Honda 450X 2005 Owner'S Manual & Competition Handbook Download

Page: 42 / 180

Fuel Tank Removal

(1)

(3)

(2)

(12)

(8)

(11)

(9)

(10)

Installation
1. Install the fuel tank on the frame.
2. Install the fuel valve (1) and tighten the bolt

(2).

3. Connect the fuel line (3) to the fuel valve.

(1) fuel valve

(3) fuel line

(2) bolt

4. Install the collar and fuel tank bolt (4) and

tighten it.

5. Hook the air cleaner cover rubber (5).
6. Install the fuel tank band (6).
7. Put the breather tube (7) in the steering stem

nut.

8. Install the shroud (8) by aligning the it’s tab

(11) with subframe (12).

(8) shroud

(12) subframe

(11) tab

9. Install the shroud B bolts (9) and shroud A

bolts/collars (10).

(9) shroud B bolts

(10) shroud A bolts/collars

(4) fuel tank bolt/collar

(6) fuel tank band

(5) air cleaner cover rubber

(7) breather tube

Servicing Your Honda

(7)

(4)

(5)

(6)

11. Install the seat (page 36).

10. Tighten the shroud B bolts to the specified

torque:

3.7 lbf·ft (5 N·m, 0.5 kgf·m)

Summary of Contents for 450X 2005

Page 1: ...2005 Honda CRF450X OWNER S MANUAL COMPETITION HANDBOOK ...

Page 2: ...s warranty Please read the Honda Motorcycle Warranties Booklet given to you by your Honda dealer at the line of purchase Be sure to keep your Honda owner s card USA only with your Warranties Booklet It is important to realize that your warranty for your Honda applies to defects in material or factory workmanship Your warranty coverage does not apply to normal wear or deterioration associated with ...

Page 3: ... will find important safety information in a variety of forms including Safety Labels on the motorcycle Safety Messages preceded by a safety alert symbol and one of three signal words DANGER WARNING or CAUTION These signal words mean You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be HURT if you don ...

Page 4: ...r 65 Valve Clearance 66 Piston Piston Rings Piston Pin 75 Chassis Suspension 83 Brakes 87 Wheels 91 Tires Tubes 92 Side Stand 94 Drive Chain 95 Additional Maintenance Procedures 98 Electrical Battery 100 Headlight Taillight 102 Appearance Care 104 Adjustments for Competition 107 Front Suspension Adjustments 108 Rear Suspension Adjustments 122 Suspension Adjustments for Track Conditions 126 Suspens...

Page 5: ...to help you ride your CRF safely Please take a few moments to read these pages This section also includes information about the location of safety labels on your CRF Important Safety Information 2 Important Safety Precaution 2 Loading 3 Accessories Modifications 4 Safety Labels 5 Motorcycle Safety 1 ...

Page 6: ... Your Honda In Safe Condition It s important to keep your CRF properly maintained and in safe riding condition Having a breakdown can be difficult especially if you are stranded off road far from your base To help avoid problems inspect your CRF before every ride and perform all recommended maintenance 2 Motorcycle Safety Do not wear loose clothing which could catch on the control levers kickstart...

Page 7: ...o your safety If you decide to carry cargo you should be aware of the following information Loading Guidelines As discussed on this page we recommended that you do not carry any cargo on this motorcycle However if you decide to carry cargo ride at reduced speeds and follow these commonsense guidelines Keep cargo small and light Make sure it cannot easily be caught on brush or other objects and tha...

Page 8: ...ny original equipment or modify your CRF in any way that would change its design or operation Such changes could seriously impair your CRF s handling stability and braking making it unsafe to ride We also advice you not to make any modifications or remove any equipment such as the USDA qualified spark arrester or emission control system components that would make the motorcycle illegal in your are...

Page 9: ...labels on your CRF Some labels warn you of potential hazards that could cause serious injury Others provide important safety information Read these labels carefully and don t remove them If the label comes off or becomes hard to read contact your Honda dealer for replacement ...

Page 10: ...6 Motorcycle Safety ...

Page 11: ...Operating Controls 7 Operating Controls Read this section carefully before you ride It presents the location of the basic controls on your CRF Component Locations 8 ...

Page 12: ...trols Component Locations clutch lever hot start lever front brake lever engine stop button fuel fill cap throttle grip tripmeter start button choke knob fuel valve shift lever side stand kickstarter rear brake pedal ...

Page 13: ...help get you prepared this section discusses how to evaluate your riding readiness and what items you should check on your CRF For information about suspension carburetor and other adjustment see page 107 Before Riding Are You Ready to Ride 10 Is Your Motorcycle Ready to Ride 11 Pre ride Inspection 11 ...

Page 14: ...r adjustments see page 107 Whether you re preparing for competition or for practice always make sure you are In good physical and mental condition Free of alcohol and drugs Wearing an approved helmet eye protection and other appropriate riding gear Although complete protection is not possible wearing the proper gear can reduce the chance or severity of injury when you ride WARNING Not wearing a he...

Page 15: ... speed for stable and proper RPM 136 Tires for damage or improper inflation pressure 92 Spokes for looseness 91 Rim locks for looseness 91 Front and rear suspension for proper operation 83 84 Front and rear brakes check operation 87 Drive chain for wear or damage and adequate lubrication 96 Drive chain guide sliders and guide rollers for damage or wear 97 Exhaust pipe Muffler inspection removal an...

Page 16: ...12 Before Riding ...

Page 17: ... how to start and stop your engine as well as break in guidelines Safe Riding Precautions 14 Side Stand 14 Tripmeter 14 Starting Stopping the Engine 15 Preparation 15 Fuel Valve 15 Starting Procedure 15 Flooded Engine 16 How to Stop the Engine 16 Shifting Gears 17 Braking 18 Parking 19 Post ride Inspection 20 Break in Guidelines 21 ...

Page 18: ...first time please review the Important Safety Precaution beginning on page 2 and the previous section titled Before Riding For your safety avoid starting or operating the engine in an enclosed area such as a garage Your CRF s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death 1 side stand 1 tripmeter 2 tripmeter reset knob 1 OFF ...

Page 19: ...Continue warming up the engine until it runs smoothly and responds to the throttle when the choke knob is pushed back all the way to fully OFF Extended use of the choke may impair piston and cylinder wall lubrication and damage the engine cont d NOTICE NOTICE Basic Operating Instructions 15 1 fuel valve The three way fuel valve is used to control the flow of fuel from the fuel tank to the carburet...

Page 20: ...e transmission into neutral with the throttle fully opened repeat kickstarter operation approximately 10 times very slowly to discharge excessive fuel from the engine Close the throttle 3 Pull the hot start lever all the way in and start the engine Do not open the throttle 4 As soon as the engine starts release the hot start lever 16 Basic Operating Instructions How to Stop the Engine 1 2 1 thrott...

Page 21: ... brake lever in 2 Pull the clutch lever all the way in 3 Depress the shift lever from neutral down to first gear 4 Release the brake lever Gradually open the throttle while you slowly release the clutch lever If the engine rpm speed is too low when you release the clutch lever the engine will stall If the engine rpm speed is too high or you release the clutch lever too quickly your CRF may lurch f...

Page 22: ... gently Generally reduce your speed or complete braking before beginning a turn Avoid braking or closing the throttle quickly while turning Either action may cause one or both wheels to slip Any wheel slip will reduce your control of your CRF When riding in wet or raining conditions or on loose surfaces the ability to maneuver and stop will be reduced All of your actions should be smooth under the...

Page 23: ...Parking Lower the side stand to support your CRF If you re through riding for the day also turn the fuel valve OFF Always choose a level place to park Basic Operating Instructions 19 ...

Page 24: ...ly clean your CRF and remove any dirt mud brush rocks or other objects you may have picked up along the way After cleaning carefully inspect your CRF for leaks or damage Be sure to lubricate the drive chain page 97 to prevent rusting 20 Basic Operating Instructions ...

Page 25: ...ying extra attention to how you ride during the first operating day or 15 miles 25 km During this period avoid full throttle starts and rapid acceleration This same procedure should be followed each time when piston is replaced piston rings are replaced cylinder is replaced crankshaft or crank bearings are replaced ...

Page 26: ...22 Basic Operating Instructions ...

Page 27: ... Manual page 166 Before You Service Your Honda The Importance of Maintenance 24 Maintenance Safety 25 Important Safety Precautions 25 Maintenance Schedule 26 General Competition Maintenance 29 Before After Competition Maintenance 33 Between Motos Practice Maintenance 33 After Competition Maintenance 33 Service Preparations Component Locations 35 Seat Removal 36 Fuel Tank Removal 37 Subframe Uprigh...

Page 28: ...signed to be ridden over rough off road terrain To help you properly care for your CRF this section of the manual provides a Maintenance Schedule The service intervals in this schedule are based on average riding conditions More frequent service is needed if you subject your CRF to severe use or ride in unusually wet or dusty areas Frequent servicing of the air cleaner is especially important to h...

Page 29: ...rom hot motorcycle parts Let the engine and exhaust system cool before touching Injury from moving parts Do not run the engine unless instructed to do so Read the instructions before you begin and make sure you have the tools and skills required To help prevent the motorcycle from falling over park it on a firm level surface using the side stand or a workstand to provide support To reduce the poss...

Page 30: ...s To avoid overlooking required service we urge you to develop a convenient way to record the number of days and or distance traveled USA miles Canada kilometers you ride If you do not feel capable of performing a given task or need assistance remember that your Honda dealer knows your CRF best and is fully equipped to maintain and repair it If you decide to do your own maintenance use only genuin...

Page 31: ... I R I L I I I I I I C I I I R R I I I R I I I I I I C I C I I I R R I I I I I R I I I I I I I I I I C I I I R R I I I R I I I I I I C I C I I I R R I I R I I R R I I I I I I I I I 41 42 55 51 53 61 66 44 44 136 49 50 49 47 95 96 97 97 88 90 87 103 56 94 83 84 65 99 91 92 98 FREQUENCY ITEMS EMISSION REALATED ITEMS NON EMISSION REALATED ITEMS NOTE mi km Month 100 150 1 600 1 000 6 1 200 2 000 12 I ...

Page 32: ...RAKE PADS WEAR BRAKE SYSTEM CLUTCH SYSTEM CONTROL CABLES EXHAUST PIPE MUFFLER SUSPENSION SWINGARM SHOCK LINKAGE FORK OIL NUTS BOLTS FASTENERS WHEELS TIRES STEERING HEAD BEARINGS NOTE 1 NOTE 2 NOTE 4 NOTE 3 NOTE 3 NOTE 5 NOTE 2 NOTE 5 NOTE 3 55 60 51 53 61 48 66 44 44 136 77 77 46 48 95 97 97 96 96 88 90 87 56 98 62 83 84 32 86 113 99 91 92 98 I I C I I I I I I I I L I I I I I I I I I L I I I I R L...

Page 33: ...igh flash point cleaning solvent such as kerosene when disassembling Lubricate any sliding surface O rings and seals before reassembling Grease parts by coating or filling where specified After any engine disassembly always install new gaskets O rings cotter pins piston pin clips snap rings etc when reassembling After reassembly check all parts for proper installation and operation All Pre ride In...

Page 34: ...rly for signs of deterioration or dirt penetration Air Cleaner Clean and oil your air cleaner regularly because the volume of air able to pass through it has a great effect on performance Both engine performance and long term durability may be affected by an air cleaner that has deteriorated and allows dirt to pass Inspect the air cleaner closely each time it s serviced for evidence of small tears...

Page 35: ...ystem in your Owner s Manual page 41 and in this supplement Fuel System page 41 Check the fuel lines for deterioration damage or leakage Replace the fuel lines if necessary Periodically drain the fuel from the tank remove and clean the fuel valve and fuel filter Replace the fuel valve O ring if there are any signs of damage or deterioration page 41 Loosen the float bowl plug and examine the fuel t...

Page 36: ...n the right crankcase cover Clean away any clogged dirt or sand if necessary Look for coolant or oil leakage Leaking coolant indicates a worn or damaged mechanical seal Leaking oil indicates a bad transmission oil seal If replacement is necessary both seals should be replaced Fork Oil Performance Disassemble clean and inspect the fork and replace the oil regularly Contamination due to the tiny met...

Page 37: ...eel above the ground and use the pressure release screws 2 to release the built up pressure in excess of normal atmospheric pressure 0 psi in the fork tubes This pressure is caused by normal fork action while riding If you are riding at altitude remember that fork pressure of 0 at sea level will increase as elevation increases 2 pressure release screws 1 2 After Competition Maintenance It is impor...

Page 38: ...ushes are available from variety drug food and hardware stores Some of these brushes are extremely useful in removing dirt from the many tight contours of the metal pieces of your CRF Avoid using stiff abrasive brushes on the plastic or rubber parts If your CRF was exposed to sea air or salt water rinse it as soon as possible after the event dry it and apply a spray lubricant to all metal parts If...

Page 39: ...transmission oil drain bolt engine oil drain bolt side stand chain guide air cleaner kickstarter spark plug steering head tripmeter cable muffler rear brake pedal exhaust pipe front wheel axle chain adjuster rear wheel axle clutch lever hot start lever front brake lever engine stop button fuel fill cap throttle grip radiator cap tripmeter start button Servicing Your Honda 35 ...

Page 40: ...stallation 1 Install the seat 2 while aligning the seat front prong 3 with the seat bracket 4 and seat rear prongs 5 with the tabs 6 of the frame 2 Install and tighten the seat bolts to the specified torque 19 lbf ft 26 N m 2 7 kgf m 1 seat bolts 2 seat 3 seat front prong 4 seat bracket 5 seat rear prongs 6 tabs 1 2 3 5 2 1 4 6 36 Servicing Your Honda ...

Page 41: ... bolt collar 7 4 breather tube 5 fuel tank band 6 air cleaner cover rubber 7 fuel tank bolt collar 9 Disconnect the fuel line 8 from the fuel valve 9 The fuel line leading to the carburetor must be disconnected not the fuel line leading to the fuel tank 8 fuel line 10 bolt 9 fuel valve WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Stop...

Page 42: ...5 6 Install the fuel tank band 6 7 Put the breather tube 7 in the steering stem nut 8 Install the shroud 8 by aligning the it s tab 11 with subframe 12 8 shroud 12 subframe 11 tab 9 Install the shroud B bolts 9 and shroud A bolts collars 10 9 shroud B bolts 10 shroud A bolts collars 4 fuel tank bolt collar 6 fuel tank band 5 air cleaner cover rubber 7 breather tube 38 Servicing Your Honda 7 4 5 6 ...

Page 43: ...p 6 Loosen the subframe upper mounting bolts 9 and remove the subframe lower mounting bolts 10 9 subframe upper mounting bolts 10 subframe lower mounting bolts Servicing Your Honda 39 7 Lift the subframe 11 as shown Tighten the subframe upper mounting bolt to the specified torque 22 lbf ft 30 N m 3 1 kgf m 1 right side cover bolt 2 right side cover 3 Open the air cleaner box cover 3 by turning the...

Page 44: ... lower mounting bolts Installation 1 Loosen the subframe upper mounting bolts 1 2 Loosely attach the lower ends of the subframe 2 to the mainframe while connecting the air cleaner connecting boot to the carburetor Be careful not to bend the subframe Install the subframe lower mounting bolts 3 Tighten the subframe upper mounting bolts first then tighten the subframe lower mounting bolts to the spec...

Page 45: ...t dust or water in the fuel tank Type Unleaded Pump Octane Number 91 or higher Refueling Procedure Fuel Tank Capacity 2 27 US gal 8 6R 1 fuel fill cap 3 steering stem nut 2 breather tube 1 To open the fuel fill cap 1 pull the breather tube 2 out of the steering stem nut 3 Turn the fuel fill cap counterclockwise and remove it 2 Add fuel until the level reaches the bottom of the filler neck Avoid ov...

Page 46: ...ank page 37 3 Remove the fuel joint 1 from fuel tank by removing the bolts 2 Wash the fuel filter 3 in high flash point cleaning solvent 4 Reassemble the fuel joint in the reverse order of removal Check that the O ring 4 is in good condition and install it onto the fuel joint Install the fuel joint in the fuel tank 5 Install the fuel tank page 38 and refill the fuel Turn the fuel valve to ON or RE...

Page 47: ...lassification SG or higher except oils labeled as energy conserving on the circular API service label suggested oil Pro Honda GN4 HP4 without molybdenum additives or HP4M with molybdenum additives 4 stroke oil or an equivalent viscosity weight SAE 10W 40 JASO T 903 standard MA or MB Your CRF does not need oil additives Use the recommended oil Do not use API SH or higher 4 stroke engine oils displa...

Page 48: ...r cap dipstick If the oil is at or near the upper level mark you do not have to add oil If the oil is below or near the lower level mark and add the recommended oil until the upper level mark Do not overfill Reinstall the engine oil filler cap dipstick Repeat steps 1 5 6 Reinsert the engine oil filler cap dipstick 7 Check for oil leaks Changing Engine Oil Filter 1 Run the engine for 3 minutes then...

Page 49: ...lter cover being careful not to damage the O ring then tighten the oil filter cover bolts to the specified torque 9 lbf ft 12 N m 1 2 kgf m 15 Install the left engine guard and bolt then tighten it NOTICE 16 Fill the crankcase with the recommended oil Capacity 0 74 US qt 0 70R at oil and filter change 0 71 US qt 0 67R at oil change 17 Install the engine oil filler cap dipstick 18 Check the engine ...

Page 50: ...ration Do not use API SH or higher 4 stroke engine oils displaying a circular API energy conserving service label on the container They may affect lubrication and clutch performance Suggested 4 stroke engine oils are equal performance to SJ oils that are not labeled as energy conserving on the circular API service label SG or higher except oils labeled as energy conserving on the circular API serv...

Page 51: ...ler hole until oil start to flow out of the oil check bolt hole Install the oil check bolt with a new sealing washer and transmission oil filler cap Repeat step 1 4 5 After inspection the oil level or adding oil tighten the oil check bolt to the specified torque Oil Check Bolt 7 lbf ft 10 N m 1 0 kgf m 6 Install the transmission oil filler cap securely Replacing Transmission Oil 1 Run the engine f...

Page 52: ...d for most operating temperatures and provides good corrosion protection Decreasing the concentration of antifreeze to less than 40 will not provide proper corrosion protection NOTICE Increasing the concentration of antifreeze is not recommended because it decreases cooling system performance Higher concentrations of antifreeze up to 60 should only be used to provide additional protection against ...

Page 53: ...ration and clamp bands for looseness 3 Check the radiator mount for looseness 4 Make sure the siphon hose 2 is connected and not clogged 5 Check the radiator fins for clogging 6 Check the water leakage check hole 3 below the water pump cover 4 for leakage Make sure the hole remains open If water leaks through the check hole the mechanical seal is damaged If oil leaks through the check hole the eng...

Page 54: ...air from the system as follows Shift the transmission into neutral Start the engine and let it idle 2 3 minutes Snap the throttle 3 4 times to bleed air from the system Stop the engine and if necessary add coolant up to the proper level Reinstall the radiator cap Check the level of coolant in the reserve tank and fill to the UPPER level if it is low If the radiator cap is not installed properly it...

Page 55: ...remature engine wear NOTICE Cleaning 1 To open the air cleaner housing cover 1 turn the quick fastener 2 counterclockwise 3 Remove the air cleaner element 5 out from the air cleaner holder 6 1 air cleaner housing cover 2 quick fastener 2 Remove the air cleaner retaining bolt 3 3 Remove the air cleaner assembly 4 while turning it as shown 5 air cleaner element 8 hole 6 air cleaner holder 9 air clea...

Page 56: ... the air cleaner element tab 9 9 Install the air cleaner assembly into the air cleaner housing 3 air cleaner retaining bolt 10 access tab 11 mark 52 Servicing Your Honda 10 11 3 10 Carefully position the sealing flange of the element to prevent dirt intrusion Align the access tab 10 of the air cleaner element holder with the mark 11 of the air cleaner housing by rotating the air cleaner assembly c...

Page 57: ...RF is ridden in the rain or often at full throttle Service the breather if you can see deposits in the transparent section of the drain tube 1 Remove the crankcase breather tube plug 1 from the tube 2 and drain the deposits into a suitable container 2 Reinstall the crankcase breather tube plug 1 crankcase breather tube plug 2 tube 1 2 ...

Page 58: ... lock nut 5 Operate the throttle grip to ensure that it functions smoothly and returns completely If you can t get the freeplay within the specified range see your Honda dealer 5 6 1 Pull the dust cover 2 back 2 Loosen the upper lock nut 3 3 Turn the upper adjuster 4 Turning the adjuster in direction will decrease freeplay and turning it in direction will increase freeplay 4 Tighten the lock nut R...

Page 59: ... all steering positions If there is a problem see your Honda dealer 3 Inspect the condition of the throttle cables from the throttle grip down to the carburetor If the cable is kinked or chafed have it replaced 4 Check the cables for tension or stress in all steering positions 5 Lubricate the cables with a commercially available cable lubricant to prevent premature rust and corrosion 1 Servicing Y...

Page 60: ... Turn the cable end adjuster in direction seats lightly and then turn it out 5 turns 2 Loosen the lock nut 3 3 Turn the integral cable adjuster 4 to obtain the specified freeplay 4 Tighten the lock nut Check the freeplay 5 Start the engine pull the clutch lever in and shift into gear Make sure the engine does not stall and the motorcycle does not creep Gradually release the clutch lever and open t...

Page 61: ...utch cable 2 Check the clutch cable for deterioration kinks or damage Clutch Cover Disc Plate Removal 1 Drain the transmission oil page 47 2 Remove the brake pedal 1 by removing the pin 2 pivot bolt 3 washer 4 and dust seals 5 Servicing Your Honda 57 1 brake pedal 4 washer 2 pin 5 dust seals 3 pivot bolt 6 clutch cover bolts 7 clutch cover 4 Remove the six clutch spring bolts and clutch springs 8 ...

Page 62: ...ng Measure the free length of each spring Service Limit 1 72 in 43 7 mm Replace the clutch springs as a set if any one of them is beyond the service limit or if the clutch plates have been burnt heat discolored 1 58 Servicing Your Honda 6 Remove the washer 10 needle bealing 11 clutch lifter 12 and clutch lifter rod 13 7 Remove the eight clutch discs and seven clutch plates 14 Assemble the clutch l...

Page 63: ...e 9 lbf ft 12 N m 1 2 kgf m 8 clutch pressure plate 9 clutch spring bolts springs 10 O ring 11 clutch cover 8 9 11 10 10 Install a new O ring 10 in the groove of the clutch cover 11 11 Install the clutch cover by tightening the six cover bolts to the specified torque 7 lbf ft 10 N m 1 0 kgf m Clutch Disc Plate Installation 1 Coat the clutch disc A 1 B 2 and plates 3 with clean transmission oil 2 S...

Page 64: ... 3 mm If necessary adjust to the specified range Adjustment Adjustments can be made with the cable end adjuster Loosen the lock nut 3 and turn the adjuster 4 Turning the adjuster in will increase free play and turning out will decrease free play After adjustment tighten the lock nut 3 lock nut increase 4 cable adjuster decrease 60 Servicing Your Honda 1 2 4 3 ...

Page 65: ...mage and the insulator for cracks Replace if you detect them 6 Check the spark plug gap 4 using a wire type feeler gauge If the gap is out of specifications replace the plug with a new one The recommended spark plug gap is 0 039 0 043 in 1 0 1 1 mm 3 sealing gasket 4 spark plug gap 3 4 Servicing Your Honda 61 Standard IFR8H11 NGK or VK24PRZ11 DENSO Optional IFR9H11 NGK or VK27PRZ11 DENSO 7 To obta...

Page 66: ...rmance 1 seat bolt 3 right side cover 2 side cover bolt 2 Loosen the muffler clamp bolt 4 3 Remove the rear muffler mounting bolt washer 5 front muffler mounting bolt 6 and muffler 7 4 muffler clamp bolt 5 rear muffler mounting bolt washer 6 front muffler mounting bolt 7 muffler 4 Remove the muffler gasket 1 3 2 5 7 6 4 Muffler Removal 1 Remove the seat bolt 1 side cover bolt 2 and right side cove...

Page 67: ...sely tighten them Tighten the front muffler mounting bolt and rear muffler mounting bolt to the specified torque 19 lbf ft 26 N m 2 7 kgf m 5 Tighten the muffler clamp bolt 8 to the specified torque 15 lbf ft 21 N m 2 1 kgf m 6 front muffler mounting bolt 7 rear muffler mounting bolt washer 8 muffler clamp bolt 9 right side cover 11 seat bolt 10 side cover bolt 6 Install the right side cover 9 and...

Page 68: ...hten the nuts to the specified torque 15 lbf ft 21 N m 2 1 kgf m 1 exhaust pipe gasket 2 exhaust pipe 3 exhaust pipe joint nuts 2 Install the muffler page 63 Exhaust Pipe Removal 1 Remove the muffler page 62 2 Remove the exhaust pipe joint nuts 1 exhaust pipe 2 and exhaust pipe gasket 3 1 exhaust pipe joint nuts 2 exhaust pipe 3 exhaust pipe gasket 1 2 3 1 3 2 ...

Page 69: ...andom sparks from the combustion process in your engine from reaching the environment 1 Allow the engine and muffler to cool 2 Remove the four bolts 1 spark arrester 2 and gasket 3 from the muffler 1 bolts 3 gasket 2 spark arrester 3 Use a brush to remove carbon deposits from the spark arrester screen Be careful to avoid damaging the spark arrester screen The spark arrester must be free of breaks ...

Page 70: ... cylinder head cover A bolt 3 cylinder head cover B bolts 4 and cylinder head cover 5 3 cylinder head cover A bolt 4 cylinder head cover B bolts 5 cylinder head cover 1 crankshaft hole cap 2 1 4 5 3 1 Refer to Safety Precautions on page 25 Excessive valve clearance will cause noise and eventual engine damage Little or no clearance will prevent the valve from closing and cause valve damage and powe...

Page 71: ...e cover In this position the piston may either be on the compression or exhaust stroke If the crankshaft passed the punch mark rotate the primary drive gear bolt clockwise again and align the punch mark with the index mark The inspection must be made when the piston is at the top of the compression stroke when both the intake and exhaust valves are closed This condition can be determined by moving...

Page 72: ...63 mm If only decompressor arm clearance needs adjustment see Decompressor Arm clearance Adjustment page 73 Camshaft Holder Assembly Removal 1 Record the intake valve clearance exhaust valve clearance and decompressor arm clearance 2 Remove the cam chain tensioner lifter cover bolt 1 and sealing washer 2 1 cam chain tensioner lifter cover bolt 2 sealing washer Use the tensioner stopper tool Tensio...

Page 73: ...s at TDC Top Dead Center on the compression storoke Loosen the camshaft holder bolts 7 in a crisscross pattern in 2 3 steps 6 Remove the camshaft holder bolts and camshaft holder assembly 8 The intake valve lifter and intake valve shim may be sticking in the camshaft holder assembly Keep the intake valve lifters and the shims so as to allow identification of the originally installed location such ...

Page 74: ...5 mm 3 Calculate the new shim thickness using the equation below A B C D A New shim thickness B Recorded valve clearance C Specified valve clearance D Old shim thickness Make sure of the correct shim thickness by measuring the shim with the micrometer Reface the intake valve seat if carbon deposits result in a calculated dimension of over 2 450 mm Reface the exhaust valve seat if carbon deposits r...

Page 75: ...stall the valve lifters in their original location into the camshaft holder assembly 4 4 Install the camshaft holder assembly onto the cylinder head with the intake cam lobes 5 facing up as illustrated below Apply the oil to the camshaft holder assembly bolt threads and seating surface Tighten the camshaft holder assembly bolts 6 to the specified torque 10 lbf ft 14 N m 1 4 kgf m Tighten the camsh...

Page 76: ...sprocket 10 cam sprocket 11 index line 12 mark 13 cam chain 7 Clean and apply a locking agent to the cam sprocket bolt threads coating width 0 26 in 6 5 mm from tip Temporarily install the cam sprocket bolt 14 by aligning the bolt holes of the cam sprocket and camshaft Rotate the primary drive gear bolt crankshaft clockwise one turn and tighten the other sprocket bolt 14 to the specified torque 15...

Page 77: ...e right side rocker arm 2 and shim 3 Right Exhaust Valve Clearance 0 011 0 001 in 0 28 0 03 mm 1 feeler gauge 3 shim 2 right side rocker arm 2 Pull out the feeler gauge 5 6 4 1 1 feeler gauge 5 adjusting screw 4 lock nut 6 right side rocker arm Recheck the decompressor arm clearance 3 Loosen the lock nut 4 and adjusting screw 5 Insert the feeler gauge 1 between the adjusting screw and right side r...

Page 78: ...stall it to the spark plug hole 2 2 1 1 spark plug hole packing 2 spark plug hole 2 Inspect the cylinder head cover packing 3 for damage or deterioration replace it if necessary Install the cylinder head cover packing into the groove of the cylinder head cover 4 4 3 3 cylinder head cover packing 4 cylinder head cover 3 Install the cylinder head cover 5 4 Tighten the cylinder head cover A bolt 6 an...

Page 79: ...ion hose 3 bolts 2 vacuum hose 4 PAIR control valve 7 primary wire connector 8 bolts clamp 9 ignition coil 14 Position the piston to top dead center on the compression stroke page 66 15 Loosen the radiator hose clamp 10 and disconnect the radiator hose 11 5 left radiator grill 6 left radiator lower mounting bolt washer Servicing Your Honda 75 cont d 10 Remove the bolts 3 and PAIR control valve 4 c...

Page 80: ...uide 15 engine hanger plate bolts 16 clutch cable stay 17 left engine hanger plate 18 right engine hanger plate 21 cylinder head nuts washers 22 cylinder head 19 cylinder head bolts 20 cylinder bolt 19 Loosen the cylinder head nuts 21 in a crisscross pattern in 2 3 steps Remove the cylinder head nuts washers and cylinder head 22 Do not let the cylinder head nuts and washers fall into the crankcase...

Page 81: ...damage the piston ring by spreading the ends too far NOTICE 2 3 1 5 4 Piston Removal 1 Place clean shop towels in the crankcase to keep the piston pin clips or other parts from falling into the crankcase 2 Remove the piston pin clips 1 using a pair of needle nose pliers 3 Press the piston pin 2 out of the piston 3 and remove the piston Do not damage the piston Always support the piston when pressi...

Page 82: ...the top ring on the piston with the marking side facing up 3 After installing the rings they should rotate freely without sticking Space the ring end gaps 180 degrees apart between top ring and upper side rail Space the ring end gaps 90 degrees apart between upper side rail spacer and lower side rail NOTICE top ring oil ring top ring mark side rail oil ring side rail spacer 78 Servicing Your Honda...

Page 83: ... intake side of the engine Install the piston pin and new piston pin clips 5 Use new piston pin clips Never reuse old piston pin clips Do not let the piston pin clips fall into the crankcase Do not align the piston pin clip end gap with the piston cut out NOTICE 1 piston 4 piston pin 2 IN mark 5 piston pin clip 3 large valve recesses 6 cut out Cylinder Installation 1 Place clean shop towels over t...

Page 84: ...4 cylinder 6 Temporarily install the cylinder bolt 6 and connect the breather tube 7 to the cylinder 7 Install the cam chain guide 8 and fit the cam chain guide tabs 9 in the cylinder cut outs 10 Push the cam chain guide until it bottoms in the crankcase guide hole 8 cam chain guide 9 cam chain guide tabs 10 cylinder cut outs Cylinder Head Installation 1 Install the dowel pins 1 and new cylinder h...

Page 85: ...inder head nuts washers 7 left engine hanger plate 8 right engine hanger plate 9 clutch cable stay 10 engine hanger plate bolts 11 engine hanger bolt 12 fuel hose guide 13 engine hanger nut 5 cylinder bolt 6 cylinder head bolts 5 Install the left engine hanger plate 7 right engine hanger plate 8 clutch cable stay 9 and engine hanger plate bolts 10 and tighten the engine hanger plate bolts until th...

Page 86: ...the cylinder head and tighten the radiator hose clamp 15 14 radiator hose 15 radiator hose clamp 7 Install the ignition coil 16 ground wire 17 and clamp bolts 18 then tighten the bolts Connect the primary wire connector 19 16 ignition coil 18 clamp bolts 17 ground wire 19 primary wire connector 15 14 19 16 18 17 21 10 Install the camshaft holder assembly page 71 11 Install the crankshaft hole cap ...

Page 87: ... check and clean all front suspension parts to assure top performance Check the dust seals for dust dirt and foreign materials Check the oil for any contamination Refer to Suspension adjustment information page 108 for make all rebound and compression damping adjustments in one click increments Adjusting two or more clicks at a time may cause you to pass over the best adjustment Test ride after ea...

Page 88: ... turns described in pages 122 and 123 Adjusting two or more increments or turns at a time may cause you to pass over the best adjustment Test ride after each adjustment If the rear suspension is too stiff soft adjust it by turning all the compression and rebound adjusters according to the procedures described in page 123 After adjusting the adjusters simultaneously suspension may be fine tuned by ...

Page 89: ... removed To avoid damage hold both the outer tube and slider when removing the fork damper NOTICE 4 dust seal 6 slider 5 guide bushing 7 outer tube 3 Drain the fork oil from the outer tube 1 Drain the fork oil from the oil hole 8 of the fork damper 1 outer tube 8 oil hole 4 Drain the fork oil by turning the outer tube 1 upside down About 12 cc of fork oil will be left in the outer tube when it is ...

Page 90: ...r as it nears full compression Minimum oil capacity 10 3 US oz 306 cm3 1 scribe mark aftermarket parts No mark factory products Optional Stiffer 0 49 kgf mm Fork Spring Standard oil capacity 11 3 US oz 335 cm3 Maximum oil capacity 13 7 US oz 405 cm3 Slightly stiffer as it nears full compression Slightly stiffer as it nears full compression Minimum oil capacity 10 5 US oz 309 cm3 3 scribe marks Be ...

Page 91: ...lock nut 1 2 To position the brake lever farther away from the handgrip turn the adjuster 2 clockwise To position the brake lever closer to the handgrip turn the adjuster counterclockwise 3 Tighten the lock nut 4 Apply the brake release it then spin the wheel and check that it rotates freely Repeat this procedure several times 5 Check freeplay by pulling in slowly on the front brake lever until th...

Page 92: ...ably air in the brake system and it must be bled Refer to the Honda Service Manual or see your Honda dealer for brake bleeding Rear Brake Fluid Level Check 2 lower level mark With the motorcycle in an upright position check the fluid level It should be above the lower level mark 2 If the level is at or below the lower level mark check the brake pads for wear page 89 Worn brake pads should be repla...

Page 93: ... m 0 1 kgf m Adding Rear Brake Fluid The recommended brake fluid is Honda DOT 4 brake fluid or an equivalent When adding brake fluid be sure the reservoir is horizontal before the cap is removed or brake fluid may spill out 4 bolts 7 diaphragm 5 reservoir cap 8 upper level mark 6 set plate 1 Remove the bolts 4 reservoir cap 5 set plate 6 and diaphragm 7 2 Fill the reservoir with DOT 4 brake fluid ...

Page 94: ...rake disc 2 front brake caliper Rear Brake Pads Inspect the brake pads 4 from the rear side of the caliper to determine the pad wear If either pad is worn anywhere to a thickness of 0 04 in 1 mm both pads must be replaced 4 brake pads 6 brake disc 5 rear brake caliper Other Inspections Check that the brake lever and pedal assemblies are positioned properly and the securing bolts are tight Make sur...

Page 95: ... service in the Maintenance Schedule pages 27 and 28 However information for wheel removal is provided for emergency situations Wheel Rims Spokes 1 rim lock nut 3 spokes 2 wheel rim 4 spoke nut 1 Inspect the wheel rims 2 and spokes 3 for damage 2 Tighten any loose spoke nut 4 and rim lock nut 1 to the specified torque Front Spoke Nut 2 7 lbf ft 3 68 N m 0 4 kgf m Rear Spoke Nut 2 7 lbf ft 3 7 N m ...

Page 96: ...ll a new cap Always check air pressure when your tires are cold If you check air pressure when your tires are warm even if your CRF has only been ridden for a few miles the readings will be higher If you let air out of warm tires to match the recommended cold pressures the tires will be underinflated The correct cold tire pressures are If you decide to adjust tire pressures for a particular riding...

Page 97: ...tion of handling braking durability and comfort across a broad range of riding conditions Front 80 100 21 51M Rear 110 100 18 64M Type bias ply tube Use a replacement tire equivalent to the original Replace the tube any time you replace a tire The old tube will probably be stretched and if installed in a new tire could fail ...

Page 98: ...utions on page 25 1 Check the side stand spring 1 for damage and loss of tension 2 Check the side stand assembly for freedom of movement 1 side stand spring If the side stand is stiff or squeaky clean the pivot area and lubricate the pivot bolt with grease 1 ...

Page 99: ...sion into neutral 2 Check slack 1 in the upper drive chain run midway between the sprockets 2 3 Drive chain slack should allow the following vertical movement by hand 1 1 3 8 in 25 35 mm Excessive chain slack may allow the drive chain to damage the engine cases 1 drive chain slack 3 driven sprocket 2 drive sprocket If the chain is found to be slack in one segment of its length and taut in another ...

Page 100: ...itting links damaged O rings or other wise appears unserviceable 3 Measure the drive chain plate 1 If the drive chain plate is worn anywhere to a thickness of 0 53 in 13 4 mm the drive chain must be replaced Replacement Chain DID520MXV 1 drive chain plate inner 4 Inspect the sprocket teeth for possible wear or damage Replace them if necessary Never install a new drive chain on badly worn sprockets...

Page 101: ...ove 3 2 chain guide slider 3 wear limit groove Drive Chain Rollers 1 Measure the diameter of the drive chain rollers 1 Replace them if below the service limit SERVICE LIMIT UPPER ROLLER 1 5 in 39 mm LOWER ROLLER 1 4 in 35 mm 2 Replace the roller if necessary as follows Install the upper drive chain roller Green 1 with the mark 2 facing toward the frame and lower drive chain roller Black 3 with the...

Page 102: ...ing head the fork bushings may be worn Refer to the Honda Service Manual for replacement or adjustment procedures or see your Honda dealer Handlebar Inspection 1 Remove the handlebar pad 2 Check the handlebar 1 for bends or cracks 3 Check that the handlebar has not moved from its proper position by inspecting the paint mark 4 Check the torque of the handlebar upper holder 2 bolts 16 lbf ft 22 N m ...

Page 103: ...lt Clutch cover bolts Cylinder bolt Oil filter cover bolts Cylinder head bolts Drive sprocket bolt Torque lbf ft N m kgf m 7 15 7 11 7 7 7 9 7 23 10 21 10 15 10 10 10 12 10 31 1 0 2 1 1 0 1 5 1 0 1 0 1 0 1 2 1 0 3 2 1 cylinder head cover bolts 2 exhaust pipe joint nuts 3 water pump cover bolts 4 crankshaft hole cap 5 transmission oil check bolt 6 clutch cover bolts 1 2 3 4 5 6 8 9 10 7 RIGHT SIDE ...

Page 104: ...ntain its service life If you do not remove the battery we recommend disconnecting the battery cables negative cable first NOTICE You will get the best storage results from removing the battery and slow trickle charging it every 30 days see Battery Charging Before you remove the battery be sure to read all the information that follows as well as the information on the battery label WARNING The bat...

Page 105: ...nded using a trickle charger 1 for home charging These units can be left connected for long periods without risking damage to the battery However do not intentionally leave the charger connected longer than the time period recommended in the charger s instructions Avoid using an automotive type battery charger An automotive charger can overheat a motorcycle battery and cause permanent damage 1 tri...

Page 106: ... to the clamp 3 Install the front visor by aligning its grommets 10 with the tabs 11 on the steering stem Install and tighten the front visor bolts 3 To pull the headlight bulb out push and turn the headlight bulb socket 6 counterclockwise 6 headlight bulb socket 4 Install a new headlight bulb 7 into the headlight unit while aligning the tabs with the groove of the headlight unit If you touch the ...

Page 107: ...he taillight uses LED illumination If the taillight does not function properly see your Honda dealer for service This model is equipped with an electric starter and battery for easy engine starting There is a possibility of damage to the lighting system if the battery is carelessly removed Never kick start the engine without the battery connected If it becomes necessary to kick start the engine wi...

Page 108: ...retor steering head bearings suspension pivot points 1 steering head bearings 2 suspension pivot points High pressure water or air can damage certain parts of your CRF You may use Pro Honda Hondabrite a multi surface cleaner degreaser to remove both dirt and petroleum based grime from paint alloy plastic and rubber surfaces Wet any heavy deposits with water first Then spray on the Hondabrite and r...

Page 109: ...rust inhibitor Lubricate the drive chain and drive sprocket after removing and thoroughly cleaning in solvent Be sure the chain is wiped clean and is dry before applying the chain lube Follow the suggestions given in the pages of this manual for lubricating items such as the brake and clutch lever pivot points and footpeg pivot pins Aluminum Frame Maintenance Aluminum corrodes when it comes in con...

Page 110: ...106 Servicing Your Honda ...

Page 111: ...to determine if your combined rider and sprung machine weight rider fully dressed for competition and machine coolant oil and fuel levels ready for competition requires an optional firmer or softer rear spring The need for either optional rear spring may need to be balanced by installing the optional fork springs of a similar rate Front Suspension Adjustments 108 Rear Suspension Adjustments 122 Su...

Page 112: ...legs by using the pressure release screws The front wheel should be off the ground before you release the pressure The air pressure should be adjusted according to the altitude and outside temperature 1 Place a workstand under the engine so that the front wheel is off the ground Do not adjust air pressure with the front wheel on the ground as this will give false pressure readings 2 Remove the pre...

Page 113: ...r cylinder upright to prevent air from entering system NOTICE Fork Springs The fork springs in CRF s are about right for riders weighing between 150 and 160 lbs less riding gear So if you re a heavier rider you have to go up on the oil level or get a stiffer spring Do not use less oil than the minimum specified for each spring or there will be a loss of rebound damping control near full extension ...

Page 114: ...inch bolts 5 disc cover 6 bolts 5 6 11 fork protector bolts 12 tripmeter cable clamp bolts 13 brake hose clamp bolts 14 fork protectors 15 caliper mounting bolts 16 brake caliper 10 Loosen the fork leg lower pinch bolts 17 then pull the fork legs down and out Do not support the brake caliper by the brake hose Do not operate the brake lever after the front wheel is removed To do so will cause diffi...

Page 115: ...rk dust seal and guide bushing when the fork damper is removed To avoid damage hold both the outer tube and slider when removing the fork damper NOTICE 21 outer tube 23 lock nut wrench 22 fork damper 24 slider lower end 21 outer tube 25 oil hole 18 slider 20 length 19 dust seal 14 Hold the outer tube 21 then remove the fork damper 22 from the outer tube using the lock nut wrench 23 Gently slide th...

Page 116: ...to the fork damper Be careful not to damage the lock nut and fork center bolt hole NOTICE 24 Remove the fork damper assembly 31 from the fork assembly 32 Remove the fork from the vise Remove the fork spring 33 from the fork 26 axle holder 30 push rod 29 lock nut 31 fork damper assembly 33 fork spring 32 fork assembly 26 28 29 27 26 30 29 31 33 32 19 Push out the fork center bolt 27 from the axle h...

Page 117: ...e fork cap and fork damper threads 1 fork damper 4 fork oil 7 Pump the fork damper piston rod 5 slowly several times to bleed the air from the fork damper 1 1 fork damper 5 piston rod 1 3 2 2 1 1 1 4 1 5 6 Extend the fork damper piston rod to maximum length Pour the recommended fork oil into the fork damper Recommended Oil Pro Honda HP Fork Oil 5 W or equivalent Recommended Amount 6 4 US oz 190 cm...

Page 118: ...mp the fork piston rod 5 to 3 9 in 100 mm slowly several times 1 3 2 10 Tighten the fork cap assembly 2 while holding the cut out of the fork damper 1 using the lock nut wrench 3 to the specified torque 22 Ibf ft 30 N m 3 1 kgf m 1 fork damper 4 fork oil 9 Apply fork oil to the bushing 6 and new O ring 7 on the fork cap assembly 2 Extend the fork damper piston rod to maximum length holding it inst...

Page 119: ...e and cause 5 9 US oz 173 cm3 of fork fluid to be left in the chamber 13 Blow the extra oil off to the fork damper 1 spring chamber 9 by pumping the fork damper piston rod to full stroke 15 Blow out the oil from the fork damper spring chamber using compressed air to the oil hole Wipe the oil completely off the fork damper 16 If you can not use compressed air remove the pressure release screw 10 on...

Page 120: ... shown Standard 0 43 0 51 in 11 13 mm Wipe the oil completely off the fork damper 2 lock nut A thread length 3 Blow out the oil completely off the fork spring 3 Install the fork spring Install the fork damper assembly 4 to the outer tube slider 1 1 outer tube slider 4 fork damper assembly 3 spring 1 Amount of fork oil left in the fork without damper and spring unit cc minute C F 30 86 20 68 10 50 ...

Page 121: ...olt fully by hand NOTICE 2 lock nut 7 O ring 5 piston base 8 fork center bolt 6 push rod 9 adjusting rod 8 Measure the length of the lock nut 2 and fork center bolt 8 clearance Standard 0 06 0 08 in 1 5 2 0 mm If the clearance is out of specification check the lock nut and center bolt installation 2 lock nut 8 fork center bolt 9 Tighten the lock nut 2 to the fork center bolt 8 closely by hand Tigh...

Page 122: ...US oz 306 cm3 Optional Softer 0 45 kgf mm Fork Spring Standard oil capacity 11 4 US oz 338 cm3 Maximum oil capacity 13 8 US oz 407 cm3 Slightly stiffer as it nears full compression Slightly softer as it nears full compression Minimum oil capacity 10 5 US oz 311 cm3 No mark factory products 2 scribe marks 1 scribe mark aftermarket parts or Optional Stiffer 0 49 kgf mm Fork Spring Standard oil capac...

Page 123: ...rque wrench scale reading 23 Ibf ft 31 N m 3 2 kgf m using a 20 in 50 cm long torque wrench 18 For ease of releasing air pressure after the forks are installed Loosen the lower pinch bolts and position the outer tubes so that the pressure release screws are in front of the rebound damping adjusters Align 15 the top surface of the upper fork clamp 16 with the outer tube 1 upper surface as shown 19 ...

Page 124: ...25 for wear or damage Install the left side collar 24 to the left wheel hub Install the trip meter gear box 25 while aligning its tabs 26 of the trip meter gear box with the grooves 27 on the right wheel hub 24 Clean the clamping surface of the axle and axle holders Install the front wheel 28 between the fork legs while inserting the disc between the pads and align 29 the tab of the tripmeter gear...

Page 125: ...ation 29 While keeping the forks parallel alternately tighten the right axle pinch bolts 37 to the specified torque 15 Ibf ft 20 N m 2 0 kgf m To avoid damage when torquing the axle pinch bolts be sure the axle is seated firmly onto the left fork leg clamp inner surface 30 Connect the tripmeter cable 38 and tighten the lock nut securely NOTICE 31 Clean the threads of the disk cover bolts and axle ...

Page 126: ...r tools safety equipment and the Honda Service Manual If your CRF is new put enough part throttle break in time about one hour on it to ensure that the suspension has worked in Rear Suspension Spring Pre Load An optional pin spanner is available for turning the lock nut and adjusting nut to adjust spring pre load 1 Place a workstand under the engine to raise the rear wheel off the ground 2 Lift th...

Page 127: ...ster High Speed Compression Damping The high speed damping can be adjusted by turning the hexagonal portion of the compression adjuster The high speed compression damping adjuster has 2 turns or more To adjust to the standard position 1 Turn the adjuster clockwise until it will no longer turn lightly seats This is the full hard setting 2 Turn the adjuster counterclockwise 3 4 1 1 4 turns and the p...

Page 128: ...pension tuning the proper rear spring pre load adjustment for your specific needs Your CRF should be at normal racing weight including fuel and transmission oil You should be wearing all your normal protective apparel You will need two helpers To calculate the proper adjustment it is necessary to measure between two fixed points from the center of the rear fender mounting bolt to the center of the...

Page 129: ...oaded dimension step 2 Free sag indicates the distance your rear suspension should sag from the weight of the sprung portion of your CRF With the spring pre load set to obtain the proper race sag the rear suspension should sag 0 4 to 1 0 in 10 to 25 mm If the rear of your CRF sags more than 1 0 in 25 mm from its own weight the spring is too stiff for your weight It is not compressed enough even th...

Page 130: ...iffer aftermarket springs front and rear may help especially if you are heavier than the average rider Your CRF may be undersprung because of the added weight of the clinging mud This additional weight may compress the suspension too much and affect traction Hard Surface For a fast hard track with no large jumps you can probably run the same spring as normal but run softer damping both ways compre...

Page 131: ...n large bumps especially downhill bumps Entire travel too soft Front end shakes Fork bottoms over any type of terrain Action Test stiffer compression damping adjustments in one click increments Test stiffer rebound damping in one click increments If suspension isn t stiff in initial travel Test stiffer compression damping adjustments in one click increments If initial travel becomes stiff because ...

Page 132: ...makes the suspension too stiff over the full range of travel test softer compression damping adjustments in one click increments until the desire compression damping for initial travel is obtained If initial travel isn t stiff Test stiffer compression damping adjustments in one click increments This should produce smooth fork action from initial to middle travel If initial and middle travel is sti...

Page 133: ...on large bumps Entire travel too stiff Entire travel too soft Rear end sways Suspension bottoms at landing after jumping Suspension bottoms after landing Suspension bottoms after end of continuous bumps Action 1 Test softer low speed compression adjustment 2 If it still feels stiff further test softer low and high speed compression adjustments simultaneously 1 Test softer high speed compression ad...

Page 134: ...der when cold engine is being started When the choke knob 1 is pulled out fuel is metered by the starter jet 2 and is mixed with air from the air passage 3 located above the throttle valve 4 to provide a rich mixture for starting The mixture discharges through the orifice 5 into the cylinder 1 choke knob 4 throttle valve 2 starter jet 5 orifice 3 air passage Hot Start Circuit A lean mixture must b...

Page 135: ...rcuit Fuel is metered by the slow jet 1 and mixed with air from the slow air jet 2 The mixture enters the venturi through the bypass 3 and pilot outlet 4 that has been metered by the pilot screw 5 1 slow jet 4 pilot outlet 2 slow air jet 5 pilot screw 3 bypass Main Circuit Fuel is metered by the main jet 1 jet needle 2 and needle jet 3 It is then mixed with air coming from the air jet 4 and enters...

Page 136: ...off the ground by placing a optional workstand or equivalent under the engine 7 Remove the shock absorber upper mounting nut 2 and bolt 3 2 upper mounting nut 3 upper mounting bolt 8 Disconnect the throttle position sensor connector 4 4 throttle position sensor connector 9 Loosen the insulator band screw 5 and remove the carburetor 6 from the insulator 7 5 insulator band screw 7 insulator 6 carbur...

Page 137: ...k arm set screw 7 When installing the link arm set screw apply a locking agent to the link arm set screw threads 4 Remove the throttle valve 8 throttle valve roller 9 and floating valve 10 7 link arm set screw 9 throttle valve roller 8 throttle valve 10 floating valve 1 3 2 6 5 4 7 8 9 10 8 11 Remove the throttle drum cover bolt 10 and throttle drum cover 11 10 throttle drum cover bolt 11 throttle...

Page 138: ...nto the accelerator pump cover 13 make sure the D ring s flat side faces down away from the float bowl 18 13 accelerator pump cover 16 spring 14 D ring 17 diaphragm 15 O ring 18 float bowl 7 Remove the holder screw 19 throttle stop screw holder 20 float bowl screws 21 tube guides 22 and float bowl 18 18 float bowl 19 holder screw 20 throttle stop screw holder 21 float bowl screws 22 tube guides 8 ...

Page 139: ... disassembly procedures To install the carburetor reverse the removal procedures Tighten the following parts to the specified torque float bowl screws 1 5 lbf ft 2 1 N m 0 2 kgf m accelerator pump cover screws 1 5 lbf ft 2 1 N m 0 2 kgf m top cover bolts 1 5 lbf ft 2 1 N m 0 2 kgf m throttle drum cover bolt 2 5 lbf ft 3 4 N m 0 3 kgf m hot start cable nut 1 5 lbf ft 2 1 N m 0 2 kgf m shock absorbe...

Page 140: ... Speed Adjustment 1 If the engine is cold start it and warm it up three minutes Then shut it off 2 Connect a tachometer to the engine 3 Shift into neutral Start the engine 4 Keep the motorcycle in an upright position 5 Adjust idle speed with the throttle stop screw 1 Idle speed 1 700 100 rpm 1 throttle stop screw 1 ...

Page 141: ...4 in the 90 100 mm range Fork Height Angle Standard Position The position of the outer tubes in the clamps is not adjustable Align the top of the fork tube 1 with the top of the upper fork clamp 2 STANDARD POSITON Wheelbase Adjusting your CRF s wheelbase can offer subtle changes in overall handling You may adjust wheelbase by adding or removing links on the drive chain If you change the wheelbase ...

Page 142: ...he first few races then changes from good to great and back to good and possibly ends the day with a slick rock hard consistency Ideally your gearing should be adjusted to suit all these conditions Wet and slippery or sandy conditions use a higher gear less teeth to keep engine rpm down and avoid unwanted wheelspin The engine may bog in certain corners so you ll need to slip the clutch to compensa...

Page 143: ...y will be less acceptable in other circumstances For example an aggressive mud tire will give excellent grip on wet loamy terrain but less impressive grip on a hard surface If you choose a tire with a sticky compound for added traction remember that it may transfer additional loads to the transmission because it grips so well especially when riding in situations that normally place unusual demands...

Page 144: ...is depressed when sitting or standing comfortably on your CRF Handlebar Position Width Shape Position the handlebar so that both gripping the bar and operating the controls is comfortable while both seated and standing while riding straight ahead and turning Tighten the forward bolts first The handlebar position may be moved rearward either 3 mm using optional handlebar lower holders or 6 mm by ro...

Page 145: ...41 Here s helpful advice on how to transport and store your Honda as well as two troubleshooting flow charts Transporting Your Motorcycle 142 Storing Your Motorcycle 143 You the Environment 145 Troubleshooting 146 ...

Page 146: ...trailer rail Attach the lower ends of two straps to the tie down hooks on your CRF Attach to the upper ends of the straps to the handlebar one on the right side the other on the left close to the fork Check that the tie down straps do not contact any control cables or electrical wiring Tighten both straps until the front suspension is compressed about half way Too much pressure is unnecessary and ...

Page 147: ...y problem before storing it That way needed repairs won t be forgotten and it will be easier to get your CRF running again To reduce or prevent deterioration that can occur during storage also follow the following procedures Preparation for Storage 1 Completely clean all parts of your CRF If your CRF has been exposed to sea air or salt water wash it down with fresh water and wipe dry 2 Change the ...

Page 148: ...e the engine and transmission oil if more than 4 months have passed since the start of storage 2 Uncover the end of the muffler and remove the rag from the muffler outlet 3 Fill the fuel tank with recommended fuel page 41 4 Charge the battery page 101 as required Install the battery 5 Pour a fresh recommended coolant mixture page 48 slowly into the radiator filler hole up to the filler neck Capaci...

Page 149: ...ing solvents away see the following guidelines for proper disposal Recycle Wastes It s illegal and thoughtless to put used engine oil in the trash down a drain or on the ground Used oil gasoline and cleaning solvents contain poisons that can hurt refuse workers and contaminate our drinking water lakes rivers and oceans Before changing your oil make sure you have the proper containers Put oil and o...

Page 150: ...ug p 61 Faulty ignition control module Broken or shorted spark plug wire Faulty exciter coil Broken or shorted ignition coil Faulty engine stop button Loose or disconnected ignition system wires Faulty ignition pulse generator 3 Test cylinder compression NORMAL Valve stuck open Worn cylinder and piston ring Leaking damaged cylinder head gasket Improper valve timing Improper decompressor clearance ...

Page 151: ...Taking Care of the Unexpected Taking Care of the Unexpected 147 This section gives practical advice to help you solve problems If a Fuse Blows 148 If Your Battery is Low or Dead 149 ...

Page 152: ...cover 3 Remove the starter magnetic switch 5 with the rubber case 4 Disconnect the wire connector 6 of the starter magnetic switch 5 Pull out the main fuse 7 If it is blown 8 install the spare main fuse 9 5 starter magnetic switch 6 starter magnetic switch connector 7 main fuse 8 blown fuse 9 spare main fuse 5 Reconnect the wire connector and install the starter magnetic switch If you do not have ...

Page 153: ...mobile battery The greater amperage of an automobile battery when the car engine is running can damage your CRF s electrical system Bump starting is also not recommended If you can t charge the battery or it appears unable to hold a charge see your Honda dealer Taking Care of the Unexpected 149 ...

Page 154: ...150 Taking Care of Unexpected ...

Page 155: ...ains dimensions capacities and other technical data Vehicle Identification 152 Specifications 153 Torque Specifications 155 Emission Control Systems 158 Oxygenated Fuels 159 Competition Logbook 160 Optional Parts List 162 Spare Parts Equipment 163 Wiring Diagram 164 ...

Page 156: ...You may record these numbers in the Quick Reference section at the rear of the manual The VIN vehicle identification number 1 appears on the Safety Certification Label attached to the right side of the frame RIGHT SIDE 1 VIN The frame number 2 is stamped on the right side of the steering head RIGHT SIDE 2 frame number The engine number 3 is stamped on the left crankcase LEFT SIDE 3 engine number 1...

Page 157: ...l filter change After disassembly After disassembly Transmission oil capacity After draining Type Identification number Main jet Jet needle Piston valve FCR04A 142 NCVU Needle clip position Slow jet Pilot screw opening Float level Liquid cooled 4 stroke 2nd groove from top 45 1 1 4 turns out Type Metric 0 67R 0 70R 0 87R 0 65R 0 75R 96 0 x 62 1 mm 8 0 mm Engine Carburetor 12 0 1 Clutch type Transm...

Page 158: ...filter change After disassembly After disassembly Transmission oil capacity After draining Type Identification number Main jet Jet needle Piston valve FCR04A 142 NCVU Needle clip position Slow jet Pilot screw opening Float level Liquid cooled 4 stroke 2nd groove from top 45 1 1 4 turns out Type Metric 0 67R 0 70R 0 87R 0 65R 0 75R 96 0 x 62 1 mm 8 0 mm Engine Carburetor 12 0 1 Clutch type Transmis...

Page 159: ...der head cover bolts Clutch cover bolts Water pump cover bolts Transmission oil check bolt Crankshaft hole cap Oil filter cover bolts Cylinder bolt Cylinder head bolts Exhaust pipe joint nut Drive Sprocket bolt Torque Remarks lbf ft N m kgf m 7 7 7 7 11 9 7 7 15 23 10 10 10 10 15 12 10 10 21 31 1 0 1 0 1 0 1 0 1 5 1 2 1 0 1 0 2 1 3 2 1 UBS nut NOTES NOTE 1 1 9 3 5 4 2 6 8 10 7 ...

Page 160: ... lower Swingarm pivot nut Fork fork damper fork cap Rear shock link nuts swingarm side shock arm side Rear shock arm nuts Shock spring lock nut Kickstarter arm bolt Torque Remarks lbf ft N m kgf m 80 16 15 16 32 65 15 94 20 40 19 40 40 32 32 65 25 22 39 39 39 32 28 108 22 20 22 44 88 20 128 27 54 26 54 54 44 44 88 34 30 53 53 53 44 38 11 0 2 2 2 0 2 2 4 5 9 0 2 0 13 1 2 8 5 5 2 7 5 5 5 5 4 5 4 5 9...

Page 161: ...Seat bolts Front brake reservoir cap screws Rear brake reservoir cap bolts Fork air pressure release screw Side stand mounting bolts upper lower Torque Remarks lbf ft N m kgf m 7 3 25 22 12 12 27 2 7 2 7 9 22 36 9 9 51 16 10 5 2 19 19 15 24 19 0 7 0 7 0 9 41 29 9 9 34 30 16 16 36 3 68 3 7 12 30 49 12 12 69 22 13 7 26 26 21 32 26 1 1 1 2 55 39 1 0 3 5 3 1 1 6 1 6 3 7 0 4 0 4 1 2 3 1 5 0 1 2 1 2 7 0...

Page 162: ...omponent which conducts exhaust gases 2 Removal of or puncturing of any part of the intake system 3 Lack of proper maintenance 4 Replacing any moving parts of the vehicle or parts of the exhaust or intake system with parts other those specified by the manufacturer Problems that May Affect Motorcycle Emissions If you are aware of any of the following symptoms have the vehicle inspected and repaired...

Page 163: ...ol MTBE Methyl Tertiary Butyl Ether 15 by Volume You may use gasoline containing up to 15 MTBE by volume METHANOL methyl or wood alcohol 5 by Volume You may use gasoline containing methanol containing up to 15 methanol by volume as long as it contains cosolvents and corrosion inhibitors to protect the fuel system Gasoline containing more than 5 methanol by volume may cause starting and or performa...

Page 164: ...ne running time on suspension components Timekeeping This Manual lists maintenance intervals for every so many races or every so many hours of running Because all races are not the same the most effective way to schedule maintenance is by the hours you have run your CRF An official guestimate is close enough for our timekeeping purposes You may choose to record your time the same way aircraft oper...

Page 165: ...cal Information 161 Date Running Location Event Comments Suspension Settings Gearing Chassis Adjustments Maintenance Time Performed etc Make several photocopies of this page for future use Competition Logbook ...

Page 166: ...t parts or 296 8 lbf in 5 30 kgf mm 26 32 lbf in 0 47 kgf mm 25 20 lbf in 0 45 kgf mm 27 44 lbf in 0 49 kgf mm FRAME Remarks Driven sprocket Standard Drive chain links 51 Teeth Aluminum 114 Optional 50 Teeth Aluminum 114 Optional no offset 52 Teeth Aluminum 116 Handlebar lower holder Standard 3 mm offset Red Blue 319 2 lbf in 5 70 kgf mm 330 4 lbf in 5 90 kgf mm Pink Silver These parts and tools m...

Page 167: ...wrench metric scale click stop style pliers standard needle nose channel lock set hammer plastic head syringe with adjustable stop tire pressure gauge tire irons tire pump or air tank feeler gauge set vernier caliper metric pressure vacuum testing equipment USA only Honda Special Tools Any special tools for your CRF purchased from your Honda dealer Clutch Center Holder 07724 0050001 or 07724 00500...

Page 168: ...164 Technical Information Wiring Diagram ...

Page 169: ...Consumer Information This section contains information about contacting Honda and how to get an official Honda service manual Authorized Manuals 166 Contacting Honda 167 Your Honda Dealer 168 The Honda Rider s Club USA only 169 ...

Page 170: ...m USA only Canada See your Honda dealer to order authorized manuals Authorized Manuals Publication Item No Description Price Each 61MEY00 2005 CRF450X Service Manual 48 00 61CM002 Common Manual 48 00 31MEY600 2005 CRF450X Owner s Manual 16 00 Prices are subject to change without notice and without incurring obligation Prices are subject to change without notice and without incurring obligation Ord...

Page 171: ...es at the dealership level If you wish to comment on your experiences with your Honda or with your dealer please send your comments to the following address USA only Motorcycle Division American Honda Motor Co Inc P O Box 2220 Torrance CA 90509 2220 mailstop 100 4W 5B telephone 866 784 1870 Canada Refer to the warrantly booklet that was supplied with your vehicle Please include the following infor...

Page 172: ...ondaline accessories USA only and Honda accessories and products Canada only The same quality that went into your Honda can be found in Genuine Honda replacement parts You ll also find comparable quality in the accessories and products available from the parts department Your dealer can inform you about competition events in your area You ll also find that your dealer is a source of information US...

Page 173: ...long as your Honda is aboard or in tow Vehicle transport to the nearest Honda dealer or service center if necessary An exclusive HRCA website complete with access to the official Honda Common Service Manual contests insider information and more Reimbursement up to 75 for Motorcycle Safety Foundation training Separate free training from the Speialty Vehicle Institute of America for ATV owners One f...

Page 174: ...t Removal 36 Fuel Tank Removal 37 Subframe Upright Position 39 Service Procedures Fluids Filters Fuel System 41 Engine Oil 43 Transmission Oil 46 Coolant 48 Air Cleaner 51 Crankcase Breather 53 Engine Throttle 54 Clutch System 56 Hot Start Lever 60 Spark Plug 61 Exhaust Pipe Muffler 62 Spark Arrester 65 Valve Clearance 66 Piston Piston Rings Piston Pin 75 Chassis Suspension 83 Brakes 87 Wheels 91 ...

Page 175: ...rol Systems 158 Oxygenated Fuels 159 Competition Logbook 160 Optional Parts List 162 Spare Parts Equipment 163 Wiring Diagram 164 Consumer Information 165 Authorized Manuals 166 Contacting Honda 167 Your Honda Dealer 168 The Honda Rider s Club USA only 169 Table of Contents 170 Index 172 Quick Reference 176 Table of Contents 171 ...

Page 176: ...95 chassis adjustment for track conditions 137 choke knob 15 cleaner air 51 cleaning appearance care 104 clutch system adjustment 56 consumer information 165 controls operating 7 component locations maintenance 35 operating controls 8 competition logbook 161 contacting Honda 167 controls operating 8 coolant 48 customer service 168 cylinder system 77 damping adjustments front 108 rear 123 dealer yo...

Page 177: ...2 oxygenated fuels 159 pads brake 90 parts optional 162 personal fit adjustments 140 pinging engine 41 plug spark 61 pre load rear suspension 122 pre ride inspection 11 protective apparel 2 rear suspension maintenance 84 Rider s Club Honda 169 riding apparel 2 basic operation 13 before 9 important safety information 2 safety precautions 2 safety a few words about Safety Messages important informat...

Page 178: ...ransmission oil 46 tuning tips 130 throttle freeplay 54 inspection 55 tires air pressure 92 flat 92 selection 93 tools 163 torque specifications 155 157 transporting 142 troubleshooting 146 tubes replacing 92 valve fuel 15 vehicle identification 152 washing your motorcycle 104 weight limit 3 wheels 91 writing diagram 164 W V T ...

Page 179: ...Memo 175 ...

Page 180: ...m2 standard IFR8H11 NGK or VK24PRZ11 DENSO optional IFR9H11 NGK or VK27PRZ11 DENSO D I D 520MXV Maintenance Pre ride Inspection Fuel Capacity Engine oil Transmission oil Tires Tire Pressure cold Spark Plug Drive Chain Quick Reference Record important information here Frame No Engine No Owner s Name Address City State Phone Dealer s Name Address City State Phone Service Mgr The following is a brief...

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