FOREWORD. This manual is a maintenance and servicing guide for the HONDA 450, the largest in the series
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1 FOREWORD This manual is a maintenance and servicing guide for the HONDA 45, the largest in the series HONDA motorcycles. The description and information is based on the Model CB45, however, since the Model CL45 is very similar in design and performance, the manual is also applicable to this model equally as well. The areas of difference are specifically noted both by description and figures. Each section contains a general description of operation for the respective components and the unique design features attributing to the superior performances of these models. Service and maintenance procedures are outlined in detail to enable the shop personnel to locate the problems rapidly and make repairs with much saving in time. This manual has been prepared by major groups, assemblies and sections for easy use. Further, all work procedures are descriptive and accompanied by many photographs and drawings for clarity. HONDA MOTOR CO., LT Service Pablications Office ALL NFORMATON, LLUSTRATONS, DREC TONS AND SPECFCATONS NCLUDED N THS PUBLCATON ARE BASED ON THE LA TEST PRODUCT NFORMATON AVALABLE AT THE TME OF APPROVAL FOR PRNTNG. HONDA MOTOR CO., LT RESERVES THE RGHT TO MAKE CHANGES AT ANY TME WTHOUT NOTCE AND WTHOUT NCUlUUNG.ANY OBLGATON WHATEVER. NO PART OF THS PUBLCATON MAY BE REPRO DUCED WTHOUT WRTTEN PERMSSON
2 l CONTENTS 1. FEATURES SPECFCA lions ENGNE... 9 Special Tools for Engine Disassembly and Reassembly SECTONAL VEW OF ENGNE Construction Dismounting the Engine C. Remounting the Engine CYLNDER HEAD Construction Disassembly C. nspection Reassembly E. Camshaft Construction F. Cam Follower Construction G. Camshaft and Cam Follower Disassembly H. Camshaft and Cam Follower nspection Camshaft and Cam Follower Reassembly J. Valve and Torsion Bar Spring K. Valve and Torsion Bar Spring Disassembly L. Valve and Torsion Bar Spring nspection M. Valve and Torsion Bar Spring Reassenbly N. Cam Chain Guide Roller Construction Cam Chain Guide Roller Disassembly P. Cam Chain Guide Roller Reassembly Q. Cylinder Construction R. Cylinder Disassembly S. Cylinder nspection T. Cylinder Reassembly U. Piston Construction V. Piston Ring Construction W. Piston and Ring Disassembly X. Piston and Ring nspection Y. Piston and Ring Reassembly CRANKCASE COVER lrghtl Construction. 38
3 2 CONTENTS ' il E. F. G. H.. J. K A 3. 5 A E. F. G. H.. J. K. L. M. N.. P. Q. R. s. T. u. v Disassembly Reassembly Oil filter Construction Oil Filter Disassembly Oil Filter Reassembly Clutch Oil Pump Construction Clutch Disassembly Clutch nspection Clutch Reassembly CRANKCASE COVER LEFTl Construction Disassembly Reassembly UPPER AND LOWER CRANKCASE Construction Oil Separator Operation Upper and Lower Crankcase Disassembly Upper and Lower Crankcase nspection Upper and Lower Crankcase Reassembly Crankshaft Construction Connecting Rod Construction Crankshaft Disassembly Crankshaft nspection Crankshaft Reassembly... 5 Transmission Construction Transmission Transmission Transmission Gear Shift Gear Shift Gear Shift Gear Shift Kick Starter Kick Starter Kick Starter Kick Starter Disassembly nspection Reassembly Construction Disassembly nspection Reassembly Construction Disassembly nspection., Reassembly Carburetor, Construction,.,, Air System Fuel System
4 CONTENTS 3, Float Chamber Choke, Carburetor Adjustment dling., Low and Cruising Speeds Medium Speed High Speed Float Level Adjustment FRAME Special Tools Required for Disassembly and Reassembly C. HANDLEBAR Construction Disassembly nspection Reassembly FORK TOP BRDGE Construction Disassembly nspection Reassembly f, :.,,.. i~ A FRONT CUSHON Construction Disassembly nspection Reassembly STEERNG STEM Construction Disassembly nspection Reassembly FUEL TANK Construction Disassembly nspection Reassembly FRAME BODY Construction Disassembly... 8 nspection Reassembly \,... 1 ~
5 CONTENTS 4. 7 SEAT AND AR CLEANER Construction Disassembly nspection Reassembly :~ ~ ~ ~ j 4. 8 STAND AND BRAKE SHOE D Construction Disassembly nspection Reassembly EXHAUST PPE AND MUFFLER Construction nspection Reassembly AR CLEANER Construction Disassembly lnspe ~ eassembly REAR FORK AND REAR FENDER Construction Disassembly nspection... 9 Reassembly... 9 REAR CUSHON Construction Disassembly nspection Reassembly FRONT WHEEL Construction Disassembly nspection Reassembly REAR WHEEL Cons traction......, 1 Disassembly nspection Reassembly
6 CONTENTS 5. ELECTRCAL PARTS ELECTRCAL EQUPMENT POWER SUPPLY SYSTEM E. GNTON CRCUT gnition system gnition coil Construction Principle of operation Testing Coil spark characteristics Spark Advancer Contact Breaker Condenser F. Spark Plug Spark Plug requirements Spark Plug Spark Plug themal characteristics Spark Plug Reach Noise Suppressor POWER CRCUT AC Generator Current Limiter nspection Operation Serving Characteristic C. Selenium Rectifier Battery Discharge Rates Vacuum Dry Charged Battery nstruction Before Using Precaution During Use Battery Troubles Battery Repair ELECTRC STARTER Starting Circuit Starting Motor Characteristics C. Stator Reduction Removal E. Servicing. 131
7 6 CONTENTS F. G. Starting Clutch Starter Solenoid E. F. G. H. SAFETY DEVCES Horn Serving TailStoplight Pilot Lamp Tachometer and Speedometer Characteristics of the Speedometer Headlight Flasher Relay Flasher relay operation Handling SWTCH Combination Switch Starter Lighting Switch C. WinkerHorn Switch WRE HARNESS NSPECTON AND ADJUSTMENT MANTENANCE Engine Tuneup Measuring Compression Tappet Adjustment Contact Breaker Point Gap and gnition Timing Adjustment Spark Plug Fuel System Cleaning Oil Filter Air cleaner cleaning Clutch Adjustment Cam Chain Adjustment Carburetor Cleaning and Adjustment Lubrication Part for which there is no periodical lublication Engine Oil Change Greace Front Fork Fluid Change C. Drive Chain Adjustment Brake Adjustment Front Brake Rear Brake
8 CONTENTS 7 E. Battery nspection F. Checking Parts for Tightness mportant Nuts and Bolts SUPPLEMENT OF CB/CL 45 K1.K COMPARSON OF CB/CL45K3 TO CB/CL45K COMPARSON OF CB/CL45K4 TO CB/CL45K COMPARSON OF CL 45 K5 TO CL 45 K3, K COMPARSON OF CB/CL 45 K6 TO CB/CL 45 K COMPARSON OF CB 45 K7 TO CB 45 K WRNG DAGRAM "!~ :,; ' ";., " i '
9 1. FEATURES CB/CL 45 SHOP MANUAL The Honda CB 45 has been specially designed for use as a sports motorcycle by increasing the engine power output and mounting it on a newly engineered lightweight frame of greater rigidity. The performance and handling is further improved by incorporating a 5speed transmission to meet the full range of condition from high speed sports riding to operating over rough country roads. The CL 45 is identical to the CB 45 with the distinct difference being in the setting of the carburetor, and design of the frame components to provide a sports motorcycle suitable for touring and rugged riding. 1. ENGNE 1 Description Aircooled, 4cycle, vertical sidebyside, twin cylinder gasoline engine with a double overhead camshaft. 2 Cylinder head and combustion chamber Cylinder head is a high strength aluminum alloy casting with a special cast iron valve seat inserts. Further, the combustion chamber is a semi spherical design incorporating a squish area for greater efficiency. 3 Crankshaft Precisionly balanced crankshaft is mounted on four main roller bearings for minimum friction. 4 Valve mechanism Camshaft is driven by and endless chain which is maintained at a constant tension by an adjustable tensioner assembly and guide rollers distributed uniformly over the entire length of the chain for greater operating stability and rugged service. n addition, torsion bar valve springs are used for increasing the power output. 5 Carburetor By the use of a dual loaded servo carburetors, a stable and smooth highly efficient engine operation is obtained over the entire speed range. 6 Lubrication A pressure lubrication system provided by the efficient plunger pump, and incorporating a dual screen and centrifugal filters provide highly purified oil to the engine moving components (crankshaft, transmission, et) assuring a minimum of wear. 7 gnition system A 12 V battery ignition system is used. 8 Air cleaner A formed box one piece air cleaner silences the air inlet noise as well as eff'rciently protecting the engine from rain dust and dirt. 9 The CL 45 mounts the same engine as the CB 45 with the difference in the exhaust system which is designed to provide a power characteristic favorable in the lower speed range for superior
10 2 1. FEATURES riding performance on rough terrain. carburetor setting is also different. n conjunction with the design in the exhaust system, the 2. FRAME 1 Frame body Main structural member of frame rs made of high strength steel tubing and designed as a semidouble cradle frame. 2 Front and rear suspension Front wheel suspension is a telescoping oil damper type having an aluminum alloy bottom ease for lightness. Rear wheel suspension is a welded steel tubing, cross member, swing arm type rear fork cushion for both the front and rear are made longer for improved comfort. 3 Big tires, for the front and for the rear are mounted on the CB 45 for greater comfort and better stability. The CL 45 mounts a on the front and on the rear wheels with block pattern tread for good stability on rough roads. 4 Friction type steering damper is used for improved handling. 5 The frame of the CL 45 is higher to prevent the components from contacting the ground in case of fall.
11 2. SPECFCATONS CB 45 (AH Type) mm lin.l TEM CB45 CB 45 K1 CB 45 K2\ CB 45 K31 CB 45 K4 CB 45 K5 CB 45 K6 CB45K7 DMENSON Overall length Overall width Overall height Seat height Ground clearance FRAME Type Semidouble cradle F. suspension, Telescopic fork + + travel R. Suspension, Swing arm travel F. tire size, PR + pressure R. tire size, + + pressure F. Broke nternal expansion it fuel capacity 13.51it. (3.3 US. gal, ) mp.gol 13.6 U.S. gall 1.6 lit. fuel reserve capacity (.5 US. gal ) +.41mp. gal ENGNE O.H.C twin Type cylinder air cooled stroke Cylinder Vertical twin + arrangement cylinder X57.6 Bore and stroke X Displacement 444 cc cuinl Compression 9. : ratio Chain driven Valve train double over head camshaft 2.61it. Oil capacity (3. us. qt ) mp. qt Lubrication Forced and wet system sump Opens ntake Closes Opens 4 Exhaust valve Closes 1 + Valve tappet cleornce + + dle speed 1rpm PRJ
12 j TEM CB45 2. SPECFCATONS CB 45 Kl ca 45 K2 j ca 45 K3j ca 45 uj ca 45 K5 CB 45 K6 CB45 K7, DRVE TRAN Clutch Transmission Primary reduction Gear ratio Gear ratio Gear ratio ll Gear ratio V Gear ratio V Final reduction Geor shift pattern ELECTRCAL gnition Starting system Alternator Battery capacity Spark plug Wet, multiplate type Fivespeed lor word constant mesh Left loot return system Battery Motor and kick pedal C generator.11 kw/4 rpm 12V12AH NGK BBES + of +.12kW/ ofof + + of of of + of of of NGK B6 ES of NGK 4rpm 8ES NDW24ES
13 2. SPECFCATONS 5 CL 45 (AH Type) mm linl DMENSON TEM CL45 CL45K1 CL 45 K2 CL 45 K3 CL 45 K4 CL45K5 CL45K6 Overall length ! Overall width 83 (32.51 Overall height 1125 (44.21 Wheel bose Seat height Genera( clearance FRAME Type Semidouble cradle F. suspension travel Telescopic fork R. suspension trove( Swing arm F. tire size, pressure PR R. tire size, pressure PR F. brake nternal expansion Fuel capacity Fuel reserve capacity ENGNE Type Cylinder arrangement 9.1it US. gal, 2. mp. gall 1.61it. O.H.C twin cylinder air cooled 4 stroke Vertical twin cylinder Bare and stroke 7X57.8 l2.756x Displacement 444cc cu inl Compression ratio 9.: 1 Valve train Oil capacity Chain driven double over head camshaft 2.81it. (6. US. qt, 5. mp. qt.l lubrication system Forced and wet sump ntake valve Opens 1 Closes 25 4 Opens 4 Closes 1 Valve lappet clearance dle speed 1rpm DRVE TRAN Clutch Forced and wet sump Transmission Fivespeed foword, constant mesh ( it. lit. 2.6US.gal 2.21mp.gol
14 6 2. SPECFCATONS TEM CL.45K CL.4SOK2 CL.45K3 CL.45K.4 CL45KS CL.45K6 Primary reduction Gear ratio Gear rotio Gear rotio ll Gear ratio V 1. Gear ratio V.844 Gear ratio V Final reduction Gear shift pattern ELECTRCAL gnition Battery left loot type return system Starting system Motor and kick pedal Alternator C generator Battery capacity 12V12A E Spark plug NGK BSES E E E NGK.11 km/ 4rpm BSES NO W2<4ES
15 2. SPECFCATONS 7 CB 45 DRVNG PERFORMANCE CURVE ;:;; (..) Sf <>::.,:... a:: 2!... 5' ~ a: en z: <5... z: "iii~ ::.:: DRVNG SPEED( KPH) CB 45 ENGNE PERFORMANCE CURVE (i) a..... => a.. 1 => t= ~ Cl) 45 v ~ 1\ v \ 4..: !""f.././ \.,.,.~ / \ / J 11 v 1\ /... r. [_.../ lox W ENGNE SPEED { R.P.M) 4. "E...: "" LL => 3.5 ~ 1 t= 3. < ::>:: en ~..c: 2.5 "' ci. 4 ::::... z: ;:::: a.. 3 ::E => en 5 (..) =>
16 2. SPECFCATONS (V'tt)6Z,\ E E z 3 <( ::... <( z v; z w ~ (9'tt)96Z
17 3. ENGNE Special Tools Required for Disassembly and Reassembly (i) ~J ~ ~ q ~ (j])
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