Honda 450X 2005 Owner's Manual & Competition Handbook
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Honda 450X 2005 Owner's Manual & Competition Handbook

Crf series off-road motorcycle
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2005
Honda CRF450X
OWNER'S MANUAL & COMPETITION HANDBOOK

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Summary of Contents for Honda 450X 2005

  • Page 1 2005 Honda CRF450X OWNER’S MANUAL & COMPETITION HANDBOOK...
  • Page 2 Honda Motorcycle Warranties Booklet established trails and riding only in approved investment, we urge you to take given to you by your Honda dealer at the line of areas, you help protect the environment and keep responsibility for keeping your CRF well purchase.
  • Page 3 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 4: Table Of Contents

    Electrical Contacting Honda..........167 Before & After Competition Maintenance..33 Battery .............100 Your Honda Dealer..........168 Headlight & Taillight ........102 The Honda Rider’s Club (USA only) .....169 Service Preparations Appearance Care ..........104 Component Locations ........35 Table of Contents...........170 Seat Removal.............36 Adjustments for Competition.......107 Fuel Tank Removal ...........37...

  • Page 5: Motorcycle Safety

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

  • Page 6: 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 7: 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 8: Accessories & Modifications

    CRF. way that would change its design or operation. Modifying your CRF or using non-Honda Because Honda cannot test all other accessories, Such changes could seriously impair your CRF’s accessories can make your CRF unsafe.

  • Page 9: 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 10 Motorcycle Safety...

  • Page 11: Operating Controls

    Operating Controls Read this section carefully before you ride. It Component Locations ..........8 presents the location of the basic controls on your CRF. Operating Controls...

  • Page 12: Component Locations

    Component Locations tripmeter hot start lever clutch lever front brake lever start button throttle grip engine stop button fuel fill cap choke knob kickstarter rear brake pedal shift lever fuel valve side stand Operating Controls...

  • Page 13: 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 14: 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 15: Is Your Motorcycle Ready To Ride

    Is Your Motorcycle Ready to Ride? Competitive riding can be tough on a motorcycle, Pre-ride Inspection so it’s important to inspect your CRF and correct any problems you find before each ride. Check the following items (page numbers are at the Check the following before each ride: right): •...
  • Page 16 Before Riding...
  • Page 17 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 ............15 Fuel Valve .............15 Starting Procedure ........15 Flooded Engine ..........16 How to Stop the Engine........16 Shifting Gears.............17...

  • Page 18: 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, please The tripmeter (1) is used to record the distance while parked (page 19). To operate, use your foot review the Important Safety Precaution traveled (USA: miles, Canada: kilometers) per to lower the side stand until it is fully extended.

  • Page 19: 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 throttle. described below. 6. About 15 seconds after the engine starts, push the choke knob back all the way to fully OFF. Your CRF can be started with the transmission in Always follow the proper starting procedure If idling is unstable, open the throttle slightly.

  • Page 20: 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 “Normal Air Temperature.” Starting the engine after a stall during riding or 2.

  • Page 21: 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 22: 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 23: Parking

    Parking Lower the side stand to support your CRF. If you’re through riding for the day, also turn the fuel valve OFF. Always choose a level place to park. Basic Operating Instructions...

  • Page 24: 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 97) to prevent rusting.

  • Page 25: 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 26 Basic Operating Instructions...

  • Page 27: Before You Service Your Honda The Importance Of Maintenance

    You’ll also find Electrical important safety precautions, information on oils, Service Preparations Battery ..............100 and tips for keeping your Honda looking good. Component Locations ........35 Headlight & Taillight ........102 Seat Removal............36 The ICM (Ignition Control Module) system is Fuel Tank Removal ..........37...

  • Page 28: 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 29: Maintenance Safety

    Be sure there is adequate ventilation whenever you operate the engine. Burns from hot motorcycle parts. Let the engine and exhaust system cool before touching. Injury from moving parts. Do not run the engine unless instructed to do so. Servicing Your Honda...

  • Page 30: 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 genuine...
  • Page 31 91,92 STEERING HEAD BEARINGS Should be serviced by your Honda dealer, unless the owner has the proper tools and service data and are mechanically qualified. Refer to the official Honda Service Manual (page 168). In the interest of safety, we recommended these items be serviced only by your Honda dealer.
  • Page 32 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. Damage from competition use is not covered by the Distributor’s Limited Warranty on your Honda.

  • Page 33: General Competition Maintenance

    General Competition Maintenance Perform maintenance on firm, level ground using the side stand, a workstand, or equivalent support. Use genuine Honda parts or their equivalent when servicing your CRF. Clean parts in non-flammable (high flash point) cleaning solvent (such as kerosene) when disassembling.
  • Page 34 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. Honda White Lithium...
  • Page 35 For added peace of mind, any way. Move the handlebar from lock to lock to be sure remove the nuts, clean the threads, and apply Honda Thread there is no cable interference. Check to be sure the top of the Lock or an equivalent prior to torquing the nuts.
  • Page 36 (containing more than 40% the suspension. Refer to the Honda Service Manual (page molybdenum disulfide additive). 168). Use only Pro Honda HP Fork Oil 5W (U.S.A. only) or equivalent which contains special additives to assure maximum performance of your CRF’s front suspension.

  • Page 37: Before & After Competition Maintenance

    (1) are in the same position on (2) pressure release screws 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...
  • Page 38 If your CRF was exposed to sea air or salt water, rinse it as soon as possible after the event, dry it, and apply a spray lubricant to all metal parts. If you decide to wash your CRF or use cleaners, refer to Appearance Care (page 104). Servicing Your Honda...

  • Page 39: Component Locations

    Servicing Your Honda...

  • Page 40: Seat Removal

    2. Install and tighten the seat bolts to the specified torque. 19 lbf·ft (26 N·m, 2.7 kgf·m) (1) seat bolts (2) seat (1) seat bolts (2) seat (3) seat front prong (4) seat bracket (5) seat rear prongs (6) tabs Servicing Your Honda...

  • Page 41: Fuel Tank Removal

    • Wipe up spills immediately. (4) breather tube (10) (5) fuel tank band (6) air cleaner cover rubber (1) shroud A bolts/collars (7) fuel tank bolt/collar (2) shroud B bolts (3) shroud (8) fuel line (10) bolt (9) fuel valve Servicing Your Honda...
  • Page 42 7. Put the breather tube (7) in the steering stem nut. (10) (9) shroud B bolts (10) shroud A bolts/collars 11. Install the seat (page 36). (4) fuel tank bolt/collar (6) fuel tank band (5) air cleaner cover rubber (7) breather tube Servicing Your Honda...

  • Page 43: Subframe Upright Position

    (5) and left side cover (6). (10) (9) subframe upper mounting bolts (10) subframe lower mounting bolts (3) air cleaner box cover (5) left side cover bolt (4) quick fastener (6) left side cover Servicing Your Honda...
  • Page 44 6. Install the right side cover (10) and right side cover bolt (11). (10) (1) subframe upper mounting bolts (2) subframe (3) subframe lower mounting bolts (11) (10) right side cover (11) right side cover bolt 7. Install the seat (page 36). Servicing Your Honda...

  • Page 45: Fuel System

    (2) fuel filter of gasoline. If pinging or spark knock persists, WARNING consult your Honda dealer. 1. Check the fuel valve (1) and fuel filter (2) for Gasoline is highly flammable and contamination.
  • Page 46 Install the fuel joint in the fuel tank. 5. Install the fuel tank (page 38) and refill the fuel. Turn the fuel valve to ON or RES; check for leaks. (1) fuel joint (3) fuel filter (2) bolts (4) O-ring Servicing Your Honda...

  • Page 47: Engine Oil

    (weight) the engine. JASO T 903 standard MA or MB NOT RECOMMENDED suggested oil* Pro Honda GN4, HP4 (without molybdenum additives) or HP4M (with • Oil is a major factor affecting the peformance molybdenum additives) and service life of the engine.
  • Page 48 27, 28. mark and add the recommended oil until the upper level mark. (Do not overfill) Reinstall the engine oil filler cap/dipstick. Repeat steps 1–5. 6. Reinsert the engine oil filler cap/dipstick. 7. Check for oil leaks. Servicing Your Honda...
  • Page 49 You should see the ”OUT-SIDE” mark steps in Checking & Adding Oil (page 44). (12) on the filter body, near the seal. Use a new genuine Honda oil filter or a filter of equal quality specified for your model. NOTICE...

  • Page 50: Transmission Oil

    NOT RECOMMENDED additives suggested oil* Pro Honda HP Trans oil, • Oil is a major factor affecting the performance Pro Honda GN4 or HP4 and service life of the transmission and clutch. (without molybdenum...
  • Page 51 1–4. 5. After inspection the oil level or adding oil, tighten the oil check bolt to the specified torque:. Oil Check Bolt: 7 lbf·ft (10 N·m, 1.0 kgf·m) 6. Install the transmission oil filler cap securely. Servicing Your Honda...

  • Page 52: 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 53 Always let the engine and radiator cool damaged. If oil leaks through the check hole, down before removing the radiator cap. the engine oil seal is damaged. See the Honda Service Manual or consult your Honda dealer for replacing the mechanical seal or the engine To properly dispose of drained coolant, refer to oil seal.
  • Page 54 If the radiator cap is not installed properly, it will cause excessive coolant loss and may result in overheating and engine damage. (3) radiator reserve tank cap (4) UPPER level line 5. Install the radiator reserve tank cap. (1) radiator cap (2) filler neck Servicing Your Honda...

  • Page 55: 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 56 Air Cleaner 7. Apply a thin coat of Honda White Lithium NOTICE Grease or equivalent to the air cleaner element of the air cleaner element holder contacting Improper installation of the air cleaner assembly surface. may allow dirt and dust to enter the engine and 8.

  • Page 57: 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...

  • Page 58: Throttle

    4. Tighten the lock nut. 5. Operate the throttle grip to ensure that it functions smoothly and returns completely. If you can’t get the freeplay within the specified range, see your Honda dealer. (–) (2) dust cover (+)increase (3) upper lock nut (–)decrease...
  • Page 59 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...

  • Page 60: 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. See your Honda dealer or refer to the official Honda Service Manual (page 166). Servicing Your Honda...
  • Page 61 Loosen the bolts in a crisscross pattern in 2 or kinks, or damage. 3 progressive steps. (1) brake pedal (4) washer (2) pin (5) dust seals 5. Remove the clutch pressure plate (9). (3) pivot bolt (8) clutch spring bolts/clutch springs (9) clutch pressure plate Servicing Your Honda...
  • Page 62 Check the plate warpage on a surface plate using (12) clutch lifter a feeler gauge. Measure the thickness of the clutch plates. Service Limit: 0.006 in (0.15 mm) Replace the clutch discs and plates as a set. (2) clutch plate Servicing Your Honda...
  • Page 63 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 2 or Lithium Grease or equivalent.

  • Page 64: Hot Start Lever

    (1) hot start lever (–) (2) freeplay Inspection (3) lock nut (+) increase Check freeplay (2). (4) cable adjuster (–) decrease Freeplay: 1/16 – 1/8 in (2 – 3 mm) If necessary, adjust to the specified range. Servicing Your Honda...

  • Page 65: 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...

  • Page 66: Exhaust Pipe/Muffler

    A damaged exhaust pipe and muffler may reduce engine performance. (4) muffler clamp bolt (1) seat bolt (3) right side cover (5) rear muffler mounting bolt/washer (2) side cover bolt (6) front muffler mounting bolt (7) muffler 4. Remove the muffler gasket. Servicing Your Honda...
  • Page 67 (10) (9) right side cover (11) seat bolt (10) side cover bolt (1) gasket (4) tab (2) muffler clamp (5) cut-out (3) muffler (6) front muffler mounting bolt (7) rear muffler mounting bolt/washer (8) muffler clamp bolt Servicing Your Honda...
  • Page 68 15 lbf·ft (21 N·m, 2.1 kgf·m) (1) exhaust pipe joint nuts (2) exhaust pipe (1) exhaust pipe gasket (3) exhaust pipe gasket (2) exhaust pipe (3) exhaust pipe joint nuts 2. Install the muffler (page 63). Servicing Your Honda...

  • Page 69: Spark Arrester

    4. Install the spark arrester and a new gasket in the muffler and tighten the four bolts (1) to the specified torque: 9 lbf·ft (12 N·m, 1.2 kgf·m) (1) bolts (1) bolts (3) gasket (2) spark arrester Servicing Your Honda...

  • Page 70: Valve Clearance

    (2) spark plug cap 4. Remove the cylinder head cover A bolt (3), cylinder head cover B bolts (4) and cylinder head cover (5). (3) cylinder head cover A bolt (4) cylinder head cover B bolts (5) cylinder head cover Servicing Your Honda...
  • Page 71 (3) primary drive gear bolt (5) index mark (4) “punch” mark (1) feeler gauge (2) valve lifters (3) intake cam lobes Valve Clearance: IN: 0.006 ± 0.001 in (0.16 ± 0.03 mm) (cont’d) Servicing Your Honda...
  • Page 72 If measured right exhaust valve clearance is 0.011 in (0.28 mm), decompressor clearance is: 0.011 in (0.28 mm) + 0.014 in (0.35 mm) = 0.025 in (0.63 mm) If only decompressor arm clearance needs adjustment, see Decompressor Arm clearance Adjustment (page 73). Servicing Your Honda...
  • Page 73 (4) cam sprocket bolts (5) cam sprocket (6) cam chain (7) bolts (8) camshaft holder assembly (10) (9) intake valve lifters (10) shims Servicing Your Honda...
  • Page 74 2.450 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...
  • Page 75 Tighten the camshaft holder assembly bolts in a crisscross pattern in 2 or 3 steps. (3) valve lifters (1) shims (4) camshaft holder assembly Exhaust side (4) camshaft holder assembly (5) intake cam lobes (6) camshaft holder assembly bolts (cont’d) Servicing Your Honda...
  • Page 76 Do not let the bolts and sprocket fall into the crankcase. (10) cam sprocket (7) primary drive gear bolt (11) index line (8) “punch” mark (12) “ ” mark (9) index mark (13) cam chain (14) (14) cam sprocket bolts Servicing Your Honda...
  • Page 77 (17) cam chain tensioner lifter cover bolt (1) feeler gauge (5) adjusting screw 10. After installing the cam shaft assembly, (4) lock nut (6) right side rocker arm perform the valve clearance and decompressor arm clearance inspection. Recheck the decompressor arm clearance. Servicing Your Honda...
  • Page 78 Install the cylinder head cover packing into the groove of the cylinder head cover (4). (8) spark plug cap (9) breather tube 6. Install the fuel tank and the seat (page 36, 38). (3) cylinder head cover packing (4) cylinder head cover Servicing Your Honda...

  • Page 79: Piston/Piston Rings/Piston Pin

    12. Remove the left radiator grill (5) and left disconnect the radiator hose (11). radiator lower mounting bolt/washer (6). (11) (10) (10) radiator hose clamp (5) left radiator grill (6) left radiator lower mounting bolt/washer (11) radiator hose (cont’d) Servicing Your Honda...
  • Page 80 (12) engine hanger nut (13) engine hanger bolt (14) fuel hose guide (15) engine hanger plate bolts (16) clutch cable stay (17) left engine hanger plate (18) right engine hanger plate (22) (21) cylinder head nuts/washers (22) cylinder head Servicing Your Honda...
  • Page 81 (2) cylinder bolt 2. Remove the dowel pins (4) and cylinder gasket (5). NOTICE Do not let the dowel pins fall into the crankcase. (1) piston pin clip (3) piston (2) piston pin (4) dowel pins (5) cylinder gasket Servicing Your Honda...
  • Page 82 We recommend you consult the Service Manual 1. Clean the piston ring groove throughly. oil ring or your authorized Honda dealer for correct 2. Apply engine oil to the piston rings and install Service Limit measurements. them. NOTICE Do not damage the piston ring by spreading the ends too far.
  • Page 83 Do not align the piston pin clip end gap with the piston cut-out. (1) dowel pins (2) cylinder gasket 4. Clean the any gasket material off the cylinder. (1) piston (4) piston pin (2) “IN” mark (5) piston pin clip (3) large valve recesses (6) cut-out (cont’d) Servicing Your Honda...
  • Page 84 Push the cam chain guide until it bottoms in the crankcase guide hole. (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 Servicing Your Honda...
  • Page 85 7. Tighten the engine hanger plate bolts to the (13) engine hanger nut specified torque: 19 lbf·ft (26 N·m, 2.7 kgf·m) Tighten the engine hanger nut to the specified (3) cylinder head torque: (4) cylinder head nuts/washers 40 lbf·ft (54 N·m, 5.5 kgf·m) (cont’d) Servicing Your Honda...
  • Page 86 13. Install the spark plug and plug cap (page 74). (17) 18. Install the subframe and muffler (page 40, 63). (19) 19. Install the fuel tank and seat (page 36, 38). (18) (16) (16) ignition coil (18) clamp/bolts (17) ground wire (19) primary wire connector Servicing Your Honda...

  • Page 87: Suspension

    • Use Pro Honda HP Fork Oil 5W or an equivalent which contains special additives to assure maximum performance of your CRF's front suspension.
  • Page 88 (page 126). Do not attempt to disassemble, service, or dispose of the damper; see your Honda dealer. 2. Lift the subframe to the upright position (page The instructions found in this owner’s manual are 39).
  • Page 89 (weight) 5 W when the fork damper is removed. To avoid suggested oil Pro Honda HP Fork Oil or damage hold both the outer tube and slider when equivalent removing the fork damper.
  • Page 90 (405 cm it nears full compression. Minimum oil 10.3 US oz Slightly stiffer as capacity (306 cm it nears full Minimum oil 10.5 US oz Slightly stiffer as compression. capacity (309 cm it nears full compression. Servicing Your Honda...

  • Page 91: Brakes

    (page 90), there is probably air in the brake system. (1) lock nut (3) piston Refer to the Honda Service Manual or see your (2) adjuster Honda dealer to have the air bled from the (–) system.
  • Page 92 Worn brake pads should be replaced. If the pads (20 mm), there is probably air in the brake are not worn, have your brake system inspected system and it must be bled. Refer to the Honda for leaks. Service Manual or see your Honda dealer for If the brake lever freeplay exceeds 0.8 in...
  • Page 93 Brakes Adding Front Brake Fluid Adding Rear Brake Fluid Other Inspection The recommended brake fluid is Honda DOT 4 The recommended brake fluid is Honda DOT 4 • Make sure there are no fluid leaks. brake fluid or an equivalent.
  • Page 94 0.04 in tight. (1 mm) Make sure there are no fluid leaks. Check for deterioration or cracks in the hoses and fittings. replace (1) brake pads (3) brake disc (2) front brake caliper Servicing Your Honda...

  • Page 95: Wheels

    It’s also important that 3. Check wheel rim runout. If runout is the rim locks are secure to prevent tire slippage. noticeable, see the Honda Service Manual for inspection instructions. It is not necessary to remove the wheels to perform the recommended service in the Axles &...

  • Page 96: Tires & Tubes

    Overinflated tires make your CRF ride more harshly, are more prone to damage from surface hazards, and wear unevenly. (1) tire tread depth Make sure the valve stem caps are secure. If necessary, install a new cap. Servicing Your Honda...
  • Page 97 • Use a replacement tire equivalent to the original. • 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...

  • Page 98: 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...

  • Page 99: 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...
  • Page 100 It should only be removed or replacement chain or sprocket(s) will wear rapidly. replaced by your Honda dealer. Excessively worn sprocket teeth have a hooked, worn appearance. Replace any The O-rings can be damaged by steam cleaning, high pressure washers, and certain solvents.
  • Page 101 Replace the chian guide slider if it is worn to the bottom of the wear limit groove (3). (1) upper drive chain roller (3) lower drive chain roller (2) “ ” mark (2) chain guide slider (3) wear limit groove Servicing Your Honda...

  • Page 102: Additional Maintenance Procedures

    (1) handlebar (2) handlebar upper holders the fork bushings may be worn. Refer to the Honda Service Manual for replacement or Control Cables adjustment procedures, or see your Honda dealer. Periodically, disconnect the throttle, clutch and hot start cables at their upper ends.
  • Page 103 (9) cylinder head bolts (10) drive sprocket bolt RIGHT SIDE (1) cylinder head cover bolts (2) exhaust pipe joint nuts (3) water pump cover bolts (4) crankshaft hole cap (5) transmission oil check bolt (6) clutch cover bolts Servicing Your Honda...

  • Page 104: Battery

    If your battery seems weak and/or is leaking the positive (+) cable (4) and remove the electrolyte (cause slow starting or other electrical battery (5). problems), see your Honda dealer. WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling.
  • Page 105 However, do not intentionally leave the charger connected longer than the time period recommended in the charger’s instructions. Avoid using an automotive-type battery charger. An automotive charger can overheat a motorcycle battery and cause permanent damage. (1) “trickle” charger Servicing Your Honda...

  • Page 106: Headlight & Taillight

    (10) with the tabs (11) on the steering stem. Remove the dust cover (5). Install and tighten the front visor bolts. (10) (11) (7) headlight bulb (8) align (3) clamp (5) dust cover (3) clamp (10) grommets (4) headlight connector (4) headlight connector (11) tabs Servicing Your Honda...
  • Page 107 (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...

  • Page 108: Appearance Care

    CRF. The force of water under extreme dry the brakes and restore normal braking pressure can penetrate the dust seals of the You may use Pro Honda Hondabrite, a performance. suspension pivot points and steering head multi-surface cleaner/degreaser, to remove both...
  • Page 109 #7447-maroon) is for removing stains on the non-coated aluminum frame only. Exhaust Pipe Maintenance The exhaust pipe is stainless steel, but may became stained by oil or mud. Remove heat stains with a liquid kitchen abrasive. (1) alternator cover Servicing Your Honda...
  • Page 110 Servicing Your Honda...

  • Page 111: Adjustments For Competition

    Adjustments for Competition This section tells you how to fine tune your CRF Front Suspension Adjustments......108 for maximum competition performance. Rear Suspension Adjustments ......122 Suspension Adjustments for Track Conditions Initial suspension adjustments should be ..............126 performed after a minimum of two hours of easy Suspension Adjustments Guidelines ....127 break-in time.

  • Page 112: 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 113 See the Service Manual or adjusters are firmly located in a detent, and not the fork is too hard on big bumps, turn the your Honda dealer for this service. between positions. damping adjuster counterclockwise 1-turn and lower the oil level in increments of 0.2 oz (5 cm...
  • Page 114 Front Suspension Adjustments 4. Loosen the upper pinch bolts (3). 7. Remove the tripmeter cable (7) and front axle Do not support the brake caliper by the brake 5. Loosen the fork damper (4), using the lock nut (8) and loosen the axle pinch bolts (9) on hose.
  • Page 115 Front Suspension Adjustments 11.Clean the fork assembly, especially the sliding 16.Temporarily install the fork damper to the NOTICE surface of the slider (18) and dust seal (19). outer tube. 12.Record the rebound damping adjuster position The outer tube can drop on the slider and 17.Set the axle holder (26) of the slider in a vise and turn the adjuster counterclockwise until it damage the fork dust seal and guide bushing...
  • Page 116 Front Suspension Adjustments 19.Push out the fork center bolt (27) from the 24.Remove the fork damper assembly (31) from (28) axle holder (26) of the slider by pushing the the fork assembly (32). (29) fork damper. While the fork center bolt (27) Remove the fork from the vise.
  • Page 117 Recommended Oil: Do not disassemble the fork cap assembly. Pro Honda HP Fork Oil 5 W or equivalent 2. Loosen the fork cap assembly (2) while Replace the fork cap as an assembly if it is...
  • Page 118 Front Suspension Adjustments 8. Extend the fork damper piston rod to 10.Tighten the fork cap assembly (2) while 12.Screw in the lock nut (8) to the fork damper piston rod (5) fully. maximum length. Adjust the oil level of the holding the cut out of the fork damper (1) fork damper as shown.
  • Page 119 Front Suspension Adjustments 15.Blow out the oil from the fork damper spring 14.Drain the extra oil from the fork damper (1). 13.Blow the extra oil off to the fork damper (1) chamber using compressed air to the oil hole. spring chamber (9) by pumping the fork damper piston rod to full stroke.
  • Page 120 Front Suspension Adjustments 2. Tighten the lock nut (2) fully and measure the Amount of fork oil left in the fork Fork Assembly (without damper and spring) unit: cc thread length (A) as shown. minute Standard: 0.43 – 0.51 in (11 – 13 mm) 1.
  • Page 121 Front Suspension Adjustments 4. Set the axle holder of the slider in a vise with 8. Measure the length of the lock nut (2) and 10.Apply fork oil to the fork center bolt (8) O- a piece of wood or soft jaws to avoid to fork center bolt (8) clearance.
  • Page 122 Optional Stiffer (0.49 kgf/mm) Fork Spring outer tube/slider (1). Standard (0.47 kgf/mm) Fork Spring No mark Recommended Oil: 3 scribe marks (factory products) Pro Honda HP Fork Oil 5 W or equivalent. 1 scribe mark (aftermarket parts) (11) Standard oil 11.4 US oz Standard oil 11.2 US oz...
  • Page 123 Front Suspension Adjustments 14.Check that the O-ring (12) on the fork damper 17.Tighten the fork damper (4) to the specified 19.Tighten the fork lower pinch bolts (13) to the assembly (4) is in good condition. Apply the torque using the lock nut wrench (14). specified torque: recommended fork oil to the O-ring.
  • Page 124 Front Suspension Adjustments 21.Clean the threads of the fork protector bolts 23.Check the left side collar (24) and tripmeter (18) and axle holder thoroughly. gear box (25) for wear or damage. (30) Apply locking agent to the fork protector bolt Install the left side collar (24) to the left wheel threads.
  • Page 125 Front Suspension Adjustments 26.Install the handlebar (34), mounting rubbers 29. While keeping the forks parallel, alternately 31.Clean the threads of the disk cover bolts and (35), washers and handlebar lower holder nuts tighten the right axle pinch bolts (37) to the axle holder thoroughly.

  • Page 126: Rear Suspension Adjustments

    Min. : 9.8 in (249 mm) gas. Do not attempt to disassemble, service, or dispose of the damper; see your Honda dealer. Spring pre-load length (Optional spring) The instructions found in this owner’s manual are Min. (Softer, 5.30 kgf/mm): 9.9 in (251 mm) Min.
  • Page 127 Rear Suspension Adjustments High Speed Compression Damping: Rear Suspension Damping The high speed damping can be adjusted by turning the hexagonal portion of the compression adjuster. Compression Damping The high speed compression damping adjuster Compression damping may be adjusted in two stages with separate adjusters.
  • Page 128 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 dimension (step 2). Setting the proper race sag (ride height) is very UNLOADED MEASUREMENT (without rider) Standard Race Sag: 3.9 in (100 mm)
  • Page 129 Rear Suspension Adjustments 6. Calculate the free sag dimension. Because of the great absorption quality of the To do this, subtract the loaded without rider shock bumper rubber, it may be difficult for you dimension (step 5) from the unloaded to notice when your CRF’s suspension is dimension (step 2).

  • Page 130: 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 131: Suspension Adjustment Guidelines

    Suspension Adjustment Guidelines Follow the procedures described below to accurately adjust your CRF, using the methods described on pages 108 - 123. Remember to make all adjustments in one-click increments. Test ride after each adjustment. Front Suspension Adjustment Adjustments for Type of Track Hard-surfaced track Begin with the standard setting.
  • Page 132 Suspension Adjustment Guidelines Symptom Action Stiff Initial travel too stiff: – Test softer compression damping adjustments in one-click increments. suspension • Stiff on small bumps while riding at full throttle in a straight line. – Reduce the rebound damping adjustments in one-click increments. •...
  • Page 133 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 preload). Example: –...

  • Page 134: Carburetor Adjustments & Tuning Tips

    Carburetor Adjustments & 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 135 Carburetor Adjustments & Tuning Tips Accelerator Pump Circuit Slow Circuit Main Circuit The accelerator pump circuit operates when the Fuel is metered by the slow jet (1) and mixed Fuel is metered by the main jet (1), jet needle (2) throttle is opened.
  • Page 136 Carburetor Adjustments & Tuning Tips 6. Raise the rear wheel off the ground by placing 9. Loosen the insulator band screw (5) and Carburetor Removal a optional workstand or equivalent under the remove the carburetor (6) from the insulator engine. (7).
  • Page 137 Carburetor Adjustments & Tuning Tips 11.Remove the throttle drum cover bolt (10) and 3. Remove the link arm set screw (7). Carburetor Disassembly/Assembly throttle drum cover (11). When installing the link arm set screw, apply a locking agent to the link arm set screw threads.
  • Page 138 Carburetor Adjustments & Tuning Tips When installing the floating valve (10) onto 5. Remove the accelerator pump cover screws 7. Remove the holder screw (19), throttle stop the throttle valve (8) make sure the floating (12) and accelerator pump cover (13). screw holder (20), float bowl screws (21), valve’s flat side faces out and the hole (11) tube guides (22) and float bowl (18).
  • Page 139 Carburetor Adjustments & Tuning Tips 9. Measure the float level (26) with the float To assemble, reverse the disassembly procedures. level gauge (27) during float tab just To install the carburetor, reverse the removal contacting the float valve and the carburetor procedures.
  • Page 140 Carburetor Adjustments & Tuning Tips Idle Speed Adjustment 1. If the engine is cold, start it and warm it up three minutes. Then shut it off. 2. Connect a tachometer to the engine. 3. Shift into neutral. Start the engine. 4.

  • Page 141: 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 142: Gearing

    Honda Service Manual, engine may bog in certain corners so you’ll with a gearing change can make you feel like sprocket changing should be done by your Honda need to slip the clutch to compensate; you’re going slower when, in reality, you’ve dealer.

  • Page 143: 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 144: Personal Fit Adjustments

    Handlebar Position, Width & Shape Apply Honda Thread Lock or an equivalent to the threads of these bolts prior to adjustment to help ensure the correct torque is retained. • Position the handlebar so that both gripping •...

  • Page 145: Tips

    Tips Here’s helpful advice on how to transport and store your Honda, as well as two troubleshooting flow charts. Transporting Your Motorcycle ......142 Storing Your Motorcycle ........143 You & the Environment ........145 Troubleshooting..........146 Tips...

  • Page 146: 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 147: Storing Your Motorcycle

    7. Remove the reserve tank cap (7). such as during the winter, thoroughly inspect (2). Disconnect the siphone tube (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 148 (2) and bolt (1). pressures. more than 4 months have passed since the 13. Place your CRF on the optional Honda start of storage. workstand or equivalent to raise both tires off 2. Uncover the end of the muffler and remove the ground.

  • Page 149: You & The Environment

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

  • Page 150: Troubleshooting

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

  • Page 151: Taking Care Of The Unexpected

    Taking Care of the Unexpected This section gives practical advice to help you If a Fuse Blows ..........148 solve problems. If Your Battery is Low (or Dead) .....149 Taking Care of the Unexpected...

  • Page 152: 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 1. To prevent an accidental short circuit, stop the engine.

  • Page 153: 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...
  • Page 154 Taking Care of Unexpected...

  • Page 155: Technical Information

    Technical Information This section contains dimensions, capacities, and Vehicle Identification ........152 other technical data. Specifications ...........153 Torque Specifications ........155 Emission Control Systems .......158 Oxygenated Fuels..........159 Competition Logbook ........160 Optional Parts List..........162 Spare Parts & Equipment.........163 Wiring Diagram..........164 Technical Information...

  • Page 156: Vehicle Identification

    Vehicle Identification The frame number (2) is stamped on the right Serial Numbers side of the steering head. RIGHT SIDE The VIN, frame and engine serial numbers are required when you register your CRF. They may also be required when ordering replacement parts.

  • Page 157: Electrical Battery

    Specifications For USA (except California) & CANADA 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 32.3 in Transmission 5-speed, constant mesh 821 mm Cylinder arrangement...
  • Page 158 Specifications For California Item English Metric Item English Metric Item English Metric Dimension Engine Drive train Overall length Type Liquid cooled, 4-stroke Clutch type Wet, multi-plate type 85.8 in 2,180 mm Overall width Transmission 5-speed, constant mesh 32.3 in 821 mm Cylinder arrangement Overall height Primary reduction...

  • Page 159: Torque Specifications

    Torque Specifications Nuts, Bolts, Fasteners Torque Remarks Check and tighten nuts, bolts, and fasteners before every outing. Item lbf•ft N•m kgf•m ENGINE Engine Cylinder head cover bolts Clutch cover bolts Water pump cover bolts Transmission oil check bolt Crankshaft hole cap Oil filter cover bolts Cylinder bolt Cylinder head bolts...
  • Page 160 Torque Specifications Frame Torque Remarks Item lbf•ft N•m kgf•m FRAME Steering stem nut 11.0 Fork bridge upper pinch bolts (11) (19) (14) Fork bridge lower pinch bolts Handlebar upper holder bolts Handlebar lower holder nuts Front axle nut Front axle holder pinch bolts Rear axle nut NOTE 2...
  • Page 161 Torque Specifications Frame Torque Remarks Item lbf•ft N•m kgf•m FRAME Front brake master (41) (29) cylinder holder bolts (38) Brake hose bolts Caliper mounting bolts NOTE 5 Front brake disc nuts NOTE 4 Rear brake disc nuts NOTE 4 Brake pedal pivot bolt Spokes (front) 3.68...

  • Page 162: Emission Control Systems

    The Vehicle Emission Control Information Label of design incorporated into any new vehicle for Honda Motor Co., Ltd. Utilizes lean carburetor (1) is attached on the rear fender. the purpose of noise control prior to its sale or...

  • Page 163: Oxygenated Fuels

    Oxygenated Fuels Some conventional gasolines are being blended If you notice any undesirable operating with alcohol or an ether compound. These symptoms, try another service station or switch gasolines are collectively referred to as to another brand of gasoline. oxygenated fuels. To meet clean air standards, some areas of the United States and Canada use Fuel system damage or performance problems oxygenated fuels to help reduce emissions.

  • Page 164: Competition Logbook

    Competition Logbook Any serious competition effort relies heavily on Tuning & Adjustment Records Racing Records 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 165 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...

  • Page 166: Optional Parts List

    Optional Parts List These parts and tools may be ordered from your TOOLS Remarks FRAME Remarks Honda dealer. Shock spring Pin spanner A To adjust spring preload. 308.0 lbf/in (5.50 kgf/mm) Standard (two spanners required) FRAME Remarks No mark Driven sprocket <...

  • Page 167: Spare Parts & Equipment

    HP4M (with molybdenum additives) brake hoses (front & rear) 4-stroke Oil Spare Parts (Engine Oil) Pro Honda HP Trans Oil or Pro Honda GN4 or General Tools spark plugs HP4 (without molybdenum additives only) 4- shims stroke Oil (Transmission Oil) air cleaner (clean &...

  • Page 168: Wiring Diagram

    Wiring Diagram Technical Information...

  • Page 169: Consumer Information

    Consumer Information This section contains information about Authorized Manuals .........166 contacting Honda and how to get an official Contacting Honda..........167 Honda service manual. Your Honda Dealer...........168 The Honda Rider’s Club (USA only) ....169 Consumer Information...

  • Page 170: Authorized Manuals

    For purchases outside U.S.A., please write to the address shown below for a quotation. manuals) Also available, but not necessary to service your model is the Honda Common Service Manual which explains theory of operation and basic service Customer Name information for various systems common to all Honda motorcycles, motor scooters and ATVs.

  • Page 171: 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 (USA only): Motorcycle Division, American Honda Motor Co., Inc., P.O.

  • Page 172: Your Honda Dealer

    Your Honda Dealer Once you purchase your new Honda, get familiar Your dealer can inform you about competition with the organization of your Honda dealer so events in your area. You’ll also find that your you can utilize the full range of services dealer is a source of information (USA only) the available.

  • Page 173: The Honda Rider's Club (Usa Only)

    Safety Foundation training. Separate free training from the Speialty Vehicle Institute of America for ATV owners. • One full year of the Honda Red Rider magazine or Honda Red Rider ATV (for ATV purchasers). • Discounts from HRCA partners for experienced rider courses.

  • Page 174: Service Preparations Component Locations

    Table of Contents The following presents the contents of each Servicing Your Honda ........23 Chassis section of your owner’s manual. Before You Service Your Honda Suspension............83 The Importance of Maintenance .......24 Brakes..............87 Motorcycle Safety..........1 Maintenance Safety...........25 Wheels...............91 Important Safety Precautions......2 Important Safety Precautions .......25...
  • Page 175 Competition Logbook ........160 Optional Parts List...........162 Spare Parts & Equipment........163 Wiring Diagram..........164 Consumer Information .........165 Authorized Manuals ........166 Contacting Honda..........167 Your Honda Dealer..........168 The Honda Rider’s Club (USA only) .....169 Table of Contents...........170 Index ...............172 Quick Reference ..........176 Table of Contents...

  • Page 176: Index

    ...........8 front suspension adjustment .......108 appearance care..........104 competition logbook ........161 front suspension inspection ......83 authorized manuals ..........168 contacting Honda ..........167 oil recommendation ........85 controls, operating ..........8 frame number...........152 coolant..............48 front brake lever adjustment ......87 customer service ..........168 front suspension maintenance......108...
  • Page 177 Index gap, spark plug...........61 maintenance, rear suspension maintenance ......84 gasohol ...............41 after competition...........33 Rider’s Club Honda .........169 gasoline ..............41 before & after competition ......34 riding, gearing .............138 between motos & practice ......33 apparel ............2 guidelines, suspension adjustment....127 general competition ........29 basic operation..........13...
  • Page 178 Index suspension, front ..............83 rear ..............84 suspension adjustment, front ............108 rear ..............122 for track conditions........139 guidelines............127 transmission oil..........46 tuning tips ............130 throttle, freeplay ............54 inspection............55 tires, air pressure............92 flat ..............92 selection ............93 tools..............163 torque specifications.........155-157 transporting ............142 troubleshooting ..........146 tubes, replacing ..........92 valve, fuel............15 vehicle identification........152 washing your motorcycle.........104...
  • Page 179 Memo...

  • Page 180: Quick Reference

    Pro Honda GN4 or HP4 (without molybdenum additives) or HP4M (with molybdenum additives) 4-stroke oil, or an equivalent. Transmission oil Pro Honda HP Trans oil, Pro Honda GN4 or HP4 (without molybdem additives) 4-stroke oil, or an equivalent. Tires Front: 80/100-21 51M...

This manual is also suitable for:

Crf450x2005 crf450x

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