Honda CRF450RX 2020 Owner's Manual & Competition Handbook
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Honda CRF450RX 2020 Owner's Manual & Competition Handbook

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Contents
MOTORCYCLE SAFETY............................. 1
Important Safety Information ........................... 2
Important Safety Precautions ........................ 2
Accessories & Modifications ........................... 3
Safety Labels .................................................... 4
INSTRUMENTS & CONTROLS.................. 5
Operation Component Locations ...................... 6
MIL Blink Pattern ......................................... 7
Current DTC/Freeze DTC............................. 7
Circuit Inspection .......................................... 8
DTC Index..................................................... 9
& Torque Control Indicator ............................ 10
Engine Mode Indicator................................ 10
Torque Control Indicator............................. 10
BEFORE RIDING......................................... 11
Are You Ready to Ride? ................................ 12
Pre-ride Inspection ...................................... 13
Safe Riding Precautions .............................. 16
Side Stand (CRF450RX)............................. 16
Starting & Stopping the Engine ...................... 17
Fast Idle Knob ............................................. 17
Preparation .................................................. 17
Starting Procedure ....................................... 17
How to Stop the Engine .............................. 18
Parking (CRF450RX) ..................................... 19
Break-in Guidelines ........................................ 20
31MKE630
SERVICING YOUR HONDA ......................21
Before You Service Your Honda
The Importance of Maintenance .....................22
Maintenance Safety .........................................23
Important Safety Precautions.......................23
Maintenance Schedule ....................................24
After Competition Maintenance ..................32
Service Preparations
Seat ..................................................................34
Fuel Tank (CRF450RX) .................................35
Fuel Tank (CRF450R/RWE) ..........................37
Subframe .........................................................39
Service Procedures
Fluids & Filters
Fuel System (CRF450RX) ..............................42
Fuel System (CRF450R/RWE) .......................52
Engine Oil .......................................................62
Coolant ............................................................65
Air Cleaner ......................................................67
Crankcase Breather .........................................69
Engine
Throttle ............................................................70
Engine Idle Speed ...........................................72
Clutch System .................................................73
Spark Plug .......................................................78
Valve Clearance ..............................................79
Piston/Piston Rings/Piston Pin ........................88
2020 CRF450R/RX/RWE
Chassis
Suspension ...................................................... 97
Brakes ........................................................... 114
Wheels .......................................................... 118
Tires & Tubes ............................................... 119
Side Stand (CRF450RX) .............................. 121
Drive Chain .................................................. 122
Exhaust Pipe/Muffler .................................... 126
Electrical
Battery .......................................................... 134
Appearance Care .......................................... 136
MOM 17046 (1901)

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  • Page 1: Table Of Contents

    Fuel System (CRF450R/RWE) .......52 Safe Riding Precautions ......16 Engine Oil ............62 Side Stand (CRF450RX)......16 Coolant ............65 Honda Selectable Torque Control ....16 Air Cleaner ............67 Starting & Stopping the Engine ...... 17 Crankcase Breather .........69 Fast Idle Knob ..........17 Engine Preparation ..........
  • Page 2 QUICK REFERENCE Current Mode ..........140 Storing Your Honda ........163 Mode Selection.......... 140 Preparation for Storage ......163 Honda Selectable Torque Control ....141 Removal from Storage .......163 Current Mode ..........141 You & the Environment ........164 Mode Selection.......... 141 Troubleshooting ..........165 HRC-Launch Control System ......
  • Page 3 2020 Honda CRF450RX/CRF450R/CRF450RWE OWNER’S MANUAL & COMPETITION HANDBOOK...
  • Page 4 CRF, other property, or the environment. parts or system. When you own a Honda, you’re part of a worldwide family of satisfied customers – people Unless you are mechanically qualified and have Abbrev.
  • Page 5 A Few Words About Safety 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, this manual contains a section devoted to Motorcycle Safety, as well as a number of Safety Messages throughout the manual.

  • Page 6: Motorcycle Safety

    Motorcycle Safety Motorcycle Safety This section presents some of the most important Important Safety Information ......2 information and recommendations to help you ride Important Safety Precautions......2 your CRF safely. Please take a few moments to Accessories & Modifications ......3 read these pages. This section also includes Safety Labels............4 information about the location of safety labels on your CRF.

  • Page 7: Important Safety Information

    Keep your Honda in Safe Condition. As an experienced rider, you know there is much Maintaining your CRF properly is critical to your you can do to protect yourself when you ride.

  • Page 8: Accessories & Modifications

    Accessories & Modifications Accessories & Modifications Accessories & Modifications Installing non-Honda accessories, removing original equipment, or modifying your CRF in any way that would change its design or operation, could seriously impair your CRF’s handling, stability, and braking, making it unsafe to ride.

  • Page 9: Safety Labels

    Safety Labels Safety Labels Read these labels carefully and don’t remove them. If a label comes off or becomes hard to read, contact your dealer for replacement. (For Canada) Motorcycle Safety...

  • Page 10: Instruments & Controls

    Instruments & Controls Instruments & Controls Read this section carefully before you ride. It Operation Component Locations .......6 presents the location of the basic controls on your MIL (Malfunction Indicator Lamp) ....7 CRF. MIL Blink Pattern..........7 Current DTC/Freeze DTC ......7 Circuit Inspection...........8 DTC Index .............9 Engine Mode &...

  • Page 11: Operation Component Locations

    Operation Component Locations Operation Component Locations engine mode select button Torque Control button front brake lever Torque Control indicator (green) clutch lever engine stop button start button MIL (amber) throttle grip Engine mode indicator (blue) Launch control system indicator (purple) fast idle knob (engine idle speed) rear brake pedal shift lever...

  • Page 12: Mil (Malfunction Indicator Lamp)

    The MIL blinks when there is any abnormality in the PGM-FI system. If the MIL comes on at any other time, reduce speed and refer to an official Honda Service Manual available for purchase from your dealer (page 186). If the MIL does not come on when the engine is started, have your dealer check it for problems.

  • Page 13: Circuit Inspection

    MIL (Malfunction Indicator Lamp) Circuit Inspection Always clean around the ECM and keep debris away from the connectors before disconnecting them. A faulty PGM-FI system is often related to poorly connected or corroded connections. Check the following connections. (1) MAP sensor connector (2) ECT sensor connector (3) TP sensor connector (4) IAT sensor connector...

  • Page 14: Dtc Index

    The series of 12 MIL blinks cannot be checked because the engine cannot be started. If the engine does not start, check all connector connections and/or refer to an official Honda Service Manual (page 186) for troubleshooting of the PGM-FI symptom.

  • Page 15: Engine Mode & Launch Control System Indicator & Torque Control Indicator

    Engine Mode & Launch Control System Indicator & Torque Control Indicator Engine Mode & Launch Control System Indicator & Torque Control Indicator Engine Mode Indicator Launch Control System Indicator Torque Control Indicator The Torque Control indicator (green) (1) is The engine mode indicator (blue) (1) is located The launch control system indicator (purple) (1) is located to the right side of the Torque Control under the engine mode select button (2).

  • Page 16: Before Riding

    Before Riding Before Riding Before each ride, you need to make sure you and Are You Ready to Ride? ........12 your CRF are both ready to ride. To help get you Is Your Motorcycle Ready to Ride? ....13 prepared, this section discusses how to evaluate Pre-ride Inspection........13 your riding readiness, and what items you should check on your CRF.

  • Page 17: Are You Ready To Ride

    Are You Ready to Ride? Are You Ready to Ride? Before riding your CRF for the first time, we WARNING strongly recommend that you read this owner’s manual, make sure you understand the safety Not wearing a helmet increases the messages, and know how to operate the controls.

  • Page 18: Is Your Motorcycle Ready To Ride

    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 Check the following before each ride: following items (page numbers are at the right): •...
  • Page 19 BLANK PAGE Before Riding...

  • Page 20: Basic Operating Instructions

    This section gives basic information on how to Safe Riding Precautions.......16 start and stop your engine as well as break-in Side Stand (CRF450RX) ......16 guidelines. Honda Selectable Torque Control....16 Starting & Stopping the Engine .......17 Fast Idle Knob..........17 Preparation ...........17 Starting Procedure........17 How to Stop the Engine .......18...

  • Page 21: Safe Riding Precautions

    Side Stand (CRF450RX) Honda Selectable Torque Control The side stand (1) is used to support your CRF When the Honda selectable torque control (Torque Before riding your CRF for the first time, please while parked (page 19). To operate, push the side...

  • Page 22: Starting & Stopping The Engine

    Starting & Stopping the Engine Starting & Stopping the Engine Always follow the proper starting procedure 3. With the throttle closed. Starting Procedure described below. Pull the clutch lever all the way in, and depress the start button (2). Always follow the proper starting procedure Your CRF can be started with the transmission in described as follows.

  • Page 23: How To Stop The Engine

    Starting & Stopping the Engine Warm Engine Starting When starting the engine, the MIL (amber) will How to Stop the Engine 1. Shift the transmission into neutral. stay on for 2 seconds, then go off. And then the 2. Pull the clutch lever and depress the start engine mode indicator (blue) indicates the current button.

  • Page 24: Parking (Crf450Rx)

    Parking (CRF450RX) Parking (CRF450RX) Lower the side stand to support your CRF. Always choose a level surface to park. Basic Operating Instructions...

  • Page 25: Break-In Guidelines

    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: Servicing Your Honda

    Fuel Tank (CRF450RX) ........35 unnecessary. If you want to check the ignition Fuel Tank (CRF450R/RWE) ......37 Appearance Care ........... 136 timing, refer to an official Honda Service Manual Subframe ............39 (page 186). Service Procedures An optional tool kit may be available. Check with Fluids &...

  • Page 27: The Importance Of Maintenance

    Improperly maintaining this motorcycle or failing to correct a problem before you ride can cause a crash in which you can be seriously hurt or killed. Always follow the inspection and maintenance recommendations and schedules in this owner’s manual. Servicing Your Honda...

  • Page 28: 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 29: Maintenance Schedule

    Procedures for items in this schedule are provided 3. Replace after the first break-in ride. in an official Honda Service Manual available for 4. Inspect after the first break-in ride. purchase from your dealer (page 186). 5. Replace the engine oil, if the clutch discs and plates are replaced.

  • Page 30: Maintenance Schedule (Crf450Rx)

    STEERING HEAD BEARINGS SIDE STAND WE RECOMMEND THESE ITEMS BE SERVICED BY REFERRING TO THE OFFICIAL HONDA SERVICE MANUAL. This maintenance schedule is based upon average riding condition. Machine subjected to severe use require more frequent servicing. NOTE: 1. Clean after every race for dusty riding condition.

  • Page 31: Maintenance Schedule (Crf450R/Rwe)

    118 – 120 STEERING HEAD BEARINGS WE RECOMMEND THESE ITEMS BE SERVICED BY REFERRING TO THE OFFICIAL HONDA SERVICE MANUAL. This maintenance schedule is based upon average riding condition. Machine subjected to severe use require more frequent servicing. NOTE: 1. Clean after every moto for dusty riding condition.

  • Page 32: General Competition Maintenance

    Use Honda Genuine Parts or their equivalents when servicing your CRF. Clean parts in non-flammable (high flash point) cleaning solvent (such as kerosene) when disassembling.
  • Page 33 Follow the servicing instructions in the Maintenance section. Use Pro Honda Foam Air Filter Oil or an equivalent. Be sure to grease the air cleaner flange where it contacts the air cleaner housing.
  • Page 34 Refer to an official Honda Service Manual to the proper torque specification. (page 186). Use only Pro Honda HP Fork Oil, A15-00 or an equivalent which contains special additives to assure maximum performance of your CRF’s front suspension.
  • Page 35 See offers added assurance and security. Remove the nuts, an official Honda Service Manual or consult your dealer for clean the threads of both the nuts and bolts, apply Pro replacing the mechanical seal or oil seal.

  • Page 36: Before & After Competition Maintenance

    • Clean the sides of the drive chain with a stiff, nylon parts-cleaning brush. Lubricate and adjust the chain as necessary. Do not perform maintenance while engine is running. Injury to your fingers or hands may result. Servicing Your Honda...

  • Page 37: After Competition Maintenance

    If you decide to wash your CRF or use cleaners, refer to Appearance Care (page 136). Remove the drive chain, clean and lubricate it (pages 123 – 124). Be sure the chain is wiped clean and is dry before lubricating the chain. Servicing Your Honda...

  • Page 38: Maintenance Component Locations

    (both left and right) caliper caliper damping adjuster Servicing Your Honda...

  • Page 39: Seat

    (6) to the specified torque: 19 lbf·ft (26 N·m, 2.7 kgf·m) (1) seat mounting bolts (3) seat (2) collars (1) seat front prong (4) seat support base slots (2) slot (5) collars (3) seat center prongs (6) seat mounting bolts Servicing Your Honda...

  • Page 40: Fuel Tank (Crf450Rx)

    (12) fuel tank band (11) collar 8. Lift the fuel tank (13) out of the frame and hang it to the left of the frame. Check the fuel tank stopper cable (14) for deterioration, kinks or other damage. (cont’d) Servicing Your Honda...
  • Page 41 (9) tab (13) shroud C bolt (10) slot (14) shroud B bolt (11) air cleaner housing cover (15) shroud A bolt 8. Install the seat (page 34). (5) breather tube (7) hose clamp (6) steering stem nut Servicing Your Honda...

  • Page 42: Fuel Tank (Crf450R/Rwe)

    7. Lift the fuel tank (11) out of the frame and (12) fuel tank stopper cable hang it to the left of the frame. (13) fuel feed hose Check the fuel tank stopper cable (12) for deterioration, kinks or other damage. (cont’d) Servicing Your Honda...
  • Page 43 (11) shroud C bolt (8) tab (12) shroud B bolt (9) slot (13) shroud A bolt (10) air cleaner housing cover 7. Install the seat (page 34). (4) breather tube (6) hose clamp (5) steering stem nut Servicing Your Honda...

  • Page 44: Subframe

    6. Disconnect the starter/ignition relay connector (3), lift the seat support base (4), and hang it to the left of the subframe (5). (10) (9) negative (–) terminal (10) battery (3) starter/ignition relay connector (4) seat support base (5) subframe (cont’d) Servicing Your Honda...
  • Page 45 (9) start magnetic switch (18) subframe upper bolts bolt stay bolt 36 lbf·ft (49 N·m, 5.0 kgf·m) (19) air cleaner connecting tube (10) wire band Left side: Right side: (3) subframe upper bolts (4) subframe lower bolts Servicing Your Honda...
  • Page 46 10. Install the left and right mufflers (page 127). 11. Install the right and left shrouds (page 36, (14) air cleaner connecting tube clamp screw (15) breather tube page 38). (16) IAT sensor connector 12. Install the seat (page 34). Servicing Your Honda...

  • Page 47: Fuel System (Crf450Rx)

    Never use stale or contaminated gasoline. Avoid getting dirt, dust or water in the fuel tank. (1) fuel quick connect fitting cover (2) fuel line 4. Install the fuel quick connect fitting cover. 5. Install the fuel tank (page 36). Servicing Your Honda...
  • Page 48 (1) fuel quick connect fitting cover (2) fuel pump (3) fuel quick connect fitting 5. Remove the bolt (4), clamp and setting rubber (5). (4) bolt (5) clamp and setting rubber (cont’d) Servicing Your Honda...
  • Page 49 Fuel pump side: • Do not use gloves or a shop towel while installing the quick connect fitting. (8) fuel joint (11) disconnected connector (12) plastic bags (7) slide retainer (8) fuel joint (9) connector housing (3) slide retainer Servicing Your Honda...
  • Page 50 (3) slide retainer (4) connector housing 7. Increase the fuel pressure (page 51). 4. Make sure the connection is secure and that the slide retainer is firmly locked into place; check visually and by pulling the connector housing. Servicing Your Honda...
  • Page 51 4. Pull the harness band clip (4) while pressing both side of the anchor and disconnect it. (2) stopper cable (5) fuel pump mounting bolts (6) stopper cable guide (7) washers (8) collars (9) conical spring washers (10) fuel pump plate Servicing Your Honda...
  • Page 52 Be careful not to damage the wires when (16) disconnecting the fuel pump wire terminals. (20) (15) hooks (17) grooves (16) tabs (13) (21) (14) (20) fuel pump stopper (21) damper rubber (13) fuel pump wire terminals (14) fuel pump base (cont’d) Servicing Your Honda...
  • Page 53 (6) while (22) routing the fuel pump red (7) and black (8) wires through the holder grooves (9) as shown. (10) damper rubber (new) (11) fuel pump stopper (23) (22) fuel pump assembly (23) fuel pump filter Servicing Your Honda...
  • Page 54 (20). Push the wire terminals until they stop as shown. Be careful not to damage the wires. (23) (22) fuel pump unit (23) O-ring (new) (24) fuel tank (cont’d) Servicing Your Honda...
  • Page 55 (27) conical spring washers (28) collars (29) washers (30) stopper cable (30) (31) stopper cable guide (32) fuel pump mounting bolts (24) fuel tank (33) harness band clip (30) stopper cable (34) hook (31) stopper cable guide Servicing Your Honda...
  • Page 56 The engine will start up with increasing the fuel pressure. If the engine does not start, check all connector connections and/or refer to an official Honda Service Manual (page 186) for troubleshooting of the PGM-FI symptom. Servicing Your Honda...

  • Page 57: Fuel System (Crf450R/Rwe)

    Never use stale or contaminated gasoline. Avoid getting dirt, dust or water in the fuel tank. (1) fuel quick connect fitting cover (2) fuel line 4. Install the fuel quick connect fitting cover. 5. Install the fuel tank (page 36). Servicing Your Honda...
  • Page 58 (1) fuel quick connect fitting cover (2) fuel pump (3) fuel quick connect fitting 5. Remove the bolt (4), clamp and setting rubber (5). (4) bolt (5) clamp and setting rubber (cont’d) Servicing Your Honda...
  • Page 59 • Do not use gloves or a shop towel while Injector side: Fuel pump side: installing the quick connect fitting. (8) fuel joint (11) disconnected connector (12) plastic bags (7) slide retainer (8) fuel joint (9) connector housing (3) slide retainer Servicing Your Honda...
  • Page 60 (3) slide retainer (4) connector housing 7. Increase the fuel pressure (page 61). 4. Make sure the connection is secure and that the slide retainer is firmly locked into place; check visually and by pulling the connector housing. Servicing Your Honda...
  • Page 61 (2) stopper cable (4) harness band clip (2) stopper cable (5) fuel pump mounting nuts (6) fuel pump mounting cap nut (7) stopper cable guide (8) washer (9) collars (10) conical spring washers (11) fuel pump plate Servicing Your Honda...
  • Page 62 Be careful not to damage the wires when (18) disconnecting the fuel pump wire terminals. (22) (17) hooks (19) grooves (18) tabs (15) (23) (16) (22) fuel pump stopper (23) damper rubber (15) fuel pump wire terminals (16) fuel pump base (cont’d) Servicing Your Honda...
  • Page 63 (6) while routing the fuel pump yellow (7) and green (8) wires through the holder grooves (9) as shown. (10) damper rubber (new) (27) (11) fuel pump stopper (24) fuel pump assembly (27) fuel pump filter Servicing Your Honda...
  • Page 64 (13) fuel pump base (23) grooves they stop as shown. (21) dust seal (new) (24) dust seal lug (22) tabs (25) index mark Be careful not to damage the wires. (29) fuel pump unit (30) fuel tank (cont’d) Servicing Your Honda...
  • Page 65 (43) hook (38) stopper cable guide (38) stopper cable guide (39) fuel pump mounting nuts (40) fuel pump mounting cap nut (41) identification mark 16. Connect the fuel line (page 54). 17. Increase the fuel pressure (page 61). Servicing Your Honda...
  • Page 66 The engine will start up with increasing the fuel pressure. If the engine does not start, check all connector connections and/or refer to an official Honda Service Manual (page 186) for troubleshooting of the PGM-FI symptom. Servicing Your Honda...

  • Page 67: Engine Oil

    JASO T 903 standard suggested oil* Pro Honda GN4 4-stroke Oil (USA & Canada), or Honda 4-stroke oil, or an equivalent motorcycle oil Suggested 4-stroke engine oils are equal performance to SJ oils that are not labeled as energy conserving or resource conserving on the circular API service label.
  • Page 68 3. Support the CRF in an upright position on a level surface. 4. Remove the engine oil fill cap/dipstick (4) from the left crankcase cover. (1) engine oil fill cap/dipstick (2) upper level mark (3) lower level mark (cont’d) Servicing Your Honda...
  • Page 69 You should see the “OUT-SIDE” mark recommended interval, see page 25. (13) on the filter body, near the rubber seal. Use a new Honda Genuine oil filter or a filter of equal quality specified for your model. Servicing Your Honda...

  • Page 70: Coolant

    Checking & Adding Coolant Coolant Recommendation Refer to Important Safety Precautions on page 23. Use Pro Honda HP Coolant or an equivalent high 1. Position your CRF on an optional workstand or (1) radiator cap (3) overflow hose...
  • Page 71 3. Check the radiator mount for looseness. A small amount of coolant weeping from the 4. Make sure the overflow hose (2) is connected bleed hole is normal. See an official Honda and not clogged. (6) fins Service Manual or consult your dealer for 5.

  • Page 72: Air Cleaner

    Your CRF’s air cleaner has very specific performance requirements. Use a new Honda Genuine air cleaner specified for your model or an (1) air cleaner retaining bolt air cleaner of equal quality.
  • Page 73 The air 8. Apply 0.05 – 0.19 oz (1.5 – 5.5 g) of Pro Honda cleaner element is made in two pieces: inner Foam Air Filter Sealer or equivalent to the air and outer, which cannot be separated.

  • Page 74: Crankcase Breather

    1. Remove the crankcase breather tube plug (1) from the crankcase breather tube (2) by sliding the clip (3) and drain deposits into a suitable container. 2. Reinstall the crankcase breather tube plug. (1) crankcase breather tube plug (2) crankcase breather tube (3) clip Servicing Your Honda...

  • Page 75: Throttle

    If you can’t get the freeplay within the specified Tighten the lock nut securely. range, contact your dealer. Make the adjustment with the lower adjuster. Servicing Your Honda...
  • Page 76 6. Install the dust cover in the reverse order. If the throttle operation is not smooth, replace the (3) throttle throttle cable. Be sure the throttle returns freely from fully open to fully closed automatically, in all steering positions. Servicing Your Honda...

  • Page 77: Engine Idle Speed

    2. Connect a tachometer to the engine. 3. Shift the transmission into neutral. Start the engine. 4. Adjust idle speed with the fast idle knob (1). Idle speed: 2,000 ± 100 rpm (–) (1) fast idle knob (+) increase (–) decrease Servicing Your Honda...

  • Page 78: 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 76). Servicing Your Honda...
  • Page 79 5. Connect the clutch cable end to the lever. with commercially available cable lubricant. 6. Install the clutch cable and turn the adjuster. 2. Check the clutch cable for deterioration, kinks, or damage. Servicing Your Honda...
  • Page 80 4. Remove the clutch pressure plate (4). (6) thrust bearing If the operation is not smooth, refer to an official Honda Service Manual (page 186) for bearing disassembly or see your dealer. (3) clutch spring bolts and springs (4) clutch pressure plate...
  • Page 81 Replace the clutch discs and plates as a set. disc C disc B disc A (1) spring seat (5) clutch discs B (2) judder spring (6) lugs (3) clutch disc A (7) groove (4) clutch plates (8) clutch disc C (2) clutch plates Servicing Your Honda...
  • Page 82 (14) clutch cover 9 lbf·ft (12 N·m, 1.2 kgf·m) 9. Fill the crankcase with the recommended oil (page 63). (12) (11) (11) clutch pressure plate (12) clutch springs and bolts Servicing Your Honda...

  • Page 83: Spark Plug

    If a plug is too tight, the threads may be new one. damaged. (3) sealing gasket 10. Connect the spark plug cap. Take care to avoid (4) spark plug gap pinching any cables or wires. 11. Install the fuel tank and seat (pages 34, 36, 38). Servicing Your Honda...

  • Page 84: Valve Clearance

    The valve clearance will change as engine temperature rises. (3) cylinder head cover socket bolts (4) cylinder head cover rubber seals (5) cylinder head cover (6) spark plug hole packing (1) breather tube (2) spark plug cap Servicing Your Honda...
  • Page 85 (2) primary drive gear bolt (3) “T” mark (4) index mark (5) decompressor weight 5. Check the timing marks (6) on the cam sprocket aligns with the camshaft holder mating surface (7) of the cylinder head. (8) rocker arms Servicing Your Honda...
  • Page 86 Camshaft Removal (this page) and select the correct shim for each (1) feeler gauge (3) camshaft cam lobes valve. (2) intake rocker arms Valve Clearance: IN: 0.005 ± 0.001 in (0.13 ± 0.03 mm) (cont’d) Servicing Your Honda...
  • Page 87 (8) set rings (9) left camshaft bearing (10) camshaft (11) cam chain Do not let the set rings fall into the crankcase. If the set rings are remained on the camshaft holder, remove the set rings carefully. Servicing Your Honda...
  • Page 88 (1) shim Do not clean the intake rocker arms using a If a calculated dimension is out of specifications, commercially available compound cleaner. have your motorcycle inspected by your dealer. 1.80 mm 1.825 mm 1.85 mm 1.875 mm Servicing Your Honda...
  • Page 89 (4) plunger bearing to the right fully. (5) decompressor weight If the operation is not smooth, refer to an official Honda Service Manual (page 186) for decompressor disassembly or see your dealer. (1) rocker arms (3) valve spring retainers (2) shims...
  • Page 90 (11) (17) camshaft holder (19) camshaft holder bolts (long) Do not let the set rings fall into the crankcase. (20) camshaft holder bolts (short) (18) “ ” mark (11) timing mark (12) camshaft holder mating surface (cont’d) Servicing Your Honda...
  • Page 91 Make sure the piston is at TDC on the the cam chain tensioner lifter cover bolt (27). compression stroke (page 80). (1) O-ring (new) (2) crankshaft hole cap (27) (26) (26) sealing washer (new) (27) cam chain tensioner lifter cover bolt Servicing Your Honda...
  • Page 92 7 lbf·ft (10 N·m, 1.0 kgf·m) (1) spark plug hole packing (2) cylinder head cover (3) cylinder head cover packing (4) cylinder head cover groove (2) cylinder head cover (7) cylinder head cover socket bolts Servicing Your Honda...

  • Page 93: Piston/Piston Rings/Piston Pin

    (4). (6) radiator hose clamp screw (7) radiator hose (8) right radiator lower mounting bolt (9) washer (1) ignition coil A connector (3) ignition coil (2) ignition coil B connector (4) ignition coil bolts Servicing Your Honda...
  • Page 94 (18) cylinder head bolts and washers (19) cylinder head (22) (13) (23) (13) cylinder head hanger bolts (14) cylinder head hanger plate bolts (15) left cylinder head hanger plate (16) right cylinder head hanger plate (22) cam chain guide (23) cylinder Servicing Your Honda...
  • Page 95 Do not let the cam chain fall into the crankcase. Do not let the dowel pins fall into the crankcase. (1) shop towels (3) piston pin (2) piston pin clips (4) piston (3) dowel pins (4) cylinder gasket Servicing Your Honda...
  • Page 96 Space the ring end gaps 180 degrees apart between top ring We recommend you consult an official Honda 1. Remove the carbon deposits from the piston and upper side rail. Space the ring end gaps 90 Service Manual or your dealer for correct Service head and piston ring grooves.
  • Page 97 Be careful not to damage or shock the piston pin. Use new pin clips. Never reuse old clips. Do not let the clips fall into the crankcase. Do not align the piston pin clip end gap with the piston cutout (8). Servicing Your Honda...
  • Page 98 Do not let the cam chain fall into the crankcase. 0.2 – 0.4 in (5 – 10 mm) (2) dowel pins (3) cylinder gasket (new) 0.2 – 0.4 in (5 – 10 mm) (4) cylinder bore (6) cam chain (1) cylinder mating surface (5) piston rings Servicing Your Honda...
  • Page 99 Install the washers and cylinder head bolts (7) and tighten them to the specified torque in a crisscross pattern in two or three steps: 37 lbf·ft (50 N·m, 5.1 kgf·m) Do not let the washers fall into the crankcase. Servicing Your Honda...
  • Page 100 (19) of the cylinder head as shown. (0 – 0.5 mm) (20) radiator hose clamp screw (12) (9) left cylinder head hanger plate (10) right cylinder head hanger plate (11) cylinder head hanger plate bolts (12) cylinder head hanger bolts (cont’d) Servicing Your Honda...
  • Page 101 7 lbf·ft (10 N·m, 1.0 kgf·m) Connect the ignition coil A connector (24) and B connector (25). (24) (22) (23) (25) (22) ignition coil (23) ignition coil bolts (24) ignition coil A connector (25) ignition coil B connector Servicing Your Honda...

  • Page 102: Suspension

    Suspension Suspension Refer to Important Safety Precautions on page 23. • Use Pro Honda HP Fork Oil, A15-00 or an 3. Inspect the wear rings (3) for wear or damage. equivalent which contains special additives to Replace the wear ring if it is 0.06 in (1.5 mm) Loose, worn, or damaged suspension components assure maximum performance of your CRF’s...
  • Page 103 Remove the bolts (4) and number (8) handlebar plate (5). 4. Loosen the fork bridge upper pinch bolts (9). 5. Loosen the fork bolts assembly (10), but do not remove them yet. (3) number plate tab (5) number plate (4) bolts Servicing Your Honda...
  • Page 104 To do so will cause (13) difficulty in fitting the brake disc between the brake pads. (24) (24) fork protector socket bolts (25) fork protectors (14) (13) disc cover (14) disc cover socket bolts (cont’d) Servicing Your Honda...
  • Page 105 The outer tube (1) can drop on the axle holder (4) suggested oil Pro Honda HP Fork Oil, A15-00 and damage the fork dust seal (5). To avoid damage, hold both the outer tube and slider when removing the fork damper.
  • Page 106 07WMA-KZ30100 • Lock nut wrench Improper disposal of drained oil is harmful to the Recommended Oil: environment. Pro Honda HP Fork Oil, A15-00 Recommended Standard Amount: Amount of fork oil left in the fork (within damper and spring) unit: cm...
  • Page 107 5. Align the groove (7) in the outer tube with the top surface of the upper fork bridge (8). Align (2) fork damper assembly (3) lock nut wrench (4) fork bolt assembly (7) groove (8) upper fork bridge Servicing Your Honda...
  • Page 108 10. Align the lower surface of the brake hose protector (14), stay A (15) and stay B (16), and assemble them. Install and tighten them to the left fork protector using the brake hose clamp bolts (17). (cont’d) Servicing Your Honda...
  • Page 109 Tighten the left axle pinch bolts (24) to the (30) specified torque: 15 lbf·ft (20 N·m, 2.0 kgf·m) (31) (32) (13) brake hose (33) bolts (30) number plate (34) number plate tab (31) tab (35) handlebar (32) slit Servicing Your Honda...
  • Page 110 • Piston base 07958-2500001 To avoid damage when torquing the axle pinch (39) compression damping adjuster (40) rebound damping adjuster bolts, be sure the axle is seated firmly onto the left fork leg clamp inner surface. (cont’d) Servicing Your Honda...
  • Page 111 (6) fork damper assembly (7) fork assembly (8) fork spring (9) spring seat collar (10) back-up ring/seat stopper (1) axle holder (3) fork center bolt lock nut (2) fork center bolt (4) piston base Servicing Your Honda...
  • Page 112 Pour the recommended fork oil into the fork damper assembly (4). Recommended Oil: Pro Honda HP Fork Oil, A15-00 (2) fork damper piston rod (5) fork bolt bushings Recommended Amount: (3) fork bolt assembly 8.4 US oz (248 cm...
  • Page 113 (1) fork center bolt lock nut (2) fork damper piston rod (7) (8) 13. Check the fork damper piston rod sliding (3) fork bolt assembly (7) O-rings (new) (5) fork bolt bushings (8) piston ring (new) surface and threads for damage. Servicing Your Honda...
  • Page 114 (2) fork damper piston rod (4) fork damper assembly Pour the drained oil into a suitable container and dispose of it in an approved manner (page 164). Improper disposal of drained fluids is harmful to the environment. (cont’d) Servicing Your Honda...
  • Page 115 (11) (12) Amount of fork oil left in the fork (without damper and spring) unit: cm (4) fork damper assembly minute (9) oil hole (11) air pressure release screws °C/°F (12) O-rings (new) 30/86 20/68 10/50 0/32 Servicing Your Honda...
  • Page 116 Make sure the black side of the back-up ring is seated on the seat stopper side. Over-tightening the vise can damage the axle holder. (3) slider bushing (6) spring seat collar (4) seat stopper (7) fork damper (5) back-up ring (cont’d) Servicing Your Honda...
  • Page 117 51 lbf·ft (69 N·m, 7.0 kgf·m) fork center bolt lock nut and fork center bolt installation. 0.06 – 0.08 in (1.5 – 2.0 mm) (17) (17) (17) fork center bolt (2) fork center bolt lock nut (17) fork center bolt Servicing Your Honda...

  • Page 118: Rear Suspension Inspection

    There • If you have a problem finding an acceptable should be no movement. If there is, have the adjustment, return to the standard position and bearings replaced by your dealer. begin again. Servicing Your Honda...

  • Page 119: Brakes

    (1) brake lever cover air in the brake system. 2. Loosen the lock nut (2). Refer to an official Honda Service Manual or see 3. To position the front brake lever farther away your dealer to have the air bled from the system.
  • Page 120 If the travel for the rear brake pedal feels leaks. excessive, there is probably air in the brake system and it must be bled. Refer to an official Honda If the pulling distance for the front brake lever Service Manual or see your dealer for brake feels excessive, there is probably air in the brake bleeding.
  • Page 121 Do not mix different types of fluid, they may not be compatible. not be compatible. •The recommended brake fluid is Honda DOT 4 •The recommended brake fluid is Honda DOT 4 Brake Fluid or an equivalent. Brake Fluid or an equivalent.
  • Page 122 0.04 in (1.0 (1.0 mm) mm), both brake pads must be replaced. minimum thickness indicator replace 0.04 in (1.0 mm) (1) brake pads (2) rear brake caliper replace 0.04 in (1.0 mm) wear indicator grooves (1) brake pads Servicing Your Honda...

  • Page 123: Wheels

    Wheel Rims & Spokes Axles & Wheel Bearings Keeping the wheels true (round) and maintaining 1. Inspect the wheel rims (1) and spokes (2) for See an official Honda Service Manual for correct spoke tension are critical to safe damage. inspection information: motorcycle operation.

  • Page 124: Tires & Tubes

    Make sure the valve stem caps are secure. If necessary, install new caps. Servicing Your Honda...
  • Page 125 • 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 126: Side Stand (Crf450Rx)

    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 molybdenum grease. Servicing Your Honda...

  • Page 127: Drive Chain

    Lubricate the drive chain (page 123) if it appears dry or shows signs of rust. Lubricate any kinked or binding links and work them free. Adjust chain slack if needed (page 123). (2) chain guide slider (3) wear limit Servicing Your Honda...
  • Page 128 Clean the threads of the lower drive chain roller be used in preference to motor oil. Pro Honda HP bolt and apply locking agent to the threads. Chain Lube or an equivalent is recommended.
  • Page 129 1. Clean the side surfaces of the chain with a dry Remove the drive chain. cloth. Use a high flash point solvent such as kerosene or Pro Honda chain cleaner – not gasoline. Do not brush the rubber O-rings. REPLACE REPLACE Brushing will damage them.
  • Page 130 Excessively worn sprocket teeth have a Service limit: 10.12 in (257.0 mm) hooked, worn appearance. Replace any sprocket which is damaged or excessively worn. MEASURE A SPAN OF 17 PINS (16 PITCHES) Servicing Your Honda...

  • Page 131: Exhaust Pipe/Muffler

    (5) right muffler mounting A bolt (6) right muffler mounting B bolt (7) washer (8) right muffler (1) side covers (3) bolts (2) air cleaner housing covers 3. Loosen the right muffler clamp bolt (4). (4) right muffler clamp bolt Servicing Your Honda...
  • Page 132 (10) left muffler mounting A bolt (11) left muffler mounting B bolt (12) washer (13) left muffler (4) left muffler mounting B bolt (5) washer (6) left muffler (7) washer (8) left muffler mounting B bolt (9) left muffler mounting A bolt Servicing Your Honda...
  • Page 133 10. Install the right muffler (11). (16) (11) (12) (16) right muffler clamp bolt (8) left muffler mounting B bolt (1) gasket (5) tab (9) left muffler mounting A bolt (2) exhaust pipe (11) right muffler (3) cutout (12) right muffler clamp Servicing Your Honda...
  • Page 134 Tighten the right and left muffler mounting B (2) exhaust pipe bolts to the specified torque: (3) gasket 16. Install the seat (page 34). 19 lbf·ft (26 N·m, 2.7 kgf·m) (4) right muffler (5) washer (6) right muffler mounting B bolt Servicing Your Honda...
  • Page 135 6. Tighten the right muffler clamp bolt, right muffler mounting A bolt and B bolt (page 127). (4) upper drive chain roller (5) left exhaust spring A (6) left muffler mounting A bolt (7) left muffler joint pipe Servicing Your Honda...
  • Page 136 8. Tighten the right and left muffler mounting A bolts to the specified torque: 19 lbf·ft (26 N·m, 2.7 kgf·m) 9. Tighten the right and left muffler mounting B bolts to the specified torque: 19 lbf·ft (26 N·m, 2.7 kgf·m) Servicing Your Honda...

  • Page 137: Additional Maintenance Procedures

    If any roughness or play is felt, but you do not see any movement in the steering head, the fork bushings may be worn. Refer to an official Honda Service Manual for replacement or adjustment procedures, or see your dealer.
  • Page 138 (2) clutch cover bolts (6) cylinder head bolts (3) water pump cover bolts (8) drive sprocket bolt (4) crankshaft hole cap (9) engine oil drain bolt (6) cylinder head bolts (7) exhaust pipe joint nuts (10) coolant drain bolt Servicing Your Honda...

  • Page 139: Battery

    The lithium-ion (li-ion) battery contains a fuse inside. If the fuse blows, the battery needs replacement. The voltage may read above 12V even with a blown battery fuse when the battery is unmounted (page 169). Servicing Your Honda...
  • Page 140 Using an existing lead-acid battery charger or battery charger that is not recommended, will damage the electrical circuits within the Li-ion battery. (1) battery (4) battery band (2) positive (+) terminal bolt (5) positive terminal cover (3) negative (–) terminal bolt Servicing Your Honda...

  • Page 141: Appearance Care

    The force of water under extreme pressure can inspect for chips and scratches. penetrate the dust seals of the suspension pivot You may use Pro Honda Hondabrite, a multi- 6. Lubricate the drive chain to prevent rusting. points and steering head bearings-driving dirt surface cleaner/degreaser, to remove both dirt and 7.
  • Page 142 The fuel tank is made of titanium material. To remove mud or dust, use a sponge or soft cloth and a stainless steel kitchen detergent, then rinse well with clean water. After washing, rinse with plenty of water and dry with a clean cloth. Servicing Your Honda...
  • Page 143 BLANK PAGE Servicing Your Honda...

  • Page 144: Adjustments For Competition

    Engine Mode Select Button ......140 for maximum competition performance. Current Mode..........140 Mode Selection ..........140 Initial suspension adjustments should be Honda Selectable Torque Control....141 performed after a minimum of 2 hours of easy Current Mode..........141 break-in time. Mode Selection ..........141 HRC-Launch Control System ......142 Optional front and rear suspension springs are Front Suspension Adjustments ......143...

  • Page 145: Engine Mode Select Button

    Engine Mode Select Button Engine Mode Select Button Current Mode Mode Selection Start the engine and push the engine mode select 1. Start the engine. button (1) with your CRF stopped. The engine 2. With your CRF stopped and the throttle closed, mode indicator (2) under the engine mode select push and hold the engine mode select button button indicates the selected mode by blinking the...

  • Page 146: Honda Selectable Torque Control

    Honda Selectable Torque Control Honda Selectable Torque Control The Honda selectable torque control reduces slip Current Mode Mode Selection and assists for an effective acceleration by temporarily decreasing the engine torque during 1. Start the engine. rear wheel spin. Start the engine.

  • Page 147: Hrc-Launch Control System

    HRC-Launch Control System HRC-Launch Control System The HRC-Launch Control System reduces slip and 4. To continue using the system, refer to step 2 in assists for an effective start by temporarily To operate the system. decreasing the rev limit and Torque Control To disable the system, quickly press the start operation when starting.

  • Page 148: Front Suspension Adjustments

    Front Suspension Adjustments Front Suspension Adjustments The front suspension can be adjusted for the rider's Front Suspension Air Pressure weight and riding conditions by using one or more of the following methods: Air is an unstable gas which builds up pressure as it is worked (such as in a fork).

  • Page 149: Front Suspension Damping

    Front Suspension Adjustments Front Suspension Damping Fork Springs Always start with full hard when adjusting The fork springs in CRF’s are about right for riders Compression Damping Adjustment damping. weighing between 170 lb (77 kg) and 200 lb (91 This adjustment affects how quickly the fork Do not turn the adjuster screw more than the given kg) (less riding gear).

  • Page 150: Fork Oil Adjustment

    Front Suspension Adjustments (CRF450R/RWE) (CRF450RX) Fork Oil Adjustment Optional Stiff 28.6 Ibf/in (5.0 N/mm) Fork Spring Oil capacity 13.2 US oz (389 cm (MAX) 1. Remove the front suspension (page 98). 2. Disassemble the fork outer tube (page 100). Oil capacity 12.0 US oz (356 cm 2 scribe marks 3.

  • Page 151: Rear Suspension Adjustments

    Optional Stiff spring (308.3 lbf/in (54 N/mm)): loosening the shock spring lock nut (1) and Honda Service Manual. 9.07 in (230.5 mm) turning the adjusting nut (2). If your CRF is new, put enough part-throttle break-...

  • Page 152: Rear Suspension Damping

    Rear Suspension Adjustments To decrease spring pre-load High Speed Damping: Rear Suspension Damping Loosen the shock spring lock nut using the The high speed damping can be adjusted by optional pin spanners (3) and turn the adjusting nut turning the hexagonal portion of the compression Compression Damping to increase the spring length (4).
  • Page 153 Rear Suspension Adjustments Low Speed Damping: The low speed damping can be adjusted by turning the center screw of the compression damping adjuster. The low speed compression damping adjuster has 13 clicks or more. Turning the adjuster one full turn changes the adjuster 4 clicks.

  • Page 154: Rear Suspension Race Sag

    Rear Suspension Adjustments unloaded: motorcycle on an optional workstand Ask the other helper to measure the loaded Rear Suspension Race Sag with rear suspension fully extended, no rider. with rider dimension. loaded with rider: motorcycle on ground, with Setting the proper race sag (ride height) is very SEAT MOUNTING BOLT rider.
  • Page 155 Rear Suspension Adjustments Spring Rates A spring that is too stiff for your weight will not If you are lighter or heavier than the average rider allow the rear tire to hook up under acceleration and cannot set the proper ride height with altering and will pass more bumps on to you.

  • Page 156: Suspension Adjustments For Track Conditions

    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 157: Suspension Adjustment Guidelines

    Suspension Adjustment Guidelines Suspension Adjustment Guidelines Follow the procedures described below to accurately adjust your CRF, using the methods described on pages 143 – 151. Remember to make all adjustments in one-click or 1/12 turn increments. Test ride after each adjustment. Front Suspension Adjustment Adjustments for Type of Track Hard-surfaced track...
  • Page 158 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 159 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 160: Tuning Tips

    Tuning Tips Tuning Tips Spark Plug Reading Using spark plugs with an improper heat range or An improperly tightened spark plug can damage Refer to Spark Plug on page 78. incorrect reach can cause engine damage. the engine. If a plug is too loose, the piston may be damaged.

  • Page 161: Chassis Adjustments

    Chassis Adjustments Chassis Adjustments The following suggestions may improve a specific Fork Height/Angle Wheelbase concern. Subtle changes in overall handling may also be noted. The position of the fork in the clamp is not Adjusting your CRF’s wheelbase can offer subtle adjustable.

  • Page 162: Gearing

    Unless you have the required mechanical know- (before and after the change) to get an accurate • Wet and slippery or sandy conditions: use a how, tools, and an official Honda Service Manual, appraisal of the change. “Seat-of-the-pants” higher gear (less teeth) to keep engine rpm sprocket changing should be done by your dealer.

  • Page 163: Tire Selection For Track Conditions

    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”...

  • Page 164: Personal Fit Adjustments

    Make sure that the bolts are torqued securely enough to prevent slippage during normal operation. Apply Pro Honda Hondalock or an equivalent to the threads of these bolts prior to adjustment to help ensure the correct torque is retained.
  • Page 165 Rear holes of fork bridge Rotating 180 degrees Refer to an official Honda Service Manual for installation instructions. Be sure to check control cable and wiring harness routing after the adjustment. • Chamfer the edges to remove burrs and other irregularities or roughness after sawing the handlebar.

  • Page 166: Tips

    Tips Tips Here’s helpful advice on how to transport and store Transporting Your Motorcycle ......162 your CRF, as well as three troubleshooting flow Storing Your Honda ........163 charts. Preparation for Storage ......163 Removal from Storage .......163 You & the Environment.........164 Troubleshooting ..........165...

  • Page 167: Transporting Your Motorcycle

    Transporting Your Motorcycle Transporting Your Motorcycle If you use a truck or motorcycle trailer to transport To secure your CRF, brace the front wheel against your CRF, we recommend that you follow these the front of the truck bed or trailer rail. guidelines: Attach the lower ends of two straps to the tie-down •...

  • Page 168: Storing Your Honda

    Storing Your Honda Storing Your Honda If you won’t be riding for an extended period, such 4. Remove the radiator cap and coolant drain bolt 11. Stuff a rag into the muffler outlet. Then tie a as during the winter, thoroughly inspect your CRF...

  • Page 169: You & The Environment

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

  • Page 170: Troubleshooting

    • Excessive carbon build- parenthesis. The items that require use of the the engine at high up in combustion CORRECT official Honda Service Manual are followed by an speed chamber • Ignition timing too asterisk (*). advance (Faulty ECM)* 8.
  • Page 171 Troubleshooting POOR HANDLING POOR PERFORMANCE AT LOW AND IDLE SPEED POOR PERFORMANCE AT HIGH SPEED CHECK POSSIBLE CAUSES CHECK POSSIBLE CAUSES Steering is heavy 1. Check the spark INCORRECT • Incorrect spark plug heat 1. Check the ignition INCORRECT • Faulty ECM* •...

  • Page 172: Taking Care Of The Unexpected

    Taking Care of the Unexpected Taking Care of the Unexpected This section gives practical advice to help you If a Fuse Blows ..........168 solve problems. If Your Battery Is Low (or Dead) ....169 Taking Care of the Unexpected...

  • Page 173: If A Fuse Blows

    If a Fuse Blows If a Fuse Blows All of the electrical circuits on your CRF have a 5. Remove the start magnetic switch stay bolt (1) 9. Install the start magnetic switch cover (4). fuse to protect them from damage caused by excess and plastic wire band (2).

  • Page 174: If Your Battery Is Low (Or Dead)

    If Your Battery Is Low (or Dead) If Your Battery Is Low (or Dead) If an overvoltage, overcurrent, or short circuit is applied, the battery fuse may blow. Do not jump-start as this can damage your CRF’s electrical system and battery. Bump starting is not recommended.
  • Page 175 BLANK PAGE Taking Care of the Unexpected...

  • Page 176: Technical Information

    Specifications..........173 Torque Specifications ........175 Nuts, Bolts, Fasteners ........175 Oxygenated Fuels...........178 Competition Logbook ........179 Optional Parts List .........181 Spare Parts & Equipment.......182 Spare Parts ..........182 General Tools..........182 Honda Special Tools........182 Chemical Products ........182 Other Products ...........182 Wiring Diagram ..........183 Technical Information...

  • Page 177: Vehicle Identification

    Vehicle Identification Vehicle Identification The engine number (2) is stamped on the right Serial Numbers crankcase. The VIN and engine serial number are required 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 this manual.

  • Page 178: Specifications

    Specifications Specifications Tire pressure, front Item English Metric Item English Metric 15 psi (100 kPa, 1.0 kgf/cm (cold) Dimension Engine Tire pressure, rear 15 psi (100 kPa, 1.0 kgf/cm CRF450RX: CRF450RX: Type Liquid cooled, 4-stroke (cold) 85.6 in 2,175 mm Overall length Cylinder Single 10°...
  • Page 179 Specifications Item English Metric Drive train Clutch type Wet, multi-plate type Transmission 5-speed, constant mesh Primary reduction 2.357 Gear ratio I 2.133 Gear ratio II 1.706 Gear ratio III 1.421 Gear ratio IV 1.211 Gear ratio V 1.043 CRF450RX: 3.846 Final reduction CRF450R/RWE: 3.769 Left foot-operated return...

  • Page 180: Torque Specifications

    Torque Specifications Torque Specifications ENGINE Nuts, Bolts, Fasteners Torque Item Remarks Check and tighten nuts, bolts, and fasteners before every outing. lbf·ft N·m kgf·m LEFT SIDE Cylinder head cover socket bolts Clutch cover bolts Water pump cover bolts Crankshaft hole cap NOTE 1 Oil filter cover bolts Cylinder head bolts...
  • Page 181 Torque Specifications LEFT SIDE FRAME (CRF450R/RWE) (16) Torque (23) Item Remarks (21) lbf·ft N·m kgf·m (13) Steering stem nut 11.0 Fork bridge upper pinch bolts (14) Fork bridge lower pinch bolts Handlebar upper holder bolts (17) Handlebar lower holder nuts NOTE 1 Front axle nut Axle pinch bolts...
  • Page 182 Torque Specifications FRAME LEFT SIDE (47) (CRF450R/RWE) (56) Torque (49) (54) (48) Item Remarks (48) lbf·ft N·m kgf·m (53) Brake hose oil bolts (42) (52) Front brake caliper (32) mounting bolts (39) (46) Front brake disc nuts NOTE 1 Rear brake disc nuts NOTE 1 (36) Brake pedal pivot bolt...

  • Page 183: Oxygenated Fuels

    Oxygenated Fuels Oxygenated Fuels Some conventional gasolines are being blended If you notice any undesirable operating symptoms, with alcohol or an ether compound. These try another service station or switch to another gasolines are collectively referred to as oxygenated brand of gasoline. fuels.

  • Page 184: Competition Logbook

    Competition Logbook Competition Logbook Any serious competition effort relies heavily on Tuning & Adjustment Records Racing Records the knowledge gained and compiled from previous Keep track of the settings and adjustments that Information worth recording for this section of racing events. The best way to organize the many worked best at a particular location.
  • Page 185 Competition Logbook Date Running Location/Event Comments (Suspension Settings, Gearing, Chassis Adjustments, Maintenance Performed, etc.) Time (Make several photocopies of this page for future use) Technical Information...

  • Page 186: Optional Parts List

    Optional Parts List Optional Parts List These parts and tools may be ordered from your FRAME Remarks FRAME Remarks authorized dealer. Fork spring CRF450RX: 27.4 lbf/in (4.8 N/mm) Shock spring CRF450RX: 296.9 lbf/in (52 N/mm) CRF450R/RWE: 319.8 lbf/in Standard 1 scribe mark or FRAME Remarks (56 N/mm)

  • Page 187: Spare Parts & Equipment

    Pro Honda GN4 4-stroke Oil following: screwdrivers: blade & Phillips No. 1, 2, 3 (Engine Oil) wrench, large adjustable Pro Honda HP Fork Oil, A15-00 Spare Parts wrenches: open end & box Honda DOT 4 Brake Fluid wrenches: hex (Allen)

  • Page 188: Wiring Diagram

    Wiring Diagram Wiring Diagram JUNCTION CONNECTOR GP SENSOR TORQUE STARTER CLUTCH FUEL CONTROL SWITCH SWITCH PUMP SWITCH STARTER RELAY SWITCH BATTERY GROUND FUEL INJECTOR BLUE ORANGE STARTER IGNITION COIL MOTOR REGULATOR/ DIODE MAIN STARTER SPARK PLUG ALTERNATOR SENSOR SENSOR SENSOR SENSOR RECTIFIER RELAY...
  • Page 189 BLANK PAGE Technical Information...

  • Page 190: Consumer Information

    Consumer Information Consumer Information This section contains information about contacting Authorized Manuals........186 Honda and how to get an official Honda Service Contacting Honda ..........187 Manual. Your Honda Dealer ........188 Consumer Information...

  • Page 191: Authorized Manuals

    Authorized Manuals The Service Manual used by your authorized dealer is available from your Honda dealer or Helm, Inc. (USA only, Canada: See your dealer to order authorized manuals.) Also available but not necessary to service your model is the Honda Common Service Manual which explains theory of operation and basic service information for various systems on Honda motorcycles, scooters and ATV.

  • Page 192: Contacting Honda

    If you wish to comment on your experiences with your CRF or with your dealer, please send your comments to the following address: Motorcycle Division, American Honda Motor Co., Inc., P.O. Box 2200, Torrance CA 90509- 2200, Mailstop: 100-4C-7B, Telephone: (866) 784-1870.

  • Page 193: Your Honda Dealer

    Your Honda Dealer Once you purchase your new Honda, get familiar Your Honda dealer can inform you about with the organization of your Honda dealer so you competition events in your area. can utilize the full range of services available.
  • Page 194 BLANK PAGE Consumer Information...

  • Page 195: Index

    ..........2 damping adjustments, appearance care ..........136 .............144 front ........186 authorized manuals ............147 rear ........188 dealer, your Honda ..........183 diagram, wiring ..........122 drive chain ..........15 basic operation ............134 battery ..........11 before riding between races (CRF450RX)/motos (CRF450R/RWE) &...
  • Page 196 Index filter, handlebar inspection ........132 maintenance, ............67 ........32 Honda, after competition ..........46, 56 ..........187 .......31 fuel pump contacting before & after competition ............63 ......16 Selectable Torque Control between races (CRF450RX)/ .........18 ........186 ..31 flooded engine, starting service manual motos (CRF450R/RWE) & practice ..........188...
  • Page 197 Index rear suspension adjustment ......146 safety, throttle, .....Safety Messages ...........70 riding, a few words about freeplay ............2 ........2 ..........71 apparel important information inspection ........15 .........2 ..........71 basic operation important precautions lubrication .............11 ............4 before labels tires, ......2 ..........23 ..........119 important safety information maintenance air pressure ........2...
  • Page 198 91 or higher tank: 1.66 US gal (6.3 ℓ) Engine Oil/Capacity Pro Honda GN4 4-stroke Oil or an equivalent motorcycle oil. 1.10 US qt (1.04 ℓ) after draining and filter change 1.06 US qt (1.00 ℓ) after draining...
  • Page 199 California Proposition 65 Warning WARNING: Operating, servicing and maintaining a passenger vehicle or off-highway motor vehicle can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm. To minimize exposure, avoid breathing exhaust, do not idle the engine except as necessary, service your vehicle in a well-ventilated area and wear gloves or wash your hands frequently when servicing your vehicle.

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