5000 MANUAL

HONDA

00 500-550 (

 

 

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PREFACE é

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This shop manual describes the maintenance, inspection and adjustment procedures of
the HONDA CBSOO. 550, 550F and 550K. The manual is divided into vaﬁous functional
groups to simpliiy the manual use. The pages for the respest‘ive groups are indexed
on this page.

Each of the groups are divided further into sections: 1. Dwiption, Z Speciﬁcations,
3. Diagnosis, It Disassembly, '5. Inspection and 6. Rausmmbly. Photographs and

illustrations are used to make the opetaﬁons easy to understand.

HONDA MOTOR CO., LTD.
Service Publications Ofﬁce

 

ALL INFORMATION, ILLUSTRATIONS, DIRED-
TIONS .AND SPECIFICATIONS INCLUDED IN THIS
PUBLICATION ARE BASED ON THE LATEST
PRODUCT [INFORMATION AVAILABLE AT THE
TIME OF APPROVAL FOR PRINTING. HONDA
MOTOR CO.; LTD. RESERVES THE RIGHT TO
MAKE CHANGES AT ANY TIME WITHOUT NOTICE
AND WITHOUT INCURRING ANY OBLIGATION
WHATEVER.

NO PART OF THIS PUBLICATION MAY BE REPRO-
DUCED WITHOUT WRITTEN PERMISSION.

 

 

 

Duke of Issue: July 20. 1977
@ HONDA MOTOR CO. LTD.. 1971

 

 

 

1. REPAIR PROCEDURE.
2. SPECIAL TOOLS . . ..
3. MAINTENANCE OPERATIONS. 7

 

 

4. ENGINE ......................... 19
1. Servicing with engine
mounted in frame ............... 20

2. Engine removal and installation... .20
Cylinder head, cylinder
and piston ...............

P3

...24

 

 

 

  

4. Valves and valve springs . ..33
5. Oil pump and oil liken. . .35
6. Clutch ............... .40
7. Gear shift mechanism. .43
8. Cam chainbensioner.... .46
9. Crankshaft and ocmnecting rod .. . . 47

10. Transmission, kick starter
and primary shaft ......
11. Carburetor.

 

  
 

5. CHASSIS . ...65'
1. Front wheel and from: brake. ..... 65
2. Rear wheel and rear brake ........ 73

3. Steering ..................
4. Front suspension
5. Rear suspension
6. Frame body ..... ' .......... ~1

6. ELECTRICAL ..............
1. General description .........
2. Ignition system .............
8. Charging system. . . .

4. Starting system .......
5. Electrical equipment ........

 

  
 
 
 
 
  
 

 

Date d Iisue: July 20, 1977
© HONDA MOTOR CO. LTD» 1977

 

7. INSPECTION AND
ADJUSTMENT DE 63550... .107

1. Clumh.u .................
8. NEW FEATURES

 
 

 
 
 
  
 

 

 

0F C3550 ................. 108
1. Blow-by Gas Scaveng
Device ........ _ ....... .108
2. Starting Motor Safe! .109
3. Front Salami“ . .. .110
4. Brake’uning Wear Indiumr....112
9. COMPARISON OF
03550 To C3500 ............... 113
10. ENGINE ............. .121
1. Clutch. .121
2. Gearshift ...................... 124
11. TROUBLE SHOOTING ......... 125
11 MAINTENANCE
SCHEDULE .................... 134

13. TECHNICAL DATA...”
14. WIRING DIAGRAM...
15. SUI’PLEMENT T0 03550111.. .149
16. SUPPLEMENT T0 035501“ . . . . 153
17. SUPPLEMENT T0 cnaaoxz

 

 

 
 

 

(‘76) .................. 170
18. INDEX 173
19. SUPPLEMENT T0

CB500 IKE/03550113 (’77) . . . . 175
20. SUPPLEMENT '1‘0

CB 550 F2 (’77) .................. 185

P-\

 

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1. SERVICE PRECAUTIONS f

"WW”um...............,.n‘. ,.

     

1. Always replace gaskets, O-rings, cotter pins, etc, with new ones when reassembling.

2. When tightening bolts, nuts or screws, begin with ﬁle larger-diameter or inner ones ﬁrst
and tighten them to the spedﬁecl torque in a climates: pattern.

3. Use genuine Hondaqecammmded parts and luhriumts when servicing.

4. Be sure to use special tools Where speciﬁed.

5. When working‘with ancther person take safety precautions.

6. Clean engine parts when disassembling. Coat thm'r sliding surfaces with a high-quality
lubricant when reassembling.

7. Coat or pack grease where speciﬁed.

8. After membling, check that each part is tightened properly and operating properly.

 

 

 

   

 

 

 

 

ENGINE
Torque values
hem Q'ry
Kg—m lbs-ft
1, Tappet adjusting nut 11 1.1-1.5 & o—1o.s
2 Cam Iprucket knack huh. 7x12 2 1. 4—1. s 10.1-10.3
3. Cylinder head nut, 8mm 12 2. 0—2.: 14.5—16.6
4. A. c. genentm mm m ball. 1 50-110 ass-80.5
5. Starting plumh screw, 6x13 cross an held screw 3 0.5-1.2 14. 5-113
6. Upper aniline: hph. 8x100 thge he: hole a “-2.5 14. 5-18;1
1. Upper mnkcm bull, 5x145 hex bolt 1 2.3—2.5 16. 5-13.11
a, Lower Mankme bolt, 8x100 hex bolt 10 21.2.5 14. 5—131
9. Connecting md nut 15 20-22 14. 5-153..-
10. 011 pump unw, 6x35 cross ﬂat head screw 3 0.8-1.2 5.7— as ,3
11. Clutch elm ﬁxing bole, 6x45 hex huh 1 0.8-1.2 57— 8.6 “
1a Spark advanuer’hult, 6x55 Phage hex hon 1 1.1-2.5 lac-10.3
1a. Tachomekel' gur hnlder mew. 6x16 cross ﬂat head screw 1 1. 0-1.4 1. 2—10.11
'14. Exhaust pipe ﬂange nut, 6mm 5 0.8—1.2 57- 8.6
15. 011 pressure switch 1 1. 5-2. o 10: 8—14. 5
16. Gear shift lever halt, axzo hex ball 1 «1.5—1.0 5.7- 7.2
17. 011 ﬁlter mm bolt 1 2.7—8.8 19.5—23.8
111 spuk plug 4 1.2—1.5 8.6—11.6
19. on drain halt 1 3.5-4.0 25. 8—3E.9
20. Clutch spring, axzo hex ball 4. viz—10. 1
21. Tapper hole cap a 7. 2-101
22 on path cap 1 7. e101
23. Gun: shift mum spring, am hol: 1 14.5-21.7
24 Dan sprocket 1 '
5mm: pan: 11H:
SCREW pan 6mm 5.1— so
SCREW ﬂat 6 mm s a- a7
BOLT 11m: 5mm 58- 8.7
BOLT ﬂange 6mm 7. 240.1
NUThexEmm 5.5-2“

 

 

 

 

 

 

Date of Issue: July 20, 1977
© HONDA MOTOR CO. LTD, 197']

   

2 L SERVICE manor!

 

 

 

 

 

 

 

 

 

 

 

FRAME
Item my Torque mm
lrg-m 1111-“

1 Rel: Intake pedal huh, 5x82 11:: halt 1 1. 3-25 1110-1& 1 .

2 Foot peg nut, 12mm 2 6.0—6.0 36. 243.1 ‘ 7
3 Engine hanger bul: A 5 1 0-4. 0 21. 7-219 ..
L Engiua hanger place a 1. 11—25 18.0411

5. Reu- foxk yam aux. 14mm 1 5.5—7.0 39. 8-50.15

0 Rear Iuspenliun upper nut, 10mm up nut 2 3.0—1.0 21.7-28'9

7. Rear sulpansiun lower bolt, 10x32 1.1.x hall 2 a 0-1 0 21. 7—23. 9

a. 011 hon a 3. H. 0 . 215.219 ( 3
9. Brake amp twitch 1 3.0.4.0 21H“
10. 17mm brake disc hm, 3mm 6 1.3—2.5 1:10—13. 1
11. 13:11:: oil joint. 6x12 hex bolt - 1 0. 8—1.0 5.3.01.2
12. Bake hose joint 1 0. 6—1.0 4.3— 7.2
LE. Mastu cylinder bull, 6x23 hex bah 2 0.3-1.0 5.7— 7,2
14. 0.11er m bolt 2 3.4-4. 0 21. Ha. 9
15. Holder join: 1101!, 8x10. 8x50 11:: halt a 1.3—2.3 13.0—16.6
16. From ﬂux-k huh 2 5. 505 as. 3—47. 0
17. Steering stem mu 1 11.0—12.0 57.0.1107
1& Steering am Lon. 10x40 hex bah 2 3.“. o 21. 7728. a
19. Rear wheel 314: mu 1 11.0-10.0 57.17203
20. From axle holder nut, 3mm 4 1. 5-13 13.0—16.5 1,.
21. Handlebar hhlder hale. 8x40 hex ha: 4 1.5—“ 13. 0—16.6 l D
22 From wheel Axle ml: 1 55-6. 5 39. 13-47. a
23. Rm braka mppex Inn hol: and nut, 8mm 1 1. 5-28 13.0-16.5
14. Fur]: top bridge bale, 8X56 hex huh 2 1. 5—1 a 11 0—16. 5
25 Drive :hnin Adjuster bolt and nut. 8mm hex bolt 2 1. 5—2. 0'” ‘ 10. $14.5
20. Driva chain adinner ﬂapper ball 2 1. 0-1 a 1:1 0—15.15
27 Main mml pivot bolt. 8x40 hex bolt 2 1.5-2.0 10.5115
28. Run: foo: peg hue, 12mm 2 4. 5-0 a 52. 5—411 4
29. Caliper john pin 1 L 5—2. 5 18.0—18.1
30. 13mm hr—ldga 2 51 0—4.0 21. 7-25. 9
31. Final dxiven sprocket 4 25. 0—4.0 21. 7—221. 9

Standard pm.

Ban hu, 5mm 0.3-1.2 5.3— 9.7
Bull hex. Em 1. 5-2. a 10. 5—10.15 )

 

 

 

 

Date af Issue: July 20, 1977
@ HONDA MOTOR CO. LTD.' 1977

 

 

g 2 SPECIAL TOOLS

 

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mun-u.

‘ Except USA. mudel, O=USED, x=NOT USED, (up)=optioml tool

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

113g- Tool No. Tool Nume c3500 c3550 Q’ty Ramada
m 07902-2000000 Spanner, pin 48mm 0 o 1
v@ 07905—0200000 Wrench, box 12mm 0 o 1 Cylinder Imad locking nut
@ 07000—0250000 Wrench, tappet adjusting o o 1
01;) ems-0000000 wmuch.spurk plug 0 o 1
4 @ 070104200101 wmuuii, F Istainu‘ o ‘ o 1 From hub din/assembling
: > @ 070104200201 Wrencb,R mminer o o 1 Rear hub dis/aasunhling
’ m 009100230000 Pliers. Sup 1111.; o o 1 ﬁgﬁghﬁiw Pm” ‘1‘”
*@ 070174230000 Wranch, hullew 5:: 6mm 0 o 1 :1:ng 1mm“ “3° “W
@ mass-2100000 Puller, mm o o 1
® mess-0230100 51.15:, hammer o x 1 P’Eﬁrwé‘iﬁ‘ﬁfﬁﬁnﬁj
® 07586—828020!) Weight, hummer 0 x 1
*@ mas—3740100 Shaft, sliding hummer x o 1 P‘éﬁfywﬁgi;t;m§ﬁ“§n
g 0794243290100 Drivm'i vulva guide 0 o 1
® 070403200200 Remover, vulva guide 0 o 1 ‘
*@ 07045—0230100 Driver A, bearing 0 x 1
{ , ® 070103200200 Driver a, bearing 0 x 1
1', ‘) ~13 0704573000500 Weight. sliding hammer x o 1
‘ / 03 0700573000300 Bearing drivzr Iﬂmhment x o 1
a 07045—3330200 Dn'vex,nmchm=nt x o 1 B;g‘“§:°§ﬁ'ﬁ§‘§fzd§m
® 07946—36qu0 Drivennttnchmun x 0 1 $55; kagﬁ'ﬁggﬁaﬁa’
03 0794079050000 Driver, atmchmam x O 1 535:1}: 33151135,??? 21:"
@ 070474200000 Guide. fork m1 0 o 1
® 070404110000 Driver, handle x o 1 Eggi‘hi‘mms' 18.10.20.
9 ems—3000000 Remover, 0111 me x o 1
@ 0795441230000 Compmasw. piston ting o o 2 a.
03 0795741290000 Compream, vulvuspiiug o o 1
a 079502500000 Bun. Pinon o o z
03 0795114290000 Ccmpressor. thank absorber o o 1
' ) @ 079574230100 AttachmmtA.d1-iver o x 1
@ 070074230200 Amuhmeu: E. driver 0 x 1
‘ @ 079074230000 Amchmu: remover o x 1
@ 0797141200100 Piston cup guide 0 o 1
9 070710230200 Cup guide 0 x 1
1 J 9 07011141000000 Reumer,valve guide x o 1
0 ® 070001230200 ernch,wburemradj1ming o o 1 (up)
@ 075010000100 Gang: set, vacuum 0 o 1 Carburetor adjusting (up)
@ 07075—500000] TunI set, chain joint 0 O I (up)
(77401—001000!) Gauge, ﬂat levcl O O 1

 

 

 

 

 

 

 

 

Date of issue: July 21}, 1977
© HONDA MOTOR CO. LTD., 1977

   

 

2. SPECIAL TOOLS

 

 

 

 

® ®

 

 

 

 

 

 

 

 

 

 

Dat f Ins July ED 1977
© HONDA MOTOR CO. LTD.. 1977

 

2. SPECIAL TOOLS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Due uf Issue: July 25, 1977
© HONDA MOTOR CO. LTD, 1977

 

 

 

) 1 TAPPET ADJUSTMENT
Adjust teppet clearance when the engine is
cold
Note:

_ Pistum are numbered left to right from

3 the rider's position

1. Remove the tank.

2. Loosen the tappet hole caps.

3. Remove the point cover and align the
“T” (1-4) mark on the spark advance: to
the ﬁming mark when the No. 1 piston
is at top-dead-center of the compression “3- 1 G) No. 1 Piston No. a Piston
stroke. ® No. 2 piston @ No. 4 piston

4. Cheek and adjust valve teppet clearances
indicated by “O" in the chart below.

5. Measure the clearances using a feeler
gauge. Adjust hy loosening the lock nut
and turning the adjusting screw. Tighten
the lock nut.

Valve tappet clearances:
JNTAKE —0. 05 mm (0. 002 in.)
EXHAUST —0. 08 mm (0. 003 111.).

6. Rotate the uankshaft one revolution and
realign the “T” (1-4) mark on the spark
advancer to the timing mark. In this
position, the No. 4 piston is at topdead-
center of the compression stroke. Check
and adjust the valve tappet clearances
indicated by “X" in the chart below.
See step 5 above for proper valve teppet

 

 

 

 

   

 

 

 

 

 

 

 

 

 

 

 

  

clearances.
) No.1 No.2 No.3 No.4
cylinder cylinder cylinder linder
Intakevulve O X 0 X
5531““ o o x x
V Note:
‘ ) ~Hold the adjusting screw so that it does
‘ not turn when tightening the luck nut. _ V V
- Make sure the clearance is not disturbed . 3 6) Lock m“ ® Feelcx gauge

 

when the lock nut is tightened. ® Adjusting screw

Dan at Issue: July an, 1971
© HONDA MOTOR co. L111, 1577

 

8 a. MAINTENANCE OPERATIONS

 

 

 

 

 

 

 

 

 

Fig. 5 (D Throttle stop screw
® 45:1. 5mm (1, 92910. 059 in)

@ Slay

 

 

 

 

 

2. CARBURETOR ADJUSTMENT
Adjust the carburetor after warming up the
engine (60—70°C/l40—158°F).

Idle adjustment

Adjust the engine idle speed to 950—1050
rpm with the throttle stop screw. Turn the
screw clockwise to increase the idle speei and
counterclockwise to decrease the idle speed.
Synchroniution adjustment

1. Remove the fuel tank.

Note:

Position the tank about 50 em (20 in.) higher

than the mounting position and reconnect

with a longer fuel line.

2. Adjust the throttle stop screw so that
the throttle lever is 49i1.5mm(1“/xsi
1built.) from the stay.

3. Install the vacuum gauge in the intake
manifolds. Remove the plugs from the
intake manifolds. Install the long
A adaptors of the vacuum gauge to’
the two inside manifolds and the short
B adaptors to the outside manifolds.

4. Start the engine, loosen the adjusting lock

nuts and turn the adjusting screws so
that all four carburetors are uniform
(16—24cm Hg) on the vacuum gauge
(H/C 39340)
Turn the screws clockwise to increase
vacuum. Turn the screws counterclock-
wise to decrease vacuum, All the carbu-
retors should be adjusted to within
3.0cm Hg of each other.

Note:

If the gauge needle is oscillating over a

wide range, dampen the movement with the

vacuum adjuster on the gauge.

 

 

Fig. 6 Q A adaptor
Q) B adsptnx
® Vacuum gauge
@ Plug hole

Fig. 7 ® Screw

® Lock nut

Date of Issue: July 2a, W77
e HONDA MOTOR 00. um, 1977

 

 

3. MAINTENANCE OPERATIONS 9

5. Snap the throttle back several times and
recheck the vacuum pressures after the
four carburetors indicate the same vacu-
um PIESSUTE.

Repeat the adjustment in step 4 if the
vacuum pressura lack uniformity.
Check the following items if the vacuum
pressure is lea than 15 cm Hg for any
of the carburetors:
1. Be sure the ignition timing is
—5“/1,150~30°/2,500 rpm BTDC.

 

2. Check the iappet clearances.
Intake: 0. 05mm (0.002in.)
Exhaust: 0.08mm (0.003in.)

3. Check the spark plug gap.

Gap: 0.6—0.7mm (0.024—0.028in.) - I
4, Check the compression pressure. t
PreEure: 11~12kglcm9 I
® ®

(156. 45—170. 67 psi.)
6. After all four carburetors have been ad-
justed to the some vacuum pressure: ad»

 

 

just the throttle stop screw to an idle Ft 8 L Hi 1:
speed of 950~1,o5o rpm, " gNgfmgfwm ® g "M“
7. Adjust the air screw on each carburetor.

 

(The standard adjustment for the air
screws is 1i3/8 turns open from the
fully closed position.)

8. Rendjust the engine idle speed to 950
el, 050 rpm with the throttle stop screw.

Note:
Tighten the intake manifold plugs after
synchronizing the carburetors.

 

Throttle Cable Adjustment
1. Turn the adjuster counterclockwise at

 

 

the handlebar and to increase free play Fig. 9 (9 lack mu [2) Adjuster
in the throttle cable. Tum it clockwise
to decrease the free play.

Note:

Lave about 3mm (0.12m) range of adjust.

merit at the cable adjuster for ﬁnal micro-

adjustment.

2. Loosen the cable lock nut and turn the
adjuster at the carburetor end to provide
3~4 mm (VINE/IX in.) free play at the
throttle grip ﬂange.

Note:
The throttle lever should hit the eccentric
pin when the grip is forced tn the fully

 

 

 

 

 

closed position. If it doesn't, replace the Fig.10 @ Adjuster @ Decrease
rat-urn table with a new one. ® Lock nut © Increue

Date of Issue: July 74}. 1577
@ HONDA MOTOR CO. LTD. 1977

'l D 3. MAINTENANCE OPERATIONS

 

 

 

Fig. 11 8 Throttle lever @ Lock nut
Eccentric pin
@ 2~s mm (a. os~o. 12 in.)

 

 

 

 

 

 

 

,_

 

 

 

  

  

Slipper @ 2-3 points

. u (D
(3) L4 points

Breaker
g) 1-4 points

 
 
 

 

Overtravel stopper adjustment
loosen the lock nut and turn the eccentric
pin. Clearance between the throttle lever
and the eccentric pin should be 2~3mm
(0. DB~0. 12 in). .

Full throttle opening stopper adjustment
Adjust the stop screw so that the throttle
valve extends 0~1. 0 mm (0~0. 04 in.) above
the throttle bore in the fully open position.

3. BREAKER POINT GA]? AND IGNI-
TION TIMING ADJUSTMENT
Check the condition of the. contact points,
point gap and ignition timing. Adjust the
ignition timing of the 1.4 points ﬁrst
Breaker point gap adjustment, 1-4 points
1r Rotate the crankshaft until the contact
breaker slipper comes up on the highest
position of the cam lobe. Measure the
point gap WM: 3 fesler gauge.
Standard point gap : 0.3~0.4mm (0.012~
0.016 in.)
2. Loosen the screw ® and move the breaker
point assembly if it needs to be adjusted.
Breaker point gap adjustment, 2-3 paints
Adjust the 2-3 point gap in the same manner
as the L4 points by loosening the screw CD.
Nate:
Clean the paint surfaces with a point ﬁle or
an oil stone if they are pitted or rough.

Date of Issue: July 20, 1977
© HONDA MOTOR CO. LTD., 1977

 

 

S. MAINTENANCE OPERATIONS l l

 

« 3
Ignition ﬁmingmdjuatmeut, 1-4 points
1. Connect a 12V test lamp to 1-4 points
primary wire (blue) and to ground, (See
Fig. 15)
2. Turn the main switch to the “ON" posi-

 

tion.

> 3. Rotate the crankshaft clockwise slowly.
If the test lamp comes on when the “F”
(1-4) mark on the spark advenoer is
aligned to the timing mark, theytiming
is correct

4. If the adjustment is necessary, align the
“F” (1-4) mark to the timing mark and
loosen the screws @, and then move the
base (D until the lamp goes on. Tighten
the screws.

 

 

 

   

Ignition timing adjustment, 2-3 points
1. Connect the 12V test lamp to the pri
mary cord (yellow) of the opposite con-
tact breaker and align the “F" (2-3)
mark to the timing mark.
2. Loosen the screw (9 and move the base
G) as shown above.

 

Ignition timing adjustment with a sua-
hoacupic timing light

The use of the sterohoscopic timing light is
recommended to obtain the most accurate
timing.

1. Plug the timing light cord into the

timing light receptacle.
2. Remove the spark plug cap from the

 

No. 4 cylinder and install the timing ’
attachment between the spark plug and . ' ‘ . /
theCaP- Ema) @Baae©
8. Connect the high tension cord of the @ SCY°W©
I J timing light to the timing attachment,

position the switch knob to TIMING,
and start the engine.
The timing light will ﬂash.
4. Aim the timing light toward the timing
-» mark and make sure the “F” (1-4) mark
‘ ) and the timing mark are aligned.
Increase the engine rpm to approximately
2500 rpm At this speed, if the timing
mark is between the two index lines
located 23.5~26.5“ before the “F” mark,

 

 

 

 

“ the ignition timing at full advance con- “‘1‘ 13 ® Timing “E1“ @ 33“?"
J dition is satisfactory 'sruatu-igfmchmem by Semce mic:-
. W| c no

Date of Issue: July 20, 1977
© HONDA MOTOR CO. LTD~ 1977

 

12 3. MAINTENANCE OPERATIONS

5. Remove the spark plug cap from the
No. 3 cylinder and install the timing
attachment between the spark plug and
the cap Check the ignition timing (“F"
2-3) as descn'hed in steps 1N4.

6. Adjust if the tithing is incorrect.

4. CLUTCH ADJUSTMENT

1. To provide free play in the clutch cable,
loosen the clutch adjuster lock bolt.

2‘ Turn the adjuster clockwise until a slight
resistance is felt, and then turn counter-
clockwise ahout 3mm (Van). At that
point, tighten the lock bolt.

3. Adjust free play in the clutch cable at the
look nut and adjuster on the engine. The
play should be 10~20mm (0.4~0.8in.).
Perform micro adjustment with the ad-
juster at the clutch lever.

    

Fig. 19 [D Luck bolt © Adjuster

Fig. 21 © Lock mu (3 Increase free play
@ Adjuster @ Deere“: free plzy

 

5. CAM CHAIN ADJUSTMENTS

Perform cam chain tension adjustment in the
following manner.
1. Remove the tappet hole caps from the
No‘ 1 cylinder.
2‘ Remove the point cover, and align the
“T” (L4) mark to the timing mark.
3. Check hath valves of the Not 1 cylinderl
If both valves are free, proceed to the next
step. If either or both of the valves are

     

@ Increase free play
(3) Decrease free play

Fig. 22 (D Lock nut
® Adjusler

   

Date of Issue: July 20. 1977
© HONDA MOTOR CO. LTD.1 1977

 

 

 

 

8. MADITENANCE OPERATIONS '13

ﬁght, rotate the crankshaft 360°, and
proceed with the next step.

4. Rotate the crankshaft Clockwise until the
spring peg on the sdvancer assembly at
the 14 position is at the right of a line
from the timing mark. This position
is 15" ATDC.

5. At this point1 loosen the lock nut so that

proper chain tension can he obtained.

automatically.
5. Reﬁghten the lock nut, and reinstall
the point cover and tappet covers.

6. SPARK PLUG INSPECTION

Remove the spark plug with a spark plug
wrench and check the gap and the insulator
for damage or fouling.

1. Clean the plug with a spark plug clea-
ner or a wire brush.

2. Check the gap with a feeler gauge and
adjust the opening to the standard 0.6~
0.7mm (0.02~0. 03 in).

3. Replace the plug or plug gasket if the
insulator or gasket is damaged
Standard s k In D-7ES G)

Par P gs x22Es((Ii)ENso
7. ENGINE OIL INSPECTION AND
CHANGE
Oil Level Inspection .
Check the oil level with the dipstick gauge
without screwing it into the case If 1:

level is below the lower mark on the gauge;

add oil to the upper mark.
Recommended ail classiﬁcation:
Honda 4- stroke oil or equivalent {£1
SAE 10W— 40 or SAE 20W— 50
Oil change
Paform the oil change while the engine is
Warm so that the oil Will drain properly
1. Loosen the drain bolt and remove the
ﬁller cap to assist draining

2. Remove the oil ﬁlter to drain the oil

completely

3. Tighten the drain bolt and ﬁll with 2. 5 l
(2.6 U.S. qt“ 2.2 Imp. qt.) of clean oil
through the ﬁller opening. Add oil as
necessary to bring the oil level to the
upper mark on the gauge.
Oil capacity: 3.0 liters (3. 2U. S. qt.,

.Glmp. q t.)

Date of Issue: July 20, 1977
© HONDA MOTOR CO. LTD, 1977

 

 

 

Fi 23 (3 Nut (3) Tim 3 mnrk
@ Adjusting screw @ Spring peg

wwwr

FII. 24 ® Gsp

 

: ller call: A Lower level
a on leve gauge Serviceahle range
@ Um. level

    

1
m. as Q) Drum bolt

 

6 Spline

29 a) Steppe
® Steppe

.‘l

 
 

 

rig. so a) Level

(D Oil ﬁlter novel 0 Washer
9 O ring

55. MAINTENANCE OPERATIONS

 

       
   
    

8 Oil ﬁlter element
@.0i1 ﬁlter center halt

rho]: 0: not @Disc ‘
1' bolt

murk

8. OIL FILTER SERVICING

Service the oil ﬁlter when changing the

engine oil.

1. Loosen the oil ﬁlter center bolt and

remove the ﬁlter element
Note:

- A small amount of oil will drip from the
ﬁlter when it is removed.

- When reinstalling the element, replace all
parts. Any pieces of rubber left on the
seat will cause poor sealing,

- Replace the oil ﬁlter element every 6,000km
(4,000 miles).

9. BRAKE INSPECTION AND
ADJUSTMENT

Adjusting Brake Caliper

Whenever the brake pads are replaoed. the

brake caliper must be adjusted. The adjust- ' :

ment is made in the following manner, so
that there is a small clearance between the
ﬁxed friction pad and die brake disc.

1. Raise the front Wheel oil the ground
using a block or jack.

2. Loosen the caliper stopper bolt lock nut.

3. Turn the stopper bolt in direction ®
until the friction pad contacts the brake
disc. When the wheel is rotated, a slight
drag should be noticed.

4.. While rotating the front Wheel, turn the
stopper bolt in direction ® until the front
wheel rotates freely.

5. Turn the stopper bolt 1/2 turn in direc-
tion ® further and tighten the lock nut.

Replenishing Brake Fluid

Remove the reservoir cap, washer and dia-
phrag‘nl. and if the level is lower~ than the
level mark engraved inside the reservoir,
ﬁll the reservoir with DOT 3 BRAKE
FLUID to the level mark. Reinstall the
diaphragm and washer, and tighten the
reservoir cap securely.

Note:

- Do not mix brands of brake ﬂuid. A chemi-

cal reaction may occur or brake problems

could result.
- Do not use any other ﬂuid in the brake

system.

Dam Di Issue: July 20.1977
Q HONDA MOTOR 00. mm, 1977

 

 

 

 

 

 

3. MAINTENANCE OPERATIONS I5

 

- Remove any brake ﬂuid which may have
spilled on a painted surface, rubber parts, A 05mm
and meter components. It may produce a
chemical reaction and damage those parts.

Brake Pad Inspection

Re lace pads A and B with new ones when

ei er of the pads is worn to the red serv-

iceable limit mark around the pad. \

 

Brake Bleeding

The brakes must he bled subsequent to work

erformed on the brake system, when the

ever becomes soft or spongy, or when lever

travel is excessive. The procedure is best i" 31 ® R :1 li

perfumed by two mechanics. I" E "E

1. Remove the dust cap from the bleeder
valve and attach the bleeder hose.

2. Place the free end of the bleeder hose
in a lass container which has some
hydrauic brake ﬂuid in it so that the
end of ﬂee hose can be submerged.

3. Fill the reservoir using only the recom—
mended brake ﬂuid. Screw the cap
partially on the reservoir to prevent
ens-y of dust.

4. As shovm in Fig. 33 attach a piece of

rubber about 15mm thick to the end of
the handle grip to decrease the strollie as
measured at die tip of the handle ever. .
Pump the brake lever several times until Fl; 32 3 3:32:53
pressure can be felt. Holding the lever
tight, open the bleedet valve about ‘lz
turn and squeeze the lever all the way
down.
Do not release the lever until the bleeds:
valve has closed ' . Repeat this
procedure until hub es cease to appear
in the ﬂuid at the end of the hose.

5. Remove the bleeder hose, tighten the
bleeder valve and install the bleedm‘
valve dust cap.

6. Do not allow the ﬂuid reservoir to be-
come ervnﬁlty during the bleeding operation
or air ‘ enter the system again. Re- - .
plenish the ﬂuid as often as necessary F1533 $133: 83332;” ® Rum,“
while bleeding. .

7. Check for proper aﬁect of bleeding and absence of leaks in the front brake lines while
holding pressure against the brake lever. Replenish the ﬂuid in the reservoir when bleed-
ing is completed. Reinstall the diaphragm, washer and reservoir cap and tighten.

After the hydraulic brake system has been drained, it should be ﬁlled as outlined below.

1. Fill the ﬂuid reservoir.

2, Open the bleeder valve by ‘/z turn, squeue the brake lever, close the valve and
release the brake lever. This procedure must be repeated in this sequence until hydraulic
ﬂuid begins m ﬂow through the bleeder hose. After ﬁlling the hydraulic system with
ﬂuid, proceed with the actual bleeding operation.

Note:

- Brake ﬂuid which has been pumped out or the system must not be used again.

~ Brake ﬂuid will damage the paint ﬁnish and instrument lenses.

 

 

 

 

 

 

 

    

 

 

 

 

 

 

Date of Issue; July 30. 1977

© HONDA MOTOR CO. LTD, 1977

 

I 6 8. MAINTENANCE OPERATIONS

Rear Brake Adjustment
1. Normal free play at the end of'the brake

pedal is 2-8cm (’/4~1’/is in.).

 

2. Perform the adjustment with the adjuster
nut.

     
    

Fig. :5 @ Adjuster um @ Dem... free play
(2 Increase free play

10. AIR CLEANER ELEMENT
SERVICING

1. Open the seat and remove the tool tray.

2. Pull the spring clip out and remove the
cleaner element.

3. Clean the element by tapping it lightly
and blowing compressed air from inside.

 

‘ , ,
Fig. 37 (D An- cluner a men: ® pring clip

Date of Issue: July 20, 1977
© HONDA MOTOR 00. L111, 1977

 

V.

3. MAINTENANCE OPERATIONS! l7

 

11. DRIVE CHAIN INSPECTION AND
ADJUSTMENT
1. Check the drive chain slack by raising
and lowering the chain at the midpnint
, between the sprockets. The normal slack
( > is 1~2cm ('ler/dn).
2. Adjust by loosening the rear axle nut
and turning the adjusting bolts on both

sideei
Note:
\ The mark: on both adjusters should be at , /
f ) the same location when the chain is pro- Adjuliing a“
perly adjusted. a Mark Lock mu

9 Axle nut o Locum
o Cutler pin 9 Tighten

12. BATTERY ELECTROLYTE
INSPECTION

Remove the light side cover and check the

electrolyte level The level should be at the

upper limit.

1. If the level is low, open the seat and
remove the tool tray to add distilled
water to the battery.

2. Remove the six battery ﬁller cap: and ﬁll
each cell with water to the upper limit.

 

13. FRONT FORK OIL REPLACEMENT

1. Remove the fork bolt and drain bolt, and
drain the oil.

Actuate the forks up and down to drain
the oil completely.

2. Flush the interior with solvent.

Note:

Do not use gasoline for ﬂushing.

3. Tighten the drain bolt securely and add
clean oil to the fork through the top
of ﬁne fork pipe.

) Recommended oil: AFT
Capacity: 16060 (5. 407$)

 

    

Fig. 41 ® Dmin belt

Date of Issue: July 20, 1977
© HONDA MOTOR CO. LTD, 1577

   

IE 8. MAINTENANCE OPERATIONS . .3

'14. COMPRESSION PRESSURE
CHECK

1. Remove the spark plugs.
2. Insert the end of the compression gauge
into the spark plug hole. ’ j

3. Set both the throttle and choke to the fully
open position and kick the kick starter.
Standard compression pressure:

12 kg/cmE (170. 67 psi)

Note:

~ Open the throttle and choke fully so that

the correct compression pressure will be in- l V

diwted on the gauge.

~ Continue the kicking until the compression

reading is at the maximum. The reading

will increase with each kick.

- To obtain the correct pressure reading, per-

form the measurement after warming the

engine up.

(Low compression pressure)

When the compression pressure is below 10
kg/m’ (142. 23psi), the probable causes are
leaks around the valves and piston rings, or
from the head and cylinder gaskets.

Adjust the Valve tappet clearances, or disss- ( >

semble the engine and inspect the piston rings ‘- . ..

and gaskets.

(High compression pressure)

When the pressure is greater than 12 lrg/croz

(170. 67 psi), the proha’oisllmuse is excessive

carbon deposits on the combustion chamber,

piston heini and the valves. Disassemble the

head and 'cylinder to remove the carbon.

  

r .42 ® Comprmon gauge

 

 

Date of Issue: July 20, 1977
© HONDA MOTOR CO. LTD. 1977

 

 

 

Date a! Issue: July 20, 1977
© HONDA MOTOR CO. LTD. 1977

 

20 4. ENGINE “)

1. SERVICING WITH ENGINE MOUNTED IN FRAME

 

 

 

 

Items Pages ‘ _

1. Cylinder Head Cover and Camshaft 24 l >
2. Cylinder Head 24

3. Cylinder and Piston 24

4 Cam Chain Tensioner 25 ,

5. on Filter and on Pump 35 I j
6. Clutch 40 "
7. Gear Shift Mechanisml 43

8. Electrical System (i. e, Generator and Starting motor) 95

 

 

2. ENGINE REMOVAL AND INSTAL-
LATION

A. Removal

. Turn the fuel valve to the “STOP" posi-
tion. Disconnect the fuel ipe at the tank
and remove the fuel t .

2. Loosen the oil drain bolt and the oil
ﬁlfer center bolt, and drain the engine
0 .

. Remove the exhaust pipe and the mufﬂer.

, Disconnect the high tension wires at the
spark plugs.

. Disconnect the ground mble at the battery
terminal.

6. Loosen the 5mm screw and disconnect
the tachometer cable at the cylinder head

cover.

7. Take the air cleaner element out, loosen
the three 6mm bolts and remove the
air cleaner wee.

e.

 

on:

01

 

    

l ‘ r V .
Fig. 44 @ Tachometer mhle ® 5mm screw lg. 45 (9 Air cleaner element @) A" cleaner 1
@ 5mm halts use ‘

Dave at Issue: July 20, 1977
© HONDA MOTOR CO. LTD, 1977

4. ENGINE 21

 

 

E. Disconnect the throttle cables at the car-
buretors,

 

9i Loosen the two 5mm screws at the
carbupemr insulator and the 4mm screws
at the air cleaner chamber. Remove the
mrhuretorsi

     
     
     

i ,
m 47 a) 5mm screw

   

(9 4mm serew

‘r
> 10. Disconnect the starting motor cable from
the magnetic switch, and then the gamer»
ator wiring at the coupler.

Fig. 43 @ Surﬁng mnlur cable Wiring
(3 Magnetic switch coupler

   

) 11‘ Remove the gear change pedal, and
‘ leasen the smting motor cover bolts.
Remove the starting motor cover and
the left crankcase coveri Disconnect the
clutch cable at the clutch lifter.

g) Clutch um:

 

, ) Fig. 49 ® Left crankmse caver
. (23 Clulch ankle

Date of Lune: July 20, 1977
© HONDA MOTOR CO. LTD, 1977

22 A 4. ENGINE _
< v

12. Remove the ﬁnal driven sprocket and
the drive chain

13‘ Disconnect the contact breaker point leads
(yellow and blue) at the connectors.

 

14. Loosen the nuts from the engine hanger
bolts, and dismount ch: engine from the
right side by raising the rear slightly.

 

 

 

 

Fig. 51 Left lid: min: hanger bolt- r
(B 8x50 hex bah "
® 10x60 hex bolt
(19 Rm upper hanger bah
a) 10x50 hex bolt
(3 Rm lower hangar hull

 

 

 

 

 

 

Fk. 52 Right sida engine hunger bolts
(D sxso hex bolt
® 10x50 he): bah
@ Rear upper hanger bolt ‘
@ 8x100 hut belt n )
@ 8x40 hex boll ‘
® Rur lower hanger bah
@ 10x80 hex halt

 

Date of But: July 20. 1977
© HONDA MOTOR CO. LTD, 1977

 

 

 

4. ENGINE

B. Engine Installation

1. Reinstall the engine in the reverse order
of removal noting the following points:
Install the engine from the right side
and tighten the hanger bolts. The bat-
tery ground cable terminal is installed
with the rear hanger bolt.

Make sure that the generator cord and
the starting motor card are not pinched
when the left crankcase cover is installed.
Make sure that the two muﬂiers on each
side are praperly connected with the
mufﬂer connecting band.
Perform the following adjustments after
the engine is installed:

Clutch adjustment

Drive chain sled: adjustment
Carburetor adjustment

Date of Issue: July 20. 1971
© HONDA MOTOR CO. LTD., 1977

 

 

 

 

 

 

 

Fig. 64 ® Generator cord
® Starling motor card

Fig. 55 (D Muﬂsr connecting hand

 

    

24 4. ENGINE

 

3. CYLINDER HEAD, CYLINDER AND 3
PISTON

A. Disassembly

2L Turn the fuel valve to the “ STOP" posi—
tion. Disconnect the fuel lines at the ,..
tank and remove the fuel tank. 5 >

. Remove the exhaust pipe and mufﬂer. -'

. Disconnect the tachometer table.

. Disconnect the high tension cords at the
spark plugs, loosen the six 6mm screws
and remove the breather cover.

5 Remove the tappet hole caps and the >

left and right side covers. Loosen the
twelve 6mm screws and six bolts, and
remove the cylinder head cover.

Note:

- Loosen the screws and bolts uniformly to
relieve pressure gradually.

weenie

 

 

 

 

 

 

 

“"57 8233335322133. . )
6. Loosen the lock nut of the cam chain

tension adjuster (leave the Wrench on

the nut). Tum the screw fully (approxi-

mately 90°) clockwise, and tighten the

lock nut.

In this condition the cam chain ten-

sioner is not applying tension to the cam

 

chain,
Fl . 59 ® nhein tension adjuster \
(:9 Lock nm 1 )
‘ ‘ . 7. Loosen the two (mm sprocket mounting _ .
' bolts and remove the camshaft from the
sprocket.

8. Remove the cam chain from the sprocket.

    

m». 5! 5) Cam 5mm: Camshaft i )
Q Cam chain (9 7mm bah

Date of Issue: July 20, 1977
© HONDA MOTOR CO. LTD, 1977

   

 

t. ENGINE 25

 

10.

ll.

13,

Separate the carburetor assembly from
the cylinder head.

Loosen the cam chain tensioner mount»
ing holt.

Loosen the twelve cylinder head mounting
nuts and two 6mm ﬂange bolts, and
remove the had Loosen the nuts in
the reverse order of tighmning shawn
in Fig. 83.

Remove the cam chain guide from the
cylinder by raising the cam chain guide
slightly. Rotate the guide 90" and
removing the. chain guide.

During this operation, do not drop the
can: chain.

Loosen the cam chain adjuster lock
nut (Fig. 58) and remove the chain ten-
siuner from the cylinder.

To facilitate removal, raise the cylinder
about 20m (1 in.), and remove the cam
chain tensioner.

Date 01 Issue: July 20, 1977
© HONDA MOTOR CO. LTD, 1977

 

    

Fig. so @ em chain tensions?
a) 0m chain tensicner mnunling hon

 

 

 

 

26

 

4l ENGINE

14, Remove the cylinder‘ 1
If the cylinder is stuck, pry if loose with

a screwdriver placed in the groove at
the base of the cylinder.

15, Remove the piston pin clip. piston pin,
and the piston.
Nate:
When removing the pin clip, be careful
nut to drop the all): into the crankcase.

16. Remove the pistun rings.

17. Screw a 6mm bolt into the rocker arm
shaft and remove the rocker arm shaft
from the cylinder heaﬂ"cover.

shnh a rhm bnlt

 

 

B. Inspection )

1. Inspect the camshaft hearing surfabes.
Camshaft bearing surfaces should be
smooth and shiny. If it is scratched or
excese'wely Worn, it should be replaced.

 

 

 

 

Date uf Issue: July 20, 1977
© HONDA MOTOR CO. LTD” 1537']

 

4. ENGINE 27

 

. Measure the can height with a micro-

meter. .
Replace the camshaft if it is beyond the
serviceable limit,

. Measure camshaft mnuut.

Support both ends of the camshaft an
V-blncka. With a dial gauge, mmsme
the radial runnut by whiting the shaft.
Replace the camshaft if it is beyond the
serviceable limit. '

Check the camshaft for scratches and
wear and replace it if necessary.

. Measure the cylinder diameter at the top,

center and bottom in hath the X and
Y axes. Rebate the cylinder if it is he-
yond the serviceable limit at any point.
When reboring the cylinder, rebate it
to ﬁt one of the four standard overaine
piatuna available.

Standard oversize: are 0.25, 0.50, 0.75
and 1.00 mm (0.009, 0.019, 0.029 and
0.089 in.).

. Measure piamn diameter.

Measure the diameter‘ at the piston
skirt, 90C to the piston pin with a micro«
meter. Replace the piston if the diameter
is beyond the serviceable limit.

 

 

 

 

 

  

 

 

m. 71 @ Mimmm

Date at Issue: July 20, 1977
© HONDA MOTOR CO. LTD, 1377

 

28 4. ENGINE

7. Measure piston ring and gap.
Insert the piston ring into the skirt of
the cylinder so that it is squarely posi-
tioned, and measure the ‘gap with a
feeler gauge.

 

8. Measure piston ring side clearance.
Install the piston rings and measure the
side clearance of the piston ring in the
ring groove with a feeler gauge.

 

Fig. 73 @ Piston rin © Feels! gauge , >

9. Measure the piston pin hole using an
inside micrometer or a cylinder gauge.

10. Inspect the piston for damage, distortion
and excessive wear.

C. Beassembly

1. 11151311 the rocker arm and the rocker arm ‘
shaft in the cylinder head eover. ‘ )
Install the rocker arm shafts with the
side having a hole facing outward.

2. Install the piston rings on the piston
with the marking on the rings facing

the top. 7
Note: ‘ H H

When installing new piston rings. roll the

rings in the ring grnnves to assure proper

clearance. If the rings roll smoothly. the

clearance is satisfactury.

‘ , ' Use piston rings of the same manufacturer ‘
Fig‘ 75 (D Marks as a set. )

 

 

 

Date of Issue: July 20, 1977
© HONDA. MUI‘UR CD. LTD., 1977

 

 

 

4, ENGINE

29

 

3. Install the piston on the connecting
rod with the piston pin and clips so that
the A mark on the piston hmd pain:
toward the front (exhaust side) as shown
in the Figs 74

Note:

Always use new pin clipat

4. Stagger the end gaps of the top. 2nd
and oil rings 120° apart. ‘
Install so that none of the gaps are on
the piston buss axis or 90“ away from it.

(Three-piece type oil ring)
a. When installing the oil ring, place the
spacer and then the rails in position,
b. The spacer and rail gaps mixst be snag-
gered 2~3cm (0.783~1.181in.).
Note:
The gap of the oil ring is also that of
the spacer.

5. Install the cylinder gasket, two dowel
pins (oriﬁce valve) and two Orings on
the upper crankcase.

Note:

Before installing the dowel pin, blow comv

pressed air through the hole to make sure

it is not clogged.

Date of Issue: July 20, 1977
© HONDA MOTOR CO. LTD., 1977

 

 

 

Fig. 77 @ Pinsn @ Rings

 

 

 

 

 

Fig. 77—1 (9 Top ring (5) Rails
@ Sewn-l ring @ Spacer

@ Dowel pins

 

    

 

30 4. ENGINE

Fig. 7;: @ Piston bases @ Pam“ ring compressors

 

 

 

 

Fig. El @ Pim

@ UP" mark

Cylinder head gasket
@ Dowel pins

 

 

 

    

6. Turn the crankshaft and place the piston ( 3
base (Tool No. 07958—2500000) under
the No‘ 2 and 3 pistons. Install the
piston ring compressors (Tool No. 07957-
3230000) on the piston rings, and insert ’_
the pistons into the cylinder. When the . 3
No. 2 and 3 pistons have entered the 1
cylinder, remove the bases and piston
ring compressorsi Turn the crankshaft
slightly and install the No. 1 and 4
pistons being careful not to expose the .
rings of the No. 2 and 3 pisums. Raise ‘ >
the cam chain at the same time.

7. With the cylinder held approximately 20
mm from the crankcase, install the cam
chain tensions: in the cylinder, hold the
tensions: down by hand and install the
O ring, steﬁ washer. and tighten the
lock mm

(3
8. Insert the cam chain guide into the
cylinder as shown in Fig. 81.

9. Install the cylinder head gasket, two dowel
pins and two O—rings on the cylinder.

Date of Issue: July 20, 1977
© HONDA MOTOR CO LTD., 1977

 

4. ENGINE 3"

 

/
> 10. Place the cylinder head and hold the cam
chain with a screwdriver to prevent the
arm chain from dropping.

11. Tighten the twelve 8mm nuts With the
special tool m a torque of 2.0~Z.2kgvm.
(14.4ﬁ~16.63 ftrlbs) in the sequence
shown in Fig. 83.

Install and torque two 6mm ﬂange bolts.

Mount the cam chain tensions: on the

cylinder head with the aluminum
is washer and 6mm bolt.

< ) Note: Fig. 83
‘ Be careful not to drop nuts or washers

into the cylinder head or will be diﬁicult

to remove them.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

12. Hold the cam chain sprocket and cam
chain together and slide the camshaft
through them from the right side, and
set it on the cylinder head bearings. In—
still the cam chain on the cam sprocket.

   

 

13. Valve timing adjustment

Remove the point cover, rotate the
crankshaft insthe clockwise direction and
align the “T” (L 4) mark of the spark
advaneer to the timing mark. Position
the camshaft so that the center of the
cutout notch on the right end of the
camshaft is aligned to the cylinder head
ﬂange surface.

 

 

 

 

\ Fig. 85 8 Cylinder hmd ﬂa-e surface
Cnmut notch 9 Spark advance:

14. Mount the cam sprocket on the camshaft
with two 7mm bolts.

15. Mount the carburetor assembly on the
cylinder head.

16, Install the two dowel pins and six sealing
rubbers on the cylinder head.

   

) . as (9 Dcwe pins ‘ ® Se Ling rubbers

" Date of Issue: July 20, 1977
© HONDA MOTOR'OO. LTD" 1377

   

32

4. ENGINE

 

 

The valve tappe!
adjusting screw is
not properly
cuntscting the
vulva.

 

' Fig- 87

 

 

 

 

 

Fig. as a) 5mm screw

(9 Chromium—slated Dapper washer
@ Head side cover set plate
6) Alminum Washer

 

 

 

17. Install the cylinder head cover with the
twelve 5 mm screws and six 6 mm bolts,
and torque to 0.8~1.2 kg-m (5. 78~8. 67
lbs-ft) so that the torque difference is
not over 0.2 kg-m (1.441bs-ft).

Nate:

- Insert ﬁngers into the tappet hale mp
upening and lift the valve tsppeb adjusting
screw to check that they are properly meet-
ing the valves.

- Use the six 6mm copper washers as shown
in Fig. 88.

- Install the head side cover set plate with
washers mounted on both sides of the 6 mm
screws (Chromium-plated cvpper washer on
top and aluminum washer on bottom).

18. Install O-rings on the dowel pins of
the left and right side eovers, and install
the side savers on the cylinder head

19. Install the breather cover with six 6 mm
screws.

Note:
High tension cord clips are mounted on both
sides with the clips facing forward.

20. Adjust the cam chain by referring to
page 12.

21. Adjust the tippers by referring to page
7.

1321:: sf Issue: July 20, 1977
© HONDA MOTOR GO. LTD. 1977

 

 

4. ENGINE

4. VALVES AND VALVE SPRINGS
A. Disassembly

1. Remove the cylinder head by referring
to sectinn 3‘ A.

Z. Compress the valve springs with a valve
spring compressor (Tool No. 07957-
3290000). Remove the valve cutters and
the valves

Note:

Do not compress The springs more than

necessary. Compressing them excessively

may damage the valve stem seals.

3. Drive the valve guide out of the cylinder
head using ﬂue valve guide remover
(Tool No. 07046—32301)

B. Inspection

1. MeasuIe valve stem clearance.

Insert the valve into the guide and measure
the clearance in both the X and Y direc»
time using a dial gauge. Replace both
the valve and guide as a set if the
clearance is beyond the serviceable limit.
Drive the guide into the cylinder head
using a valve guide driver ('I‘ool Nat
079424290100) and ﬁnish ream the guide
to due proper size with the reamer (Tool
No. 0798441980000). Standard valve guide
inside diameter for both the inmke and
exhaust is 5.475N5.4B5mm (0.2153in.~
0.2157 in.)

Date of Issue: July 20. 1977
© HONDA MOTOR CO. LTD. 1977

33

 

 

 

 

 

Fig. 92 ® VIlve

Fig. 90 (a v.1” spring compressor
@ Cylinder head

a) a] gauge

 

    

 

34 l. ENGINE ‘ W

2. Check the valve seat contact width and '
remndition if necessary
Apply a thin coat of red lead to the
valve seat surface. Press the valve
against the seat and rotate it to check
if the contact width is uniform. Ifnot,
lap the valve seat and again check the
contact width. If necessary, recondition
the valve seat using a valve seat grinderr
Seat width 1.0~1.5mm (0.039~0.059

   

in.).

3. Masure valve runout. ‘ 3
Place the valve on s V-blcck and measure '
the runout of the valve with a dial
gauge applied to the face of the valve
while running it. Replace the Valve
if the mout exceeds the serviceable
limit.

4. Measure the valve springs.

Measure the free length of the valve
spring with a Vernier caliperr

 

Place a straight edge on the cylinder
head surfaoe and measure the clearance
at several points with a feelet gauge.
If the clearance exceeds the serviceable
limit, lap the cylinder head surface on
the surface plate using lapping com-
pound or replace the head if it mnnol
be repaired.

5. Measure the ﬂatness of the cylinder head. , ,
I 3

  

Figigspm® ( )

   

he!” gauge

Dale of Issue: July 20, 1977
© HONDA MOTOR CO. LTD, 1977

 

4. ENGINE 35

 

(r) C. Reassemhly
1. Wash all compqnent parts in salvent and reassemble the parts in the reverse order of
disagsem'blyr

 

 

 

 

 

Fig. 87 Cnmponem pm: of the cylinder held

(D Exhaust valve ® Valve spring outu ml @ Rctainer
@ Intake valve (7) Valva spring inﬂux srar @ Cutter
3 J @ 10x15 0 ring Valve stem seal @ Valve racket arm slim

/ (g) Exhaust vrlvc guide ® Innrr vulva spring @ Valve rocker Inn

@ Imsks valve guide @ Outer valve spring
Note:
) When installing the valves, apply a liberal amount o‘f‘goil on the valve stem.
g 2. Install the cylinder head in accordance with sectioii‘ 3‘ C, page 2&

Date of Issue: July 20. 1977
© HONDA MOTOR CO. LTD.. 1977

 

36 ‘ 4. ENGINE
Lubricating System 1510:]: Diagram

Racket am slipper Ruckm- axm shah Valve mm
Camshaft benxing #—I

6. Oil Pump and Oil
Filter

The oil pump is a trochnid
ty'pe driven by the pri»
mary shaft. The screen
and paper element ﬁlters
aie used to provide clean
oil to the engine.

 

       

 

 

 

 

 

 

 

 

 

 

 

. Fix. 98 Oil Lnbxicating Diagram
6) Oil cleaner clemam (2 Oil pump ® Reliaf valve © Oil screen ﬁlm

Date of Issue! July 20. 1977
@ HONDA MOTOR ca. 1113., 1977

4. ENGINE 37

{ j A. Disassembly
Oil Pump

1‘ Drain the engine oil in accordance with
section 7, page 13.

2. Remove the sterling momr cover, shift
lever and the left crankcase cover.

3. Loosen the 4mm bolt and remove the
pressure switch wiring. Remove the
three 6mm screws and the oil pump.

 

 

 

 

   
   

g > Fig. 99 Amm"bnlt
@ 5mm screw:

4. Remove the cap and disassemble the re-
lief valve and spring,

r, V ‘ . .e...‘
D ' (:3 Spring
on Screen Filter‘

1. Drain the engine oil in accordance with
V section 7, page 13‘ ‘
2‘ Loosen the ten 6mm bolts from the oil
pan. Remove the oil pan, and the oil
screen ﬁlter m be removed.

 

 

Date of Issue: July 20. 1977
© HONDA MOTOR CO. LTD., 1977

 

3B 4. ENGINE

    
    

z. 102 (9 Peeler gauge
(3 Inner rotor

ma (9 Feeler gauge
(9 Pump hody

 

 

Oil Filter

 

 

 

 

 

 

 

Fig. 104 ® Relief valve seat

 

1. Drain the engine oil in accordance with
section 7, page 13.

2‘ Loosen the center bolt to remove the
oil ﬁlter.

B. Oil Pump Inspection

1. Measure the clearance between the inner
and outer rotors.
Use a feeler gauge to measure the
clearance between the rotors. If the
clearance exceeds 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 the
pump body. If the clearance exceeds
the serviceable limit, replace the pump.

3. Inspect the operation of the relief valve.
Make sure that the relief valve is not
stuck in the pump body. Also check
for any foreign objects which may be
lodged between the valve and seat.

4. Inspect the screen ﬁlter.

Wash and inspect the semen ﬁlter. Re-
place the ﬁlter if it is damaged.

Date of Issue: July 20, 1977
© HONDA MOTOR CD. LTD, 1977

 

 

 

 

L ENGINE - 39

 

 

(,
j C. Reuaaembly
Oil Filter
1» Insert the oil ﬁlter center bolt through

the oil ﬁlter case and assemble the spring,

, ‘3 spring seat and element, Screw the

center bolt intokthe engine.
0 “3,.

 

 

 

new ,2

on Sal-Sen Filter

 

 

 

 

 

 

 

1. Mount the screen ﬁlter on the lower

 

      

Fig. 105
v crankcase“ . r . (n on 51m mm lmlt @ Filter element m
2. Mount the oil pan on the engme With 8 15x25 Oq—ing mar-E
the ten 6mm bolts. on ﬁlm use (a) 5 ter spring seat

 

Oil Pump

 

 

 

1‘ Insert the drive pump shaft into the oil
pump body and install the drive pin into
the shaft.

2. Align the cute and inner rotor punch
marks and install into the pump body.
The surfaces with the punch marks may
be set to the pump body side‘or the
pump never side.

 

3, Install the 47mm O-ring on the oil
pump body .and install the oil pump
cover with the three 6 mm screws.

 

 

v ‘ ) 4. Install the relief valve and spring into
the oil pump body, and install the cap.

5. Install the two O-ring collars, two 14
mm O-rings, and a 47 mm O-ring into the
oil pump body and then install the oil
pump on the crankcase with the three 6
mm screws.

6. Connect the pressure switch wires

7. Install the left crankcase with the four 6
mm screws and the gear change pedal.

‘ 8‘ Install the starting motor cover. . , r ».
e ) 1g. 102;~ @ O-nng collar @ 47 mm O-rmg
* ® 14 mm 0mg

 

Date of Issue: July 2D, 1977
© HONDA MOTOR CO. LTD. 1977

 

4o 4. ENGINE A
G. CLUTCH 3

 

    
    

Fig.110 @ 25mm snap ring
@ cmch assembly

 

11,

Fig. 112 Clutch lifter rod

Disassemhly
Drain the engine oil in accordance with

section 7, page 13.

, Remove thekick starter pedal

Loosen the ten 6 mm screws arid remove
the right crank case cover.

. Loosen the four clutch preyseure plate

mounting bolts, and remove the clutch
pressure plate and four clutch springs.

Remove the clutch lifter joint piecei
Remove the25mm snap ring, shims (some
engines may not have shims insmlled],
and the clutch assembly from the main
shaft

Disassemble the clutch disc, clutch plate
and clutch center from the clutch outer‘

. Remove the left crankcase cover.

Disconnect the clutch cable from the
clutch lifter‘ ,

Loosen the clutch adjuster lock bolt and
remove the clutch adjuster from the left
crankcase covert

Pull the clutch lifter rod out.

Data uf issue: July 20. 1977
© HONDA MOTOR OD. LTD., 1977

 

 

 

 

 

4. ENGINE 41

B. Inspection
1. Measure the friction disc thickness with

a Vernier caliper. Replace it if it exceeds
the serviceable limit

2. Check; the clutch plate for warp age.
Place the clutch plate on the surface
plate and measure the amount of warp
age with a feeler gauge. If the warp
exceeds ﬂue serviceable limit, replace the
clutch plate.

3. Measure the clutch spring.

Measure the free length of the clutch
spring with a Vernier caliper and replace
it if it exceeds the serviceable limit.

4. Inspect the rivets mounting the clutch
cuter tc 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 end is
facing the right side.

2. Applygrease to the clutch lifter and
assemble it to the left crankcase ccver
with the adjusterr Tighten the lack bolt
and reccnnect the clutch cable to the
clutch lifter.

3‘ Install the clutch lifter rod, set the steel
ball into the clutch lifter, and mount
the left crankcase cover with four 6mm
screws.

Date of Ilene: July 20, 1977
© HONDA MOTOR Cor LTD“ 1977

 

  

mo

Fig.115 (D Driven gear @ Rivet:

    

 

 
 

Fig. 115 6) Chm: lifter G) Adl‘m“

 

 

42 4 ENGINE

 

4 Install the clutch outer to the mainshaft
and install the clutch center.

    

Fix. 117 Q) Clulch center Clutch outer >

5‘ Apply engine oil on the friction discs
(7 pieces) and assemble them on the
clutch cenmr alternately with the clutch
plates (6 pieces). Assemble them into
the clutCh outei:

Note:

When assembling the friction discs,
assemble them on the clutch center so
that the oil grooves are facing as in
Fig. 113.

 

 

5‘ After assembling the friction discs and
clutch plains, set them with the 25mm
snap ﬁng. Place a dial gauge against
the end of the clutch assembly to check
for looseness. If the measured value of
looseness is greater than 0.1 mm (0.004
in.), install a spacer on ﬁne inside of the
snap ring. Spacezs are available in
thicknesses of 0.1, 0.3 and 0.5 mm.

 

 

 

 

Fig. 119 (9 mm piece 25mm snap ring
@ Spam ‘ J
7. Insert the clutch lifter joint piece into
the mainsliaft and ﬁx the clutch plates
with four piece of the clutch spring,
washer and 6mm screw.
8, Install a new gasket and the right crank \
case cover. ' )

9‘ Adjust the clutch,

 

Date uf Issue: July 20, 1977
© HONDA MOTOR CO. LTD“ 1977

   

A. ENGINE

7. GEAR SHIFT MECHANISM

A
l

.N

10.

Fig. 124 a) Guide pin clip

Disassembly

Disassemble the clutch in accordance with
section 6‘ A, page 40.

Remove the gear change pedal.
Remove the gear shift arm while holding
the gear shift arm down.

Remove the shift drum stopper bolt and
the shift drum neutral stopper bolt. Re-
move the shift drum shopper and shift
drum neutral stopper.

. Loosen the 6mm screw and remove the

oil guide plate and bearing set plate.
Loosen the 6mm screw and cam plate.
Disassemble the upper and lower crank-
case and disassemble the transmission
gears in accordance with section 9. A.,
page 47.

. Remove the neutral stopper switch from

the gear shift drum.

Remove the shift drum guide screw from
the upper crankcase and then remove
the guide screw collar.

Remove the guide pin dip and guide pin
and pull the gear shift drum out of
the crankcase.

@ Gear
@ Guide pin

Date of 1.5m: July 20, 1977
© HONDA MOTOR CO LTD. 1977

 

m. 122 @ shin drum stopper
(2) 511m drum stopper bah

Shift dmm neutral stopper

@ sum drum neutral stepper bah
® Bearing set plate

6mm screw

@ 0:1 guide plate

Cum plate

   

43

 

   
   

 

44 A. ENGINE

um

118.1% (DGeusxtfmk

 

 

 

 

 

Fig. 128 Q: Guide pin clips

 

 

 

B. Inspection

1. Measure the gear shift drum diameter
with a micrometer and the shift fork
with an inside micrometer. Replace any
part that exceeds the serviceable limit.

2. Measure the width of the gear shift
fork ﬁngers with a micrometer.
Replace if it exceeds the serviceable limit.

C. Reassembly
1. Set die left, right and center gear shift

forks into the upper mnkmse as shown
in Fig. 127. Install the gear shift drum.

2. Insert the guide pin into the shift fork
and seeuxe it with the guide pin clip.

Note:

Make sure that the guide pin clip is in-

stalled in the prnper direction.

134:; 9f Ian-2: July 20: 1977
© HONDA MOTOR CO. LTD., 15'”

 

 

 

4. ENGINE

45

 

3. Place the oounterbored section of the
shift drum as shown in Fig. 128‘ Install
the steel ball, the spring cap, and the
spring. Lock with the shift drum screw.
Bend the mb up on the guide screw lock
washer to lock the guide screw.

 

 

 

Fig. 129 ® Guide screw
(3 Guide screw

4. Align the neutral switch to the groove
in the gear shift drum and look in place
with the 5mm screwr

@

     

% gym
yrmg on
lock. washer 0 Steel amp
0 ing 0 Counterhmerl section

A -:=

 

 

5. Assemble the transmission into the upper
crankcase in accordance with section 10.
C, page 55 and assemble the upper and
lower crankcases.

6. Install the cam plate on the pin of the
gear shift drum with the 5 mm ﬂat head
screw which has been coated with thread
look cement

Note:
The pin and the pin hole in the cam plate

 

 

must be aligned.

7. Attach the shift drum stopper spring to
the drum stopper and the drum neun’al
stopper as shown in Fig. 132. Tighwn
the drum stop bolt and neutral stop bolt.
Tighten the bearing set plate together.

8‘ Tighten the oil _guide plate. After
tightening, rotate ﬂie shift drum and
check to he sure that each component
pert operates smoothly.

Note:

Make sure that the guide plate comes in con-

tact with the primary drive gear.

 

Date of latte: July 20. 1977
© HONDA MOTOR CO. LTD., 1977

 

E. 132

®

 

. re .
1 t rum stopper spring

Shift drum stopper

Shift drum neutral stopper

 

 

46 4‘ ENGINE , ,
r 3

9. Insmll the gear shift arm and make sure that it operates smoothly in both directions.
10. Install the clutch in accordance with section 6. 0., page 41. A

8. CAM CHAIN TENSIONER ,
The cam chain tensioner is constructed of spring steel on which a layer of heat resistant ‘ N)
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 the
tension side of the cam chain also controls chain vibration.

An adjustment screw is located at the rear of the cylinder block.

 

 

 

 

 

Fig. 133 i )

® Cam chain guide Lock nut
® Cam chain tensianer (0 Screw

Date at Issue: July 20, m7
@ HONDA MOTOR co. LTD., 1977

 

,_‘

H9

5"

_4. ENGINE

Disassembly

. Remove the cam chain tensioner and the

chain guide in accordance with section
3. A., page 24.

. Inspection

Make sure that the cam chain tensioner
adjuster gear is properly meshed with
the rack. Inspect for smooth operation.
To adjust the cam chain, see page 14.

Reassembly

. Perform reassembly in accordance with

section 3. C., page 28‘

CRANKSHAFT AND CONNECTING
ROD

Diaaeeemhly

Dismount the engine in accordance with
section 2. A., page 20.

Disassemble the cylinder head, cylinder,
and piston in accordance with section 8.
A., page 24.

Remove the generator cover and remove
the rotor using‘a generator rotor puller.
[Tool No 079334160000)

Remove the point cover and the special
Washer by removing the 6mm bolt.
Loosen the three 5mm screws and re-
move the contact breaker assembly and
the spark advancer.

Remove the clutch and the gear shift
arm in accordance with section 6, A.,
page 40.

Remove the starting motor cover and
dismount the starting motor.

Date of Issue: July 20. 1977
© HONDA MOTOR CO. LTD, 1977

 

g. 131 (9 Starting motor

 

47

gr 155 @ Generator rotor

(2) Generator rate: puller

(D 6mm bolt

0 Special washer

0 5mm screws

© Contact breaker assembly

 

n

 

43 4. ENGINE

7. Place die engine upside down and loosen
the ten 6 mm bolts to remove the oil pan.

8. Loosen the ten 8mm bolts and the
twelve 6 mm bolts from the lower cnniik~
case. Loosen the 8mm belts in the-
reverse order shown in Fig 152.

9. Place the engine in an upright position
and loosen the three 8mm and 6mm
bolts Tap the upper crankcase lightly
with a wooden hammer and separate the
upper and lower crankcases.

10. Loosen the two 6mm bolts and remove
the bearing set plate.

11. Pull the primary shaft out using a
primary shaft hammer (Tool No. 07936-
3230100) and a Weight hammer (Tool. No.
07936—3230200). On the model CB 550,
use a primary shaft hammer (Tool No.
mess—3740100) and weight hammer
(Tool No. 079454000500).

Note:

Disassemhly of the primary shaft, trans-
mission, and kick starter can be per-
formed without removing the cylinder
head, cylinder or piston. When remov-
ing the lower crankcase, follow the se-
quence 10, 11, 9 and 8 above.

12. Remove the starting clutch from the
primary chain.

13. Remove the primary chainand the mm
chain from the crankshaft.

 

    
     

Fig. 139 @ Primary shaft :3) Primary shaft puller
Weight hammer

B. Inspection

1. Measure crankshaft runout
Support both ends of the crankshaft on a
V-block and measure the amount of bend
in the crankshaft by applying a dial
gauge to the center journal and rotating
the crankshaft. If the runout exceeds
the serviceable limit on the dial gauge,
replace the crankshaft.

-2. Inspect the crankshaft journals with a
micrometer for scoring and uneven wear.
If any journal is cutoﬁround or tapered
more than the serviceable limit, replace
the crankshaft

Data of Issue; July Z0. 1977
© HONDA MOTOR CO. LTD“ 1977

(g) cmmhm

 

Fix. 141 a) 13.31 gauge

 

     

 

 

4. ENGINE 49

 

 

3. Measure the diameter of the crankshaft

4. According to the letter and the ﬁgure

3. Measure the crankshaft joumal wearr
Cut a length of plasti gauge to the
width of the bearing cap. Place the
gauge on the bearing parallel tn the
crankshaft. Assemble the crankshaft and
torque the crankcase down in accarclance
with Fig. 152.

Disassemble the crankcase and measure
the plasti gauge using the scale provided
If there is a clearance in excess of 0.08

mm (0.0031in.), replace the hearing.
Note:
When measuring with the plasti gauge, do
not turn the crankshaft.

Bearing Selection
1, Remove the bearing. Assemble and tigh-

ten the upper and lower crankcases, Refer
to Fig. 152.

2. Measure the inside diameter of all the

hearing seats in the vertical direction with
a cylinder gauge s'nd select the corre-
sponding letter from the table below.

mm (in)

 

 

 

c as 111545.024
(1. 4179~1. 4182)

B as. amuse. ms
(L ms~1. 4179)

A as ooo~ae one
(1. 41734. 4176)

 

 

 

 

juumal with a micrometer and select

the oorresponding ﬁgure 1 or 2 from
the table below.

 

 

1 2
92; 99~3a. no 32. sswsz 99
(1. 2957~1. 2992) (1. mama. 2937)

 

 

from items 2 and 3, select the proper
hearing from A1 B, C and D in the table
helow.

 

 
  
  
 

 

 

 

 

 

 

 

Crankshaft
classiﬁmu'uu No.
1 2
Crenkcsse
clusiﬁmkion mark
C E A
(Brown) (Black)
B c B
(Green) (Brown)
A D C
(Yellow) (Green)

 

Dale af Issue: Iuly 20, 1971
© HONDA MOTOR CO. LTD, 1977

 

 

 

 

Fig. 144

Note:

The lower crankcase and crankshaft are
marked with letters or numbers at the fac-
tory. These are production codes and should
not be used or referred to during servicing
or repairing.

 

50 4. ENGINE

 

 

 

 

 

 

 

 

 

 

 

Code Weight (gm)
A zs1~285
B 236~290
I: 291495
D l 295~3uo
E l 301~sus
F ‘ sne~am
G ‘ 311415

 

 

 

Fig. 146 @ Weight code number

    
    

Fig. 147 ® Feelet gauge
® Cannecting rod

 

 

Fiz. 14!! G) inside dial gauge

 

5. Measure cnnnecting rod large end weer.

Separate the cap from the connecting rod.
After setting the plasti-gange in place,
torque the two red nuts to 2.0—2.2kg-m
(14.46—15.911he-ft).
Disassemble the cap and measure the
plasti-gauge. Replace the hearing with
a new one if it exceeds the serviceable
limit.

Note:

Do not turn the crankshaft while the plnsti

gauge is installed.

6. Method of designating connecting rod
weight
When replacing the connecting rod, re-
place with one having the same weight
code. The weight code is stamped at
the large end of the connecting rod.
When replacing all of the cementing
rods, the tolerance of the respective rods
should be within 5 grams.

Note:

The connecting rod weight includes the

weight of the cap and two bolts, but not

the hearings.

7. Measure axial clearance using a feeler
gauge.
Replace if it exceeds the serviceable limit.

8. Measure the connecting rod small and
Measure the diameter of the connect-
ing rod small end with an inside dial
gauge, Replace if it exceeds the service-
able limit.

Date of Issue: July 20, 1977
© HONDA MOTOR 001 LTD” 1977

 

l we)

4. ENGINE

Selection of‘ The Bearing

 

 

1. Measure crankshaft pin diameter with
a mimmeter and select the correspend—
ing letter from the table below.

 

A B

 

84. BB~35. GD 54» 93~8L 99
(1. S775~L 8750) (l, 3771~L 3775)

 

 

 

 

2‘ Select the hearing from the tahle belqw
which coincides with the number (1, 2, 3)
stamped on the large end of the connect-

 

 

 

 

 

 

 

 

 

ing red.
(1 all '
messes m A B
Connecting \
rod code No.
3 E (Brown) A (Black)
a c (Green) E (Brawn)
1 D (Yellaw) c (Green)
Note:

. The numbers marked on the crankshnft
are prbductinn cudes and should not he
referred to during servicing.

- The hearings must he installed on the
connecting rod with the key toward the
front.

C. Reassembly

1, Install the primary chain and the cam
chain on the crankshaft.

2. Install the crankshaft into the lower
crankcase.

3. Position the starting clutch and starter
gearas in Fig. 151,theu drive the primary
shaft in from the right to left, Use care
in the needle bearing assembly sequence
shown in Fig 166.

Date of Issue: July 20, 1977
,© HONDA MOTOR CO. LTD, 1977

   

 

 

 

 

 

 

 

 

Fig. 150 Q) Key (projection)

m
Fig. 151 a) Sun ng clutch
(2) 3mm gear

 

     

@ Primary shah

 

 

 

52

 

 

 

A, ENGINE

4. Install the bearing set plate with two
6 mm bolts.

5. Apply a thin coat of gasket paste on
the mounting ﬂange of the lower crank-
case (a heavy coat will cause the paste
to fall inside the crankcase).

Install two dowel pins. Mount the up-
per crankcase on the lower crankcase.

Fig. 153 6min mounting bolts

6. Place the engine upside down so that
the parting surfaces will not be separated.
Install the ten 8mm bolts. Torque the
8mm bolts in the sequence shown in
Fig. 152 to a torque of 2.3—2.5kg-m.
(16.63—18.081hs-ft).

Tighten the thirteen 6mm bolts. (Fig
153)

Note:

Note the position of the two 8mm bolt:

whinh are stamped on the bolt head with

the number “9”.

7. Position the upper crankcase on top and
install with the three 6mm and 8mm
bolts (Fig. 154)

Note:

Note position of the two 8mm bolts which

are stamped on the hall: head with the

number “8".

8, Install the oil screen ﬁlter and mount
the oil pan with the ten 6mm bolts

9. Mount the starting motor with the two
6 mm bolts,

10. Install the gear shift arm in accordance
with section 7. 0., page 44.

11, Install the clutch in accordance with
section 6. 0., page 41.

12. Insert the spark advance! dowel pin into
the pin hole in the crankshaft and mount
the contact breaker with the three 5mm
screws.

Date of Issue: July 20. 1977
© HONDA MOTOR CO. LTD» 1577

 

    

 

4. ENGINE 53

13. Install the special advancer washer with
the 6mm bolt and install the point
cover.

14. Adjust ﬁning and point gap,

15‘ Mount the generator rotor with the
10 mm bolt.

16. Install the generator cover.

17‘ Assemble the piston, cylinder, cylinder
head, and head cover in accordance with
section 3‘ Cr, page 28,

10. TRANSMISSION, KICK STARTER
AND PRIMARY SHAFT

A. Disassemhly

1, Dismount the engine from the frame in
accordance with section 2. A., page 20.

2, Remove the clutch in accordance with
section 6. A., page 40.

3‘ Separate the upper and lower crankcase
in accordance with section 9. A., page
47.

4. Remove the transmission and disassemble
the gears from the respective shafts.

 

Kick Starter

5. Remove the 18mm snap ring and the
return spring.

6. Remove the 12 mm mp ring and dis»
assemble the kick starter shaft from the
lower crankcase '

 

 

 

Date of Issue: July 20, 1977
© HONDA MOTOR CO. LTD., 1977

    
  

157 g) Generator mlor
® 10mm halt

 

   
 

v- we 1
Fig. 158 (9 18mm snap ring
(2) Return swing

 
   

Fig. 159 (9 12 mm map nng @ Kick mner shah

 

 

 

54 4. ENGINE A)

Primary Shaft

 

 

 

7. Remove the primary shaft in accordance
with section B. A, page 47 and remove
the 20mm snap ring and primary drive

gear. 5 i >

8. Remove the side collar and pull the
#6205 ball bearing out

9. Remove the 30mm snap ring. primary
driven sprocket, starting clutch, and pull
the damper rubbers out.

    
    
    

m. 151 a) 30mm snap ring ‘ .
® 12mm driven sprocket :

10. Loosen the three 6mm ﬂat head screws
and remove the starting clutch outer.

 

Fig. 162 @ (5qu ﬂat head screws
(3 Starting clutch outer

B. Inspection
1. Measure gear backlash

Set the pointer of a dial gauge against
the tooth of the gear and measure the

backlash. l )

m». 163 ® Dial gauge

Date of I-ue: July so! 1977
© HONDA MOTOR col LTD" 1977

 

4» ENGINE 55

 

 

2. Inspect the dogs and replace any gears
with excessively worn dogs. Make sure
that the gears slide smoothly over the
splined shaft.

 

C. Reaseembly
Primary Shaft

[ W 1. Install the starting clutch outer and prim-
ary driven sprocket hub with the three
6 mm ﬂat head screws coated with thread
lock cement. Then stake the screw heads
with a punch to prevent loosens-es.

 

 

 

 

 

2. Assemble the damper rubbers on the

primary driven sprocket, and install on

v the starting clutch with a 80 mm set ring.

{ > 3. Drive the $6205 ball bearing into the
’ primary shaft.

 

  

A .
Fig. 166 ® Primnry driven sprocket
@ Damper rubbers

 

 

4. Mount the starting clutch gear on the I 8
starting clutch, and insert the needle hear: 0 ®0 Q

, ) ing and 25mm spacer into the starting
l _ clutch gear. Fit the 25 mm thrust Washer ‘*
and the snap ring on the primary shaft,

and install the primary shaft in the
crankcase,

 

 

 

 

 

 

 

 

 

Igl—H

 

 

 

 

 

 

 

Fig. ms 6; Starting clutch gear
® Needle bearing (25x29x17)
25 mm spacer
@ 25 mm thrust washer
) ‘ @ 25mm snip ring

@ 22 mm thrust washer

Den: of Issue: July 20. 1977
© HONDA MOTOR 00‘ LTD, 1977

 

56 4. ENGINE

 

 

Kick Starter

5. Reassemble the kick starver components
in accordance with Fig. 167.

Note:
Be sure to install the 18 mm washer.

 

 

Transmission

 

 

 

6. Assemble the transmission gears on the
respective main and counter shafts

 

 

 

 

Fig. 167 (D Kick miner pinian

® 20mm thrust washer

Starter pinion let spring

® Kick sum: racket
® 15 mm thrust wushu
(5) Kick staxter nehetipxing
(3 Rachel guide plate
® Chain guide thrust
(9 12min snap ring
® 18mm washer
® 18mm snap ring
@ Kick starlet lpxing
@ Kink wtu‘ spindle

 

a) 57 min heading :2: xing

® 25mm smp ring

@ 5205 spacial ball bearing

© 245mm Orring

® Tnnsmisaiun counter
shaft: i

© 33x57><7 oil seal

@ Drive sﬁmcket (171')

Driv‘g sprocket ﬁxing
plat:

® Gen: shift fork Fin

® 20 mm needle beating

® Counter shaft low gm
(40 T)

® Cmm shaft inurth
gear (29 T)

® 25mm thrust washer

@ Gaunt“ shah ihird gas:
(337)

@ 25mm lock Wilhel

® 25 mm umm washer

® Counter shah second
gear (as T)

Q Cuumer shaft top gear
(27 T)

@ 52 mm blaring 5:: ring

® 5205145 hull bwing

® Transmissian innin shah
(24 T)

@ Mnin Ihair fourth gear
(23 T)

@ Main shaft saccmd, third
gear (a T. 25 T)

g Mainshuﬂ «up must: T)

® 20mm than: Waxhcr

@ 22mm needle hearing

a exams oil ml

Fig. 163

 

 

 

 

Date of hue: July 2|), 1977
© HONDA MOTOR CO. LTD., 1977

     

4. ENGINE , 57

 

 

7. Install the two bearing set rings and
the dowel pins in the upper crankcase.
Install the transmission.

8. Rjzasemble the upper and the lower
crankcase in accordance with section 9. C.,

, ’7) page 51.

9. 11150211 the clutch in accordance with sec-
tion 6. 0., page 4L

10. Mount the engine in the frame in ac-

cordance with 2. 13., page 28.

 

11. CABBURETOR

 

A. Disassembly

l. Remow the carburetor unit from the
engine in accordance with sectian 2 A.,
page 20.

Stay Plate And Carburetor
2. Unhook the throttle return spring from

 

    
     

the link lever. . r m .
Nate: Fig. 170 @ Throttle return spring
Be careful not tn damage the hook end of ® Link 10"”
I \ the spring.
\ > 3. Loosen the hex nuts, and remove the

stay plate Br Remove the cap nutsr

L

    

/) Flg'. 171 (D Stay mm Q) Ca}: nuts
, (2 Stay plale E ,

Date of lame: July 20, 1977
© HONDA MOTOR CO. LTD‘, 1977

     

53

 

 

Fig.1'75 (D Link .m

 

 

    

t. ENGINE

4 Remove the adjuster holders from the
link arm.

5. Loosen the eight 6mm ﬂat head screws
from the stay plate and remove the carbu-
retor unit.

____.—__—
Throttle Valve And Jet Needle
f,—

 

& Loosen the two carburetor mp mount—
ing screws from each carburetor and re.
move the tops.

7. Place the throttle valve in the fully open
posiﬁon and straighben the tabs of the
two tongued washers

8. Remove the 6mm bolt from the shaft
end and remove the link arm in direc-
tion A using a mewdriver.

pm of Issue: July 201 1977
@ HONDA MOTOR co. LTD., 1977

 

 

 

4. ENGINE 59

 

9. Loosen the_6 mm bolt on the throttle side
about 1/2 tum, insert a screwdriver be!
tween the throttle shaft and link arm and
pry loose in direction A.

   
  
  
 
  
   
   

Fxg. 176 G) 6mm be]!

(2) Throttle shaft

10. loosen the two 3mm screws, rotate the
valve plate 90“ in either direction an I
align the 1211) on the valve plate to the"
groove in the shaft. Remove the valve h
plate. '

11. Remove the jet needle from the throttle
valve.

 

 

 

Adjuster Holder

1. Remove the carburetor from the stay
plate in accordance with steps l~5, page
57.

2. Remove the adjusting screw from the
adjuster holder-l

 

Fig. 175 a) Adjusting mew
® Adjuster may
3. Position the throttle valve at the inter-
mediate position and remove the adjuster
holder.

 

Flg. 179 ® Adinsler holder

Date of hue: July 20, 1977
© HONDA MOTOR CO. LTD” 1977

 
 

60 ‘ 4. ENGINE

 

Float, Main Jet, And Slow Jet

 

 

 

1. Remove the ﬂoat chamber body.
2‘ Remove the leaf spring and the main jet.

 

3‘ Pull the ﬂoat arm pin out and remove
the ﬂoat.

 

4. Disengage the clip plate and remove the
valve seat.

     
  

® Clip plate

   

1333.182 @ Valve mm

B. Inspection

1. Fuel level adjustment.
Position the ﬂoat so that the ﬂoat arm
barely touches the tip of the ﬂoat valve.
Measure the distance from the ﬂange to
the top of the ﬂoat with the ﬂoat level
gauge The standard value is 22mm
(0.89 in.)

Fir. 133 ® Plants

® Float level gauge
(Ton! Na. 07401-0010000)

 
 

Date of lune: July 20, 1977
© HONDA MOTOR CO. LTD, 1977

 

 

4. ENGINE 6|

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

C. Reassemllly Carhnretar “my“; data
Float. Main Jet, Ami Slow Jet ”WW“ N»
Main jet It mu
1. Install the valve seat with the clip plate.
‘ '~ 2. Install the ﬂoat. A“ 5” “150
l > 3, Place the leaf spring on the main jet Slow jel 340
' and install them on top of the needle W “‘5
jet holder.
4. Install the ﬂoat chamber body. A“ "‘3‘" ”ﬁning 111/3
K “
4 ) Adjuster Holder

 

 

 

1‘ Insert the coil spring 13 and spring seat
B into the adjuster holder. Position the
throttle valve to about 1/2 open and in-
sert approximately 1/4 of the connector
shaft into the holder window Install
them while holding the spring seat down
with a screwdriver.

2. Mount the carburetor on the stay plate
in accordance with sections 7 and '8‘

  
    

 

Fig. 134 (D Adjuster 1mm" @ Spring seat B
@ Coil spring 13

 

 

Throttle Valve And Jet Needle

1. Install the jeL‘needle on the throttle valve.

2. Place two spring Washers and 3mm
screws on the valve plate. Place the valve
plate tab to the slot of the throttle valve
and push. down to the bottom. Rotate
the Valve plate 90" toward the link
arm and install the 3mm screws,

 

 

 

135 @ Valve plate Spring waiher
(3 3mm screw g) Throttle valve

l ) 3. Install the throttle valve in the carbur—
etor body so that the throttle valve cut-
away section is facing the choke velvet

 

 

 

Dlte of Issue: July 20, 1977
© HONDA MOTOR 00. LTD, 1977

   

62 4, ENGINE

4. Inosen the 6mm halt from the thruttle
shaft and push the spherical and of the
link arm into the throttle shaft while
pulling the throttle shaft up.

, ‘ I \i .
Fig. 187 ® 6mm hult
® Throttle shah

    

 

5. Install the tongued washer with the
tongue positioned as shown in Fig. 188i
Tighten the 6mm bolt, and bend the
washer tongue up against the bolt head,

6. Install the carburetor top with the two
5mm screwst

 

 

 

7. Combine the two carburetors with the
"T” type joint and the rubber pipe.

 

 

Fig. “9 (i) Rubhex pipe ® T type Jumt

8. Mount the spring set plate, and hook
up the return spring.
Positiun the four carburetors, install the
set plate, and tighten with the eight
6mm ﬂat head mews.

 

Date of Issue: July 20, 1977
© HONDA MOTOR CO. LTD., 1977

 

44 ENGINE 63

/,
a > 9. Install the dust plate A, and mount the [7"
adjuster holder to the link arm,

i

    
   

I > mg. 191 a) Dusl plate A @ Link arm
® Adjuster may

10. Insert the csil spring B and tighten it
with the up nut.

 

11‘ Install the special washer D, stay plate
B, and ﬂat washer on the adjuster screw
and tighten the nuts,

   
  
   

Fig. 193 a) Special washer D @ Washers
@ Stay plus B (9 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. 194.

i _ J 14. Mount the carburetor unit on the engine

' in the reverse order as described in section

2. A, page 20.

 

Fig. 194 @ Fuel mi»:

 

Date of Issun: July 20, 19777
© HONDA MOTOR CO. LTD., 1977

 

  

5. CHASSIS

 

mm“...

1; FRONT WHEEL AND FRONT BRAKE

 

 

Fig. 195

® Axle shnﬁ.

® 5X15nun oval mew

® Speedometer gear lmx

G) B'x 102 mm bolt

(5) Gear box retainer cover

@ Gear box retainzr

® O-ring

6:1qu hall hearing

® Front axle distance collar

® Fm: spoke B

@ From wheel hub

® me wheel tube

® Front wheel ﬁre

a: From ﬁn! ﬂap

@ Wheel balance:

43 Front spoke A

3) From wheel rim

® 6302K ball bearing

® 22368 dust seal

@ From wheel bearing
laminar

® Front wheel calls:

a) Front wheel axle nut

 

 

 

 

Front Wheel
A. Disassembly
1‘ Place a block under the engine to raise the from wheel off the groundt
2. Disconnect the speedometer able from ﬁne speedometer gear box
3. Loosen the axle holder mounting nuts and remove the front wheel assembly from
the front fork ‘
4L Loosen the front wheel axle nut and remove the front axle.

    

Fig 9a a; Speedometer cable Fig. 197 (D Front axle m

Dam of Issue; July 20. 1977
@ HONDA MOTOR co. L111. 1977

     

66 5, CHASSIS

5 Remove the bearing retainer (Tool No.
07910-3230101) from the wheel hub, and
the dust seal from the hearing retainer.

 

6, To remove the brake disc from the
wheel, straighten the‘tongues on the
magnet] washers and loosen the disc
mounting nuts.

7. Remove the speedometer gear box and
retainer cover from the opposite side.

8. Remove the front wheel bearing.

    

Fig. 199 ® Disc munung nuts
e) Tnngued washer:

Inspection

. Brake disc inspection.

Place the disc on a surface plate and
measure the trueness'using a dial gauge
as shown in Fig. 199. Replace the disc
if it exceeds the serviceable limit.

. Rim wobble and wheel runout check.
Spin the wheel by hand and check both
wobble and runout using a dial gauge
as shown in Fig. 201.

 

 

Fig. 201 ® Dial gauge

Date of Illue: July 20, 1977
© HONDA MOTOR CO. Lme 1977

5. CHASSIS 67

l

) 3. Wheel bearings check. 7
Measure beating wear in both axial and El!
radial directions.

¢ Check for loose or bent spokes.
Tighten loose spokes and straighten or

(/ W replace bent spokes.

,, 5. If tire prasure is low, check for leaks
around the valve stem and the valve.

6. Check the condition of the tire inside
and outside for cuts, hnﬁsﬁ, and im-
bedded nails.

7. Check to he sure that the tire is cor-
rectly inﬂated.

Tire inﬂation pressure: 1.3kg/cm’
(25.6w)

8. Check if air leaks from the tire valve.

0. Reassemhly

Note:

Before installing the front wheel bearings,

install the distance collar. “’

l. dee the 6302R wheel ball bearing into
the hub using a bearing driver.

Use a drive ethichmeut (T 001 No. 07946~

‘ , 9350200) and dﬁvet handle (Tool No.

l 7 07949-5110000).

" 2. Install the dust seal in the wheel hear-
ing reminer. Mount the retainer into the
wheel hub and install the O-ring into
the hub.

3. Install the gear box retainer cover on
the gear box retainer so that the cover
matcha the slot.

   

 

, R .
» Fig. 204 (9 Gm box retainer
. J (g) O-ring

4. Mount the brake disc on the wheel with

bolts, tongued Washers, and nuts. After

( > tightening, bend the tongues up on the
"“J washers to lock the nuts.

  

Fig. 205 @ Tongues wuhen

 

   

Date of Issue: July 20, 1977
© HONDA MOTOR CO. LTD, 1977

63 5. CHASSIS

 

5. Install the Speedometer gear box on the
opposite side of the brake disc, and
insert the front axle into the hub through
the speedometer gear box.

6, Mount the front Wheel on the front fork.
Install the axle holders and tighten the
nuts.

Note:

Make sure that the speedometer gear box

is'pmperly mounted.

Tighten the axle holder on the left side

ﬁrst (brake disc side), then the right side.

Tighten the front nuts on the axle holder

ﬁrst.

7. Connect the speedometer able to the
gear box.

8. Wheel balance check.

a. Mark the side of the tire and rotate
the wheel lightly several times. Note
the position the mark comes to rest.

b. If the wheel is not statically balanced,
the mark on the tire will come to
rest at the same V'position. (Heavier
section will he at the bottom).

c. Attach a balance weight on the spoke
at the lighter section (the top).

d. The wheel is balanced if it does
not stop at any deﬁnite position after
rotating several times
The balance weights are available in
four diﬂerent weight sizes (5, 10, 15
and 20 grams),

e. The front wheel should be balanced
with the brake disc installed.

 

    

Fig. 205 ® Gm box retainer
(23 Speedometer gut box

 

 

 

 

 

Fig. 203

Front disc brake

The disc brake system consists of the brake lever and master cylinder on the right handle-
bar, the caliper mounted on the left side of the front fork, and the special stainless steel
brake disc mounted on the wheel huh.

(Operation)

1. When the brake lever ® is gripped, the cam Q) at the base of the lever actuates a
piston in the master cylinder.

2. The piston moves the primary cup (9 that blocks the passage to the reservoir and
pressurizes the ﬂuid within the master cylinderi This pressure is transmitted to the
caliper chamber through the brake hose B (D, the 3 way joint ©, and the brake hose A ®l
The stop light pressure switch © mounted on the 3 way joint is also actuated.

3. Thehydraulicpressurewithin caliper chamber A applies pressure against thepiston®,which
forces padA ® against the brake disc. Since the caliper assembly is mounted on an
arm which pivots at the front fork, it is free to swivel, therefore, the reaction from
pad A OD is transmitted to pad B, resulting in equalized pressure being applied by the
pads to both sides of the brake disc.

Date of Issue: July 20, 1977
© HONDA MOTOR CO. LTD. 1977

 

69

5, CHASSIS

 

 

 

 

5
From lvnke lever 0 Three way juim El Piston
From bake lever um 13 Slap switch .m Pad A
Primal: cup a From brake has: A
ant nke hose B Q) Caliper A
l ) F12. 209
’ A. Disassembly
1. Remove the front Wheel.
2. Loosan the oil joint bolt and disconnect
the brake hose.
1' 3. Loosen the three caliper mounting§;bolts

and a caliper adjusting bolt, and remove
the caliper assembly.

4. Loosen the two caliper set bolts and
separate calipers A and B.

 

» ‘ 9. I L'
Fig. 211 ® Caliper moummg bolt:
J @ Caliper adjusting bolt 6) Caliper E
@ Caliper sel bolts K5I Cnliper A

 

Date of Issual July 20,1977
a HONDA MOTOR co. LTD, 1977

   

 

70 5. CHASSE

5. Remove pad A and the pistun from
caliper A,
Use compressed air to remove the piston.
6. Remove pad B from caliper B.

7. Loosm the master cylinder joint bolt
and remove the brake hose.

8. LODSEn the master cylinder mounting
bolts and remove thé-‘master’cylinder
unit from the handlebar.

9. Disassemble the master cylinder.

 

» .M
(1) Iain! halt
Mute: cylinder unit
Bake 110::

Q) Mailer eyUndernuunting hols

    

 

 

 

 

 

(D Brake lever up 0 Piston Reservuir cap 5mm hex belt
a link: lever 0 Secondary cup Mum- cylinder plats Joint bolt washer
9 5mm! wuhu 0 Primary cup Dinyhngm a Joint bolt
Boot .m 5 ing Master cylinder body 9 Ram brake base
13mm internal snap ring C eck valve Mute: cylindn hulder
® 10. 5mm washer {male lever pivotﬁnltzm 5mm spring washa'
g.

Date of Issue: July 20. 1977
© HONDA MOTOR COi LTD, 1577

   

10.

6. CHASSIS 7|

Remove the boot and the snap ring from
the master cylinder body with the snap
ring plier (Tool No. 07914—3230001)
Remove the 105 mm washer, piston,
secondary cup, spring, and check Valve.

Inspection

Checking the disc brake pad wear. Red
grooves are provided for both pads A and
B as a wear limit indicatorr When the
pad is warm to this rd groove, the pad
should be replaced. Aim replacing the
pads, adjust the clearance between the
brake disc and pad to 0.15 mm (0.006 ill.)
with the caliper adjusting bolt.

‘Adjust by turning the caliper adjusting

halt until the pad drags slightly against
the brake disc, and from this position
back off 1/2 rum and tighten the lock

nut

Checking the caliper cylinder and piston.
Measure the inside diameter of due caliper
cylinder and the outside diameter of the
piston using a cylinder gauge and a micro-
meter. If the clearance exceeds the
serviceable limit. replace the part.

Date of Issue: July 20, 1977
© HONDA MOTOR CO. LTD,, 1977

  

 

 

 

F1521!» a) Msshannglin
@ Snap ring

 

 

mar-immune...)

 

  

 

E @ Brake disc
ad A @ Wm 1mm indicator

 

 

® Fismn
G) Micrometer

   

® Cylinder gauge

 

72 5. CHASSIS

   
   

Fig. 218—1 0 Calipu E
9 Paul B
6) Apply grease in part marked (X)

m

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Fig. 219 1 Caliper B Par] A
8 Pad 13 @ Caliper A

5. Checking the master cylinder and piston.
Measure the inside diameter of the cylin—
der and the outside diameter of the
piston using a cylinder gauge and a micro-
meter. If the clearance exceeds the
serviceable limit, replace the part

C. Reassemhly

1‘ Perform reassembly in the reverse order
of disassemhly.

2. Assemble pads A and B.

Note:

Apply silicone sealing grease on the pads

sliding surfaces of the caliper before as-

semblying pads A and B. This serves as

a dust preventative as well as a water re-

pellent. Do not apply grease on the pad

friction surface.

3. Apply a cost of brake ﬂuid to the inside
surface of the cylinder.

4. lusmll the check valve to due return
spring and install them both in the
cylinder.

CAUTION:

When installing the check valve and return

spring in the cylinder, make sure that the

valve is facing wu‘ectly and that the
spring is in the correct position.

5. Apply a thin mat of brake ﬂuid m the
outside shrine of the primary cup.
Insmll the primary cup being careful not
to all/aw dust to attach to it er not to
damage it. Make sure that the cup is not
inclined or reversed in the cylinder.

Nate:

When the primary cup has been disassem-

bled, replace it with a new one.

6‘ Install the 18mm internal snap ringi
Turn the snap ring to check for proper
ﬁt.

 

 

 

 

 

 

 

Fir. 220 ® Primary cup

Fig. 221 (9 Spring

Date of Issue: July so, 1977
© HONDA MOTOR co. LTD“ 1977

   

5. CHASSIS 73

 

D. Brake adjustment

When the brake has been disassembled al-
ways perform the air bleeding operation of
the hydraulic brake and than adjust the brake.

1. Brake lever free play
Lever free play of 2~5 mm (D.08~0.2
in.) measured at the end of the lever is
normal. H the play is excessive, inspect
the brake system and replace any were
or defective part.

2, Brake ﬂuid level ,
Fill the reservoir with brake ﬂuid to' the
level line.

Note: .

Brake ﬂuid will damage paint ﬁnish, rubber

parts, and meter components, therefore,

use care in handling and immediately wipe
in case of spillage.

- To air bleed the brake system refer page

15.

 

 

.W

1712.223 (9 Diaphxigm @ Mme: cylinder
Bmke ﬂuid

    

2. REAR WHEEL AND REAR BRAKE

 

® 530w ball bearing

@ Distance mu“

(9 Wheel balance:

(9 Tire

@ Tube

@ Tire ﬂap

® Wheel hub

® Rim '

® O-ring

® Wheel damper A

® Wheel dunper B

@ Final driven ﬂange

® Dianne: Dolls: 13

® eaosu ball bearing

a; Beuing reminzx

a 10x43 driven spretket
ball

® Side cellar

@ Final driven sprocket

@ 31559 oil ml

® D—ring

® Smacks: side plate

9 Tunguerl washer

9 10mm nut

 

 

 

 

Fig. 224

Date ui Issue: July 20, 1977
© HONDA MOTOR CO. LTD, 1977

74 5. CHASSIS

A. Disassembly

1. Disconnect the rear brake rod.

2. Remove the reAr brake panel stopper
bolt to disconnect the brake stopper arm.

     
   

Fig. 225 (D Brake Mower Arm

(2 Stopper arm cushion rubber
@ 8mm nu:

@ Panel stopper huh

(5) Lock pin

3. Loosen the drive chain adjusting bolt on
both sides, remove the cutter pin, and
loosen the axle nut.

4. Push the wheel forward, and lift the
chain oﬁ the driven sprocket. Remove
the lock bolts, chain adjusting stoppers anti
pull the wheel rearward to remove the
wheel and axle from the rear wheel.

5. Straighten the tongued washers and
loosen the four nuts to remove the driven
sprocket

Fit. 223 ® Cotter Pin 6. Remove the rear wheel bearing retainer
6) Axle nu: . . .
® Adjusting halt With the bearing retainer remover, and
Q Lock um drive the bearing out of the hub.
r9 Lock halt Note:
@ Chm" “mm“?! mm)" The hearing retainer has a left hand thread.

 

    

 

F . 227 (human sprocket Fig. 228 (D Bearing retainer remover
@ Tungued washer (3 hearing dam

 

® Lock nut

Date of Issue: July 20, 1977
© HONDA MOTOR CO. LTD., 1977

 

E. CHASSIS

7. Remove the two cotter pins and washer
from the Brake; shoe anchor posts.

Inspection
Check rim runout and wobble.

Check rear axle shaft runout.
Check brake lining wear,
Check brake drum wear.
. Check ball bearing wear.

Check for loose spokes, bending and da-
mage. Tighten, straighten or replace as
necessary.

7. Check the tire inside and oumide for cuts,
bruises, and imbedded nails. Repair or

replace as necessary.

massive.“

Dita of Issue: July 20. 1977
@ HONDA MOTOR CO‘ LTD., 1977

@ Pin washer

 

Fig. 231 G) Vernier caliper

 

 

75

@ Brake 51m spring

 

    

 

76 5. CHASSIS

 

 

Fig. 234 ® Cotter pm
® Axle nul
@ Adjusting halt

: I
.235 @Adjuuin bolt
(1) Brake pedal

 
 

Fig. 286 (D Adjusting nu

      

 

Renssembly

1. Perform reassembly in the reverse order
of dissssemhly.

2. Install the brake shoes on the brake
panelt

Note:

Do not allow oil, grease, dust or dirt tn‘get

inside the brake shoes and wheel hub.

Use thread lock cement when installing the

bearing retainer.

Apply grease on the friction surfaces of

the ﬂange and wheel hub.

3. Fill the cavity in each ball bearing and
inside the wheel hub with grease Install
the bearings using the healing driver B
attachment (Tool No, 079454230200), on
the CB 550 model, Use a driver attach-
ment (Tool Nor 0794673600000) and
driver handle (Tool No. 07949-5110000),
being careful not to allow the syace collars
to incline.

4. Mount the brake panel en the huh and
the drive chain on the sprocket. Insert
the wheel axle through the assembled
wheel huh, and mount the wheel on the
rear fork I

5‘ After completing the reassembly, adjust
the drive chain slack.

a. Normal chain slack is 10~20 mm
(3/8N3/4 in) with a slight drag.

b. Loosen the axle nut and adjust the
drive chain with the adjusting halt,
making sure the adjuster marks on
both sides are in the same position
when completed.

6. Install the rear brake stopper arm, and
adjust the height and play of the brake
parish
5. Adjust the height of the pedal with
the adjusting halt

b. Adjust the free play of the pedal to
ZD~30mm (=/.~1 s/xsin) with the
adjusting nut an the end of the brake
rod.

7. Check to be sure that the tire is cor—
rectly inﬂamd.

Date of Issue: July 20, 1977
© HONDA MOTOR CO. LTD., 1977

5. CHASSIS 77

 

3. STEERING

The steel tube handlebar is mounted on the
front fork top bridge with the handlebar
holders, The top bridge is bolted to the front
fork and steering stem. The steering stem
is mounted on the frame head piper

 

 

 

 

    
  
   

9 Handle bar holder
0 Steering stem mu
8 Steering stem washer
5 Fork mp bridge
Steering head mp nut
a) Steering head (up cane me
Steel ball
9 Steering mp bell race
3 Steering head

Steering stem
6; Steering hanum ball race
see he

Fig. 237 Steering handle bar

A. Disassembly @ 3:215 rum“ W“ "C!
1. Loosen the two bolts to remove the master ‘ 'V m
cylinder unit,
2. Disconnect the clutch cable at the clutch
levy.

3. Remove the lighting switch and discon»
neat the throttle cable from the throttle
grip pipe

4. Remove the headlight unit from the head
light case and disconnect the wiring at
the harness. within the case.

5. Loosen the four bolts, remove the handle-
bar holders and disconnect the wire
ham-ﬁe

Date nf lune: July 20. 1977
© HONDA MOTOR CO. LTD. 1977

     

7e 5. CHASSIS I, .
x 7

6. Loosen the two mounting balm and I
remove the speedometer and tachometer.

7. Loosen the stem nut, and remove the
8mm bolts and the fork top bridge.

 

 

\c . ‘ .

u. 240 a) Fork mp bridge @ Stem nut a D
Q) Fork mp balls (9 8mm bolts

8. Remove the front fork.

9. Loosen the steering stem head nut with
the 48mm pin’ spanner (Tool No. 07902—
200000).

10. Remove the steering stem from the .
bottom.

Note:

#8 Steel balls will drop out. therefore,

be careful not to lose them.

    

F 241 @ 48:11:11 pm spanner
® Steering stein-Ahead nut B. Inspection
1. Check the handlebar for twisting 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 wear.
5. Check the stop for deformation or cracks.

C. Reassembly

1. Mix the steel balls in grease and assem-
ble 18 into the upper race and 19 into
the lower cone. . >

2. Install the steering stem into the head 4
pipe being careful not to drop the steel
balls.

3. Assemble the top cone race and tighten
the steering stem hea'd nut. \
Tighten the steering head top thread i )
fully, then hank it all just to the point ,.
where the handlebar can be turned with
reasonable ease.

 

Note:
‘ ' , Before assembly, wash the cane and hell .
Fig. 243 9 45 mm pin spanner races. and steel hells. Mix the balls in new A. J
(2) Steering stem head mu grease. -

once of Issue: July 20, 1571
© HONDA MOTOR co. LTD, 1917

 

\_/

5. CHA$lS 79

 

4. Aseemble the front fork.

5. Assemble the fxont fork top bridge, and
mount the speedometer and tachometer.

6. Install the handlebar.

Note:

Align the punch marks an the handlebar to

the parting 511:wa of the holder. Tighten

the front holder bolts ﬁrst.

 

 

7. Reconnect the electrical Wiring.

8. Reconnect the clutch and throttle cables,
and the brake hose to the master cylinder
unit.

Note:

- Make sure the cables and the electrical
wirings are free from binding when the
handle is turned fully to both sides.

- Adjust cable freepIay.

Clutch lever: 10.0~20.0|um (3/SN3/4in.)

 

 

 

 

at the end of the lever.
_ Fig. 245 @ Chm. cahle @ Wire harness
Brake lever: 2~5mm (5/64l-«13/G41n.) (9 FM“ hm“ 11m (5) Fork my kid“
at the end of the lever. G) Thmttle able

4. FRONT SUSPENSION

The front fork unit consists of a lightweight aluminium front fork bottom case with a
dual action mlesooping shock absorber oil damper. Cushioning Havel is 91mm (3.15in.) on
compression and 31mm (1.22 in.) on extension strokes.

 

 

 

 

 

FIR. 245 Front fork unit

® From fork halt ® Holdu

@ O-xing @ Collar

@ Lock nut ® Front [ark huttambcase
(9 anl furl: pipe ® Dampex case

6) Front suspension spring ® Axle holder

© Fxont fork boot ® Plain washer

@ Dumper rad @ Spring wuher

® Snap ring @ Nut

®Oilsul

Dale of Issue: July 20, 1577
© HONDA MOTOR CO. LTD. 1977

BO 5. CHA$IS

A. Disaeaembly

1, Loosen the fork bolt, remove the drain
plug and chain the damper oil.

2. Remove the front wheel.

3‘ Loosen the three caliper mounting bolts
and an adjusting screw, and remove
the caiiper from the Mt front fork.

    

m. 247 (9 Caliper mounting

(9 AdJusting screw
@ Caliper 5:: bolts
(9 Caliper B
@ caupu A

4. Loosen the 8X56mm and Lhe 10x
35mm bolts, and pull the forks of the 467.-
bottom.

 

5. Loosen the front fork bolt, from the
piston rod look nut, and remove the front
fork spring and cushion spring seat
Separate the front fork pipe and bottom
case. '

6. Loosen the 8mm bottom case bolt using
a hollow set wrench (Tool No. 07917—
, 8230000) and remove the damper unit
from the bottom case. (Fig. 252)

 

         

9

Fig. 249 a) Snap ring (D F: (1) 5mm bolt
® L Damper unit
@ Cushion spring seat Fork spring
(Q Snap ring ® Fork pipe
(9 on seal , @ Special tool

© Bottom case

Date of lime: July 20, 1977
© HONDA MOTOR CO LTD., 1977

5. CHASSIS 81

 

B. Inspection Tilt
1. Check the front suspension spring. l
2. Check the fork pipe and bottom case for
damage or looseness.

3. Check the oil seal for scratches and
damage.

4. Check for excessive clearance between
the shock absorber piston and the cylinder.

   

Free length

 

  
 
 

 

 

 

C, Reassembly Fig. 251 Measuring the in: length

l. Rwssemble in the reverse order of dis»
assembly. Be careful not to allow dust,
or other foreign matters to adhae to the
component parts

2. Install the fork pipe into the bottom
case. Apply a coat of thread lock cement
to the socket bolt and tighten it using
a socket wrench.

3. Apply a coat of Honda ATF (Automa-
tic Transmission Fluid) to both sides of
the oil am] and install it using a fork an]
driver (Tool No. 07947—3290000).

Note:

a Do not forget to install the snap ring.

0 Replace the removed seal with a new one,

4. Apply a coat of thread lock cement to
the threaded part of the damper. Making
sure that the 8 mm luck nut is completely
screwed on the threaded part of the
damper, tighten the fork bolt.

5. Remove the front fork bolt and pour a
speciﬁed amount of Honda ATP into the
front fork pipe.

Capacity: 155~165 cc (5.3~5.6 oz.)
(at disassembly)

6. Install and tighten the front fork halt.

7. Route the front forks through the holﬁ
in the fork top bridge and tighten them
with the 8mm setting bolts and 10mm
setting bolts.

Note:

Remove any oil from around the front forks.

8. After reassemhling, check the front forks
for smooth movement. Also check for
oil leaks from the oil seals.

 

 

Fig. 252 (9 ka pipe

I

 

  
  

 

 

 

Fit. 252-1 © Oil SE1 ® Fork seal driver

' I

Fig. 263 G) 8mm setting bolt
@ 1a mm setting bolt

 

Dam of Issue: July 20, 12777
© HONDA MOTOR co. LTD, 1977

     

82 5. CHASSIS

9. Adjust the front brake caliperl
Adjust the clearance between brake disc
and pad B to 0.15 mm (0.006 in.) with
the caliper adjusting screw. ~

5. REAR SUSPENSION )
The rear suspension is equipped with dual '
action telescoping shock absorbers

The rear fork is a swing arm type of tubular

construction that provides greater rigidity.

A. Disassembly ' )
Remove the muﬂlers.

Remove the rear Wheel

Remove the rear suspension mounting

nut and bolt, and then remove the

suspension from the frame and rear fork.

Fig. 254. ® Pad 3 © Nut AL Compress the rear suspension spring using

® Pad A (9 Caliper séjming saw a special suspension compressor tool(Tool
@ Brake dine No. 07959—3290000) and disassemble.

 

 

 

  

59.”?

—@

.JJGMWJDEM

 

 

 

 

   

 

 

 

 

Fig. 255 (D Rm for]: pivot collar
® Torque link am
® Ru: fork pivot shah ,
(3 Re" “’1‘ , 257 ® Rm .usnnnnan assembly
@ Suspensinn oompreasor moi )
(9 Spring seat stopper
@ Rear suspension upper cover
(9 Spring mt
@ Rear suspensien spring
(9 Joint rubber @ Spring seal
Joint 9 Spring adjuster /
Nut @ Rear damper J
® Rubber

Dale of Issue: July 20. 1977
© HONDA MOTOR CO. LTD., 1977

 

5. CHASSIS

5. Remove the rear fork pivot nut and
shaft, and separate the fork from the
frame.

13. Inspection

Check the rear suspension spring.

Check damper for oil leaks.

Inspect the damper upper case and rod

for dents and bending. Make sure the

oil damper operates smoothly in both

directions.

4. Inspect the damper case and stopper for
damage and dents.

5. Check the clearance between the rear
fork pivot bushing and shaft.

6. Check the pivot shaft for bending.

7. Check the rear fork swing arm for bend-

ing, twisting, and cracking.

PN!‘

C. Reassembly

1. Mount the rear brake arm stopper to
the rear fork.

2. Apply grease on the fork pivot bushing
and instsH the rear fork on the frame
with the pivot shaft.

3. Mount the rear suspension between the
frame and fork on both sides and tighten
the nip nuts and bolts.

4. Mount the rear wheel.

Note:

When the reassembly is completed, adjust
the rear brake and the drive chain tension.

Date of Issue: July 20, 1977 .
© HONDA MOTOR CO. LTD" 1977

 

HR. 255

33

   

x 4...». ’ .
t shaft

* m
5) Ron: fork (2) Rear fork piv

 

 

 

 

P. RE
208

135

33.5

 

 

 

 

 

 

 

 

 

l
/\2 73 I03
1m _. “m,

 

 

Fix. 255

Fig. 261

 

Rm shock absorber spring
characteristic

 

 

@ Inside am gouge
® Rm fork bushing

 

BA 5. CHASSIS

6. FRAME BODY

A. Construction V
The double cradle frame is constructed
of steel tubes and plates. The head pipe
section is of drawn tubing construction
which provides high rigidity and strength
for good handling at high riding speed.

B. Disassembly
1. Position the fuel Valve lever to ‘STOP ',
disconnect the fuel tube from the fuel
valve, and dismount the fuel tank from
the frame,
2. Remove the muﬂlers and dismount the
engine.
3‘ Remove the front wheel and the front
fork. -
4, Remove the handlebar-And the steexing
stem from the frame.
(3) Caner pin 5. Remove the rear wheel. rear fork, and
@ Air cleaner rear fender.
" l ' 6. Remove the seat, the tool tray, and the
air cleaner element.

Fig. 268 G) Seen mounting bolt

. Detach the electrical equipment.

8. To remove the main stand, loosen the
two mounting bolts, remove the cotter
pin, and exmact the main stand pivot

pipe.

‘7

 

Fig. 295 Mounting bah
% Caner pin

pm of Issue: July 20, 1901
@ HONDA. MOTOR 00.1311, 1577

 

5. CHASSIS 35

9. Remove the top and bottom ball races
from the steering head piper

Note:

Use a Ball race remover (Tool Nu. 07953—

3330000) to prevent damage when driving

out the ball races.

C. Inspection

ll Check the frame main unit for twisting,
deformation; and cracking around the
welded areas, and the pipes for bending
and Cracks.

2. Inspect the top and bottom races for

scoring and wear.

Check the head pipe {or misalignmenl

Check the seat cover for tears.

5 Check the fuel tank for leaks, the fuel
tubes for aging or damage, and the fuel
valve gasket and strainer cup O-rlng for
damage.

Flush the tank
gasoline.

6. Remove dust from the air cleaner ele»
ment by hlowing compressed air from
inside Check the element for damage.

7. Replace the exhaust pipe gasket if it is
damaged‘

P93

interior with clean

D. Reassemhly
1. Install the main stand on the frame,
2. Install the rear fender and the electrical
equipment on the frame.
3. Install the rear fork, rear cushion and
the rear wheel
4. Install the steering stem, front fork and
front wheel.
5. Mount the air cleaner case, the battery,
the seat, and the fuel tank

Date of lune: July 20, 1.977
© HONDA MOTOR CO. LTD, 1977

     

265 (a Ball race remover
(2 Bull race
a) Headnpipe

 

 

 

O-Ilng
@ Fuel strainer screen
G) 6mm cross screws
® Fuel valve body
@ Fuel valve gasket
® Fuel valve lever
Valve lever spring
(3 Setting ﬂute
G}: 6mm screw

    

Fig. 268 (2) Air cleaner element

 

 

 

 
  
 

_...- ..-mi,,i...i_..,.n........i

1. GENERAL DESCRIPTION

6 ELECTRICAL

 

 

 

696

   

960666

@@®

 
     

@®®@®®®®®®

 

 

 

Fig. 259 Complute electrical system diagram

(2) Tnnhomeiez pilnr lamp
(9 Speedometer pile: lamp
(9 Head light

G) Posiiion limp (except USA type)
@ me brake may switch
© From winku lamp

@ Emergency switch

® Held light switch

® 5mm switch

® High beam pilut lamp
® Nam-.1 Imp

@ on Winning Lamp

63 Winker vile: lamp

3; speed winning imp (exéept USA many

a; Winker switch

(:3 Hum button

® Ignition cvil

@ Spezd wnming system (except USA iype)

Date of Issue: July 20, 1971
® HONDA MOTOR co. LTD., 1977

 

® Contact breaker wen-Hy
Q Emery

@ Horn

@ Main twitch

Q Spark plug

8 AC generator

@ Oil pIEium .yimii

@ Surﬁng motor

® Neutral switch

Q Rear brake stop swiich
® Fuse bolder

® Silicon: xactiﬁzz

@ Winkerﬂrélay

® Magma: switch

(a Vuluge ragulmr

g Tail/stop imp

® Rn: winku Lump

 

 

 

85 E,

2. IGNITION SYSTEM

ELECTRICAL

 

 

 

 

 

 

 

 

 

.6

 

 

 

 

 

 

 

 

 

 

 

(D Spark plugs
® Ignition coil:

Fig. 270
Candensm-s
® Contact bre-ker

@ Battery

The ignition system consists of two ignition coils, two contact breakers, four spark plugs,

an ignition switch and a battery.

The current from the battery ﬂows through the primary winding of the ignition coil, and the
circuit is completed by grounding through the contact breaker. The contact breaker is contained
in the Contact breaker housing at the right end of the crankﬂlaft. There are two contact
breakers which are 180" out of phase. One of the breakers furnishm high voltage 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 tension plug cords. Since no distributor is used, the construction is simple and

the system is easy to service.

SERVICE DATA

Ignition can .
a point spark gap opwg

7mm min. (0. 27 in.)

 

 

 

Spark plug
lepe (standard) NGK D—7 ES, DENSO X 22 ES
P ug guy a e~o. 7 mm (a, new. 027 in.)
Content breaker '
Point gap 0. SND. 4 mm (0. 01%0. 016 in.)
Spring tom eeu~aso g (1. as~r 57 lbs.)
Condenser
Capacity [La/11711095

Insulation resistance

Over 10 MD (1, non meggex)

 

Spark advance!
Start of advance (crankshaft speed)
Full advance (crankshaft spend)
Advance angle

 

 

1, 1541 rpm
2, some, 500 rpm
25.

 

Date of Issue: July 20, 1977
@ HONDA MOTOR co. LTD, 1977

 

 

6. EUECTRICAL

E9

 

) Ignition Coil
The ignition coil consists of a primary coil
with 420 turns of copper wire wound around
an iron core of laminated silicon steel sheets.
A secondary coil with 13,000 turns of wire
‘ is wound on top of the primary coil. Each
,l‘ secondary coil has two high tension cords to
two spark plugs,

A. Disassemhly
1. Open the seat and remove the fuel tank.
2. Disconnect the ignition coil leads.
(yellow, blue and black/white)
3. Loosen the two 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 primary
coil terminals.
Right coil: yellow and black/White leads
Left coil: blue and black/White leads
Secondary coils
Check for continuity between the termi-
nals of the high tension cords,
If there is no continuity, the coil is open
and must be replaced.

Date of Issue: July 20. 1977
© HONDA MUIOR CO. LTD.. 1577

 

 

 

 

 

 

 

 

Fig. 271 @ Pxinmy coil
@ Tron core
@ Bobbin
a) Secondary coil
@ Primary terminal
High tension cord
® High tensiun terminal

 

 

 

 

 

 

Pix. 273 Ignition col] continuity test

 

90 E. ELECTRICAL

 

 

 

 

Fig. 215 Spark performance

 

Ignition coil perfomance test
Coil may mt satisfactorily for continuity but
it may not perform satisfactorily due to dete»
rioration from long use. therefore, perform-
ance should be checked to determine its con—
dition.
Connect the service tester power cord to a
12V battery and ground the ground cable.
Connect the ignition primary test lead to
the tester and connect the opposite terminal
ends to the primary terminals of the coil. Con-
nect the red test lead to the black terminal of
the ignition coil and the white test lead to
the yellow cord of the ldt coil (to the blue
cord for the right coil)
Position the selector knob to COIL TEST.
Adjust the three point spark tester to the
maximum distance spark is maintained.
Measure this distance. The coil is satis-
factory if the distance is greater than 7mm.
(0.27 in.)

Note:

Sinee a dual sparking ignition coil is used,

note the spark condition. If the spark a]:-

pears as B in Fig. 276, the connection to the

primary coil is reversed.

Date of Issue: July 20, 1977
© HONDA MOTOR CO. LTD.. 1977

 

6. ELECTRICAL

Spark plug
A. Removal

1. Remove any dirt from around the spark
plug by using compressed air.

2‘ Remove the spark plugs with a plug
wrench.

B. Inspection

Inspect the spark plug for worn electrodes,
excessive gap, fouled condition and damaged
porcelain insulator.

1. Clean dirty spark plug with a plug
cleaner or wire brush, ,

2. Measure the electrode gap with a feeler
gauge and, if necessary‘ adjust to the
speciﬁed gap.

Standard gap: 0.6~0.7 mm (0.023~
0.027 in.)

3‘ Replace the spark plug if the porcelain
insulator is damaged, or the gasket if it
is damaged or distorted.

Standard spark plug: D-7ES (NGK),
XZZES (DENSO)
C. Reinataﬂltinn

1. Install the spark plugs in the reverse
order of removal
Torque: 1.5~2.0 kg-m (11~14ft-lbs)

Nate:

1. DD not ﬂrnp the plug gasket.

2. A loose plug will not properly dissipate
the heat and may result; in engine mal-
function.

Date of lune: July 20. 1977
© HONDA MOTOR CO. LTD., 1977

 

...
a) Spark plug

(:3) Sim ME

91

    

 

92 6. FJJECT‘RICAL

/ Contact Breaker and Condenser
t= A. Disassembly

1. Remove the point cover.

2. Disconnect the leads (yellow, blue) at
the connectors located at the center of the
frame.

3. Loosen the 6mm bolt, remove the special
washer, loosen the base plate mounting
screws, and then remove the contact
breaker assembly

B. Inspection

- For adjustment of breaker point and
garjﬁzsm ignition timing, refer to the “Maine-
@ Contact breaker plule Dance Operations” swim
- Condenser

Measure the capacitance of the condenser

using the service tester.

Standard value: 0.22~0.26#F

Note:
The points should be open when testing.

 
     
 
   

mg. 275 8 5mm box
Special washer

 

 

 

 

Spark Advancer
A. Disassembly
1‘ Remove the point cover and the Contact
breaker assembly.
2, Remove the spark advancer from the
spark advanoer shaft.
Inspection
Clean dust and foreign matters from
friction surfaces, and make sure opera-
tion is smooth.
2. Check spring tension and advanoer pin
wear.
Standard spring tension:
680~850gr. (1.43N1.87Ibs)
C. Reassembly
1. Install the dowel pin by aligning the
hole
2. Reassemble in the reverse order of re-
moval,

#5“

Fig. 381 ® Spark udvanoer @ Crankshaft

Date of Lime: July 20, 1977
© HONDA MOTOR CO_ LTD., 1977 V

 

S, ELECTRICAL I 93

 

3. CHARGJNG SYSTEM V

The charging system for the CB 500 is made up of the exciter ﬁeld 3-phese AC generator,
rectiﬁer, voltage regulator and the fuse. The generator consists of the ﬁeld coil, stator coil
and the rotor; it does not contain slip rings or brushes.

In order for the stator coil to produce constant voltage, the current from the battery to
produce the exciter ﬁeld is regulated to very close limits by the dual contact regulator. The
generator output is rectiﬁed by the silicon rectiﬁer before being sent to recharge the battery.
The generator performs two functions depending upon the charge condition of the battery.
The electrical current from the battery ﬂows through the switch and into the regulator. When
the battery voltage is lower than normal (less than 13.5V at the battery terminal), the
current ﬂows through the upper contact 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 LEA. This produces an output volmge of corresponding
strength which is used to charge the battery.

When the battery voltage exceeds approximately 14.5 V, the armature coil pulls the armature
away from the upper contacts and closes the lower contactsto insert a 100 resistance into
the ﬁeld coil c'uctu‘t. The current to the ﬁeld coil is thus reduced to 0.7A and, consequently,
a lower voltage is produced by the generator, limiting the amount of charge to the battery.
This function of inserting or removing the resistance into the generator ﬁeld coil is performed
by the voltage regulator in accordance with the charge condition of the battery.

 

    

®

 

 

 

. Fur. 252 ‘
G) Silicon rectiﬁer ® Regulator Relay coil
® Coupler E) Upper Contact @ sum coil
@ Ems-y 12 v. 12 AH (D Moving mum ® Field coil
' © Main switch © Lower 00th ® To load

Date of Issue: July 20, 1977
© HONDA MOTOR CO. LTD., 1977

 

94

at ELECTRICAL

 

 

 

 

 

Fig. 233 a) Red/white lend @ antmeter
@ Ammm (9 Battery

Charging Test

1. Perform the test using the ammeter and
voltmeter,

2. The battery charge condition is deter-
mined by measuring the speciﬁc gravity
of the battery electrolyte, If the speciﬁc
gravity is lower than 1.26 (at 20°C/68°F),
recharge the battery so that the speciﬁc
gravity is up to 1.26~1.28 (at 20°C/GB°F),
and then perform the following test.

V 3‘ Dismnnect the battery cable from the ED

terminal of the battery, and connect it
to the 63 side of the meter,

Next, connect the 6 side of the meter to the 6) terminal of the battery.

Connect the (9 side of the voltmeter to the (-9 end of the battery cable, and ground the

6) side of the voltmeter. (Fig. 283)
4‘ Start the engine, operate it under both the NIGHT RIDING and DAY RIDING

conditions and check to see if the measured values conform to those speciﬁed in the

table below.

If the values are less than those speciﬁed, adjust the regulator.

Note :

The charge condition of the battery may cause the charge current to vary slightly.

 

 

 

 

 

 

 

 

 

0
®

 

 

® AC. Genentovr
® Silicen rectiﬁer

Fig. 28¢
@ Ammetez

(E Main switch

Headlight law beam
® Headlight high beam

 

 

 

 

Voltage regulator ® Battery
® Volmem Headlight switch
Engine RPM
\ 1, 000 2,000 a, nun 4.0m: 5.000 a, two 7, cm: 2.000

Charging men: (A)
Day riding 6, 5 0 2, 4 1. 3 1. U 1, 0 I). E 0. 6
Night riding 2—8 1 1 1 1 1 1 1
Battery terminal voltage (v) 12 12. 4 13. 2 14. 6 14. 5 14. 5 14. 5 1L 5

 

 

 

 

 

 

 

 

 

 

 

Date of Ilsue: July 20, 1977
© HONDA MOTOR CO. LTD, 1977

 

s. ELECTRICAL 95

 

A. C. Generator

 

 

 

 

 

 

Speciﬁcations
12:;ij LDllo—Dl, Hitachi
Output 150 W
Battery voltage 12 V
Polarity (9 ground '
Charging spea‘l 10004000 rpm
Weight 3 kg (66 lbs)

 

 

 

 

 

A. Disassembly

1. Remove the generator cover and pull the
rotor out using the rotor puller (Special
Tool No. 07933—2160000).

2. Loosen the three 6mm screws from
inside the generator cover and remove
the stator will

8. Loosen the three 6mm screws from
the outside the generator cover and
remove the ﬁeld coil.

 

 

B. Inspection

1. Field coil resistance tat
Check resistance between the two ﬁeld
coil leads (White Green) using the Ser-
vice Tester OHMS function

' STANDARD RESISTANCE VALUE:

4.90:10‘7,
NOTE: Test may be performed without
removing the ﬁeld coil. ‘
2. Stator coil resistance test

2:. Check resistance between any two of
the three yellow alternator (stator)
leads.

b. Leave either tester lead connected to
the yellow wire. Attach another tester
lead to the third yellow stator wire.

STANDARD RESISTANCE VALUE:
0.350i10% at a.
0.350:10% at 1:.

NOTE: Test may be performed without re.
moving the stator.

TEST RESULT INDICATION

 

Figr me (0 Side cover @ Field can
® Generator cover @ Stator coil

 

    
    

Fig. 237 Field can

 

 

1 (ﬁeld coil) if; 1:33; or Defective

 

2 (stator) a No reading or

or l: low reading Defective

 

 

 

 

’ Fig. 288 sum cm'l

 

Dlte of Issue: July 20, 1977
© HONDA MOTOR CO. LTD, 1977

   

96 E.

 

 

 

 

 

m. 239

a; Point gap @ Voltage adjusting screw
® Upper Contact @ Lock not

@ Armature @ Coil

@ Cor: gap @ Point gap adjusting screw
6) Yak: gap @ Core gap adjusting screw
G) Sprlng @ Contact set

@ Yoke at Lower comm

@ Adjusting spring

 

ng screw

 

Fig. 291 @ Voltage adjust)
r23 Lock m“

     

ELECTRICAL

Regulator

The regulator is a dual contact type. It
maintains a constant voltage by placing
the resistance circuit into the field coil circuit
when the generating voltage rises to a certain
value, and cutting the resistance circuit out
when the voltage drops below a set limit.

A. Disassembly

1. Disconnect the leads at the connectors
and loosen the two 6mm regulator
mounting bolts

2. Loosen the two screws and remove the
regulator cover.

B. Inspection and Adjustment

Regulating voltage adjustment -

1. To adjust for low charge current or low
battery voltage, loosen the look not on
the voltage adjusting screw and turn the
adjusting screw clockwise. When the
regulator is set too high, turn the adjust-
ing screw counterclockwise.

2. Upon completing the adjustment, recheck
regulator performance after installation.

V Core gap adjustment

Measure the core gap with a feeler gauge. If
it requires adjustment, loosen the core gap
adjusting screw and move the point body up
or down.
Standard core gap value:

D.6~1.0 mm (0.02~[l.40 in.)

Point gap adjustment
Measure the point gap with a feeler gauge.
If it requires adjustment, loosen the point gap
adjusting screw and move the lower point up
or down Standard point gap value:
0.2 mm (0.008 in.)

Note: If the points are pitted or fouled

polish with a $500~600 emery pap .

 

   
   

Fig. 292 (.9 am: gap
® Point gap
(9 Care gap adjusting screw
(2) Point gap adjusting screw
@ Lower point

Date of Issue: July 20, 1977
© HONDA MOTOR CO. LTD.. 1977

 

 

6‘ ELECTRICAL 97

Silicon Rectiﬁer

Inspection

The condition of the silicon rectiﬁer is tested
by disconnecting the electrical connections
and testing the rectifying function in both
the normal and reverse directions. Continuity
in the normal direction indicates good con—
dition Continuity‘iu both directions indicates
a defective rectiﬁer,

Note: ’

1. Do not use a megger for the test as the ,

high voltage will damage the silicon
diodea

2. Observe the polarity of the battery. Con-
necting the battery terminals in reverse
will shorten the battery life as- well as
cause a large current to ﬂow through the
electrical system, causing damage to the
silicon rectiﬁer and destroying the wire
harness.

3. Do not operate the generator at a. high
RPM with the “P” terminal (red/white
cord from the magnetic switch) of the
silicon rectiﬁer disconnected. The high
voltage generated may damage the silicon
rectiﬁer.

4, When charging the battery mounted on the
motorcycle from an external source with a
high charge rate such as a l‘quick charge",
the silicon rectiﬁer wiring should be discon—
nected at the couple): to prevent damage.

Date of Issue: July 20. 1977
® HONDA MOTOR CO. LTD, 1977

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Fig. 294 @,®,. Yellow -
@ Yellow/While
® Green

98 E. ELECTRICAL

4. STARTING SYSTEM

The starter is a device which converts the electrical energy of the battery w the mechnical
energy to start the engine. The starting circuit consists of a push button switch mounted
on the right side of the handlebar which, when the starter button is prased, energizes the
sterner magnetic switch and closes the starter circuit contactsi This permits approximately
120A of current to ﬂow from the battery to the starting motor, which then rotates the

engine to perform the starting.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Fig. 295 Starting Circuix

® Enuh @ Field coil @ 5mm human
(:9 Annamre ® Stan-m magnetic wimh ® Battery

@ Smning mom: ® Electmmgnet @ Plunger

@ Pole ® Lgniu‘on switch

 

 

 

 

 

Fig. 2% Starting mater installation
® Surﬁng mutm' ® Smner reductian gear

Date of Issue: July 2:), i977
© HONDA MOTOR CO. LTD” 1977

6. ELECTRICAL 99

 

 

 

 

 

 

Starting Motor
The starting motor is mounted on the crank—
case behind the cylinder and drives the
crankshaft through the starting clutch.
Speciﬁcations
y Rated voltage 12 V
" Rated output 0.6 KW
Rated operation Continuous for 30
seconds
Without Iced With load
? Voltage 11 v a. 5 v
Amperage as A 120 A
0.121: mm
Tm!“ ’“ (or as tin»)
Revulutiun 110005000: m 3200mm

 

 

 

 

 

 

 

m». 297 Starting motor diussemhly drawing

A. Disasseth
1. Disconnect the sterling motor cable at
the magnetic switch.
2. Remove the starting motor cover, left
crankcase cover and loosen the two
\ 6mm starting motor mounting bolts.
) 3. The starting motor can now be pulled out.
4 Loosen the two 6mm screws and re-
move the starting motor side cover.

  

Fig. 298 (3 Magnetic switch
@ Starting mom! cable

    

u

® Starting motor
@ 6 mm bolts

 

Date of Issue: July 20. 1977
© HONDA MOTOR CO. LTD, 1977

 

I DO 6, ELECTRICAL

B. Inspection
1. Carbon brush inspection
Worn carbon brush, pitted or rough con-
tact surface and weakened brush spring
will cause starting djﬂiculty, therefore,
they should be replaced. 3
2. Commutator cleaning ’
Dirty commutator will give poor starting
motor performance.
The commutator surface should be
polished with a ﬁne grade emery paper -
and completely washed before reassembly. )

       

Fig. 300 ® Carbon brushe-

® Sin-1113s

   

© Cummumor

 

3. Stator coil inspection
Check continuity between the brush
Wired to the stator coil and the starting
motor cable. Lack of continuity indicates
an open stator coil and should be replaced.

 

 

4i Armature coil inspection
A grounded armature coil will render the
starting motor inoperative.
Perform a continuity test between the
commutator and the core. A continuity
condition indicates a grounded stator coil
and should be replaced.

 

 

 

 

Fig. 802 Armature cuil inspection

Date of Issue: July 20, 1971
© HONDA MOTOR CO. LTD, 1977

 

E, ELECTRICAL

Starter Magnetic Switch

The starting motor requires a current of
approximately 100 A to operate. To minimize
resistance, a large cable is used for wiring.
A switch with heavy duty contacts is
required. Sparking across the contacw will
result, as well as resistance depending upon
the contact pressure, when the contacts are
opened suddenly to shut off the ﬂow of large
current. To cope with these conditions, a
magnetic switch is used separately which is
operated electrically by a small current
through a push button starter switch.

Inspection
1. Primary coil continuity 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, the magnetic switch con-
tacts will become pitted or burnt from
the large current which ﬂows across it,
and gradually build up resistance which
may prevent the current ﬂow.
Connect 12V to the primary coil leads
of the magnetic switch If there is no
continuity across the switch contacts,
the switch is defective.

Date of Issue: July 20, 1977
© HONDA MOTOR co, rm, 1977

 

 

     

omuwwaw~_

 

IOI

 

 

Fig. 303
® Stopper
® Stopper holder
Washer
@ Roller A
(5) Contact lpring
® Flat washer
(1) Plunger holder
Plunger shaft
(3 Plunger

 

® Contact bah
® Case

® Contact plate
as Yoke

@ Coil bobbin
@ Coil complete
@ Return spring
of?) Body

 

 

“12 6. HECTRJCAL

 

 

 

Fig. 305 ® I13er level Electrolyte
® ydrcmetcr

 

Laun ®

In an :m 40 En an 7n ﬂu 90 Ian

® (90

 

Fig. 309 Speciﬁc gravity A
Relation between speciﬁc gravity
a) Residual Charge (95)

 

 

 

 

Fig. 3M 8 Sediment ® Plates
Battery case

 

Fig. 308 Charger hookup

 

 

    

 

 

 

Battery
A. Speciﬁcation
Type 12N12A—4 A-l
Voltage 12v
Capacity 12 AH

 

 

 

 

B. Speciﬁc gravity measurement
Battery electrolyte is measured with a bulb
type hydrorneter. When the s eciﬁc gravity
is below 1.200 (at 20°C), the artery should
be recharged.

When making a reading, the hydrometer
should be held vertical with the electrolyte
liquid level, held at the eye level and the value
on the ﬂoating scale read at the point where
the liquid separates from the stem of the ﬂoat

C. Inspection and replenishment

l. Electrolyte in each battery cell should
be inspected every three months or
1,500 milm, and distilled water added to
bring the level to the upper mark when~
ever ﬂue electrolyte level is below the
level mark.

2. Whenever there is rapid lowering of the
electrolyte level, the charging system
should be inspected.

3. Periodically measure the speciﬁc gravity.
Alter adding distilled water, allow the
battery to be charged and the electrolyte
suﬂiciently agitate before making the
measurement.

4‘ Primary battery troubles are due to cor»
meion around the connectors and terminals
causing poor contact, separation of the
battery paste, and sulfation, A battery
which is left in u discharged condition
for a long eriod will have lead sulfate
formed on t e plates and rechargin will
not restore it to its ori iual con ition.
Battery inspection shoul be performed
periodically and thoroughly.

Note:

When sediment has formed at the bottom
as shown in Fig. 307, the battery should
be replaced.

D. Battery charging
(Caution)

1i Refrain from charging the battery at a
fast rate (quick charge) as it shortens
battery life. When rapid charging is
necessary, limit the charging rate to a
maximum of 2.0A.

2‘ Hydrogen gas is generated during the
charging process, therefore, keep ﬁre
away.

3. After battery charging is completed, wash
the battery with water to remove spilled
electrolyte. Apply grease to the terminals.

Date of Issue: July 20, 1977
© HONDA MOTOR CO. LTD., 1977

   

 

6. ELECTRICAL l 03

 

5. ELECTRICAL EQUIPMENT
1. Main switch inspection

With the switch in both the ON and OFF
positions, check to see that the continuity
conditions in the chart below are satisﬁed.
The switch is defective if there is no
continuity where speciﬁed, or if there is
continuity where not speciﬁed.

BAT 1G TL: TL7
0 Red Black

 

 

 

Exam:

 

cords white

Fig. 3G9 G) Black 6) Brcwn

© Brown/while @ Red
K9. 1 0
[human

2 O

 

2. Front stop switch inspection

Apply tester lead probes to the terminals

of the front stop switch cords (black,

green/yellow), operate brake lever and

check for continuity.

Check the lever free play 2~5 mm

(0.08~0.2 in.)

The stop light should come on when the ‘

brake lever ”“615 beym‘d the lever Fig. 310 Pm: mp switch inspection

free play. a) From amp switch

3. Rear stop switch inspection
After connecting the stop switch spring,
apply the tester lead probes to the switch
terminals (green/yellow, black cords) and
check for continuity. When the brake
pedal is depressed 20mm (0.8 in.) at the
front end of the pedal, the stop light
should come on at this point.
Adjustment.
If the stop light is late in coming on,
turn the adjuster nut clockwise, and if
too early, turn counterclockwise.

4. Horn Inspection

Check for continuity across the horn

lead terminals.

An alternate method is to connect the

horn to a fully charged 12V battery and

check its operation.

    

 

 

 

 

 

Fin. 312 Horn continuity ms!

Date of Issue: July 20, 1977
© HONDA MOTOR CO. LTD. 1977

     

E. ELECTRICAL

 

 

 

 

 

 

 

 

 

 

 

 

 

104
m. 313 (D Hum button
@ Light gxee’n mi
me. 314 (D Winks: switch
® Light blue and
@ Gmy card
@ Grunge cord
m. 315 a; Lighting switch

(3 Black card
(3) Blue card

(9 Brown/white ma
@ wring curd

 

5. Horn button inspection
With the tester lead probes, contact‘ the
light green cord terminal within the
headlight case and the handlebar, and
then press the horn button to check for
continuity. If continuity exists, the horn
button is satisfactory.

6. Winker switch inspection.
Disconnect the winks: switch wiring
within the headlight ease. Check con-
tinuity between the gray oord terminal
and the orange card terminal (left
winker), and between the gray cord
terminal and light blue card terminal
(right winker) oi the winker switch.
Continuity for the respective tests should
exist according to the switch connections
shown in the table below.

us _ e
Knnb cord Guy curd curds
R O 0

OFF (neuter)
L

 

7. Lighting switch inspection.
Using a tester inspect for broken wires
and defective contact between the respec-
tive switch cords. Continuity between
the diﬂerent cords should exist in accord-
ance with the switching position table
shown below. If continuity exists where
not indicated the switch is defecﬁve.
cm m 3:2 :22. am we.
H

ON P
L

OFF

 

Date of Issue: July 20, 1977
© HONDA MOTOR CO. LTD, 1977

6, ELECTRICAL I 05

 

8. Emergency switch and starter switch in-
spection.
Inspect for broken wires and defective
contact between the respective switch
cords. Continuity between the different
cards should exist in accordance with the
switching position table shown below.
If continuity exists Where not indicated,
the switch is defective.

 

 

 

 

 

 

 

 

 

 

 

 

Emergency switch 1131.315 (9 Emu‘gency switch @ Black/white

cm color Blnck Black/white © “Mk

0N 0—40

on:

Starter switch

Cord color Yellow/red

0N o———o

OF?

 

 

 

 

 

9. Oil pressure switch inspection
Lubrimting oil is supplied under pressure
of 4~fikg/¢:1uz (56.8~85.31he/i11.z) by
the oil pump to various parts of the
mgine. When the oil pressure drops,
the oil supply becomes low The oil
system is designed so that when the oil
pressure drops below 0.5kg/cmz (7 lbs/
in“), the oil pressure switch operates and
the warning lamp comes on. _
Without smting the engine and with
the main switch on, check the oil pres-
sure switch for continuity. If there is
continuity, the switch is satisfactory. It
is normal for the warning lamp to go
out when the engine is skirted.

If the warning lamp does not go out
after starting, and the pressure switch
is satisfactory, the oil system should be

inspected.

 

 

 

 

Fig. 317 a) 5mm switch
(3 Yellow/red

 

Date of Issue: July 20, 1977
© HONDA MOTOR CO. LTD. 1977

   

we a. ELMTRICAL

 

10. Neutral switch inspection

The neutral switch is mounted on the left
side of the uyper crankcase. When the
transmission is in neutral, the switch is
grounded and the neutral pilot lamp
comes on. Place the unmission in 3
neutral, remove the left crankcase cover /
and check the continuity of the neutral

switch The switch is satisfactory if

there is continuity

 

 

 

 

. Fig. 315 Neutral switn'h inspection )
(1) Neutral switch

D“: of Issue: July 20. 197']
© HONDA MUI‘OR CO. LTD, 1977

   

 

  

Fig. 320 @ Clutch Zdjustr lock nut
@ Clutch adjuster

   

Fig. 321 @ Alignment marks

 

. 322 @ Clutch wble adjuster bolt
5) Lock nut

Date of Issue: July 20, 1977
© HONDA MOTOR CO. LTD“ 1977

 

L Clutch

The clutch must be adjusted so that the
engine an be completely disconnected from
the transmission when the clutch lever is
squeezed, but not to the point where the clutch
Will slip when accelerating the motorcycle.

The clutch cable should be adjusted to
provide 10~20mm (0.4~0.8in.) free play
measured at the tip of the clutch lever.

To adjust, proceed as follows:

1. Loosen the clutch adjuster lock nut ®
and turn the adjuster @ to align the
marks ® on the actuating arm and
the engine side cover.

2. Clutch cable adjustment can be made
by means of the adjusters at the upper
and lower ends of the clutch cable.
Loosen the lock nut © (. at the lower
and) at the clutch lever and turn the
cable adjuster bolt @ (nut CD at the
lower end) in either direction. Turning
the cable adjuster bolt or nut at the
lower end in direction ® will increase
the free play and turning it in the
direction [3 will decrease the free play.
Tighten the lock nut,

3. After adjusting, cheek to see if the clutch
is slipping and if it is properly disen—
gaging.

Start the engine and shift into gear. There

should be no excessive grinding from the

Ir'zmsmission, and the motorcycle should not

creep when the clutch lever is squeezed.

Drive the motorcycle to check for clutch

slippage.

  

.' v ~"“
Fig. 323 a; hunk nut
@ Clutch cable adjuster nut

 

      

NEW FEATURES

 

 

 

 

 

 

 

Fig. 823 (9 Cylinder head (D Seal plate
9 Eruther tube a Punching metal
9 Carburemr 0 Element E

0 Air cleaner chamber l!» Element never
9 Element sell case ® Air cleaner
@ Drain tube element spring

1. BLOW-BY GAS SCAVENGING
DEVICE

The blow-by gas scavenging device was added
to minimize pollution The description given
here refers to Fig. 323 above.

The blow-by gas within the cylinder head is
conducted into the element sesl use through
the breather tube. Gas is then conducted
into the element B through the openings on
both sides in the seal plate and punching
metal, Where oil is separated from the gas
at each section. The gas enters the air
cleaner element on the upper part of the
seal case ﬂirough the pipe within the element
cover and is ﬁltered again. The gas so ﬁltered
is drawn into the carburetor chamber and
returns to the combustion chamber for burn—
ing through the carburetor, Now the gas
is again burnt in the combustion chamber
to minimize pollution by the exhaust gases

 

 

Date of Issue: July 20, 1977
© HONDA MOTOR CO. LTD. 1977

 

 

& NEW FMTURES OF THE C5560 109

 

- Blow-by gas
The exhaust gases contain when monoxide, hydrocarbon, hydrogen sulﬁde, nitrogen dioxide,
selenium oxide, etc. which are poisonous ingredients contributing to pollution.
The exhaust gasa consist of not only the remainder of bumed mixture and combustion
products, but also a compression leakage past the cylinder wall or from the orankwse, The
Latter is known as “blow-lay gas", and accounts for 20 to 40% of the total hydrocarbon
amount to be emitted in the airl Since blow-by gases have not been completely burned,
they must be burned again by means of the. blow-by gas scavenging device to minimize
the amount of the gas to he emitted into the air.

2. STARTING MOTOR SAFETY UNIT

- Description
The surﬁng motor safety unit operats in the way that the starting motor functions only
when the transmition is in neutral or while the clutch lever is being squeezed in any
gee: position, assuring rider safety and preventing engine and transmission damage.

- Circuits and opemtions

 

 

 

3% ‘, as s
9 ’—
gg v o @ i

 

 

 

 

 

 

 

 

 

l
.|.

 

 

Fig. 326 Circuit of models without safety unit

(3 Starting mom (g Main switch
@ Starter buttnn switch 6.) Fuse
@ 5mm magnetic switch @ Battery

When the engine switch is turned on, electricity is usually applied to the starter magnetic
switch ooil. lithe sinner button switch is then turned on, the starter magnetic switch will
operate to cause the starting motor to turn, In other words, the motorcycle begins to move
when the main switch and starter button switch are turned on with the transmission in gear.

Date of Issue: July 20. }977
© HONDA MOTOR CO. LTD.. 1977

 

 

”0 8. NEW FEATURES OF THE (75550

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Fig. 327 Circuit of model (03550) with safety unit

Starting mm! ® Battery

(3) Starter huttnn Switch @ Clutch level switch
(9 Sum: magnetic switch @ Neutral switch

© Main switch ® Slfety unit

® Fuse

The ground side of the starter button switch is connected to the body through the clutch
lever switch and neutral- switch. When the clutch lever switch or the neutral switch is
turned on. the starter magnetic switch will operate, causing the starting motor to turn.
(1) Clutch lever switch
The clutch lever switch is dmigned to he turned on when the clutch lever is squeezed
to cause the clutch to he disengaged only. (This switch has the same construction and
funclion as those of the front stop switch.)

3. FRONT SUSPENSION ,
The front: fork used on the CB 550 is a free valve type which is used in a telescopic type
shock absorber.

The damping force can be adjusted by changing is stroke to meet diﬁerent road condi-
tions, and it will always provide a comfortable ride even under severe driving condin'ons.
The CB500 is incrporated with a rod type shook absorber which is also used in a Tele-

scopic type.

Date oi Issue: July 20, 1977
® HONDA MOTOR CO. LTD” 1977

 

 

8. NEW FEATURES OF THE CB 550 ill

 

Operation

- When the wheel meets holes or bumps in
the road, it moves up and down This
up-encl-clown movement of the wheel is
transmitted to the bottom leg.
Since the bottom leg is integrated with a
we, the pipe also moves up and down,

ith either action. two springs an the pipe

ﬂux and rebound, absorbing the road
shocks
In this case, oil in the chamber ® pushes
the free valve up and ﬂows into the space
(E freely. ‘
At the same time, oil in the chamber ®
also ﬂows through oriﬁces in the lower
end of the spring under the seat into the

space © by the amount the pipe moves

up
- Extension

As the wheel passes the hump or hole.
it moves down. To eliminate excessive
upiand-down motion of the spring

w eel, there will he a restraint on the
spring and wheel action.

In 0 lion, as the wheel moves down,
the rec valve is clued, introducin high
pressure in the space @. This higlg pres-
sure then fumes the oil out and into the
space © through the oriﬁces in the spring
under the seat

Since the oil encounters a rmtraint as it
passes through the oriﬁces, excessive wheel
and spring movement. as Well as spring
oscillation, are preventedi

 

 

 

 

 

 

 

 

 

 

 

ii 3

\lmm

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Fig. 328 ® Compression ® Extension

Date of Issue: July 20. 1977
© HONDA MOTOR CO. LTD. 1977

 

 

a a
Fig. 329 (9 Front spring @ me re-
@ me fork pipe bound spring
@ Front fork dust ml ® Fm valve
in on seal 13mm pip:
@ Piston ring @ on lack piece

@ ant {ark bottom leg

 

'IIZ & NEW FMTURES OF THE CB 560

4. BRAKE IMO: WEAR mDICATOR

Discription

’Dne brake lining wear indicator is provided to check the brake lining wear conditiun visually ‘
from outside. As shown in the ﬁgure below, the indicator plate is attached to the brake

am. As the brake lining wears, the brake cam moves excessively. Such can movement is

checked by the arrow on the periphery of the indicator. The lmLke panel cam boss is also

provided with the "wear limit” mark to make it possible to check the service limit (re ~

ment time) of the lining easily with the brake panel installed

Descriptive illustration

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1312.380 (3 Indicawr gm @ Brake panel cm bass
:9 Brake Cam @ “Wear limit” mu]:
@ Brake mu (9 Arrow

Date of Issue: July 20, 1977
© HONDA MOTOR co. LTD, 1977

     
 

COMPARISON OF CB550 TO CBS

 

l .. WM

00:

     

 

 

 

 

 

 

 

 

 

 

 

 

 

(Engine)
Pm or men: Model 013500 Model (213550 Madiﬁed pm
Cylindee lmte - Cylinder
- Pistnns
‘ L ‘ ~ Pinon ring:
u e . Upplr crankcase
a - Cylinder gasket
'5 -Cylinder bend
g? geeke:
Fig. 331
Diammr : 55.0mm (2mm) Diameter: 58.5 mm (2303M)
(Piston displacement: (Flem displacement:
485m: at 30.4mm.) 544w or S8.2:u.in,)
Clutch . Clutch outer

- Clutch center

- Clutch pressure
pm:

- Clutch springs
. Clutch lifter rad

- Right and left
cruel-nus: cove"

- Friction discs

 

 

 

 

 

m. 333 013550 (Exploded, from right)

 

 

Date of Issue: July 20, 1977
© HONDA MOTOR CO. LTD, 1977

     

H4 9. COMPARISON OF 03560 TO 03500

Clutch operation

 

Model CB 500

Model CB 550

 

Refer to Fig 334 an page 115.

The clutch connects and diaecuneets the engine
(rent the transmission.

As shown in Fig. 334.1:he clutch plates ® ("drive
plates”), which are capable of sliding axially an
the clutch center 5), are "sandwiched" between
the friction discs ® (“driven discs") engaged in the
clutch enter @. In nnrinal engaged candition of
the clutch, the pressure plate 6). upon which the
clutch springs 5) force is acting, presses the
stacks of the discs and plates against the clutch
outer. Under this cunditinn, the engine power
is transmitted through the primary drive gear ®.
clutch outer, friction discs, pistes and clutch center
to the transmission main shaft. As the clutch
lever is squeezed to disengage the clutch, the clutch
Lifter @, connected tn the clutch cable, is rotated
and {arsed out. This clutch hall fame is transmitted
through the :10 steel ball an, clutch lifter rad ®
and clutch lifter joints piece to the clutch
pressure plate tn compress the clutch lpringl
prsaueing clearance between the trictien discs and
plates. Now the face pressure on the (rictian Eur»
facet of the power transmitting parts is reduced
to zero. resulting in clutch disengagement.

 

 

Refer to Fig. 335 ma page 115.

As Shawn in the ﬁgure, the clutch plates (I), which
an: cupnhle of sliding axially Lm the clutch center
©, are undwiched between the friction discs ®
engaged in the clutch nutter ®v In normal engaged
conditian sf the clutch, the pressure plate @,
upon which the clutch springs© farce is acting,
presses the stacks af the discs and plum agninst
the clutch cuter. Under this condition, the engine
power is transmitted thrnngh the primary drive
gear, clutch enter, friction discs, plates and clutch
center to the transmission mainshaft. As the
elutch lever is squeezed to disengage the clutch.
the clutch arm connected tn the clutch ce‘nle oper-
ates and the clutch litter cm (i) rotates to cause
the clutch adjusting lava (2) cc be forced against
the dutch lifter rad @. This force is mummiﬁed
through the clutch lifter plate (9 tn the clutch
center, producing clearance between the friction
diam: and plates. Now the face pressure on the
friction surfsnes oi the pewer transmitting parts il
rduced to zero. resulting in clutch disengagement.

 

 

 

Date cl Issue: July 20. 1977
© HONDA MOTOR CO. LTD., 1977

 

B. COMPARISON OF C3550 TO (18500 ”5

r
‘ 3 Construction of 03500 clutch system

 

 

   

 

 

 

Fig. 834

Construction of 013550 clutch system

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

"« ) Fig 335

Date aff‘IssI-z: July 20, 1977
© HONDA MOTOR CO. LTD“ 1977

 

 

 

”6 B. COMPARISON OF 03550 To 013500
Put or item Model 013500 Model CBEED Madiﬁed pm
Cmmershaft - Cnuneerahefc
lubmmiun - Tronheid pump

 

 

 

Fig. 535 By splashing

 

Fig, 337 By pump 17:35:11”
(3 Tmclmid pump

- The oil strainer assembly
is provided with the
xnusmissinn nil pipe. The
oil comes up w the rigln
sida of thc countexshaft
through the oil passage
in the right side uf tbs
lower crankcase and i:
fzd to (he L‘mmtarahl‘ft
35:511th by mama of the
trochoid pump. (See Fig‘
339.)

 

 

hearing (Added)

 

 

k v
Fig. 332 a) Trochoid pump
(2) Cunnteﬂhnﬂ assembly

 

    

Data of Inna: July 20, 1977
© HONDA MOTOR CO. LTD.. 1977

 

\\_/

9. COMPARISON OF CB 550 TO CBEDU H7

 

 

 

 

 

Fig. 339 (9 031 pump
® Txuchoirl pump
@ Transmiuion ail pip:

‘ Oil w caununhah
“w on m cylinder head and cunkshnft through oil pump

Date of lune: July 20. 1977
© HONDA MOTOR CO. LTD., 1971

 

”3 9. COMPARISON OF 0355!] T015350!)

 

Unit : mm

 

Fan or item Model C3500 Model C3550 Modiﬁed part

 

Gee: shaft :pindle > Gear shift spindle

 

 

 

 

 

 

 

5"" m“ M. of teeth Pm name Ne. of mu.
64 Primary driven gear as
23 Primary drive gear 24

 

 

 

 

 

 

, Right gear shih
fork

- Left gm shift fork

- Center gear- shift

Gm shif: fork
shit (Added)

 

 

 

fox-l:
- Geax Ihift fork ‘»
51:31: (Added) )
Fig. 342 F15. 343
® Right and left gel: shift ® Gear shift {ark Ilmf:
50ku ® Gear shift drum
® Gear :hift drum @ Center gear shift furk
@ Center 323: shin fork @ Right and left gear shift
~Au fork: m installai m M"
the drum. - The center {ark in in-
nnlled to the drum and
the right and lair forks
m the furl: shaft.
Gm :hih drum ‘ Gear shift drum )

- Upper crankcase

Fig. 844 Fig. 345 ,
(i) Groove far gear shift (3 Press bearing m here }

dxum guide screw . The gmuve for the drum

guide screw was real.
island. 1mm a mans
Iadill ball hearing was
pressed in.

 

 

 

 

 

Date of Issue: July 20, 1977
© HONDA MOTOR CO. LTD" 1977

       

9. COMPARISON OF CEESD TO C8500 ‘ U9

 

(Frame)

 

Part or item ‘ Model 03500 Medal CBSSD Modiﬁed part

 

- Air cleaner
chamber
- Element caver
- Element cover
seal
- Element
(Wf type)
- PL“: seal
~Aix cleaner
element.
(dry Wye)

Aix cleaner

 

Fig.3“ Air cleaner ele-
‘ men: sea] case

 

Fig. 847

-In cnmmctinn with emplay-

mam: of the blow-by gl:
scavenging davice, the mix
cleaner shnpe was changed.

 

Finnl :11le

Number of teeth: 34 Number of teeth: 37
sprocket

 

 

- The tum signal]
hum switch was
changed tn the
mm ﬁnal/hm]
dimmer swim]:
(comm with
that of 03750»

Turn Iignnl/
horn switch

   

 

Fig. M9
(9 Turn signal switch Turn signal switch
(9 Hum switch g) Hum switch
@ Dimmer switch
Stunt] - The Stamr/hbud»
headlight] light/igniﬁun
ignition switch switch shape was
changed.

   

Fir. 860
(9 Ignition switch (D Ignition switch
@ Headlight switch ® Headlight switch
@ Smear switch (a) 5mm twitch

 

 

 

 

 

Duke crf Issue: July 20, 1977
© HONDA MOTOR CO. LTD” 1977

     

   

g 10. ENGINE

 

1. CLUTCH
A. Disassembly
. 1. Drain the engine oil. (See page 20 of the
CB500 Shop Manual issued separately).
2. Remove the kick starter pedal.
3‘ Remove the ten 6mm screws and the
right crankcase cover.

 

a) Right crankcase cover

IL Remove the clutch lifter rod.

5. Remove the fcur clutch pressure plate
mounting bolts.

6. Remove the clutch lifter plate.

7. Remove the 25mm snap ring and shim
and remove the clutch assembly ham

.1», mm s 33:34:15?
8. Remove the clutch outer and mner at Lifter Mm

 

the same time.
(Refer m page 40, Fig. 110)

    

Fig. 35 ® 25mm snap rmg
@ Shim
@ Main sheik

 

Dale of hale: July 20, 1977
© HONDA MOTOR CO. LTD“ 1977

 

I22 10. ENGINE

9. Remove the cotter pin from inside the
right mnkesse cover and pull the clutch
lever out.

Fig. 356 (9 Caner pin a; Cinch adjusting lever
@ Clutch lever

10. Remove the 6mm nut and the clutch
adjusting lever.

B. Inspection

See page 41 of the CBSOO Shop Manual
issued separately.

Measurement of friction disc thickness.
Using a Vernier caliper, measure the thickness
of eaeh friction discl Replace a disc whose

thickness is below the service limit.
Unit: mm (in)

 

 

 

 

 

 

Assembly standard Service limit
2. 7 (a. 1063) 2. 4 (a. 0945)
C. Assembly

1. Install and tighten the 6mm nut attach~
ing the clutch adjusting lever.

2. As shown in Fig. 358, install the clutch
lever spring and 10mm washer en the
clutch lever. Insert the cotter pin and
spread its ends.

3. Install the 25mm collar in the clutch
outer.

4. Install the seven friction discs and six
plates alternatively to die clutch center
and to the clutch outer. Install to the
mainshaft.

      

Clutch cenler
Friction diam ind plata
a 01m}. outer
0 25mm collaY

‘ Fig, 359‘ g

Data of lune: .Tuly 20, 1977
© HONDA MOTOR CO. LTD, 1977

 

‘\_,/

ID. ENGINE 123

 

5. Attach a. dial gauge to the end face of
the clutch assembly to check for exces-
sive lulleness. If it exceeds 0.1mm (0.0039
in), install a washer or washers behind \ﬁ‘
the snap ring. The washers axe available
in three thicknesses: 01mm (0.0039in.),
0.3mm (0,0115in,) and 0.5mm (0‘0197in.)‘

6, Install the four clutch springs. Install
the lifter plate and tighten the four 6mm
bolts in a cries-cross pattern.

7. Insert the lifter rod.

8. Install the right crankcase cover and kick Fig. 3“
starter pedal,

 

 

 

 

 

 

 

 

 

 

 

 

Date of Issue: July 20, 1977
© HONDA MOTOR CO. LTD. 1977

 

IZA 10. ENGINE

2. GEARSEIF‘T MECHANISM

A. Disassembly

1. Remove the clutch. (See page 121.)

2. Remove the gear change pedal.

3. While holding the gearshift arm down
as shown in Fig. 262, pull the gearshift
spindle out.

4. Remove the shift drum stop bolt, the
neutral stop bolt, the shift drum stop
and the neutral stop.

   

Fig. sea (9 SIM: drum neutral slap all
Shift drum slop bolt
5m: drum stop @ Neutral 1an

 
  
 

5. Remove the 6mm bolt and the bearing
set plate on the primary shalt side.

6. Remove the twb 6mm bolts and the

hearing set plate on the gearshift drum

side. _

.2 «.1

n pnmsry :11! I si e
1: shift drum sirle ,

7. Remove the 6mm bolt, the drum stop
cam plate and the drum gearshift center.

 
   

6mm bolt (3 Drum gearshift cemer
Stop cam plate

N Fig. 365 8

Date of Issue: My 20, 1577
@ HONDA MOTOR co. LTD., 1977

     

ll). ENGINE l 25

 

8. Separate the crankcase into the upper
and lower parts and remove the trans-
mission gears. (See page 43 of the
CB500 Shop Manual issued separately.)

9, Remove the neutral stop switch from the
gearshift drum

 

10. Remove the guide pin slip and guide
pin and pull the gearshift drum from
the upper crankcase.

B. Inspection
See page 44 of the CB500 Shop Manual
issued separately.

C. Assembly

1. Position the center gearshift fork on
the drum as shown in Fig. 358.

2. Insert the guide pin into the center gear-
shift {ark and secure with the guide pin
clip.

NOTE:

Install the guide pin clip with it facing

correctly. (See Fig. 357.)

    
  

Fug, ass @Cemu gemshiit {m (a Drum

3. Put the right and left gearshift forks ’ ‘ "'7"
in the upper crankcase and insert the '
gearshift fork shaft as shown in Fig.
369.

(9 ght gems in {or}:
[2) Let: gearshift ion;
(a) Gearshift fork shah

 

Date ef Issue: July 20, 1977
© HONDA MOTOR CO. LTD» 1977

126 10. ENGINE

4. Make sure that the gearshift forks are
installed correctly and securely.
5. Instsl the neutral stop switch to the gee:-
shiit drum by ﬁtting the lug into the
groove in the drum and secure with _
the 5mm screw. )

6. Install the transmission gears in the ‘
upper crankcase and put the upper and
lower crankcases together. Install the
primary shaft and tighten the crankeases
securely.

7, Install the bearing set plate on the drum
side and secure with the two 6mm bolts.

8. Install the drum getushift center. )
NOTE:

Properly ﬁt the lug of the drum into the

hole in the drum gearshift center.

9. Install the drum stop cam plate.

NOTE:

Properly ﬁt the gearshift drum pin into

the hole in the drum stop cam plate.

 

® Drum nap cam plate
@ Lug )
10. Instsl the bearing set plate on the drum
side.
11. As shown in Fig. 373, install the gear—
shift dxum stop spring to the drum stop
and the neutral stop and tighten the
drum stop bolt, and neutral stop bolt )
securely. Also tighten the bearing set
plate on the primary shaft side as shown
in Fig. 373.

 

Date of Issue: July 20, 1977
@ HONDA MOTOR CO. LTD., 1577

   

lo. ENGINE 127

 

12. Rotate the gal-shift drum and check
each component for smooth movanent,

18. Install the gearshift arm and check to
see if it moves smoothly and equally in
both directions.

14. Install the clutch. (See page 121.)

 

But: of lame: July 20. 1977
© HONDA MOTOR CO. LTD.. 1977

 

ENGINE

 

 

M
11.

   

   

new..." i.............a.

TROUBLE SHOOTING

 

 

mm“.

 

Trnnhle

Pruhnhla Cause:

Remedias

 

Engine does not
amt

. Exceaaive pinion ring er cylinder wen
. Seized valve in valve guide

. Seized piston

. Faulty valve timing

, Law at lack of cmpmeinn grew:

cinema».-

- Preuuxe leak
5. Blown out cylinde: head gasket
6. Wuped gasketing surface cf the cylinder
and cylinder head

Replace

Replace

Replme

Adjust

Lap the valve to obtain gaod valve seating
er replace

Replace

Repair ax rapllce

 

Poor engine
idling

Vllve Mechanism
1. lament Hype! clearance

Adjust to :tnndu‘d value

 

 

 

 

z Law or lack of compressian mum Repair
8, Excessive valve guid: cleaxa'nce Realm valve and guide
he. of pawer 1. Valve sticking open Replace
a Incorrect seating 0f valve Lap valve
3. Walk or broken valve spring Replica
4. Faulty valve timing Check valve timing and Idiust if necslary
5. Elnwn out cylinder head gasket Reyhee
e. Excmive cylinder and piston weer Replace
7. Warn, weak or lucken pinch ring Replaaa
5. Lease spark plug Retighlen
Overheating 1. Heavy Cuban deposit on combustion Remuve when
chili-11b" and piston head
2 Lean feel mixture Adj’ult the carburetor
s. Remaad ignition timing Adiust ignition :iming
4. Law ail level, puor quaﬁly Add gmd grad: oil
5. Extendeﬁ aperatian in law gut
Emmi-e L Inlet-treat wilting oi intuka valve Check the valve .eazing
2. Fullty valve timing Adjust
a. 1mm: ignition timing Adjusi
4i Exaaeaive spark plug gap Adjust the gap to 0.02M.023in(0.6~0.7mm)
5. anrupet fuel Replace
White exiuvnn 1, Excessive cylinder and piston ww Replace tbs pimn
smoke 2n Overallecl engine oil Adjust the nil level

a, Excessively high oil measure
4. Paar quality ail

Check «he breather
Replace with good qunLiey nil

 

Black exhaust
smoke

 

Rich fuel mixture

 

Adjust the enhancer

 

 

 

Date cf Issue: July 20, 1977
D HONDA MOTOR (X). LTD., 1977

 

'v/

 

11. TROUBLE SHOOTING

I29

 

 

Tumble Prob-Illa Cull" Ramuiiel
Diniuult gear 1. Improper clutch disengagemeni Adjust the shrink
llliftlug 2. Dnnuged gen or ioreign object lodgadin Rephce the defective pans

the gm

8. Gm shift fork innpemive

4. lncurrem: operation uf the gear shift drum
mapper and change pednl
Msinshnfz and ennncerrhah out of aﬁgnmn
High oil vireesiry

Repair or replree
Reprir or replace

Repair ur repleee
Chenge the oil

 

Excessive high
gear noise

5.

6.

L Exes-rive gear backlash

a Warn main Ind wumershuft bearing

Repair or replree
Repair or replace

 

Gear Ilip out

1. Warn ﬁngers on gear shift lerlr
2 Wm. gear dug hale
a Warn spline

Replace
Replace
Replace

 

Clutch allpplge

1. No clutch lever play
2. Weak or no uniform clutch pressure
plate spring

Arljult the clutch lever
Repleee the weak spring

 

 

 

 

3. Worn or glazed friction disc Rsphbe
Poor clutch 1. Excurive clutch lever play Adjust alum}: lever play
engngernenr z Warped fricﬁcn disc Replace

3. Warped preuure plate Raglan

4. Ben: main shaft Replaoe
Pedal does nut 1. Faulty return spring Reylace
return 2. Unbcak return spring Honk retum rpring
Kick starter 1. Exoesive kick sinner pnwl weur Replace
gear doe: mil
rot.“
Engine do“ nut Carburetnr

' l. Choke fully epen Close elmlre

“art

2. Carburetor nir screw imprupsrly m

a. Air leaking into the c‘ylimler head

4, clogged urbnremr slow jet

5. Clogged fuel valve or piping

a. clogged vent hole in the fuel rink eep
‘7. No fuel in the tank

Adjust nir screw

Reriglicen eerhnreier cumming tube
Cher-Jr, clean and ratigbten
Disresemble end eleen

Diuuemble snrl clean

will ink with gmline

 

 

Pour Engine Carburetnr
idling 1. Clogged or loose carburetor claw jet Check, clean and reﬁglaten

z Imprupar ﬂaat level Adjust

3. Incorrect air suew adjustment Adjusc

44 Curlmremr linkage malfunction Adjust

5. Air leaks Tighten all air plunge connection-
Impmpet rnn- Carburetnr

nlng of engine

 

 

1. 1'3: size rm small

Improper ﬂoat level

Clogged carburetor main jet
Carburumr linkage mullunction
Air leaks

P9)”

.0!

 

Repleee with larger rise in
Adjuri

Clean and retighieu

Adjust

Tigl-nen eu ulr peerage connections

 

 

Dale of lime: July 20, 1977
© HONDA MOTOR CO. LTD, 1977

 

ISO

CHASSIS

11.

TROUBLE SHOOTING

 

Trouble

Prob-hie Cause:

 

Heavy [tearing

1. Stem-ins mm exuaaively tigl-nened
z Damaged steering mm steel ball:
a Bent steering

4. 1m {mm tire pressure

Ramediu
Lumen the steering mm nut
Replace
Replace

Add air m the speciﬁed prexaure a! 1.8kg/cm’
(25.6 psi)

 

Frank Ind rear
wheel wuhlale

1. Loon steering slam mmmting belt
2 Warm hunt and ma: wheel heaxinga
3. Frank a: rear wheel much: a: dinoﬂed

Returque
Replace bearing
Repair :1: replace

 

 

 

 

 

 

4. Loose epeke Retorq‘le
5. Deiecﬁve tire Replace
En“ napeneima 1. Lou of spring Malian Replace
z Excessive load
End 1. Reﬂective from furk damper Repair
anapenaiou 2. lnaﬁeclive rear damper Replace
Suapenaion L From cane or rear damper rubbing Impact cuahinu apring and mae
nolaa z. Interference between eushinn cue emi Repair or replace
sprint!
3. Fault: {wk atopper mbher Replace
4. Insufﬁcient from far]: oil Add damper oil
Defective blah L me brake ﬂuid
- Inenﬁeent brake ﬂuid Add brake ﬂuid
- A5: in the brake eyntem 31ml brake system
- Worn brake pd Replace pad
~ Wm pismaa Replace pimn
v Worn m- vlinoned from brake die: Replace disc
>Bnke lever we of adiaatmen: Readjust
1 Rear brake
- Warn brake lining Replace
- Wan-n brake shoe pr pm came-ms Replace
- Worn brake em Replace
- Wet brake {mm water or oil Clean
- Worn brake duh Replace
- nuke pedal one of adiuamem Readjun

 

 

 

 

Date of Issue: July 20, 1971
© HONDA MOTOR CD. 1.111. 1977

 

ELECTRICAL

v11. TROUBLE SHOOTING

131

 

Troubles

Probable causes

“Amalie!

 

Engine dues Mt L Battery
start - Discharged Rachurge or replace
- Poor battery terminals cantact Repair -
2, Main switch
- 0pm or abortsd circuit, dismaected Rep-ix
cunnectwns
- Poor contact between main Repair
switch wire and wire harness
s. Ignition coil
- Improperly insulated high tension civil Replace
- Open Dl‘ shorted circuit in’igaition coil Replace
L Contact breaker
. Open circuit in the primary coil Repair
~ Dirty pound paint with oil or dust Clean
- Paint gap nut of adjustment Readjust
-Impruperly charged wudenser Raplane

 

Starting motor
am mt «pants

1. Detective battery
2. Pour magnetic switch contact
9. Poor starting mom carbon brush contact

Charge or replace
Rzpair or replace
Rspair m replava

 

Hm inopera-

1, Hum

 

 

 

 

 

 

tive, lioor Inuml - Cracked diaphragm Replaza
or too weak 2. Hum button
sound ‘ Pout gmumling Repair
3. Wiring
-Poor contact Repair
4. Adjusting screw
- Out of Idiuitment Readjusl
Tall light and 1. Fuse
head light - Blown fuss or burnt hull: ﬁlament Raplaae
[nonnative 2 Bulb
- Burnt bulb ﬁlament Rudjuat
8. Switch
- Poor lighting switch contact Radius:
«L Wiring
Stup light L Bulb
imperative - Burnt or bruken bull: ﬁlament Raglan:
a Front and tail stop light switch
- Malfunction of switch Radius!
a Wiring
- Paar contact of lesda Rasdjuat
Winker lamp 1‘ Bulb
blinks ton {m - Blinks unusually fast: imymperly Replac:
or ton slnw ”mated ”1w
2. Wiring
- Blink: too fast: bulb with unsuitable Replica
wattage
- Ellnks too slow: burn: or brokcn bull: Replace
a, Defective ralay Replace

 

 

Date of laws: July 20, 1977
© HONDA MOTOR CO. LTD._ 1977

 

 

 

 

 

 

 

 

 

132 11. TROUBLE SHOOTING
Trouble Prob-Me ulnaes Remedies
Winker lump 1. Winker lamp switch
inoperative ‘ Poor winker relay cannot Replace
-opea circuit in winker relay coil Replace
2 Bulb
- Bulb wattage is smaller than raced wattage Replace
& Rdey
~ Pour winker relay camact Replace
- lmpruperly emaemd lends Repllee
Na then-ring L Broken wire ar [hone-‘1, lunse conueetinn Repair or replame
2‘ Faulty mil due to thorn or grounding Replace
3. Faulty er Ihmted aillcnn diede Replace
4. Brukeu or shorted lead wire at. regulamr Repair or replace
5 Regulator valrage a: no load in ma law Reaaiua:
Illsnﬁeient L Wiring
dangle: - Broken ylre. intermittent shaming as loose Repair, relighxen
connection
2‘ Generate:
- Slam-ting amass layer in the ﬁeld coil Replace
(resismce indicated in cuntinulry nest) '
- Shading across layer in mm- mil Repleee
, Opel-l mm in ﬁne of the rmor coll Replace
- Faulxy ar lhoﬂeﬂ silitun diode Replace
S. Regulatar
- Velma: below speciﬁed value n: no land Readjust
- Dirty or pine-l palms Pol'eh or replace
- Coil car resistor internally llmrted Replace
4. Battery 5.-
vLcw electrolyge level Add distilled water
- Defective banexy platen Replace
Exeeealve 1. Wiring
charging P terminal circuit and F terminal elreuit Replir
lhoned resulting in split wound generator
2. Battery
Internal short Replace
3. Regulnwr
~ Exceslive voltage at no load voltage Repair
‘ - Improper grounding Provide proper grnunrl
- Emlren cell lead wire Repair. replace
Unstable 1 Wiring
duping -Bnre wire shorting imermiltently under Repair a: replnoe
"It." 3:32;: a! bmksa wire making partial

 

 

2. Generalur
~ Lnye: shun (intermittem shorting)
3. Generalcr
- Intermittent open circuit in the wall
- Improperly adjusted voltage
- Delecuve key switch
- Dirty paints

 

Repair ax replace

Repair ax replace
Readjaa:

Replace

Clean

 

 

Date of Issue: July 20. 1977
© HONDA MOTOR CO. LTD., 1977

 

l3:

 

 

 

 

 

 

 

 

 

 

 

 

11. TROUBLE SHOOTING
Trouble Prahlhle cancel Remedial?
Self diachnrge 1. Dirty cantact areas and use. 1. Always keep the exteriar clean.
Battery discharges in nd- 2. Contaminated eleetmlytenrelectrelyte 2. Hnndle the replenishing electrolyte
ditim m that mused by exceuivcly concentrated. with use.
the eunneeted load.
0. Large disshsrge me 1. Thsinsssndthe wiring sresrtistectary, 1. When the speciﬁc grsvity falls hslaw
Speciﬁc gravity “an”, hut loads snsh ss winker and horn do 1,200 (20°C: SST). the hnttery shsnld
lowers “a ma 1,150 net function. be recharged immediately.
(53,; a“ wink“ ”d In this eendirien the rnatnreycle will 2. When the buttery frequently bennrnes
hm, m, long“ (“mam operate but with long use. both 63 discharged while operating at normal
and e plutu will react with 5111- speed, check the geneﬁlnr for proper
{uric acid and term lend sulﬁde de- cutput.
parin;(snuntinn) tnnlringit hnpdrsihle a. If the battery discharges undu nor-
to recharge. mul charge uutpnt1 it is an indiutiun
ed overloading. Remove some of the
excuse load.
High eharginz rate 1. The deguslt will heavily nesnrnnlste 1. Check to assure proper charging rats.
The electrolyte level at the hattnm and will cause interns]
drops rapidly but the shorting and battery damage.
shnrge is rlwnys main.
tnined It 100% and the
condition appears satis-
iactnry. (Speciﬁngmvlty
over 1.2m)
Speciﬁc gnvity drnp 1. shorted. 1. Check speciﬁc gravity measurement.
Eleclmlyte evaporates z lnsuiheient charging. 2. I! the addition of distilled mter caus-
3. Distilled water overﬁlled. a drop inspeciﬁc gravity. Add sulfuric
d. Contaminated electrolyte. acid and adjust m prnper Vllue.
Sulfatlnn 1. Charging rule it too Hull 0: too 1. When motnrcycle is in "huge, the
The electrode plats: Ire large. battery shauld be recharged ance a
covered with n white 2 The speciﬁc gravity er the mixture mnnth even thnugh the motorcycle
layer nr spate. er the electrolyte is improper. is net nsed.
a Battery left in r disehnrge ennditinn 2. Cheek the electrolyte Periodimlly and
[or n lnng pen'mi. (lstt with he always mine-in the proper level.
switch turned an) 3 ln s lightly discharged cundltinn,
4. Exposed is excessive vibration due perlem rcchlrging .nd discharging
tc improper ineulatinn. sevenl times by starting the engine.
5. Mnmrcyrle stored during the cold
rem with the battery connected.
Spark plug electrode 1. Tue rich I fuel mixture. Adjust carburetnr.
sorted with urban l' 2. Excessive idle spEEd. Adjust idle speed,
depneii 3. Poor qnnlity gasoline. Use gand qnslity gssaiine
4. Clogged sir cleanerr Servlss the sir cleaner.
5. Use of cold spat]: plug. Use praper hen: rungs plug.
Spark plug electrode 1. Worn piston Xingr Replace piston ring.
{willed with oil 2. Warn pietnn and cylinder. Replace piston or Eylinderr
8. Excessive clearance between valve Replnce valve guide or Valve.
guide and valve stem.
Spark plug electrode 1. Use ul hut spark plug. Use preper heat range plug.
ovsrhealed or burnt 2r Engine overheating.
e. lrsprnner ignition dining Renditnt ignitinn timing.
4. Lease spas-k plug m damaged spark Redghten plug or replace cylinder head.
plug hole thread.
5, Ten lean a fuel mixture. Adiuet carburetor.

 

 

Dalluge

1 Spark plug nverrmqued.

 

Replace with s new spuk plug.

 

Date of IHIIEZ July 20. 1977
© HONDA MOTOR CO. LTD, 1977

 

 

    

 

,,HI.I.‘_.....,..,,

 

dummy—n...

.I.....,......uIMun—MM...mm.

12. MAINTENANCE SCHEDULE:

   

  

«I.

 

REGULAR SERVICE PERIOD

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

T1135 ”Imam“ schedule is Ema up“ nverage s‘gﬁc‘: MW 3 m” magma mm“, a,
ndmg mndltwm. PERIOD mileage interval, whichever occurs
Machines subjected to mm use, ar ridden in Am.
unusually dusty areas. requim more frequent sun mm. 1 month 3 mun-a a mom}.- 11mm.-
nrvicillg. Mm mil! 1,600 mile! le IIIﬂEl (.000 milm
. “"1"“ 1?ka 2.5mm muohn In onukm
ENGINE DEL—{mange o O
OIL FILTER ELEMENTﬁ‘Replue . o
OIL FILTER SCREENrCIeun o
SPARK PLUGS o
—Cleun and adjust gap or replace if necessary.
‘CONTACT POINTS AND IGNITION TIMING . ‘ O
—Claan, check, and ldjgst or replace if necessary.
*VALVE TAPPET CLEARANCE . 0
42115ch and .dyuu if mmry.
*CAM CHAIN TENSION—Adjust o O
PAPER AIR FILTER ELEMENT AND
POLYURETHAN FOAM ELEMENT—Clean (Serviréedqmr: frequently if) 0
PAPER ALR FILTER ELEMENT—Replace ”1"“ a m “”y ”a" o
*CAREURETORS—Check, and adjust II actuary. . o
THROTTLE OPERATION . 0
71mm cabls. Check. and adjust frea play.
FUEL FILTER SCREEN—Clean O
FUEL LINES—Check O
“CLUTCH—Check apenﬂon, and adjust II gammy, O O
DRIVE CHAIN
—Check, lubn'cne, and ads“: II necessary “0 0
BRAKE FLUID LEVEL . o
—Cheuk, and add ﬂuid if necessary.
*3me SHOES/PADS 0
43mm, and mm: iI warn.
BRAKE CONTROL LENKAGE . O
——Ch:ck Range, and «dim Im play i! necessary.
“WHEEL RIMS AND STOKES—cheek o
Tighten spake: and true wheels. if neuessuy. O
TIRES—Inspect and check air yreuure. . O
FRONT PORK OIL—Drain ma reﬁll. M. O
FRONT AND REAR SUSPENSION 0
—-Check opemtion. O
REAR FORK BUSHING
—Gnase, chuck for excssive lemmas.
‘STEERING HEAD BEARING—Adjust O
BATTERY—Check 31¢:ch (a level, 0
an arid was if necusuy. .
LIGHTING EQUIPMENT
.42ka and adjust ii Dummy. 0 0
ALL NUTS, BOLTS. AND OTHER FASTENERS . O
—Cheuk szcurity and tighten if unwary.

 

 

 

 

 

 

Items muked * should be serviced by an auﬂaoriled Honda dealer, “BIHE :11: ‘owner has proper ﬁnals and
is mechaniully proﬁcient. other maintenance item are simpl: m perform and may ha serviced by she

awn.
“ INITIAL SERVICE PERIOD ZDD M'IIES
”* INITLAL SERVICE PERIOD 1,500 MILES

Dam of lime: July 20. 1977
© HONDA MUFOR CO, LTD., 1977

 

 

‘n ......,...,..,.. nun

.i..-...........n.n....nn,m....»..i....m..m.....n.........iim,,.....i...n... .n.‘

 

13. TECHNICAL DATA E

m.,....wmn n.

 

A. Speciﬁcations of 013500

(CB 500 K1, K2]

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Item Metric Englidl
Overall ngth 2, ms mm [2,120 mm] as. u in. (as. 5 in.)
Ovamll Width 325 mm 32 5 in
z Ovexnll Height 1, 115 mm 44. o in
E Wheel Bu: 1, 405mm 5. Sin.
E Seat Height 805mm 31. 7in.
a Font Peg HAight 315 mm 12.4im
Gram-id Clearance 165 mm a. 5 in.
Dry Weight 153 kg 403.5111.
Type Double cradle tubular neel
F1 Suspension, Txnve'l Tﬂeawpic fm'k, travel 121 mm, 4. s in.
R. Suspension, Travel Swing aim, naval 76.5mm, & lin.
Fl Tire 5m. Type (E'lgfggg (14311911) Rib tin. tin Iir prslnll ﬂag: Egg;
R. Tire Size, Tm 3.50—18 (4 PR) Block lixe. iixe nix prism-e 2, Dkg/m' 25.5w
g F. Brake, Lining Axes Disc brake, lining mi 283.8m’x2 sz,ssin=><z
g R. Enke, Lining Am Internal expanding shoe, lining area lEREcIn’XZ 25.23in’x2
Fuel Capacity 141 om. a 711.5. gni. 3.11mp.gn1
Fuel 11mm Clpacity A. a lit. 1. a U5. gal. 0, 911111). gal.
Cum Angle 64“
mil meh 105 mm L 1 in.
Finn: Fur]: on Capacity 160 on a 4 on
Type Air-cooled, nil-ole, OHC engine
Cylinde: Arrangement 4~cyljnder in-ling
Bore and Stroke an ox so. 5 mm 2 2115 X1. 992 in.
Displacement 498 a: so. a: an in
g, Cumpresﬁan Ratio 9. o
E Carburalm', Vemuri Din. Four. piiton v.1", 22mm din.
é Valve Train Chain an'vn overhead umbnft
Maximum Horiepawer 50 BE? (5,433/9,001:me (4.4an (SAD/9. 000 rpm]
Maximum Torqu: A. 2 kg-m/7. 500 rpm :0. ugh/1,500 rpm
Oil Capacity 3, 015L 3. 2 Us. qi., z s Imp. gl
Lubnmlion System Famed pmxsnm and wet sump

 

 

 

 

 

Dale of 15511:: July 20, 1977
© HONDA MOTOR CO. LTD” 1577

       

136

18, TECHNICAL DATA CB SOD

 

Item

Mari: English

 

Air Filter

Papa element

 

Valve Tappet Clearance

1'N:0.05,EX:0l08mm l'N:0l002,EX:0.0USin.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5 Engine weight 65 kg 1521b,
a Air Screw Opening 1:1/8 turns
1&1: Spend 1,000rpm
Clutch Wet, multi-plute
Tnnsmiuinn 54pm], constant mesh
Pximury Rnductian z our)
E Gm Ratio 1 2353
E rv II 1. 636
E u m 1‘ 259
F; ” 1v 1. 036
v V ‘ 0. 900 ,
Final Reduckion 2,000, drive sprockﬂ 17, driven Iprocket 841T
Gear Shift Fattam Len foo: mum my:
Ignition Emmy and ignixiun mil
Starting System Electrical mum: and kick psdn]
Altaxnnur The phase AC. 12 V—0. 2 KW/E, 000 rpm
Emery Capacity 12 V712AH
, Spuk Plug NGK D-7 ES, DENSO X—ZZES
g Headlight Low/high, 12 V—40 W/50 W
E Tall/stoplight Tail/Slop, 12 V432 W/s or [12 v4 cP/sz cm
E Turn Signal light Frans/Rm :2 V»25 W/ZS w (12 was: 013/32 up)
Speedometer Light 12 v- s w (12 v—z c171
Tachomem Liam 12 V— 3 W [12 V‘—2 CF]
Nsntxal Indicator Light 12 V7 3 w [12 v—z CP)
Turn Signal Indimwr Light 12 V— 3 W [12 V-2 GP]
High Beam Indium Light 12 v— a W (12 v—z or;

 

Date of Jane: July 20, 1977

© HONDA MOTOR CO. LTD.I 1977

   

 

 

 

A. Speciﬁcations of CB 550

l37

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

item Metric English
aveinn Lang—iii 2,120 inn; 83.5in.
0min Width 825 min 32.5 in.
5 Overall Height 1,115mm 433 in.
E W'hegl Ease moannn sans-in
E ant Height ans mm am in.
3 Foot Peg Height 315mm 1min.
memd Clearance 160mm as in.
Dry Weight 192kg 42311.,
Type Douyle cradle frame
F. sinneniinn, Travel Telescopic fork, travel 121 inn is in.
R. Suspensinn,’1‘rav:1 Swing arm, travel 77.3mm an in.
F. Tin Size. Type 325—19 [4 PR) Rib tin, tin air pinning Ziﬂkg/cm‘ 25 psi
R. Tire Size, Type 3.75-18 (4m) Block lire, tire iii pmim u kg/cm‘ 34 psi
E 1:. Brake, Lining Am Dixk bnke, lining mn 25&ch’x2 3235 in‘xz
E R Brake, Lining Anni Inlemal expanding shoe, lining arm 159.5 cm‘xz 26.28in’x2
Fuel Capacity ‘ 14.05:. 37 U.S.gII. 3.11:”. gm.
m1 Reserve cipnciiy 4.0m. 1.1U.S.galn 0.9!mp.gaL
Caster Angle 54-
Tina Length 105 nnnn u in
Front Fork Oil Capacity 135—191 c: 83-65%
Type Aix-malad, minke, 0.1m engine
Cylinder Anangmmt l-cylindex in-line
Bore and Stroke sssxsimnun mamszin.
Displacement 544 cc 95.19 cu. in
E Compression Ratio an
E Car'bnmtax, vinmni Dia. Four, pimn vAlve, minim din.
E Valve min Chain drive overhead camshaft
Mudmum Humepower so am: (SAID/8.500 xpm
Maximum Turque 4.2 mini/1,500 rpm ao.4ib.n/7,5uoxpni
on Cnpacity an liL 3.2 U5 in, as In‘lpn q;
Lubrication Syslam Forced pressure and wat Hump

 

 

Dam of king: July 20, 1977
© HONDA MOTOR CO. LTD" 1977

 

   

 

138

13, TECHNICAL DATA CB 550

 

Item

Metric English

 

A5: Film

Papa: element

 

Valve Tappel Clearance

IN: 0.05. EX: 0.08 mm IN: 0.002. EX: UJJUSin.

 

 

 

 

 

 

 

 

 

 

 

 

E Engine weight 72 kg 15910.

5 Air Scraw Opening l’lzt’lxtumi
Idle speed 1.000 rpm
Clutch Wet, multi-plate
Tmnsmissinn 6»speed, mutant mesh
Primary Rcducﬁcm 3.055

E Gear 12min I 21,863

E a 11 1.535

E « m 1200

a I! IV 1.035

a v 0.000

 

Final Reducﬁnn

2.176. drive sprocket 17. driven molt“ 871‘

 

Gm Shift Pattern

Lgft ion: mum: typ:

 

Ignition

Emery and ignitim tail

 

Stuting System

Electrical mater and kick pednl

 

Alternator

Three phase A,C. 12V—0.11 [GU/2,000 rpm

 

Battery Copmzity

12 V—12 AH

 

 

 

 

ELECTRICAL

 

 

 

 

 

 

Spuk Plug NGK D—7 E5, DENSO X-ZZ ES
Headlight Low/high, 12 V40 W150 W
Taﬂ/swpﬁgh: Tail/Stop 12 V—sa W/s CP
Turn Signal ugh: Front/Rear 12 v—az W182 w
Spudnmeter um 12 v—a W
Tadnrmeter Light 12 V4 W
Neutral Indicator Lighr 12 V44 W
Tum Sigul Indium: Light 12 V—8 W

12 V4 W

High Beam Indium: Light

 

 

 

 

Date of Issue: July 20, 1977
© HONDA MOTOR CO. LTD. 1977

 

 

13. TECHNICAL DATA C3500

B. Service Data (CB 500)

 

 

 

 

ENGINE
nun an.)
1mm Standard value Suvicenble limit
Intake cam 84: 93,484, 97
height (11 a142~11 37m) 3455 (1- 372“)
Exhaust 34. 5:1»«34, 57
cum height (1. ss9s~1s. 510) 3145(13553)
Runuu: #— o.1 (01004 )

 

 

Item Sundard value

Serviuenble limit

 

 

 

 

 

 

 

 

 

 

 

 

 

 

53'3“" (2.556111555921115) 56- i (Z 209)
Run Suuaua value Suvicuhle limit
Pistun an (35731555255 55. as (2. 193)
Pam pinhole i 15. as (01593)
Run Sundud value Servicmhle limit
53321; Hz (on333 258) 0' 7 (0' 027)
55333;; Standud value Servicmble Emu
Top ring (f'ﬂgfgj; 83%;) 0.121(01007)
Swami ring (0?bg§g:3;ggw o.15(o.uns)
on ring (oFngPIZEI 33:1) 0. 15 (o. 005)

 

 

Item Standard vain:

Service-bl: Jimi

 

 

 

 

 

 

 

 

 

 

 

 

Ring atom 15. ODE/~15. 00E Raglan: if aver
clasrame (0159063~D.59087) 15. 030 (0. 5937)
Servimhl:
Standard "In: limit
0. 010~IL 035 0. 030
Valve “m (o. oooaaw. 00137) (a. 0031)
ﬁle-rune: Exhausc
01 080%. 050 01 ID
(0. 0011~0, 0019) (0. DOSE)
Inuk:
5. 45D~5. 465
VA“ m,“ (12145412150)
diameter Exhaust
5. 430%. 445
(0. 2137.41, 2142)
Valve face _ o. as
mnnu! (D. 009)

 

 

 

Date of Issue: July 20. 1977

© HONDA MOTOR CO. LTD” 1977

l39

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

mm [in.)
Sexvneeahle
Item Stu-mud nlue imir
Cylinder head _ n. 5
sum; (M11)
Item Standard vulue 531$?be
2,115” {m om: 4a.4(1,55) as (1. 53)
$1,531, Inner as. 7 (1.40) 34.5 (1.25)
Sum
27. 9 nun/45. 6~50. 6 kg
(1. can
7mm 10054411571341)
(referenae) 7mm
23. 2 nun/19. INZI. 1 kg
(a. 91:4
421. 1.5464. 351M»
Clutch
place mm —- 0.301.011)
on pump Standard value serviceable limit
Inns: and aunt
mm dunno: — “-55 (0- “13)
Outer romr uud
bodLulux-ance * °‘ 55 (9- “133
hem smuduxd value Suvicaublelimit
Truman disc
mm”; a. s (0.15) a. o (a. 11)
Standard um &'E‘fn§f“=
munch
Eng 3L 9 (1. 25) so. 5 (1. 20)
xueleugg
1 81. has kg at 28
SW“; 7. 3443116
“”3”“ a: 0. so in
Item Suandud value Sexviceahle limit
Gm duh sa 975~sa 95
drum 0.1). (11 57379-41. 57221) 39' 9 (1' 570‘”
sum iuuk 40.00.40.115
, . (1. 57434. 5757) 40‘ ”’5 (1-5797)
5323'“ Standard vquu Serviceablelimi't
5. ss~a. oo 5. so
cm" (o. 233%. 235) (a. 220)
. 4. saws o 4. so
RJght&laft (a. 194-401 157) (a 131)
Item smauxd value Service-131215116:
Crankshaft
~ 0. 020~D. 046
you 01 can (a. 0031)
mum (o. ooa79~a. 00131)
Rnnuut — 0. US (0. 0019)
Journal _
“a mm 0.05 (0.0019)

 

 

140 13. TECHNICAL DATA

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Item ' smmd value Servicen'blelimit Item smam vllue 53m?“
53%;? o. 02~0. 0 46 Disc mums: 7 0.0(0. 011)
m0 (0.00070~o.001e1) “5‘“ 0°31) Caliyer and
chant-me 9km 01mm. _ 011(0004)

mm (Em) Mute; cylinder

1m 51mm value 52101015000000: gamma — 011(0004)

““9?“ o. 12~0. 27 0. 35 ,
“Sign; (0004740100) (0.0150) mm (m)

Rear 1x12 shah Standard val“: “1:?”
11m 51000.10 value serviceable limit Em TIR 0401(Mun4) 0. 2(0. 000)
Cunnmmng
151 010~1s. 034 15. 07
mrl 5111-11 and
clearance (”-5911NO‘5913) (“-593“) Bnkalining swam v1.0.2 Sexviceablelimit
4 Th'ckness 5.0 0. 200 210 0.030
1m. smami vllue 5571311“: ' ( ) ( )

 

 

151. 2nd. 3er ROMA/0.138 Brake Drum Standard vnlue Sexvioeablelimii

01 2
gear: backlash (0. 0017~D. 0051) (D. 0078)

4011 and 50b 0. MENU. 1“) 0, 2
geanbnckluh (0.0010~0,0055) (0.007s)

 

 

. 1 179.0~100.0
lnndzdza. (107954.087) 181.007.2125)

 

 

 

 

 

Item Standard value Seryiczahle limit

 

Axial. Tm 000(00023) 0.107.004)
11.00:], m 0. 009(0. 00011) 0. 05 (0. 002)

 

CHASSIS
thel Smudaxd value Sexviceable Iimiﬁ

 

 

 

 

 

Stamina] vain: Serviceable limit

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Rim wobble 05(0020) 2.0mm)
Front
mg: 0. 5(0. 020) z 0 (0. 05) suspensinn 42(1. 05)
spring 113.
- ‘51. 17.73 425 l .
Wheel bearing 51:50.? 3011233010 Free lust}: 7( ) ( 6 75)
me wheel bearing ' Tilt 5(04 02> 8(0. 08)
“in! direction. 1111 007(0020) 0.10.004)
i’ﬁ‘;§§£¥:§éﬁi“ﬁ (0953822, 0.050002) km 50.1030 “1“. Servicea‘nlelimit
Rear
‘ 210.4 8. 3 205 5,070
Front brake 31.00.00 value Servimhlalimit $331233; ( 28) ( )
Cdlipu 1. .
315% .. (5301:8135) 38. 215(1 504) Item Standard val“! Senioeable 11am
mum N o. 1~0. a
”“33 0' ( 350101; 1:105, {:89 ) 381105(1.500) Cleanup: (0’0“qu 012) 0.5mm)
on s: e .4.
Rear £011:
pughing' (ﬁlﬁﬁﬁzﬁj) 21.301052)
Front brake Sundlrd value Servxcaamenmn made d-L ' '
Master 14 0 14 043 503%” “8‘27 ”331-“ 21 4(0 342)
. ~ . . . 0‘ N . I ‘
cylinder (01 551141. 5528) 1‘~°55(°‘533) ems-dc dm- ( ‘3 M4)
Piston (ﬂaggﬁgg; 10.940(o.540) . ELECTRICAL
‘ Serviuuble
Item Standard wlue limit
W'heel Stand-rd value Servicen'nlelimi! Carbon brush 12~31mm 5.5mm
Rs 1mm (047415110) (0.20:)
in Iunnut,
. ”(0.02 2.0(0.0s Brush 5 mg 0. 5~0.Ek 0,40,;
:33“! “a ) ) tension PI (1.1~1_ 3103;) (o. 010.)

 

 

 

 

 

D210: of 10511:: July 20. 1977
© HONDA MOTOR C01 LTD.. 191']

18. TECHNICAL DATA

141

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

   

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

mm (in)
3- Service Data (013550) llau. Standaxd value Se’ﬁﬁfble
Cylindu head 0.3
ENGINE ﬂatness — (ml 011)
m (in)
1m Scaudud vnlue Servicaalale limit. ham Stanﬁeld valua 5313;?“
1mm cam 34. 93~s4,97 Valve Outer 40.4(1. 59) 39(LSS)
. ~ 34. 85(1. 3720) -
“‘3‘“ (1‘3”? 1' 3755) 73;?" quer 557(1. 40) 34.5(1. 35)
Exhaust 54. ss~a¢l 57
, ~ 541503553) Outer
ma helght (mass 1mm) ﬁ'gwﬁwsmw
, lu
Rm“ — M (0- "04) Loading 100.54~111.57lba-n)
(reference) 1“,,
Item Standard valua Sexvicenblc lu‘uil 2% gum/19. 1~21. 1kg
. m
Cylinder 53, 50..“ 51 421. 15~454l 35 Harri!)
but: (2.am~2land) 55* 5“ 3°") 01 h
“CC
PM warp — o.a(o.o11)
Item Suudard value Sexviceablelimit
Flam dla. mgﬁgg) 55, 35(2. 302) 0:1 pump Standaxd valueSexvxce-ble 1mm
Inner and autax _ a 35 (a 015)
Pinon pinhole —— 15. 08(0. 595) 3:23:33;
budy cleaxanue ¥ 0‘ 35 (o. 013)
Item Standard value Servinaable limit .
T Standard value Serviccnblelxmit
op 1115.40.35 ,
P‘ston 0. 7(0. 027) a Fr}
Jug end 2’“ (”Eff-:13) mob,“ 2.60.12) 2.3m. as)
SIP oil - : ~ 1.1mm) .
(0.01 0.035) 3‘ d "I“ Serﬁllfsihlz
Plnan : . . . Gulch
Side deuglngce 5mm“ "1““ 53mm“ 1““ spring 55. 5(1. 45) 35.40. 39)
0 m4 075 freelzngth
T°P ““8 (0.00154. 0029) 0113mm) 5 , 22.1.4412 1: 28mm
533% (221 86130283. 6)
a U. 025~0. 05 at a in
Sand 1mg [o‘ooogwt om) ol15(u.oo5)
on ring i _ ’Iten Standard valua Serviceable limit
Gm alam 89.975~59.95
Item Standard value Serviceablalimit drum 0.1:. (1. 5733.4 5728) 39-°(’~57°93
Rin muv: 15. 002/45 003 Raplmlt ovu Shift for]: 40. 0044:4325
chagagce (o.saoaa~n.5auzv) 15. 090(1). 6937) 1.13, (L 574a~1. 5751) 4o.o75(1.5791)
Standard valua Sﬂ‘fﬁf“ “a?“ Standard vllue Servicubl: limit
Mike 5.9%6. 5.50
o. ozo~u.a45 0.080 0W" (a zas~o.g§s) (0.220)
Valve stem (0- WM- 00177) (n. 0031)
alumnae ham . d Ea~5. o 4. en
a. oao~u,usu 0.10 mg!“ 3‘“ (o.194~o.197) (0.131)
(D. 0011~0. £019) (0, 0039)
Item Sundard value Serviceablelimi:
( 5 it? 3?: ) G: k we
Valve stem 0,2 ‘ 0 A a“ El “WW-”45 o 030 o 0031
diam“! 11mm ﬁgs-“nee (0- "0°79” 00131) ' ( ' J
5l4ao~5.445
(0‘ 2137.4], 2142) Rumut — 0. 05m 0019)
Valve {use 0.05 jam-l
runout * (a. 009) and Inper — “- 05 (0- 0°19)
Dﬂke of 15511:: July 20, 1977

© HONDA MOTOR CO. LTD, 1977

 

 

 

‘42 13, TECHNICAL DATA

, ‘3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1m Scandnrd value Serviuublelimit ham Standard vllue Sergei!“
Connectin .
”a hm ‘3 0. 02 ~41. 040 0 03(0 0031) Dlsc lruaaaaa * 0.310.011)
and (0000704100101) 4 ‘ Can?" and
clearanca Pimhdwme — 0.1101004)
mm (“1-) Mum; cylindar )
Item Standard value Servicuble limit 313:5“ — 0.11(0.0o4)
cmmang 0 12~0 27 0 as
$1}; (00047410105) (0. 0138) mm Ga.)
Raunxla ahdt Standard value 59%;?“
Item Standard valua Suvineablelimit Em TIR 0. 01(0. 0004) 0.2 (o. 009) )
Gamma
mdsmﬂlfﬁléﬁégi‘iiﬁsbgiél (0123370)
alumna - ' - Brak: lining suuduad value Service-bleﬁmit
Thick 5. D 0. 2m 2. D 0. HBO
Ilem Standard value 5911;?“ “a" ( ) ( ’

 

 

10:. 2nd. 3rd 0. DAMNO. 1% 0. 2
gears backlash (0. 0017~1L 0051) (0. 0073)

4th and 50: 0. 040w. 140 0.2
gears hacklaala (0. 0m~0 0055) (0. 0070)

Brake Drum Slandaxd value Sexviceeblelimit

 

 

- - 1‘79. E~130. D
Ind: din. (7‘ 079%. 087) 181. 0(7. 125)

 

 

 

 

 

Item Standaxd value Serviceableh'mit

 

Axial, Tm 0. 07(0. 0023) 0.101004)

 

 

 

 

 

 

 

 

 

 

 

 

 

CHASSIS Radial, Tm 010036100011) 0. 05(0. 002) ‘

Whea‘l Standard valua Servicublelimlt ‘ )
Rim “We 0501020) 2.0000) Standard valua Suvicmhlalimit '

“'1 0. s (0. 020) a 0 (0. 00) furfgeilsion 42(1. 65)
"“"m , spring LD.

, - Free langth 451.7(17. 7s) 425(10. 73)
Wheel haamg 53:11?“ Se’fgﬁfb‘“
T0: 5(0. 02) a (0. us)

 

me wheel bearing
5:531 dixeclicm. TR 0. 07 (0. 023) 0. 1(0. 004)

Frantwheel bearing 0.003 . ..
mammrmimﬂm (0.00012) o.us(0.002) Item Standard value Sznucaablellmxt

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Rae:
'aa 210.4 3.230 205 0,070
mm brake suadaad value Serviueableljmit KSEm ( ) ( )
Caliper. .
$333”, (fgﬁﬁéﬁggl 90.215005“) hem Standard valua Sawlcaablellmll
Call at o. 1~0.8 ‘
ping-a (ﬁngfjaﬁ‘fg) asllusujoo) Gleam" (000443.012) “(0.02) )
nuksida dla - -
Rear for}: 21 m~21 5
laualaluii (a. m ~41. 8-46) 21.5mm)
Front brake Sundnni valua Serviceablelimit mic a
M1502: 14.0~14.04e $1535.?” . 65,5523 21-40342)
cylinder (o.5511~0.5528) 14.055(0.ssa) oumde an. ' ‘
. m.057~1a. 004 ELECTRICAL
Puma (0.5m~0.5505) 1054000549) , )
Item Standnrd value SHEEN“
Whaal Sllnllud value Servinenhlalimit Cuban brush 12~31mm 5.6mm
. length (0.47%.51in) (0.2m)
$3 rumt,
. 0.5 0.02 2.0 003) Brush 5 ing 0.5~D.5kg 0.41:.
£1";th "“1 ( ) ( tension 1“ (1.14.0100 (0.30») )

 

 

 

 

 

 

Date of Issue: July 20. 1917
© HONDA MOTOR CO. LTD, 1977

       

     

SEE 55a .5. 55m 5:25:

.EE 5% :2 =25. as:
c
3.. =ng

          

EB.—

 

z

 

 

       

  
  

$3.53 5.:

   

 

5555:

 

as: is!

  

EE

 

ES:
2: 5% x5: 55

 

.s

   
 

      

L E: ES :9.

.55.
mat—ﬁxing; 35m 1%:

 

Eu. Es:

            

SE“ Ems. 5:25

tot”?

WIRING DIAGRAM

" .5555
A: 3; u .3

3:3

14.

    

m
n
a

l
g

   

  

.33

$85
5.... SE .2: E:

  

5E.“ 55 g: L.

     

S: :5

     

5:5: 5:38

  

:25 35

vs

   

      
     

ﬁsh 3E:

     

u :3 :55“
_ h 3%..
Lb :EEE cg ESE—S E5 is gm :2: use

   

:— 2. a. k:
£5335 55:95.13“

 

can no

© HONDA MOTOR CO, LTD.V 1977

D“: of Issue: July 20, 1977

14. WIRmG DIAGRAM

 

144

 

 

 

      

 

     
      

 

 

 

 

 

      

 

55m .3an =5: 5:3 is
O O N
0O 0.0 a .
5 SEE =85 E
e 1: a 5 h $77—$77 5
533772 77277: is:
.7273 =3. 772775.752

 

 

 

  

   
 

     
   

Ewan“; .7565 ER. .591.—

   
                         

a?
EN EN
ENE—Eu.— §5§_ .53 55.7.
3:55: Eggs 5
S: 55:27 77.57! m H
Ea: 7.3.27: .52 i: m ©

of Issue: July 2n, 1917
ONDA MOTOR co. LTD.. 1977

            

    

”Emm%7ufms

.52:
“75: 3.5 E2 .755

7 E

>

  

23mg

              

r 478 .355.

ENE“ :5: 557535

 

7
7
7
7
7

      

52%

"as; EEEm {mints

«U177

llllllIIIIIL

  

  
                     

71

\IL

7.5::
E: E: .77:

§§$7§ ES:

       

Tiialwﬂ
an: x57”

0

  

7; .52.— 5.5.2346

55:
E: .3375 573 an:

          

 

 

 

 

 

 

         

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

. E
Emma; 7715.:
OO 3 E 0.0 o 7 7375555778
5 O0 s 0990 .7 .77. 7735775 7.
to 00:0 .7
u 5 E 97 s g a. .77 523 m “a ‘ 7§_=§7.§% .23 535.
£5.» 77275 €52.57. 5:5 \ .
5:35 $9.23 .5523 5mm .caiﬁz N M OOm ”0 29:3 Egg SEES

 

E Egg”:

14. WIRING DIAGRAM

 

5.... ES:
E! as: 5.2» man:

Ear-E.-

                 

a

    

   

_.
:55... 5...: SE .3. .55:
Eggs—E E55: .5

55 25:"

§.§§§n§=id .

     

Eﬁeﬁﬁ .E.
E :5: sin I: 55

                           

an: in a:

Emisﬁc= E: a; q a:

is: 5

   

Eggsagﬁsﬁ is: 3555.5qu
55. =S§.§_
iv...
E; ii.
awn-hm“. 55“!“ Sa.§§§§.§:ﬁ§§.
J; 3;. air“; .5 ES: 3:. :55
.a. l. EL. 35.; ESE

 

© HONDA MOTOR CO‘ LTD.. 1977

Data af Issue: July 20, 1977

146 1.4. WIRING DIAGRAM

Wiring diagram of 03550
Refer to the following illustrations for the location of wires, cables, and leads.

 

 

 

 

 

 

 

6 O o O o
. , 3
4 O (Moo
0 O O / o
D Dd“:
\ ‘ "/
5

 

 

 

 

 

©‘Speedumem @ Clutch cable 0 Throttle cables
® Tachometar ® Clutch switch Win 0 Headlight case
® Prom link: has: Clip 0 Win llamas

Date of hsue: July 20, 1977
© HONDA MOTOR CO. LTD-y 1977

 

14. WIRING DIAGRAM I47

 

 

 

 

 

 

 

 

 

 

(D Wire harness © Starter magneﬁc switch (1) Air clemar tube
Q) Clutch cable (9 Siricun rectiﬁer (D Thmttle cables
® Terminal new: @ {nae bnx

Date of Issue: July 20, 1977
© HONDA MOTOR CO LTD. 1977

   

1. FUEL VALVE

The fuel valve is new for the revised model.
The indication marks and the fuel valve
positions were changedl

Inspection and cleaning

1.

Place the fuel lever in the “OFF" posi-
tion; diamnnect the fuel tubes. Take
the fuel tank ouL

. Drain the fuel tank thoroughly.
. Loosen the fuel valve ﬁxing nut and re

move the fuel valve and fuel ﬁlter from
the fuel kink.

. Check the gasket for damage. Replace

with a new one, if it is damaged.

. Wash the fuel ﬁlter in solvent and dry

with compressed ail: Replace the ﬁlter
wiﬂn a new one if it is clogged.

. Install the fuel ﬁlter to the fuel valve

with the ﬁxing nut. Install the gasket
into the groove of the ﬁxing nut.

. Install the fuel valve to the fuel tank

with the ﬁxing nut.

Install the fuel tank in place on the
frame. Connect the tubes and secure
with the clips.

Fill me tank with fuel. With the fuel
valve lever in the "ON" position, check
for leaks past the tube joint: or connec-
ﬁons.

Date of Issue: July 20, 1977
@ HONDA MOTOR co. LTD., 1977

   

15. SUPPLEMENT T0 CB550K1 :

mum..."ulul...wm...u.,..,lmm...

 

"I.”Multanmnt
l

 

 

mmuutnm.m..n...-m.......twant."

 

 

 

 

 

Fir. lu—z @ F

m. 151—1 (D Fuel valve
® Lever
Fuel valve ﬁxing um

 

valve
(3 Fixing nut
® Gasket

(3 Fuel ﬁltey

 

 

'50 15. SUPPLEMENT TO CB 550K1

 

2. THROTTLE GRIP
The throttle grip adjuster, Fig. K143, was
discontinued.

 

 

 

 

 

Fig. mix @ Thmttle grip @ Spring adjuster
© Adjusting bolt

.3, SIDE STAND

The side stand was changed to a new type

with a shock absorbing rubber pad. The side

stand must be inspected periodically to deter-

mine that it is in good cmditien.

Inspection

1. Check the entire stand assembly (side

stand her, bracket and rubber pad) for
installation, deformation or excessive

   
      

 

damage.
® , ”can 3‘, © mm 2. Check the spring for damage or other
® Spring ® Side stand pivut dgfemg.
R‘M’" pad 1”“ 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. Attach a spring scale to the lower end
of the stand and measure the force
with which the stand is returned to
its original position

c. The stand mndiﬁon is correct if the
measurement falls Within 2~3kg
(4.4~6.61bs.).

If the stand requires force exceeding
the above innit1 this may he due to
neglected lubrication, overtighteued
side smnd pivot boltJ Worn stand her
or bracket, or mive tension. Re-
place if necessary.
4. Check the rubber pad for deterioration
or wear. When the rubber pad wear is
so excessive it is Worn to the wear line,

O X replace it with a new one.

Fig. III—6 (1) Wear line

 

 

 

 

 

 

 

Date of Issue: July 20, 1971
© HONDA MOTOR CO. LTD, 1977

L5. SUPPLEMENT TO CB 5501(1 151

 

Rubber pad replacement

1. Remnve the 6mm bolt. Separate the
rubber pad from the bracket at the side
stand.

2. After the collar is installed, place a new
mhher pad in the bracket with the arrow
mark out.

Note:

Use a rubber pail having the mark “OVER

2601])! ONL ”.

3. Secure the rubber pad with the EM
bolt.

4. TURN SIGNAL LIGHT

The front and rear turn signal lighis were
changed to new, larger type; See Figs. K1—
8 and Kl—Q.

5. MAINTENANCE SCHEDULE

 

K1-7 @ Rubber pad

 

 

@ Collar

 

Some additions maimed in the MAINTENANCE SCHEDULE. They are shown below:

 

This maimeume schedule is based upun average
riding conditions. Machines subjected to revere
use, or ridden in unusually dusty areas, require
mare frequent servicir‘igl

INITIAL
SERVICE
PERIOD

REGULAR SERVICE PERIOD
Perform at every indicated month or
mileage interval. whichever endure:
ﬁrst.

 

son miles
300le

x month ll munths 0 months 12 months

 

5M miles 1.50!) miles 3,00nml'lu amninllea
EDOkm 2.5001mi awoken ID,Dﬂka

 

*SDDE STAND—cheek installation.
operation. defamation, damage and wear.

 

 

 

 

 

 

O

 

 

Items marked : should he serviced by an unarmed Honda dealer. unless :he owner has pmper tools and is
mechanically predciem. other maiezeeenee nears are simple tn perform and may be serviced by the owner,

Date of Issue: July 20, 1977
© HONDA MOTOR CO. LTD“ 1577

 

15, SUPPLEMENT TO CB 550K1

152

 

e. WIRING DIAGRAM 013550111

ESE. 5......

55525.3 35...

n 5 an BE; :i:
$5.535: .555“ . s: .

_

E 552 , lg-

Eaﬂﬁﬁ s: :5... in i:

§§_§u§§§:

s §§§§§.§i§§

.11..
Ease»: iii. 5 .
I7. 5. giﬁswa

      
 

© HONDA MOTOR CO‘ LTD. 1977

Date nf Ins“: July 20, 1977

 

,M

 

ENGINE
GEAR SHIFT MECHANISM

A.
1.

2.
3,

Disasembly

Remove the clutch assembly. (See page
121,)

Remove the gear change pedal.
Remove the shift drum stop bolt, the
neutral stop bolt, shift drum stop and
neutral stop.

Lower the gear shift arm as shown in
Fig‘ 1—2 and remove the gear shift
spindle.

Inspection

. Check the shift drum stop and neutral

stop for bending or damage.
Check the shift drum stop and neutral
shop rollers for wear.

Data of Issue: July 20. 1977
© HONDA MOTOR CO. L111, 1977

 

16. SUPPLEMENT TD CB550F

       
  

Fig. 1»1 ® Shift drum stop halt
® Neutral slap halt

(a Gm 511m arm
® Gm shift spindle

 

 

154 16, SUPPLEMENT TO CBESDF

C. Reassembly
To reassemble the gear shift mechanism,
reverse the disassembly procedure. Note the
following items:

1. As shown in Fig. 1-3, 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. Secure the shift drum stay and

> _ l ‘ shift drum neutral stop using the neutral \

F”- H 332;: 33m :23; spring! stop bolt and shift drum stop bolt and )
@ 511m drum mm} amp Dollar.
2. Tum the gear shifty drum and check if
each part moves smoothly.
3. Install the gear shift arm and check that
it moves smoothly in either direction,
4. Install the clutch assembly. (See page

      
     

 

122.)
, «1m; m. e ’

Fig. 1-4 @ Banting 5:: plate on shift amm side

® Shift drum neutral mp

@ Shah drum stap

G) Bearing set plate on primary shalt side

® Gear shift spindle

Bushings

A bushing is pressed in the main shaft fourth
gear and top gear. (The 013550 model gears
do not cantain bushings.)

 

 

 

 

Fig. 1-5 ® Main shaft faunh gear
(2 Main shaft top gear )
@ Bushings

Date of Issue: July 20, 1977
© HONDA MOTOR co. mm, 1977

     

16, SUPPLEMENT TO CBESDF 155

FRAME
FRONT SUSPENSION

 

 

 

 

 

Figr 2-1 (9 Right rm: fork (3 Oil luck pizza ® Axle holder
@ Front fork bolt Oil seal mp mg @ Fork cove: shock absorber A
@ 23 x2.3mm O-xing @ 35x48x11mm oil seal 33 Left from cover
@ Front shock absorber spring @ Banana me an Wire and grommet
@ Pom ring @ 6x10mm 1m]: @ Fork cover gunk absorber B
Bottom pipe ® Oil lock bolt ® Front fork boot

Ar Disassembly

l. Loosen the front fork bolt, but do not
remove it.

2. Remove the front Wheel referring to
page 55.

3. Remove the caliper assembly from the
left front fork.

4. Remove the front fender, the front fork
pipe retaining bolts, and pull the front
fork out and down.

5. Remove the front fork bolt and chain
the front shock absorber oil.

    

(Z) From fork 1:91:

Date of Lena: July 20, 1517
@ HONDA MOTOR co. LTD., 197v

 

I56

 

 

 

 

 

Fig. 2-4 (9 on m1 smp ring (2) on an]

 

 

 

Fig. 2-5 ® Front shock absorber spring
Front far]: pipe
6) Button: pipe
© Bnﬂnm 'mse

 

 

 

 

 

Fig. 2—6 ® Allen held wrench ® Bottom case

6.

B.

C.

16, SUPPLEMENT TO CBSSUF-A

With the front fork bottom ease held in
a vise, remove the socket bolt using an
Allen head “Hench (Tool No. 07917—
3230000) and separate the fork pipe from
the fork bottom case.

Remove the front shock absorber spring
and bottom pipe.

Remove the oil lock piece from the
bottom easel

Remove the front fork oil seal stop ring
and the oil seal.

Inspectian

Measure the front shock absorber spring
free length. Check the spring for ten-
sion.

Check the front fork piston ring wear.
Check the front fork pipe to bottom
case clearance.

Check the oil seal for scores, scratches
or breakage

Check the front fork pipe sliding surface
for scores or scratches.

Reassembly

To reassemble the front suspension, reverse

the
ing
1.

disassembly procedure. Note the follow-
items:

Instxll the fork pipe into the bottom case.
Apply a coat of thread lock cement to
the socket bolt and tighten it using an
Allen head wrench.

Dam of hue: July 20. 1977‘
© HONDA MOTOR 50.7.11), 1971

 

15. SUPPLEMENT TO CEEEOF l5

2. Apply a mat of ATF (automatic trans~
misson ﬂuid) to the inner and outer
circumferences of the oil seal, then
install it using a fork seal driver (Tool
1N0. 0794743290000).

NOTES:

1‘ Install the oil seal stop ting properly.

2. Use a. new oil seal.

8‘ Fill the fork pipe with ATF to the
speciﬁed amount.

Capacity: 165N170 cc (5. 6N5. Bozs)
To ﬁll dry fork assembly

 

 

 

 

4 Install the right and left front forks so
that their heights are equal. The chem»
fered edge on the fark pipe should align
with the upper surface of the fork top
bridge as ShDWD.

NOTE:

Wipe oil, if any, «If the fork pipes.

5‘ After installing the front fork, check:
0 Smooth movement of the fork.

I Oil leakage from the oil seal.

Front shock absorber oil change

1. Remove the front fork bolt and drain
belt. With the front brake applied and
the handlebar held, move the front ﬁve
or six times to drain the oil

2. Install the drain bolt and ﬁll the fork
pipe with new ATF from the upper
side to the speciﬁed amount,

Dale of Issue: July 20, 1977
© HONDA MOTOR CO. LTD., 1977

 

 

 

 

 

Fig. 277 @ on m1
(2) Far): seal driver

 

    

g. 9 @antfox drain bolt

158 1.6. SUPPLEMENT TD (735501“

AIR CLEANER,

1. Raise the seen loosen the wing nuts, and
remave the air clmet cover. ‘
2. Remove the retaining clip, and the air
cleaner element )

2.10 a) Air leaner ms: 5
@ Running clip
@ Air cleaner :1

3. Clean the element lay tapping it lightly
If the element is sﬁll dirty, apply air
from inside of the element with an air
nozzle.

‘\_/

4. Remove the element cover, and the
breather element.

 

5. Immerse the breather element in soiapsuds )
and lightly squeeze it. Then immerse
the element in new ATF, squeeze it
lightly, and instalL
WARNING:
Gasoline at low ﬂash point solvents are
highly ﬂammable and must not be used to )
clean the breather elements. ‘

  

11 he: element cave!
Breather element
® Element cover seal

\_.

 

Date of Inna: July 20, 1977
© HONDA MOTOR CO. LTD., 1977

 

15. SUPPLEMENT TO CESEDF 159

 

6. Squeeze the end of the drain tube as
shown in Fig. 2—14 and drain any oil
or water that remains in the tube,

7‘ Install the air cleaner in the reverse
order of the removal procedure.

) NOTE:

Check the drain tube for clogging and
routing.

 

 

 

EXHAUST MUFFLER

A. Disassembly
1. Remove the 10mm bolt, and the exhaust
mufﬂer.

 

2. Remove the eight joint nuts, loosen the
exhust pipe joints and joint collars, and
remove the exhaust pipes.

  

Fig. 2—16 (3 Joint nus
® Exhaust pipe joiuls

 

Dm |1f Issue: July 20, m7
© HONDA MOTOR co. LTD., 1971

160 16. SUPPLEMENT TO 013550}?

3. Remove the protector hands Aand B, and the protector; Remove the mufﬂer stay and
the mufﬂer band bolt. Separate the four exhaust pipes and sealing gasket from the
mufﬂer,

)3. Inspection

1. Check for exhaust pipe gaskets damage.
2. Check for mufﬂer sealing gasket damage.

 

 

 

 

 

Fig. 2—17 (9 Exhaust pipe joint (9 Muﬂier hand @ Mufﬂer my
(D Exhaust pipe joint. collar ® Mufﬂer sealing gasket ® Stand stop rubber A
© Exhaust pipe gaskets @ Protector band B
(0 Exhaust pip: protector (a) Protester hand A

C. Reassembly

1. Install the sealing gasket and connect
the exhaust pipes to the muﬁer.

2‘ Install the muﬂier hand, attach the pro-
tector bands A and B to the exhaust
pipe protector, and tighten] the screws
securely

3‘ Install the exhaust mufﬂer.

Mufﬂer band
(3) szemr hand A
Mufﬂer hand halt

 

Date of Issue: July 20, 1577
© HONDA MOTOR m. LTD. 1977

 

16. SUPPLEMENT TO CE550F l6l

 

ELECTRICAL SYSTEM INSPECTION

1. Clutch switch

Attach the service tester probes to the green
and green/red leads of the clutch switch
contained in the headlight case and operate
the clutch lever to check for continuity
There should lie continuity only when the
clutch is disengaged.

  

L
Fig. 2.19 a) 01mm switch lead
@ Green lead

    

2. Starting Switch

Remove the fuel tank and‘ the connector
cover by loosening the 6mm screw. Take
the starting switch terminal out of the con-
nectar.

175524-30 @ Connector cover Connector
@ 5mm mew

    
   
 

Check the switch for continuity between the
circuits (070) shown in the table below.
If there is continuity, the switch is in good
condition

 

Terminal 5T1 STZ HL

 

Wire color Black Yellow/red Black/red

 

 

FREE (2 0
PUSH o——o

 

 

 

 

 

 

 

2-21 ® sums switch @ Buck/ma lead
:2) Elacl: 1m (9 Yellow/red 1m

1

 
 

 
 

3. Silicon diode

Using a service tester, check the diode for
continuity in the normal and reverse direc-
tions. If there is continuity in the normal
direction only, the diode is in good condition.
If there is ocntinuity or no continuity in
both directions, the diode is defective.
CAUTION:

Do not use a megger for this test. High
voltage applied to the diode may damage it.

 
 

Mo ,
Fig 2—22 ® Sillcon dinde

 

Data at June: July 20, 1977
© HONDA MOTOR CO. LTD, 1977

 

am \ l .2: .

Fig. 2—23 Q) Main switch
Brown

Brawn/White

 
  
   

Fig. 2-24 ® Dimmer iwilch
(2) Turn signal control switch

minus <3) Brawn/blue
(2) White
(9 Elue
@ Black/yellow
@ Light blue/white
@ Orange/white

16, SUPPLEMENT TO CESSOF

 
   

@ Brown ‘
@ Red
Black

 

@ Light blue

Orange
Brown/white

@ Gleen

® Light gram

 

4. Main switch

Place the switch key in OFF, ON or PARK
position and check the switch for continuity
between the circuits (070) shown in the
table below. If there is no continuity or
if there is continuity between circuits other
than those shown in due table, the switch is
defective.

 

Terminal BAT IG TL1 TLZ PA

 

Wire color Red Black Brown Brown/Whlte Blown

 

Lock
OFF

 

 

 

 

RUN D-—O 0
PA 0 . O

 

 

 

 

 

 

 

 

 

 

5. Dimmer switch and turn signal
control switch

Remove the fuel tank, and the connector
cover, Take the leads out as shown in the
table below Check each switch for continuity
between the circuits (O—O) shown in the
table. If there is continuity. the switch is
in good condition. If there is no continuity,
the switch is defective.

Terminal . w B L
Wire color Green El‘éraown Orange
Li
L,
N
R!
“2

Terminal TL1 PL PR HO

‘ awn range Li ht lus s t
Wire ml” white wh 5 EW De reen

ll

Terminal HL Hi in
wire color Black/yellow Blue white

 

Date of Issue: July 20, 1917
© HONDA MOTOR co. LTD. 1977

16. SUPPLEMENT TO CBSEDF 163

6. Born switch

Remove the fuel tank and remove the cam
nectar cover. Then take out the light green
lead as shown in Fig‘ 2—26 Attach one
pmbe of a radio tester tn the body and the
other probe to the gray lead. There should
be continuity when the horn button is
pushed.

7. Engine stop switch

Remove the fuel tank and the connector
cover. Check the switch for continuity he-
tweeu the circuits (O—O) shown in the table
below If there is no continuity, the switch
is defective.

 

 

 

 

 

Terminal IG RUN
Wile color Black Bleak/white
OFF
RUN o—-——o
OFF

 

 

 

 

 

pm of Issue: July 20, 1977
@ IjIONDA MOTOR co. LTD, 1971

 

 

    

2225 @ Hum switch ‘
(g) Liam green lead

m

Fig. 2.27 (9 Engine nap switch
a) Black
@ Bladdwhit:

 

164 16‘ SUPPLEMENT TO 01355017

COMBINATION LIGHT

A. Disassembly
1. Remove the three 4mm screws and the
combination light cover

2. Remove each bulb.
To remove a bulb, turn it counterclock-
wise while pushing it in.

Hit

Aime my

N37 ’ \ .
Bulb (12v, 3.4-W)

3. Remove the combination light case.
To remove the case, remove the 8mm
nut securing the speedometer and tacho—
meter stay. Straighten the stay and re—
move the 5mm screws as shown

B. Reassembly
To reassemble the combination light, reverse
the disassembly procedure.

 

    

3. 2-31 ® 5mm 5mm
@ Combination light case

Date oi Issue: July 20, 1977
© HONDA MOTOR CO. LTD» 1977

 

16. SUPPLEMENT TO CE550F 165

REAR WHEEL

The CB550F differs from the CB550 in
that the rear ends of the rear fork are con-
structed to prevem the rear wheel from
coming off.

A. Disassembly

See page 74 of CB500~550, steps 1—4 Push
the wheel forward, and lift the chain off the
driven sprocket. Remove the back bolts and x ‘ . l
the chain adjusting stoppers. Pull the wheel Figl 24:2 (D Cutter pin

backward and the axle to the left to remove a; Axle nm
the Wheel. @ Rear wheel axle .hm

    

Carburetor setting fable

 

 

 

 

 

 

 

 

 

 

013500 Item CBBWFVA
022A Setting no. 069A
#100 Main in #93
251542—2vsol—4 grooves Jet needle 2. 495¢—S”Uu'—2 groove:
1-11213/8 tape! 12" Al: suew 1—1/2i112 tape: 15.
o. 9¢x2 Air bleed 1 o. 7¢><2
o. 94} x2 Air bleed 2 o. 7¢x2
ol9¢x2 Air bleed a alwxz
0.9¢x2 ij bleed 4 u7¢xz
ola¢><2 Aix bleed 5 o.7¢xz

 

 

 

 

 

Dale of Issue: Julv 20; l977
© HONDA MOTOR CO. LTD, 1977

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

I66 15. SUPPLEMENT TO CBSSDF
Item Metric Englilh
Air Filter Pupar clement
Valve Tapper Clauamze m: 0.05, EX: 0.08mm IN: 0.002, EX: 0. 003 in.
ENGINE Engine weight 72kg 159 Hz
Air Suew Opming 1-3/4i1/2 cum;
Idle Spud l, moi-pm
Clutch Wet, multi-plam
Transmission 5-:pezd, constant mesh
Primnry Reduciiun 3. 062
Gal: Ratio I 2. 353
w 11 1. 636
DRIVE TRAIN ,, HI .1. 269
:1 IV 1. 036
~ v 0. 900
Final Rednminn 2.176, drive sprockec 17, driven :prmket 371‘
Gear Shift Pattern Left too: rum type
[g-nitian Battery and ignitiun mil
Starting System Eiectriul motor and kid: pedni
Alternator Three phasn A.C. 12V—o‘ukW/z, 000me
Blltery Capacity lzv—IZAH
Spark Plug NGK D4135. DENSO X—ZZFS
Headlight Low/high. lZV—SUWISOW
ELECTRICAL Tail/stoplight TIiI/Slnp 12V— SWIZ’IW
Turn Signal light Fran/Rm RV—ZSW/ZSW
Speedcmtex Light lZV—S, 4W
Tachometer Light 1217—8. 4W
Neutﬂl Indium: Light 12V—3.4W
Turn Signal Indian“ Light lZV—SJ-W
High Em Indiumr Light 12V—s.4W

 

 

 

 

 

Date of Issue: July 20. 1977
© HONDA MOTOR CO. LTD.. 1?"

     

 

16. SUPPLEMENT TO CBEEUF ' I67

WIRING DIAGRAM

 

 

 

 

 

(1) Clutch cable © Thmnle cable
® Clutch lever switch cl'ble ® Throttle table
® Handle switch (L) curd Handle (R) (L) swim}: card

(9 Handle switch (R) card (5) Throttle cable (R) (L)
@ mm brake has:

Date of Lime: July 2|), 1977
© HONDA MOTOR CO. LTD, 1977

165 16. SUPPLEMENT TO CEEEDF

   

® Tachnmecer cable
@ Main wire human

0 Samar magnetic switch
a; Tm signal xeluy

® Rectiﬁer

53 Rectiﬁer

@z Fuse lmx

 

 

 

 

 

 

 

[E @

 

Date uf Issua: July 20, 1977
© HONDA MOTOR CO. LTD. 1977

16?

16. SUPPLEMENT TC CBBSDP

 

WIRING DIAGRAM CB 550 F—A

«E558

:55555

$55352:
E: as a E

.555

E: ski—5:

                        

    

:2: =5: 3
:55

5E

   

._ SEES =§_§§E.§g§5§a

. .2: $355..§E§

gﬁa

.355

5333:...

E:
“Eu: 3
BE

.53.: is:

            

E:
F535.
5.. 55! E. ,3

ﬁg,
gs. £5
.55 km: S

  

i. _§_i.._ Ea 3.7L.
E. in ii:

5.. Esca- E595

    

Ex _ man

        

53513:; ia_§u§§=§.§§a§§

 

Date of Issue: July 20, 1917
© HONDA MOTOR CO. LTD., 1977

 

    
  
 

Wuhan... m"mun...“HlHn...........m..n..n..”human...umu‘m......,.umu..mm

17. SUPPLEMENT T0 CB550K2 (’76)

  

 

 

 

Engine No. CB550E—1067334 and subsequent
Frame No. CB550Eg1230001 and subsequent

 

1.‘ BREATHER TUBE
The breather tube has been rerouted as shown
in Fig. [(2—1,

 

 

 

 

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 nutsl
Tighmning torque: Z70—330kg—cm

(20—24 lbs-ft)

   

Fig. K242 a) mm hmke Am
UBS mu
, 3. FORK TOP BRIDGE
Flange bolts used for tightening the fork top
bridge will be changed from 8111111 to 7mm.
Tightening torque: lSO—ZBOkg-cm
(13—18 lbs-ft)

4. REAR FORK

The max fork pivot pipe now has a grease
nipple at its semen The grease nipﬁles
formerly located at both ends of the rear fork
pivot bolt were discontinued.

‘ @ Grease nipple

‘ Date of lame: July 20, 1977
© HONDA MOTOR CO. LTD. 1977

 

 

17. SUPPLEMENT TO CESSDKZ ('76)

4. SPECIFICATIONS (03550 ’76)

I71

 

[tam

 

DIMENSION
Overall Lengﬂ:

2,120 mm ( 33.5in.)

 

Overnll Widrh

325mm ( 325m.)

 

Oman Height

1,115mm ( 44.0 in.)

 

Wheel Baa:

1,405mm ( 55551:.)

 

Sen Height

805 mm ( 31.7in)

 

an Peg Haigl-lc

315mm ( lZAin.)

 

Ground Clearance

150mm ( Gain.)

 

 

Dry Weight 19mg (423117.)
FRAME
Type Double cradle frame

 

F. Suipmiian, Tnvel

Talesoopic fork. travel 121 mm (4,8in.)

 

R. Suspemiun, Travel

Swing arm, travel 77.3mm (3.0m)

 

P. Tire 5m, Type

3r25_19—4PR.R:'L. tire air pressure 1.75/2.0kg/cm’ (ZS/zapsi)

 

Rn Tire size, Type

3.75—18—4PR Block, tire nir pressure 2.0 /2.5 kg/cm’ (ZS/aﬁpii)

 

Fr Brake

Disc brake

 

R. Brake

1mm: expanding shoe

 

Fuel Capacity

mom (3.7U5gn1. 3‘11mp.gal.)

 

Fuel Reserve Capacity

5.11m. (13 usgal. 1.1]mp.gal.)

 

 

 

Caster Angle w

Trail Length 105mm (4.1m)
ENGINE

Type Air»uuolnd 4.5mm 0.1m. engine

 

Cylinder Anmment

4 cylindu in line

 

Bore and Shaka

SB‘SXSO‘Emm (ZSMX 1.992in.

 

Displacemem

544m: (33.19cuin.)

 

Comprwinn Ratin

9:1

 

Carburetnr, Venturi Din.

Four Piltm valve type, venturi dim 22mm (0.866in.)

 

Chan driven over head camshaft

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Valve Txlin
Oil Capacity 3.0m. (32U.S.qt 2.01mp.qt)
Lubricnnian Syﬂm Forced prexsnre and Wet sump
Fugl Required Lawdead gasoline with 91 octane number or higher
Air Filter Piper ﬁlter
Valve Tappat Clunnm: D1: 005, EX: 0.08111": (IN: 0.002, EX: 0.003 in.)
Air Screw Opening l‘lx
Idle Speed mom-pm
DRIVE TRAIN
Clutch Wet multi-plaua
Trmmisiun 5—Speed constant maul:
Primary Reduction 3.065
Gear thio I 2.353
11 1.635
111 1.269
IV L036
V 0.900

 

Flu] Reductian

2.176, drive sprocket NT. driven sprocket 37T

 

Gen Shiil. Pattern

Lair {not uperaxed rctum :ystu'n

 

 

 

 

 

 

 

ELECTRICAL
Ignition Batrery and ignitinn coil
Starting System Surfing mater and kick mm:
Alternator AC, Generator QISkw/ZﬁOOrpm
Battery Capacity 12V—12AH
Spark plug NGK D755 or ND X2255

 

 

Date or Issue: July 20. 1977

© HONDA MOTOR CO. LTD» 1977

 

 

l7. SUPPLEMENT TO CBSEOKZ (’76)

172

 

5. WIRING DIAGRAM (CB§50 ’76)

                          

 

 

\} N; ,
8.32.58
. W
u... gas: in 2.18. 9
ET; iii. 1
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Bari 1.5.5.. W L
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as: u u A
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SEES .. H
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rvllvl‘ I: ‘1 xlxwlglxmnﬁurlulg

 

s

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pa:

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E

5.6.: .
53: 5.53

_ A _

Adjuet ignitian timing
—- valve tnppet clan-me
—- cum ch:

  
  
 

— carburetor
Alter-um genemm
Air cleaner

 

 

Battery.
Bleeding brake rynm
Brakes
Brake caliper adjustmem
Bulce leve- tnvel
Brake pedal travel
Brake lining wen mcl-ucor

   

 

  
    
 
 
  

Bore .nd “rake.
Blow-by gnu .

  
 

Bull:
_ C _
Cm nlnln mule-1e: ...la,4s
Carlmmmx 57
Cumin“:
— holdex

Charging uyltem
Chung: oil and oil ﬁlter ..
Clutch .40. 107, 114, us
Compulsion min

 

 

 

 

—— ten

 

i pressure
Condenser
Canneckina 'wd
Contact breaker
Cxulkshah
Cylinder

— nxnngnment

   
 
 
 

 

 

— lame
Cylinder head

 

—-D—

Displacement .
Drive cluin

 
 

—E—

 

Engine imullntian ..

Date of he“: July 20, 1977
© HONDA MOTOR co. LTD., 1571

 

 

Engine removal ..

_ F _.
Final drive ,.
Final reduction
Franz brake l.

ant suspensinn

 

 
 

 
  
 
 

ant wheel and m-
Fuel unk capacity
Fuel strainer"

 

 

    

Gut lhlft drum
Gear shift drum mapper
Genernm- ..

  

Home

 

 

Idling speed l.
Ignition ﬁning ..
lgnitien lynem
Ignition mil ..

_ K _
Kick lune! pedal ..

 

 

~_ L W
Lubric-cion mum

__ M ._
Main igniﬁun Mitch
Muintmance operatiun W 7

 

 

—-N—

Neutral switch .

 

 

Oil ﬁlter
— element
on pump

on pressure switch .

 

 

 

on winning lamp
on meen
on dra'm plug...

 

 

 

 

 

Piston“
Pismn pin
Piswn ring
Primlry chum
Primary shaft

 
  
 
 

,R_

Rea! brake
Rear suepennan
Ru: {ark
Rear wheel
Regulate!
Relief vllv:
Rocker urn
—— shaft ..

 
 
 
 
 
 
 
 

~S—

Service air deanzr l
— buttery 4.

   
   
 
  
  
  

— spark plug
Special mall .V
Silicone rectiﬁer
Spaxk .dvnncer
Spuk plug .
Speciﬁcations ‘
Surﬁng chm:
Starts! mgneﬁc :wicdu
Starting mntm
Starting mote: safety unit

— able
Steering .
Stop switch

   

__ T—
Techniul data .

   

Throttle valve ..
Trmnble shouting
Transmissian“. l.

Valve
Vacuum gang
v.1ve timing .V

    

 

_ w _
Winku switch
Wiring diagram..."

 

 

 

 

174

18‘ INDEX

MEMO

Date of In”: July 20. 1977
© HONDA MOTOR CO. LTD.. 1977

 

h,

19. SUPPLEMENT TO CB500K3/CBS50K3 ("77)

 

imam...“

   

Engine No. CB550E—2000001 and subsequent
Frame N0. CBSSOK—ZOOOOOI and subsequent
Engine No. CB500E—2200001 and subsequent
Frame No. CB500—1000001 and subsequent

l. CABBURETOR

A. Removal and installation
1. Turn the fuel valve lever to the “OFF”
position smi disconnect the fuel tube at
the fuel valve and remove the over ﬂow
tube.
2‘ Open the seat and remove the fuel tank.
‘ Remove the air cleaner case.
. Remove the choke and throttle cables
from the cable holders and disconnect

pm

 

them from each shaft lever. Fig. [(34 (1) Choke cable
@ Throttle can“
@ Cable holders

5. Loosen the carburetor insulator bands and
the air cleaner connecting hands. Take
the carburetor assembly out

6. To install the carburetor assembly, re-
verse the removal procedure.

    

® Air cleaner cementing hand

Date of lame: July 20, 1977
© HONDA MOTOR CO. LTD” 1977

 

176 19. SUPPLEMENT TO CB 500 KS/CE 5511 K3 ('77)

 

B. Disassembly

Carburetor, throttle valve and jet needle:

1. Remove the oarhuremr assembly {mm
the engine

2. Remove the rear stays from the carbu-
retor assembly by remnving the four
bolts.

 

 

F . KH @ Boll
”w" . ‘ , 8. Unhook the throttle return spring from
’ ms shopper arm. Remove the stay plate
by removing the eight screws.
Unhook ﬂne choke relief spring at the
choke lever.

 

Mi
(3 Throttle return spring
(3 Screw Suy plate

 

4. Remove the carburetor top by removing
the two screws. Loosen the link arm
ﬁxing screw.
loosen the lock nut and remove the
throttle lever set screw.

 

    
    

, x W4
Fig. Ka-s (D Link arm ﬁxing screw
(9 Set screw @ Luck gm
5. Remove the choke valve from the choke
shaft by removing the two screws.
6. Separate the carburetors.

. K345 (D Screw ® Choke valve

Date of Issue: July 20, 1977
© HONDA MOTOR CO. LTD“ 1977

 

 

19. SUPPLWT T0 CB 500 KSICE 550 KS ('77) V7

7. Remove the link arm assembly from the
carburetor.

8‘ Remove the two screws and remove the
throttle valve and jet needle from the
link arm

Fig. K34 (3 Link arm
® Throttle valve

 

Float, mm et and slow jet:
1. Remove the carburetor assembly from

ﬁne engine.

2. Remove the Three screws and the ﬂoat
chamber body from the carburetor.

3, Remove the ﬂoat and ﬂoat valve by
pulling the ﬂoat arm pin out.

4 Remove the main jet and slow jet.

 

;.

Fig. KS—s @ rim arm pin (9 Main jet
0 Float (5) Slow jet
0 Float valve

0. Assembly

To assemble the carburetors reverse the dis-
assemhly procedure. Observe the following
notes:

1. Install the ﬂnrottle valve to the link arm
so that the throttle valve cutaway faces
the choke valve when it is installed in
the carburetor hody.

   

me

g, K 9 a) Throttle valve utnway

   

2. The link arm which is not equipped wiﬂn
the adjusting screw should he installed
in the No. 2 carburetor.

Link arm for o. 2 carburetor
Link arm for No. L 3 end 4 carburetor

 

Date of lsue: July 20, 1977
© HONDA MOTOR CO. LTD, 1977

   

 

175 19. SUPPLEMENT T0 CBSOOKS/CE 50 K3 ('77)

3‘ Install the choke shaft levexs and springs
as shown in Fig KSrll.

‘4. luslall the choke valve to the choke
shaft by using the lock washer and hex
head screWs. Bend the lock tabs to lock
the screws.

NOTE:

The choke valve securing screws are peenerl
when assembling the carburetor at the
factory. Discard the used screws.

 

 

Fig, K342 (D Choke mm D. Carburetor setting table

 

 

 

 

 

 

 

 

Elfiewiiiti Item 013550 K3 0135mm
Q) Hg: head mew Main jet #90 #90
Air jet #130 #120
Slow jet was $42
a Slow air jet #150 5:150
Jet needle 3rd. groove 2nd groove
setting E23491? E35OF
Float height 145mm 14,5mm
(0.57in.) (0.5753)
E. Adjustment
Idle speed:
Make the adjustment with the engine warmed
up‘ . .

1. Adjust"1:he idle amp screw to allow the
engine to run at the idle speed of 1050
rpm.

2. Turn the pilot screws either in or out
to obtain the highest idle speed. Usually
the correct setu'ng will be found to be
1‘]; turns open from a fully closed posi—

    

. lion.
Fig. K343 (x) Idle step screw 3‘ If. idle speed chafiges after adjusting the
[:9 Pilot screw pilot screw, readjust the idle shop screw.

Date of Issue: July 20. 1977
© HONDA MOTOR CD, LTD, 1977

   

 

 

19. SUPPLEMENT TO CB 5130 KE/CB 550 K8 (’77) 179

 

Synchronizing carburetors:

l. Rmove the fuel tank. Position ﬁne fuel
tank higher than the carburetors and re-
connect With a longer fuel tube.

2. Connect the vacuum gauge set to the
carburetors.

3. Run the engine at the speciﬁai idle speed
and read the vacuum. The vacuum
gauge readings should be the same on
all four gauges.

4. To adjust, proceed as follows:

3. Remove the carburetbr tops from the
No. l, 5 and 4 cal—Meters. .

h.Lousen the lock nut and turn the ad-
justing screw until the vacuum read-
ing is the same as the No. 2 carburetor
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 lamb in and turn the
adjusting screw in 2% turns
Fast choke idle speed: WOO—4000:1311:

 

2. SWITCH HOUSING

When installing the right or left switch hens»
ing, align the mating edges of the housing
with the punnh mark on the handlebar and
tighten the two screws securely.

The aligning mark on the brake lever
bracket holder should also be lined up with
the punch mark.

  

Fig. K341 5) un
® Swami huusi‘ng
@ Aligning mm on holder

 

Dlte of Issue: July 20, 1977
© HONDA MOTOR CO. LTD‘, 1977

       

180 18. SUPPLEMENT TO CB 500 KBICE 550 KS ('77)

3. SERVICE DATA

 

Standlrd vllne

Service limit

 

me shank nbsnrher spring he: length 4435mm (17,46

in)

4095.1“; (15.1mm)

 

Rear shock absnrbez spring Ire: lenglh

210.4mm (KZBIIL)

205 mm (am in)

 

Caliper cylinder 1D.

33.18-38.231-11111 (LEGS—1.505 in)

35.245 mm (1.506 in.)

 

Front brake
Caliper p'EtDn oiDi ,

 

 

SELLS—38.148 mm (1501—1502 in)

 

38.105 mm (1.500 in.)

 

 

4. SPECIFICATIONS (CBEOOK3/CB550K3 ’77)

 

 

 

 

 

 

 

 

 

 

 

 

mm Ty" ILS.A [Canada] 'Genexel end Australia Europe (CE 500) Frame:
DIMENSION

Overall Length 2,150“: (84.7in.) 2,160mmv 2,156mm

Overall Width 825mm (32,5ie.) . 750mm

Overall Height 1.115;“: (Mom) 1,1oomm

W'heel Ease IMEmm (555m)

Seat Height 300mm [31.5in.) I 825mm (32.5w

Gxuund Clearance 160mm (5.3m)

Dry Weight 193.5kg (426m) \ 156kg
FRAME

Type Double meme frame

 

P. Suspension. Tuvel

Telesmpic fork, travel 121mm (43in)

 

R. Seepeeeien. vael

Swing arm, mvel 90.0mm (as in.)

 

F. Tin Size, Type

3.25S194PR Rib, sire air pressure l.75[2,Dkg/cm' (wzspei)

 

R. Tire Size. Type

mam-APR Block, tit: 55: pressure 2,0 /2.5kg/un’ (as/says)

 

Elk-Ike

Disc Brake

 

R. Brake

Internal expanding shoe

 

Fuel Capacity

16.01it. (e2 used, 3.51mp.gel)

 

Fuel sterve Capacity

4.0 In. (LDUSigal. OiEImngL)

 

 

 

seize: Angls 54'

Teen Length 104mm (4,1ie.)
ENGINE -

Typ: Air-maxed d-struke. O.H.C. engine

 

Cylinder AImngcmanr

4 eylindez in line

 

Born and Smoke

53.5 Xﬁﬂrﬁmm (2.303 x 1.992iu.) (5543x5416 mm)

 

Displacement

544cc (amen-in) (493cc)

 

Cumpresiion Ruin

9:1

 

Carburetor, Venturi Die.

Fam- Pinon vulva type. vmturi din. 22mm (DJSSGIIL)

 

Valve Train

Cms‘drilaen oval-lead camshaft

 

Oil Capncity

3.2 lit. (3.411.841: 251ml. qt)

 

Lubrieerioe System

Faxcad pressure end we: sump

 

Fuel quuired

Low-lead geeeune with 91 octane number or higher

 

 

 

 

 

 

 

 

Air Filtrer Paper ﬁlter
lncnke Valve:
Opens 5“ BTDC
Closes 35" ABDC
Exhaust Valve:
Opens 35' BBDC
Closes 5' ATDC
Valve Tappet Clearanbe 1N: 0.05m EX: 0.08mru (IN: 0.002in, EX: 0.0mm.)
Pilot Smew Opening l ‘/::l:‘/x
Idle Speed 1050mm

 

Date of Issue: July an, 1977
© HONDA MOTOR co. LTD.. 1977

 

 

 

 

 

 

 

 

 

 

 

15. SUPPLEMENT TO CB 500 KSICB 550 KB (’77) 18]
‘ Item
DRIVE TRAIN

Clutch Wet multiqﬂm
Trunmission 5-Spead mutant mesh
Primary Reducthm 8.063
Gear Ratio 1 2.353

If L636

III 1.269

IV 1.035

V 0.9m

 

Final Redunﬁon

2.176, dxiva sprocket 171'. driven sprocket 371‘

 

Gear Shift Pattern

Left {out operated mum Imam

 

 

 

 

 

 

 

ELECTRICAL
Igniﬁon Battery and ignition coil
Igniﬁrm Advance:
"F" mark 5' BTDC
Max advnuﬁe ” 2§“—61° BTDC
£13? :33; m 1. zoo—2,500 rpm
Dwell Angle, 19015“
Starting System Suning more: nnd kick “me:
Alternator A.C. Generator 0.18kw/2.0001pm
Emery 12V—12AH
Spuk plug NGK D7135 m ND X22135 NGK DR7ES or
(NGK DR7ES or ND XZZESR-V) ND XZZESR—U

 

 

Candenser Capacity

 

 

0. 02-0. 24 [AF

 

 

Date nf I-ue: July 20, 1977

© HONDA MUI‘OR CO. LTD., 1977

 

>19. SUPPLEMENT T0 CE 50D KS/CB 550 K3 (’77)

182

 

51 wnuNG DIAGRAM

.A. Type and Canada Type)

CB550K3 ’77 (11.5

              

       

   
   

   

   

      

   
  

 

  

     
            

 

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5....“ . $5.2: EE...Em WEE A
$5.: 5.5: 55.. .m D
SEN—25:. saw—ﬁn , “5:5 55.. £139:— :25: 3 .1 N
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is is“ as: 5.: is :5: E: E: 55 :5 :25 e m
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555: .555 :

                                   

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SEEK. A

wwwwww .5: SEE
:Emsiiﬁz . :33: E
555 . 5.

5:35 E259.

.332: is
5:25: .255:

352"- :6:

5:355 .33“ x5:

EEEE .5:

— E5.

 

 

5.25s.
5: g:

  

p Egg: :5:

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g: :5

   

:52
55%

       

:8 SE:

Sag

      

as,”
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raise!"—
§=.=._§ E: S:

 

  

gum: (.5 (uni m2
E:— m— u
5» a...

E
ii “in 33%.. is

183

19. SUPPLEMENT TO CB 500 KBICB 550 K3 (’77)

 

CBSOOKB/CBEEUKS ’77 (Europe Type)

8 Elglecnoo

                          

ll. .51. is... 5.3.). 1 l‘ 3}.
Fl. 1|. ...I. sud as}. 11.
51.. (ST: .51“ ilk-9|: 1.2!:
11.. it. I.) «is: El. il-
ll. in); sin .1!- .....v. 3!...

3|. 1...; 1.3. I...- xil. Iii.

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Eﬁﬁhﬂﬁhﬁﬂ as? ea. 3:? .

arr-3:8.

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_
_
_
“lxr‘L

é... iii-EEK

Eﬁsflkf I

   

gamﬁﬁ :1. $2 a
h. i. 9.2..." A

§

© HONDA MOTOR CO. LTDN 1977

Data of Issue: July 20, 1977

 

,
,
k
ﬂ

HE:

19. SUPPLEMENT m casuoKS/casaoxs ('77)

CBSEDKB ’77 (General Type and Australia Type)

zigzag... :13
E: a I.
z! « .3

 

 

51...... 3...... 19.9...

                

 

 

            

 

Elfirﬁ. _.. ﬁﬁaﬂrﬁwﬁ: gm

5... ¢ 5.... .. .11....5Ei

 

S}... .E. _E.u&a=

.15...

l

.3... 2.3... ...... .. EH...

        

5....
x.

.

 

255.....Ei H.555... 3:313... $.13.

u. .. 3.3.5..
.2... .5.

   

             

. £11. . i... ... .1.» $1.... 3......E...
is 5.5 E u... 5...:

.55 1.5.2.... .3; E E
Eula“! ..

 

x. « talisu « s.

:3... ..i.... ..~ 2.}

© HONDA MOTOR CO. LTD.. 1977

Dne at Issue: July 20, 1577

 

. .i .1113...

M...“v..,...............

i 20. SUPPLEMENT T0 CB550F2 (’77)

 

“w"... ll.,.....y..........«W..."

 

.......,...‘......ll............~...m

 

Mutant...”

   

.,..,...,..,»....,WW"

Engine No. CBS50E—1135380 and subsequent
Frame No. CB550Fi2100001 and subsequent

l. CLUTCH

The clutch plate B© differs in construction
from the ﬁve other cluch plates B®.

Install the clutch plate 36) at the fourth
position as counted from the clutch center (D.

2. FUEL VALVE

The valve positions are indicated by the ex-
row on the lever.
Insgention and cleaning:

1. Place the fuel lever in the “ OFF ” posi-
tion and disconnect the fuel lines. Re-
move the fuel tank

2. Drain the fuel hank thoroughly.

3. Loosen the fuel valve ﬁxing nut and
remove 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 the ﬁlter
with a new one if it is clogged and not
cleanahle.

6, Install the fuel ﬁlter to the fuel valve
with the ﬁxing nut. Do not forget to
insmll the gasket into the groove of the
ﬁxing nut.

7. Install the fuel valve to the fuel tank
with the ﬁxing nut.

8. Install the fuel tank on the frame and
connect the fuel line: and secure with
the clip.

9. Fill the bank with fuel. With the fuel
valve lever in the “ ON " position, check
for any leakage past the tube joints or
connections.

Date of lune: July 20, 1977
© HONDA MOTOR CO. LTD. 1977

   

 

 

 

 

 

    
 
    

Fig. F2-1 (D Clutch ne r
9 Clutch fri ’on disk 13
9 Clutch pla B
Clutch friction disk
Clutch plate B eomp.
@ Clutch outer Damp.

F FZ—B 8 Fuel valve
Gasket
® Fuel ﬁller screen

   

186 20. SUPPLEMENT TO CE 550F2 (’77)

3. SIDE STAND (German Type)

Two springs are installed on the side stand.

      

L ’ Alt L a .
Fig. F274 (9 Side mud he! @46 mm iiolt
@ Spring @ Side mud
Rubber pad pivot halt
» . 4. ELECTRICAL SYSTEM

INSPECTION
(Except U.S.A. and Canadian Type)

1. Clutch switch

See Page 161.

2. Starting switch

Remove the fuel tank and the connector cover

by loosening The 6mm screw. Take the

starting switch terminal out of the oonnectoi:

Check the switch for continuity between the

Fig. FH (D Surﬁng switch " sircuits (O—O) shown in the table below.
® Black/red lead If there is continuity, the switch is in good

@ Black lead V .
@ Yellow/yea lad mdltlon

    
    

 

Terminal ST’I 5T2 HL

 

Wire color Black Yellow/red Black/red

 

 

FREE 0 O

 

 

 

 

“ PUSH O——O

 

 

 

3. Main switch

Place the switch key in OFF, ON or PARK
position and check the switch for continuity
between the circuits (O—O) ﬂnown in the
liable below. If there is no continuity m: if
there is continuity between circuits other
than those shown in the table, ﬂ’le switch is
defecﬁve.

 

Terminal BAT IG TL’l TLZ PA

 

Wire color Red Black Brown Blown/White Blown

 

@ Brawn lad

 

 

 

 

 

 

 

 

 

 

 

@ Brawn lead @ Red lead 0”
® Brawn/white lead @ Blank lead ON o——o o 0
PA 0 I, O

 

Date of Issue: July 20, 1977
© HONDA MOTOR CO. LTD., 1977

 

 

     

20. SUPPLEALENT TO CE 550 F2 [‘77)

 

4. Dimmer switch and turn sigmil
control switch

Remove the fuel tank, and the mnnector
covert Then take out the leads shown in the
table below. Check each switch for con-
tinuity between the circuits (O‘O) shown
in the table. If there is continuity, the
switch is in good condition If there is no
continuity, the switch is defective.

Terminal W B L R

wire color Green Brawyue 0'3”“ nghBtlue

L;
1-.

 

 

 

 

N ,
Rr
R:
Terminal HL Lo Hi
Wire color Black/Yellow White Blue
L 07—0
H C O

 

 

 

 

 

 

 

5. Horn switch and passing- switch
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 blank lead and the other
probe m the light green lead.

There should be continuity when the horn
button is pushed m
To test the passing switch, follow the same
instructions as for the hem switch.

 

    
     

W. m. m, l. , , r
Fig. F2—7 6) Turn signal warm] switch
Dimmer switch

  

Fig. FZ-S ® Brown lend Light blue lead

a) Brawn/blue lead @ Grunge lead
@ Black/yellow led Green lead
(9 White lead
@ Blue lend

@ Light green lead

 

 

 

 

Terminal [O HO Hi
Wire color Black Light green Blue
HORNLpush) o——o

l’A(push) c o

 

 

 

 

 

 

 

Date of Issue: July 20. 1577
© HONDA MOTOR 00. LTD‘, 1977

 

 

 

Fig. EH ® Horn and passing switch
@ Light guen lend

153 20. SUPPLEMENT TO CB 55032 (’77)

 

6. Engine stop swish

Remove the fuel tank and the connector
coverl Check the switch for continuity be-
tween the circuits (070) shown in the
table below If there is no continuity, the
switch is defective.

 

 

    
  

 

 

 

 

 

 

 

Terminal 1c RUN
Wire color Black Black/white
‘ OFF '
Fig. 172—111 ® Engine stop swatch RUN o———-o
© Blauklwhite lead
@ Blank lad OFF

 

7. Lighting switch

Remove the Fuel tank and the connector
cover Check the switch for continuity be-
tween the circuits (O—O) shown in the
table below. If there is no continuity, the
switch is defective.

 

Terminal IG P HL

 

Wire Colo! Black Blown/blue Black/red

 

   

 

 

 

 

 

 

 

{57 I
Fig. F241» gliting switch P 07—.0
(2) Brown/blue lead
Black/zed lend H o———o——-—o

 

5. BRAKE lNSPECTION

Replenishing Brake Fluid
Remove the reservoir cap, washer and dia-
phram, and whenever the level is lower than
the level mark engraved inside the reservoir
(Up to the line shown for semi-transyareut
reservoir), ﬁll the reservoir with DOT 3
BRAKE FLUID (or SAE 11703) up to the
level mark. Reinstall the diaphram and
washer, and tighten the reservoir cap se-
curely.

NOTE:

- Do not mix diﬁerent brands of brake ﬂuid
as chemical action will take place and may
cause brake trouble

~ Do not use any other ﬂuid in the brake
system

- Remove any brake ﬂuid which may become
spilled on the painted surface, rubber parts,
and meter as it will produce chemical ac-
tion and cause damage to these parts.

 

Date of Issue: July 20, 1977
© HONDA MOTOR OD. LTD, 1977

20. SUPPLEMENT TO (213550172 [‘77) 139

 

3. SPECIFICATIONS (CB 550F2 ’77)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1m“ “'1" [$351] Australia] General Fmss U.K. Eurap: Germany
DIMENSION 12' l

Overall Lﬂgth mmﬁn.) 2,115 (83.3) 105 [82.8)2,110 (BBJ 2,115 (54,8)

Overall Width 211511611.) 335 (323)

Overall Htight mmﬁnj 1,100 (43.3” 1,11! (43.7)

Whaal Base mm (in) 1,4D5 (55.3)

Seat Height man.) 305 (amt son (31.5)

Grand Clearance man.) 160( 5.3)

Dry Weight 151 kg (4211b) l 192 kg (4251a)
FRAME

Type Double cradle {mm

 

F. Suspension, Travel

Telaacnpic fork, Travel 121 mm (43in)

 

R. Suspension, vasl

Swing Arm, Travel 90mm (5.5in.)

 

F. Tire Sire, Type

3.25519-4PR Rib. the air prﬁsure 2.0 kg/cm’ (23 psi)

 

R. The Size, Type

315513-41211 Block. lire air pressure 25 kglcm‘ (aﬁpsi)

 

 

 

 

 

 

F. Brake Disc brake

R. Brake lmsmsl expanding shoe

Fuel Capacity mom. (4211.3. gal. 3.5Imp.gs1.)

Casts: Angl: 25°

Trail ngth 1115 mm (4.1an
ENGINE

Type Alr cooled d—atmke o.H.c. engins

 

Cylindu- Arrangcmunt

A cylinder in line

 

Burs and Stmke

58.5 X 50.6 nun (2.303 X 1.392 in.)

 

Displacm-nenl

544$

 

Cumprﬁinn Ratio

93:1

 

Carburatnr, Venturi Dia.

4 Pinon valve Type, Venturi Ala. 22 mm (OﬁseinJ

 

Vslvs Train
on Capacity

Chain driven uvar head ssmslsm
3.2 m. (3.4 Us qt. 21; Imp. qt)

 

Lnbn'catim Systm

Famed pressura and ws: sump

 

Fuel Required

Law-lend gasoline with 91 octane numbar or higher

 

 

 

 

 

 

 

 

 

 

 

 

Air Filtration Paper ﬁlter
Valve Tappet Clearance Ile 0.05 mm (@002 in) EX: 0.03 mm (0.0081'11.)
Air Screw Opening 1%
Idle Speed , 1,000 x.p.m.
DRIVE TRAIN

clnmls We! mam plate
Transmission 5-5peer1 canstam mash.
Primary Reductian 3,052
Gear Ratio I 2.353

n 11 1.685

s 111 1.269

'1 IV 1.036

~ v 0.900

 

Final Reductian

2.176 drive sprocket 17T, driven aprnckec 87T

 

Gaar Shift Panel-n

Left foot apﬂated remxn system

 

 

 

 

 

 

 

ELECTRICAL
Igniliml Battery and Ignitilm coil
Starting System Electric mum and kick pedal
Alternator A.c. Genuamr 0.1a kwmouo mm
Battery Capacity 12V—12AH
NG ms or N
313”“ PM? [NEZEKDDR'IBS orDNﬁEEESR—U]

 

 

Data of Issue: July 20, 1977

© HONDA MOTOR CO. LTD“ 1977

 

 

20. SUPPLEMENT TO CB 550 F2 ('77)

190

 

   

               

E: SE. .25 max:
5.55.:

.5395
E: 3.55:

  

5.5
“““ .55....- ___.=.sa: is!

 

                   

$2535
is $55;

5:3

  

 

E:- E: E:

E...
Eu: 5
is:
:3
an. i:
Smas—
i. £55 in a:

ﬁg
5.552 5::

5.5: E. 55:.

(USA. Type and Canada Type)

«x5582 5: ES: ESE:

5. IS

          

swungﬁasiﬁ §£§_§EE.§§E§E

4. WIRING DIAGRAM CB 550F2 ’77

553% 5.55:: E: in: 3:5 .

Date of Issue: July 20, 1977

© HONDA MOTOR CO. LTD, 1977

 

19]

20‘ SUPPLEMENT T0 CB 550 F2 (’17)

 

(GENERAL TYPE)

$.38

5.:
Eggs!

 
       

.Eaessﬁgis

§_ :3 S35: Elsi

is :5 435.35

© HONDA MOTOR CO. LTD" 1977

Date uf Issue: July 20. 1977

20. SUPPLEMENT To CB 550 F2 ('77)
(UK. EUROPEAN TYPE)

 

192

Naeooéanomoa

              

35. an: ESE . . .V

Is. 5. an“ :2 3:

£5.15 55575
in; .51...

Si... .555

IE§§I:E:

© HONDA MOTOR CO. LTD” 1977

Date of Issue: July 20, 197']

 

193

20. SUPPLEMENT TO 013550 F2 ('71)
(FRENCH TYPE)

 

Evian:

 

 

 

 

         

 

 

 

 

 

 

 

 

 

    

5.x... Eazsé

 

 

._.:

 

EE ES. :53.
Ea. .3525 u. snai- 55.5...

5%

               

IE. “is up... .553 a :3

Eaggﬁ gigging“;

a:
I;

”Engage!

§
5.3.3 :33...
3.. 8555 a s5;

55 EB 5.355 an!

Date of Issue: July 20, 1977
© HONDA MOTOR CO. LTD.. 1977

 

20. SUPPLEMENT TO OBSSD F2 ('77)

I94

 

(GERMANY TYPE)

Eai‘ams

                      

:3: EE—

.Eaaééiﬁﬁln

iii: 3: =55.

  

r‘\\\¥!. irilll“>
E.
SEE

95
ﬁgs:

   

ES.

5.33

in.

is as “5355::
SE.

            

EN. Egg
SE
5455:!

Is: :5! 5.! 3...... .EsmEQN 259.
5:55!
a. 5:35;

ggﬁiiiiu

 

© HONDA MOTOR CO. LTD” 1977

Date uf Issue: July 20, 1977