142: ...y7t AI TER ITCI Br B cri Bl bc ii l t tG 14 1 c R ltd G een y y 3 8 81 o G Grl L8 l1 4 Slit 0 0 1f SAHERY 12 lZM ry Ir li USE 7AJ AIIUOIJ fUS 15A W rust 5A fML LO IR I i IB __ RREAR Uil S N l UQff 12V...

Page 143: ...ble 10 Front brake switch wire 5 Harness band Lighting kill switch wire Lighting kill switch cable Front brake switch cable Clutch cable Choke cable Wire harness clip Clutch clamp i Throttle cable A T...

Page 144: ...able B 13 WIRING DIAGRAM Throttle cable A s Choke cable Point breather tube Ignition coil primary lead Wire harness A Contact breaker wire D Wi re harn ess assy Wire harness band Siricon rectifier Thr...

Page 145: ...Cam chain tensioner 13 46 Carburetor 57 Camshaft 24 ldling speed 9 Ignition timing 11 Ignition system 89 Igni tion coil 89 Special tools 3 Silicone rectifier 97 Spark advancer 92 Spark plug 13 91 Spe...

Page 146: ...4 Check the gasket to see if it is not damaged Replace with a new one if found to be damaged too badly beyond use 5 Wash the fuel filter in solvent and dry with compressed air Any slightest damage can...

Page 147: ...Check the spring for freedom from damage or other defects 3 Check the side stand for proper return operation a With the side stand applied raise the stand off the ground by using the main stand b Atta...

Page 148: ...ns occured in the MAINTENANCE SCHEDULE of which detailes are as shown immediately below INITIAL REGULAR SERVICE PERIOD This maintenance schedule is based upon average SERVICE Perform at every indicate...

Page 149: ...r 1 W 1 1 IUGEIC START S i 1l0t J UMEJ 1 I j 1 l 1 I l r S If 8atl w LG t f c R 111d G Gret0 lll RYIIVll 1 1 i I I J lt B e G Ci Oy lS 4 191 e 0 rc J lS 1 8 G Al SICPU fl 12V l1c BW 25W LRUflII I SG...

Page 150: ...Remove the shift drum stop bolt then remove the neutra l stop bolt shift drum stop and neutral stop 4 Lower the gear shift arm as shown and remove the gear shift spindle B Inspection 1 Check the shif...

Page 151: ...attach one of the shift drum stop springs to the shift drum stop and shift drum neutral stop then attach the other shift drum stop spring to the arm and body of the shift drum stop After that secure t...

Page 152: ...leave it loosened 2 Remove the front wheel referring to page 65 3 Remove the caliper assembly from the le t front fork 4 Remove the front fender remove the front fork pipe retain ing bolts then pull t...

Page 153: ...ve the oil lock piece from the bottom case 9 Remove the front fork oil seal then remove the oil seal stop ring B Inspection 1 Measure the front shock absorber spring free length Also check the spring...

Page 154: ...fered edge on the fork pipe should align with the upper surface of the fork top bridge as shown NOTE Wipe oil if any off the fo rk pipes com plete ly 5 After installing the front fork check Smooth mov...

Page 155: ...er 2 Remove the retaining clip then remove the air cleaner element 3 Clean the element by tapping it light ly If the element is still dirty aplly air inside of the element 4 Remove the element cover t...

Page 156: ...procedures NOTE Check the drain tube for clogging and routing EXHAUST MUFFLER A Disassembly 1 Remove the 10mm bolt then remove the exhaust muffier 2 Remove the eight joint nuts loosen the exhust pipe...

Page 157: ...Exhaust pipe joint Exhaust pipe joint collar Exhaust pipe gaskets Muffler stay Fig 2 18 D Muffler band 8 of 18 Protector band A Muffler band bolt Muffler band Muffler sealing gask et CVPrptector band...

Page 158: ...below If there is continuity the switch is in good condition Te rminal ST1 I ST2 HL Wire colo r Black Yellow red Black red FREE v I PUSH 3 Silicon diode Using a tester check the diode for continuity i...

Page 159: ...en other circuits than those shown in the table the switch is defective Terminal BAT IC TL1 TL2 PA Wir e color Red Blac k Brown Brown White Brown Lock OFF RUN 0 f 0 PA 5 Dimmer switch and tum sign al...

Page 160: ...ntinuity when the horn button is pushed 7 Engine stop switch Remove the fuel tank and remove the con nector cover Check the switch for continuity between the circuits 0 0 shown in the tab le below If...

Page 161: ...e combinat ion light case To remove the case remove the 8mm nut securing the speedometer and tacho meter stay together stra ighten the stay then remove the 5mm screws as shown B Reassembly To reassemb...

Page 162: ...s and chain adjusting stoppers and pull the wheel rearward and the axle to left to remove the wheel Fig 2 32 CD Cotter pin Axle nut 022A 100 CB500 2 515 2 30 4 grooves 1 1 2 3 8 taper 12 0 9 x 2 0 9 x...

Page 163: ...176 drive sprocket 17 driven sproket 37T Gear Shift Pattern Left foot return type Ignition Battery and ignition coil IStarting System Electrical motor and kick pedal Alternator T hree phase A C 12V O...

Page 164: ...ING ILLUST CD Clutch cable Clutch lever switch cable Handle switch L cord Handle switch R cord Front brake hose Throttle cable Z Throttle cable Handle R L switch cord Throttle cable R L 167 15 of 18 N...

Page 165: ...168 Tacho meter cable Main wire harness Starter magnetic switch Turn signal relay Rectifier Rectifier Fuse box 16 of 18 CB550 F A ADDENDUM SHEET Next Page Contents Prev Page...

Page 166: ...1 I Dr 4 D I If 51 COO ACT BREAKER COOENSER FUS IMlX rn RR B Br BI R8r G Gr R Red W W wt Br Br ll llla k LG l 1 r Bl i tttl l E i ij I I G R w I c 1 J Lfll l T 1111N StGIW UGHT POSITDI UGHT JM2 lq 23...

Page 167: ...2 FRONT WHEEL The front brake will no longer use the tanged washer and nut arrangement for the attach ment of the brake disc to the wheel hub The disc is now tightened with UBS nuts Tightening torque...

Page 168: ...4i n 150mm 6 3 in 192kg 423lb Double crad le frame Telescopic fork travel 121 mm 4 8 in Swing arm travel 77 3mm 3 0in 3 25 19 4PR Rib tire air pressure 1 75 2 0kg cm2 25128psi 3 7518 4 PR Block tire...

Page 169: ...WITCH B R J RN SIGNAi 11 JZZER 1 8 I l TU 8 I l __ _I 1 f T r A N Lf l lll I SIGNAL lDfl l iiiTT otHIPL POSIT lDfl 12 132 lcp HEADUQfl OOIMER 11J SllNI L tlllN SllllCH o llNIN SIGNAL llllN HLIWJ l all...

Page 170: ...position and disconnect the fuel tube at the fuel valve and remove the over flow tube 2 Open the seat and remove the fuel tank 3 Remove the air cleaner case 4 Remove the choke and throttle cables fro...

Page 171: ...e carbu retor assembly by removing the four bolts 3 Unhook the throttle return spring from the stopper arm Remove the stay plate by removing the eight screws Unhook the choke relief spring at the chok...

Page 172: ...and slow jet C Assembly To assemble the carburetors reverse the dis assembly procedure Observe the following notes 1 Install the throttle valve to the link arm so that the throttle valve cutaway faces...

Page 173: ...table Item I CB550 K3 Main jet I 90 Air jet lfl30 Slow jet 38 Slow air jet 150 Jet needle 3rd groove setting E2349F lFloat height 14 5mm I 0 57in E Adjustment Idle speed I CB500K3 I 90 120 42 150 2nd...

Page 174: ...etor reading Fast idle 1 Remove the fuel tank 2 Pull the choke knob out fully and turn the adjusting screw until it touches the stopper 3 Push the choke knob in and turn the adjusting screw in 21 2 tu...

Page 175: ...3 25Sl9 4PR Rib tire air pressure 1 75 2 0kg cm 2 25 28psi R Tire Size Type 1 3 75Sl8 4PR Block tire air pressure 2 0 2 5kg cm 2 28 36psi F Brake Disc brake R Brake Internal expanding shoe Fue l Capa...

Page 176: ...operated return system ELECTRICAL Ignition Battery and ignition coil Ignition Advance F mark 5 BTDC Max advance 28 31 BTDC PPM from F to 1 200 2 500 rpm max advance Dwell Angle 190 5 Starting System...

Page 177: ...AI IJ L N Ri RI c n R Rtd w w a a own 8l B t LG lcfltGrttA _J_ y Ytlo w 9 9 0 0rang c G ty FUSE BOX fUSE ISA II I I FUSE 74 HE ADl lGHT FUSE 7A UllllGHT r I STARTER MAGN IIC NEUTRAL SWITCH S IIIICH L8...

Page 178: ...550 K3 77 CB500K3 CB550K3 77 Europe Type Date of Issue July 20 1977 HONDA MOTOR CO LTD 1977 I I m i i j Hdf i i 6 o c JdHJ J l Jo I l H d i I l J _ i f i 12 I I j I j j 183 0 0 0 I to 0 to I N 0 I 0 0...

Page 179: ...pe and Australia Type ii iii O r i i i MB ______ _ j f 1 1 ll 1 fij J i 1 jJ l Ji1 1111 i IO I JH d I I I I s II j J I j z 0 0 co 0 I 0 I N 0 c 0 0 I i jg f J I i 11 i a ii ct I I t j z Date ot Issue...

Page 180: ...the fuel valve and fuel filter from the fuel tank 4 Check the gasket to see that it is not damaged 5 Wash the fuel filter in solvent and dry with compressed air No damage can be tolerated here Replace...

Page 181: ...loosening the 6 mm screw Ta ke the starting switch terminal out of the connector Check the switch for continuity between the sircuits 0 0 shown in the table below If there is continuity the switch is...

Page 182: ...ch Remove the fuel tank and the connector cover Then take out the light green lead as shown Attach one probe of a radio tester to the body or the black lead and the other probe to the light green lead...

Page 183: ...C P HL Wir e color Black Brown blue Blac k red p H 5 BRAKE INSPECTION Replenishing Brake Fluid Remove the reservoir cap washer and dia phram and whenever the level is lower than the level mark engrave...

Page 184: ...r Arra ng ement 4 cylinder in line Bore and Stroke 58 5x 50 6 mm 2 303x 1 992 in Displacement 544 cc Compression Ratio 9 0 1 Carburetor Venturi Dia 4 Piston valve Type Venturi dia 22 mm 0 866 in Valve...

Page 185: ...l ll 9 l4W G NEUTRAl HllCATOR WIT ll ll 9 3 4W CllPRESSU E J ITOR LOfT12 1Zt p l4W _ __ _ El ACl l l R lllUlW llt t 11V2cp l4W X21 B 1I 1 111 1 1 e1 J u 1 H r e I I y 1 C U l B JW 8 W1 u s 1 816 81 W...

Page 186: ...lB lii 111 o lRfM11MSGW UM 11 ZJII TAI l SIC lOiT lm ZlW POSI TOI W l 12 UW nl uu e t 4 rt r 1 l _ a iiitt l f it I tll rk 1 fl l I I 1URN SOlll tOIN PASSH KAlU I R I l l ltl I SWl T CMARRAJall Jll K...

Page 187: ...8EAII IIOCA Ofl tn T12 l lW R TIMIS IClCAIOfl lO T 12 13 IW I I I I I I Il l w J STAR IN IC JOfl Except U K Type m F1JS 80I C Wun I Rld Mw tt ll 8 ow11 11 l tC l ctilCtttt1 Y Ttl ow O Oqt c c li lci t...

Page 188: ..._ L fflt ci r tc c t G t LIii 00 COO IAKI AJIAl R cmT 1 111111 u y jl c 9 IIN c ll O or 1 ct P rost I t t Wf I 0 flU liM I ETll SIC 1M 11 W r l o 1 wE cH l r91l 1 ill r 1 c ll ll e c i 1 C l 1 15 r _...

Page 189: ...R H 7A S J Rl R SICHERl l 7A SOI USSUCHl SIC Rt c SUSl K or I li1 tj ITI I LI I I I I S1 tfMI _ sthw rz W 9 f SS cl te G l II y tlb s tl J Gt ao lS tdbl J l onc t p os B P ocu HT HIO M RIClf S 11 IIW...

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