Honda CBX550 Four Repair Manual 1982-1986

The Honda CBX550 Four Repair Manual by Haynes covers models indicated, including:

• Honda CBX550FC, 1982-1985
• Honda CBX550F2C, 1982-1985
• Honda CBX550FD, 1984-1986
• Honda CBX550F2D, 1984-1986

Book Excerpt: 1982-1986 Honda CBX550 Four Repair Manual TROUBLESHOOTING

JUMPING OUT OF GEAR

• Stopper arm assembly worn or damaged. Wear of the roller and the cam with which it locates and breakage of the detent spring can cause imprecise gear selection resulting in jumping out of gear. Replace the damaged components.
• Gear pinion dogs worn or damaged. Rounding off the dog edges and the mating recesses in adjacent pinion can lead to jumping out of gear when under load. The gears should be inspected and replaced. Attempting to reprofile the dogs is not recommended.
• Selector forks, gearchange drum and pinion grooves worn. Extreme wear of these interconnected items can occur after high mileages especially when lubrication has been neglected. The worn components must be replaced.
• Gear pinions, bushes and shafts worn. Replace the worn components.
• Bent gearchange shaft. Often caused by dropping the machine on the gear lever.
• Gear pinion tooth broken. Chipped teeth are likely to cause jumping out of gear once the gear has been selected fully; a tooth which is completely broken off, however, may cause problems in this respect and in any event will cause transmission noise.

ELECTRICAL SYSTEM

STARTER MOTOR: REMOVAL AND OVERHAUL

1. Check that the ignition switch is off and disconnect the battery negative (-) lead to isolate the system. Remove the starter lead at the motor terminal. Release the two motor retaining bolts and remove the motor by pulling it clear of the casing.
2. Remove the two long screws which retain the motor end covers and lift away the brush cover. Ease the brush plate away from the motor casing until the brushes spring clear of the commutator. Disengage the field coil brushes from the brush plate to free it.
3. Remove the end cover and reduction gear assembly then slide the armature out of the motor casing. Note that shims are fitted to both ends of the armature. These must be kept separate and refitted in their original positions.
4. Measure the length of the brushes using a Vernier caliper, replacing them as a set if any have worn beyond the 6.5 mm (0.26 in) service limit. If a spring balance or some weights are available, check that the brush springs are able to exert at least 680 gm (24.0 oz) pressure.
5. Clean the commutator segments with methylated spirit and inspect each one for scoring or discoloration. If any pair of segments is discolored, a shorted armature winding is indicated. The manufacturer supplies no information regarding skimming and re-cutting the armature in the event of serious scoring or burning, and so by implication suggests that a new armature is the only solution. It is suggested, however, that the advice of a vehicle electrical specialist is sought first; professional help may work out a lot cheaper.
6. Honda advises against cleaning the commutator segments with abrasive paper, presumably because of the risk of abrasive particles becoming embedded in the soft segments. It is suggested, therefore, that an ink eraser be used to burnish the segments and remove any surface oxide deposits before installing the brushes.

Subject: 1982, 1983, 1984, 1985, 1986 Honda CBX550 Four service, maintenance, repair. ISBN-10: 0856969400 | ISBN-13: 9780856969409 | Haynes 940