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Honda CRF450R 2020, Owner'S Manual & Competition Handbook

The Honda CRF450R 2020 offers superior performance on the dirt track. With its cutting-edge technology and powerful engine, this motocross beast is a force to be reckoned with. Ensure optimal maintenance and safety with our comprehensive Owner's Manual & Competition Handbook, available for download free at manualshive.com.

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Wiring Diagram

Technical Information

183

Wiring Diagram

WPC

24P

A-33

A-32

A-31

A-30

A-29

A-28

A-27

A-26

A-25

A-24

A-23

A-22

A-21

A-20

A-19

A-18

A-17

A-16

A-15

A-14

A-13

A-12

A-1

1

A-10

A-9

A-8

A-7

A-6

A-5

A-4

A-3

A-2

A-1

LG

SCS

PCP

PCM

PG2

TW

TA

SG

GP

TH

HSTC SW

VCC

IG

FLP

ST

AR

TER RL

Y

ST

AR

T

 SW

PG1

MAP

 MODE IND

INJ MAIN

IGP

PRC

HSTC IND

W

ARN

PB

K-LINE

ENG ST

OP

 SW

MAP

 MODE SW

ST

 MODE SW

WPC

33P

Bl

WPC

4P

Bl

10A

CHARGE

CHARGE

CHARGE

-

+

6P

WPC

3P
Bu

WPC

2P

Bl

WPC

2P

Bl

VCC

GND

V OUT

WPC

3P

Bl

WPC

2P
Gr

E

IG

E

IG

WPC

8P
Gr

WPC

6P

Bl

WPC

2P

Bl

+

-

WPC

5P

WPC

4P

R

E

IG

E

IG

E

IG

WPC

6P

Bl

1

N

2

3

4

5

WPC

2P

Bl

FREE

E

IG

PUSH

COLOR Bl/W    Bl/Y

FREE

E

IG

PUSH

COLOR

G

Bl

FREE

E

IG

PUSH

COLOR

W

G

FREE

E

IG

PUSH

COLOR

Lg

G

FREE

E

IG

PUSH

COLOR

G

V

COLOR COMB : GROUND/MARKING

Be

Beige

Bl

Black

Y

Yellow

V

Violet

Bu

Blue

G

Green

R

Red

Sb

Sky blue
White

W

Br

Brown

O

Orange

Lg

Light Green

P

Pink

Gr

Gray

WPC

6P

W

JUNCTION CONNECTOR

GP SENSOR

RESISTOR

RESISTOR

LED
ORANGE

LED
BLUE

ENGINE MODE
SELECT SWITCH

ENGINE STOP
SWITCH

STARTER
SWITCH

CLUTCH
SWITCH

DLC

FUEL
PUMP

ECM

FUEL
INJECTOR

GROUND

IGNITION COIL

SPARK PLUG

ALTERNATOR

CKP SENSOR

IAT
SENSOR

ECT
SENSOR

MAP
SENSOR

TP
SENSOR

REGULATOR/
RECTIFIER

STARTER
RELAY
SWITCH

STARTER
RELAY

DIODE

STARTER
MOTOR

MAIN
RELAY

RESISTOR

RESISTOR

ENGINE MODE
SELECT SWITCH

TORQUE CONTROL
SWITCH

ENGINE STOP
SWITCH

STARTER SWITCH

CLUTCH SWITCH

BATTERY

RESISTOR

LED

TORQUE
CONTROL
SWITCH

Bl/G

Y/Bl

G/Bl

R/W

W/Bl

Bl/Y

Bl

Y

Y Y

G

G

R/W

Bl/G

G

Sb

R

G

Y

R

G

Gr

G

P

G/R

W/Y

Bu/Y

Y/Bu

Bu/Y

G

G

G

G

G

G

WW

Be

Be

W

Lg

G

Lg

Bu

Bu

Bl

W

Be

G

Lg

Bu

Bl

G

G/W

Y

Y

Y

W/Y

Bu/Y

Y

Y

Y

P

Bl

Bl

Bl

Bl

G

Bl

Bl

G

Bl

W

Br

O/Bl

W

G/W

Bl/W

G/Bl

Br

Sb

O/Bl

W/Y

Bu/Y

G

P

Gr

Br

G

Y/Bu

W

Y/Bl

Y

R

G

Bu

P

W/Bl

Bl

Be

Lg

Bl/W

Bl/G

Bl/W

Bl/Y

Bl/W

Bl/W

Bl/G

G/Bl

Bl

V

G

Gr

Bl

V

G

Gr

Bl

V

G

Gr

G/R

Gr

G

G

G

G

R

R

R

Bl

Bl

Bl

Bl

Bl

Bl

Bl

Bl

Br

G

B

Br

G

V

Summary of Contents for CRF450R 2020

Page 1: ...NG YOUR HONDA 21 Before You Service Your Honda The Importance of Maintenance 22 Maintenance Safety 23 Important Safety Precautions 23 Maintenance Schedule 24 Maintenance Schedule CRF450RX 25 Maintenance Schedule CRF450R RWE 26 General Competition Maintenance 27 Before After Competition Maintenance 31 Between Races CRF450RX Motos CRF450R RWE Practice Maintenance 31 After Competition Maintenance 32 ...

Page 2: ...ase 156 Gearing 157 Tire Selection for Track Conditions 158 Personal Fit Adjustments 159 Control Positioning 159 Handlebar Position Width Shape 159 TIPS 161 Transporting Your Motorcycle 162 Storing Your Honda 163 Preparation for Storage 163 Removal from Storage 163 You the Environment 164 Troubleshooting 165 TAKING CARE OF THE UNEXPECTED 167 If a Fuse Blows 168 If Your Battery Is Low or Dead 169 T...

Page 3: ...2020 Honda CRF450RX CRF450R CRF450RWE OWNER S MANUAL COMPETITION HANDBOOK ...

Page 4: ...g of each section and an index at the back of the book As you read this manual you will find information that is preceded by a symbol This information is intended to help you avoid damage to your CRF other property or the environment Unless you are mechanically qualified and have the proper tools you should see your dealer for the service and adjustment procedures discussed in this manual An offic...

Page 5: ...ages throughout the manual Safety Messages are preceded by a safety alert symbol and one of three signal words DANGER WARNING or CAUTION These signal words mean Of course it is not practical or possible to warn you about all hazards associated with operating or maintaining a motorcycle You must use your own good judgment You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN...

Page 6: ...t information and recommendations 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 Precautions 2 Accessories Modifications 3 Safety Labels 4 ...

Page 7: ...how this one operates and responds to your commands before placing your machine and yourself in competition Learn and Respect Your Limits Never ride beyond your personal abilities or faster than conditions warrant Remember that alcohol drugs illness and fatigue can reduce your ability to perform well and ride safety Don t Drink and Ride Alcohol and riding don t mix Even one drink can reduce your a...

Page 8: ...ny way that would change its design or operation could seriously impair your CRF s handling stability and braking making it unsafe to ride Accessories Modifications WARNING Improper accessories or modifications can cause a crash in which you can be seriously hurt or killed Follow all instructions in this owner s manual regarding modifications and accessories ...

Page 9: ...Safety Labels 4 Motorcycle Safety Read these labels carefully and don t remove them If a label comes off or becomes hard to read contact your dealer for replacement For Canada Safety Labels ...

Page 10: ...of the basic controls on your CRF Operation Component Locations 6 MIL Malfunction Indicator Lamp 7 MIL Blink Pattern 7 Current DTC Freeze DTC 7 Circuit Inspection 8 DTC Index 9 Engine Mode Launch Control System Indicator Torque Control Indicator 10 Engine Mode Indicator 10 Launch Control System Indicator 10 Torque Control Indicator 10 ...

Page 11: ...ver clutch lever engine mode select button engine stop button MIL amber Engine mode indicator blue Launch control system indicator purple start button throttle grip Torque Control button Torque Control indicator green shift lever fast idle knob engine idle speed side stand CRF450RX rear brake pedal ...

Page 12: ...nds the short blinking lasts for 0 4 seconds One long blink is the equivalent of 10 short blinks For example when one long blink is followed by two short blinks the MIL is 12 one long blink 10 blinks plus two short blinks When the ECM stores more than one DTC the MIL will indicate them by blinking in the order from the lowest number to highest number The DTC is indicated in two ways according to t...

Page 13: ...lated to poorly connected or corroded connections Check the following connections Remember circuit inspection is not a cure all for other problems in your engine s PGM FI system Circuit Inspection 1 MAP sensor connector 2 ECT sensor connector 3 TP sensor connector 4 IAT sensor connector 5 Injector connector 6 CKP sensor connector 7 ECM connector 8 GP sensor connector 3 4 2 6 1 5 7 8 ...

Page 14: ...ual page 186 for troubleshooting of the PGM FI symptom DTC Index MIL blinks Function Failure Symptom Fail safe function 1 MAP sensor circuit malfunction Poor performance driveability 2 MAP sensor performance problem Poor performance driveability 7 ECT sensor circuit malfunction Hard start at a low temperature 8 TP sensor circuit malfunction Poor engine acceleration 9 IAT sensor circuit malfunction...

Page 15: ...to standby The launch control system indicator purple comes on while the system is operating If the launch control system indicator does not come on when it should have your dealer check it for problems The Torque Control indicator green 1 is located to the right side of the Torque Control button 2 on the left side of the handlebar Torque Control indicator green indicates the currently selected mo...

Page 16: ...re both ready to ride To 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 and other adjustments see page 139 Are You Ready to Ride 12 Is Your Motorcycle Ready to Ride 13 Pre ride Inspection 13 ...

Page 17: ...n and other adjustments see page 139 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 we...

Page 18: ...operation 71 Tires for damage or improper inflation pressure 119 Spokes for looseness 118 Rim locks for looseness 118 Front and rear suspension for proper operation 97 113 Front and rear brakes check operation 114 Drive chain for correct slack and adequate lubrication 122 123 Drive chain sliders and drive chain rollers for damage or wear 122 123 Exhaust pipe Muffler for looseness 126 Every possibl...

Page 19: ...14 Before Riding BLANK PAGE ...

Page 20: ...formation on how to start and stop your engine as well as break in guidelines Safe Riding Precautions 16 Side Stand CRF450RX 16 Honda Selectable Torque Control 16 Starting Stopping the Engine 17 Fast Idle Knob 17 Preparation 17 Starting Procedure 17 How to Stop the Engine 18 Parking CRF450RX 19 Break in Guidelines 20 ...

Page 21: ...he Torque Control level selected Rear wheel spin during acceleration is reduced at the higher Torque Control level setting Select a level that is appropriate for your skill and riding conditions Torque Control does not work during deceleration and will not prevent the rear wheel from skidding due to engine braking Do not close the throttle suddenly especially when riding on slippery surfaces Torqu...

Page 22: ...d Adjustment on page 72 Make sure that the transmission is in neutral Always follow the proper starting procedure described as follows Check the engine oil and coolant levels before starting the engine pages 63 65 Cold Engine Starting 1 Shift the transmission into neutral 2 If the temperature is 50 F 10 C or below pull the fast idle knob 1 fully up 3 With the throttle closed Pull the clutch lever ...

Page 23: ...ottle Snapping the throttle or fast idling for more than about 5 minutes may cause exhaust pipe and muffler discolorations When starting the engine the MIL amber will stay on for 2 seconds then go off And then the engine mode indicator blue indicates the current engine mode for 0 8 seconds then goes off If the MIL engine mode indicator 1 does not come on or go off when it should have your dealer c...

Page 24: ...Parking CRF450RX Basic Operating Instructions 19 Parking CRF450RX Lower the side stand to support your CRF Always choose a level surface to park ...

Page 25: ...ance by paying 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: ...department Before You Service Your Honda The Importance of Maintenance 22 Maintenance Safety 23 Important Safety Precautions 23 Maintenance Schedule 24 General Competition Maintenance 27 Before After Competition Maintenance 31 Between Races CRF450RX Motos CRF450R RWE Practice Maintenance 31 After Competition Maintenance 32 Service Preparations Maintenance Component Locations 33 Seat 34 Fuel Tank C...

Page 27: ...e are especially important because your CRF is designed to be ridden in off road competition Remember proper maintenance is your responsibility Be sure to inspect your CRF before each ride and follow the Maintenance Schedule in this section WARNING Improperly maintaining this motorcycle or failing to correct a problem before you ride can cause a crash in which you can be seriously hurt or killed A...

Page 28: ... 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 CRF450RX an optional workstand or a maintenance stand to provide support To reduce the poss...

Page 29: ... avoid overlooking required service we urge you to develop a convenient way to record the number of races CRF450RX motos CRF450R RWE and or hours 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 Honda Genuine Parts or...

Page 30: ... about 3 5 hours Every 2 races or about 7 5 hours Every 4 races or about 15 0 hours Every 6 races or about 22 5 hours Every 8 races or about 30 0 hours Ref Page FUEL LINE NOTE 6 I R 42 FUEL PUMP FILTER NOTE 6 R 46 51 THROTTLE OPERATION I 71 AIR FILTER NOTE 1 C 67 68 CRANKCASE BREATHER I 69 SPARK PLUG I 78 VALVE CLEARANCE DECOMPRESSOR SYSTEM NOTE 4 I 79 87 ENGINE OIL NOTE 3 NOTE 5 I R 63 ENGINE OIL...

Page 31: ...ch race or about 2 5 hours Every 3 races or about 7 5 hours Every 6 races or about 15 0 hours Every 9 races or about 22 5 hours Every 12 races or about 30 0 hours Ref Page FUEL LINE NOTE 6 I R 52 FUEL PUMP FILTER NOTE 6 R 52 61 THROTTLE OPERATION I 71 AIR FILTER NOTE 1 C 67 68 CRANKCASE BREATHER I 69 SPARK PLUG I 78 VALVE CLEARANCE DECOMPRESSOR SYSTEM NOTE 4 I 79 87 ENGINE OIL NOTE 3 NOTE 5 I R 63...

Page 32: ...rn Use Honda Genuine Parts or their equivalents when servicing your CRF Clean parts in non flammable high flash point cleaning solvent such as kerosene when disassembling Lubricate any sliding surfaces 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 w...

Page 33: ...e serviced air cleaner between races CRF450RX motos CRF450R RWE Be careful not to over oil the air cleaner While it is important to oil the air cleaner thoroughly over oiling will cause an overall rich running condition probably more noticeable off idle and in low rpm performance Follow the servicing instructions in the Maintenance section Use Pro Honda Foam Air Filter Oil or an equivalent Be sure...

Page 34: ... as part of your overall competition maintenance program Periodically inspect the frame closely for possible cracking or other damage It makes good racing sense Cylinder head Cylinder Put a little grease on the dowel pins of the cylinder head and cylinder to prevent corrosion from dissimilar metals The tolerances are quite tight so it s important to keep these dowels absolutely clean pages 93 94 E...

Page 35: ...ake sure that there is no continuous coolant leakage from the bleed hole while operating the engine A small amount of coolant weeping from the bleed hole is normal See an official Honda Service Manual or consult your dealer for replacing the mechanical seal or oil seal Both seals should be replaced at the same time Suspension Linkage Lubrication Disassemble clean inspect and lubricate all suspensi...

Page 36: ...h a stiff nylon parts cleaning brush Lubricate and adjust the chain as necessary Do not perform maintenance while engine is running Injury to your fingers or hands may result After adjustment check that the chain adjuster index marks 1 are in the same position on each side This will ensure that the rear wheel is in proper alignment and allow maximum performance from the rear disc brake Maintaining...

Page 37: ...et Remove the drive chain clean and lubricate it pages 123 124 Be sure the chain is wiped clean and is dry before lubricating the chain Routine Cleaning If your CRF is only slightly dirty it is best to clean it by hand with the aid of a stiff bristled nylon brush and some clean rags Take care to prevent catching your fingers between the chain and sprocket A variety of reasonably priced cleaning br...

Page 38: ... adjuster rear suspension low speed compression damping adjuster front suspension compression damping adjuster both left and right fast idle knob engine idle speed engine oil filter crankcase breather tube drive chain front brake caliper engine oil fill cap air cleaner rear suspension spring pre load adjuster spark plug engine oil drain bolt rear brake pedal rear brake fluid reservoir rear brake c...

Page 39: ...eat while aligning the seat front prong 1 with the slot 2 of the fuel tank and seat center prongs 3 with the seat support base slots 4 2 Install and tighten the collars 5 and seat mounting bolts 6 to the specified torque 19 lbf ft 26 N m 2 7 kgf m 1 seat mounting bolts 3 seat 2 collars 3 1 1 2 1 seat front prong 4 seat support base slots 2 slot 5 collars 3 seat center prongs 6 seat mounting bolts ...

Page 40: ... bolt 10 and collar 11 7 Unhook the fuel tank band 12 8 Lift the fuel tank 13 out of the frame and hang it to the left of the frame Check the fuel tank stopper cable 14 for deterioration kinks or other damage Do not support the fuel tank by the fuel feed hose 15 1 shroud A bolt 2 shroud B bolt 3 shroud C bolt 4 shroud D bolt 5 shroud 6 air cleaner housing cover 6 3 2 1 5 4 7 hose clamp 9 steering ...

Page 41: ...ab 9 and the slot 10 on the air cleaner housing cover 11 is aligned 7 Install the shroud D bolt 12 shroud C bolt 13 shroud B bolt 14 and shroud A bolt 15 Tighten the shroud A and B bolts to the specified torque 7 lbf ft 10 N m 1 0 kgf m Tighten the shroud C and D bolts to the specified torque 3 8 lbf ft 5 2 N m 0 5 kgf m The right and left shrouds can be installed in the same manner 8 Install the ...

Page 42: ...er cable 12 for deterioration kinks or other damage Do not support the fuel tank by the fuel feed hose 13 The fuel tank is made of titanium material Since the fuel tank has not been painted it might be discolored with mud and dust To remove mud or dust use a sponge or soft cloth and a stainless steel kitchen detergent then rinse well clean water After washing rinse with plenty of water and dry wit...

Page 43: ...amp 6 from the breather tube 5 Slide the shroud 7 toward the down so that the shroud tab 8 and the slot 9 on the air cleaner housing cover 10 is aligned 6 Install the shroud C bolt 11 B bolt 12 and shroud A bolt 13 Tighten the shroud A and B bolts to the specified torque 7 lbf ft 10 N m 1 0 kgf m Tighten the shroud C bolt to the specified torque 3 8 lbf ft 5 2 N m 0 5 kgf m The right and left shro...

Page 44: ...Loosen the air cleaner connecting tube clamp screw 8 9 Disconnect the negative terminal 9 from the battery 10 10 Remove the start magnetic switch stay bolt 11 and plastic wire band 12 Pull out the start magnetic switch 13 Remove the start magnetic switch cover 14 Remove the battery cable terminal bolt 15 and disconnect the battery cable terminal 16 from the start magnetic switch 1 seat support bas...

Page 45: ...ttery cable terminal 5 to the start magnetic switch 6 Install and tighten the battery cable terminal bolt 7 to the specified torque 5 2 lbf ft 7 N m 0 7 kgf m Install the start magnetic switch cover 8 Install the start magnetic switch Install and tighten the start magnetic switch stay bolt 9 to the specified torque 9 lbf ft 12 N m 1 2 kgf m Install the plastic wire band 10 5 subframe 17 subframe l...

Page 46: ...tall the seat support base 18 8 Install and tighten the collars 19 and seat support base mounting bolts 20 to the specified torque 7 lbf ft 10 N m 1 0 kgf m 9 Tighten the right and left muffler mounting A bolts and install the right and left exhaust springs A page 133 CRF450RWE only 10 Install the left and right mufflers page 127 11 Install the right and left shrouds page 36 page 38 12 Install the...

Page 47: ...nk 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 4 Fuel Tank Capacity 2 25 US gal 8 5 ℓ Be careful not to damage the fuel pump while filling the fuel tank Avoid overfilling the tank There should be no fuel in the filler neck 3 Close the fuel...

Page 48: ...de of the frame 3 Remove the fuel quick connect fitting cover 1 from the fuel pump 2 4 Check the fuel quick connect fitting 3 for dirt and clean if necessary 5 Remove the bolt 4 clamp and setting rubber 5 6 Place a shop towel 6 over the fuel quick connect fitting Fuel Pressure Relieving 1 fuel pump connector 1 Fuel Line Replacement 1 fuel quick connect fitting cover 2 fuel pump 3 fuel quick connec...

Page 49: ...ith plastic bags 12 Connection 1 Install the rubber cover 1 onto the fuel joint 2 of the fuel pump as shown 2 Be sure that the slide retainer 3 is completely pulled up before connecting the quick connect fitting Do not bend or twist the fuel feed hose Do not reuse the kinked or damaged fuel hose Do not use gloves or a shop towel while installing the quick connect fitting WARNING Gasoline is highly...

Page 50: ...d into place check visually and by pulling the connector housing 5 Install the setting rubber 5 clamp 6 and bolt 7 by aligning the clamp tab 8 with the groove 9 of the stay Tighten the bolt securely 6 Install the fuel quick connect fitting cover 10 Be sure the rubber cover 1 is properly installed between the fuel quick connect fitting cover and fuel pump 7 Increase the fuel pressure page 51 2 fuel...

Page 51: ...while pressing both side of the anchor and disconnect it 5 Remove the fuel pump mounting bolts 5 stopper cable guide 6 stopper cable 2 washers 7 collars 8 conical spring washers 9 and fuel pump plate 10 while holding the fuel tank Fuel Pump Filter Replacement WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Stop the engine and keep heat s...

Page 52: ...unit as an assembly 9 Release the hooks of the fuel pump unit holder from the grooves 17 in the fuel pump base tabs while pushing the holder against the base and slightly spreading the base tabs Be careful not to damage the hooks and tabs 10 Remove the fuel pump unit holder assembly 18 from the fuel pump base 14 and remove the O ring 19 Wipe the spilled out fuel immediately 11 Remove the fuel pump...

Page 53: ...oil to a new O ring 5 Install a new O ring to the fuel pump assembly 2 3 Install the fuel pump assembly with fuel pump filter into the fuel pump unit holder 6 while routing the fuel pump red 7 and black 8 wires through the holder grooves 9 as shown 4 Install a new damper rubber 10 to the fuel pump assembly as shown Install fuel pump stopper 11 22 fuel pump assembly 23 fuel pump filter 24 O ring 25...

Page 54: ...e wires 8 Apply 0 02 oz 0 5 g maximum of engine oil to a new O ring 21 Install a new O ring onto the fuel pump unit 22 9 Apply small amount of engine oil to a new O ring 23 Install a new O ring into the fuel tank groove 10 Install the fuel pump unit 22 into the fuel tank 24 with its hose joint facing forward Be careful not to damage the fuel pump unit 11 Install the fuel pump plate 25 with its ide...

Page 55: ... shown 8 lbf ft 11 N m 1 1 kgf m 14 Install the harness band clip 33 to the stopper cable guide 31 15 Install the stopper cable 30 to the hook 34 of the frame while holding the fuel tank 24 16 Connect the fuel line page 44 17 Increase the fuel pressure page 51 27 conical spring washers 28 collars 29 washers 30 stopper cable 31 stopper cable guide 32 fuel pump mounting bolts 31 29 28 32 27 Fuel tan...

Page 56: ...easing fuel pressure With the throttle closed Pull the clutch lever all the way in and depress the start button The engine will start up with increasing the fuel pressure If the engine does not start check all connector connections and or refer to an official Honda Service Manual page 186 for troubleshooting of the PGM FI symptom Fuel Pressure Increasing ...

Page 57: ... tank 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 4 Fuel Tank Capacity 1 66 US gal 6 3 ℓ Be careful not to damage the fuel pump while filling the fuel tank Avoid overfilling the tank There should be no fuel in the filler neck 3 Close the f...

Page 58: ...side of the frame 3 Remove the fuel quick connect fitting cover 1 from the fuel pump 2 4 Check the fuel quick connect fitting 3 for dirt and clean if necessary 5 Remove the bolt 4 clamp and setting rubber 5 6 Place a shop towel 6 over the fuel quick connect fitting Fuel Pressure Relieving 1 fuel pump connector 1 Fuel Line Replacement 1 fuel quick connect fitting cover 2 fuel pump 3 fuel quick conn...

Page 59: ...with plastic bags 12 Connection 1 Install the rubber cover 1 onto the fuel joint 2 of the fuel pump as shown 2 Be sure that the slide retainer 3 is completely pulled up before connecting the quick connect fitting Do not bend or twist the fuel feed hose Do not reuse the kinked or damaged fuel hose Do not use gloves or a shop towel while installing the quick connect fitting WARNING Gasoline is highl...

Page 60: ...ed into place check visually and by pulling the connector housing 5 Install the setting rubber 5 clamp 6 and bolt 7 by aligning the clamp tab 8 with the groove 9 of the stay Tighten the bolt securely 6 Install the fuel quick connect fitting cover 10 Be sure the rubber cover 1 is properly installed between the fuel quick connect fitting cover and fuel pump 7 Increase the fuel pressure page 61 2 fue...

Page 61: ...the anchor and disconnect it 5 Remove the fuel pump mounting nuts 5 fuel pump mounting cap nut 6 stopper cable guide 7 stopper cable 2 washer 8 collars 9 conical spring washers 10 and fuel pump plate 11 while holding the fuel tank Fuel Pump Filter Replacement WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Stop the engine and keep heat s...

Page 62: ...p unit as an assembly 9 Release the hooks of the fuel pump unit holder from the grooves 19 in the fuel pump base tabs while pushing the holder against the base and slightly spreading the base tabs Be careful not to damage the hooks and tabs 10 Remove the fuel pump unit holder assembly 20 from the fuel pump base 16 and remove the O ring 21 Wipe the spilled out fuel immediately 11 Remove the fuel pu...

Page 63: ... amount of engine oil to a new O ring 5 Install a new O ring to the fuel pump assembly 2 3 Install the fuel pump assembly with fuel pump filter into the fuel pump unit holder 6 while routing the fuel pump yellow 7 and green 8 wires through the holder grooves 9 as shown 4 Install a new damper rubber 10 to the fuel pump assembly as shown Install fuel pump stopper 11 24 fuel pump assembly 25 fuel pum...

Page 64: ...1 by aligning its tabs 22 with the fuel pump unit grooves 23 Check the dust seal lug 24 which is located the index mark 25 of the fuel pump base 13 9 Apply small amount of engine oil to a new O ring 26 Install a new O ring into the between the collar A 27 and collar B 28 of the fuel pump unit 29 10 Install the fuel pump unit 29 into the fuel tank 30 with its hose joint facing forward Be careful no...

Page 65: ...fied torque in the specified sequence as shown 8 lbf ft 11 N m 1 1 kgf m 14 Install the harness band clip 42 to the stopper cable guide 38 15 Install the stopper cable 37 to the hook 43 of the frame while holding the fuel tank 30 16 Connect the fuel line page 54 17 Increase the fuel pressure page 61 24 dust seal lug 31 fuel pump plate 32 fuel pump plate groove 33 fuel pump unit lug 24 32 33 31 31 ...

Page 66: ...reasing fuel pressure With the throttle closed Pull the clutch lever all the way in and depress the start button The engine will start up with increasing the fuel pressure If the engine does not start check all connector connections and or refer to an official Honda Service Manual page 186 for troubleshooting of the PGM FI symptom Fuel Pressure Increasing ...

Page 67: ...ne oils displaying a circular API energy conserving or resource conserving service label on the container They may affect lubrication Other viscosities shown in the following chart may be used when the average temperature in your riding area is within the indicated range JASO T 903 standard The JASO T 903 standard is an index for engine oils for 4 stroke motorcycle engines There are two classes MA...

Page 68: ... or near the lower level mark add the recommended oil until it reaches the upper level mark Do not overfill Reinstall the engine oil fill cap dipstick Repeat steps 1 5 6 Check that the O ring 4 is in good condition and replace it if necessary 7 Reinstall the engine oil fill cap dipstick 1 8 Check for oil leaks 1 Remove the engine guard A bolts washers 1 B bolt washer 2 and engine guard 3 2 Run the...

Page 69: ... spring end then install the spring into a new oil filter 12 Position the spring against the engine crankcase and install a new oil filter with the rubber seal 12 facing out away from the engine You should see the OUT SIDE mark 13 on the filter body near the rubber seal Use a new Honda Genuine oil filter or a filter of equal quality specified for your model If the oil filter is not installed prope...

Page 70: ...eases cooling system performance Higher concentrations of antifreeze up to 60 should only be used to provide additional protection against freezing Check the cooling system frequently during freezing weather Refer to Important Safety Precautions on page 23 1 Position your CRF on an optional workstand or equivalent support so that it is securely held in place in an upright position 2 With the engin...

Page 71: ...placed at the same time 7 Check the radiator air passages for clogging or damage Straighten bent fins 6 and remove insects mud or other obstructions with compressed air or low water pressure Replace the radiator if the air flow is restricted over more than 20 of the radiating surface Radiator should be replaced by your dealer unless you have the proper tools and service data and are mechanically q...

Page 72: ... has very specific performance requirements Use a new Honda Genuine air cleaner specified for your model or an air cleaner of equal quality Using the wrong air cleaner may result in premature engine wear Proper air cleaner maintenance can prevent premature engine wear or damage expensive repairs low engine power poor gas mileage and spark plug fouling Improper or lack of proper air cleaner mainten...

Page 73: ...stall the holder tab in the hole of the air cleaner element 8 Apply 0 05 0 19 oz 1 5 5 5 g of Pro Honda Foam Air Filter Sealer or equivalent to the air cleaner element contact area 9 of the air cleaner housing 9 Install the air cleaner assembly 2 into the air cleaner housing stay 10 with the UP mark tab 11 facing up 10 Carefully position the sealing flange of the element to prevent dirt intrusion ...

Page 74: ... the transparent section of the crankcase breather tube If the breather tube overflows the air filter may become contaminated with engine oil causing poor engine performance 1 Remove the crankcase breather tube plug 1 from the crankcase breather tube 2 by sliding the clip 3 and drain deposits into a suitable container 2 Reinstall the crankcase breather tube plug Draining 1 crankcase breather tube ...

Page 75: ...urn the adjuster all the way in and back out one turn Tighten the lock nut securely Make the adjustment with the lower adjuster Lower Adjustment The lower adjuster is used for major freeplay adjustment such as after replacing the throttle cables or removing the throttle body It is also used if you cannot get the proper adjustment with the upper adjuster 1 Loosen the lock nut 1 2 Turn the adjuster ...

Page 76: ...ulti purpose grease to sliding surface of the throttle cable ends 1 Slide the dust cover 1 2 Remove the throttle housing bolts 2 3 Remove the throttle housing 3 from the throttle pipe 4 4 Thoroughly lubricate the throttle cable ends 5 with multi purpose grease 5 Install the throttle housing then tighten the throttle housing bolts to the specified torque 7 lbf ft 10 N m 1 0 kgf m Align the lugs 6 o...

Page 77: ...e for accurate idle speed adjustment When pushed in the fast idle knob acts as the idle adjustment screw Turning it counterclockwise results in a faster higher idle speed Turning it clockwise results in a slower lower idle speed 1 If the engine is cold start it and warm it up 3 minutes Then shut it off 2 Connect a tachometer to the engine 3 Shift the transmission into neutral Start the engine 4 Ad...

Page 78: ... the cable end adjuster is threaded out near its limit or the correct freeplay cannot be obtained 1 Turn the cable end adjuster in direction until it seats lightly and then turn it out five turns 2 Loosen the lock nut 1 3 Slide the rubber boot 2 off and turn the integral cable adjuster 3 to obtain the specified freeplay 4 Once the specified freeplay has been obtain slide the rubber boot on and tig...

Page 79: ... grease to sliding surface of the clutch cable ends 1 Release the dust cover 1 2 Turn the adjuster 2 and remove the clutch cable 3 3 Disconnect the clutch cable end from the clutch lever 4 4 Thoroughly lubricate the clutch cable end 5 with multi purpose grease 5 Connect the clutch cable end to the lever 6 Install the clutch cable and turn the adjuster 7 Remove the clutch cable end adjuster 6 8 App...

Page 80: ...of the thrust bearing 6 built in clutch lifter with your finger The bearing should turn smoothly and quietly If the operation is not smooth refer to an official Honda Service Manual page 186 for bearing disassembly or see your dealer 7 Remove the seven clutch discs six clutch plates judder spring and spring seat 7 Clutch Disc Plate Removal 1 clutch cover bolts 2 clutch cover 3 clutch spring bolts ...

Page 81: ...ce the clutch spring as a set If you feel the clutch slipping after replacing the clutch disc and plate replace the clutch springs 1 Install the spring seat 1 and judder spring 2 onto the clutch center as shown Coat the clutch discs with engine oil 2 Install the clutch disc A larger I D disc 3 onto the clutch outer Stack the six clutch plates 4 five clutch discs B 5 alternately while aligning the ...

Page 82: ...d torque 9 lbf ft 12 N m 1 2 kgf m 7 Apply engine oil to a new O ring 13 and install it in the groove of the clutch cover 14 8 Install the cover by tightening the six cover bolts in a crisscross pattern in two or three steps to the specified torque 7 lbf ft 10 N m 1 0 kgf m 9 Fill the crankcase with the recommended oil page 63 9 clutch lifter 10 clutch lifter rod 11 clutch pressure plate 12 clutch...

Page 83: ...f the gap is out of specifications replace the plug with a new one The recommended spark plug gap is 0 031 0 035 in 0 8 0 9 mm 7 To obtain accurate spark plug readings accelerate up to speed on a straightaway Press and hold the engine stop button and disengage the clutch by pulling the lever in Coast to a stop then remove and inspect the spark plug The porcelain insulator around the center electro...

Page 84: ...e should be performed while the engine is cold The valve clearance will change as engine temperature rises Before inspection clean the engine thoroughly to keep dirt from entering the engine 1 Remove the seat and hang the fuel tank to the left of the frame pages 34 35 37 2 Disconnect the breather tube 1 and spark plug cap 2 3 Remove the cylinder head cover socket bolts 3 rubber seals 4 cylinder he...

Page 85: ... clockwise again and align the T mark with the index mark Make sure that the decompressor weight 5 is upper position 5 Check the timing marks 6 on the cam sprocket aligns with the camshaft holder mating surface 7 of the cylinder head 6 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 determi...

Page 86: ...lve clearance and exhaust valve clearance need adjustment see Camshaft Removal this page and select the correct shim for each valve 1 Make sure the piston is at TDC on the compression stroke page 80 Record the intake valve and exhaust valve clearances this page 2 Remove the cam chain tensioner lifter cover bolt 1 and sealing washer 2 Valve Clearance Inspection 1 feeler gauge 3 camshaft cam lobes 2...

Page 87: ...aft holder 7 and set rings 8 As you remove the camshaft holder set rings may be sticking in the camshaft holder Do not let the set rings fall into the crankcase If the set rings are remained on the camshaft holder remove the set rings carefully 5 Slide the left camshaft bearing 9 and remove the camshaft 10 by removing the cam chain 11 Suspend the cam chain with a piece of wire to prevent the chain...

Page 88: ...he 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 a micrometer Reface the exhaust valve seat if carbon deposits result in a calculated dimension of over 3 000 mm Do not lap the intake valves They are titanium and have a thin oxide ...

Page 89: ...e oil a mixture of 1 2 engine oil and 1 2 molybdenum disulfide grease containing more than 3 molybdenum disulfide additive Moly Paste 77 to the following parts camshaft cam lobes plunger whole surface 5 Install the camshaft 6 onto the cylinder head with the decompressor weight 5 facing up as illustrated below 6 Install the cam chain 7 over the cam sprocket 8 While holding the left camshaft bearing...

Page 90: ...a crisscross pattern in two or three steps 11 Remove the tensioner stopper 21 from the cam chain tensioner lifter 12 Make sure that the piston is at TDC on the compression stroke page 80 Check that the timing mark 11 on the cam sprocket aligns with the camshaft holder mating surface 12 of the cylinder head If the timing mark doesn t align with the camshaft holder mating surface insert the tensione...

Page 91: ...6 and tighten the cam chain tensioner lifter cover bolt 27 1 Install the spark plug page 78 2 Coat a new O ring 1 with engine oil and install it onto the crankshaft hole cap 2 Apply grease to the crankshaft hole cap threads Install and tighten the crankshaft hole cap to the specified torque 11 lbf ft 15 N m 1 5 kgf m 22 T mark 23 primary drive gear 24 index mark 23 24 22 IN 0 005 0 001 in 0 13 0 0...

Page 92: ...cover groove 3 Check that the rubber seals 5 are in good condition replace them if necessary Install the rubber seals onto the cylinder head cover with the UP marks 6 facing up 4 Install the cylinder head cover 2 and tighten the cylinder head cover socket bolts 7 to the specified torque 7 lbf ft 10 N m 1 0 kgf m 5 Connect the spark plug cap 8 and breather tube 9 6 Install the fuel tank and seat pa...

Page 93: ... the camshaft holder camshaft and shims page 81 11 Disconnect the ignition coil A connector 1 and B connector 2 Remove the ignition coil 3 by removing the ignition coil bolts 4 12 Disconnect the ECT sensor connector 5 13 Loosen the radiator hose clamp screw 6 and disconnect the radiator hose 7 14 Remove the right radiator lower mounting bolt 8 and washer 9 15 Loosen the insulator band screw 10 and...

Page 94: ... steps Do not let the washers and cam chain fall into the crankcase 19 Remove the dowel pins 20 and cylinder head gasket 21 Do not let the dowel pins and cam chain fall into the crankcase 20 Remove the cam chain guide 22 from the cylinder 23 13 cylinder head hanger bolts 14 cylinder head hanger plate bolts 15 left cylinder head hanger plate 16 right cylinder head hanger plate 14 13 15 Left side Ri...

Page 95: ...piston 4 and remove the piston CRF450RX Under racing conditions the piston rings and piston pin should be replaced every 4 races or about every 15 0 hours of running CRF450R RWE Under racing conditions the piston rings and piston pin should be replaced every 6 races or about every 15 0 hours of running Be careful not to damage or shock the piston pin Do not clean the piston pin using a commerciall...

Page 96: ...ide rails 2 to the piston 3 4 Install the top ring 4 to the piston with 1R mark 5 side facing up Do not damage the piston ring by spreading the ends too far Do not damage the piston during piston ring installation 5 After installing the piston 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 d...

Page 97: ...Apply molybdenum disulfide oil a mixture of 1 2 engine oil and 1 2 molybdenum disulfide grease containing more than 3 molybdenum disulfide additive Moly Paste 77 to the piston pin 6 outer surface Apply engine oil to the piston outer surface and piston pin hole inner surface Install the piston pin and new piston pin clips 7 Be careful not to damage or shock the piston pin Use new pin clips Never re...

Page 98: ...nd a new cylinder gasket 3 Do not let the dowel pins fall into the crankcase 5 Apply engine oil to the cylinder bore 4 piston outer surface and piston rings 5 Route the cam chain 6 through the cylinder Install the cylinder over the piston rings by hand while compressing the piston rings Do not damage the piston rings and cylinder bore Do not let the cam chain fall into the crankcase Cylinder Insta...

Page 99: ...Do not damage mating surfaces when installing the cylinder head 5 Apply engine oil to all cylinder head bolt threads and seating surface Install the washers and cylinder head bolts 7 and tighten them to the specified torque in a crisscross pattern in two or three steps 37 lbf ft 50 N m 5 1 kgf m Do not let the washers fall into the crankcase 6 Install the cylinder bolt 8 and tighten it to the spec...

Page 100: ...insulator and tighten the insulator band screw 15 so the distance between the band ends is 0 43 0 04 in 11 0 1 0 mm 9 Install and tighten the washer 16 and right radiator lower mounting bolt 17 securely 10 Connect the radiator hose 18 to the water hose joint 19 of the cylinder head as shown 11 Tighten the radiator hose clamp screw 20 as illustrated below 9 left cylinder head hanger plate 10 right ...

Page 101: ...t hole cap page 86 16 Install the cylinder head cover page 87 17 Install the spark plug page 78 18 Install the exhaust pipe page 129 19 Install the subframe page 40 and left and right mufflers page 127 20 Install the fuel tank and seat pages 34 36 38 21 Fill and bleed the cooling system page 163 Check for the following compression leaks abnormal engine noise secondary air leaks exhaust gas leaks c...

Page 102: ... your CRF s front suspension Periodically 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 Guidelines page 152 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 th...

Page 103: ...Remove the bolts 4 and number plate 5 2 Place your CRF on an optional workstand or equivalent support with the front wheel off the ground 3 Remove the handlebar protector handlebar upper holder bolts 6 handlebar upper holders 7 and handlebar 8 Keep the master cylinder upright to prevent air from entering system 4 Loosen the fork bridge upper pinch bolts 9 5 Loosen the fork bolts assembly 10 but do...

Page 104: ...ve the front brake caliper mounting bolts 22 and brake caliper 23 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 difficulty in fitting the brake disc between the brake pads 11 Remove the fork protector socket bolts 24 and fork protectors 25 9 fork bridge upper pinch bolts 10 fork bolt assembly 11 fork damper as...

Page 105: ...ntly slide the outer tube down onto the lower end axle holder 4 Lock nut wrench 07WMA KZ30100 The outer tube 1 can drop on the axle holder 4 and damage the fork dust seal 5 To avoid damage hold both the outer tube and slider when removing the fork damper 3 Drain the fork oil from the outer tube 1 and oil holes 6 of the fork damper assembly 2 Remove the O ring 7 from the fork damper assembly 26 for...

Page 106: ...ff the amount of the remaining oil in the fork from the recommended standard fork oil capacity Refer to Front Suspension Adjustments on page 143 2 Apply the recommended fork oil to a new O ring 2 Install the O ring on the fork damper assembly 3 3 Pull up the fork outer tube 1 slowly and temporarily tighten the fork damper assembly 3 using the lock nut wrench 4 Lock nut wrench 07WMA KZ30100 1 outer...

Page 107: ...leverage so the torque wrench reading will be less than the torque actually applied to the fork damper assembly 3 Tighten the fork bolt assembly 4 to the specified torque 22 lbf ft 30 N m 3 1 kgf m 4 For ease of releasing air pressure after the forks are installed loosen the fork bridge lower pinch bolts 1 and position the outer tubes so that the fork air pressure release screws 5 are in front of ...

Page 108: ...re that the brake hose is not twisted An improperly routed brake hose may rupture and cause a loss of braking efficiency 10 Align the lower surface of the brake hose protector 14 stay A 15 and stay B 16 and assemble them Install and tighten them to the left fork protector using the brake hose clamp bolts 17 11 Clean the threads of the front brake caliper mounting bolts 18 and brake caliper thoroug...

Page 109: ...lder bolts 27 and tighten the handlebar upper holder bolts to the specified torque 16 lbf ft 22 N m 2 2 kgf m Install the handlebar upper holder with the punch marks 28 facing forward Align the paint mark 29 on the handlebar with the end of the left handlebar holders First tighten the bolts on front side of the handlebar upper holders 16 Install the handlebar protector Install the number plate 30 ...

Page 110: ...inal settings Refer to Front Suspension Damping on page 144 1 Remove the front suspension page 98 2 Disassemble the fork outer tube page 100 3 Place the lower end axle holder 1 of the slider in a vise with a piece of wood or soft jaws to avoid damage Over tightening the vise can damage the axle holder 4 Loosen the fork center bolt 2 5 Pull up the fork outer tube slowly and temporarily tighten the ...

Page 111: ...er tube Be careful not to damage the lock nut and fork center bolt hole 10 Remove the fork damper assembly 6 from the fork assembly 7 Remove the fork from the vise Remove the fork spring 8 spring seat collar 9 and back up ring seat stopper 10 from the fork damper assembly Do not attempt to separate the fork assembly and drop the axle holder out from the outer tube which can damage the guide bushin...

Page 112: ...ushings 5 Do not disassemble the fork bolt assembly Replace the fork bolt as an assembly if it is damaged 5 Empty the fork oil from the fork damper assembly 4 by pumping the damper rod several times 6 Clean the fork bolt and fork damper assembly threads 6 7 Extend the fork damper piston rod to maximum length Pour the recommended fork oil into the fork damper assembly 4 Recommended Oil Pro Honda HP...

Page 113: ...h the fork bolt assembly in slowly while pulling the piston rod out Be careful not to damage the fork bolt piston ring 11 Temporarily tighten the fork bolt assembly 3 to the fork damper assembly 4 12 Completely screw in the fork center bolt lock nut 1 to the fork damper piston rod 2 13 Check the fork damper piston rod sliding surface and threads for damage 2 fork damper piston rod 4 fork damper as...

Page 114: ...he fork damper assembly 4 by pumping the fork damper piston rod to full stroke 16 Drain the extra oil from the oil holes 9 of the fork damper assembly 4 By doing above procedure about 0 2 US oz 5 cm3 of fork oil will be drained from the fork damper through the oil hole and cause 8 2 US oz 243 cm3 of fork oil to be left in the fork damper assembly Pour the drained oil into a suitable container and ...

Page 115: ...for smooth operation If the piston rod operation is not smooth check the piston rod for bends or damage 1 Drain the fork oil from the fork assembly 1 by placing it upside down About 0 2 US oz 5 4 cm3 of fork oil will be left in the fork assembly when it is left inverted for about 20 minutes at 20 C 68 F To properly dispose of drained fluids refer to You the Environment on page 164 Improper disposa...

Page 116: ...g 8 Put the fork spring on the fork damper assembly 9 Install the spring fork damper assembly into the fork assembly 1 5 Temporarily tighten the fork damper assembly 9 to the outer tube 10 using the lock nut wrench 11 Lock nut wrench 07WMA KZ30100 6 Place the lower end axle holder 12 of the slider in a vise with a piece of wood or soft jaws to avoid to damage Over tightening the vise can damage th...

Page 117: ...er bolt 17 Standard 0 06 0 08 in 1 5 2 0 mm If the clearance is out of specification check the fork center bolt lock nut and fork center bolt installation 11 Tighten the fork center bolt lock nut 2 to the fork center bolt 17 closely by hand Tighten the fork center bolt lock nut to the specified torque 21 lbf ft 28 N m 2 9 kgf m 12 Apply locking agent to the fork center bolt threads Remove the pist...

Page 118: ...ard suspension settings before attempting to adjust the rear suspension Refer to Suspension Adjustment Guidelines page 154 for making all rebound and compression damping adjustments in one click or 1 12 turn increments Adjusting two or more clicks 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 ...

Page 119: ...nut 2 3 To position the front brake lever farther away from the handgrip turn the adjuster 3 clockwise To position the front brake lever closer to the handgrip turn the adjuster counterclockwise 4 While holding the adjuster tighten the lock nut to the specified torque 4 4 lbf ft 5 9 N m 0 6 kgf m 5 Apply silicone grease to the contacting areas of the adjuster and knocker arm 4 6 Install the front ...

Page 120: ... Make sure there are no fluid leaks Check for deterioration or cracks in the hoses and fittings Rear Brake Fluid Level Check With the motorcycle in an upright position check the fluid level It should be above the LOWER mark 1 If the level is at or below the LOWER mark check the brake pads for wear page 117 Worn brake pads should be replaced If the pads are not worn have your brake system inspected...

Page 121: ... m 0 1 kgf m Adding Rear Brake Fluid Spilled brake fluid will severely damage painted surfaces It is also harmful to some rubber parts Be careful whenever you remove the reservoir cap make sure the reservoir is horizontal first Always use fresh DOT 4 brake fluid from a sealed container when servicing the system Do not mix different types of fluid they may not be compatible The recommended brake fl...

Page 122: ...e Pads Inspect the brake pads 1 from the rear side of the caliper 2 to determine the brake pad wear If either brake pad is worn anywhere to a thickness of 0 04 in 1 0 mm both brake pads must be replaced Check that the front brake lever and rear brake pedal assemblies are positioned properly page 114 and the securing bolts are tight Make sure there are no fluid leaks Check for deterioration or crac...

Page 123: ...It s also important that the rim locks are secure to prevent tire slippage 1 Inspect the wheel rims 1 and spokes 2 for damage 2 Tighten any loose spokes and rim locks 3 to the specified torque Spokes 2 7 lbf ft 3 7 N m 0 4 kgf m Rim Locks 9 lbf ft 12 N m 1 2 kgf m 3 Check wheel rim runout If runout is noticeable see an official Honda Service Manual for inspection instructions See an official Honda...

Page 124: ...t 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 condition make changes a little at a time Take time to inspect your tires and wheels before you ride Inspect carefully for bumps or bulges in the side of the tire or the tread Replace any tire that has a b...

Page 125: ...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 Tire Replacement WARNING Installing improper tires on your motorcycle can affect handling and stability This can cause a crash in which you can be seriously hurt or killed Always use the size and type of tires recommended in this owner s manual Front 90 90 21 ...

Page 126: ...t Safety Precautions on page 23 1 Check the side stand spring 1 for damage and loss of tension 2 Check the side stand assembly for freedom of movement If the side stand is stiff or squeaky clean the pivot area and lubricate the pivot bolt with molybdenum grease 1 side stand spring 1 ...

Page 127: ...ral points along the chain The slack should remain constant If it isn t some links may be kinked and binding Lubricating the chain will often eliminate binding and kinking Excessive chain slack may allow the drive chain to damage the engine cases 4 Inspect the drive chain for damaged rollers loose pins dry or rusted links kinked or binding links excessive wear Replace the drive chain page 124 if i...

Page 128: ... ft 128 N m 13 1 kgf m 4 Recheck chain slack and adjust as necessary 5 Turn the adjusting bolt counterclockwise until it touches the axle plates lightly Then tighten the chain adjuster lock nuts to the specified torque while holding the adjusting bolts with a wrench 20 lbf ft 27 N m 2 8 kgf m CRF450RX Lubricate the drive chain with Pro Honda HP Chain Lube or an equivalent chain lubricant or drive ...

Page 129: ...r wear or damage We recommend replacing the sprocket whenever a new chain is installed Both chain and sprockets must be in good condition or the new replacement chain or sprocket s will wear rapidly Excessively worn sprocket teeth have a hooked worn appearance Replace any sprocket which is damaged or excessively worn Use of a new chain with worn sprockets will cause rapid chain wear 5 Lubricate th...

Page 130: ... from pin center to pin center If the measurement exceeds the service limit replace the chain After the chain is measured shift the transmission into neutral again before proceeding with inspection and service 9 Lubricate the drive chain page 123 10 Pass the chain over the sprockets and join the ends of the chain with the master link For ease of assembly hold the chain ends against adjacent driven...

Page 131: ... 1 Remove the seat page 34 2 Remove the side covers 1 and air cleaner housing covers 2 by removing the bolts 3 The procedure is the same for the both right and left side 3 Loosen the right muffler clamp bolt 4 4 Remove the right muffler mounting A bolt 5 B bolt 6 washer 7 and right muffler 8 Exhaust Pipe Muffler Inspection Muffler Removal 1 side covers 3 bolts 2 air cleaner housing covers 4 right ...

Page 132: ...nstall a new gasket onto the exhaust pipe 2 3 Align the cutout 3 of the left muffler 4 with the tab 5 of the left muffler clamp 6 4 Install the left muffler 5 Install the washer 7 left muffler mounting B bolt 8 and A bolt 9 9 left muffler clamp bolt 10 left muffler mounting A bolt 11 left muffler mounting B bolt 12 washer 13 left muffler 9 11 12 10 13 1 right muffler mounting B bolt 2 washer 3 rig...

Page 133: ...ecified torque 15 lbf ft 20 N m 2 0 kgf m 13 Tighten the right muffler mounting B bolt 14 and A bolt 15 to the specified torque 19 lbf ft 26 N m 2 7 kgf m 14 Tighten the left muffler mounting B bolt 8 and left muffler mounting A bolt 9 to the specified torque 19 lbf ft 26 N m 2 7 kgf m 10 left muffler clamp bolt 1 gasket 5 tab 2 exhaust pipe 11 right muffler 3 cutout 12 right muffler clamp 10 12 2...

Page 134: ...ght muffler mounting B bolt 6 but do not tighten the bolt yet Tighten the right and left muffler mounting B bolts to the specified torque 19 lbf ft 26 N m 2 7 kgf m 3 Install the air cleaner housing covers and side covers this page 4 Install the seat page 34 CRF450R RX 1 Remove the right and left mufflers page 126 2 Remove the exhaust pipe joint nuts 1 exhaust pipe 2 and gasket 3 17 air cleaner ho...

Page 135: ...exhaust pipe joint nuts 3 but do not tighten the nuts yet 3 Install the left and right mufflers page 129 but do not tighten the bolts yet 4 Tighten the exhaust pipe joint nuts to the specified torque 15 lbf ft 20 N m 2 0 kgf m 5 Tighten the left muffler clamp bolt left muffler mounting A bolt and B bolt page 127 6 Tighten the right muffler clamp bolt right muffler mounting A bolt and B bolt page 1...

Page 136: ...ts to the specified torque 15 lbf ft 20 N m 2 0 kgf m 8 Tighten the right and left muffler mounting A bolts to the specified torque 19 lbf ft 26 N m 2 7 kgf m 9 Tighten the right and left muffler mounting B bolts to the specified torque 19 lbf ft 26 N m 2 7 kgf m 10 Install the left and right exhaust springs A 11 11 Install the upper drive chain roller 12 page 123 12 Install the exhaust spring B t...

Page 137: ...ures or see your dealer 1 Remove the handlebar protector and check the handlebar 1 for bends or cracks 2 Check that the handlebar has not moved from its original position where the end of the left handlebar holders 2 is aligned with the paint mark 3 3 Check the torque of the handlebar upper holder bolts 4 16 lbf ft 22 N m 2 2 kgf m Tighten the front bolts first 4 Install the handlebar protector Pe...

Page 138: ...1 15 1 5 5 Oil filter cover bolts 7 10 1 0 6 Cylinder head bolts 37 50 5 1 7 Exhaust pipe joint nuts 15 20 2 0 8 Drive sprocket bolt 23 31 3 2 9 Engine oil drain bolt 13 18 1 8 10 Coolant drain bolt 7 10 1 0 1 cylinder head cover socket bolts 2 clutch cover bolts 3 water pump cover bolts 4 crankshaft hole cap 6 cylinder head bolts 7 exhaust pipe joint nuts 10 coolant drain bolt 3 4 10 7 6 1 2 1 cy...

Page 139: ...The voltage may read above 12V even with a blown battery fuse when the battery is unmounted page 169 Before you remove the battery be sure to read all the information that follows as well as the information on the battery label If you do not remove the battery we recommend disconnecting the battery cables negative cable first The battery is located under the seat Removal 1 Remove the seat page 34 ...

Page 140: ...he battery We recommend using a charger recommended by your lithium ion li ion battery manufacturer which can be purchased from your dealer These units can be left connected for long periods without risking damage to the battery However the lithium ion li ion battery may degrade if stored with a charger connected Do not intentionally leave the charger connected longer than the time period recommen...

Page 141: ...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 Pro Honda Hondabrite and rinse with a low pressure garden hose at full pressure Stubborn deposits may require a quick wipe with a sponge Allow the engine muffler brakes and other high temperature parts to cool before wash...

Page 142: ...ent then rinse well with clean water Dry the frame with a soft clean cloth using strokes parallel to the length of the frame Do not use steel wool to clean the frame as it could damage or discolor the frame surface Scotch Brite Hand Pad 7447 maroon is for removing stains on the non coated aluminum frame only The fuel tank is made of titanium material To remove mud or dust use a sponge or soft clot...

Page 143: ...138 Servicing Your Honda BLANK PAGE ...

Page 144: ...er 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 Engine Mode Select Button 140 Current Mode 140 Mode Selection 140 Honda Selectable Torque Control 141 Current Mode 141 Mode Selection 141 HRC Launch Control System 142 Front Suspension Adjustments 143 Front Suspension Air Pressure 143 Front Suspension ...

Page 145: ...t the engine 2 With your CRF stopped and the throttle closed push and hold the engine mode select button for 1 or more second Make sure that the fast idle knob is pushed in page 17 If the fast idle knob is pulled out the engine mode will not change 3 Release the engine mode select button The engine mode indicator will indicate a selected mode by the number of times the indicator blue blinks 4 Repe...

Page 146: ... the button The Torque Control indicator green will indicate a selected mode by the number of times the indicator blinks The last mode selected will be saved The factory setting is mode 2 Torque Control can be turned on and off by press and hold the Torque Control button Torque Control mode Rear wheel slip 1 High 2 Middle 3 Low OFF No operation 1 Torque Control button 2 Torque Control indicator gr...

Page 147: ...system refer to step 2 in To operate the system To disable the system quickly press the start button The launch control system indicator stops blinking and the system is disabled To operate the system 1 Perform steps 1 and 2 in To change the level 2 Shift into 1st or 2nd gear 3 When launching open the throttle halfway or more The system operates The reduced rev limit and engine torque is controlle...

Page 148: ...e acts as a progressive spring and affects the entire range of fork travel This means the fork action on your CRF will get stiffer during a race CRF450RX moto CRF450R RWE For this reason release built up air pressure in the fork legs between race CRF450RX moto CRF450R RWE Be sure the fork is fully extended with the front tire off the ground when you release the pressure The standard air pressure i...

Page 149: ...ng Do not turn the adjuster screw more than the given positions or the adjuster may be damaged Be sure that the compression and rebound adjusters are firmly located in a detent and not between positions Both compression and rebound damping can be increased by turning the adjuster clockwise The fork springs in CRF s are about right for riders weighing between 170 lb 77 kg and 200 lb 91 kg less ridi...

Page 150: ...y CRF450RX 10 5 US oz 309 cm3 Slightlysofter asitnearsfull compression CRF450R RWE 10 3 US oz 304 cm3 1 scribe mark or no mark factory products 2 scribe marks or no mark factory products Force N Stroke mm Oil capacity 13 3 US oz 394 cm3 MAX Oil capacity 12 3 US oz 363 cm3 STANDARD Oil capacity 10 5 US oz 309 cm3 MIN Standard oil capacity CRF450RX 12 2 US oz 361 cm3 CRF450R RWE 12 2 US oz 361 cm3 M...

Page 151: ...equivalent support with the rear wheel off the ground 2 Remove the subframe page 39 3 Remove the right muffler joint pipe page 129 CRF450RWE only 4 Check that the spring pre load is adjusted to the standard length Adjust as necessary by loosening the shock spring lock nut 1 and turning the adjusting nut 2 Each complete turn of the adjusting nut changes the spring length by 0 06 in 1 5 mm After adj...

Page 152: ... avoid damage Both the high and low speed compression damping can be increased by turning the appropriate adjuster clockwise Adjust the high speed compression damping adjuster in 1 4 turn increments Be sure the high speed compression adjuster is firmly located in a detent and not between positions High Speed Damping The high speed damping can be adjusted by turning the hexagonal portion of the com...

Page 153: ... at the lower end of the rear shock absorber It has 17 clicks or more Turning the adjuster one full turn changes the adjuster 8 clicks Rotate adjuster gently to prevent damage to the rear shock absorber When adjusting the rebound damping adjuster make sure to use the proper size tool to avoid damage Rebound damping can be increased by turning the adjuster clockwise Be sure that the rebound adjuste...

Page 154: ...e loaded with rider dimension Remove the workstand With two helpers available sit as far forward as possible on your CRF s seat wearing your riding apparel Ask one helper to steady your CRF perfectly upright so you can put both feet on the pegs Bounce your weight on the seat a couple of times to help the suspension overcome any situation and settle to a good reference point Ask the other helper to...

Page 155: ...terrain It may even top out when you dismount your CRF Because of the great absorption quality of the shock bumper rubber it may be difficult for you to notice when your CRF s suspension is bottoming Some riders may think the damping or perhaps the leverage ratio is too harsh In reality the problem is most likely insufficient spring pre load or a spring that is too soft Either situation prevents u...

Page 156: ...ity In a muddy event stiffer optional springs front and rear may help especially if you are heavier than the average rider Your CRF may be under sprung 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 dam...

Page 157: ...fer rebound damping in one click increments Middle travel too soft Front end dives when cornering If suspension isn t stiff in initial travel Test stiffer compression damping adjustments in one click increments If initial travel becomes stiff because of the above adjustment Reduce the rebound damping in one click increments Test softer compression damping adjustments in one click increments If tha...

Page 158: ...itial 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 stiff Test softer compression damping adjustments in one click increments Reduce the rebound damping in one click increments Final travel too stiff Doesn t bottom on landings but feels stiff Stiff on large...

Page 159: ...ll feels stiff further test softer low and high speed compression adjustments simultaneously Suspension feels stiff on large bumps 1 Test softer high speed compression adjustment 2 If it still feels stiff further test softer low and high speed compression adjustments simultaneously Entire travel too stiff 1 Test softer high and low speed compression adjustments and rebound adjustment simultaneousl...

Page 160: ... a gray ring around the center electrode where it exits the porcelain Light gray or white color streaks the porcelain insulator and center electrode indicate lean air fuel mixture Wet or black sooty streaks on the porcelain indicate rich air fuel mixture An improperly tightened spark plug can damage the engine If a plug is too loose the piston may be damaged If a plug is too tight the threads may ...

Page 161: ...eep the race sag adjustment page 149 in the 3 7 4 5 in 95 115 mm range The position of the fork in the clamp is not adjustable Standard Position The groove 1 in the outer tube is aligned with the top surface of the upper fork bridge 2 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...

Page 162: ...CRF450R RWE 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 compensate down...

Page 163: ...n use remember they 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 pla...

Page 164: ...lternative consider wrapping the handlebar area under the control assemblies with Teflon tape Then tighten the assemblies to their normal torque Upon impact the fully tightened assemblies should rotate on the Teflon tape Position the shift lever and rear brake pedal so they are close to your boot for rapid access but not so close that either is depressed when sitting or standing comfortably on you...

Page 165: ...egrees Handlebar width can be trimmed with a hacksaw to better suit your particular shoulder width and riding preference Think this through carefully and cut off just a small amount at a time from both sides equally It is obviously much easier to make the handlebar narrower than it is to add material Chamfer the edges to remove burrs and other irregularities or roughness after sawing the handlebar...

Page 166: ...ce on how to transport and store your CRF as well as three troubleshooting flow charts Transporting Your Motorcycle 162 Storing Your Honda 163 Preparation for Storage 163 Removal from Storage 163 You the Environment 164 Troubleshooting 165 ...

Page 167: ...t wheel against the front of the truck bed or trailer rail Attach the lower ends of two straps to the tie down hooks on truck bed or trailer rail Attach 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 com...

Page 168: ...es to their recommended pressures 10 Place your CRF on an optional workstand or equivalent to raise both tires off the ground 11 Stuff a rag into the muffler outlet Then tie a plastic bag over the end of the muffler to prevent moisture from entering 12 Store your CRF in an unheated area free of dampness away from sunlight with a minimum of daily temperature variation 13 Cover your CRF with a porou...

Page 169: ...hrow cleaning 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 coolant 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 contai...

Page 170: ...damaged Fuel contaminated ENGINE LACKS POWER CHECK POSSIBLE CAUSES 1 Check the wheel spin smoothness Brake dragging Worn or damaged wheel bearings Bent axle shaft Drive chain too tight 2 Check the tire pressure P 119 Faulty valve core Punctured tire 3 Check the engine speed change accordingly when clutch is engaged Clutch slipping Improperly adjusted clutch lever freeplay P 73 Worn clutch discs pl...

Page 171: ...park plug wire Faulty CKP sensor Loose or disconnected ignition system wires Faulty engine stop button Faulty regulator rectifier CORRECT INCORRECT CORRECT INCORRECT CORRECT INCORRECT CORRECT INCORRECT CORRECT INCORRECT CORRECT INCORRECT WEAK OR INTERMITTENT SPARK POOR PERFORMANCE AT HIGH SPEED CHECK POSSIBLE CAUSES 1 Check the ignition timing Faulty ECM Faulty CKP sensor 2 Check the air cleaner P...

Page 172: ...g Care of the Unexpected Taking Care of the Unexpected 167 Taking Care of the Unexpected This section gives practical advice to help you solve problems If a Fuse Blows 168 If Your Battery Is Low or Dead 169 ...

Page 173: ...l the spare main fuse 7 9 Install the start magnetic switch cover 4 10 Install the start magnetic switch 3 Install and tighten the start magnetic switch stay bolt 1 to the specified torque 9 lbf ft 12 N m 1 2 kgf m 11 Install the plastic wire band 2 12 Connect the negative terminal page 135 If you do not have a replacement fuse with the proper rating for the circuit install one with a lower rating...

Page 174: ...F s electrical system and battery Bump starting is not recommended Check the battery voltage using a digital multi meter with the cable connected Below 1V The battery has failed replace the battery Between 1V and 8V The battery may have failed charge the battery using a li ion battery charger and then recheck see page 135 Battery Charging If you can t charge the battery or it appears unable to hol...

Page 175: ...170 Taking Care of the Unexpected BLANK PAGE ...

Page 176: ... data Vehicle Identification 172 Serial Numbers 172 Specifications 173 Torque Specifications 175 Nuts Bolts Fasteners 175 Oxygenated Fuels 178 Competition Logbook 179 Optional Parts List 181 Spare Parts Equipment 182 Spare Parts 182 General Tools 182 Honda Special Tools 182 Chemical Products 182 Other Products 182 Wiring Diagram 183 ...

Page 177: ...your CRF They may also be required when ordering replacement parts You may record these numbers in the Quick Reference section at the rear of this manual The VIN vehicle identification number 1 is stamped on the right side of the steering head The engine number 2 is stamped on the right crankcase Serial Numbers 1 VIN 1 2 engine number 2 ...

Page 178: ...ear cold 15 psi 100 kPa 1 0 kgf cm2 F brake swept area Single disc brake 56 0 in2 361 0 cm2 R brake swept area Single disc brake 60 5 in2 390 3 cm2 Fuel unleaded gasoline pump octane number of 91 or higher Fuel tank capacity CRF450RX 2 25 US gal CRF450R RWE 1 66 US gal CRF450RX 8 5 ℓ CRF450R RWE 6 3 ℓ Caster angle CRF450RX 27 26 CRF450R RWE 27 22 Trail length 4 6 in 116 mm Fork oil capacity except...

Page 179: ...atio III 1 421 Gear ratio IV 1 211 Gear ratio V 1 043 Final reduction CRF450RX 3 846 CRF450R RWE 3 769 Gear shift pattern Left foot operated return system 1 N 2 3 4 5 Electrical Battery HY85S lithium ion li ion 12 V 2 0 Ah 20 HR Ignition ECM Starting system Electric Spark plug NGK Standard SILMAR9A 9S For extended high speed riding NGK SILMAR10A 9S Spark plug gap 0 031 0 035 in 0 8 0 9 mm Fuse Mai...

Page 180: ...m 1 Cylinder head cover socket bolts 7 10 1 0 2 Clutch cover bolts 7 10 1 0 3 Water pump cover bolts 7 10 1 0 4 Crankshaft hole cap 11 15 1 5 NOTE 1 5 Oil filter cover bolts 7 10 1 0 6 Cylinder head bolts 37 50 5 1 NOTE 2 7 Exhaust pipe joint nuts 15 20 2 0 8 Drive sprocket bolt 23 31 3 2 9 Engine oil drain bolt 13 18 1 8 NOTE 2 10 Coolant drain bolt 7 10 1 0 NOTES 1 Apply grease to the threads 2 ...

Page 181: ...ger plate nuts 19 26 2 7 11 Lower engine hanger nut 40 54 5 5 12 Cylinder head hanger bolts 40 54 5 5 13 Cylinder head hanger plate bolts 24 32 3 3 14 Rear suspension upper 32 44 4 5 NOTE 1 lower 32 44 4 5 NOTE 1 15 Swingarm pivot nut 65 88 9 0 NOTE 1 16 Fork fork damper assembly 56 76 7 7 fork bolt assembly 22 30 3 1 17 Rear shock arm nuts swingarm side 38 52 5 3 NOTE 1 5 shock link side 38 52 5 ...

Page 182: ...et bolts 5 2 7 0 0 7 NOTE 4 37 Left right muffler clamp bolt CRF450R RX 15 20 2 0 38 Driven sprocket nuts 24 32 3 3 NOTE 1 39 Seat mounting bolts 19 26 2 7 40 Front brake reservoir cap screws 0 7 1 0 0 1 41 Rear brake reservoir cap bolts 0 7 1 0 0 1 42 Fork air pressure release screw 1 0 1 3 0 1 43 Right left muffler mounting bolt A 19 26 2 7 Right left muffler mounting bolt B 19 26 2 7 44 Throttl...

Page 183: ... to 10 ethanol by volume Gasoline containing ethanol may be marketed under the name Gasohol METHANOL methyl or wood alcohol up to 5 by volume You may use gasoline containing up to 5 methanol by volume as long as it also contains cosolvents and corrosion inhibitors to protect the fuel system Gasoline containing more than 5 methanol by volume may cause starting and or performance problems It may als...

Page 184: ...ng time on suspension components Timekeeping This Manual lists maintenance intervals for every so many races CRF450RX motos CRF450R RWE or every so many hours of running Because all races CRF450RX motos CRF450R RWE are not the same the most effective way to schedule maintenance is by the hours you have run your CRF An official guesstimate is close enough for our timekeeping purposes You may choose...

Page 185: ...ition Logbook 180 Technical Information Date Running Time Location Event Comments Suspension Settings Gearing Chassis Adjustments Maintenance Performed etc Make several photocopies of this page for future use ...

Page 186: ...s To extend the life of brake pads in muddy conditions TOOLS Remarks Pin spanner A To adjust spring preload two spanners required Workstand For maintenance Air gauge For checking tire air pressure FRAME Remarks Fork spring CRF450RX 27 4 lbf in 4 8 N mm Standard Medium CRF450R RWE 28 6 Ibf in 5 0 N mm Optional Soft CRF450RX 26 3 lbf in 4 6 N mm CRF450R RWE 27 4 Ibf in 4 8 N mm Stiff CRF450RX 28 6 l...

Page 187: ...style pliers standard needle nose channel lock set hammer plastic head syringe with adjustable stop air pressure gauge tire irons tire pump or air tank feeler gauge set Vernier caliper metric pressure vacuum testing equipment Any special tools for your CRF purchased from your dealer Tensioner stopper 07AMG 001A100 Lock Nut Wrench 07WMA KZ30100 Spoke Wrench 07JMA MR60100 Spoke Wrench 070MA KZ30100 ...

Page 188: ... Sb Sky blue White W Br Brown O Orange Lg Light Green P Pink Gr Gray WPC 6P W JUNCTION CONNECTOR GP SENSOR RESISTOR RESISTOR LED ORANGE LED BLUE ENGINE MODE SELECT SWITCH ENGINE STOP SWITCH STARTER SWITCH CLUTCH SWITCH DLC FUEL PUMP ECM FUEL INJECTOR GROUND IGNITION COIL SPARK PLUG ALTERNATOR CKP SENSOR IAT SENSOR ECT SENSOR MAP SENSOR TP SENSOR REGULATOR RECTIFIER STARTER RELAY SWITCH STARTER REL...

Page 189: ...184 Technical Information BLANK PAGE ...

Page 190: ...on Consumer Information 185 Consumer Information This section contains information about contacting Honda and how to get an official Honda Service Manual Authorized Manuals 186 Contacting Honda 187 Your Honda Dealer 188 ...

Page 191: ...nction with the Owner s Manual and Service Manual can help you prepare your Honda motorcycle scooter ATV and SxS for winter storage These Honda manuals are written for the professional technician but most mechanically capable owners should find them helpful if they have the proper tools and skills Special Honda tools are necessary for some procedures Order online www helminc com Order Toll Free 1 ...

Page 192: ...s at the dealership level If you wish to comment on your experiences with your CRF or with your dealer please send your comments to the following address Motorcycle Division American Honda Motor Co Inc P O Box 2200 Torrance CA 90509 2200 Mailstop 100 4C 7B Telephone 866 784 1870 Canada Honda Canada Inc Customer Relations Dept 180 Honda Boulevard Markham Ontario L6C 0H9 telephone 888 946 6329 facsi...

Page 193: ...partment offers Honda Genuine Parts Pro Honda products Honda Genuine Accessories USA only and Honda accessories and products Canada only The same quality that went into your Honda can be found in Honda Genuine replacement parts You ll also find comparable quality in the accessories and products available from the parts department Your Honda dealer can inform you about competition events in your ar...

Page 194: ...Consumer Information 189 BLANK PAGE ...

Page 195: ...evel 115 lever front adjustment 114 pad wear 117 pedal height 114 break in guidelines 20 capacity fuel 42 52 care appearance 136 chain drive 122 chassis adjustments 156 cleaner air 67 cleaning appearance care 136 competition logbook 179 consumer information 185 contacting Honda 187 controls 5 coolant 65 customer service 188 cylinder system 90 damping adjustments front 144 rear 147 dealer your Hond...

Page 196: ...le 172 idle knob fast 17 72 idle speed engine 72 indicator circuit inspection 8 DTC index 9 engine mode 10 140 launch control system 10 MIL blink 7 torque control 10 inspection pre ride 13 instruments 5 labels safety 4 launch control system 10 logbook competition 179 maintenance after competition 32 before after competition 31 between races CRF450RX motos CRF450R RWE practice 31 component location...

Page 197: ...ance 78 reading 155 specifications 173 spring pre load rear suspension 146 starting engine 17 troubleshooting 165 steering stem inspection 132 stopping engine 18 storage 163 subframe 39 suspension adjustment for track conditions 151 front 143 guidelines 152 rear 146 suspension front 97 rear 113 throttle freeplay 70 inspection 71 lubrication 71 tires air pressure 119 flat 119 selection 120 tools 18...

Page 198: ...h race or about 2 5 hours every 3 races or about 7 5 hours every 6 races or about 15 0 hours every 9 races or about 22 5 hours and every 12 races or about 30 0 hours Pre ride Inspection Check the items listed on the Pre ride Inspection checklist each time before you ride page 13 Fuel Tank Capacity CRF450RX unleaded gasoline pump octane number of 91 or higher tank 2 25 US gal 8 5 ℓ CRF450R RWE unle...

Page 199: ...hthalates and lead which are known to the State of California to cause cancer and birth defects or other reproductive harm To minimize exposure avoid breathing exhaust do not idle the engine except as necessary service your vehicle in a well ventilated area and wear gloves or wash your hands frequently when servicing your vehicle For more information go to www P65Warnings ca gov passenger vehicle ...

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