Honda CRF450X 2007 Owner's Manual

2007 honda crf450x

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Summary of Contents for Honda CRF450X 2007

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 2007 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 Please report any change of address or ownership off-road motorcycle. is available (page 166). It is the same manual to your Honda dealer so we will be able to your dealer uses. If you plan to do any service contact you concerning important production When you own a Honda, you’re part of a...
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
Electrical Contacting Honda..........169 Before & After Competition Maintenance..33 Battery .............100 Your Honda Dealer..........170 Headlight & Taillight ........102 The Honda Rider’s Club (USA only) .....171 Service Preparations Appearance Care ..........104 Maintenance Component Locations....35 Table of Contents...........172 Seat Removal.............36 Adjustments for Competition.......107 Fuel Tank Removal ...........37...
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 Loading..............3 moments to read these pages. This section also Accessories & Modifications .......4 includes information about the location of the Safety Labels ............5 safety labels on your CRF.
Page 7: 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 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
Modifying your CRF or using non-Honda specifically designed and tested for your CRF. way that would change its design or operation. Because Honda cannot test all other accessories, Such changes could seriously impair your CRF’s accessories can make your CRF unsafe.
Page 10: 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 11 Motorcycle Safety...
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...
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...
Page 14: 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 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 the following items (page numbers are at the Check the following before each ride: right): •...
Page 17 Before Riding...
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 ............15 Fuel Valve .............15 Starting Procedure ........15 Flooded Engine ..........16 How to Stop the Engine........16 Shifting Gears.............17...
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, please The tripmeter (1) is used to record the distance while parked (page 19). To operate, use your foot 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 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 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 “Normal Air Temperature.” Starting the engine after a stall during riding or 2.
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...
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 97) 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...
Page 28: Servicing Your Honda
You’ll also find Electrical important safety precautions, information on oils, Service Preparations Battery ..............100 and tips for keeping your Honda looking good. Maintenance Component Locations....35 Headlight & Taillight ........102 Seat Removal............36 The ICM (Ignition Control Module) system is Fuel Tank Removal ..........37...
Page 29: 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 30: 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 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 genuine...
Page 32 91,92 STEERING HEAD BEARINGS Should be serviced by your Honda dealer, unless the owner has the proper tools and service data and is mechanically qualified. Refer to the official Honda Service Manual (page 166). In the interest of safety, we recommend these items be serviced only by your Honda dealer.
Page 33 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 34: General Competition Maintenance
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 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...
Page 36 For added peace of mind, may restrict throttle control in any way. Move the handlebar remove the nuts, clean the threads, and apply Pro Honda from lock to lock to be sure there is no cable interference.
Page 37 Refer to the Honda Service Manual (page 166). Use only Pro Honda HP Fork Oil 5W (USA only) 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 (2) pressure release screw 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 39 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 40: Maintenance Component Locations
Servicing Your Honda...
Page 41: Seat Removal
2. Install and tighten the seat bolts (1) 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 42: 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 43 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 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...
Page 45 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 46: Fuel System
If pinging or spark knock persists, WARNING 1. Check for leaks. consult your Honda dealer. 2. Check the fuel line (1) for cracks, Gasoline is highly flammable and deterioration, damage, or leakage. Replace the Never use stale or contaminated gasoline.
Page 47 Reassemble the fuel joint in the reverse order of removal. 6. Install the fuel tank (page 38) and refill the fuel. Turn the fuel valve to ON or RES; check for leaks. Servicing Your Honda...
Page 48: Engine Oil
(weight) the engine. JASO T 903 standard MA NOT RECOMMENDED suggested oil* Pro Honda GN4, HP4 (without molybdenum additives) 4-stroke oil or an • Oil is a major factor affecting the peformance equivalent* and service life of the engine.
Page 49 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. Install the engine oil filler cap/dipstick securely. 7. Check for oil leaks. Servicing Your Honda...
Page 50 18.Check the engine oil level by following the SIDE” mark on the filter body, near the rubber steps in Checking & Adding Oil (page 44). seal (12). Use a new genuine Honda oil filter or a filter of equal quality specified for your model. NOTICE (4) bolt...
Page 51: 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 52: Checking And Adding Oil
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 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 3. Check the radiator mount for looseness. Refer to the Honda Service Manual (page 166). 4. Make sure the siphon hose (2) is connected and not clogged. WARNING 5.
Page 55 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 56: Air Cleaner
Service the air cleaner more frequently if you ride in unusually wet or dusty areas. Your Honda dealer can help you determine the correct service interval for your riding conditions.
Page 57 Air Cleaner 8. Apply a thin coat of Pro Honda White NOTICE Lithium Grease or equivalent to the sealing surface between the air cleaner element and Improper installation of the air cleaner assembly air cleaner element holder. may allow dirt and dust to enter the engine and 9.
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...
Page 59: Throttle
5. Operate the throttle grip to ensure that it functions smoothly and returns completely. (–) 6. Install the fuel tank (page 38). 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 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...
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...
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, kinks, or damage. (9) clutch spring bolts/clutch springs (10) clutch pressure plate (cont’d) Servicing Your Honda...
Page 63 (12) needle bearing (15) clutch discs/clutch plates a feeler gauge. (13) clutch lifter Measure the thickness of each clutch plate. Service Limit: 0.006 in (0.15 mm) Replace the clutch discs and plates as a set. (2) clutch plate Servicing Your Honda...
Page 64 12. Lubricate the dust seals (12), rear brake pedal Clutch Disc/Plate Installation 8. Install the six clutch springs and bolts (9). (13) pivot and pivot bolt (14) with Pro Honda 9. Tighten the bolts in a crisscross pattern in 2 or White Lithium Grease or equivalent.
Page 65: Hot Start Lever
(1) hot start lever (–) (2) freeplay Inspection (3) lock nut (+) increase Check freeplay (2). (4) adjuster (–) decrease Freeplay: 1/16 – 1/8 in (2 – 3 mm) If necessary, adjust to the specified range. Servicing Your Honda...
Page 66: Spark Plug
If a plug is too tight, the threads may out of specification, replace the spark plug be damaged. with a new one. 10. Connect the spark plug cap. (3) sealing gasket 11. Install the fuel tank and seat (pages 36, 38). (4) spark plug gap Servicing Your Honda...
Page 67: 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 68 (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 69 3. Tighten the nuts to the specified torque: 15 lbf·ft (21 N·m, 2.1 kgf·m) (1) exhaust pipe joint nuts (2) exhaust pipe (3) exhaust pipe gasket (1) exhaust pipe gasket (2) exhaust pipe (3) exhaust pipe joint nuts 4. Install the muffler (page 63). Servicing Your Honda...
Page 70: Spark Arrester
4. Install a new gasket and the spark arrester 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 71: 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 72 (2) primary drive gear bolt (4) index mark (3) “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 73 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 74 (10) (4) cam sprocket bolts (7) camshaft holder bolts (5) cam sprocket (8) camshaft holder assembly (6) cam chain (9) intake valve lifters (10) shims Servicing Your Honda...
Page 75 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 76 Tighten the camshaft holder assembly bolts in a crisscross pattern in 2 or 3 steps. (1) shims (2) valve lifters (3) camshaft holder assembly Exhaust side (3) camshaft holder assembly (4) intake cam lobes (5) camshaft holder assembly bolts (cont’d) Servicing Your Honda...
Page 77 Do not let the bolts and sprocket fall into the (9) cam sprocket (6) primary drive gear bolt crankcase. (10) index line (7) “punch” mark (11) “ ” mark (8) index mark (12) cam chain (13) (13) cam sprocket bolts Servicing Your Honda...
Page 78 (16) 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 79 Install the cylinder head cover packing into the groove of the cylinder head cover (4). (7) spark plug cap (8) breather tube 6. Install the fuel tank and the seat (pages 36, 38). (3) cylinder head cover packing (4) cylinder head cover Servicing Your Honda...
Page 80: Piston/Piston Rings/Piston Pin
(page 68). 12. Remove the left radiator grill (6) and left (12) radiator lower mounting bolt/washer (7). (11) (11) radiator hose clamp (12) radiator hose (6) left radiator grill (7) left radiator lower mounting bolt/washer (cont’d) Servicing Your Honda...
Page 81 (13) engine hanger nut (14) engine hanger bolt (15) fuel hose guide (16) engine hanger plate bolts (17) clutch cable stay (18) left engine hanger plate (19) right engine hanger plate (23) (22) cylinder head nuts/washers (23) cylinder head Servicing Your Honda...
Page 82 (2) cylinder bolt 3. Remove the dowel pins (4) and cylinder gasket (5). (1) piston pin clip (3) piston (2) piston pin NOTICE Do not let the dowel pins fall into the crankcase. (4) dowel pins (5) cylinder gasket Servicing Your Honda...
Page 83 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 84 Do not align the piston pin clip end gap with the piston cut-out. (1) dowel pins (2) cylinder gasket 5. 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 85 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 86 (12) fuel hose guide 19 lbf·ft (26 N·m, 2.7 kgf·m) (13) engine hanger nut 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 (cont’d) Servicing Your Honda...
Page 87 20. Install the fuel tank and seat (pages 36, 38). 21. Fill and bleed the cooling system (page 50). 22. Add engine oil (page 44). (16) (16) ignition coil (18) clamp/bolts (17) ground wire (19) primary wire connector Servicing Your Honda...
Page 88: 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 89 (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 90 (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 91 (405 cm it nears full compression. compression. Minimum oil 10.3 US oz Slightly softer as Minimum oil 10.5 US oz Slightly softer as capacity (306 cm it nears full capacity (309 cm it nears full compression. compression. Servicing Your Honda...
Page 92: 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 93 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 94 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 DOT 4 brake fluid or an equivalent. DOT 4 brake fluid or an equivalent.
Page 95 0.04 in (1 mm) tight. 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 96: Wheels
It’s also important that the rim locks are 3. Check wheel rim runout. If runout is 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 Regular Axles &...
Page 97: Tires & Tubes
Overinflated tires make your CRF ride harshly, are more prone to damage from surface hazards, and wear unevenly. (1) tread depth Make sure the valve stem caps are secure. If necessary, install a new cap. Servicing Your Honda...
Page 98 • 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 99: 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 100: 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 101 It should only be removed or rapidly. replaced by your Honda dealer. Excessively worn sprocket teeth have a The O-rings can be damaged by steam cleaning, hooked, worn appearance. Replace any high pressure washers, and certain solvents.
Page 102 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 103: Additional Maintenance Procedures
(1) handlebar (2) handlebar upper holder bolts 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 104 (11) engine oil drain bolt RIGHT SIDE (12) transmission oil drain bolt (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 105: Battery
If your battery seems weak and/or is leaking then the positive (+) terminal (4) and remove electrolyte (cause slow starting or other electrical the battery (5). problems), see your Honda dealer. WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. (1) battery band Wash hands after handling.
Page 106 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 107: Headlight & Taillight
Remove the dust cover (5). Install and tighten the front visor bolts. (11) (12) (7) headlight bulb (9) groove (8) tab (3) clamp (5) dust cover (3) clamp (11) grommets (4) headlight connector (4) headlight connector (12) tabs Servicing Your Honda...
Page 108 (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 109: 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 110 Dry with chamois or a soft towel. If necessary, remove heat stains by using a commercially available fine texture compound. Then rinse by the same manner as removing mud or dust. Servicing Your Honda...
Page 111 Servicing Your Honda...
Page 112: 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 Initial suspension adjustments should be Conditions ............126 performed after a minimum of two hours of easy Suspension Adjustment Guidelines....127 break-in time.
Page 113: 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 114 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 115 Front Suspension Adjustments 4. Loosen the top bridge 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 116 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 and compression damping The outer tube can drop on the slider and 17.Set the axle holder (26) of the slider in a vise adjuster positions and turn the adjuster damage the fork dust seal and guide bushing...
Page 117 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 is Remove the fork from the vise.
Page 118 Recommended Oil: Do not disassemble the fork cap assembly. Pro Honda HP Fork Oil 5 W or equivalent 2. Make sure the compression damping adjuster Replace the fork cap as an assembly if it is Recommended Amount: is set to the softest position.
Page 119 Front Suspension Adjustments 14.Screw in the lock nut (8) to the fork damper 9. Extend the fork damper piston rod to 11.Place the fork damper (1) in a vise with a piston rod (5) fully. maximum length. Adjust the oil level of the piece of wood or soft jaws to avoid damage.
Page 120 Front Suspension Adjustments 17.Blow out the oil from the fork damper spring 15.Cover the fork piston rod end with soft jaws 16.Drain the extra oil from the fork damper (1). chamber using compressed air to the oil hole. to prevent fork damage. Blow the extra oil off to the fork damper (1) Wipe the oil completely off the fork damper.
Page 121 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 122 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 O-ring a piece of wood or soft jaws to avoid to fork center bolt (8) clearance.
Page 123 Optional Stiffer (0.49 kgf/mm) Fork Spring outer tube (1). Standard (0.47 kgf/mm) Fork Spring No mark Recommended Oil: (factory products) 3 scribe marks Pro Honda HP Fork Oil 5 W or equivalent. 1 scribe mark (aftermarket parts) (11) Standard oil 11.3 US oz Standard oil 11.2 US oz...
Page 124 Front Suspension Adjustments 14.Check that the O-ring (12) on the fork damper 17.Tighten the fork damper (4) to the specified (16) assembly (4) is in good condition. Apply fork torque, using the lock nut wrench (14). oil to the O-ring. Actual: 15.Pull up the outer tube (1) slowly and install 25 Ibf·ft (34 N·m, 3.5 kgf·m)
Page 125 Front Suspension Adjustments 21.Clean the threads of the fork protector bolts 24.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 to the left wheel threads.
Page 126 Front Suspension Adjustments 27.Install the handlebar (34), mounting rubbers 30. While keeping the forks parallel, alternately 32.Install the disc cover (39) and tighten the bolts (35), washers and handlebar lower holder nuts tighten the right axle pinch bolts (37) to the (40) to the specified torque: (36) and tighten the handlebar lower holder 10 Ibf·ft (13 N·m, 1.3 kgf·m)
Page 127: 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) Min. (Softer, 5.30 kgf/mm): 9.9 in (251 mm) The instructions found in this owner’s manual are limited to adjustments of the rear shock absorber Min.
Page 128 Rear Suspension Adjustments High Speed Compression Damping: Rebound Damping Rear Suspension Damping The high speed damping can be adjusted by The rebound damping adjuster (3) is located at turning the hexagonal portion of the compression the lower end of the shock absorber. Compression Damping adjuster.
Page 129: Spring Pre-Load & Race Sag Adjustment
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 dimension (step 2).
Page 130 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 131: 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 132: 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 133 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 134 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 135: Carburetor Adjustment & Turning 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 136 Carburetor Adjustment & 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 137 Carburetor Adjustment & Tuning Tips 6. Raise the rear wheel off the ground by placing 9. Loosen the insulator band screw (5) and Carburetor Removal an optional workstand or equivalent under the remove the carburetor (6) from the insulator engine. (7).
Page 138 Carburetor Adjustment & Tuning Tips 11.Remove the throttle drum cover bolt (10) and 3. Remove the link arm torx screw (7). Carburetor Disassembly/Assembly throttle drum cover (11). When installing the link arm torx screw, apply a locking agent to the link arm torx screw 1.
Page 139 Carburetor Adjustment & 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 140 Carburetor Adjustment & 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 141 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 into neutral. Start the engine. 4.
Page 142: 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 143: Gearing
Honda Service Manual, • Wet and slippery or sandy conditions: use a (before and after the change) to get an accurate sprocket changing should be done by your Honda higher gear (less teeth) to keep engine rpm appraisal of the change. “Seat-of-the-pants”...
Page 144: 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 145: Personal Fit Adjustments
Handlebar Position, Width & Shape Apply Pro Honda Hondalock 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 146: Tips
Tips Here’s helpful advice on how to transport and store your Honda, as well as three troubleshooting flow charts. Transporting Your Motorcycle ......142 Storing Your Honda..........143 You & the Environment ........145 Troubleshooting..........146 Tips...
Page 147: 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 148: Storing Your Honda
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 149 Storing Your Honda 9. Install the center engine guard (4) while 11. Remove the battery and charge it fully. Store Removal from Storage aligning its tabs (10) with the grooves (11) of in an area protected from freezing the radiator reserve tank.
Page 150: 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 151: Troubleshooting
The items that require use of the FUEL FLOW • Lack of fuel in tank 1. Disconnect fuel CHECK POSSIBLE CAUSES Honda Service Manual are followed by an (P.41) line at carburetor RESTRICTED • Over-oiled air cleaner 1. Check if air INCORRECT •...
Page 152: 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 153: 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 154: 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 155 Taking Care of Unexpected...
Page 156: Technical Information
Technical Information This section contains dimensions, capacities, and Vehicle Identification ........152 other technical data. Specifications ...........153 Torque Specifications ........154 Emission Control Systems .......157 Oxygenated Fuels..........159 Competition Logbook ........160 Optional Parts List..........162 Spare Parts & Equipment.........163 Wiring Diagram..........164 Technical Information...
Page 157: Vehicle Identification
Vehicle Identification The engine number (2) is stamped on the left Serial Numbers crankcase. The VIN and engine serial numbers 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 158: Specifications
Specifications For USA & CANADA 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 Single 6 inclined from Transmission 5-speed, constant mesh 32.3 in 821 mm...
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 Top bridge pinch bolts (21) Bottom bridge pinch bolts (19) (11) Handlebar upper (14) holder bolts Handlebar lower holder nuts Front axle nut Axle pinch bolts Rear axle nut 13.1 NOTE 2...
Page 161 Torque Specifications Frame Torque Remarks Item lbf•ft N•m kgf•m FRAME Front brake master (46) (32) cylinder holder bolts (43) Brake hose bolts Caliper mounting bolts NOTE 4 Front brake disc nuts NOTE 2 Rear brake disc nuts NOTE 2 Brake pedal pivot bolt (39) Spokes (front)
Page 162: Emission Control Systems
Honda dealer. (1) The removal or rendering inoperative by any useful life, when operated and maintained 1. Hard starting or stalling after starting.
Page 163 Carbon monoxide does not react in the same way, but it is toxic. Honda Motor Co., Ltd. utilizes various systems to reduce carbon monoxide, oxides of nitrogen and hydrocarbons. Exhaust Emission Control System The exhaust emission control system is composed of appropriate carburetor settings.
Page 164: 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 165: 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 166 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 167: 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 pre-load. 308.0 lbf/in (5.50 kgf/mm) Standard (two spanners required) FRAME Remarks No mark Driven sprocket <...
Page 168: Spare Parts & Equipment
(L & R) Pro Honda GN4, HP4 (without molybdenum brake hoses (front & rear) additives) 4-stroke Oil (Engine Oil) Pro Honda HP Trans Oil or Pro Honda GN4 or Spare Parts HP4 (without molybdenum additives) 4-stroke General Tools...
Page 169: Wiring Diagram
Wiring Diagram Technical Information...
Page 170: Consumer Information
Consumer Information This section contains information about Authorized Manuals .........166 contacting Honda and how to get an official Warranty Coverage...........167 Honda service manual. Warranty Service ..........168 Contacting Honda..........169 Your Honda Dealer...........170 The Honda Rider’s Club (USA only) ....171 Consumer Information...
Page 171: 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 172: Warranty Coverage
There are responsibilities, restrictions, and exclusions which apply to these warranties. Please read the Honda Motorcycle Warranties Booklet given to you by your Honda dealer at the time of purchase. Be sure to keep your Honda owner’s card (USA only) with your Warranties Booklet.
Page 173: 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 174: 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 175: 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 176: The Honda Rider's Club (Usa Only)
• 24-hour, toll-free roadside assistance for your new Honda (includes roadside assistance for your transport vehicle [up to one ton] as long as your Honda is aboard or in tow). For street- legal motorcycles and scooters only. • An exclusive HRCA website complete with...
Page 177: Table Of Contents
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 178 Optional Parts List...........162 Spare Parts & Equipment........163 Wiring Diagram..........164 Consumer Information .........165 Authorized Manuals ........166 Warranty Coverage..........167 Warranty Service ..........168 Contacting Honda..........169 Your Honda Dealer..........170 The Honda Rider’s Club (USA only) .....171 Table of Contents...........172 Index ...............174 Quick Reference Table of Contents...
Page 179: Index
..............51 front suspension..........108 competition logbook ........160 oil ..............44 tires ...............92 contacting Honda ..........169 flooded engine, starting ........16 apparel, protective..........2 controls, operating ..........7 fork, appearance care..........104 coolant..............48 front suspension adjustment .......108 authorized manuals ..........166 customer service ..........170...
Page 180 Index gap, spark plug...........61 maintenance, rear suspension maintenance ......84 gasohol .............159 after competition...........33 Rider’s Club Honda .........171 gasoline ..............41 before & after competition ......33 riding, gearing .............138 between motos & practice ......33 apparel ............2 guidelines, suspension adjustment....127 component locations ........35 basic operation..........13...
Page 181 Index suspension, front ..............83 rear ..............84 suspension adjustment, front ............108 rear ..............122 for track conditions........126 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.........154-156 transporting ............142 tripmeter.............14 troubleshooting ..........146 tubes, replacing ..........92 valve, fuel............15 vehicle identification no.
Page 182 Memo...
Page 183 Memo...
Page 184 Memo...
Page 185: Quick Reference
2.27 US gal (8.6R), reserve: 0.37 US gal (1.4R) Engine oil Pro Honda GN4, HP4 (without molybdenum additives) 4-stroke oil or an equivalent. Transmission oil Pro Honda HP Trans oil, Pro Honda GN4 or HP4 (without molybdenum additives) 4-stroke engine oil or an equivalent. Tires 80/100-21 51M...

Honda CRF450X 2007 Owner's Manual

Table of Contents

Basic Operating Instructions

Servicing Your Honda/Before You Service Your Honda

Adjustments for Competition

Tips

Technical Information

Table of Contents

Index

Quick Reference

Quick Links

Chapters

Related Manuals for Honda CRF450X 2007

Summary of Contents for Honda CRF450X 2007

Table of Contents