STEP -3 Kemove bolt securing

master cylinder to front shipping

brace.
CAUTION:
Do not operate front brake lever
until front wheel is installed.
MODEL CB500T HONDA

STEP -7 Unpack remaining loose parts and check against this iJ]ustration.
HONDA MODEL CB500T

Punch Marks

STEP -11 Position upper holders

on handlebar with punch marks
on holders facing forward.
Attach each holder loosely at rear,
using 8 x 36 flange bolts.

Hole

Index

STEP -15 Reassemb]e switch

assembly by aligning index
pin with hole in handlebar.
Reinstal] and tighten two screws
securing assembly together.
Check if grip rotates freely.
MODEL CB500T HONDA
HONDA MODEL CB500T

STEP -23 InstaJl speedometer/I

tachometer mount using two 8mmI
plain washers, lock washers and

nuts. Tighten securely.

 MODEL CB500T. HONDA

~
-~-
Headlight
Socket
Headl ight

Turn Signal

STEP -29 Install each turo signal STEP -31 Install headlight socket
using 6mm bolt, two plaiD washers to head1ight assembly as shown.
and fiuto Hold turo signal wires
with fork upper case clamper, then
route into headlight case.

STEP -32 lnstall headIight using

three screws.

25 Hex Bolts
Hex Bolts
6 x

STEP -36 Insert front fender

between front fork legs from the
STEP -35 Remove two 6 x 25 rear. STEP -37 lnstall another fender
hex bol ts and washers securing Install front fender bracket to left bracket to right fork legsand fender
brake caliper mount. fork leg using two 6 x 25 hex braces to bolli fork legs using four
bolts and washers removed in 6 x 16 hex bolts. Tighten alI
STEP-35 above through caliper bolts securely.
mount.

.
~

1 HONDA
STEP -39 Route taillight wires
through rear grommet of rear
fender, wire tunnel under fender
and through front grommet as
Ishown.
STEP -44 Temporarily install STEP -45 Temporariiy tighten
rear pipe to frame using 8 x 45 6 x 28 bolts and 6 x 20 bolts,
bolts. then retighten ali bolts loosely
tigh tened to specified torque.
I!
cf
MODEL CB500T
STEP -40 Pull out taillight wires
from under part A. Route taillight
wii"esand turo signal wires to main
hamess at connector cover and
connect, color to coloroI
Cover connections with connector
cover.
I Sl'EP -43 As shown set rear
pipe and taillight and put in taillight
mount collars.
STEP -46 Hook wide end of foot
peg return spring over foot peg
and narrow end over step bar as
shown. (Right foot peg shown,
left peg similar.)I
 f
MODEL CB500T HONDA

STEP -47 Insert clevis pin and

STEP -48 Thorough1Y clean front STEP -49 Remove and discard
secure with plain washer and cotter
brake disc using good quality vinyl dust seal.
pino
degreasing agent. Wipe with a
Spread cotter pin ends as shown.
clean cloth.
(Right foot peg shown, left peg
similar.)

STEP -50 Install speedometer STEP -51 Insert front ax1e from STEP -52 Install axle collar onto
gearbox, making sure lugs afe speedometer gearbox side. axle and into front wheel oil selli.
aligned with slots in retainer.

ò3 I ~F' -;J;J;:)crap~ ulr alI pr~-servative

and residue from eachbrake

STEP -54 Kemove separator "y
rado Reinstall inside brakepad
removing strapo Remove two hex
and tighten to specified torque.
bolts securing inside brake parlo
Torque specification: 300-
Remove brake parlo
400kg-cm
(260- 345Ibs-in)
 HONDA MODEL CB500T

STEP -56 InstaIl front wheel

between fork legs being careful

to fit brake disc between brakeI
pads.

: STEP -59 Route speedometer

STEP -58 Route speedometer STEP -60 Insert brake hose
cable through speedometer gear-
cable through fender grommet and grommet into brake hose clip and
box by aligning slot in cable with
cable guide. squeeze clip to hold grommet.
bIade of speedometer gearbox.
Secure cable by screwing 5 x 16
screw in gearbox.

: STEP -61 Lift fuel tank rear

cushion, then lift the front of
tank as shown.

I
 ij
MODEL CB500T HONDA

STEP -64 Connect handlebar STEP -65 Route wires into wire
switch wires to wire harness. harness case, then install harness
cover.

ST.EP -69 Service battery as

described in shop manual or battery
preparation book1et packed with
STEP -67 Remove right side battery. Connect battery vent tube.
cover. InstaII battery with terminaIs facing
right side. Connect positive termi-
naI first, then connect negative
terminaI.

II:~ -l:l lnstaJl seat usmg hmge

pino
Insert lock pin through hoie in
hinge pino

-
:)
HONDA MODEL CB500T

STEP -73 fustall gearshift pedal STEP -74 lnstall kick starter
rubber. pedal rubber with letters up.

STEP -77 Replace the drain plug
and till the crankcase with oil as
described in the owner's manual
or the shop manual.
STEP -78 AdJust cam cham
tensioner by loosening lock nut
and tensioner bolt, as described
in the owner's manual or the shop
manual.

STEP -80 Lhecl<.pomt gap.

STEP -79 (';heck tappet clearance.
lntake: U.UJmm ~U.W12 In). Adjust, points, if necessary, as
Adjust tappets, if necessary,
Exhaust: 0.03mm (0.0012 in). described in owner's manual or
as described in owner's manual or
"LT" TDC left cylinder shop manual.
shop manual.
Reinstall cylinder head covers and "T" TDC right cylinder Point gap: 0.3 -0.4mm
point cover. (0.012 -0.016 in)
 ,/3

MODEL CB500T HONDA

STEP -81 Usìng a stroboscopìc

timing !ight, check ignition timing
at idle and at fu!! advance. STEP -82 Adjust and synchronize
Adjust timing, if necessary, as the carburetors using the vacuum
described in owner's rnanual or gauge sei as described in the shop
shop manual. manual.
Reinstal! point and generator
covers.

:) I EP -84 AdJust and lubncateI

drive chain as described in theI
owner's manual or the shop manual.
HONDA MODEL CB550F
NOTE: Check alI items listed on the
following Pre-delivery Service Check
List. Always test ride the unit to make
sure that it'is functioning properly.
 /;:;-
?"-

MODEL CB 500T

PARTS PACKAGE CONTENTS

The following is a list of iterns contained in the p~ckage carton packed behind the front
forks:

DESCRIPTION PART NUMBER

Battery 31500-292-670
Headlight 33100-375-003
Collar (3 reqd) headIight 61304-292-000
Washer,lock 5mm (3 reqd) headlight 94111-05000
Screw, pro 5 x 16 (3 reqd) headlight 93500-05016
Socket, headlight cord 33130-323-003

Rear Pipe 50400-3

Bolt, hex 8 x 45 (2 reqd) rear pipe 93000-0
Grommet, wire cord (l reqd) rear fender 32983-011-000602823-70075-00002030
Bolt, hex 6 x 28 (4 reqd) taillight & turnsignals 92000-0
Washer,6.5 x 18 (2 reqd) taillight 90545-3
Collar, number plate bracket (2 reqd) taillight 84706-3
Bolt, hex 6 x 20 (2 reqd) taillight 92000-6
WasherB, handle holder set (2 reqd) taillight 90525-0

Bolt, front tum signal (2 reqd) tum signals 90129-375-000

Washer,plain 6mm (4 reqd) tum signals 94101-06000
Nut, hex 6mm (2 reqd) tum signals 94001-06000

Speedometergearbox 44800-323-000
Screw, ova15 x 16 (1 reqd) speedometergearbox 93000-05016

Front wheel axle 44301-300-000

Front wheel collar 44311-300-000
Front axle nut 90305-300-000

Front axle holder (2 reqd) 95014-41000

Washer,plain 8mm (4 reqd) axle holders 94101-08000
Washer,lock 8mm (4 reqd) axle holders 94111-08000
Nut, hex 8mm (4 reqd) axle holders 94030-08000

Holder, handle upper (2 reqd) handlebar 95014-22200

Bolt, flange 8 x 36 (4 reqd) handlebar 90111-362-000

Master cylinder holder 45517-300-003

Bolt, hex 6 x 25 (2 reqd) master cylinder holder 92000-06020
Washer,plain 6mm (2 reqd) master cylinder holder 94101-06000

Foot peg, right

75-0008045
 .../6

MODEL CB-500T

PARTS PACKAGE CONTENTS (Continued)

DESCRIPTIDN PART NUMBER

Foot peg, right

Foot peg return spring, right (1 reqd) 50617-283-000
Foot pegclevis pin (1 reqd) 50603-033-000
Washer,plain 8mm (1 reqd) 94101-08000
Cotter pin 1.6 x 15mm(1 reqd) 94201-16150

Washer,lock 8mm (2 reqd) speedometer/tachometer 94111-08000

Washer,plain 8mm (2 reqd) speedometer/tachometer 94101-08000
Nut, hex 8mm (2 reqd) speedometer/tachometer 94001-08000

Seathinge pin (1 reqd) seat 77103-369-000

LOCKpin, 6mm (1 reqd) seat 94251-06000

Screw, pan, 6 x l2mm (1 reqd) combination pilot 93500-06012

Washer,lock 6mm (1 reqd) combination pilot 94111-06000

Bolt, hex 6 x 16 (4 reqd) front fender 92000-06016

Washer,plain 6mm (4 reqd) front fender 94101-06000

Rear view mirror, right 88100-333-004

Rear view mirror, left 88120-333-004
Disk cover 45140-333-000
Owner's manual CB500T 3237501
Pedal, rubber change 95011-40000
Rubber, kick starter 28311-329-000
Battery cover 31532-369-000
Battery band (l reqd) battery cover 95014-13000
Tool kit: 89010-375-000
Toolbag 99008-02000
8 x 12mm open end wrench 99001-08120
IO x 14mm open end wrench 99001-10140
17 x 19mm open end wrench 99001-17190
Pliers 99002-13500
Screwdriver, crosshead#2 99003-10000
Screwdriver, crosshead#3 99003-20000
Screwdriver, slot #2 99003-30000
Screwdriver"T" handle 99003-40000
Screwdriverhandle 99003-50000
Spark plug wrench 99004-21001
Box wrench handle 99006-12000
26mm box wrench 99006-26000
45mm pin wrench 99007-45000
 ~

MODEL CB-500T

PARTS PACKAGE CONTENTS (Continued)

The following is a list of iterns in the parts package carton located by the rear wheel:

DESCRIPTION PART NUMBER

Speedometer(Mile) (37200-375-671 )
Speedometer(Km) (37200-375-681 )
Tachometer (37250-375-008)
Speedometer/tachometermount 37211-375-008
Combination pilot 37600-375-008
Front tum signal, right 33600-306-670
Front tum signal, left 36650-306-670

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