1965-1977 Honda 450 & 500cc TWINS Service Manual - PDF DOWNLOAD

1965-1977 Honda 450 & 500cc TWINS Service Manual - PDF DOWNLOAD

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1965-1977 Honda 450 & 500cc TWINS Service Manual - PDF DOWNLOAD

Language :English
Pages :176
Downloadable : Yes
File Type : PDF

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1965-1977 Honda 450 & 500cc TWINS Service Manual - PDF DOWNLOAD

GENERAL INFORMATION

Introduced in 1965, the Honda 450 was the first Japanese bike to make any headway against the British twins and Harley Sportsters. The engine, ahead of its time in 1965, is still exotic and innovative enough to keep this workhorse in the Honda model line in an enlarged version. The CB500T, introduced in 1975, has a refined 498cc dual overhead cam engine that is a direct descendant of the original 450.

MANUAL ORGANIZATION

• This book provides service information and procedures for all Honda 450 and 500 twins built from 1965 through 1976. Most dimensions and capacities are expressed in English units familiar to U.S. mechanics, as well as in metric units. Where conversion to inches could introduce errors in critical dimensions, only metric measure is specified. In any case, metric tools are required to work on the Honda.
• This chapter provides general information specifications. Figures 1 and 2 show the location bf all identification tags. Chapter Two provides methods and suggestions for finding and fixing troubles fast. Troubleshooting procedures discuss typical symptoms and logical methods to pinpoint the trouble. It also covers some test equipment useful for both preventive maintenance and troubleshooting.
• Chapter Three explains all periodic lubrication and routine maintenance required to keep your bike in top running condition. Chapter Three also includes recommended engine tune-up procedures, eliminating the need to constantly consult chapters covering the various subassemblies.
• Subsequent chapters describe specific systems such as the engine, transmission, and electrical system. Each chapter provides complete disassembly, repair, and assembly procedures in simple step-by-step form. If a repair is impractical for the home mechanic, it is so indicated.
• It is usually faster and less expensive to take such repairs to a dealer or competent repair shop. Specifications concerning a particular system are included at the end of the appropriate chapter. Some of the procedures in this manual specify special tools. In all cases, the tool is illustrated either in actual use or alone. A well-equipped mechanic may find that he can substitute similar tools already on hand or that he can fabricate his own.
• The terms NOTE, CAUTION, and WARNING have specific meanings in this manual. A NOTE provides additional information to make a step or procedure easier or clearer. Disregarding a NOTE could cause inconvenience, but would not cause damage or personal in jury.

TABLE OF CONTENTS:

1965-1977 Honda 450 & 500cc TWINS Service Manual - PDF DOWNLOAD

QUICK REFERENCE DAT A IX
CHAPTER ONE
GENERAL INFORMATION
Manual organization
Service hints
1
Safety first
CHAPTER TWO
Parts replacement
Serial number location
TROUBLESHOOTING 5
Operating requirements
Starting difficulties
Poor idling
Misfiring
Flat spots
Lack of power
Overheating
Backfiring
Engine noises
CHAPTER THREE
PERIODIC LUBRICATION AND MAINTENANCE
Routine checks
Periodic maintenance
500 mile/monthly maintenance
1,500 mile/3-month maintenance
Piston seizure
Vibration
High oil consumption
Clutch slip or drag
Transmission problems
Poor handling
Brake system
Lighting system
Troubleshooting guide
10
3,000 mile/6-month maintenance
6,000 mile/12-month maintenance
Engine tune-up
CHAPTER FIVE
Valves and valve gear
Oil filter
Oil pump
Crankcase side covers
Crankcase
Crankshaft
CLUTCH AND TRANSMISSION 53
Clutch Transmission (5-speed)
Transmission ( 4-speed) Kickstarter
CHAPTER SIX
FUEL AND EXHAUST SYSTEMS 74
Air cleaners Fuel tank
Carburetors Exhaust system
Throttle linkage
CHAPTER SEVEN
ELECTRICAL SYSTEM
Charging system
Battery
89
Alternator
Rectifier
Regulator
Ignition system
Ignition coils
Condensers
CHAPTER EIGHT
FRONT SUSPENSION AND STEERING
Front wheel (drum brake)
Front wheel (disc brake)
Front forks (early, 2-spring)
Front forks (early, I-spring)
CHAPTER NINE
Starter motor
Starter clutch
Starter solenoid
Lighting system
Horn
Fuse
Wiring harness
Wiring diagrams
Front forks (CB450 K3 and K4)
Front forks (CB450 K5-K7)
Front forks (CB500T)
110
REAR SUSPENSION 133
Rear wheel
Drive chain
Sprocket
Rear shocks
CHAPTER TEN
BRAKES 144
Front drum brake
Front disc brake
CHAPTER ELEVEN
Rear drum brake
FRAME 154
Kickstand (sidestand)
Centerstand
APPENDIX
Stripping the frame
Painting the frame
SPECIFICATIONS 157
INDEX 160
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S.M 17/3/2025