Table Of Contents - Honda 1982 CBX550 Four Owners Workshop Manual

Table of Contents

Contents4
Introduction7
Model Dimensions And Weights7
Ordering Spare Parts8
Safety9
Asbestos9
Fire9
Fumes9
Tools And Working Facilities10
Maintenance And Minor Repair Tool Kit11
Repair And Overhaul Toolkit11
Specialized Tools11
Care And Maintenance Of Tools11
Spanner Size Comparison12
Standard Torque Settings12
Choosing And Fitting Accessories13
Luggage Racks Or Carriers14
Luggage14
Handlebars14
Crashbars15
Exhaust Systems15
Electrical Equipment15
Accessories - General15
Faults Diagnosis16
Starter Motor Problems17
Engine Does Not Start When Turned Over17
Starter Motor Not Rotating17
Starter Motor Rotates But Engine Does Not Turn Over17
Engine Stalls After Starting18
Weak Spark At Plug18
Compression Low18
General Causes18
Acceleration Poor19
Poor Running Or Lack Of Power At High Speeds19
Knocking Or Pinking19
Overheating19
Gear Selection Problems20
Abnormal Engine Noise20
Clutch Drag20
Gear Lever Does Not Return20
Abnormal Transmission Noise21
Exhaust Smokes Excessively21
Valve Noise Or Tapping From The Cylinder Head21
Transmission Noise21
Oil Pressure Indicator Lamp Goes On22
Poor Handling Or Roadholding22
Engine Lubrication System Failure22
Electrical System Failure22
Abnormal Frame And Suspension Noise23
Brake Problems23
Brake Drag23
Disc Brake Noise23
Electrical Problems24
Battery Dead Or Weak24
Battery Overcharged24
Total Electrical Failure24
Check List25
Adjustment Data25
Recommended Lubricants25
Routine Maintenance26
Tyres26
Tyre Pressures26
Engine Oil27
Electrical System27
Brake Fluid27
Final Drive Chain: Lubrication And Adjustment29
Safety Check29
Engine Oil: Changing30
Carburetors And Fuel System: Checking And Adjustment30
Air Filter Element: Cleaning30
Crankcase Breather: Draining30
Spark Plugs: Cleaning And Adjustment31
Valve Clearances: Adjustment31
Oil Filter: Renewal32
Braking System: Inspection And Pad Renewal32
Clutch: Adjustment33
Checking The Electrical System34
Checking And Lubricating The Stands34
Checking The Suspension And Steering34
Checking The Wheels34
Engine, Clutch And Gearbox35
General Description38
Operations With The Engine/Gearbox Unit In The Frame38
Removing The Engine/Gearbox Unit38
Dismantling The Engine/Gearbox Unit38
Cylinder Head39
Dismantling The Engine/Gearbox Unit: Removing The Cylinder Block And Pistons40
Dismantling The Engine/Gearbox Unit: Removing The Alternator40
Dismantling The Engine/Gearbox Unit: Removing The Starter Drive, Starter Motor And Ignition Pick Up Assembly40
Dismantling The Engine/Gearbox Unit: Removing The Clutch40
Dismantling The Engine/Gearbox Unit: Removing The External Gearchange Components41
Dismantling The Engine/Gearbox Unit: Separating The Crankcase Halves41
Examination And Renovation: General41
Examination And Renovation: Crankshaft, Big End And Main Bearings And Connecting Rods42
Crankshaft43
Camshafts And Rocker Arms46
Examination And Renovation: Starter Drive And Clutch48
Examination And Renovation: Clutch Assembly49
Examination And Renovation: Gearbox Components49
Engine Reassembly: General Preparation52
Engine Reassembly: Refitting The Crankcase Components52
Gearbox Components59
Gearchange Mechanism60
Engine Reassembly: Joining The Crankcase Halves61
Refitting The Alternator And Selector Mechanism Cover61
Engine Reassembly: Refitting The Clutch63
Refitting The Ignition Pick-Up Assembly And Starter Drive65
Installing The Pistons And Cylinder Block67
Camshaft Installation And Valve Timing69
Fuel System And Lubrication78
Fuel Tank: Removal And Replacement79
Fuel Tap: Removal, Overhaul And Reassembly80
Fuel And Vacuum Pipes: Examination80
Carburetors: Removal And Installation80
Carburetors: Dismantling, Overhaul And Reassembly81
Carburetors83
Measuring The Float Height83
Carburetors: Separation84
Carburetor Linkages84
Carburetors: Synchronisation85
Carburetors: Adjustments85
Exhaust System85
Air Filter85
Engine Lubrication86
Oil Pump: Dismantling, Examination And Reassembly86
Oil Filter87
Oil Cooler87
Ignition System88
Electronic Ignition System: Testing89
Ignition And Kill Switches: Tasting89
Wiring And Connection Test89
Spark Test89
Ignition Coils: Testing90
Pulser Coils: Testing90
Spark Unit: General90
Ignition Timing: General90
Frame And Forks91
Front Yokes And Steering Head Bearings: Removal And Replacement93
Front Forks Legs94
Front Forks96
Anti-Drive Mechanism97
Frame97
Rear Suspension Assembly98
Rear Suspension Unit102
Stands103
Footrests103
Fairing103
Wheels, Brakes And Tyres104
Wheels105
Front Wheel105
Front Wheel Bearings: Renewal107
Rear Wheel107
Rear Wheel Bearings107
Brake Disc And Caliper109
Front Brake Master Cylinder113
Rear Brake Master Cylinder114
Bleeding The Hydraulic Brake System115
Wheel Balancing115
Tubeless Tyres115
Brake Pads115
Puncture Repair And Tyre Renewal116
Tyre Valves117
Testing The Electrical System119
Charging System119
Regulator/Rectifier Unit120
Starter Motor120
Battery120
Starter System120
Headlamp122
Turn Signal And Tail/Brake Lamps122
Instrument Panel124
Horn124
Flash Unit124
Ignition Switch124
Handlebar Switches125
Neutral Switch125
Switch Testing Procedure125
Clutch Interlock Switch125
Wiring Diagram128
Metric Conversion Tables129
Conversion Factors130
Index131