1978–1979 Honda CX500 Service Manual (P/N 6641500)

• Covers the 1978–1979 Honda CX500 in a 419-page multilingual PDF, with standard/general-type specifications, Canada-type connector views, and Australian- and South African-market references.
• Engine repair coverage runs from removal and installation through cylinder-head and valve-train overhaul, camshaft and cam-chain service, piston inspection, and crankshaft bearing selection.
• Details wet-clutch and oil-pump overhaul, plus five-speed transmission disassembly, gear and shift-fork inspection, and final-shaft damper service.
• Documents VB36A carburetor overhaul and synchronization, along with radiator pressure testing, thermostat checks, and water-pump mechanical-seal replacement.
• Shaft final-drive repair includes ring-gear removal, bearing and seal replacement, backlash adjustment, preload checks, and gear-tooth contact-pattern evaluation.
• Chassis procedures cover front-fork rebuilding, steering-head and swingarm bearings, rear shocks, and brake repair for single- and double-disc front systems and the rear drum.
• Electrical diagnosis covers charging output, regulator/rectifier testing, C.D.I. and pulser checks, and starter-motor faults, supported by component schematics and connector illustrations.

Model Coverage and Multilingual Format

This scan reproduces Honda's CX500 shop manual marked '78–'79; its foreword bases the technical information on the model available in 1978. English service procedures appear alongside French, German, and Spanish material. The opening specifications, general torque table, and several reference pages are in German, so this is not an English-only edition.

The brake chapter provides separate master-cylinder, caliper, and disc inspection specifications for the two front-brake arrangements. Full-motorcycle wiring-diagram sheets are not included in this scan; electrical coverage consists of component circuits and cable-routing views.

Engine and Chassis Documentation

The engine chapters address the liquid-cooled, 496 cc, 80-degree V-twin's pushrod valve train. Head inspection extends to rocker shafts, valve guides, springs, seat refacing, and head flatness. Cylinder heads, clutch, and oil pump can be serviced with the engine in the frame; crankshaft, transmission, and specified rear-cover work require engine removal.

Bottom-end repair goes beyond general teardown illustrations. Color-coded rod and main-bearing selection charts connect identification codes to replacement bearing sizes, with Plastigage checks for connecting-rod bearing clearance. Piston-ring inspection, cylinder wear assessment, and main-journal bearing removal and installation are covered. Tool references include the main-bearing disassembly/assembly tool 07973-4150000 and clutch center holder 07923-4150000.

The Lubrication Diagram traces oil distribution; the oil-pump section covers rotor clearances, the strainer, pressure-relief valve, and drive-chain adjustment. The Cooling System drawing accompanies radiator-cap testing, coolant-temperature sender checks, and coolant replacement and air bleeding.

Working on vintage motorcycles carries inherent physical risks, particularly during engine lifting and brake work. Always verify shop procedures and wear appropriate protective equipment before starting any teardown.

Carburetors, Final Drive, and Running Gear

Fuel-system coverage includes vacuum-piston inspection, float-valve and float-level checks, air-cutoff diaphragm service, and idle and fast-idle adjustment. The carburetor cautions explain how cleaning jets with wire or drills can enlarge their calibrated openings.

Final-drive setup includes ring-gear shim selection and separate pinion and assembled-unit preload checks. The Gear Tooth Contact Pattern Check illustrations distinguish normal contact from patterns requiring correction; preload inspection tool 07998-4150000 is identified. Propeller-shaft spline and universal-joint inspection are covered separately from the rear hub.

Comstar wheel coverage includes runout checks, wheel-bearing replacement, and rear drive-flange service. The rim/spoke-plate assemblies themselves are treated as non-repairable. Suspension coverage includes fork seals, spring checks, and steering-bearing race replacement. Brake sections extend to master-cylinder and caliper overhaul, fluid replacement, bleeding, and rear shoe and drum inspection.

Electrical Tests and Technical Specification Preview

The C.D.I. Unit circuit and pulser-waveform charts explain capacitive discharge ignition and electronic advance. Ignition timing is checked, not adjusted. The terminal test table specifies the SANWA tester 07308-0020000 or KOWA TH-5H; incorrect tester selection or range can produce misleading readings. Regulator/rectifier cautions also identify damage from high-voltage insulation testing.

The Starter Motor circuit shows the magnetic switch, diode, neutral switch, and clutch-switch connections. Brush, commutator, armature, and field-coil inspections support fault isolation beyond battery checks.

Reference data includes maintenance schedules, component torque tables, fluid capacities, compression specifications, tire pressures, standard dimensions, service limits, and electrical test values.