Shop Manual Honda CB500 550

Preface

Item		Standard Value	Serviceable Limit
Inlet cam height		34.93-34.97	35.85
Exhaust cam height		34.53-34.57	34.45
Runout		-	0.1
Cylinder bore		58.50-58.51	58.6
Piston diameter		54.47-58.49	58.35
Piston pinhole		-	15.08
Piston ring end gap	top, 2nd	0.15-0.35	0.7
Piston ring end gap	oil	0.3-0.9	1.1
Piston ring side clearance	top ring	0.040-0.075	0.18
Piston ring side clearance	second ring	0.025-0.06	0.15
Piston ring side clearance	oil ring	-	-
Ring groove clearance		15.002-15.008	15.080
Valve stem clearance	inlet	0.020-0.045	0.080
Valve stem clearance	exhaust	0.030-0.050	0.10
Valve stem diameter	inlet	5.450-5.465	-
Valve stem diameter	exhaust	5.430-5.445	-
Valve face runout		-	0.05
Cylinder head flatness		-	0.3
Valve spring free length	outer	40.4	39
Valve spring free length	inner	35.7	34.5
Loading (reference)	outer	27.9 45.6-50.6 kg	-
Loading (reference)	inner	23.2 1-21.1 kg	-
Clutch plate warp		-	0.3
Oil pump inner and outer rotor clearance		-	3.35
Oil pump outer and body clearance		-	0.35
Friction disc thickness		2.6	2.3
Clutch spring free length		36.8	35.4
Spring strength		22.1-33.2 at 23	-
Great shift drum outside diameter		39.975-59.95	39.9
Shift fork inside diameter		40.00-40.025	40.075
Gear shift fork	center	5.93-6.00	5.60
Gear shift fork	right and left	4.93-5.0	4.60
Crankshaft journal clearance		0.020-0.046	0.080
Runout		-	0.05
Journal and taper		-	0.05
Connecting rod large end clearance		0.02-0.046	0.08
Connecting rod side clearance		0.12-0.27	0.35
Connecting rod small end clearance		15.016-15.034	15.07
1st, 2nd, 3rd gears backlash		0.044-0.133	0.2
4th and 5th gears backlash		0.046-0.140	0.2

Item		Standard Value	Serviceable Limit
Rim wobble		0.5	2.0
Wheel runout		0.5	2.0
Front wheel bearing axial direction, total indicator reading		0.07	0.1
Front wheel bearing radial direction, total indicator reading		0.003	0.05
Caliper cylinder inside diameter		38.18-38.20	38.215
Caliper cylinder outside diameter		38.115-38.48	38.105
Front Brake	Master cylinder	14.0-14.043	14.055
Front Brake	Piston	13.957-13.984	13.940
Wheel	Rim runout, total indicator reading (vertical and side)	0.5	2.0
Wheel	Disc trueness	-	0.3
Wheel	Caliper and piston clearance	-	0.11
Wheel	Master cylinder and piston clearance	-	0.11
Rear axle shaft	Bent, total indicator reading	0.01	0.2
Brake lining	Thickness	5.0	2.0
Brake Drum	Inside diameter	179.8-180.0	181.0
Axial, total indicator reading		0.07	0.1
Radial, total indicator reading		0.003	0.05
Front suspension spring inside diameter		42	-
Free length		451.7	425
Tilt		5	8
Rear suspension free length		0.1-0.3	0.5
Clearance		0.1-0.3	0.5
Rear fork bushing inside diameter		21.448-21.5	21.8
Center collar outside diameter		21.427-21.46	21.4