Topic: Questions about reassembling a CB500 - manual isn't much help

[Tugboat]

I’ve recently been working at Southern Cycles here in Nashville restoring a 1971 CB500/4. The entire thing was disassembled when I started, as the guy who was working on it quit and left all of this in a pile. I just finished putting the motor back together and am finally ready to start reassembling the bike. Problem is: I didn’t take it apart and don’t have any pictures of how components were originally installed – and to make matters worse, most of the parts are just in boxes.. not even bagged & tagged. Also some of the parts are missing, which of course I don’t discover until I start putting those assemblies back together. Some of the assemblies are already put together though, so all I need to do for those is figure out what the mounting hardware is.

I’ve printed out the entire parts diagram, but as you know it’s broken down by component and none of it really shows how the whole thing goes together. Plus the exploded views are sometimes pretty confusing. Do the Clymer or Haynes manuals contain that kind of thing – and/or a better “walkthrough” for reassembly? The manual provides a decent overview, but lacks detail.

[brooze72]

I've got a 72, rebuilt last year & have some pics of the process, let me know what areas got you knarly & I'll see what I can send OR post a pic of the parts & the guys here on SOHC4 will absolutely know how it goes back together.

[Bankerdanny]

Have you downloaded the factory manual that you will find here: http://forums.sohc4.net/index.php?topic=17788.0

[Tugboat]

I do have the factory manual. What I'm looking for is more of an "OK, so you have a pile of parts. This is how you put it all together in this order..." kind of thing. Really what I need are a bunch of pictures of how it looked already assembled. But I figured maybe the Clymer book has that kind of thing? Didn't want to spend the $30 to find out so thought I'd ask here.

[Bankerdanny]

I don't think you are going to get that. They are repair manuals, not assembly instructions.

It would seem to me that the engine is the hardest part. If you have that together, the rest shouldn't be that hard. Think of it as a jigsaw puzzle that needs to be assembled in stages. First you sort the pieces looking for the edges then work in.

You need to sort out the rest of the parts. Identify all the easy stuff first and group them together. Then spread out the unidentified parts and pick a section i.e. fork, swingarm etc and use the diagrams to find the missing pieces of those assemblies. If you are systematic you should be able to ID most of what you have.

If you are left with pieces post pictures and ask for help with identification.

[CycleRanger]

The closest thing to an "assembly" manual you will find is the Honda Parts List and the Honda Shop Manual.
The Haynes/Clymer/Chilton manuals are useless for what you are looking for.
There are no step-by-step instructions for assembling a Honda CB. 

[Tugboat]

That's what I was wondering. Thanks guys - you just saved me $30!

More questions to come.

[CycleRanger]

I have Ford factory assembly manuals for my '67 Mustang.  They are authorized reproductions.
Very cool, illustrated step-by-step instructions details exactly what nut, bolt, and fastener is used where.

Certainly the same thing for Honda motorcycles exist but Honda has never seen fit to release or license them.
Even if they did they'd have to be translated.

[SohRon]

This is similar to the problem I had when I first found this site. How do you put one of these things back together? This thread  http://forums.sohc4.net/index.php?topic=86697.0 will get you started (it's for a CB550, but the bikes are pretty much the same), and I will be posting more soon.