1979–1982 Honda CB650 Factory Shop Manual (P/N 07703-0010100, 07716-0020202)

This 459-page PDF set pairs the official 233-page Honda Shop Manual for the 1979 U.S.-market CB650 with a 226-page ED/export-market CB650 edition. The pages are dated December 1978. Both books use the same 20-section repair structure, while the export volume adds market-specific information for DK, DM, E, F, G, and U.

• Configuration coverage: Distinguishes the U.S. PD50A carburetor setup from the export PD51A system, plus U.S. emissions equipment, export lighting and switch arrangements, single- and dual-front-disc applications, and the ED-specific final-drive configuration.
• Engine repair: Covers engine removal and installation, cylinder-head and camshaft service, valve-guide replacement and valve-seat refacing, cylinder and piston inspection, crankcase separation, and select-fit crankshaft and connecting-rod bearing work.
• Clutch and transmission work: Details clutch removal and plate inspection, gearshift-linkage service, primary-shaft and starter-clutch disassembly, five-speed transmission teardown, shift-drum and fork inspection, and factory reassembly procedures.
• Fuel and lubrication procedures: Includes carburetor-bank removal and separation, float and accelerator-pump service, pilot-screw and fast-idle adjustment, carburetor synchronization, oil-pressure testing, oil-pump inspection, and oil-strainer service.
• Chassis and brake service: Addresses front and rear wheel bearings, fork overhaul, steering-stem bearings, rear shocks and swingarm, drum-brake components, hydraulic-brake bleeding, and master-cylinder and caliper repair for the covered brake layouts.
• Electrical diagnosis: Provides wiring diagrams, harness-routing views, charging-system tests, transistorized-ignition checks, starter-motor and relay procedures, switch continuity tables, and factory troubleshooting charts for hard starting, loss of power, low- and high-speed running, and poor handling.

Factory Repair Depth

The engine chapters identify which assemblies can be repaired with the engine still in the frame and which jobs require removal and crankcase separation. In-frame work covers the clutch, AC generator, pistons, shift linkage, starter motor, cam-chain tensioner, camshaft, cylinder head, oil pump, carburetors, and cylinder. Internal transmission, primary-shaft, crankshaft, and connecting-rod work is covered after the cases are split.

The cylinder-head section goes through camshaft removal, head disassembly, valve and guide inspection, guide replacement, seat inspection and refacing, and final assembly. The lower-end chapters add primary-chain and tensioner service, starter-clutch inspection, transmission gear and shaft checks, shift-mechanism setup, and color-coded bearing selection for the crankshaft and rods.

U.S. and Export Differences

The U.S. book is specifically identified as the official CB650 '79 shop manual and includes EPA-related service information and the crankcase emission-control system. The companion volume is based on the ED European direct-sales model, with callouts for the DK and DM general-export versions, plus E (U.K.), F (France), G (Germany), and U (Australia). Those distinctions affect carburetor settings, brake procedures, lighting circuits, switch tests, rear-wheel information, and final-drive data.

The two fuel-system chapters are not interchangeable. The U.S. manual identifies PD50A carburetors, while the export book uses PD51A units and its own calibrated adjustment information. The export chassis chapters also separate the DK/DM single-front-disc setup from the dual-disc arrangement used on E, ED, F, G, and U machines.

Diagrams, Tools, and Reference Data

Diagram and circuit titles include the CB650 Wiring Diagram, Cable & Harness Routing, Engine Lubrication System, Battery/Charging System, Transistorized Ignition System, and Electric Starter. Exploded assembly views support the carburetor bank, cylinder head, clutch, crankcase, transmission, wheels, suspension, and brake sections.

Factory tool listings identify Valve Adjusting Wrench 07908-3230000, Oil Pressure Gauge Attachment 07510-4220100, Piston Ring Compressor 07954-3740000, Carburetor Pilot Screw Wrench 07908-4220201, Lock Nut Wrench Socket 07716-0020202, and Ball Race Remover 07953-3330000.

Each repair section carries the related torque tables, fluid and lubrication data, pressure-test specifications, and service limits. The manuals also provide bearing-selection tables, charging curves, ignition test values, and switch-continuity charts.

Scope and Repair Cautions

Both volumes are labeled CB650; they do not contain a separately identified CB650C/Custom section or supplement. Wheel removal, bearing service, rim inspection, and wheel assembly are covered, but the export book refers tubeless-tire repair to Honda's separate Tubeless Tire Manual.

The crankshaft chapter relies on color-coded, select-fit bearing shells and calls for clearance confirmation after replacement. Mixing bearing grades can produce incorrect oil clearance and damage the bearing or journal. The ComStar wheel instructions also warn against disturbing the rivets, nuts, or pins joining the rim, spoke plate, and hub, or attempting to straighten the rim by bending it.

Fuel-system work, battery charging, hydraulic-brake service, and engine removal carry the hazards identified in the manuals. Support the motorcycle and engine securely, isolate the battery, protect painted surfaces from brake fluid, and follow the factory safety notes before beginning repair work.