1965–1977 Honda CB450 / CL450 / CB500T Clymer Service & Repair Manual (P/N 0-89287-685-9)

This Clymer repair manual covers the 1965–1977 Honda CB450 and 1975–1977 CB500T, with CL450-specific service information and separate 4-speed and 5-speed transmission sections. It is the seventh edition of Honda 450 & 500cc Twins, copyright 1978, ISBN 0-89287-685-9.

Search, navigation, and diagram detail: PDF text search and embedded bookmarks are unavailable. Small wiring labels require zooming. The opening Quick Reference Data pages are dark, with page IX largely unreadable; some photographs also lose detail in dark areas.

• Engine repair: Engine removal and internal inspection, camshaft and torsion-bar valve gear service, valve timing, centrifugal oil-filter cleaning, and oil-pump work.

• Clutch and transmission: Separate 4-speed and 5-speed disassembly, inspection, and assembly procedures, plus clutch adjustment, gearshift-fork and drum checks, and kickstarter service.

• Fuel and exhaust: Keihin carburetor disassembly, float-level adjustment, throttle synchronization, fuel-tank and petcock service, and exhaust-system removal and installation.

• Electrical diagnosis: Charging and ignition tests, starter-motor repair, starter-clutch and solenoid service, wiring-harness routing, and U.S./U.K. wiring diagrams.

• Suspension and steering: Front-fork rebuilds by design, steering-stem service, wheel-bearing inspection, spoke adjustment, rear-shock service, and swinging-arm inspection.

• Brake repair: Front and rear drum-brake service, disc-caliper inspection and adjustment, master-cylinder overhaul, hydraulic bleeding, and component wear limits.

It suits owners comfortable with hand tools for routine service; major engine disassembly calls for more experience, while valve-guide replacement and valve-seat reconditioning are referred to specialist shops.

Engine, Valve Gear, and Transmission

Cylinder-head, piston, connecting-rod, and cam-follower inspections are supported by standard-dimension and wear-limit tables. Lubrication-system and cam-chain routing diagrams show oil paths and guide-roller locations, while early and late oil pumps are handled separately.

The valve-timing section warns that incorrect cam timing can cause valve-to-piston contact. Torsion-bar instructions explain why small nicks or scratches can cause failure and identify the non-interchangeable A/B bars.

Valve replacement notes distinguish early and late valves for high-lift cams. Shared 450/500 engine procedures do not mean every part interchanges; parts-ordering guidance uses engine and frame identification.

Transmission gear-identification drawings accompany shaft, bearing, gearshift-drum, and fork inspections. Clutch specifications flag measurements that do not apply to the CB500T.

Keihin Carburetors and the CB500T Breather System

Exploded views distinguish Keihin 14C/14E carburetors, 14H units, and CB500T carburetors with air-cut valves. Coverage extends to needle and jet layouts, float-level adjustment, pilot-screw adjustment, and synchronization of the two carburetors.

The CB500T blow-by gas circulation diagram explains the breather box and element. Separate 450 and CB500T exhaust layouts identify the different muffler and pipe arrangements, including the CB500T pre-chamber.

Charging, Ignition, and Troubleshooting

Charging-output tables and alternator tests support diagnosis of weak charging. Rectifier testing distinguishes lead arrangements and the CB500T silicon-diode unit; ignition-coil and condenser checks complement strobe-light timing procedures.

U.S. and U.K. wiring diagrams separate 4-speed and 5-speed circuits. The Spark Plug Condition chart and symptom-based troubleshooting guide support investigation of hard starting, misfiring, power loss, and gearshifting trouble.

Fork Variants, Brakes, and Frame

Fork rebuild coverage distinguishes early one- and two-spring designs, CB450 K3/K4, K5-K7, and CB500T forks. Matching these sections to the fork fitted helps avoid applying the wrong disassembly method or oil specification.

Front-disc brake procedures cover caliper clearance, piston inspection, master-cylinder repair, and bleeding. Rear suspension coverage includes chain and sprocket inspection, shock springs, and swinging-arm bushings; the 450 rear damper is replaced as a unit rather than rebuilt.

Frame stripping, refinishing preparation, and centerstand service are also covered. Torque tables address engine mounts, axles, steering, and handlebar hardware, alongside lubricant recommendations and fluid capacities.

Engine lifting, fuel handling, and brake repairs require appropriate workshop precautions and inspection before the motorcycle returns to service.

Printable PDF and Included Pages

The English-language manual is supplied as one printable, 176-page PDF: 10 preliminary pages, 156 service-chapter pages, 3 specification-appendix pages, 3 index pages, 3 additional wiring-diagram pages, and 1 maintenance-log page. The preliminary pages include the title and copyright pages, contents, chapter guide, publisher information, one blank page, and two Quick Reference Data pages; all are already included in the total.