Honda 2020 CRF450R Off-road Competition

User Manual - Transcript

• Page 1 - English - : Contents MOTORCYCLE SAFETY 1 Important Safety Information 2 Important Safety Precautions 2 Accessories amp Modifications 3 Safety Labels 4 INSTRUMENTS amp CONTROLS 5 Operation Component Locations 6 MIL Malfunction Indicator Lamp 7 MIL Blink Pattern 7 Current DTCFreeze DTC 7 Circuit Inspection 8 DTC Index 9 Engine Mode amp Launch Control System Indicator amp Torque Control Indicator 10 Engine Mode Indicator 10 Launch Control System Indicator 10 Torque Control Indicator 10 BEFORE RIDING 11 Are You Ready to Ride 12 Is Your Motorcycle Ready to Ride 13 Preride Inspection 13 BASIC OPERATING INSTRUCTIONS 15 Safe Riding Precautions 16 Side Stand CRF450RX 16 Honda Selectable Torque Control 16 Starting amp Stopping the Engine 17 Fast Idle Knob 17 Preparation 17 Starting Procedure 17 How to Stop the Engine 18 Parking CRF450RX 19 Breakin Guidelines 20 SERVICING YOUR HONDA21 Before You Service Your Honda The Importance of Maintenance 22 Maintenance Safety 23 Important Safety Precautions23 Maintenance Schedule 24 Maintenance Schedule CRF450RX 25 Maintenance Schedule CRF450RRWE 26 General Competition Maintenance 27 Before amp After Competition Maintenance 31 Between Races CRF450RXMotos CRF450RRWE amp Practice Maintenance 31 After Competition Maintenance 32 Service Preparations Maintenance Component Locations 33 Seat 34 Fuel Tank CRF450RX 35 Fuel Tank CRF450RRWE 37 Subframe 39 Service Procedures Fluids amp Filters Fuel System CRF450RX 42 Fuel System CRF450RRWE 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 PistonPiston RingsPiston Pin 88 Chassis Suspension 97 Brakes 114 Wheels 118 Tires amp Tubes 119 Side Stand CRF450RX 121 Drive Chain 122 Exhaust PipeMuffler 126 Additional Maintenance Procedures 132 Electrical Battery 134 Appearance Care 136 2020 CRF450RRXRWE 31MKE630 MOM 17046 1901
• Page 2 - English - : Contents Contents ADJUSTMENTS FOR COMPETITION 139 Engine Mode Select Button 140 Current Mode 140 Mode Selection 140 Honda Selectable Torque Control 141 Current Mode 141 Mode Selection 141 HRCLaunch Control System 142 Front Suspension Adjustments 143 Front Suspension Air Pressure 143 Front Suspension Damping 144 Fork Springs 144 Fork Oil Adjustment 145 Rear Suspension Adjustments 146 Rear Suspension Spring PreLoad 146 Rear Suspension Damping 147 Rear Suspension Race Sag 149 Suspension Adjustments for Track Conditions 151 Suspension Adjustment Guidelines 152 Tuning Tips 155 Spark Plug Reading 155 Chassis Adjustments 156 Rear End 156 Fork HeightAngle 156 Wheelbase 156 Gearing 157 Tire Selection for Track Conditions 158 Personal Fit Adjustments 159 Control Positioning 159 Handlebar Position Width amp Shape 159 TIPS161 Transporting Your Motorcycle 162 Storing Your Honda 163 Preparation for Storage163 Removal from Storage163 You amp the Environment 164 Troubleshooting 165 TAKING CARE OF THE UNEXPECTED167 If a Fuse Blows 168 If Your Battery Is Low or Dead 169 TECHNICAL INFORMATION171 Vehicle Identification 172 Serial Numbers 172 Specifications 173 Torque Specifications 175 Nuts Bolts Fasteners175 Oxygenated Fuels 178 Competition Logbook 179 Optional Parts List 181 Spare Parts amp Equipment 182 Spare Parts 182 General Tools182 Honda Special Tools182 Chemical Products182 Other Products 182 Wiring Diagram 183 CONSUMER INFORMATION 185 Authorized Manuals 186 Contacting Honda 187 Your Honda Dealer 188 INDEX190 QUICK REFERENCE
• Page 3: Honda CRF450RXCRF450RCRF450RWE OWNERS MANUAL amp COMPETITION HANDBOOK
• Page 4 - English - : Introduction Introduction Introduction Congratulations on choosing your Honda CRF off road racing CRF450RXmotocross CRF450R RWE motorcycle When you own a Honda youre part of a worldwide family of satisfied customers people who appreciate Hondas reputation for building quality into every product Your CRF is a high performance racing motorcycle that utilizes the latest offroad racing CRF450RXmotocross CRF450RRWE technology and is intended for competition use in sanctioned closedcourse events by experienced riders only Be aware that offroad racing CRF450RX motocross CRF450RRWE is a physically demanding sport that requires more than just a fine motorcycle To do well you must be in excellent physical condition and be a skillful rider For the best results work diligently on your physical conditioning and practice frequently Before riding take time to get acquainted with your CRF and how it works To protect your investment we urge you to take responsibility for keeping your CRF well maintained Scheduled service is a must of course But its just as important to observe the breakin guidelines and perform all the preride and other periodic checks detailed in this manual You should also read the owners manual before you ride Its full of facts instructions safety information and helpful tips To make it easy to use the manual contains a table of contents a detailed list of topics at the beginning of each section and an index at the back of the book As you read this manual you will find information that is preceded by a symbol This information is intended to help you avoid damage to your CRF other property or the environment Unless you are mechanically qualified and have the proper tools you should see your dealer for the service and adjustment procedures discussed in this manual An official Honda Service Manual for your CRF is available page 186 It is the same manual your dealer uses If you plan to do any service on your CRF beyond the standard maintenance procedures in this manual you will find an official Honda Service Manual a valuable reference If you have any questions or if you ever need a special service or repairs remember that your Honda dealer knows your CRF best and is dedicated to your complete satisfaction Please report any change of address or ownership to your dealer so we will be able to contact you concerning important product information You may also want to visit our website at USA wwwpowersportshondacom Canada wwwhondaca Happy riding ABBREVIATION Throughout this manual the following abbreviations are used to identify the respective parts or system Abbrev term Full term CKP sensor Crankshaft Position sensor DLC Data Link Connector DTC Diagnostic Trouble Code ECM Engine Control Module ECT sensor Engine Coolant Temperature sensor GP sensor Gear Position sensor IAT sensor Intake Air Temperature sensor MAP sensor Manifold Absolute Pressure sensor MIL Malfunction Indicator Lamp PGMFI Programmed Fuel Injection TDC Top Dead Center TP sensor Throttle Position sensor
• Page 5 - English - : Safety Messages 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 Safety Messages are preceded by a safety alert symbol and one of three signal words DANGER WARNING or CAUTION These signal words mean Of course it is not practical or possible to warn you about all hazards associated with operating or maintaining a motorcycle You must use your own good judgment You WILL be KILLED or SERIOUSLY HURT if you dont follow instructions You CAN be KILLED or SERIOUSLY HURT if you dont follow instructions You CAN be HURT if you dont follow instructions DANGER WARNING CAUTION
• Page 6 - English - : Motorcycle Safety Motorcycle Safety 1 Motorcycle Safety This section presents some of the most important information and recommendations to help you ride your CRF safely Please take a few moments to read these pages This section also includes information about the location of safety labels on your CRF Important Safety Information 2 Important Safety Precautions2 Accessories amp Modifications3 Safety Labels4
• Page 7 - English - : Important Safety Information 2 Motorcycle Safety Important Safety Information Your CRF can provide many years of pleasure if you take responsibility for your own safety and understand the challenges you can meet in competitive racing As an experienced rider you know there is much you can do to protect yourself when you ride The following are a few precautions we consider to be most important Never Carry a Passenger Your CRF is designed for one operator only Carrying a passenger can cause a crash in which you and others can be hurt Wear Protective Gear Whether youre practicing to improve your skills or riding in competition always wear an approved helmet eye protection and proper protective gear Take Time to Get to Know Your CRF Because every motorcycle is unique take time to become thoroughly familiar with how this one operates and responds to your commands before placing your machine and yourself in competition Learn and Respect Your Limits Never ride beyond your personal abilities or faster than conditions warrant Remember that alcohol drugs illness and fatigue can reduce your ability to perform well and ride safety Dont Drink and Ride Alcohol and riding dont mix Even one drink can reduce your ability to respond to changing conditions and your reaction time gets worse with every additional drink So dont drink and ride and dont let your friends drink and ride either Keep your Honda in Safe Condition Maintaining your CRF properly is critical to your safety A loose bolt for example can cause a breakdown in which you can be seriously injured LithiumIon LiIon Battery If you smell an unusual odor coming from the lithiumion liion battery park your CRF in a safe place outside and away from flammable objects then stop the engine Have your CRF inspected by your dealer immediately Important Safety Precautions
• Page 8 - English - : Accessories amp Modifications Motorcycle Safety 3 Accessories amp Modifications Installing nonHonda accessories removing original equipment or modifying your CRF in any way that would change its design or operation could seriously impair your CRFs handling stability and braking making it unsafe to ride Accessories amp Modifications WARNING Improper accessories or modifications can cause a crash in which you can be seriously hurt or killed Follow all instructions in this owners manual regarding modifications and accessories
• Page 9 - English - : Safety Labels 4 Motorcycle Safety Read these labels carefully and dont remove them If a label comes off or becomes hard to read contact your dealer for replacement For Canada Safety Labels
• Page 10 - English - : Instruments amp Controls Instruments amp Controls 5 Instruments amp Controls Read this section carefully before you ride It presents the location of the basic controls on your CRF Operation Component Locations6 MIL Malfunction Indicator Lamp7 MIL Blink Pattern7 Current DTCFreeze DTC 7 Circuit Inspection8 DTC Index 9 Engine Mode amp Launch Control System Indicator amp Torque Control Indicator10 Engine Mode Indicator 10 Launch Control System Indicator10 Torque Control Indicator10
• Page 11 - English - : Operation Component Locations 6 Instruments amp Controls Operation Component Locations front brake lever clutch lever engine mode select button engine stop button MIL amber Engine mode indicator blue Launch control system indicator purple start button throttle grip Torque Control button Torque Control indicator green shift lever fast idle knob engine idle speed side stand CRF450RX rear brake pedal
• Page 12 - English - : MIL Malfunction Indicator Lamp Instruments amp Controls 7 MIL Malfunction Indicator Lamp The MIL 1 on your CRF keeps you informed alerts you to possible problems and makes your riding safer and more enjoyable Refer to the MIL frequently When starting the engine the MIL amber will stay on for 2 seconds and then go off This is normal The MIL blinks when there is any abnormality in the PGMFI 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 The MIL will blink the appropriate DTC number if the ECM detects an active problem while the engine is running at less than 4000 rpm The MIL will stay on when engine speed is over 4000 rpm The MIL has two types of blinks a long blink and short blink The long blinking lasts for 12 seconds the short blinking lasts for 04 seconds One long blink is the equivalent of 10 short blinks For example when one long blink is followed by two short blinks the MIL is 12 one long blink 10 blinks plus two short blinks When the ECM stores more than one DTC the MIL will indicate them by blinking in the order from the lowest number to highest number The DTC is indicated in two ways according to the failure status When the engine starts the MIL stays on for 2 seconds then goes off If the ECM detects a DTC the MIL starts blinking indicating the DTC number by the number of blinks in amber Even when the MIL is blinking you can change the engine modes However you cannot change the engine modes when the indicator is blinking DTC 1 2 or 8 After an engine mode is selected the MIL restarts blinking the current DTC number In the case that the ECM does not detect an active problem but has recorded a previous problem in its memory the MIL will not come on If it is necessary to retrieve any past problems stored in the memory refer to an official Honda Service Manual 1 MIL amber 1 MIL Blink Pattern Current DTCFreeze DTC
• Page 13 - English - : 8 Instruments amp Controls MIL Malfunction Indicator Lamp Always clean around the ECM and keep debris away from the connectors before disconnecting them A faulty PGMFI system is often related to poorly connected or corroded connections Check the following connections Remember circuit inspection is not a cureall for other problems in your engines PGMFI system Circuit Inspection 1 MAP sensor connector 2 ECT sensor connector 3 TP sensor connector 4 IAT sensor connector 5 Injector connector 6 CKP sensor connector 7 ECM connector 8 GP sensor connector 3 4 2 6 1 5 7 8
• Page 14 - English - : Instruments amp Controls 9 MIL Malfunction Indicator Lamp Refer to MIL Blink Pattern on page 7 Should be serviced by your dealer unless the owner has proper tools and is technically qualified 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 andor refer to an official Honda Service Manual page 186 for troubleshooting of the PGMFI symptom DTC Index MIL blinks Function Failure SymptomFailsafe function 1 MAP sensor circuit malfunction Poor performance driveability 2 MAP sensor performance problem Poor performance driveability 7 ECT sensor circuit malfunction Hard start at a low temperature 8 TP sensor circuit malfunction Poor engine acceleration 9 IAT sensor circuit malfunction Engine operates normally 12 Injector circuit malfunction Engine does not start Injector fuel pump and ignition shut down 41 GP sensor circuit malfunction Engine operates normally
• Page 15 - English - : Engine Mode amp Launch Control System Indicator amp Torque Control Indicator 10 Instruments amp Controls Engine Mode amp Launch Control System Indicator amp Torque Control Indicator The engine mode indicator blue 1 is located under the engine mode select button 2 The engine mode indicator indicates the currently selected mode by blinking the mode number once when the engine is started The engine mode indicator indicates a selected mode when you operate the engine mode select button page 140 If the engine mode indicator stays on or does not come on when it should have your dealer check it for problems The launch control system indicator purple 1 is located under the engine mode select button 2 The launch control system indicator indicates the currently selected level by blinking the level number while launch control system goes into standby The launch control system indicator purple comes on while the system is operating If the launch control system indicator does not come on when it should have your dealer check it for problems The Torque Control indicator green 1 is located to the right side of the Torque Control button 2 on the left side of the handlebar Torque Control indicator green indicates the currently selected mode by blinking the mode number thrice when the engine is started The Torque Control indicator green comes on while the system is operating The Torque Control indicator indicates a selected mode when you operate the Torque Control button page 141 If the Torque Control indicator does not come on when it should have your dealer check it for problems Engine Mode Indicator 1 engine mode indicator blue 2 engine mode select button 2 1 Launch Control System Indicator 1 launch control system indicator purple 2 engine mode select button 2 1 Torque Control Indicator 1 Torque Control indicator green 2 Torque Control button 2 1
• Page 16 - English - : Before Riding Before Riding 11 Before Riding Before each ride you need to make sure you and your CRF are both ready to ride To help get you prepared this section discusses how to evaluate your riding readiness and what items you should check on your CRF For information about suspension and other adjustments see page 139 Are You Ready to Ride12 Is Your Motorcycle Ready to Ride 13 Preride Inspection13
• Page 17 - English - : Are You Ready to Ride 12 Before Riding Are You Ready to Ride Before riding your CRF for the first time we strongly recommend that you read this owners manual make sure you understand the safety messages and know how to operate the controls Before each ride its also important to make sure you and your CRF are both ready to ride For information about suspension and other adjustments see page 139 Whether youre preparing for competition or for practice always make sure you are In good physical and mental condition Free of alcohol and drugs Wearing an approved helmet eye protection and other appropriate riding gear Although complete protection is not possible wearing the proper gear can reduce the chance or severity of injury when you ride WARNING Not wearing a helmet increases the chance of serious injury or death in a crash Be sure you always wear a helmet eye protection and other protective apparel when you ride
• Page 18 - English - : Is Your Motorcycle Ready to Ride Before Riding 13 Is Your Motorcycle Ready to Ride Competitive riding can be tough on a motorcycle so its important to inspect your CRF and correct any problems you find before each ride Check the following items page numbers are at the right Check the following before each ride Engine oil level 63 Fuel line for condition 42 Coolant for proper level 65 Cooling system and hoses for condition 66 Spark plug for proper heat range carbon fouling and spark plug wire terminal for looseness 78 Air cleaner for condition and contamination 67 Clutch lever freeplay 73 Breather drain for cleaning 69 Steering head bearing and related parts for condition 132 Throttle operation 71 Tires for damage or improper inflation pressure 119 Spokes for looseness 118 Rim locks for looseness 118 Front and rear suspension for proper operation 97 113 Front and rear brakes check operation 114 Drive chain for correct slack and adequate lubrication 122 123 Drive chain sliders and drive chain rollers for damage or wear 122 123 Exhaust pipeMuffler for looseness 126 Every possible part for looseness such as cylinder head bolts engine mounting bolts nuts axle nuts handlebar holder bolts fork bridge pinch bolts drive chain adjuster lock nuts drive chain roller boltnut wire harness connectors175177 MIL operation 7 WARNING Improperly maintaining this motorcycle or failing to correct a problem before riding can cause a crash in which you can be seriously hurt or killed Always perform a preride inspection before every ride and correct any problems Preride Inspection
• Page 20 - English - : Basic Operating Instructions Basic Operating Instructions 15 Basic Operating Instructions This section gives basic information on how to start and stop your engine as well as breakin guidelines Safe Riding Precautions16 Side Stand CRF450RX 16 Honda Selectable Torque Control16 Starting amp Stopping the Engine17 Fast Idle Knob17 Preparation17 Starting Procedure17 How to Stop the Engine18 Parking CRF450RX 19 Breakin Guidelines 20
• Page 21 - English - : Basic Operating Instructions 16 Basic Operating Instructions Basic Operating Instructions Before riding your CRF for the first time please review the Important Safety Precautions beginning on page 2 and the previous section titled Before Riding For your safety avoid starting or operating the engine in an enclosed area such as a garage Your CRFs exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death The side stand 1 is used to support your CRF while parked page 19 To operate push the side stand down Slowly lean your CRF to the left until its weight rests on the side stand Turn the handlebar fully to the left Before riding raise the side stand When the Honda selectable torque control Torque Control detects rear wheel spin during acceleration the system will limit the amount of torque applied to the rear wheel based on the Torque Control level selected Rear wheel spin during acceleration is reduced at the higher Torque Control level setting Select a level that is appropriate for your skill and riding conditions Torque Control does not work during deceleration and will not prevent the rear wheel from skidding due to engine braking Do not close the throttle suddenly especially when riding on slippery surfaces Torque Control may not compensate for rough track conditions or rapid throttle operation Always consider track and weather conditions as well as your skills and condition when applying throttle Always use the recommended tires and sprockets to ensure correct Torque Control operation Safe Riding Precautions WARNING Running the engine of your vehicle while in an enclosed or even partially enclosed area can cause a rapid buildup of toxic carbon monoxide gas Breathing this colorless odorless gas can quickly cause unconsciousness and lead to death Only run your vehicles engine when it is located in a well ventilated area outdoors Side Stand CRF450RX 1 side stand 1 Honda Selectable Torque Control
• Page 22 - English - : Starting amp Stopping the Engine Basic Operating Instructions 17 Starting amp Stopping the Engine Always follow the proper starting procedure described below Your CRF can be started with the transmission in gear by pulling in the clutch lever before operating the start button The fast idle knob has two functions When pulled out the fast idle knob assists in firsttime startup for cold weather starting When pushed in it acts like an idle adjustment screw Refer to Idle Speed Adjustment on page 72 Make sure that the transmission is in neutral Always follow the proper starting procedure described as follows Check the engine oil and coolant levels before starting the engine pages 63 65 Cold Engine Starting 1 Shift the transmission into neutral 2 If the temperature is 50F 10C or below pull the fast idle knob 1 fully up 3 With the throttle closed Pull the clutch lever all the way in and depress the start button 2 4 About a minute after the engine starts push the fast idle knob back all the way to fully OFF If idling is unstable open the throttle slightly Fast Idle Knob Preparation Starting Procedure 1 fast idle knob 1 2 start button 2
• Page 23 - English - : 18 Basic Operating Instructions Starting amp Stopping the Engine Warm Engine Starting 1 Shift the transmission into neutral 2 Pull the clutch lever and depress the start button Do not open the throttle Starting the engine excessively charged with fuel by throttle blipping or other reasons 1 Shift the transmission into neutral 2 With the throttle fully opened pull the clutch and depress the start button for 5 seconds to discharge excessive fuel from the engine 3 Pull the clutch lever and depress the start button Do not open the throttle Snapping the throttle or fast idling for more than about 5 minutes may cause exhaust pipe and muffler discolorations When starting the engine the MIL amber will stay on for 2 seconds then go off And then the engine mode indicator blue indicates the current engine mode for 08 seconds then goes off If the MILengine mode indicator 1 does not come on or go off when it should have your dealer check it for problems Normal Engine Stop 1 Shift the transmission into neutral 2 Push and hold the engine stop button 1 until the engine stops completely Emergency Engine Stop To stop the engine in an emergency push and hold the engine stop button 1 MIL amber engine mode indicator blue 1 How to Stop the Engine 1 engine stop button 1
• Page 24: Parking CRF450RX Basic Operating Instructions 19 Parking CRF450RX Lower the side stand to support your CRF Always choose a level surface to park
• Page 25 - English - : Breakin Guidelines 20 Basic Operating Instructions Breakin Guidelines Help assure your CRFs 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 fullthrottle starts and rapid acceleration This same procedure should be followed each time when piston is replaced piston rings are replaced cylinder is replaced crankshaft or crank bearings are replaced
• Page 26 - English - : Servicing Your Honda Servicing Your Honda 21 Servicing Your Honda Keeping your CRF well maintained is absolutely essential to your safety Its also a good way to protect your investment get maximum performance avoid breakdowns and have more fun To help keep your CRF in good shape this section includes a Maintenance Schedule for required servicing and stepbystep instructions for specific maintenance tasks Youll also find important safety precautions information on oils and tips for keeping your CRF looking good An ECM system is used on this motorcycle consequently routine ignition timing adjustment is unnecessary If you want to check the ignition timing refer to an official Honda Service Manual page 186 An optional tool kit may be available Check with your dealers parts department Before You Service Your Honda The Importance of Maintenance22 Maintenance Safety23 Important Safety Precautions23 Maintenance Schedule24 General Competition Maintenance27 Before amp After Competition Maintenance 31 Between Races CRF450RXMotos CRF450RRWE amp Practice Maintenance31 After Competition Maintenance 32 Service Preparations Maintenance Component Locations 33 Seat34 Fuel Tank CRF450RX 35 Fuel Tank CRF450RRWE 37 Subframe39 Service Procedures Fluids amp Filters Fuel System CRF450RX42 Fuel System CRF450RRWE52 Engine Oil62 Coolant65 Air Cleaner67 Crankcase Breather69 Engine Throttle70 Engine Idle Speed72 Clutch System73 Spark Plug78 Valve Clearance79 PistonPiston RingsPiston Pin88 Chassis Suspension 97 Front Suspension Inspection 97 Rear Suspension Inspection 113 Brakes 114 Wheels 118 Tires amp Tubes 119 Side Stand CRF450RX 121 Drive Chain 122 Exhaust PipeMuffler 126 Additional Maintenance Procedures 132 Electrical Battery 134 Appearance Care 136
• Page 27 - English - : The Importance of Maintenance 22 Servicing Your Honda The Importance of Maintenance Keeping your CRF wellmaintained is absolutely essential to your safety Its also a good way to get maximum performance during each race CRF450RXmoto CRF450RRWE Careful preride inspections and good maintenance are especially important because your CRF is designed to be ridden in offroad competition Remember proper maintenance is your responsibility Be sure to inspect your CRF before each ride and follow the Maintenance Schedule in this section WARNING 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 owners manual
• Page 28 - English - : Maintenance Safety Servicing Your Honda 23 Maintenance Safety This section includes instructions on how to perform some important maintenance tasks Some of the most important safety precautions follow However we cannot warn you of every conceivable hazard that can arise in performing maintenance Only you can decide whether or not you should perform a given task Make sure the engine is off before you begin any maintenance or repairs This will help eliminate several potential hazards Carbon monoxide poisoning from engine exhaust 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 Read the instructions before you begin and make sure you have the tools and skills required To help prevent the motorcycle from falling over park it on a firm level surface using the side stand CRF450RX an optional workstand or a maintenance stand to provide support To reduce the possibility of a fire or explosion be careful when working around gasoline Use only a nonflammable high flash point solvent such as kerosene not gasoline to clean parts Keep cigarettes sparks and flames away from all fuelrelated parts WARNING Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or killed Always follow the procedures and precautions in this owners manual Important Safety Precautions
• Page 29 - English - : Maintenance Schedule 24 Servicing Your Honda Maintenance Schedule To maintain the safety and reliability of your CRF regular inspection and service is required as shown in the Maintenance Schedule that follows The Maintenance Schedule lists items that can be performed with basic mechanical skills and hand tools Procedures for these items are provided in this manual The Maintenance Schedule also includes items that involve more extensive procedures and may require special training tools and equipment Therefore we recommend that you have your dealer perform these tasks unless you have advanced mechanical skills and the required tools Procedures for items in this schedule are provided in an official Honda Service Manual available for purchase from your dealer page 186 Service intervals in the maintenance schedule are expressed in terms of races CRF450RXmotos CRF450RRWE and riding hours To avoid overlooking required service we urge you to develop a convenient way to record the number of races CRF450RXmotos CRF450RRWE and or hours you ride If you do not feel capable of performing a given task or need assistance remember that your Honda dealer knows your CRF best and is fully equipped to maintain and repair it If you decide to do your own maintenance use only Honda Genuine Parts or their equivalents for repair or replacement to ensure the best quality and reliability Perform the preride inspection page 13 at each scheduled maintenance period Summary of Maintenance Schedule Notes and Procedures Notes 1 CRF450RX Clean after every race for dusty riding condition CRF450RRWE Clean after every moto for dusty riding condition 2 Replace every 2 years Replacement requires mechanical skill 3 Replace after the first breakin ride 4 Inspect after the first breakin ride 5 Replace the engine oil if the clutch discs and plates are replaced 6 Replace every year Maintenance Procedures I inspect and clean adjust lubricate or replace if necessary C clean A adjust L lubricate Rreplace
• Page 30 - English - : Maintenance Schedule CRF450RX Servicing Your Honda 25 Maintenance Schedule CRF450RX Perform the Preride Inspection page 13 at each scheduled maintenance period I Inspect and Clean Adjust Lubricate or Replace if necessary C Clean R Replace A Adjust L Lubricate 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 1Clean after every race for dusty riding condition 2Replace every 2 years Replacement requires mechanical skill 3Replace after the first breakin ride 4Inspect after the first breakin ride 5Replace the engine oil if the clutch discs and plates are replaced 6Replace every year FREQUENCY ITEMS CRF450RX NOTE Each race or about 35 hours Every 2 races or about 75 hours Every 4 races or about 150 hours Every 6 races or about 225 hours Every 8 races or about 300 hours Ref Page FUEL LINE NOTE 6 I R42 FUEL PUMP FILTER NOTE 6 R 46 51 THROTTLE OPERATION I 71 AIR FILTER NOTE 1 C 67 68 CRANKCASE BREATHER I 69 SPARK PLUG I 78 VALVE CLEARANCEDECOMPRESSOR SYSTEM NOTE 4 I 79 87 ENGINE OIL NOTE 3 NOTE 5 IR 63 ENGINE OIL FILTER NOTE 3 R 63 64 ENGINE IDLE SPEED I 72 PISTON AND PISTON RINGS R 90 92 PISTON PIN R 90 92 RADIATOR COOLANT NOTE 2 I 65 66 COOLING SYSTEM I 66 DRIVE CHAIN I L R 122 124 DRIVE CHAIN SLIDER I 122 DRIVE CHAIN ROLLER I 123 DRIVE SPROCKET I 124 DRIVEN SPROCKET I 124 BRAKE FLUID NOTE 2 I 115 116 BRAKE PADS WEAR I 117 BRAKE SYSTEM I 114 CLUTCH SYSTEM NOTE 5 I 73 77 CONTROL CABLES I L 132 EXHAUST PIPEMUFFLER I 126 130 SUSPENSION I 97 113 SWINGARMSHOCK LINKAGE L 30 113 FORK OIL NOTE 3 R 100 101 105 113 NUTS BOLTS FASTENERS I 133 175 177 WHEELSTIRES I 118 120 STEERING HEAD BEARINGS I 132 SIDE STAND I 121
• Page 31 - English - : Maintenance Schedule CRF450RRWE 26 Servicing Your Honda Maintenance Schedule CRF450RRWE Perform the Preride Inspection page 13 at each scheduled maintenance period I Inspect and Clean Adjust Lubricate or Replace if necessary C Clean R Replace A Adjust L Lubricate 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 1Clean after every moto for dusty riding condition 2Replace every 2 years Replacement requires mechanical skill 3Replace after the first breakin ride 4Inspect after the first breakin ride 5Replace the engine oil if the clutch discs and plates are replaced 6Replace every year FREQUENCY ITEMS CRF450RRWE NOTE Each race or about 25 hours Every 3 races or about 75 hours Every 6 races or about 150 hours Every 9 races or about 225 hours Every 12 races or about 300 hours Ref Page FUEL LINE NOTE 6 I R52 FUEL PUMP FILTER NOTE 6 R 52 61 THROTTLE OPERATION I 71 AIR FILTER NOTE 1 C 67 68 CRANKCASE BREATHER I 69 SPARK PLUG I 78 VALVE CLEARANCEDECOMPRESSOR SYSTEM NOTE 4 I 79 87 ENGINE OIL NOTE 3 NOTE 5 IR 63 ENGINE OIL FILTER NOTE 3 R 63 64 ENGINE IDLE SPEED I 72 PISTON AND PISTON RINGS R 90 92 PISTON PIN R 90 92 RADIATOR COOLANT NOTE 2 I 65 66 COOLING SYSTEM I 66 DRIVE CHAIN I L R 122 123 125 DRIVE CHAIN SLIDER I 122 DRIVE CHAIN ROLLER I 123 DRIVE SPROCKET I 124 DRIVEN SPROCKET I 124 BRAKE FLUID NOTE 2 I 115 116 BRAKE PADS WEAR I 117 BRAKE SYSTEM I 114 CLUTCH SYSTEM NOTE 5 I 73 77 CONTROL CABLES I L 132 EXHAUST PIPEMUFFLER I 126 130 SUSPENSION I 97 113 SWINGARMSHOCK LINKAGE L 30 113 FORK OIL NOTE 3 R 100 101 105 113 NUTS BOLTS FASTENERS I 133 175 177 WHEELSTIRES I 118 120 STEERING HEAD BEARINGS I 132
• Page 32 - English - : General Competition Maintenance Servicing Your Honda 27 General Competition Maintenance Perform maintenance on firm level ground using the side stand CRF450RX an optional workstand or equivalent support When tightening bolts nuts or screws start with the larger diameter or inner fasteners and tighten them to the specified torque using a crisscross pattern Use Honda Genuine Parts or their equivalents when servicing your CRF Clean parts in nonflammable high flash point cleaning solvent such as kerosene when disassembling Lubricate any sliding surfaces Orings and seals before reassembling Grease parts by coating or filling where specified After any engine disassembly always install new gaskets Orings cotter pins piston pin clips snap rings etc when reassembling After reassembly check all parts for proper installation and operation All Preride Inspection Items Refer to Preride Inspection on page 13
• Page 33 - English - : General Competition Maintenance 28 Servicing Your Honda Spark Plug Some nonresistor plugs may cause ignition problems Refer to the recommendations elsewhere in this manual for specific types so you will be sure to use the proper reach and heat range Replace periodically as specified in the Maintenance Schedule pages 25 26 Spark Plug Cap Install a small plastic wire band around the spark plug cap to reduce any possibility of it loosening or of water penetration Air Cleaner Clean and oil your air cleaner regularly because the volume of air able to pass through it has a great effect on performance Both engine performance and long term durability may be affected by an air cleaner that has deteriorated and allows dirt to pass Inspect the air cleaner closely each time its serviced for evidence of small tears or seam separation Keep a spare air cleaner oiled and ready to install sealed in a plastic bag Riding in dusty conditions may require servicing the air cleaner or replacing it with a preserviced air cleaner between races CRF450RXmotos CRF450RRWE Be careful not to over oil the air cleaner While it is important to oil the air cleaner thoroughly over oiling will cause an overall rich running condition probably more noticeable off idle and in low rpm performance 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 Pro Honda Foam Air Filter Sealer or an equivalent is handy for this because any dirt that penetrates this sealing area will show up clearly page 67 Use the Honda Genuine air cleaner or an equivalent air cleaner specified for your model Using the wrong Honda air cleaner or a nonHonda air cleaner which is not of equivalent quality may cause premature engine wear or performance problems Engine Oil and Filter Drain and replace engine oil often to ensure the greatest service life of the piston cylinder crankshaft transmission and clutch Also replace engine oil filter often to ensure the greatest service life Frequent changes will also assure consistent performance of power response both shifting and clutch action page 63
• Page 34 - English - : General Competition Maintenance Servicing Your Honda 29 Handgrips CRF450RXR Always use Honda Bond A Pro Honda Handgrip Cement USA only when replacing handgrips CRF450RWE Always use doublesided tape of Honda genuine parts when replacing handgrips Refer to an official Honda Service Manual page 186 for installation instructions Throttle GripHandlebar Grip Right throttle grip Align the index mark on the throttle grip with the index mark of the throttle pipe Left handlebar grip Align the index mark on the left handlebar grip with the paint mark on the handlebar Gaskets Always use new gaskets when reassembling components Fuel Line Refer to Fuel Line Inspection on pages 42 and 52 Check the fuel line for deterioration damage or leakage Replace the fuel line every year For added security you may choose to bind the handgrips to the handlebar and throttle pipe with safety wires to prevent the possibility of them loosening Position the twisted wire ends away from your palms and be sure to bend the wire ends well into the handgrip rubber so they will not snag your glove Engine Mounting Bolts and Nuts Make sure the engine mounting bolts and nuts are tightened to the proper torque specification Frame Because your CRF is a highperformance machine the frame should not be overlooked as part of your overall competition maintenance program Periodically inspect the frame closely for possible cracking or other damage It makes good racing sense Cylinder headCylinder Put a little grease on the dowel pins of the cylinder head and cylinder to prevent corrosion from dissimilar metals The tolerances are quite tight so its important to keep these dowels absolutely clean pages 93 94 Electrical Connectors Clean electrical connectors and wrap them with electrical tape to reduce the possibility of unwanted disconnections water shorts or corrosion Fuse Check the fuse before looking elsewhere for the cause of an electrical problem Battery The start button uses current from the battery Limited operation also allows the battery to discharge If you do not ride frequently we recommend that you charge the battery frequently see Battery Charging on page 135 If you do not expect to ride your CRF for at least 2 weeks we recommend you remove the battery or at least disconnect the battery cables negative cable first Fork OilPerformance Disassemble clean and inspect the fork and replace the oil regularly Contamination due to the tiny metal particles produced from the normal action of the fork as well as normal oil breakdown will deteriorate the performance of the suspension Refer to an official Honda Service Manual page 186 Use only Pro Honda HP Fork Oil A1500 or an equivalent which contains special additives to assure maximum performance of your CRFs front suspension
• Page 35 - English - : General Competition Maintenance 30 Servicing Your Honda Brake Fluid Replacement Refer to Brake Pad Wear on page 117 Brake Caliper Inspection Be sure both the front and rear calipers are able to move freely on the caliper pin and caliper bracket pins Check pad thickness periodically and replace the pads when minimum thickness is reached If the brakes fade when they are hot inspect the pads for glazing or damage and replace if necessary Brake Fluid Replacement Refer to an official Honda Service Manual page 186 for brake fluid replacement instructions Replace the brake fluid in the brake system every 2 years Replace the fluid more frequently if you subject your brakes to severe use Heavy braking heats the brake fluid and it may deteriorate sooner than expected Any type of riding that requires frequent use of the brakes such as in tight woods can shorten the service life of brake fluid Spokes Check spoke tension frequently between the first few rides As the spokes spoke nuts and rim contact points seatin the spokes may need to be retightened Once past this initial seatingin period the spokes should hold their tension Still be sure your race CRF450RXmoto CRF450R RWE maintenance program includes checking spoke tension and overall wheel condition on a regular basis page 118 Nuts Bolts Etc Application of a thread locking agent to essential fasteners offers added assurance and security Remove the nuts clean the threads of both the nuts and bolts apply Pro Honda Hondalock or an equivalent and tighten to the specified torque page 175 177 Bleed Hole After every race CRF450RXmoto CRF450RRWE check the bleed hole below the water pump cover for leakage Clean away any clogged dirt or sand if necessary Check for signs of seal leakage If water leaks through the bleed hole replace the mechanical seal If oil leaks through the bleed hole replace the oil seal Make sure that there is no continuous coolant leakage from the bleed hole while operating the engine A small amount of coolant weeping from the bleed hole is normal See an official Honda Service Manual or consult your dealer for replacing the mechanical seal or oil seal Both seals should be replaced at the same time Suspension Linkage Lubrication Disassemble clean inspect and lubricate all suspension linkage pivot bearings with molybdenum disulfide grease containing more than 3 molybdenum disulfide additive Moly Paste 77 after each 75 hours of running time in order to maintain proper suspension performance and minimize component wear Steering Head Bearings Periodically clean inspect and regrease the steering head bearings especially if wet muddy or extremely dusty courses are encountered often Use urea based multipurpose grease designed for high temperature high pressure performance example EXCELITE EP2 manufactured by KYODO YUSHI Japan or equivalent Footpegs Worn footpeg teeth can be repaired by filing the grooves between the teeth with a triangular shaped file Be aware that filing them too sharp will reduce boot sole lifespan Sharpen only the points of the teeth Filing the grooves deeper will weaken the footpegs Be sure the pegs are free to pivot freely and that the pivot pin retaining cotter pins are in good condition Swingarm Do not attempt to weld or otherwise repair a damaged swingarm Welding will weaken the swingarm Swingarm Pivot Lubrication Clean inspect and lubricate the swingarm and suspension linkage pivots with molybdenum disulfide grease containing more than 3 molybdenum disulfide additive Moly Paste 77 Be sure all of the dust seals are in good condition Throttle Control Remove the throttle control every few rides clean the inside of the throttle pipe and handlebar thoroughly Inspect the cable carefully for kinks or other damage that may restrict throttle control in anyway Move the handlebar from lock to lock to be sure there is no cable interference Make certain the throttle operation is perfect after servicing and inspecting
• Page 36 - English - : Before amp After Competition Maintenance Servicing Your Honda 31 Before amp After Competition Maintenance After practice or between races CRF450RX motos CRF450RRWE you have a chance to make additional checks and adjustments Clean accumulated dirt from under the fenders and off the wheels suspension components handgrips controls and footpegs A stiff nylon parts cleaning brush works well Check tire air pressure Check spoke tension and make sure the rim locks are secure Check to make sure the sprocket bolts and nuts are secure Clean the sides of the drive chain with a stiff nylon partscleaning brush Lubricate and adjust the chain as necessary Do not perform maintenance while engine is running Injury to your fingers or hands may result After adjustment check that the chain adjuster index marks 1 are in the same position on each side This will ensure that the rear wheel is in proper alignment and allow maximum performance from the rear disc brake Maintaining proper wheel alignment will also extend brake pad lifespan Suspend the front wheel above the ground and use the pressure release screws 2 to release the builtup pressure in the forks This pressure is caused by normal fork action while riding Between Races CRF450RXMotos CRF450RRWE amp Practice Maintenance 1 chain adjuster index marks 1 2 pressure release screw 2
• Page 37 - English - : 32 Servicing Your Honda Before amp After Competition Maintenance It is important to the long term performance of your CRF to practice a consistent maintenance program Right after the event is a good time to begin your next maintenance cycle After Race CRF450RXMoto CRF450RRWE Lubrication Apply a light coating of rustinhibiting oil to the drive sprocket and any steel portions of the chassis or engine where the paint has worn away This will prevent rusting of the exposed metal Apply rustinhibiting oil more heavily if the event was particularly wet or muddy Take care to avoid spraying any oil near the brake pads or the brake discs Take care to prevent catching your fingers between the chain and sprocket 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 Routine Cleaning If your CRF is only slightly dirty it is best to clean it by hand with the aid of a stiff bristled nylon brush and some clean rags Take care to prevent catching your fingers between the chain and sprocket A variety of reasonably priced cleaning brushes are available from variety drug food and hardware stores Some of these brushes are extremely useful in removing dirt from the many tight contours of the metal pieces of your CRF Avoid using stiff abrasive brushes on the plastic or rubber parts If your CRF was exposed to sea air or salt water rinse it as soon as possible after the event dry it and apply a spray lubricant to all metal parts If you decide to wash your CRF or use cleaners refer to Appearance Care page 136 After Competition Maintenance
• Page 38 - English - : Maintenance Component Locations Servicing Your Honda 33 Maintenance Component Locations clutch lever front brake fluid reservoir front brake lever throttle grip radiator cap fuel fill cap rear suspension rebound damping adjuster rear suspension high speed compression damping adjuster rear suspension low speed compression damping adjuster front suspension compression damping adjuster both left and right fast idle knob engine idle speed engine oil filter crankcase breather tube drive chain front brake caliper engine oil fill cap air cleaner rear suspension spring preload adjuster spark plug engine oil drain bolt rear brake pedal rear brake fluid reservoir rear brake caliper front suspension rebound damping adjuster both left and right battery
• Page 39 - English - : Seat 34 Servicing Your Honda Seat Refer to Important Safety Precautions on page 23 Removal 1 Remove the seat mounting bolts 1 and collars 2 2 Remove the seat 3 by pulling it backward Installation 1 Install the seat while aligning the seat front prong 1 with the slot 2 of the fuel tank and seat center prongs 3 with the seat support base slots 4 2 Install and tighten the collars 5 and seat mounting bolts 6 to the specified torque 19 lbfft 26 Nm 27 kgfm 1 seat mounting bolts 3 seat 2 collars 3 1 12 1 seat front prong 4 seat support base slots 2 slot 5 collars 3 seat center prongs 6 seat mounting bolts 1 3 42 6 5 6
• Page 40 - English - : Fuel Tank CRF450RX contd Servicing Your Honda 35 Fuel Tank CRF450RX Refer to Important Safety Precautions on page 23 Removal 1 Remove the seat page 34 2 Remove the shroud A bolt 1 shroud B bolt 2 shroud C bolt 3 and shroud D bolt 4 3 Slide the shroud 5 toward the up to separate them from the air cleaner housing cover 6 and then remove the shroud The right and left shrouds can be removed in the same manner 4 Install a hose clamp 7 to the breather tube 8 and set the hose clamp securely 5 Pull the breather tube out of steering stem nut 9 6 Remove the fuel tank bolt 10 and collar 11 7 Unhook the fuel tank band 12 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 Do not support the fuel tank by the fuel feed hose 15 1 shroud A bolt 2 shroud B bolt 3 shroud C bolt 4 shroud D bolt 5 shroud 6 air cleaner housing cover 6 3 2 1 5 4 7 hose clamp 9 steering stem nut 8 breather tube 10 fuel tank bolt 12 fuel tank band 11 collar 8 7 9 11 10 12 WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Stop the engine and keep heat sparks and flame away Handle fuel only outdoors Wipe up spills immediately 13 fuel tank 14 fuel tank stopper cable 15 fuel feed hose 13 14 15
• Page 41 - English - : 36 Servicing Your Honda Fuel Tank CRF450RX 9 Check for interference between the frame and tank and adjust the cushion rubbers 16 on the both sides of the frame if necessary Installation 1 Install the fuel tank 1 on the frame 2 Install and tighten the collar 2 and fuel tank bolt 3 to the specified torque 7 lbfft 10 Nm 10 kgfm 3 Hook the fuel tank band 4 4 Put the breather tube 5 in the steering stem nut 6 5 Remove the hose clamp 7 from the breather tube 6 Slide the shroud 8 toward the down so that the shroud tab 9 and the slot 10 on the air cleaner housing cover 11 is aligned 7 Install the shroud D bolt 12 shroud C bolt 13 shroud B bolt 14 and shroud A bolt 15 Tighten the shroud A and B bolts to the specified torque 7 lbfft 10 Nm 10 kgfm Tighten the shroud C and D bolts to the specified torque 38 lbfft 52 Nm 05 kgfm The right and left shrouds can be installed in the same manner 8 Install the seat page 34 16 cushion rubbers 16 335 010 in 850 25 mm 1 fuel tank 3 fuel tank bolt 2 collar 4 fuel tank band 5 breather tube 7 hose clamp 6 steering stem nut 2 4 3 1 5 7 6 8 shroud 12 shroud D bolt 9 tab 13 shroud C bolt 10 slot 14 shroud B bolt 11 air cleaner housing cover 15 shroud A bolt 8 13 14 15 10 12 9 11
• Page 42 - English - : Fuel Tank CRF450RRWE contd Servicing Your Honda 37 Fuel Tank CRF450RRWE Refer to Important Safety Precautions on page 23 Removal 1 Remove the seat page 34 2 Remove the shroud A bolt 1 shroud B bolt 2 and shroud C bolt 3 3 Slide the shroud 4 toward the up to separate them from the air cleaner housing cover 5 and then remove the shroud The right and left shrouds can be removed in the same manner 4 Install a hose clamp 6 to the breather tube 7 and set the hose clamp securely 5 Pull the breather tube out of steering stem nut 8 6 Remove the fuel tank bolts 9 and washers 10 7 Lift the fuel tank 11 out of the frame and hang it to the left of the frame Check the fuel tank stopper cable 12 for deterioration kinks or other damage Do not support the fuel tank by the fuel feed hose 13 The fuel tank is made of titanium material Since the fuel tank has not been painted it might be discolored with mud and dust To remove mud or dust use a sponge or soft cloth and a stainless steel kitchen detergent then rinse well clean water After washing rinse with plenty of water and dry with a clean cloth 1 shroud A bolt 2 shroud B bolt 3 shroud C bolt 4 shroud 5 air cleaner housing cover 4 5 3 2 1 6 hose clamp 8 steering stem nut 7 breather tube 9 fuel tank bolts 10 washers 7 6 8 10 9 10 WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Stop the engine and keep heat sparks and flame away Handle fuel only outdoors Wipe up spills immediately 11 fuel tank 12 fuel tank stopper cable 13 fuel feed hose 11 12 13
• Page 43 - English - : 38 Servicing Your Honda Fuel Tank CRF450RRWE 8 Check for interference between the frame and tank and check the cushion rubbers 14 on both sides of the frame for hardening or cracks Do not ride your CRF if the cushion rubbers have been removed It may cause fuel tank cracking Installation 1 Install the fuel tank 1 on the frame 2 Install and tighten the washers 2 and fuel tank bolts 3 to the specified torque 7 lbfft 10 Nm 10 kgfm 3 Put the breather tube 4 in the steering stem nut 5 4 Remove the hose clamp 6 from the breather tube 5 Slide the shroud 7 toward the down so that the shroud tab 8 and the slot 9 on the air cleaner housing cover 10 is aligned 6 Install the shroud C bolt 11 B bolt 12 and shroud A bolt 13 Tighten the shroud A and B bolts to the specified torque 7 lbfft 10 Nm 10 kgfm Tighten the shroud C bolt to the specified torque 38 lbfft 52 Nm 05 kgfm The right and left shrouds can be installed in the same manner 7 Install the seat page 34 14 cushion rubbers 14 1 fuel tank 2 washers 3 fuel tank bolts 4 breather tube 6 hose clamp 5 steering stem nut 2 1 3 2 4 6 5 7 shroud 11 shroud C bolt 8 tab 12 shroud B bolt 9 slot 13 shroud A bolt 10 air cleaner housing cover 7 11 12 13 10 9 8
• Page 44 - English - : Subframe contd Servicing Your Honda 39 Subframe Refer to Important Safety Precautions on page 23 Removal 1 Remove the seat page 34 2 Remove the right and left shrouds page 35 page 37 3 Remove the right and left mufflers page 126 4 Remove the right and left exhaust springs A then remove the right and left muffler mounting A bolts page 130 CRF450RWE only 5 Remove the seat support base mounting bolts 1 and collars 2 6 Disconnect the starterignition relay connector 3 lift the seat support base 4 and hang it to the left of the subframe 5 7 Disconnect the breather tube 6 and IAT sensor connector 7 8 Loosen the air cleaner connecting tube clamp screw 8 9 Disconnect the negative terminal 9 from the battery 10 10 Remove the start magnetic switch stay bolt 11 and plastic wire band 12 Pull out the start magnetic switch 13 Remove the start magnetic switch cover 14 Remove the battery cable terminal bolt 15 and disconnect the battery cable terminal 16 from the start magnetic switch 1 seat support base mounting bolts 2 collars 3 starterignition relay connector 4 seat support base 5 subframe 1 2 4 5 3 6 breather tube 7 IAT sensor connector 8 air cleaner connecting tube clamp screw 9 negative terminal 10 battery 8 6 7 9 10 11 start magnetic switch stay bolt 12 wire band 13 start magnetic switch 14 start magnetic switch cover 15 battery cable terminal bolt 16 battery cable terminal 16 15 14 1311 12
• Page 45 - English - : 40 Servicing Your Honda Subframe 11 Remove the subframe lower bolts 17 and upper bolts 18 Remove the subframe 5 while disconnecting the air cleaner connecting tube 19 Installation 1 Align the upper and lower ends of the subframe to the main frame while connecting the air cleaner box 1 to the air cleaner connecting tube 2 and loosely install all subframe bolts 2 Tighten the subframe upper bolts 3 first and then tighten the lower bolts 4 to the specified torque subframe upper bolts 24 lbfft 32 Nm 33 kgfm subframe lower bolts 36 lbfft 49 Nm 50 kgfm 3 Connect the battery cable terminal 5 to the start magnetic switch 6 Install and tighten the battery cable terminal bolt 7 to the specified torque 52 lbfft 7 Nm 07 kgfm Install the start magnetic switch cover 8 Install the start magnetic switch Install and tighten the start magnetic switch stay bolt 9 to the specified torque 9 lbfft 12 Nm 12 kgfm Install the plastic wire band 10 5 subframe 17 subframe lower bolts 18 subframe upper bolts 19 air cleaner connecting tube 5 17 17 18 19 18 1 air cleaner box 2 air cleaner connecting tube 3 subframe upper bolts 4 subframe lower bolts 1 2 Left side Right side 3 4 4 3 5 battery cable terminal 8 start magnetic switch cover 6 start magnetic switch 7 battery cable terminal bolt 9 start magnetic switch stay bolt 10 wire band 5 7 8 69 10
• Page 46 - English - : Servicing Your Honda 41 Subframe 4 Connect the negative terminal 11 to the battery 12 Tighten the negative terminal bolt 13 to the specified torque 15 lbfft 20 Nm 02 kgfm 5 Make sure that the air cleaner box and the air cleaner connecting tube are correctly connected and tighten the air cleaner connecting tube clamp screw 14 so the distance between the clamp ends is 024 035 in 6 9 mm 6 Connect the breather tube 15 and IAT sensor connector 16 7 Connect the starterignition relay connector 17 and install the seat support base 18 8 Install and tighten the collars 19 and seat support base mounting bolts 20 to the specified torque 7 lbfft 10 Nm 10 kgfm 9 Tighten the right and left muffler mounting A bolts and install the right and left exhaust springs A page 133 CRF450RWE only 10 Install the left and right mufflers page 127 11 Install the right and left shrouds page 36 page 38 12 Install the seat page 34 11 negative terminal 12 battery 13 negative terminal bolt 12 11 13 14 air cleaner connecting tube clamp screw 15 breather tube 16 IAT sensor connector 15 14 024 035 in 6 9 mm 14 16 17 starterignition relay connector 18 seat support base 19 collars 20 seat support base mounting bolts 17 18 20 19
• Page 47 - English - : Fuel System CRF450RX 42 Servicing Your Honda Fuel System CRF450RX Refer to Important Safety Precautions on page 23 Use only unleaded fuel in your CRF If you ride your CRF in a country where leaded fuel might be available take precautions to use only unleaded fuel Your engine is designed to use any unleaded gasoline that has a pump octane number of 91 or higher Gasoline pumps at service stations normally display the pump octane number For information on the use of oxygenated fuels see page 178 Use of lower octane gasoline can cause persistent pinging or spark knock a louder rapping noise which if severe can lead to engine damage Light pinging experienced while operating under a heavy load such as climbing a hill is no cause for concern If pinging or spark knock occurs at a steady engine speed under normal load change brands of gasoline If pinging or spark knock persists consult your dealer Never use stale or contaminated gasoline Avoid getting dirt dust or water in the fuel tank 1 To open the fuel fill cap 1 pull the breather tube 2 out of the steering stem nut 3 Turn the fuel fill cap counterclockwise and remove it 2 Add fuel until the level reaches the bottom of the filler neck 4 Fuel Tank Capacity 225 US gal 85 ℓ Be careful not to damage the fuel pump while filling the fuel tank Avoid overfilling the tank There should be no fuel in the filler neck 3 Close the fuel fill cap and insert the breather tube into the steering stem nut 1 Hang the fuel tank to the left side of the frame page 35 2 Remove the fuel quick connect fitting cover 1 3 Check the fuel line 2 for cracks deterioration damage or leakage Replace the fuel line if necessary 4 Install the fuel quick connect fitting cover 5 Install the fuel tank page 36 Fuel Type Unleaded Pump Octane Number 91 or higher Refueling Procedure 1 fuel fill cap 3 steering stem nut 2 breather tube 4 filler neck bottom 3 4 2 1 WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Stop the engine and keep heat sparks and flame away Handle fuel only outdoors Wipe up spills immediately Fuel Line Inspection 1 fuel quick connect fitting cover 2 fuel line 2 1
• Page 48 - English - : Fuel System CRF450RX contd Servicing Your Honda 43 1 Hang the fuel tank to the left side of the frame page 35 2 Disconnect the fuel pump connector 1 3 Reposition the fuel tank and start the engine and let it idle until the engine stalls Disconnection 1 Relieve the fuel pressure this page 2 Hang the fuel tank to the left side of the frame 3 Remove the fuel quick connect fitting cover 1 from the fuel pump 2 4 Check the fuel quick connect fitting 3 for dirt and clean if necessary 5 Remove the bolt 4 clamp and setting rubber 5 6 Place a shop towel 6 over the fuel quick connect fitting Fuel Pressure Relieving 1 fuel pump connector 1 Fuel Line Replacement 1 fuel quick connect fitting cover 2 fuel pump 3 fuel quick connect fitting 4 bolt 5 clamp and setting rubber 1 23 Fuel pump sideInjector side 4 5 6 shop towel Injector side Fuel pump side 6
• Page 49 - English - : 44 Servicing Your Honda Fuel System CRF450RX 7 Unlock the slide retainer 7 of the quick connect fitting by completely pulling it up Release the fuel quick connect fitting from the fuel joint 8 while holding the connector housing 9 Use a shop towel to absorb the remaining fuel in the fuel feed hose Be careful not to damage the hose or other parts Do not use tools Dirt intruding into the connector housing may cause slide retainer sticking 8 Remove the rubber cover 10 from the fuel joint of the fuel pump 9 To prevent damage and keep foreign matter out cover the disconnected connector 11 and fuel joint 8 with plastic bags 12 Connection 1 Install the rubber cover 1 onto the fuel joint 2 of the fuel pump as shown 2 Be sure that the slide retainer 3 is completely pulled up before connecting the quick connect fitting Do not bend or twist the fuel feed hose Do not reuse the kinked or damaged fuel hose Do not use gloves or a shop towel while installing the quick connect fitting WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Stop the engine and keep heat sparks and flame away Handle fuel only outdoors Wipe up spills immediately 7 slide retainer 8 fuel joint 9 connector housing Injector side Fuel pump side 7 9 8 7 8 9 10 rubber cover 8 fuel joint 11 disconnected connector 12 plastic bags 10 12 11 8 1 rubber cover 2 fuel joint 3 slide retainer 1 2 3
• Page 50 - English - : Servicing Your Honda 45 Fuel System CRF450RX 3 Connect the quick connect fitting to the fuel joint 2 until you hear the click while holding the connector housing 4 Lock the slide retainer 3 by pushing it until you hear the click If it is hard to connect put a small amount of engine oil on the pipe end of the fuel joint 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 5 Install the setting rubber 5 clamp 6 and bolt 7 by aligning the clamp tab 8 with the groove 9 of the stay Tighten the bolt securely 6 Install the fuel quick connect fitting cover 10 Be sure the rubber cover 1 is properly installed between the fuel quick connect fitting cover and fuel pump 7 Increase the fuel pressure page 51 2 fuel joint 3 slide retainer 4 connector housing Injector side Fuel pump side 3 4 2 4 3 2 5 setting rubber 8 clamp tab 6 clamp 9 groove 7 bolt 6 7 5 9 8 1 rubber cover 10 fuel quick connect fitting cover 10 1
• Page 51 - English - : 46 Servicing Your Honda Fuel System CRF450RX Empty the fuel tank by transferring fuel into an approved gasoline container using a commercially available hand siphon or an equivalent method Be careful not to damage the fuel pump while draining the fuel in the fuel tank Removal 1 Relieve the fuel pressure page 43 2 Disconnect the fuel line from the fuel pump page 43 3 Remove the fuel tank 1 by releasing the stopper cable 2 from the hook 3 of the frame 4 Pull the harness band clip 4 while pressing both side of the anchor and disconnect it 5 Remove the fuel pump mounting bolts 5 stopper cable guide 6 stopper cable 2 washers 7 collars 8 conical spring washers 9 and fuel pump plate 10 while holding the fuel tank Fuel Pump Filter Replacement WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Stop the engine and keep heat sparks and flame away Handle fuel only outdoors Wipe up spills immediately 1 fuel tank 3 frame hook 2 stopper cable 4 harness band clip 2 3 1 4 2 stopper cable 5 fuel pump mounting bolts 6 stopper cable guide 7 washers 8 collars 9 conical spring washers 10 fuel pump plate 6 7 2 5 8 9 10