Honda 2009 CRF450X Owner's Manual & Competition Handbook
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Honda 2009 CRF450X Owner's Manual & Competition Handbook

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CRF450X
 Honda Motor Co., Ltd. 2008
1
OWNER'S MANUAL & COMPETITION HANDBOOK
MANUEL DU CONDUCTEUR ET DE COMPETITION
FAHRER-HANDBUCH und WETTBEWERBSANLEITUNG
INSTRUCTIEBOEK JE & WEDSTRIJDHANDBOEK
MANUAL DEL PROPIETARIO Y GUÍA DE COMPETICIONES
MANUALE D'USO E DEGLI ASSETTI DA COMPETIZIONE
08.7.22, 9:59
HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200
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F
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  • Page 1 MANUEL DU CONDUCTEUR ET DE COMPETITION FAHRER-HANDBUCH und WETTBEWERBSANLEITUNG INSTRUCTIEBOEK JE & WEDSTRIJDHANDBOEK MANUAL DEL PROPIETARIO Y GUÍA DE COMPETICIONES MANUALE D’USO E DEGLI ASSETTI DA COMPETIZIONE  Honda Motor Co., Ltd. 2008 08.7.22, 9:59 HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 2 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 3 Honda CRF450X OWNER’S MANUAL & COMPETITION HANDBOOK...
  • Page 4 When you own a Honda, you’re part of a given to you by your Honda dealer at the line of hot. Additionally, when riding in mud or sand, or worldwide family of satisfied customers–people purchase.
  • Page 5 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, we have provided operating procedures and other information on labels and in this manual. This information alerts you to potential hazards that could hurt you or others.

  • Page 6: Table Of Contents

    Specifications ..........159 Wheels...............92 Torque Specifications ........161 SERVICING YOUR HONDA ......23 Tyres & Tubes ...........93 Petrol Containing Alcohol.......165 Before You Service Your Honda Side Stand............95 Competition Logbook ........166 The Importance of Maintenance .......24 Drive Chain ............96 Optional Parts List...........168 Maintenance Safety...........25 Steering Damper..........99...

  • Page 7: Motorcycle Safety

    CRF safely. Please take a few Loading..............3 moments to read these pages. This section also Accessories & Modifications .......4 includes information about the location of safety Safety Labels ............5 labels on your CRF. Motorcycle Safety HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 8: Important Safety Information

    Important Safety Information Do not wear loose clothing which could catch on Keep Your Honda in Safe Condition. It’s Important Safety Precautions the control levers, kickstarter, footpegs, drive important to keep your CRF properly maintained chain, or wheels. and in safe riding condition. Having a breakdown...

  • Page 9: Loading

    WARNING Overloading or carrying a passenger can cause a crash and you can be seriously hurt or killed. Follow all loading guidelines in this manual. Motorcycle Safety HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 10: Accessories & Modifications

    Accessories & Modifications Accessories Modifications Accessories & Modifications We strongly recommend that you use only Honda We strongly advise you not to remove any Genuine Accessories that have been specifically original equipment or modify your CRF in any designed and tested for your CRF. Because way that would change its design or operation.

  • Page 11: Safety Labels

    This page shows the 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. Motorcycle Safety...
  • Page 12 Motorcycle Safety HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 13: Operating Controls

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

  • Page 14: Operation Component Locations

    Operation Component Locations tripmeter hot start lever clutch lever front brake lever start button throttle grip engine stop button choke knob kickstarter rear brake pedal shift lever fuel valve Operating Controls HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 15: Before Riding

    Before Riding Before each ride, you need to make sure you and Are You Ready to Ride?........10 your Honda are both ready to ride. To help get Is Your Motorcycle Ready to Ride? ....11 you prepared, this section discusses how to Pre-ride Inspection........11...

  • Page 16: Are You Ready To Ride

    • 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. Before Riding HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 17: Is Your Motorcycle Ready To Ride

    • Every possible part for looseness (such as cylinder head nuts, engine mounting bolts/nuts, axle nuts, handlebar holder bolts, fork bridge pinch bolts, drive chain adjuster, drive chain guide, wire harness connectors, kickstarter mounting bolt, etc.)...161–164 Before Riding HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 18 Before Riding HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 19: Basic Operating Instructions

    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 Basic Operating Instructions Basic Operating Instructions HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 20: Safe Riding Precautions

    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 Basic Operating Instructions HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 21: Starting & Stopping The Engine

    RES–Turning the fuel valve to RES allows fuel NOTICE to flow from the reserve fuel supply to the carburetor. Allowing the kickstarter to snap back freely against the pedal stop can damage the engine case. Basic Operating Instructions HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 22: Flooded Engine

    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. Basic Operating Instructions HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 23: Shifting Gears

    7. To shift down to a lower gear, close the throttle, pull the clutch lever in, and depress the shift lever. After shifting, release the clutch lever and apply the throttle. Basic Operating Instructions HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 24: Braking

    When you brake to a stop, pull the clutch lever in before stopping completely to prevent stalling the engine. For support, put your left foot on the ground first, then your right foot when you have finished braking. Basic Operating Instructions HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 25: Parking

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

  • Page 26: Post-Ride Inspection

    After cleaning, carefully inspect your CRF for leaks or damage. Be sure to lubricate the drive chain (page 98) to prevent rusting. Basic Operating Instructions HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 27: Break-In Guidelines

    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 HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 28 Basic Operating Instructions HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 29: Servicing Your Honda

    You’ll also find Side Stand............95 important safety precautions, information on oils, Service Preparations Drive Chain ............96 and tips for keeping your Honda looking good. Maintenance Component Locations....34 Steering Damper..........99 Seat ..............35 Additional Maintenance Procedures ....102 An ICM (Ignition Control Module) system is Fuel Tank............36...

  • Page 30: The Importance Of Maintenance

    If your CRF overturns or is involved in a crash, be sure your Honda dealer inspects all major parts, even if you are able to make some repairs. Remember, proper maintenance is your responsibility.

  • Page 31: Maintenance Safety

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

  • Page 32: Maintenance Schedule

    If you do not feel capable of performing a given task or need assistance, remember that your Honda dealer knows your CRF best and is fully equipped to maintain and repair it. If you decide to do your own maintenance, use only Honda...
  • Page 33 Maintenance Schedule MAINTENANCE SCHEDULE – COMPETITION USE All items should be checked before each competition event. See your Honda dealer unless you are mechanically qualified and have the proper tools. Perform the Pre-ride Inspection (page 11) at each scheduled maintenance period.

  • Page 34: General Competition Maintenance

    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.
  • Page 35 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...
  • Page 36 For added peace of mind, lock to be sure there is no cable interference. Make certain remove the nuts, clean the threads, and apply Honda Thread the throttle operation is perfect after servicing and Lock or an equivalent prior to torquing the nuts.
  • Page 37 A small amount of “weeping” from the bleed offers added assurance and security. Remove the nuts, clean hole is normal. the threads of both the nuts and bolts, apply Honda Thread Lock or an equivalent and tighten to the specified torque. Servicing Your Honda...

  • Page 38: Before & After Competition Maintenance

    This will ensure that the rear wheel is in proper alignment and allow maximum performance from the rear disc brake. Maintaining proper wheel alignment will also extend brake pad wear. Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 39 If you decide to wash your CRF or use cleaners, refer to Appearance Care (page 108). Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 40: Maintenance Component Locations

    Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 41: Seat

    26 N·m (2.7 kgf·m, 19 lbf·ft) (1) seat mounting bolts (2) seat (1) seat (2) seat front prong (3) seat bracket (4) seat rear prongs (5) tabs (6) seat mounting bolts Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 42: Fuel Tank

    (5) fuel tank band (10) (6) air cleaner cover rubber (7) fuel tank bolt/collar (1) shroud A bolts/collars (2) shroud B bolts (3) shroud (8) fuel line (10) fuel valve bolt (9) fuel valve Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 43 (13) (12) shroud B bolts (13) shroud A bolts/collars 11.Install the seat (page 35). (5) fuel tank bolt/collar (7) fuel tank band (6) air cleaner cover rubber (8) breather tube Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 44: Subframe Upright Position

    (5) and left side cover (6). (10) (9) subframe upper mounting bolts (10) subframe lower mounting bolts (3) air cleaner housing cover (5) left side cover bolt (4) quick fastener (6) left side cover Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 45 (13). (1) subframe upper mounting bolts (2) subframe (3) subframe lower mounting bolts (12) (13) (12) right side cover (13) right side cover bolt 8. Install the seat (page 35). Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 46: Fuel System

    You can be burned or seriously injured when handling fuel. • Stop the engine and keep heat, sparks and flame away. • Handle fuel only outdoors. • Wipe up spills immediately. Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 47 3. Remove the fuel joint (2) from the fuel tank by removing the bolts (3). (4) fuel filter (5) O-ring (1) fuel valve and fuel lines (2) fuel joint (3) bolts Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 48: Engine Oil

    • Oil is a major factor affecting the performance and service life of the engine. Other viscosities shown in the following chart may be used when the average temperature in your riding area is within the indicated range. Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 49 (1) engine oil filler cap/dipstick Repeat steps 1 – 5. (2) engine oil drain bolt 6. Install the engine oil filler cap/dipstick (3) sealing washer securely. 7. Check for oil leaks. (cont’d) Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 50 (11) facing out, away from the engine. You should see the “OUT-SIDE” mark (12) on the filter body, near the seal. Use a new Honda Genuine oil filter or a filter of equal quality specified for your model. Servicing Your Honda...

  • Page 51: Transmission Oil

    For example, the following label shows the MA conserving” service label on the container. They classification. may affect lubrication and clutch performance. NOT RECOMMENDED (1) code number of the sales company of the oil (2) oil classification Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 52 5. After inspection the oil 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. Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 53: Coolant

    (1) UPPER level mark (3) reserve tank Decreasing the concentration of antifreeze to less (2) LOWER level mark than 40% will not provide proper corrosion protection. Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 54 (4) for leakage. Check for signs of seal leakage. A small amount of “weeping” Always let the engine and radiator cool from the bleed hole is normal. See the Honda down before removing the radiator cap. Shop Manual or consult your Honda dealer for replacing the water seal or the oil seal.
  • Page 55 (3) reserve tank cap (4) UPPER level line 5. Install the reserve tank cap. (1) radiator cap (2) filler neck Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 56: Air Cleaner

    Service the air cleaner more frequently if you ride in unusually wet or dusty areas. Your Honda dealer can help you determine the correct service interval for your riding conditions.
  • Page 57 (9). Improper installation of the air cleaner assembly 9. Apply 1.5 – 5.5 g (0.05 – 0.19 oz) of Honda may allow dirt and dust to enter the engine and White Lithium Grease or equivalent to the air cause rapid wear of the piston rings and cylinder.

  • Page 58: Crankcase Breather

    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 Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 59: Throttle

    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. (2) dust cover (+) increase (3) upper lock nut (–) decrease (4) upper adjuster Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 60 If the cable is kinked or chafed, have it replaced. 4. Check the cables for tension or stress in all steering positions. 5. Lubricate the cables with a commercially available cable lubricant to prevent premature rust and corrosion. Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 61: 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 57). Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 62 1. Check for smooth clutch lever operation. If necessary, lubricate the clutch lever pivot or (8) clutch spring bolts/clutch springs clutch cable. (9) clutch pressure plate 2. Check the clutch cable for deterioration, kinks, or damage. Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 63 Check the plate warpage on a surface plate using (12) clutch lifter a feeler gauge. Service Limit: 0.15 mm (0.006 in) Replace the clutch discs and clutch plates as a set. (2) clutch plate Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 64 12. Lubricate the dust seals (12), rear brake pedal Clutch Disc/Plate Installation 8. Install the six clutch springs and bolts (9). (13) pivot and pivot bolt (14) with Honda 9. Tighten the bolts in a crisscross pattern in two White Lithium Grease or equivalent.

  • Page 65: Hot Start Lever

    (2) freeplay (–) Inspection Check freeplay (2). (1) lock nut (+) increase (2) adjuster (–) decrease Freeplay: 2 – 3 mm (0.08 – 0.12 in) If necessary, adjust to the specified range. Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 66: Spark Plug

    “leaf-type feeler gauge’’. • Do not adjust the spark plug gap. If the gap is out of specification, replace the spark plug with a new one. (3) sealing gasket (4) spark plug gap Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 67 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). Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 68: Exhaust Pipe/Muffler

    A damaged exhaust pipe and muffler may reduce engine performance. (4) muffler clamp bolt (1) seat mounting bolt (3) right side cover (5) rear muffler mounting bolt/washer (2) side cover bolt (6) front muffler mounting bolt (7) muffler Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 69 (8) rear muffler mounting bolt/washer tab (5) of the muffler clamp with the cut-out (9) muffler clamp bolt (6) of the muffler. (2) muffler clamp (5) tab (4) muffler (6) cut-out Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 70 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. Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 71: Spark Arrester

    5. Install a new gasket and the spark arrester in the muffler and tighten the bolts (1) to the specified torque: 6 N·m (0.6 kgf·m, 4.4 lbf·ft) (1) bolts (3) gasket (2) spark arrester (1) bolts Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 72: Valve Clearance

    (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 Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 73 (2) primary drive gear bolt (4) index mark (1) feeler gauge (3) punch mark (2) valve lifters (3) intake cam lobes Valve Clearance: IN: 0.16 ± 0.03 mm (0.006 ± 0.001 in) Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 74 (4) cam sprocket bolts Then insert the tensioner stopper fully to hold (5) cam sprocket the stopper in the fully retracted position. (6) cam chain (3) tensioner stopper Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 75 (9) intake valve lifters (10) decompressor shaft (11) plunger (7) camshaft holder assembly bolts (8) camshaft holder assembly NOTICE Do not let the valve lifters, shims, decompressor shaft and plunger fall into the crankcase. Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 76 2.450 mm. Reface the exhaust valve seat if carbon deposits result in a calculated dimension of over 3.000 mm. (1) valve lifter (2) shim 1.80 mm 1.825 mm 1.85 mm 1.875 mm Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 77 – each valve lifter outer surface – plunger whole surface – decompressor shaft sliding area (9) camshaft holder assembly (10) intake cam lobes (11) camshaft holder assembly bolts (8) valve lifters (9) camshaft holder assembly (cont’d) Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 78 When installing the cam sprocket, position the decompressor weight pin (19) toward the front (25) cam sprocket bolts side. (25) (23) coating width (24) no coating width (25) cam sprocket bolt Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 79 (13) punch mark (14) index mark (17) timing mark (18) “ ” mark (29) (28) (26) (28) sealing washer (29) cam chain tensioner lifter cover bolt (26) tensioner stopper Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 80 (4). (4) cylinder head cover (7) cylinder head cover A bolt/rubber seal (8) cylinder head cover B bolts/rubber seals (3) cylinder head cover packing (4) cylinder head cover Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 81 6. Install the spark plug (page 60) 7. Connect the spark plug cap (9) and breather tube (10). (10) (9) spark plug cap (10) breather tube 8. Install the fuel tank and seat (pages 35, 37). Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 82: Piston/Piston Rings/Piston Pin

    (5) ignition coil 15.Loosen the radiator hose clamp (6) and disconnect the radiator hose (7). (1) left radiator grill (2) left radiator mounting bolts/washers (6) radiator hose clamp (7) radiator hose Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 83 (10) fuel hose guide (11) engine hanger plate bolts (12) clutch cable stay (13) left engine hanger plate (14) right engine hanger plate (18) (17) cylinder head nuts/washers (18) cylinder head Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 84 3. Remove the dowel pins (4) and cylinder gasket (5). NOTICE (1) piston pin clips (3) piston (2) piston pin Do not let the dowel pins fall into the crankcase. (4) dowel pins (5) cylinder gasket Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 85 We recommend you consult the Shop Manual or 1. Remove the carbon deposits from the piston your Honda dealer for correct Service Limit head and piston ring grooves with the 3. After installing the rings they should rotate measurements.
  • Page 86 (1) dowel pins (2) cylinder gasket 4. Clean any gasket material off the cylinder. (1) piston (4) piston pin (2) “IN” mark (5) piston pin clips (3) large valve recesses (6) piston cut-out Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 87 (1) dowel pins (2) cylinder head gasket (3) cam chain (5) piston rings (4) cylinder (10) (8) cam chain guide (9) cam chain guide tabs (10) cylinder cut-outs (cont’d) Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 88 26 N·m (2.7 kgf·m, 19 lbf·ft) (13) engine hanger nut Tighten the engine hanger nut to the specified torque: 54 N·m (5.5 kgf·m, 40 lbf·ft) (3) cylinder head (4) cylinder head nuts/washers Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 89 (23) left radiator grill 12.Install the camshaft holder assembly (page 71). 13.Install the crankshaft hole cap (page 74). 14.Install the cylinder head cover (page 74). 15.Install the spark plug and plug cap (page 60). Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 90: Suspension

    (Adjusting two or more your CRF. If any suspension components appear clicks at a time may cause you to pass over worn or damaged, see your Honda dealer for the best adjustment.) Test ride after each further inspection. Your dealer is qualified to adjustment.

  • Page 91: Rear Suspension Inspection

    (pages 128 – 130). Do not attempt to disassemble, service, or dispose of the damper; see your Honda dealer. 2. Lift the subframe to the upright position The instructions found in this owner’s manual are (page 38).

  • Page 92: Recommended Fork Oil

    (About 12 cm (0.4 US oz, 0.4 Imp oz) of fork oil will be left in the outer tube when it is left inverted for about 20 minutes at 20°C/68°F.) Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 93 (10.5 US oz, it nears full 10.9 Imp oz) compression. (1) outer tube Be sure the oil capacity is the same in both fork (2) fork damper legs. (9) O-ring Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 94: Brakes

    (1) lock nut (3) piston system. Refer to the Honda Shop Manual or see (2) adjuster your Honda dealer to have the air bled from the (–) system. 1. Loosen the lock nut (1). 2. To position the brake lever farther away from the handgrip, turn the adjuster (2) clockwise.

  • Page 95: Fluid Level Inspection

    (0.8 in), there is probably air in the brake for leaks. system and it must be bled. Refer to the Honda If the brake lever freeplay exceeds 20 mm Shop Manual or see your Honda dealer for brake (0.8 in), there is probably air in the brake...
  • Page 96 4. Install and tighten the rear brake reservoir cap 4. Tighten the front brake reservoir cap screws to bolts to the specified torque: the specified torque: 1 N·m (0.1 kgf·m, 0.7 lbf·ft) 1 N·m (0.1 kgf·m, 0.7 lbf·ft) Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 97 1 mm (0.04 in) (1) brake pads (3) brake disc (2) rear brake caliper replace 1 mm (0.04 in) wear indicator grooves (1) brake pads (3) brake disc (2) front brake caliper Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 98: Wheels

    Excessively loose spokes 3. Check wheel rim runout. If runout is may result in instability at high speeds and the noticeable, see the Honda Shop Manual for possible loss of control. It’s also important that inspection instructions.

  • Page 99: Tyres & Tubes

    CRF ride harshly, are more prone to damage rim. from surface hazards, and wear unevenly. Make sure the valve stem caps are secure. If necessary, install new caps. Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 100 • 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 HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 101: Side Stand

    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. Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 102: Drive Chain

    Kinking and binding can frequently be 27 N·m (2.8 kgf·m, 20 lbf·ft) eliminated by thorough cleaning and lubrication. If the drive chain requires adjustment, procedure is as follows: Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 103 13.4 mm (0.53 in), the drive chain must be replaced. Replacement chain: Size/link: DID520MXV/114 NOTICE Use of a new chain with worn sprockets will cause rapid chain wear. 13.4 mm (0.53 in) (1) drive chain plate (inner) Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 104 Replace the chain guide slider if it is worn to the bottom of the wear limit (3). (1) upper drive chain roller (Green) (2) lower drive chain roller (Black) (3) “ ” mark (2) chain guide slider (3) wear limit Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 105: Steering Damper

    CRF. If any steering damper there is any abnormality. components appear worn or damaged, see your Refer to Honda Shop Manual or see your Honda dealer for further inspection. Your dealer Honda dealer for steering damper disassembly.
  • Page 106 If the damper rod does not extend to its maximum length, disassemble and inspection for steering damper. Refer to the Honda Shop Manual or see your Honda dealer. (2) front visor (7) grommets (3) headlight connector...
  • Page 107 (2) facing up and forward. Turn the move smoothly and quietly. damper rod and its stopper ring (3) facing Refer to the Honda Shop Manual or see your toward the front side. Honda dealer. 3. Install the collar A (4), collar B (5) and steering damper mounting bolts (6).

  • Page 108: Additional Maintenance Procedures

    If any roughness or play is felt, but you do not (2) paint mark see any movement in the steering head, the fork bushings may be worn. Refer to the Honda Shop Manual for replacement or adjustment procedures, or see your Honda dealer.
  • Page 109 (7) cylinder bolt Coolant drain bolt (8) cylinder head bolts (9) exhaust pipe joint nuts (13) coolant drain bolt (10) drive sprocket bolt (11) engine oil drain bolt (12) transmission oil drain bolt Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 110: Battery

    Always 4. Disconnect the negative (–) terminal (3) first, confirm local regulations for battery disposal. then the positive (+) terminal (4) and remove the battery (5). (1) battery band Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 111 Avoid using an automotive-type battery charger. An automotive charger can overheat a motorcycle battery and cause permanent damage. (1) “trickle” charger Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 112: Headlight & Taillight

    Install and tighten the front visor bolts. Remove the dust cover (4). (10) (11) (3) headlight connector (6) headlight bulb (8) groove (4) dust cover (3) headlight connector (7) tab (10) grommets (11) tabs Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 113 (1) adjusting screw Taillight The taillight uses LED illumination. If the taillight does not function properly, see your Honda dealer for service. Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 114: Appearance Care

    Detergent Frequent cleaning and polishing will keep your wheel hubs Honda looking newer longer. Frequent cleaning muffler outlet also identifies you as an owner who values his area under seat 1. Rinse your CRF thoroughly with cool water to motorcycle.
  • Page 115 Dry with chamois or a soft towel. If necessary, remove heat stains by using a commercially available fine texture compound. Then rinse by the same manner as removing mud or dust. Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 116 Servicing Your Honda HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 117: Adjustments For Competition

    Steering Damper Adjustment Guidelines..142 Chassis Adjustments.........143 Rear End .............143 Fork Height/Angle ........143 Wheelbase ...........143 Gearing .............144 Tyre Selection for Track Conditions ....145 Personal Fit Adjustments .........146 Control Positioning ........146 Handlebar Position, Width & Shape...146 Adjustments for Competition HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 118: Front Suspension Adjustments

    1.2 N·m (0.1 kgf·m, 0.9 lbf·ft) Make sure that both fork legs are adjusted to the same position. (1) fork air pressure release screw (2) O-ring (1) compression damping adjuster (2) rebound damping adjuster Adjustments for Competition HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 119: Fork Springs

    (13.6 US oz, 14.2 Imp oz) (MAX) Oil level 324 cm (11.0 US oz, 11.4 Imp oz) (STANDARD) Oil level 306 cm (10.3 US oz, 10.8 Imp oz) (MIN) Stroke (mm) Adjustments for Competition HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 120 (19). disc cover bolts (9). rubbers The fork protector bolts and caliper mounting (4) handlebar bolts have a locking agent applied. (8) disc cover (9) disc cover bolts Adjustments for Competition HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 121 (28) (29) (24) (25) (20) (6) fork damper (24) outer tube (7) lock nut wrench (25) axle holder (20) fork bridge lower pinch bolts (28) outer tube/slider (29) oil holes (cont’d) Adjustments for Competition HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 122 (34) (25) (30) (36) (35) (25) axle holder (31) piston base (34) fork damper assembly (36) fork spring (30) fork centre bolt (32) fork centre bolt lock nut (35) fork assembly Adjustments for Competition HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 123: Damper Oil Change

    (1) fork damper (6) fork damper piston rod (4) oil holes (5) fork damper spring chamber 5. Clean the fork cap and fork damper threads. (cont’d) Adjustments for Competition HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 124 Inspect the fork damper oil level again. 100 mm (3.9 in) (1) fork damper (6) fork damper piston rod (1) fork damper (7) bushing (2) fork cap assembly (8) O-rings Adjustments for Competition HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 125 (12) fork cap Pour the drained oil into a suitable container and dispose of it in an approved manner (page 151). NOTICE Improper disposal of drained fluids is harmful to the environment. Adjustments for Competition HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 126: Fork Assembly

    To properly dispose of drained fluids, refer to fork assembly (1). You & the Environment (page 151). NOTICE Improper disposal of drained fluids is harmful to the environment. (1) fork assembly (4) fork damper assembly (3) fork spring Adjustments for Competition HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 127 (2) fork centre bolt lock nut (7) O-ring (5) piston base (8) fork centre bolt (10) length (6) push rod (9) adjusting rod (2) fork centre bolt lock nut (8) fork centre bolt (cont’d) Adjustments for Competition HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 128 Optional Stiffer 4.81 N/mm (27.47 lbf/in) Fork Spring fork assembly (1). Standard 4.61 N/mm (26.32 lbf/in) Fork Spring No mark Recommended Oil: 3 scribe marks (factory products) Honda ULTRA CUSHION OIL SPECIAL 5W or equivalent. 1 scribe mark (aftermarket parts) Standard oil 327 cm Standard oil...
  • Page 129 Align (18) the top the outer tube (19) with the top surface of the fork top bridge (20). (13) fork bridge lower pinch bolts (13) fork bridge lower pinch bolts (21) fork bridge upper pinch bolts (cont’d) Adjustments for Competition HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 130 (37) left axle pinch bolts (22) (26) (27) (22) fork protector bolts (23) fork protectors (24) brake hose clamp bolts (25) tripmeter cable clamp screws (26) brake caliper (27) brake caliper mounting bolts Adjustments for Competition HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 131 (41) right axle pinch bolts (42) tripmeter cable (45) (45) rebound damping adjuster (46) compression damping adjuster 33.Install the steering damper (page 101) and handlebar pad. Adjustments for Competition HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 132: Rear Suspension Adjustments

    Do not attempt to disassemble, service, or tighten the shock spring lock nut to the for optional pin spanners. dispose of the damper; see your Honda dealer. specified torque: The instructions found in this owner’s manual are 44 N·m (4.5 kgf·m, 32 lbf·ft)

  • Page 133: Rear Suspension Damping

    2. Turn the adjuster counterclockwise 10 – 13 clicks with the punch marks on the adjuster and the shock absorber aligned. (1) high speed compression damping adjuster (2) low speed compression damping adjuster Adjustments for Competition HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 134: Rear Suspension Race Sag

    = 50 mm (2.0 in) or equivalent with the rear wheel off the – Loaded = 500 mm (19.7 in) ground. (Without Rider) Race Sag = 100 mm (3.9 in) 2. Measure the unloaded dimension. Adjustments for Competition HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 135 The rear end may top out from light braking, or kick sideways over lips and square-edged terrain. It may even top-out when you dismount your CRF. Adjustments for Competition HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 136: Suspension Adjustments For Track Conditions

    With a lot of rebound damping, the wheel returns very slowly and doesn’t contact the ground quickly enough after each bump. The result is a loss of traction and slower lap times. Adjustments for Competition HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 137: Suspension Adjustment Guidelines

    – Install the optional stiff spring. • Front end shakes. – Test stiffer compression damping adjustments in one-click increments. • Fork bottoms over any type of terrain. – Increase rebound damping in one-click increments. Adjustments for Competition HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 138 – Test softer compression damping adjustments in one-click increments. • Stiff suspension on any type of terrain. – Reduce the rebound damping in one-click increments. – Lower the oil capacity by 5 cm (0.2 US oz, 0.2 Imp oz). Adjustments for Competition HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 139 2. If it still bottoms, test stiffer high and low speed compression adjustments and softer rebound damping adjustment, and replace the spring with a stiffer spring (optional) if necessary. Adjustments for Competition HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 140: Carburetor Adjustment & Tuning Tips

    (5) into the cylinder. (1) hot start valve (2) main bore (3) hot start air passage (1) choke knob (4) throttle valve (2) starter jet (5) orifice (3) air passage Adjustments for Competition HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 141 (6) outlet check valve (3) diaphragm (7) accelerator nozzle (4) inlet check valve (1) main jet (5) baffle plate (2) jet needle (6) float (3) needle jet (7) float valve (4) air jet Adjustments for Competition HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 142: Carburetor Removal

    Improper disposal of drained fluids is harmful to the environment. (8) hot start cable nut (4) throttle position sensor connector (9) hot start valve (1) carburetor drain screw Adjustments for Competition HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200 HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 143: Carburetor Disassembly

    (12) throttle cable lock nut (15) throttle cables (13) adjuster (16) throttle drum (7) throttle valve roller (14) throttle cable bolt (8) floating valve (4) jet needle/holder assembly (5) throttle valve (cont’d) Adjustments for Competition HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200 HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 144 (23) (11) accelerator pump cover (14) spring (12) U-ring (15) diaphragm (13) O-ring (16) float bowl (21) pump rod (23) link lever (22) rod passage Adjustments for Competition HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200 HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 145: Carburetor Assembly

    (8) as illustrated (next page). (27) leak jet • Check that the U-ring and O-ring are in good (28) O-ring condition. Replace them if necessary. Adjustments for Competition HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200 HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 146: Idle Speed Adjustment

    0 – 3 mm (0 – 0.1 in) (1) throttle stop screw (5) air vent hoses (6) overflow hose (7) fuel line (8) fuel line clamps Adjustments for Competition HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200 HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 147: Steering Damper Adjustment

    Do not turn the adjuster more than the given positions or the adjuster may be damaged. Be sure that the steering damper adjuster is firmly located in a detent, and not between positions. (1) steering damper adjuster Adjustments for Competition HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 148: Steering Damper Adjustment Guidelines

    Adjust the steering damper adjuster to stiffer setting. Steering is wobbling at sand track Adjust the steering damper adjuster to stiffer setting. Steering is heavy when cornering Adjust the steering damper adjuster to softer setting. Adjustments for Competition HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 149: Chassis Adjustments

    Keep the race sag adjustment (page 128) in the standard setting or a shorter wheelbase will offer 90 – 110 mm (3.5 – 4.3 in) range. more overall benefits. Adjustments for Competition HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200 HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 150: Gearing

    Unless you have the required mechanical • Wet and slippery or sandy conditions: use a (before and after the change) to get an accurate knowhow, tools, and an official Honda Shop higher gear (less teeth) to keep engine rpm appraisal of the change. “Seat-of-the-pants”...

  • Page 151: Tyre Selection For Track Conditions

    Loose, Sandy Soil Use a tyre that is similar in construction to those hard surface. needed for tacky soil and mud, but with a few more knobs. Adjustments for Competition HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200 HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 152: 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 Handlebar Position, Width & Shape the threads of these bolts prior to adjustment to help ensure the correct torque is retained.

  • Page 153: Tips

    Tips 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: Transporting Your Motorcycle

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

  • Page 155: Storing Your Honda

    (2). Disconnect the siphon hose (8) from the your Honda and correct any problem before Remove the centre engine guard mounting reserve tank (9). storing it. That way, needed repairs won’t be bolts, collars (3) and centre engine guard (4).

  • Page 156: Removal From Storage

    (4) centre engine guard (10) tabs Bleed air from the system (page 49). (11) grooves 6. Perform all maintenance checks (page 11). 10.Lubricate the drive chain (page 98). Tips HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 157: You & The Environment

    Call your local of public works or environmental services to find a recycling centre in your area and get instructions on how to dispose of non- recyclable wastes. Tips HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 158: Troubleshooting

    The items that require use of the 1. Disconnect fuel FUEL FLOW • Lack of fuel in tank CHECK POSSIBLE CAUSES Honda Shop Manual are followed by an (P.40) line at carburetor RESTRICTED 1. Check if air INCORRECT • Over-oiled air cleaner •...

  • Page 159: Taking Care Of The Unexpected

    Taking Care of the Unexpected This section gives practical advice to help you If a Fuse Blows ..........154 solve problems. If Your Battery Is Low (or Dead).....155 Taking Care of the Unexpected HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 160: If A Fuse Blows

    CRF. side cover. Leave the blown fuse in that circuit and have your CRF checked by your Honda dealer. Recommended Main Fuse: 15A 7. Install the left side cover and left side cover 1. To prevent an accidental short circuit, stop the bolt.

  • Page 161: If Your Battery Is Low (Or Dead)

    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 HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 162 Taking Care of the Unexpected HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 163: Technical Information

    This section contains dimensions, capacities, and Vehicle Identification ........158 other technical data. Specifications ...........159 Torque Specifications ........161 Petrol Containing Alcohol........165 Competition Logbook ........166 Optional Parts List..........168 Spare Parts & Equipment.........169 Wiring Diagram..........170 Technical Information HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 164: Vehicle Identification

    CRF. They may also be LEFT SIDE required when ordering replacement parts. The VIN (vehicle identification number) (1) is stamped on the right side of the steering head. RIGHT SIDE (2) engine number (1) VIN Technical Information HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 165: Specifications

    Jet needle NKJU Needle clip position 2nd groove from top Slow jet Pilot screw opening 1-1/8 turns out Float level 8.0 mm 0.31 in 1,700 ± 100 min Idle speed –1 (rpm) Technical Information HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 166: Electrical Battery

    Electric, Kickstarter Spark plug : Standard IFR8H11 DENSO VK24PRZ11 Optional IFR9H11 DENSO VK27PRZ11 Spark plug gap 1.0 – 1.1 mm (0.039 – 0.043 in) Light Headlight 12V-35 W Fuse Main fuse 15 A Technical Information HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 167: Torque Specifications

    Transmission oil drain bolt NOTE 3 (10) Coolant drain bolt NOTES: 1. UBS bolt. 2. Apply grease to the threads. 3. Apply oil to the threads and seating surface. (11) (12) (13) Technical Information HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 168 5. Alock bolt: replace with a new one. 6. Apply molybdenum oil to the threads and flange surface. (10) 7. Apply a seizure inhibitor (Three Bond 1901 or equivalent) to the bolt threads. (18) (11) (17) Technical Information HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 169 5. Alock bolt: replace with a new one. (23) (30) 6. Apply molybdenum oil to the threads and flange surface. (35) 7. Apply a seizure inhibitor (Three Bond 1901 or equivalent) (34) to the bolt threads. (30) Technical Information HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 170 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 1901 or equivalent) (46) (44) (50) to the bolt threads. (45) (47) Technical Information HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 171: 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. Before buying fuel from an unfamiliar station, try to find out if the fuel contains alcohol.

  • Page 172: Competition Logbook

    In addition, you should record any irregularities tenths of an hour (each six minutes represents noted in component wear so you’ll remember to one tenth of an hour). keep a close eye on these areas in the future. Technical Information HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 173 Competition Logbook Date Running Location/Event Comments (Suspension Settings, Gearing, Chassis Adjustments, Maintenance Time Performed, etc.) (Make several photocopies of this page for future use) Technical Information HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 174: Optional Parts List

    The standard fork spring and shock spring mounted on the motorcycle when it leaves the factory are not marked. Before replacing the springs, be sure to mark them so they can be distinguished from other optional springs. Technical Information HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 175: Spare Parts & Equipment

    (Engine and Transmission Oil) wheels & tyres (front & rear, mounted) SAE 80 or 90 gear oil clutch discs and plates Honda ULTRA CUSHION OIL SPECIAL 5W Technical Information HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 176: Wiring Diagram

    Wiring Diagram Technical Information HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 177 Technical Information HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 178: Table Of Contents

    Spark Arrester............65 You & the Environment ........151 Valve Clearance..........66 Troubleshooting..........152 Piston/Piston Rings/Piston Pin......76 TAKING CARE OF THE UNEXPECTED ..........153 If a Fuse Blows ..........154 If Your Battery Is Low (or Dead)....155 Table of Contents HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 179 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 Table of Contents HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 180: Index

    ..............127 fuel, brakes, diagram, wiring..........170 filter...............41 fluid level ............89 drive chain............96 line ..............40 lever, front adjustment ........88 recommendation ...........40 pad wear............91 refueling............40 pedal height ..........88 system ............40 break-in guidelines..........21 tank capacity ..........40 valve..............15 Index HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 181 ..............84 importance ............24 basic operation..........13 rear ..............85 safety.............25 before ..............9 suspension adjustment, schedule ..........26, 27 important safety information ......2 for track conditions........130 modifications ............4 safety precautions ...........2 front ............112 guidelines............131 rear ..............126 Index HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 182 ..........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 Index HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

  • Page 183: Manufacturer And Authorised Representative For Eu Market

    EU Market Honda Motor Co., Ltd. Honda Motor Europe Ltd. No.1–1, 2–chome, Minami–Aoyama, Minato–ku, Aalst Office Tokyo 107–8556, Japan Wijngaardveld 1 (Noord V), B-9300 Aalst Belgium Manufacturer and Authorised Representative for EU Market HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...
  • Page 184 Memo HONDA O/M CRF450X (Eu) 3RMEY620 00X3R-MEY-6200...

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