Honda CBX550F / CBX400F Service Manual – 1987 (P/N 66MA600)

Honda’s factory shop manual (P/N 66MA600) covers the CBX400F and CBX550F in 21 numbered sections.

PDF Navigation and Languages

Bookmarks and diagram detail: PDF bookmarks open the cover, index, and each numbered section. Text search is unavailable. Small wire codes are easier to read when zoomed in, and some starter-circuit labels are clipped.

The ZIP contains one printable PDF with 492 pages, including the original cover. Illustrated English procedures are accompanied by French, German, and Spanish text. The maintenance schedules and final troubleshooting charts are in German.

Engine, Chassis, and Electrical Service

These are selected workshop procedures. The manual also covers headlight aim and steering-stem bearing race replacement.

• Engine repair: Step-by-step procedures for engine removal and installation, cylinder-head disassembly, valve-guide replacement, valve-seat refacing, piston inspection, and camshaft timing.

• Clutch and transmission: Wet clutch and starter clutch service, crankcase separation, gearbox disassembly, shift-fork inspection, and crankshaft and primary-drive service.

• Carburetors: Bank separation and reassembly, vacuum-piston inspection, float-level and pilot-screw adjustment, and carburetor synchronization.

• Hydraulic brakes: Master-cylinder and caliper rebuilding, fluid bleeding, and inboard front disc removal for the single-disc and dual-disc assemblies.

• Suspension: Front-fork and anti-nose-dive service, plus Pro-Link rear shock seal replacement, linkage inspection, and swingarm bearing replacement.

• Electrical diagnosis: Charging-output and alternator tests, transistorized ignition checks, starter-motor inspection, and switch-continuity testing.

• Scheduled maintenance: Separate schedules for the two models, with procedures for valve-clearance inspection, drive-chain adjustment, and oil and filter changes.

This manual suits mechanics familiar with internal engine measurement and the use of special tools for press-fit components.

Engine Inspection and Lubrication

The DOHC inline-four sections cover rocker arms, valve springs, camshaft journals, and the automatic cam-chain tensioner. The crankshaft chapter pairs Plastigauge clearance checks with color-coded bearing tables. Separate connecting-rod tables let you match replacement bearing inserts to the crankpin and rod codes, while the main-bearing table uses the crankcase and journal codes.

The Engine Lubrication Diagram maps the oil circuit. Related procedures cover oil-pressure testing, inspection of the engine-side and oil-cooler-side pump rotors, and service of the strainer and pressure-relief valve. The CBX550F maintenance schedule also calls out crankcase-breather service.

Fuel Delivery and Carburetor Identification

The fuel-line diaphragm test checks for fuel flow without vacuum and for restricted flow under vacuum. The Carburetors drawings show how the bystarter circuit enriches the mixture for cold starting.

The fuel-system chapter pairs main-jet specifications with the VE50A carburetor on the CBX400F and the market-specific VE52A, VE52B, and VE52C carburetors on the CBX550F. It identifies pilot-screw wrench 07908-4220201 and warns that separating the carburetor bank incorrectly can damage the fuel and air joint pipes and choke linkage.

Inboard Brakes, Wheels, and Suspension

The Inboard Ventilated Disc Brakes cutaways show the enclosed disc and caliper. Separate front-wheel assembly views identify the CBX400F’s single disc and the CBX550F’s dual discs. Wheel-bearing and axle inspections are covered. Damage to a COMSTAR rim, spoke, or hub calls for complete wheel replacement. Tubeless tire mounting and repair are referred to a separate Honda manual.

The Anti-Nose Dive Front Suspension drawings show the control piston, orifices, and check valves. Excessive air pressure can damage components inside the fork tubes. Pro-Link spring and damping charts explain the rear linkage’s rising-rate action. Rear shock service covers hydraulic-press use with oil-seal driver 07965-MA60000 and damper-oil filling.

Charging, Ignition, and Starting

The Battery Charging System and Transistorized Ignition System schematics accompany regulator/rectifier resistance checks and ignition-coil and pulse-generator tests. Starter diagnosis covers brushes, the commutator, field coils, and the relay. Separate fuel-sender resistance and fuel-gauge function tests help distinguish a sender fault from a gauge fault.

The full vehicle wiring diagram and general cable-routing pages are absent from this PDF. The final troubleshooting charts address hard starting, poor power at low and high engine speeds, and handling faults. The service chapters also provide torque tables, fluid capacities, wear limits, and adjustment data.

Consult a qualified motorcycle technician before performing engine, brake, or pressurized-suspension service, and follow the manual’s safety precautions.

Compression and Ignition Test Values at a Glance

The cranking compression check specifies 170 ± 14 psi for the CBX400F and 177 ± 21 psi for the CBX550F with the engine warm and the throttle and choke fully open.

For both models, the ignition chapter specifies a pulse-generator coil resistance of 110 ± 11 Ω at 68°F (20°C).