This is a parts list of everything you should require at a minimum to complete a triple or quadruple bypass on a Honda CX or GL motorcycle (CX500, GL500, CX650, GL650). For more info on the procedure – and this is a work that’s currently in progress – check here.
The David Silver (US) links are broken currently – working on fixing them.
David Silver Spares – USADS (US)
Cam Chain, Tensioner, Guide
Part |
No. |
Part Number |
Where to buy |
Notes |
Cam chain |
1 |
14401-MA1-013
14401-415-003 |
eBay, DS (UK), DS (US), PZ |
All models take the same chain. Do NOT buy used |
Tensioner blade, manual models |
1 |
14500-470-751 |
eBay, DS (UK), DS (US) |
Only required for manual tensioner models. What are the manual/auto differences? The O-ring requires dropping the engine to replace so replace it while the engine is out. |
Tensioner blade, manual models, reproduction alternative |
1 |
14500-470-751P |
DS (UK), DS (US) |
Manual tensioner bolt O-ring |
1 |
91312-415-000 |
eBay, DS (US), DS (UK), PZ |
Guide blade, manual models |
1 |
14620-415-014 |
eBay, DS (UK), DS (US) |
Tensioner blade, auto models |
1 |
14511-MC7-000 |
DS (UK), DS (US) |
Only required for auto tensioner models. What are the manual/auto differences? |
Guide blade, auto models |
1 |
14620-MC7-000 |
DS (UK), DS (US) |
Consumables
Part |
No. |
Part Number |
Where to buy |
Notes |
Oil |
~4L available should suffice for any model |
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Coolant |
~2.5L available should suffice for all models |
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Gaskets
Part |
No. |
Part Number |
Where to buy |
Notes |
Front cover gasket |
1 |
11391-449-306 |
eBay, DS (UK), DS (US), PZ |
Also called the transmission cover gasket. |
Clutch cover gasket |
0-1 |
11372-449-306 |
eBay, DS (UK), DS (US), PZ |
You don’t have to remove this cover if you are removing the front cover |
Rear cover gasket |
1 |
11394-449-306 |
eBay, DS (UK), DS (US), PZ |
Thickness critical – 0.8mm required |
Pulser cover gasket – CDI |
1 |
11432-415-306 |
eBay, DS (UK), DS (US), PZ |
Only required for CDI models |
Pulser cover gasket – TI 500 and all 650 models |
1 |
30373-MC7-306
30373-MC7-000 |
eBay, DS (UK), DS (US), PZ |
Only required for TI engines |
Water pump/impeller gasket |
See “O-rings” section |
Exhaust gasket |
2 |
18291-286-306 |
eBay, AMA , DS (UK), DS (US), PZ |
Goes between the head and the exhaust header |
Exhaust gasket |
2 |
18392-MK4-000 |
eBay, AMA , DS (UK), DS (US), PZ |
Goes between the header and H-box |
Exhaust gasket |
2 |
18392-MG7-750 |
eBay, AMA , DS (UK), DS (US), PZ |
Goes between the H-box and silencers |
O-rings and seals
Part |
No. |
Part Number |
Where to buy |
Notes |
External water pipe O-ring |
1 |
91302-415-003 |
eBay, DS (UK), DS (US), PZ |
For 650 motors |
External water pipe O-ring |
1 |
91301-MB6-003 |
AMA, eBay, DS (UK), DS (US), PZ |
21.9×2.3 – For 500 motors |
Water pump cover O-ring |
1 |
11396-415-000 |
eBay, DS (UK), DS (US), PZ |
127×3, 126×3 or 128×3.5 O-rings fits as well, if the OEM part is unavailable |
Shift shaft seal |
1 |
91251-ZW5-003 |
eBay, AMA , DS (UK), DS (US), PZ |
– |
Rear cover water transfer pipe O-rings |
2 |
94608-50000 |
eBay, AMA , DS (UK), DS (US), PZ |
23×2.8mm |
Inspection cover O-ring |
0-2 |
91302-001-020 |
eBay US, eBay UK, eBay CA, eBay AU, AMA, PZ |
27.5mm O-rings do not fit – part number 91302-001-000 and 91302-001-710 aren’t correct. 30.8mm. One for inspection cover on rear cover, one for front cover. You don’t strictly have to replace them but most of them are well and truly flat by now. |
Camshaft oil seal |
1 |
91202-283-013 |
eBay, AMA , DS (UK), DS (US), PZ |
18x28x6 |
Mechanical Seal |
1 |
19217-611-000 |
eBay, DS (UK), DS (US), PZ |
Early engines will require aperture to be reamed out to fit this larger seal |
Mechanical seal
Cheaper Alternative |
1 |
11H-12438-10-00 |
eBay, PZ |
Yamaha item – like the Honda it’s larger than the older bike seals (NLA) so this requires reaming out the aperture to fit if you have an early engine and fits properly with the later 500s and all 650s. |
Oil pipe O-rings |
2 |
91301-268-020 |
eBay, DS (UK), DS (US), PZ |
Fit under front cover – one above clutch, one on oil pump – DO NOT OMIT – 13.6×2.4 |
Oil orifice O-ring |
1 |
91306-HB3-003 |
PZ |
Don’t omit this either! See here for where it should go. |
Rear cover
Part |
No. |
Part Number |
Where to buy |
Notes |
Dowels |
0-2 |
94301-10160 |
eBay, AMA , DS (UK), DS (US), PZ |
May be necessary if these are damaged/corroded |
Gear shift spring |
0-1 |
24623-415-000 |
eBay |
May be necessary if it gets stretched on rear cover removal |
Stator
Part |
No. |
Part Number |
Where to buy |
Notes |
Stator: G47, CDI |
1 |
31120-415-005 |
eBay, AMA , WM (UK), WM (AU), DS (UK), DS (US) |
Which is which? – double check what you’re getting, particularly on eBay/Amazon/etc. |
Stator: G8, TI |
1 |
31120-MA1-005 |
eBay, AMA , DS (US), DS (UK), WM (AU), WM (UK) |
Starter Clutch (Quadruple Bypass)
Part |
No. |
Part Number |
Where to buy |
Notes |
Starter clutch spring |
3 |
28125-516-030 |
eBay, AMA , PZ, DS (UK), DS (US) |
Strongly recommend ONLY using Honda springs |
Starter clutch Torx bolts |
3 |
90010-KCJ-690 |
PZ |
If you remove them, replace with new. No need to remove unless they are loose or have shifted |
Water Pump/Impeller/Cover
Part |
No. |
Part Number |
Where to buy |
Notes |
Copper crush washer |
1 |
90441-706-000 |
eBay, AMA , PZ, DS (UK), DS (US) |
– |
Impeller cover gasket/O-ring |
See “O-rings” section |
Any corrections, additions or comments are welcome.