Honda CRF450X 2009 Owner'S Manual & Competition Handbook Download

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HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200

Technical Information

159

Specifications

Overall length

Overall width

Overall height

Wheelbase

Seat height

Footpeg height

Ground clearance

Item

Dimension

English

85.7 in

32.3 in

50.1 in

58.3 in

37.9 in

17.0 in

13.6 in

Metric

2,178 mm

821 mm

1,273 mm

1,480 mm

963 mm

431 mm

345 mm

Item

Cylinder arrangement

Bore and stroke

Displacement

Compression ratio

Engine oil capacity
After draining

After draining and
oil filter change

After disassembly

Transmission oil capacity
After draining

Type

Identification number

Main jet

Jet needle

Piston valve

FCR04C

#145

NKJU

Needle clip position

Slow jet

Pilot screw opening

Float level

Idle speed

Liquid cooled, 4-stroke

2nd groove from top

#45

1-1/8 turns out

1,700

100 min

–1

(rpm)

Type

Engine

Carburetor

12.0 : 1

Valve clearance (cold)

Intake:

0.16

0.03 mm

(0.006

0.001 in)

Exhaust: 0.28

0.03 mm

(0.011

0.001 in)

English

3.78 x 2.44 in

0.31 in

27.4 cu-in

0.71 US qt,
0.59 Imp qt

0.74 US qt,
0.62 Imp qt

0.92 US qt,
0.77 Imp qt

0.69 US qt,
0.57 Imp qt

0.79 US qt,
0.66 Imp qt

1.28 US qt,
1.06 Imp qt

1.53 US qt,
1.28 Imp qt

After disassembly

Cooling system,capacity
After draining

Single 6 inclined from

vertical

Metric

96.0 x 62.1

8.0 mm

449 cm

0.65

0.75

1.21

1.45

0.70

0.87

0.67

Item

Type

Frame

Fork oil capacity
(except fork damper
per leg)

F. suspension

R. suspension

F. brake, swept area

R. brake, swept area

Fuel recommendation

Fuel capacity

Caster angle

Trail length

Twin tube

Telescopic fork,

travel 279 mm (11.0 in)

stroke 315 mm (12.4 in)

Pro-link,

travel 313 mm (12.3 in)

Single disc brake

334.5 cm

(51.8 in

)

Single disc brake

391.1 cm

(60.6 in

)

unleaded petrol,

research octane number

of 95 or higher

27 03

Tyre pressure, front (cold) 100 kPa (1.0 kgf/cm

, 15 psi)

Tyre pressure, rear (cold) 100 kPa (1.0 kgf/cm

, 15 psi)

Tyre type

bias-ply, tube

Fuel reserve capacity

English

1.90 US gal,
1.58 Imp gal

4.52 in

11.0 US oz,
11.4 Imp oz

0.42 US gal,
0.35 Imp gal

Metric

324 cm

114.7 mm

1.6

7.2

Tyre size, front

90/90-21M/C 54R

BRIDGESTONE

ED663

Tyre size, rear

140/80-18M/C 70R

BRIDGESTONE

ED668

Summary of Contents for CRF450X 2009

Page 1: ...TITION HANDBOOK E MANUEL DU CONDUCTEUR ET DE COMPETITION F FAHRER HANDBUCH und WETTBEWERBSANLEITUNG G INSTRUCTIEBOEKJE WEDSTRIJDHANDBOEK D MANUAL DEL PROPIETARIO Y GUÍA DE COMPETICIONES S MANUALE D USO E DEGLI ASSETTI DA COMPETIZIONE I Honda Motor Co Ltd 2008 08 7 22 9 59 1 ...

Page 2: ...CTURED FOR COMPETITION USE ONLY AND IS SOLD AS IS WITH NO WARRANTY IT DOES NOT CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARDS AND OPERATION ON PUBLIC STREETS ROADS OR HIGHWAYS IS ILLEGAL STATE LAWS PROHIBIT OPERATION OF THIS MOTORCYCLE EXCEPT IN AN ORGANIZED RACING OR COMPETITIVE EVENT UPON A CLOSED COURSE WHICH IS CONDUCTED UNDER THE AUSPICES OF A RECOGNIZED SANCTIONING BODY OR BY PERMIT ISSUE...

Page 3: ...Honda CRF450X OWNER S MANUAL COMPETITION HANDBOOK ...

Page 4: ... warranty Please read the Honda Motorcycle Warranties Booklet given to you by your Honda dealer at the line of purchase 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 using the motorcycle Your warranty coverage will not be voided if you choose to...

Page 5: ... 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 6: ...e Breather 52 Engine Throttle 53 Clutch System 55 Hot Start Lever 59 Spark Plug 60 Exhaust Pipe Muffler 62 Spark Arrester 65 Valve Clearance 66 Piston Piston Rings Piston Pin 76 Chassis Suspension 84 Brakes 88 Wheels 92 Tyres Tubes 93 Side Stand 95 Drive Chain 96 Steering Damper 99 Additional Maintenance Procedures 102 Electrical Battery 104 Headlight Taillight 106 Appearance Care 108 ADJUSTMENTS ...

Page 7: ...n 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 Loading 3 Accessories Modifications 4 Safety Labels 5 Motorcycle Safety 1 ...

Page 8: ...ch any part of the hot exhaust system Wear clothing that fully covers your legs Keep 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...

Page 9: ...to 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 th...

Page 10: ...avel alter your riding position or interfere with operating any controls Modifications We strongly advise you not to remove any 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 4 Motorcycle Safety Accessories Modifications Modifying your CRF or using non ...

Page 11: ...he locations of safety 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 12: ...HONDA O M CRF450X Eu 3RMEY620 00X3R MEY 6200 6 Motorcycle Safety ...

Page 13: ... Controls 7 HONDA O M CRF450X Eu 3RMEY620 00X3R MEY 6200 Operating Controls Read this section carefully before you ride It presents the location of the basic controls on your CRF Operation Component Locations 8 ...

Page 14: ...00X3R MEY 6200 8 Operating Controls Operation Component Locations clutch lever hot start lever front brake lever engine stop button throttle grip tripmeter start button choke knob fuel valve shift lever kickstarter rear brake pedal ...

Page 15: ...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 carburetor and other adjustments see page 111 Before Riding Are You Ready to Ride 10 Is Your Motorcycle Ready to Ride 11 Pre ride Inspection 11 ...

Page 16: ...on carburetor and other adjustments see page 111 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 WA...

Page 17: ...buretor throttle operation 53 Engine idle speed for stable and proper rpm 140 Tyres for damage or improper inflation pressure 93 Spokes for looseness 92 Rim locks for looseness 92 Front and rear suspension for proper operation 84 85 Front and rear brakes check operation 88 Drive chain for correct slack and adequate lubrication 96 98 Drive chain sliders and drive chain rollers for damage or wear 98...

Page 18: ...HONDA O M CRF450X Eu 3RMEY620 00X3R MEY 6200 12 Before Riding ...

Page 19: ...es basic information on 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 20: ...rst time please review the Important Safety Precautions 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 1...

Page 21: ... 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 NOTICE NOTICE Basic Operating Instructions 15 HONDA O M CRF450X Eu 3RMEY620 00X3R MEY 6200 1 fuel valve The three way fuel valve is used to control the flow of fuel from the fuel tank to the ...

Page 22: ... the choke 2 Shift the transmission into neutral with the throttle fully opened repeat kickstarter operation approximately ten 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 t...

Page 23: ...d gears in a one down four up shift pattern To start riding after the engine has been warmed and the side stand raised 1 Close the throttle and pull the 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...

Page 24: ... 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 these conditions Rapid acce...

Page 25: ...er the side stand to support your CRF If you re through riding for the day turn the fuel valve OFF Always choose a level surface to park Basic Operating Instructions 19 HONDA O M CRF450X Eu 3RMEY620 00X3R MEY 6200 ...

Page 26: ...emove 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 98 to prevent rusting 20 Basic Operating Instructions HONDA O M CRF450X Eu 3RMEY620 00X3R MEY 6200 ...

Page 27: ...operating day or 25 km 15 miles 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 Basic Operating Instructions 21 HONDA O M CRF450X Eu 3RMEY620 00X3R MEY 6200 ...

Page 28: ...HONDA O M CRF450X Eu 3RMEY620 00X3R MEY 6200 22 Basic Operating Instructions ...

Page 29: ...arts department Before You Service Your Honda The Importance of Maintenance 24 Maintenance Safety 25 Important Safety Precautions 25 Maintenance Schedule 26 General Competition Maintenance 28 Before After Competition Maintenance 32 Between Motos Practice Maintenance 32 After Competition Maintenance 32 Service Preparations Maintenance Component Locations 34 Seat 35 Fuel Tank 36 Subframe Upright Pos...

Page 30: ...because your CRF is designed 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 esp...

Page 31: ...e the engine Burns from 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 an optional workstand to prov...

Page 32: ...e expressed in terms of riding days as well as miles To avoid overlooking required service we urge you to develop a convenient way to record the number of days and or distance traveled 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 main...

Page 33: ...IPE MUFFLER SUSPENSION SWINGARM SHOCK LINKAGE FORK OIL EXCEPT DAMPER FORK OIL DAMPER NUTS BOLTS FASTENERS WHEELS TYRES STEERING HEAD BEARINGS NOTE 1 NOTE 4 NOTE 3 NOTE 3 NOTE 5 NOTE 2 NOTE 2 NOTE 3 54 59 50 52 60 66 42 43 140 78 78 45 47 47 96 98 98 97 97 89 91 88 55 102 62 84 85 31 86 117 103 161 164 92 93 102 I I C I I I I I I I L I I I I I I I I I L I I I I R L R I R R R R R I R FREQUENCY NOTE ...

Page 34: ...n Use Honda Genuine Parts or their equivalent when servicing your CRF Clean parts in non flammable high 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...

Page 35: ...or 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 or s...

Page 36: ...mage or deterioration page 41 Fuel Contamination Refer to Fuel System in your Owner s Manual page 40 Check the fuel lines for deterioration damage or leakage Replace the fuel lines if necessary Periodically drain the fuel from the fuel tank remove and clean the fuel valve filter Replace the fuel valve O ring if there are any signs of damage or deterioration page 41 Loosen the carburetor drain scre...

Page 37: ... high temperature high pressure performance example EXCELITE EP2 manufactured by KYODO YUSHI Japan or Shell Stamina EP2 or equivalent Bleed Hole After every race check the bleed hole located just below the water pump cover on the right crankcase cover Clean away any clogged dirt or sand if necessary Check for signs of seal leakage A small amount of weeping from the bleed hole is normal Fork Oil Pe...

Page 38: ...wear 1 chain adjuster index marks Suspend the front wheel above the ground and use the fork air pressure release screws 2 to release the built up pressure in excess of normal atmospheric pressure 0 kpa 0 kgf cm2 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 in...

Page 39: ...cket A variety of reasonably priced cleaning brushes 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 an...

Page 40: ...lt engine oil filler cap dipstick air cleaner spark plug battery main fuse rear suspension high speed compression damping adjuster rear suspension low speed compression damping adjuster rear suspension rebound damping adjuster front suspension compression damping adjuster transmission oil filler cap transmission oil check bolt front suspension rebound damping adjuster rear brake pedal rear brake f...

Page 41: ... backward 1 seat mounting bolts 2 seat Installation 1 Install the seat 1 while aligning the seat front prong 2 with the seat bracket 3 and seat rear prongs 4 with the tabs 5 of the frame 2 Install and tighten the seat mounting bolts 6 to the specified torque 26 N m 2 7 kgf m 19 lbf ft 1 seat 2 seat front prong 3 seat bracket 4 seat rear prongs 5 tabs 6 seat mounting bolts 1 2 2 4 1 6 3 5 ...

Page 42: ...r rubber 6 8 Remove the fuel tank 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 10 Remove the fuel valve bolt 10 and fuel valve 11 Remove the fuel tank 8 fuel line 10 fuel valve bolt 9 fuel val...

Page 43: ...nstall and tighten the fuel tank bolt collar 5 5 Hook the air cleaner cover rubber 6 6 Install and hook the fuel tank band 7 7 Put the breather tube 8 in the steering stem nut 8 Install the shrouds 9 by aligning its tab 10 with subframe 11 9 shroud 11 subframe 10 tab 9 Install the shroud B bolts 12 and shroud A bolts collars 13 10 Tighten the shroud B bolts to the specified torque 5 N m 0 5 kgf m ...

Page 44: ...7 screw 8 air cleaner connecting boot clamp 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 7 Lift the subframe 11 as shown Tighten the subframe upper mounting bolts to the specified torque 49 N m 5 0 kgf m 36 lbf ft 1 right side cover bolt 2 right side cover 3 Open the air cleaner housing...

Page 45: ...cover 12 and right side cover bolt 13 1 subframe upper mounting bolts 2 subframe 3 subframe 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 sub...

Page 46: ...onsult your Honda dealer Never use stale or contaminated petrol or an oil petrol mixture Avoid getting dirt dust or water in the fuel tank Type Unleaded Research Octane Number 95 or higher Refueling Procedure Fuel Tank Capacity 7 2R 1 90 US gal 1 58 Imp gal 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...

Page 47: ...to an approved petrol container Disconnect the fuel valve and fuel lines 1 3 Remove the fuel joint 2 from the fuel tank by removing the bolts 3 4 fuel filter 5 O ring 4 5 1 3 2 1 fuel valve and fuel lines 2 fuel joint 3 bolts 4 Wash the fuel filter 4 in high flash point cleaning solvent 5 Check that the O ring 5 is in good condition 6 Install the fuel joint in the fuel tank by tightening the bolts...

Page 48: ...dation API classification SG or higher except oils labeled as energy conserving on the circular API service label suggested oil Honda 4 STROKE MOTORCYCLE OIL or equivalent viscosity weight SAE 10W 30 JASO T 903 standard MA Your CRF does not need oil additives Use the recommended oil Do not use API SH or higher 4 stroke engine oils displaying a circular API energy conserving service label on the co...

Page 49: ...r 3 level marks on the engine oil filler 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 add the recommended oil until the upper level mark Do not overfill Reinstall the engine oil filler cap dipstick Repeat steps 1 5 6 Install the engine oil filler cap dipstick securely 7 Check for oil leaks Changing Engine Oil...

Page 50: ...e oil level by following the steps in Checking Adding Oil page 43 Pour the drained oil into a suitable container and dispose of it in an approved manner page 151 Improper disposal of drained fluids is harmful to the environment NOTICE NOTICE 8 Remove the oil filter cover bolts 6 and oil filter cover 7 9 Remove the oil filter 8 from the filter cover 10 Check that the oil filter cover O ring 9 is in...

Page 51: ... API classification 4 stroke engine oil only Viscosity weight JASO T 903 standard others suggested oil SG or higher except oils labeled as energy conserving on the circular API service label SAE 10W 30 MA without friction modifiers such as molybdenum additives Honda 4 STROKE MOTORCYCLE OIL or equivalent Your CRF does not need oil additives Use the recommended oil Do not use oils with graphite or m...

Page 52: ...l level or adding oil tighten the oil check bolt to the specified torque 10 N m 1 0 kgf m 7 lbf ft 6 Install the transmission oil filler cap securely Replacing Transmission Oil 1 Run the engine at idle for 3 minutes then shut it off 2 Support the CRF in an upright position on a level surface 3 Remove the transmission oil filler cap 1 from the right crankcase cover 4 Place an oil drain pan under th...

Page 53: ...ed 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 54: ...l for troubleshooting of leaks 2 Check the water hoses 1 for cracks deterioration and radiator hose clamp 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 bleed hole 3 below the water pump cover 4 for leakage Check for signs of seal leakage A small amount of weeping from the bleed ho...

Page 55: ...he UPPER level line 4 4 Bleed air from the system as follows Shift the transmission into neutral Start the engine and let it idle 2 3 minutes Snap the throttle three four 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 radi...

Page 56: ...ug fouling Improper or lack of proper air cleaner maintenance can cause poor performance and premature engine wear NOTICE NOTICE Cleaning 1 Open the air cleaner housing cover 1 by turning the quick fastener 2 counterclockwise 4 Remove the air cleaner element 5 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 clean...

Page 57: ... element tab 9 9 Apply 1 5 5 5 g 0 05 0 19 oz of Honda White Lithium Grease or equivalent to the air cleaner housing contact area of the air cleaner element 10 Install the air cleaner assembly into the air cleaner housing 11 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 ho...

Page 58: ...f your CRF 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 Draining 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 59: ...4 N m 0 4 kgf m 3 0 lbf ft 5 Operate the throttle grip to ensure that it functions smoothly and returns completely 6 Install the fuel tank and seat pages 35 37 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 i...

Page 60: ...e throttle 1 from fully open to fully closed in 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 pre...

Page 61: ...lock nut increase 2 integral cable adjuster decrease 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 Turn the integral cable adjuster 2 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 motor...

Page 62: ...tion If necessary lubricate the clutch lever pivot or clutch cable 2 Check the clutch cable for deterioration kinks or damage Clutch Cover Disc Plate Removal 1 Drain the transmission oil page 46 2 Remove the rear brake pedal 1 by removing the pin 2 pivot bolt 3 washer 4 and dust seals 5 1 rear brake pedal 4 washer 2 pin 5 dust seals 3 pivot bolt 6 clutch cover bolts 7 clutch cover 4 Remove the six...

Page 63: ...tch Spring Inspection 1 clutch spring Measure the free length of each spring Service Limit 43 7 mm 1 72 in Replace the clutch springs as a set if any one of them is below the service limit or if the clutch plates have been burnt heat discoloured 1 6 Remove the washer 10 needle bearing 11 clutch lifter 12 and clutch lifter rod 13 7 Remove the eight clutch discs and seven clutch plates 14 Assemble t...

Page 64: ...ree steps to the specified torque 12 N m 1 2 kgf m 9 lbf ft 10 Apply oil to a new O ring 10 and install it in the groove of the clutch cover 11 11 Install the clutch cover by tightening the six clutch cover bolts in a crisscross pattern in two or three steps to the specified torque 10 N m 1 0 kgf m 7 lbf ft 8 clutch pressure plate 9 clutch spring bolts springs 10 O ring 11 clutch cover 9 8 10 11 C...

Page 65: ...heck freeplay 2 Freeplay 2 3 mm 0 08 0 12 in If necessary adjust to the specified range Adjustment Adjustments can be made with the cable end adjuster Loosen the lock nut 1 and turn the adjuster 2 Turning the adjuster clockwise will increase freeplay and turning it counterclockwise will decrease freeplay After adjustment tighten the lock nut 1 lock nut increase 2 adjuster decrease 1 2 2 1 ...

Page 66: ...park plug 5 Check the electrodes for wear or deposits the sealing gasket 3 for damage 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 1 0 1 1 mm 0 039 0 043 in 3 sealing gasket 4 spark plug gap 3 4 Standard IFR8H11 NGK or VK24PRZ1...

Page 67: ...n improperly tightened spark plug can damage the engine If a plug is too loose a piston may be damaged If a plug is too tight the threads may be damaged 10 Connect the spark plug cap Take care to avoid pinching any cables or wires 11 Install the fuel tank and seat pages 35 37 NOTICE ...

Page 68: ...A damaged exhaust pipe and muffler may reduce engine performance 1 seat mounting 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 1 3 2 5 7 6 4 Muffler Removal 1 Remove the seat mount...

Page 69: ...mounting bolt washer 8 and loosely tighten them Tighten the front muffler mounting bolt and rear muffler mounting bolt to the specified torque 26 N m 2 7 kgf m 19 lbf ft 6 Tighten the muffler clamp bolt 9 to the specified torque 21 N m 2 1 kgf m 15 lbf ft 7 front muffler mounting bolt 8 rear muffler mounting bolt washer 9 muffler clamp bolt 10 right side cover 12 seat mounting bolt 11 side cover b...

Page 70: ...ffler page 63 but do not tighten the bolts yet 4 Tighten the exhaust pipe joint nuts to the specified torque 21 N m 2 1 kgf m 15 lbf ft 5 Tighten the muffler clamp bolt front muffler mounting bolt and rear muffler mounting bolt page 63 6 Installation can be done in the reverse order of removal Exhaust Pipe Removal 1 Remove the muffler page 62 2 Remove the exhaust pipe joint nuts 1 exhaust pipe 2 a...

Page 71: ...rrester 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 and holes Replace if necessary 4 Apply a seizure inhibitor Three bond 1901 or equivalent to the bolts threads 5 Install a new gasket and the spark arrester in...

Page 72: ...the cylinder head cover A bolt rubber seal 3 cylinder head cover B bolts rubber seals 4 and cylinder head cover 5 3 cylinder head cover A bolt rubber seal 4 cylinder head cover B bolts rubber seals 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 t...

Page 73: ...dex mark 4 on the right crankcase 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 condi...

Page 74: ...he tensioner stopper 3 until it stops in order to retract the tensioner fully Then insert the tensioner stopper fully to hold the stopper in the fully retracted position 3 tensioner stopper 2 1 3 4 Loosen the cam sprocket bolt 4 Rotate the primary drive gear bolt crankshaft clockwise one turn and remove the other sprocket bolt Rotate the primary drive gear bolt crankshaft clockwise one turn again ...

Page 75: ... the intake valve lifters and intake valve shims may be sticking in the camshaft holder assembly Keep the intake valve lifters and the shims separate so you can easily identify the originally installed location such as intake or exhaust right or left 7 Remove the intake valve lifters 9 decompressor shaft 10 and plunger 11 8 Remove the valve shims 12 7 camshaft holder assembly bolts 8 camshaft hold...

Page 76: ...mm thickness in intervals of 0 025 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 a micrometer Reface the intake valve seat if carbon deposits result in a calculated dimension of over 2 450 mm Reface the exhaust ...

Page 77: ...the plunger shown Check the operation of the plunger by turning the decompressor shaft with your finger then pushing down and pull up the plunger smoothly 5 Install the camshaft holder assembly 9 onto the cylinder head with the intake cam lobes 10 facing up as illustrated below Apply engine oil to the camshaft holder assembly bolt threads and seating surface Tighten the camshaft holder assembly bo...

Page 78: ...its hole 21 with out side weight pin 22 as shown 15 cam chain 19 decompressor weight pin 16 cam sprocket 20 decompressor weight 17 timing mark 21 hole 18 mark 22 out side weight pin 9 Clean and apply a locking agent to the cam sprocket bolt 25 threads coating width as shown 10 Temporarily install the cam sprocket bolt 25 by aligning the bolt holes of the cam sprocket and camshaft Rotate the primar...

Page 79: ... the mark 18 on the camshaft holder assembly If the timing mark doesn t align with the mark remove the cam sprocket Then realign the valve timing 13 punch mark 14 index mark 17 timing mark 18 mark 28 29 28 sealing washer 29 cam chain tensioner lifter cover bolt 14 Measure the intake valve and exhaust valve clearances by inserting a feeler gauge 27 Valve Clearance IN 0 16 0 03 mm 0 006 0 001 in EX ...

Page 80: ...le 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 Check the rubber seals 5 are in good condition replace them if necessary Install the rubber seals onto the c...

Page 81: ...Your Honda 75 HONDA O M CRF450X Eu 3RMEY620 00X3R MEY 6200 6 Install the spark plug page 60 7 Connect the spark plug cap 9 and breather tube 10 9 10 9 spark plug cap 10 breather tube 8 Install the fuel tank and seat pages 35 37 ...

Page 82: ...uretor page 136 8 Remove the exhaust pipe page 64 9 Remove the spark plug page 60 10 Remove the cylinder head cover page 66 11 Position the piston at top dead centre on the compression stroke page 66 12 Remove the camshaft holder assembly lifters and shims page 68 13 Remove the left radiator grill 1 and left radiator mounting bolts washers 2 3 primary wire connector 4 bolt 5 ignition coil 15 Loose...

Page 83: ...nger bolt 10 fuel hose guide 11 engine hanger plate bolts 12 clutch cable stay 13 left engine hanger plate 14 right engine hanger plate 17 cylinder head nuts washers 18 cylinder head 15 cylinder head bolts 16 cylinder bolt 19 Remove the cylinder head nuts washers 17 and cylinder head 18 Loosen the nuts in a criss cross pattern in two or three steps Do not let the nuts washers and cam chain fall in...

Page 84: ...linder gasket Piston Ring Removal Spread each piston ring 1 and remove by lifting it up at a point just opposite the gap Do not 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...

Page 85: ... installation NOTICE top ring oil ring top ring mark side rail oil ring side rail spacer piston Piston Piston Pin Piston Ring Inspection We recommend you consult the Shop Manual or your Honda dealer for correct Service Limit measurements To install the oil ring install the spacer first then install the side rails Install the top ring on the piston with the marking side facing up 3 After installing...

Page 86: ...n pin hole inner surface 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 6 NOTICE 1 piston 4 piston pin 2 IN mark 5 piston pin clips 3 large valve recesses 6 piston cut out Cylinder Installation 1 Clean off any gasket m...

Page 87: ...5 piston rings 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...

Page 88: ... 10 N m 1 0 kgf m 7 lbf ft 3 cylinder head 4 cylinder 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 an...

Page 89: ... Tighten the radiator hose clamp screw 15 as illustrated below 15 radiator hose clamp screw 10 Install the ignition coil 16 ground wire 17 and bolt 18 then tighten the bolt Connect the primary wire connector 19 Clamp the siphon hose 20 to the clamp 21 16 ignition coil 19 primary wire connector 17 ground wire 20 siphon hose 18 bolt 21 clamp 14 19 16 20 18 17 21 23 16 Install the exhaust pipe page 6...

Page 90: ...eriodically 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 131 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 af...

Page 91: ...and compression damping adjustments in one click or 1 12 turn increments 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 127 After adjusting the adjusters simultaneous...

Page 92: ... when the fork damper is removed To avoid damage hold both the outer tube and slider when removing the fork damper NOTICE 1 outer tube 6 fork dust seal 5 slider 7 guide bushing 4 Drain the fork oil from the outer tube 1 Drain the fork oil from the oil holes 8 of the fork damper 1 outer tube 8 oil holes 5 Drain the fork oil by turning the outer tube 1 upside down About 12 cm3 0 4 US oz 0 4 Imp oz o...

Page 93: ... mm 27 47 lbf in Fork Spring Standard oil capacity 327 cm3 11 1 US oz 11 5 Imp oz Maximum oil capacity 405 cm3 13 7 US oz 14 3 Imp oz Slightly stiffer as it nears full compression Slightly softer as it nears full compression Minimum oil capacity 309 cm3 10 5 US oz 10 9 Imp oz 3 scribe marks 7 Check that the O ring 9 on the fork damper 2 is in good condition Apply the recommended fork oil to the O ...

Page 94: ...tion 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 While holding the adjuster tighten the lock nut to the specified torque 5 9 N m 0 6 kgf m 4 4 lbf ft 4 Apply the brake release it then spin the wheel and check that it rotates freely Repeat this procedure several times 5 Check fre...

Page 95: ...m 0 8 in there is probably air in the brake system and it must be bled Refer to the Honda Shop Manual or see your Honda dealer for brake bleeding Rear Brake Fluid Level Check 1 LOWER mark 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 91 Worn brake pads should be repl...

Page 96: ...e 1 N m 0 1 kgf m 0 7 lbf ft Adding Rear Brake Fluid Spilled brake fluid will severely damage instrument lenses and 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 DOT4 brake fluid from a sealed container when servicing the system Do not mix different types of fluid they may not b...

Page 97: ...placed 1 brake pads 3 brake disc 2 front brake caliper Rear Brake Pads Inspect the brake pads 1 from the rear side of the caliper to determine the pad wear If either pad is worn anywhere to a thickness of 1 mm 0 04 in both pads must be replaced 1 brake pads 3 brake disc 2 rear brake caliper 3 2 1 1 mm 0 04 in wear indicator grooves replace 1 mm 0 04 in minimum thickness indicator 1 3 2 replace 1 m...

Page 98: ...ssary to remove the wheels to perform the recommended service in the Maintenance Schedule page 27 However information for wheel removal is provided for emergency situations Wheel Rims Spokes 1 wheel rim 3 rim lock 2 spoke 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 front 3 68 N m 0 4 kgf m 2 7 lbf ft rear 3 7 N m 0 4 ...

Page 99: ...from surface hazards and wear unevenly Make sure the valve stem caps are secure If necessary install new caps Always check air pressure when your tyres are cold If you check air pressure when your tyres 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 tyres to match the recommended cold pressures the tyres will be underinflated T...

Page 100: ...quivalent to the original Replace the tube any time you replace a tyre The old tube will probably be stretched and if installed in a new tyre could fail WARNING Installing improper tyres 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 tyres recommended in this owner s manual Front 90 90 21M C 5...

Page 101: ... Refer to Safety Precautions 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 102: ...he drive 2 and driven 3 sprockets Drive chain slack should allow the following vertical movement by hand 25 35 mm 1 0 1 4 in 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 this indicates that some of the links are either worn kinked o...

Page 103: ...rollers loose fitting links damaged O rings or otherwise appears unserviceable 3 Measure the drive chain plate 1 If the drive chain plate is worn anywhere to a thickness of 13 4 mm 0 53 in the drive chain must be replaced Replacement chain Size link DID520MXV 114 1 drive chain plate inner 4 Inspect the sprocket teeth for possible wear or damage Replace them if necessary Never install a new drive c...

Page 104: ... limit 3 2 chain guide slider 3 wear limit Drive Chain Rollers 1 Measure the diameter of the upper 1 and lower 2 drive chain rollers Replace them if below the service limit Service Limit UPPER ROLLER 39 mm 1 5 in LOWER ROLLER 35 mm 1 4 in 2 Replace the roller if necessary as follows Install the upper drive chain roller Green with the mark 3 facing toward the frame and lower drive chain roller Blac...

Page 105: ...tments Check the spherical bearings and dust seal for dust dirt and foreign materials Make all 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 each adjustment If you have a problem finding an acceptable adjustment return to the standard position and begin again 1 Remove the front visor bolts 1 and pul...

Page 106: ... Remove the front visor page 99 2 Remove the steering damper mounting bolts 1 collar A 2 collar B 3 and steering damper 4 4 3 1 2 1 steering damper mounting bolts 2 collar A 3 collar B 4 steering damper Inspection 1 Check the damper rod 1 operation The damper rod is fully extended and compressed by hand Release the damper rod then check that it extends to its maximum length If the damper rod does ...

Page 107: ...the steering damper 1 with its UP mark 2 facing up and forward Turn the damper rod and its stopper ring 3 facing toward the front side 3 Install the collar A 4 collar B 5 and steering damper mounting bolts 6 Be sure to install the collar A and collar B with its wide flange side facing toward the steering head pipe side 4 Tighten the steering damper mounting bolts to the specified torque 20 N m 2 0...

Page 108: ...the Honda Shop 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 2 4 Check the torque of the handlebar upper holder bolts 3 22 N m 2 2 kgf m 16 lbf ft Tighten the front bolts first 1 handleb...

Page 109: ...pe joint nuts Drive sprocket bolt Engine oil drain bolt Transmission oil drain bolt Coolant drain bolt Torque lbf ft 7 7 7 7 11 7 7 7 15 23 12 12 7 N m 10 10 10 10 15 10 10 10 21 31 16 16 10 kgf m 1 0 1 0 1 0 1 0 1 5 1 0 1 0 1 0 2 1 3 2 1 6 1 6 1 0 1 cylinder head cover bolts 2 clutch cover bolts 3 water pump cover bolts 4 transmission oil check bolt 5 crankshaft hole cap 9 exhaust pipe joint nuts...

Page 110: ...y 30 days to maintain its service life If you do not remove the battery we recommend disconnecting the battery cables negative cable first You will get the best storage results from removing the battery and slow trickle charging it every 30 days see Battery Charging on page 105 Before you remove the battery be sure to read all the information that follows as well as the information on the battery ...

Page 111: ...the battery We recommended 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 ...

Page 112: ...tor 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 5 counterclockwise 5 headlight bulb socket 4 Install a new headlight bulb 6 into the headlight unit while aligning the tab 7 with the groove 8 of the headlight unit If you touch the bulb wi...

Page 113: ...sting screw Taillight The 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 k...

Page 114: ...ng head bearings 2 suspension pivot points High pressure water or air can damage certain parts of your CRF You may use 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 multi surface cleaner degreaser and rinse with a garden hose at full pressure Stubborn deposits ma...

Page 115: ...polish the surface using strokes parallel to the length of the frame Clean the frame using a wet sponge and a mild detergent 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 discolour the frame surface Muffler stain remover Scotch Brite Hand Pad 7447 maroon is for ...

Page 116: ...110 Servicing Your Honda HONDA O M CRF450X Eu 3RMEY620 00X3R MEY 6200 ...

Page 117: ...anced by installing the optional fork springs of a similar rate Front Suspension Adjustments 112 Front Suspension Air Pressure 112 Front Suspension Damping 112 Fork Springs 113 Front Suspension Disassembly 113 Damper Oil Change 117 Fork Assembly 120 Rear Suspension Adjustments 126 Rear Suspension Spring Pre Load 126 Rear Suspension Damping 127 Rear Suspension Race Sag 128 Suspension Adjustments fo...

Page 118: ...sing the fork air 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 an optional 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 Remo...

Page 119: ... fork springs in CRF s are about right for riders weighing between 68 kg 150 lbs and 73 kg 160 lbs less riding gear So if you re a heavier rider you have to go up on the oil capacity 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 If the fork is too hard on big bumps turn the damping adjus...

Page 120: ...he disc cover bolts 9 8 disc cover 9 disc cover bolts 8 9 10 tripmeter cable 12 axle pinch bolts 11 front axle nut 13 front axle shaft 8 Remove the fork protector bolts 14 tripmeter cable clamp screws 15 brake hose clamp bolts 16 and fork protectors 17 Remove the brake caliper mounting bolts 18 and brake caliper 19 The fork protector bolts and caliper mounting bolts have a locking agent applied 5 ...

Page 121: ...the outer tube and slider when removing the fork damper NOTICE 6 fork damper 24 outer tube 7 lock nut wrench 25 axle holder 28 outer tube slider 29 oil holes 21 sliding surface 23 length 22 fork dust seal 12 Hold the outer tube 24 then remove the fork damper 6 from the outer tube using a lock nut wrench 7 Gently slide the outer tube down onto the lower end axle holder 25 27 24 26 22 22 21 23 7 24 ...

Page 122: ...k from the vise Remove the fork spring 36 from the fork assembly 34 fork damper assembly 36 fork spring 35 fork assembly 25 31 32 30 34 36 35 17 Make the mechanic s stopper tool out of a thin piece of steel 2 0 mm 0 08 in thick as shown if you do not have the special tool 39 mm 1 5 in 15 mm 0 6 in 55 mm 2 2 in 25 mm 1 0 in R7 5 mm 0 30 in 14 Temporarily install the fork damper to the outer tube 15...

Page 123: ... oil holes 5 fork damper spring chamber 5 Clean the fork cap and fork damper threads 1 fork damper 7 Pump the fork damper piston rod 6 slowly several times to bleed the air from the fork damper 1 1 fork damper 6 fork damper piston rod 1 3 2 2 1 5 4 1 1 6 6 Extend the fork damper piston rod to maximum Pour the recommended fork oil into the fork damper 1 Recommended Oil Honda ULTRA CUSHION OIL SPECI...

Page 124: ... 1 in an upright position and pump the fork damper piston rod 6 to 100 mm 3 9 in slowly several times 1 3 2 10 Place the fork damper 1 in a vise with a piece of wood or soft jaws to avoid damage 11 Tighten the fork cap assembly 2 while holding the cut out of the fork damper using a lock nut wrench 3 to the specified torque 30 N m 3 1 kgf m 22 lbf ft 1 fork damper 9 Apply fork oil to the bushing 7 ...

Page 125: ...ing chamber 5 By doing this procedure about 17 cm3 0 6 US oz 0 6 Imp oz of fork fluid will be drained from the damper spring chamber through the oil hole and cause 175 cm3 5 9 US oz 6 2 Imp oz of fork fluid to be left in the chamber 14 Blow the extra oil off to the fork damper spring chamber 5 by pumping the fork damper piston rod to full stroke 16 Blow out the oil from the fork damper spring cham...

Page 126: ...ent NOTICE 2 Tighten the fork centre bolt lock nut 2 fully and measure the thread length A as shown Standard 11 13 mm 0 4 0 5 in Wipe the oil completely off the fork damper 2 fork centre bolt lock nut A thread length 3 Blow out the oil completely off the fork spring 3 using the compressed air Install the fork spring Install the fork damper assembly 4 to the fork assembly 1 1 fork assembly 4 fork d...

Page 127: ...g 5 piston base 8 fork centre bolt 6 push rod 9 adjusting rod 8 Measure the length of the fork centre bolt lock nut 2 and fork centre bolt 8 clearance Standard 1 5 2 0 mm 0 06 0 08 in If the clearance is out of specification check the fork centre bolt lock nut and fork centre bolt installation 2 fork centre bolt lock nut 8 fork centre bolt 9 Tighten the fork centre bolt lock nut 2 to the fork cent...

Page 128: ...S oz 10 8 Imp oz Optional Softer 4 41 N mm 25 18 lbf in Fork Spring Standard oil capacity 330 cm3 11 2 US oz 11 6 Imp oz Maximum oil capacity 407 cm3 13 8 US oz 14 3 Imp oz Slightly stiffer as it nears full compression Slightly softer as it nears full compression Minimum oil capacity 311 cm3 10 5 US oz 10 9 Imp oz No mark factory products 2 scribe marks 1 scribe mark aftermarket parts or Optional ...

Page 129: ...in long deflecting beam type torque wrench The lock nut wrench increases the torque wrench s leverage so the torque wrench reading will be less than the torque actually applied to the fork damper 18 For ease of releasing air pressure after the forks are installed loosen the fork bridge lower pinch bolts and position the outer tubes so that the fork air pressure release screws 16 are in front of th...

Page 130: ...and tripmeter gear box 29 for wear or damage Apply grease to the dust seal lips Install the left side collar to the left wheel hub Install the tripmeter gear box while aligning its tabs 30 of the tripmeter gear box with the grooves 31 on the right wheel hub 25 Clean the clamping surface of the axle shaft and axle holders Install the front wheel 32 between the fork legs while inserting the disc bet...

Page 131: ...y tighten the right axle pinch bolts 41 to the specified torque 20 N m 2 0 kgf m 15 lbf ft To avoid damage when torquing the axle pinch bolts be sure the axle is seated firmly onto the right fork leg clamp inner surface 30 Connect the tripmeter cable 42 and tighten the lock nut securely NOTICE 31 Install the disc cover 43 and tighten the disc cover bolts 44 to the specified torque 13 N m 1 3 kgf m...

Page 132: ...proper tools safety equipment and the Honda Shop Manual If your CRF is new put enough part throttle break in time about 1 hour on it to ensure that the suspension has worked in Rear Suspension Spring Pre Load Pre load should be adjusted when the engine is cold because it is necessary to remove the muffler page 62 Optional pin spanners are available for turning the lock nut and adjusting nut to adj...

Page 133: ...peeds 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 12 turn increments Be sure the low speed compression damping adjuster is firmly located in a detent and not between positions 1 high speed compression damping adjuster 2 low speed compression damping adjuster High Speed Compres...

Page 134: ...y suspension 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 centre of the rear fender mounting bolt to the centre o...

Page 135: ...ion step 5 from the unloaded 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 10 to 25 mm 0 4 to 1 0 in If the rear of your CRF sags less than 10 mm 0 4 in from its own weight the spring is too stiff for your weight It is not co...

Page 136: ...ty In a muddy event stiffer 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 da...

Page 137: ... on landings Bottoms on 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 ...

Page 138: ... spring makes the suspension too stiff over the full range of travel Test softer compression damping adjustments in one click increments until the desired 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 trav...

Page 139: ...spension feels stiff 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...

Page 140: ...elivered to the cylinder when a 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 Circui...

Page 141: ...let check valve Slow Circuit Fuel is metered by the slow jet 1 and mixed with air from the air passage 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 air passage 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...

Page 142: ...lt 3 2 shock absorber upper mounting nut 3 shock absorber upper mounting bolt 9 Disconnect the throttle position sensor connector 4 4 throttle position sensor connector 10 Loosen the insulator band screw 5 and remove the carburetor 6 from the insulator 7 5 insulator band screw 7 insulator 6 carburetor 11 Loosen the hot start cable nut 8 and remove the hot start valve 9 from the carburetor 8 hot st...

Page 143: ...nk arm torx screw 6 and throttle valve 5 When installing the link arm torx screw apply a locking agent to the link arm torx screw threads 7 throttle valve roller 8 floating valve 3 1 2 4 5 5 4 6 5 5 8 7 12 Remove the throttle drum cover bolt 10 and throttle drum cover 11 10 throttle drum cover bolt 11 throttle drum cover 13 Loosen the throttle cable lock nut 12 adjuster 13 throttle cable bolt 14 a...

Page 144: ...4 and diaphragm 15 Clean the diaphragm When installing the U ring into the accelerator pump cover 11 make sure the U ring flat side faces down away from the float bowl 16 11 accelerator pump cover 14 spring 12 U ring 15 diaphragm 13 O ring 16 float bowl 8 Remove the holder screw 17 throttle stop screw holder 18 float bowl screws 19 tube guides 20 and float bowl 16 16 float bowl 17 holder screw 18 ...

Page 145: ... m 1 5 lbf ft carburetor top cover bolts 2 1 N m 0 2 kgf m 1 5 lbf ft jet needle holder assembly 2 1 N m 0 2 kgf m 1 5 lbf ft link arm torx screw 2 1 N m 0 2 kgf m 1 5 lbf ft throttle drum cover bolt 3 4 N m 0 3 kgf m 2 5 lbf ft hot start cable nut 2 1 N m 0 2 kgf m 1 5 lbf ft throttle cable lock nut 4 0 N m 0 4 kgf m 3 0 lbf ft throttle cable bolt 4 0 N m 0 4 kgf m 3 0 lbf ft shock absorber upper...

Page 146: ... 5 6 8 8 0 3 mm 0 0 1 in 140 Adjustments for Competition Idle Speed Adjustment 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 Keep the motorcycle in an upright position 5 Adjust idle speed with the throttle stop screw 1 Idle speed 1 700 100 min 1 rpm 1 throttle stop screw 1 ...

Page 147: ...kwise advances the adjuster six positions To adjust the adjuster to the standard setting proceed as follows Turn the adjuster clockwise until it will no longer turn lightly seats This is the full hard position The adjuster is set in the standard position when the adjuster is turned counterclockwise 9 clicks Damping can be increased by turning the adjuster clockwise Always start with full hard when...

Page 148: ...d settings Turn the steering damper adjuster in one click increments at a time Adjusting two or more clicks at a time may cause you to pass over the best adjustment Test ride after each adjustment Symptom Action Steering is wobbling on large bumps Adjust the steering damper adjuster to stiffer setting Steering is wobbling at sand track Adjust the steering damper adjuster to stiffer setting Steerin...

Page 149: ...ravel Keep the race sag adjustment page 128 in the 90 110 mm 3 5 4 3 in range Fork Height Angle Standard Position The position of the outer tubes in the clamps is not adjustable Align the top of outer tube 1 with the top of 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 o...

Page 150: ...during the 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 ...

Page 151: ...designed for special terrain use remember they will be less acceptable in other circumstances For example an aggressive mud tyre will give excellent grip on wet loamy terrain but less impressive grip on a hard surface If you choose a tyre 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 s...

Page 152: ...pid access but not so close that either 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 0 1 in using...

Page 153: ...MEY 6200 Tips Tips 147 Here s helpful advice on how to transport and store your Honda as well as three troubleshooting flow charts Transporting Your Motorcycle 148 Storing Your Honda 149 Preparation for Storage 149 Removal from Storage 150 You the Environment 151 Troubleshooting 152 ...

Page 154: ...ront of the truck bed or trailer rail Attach the lower ends of two straps to the tie down hooks on your CRF 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 compressed about half way Too much pressu...

Page 155: ...blem 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 engin...

Page 156: ... if more than 4 months have passed since the start of storage pages 43 46 2 Uncover the end of the muffler and remove the rag from the muffler outlet 3 Fill the fuel tank with recommended fuel page 40 4 Charge the battery page 105 as required Install the battery 5 Pour a fresh recommended coolant mixture page 47 slowly into the radiator filler hole up to the filler neck Capacity 1 45R 1 53 US qt 1...

Page 157: ...ve ozone layer Don t throw 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 petrol 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 p...

Page 158: ...ather tube P 40 Faulty spark plug P 60 Fouled spark plug P 60 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 CORRECT Valve stuck open Worn cylinder and piston ring Leaking damaged cylinder head gasket...

Page 159: ...F450X Eu 3RMEY620 00X3R MEY 6200 Taking Care of the Unexpected Taking Care of the Unexpected 153 This section gives practical advice to help you solve problems If a Fuse Blows 154 If Your Battery Is Low or Dead 155 ...

Page 160: ... 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 wire connector 7 main fuse 8 blown fuse 9 spare main fuse 6 Reconnect the wire connector and install the starter magnetic switch If you do not have a replacement fuse with ...

Page 161: ...ter 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 155 HONDA O M CRF450X Eu 3RMEY620 00X3R MEY 6200 ...

Page 162: ...HONDA O M CRF450X Eu 3RMEY620 00X3R MEY 6200 156 Taking Care of the Unexpected ...

Page 163: ...cal Information This section contains dimensions capacities and other technical data Vehicle Identification 158 Specifications 159 Torque Specifications 161 Petrol Containing Alcohol 165 Competition Logbook 166 Optional Parts List 168 Spare Parts Equipment 169 Wiring Diagram 170 ...

Page 164: ...engine serial number are required when you register your CRF They may also be required when ordering replacement parts The VIN vehicle identification number 1 is stamped on the right side of the steering head VIN RIGHT SIDE The engine number 2 is stamped on the left crankcase ENGINE No LEFT SIDE 1 VIN 2 engine number 1 2 ...

Page 165: ...27 4 cu in 0 71 US qt 0 59 Imp qt 0 74 US qt 0 62 Imp qt 0 92 US qt 0 77 Imp qt 0 69 US qt 0 57 Imp qt 0 79 US qt 0 66 Imp qt 1 28 US qt 1 06 Imp qt 1 53 US qt 1 28 Imp qt After disassembly Cooling system capacity After draining Single 6 inclined from vertical Metric 96 0 x 62 1 mm 8 0 mm 449 cm3 0 65R 0 75R 1 21R 1 45R 0 70R 0 87R 0 67R Item Type Frame Fork oil capacity except fork damper per leg...

Page 166: ...K DENSO ICM Electric Kickstarter Battery 12V 6 Ah Light Headlight 12V 35 W Clutch type Transmission Primary reduction Gear ratio I Gear ratio II Gear ratio III Gear ratio IV Gear ratio V Final reduction Item Gear shift pattern Ignition Starting system Spark plug Standard Optional Spark plug gap 1 0 1 1 mm 0 039 0 043 in Fuse Main fuse 15 A Left foot operated return system 1 N 2 3 4 5 IFR8H11 VK24P...

Page 167: ...k bolt Crankshaft hole cap Oil filter cover bolts Cylinder bolt Cylinder head bolts Exhaust pipe joint nuts Drive sprocket bolt Engine oil drain bolt Transmission oil drain bolt Coolant drain bolt Torque Remarks lbf ft N m kgf m 7 7 7 7 11 7 7 7 15 23 12 12 7 10 10 10 10 15 10 10 10 21 31 16 16 10 1 0 1 0 1 0 1 0 1 5 1 0 1 0 1 0 2 1 3 2 1 6 1 6 1 0 1 UBS bolt 2 Apply grease to the threads 3 Apply ...

Page 168: ... swingarm side shock link side Rear shock link nuts Shock spring lock nut Kickstarter arm bolt Shroud B bolts Torque Remarks N m kgf m lbf ft 108 22 20 22 44 88 20 128 27 54 54 54 26 44 44 88 34 30 53 53 53 44 38 5 11 0 2 2 2 0 2 2 4 5 9 0 2 0 13 1 2 8 5 5 5 5 5 5 2 7 4 5 4 5 9 0 3 5 3 1 5 4 5 4 5 4 4 5 3 9 0 5 80 16 15 16 32 65 15 94 20 40 40 40 19 32 32 65 25 22 39 39 39 32 28 3 7 NOTE 1 NOTE 2 ...

Page 169: ...ose guide bolts Muffler mounting bolts front rear Muffler clamp bolt Driven sprocket nuts Seat mounting bolts Torque Remarks N m kgf m lbf ft 4 4 4 4 7 3 25 22 12 12 27 2 7 2 7 9 36 36 9 9 51 16 10 5 2 0 5 3 8 19 19 15 24 19 0 6 0 6 1 0 3 5 3 1 1 6 1 6 3 7 0 4 0 4 1 2 5 0 5 0 1 2 1 2 7 0 2 2 1 3 0 7 0 1 0 5 2 7 2 7 2 1 3 3 2 7 6 5 9 9 9 34 30 16 16 36 3 68 3 7 12 49 49 12 12 69 22 13 7 0 7 5 2 26 ...

Page 170: ...amper mounting bolts Fuel joint mounting bolts Throttle cable adjuster lock nuts Torque Remarks N m kgf m lbf ft 0 7 0 7 0 9 41 22 15 7 3 0 0 1 0 1 0 1 5 6 3 1 2 0 1 0 0 4 1 1 1 2 55 30 20 10 4 NOTE 5 1 U nut 2 UBS nut 3 SH bolt 4 Apply locking agent to the threads 5 Alock bolt replace with a new one 6 Apply molybdenum oil to the threads and flange surface 7 Apply a seizure inhibitor Three Bond 19...

Page 171: ...tors for methanol Never use petrol containing more than 5 methanol even if it has cosolvents and corrosion inhibitors Engine performance problems resulting from the use of fuels that contain alcohol are not covered under the warranty Honda cannot endorse the use of fuels containing methanol since evidence of their suitability is not yet complete Before buying fuel from an unfamiliar station try to...

Page 172: ...terval maintenance repairs running time on engine running time on suspension components Timekeeping This Manual lists maintenance intervals for every so many hours of running 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 to record your time the same way aircraft operators do b...

Page 173: ...DA O M CRF450X Eu 3RMEY620 00X3R MEY 6200 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 174: ...cts Red paint aftermarket parts or 52 0 N mm 296 9 lbf in 4 61 N mm 26 32 lbf in 4 41 N mm 25 18 lbf in 4 81 N mm 27 47 lbf in Red Blue 55 9 N mm 319 2 lbf in Pink TOOLS Remarks For checking tyre air pressure Pin spanner A Workstand To adjust spring pre load two spanners required For maintenance Air gauge FRAME Remarks Driven sprocket Standard Drive chain links 51 Teeth Aluminum 114 Optional 50 Te...

Page 175: ... hex Allen wrench spoke torque wrench metric scale click stop style pliers standard needle nose channel lock set hammer plastic head syringe with adjustable stop tyre pressure gauge tyre irons tyre pump or air tank feeler gauge set vernier caliper metric Honda Special Tools Any special tools for your CRF purchased from your Honda dealer Lock Nut Wrench 07WMA KZ30100 Tensioner Stopper 070MG 0010100...

Page 176: ...170 Technical Information HONDA O M CRF450X Eu 3RMEY620 00X3R MEY 6200 Wiring Diagram ...

Page 177: ...Technical Information 171 HONDA O M CRF450X Eu 3RMEY620 00X3R MEY 6200 ...

Page 178: ... Competition Maintenance 32 Service Preparations Maintenance Component Locations 34 Seat 35 Fuel Tank 36 Subframe Upright Position 38 Service Procedures Fluids Filters Fuel System 40 Engine Oil 42 Transmission Oil 45 Coolant 47 Air Cleaner 50 Crankcase Breather 52 Engine Throttle 53 Clutch System 55 Hot Start Lever 59 Spark Plug 60 Exhaust Pipe Muffler 62 Spark Arrester 65 Valve Clearance 66 Pisto...

Page 179: ...ORMATION 157 Vehicle Identification 158 Specifications 159 Torque Specifications 161 Petrol Containing Alcohol 165 Competition Logbook 166 Optional Parts List 168 Spare Parts Equipment 169 Wiring Diagram 170 TABLE OF CONTENTS 172 INDEX 174 MANUFACTURER AND AUTHORISED REPRESENTATIVE FOR EU MARKET 177 ...

Page 180: ...0 assembly 139 circuit functions 134 components 134 disassembly 137 idle speed 140 removal 136 care appearance 108 chain drive 96 chassis adjustments 143 choke knob 15 cleaner air 50 cleaning appearance care 108 clutch system adjustment 55 competition logbook 166 controls operating 7 coolant 47 cylinder system 78 damping adjustments front 112 rear 127 diagram wiring 170 drive chain 96 engine flood...

Page 181: ...l containing alcohol 165 pinging engine 40 plug spark 60 pre load rear suspension 126 pre ride inspection 11 protective apparel 2 rear suspension maintenance 85 riding apparel 2 basic operation 13 before 9 important safety information 2 safety precautions 2 safety a few words about Safety Messages important information 2 important precautions 2 labels 5 maintenance 25 riding precautions 14 schedul...

Page 182: ...arburetor 139 engine 161 frame 162 164 transmission oil 45 transporting 148 tripmeter 14 troubleshooting 152 tubes replacing 93 tuning tips 134 tyres air pressure 93 flat 93 selection 94 valve clearance 66 valve fuel 15 vehicle identification no VIN 158 washing your motorcycle 108 weight limit 3 wheels 92 wiring diagram 170 W V T ...

Page 183: ...presentative for EU Market 177 HONDA O M CRF450X Eu 3RMEY620 00X3R MEY 6200 Manufacturer Honda Motor Co Ltd No 1 1 2 chome Minami Aoyama Minato ku Tokyo 107 8556 Japan Honda Motor Europe Ltd Aalst Office Wijngaardveld 1 Noord V B 9300 Aalst Belgium Authorised Representative for EU Market ...

Page 184: ...178 Memo HONDA O M CRF450X Eu 3RMEY620 00X3R MEY 6200 ...

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Honda CRF450X 2009, Owner'S Manual & Competition Handbook

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