Honda CRF450X 2006 Manuals

Manuals and User Guides for Honda CRF450X 2006. We have 1 Honda CRF450X 2006 manual available for free PDF download: Service Manual

Honda CRF450X 2006 Service Manual

Honda CRF450X 2006 Service Manual (465 pages)

Motorcycle

Brand: Honda | Category: Motorcycle | Size: 57.18 MB

Table of Contents

How to Use this Manual
3
Contents
3
Symbols
4
Table of Contents
5
General Information Contents
5
Service Rules
6
Model Identification
6
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
Battery/Charging System Specifications
16
Hydraulic Brake Specifications
16
Ignition System Specifications
16
Electric Starter Specification
17
Lights/Meter/Switches Specifications
17
Engine and Frame Torque Values
18
Standard 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
- Exhaust Emission Control System (Pulse Secondary Air Injection System): 05 and 06 California Type, after 06
  45
- Prohibited Actions
  45
- Servicing the Honda
  45
- Fuel Permeation Emission Control System (after 07)
  46
- Noise Emission Control System
  46
- Rebuilt Engine
  46
- Technical Feature Contents
  47
- After the Engine Starts
  48
- Auto-Decompression System (after 07)
  48
- During Starting (When Engine Is Off)
  48
- HPSD: after 07
  49
- HPSD Characteristics
  50
- Frame/Body Panels/Exhaust System Contents
  53
- Service Information
  54
- Torque Values
  54
- Troubleshooting
  54
- Exhaust System
  61
- Competition Maintenance Schedule
  74
- Additional Items Requiring Frequent Replacement
  75
- Fuel Line
  76
- Fuel Strainer Screen
  76
- Throttle Operation
  77
- Air Cleaner
  78
- Hot Start
  78
- Crankcase Breather
  79
  - Spark Plug Inspection
    80
  - Spark Plug Removal
    80
- Radiator Coolant
  81
- Cooling System
  82
- Engine Idle Speed
  90
- Oil Level Inspection
  90
- Transmission Oil
  90
- Transmission Oil Change
  91
- Drive Chain
  92
- Drive Chain Slider
  95
- Drive Chain Roller
  96
- Drive/Driven Sprocket
  96
- Brake Fluid
  97
  - Fluid Filling
    97
  - Fluid Level Inspection
    97
- Brake Pad Wear
  98
- Brake System
  98
  - Lever Position Inspection
    98
  - Brake Pedal Height
    99
- Clutch System
  99
- Headlight Aim
  99
- Control Cables
  100
- Exhaust Pipe/Muffler
  101
  - Exhaust System Inspection
    101
  - Spark Arrester Inspection/Cleaning
    101
  - Spark Arrester Removal
    101
  - Front Suspension Inspection
    102
  - Sidestand Inspection
    102
  - Spark Arrester Installation
    102
  - Rear Suspension Inspection
    103
- Swingarm/Shock Linkage
  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
  - Oil Jet Removal/Inspection
    112
  - Pressure Relief Valve Installation
    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
  - Best Idle (05, 06: 49 States and Canada Type Only)
    141
  - Pilot Screw Adjustment
    141
  - Idle Drop Procedure (05 and 06 California Type, 07, after 07)
    142
  - System Inspection
    143
  - Pair Check Valve Ispection
    144
  - Pair Control Valve Removal/Installation
    144
  - Air Supply Pipe Removal/Installation
    145
  - Cooling System Contents
    147
  - System Flow Pattern
    148
  - Cooling System Service Information
    149
  - Cooling System Troubleshooting
    150
  - Coolant (Hydrometer Test)
    151
  - Coolant Gravity Chart
    151
  - System Testing
    151
  - Coolant Replacement Preparation
    152
  - Radiator Cap/System Pressure Inspection
    152
  - Replacement/Air Bleeding
    153
  - Radiator Removal/Installation
    154
  - Mechanical/Oil Seal Inspection
    155
  - Radiator Reserve Tank Removal/Installation
    155
  - Water Pump
    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 Installation
    166
  - Drive Sprocket Removal
    166
  - Engine Removal
    167
- 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
  - Cam Sprocket/Decompressor Weight/Spring Inspection
    192
  - Decompressor Shaft/Plunger 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
  - Cylinder Inspection
    222
- Piston Removal
  222
  - Piston Ring Removal
    222
  - Piston/Piston Ring Inspection
    223
  - Cam Chain Tensioner Lifter Inspection
    224
  - Connecting Rod 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 Center Inspection
    238
  - Clutch Discs Inspection
    238
  - Clutch Lifter/Needle Bearing Inspection
    238
  - Clutch Plates Inspection
    238
  - Clutch Lifter Lever Inspection
    239
  - Clutch Outer Guide Inspection
    239
  - Clutch Outer Inspection
    239
  - Needle Bearing Inspection
    239
  - Clutch Installation
    240
  - Kickstarter Disassembly
    243
  - Kickstarter Inspection
    243
  - Kickstarter Removal
    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
  - Flywheel Removal
    261
  - Stator Removal
    261
  - Flywheel Installation
    262
- Left Crankcase Cover Installation
  262
- Crankcase Separation
  274
  - Transmission Disassembly
    275
  - Bushing Inspection
    276
  - Gear 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
  - Left Crankcase
    282
  - Transmission/Balancer Bearings
    282
  - Right Crankcase
    284
- Crankshaft Installation
  285
- Transmission Assembly
  286
  - Countershaft (05-07)
    287
  - Mainshaft (after 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
  - Axle Inspection
    298
  - Front Wheel Removal
    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
  - Bushing/Back-Up Ring Inspection
    310
  - Fork Damper Inspection
    310
  - Fork Spring 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
  - Bladder Replacement
    357
  - Shock Absorber Disassembly
    357
  - Damper Disassembly
    360
  - Damper Rod Disassembly
    362
  - Piston Ring Replacement
    362
  - Damper Rod Inspection
    364
  - Rod Guide Case 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 Replacement
    394
- Brake Pad/Disc
  394
  - Brake Disc Inspection
    395
  - Front Master Cylinder Disassembly
    396
  - Front Master Cylinder Removal
    396
  - Front Master Cylinder Inspection
    397
  - Front Master Cylinder Assembly
    398
  - Front Master Cylinder Installation
    398
  - Rear Master Cylinder Disassembly
    399
  - Rear Master Cylinder Removal
    399
  - Rear Master Cylinder Assembly
    400
  - Rear Master Cylinder Inspection
    400
  - Rear Master Cylinder Installation
    401
  - Front Brake Caliper Disassembly
    402
  - Front Brake Caliper Removal
    402
  - Front Brake Caliper Assembly
    403
  - Front Brake Caliper Inspection
    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 Installation
    408
  - Brake Pedal Removal
    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 Charging (USA Only)
    416
  - Battery Removal/Installation
    416
  - Battery Testing
    416
  - Voltage Inspection
    416
- Charging System Inspection
  417
  - Charging Voltage Inspection
    417
  - Current Leakage Inspection
    417
  - Alternator Charging Coil Inspection
    418
  - Regulator/Rectifier Removal/Installation
    418
  - Regulator/Rectifier System 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 Coil Primary Peak Voltage
    423
  - Ignition System Inspection
    423
  - Exciter Coil Resistance
    424
  - Ignition Pulse Generator Peak Voltage
    424
  - Ignition Coil Inspection
    425
  - Ignition Control Module (ICM) Removal/Installation
    425
- Ignition Timing
  426
- Ignition Coil Removal/Installation (after 07)
  426
- Ignition Coil Removal/Installation (05-07)
  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
- Ground Line
  441
- Starter Relay Switch Inspection
  441
- Starter Motor Installation
  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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