10 Steps on How to Replace Parts on a Honda Motorcycle

Step 1 - Get a Honda service manual for the year and model of your motorcycle. Most manuals have troubleshooting procedures that help isolate problems. All Honda motorcycle service manuals have procedures for changing clutch plates, lights, filters and brake pads, to name a few.

Step 2 - Have on hand a selection of metric sockets, a ratchet and a socket extension. Include a spark plug socket. Purchase a set of metric wrenches that range from 2 mm to 25 mm. Keep a set of metric Allen wrenches on hand too. This basic set of tools will take care of most of the bolts when you are replacing parts on your motorcycle.


step 3 - Obtain a reliable repair stand that is rated for your motorcycle. A CB650 is a lot heavier than a typical XR150. Make sure the stand is relatively easy to operate.


Step 4 - Purchase a voltage tester and spare batteries. You can check the battery voltage in less than a minute using a voltage tester. Voltage testers are a necessity when installing electrical accessories, such as an ignition switch and lights.


Step 5 - Follow the procedures in your Honda repair manual when replacing parts. Make sure to note when any wires or cables must be disconnected. It's also helpful to label wires and cables to prevent confusion during reassembly. Certain parts, such as the rear brake pedal, gear-shift pedal and hand levers, are removed by loosening a compression bolt with a metric socket or Allen wrench. Use an open-end wrench to back up nuts when removing bolts for fenders or a chain guard.

Step 6 - Save all bolts, nuts, washers and screws in a clean, glass jar as you go. This is easier than digging through a can or looking behind the workbench when trying to find a particular bolt and washer setup.

Step 7 - Disconnect the negative battery cable before doing any electrical-related parts work. Depending on the particular circuit, a fuse holder and fuse may be wired in-line. Remove the fuse and reinstall it after the electrical part is installed. Reconnect the negative battery cable last.


Step 8  -  Make sure you have the correct part before taking it out of the packaging. Most parts suppliers will not accept return of a part that was unsuccessfully fitted onto a motorcycle. The right part should fit and bolt on with a minimum of effort.

Step 9 - Install new parts in the reverse order that you removed the old parts. Most often, removing the seat or a fairing is necessary to access carburetors and air filters. Fuel lines and cables are reconnected after a carburetor or a hand lever has been installed. Refer to the service manual. Keep notes on the order in which all parts were removed.

Step 10 - Use the provided gaskets and clips when installing new parts from a kit. New exhaust gaskets and intake gaskets are a must when you replace pipes or a carburetor. Using the provided clips for wires and cables ensures these remain out of harm's way.