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Honda Manuals
Motorcycle
CRF450X 2005
Service manual
Table Of Contents - Honda CRF450X 2005 Service Manual
Motorcycle
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Also See for CRF450X 2005
:
Owner's manual & competition handbook
(180 pages)
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Advertisement
Table of Contents
How To Use This Manual
3
Contents
3
Symbols
4
General Information Contents
5
Table Of Contents
5
Service Rules
6
Model Identification
6
Vehicle Identification Number
7
Engine Serial Number
7
Carburetor Identification Number
7
Name Plate (U.s.a.) Or Safety Certification Label (Canada)
7
Emission Control Information Label
8
General Specifications
9
Lubrication System Specifications
11
Fuel System Specifications
11
Cooling System Specifications
11
Cylinder Head/Valves Specifications
12
Cylinder/Piston Specifications
12
Clutch/Starter Clutch/Kickstarter/Gearshift Linkage Specifications
13
Crankcase/ Crankshaft/ Transmission / Balancer Specifications (,Os - ·07)
13
Crankcase/Crankshaft/ Transmission / Balancer Specifications Iafter ·07)
14
Front Wheel/Suspension/Steering Specifications
15
Hydraulic Brake Specifications
16
Battery/Charging System Specifications
16
Ignition System Specifications
16
Electric Starter Specification
17
Lights/Meter/Switches Specifications
17
Standard Torque Values
18
Engine And Frame Torque Values
18
Insulator Band
21
Cylinder Head Side Insulator Band (After'07)
21
Cylinder Stud Bolt
21
Water Hose Clamp
21
Frame
22
Lubrication And Seal Points
25
Cable And Harness Routing (05-07)
29
Secondary Air Supply System (05 And 06 California Type, 07)
35
Cable And Harness Routing (After 07)
36
Optional Parts
41
Parts
42
Emission Control Systems
44
Source Of Emissions
44
Exhaust Emission Control System
44
Crankcase Emission Control System
44
Exhaust Emission Control System (Pulse Secondary Air Injection System): 05 And 06 California Type, After 06
45
Servicing The Honda
45
Prohibited Actions
45
Noise Emission Control System
46
Fuel Permeation Emission Control System (After 07)
46
Rebuilt Engine
46
Technical Feature Contents
47
Auto-Decompression System (After 07)
48
During Starting (When Engine Is Off)
48
After The Engine Starts
48
Hpsd: After 07
49
Hpsd Characteristics
50
Frame/Body Panels/Exhaust System Contents
53
Service Information
54
Torque Values
54
Troubleshooting
54
Seat Removal
55
Seat Installation
55
Side Cover Removal/Installation
55
Radiator Shroud Removal/Installation
56
Left/Right Engine Guard Removal/Installation
57
Center Engine Guard Removal/Installation
57
Front Visor Removal/Installation
57
Front Visor Removal/Installation (After 07)
58
Sub-Frame Removal
58
Sub-Frame Installation
59
Fuel Tank Removal/Installation
60
Exhaust System
61
Muffler Removal/Installation (05-07)
61
Muffler Removal/Installation (After 07)
63
Exhaust Pipe Removal
65
Exhaust System Installation
66
Maintenance Contents
69
Maintenance Service Information
70
Maintenance Schedule (05, 06)
72
Maintenance Schedule (After '06)
73
Competition Maintenance Schedule
74
Additional Items Requiring Frequent Replacement
75
Fuel Line
76
Fuel Strainer Screen
76
Throttle Operation
77
Hot Start
78
Air Cleaner
78
Crankcase Breather
79
Spark Plug Removal
80
Spark Plug Inspection
80
Radiator Coolant
81
Cooling System
82
Secondary Air Supply System (05 And 06 California Type, After 06)
82
Valve Clearance/Decompressor System
83
Valve Clearance Inspection
83
Valve Clearance Adjustment
84
Decompressor Clearance Inspection/Adjustment (05-07)
86
Engine Oil/Oil Filter
87
Decompressor System (After 07)
87
Oil Level Inspection
87
Engine Oil And Filter Change
88
Engine Idle Speed
90
Transmission Oil
90
Transmission Oil Change
91
Drive Chain
92
Drive Chain Slack Inspection
92
Drive Chain Adjustment
92
Drive Chain Cleaning And Lubrication
92
Drive Chain Replacement
93
Drive Chain Slider
95
Drive Chain Roller
96
Drive/Driven Sprocket
96
Brake Fluid
97
Fluid Level Inspection
97
Fluid Filling
97
Brake Pad Wear
98
Brake System
98
Lever Position Inspection
98
Headlight Aim
99
Clutch System
99
Brake Pedal Height
99
Control Cables
100
Exhaust Pipe/Muffler
101
Exhaust System Inspection
101
Spark Arrester Removal
101
Spark Arrester Inspection/Cleaning
101
Spark Arrester Installation
102
Sidestand Inspection
102
Front Suspension Inspection
102
Swingarm/Shock Linkage
103
Rear Suspension Inspection
103
Nuts, Bolts, Fasteners
104
Wheels/Tires
104
Steering Head Bearings
105
Lubrication System Contents
107
Lubrication System Diagram
108
Lubrication System Service Information
109
Oil Strainer Removal/Inspection
110
Oil Strainer Installation
111
Pressure Relief Valve Removal/Inspection
111
Pressure Relief Valve Installation
112
Oil Jet Removal/Inspection
112
Oil Jet Installation
113
Oil Pump Disassembly
113
Oil Pump Inspection
113
Oil Pump Assembly
114
Fuel System Contents
115
Fuel System Component Location
116
Fuel System Service Information
117
Carburetor Adjustment
120
Idle Mixture And Idle Speed
120
Air Cleaner Housing Removal
121
Air Cleaner Housing Installation
123
Carburetor Removal
125
Carburetor Disassembly
127
Jet Needle/Throttle Valve
127
Choke Knob/Throttle Sensor
128
Accelerator Pump/Float/Jets
129
Carburetor Assembly
132
Carburetor Installation
138
Throttle Position Sensor Replacement
140
Pilot Screw Adjustment
141
Best Idle (05, 06: 49 States And Canada Type Only)
141
Idle Drop Procedure (05 And 06 California Type, 07, After 07)
142
System Inspection
143
Pair Control Valve Removal/Installation
144
Pair Check Valve Ispection
144
Air Supply Pipe Removal/Installation
145
Cooling System Contents
147
System Flow Pattern
148
Cooling System Service Information
149
Cooling System Troubleshooting
150
System Testing
151
Coolant (Hydrometer Test)
151
Coolant Gravity Chart
151
Coolant Replacement Preparation
152
Radiator Cap/System Pressure Inspection
152
Replacement/Air Bleeding
153
Radiator Removal/Installation
154
Radiator Reserve Tank Removal/Installation
155
Water Pump
155
Mechanical/Oil Seal Inspection
155
Water Pump Removal
156
Bearing/Mechanial Seal/Oil Seal Replacement
158
Water Pump Installation
159
Engine Removal/Installation Contents
163
Engine Component Location
164
Engine Removal
164
Engine Service Information
165
Drive Sprocket Removal
166
Drive Sprocket Installation
166
Engine Installation
170
Drive Sprocket
171
Cylinder Head/Valves Contents
173
Cylinder Head/Valves Component Location
174
Cylinder Head/Valves Service Information
175
Cylinder Compression Test
179
Cylinder Head Cover Removal
179
Camshaft Removal (05-07)
180
Camshaft Disassembly
182
Camshaft Inspection
183
Camshaft Assembly
186
Camshaft Removal (After 07)
188
Rocker Arm Inspection
191
Rocker Arm Shaft Inspection
191
Decompressor Shaft/Plunger Inspection
192
Cam Sprocket/Decompressor Weight/Spring Inspection
192
Camshaft Holder Bearing Replacement
193
Camshaft Holder Inspection
193
Valve Lifter Inspection
193
Camshaft Holder Bearing Assembly
194
Cylinder Head Removal
196
Cam Chain Tensioner/Cam Chain Guide Removal
197
Cam Chain Tensioner/Cam Chain Guide Inspection
198
Cam Chain Tensioner/Cam Chain Guide Installation
198
Cylinder Head Disassembly
199
Cylinder Head Inspection
200
Valve Spring Inspection
200
Valve/Valve Guide Inspection
200
Valve Guide Replacement
201
Valve Seat Inspection/Refacing
202
Valve Seat Refasing
203
Cylinder Head Assembly
205
Cylinder Head Installation
208
Camshaft Installation (05-07)
209
Camshaft Installation (After 07)
211
Cylinder Head Cover Installation
214
Cylinder/Piston Contents
217
Cylinder/Piston Component Location
218
Cylinder/Piston Service Information
219
Cylinder/Piston Troubleshooting
220
Cylinder Removal
221
Piston Removal
222
Piston Ring Removal
222
Cylinder Inspection
222
Piston/Piston Ring Inspection
223
Connecting Rod Inspection
224
Cam Chain Tensioner Lifter Inspection
224
Piston Installation
225
Piston Ring Installation
225
Cylinder Installation
226
Clutch/Starter Clutch/Kickstarter/Gearshift Linkage Contents
229
Clutch/Starter Clutch/Kickstarter/Gearshift Linkage Component Location
230
Clutch/Starter Clutch/Kickstarter/Gearshift Linkage Service Information
231
Right Crankcase Cover Removal
233
Right Crankcase Cover Installation
234
Clutch Removal
235
Clutch Spring Inspection
237
Clutch Discs Inspection
238
Clutch Plates Inspection
238
Clutch Center Inspection
238
Clutch Lifter/Needle Bearing Inspection
238
Clutch Outer Inspection
239
Clutch Outer Guide Inspection
239
Needle Bearing Inspection
239
Clutch Lifter Lever Inspection
239
Clutch Installation
240
Kickstarter Removal
243
Kickstarter Disassembly
243
Kickstarter Inspection
243
Kickstarter Assembly
245
Kickstarter Installation
246
Starter Clutch Removal
247
Starter Clutch Disassembly/Inspection
248
Starter Clutch Assembly
250
Starter Clutch Installation
251
Gearshaft Linkage Removal
252
Gearshaft Linkage Inspection
253
Gearshift Spindle Inspection
253
Ratchet Pawl Inspection
253
Gearshift Linkage Installation
254
Alternator Contents
257
Alternator Component Location
258
Alternator Service Information
259
Stator
259
Left Crankcase Cover Removal
260
Stator Removal
261
Flywheel Removal
261
Left Crankcase Cover Installation
262
Flywheel Installation
262
Crankcase/Crankshaft/Transmission/Balancer Contents
265
Crankcase/Crankshaft/Transmission/Balancer Component Location
266
Crankcase/Crankshaft/Transmission/Balancer Component Service Information
267
Crankcase/Crankshaft/Transmission/Balancer Troubleshooting
271
Balancer/Gear Balancer Removal
272
Balancer/Gear Balancer Inspection
272
Balancer/Gear Balancer Installation
272
Crankcase Separation
274
Transmission Disassembly
275
Gear Inspection
276
Bushing Inspection
276
Mainshaft/Countershaft Inspection
277
Shift Fork Inspection
277
Shift Fork Shaft Inspection
277
Crankshaft Removal
278
Shift Drum Inspection
278
Transmission Bearing Inspection
278
Crankshaft Inspection
279
Crankcase Bearing Replacement
280
Crankcase Bearing/Oil Seal Location
280
Crankshaft Bearing
280
Transmission/Balancer Bearings
282
Left Crankcase
282
Right Crankcase
284
Crankshaft Installation
285
Transmission Assembly
286
Mainshaft (After 07)
287
Countershaft (05-07)
287
Countershaft (After 07)
288
Transmission Installation
288
Crankcase Assembly
289
Front Wheel/Suspension/Steering Contents
291
Front Wheel/Suspension/Steering Component Location
292
Front Wheel/Suspension/Steering Service Information
294
Front Wheel/Suspension/Steering Troubleshooting
297
Front Wheel Removal
298
Axle Inspection
298
Front Wheel Disassembly
299
Wheel Bearing Inspection
299
Wheel Rim Inspection
299
Front Wheel Assembly
300
Front Wheel Installation
302
Fork Removal
303
Fork Disassembly
305
Outer Tube And Slider Disassembly
307
Fork Damper Disassembly
308
Fork Cap Inspection
309
Fork Center Bolt Inspection
309
Slider/Outer Tube Inspection
309
Fork Spring Inspection
310
Bushing/Back-Up Ring Inspection
310
Fork Damper Inspection
310
Fork Assembly
311
Outer Tube And Slider Assembly
311
Fork Damper Refilling/Assembly
312
Fork Damper Operation Inspection
315
Fork Damper Instllation/Preparation
316
Fork Damper Installation
317
Fork Installation
320
Oil Capacity Adjustment
320
Standard Position
321
Handlebar Removal
322
Handlebar Installation
324
After '07
327
Hpsd (Honda Progressive Steering Damper): After 07 Removal/Installation
328
Hpsd (Honda Progressive Steering Damper): After 07 Inspection
329
Spherical Bearing Replacement
329
Hpsd (Honda Progressive Steering Damper): After 07 Disassembly
330
Hpsd Assembly
332
Steering Stem Removal
337
Bearing Replacement
338
Steering Stem Installation
340
Clutch Lever Removal/Installation
342
Rear Wheel/Suspension Contents
343
Rear Wheel/Suspension Component Location
344
Rear Wheel/Suspension Service Information
345
Rear Wheel/Suspension Troubleshooting
349
Rear Wheel Removal
350
Rear Wheel Disassembly
351
Rear Wheel Assembly
352
Rear Wheel Installation
355
Shock Absorber Removal
356
Shock Absorber Disassembly
357
Bladder Replacement
357
Damper Disassembly
360
Piston Ring Replacement
362
Damper Rod Disassembly
362
Rod Guide Case Inspection
364
Damper Rod Inspection
364
Damper Assembly
365
Shock Absorber Installation
371
Shock Linkage Removal
372
Shock Absorber Inspection
374
Shock Arm Needle Bearing
374
Shock Link Needle Bearing
376
Swingarm Removal
378
Swingarm Disassembly
380
Swingarm Assembly
381
Swingarm Installation
382
Hydraulic Brake Contents
385
Hydraulic Brake Component Location
386
Hydraulic Brake Service Information
387
Hydraulic Brake Troubleshooting
389
Brake Fluid Replacement/Air Bleeding
390
Brake Fluid Filling/Air Bleeding
391
Brake Pad/Disc
394
Brake Pad Replacement
394
Brake Disc Inspection
395
Front Master Cylinder Removal
396
Front Master Cylinder Disassembly
396
Front Master Cylinder Inspection
397
Front Master Cylinder Assembly
398
Front Master Cylinder Installation
398
Rear Master Cylinder Removal
399
Rear Master Cylinder Disassembly
399
Rear Master Cylinder Inspection
400
Rear Master Cylinder Assembly
400
Rear Master Cylinder Installation
401
Front Brake Caliper Removal
402
Front Brake Caliper Disassembly
402
Front Brake Caliper Inspection
403
Front Brake Caliper Assembly
403
Front Brake Caliper Installation
404
Rear Brake Caliper Removal
404
Rear Brake Caliper Disassembly
405
Rear Brake Caliper Inspection
406
Rear Brake Caliper Assembly
407
Rear Brake Caliper Installation
407
Brake Pedal Removal
408
Brake Pedal Installation
408
Battery/Charging System Contents
411
Battery/Charging System Component Location
412
Battery/Charging System Diagram
412
Battery/Charging System Service Information
413
Battery/Charging System Troubleshooting
415
Battery Removal/Installation
416
Voltage Inspection
416
Battery Testing
416
Battery Charging (Usa Only)
416
Charging System Inspection
417
Current Leakage Inspection
417
Charging Voltage Inspection
417
Regulator/Rectifier System Inspection
418
Regulator/Rectifier Removal/Installation
418
Alternator Charging Coil Inspection
418
Ignition System Contents
419
Ignition System Component Location
420
Ignition System System Diagram
420
Ignition System Service Information
421
Ignition System Troubleshooting
422
Ignition System Inspection
423
Ignition Coil Primary Peak Voltage
423
Exciter Coil Resistance
424
Ignition Pulse Generator Peak Voltage
424
Ignition Control Module (Icm) Removal/Installation
425
Ignition Coil Inspection
425
Ignition Timing
426
Ignition Coil Removal/Installation (05-07)
426
Ignition Coil Removal/Installation (After 07)
426
Throttle Position Sensor Inspection
427
Electric Starter Contents
429
Electric Starter Component Location
430
Electric Starter System Diagram
430
Electric Starter Service Information
431
Electric Starter Troubleshooting
432
Starter Motor Removal
434
Starter Motor Disassembly/Inspection
434
Starter Motor Assembly
438
Starter Relay Switch Inspection
441
Starter Motor Installation
441
Ground Line
441
Starter Relay Switch Removal/Installation
442
Power Input Line
442
Operation Check
442
Lights/Meter/Switches Contents
443
Lights/Meter/Switches Component Location
444
Lights/Meter/Switches Service Information
445
Headlight Bulb Replacement
446
Headlight Removal/Installation (05-07)
447
Headlight Removal/Installation (After 07)
448
Tail Light Inspection
448
Tail Light Removal/Installationn
448
Engine Stop Button Inspection
449
Clutch Switch Inspection
450
Clutch Switch Removal/Installation
450
Starter Switch Inspection
451
Tripmeter Removal/Installation
452
Wiring Diagram
454
Troubleshooting Contents
455
Engine Does Not Start Or Is Hard To Start
456
Engine Lacks Power
457
Poor Performance At Low And Idle Speed
459
Poor Performance At High Speed
460
Poor Handling
461
Index
463
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Page
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...
464
465
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Table of Contents
Troubleshooting
Service information
54
Cooling system troubleshooting
150
Cylinder/piston troubleshooting
220
Crankcase/crankshaft/transmission/balancer troubleshooting
271
Front wheel/suspension/steering troubleshooting
297
Rear wheel/suspension troubleshooting
349
Hydraulic brake troubleshooting
389
Battery/charging system troubleshooting
415
Ignition system troubleshooting
422
Electric starter troubleshooting
432
Troubleshooting contents
455
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Crf450x 2007
Crf450x 2006
Crf450x 2008
Crf450x 2010
Crf450x 2009
Crf450x 2011
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Crf450r 2007
Crf450r 2009
Crf450r 2008
Crf450r 2011
Crf450r 2010
Crf450x 2012
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