Honda 2005 CRF450R Owner's Manual page 57

Clutch System
Clutch Spring Inspection
(1) clutch spring
Measure the free length of each spring.
Service Limit: 1.72 in (43.7 mm)
Replace the clutch springs as a set if any one of
them is below the service limit or if the clutch
plates have been burnt/heat discolored.
Clutch Disc/Plate Installation
1. Coat the clutch plates (1) with engine oil.
2. Install the eight clutch discs (2) and seven
clutch plates (1) alternately, starting with a disc.
(2)
(1)
(1) seven clutch plates
(2) eight clutch discs
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Servicing Your Honda
3. Apply grease to the clutch lifter rod (3).
4. Insert the clutch lifter rod into the mainshaft.
5. Apply engine oil to the needle bearing (4) and
washer (5) and install them onto the clutch
lifter (6).
6. Install the clutch lifter onto the rod.
(1)
(3)
(5)
(3) clutch lifter rod
(4) needle bearing
7. Install the clutch pressure plate (7).
8. Install the six clutch springs and bolts (8).
9. Tighten the bolts in a crisscross pattern in 2
or 3 steps, to the specified torque:
9 lbf·ft (12 N·m, 1.2 kgf·m)
(7)
(7) clutch pressure plate
(8) clutch springs and bolts
10. Install a new O-ring (9) in the groove of the
11. Install the clutch cover by tightening the six
(9)
(9) O-ring
(6)
(4)
12. Apply grease to the rear brake pedal pivot bolt
(5) washer
(6) clutch lifter
13. Install the dust seals (12) into the rear brake
14. Apply locking agent to the brake pedal pivot
(8)
(11) pivot bolt
(12) dust seals
15. Add the transmission oil (page 40).
clutch cover (10).
cover bolts to the specified torque:
7 lbf·ft (10 N·m, 1.0 kgf·m)
(10)
(10) clutch cover
(11) sliding surface.
pedal (13).
bolt threads and tighten it to the specified
torque:
27 lbf·ft (36 N·m, 3.7 kgf·m)
Connect the brake pedal return spring (14) if
it was removed.
(13)
(14) (12)
(13) rear brake pedal
(14) return spring
(11)