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CRF450X 2005
Service manual
Honda CRF450X 2005 Service Manual
Motorcycle
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Also See for CRF450X 2005
:
Owner's manual & competition handbook
(180 pages)
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
How to Use this Manual
Contents
Symbols
Table of Contents
General Information Contents
Service Rules
Model Identification
Vehicle Identification Number
Engine Serial Number
Carburetor Identification Number
Name Plate (U.S.A.) or Safety Certification Label (Canada)
Emission Control Information Label
General Specifications
Lubrication System Specifications
Fuel System Specifications
Cooling System Specifications
Cylinder Head/Valves Specifications
Cylinder/Piston Specifications
Clutch/Starter Clutch/Kickstarter/Gearshift Linkage Specifications
Crankcase/ Crankshaft/ Transmission / Balancer Specifications (,Os - ·07)
CRANKCASE/CRANKSHAFT/ TRANSMISSION / BALANCER SPECIFICATIONS Iafter ·07)
Front Wheel/Suspension/Steering Specifications
Battery/Charging System Specifications
Hydraulic Brake Specifications
Ignition System Specifications
Electric Starter Specification
Lights/Meter/Switches Specifications
Engine and Frame Torque Values
Standard Torque Values
Insulator Band
Cylinder Head Side Insulator Band (After'07)
Cylinder Stud Bolt
Water Hose Clamp
Frame
Lubrication and Seal Points
Cable and Harness Routing (05-07)
Secondary Air Supply System (05 and 06 California Type, 07)
Cable and Harness Routing (after 07)
Optional Parts
Parts
Source of Emissions
Exhaust Emission Control System
Crankcase Emission Control System
Emission Control Systems
Exhaust Emission Control System (Pulse Secondary Air Injection System): 05 and 06 California Type, after 06
Prohibited Actions
Servicing the Honda
Fuel Permeation Emission Control System (after 07)
Noise Emission Control System
Rebuilt Engine
Technical Feature Contents
After the Engine Starts
Auto-Decompression System (after 07)
During Starting (When Engine Is Off)
HPSD: after 07
HPSD Characteristics
Frame/Body Panels/Exhaust System Contents
Service Information
Torque Values
Troubleshooting
Seat Installation
Seat Removal
Side Cover Removal/Installation
Radiator Shroud Removal/Installation
Center Engine Guard Removal/Installation
Front Visor Removal/Installation
Left/Right Engine Guard Removal/Installation
Front Visor Removal/Installation (after 07)
Sub-Frame Removal
Sub-Frame Installation
Fuel Tank Removal/Installation
Exhaust System
Muffler Removal/Installation (05-07)
Muffler Removal/Installation (after 07)
Exhaust Pipe Removal
Exhaust System Installation
Maintenance Contents
Maintenance Service Information
Maintenance Schedule (05, 06)
Maintenance Schedule (after '06)
Competition Maintenance Schedule
Additional Items Requiring Frequent Replacement
Fuel Line
Fuel Strainer Screen
Throttle Operation
Air Cleaner
Hot Start
Crankcase Breather
Spark Plug Inspection
Spark Plug Removal
Radiator Coolant
Cooling System
Secondary Air Supply System (05 and 06 California Type, after 06)
Valve Clearance Inspection
Valve Clearance/Decompressor System
Valve Clearance Adjustment
Decompressor Clearance Inspection/Adjustment (05-07)
Decompressor System (after 07)
Engine Oil/Oil Filter
Oil Level Inspection
Engine Oil and Filter Change
Engine Idle Speed
Oil Level Inspection
Transmission Oil
Transmission Oil Change
Drive Chain
Drive Chain Adjustment
Drive Chain Cleaning and Lubrication
Drive Chain Slack Inspection
Drive Chain Replacement
Drive Chain Slider
Drive Chain Roller
Drive/Driven Sprocket
Brake Fluid
Fluid Filling
Fluid Level Inspection
Brake Pad Wear
Brake System
Lever Position Inspection
Brake Pedal Height
Clutch System
Headlight Aim
Control Cables
Exhaust Pipe/Muffler
Exhaust System Inspection
Spark Arrester Inspection/Cleaning
Spark Arrester Removal
Front Suspension Inspection
Sidestand Inspection
Spark Arrester Installation
Rear Suspension Inspection
Swingarm/Shock Linkage
Nuts, Bolts, Fasteners
Wheels/Tires
Steering Head Bearings
Lubrication System Contents
Lubrication System Diagram
Lubrication System Service Information
Oil Strainer Removal/Inspection
Oil Strainer Installation
Pressure Relief Valve Removal/Inspection
Oil Jet Removal/Inspection
Pressure Relief Valve Installation
Oil Jet Installation
Oil Pump Disassembly
Oil Pump Inspection
Oil Pump Assembly
Fuel System Contents
Fuel System Component Location
Fuel System Service Information
Carburetor Adjustment
Idle Mixture and Idle Speed
Air Cleaner Housing Removal
Air Cleaner Housing Installation
Carburetor Removal
Carburetor Disassembly
Jet Needle/Throttle Valve
Choke Knob/Throttle Sensor
Accelerator Pump/Float/Jets
Carburetor Assembly
Carburetor Installation
Throttle Position Sensor Replacement
Best Idle (05, 06: 49 States and Canada Type Only)
Pilot Screw Adjustment
Idle Drop Procedure (05 and 06 California Type, 07, after 07)
System Inspection
Pair Check Valve Ispection
Pair Control Valve Removal/Installation
Air Supply Pipe Removal/Installation
Cooling System Contents
System Flow Pattern
Cooling System Service Information
Cooling System Troubleshooting
Coolant (Hydrometer Test)
Coolant Gravity Chart
System Testing
Coolant Replacement Preparation
Radiator Cap/System Pressure Inspection
Replacement/Air Bleeding
Radiator Removal/Installation
Mechanical/Oil Seal Inspection
Radiator Reserve Tank Removal/Installation
Water Pump
Water Pump Removal
Bearing/Mechanial Seal/Oil Seal Replacement
Water Pump Installation
Engine Removal/Installation Contents
Engine Component Location
Engine Removal
Engine Service Information
Drive Sprocket Installation
Drive Sprocket Removal
Engine Removal
Engine Installation
Drive Sprocket
Cylinder Head/Valves Contents
Cylinder Head/Valves Component Location
Cylinder Head/Valves Service Information
Cylinder Compression Test
Cylinder Head Cover Removal
Camshaft Removal (05-07)
Camshaft Disassembly
Camshaft Inspection
Camshaft Assembly
Camshaft Removal (after 07)
Rocker Arm Inspection
Rocker Arm Shaft Inspection
Cam Sprocket/Decompressor Weight/Spring Inspection
Decompressor Shaft/Plunger Inspection
Camshaft Holder Bearing Replacement
Camshaft Holder Inspection
Valve Lifter Inspection
Camshaft Holder Bearing Assembly
Cylinder Head Removal
Cam Chain Tensioner/Cam Chain Guide Removal
Cam Chain Tensioner/Cam Chain Guide Inspection
Cam Chain Tensioner/Cam Chain Guide Installation
Cylinder Head Disassembly
Cylinder Head Inspection
Valve Spring Inspection
Valve/Valve Guide Inspection
Valve Guide Replacement
Valve Seat Inspection/Refacing
Valve Seat Refasing
Cylinder Head Assembly
Cylinder Head Installation
Camshaft Installation (05-07)
Camshaft Installation (after 07)
Cylinder Head Cover Installation
Cylinder/Piston Contents
Cylinder/Piston Component Location
Cylinder/Piston Service Information
Cylinder/Piston Troubleshooting
Cylinder Removal
Cylinder Inspection
Piston Removal
Piston Ring Removal
Piston/Piston Ring Inspection
Cam Chain Tensioner Lifter Inspection
Connecting Rod Inspection
Piston Installation
Piston Ring Installation
Cylinder Installation
Clutch/Starter Clutch/Kickstarter/Gearshift Linkage Contents
Clutch/Starter Clutch/Kickstarter/Gearshift Linkage Component Location
Clutch/Starter Clutch/Kickstarter/Gearshift Linkage Service Information
Right Crankcase Cover Removal
Right Crankcase Cover Installation
Clutch Removal
Clutch Spring Inspection
Clutch Center Inspection
Clutch Discs Inspection
Clutch Lifter/Needle Bearing Inspection
Clutch Plates Inspection
Clutch Lifter Lever Inspection
Clutch Outer Guide Inspection
Clutch Outer Inspection
Needle Bearing Inspection
Clutch Installation
Kickstarter Disassembly
Kickstarter Inspection
Kickstarter Removal
Kickstarter Assembly
Kickstarter Installation
Starter Clutch Removal
Starter Clutch Disassembly/Inspection
Starter Clutch Assembly
Starter Clutch Installation
Gearshaft Linkage Removal
Gearshaft Linkage Inspection
Gearshift Spindle Inspection
Ratchet Pawl Inspection
Gearshift Linkage Installation
Alternator Contents
Alternator Component Location
Alternator Service Information
Stator
Left Crankcase Cover Removal
Flywheel Removal
Stator Removal
Flywheel Installation
Left Crankcase Cover Installation
Crankcase/Crankshaft/Transmission/Balancer Contents
Crankcase/Crankshaft/Transmission/Balancer Component Location
Crankcase/Crankshaft/Transmission/Balancer Component Service Information
Crankcase/Crankshaft/Transmission/Balancer Troubleshooting
Balancer/Gear Balancer Inspection
Balancer/Gear Balancer Installation
Balancer/Gear Balancer Removal
Crankcase Separation
Transmission Disassembly
Bushing Inspection
Gear Inspection
Mainshaft/Countershaft Inspection
Shift Fork Inspection
Shift Fork Shaft Inspection
Crankshaft Removal
Shift Drum Inspection
Transmission Bearing Inspection
Crankshaft Inspection
Crankcase Bearing Replacement
Crankcase Bearing/Oil Seal Location
Crankshaft Bearing
Left Crankcase
Transmission/Balancer Bearings
Right Crankcase
Crankshaft Installation
Transmission Assembly
Countershaft (05-07)
Mainshaft (after 07)
Countershaft (after 07)
Transmission Installation
Crankcase Assembly
Front Wheel/Suspension/Steering Contents
Front Wheel/Suspension/Steering Component Location
Front Wheel/Suspension/Steering Service Information
Front Wheel/Suspension/Steering Troubleshooting
Axle Inspection
Front Wheel Removal
Front Wheel Disassembly
Wheel Bearing Inspection
Wheel Rim Inspection
Front Wheel Assembly
Front Wheel Installation
Fork Removal
Fork Disassembly
Outer Tube and Slider Disassembly
Fork Damper Disassembly
Fork Cap Inspection
Fork Center Bolt Inspection
Slider/Outer Tube Inspection
Bushing/Back-Up Ring Inspection
Fork Damper Inspection
Fork Spring Inspection
Fork Assembly
Outer Tube and Slider Assembly
Fork Damper Refilling/Assembly
Fork Damper Operation Inspection
Fork Damper Instllation/Preparation
Fork Damper Installation
Fork Installation
Oil Capacity Adjustment
Standard Position
Handlebar Removal
Handlebar Installation
After '07
HPSD (Honda Progressive Steering Damper): after 07 Removal/Installation
HPSD (Honda Progressive Steering Damper): after 07 Inspection
Spherical Bearing Replacement
HPSD (Honda Progressive Steering Damper): after 07 Disassembly
HPSD Assembly
Steering Stem Removal
Bearing Replacement
Steering Stem Installation
Clutch Lever Removal/Installation
Rear Wheel/Suspension Contents
Rear Wheel/Suspension Component Location
Rear Wheel/Suspension Service Information
Rear Wheel/Suspension Troubleshooting
Rear Wheel Removal
Rear Wheel Disassembly
Rear Wheel Assembly
Rear Wheel Installation
Shock Absorber Removal
Bladder Replacement
Shock Absorber Disassembly
Damper Disassembly
Damper Rod Disassembly
Piston Ring Replacement
Damper Rod Inspection
Rod Guide Case Inspection
Damper Assembly
Shock Absorber Installation
Shock Linkage Removal
Shock Absorber Inspection
Shock Arm Needle Bearing
Shock Link Needle Bearing
Swingarm Removal
Swingarm Disassembly
Swingarm Assembly
Swingarm Installation
Hydraulic Brake Contents
Hydraulic Brake Component Location
Hydraulic Brake Service Information
Hydraulic Brake Troubleshooting
Brake Fluid Replacement/Air Bleeding
Brake Fluid Filling/Air Bleeding
Brake Pad Replacement
Brake Pad/Disc
Brake Disc Inspection
Front Master Cylinder Disassembly
Front Master Cylinder Removal
Front Master Cylinder Inspection
Front Master Cylinder Assembly
Front Master Cylinder Installation
Rear Master Cylinder Disassembly
Rear Master Cylinder Removal
Rear Master Cylinder Assembly
Rear Master Cylinder Inspection
Rear Master Cylinder Installation
Front Brake Caliper Disassembly
Front Brake Caliper Removal
Front Brake Caliper Assembly
Front Brake Caliper Inspection
Front Brake Caliper Installation
Rear Brake Caliper Removal
Rear Brake Caliper Disassembly
Rear Brake Caliper Inspection
Rear Brake Caliper Assembly
Rear Brake Caliper Installation
Brake Pedal Installation
Brake Pedal Removal
Battery/Charging System Contents
Battery/Charging System Component Location
Battery/Charging System Diagram
Battery/Charging System Service Information
Battery/Charging System Troubleshooting
Battery Charging (USA Only)
Battery Removal/Installation
Battery Testing
Voltage Inspection
Charging System Inspection
Charging Voltage Inspection
Current Leakage Inspection
Alternator Charging Coil Inspection
Regulator/Rectifier Removal/Installation
Regulator/Rectifier System Inspection
Ignition System Contents
Ignition System Component Location
Ignition System System Diagram
Ignition System Service Information
Ignition System Troubleshooting
Ignition Coil Primary Peak Voltage
Ignition System Inspection
Exciter Coil Resistance
Ignition Pulse Generator Peak Voltage
Ignition Coil Inspection
Ignition Control Module (ICM) Removal/Installation
Ignition Timing
Ignition Coil Removal/Installation (after 07)
Ignition Coil Removal/Installation (05-07)
Throttle Position Sensor Inspection
Electric Starter Contents
Electric Starter Component Location
Electric Starter System Diagram
Electric Starter Service Information
Electric Starter Troubleshooting
Starter Motor Removal
Starter Motor Disassembly/Inspection
Starter Motor Assembly
Ground Line
Starter Relay Switch Inspection
Starter Motor Installation
Starter Relay Switch Removal/Installation
Power Input Line
Operation Check
Lights/Meter/Switches Contents
Lights/Meter/Switches Component Location
Lights/Meter/Switches Service Information
Headlight Bulb Replacement
Headlight Removal/Installation (05-07)
Headlight Removal/Installation (after 07)
Tail Light Inspection
Tail Light Removal/Installationn
Engine Stop Button Inspection
Clutch Switch Inspection
Clutch Switch Removal/Installation
Starter Switch Inspection
Tripmeter Removal/Installation
Wiring Diagram
Troubleshooting Contents
Engine Does Not Start or Is Hard to Start
Engine Lacks Power
Poor Performance at Low and Idle Speed
Poor Performance at High Speed
Poor Handling
Index
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Quick Links
1
Lubrication System Specifications
2
Cylinder Head/Valves Specifications
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See also:
Owner's Manual & Competition Handbook
Table of
Contents
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Table of Contents
Troubleshooting
Service information
54
Cooling system troubleshooting
150
Cylinder/piston troubleshooting
220
Crankcase/crankshaft/transmission/balancer troubleshooting
271
Front wheel/suspension/steering troubleshooting
297
Rear wheel/suspension troubleshooting
349
Hydraulic brake troubleshooting
389
Battery/charging system troubleshooting
415
Ignition system troubleshooting
422
Electric starter troubleshooting
432
Troubleshooting contents
455
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This manual is also suitable for:
Crf450x 2007
Crf450x 2006
Crf450x 2008
Crf450x 2010
Crf450x 2009
Crf450x 2011
...
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Crf450r 2012
Crf450r 2005
Crf450r 2006
Crf450r 2007
Crf450r 2009
Crf450r 2008
Crf450r 2011
Crf450r 2010
Crf450x 2012
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