Honda CMX450C Rebel User Manual

Provides essential safety precautions and warnings for operating the motorcycle.

Outlines the rules and guidelines for performing maintenance and service on the motorcycle.

Details how to identify the motorcycle's model using VIN and frame serial numbers.

Lists key technical specifications for the motorcycle, including dimensions and engine details.

Provides specific torque values for various fasteners and components for correct assembly.

Provides general information and specifications related to the lubrication system of the motorcycle.

Lists oil capacity, oil recommendation, and oil pressure specifications for the engine.

Specifies torque values for oil drain bolt, filter bolt, and oil pressure switch.

Lists specialized tools required for lubrication-related service tasks, such as oil pressure gauges.

Provides an overview of maintenance procedures, including engine oil and filter checks.

Lists specifications for spark plugs, valve clearance, and carburetor synchronization.

Details maintenance specifications for frame components like drive chain slack, brake pedal, and tire depth.

Lists specialized and common tools required for various maintenance tasks.

Provides torque values for fuel cup, balancer stopper, rear axle nut, and valve adjuster.

Outlines the recommended maintenance schedule based on mileage intervals for various motorcycle components.

Provides general information on fuel system servicing, including hose connections and safety precautions.

Lists specifications for carburetor venturi diameter, float level, idle speed, and jet sizes.

Lists special and common tools for fuel system maintenance, such as pressure gauges.

Offers probable causes and solutions for common fuel system issues like engine not starting or poor performance.

Step-by-step instructions for removing the carburetor, including disconnecting fuel and air lines.

Details the procedure for removing and inspecting the vacuum chamber, spring, and piston.

Instructions for removing the float chamber and its components.

Explains how to measure and adjust the float level in the carburetor for correct fuel delivery.

Guidance on removing and inspecting the float, float valve, and jets for wear or damage.

Instructions for assembling the float chamber components, including O-rings and fuel joint tubes.

Details the removal and assembly of the carburetor choke mechanism.

Explains how to inspect the choke valve for wear or weakness and install it correctly.

Provides steps for the disassembly, inspection, and adjustment of the accelerator pump.

Details the adjustment procedure for the accelerator pump rod and stopper arm.

Instructions for separating the carburetors by removing the choke rod, arms, and fuel joint tubes.

Describes removing the front and rear stays that connect the carburetors.

Provides instructions for removing and inspecting the air cut-off valve and its diaphragm.

Steps for cleaning carburetor jets, valves, and body using compressed air.

Instructions for assembling the carburetors, including fuel joint tubes and O-rings.

Details installing the choke arms, rod, and spring, and adjusting throttle stop screws.

Step-by-step guide for installing carburetors, including routing fuel and vacuum lines.

Explains the idle drop procedure for pilot screw adjustment in U.S.A. models.

Provides detailed steps and cautions for adjusting pilot screws and idle speed.

Instructions for installing the limiter cap on the carburetor for proper fuel mixture control.

Details high altitude adjustments for carburetors, advising on idle speed and emissions.

Covers fuel tank removal, installation, and inspection for leaks or damage.

Instructions for inspecting the fuel valve and vacuum pump for proper function and leaks.

Steps for draining the fuel tank and cleaning the fuel strainer and O-ring.

Instructions for removing and installing the air cleaner case and its related components.

Checks for the evaporative emission control system components, including the purge control valve and charcoal canister.

Details the inspection and testing procedure for the purge control valve (PCV).

Explains how to connect a vacuum pump to test the PCV and charcoal canister.

Illustrates engine mounting bolts and torque values for removal and installation.

Details the steps for removing the engine, including draining oil, disconnecting lines, and removing components.

Covers disconnecting electrical connectors, breather hoses, and securing the engine with a jack.

Provides instructions for installing the engine, aligning mounting points, and tightening bolts.

Provides overview and specifications for cylinder head and valve servicing, including component identification.

Lists specifications for camshaft, rocker arm, and valve guides, including service limits.

Details specifications for cylinder head, valve guides, and valve seats, including service limits.

Lists torque values for cylinder head cover, cam sprocket, and mounting bolts.

Lists specialized and common tools for valve guide and spring servicing.

Covers troubleshooting for low compression, excessive noise, and other cylinder head related issues.

Step-by-step instructions for removing the cylinder head cover, including disconnecting hoses and CDI unit.

Instructions for removing the camshaft, including the guide plate, oil pipe, and tensioner holder.

Explains how to measure camshaft oil clearance using plastigauge.

Details removing the camshaft holder dowel pins and securing the wedge.

Guidance on inspecting camshaft runout using a dial indicator.

Steps for removing the engine mounting brackets and the cylinder head.

Instructions for removing the oil pipe and cylinder head.

Procedure for disassembling the camshaft holder, including removing stopper pins and rocker arms.

Guidance on inspecting rocker arms and shafts for wear or damage.

How to inspect cam bearing surfaces for damage and ensure oil passages are clear.

Steps for disassembling the cylinder head, including removing valve springs and cotters.

Instructions for inspecting valve spring length, checking for carbon deposits, and cleaning gasket surfaces.

Guidance on inspecting spark plug holes, valve areas for cracks, and cylinder head warpage.

Explains how to measure valve stem O.D. and check for bending or burning.

Detailed procedure for replacing valve guides, including heating the cylinder head and using specialized tools.

Instructions for removing and installing new valve guides using appropriate tools.

Covers cleaning valves, inspecting seats, and grinding valve seats for proper sealing.

Illustrates different valve seat cutters and their angles used for refacing valve seats.

Explains the process of refacing valve seats using 45, 32, and 60-degree cutters.

Details applying Prussian Blue to check valve seat contact and refacing seats for proper sealing.

Instructions for assembling the cylinder head, including installing valve springs, seals, and retainers.

Details installing valve cotters, checking for spring loss, and installing rocker arms.

Provides steps for cleaning gasket surfaces, installing dowel pins, gasket, and the cylinder head.

Instructions for installing camshaft holders, mounting brackets, and exhaust pipes/mufflers.

Guidance on lubricating camshaft bearings and installing the camshaft and cam sprocket with timing marks.

Details turning the crankshaft, aligning timing marks, and installing the cam chain and sprocket bolts.

Instructions for installing camshaft holders, tensioner, exhaust pipes, and carburetors.

Explains aligning timing marks on the crankshaft and camshaft, and installing dowel pins.

Details installing camshaft holders, cylinder head bolts, oil pipe, and sealing washers.

Instructions for installing the cylinder head cover, including gasket preparation and tightening cover bolts.

Lists specifications for cylinder, piston, rings, and connecting rod dimensions and service limits.

Details specifications for piston ring end gap, piston pin bore, and connecting rod I.D.

Lists specialized tools for piston and ring work, such as piston base and ring compressors.

Addresses common cylinder and piston issues like low compression, excessive smoke, and knocking.

Instructions for removing the cylinder head and cleaning gasket surfaces.

Guidance on inspecting cylinders for warpage.

Steps for removing piston clips and pressing out the piston pin.

Instructions for inspecting piston rings for wear and checking piston ring-to-ring groove clearance.

Details measuring piston pin I.D. and O.D., and piston-to-piston bore clearance.

Guidance on measuring cylinder bore for scratches, wear, and checking for taper and out-of-round.

Instructions for measuring cylinder taper and out-of-round, and checking cam chain tensioner.

Steps for cleaning piston grooves and installing piston rings with proper gap alignment.

Instructions for positioning the piston with the 'IN' mark towards the intake valve and installing piston pin clips.

Details cleaning gasket surfaces and installing dowel pins and cylinder base gasket.

Instructions for coating cylinder bores and piston rings with oil, and installing pistons.

Overview of servicing procedures for clutch, gearshift linkage, and oil pump components.

Lists specifications for clutch, oil pump, and relief valve, including service limits.

Provides torque values for clutch lock nut, primary drive gear bolt, and brake pedal bolt.

Lists common and special tools for clutch and gearshift maintenance.

Addresses common issues with clutch operation, gear shifting, and transmission.

Instructions for removing the right crankcase cover, including disconnecting brake pedal and clutch cable.

Details removing the clutch lifter piece, spring, and shaft from the right crankcase cover.

Instructions for installing the clutch lifter shaft, spring, and piece.

Steps for clutch disassembly, including removing bolts, plates, and springs.

Instructions for removing the lock nut, clutch center, discs, and pressure plate.

Details removing the thrust washer, clutch outer, and guide.

Guidance on inspecting the clutch center and plate B for clearance and wear.

Instructions for measuring clutch spring free length, disc thickness, and plate warpage.

Steps for assembling the clutch, including installing springs, discs, and plates.

Instructions for installing the collar, clutch outer guide, and clutch discs/plates.

Details installing the lock washer, lock nut, and clutch center holder.

Instructions for disassembling the gearshift linkage, including the pedal, arm, and spindle.

Details removing the shift drum cam plate, stopper bolt, and installing components.

Instructions for removing and installing the primary drive gear, including using a gear holder.

Details installing the thrust washer, primary drive gear, and spacer.

Instructions for removing the oil pump driven sprocket and oil pump.

Provides steps for removing the oil pump cover and inspecting pump body clearance and tip clearance.

Instructions for assembling the oil pump, including pump body, rotors, and drive pins.

Details installing the oil pump, driven sprocket, and drive chain.

Instructions for removing and disassembling the oil pressure relief valve.

Steps for cleaning mating surfaces and installing the right crankcase cover with gasket.

Overview of alternator and pulse generator servicing, including required torque values.

Lists torque values for flywheel bolt and gearshift pedal arm bolt.

Lists common tools such as a universal holder and rotor puller.

Instructions for removing the gearshift pedal and left crankcase cover.

Details removing the flywheel using a universal holder and rotor puller.

Instructions for disconnecting the stator and pulse generator and replacing them.

Steps for installing the flywheel, including the Woodruff key and aligning timing marks.

Instructions for installing the gasket and left crankcase cover.

Details installing the footpeg and tightening mounting bolts, and checking ignition timing.

Overview of crankcase, crankshaft, and transmission servicing, referencing other sections for specific tasks.

Lists specifications for balancer, crankshaft, and transmission components, including service limits.

Details specifications for shift drum, case I.D., shift fork, and fork I.D.

Lists torque values for crankcase bolts, connecting rod nuts, and starter clutch bolts.

Lists common tools for internal engine work, such as torque drivers and attachments.

Addresses common issues with crankcase, transmission, and bearings, such as excessive noise or hard shifting.

Instructions for separating the crankcase, including bolt removal and pattern.

Details removing the oil strainer and crankshaft bearing holder.

Instructions for removing bearing bolts, front chain guide, and the rear balancer shaft.

Guidance on measuring balancer I.D. and O.D. for wear or damage.

Instructions for checking connecting rod side clearance and removing bearing caps and rods.

Guidance on inspecting crankshaft runout using a dial gauge.

Instructions for inspecting bearing inserts for damage and using plastigauge for clearance checks.

Details checking main bearing journals for damage and measuring compressed plastigauge.

Guidance on selecting replacement bearings based on I.D. and O.D. code numbers.

Instructions for removing the starter clutch and idle gear.

Details removing rollers, plungers, and springs from the starter clutch.

Steps for installing springs, plungers, and rollers into the starter clutch.

Instructions for removing the starter idle gear and stopper bolt.

Details installing the O-ring, idle gear, and shaft.

Instructions for installing connecting rod bearings and caps, ensuring correct orientation.

Steps for disassembling the transmission, including checking gear backlash and removing components.

Details inspecting gears for freedom of movement and checking gear dog clearance.

Guidance on inspecting gear I.D., O.D., and bushing dimensions.

Instructions for measuring mainshaft and countershaft O.D. and bushing clearance.

Details replacing the mainshaft bearing using a bearing puller and driver.

Instructions for removing the bearing set plate, shift shafts, and shift forks.

Details inspecting shift drum end for scoring and measuring gear shift drum O.D.

Instructions for checking shift fork guide pins and measuring shift fork I.D. and claw thickness.

Steps for installing shift forks, shafts, and the neutral/overdrive switch.

Instructions for assembling the mainshaft, including gears, washers, and splined collars.

Details assembling the countershaft, gears, bushings, and stopper washers.

Instructions for installing the mainshaft and countershaft assemblies, aligning shift forks and grooves.

Steps for installing the balancer chain and balancer shaft.

Instructions for aligning timing marks and installing the crankshaft index.

Details installing the rear balancer shaft, chain guide, and ensuring proper alignment.

Instructions for installing the stopper plate, nuts, and checking crankshaft timing marks.

Steps for cleaning crankcase mating surfaces and installing dowel pins and a new O-ring.

Instructions for assembling the crankcase, including positioning the lower case and tightening bolts to specified torques.

Overview of front wheel, suspension, and steering servicing, including safety precautions.

Lists specifications for axle runout, fork dimensions, and steering head bearing preload.

Provides torque values for front brake, axle, fork, and steering components.

Lists specialized tools for steering and bearing maintenance.

Addresses common steering and suspension issues like hard steering, wheel wobble, and fork problems.

Instructions for removing handlebar components like wire bands, turn signals, and switches.

Details disconnecting clutch switch wires and removing left handlebar switches and choke lever.

Instructions for removing handlebar weights and brake components.

Steps for installing handlebar components like grips, throttle cables, and switches.

Details installing handlebar weights, brake master cylinder, and switches.

Instructions for installing turn signals, wire bands, and aligning components.

Instructions for removing the front wheel, including disconnecting the speedometer cable.

Details raising the front wheel and removing the axle and spacers.

Guidance on inspecting the axle for runout and the wheel rim for runout.

Instructions for checking wheel bearings for smooth rotation and proper fit.

Explains the importance of wheel balance and how to check it.

Details the procedure for balancing the wheel by adding weights to the rim.

Instructions for replacing spokes, nipples, and tightening them to the correct torque.

Details replacing inner and outer spokes and nipples on the front wheel.

Instructions for installing spokes and nipples into the rim and hub for wheel truing.

Instructions for removing dust seals and the speedometer gear retainer from the front wheel hub.

Details removing the front brake disc and bearings from the wheel hub.

Instructions for greasing brake discs, installing bearings, and dust seals.

Details installing the speedometer gear box, drive gear, and plain washer.

Instructions for installing the front wheel, aligning the axle, and tightening nuts.

Details removing the front fender, brake caliper, and fork components.

Instructions for loosening fork tube caps and pinch bolts.

Details removing the fork tube cap, spacer, spring, and slider.

Instructions for removing dust seal, set ring, oil lock piece, and fork tube bushing.

Guidance on measuring fork spring free length and inspecting fork tube, slider, and piston.

Steps for assembling the fork, including installing seals, springs, and sliders.

Instructions for installing fork slider, fork tube cap, and tightening pinch bolts.

Details installing the front fork, aligning the top end, and tightening pinch bolts.

Instructions for removing handlebar, front fork bridge, and steering stem nut.

Details removing the lock washer, lock nut, and steering stem socket.

Instructions for removing dust seal, upper and lower bearings, and grease retainer.

Instructions for replacing steering head bearings and races.

Details pressing in new bearings and seals for the steering stem.

Steps for installing the steering stem, tightening the adjustment nut, and seating the bearings.

Explains how to adjust and set the steering head bearing preload.

Overview of rear wheel, brake, and suspension servicing, including specifications and torque values.

Lists specifications for axle runout, brake drum, and brake shoe lining thickness.

Provides torque values for various rear wheel, brake, and suspension fasteners.

Lists specialized tools for rear wheel and suspension maintenance, such as bearing drivers.

Addresses common issues with oscillation, soft suspension, hard suspension, and suspension noise.

Instructions for removing the rear wheel, including chain adjustment and brake panel.

Guidance on inspecting the rear axle for runout and the wheel rim for runout.

Instructions for checking the final driven sprocket teeth and replacing worn sprockets.

Explains how to check and maintain wheel balance.

Instructions for replacing spokes and nipples on the rear wheel.

Details spoke replacement for the rear wheel, including tightening spoke nipples.

Instructions for removing the final driven sprocket and flange.

Details removing damper rubber, O-ring, and bearings from the final driven flange.

Instructions for assembling the final driven flange, bearings, and retainer.

Details installing the brake panel, rear wheel, and tightening the chain adjuster and axle nut.

Instructions for removing the rear wheel and brake panel.

Guidance on measuring rear brake drum I.D. and brake lining thickness.

Instructions for assembling the brake cam and brake panel.

Details installing brake shoes, springs, and the brake panel.

Instructions for removing and disassembling the rear shock absorber.

Guidance on inspecting the shock absorber rod, seals, and spring.

Instructions for assembling the rear shock absorber, including spring, seat, and damper.

Details installing the rear shock absorber and tightening mounting bolts.

Instructions for removing the rear wheel, shock absorbers, and swingarm.

Details removing pivot collars and the chain slider/torque link.

Instructions for removing and replacing swingarm pivot bearings.

Details pressing in new needle bearings and grease retainers for the swingarm pivots.

Instructions for installing the swingarm, pivot bolts, and chain slider.

Instructions for removing the rear fender and seat.

Details removing shock absorber mounts, turn signals, and rear fender bolts.

Overview of hydraulic brake system servicing, including safety precautions and specifications.

Lists specifications for brake disc, caliper, and master cylinder dimensions and service limits.

Provides torque values for brake bleed valve, caliper bolts, and mounting bolts.

Addresses common hydraulic brake issues like lever feel, fluid leaks, and brake grabs.

Detailed instructions for draining, filling, and bleeding the hydraulic brake system.

Explains the procedure for bleeding brake lines and master cylinder reservoir refill.

Instructions for removing and installing brake pads, including caliper removal and pin replacement.

Details installing new pads, caliper pistons, and retainer pins.

Instructions for removing the front wheel and brake disc for inspection.

Guidance on measuring brake disc thickness and replacing it if worn.

Instructions for removing and disassembling the brake caliper, including pads and springs.

Details inspecting caliper pistons and bores for scoring or damage.

Instructions for assembling the brake caliper, including pistons, seals, and pads.

Details installing the brake caliper and tightening mounting bolts.

Instructions for removing and disassembling the brake master cylinder.

Guidance on inspecting master cylinder cups and piston for wear or damage.

Instructions for assembling the master cylinder, including piston, cups, and spring.

Details installing the master cylinder, tightening bolts, and connecting brake switch wires.

Overview of battery and charging system servicing, including safety precautions and specifications.

Lists battery capacity, specific gravity, charging rate, and regulator/rectifier specifications.

Lists tools required for battery and charging system testing, such as circuit testers.

Addresses common battery and charging system issues like no power, low battery voltage, and charging system failure.

Instructions for removing battery cover, disconnecting cables, and checking electrolyte level.

Explains how to test battery specific gravity using a hydrometer and interpret results.

Instructions for charging the battery and checking charging rate.

Details voltage leak test for the charging system.

Explains charging voltage inspection using a voltmeter.

Instructions for inspecting the regulator/rectifier connections and components.

Details removing the battery tray and regulator/rectifier for replacement.

Instructions for checking continuity of the charging coil terminals.

Overview of ignition system servicing, including CDI unit and ignition coil checks.

Lists specifications for spark plug gap, ignition coil resistance, and exciter coil resistance.

Addresses common ignition system issues like engine not starting, no spark, or poor performance.

Instructions for removing the fuel tank and disconnecting the CDI unit.

Details removing the ignition coil and measuring primary and secondary coil resistance.

Instructions for removing the alternator wire connector and measuring exciter coil resistance.

Details disconnecting the pulse generator coupler and measuring wire resistance.

Explains how to check ignition timing using a timing light.

Overview of electric starter servicing, including specifications and troubleshooting.

Lists specifications for starter motor brush length and spring tension.

Addresses common electric starter issues like motor not rotating or turning slowly.

Instructions for removing the starter motor, mounting bolts, and protector cover.

Details inspecting starter motor brushes and measuring brush length and spring tension.

Guidance on inspecting the commutator for discoloration and checking continuity.

Instructions for assembling the starter motor, including carbon brushes and brush holder.

Details installing the starter motor, mounting bolts, and protector cover.

Instructions for checking the starter relay operation by listening for a click.

Explains checking continuity of the starter relay terminals using an ohmmeter.

Instructions for removing the clutch diode and checking its continuity.

Overview of lighting, switches, and horn servicing, including wire color codes.

Instructions for replacing headlight bulbs and checking couplers.

Details replacing turn signal light bulbs and lenses.

Instructions for replacing tail/brake light bulbs and lenses.

Details replacing the license light bulb and case/lens.

Instructions for replacing indicator light bulbs and speedometer light bulbs.

Details removing and installing instrument panel components, including meter lower cover.

Instructions for assembling and installing instrument panel components.

Instructions for checking the oil pressure switch continuity.

Details checking continuity of the neutral/overdrive switch wires.

Instructions for checking the rear brake light switch operation.

Details checking continuity of the front brake light switch.

Instructions for checking continuity of the clutch switch.

Instructions for removing and disassembling handlebar switches.

Details removing and disassembling the ignition switch.

Instructions for disconnecting the horn connectors and checking operation.

Provides a comprehensive wiring diagram for the 1986-1987 Honda CMX450C motorcycle.

Illustrates the electrical system layout, component connections, and wire color coding.

Shows the electrical system with a diagram key for understanding connections and grounds.

Guides users through diagnosing and resolving engine starting issues.

Helps identify causes for lack of engine power, including fuel, ignition, and carburetor issues.

Provides solutions for poor engine performance at low and idle speeds.

Guides users in diagnosing and resolving poor performance issues at high speeds.

Addresses causes of poor handling, such as steering issues or wheel wobble.

Helps diagnose and fix issues related to weak or no spark from the ignition system.

Troubleshooting steps for engine starting problems, including fuel, spark, and compression checks.

Troubleshooting guide for engine power loss, covering wheel drag, tire pressure, and clutch slipping.

Diagnosing poor idle and low-speed performance, checking ignition timing and carburetor adjustments.

Troubleshooting high-speed performance issues, including valve clearance and fuel flow.

Diagnosing poor handling, focusing on steering bearings and wheel alignment.

Troubleshooting steps for weak or no spark, checking spark plugs, coils, and CDI unit.

Guides users on testing and diagnosing battery charge issues.

Troubleshooting steps for ignition system problems when there is weak or no spark.