Author Topic: Engine teardown and inspection  (Read 7839 times)

Offline Trigger

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Re: Engine teardown and inspection
« Reply #105 on: November 28, 2020, 01:45:23 PM »
Is the shaft the same as the 550 ?

Nope, 550 is 374 and the 500 is 323  ;)

Trigger can I ask if I find a good condition second hand one how would I tell the difference between a 500 and 550 as the images in the parts manuals look the same. I know I can't trust the manual so advice appreciated


The 550 (374) has 3 groves in the shaft and the 500 (323) has 2 groves in the shaft. That is the easy way to visually identify them   ;)

Offline cantarauk

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Re: Engine teardown and inspection
« Reply #106 on: November 28, 2020, 05:28:01 PM »
Oddjob if you have on that would be great thank you

Tigger not sure I understand what you mean by grooves. Image below from shaft I removed from 500 (Had to do some dremel work to get the washer and 2/3rd gear out due to the damage) Are we talking the pink or blue in the image or am i way off.


Offline Trigger

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Re: Engine teardown and inspection
« Reply #107 on: November 28, 2020, 06:31:54 PM »
Yes they are the groves but, i think that i maybe  wrong about the groves >>> https://www.cmsnl.com/honda-cb500k2-four-1973-usa_model461/countershaft-trns_23220323000/#.X8KWhOlxepg

I only have 500 gearboxes in the workshop at the moment. I will have to go to the stores to find a 550 so, i can compare  :o

Offline Oddjob

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Re: Engine teardown and inspection
« Reply #108 on: November 28, 2020, 10:51:16 PM »
2nd gear counter shaft is the same as the 550. Only 2 of the gears are not and that's the 1st and 5th gears or as you look at the countershaft the first on and the last on.  The other 3 gears are the same for the 500 and 550. That includes all the circlips and thrust washers. I pretty certain you could at a pinch use the 550 countershaft in the 500 so long as you use all the 500 gears and needle bearing, except of course for your wrecked 2nd gear, use that one off the 550.

I'll have a look for a spare 2nd and countershaft for you on Monday as I'm working all day tomorrow
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Offline cantarauk

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Re: Engine teardown and inspection
« Reply #109 on: December 01, 2020, 06:14:26 PM »
Thanks all for the help, advise and guidance. New 2nd gear and countershaft on its way so be working through all the info above to get this assembled again. Did not want to take the chance with the parts after what I found.

Offline cantarauk

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Re: Engine teardown and inspection
« Reply #110 on: December 09, 2020, 06:51:49 PM »
New (well) parts have arrived so can kick this off again






Offline Oddjob

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Re: Engine teardown and inspection
« Reply #111 on: December 09, 2020, 08:40:54 PM »
If the new shaft is anything like mine from DS the bearing grease has virtually solidified, you can only move the bearing with effort. Wash it in petrol if that's the case with yours. 
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Offline cantarauk

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Re: Engine teardown and inspection
« Reply #112 on: December 09, 2020, 08:51:19 PM »
Just went to go and check and yes exactly the same moving but requires effort. Also some surface rust on the bearing but will clean that up

Offline cantarauk

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Re: Engine teardown and inspection
« Reply #113 on: December 10, 2020, 09:51:52 PM »
Been re-assembling the countershaft and when it comes to the thrust washer and the tab washer is there some special way you get these assembled ? I have put the thrust washer in first so it sits against the new replacement second gear and then the lock washer with the tabs facing the thrust washer. What I have now is a gap between the thrust and lock washer because of the lock washer tabs.

What am i doing wrong ?





« Last Edit: December 10, 2020, 10:31:07 PM by cantarauk »

Offline Bryanj

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Re: Engine teardown and inspection
« Reply #114 on: December 10, 2020, 10:19:12 PM »
Its a long time but i remember the tabs being only ever other groove and the thrust being the same so the tabs went into the thrust

Offline Trigger

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Re: Engine teardown and inspection
« Reply #115 on: December 10, 2020, 11:12:49 PM »
You have it correct but, push the first washer down and place the tab washer on top as, you have in your second picture. Then turn the first washer in the groove on the shaft and the tab washer will key in  ;)

With your first washer and the circlips you, must have these facing the correct way.

Offline cantarauk

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Re: Engine teardown and inspection
« Reply #116 on: December 11, 2020, 08:07:42 AM »
Thank both. Trigger what you said made sense and I checked with out the 2nd gear. Seems the gear I have been sent is the wrong part and is longer which is why the washer was not able to use the grove to rotate so the lock washer can drop in. Compared to the old damaged gear and it is noticeable.

New on the left





« Last Edit: December 11, 2020, 08:11:33 AM by cantarauk »

Offline cantarauk

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Re: Engine teardown and inspection
« Reply #117 on: January 09, 2021, 01:29:06 PM »
With the new parts that arrived and over the Xmas period to escape the insanity of been cooped up I braved the cold in the  garage to get some more work done.

Mainshaft assembly

All parts cleaned and checked 


Before the first gear goes on the shaft there should be a circlip against the bearing. Note - Circlips are Honda specific which are flat one side and rounded/curved the other and shaped as show below.


Forth gear then gets pushed against the bearing flat side first.


Next the thurst washer and circlip to hold the gear in place


2nd and third mainshaft gear


mainshaft top gear


thrust washer


roller bearing and then all painted with some assembly lube


Drop the mainshaft into the top case aligning the middle gear shifter fork to sit between second and third gear. Align pin with the roller bearing and give a spin.
« Last Edit: January 09, 2021, 08:31:19 PM by cantarauk »

Offline cantarauk

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Re: Engine teardown and inspection
« Reply #118 on: January 09, 2021, 01:51:56 PM »
Countrshaft cleaned and checked ready for assembly


replacement countershaft


Tope gear and circlip




Thrust washer and second gear




Thurst washer and lock washer which now fit since another replacement gear received


Third gear thrust washer and circlip





Forth gear


Lower gear with bush inserted with the flange side sitting against the forth gear


Needle bearing to top it off


Drop the countershaft in aligning the outer gear shifter forks to be positioned on forth and top gears

Offline SteveD CB500K0

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Re: Engine teardown and inspection
« Reply #119 on: January 09, 2021, 02:53:36 PM »
The people who designed these (without computers) have my admiration.


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