Honda 1982 CBX550 Four Manuals

Manuals and User Guides for Honda 1982 CBX550 Four. We have 1 Honda 1982 CBX550 Four manual available for free PDF download: Owners Workshop Manual

Honda 1982 CBX550 Four Owners Workshop Manual (135 pages)

Brand: Honda | Category: Motorcycle | Size: 50.46 MB

Contents
4
Introduction
7
Model Dimensions and Weights
7
Ordering Spare Parts
8
Safety
9
Asbestos
9
Fire
9
Fumes
9
Tools and Working Facilities
10
Maintenance and Minor Repair Tool Kit
11
Repair and Overhaul Toolkit
11
Specialized Tools
11
Care and Maintenance of Tools
11
Spanner Size Comparison
12
Standard Torque Settings
12
Choosing and Fitting Accessories
13
Luggage Racks or Carriers
14
Luggage
14
Handlebars
14
Crashbars
15
Exhaust Systems
15
Electrical Equipment
15
Accessories - General
15
Faults Diagnosis
16
Starter Motor Problems
17
Engine Does Not Start When Turned over
17
Starter Motor Not Rotating
17
Starter Motor Rotates but Engine Does Not Turn over
17
Engine Stalls after Starting
18
Weak Spark at Plug
18
Compression Low
18
General Causes
18
Acceleration Poor
19
Poor Running or Lack of Power at High Speeds
19
Knocking or Pinking
19
Overheating
19
Gear Selection Problems
20
Abnormal Engine Noise
20
Clutch Drag
20
Gear Lever Does Not Return
20
Abnormal Transmission Noise
21
Exhaust Smokes Excessively
21
Valve Noise or Tapping from the Cylinder Head
21
Transmission Noise
21
Oil Pressure Indicator Lamp Goes on
22
Poor Handling or Roadholding
22
Engine Lubrication System Failure
22
Electrical System Failure
22
Abnormal Frame and Suspension Noise
23
Brake Problems
23
Brake Drag
23
Disc Brake Noise
23
Electrical Problems
24
Battery Dead or Weak
24
Battery Overcharged
24
Total Electrical Failure
24
Check List
25
Adjustment Data
25
Recommended Lubricants
25
Routine Maintenance
26
Tyres
26
Tyre Pressures
26
Engine Oil
27
Electrical System
27
Brake Fluid
27
Final Drive Chain: Lubrication and Adjustment
29
Safety Check
29
Engine Oil: Changing
30
Carburetors and Fuel System: Checking and Adjustment
30
Air Filter Element: Cleaning
30
Crankcase Breather: Draining
30
Spark Plugs: Cleaning and Adjustment
31
Valve Clearances: Adjustment
31
Oil Filter: Renewal
32
Braking System: Inspection and Pad Renewal
32
Clutch: Adjustment
33
Checking the Electrical System
34
Checking and Lubricating the Stands
34
Checking the Suspension and Steering
34
Checking the Wheels
34
Engine, Clutch and Gearbox
35
General Description
38
Operations with the Engine/Gearbox Unit in the Frame
38
Removing the Engine/Gearbox Unit
38
Dismantling the Engine/Gearbox Unit
38
Cylinder Head
39
Dismantling the Engine/Gearbox Unit: Removing the Cylinder Block and Pistons
40
Dismantling the Engine/Gearbox Unit: Removing the Alternator
40
Dismantling the Engine/Gearbox Unit: Removing the Starter Drive, Starter Motor and Ignition Pick up Assembly
40
Dismantling the Engine/Gearbox Unit: Removing the Clutch
40
Dismantling the Engine/Gearbox Unit: Removing the External Gearchange Components
41
Dismantling the Engine/Gearbox Unit: Separating the Crankcase Halves
41
Examination and Renovation: General
41
Examination and Renovation: Crankshaft, Big End and Main Bearings and Connecting Rods
42
Crankshaft
43
Camshafts and Rocker Arms
46
Examination and Renovation: Starter Drive and Clutch
48
Examination and Renovation: Clutch Assembly
49
Examination and Renovation: Gearbox Components
49
Engine Reassembly: General Preparation
52
Engine Reassembly: Refitting the Crankcase Components
52
Gearbox Components
59
Gearchange Mechanism
60
Engine Reassembly: Joining the Crankcase Halves
61
Refitting the Alternator and Selector Mechanism Cover
61
Engine Reassembly: Refitting the Clutch
63
Refitting the Ignition Pick-Up Assembly and Starter Drive
65
Installing the Pistons and Cylinder Block
67
Camshaft Installation and Valve Timing
69
Fuel System and Lubrication
78
Fuel Tank: Removal and Replacement
79
Fuel Tap: Removal, Overhaul and Reassembly
80
Fuel and Vacuum Pipes: Examination
80
Carburetors: Removal and Installation
80
Carburetors: Dismantling, Overhaul and Reassembly
81
Carburetors
83
Measuring the Float Height
83
Carburetors: Separation
84
Carburetor Linkages
84
Carburetors: Synchronisation
85
Carburetors: Adjustments
85
Exhaust System
85
Air Filter
85
Engine Lubrication
86
Oil Pump: Dismantling, Examination and Reassembly
86
Oil Filter
87
Oil Cooler
87
Ignition System
88
Electronic Ignition System: Testing
89
Ignition and Kill Switches: Tasting
89
Wiring and Connection Test
89
Spark Test
89
Ignition Coils: Testing
90
Pulser Coils: Testing
90
Spark Unit: General
90
Ignition Timing: General
90
Frame and Forks
91
Front Yokes and Steering Head Bearings: Removal and Replacement
93
Front Forks Legs
94
Front Forks
96
Anti-Drive Mechanism
97
Frame
97
Rear Suspension Assembly
98
Rear Suspension Unit
102
Stands
103
Footrests
103
Fairing
103
Wheels, Brakes and Tyres
104
Wheels
105
Front Wheel
105
Front Wheel Bearings: Renewal
107
Rear Wheel
107
Rear Wheel Bearings
107
Brake Disc and Caliper
109
Front Brake Master Cylinder
113
Rear Brake Master Cylinder
114
Bleeding the Hydraulic Brake System
115
Wheel Balancing
115
Tubeless Tyres
115
Brake Pads
115
Puncture Repair and Tyre Renewal
116
Tyre Valves
117
Testing the Electrical System
119
Charging System
119
Regulator/Rectifier Unit
120
Starter Motor
120
Battery
120
Starter System
120
Headlamp
122
Turn Signal and Tail/Brake Lamps
122
Instrument Panel
124
Horn
124
Flash Unit
124
Ignition Switch
124
Handlebar Switches
125
Neutral Switch
125
Switch Testing Procedure
125
Clutch Interlock Switch
125
Wiring Diagram
128
Metric Conversion Tables
129
Conversion Factors
130
Index
131

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Honda 1982 CBX550 Four Owners Workshop Manual (135 pages)

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