Splitting 450 Cases (yep, starter clutch) - Honda Rebel Forum
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post #1 of 113 Old 05-29-2012, 05:57 PM Thread Starter
 
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Splitting 450 Cases (yep, starter clutch)

I'm trying to get the cases apart on a 86 450. I can't even find a cheap single socket big enough to make the special tool for the clutch hub nut, but I know I can find one somewhere and do the work.

My real problem is the flywheel. What kind of tool do I use, and how do I use it? The bell has threads in it, one big threaded hole in the middle.

How do ya'll pull the flywheel?
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post #2 of 113 Old 05-29-2012, 06:21 PM
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On the 250, it's with a 16mm bolt that threads into the hole.

Keepin' all the left over parts. Gonna use 'em to build another bike!

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post #3 of 113 Old 05-29-2012, 08:53 PM Thread Starter
 
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Thanks, I've read up on the 250 process and it's not the same. No jaw puller is going to work on the 450.
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post #4 of 113 Old 05-30-2012, 05:54 AM Thread Starter
 
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Nothing? I really, really need help on this one. The warranty on the starter clutch is 30 days; I'm desperate to get the motor back together before that time is up.
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post #5 of 113 Old 06-01-2012, 01:48 PM
 
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Coffee, the flywheel puller looks like this: HONDA CB400 A/T/SC,CM450,CMX450C,CX500 FLYWHEEL PULLER | eBay

Looks like you need a bolt 20mm X 1.5mm to pop it loose.
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post #6 of 113 Old 06-01-2012, 02:41 PM Thread Starter
 
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Thanks, I got it off yesterday with a $3 bolt from the local fastener warehouse. Yep, 20 x 1.5. Doesn't matter that it's longer than the one in the listing, with a regular hex head on it, just a half a turn after snug and it popped right off.
I'm waiting now on the socket thingy to remove the clutch. Turns out that same socket tool will also remove the clutch on my CX500, and is also necessary to remove the swingarm pivot out of my VFR700--both jobs I know I will need to do in the next six months. I found the tool for $18 shipped from a VFR forum member, so now I'm just waiting again.
Stator tests good, at any rate.
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post #7 of 113 Old 06-01-2012, 03:16 PM
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Sounds like you have it well in hand.




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post #8 of 113 Old 06-01-2012, 03:38 PM
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Like your determination!

Keepin' all the left over parts. Gonna use 'em to build another bike!

'01 & '09 Rebel 250, '06 Ninja 250, '89 VN 750
Putting your bike year and model in your signature helps others help you!
Here's how: https://www.hondarebelforum.com/f19/...re-121087.html
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post #9 of 113 Old 06-01-2012, 04:11 PM
 
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Coffee, are you just swapping out the starter clutch, or is this a teardown/rebuild?

You may be the first american (with internet access) to tear into a 450

Derek
87 450
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post #10 of 113 Old 06-01-2012, 10:50 PM Thread Starter
 
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Well I was considering a rebuild but I'm scared to say, I'm not the first to split the cases on this engine. With less than 20k on the speedo, I must assume that either 1) the speedo is not accurate or 2) whoever went in there first did something wrong, is why it won't run.
I did have spark, although rather weak, and I'm positive I got enough fuel to run, even a couple tries with just starter fluid.
I'm not scared of rebuilding carbs, it's jetting away from stock I've not done yet.

The rings look great. Pistons, cylinder walls, cam lobes, all look fantastic. I don't see any damage whatsoever. Just the right amount of wiggle at the con rods. I finally got the ruined bolt out of the starter motor and took it apart to find normal carbon buildup but no damage or heavy wear. It spins very well off the bike. Heck it spins very well ON the bike, just doesn't turn the engine with it.

I better take more photos. Someone after me might need it. Goodness knows I've been under-whelmed by the amount of knowledge on this machine. It's not a throw-away bike, it's a rather rare old Honda that is not marred by bad engineering, other than this stupid starter clutch and the notorious ignition system problems, which are easily accessed and diagnosed.

I've split cases on a parallel twin before but I have never done this particular job. Will it be easier to pull the good starter clutch off the donor crank, or should I replace the whole crank? Won't replacing the crank involve main bearings? I need info from those who have done a crank before, please....
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450 manual, 450 starter clutch repair

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