Honda CMX450C Rebel 1986–1987 Service & Parts Manual Set (P/N 61MM201)

Use the model-specific procedures and settings alongside the Common Service Manual’s explanations of system operation and general inspection methods. The parts reference helps identify components and quantities when planning a repair; its price column does not represent current pricing or availability.

The Common Service Manual is supplemental. Its cooling-system and V-Matic chapters describe other Honda configurations, not equipment fitted to the CMX450C. The parts reference supports identification rather than replacing repair procedures.

PDF Search, Bookmarks and Wiring Detail

Search and diagram readability: Neither service manual supports PDF text search; the parts tables are searchable. The Common Service Manual and parts reference have chapter or assembly bookmarks. The CMX450C manual uses page bookmarks with file-code labels. Small CMX450C wiring labels require zooming, and some remain difficult to distinguish.

The RAR download contains three printable English PDFs. The 781-page total includes covers and front matter, 11 memo pages in each service manual, one blank parts-reference page, and two additional color wiring pages in the CMX450C file.

Engine Overhaul, Carburetor Service and Electrical Diagnosis

These selected content highlights summarize the main repair areas. Other documented topics include fuel-strainer cleaning and headlight aiming.

• Engine and transmission: Engine removal and installation, cylinder-head and piston service, clutch repair, crankcase separation, bearing selection, balancer timing, and transmission disassembly.

• Fuel and emissions: Dual CV carburetor overhaul and synchronization, pilot-screw and high-altitude adjustments, plus California canister, purge-control-valve, and vacuum-hose checks.

• Chassis and brakes: Wheel and spoke service, fork rebuilding, steering-bearing replacement, swingarm and shock service, rear drum-brake repair, and front hydraulic-brake overhaul.

• Electrical diagnosis: Charging and leakage tests, regulator/rectifier inspection, CDI checks, starter-motor service, relay testing, clutch-diode checks, and switch continuity tests.

• Factory reference data: Torque tables, lubrication and capacity data, wear limits, bearing and gear-selection information, suspension and brake specifications, and electrical test values.

The material suits experienced technicians and mechanically qualified owners with the specified tools and test equipment; Honda recommends dealer-only servicing for selected safety-related maintenance items.

Engine Repair and Maintenance Planning

The model-specific chapters address the air-cooled parallel twin and its drivetrain. Most repair sections combine service information and troubleshooting with illustrated, step-by-step procedures.

Top-end repair: Coverage includes camshaft and rocker-arm inspection, valve-guide replacement, valve-seat inspection and grinding, cylinder-head assembly, and cam timing. Factory cautions identify vulnerable camshaft-holder mating and bearing surfaces and the risk of a jammed cam chain during timing checks.

Lower-end repair: Piston and ring inspection, oil-pump service, crankshaft and connecting-rod bearing selection, and starter-clutch work are covered. Transmission procedures extend to gear dogs, shift forks, the shift drum, and the overdrive gearset, followed by balancer installation and crankcase assembly.

Maintenance information includes valve-clearance inspection, balancer-chain adjustment, cylinder-compression testing, drive-chain service, and steering-head checks. Opening sections provide identification references and U.S. emission-control information.

Specified tooling: The tool chart lists vacuum gauge 07404-0030000, pilot-screw wrench 07908-4220201, and clutch-center holder 07923-KE10000.

Steering-stem socket 07916-3710100 and fork-seal driver 07747-0010100 appear alongside bearing, valve-guide, and shock-compressor tooling.

Carburetors and California Emission Controls

The fuel chapter distinguishes VE24A carburetors from the California VE28A configuration. Detailed procedures cover carburetor separation, vacuum-piston and diaphragm inspection, float and jet service, accelerator-pump work, and the air cut-off valve.

California-specific material covers the evaporative canister and purge-control valve, with hose-routing references for matching the connections to the correct configuration.

Wheels, Suspension and Brake Repair

Front end: Procedures cover handlebar removal, spoke replacement, wheel balancing, hub and bearing service, fork teardown, and seal and bushing installation. Steering work includes race replacement and bearing-preload checks.

Rear end: Coverage includes the wheel and driven flange, drum-brake disassembly, shock spring removal and damper inspection, swingarm pivot-bearing replacement, and rear fender and seat removal.

The hydraulic-brake chapter provides fluid replacement and bleeding procedures, pad and disc inspection, caliper overhaul, and master-cylinder disassembly and assembly. Its assembly cautions address turned-over piston-cup lips that can compromise hydraulic sealing.

Circuit Diagrams and Fault Isolation

Routing references include Cable & Harness Routing and the California Vacuum Hose Routing Diagram. Electrical drawings cover the Battery/Charging System, Ignition System, Electric Starter interlock circuit, and complete Wiring Diagram.

Charging-coil, pulse-generator, and exciter-coil tests support component diagnosis. Ignition timing is factory preset; the timing procedure checks CDI-system operation rather than providing an adjustment.

The troubleshooting charts trace starting faults, low power, fuel-flow problems, charging complaints, and abnormal wheel or suspension behavior. Comparing these fault paths with the component tests helps narrow the area requiring further inspection.

Factory safety information addresses gasoline, battery electrolyte, brake-fluid contamination, and brake dust. Carburetor synchronization and other engine-running tests require proper shop ventilation.

A Preview of Oil-Pressure and Float-Level Specifications

The CMX450C lubrication chapter specifies an oil-pressure test value of 630 kPa (90 psi) at 6,000 rpm and 80°C (176°F). The associated procedure identifies the pressure-gauge connection and required test equipment.

For the carburetor float inspection, the specified float level is 18.5 mm (0.73 in), measured with the float tang just contacting the float valve. This accompanies the float, valve, and jet inspection material.