Detailed Service Manual for Honda CMX450C Rebel Cruiser (1986–1987) – 243 P. Manual | Factory Grade

Honda CMX450C Rebel Factory Precision Data

The 1986–1987 Honda Rebel 450 represents a pinnacle of mid-sized cruiser engineering. Utilizing this professional-grade technical documentation ensures that the vehicle operates within its original design parameters, safeguarding mechanical integrity and ensuring long-term uptime. Adhering to these factory standards is the most effective method for maintaining high-level performance and preserving the vintage value of the PC17 series.

Document Metadata & Logistics

• Total Page Count: 243 Pages
• File Format: Searchable PDF
• Publication Ref: Honda Motor Co., Ltd. 1986
• Print Code: LIT-11616-05-36

Identification & Compatibility Guide

This documentation is specifically tailored for the Honda CMX450C (PC17) chassis and the corresponding 447cc PC17E parallel-twin engine. It covers the full production run from 1986 through 1987, including all regional emission variants and global export specifications.

Professional ROI & Accuracy

• Eliminate Trial-and-Error: Direct access to OEM specifications prevents the costly mechanical failures associated with incorrect assembly.
• Maintenance Precision: Factory-defined service intervals and wear limits allow for proactive part replacement before catastrophic failure occurs.
• Maximum Resale Value: Comprehensive service records backed by factory-correct procedures ensure the highest possible appraisal for classic machinery.

Mechanical Integrity Guide

The following technical benchmarks are essential for the 447cc powerplant and chassis:

• Compression Ratio: 9.3:1 (Critical for fuel grade selection)
• Cylinder Pressure: 171–199 psi @ 400 RPM (Primary engine health indicator)
• Valve Clearance (Cold): 0.10 mm (Inlet/Exhaust)
• Spark Plug Gap: 0.6–0.7 mm (NGK DP8EA-9)
• Main Oil Pressure: 57–71 psi @ 5,000 RPM

Comprehensive Service Index

• Chapter 1: General Maintenance & Lubrication Schedules
• Chapter 2: Fuel System, Carburetor Cleaning, and Sync
• Chapter 3: Cylinder Head & Valve Train Management
• Chapter 4: Clutch and Six-Speed Transmission Logic
• Chapter 5: Crankshaft, Piston, and Bottom End Service
• Chapter 6: Front Wheel, Suspension, and Steering Head
• Chapter 7: Rear Wheel, Brake System, and Final Drive
• Chapter 8: CDI Ignition, Charging System, and Wiring

Workshop Diagnostic Logic

The diagnostics section utilizes a structured logical approach to fault isolation. It focuses on the specific electrical resistance values of the pulse generator and ignition coils, as well as vacuum-circuit testing for the dual Constant Velocity (CV) carburetors. This systematic methodology allows technicians to resolve complex driveability issues without the need for redundant component swapping.

High-Resolution Technical Schematics

Visual documentation includes high-contrast, scalable wiring diagrams and exploded views of all major sub-assemblies. These diagrams offer professional-grade clarity for the routing of the main harness and the intricate placement of internal transmission shims, ensuring that every component is returned to its factory-mandated position during reassembly.

FAQ

What are the cylinder health benchmarks for the CMX450C engine?

The manual specifies that for the 447cc PC17E engine, the standard cylinder compression should range between 171 and 199 psi at 400 RPM. This technical benchmark is the primary indicator of ring and valve seat integrity; dropping below this range often signals a need for top-end service to restore factory power output and fuel efficiency.

Can I use this manual to troubleshoot the 1986 Rebel 450 ignition system?

Yes, the guide provides specific solid-state CDI diagnostic values, such as the pulse generator resistance which must be within the factory range to ensure consistent timing. Understanding these exact Ohm values allows a technician to isolate a faulty ignition coil or pulse generator without the expensive trial-and-error of replacing functional components.

Is the North American PC17 model coverage included?

The documentation covers the complete 1986–1987 series, including VIN ranges starting with JH2PC17. This ensures that mechanics working on US-specific models have access to the exact wiring diagrams and emission routing required for localized legal compliance and mechanical accuracy during a restoration.

What is the precise valve clearance for the Rebel 450?

For the PC17E parallel-twin, the valve gap must be set to 0.10 mm (0.004 inches) for both the intake and exhaust valves while the engine is cold. Maintaining this precise gap is vital to prevent valve train noise and ensure the camshaft lobes do not suffer premature wear due to excessive heat expansion.

How does high-resolution digital access improve carburetor maintenance?

The manual features high-detail schematics of the dual Constant Velocity (CV) carburetors, allowing for significant zoom levels when identifying the placement of tiny O-rings and jet needles. This visual clarity is critical when synchronizing the two units to maintain a steady 1,200 RPM idle and smooth throttle response across the power band.

What are the fork oil requirements for a front-end rebuild?

When servicing the front suspension, the manual dictates a capacity of 13.0 oz (385cc) of fork oil per leg. Using this exact volume ensures the hydraulic damping remains consistent, preventing front-end dive during heavy braking and maintaining the stability of the 60.2-inch wheelbase chassis.