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Table Of Contents - Honda CMX450C Rebel Service Manual

Table Of Contents

Table of Contents

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Table of Contents

General Information3

General Safety3

Model Identification4

Specifications5

Standard Torque Values8

Cable & Harness Routing10

Connecting Sequence Of Couplers In The Junction Box12

Emission Control Systems16

Source Of Emissions16

Exhaust Emission Control System16

Crankcase Emission Control System16

Evaporative Emission Control System17

Noise Emission Control System17

Emission Control Information Labels18

Emission Control Information Update Label18

Vacuum Hose Routing Diagram Label18

Service Information21

Lubrication Specifications21

Lubrication Torque Values21

Lubrication Troubleshooting22

Engine Oil Level23

Engine Oil & Filter Change23

Oil Pressure Check24

Control Cable Lubrication25

Lubrication Points25

Maintenance Specifications27

Maintenance Tools28

Maintenance Torque Values28

Maintenance Schedule29

Fuel Strainer31

Throttle Operation31

Carburetor Choke32

Crankcase Breather33

Valve Clearance34

Balancer Chain Tension35

Carburetor Synchronization36

Carburetor Idle Speed36

Cylinder Compression37

Replacement Drive Chain: Did525V Or Rk525Smo-Z138

Brake Shoe/Pad Wear39

Brake Pedal Height40

Brake Light Switch41

Headlight Aim41

Brake Pedal Free Play41

Front Suspension43

Rear Suspension43

Nuts, Bolts, Fasteners44

Steering Head Bearings44

Tire Pressure44

Fuel System Specifications47

Fuel System Tools47

Fuel System Troubleshooting48

Carburetor Removal49

Vacuum Chamber49

Float Chamber Removal50

Float And Jets51

Carburetor Choke Removal52

Float Chamber Assembly52

Accelerator Pump Disassembly53

Accelerator Pump Inspection53

Carburetor Separation54

Accelerator Pump Adjustment54

Air Cut-Off Valve55

Carburetor Cleaning56

Carburetor Assembly56

Carburetor Installation58

Pilot Screw Adjustment58

Idle Drop Procedure58

Limiter Cap Installation59

High Altitude Adjustment59

Fuel Tank Removal/Installation60

Fuel Valve Inspection60

Fuel Strainer Cleaning61

Air Cleaner Case62

Purge Control Valve (Pcv) Inspection63

Engine Removal66

Engine Installation68

Cylinder Head/Valves71

Cylinder Head/Valves Specifications71

Cylinder Head/Valves Torque Values72

Cylinder Head/Valves Tools72

Cylinder Head/Valves Tools Troubleshooting73

Cylinder Head Cover Removal74

Camshaft Removal74

Camshaft Oil Clearance75

Camshaft Inspection76

Cylinder Head Removal77

Camshaft Holder Disassembly78

Cylinder Head Disassembly79

Rocker Arm Inspection79

Rocker Arm Shaft Inspection79

Cam Bearing Surface Inspection79

Valve Guide Replacement81

Valve Seat Inspection And Grinding82

Valve Seat Cutters83

Valve Seat Refacing83

Cylinder Head Assembly84

Cylinder Head Installation85

Camshaft Holder Assembly85

Camshaft Installation87

Cylinder Head Cover Installation90

Cylinder/Piston Specifications93

Cylinder/Piston Tools93

Cylinder/Piston Troubleshooting93

Cylinder Removal94

Piston Removal94

Cylinder Inspection96

Cam Chain Tensioner/Guide Inspection96

Piston Installation97

Piston Ring Installation97

Cylinder Installation98

Clutch/Gearshift Linkage/Oil Pump Exploded View100

Clutch/Gearshift Linkage/Oil Pump Service Information101

Clutch/Gearshift Linkage/Oil Pump Specifications101

Clutch/Gearshift Linkage/Oil Pump Troubleshooting102

Right Crankcase Cover Removal103

Clutch Lifter Removal103

Clutch Disassembly104

Clutch Lifter Installation104

Gearshift Linkage Disassembly109

Gearshift Linkage Assembly110

Primary Drive Gear Removal111

Primary Drive Gear Installation111

Oil Pump Removal112

Oil Pump Inspection113

Oil Pump Assembly114

Oil Pump Installation114

Oil Pressure Relief Valve115

Right Crankcase Cover Installation115

Alternator Overview118

Alternator Service Information119

Left Crankcase Cover Removal120

Flywheel Removal120

Stator/Pulse Generator Replacement121

Flywheel Installation121

Left Crankcase Cover Installation121

Crankcase/Crankshaft/Transmission Overview124

Crankcase/Crankshaft/Transmission125

Crankcase/Crankshaft/Transmission Service Information126

Crankcase/Crankshaft/Transmission Specifications126

Crankcase/Crankshaft/Transmission Troubleshooting127

Crankcase Separation128

Balancer Removal128

Crankshaft/Connecting Rod Removal130

Crankshaft Inspection130

Bearing Inspection131

Connecting Rods131

Main Bearings131

Bearing Selection132

Connecting Rod Bearing Inserts132

Main Bearing133

Starter Clutch Removal134

Starter Clutch Installation134

Connecting Rod Installation135

Starter Idle Gear Removal135

Starter Idle Gear Installation135

Transmission Disassembly136

Shift Fork And Shift Drum Removal138

Shift Fork And Shift Drum Inspection138

Shift Fork And Shift Drum Installation139

Transmission Assembly140

Countershaft141

Balancer Installation142

Crankcase Assembly145

Front Wheel/Suspension/Steering Overview148

Front Wheel/Suspension/Steering Service Information149

Front Wheel/Suspension/Steering Specifications149

Front Wheel/Suspension/Steering Troubleshooting150

Handlebar Removal151

Handlebar Installation153

Front Wheel Removal155

Front Wheel Inspection156

Front Wheel Balance156

Spoke Replacement157

Front Wheel Disassembly160

Front Wheel Assembly161

Front Fork Removal163

Front Wheel Installation163

Front Fork Disassembly164

Front Fork Inspection165

Front Fork Assembly166

Front Fork Installation168

Steering Stem Removal169

Bearing Replacement170

Steering Stem Installation172

Steering Head Bearing Preload173

Rear Wheel/Brake/Suspension Overview174

Rear Wheel/Brake/Suspension Service Information175

Rear Wheel/Brake/Suspension Specifications175

Rear Wheel/Brake/Suspension Troubleshooting176

Rear Wheel Removal177

Rear Wheel Inspection177

Rear Wheel Balance178

Rear Wheel Spoke Replacement178

Rear Wheel Disassembly179

Rear Wheel Assembly181

Rear Wheel Installation182

Rear Brake Removal183

Rear Brake Inspection183

Rear Brake Disassembly183

Rear Brake Assembly184

Shock Absorber Removal185

Shock Absorber Disassembly185

Shock Absorber Inspection185

Shock Absorber Assembly186

Shock Absorber Installation186

Swingarm Removal187

Pivot Bearing Replacement188

Swingarm Installation189

Rear Fender And Seats190

Hydraulic Brake Overview192

Hydraulic Brake Service Information193

Hydraulic Brake Specifications193

Hydraulic Brake Troubleshooting193

Brake Fluid Draining194

Brake Fluid Filling/Bleeding194

Brake Pad Replacement195

Brake Disc Inspection197

Brake Caliper Removal198

Brake Caliper Disassembly198

Brake Caliper Inspection199

Brake Caliper Assembly199

Brake Caliper Installation199

Brake Master Cylinder Removal200

Brake Master Cylinder Disassembly200

Brake Master Cylinder Inspection201

Brake Master Cylinder Assembly201

Brake Master Cylinder Installation202

Battery/Charging System Overview204

Battery/Charging System Service Information205

Battery/Charging System Troubleshooting205

Battery/Charging System Specifications205

Battery Removal206

Testing Specific Gravity206

Battery Charging206

Charging System207

Voltage Leak Test207

Charging Voltage Inspection207

Regulator/Rectifier Inspection208

Regulator/Rectifier Replacement208

Charging Coil209

Ignition System Overview210

Ignition System Service Information211

Ignition System Specifications211

Ignition System Troubleshooting212

Ignition Coil213

Exciter Coil214

Pulse Generator214

Ignition Timing214

Electric Starter Overview216

Electric Starter Service Information217

Electric Starter Troubleshooting217

Electric Starter Specifications217

Starter Motor Removal218

Starter Motor Brush Inspection218

Commutator Inspection219

Case Inspection219

Starter Motor Assembly220

Starter Relay221

Starter Motor Installation221

Clutch Diode222

Lights/Switches/Horn Service Information223

Turn Signal Light224

Bulb Replacement224

Tail/Brake Light Bulb Replacement225

License Light Bulb Replacement225

Indicator Light Bulb Replacement226

Speedometer Light Bulb Replacement226

Oil Pressure Switch228

Neutral/Overdrive Switch228

Rear Brake Light Switch228

Front Brake Light Switch229

Clutch Switch229

Handlebar Switch229

Ignition Switch Inspection230

Ignition Switch Disassembly/Assembly231

Wiring Diagram233

1986-1987 Cmx450C234

Troubleshooting236

Engine Does Not Start Or Is Hard To Start236

Engine Lacks Power237

Poor Performance At Low And Idle Speeds238

Poor Performance At High Speeds239

Poor Handling239

Undercharged/Overcharged Battery240

Wear Or No Spark241

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Table of Contents

Troubleshooting