The Honda CB450K5 Owners Manual (1972)



Table of Contents

 Vehicle Stopping Distance

Acceleration & Passing Ability

 WIRING DIAGRAMS

 Serial Number Location

  Specifications

 General

US

 OPERATING INSTRUCTIONS

 Instruments and Indicator Lights

 Controls Locations

 Main Switch

 Emergency Switch

Starter Button

 Headlight Control Switch

 Turn Signal Control Switch

Horn Button

  Stoplight Switches

Steering Lock 

 Seat Lock

 Helmet Holder

 Document Box

Rear Shock Absorber

 Gear Change Pedal

Choke Lever

 FUEL and OIL

 Fuel Valve

 Fuel Tank

 Engine Oil Recommendation

 Viscosity

STARTING THE ENGINE

Cold Engine Starting Procedure

Starting in Extreme Cold Weather 

Warm Engine Starting Procedure 

RIDING THE MOTORCYCLE

 PRE-RIDING INSPECTION 

 BREAK-IN PROCEDURE

RIDING THE MOTORCYCLE

PARKING

     MAINTENANCE

 MAINTENANCE SCHEDULE

 Engine Oil Replenishment and Change

 Oil Filter Maintenance

 Spark Plugs Replacement and Adjustment

 Contact Breaker Point Gap and Ignition Timing Adjustment

 Valve Tappet Adjustment

 Cam Chain Adjustment

 Air Cleaner Maintenance

 Throttle Cable

 Carburetor Adjustment

 Fuel Strainer Maintenance

 Clutch Adjustment

 Drive Chain Maintenance

 Brakes Maintenance

 Suspensions

 Battery Maintenance

 Wheel Balance

  Wheel Removal

 Lights

 TOOL KIT

TIRE RECOMMENDATION 



Acceleration and Passing Ability

This figure indicates passing times and distances that can be met or exceeded by the vehicles to which it applies, in the situations diagrammed on the next page. The low-speed pass assumes an initial speed of 20 MPH and a limiting Speed of 35MPH. The high-speed pass assumes an initial speed of 50MPH and a limiting speed of 80 MPH.

NOTICE: The information presented represents results obtainable by skilled drivers under controlled road and vehicle conditions, and the information may not be correct under other conditions.

 

Summary Table

Riding condition

Passing Distance (feet)

Passing Time (sec.)

Low-speed pass

344

7.1

High-speed pass

1,000

10.2

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Air Cleaner Maintenance

Air cleaner element cleaning and/or replacement depends on the motorcycle operating conditions. Your HONDA dealer can help you to determine the frequency of cleaning or replacing the element.

  1. Remove air cleaner case.
  2. Unscrew air cleaner cover setting bolt (1) and then remove the air cleaner cover (2).
  3. Unscrew the air cleaner setting bolt (3) loosen the air cleaner connecting tube band setting screw (4) and remove the air cleaner element (5) (see figure below).
  4. Tap the element to loosen the dust and then apply dry compressed air from the inside of the element to remove the dust.

   

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Battery Maintenance

Battery Electrolyte Replenishment:

The battery is mounted under the seat, and is accessible by releasing the seat lock and raising the right side.

Raise the battery slightly to check the battery electrolyte.

Battery electrolyte level should be checked once a month. The electrolyte level must be maintained between the upper (3) and lower (4) marks on the side of the battery.

 

If the electrolyte level is found to be low, remove the battery filler caps and carefully add distilled water until the electrolyte level in each cell is between the upper and lower marks. Use a small syringe or plastic funnel to add water. Only distilled water should be added, to avoid contaminating the electrolyte

Battery Removal and Installation:

Battery removal may be necessary when battery electrolyte specific gravity reading is below 1.200, indicating the need of battery recharging, or when the battery is removed for storage.

  1. Remove battery retainer and disconnect the ground (-) negative cable connection first and then the positive (+) cable. The battery can now be lifted from its mounting. Note the positioning of the cables, protective rubber (+) terminal cover and battery mount rubber pads as well as the routing of the battery vent tube. Before installing the battery, clean the battery and its mounting area with water. Baking soda and water can be used to remove any existing corrosion.
  2. Battery installation is performed in the reverse order of removal. Pay particular attention to the battery rubber mounts pads and the vent tube routing. Connect and protect the positive (+) terminal with the rubber insulator first and then connect the negative (-) terminal.

NOTE: When installing the battery, be careful not to bend or twist the vent tube.

Battery Charging:

During the use of the motorcycle, should battery electrolyte specific gravity reading (measured with a hydrometer) drop below 1.200 @ 68F (20C), the battery should be charged at a rate not to exceed 1.2 amps until the specific gravity reading is between 1.260 and 1.280 @ 68F (20C). Frequent discharging or partial discharged battery condition is sometimes the result of improper starting procedure, poor engine condition and/or electrical system problems. To locate and correct the cause of this condition, we suggest you contact your HONDA dealer.

When storing the motorcycle or if it is not being used for an extended period, the battery negative (-) cable should be disconnected or the battery removed and stored in a cool place. The battery should be charged at least once a month during the storage period to preserve the battery life.

 

Fuse:

The fuse holder (1) is located in the battery compartment. The recommended fuse for the CB450 is 15 A. When frequent failure of the fuse occurs, it usually indicates a short circuit or on overload in the electrical system. In this case the electrical system should be checked visually for shorts or other possible malfunctions. If the problem cannot be located visually, the motorcycle should be examined by an authorized HONDA dealer.

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Brakes

Front Brake Maintenance

The CB 450 front brake is a hydraulic operated caliper/disc type. This type brake will provide reliable operation and excellent braking qualities at much higher operating temperatures than the drum type brake.

When the brake lever is applied, brake fluid transmits the pressure to the brake piston in the caliper, pressing the friction pads against the disc. Brake fluid is a medium for transmitting pressure and plays a vital role in the brake system. Therefore when the scheduled brake maintenance is performed, it is imperative that the front brake system is inspected to insure that there is no fluid leakage.

As the friction pads wear, additional fluid is taken into the system from the fluid reservoir to compensate for the friction pad wear. Because of this feature, the disc brake is self adjusting and the brake control lever free travel will remain constant once the free travel has been established and providing the hydraulic system is free of air.

If the control lever free travel becomes excessive, and the friction pads are not worn beyond the recommended limit , there is probably air in the brake system and it must be bled.


Replenishing Brake Fluid

The brake fluid level in the reservoir must be checked at regular intervals as in the MAINTENANCE SCHEDULE and replenished whenever the level is below the level mark engraved inside the reservoir. Remove the reservoir cap (1) and fill the reservoir to the lever mark. Use only brake fluid which is designated "DOT 3" on the container. "DOT 3" brake fluid meets the SAE J1703 specification. Outside the U.S.A., Use SAE J1703 brake fluid. Tighten the reservoir cap securely.

   

 

Bleeding the brake system

The brakes must be bled with great care subsequent to work performed on the brake system, when the lever becomes soft or spongy or when lever travel is excessive. This procedure is best performed by two mechanics.

  1. Remove the dust cup from the bleeder valve and attach bleeder hose (3)
  2. Place the free end of the bleeder hose into a glass container which has some hydraulic brake fluid in it so that the end of the hose can be submerged.
  3. Fill the reservoir with only the recommended brake fluid. Screw the cap partially on the reservoir to prevent the entry of dust.
  4. Rapidly pump the brake lever several times until pressure can be felt. Holding the lever tight, open the bleeder valve by about one half turn and squeeze the lever all the way down. Do not release the lever until the bleeder valve has been closed again.
  5. Remove the bleeder hose, tighten the bleeder valve and install the bleeder valve dust cap.
  6. Do not allow the fluid reservoir to become empty during the bleeding operation as this will allow air to enter the system again. Replenish the fluid as often as necessary while bleeding.
  7. Check the effect of bleeding and absence of leaks in the front brake lines while holding pressure against the brake lever.

Replenish fluid in the reservoir when bleeding is completed. Reinstall the diaphragm, washer and reservoir cap and tighten.

When the hydraulic brake system has been drained, it should be first filled as outlined below.

  1. Fill the fluid reservoir.
  2. Open the bleeder valve by one half turn, squeeze the brake lever, close the valve and release the brake lever. This procedure must be repeated in this sequence until hydraulic fluid begins to flow through the bleeder hose. Having filled the hydraulic system with fluid, proceed with the actual bleeding operation.

NOTE:

Brake Pads:

Brake pad wear will depend upon the severity of usage, type of driving and condition of the roads. It may be expected that the pads will wear faster on dirty and wet roads. Visually inspect the pads during all regular service intervals to determine the pad wear.

The remaining thickness of pad linings can be determined by measuring the clearance between the face of the caliper inner housing and the brake disc by pressing the inner housing toward the disc. If the clearance is less than 0.12 in. (3.0 mm), replace with new pads as a set.

 

NOTE: Use only HONDA genuine replacement friction pads offered by authorized HONDA dealers. When service is necessary on the brakes, consult your HONDA dealer.

Brake Caliper Adjustment:

Whenever the brake pads are replaced, the brake caliper (1) must be adjusted. This adjustment is made in the following manner, so there is a small clearance between the fixed friction pad and the brake disc.

  1. Raise the front wheel off the ground using a suitable prop.
  2. Loosen the caliper stopper bolt lock nut (2).
  3. Using a suitable screw driver, turn the stopper bolt (3) in direction (B) until the friction pad contact the brake disc. When the wheel is rotated, some resistance should be noticed.
  4. While rotating the front wheel, turn the stopper bolt in direction W until the front wheel rotates freely.
  5. Turn the stopper bolt in direction (A) 1/2 turn further and tighten the lock nut.

 


Rear Brake Adjustment

  1. Raise the rear wheel off the ground by placing the main stand under the motorcycle.
  2. Rotate the rear wheel by hand and note the distance of the pedal tip travel (2) before the brake holds.
  3. Normal free travel is 0.8-1.2 in. (20-30 mm). If adjustment is necessary, make the adjustment by turning the rear brake adjusting nut (3). Turn clockwise for less free travel, counterclockwise for greater free travel.

    

 

NOTE: Make sue that the cut-out on the adjusting nut is seated on the brake arm pin after the final adjustment has been made. If the rear wheel assembly has been moved forward or rearward, during drive chain adjustment, the rear brake may require adjustment. Whenever the rear wheel is removed, examine the brake shoes for lining thickness and even wear.

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Break-In Procedure

The motorcycle should not be exposed to severe or abusive riding condition. This precaution will be rewarded with extra-long trouble free life of the motorcycle.

It is recommended that for the first 600 miles (1,OOOkm), the motorcycle should not be operated in excess of 80% of the maximum speed in the respective gears.

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Cam Chain Adjustment

A loose cam chain will cause the timing of the valve to change, resulting in poor engine performance. It will cause a drop in power output and also produce excessive noise.

  1. Adjustment is made by loosening the tensioner lock nut (2) and tensioner lock bolt (1) this will cause the tensioner push bar to automatically apply the proper tension to the chain.
  2. After completing the adjustment, tighten the lock nut.

NOTE: Do not apply additional pressure on the tension push bar as this will apply excessive tension to the chain and the guide rollers, shortening their service life.

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Carburetor Adjustment

A carburetor which is out of adjustment will adversely affect the performance of the engine, therefore it is important that the carburetor always be maintained in perfect adjustment.

   

 

Carburetor adjustment should only be made when the engine is at operating temperature.

  1. Adjust the stop screw (1) so that the exhaust pressure is the same for both the right and left side. If the engine speed does not decrease when the stop screw is screwed out, loosen the lock nut (5) and screw in the cable adjuster (4) about one turn. The engine rpm at this point is 1,200 rpm.
  2. Starting with either the right or left carburetor, manipulate the pilot screw (3) and find the point of highest rpm; the same should be done with the opposite carburetor. Turning the pilot screw in will give a lean fuel air mixture, turning the screw out will give a rich mixture. The pilot screw (3) should be set at a point of one turn out from full close.
  3. After completing the adjustment in paragraph 2 above, recheck the exhaust pipe pressure on both the right and left sides and if necessary, readjust the stop screw as was done in paragraph 1.
  4. Repeat the procedure from paragraph 1 through 3 several times so that the pilot screw is set to give the optimum mixture, while the stop screws are set to provide the specified rpm and the same exhaust pressure on both the right and left sides.
  5. Next, make the adjustment so that the right and left throttle valves will both move by the same amount when the throttle grip is moved slightly. This adjustment can be made by placing your hand under the carburetor and noting the movement of the throttle lever, or by observing the movement while the throttle grip is slowly moved and checking to see that the throttle levers start moving at the same time. If adjustment is required, loosen the lock nut (5) and perform the adjustment with the throttle cable adjuster (4).

 

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CB 450 K5 Specifications (1972)

  SPECIFICATIONS of USA type
  ( Indicates General type)
   
DIMENSIONS  
Overall length 83.2 in. (2,115 mm)
Overall width 32.7 in. ( 830 mm) 23.3 in (820 in m)
Overall height 45.3 in. (1,150 mm)
Wheel base 54.1 in. (1,375 mm)
WEIGHT  
Dry weight 394.7 lbs (179 kg)
CAPACITIES  
Engine oil 3.0 US qt (2.8 liter)
Fuel tank 3.5 US gal. (13.5 liter)
Fuel reserve tank 0.5 US gal. (1.8 1 liter)
Front fork 5.3 ~5.6 ozs. (155~165 cc)
   
ENGINE  
Bore and stroke 2.756x2.276 in. (70x57.8 mm)
Compression ratio 9.0:1
Displacement 27.09 cu in. (444 cc)
Contact breaker point gap 0.012~0.016 in. (0.3~0.4 mm)
Spark plug gap 0.028~0.032 in. (0.7~0.8mm)
Valve tappet clearance 0.0012 in. (0.03 mm)
   
CHASSIS AND SUSPENSION  
Caster 6230'
Trail 4.1 in. (104 mm)
   
Tire size, front 3.25-19 (4 PR)
Tire size, rear 3.50-18 (4 PR)
   
POWER TRANSMISSION  
Primary reduction 3.304
Final reduction 2.333
   
Gear ratio  
1st. 2.412
2nd. 1.636
   
3rd. 1.269
4th. 1.000
5th 0.844
   
ELECTRICAL  
Battery 12 V-12 AH
Generator A. C. generator, 0.11 kW/4,000 rpm
LIGHTS  
Headlight 12 V-35/50 W
Tail/stoplight 12 V-8/23 W (SAE TRADE NO. 1157 12 V-7/23 W
   
Turn signal light 12 V-23 W 12 V-25 W
Meter light 12 V-3 W
Neutral indicator light 12 V-3 W
Turn signal indicator light 12 V-3 W
High beam indicator light 12 V-3 W
Fuse 15 amp

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Choke Lever

The choke lever (1) is located at the left side of the carburetor. When the choke lever is up (A), the choke valves are fully closed. (cold engine starting position). When the choke lever is down the chokes are fully open, warm engine starting position.

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Clutch Adjustment

The clutch should be adjusted so that the application of the clutch lever will completely disengage the transmission of power. If the clutch does not completely disengage, the engine will stall when shifting into gear or else the motorcycle will have the tendency to creep even with the clutch lever disengaged.

However, in the other case, if the clutch does not fully engage, the clutch will slip and the motorcycle will not accelerate in response to the acceleration of the engine. In order for the full engine output to be delivered to the rear wheel, it is necessary to have the clutch properly adjusted.

The normal clutch lever free play (2) is measured 0.4-0.8in. (10-20mm) at lever end before the clutch starts to disengage.

Adjust as follows:

  1. Loosen the clutch adjuster locking bolt (4) and adjust with the adjuster (3). Turning the adjuster clockwise (A) will decrease the clutch play and turning counterclockwise (B) will increase the play.
  2. Minor adjustment can also be made with the adjusters at both ends of the clutch cable. Adjustment is made at the drive chain cover end of the clutch cable by loosening the lock nut (6) and turning the clutch cable lower adjuster (5). Screwing the lower adjuster in will increase the play and screwing the lower adjuster out will decrease the play.

       

     

    The adjustment at the clutch lever is made by loosening the lock nut and by turning the circular adjuster (8) Turning in (A) will increase the play and screwing the adjuster out (B) will decrease the play.

  3. After the adjustment has been made, check to see that the clutch is not slipping or that the clutch is properly disengaging according to the following procedure.

After the engine starts, pull in the clutch lever and shift into gear, and make sure that the engine does not stall, nor the motorcycle start to creep. Gradually release the clutch lever and open the throttle, the motorcycle should start smoothly and accelerate gradually.

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Commands and Controls

(1) Speedometer (9) Rear brake pedal
(2) High beam indicator light (10) Foot rest
(3) Tachometer (11) Kick starter pedal
(4) Disc brake fluid reservoir (12) Rear foot rest
(5) Front brake lever (13) Clutch lever
(6) Throttle grip (14) Turn signal control switch (above) Horn button (below)
(7) Emergency switch (15) Fuel tank cap
(8) Headlight control switch (above); Starter Button (below) (16) Gear change pedal

 

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Contact Breaker Point Gap and ignition Timing Adjustment

Adjustment of the point gap and ignition timing should be made for both R/H and L/H cylinder at one time. To adjust, proceed as follows:

Contact Breaker Point Gap:

Turn the generator rotor counterclockwise and check the point gap when it is maximum. The correct gap is 0.012-0.016 in. (0.3-0.4 mm) for the L/H and R/H points. Then loosen the contact breaker plate locking screws (5) when the point cam (1) is at maximum lift and move the contact breaker point plate (4). Tighten the locking screws when the correct gap is obtained. Adjust both L/H and R/H points in the same manner. Recheck the gap after tightening the locking screws.

NOTE: Wipe the contact breaker point surfaces with clean rag if dirty.

 

Ignition Timing: Adjust the ignition timing upon completing the adjustment of the contact breaker point gap. L/H side

  1. Turn the generator rotor (6) counterclockwise and align "LF" mark (8) (on L/H cylinder) to timing mark (7). The ignition timing is correct. if the L/H contact breaker point (2) starts opening. To check the ignition timing, connect a 12V-3W bulb as shown in the figure and observe the moment the bulb comes on (see figure below)
  2. If the ignition timing is incorrect (either advanced or retarded), align "LF" mark to the timing mark, loosen base plate locking screws (10) and slowly turn base plate (11) until the bulb comes on.

       

     

    NOTE: The ignition timing will be advanced if the base plate is turned clockwise; it will be retarded if the base plate is turned counterclockwise.

    Tighten the base plate locking screws upon completion of the adjustment. Turn the generator rotor again and check if the contact breaker point gap of 0.012-0.016 in. (0.3-0.4 mm) is maintained for the L/H breaker point.

    R/H side

  3. Then connect the bulb to the R/H contact breaker point. Turn the generator rotor counterclockwise 180 degrees (1/2 turn) and align "F" mark (9) with timing mark (7). If the bulb comes on when the marks are aligned, the ignition timing is correct. If the ignition timing is incorrect, loosen contact breaker base plate locking screws (12) and vary the R/H point gap within the range of correct gap to adjust the ignition timing.
  4. When the correct ignition timing is not obtained even if the R/H point gap is varied within the range of correct gap, a readjustment is required in conjunction with the ignition timing of the L/H cylinder.

When this is the case, proceed as follows:

  1. Move the R/H contact breaker plate in the direction of adjusting the ignition timing within the range where the R/H point gap of 0.0120.016 in. (0.3-0.4 mm) is maintained, and tighten the plate lock screws. (reduce the point gap if the ignition timing is advanced and increase the gap if it is retarded.) Then loosen the base plate locking screws and turn the base plate until the correct ignition timing is obtained for the R/H cylinder.
  2. Move the L/H contact breaker plate in the direction of adjusting the ignition timing within the range where the L/H correct point gap is maintained.

 

Repeat the operation outlines in pars. 1) and 2) until the correct ignition timing is obtained for both L/H and R/H cylinders. If the correct ignition timing is not obtained for either L/H or R/H cylinder within the point gap range of correct gap, replace the contact breaker point assembly with a new one and make a readjustment.

NOTE:

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Drive Chain Maintenance

Proper tensioning and lubrication will help to extend the service life of the drive chain and ensure smooth power transmission to the rear wheel. Under average usage, the drive chain should be lubricated, and tension checked, every month. Under severe usage, or when the motorcycle is ridden in unusually duty areas, more frequent maintenance is necessary.

Tension Adjustment:

  1. Place the motorcycle on the main stand to raise the rear wheel off the ground. Shift the transmission into neutral.
  2. Check vertical movement of the lower length of the drive chain at a point midway between the sprockets. Move the chain up and down with your fingers and observe the amount of slack. Drive chain tension should be adjusted to allow approximately in. vertical movement at this point.

    Rotate the rear wheel and check drive chain tension throughout its length. Drive chain tension should remain constant as the wheel is rotated.

    If the chain is found to be slack in one segment of its length and taut in another, this indicates that some of the links are either worn or kinked and binding. Kinking and binding can frequently be eliminated by lubrication. Worn or damaged drive chain must be replaced.

  3. If the drive chain is found to require adjustment, the procedure is as follows:
  4. Remove the rear axle nut cotter pin (2) and loosen the rear axle nut (3)
  5. Loosen the lock nut (6) and turn the adjusting bolts (7) on both the right and left chain adjusters to increase or decrease chain tension. Align the chain adjust index marks (5) to corresponding scale (4) graduations on both sides of the rear fork.
  6. Tighten the rear axle nut and secure the nut with the cotter pin (replace the cotter pin if it has become broken or damaged). Tighten the lock nuts.
  7. Recheck drive chain tension.
  8. Rear brake pedal free travel is affected when repositioning the rear wheel to adjust drive chain tension. Check rear brake pedal free travel and adjust as necessary.

   

 

Lubrication:

Normally rear drive chain lubrication is performed without removing the chain, at the time of chain adjustment.

More frequent inspection and servicing is required under severe operating conditions.

The CB450 is equipped with the endless type drive chain and requires periodic inspection. If dirty or rusted, clean with brush and solvent, wipe dry with a clean rag. Inspect the chain for wear (sloppy joints), stiffness and binding at the joints, and broken or separated rollers. Apply a liberal amount of good engine oil or chain lubricant.

If damaged or worn, the chain should be replaced. Replacement of the endless chain requires a special tool, therefore your HONDA dealer should be consulted.

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Oil Related Operations

Engine Oil Replenishment

Check the engine oil level in the pre-riding inspection and add oil when the level is below the lower level mark. Check the level with the oil filler cap dipstick without screwing it in.

Engine Oil Change

The engine oil is the chief factor affecting the performance and the service life of the engine. Therefore, the oil recommended should be used and the oil should always be maintained at the proper level. Further, the oil should be changed as shown in the MAINTENANCE SCHEDULE . Perform engine oil changes in the following manner. Drain the oil while the engine is still warm as this will assure complete and rapid draining.

  1. Remove the oil filler cap from the right crankcase cover.
  2. Place an empty vessel of adequate size under the crankcase to catch the oil, and then remove the drain plug (4) with a 19mm wrench.
  3. After the oil stops draining from the crankcase, operate the kick starter several times to drain any oil which may be left in the recesses of the engine.
  4. When the oil has been completely drained, reinstall the drain plug (4), making sure that the drain packing used on the drain plug is in good condition and tighten the plug.
  5. Fill the crankcase through the oil filler opening with approximately 3 US qt. (2.8 liters) of recommended grade oil. The oil level should be between the upper (2) and lower (3) level marks on the dipstick. When checking the oil make certain that the motorcycle is upright and level on its stand.

NOTE:

 

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Fuel Strainer Maintenance

The fuel strainer is incorporated in the fuel valve (1) which is mounted on the bottom on the fuel tank at the right side. Accumulation of dirt in the strainer will restrict the flow of the fuel and cause the carburetors to malfunction, therefore, the fuel strainer should be serviced periodically. Turn the fuel valve to "STOP" position and unscrew the strainer cap, remove the O ring seal (3) and the screen filter (2) can be lifted out. Wash in solvent and reassemble. Turn fuel valve to "ON" position and check for leaks.

    

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Fuel Petcock (Valve)

Fuel Valve

The fuel valve (1) is mounted on the right under side of the fuel tank.

"STOP" position

When the fuel valve is turned to the "STOP" position, fuel cannot flow from the fuel tank to the carburetor. Set the valve in this position whenever the motorcycle is not in use.

"ON" position

When the fuel valve is turned to the "ON" position, fuel will flow from the main fuel supply to the carburetor.

Set the valve in this position when the engine is to be operated from the main fuel supply.

"RES" position

When the fuel vale is turned to the "RES" position, fuel will flow the reserve fuel supply to the carburetor. The fuel valve should be set in this position only after the main fuel supply has been consumed. The reserve fuel supply is 0.5 US gal. (1.81). When it becomes necessary to switch to the reserve fuel supply, this serves as a warning to the rider that it is time to refill the fuel tank.

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Fuel Tank

Fuel tank capacity is 3.5 US gal. (13.51) including 0.5 US gal. (1.81) in the reserve supply. Press down on the cap (1) and then push in the lock to open the fuel tank cap.

It is recommended that 90 or higher octane number gasoline containing a small percentage of lead. When refueling take care to exclude dirt, water, or other contaminates from the fuel tank.

WARNING:

Gasoline is flammable, and explosive under certain conditions. Always stop the engine and do not smoke or allow open flames or sparks near the motorcycle when refueling.

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Gear Change Pedal

The gear change pedal (1) located near the left foot rest is of the progressive shift positive stop type, which means one full stroke of the gear change pedal will shift only one gear position. The shifting sequence is arranged as shown in the figure.

Shifting from the neutral position into low (1st) gear is performed by depressing the gear change pedal with the toe. Shifting to 2nd, 3rd, 4th and 5th (top) gear is performed by progressively raising the pedal. Shifting down to the lower gears is performed by progressively depressing the pedal. The transmission neutral position is located between 1st and 2nd gear.

   

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Helmet Holder and Document Box

Helmet Holder

Two helmet holders (1) are provided as shown in the photo. Hang the helmet belt on the holder hook and lock the seat with the seat lock.

   

Document Box

The document box (2) is located under the seat. Utilize the box keeping the owner's manual, maps, etc.

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Instruments and Indicator Lights

These instruments are grouped together and mounted above the headlight case. The indicator lights are incorporated within the instruments. Their functions are shown in the table on the next page.

     

 

Ref. No. Description Function
1. Speedometer Indicates the bike's road speed.
2. Odometer Indicates total accumulated distance travelled.
3. High beam indicator light The light glows when the headlight is on (red) - high beam.
4. Neutral indicator light (green) The light glows when the transmission is in neutral.
5. Tachometer Indicates engine rpm.
6. Turn signal indicator light (amber) The light flashes, when turn signal light is operating.
7. Tachometer red zone During acceleration, engine revolution may enter the red zone from time to time. However, the motorcycle should not be operated in the red zone for long time and should not be operated beyond it.
8. Trip-meter Indicates distance traveled.
9. Trip-meter reset knob Reset the trip-meter to zero (0) by turning the trip-meter reset knob

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Left Switches

Headlight Control Switch

The headlight control switch (3) is located on the right handle grip switch housing. It can be operated without taking the hand off the handle grip. The red dot is the off position (headlight and tail-light off). "L" is the low beam position (low beam light and tail-light on). "H" is the high beam position (high beam light and tail-light on). The headlight will only operate when the main switch is in the on position.

Turn Signal Control Switch

The turn signal control switch (1) is located on the left handle grip switch housing. It can be operated without taking the hand off the handle grip. To signal a left turn move the switch knob to the "L" position. To signal a right turn move the switch knob to the "R" position. When the turn has been completed the switch knob must be returned to the off (center) position.

 

Horn Button

The horn button (2) is located directly below the turn signal control switch. While the horn button is depressed the horn will operate.

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Lights

Headlight Beam Adjustment

The headlight must be properly adjusted for safe night driving. This motorcycle has provisions to adjust the headlight in the vertical and also horizontal directions.

  1. The vertical adjustment is made by loosening the bolts (1) which mount the headlight assembly. The headlight is normally adjusted in the vertical direction.
  2. The horizontal beam adjustment is made with the adjusting screw (2) located on the left side of the headlight when facing the motorcycle. Turning the screw in will focus the beam toward the left side of the rider and turning the screw out will focus the beam toward the right side. Adjust the beam to coincide with the center line of the motorcycle.

 

Stoplight Switch Adjustment

The stoplight switch adjustment is made at the stoplight switch (1) located on the right side toward the rear of the engine.

  1. First check the adjustment of the rear brake pedal to make sure that the brake is properly adjusted.
  2. Turn on the main switch (red dot position).
  3. Adjust the stoplight switch so that the stoplight will come on when the brake pedal is depressed to the point where the brake just starts to take hold. If the stoplight switch is late in switching on the stop light, screw in (A) the switch adjusting nut (2) and if the stoplight comes on too early, screw out (B) the switch adjusting nut

 

Headlight Bulb Replacement

  1. Remove the three headlight setting screws and remove the headlight from the headlight case.
  2. Remove the headlight socket (1) from the sealed beam unit.
  3. Remove the two retaining lock pins and screws from the headlight rim.
  4. Remove the beam adjusting screw from the headlight rim (3).
  5. Remove the sealed beam unit (2) from the headlight rim.

 

Tail/stoplight Bulb Replacement

  1. Remove the two screws retaining the tail/stoplight lens.
  2. Press the bulb (1) inward A and twist to the left B, and the bulb can be removed C.
  3. Replace with a good bulb.
  4. When installing the tail/stoplight lens, do not overtighten the screws, as this may damage the lens.

 

Turn Signal light Bulb Replacement

Bulb replacement is made in the same manner as for the tail/stoplight bulb in the above paragraph.

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Main Switch

The main switch (1) is located on the left side under the forward end of the fuel tank. Functions of the respective switch positions are shown in the chart below.

 

Key Position Function Key Removal
OFF All electrical circuits are open; engine does not start. Key can be removed
ON

(red dot)

Electrical circuits except parking light are completed; engine can be started; headlight, tail/stop light and turn signal light can be operated; neutral indicator light is on when the transmission is in neutral. Key cannot be removed
PARKING

(black dot)

Only the parking light circuit is closed; engine does not start; the parking light is on. Key can be removed

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Maintenance Schedule

The mileage intervals shown in the MAINTENANCE SCHEDULE are intended as a guide for establishing regular maintenance and lubrication periods for your HONDA. Sustained severe or high speed operation under adverse conditions may necessitate more frequent servicing. To determine the specific recommendation for conditions under which you use your motorcycle, consult your authorized HONDA dealer. If your HONDA CB450 is ever over turned or involved in a collision, have your HONDA dealer carefully inspect the major components, e.g. frame, suspension and steering parts, for misalignment or damage to insure further safe operation.

 

  Months or Miles, whichever occurs first
Service Required

First

Second

Third

Thereafter Repeat every

Month

-

6

12

6

12

Mile

200

3,000

6,000

3,000

6,000

km

300

5,000

10,000

5,000

10,000

Engine Oil-change

Every 1,000 miles (1,600 km)

Oil Filter - clean    

   
Spark plugs-clean and adjust or replace  

 
Contact Breaker Points - check or service  

 
Ignition Timing-check or adjust

 
Valve Tappet Clearance-check or adjust

 
Cam Chain-adjust

 
Air cleaner - clean  

 

 
Air cleaner - replace    

 

Throttle Operation-check  

 
Carburetor-check or adjust  

 
Fuel Valve Strainer-clean  

 
Fuel Tank and fuel lines-check  

 
Clutch- check or adjust

 
Drive Chain and Sprockets - adjust and lubricate or replace

 
Brake Fluid Level - check and replenish if necessary

 
Front Brake Pads-check or replace  

 
Front Brake Lines-check  

 
Rear Brake Pedal-adjust

 
Rear Brake Shoes check or replace    

 

Rear Brake Links-check  

 
Wheel Rims and Spokes - check

 
Tires-check or replace  

 
Front Fork Oil - check  

   

Front Fork Oil - change    

 

Steering Head Bearings - check or adjust    

 

Steering Handle Lock - check for operation    

 

Side stand springs-check  

 
Rear Fork Bushing-grease  

 
Battery Electrolyte Level - check and replenish if necessary

 
Lights, Horn, Speedometer and Tachometer - check for operation or adjust  

 

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Oil Filter Maintenance

 

The oil filter (2) is of the centrifugal type. The principle operation of this type filter is to separate all the impurities and metal chips from the oil by centrifugal force and permit only the purified oil to come in contact with the moving parts of the engine. Clean oil filter in the following manner.

  1. The oil filter is accessible by removing the oil filter cover (1) located on the right crankcase cover.

    NOTE: When the oil filter cover is removed, a small amount of oil will flow out.

  2. Remove the snap ring and disassemble the oil filter cap (3) from the oil filter rotor (4).
  3. Wash the oil filter cap (3) and the oil filter rotor (4) internally in solvent or gasoline and then clean dry with air.

NOTE: When assembling the oil filter cap (3) to the oil filter rotor (4), make sure that the rib on the cap fits in the groove of the rotor and then install the snap ring.

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Oil

Engine Oil Recommendation

Use only high detergent, premium quality motor oil certified to meet or exceed US automobile manufacturer's requirements for Service Classification SE (previously Service Classification MS).

Motor oils intended for Service SE or MS will show this designation on the container.

The regular use of special oil additives is unnecessary and will only increase operating expenses.

Engine oil should be changed at the intervals prescribed in the Maintenance Schedule.

NOTE: Engine oil is a major factor affecting the performance and service life of the engine. Non detergent and low quality oils are specifically not recommended.

Viscosity

Viscosity selection should be based on the average atmospheric temperature in your riding area. Change to the proper viscosity oil whenever the average atmospheric temperature changes substantially.

Recommended oil viscosity:  
   
General, all temperatures: SAE 10W-40
Extreme, high temperatures: SAE 20W-50
   
Alternate:  
Above 59F SAE 30 or 30W
32" to 59F SAE 20 or 20W
Below 32F SAE 10W
32" to 59F SAE 20 or 20W
Below 32F SAE 10W

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Parking

 

When parking the motorcycle, position the main switch to the "OFF" position and remove the key. The steering should also be locked. Turn the fuel valve to the "STOP" position. When parking at night near traffic, the main switch can be positioned to the parking position and the key removed. This will turn on the taillight and make the motorcycle visible to traffic.

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Pre-Riding Inspection

Prior to starting your motorcycle, it is advised that you inspect the cycle as a matter of habit to make sure that it is in good, safe riding condition. This inspection will only require a few minutes and can save you much time and expense in the long run.

Check the following items and if adjustment or servicing is necessary, refer to the appropriate section in the manual.

1. Engine oil level add engine oil if it is below the lower level mark on dipstick.
2. Fuel level fill gasoline tank when quantity is not enough for travel .
3. Front and rear brakes adjust free play in the front brake lever and brake pedal if it is incorrect.
4. Tire air pressure inflate tires if pressure is too low.
5. Drive chain adjust chain tension when it is too loose.
6. Throttle operation repair if it is not smooth.
7. Turn signal light, tail/stoplight and headlight repair when the signal lights do not light properly.

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Rear Shock Absorbers

Each rear shock absorber (1) has three adjustment positions for different types of road or riding conditions. Position (I) is for light loads and smooth road conditions. Positions (II) and (III) progressively increase spring tension for stiffer rear suspension, and are used when the motorcycle is heavily laden or operated on rough roads.

   

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Riding the Motorcycle

 

  1. After the engine has been warmed up, the motorcycle is ready for riding.
  2. While the engine is idling, pull in the clutch lever and depress the gear change pedal to shift into low (1st) gear.
  3. Slowly release the clutch lever and at the same time gradually increase engine speed by twisting the throttle grip open. Coordination of the throttle and clutch lever will assure a smooth positive start.
  4. When the motorcycle attains a speed of approximately 15 mph close the throttle, pulling in the clutch lever and shift to 2nd gear by raising the gear change pedal.
  5. This sequence is repeated to progressively shift to 3rd, 4th and 5th (top) gear. The shifting pattern is indicated in the Gear Change Paragraph.

    NOTE: When shifting gear either up or down, the throttle should be closed and the clutch disengaged. Also, special attention must be given when operating in low (1st) and 2nd gears as it will very easy to exceed engine maximum (red zone) rpm during rapid acceleration.

  6. When decelerating the motorcycle, coordination of the throttle and the front and rear brakes is most important.
  7. The smooth gradual application of both the front and rear brakes together with the required throttle coordination will, under most conditions, assure positive speed reduction and stability. As the motorcycle speeds are reduced, it is common practice to shift the transmission progressively into the gear appropriate for the motorcycle. This assures maximum control through better braking effectiveness and acceleration when necessary.
  8. For maximum deceleration and stopping, close the throttle, disengage the clutch and apply both the front and rear brakes. This maneuver requires smooth coordination of the controls and to maintain skill it should be practiced frequently.

    Independent application of either the front or rear brakes is possible, but if only one brake is applied strongly enough to lock the respective wheel, braking effectiveness is greatly reduced and control of the motorcycle is difficult.

NOTE: When descending a steep grade, the engine may be used for braking without causing damage to the engine as long as the maximum rpm (red zone) is not exceeded.

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Right Switches

Emergency Switch

The three position emergency switch (1) is located on top the right handle grip switch housing. In the "ON" position (center) the ignition will operate. In the "OFF" position (either side of center) the ignition circuit will be open and the engine will not operate.

This switch is intended primarily as a safety or emergency switch and can normally remain in the "ON" position.

The ignition will not operate unless the main switch is in the on position.

 

Starter Button

The starter button (2) is located directly below the headlight control switch (3). While the starter button is depressed, the starter motor will crank the engine. Refer to the paragraph "Starting the Engine" for the correct starting procedure.

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Serial Number Location

The frame serial number (1) is stamped on the left of the steering head tube and the engine serial number (2) is located on top of the upper crankcase left side. These numbers are required when registering the motorcycle. Further, when ordering spare parts, the engine serial number for engine parts and the frame serial number for frame parts should be stated.

   

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Spark Plugs Replacement and Adjustment

Spark plugs, NGK B8ES, are used on this model.

For most riding conditions this spark plug heat range number is satisfactory. However, if the motorcycle is going to be operated for extended periods at high speeds and near maximum power in hot climates, the spark plugs should be changed to a colder heat range number, such as the NGK B10E (option) or its equivalent.

Spark plug cleaning and adjustment is done in the following manner.

  1. Detach the high tension cord cap and remove the spark plugs with the spark plug wrench provided in the tool kit.
  2. Inspect the electrodes and center porcelain of the spark plug for deposits, eroded electrodes, or carbon fouling. If the spark plugs deposits are heavy, or the electrodes appear to be eroded excessively, replace the spark plug with a new one. If the spark plug is carbon or wet fouled, the plug can sometimes be cleaned with a stiff wire brush.
  3. Adjust the spark plug gap (1) to 0.0280.032 in. (0.7-0.8 mm). The gap can be measured with a feeler gauge. The adjustment is made by bending the negative (grounded) electrode (2)
  4. When installing the spark plug, tighten firmly, but do not overtighten.

NOTE:

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Starting the Engine

Cold Engine Starting Procedure

  1. Turn the fuel valve to the "ON" position.
  2. Insert the key into the main switch and turn to the on position. At this time, observe the green neutral indicator light on the left side of the tachometer. The light will be lighted when the transmission is in the neutral position.
  3. Make sure that the emergency switch is in the "ON" position.
  4. Raise the choke lever to the full closed position.
  5. Twist the throttle grip inward slightly and depress the starter button. If the engine does not start within 5 seconds, release the starter button and allow the starter motor to rest for approximately 10 seconds before again pressing the starter button. If the engine does not start readily with the starter motor, to prevent excess battery discharge, use the kick starter pedal to start the engine. If the engine fails to start after several repeated attempts, it may have become flooded with excess fuel. To deflood the engine, turn off the main switch and lower the choke lever to the full open position, twist the throttle grip open fully and crank the engine using the kick starter pedal. This is then followed by turning the main switch to the on position and following the starting procedure outlined in steps 1 through 5. However, at this time use of the choke is not necessary.
  6. After the engine starts, operate it at approximately 1,500 rpm until the engine will properly respond to the throttle when the chock is open.

Starting in Extremely Cold Weather

Prime the engine before starting by cranking several times with the kick starter pedal. The main switch or emergency switch should be turned to "OFF". The choke should be fully closed and the throttle opened. Then follow the procedure for starting a cold engine.

Warm Engine Starting Procedure

When the engine is to be re-started while it is still warm, proceed as for cold engine starting procedure. However, the use of the choke is not necessary.

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Steering Lock and Seat Lock

Steering Lock

The steering lock (1) is located on the steering stem directly below the headlight case. Turn the handlebar all the way to the steering stop, either to the left or right, insert the key into the lock, turn key 60 to the left and press in, turn the key back to the original position and remove the key. This locks the steering to prevent theft.

   

Seat Lock

The seat lock (2) is located below the center right side of the seat. Insert the main switch key into the seat lock and turn the key counterclockwise. Than the lock is released and the seat can be raised.

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Stop Light Switches

These switches operate the stop light when the front or rear brake is applied. The front brake switch is incorporated in the front brake system and requires no adjustment. The rear brake switch, which is adjustable plunger type, is located near the rear brake pedal.

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Suspensions

Front Suspension Inspection

Check the front fork assembly by locking the front brake and pumping the fork up and down vigorously.

Inspect for smooth cushion action and oil seepage around the cushion oil seals.

Carefully inspect all front suspension fasteners for tightness, this includes the attachment points of the fork tubes, brake components and handle bar.

Front Fork Oil Change

To maintain good riding characteristics and increase fork service life, the oil in the front fork should be changed periodically.

  1. Unscrew the front fork drain plug (1) at the bottom of fork cylinder. Drain the oil by pumping the fork while the plug is out. Replace the plug securely after draining.
  2. Remove the top filler plug (2) and fill each front fork cylinder with 5.3-5.6ozs.(155-165cc) of premium quality ATF. Securely tighten the top filler plug after filling.

    

Rear Suspension Inspection

Check the rear suspension periodically by careful visual examination. Check the rear suspension by pushing hard against the side of the rear wheel while the motorcycle is on the main stand and feel for looseness of the fork bushings. If excessive looseness is felt, consult your HONDA dealer for further inspection. Check all suspension component attachment points for security of their respective fasteners.

Rear Fork Bushing:

It is recommended that lubrication be performed every 3,OOO miles (5,000 km) or 6 months, whichever occurs first, with multipurpose grease, type NLGI No. 2.

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Throttle Cable

Throttle Cable Inspection

For safe operation and positive engine response, the throttle cable must be properly adjusted.

  1. Check for smooth rotation of the throttle grip from the full open to the fully closed positions. Check when at full left and full right steering positions.
  2. Inspect the condition of throttle cables from the throttle grip down to each of the carburetors. If the cables are kinked, chafed or improperly routed, they should be replaced and/or rerouted. Recheck cables for tension or stress at both full left and full right steering positions

 

Throttle Grip Play Adjustment

Standard throttle grip play is approximately 10-15 of the grip rotation. This play can be attained by adjustment of the grip play adjuster (2). Loosen the grip play adjuster lock nut (1) and turn the adjuster in either direction to obtain the grip free play rotation of 10-15. Retighten the lock nut.

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Tire Recommendation

Correct inflation pressure will provide maximum stability, riding comfort and tire life. Be sure to follow the tire specification.

NOTE: Over or under inflation of the tires causes abnormal tread wear or other defects which may result in serious accidents. Riding with under-inflated tires will cause the tires to slip out of place in the rims, damaging the inner tube valves. From time to time check the tires for inflation pressure and correct it, if necessary.

 

Cold tire

pressure

psi

(kg/cm2)

Up to

200 lbs load

Front:

28 (2.0)

Rear:

28 (2.0)

Up to vehicle capacity load

Front:

28 (2.0)

Rear:

34 (2.4)

Vehicle

capacity load

300 lbs

(135 kg)

Tire size

Front: 3.25-19
Rear: 3.50-18

Dunlop

Front: F6
Rear: K87

Bridgestone

Front: Super speed 21F2
Rear: Super speed 2182

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Tool Kit

The tool kit (1) is mounted in the compartment located in the center of the motorcycle directly behind the engine. Minor adjustment and parts replacement can be performed with the tools contained in the kit. Adjustments or repairs which cannot be performed with the tools in the kit should be referred to your HONDA dealer.

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Valve Tappet Adjustment

Excessive valve clearance will cause tappet noise and negative clearance will cause valve damage, excessive wear of the cam follower, and loss of power.

Therefore, the valve tappet clearance should be maintained properly.

  1. Turn the fuel valve to the "STOP" position, remove the fuel lines from the fuel valve body, raise the seat and remove the fuel tank.
  2. Remove the cylinder head cover A (inlet side) and B (exhaust side).
  3. Remove the point cover and the dynamo cover.
  4. Rotate the generator rotor counterclockwise and align the "LT" mark (1) on the generator rotor with the index mark (2) on the stator. If the index marks of both the inlet and exhaust camshafts are aligned to the index marks on the bearing holders, this position is the top dead center of the intake stroke, therefore, the rotor should be turned one complete revolution to bring it to the top dead center of the compression stroke, in other words, the purpose is to place the left hand piston at the top dead center of the compression stroke.
  5. Check the left hand cylinder tappet clearances in the exhaust and inlet valves. Insert the feeler gauge (3) between the cam and the cam follower. If a slight drag or resistance is felt as the gauge is inserted, the clearance is correct. If the clearance is too close or too loose, adjust the tappet. The standard clearance for both the inlet and exhaust valves is 0.0012 in. (0.03 mm) when the engine is cold. Adjustment by loosening the cam follower shaft lock nut (5) and turning the cam follower shaft (4) with a screw driver as shown in the photo. Specific clearance can be obtained at two positions of the follower shaft, but only one of these is the correct adjustment point.

     

    The clearance is reduced when the adjustment is made as shown in the table below.

    Right side

    Inlet: Turn counterclockwise
    Exhaust: Turn clockwise

    Left side

    Exhaust: Turn counterclockwise
    Inlet: Turn clockwise

    NOTE: The check or adjustment of the tappet clearance should be performed while the engine is cold. The clearance may tend to increase as the temperature rises. Make sure that the adjustment has not been disturbed while tightening the lock nut, by rechecking the clearance after the lock nut has been tightened.

  6. Next, rotate the generator rotor 180 counterclockwise to bring the right hand piston to the top dead center of the compression stroke and then check both the right inlet and exhaust valve tappet clearances in the same manner as for the left hand side.

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Vehicle Stopping Distance

This table indicates the braking performance that can be met or exceeded by the CB450K5, without locking the wheels under different load conditions.

The information presented represents results obtainable by skilled drivers under controlled road and vehicle conditions, and the information may not be correct under other conditions.

Stopping Distance in Feet from 60 mph

 

Load

Stopping distance in Feet

Light

146

Maximum

169

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Wheel Balance

During high speed riding, the balance of the wheel will have considerable effect on the steering stability, therefore, the balance should be checked when the steering is not normal. Balance weights are available to correct unbalance.

Perform the balancing in the following manner.

  1. Raise the wheel off the ground and lightly rotate.
  2. Lightly attach an appropriate weight on the spoke adjacent to the nipple which stop at the highest position. Weights are available in four types, 5gr, 10gr, 15 gr. and 20gr.

  3. The wheel is in proper balance if the wheel after spinning will come to rest at no definite position.
  4. If the wheel does not statically balance, change the weight and re-perform items 2 and 3.
  5. Lock the weight with pliers after completing the balance.

NOTE:

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Wheel Removal

Front wheel Removal

Removal of the front wheel is performed in the following manner.

  1. Raise the front wheel off the ground by placing a support under the engine.
  2. Remove the speedometer cable (1) from the front wheel hub assembly.
  3. Remove the axle holder nuts (2) and the front wheel assembly can be removed from the front fork.

To install the front wheel, reverse the sequence outlined above.

NOTE: Do not depress the brake lever when the wheel is off the motorcycle as this can cause the caliper piston to be forced out of the cylinder with a subsequent loss of brake fluid. If this does occur, servicing of the brake system will be necessary.

 

Rear Wheel Removal

Removal of the rear wheel is performed in the following manner.

  1. Raise the rear wheel off the ground by placing its main stand.
  2. Unscrew the rear brake adjusting nut (1) and disassemble the brake rod from the brake stopper arm and disconnect the stopper arm from the panel.
  3. Pull out the rear axle by removing the cotter pin (2) and rear axle nut (3). Move the rear wheel forward, and remove the drive chain from the driven sprocket. Then remove the rear wheel.

    

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