Honda CB500 Service and Repair Manual.pdf

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HAYNES SERVICE
&
REPAIR MANUAL
CB5DD TWin
'93
to
'01
"Haynes Manuals just cannot be beaten"
Molor Cycle News
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-
-
•
Performance data
.
Model
history
.
Wiring diagrams
•
Tools and workshop lips
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IN FULL COLOUR
,
•
•
,
Honda CB500
Service and Repair Manual
by Phil Mather
Models covered
CBSOO. 499cc. 1993 to 2001
CBSOOS. 499cc.
1998
to
2001
(3753-256-4AD1)
•
,
I
•
•
,
o
Ha)'llM
Publishing 2004
PrInted in
USA
Hayne. Publishing
Spat1<ford, Yeovil, Somerset BA22 7
JJ,
England
All ri9htl ,allMWd.
No
part of thl, book may 1M reproduced or transmitted
in
any
loon
or by any means,
e
leetronle
or meehanlcal, Including photo-
copying,
racordlng
or by any Informallon
Itor8g8
or
r.tri
....al
sys
tem
,
without
permlMlon
In
wrttlng
from
the
copyright
holder.
Haynes North America, Inc
861 Lawrence Drive, Newbury Park,
California 91320,
USA
Editions Haynes
4. Rue
de
l'Abreuvoif
ISBN
I
85IIIJO
753 5
92415
COURBEVOIE
CEDEX. France
Haynes PubJishing Nonliska AB
Box 1504,
751
45 UPPSAlA,
Sweden
8ritIth
Ulnory Cataloguing
In
Publication
Oat.
A
catalogue record
lor
!his
book is ....allable
II'Om
the
Bf1'tIsh
Ubray
-
Contents
LIVING WITH YOUR HONDA CB
Introduction
The Birth of a Dream
Acknowledgements
About this manual
-
Page
Page
Page
Page
Identification
numbers
Buying spare parts
Performance data and Bike spec
Safety Firstl
Page
Page
0-10
Page
0-12
0"
0'8
0'8
0·.
0'.
Daily (pre-ride) checks
EnglneJtransmisslon oil level check
Brake fluid level checks
Tyre checks
Page
0-1
3
Page
0-14
Coolant
level
check
Suspension,
steering
and
final drive checks
Page
0-15
Page
0-1
6
Page
0-16
Page
0-16
Legal and safety checks
MAINTENANCE
Routine maintenance and servicing
Specifications
Recommended lubricants
and
fluids
Page
Page
Page
1"
Maintenance
schedule
Component
locations
Maintenance procedures
"3
1"
1'6
'"
Page
Page
Contents
REPAIRS AND OVERHAUL
Engine, transmission and associated systems
Engine, clutch and
transmission
Cooling system
Fuel and exhaust systems
Ignition system
Chassis and bodywork components
Frame and suspension
Final
drive
Brakes
Wheels
Page
Page
Page
6-15
6·'
Page
7·'
7-15
9·'
Tyres
Fairing and bodywork
Page
7'21
Page
..
,
Electrical system
Wiring diagrams
Page
Page
9-23
REFERENCE
Tools
and Workshop Tips
Page
REF-2
Security
Lubricants and
fluids
Conversion
Factors
MOT
test
checks
Page
REF·20
Page
REF·23
Page
REF-26
Page
REF-27
Page
Page
REF-32
REF-3S
Storage
Fault finding
Fault finding equipment
Technical
terms explained
Page
REF-45
Page
Page
REF-49
Index
REF-53
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0· 4
Introduction
The Birth of a
by Julian Ryder
started manufacturing his own engine,
known
as the 'chimney', either because of the
elongated cylinder head or the smoky
exhaust or perhaps both. The chimney made
all of half a horsepower from Its 50 cc engine
but It was a major success and became
the
Honda A-type.
Less than two years after he'd set up In
Hamamatsu, Solchiro Honda founded the
Honda Motor Company In September 1948.
8y then, the A-type had
been
developed into
the 90 cc 8-type engine, which Mr Honda
decided deserved its own chassis not a
bicycle frame, Honda was about to become
Japan's fIrst post-war manufacturer of
complete motorcycles. In August 1949 the
first prototype was ready, With an output of
three horsepow8f, the 96 cc D-type was still a
simple two-stroke but It had a two-speed
transmission and most Importantly a
pressed
steel frame with telescopic forks and hard tail
rear end. The frame was almost triangular In
profile With
the
top rail gOing In a straight line
from the maSSively braced staenng head to
the rear axle. legend has it that after the
D-type's first tests the entire workforce went
for a drink to celebrate and
try
and
think of a
name for the bike. One man broke one of
those silences you get when people are
thinking, exclaiming
'This
IS
like a dream!'
'That's
it!'
shouted
Honda,
and
so
the
Honda
Dream was chnstened
T
here (s no better example of the
Japanese post-war Industrial miracle
than Honda. Like otnar compames which
have become
household
1'l8me8,
~
started with
one man's vision. In this case the man was the
4().year old SoIchiro Honda who had
sold
his
Piston-ring manufacturing buSIness to Toyota
in 1945 and was happily spending the
proceeds
on
prolonged
parties
for his mends.
However, the difficulties of getting around In
the chaos of post-war Japan lr'Ked Honda, so
when he came across a Job lot 01 generator
engines he realised that here was a way of
getting people mobile again allow cost.
A 12 by 18-fool shack In Hamamatsu
became his first bike factory, flttmg the
generator motors Into pushblkes. Before
long
he'd used up all 500 gen8fator motors and
'This is like a dream!'
'That's it'
shouted Honda
r Honda was a brilliant, intuitive
engIneer and designer but he did not
bother himself With the marketing side
01 his business. With hindsight.
it
is possible
to see that employing Takeo Fujlsawa who
would both
sort
out the
home
market and plan
the eventual expansion into overseas markets
was a masterstroke. He arrived in October
1949 and
In
1950 was made Sales Director.
Anothar vital new name was Kiyoshl
Kawashima. who along With Honda himself,
designed
the
company's first four-stroke after
Kawashima had
told
them
that
the four-stroke
Opposition to Honda's two-strokes sounded
nicer and therefore sold better.
The
result of
that statement was the overhead-valve 148 cc
E-type which first ran
In
July 1951 just two
monlhs aft8f the first drawings were made.
Kawashima was made a director of
the
Honda
Company at 34 years old.
The E-type was a massive success, over
32,000 were made In 1953 alone, a feat of
mass-production that was astounding by the
M
Honda C70 and COO OHV- engined models

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