Honda CRF450X 2017 Owner's Manual & Competition Handbook
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Honda CRF450X 2017 Owner's Manual & Competition Handbook

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FOR RECREATIONAL OFF-ROAD OR COMPETITION USE ONLY
This motorcycle is designed and manufactured for recreational off-road use or competition only and is
covered by noise control warranty. It does not conform to federal motor vehicle safety standards or US
EPA On Highway Exhaust Emission regulations, and operation on public streets, roads, or highways
is illegal. The vehicle is equipped with a USDA qualified spark arrester. If you need to cross a paved or
public road, get off and walk your motorcycle across.
Do not modify any emission-related items except for competition use. Any emission-related
modifications should be restored to standard factory specifications before resuming recreational off-
road use.
NO PASSENGERS
This motorcycle is designed and constructed as an operator-only model. The motorcycle load limit and
seating configuration do not safety permit the carrying of a passenger.
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. reserves the right to make changes at any time without notice and without incurring any obligation.
No part of this publication may be reproduced without written permission.
This vehicle pictured in this owner's manual may not match your actual vehicle.
© Honda Motor Co., Ltd., 2016
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IMPORTANT NOTICES
2016/06/08   11:45:31
2016/06/08   11:45:31

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Summary of Contents for Honda CRF450X 2017

  • Page 1 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 2 2017 Honda CRF450X OWNER’S MANUAL & COMPETITION HANDBOOK FOR OFF-ROAD USE ONLY This vehicle is designed and manufactured for off-road use only. USA only: It conforms to US EPA Noise Emission regulations, but does not conform to Federal Motor Vehicle Safety Standards or US EPA On Highway Exhaust Emission regulations, and operation on public streets, roads, or highways is illegal.
  • Page 3 If you plan to do any service concerning important product information. When you own a Honda, you’re part of a on your CRF beyond the standard maintenance worldwide family of satisfied customers–people...
  • Page 4 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 5: Table Of Contents

    Contacting Honda ...........177 SERVICING YOUR HONDA ......23 Your Honda Dealer .........178 Electrical Before You Service Your Honda The Honda Rider’s Club (USA only) .....179 Battery .............104 The Importance of Maintenance .......24 Headlight & Taillight ........106 INDEX ............180 Maintenance Safety ...........25 Appearance Care ..........108...

  • Page 6: Motorcycle Safety

    Motorcycle Safety This section presents some of the most important Important Safety Information ......2 information and recommendations to help you Important Safety Precautions ......2 ride your CRF safely. Please take a few moments Loading ..............3 to read these pages. This section also includes Accessories &...

  • Page 7: Important Safety Information

    Important Safety Information Keep Your Honda in Safe Condition. It’s Do not wear loose clothing which could catch Important Safety Precautions on 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 8: Loading

    Loading Your CRF was designed as a rider-only Loading Guidelines motorcycle. It was not designed to carry a As discussed on this page, we recommended that passenger or cargo. A passenger or cargo could you do not carry any cargo on this motorcycle. interfere with your ability to move around to However, if you decide to carry cargo, ride at maintain your balance and control of the CRF.

  • Page 9: 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 Modifying your CRF or using non-Honda designed or approved and tested for your CRF.

  • Page 10: Safety Labels

    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 dealer for replacement. (For Canada) Motorcycle Safety 17 CRF450X̲31MEY710.indb   5...
  • Page 11 Motorcycle Safety 17 CRF450X̲31MEY710.indb   6 17 CRF450X̲31MEY710.indb   6 2016/06/08   11:45:32 2016/06/08   11:45:32...

  • Page 12: 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 17 CRF450X̲31MEY710.indb   7 17 CRF450X̲31MEY710.indb   7 2016/06/08   11:45:32 2016/06/08   11:45:32...

  • Page 13: 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 17 CRF450X̲31MEY710.indb   8 17 CRF450X̲31MEY710.indb   8 2016/06/08   11:45:33 2016/06/08   11:45:33...

  • Page 14: Before Riding

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

  • Page 15: Are You Ready To Ride

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

  • Page 16: 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 Check the following before each ride: the following items (page numbers are at the •...
  • Page 17 Before Riding 17 CRF450X̲31MEY710.indb   12 17 CRF450X̲31MEY710.indb   12 2016/06/08   11:45:33 2016/06/08   11:45:33...

  • Page 18: Basic Operating Instructions

    Basic Operating Instructions This section gives basic information on how to Safe Riding Precautions ....... 14 start and stop your engine as well as break-in Side Stand ............. 14 guidelines. Tripmeter ............14 Starting & Stopping the Engine ......15 Preparation ............

  • Page 19: Safe Riding Precautions

    Basic Operating Instructions Side Stand Safe Riding Precautions Tripmeter The side stand (1) is used to support your CRF Before riding your CRF for the first time, The tripmeter (1) is used to record the distance while parked (page 19). To operate, use your foot please review the Important Safety Precautions traveled (USA: miles, Canada: kilometers) per to lower the side stand until it is fully extended.

  • Page 20: Starting & Stopping The Engine

    Starting & Stopping the Engine Always follow the proper starting procedure 5. Warm up the engine; don’t operate the Starting Procedure described below. throttle. 6. About 15 seconds after the engine starts, push Your CRF can be started with the transmission Always follow the proper starting procedure the choke knob back all the way to fully OFF.

  • Page 21: Flooded Engine

    Starting & Stopping the Engine Hot Engine Starting Flooded Engine How to Stop the Engine 1. Pull the hot start lever (3) all the way in and start the engine following step 4 under Starting the engine after a stall during riding or “Normal Air Temperature.”...

  • Page 22: Shifting Gears

    Shifting Gears Remember to close the throttle and pull the clutch lever in completely before shifting. NOTICE Improper shifting may damage the engine, transmission, and drive train. Learning when to shift gears comes with experience. Upshift to a higher gear or reduce throttle before engine rpm (speed) gets too high.

  • Page 23: Braking

    Braking To slow or stop, apply the front brake lever and rear brake pedal smoothly, while downshifting to match your speed. Gradually increase braking as you feel the brakes slowing your speed. To prevent stalling the engine, pull the clutch lever in before coming to a complete stop.

  • Page 24: 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 17 CRF450X̲31MEY710.indb   19 17 CRF450X̲31MEY710.indb   19 2016/06/08   11:45:34 2016/06/08   11:45:34...

  • Page 25: Post-Ride Inspection

    Post-ride Inspection When you return home after riding, thoroughly clean your CRF and remove any dirt, mud, brush, rocks or other objects you may have picked up along the way. After cleaning, carefully inspect your CRF for leaks or damage. Be sure to lubricate the drive chain (page 98) to prevent rusting.

  • Page 26: 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 15 miles (25 km). During this period, avoid full-throttle starts and rapid acceleration. This same procedure should be followed each time when: •...
  • Page 27 Basic Operating Instructions 17 CRF450X̲31MEY710.indb   22 17 CRF450X̲31MEY710.indb   22 2016/06/08   11:45:34 2016/06/08   11:45:34...

  • Page 28: Servicing Your Honda

    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 ....35 Steering Damper ..........99 Seat ..............36 Additional Maintenance Procedures ....102 An ICM (Ignition Control Module) system is Fuel Tank ............

  • Page 29: The Importance Of Maintenance

    Remember, proper maintenance is your responsibility. Be sure to inspect your CRF before each ride and follow the Maintenance Schedule in this section. Servicing Your Honda 17 CRF450X̲31MEY710.indb   24 17 CRF450X̲31MEY710.indb   24 2016/06/08   11:45:34 2016/06/08   11:45:34...

  • Page 30: 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 17 CRF450X̲31MEY710.indb   25 17 CRF450X̲31MEY710.indb   25 2016/06/08   11:45:34 2016/06/08   11:45:34...

  • Page 31: 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 32 92, 93 STEERING HEAD BEARINGS Should be serviced by your dealer, unless the owner has the proper tools and service data and is mechanically qualified. Refer to the official Honda Service Manual (page 174). In the interest of safety, we recommend these items be serviced only by your dealer.
  • Page 33 All items should be checked before each competition event. See your dealer unless you are mechanically qualified and have the proper tools. Damage from competition use is not covered by the Distributor’s Limited Warranty on your Honda. 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 Pro Honda Foam Filter Oil or an equivalent. Be sure to grease the air cleaner flange where it contacts the air cleaner housing. Pro Honda White Lithium...
  • Page 36 For added peace of mind, from lock to lock to be sure there is no cable interference. remove the nuts, clean the threads, and apply Pro Honda Make certain the throttle operation is perfect after servicing Hondalock or an equivalent prior to torquing the nuts.
  • Page 37 Refer to the Honda Service Manual (page 174). Use only Pro Honda HP Fork Oil 5W or equivalent which contains special additives to assure maximum performance of your CRF’s front suspension.

  • Page 38: Before & After Competition Maintenance

    (1) are in the same position on each side. This will ensure that the rear wheel is in proper alignment and allow maximum performance from the rear disc brake. Maintaining proper wheel alignment will also extend brake pad wear. Servicing Your Honda 17 CRF450X̲31MEY710.indb   33 17 CRF450X̲31MEY710.indb   33 2016/06/08   11:45:35 2016/06/08   11:45:35...
  • Page 39 If you decide to wash your CRF or use cleaners, refer to Appearance Care (page 108). Servicing Your Honda 17 CRF450X̲31MEY710.indb   34 17 CRF450X̲31MEY710.indb   34 2016/06/08   11:45:35...

  • Page 40: Maintenance Component Locations

    Servicing Your Honda 17 CRF450X̲31MEY710.indb   35 17 CRF450X̲31MEY710.indb   35 2016/06/08   11:45:35 2016/06/08   11:45:35...

  • Page 41: Seat

    19 lbf·ft (26 N·m, 2.7 kgf·m) (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 17 CRF450X̲31MEY710.indb   36 17 CRF450X̲31MEY710.indb   36 2016/06/08   11:45:35 2016/06/08   11:45:35...

  • Page 42: Fuel Tank

    (5) fuel tank band (6) air cleaner cover rubber (7) fuel tank bolt (10) (1) shroud A bolts/collars (2) shroud B bolts (3) shroud (8) fuel line (9) fuel valve (10) fuel valve bolt Servicing Your Honda 17 CRF450X̲31MEY710.indb   37 17 CRF450X̲31MEY710.indb   37 2016/06/08   11:45:36 2016/06/08   11:45:36...
  • Page 43 (12) nut. (13) (12) shroud B bolts (13) shroud A bolts/collars (5) fuel tank bolt (7) fuel tank band (6) air cleaner cover rubber (8) breather tube 11. Install the seat (page 36). Servicing Your Honda 17 CRF450X̲31MEY710.indb   38 17 CRF450X̲31MEY710.indb   38 2016/06/08   11:45:36 2016/06/08   11:45:36...

  • 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 17 CRF450X̲31MEY710.indb   39 17 CRF450X̲31MEY710.indb   39 2016/06/08   11:45:36 2016/06/08   11:45:36...
  • Page 45 7. Install the right side cover (12) and right side cover bolt (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 36). Servicing Your Honda 17 CRF450X̲31MEY710.indb   40 17 CRF450X̲31MEY710.indb   40 2016/06/08   11:45:36 2016/06/08   11:45:36...

  • Page 46: Fuel System

    Type Unleaded Pump Octane Number 91 (or higher) Use only unleaded fuel in your Honda. If you ride your Honda in a country where leaded fuel might be available, take precautions to use only unleaded fuel. Your engine is designed to use any unleaded...
  • Page 47 (1). 3. Remove the fuel joint (2) from the fuel tank by removing the bolts (3). (4) fuel fi lter (5) O-ring (1) fuel valve and fuel lines (2) fuel joint (3) bolts Servicing Your Honda 17 CRF450X̲31MEY710.indb   42 17 CRF450X̲31MEY710.indb   42 2016/06/08   11:45:38 2016/06/08   11:45:38...

  • Page 48: Engine Oil

    (weight) the engine. JASO T 903 standard suggested oil* Pro Honda GN4 4-stroke oil (USA NOT RECOMMENDED & Canada), or Honda 4-stroke oil, or an equivalent motorcycle oil* • Oil is a major factor affecting the performance and service life of the engine.
  • Page 49 (Do not overfill) (3) sealing washer Reinstall the engine oil fill cap/dipstick. Repeat steps 1 – 5. 6. Install the engine oil fill cap/dipstick securely. 7. Check for oil leaks. Servicing Your Honda 17 CRF450X̲31MEY710.indb   44 17 CRF450X̲31MEY710.indb   44 2016/06/08   11:45:38 2016/06/08   11:45:38...
  • 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 17 CRF450X̲31MEY710.indb   45...

  • Page 51: Transmission Oil

    Pro Honda GN4 4-stroke oil (USA & Canada), or Honda 4-stroke oil, or an equivalent motorcycle oil* * Suggested 4-stroke engine oils are equal performance to SJ oils that are not labeled as...
  • Page 52 Tighten the oil check bolt to the specified torque: 7 lbf·ft (10 N·m, 1.0 kgf·m) 6. Install the transmission oil fill cap securely. Servicing Your Honda 17 CRF450X̲31MEY710.indb   47 17 CRF450X̲31MEY710.indb   47 2016/06/08   11:45:40 2016/06/08   11:45:40...

  • Page 53: Coolant

    Coolant Recommendation Checking & Adding Coolant Use Pro Honda HP Coolant or an equivalent high Refer to Safety Precautions on page 25. quality ethylene glycol antifreeze containing corrosion protection inhibitors specifically 1. With the engine at normal operating recommended for use in aluminum engines.
  • 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. Service Manual or consult your dealer for replacing the water seal or the oil seal.
  • Page 55 (3) reserve tank cap overheating and engine damage. (4) UPPER level line 5. Install the reserve tank cap. (1) radiator cap (2) fi ller neck Servicing Your Honda 17 CRF450X̲31MEY710.indb   50 17 CRF450X̲31MEY710.indb   50 2016/06/08   11:45:42 2016/06/08   11:45:42...

  • Page 56: Air Cleaner

    7. Allow the air cleaner element to dry repairs, low engine power, poor gas mileage, and thoroughly. After drying, soak the air cleaner element in clean Pro Honda Foam Filter Oil spark plug fouling. or an equivalent air cleaner oil.
  • Page 57 9. Apply 0.05 – 0.19 oz (1.5 – 5.5 g) of Pro engine and cause rapid wear of the piston rings Honda White Lithium Grease or equivalent to and cylinder. the air cleaner housing contact area of the air cleaner element.

  • 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 17 CRF450X̲31MEY710.indb   53 17 CRF450X̲31MEY710.indb   53 2016/06/08   11:45:42 2016/06/08   11:45:42...

  • Page 59: Throttle

    5. Install the fuel tank and seat (pages 36, 38). (–) If you can’t get the freeplay within the specified range, see your dealer. (2) dust cover (+) increase (3) upper lock nut (–) decrease (4) upper adjuster Servicing Your Honda 17 CRF450X̲31MEY710.indb   54 17 CRF450X̲31MEY710.indb   54 2016/06/08   11:45:42 2016/06/08   11:45:42...
  • 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 17 CRF450X̲31MEY710.indb   55 17 CRF450X̲31MEY710.indb   55 2016/06/08   11:45:43 2016/06/08   11:45:43...

  • 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 58). Servicing Your Honda 17 CRF450X̲31MEY710.indb   56 17 CRF450X̲31MEY710.indb   56 2016/06/08   11:45:44...
  • Page 62 1. Check for smooth clutch lever operation. If necessary, lubricate the clutch lever pivot or clutch cable. 2. Check the clutch cable for deterioration, (8) clutch spring bolts/clutch springs kinks, or damage. (9) clutch pressure plate (cont’d) Servicing Your Honda 17 CRF450X̲31MEY710.indb   57 17 CRF450X̲31MEY710.indb   57 2016/06/08   11:45:44 2016/06/08   11:45:44...
  • Page 63 Check the plate warpage on a surface plate using (13) clutch lifter rod (14) clutch discs/clutch plates a feeler gauge. Service Limit: 0.006 in (0.15 mm) Replace the clutch discs and clutch plates as a set. (2) clutch plate Servicing Your Honda 17 CRF450X̲31MEY710.indb   58 17 CRF450X̲31MEY710.indb   58 2016/06/08   11:45:45 2016/06/08   11:45:45...
  • Page 64 12. Lubricate the dust seals (12), rear brake pedal 7. Install the clutch pressure plate (8). Clutch Disc/Plate Installation (13) pivot and pivot bolt (14) with Pro Honda 8. Install the six clutch springs and bolts (9). White Lithium Grease or equivalent.

  • Page 65: Hot Start Lever

    (1) hot start lever (2) freeplay (–) Inspection Check freeplay (2). Freeplay: 1/16 – 1/8 in (2 – 3 mm) (1) lock nut (+) increase If necessary, adjust to the specified range. (2) adjuster (–) decrease Servicing Your Honda 17 CRF450X̲31MEY710.indb   60 17 CRF450X̲31MEY710.indb   60 2016/06/08   11:45:46 2016/06/08   11:45:46...

  • Page 66: Spark Plug

    10. Connect the spark plug cap. Take care to (3) sealing gasket avoid pinching any cables or wires. (4) spark plug gap 11. Install the fuel tank and seat (pages 36, 38). Servicing Your Honda 17 CRF450X̲31MEY710.indb   61 17 CRF450X̲31MEY710.indb   61 2016/06/08   11:45:47 2016/06/08   11:45:47...

  • Page 67: Exhaust Pipe/Muffler

    A damaged exhaust pipe and muffler may reduce engine performance. (4) muffler clamp bolt (1) seat mounting bolt (5) rear muffler mounting bolt/washer (2) side cover bolt (6) front muffler mounting bolt (3) right side cover (7) muffler Servicing Your Honda 17 CRF450X̲31MEY710.indb   62 17 CRF450X̲31MEY710.indb   62 2016/06/08   11:45:47 2016/06/08   11:45:47...
  • Page 68 4. Install the muffler clamp (2) by aligning the (9) muffler clamp bolt tab (5) of the muffler clamp with the cut-out (6) of the muffler. (2) muffler clamp (5) tab (4) muffler (6) cut-out Servicing Your Honda 17 CRF450X̲31MEY710.indb   63 17 CRF450X̲31MEY710.indb   63 2016/06/08   11:45:47 2016/06/08   11:45:47...
  • Page 69 15 lbf·ft (21 N·m, 2.1 kgf·m) 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 17 CRF450X̲31MEY710.indb   64 17 CRF450X̲31MEY710.indb   64 2016/06/08   11:45:47 2016/06/08   11:45:47...

  • Page 70: Spark Arrester

    5. Install a new gasket and the spark arrester in the muffler and tighten the bolts (1) to the specified torque: 4.4 lbf·ft (6 N·m, 0.6 kgf·m) (1) bolts (1) bolts (3) gasket (2) spark arrester Servicing Your Honda 17 CRF450X̲31MEY710.indb   65 17 CRF450X̲31MEY710.indb   65 2016/06/08   11:45:48 2016/06/08   11:45:48...

  • Page 71: 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 17 CRF450X̲31MEY710.indb   66 17 CRF450X̲31MEY710.indb   66 2016/06/08   11:45:49 2016/06/08   11:45:49...
  • Page 72 (2) primary drive gear bolt (1) feeler gauge (3) punch mark (2) valve lifters (4) index mark (3) intake cam lobes Valve Clearance: IN: 0.006 ± 0.001 in (0.16 ± 0.03 mm) Servicing Your Honda 17 CRF450X̲31MEY710.indb   67 17 CRF450X̲31MEY710.indb   67 2016/06/08   11:45:49 2016/06/08   11:45:49...
  • Page 73 Do not let the bolts, sprocket and cam chain fall into the crankcase. (3) tensioner stopper (1) cam chain tensioner lifter cover bolt (2) sealing washer (4) cam sprocket bolts (5) cam sprocket (6) cam chain Servicing Your Honda 17 CRF450X̲31MEY710.indb   68 17 CRF450X̲31MEY710.indb   68 2016/06/08   11:45:50 2016/06/08   11:45:50...
  • Page 74 (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 17 CRF450X̲31MEY710.indb   69 17 CRF450X̲31MEY710.indb   69 2016/06/08   11:45:51 2016/06/08   11:45:51...
  • Page 75 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 17 CRF450X̲31MEY710.indb   70 17 CRF450X̲31MEY710.indb   70 2016/06/08   11:45:51 2016/06/08   11:45:51...
  • Page 76 – 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 (cont’d) (8) valve lifters (9) camshaft holder assembly Servicing Your Honda 17 CRF450X̲31MEY710.indb   71 17 CRF450X̲31MEY710.indb   71 2016/06/08   11:45:52 2016/06/08   11:45:52...
  • Page 77 (25) assembly. When installing the cam sprocket, position (25) cam sprocket bolts the decompressor weight pin (19) toward the front side. (25) (23) coating width (24) no coating width (25) cam sprocket bolt Servicing Your Honda 17 CRF450X̲31MEY710.indb   72 17 CRF450X̲31MEY710.indb   72 2016/06/08   11:45:53 2016/06/08   11:45:53...
  • Page 78 (13) punch mark (14) index mark (17) timing mark (29) (18) “ ” mark (28) (26) (28) sealing washer (29) cam chain tensioner lifter cover bolt (26) tensioner stopper Servicing Your Honda 17 CRF450X̲31MEY710.indb   73 17 CRF450X̲31MEY710.indb   73 2016/06/08   11:45:53 2016/06/08   11:45:53...
  • Page 79 (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 17 CRF450X̲31MEY710.indb   74 17 CRF450X̲31MEY710.indb   74 2016/06/08   11:45:54 2016/06/08   11:45:54...
  • Page 80 6. Install the spark plug (page 61) 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 36, 38). Servicing Your Honda 17 CRF450X̲31MEY710.indb   75 17 CRF450X̲31MEY710.indb   75 2016/06/08   11:45:55 2016/06/08   11:45:55...

  • Page 81: Piston/Piston Rings/Piston Pin

    (page 68). 15. Remove the left radiator grill (7) and left radiator mounting bolts/washers (8). (12) (12) radiator hose clamp (13) radiator hose (7) left radiator grill (8) left radiator mounting bolts/washers Servicing Your Honda 17 CRF450X̲31MEY710.indb   76 17 CRF450X̲31MEY710.indb   76 2016/06/08   11:45:56 2016/06/08   11:45:56...
  • Page 82 (15) engine hanger bolt (16) fuel hose guide (17) engine hanger plate bolts (18) clutch cable stay (19) left engine hanger plate (20) right engine hanger plate (24) (23) cylinder head nuts/washers (24) cylinder head Servicing Your Honda 17 CRF450X̲31MEY710.indb   77 17 CRF450X̲31MEY710.indb   77 2016/06/08   11:45:56 2016/06/08   11:45:56...
  • Page 83 3. Remove the dowel pins (4) and cylinder gasket (5). NOTICE (1) piston pin clips Do not let the dowel pins fall into the crankcase. (2) piston pin (3) piston (4) dowel pins (5) cylinder gasket Servicing Your Honda 17 CRF450X̲31MEY710.indb   78 17 CRF450X̲31MEY710.indb   78 2016/06/08   11:45:58 2016/06/08   11:45:58...
  • Page 84 NOTICE mark Do not damage the piston ring by spreading the top ring ends too far. Do not damage the piston during piston ring side rail installation. spacer ring side rail piston Servicing Your Honda 17 CRF450X̲31MEY710.indb   79 17 CRF450X̲31MEY710.indb   79 2016/06/08   11:45:59 2016/06/08   11:45:59...
  • Page 85 (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 17 CRF450X̲31MEY710.indb   80 17 CRF450X̲31MEY710.indb   80 2016/06/08   11:45:59 2016/06/08   11:45:59...
  • Page 86 (1) dowel pins (2) cylinder head gasket (3) cam chain (4) cylinder (5) piston rings (10) (8) cam chain guide (9) cam chain guide tabs (10) cylinder cut-outs (cont’d) Servicing Your Honda 17 CRF450X̲31MEY710.indb   81 17 CRF450X̲31MEY710.indb   81 2016/06/08   11:45:59 2016/06/08   11:45:59...
  • Page 87 (13) engine hanger nut 19 lbf·ft (26 N·m, 2.7 kgf·m) Tighten the engine hanger nut to the specified torque: 40 lbf·ft (54 N·m, 5.5 kgf·m) (3) cylinder head (4) cylinder head nuts/washers Servicing Your Honda 17 CRF450X̲31MEY710.indb   82 17 CRF450X̲31MEY710.indb   82 2016/06/08   11:46:00 2016/06/08   11:46:00...
  • Page 88 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 61). Servicing Your Honda 17 CRF450X̲31MEY710.indb   83 17 CRF450X̲31MEY710.indb   83 2016/06/08   11:46:01...

  • Page 89: Suspension

    4. Make a quick check of fork operation by replacement. locking the front brake and pushing down on • Use Pro Honda HP Fork Oil 5W or an the handlebar several times. equivalent which contains special additives to assure maximum performance of your CRF’s front suspension.

  • Page 90: Rear Suspension Inspection

    5. Push the rear wheel sideways to check for adjustment, return to the standard position and worn or loose swingarm bearings. There begin again. should be no movement. If there is, have the bearings replaced by your dealer. Servicing Your Honda 17 CRF450X̲31MEY710.indb   85 17 CRF450X̲31MEY710.indb   85 2016/06/08   11:46:02 2016/06/08   11:46:02...

  • Page 91: Recommended Fork Oil

    20 minutes at 20 viscosity (weight) 5 W (7) when the fork damper is removed. To avoid °C/68°F.) suggested oil Pro Honda HP Fork Oil or damage hold both the outer tube and slider when equivalent removing the fork damper. Fork Oil Change Refer to Front Suspension Disassembly on page 113.
  • Page 92 10.5 US oz Slightly softer as compression. capacity (309 cm it nears full compression. Be sure the oil capacity is the same in both fork legs. (1) outer tube (2) fork damper (9) O-ring Servicing Your Honda 17 CRF450X̲31MEY710.indb   87 17 CRF450X̲31MEY710.indb   87 2016/06/08   11:46:04 2016/06/08   11:46:04...

  • Page 93: Brakes

    If they are not worn beyond the recommended limit (page 91), there is probably air in the brake system. Refer to the (1) lock nut Honda Service Manual or see your dealer to have (2) adjuster (3) piston the air bled from the system.
  • Page 94 Refer to the Honda Service If the brake lever freeplay exceeds 13/16 in (20 Manual or see your dealer for brake bleeding.
  • Page 95 Do not mix different types of fluid, they may not be compatible. not be compatible. • The recommended brake fluid is Pro Honda • The recommended brake fluid is Pro Honda DOT4 brake fluid or an equivalent. DOT4 brake fluid or an equivalent.
  • Page 96 Make sure there are no fluid leaks. Check for deterioration or cracks in the hoses and fittings. wear indicator grooves (1) brake pads (2) front brake caliper (3) brake disc Servicing Your Honda 17 CRF450X̲31MEY710.indb   91 17 CRF450X̲31MEY710.indb   91 2016/06/08   11:46:05 2016/06/08   11:46:05...

  • Page 97: 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 Service Manual for possible loss of control. It’s also important that inspection instructions.

  • Page 98: Tires & Tubes

    Make sure the valve stem caps are secure. If necessary, install new caps. Servicing Your Honda 17 CRF450X̲31MEY710.indb   93 17 CRF450X̲31MEY710.indb   93 2016/06/08   11:46:05 2016/06/08   11:46:05...
  • Page 99 • Replace the tube any time you replace a tire. The old tube will probably be stretched and, if installed in a new tire, could fail. Servicing Your Honda 17 CRF450X̲31MEY710.indb   94 17 CRF450X̲31MEY710.indb   94 2016/06/08   11:46:05 2016/06/08   11:46:05...

  • Page 100: 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 17 CRF450X̲31MEY710.indb   95 17 CRF450X̲31MEY710.indb   95 2016/06/08   11:46:05 2016/06/08   11:46:05...

  • Page 101: Drive Chain

    20 lbf·ft (27 N·m, 2.8 kgf·m) binding. Kinking and binding can frequently be eliminated by thorough cleaning and lubrication. If the drive chain requires adjustment, procedure is as follows: Servicing Your Honda 17 CRF450X̲31MEY710.indb   96 17 CRF450X̲31MEY710.indb   96 2016/06/08   11:46:05 2016/06/08   11:46:05...
  • Page 102 0.53 in (13.4 mm), 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. 0.53 in (13.4 mm) (1) drive chain plate (inner) Servicing Your Honda 17 CRF450X̲31MEY710.indb   97 17 CRF450X̲31MEY710.indb   97 2016/06/08   11:46:06 2016/06/08   11:46:06...
  • Page 103 1. Check the chain slider (1) for wear. 1. Measure the diameter of the upper (1) and Lubricate the drive chain with Pro Honda HP If the wear is 0.2 in (5 mm) or more, replace lower drive chain rollers (2). Replace them if Chain Lube or an equivalent chain lubricant below the service limit.

  • Page 104: Steering Damper

    CRF. If any steering abnormality. Refer to Honda Service Manual damper components appear worn or damaged, or see your dealer for steering damper see your dealer for further inspection.
  • Page 105 If the damper rod does not extend to its maximum length, disassemble and inspection for steering damper. Refer to the Honda Service Manual or see your dealer. (2) front visor (7) grommets (3) headlight connector...
  • Page 106 (2) facing up and forward. Turn the move smoothly and quietly. damper rod and its stopper ring (3) facing Refer to the Honda Service Manual or see toward the front side. your dealer. 3. Install the collar A (4), collar B (5) and steering damper mounting bolts (6).

  • Page 107: Additional Maintenance Procedures

    Refer to the Steering Head Bearing Inspection 1. Remove the handlebar pad. Honda Service Manual for replacement or 2. Check the handlebar (1) for bends or cracks. adjustment procedures, or see your dealer. 1. With your CRF on a box or optional 3.
  • Page 108 (10) drive sprocket bolt Transmission oil drain (5) crankshaft hole cap (11) engine oil drain bolt bolt (9) exhaust pipe joint nuts (12) transmission oil drain bolt Coolant drain bolt (13) coolant drain bolt Servicing Your Honda 17 CRF450X̲31MEY710.indb   103 17 CRF450X̲31MEY710.indb   103 2016/06/08   11:46:08 2016/06/08   11:46:08...

  • Page 109: Battery

    If you do not remove the battery, we recommend (1) battery band (4) positive (+) terminal disconnecting the battery cables (negative cable (2) positive terminal cover (5) battery first). (3) negative (–) terminal Servicing Your Honda 17 CRF450X̲31MEY710.indb   104 17 CRF450X̲31MEY710.indb   104 2016/06/08   11:46:08 2016/06/08   11:46:08...
  • Page 110 Improper charging may damage the battery. We recommended using a charger (1) designed specifically for your Honda, which can be purchased from your dealer. These units can be left connected for long periods without risking damage to the battery. However, do...

  • Page 111: Headlight & Taillight

    Install and tighten the front visor bolts. (10) (3) headlight connector (11) (4) dust cover (6) headlight bulb (7) tab (3) headlight connector (8) groove (10) grommets (11) tabs Servicing Your Honda 17 CRF450X̲31MEY710.indb   106 17 CRF450X̲31MEY710.indb   106 2016/06/08   11:46:08 2016/06/08   11:46:08...
  • Page 112 (1) adjusting screw Taillight The taillight uses LED illumination. If the taillight does not function properly, see your dealer for service. Servicing Your Honda 17 CRF450X̲31MEY710.indb   107 17 CRF450X̲31MEY710.indb   107 2016/06/08   11:46:09 2016/06/08   11:46:09...

  • Page 113: Appearance Care

    Wet any heavy deposits apply the brakes several times. This will help with water first. Then spray on the Pro Honda dry the brakes and restore normal braking Hondabrite and rinse with a garden hose at full performance.
  • Page 114 Do not use steel wool to clean the frame as it could damage or discolor the frame surface. Muffler stain remover (Scotch-Brite Hand Pad #7447-maroon) is for removing stains on the non- coated aluminum frame only. Servicing Your Honda 17 CRF450X̲31MEY710.indb   109 17 CRF450X̲31MEY710.indb   109 2016/06/08   11:46:09 2016/06/08   11:46:09...
  • Page 115 Servicing Your Honda 17 CRF450X̲31MEY710.indb   110 17 CRF450X̲31MEY710.indb   110 2016/06/08   11:46:09 2016/06/08   11:46:09...

  • Page 116: Adjustments For Competition

    Adjustments for Competition This section tells you how to fine tune your CRF Front Suspension Adjustments ......112 for maximum competition performance. Front Suspension Air Pressure ....112 Front Suspension Damping ......112 Initial suspension adjustments should be Fork Springs ..........113 performed after a minimum of 2 hours of easy Front Suspension Disassembly ....

  • Page 117: Front Suspension Adjustments

    Front Suspension Adjustments The front suspension can be adjusted for the Front Suspension Air Pressure Front Suspension Damping rider’s weight and riding conditions by using one or more of the following methods: Air is an unstable gas which builds up pressure Rebound Damping Adjustment as it is worked (such as in a fork).

  • Page 118: Fork Springs

    Front Suspension Adjustments Both compression and rebound damping can be Fork Springs Front Suspension Disassembly increased by turning the adjuster clockwise. The fork springs in CRF’s are about right for • If your CRF is brand-new, put enough part- NOTICE riders weighing between 150 lb (68 kg) and throttle break-in time (about 1 hour) on it to Always start with full hard when adjusting...
  • Page 119 Front Suspension Adjustments 3. Loosen the fork bridge upper pinch bolts (5). 6. Remove the tripmeter cable (10) and front 1. Place your CRF on an optional workstand or 4. Loosen the fork damper (6) using a lock nut axle nut (11) and loosen the axle pinch bolts equivalent support with the front wheel off wrench (7), but do not remove it yet.
  • Page 120 Front Suspension Adjustments Do not support the brake caliper by the brake 10. Clean the fork assembly, especially the NOTICE hose. Do not operate the brake lever after the sliding surface (21) of the slider and fork dust The outer tube (24) can drop on the slider (26) front wheel is removed.
  • Page 121 Front Suspension Adjustments 14. Temporarily install the fork damper to the 17. Make the mechanic's stopper tool out of a 20. Remove the push rod (33) from the fork damper. outer tube. thin piece of steel (0.08 in (2.0 mm) thick) as 21.

  • Page 122: Damper Oil Change

    1. Place the fork damper (1) in a vise with a Recommended Oil: Be careful not to damage the fork cap bushing. Pro Honda HP Fork Oil 5 W or equivalent piece of wood or soft jaws to avoid damage. Do not disassemble the fork cap assembly.
  • Page 123 Front Suspension Adjustments 8. Extend the fork damper piston rod to 10. Place the fork damper (1) in a vise with a 13. Screw in the fork center bolt lock nut (9) to maximum. Adjust the oil level of the fork piece of wood or soft jaws to avoid damage.
  • Page 124 Front Suspension Adjustments 16. Blow out the oil from the fork damper spring 14. Blow the extra oil off to the fork damper 15. Drain the extra oil from the oil holes (4) of chamber using compressed air to the oil hole. spring chamber (5) by pumping the fork the fork damper spring chamber (5).

  • Page 125: Fork Assembly

    Front Suspension Adjustments 2. Tighten the fork center bolt lock nut (2) fully Amount of fork oil left in the fork Fork Assembly (without damper and spring) unit: cm and measure the thread length (A) as shown. minute 1. Drain the fork oil from the fork assembly (1) Standard: 0.4 –...
  • Page 126 Front Suspension Adjustments 4. Place the lower end (axle holder) of the slider 8. Measure the length of the fork center 10. Remove the piston base or mechanic's stopper in a vise with a piece of wood or soft jaws to bolt lock nut (2) and fork center bolt (8) tool while pushing to the fork damper.
  • Page 127 (1). Standard 26.32 lbf/in (4.61 N/mm) Fork Spring Recommended Oil: No mark (factory products) 3 scribe marks Pro Honda HP Fork Oil 5 W or equivalent. 1 scribe mark (aftermarket parts) (11) Standard oil 11.1 US oz Standard oil 11.0 US oz...
  • Page 128 Front Suspension Adjustments 14. Check that the O-ring (12) on the fork 17. Tighten the fork damper (14) to the specified (16) damper assembly (4) is in good condition. torque using a lock nut wrench (15). (17) Apply the recommended fork oil to the O- Actual: (20) ring.
  • Page 129 Front Suspension Adjustments 21. Clean the threads of the fork protector bolts 24. Check the left side collar (28) and tripmeter (22) and axle holder thoroughly. gear box (29) for wear or damage. (34) Apply locking agent to the fork protector bolt Apply grease to the dust seal lips.
  • Page 130 Front Suspension Adjustments 27. Install the handlebar (38), mounting rubbers 29. While keeping the forks parallel, alternately 31. Install the disc cover (43) and tighten the disc (39), washers and handlebar lower holder tighten the right axle pinch bolts (41) to the cover bolts (44) to the specified torque: nuts (40) and tighten the handlebar lower 10 Ibf·ft (13 N·m, 1.3 kgf·m)

  • Page 131: Rear Suspension Adjustments

    Min. (Stiffer, 319.2 lbf/in (55.9 N/mm)): 9.9 in (251 mm) the proper tools, safety equipment and the Honda Service Manual. If your CRF is new, put enough part-throttle break-in time (about 1 hour) on it to ensure that the suspension has worked in.

  • Page 132: Rear Suspension Damping

    Rear Suspension Adjustments High Speed Compression Damping: Rebound Damping Rear Suspension Damping The high speed compression damping can be The rebound damping adjuster (1) is located at adjusted by turning the hexagonal portion of the the lower end of the shock absorber. Compression Damping compression adjuster.

  • Page 133: Rear Suspension Race Sag

    Rear Suspension Adjustments 4. Calculate the race sag dimension. REAR FENDER MOUNTING BOLT Rear Suspension Race Sag To do this, subtract the loaded with rider dimension (step 3) from the unloaded Setting the proper race sag (ride height) is very UNLOADED MEASUREMENT dimension (step 2).
  • Page 134 Rear Suspension Adjustments 6. Calculate the free sag dimension. Because of the great absorption quality of the To do this, subtract the loaded without shock bumper rubber, it may be difficult for rider dimension (step 5) from the unloaded you to notice when your CRF’s suspension is dimension (step 2).

  • Page 135: 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 136: Suspension Adjustment Guidelines

    Suspension Adjustment Guidelines Follow the procedures described below to accurately adjust your CRF, using the methods described on pages 112 – 130. 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 Begin with the standard setting.
  • Page 137 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 138 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 139: Carburetor Adjustment & Tuning Tips

    Carburetor Adjustment & Tuning Tips The carburetor used on your CRF will seldom Hot Start Circuit Carburetor Components experience trouble with the standard settings A lean mixture must be delivered to the cylinder under average load, and average climatic and when a hot engine is being started.
  • Page 140 Carburetor Adjustment & Tuning Tips Accelerator Pump Circuit Slow Circuit Main Circuit The accelerator pump circuit operates when Fuel is metered by the slow jet (1) and mixed Fuel is metered by the main jet (1), jet needle the throttle is opened. As the throttle valve (1) with air from the air passage (2).

  • Page 141: Carburetor Removal

    Carburetor Adjustment & Tuning Tips 7. Tighten the carburetor drain screw. 10. Loosen the insulator band screw (5) and Carburetor Removal 8. Remove the shock absorber upper mounting remove the carburetor (6) from the insulator nut (2) and bolt (3). (7).

  • Page 142: Carburetor Disassembly

    Carburetor Adjustment & Tuning Tips 12. Remove the throttle drum cover bolt (10) and 4. Remove the link arm torx screw (6) and Carburetor Disassembly throttle drum cover (11). throttle valve (5). When installing the link arm torx screw, 1. Pull up the cable clamp (1). apply a locking agent to the link arm torx (10) 2.
  • Page 143 Carburetor Adjustment & Tuning Tips When installing the floating valve (8) onto 6. Remove the accelerator pump cover screws 8. Remove the holder screw (17), throttle stop the throttle valve (5) make sure the floating (10) and accelerator pump cover (11). screw holder (18), float bowl screws (19), valve’s flat side faces out and the hole (9) tube guides (20) and float bowl (16).

  • Page 144: Carburetor Assembly

    Carburetor Adjustment & Tuning Tips 10. Measure the float level (24) with the float • After installing the carburetor, check the Carburetor Assembly level gauge (25) during float tab is just air vent hoses (5) and overflow hose (6) for contacting the float valve and the carburetor kinking or pinching and correct routing.

  • Page 145: Idle Speed Adjustment

    Carburetor Adjustment & Tuning Tips Idle Speed Adjustment 1. If the engine is cold, start it and warm it up 3 minutes. Then shut it off. 2. Connect a tachometer to the engine. 3. Shift the transmission into neutral. Start the engine.

  • Page 146: Steering Damper Adjustment

    Steering Damper Adjustment The steering damper can be adjusted for riding Steering Damper Adjustment conditions by using following method: • Damping – Turning the steering damper The steering damper adjuster (1) has 11 positions adjuster adjusts how quickly the steering or more.

  • Page 147: Steering Damper Adjustment Guidelines

    Steering Damper Adjustment Guidelines Follow the procedures described below to accurately adjust your CRF, using the methods described on this page. Symptoms and Adjustment • Always begin with the standard settings. • Turn the steering damper adjuster in one-click increments at a time. Adjusting two or more clicks at a time may cause you to pass over the best adjustment. Test ride after each adjustment.

  • Page 148: Chassis Adjustments

    Chassis Adjustments The following suggestions may improve a Fork Height/Angle Wheelbase specific concern. Subtle changes in overall handling may also be noted. Standard Position Adjusting your CRF’s wheelbase can offer subtle The position of the outer tubes in the clamps is changes in overall handling.

  • Page 149: Gearing

    Unless you have the required mechanical (before and after the change) to get an accurate • Wet and slippery or sandy conditions: use knowhow, tools, and an official Honda Service appraisal of the change. “Seat-of-the-pants” a higher gear (less teeth) to keep engine Manual, sprocket changing should be done by feelings can’t be trusted.

  • Page 150: Tire Selection For Track Conditions

    Tire Selection for Track Conditions Choosing the correct tire tread pattern and rubber If you choose a tire with a sticky compound for compound can affect your placing in competition. added traction, remember that it may transfer The tires on your CRF offer a “happy medium” additional loads to the transmission because it for the variety of soil conditions the majority of grips so well, especially when riding in situations...

  • Page 151: Personal Fit Adjustments

    Make sure that the bolts are torqued securely enough to prevent slippage during normal operation. Apply Pro Honda Hondalock 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 152: 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 ..........

  • Page 153: 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 154: Storing Your Honda

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

  • Page 155: Removal From Storage

    Storing Your Honda 9. Install the center engine guard (4) while 11. Remove the battery and charge it fully. Removal from Storage aligning its tabs (10) with the grooves (11) of Store in an area protected from freezing the radiator reserve tank.

  • Page 156: You & The Environment

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

  • Page 157: Troubleshooting

    The items that require use of • Lack of fuel in tank 1. Disconnect fuel FUEL FLOW CHECK POSSIBLE CAUSES the Honda Service Manual are followed by an (P.41) line at carburetor RESTRICTED 1. Check if air INCORRECT •...

  • Page 158: 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 17 CRF450X̲31MEY710.indb   153 17 CRF450X̲31MEY710.indb   153 2016/06/08   11:46:27 2016/06/08   11:46:27...

  • Page 159: If A Fuse Blows

    If a Fuse Blows All of the electrical circuits on your CRF have 3. Remove the starter magnetic switch (5) with NOTICE a fuse to protect them from damage caused by the rubber case. Replacing a fuse with one that has a higher excess current flow (short circuit or overload).

  • Page 160: If Your Battery Is Low (Or Dead)

    If Your Battery Is Low (or Dead) Jump-starting is not recommended, especially if you use an automobile battery. The greater amperage of an automobile battery when the car engine is running can damage your CRF’s electrical system. Bump starting is also not recommended. If you can’t charge the battery or it appears unable to hold a charge, see your dealer.
  • Page 161 Taking Care of the Unexpected 17 CRF450X̲31MEY710.indb   156 17 CRF450X̲31MEY710.indb   156 2016/06/08   11:46:27 2016/06/08   11:46:27...

  • Page 162: Technical Information

    Technical Information This section contains dimensions, capacities, and Vehicle Identification ........158 other technical data. Specifications ........... 159 Torque Specifications ........160 Emission Control Systems ....... 164 Oxygenated Fuels ..........166 Competition Logbook ........167 Optional Parts List ........... 169 Spare Parts &...

  • Page 163: Vehicle Identification

    Vehicle Identification The engine number (2) is stamped on the left Serial Numbers crankcase. The VIN and engine serial number are required LEFT SIDE when you register your CRF. They may also be required when ordering replacement parts. You may record these numbers in the Quick Reference section at the rear of the manual.

  • Page 164: Specifications

    Specifications Item English Metric Item English Metric Item English Metric Dimension Engine Drive train Overall length 85.8 in Type Liquid cooled, 4-stroke Clutch type Wet, multi-plate type 2,180 mm Overall width Single 6 inclined from Transmission 5-speed, constant mesh 32.3 in 820 mm Cylinder arrangement vertical...

  • Page 165: Torque Specifications

    Torque Specifications ENGINE Nuts, Bolts, Fasteners Torque Remarks Item lbf•ft N•m kgf•m Check and tighten nuts, bolts, and fasteners before every outing. Cylinder head cover bolts Engine Clutch cover bolts Water pump cover bolts Transmission oil check bolt Crankshaft hole cap NOTE 2 Oil filter cover bolts Cylinder bolt...
  • Page 166 Torque Specifications Frame FRAME Torque Item Remarks lbf•ft N•m kgf•m Steering stem nut 11.0 Fork bridge upper pinch bolts (21) Fork bridge lower pinch (14) (19) bolts (13) Handlebar upper holder bolts Handlebar lower holder nuts Front axle nut Axle pinch bolts Rear axle nut NOTE 1 13.1...
  • Page 167 Torque Specifications Frame FRAME Torque Remarks Item lbf•ft N•m kgf•m Spark arrester mounting bolts NOTE 7 (43) Brake pedal adjuster (32) lock nut (39) Front brake master cylinder holder bolts Brake hose bolts Front brake caliper (42) (27) mounting bolts NOTE 5 Front brake disc nuts NOTE 1...
  • Page 168 Torque Specifications Frame FRAME Torque Remarks Item lbf•ft N•m kgf•m Front brake reservoir (48) (49) cap screws Rear brake reservoir cap bolts Fork air pressure release screw Right/left step bracket mounting bolts (upper) (lower) Steering damper mounting bolts NOTE 5 Fuel joint mounting bolts Throttle cable adjuster lock nuts...

  • Page 169: Emission Control Systems

    Emission Control Systems Exhaust Emission Requirements Noise Emission Control System Problems that May Affect Motorcycle The U.S. Environmental Protection Agency TAMPERING WITH THE NOISE CONTROL Emissions (EPA), the California Air Resources Board SYSTEM IS PROHIBITED: U.S. federal law If you are aware of any of the following (CARB), and Environment Canada (EC) require symptoms, have the vehicle inspected and prohibits, or Canadian provincial laws may...
  • Page 170 Honda Motor Co., Ltd. utilizes various systems Tampering with the fuel tank, fuel hoses, or to reduce carbon monoxide, oxides of nitrogen fuel vapor charge hoses to reduce or defeat the and hydrocarbons.

  • Page 171: Oxygenated Fuels

    Oxygenated Fuels Some conventional gasolines are being Fuel system damage or performance problems blended with alcohol or an ether compound. resulting from the use of an oxygenated fuel These gasolines are collectively referred to as containing more than the percentages of oxygenated fuels.

  • Page 172: Competition Logbook

    Competition Logbook Any serious competition effort relies heavily Tuning & Adjustment Records Racing Records on the knowledge gained and compiled from Keep track of the settings and adjustments that Information worth recording for this section of previous racing events. The best way to organize worked best at a particular location.
  • Page 173 Competition Logbook Date Running Time Location/Event Comments (Suspension Settings, Gearing, Chassis Adjustments, Maintenance Performed, etc.) (Make several photocopies of this page for future use) Technical Information 17 CRF450X̲31MEY710.indb   168 17 CRF450X̲31MEY710.indb   168 2016/06/08   11:46:29 2016/06/08   11:46:29...

  • Page 174: Optional Parts List

    Optional Parts List These parts and tools may be ordered from your TOOLS Remarks FRAME Remarks dealer. Shock spring Pin spanner A To adjust spring pre-load. 307.8 lbf/in (53.9 N/mm) Standard (two spanners required) FRAME Remarks No mark Driven sprocket <...

  • Page 175: Spare Parts & Equipment

    In addition to the usual nuts and bolts, radiator hoses Pro Honda GN4 4-stroke Oil (Engine and consider the following: radiator shrouds (L & R) Transmission Oil) brake hoses (front &...

  • Page 176: Wiring Diagram

    Wiring Diagram Technical Information 17 CRF450X̲31MEY710.indb   171 17 CRF450X̲31MEY710.indb   171 2016/06/08   11:46:29 2016/06/08   11:46:29...
  • Page 177 Technical Information 17 CRF450X̲31MEY710.indb   172 17 CRF450X̲31MEY710.indb   172 2016/06/08   11:46:29 2016/06/08   11:46:29...

  • Page 178: Consumer Information

    Consumer Information This section contains information about Authorized Manuals ......... 174 contacting Honda and how to get an official Warranty Coverage .......... 175 Honda service manual. Warranty Service ..........176 Contacting Honda ..........177 Your Honda Dealer .......... 178 The Honda Rider’s Club (USA only) ....179 Consumer Information 17 CRF450X̲31MEY710.indb   173...

  • Page 179: Authorized Manuals

    Authorized Manuals The Service Manual used by your authorized dealer is available from your Honda dealer or Helm, Inc (USA only, Canada: See your dealer to order authorized manuals.) Also available, but not necessary to service your model, is the Honda Common Service Manual, which explains basic service information for various systems on Honda motorcycles, scooters, and ATV.

  • Page 180: Warranty Coverage

    • Noise Control Warranty (USA only) Your new Honda is covered by certain warranties as described in the Honda Motorcycle Warranties Booklet that was provided to you by your Honda dealer. Please read this booklet and be aware of the responsibilities, restrictions, and exclusions which apply.

  • Page 181: Warranty Service

    (such as brakes, tires, etc.) If you believe you have a problem with your Honda, call the service department of your Honda dealer. Make an appointment for an inspection and diagnosis. Remember, as the owner of the motorcycle, you will be asked to authorize that inspection.

  • Page 182: Contacting Honda

    If you wish to comment on your experiences with your Honda or with your dealer, please send your comments to the following address: Motorcycle Division, American Honda Motor Co., Inc., P.O.

  • Page 183: Your Honda Dealer

    Parts, Pro Honda products, Honda Genuine Accessories (USA only), and Honda accessories and products (Canada only). The same quality that went into your Honda can be found in Honda Genuine replacement parts. You’ll also find comparable quality in the accessories and products available from the parts department.

  • Page 184: The Honda Rider's Club (Usa Only)

    The Honda Rider’s Club (USA only) The Honda Rider’s Club of America (HRCA) sponsors local riding chapters at Authorized Honda Dealerships across the country. Consumer Information 17 CRF450X̲31MEY710.indb   179 17 CRF450X̲31MEY710.indb   179 2016/06/08   11:46:29 2016/06/08   11:46:29...

  • Page 185: Index

    ............... 41 fluid level ............. 89 rear ............. 127 oxygenated ..........166 lever, front adjustment ......... 88 dealer, your Honda .......... 178 recommendation .......... 41 pad wear ............91 diagram, wiring ..........171 refueling ............41 pedal height ..........88 drive chain ............
  • Page 186 ..........61 maintenance, rear suspension maintenance ......85 gasohol ............166 after competition .......... 33 Rider’s Club Honda ........179 gasoline ............. 41 before & after competition ......33 riding, gearing ............. 144 between motos & practice ......33 apparel ............
  • Page 187 Index steering head bearing inspection ..... 102 stopping engine ..........16 storage ............. 149 warranty, subframe ............39 coverage ............. 175 suspension, extended ............. 175 front .............. 84 washing your motorcycle ........ 108 rear ............... 85 weight limit ............3 suspension adjustment, wheels ...............

  • Page 188: Quick Reference

    91 or higher tank: 1.90 US gal (7.2 ℓ), reserve: 0.42 US gal (1.6 ℓ) Engine oil Pro Honda GN4 4-stroke oil (USA & Canada), or Honda 4-stroke oil, or an equivalent motorcycle oil. Transmission oil Pro Honda GN4 4-stroke oil (USA &...
  • Page 189 Quick Reference These symbols are used in Operating Controls and Basic Operating Instructions sections: SYMBOL COMPONENT SEE PAGE choke knob 8,15 START button 8,15 Quick Reference 17 CRF450X̲31MEY710.indb   184 17 CRF450X̲31MEY710.indb   184 2016/06/08   11:46:30 2016/06/08   11:46:30...

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