CB650SC Manual Cyclepedia - 620 Pag

9/23/2010 Honda CB550SC/CB650SC Online Repair …
Honda CB550SC and CB650SC Repair Manual

Periodic Maintenance > Periodic Maintenance Chart
Periodic Maintenance Chart
Periodic Maintenance
Periodic maintenance is required to keep the motorcycle safe and

performing properly. For motorcycles with operation time greater than
2,400 miles (24 months), repeat the frequency intervals indicated by the
chart.
I = Inspect, clean, lubricate and adjust as necessary

R = Replace
T = Tighten
* = Maintenance item specifically for the 1984 CB650SC
km 1,000 6,000 12,800 19,200 25,600 32,000 38,400

Item miles 600 4,000 8,000 12,000 16,000 20,000 24,000
months 1 6 12 18 24
Spark Plugs R R R R R R
Air Filter I R I R I R
Engine Oil R R R R R R R
Engine Oil Filter R R R R R R R
Crankcase Breather I I I I I I
I I I I I I
Fuel line
Replace every four years
Fuel Filter I I I I I I I
* EVAP Emission Control I I I
Engine Idle Speed I I I I I I I
Throttle Free Play I I I I I I I
Carburetor Synchronization I I I I I I I
I I I R I I R
Clutch Fluid
Replace every two years
Final Drive Oil I I R
Battery I I I I I I I
Brakes I I I I I I
Brake Light Switch I I I I I I I
Headlight Aim I I I I I I I
I I I I I I I
Brake Hoses
Replace every four years
I I I R I I R
Brake Fluid
Replace every two years
Steering I I I I
www.cyclepedia.com/manuals/CPP-154/ 1/2
Side Stand I I I I I I
Wheels I I I I I I I
Forks I I I I I I I
Rear Suspension I I I I I I I
Chassis bolts and nuts T T T T T T T
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online at http://www.cyclepedia.com before attempting any repairs. Updates are
made without notice.

Quick Reference > VIN and Engine Number Location
VIN and Engine Number Location
The Vehicle Identification Number (VIN) is located on the left side of the
steering head. The frame serial number is stamped onto the right side of
the steering head.
The engine number is stamped into the right side of the engine case.
The carburetor type is stamped on the right side of the carburetor.
Quick Reference > Honda CB650SC Specifications
Honda CB650SC Specifications
General Specifications
DIMENSIONS
Overall length 2,140 mm (84.3 in)
Overall width 805 mm (31.7 in)
Overall height 1,145 mm (45.1 in)
Wheelbase 1,460 mm (57.5 in)
Seat height 790 mm (31.1 in)
Ground clearance 150 mm ( 5.9 in)
Dry weight '83 197 kg (434 lb)
FRAME
Type Double cradle tubular steel
Front suspension, travel Telescopic fork 160 mm (6.3 in)
Rear suspension, travel Swingarm 110 mm (4.3 in)
Front tire size 100/90-19 57H
Rear tire size 130/90-16 67 H
Front brake, lining swept area Disc brake, 904 cm2

(140 sq in)
Rear brake, lining swept area Drum brake, 201 cm2

(31 sq in)
Fuel capacity 13.0 liters (3.43 US gal, 2.86 Imp gal)
Fuel reserve capacity 2.0 liters (0.53 US gal, 0,44 Imp gal)
Caster angle 61° 30'
Trail 98 mm (3.9 in)
FORK OIL CAPACITY

Right 447 - 452 cc (15.2 - 15.3 oz)
Left 462 - 467 cc (15.6 - 15.8 oz)
TIRE INFLATION
Front 225 kPa
(32 psi)
Driver only
Rear 225 kPa
(32 psi)
Front 225 kPa
(32 psi)
Driver and passenger
Rear 280 kPa
(40 psi)
ENGINE
Type Air cooled 4-stroke, DOHC
Vertical in line four
Cylinder arrangement Bore and stroke
60.0 x 58.0 mm (2.36 x 2.28 in)
Displacement 655 cm3 (39.9 cu in)
Compression ratio 9.5 : 1
Valve train Chain driven DOHC, 4 valves per cylinder
53.7 kw/9,500 rpm
Maximum horsepower
73 PS/9,500 rpm
57 N-m/8,000 rpm
57 N-m/8,000 rpm
Maximum torque
5.7 kg-m/8,000 rpm
Oil capacity 3.2 liters (3.4 US qt, 2.8 Imp qt)
Lubrication system Wet sump
Air filtration Paper
Cylinder compression 1176.8 ±98.1 kPa (170 ± 14 psi)
5 (BTDC) at 1 mm lift,
58 (BTDC) at 0 lift
Intake valve Opens Closes
40° (ABDC) at 1 mm lift,
101° (ABDC) at 0 lift
35° (BBDC) at 1 mm lift,
87° (BBDC) at 0 lift
Exhaust valve Opens Closes
10° (ATDC) at 1 mm lift,
72° (ATDC) at 0 lift
Engine Specifications
Valve clearance 0 mm: HYDRAULIC

ENGINE Engine weight 75 kg (165 lb)
Idle speed 1,100 ± 100 rpm
Carburetor type VE type, 29 mm (1.14 in) Venturi bore
Identification
VE54A
number
'83-84: VE54A
CARBURETOR
'84
VE75A
CALIFORNIA:
Pilot screw See Pilot Screw Adjustment
Float level 18.5 mm (0.73 in)
Clutch Wet, multi-plate
Transmission 5 speed + O.D. (6 speed)
Primary
1.704 (92/54): 1
reduction
Gear ratio 1 2.769 : 1
Gear ratio II 1.850 : 1
DRIVE TRAIN Gear ratio III 1.429 : 1
Gear ratio IV 1.154 : 1
Gear ratio V 0.966 : 1
Gear ratio O.D. 0.821 : 1
Final reduction 1.125x3.091 (18/16x34/11) : 1
Gear shift Left foot operated return system,
pattern 1-N-2-3-4-5-(O.D.)
Oil pump service data

STANDARD SERVICE LIMIT
Rotor tip clearance 0.10 mm (0.004 in) 0.15 mm (0.006 in)
Pump body clearance 0.15-0.22 mm (0.006-0.009 in) 0.35 mm (0.014 in)
Pump end clearance 0.02-0.07 mm (0.001-0.003 in) 0,10 mm (0.004 in)
Spark plugs
Standard For cold climate (below 5°C, 41°F) For extended high speed riding
NGK ND NGK ND NGK ND
DPR8EA-9 X24EPR-U9 DPR7EA-9 X22EPR-U9 DPR9EA-9 X27EPR-U9
Spark plug gap: 0.8-0.9 mm (0.031-0.035 in)
IGNITION TIMING
At idle: 10° BTDC
Full advance: 32° BTDC at 3.000 ± 250 rpm
Idle speed: 1100 ± 100 rpm
Carburetor All carburetors within 50 mm (2.0 in) Hg of each
synchronization: other.
Cylinder compression: 1176.8 ± 98.1 kPa (170 ± 14 psi)
Throttle grip free play: 2-6 mm (1/8-1/4 in)
CYLINDER HEAD/VALVES
ITEM STANDARD SERVICE LIMIT
1079-1275 kPa
Compression pressure 1177 kPa (171 psi)
(156-185 psi)
Cam 31.85 mm (1.252
IN, EX 31.901 mm (1.2559 in)
height in)
INI, IN4, 22.939-22.970 mm 22.91 mm (0.902
EX1, EX4 (0.9031-0.9043 in) in)
O.D.
IN2, IN3, 22.909-22.930 mm 22.88 mm (0.901
Camshaft EX2, EX3 (0.9019-0.9028 in) in)
IN 1, IN4, 0.030-0.072 mm
0.13 mm (0.005 in)
Oil EX1, EX4 (0.0012-0.0028 in)
clearance IN2, IN3, 0.070-0.112 mm
0.16 mm (0.006 in)
EX2, EX3 (0.0028-0.0044 in)
Runout 0.03 mm (0.001 in)
Free- IN, EX Outer 34.61 mm (1.363 in) 33.4 mm (1.31 in)
length IN, EX inner 33.90 mm (1.335 in) 32.7 mm (1.29 in)
Valve 27.6-31.8 kg/22.2 mm
spring IN, EX Outer
Preload/ (60.1-70.1 lb/0.875 in)
length 8.65-9.95 kg/18.4 mm
IN, EX inner
(19.1-21.9 lb/0.726 in)
SERVICE-
ITEM STANDARD
LIMIT
4.975-4.990 mm (0.1959- 4.97 mm
IN
0.1965 in) (0.195 in)
Valve stem O.D.
4.955-4.970 mm (0.1951- 4.94 mm
EX
0.1957 in) (0.194 in)
IN, 5.0-5.012 mm (0.1969- 5.04 mm
Valve guide I.D.
Valve, Valve EX 0.1973 in) (0.198 in)
guide 0.010-0.037 mm (0.0004- 0.07 mm
IN
Stem-to-guide 0.015 in) (0.003 in)
clearance 0.030-0.057 mm (0.0012- 0.09 mm
EX
0.0022 in) (0.004 in)
IN, 1.41-1.98 mm (0.056- 2.0 mm (0.08
Valve face width
EX 0.078 in) in)
0.10 mm
Warpage
(0.004 in)
Cylinder Valve seat width 1.5 mm (0.06
1.0 mm (0.04 in)
head IN/EX in)
23 000-23.021 mm 23.05 mm
Camshaft journal I.D.
(0.9055-0 90 3 in) (0.907 in)
SERVICE
STANDARD
LIMIT
60.000-60.010 mm 60.10 mm
I.D.
(2.3622-2.3626 in) (2.367 in)
Cylinder
0.10 mm
Warpage
(0.004 in)
0.015-0.045 mm 0.06 mm
TOP
Piston ring-to-ring (0.0006-0.0018 in) (0.002 in)
groove clearance 0.015-0.045 mm 0.06 mm
SECOND
(0.0006-0.0018 in) (0.002 in)
0.15-0.30 mm 0.5 mm
TOP
(0.0059-0.012 in) (0.02 in)
0.15-0.30 mm 0.5 mm
SECOND
SECOND
Ring end gap (0.0059-0.012 in) (0.02 in)
OIL
0.30-0.90 mm 1.1 mm
(SIDE
(0.012-0.035 in) (0.04 in)
Piston, piston RAIL)
rings and piston 59.970-59.990 mm 59.9 mm
Piston O.D.
pin (2.3610-2.3618 in) (2.36 in)
15.002-15.008 mm 15.05 mm
Piston pin bore
(0.5906-0.5909 in) (0.592 in)
15.016-15.034 mm 15.07 mm
Connecting rod small end I.D.
(0.5912-0.5909 in) (0.593 in)
14.994-15.000 mm 14.98 mm
Piston pin O.D.
(0.5903-0.5906 in) (0.589 in)
0.002-0.014 mm 0.04 mm
Piston-to-piston pin clearance
(0.0001-0.0006 in) (0.002 in)
0.010-0.050 mm 0.10 mm
Cylinder-to-piston clearance
(0.0003-0.0020 in) (0.004 in)
SERVICE
ITEM STANDARD
LIMIT
14.000—14.043 mm 14.06 mm
Cylinder I.D.
Clutch master (0.6512-0.5524 in) (0.553 in)
cylinder 13.957—13.984 mm 13.94 mm
Piston O.D.
(0.5495-0.5506 in) (0.549 in)
38.100—38.162 mm (1.500- 38.18 mm
Cylinder I.D.
Clutch slave 1.5024 in) (1.503 in)
cylinder 38.036-38.075 mm (1.4975- 38.02 mm
Piston O.D.
1.4990 in) (1.479 in)
31.984-32.000 mm (1.2592- 31.95 mm
A
Outer guide 1.2598 in) (1.258 in)
O.D. 41.989-42.000 mm (1.6531- 41.95 mm
B
1.6535 in) (1.652 in)
34.0 mm (1.34
Spring free length 35.5 mm (1.40 in)
in)
Spring 21.2-23.2 kg/23.8 mm (46-
Clutch _
preload/length 51 lb/0.94 in)
2.6 mm (0.10
Disc thickness 3.22-3.38 m (0.127-0.133 in)
in)
0.30 mm
Plate warpage -
(0.012 in)
Primary driven 42 005-42 021 mm (1 6537- 42.05 mm
gear I.D. 1.6544 m) (1.656 in)

42.175-
Drive
42.200 mm 42.16 mm
gear
(1.6604- (1.660 in)
O.D.
1.6614 in)
24.987-
Collar 25.000 mm 24.96 mm
O.D. (0.9837- (0.983 in)
0.9843 in)
SERVICE
ITEM STANDARD
LIMIT
Connecting rod big end 0.05-0.20 mm (0.002- 0.3 mm (0.01
side clearance 0.0079 in) in)
0.05 mm
Runout _
(0.002 in)
Crankshaft
0.024-0.057 mm (0.0009- 0.07 mm
Crankpin oil clearance
0.0022 in) (0.003 in)
0.019-0.043 mm (0.0007- 0.06 mm
Main journal oil clearance
0.0017 in) (0.002 in)
323.05-324.05 mm 327.0 mm
Cam chain Length
(12.750-12.758 in) (12.87 in)
Alternator 136.50-136.70 mm 137.8 mm
Length
chain (5.374-5.382 in) (5.43 in)
MAIN BEARING
MAIN JOURNAL OD CODE NO.
1 2 3 4
32.994- 32.988- 32.982- 32.976-
33.000 mm 32.994 mm 32.988 mm 32.982 mm
(1.2990- (1.2987- (1.2985- (1.2983-
1.2992 in) 1.2990 in) 1.2987 in) 1.2985 in)
36.000-36.006 mm
A Pink Yellow Green Brown
(1.4173-1.4176 in)
CRANKCASE
36.006-36.012 mm
I D. CODE B Yellow Green Brown Black
(1.4176-1.4178 in)
NO.
36.012-36.018 mm
C Green Brown Black Blue
(1.4178-1.4180 in)
MAIN BEARING INSERT THICKNESS

Blue 1.511-1.514 mm (0.0595-0.0596 in)
Black 1.508-1.511 mm (0.0594-0.0595 in)
Brown 1.505-1.508 mm (0.0593-0.0594 in)
Green 1.502-1.505 mm (0.0591 -0.0593 in)
Yellow 1.499-1.502 mm (0.0590-0.0591 in)
Pink 1.496-1.499 mm (0.0589-0.0590 in)
CONNECTING ROD BEARING

CRANKPIN O.D. CODE
1 2 3
37.000-37.008 mm 37.008-37.016 mm 37.016-37.024 mm
(1.4567-1.4570 in) (1.4570-1.4573 in) (1.4573-1.4576 in)
40.000-
40.008 mm
A Yellow Green Brown
(1.5748-
1.5751 in)
40.008-
CONNECTING
40.016 mm
ROD l.D. CODE B Green Brown Black
(1.5751 -
NO.
1.5754 in)
40.016-
40.024 mm
C Brown Black Blue
(1.5754 -
1.5757 in)
BEARING INSERT THICKNESS:

Blue 1.502-1.506 mm (0.0591-0.0593 in)
Black 1.498-1.502 mm (0.0590-0.0591 in)
Brown 1.494-1.498 mm (0.0588-0.0590 in)
Green 1.490-1.494 mm (0.0587-0.0588 in)
Yellow 1.486-1.490 mm (0.0585-0.0587 in)
TRANSMISSION
SERVICE
ITEM STANDARD
LIMIT
0.044-0.133 mm 0.20 mm
Low, 2nd, 3rd
(0.0017-0.0052 in) (0.008 in)
0.034-0.102 mm 0.15 mm
Backlash 4th
(0.0013-0.0040 in) (0.006 in)
0.046-0.140 mm 0.18 mm
5th, 6th
5th, 6th
(0.0018-0.0055 in) (0.007 in)
28.020-28.041 mm 28.06 mm
M5, M6
(1.1031-1.1040 in) (1.105 in)
24.020-2.4041 mm 24.06 mm
Gear I.D. C1
(0.9457-0.9465 in) (0.947 in)
28.020-28.041 mm 28.06 mm
C2, C3, C4
(1.1031-1.1040 in) (1.105 in)
27.979-28.000 mm 27.96 mm
M5, C4
(1.1015-1.1024 in) (1.101 in)
27.979-28.000 mm 27.96 mm
M6
(1.1015-1.1024 in) (1.101 in)
Gear bushing O.D.
23.984-24.005 mm 23.97 mm
C1
(0.9443-0.9451 in) (0.944 in)
27.979-28.000 mm 27.96 mm
C2, C3
(1.1015-1.1024 in) (1.101 in)
24.985-25.006 mm 25.04 mm
M5, C4
(0.9837-0.9845 in) (0.986 in)
Gear bushing I.D.
20.000-20.021 mm 20.04 mm
C1
(0.7874-0.7882 in) (0.789 in)
24.959-24.980 mm 24.80 mm
Mainshaft O.D. (M5)
(0.9826-0.9835 in). (0.980 in)
19.980-19.993 mm 19.93 mm
C1
(0.7866-0.7871 in) (0.785 in)
Countershaft O.D.
24.959-24.980 mm 24.90 mm
C4
(0.9826-0.9835 in) (0.980 in)
M5, M6, C4 gear 0.020-0.062 mm 0.08 mm
to bushing (0.0008-0.0024 in) (0.003 in)
M5, C4 bushing 0.005-0.047 mm 0.07 mm
to shaft (0.0002-0.0019 in) (0.003 in)
Gear-to-bushing or C1 gear to 0.015-0.057 mm 0.08 mm
shaft clearance bushing (0.0006-0.0022 in) (0.003 in)
C1 bushing to 0.007-0.041 mm 0.06 mm
shaft (0.0003-0.0016 in) (0.002 in)
C2, C3 gear to 0.020-0.062 mm 0.08 mm
bushing (0.0008-0.0024 in) (0.003 in)
0.08-0.18 mm (0.003-0.007 0.30 mm (0.012

Gear backlash
in) in)
Gear assembly preload 0.2-0.4 N-m (1.7-2.9 in-lb)
Damper case oil capacity 20 cc (0.71 oz)
Damper cam spring free
53 mm (2.1 in) 51.5 mm (2.03 in)
length
Fluid Specifications
2.5 liter (2.6 US qt, 2.2 imp qt) after oil filter and oil change
Oil capacity 2.2 liter (2.3 US qt, 1.9 imp qt) after oil change
3.2 liter (3.5 US qt, 2.8 imp qt) after disassembly
OIL VISCOSITIES Use Honda 4-Stroke Oil or equivalent. API Service
Oil Classification: SE or SF. Viscosity: SAE 10W-40 Other viscosities shown in the
recommendation chart may be used when the average temperature in your riding area is within the
indicated range.
Oil pressure (at
490.3 kPa/7,000 rpm 80° C (176° F)
oil pressure
(71 PSI/7,000 rpm)
switch)
Oil pump
36.0 liter (38.05 U.S. qt, 31.68 imp qt)/min./7,000 rpm
delivery
Final drive gear

'83 170 cm3 (5.78 oz)
Oil capacity
'84 150 cm3 (4.9 oz)
Recommended '83 Hypoid gear oil: Above 5°C/41°F, SAE #90 Below 5°C/41°F, SAE #80
oil '84 Hypoid gear oil: SAE #80
Carburetor Specifications
Venturi dia. 29.2 mm (1.15 in)

'83-'84 E54A
Identification mark
'84 California VE75A
Main jet #115
Idle speed 1100 ± 100 rpm
Throttle grip free play 2-6 mm (0.08-0.24 i
Fast idle 3000 ± 500 rpm
Pilot screw opening See pilot screw adjustment
Choke Valve Stroke 5-7 mm (3/16-1/4 in)
Electrical Specifications
Capacity 12V 12 AH
Battery Specific gravity 1.270-1.290/20°C (68°F)
Charging rate 1.2 amperes maximum
Capacity 2400 rpm 6000 rpm
Alternator
12.6 A min (No load) 10A min {No load)
Voltage regulator Transistorized non-adjustable
'83 STATOR
RPM Amperage Output
2500 2 amps
2000—2100 0±1 amp
1500 -5 ± 1 amp
1000 -10 ± 1 amp
'84 STATOR
RPM Amperage Output
2500 2 amps
1700—1800 0 ± 1 amp
1500 -3 ± 1 amp
1000 -9 ± 1 amp
ND X24EPR-U9, X22EPR-U9, X27EPR-U9

Spark plug
NGK DPR8EA-9, DPR7EA-9, DPR9EA-9
Spark plug gap 0.8- 0.9 mm (0.031-0.035 in)
At idle min-1 (rpm) 10° (BTDC)
Ignition timing
Full advance/min"1 (rpm) 32° BTDC/3,000
Ignition coil 3-point spark test 8 mm (1/4 in) minimum
SERVICE
ITEM STANDARD
LIMIT
Brush spring
800 ± 120 g (28.2 ± 4.2 oz) 680 g (24.0 oz)
Starter tension
motor 12.0-13.0 mm (0.47-0.51
Brush length 6.5 mm (0.26 in)
In)
Ignition Transistorized
Ignition timing
Ignition timing
10° BTDC at 1,400 ± 200 rpm
"F" mark
Full advance 32° BTDC at 3,000 ± 250 rpm
ELECTRICAL Starting system Starting motor only
Three phase alternator 280W/6,000 rpm (Air
Generator
Cooled)
Battery
12V ~ 12 AH
capacity
Headlight
12V - 60/55 W H4 BULB (Phillips 12342/99 or
(high/low
equivalent)
beam)
Tail/stoplight 12V-3/32 CP SAE NO. 1157
Turn signal light 12V-32 CP SAE NO. FRONT 1034 REAR
(front/rear) 1073
Instrument 12V-2 CP SAE NO. 57
Neutral
LIGHTS 12V -2 CP
indicator
Turn signal
12V - 2 CP
indicator
High beam
12V -2 CP
indicator
Oil pressure
12V-2 CP
warning light
Position light 12V-3 CP SAE NO. 1034
15A (Headlight, turn signal/Brake light, neutral/
FUSE
oil light, meter light) 30A (Main fuse)
FUEL SENSOR
FLOAT POSITION RESISTANCE
TOP (FULL) 4 - 10 Ω
BOTTOM (EMPTY) 90 - 100 Ω
Brake, Wheel, Tires and Suspension Specifications
Front Rear
Tire size 100/90--19 130/90—16
57H 67H
Up to 90 kg (200 lbs) load 225 (32) 225 (32)
Cold tire pressure
kPa (PSI) 90 kg (200 lbs) load to vehicle
225 (32) 280 (40)
capacity load
Bridgestone L303 G508
Tire brand
Dunlop F11 K627
Suspension air pressure Front 0-40 kPa (0-6 psi)
Rear brake pedal free play 20-30 mm (3/4-1-1/4 in)
SERVICE
ITEM STANDARD
LIMIT
0.2 mm (0.01
Axle shaft runout _
in)
2.0 mm (0.08
Radial 0.3 mm (0.01 in) max.
Front wheel rim in)
runout 2.0 mm (0.08
Axial 0.3 mm (0.01 in) max
in)
0.03 mm (0.001
Wheel bearing play _
in)
512.4 mm (20.2
Fork spring free length 522.9 mm (20.6 in)
in)
0.2 mm (0.01
Fork tube runout -
in)
Right 450 cc (15.2 oz) Left 465 cc
Front fork fluid capacity _
(15.7 oz)
Front fork air pressure 0-40 kPa (0~6 psi) -

Axle runout 0.2 mm (0.01 in)
Radial 2.0 mm (0.08 in)
Rear wheel rim run out
Axial 2.0 mm (0.08 in)
0.03 mm (0.001
Wheel bearing play
in)
Shock absorber spring free 213.2 mm (8.40
217.6 mm (8.57 in)
length in)
160.0-160.3 mm (6.30-6.31 161.0 mm (6.34
Brake drum I.D.
in) in)
Rear brake lining thickness 4.9-5.0 mm (0.19-0.20 in) 2.0 mm (0.08 in)

Front disc thickness 4.8-5.2 mm (0.19-0.20 in) 4.0 mm (0.16 in)
Front disc runout 0.30 mm (0.012 in)
Front master cylinder 15.870-15.913 mm (0.6248-
15.93 mm (0.627 in)
I.D. 0.6265 in)
Front master piston 15.827-15.854 mm (0.6231-
15.82 mm (0.623 in)
O.D. 0.6242 in)
Front caliper piston 31.948-31.998 mm (1.2578- 31.940 mm (1.2578
O.D. 1.2598 in) in)
Front caliper cylinder 32.030-32.080 mm (1.2610- 32.090 mm (1.2634
I.D. 1.2630 in) in)
Quick Reference > Supplemental Honda CB550SC Specifications
Supplemental Honda CB550SC Specifications
Overall length 2150 mm (84.6 in)

Overall height 1160 mm (45.7 in)
DIMENSIONS Wheelbase 1440 mm (56.7 in)
Dry weight 190 kg (419 lb)
Front suspension,
Telescopic fork 160 mm (6.3 in)
travel
Rear suspension,
Swingarm 105 mm (4.1 in)
travel
Front tire size 100/90-19 57S
Rear tire size 130/90-16 67S
Driver
Cold tire Front 200 kPa (28 psi) Rear 200 kPa (28 psi)
only
Driver
pressures and Front 200 kPa (28 psi) Rear 250 kPa (36 psi)
FRAME passenger
Front brake, lining
Disc Brake, 490 cm2(76.0 sq in)
swept area
Rear brake, lining
Drum brake, 1 76 cm2(27.3 sq in)
swept area
Fuel capacity 1 2 liters (3.17 US gal, 2.64 Imp gal)
Fuel reserve
2.5 liters (0.66 US gal, 0.55 Imp gal)
capacity
Caster angle 29°
Front fork oil
375 cc (12.7 oz)
capacity
Cylinder
Vertical in-line four
arrangement
Bore and stroke 60.0 x 50.6 mm (2.36 x 1.99 in)
Maximum
47.7 kw/9,500 rpm 62 PS/9,500 rpm
horsepower
Maximum torque 49.8 N m/8,000 rpm 5.05 kg-m/8,000 rpm
ENGINE Air filtration Paper
Cylinder
1176.8 ± 98.1 kPa (170 ± 14 psi)
compression
5 ° (BTDC) at 1 mm lift,
Intake valve Opens
Intake valve 58 0 (BTDC) at 0 lift
Closes
101 ° (ABDC) at 0 lift
35 ° (BBDC) at 1 mm lift,
Exhaust valve
87 ° (BBDC) at 0 lift
Opens Exhaust
10 ° (ATDC) at 1 mm lift,
valve Closes
Valve clearance 0 mm / HYDRAULIC TAPPETS
Engine weight 75 kg (165 lb)
Venturi diameter 32 mm (1.3 in)
Identification No. VE 62A
Transmission 5 speed + O.D.
Primary reduction 1 .863 : 1
Gear ratio I 2.769 : 1
Gear ratio III 1.429 : 1
Gear ratio IV 1.1 54 : 1
Gear ratio VI 0.821 : 1
Final reduction 1.125 x 3.091 (18/16 x 34/1 1) : 1
Left-foot operated return system,
Gear shift pattern
1 -N-2-3-4-5-(O.D.)
Headlight
12V - 60/55 W H4 BULB
(high/low
(Phillips 12342/99 or equivalent)
beam)
Turn signal
light 12V-32 CP SAE NO. FRONT 1034 REAR 1073
(front/rear)
LIGHTS Neutral
12V -2 CP
indicator
Turn signal
12V - 2 CP
indicator
High beam
12V -2 CP
indicator
Oil pressure
12V-2 CP
warning light
15A (Headlight, turn signal/Brake light, neutral/ oil light, meter light)
FUSE
30A (Main fuse)
MAIN BEARING
1 2 3 4
32.994- 31 988- 31.982 - 31.976-
32.000mm 31.994mm 31.988mm 31.982mm
(1.2596- (1.2594- (1.2591- (1.2589-
1.2598 in) 1.2596 in) 1.2594 in) 1.2591 in)
35.000-
35.006 mm
(1.3780-
1.3782 in)
35.006-
CRANKCASE
35.012 mm
(1.3782-
NO.
1.3784 in)
35.012-
35.018 mm
(1.3784-
1.3787 in)

Blue 1.511-1.514 mm (0.0595-0.0596 in)
Black 1.508-1.511 mm (0.0594-0.0595 in)
Brown 1.505-1.508 mm (0.0593-0.0594 in)
Green 1.502-1.505 mm (0.0591 -0.0593 in)
Yellow 1.499-1.502 mm (0.0590-0.0591 in)
Pink 1.496-1.499 mm (0.0589-0.0590 in)

CRANKPIN O.D. CODE NO.
A B C
31.992-32.000 31.992-31.984 31.976-31.984

Quick Reference > Torque Specifications
fuelTorque Specifications
Engine
Thread
Torque N.m (ft-
ITEM Qty Dia. Remarks
lb)
(mm)
Camshaft holder 20 6 11-13 (8-9)
Cylinder head 12 8 20-24 (14-17)
U.B.S., Apply a locking
Cam sprocket 4 7 18-22 (13-16)
agent to the threads.
Spark plug 4 12-18 (9-13)
Crankcase 8 mm 11 8 21-25 (15-18) Apply motor oil to the
Crankcase 6 mm 20 6 10-14 (7-10) threads
Connecting rod nut 8 8 30-34 (22-25)
Pulse rotor 1 10 31-39 (22-28)
Alternator rotor bolt 1 10 31-39 (22-28)
Mainshaft lock nut 1 22 47-53 (34-38)
Oil filter case 1 20 28-32 (20-23)
Apply a liquid sealant to
Oil pressure switch 1 — 16-20 (12-14)
the threads.
Oil control bolt 6
2 6 10-14 (7-10)
mm
Oil control bolt 8
4 8 12-16(9-12)
mm
Oil control bolt 10
1 10 16-20(12-14)
mm
Oil drain plug 1 12 30-40 (22-29)
Alternator chain Apply a locking agent to
4 6 10-14 (7-10)
tensioner guide the threads.
Pulse generator Apply a liquid sealant to
4 5 5-7 (4-5)
assembly the threads.
Cylinder nut 3 6 8-12 (6-7)
Oil pump 3 6 10-14(7-10)
Alternator shaft
1 16 38-42 (27-30)
locknut
Fuel Cup 3-5 N-m(2-4 ft-lb)
Cam chain tensioner 20-24 N-m (14-17 ft-lb)

Oil pipe joint bolt 6 mm 10-14 N-m (7-10 ft-lb)
Oil pipe joint bolt 10 mm 16--20 N-m (12-14 ft-lb)
Clutch hose oil bolts 25-35 N-m (18-25 ft-lb)

Clutch fluid reservoir cover 1 -2 N-m (0.7-0.9 ft-lb)
Clutch lever pivot nut 5-7 N-m (4-5 ft-lb)
Clutch center lock nut 47-53 N-m (34-38 ft-lb)
Stopper arm pivot bolt 10-14 N-m (7-10 ft-lb)
Crankpin 30-34 N-m (22-25 ft-Ib)

Crankshaft 21-25 N-m (15-18 ft-Ib)
30-34 N m (22-25
Output gearcase
ft-lb)
Driven gear bearing 30-34 N-m (22-25
holder ft-lb) Apply engine oil to the
Countershaft bearing 30-34 N m (22-25 bolt threads
holder ft-lb)
90-110 N-m (65-
outer :
Countershaft bearing 80 ft-lb)
lock nut 70-80 N.m (51-58
inner :
ft-lb) Apply engine oil to the
90-110 N-m (65- threads
outer :
Driven gear bearing 80 ft-lb)
lock nut 70-80 N-m (51-58
inner :
ft-lb)
Pinion nut 100-120 N-m (72-87 ft-lb)

Gear case cover bolt 10 mm (locking
45-50 N-m (32-36 ft-lb)
agent)
8 mm (locking agent) 23-28 N-m (17-20 ft-lb)
Final gear case attaching nut 60-70 N-m (43-51 ft-lb)
Chassis
Thread Torque
Item Qty Dia. N-m Remarks
(mm) (ft-lb)
90-
120
Steering stem nut 1 24
(65-
87)
9-13
Front fork top bridge 2 7
(6-9)
20-30
Handle bar holder 4 8 (14-
22)
45-55
Front fork pinch bolt 2 10 (33-
40)
55-65
Front axle 1 12 (40-
47)
15-25
Front axle pinch bolt 1 8 (11-
18)
20-30
Engine mounting bolts
8 8 (14-
8 mm
22)
45-60
Engine mounting bolts 10 mm 5 10 (33-
43)
60-80
Rear axle 1 16 (43-
58)
60-70
Final gear case 5 10 (43- U.B.S
51)
18-25
Rear brake torque link 2 8 (13-
18)
30-40
Rear shock 2 10 (22-
29)
30-40
Foot peg 2 10 (22-
29)
18-25
Gearshift pedal pivot 1 8 (13-
18)
20-30
Rear axle pinch bolt 1 8 (14-
22)
8-12
Swingarm pivot-Right 1 23
(6-9)
80-
120
Swingarm pivot -Left 1 23
(58-
87)
80-
120
Swingarm pivot lock nut 1 23
(58-
87)
25-35
Final drive case oil bolt 1 10 (18-
25)
Thread Dia. Torque N-m

Item Qty Remarks
(mm) (ft-lb)
Brake bleeder 2 7 4-7 (3-5)
Brake and clutch master cylinder
4 6 10-14 (7-10)
holder
Brake pedal 1 8 20-28 (14-20)
Gearshift pedal 1 6 10-15 (7-11)
Bolt 1 10 10-20 (7-14)
Side stand
Nut 1 10 35-45 (25-33)
Main stand 2 10 35-45 (25-33)
Muffler joint bolt 1 8 24-30 (17-22) U.B.S
Muffler bracket 2 8 24-30 (17-22)
Headlight bracket 2 8 20-28 (14-20)
Front fork brace 4 8 18-28 (13-20)
Brake and clutch master cylinder
4 4 2-3.5 (1-3)
cap
Final gear oil cap 1 30 10-14 (7-10)
Front brake caliper Left (upper) 1 10 35-45 (25-33)
Left (lower) 1 8 20-25 (14-20)
Right 2 10 30-40(22-29)
ITEM TORQUE N-m (ft-lb)

Final drive flange bolts 50-60 (36-43)
Handlebar upper holder 20-30 N-m (14-22 ft-Ib)

Upper mount bolt (L) 35-45 N-m (25-33 fMb)
Piston pin bolt (L) 20-25 N-m (14-18 ft-Ib)
Tower mount bolt (L) 20-25 N-m (14-18 ft-Ib)
Front axle 55-65 N-m (40-47 ft-Ib)
Caliper mounting bolt (R) 30-40 N-m (22-29 ft-Ib)
Axle pinch bolt 15-25 N-m (11-18 ft-Ib)
Profit fork socket bolt 15-25 N-m (11-18 ft-Ib)
Fork tube cap 15-30 N-m (11-22 ft-Ib)
Brake disc bolts 35-40 N-m (25-29 ft-Ib)
Fork top bridge pinch bolt 9-13 N-m (7-9 ft-Ib)
Fork lower pinch bolt 45-55 N-m (33-40 ft-Ib)
Rear axle nut 60-80 N-m (43-58 ft-lb)

Rear axle pinch bolt 20-30 N-m (14-22 ft-lb)
Brake arm 24-30 N-m (17-22 ft-lb)
Shock absorber mount bolt/nut 30-40 N-m (22-29 ft-lb)
Final gear case attaching nuts 60-70 N-m (43-51 ft-lb)
Swingarm left pivot bolt 80-120 N-m (58-87 ft-lb)
Swingarm right pivot bolt 8-12 N-m (6-9 ft-lb)
Swingarm pivot lock nut 80-120 N-m (58-87 ft-lb)
Brake torque link 18-25 N-m (13-18 ft-lb)
Brake hose bolt 25-35 N-m (18-25 ft-lb)

Front brake caliper bracket (R) 30-40 N-m (22-29 ft-lb)
Front brake caliper bolt 20-25 N-m (14-18 ft-lb)
Front brake caliper shaft 25-30 N-m (18-22 ft-lb)
Upper mount bolt (L) 35-45 N-m (25-33 ft-lb)
Lower mount bolt (L) 20--25 N-m (14-18 ft-lb)
If you do not see an item listed check the General Torque Specifications
topic.

Quick Reference > General Torque Specifications
General Torque Specifications
General torque specifications are only to be used when specific torque

specifications for a fastener are not provided. These specifications are for
clean unlubricated threads.
Torque N-m (kg-m, Torque N-m (kg-m, ft-

Type Type
ft-lb) !b)
5 mm bolt, 4.5-6 (0.45-0.6, 3.5- 3.5-5 (0.35-0.5, 2.5-
5 mm screw
nut 4.5) 3.6)
6 mm bolt,
8-12 (0.8-1.2, 6-9) 6 mm screw 7-11 (0.7-1.1, 5-8)
nut
8 mm bolt, 18-25 (1.8-2.5, 13- 6 mm flange bolt,
10-14 (1.0-1.4,7-10)
nut 18) nut
10 mm bolt, 30-40 (3.0-4.0, 22- 8 mm flange bolt, 24-30 (2.4-3.0, 17-
nut 29) nut 22)
12 mm bolt, 50-60 (5.0-6.0, 36- 10 mm flange bolt, 30-40 (3.0-4.0, 22-
nut 43) nut 29)

Fuel System > Carburetor Removal
Carburetor Removal
SAFETY FIRST: Protective gloves and eyewear are recommended

at this point.
Remove the fuel tank. See the Fuel Tank topic for more information.
Remove the airbox. See the Airbox topic for more information.
The CB650SC uses four carburetors. All four carburetors are connected to
each other and will come out from the motorcycle as a single unit.
Use a #2 Phillips screwdriver and loosen the screws on all four air cleaner
connecting bands. Loosen the screws on all four intake port connecting
bands.
The two throttle cables and the choke cable can be found in the center of
the carburetor assembly.
Loosen the rearward throttle cable lock nut using a 10 mm wrench.

Remove the throttle cable from the plate.
Remove the rearward throttle cable from the throttle drum.
Loosen the forward throttle cable lock nut. Remove the forward throttle
cable from the plate and the throttle drum.
Loosen the choke cable clamp screw using a #2 Phillips screwdriver.

Remove the choke cable.
Pull the carburetors back and out of the insulator boots. Remove the
carburetors out the right side.
Remove the protector.
Free the throttle cables from the throttle drum.
Remove the evaporative emission control system hoses from the bottom of
the carburetors on the California models.
Cover the intake ports with lint free rags to prevent debris from entering the
engine.
For disassembly see the Carburetor Disassembly topic for more

information.

Fuel System > Carburetor Installation
Carburetor Installation
at this point.
Install the protector over the cylinder head cover.
Install the choke cable into the slide. Install the choke cable housing into the
choke clamp on the center plate of the carburetor assembly.
Install the throttle cable into the throttle drum. Install the throttle cable
adjuster nut into the center plate. Tighten the lock nut.
Install the other throttle cable into the drum.
Install the throttle cable adjuster nut into the center plate. Tighten the lock
nut.
Install the carburetor assembly into the intake port boots.
Tighten the intake port connecting bands using a #2 Phillips screwdriver.

Install the air cleaner boots onto the carburetor and tighten the air cleaner
connecting bands using a #2 Phillips screwdriver.
Install the airbox. See the Airbox topic for more information.
Adjust the throttle free play. See the Throttle Free Play topic for more
information.
Synchronize the carburetors. See the Carburetor Synchronization topic for

more information.
Install the fuel tank. See the Fuel Tank topic for more information.
Adjust the engine idle speed. See the Engine Idle Speed topic for more
information.

Fuel System > Carburetor Assembly
Carburetor Assembly

at this point.
Note: Take care when installing the brass carburetor components like jets.
These parts are soft and can be easily damaged.
Install the pilot screw. If the pilot screw was not replaced then it will need a
new O-ring. DO NOT seat the pilot screw without the limiter cap installed.
See the Pilot Screw Adjustment topic for more information.
Thread in the idle speed adjustment knob.
Install the choke shaft spring. The fuel pipe joints will need new O-rings.
Apply a light coat of oil to the O-rings. Install the fuel joint pipes.
On a flat surface, put the carburetors together. The carburetors should be

numbered 1-4 from left to right.
Fit the front bracket.
Thread in the screws and loosely secure them using a #3 Phillips

screwdriver. Press the carburetors together evenly as you tighten the
screws. Only tighten two screws at a time to prevent carburetor
misalignment.
Fit the rear bracket.
Thread in the screws and loosely secure them with a #2 Phillips

screwdriver. Press the carburetors together as you tighten the screws.
Tighten only two screws at a time to prevent carburetor misalignment.
Install the choke shaft from the left side into the choke shaft clamps.
Thread in the choke shaft screws and tighten them with a #2 Phillips
screwdriver.
Hook the relief spring.
Tighten the synchronization screws until seated. Turn the screws out by the
number of turns determined in the carburetor disassembly procedure.
Install the slow jet using a flat blade screwdriver. Do not over tighten
Install the main jet holder. Install the main jet.
Use a 7 mm wrench to tighten the main jet holder. Tighten the main jet
securely using a flat blade screwdriver. Do not over tighten.
Install the float valve into the float.
Fit the float into the float chamber.
Install the float pin.
Recheck the float clearance. Tilt the carburetors at a 15-45 degree angle
from vertical. The float tang should just be touching the float valve. Replace
the float assembly if it does meet specification.
Fit the float chamber cover. Thread in the mounting screws. Tighten
securely with a #2 Phillips screwdriver.
Install the float chamber drain screw.
Install the jet needle into the piston. Install the jet needle holder.
Install the vacuum piston into the carburetor body. Make sure the tab on the
vacuum piston diaphragm is lined up with the bump on the carburetor body.
Install the spring. Install the vacuum cylinder cover.
Thread in the screws. Tighten the screws using a #2 Phillips screwdriver.
Install fuel hose.
Install the air vent hoses.
Test the throttle operation to make sure it moves smoothly.
To install the carburetor see the Carburetor Installation topic.
If the pilot screws were removed or replaced they will have to be adjusted.
See the Pilot Screw Adjustment topic for more information.

Fuel System > Carburetor Disassembly
Carburetor Disassembly

at this point.
NOTE: Always wear safety glasses when using compressed air and never
point it directly at yourself or anyone else.
Remove the carburetors. See the Carburetor Removal topic for more
information.
Inspect the air vent, vacuum, and fuel hoses for damage and deterioration.
Remove the two air vent hoses and the fuel line.
Use a #2 Phillips screwdriver to remove the vacuum cylinder cover screws.
Remove the vacuum cylinder cap. Remove the spring.
Note the position of the tab on the vacuum piston in the carburetor body.
Remove the vacuum piston. Test to see if the piston and jet needle move
up and down freely inside the cylinder.
Remove the needle stopper.
Separate the jet needle from the piston.
Use compressed air to blow out the jets in each carburetor.
Remove the float bowl drain screws using a flat blade screwdriver.
Use a #2 Phillips to remove the float chamber cover screws.
Remove the float chamber cover.
Tilt the carburetors at a 15-45 degree angle from vertical. The float tang
should just be touching the float valve. Replace the float assembly if it does
meet specification.
The float is held in place with a pin.
Remove the float pin with a pair of pliers. Remove the float and float valve.
The float valve is connected to the float. Remove the float valve.
Inspect the float valve and seat. If there are any grooves, nicks or deposits
the float valve and seat should be replaced.
Arrow #1 is the Main Jet. Arrow #2 is the Slow Jet.
Use a 7 mm wrench and a flat blade screwdriver to remove the main jet.
Use a 7 mm wrench to remove the main jet holder.
Use a flat blade screwdriver to remove the slow jet.
Hold all of the jets up to a light, you should see a clear, round opening.
Clean any jets and body passages that are blocked or restricted using
aerosol carburetor cleaner and/or compressed air. Do not clean jets with
wire. Replace the jets if they are damaged.
Tighten each synchronization screw until it seats and count the number of
turns. Now, loosen the synchronization screw for each carburetor until there
is no spring tension on the screw.
Loosen the choke arm locking screw for each carburetor using a #2
Phillips screwdriver.
Remove the end choke arm locking screw using a #2 Phillips screw driver.
Pull the choke shaft out from the right side. Remove the clamps and shaft
guides.
Remove the rear bracket screws using a #2 Phillips screwdriver.
Remove the rear bracket.
Remove the front bracket screws using a #3 Phillips screwdriver.
Remove the front bracket.
Separate the No. 4 carburetor from the No. 3 carburetor. Separate the No.
3 carburetor from the No. 2 carburetor.
Separate the No. 2 carburetor from the No. 1 carburetor.
Remove the two fuel joint pipes.
Remove the central fuel joint pipe.
Remove the two springs.
Remove the idle speed screw by turning the knob.
Tighten the pilot screws until they seat. Count the number of turns until the
screws were seated. Remove the limiter caps. The pilot screws are now
exposed. Loosen the pilot screws using a flat blade screw driver.
Caution:Do not remove the limiter caps before seating the pilot screws. If
the pilot screws are seated without the limiters damage will occur.
Remove the pilot screws.
To assemble the carburetor see the Carburetor Assembly topic.
DIMENSIONS
FRAME

(140 sq in)

(31 sq in)
FORK OIL CAPACITY

Right 447 - 452 cc (15.2 - 15.3 oz)
Left 462 - 467 cc (15.6 - 15.8 oz)
TIRE INFLATION
Front 225 kPa
(32 psi)
Driver only
Rear 225 kPa
(32 psi)
Front 225 kPa
(32 psi)
Rear 280 kPa
(40 psi)
ENGINE
60.0 x 58.0 mm (2.36 x 2.28 in)
53.7 kw/9,500 rpm
Maximum horsepower
73 PS/9,500 rpm
57 N-m/8,000 rpm
57 N-m/8,000 rpm
Maximum torque
5.7 kg-m/8,000 rpm
58 (BTDC) at 0 lift

Identification
VE54A
number
'83-84: VE54A
CARBURETOR
'84
VE75A
CALIFORNIA:
Primary
1.704 (92/54): 1
reduction
pattern 1-N-2-3-4-5-(O.D.)

Spark plugs
IGNITION TIMING
At idle: 10° BTDC
1079-1275 kPa
(156-185 psi)
Cam 31.85 mm (1.252
IN, EX 31.901 mm (1.2559 in)
height in)
INI, IN4, 22.939-22.970 mm 22.91 mm (0.902
EX1, EX4 (0.9031-0.9043 in) in)
O.D.
IN2, IN3, 22.909-22.930 mm 22.88 mm (0.901
IN 1, IN4, 0.030-0.072 mm
0.13 mm (0.005 in)
Oil EX1, EX4 (0.0012-0.0028 in)
0.16 mm (0.006 in)
EX2, EX3 (0.0028-0.0044 in)
Valve 27.6-31.8 kg/22.2 mm
spring IN, EX Outer
Preload/ (60.1-70.1 lb/0.875 in)
length 8.65-9.95 kg/18.4 mm
IN, EX inner
(19.1-21.9 lb/0.726 in)
SERVICE-
ITEM STANDARD
LIMIT
4.975-4.990 mm (0.1959- 4.97 mm
IN
0.1965 in) (0.195 in)
Valve stem O.D.
4.955-4.970 mm (0.1951- 4.94 mm
EX
0.1957 in) (0.194 in)
IN, 5.0-5.012 mm (0.1969- 5.04 mm
Valve guide I.D.
guide 0.010-0.037 mm (0.0004- 0.07 mm
IN
clearance 0.030-0.057 mm (0.0012- 0.09 mm
EX
0.0022 in) (0.004 in)
IN, 1.41-1.98 mm (0.056- 2.0 mm (0.08
Valve face width
EX 0.078 in) in)
0.10 mm
Warpage
(0.004 in)
1.0 mm (0.04 in)
head IN/EX in)
23 000-23.021 mm 23.05 mm
(0.9055-0 90 3 in) (0.907 in)
SERVICE
STANDARD
LIMIT
60.000-60.010 mm 60.10 mm
I.D.
(2.3622-2.3626 in) (2.367 in)
Cylinder
0.10 mm
Warpage
(0.004 in)
0.015-0.045 mm 0.06 mm
TOP
SECOND
(0.0006-0.0018 in) (0.002 in)
0.15-0.30 mm 0.5 mm
TOP
(0.0059-0.012 in) (0.02 in)
0.15-0.30 mm 0.5 mm
SECOND
SECOND
Ring end gap (0.0059-0.012 in) (0.02 in)
OIL
0.30-0.90 mm 1.1 mm
(SIDE
(0.012-0.035 in) (0.04 in)
Piston O.D.
pin (2.3610-2.3618 in) (2.36 in)
15.002-15.008 mm 15.05 mm
Piston pin bore
(0.5906-0.5909 in) (0.592 in)
15.016-15.034 mm 15.07 mm
(0.5912-0.5909 in) (0.593 in)
14.994-15.000 mm 14.98 mm
Piston pin O.D.
(0.5903-0.5906 in) (0.589 in)
0.002-0.014 mm 0.04 mm
(0.0001-0.0006 in) (0.002 in)
0.010-0.050 mm 0.10 mm
(0.0003-0.0020 in) (0.004 in)
SERVICE
ITEM STANDARD
LIMIT
14.000—14.043 mm 14.06 mm
Cylinder I.D.
cylinder 13.957—13.984 mm 13.94 mm
Piston O.D.
(0.5495-0.5506 in) (0.549 in)
38.100—38.162 mm (1.500- 38.18 mm
Cylinder I.D.
cylinder 38.036-38.075 mm (1.4975- 38.02 mm
Piston O.D.
1.4990 in) (1.479 in)
31.984-32.000 mm (1.2592- 31.95 mm
A
O.D. 41.989-42.000 mm (1.6531- 41.95 mm
B
1.6535 in) (1.652 in)
34.0 mm (1.34
in)
Spring 21.2-23.2 kg/23.8 mm (46-
Clutch _
2.6 mm (0.10
in)
0.30 mm
Plate warpage -
(0.012 in)
gear I.D. 1.6544 m) (1.656 in)

42.175-
Drive
42.200 mm 42.16 mm
gear
(1.6604- (1.660 in)
O.D.
1.6614 in)
24.987-
O.D. (0.9837- (0.983 in)
0.9843 in)
SERVICE
ITEM STANDARD
LIMIT
0.05 mm
Runout _
(0.002 in)
Crankshaft
0.024-0.057 mm (0.0009- 0.07 mm
0.0022 in) (0.003 in)
0.019-0.043 mm (0.0007- 0.06 mm
0.0017 in) (0.002 in)
323.05-324.05 mm 327.0 mm
Cam chain Length
(12.750-12.758 in) (12.87 in)
Alternator 136.50-136.70 mm 137.8 mm
Length
chain (5.374-5.382 in) (5.43 in)
MAIN BEARING
1 2 3 4
32.994- 32.988- 32.982- 32.976-
33.000 mm 32.994 mm 32.988 mm 32.982 mm
(1.2990- (1.2987- (1.2985- (1.2983-
1.2992 in) 1.2990 in) 1.2987 in) 1.2985 in)
36.000-36.006 mm
(1.4173-1.4176 in)
CRANKCASE
36.006-36.012 mm
(1.4176-1.4178 in)
NO.
36.012-36.018 mm
(1.4178-1.4180 in)

Blue 1.511-1.514 mm (0.0595-0.0596 in)
Black 1.508-1.511 mm (0.0594-0.0595 in)
Brown 1.505-1.508 mm (0.0593-0.0594 in)
Green 1.502-1.505 mm (0.0591 -0.0593 in)
Yellow 1.499-1.502 mm (0.0590-0.0591 in)
Pink 1.496-1.499 mm (0.0589-0.0590 in)

CRANKPIN O.D. CODE
1 2 3
37.000-37.008 mm 37.008-37.016 mm 37.016-37.024 mm
(1.4567-1.4570 in) (1.4570-1.4573 in) (1.4573-1.4576 in)
40.000-
40.008 mm
(1.5748-
1.5751 in)
40.008-
CONNECTING
40.016 mm
(1.5751 -
NO.
1.5754 in)
40.016-
40.024 mm
C Brown Black Blue
(1.5754 -
1.5757 in)

Blue 1.502-1.506 mm (0.0591-0.0593 in)
Black 1.498-1.502 mm (0.0590-0.0591 in)
Brown 1.494-1.498 mm (0.0588-0.0590 in)
Green 1.490-1.494 mm (0.0587-0.0588 in)
Yellow 1.486-1.490 mm (0.0585-0.0587 in)
TRANSMISSION
SERVICE
ITEM STANDARD
LIMIT
0.044-0.133 mm 0.20 mm
Low, 2nd, 3rd
(0.0017-0.0052 in) (0.008 in)
0.034-0.102 mm 0.15 mm
Backlash 4th
(0.0013-0.0040 in) (0.006 in)
0.046-0.140 mm 0.18 mm
5th, 6th
5th, 6th
(0.0018-0.0055 in) (0.007 in)
28.020-28.041 mm 28.06 mm
M5, M6
(1.1031-1.1040 in) (1.105 in)
24.020-2.4041 mm 24.06 mm
Gear I.D. C1
(0.9457-0.9465 in) (0.947 in)
28.020-28.041 mm 28.06 mm
C2, C3, C4
(1.1031-1.1040 in) (1.105 in)
27.979-28.000 mm 27.96 mm
M5, C4
(1.1015-1.1024 in) (1.101 in)
27.979-28.000 mm 27.96 mm
M6
(1.1015-1.1024 in) (1.101 in)
Gear bushing O.D.
23.984-24.005 mm 23.97 mm
C1
(0.9443-0.9451 in) (0.944 in)
27.979-28.000 mm 27.96 mm
C2, C3
(1.1015-1.1024 in) (1.101 in)
24.985-25.006 mm 25.04 mm
M5, C4
(0.9837-0.9845 in) (0.986 in)
Gear bushing I.D.
20.000-20.021 mm 20.04 mm
C1
(0.7874-0.7882 in) (0.789 in)
24.959-24.980 mm 24.80 mm
Mainshaft O.D. (M5)
(0.9826-0.9835 in). (0.980 in)
19.980-19.993 mm 19.93 mm
C1
(0.7866-0.7871 in) (0.785 in)
Countershaft O.D.
24.959-24.980 mm 24.90 mm
C4
(0.9826-0.9835 in) (0.980 in)
M5, M6, C4 gear 0.020-0.062 mm 0.08 mm
to bushing (0.0008-0.0024 in) (0.003 in)
M5, C4 bushing 0.005-0.047 mm 0.07 mm
to shaft (0.0002-0.0019 in) (0.003 in)
C1 bushing to 0.007-0.041 mm 0.06 mm
shaft (0.0003-0.0016 in) (0.002 in)
C2, C3 gear to 0.020-0.062 mm 0.08 mm
bushing (0.0008-0.0024 in) (0.003 in)
0.08-0.18 mm (0.003-0.007 0.30 mm (0.012

Gear backlash
in) in)
53 mm (2.1 in) 51.5 mm (2.03 in)
length
indicated range.
Oil pressure (at
490.3 kPa/7,000 rpm 80° C (176° F)
oil pressure
(71 PSI/7,000 rpm)
switch)
Oil pump
delivery
Final drive gear

'83 170 cm3 (5.78 oz)
Oil capacity
'84 150 cm3 (4.9 oz)

'83-'84 E54A
Identification mark
Main jet #115
Capacity 12V 12 AH
Alternator
'83 STATOR
RPM Amperage Output
2500 2 amps
2000—2100 0±1 amp
1500 -5 ± 1 amp
1000 -10 ± 1 amp
'84 STATOR
RPM Amperage Output
2500 2 amps
1700—1800 0 ± 1 amp
1500 -3 ± 1 amp
1000 -9 ± 1 amp

Spark plug
Ignition timing
SERVICE
ITEM STANDARD
LIMIT
Brush spring
800 ± 120 g (28.2 ± 4.2 oz) 680 g (24.0 oz)
Starter tension
motor 12.0-13.0 mm (0.47-0.51
In)
Ignition timing
Ignition timing
10° BTDC at 1,400 ± 200 rpm
"F" mark
Generator
Cooled)
Battery
12V ~ 12 AH
capacity
Headlight
(high/low
equivalent)
beam)
(front/rear) 1073
Neutral
LIGHTS 12V -2 CP
indicator
Turn signal
12V - 2 CP
indicator
High beam
12V -2 CP
indicator
Oil pressure
12V-2 CP
warning light
FUSE
FUEL SENSOR
Front Rear
Tire size 100/90--19 130/90—16
57H 67H
Up to 90 kg (200 lbs) load 225 (32) 225 (32)
Cold tire pressure
225 (32) 280 (40)
capacity load
Tire brand
Dunlop F11 K627
SERVICE
ITEM STANDARD
LIMIT
0.2 mm (0.01
Axle shaft runout _
in)
2.0 mm (0.08
Front wheel rim in)
runout 2.0 mm (0.08
in)
0.03 mm (0.001
in)
512.4 mm (20.2
in)
0.2 mm (0.01
Fork tube runout -
in)
(15.7 oz)

0.03 mm (0.001
Wheel bearing play
in)
217.6 mm (8.57 in)
length in)
160.0-160.3 mm (6.30-6.31 161.0 mm (6.34
Brake drum I.D.
in) in)

15.93 mm (0.627 in)
I.D. 0.6265 in)
15.82 mm (0.623 in)
O.D. 0.6242 in)
O.D. 1.2598 in) in)
I.D. 1.2630 in) in)
Fuel System > Fuel Level Sensor
Fuel Level Sensor

at this point.
Removal
Drain the fuel from the fuel tank and remove the tank. See the Fuel Tank
topic for more information.
Remove the four fuel level sensor bolts with an 8 mm socket.
Remove the fuel level sensor from the bottom of the fuel tank.
Inspect the fuel level sensor rubber seal. Replace the seal as needed.
Inspection
You will need a digital multimeter set to ohms of resistance (Ω) to check
the fuel level sensor. Measure the resistance of the fuel level sensor at
different levels to determine if the sensor is working properly.
FUEL SENSOR
To test the fuel level gauge disconnect the fuel level sensor connector and
jump a wire between the green and yellow wire terminals. When the ignition
switch is turned on the fuel gauge should show a full tank.
To check the accuracy of the fuel gauge jump the green and yellow wire
terminals with two different resistors. Turn the ignition switch on and check
the fuel gauge.
Resistor Fuel Gauge

103 - 117 Ω Empty
1-5Ω Full
Installation
Install the fuel sensor rubber seal into the bottom of the fuel tank.
Install the fuel level sensor into the fuel tank.
Thread in the four fuel level sensor mounting bolts. Tighten the bolts in a
crisscross manner. Tighten the bolts securely with an 8 mm socket.

Fuel System > Fuel Strainer
Petcock and Fuel Filter

at this point.
Removal
Drain the fuel, and remove the fuel tank. See the Fuel Tank topic for more
information.
Remove the petcock lock nut using a wrench.
Remove the petcock from the fuel tank.
Remove the four petcock screws with a #2 Phillips screwdriver.
Remove the vacuum chamber cover, the diaphragm, and the spring.
Inspect the petcock for damage and clogging. Check the fuel strainer for
tears and foreign particles. Clean the petcock with a high flash point
solvent and compressed air. Discard the O-ring at the base of the fuel
strainer and replace it with a new item.

at this point.
If you need to remove the petcock valve knob loosen its screw with a #2
Phillips screwdriver. Remove the screw, washer and knob.
Installation
Install the petcock valve knob. Insert its screw with washer and tighten the
screw securely with a #2 Phillips screwdriver.
Place a new O-ring over the fuel strainer slide it down to the base of the
petcock.
Install the spring, the diaphragm and the cover.
Insert the four screws and tighten them securely with a #2 Phillips
screwdriver.
Insert the fuel strainer into the fuel tank so that the petcock knob faces
outside.
Tighten the petcock lock nut using a wrench.
To install the fuel tank see the Fuel Tank topic.

Fuel System > Airbox
Airbox

at this point.
Removal
Remove the side covers. See the Side Covers topic for more information.
Remove the seat. See the Seat topic for more information.
Remove the tail section. See the Tail Section topic for more information.
Remove the rear fender. See the Rear Fender topic for more information.
Remove the battery. See the Battery topic for more information. Remove
the battery holder.
Remove the airbox mounting nuts using a 10 mm socket.
Remove the airbox hanger nuts using a 10 mm socket. Loosen the airbox
to carburetor connection bands.
Remove the pulse generator couplers.
Remove the spark unit bolts and brackets using a 10 mm socket.
Remove the spark unit.
Disconnect the oil pressure switch connector.
Remove the airbox from the rear.
Installation
Fit the airbox from the rear.
Thread on the airbox hanger nuts and tighten securely with a 10 mm

socket.
Thread on the airbox mounting nuts and tighten with a 10 mm socket.
Install the battery holder.
Connect the oil pressure switch wires.
Fit the spark unit to the frame.
Fit the brackets and thread in the bolts. Tighten securely using a 10 mm
socket.
Connect the pulse generator couplers.
Install the battery. See the Battery topic for more information.
Install the rear fender. See the Rear Fender topic for more information.
Install the tail section. See the Tail Section topic for more information.
Install the seat. See the Seat topic for more information.
Install the side covers. See the Side Covers topic for more information.
Fuel System > Emissions
Emissions (California Model 84'+)

at this point.
Some models are equipped with an air injection emissions system
Purge Control Valve
If it the motorcycle is difficult to start when the engine is hot, the purge
control valve should be inspected.
The Purge Control Valve (PCV) is located under the carburetors. Check
the hoses on the PCV, the fuel tank and the charcoal canister to make sure
they are not kinked or have any signs of damage or deterioration.
Remove the PCV hose from the 5-way joint. Remove the hose from the No.
3 carburetor. Remove the hose from the charcoal canister. Remove the
PCV from its mount under the carburetors. There is a hose routing diagram
on the right side cover.
Using a vacuum pump, apply the specified vacuum to the PCV by

connecting the pump to the 8 mm I.D. hose. The 8 mm I.D. hose is the hose
on the PCV that attaches to the 5-way joint.
Specified vacuum 250 mm (9.8 in) Hg
The specified vacuum should be steady. If it fluctuates, the PCV should be

replaced.
Remove the vacuum pump from the 8 mm I.D. hose and connect it to the
hose that connects to the No. 3 carburetor. Apply the specified vacuum to
the PCV.
The specified vacuum should be steady. If it fluctuates, the PCV should be

replaced.
Connect a pressure pump to the 8 mm I.D. hose that connects to the

charcoal canister. Using the vacuum pump that is attached to the PCV
hose that connects to the No. 3 carburetor, apply the specified vacuum.
Now, use the pressure pump to pump air through the PCV hose that
connects to the charcoal canister. Air should flow through the PCV and out
of the hose that connects to the 5-way joint. Replace the PCV if air does
not flow out.
Remove the pumps from the PCV. Install the PCV on its mount under the
carburetors. Route and reconnect all of the hoses according to the
diagram.

External Components > Seat
Seat

at this point.
Removal
Remove the seat mounting bolt from either side of the motorcycle using a
10 mm socket.
Lift the seat off of the frame.
Installation
Fit the seat onto the frame. Line up the seat mounting brackets with the
seat mounting bolt holes on the frame.
Thread in the bolts and tighten securely using a 10 mm socket.

External Components > Fuel Tank
Fuel Tank

at this point.
Inspect the fuel, vent and vacuum hoses for damage and deterioration.
Replace the hoses as needed.
Removal
The fuel level sending unit coupler is located on the left side of the
motorcycle, beneath the seat. Disconnect the fuel lever coupler.
Turn the petcock valve to the on position. To drain the fuel tank remove the
fuel line from the carburetors. Place the open end of the fuel line in a
suitable container and turn the petcock to the 'ON' position.
Squeeze the fuel hose clamp and slide it back. Remove the fuel hose from
the petcock.
Remove the vacuum line from the petcock.
Remove the fuel tank mounting bolt using a 12 mm socket.
Lift up on the rear of the fuel tank and slide it back to free the tab on the fuel
tank from the frame. Remove the fuel tank.
Inspect the rubber bumpers on the sides of the tank for damage and
deterioration. Replace the dampers as needed.
Remove the collars and rubber bumpers from the front and rear of the
frame. Replace the components as needed.
To remove the petcock see the Petcock topic.
To remove the fuel level sensor see the Fuel Level Sensor topic.
Installation
Install the rubber collar into the rear of the fuel tank. Install the side rubber
grommets, which are located on the underside of the fuel tank towards the
front.
Set the fuel tank into place on the frame.
Place the tab located on the rear of the tank over the rubber piece on the
frame. Install the washer and bolt. Tighten securely using a 12 mm socket.
Install the vacuum line onto the petcock.
Connect the fuel line to the petcock. Secure the fuel line with its clamp.
Plug in the fuel level coupler on the left side of the tank.
Install the seat. See the Seat for more information.

External Components > Tail Section
Tail Section

at this point.
Removal
The passenger grab handle is attached to the frame using two bolts.
Remove these bolts using a 12 mm socket.
Remove the passenger grab handle.
The taillight and turn signal connectors are located underneath the rear tail
section and can be accessed with the seat removed.
Disconnect the turn signals (light blue/green and orange/green wires)
Disconnect the taillight.
Disconnect the brake/tail light sensor connector.
The rear tail section is attached to the frame using four bolts located on the
underside of the tail section.
Remove the four bolts using a 12 mm socket.
Remove the tail section by lifting it upwards.
Installation
Fit the tail section to the frame. Do not bolt it down yet.
Connect the taillight, the turn signals and the brake/taillight sensor coupler
as shown.
Thread in the tail section mounting bolts and tighten securely using a 12
mm socket.
Tuck the taillight, turn signal and brake/taillight sensor coupler wires under
the rear of the tail section.
Fit the passenger grab handle.
Thread in the bolts and tighten securely using a 12 mm socket.

External Components > Footpegs
Footpegs

at this point.
Removal
Front
Remove the rear brake pedal.
Remove the rear brake return spring from the passenger foot peg bracket.
Remove the cotter pin and the bolt.
Remove the rear brake pedal cam.
The front foot pegs are connected to the frame through the passenger foot
peg brackets.
Remove the front foot peg mounting bolt using an Allen wrench.
Inspect the foot pegs for any significant damage or wear such as cracks.
Remove the cotter pin. Remove the washer.
Remove the bolt.
Pull the foot peg out from the foot peg bracket. Remove the return spring.
Remove the passenger foot peg bracket mounting bolts using a 6 mm

Allen wrench.
Remove the passenger foot pegs and brackets.
Installation
Fit the passenger foot peg bracket to the frame and thread in the bolt.
Tighten the bolts to specification using a 6 mm Allen wrench.
Item Qty Thread Dia. (mm) Torque N-m (ft-lb)

Foot peg 2 10 30-40 (22-29)
Fit the return spring into the front foot peg bracket. Insert the foot peg into
the front foot peg bracket. Be sure to insert the foot pegs so that when
mounted on the motorcycle the rubber side of the foot peg will be up.
Insert the foot peg to foot peg bracket bolt.

Install the washer. Install a new cotter pin.
Fit the front foot peg bracket to the frame. Thread in the mounting bolt at
tighten to specification using an Allen wrench.

Foot peg 2 10 30-40 (22-29)
Insert the rear brake pedal cam.
Insert the cam to lever bolt and install a new cotter pin.
Attach the brake pedal return spring to the passenger foot peg bracket.
Install the rear brake pedal.

External Components > Gearshift Pedal
Gearshift Pedal
at this point.
Adjustment
Remove the drive gear cover.
The top of the gearshift pedal should sit 54 mm (2.1 in) below the top of the
footpeg. Loosen the locknuts and adjust the shifter until it is within
specification. Tighten the locknuts securely when finished.
Removal
Remove the shifter pinch bolt using a 10 mm socket. Note the position of
the punch marks on the shaft and clamp as they will be used to install the
pedal. Remove the gearshift pedal pinch bolt.
Remove the gearshift pivot bolt using a 12 mm socket. Pull the gearshift
pedal straight out and off of its shaft.
Installation
Thread in the gear shift pedal pivot bolt and tighten to specification using a
12 mm socket.

Gearshift pedal pivot 1 8 18-25 (13-18)
Fit the gearshift clamp onto the shift shaft. Install the pinch bolt and tighten it
securely using a 10 mm socket. Make sure the punch marks on the
gearshift clamp and the shaft line up.
Adjust the pedal height. See the adjustment section at the top of this topic.

External Components > Handlebar
Handlebar
at this point.
Removal
To remove the front brake master cylinder see the Master Cylinder topic.
Remove the light switch assembly screw using a #2 Phillips screwdriver.
Separate the two halves of the light switch assembly and remove from the
handlebar.
Remove the clutch lever/choke lever assembly bolts using an Allen wrench.
Separate the clutch lever/choke lever assembly from the handlebar.
Remove the choke cable from the lever.
Remove the throttle body mounting screws using a #2 Phillips screwdriver.
Separate the halves of throttle body from the handlebar.
Remove the throttle cables.
Remove the throttle tube and grip.
Disconnect the starter button coupler.
Remove the handlebar cover.
Remove the handlebar bolt caps.
Remove the handlebar bolts using an Allen wrench.
Remove the handlebar clamps.
Remove the handlebar.
Grips
If you plan to replace the grips you can slice them lengthwise with a razor
blade and peel them off. To remove the grips without cutting them use a
screwdriver to open a gap between the grip and the handlebar. Spray in
contact cleaner to break up the grip cement. Use compressed air to
expand the grip so it can be easily slid off the end of the handlebar and if
you don't have air just twist. Note the relationship between the angle of the
grip and the throttle tube so that the new grip can be installed with the
correct angle.
Before installing the grips to either the throttle tube or the handlebar, wipe
down the area with a brake or parts cleaner that will dry without leaving a
residue. When you are sure the area is dry apply grip cement to the bar or
tube. Install the left grip at an angle of your preference. Install the throttle
grip onto the tube with the same angle as the original grip.
Installation
Fit the handlebar onto the steering clamp.
Fit the handlebar clamps over the handlebar.
Thread in the handlebar bolts and tighten to specification using an Allen

wrench.

Handle bar holder 4 8 20-30 (14-22)
Install the handlebar bolt caps.
Install the handlebar cover.
Connect the starter button coupler.
Install the throttle grip onto the right side of the handlebar.
Install the throttle cables.
Install the throttle body halves over the right side of the handlebar.
Thread in the throttle body mounting screw and tighten securely using a #2
Install the light switch assembly halves over the left side of the handlebar.
Thread in the light switch assembly screw and tighten using a #2 Phillips
screwdriver.
To install the front brake master cylinder see the Master Cylinder topic.
Adjust the throttle fee play. See the Throttle Free Play topic for more
information.

External Components > Front Fender
Front Fender

at this point.
Removal
Remove the front wheel. See the Front Wheel topic for more information.
Remove the four front fender mounting bolts using a 10 mm socket.
Slide out the mounting brackets.
Remove the front fender.
Remove the fork brace bolt caps using a flat blade screwdriver. Loosen the
fork brace bolts using a 6 mm Allen wrench. Remove the bolts.
Remove the fork brace.

Remove
9/23/2010 the fork brace. Honda CB550SC/CB650SC Online Repair …
Installation
Fit the front fender into the front fork assembly.
Slide in the mounting brackets.
Thread in the four mounting bolts and tighten securely using a 10 mm

socket.
Look at the underside of the fork brace to determine which way to fit it to
the forks. The arrow on the underside of the brace should point towards the
front of the motorcycle.
Fit the fork brace to the forks.
Thread in the bolts. Tighten the bolts to specification using a 6 mm Allen

wrench. Install the fork bolt caps.

Item Qty
(mm) (ft-lb)
Front fork brace 4 8 18-28 (13-20)
Install the front wheel. See the Front Wheel topic for more information.

External Components > Rear Fender
Rear Fender

at this point.
Removal
Remove the two rear fender top mounting nuts using a 10 mm socket.
Unclip the wire bundle from the left side of the frame.
Remove the rear fender.
Installation
Fit the rear fender into position on the frame.
Fit the wire bundle into the clip.
Install the two rear fender top mounting nuts and tighten securely.
Install the tail section. See the Tail Section topic for more information.
Install the seat. See the Seat for more information.

External Components > Exhaust System
Exhaust System

at this point.
Removal
The exhaust system on the CB650SC consists of two 2-1 muffler pipes
connected with a cross pipe that runs underneath the motorcycle.
Remove the muffler mounting nuts using a 10 mm socket. Remove the

header pipe joint.
Remove the header pipe joint collar.
Remove the center muffler mounting bolts using a 12 mm socket.
Remove the center muffler joint bolt using a 12 mm socket.
Remove the muffler mounting bolts using a 17 mm socket.
Remove the rear brake pedal bolt using a 12 mm socket. Remove the rear
brake pedal.
Carefully lower and remove the muffler.
Installation
Lift the muffler into position and support it using a jack or a stand.
Thread in the muffler mounting bolts and tighten securely using a 17 mm

socket.
Thread in the muffler joint bolt and tighten to specification.
Thread
Item Qty Dia. Torque N-m (ft-lb)
(mm)
Muffler
24-30
joint 1 8
(17-22)
bolt
Thread in the muffler mounting bolts and tighten to specification using a 12

mm socket.
Thread
Item Qty Dia. Torque N-m (ft-lb)
(mm)
Muffler 24-30
2 8
bracket (17-22)
Install the header pipe joint collars.
Install the header pipe joint. Make sure the arrow on the joints is facing
down. Thread on the header pipe nuts. Tighten them securely, but do not
over-tighten them.
DIMENSIONS
FRAME

(140 sq in)

(31 sq in)
FORK OIL CAPACITY

Right 447 - 452 cc (15.2 - 15.3 oz)
Left 462 - 467 cc (15.6 - 15.8 oz)
TIRE INFLATION
Front 225 kPa
(32 psi)
Driver only
Rear 225 kPa
(32 psi)
Front 225 kPa
(32 psi)
Rear 280 kPa
(40 psi)
ENGINE
60.0 x 58.0 mm (2.36 x 2.28 in)
53.7 kw/9,500 rpm
Maximum horsepower
73 PS/9,500 rpm
57 N-m/8,000 rpm
57 N-m/8,000 rpm
Maximum torque
5.7 kg-m/8,000 rpm
58 (BTDC) at 0 lift

Identification
VE54A
number
'83-84: VE54A
CARBURETOR
'84
VE75A
CALIFORNIA:
Primary
1.704 (92/54): 1
reduction
pattern 1-N-2-3-4-5-(O.D.)

Spark plugs
IGNITION TIMING
At idle: 10° BTDC
1079-1275 kPa
(156-185 psi)
Cam 31.85 mm (1.252
IN, EX 31.901 mm (1.2559 in)
height in)
INI, IN4, 22.939-22.970 mm 22.91 mm (0.902
EX1, EX4 (0.9031-0.9043 in) in)
O.D.
IN2, IN3, 22.909-22.930 mm 22.88 mm (0.901
IN 1, IN4, 0.030-0.072 mm
0.13 mm (0.005 in)
Oil EX1, EX4 (0.0012-0.0028 in)
0.16 mm (0.006 in)
EX2, EX3 (0.0028-0.0044 in)
Valve 27.6-31.8 kg/22.2 mm
spring IN, EX Outer
Preload/ (60.1-70.1 lb/0.875 in)
length 8.65-9.95 kg/18.4 mm
IN, EX inner
(19.1-21.9 lb/0.726 in)
SERVICE-
ITEM STANDARD
LIMIT
4.975-4.990 mm (0.1959- 4.97 mm
IN
0.1965 in) (0.195 in)
Valve stem O.D.
4.955-4.970 mm (0.1951- 4.94 mm
EX
0.1957 in) (0.194 in)
IN, 5.0-5.012 mm (0.1969- 5.04 mm
Valve guide I.D.
guide 0.010-0.037 mm (0.0004- 0.07 mm
IN
clearance 0.030-0.057 mm (0.0012- 0.09 mm
EX
0.0022 in) (0.004 in)
IN, 1.41-1.98 mm (0.056- 2.0 mm (0.08
Valve face width
EX 0.078 in) in)
0.10 mm
Warpage
(0.004 in)
1.0 mm (0.04 in)
head IN/EX in)
23 000-23.021 mm 23.05 mm
(0.9055-0 90 3 in) (0.907 in)
SERVICE
STANDARD
LIMIT
60.000-60.010 mm 60.10 mm
I.D.
(2.3622-2.3626 in) (2.367 in)
Cylinder
0.10 mm
Warpage
(0.004 in)
0.015-0.045 mm 0.06 mm
TOP
SECOND
(0.0006-0.0018 in) (0.002 in)
0.15-0.30 mm 0.5 mm
TOP
(0.0059-0.012 in) (0.02 in)
0.15-0.30 mm 0.5 mm
SECOND
SECOND
Ring end gap (0.0059-0.012 in) (0.02 in)
OIL
0.30-0.90 mm 1.1 mm
(SIDE
(0.012-0.035 in) (0.04 in)
Piston O.D.
pin (2.3610-2.3618 in) (2.36 in)
15.002-15.008 mm 15.05 mm
Piston pin bore
(0.5906-0.5909 in) (0.592 in)
15.016-15.034 mm 15.07 mm
(0.5912-0.5909 in) (0.593 in)
14.994-15.000 mm 14.98 mm
Piston pin O.D.
(0.5903-0.5906 in) (0.589 in)
0.002-0.014 mm 0.04 mm
(0.0001-0.0006 in) (0.002 in)
0.010-0.050 mm 0.10 mm
(0.0003-0.0020 in) (0.004 in)
SERVICE
ITEM STANDARD
LIMIT
14.000—14.043 mm 14.06 mm
Cylinder I.D.
cylinder 13.957—13.984 mm 13.94 mm
Piston O.D.
(0.5495-0.5506 in) (0.549 in)
38.100—38.162 mm (1.500- 38.18 mm
Cylinder I.D.
cylinder 38.036-38.075 mm (1.4975- 38.02 mm
Piston O.D.
1.4990 in) (1.479 in)
31.984-32.000 mm (1.2592- 31.95 mm
A
O.D. 41.989-42.000 mm (1.6531- 41.95 mm
B
1.6535 in) (1.652 in)
34.0 mm (1.34
in)
Spring 21.2-23.2 kg/23.8 mm (46-
Clutch _
2.6 mm (0.10
in)
0.30 mm
Plate warpage -
(0.012 in)
gear I.D. 1.6544 m) (1.656 in)

42.175-
Drive
42.200 mm 42.16 mm
gear
(1.6604- (1.660 in)
O.D.
1.6614 in)
24.987-
O.D. (0.9837- (0.983 in)
0.9843 in)
SERVICE
ITEM STANDARD
LIMIT
0.05 mm
Runout _
(0.002 in)
Crankshaft
0.024-0.057 mm (0.0009- 0.07 mm
0.0022 in) (0.003 in)
0.019-0.043 mm (0.0007- 0.06 mm
0.0017 in) (0.002 in)
323.05-324.05 mm 327.0 mm
Cam chain Length
(12.750-12.758 in) (12.87 in)
Alternator 136.50-136.70 mm 137.8 mm
Length
chain (5.374-5.382 in) (5.43 in)
MAIN BEARING
1 2 3 4
32.994- 32.988- 32.982- 32.976-
33.000 mm 32.994 mm 32.988 mm 32.982 mm
(1.2990- (1.2987- (1.2985- (1.2983-
1.2992 in) 1.2990 in) 1.2987 in) 1.2985 in)
36.000-36.006 mm
(1.4173-1.4176 in)
CRANKCASE
36.006-36.012 mm
(1.4176-1.4178 in)
NO.
36.012-36.018 mm
(1.4178-1.4180 in)

Blue 1.511-1.514 mm (0.0595-0.0596 in)
Black 1.508-1.511 mm (0.0594-0.0595 in)
Brown 1.505-1.508 mm (0.0593-0.0594 in)
Green 1.502-1.505 mm (0.0591 -0.0593 in)
Yellow 1.499-1.502 mm (0.0590-0.0591 in)
Pink 1.496-1.499 mm (0.0589-0.0590 in)

CRANKPIN O.D. CODE
1 2 3
37.000-37.008 mm 37.008-37.016 mm 37.016-37.024 mm
(1.4567-1.4570 in) (1.4570-1.4573 in) (1.4573-1.4576 in)
40.000-
40.008 mm
(1.5748-
1.5751 in)
40.008-
CONNECTING
40.016 mm
(1.5751 -
NO.
1.5754 in)
40.016-
40.024 mm
C Brown Black Blue
(1.5754 -
1.5757 in)

Blue 1.502-1.506 mm (0.0591-0.0593 in)
Black 1.498-1.502 mm (0.0590-0.0591 in)
Brown 1.494-1.498 mm (0.0588-0.0590 in)
Green 1.490-1.494 mm (0.0587-0.0588 in)
Yellow 1.486-1.490 mm (0.0585-0.0587 in)
TRANSMISSION
SERVICE
ITEM STANDARD
LIMIT
0.044-0.133 mm 0.20 mm
Low, 2nd, 3rd
(0.0017-0.0052 in) (0.008 in)
0.034-0.102 mm 0.15 mm
Backlash 4th
(0.0013-0.0040 in) (0.006 in)
0.046-0.140 mm 0.18 mm
5th, 6th
5th, 6th
(0.0018-0.0055 in) (0.007 in)
28.020-28.041 mm 28.06 mm
M5, M6
(1.1031-1.1040 in) (1.105 in)
24.020-2.4041 mm 24.06 mm
Gear I.D. C1
(0.9457-0.9465 in) (0.947 in)
28.020-28.041 mm 28.06 mm
C2, C3, C4
(1.1031-1.1040 in) (1.105 in)
27.979-28.000 mm 27.96 mm
M5, C4
(1.1015-1.1024 in) (1.101 in)
27.979-28.000 mm 27.96 mm
M6
(1.1015-1.1024 in) (1.101 in)
Gear bushing O.D.
23.984-24.005 mm 23.97 mm
C1
(0.9443-0.9451 in) (0.944 in)
27.979-28.000 mm 27.96 mm
C2, C3
(1.1015-1.1024 in) (1.101 in)
24.985-25.006 mm 25.04 mm
M5, C4
(0.9837-0.9845 in) (0.986 in)
Gear bushing I.D.
20.000-20.021 mm 20.04 mm
C1
(0.7874-0.7882 in) (0.789 in)
24.959-24.980 mm 24.80 mm
Mainshaft O.D. (M5)
(0.9826-0.9835 in). (0.980 in)
19.980-19.993 mm 19.93 mm
C1
(0.7866-0.7871 in) (0.785 in)
Countershaft O.D.
24.959-24.980 mm 24.90 mm
C4
(0.9826-0.9835 in) (0.980 in)
M5, M6, C4 gear 0.020-0.062 mm 0.08 mm
to bushing (0.0008-0.0024 in) (0.003 in)
M5, C4 bushing 0.005-0.047 mm 0.07 mm
to shaft (0.0002-0.0019 in) (0.003 in)
C1 bushing to 0.007-0.041 mm 0.06 mm
shaft (0.0003-0.0016 in) (0.002 in)
C2, C3 gear to 0.020-0.062 mm 0.08 mm
bushing (0.0008-0.0024 in) (0.003 in)
0.08-0.18 mm (0.003-0.007 0.30 mm (0.012

Gear backlash
in) in)
53 mm (2.1 in) 51.5 mm (2.03 in)
length
indicated range.
Oil pressure (at
490.3 kPa/7,000 rpm 80° C (176° F)
oil pressure
(71 PSI/7,000 rpm)
switch)
Oil pump
delivery
Final drive gear

'83 170 cm3 (5.78 oz)
Oil capacity
'84 150 cm3 (4.9 oz)

'83-'84 E54A
Identification mark
Main jet #115
Capacity 12V 12 AH
Alternator
'83 STATOR
RPM Amperage Output
2500 2 amps
2000—2100 0±1 amp
1500 -5 ± 1 amp
1000 -10 ± 1 amp
'84 STATOR
RPM Amperage Output
2500 2 amps
1700—1800 0 ± 1 amp
1500 -3 ± 1 amp
1000 -9 ± 1 amp

Spark plug
Ignition timing
SERVICE
ITEM STANDARD
LIMIT
Brush spring
800 ± 120 g (28.2 ± 4.2 oz) 680 g (24.0 oz)
Starter tension
motor 12.0-13.0 mm (0.47-0.51
In)
Ignition timing
Ignition timing
10° BTDC at 1,400 ± 200 rpm
"F" mark
Generator
Cooled)
Battery
12V ~ 12 AH
capacity
Headlight
(high/low
equivalent)
beam)
(front/rear) 1073
Neutral
LIGHTS 12V -2 CP
indicator
Turn signal
12V - 2 CP
indicator
High beam
12V -2 CP
indicator
Oil pressure
12V-2 CP
warning light
FUSE
FUEL SENSOR
Front Rear
Tire size 100/90--19 130/90—16
57H 67H
Up to 90 kg (200 lbs) load 225 (32) 225 (32)
Cold tire pressure
225 (32) 280 (40)
capacity load
Tire brand
Dunlop F11 K627
SERVICE
ITEM STANDARD
LIMIT
0.2 mm (0.01
Axle shaft runout _
in)
2.0 mm (0.08
Front wheel rim in)
runout 2.0 mm (0.08
in)
0.03 mm (0.001
in)
512.4 mm (20.2
in)
0.2 mm (0.01
Fork tube runout -
in)
(15.7 oz)

0.03 mm (0.001
Wheel bearing play
in)
217.6 mm (8.57 in)
length in)
160.0-160.3 mm (6.30-6.31 161.0 mm (6.34
Brake drum I.D.
in) in)

15.93 mm (0.627 in)
I.D. 0.6265 in)
15.82 mm (0.623 in)
O.D. 0.6242 in)
O.D. 1.2598 in) in)
I.D. 1.2630 in) in)

Engine > Camshaft Removal
Camshaft Removal

at this point.
Remove the cylinder head cover. See the Cylinder Head Cover topic for
more information.
Remove the oil pipe bolts, indicated by the red arrows. The center pipe
bolts are connected with a bracket. Use a 10 mm socket to remove all the
bolts.
Remove the oil pipes.
Remove the oil hole caps and check the inner lips of the caps for damage.
If they are damaged, they must be replaced.
The pulse generator is located on the left side of the engine.
Remove the pulse generator cover bolts using a 5 mm Allen wrench.
Remove the pulse generator cover.
Remove the cam sprocket bolts using a 10 mm socket.
Loosen the cam chain by pushing the lock pin down and pulling the lock
plate up with a flat blade screwdriver.
Turn the crankshaft counterclockwise (in the direction of the arrow) in order
to make the other cam sprocket bolts accessible.
Using a 10 mm socket, remove the other cam sprocket bolts. Remove the
sprockets from the camshaft flanges. The sprockets cannot be removed
from the camshafts until the camshafts have been removed from the
cylinder head.
Remove the camshaft holder bolts using a 10 mm socket.
Remove the camshaft holders as shown.
Note:The camshaft holders are marked EX1, EX2, EX3, and EX4 from
the No. 1 cylinder at the exhaust side. The other camshaft holders are
marked IN1, IN2, IN3 and IN4 from the No. 1 cylinder on the intake side.
Remove the dowels.
Remove the camshafts from the cylinder head. Remove the cam sprockets
from the camshafts. The camshafts are marked EX for exhaust and IN for
intake.
Remove the rocker arms. There are 16 rocker arms. Inspect the rocker
arms for damage or abnormal wear. Replace if damaged or worn.
Remove the hydraulic tappets. There are 16 tappets.
Inspection
Use a dial gauge to inspect the camshaft runout. Replace the camshafts if
they are out of specification.
ITEM SERVICE LIMIT

Use a micrometer to measure the cam lobe height. If the lobes are out of
the specification the camshaft must be replaced. Inspect the lobes for
scoring or scratches. Replace if damaged.

Cam height IN, EX 31.901 mm (1.2559 in) 31.85 mm (1.252 in)
Inspect the camshaft journal outer diameter with a micrometer. If the outer
diameter is out of specification, the camshaft must be replaced.

22.939-22.970 mm
INI, IN4, EX1, EX4 22.91 mm (0.902 in)
(0.9031-0.9043 in)
O.D.
22.909-22.930 mm
IN2, IN3, EX2, EX3 22.88 mm (0.901 in)
(0.9019-0.9028 in)
Use plastigauge to check the clearance between camshafts and the holder
journals. Place the plastigauge over the camshaft where the holder fits.
Install the holder to its original position and torque the bolts to specification
with a 10 mm socket. Remove the camshaft holders and check the
plastigauge according to its clearance chart. Measure at the widest
section of the plastigauge for an accurate measurement.
Torque N.m (ft-

ITEM Qty Thread Dia. (mm)
lb)
IN 1, IN4, EX1, 0.030-0.072 mm 0.13 mm (0.005

Oil EX4 (0.0012-0.0028 in) in)
clearance 0.070-0.112 mm 0.16 mm (0.006
IN2, IN3, EX2, EX3
(0.0028-0.0044 in) in)
Inspect the cam sprockets for wear or damage. Replace if worn or

damaged.
Bleed the tappets using a tappet bleeder as shown. Pump until air bubbles
stop coming out.
Special tool: Tappet Bleeder 07973-ME90000
To install the camshaft see the Camshaft Installation topic.

Engine > Camshaft Installation
Camshaft Installation

at this point.
Install the 16 tappets as shown.
Turn the crankshaft counterclockwise with a 14 mm socket, until the 'T'

mark lines up with the triangle punch mark on the crankcase.
Lubricate the camshaft journals with molybdenum disulfide grease.
Insert the dowel pins.
Set the cam sprockets onto the camshaft flanges. Make sure the timing
mark is facing out.
Place the camshafts into the cylinder head. Make sure the No. 1 cam lobe
is pointing up on both the exhaust and intake camshafts. The exhaust
camshaft (EX) goes in the front camshaft journals while the intake (IN)
camshaft goes in the rearward camshaft journals.
Install each camshaft holder to its original position with the arrow marks
facing towards the front of the motorcycle.
Install new O-rings onto the oil pipes. Coat the O-rings in engine oil. Fit the
oil pipes into the cylinder head as shown (indicated in red in the second
photo).
Thread in the oil pipe mounting bolts. Tighten the two center bolts.
Torque N.m (ft-

lb)
Oil control bolt 6
2 6 10-14 (7-10)
mm
Fill the oil pocket of the camshaft holders with clean engine oil.
Tighten the camshaft holder bolts to the specified torque in a criss-cross

pattern, tightening 2 to 3 bolts at a time.
Torque N.m (ft-

lb)
Align the 'IN' mark on the cam sprocket with the cylinder head surface as
shown in the first picture. Alight the sprocket bolt holes by turning the
crankshaft clockwise. Thread in the intake sprocket bolt, but do not torque
it yet. Return the crankshaft and align the 'EX' mark on the exhaust
camshaft sprocket with the cylinder head surface as shown in the third
picture. Thread in the exhaust cam sprocket bolt. Tighten all four cam
sprocket bolts to specification using a 10 mm socket.
Thread
Torque N.m (ft-
Item Qty Dia. Remarks
lb)
(mm)
U.B.S., Apply a locking
Cam sprocket 4 7 18-22 (13-16)
Cam sprocket 4 7 18-22 (13-16)
agent to the threads.
Install the cylinder head cover. See the Cylinder Head cover topic for more
information.
Install the spark plugs. See the Spark Plugs topic for more information.

Engine > Cylinder Head Cover
Cylinder Head Cover

at this point.
Removal
Remove the spark plugs. See the Spark Plugs topic for more information.
Remove the ignition coils. See the Ignition System topic for more
information.
Remove the Pair control valve if your model is equipped with the
secondary air injection emissions system. See the Emissions topic for
more information.
Remove the cylinder head cover bolts using a 5 mm Allen wrench.
Check the chain slipper for damage and wear. If the slipper is worn or
damaged, replace it. Remove the four slipper mounting bolts using a 10
mm Allen wrench. Install a new slipper. Thread in the bolts and tighten
securely using a 10 mm Allen wrench.
Lightly tap the cylinder head cover with a rubber mallet if it will not come off
easily.
Remove the cylinder head cover. If the engine is still in the frame, lift the
cover up and out to the side, taking care not to damage the cover on the
frame. Remove the gasket.
Remove the cylinder head hole plugs.
Remove the dowel pins.
Installation
Install the dowel pins.
Install the cylinder head hole plugs.
Install a new gasket onto the cylinder head, then fit the cylinder head cover.
Thread in the cylinder head cover bolts.
Tighten the cylinder head cover bolts using a 5 mm Allen wrench. Gradually
tighten two opposed bolts at a time in order to prevent cover warpage or a
bad seal. Continue tightening the bolts in this manner until all bolts have
reached torque specification.
ITEM Torque N.m (ft-lb)

Cylinder head 20-24 (14-17)
Install the Pair control valve if your model is equipped with the secondary
air injection emissions system. See the Emissions topic for more
information.
Install the spark plugs and frame cross bar. See the Spark Plugs topic for
more information.
Install the ignition coils. See the Ignition System topic for more information.
Install the fuel tank. See the Fuel Tank topic for more information.

Engine > Cylinder Head
Cylinder Head
at this point.
Removal
Remove the cylinder head cover. See the Cylinder Head Cover topic for
more information.
Remove the camshaft. See the Camshaft topic for more information.
Remove the rocker arms. There are 16 rocker arms. Inspect the rocker
arms for damage or abnormal wear. Replace if damaged or worn.
Remove the rocker arm holder bolts using a 10 mm socket.

Remove the rocker arm holders.
Remove the dowel pins from the cylinder head.
Remove the four oil control orifices.
Remove the four cam chain tensioner cap nuts.
Remove the cam chain tensioner. Remove the clip.
Remove the pin to separate the tensioner, slider and chain. Attach wire to
the cam chain and hang it so it will not fall into the crankcase.
Inspect the cam chain guide and tensioner for excessive wear or damage.
Replace the tensioner and/or guide if excessive wear or damage is
present. Inspect the tensioner slider for excessive wear and replace if
worn. Replace the tensioner spring if it is weak or is damaged.
The oil pipe is located on the back of the engine.
Remove the oil pipe bolts and crush washers using a 10 mm socket.
Discard the crush washers.
Remove the oil pipe from the cylinder head.
Remove the rear cylinder head bolts using a 10 mm socket.
Remove the front cylinder head bolts using a 10 mm socket.
Loosen the cylinder head cap nuts in a criss cross pattern using a 12 mm
socket. Remove the cap nuts.
Remove the exhaust gaskets.
Lightly tap the cylinder head to loosen it for removal.
Lift the cylinder head up and off of the bolts. Remove the gasket.
Remove the cam chain guide.
Remove the carburetor insulator bolts using a 5 mm Allen wrench. Remove

the insulators.
To remove the valves see the Valves topic.
Installation
Install the valves. See the Valves topic for more information.
Clean the cylinder head mating surfaces of any old gasket material.
Fit the carburetor insulators to the cylinder head. Thread in the bolts.
Tighten the bolts securely using a 5 mm Allen wrench.
Install the cam chain guide as shown.
Install a new cylinder head gasket. In order to set the cylinder head the cam
chain guide will need to be pulled up slightly and pushed forward while the
cylinder head is fitted onto the bolts as shown.
Push the tensioner arm and lock it into place by locking the lock plate onto
the lock pin.
Fit the cam chain over the tensioner body, and install the tensioner slider,
pins and clips as shown.
Make sure your assembled tensioner assembly matches the one in the
photo above. Coat the tensioner mating surface with sealant and fit it into
the cylinder head.
Install the washer and loosely thread on the cap nut. Do not tighten yet.
Install the exhaust gaskets.
Apply molybdenum grease to the threads of the cylinder head bolts.Thread

on the cylinder head cap nuts. Tighten to specification in the numbered
criss-cross pattern shown above.
Torque N.m (ft-

Item Qty Thread Dia. (mm)
lb)
Cylinder head 12 8 20-24 (14-17)
Thread in the front and rear cylinder head center bolts.
Tighten the front and rear cylinder head center bolts using a 10 mm socket.
Tighten them in a criss-cross pattern.
Blow the oil pipe and the oil control bolts with compressed air. Fit the oil
pipe to the cylinder head.
Note the position of the different color bolts.
Thread in the oil pipe banjo bolts with two new crush washers as shown.
Tighten to specification using a 10 mm socket.
Torque
ITEM N-m
(ft-lb)
12-
Oil control bolt 8 mm 16(9-
12)
Install the 16 tappets. The tappets should be bled anytime that the
camshaft is removed. See the Camshaft Removal topic for more
information.
Fit the rocker arm holders as shown.
Thread in the rocker arm holder bolts and tighten the bolts securely with a
10 mm socket.
Install the rocker arms. There are 16 rocker arms.
Install the camshaft. See the Camshaft Installation topic for more
information.

Engine > Valves
Valves

at this point.
Removal
Record the position of all parts so they can be returned to their proper
place during reassembly.
Push down the valve springs with a valve spring compressor.
Special Tools-
Valve Lifter: 09916-14510
Valve Lifter Attachment: 09916-14910
Remove the valve keepers using a magnet.
Remove the spring retainer cap and the valve springs.
Remove the valve as shown.
Remove the valve stem seals. Remove the valve spring seats.
Inspection
Use a micrometer to measure the valve spring free-length and preload

length.

IN, EX Outer 34.61 mm (1.363 in) 33.4 mm (1.31 in)
Free-length
IN, EX inner 33.90 mm (1.335 in) 32.7 mm (1.29 in)
ITEM STANDARD
27.6-31.8 kg/22.2 mm
IN, EX Outer
(60.1-70.1 lb/0.875 in)
Preload/ length
8.65-9.95 kg/18.4 mm
IN, EX inner
(19.1-21.9 lb/0.726 in)
Measure the valve guide inner diameter as shown. Also measure the stem-
to-guide clearance.
ITEM STANDARD SERVICE-LIMIT

Valve guide I.D. IN, EX 5.0-5.012 mm (0.1969-0.1973 in) 5.04 mm (0.198 in)
SERVICE-
ITEM STANDARD
LIMIT
0.010-0.037 mm (0.0004-0.015 0.07 mm (0.003
IN
Stem-to-guide in) in)
clearance 0.030-0.057 mm (0.0012-0.0022 0.09 mm (0.004
EX
in) in)

IN 4.975-4.990 mm (0.1959-0.1965 in) 4.97 mm (0.195 in)
Valve stem O.D.
EX 4.955-4.970 mm (0.1951-0.1957 in) 4.94 mm (0.194 in)
Valve face width IN, EX 1.41-1.98 mm (0.056-0.078 in) 2.0 mm (0.08 in)
Valve Guides
You will need to resurface the valve seats when you replace the guides. To
remove the valve guides you must heat the area around the valve guide to
120° - 150°C (248° - 302°F) with an oven. Do not use a torch because of
the possibility of warping the head.
Gently hammer out the valve guide using a valve guide driver. Insert the
driver through the valve opening and drive out the guide towards the top of
the cylinder head. Be very careful to avoid damaging the cylinder head.
Special Tool- Valve Guide Arbor 4.5 mm: 57001-1331
If a valve guide arbor is unavailable an alternate method can be used. Run

a suitable sized tap into the valve guide from the top. Clean away any
metal shavings with compressed air.
Thread a bolt into the recently tapped valve guide.
Insert a punch into the valve guide from the combustion chamber side.
Knock the valve guide out with a hammer.
Drive in the new valve guide with the special valve guide driver. Drive in the
guides from the top of the cylinder head, and take care to avoid damaging
the head. If using the factory valve guide driver the guide will be at the
correct height when the tool touches the cylinder head. If using a generic
tool or to double check measure the height of the valve guide from the
cylinder head.
Special Tool- Valve Guide Driver 4.5 mm: 57001-1564
When the valve guides have been installed you must ream them to be
ready to accept the valves. Use a valve guide reamer with cutting oil. Insert
the reamer through the valve opening in the combustion chamber. Only turn
the reamer clockwise. It is also necessary to ream the valve guides when
installing a new valve.
Special Tool- Valve Guide Reamer 4.5 mm: 57001-1333
Valve Seat
Coat the valve face with a thin layer of Prussian blue and install the valve
into guide.
Using a valve lapping tool, spin the valve in a back and forth circular motion
while applying downward pressure onto the valve.
Pull the valve up and look for a complete impression of the Prussian blue
all the way around valve seat. Measure the width of the valve seat and
compare it to the specification. If there is a break in the compound on the
seat or the width doesn't meet the service limit, you will need to re-cut the
valve seat.
Measure the outside diameter of the valve seating surface (the area free of
carbon buildup). Measure the width of the valve seating surface.
If the measurements are out of specification or inconsistent around the
circumference the valve seat must be repaired.

Valve seat width IN/EX 1.0 mm (0.04 in) 1.5 mm (0.06 in)
Valve Seat Cutting
The valve seats have three different angle cuts to them as shown by the
special cutting tools. Use tool manufacturers instructions for cutting.
Special Tools-
Valve seat Cutter Holder dia. 4.5 mm: 57001-1330
Valve seat Cutter Holder Bar: 57001-1128
Exhaust Valve Special Tools-

Valve Seat Cutter 45°, dia. 27.5 mm: 57001-1114
Valve Seat Cutter 32°, dia. 28 mm: 57001-1119
Intake Valve Special Tools-

If using the factory tools lubricate the cutters with engine oil and clean away
the metal shavings with washing oil.
Clean the valve seat with a rag or soft bristle brush. Do not use a stiff
bristle brush or it will damage the valve seat.
The photos below show the valve resurfacing in a professional machine

shop, but the process is essentially the same.
Install the pilot guide into the valve guide and rotate it 1/2 a turn while
pushing it in.
Coat the valve seat in machinist dye so that it is easy to check your
progress.
Install the 45 degree cutter onto the pilot making sure it fits snug.
Rotate the cutter one to two times in a to clean up the seat.
NOTE: Cut only the minimum that you need and use light pressure.
Inspect the valve seat as shown above. If pitting is still evident repeat the
process.
If the contact area on the exhaust is too wide (outside diameter) you will
need to use the 32° cutter. This will help narrow and lower the fit of the
valve to the seat.
Inspect the valve seat after each turn of the cutter.
If the contact area is too narrow (outside diameter) you will need to use the
60° cutter.
After making the other cuts, use the 45° degree cutter to clean up any
imperfections or burrs that remain on the valve seat and bring the seating
surface to the correct width.
Do not lap the valves. The titanium valves on the KX250F and RM-Z250
will be damaged if lapped.
Clean away the valve seat metal shavings with compressed air and
washing oil.
Assembly
Install the valve spring seats. Install the valve stem seals.
Install new seals on the valve stems. Lubricate the valve stems with
molybdenum grease. Insert the valve into the valve guide.
Note:Turn the valve slowly while inserting to avoid damaging the seal.
Install the valve springs as shown. Install the retainers as shown. Install the
valve keepers.
Push down the valve springs with a valve spring compressor and install the
cotters. Lightly tap the valve stems with a rubber mallet to firmly seat the
cotters.
Clean the cylinder head with solvent. Blow the oil passages with
compressed air. Wear safety glasses while using compressed air.
Install the 16 tappets as shown.
To install the cylinder head see the Cylinder Head Installation topic.

Electrical System > Starter Motor
Starter System

at this point.
Troubleshooting
If the electric starter does not turn perform the following checks. You will
need a digital multimeter for these tests.
If the starter motor turns but doesn't turn the engine over inspect the starter
clutch. See the Starter Clutch topic for more information.
1. Turn the ignition switch to the on position, shift the transmission into
neutral and pull in the clutch lever. Make sure the engine stop switch is in
the run position. Hit the starter button and listen for the starter relay to click.
The starter relay is located on the left side of the motorcycle.
If the starter relay clicks move on to step 2. If the starter relay doesn't click
move to step 3.
2. Remove the starter motor, using a jumper wire apply 12 volts DC to the
starter motor and if it does not turn over it is a bad starter. If the starter
motor does turn check for the following faults.
Starter Relay
Loose Starter Motor Lead
Ignition Switch
Engine Stop Switch
Clutch Switch
Neutral Switch
Turn Signal Switch/ Side Stand Relay
Starter Button
Bad Connector
Pinched or Broken Wires
3. Set your digital multimeter to read voltage. Touch you positive meter
lead to the black/yellow starter relay connector and the negative to the
black/white starter relay connector. Hit the starter button and check for
voltage.
If there is voltage check the starter relay. If there is no voltage check for the
following faults.
Ignition Switch
Engine Stop Switch
Clutch Switch
Neutral Switch
Starter Button
Bad Connector
4. If the starter motor will run in neutral, but not in any gear, and the side
stand is up check the side stand switch.
If the side stand switch checks out. Look for a bad connector or a pinched
or broken wire in the harness.
Starter Relay
Remove the right side cover. See the Side Cover topic for more
information.
Loosen the negative battery cable screw with a #3 Phillips head

screwdriver or a 10 mm socket. Disconnect the cable from the battery.
Remove the starter relay from its holder.
Remove the starter relay leads with a 10 mm socket.
Unplug the starter relay connector. Remove the starter relay from its metal
fingers. Inspect the fuse and replace as needed.
Jump 12 volts to the terminals as shown. The starter relay should click and
the lead terminals should show continuity.
Caution: Jumping 12 volts to the starter relay for more than five seconds
could result in damaging the relay coil.
Check the resistance of the starter relay terminals with an ohmmeter, as

shown.
If there is continuity then the switch is normal.
Clutch Diode Inspection
Remove the clutch diode from the wiring harness as shown.
Use an ohmmeter to check continuity. Touch the meter probes to the

terminal as shown. There should be continuity when the probes are
attached in one direction, and no continuity when the probes are places in
the reverse direction.
Starter Motor
Removal
The starter motor is located on the right side of the engine.
Loosen the starter cable mounting nut using a 10 mm socket. Remove the
starter cable from the starter motor.
Remove the two starter motor mounting bolts using a 10 mm socket.
Remove the starter motor from the engine.
Disassembly and Inspection
Remove the O-ring from the output end of the starter motor.
Loosen the two starter motor housing bolts with a #2 Phillips screwdriver.
Remove the housing bolts and washers.
Slide off the output end cap. Remove the lock washer.
Remove the O-ring from the end cap.
Remove the three shims from the armature shaft
Remove the rear end cap.
Remove the three shims from the rear end of the armature shaft.
The brushes are held in place by the commutator end of the armature.
Remove the armature from the starter motor body. The brushes will pop out
of their holders.
Remove the starter cable terminal nut using a 10 mm socket. Remove the
washers.
Remove the insulators from the starter cable terminal.
Remove the starter cable terminal bracket and brush holder from the
starter motor case.
Remove the starter cable terminal bracket from the brush holder. Remove
the insulator collar from the starter cable terminal. Remove the starter cable
terminal from the terminal bracket.
Inspect the connection points of the two brushes on the starter cable
terminal bracket. Replace the entire bracket if one or both brush
connections are worn or damaged. Inspect the two brush connections on
the brush holder. If one or both connections are worn or damaged, replace
the brush holder. Measure the length of the brushes. Measure the brush
spring tension using a spring scale. Inspect the brushes for wear and
damage. Replace all the brushes if one is damage or excessively worn.
The brushes on our motorcycle's starter motor were excessively worn and
needed to be replaced.
SERVICE
ITEM STANDARD
LIMIT
Brush spring
800 ± 120 g (28.2 ± 4.2 oz) 680 g (24.0 oz)
Starter tension
motor 12.0-13.0 mm (0.47-0.51
In)
Remove the O-ring from the rear of the starter motor case.
Install the starter cable terminal into the starter motor case using the
insulators, washers and nut. Test the continuity between the cable terminal
and the case as shown. There should be no continuity.
Test the continuity between the cable terminal and the brush as shown.
There should be continuity.
Inspect the armature for wear and discoloration. There should be a an

undercut between the commutator strips.
The commutator strips can be cleaned up with fine grit sand paper or an
emery cloth. Scrape out the insulator with a razor blade if the undercut is
not present.
Using a digital multimeter set to ohms of resistance, touch one meter lead
to any one commutator strip and touch the other meter lead to all of the
other commutator strips one by one. Polarity of the meter leads does not
matter. There should be continuity for all of the readings, if any readings
show no continuity the armature must be replaced.
to any one commutator strip and touch the other meter lead to the steel
shaft of the armature. Polarity of the meter leads doesn't matter, and you
only need to check one of the commutator strips. There should be no
continuity, if there is the armature must be replaced.
Inspect the bearing and seal in the out put side starter motor end cap.
Replace the end cap if necessary.
Clean all of the starter motor parts with aerosol electrical contact cleaner
and a lint free cloth.
Assembly
Install the O-ring at the back of the motor case.
Install the cable terminal into the terminal bracket. Install the insulator collar
onto the cable terminal. Install the terminal bracket onto the brush holder.
Install the brush holder and terminal bracket into the motor case. Make sure
the tab on the brush holder lines up with the notch on the motor case.
Install the insulators onto the cable terminal.
Install the washers onto the cable terminal. Use a 10 mm socket to tighten
the nut securely.
Install the armature into the motor case so that the brushes fit around the
outside of the commutator.
Install the three shims at the rear of the armature as shown.
Install the end cap, making sure the alignment marks are aligned as shown.
Install the three shims onto the front of the armature shaft as shown .
Install the O-ring onto the front of the motor case.
Install the lock nut into the front end cap as shown. Fit the front end cap to
the motor case.
Make sure to align the marks on the motor case and front end cap.
Thread in the screws and tighten securely using a #2 Phillips screwdriver.
Install the O-ring on the front of the starter motor as shown. Apply a light
coat of motor oil to the O-ring. Turn the armature shaft by hand. It should
turn smoothly.
Installation
Insert the starter motor into place.
Insert the two starter motor mounting bolts and tighten them to specification
with a 10 mm socket.
Type Torque N-m (kg-m, ft-lb)

10 mm bolt, nut 30-40 (3.0-4.0, 22-29)
Install the starter motor lead to the starter motor as shown. Tighten the bolt
securely with a 10 mm socket.
Slide the rubber cover into place.

Engine > Cylinders and Pistons
Cylinder and Piston

at this point.
Disassembly
Remove the cylinder head. See the Cylinder Head topic for more
information.
Remove the front cylinder holding nuts using a 10 mm socket.
Remove the rear cylinder holding nut using a 10 mm socket.
Give the cylinder a light tap with a rubber mallet to help remove it.
Remove the cylinder and cylinder gasket.
Stuff rags under the pistons to prevent parts from falling into the crankcase.
Remove the piston pin clip using pliers.
Remove the piston pins and remove the pistons. Mark each piston to
indicate where it is in the cylinder to aid in reassembly.
Remove the cylinder head. See the Cylinder Head topic for more
information.
Inspection
Inspect the cylinder bores inner diameter to make sure it is within

specification. Record this measurement as it will be used in conjunction
with the piston outer diameter to determine the cylinder-to-piston
clearance.

I.D. 60.000-60.010 mm (2.3622-2.3626 in) 60.10 mm (2.367 in)
Inspect the cylinder for warpage using a straight edge and feeler gauge as
shown.
ITEM SERVICE LIMIT

Warpage 0.10 mm (0.004 in)
Use a feeler gauge as shown to check the piston ring to groove clearance.
If the measurement is out of specification, the piston and rings should be
replaced. Inspect the pistons for damage and cracks and the ring grooves
for wear.
SERVICE
ITEM STANDARD
LIMIT
0.015-0.045 mm (0.0006- 0.06 mm
TOP
Piston ring-to-ring groove 0.0018 in) (0.002 in)
clearance 0.015-0.045 mm (0.0006- 0.06 mm
SECOND
0.0018 in) (0.002 in)
Measure the piston outer diameter. Take the measurement 14 mm below

the bottom of the piston skirt and at a 90 degree angle to the piston pin
bore.

Piston O.D. 59.970-59.990 mm (2.3610-2.3618 in) 59.9 mm (2.36 in)
Use the cylinder bore inner diameter measurement you took earlier in
conjunction with the piston outer diameter measurement to determine the
cylinder-to-piston clearance.
(cylinder I.D. - piston O.D. = cylinder-to-piston clearance)

Cylinder-to-piston 0.010-0.050 mm (0.0003-0.0020 0.10 mm (0.004
clearance in) in)
Measure the piston pin outer diameter. Record this measurement as it will
be used in conjunction with the piston bore inner diameter to determine the
piston to piston pin clearance.

Piston pin O.D. 14.994-15.000 mm (0.5903-0.5906 in) 14.98 mm (0.589 in)
Measure the piston pin bore.
SERVICE
SERVICE
ITEM STANDARD
LIMIT
Piston
15.002-15.008 mm 15.05 mm
pin
(0.5906-0.5909 in) (0.592 in)
bore
Use the piston pin bore measurement in conjunction with the piston pin
outer diameter to determine the piston to piston pin clearance.
(Piston pin bore - piston pin outer diameter = piston to piston pin
clearance)
SERVICE
ITEM STANDARD
LIMIT
Piston-to-piston pin 0.002-0.014 mm (0.0001-0.0006 0.04 mm (0.002
clearance in) in)
Inspect the connecting rod small end inner diameter.

Connecting rod small end 15.016-15.034 mm (0.5912- 15.07 mm (0.593
I.D. 0.5909 in) in)
Remove the piston rings and oil control ring from the piston as shown.
Insert each piston ring into the cylinder and inspect the ring end gap.

TOP 0.15-0.30 mm (0.0059-0.012 in) 0.5 mm (0.02 in)
SECOND 0.15-0.30 mm (0.0059-0.012 in) 0.5 mm (0.02 in)
OIL (SIDE RAIL) 0.30-0.90 mm (0.012-0.035 in) 1.1 mm (0.04 in)
Assembly
Clean the piston grooves, and apply fresh engine oil to the piston rings.
Spread the rings the minimum amount possible to install them. Install the
piston rings as shown. After installation the rings should move freely in the
grooves. Make sure the piston ring end gaps do not align with each other.
They should be spaced at 120 degrees.
Apply molybdenum grease to the connecting rod small ends and then
install the pistons as shown. Install the piston pins. Make sure the 'IN' mark
on top of the pistons is facing the intake side of the engine.
Install the piston pin clip as shown.
Install the dowel pins and a new gasket. The gasket should be marked
which side is up.
Coat the inside of the cylinder, piston rings, and piston in fresh engine
oil. Put the No.2 and No. 3 pistons at top dead center (TDC). Use piston
ring compressors to compress the piston rings on No. 2 and No. 3 and
slide cylinder over the pistons. Use the ring compressor on the No.1 and
No. 4 piston rings and install the cylinder.
Thread on the rear cylinder holding nut and tighten securely with a 10 mm
socket.
Install the front cylinder holding nuts and tighten securely using a 10 mm
socket.
Install the cylinder head. See the Cylinder Head topic for more information.

Engine > Starter Clutch
Starter Clutch
at this point.
Note: the starter clutch does not have to be taken off to split the cases or
remove the crankshaft.
Removal and Disassembly
Remove the mainshaft and clutch basket.
Use a 5 mm Allen wrench to remove the alternator chain slider.
Use a flat blade screwdriver to remove the alternator shaft cap.
Use a 20 mm socket to remove the alternator set nut.
Remove the alternator shaft bearing holder bolts using an 8 mm socket.

Remove the starter idle gear shaft as shown.
Remove the drive gear as shown.
Remove the spacer.
Remove the collar. Remove the needle bearing.
Remove the drive gear. Remove the rollers and inspect them for excessive
wear. Replace if worn.
Measure the drive gear outer diameter. Measure the collar outer diameter.
SERVICE
ITEM STANDARD
LIMIT
Drive
42.175-42.200 mm 42.16 mm
gear
(1.6604-1.6614 in) (1.660 in)
O.D.
Collar 24.987-25.000 mm 24.96 mm
O.D. (0.9837-0.9843 in) (0.983 in)
Press the shaft and bearing out of the housing. Then press the shaft out of
the bearing. Inspect the bearing for smooth operation. Replace if damaged
or worn.
Special tool: bearing press 07949-3710000
Remove the O-ring and dust seal from the shaft housing. Inspect and
replace if damaged or worn.
Inspect the shaft for wear or damage. Replace if worn or damaged.
Inspect the starter idle gear and shaft for excessive wear or damage.
Replace any components that are worn or damaged.
Installation
Install the springs, plungers and rollers into the starter clutch. Install the
drive gear onto the starter clutch as shown.
Install the needle bearing and collar into the drive gear as shown.
Install the spacer onto the starter clutch as shown.
Install the drive gear/starter clutch assembly into the crankcase as shown.
Install the dust seal and O-ring into the starter shaft housing.
Press the shaft into the bearing using a press or a special tool. Press the
shaft and bearing into the housing using a press or a special tool.
Special tools: 07746-0040400, 07746-0010200, 07749-0010000
Install the starter shaft into the starter clutch.
Thread on the alternator nut. Tighten to specification using a 20 mm

socket.
Thread
Torque N.m
ITEM Qty Dia.
(ft-lb)
(mm)
Alternator
shaft 1 16 38-42 (27-30)
locknut
Install the alternator shaft cap as shown.
Install the alternator chain slider. Thread in the slider mounting bolt and
tighten securely using a 5 mm Allen wrench.
Install the mainshaft/clutch basket into the crankcase as shown.

Engine > Clutch Removal
Clutch Removal

at this point.
Drain the engine oil. See the Engine Oil topic for more information.
Remove the brake pedal. See the Rear Brake Pedal topic for more
information.
Note:Do not operate the clutch lever after removing the clutch. If the lever
is operated, reassembly of the clutch will be very difficult.
Remove the 8 clutch cover bolts using a 5 mm Allen wrench.
Remove the clutch cover a O-ring. If the cover is stuck, tap it gently using a
rubber mallet.
Remove the clutch bolts using a 10 mm socket. Remove the springs and
washers.
Remove the clutch pressure plate and lifter guide. Remove the release
bearing.
Remove the clutch lifter rod.
Remove the clutch friction plates and steel plates.
Make sure the transmission is shifted into TOP gear. Reinstall the brake
pedal and depress it while using a 27 mm socket to remove the clutch lock
nut and washer.
Note:If the engine has been removed from the frame, use tool 07924-
ME5000 to hold the output shaft while removing the lock nut.
Remove the clutch hub.
The crankcase will need to be split in order to remove the clutch basket.
For more information see the Crankcase Splitting topic for more
information. Remove the clutch basket and mainshaft from the crankcase.
Separate the clutch basket from the mainshaft.
Inspection
Inspect the clutch spring free length with a micrometer as shown. Inspect
the spring preload/length. Replace if out of specification.

Spring free length 35.5 mm (1.40 in) 34.0 mm (1.34 in)
SERVICE
ITEM STANDARD
LIMIT
Spring 21.2-23.2 kg/23.8 mm (46-51 lb/0.94
_
preload/length in)
Inspect the clutch disc thickness with a micrometer as shown. Replace if

out of specification.

Disc thickness 3.22-3.38 m (0.127-0.133 in) 2.6 mm (0.10 in)
Inspect the clutch plate warpage with a feeler gauge as shown.
ITEM SERVICE LIMIT
Plate warpage 0.30 mm (0.012 in)
Inspect the outer guide outer diameter. Replace if out of specification.

31.984-32.000 mm (1.2592-1.2598 31.95 mm (1.258
A
Outer guide in) in)
O.D. 41.989-42.000 mm (1.6531-1.6535 41.95 mm (1.652
B
in) in)

Primary driven gear 42 005-42 021 mm (1 6537-1.6544 42.05 mm (1.656
I.D. m) in)
Inspect the clutch basket for signs of damage. Replace if damaged.
Inspect the clutch hub for signs of damage. Replace if damaged.
To install the clutch see the Clutch Installation topic.

Engine > Clutch Installation
Clutch Installation

at this point.
Install the main shaft and outer guides into the clutch basket. See the
Transmission Installation topic for more information. Assemble the
crankcase. See the Crankcase Assembly topic for more information.
Install the clutch hub as shown.
Install the washer with the dished side facing the inside. Thread on the
locknut. Shift the transmission into the TOP gear and depress the brake
pedal in order to tighten the locknut to specification.
Clutch center lock nut 47-53 N-m (34-38 ft-lb)
Coat the friction plates and steel discs in clean engine oil. Install a friction
plate first, then a steel disc. Continue installing the plates and discs in that
alternating fashion. The last piece should be a friction plate.
Install the lifter rod onto the mainshaft.

Install the lifter guide and release bearing onto the pressure plate. Install
the pressure plate, making sure that the index mark on the pressure plate
lines up with the punch mark on the clutch hub, as shown.
Install the clutch springs and washers. Thread in the bolts. Use a 10 mm
socket to tighten the bolts to specification in a star pattern as shown.
Install a new O-ring onto the clutch cover. Coat it in a light film of engine oil.
Thread in the 8 clutch cover bolts and tighten securely using a 5 mm Allen
wrench.
Fill the engine oil. See the Engine Oil topic for more information.
Install the upper fairings. See the Upper Fairings topic for more
information.

Engine > Engine Removal
Engine Removal
at this point.
Before removing the engine from the frame we recommend cleaning it with
a steam cleaner or a pressure washer with a grease dissolving solvent.
Remove the drive gear cover and gear shift pedal. See the Gearshift Pedal
Disconnect the oil pressure switch connector and the pulse generator
couplers. See the Airbox topic for more information.
Remove the carburetors. See the Carburetor topic for more information.
Turn the fuel petcock to the 'OFF' position. Disconnect the fuel lines.
Remove the exhaust system. See the Exhaust System topic for more
information.
Remove the brake pedal. See the Rear Brake Pedal topic for more
information.
Remove the spark plug caps. See the Spark Plug topic for more
information.
Remove the ignition coil. See the Ignition Coil topic for more information.
Remove the crankcase breather tube. See the Crankcase Breather topic
for more information.
Disconnect the starter cable and ground wire at the starter motor. See the
Starter topic for more information.
Remove the oil cooler. See the Oil Cooler topic for more information.
Remove the clutch slave cylinder. See the Clutch Maintenance topic for
more information.
(1983 CB550SC: Remove the brake pedal and right footpeg bracket. See
the Rear Brake Pedal and Footpeg topics for more information. Remove
the gearshift pedal and the left footpeg. See the Gearshift Pedal topic for
more information.)
Disconnect the couplers for the alternator and running lights.
Remove the swingarm pivot bolt caps.

Remove the swingarm lock nut using a special tool.
Special tool: Swingarm pivot lock nut wrench 07908-ME90000
Remove the left swingarm pivot using a 14 mm Allen wrench. Remove the
right swingarm pivot using a 10 mm Allen wrench.
Pull the drive shaft boot back from the engine.
Disengage the drive shaft by holding the universal joint with a flat blade
screwdriver as shown above.
Support the engine using a jack as shown.
Remove the right rear mount nut using a 14 mm socket.
Remove the left rear mount bolt using a 14 mm socket.
Remove the lower mount bolt using a 14 mm socket. Remove the rubber
bushing.
Use a 14 mm socket to remove the lower mount bracket nuts and bolts
Remove the lower mount bracket.
Remove the left lower mount bolt using a 14 mm socket. Remove the
rubber bushing.
Use a 14 mm socket and wrench as shown to loosen the front hanger

mount bolts and nuts. Remove the nuts.
Remove the front hanger mount bolts.
Use a 12 mm socket to remove the front hanger bracket bolts. Remove the
front hanger brackets.
Remove the rear brake light switch as shown.
Using a 12 mm socket, remove the right side rear hanger bracket bolts.
Remove the right side rear hanger bracket.
Remove the shield.
Remove this rear hanger bracket spacer.
Remove the ignition coil brackets using a 10 mm socket.
Lift the engine out of the frame from the right side. Make sure not to hit the
engine on the rear hanger bracket.
Carefully separate the engine from the drive shaft as shown.
Set the engine on a wooden stand as shown.
To install the engine see the Engine Installation topic.

Engine > Engine Installation
Engine Installation
at this point.
Note: Use new nuts with the engine mounting bolts.
Position the engine on a jack and guide it into the frame.
Use the jack to help you move the engine to line up its mounts.
Install the counter shaft splines into the drive shaft.
Fit the right rear hanger bracket. Fit the rear hanger bolt collar.
Thread in the bolts and tighten to specification using a 12 mm socket.
Thread Torque
ITEM Qty Dia. N-m
(mm) (ft-lb)
20-30
8 8 (14-
8 mm
22)
Fit the front hanger bracket. Make sure the 'IN' mark is facing towards the
inside of the frame. Thread in the bolts and tighten to specification using a
12 mm socket.
Thread Torque
ITEM Qty Dia. N-m
(mm) (ft-lb)
20-30
8 8 (14-
8 mm
22)
Insert the front mount bolts.
Thread on the nuts to the front mount bolts. Use a 14 mm wrench and
socket as shown to tighten the nut to specification.
Thread Torque
ITEM Qty Dia. N-m
(mm) (ft-lb)
45-60
5 10 (33-
10 mm
43)
Thread in the left side lower mount bolt with rubber bushing.
Insert the rear mount bolt from the left side. Use a 14 mm socket to tighten
the bolt and nut to specification.
Thread Torque
ITEM Qty Dia. N-m
(mm) (ft-lb)
45-60
5 10 (33-
10 mm
43)
Fit the right side lower mount bracket as shown.
Thread in the right side lower mount bracket bolts and install the nuts. Hold
the nuts with a 12 mm wrench and use a 12 mm socket to tighten the bolts
to specification.
Thread Torque
ITEM Qty Dia. N-m
(mm) (ft-lb)
20-30
8 8 (14-
8 mm
22)
Install the right side rubber bushing and thread in the bolt. Tighten the bolt
to specification using a 14 mm socket.
Thread Torque
ITEM Qty Dia. N-m
(mm) (ft-lb)
45-60
5 10 (33-
10 mm
43)
Fit the drive shaft boot with the 'UP' mark facing up as shown.
Apply grease to the tips of the pivot bolts. Fit them into the swingarm pivot.
Tighten the right swingarm pivot bolt to specification using a 10 mm Allen

wrench. Tighten the left swingarm pivot bolt to specification using a 14 mm
Allen wrench.
ITEM Qty Thread Dia. (mm) Torque N-m (ft-lb) Remarks

Swingarm pivot-Right 1 23 8-12 (6-9)
Swingarm pivot -Left 1 23 80-120 (58-87)
Install the pivot bolt locknut and tighten to specification using the special
tool.
ITEM Qty Thread Dia. (mm) Torque N-m (ft-lb) Remarks

Swingarm pivot lock nut 1 23 80-120 (58-87)
Install the swingarm pivot bolt caps.
Install the rear brake light switch as shown.
Install the protector as shown.
Install the ignition coil brackets. Thread in the bolts and tighten securely
using a 10 mm socket.
Install the clutch slave cylinder. See the Clutch Maintenance topic for more
information.
Install the oil cooler. See the Oil Cooler topic for more information.
Disconnect the starter cable and ground wire at the starter motor. See the
Starter topic for more information.
Install the crankcase breather tube. See the Crankcase Breather topic for
more information.
Install the ignition coil. See the Ignition Coil topic for more information.
Install the spark plug caps. See the Spark Plug topic for more information.
Install the brake pedal. See the Rear Brake Pedal topic for more
information.
Install the exhaust system. See the Exhaust System topic for more
information.
Turn the fuel petcock to the 'OFF' position. Disconnect the fuel lines. Install
the fuel tank. See the Fuel Tank topic for more information.
Install the carburetors. See the Carburetor topic for more information.
Disconnect the oil pressure switch connector and the pulse generator
couplers. See the Airbox topic for more information.
Install the drive gear cover and gear shift pedal. See the Gearshift Pedal
(1983 CB550SC: Install the brake pedal and right footpeg bracket. See
the Rear Brake Pedal and Footpeg topics for more information. Install the
gearshift pedal and the left footpeg. See the Gearshift Pedal topic for more
information.)

Engine > Crankcase Splitting
Crankcase Splitting
at this point.
Remove the engine from the frame. See the Engine Removal topic for
more information.
Remove the cylinder head. See the Cylinder Head Removal topic for more
information.
Remove the cylinder and pistons. See the Cylinder and Pistons topic.
Remove the starter motor. See the Starter Motor topic for more
information.
Remove the alternator. See the Alternator topic for more information.
Remove the signal generator and oil pressure switch. See the Signal
Generator topic for more information.
Remove the clutch. See the Clutch topic for more information.
Remove the gearshift. See the Gearshift topic for more information.
Remove the oil pan. See the Oil Pan topic for more information.
Remove the cylinder bolts as shown.
Remove the crankcase bolts from the bottom. There are 10 bolts that
require a 12 mm socket and 18 bolts that require a 10 mm socket.
There are three bolts on the top side of the crankcase that have to be
removed.
Remove the lower bolt on the top side of the crankcase using a 12 mm
socket.
Remove the upper top-side crankcase bolts using a 10 mm socket.
Remove the oil pipe bolt using a 10 mm socket, as shown.
Remove the oil pipe. Inspect the condition of the O-ring and replace if
deteriorated or damaged.
Use a rubber mallet to lightly tap the crankcase in order to loosen the
crankcase halves.
Separate the crankcase halves.
Caution:Do not pry the crankcase halves apart.
Remove the O-ring.
To remove the transmission see the Transmission topic.
To remove the crankshaft see the Crankshaft topic.
To remove the oil pump see the Oil Pump topic.
For crankcase assembly see the Crankcase Assembly topic.
Engine > Crankshaft
Crankshaft and Rods

at this point.
Removal
Separate the halves of the crankcase. See the Crankcase Splitting for
more information.
Use a 5 mm Allen wrench to remove the alternator chain slider.
Check the connecting rod side clearance using a feeler gauge.
SERVICE
ITEM STANDARD
LIMIT
Connecting
rod big 0.05-0.20 mm 0.3 mm
end side (0.002-0.0079 in) (0.01 in)
clearance
Paint or mark one side of each connecting rod in order to properly reinstall
them in the correct orientation.
Use a 12 mm socket to remove the bearing cap nuts and connecting rod
nuts.
Remove the connecting rods.
Lift the crankshaft out of the crankcase as shown.
Crankshaft Inspection
Remove the alternator chains from the crankshaft. Remove the camshaft
chains from the alternator. Set a dial indicator on the center main journal of
the crankshaft, then rotate the crankshaft by two revolutions. Record the
measurement of the run out at the center journal. The actual run out will only
be 1/2 of the total amount shown by the dial indicator.
ITEM SERVICE LIMIT

Install the cam chain around the two cam sprockets. Anchor one cam
sprocket down and pull on the other cam sprocket using a spring scale, in
order to make the chain taut. Pull the spring scale to 127 N (13 kg, 28.7 lb)
of tension. Measure the length of the cam chain between the index marks
as shown.

Cam 323.05-324.05 mm 327.0 mm
Length
chain (12.750-12.758 in) (12.87 in)
Install the alternator chain over the alternator driven gears. Anchor one of
the gears. Apply 127 N (13 kg, 28.7 lb) of tension to the other gear.
Measure the distance between the center of each gear as shown in order
to determine the length of the alternator chain.

Alternator 136.50-136.70 mm 137.8 mm
Length
chain (5.374-5.382 in) (5.43 in)
Connecting Rod-Crank Pin Bearings
Inspect the bearing inserts for any separation or damage. Clean all of the
oil out of the bearing inserts and crankpins. Put the crankshaft into the
crankcase. Put a piece of plastigage onto each crank pin avoiding the oil
hole as shown. Install the bearing caps and torque evenly to 30-34 N-m
(22-25 ft-lb). DO NOT turn the crank. Remove the caps and measure the
compressed plastigage sitting on each crankpin.
SERVICE
ITEM STANDARD
LIMIT
Crankpin oil 0.024-0.057 mm (0.0009- 0.07 mm (0.003
Crankshaft
clearance 0.0022 in) in)
Special Tools- Plastigauge 09900-22301
If the oil clearance reading exceeds the service limit the bearings must be
replaced as a set.
Crankcase-Crankshaft Main Bearings
Note: Do not remove the crankshaft journal bearings unless necessary.
Inspect the bearing inserts for any separation or damage. Clean all of the
oil out of the bearing inserts and journals. Put a piece of plastigage on
each journal, taking care to avoid the oil holes.
Install the main bearings onto the correct journals of the lower crankcase
half. Fit the two crankcase halves. Tighten the main bearing bolts in the
sequence shown above, moving in 2-3 steps at a time in order to tighten
evenly. Tighten to specification.

Crankcase 8 mm 21-25 (15-18)
Measure the compressed plastigage on each journal as shown above.
SERVICE
ITEM STANDARD
LIMIT
Main journal oil 0.019-0.043 mm (0.0007- 0.06 mm
Crankshaft
clearance 0.0017 in) (0.002 in)
Bearing Selection
Connecting Rod Bearings
and record the corresponding crankpin outer diameter code on the
crankshaft. If there is no code, measure the outer diameter of the crankpin.
Match the crankpin O.D. code with the connecting rod I.D. code to
determine the bearing to use. The bearings are differentiated via color
codes painted on the edge of bearing, as shown above. Choose the
bearing that corresponds with the connecting rod I.D. and the crankpin
O.D. codes.
Note:The crankpin O.D. codes are listed as either A, B or C on the

outside crankshaft weight.

CRANKPIN O.D. CODE
1 2 3
37.000-37.008 mm 37.008-37.016 mm 37.016-37.024 mm
(1.4567-1.4570 in) (1.4570-1.4573 in) (1.4573-1.4576 in)
40.000-
40.008 mm
(1.5748-
1.5751 in)
40.008-
CONNECTING
40.016 mm
(1.5751 -
NO.
1.5754 in)
40.016-
40.024 mm
C Brown Black Blue
(1.5754 -
1.5757 in)

Blue 1.502-1.506 mm (0.0591-0.0593 in)
Black 1.498-1.502 mm (0.0590-0.0591 in)
Brown 1.494-1.498 mm (0.0588-0.0590 in)
Green 1.490-1.494 mm (0.0587-0.0588 in)
Yellow 1.486-1.490 mm (0.0585-0.0587 in)
1983 CB550SC

CRANKPIN O.D. CODE NO.
A B C
31.992-32.000 31.992-31.984 31.976-31.984
mm (1.2595- mm (1.2592- mm (1.2589-
1.2598 in) 1.2595 in) 1.2592 in)
35.000-35.008 mm
1 Yellow Green Brown
(1.3780-1.3783 in)
CONNECTING
35.008 -35 01 6 mm
ROD I.D. CODE 2 Green Brown Black
(1.3783-1.3786 in)
NO.
35.016-35.024 mm
3 Brown Black Blue
(1.3786-1.3789 in)

Blue : 1.502-1.506 mm (0.0591-0.0593 in)
Black : 1.498-1.502 mm (0.0590-0.0591 in)
Brown : 1.494-1.498 mm (0.0588-0.0590 in)
Green : 1.490-1.494 mm (0.0587-0.0588 in)
Yellow : 1.486-1.490 mm (0.0585-0.0587 in)
diameter codes. The codes are listed as number 1,2,3 or 4 from left to
right. Match up the crankcase I.D. code with the main journal O.D. code to
determine the bearing to use. The bearings are differentiated by color
codes.
MAIN BEARING
1 2 3 4
32.994- 32.988- 32.982- 32.976-
33.000 32.994 32.988 32.982
mm mm mm mm
(1.2990- (1.2987- (1.2985- (1.2983-
1.2992 1.2990 1.2987 1.2985
in) in) in) in)
36.000-
36.006
mm
(1.4173-
1.4176
in)
36.006-
36.012
CRANKCASE mm
B Yellow Green Brown Black
I.D. CODE NO. (1.4176-
1.4178
in)
36.012-
36.018
mm
(1.4178-
1.4180
in)

Blue 1.511-1.514 mm (0.0595-0.0596 in)
Black 1.508-1.511 mm (0.0594-0.0595 in)
Brown 1.505-1.508 mm (0.0593-0.0594 in)
Green 1.502-1.505 mm (0.0591 -0.0593 in)
Yellow 1.499-1.502 mm (0.0590-0.0591 in)
Pink 1.496-1.499 mm (0.0589-0.0590 in)
1983 CB550SC
MAIN BEARING
1 2 3 4
32.994- 31 988- 31.982 - 31.976-
32.000mm 31.994mm 31.988mm 31.982mm
(1.2596- (1.2594- (1.2591- (1.2589-
1.2598 in) 1.2596 in) 1.2594 in) 1.2591 in)
35.000-
35.006 mm
(1.3780-
1.3782 in)
35.006-
CRANKCASE
35.012 mm
(1.3782-
NO.
1.3784 in)
35.012-
35.018 mm
(1.3784-
1.3787 in)

Blue 1.511-1.514 mm (0.0595-0.0596 in)
Black 1.508-1.511 mm (0.0594-0.0595 in)
Brown 1.505-1.508 mm (0.0593-0.0594 in)
Pink 1.496-1.499 mm (0.0589-0.0590 in)
Installation
Apply molybdenum grease to the upper and lower main bearings. Install
the main bearings into the upper and lower crankcases.
Install the alternator chain and cam chain around the crankshaft and install
the crankshaft into the crankcase.
Check the weight code combinations for each connecting rod.
FACTORY SET CODE AVAILABLE CODE

A
B
B
C
D D
E
F
G E
H
Install the connecting rods as shown. Make sure the oil holes on each
connecting rod point toward the front. Install the bearing caps. Cross
reference the cap I.D. and connecting rod I.D. codes to make sure the rods
and caps are correctly matched.Tighten the connecting rod cap nuts in 2-3
steps to specification using a 12 mm socket. Check that the connecting
rods move freely.

Connecting rod nut 30-34 (22-25)
Apply thread lock agent to the alternator chain slider bolt. Use a 5 mm
Allen wrench to tighten the alternator chain slider bolt securely.
Assembly transmission. See the Transmission Installation topic for more

information.
Assemble the crankcases. See the Crankcase Assembly topic for more
information.

Engine > Crankcase Assembly
Crankcase Assembly
at this point.
If the gearshift, shift drum and shift forks are installed in the lower
crankcase, shift the linkage to neutral. This will ease assembly.
Make sure to apply molybdenum grease to the grooves between the M2

and M3, C5, C6 gears. Also apply molybdenum grease to the crankshaft
main bearings.
Thoroughly clean the crankcase mating surfaces. Apply liquid sealant to

both of the mating surfaces as shown.
Assemble the halves of the crankcase remembering to align the shift fork
claws with the grooves in the M2, M3, C5 and C6 gears. Also remember to
align the alternator chain slider and cam chain slider with the grooves in the
lower crankcase half.
Install the special assembly pins into the holes indicated by the red arrows
in the picture above. Thread 6x20 mm bolts into the pins from the lower
case side and tighten to specification. Doing this will precisely align the
crankcase halves for reassembly.

Assembly pins/6x20 mm bolts 10-14 (1.0-1.4)
special tool: assembly pin 07973-ME50000
Apply molybdenum grease to the threads and the flanges of the ten 8 mm
crankshaft bearing bolts (#1-10 in the photo above). Install new copper
washers on the crankcase bolts with the triangle mark on the crankcase.
Torque the crankcase bolts in the numerical sequence depicted in the
photo above left. There are 10 bolts that require a 12 mm socket and 18
bolts that require a 10 mm socket.
Thread Dia. Torque N.m (ft-

ITEM Qty Remarks
(mm) lb)
Crankcase 8 mm 11 8 21-25 (15-18) Apply motor oil to the
Crankcase 6 mm 20 6 10-14 (7-10) threads
Remove the 6x20 mm bolts and assembly pins from the crankcase.
Caution:Do not damage the crankcases if the pins must be tapped out
with a hammer.
Torque the upper top-side crankcase bolts using a 10 mm socket. Tighten

the lower bolt on the top side of the crankcase securely using a 12 mm
socket.
Crankcase 8 mm 21-25 N.m(15-18 ft-lb)
Fit the oil pipe as shown. Thread in the bolt. Tighten to specification using
a 10 mm socket.
Install the cylinder pins as shown and tighten securely using a 10 mm

wrench.
Install the oil pump. See the Oil Pump topic for more information.
Install the oil pan. See the Oil Pan topic for more information.
Install the gearshift. See the Gearshift topic for more information.
Install the clutch. See the Clutch Installation topic for more information.
Install the signal generator and oil pressure switch. See the Signal
Generator topic for more information.
Install the alternator. See the Alternator topic for more information.
Install the starter motor. See the Starter Motor topic for more information.
Install the cylinder and pistons. See the Cylinder and Pistons topic for more
information.
Install the cylinder head. See the Cylinder Head Installation topic for more
information.
Return the engine to the frame. See the Engine Installation topic for more
information.

Engine > Transmission Removal
Transmission Removal

at this point.
Mainshaft Removal and Disassembly
Split the crankcases. See the Crankcase Splitting topic for more
information.
Remove the clutch basket and mainshaft from the crankcase. Remove the
mainshaft from the clutch basket as shown.
Reinstall the mainshaft and inspect the backlash on each gear. After
inspection remove the mainshaft from the crankcase.
Low, 2nd, 0.044-0.133 mm (0.0017-0.0052 0.20 mm (0.008
3rd in) in)
0.034-0.102 mm (0.0013-0.0040 0.15 mm (0.006
Backlash 4th
in) in)
0.046-0.140 mm (0.0018-0.0055 0.18 mm (0.007
5th, 6th
in) in)
Remove the bearing race and needle bearing from the mainshaft as
shown.
Remove the needle bearing and bearing inner race as shown.
Remove the washer.
Remove the bearing race from the other side of the mainshaft. Remove the
needle bearing and the washer.
Remove the M4 gear. Remove the washer.
Remove the washer. Remove the M6 gear.
Remove the spacer as shown.
Remove the washer. Remove the snap ring using snap ring pliers.
Remove the M2/M3 gears.
Remove the snap ring using snap ring pliers.
Remove the washer. Remove the M5 gear.
Remove the bushing.
Countershaft Removal and Disassembly
Remove bolts #1,#2 and #3 using a 12 mm socket. Remove bolt #4 using

a 10 mm socket.
Pull the countershaft partially out of the crankcase as shown.
Remove the bushing. Remove the C1 gear.
Remove the thrust washer. Remove the C5 gear.
Remove the spline collar as shown.
Remove the C2 gear and thrust washer as shown.
Remove the countershaft the rest of the way out of the crankcase.
Remove the washer. Remove the C3 gear.
Remove the C3 gear bushing as shown.
Remove the snap ring using snap ring pliers as shown.
Remove the C6 gear as shown.
Remove the washer. Remove the C4 gear.
Remove the bushing as shown.
Shifter Forks and Drum

Removal
Remove the transmission. See the Transmission Removal topic for more
information.
Remove the gearshift assembly. See the Gearshift topic for more
information.
Remove the bearing stopper plate bolt using a 10 mm socket. Remove the
plate.
Remove the shift fork guide shaft mounting bolts using a 10 mm socket.
Hold the shift forks while pulling out the shift fork shafts.
Remove the shift drum as shown.
Remove the bearing from the shift drum as shown.
Inspection
Inspect the shift drum grooves for any kind of damage. Check the outer
edges of the drum for evidence of poor lubrication e.g. scoring, scratches
gouges etc.
Inspect the shift fork shaft outer diameter using a micrometer. If the shafts
are out of specification, replace them.
SERVICE LIMIT 11.90 mm (0.469 in)
Inspect the shift fork claw thickness and inner diameter. Replace if out of
specification.
ITEM SERVICE LIMIT

I.D. 12.04 mm (0.474 in)
Claw
4.6 mm (0.18 in)
Thickness
Installation
Install the bearing onto the shift drum.
Install the shift drum into the crankcase as shown.
Install the shift fork shafts and shift forks as shown.
Thread in the shift fork shaft mounting bolts and tighten securely using a 10
mm socket.
Fit the bearing stopper plate as shown. Thread in the bolt and tighten
securely using a 10 mm socket.
Inspection
TRANSMISSION
SERVICE
ITEM STANDARD
LIMIT
M5, M6, C4 gear 0.020-0.062 mm 0.08 mm
to bushing (0.0008-0.0024 in) (0.003 in)
M5, C4 bushing to 0.005-0.047 mm 0.07 mm
shaft (0.0002-0.0019 in) (0.003 in)
Gear-to-bushing or 0.015-0.057 mm 0.08 mm
C1 gear to bushing
shaft clearance (0.0006-0.0022 in) (0.003 in)
C1 bushing to 0.007-0.041 mm 0.06 mm
shaft (0.0003-0.0016 in) (0.002 in)
C2, C3 gear to 0.020-0.062 mm 0.08 mm
bushing (0.0008-0.0024 in) (0.003 in)
Measure the inner diameter of each gear.

28.020-28.041 mm (1.1031-1.1040 28.06 mm (1.105
M5, M6
in) in)
Gear 24.020-2.4041 mm (0.9457-0.9465 24.06 mm (0.947
C1
I.D. in) in)
C2, C3, 28.020-28.041 mm (1.1031-1.1040 28.06 mm (1.105
C4 in) in)
Measure the inner and outer diameter of the gear bushings.

M5, 27.979-28.000 mm (1.1015- 27.96 mm (1.101
C4 1.1024 in) in)
27.979-28.000 mm (1.1015- 27.96 mm (1.101
M6
Gear bushing 1.1024 in) in)
O.D. 23.984-24.005 mm (0.9443- 23.97 mm (0.944
C1
0.9451 in) in)
C2, 27.979-28.000 mm (1.1015- 27.96 mm (1.101
C3 1.1024 in) in)
M5, 24.985-25.006 mm (0.9837- 25.04 mm (0.986
Gear bushing C4 0.9845 in) in)
I.D. 20.000-20.021 mm (0.7874- 20.04 mm (0.789
C1
0.7882 in) in)
Measure the mainshaft outer diameter.
SERVICE LIMIT at M5 bushing 24.90 mm (0.980 in)
SERVICE LIMIT at C1 bushing (A) 19.93 mm (0.785 in)

SERVICE LIMIT at C4 bushing (B) 24.90 mm (0.980 in)
Calculate the clearance between the gears and the gear shaft or bushing.
SERVICE
ITEM STANDARD
LIMIT
M5, M6, C4 gear 0.020-0.062 mm 0.08 mm
to bushing (0.0008-0.0024 in) (0.003 in)
M5, C4 bushing to 0.005-0.047 mm 0.07 mm
shaft (0.0002-0.0019 in) (0.003 in)
Gear-to-bushing or 0.015-0.057 mm 0.08 mm
C1 gear to bushing
shaft clearance (0.0006-0.0022 in) (0.003 in)
C1 bushing to 0.007-0.041 mm 0.06 mm
shaft (0.0003-0.0016 in) (0.002 in)
C2, C3 gear to 0.020-0.062 mm 0.08 mm
bushing (0.0008-0.0024 in) (0.003 in)

Lubrication System > Oil Pump
Oil Pump

at this point.
Removal
Remove the oil pipe.
Loosen the oil pump mounting bolts using a 10 mm socket.
Remove the oil pump chain and support it. Do not let it fall into the
crankcase.
Remove the oil pump.
Remove the oil pump driven sprocket bolt using a 10 mm socket. Remove
the washer.
Remove the oil pump driven sprocket from the oil pump.
Remove the O-ring and replace it.
Remove the oil pump body cover using a 10 mm socket.
Remove the oil pump body cover. Remove the dowel pin from the oil pump
body. Remove the washer.
Remove the drive pin and then remove the drive shaft.
Remove the inner rotor and then remove the outer rotor.
Measure the clearance between the inner and outer rotor using a feeler
gauge.
Measure the clearance between the outer rotor and the oil pump body
using the feeler gauge.
Measure the clearance between the inner and outer rotors, and the oil
pump body by using a straight edge and a feeler gauge.
Reassembly
Install the dowel pin.
Install the outer rotor. Install the inner rotor.
Install the drive pin into the drive shaft. Align the pin with the slots in the
inner rotor. Install the drive shaft.
Install the washer. Fit the oil pump body cover.
Thread in the bolts and tighten using a 10 mm socket.
Install a new O-ring.
Install the oil pump driven sprocket.
Install the washer and thread in the bolt. Tighten to specification using a 10
mm socket.

10 mm bolt, nut 30-40 (3.0-4.0, 22-29)
Installation
Fit the oil pump into the crankcase.
Fit the drive chain over the driven sprocket.
Thread in the oil pump bolts. Tighten to specification using a 10 mm

socket.
Torque N.m (ft-

lb)
Oil pump 3 6 10-14(7-10)
Install the oil pipe.

Engine > Gearshift
Gearshift

at this point.
Removal
Remove the shift pedal. See the Gearshift Pedal topic for more
information.
Remove the clutch slave cylinder. See the Clutch Maintenance topic for
more information.
Remove the gear position light switch using a #3 Phillips screwdriver.
Remove the 8 gearshift cover bolts using an 8 mm socket.
Bolts with triangle punch marks on the crankcase next to them have
washers.
Remove the gearshift cover. Remove the gasket.
Remove the seal using a seal pick as shown.
Remove the inner seal.
Remove the socket bolt using a 6 mm Allen wrench. Remove the cam plate
and joint.
Remove the roller stopper pins as shown.
Remove the drum stopper bolt with a 10 mm socket. Remove the drum
stopper arm.
Remove the drum stopper arm pivot and spring.
Remove the gearshift spindle washer. Pull the gearshift spindle out of the
case.
Remove the roller stopper plate as shown. Remove the roller stopper plate
pin as shown.
Remove the bearing stopper plate bolt using a 10 mm socket. Remove the
plate.
Installation
Fit the roller bearing plate as shown. Thread in the bolt and tighten securely
Fit the roller stopper plate pin as shown. Fit the roller stopper plate as
shown.
Fit the gearshift spindle as shown. Install the gearshift spindle washer as
shown.
Fit the drum stopper arm spring and pivot.
Thread in the drum stopper arm bolt and tighten to specification using a 10
mm socket.
Stopper arm pivot bolt 10-14 N-m (7-10 ft-lb)
Fit the roller stopper pins as shown.
Install the cam plate. Thread in the socket bolt and tighten securely using a
6 mm Allen wrench.

Install the
9/23/2010 dowel pins. Honda CB550SC/CB650SC Online Repair …
Install the inner seal as shown.
Install the outer seal.
Install a new gasket and fit the cover.
Thread in the bolts and tighten to specification using an 8 mm socket.
Thread Dia. Torque N.m (ft-

ITEM Qty Remarks
(mm) lb)
Apply engine oil to the
Crankcase 6 mm 20 6 10-14 (7-10)
threads
Install the clutch. See the Clutch Installation topic for more information.
Install the shift pedal. See the Gearshift Pedal topic for more information.

Lubrication System > Oil Cooler
Oil Cooler

at this point.
Removal
The oil cooler sits at the front of the frame under the head tube.
Remove the oil pipe bolts using an Allen wrench. Remove the oil filter bolt
Remove the oil pipe and the O-ring. Discard the O-ring and replace it with
a new one.
Remove the oil filter.
Remove the bolt using a 12 mm socket.
Remove the oil cooler and oil filter.
Note:If the oil pipe was removed from the oil cooler, apply liquid sealant to
the threads of the oil pipe to oil cooler joint. Tighten the oil pipe nut by
holding the oil pipe elbow with a wrench.
Installation
Fit the oil cooler and oil filter onto the motorcycle as shown.
Thread in the oil cooler hanger bolt. Tighten to specification using a 12 mm

socket.

12 mm bolt, nut 50-60 (5.0-6.0, 36-43)
Install the oil filter. Tighten the oil filter bolt to specification using a 12 mm
socket.

12 mm bolt, nut 50-60 (5.0-6.0, 36-43)
Install a new O-ring onto the oil pipe. Install the oil pipe into the oil filter.
Thread in the oil pipe bolts. Tighten to specification using an Allen wrench.

Lubrication System > Oil Pan
Oil Pan

at this point.
Removal
Remove the exhaust system. See the Exhaust System topic for more
information.
Remove the 14 bolts from the oil pan using a 10 mm socket. Remove the
bolts in a criss cross pattern to prevent warpage of the oil pan.
The bolts on the oil pan that are marked with a triangle have a crush
washer. Remove the washer and discard it. It will have to be replaced.
Remove the engine bracket.
Remove the oil pan.
Inspect the inside of the oil pan for metal flakes. This oil pan had an
excessive amount of metal flakes in the remaining oil. Metal shavings or
flakes are indicative of a serious problem with the engine.
Installation
Install a new oil pan gasket onto the oil pan. Fit the oil pan onto the
crankcase.
Install the engine bracket.
Install a new crush washer on any bolt holes in the oil pan that are marked
with a triangle.
Thread in the 14 oil pan bolts. Use a 10 mm socket to lightly seat the oil
pan bolts in a criss cross pattern. Tighten them to specification in a criss-
cross pattern.

10 mm bolt 30-40 (3.0-4.0, 22-29)

Lubrication System > Oil Pump
Oil Pump

at this point.
Removal
Remove the oil pipe.
Loosen the oil pump mounting bolts using a 10 mm socket.
Remove the oil pump chain and support it. Do not let it fall into the
crankcase.
Remove the oil pump.
Remove the oil pump driven sprocket bolt using a 10 mm socket. Remove
the washer.
Remove the oil pump driven sprocket from the oil pump.
Remove the O-ring and replace it.
Remove the oil pump body cover using a 10 mm socket.
Remove the oil pump body cover. Remove the dowel pin from the oil pump
body. Remove the washer.
Remove the drive pin and then remove the drive shaft.
Remove the inner rotor and then remove the outer rotor.
Measure the clearance between the inner and outer rotor using a feeler
gauge.
Measure the clearance between the outer rotor and the oil pump body
using the feeler gauge.
Measure the clearance between the inner and outer rotors, and the oil
pump body by using a straight edge and a feeler gauge.
Reassembly
Install the dowel pin.
Install the outer rotor. Install the inner rotor.
Install the drive pin into the drive shaft. Align the pin with the slots in the
inner rotor. Install the drive shaft.
Install the washer. Fit the oil pump body cover.
Thread in the bolts and tighten using a 10 mm socket.
Install a new O-ring.
Install the oil pump driven sprocket.
Install the washer and thread in the bolt. Tighten to specification using a 10
mm socket.

10 mm bolt, nut 30-40 (3.0-4.0, 22-29)
Installation
Fit the oil pump into the crankcase.
Fit the drive chain over the driven sprocket.
Thread in the oil pump bolts. Tighten to specification using a 10 mm

socket.
Torque N.m (ft-

lb)
Oil pump 3 6 10-14(7-10)
Install the oil pipe.

Lubrication System > Engine Oil
Engine Oil
Type and Capacity

Oil Classification: SE or SF. Viscosity: SAE 10W-40.
recommendation Other viscosities shown in the chart may be used when the average
temperature in your riding area is within the indicated range.
Oil 2.5 liter (2.6 US qt, 2,2 Imp qt) after oil filter and oil change
2.2 liter (2.3 US qt, 1.9 imp qt) after oil change
capacity
3.2 liter (3.5 US qt, 2,8 imp qt) after disassembly

at this point.
Inspection
Let the engine warm up for three minutes and then shut it off and wait for
three minutes.
The oil filler cap/dipstick is located on the left side of the motorcycle next to
the gearshift lever.
Unscrew the oil filler cap/dipstick and examine the oil lever on the dipstick.
The oil should be between the upper and lower marks on the dipstick,
indicated in the photograph by the red arrows.
Servicing
Start and run the engine for several minutes, this will heat the engine and
allow the oil to drain out faster and more completely. Shut off the engine.
NOTE: Hot engine oil can burn you, take precautions not to touch
the oil when draining.
Remove the oil filler cap/dipstick for faster draining.
Loosen the oil drain bolt with a 17 mm socket. Remove the drain bolt and
sealing washer. Allow the oil to drain into the oil pan.
Discard the old sealing washer. When the oil has drained completely install
the drain bolt with a new sealing washer. Torque the drain bolt to
specification with a 17 mm socket.
Thread
Torque
Item Qty Dia.
N.m (ft-lb)
(mm)
Oil
drain 1 12 30-40 (22-29)
plug
Remove the oil filter with a 12 mm socket.
Inspect the oil filter O-ring. Replace if it is damaged or worn.
Remove the oil filter cap bolt and inspect the O-ring. Replace the O-ring if it
is damaged or worn.
Remove the old oil filter. Pour some clean engine oil into the new filter.
Also, coat its seal with oil. Install the new filter and tighten to specification
Thread
Torque
N.m (ft-lb)
(mm)
Oil
filter 1 20 28-32 (20-23)
case
Refilling
Oil 2.5 liter (2.6 US qt, 2,2 Imp qt) after oil filter and oil change
capacity 2.2 liter (2.3 US qt, 1.9 imp qt) after oil change
Add the proper type and quantity of oil and install the oil filler cap/dipstick.
Start the engine and let it run for several minutes. Check for any oil leaks.
Inspect the oil level. See Above for more information.
Oil Pressure Check
Start the engine and check the oil light. If the oil light remains on check the
oil pressure switch. See the Switches topic for more information. If the
switch check out inspect the engine oil pressure.
The pulse generator cover is located on the right side of the engine.
Remove the pulse generator cover.
Pull back the rubber cover from the oil pressure switch
Remove the oil pressure mounting screw using a #2 Phillips
Remove the oil pressure switch using a 24 mm socket.
Connect an oil pressure gauge to the oil pressure switch hole.
Check the oil pressure at 7,000 rpm.
Oil pressure (at oil pressure 490.3 kPa/7,000 rpm 80° C (176° F) (71
switch) PSI/7,000 rpm)
Special Tools-
Oil Pressure Gauge: 09915-74510
Oil Pressure Gauge Attachment: 09915-74540
Meter: 09915-77330
Low Oil Pressure Common Problems

Clogged filter
Oil leak/s
Damaged seals
High Oil Pressure Common Problems

Engine oil viscosity too high
Clogged oil passage/s
Coat the threads of the oil pressure switch with liquid sealant, then reinstall.
Thread
Torque
N.m (ft-lb)
(mm)
Apply a
Oil liquid
pressure 1 — 16-20 (12-14) sealant
switch to the
threads.

Final Drive > Drive Shaft
Drive Shaft

at this point.
Removal
Put the motorcycle on the center stand.
Remove the rear wheel. See the Rear Wheel topic for more information.
Drain the final drive oil. See the Final Drive Oil topic for more information.
Remove the left shock absorber lower bolt. See the Rear Suspension topic
Remove the three final drive case attaching nuts using a 14 mm socket.
Remove the final gear case and drive shaft.
Remove the universal joint from the swingarm.
If the drive shaft did not come out of the drive gear case upon removal it will
have to be removed with the use of a vice. Put the drive axle into a vice
with soft jaws or shop rags stuffed in the jaws. Clamp the axle with the vice,
and put the oil drain between the jaws to stabilize the drive gear case.
Place an oil drain pan under the damper case in order to capture the oil
that will spill out when the drive shaft is removed. Separate the damper
case from the gear case by gently pulling on the drive shaft with a circular
motion.
Use a rear shock absorber compressor to compress the drive shaft.
Special tools: Attachment A 07964-MB00100 and Rear Shock Absorber

Compressor 07959-3290001
Drain the gear oil from the damper case into a proper container.
Remove the large spring clip from the damper cam, for the purpose of
avoiding any damage to it.
Remove the spring stop ring. Then remove the drive shaft from the
compressor.
Remove the spring stop, damper cam and damper lifter from the drive
shaft, and check the damper lifter and cam for wear or damage.
Note:Install a new stop ring when reassembling these parts.
Remove the oil seal and oil seal guide from the damper case. Replace the
oil seal with a new one when removed.
Remove the damper cam spring. Measure the damper cam spring free-
length.
ITEM STANDARD LIMIT

Damper cam spring free length 53 mm (2.1 in) 51.5 mm (2.03 in)
Remove the damper case and O-ring from the drive shaft. Remove the
snap ring and spring.
Assembly
Note:Remember to install new O-rings, oil seals and stop rings when
reassembling the drive shaft.
Install the damper cam spring into the damper case.
Use a special tool to drive the oil seal guide and oil seal into the damper
case.
Special tool: Driver 07749-0010000, Attachment 52x55 mm 07746-

0010400
The remaining parts can be assembled in the reverse order of

disassembly.
Installation
Fill the damper case with oil.
Final drive gear

Hypoid gear oil: Above 5°C/41°F, SAE #90 Below
Recommended '83 5°C/41°F, SAE #80
oil
'84 Hypoid gear oil: SAE #80
Keep the damper case vertical so the oil won't spill out and install the final
drive gear case over the damper cam. Use caution so the drive shaft oil
seal is not damaged.
Install the universal joint into the swingarm.
Fit the drive shaft assembly into the swingarm, making sure the splines of
the drive shaft fit into the universal joint.
Thread on the three final drive gear case attaching nuts. Do not tighten
them yet. Install the rear wheel. See the Rear Wheel topic for more
information.
Tighten the three final drive gear case attaching nuts to specification.

Final gear case attaching nut 60-70 (43-51)
Install the left rear shock absorber lower bolt. See the Rear Suspension
Add final drive oil. See the Final Drive Oil topic for more information.

Final Drive > Drive Gear
Drive Gear

at this point.
Removal
Put the motorcycle on the center stand.
Drain the final drive oil. See the Final Drive Oil topic for more information.
Remove the left shock absorber lower bolt. See the Rear Suspension topic
Remove the drive shaft. See the Drive Shaft topic for more information.
Ring Gear Removal
Remove the distance collar. Remove the dust guard plate.
Remove the case cover bolts. Remove the cover.
Remove the ring gear.
Remove the O-ring guide. Tap if from the other side with a soft hammer to
remove it.
Special tools: Attachment 32x35 mm 07746-0010100, Pilot 30 mm

07746-0040700, Attachment 07947-6340201
Ring Gear Bearing Removal
Remove the ring gear bearing. Remove the gear adjusting spacer.
Case Cover Oil Seal Replacement
Remove the oil seal from the case cover. Install a new oil seal.
Pinion Gear Removal

Remove the pinion shaft nut by installing the pinion joint holder onto the
pinion joint. Remove the pinion joint holder and pinion joint.
Special tool: Pinion Joint Holder 07926-ME90000
Remove the retainer lock tab from the bolt.
Use the retainer B wrench to remove the pinion retainer.
Special tool: Lock Nut Wrench 30/64 mm
Use the pinion puller to remove the pinion assembly.
Special tool: Pinion Puller Attachment Kit 07931-MB00000 with 07931-

4630200 or 7935-MB00000
Pinion Bearing Removal
Use a bearing puller to remove the bearing inner and outer races.
Use the same tool to remove the other inner race and remove the pinion
adjustment spacer.
Pinion Retainer Oil Seal Replacement
Remove the O-ring and the oil seal from the pinion retainer.
Drive a new oil seal in the retainer.
Special tools: Driver 07749-0010000, Driver Attachment 07945-3330100
Lightly coat a new O-ring with oil. Install it onto the retainer.
Special tool: Driver attachment 07945-3330300
Case Bearing and Oil Seal Replacement
Use a heat gun or oven to heat the gear case to 80°C (176°F).
Use a soft hammer and remove the ring gear and pinion bearings.
Special tool: Bearing Remover 07936-371040

Caution:Wear gloves when handling the gear case after it has been
heated. Otherwise burns could occur.
Remove the oil seal from the ring gear shaft. Use the special tool to drive in
a new oil seal to the case.
Special tool: Driver 07749-0010000, Attachment 07945-3330300
Use the special tools to drive new pinion and ring gear bearings into the
case.
Special tool: Driver 07749-0010000, Attachment 32x35 mm 07746-

0010100, Attachment 52x55 mm 07746-0010400
Breather Hole Cleaning
Remove the breather hole cap. Use compressed air to blow through the
breather hole.
Caution:Wear safety goggles when using compressed air.
Pinion Gear Assembly
Install the pinion gear spacer. If the gear set, pinion bearing and/or the gear
case has been replaced, use a 2.0 mm thick spacer.
Use the special tools to press the pinion bearing onto the shaft. Press the
bearing until it seats. Only press on the inner race.
Special tool: Driver 07746-0030100 or 07945-3710200, Attachment 25

mm I.D. 07746-0030200
Insert the pinion assembly into the gear housing. Apply gear oil to the
threads on the pinion retainer and the O-ring. Install the O-ring guide tool.
Use the pinion retainer to press the pinion bearing in place. Tighten it to
specification.
Ring Gear Assembly
Install the spacer onto the ring gear. If the gear set, pinion bearing and/or
the gear case has been replaced, use a 2.0 mm thick spacer.
Install the ring gear bearing over the ring gear shaft.
Install a new ring gear bearing over the ring gear shaft. Put the old bearing
on top of the new bearing. Use the special tools to drive the new bearing
onto the shaft. Remove the old bearing.
Special tools: Driver Handle A 07749-0010000, Attachment 07947-

6340201
Fit a new O-ring into the O-ring guide. Apply some grease to the O-ring
and use the special tool to drive it onto the ring gear shaft.
Special tool: Driver 07749-0010000, Attachment, 42x47 mm 07746-

0010300
Fit the ring gear into the gear case cover. Measure the clearance between
the ring gear and the ring gear stop pin with a feeler gauge.
CLEARANCE 0.30-0.60 mm (0.012-0.024 in)
In the event that the clearance is not within specification, remove the ring
gear. Heat the gear case cover to approximately 80°C (176°F) using a
heat gun or oven. Remove the stop pin by tapping the side of the cover
opposite the pin.
Caution:Wear gloves when handling the heated gear case.
A stop pin shim must be installed to get the correct clearance. Install the
correct sized shim and install the stop pin into the case cover.
Clean the mating surfaces of the gear case and cover. Make sure there is
no remaining sealing material. Also remember to keep dust and dirt out of
the gear case. The mating surfaces are made of a soft metal and care
should be taken to avoid damaging the mating surfaces.
Gear Tooth Contact Pattern Check
Apply a coat of Prussian Blue to the teeth of the pinion gear. Install the
wave washer and ring gear into the gear case. Apply gear oil to the lip of
the oil seal that is on the gear case cover. Install the gear case cover.
Apply a locking agent to the threads of the cover bolts. The cover bolts
must be lightly tightened in 2-3 steps in order to evenly mate the cover to
the gear case. When the case and cover are evenly mated, tighten the
bolts to specification. There are 8 bolts in total. Six of the bolts have an 8
mm thread diameter. Tighten these bolts to the torque specification that
follows:
ITEM THREAD DIA. TORQUE N-m (ft-lb)

Cover bolts 8 mm 23-28 (17-20)
Two of the bolts have a thread diameter of 10 mm. These bolts should be
torqued to the following specification:

Cover bolts 10 mm 45-50 (33-36)
Remove the oil filler cap. It is located on the final gear case.
Rotate the ring gear in the normal direction of rotation. Perform several
rotations.
Look through the oil filler hole to check the gear tooth pattern. The Prussian
Blue will indicate the gear tooth pattern. If the contact pattern is normal, the
Prussian Blue will be transferred to the center of each tooth and a little
towards the face.
In the event that the patterns are not correct the pinion spacer must be
removed and replaced. If the contact patches are too high, replace the
spacer with one that is thicker. If the contact patches are too low, replace
the spacer with one that is thinner.
For every 0.1 mm (0.004 in) of spacer thickness change, the Prussian Blue
patterns on the gear teeth will change by about 1.5-2.0 mm (0.06-0.08 in).
Pinion Spacer
A 1.82 mm (0.072 in)
B 1.88 mm (0.074 in)
C 1.94 mm (0.076 in)
D 2.00 mm (0.079 in) standard
E 2.06 mm (0.081 in)
F 2.12 mm (0.083 in)
G 2.18 mm (0.086 in)
Backlash Inspection
Remove the oil filler cap. Hold the final gear assembly steady by setting it
into a jig or a stand.
Stick a horizontal type dial indicator through the oil filler hole and onto the
ring gear.
While holding the pinion gear spline by hand, rotate the ring gear by hand
until the slack in the gear is taken up.
In order to read the backlash, turn the ring gear back and forth.
ITEM STANDARD LIMIT

Gear backlash 0.08-0.18 mm (0.003-0.007 in) 0.30 mm (0.012 in)
Remove the dial indicator from the oil filler hole and turn the ring gear 120°.
Measure the backlash again in the same way as before. Repeat this
process one more time.
DIFFERENCE OF MEASUREMENT
Service Limit 0.10 mm (0.004 in)
In the event that the difference in measurements exceeds the limit, it means
that the bearing is not squarely installed. Check the bearings and install
them again.
If the backlash is excessively out of specification, replace the ringer gear

spacer with one that is thicker.
It the backlash is too little, replace the ring gear spacer with one that is
thinner.
For every 0.10 mm (0.004 in) of change in spacer thickness the backlash
will be changed by about 0.06-0.07 mm (0.002-0.003 in).
RING GEAR SPACER THICKNESS

A 1.82 mm (0.072 in)
B 1.88 mm (0.074 in)
C 1.94 mm (0.076 in)
D 2.00 mm (0.079 in) standard
E 2.06 mm (0.081 in)
F 2.12 mm (0.083 in)
G 2.18 mm (0.086 in)
H 2.24 mm (0.088 in)
I 2.30 mm (0.091 in)
Pinion Joint Installation
The appropriate pinion lock tab must be installed. There are two types of
lock tabs.
Apply gear oil to the oil seal lip of the pinion joint. Install the pinion joint.
Tighten the pinion nut to specification using the special tool.
Special tool: Pinion Joint Holder 07926-ME90000
Check if the gear assembly rotates smoothly. There should be no binding

when the pinion joint is turned.
Install the dust guard plate to the gear case. Torque the bolts to
specification. There are 8 bolts in total. Six of the bolts have an 8 mm
thread diameter. Tighten these bolts to the torque specification that follows:

Cover bolts 8 mm 23-28 (17-20)
Two of the bolts have a thread diameter of 10 mm. These bolts should be
torqued to the following specification:

Cover bolts 10 mm 45-50 (33-36)
Remove the oil filler cap. It is located on the final gear case.
Install the distance collar.
Final Drive Gear Installation
The damper case must be filled with the proper type and amount of gear
oil.
While keeping the damper case vertical, install the final drive gear case
over the damper cam. Take care not to damage the drive shaft oil seal. Do
not let the gear case and damper case separate or the oil will spill.
Install the drive shaft. See the Drive Shaft topic for more information.
Loosely install the three final gear case attaching nuts.
Install the rear wheel. For more information see the Rear Wheel topic.
Torque the three final gear case nuts to specification.
Final gear case attaching nut 60-70 N-m (43-51 ft-lb)
1983 CB550SC Final gear case attaching nut 20-24 N-m (14-18 ft-lb)
Fill the final drive oil. See the Final Drive Oil topic for more information.
Install the left shock absorber lower bolt. See the Rear Suspension topic

Final Drive > Swingarm
Swingarm

at this point.
Removal
Remove the rear shock absorbers. See the Rear Suspension topic for
more information.
Remove the drive shaft. See the Drive Shaft topic for more information.
Remove the swingarm pivot bolt caps.
Remove the swingarm lock nut using a special tool.
Remove the left swingarm pivot using a 14 mm Allen wrench. Remove the
right swingarm pivot using a 10 mm Allen wrench.
Pull the drive shaft boot back from the engine.
Disengage the drive shaft by holding the universal joint with a flat blade
screwdriver as shown above.
Remove the swingarm from the frame.
Remove the cotter pin from the brake torque arm connecting bolt.
Hold the brake torque arm bolt with a 14 mm wrench and loosen the nut
Remove the nut, the two washers and the bolt from the brake torque arm.
Remove the brake torque arm from the swingarm.
Remove the dust seals with a seal pick.
Remove the right side dust seal. Remove the right side bearing.
Remove the dust seal from the left side. Remove the left side bearing.
There is one bearing race and grease retainer on each side of the
swingarm pivot.
Insert a bearing driver through the grease retainer that has a hole and
place the end of the bearing driver against the inner wall of the opposite
grease retainer. Use a hammer to tap out the grease retainer. Repeat for
the other side.
Assembly
Install the new left side bearing race and grease retainer into the left side of
the swingarm using a bearing driver and hammer. Install the new right side
bearing race and grease retainer into the right side of the swingarm.
Make sure the bearing races and grease retainers are seated properly in
the swingarm.
Apply grease to the left side bearing and install it into the left side of the
swingarm. Apply grease to the underside of the left side dust seal and
install it over the bearing into the left side of the swingarm.
Apply grease to the right side bearing and install it into the right side of the
swingarm. Apply grease to the underside of the right side dust seal and
install it over the bearing into the right side of the swingarm.
Use a bearing driver and hammer to seat the bearing and dust seals into
the swingarm.
Fit the brake torque arm to the swingarm.
Fit the brake torque arm bolt. Install the washers and nut.
Use a 14 mm wrench to hold the bolt and tighten the nut to specification

Rear brake torque link 2 8 18-25 (13-18)
Install a new cotter pin into the hole on the brake torque arm bolt.
Installation
Fit the swingarm into the frame, with the drive axle side on the left. Support
the swingarm.
Push the drive shaft boot back onto the engine. Make sure the arrow and
word 'UP' are facing up.
Apply grease to the tips of the pivot bolts. Fit them into the swingarm pivot.
Tighten the right swingarm pivot bolt to specification using a 10 mm Allen

wrench. Tighten the left swingarm pivot bolt to specification using a 14 mm
Allen wrench.
Item Qty Thread Dia. (mm) Torque N-m (ft-lb) Remarks

Swingarm pivot-Right 1 23 8-12 (6-9)
Swingarm pivot -Left 1 23 80-120 (58-87)
Install the pivot bolt locknut and tighten to specification using the special
tool.
Item Qty Thread Dia. (mm) Torque N-m (ft-lb) Remarks

Swingarm pivot lock nut 1 23 80-120 (58-87)
Install the swingarm pivot bolt caps.
Install the lower bolt on the left rear shock absorber. See the Rear
Suspension topic for more information.
Install the rear wheel. See the Rear Wheel topic for more information.

Front Brake > Brake Disc
Brake Disc

at this point.
Inspection
Runout
Look over the brake discs for damage. Measure the thickness of the disc
with a micrometer and check the runout with a dial gauge. Replace the
brake discs as needed.

Special Tools-
Micrometer (0 - 25 mm): 09900-20205
Dial Gauge (1/100 mm): 09900-20606
Magnetic Stand: 09900-20701
Removal
Remove the 6 disc bolts with a 6 mm Allen wrench from both front discs.
Remove the left side disc. Remove the right side disc.
Remove the washers. Replace the washers if they are damaged or worn,
or rusted as was the case with our motorcycle.
The front discs are stamped with 'R' and 'L' to indicate the right side disc
and the left side disc.
Installation
Coat the threads of the mounting bolts in Loctite. Install the brake disc
mounting bolts with a 6 mm Allen wrench. Tighten the bolts to specification
a few turns at a time in a crisscross pattern.
Brake disc bolts 35-40 N-m (25-29 ft-Ib)

Front Brake > Master Cylinder
Master Cylinder

at this point.
Warning: Brake fluid is very caustic and can damage paint, chrome
and plastic. Wipe up any spills immediately.
Removal
Use a 5 mm Allen wrench to remove the master cylinder clamp bolts.
Separate the master cylinder and clamp from the right side of the
handlebar. Unplug the brake switch from the bottom of the master cylinder.
Disassembly
Use a #2 Phillips screwdriver to loosen the brake switch mounting screw.
Remove the mounting screw and the brake switch.
Using a flat blade screwdriver and a 10 mm wrench, remove the brake

lever bolt.
Remove the brake lever from the master cylinder.
Remove the piston boot.
Use snap ring pliers to remove the snap ring from the piston.
Remove the piston, secondary cup, spring and primary cup.
Inspect the piston, secondary cup, primary cup and spring for damage or
deterioration. If any of these components are damaged or worn, they
should be replaced.
Clean the inside of the master cylinder and reservoir with brake fluid.
NOTE: Brake fluid is a corrosive chemical and can damage paints and
some plastics. Avoid contact with skin.
Reassembly
Place a film of clean DOT 4 brake fluid on the piston, spring and master
cylinder bore.
Install the spring and primary sealing cup. The large diameter end of the
spring goes in first. Install the piston and secondary sealing cup.
Push down on the piston and install the snap ring into its groove.
Install the piston boot.
Fit the brake switch to the master cylinder so that the post on the switch fits
into the hole on the master cylinder. Install the front brake switch mounting
screw. Tighten the screw securely with a #2 Phillips screwdriver.
Install the front brake lever to the master cylinder.
Apply a light coat of grease to the brake lever pivot bolt. Insert the bolt from
the top and tighten it with a flat blade screwdriver. Thread on the nut and
tighten it securely with a 10 mm wrench.
Installation
Mount the front brake master cylinder onto the right handlebar at the punch
mark. Make sure the arrow on the clamp faces up. Use a 5 mm Allen
wrench to torque the upper bolt to specification first, then torque the lower
bolt.
Torque N-m
ITEM
(ft-lb)
Brake and clutch master cylinder holder 10-14 (7-10)
Plug in the front brake switch connector.
Fill the master cylinder reservoir with brake fluid from a tightly sealed
container and bleed the brakes. See the Brake Fluid topic for more
information.

Front Brake > Front Brake Hoses
Front Brake Hoses

at this point.
Removal
Drain the brake fluid in the front brake system. See the Brake Fluid topic
Pull back the rubber cover from the master cylinder banjo bolt.
Place a rag below the brake hose where it meets the master cylinder.
Loosen the brake hose banjo bolt with a 12 mm socket. Allow the
remaining brake fluid to drain into a suitable container. Do not allow the
brake fluid to fall on a painted surface.
The left caliper hose and right caliper hose are connected together with the
master cylinder by the 3-way joint, pictured here.
Loosen the 3-way joint bolts using a 10 mm socket.
Remove the wires from the backside of both horns.
Remove the 3-way joint assembly. Remove the two banjo bolts from the
hose joint using a 12 mm socket. Discard the two crush washers from each
banjo bolt.
Remove the brake hose from the hose clamps on the front forks.
Remove the banjo bolt from the left caliper using a 12 mm socket. Discard
the crush washers. Allow any remaining brake fluid to drain into a suitable
container.
Remove the banjo bolt from the right caliper using a 12 mm socket.
Discard the crush washers. Allow any remaining brake fluid to drain into a
suitable container.
Installation
Install the right side banjo bolt with new crush washers. Torque the bolt to
specification using a 12 mm socket.
Install the left side banjo bolt with new crush washers. Torque the bolt to
Fit the brake hoses into the hose clamps on the front forks.
Attach the upper ends of the left and right brake hoses to the 3-way joint.
Use two new crush washers on each bolt in the same fashion as the caliper
mounted banjo bolts. Torque the banjo bolts to specification using a 12
mm socket.
Install the horn wires onto the prongs at the back of the two horns.
Install the 3-way joint. Tighten the bolts securely with a 10 mm socket.
Connect the brake hose the master cylinder with two new sealing washers.
Torque the banjo bolt to specification with a 12 mm socket.
Fill and bleed the brakes. See the Brake Fluid topic for more information.

Front Brake > Front Brake Caliper
Caliper
at this point.
Warning: Brake fluid is very caustic and can damage paint, chrome
and plastic. Wipe up any spills immediately.
Warning: Always check brake function prior to riding the

motorcycle.
Removal
If you plan to disassemble the brake calipers, first drain the brake fluid.
See the Brake fluid topic for more information. This doesn't need to be
done when changing the brake pads. Remove the brake hose banjo bolts
from the calipers with a 8 mm socket. Discard the sealing washers. Allow
any remaining brake fluid to drain into a suitable container.
Locate the caliper shaft (upper arrow) and the caliper bolt (lower arrow) for
the left side caliper.
Loosen the caliper shaft for the left side caliper using a 14 mm socket and
remove the shaft. Loosen the caliper bolt for the left side caliper using a 12
mm socket and remove the bolt.
Remove the left side caliper. Push the calipers in towards the brake disc to
push the pistons all the way into the caliper. Slide the brake caliper back
and off of the disc.
Remove the right side caliper bolt using a 12 mm socket.
Remove the right side caliper shaft using a 14 mm socket.
Remove the right side caliper. Push the calipers in towards the brake disc
to push the pistons all the way into the caliper. Slide the brake caliper back
and off of the disc.
Pad Removal
Remove the pad pin retainer bolt using a 10 mm socket.
Remove the pad pin retainer.
Locate the pad pins and remove the pins. Clean the pad pin with a wire
brush.
Remove the brake pads. Inspect the wear grooves. If the wear exceeds the
groove depth at any location both pads for the caliper should be replaced.
Clean the pistons with a rag.
Disassembly
Drain the brake fluid. See the Brake Fluid topic for more information.
Remove the calipers. See Above.
Remove the brake pads. See Above.
Remove the banjo bolt from the left caliper using a 12 mm socket. Discard
the crush washers.
Remove the banjo bolt from the right caliper using a 12 mm socket.
Discard the crush washers.
Remove the pad spring.
Place a strip of wood or a shop rag between the caliper pistons and the
inside surface of the brake caliper. Blow compressed air into the banjo bolt
opening to remove the caliper pistons. The pistons are a tight fit in the
brake caliper and will pop out with a lot of force.
Caution: Do not place your fingers over the caliper pistons while removing
them as serious injury could result.
Remove the pistons from the right and left caliper. Clean the pistons with
steel wool or a rag.
Inspect the pistons and piston bores for wear and damage. Check the
piston for scoring, scratches or other damage. Replace if damaged.
Check the piston diameter using a micrometer. Also check the piston bore
inner diameter using a micrometer. If the piston is out of specification, the
piston will have to be replaced. If the piston bore is out of specification, the
caliper body will have to be replaced.

O.D. 1.2598 in) in)

I.D. 1.2630 in) in)
Remove the dust seals from the right and left calipers using a small pick.
Remove the fluid seals from the left and right calipers. Clean the seal
grooves with brake fluid.
Pull out the caliper pivot collars and boots from the left and right calipers.
Inspect the boots for wear and deterioration. Replace the boots as
needed.
Discard the old seals. Clean the brake caliper components using fresh
brake fluid.
Assembly
Replace the piston seals with new ones. Lubricate the caliper pistons, the
caliper piston bores and the seals with DOT 4 brake fluid from a tightly
sealed container. Perform all steps for both the left and right calipers.
Install new fluid seals and dust seals. Be sure the seals are all fully seated
in their grooves.
Install the pistons. Push the caliper pistons completely into the caliper
closed end first. You can use an old brake pads to push in both pistons at
the same time.
Install the brake caliper pivot collars and boots.
Install the brake pad spring.
Install the right side banjo bolt with two new crush washers. Tighten to
Install the left side banjo bolt with two new crush washers. Tighten to
Pad Installation
Slide in the brake pads into both front calipers.
Install the pad pins on both front calipers.
Fit the pad pin retainer.
Thread in the pad pin retainer bolt. Tighten it securely using a 10 mm

socket.
Installation
Assembly the calipers. See Above.
Install the brake pads. See Above.
Fit the left side caliper onto the caliper bracket. Slide the brake disc
between the pads. Support the caliper.
Thread in the left side caliper bolt and left side caliper shaft. Torque the
caliper bolt to specification using a 12 mm socket. Torque the caliper shaft
to specification using a 14 mm socket.

Fit the right side caliper. Slide the pads over the disc.
Thread in the right side caliper shaft and torque to specification using a 14
mm socket.
Thread in the right side caliper bolt and torque to specification using a 12
mm socket.
Fill the brake fluid and bleed the system. See the Brake Fluid topic for
more information.
DIMENSIONS
FRAME

(140 sq in)

(31 sq in)
FORK OIL CAPACITY

Right 447 - 452 cc (15.2 - 15.3 oz)
Left 462 - 467 cc (15.6 - 15.8 oz)
TIRE INFLATION
Front 225 kPa
(32 psi)
Driver only
Rear 225 kPa
(32 psi)
Front 225 kPa
(32 psi)
Rear 280 kPa
(40 psi)
ENGINE
60.0 x 58.0 mm (2.36 x 2.28 in)
53.7 kw/9,500 rpm
Maximum horsepower
73 PS/9,500 rpm
57 N-m/8,000 rpm
57 N-m/8,000 rpm
Maximum torque
5.7 kg-m/8,000 rpm
58 (BTDC) at 0 lift

Identification
VE54A
number
'83-84: VE54A
CARBURETOR
'84
VE75A
CALIFORNIA:
Primary
1.704 (92/54): 1
reduction
pattern 1-N-2-3-4-5-(O.D.)

Spark plugs
IGNITION TIMING
At idle: 10° BTDC
1079-1275 kPa
(156-185 psi)
Cam 31.85 mm (1.252
IN, EX 31.901 mm (1.2559 in)
height in)
INI, IN4, 22.939-22.970 mm 22.91 mm (0.902
EX1, EX4 (0.9031-0.9043 in) in)
O.D.
IN2, IN3, 22.909-22.930 mm 22.88 mm (0.901
IN 1, IN4, 0.030-0.072 mm
0.13 mm (0.005 in)
Oil EX1, EX4 (0.0012-0.0028 in)
0.16 mm (0.006 in)
EX2, EX3 (0.0028-0.0044 in)
Valve 27.6-31.8 kg/22.2 mm
spring IN, EX Outer
Preload/ (60.1-70.1 lb/0.875 in)
length 8.65-9.95 kg/18.4 mm
IN, EX inner
(19.1-21.9 lb/0.726 in)
SERVICE-
ITEM STANDARD
LIMIT
4.975-4.990 mm (0.1959- 4.97 mm
IN
0.1965 in) (0.195 in)
Valve stem O.D.
4.955-4.970 mm (0.1951- 4.94 mm
EX
0.1957 in) (0.194 in)
IN, 5.0-5.012 mm (0.1969- 5.04 mm
Valve guide I.D.
guide 0.010-0.037 mm (0.0004- 0.07 mm
IN
clearance 0.030-0.057 mm (0.0012- 0.09 mm
EX
0.0022 in) (0.004 in)
IN, 1.41-1.98 mm (0.056- 2.0 mm (0.08
Valve face width
EX 0.078 in) in)
0.10 mm
Warpage
(0.004 in)
1.0 mm (0.04 in)
head IN/EX in)
23 000-23.021 mm 23.05 mm
(0.9055-0 90 3 in) (0.907 in)
SERVICE
STANDARD
LIMIT
60.000-60.010 mm 60.10 mm
I.D.
(2.3622-2.3626 in) (2.367 in)
Cylinder
0.10 mm
Warpage
(0.004 in)
0.015-0.045 mm 0.06 mm
TOP
SECOND
(0.0006-0.0018 in) (0.002 in)
0.15-0.30 mm 0.5 mm
TOP
(0.0059-0.012 in) (0.02 in)
0.15-0.30 mm 0.5 mm
SECOND
SECOND
Ring end gap (0.0059-0.012 in) (0.02 in)
OIL
0.30-0.90 mm 1.1 mm
(SIDE
(0.012-0.035 in) (0.04 in)
Piston O.D.
pin (2.3610-2.3618 in) (2.36 in)
15.002-15.008 mm 15.05 mm
Piston pin bore
(0.5906-0.5909 in) (0.592 in)
15.016-15.034 mm 15.07 mm
(0.5912-0.5909 in) (0.593 in)
14.994-15.000 mm 14.98 mm
Piston pin O.D.
(0.5903-0.5906 in) (0.589 in)
0.002-0.014 mm 0.04 mm
(0.0001-0.0006 in) (0.002 in)
0.010-0.050 mm 0.10 mm
(0.0003-0.0020 in) (0.004 in)
SERVICE
ITEM STANDARD
LIMIT
14.000—14.043 mm 14.06 mm
Cylinder I.D.
cylinder 13.957—13.984 mm 13.94 mm
Piston O.D.
(0.5495-0.5506 in) (0.549 in)
38.100—38.162 mm (1.500- 38.18 mm
Cylinder I.D.
cylinder 38.036-38.075 mm (1.4975- 38.02 mm
Piston O.D.
1.4990 in) (1.479 in)
31.984-32.000 mm (1.2592- 31.95 mm
A
O.D. 41.989-42.000 mm (1.6531- 41.95 mm
B
1.6535 in) (1.652 in)
34.0 mm (1.34
in)
Spring 21.2-23.2 kg/23.8 mm (46-
Clutch _
2.6 mm (0.10
in)
0.30 mm
Plate warpage -
(0.012 in)
gear I.D. 1.6544 m) (1.656 in)

42.175-
Drive
42.200 mm 42.16 mm
gear
(1.6604- (1.660 in)
O.D.
1.6614 in)
24.987-
O.D. (0.9837- (0.983 in)
0.9843 in)
SERVICE
ITEM STANDARD
LIMIT
0.05 mm
Runout _
(0.002 in)
Crankshaft
0.024-0.057 mm (0.0009- 0.07 mm
0.0022 in) (0.003 in)
0.019-0.043 mm (0.0007- 0.06 mm
0.0017 in) (0.002 in)
323.05-324.05 mm 327.0 mm
Cam chain Length
(12.750-12.758 in) (12.87 in)
Alternator 136.50-136.70 mm 137.8 mm
Length
chain (5.374-5.382 in) (5.43 in)
MAIN BEARING
1 2 3 4
32.994- 32.988- 32.982- 32.976-
33.000 mm 32.994 mm 32.988 mm 32.982 mm
(1.2990- (1.2987- (1.2985- (1.2983-
1.2992 in) 1.2990 in) 1.2987 in) 1.2985 in)
36.000-36.006 mm
(1.4173-1.4176 in)
CRANKCASE
36.006-36.012 mm
(1.4176-1.4178 in)
NO.
36.012-36.018 mm
(1.4178-1.4180 in)

Blue 1.511-1.514 mm (0.0595-0.0596 in)
Black 1.508-1.511 mm (0.0594-0.0595 in)
Brown 1.505-1.508 mm (0.0593-0.0594 in)
Green 1.502-1.505 mm (0.0591 -0.0593 in)
Yellow 1.499-1.502 mm (0.0590-0.0591 in)
Pink 1.496-1.499 mm (0.0589-0.0590 in)

CRANKPIN O.D. CODE
1 2 3
37.000-37.008 mm 37.008-37.016 mm 37.016-37.024 mm
(1.4567-1.4570 in) (1.4570-1.4573 in) (1.4573-1.4576 in)
40.000-
40.008 mm
(1.5748-
1.5751 in)
40.008-
CONNECTING
40.016 mm
(1.5751 -
NO.
1.5754 in)
40.016-
40.024 mm
C Brown Black Blue
(1.5754 -
1.5757 in)

Blue 1.502-1.506 mm (0.0591-0.0593 in)
Black 1.498-1.502 mm (0.0590-0.0591 in)
Brown 1.494-1.498 mm (0.0588-0.0590 in)
Green 1.490-1.494 mm (0.0587-0.0588 in)
Yellow 1.486-1.490 mm (0.0585-0.0587 in)
TRANSMISSION
SERVICE
ITEM STANDARD
LIMIT
0.044-0.133 mm 0.20 mm
Low, 2nd, 3rd
(0.0017-0.0052 in) (0.008 in)
0.034-0.102 mm 0.15 mm
Backlash 4th
(0.0013-0.0040 in) (0.006 in)
0.046-0.140 mm 0.18 mm
5th, 6th
5th, 6th
(0.0018-0.0055 in) (0.007 in)
28.020-28.041 mm 28.06 mm
M5, M6
(1.1031-1.1040 in) (1.105 in)
24.020-2.4041 mm 24.06 mm
Gear I.D. C1
(0.9457-0.9465 in) (0.947 in)
28.020-28.041 mm 28.06 mm
C2, C3, C4
(1.1031-1.1040 in) (1.105 in)
27.979-28.000 mm 27.96 mm
M5, C4
(1.1015-1.1024 in) (1.101 in)
27.979-28.000 mm 27.96 mm
M6
(1.1015-1.1024 in) (1.101 in)
Gear bushing O.D.
23.984-24.005 mm 23.97 mm
C1
(0.9443-0.9451 in) (0.944 in)
27.979-28.000 mm 27.96 mm
C2, C3
(1.1015-1.1024 in) (1.101 in)
24.985-25.006 mm 25.04 mm
M5, C4
(0.9837-0.9845 in) (0.986 in)
Gear bushing I.D.
20.000-20.021 mm 20.04 mm
C1
(0.7874-0.7882 in) (0.789 in)
24.959-24.980 mm 24.80 mm
Mainshaft O.D. (M5)
(0.9826-0.9835 in). (0.980 in)
19.980-19.993 mm 19.93 mm
C1
(0.7866-0.7871 in) (0.785 in)
Countershaft O.D.
24.959-24.980 mm 24.90 mm
C4
(0.9826-0.9835 in) (0.980 in)
M5, M6, C4 gear 0.020-0.062 mm 0.08 mm
to bushing (0.0008-0.0024 in) (0.003 in)
M5, C4 bushing 0.005-0.047 mm 0.07 mm
to shaft (0.0002-0.0019 in) (0.003 in)
C1 bushing to 0.007-0.041 mm 0.06 mm
shaft (0.0003-0.0016 in) (0.002 in)
C2, C3 gear to 0.020-0.062 mm 0.08 mm
bushing (0.0008-0.0024 in) (0.003 in)
0.08-0.18 mm (0.003-0.007 0.30 mm (0.012

Gear backlash
in) in)
53 mm (2.1 in) 51.5 mm (2.03 in)
length
indicated range.
Oil pressure (at
490.3 kPa/7,000 rpm 80° C (176° F)
oil pressure
(71 PSI/7,000 rpm)
switch)
Oil pump
delivery
Final drive gear

'83 170 cm3 (5.78 oz)
Oil capacity
'84 150 cm3 (4.9 oz)

'83-'84 E54A
Identification mark
Main jet #115
Capacity 12V 12 AH
Alternator
'83 STATOR
RPM Amperage Output
2500 2 amps
2000—2100 0±1 amp
1500 -5 ± 1 amp
1000 -10 ± 1 amp
'84 STATOR
RPM Amperage Output
2500 2 amps
1700—1800 0 ± 1 amp
1500 -3 ± 1 amp
1000 -9 ± 1 amp

Spark plug
Ignition timing
SERVICE
ITEM STANDARD
LIMIT
Brush spring
800 ± 120 g (28.2 ± 4.2 oz) 680 g (24.0 oz)
Starter tension
motor 12.0-13.0 mm (0.47-0.51
In)
Ignition timing
Ignition timing
10° BTDC at 1,400 ± 200 rpm
"F" mark
Generator
Cooled)
Battery
12V ~ 12 AH
capacity
Headlight
(high/low
equivalent)
beam)
(front/rear) 1073
Neutral
LIGHTS 12V -2 CP
indicator
Turn signal
12V - 2 CP
indicator
High beam
12V -2 CP
indicator
Oil pressure
12V-2 CP
warning light
FUSE
FUEL SENSOR
Front Rear
Tire size 100/90--19 130/90—16
57H 67H
Up to 90 kg (200 lbs) load 225 (32) 225 (32)
Cold tire pressure
225 (32) 280 (40)
capacity load
Tire brand
Dunlop F11 K627
SERVICE
ITEM STANDARD
LIMIT
0.2 mm (0.01
Axle shaft runout _
in)
2.0 mm (0.08
Front wheel rim in)
runout 2.0 mm (0.08
in)
0.03 mm (0.001
in)
512.4 mm (20.2
in)
0.2 mm (0.01
Fork tube runout -
in)
(15.7 oz)

0.03 mm (0.001
Wheel bearing play
in)
217.6 mm (8.57 in)
length in)
160.0-160.3 mm (6.30-6.31 161.0 mm (6.34
Brake drum I.D.
in) in)

15.93 mm (0.627 in)
I.D. 0.6265 in)
15.82 mm (0.623 in)
O.D. 0.6242 in)
O.D. 1.2598 in) in)
I.D. 1.2630 in) in)

Rear Brake > Rear Brake Drum
Rear Brake Drum

at this point.
Removal
Note: The rear brake pedal removal/installation topic is located in the

external components section.
Lift the rear brake panel out of the rear wheel hub.
Inspection
Inspect the underside of the brake panel. The brake shoes are attached to
the brake panel.
Inspect the lining thickness using a micrometer.

Remove the brake torque arm bolt.
Remove the cotter pins and retention plate.
Remove the brake shoes.
Remove the brake arm bolt using a 12 mm socket.
Make a mark across the brake arm and brake cam in order to facilitate
correct reinstallation. Remove the brake arm.
Remove the wear indicator. Remove the felt seal. Discard the felt seal.
Remove the brake arm cam.
Inspect the rear drum inner diameter.

Brake drum I.D. 160.0-160.3 mm (6.30-6.31 in) 161.0 mm (6.34 in)
Installation
Install the brake arm cam.
Install a new felt seal. Install the wear indicator.
Install the brake arm.
Thread in the brake arm bolt. Tighten to specification using a 12 mm

socket.

Brake arm 24-30 (17-22)
Fit the brake shoes into the brake panel as shown.
Fit brake shoe retention plate. Install new cotter pins and bend them to
secure the plate in place.
Install the brake torque arm bolt.

Install the
9/23/2010 brake torque arm bolt. Honda CB550SC/CB650SC Online Repair …
Install the assembled brake panel into the rear wheel hub as shown.

Wheels > Wheel and Axle Inspection
Wheel and Axle Inspection

at this point.
Raise the front wheel off the ground with a suitable jack or stand. Rotate
the front wheel and check for excessive play or roughness. Do the same for
the rear.
Inspect the wheel bearings by turning them with a finger. The bearings
should turn smoothly without noise, roughness, or excessive play in the hub.
If the bearings have play in them or are rough replace all the bearings for
that wheel. Also, replace the bearings if the seal is damaged. See the
Bearing Replacement for more information.
Place the wheel on a truing stand and use a dial indicator to check if the
rim is out or true. The specifications for the front and rear wheels are the
same.

Radial 0.3 mm (0.01 in) max. 2.0 mm (0.08 in)
Front wheel rim runout
Axial 0.3 mm (0.01 in) max 2.0 mm (0.08 in)
ITEM SERVICE LIMIT
If the wheel runout exceeds the service limit the bearings may be at fault. If
you replace the bearings and the wheel is still out of specification the wheel
must be replaced.
Check the axle runout. Place the axle on a set of V-blocks and use a dial
gauge with magnetic stand to measure the runout.
ITEM SERVICE LIMIT

Axle shaft runout 0.2 mm (0.01 in)
Special Tools-
Dial gauge (1/100 mm): 09900-20606
Magnetic stand: 09900-20701
V-block set: 09900-21304

Wheels > Front Wheel
Front Wheel

at this point.
Removal
Place the motorcycle on its center stand and secure it. Jack up the front of
the motorcycle so that the front wheel is off the ground and the rear wheel is
resting on the ground.
Remove the front brake left caliper bracket. See the Front Caliper Bracket
Remove the speedometer set screw using a #2 Phillips screwdriver.
Remove the speedometer cable.
Remove the fork pinch bolt cap using a flat blade screwdriver. Loosen the
pinch bolt using a 6 mm Allen wrench.
Use a 17 mm socket to loosen the front axle and remove the axle.
Roll the front wheel out and away from the forks.
Inspect the front wheel. See the Wheel Inspection topics for more
information.
Installation
Make sure the brake discs are free of oil and grease. Place the wheel
between the fork legs. The arrow on the on the spoke indicates the
direction of rotation.
Insert the front axle as shown. Use a 17 mm socket and wrench to torque to
axle nut to specification.

Front axle 1 12 55-65 (40-47)
Use a 6 mm Allen wrench to tighten the axle pinch bolt to specification.

Front axle pinch bolt 1 8 15-25 (11-18)
Install the speedometer cable.
Secure the speedometer cable set screw using a #2 Phillips screwdriver.
Remove the stand or jack and set the front wheel on the ground. Hold the
front brake, and pump the front end several times to seat the axle. If the
front brake will not pump up, the brakes will have to be bled. See the Brake
Bleeding topic for more information.

Wheels > Rear Wheel
Rear Wheel

at this point.
Removal
Place the motorcycle on the centerstand.
Loosen the axle nut using a 24 mm socket.
Remove the axle nut.
Use a 12 mm socket to loosen the axle pinch bolt.
Lightly tap on the axle with a rubber hammer to loosen it. Pull out the axle.
Remove the axle spacer.
Remove the cotter pin from the brake torque arm. Use a 10 mm socket to
remove the rear brake torque arm nut. Remove the washers.
Remove the rear brake torque arm.

Remove
9/23/2010 the rear brake torque arm.
Honda CB550SC/CB650SC Online Repair …
Use a 14 mm socket to remove the rear brake adjusting nut. Remove the
cam and the spring.
Use a 14 mm socket to remove the right side rear shock absorber lower
bolt.
Remove the rear wheel as shown.
Inspect the rear wheel. See the Wheel and Axle Inspection topic for more
information.
To remove the rear brake drum see the Rear Brake Drum topic.
Installation
Apply multipurpose NLGI No. 2 grease to the final driven flange splines and
the ring gear engagement splines using a brush.
Fit the rear wheel as shown.
Fit the right side rear shock absorber to the swingarm as shown. Thread in
the bolt and tighten to specification using a 14 mm socket.

Rear shock 2 10 30-40 (22-29)
Coat the rear axle in grease. Install the rear axle spacer and push in the
rear axle.
Tighten the axle pinch bolt to specification using a 12 mm socket.

Rear axle pinch bolt 1 8 20-30 (14-22)
Thread on the rear axle nut. Tighten to specification using a 24 mm socket.
ITEM Torque N-m (ft-lb)

9/23/2010 ITEM Torque
Honda CB550SC/CB650SC N-m
Online (ft-lb)
Repair …
Rear axle 60-80 (43-58)

1983 CB550SC Rear Axle 50-80 (36-58)
Install the rear brake rod spring. Install the rear brake rod cam. Thread on
the rear brake adjusting nut. Tighten the nut until the rear brake pedal
height is within specification. For more information see the Rear Brake
Inspection topic.
Install the rear brake torque arm.
Install the washers. Thread on the nut. Tighten the nut to specification using
a 10 mm socket. Install a new cotter pin.

Rear brake torque link 2 8 18-25 (13-18)
Bend the cotter pin as shown to secure the nut.

Wheels > Bearing Replacement
Bearing Replacement

at this point.
Replace bearings as a set, and do not reuse old bearings.
Front Wheel
Removal
Warning: Do not set wheels on their brake discs when removing

bearings.
To remove the brake discs see the Brake Disc topic.
Remove the side collar.
Use a seal pick to remove the right side seal, exposing the right side
bearing.
Remove the speedometer gear from the left side of the wheel. Remove the
left side seal with a seal pick.
Remove the speedometer gear retainer from the left side.
Remove the distance collar.
Remove one of the wheel bearings using a bearing puller. If a bearing

puller is not available, you can use a long flat faced punch and a steel
hammer. With either technique, heating the wheel around the bearing with
a heat gun will make this job much easier. Remove the bearing from the
other side of the wheel.
Special Tool-
Bearing Remover: 09941-50111
Installation
Note; The new bearings should be installed with the sealed side
facing out.
Place the new bearings in the freezer for about an hour before installing
them.
Apply grease to the bearings. Install the left bearing first. Heat the bearing
area of the wheel with a heat gun. Drive in the bearing by its outside
diameter with a suitable bearing driver.
Install the distance collar.
Drive in the right bearing with a suitable bearing driver.
Install the speedometer gear retainer into the left side of the wheel as
shown.
Install the seal into the left side of the wheel. Install the speedometer gear.
Install the right side seal. Install the side collar into the right side.
Rear Wheel
Removal
Remove the rear brake drum panel. For more information see the Rear
Brake topic.
Remove the five final driven flange bolts using a 14 mm socket. Remove
the final driven flange.
Remove the O-ring from the final driven flange.
Use a bearing puller to extract the left side rear wheel bearing. If a bearing
puller is not available, you can use a long flat faced punch and a steel
hammer. With either technique, heating the wheel around the bearing with
a heat gun will make this job much easier
Remove the left side rear wheel bearing and the distance collar.
Use a bearing puller to remove the right side rear bearing puller. If a
bearing puller is not available, you can use a long flat faced punch and a
steel hammer. With either technique, heating the wheel around the bearing
with a heat gun will make this job much easier.
Installation
Note; The new bearings should be installed with the sealed side
facing out.
Place the new bearings in the freezer for about an hour before installing
them.
Lubricate the bearings with multipurpose NLGI No. 2 Grease (MoS2

additive).
Heat the bearing area of the wheel with a heat gun, take one of the
bearings out of the freezer and install it the right side. You can use a
bearing installer tool, bearing driver, or a socket with the same outside
diameter as the OD of the bearing. Make sure the bearing is fully seated
and the marked side is facing out.
Install the distance collar from the left side.
Heat the wheel with a heat gun, remove the other wheel bearing from the
freezer and install it in the LEFT SIDE. If you freeze the bearings and heat
the wheel, the bearings should drop into place with very little pressure
required. If the bearing won't drop in, use a bearing driver.
Install the right side bearing in the same manner as the left.
Install a new O-ring around the driven flange gear.
Apply liquid sealant to the mating surfaces of the final drive flange and the
bolt threads.
Thread in the final drive flange bolts and tighten to specification using a 14
mm socket.

Final drive flange bolts 50-60 (36-43)
Install the rear brake drum panel. See the Rear Brake Drum topic for more
information.

Steering > Removal
Steering Removal
Turn the handlebars back and forth. If the steering feels rough or notchy you
may need to replace your steering head bearings.

at this point.
Remove the front forks. See the Fork Removal and Installation topic for
more information.
Remove the handlebar. See the Handlebar topic for more information.
Use a 30 mm socket and extension bar to loosen the steering stem/bridge

nut. Remove the nut and washer.
Remove the fork bridge.
Use a pin spanner to loosen the steering stem adjuster nut.
Special tool: 07914-3710100
Remove the steering stem adjuster nut. Remove the bearing cover and
steel balls.
Remove the steering stem. Remove the steering stem lower set of steel
balls.
Loosen the upper and lower ball races with a steering stem driver. Gently
tap the driver around the base of the race to dislodge it.
Remove the races.
Use a flat blade screw driver to remove the cone race and dust seal from
the steering stem.
To install the steering components see the Steering Installation topic.

Steering > Installation
Installation

at this point.
Fit the upper and lower ball races into the head tube.
Use a ball race driver tool to seat the upper and lower ball races.
Apply a coat of bearing grease to the upper ball race and install the 18
steel balls.
Apply a coat of bearing grease to the lower cone race and install the 19
steel balls.
Grease: Mitsubishi EH-700 or equivalent about 5.5 g
Install the steering stem.
Install the upper bearing seal.
Thread on the adjuster nut.
Tighten the adjuster nut securely using a pin spanner.
Special tool: 07914-3710100
Install the fork bridge.
Install the washer and steering stem nut. Tighten the nut to specification

Steering stem nut 1 24 90-120 (65-87)
Install the handlebar. See the Handlebar topic for more information.
Install the front forks. See the Fork Removal and Installation topic for more
information.

Front Suspension > Fork Removal and Installation
Fork Removal and Installation

at this point.
Removal
Remove the front fender. The fender brace must also be removed. See the
Front Fender topic for more information.
Remove the front brake hoses from their clamps on the front forks.
Remove the reflector.
Remove the fork air valve caps.
Use a flat blade screwdriver to release the air pressure from the fork caps.
Use a 6 mm Allen wrench to remove the top clamp bolts.
Note: If you plan to disassemble the forks go ahead and break the fork
caps loose while the forks are being held in place by the lower fork clamps.
Use a 27 mm socket to loosen the fork caps.
Remove the lower fork clamp bolts using an 8 mm Allen wrench.
Slide the forks down and out of the fork clamps using a twisting motion.
To disassemble the forks see the Front Fork Disassembly topic for more
information.
Installation
Slide the fork legs up into the lower and upper fork clamps using a twisting
motion.
Install the fork legs so that the top surface of the outer fork tube is flush with
the top surface of the clip-on handlebar.
Torque the lower fork clamp bolts to specification with an 8 mm Allen

wrench.
Fork lower pinch bolt 45-55 N-m (33-40 ft-Ib)
If the fork was disassembled tighten the fork caps to specification with a 24
mm socket.
Tighten the upper fork clamp pinch bolts to specification with a 12 mm

socket.
Fork top bridge pinch bolt 9-13 N-m (7-9 ft-Ib)
Install the front brake hoses into their clamps on the front forks.
Install the reflectors.
Install the front fender. See the Front Fender topic for more information.

Front Suspension > Front Fork Assembly
Front Fork Assembly

at this point.
Clean all of the fork components with aerosol brake cleaner and a lint free
cloth. Coat the bushings and seals with fork oil before installation. Take
care to not damage the coating on the bushings during installation.
Apply thread lock to the screw. Install the check ball, the valve spring, the
washer and the screw. Use a #2 Phillips screwdriver to tighten the screw
securely.
Install the orifice. Install the setting plate. Install a circlip.
Install the orifice pin as shown.
Apply a coating of ATF to the O-ring and the piston. Install a the O-ring.
Install the piston.
Install the spring. Fit the anti-dive case to the fork.
Thread in the four anti-dive case bolts. Tighten the bolts securely using a 5
mm Allen wrench.
Install new snap rings as shown.
Apply silicone grease to the pivot bolt collar. Install the pivot bolt collar, the
pivot bolt collar holder and the pivot bolt.
Install the fork tube bushing. Use a new bushing if the old one was
removed.
Install the pistons and rebound springs into the fork tube.
On the left fork install the stopper ring, the spring seat and the valve spring.
On the
9/23/2010 left fork install the stopper ring,
Hondathe spring seat Online
CB550SC/CB650SC and the valve
Repair … spring.
On the left fork install the oil lock valve. Install a stopper ring.
Install the oil lock onto the end of the piston.
Insert the fork tubes into the sliders as shown.
Thread in the socket bolt. Use a 6 mm Allen wrench to tighten it to

specification. Place the fork tube in a soft jaw vice or a vice with a towel in
to if the bolt won't tighten.
Profit fork socket bolt 15-25 N-m (11-18 ft-Ib)
Put the slider bushing over the fork tube. Let it rest on top of the slider. Put
the back up ring on top of the slider bushing. Drive the new slider bushing
and ring into place with a fork seal driver. Coat a new oil seal in ATF. Install
it over the slider with the markings facing up. Drive the seal in with the fork
seal driver. Repeat for the other fork.
Install a new snap ring on each fork. Install a new plastic washer on each
fork. Install a new sponge washer on each fork. Install a new dust seal on
each fork.
Pour in fork oil in each fork to the specified amount.
ITEM STANDARD
Front fork fluid capacity Right 450 cc (15.2 oz) Left 465 cc (15.7 oz)
ITEM STANDARD
1983 CB550SC 375 cc (12.7
Front fork fluid capacity oz)
Insert the fork springs into the fork tubes. The tighter windings should face
towards the top.
Install the washer and spacer into each fork.
Thread on the top cap and tighten to specification using a 27 mm socket.
Install the fork air valve caps.
Install the front forks. See the Front Fork Installation topic for more
information.

Front Suspension > Front Fork Disassembly
Front Fork Disassembly

at this point.
Remove the front forks. See the Front Fork Removal topic for more
information.
Place the motorcycle on a stand so the front wheel is off of the ground.
Note: Clean the outside of the forks before disassembly and inspect them
for any cracks, dents or other damage.
Note: Clean the fork components with a high flash point solvent. Discard
the old fork seals and bushings.
Remove the fork air valve caps.
Use a flat blade screwdriver to release the air pressure from the fork cap
valves.
Use a 27 mm socket to loosen the fork top caps. Remove the fork top
caps.
Remove the spacers. Remove the washers.
Remove the springs.
Drain the oil from each fork tube into an appropriate container. Pump the
tube several times to drain the last bits of oil.
Use a 6 mm Allen wrench to remove the bolts from the bottom of each fork
slider. Put the fork tube in a soft jaw vice or a vice with a towel if the bolt is
hard to remove.
Remove the dust seals from each fork using a flat blade screwdriver.
Remove the sponge washers.
Remove the plastic washers and the snap rings from each fork.
Separate the fork tubes and sliders. Pull the fork tube out of the slider until
resistance is felt. Then move the fork tube in and out a little bit at a time
while tapping the bushing lightly until the slider separates from the fork
tube.
Remove the oil lock piece from the end of the piston.
From the left fork, remove the stopper ring and the oil lock valve.
From the left fork, remove the oil lock spring. Remove the spring seat.
Remove the stopper ring.
Now, remove the pistons and rebound springs from both forks.
The fork tube bushing should only be removed if it needs to be replaced

with a new one. To remove it, use a flat blade screwdriver to pry it off the
tube.
Remove the slider bushing. Remove the back up ring. Remove the oil seal.
The anti-dive mechanism is located on the left fork slider.
There are four adjustment settings on the anti-dive mechanism. See the
Suspension topic for more information.
Remove the pivot bolt and pivot bolt collar.
Using snap ring pliers, remove the snap ring.
Remove the snap ring from the other side.
Using a 5 mm Allen wrench, remove the four anti-dive case bolts.
Separate the case from the fork tube. Remove the spring. Inspect the
spring for damage or wear. Replace if damaged or worn.
Remove the piston. Remove the rubber seal. Inspect the piston and seal
for damage or wear. Replace if damaged or worn.
Remove the orifice pin.
Remove the circlip. Remove the setting plate. Remove the orifice. Check
the orifice for clogs by applying compressed air. If the orifice is damaged
in any way, replace it.
Use a #2 Phillips screwdriver to remove the check valve setting screw and
washer, valve spring and check ball.
Inspection
Inspect the fork cap for damage. Inspect the fork cap O-ring for damage
and replace if damaged or deteriorated.
Inspect the fork tube bushing for damage or wear. Replace if damaged or
worn.
Inspect the fork tubes and sliders for damage or wear. Replace the
component if damaged or worn.
Inspect the fork tube runout. Use a dial gauge.

Fork tube runout - 0.2 mm (0.01 in)
Inspect the piston and rebound spring for damage or wear. Replace if
damaged or worn.
Measure the free length of the fork spring. Replace the fork spring if the
free length is below the service limit or the fork springs vary dramatically
between the forks

Fork spring free length 522.9 mm (20.6 in) 512.4 mm (20.2 in)
SERVICE
ITEM STANDARD
LIMIT
1983 CB550SC 551.5 mm 540.5 mm
Fork spring free length (21.71 in) (21.28 in)
Inspect the other fork components for damage and wear and replace them
as needed.
For Assembly see the Fork Assembly topic for more information.

Rear Suspension > Rear Suspension Removal
Rear Suspension
at this point.
Removal
With the motorcycle secured, move the swingarm up and down to check for
free play in the rear suspension. If the swingarm has excessive play this
could indicate the need for new bearings.
To disassemble the rear suspension components see the Rear

Suspension Disassembly topic.
Remove the nut from the top of the right side shock absorber using a 14
mm socket. Remove the washer. Remove the bolt from the bottom of the
right side shock absorber using a 14 mm socket.
Remove the right shock absorber.
Remove the nuts on the left side shock absorber using a 14 mm socket.
Remove the left side shock absorber.
Remove the washer from the drive gear.
Carefully lower the drive gear and drive shaft to the ground.
Installation
Install a new washer on the drive gear suspension mounting bolt. Lift the
drive gear/shaft assembly up and support it.
Thread on the left side shock absorber nuts and tighten to specification
ITEM TORQUE
Install the right side shock absorber. Thread the nut on top and tighten to
specification using a 14 mm socket. Thread in the bolt on the bottom of the
shock and tighten to specification using a 14 mm socket.
ITEM TORQUE

Rear Suspension > Rear Suspension Removal
Rear Suspension
at this point.
Removal
With the motorcycle secured, move the swingarm up and down to check for
free play in the rear suspension. If the swingarm has excessive play this
could indicate the need for new bearings.
To disassemble the rear suspension components see the Rear

Suspension Disassembly topic.
Remove the nut from the top of the right side shock absorber using a 14
mm socket. Remove the washer. Remove the bolt from the bottom of the
right side shock absorber using a 14 mm socket.
Remove the right shock absorber.
Remove the nuts on the left side shock absorber using a 14 mm socket.
Remove the left side shock absorber.
Remove the washer from the drive gear.
Carefully lower the drive gear and drive shaft to the ground.
Installation
Install a new washer on the drive gear suspension mounting bolt. Lift the
drive gear/shaft assembly up and support it.
Thread on the left side shock absorber nuts and tighten to specification
ITEM TORQUE
Install the right side shock absorber. Thread the nut on top and tighten to
specification using a 14 mm socket. Thread in the bolt on the bottom of the
shock and tighten to specification using a 14 mm socket.
ITEM TORQUE
Rear Suspension > Rear Suspension Disassembly
Rear Suspension

at this point.
Remove the swingarm from the frame and linkage. See the Rear
Suspension Removal topic for more information.
Disassembly
To remove the spring stopper, press down on the adjuster case A and
spring seat stopper.
Remove the spring stopper, the spring seat stopper and the adjuster case
A.
Remove the coil springs.
Remove adjuster case B.
Remove the steel balls.
Compress the spring by 30 mm using a spring compressor.
Special tool: 07959-MB10000.
Remove the lock seat and collar. Remove the spring compressor.
Remove the spring.
Inspection
Measure the rear shock spring free length. Make sure it is within
specifications. If the spring is out of specification it should be replaced.

Shock
absorber
spring 217.6 mm 213.2 mm
(8.57 in) (8.40 in)
free
length

1983
CBB550SC
Shock 228.2 mm 223.6 mm
absorber (8.98 in) (8.80 in)
spring free
length
Assembly
Install the spring onto the absorber.
Compress the spring by 30 mm.
Install the collar. Install the lock seat. Remove the spring compressor.
Install the steel balls. Install the adjuster case B. Install the four coil springs.
Install the adjuster case A. Install the spring seat stopper and the spring
seat.
Rear Suspension > Rear Suspension Disassembly
Rear Suspension

at this point.
Remove the swingarm from the frame and linkage. See the Rear
Suspension Removal topic for more information.
Disassembly
To remove the spring stopper, press down on the adjuster case A and
spring seat stopper.
Remove the spring stopper, the spring seat stopper and the adjuster case
A.
Remove the coil springs.
Remove adjuster case B.
Remove the steel balls.
Compress the spring by 30 mm using a spring compressor.
Remove the lock seat and collar. Remove the spring compressor.
Remove the spring.
Inspection
Measure the rear shock spring free length. Make sure it is within
specifications. If the spring is out of specification it should be replaced.

Shock
absorber
spring 217.6 mm 213.2 mm
(8.57 in) (8.40 in)
free
length

1983
CBB550SC
Shock 228.2 mm 223.6 mm
absorber (8.98 in) (8.80 in)
spring free
length
Assembly
Install the spring onto the absorber.
Compress the spring by 30 mm.
Install the collar. Install the lock seat. Remove the spring compressor.
Install the steel balls. Install the adjuster case B. Install the four coil springs.
Install the adjuster case A. Install the spring seat stopper and the spring
seat.
DIMENSIONS
FRAME

(140 sq in)

(31 sq in)
FORK OIL CAPACITY

Right 447 - 452 cc (15.2 - 15.3 oz)
Left 462 - 467 cc (15.6 - 15.8 oz)
TIRE INFLATION
Front 225 kPa
(32 psi)
Driver only
Rear 225 kPa
(32 psi)
Front 225 kPa
(32 psi)
Rear 280 kPa
(40 psi)
ENGINE
60.0 x 58.0 mm (2.36 x 2.28 in)
53.7 kw/9,500 rpm
Maximum horsepower
73 PS/9,500 rpm
57 N-m/8,000 rpm
57 N-m/8,000 rpm
Maximum torque
5.7 kg-m/8,000 rpm
58 (BTDC) at 0 lift

Identification
VE54A
number
'83-84: VE54A
CARBURETOR
'84
VE75A
CALIFORNIA:
Primary
1.704 (92/54): 1
reduction
pattern 1-N-2-3-4-5-(O.D.)

Spark plugs
IGNITION TIMING
At idle: 10° BTDC
1079-1275 kPa
(156-185 psi)
Cam 31.85 mm (1.252
IN, EX 31.901 mm (1.2559 in)
height in)
INI, IN4, 22.939-22.970 mm 22.91 mm (0.902
EX1, EX4 (0.9031-0.9043 in) in)
O.D.
IN2, IN3, 22.909-22.930 mm 22.88 mm (0.901
IN 1, IN4, 0.030-0.072 mm
0.13 mm (0.005 in)
Oil EX1, EX4 (0.0012-0.0028 in)
0.16 mm (0.006 in)
EX2, EX3 (0.0028-0.0044 in)
Valve 27.6-31.8 kg/22.2 mm
spring IN, EX Outer
Preload/ (60.1-70.1 lb/0.875 in)
length 8.65-9.95 kg/18.4 mm
IN, EX inner
(19.1-21.9 lb/0.726 in)
SERVICE-
ITEM STANDARD
LIMIT
4.975-4.990 mm (0.1959- 4.97 mm
IN
0.1965 in) (0.195 in)
Valve stem O.D.
4.955-4.970 mm (0.1951- 4.94 mm
EX
0.1957 in) (0.194 in)
IN, 5.0-5.012 mm (0.1969- 5.04 mm
Valve guide I.D.
guide 0.010-0.037 mm (0.0004- 0.07 mm
IN
clearance 0.030-0.057 mm (0.0012- 0.09 mm
EX
0.0022 in) (0.004 in)
IN, 1.41-1.98 mm (0.056- 2.0 mm (0.08
Valve face width
EX 0.078 in) in)
0.10 mm
Warpage
(0.004 in)
1.0 mm (0.04 in)
head IN/EX in)
23 000-23.021 mm 23.05 mm
(0.9055-0 90 3 in) (0.907 in)
SERVICE
STANDARD
LIMIT
60.000-60.010 mm 60.10 mm
I.D.
(2.3622-2.3626 in) (2.367 in)
Cylinder
0.10 mm
Warpage
(0.004 in)
0.015-0.045 mm 0.06 mm
TOP
SECOND
(0.0006-0.0018 in) (0.002 in)
0.15-0.30 mm 0.5 mm
TOP
(0.0059-0.012 in) (0.02 in)
0.15-0.30 mm 0.5 mm
SECOND
SECOND
Ring end gap (0.0059-0.012 in) (0.02 in)
OIL
0.30-0.90 mm 1.1 mm
(SIDE
(0.012-0.035 in) (0.04 in)
Piston O.D.
pin (2.3610-2.3618 in) (2.36 in)
15.002-15.008 mm 15.05 mm
Piston pin bore
(0.5906-0.5909 in) (0.592 in)
15.016-15.034 mm 15.07 mm
(0.5912-0.5909 in) (0.593 in)
14.994-15.000 mm 14.98 mm
Piston pin O.D.
(0.5903-0.5906 in) (0.589 in)
0.002-0.014 mm 0.04 mm
(0.0001-0.0006 in) (0.002 in)
0.010-0.050 mm 0.10 mm
(0.0003-0.0020 in) (0.004 in)
SERVICE
ITEM STANDARD
LIMIT
14.000—14.043 mm 14.06 mm
Cylinder I.D.
cylinder 13.957—13.984 mm 13.94 mm
Piston O.D.
(0.5495-0.5506 in) (0.549 in)
38.100—38.162 mm (1.500- 38.18 mm
Cylinder I.D.
cylinder 38.036-38.075 mm (1.4975- 38.02 mm
Piston O.D.
1.4990 in) (1.479 in)
31.984-32.000 mm (1.2592- 31.95 mm
A
O.D. 41.989-42.000 mm (1.6531- 41.95 mm
B
1.6535 in) (1.652 in)
34.0 mm (1.34
in)
Spring 21.2-23.2 kg/23.8 mm (46-
Clutch _
2.6 mm (0.10
in)
0.30 mm
Plate warpage -
(0.012 in)
gear I.D. 1.6544 m) (1.656 in)

42.175-
Drive
42.200 mm 42.16 mm
gear
(1.6604- (1.660 in)
O.D.
1.6614 in)
24.987-
O.D. (0.9837- (0.983 in)
0.9843 in)
SERVICE
ITEM STANDARD
LIMIT
0.05 mm
Runout _
(0.002 in)
Crankshaft
0.024-0.057 mm (0.0009- 0.07 mm
0.0022 in) (0.003 in)
0.019-0.043 mm (0.0007- 0.06 mm
0.0017 in) (0.002 in)
323.05-324.05 mm 327.0 mm
Cam chain Length
(12.750-12.758 in) (12.87 in)
Alternator 136.50-136.70 mm 137.8 mm
Length
chain (5.374-5.382 in) (5.43 in)
MAIN BEARING
1 2 3 4
32.994- 32.988- 32.982- 32.976-
33.000 mm 32.994 mm 32.988 mm 32.982 mm
(1.2990- (1.2987- (1.2985- (1.2983-
1.2992 in) 1.2990 in) 1.2987 in) 1.2985 in)
36.000-36.006 mm
(1.4173-1.4176 in)
CRANKCASE
36.006-36.012 mm
(1.4176-1.4178 in)
NO.
36.012-36.018 mm
(1.4178-1.4180 in)

Blue 1.511-1.514 mm (0.0595-0.0596 in)
Black 1.508-1.511 mm (0.0594-0.0595 in)
Brown 1.505-1.508 mm (0.0593-0.0594 in)
Green 1.502-1.505 mm (0.0591 -0.0593 in)
Yellow 1.499-1.502 mm (0.0590-0.0591 in)
Pink 1.496-1.499 mm (0.0589-0.0590 in)

CRANKPIN O.D. CODE
1 2 3
37.000-37.008 mm 37.008-37.016 mm 37.016-37.024 mm
(1.4567-1.4570 in) (1.4570-1.4573 in) (1.4573-1.4576 in)
40.000-
40.008 mm
(1.5748-
1.5751 in)
40.008-
CONNECTING
40.016 mm
(1.5751 -
NO.
1.5754 in)
40.016-
40.024 mm
C Brown Black Blue
(1.5754 -
1.5757 in)

Blue 1.502-1.506 mm (0.0591-0.0593 in)
Black 1.498-1.502 mm (0.0590-0.0591 in)
Brown 1.494-1.498 mm (0.0588-0.0590 in)
Green 1.490-1.494 mm (0.0587-0.0588 in)
Yellow 1.486-1.490 mm (0.0585-0.0587 in)
TRANSMISSION
SERVICE
ITEM STANDARD
LIMIT
0.044-0.133 mm 0.20 mm
Low, 2nd, 3rd
(0.0017-0.0052 in) (0.008 in)
0.034-0.102 mm 0.15 mm
Backlash 4th
(0.0013-0.0040 in) (0.006 in)
0.046-0.140 mm 0.18 mm
5th, 6th
5th, 6th
(0.0018-0.0055 in) (0.007 in)
28.020-28.041 mm 28.06 mm
M5, M6
(1.1031-1.1040 in) (1.105 in)
24.020-2.4041 mm 24.06 mm
Gear I.D. C1
(0.9457-0.9465 in) (0.947 in)
28.020-28.041 mm 28.06 mm
C2, C3, C4
(1.1031-1.1040 in) (1.105 in)
27.979-28.000 mm 27.96 mm
M5, C4
(1.1015-1.1024 in) (1.101 in)
27.979-28.000 mm 27.96 mm
M6
(1.1015-1.1024 in) (1.101 in)
Gear bushing O.D.
23.984-24.005 mm 23.97 mm
C1
(0.9443-0.9451 in) (0.944 in)
27.979-28.000 mm 27.96 mm
C2, C3
(1.1015-1.1024 in) (1.101 in)
24.985-25.006 mm 25.04 mm
M5, C4
(0.9837-0.9845 in) (0.986 in)
Gear bushing I.D.
20.000-20.021 mm 20.04 mm
C1
(0.7874-0.7882 in) (0.789 in)
24.959-24.980 mm 24.80 mm
Mainshaft O.D. (M5)
(0.9826-0.9835 in). (0.980 in)
19.980-19.993 mm 19.93 mm
C1
(0.7866-0.7871 in) (0.785 in)
Countershaft O.D.
24.959-24.980 mm 24.90 mm
C4
(0.9826-0.9835 in) (0.980 in)
M5, M6, C4 gear 0.020-0.062 mm 0.08 mm
to bushing (0.0008-0.0024 in) (0.003 in)
M5, C4 bushing 0.005-0.047 mm 0.07 mm
to shaft (0.0002-0.0019 in) (0.003 in)
C1 bushing to 0.007-0.041 mm 0.06 mm
shaft (0.0003-0.0016 in) (0.002 in)
C2, C3 gear to 0.020-0.062 mm 0.08 mm
bushing (0.0008-0.0024 in) (0.003 in)
0.08-0.18 mm (0.003-0.007 0.30 mm (0.012

Gear backlash
in) in)
53 mm (2.1 in) 51.5 mm (2.03 in)
length
indicated range.
Oil pressure (at
490.3 kPa/7,000 rpm 80° C (176° F)
oil pressure
(71 PSI/7,000 rpm)
switch)
Oil pump
delivery
Final drive gear

'83 170 cm3 (5.78 oz)
Oil capacity
'84 150 cm3 (4.9 oz)

'83-'84 E54A
Identification mark
Main jet #115
Capacity 12V 12 AH
Alternator
'83 STATOR
RPM Amperage Output
2500 2 amps
2000—2100 0±1 amp
1500 -5 ± 1 amp
1000 -10 ± 1 amp
'84 STATOR
RPM Amperage Output
2500 2 amps
1700—1800 0 ± 1 amp
1500 -3 ± 1 amp
1000 -9 ± 1 amp

Spark plug
Ignition timing
SERVICE
ITEM STANDARD
LIMIT
Brush spring
800 ± 120 g (28.2 ± 4.2 oz) 680 g (24.0 oz)
Starter tension
motor 12.0-13.0 mm (0.47-0.51
In)
Ignition timing
Ignition timing
10° BTDC at 1,400 ± 200 rpm
"F" mark
Generator
Cooled)
Battery
12V ~ 12 AH
capacity
Headlight
(high/low
equivalent)
beam)
(front/rear) 1073
Neutral
LIGHTS 12V -2 CP
indicator
Turn signal
12V - 2 CP
indicator
High beam
12V -2 CP
indicator
Oil pressure
12V-2 CP
warning light
FUSE
FUEL SENSOR
Front Rear
Tire size 100/90--19 130/90—16
57H 67H
Up to 90 kg (200 lbs) load 225 (32) 225 (32)
Cold tire pressure
225 (32) 280 (40)
capacity load
Tire brand
Dunlop F11 K627
SERVICE
ITEM STANDARD
LIMIT
0.2 mm (0.01
Axle shaft runout _
in)
2.0 mm (0.08
Front wheel rim in)
runout 2.0 mm (0.08
in)
0.03 mm (0.001
in)
512.4 mm (20.2
in)
0.2 mm (0.01
Fork tube runout -
in)
(15.7 oz)

0.03 mm (0.001
Wheel bearing play
in)
217.6 mm (8.57 in)
length in)
160.0-160.3 mm (6.30-6.31 161.0 mm (6.34
Brake drum I.D.
in) in)

15.93 mm (0.627 in)
I.D. 0.6265 in)
15.82 mm (0.623 in)
O.D. 0.6242 in)
O.D. 1.2598 in) in)
I.D. 1.2630 in) in)

Electrical System > Ignition System
Ignition System
The ignition timing is set at the factory and is not adjustable. To

troubleshoot the ignition system, you will need a digital multimeter and a
Peak Voltage Adapter (PVA). Perform the following checks. Before
performing any tests make sure the electrical connections are not loose or
corroded. Also, make sure the engine has good compression, the
transmission is in neutral, The engine kill switch is in the run position, the
main fuse is not blown, and the battery has a full charge.

at this point.
Spark Check
Caution: Do not touch the spark plug or spark plug wire while cranking or
running the engine as this can result in a severe shock.
Check the spark plug to see if it is the correct type and gapped properly. If
the spark plug is black and fouled, replace it. See the Spark Plug topic for
more information.
Disconnect the spark plug caps from the spark plugs. Check the spark
plugs for spark one at a time.
Connect a known good spark plug to the cap and ground the plug to the
frame. Push the engine start button and check that the plug will spark.
Repeat the process with the other spark plugs. If the plug does not spark
go through the following procedures to find the problem.
Ignition Coils
Removal
Remove the spark plug caps from the spark plugs. See the Spark Plugs
There are two ignition coil mounting bolts.
Loosen the ignition coil mounting bolts using a 10 mm socket. Remove the
bolts.
Remove the ignition coil from the frame.
Remove the leads from the ignition coil terminals.
Free the spark plug wires from the stay. Remove the ignition coils and
spark plug wires from the engine.
Continuity Test
Note: In order to test peak voltage, a Peak Voltage Adaptor (PVA)

must be used. PVAs can be found at most automotive or electrical
stores.
Measure the resistance of the primary coil as shown. Make sure the
resistance is within specifications.
Resistance 2.8 Ω
Measure the resistance of the secondary coil as shown. Leave the spark
plug caps in place on the ignition coil.
Resistance 21-28 k Ω
Remove the spark plug caps. Attach the multimeter leads as shown and
test the secondary coil resistance.
Resistance 13.6-15.5 Ω
Performance Test
Perform a 3 point spark test using a coil tester.
Arc Length 8 mm (5/16 in) Min.
Installation
Plug in the ignition coil connectors as shown.
Fit the ignition coil as shown.
Thread in the mounting bolts and tighten securely using a 10 mm socket.
Install the spark plug wires and ignition coils to the engine.
Pulse Generator
Resistance test
To remove the signal generator see the Signal Generator topic for more
information.
Disconnect the pulse generator couple in order to measure the coil

resistance.
Measure the resistance between the white and yellow wires (No. 2 and
No.3 cylinders). Measure the resistance between the white and blue wires
(No. 1 and No. 4 cylinders).
Pulse generator coil resistance 330 ± 10% Ω
Installation
Attach the leads to the ignition coils.
Fit the ignition coil into the frame.
Thread in the mounting bolts.
Tighten the bolts securely using a 10 mm socket.
Install the spark plug wires to the stay. Install the ignition coils and spark
plug wires to the engine.

Electrical System > Signal Generator
Pulse Generator

at this point.
To inspect the pulse generator see the Ignition Timing topic.
Removal
The pulse generators are located behind the pulse generator cover on the
left side of the motorcycle.
Remove the pulse generator cover. Check the cover O-ring for signs of
deterioration or damage. Replace if necessary.
There are two pulse generators as shown.
Remove the pulse generator mounting screws using a #2 Phillips

screwdriver.
Remove the lower mounting screws. Remove the pulse generators.
Remove the pulse generator wire bundle from the pulse generator case
and from the frame.
Disconnect the pulse generator coupler from the spark unit.
Installation
If the ignition timing was out of specification, two new pulse generators will
need to be installed.
Install the pulse generator coupler into the spark unit.
Route the pulse generator wire bundle through the frame and into the pulse
generator case as shown.
Fit the pulse generators into the pulse generator case. Fit the mounting
plates and thread in the screws. Tighten securely with a #2 Phillips
screwdriver.
Fit the upper mounting plate and thread in the screws. Tighten securely
with a #2 Phillips screwdriver.
The pulse generators should be installed as shown. Note the color and
placement of the wires.
Install the pulse generator cover with a new O-ring.
Thread in the bolts. Tighten the bolts securely with a 5 mm Allen wrench.

Electrical System > Charging System
Charging System
at this point.
Note: You will need a digital multimeter to inspect the charging system
Battery
Removal
Remove the right side cover. See the Side Covers topic for more
information.
Pull the battery fluid drain hose out of the battery holder bracket.
To remove the battery, remove the battery holder bolt using a 10 mm
socket.
Swing the battery holder out of the way.
Disconnect the negative cable from the battery negative terminal using a
#3 Phillips screwdriver. Disconnect the secondary ground cable.
Note:Always remove the negative terminal BEFORE removing the

positive terminal.
Pull the battery out.
Remove the positive battery terminal using a #3 Phillips screwdriver.
Installation
Connect the secondary ground cable.
Connect the positive terminal FIRST using a #3 Phillips screwdriver.
Slide the battery into the battery box.
Using a #3 Phillips screwdriver, connect the negative terminal.
Caution:Do not allow the screwdriver or any part of your person to contact
the positive terminal when connecting the negative terminal. Electric shock
could occur.
Swing the battery holder bracket into place. Thread in the bolt and tighten
securely using a 10 mm socket.
Insert the battery fluid drain tube through the hole in the battery holder
bracket as shown.
If the fluid in the battery was at or below the low mark, refill the fluid. See the
Battery topic in the Periodic Maintenance section for more information.
Inspection
SPECIFIC GRAVITY
Test each battery cell with a hydrometer.
Specific gravity 1.270-1.290/20°C (68°F)
If the specific gravity falls below 1.270, it means the battery is

undercharged.
If the specific gravity falls below 1.230, the battery is ruined and needs to
be replaced.
If sulfation is evident, the battery needs to be replaced.
BATTERY CHARGING
Caution:BEFORE charging remove the caps from each cell in the battery.
Caution: Keep sparks and flames away from any charging batteries
Caution: Do not disconnect the charger leads unless the charger is turned
off.
Caution: Discontinue charging if the temperature of the electrolytes

exceeds 45 degrees Celsius (113 degrees Fahrenheit).
Connect the positive (+) lead from the charger to the positive (+) terminal
on the battery. Connect the negative (-) lead from the charger to the
negative (-) terminal on the battery.
Charge the battery until the specific gravity is within specification.
Specific gravity 1.270-1.290/20°C (68°F)
Charging System
Charging Output Test
Note: A fully charged battery is required for this test.
Remove the positive battery cable from the starter relay.
Connect the positive lead of a 20V voltmeter to the end of the positive
battery cable that was just removed from the starter relay. Connect the
negative lead of the voltmeter to a frame ground. Connect a 20A ammeter
between the positive cable and the starter relay terminal as shown.
Start the engine. Allow the engine to warm for 10 minutes at 2000-2100
RPM.
'83 STATOR
RPM Amperage Output
2500 2 amps
2000—2100 0±1 amp
1500 -5 ± 1 amp
1000 -10 ± 1 amp
'84 STATOR
RPM Amperage Output
2500 2 amps
1700—1800 0 ± 1 amp
1500 -3 ± 1 amp
1000 -9 ± 1 amp
Let the voltage stabilize to 14-15 volts. Check the amperage output against
the output specified in the table above.
For information on the generator, see the Generator topic.
Voltage Regulator/Rectifier
Removal
The voltage regulator rectifier is located on the left side of the frame.
Remove the two regulator/rectifier couplers.
Remove the two regulator/rectifier mounting bolts using a 10 mm socket.
Remove the regulator/rectifier from the frame.
Inspection and Installation
Note:Use a SANWA [SP-10D] or KOWA [TH-5H] tester, or a KOWA

DIGITAL TESTER [KS-AHM 32-CO3] to test the continuity of the
regulator/rectifier. The regulator/rectifier has a semi conductor so testers
other than those listed won't provide proper readings.
Check the resistance between the leads using one of the above mentioned
ohmmeters.
RESISTANCE IN ONE DIRECTION OF CURRENT

Green and any yellow 5-40 Ω
Red/white and any yellow 5-40 Ω
RESISTANCE IN REVERSE DIRECTION

Red/white and any yellow 2000 Ω minimum
Green and any yellow 2000 Ω minimum
Fit the regulator/rectifier to the frame.
Thread in the regulator/rectifier mounting bolts. Tighten them securely with

a 10 mm socket.
Connect the two regulator/rectifier couplers as shown.
Now that all of the components are installed, start the engine and inert the
positive probe of a voltmeter into the black wire of the 4-pin coupler as
shown. Connect the negative probe to ground.
Rev the engine to 2500 RPM. The voltmeter should read 14-15 volts.
If the voltage is not within specifications, replace the regulator/rectifier and
retest.

Electrical System > Starter Motor
Starter System

at this point.
Troubleshooting
If the electric starter does not turn perform the following checks. You will
need a digital multimeter for these tests.
If the starter motor turns but doesn't turn the engine over inspect the starter
clutch. See the Starter Clutch topic for more information.
1. Turn the ignition switch to the on position, shift the transmission into
neutral and pull in the clutch lever. Make sure the engine stop switch is in
the run position. Hit the starter button and listen for the starter relay to click.
The starter relay is located on the left side of the motorcycle.
If the starter relay clicks move on to step 2. If the starter relay doesn't click
move to step 3.
2. Remove the starter motor, using a jumper wire apply 12 volts DC to the
starter motor and if it does not turn over it is a bad starter. If the starter
motor does turn check for the following faults.
Starter Relay
Loose Starter Motor Lead
Ignition Switch
Engine Stop Switch
Clutch Switch
Neutral Switch
Starter Button
Bad Connector
3. Set your digital multimeter to read voltage. Touch you positive meter
lead to the black/yellow starter relay connector and the negative to the
black/white starter relay connector. Hit the starter button and check for
voltage.
If there is voltage check the starter relay. If there is no voltage check for the
following faults.
Ignition Switch
Engine Stop Switch
Clutch Switch
Neutral Switch
Starter Button
Bad Connector
4. If the starter motor will run in neutral, but not in any gear, and the side
stand is up check the side stand switch.
If the side stand switch checks out. Look for a bad connector or a pinched
or broken wire in the harness.
Starter Relay
Remove the right side cover. See the Side Cover topic for more
information.
Loosen the negative battery cable screw with a #3 Phillips head

screwdriver or a 10 mm socket. Disconnect the cable from the battery.
Remove the starter relay from its holder.
Remove the starter relay leads with a 10 mm socket.
Unplug the starter relay connector. Remove the starter relay from its metal
fingers. Inspect the fuse and replace as needed.
Jump 12 volts to the terminals as shown. The starter relay should click and
the lead terminals should show continuity.
Caution: Jumping 12 volts to the starter relay for more than five seconds
could result in damaging the relay coil.
Check the resistance of the starter relay terminals with an ohmmeter, as

shown.
If there is continuity then the switch is normal.
Clutch Diode Inspection
Remove the clutch diode from the wiring harness as shown.
Use an ohmmeter to check continuity. Touch the meter probes to the

terminal as shown. There should be continuity when the probes are
attached in one direction, and no continuity when the probes are places in
the reverse direction.
Starter Motor
Removal
The starter motor is located on the right side of the engine.
Loosen the starter cable mounting nut using a 10 mm socket. Remove the
starter cable from the starter motor.
Remove the two starter motor mounting bolts using a 10 mm socket.
Remove the starter motor from the engine.
Remove the O-ring from the output end of the starter motor.
Loosen the two starter motor housing bolts with a #2 Phillips screwdriver.
Remove the housing bolts and washers.
Slide off the output end cap. Remove the lock washer.
Remove the O-ring from the end cap.
Remove the three shims from the armature shaft
Remove the rear end cap.
Remove the three shims from the rear end of the armature shaft.
The brushes are held in place by the commutator end of the armature.
Remove the armature from the starter motor body. The brushes will pop out
of their holders.
Remove the starter cable terminal nut using a 10 mm socket. Remove the
washers.
Remove the insulators from the starter cable terminal.
Remove the starter cable terminal bracket and brush holder from the
starter motor case.
Remove the starter cable terminal bracket from the brush holder. Remove
the insulator collar from the starter cable terminal. Remove the starter cable
terminal from the terminal bracket.
Inspect the connection points of the two brushes on the starter cable
terminal bracket. Replace the entire bracket if one or both brush
connections are worn or damaged. Inspect the two brush connections on
the brush holder. If one or both connections are worn or damaged, replace
the brush holder. Measure the length of the brushes. Measure the brush
spring tension using a spring scale. Inspect the brushes for wear and
damage. Replace all the brushes if one is damage or excessively worn.
The brushes on our motorcycle's starter motor were excessively worn and
needed to be replaced.
SERVICE
ITEM STANDARD
LIMIT
Brush spring
800 ± 120 g (28.2 ± 4.2 oz) 680 g (24.0 oz)
Starter tension
motor 12.0-13.0 mm (0.47-0.51
In)
Remove the O-ring from the rear of the starter motor case.
Install the starter cable terminal into the starter motor case using the
insulators, washers and nut. Test the continuity between the cable terminal
and the case as shown. There should be no continuity.
Test the continuity between the cable terminal and the brush as shown.
There should be continuity.
Inspect the armature for wear and discoloration. There should be a an

undercut between the commutator strips.
The commutator strips can be cleaned up with fine grit sand paper or an
emery cloth. Scrape out the insulator with a razor blade if the undercut is
not present.
to any one commutator strip and touch the other meter lead to all of the
other commutator strips one by one. Polarity of the meter leads does not
matter. There should be continuity for all of the readings, if any readings
show no continuity the armature must be replaced.
to any one commutator strip and touch the other meter lead to the steel
shaft of the armature. Polarity of the meter leads doesn't matter, and you
only need to check one of the commutator strips. There should be no
continuity, if there is the armature must be replaced.
Inspect the bearing and seal in the out put side starter motor end cap.
Replace the end cap if necessary.
Clean all of the starter motor parts with aerosol electrical contact cleaner
and a lint free cloth.
Assembly
Install the O-ring at the back of the motor case.
Install the cable terminal into the terminal bracket. Install the insulator collar
onto the cable terminal. Install the terminal bracket onto the brush holder.
Install the brush holder and terminal bracket into the motor case. Make sure
the tab on the brush holder lines up with the notch on the motor case.
Install the insulators onto the cable terminal.
Install the washers onto the cable terminal. Use a 10 mm socket to tighten
the nut securely.
Install the armature into the motor case so that the brushes fit around the
outside of the commutator.
Install the three shims at the rear of the armature as shown.
Install the end cap, making sure the alignment marks are aligned as shown.
Install the three shims onto the front of the armature shaft as shown .
Install the O-ring onto the front of the motor case.
Install the lock nut into the front end cap as shown. Fit the front end cap to
the motor case.
Make sure to align the marks on the motor case and front end cap.
Thread in the screws and tighten securely using a #2 Phillips screwdriver.
Install the O-ring on the front of the starter motor as shown. Apply a light
coat of motor oil to the O-ring. Turn the armature shaft by hand. It should
turn smoothly.
Installation
Insert the starter motor into place.
Insert the two starter motor mounting bolts and tighten them to specification

10 mm bolt, nut 30-40 (3.0-4.0, 22-29)
Install the starter motor lead to the starter motor as shown. Tighten the bolt
securely with a 10 mm socket.
Slide the rubber cover into place.

Electrical System > Switches
Switches

at this point.
To test these switches, you will need a digital multimeter set to Ω (Ohms of
resistance). If a switch does not meet specification replace it. The switch
continuity diagrams are also shown on the wiring diagrams.
Oil Pressure Warning Switch
Attach an air pump to the oil pressure switch and apply pressure to the
switch while checking for continuity as shown. There should be continuity
below 2.8 psi. There should be NO continuity above 2.8-5.6 psi.
Brake Switches
Front
Disconnect the front brake light wires.
With the front brake applied, check the connectors for continuity. There
should be continuity with the front brake applied and NO continuity with the
front brake released.
Rear
Remove the right side cover. See the Side Cover topic for information.
Disconnect the white/green and green/yellow lead connector.
Check the rear brake light switch for continuity as shown. There should be
continuity with the rear brake applied. There should be NO continuity with
the rear brake released.
Gear Change Switch
Remove the left side cover. See the Side Cover topic for information.
Disconnect the gear change switch coupler.
Check the continuity between each terminal and ground for each gear.
1st
yellow
gear
Neutral green
2nd
blue
gear
3rd
white
gear
4th
red
gear
5th
brown
gear
OD light green
1983 CB550SC GEAR POSITION SWITCH CONTINUITY ADDENDUM

N G and Ground
OD Bu and Ground
In order to access the gear change switch (red arrow), the gear change
lever must be removed.
Remove the gear change lever bolt using a 12 mm socket.
Remove the gear change switch bolts using a socket. Our gear change
switch was held on with two screws and could be removed with a #3
Remove the gear change switch. Align the switch joint pin with the index
mark (neutral position) on the switch. Install the gear change switch into the
switch drum so the joint pin fits into the groove on the drum.
Handlebar Switches
The wires are color coded. The abbreviations for the colors are listed
below.
B= Black
Bl= Blue
Br= Brown
Lg= Light green
W= White
G= Green
Gr= Grey
Lb = Light blue
O= Orange
R= Red
Y= Yellow
Check for continuity between the color coded wires.
TUR SIGAL
Right turn Lb/W and O Gr and Bl/W
Not pressed Gr and Br/W and Bl/W
Left turn Gr and Br/W
DIMMER
Lo W and Bl
N W and Bl and O/W
Hi W and O/W
HOR
Button out --
Pushed Lg and W/G
EGIE STOP SWITCH

Off --
Run B/W and B
STARTER
Pushed Y/R and B
Button out B/R and Bl/W
Ignition Switch
Removal and Installation
Use a 10 mm socket to remove the ignition lock retaining bolts. Slide the
ignition lock out of the fork brace. To install: slide the lock back into the fork
brace and secure it into position by tightening the mounting bolts with a 10
mm socket.
Disassembly and Assembly
Switch the key to the 'ON' position.
Use a flat blade screwdriver to push in the locking tab on the bottom of the
ignition lock assembly.
Remove the cap. Remove the wire connector.
Assembly is the reverse of disassembly.
Check for continuity between the wires on the switch side as indicated.
POSITIO TERMIALS
ON Br/W and Br Br and B
OFF --
P Br/W and R
Clutch Switch
Remove the clutch switch wires from the underside of the clutch lever as
shown. Check the continuity of the clutch lever safety switch as shown.
CLUTCH LEVER SWITCH

lever applied continuity
lever not applied no continuity
Fuel Sensor
Remove the fuel sensor nuts using a 10 mm socket. Remove the fuel
sensor.
Connect the ohmmeter to the fuel sensor coupler. Inspect the resistance of
the float at the top and bottom positions.

Top (Full Tank) 4-10 Ω
Bottom (Empty Tank) 90-100 Ω
Connect the fuel sensor coupler. Turn the ignition to the 'ON' position.
Make sure the battery is fully charged. Inspect the function of the fuel gauge
by moving the fuel sensor float up and down and observing if the gauge
needle moves throughout its range.
Brake and Taillight Sensor
Disconnect the taillight sensor Br connector. Turn the ignition to the 'ON'
position and see if the taillight sensor warning light comes on.
If the taillight warning light does not come on, check the voltage at the G
and B/Br terminals of the taillight sensor coupler. If no voltage is measured,
repair the circuit and connections. If there is voltage, measure the voltage
at the G (negative) and W/Y (positive) terminals.
VOLTAGE 9-14 V
If there is no voltage between the G and W/Y terminals, replace the taillight
sensor.

Electrical System > Lights
Lights

at this point.
Do not touch the light bulbs with your bare hand. The oils on your hand can
cause the failure of the bulb when it gets hot. Clean the bulb with a lint free
towel and alcohol if you touch it bare handed.
Fuses
If a light is not working check the fuses.
Remove the fuse box lid and replace the blown fuses as necessary.
Taillight
Removal
Remove the Tail Section. See the Tail Section topic for more information.
The taillight bulb can be removed from the rear of the taillight.
Remove the bulb from the socket and replace if necessary.
Remove the taillight bracket bolts using a 10 mm socket.
Remove the taillight bracket assembly.
Installation
Fit the taillight bracket assembly.
Thread in the taillight bracket bolts. Tighten securely using a 10 mm

socket.
Install the taillight bulb into the bulb socket. Install a new bulb if the previous
bulb is old or non-functional.
Install the taillight bulb and socket into the taillight housing. Make sure the
tabs on the socket line up the notches in the housing, and twist the socket
to lock it in place.
Front Turn Signals

Remove the headlight. See the Headlight topic for more information.
Loosen the turn signal nuts using a 17 mm wrench. Remove the nuts and
slide them off the wires.
Remove the turn signals from the turn signal brackets.
Remove the turn signal bracket bolts using a 10 mm socket. Remove the
bracket.
Remove and replace the turn signal bulbs if they are old or non-functional.
Remove the three turn signal lens screws using a #2 Phillips screwdriver.
Remove the lens. Remove the dust seal.
Remove the bulb and replace if necessary.
Rear Turn Signals
Loosen the rear turn signal nut using a 17 mm wrench.
Remove the nut and the bracket.
Remove the rear turn signal bulbs as shown above.

Electrical System > Headlights
Headlights

at this point.
Removal
Headlight and Bulb
Remove the headlight mounting screw using a #2 Phillips screwdriver.
Remove the headlight bracket and the headlight.
Disconnect the bulb from the coupler.
Remove the headlight bulb seal.
Remove the headlight by removing the headlight clip.
Headlight Case
Gently pull out the wires from the headlight case so they can all be
disconnected.
Disconnect the leads and couplers inside the headlight case as shown.
Inspect the couplers for corrosion or damage.
Remove the headlight case mounting bolt using a 10 mm socket.
Remove the wires from the back of the headlight case.
Disconnect the high beam indicator leads.
Remove the headlight case.
Installation
Headlight Case
Fit the headlight case to the mounting brackets.
Connect the high beam indicator light leads.
Insert the leads and couplers into the back of the headlight case as shown.
Thread in the headlight case mounting bolts and tighten it to specification

using a 10 mm socket. Line up the punch marks on the brackets with the
index marks on the headlight case.

Item Qty
(mm) (ft-lb)
Headlight bracket 2 8 20-28 (14-20)
Connect all of the couplers and leads inside the headlight case as shown.
Tuck the wires towards the rear of the headlight case in order to make
room for the headlight.
Replace the bulb if necessary.
Install the bulb into the headlight case. Secure the bulb with the clip.
Install the headlight bulb seal.
Connect the headlight coupler
Install the headlight and holder.
Secure the bracket with the mounting screw. Tighten the screw securely
with a #2 Phillips screwdriver.

Electrical System > Instrument Panel
Instrument Panel

at this point.
Removal
Remove the headlight. See the Headlight topic for more information.
Remove the headlight case. See the Headlight topic for more information.
The tachometer, speedometer, fuel gauge, gear indicator and indicator

lights are all contained in one single instrument panel unit.
Remove the speedometer cable using pliers.

The 3-way joint will have to be removed.
Loosen the 3-way joint bolts using a 10 mm socket.
Remove the wires from the backside of both horns.
Remove the 3-way joint assembly. Remove the two banjo bolts from the
hose joint using a 12 mm socket. Discard the two crush washers from each
banjo bolt.
Remove the fuse box cover under the headlight.
Remove the fuse box mounting screw using a 10 mm socket. Our

CB650SC had screws instead of bolts.
Remove the fuse box.
Disconnect the engine stop switch from the fuse box.
Disconnect the ignition switch from the fuse box.
Disconnect the main wire harness from the fuse box.
Disconnect the brake light switch and inspect it for corrosion.
Disconnect the main wire harness coupler from the fuse box.
Disconnect the instrument coupler from the fuse box.
Disconnect the turn signal switch from the fuse box.
Disconnect the ignition switch from the fuse box.
Remove the bolts using a 12 mm socket.
Remove the instrument panel.
Disassembly
Four screws hold the instrument panel halves together.
Using a #2 Phillips screwdriver, remove the four mounting screws.

Separate the two halves of the instrument case.
Honda CB650SC WIRING DIAGRAM
Fuse Box
High Beam Left Turn Right Turn Broken Wire Oil Pressure Neutral
Fuse 15A Neutral-

Signal- Front Rear
Indicator Signal Signal Indicator Warning Light Light Indicator Oil Pressure
Fuse 15A Meter
Fuse 15A Turn

Engine Stop Front Brake
Brake- Horn
Light - Tail
12V3.4W Indicator 12V3.4W 12V3.4W 12V3.4W
Oil Light
12V3.4W Switch
HeadLight
Fuse 15A
Starter Switch Switch Light Switch Ignition Switch Gear Position Indicator
12V3.4W
FREE OFF OFF ON ON
PUSH RUN ON OFF OFF R/W +
Starter Relay
PARK
Bl/W
W/G
Bl/R
B/W
Y/R
0D
G/Y
B/R
B
+
N
1
2
4
5
3
Battery
Br/W
Lg/R
Bl/R
W/Y
B/Br
B/Br
B/Br
Lb
Br
Br
Bl
G
G
O
R
B
12V12AH
W/Bl
Lg/R
R/W
Br/Y
B/Br
G/O
B/Y
Y
Chenge Switch
M Turn Signal
Starter
Relay
0D
N
1
5
4
2
Motor
3
Br/W
W/G
B/Br
B/R
B
W/Bl
Lg/R
R/W
Br/Y
G/O
B/Y
Y
Turn Signal
G/R
Y/R
12V32/3cp Fuel Gauge
W/G
Gr
G
Lb
Lb/W
G Br/W
Br/W
W/G
Turn Signal
Bl/W 12V32cp
B Lb
Y/W
G
B/R G
G
Br/W
Tachometer Light Br/W
12V3.4W B/Br
G
Turn Signal
12V32cp
Y
Tachometer B/Br G
G G/Y O
W
Tachometer Light Br/W Y/R
12V3.4W G
Lg/R
Bl/R Stop/Tail Light
Fuel Meter Light Br/W
12V3.4W Bl 12V32/3cp
G
W/Y
G/Y G/Y
Y/W
Br Br
G G
Y/W Gr
Feul Meter
Unit B/Br G/R
G Br/W
Bl/W
W/G
W/Y
B/Br
Speedometer Light Br/W
G/Y
G/Y
Br
Br
G
G
12V3.4W G
G
G
W/G
G/Y
Speedometer Light Br/W WIRE COLORS
12V3.4W G Ground OFF B : Black
Lb ON BI : BIue
O Rear Brake Broken Wire Warning Unit Br : Brown
G Light Switch G : Green
Lb Gr : Gray
Lb Lb : Light Blue
Lg : Light Green
O
O : Orange
O R : Red
W : White
R/W
Lb/W Y : Yellow
Bl
G
B/Br : Black with Brown tracer
O/W B/R : Black with Red tracer
B/W : Black with White tracer
B/W
B/W
Bl
Y
G B/Y : Black with Yellow tracer

HeadLight G Bl/W: Blue with White tracer
G Br/W: Brown with White tracer
12V60/55W
Lg Br/Y : Brown with Yellow tracer
4 2
Lg/R
G/R
Bl Bl G/O : Green with Orange tracer

G/R : Green with Red tracer
Bl
W
W
W W
Y
Y
Y
Y
3 2-3 1 1-4 G/Y : Green with Yellow tracer
G G Lb/W: Light Blue with White tracer
Lg/R: Light Green with Red tracer
Silicon Rectifier Ignition Coil Ignition Coil O/W: Orange with White tracer
Turn Signal R/W : Red with White tracer
B/W
R/W
Bl
Bl
W
W
G W/Bl:: White with Blue tracer
Bl
W
G
Y
Y
Y
B
B
12V32/3cp
W/G:: White with Green tracer
Lg
Lb/W
W/Y : White with Yellow tracer

G
Br/W
Bl/W
W/G
O/W
G/R
Lb
Lg
Gr
Bl
W
O Pulse Y/R : Yellow with Red tracer

O/W 4 3 2 1 Generator Y/W:: Yellow with White tracer
Alternator
G LO R
N N FREE OUT
HI L PUSH IN Spark Plugs
Horn Switch Clutch Switch Dual Horn Regulator/Rectifier
Dimmer Switch Turn Signal Switch SPARK UNIT
© 2008 Cyclepedia Press LLC Honda.CB_01.pdf

Honda CB550SC WIRING DIAGRAM
Fuse Box
Over Drive High Beam Left Turn Right Turn Broken Wire Oil Pressure Neutral
Fuse 15A Neutral-

Signal- Front Rear
Indicator Indicator Signal Signal Indicator Warning Light Light Indicator Oil Pressure
Fuse 15A Meter
Fuse 15A Turn

Engine Stop Front Brake
Brake- Horn
Light - Tail
12V3.4W 12V3.4W Indicator 12V3.4W 12V3.4W 12V3.4W
Oil Light
12V3.4W Switch
HeadLight
Fuse 15A
Starter Switch Switch Light Switch Ignition Switch
12V3.4W
FREE OFF OFF ON ON
PUSH RUN ON OFF OFF R/W +
Starter Relay
PARK
Bl/W
W/G
Bl/R
B/W
Y/R
G/Y
B/R
B
B
Battery
Br/W
Lg/R
Bl/R
W/Y
B/Br
B/Br
B/Br
B/Br
G/O
Lb
Br
Br
Bl
G
G
O
R
B
12V12AH
M Turn Signal
Starter
Relay
Motor
Br/W
W/G
B/Br
B/R
B
Licence Light
12V32cp
Bl
G
Br
G/R
Y/R
G
W/G
Gr
G
Turn Signal
Lg/R
G/O
12V32/3cp
Br/W
Lb Br/W
Lb/W W/G
G Turn Signal
Bl/W 12V32cp
B Lb
B/R G
G
Br/W
Tachometer Light Br/W
12V3.4W B/Br
G
Turn Signal
12V32cp
Y
Tachometer B/Br G
G G/Y O
W
Tachometer Light Br/W Y/R
12V3.4W G
Lg/R
Bl/R Stop/Tail Light
Bl 12V32/3cp
W/Y
G/Y G/Y
G/O
Br Br
G G
Gr
G/R
Br/W
Bl/W
W/G
W/Y
B/Br
Speedometer Light Br/W
G/Y
G/Y
Br
Br
G
G
12V3.4W G
G
G
W/G
G/Y
Speedometer Light Br/W WIRE COLORS
12V3.4W G Ground OFF B : Black
Lb ON BI : BIue
O Rear Brake Broken Wire Warning Unit Br : Brown
G Light Switch G : Green
Lb Gr : Gray
Lb Lb : Light Blue
Lg : Light Green
O
O : Orange
O R : Red
W : White
R/W
Lb/W Y : Yellow
Bl
G
B/Br : Black with Brown tracer
O/W B/R : Black with Red tracer
B/W : Black with White tracer
B/W
B/W
Bl
Y
G B/Y : Black with Yellow tracer

HeadLight G Bl/W: Blue with White tracer
G Br/W: Brown with White tracer
12V60/55W
Lg Br/Y : Brown with Yellow tracer
4 2
Lg/R
G/R
Bl Bl G/O : Green with Orange tracer

G/R : Green with Red tracer
Bl
W
W
W W
Y
Y
Y
Y
3 2-3 1 1-4 G/Y : Green with Yellow tracer
G G Lb/W: Light Blue with White tracer
Lg/R: Light Green with Red tracer
Silicon Rectifier Ignition Coil Ignition Coil O/W: Orange with White tracer
Turn Signal R/W : Red with White tracer
B/W
R/W
Bl
Bl
W
W
G W/Bl:: White with Blue tracer
Bl
W
G
Y
Y
Y
B
B
12V32/3cp
W/G:: White with Green tracer
Lg
Lb/W
W/Y : White with Yellow tracer

G
Br/W
Bl/W
W/G
O/W
G/R
Lb
Lg
Gr
Bl
W
O Pulse Y/R : Yellow with Red tracer

O/W 4 3 2 1 Generator Y/W:: Yellow with White tracer
Alternator
G LO R
N N FREE OUT
HI L PUSH IN Spark Plugs
Horn Switch Clutch Switch Horn Regulator/Rectifier
Dimmer Switch Turn Signal Switch SPARK UNIT
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9/23/2010 Honda CB550SC/CB650SC Online Repair …

Honda CB550SC and CB650SC Repair Manual

Periodic Maintenance Chart

Periodic maintenance is required to keep the motorcycle safe and

I = Inspect, clean, lubricate and adjust as necessary

km 1,000 6,000 12,800 19,200 25,600 32,000 38,400

Copyright 2010 - Cyclepedia Press LLC

Honda CB550SC and CB650SC Repair Manual

VIN and Engine Number Location

The carburetor type is stamped on the right side of the carburetor.

Copyright 2010 - Cyclepedia Press LLC

Honda CB650SC Specifications

Front brake, lining swept area Disc brake, 904 cm2

Rear brake, lining swept area Drum brake, 201 cm2

FORK OIL CAPACITY

Valve clearance 0 mm: HYDRAULIC

Oil pump service data

ITEM STANDARD SERVICE LIMIT

MAIN BEARING INSERT THICKNESS

CONNECTING ROD BEARING

BEARING INSERT THICKNESS:

0.08-0.18 mm (0.003-0.007 0.30 mm (0.012

Final drive gear

Damper case oil capacity 20 cc (0.71 oz)

Venturi dia. 29.2 mm (1.15 in)

Choke Valve Stroke 5-7 mm (3/16-1/4 in)

ND X24EPR-U9, X22EPR-U9, X27EPR-U9

Brake, Wheel, Tires and Suspension Specifications

Suspension air pressure Front 0-40 kPa (0-6 psi)

Rear brake pedal free play 20-30 mm (3/4-1-1/4 in)

ITEM STANDARD SERVICE LIMIT

ITEM STANDARD SERVICE LIMIT

Copyright 2010 - Cyclepedia Press LLC

Supplemental Honda CB550SC Specifications

Overall length 2150 mm (84.6 in)

MAIN BEARING INSERT THICKNESS

CONNECTING ROD BEARING

Honda CB550SC and CB650SC Repair Manual

Cam chain tensioner 20-24 N-m (14-17 ft-lb)

Clutch hose oil bolts 25-35 N-m (18-25 ft-lb)

Stopper arm pivot bolt 10-14 N-m (7-10 ft-lb)

Crankpin 30-34 N-m (22-25 ft-Ib)

Pinion nut 100-120 N-m (72-87 ft-lb)

Thread Dia. Torque N-m

ITEM TORQUE N-m (ft-lb)

Handlebar upper holder 20-30 N-m (14-22 ft-Ib)

Rear axle nut 60-80 N-m (43-58 ft-lb)

Brake hose bolt 25-35 N-m (18-25 ft-lb)

Copyright 2010 - Cyclepedia Press LLC

Honda CB550SC and CB650SC Repair Manual

General Torque Specifications

General torque specifications are only to be used when specific torque

Torque N-m (kg-m, Torque N-m (kg-m, ft-

Copyright 2010 - Cyclepedia Press LLC

Honda CB550SC and CB650SC Repair Manual

SAFETY FIRST: Protective gloves and eyewear are recommended

Loosen the rearward throttle cable lock nut using a 10 mm wrench.

Remove the rearward throttle cable from the throttle drum.

Loosen the choke cable clamp screw using a #2 Phillips screwdriver.

Remove the protector.

Free the throttle cables from the throttle drum.

For disassembly see the Carburetor Disassembly topic for more

Copyright 2010 - Cyclepedia Press LLC

Honda CB550SC and CB650SC Repair Manual