1987 Honda CBX550F / CBX400F Service Manual (P/N 66MA6000000)

• A 492-page PDF of Honda Motor Co., Ltd.’s factory shop manual for the CBX400F and CBX550F, organized into 21 numbered sections. This is a mixed-language scan with omissions noted below.
• Engine repair coverage extends from removal and installation to cylinder-head disassembly, valve-guide replacement, valve-seat refacing, piston inspection, and camshaft timing.
• Drivetrain procedures cover the wet clutch, starter clutch, six-speed constant-mesh transmission, shift forks, crankcase separation, and crankshaft/primary-drive assemblies.
• Carburetor work includes bank separation and assembly, vacuum-piston inspection, float-level and pilot-screw adjustment, and synchronization.
• Hydraulic-brake repair covers master-cylinder and caliper rebuilding, fluid bleeding, and model-specific inboard-disc removal.
• Front-fork and anti-nose-dive service is paired with Pro-Link rear-suspension work, including shock-seal replacement, linkage inspection, and swingarm-bearing replacement.
• Electrical diagnosis addresses charging output, alternator and regulator/rectifier testing, transistorized ignition, starter-motor inspection, and switch-continuity checks.

Model Coverage and Scan Format

The model-code table identifies CBX400F: F (France) and ED (Europe). For the CBX550F, it lists E (Great Britain), G1 (Germany, unrestricted), G2 (Germany, restricted), B (Belgium), ED (Europe), U (Australia), and SA (South Africa). These codes do not apply interchangeably to both models.

Illustrated English procedure pages alternate with French, German, and Spanish text pages. The maintenance schedules and final troubleshooting charts are in German. This is not a complete English-language edition. Omissions include printed general-information pages 1-4 and 1-9 through 1-11, including the full wiring diagram and general cable-routing pages. Electrical subsystem schematics remain within the repair chapters.

Technical Coverage and Maintenance Data

The engine sections address the DOHC inline-four’s rocker arms, valve springs, camshaft journals, and automatic cam-chain tensioner. Bottom-end inspection includes Plastigauge checks and color-coded bearing-selection charts, with separate connecting-rod bearing tables for the two models. These charts relate bearing selection to the crankshaft, connecting-rod, and crankcase identification codes.

Lubrication coverage goes beyond oil changes. The Engine Lubrication Diagram supports oil-pressure testing and inspection of the pump’s engine-side and oil-cooler-side rotors, strainer, and relief valve. Separate factory maintenance schedules distinguish the two models, including crankcase-breather service on the 550.

Fuel-system diagnosis includes the vacuum-operated fuel-line diaphragm test. The Carburetors technical-feature drawings explain the bystarter circuit and fuel passages. Carburetor service notes flag a specific repair hazard: incorrect bank separation can damage the fuel/air joint pipes and choke linkage.

Inboard Brakes, Wheels, and Suspension

Separate front-wheel assembly views distinguish the CBX400F’s single front disc from the CBX550F’s dual front discs. The Inboard Ventilated Disc Brakes cutaway views explain the enclosed disc-and-caliper arrangement. Wheel-bearing and axle inspections are covered, but damaged COMSTAR rims, spokes, or hubs call for complete wheel replacement rather than structural repair.

The Anti-Nose Dive Front Suspension illustrations show the control piston, orifices, and check-valve circuits. Pro-Link spring and damping charts explain the rear linkage’s rising-rate action. The shock section extends to hydraulic-press-assisted seal replacement and damper-oil filling, not just removal of the complete unit. Fork-service cautions identify internal component damage caused by excessive air-charging pressure.

Tubeless-tire mounting and repair are referred to a separate Honda Tubeless Tire Manual, which is not included in this PDF.

Factory Specifications and Electrical References

Torque tables, fluid capacities, compression and oil-pressure specifications, wear limits, adjustment data, and electrical test values accompany the relevant assemblies. The tool listings identify the carburetor pilot-screw wrench 07908-4220201 and shock-absorber oil-seal driver 07965-MA60000.

The Transistorized Ignition System schematic supports pulse-generator and ignition-coil testing. Charging-system references include regulator/rectifier resistance checks; starter diagnosis extends to brushes, commutator, field coils, and the relay. Fuel-sender resistance checks and fuel-gauge function tests are also covered. Final troubleshooting charts address hard starting, poor power, low- and high-speed running faults, and handling problems.

This document is a technical reference for workshop use. Consult a qualified motorcycle technician before performing engine, brake, or pressurized-suspension service, and follow the manual’s safety precautions.