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Honda CRF450RX 2019 Owner's Manual & Competition Handbook

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OWNER'S MANUAL & COMPETITION HANDBOOK
MANUEL DU CONDUCTEUR ET DE COMPETITION
FAHRERHANDBUCH und WETTBEWERBSANLEITUNG
CRF450RX/R
INSTRUCTIEBOEKJE & WEDSTRIJDHANDBOEK
MANUAL DEL PROPIETARIO Y GUÍA DE COMPETICIONES
MANUALE D'USO E DEGLI ASSETTI DA COMPETIZIONE

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Summary of Contents for Honda CRF450RX 2019

  • Page 1 CRF450RX/R OWNER’S MANUAL & COMPETITION HANDBOOK INSTRUCTIEBOEKJE & WEDSTRIJDHANDBOEK MANUEL DU CONDUCTEUR ET DE COMPETITION MANUAL DEL PROPIETARIO Y GUÍA DE COMPETICIONES FAHRERHANDBUCH und WETTBEWERBSANLEITUNG MANUALE D’USO E DEGLI ASSETTI DA COMPETIZIONE...
  • Page 2 CRF450RX/R OWNER’S MANUAL & COMPETITION HANDBOOK © Honda Motor Co., Ltd., 2019...
  • Page 3 This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when it is resold. All information in this publication is based on the latest product information available at the time of approval for printing. Honda Motor Co., Ltd.
  • Page 4 Honda CRF450RX/CRF450R OWNER’S MANUAL & COMPETITION HANDBOOK...
  • Page 5 Honda, other property, or the environment. parts or system. When you own a Honda, you’re part of a worldwide family of satisfied customers – people Unless you are mechanically qualified and have Abbrev.
  • Page 6 A Few Words About Safety A Few Words About Safety Your safety, and the safety of others, is very important. And operating this motorcycle safely is an important responsibility. To help you make informed decisions about safety, this manual contains a section devoted to Motorcycle Safety, as well as a number of Safety Messages throughout the manual.

  • Page 7: Table Of Contents

    Fuel Line Inspection ........56 Camshaft Removal ........85 Side Stand (CRF450RX)......20 Fuel Pressure Relieving .......57 Shim Selection..........87 Honda Selectable Torque Control ....20 Fuel Line Replacement ........57 Camshaft Installation........88 Starting & Stopping the Engine....... 21 Fuel Pump Filter Replacement ....60 Crankshaft Hole Cap Installation ....
  • Page 8 Fork Damper Installation ......114 Battery Charging........137 Transporting Your Motorcycle ..... 166 Rear Suspension Inspection ...... 117 Appearance Care ...........138 Storing Your Honda ........167 Brakes ............118 General Recommendations ......138 Preparation for Storage......167 Front Brake Lever Adjustment....118 Washing Your Motorcycle with a Mild Removal from Storage.......

  • Page 10: Motorcycle Safety

    Motorcycle Safety Motorcycle Safety This section presents some of the most important Important Safety Information ......2 information and recommendations to help you ride Important Safety Precautions......2 your CRF safely. Please take a few moments to Accessories & Modifications ......3 read these pages. This section also includes Labels (ED type) ..........4 information about the location of safety labels on Safety Labels (U type) ........8...

  • Page 11: Important Safety Information

    Keep your Honda in Safe Condition. As an experienced rider, you know there is much Maintaining your CRF properly is critical to your you can do to protect yourself when you ride.

  • Page 12: Accessories & Modifications

    Accessories & Modifications Accessories & Modifications Accessories & Modifications Installing non-Honda accessories, removing original equipment, or modifying your CRF in any way that would change its design or operation, could seriously impair your CRF’s handling, stability, and braking, making it unsafe to ride.

  • Page 13: Labels (Ed Type)

    Others provide important safety information. Read this information carefully and don’t remove the labels. If a label comes off or becomes hard to read, contact your Honda dealer for a replacement. There is a specific symbol on each label. The meanings of each symbol and label are as follows.
  • Page 14 CAUTION LABEL IMPORTANT INFORMATION • Operator only. No passengers. • This Honda CRF is sold as is without warranty, and the entire risk as to quality and performance is with the buyer. READ OWNER’S MANUAL. • This vehicle is designed and manufactured for competition use only.
  • Page 15 Labels (ED type) BATTERY LABEL DANGER • Do not dismantle, modify or solder the main unit and battery terminals. Doing so may cause leakage, heat generation, explosion, fire or loss of vision due to leaked electrolyte. If electrolyte gets into one's eye, immediately wash the eye with plenty of water, and receive treatment from an eye specialist (ophthalmologist) as soon as possible.
  • Page 16 Labels (ED type) DRIVE CHAIN LABEL CAUTION LABEL BATTERY LABEL FUEL LABEL RADIATOR CAP LABEL REAR CUSHION LABEL (cont’d) Motorcycle Safety...

  • Page 17: Safety Labels (U Type)

    Safety Labels (U type) Safety Labels (U type) Read these labels carefully and don’t remove them. If a label comes off or becomes hard to read, contact your dealer for replacement. Motorcycle Safety...

  • Page 18: Instruments & Controls

    Instruments & Controls Instruments & Controls Read this section carefully before you ride. It Operation Component Locations .....10 presents the location of the basic controls on your MIL (Malfunction Indicator Lamp) ....11 CRF. MIL Blink Pattern........11 Current DTC/Freeze DTC ......11 Circuit Inspection.........12 DTC Index ...........13 Engine Mode &...

  • Page 19: Operation Component Locations

    Operation Component Locations Operation Component Locations engine mode select button Torque Control button front brake lever Torque Control indicator (green) clutch lever engine stop button start button MIL (amber) throttle grip Engine mode indicator (blue) Launch control system indicator (purple) fast idle knob (engine idle speed) rear brake pedal shift lever...

  • Page 20: Mil (Malfunction Indicator Lamp)

    The MIL blinks when there is any abnormality in the PGM-FI system. If the MIL comes on at any other time, reduce speed and refer to an official Honda Shop Manual available for purchase from your dealer. If the MIL does not come on when it should, have your dealer check it for problems.

  • Page 21: Circuit Inspection

    MIL (Malfunction Indicator Lamp) Circuit Inspection Always clean around the ECM and keep debris away from the connectors before disconnecting them. A faulty PGM-FI system is often related to poorly connected or corroded connections. Check the following connections. (1) MAP sensor connector (2) ECT sensor connector (3) TP sensor connector (4) IAT sensor connector...

  • Page 22: Dtc Index

    The MIL blinks of the 12 times can not be checked because the engine can not start at the situation. If the engine does not start, check all connector connections and/or refer to an official Honda Shop Manual for troubleshooting of the PGM-FI symptom.

  • Page 23: Engine Mode & Launch Control System Indicator & Torque Control Indicator

    Engine Mode & Launch Control System Indicator & Torque Control Indicator Engine Mode & Launch Control System Indicator & Torque Control Indicator Engine Mode Indicator Launch Control System Indicator Torque Control Indicator The engine mode indicator (blue) (1) is located The launch control system indicator (purple) (1) is The Torque Control indicator (green) (1) is under the engine mode select button (2).

  • Page 24: Before Riding

    Before each ride, you need to make sure you and Are You Ready to Ride? ........16 your Honda are both ready to ride. To help get you Is Your Motorcycle Ready to Ride? ....17 prepared, this section discusses how to evaluate Pre-ride Inspection........17...

  • Page 25: Are You Ready To Ride

    Are You Ready to Ride? Are You Ready to Ride? Before riding your CRF for the first time, we WARNING strongly recommend that you read this owner’s manual, make sure you understand the safety Not wearing a helmet increases the messages, and know how to operate the controls.

  • Page 26: Is Your Motorcycle Ready To Ride

    Is Your Motorcycle Ready to Ride? Is Your Motorcycle Ready to Ride? Competitive riding can be tough on a motorcycle, Pre-ride Inspection so it’s important to inspect your CRF and correct any problems you find before each ride. Check the Check the following before each ride: following items (page numbers are at the right): •...
  • Page 27 Before Riding...

  • Page 28: Basic Operating Instructions

    This section gives basic information on how to Safe Riding Precautions.......20 start and stop your engine as well as break-in Side Stand (CRF450RX) ......20 guidelines. Honda Selectable Torque Control....20 Starting & Stopping the Engine .......21 Fast Idle Knob..........21 Preparation ...........21 Starting Procedure........21 How to Stop the Engine .......22...

  • Page 29: Safe Riding Precautions

    Before riding your CRF for the first time, please The side stand (1) is used to support your CRF When the Honda selectable torque control (Torque review the Important Safety Precautions while parked (page 23). To operate, push the side...

  • Page 30: Starting & Stopping The Engine

    Starting & Stopping the Engine Starting & Stopping the Engine Always follow the proper starting procedure 3. With the throttle closed. Starting Procedure described below. Pull the clutch lever all the way in, and depress the start button (2). Always follow the proper starting procedure Your CRF can be started with the transmission in described as follows.

  • Page 31: How To Stop The Engine

    Starting & Stopping the Engine Warm Engine Starting When starting the engine, the MIL (amber) will How to Stop the Engine 1. Shift the transmission into neutral. stay on for 2 seconds, then go off. And then the 2. Pull the clutch lever and depress the start engine mode indicator (blue) indicates the current button.

  • Page 32: Parking (Crf450Rx)

    Parking (CRF450RX) Parking (CRF450RX) Lower the side stand to support your CRF. Always choose a level surface to park. Basic Operating Instructions...

  • Page 33: Break-In Guidelines

    Break-in Guidelines Break-in Guidelines Help assure your CRF’s future reliability and performance by paying extra attention to how you ride during the first 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: •...

  • Page 34: Servicing Your Honda

    Tyres & Tubes ..........123 unnecessary. If you want to check the ignition Fuel Tank (CRF450R) ........41 Side Stand (CRF450RX) ....... 125 timing, refer to an official Honda Shop Manual. Subframe ............43 Drive Chain ........... 126 Exhaust Pipe/Muffler........130 An optional tool kit may be available. Check with Service Procedures Additional Maintenance Procedures....

  • Page 35: The Importance Of Maintenance

    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. Always follow the inspection and maintenance recommendations and schedules in this owner’s manual. Servicing Your Honda...

  • Page 36: Maintenance Safety

    Be sure there is adequate ventilation whenever you operate 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. Servicing Your Honda...

  • Page 37: Maintenance Schedule

    Procedures for items in this schedule are provided 3. Replace after the first break-in ride. in an official Honda Shop Manual available for 4. Inspect after the first break-in ride. purchase. 5. Replace the engine oil, if the clutch discs and plates are replaced.

  • Page 38: Maintenance Schedule (Crf450Rx)

    STEERING HEAD BEARINGS SIDE STAND *WE RECOMMEND THESE ITEMS BE SERVICED BY REFERRING TO THE HONDA SHOP MANUAL. This maintenance schedule is based upon average riding condition. Machine subjected to severe use require more frequent servicing. NOTE: 1. Clean after every race for dusty riding condition.

  • Page 39: Maintenance Schedule (Crf450R)

    122 – 124 STEERING HEAD BEARINGS *WE RECOMMEND THESE ITEMS BE SERVICED BY REFERRING TO THE HONDA SHOP MANUAL. This maintenance schedule is based upon average riding condition. Machine subjected to severe use require more frequent servicing. NOTE: 1. Clean after every heat for dusty riding condition.

  • Page 40: General Competition Maintenance

    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.
  • Page 41 –1 (rpm) performance. Follow the servicing instructions in the Maintenance section. Use Honda Foam Air Filter Oil or an equivalent. Be sure to grease the air cleaner flange where it contacts the air cleaner housing. Honda White Lithium Grease or an equivalent is handy for this because any dirt that penetrates this sealing area will show up clearly (page 71).
  • Page 42 Refer to an official Honda Shop Manual. Make sure the engine mounting bolts and nuts are tightened to the proper torque Use only Pro Honda HP Fork Oil, A15-00 or an equivalent specification. which contains special additives to assure maximum performance of your CRF’s front suspension.
  • Page 43 Remove the nuts, clean leaks through the bleed hole, the oil seal is damaged. See an official the threads of both the nuts and bolts, apply Honda Thread Honda Shop Manual or consult your dealer for replacing the mechanical Lock or an equivalent and tighten to the specified torque seal or oil seal.

  • Page 44: Before & After Competition Maintenance

    • Clean the sides of the drive chain with 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. Servicing Your Honda...

  • Page 45: After Competition Maintenance

    If you decide to wash your CRF or use cleaners, refer to Appearance Care (page 138). Remove the drive chain, clean and lubricate it (pages 127 - 129). Be sure the chain is wiped clean and is dry before lubricating the chain. Servicing Your Honda...

  • Page 46: Maintenance Component Locations

    (both left and right) Servicing Your Honda...

  • Page 47: Seat

    (6) to the specified torque: 26 N·m (2.7 kgf·m, 19 lbf·ft) (1) seat mounting bolts (3) seat (2) collars (1) seat front prong (4) seat support base slots (2) slot (5) collars (3) seat centre prongs (6) seat mounting bolts Servicing Your Honda...

  • Page 48: Fuel Tank (Crf450Rx)

    (12) fuel tank band (11) collar 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. (cont’d) Servicing Your Honda...
  • Page 49 (9) tab (13) shroud C bolt (10) slot (14) shroud B bolt (11) air cleaner housing cover (15) shroud A bolt 8. Install the seat (page 38). (5) breather tube (7) hose clamp (6) steering stem nut Servicing Your Honda...

  • Page 50: Fuel Tank (Crf450R)

    7. Lift the fuel tank (11) out of the frame and (12) fuel tank stopper cable hang it to the left of the frame. (13) fuel feed hose Check the fuel tank stopper cable (12) for deterioration, kinks or other damage. (cont’d) Servicing Your Honda...
  • Page 51 (11) shroud C bolt (8) tab (12) shroud B bolt (9) slot (13) shroud A bolt (10) air cleaner housing cover 7. Install the seat (page 38). (4) breather tube (6) hose clamp (5) steering stem nut Servicing Your Honda...

  • Page 52: Subframe

    (3), lift the seat support base (4), and hang it to (15) battery cable terminal bolt (16) battery cable terminal the left of the subframe (5). (10) (9) negative (–) terminal (10) battery (3) starter/ignition relay connector (4) seat support base (5) subframe (cont’d) Servicing Your Honda...
  • Page 53 (9) start magnetic switch (18) subframe upper bolts bolt stay bolt 49 N·m (5.0 kgf·m, 36 lbf·ft) (19) air cleaner connecting tube (10) wire band Left side: Right side: (3) subframe upper bolts (4) subframe lower bolts Servicing Your Honda...
  • Page 54 9. Install the left and right mufflers (page 131). 10. Install the right and left shrouds (page 40, 42). (14) (16) 11. Install the seat (page 38). (14) air cleaner connecting tube clamp screw (15) breather tube (16) IAT sensor connector Servicing Your Honda...

  • Page 55: Fuel System (Crf450Rx)

    Never use stale or contaminated petrol. Avoid getting dirt, dust or water in the fuel tank. (1) fuel quick connect fitting cover (2) fuel line 4. Install the fuel quick connect fitting cover. 5. Install the fuel tank (page 40). Servicing Your Honda...

  • Page 56: Fuel Pressure Relieving

    (1) fuel quick connect fitting cover (2) fuel pump (3) fuel quick connect fitting 5. Remove the bolt (4), clamp and setting rubber (5). (4) bolt (5) clamp and setting rubber (cont’d) Servicing Your Honda...
  • Page 57 Fuel pump side: • Do not use gloves or a shop towel while installing the quick connect fitting. (8) fuel joint (11) disconnected connector (12) plastic bags (7) slide retainer (8) fuel joint (9) connector housing (3) slide retainer Servicing Your Honda...
  • Page 58 (3) slide retainer 7. Increase the fuel pressure (page 55). (4) connector housing 4. Make sure the connection is secure and that the slide retainer is firmly locked into place; check visually and by pulling the connector housing. Servicing Your Honda...

  • Page 59: Fuel Pump Filter Replacement

    4. Pull the harness band clip (4) while pressing both side of the anchor and disconnect it. (2) stopper cable (5) fuel pump mounting bolts (6) stopper cable guide (7) washers (8) collars (9) conical spring washers (10) fuel pump plate Servicing Your Honda...
  • Page 60 Be careful not to damage the wires when (16) disconnecting the fuel pump wire terminals. (15) hooks (17) grooves (20) (16) tabs (13) (21) (14) (20) fuel pump stopper (21) damper rubber (13) fuel pump wire terminals (14) fuel pump base (cont’d) Servicing Your Honda...
  • Page 61 (6) while (22) routing the fuel pump red (7) and black (8) wires through the holder grooves (9) as shown. (10) damper rubber (new) (11) fuel pump stopper (23) (22) fuel pump assembly (23) fuel pump filter Servicing Your Honda...
  • Page 62 (20). Push the wire terminals until they stop as shown. Be careful not to damage the wires. (23) (22) fuel pump unit (23) O-ring (new) (24) fuel tank (cont’d) Servicing Your Honda...
  • Page 63 (27) conical spring washers (28) collars (29) washers (30) stopper cable (31) stopper cable guide (30) (32) fuel pump mounting bolts (24) fuel tank (33) harness band clip (30) stopper cable (34) hook (31) stopper cable guide Servicing Your Honda...

  • Page 64: Fuel Pressure Increasing

    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 Shop Manual for troubleshooting of the PGM-FI symptom. Servicing Your Honda...

  • Page 65: Fuel System (Crf450R)

    Never use stale or contaminated petrol. Avoid getting dirt, dust or water in the fuel tank. (1) fuel quick connect fitting cover (2) fuel line 4. Install the fuel quick connect fitting cover. 5. Install the fuel tank (page 40). Servicing Your Honda...

  • Page 66: Fuel Pressure Relieving

    (1) fuel quick connect fitting cover (2) fuel pump (3) fuel quick connect fitting 5. Remove the bolt (4), clamp and setting rubber (5). (4) bolt (5) clamp and setting rubber (cont’d) Servicing Your Honda...
  • Page 67 Fuel pump side: • Do not use gloves or a shop towel while installing the quick connect fitting. (8) fuel joint (11) disconnected connector (12) plastic bags (7) slide retainer (8) fuel joint (9) connector housing (3) slide retainer Servicing Your Honda...
  • Page 68 (3) slide retainer 7. Increase the fuel pressure (page 65). (4) connector housing 4. Make sure the connection is secure and that the slide retainer is firmly locked into place; check visually and by pulling the connector housing. Servicing Your Honda...

  • Page 69: Fuel Pump Filter Replacement

    (2) stopper cable (5) fuel pump mounting nuts (6) fuel pump mounting cap nut (7) stopper cable guide (8) washer (9) collars (10) conical spring washers (11) fuel pump plate Servicing Your Honda...
  • Page 70 Be careful not to damage the wires when disconnecting the fuel pump wire terminals. (18) (22) (17) hooks (19) grooves (18) tabs (15) (23) (16) (22) fuel pump stopper (23) damper rubber (15) fuel pump wire terminals (16) fuel pump base (cont’d) Servicing Your Honda...
  • Page 71 (6) while routing the fuel pump yellow (7) and green (8) wires through the holder grooves (9) as shown. (10) damper rubber (new) (27) (11) fuel pump stopper (24) fuel pump assembly (27) fuel pump filter Servicing Your Honda...
  • Page 72 (13) fuel pump base (23) grooves Be careful not to damage the wires. (21) dust seal (new) (24) dust seal lug (22) tabs (25) index mark (29) fuel pump unit (30) fuel tank (cont’d) Servicing Your Honda...
  • Page 73 (37) stopper cable (43) hook (39) fuel pump mounting nuts (38) stopper cable guide (40) fuel pump mounting cap nut (41) identification mark 16. Connect the fuel line (page 58). 17. Increase the fuel pressure (page 65). Servicing Your Honda...

  • Page 74: Fuel Pressure Increasing

    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 Shop Manual for troubleshooting of the PGM-FI symptom. Servicing Your Honda...

  • Page 75: Engine Oil

    (1) oil code conserving or resource riding area is within the indicated range. (2) oil classification conserving on the circular API service label viscosity SAE 10W-30 (weight) JASO T 903 standard suggested oil Honda “4-STROKE MOTORCYCLE OIL” or equivalent Servicing Your Honda...

  • Page 76: Checking & Adding Oil

    3. Support the CRF in an upright position on a level surface. 4. Remove the engine oil fill cap/dipstick (4) from the left crankcase cover. (1) engine oil fill cap/dipstick (2) upper level mark (3) lower level mark (cont’d) Servicing Your Honda...
  • Page 77 However, if you replace only the oil before the (13) on the filter body, near the rubber seal. recommended interval, see page 29. Use a new Honda Genuine oil filter or a filter of equal quality specified for your model. Servicing Your Honda...

  • Page 78: Coolant

    Decreasing the concentration of antifreeze to less 4. Install the radiator cap securely. than 40% will not provide proper corrosion protection. If the radiator cap is not installed properly, it will cause excessive coolant loss and may result in overheating and engine damage. Servicing Your Honda...

  • Page 79: Cooling System Inspection

    3. Check the radiator mount for looseness. A small amount of coolant weeping from the 4. Make sure the overflow hose (2) is connected bleed hole is normal. See an official Honda and not clogged. (6) fins Shop Manual or consult your dealer for 5.

  • Page 80: Air Cleaner

    Your CRF’s air cleaner has very specific performance requirements. Use a new Honda Genuine air cleaner specified for your model or an (1) air cleaner retaining bolt air cleaner of equal quality.
  • Page 81 Then wash in hot, soapy water, rinse cleaner element. well, and allow to dry thoroughly. The air 8. Apply 1.5 – 5.5 g (0.05 – 0.19 oz) of Honda cleaner element is made in two pieces: inner White Lithium Grease or equivalent to the air and outer, which cannot be separated.

  • Page 82: Crankcase Breather

    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. (1) crankcase breather tube plug (2) crankcase breather tube (3) clip Servicing Your Honda...

  • Page 83: Throttle

    If you can’t get the freeplay within the specified Tighten the lock nut securely. range, contact your dealer. Make the adjustment with the lower adjuster. Servicing Your Honda...

  • Page 84: Throttle Inspection

    6. Install the dust cover in the reverse order. (3) throttle If the throttle operation is not smooth, replace the throttle cable. Be sure the throttle returns freely from fully open to fully closed automatically, in all steering positions. Servicing Your Honda...

  • Page 85: Engine Idle Speed

    2. Connect a tachometer to the engine. 3. Shift the transmission into neutral. Start the engine. 4. Adjust idle speed with the fast idle knob (1). Idle speed: 2,000 ± 100 min (rpm) (–) (1) fast idle knob (+) increase (–) decrease Servicing Your Honda...

  • Page 86: Clutch System

    If you can’t get proper adjustment, or the clutch does not work properly, the cable may be kinked or worn, or the clutch discs may be worn. Inspect the clutch discs and plates (page 80). Servicing Your Honda...

  • Page 87: Other Inspections

    5. Connect the clutch cable end to the lever. 2. Check the clutch cable for deterioration, kinks, 6. Install the clutch cable and turn the adjuster. or damage. Servicing Your Honda...

  • Page 88: Clutch Disc/Plate Removal

    4. Remove the clutch pressure plate (4). (6) thrust bearing If the operation is not smooth, refer to an official Honda Shop Manual for bearing disassembly or see your dealer. (3) clutch spring bolts and springs (4) clutch pressure plate...

  • Page 89: Clutch Disc/Plate/Spring Inspection

    Replace the clutch discs and plates as a set. disc C disc B disc A (1) spring seat (5) clutch discs B (2) judder spring (6) lugs (3) clutch disc A (7) groove (4) clutch plates (8) clutch disc C (2) clutch plates Servicing Your Honda...
  • Page 90 (14) clutch cover 12 N·m (1.2 kgf·m, 9 lbf·ft) 9. Fill the crankcase with the recommended oil (page 67). (12) (11) (11) clutch pressure plate (12) clutch springs and bolts Servicing Your Honda...

  • Page 91: Spark Plug

    If a plug is too tight, the threads may be new one. damaged. 10. Connect the spark plug cap. Take care to avoid (3) sealing gasket (4) spark plug gap pinching any cables or wires. 11. Install the fuel tank and seat (pages 38, 40, 42). Servicing Your Honda...

  • Page 92: Valve Clearance

    The valve clearance will change as engine temperature rises. (3) cylinder head cover socket bolts (4) cylinder head cover rubber seals (5) cylinder head cover (6) spark plug hole packing (1) breather tube (2) spark plug cap Servicing Your Honda...

  • Page 93: Positioning At Tdc On The Compression Stroke

    (2) primary drive gear bolt (3) “T” mark (4) index mark (5) decompressor weight 5. Check the timing marks (6) on the cam sprocket aligns with the camshaft holder mating surface (7) of the cylinder head. (8) rocker arms Servicing Your Honda...

  • Page 94: Valve Clearance Inspection

    Camshaft Removal (this page) and select the correct shim for each (1) feeler gauge (3) camshaft cam lobes valve. (2) intake rocker arms Valve Clearance: IN: 0.13 ± 0.03 mm (0.005 ± 0.001 in) (cont’d) Servicing Your Honda...
  • Page 95 (8) set rings (9) left camshaft bearing (10) camshaft (11) cam chain 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. Servicing Your Honda...

  • Page 96: Shim Selection

    (1) shim Do not clean the intake rocker arms using a If a calculated dimension is out of specifications, commercially available compound cleaner. have your motorcycle inspected by your dealer. 1.80 mm 1.825 mm 1.85 mm 1.875 mm Servicing Your Honda...

  • Page 97: Camshaft Installation

    (10) and slide the left camshaft bearing to the right fully. (4) plunger (5) decompressor weight If the operation is not smooth, refer to an official Honda Shop Manual for decompressor disassembly or see your dealer. (1) rocker arms (3) valve spring retainers (2) shims...
  • Page 98 (11) (17) camshaft holder (19) camshaft holder bolts (long) Do not let the set rings fall into the crankcase. (18) “ ” mark (20) camshaft holder bolts (short) (11) timing mark (12) camshaft holder mating surface (cont’d) Servicing Your Honda...

  • Page 99: Crankshaft Hole Cap Installation

    Make sure the piston is at TDC on the the cam chain tensioner lifter cover bolt (27). compression stroke (page 84). (1) O-ring (new) (27) (2) crankshaft hole cap (26) (26) sealing washer (new) (27) cam chain tensioner lifter cover bolt Servicing Your Honda...

  • Page 100: Cylinder Head Cover Installation

    10 N·m (1.0 kgf·m, 7 lbf·ft) (1) spark plug hole packing (2) cylinder head cover (3) cylinder head cover packing (4) cylinder head cover groove (2) cylinder head cover (7) cylinder head cover socket bolts Servicing Your Honda...

  • Page 101: Piston/Piston Rings/Piston Pin

    (4). (6) radiator hose clamp screw (7) radiator hose (8) right radiator lower mounting bolt (9) washer (1) ignition coil A connector (3) ignition coil (2) ignition coil B connector (4) ignition coil bolts Servicing Your Honda...
  • Page 102 (18) cylinder head bolts and washers (19) cylinder head (22) (13) (23) (13) cylinder head hanger bolts (14) cylinder head hanger plate bolts (15) left cylinder head hanger plate (16) right cylinder head hanger plate (22) cam chain guide (23) cylinder Servicing Your Honda...

  • Page 103: Cylinder Removal

    Do not let the cam chain fall into the crankcase. Do not let the dowel pins fall into the crankcase. (1) shop towels (3) piston pin (2) piston pin clips (4) piston (3) dowel pins (4) cylinder gasket Servicing Your Honda...

  • Page 104: Piston/Piston Pin/Piston Ring Inspection

    Space the ring end gaps 180 degrees apart between top ring We recommend you consult an official Honda 1. Remove the carbon deposits from the piston and upper side rail. Space the ring end gaps 90 Shop Manual or your dealer for correct Service head and piston ring grooves.

  • Page 105: Piston Installation

    Be careful not to damage or shock the piston pin. Use new pin clips. Never reuse old clips. Do not let the clips fall into the crankcase. Do not align the piston pin clip end gap with the piston cutout (8). Servicing Your Honda...

  • Page 106: Cylinder Installation

    Do not let the cam chain fall into the crankcase. – 10 mm – (0.2 0.4 in) (2) dowel pins (3) cylinder gasket (new) – 10 mm – (0.2 0.4 in) (1) cylinder mating surface (4) cylinder bore (6) cam chain (5) piston rings Servicing Your Honda...

  • Page 107: Cylinder Head Installation

    Install the washers and cylinder head bolts (7) and tighten them to the specified torque in a crisscross pattern in two or three steps: 50 N·m (5.1 kgf·m, 37 lbf·ft) Do not let the washers fall into the crankcase. Servicing Your Honda...
  • Page 108 (19) of the cylinder head as shown. (0 – 0.02 in) (20) radiator hose clamp screw (12) (9) left cylinder head hanger plate (10) right cylinder head hanger plate (11) cylinder head hanger plate bolts (12) cylinder head hanger bolts (cont’d) Servicing Your Honda...
  • Page 109 10 N·m (1.0 kgf·m, 7 lbf·ft) Connect the ignition coil A connector (24) and B connector (25). (24) (22) (23) (25) (22) ignition coil (23) ignition coil bolts (24) ignition coil A connector (25) ignition coil B connector Servicing Your Honda...

  • Page 110: Suspension

    Suspension Suspension Refer to Important Safety Precautions on page 27. • Use Pro Honda HP Fork Oil, A15-00 or an 3. Inspect the wear rings (3) for wear or damage. equivalent which contains special additives to Replace the wear ring if it is 1.5 mm (0.06 in) Loose, worn, or damaged suspension components assure maximum performance of your CRF’s...

  • Page 111: Front Suspension Removal

    Remove the bolts (4) and number (8) handlebar plate (5). 4. Loosen the fork bridge upper pinch bolts (9). 5. Loosen the fork bolts assembly (10), but do not remove them yet. (3) number plate tab (5) number plate (4) bolts Servicing Your Honda...
  • Page 112 To do so will cause (13) difficulty in fitting the brake disc between the brake pads. (24) (24) fork protector socket bolts (25) fork protectors (14) (13) disc cover (14) disc cover socket bolts (cont’d) Servicing Your Honda...

  • Page 113: Recommended Fork Oil

    The outer tube (1) can drop on the axle holder (4) suggested oil Pro Honda HP Fork Oil, A15-00 and damage the fork dust seal (5). To avoid damage, hold both the outer tube and slider when removing the fork damper.

  • Page 114: Fork Oil Refilling

    (1) outer tube 07WMA-KZ30100 • Lock nut wrench Recommended Oil: Improper disposal of drained oil is harmful to the Pro Honda HP Fork Oil, A15-00 environment. Recommended Standard Amount: Amount of fork oil left in the fork (CRF450RX) (within damper and spring)

  • Page 115: Front Suspension Installation

    5. Align the groove (7) in the outer tube with the top surface of the upper fork bridge (8). Align (2) fork damper assembly (3) lock nut wrench (4) fork bolt assembly (7) groove (8) upper fork bridge Servicing Your Honda...
  • Page 116 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). (cont’d) Servicing Your Honda...
  • Page 117 Tighten the left axle pinch bolts (24) to the specified torque: (30) 20 N·m (2.0 kgf·m, 15 lbf·ft) (31) (32) (13) brake hose (33) bolts (30) number plate (34) number plate tab (31) tab (35) handlebar (32) slit Servicing Your Honda...

  • Page 118: Fork Damper Disassembly

    • Piston base 07958-2500001 To avoid damage when torquing the axle pinch (39) compression damping adjuster (40) rebound damping adjuster bolts, be sure the axle is seated firmly onto the left fork leg clamp inner surface. (cont’d) Servicing Your Honda...
  • Page 119 (6) fork damper assembly (7) fork assembly (8) fork spring (9) spring seat collar (10) back-up ring/seat stopper (1) axle holder (3) fork centre bolt lock nut (2) fork centre bolt (4) piston base Servicing Your Honda...

  • Page 120: Damper Oil Change

    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 Fork Oil, A15-00 (2) fork damper piston rod (5) fork bolt bushings Recommended Amount: (3) fork bolt assembly 248 cm (8.4 US oz, 8.7 Imp oz)
  • Page 121 (1) fork centre bolt lock nut (2) fork damper piston rod (7) (8) 13. Check the fork damper piston rod sliding (3) fork bolt assembly (7) O-rings (new) (5) fork bolt bushings (8) piston ring (new) surface and threads for damage. Servicing Your Honda...
  • Page 122 (2) fork damper piston rod (4) fork damper assembly Pour the drained oil into a suitable container and dispose of it in an approved manner (page 168). Improper disposal of drained fluids is harmful to the environment. (cont’d) Servicing Your Honda...

  • Page 123: Fork Damper Installation

    (11) (12) (4) fork damper assembly Amount of fork oil left in the fork (9) oil hole (without damper and spring) unit: cm (11) air pressure release screws minute (12) O-rings (new) °C/°F 30/86 20/68 10/50 0/32 Servicing Your Honda...
  • Page 124 Make sure the black side of the back-up ring is seated on the seat stopper side. Over-tightening the vise can damage the axle holder. (3) slider bushing (6) spring seat collar (4) seat stopper (7) fork damper (5) back-up ring (cont’d) Servicing Your Honda...
  • Page 125 69 N·m (7.0 kgf·m, 51 lbf·ft) fork centre bolt lock nut and fork centre bolt installation. 1.5 – 2.0 mm (0.06 – 0.08 in) (17) (17) (17) fork centre bolt (2) fork centre bolt lock nut (17) fork centre bolt Servicing Your Honda...

  • Page 126: Rear Suspension Inspection

    • If you have a problem finding an acceptable worn or loose swingarm bearings. There adjustment, return to the standard position and should be no movement. If there is, have the begin again. bearings replaced by your dealer. Servicing Your Honda...

  • Page 127: Brakes

    (1) brake lever cover air in the brake system. 2. Loosen the lock nut (2). Refer to an official Honda Shop Manual or see 3. To position the front brake lever farther away your dealer to have the air bled from the system.

  • Page 128: Fluid Level Inspection

    Refer to an official Honda If the pulling distance for the front brake lever Shop Manual or see your dealer for brake bleeding.
  • Page 129 1.0 N·m (0.1 kgf·m, 0.7 lbf·ft) (1) rear brake reservoir cap bolts (2) reservoir cap (3) set plate (4) diaphragm (1) front brake reservoir cap screws (5) upper level mark (2) reservoir cap (3) diaphragm (4) upper level mark Servicing Your Honda...

  • Page 130: Brake Pad Wear

    1.0 mm (0.04 in), both brake pads must be replaced. (0.04 in) minimum thickness indicator 1.0 mm (0.04 in) replace (1) brake pads (2) rear brake caliper replace 1.0 mm (0.04 in) wear indicator grooves (1) brake pads Servicing Your Honda...

  • Page 131: Wheels

    Wheel Rims & Spokes Axles & Wheel Bearings Keeping the wheels true (round) and maintaining 1. Inspect the wheel rims (1) and spokes (2) for See an official Honda Shop Manual for inspection correct spoke tension are critical to safe damage. information: motorcycle operation.

  • Page 132: Tyres & Tubes

    Make sure the valve stem caps are secure. If necessary, install new caps. Servicing Your Honda...

  • Page 133: Tyre Replacement

    • Use a replacement tyre equivalent 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. Servicing Your Honda...

  • Page 134: Side Stand (Crf450Rx)

    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 molybdenum grease. Servicing Your Honda...

  • Page 135: Drive Chain

    Lubricate the drive chain (page 127) if it appears dry or shows signs of rust. Lubricate any kinked or binding links and work them free. Adjust chain slack if needed (page 127). (2) chain guide slider (3) wear limit Servicing Your Honda...

  • Page 136: Drive Chain Rollers

    (Black) with the “ ” mark facing be purchased at most motorcycle shops and should toward outside. be used in preference to motor oil. Pro Honda HP Chain Lube or an equivalent is recommended. Clean the threads of the lower drive chain roller bolt and apply locking agent to the threads.

  • Page 137: Removal, Cleaning & Replacement (Crf450Rx)

    1. Clean the side surfaces of the chain with a dry Remove the drive chain. cloth. Use a high flash point solvent such as kerosene or Honda chain cleaner – not petrol. Do not brush the rubber O-rings. Brushing will REPLACE REPLACE damage them.

  • Page 138: More About Drive Chain (Crf450R)

    Excessively worn sprocket teeth have a hooked, proceeding with inspection and service. worn appearance. Replace any sprocket which is damaged or excessively worn. Service limit: 257.0 mm (10.12 in) MEASURE A SPAN OF 17 PINS (16 PITCHES) Servicing Your Honda...

  • Page 139: Exhaust Pipe/Muffler

    (5) right muffler mounting A bolt (6) right muffler mounting B bolt (7) washer (8) right muffler (1) side covers (3) bolts (2) air cleaner housing covers 3. Loosen the right muffler clamp bolt (4). (4) right muffler clamp bolt Servicing Your Honda...

  • Page 140: Muffler Installation

    (12) washer (11) (12) (13) left muffler (1) gasket (5) tab (2) exhaust pipe (11) right muffler (3) cutout (12) right muffler clamp (7) washer (8) left muffler mounting B bolt (9) left muffler mounting A bolt (cont’d) Servicing Your Honda...
  • Page 141 (17) air cleaner housing covers (19) bolts 26 N·m (2.7 kgf·m, 19 lbf·ft) (18) side covers 16. Install the seat (page 38). (16) (16) right muffler clamp bolt (8) left muffler mounting B bolt (9) left muffler mounting A bolt Servicing Your Honda...

  • Page 142: Exhaust Pipe Removal

    20 N·m (2.0 kgf·m, 15 lbf·ft) 5. Tighten the left muffler clamp bolt, left muffler mounting A bolt and B bolt (page 131). 6. Tighten the right muffler clamp bolt, right muffler mounting A bolt and B bolt (page 131). Servicing Your Honda...

  • Page 143: Additional Maintenance Procedures

    If any roughness or play is felt, but you do not see any movement in the steering head, the fork bushings may be worn. Refer to an official Honda Shop Manual for replacement or adjustment procedures, or see your dealer.

  • Page 144: Nuts, Bolts, Fasteners

    (5) oil filter cover bolts (3) water pump cover bolts (6) cylinder head bolts (4) crankshaft hole cap (8) drive sprocket bolt (6) cylinder head bolts (9) engine oil drain bolt (7) exhaust pipe joint nuts (10) coolant drain bolt Servicing Your Honda...

  • Page 145: Battery

    The lithium-ion (li-ion) battery contains a fuse inside. If the fuse blows, the battery needs replacement. The voltage may read above 12V even with a blown battery fuse when the battery is unmounted (page 173). Servicing Your Honda...

  • Page 146: Battery Charging

    Using an existing lead-acid battery charger or battery charger that is not recommended, will damage the electrical circuits within the Li-ion battery. (1) battery (4) battery band (2) positive (+) terminal bolt (5) positive terminal cover (3) negative (–) terminal bolt Servicing Your Honda...

  • Page 147: Appearance Care

    Detergent Frequent cleaning and polishing will keep your brake master cylinders Honda looking newer longer. Frequent cleaning drive chain Allow the engine, muffler, brakes, and other high- also identifies you as an owner who values his electrical circuit temperature parts to cool before washing.

  • Page 148: After Cleaning Lubrication

    The fuel tank is made of titanium material. To remove mud or dust, use a sponge or soft cloth and a stainless steel kitchen detergent, then rinse well with clean water. After washing, rinse with plenty of water and dry with a clean cloth. Servicing Your Honda...
  • Page 149 Servicing Your Honda...

  • Page 150: Adjustments For Competition

    Engine Mode Select Button ......142 for maximum competition performance. Current Mode..........142 Mode Selection ..........142 Initial suspension adjustments should be Honda Selectable Torque Control....143 performed after a minimum of 2 hours of easy Current Mode..........143 break-in time. Mode Selection ..........143 HRC-Launch Control System ......144 Optional front and rear suspension springs are Front Suspension Adjustments ......145...

  • Page 151: Engine Mode Select Button

    Engine Mode Select Button Engine Mode Select Button Current Mode Mode Selection Start the engine and push the engine mode select 1. Start the engine. button (1) with your CRF stopped. The engine 2. With your CRF stopped and the throttle closed, mode indicator (2) under the engine mode select push and hold the engine mode select button button indicates the selected mode by blinking the...

  • Page 152: Honda Selectable Torque Control

    Honda Selectable Torque Control Honda Selectable Torque Control The Honda selectable torque control reduces slip Current Mode Mode Selection and assists for an effective acceleration by temporarily decreasing the engine torque during Start the engine. 1. Start the engine. rear wheel spin.

  • Page 153: Hrc-Launch Control System

    HRC-Launch Control System HRC-Launch Control System The HRC-Launch Control System reduces slip and 4. To continue using the system, refer to step 2 in assists for an effective start by temporarily To operate the system. decreasing the rev limit and Torque Control To disable the system, quickly press the start operation when starting.

  • Page 154: Front Suspension Adjustments

    Front Suspension Adjustments Front Suspension Adjustments The front suspension can be adjusted for the rider's 4. Install and tighten the pressure release screw to Front Suspension Air Pressure weight and riding conditions by using one or more the specified torque: 1.3 N·m (0.1 kgf·m, 1.0 lbf·ft) of the following methods: Air is an unstable gas which builds up pressure as it...

  • Page 155: Front Suspension Damping

    Front Suspension Adjustments Front Suspension Damping Fork Springs Always start with full hard when adjusting The fork springs in CRF’s are about right for riders Compression Damping Adjustment damping. weighing between 77 kg (170 lb) and 91 kg (200 This adjustment affects how quickly the fork Do not turn the adjuster screw more than the given lb) (less riding gear).

  • Page 156: Fork Oil Adjustment

    Front Suspension Adjustments Example: Front fork characteristics when a (CRF450RX) Fork Oil Adjustment Optional Soft 4.6 N/mm (26.3 Ibf/in) Fork Spring standard spring 1. Remove the front suspension (page 102). (CRF450RX) 2. Disassemble the fork outer tube (page 104). 1 scribe mark Oil capacity 394 cm 3.
  • Page 157 Front Suspension Adjustments (CRF450RX) Optional stiff 5.0 N/mm (28.6 Ibf/in) Fork Spring 2 scribe marks (CRF450R) Optional stiff 5.2 N/mm (29.7 Ibf/in) Fork Spring 3 scribe marks 358 cm CRF450RX (12.1 US oz, Standard 12.6 Imp oz) 350 cm capacity CRF450R (11.8 US oz, 12.3 Imp oz)

  • Page 158: Rear Suspension Adjustments

    (2). proper tools, safety equipment and an official Optional Stiff spring (54 N/mm (308.3 lbf/in)): Each complete turn of the adjusting nut Honda Shop Manual. 230.5 mm (9.07 in) changes the spring length by 1.5 mm (0.06 in). (CRF450R)

  • Page 159: Rear Suspension Damping

    Rear Suspension Adjustments To decrease spring pre-load High Speed Damping: Rear Suspension Damping Loosen the shock spring lock nut using the The high speed damping can be adjusted by optional pin spanners (3) and turn the adjusting nut turning the hexagonal portion of the compression to increase the spring length (4).
  • Page 160 Rear Suspension Adjustments Low Speed Damping: The low speed damping can be adjusted by turning the centre screw of the compression damping adjuster. The low speed compression damping adjuster has 13 clicks or more. Turning the adjuster one full turn changes the adjuster 4 clicks.

  • Page 161: Rear Suspension Race Sag

    Rear Suspension Adjustments unloaded: motorcycle on an optional workstand Ask the other helper to measure the loaded Rear Suspension Race Sag with rear suspension fully extended, no rider. with rider dimension. loaded with rider: motorcycle on ground, with SEAT MOUNTING BOLT Setting the proper race sag (ride height) is very rider.
  • Page 162 Rear Suspension Adjustments Spring Rates A spring that is too stiff for your weight will not If you are lighter or heavier than the average rider allow the rear tyre to hook up under acceleration and cannot set the proper ride height with altering and will pass more bumps on to you.

  • Page 163: Suspension Adjustments For Track Conditions

    Suspension Adjustments for Track Conditions Suspension Adjustments for Track Conditions Soft Surface On soft ground, sand, and especially mud, consider increasing compression damping front and rear. Sand often requires a bit more rebound damping to minimize rear end kick. Although sand bumps are usually larger, there’s more distance between them, giving the shock more time to recover.

  • Page 164: Suspension Adjustment Guidelines

    Suspension Adjustment Guidelines Suspension Adjustment Guidelines Follow the procedures described below to accurately adjust your CRF, using the methods described on pages 145 – 154. Remember to make all adjustments in one-click or 1/12 turn increments. Test ride after each adjustment. Front Suspension Adjustment Adjustments for Type of Track Hard-surfaced track...
  • Page 165 Suspension Adjustment Guidelines Symptom Action Stiff suspension Initial travel too stiff: – Test softer compression damping adjustments in one-click increments. • Stiff on small bumps while riding at full throttle in a straight line. – Reduce the rebound damping adjustments in one-click increments. •...
  • Page 166 Suspension Adjustment Guidelines Rear Suspension Adjustment Adjustments for Type of Track Hard-surfaced track Begin with the standard settings. If the suspension is too stiff/soft, adjust according to the chart below. Sand track Lower the rear end (to improve front wheel stability) by increasing Race Sag (reduce spring pre-load). Example: –...

  • Page 167: Tuning Tips

    Tuning Tips Tuning Tips An optional PGM-FI setting tool can change the ignition timing and amount of the fuel injection (page 186). Using spark plugs with an improper heat range or An improperly tightened spark plug can damage Be sure to observe the PGM-FI setting by checking incorrect reach can cause engine damage.

  • Page 168: Chassis Adjustments

    Chassis Adjustments Chassis Adjustments The following suggestions may improve a specific Fork Height/Angle Wheelbase concern. Subtle changes in overall handling may also be noted. The position of the fork in the clamp is not Adjusting your CRF’s wheelbase can offer subtle adjustable.

  • Page 169: Gearing

    Unless you have the required mechanical know- time. Your goal is the fastest overall lap time, even these conditions. how, tools, and an official Honda Shop Manual, if the cost is some sections where the gearing feels • Wet and slippery or sandy conditions: use a sprocket changing should be done by your dealer.

  • Page 170: Tyre Selection For Track Conditions

    Tyre Selection for Track Conditions Tyre Selection for Track Conditions Choosing the correct tyre tread pattern and rubber If you choose a tyre with a sticky compound for compound can affect your placing in competition. added traction, remember that it may transfer The tyres on your CRF offer a “happy medium”...

  • Page 171: Personal Fit Adjustments

    Make sure that the bolts are torqued securely enough to prevent slippage during normal operation. Apply Honda Thread Lock or an equivalent to the threads of these bolts prior to adjustment to help ensure the correct torque is retained.
  • Page 172 Rear holes of fork bridge Rotating 180 degrees Refer to an official Honda Shop Manual for installation instructions. Be sure to check control cable and wiring harness routing after the adjustment. • Chamfer the edges to remove burrs and other irregularities or roughness after sawing the handlebar.
  • Page 173 Adjustments for Competition...

  • Page 174: Tips

    Tips Tips Here’s helpful advice on how to transport and store Transporting Your Motorcycle ......166 your CRF, as well as three troubleshooting flow Storing Your Honda ........167 charts. Preparation for Storage ......167 Removal from Storage .......167 You & the Environment.........168 Troubleshooting ..........169...

  • Page 175: Transporting Your Motorcycle

    Transporting Your Motorcycle If you use a truck or motorcycle trailer to transport To secure your CRF, brace the front wheel against your Honda, we recommend that you follow these the front of the truck bed or trailer rail. guidelines: Attach the lower ends of two straps to the tie-down •...

  • Page 176: Storing Your Honda

    Storing Your Honda Storing Your Honda If you won’t be riding for an extended period, such 4. Remove the radiator cap and coolant drain bolt 12. Store your CRF in an unheated area, free of as during the winter, thoroughly inspect your CRF...

  • Page 177: You & The Environment

    You & the Environment You & the Environment Owning and riding a motorcycle can be enjoyable, but you must do your part to protect nature. When you show respect for the land, wildlife, and other Improper disposal of drained fluids is harmful to people, you also help preserve the sport of off-road the environment.

  • Page 178: Troubleshooting

    • Faulty fuel injector accelerate or run • Excessive carbon build- parenthesis. The items that require use of an the engine at high up in combustion official Honda Shop Manual are followed by an CORRECT speed chamber asterisk (*). • Ignition timing too...
  • Page 179 Troubleshooting POOR HANDLING POOR PERFORMANCE AT LOW AND IDLE SPEED POOR PERFORMANCE AT HIGH SPEED CHECK POSSIBLE CAUSES CHECK POSSIBLE CAUSES Steering is heavy 1. Check the spark INCORRECT • Incorrect spark plug heat 1. Check the ignition INCORRECT • Faulty ECM* •...

  • Page 180: Taking Care Of The Unexpected

    Taking Care of the Unexpected Taking Care of the Unexpected This section gives practical advice to help you If a Fuse Blows ..........172 solve problems. If Your Battery Is Low (or Dead) ....173 Taking Care of the Unexpected...

  • Page 181: If A Fuse Blows

    If a Fuse Blows If a Fuse Blows All of the electrical circuits on your CRF have a 5. Remove the start magnetic switch stay bolt (1) 9. Install the start magnetic switch cover (4). fuse to protect them from damage caused by excess and plastic wire band (2).

  • Page 182: If Your Battery Is Low (Or Dead)

    If Your Battery Is Low (or Dead) If Your Battery Is Low (or Dead) If an overvoltage, overcurrent, or short circuit is applied, the battery fuse may blow. Do not jump-start as this can damage your CRF’s electrical system and battery. Bump starting is not recommended.
  • Page 183 Taking Care of the Unexpected...

  • Page 184: Technical Information

    Torque Specifications ........179 Nuts, Bolts, Fasteners ........179 Petrol Containing Alcohol ......182 Competition Logbook ........183 Optional Parts List .........185 Spare Parts & Equipment.......186 Spare Parts ..........186 General Tools..........186 Honda Special Tools........186 Chemical Products ........186 Other Products ...........186 Wiring Diagram ..........187 Technical Information...

  • Page 185: Vehicle Identification

    Vehicle Identification Vehicle Identification The engine number (2) is stamped on the right Serial Numbers crankcase. The VIN and 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.

  • Page 186: Specifications

    Specifications Specifications Tyre type bias-ply, tube Item Metric English Item Metric English Tyre pressure, front (cold) 100 kPa (1.0 kgf/cm , 15 psi) Dimension Engine Tyre pressure, rear (cold) 100 kPa (1.0 kgf/cm , 15 psi) CRF450RX: CRF450RX: Type Liquid cooled, 4-stroke 2,175 mm 85.6 in Single disc brake...
  • Page 187 Specifications Item Metric English Drive train Clutch type Wet, multi-plate type Transmission 5-speed, constant mesh Primary reduction 2.357 Gear ratio I 2.133 Gear ratio II 1.706 Gear ratio III 1.421 Gear ratio IV 1.211 Gear ratio V 1.043 CRF450RX: 3.846 Final reduction CRF450R: 3.769 Left foot-operated return...

  • Page 188: Torque Specifications

    Torque Specifications Torque Specifications ENGINE Nuts, Bolts, Fasteners Torque Item Remarks Check and tighten nuts, bolts, and fasteners before every outing. N·m kgf·m lbf·ft LEFT SIDE Cylinder head cover socket bolts Clutch cover bolts Water pump cover bolts Crankshaft hole cap NOTE 1 Oil filter cover bolts Cylinder head bolts...
  • Page 189 Torque Specifications LEFT SIDE FRAME (CRF450R) (16) (23) Torque Item Remarks (21) N·m kgf·m lbf·ft (13) Steering stem nut 11.0 Fork bridge upper pinch (14) bolts Fork bridge lower pinch bolts (17) Handlebar upper holder bolts Handlebar lower holder nuts NOTE 1 Front axle nut Axle pinch bolts...
  • Page 190 Torque Specifications FRAME LEFT SIDE (47) (CRF450R) (56) Torque (49) (54) (48) Item Remarks (48) (53) N·m kgf·m lbf·ft (42) (52) Brake hose oil bolts (32) Front brake caliper mounting bolts (39) (46) Front brake disc nuts NOTE 1 Rear brake disc nuts NOTE 1 (36) Brake pedal pivot bolt...

  • Page 191: Petrol Containing Alcohol

    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.

  • Page 192: Competition Logbook

    Competition Logbook Competition Logbook Any serious competition effort relies heavily on Tuning & Adjustment Records Racing Records the knowledge gained and compiled from previous Keep track of the settings and adjustments that Information worth recording for this section of worked best at a particular location. These items racing events.
  • Page 193 Competition Logbook Date Running Location/Event Comments (Suspension Settings, Gearing, Chassis Adjustments, Maintenance Performed, etc.) Time (Make several photocopies of this page for future use) Technical Information...

  • Page 194: Optional Parts List

    Optional Parts List Optional Parts List These parts and tools may be ordered from your FRAME Remarks FRAME Remarks authorized dealer. Fork spring CRF450RX: 4.8 N/mm (27.4 lbf/in) Shock spring CRF450RX: 52 N/mm (296.9 lbf/in) CRF450R: 56 N/mm (319.8 lbf/in) Standard 1 scribe mark or FRAME...

  • Page 195: Spare Parts & Equipment

    Spare Parts wrenches: open end & box SAE 80 or 90 gear oil wrenches: hex (Allen) Pro Honda HP Fork Oil, A15-00 spark plugs wrench, spoke DOT 4 Brake Fluid air cleaner (clean & oiled, sealed in a plastic bag) torque wrench (metric scale, click-stop style) Drive chain lubricant.

  • Page 196: Wiring Diagram

    Wiring Diagram Wiring Diagram JUNCTION CONNECTOR GP SENSOR TORQUE STARTER CLUTCH FUEL CONTROL SWITCH SWITCH PUMP SWITCH STARTER RELAY SWITCH BATTERY GROUND FUEL INJECTOR BLUE ORANGE STARTER IGNITION COIL MOTOR REGULATOR/ DIODE MAIN STARTER SPARK PLUG ALTERNATOR SENSOR SENSOR SENSOR SENSOR RECTIFIER RELAY...

  • Page 197: Index

    Index Index .............3 ..........46, 56 accessories capacity, fuel engine, .........138 .........169 adjustments, care, appearance does not start ..........159 ..........126 ...........22 chassis chain drive flooded ......74, 77, 118 ........159 ..........76 control freeplay chassis adjustments idle speed for competition ........141 cleaner, air ...........71 lacks power ...........169...
  • Page 198 ............27 safety handlebar inspection ........134 ..........28 schedule ......144 HRC-launch control system ........14, 142 mode indicator ....20 Honda Selectable Torque Control safety, modifications ..........3 .....Safety Messages a few words about ........2 important information ........2 important precautions ...........8 labels (U type) .........176...
  • Page 199 Index suspension adjustment, ........154 for track conditions .............145 front ..........155 guidelines ............149 rear suspension, .............101 front ............117 rear throttle, ...........74 freeplay inspection ..........75 ............186 tools torque specifications, ...........179 engine ..........180, 181 frame ..........166 transporting ..........169 troubleshooting ..........123 tubes, replacing ..........158 tuning tips tyres, ..........123...

  • Page 200: Manufacturer, Authorised Representative And Importer For Eu Market

    Manufacturer, Authorised Representative and Importer for EU Market Manufacturer Authorised Representative and Importer for EU Market Honda Motor Co., Ltd. Honda Motor Europe Ltd - Aalst Office 2-1-1, Minami-Aoyama, Minato-ku, Wijngaardveld 1 (Noord V) Tokyo, 107-8556, Japan 9300 Aalst - Belgium...
  • Page 201 2020.XXXX.XX.L 3RMKE630 00X3R-MKE-6300 Printed in Japan...

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