Contents
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 (Malfunction Indicator Lamp) ................. 7
MIL Blink Pattern ......................................... 7
Current DTC/Freeze DTC............................. 7
Circuit Inspection .......................................... 8
DTC Index..................................................... 9
Engine Mode &
Launch Control System Indicator ................... 10
Engine Mode Indicator................................ 10
Launch Control System Indicator ............... 10
BEFORE RIDING......................................... 11
Are You Ready to Ride? ................................ 12
Is Your Motorcycle Ready to Ride? ............... 13
Pre-ride Inspection ...................................... 13
BASIC OPERATING INSTRUCTIONS .... 15
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
SERVICING YOUR HONDA ......................21
Before You Service Your Honda
The Importance of Maintenance .....................22
Maintenance Safety .........................................23
Important Safety Precautions.......................23
Maintenance Schedule ....................................24
Maintenance Schedule (CRF450RX) .............25
Maintenance Schedule (CRF450R/RWE) ......26
General Competition Maintenance .................27
Before & After Competition Maintenance .....31
Between Races (CRF450RX)/Motos
(CRF450R/RWE) & Practice Maintenance
...31
After Competition Maintenance ..................32
Service Preparations
Maintenance Component Locations ...............33
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
Chassis
Suspension ...................................................... 97
Brakes ........................................................... 114
Wheels .......................................................... 118
Tires & Tubes ............................................... 119
Side Stand (CRF450RX) .............................. 121
Drive Chain .................................................. 122
Exhaust Pipe/Muffler .................................... 126
Additional Maintenance Procedures ............. 132
Electrical
Battery .......................................................... 134
Appearance Care .......................................... 136
2019 CRF450RX/R/RWE
31MKE620
M
OM 16609 (1803)
Contents
Contents
ADJUSTMENTS FOR COMPETITION
... 139
Engine Mode Select Button .......................... 140
Current Mode ............................................ 140
Mode Selection.......................................... 140
HRC-Launch Control System ...................... 141
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 Pre-Load............. 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 Height/Angle..................................... 156
Wheelbase ................................................. 156
Gearing ......................................................... 157
Tire Selection for Track Conditions ............. 158
Personal Fit Adjustments .............................. 159
Control Positioning ................................... 159
Handlebar Position, Width & Shape ......... 159
TIPS...............................................................161
Transporting Your Motorcycle .....................162
Storing Your Honda ......................................163
Preparation for Storage ..............................163
Removal from Storage ...............................163
You & the Environment ................................164
Troubleshooting ............................................165
TAKING CARE OF THE
UNEXPECTED ............................................167
If a Fuse Blows .............................................168
If Your Battery Is Low (or Dead) .................169
TECHNICAL INFORMATION.................171
Vehicle Identification ....................................172
Serial Numbers ..........................................172
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
CONSUMER INFORMATION .................185
Authorized Manuals ......................................186
Contacting Honda .........................................187
Your Honda Dealer .......................................188
INDEX .......................................................... 190
QUICK REFERENCE
2019
Honda CRF450RX/CRF450R/CRF450RWE
OWNER’S MANUAL & COMPETITION HANDBOOK
Introduction
Introduction
Introduction
Congratulations on choosing your Honda CRF off-
road racing (CRF450RX)/motocross (CRF450R/
RWE), motorcycle.
When you own a Honda, you’re part of a
worldwide family of satisfied customers – people
who appreciate Honda’s reputation for building
quality into every product.
Your CRF is a high performance racing
motorcycle that utilizes the latest off-road racing
(CRF450RX)/motocross (CRF450R/RWE)
technology and is intended for competition use in
sanctioned, closed-course events by experienced
riders only.
Be aware that off-road racing (CRF450RX)/
motocross (CRF450R/RWE) 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 it’s just as
important to observe the break-in guidelines, and
perform all the pre-ride and other periodic checks
detailed in this manual.
You should also read the owner’s manual before
you ride. It’s 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: www.powersports.honda.com.
Canada: www.honda.ca.
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
PGM-FI Programmed Fuel Injection
TDC Top Dead Center
TP sensor Throttle Position sensor
Safety Messages
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 don’t follow instructions.
You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be HURT if you don’t follow instructions.
DANGER
WARNING
CAUTION
Motorcycle Safety
Motorcycle Safety 1
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 Precautions.........................2
Accessories & Modifications.............................3
Safety Labels......................................................4
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 you’re 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.
Don’t Drink and Ride.
Alcohol and riding don’t mix. Even one drink can
reduce your ability to respond to changing
conditions, and your reaction time gets worse with
every additional drink. So don’t drink and ride, and
don’t 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.
Lithium-Ion (Li-Ion) Battery.
If you smell an unusual odor coming from the
lithium-ion (li-ion) 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
Accessories & Modifications
Motorcycle Safety 3
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.
Accessories & Modifications
WARNING
Improper accessories or modifications
can cause a crash in which you can be
seriously hurt or killed.
Follow all instructions in this owner’s
manual regarding modifications and
accessories.
Safety Labels
4 Motorcycle Safety
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)
Instruments & Controls
Instruments & Controls 5
Read this section carefully before you ride. It
presents the location of the basic controls on your
CRF.
Operation Component Locations
.......................6
MIL (Malfunction Indicator Lamp) ...................7
MIL Blink Pattern..........................................7
Current DTC/Freeze DTC .............................7
Circuit Inspection...........................................8
DTC Index .....................................................9
Engine Mode &
Launch Control System Indicator ....................10
Engine Mode Indicator ................................10
Launch Control System Indicator................10
Operation Component Locations
6 Instruments & Controls
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
shift lever
fast idle knob (engine idle speed)
side stand (CRF450RX)
rear brake pedal
MIL (Malfunction Indicator Lamp)
Instruments & Controls 7
The MIL (1) on your CRF keeps you informed,
alerts you to possibl
e 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 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.
The MIL will blink the appropriate DTC number if
the ECM detects an active problem while the
engine is running at less than 4,000 rpm.
The MIL will stay on when engine speed is over
4,000 rpm.
The MIL has two types of blinks: a long blink and
short blink. The long blinking lasts for 1.2 seconds,
the short blinking lasts for 0.4 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
sec
onds, then goe
s 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 c
hange
the
engine modes. However, you cannot c
hange
the
engine modes when the indicator is b
linking
DTC 1, 2 or 8.
After an engine mode is selected, the MIL
restar
ts blinking the current DTC number.
– In the case that the EC
M 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 DTC/Freeze DTC
8 Instruments & Controls
MIL (Malfunction Indicator Lamp)
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.
Remember, circuit inspection is not a “cure-all” for
other problems in your engine’s PGM-FI 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)
Instruments & 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 and/or refer to an official Honda Service
Manual (page 186) for troubleshooting of the PGM-FI symptom.
DTC Index
MIL blinks
Function Failure Symptom/Fail-safe 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
Engine Mode & Launch Control System Indicator
10 Instruments & Controls
Engine Mode & Launch Control System 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 comes on
(purple) 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.
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)
Before Riding
Before Riding 11
Before each ride, you n
eed 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 Ride? ..................................12
Is Your Motorcycle Ready to Ride? ................13
Pre-ride Inspection.......................................13
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 owner’s
manual, make sure you understand the safety
messages, and know how to operate the controls.
Before each ride, it’s 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 you’re 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.
Is Your Motorcycle Ready to Ride?
Before Riding 13
Competitive riding can be tough on a motorcycle,
so it’s important to inspect your CRF and correct
any
problems you find before each ride. Check the
following items (page numbers are at the 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
• F
ront 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 pipe/Muffler 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 bolt/nut, wire harness
connectors)......................................... 175-177
• 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 pre-ride inspection
before every ride and correct any
problems.
Pre-ride Inspection
14 Before Riding
BLANK PAGE
Basic Operating Instructions
Basic Operating Instructions 15
This section gives basic information on how to
start and stop your engine as well as break-in
guidelines.
Safe Riding Precautions
...............................1
6
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
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 CRF’s 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.
Safe Riding Precautions
WARNING
Running the engine of your vehicle while
in an enclosed or even partially enclosed
area can cause a rapid build-up of toxic
carbon monoxide gas.
Breathing this colorless, odorless gas can
quickly cause unconsciousness and lead
to death.
Only run your vehicle's engine when it is
located in a well ventilated area outdoors.
Side Stand (CRF450RX)
(1) side stand
(1)
Starting & Stopping the Engine
Basic Operating Instructions 17
Always follow the proper starting procedure
describe
d 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
first-time start-up 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 50°F (10°C) 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)
18 Basic Operating Instructions
Starting & 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 0.8 seconds, then goes off. If the
MIL/engine 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)
Parking (CRF450RX)
Basic Operating Instructions 19
Lower the side stand to support your CRF.
Always choose a level surface to park.
Break-in Guidelines
20 Basic Operating Instructions
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:
• piston is replaced
• piston rings are replaced
• cylinder is replaced
• crankshaft or crank bearings are replaced
Servicing Your Honda
Servicing Your Honda 21
Keeping your CRF well maintained is absolutely
essential to your safety. It’s also a good way to
protect your investment, g
et 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 step-by-step instructions for specific
maintenance tasks. You’ll 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 dealer’s parts department.
Before You Service Your Honda
The Importance of Maintenance ......................22
Maintenance Safety..........................................23
Important Safety Precautions.......................23
Maintenance Schedule .....................................24
General Competition Maintenance ..................27
Before & After Competition Maintenance ......31
Between Races (CRF450RX)/Motos
(CRF450R/RWE) & Practice Maintenance.31
After Competition Maintenance ..................32
Service Preparations
Maintenance Component Locations ................33
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
Chassis
Suspension....................................................... 97
Front Suspension Inspection ....................... 97
Rear Suspension Inspection....................... 113
Brakes ............................................................ 114
Wheels ........................................................... 118
Tires & Tubes ................................................ 119
Side Stand (CRF450RX) ............................... 121
Drive Chain ................................................... 122
Exhaust Pipe/Muffler..................................... 126
Additional Maintenance Procedures.............. 132
Electrical
Battery ........................................................... 134
Appearance Care ........................................... 136
The Importance of Maintenance
22 Servicing Your Honda
The Importance of Maintenance
Keeping your CRF well-maintained is absolutely
essential to your safety. It’s also a good way to get
maximum performance during each race
(CRF450RX)/moto (CRF450R/RWE).
Careful pre-ride inspections and good maintenance
are especially important because your CRF is
designed to be ridden in off-road 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 owner’s manual.
Maintenance Safety
Servicing Your Honda 23
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 non-flammable (high flash point)
solvent such as kerosene –not gasoline– to
clean parts. Keep cigarettes, sparks, and flames
away from all fuel-related 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 owner’s manual.
Important Safety Precautions
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 (CRF450RX)/motos
(CRF450R/RWE) and riding hours. To avoid
overlooking required service, we urge you to
develop a convenient way to record the number of
races (CRF450RX)/motos (CRF450R/RWE) 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 pre-ride 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.
(CRF450R/RWE)
Clean after every moto for dusty riding
condition.
2. Replace every 2 years. Replacement requires
mechanical skill.
3. Replace after the first break-in ride.
4. Inspect after the first break-in 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
R: replace
Maintenance Schedule (CRF450RX)
Servicing Your Honda 25
Perform the Pre-ride 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: 1.Clean after every race for dusty riding condition.
2.Replace every 2 years. Replacement requires mechanical skill.
3.Replace after the first break-in ride.
4.Inspect after the first break-in ride.
5.Replace the engine oil, if the clutch discs and plates are replaced.
6.Replace every year.
FREQUENCY
ITEMS
CRF450RX
NOTE
Each race or
about
3.5 hours
Every 2 races or
about
7.5 hours
Every 4 races or
about
15.0 hours
Every 6 races or
about
22.5 hours
Every 8 races or
about
30.0 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 CLEARANCE/DECOMPRESSOR 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 PIPE/MUFFLER I 126 – 130
SUSPENSION I 97, 113
SWINGARM/SHOCK LINKAGE L
30, 113
FORK OIL
(NOTE 3)
R
1
00, 101,
105 – 113
NUTS,
BOLTS, FASTENERS I 133, 175 – 177
WHEELS/TIRES I 118 – 120
STEERING HEAD BEARINGS I 132
SIDE STAND I 121
Maintenance Schedule (CRF450R/RWE)
26 Servicing Your Honda
Perform the Pre-ride 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: 1.Clean after every moto for dusty riding condition.
2.Replace every 2 years. Replacement requires mechanical skill.
3.Replace after the first break-in ride.
4.Inspect after the first break-in ride.
5.Replace the engine oil, if the clutch discs and plates are replaced.
6.Replace every year.
FREQUENCY
ITEMS
CRF450R/RWE
NOTE
Each race or
about
2.5 hours
Every 3 races or
about
7.5 hours
Every 6 races
or about
15.0 hours
Every 9 races
or about
22.5 hours
Every 12 races
or about
30.0 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 CLEARANCE/DECOMPRESSOR 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 125
DRIVEN SPROCKET I 125
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 PIPE/MUFFLER I 126 – 130
SUSPENSION I 97, 113
SWINGARM/SHOCK LINKAGE L
30, 113
FORK OIL
(NOTE 3) R
100, 101,
105 – 113
NUTS, BOLTS, FASTENERS I 133, 175 – 177
WHEELS/TIRES I 118 – 120
STEERING HEAD BEARINGS I 132
General Competition Maintenance
Servicing Your Honda 27
Perform mainte
nance 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 non-flammable (high flash point)
cleaning solvent (such as kerosene) when
disassembling. Lubricate any sliding surfaces,
O-rings, and seals before reassembling. Grease
parts by coating or filling where specified.
After any engine disassembly, always install new
gaskets, O-rings, cotter pins, piston pin clips, snap
rings, etc. when reassembling. After reassembly,
check all parts for proper installation and
operation.
All Pre-ride Inspection Items
Refer to Pre-ride Inspection on page 13.
General Competition Maintenance
28 Servicing Your Honda
Spark Plug
Some non-resistor 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 it’s 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
pre-serviced air cleaner between races (CRF450RX)/motos
(CRF450R/RWE). 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 non-Honda 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).
General Competition Maintenance
Servicing Your Honda 29
Handgrips
Always use Honda Bond A, Pro Honda Handgrip Cement
(U.S.A. only) when replacing handgrips.
Refer to an official Honda Service Manual (page 186) for
installation instructions.
Throttle Grip/Handlebar 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 high-performance 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 head/Cylinder
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 it’s 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 Oil/Performance
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, A15-00 or an
equivalent which contains special additives to assure
maximum performance of your CRF’s front suspension.
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 seat-in,
the spokes may need to be retightened. Once past this initial
seating-in period, the spokes should hold their tension.
Still, be sure your race (CRF450RX)/moto (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 (CRF450RX)/moto (CRF450R/RWE), 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 7.5 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 multi-purpose 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.
Before & After Competition Maintenance
Servicing Your Honda 31
After practice or between races (CRF450RX)/
motos (CRF450R/RWE)
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 t
he 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 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.
• 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 built-up pressure in the forks. This pressure
is caused by normal fork action while riding.
Between Races (CRF450RX)/Motos
(CRF450R/RWE) & Practice
Maintenance
(1) chain adjuster index marks
(1)
(2) pressure release screw
(2)
32 Servicing Your Honda
Before & 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
(CRF450RX)/Moto (CRF450R/RWE)
Lubrication
Apply a light coating of rust-inhibiting 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 rust-inhibiting 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 – 125). 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
Maintenance Component Locations
Servicing Your Honda 33
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
pre-load 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
Seat
34 Servicing Your Honda
Refer to Important Safety Precautions on page 23.
Rem
oval
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 lbf·ft (26 N·m, 2.7 kgf·m)
(1) seat mounting bolts (3) seat
(2) collars
(3)
(1)
(1)(2)
(1) seat front prong (4) seat support base slots
(2) slot (5) collars
(3
) seat center prongs (6)
seat mounting bolts
(1)
(3)
(4)(2)
(6)
(5)
(6)
Fuel Tank (CRF450RX)
(cont’d)
Servicing Your Honda 35
Refer to Important Safety Precautions on page 23.
Re
mo
val
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 (1
3) out of the frame and
hang it to the left of the frame.
Check the fuel tank stopper cable (14) for
de
terioration, 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)
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 lbf·ft (10 N·m, 1.0 kgf·m)
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 lbf·ft (10 N·m, 1.0 kgf·m)
Tighten the shroud C and D bolt to the
specified torque:
3.8 lbf·ft (5.2 N·m, 0.5 kgf·m)
The right and left shrouds can be installed in
the same manner.
8. Install the seat (page 34).
(16) cushion rubbers
(16)
3.35 ± 0.10 in
(85.0 ± 2.5 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)
Fuel Tank (CRF450R/RWE)
(cont’d)
Servicing Your Honda 37
Refer to Important Safety Precautions on page 23.
Re
mo
val
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
de
terioration, 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)
38 Servicing Your Honda
Fuel Tank (CRF450R/RWE)
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 lbf·ft (10 N·m, 1.0 kgf·m)
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 lbf·ft (10 N·m, 1.0 kgf·m)
Tighten the shroud C bolt to the specified
torque:
3.8 lbf·ft (5.2 N·m, 0.5 kgf·m)
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)
Subframe
(cont’d)
Servicing Your Honda 39
Refer to Important Safety Precautions on page 23.
Re
mo
val
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. Loosen the right and left muffler joint pipe
clamp bolts, 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 starter/ignition relay c
onnector
(3),
lift the seat support base (4), and hang it
to
the left of the subf
rame (5).
7. Disconnect th
e breather tube (6) and IAT
sensor connector (
7).
8. Loosen the air cleaner connecting tu
be 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) starter/ignition 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)
(13)(11)
(12)
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 lbf·ft (32 N·m, 3.3 kgf·m)
subframe lower bolts:
36 lbf·ft (49 N·m, 5.0 kgf·m)
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:
5.2 lbf·ft (7 N·m, 0.7 kgf·m)
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 lbf·ft (12 N·m, 1.2 kgf·m)
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)
(6)(9)
(10)
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:
1.5 lbf·ft (2.0 N·m, 0.2 kgf·m)
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 0.24 - 0.35
in (6 - 9 mm).
6. Connect the breather tube (15) and IAT sensor
connector (16).
7. Connect the starter/ignition 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 lbf·ft (10 N·m, 1.0 kgf·m)
9. Tighten the right and left muffler mounting A
bolts, and right and left muffler joint pipe
clamp bolts (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)
0.24 - 0.35 in (6 - 9 mm)
(14)
(16)
(17) starter/ignition relay connector
(18) seat support base
(19) collars
(20) seat support base mounting bolts
(17)
(18)
(20)
(19)
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), pul
l the breather
tube (2) out of the steering stem nut (3). Turn
the
fuel fill cap c
ounterclockwise and remove
it.
2. Add fuel until the level reaches the bottom of
the filler neck (4).
Fuel
Tank Capacity: 2.25 US gal (8.5 ℓ)
• Be careful not to damage the fuel pump whi
le
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)
Fuel System (CRF450RX)
(cont’d)
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)
(2)(3)
Fuel pump side:Injector side:
(4)
(5)
(6) shop towel
Injector side:
Fuel pump side:
(6)
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)
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)
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)
Fuel System (CRF450RX)
(cont’d)
Servicing Your Honda 47
6. Remove the fuel pump unit (11) and O-rings
(12).
Be careful not to damage the fuel pump unit.
7. Disconnect the fuel pump wire terminals (13)
from the fuel pump base (14).
Be careful not to damage the wires when
disconnecting the fuel pump wire terminals.
8. Check the hooks (15) of the fuel pump unit
holder and tabs (16) on the fuel pump base for
damage or discoloration.
If the hooks and tabs are damaged or
discolored, replace the fuel pump unit as an
assembly.
9. Release the hooks of the fuel pump unit holder
from the grooves (17) in the fuel pump base
tabs while pushing the holder against the base
and slightly spreading the base tabs.
Be careful not to damage the hooks and tabs.
10. Remove the fuel pump unit holder assembly
(18) from the fuel pump base (14) and remove
the O-ring (19).
Wipe the spilled out fuel immediately.
11. Remove the fuel pump stopper (20) and
damper rubber (21).
(11) fuel pump unit
(12) O-rings
(13) fuel pump wire terminals
(14) fuel pump base
(11)
(12)
(14)
(13)
(15) hooks (17) grooves
(16) tabs
(17)
(17)
(16)
(16)
(15)
(15)
(14) fuel pump base
(18) fuel pump unit holder assembly
(19) O-ring
(20) fuel pump stopper
(21)
d
amper rubber
(18)
(19)
(14)
(20)
(21)
48 Servicing Your Honda
Fuel System (CRF450RX)
12. Remove the fuel pump assembly (22) with fuel
pump filter (23), O-ring (24) from the fuel
pump unit holder (25).
13. Check the fuel pump filter (23) for clog,
damage or deterioration and replace it if
necessary.
14. Remove the fuel pump filter from the fuel
pump assembly (22).
Installation
1. Install the fuel pump filter (1) onto the fuel
pump assembly (2) aligning its hook (3) with
the joint boss (4) completely.
Be careful not to damage the hook.
2. Apply small amount of engine oil to a new
O-ring (5).
Install a new O-ring to the fuel pump assembly
(2).
3. Install the fuel pump assembly with fuel pump
filter into the fuel pump unit holder (6) while
routing the fuel pump red (7) and black (8)
wires through the holder grooves (9) as shown.
4. Install a new damper rubber (10) to the fuel
pump assembly as shown.
Install fuel pump stopper (11).
(22) fuel pump assembly
(23) fuel pump filter
(24) O-ring
(25) fuel pump unit holder
(22) fuel pump assembly
(23) fuel pump filter
(22)
(24)
(25)
(23)
(22)
(23)
(1) fuel pump filter (3) hook
(2) fuel pump assembly (4) joint boss
(2)
(3)
(4)
(1)
(2) fuel pump assembly (7) red wire
(5) O-ri
ng (new) (
8) black wire
(6) fuel pump unit holder (9) grooves
(10) damper rubber (new) (11) fuel pump stopper
(6)
(2)
(7)
(9)
(8)
(5)
(11)
(10)
Fuel System (CRF450RX)
(cont’d)
Servicing Your Honda 49
5. Apply small amount of engine oil to a new
O-ring (12).
Install a new O-ring to the fuel pump base (13).
6. Install the fuel pump unit holder assembly (14)
into the fuel pump base while aligning its
hooks (15) with the grooves (16) in the fuel
pump base tabs (17).
If the gap between the hooks and tabs is more
than 0.04 in (1.0 mm), replace the fuel pump
unit.
Be sure that the hooks are completely seated.
7. Connect the fuel pump red (18) and black (19)
wire terminals to the fuel pump base terminals
(20). Push the wire terminals until they stop as
shown.
Be careful not to damage the wires.
8. Apply 0.02 oz (0.5 g) maximum of engine oil
to a new O-ring (21).
Install a new O-ring onto the fuel pump unit
(22).
9. Apply small amount of engine oil to a new
O-ring (23).
Install a new O-ring into the fuel tank groove.
10. Install the fuel pump unit (22) into the fuel tank
(24) with its hose joint facing forward.
Be careful not to damage the fuel pump unit.
11. Install the fuel pump plate (25) with its
identification mark (26) facing forward the
front side and facing up.
(12) O-ring (new) (15) hooks
(13) fuel pump base (16) grooves
(14) fuel pump unit holder assembly (17) tabs
(13)
(16) (17)
(12)
(17)(16)
(14)
(15)
(18) red wire terminal (21) O-ring (new)
(19) black wire terminal (22) fuel pump unit
(20) fuel pump base terminals
(22) fuel pump unit
(23
) O-ring (new)
(24) fu
el tank
(18)
(19)
(21)
(19)
(20)
(18)
(20)
(22)
(22)
(24)
(23)
(25) fuel pump plate
(26) identification mark
(26)
(25)
50 Servicing Your Honda
Fuel System (CRF450RX)
12. Install the conical spring washers (27), collars
(28), washers (29), stopper cable (30), stopper
cable guide (31) and fuel pump mounting bolts
(32).
Make sure that the convex surfaces of the conical
spring washers are upside.
13. Tighten the fuel pump mounting bolts (32) to
the specified torque in the specified sequence
as shown:
8 lbf·ft (11 N·m, 1.1 kgf·m)
14. Install the harness band clip (33) to the stopper
cable guide (31).
15. Install the stopper cable (30) to the hook (34)
of the frame while holding the fuel tank (24).
16. Connect the fuel line (page 44).
17. Increase the fuel pressure (page 51).
(27) conical spring washers
(28) collars
(29) washers
(30) stopper cable
(31) stopper cable guide
(32) fuel pump mounting bolts
(31)
(29)
(28)
(32)
(27)
Fuel tank side
(30)
(27)
(32) fuel pump mounting bolts
(24) fuel tank (33) harness band clip
(30) stopper cable (34) hook
(31) stopper cable guide
1
2
3
4
5
6
(32)
(34)
(24)
(33)(31)
(30)
Servicing Your Honda 51
Fuel System (CRF450RX)
Make sure enough fuel remains (0.3 US gal (1.0 Ɛ)
minimum) in the fuel tank and add fuel if
necessary before increasing fuel pressure.
With the throttle closed.
Pull the clutch lever all the way in, and depress the
start button.
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.
Fuel Pressure Increasing
Fuel System (CRF450R/RWE)
52 Servicing Your Honda
Fuel System (CRF450R/RWE)
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), pul
l the breather
tube (2) out of the steering stem nut (3). Turn
the
fuel fill cap c
ounterclockwise and remove
it.
2. Add fuel until the level reaches the bottom of
the filler neck (4).
Fuel
Tank Capacity: 1.66 US gal (6.3 ℓ)
• Be careful not to damage the fuel pump whi
le
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)
Fuel System (CRF450R/RWE)
(cont’d)
Servicing Your Honda 53
1. Hang the fuel tank to the left side of the frame
(page 37).
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)
(2)(3)
Fuel pump side:Injector side:
(4)
(5)
(6) shop towel
Injector side:
Fuel pump side:
(6)
54 Servicing Your Honda
Fuel System (CRF450R/RWE)
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 damage
d fuel
hose.
•
D
o 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)
Servicing Your Honda 55
Fuel System (CRF450R/RWE)
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 61).
(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)
56 Servicing Your Honda
Fuel System (CRF450R/RWE)
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 53).
2. Disconnect the fuel line from the fuel pump
(page 53).
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 nuts (5), fuel
pump mounting cap nut (6), stopper cable
guide (7), stopper cable (2), washer (8), collars
(9),
conical spring washers (10) and fuel
pump
plate (11) 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 nuts
(6) fuel pump mounting cap nut
(7) stopper cable guide
(8) washer
(9) collars
(10) conical spring washers
(11) fuel pump plate
(6)
(5)
(2)
(7)
(8)
(9)
(10)
(11)
Fuel System (CRF450R/RWE)
(cont’d)
Servicing Your Honda 57
6. Remove the fuel pump unit (12), dust seal (13)
and O-ring (14).
Be careful not to damage the fuel pump unit.
7. Disconnect the fuel pump wire terminals (15)
from the fuel pump base (16).
Be careful not to damage the wires when
disconnecting the fuel pump wire terminals.
8. Check the hooks (17) of the fuel pump unit
holder and tabs (18) on the fuel pump base for
damage or discoloration.
If the hooks and tabs are damaged or
discolored, replace the fuel pump unit as an
assembly.
9. Release the hooks of the fuel pump unit holder
from the grooves (19) in the fuel pump base
tabs while pushing the holder against the base
and slightly spreading the base tabs.
Be careful not to damage the hooks and tabs.
10. Remove the fuel pump unit holder assembly
(20) from the fuel pump base (16) and remove
the O-ring (21).
Wipe the spilled out fuel immediately.
11. Remove the fuel pump stopper (22) and
damper rubber (23).
(12) fuel pump unit (14) O-ring
(13) dust seal
(15) fuel pump wire terminals
(16) fuel pump base
(13)
(12)
(14)
(16)
(15)
(17) hooks (19) grooves
(18) tabs
(18)
(19)
(18)
(17)
(17)
(16) fuel pump base
(20) fuel pump unit holder assembly
(21) O-ring
(22) fuel pump stopper
(23) damper rubber
(20)
(21)
(16)
(22)
(23)
58 Servicing Your Honda
Fuel System (CRF450R/RWE)
12. Remove the fuel pump assembly (24) from the
fuel pump unit holder (25).
13. Remove the O-ring (26) from the fuel pump
assembly (24).
14. Remove the fuel pump filter (27) from the fuel
pump assembly (24).
15. Check the fuel pump filter for clog, damage or
deterioration and replace it if necessary.
Installation
1. Install the fuel pump filter (1) onto the fuel
pump assembly (2) aligning its hook (3) with
the joint boss (4) completely.
Be careful not to damage the hook.
2. Apply small amount of engine oil to a new
O-ring (5).
Install a new O-ring to the fuel pump assembly
(2).
3. Install the fuel pump assembly with fuel pump
filter into the fuel pump unit holder (6) while
routing the fuel pump yellow (7) and green (8)
wires through the holder grooves (9) as shown.
4. Install a new damper rubber (10) to the fuel
pump assembly as shown.
Install fuel pump stopper (11).
(24) fuel pump assembly
(25) fuel pump unit holder
(26) O-ring
(24) fuel pump assembly
(27) fuel pump filter
(26)
(24)(25)
(24)
(27)
(1) fuel pump filter (3) hook
(2) fuel pump assembly (4) joint boss
(2)
(3)
(4)
(1)
(2) fuel pump assembly (7) yellow wire
(5) O-ring (new) (8) green wire
(6) fuel pump unit holder (9) grooves
(10) damper rubber (new)
(11) fuel pump stopper
(9)
(8)(6)
(7) (5)
(2)
(11)
(10)
Fuel System (CRF450R/RWE)
(cont’d)
Servicing Your Honda 59
5. Apply small amount of engine oil to a new
O-ring (12).
Install a new O-ring to the fuel pump base (13).
6. Install the fuel pump unit holder assembly (14)
into the fuel pump base while aligning its
hooks (15) with the grooves (16) in the fuel
pump base tabs (17).
If the gap between the hooks and tabs is more
than 0.04 in (1.0 mm), replace the fuel pump
unit.
Be sure that the hooks are completely seated.
7. Connect the fuel pump yellow (18) and green
(19) wire terminals to the fuel pump base
terminals (20). Push the wire terminals until
they stop as shown.
Be careful not to damage the wires.
8. Install a new dust seal (21) by aligning its tabs
(22)
with the fuel pump unit grooves (23).
C
heck the dust seal lug (24) which is located the
index mark (25) of the fuel pump base (13).
9. Apply small amount of engine oil to a new
O-ring (26).
Install a new O-ring into the between the collar
A (27) and collar B (28) of the fuel pump unit
(29).
10. Install the fuel pump unit (29) into the fuel tank
(30)
with its hose joint facing forward.
Be caref
ul not to damage the fuel pump unit.
(12) O-ring (new)
(13) fuel pump base
(14) fuel pump unit holder assembly
(15) hooks
(16) grooves
(17) tabs
(13)
(16) (17)
(12)
(17)(16)
(14)
(15)
(18) yellow wire terminal
(19) green wire terminal
(20) fuel pump base terminals
(13) fuel pump base (23) grooves
(21) dust seal (new) (24) dust seal lug
(22) tabs (25) index mark
(18)
(19)
(20)
(18)
(20)
(19)
(13)
(21)
(24)
(25)
(24)
(23)(22)
(26) O-ring (new) (28) collar B
(27) collar A (29) fuel pump unit
(29) fuel pump unit
(30) fuel tank
(28)
(29)
(26)
(27)
(29)
(30)
60 Servicing Your Honda
Fuel System (CRF450R/RWE)
11. Install the fuel pump plate (31) by aligning
with its groove (32) with fuel pump unit lug
(33).
Check the dust seal lug (24) is in position as
shown.
12. Install the conical spring washers (34), collars
(35), washer (36), stopper cable (37), stopper
cable guide (38), fuel pump mounting nuts (39)
and fuel pump mounting cap nut (40).
Make sure that the convex surfaces of the conical
spring washers are upside.
Make sure that the cap nut is in position of the
identification mark (41) on the fuel pump plate
(31).
13. Tighten the fuel pump mounting nuts (39) and
cap nut (40) to the specified torque in the
specified sequence as shown:
8 lbf·ft (11 N·m, 1.1 kgf·m)
14. Install the harness band clip (42) to the stopper
cable guide (38).
15. Install the stopper cable (37) to the hook (43)
of the frame while holding the fuel tank (30).
16. Connect the fuel line (page 54).
17. Increase the fuel pressure (page 61).
(24) dust seal lug
(31) fuel pump plate
(32) fuel pump plate groove
(33) fuel pump unit lug
(24) (32)
(33)
(31)
(31) fuel pump plate
(34) conical spring washers
(35) collars
(36) washer
(37) stopper cable
(38) stopper cable guide
(39) fuel pump mounting nuts
(40) fuel pump mounting cap nut
(41) identification mark
(35)
(36)
(34)
(39)
(31)(41)
(34)
Fuel tank side
(38)
(37)
(40)
(39) fuel pump mounting nuts
(40) fuel pump mounting cap nut
(30) fuel tank (42) harness band clip
(37) stopper cable (43) hook
(38) stopper cable guide
1
2
3
4
5
6
(39)
(40)
(43)
(30)
(42)
(37)
(38)
Servicing Your Honda 61
Fuel System (CRF450R/RWE)
Make sure enough fuel remains (0.3 US gal (1.0 Ɛ)
minimum) in the fuel tank and add fuel if
necessary before increasing fuel pressure.
With the throttle closed.
Pull the clutch lever all the way in, and depress the
start button.
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.
Fuel Pressure Increasing
Engine Oil
62 Servicing Your Honda
Engine Oil
Refer to Important Safety Precautions on page 23.
Using the proper oil, and regularly checking,
adding, and changing oil will help extend the
service life of the engine. Even the best oil wears
out. Changing oil helps get rid of dirt and deposits.
Operating the engine with old or dirty oil can
damage your engine. Running the engine with
insufficient oil can cause serious damage to the
engine.
* 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.
• Your CRF does not need oil additives.
Use the recommended oil.
• Do not use API SH or higher 4-stroke engine oils
displaying a circular API “energy conserving” or
“resource conserving” service label on the
container. They may affect lubrication.
Other viscosities shown in the following chart may
be used when the average temperature in your
riding area is within the indicated range.
JASO T 903 standard
The JASO T 903 standard is an index for engine
oils for 4-stroke motorcycle engines.
There are two classes: MA and MB.
Oil conforming to the standard is labeled on the oil
container. For example, the following label shows
the MA classification.
Oil Recommendation
API
classification
SG or higher except oils
labeled as energy
conserving or resource
conserving on the circular
API service label
viscosity
(weight)
SAE 10W-30
JASO T 903 standard MA
suggested oil* Pro Honda GN4 4-stroke
Oil (USA & Canada), or
Honda 4-stroke oil, or an
equivalent motorcycle oil
NOT RECOMMENDED RECOMMENDED
(1) oil code
(2) oil classification
(1)
(2)
Engine Oil
(cont’d)
Servicing Your Honda 63
1. Run the engine at idle for 3 minutes, then shut
it off.
2. Wait 3 minutes after shutting off the engine to
allow the oil to properly distribute itself in the
engine.
3. Support the CRF in an upright position on a
level surface.
4. Remove the engine oil fill cap/dipstick (1)
from the left crankcase cover, wipe it clean,
and insert it without screwing it in. Remove the
oil fill cap/dipstick.
5. Check that the oil level is between the upper
(2) and lower (3) level marks on the engine oil
fill cap/dipstick.
• If the oil is at or near the upper level mark,
you do not have to add oil.
• If the oil is below or near the lower level
mark, add the recommended oil until it
reaches the upper level mark. (Do not
overfill.)
Reinstall the engine oil fill cap/dipstick.
Repeat steps 1 – 5.
6. Check that the O-ring (4) is in good condition
and replace it if necessary.
7. Reinstall the engine oil fill cap/dipstick (1).
8. Check for oil leaks.
1. Remove the engine guard A bolts/washers (1),
B bolt/washer (2) and engine guard (3).
2. Run the engine at idle for 3 minutes, then shut
it off.
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.
Checking & Adding Oil
(1) engine oil fill cap/dipstick
(2) upper level mark
(3) lower level mark
(1)
(2)
(3)
(1) engine oil fill cap/dipstick
(4) O-ring
(1)
(4)
Changing Engine Oil & Filter
(1) engine guard A bolts/washers
(2) engine guard B bolt/washer
(3) engine guard
(1)
(3)
(2)
64 Servicing Your Honda
Engine Oil
5. Place an oil drain pan under the engine to catch
the oil. Then remove the engine oil drain bolt
(5)
and O-ring (6).
6. With the engine stop but
ton pushed, pull the
clutch lever all the way in, and depress the start
button to drain the engine oil completely.
7. After the oil has drained, apply engine oil to
the drain bolt threads, seating surface and a
new O-ring, then install the O-ring on the drain
bolt and tighten the drain bolt to the specified
torque:
13 lbf·ft (18 N·m, 1.8 kgf·m)
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.
8. (CRF450RX)
It is recommended to replace the oil and filter
every 4 races or about every 15.0 hours.
However, if you replace only the oil before the
recommended interval, see page 25.
(CRF450R/RWE)
It is recommended to replace the oil and filter
every 6 races or about every 15.0 hours.
However, if you replace only the oil before the
recommended interval, see page 26.
9. Remove the oil filter cover bolts (7) and oil
filter cover (8).
10. Remove the oil filter (9), O-ring (10) and
spring (11).
Using the wrong oil filter may result in leaks or
engine damage.
11. Apply grease to the filter side of the spring end,
then install the spring into a new oil filter.
12. Position the spring against the engine
crankcase and install a new oil filter with the
rubber seal (12) facing out, away from the
engine. You should see the “OUT-SIDE” mark
(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.
If the oil filter is not installed properly, it will
cause serious engine damage.
13. Apply engine oil to a new O-ring and install it
to the oil filter cover.
14. Install the oil filter cover being careful not to
damage the O-ring, then tighten the oil filter
cover bolts to the specified torque:
7 lbf·ft (10 N·m, 1.0 kgf·m)
15. Install the engine guard, then tighten the
engine guard A bolts/washers and B bolt/
washer to the specified torque:
7 lbf·ft (10 N·m, 1.0 kgf·m)
16. Fill the crankcase with the recommended oil.
17. Install the engine oil fill cap/dipstick.
18. Check the engine oil level by following the
steps in Checking & Adding Oil (page 63).
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.
(4) engine oil fill cap/dipstick
(5) engine oil drain bolt
(6) O-ring (new)
(6)
(4) (5)
(7) oil filter cover bolts
(8) oil filter cover
(9) oil filter
(10) O-ring
(11) spring
(12) rubber seal
(13) “OUT-SIDE” mark
(7)
(8)(10)(9)(11)
(12)(13)
Capacity: 1.10 US qt (1.04 ℓ)
after draining and filter change
1.06 US qt (1.00 ℓ)
after draining
Coolant
Servicing Your Honda 65
Refer to Important Safety Precautions on page 23.
Your CRF’s liquid cooling system dissipates
engine h
eat through the coolant jacket that
surrounds the cylinder and cylinder head.
Maintaining the coolant will allow the cooling
system to work properly and prevent freezing,
overheating, and corrosion.
Use Pro Honda HP Coolant or an equivalent high
quality ethylene glycol antifreeze containing
corrosion protection inhibitors specifically
recommended for use in aluminum engines. Check
the antifreeze container label.
Use only distilled water as a part of the coolant
solution. Water that is high in mineral content or
salt may be harmful to the aluminum engine.
Using coolant with silicate inhibitors may cause
premature wear of the mechanical seal or
blockage of the radiator passages. Using tap
water may cause engine damage.
The factory provides a 50/50 solution of antifreeze
and water in this motorcycle. This coolant solution
is recommended for most operating temperatures
and provides good corrosion protection.
Decreasing the concentration of antifreeze to less
than 40% will not provide proper corrosion
protection.
Increasing the concentration of antifreeze is not
recommended because it decreases cooling system
performance. Higher concentrations of antifreeze
(up to 60%) should only be used to provide
additional protection against freezing.
Check the cooling system frequently during
freezing weather.
Refer to Important Safety Precautions on page 23.
1. Position your CRF on an optional workstand or
equivalent support so that it is securely held in
place in an upright position.
2. With the engine cold, remove the radiator cap
(1) and check coolant level. The coolant level
is correct when it is at the bottom of the
radiator filler neck (2).
3. If the coolant level is low, add the coolant up to
the filler neck.
Inspect the coolant level before each outing.
A coolant loss of 0.7 – 2.0 US oz (20 – 60 cm
3
)
through the overflow hose (3) is normal. If
coolant loss is more than this, inspect the
cooling system.
Capacity:
(CRF450RX)
1.22 US qt (1.15 ℓ) after disassembly
1.13 US qt (1.07 ℓ) after draining
(CRF450R/RWE)
1.19 US qt (1.13 ℓ) after disassembly
1.13 US qt (1.07 ℓ) after draining
4. Install the radiator cap securely.
If the radiator cap is not installed properly, it will
cause excessive coolant loss and may result in
overheating and engine damage.
Coolant Recommendation
Checking & Adding Coolant
WARNING
Removing the radiator cap while the
engine is hot can cause the coolant to
spray out, seriously scalding you.
Always let the engine and radiator cool
down before removing the radiator cap.
(1) radiator cap (3) overflow hose
(2) radiator filler neck
(1)
(3)
(2)
66 Servicing Your Honda
Coolant
1. Check the cooling system for leaks (see an
official Honda Service Manual for
troubleshooting of leaks).
2. Check the radiator hoses (1) for cracks,
deterioration, and radiator hose clamps for
looseness.
3. Check the radiator mount for looseness.
4. Make sure the overflow hose (2) is connected
and not clogged.
5. Check the radiator fins (3) for clogging.
6. Check the bleed hole (4) below the water pump
cover (5) for leakage. Clean away any clogged
dirt or sand, if necessary. Check the bleed hole
of the water pump 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.
7. Check the radiator air passages for clogging or
damage.
Straighten bent fins (6), and remove insects,
mud or other obstructions with compressed air
or low water pressure.
Replace the radiator if the air flow is restricted
over more than 20% of the radiating surface.
Radiator should be replaced by your dealer, unless
you have the proper tools and service data and are
mechanically qualified. Refer to an official Honda
Service Manual (page 186).
Refer to Important Safety Precautions on page 23.
Coolant should be replaced by your dealer, unless
you have the proper tools and service data and are
mechanically qualified. Refer to an official Honda
Service Manual (page 186).
To properly dispose of drained coolant, refer to
You & the Environment on page 164.
Improper disposal of drained fluids is harmful to
the environment.
Cooling System Inspection
(1) radiator hoses (3) radiator fins
(2) overflow hose
(2)(1)
(3) (3)
(4) bleed hole
(5) water pump cover
(4)(5)
(6) fins
Coolant Replacement
WARNING
Removing the radiator cap while the
engine is hot can cause the coolant to
spray out, seriously scalding you.
Always let the engine and radiator cool
down before removing the radiator cap.
(6)
Air Cleaner
(cont’d)
Servicing Your Honda 67
Refer to Important Safety Precautions on page 23.
The air cleaner uses polyurethane inner and outer
pieces which can’t be separated.
A dirty air cleaner
will reduce engine power.
Proper air cleaner maintenance is very important
for off-road vehicles. A dirty, water-soaked, worn-
out, or defective air cleaner will allow dirt, dust,
mud, and other impurities to pass into the engine.
Service the air cleaner more frequently if you ride
in unusually wet or dusty areas. Your dealer can
help you determine the correct service interval for
your riding conditions.
Your CRF’s air cleaner has very specific
performance requirements. Use a new Honda
Genuine air cleaner specified for your model or an
air cleaner of equal quality.
Using the wrong air cleaner may result in
premature engine wear.
Proper air cleaner maintenance can prevent
premature engine wear or damage, expensive
repairs, low engine power, poor gas mileage, and
spark plug fouling.
Improper or lack of proper air cleaner
maintenance can cause poor performance and
premature engine wear.
1. Remove the seat (page 34).
2. Remove the air cleaner retaining bolt (1) and
air cleaner assembly (2).
3. Remove the air cleaner element (3) from the air
cleaner holder (4) by releasing the hole (5) of
the air cleaner element from the holder tab (6).
Cleaning
(1) air cleaner retaining bolt
(2) air cleaner assembly
(3) air cleaner element (5) hole
(4) air cleaner holder (6) holder tab
(1)
(2)
(5)
(6)
(3)
(4)
68 Servicing Your Honda
Air Cleaner
4. Wash the air cleaner in clean non-flammable
cleaning solvent such as Pro Honda foam air
filter cleaner. Then wash in hot, soapy water,
rinse well, and allow to dry thoroughly. The air
cleaner element is made in two pieces: inner
and outer, which cannot be separated.
5. Clean the inside of the air cleaner housing (7).
6. Allow the air cleaner to dry thoroughly. After
drying, apply 1.4 US oz (40 cm
3
) of clean Pro
Honda Foam Air Filter Oil or an equivalent air
cleaner oil from the inside of the element.
Place the element into a plastic bag (8) and
spread the oil evenly by hand.
7. Assemble the air cleaner element and holder.
Install the holder tab in the hole of the air
cleaner element.
8. Apply 0.05 – 0.19 oz (1.5 – 5.5 g) of Pro Honda
Foam Air Filter Sealer or equivalent to the air
cleaner element contact area (9) of the air
cleaner housing.
9. Install the air cleaner assembly (2) into the air
cleaner housing stay (10) with the “UP” mark
tab (11) facing up.
10. Carefully position the sealing flange of the
element to prevent dirt intrusion.
11. Install and tighten the air cleaner retaining bolt
(1) to the specified torque:
1.7 lbf·ft (2.4 N·m, 0.2 kgf·m)
Improper installation of the air cleaner assembly
may allow dirt and dust to enter the engine and
cause rapid wear of the piston rings and cylinder.
12. Install the seat (page 34).
(7) air cleaner housing
(8) plastic bag
(7)
(8)
(2) air cleaner assembly
(9) contact area
(10) air cleaner housing stay
(11) “UP” mark tab
(11) (11)
(10)
(2)
(9)
(1) air cleaner retaining bolt
(1)
Crankcase Breather
Servicing Your Honda 69
Refer to Important Safety Precautions on page 23.
Service more frequently if your CRF is ridden in
the rain or often at full throttle.
Service the breather if you can see deposits in the
transparent section of the crankcase breather tube.
If the breather tube overflows, the air filter may
become contaminated
with engine oil causing poor
engine performance.
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.
Draining
(1) crankcase breather tube plug
(2) crankcase breather tube
(3) clip
(2) (1)
(3)
Throttle
70 Servicing Your Honda
Refer to Important Safety Precautions on page 23.
Inspection
Check freeplay (1).
Freeplay: 1/16 – 1/4 in (2 – 6 mm)
If necessary, adjust to the specified range.
Upper Adjustment
Minor adjustments are generally made with the
upper adjuster.
1. Loosen the lock nut (1).
2. Turn the adjuster (2).
Turning the adjuster in direction (–) will
decrease freeplay and turning it in direction (+)
will increase freeplay.
3. Tighten the lock nut securely.
4. After adjustment, check for smooth rotation of
the throttle grip from fully closed to fully open
in all steering positions.
If the adjuster is threaded out near its limit or
the correct freeplay cannot be reached, turn the
adjuster all the way in and back out one turn.
Tighten the lock nut securely.
Make the adjustment with the lower adjuster.
Lower Adjustment
The lower adjuster is used for major freeplay
adjustment, such as after replacing the throttle
cables or removing the throttle body. It is also used
if you cannot get the proper adjustment with the
upper adjuster.
1. Loosen the lock nut (1).
2. Turn the adjuster (2) in direction (–) to
decrease freeplay, and in direction (+) to
increase freeplay.
3. Tighten the lock nut to the specified torque:
3.0 lbf·ft (4.0 N·m, 0.4 kgf·m)
4. Operate the throttle grip to ensure that it
functions smoothly and returns completely.
If you can’t get the freeplay within the specified
range, contact your dealer.
Throttle Freeplay
(1) freeplay
(1)
(1) lock nut (+) increase freeplay
(2) adjuster (–) decrease freeplay
(2)
(1)
(+)
(–)
(1) lock nut (+) increase freeplay
(2) adjuster (–) decrease freeplay
(1)
(2)
(–)
(+)
Servicing Your Honda 71
Throttle
1. Check that the throttle assembly is positioned
properly (the end of the throttle housing (1) is
aligned with the paint mark (2) on the
handlebar) and the securing bolts are tight.
2. Check for smooth rotation of the throttle (3)
from fully open to fully closed in all steering
positions. If there is a problem, see your dealer.
3. Inspect the condition of the throttle cables
from the throttle grip down to the throttle body.
If the cable is kinked or chafed, have it
replaced.
4. Check the cables for tension or stress in all
steering positions.
5. Lubricate the cables with a commercially
available cable lubricant.
Check for smooth rotation of the throttle. If
necessary, apply multi-purpose grease to sliding
surface of the throttle cable ends.
1. Slide the dust cover (1).
2. Remove the throttle housing bolts (2).
3. Remove the throttle housing (3) from the
throttle pipe (4).
4. Thoroughly lubricate the throttle cable ends (5)
with multi-purpose grease.
5. Install the throttle housing, then tighten the
throttle housing bolts to the specified torque:
7 lbf·ft (10 N·m, 1.0 kgf·m)
Align the lugs (6) of the wire guide with the
grooves (7) of the throttle housing.
6. Install the dust cover in the reverse order.
If the throttle operation is not smooth, replace the
throttle cable.
Be sure the throttle returns freely from fully open
to fully closed automatically, in all steering
positions.
Throttle Inspection
(1) throttle housing
(2) paint mark
(3) throttle
(2) (1)
(3)
Throttle Cable Lubrication
(1) dust cover (5) throttle cable ends
(2) housing bolts (6) lugs
(3) throttle housing (7) grooves
(4) throttle pipe
(5)
(2)
(1) (3)
(6)
(4)
(7)
(7)
Engine Idle Speed
72 Servicing Your Honda
Engine Idle Speed
Refer to Important Safety Precautions on page 23.
Remember, idle speed adjustment is not a “cure
-
all” for other problems in your engine’s PGM-FI
system. Adjusting the idle speed will not
compensate for a fault elsewhere.
The engine must be at normal operating
temperature for accurate idle speed adjustment.
When pushed in, the fast idle knob acts as the idle
adjustment screw.
Turning it counterclockwise results in a faster/
higher idle speed.
Turning it clockwise results in a slower/lower idle
speed.
1. If the engine is cold, start it and warm it up 3
minutes. Then shut it off.
2. Connect a tachometer to the engine.
3. Shift the transmission into neutral. Start the
engine.
4. Adjust idle speed with the fast idle knob (1).
Idle speed: 2,000 ± 100 rpm
Idle Speed Adjustment
(1) fast idle knob
(+) increase
(–) decrease
(1)
(–)
(+)
Clutch System
Servicing Your Honda 73
Refer to Important Safety Precautions on page 23.
Inspection
Check freeplay (1).
Freeplay: 3/8 – 13/16 in (10 – 20 mm)
If necessary, adjust to the specified range.
Improper freeplay adjustment can cause premature
clutch wear.
Make sure to adjust the clutch lever freeplay after
the clutch cable is disconnected.
Cable End Adjustment
Minor adjustments are generally made with the
clutch cable end adjuster.
Turning the clutch cable end adjuster (1) in
direction (+) will increase freeplay and turning it in
direction (–) will decrease freeplay.
If the adjuster is threaded out near its limit or the
correct freeplay cannot be reached, turn the
adjuster all the way in and back out five turns and
make the adjustment with the integral cable
adjuster.
Integral Cable Adjustment
The integral cable adjuster is used if the cable end
adjuster is threaded out near its limit — or the
correct freeplay cannot be obtained.
1. Turn the cable end adjuster in direction (+)
until it seats lightly and then turn it out five
turns.
2. Loosen the lock nut (1).
3. Slide the rubber boot (2) off and turn the
integral cable adjuster (3) to obtain the
specified freeplay.
4. Once the specified freeplay has been obtain,
slide the rubber boot on and tighten the lock
nut.
5. Start the engine, pull the clutch lever in, and
shift into gear. Make sure the engine does not
stall and the motorcycle does not creep.
Gradually release the clutch lever and open the
throttle. Your CRF should move smoothly and
accelerate gradually.
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).
Clutch Lever Freeplay
(1) freeplay
(1)
(1) clutch cable end adjuster
(+) increase freeplay
(–) decrease freeplay
(1)
(–)
(+)
(1) lock nut (+) increase freeplay
(2) rubber boot (–) decrease freeplay
(3) integral cable adjuster
(1)
(–)
(+)
(3)
(2)
74 Servicing Your Honda
Clutch System
• Check that the clutch lever assembly is
positioned properly (the end of the holder (1) is
aligned with the paint mark (2) on the
handlebar) and the securing bolts are tight.
• Check the clutch cable for kinks or signs of
wear. If necessary, have it replaced.
1. Check for smooth clutch lever operation. If
necessary, lubricate the clutch lever pivot bolt
sliding surface with grease and/or clutch cable
with commercially available cable lubricant.
2. Check the clutch cable for deterioration, kinks,
or damage.
Check for smooth clutch lever operation. If
necessary, apply multi-purpose grease to sliding
surface of the clutch cable ends.
1. Release the dust cover (1).
2. Turn the adjuster (2) and remove the clutch
cable (3).
3. Disconnect the clutch cable end from the
clutch lever (4).
4. Thoroughly lubricate the clutch cable end (5)
with multi-purpose grease.
5. Connect the clutch cable end to the lever.
6. Install the clutch cable and turn the adjuster.
7. Remove the clutch cable end adjuster (6).
8. Apply multi-purpose grease to the clutch cable
end adjuster inside surface.
9. Recheck clutch lever freeplay and adjust as
necessary (page 73).
If the clutch lever operation is not smooth, replace
the clutch cable.
Other Inspections
(1) holder
(2) paint mark
Clutch Operation
(1)(2)
Clutch Cable Lubrication
(1) dust cover (4) clutch lever
(2) adjuster (5) clutch cable end
(3) clutch cable
(1) (2)
(3) (5) (4)
(6) clutch cable end adjuster
(6)
Servicing Your Honda 75
Clutch System
1. Drain the engine oil (page 63).
2. Remove the six clutch cover bolts (1) and
clutch cover (2).
3. Remove the six clutch spring bolts and springs
(3).
Loosen the bolts in a crisscross pattern in two or
three progressive steps.
4. Remove the clutch pressure plate (4).
5. Remove the clutch lifter (5).
6. Check the operation of the thrust bearing (6)
built in clutch lifter with your finger. The
bearing should turn smoothly and quietly.
If the operation is not smooth, refer to an official
Honda Service Manual (page 186) for bearing
disassembly or see your dealer.
7. Remove the seven clutch discs, six clutch
plates, judder spring and spring seat (7).
Clutch Disc/Plate Removal
(1) clutch cover bolts (2) clutch cover
(3) clutch spring bolts and springs
(4) clutch pressure plate
(2)
(1)
(4)
(3)
(5) clutch lifter
(6) thrust bearing
(5)
(6)
(7) clutch discs, clutch plates, judder spring and spring
seat
(7)
76 Servicing Your Honda
Clutch System
• Replace the clutch discs (1) if they show signs of
scoring or discoloration.
Measure the thickness of each clutch disc.
Service Limit: 0.112 in (2.85 mm)
Replace the clutch discs and clutch plates as a
set.
• Check the clutch plates (2) for excessive
warpage or discoloration.
Check the plate warpage on a surface plate using
a feeler gauge.
Service Limit: 0.006 in (0.15 mm)
Replace the clutch discs and plates as a set.
• Check the clutch springs (3) for wear or damage.
Measure the free length of each clutch spring.
Service Limit: 1.917 in (48.70 mm)
Replace the clutch spring as a set.
• If you feel the clutch slipping after replacing the
clutch disc and plate, replace the clutch springs.
1. Install the spring seat (1) and judder spring (2)
onto the clutch center as shown.
Coat the clutch discs with engine oil.
2. Install the clutch disc A (larger I.D. disc) (3)
onto the clutch outer.
Stack the six clutch plates (4), five clutch discs
B (5) alternately while aligning the lugs (6) of
the clutch center with the groove (7) of the
clutch plates as shown.
Install the clutch disc C (8).
Clutch Disc/Plate/Spring Inspection
(1) clutch discs
(2) clutch plates
(1)
(2)
(3) clutch springs
(3)
Clutch Disc/Plate Installation
(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
(8)
disc C disc B disc A
(5)
(6)
(7)
(3) (2) (1)(4)
Servicing Your Honda 77
Clutch System
3. Install the clutch lifter (9) onto the clutch lifter
rod (10).
4. Install the clutch pressure plate (11).
5. Install the six clutch springs and bolts (12).
6. Tighten the bolts in a crisscross pattern in two
or three steps to the specified torque:
9 lbf·ft (12 N·m, 1.2 kgf·m)
7. Apply engine oil to a new O-ring (13) and
install it in the groove of the clutch cover (14).
8. Install the cover by tightening the six cover
bolts in a crisscross pattern in two or three
steps to the specified torque:
7 lbf·ft (10 N·m, 1.0 kgf·m)
9. Fill the crankcase with the recommended oil
(page 63).
(9) clutch lifter (10) clutch lifter rod
(11) clutch pressure plate
(12) clutch springs and bolts
(10)
(9)
(11)
(12)
(13) O-ring (new)
(14) clutch cover
(13)
(14)
Spark Plug
78 Servicing Your Honda
Spark Plug
Refer to Important Safety Precautions on page 23.
The recommended standard spark plug is
satisfactory for most racing conditions.
Use only the recommended type of spark plugs in
the recommended heat range.
Using a spark plug with an improper heat range or
incorrect reach can cause engine damage.
Using a non-resistor spark plug may cause
ignition problems.
This motorcycle uses a spark plug that has an
iridium tip in the center electrode and a platinum
tip in the side electrode.
Be sure to observe the following when servicing
the spark plug.
• Do not clean the spark plug. If an electrode is
contaminated with accumulated objects or dirt,
replace the spark plug with a new one.
• To check the spark plug gap, use only a “wire-
type feeler gauge.” To prevent damaging the
iridium tip of the center electrode and platinum
tip of the side electrode, never use a “leaf-type
feeler gauge.”
• Do not adjust the spark plug gap. If the gap is out
of specification, replace the spark plug with a
new one.
1. Remove the seat and hang the fuel tank to the
left of the frame (pages 34, 35, 37).
2. Disconnect the spark plug cap (1).
3. Clean any dirt from around the spark plug
base.
4. Remove the spark plug (2).
5. Check the electrodes for wear or deposits, the
sealing gasket (3) for damage, and the insulator
for cracks. Replace if you detect them.
6. Check the spark plug gap (4), using a wire-type
feeler gauge. If the gap is out of specifications,
replace the plug with a new one.
The recommended spark plug gap is:
0.031 – 0.035 in (0.8 – 0.9 mm)
7. To obtain accurate spark plug readings,
accelerate up to speed on a straightaway.
Press and hold the engine stop button and
disengage the clutch by pulling the lever in.
Coast to a stop, then remove and inspect the
spark plug. The porcelain insulator around the
center electrode should appear tan or medium
gray.
If you’re using a new plug, ride for at least 10
minutes before taking a plug reading; a brand-new
plug will not color initially.
If the electrodes appear burnt, or the insulator is
white or light gray (lean) or the electrodes and
insulator are black or fouled (rich), there is a
problem elsewhere (page 155).
Check the PGM-FI system and ignition timing.
8. With the sealing gasket attached, thread the
spark plug in by hand to prevent cross-
threading.
9. Tighten the spark plug.
• If the old plug is good:
1/12 turn after it seats.
• If installing a new plug, tighten it twice to
prevent loosening:
a) First, tighten the plug:
1/4 turn after it seats.
b) Then loosen the plug.
c) Next, tighten the plug again:
1/12 turn after it seats.
An improperly tightened spark plug can damage
the engine. If a plug is too loose, the piston may be
damaged. If a plug is too tight, the threads may be
damaged.
10. Connect the spark plug cap. Take care to avoid
pinching any cables or wires.
11. Install the fuel tank and seat (pages 34, 36, 38).
Spark Plug Recommendation
Standard SILMAR9A – 9S (NGK)
Optional SILMAR10A – 9S (NGK)
Spark Plug Inspection & Replacement
(1) spark plug cap (2) spark plug
(3) sealing gasket
(4) spark plug gap
(1) (2)
(3)
(4)
Valve Clearance
Servicing Your Honda 79
Refer to Important Safety Precautions on page 23.
Excessive valve clearance will cause noise and
eventual engine
damage. Little or no clearance will
prevent the valve from closing and cause valve
damage and power loss. Check valve clearance
when the engine is cold at the intervals specified in
the Maintenance Schedule (pages 25, 26).
The checking or adjusting of the valve clearance
should be performed while the engine is cold.
The valve clearance will change as engine
temperature rises.
Before inspection, clean the engine thoroughly to
keep dirt from entering the engine.
1. Remove the seat and hang the fuel tank to the
left of the frame (pages 34, 35, 37).
2. Disconnect the breather tube (1) and spark
plug cap (2).
3. Remove the cylinder head cover socket bolts
(3), rubber seals (4), cylinder head cover (5)
and spark plug hole packing (6).
Cylinder Head Cover Removal
(1) breather tube (2) spark plug cap
(2)
(1)
(3) cylinder head cover socket bolts
(4) cylinder head cover rubber seals
(5) cylinder head cover
(6) spark plug hole packing
(5)
(3)
(6)
(3)
(4)
80 Servicing Your Honda
Valve Clearance
1. Remove the crankshaft hole cap (1).
2. Remove the spark plug (page 78).
3. Remove the cylinder head cover (page 79).
4. Rotate the crankshaft by turning the primary
drive gear bolt (2) clockwise until “T” mark (3)
on the primary drive gear aligns with the index
mark (4) on the clutch cover. In this position,
the piston may either be on the compression or
exhaust stroke at TDC. If the primary drive
gear passed the “T” mark, rotate the primary
drive gear bolt clockwise again and align the
“T” mark with the index mark.
Make sure that the decompressor weight (5) is
upper position.
5. Check the timing marks (6) on the cam
sprocket aligns with the camshaft holder
mating surface (7) of the cylinder head.
6. The inspection must be made when the piston
is at the top of the compression stroke when
both the intake and exhaust valves are closed.
This condition can be determined by moving
the rocker arms (8).
Positioning At TDC On The
Compression Stroke
(1) crankshaft hole cap
(1)
(2) primary drive gear bolt
(3) “T” mark
(4) index mark
(5) decompressor weight
(2)
(3)
(4)
(5)
crankshaft side: camshaft side:
(6) timing marks
(7) camshaft holder mating surface
(8) rocker arms
(6)
(7)
(8)
(8)
Valve Clearance
(cont’d)
Servicing Your Honda 81
1. Set the piston at TDC on the compression
stroke (page 80).
2. Measure the intake valve clearances by
inserting a feeler gauge (1) between the intake
rocker arms (2) and camshaft cam lobes (3).
Be careful not to damage the intake rocker arms.
Valve Clearance:
3. Measure the exhaust valve clearances by
inserting a feeler gauge (1) between the
exhaust rocker arms (4) and shims (5).
Valve Clearance:
If intake valve clearance and exhaust valve
clearance need adjustment, see Camshaft Removal
(this page) and select the correct shim for each
valve.
1. Make sure the piston is at TDC on the
compression stroke (page 80).
Record the intake valve and exhaust valve
clearances (this page).
2. Remove the cam chain tensioner lifter cover
bolt (1) and sealing washer (2).
Valve Clearance Inspection
(1) feeler gauge (3) camshaft cam lobes
(2) intake rocker arms
IN: 0.005 ± 0.001 in (0.13 ± 0.03 mm)
(3)
(1)
(2)
(3) (1)
(3)
(2)
(1) feeler gauge (5) valve shims
(4) exhaust rocker arms
EX: 0.011 ± 0.001 in (0.28 ± 0.03 mm)
(5)
(1)
(4)
(5)
(1)
(4)
(5)
(4)
Camshaft Removal
(1) cam chain tensioner lifter cover bolt
(2) sealing washer
(1)
(2)
82 Servicing Your Honda
Valve Clearance
3. Insert the tensioner stopper (3) into the cam
chain tensioner lifter (4).
Turn the tensioner stopper clockwise and lock
the cam chain tensioner lifter by pushing the
handle (5) to the cam chain tensioner lifter.
• Tensioner stopper 07AMG-001A100
4. Check the piston is at TDC on the compression
stroke (page 80).
Loosen the camshaft holder bolts (6) in a
crisscross pattern in two or three steps.
Remove the camshaft holder bolts, camshaft
holder (7) and set rings (8).
As you remove the camshaft holder, set rings may
be sticking in the camshaft holder.
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.
5. Slide the left camshaft bearing (9) and remove
the camshaft (10) by removing the cam chain
(11).
Suspend the cam chain with a piece of wire to
prevent the chain from falling into the crankcase.
Do not let the cam chain fall into the crankcase.
(3) tensioner stopper
(4) cam chain tensioner lifter
(5) handle
(4)
(5)
(3)
(6) camshaft holder bolts
(7) camshaft holder
(8) set rings
(8)
(6)
(7)
(9) left camshaft bearing
(10) camshaft
(11) cam chain
(10)(11)
(9)
Servicing Your Honda 83
Valve Clearance
6. Lift the rocker arms (12) up and remove the
shims (13).
Be careful not to damage the intake rocker arms.
Do not clean the intake rocker arms using a
commercially available compound cleaner.
1. Measure the shim thickness with a micrometer
and record it.
Seventy-three different shims (1) are available
in 0.025 mm thickness intervals, from 1.200
mm (the thinnest) to 3.000 mm (the thickest).
2. Calculate the new shim thickness using the
equation below.
A = (B – C) + D
A: New shim thickness
B: Recorded valve clearance
C: Specified valve clearance
D: Old shim thickness
• Make sure of the correct shim thickness by
measuring the shim with a micrometer.
• Reface the exhaust valve seat if carbon deposits
result in a calculated dimension of over 3.000
mm.
Do not lap the intake valves. They are titanium and
have a thin oxide coating. Lapping will damage
this coating.
If a calculated dimension is out of specifications,
have your motorcycle inspected by your dealer.
(12) rocker arms
(13) shims
(13)
(12)
(13)
(12)
Shim Selection
(1) shim
(1)
1.80 mm 1.825 mm 1.85 mm
1.875 mm
84 Servicing Your Honda
Valve Clearance
1. Lift the rocker arms (1) up and install the
newly selected shims (2) on the valve spring
retainers (3).
Do not let the shims fall into the crankcase.
2. Check the operation of the plunger (4) by
turning the decompressor weight (5) with your
finger. The plunger should be retracted and
protruded smoothly.
If the operation is not smooth, refer to an official
Honda Service Manual (page 186) for
decompressor disassembly or see your dealer.
3. Make sure the piston is at TDC on the
compression stroke (page 80).
4. Apply molybdenum disulfide oil (a mixture of
1/2 engine oil and 1/2 molybdenum disulfide
grease containing more than 3% molybdenum
disulfide additive Moly Paste 77) to the
following parts.
– camshaft cam lobes
– plunger whole surface
5. Install the camshaft (6) onto the cylinder head
with the decompressor weight (5) facing up as
illustrated below.
6. Install the cam chain (7) over the cam sprocket
(8).
While holding the left camshaft bearing (9) to
the left fully, install the camshaft (6) onto the
cylinder head (10) and slide the left camshaft
bearing to the right fully.
Camshaft Installation
(1) rocker arms (3) valve spring retainers
(2) shims
(2)
(3)
(1)
(1)
(2)
(3)
(3)
(4) plunger
(5) decompressor weight
(5)
(4)
(5) decompressor weight (8) cam sprocket
(6) camshaft (9) left camshaft bearing
(7) cam chain (10)
cylinder hea
d
(7)
(9)
(8)
(6)
(5)
(10)
Valve Clearance
(cont’d)
Servicing Your Honda 85
7. Make sure that the timing mark (11) on the cam
sprocket aligns with the camshaft holder
mating surface (12) of the cylinder head.
8. Make sure that the dowel pins (13) are installed
into the camshaft holder (14).
9. Install the set rings (15) on the camshaft
bearing grooves (16).
Do not let the set rings fall into the crankcase.
10. Apply engine oil to the camshaft holder bolt
threads.
Install the camshaft holder (17) with the “ ”
mark (18) facing forward.
Install the camshaft holder bolts (19) (20) and
tighten the camshaft holder bolts to the
specified torque:
11 lbf·ft (15 N·m, 1.5 kgf·m)
Tighten the camshaft holder bolts in a crisscross
pattern in two or three steps.
11. Remove the tensioner stopper (21) from the
cam chain tensioner lifter.
12. Make sure that the piston is at TDC on the
compression stroke (page 80).
Check that the timing mark (11) on the cam
sprocket aligns with the camshaft holder
mating surface (12) of the cylinder head.
If the timing mark doesn’t align with the camshaft
holder mating surface, insert the tensioner stopper
into the cam chain tensioner lifter (page 82) and
then remove the cam chain and realign the timing
mark.
(11) timing mark
(12) camshaft holder mating surface
(13) dowel pins (14) camshaft holder
(11)
Align
(12)
(13)
(14)
(15) set rings
(16) camshaft bearing grooves
(17) camshaft holder (19) camshaft holder bolts (long)
(18) “ ” mark
(20) camshaft holder bolts (short)
(15)
(16)
(20)
(19)
(18)
(17)
(21) tensioner stopper
(11) timing mark
(12) camshaft holder mating surface
(21)
Align Align
(11)
(12)
86 Servicing Your Honda
Valve Clearance
13. Check that “T” mark (22) on the primary drive
gear (23) aligns with the index mark (24) on
the right crankcase cover.
14. Rotate the camshaft by rotating the crankshaft
clockwise several times.
Make sure the piston is at TDC on the
compression stroke (page 80).
15. Measure the intake and exhaust valve
clearances by inserting a feeler gauge (25).
Valve Clearance:
16. Install a new sealing washer (26) and tighten
the cam chain tensioner lifter cover bolt (27).
1. Install the spark plug (page 78).
2. Coat a new O-ring (1) with engine oil and
install it onto the crankshaft hole cap (2).
Apply grease to the crankshaft hole cap
threads. Install and tighten the crankshaft hole
cap to the specified torque:
11 lbf·ft (15 N·m, 1.5 kgf·m)
(22) “T” mark
(23) primary drive gear
(24) index mark
(23)
(24)
(22)
IN: 0.005 ± 0.001 in (0.13 ± 0.03 mm)
EX: 0.011 ± 0.001 in (0.28 ± 0.03 mm)
(25) feeler gauge
(26) sealing washer (new)
(27) cam chain tensioner lifter cover bolt
(25)
(25)
Intake side: Exhaust side:
(27)
(26)
Crankshaft Hole Cap Installation
(1) O-ring (new)
(2) crankshaft hole cap
(2)
(1)
Servicing Your Honda 87
Valve Clearance
1. Check that the spark plug hole packing (1) is in
good condition and replace it if necessary.
Apply engine oil to the spark plug hole packing
and install it to the cylinder head cover (2).
2. Check that the cylinder head cover packing (3)
is in good condition and replace it if necessary.
Clean and apply liquid sealant (TB1207B or
equivalent) to the cylinder head cover groove
(4)
in the shown and install the cylinder head
cover packing into the cylinder head cover
groove.
3. Check that the rubber seals (5) are in good
condition, replace them if necessary.
Install the rubber seals onto the cylinder head
cover with the “UP” marks (6) facing up.
4. Install the cylinder head cover (2) and tighten
the cylinder head cover socket bolts (7) to the
specified torque:
7 lbf·ft (10 N·m, 1.0 kgf·m)
5. Connect the
spark plug cap (8) and breather
tube (9).
6. Install the fuel tank and seat (pages 34, 36, 38).
Cylinder Head Cover Installation
(1) spark plug hole packing
(2) cylinder head cover
(3) cylinder head cover packing
(4) cylinder head cover groove
(3)
(2)
(1)
(4)
(5) rubber seals
(6) “UP” marks
(2) cylinder head cover
(7) cylinder head cover socket bolts
(6)
(6)
(5)
(7)
(2)
(8) spark plug cap
(9) breather tube
(8)
(9)
Piston/Piston Rings/Piston Pin
88 Servicing Your Honda
Piston/Piston Rings/Piston Pin
Refer to Important Safety Precautions on page 23.
1. Clean the area above the engine before
disassembly to prevent dirt falling into the
engine.
2. Drain the radiator coolant after cooling the
motorcycle (page 163).
3. Remove the seat and hang the fuel tank to the
left of the frame (pages 34, 35, 37).
4. Remove the left and right mufflers (page 126).
5. Remove the exhaust pipe (page 130).
6. Remove the subframe (page 39).
7. Remove the spark plug (page 78).
8. Remove the cylinder head cover (page 79).
9. Set the piston at TDC on the compression
stroke (page 80).
10. Remove the camshaft holder, camshaft and
shims (page 81).
11. Disconnect the ignition coil A connector (1)
and B connector (2).
Remove the ignition coil (3) by removing the
ignition coil bolts (4).
12. Disconnect the ECT sensor connector (5).
13. Loosen the radiator hose clamp screw (6) and
disconnect the radiator hose (7).
14. Remove the right radiator lower mounting bolt
(8) and washer (9).
15. Loosen the insulator band screw (10) and pull
the throttle body (11) out from the insulator
(12).
Do not hang the throttle body and support it with a
suitable strap.
Cylinder Head Removal
(1) ignition coil A connector (3) ignition coil
(2) ignition coil B connector (4) ignition coil bolts
(4)
(3)
(2)
(1)
(5) ECT sensor connector
(6) radiator hose clamp screw
(7) radiator hose
(8) right radiator lower mounting bolt
(9) washer
(5)
(6)
(7)
(9) (8)
(10) insulator band screw
(11) throttle body
(12) insulator
(10)
(11)
(12)
Servicing Your Honda 89
Piston/Piston Rings/Piston Pin
16. Remove the cylinder head hanger bolts (13).
Remove the cylinder head hanger plate bolts
(14), left cylinder head hanger plate (15) and
right cylinder head hanger plate (16).
17. Remove the cylinder bolt (17).
18. Remove the cylinder head bolts, washers (18)
and cylinder head (19).
Loosen the bolts in a crisscross pattern in two or
three steps.
Do not let the washers and cam chain fall into the
crankcase.
19. Remove the dowel pins (20) and cylinder head
gasket (21).
Do not let the dowel pins and cam chain fall into
the crankcase.
20. Remove the cam chain guide (22) from the
cylinder (23).
(13) cylinder head hanger bolts
(14) cylinder head hanger plate bolts
(15) left cylinder head hanger plate
(16) right cylinder head hanger plate
(14)
(13)
(15)
Left side:
Right side:
(14)
(16)
(13)
(17) cylinder bolt
(18) cylinder head bolts and washers
(19) cylinder head
(18)
(19)
(17)
(20) dowel pins
(21) cylinder head gasket
(22) cam chain guide
(23) cylinder
(20)
(21)
(22)
(23)
90 Servicing Your Honda
Piston/Piston Rings/Piston Pin
1. Remove the cylinder (1) while holding the
piston (2).
Do not let the cam chain fall into the crankcase.
Do not pry on or strike the cylinder.
2. Remove the dowel pins (3) and cylinder gasket
(4).
Do not let the cam chain fall into the crankcase.
Do not let the dowel pins fall into the crankcase.
1. Place clean shop towels (1) in the crankcase to
keep the piston pin clips, or other parts, from
falling into the crankcase.
2. Remove the piston pin clips (2) using a pair of
needle-nose pliers.
3. Press the piston pin (3) out of the piston (4),
and remove the piston.
(CRF450RX)
Under racing conditions, the piston, rings and
piston pin should be replaced every 4 races or
about every 15.0 hours of running.
(CRF450R/RWE)
Under racing conditions, the piston, rings and
piston pin should be replaced every 6 races or
about every 15.0 hours of running.
Be careful not to damage or shock the piston pin.
Do not clean the piston pin using a commercially
available compound cleaner.
Spread each piston ring (1) and remove by lifting it
up at a point just opposite the gap.
Do not damage the piston ring by spreading the
ends too far.
Cylinder Removal
(1) cylinder (2) piston
(3) dowel pins (4)
cylinder gasket
(2)
(1)
(3)
(4)
Piston Removal
(1) shop towels (3) piston pin
(2) piston pin clips (4) piston
(2)
(4)
(3)
(1)
Piston Ring Removal
(1) piston ring
(1)
Servicing Your Honda 91
Piston/Piston Rings/Piston Pin
We recommend you consult an official Honda
Service Manual or your dealer for correct Service
Limit measurements.
1. Remove the carbon deposits from the piston
head and piston ring grooves.
Do not damage the piston when removing the
carbon deposit.
2. Apply engine oil to each piston ring whole
surface.
3. Install the spacer (1) first, then install the side
rails (2) to the piston (3).
4. Install the top ring (4) to the piston with “1R”
mark (5) side facing up.
Do not damage the piston ring by spreading the
ends too far.
Do not damage the piston during piston ring
installation.
5. After installing the piston rings they should
rotate freely, without sticking. Space the ring
end gaps 180 degrees apart between top ring
and upper side rail. Space the ring end gaps 90
degrees apart between upper side rail, spacer
and lower side rail.
Piston/Piston Pin/Piston Ring Inspection Piston Ring Installation
(1) spacer (4) top ring
(2) side rails (5) “1R” mark
(3) piston
(4)
(2)
(1)
(2)
(5)
(4)
(2)
(1)
(2)
(3)
92 Servicing Your Honda
Piston/Piston Rings/Piston Pin
1. Place clean shop towels (1) over the crankcase
opening to keep the piston pin clips from
falling into the crankcase.
2. Apply molybdenum disulfide oil (a mixture of
1/2 engine oil and 1/2 molybdenum disulfide
grease containing more than 3% molybdenum
disulfide additive Moly Paste 77) to the
connecting rod small end (2) inner surface.
3. Install the piston (3) with the “IN” mark (4)
and/or the large valve recesses (5) facing the
intake side of the engine.
Apply molybdenum disulfide oil (a mixture of
1/2 engine oil and 1/2 molybdenum disulfide
grease containing more than 3% molybdenum
disulfide additive Moly Paste 77) to the piston
pin (6) outer surface. Apply engine oil to the
piston outer surface and piston pin hole inner
surface. Install the piston pin and new piston
pin clips (7).
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).
Piston Installation
(1) shop towels
(2) connecting rod small end
(1)
(2)
(3) piston (5) large valve recesses
(4) “IN” mark
(4)
(5)
(3)
(6) piston pin (8) piston cutout
(7) piston pin clips (new)
(6)
(8)
(7)
(7)
Servicing Your Honda 93
Piston/Piston Rings/Piston Pin
1. Clean the cylinder mating surfaces (1) of the
crankcase, being careful not to let any material
fall into the crankcase.
2. Remove the shop towels.
3. Apply liquid sealant (TB1141G manufactured
by ThreeBond or equivalent) to the cylinder
mating surface of the crankcase side as shown.
4. Install the dowel pins (2) and a new cylinder
gasket (3).
Do not let the dowel pins fall into the crankcase.
5. Apply engine oil to the cylinder bore (4),
piston outer surface and piston rings (5). Route
the cam chain (6) through the cylinder. Install
the cylinder over the piston rings by hand
while compressing the piston rings.
Do not damage the piston rings and cylinder bore.
Do not let the cam chain fall into the crankcase.
Cylinder Installation
(1) cylinder mating surface
0.2 – 0.4 in
(5 – 10 mm)
0.2 – 0.4 in
(5 – 10 mm)
(1)
(2) dowel pins (3)
cylinder gasket
(new)
(2)
(3)
(4) cylinder bore (6) cam chain
(5) piston rings
(6)
(5)
(4)
94 Servicing Your Honda
Piston/Piston Rings/Piston Pin
1. Clean any gasket material off cylinder head.
2. Install the cam chain guide (1) and fit the cam
chain guide tabs (2) in the cylinder cutouts (3).
Push the guide until it bottoms in the crankcase
guide groove.
3. Install the dowel pins (4) and a new cylinder
head gasket (5).
Do not let the dowel pins fall into the crankcase.
4. Route the cam chain through the cylinder head
and install the cylinder head (6).
Do not damage mating surfaces when installing
the cylinder head.
5. Apply engine oil to all cylinder head bolt
threads and seating surface.
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.
6. Install the cylinder bolt (8) and tighten it to the
specified torque:
7 lbf·ft (10 N·m, 1.0 kgf·m)
Cylinder Head Installation
(1) cam chain guide (3) cylinder cutouts
(2) cam chain guide tabs
(1)
(3)
(2)
(4) dowel pins
(5) cylinder head gasket (new)
(4)
(5)
(6) cylinder head
(7) washers and cylinder head bolts
(8) cylinder bolt
(7)
(6)
(8)
Piston/Piston Rings/Piston Pin
(cont’d)
Servicing Your Honda 95
7. Install the left cylinder head hanger plate (9)
and right cylinder head hanger plate (10), then
loosely install the cylinder head hanger plate
bolts (11) and cylinder head hanger bolts (12).
Tighten the cylinder head hanger bolts and
cylinder head hanger plate bolts to the
specified torque:
cylinder head hanger bolts:
40 lbf·ft (54 N·m, 5.5 kgf·m)
cylinder head hanger plate bolts:
24 lbf·ft (32 N·m, 3.3 kgf·m)
8. Install the throttle body (13) to the insulator
(14) by aligning the tab of the throttle body
with the groove of the insulator and tighten the
insulator band screw (15) so the distance
between the band ends is 0.43 ± 0.04 in (11.0 ±
1.0 mm).
9. Install and tighten the washer (16) and right
radiator lower mounting bolt (17) securely.
10. Connect the radiator hose (18) to the water
hose joint (19) of the cylinder head as shown.
11. Tighten the radiator hose clamp screw (20) as
illustrated below.
(9) left cylinder head hanger plate
(10) right cylinder head hanger plate
(11) cylinder head hanger plate bolts
(12) cylinder head hanger bolts
Left side:
(9)
(12)
(11)
Right side:
(11)
(10)
(12)
(13) throttle body (15) insulator band screw
(14) insulator
(15)
(13)
Align
(14)
0.43 ± 0.04 in
(11.0 ± 1.0 mm)
(15)
(16) washer
(17) right radiator lower mounting bolt
(18) radiator hose
(19) water hose joint
(20) radiator hose clamp screw
(16)
(17)
(18)
(19)
0 – 0.02 in
(0 – 0.5 mm)
(20)
96 Servicing Your Honda
Piston/Piston Rings/Piston Pin
12. Connect the ECT sensor connector (21).
13. Install the ignition coil (22) and tighten the
ignition coil bolts (23) to the specified torque:
7 lbf·ft (10 N·m, 1.0 kgf·m)
Connect the ignition coil A connector (24) and
B connector (25).
14. Install the shims, camshaft and camshaft
holder (page 84).
15. Install the crankshaft hole cap (page 86).
16. Install the cylinder head cover (page 87).
17. Install the spark plug (page 78).
18. Install the exhaust pipe (page 130).
19. Install the subframe (page 40) and left and
right mufflers (page 127).
20. Install the fuel tank and seat (pages 34, 36, 38).
21. Fill and bleed the cooling system (page 163).
Check for the following:
– compression leaks
– abnormal engine noise
– secondary air leaks
– exhaust gas leaks
– coolant leaks
– oil leaks
(21) ECT sensor connector
(22) ignition coil
(23) ignition coil bolts
(24) ignition coil A connector
(25) ignition coil B connector
(21)
(25)
(23)
(22)(24)
Suspension
(cont’d)
Servicing Your Honda 97
Refer to Important Safety Precautions on page 23.
Loose, w
orn, or damaged suspension components
may adversely affect the handling and stability of
your CRF. If any suspension components appear
worn or damaged, see your dealer for further
inspection. Your dealer is qualified to determine
whether or not replacement parts or repairs are
needed.
• When your CRF is new, break it in for
approximately 1 hour to ensure that the
suspension has worked in (page 20).
• After break-in, test run your CRF with the
front suspension at the standard setting before
attempting any adjustments.
• For optimum fork performance, we
recommend that you disassemble and clean the
fork after riding your CRF for 3 hours.
See page 98 for front suspension removal.
• (CRF450RX)
Replace the fork oil every 6 races or 22.5 hours
of running. See page 100, 101, 105 – 113 for
fork oil replacement.
• (CRF450R/RWE)
Replace the fork oil every 9 races or 22.5 hours
of running. See page 100, 101, 105 – 113 for
fork oil replacement.
• Use Pro Honda HP Fork Oil, A15-00 or an
equivalent which contains special additives to
assure maximum performance of your CRF’s
front suspension.
Periodically check and clean all front
suspension parts to assure top performance.
Check the dust seals for dust, dirt, and foreign
materials. Check the oil for any contamination.
•Refer to Suspension Adjustment Guidelines
(page 152). Make all rebound and compression
damping adjustments in one-click increments.
(Adjusting two or more clicks at a time may
cause you to pass over the best adjustment.)
Test ride after each adjustment.
• If you become confused about adjustment
settings, return to the standard position and
start over.
• If the fork is still too stiff/soft after adjusting
compression damping, determine which
portion of the travel is still too stiff/soft. This is
an important step that will help you solve
suspension problems.
1. Make sure that the fork protectors (1) and dust
seals (2) are clean and not packed with mud
and dirt.
2. Check for signs of oil leakage. Damaged or
leaking fork seals should be replaced before
your CRF is ridden.
3. Inspect the wear rings (3) for wear or damage.
Replace the wear ring if it is 0.06 in (1.5 mm)
or flush with the outer tube (4). Remove the
fork leg when replacing the wear ring
(page 98).
Install the wear ring with its end gap (5) facing
rearward.
Front Suspension Inspection
(1) fork protectors (2) dust seals
(1)
(2)
(3) wear rings (4) outer tube
(3) wear rings (5) end gaps
0.06 in (1.5 mm)
(4)
(3) (3)
(3)
(5)
98 Servicing Your Honda
Suspension
4. Make a quick check of fork operation by
locking the front brake and pushing down on
the handlebar several times.
• When disassembling the fork, turn the
compression (1) and rebound (2) damping
adjusters counterclockwise to the softest
position to prevent damaging the adjustment
needle (be sure to record the number of turns
from the starting position).
1. Unlock the number plate tab (3) from the
handlebar. Remove the bolts (4) and number
plate (5).
2. Place your CRF on an optional workstand or
equivalent support with the front wheel off the
ground.
3. Remove the handlebar protector, handlebar
upper holder bolts (6), handlebar upper holders
(7) and handlebar (8).
Keep the master cylinder upright to prevent air
from entering system.
4. Loosen the fork bridge upper pinch bolts (9).
5. Loosen the fork bolts assembly (10), but do not
remove them yet.
Front Suspension Removal
(1) compression damping adjuster
(2) rebound damping adjuster
(3) number plate tab (5) number plate
(4) bolts
(1)
(2)
(5)
(4)
(3)
(6) handlebar upper holder bolts
(7) handlebar upper holders
(8) handlebar
(7)
(6)
(7)
(8)
Suspension
(cont’d)
Servicing Your Honda 99
6. Loosen the fork damper assembly (11) using
the lock nut wrench (12), but do not remove
them.
• Lock nut wrench 07WMA-KZ30100
Do not use an adjustable wrench to loosen the fork
damper: it may damage them.
7. Remove the disc cover (13) by removing disc
cover socket bolts (14).
8. Remove the front axle nut (15) and loosen the
axle pinch bolts (16) on both forks.
Pull the front axle shaft (17) out of the wheel
hub and remove the front wheel with collars
(18).
9. Remove the brake hose clamp bolts (19), stay
A (20) and stay B (21).
10. Remove the front brake caliper mounting bolts
(22) and brake caliper (23).
• Do not support the brake caliper by the brake
hose.
• Do not operate the brake lever after the front
wheel is removed. To do so will cause
difficulty in fitting the brake disc between
the brake pads.
11. Remove the fork protector socket bolts (24)
and fork protectors (25).
(9) fork bridge upper pinch bolts
(10) fork bolt assembly
(11) fork damper assembly
(12) lock nut wrench
(13) disc cover (14) disc cover socket bolts
(11)
(9)
(12)
(10)
(13)
(14)
(15) front axle nut (17) front axle shaft
(16) axle pinch bolts (18) collars
(16)
(17) (18)
(16)
(15)(18)
(19) brake hose clamp bolts
(20) stay A
(21) stay B
(22) front brake caliper mounting bolts
(23) brake caliper
(24) fork protector socket bolts
(25) fork protectors
(22)
(23)
(19)
(20)
(21)
(25)
(24)
(24)
(25)
100 Servicing Your Honda
Suspension
12. Loosen the fork bridge lower pinch bolts (26),
then pull the fork legs down and out.
13. Clean the fork assembly, especially the sliding
surface (27) of the slider and fork dust seal
(28).
14. Measure the length (29) between the axle
holder and outer tube and record it before
disassembling the fork.
Refer to Front Suspension Removal on page 98.
1. Clean the fork assembly, especially the sliding
surface of the slider and dust seal.
2. Hold the outer tube (1), then remove the fork
damper assembly (2) from the outer tube using
the lock nut wrench (3). Gently slide the outer
tube down onto the lower end (axle holder) (4).
• Lock nut wrench 07WMA-KZ30100
The outer tube (1) can drop on the axle holder (4)
and damage the fork dust seal (5). To avoid
damage, hold both the outer tube and slider when
removing the fork damper.
3. Drain the fork oil from the outer tube (1) and
oil holes (6) of the fork damper assembly (2).
Remove the O-ring (7) from the fork damper
assembly.
(26) fork bridge lower pinch bolts
(27) sliding surface (29) length
(28) fork dust seal
(26)
(29)
(28)
(27)
Recommended Fork Oil
suggested oil Pro Honda HP Fork Oil, A15-00
Fork Outer Tube Disassembly
(1) outer tube (3) lock nut wrench
(2) fork damper assembly (4) axle holder
(1)
(4)
(2)
(1)
(3)
(1) outer tube (5) fork dust seal
(4) axle holder
(1) outer tube (6) oil holes
(2) fork damper assembly (7) O-ring
(1)
(5)
(4)
(1)
(2)
(7)
(6)
Servicing Your Honda 101
Suspension
4. Drain the fork oil by turning the outer tube (1)
upside down. (About 0.46 US oz (13.7 cm
3
) of
fork oil will be left in the outer tube when it is
left inverted for about 20 minutes at 68°F/
20°C.)
Pour the drained oil into a suitable container and
dispose of it in an approved manner (page 164).
Improper disposal of drained oil is harmful to the
environment.
1. Pour the recommended fork oil into the outer
tube (1).
Be sure the oil capacity is the same in both fork
legs.
Recommended Oil:
Pro Honda HP Fork Oil, A15-00
Recommended Standard Amount:
(CRF450RX)
12.2 US oz (360 cm
3
)
(CRF450R/RWE)
12.0 US oz (356 cm
3
)
Fill the fork oil which is obtained by docking off
the amount of the remaining oil in the fork from the
recommended standard fork oil capacity.
Refer to Front Suspension Adjustments on
page 143.
2. Apply the recommended fork oil to a new O-ring
(2). Install the O-ring on the fork damper
assembly (3).
3. Pull up the fork outer tube (1) slowly and
temporarily tighten the fork damper assembly
(3) using the lock nut wrench (4).
• Lock nut wrench 07WMA-KZ30100
(1) outer tube
Amount of fork oil left in the fork
(within damper and spring) unit: cm
3
minute
°C/°F
5 1020355585145
30/86 16.5 14.1 12.7 11.8 11 10.1 8.6
20/68 17.4 15 13.7 12.6 11.5 10.5 9.1
10/50 18.9 16.5 14.8 13.7 12.5 11.4 9.8
0/32 20 18.4 15.9 14.5 13.7 13 11.7
(1)
Inverted time
0°C/32°F
10°C/50°F
20°C/68°F
30°C/86°F
Amount of fork oil
(minutes)
Fork Oil Refilling
(1) outer tube
(1)
(2) O-ring (new) (3) fork damper assembly
(1) outer tube (4) lock nut wrench
(3) fork damper assembly
(2)
(3)
(4)
(3)
(1)
102 Servicing Your Honda
Suspension
1. Insert both fork legs into the fork clamps.
Tighten the fork bridge lower pinch bolts (1) to
the specified torque:
15 lbf·ft (20 N·m, 2.0 kgf·m)
2. Tighten the fork damper assembly (2) to the
specified torque using the lock nut wrench (3):
Actual:
56 lbf·ft (76 N·m, 7.7 kgf·m)
Torque wrench scale reading:
51 lbf·ft (69 N·m, 7.0 kgf·m), using a 20 in
(500 mm) long deflecting beam type torque
wrench.
• Lock nut wrench 07WMA-KZ30100
When using the lock nut wrench, use a 20 in (500
mm)
long deflecting beam type torque wrench.
The
lock nut wrench increases the torque wrench’s
leverage, so the torque wrench reading will be less
than the torque actually applied to the fork damper
assembly.
3. Tighten the fork bolt assembly (4) to the
specified torque:
22 lbf·ft (30 N·m, 3.1 kgf·m)
4. For ease of releasing air pressure after the forks
are installed, loosen the fork bridge lower
pinch bolts (1) and position the outer tubes so
that the fork air pressure release screws (5) are
in front of the compression damping adjuster
(6).
5. Align the groove (7) in the outer tube with the
top surface of the upper fork bridge (8).
Front Suspension Installation
(1) fork bridge lower pinch bolts
(1)
(2) fork damper assembly
(3) lock nut wrench
(4) fork bolt assembly
(4)
(3)
(2)
(1) fork bridge lower pinch bolts
(5) pressure release screw
(6) compression damping adjuster
(7) groove (8) upper fork bridge
(6)
(5)
(1)
Align
(7)
(8)
Suspension
(cont’d)
Servicing Your Honda 103
6. Tighten the fork bridge lower pinch bolts (1) to
the specified torque:
15 lbf·ft (20 N·m, 2.0 kgf·m)
7. Tighten the fork bridge upper pinch bolts (9) to
the specified torque:
16 lbf·ft (22 N·m, 2.2 kgf·m)
Over-tightening the pinch bolts can deform the
outer tubes. Deformed outer tubes must be
replaced.
8. Clean the threads of the fork protector socket
bolts (10) and axle holder thoroughly.
Apply locking agent to the bolt threads.
Install the fork protectors (11), fork protector
socket bolts.
Tighten the fork protector socket bolts to the
specified torque:
5.2 lbf·ft (7 N·m, 0.7 kgf·m)
9. Align the brake caliper (12) and brake hose
(13) with the left fork leg, making sure that the
brake hose is not twisted. An improperly
routed brake hose may rupture and cause a loss
of braking efficiency.
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).
11. Clean the threads of the front brake caliper
mounting bolts (18) and brake caliper
thoroughly.
Apply locking agent to the bolt threads.
Install the brake caliper (12) on the axle holder
and tighten the front brake caliper mounting
bolts to the specified torque:
22 lbf·ft (30 N·m, 3.1 kgf·m)
(1) fork bridge lower pinch bolts
(9) fork bridge upper pinch bolts
(1)
(9)
(10) fork protector socket bolts
(11) fork protectors
(10)
(10)
(11)
(11)
(12) brake caliper
(13) brake hose
(14) brake hose protector
(15) stay A
(16) stay B
(17) brake hose clamp bolts
(18) front brake caliper mounting bolts
(17) (12)
(18)(13)
(16)
(15)
Align
(14)
104 Servicing Your Honda
Suspension
12. Clean the surfaces where the axle and axle
clamps contact each other.
Apply grease to each dust seal lips (19) of the
front wheel.
Install the left side collar (20) and right side
collar (21) into the wheel hub.
13. Install the front wheel between the fork legs
while inserting the brake disc between the
brake pads, being careful not to damage the
pads.
14. Insert the front axle shaft (22) through the
forks and wheel hub from the right side. Make
sure that the front axle shaft is seated firmly
onto the left fork leg clamp inner surface.
Tighten the front axle nut (23) to the specified
torque:
65 lbf·ft (88 N·m, 9.0 kgf·m)
Tighten the left axle pinch bolts (24) to the
specified torque:
15 lbf·ft (20 N·m, 2.0 kgf·m)
15. Install the handlebar (25), handlebar upper
holders (26) and handlebar upper holder bolts
(27)
and tighten the handlebar upper holder
bolts to the specified torque:
16 lbf·ft
(22 N·m, 2.2 kgf·m)
• Install the handlebar upper holder with the
punch marks (28) facing forward.
• Align the paint mark (29) on the handlebar with
the end of the left handlebar holders.
• First, tighten the bolts on front side of the
handlebar upper holders.
16. Install the handlebar protector.
Install the number plate (30) by aligning its tab
(31)
with the slit (32) on the front fender.
Install and tight
en the bolts (33).
Route the number plate tab (34) around the
handlebar (35) as shown. Make sure that the
brake hose (13) is routed properly in front of
the number plate.
(19) dust seal lips (21) right side collar
(20) left side collar
(20)
(21)
(19)
(19)
(22) front axle shaft
(23) front axle nut
(24) left axle pinch bolts
(23)
(24)
(22)
(25) handlebar
(26) handlebar upper holders
(27) handlebar upper holder bolts
(28) punch marks
(29) paint mark
(13) brake hose (33) bolts
(30) number plate (34) number plate tab
(31) tab (35) handlebar
(32) slit
(28)
(27)
(25)
(26)
(28)
(29)
(26)
(26)
(13)
(35)
(30)
(31)
(32)
(34)
(33)
Suspension
(cont’d)
Servicing Your Honda 105
17. With the front brake applied, pump the fork up
and down several times to seat the axle and
check front brake operation.
18. While keeping the forks parallel, alternately
tighten the right axle pinch bolts (36) to the
specified torque:
15 lbf·ft (20 N·m, 2.0 kgf·m)
To avoid damage when torquing the axle pinch
bolts, be sure the axle is seated firmly onto the left
fork leg clamp inner surface.
19. Install the disc cover (37) and tighten the disc
cover socket bolts (38) to the specified torque:
10 lbf·ft (13 N·m, 1.3 kgf·m)
20. Turn the compression damping (39) and
rebound damping (40) adjuster screws back to
their original settings.
Refer to Front Suspension Damping on page 144.
1. Remove the front suspension (page 98).
2. Disassemble the fork outer tube (page 100).
3. Place the lower end (axle holder) (1) of the
slider in a vise with a piece of wood or soft
jaws to avoid damage.
Over-tightening the vise can damage the axle
holder.
4. Loosen the fork center bolt (2).
5. Pull up the fork outer tube slowly and
temporarily tighten the fork damper assembly
(page 101). Push the outer tube until the fork
center bolt lock nut (3) is fully exposed and
install the piston base (4) or mechanic’s
stopper tool between the axle holder (1) and
fork center bolt lock nut.
• Piston base 07958-2500001
(36) right axle pinch bolts
(36)
(37) disc cover (38) disc cover socket bolts
(39) compression damping adjuster
(40) rebound damping adjuster
(37)
(38)
(39)
(40
Fork Damper Disassembly
(1) axle holder (2) fork center bolt
(1)
(2)
106 Servicing Your Honda
Suspension
6. Make the mechanic’s stopper tool out of a thin
piece of steel (0.08 in (2.0 mm) thick) as shown
if you do not have a special tool.
7. Hold the fork center bolt lock nut (3) and
remove the fork center bolt (2) from the fork
damper.
Do not remove the lock nut from the fork damper
piston rod. If the lock nut is removed, the piston
rod will fall in the fork damper and you may not
reassemble the fork damper.
8. Remove the push rod (5) from the fork damper.
9. Remove the piston base (4) or mechanic’s
stopper tool between the axle holder (1) and
fork center bolt lock nut (3) while pushing the
fork outer tube.
Be careful not to damage the lock nut and fork
center bolt hole.
10. Remove the fork damper assembly (6) from
the fork assembly (7).
Remove the fork from the vise.
Remove the fork spring (8), spring seat collar
(9) and back-up ring/seat stopper (10) from the
fork damper assembly.
Do not attempt to separate the fork assembly and
drop the axle holder out from the outer tube, which
can damage the guide bushings (11).
To avoid damage, hold both the outer tube and
slider.
(1) axle holder (3) fork center bolt lock nut
(2) fork center bolt (4) piston base
2.2 in (55 mm)
1.0 in
(25 mm)
0.30 in
(7.5 mm)
0.6 in
(15 mm)
1.5 in (39 mm)
(1)
(3)
(4)
(2)
(1) axle holder (4) piston base
(3) fork center bolt lock nut (5) push rod
(1)
(4)
(5)
(3)
(11) guide bushing
(6) fork damper assembly
(7) fork assembly
(8) fork spring
(9) spring seat collar
(10) back-up ring/seat stopper
(11)
(9)
(6)
(7)
(8)
(10)
Suspension
(cont’d)
Servicing Your Honda 107
1. Check the fork center bolt lock nut (1) is
installed on the fork damper piston rod (2)
properly.
If the lock nut was removed, the piston rod will fall
into the fork damper and you will not be able to
reassemble the fork damper.
2. Loosen the fork bolt assembly (3) while
holding the fork damper assembly (4).
3. Remove the fork bolt assembly (3) from the
fork damper threads and then pop it out by
pumping the fork damper piston rod (2)
slowly.
4. Remove the fork bolt assembly (3).
Be careful not to damage the fork bolt bushings (5).
Do not disassemble the fork bolt assembly.
Replace the fork bolt as an assembly if it is
damaged.
5. Empty the fork oil from the fork damper
assembly (4) by pumping the damper rod
several times.
6. Clean the fork bolt and fork damper assembly
threads (6).
7. Extend the fork damper piston rod to
maximum length.
Pour the recommended fork oil into the fork
damper assembly (4).
Recommended Oil:
Pro Honda HP Fork Oil, A15-00
Recommended Amount:
8.2 US oz (243 cm
3
)
Damper Oil Change
(1) fork center bolt lock nut
(2) fork damper piston rod
(3) fork bolt assembly (4) fork damper assembly
(1)
(2)
(3)
(4)
(2) fork damper piston rod (5) fork bolt bushings
(3) fork bolt assembly
(4) fork damper assembly
(2)
(5)
(3)
(4)
(6) fork bolt and fork damper assembly threads
(4) fork damper assembly
(6)
(4)
108 Servicing Your Honda
Suspension
8. Pump the fork damper piston rod (2) slowly
several times to bleed the air from the fork
damper assembly (4).
9. Apply the recommended fork oil to the fork
bolt bushings (5), new O-rings (7) and new
piston ring (8) on the fork bolt assembly (3).
10. Cover the oil holes (9) of the fork damper
assembly with a shop towel and compress the
piston rod (2) all the way.
Pull the piston rod out 0.8 in (20 mm) and
install the fork bolt assembly (3) into the fork
damper assembly (4).
Push the fork bolt assembly in slowly while
pulling the piston rod out.
Be careful not to damage the fork bolt piston ring.
11. Temporarily tighten the fork bolt assembly (3)
to the fork damper assembly (4).
12. Completely screw in the fork center bolt lock
nut (1) to the fork damper piston rod (2).
13. Check the fork damper piston rod sliding
surface and threads for damage.
(2) fork damper piston rod
(4) fork damper assembly
(3) fork bolt assembly (7) O-rings (new)
(5) fork bolt bushings (8) piston ring (new)
(4)
(2)
(7)
(7) (8)(7)
(3)(5)
(2) fork damper piston rod (4) fork damper assembly
(3) fork bolt assembly (9) oil holes
(3)
(4)
(2)
(9)
(3) fork bolt assembly (4) fork damper assembly
(1) fork center bolt lock nut
(2) fork damper piston rod
(4)
(3)
(1)
(2)
Suspension
(cont’d)
Servicing Your Honda 109
14. Hold the fork damper assembly (4) in an
upright position and pump the fork damper
piston rod (2) 3.9 in (100 mm) slowly, several
times.
Be careful not to bend or damage the fork damper
piston rod when the piston rod is stroked.
15. Cover the fork damper piston rod end with
shop towel (10) to prevent fork damage.
Cover the oil holes with shop towel to prevent
blow out of fork oil.
Blow the extra oil off from the fork damper
assembly (4) by pumping the fork damper
piston rod to full stroke.
16. Drain the extra oil from the oil holes (9) of the
fork damper assembly (4).
By doing above procedure, about 0.2 US oz (5
cm
3
) of fork oil will be drained from the fork
damper through the oil hole and cause 8.2 US oz
(243 cm
3
) of fork oil to be left in the 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.
(2) fork damper piston rod (4) fork damper assembly
(4)
(2)
(4) fork damper assembly (10) shop towel
(10)
(10)
(4)
(4) fork damper assembly (9) oil holes
(4)
(9)
110 Servicing Your Honda
Suspension
17. Blow out any oil from the oil hole (9) of the
fork damper assembly (4) using compressed
air.
Wipe off the oil completely from the fork
damper.
18. If you cannot use compressed air, remove the
fork air pressure release screws (11) from the
fork bolt assembly.
Hold the fork damper upside down for 20
minutes and drain the fork oil.
Apply the recommended fork oil to a new O-
ring (12), and then install a new O-rings on the
air pressure release screws (11).
Tighten the air pressure release screws to the
specified torque:
1.0 lbf·ft (1.3 N·m, 0.1 kgf·m)
19. Fully stroke the piston rod (2) by pushing
down the fork damper assembly (4).
Check the piston rod for smooth operation.
If the piston rod operation is not smooth, check
the piston rod for bends or damage.
1. Drain the fork oil from the fork assembly (1)
by placing it upside down.
(About (0.2 US oz (5.4 cm
3
) of fork oil will be
left in the fork assembly when it is left inverted
for about 20 minutes at 20 °C/68 °F)
To properly dispose of drained fluids, refer to You
& the Environment on page 164.
Improper disposal of drained fluids is harmful to
the environment.
(4) fork damper assembly
(9) oil hole
(11) air pressure release screws
(12) O-rings (new)
(4)
(9) (11) (12)
(2) fork damper piston rod
(4) fork damper assembly
(4)
(2)
Fork Damper Installation
(1) fork assembly
Amount of fork oil left in the fork
(without damper and spring) unit: cm
3
minute
°C/°F
5 1020355585145
30/86 6.5 5.7 5.2 4.5 4.1 3.7 3.3
20/68 6.7 6.2 5.4 4.7 4.4 3.8 3.5
10/50 7.3 6.4 5.6 5 4.6 4.2 3.8
0/32 8.6 8.2 7.9 7.6 7.3 6.8 6
(1)
Suspension
(cont’d)
Servicing Your Honda 111
2. Tighten the fork center bolt lock nut (2) fully
and measure the thread length (A) as shown.
Standard: 0.35 – 0.43 in (9 – 11 mm)
Wipe the oil completely off the fork damper.
3. Apply the recommended fork oil to the slider
bushing (3).
Install the seat stopper (4), back-up ring (5)
and spring seat collar (6) to the fork damper
(7).
Make sure the black side of the back-up ring is
seated on the seat stopper side.
4. Blow out the oil completely off the fork spring
(8).
Put the fork spring on the fork damper
assembly (9).
Install the spring/fork damper assembly into
the fork assembly (1).
5. Temporarily tighten the fork damper assembly
(9)
to the outer tube (10) using the lock nut
wrench (11).
• L
ock nut wrench 07WMA-KZ30100
6. Place the lower end (axle holder) (12) of the
slider in a vise with a piece of wood or soft
jaws to avoid to damage.
Over-tightening the vise can damage the axle
holder.
(2) fork center bolt lock nut (A) thread length
(3) slider bushing (6) spring seat collar
(4) seat stopper (7) fork damper
(5) back-up ring
(A)
(2)
(4)
(5)
(7)
(4)
(5)
(6) (3)
(1) fork assembly (9) fork damper assembly
(8) fork spring
(9)
(8)
(1)
(9) fork damper assembly (11) lock nut wrench
(10) outer tube
(9)
(10)
(11)
112 Servicing Your Honda
Suspension
7. Push the outer tube until the fork center bolt
lock nut (2) is fully exposed and install the
piston base (13) or mechanic’s stopper tool
between the axle holder (12) and fork center
bolt lock nut.
Measure the thread length again.
Standard: 0.35 – 0.43 in (9 – 11 mm)
• Piston base 07958-2500001
8. Install the push rod (14) into the piston rod (15)
until it stops.
9. Apply fork oil to new O-ring (16) and install it
to the fork center bolt (17).
Install the fork center bolt to the fork damper
piston rod (15) by aligning the each flat-side of
the fork center bolt adjusting rod and the push
rod (14).
Tighten the fork center bolt fully by hand.
10. Measure the clearance between the fork center
bolt lock nut (2) and fork center bolt (17).
Standard: 0.06 – 0.08 in (1.5 – 2.0 mm)
If the clearance is out of specification, check the
fork center bolt lock nut and fork center bolt
installation.
11. Tighten the fork center bolt lock nut (2) to the
fork center bolt (17) closely by hand. Tighten
the fork center bolt lock nut to the specified
torque:
21 lbf·ft (28 N·m, 2.9 kgf·m)
12. Apply locking agent to the fork center bolt
threads.
Remove the piston base or mechanic’s stopper
tool while pushing the outer tube.
Install the fork center bolt (17) to the axle
holder and tighten it to the specified torque:
51 lbf·ft (69 N·m, 7.0 kgf·m)
(2) fork center bolt lock nut (14) push rod
(12) axle holder (15) piston rod
(13) piston base
(12)
(2)
(13)
(15)
(14)
0.35 – 0.43 in
(9 – 11 mm)
(14) push rod (16) O-ring (new)
(15) piston rod (17) fork center bolt
(2) fork center bolt lock nut (17) fork center bolt
(15)
(14)
(17)
(16)
Align
(2)
(17)
0.06 – 0.08 in
(1.5 – 2.0 mm)
(2) fork center bolt lock nut
(17) fork center bolt
(17) fork center bolt
(2)
(17)
(17)
Servicing Your Honda 113
Suspension
13. Remove the fork from the vice.
14. Measure the length between the axle holder
and outer tube.
Standard: 12.3 ± 0.1 in (312 ± 2 mm)
15. Compare the length (18) at assembly and at
disassembly. They should be the same length.
If the length at assembly is longer than at
disassembly, check the fork center bolt and fork
center bolt lock nut installation.
16. Refilling the fork oil (page 101).
17. Install the front suspension (page 102).
The swingarm is controlled by one hydraulic shock
absorber with an aluminum reservoir for oil and
nitrogen gas pressure. The gas pressure in the
reservoir is contained within a rubber bladder.
The rear suspension’s spring pre-load and damping
adjustments (compression and rebound) should be
adjusted for the rider’s weight and track conditions
(pages 149, 151, 154).
Do not attempt to disassemble, service, or dispose
of the damper; see your dealer.
The instructions found in this owner’s manual are
limited to adjustments of the shock assembly only.
• When your CRF is new, break it in for
approximately 1 hour with the standard
suspension settings before attempting to adjust
the rear suspension.
•Refer to Suspension Adjustment Guidelines
(page 154) for making all rebound and
compression damping adjustments in one click
or 1/12 turn increments. (Adjusting two or
more clicks or turns at a time may cause you to
pass over the best adjustment.)
Test ride after each adjustment.
• If the rear suspension is too stiff/soft, adjust it
by turning all the compression and rebound
adjusters according to the procedures
described in page 154. After adjusting the
adjusters simultaneously, suspension may be
fine-tuned by turning one of the compression
and rebound damping adjusters in one click or
in 1/12 turn increments.
• If you have a problem finding an acceptable
adjustment, return to the standard position and
begin again.
1. Bounce the rear of the motorcycle up and down
and check for smooth suspension action.
2. Remove the right and left mufflers (page 126),
and subframe (page 39).
3. Check for a broken or collapsed spring.
4. Check the rear shock absorber (1) for a bent
rod or oil leaks.
5. Push the rear wheel sideways to check for
worn or loose swingarm bearings. There
should be no movement. If there is, have the
bearings replaced by your dealer.
(18) length
(18)
Rear Suspension Inspection
(1) rear shock absorber
(1)
Brakes
114 Servicing Your Honda
Refer to Important Safety Precautions on page 23.
B
oth the front and rear brakes are the hydraulic
disc type. As the brake pads wear, the brake fluid
level will drop. A leak in the system will also cause
the level to drop.
Frequently inspect the system to ensure there are
no fluid leaks. Periodically inspect the brake fluid
level and the brake pads for wear.
If the braking response of the front brake lever or
rear brake pedal feels unusual, check the brake
pads. If the brake pads are not worn beyond the
recommended limit (page 117), there is probably
air in the brake system.
Refer to an official Honda Service Manual or see
your dealer to have the air bled from the system.
1. Slide the front brake lever cover (1).
2. Loosen the lock nut (2).
3. To position the front brake lever farther away
from the handgrip, turn the adjuster (3)
clockwise.
To position the front brake lever closer to the
handgrip, turn the adjuster counterclockwise.
4. While holding the adjuster, tighten the lock nut
to the specified torque:
4.4 lbf·ft (5.9 N·m, 0.6 kgf·m)
5. Apply silicone grease to the contacting areas of
the adjuster and knocker arm (4).
6. Install the front brake lever cover in the reverse
order.
The rear brake pedal height should be
approximately level with the right footpeg.
1. Loosen the lock nut (1) and turn the push rod
(2) in direction (+) to raise the rear brake pedal
(3)
or in direction (–) to lower it.
2. Tighten the push rod lock nut to the specified
torque at the desired pedal height.
4.4 lbf·ft (5.9 N·m, 0.6 kgf·m)
Front Brake Lever Adjustment
(1) brake lever cover
(2) lock nut (4) knocker arm
(3) adjuster
(1)
(3)
(2)
(4)
Rear Brake Pedal Height
(1) lock nut (+) raise the pedal height
(2) push rod (–) lower the pedal height
(3) rear brake pedal
(1)
(3)
(2)
(–)
(+)
Servicing Your Honda 115
Brakes
Front Brake Fluid Level Check
With the motorcycle in an upright position, check
the fluid level.
It should be above the LWR mark (1). If the level
is at or below the LWR mark, check the brake pads
for wear (page 117).
Worn brake pads should be replaced. If the pads
are not worn, have your brake system inspected for
leaks.
If the pulling distance for the front brake lever
feels excessive, there is probably air in the brake
system and it must be bled. Refer to an official
Honda Service Manual or see your dealer for brake
bleeding.
Honda recommends using Honda DOT 4 Brake
Fluid from a sealed container, or an equivalent.
Other Checks:
Make sure there are no fluid leaks. Check for
deterioration or cracks in the hoses and fittings.
Rear Brake Fluid Level Check
With the motorcycle in an upright position, check
the fluid level.
It should be above the LOWER mark (1). If the
level is at or below the LOWER mark, check the
brake pads for wear (page 117).
Worn brake pads should be replaced. If the pads
are not worn, have your brake system inspected for
leaks.
If the travel for the rear brake pedal feels
excessive, there is probably air in the brake system
and it must be bled. Refer to an official Honda
Service Manual or see your dealer for brake
bleeding.
Honda recommends using Honda DOT 4 Brake
Fluid from a sealed container, or an equivalent.
Other Checks:
Make sure there are no fluid leaks. Check for
deterioration or cracks in the hoses and fittings.
Fluid Level Inspection
(1) LWR mark
(1)
(1) LOWER mark
(1)
116 Servicing Your Honda
Brakes
Adding Front Brake Fluid
Spilled brake fluid will severely damage painted
surfaces. It is also harmful to some rubber parts.
Be careful whenever you remove the reservoir
cap; make sure the reservoir is horizontal first.
•Always use fresh DOT 4 brake fluid from a
sealed container when servicing the system.
Do not mix different types of fluid, they may
not be compatible.
•The recommended brake fluid is Honda DOT 4
Brake Fluid or an equivalent.
1. Remove the front brake reservoir cap screws
(1), reservoir cap (2) and diaphragm (3).
2. Fill the reservoir with DOT 4 brake fluid to the
upper level mark (4). Do not overfill.
3. Install the diaphragm and reservoir cap.
4. Tighten the front brake reservoir cap screws to
the specified torque:
0.7 lbf·ft (1.0 N·m, 0.1 kgf·m)
Adding Rear Brake Fluid
Spilled brake fluid will severely damage painted
surfaces. It is also harmful to some rubber parts.
Be careful whenever you remove the reservoir
cap; make sure the reservoir is horizontal first.
•Always use fresh DOT 4 brake fluid from a
sealed container when servicing the system.
Do not mix different types of fluid, they may
not be compatible.
•The recommended brake fluid is Honda DOT 4
Brake Fluid or an equivalent.
1. Remove the rear brake reservoir cap bolts (1),
reservoir cap (2), set plate (3) and diaphragm
(4).
2. Fill the reservoir with DOT 4 brake fluid to the
upper level mark (5). Do not overfill.
3. Install the diaphragm, set plate and reservoir
cap.
4. Tighten the rear brake reservoir cap bolts to the
specified torque:
0.7 lbf·ft (1.0 N·m, 0.1 kgf·m)
(1) front brake reservoir cap screws
(2) reservoir cap
(3) diaphragm
(4) upper level mark
(3)
(2)
(4)
(1)
(1) rear brake reservoir cap bolts
(2) reservoir cap
(3) set plate
(4) diaphragm
(5) upper level mark
(1)
(2)
(3)
(5)
(4)
Servicing Your Honda 117
Brakes
Brake pad wear depends on the severity of usage
and track conditions. (Generally, the pads will
wear faster with wet and dirty track conditions.)
Inspect the brake pads at each regular maintenance
interval (pages 25, 26).
Front Brake Pads
Inspect the brake pads (1) through the front wheel
to determine the brake pad wear. If either brake
pad is worn anywhere to a thickness of 0.04 in (1.0
mm), both brake pads must be replaced.
Rear Brake Pads
Inspect the brake pads (1) from the rear side of the
caliper (2) to determine the brake pad wear. If
either brake pad is worn anywhere to a thickness of
0.04 in (1.0 mm), both brake pads must be
replaced.
Check that the front brake lever and rear brake
pedal assemblies are positioned properly
(page 114) and the securing bolts are tight.
Make sure there are no fluid leaks. Check for
deterioration or cracks in the hoses and fittings.
Brake Pad Wear
(1) brake pads
minimum
thickness indicator
0.04 in
(1.0 mm)
0.04 in (1.0 mm)
replace
wear indicator
grooves
(1)
(1)
(1) brake pads
(2) rear brake caliper
minimum
thickness indicator
0.04 in
(1.0 mm)
replace
(2)
(1)
Other Inspections
Wheels
118 Servicing Your Honda
Refer to Important Safety Precautions on page 23.
Keeping the wheels true (round) and maintaining
correct spoke tension are critical to safe
motorcycle operation. During the first few rides,
spokes will loosen more rapidly due to the initial
seating
of the parts. Excessively loose spokes may
result in instability at high speeds and the possible
loss of control. It’s also important that the rim
locks are secure to prevent tire slippage.
1. Inspect the wheel rims (1) and spokes (2) for
damage.
2. Tighten, any loose spokes and rim locks (3) to
the specified torque:
Spokes: 2.7 lbf·ft (3.7 N·m, 0.4 kgf·m)
Rim Locks: 9 lbf·ft (12 N·m, 1.2 kgf·m)
3. Check wheel rim runout. If runout is
noticeable, see an official Honda Service
Manual for inspection instructions.
See an official Honda Service Manual for
inspection information:
1. Check the axle shaft for runout.
2. Check the condition of the wheel bearings.
Wheel Rims & Spokes
(1) wheel rim (3) rim lock
(2) spokes
(2)
(3)
(1)
Axles & Wheel Bearings
Tires & Tubes
Servicing Your Honda 119
Refer to Important Safety Precautions on page 23.
To safely operate your CRF, the tires must be the
proper type (off-road) and size, in good condition
with adequate tread, and correctly inflated.
The following pag
es give detailed information on
how and when to check your air pressure, how to
inspect your tires for wear and damage, and our
recommendations on tire repair and replacement.
Properly inflated tires provide the best
combination of handling, tread life, and riding
comfort. Generally, underinflated tires wear
unevenly, adversely affect handling, and are more
likely to fail from being overheated.
Underinflated tires can also cause wheel damage
on hard terrain. Overinflated tires make your CRF
ride harshly, are more prone to damage from
surface hazards, and wear unevenly.
Make sure the valve stem caps are secure. If
necessary, install new caps.
Always check air pressure when your tires are
“cold.” If you check air pressure when your tires
are “warm” — even if your CRF has only been
ridden for a few miles — the readings will be
higher. If you let air out of warm tires to match the
recommended cold pressures, the tires will be
underinflated.
The correct “cold” tire pressures are:
If you decide to adjust tire pressures for a
particular riding condition, make changes a little at
a time.
Take time to inspect your tires and wheels before
you ride.
• Inspect carefully for bumps or bulges in the
side of the tire or the tread. Replace any tire
that has a bump or bulge.
• Look closely for cuts, slits, or cracks in the
tires. Replace a tire if you can see fabric or
cord.
• Check for rocks or other objects embedded in
the tire or tread. Remove any objects.
• Check the position of both valve stems. A
tilted valve stem indicates the tube is slipping
inside the tire or the tire is slipping on the rim.
If a tube is punctured or damaged, you should
replace it as soon as possible. A repaired tube may
not have the same reliability as a new one, and it
may fail while you are riding.
Use a replacement tube equivalent to the original.
WARNING
Using tires that are excessively worn or
improperly inflated can cause a crash in
which you can be seriously hurt or killed.
Follow all instructions in this owner’s
manual regarding tire inflation and
maintenance.
Air Pressure
Front 15 psi (100 kPa, 1.0 kgf/cm
2
)
Rear 15 psi (100 kPa, 1.0 kgf/cm
2
)
Inspection
Tube Replacement
120 Servicing Your Honda
Tires & Tubes
The tires that came on your CRF were designed to
provide a good combination of handling, braking,
durability, and comfort across a broad range of
riding conditions.
(CRF450RX)
(CRF450R/RWE)
• When replacing, use the original equipment
tires or equivalent tires of the same size,
construction, speed rating, and load range as
the original.
• Replace the tube any time you replace a tire.
The old tube will probably be stretched and, if
installed in a new tire, could fail.
Tire Replacement
WARNING
Installing improper tires on your
motorcycle can affect handling and
stability. This can cause a crash in which
you can be seriously hurt or killed.
Always use the size and type of tires
recommended in this owner’s manual.
Front
90/90-21 54M
DUNLOP AT81F
Rear
120/90-18 65M
DUNLOP AT81
Type bias-ply, tube
Front
80/100-21 51M
DUNLOP MX3SF
Rear
120/80-19 63M
DUNLOP MX3S
Type bias-ply, tube
Side Stand (CRF450RX)
Servicing Your Honda 121
Refer to Important Safety Precautions on page 23.
1. Check
the side stand spring (1) for damage and
loss of tension.
2. Check the side stand assembly for freedom of
movement.
If the side stand is stiff or squeaky, clean the pivot
area and lubricate the pivot bolt with molybdenum
grease.
(1) side stand spring
(1)
Drive Chain
122 Servicing Your Honda
Drive Chain
Refer to Important Safety Precautions on page 23.
The service life of the chain depends on proper
lubrication and adjustment. Poor maintenance can
cause premature wear or damage to the drive chain
or sprockets.
When the motorcycle is ridden on unusually dusty
or muddy tracks, more frequent maintenance will
be necessary.
Before servicing your drive chain, turn the engine
OFF and check that your transmission is in neutral.
1. Turn the engine off, raise the rear wheel off the
ground by placing an optional workstand or
equivalent support under the engine and shift
the transmission into neutral.
2. Check the drive chain slack (1) in the upper
drive chain run midway between the drive
sprocket (2) and driven sprocket (3). Drive
chain slack should allow the following vertical
movement by hand:
1 3/8 – 1 3/4 in (35 – 45 mm)
3. Check drive chain slack at several points along
the chain. The slack should remain constant. If
it isn’t, some links may be kinked and binding.
Lubricating the chain will often eliminate
binding and kinking.
Excessive chain slack may allow the drive chain to
damage the engine cases.
4. Inspect the drive chain for:
• damaged rollers
•loose pins
• dry or rusted links
• kinked or binding links
• excessive wear
Replace the drive chain (pages 124, 125) if it has
damaged rollers, loose pins, or kinks that cannot be
free. 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).
1. Check the chain slider (1) for wear.
Replace it if below the service limit.
SERVICE LIMIT:
upper side: 0.2 in (5 mm)
lower side: 0.10 in (2.5 mm)
2. Check the chain guide slider (2) for wear.
Replace the guide slider if it is worn to the
bottom of the wear limit (3).
Inspection
(1) drive chain slack (3) driven sprocket
(2) drive sprocket
(2)
(3)
(1) 1 3/8 – 1 3/4 in (35 – 45 mm)
Drive Chain Sliders
(1) chain slider
(2) chain guide slider (3) wear limit
0.2 in
(5 mm)
0.10 in
(2.5 mm)
(1)
(1)
(2)
(3)
(3)
Drive Chain
Servicing Your Honda 123
Check the upper drive chain roller (1) and lower
drive chain roller (2) for wear or damage.
Measure the
diameter of the drive chain rollers and
replace them if below the service limit.
Service Limit:
Upper roller: 1.2 in (31 mm)
Lower roller: 1.2 in (31 mm)
Replace the roller if necessary as follows.
Install the upper drive chain roller (Green) with the
“ ” mark (3) facing toward the bracket and lower
drive chain roller (Black) with the “ ” mark facing
toward outside.
Clean the threads of the lower drive chain roller
bolt and apply locking agent to the threads.
Install new a drive chain roller bolt (4) and nut (5).
Tighten the drive chain roller bolt and nut to the
specified torque:
9 lbf·ft (12 N·m, 1.2 kgf·m)
1. Loosen the rear axle nut (1).
2. Loosen the chain adjuster lock nuts (2) and
turn the adjusting bolts (3) counterclockwise to
decrease slack or clockwise to increase slack.
Align the index marks (4) of the axle plates (5)
with the same reference marks (6) on both
sides of the swingarm.
3. Tighten the rear axle nut to the specified
torque:
94 lbf·ft (128 N·m, 13.1 kgf·m)
4. Recheck chain slack and adjust as necessary.
5. Turn the adjusting bolt counterclockwise until
it touches the axle plates lightly. Then tighten
the chain adjuster lock nuts to the specified
torque while holding the adjusting bolts with a
wrench:
20 lbf·ft (27 N·m, 2.8 kgf·m)
(CRF450RX)
Lubricate the drive chain with Pro Honda HP
Chain Lube or an equivalent chain lubricant or
drive chain lubricant designed specifically for use
with O-ring chains. Wipe off the excess chain
lubricant.
Commercial chain lubricants not designed for
motorcycle drive chains may contain solvents
which could damage the O-rings.
(CRF450R/RWE)
Commercially prepared drive chain lubricants may
be purchased at most motorcycle shops and should
be used in preference to motor oil. Pro Honda HP
Chain Lube or an equivalent is recommended.
Saturate each chain joint so that the lubricant
penetrates the space between adjacent surfaces of
the link plates and rollers.
Drive Chain Rollers
(1) upper drive chain roller (Green)
(2) lower drive chain roller (Black)
(3) “ ” mark
(4) drive chain roller bolt (new)
(5) drive chain roller nut
(3)
(2)
(1)
(3)
(4)
(5)
Adjustment
(1) rear axle nut (4) index marks
(2) chain adjuster lock nuts (5) axle plates
(3) adjusting bolts (6) reference marks
(3)(6)(1)
(5)
(6) (4) (2)
Lubrication
124 Servicing Your Honda
Drive Chain
For maximum service life, the drive chain should
be cleaned, lubricated, and adjusted before each
outing. Your CRF has an endless (riveted master
link) type chain. It should only be removed or
replaced by your dealer.
The O-rings can be damaged by steam cleaning,
high pressure washers, and certain solvents.
1. Clean the side surfaces of the chain with a dry
cloth. Use a high flash point solvent such as
kerosene or Pro Honda chain cleaner – not
gasoline. Do not brush the rubber O-rings.
Brushing will damage them. Use of a solvent
may also damage the O-rings.
2. Replace the drive chain if it has damaged
rollers, loose fitting links, damaged O-rings, or
otherwise appears unserviceable.
3. Measure the drive chain plate (1). If the height
of any of the drive chain plates is less than
0.52 inch (13.3 mm), the drive chain must be
replaced.
Chain:
4. Inspect the sprocket teeth for wear or damage.
We recommend replacing the sprocket
whenever a new chain is installed.
Both chain and sprockets must be in good
condition, or the new replacement chain or
sprocket(s) will wear rapidly.
Excessively worn sprocket teeth have a
hooked, worn appearance. Replace any
sprocket which is damaged or excessively
worn.
Use of a new chain with worn sprockets will cause
rapid chain wear.
5. Lubricate the drive chain (page 123).
6. Recheck chain slack and adjust if necessary.
Removal, Cleaning & Replacement
(CRF450RX)
Size/link:
RK520EXU/114LE
(1) drive chain plate (inner)
(1)
0.52 in (13.3 mm)
Normal Sprocket Teeth
Damaged Sprocket
Teeth
Worn Sprocket
Teeth
REPLACEREPLACE
GOOD
Servicing Your Honda 125
Drive Chain
For maximum service life, the drive chain should
be cleaned, lubricated, and adjusted before each
outing.
1. Remove the master link retaining clip (1) with
pliers.
Do not bend or twist the clip.
2. Remove the master link (2) and link plate (3).
Remove the drive chain.
3. Clean the drive chain in high flash-point
solvent and allow it to dry.
4. Inspect the drive chain for possible wear or
damage. Replace the drive chain if it has
damaged rollers, loose fitting links, or
otherwise appears unserviceable.
Chain:
5. Inspect the sprocket teeth for wear or damage.
We recommend replacing the sprocket
whenever a new chain is installed.
Both chain and sprockets must be in good
condition, or the new replacement chain or
sprocket(s) will wear rapidly.
Excessively worn sprocket teeth have a
hooked, worn appearance. Replace any
sprocket which is damaged or excessively
worn.
Use of a new chain with worn sprockets will cause
rapid chain wear.
6. Install the chain.
7. Measure a section of the drive chain to
determine whether the chain is worn beyond its
service limit. Put the transmission in gear, and
then turn the rear wheel forward until the lower
section of the chain is pulled taut. With the
chain held taut and any kinked joints
straightened, measure the distance between a
span of 17 pins, from pin center to pin center.
If the measurement exceeds the service limit,
replace the chain. After the chain is measured, shift
the transmission into neutral again before
proceeding with inspection and service.
8. Lubricate the drive chain (page 123).
9. Pass the chain over the sprockets and join the
ends of the chain with the master link. For ease
of assembly, hold the chain ends against
adjacent driven sprocket teeth while inserting
the master link. Install the master link retaining
clip so that the closed end of the clip will face
the direction of forward wheel rotation.
10. Recheck chain slack and adjust as necessary.
• The master link is the most critical element of
drive chain security. Master links are reusable,
as long as they remain in excellent condition.
We recommend installing a new master link
retaining clip when the drive chain is
reassembled.
• You may find it easier to install a new chain by
connecting it to the old chain with a master link
and pulling the old chain to position the new
chain on the sprockets.
Removal, Cleaning & Replacement
(CRF450R/RWE)
(1) master link retaining clip (3) link plate
(2) master link
Size/link:
RK520TXZ/114RJ (CRF450R)
GB520TXZ/114RJ (CRF450RWE)
(1) (3)
(2)
Normal Sprocket Teeth
Damaged Sprocket
Teeth
Worn Sprocket
Teeth
REPLACEREPLACE
GOOD
Service limit: 10.20 in (259.0 mm)
More About Drive Chain
(CRF450R/RWE)
MEASURE A SPAN OF 17 PINS (16 PITCHES)
Exhaust Pipe/Muffler
126 Servicing Your Honda
Exhaust Pipe/Muffler
Refer to Important Safety Precautions on page 23.
Check the mounting bolts and exhaust pipe joint
nuts for tightness.
Check the exhaust pipe and mufflers for cracks or
deformation.
A damaged exhaust pipe and mufflers may reduce
engine performance.
(CRF450R/RX)
1. Remove the seat (page 34).
2. Remove the side covers (1) and air cleaner
housing covers (2) by removing the bolts (3).
The procedure is the same for the both right and
left side.
3. Loosen the right muffler clamp bolt (4).
4. Remove the right muffler mounting A bolt (5),
B bolt (6), washer (7), and right muffler (8).
Exhaust Pipe/Muffler Inspection
Muffler Removal
(1) side covers (3) bolts
(2) air cleaner housing covers
(4) right muffler clamp bolt
(2) (3)
(1)
(4)
(5) right muffler mounting A bolt
(6) right muffler mounting B bolt
(7) washer
(8) right muffler
(8)
(6) (7) (5)
Servicing Your Honda 127
Exhaust Pipe/Muffler
5. Loosen the left muffler clamp bolt (9).
6. Remove the left muffler mounting A bolt (10),
B bolt (11), washer (12) and left muffler (13).
(CRF450RWE)
1. Remove the seat (page 34).
2. Remove the side covers and air cleaner
housing covers (page 126).
3. Remove the right muffler mounting B bolt (1),
washer (2) and right muffler (3).
4. Remove the left muffler mounting B bolt (4),
washer (5) and left muffler (6).
(CRF450R/RX)
1. Remove the current gasket (1).
2. Install a new gasket onto the exhaust pipe (2).
3. Align the cutout (3) of the left muffler (4) with
the tab (5) of the left muffler clamp (6).
4. Install the left muffler.
5. Install the washer (7), left muffler mounting B
bolt (8) and A bolt (9).
(9) left muffler clamp bolt
(10) left muffler mounting A bolt
(11) left muffler mounting B bolt
(12) washer
(13)
left
muffler
(9)
(11)(12)
(10)
(13)
(1) right muffler mounting B bolt
(2) washer
(3) right muffler
(4) left muffler mounting B bolt
(5) washer
(6) left muffler
(1)
(2)
(3)
(6)
(4)
(5)
Muffler Installation
(1) gasket (4) left muffler
(2) exhaust pipe (5) tab
(3) cutout (6)
left muffler clamp
(7) washer
(8) left mu
ffler mounting B bolt
(9) left muffler mounting A bolt
(4)(6)(2)
(5)
(3)
(1)
(7)
(8)
(9)
128 Servicing Your Honda
Exhaust Pipe/Muffler
6. Tighten the left muffler clamp bolt (10) to the
specified torque:
15 lbf·ft (20 N·m, 2.0 kgf·m)
7. Remove the current gasket (1).
8. Install a new gasket onto the exhaust pipe (2).
9. Align the cutout (3) of the right muffler (11)
with the tab (5) of the right muffler clamp (12).
10. Install the right muffler (11).
11. Install the washer (13), right muffler mounting
B bolt (14) and A bolt (15).
12. Tighten the right muffler clamp bolt (16) to the
specified torque:
15 lbf·ft (20 N·m, 2.0 kgf·m)
13. Tighten the right muffler mounting B bolt (14)
and A bolt (15) to the specified torque:
19 lbf·ft (26 N·m, 2.7 kgf·m)
14. Tighten the left muffler mounting B bolt (8)
and left muffler mounting A bolt (9) to the
specified torque:
19 lbf·ft (26 N·m, 2.7 kgf·m)
(10) left muffler clamp bolt
(1) gasket (5) tab
(2) exhaust pipe (11) right muffler
(3) cutout (12)
right muffler clamp
(10)
(12)
(2)
(5)
(3)
(1)
(11)
(13) washer
(14) right muffler mounting B bolt
(15) right muffler mounting A bolt
(16) right muffler clamp bolt
(14)
(13)
(15)
(16)
(14) right muffler mounting B bolt
(15) right muffler mounting A bolt
(8) left muffler mounting B bolt
(9) left muffler mounting A bolt
(15)
(14)
(8)
(9)
Servicing Your Honda 129
Exhaust Pipe/Muffler
15. Install the air cleaner housing covers (17) and
side covers (18), and then tighten the bolts (19)
to the specified torque:
7 lbf·ft (10 N·m, 1.0 kgf·m)
The procedure is the same for the both right and
left side
16. Install the seat (page 34).
(CRF450RWE)
1. Install the left muffler (1), the washer (2) and
left muffler mounting B bolt (3).
Tighten the left muffler mounting B bolt to the
specified torque:
19 lbf·ft (26 N·m, 2.7 kgf·m)
2. Install the right muffler (4), the washer (5) and
right muffler mounting B bolt (6).
Tighten the right muffler mounting B bolt to
the specified torque:
19 lbf·ft (26 N·m, 2.7 kgf·m)
3. Install the air cleaner housing covers and side
covers (this page).
4. Install the seat (page 34).
(17) air cleaner housing covers (19) bolts
(18) side covers
(17)
(18)
(19)
(1) left muffler
(2) washer
(3) left muffler mounting B bolt
(4) right muffler
(5) washer
(6) right muffler mounting B bolt
(1)
(3)
(2)
(4)
(6)
(5)
130 Servicing Your Honda
Exhaust Pipe/Muffler
(CRF450R/RX)
1. Remove the right and left mufflers (page 126).
2. Remove the exhaust pipe joint nuts (1),
exhaust pipe (2) and gasket (3).
(CRF450RWE)
1. Remove the right and left muffler (page 127).
2. Loosen the right muffler joint pipe clamp bolt (1).
3. Remove the right muffler mounting A bolt (2)
and right muffler joint pipe (3).
4. Remove the upper drive chain roller (4)
(page 123).
5. Loosen the left muffler joint pipe clamp bolt
(5).
6. Remove the left muffler mounting A bolt (6)
and left muffler joint pipe (7).
7. Remove the exhaust pipe (this page CRF450R/
RX step 2).
(CRF450R/RX)
1. Install a new exhaust pipe gasket (1).
2. Install the exhaust pipe (2) and exhaust pipe
joint nuts (3) but do not tighten the nuts yet.
3. Install the left and right mufflers (page 129)
but do not tighten the bolts yet.
4. Tighten the exhaust pipe joint nuts to the
specified torque:
15 lbf·ft (20 N·m, 2.0 kgf·m)
5. Tighten the left muffler clamp bolt, left muffler
mounting A bolt and B bolt (page 127).
6. Tighten the right muffler clamp bolt, right
muffler mounting A bolt and B bolt
(page 127).
Exhaust Pipe Removal
(1) exhaust pipe joint nuts
(2) exhaust pipe
(3) gasket
(1) right muffler joint pipe clamp bolt
(2) right muffler mounting A bolt
(3) right muffler joint pipe
(2)
(3)
(1)
(2)
(3)
(1)
(4) upper drive chain roller
(5) left muffler joint pipe clamp bolt
(6) left muffler mounting A bolt
(7) left muffler joint pipe
(4)
(6)
(7)
(5)
Exhaust Pipe Installation
(1) exhaust pipe gasket (new)
(2) exhaust pipe
(3) exhaust pipe joint nuts
(2)
(1)
(3)
Servicing Your Honda 131
Exhaust Pipe/Muffler
(CRF450RWE)
1. Install a new exhaust pipe gasket (1).
2. Install the exhaust pipe (2) and exhaust pipe
joint nuts (3) but do not tighten the nuts yet.
3. Attach the left muffler joint pipe (4) with the left
muffler joint pipe clamp (5) so that the distance
from the stopper ring (6) of the exhaust pipe to the
left muffler joint pipe is 0.4 in (10 mm) or shorter.
4. Attach the right muffler joint pipe (7) with the right
muffler joint pipe clamp (8) so that the distance
from the stopper ring (9) of the exhaust pipe to the
right muffler joint pipe is 0.4 in (10 mm) or shorter.
5. Install the left muffler mounting A bolt (10)
but do not tighten the bolt yet.
6. Install the right muffler mounting A bolt (11)
but do not tighten the bolt yet.
7. Tighten the exhaust pipe joint nuts to the
specified torque:
15 lbf·ft (20 N·m, 2.0 kgf·m)
8. Tighten the left muffler joint pipe clamp bolt (12)
at the specified torque so that the left muffler joint
pipe clamp is at the position described below.
• The distance from the left muffler joint pipe
clamp to the tip of the left muffler joint pipe
is 0.08 - 0.12 in (2.0 - 3.0 mm)
• Position the left muffler joint pipe clamp at
the angle shown in the illustration
6.3 lbf·ft (8.5 N·m, 0.9 kgf·m)
9. Tighten the right muffler joint pipe clamp bolt (13)
at the specified torque so that the right muffler
joint pipe clamp is at the position described below.
• The distance from the right muffler joint pipe
clamp to the tip of the right muffler joint pipe is
0.08 - 0.12 in (2.0 - 3.0 mm)
• Position the right muffler joint pipe clamp at
the angle shown in the illustration
6.3 lbf·ft (8.5 N·m, 0.9 kgf·m)
10. Tighten the left muffler mounting A bolt to the
specified torque:
19 lbf·ft (26 N·m, 2.7 kgf·m)
11. Tighten the right muffler mounting A bolt to
the specified torque:
19 lbf·ft (26 N·m, 2.7 kgf·m)
12. Install the upper drive chain roller (14) (page 123).
13. Install the left and right muffler
(page 129).
(1) exhaust pipe gasket (new)
(2) exhaust pipe
(3) exhaust pipe joint nuts
(2)
(1)
(3)
(4) left muffler joint pipe
(5) left muffler joint pipe clamp
(6) stopper ring
(10) left muffler mounting A bolt
(12) left muffler joint pipe clamp bolt
(14) upper drive chain roller
0.0 - 0.4 in (0 - 10 mm)
(14)
(5)
(12)
(10)
(4)
(4)
(5)
(6)
(5)
(4)
0.08 - 0.12 in (2.0 - 3.0 mm)
(12)
(7) right muffler joint pipe
(8) right muffler joint pipe clamp
(9)
stopper
ring
(11) right muffler mounting A bolt
(13) right muffler joint pipe clamp bolt
(7)
(11)
(8)
(7)
0.0 - 0.4 in (0 - 10 mm)
0.08 - 0.12 in (2.0 - 3.0 mm)
(7)
(8)
(9)
(8)
(13)
(13)
25°
Additional Maintenance Procedures
132 Servicing Your Honda
Additional Maintenance Procedures
Refer to Important Safety Precautions on page 23.
1. With your CRF on an optional workstand or
equivalent support (front wheel elevated), turn
the handlebar to the right and left to check for
roughness in the steering head bearings.
2. Stand in front of your CRF, grab the fork (at
the axle), look at the steering head, and push
the fork in and out (toward the engine) to check
for play in the steering head bearings.
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.
1. Remove the handlebar protector and check the
handlebar (1) for bends or cracks.
2.
Check that the handlebar has not moved from its
original position where the end of the left handlebar
holders (2) is aligned with the paint mark (3).
3. Check the torque of the handlebar upper holder
bolts (4):
16 lbf·ft (22 N·m, 2.2 kgf·m)
Tighten the front bolts first.
4. Install the handlebar protector.
Periodically, disconnect the clutch cables at their
upper ends. Thoroughly lubricate the cable pivot
points with a commercially available cable
lubricant. If the clutch lever and throttle operation
is not smooth, replace the cable.
Be sure the throttle returns freely from fully open
to fully closed automatically, in all steering
positions.
Steering Head Bearing Inspection
Handlebar Inspection
(1) handlebar
(2) left handlebar holders
(3) paint mark
(4) handlebar upper holder bolts
(4)
(4)
(2)
(1)
(3)
Control Cables
Servicing Your Honda 133
Additional Maintenance Procedures
Check and tighten nuts, bolts, and fasteners before
every outing.
RIGHT SIDE LEFT SIDE
Nuts, Bolts, Fasteners
ENGINE
Item
Torque
lbf·ft N·m kgf·m
1 Cylinder head cover
socket bolts 7 10 1.0
2 Clutch cover bolts 7 10 1.0
3 Water pump cover bolts 7 10 1.0
4 Crankshaft hole cap 11 15 1.5
5 Oil filter cover bolts 7 10 1.0
6 Cylinder head bolts 37 50 5.1
7 Exhaust pipe joint nuts 15 20 2.0
8 Drive sprocket bolt 23 31 3.2
9 Engine oil drain bolt 13 18 1.8
10 Coolant drain bolt 7 10 1.0
(1) cylinder head cover socket bolts
(2) clutch cover bolts
(3) water pump cover bolts
(4) crankshaft hole cap
(6) cylinder head bolts
(7) exhaust pipe joint nuts
(10) coolant drain bolt
(3)
(4) (10)
(7)
(6)
(1)
(2)
(1) cylinder head cover socket bolts
(5) oil filter cover bolts
(6) cylinder head bolts
(8) drive sprocket bolt
(9) engine oil drain bolt
(6)
(9)
(1)
(8)
(5)
Battery
134 Servicing Your Honda
Refer to Important Safety Precautions on page 23.
Your CRF
has a lithium-ion (li-ion) battery.
Clean the battery terminals if they become dirty or
corroded.
An improperly disposed of battery can be harmful
to the environment and human health.
Always confirm local regulations for proper
battery disposal instruction.
Power of 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 plan to store your CRF, see Battery Storage
(this page).
If your battery seems weak and/or is leaking
electrolyte (cause slow starting), see your dealer.
If you smell an unusual odor coming from the
lithium-ion (li-ion) battery, park your CRF in a
safe place outside and away from flammable
objects, then push and hold the engine stop button
until the engine stops completely.
The battery has a limited life span.
Consult your dealer about when you should
replace the battery. Always replace the battery
with another lithium-ion (li-ion) battery of the
same type.
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).
Before you remove the battery, be sure to read all
the information that follows, as well as the
information on the battery label.
If you do not remove the battery, we recommend
disconnecting the battery cables (negative cable
first).
The battery is located under the seat.
Removal
1. Remove the seat (page 34).
2. Remove the battery band (1).
3. Disconnect the negative (–) terminal (2).
4. Remove the positive terminal cover (3).
5. Disconnect the positive (+) terminal (4) and
remove the battery (5).
6. Unless you have been riding regularly, charge
the battery (page 135).
7. Store your battery in an easy-to-reach location
off the floor, in an area protected from freezing
temperatures and direct sunlight.
8. Clean the battery box after removing the
battery for storage. Dry the battery box.
9. Slow charge the battery (page 135) once every
30 days.
Battery Storage
WARNING
The battery contains flammable organic
solvent as electrolyte.
You can be burned or seriously injured if
the battery is handled improperly.
• Keep the battery away from heat,
sparks, and flame.
• Keep the battery out of the reach of
children.
• Do not disassemble or modify the
battery or battery terminals.
• Do not short-circuit the battery with
metal tools or other metal objects.
• Do not subject the battery to impacts.
(1) battery band (4) positive (+) terminal
(2) negative (–) terminal (5) battery
(3) positive terminal cover
(5)
(2)
(3)
(1)
(4)
Servicing Your Honda 135
Battery
Installation
1. Reinstall the battery (1) in the reverse order of
removal. Be sure to connect the positive (+)
terminal first, then the negative (–) terminal.
2. Tighten the positive (+) terminal bolt (2) and
negative (–) terminal bolt (3) to the specified
torque:
1.5 lbf·ft (2.0 N·m, 0.2 kgf·m)
3. Install the battery band (4).
Be sure to read the information that came with
your battery charger and follow the instructions on
the battery. Improper charging may damage the
battery.
We recommend using a charger recommended by
your lithium-ion (li-ion) battery manufacturer
which can be purchased from your dealer. These
units can be left connected for long periods without
risking damage to the battery. However, the
lithium-ion (li-ion) battery may degrade if stored
with a charger connected. Do not intentionally
leave the charger connected longer than the time
period recommended in the charger’s instructions.
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 (3)
negative (–) terminal bolt
(2)
positive (+) terminal bolt
(4) battery band
(1)
(3)
(4)
(2)
Battery Charging
Appearance Care
136 Servicing Your Honda
Appearance Care
Refer to Important Safety Precautions on page 23.
Frequent cleaning and polishing will keep your
CRF looking newer longer. Frequent cleaning also
identifies you as an owner who values his
motorcycle. A clean CRF is also easier to inspect
and service.
While you’re cleaning, be sure to look for damage,
wear, and gasoline or oil leaks.
• To clean your CRF you may use:
–water
– Hondabrite
– a mild, neutral detergent and water
– a mild spray and wipe cleaner/polisher
– a mild spray and rinse cleaner/degreaser and
water
• Avoid products that contain harsh detergents
or chemical solvents that could damage the
metal, paint, and plastic on your CRF or
discolor the seat and decals.
• If your CRF is still warm from recent
operation, give the engine and exhaust system
time to cool off.
• We recommend the use of a low pressure
garden hose to wash your CRF. High pressure
washers (like those at coin-operated car
washes) can damage certain parts of your CRF.
The force of water under extreme pressure can
penetrate the dust seals of the suspension pivot
points and steering head bearings-driving dirt
inside and needed lubrication out.
If you use a high pressure washer, avoid spraying
the following areas:
brake master cylinders
drive chain
electrical circuit
engine stop button
muffler outlet
steering head bearings (1)
suspension pivot points (2)
throttle body
under fuel tank
under seat
High pressure water (or air) can damage certain
parts of your CRF.
You may use Pro Honda Hondabrite, a multi-
surface cleaner/degreaser, to remove both dirt and
petroleum-based grime from paint, alloy, plastic,
and rubber surfaces. Wet any heavy deposits with
water first. Then spray on Pro Honda Hondabrite
and rinse with a low pressure garden hose at full
pressure. Stubborn deposits may require a quick
wipe with a sponge.
Allow the engine, muffler, brakes, and other high-
temperature parts to cool before washing.
1. Rinse your CRF thoroughly using a low
pressure garden hose to remove loose dirt.
2. Fill a bucket with cool water. Mix in a mild,
neutral detergent, such as dish washing liquid
or a product made especially for washing
motorcycles or automobiles.
3. Wash your CRF with a sponge or a soft towel.
As you wash, check for heavy grime. If
necessary, use a mild cleaner/degreaser to
remove the grime.
Do not use steel wool to clean the frame as it could
damage or discolor the frame surface.
Muffler stain remover (Scotch Brite Hand Pad
#7447-maroon) is for removing stains on the non-
coated aluminum frame only.
4. After washing, rinse your CRF thoroughly
with plenty of clean water to remove any
residue.
Detergent residue can corrode alloy parts.
5. Dry your CRF with a chamois or a soft towel.
Leaving water on the surface to air dry can
cause dulling and water spots. As you dry,
inspect for chips and scratches.
6. Lubricate the drive chain to prevent rusting.
7. Start the engine and let it idle for several
minutes. The engine heat will help dry moist
areas.
8. As a precaution, ride at a slow speed and apply
the brakes several times. This will help dry the
brakes and restore normal braking
performance.
General Recommendations
(1) steering head bearings
(2) suspension pivot points
(1)
(2)
Washing Your Motorcycle with a Mild
Detergent
Servicing Your Honda 137
Appearance Care
There are some things you should do just after
washing your CRF to help prevent rust and
corrosion.
Once your CRF is clean and dry, you should
protect any bare steel from rusting by applying a
light coating of a rust-inhibitor. Lubricate the drive
chain and drive sprocket after removing and
thoroughly cleaning in solvent. Be sure the chain is
wiped clean and is dry before applying the chain
lube.
Follow the suggestions given in the pages of this
manual for lubricating items such as the brake and
clutch lever pivot points and footpeg pivot pins.
Aluminum corrodes when it comes in contact with
dust, mud and road salt.
To remove stains, use Scotch Brite Hand Pad
#7447 (maroon) or an equivalent.
Wet the pad and polish the surface using strokes
parallel to the length of the frame.
Clean the frame using a wet sponge and a mild
detergent, then rinse well with clean water. Dry the
frame with a soft clean cloth, using strokes parallel
to the length of the frame.
Do not use steel wool to clean the frame as it could
damage or discolor the frame surface.
Scotch Brite Hand Pad #7447-maroon is for
removing stains on the non-coated aluminum
frame only.
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.
The exhaust pipe and muffler are titanium
(CRF450RWE only) and stainless steel but may
became stained by mud or dust.
To remove mud or dust, use a wet sponge and a
liquid kitchen abrasive, then rinse well with clean
water. Dry with chamois or a soft towel.
If necessary, remove heat stains by using a
commercially available fine texture compound.
Then rinse by the same manner as removing mud
or dust.
After Cleaning Lubrication Aluminum Frame Maintenance
Titanium Fuel Tank Maintenance
(CRF450R/RWE)
Exhaust Pipe and Muffler Maintenance
138 Servicing Your Honda
BLANK PAGE
Adjustments for Competition
Adjustments for Competition 139
This section tel
ls you how to fine tune your CRF
for maximum competition performance.
Initial suspension adjustments should be
performed after a minimum of 2 hours of easy
break-in time.
Optional front and rear suspension springs are
available in order to tailor your CRF specifically
for your weight, riding style and course conditions.
Follow the instructions given in the rear
suspension sag setting section of Rear Suspension
Adjustments to determine if your combined rider
and sprung machine weight (rider fully dressed for
competition and machine coolant, oil and fuel
levels ready for competition) requires an optional
stiffer or softer rear spring. The need for either
optional rear spring may need to be balanced by
installing the optional fork springs of a similar rate.
Engine Mode Select Button ...........................140
Current Mode.............................................140
Mode Selection ..........................................140
HRC-Launch Control System ........................141
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 Pre-Load .............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 Height/Angle .....................................156
Wheelbase..................................................156
Gearing...........................................................157
Tire Selection for Track Conditions ..............158
Personal Fit Adjustments ...............................159
Control Positioning ....................................159
Handlebar Position, Width & Shape..........159
Engine Mode Select Button
140 Adjustments for Competition
Engine Mode Select Button
You can change engine output characteristic
depending on track conditions by using the engine
mode select button (1).
• PGM-FI mode 1: standard setting
• PGM-FI mode 2: smooth setting (reduce
throttle response from the standard setting)
• PGM-FI mode 3: aggressive setting (increase
throttle response from the standard setting)
Start the engine and push the engine mode select
button (1) with your CRF stopped. The engine
mode indicator (2) under the engine mode select
button indicates the selected mode by blinking the
mode number in blue 3 times.
1. Start the engine.
2. With your CRF stopped and the throttle closed,
push and hold the engine mode select button
for 1 or more second.
Make sure that the fast idle knob is pushed in
(page 17). If the fast idle knob is pulled out, the
engine mode will not change.
3. Release the engine mode select button. The
engine mode indicator will indicate a selected
mode by the number of times the indicator blue
blinks.
4. Repeat steps 2 – 3 until the desired mode is
indicated.
(1) engine mode select button
(1)
Current Mode
(1) engine mode select button
(2) engine mode indicator (blue)
(1)
(2)
Mode Selection
PGM-FI mode 1
PGM-FI mode 2
PGM-FI mode 3
PGM-FI mode 1:
The indicator blue
blinks once and
repeats it 3 times.
PGM-FI mode 2:
The indicator blue
blinks 2 times and
repeats it 3 times.
PGM-FI mode 3:
The indicator blue
blinks 3 times and
repeats it 3 times.
HRC-Launch Control System
Adjustments for Competition 141
The HRC-Launch
Control System reduces slip and
assists for an effective start by temporarily
decreasing the rev limit when starting.
You can select the rev limit level while the system
is operating according to your skill and track
conditions.
To change the level
1. Start the engine and wait more than 2 seconds.
2. Close the throttle completely, press and hold
the start button (1) while pulling the clutch
lever in until the launch control system
indicator (2) blinks (purple).
– The system goes into standby, and the
launch control system indicator indicates
the selected level by blinking (purple).
– From standby, the control to decrease the rev
limit starts.
– The system may become disabled if you
snap the throttle excessively.
– If the idle speed is low, the system may not
go into standby. Set the idle speed to
standard rpm, see page 72.
– To disable the system, quickly press the start
button. The launch control system indicator
stops blinking.
3. Press and hold the start button. The level
changes every time you press and hold.
– The level selected last is saved.
– The factory setting is level 2.
4. To continue using the system, refer to step 2 in
To operate the system (next page).
To disable the system, quickly press the start
button. The launch control system indicator
stops blinking and the system is disabled.
(1) start button
(2) launch control system indicator (purple)
Level
Rev limit during
launch control
Number of launch control
system indicator blinks
1 High 1
2 Middle 2
3 Low 3
(1)
(2)
Level 1
Level 2
Level 3
: Pressing and holding the start button
while the launch control system is in
standby
142 Adjustments for Competition
HRC-Launch Control System
To operate the system
1. Perform steps 1 and 2 in To change the level.
2. Shift into 1st or 2nd gear.
3. When launching, open the throttle halfway or
more. The system operates.
– The reduced rev limit is controlled and will
gradually return to normal in a few seconds.
Once the rev limit returns to normal, the
system is disabled.
– The launch control system indicator comes
on (purple) while the system is operating.
– If you open the throttle halfway or more
before starting, control system stops before
starting and there is no effect.
– If you close the throttle immediately, the
system may not operate.
– When the launch control system operates,
these following conditions will disable
launch control:
• Vehicle is in 3rd gear
• The throttle completely closed
4. Make sure that the launch control system
indicator is off. If it is not off, the system is not
disabled. Quickly press the start button to
disable the system.
Front Suspension Adjustments
Adjustments for Competition 143
The front s
uspension can be adjusted for the rider's
weight and riding conditions by using one or more
of the following methods:
• Oil volume — The effects of higher or lower
fork oil capacity are only felt during the final
3.9 in (100 mm) of fork travel.
• Compression damping — Turning the
compression damping adjuster (1) adjusts how
quickly the fork compresses.
• Rebound damping — Turning the rebound
damping adjuster (2) adjusts how quickly the
fork extends.
•Fork springs — Optional springs are
available in softer and stiffer types than the
standard rate. (page 181)
The inverted fork on your CRF features sealed
damper cartridges with dual (separate air and oil)
chambers to prevent aeration. The design also
isolates the oil in each fork/damper, which may
contain air bubbles and/or metal particles, from the
sealed cartridge to provide more consistent
damping.
Air is an unstable gas which builds up pressure as it
is worked (such as in a fork). Air pressure acts as a
progressive spring and affects the entire range of
fork travel. This means the fork action on your CRF
will get stiffer during a race (CRF450RX)/moto
(CRF450R/RWE). For this reason, release built-up
air pressure in the fork legs between race
(CRF450RX)/moto (CRF450R/RWE). Be sure the
fork is fully extended with the front tire off the
ground when you release the pressure.
The standard air pressure is 0 psi (0 kPa, 0 kgf/cm
2
).
You may relieve accumulated air pressure in the fork
legs by using the pressure release screws. The front
wheel should be off the ground before you release the
pressure. The air pressure should be adjusted
according to the altitude and outside temperature.
1. Place an optional workstand under the engine,
so that the front wheel is off the ground.
Do not adjust air pressure with the front wheel
on the ground as this will give false pressure
readings.
2. Remove the pressure release screw (1).
3. Apply recommended fork oil to a new O-ring
(2), and then install a new O-rings.
4. Install and tighten the pressure release screw to
the specified torque:
1.0 lbf·ft (1.3 N·m, 0.1 kgf·m)
(1) compression damping adjuster
(2) rebound damping adjuster
(1)
(2)
Front Suspension Air Pressure
(1) pressure release screw (2) O-ring (new)
(2)
(1)
144 Adjustments for Competition
Front Suspension Adjustments
Compression Damping Adjustment
This adjustment affects how quickly the fork
compresses. The fork compression damping
adjuster has 16 clicks or more. Turning the
compression damping adjuster screw (1) one full
turn changes the adjuster 4 clicks. To adjust the
adjuster to the standard position, proceed as
follows:
Turn the adjuster clockwise (harder) until it will no
longer turn (lightly seats). Turn the adjuster
counterclockwise (softer) until it clicks. This click
is position 1.
(CRF450RX)
The standard position is 7 clicks.
(CRF450R/RWE)
The standard position is 8 clicks.
Make sure that both fork legs are adjusted to the
same position.
Rebound Damping Adjustment
This adjustment affects how quickly the fork
extends.
The fork rebound damping adjuster has 16 clicks
or more. Turning the rebound damping adjuster
screw (2) one full turn changes the adjuster 4
clicks. To adjust the rebound damping to the
standard setting, proceed as follows:
Turn the adjuster clockwise (harder) until it will no
longer turn (lightly seats). Turn the adjuster
counterclockwise (softer) until it clicks. This click
is position 1.
(CRF450RX)
The standard position is 15 clicks.
(CRF450R/RWE)
The standard position is 12 clicks.
Make sure that both fork legs are adjusted to the
same position.
Always start with full hard when adjusting
damping.
Do not turn the adjuster screw more than the given
positions or the adjuster may be damaged.
Be sure that the compression and rebound
adjusters are firmly located in a detent, and not
between positions.
Both compression and rebound damping can be
increased by turning the adjuster clockwise.
The fork springs in CRF’s are about right for riders
weighing between 170 lb (77 kg) and 200 lb (91
kg) (less riding gear). So if you’re a heavier rider,
you have to go up on the oil capacity or get a stiff
spring. Do not use less oil than the minimum
specified for each spring or there will be a loss of
rebound damping control near full extension. If the
fork is too stiff on big bumps, turn the compression
damping adjuster counterclockwise 1-click and
lower the oil capacity in increments of 0.2 US oz
(5 cm
3
) in both fork legs until the desired
performance is obtained. Do not, however, lower
the oil capacity below the minimum oil capacity.
When adjusting oil capacity, bear in mind that the
air in the fork will increase in pressure while
riding; therefore, the higher the oil capacity, the
higher the eventual pressure of any air in the fork.
Front Suspension Damping
(1) compression damping adjuster screw
(2) rebound damping adjuster screw
(1)
(2)
Fork Springs
Minimum oil capacity (CRF450RX):
Standard spring: 10.7 US oz (317 cm
3
)
Soft spring: 10.7 US oz (315 cm
3
)
Stiff spring: 10.3 US oz (304 cm
3
)
Minimum oil capacity (CRF450R/RWE):
Standard spring: 10.4 US oz (307 cm
3
)
Soft spring: 10.6 US oz (312 cm
3
)
Stiff spring: 10.2 US oz (301 cm
3
)
Adjustments for Competition 145
Front Suspension Adjustments
1. Remove the front suspension (page 98).
2. Disassemble the fork outer tube (page 100).
3. Disassemble the fork damper (page 105).
Fork Oil Capacity:
(CRF450RX)
Standard 27.4 Ibf/in (4.8 N/mm) Fork Spring
(CRF450R/RWE)
Standard 28.6 Ibf/in (5.0 N/mm) Fork Spring
Example: Front fork characteristics when a standard spring
(CRF450RX)
(CRF450R/RWE)
(CRF450RX)
Optional Soft 26.3 Ibf/in (4.6 N/mm) Fork Spring
(CRF450R/RWE)
Optional Soft 27.4 Ibf/in (4.8 N/mm) Fork Spring
(CRF450RX)
Optional Stiff 28.6 Ibf/in (5.0 N/mm) Fork Spring
(CRF450R/RWE)
Optional Stiff 29.7 Ibf/in (5.2 N/mm) Fork Spring
4. Assemble the fork damper (page 110).
5. Refilling the fork oil (page 101).
6. Install the front suspension (page 102).
Fork Oil Adjustment
Standard
oil capacity
CRF450RX
12.2 US oz
(360 cm
3
)
CRF450R/
RWE
12.0 US oz
(356 cm
3
)
Maximum
oil capacity
CRF450RX
13.6 US oz
(402 cm
3
)
Slightly stiffer
as it nears full
compression.
CRF450R/
RWE
13.3 US oz
(392 cm
3
)
Minimum
oil capacity
CRF450RX
10.7 US oz
(317 cm
3
)
Slightly softer
as it nears full
compression.
CRF450R/
RWE
10.4 US oz
(307 cm
3
)
1 scribe mark or
no mark (factory products)
2 scribe marks or
no mark (factory products)
Force (N)
Stroke (mm)
Oil capacity 13.6 US oz (402 cm
3
)
(MAX)
Oil capacity 12.2 US oz (360 cm
3
)
(STANDARD)
Oil capacity 10.7 US oz (317 cm
3
)
(MIN)
Standard
oil capacity
CRF450RX
12.1 US oz
(358 cm
3
)
CRF450R/
RWE
12.2 US oz
(361 cm
3
)
Maximum
oil capacity
CRF450RX
13.5 US oz
(400 cm
3
)
Slightly stiffer
as it nears full
compression.
CRF450R/
RWE
13.4 US oz
(397 cm
3
)
Minimum
oil capacity
CRF450RX
10.7 US oz
(315 cm
3
)
Slightly softer
as it nears full
compression.
CRF450R/
RWE
10.6 US oz
(312 cm
3
)
Force (N)
Stroke (mm)
Oil capacity 13.3 US oz (392 cm
3
)
(MAX)
Oil capacity 12.0 US oz (356 cm
3
)
(STANDARD)
Oil capacity 10.4 US oz (307 cm
3
)
(MIN)
1 scribe mark
1 scribe mark
Standard
oil capacity
CRF450RX
11.7 US oz
(347 cm
3
)
CRF450R/
RWE
11.8 US oz
(350 cm
3
)
Maximum
oil capacity
CRF450RX
13.2 US oz
(389 cm
3
)
Slightly stiffer
as it nears full
compression.
CRF450R/
RWE
13.1 US oz
(386 cm
3
)
Minimum
oil capacity
CRF450RX
10.3 US oz
(304 cm
3
)
Slightly softer
as it nears full
compression.
CRF450R/
RWE
10.2 US oz
(301 cm
3
)
2 scribe marks
3 scribe marks
Rear Suspension Adjustments
146 Adjustments for Competition
Rear Suspension Adjustments
The rear suspension can be adjusted for the rider’s
weight and riding conditions by changing the
spring pre-load and the rebound and compression
damping.
The rear suspension assembly includes a damper
unit that contains high pressure nitrogen gas. Do
not attempt to disassemble, service, or dispose of
the damper; see your dealer. The instructions
found in this owner’s manual are limited to
adjustments of the shock assembly only.
Puncture or exposure to flame may also result in an
explosion, causing serious injury.
Service or disposal should only be done by your
dealer or a qualified mechanic, equipped with the
proper tools, safety equipment and an official
Honda Service Manual.
If your CRF is new, put enough part-throttle break-
in time (about 1 hour) on it to ensure that the
suspension has worked in.
Pre-load should be adjusted when the engine is
cold because it is necessary to remove the muffler.
An optional pin spanner is available for turning the
shock spring lock nut and adjusting nut to adjust
spring pre-load.
1. Place your CRF on an optional workstand or
equivalent support with the rear wheel off the
ground.
2. Remove the subframe (page 39).
3. Remove the right muffler joint pipe
(page 130). (CRF450RWE only)
4. Check that the spring pre-load is adjusted to
the standard length. Adjust as necessary by
loosening the shock spring lock nut (1) and
turning the adjusting nut (2).
Each complete turn of the adjusting nut
changes the spring length by 0.06 in (1.5 mm).
After adjustment, hold the adjusting nut and
tighten the shock spring lock nut to the
specified torque:
32 lbf·ft (44 N·m, 4.5 kgf·m)
Refer to the following pages for the installation
procedure of the removed parts:
• air cleaner case and air cleaner connecting
tube: page 41
• subframe: page 40
To increase spring pre-load
Loosen the shock spring lock nut using the
optional pin spanners (3) and turn the adjusting nut
to shorten the spring length (4). Do not shorten to
less than:
(CRF450RX)
Standard (Medium) spring (296.9 lbf/in (52 N/mm)):
8.88 in (225.5 mm)
Optional Soft spring (285.5 lbf/in (50 N/mm)):
8.86 in (225.0 mm)
Optional Stiff spring (308.3 lbf/in (54 N/mm)):
9.04 in (229.5 mm)
(CRF450R/RWE)
Standard (Medium) spring (319.8 lbf/in (56 N/mm)):
9.02 in (229.0 mm)
Optional Soft spring (308.3 lbf/in (54 N/mm)):
9.04 in (229.5 mm)
Optional Stiff spring (331.2 lbf/in (58 N/mm)):
9.09 in (231.0 mm)
Rear Suspension Spring Pre-Load
(1) shock spring lock nut (3) pin spanners
(2) adjusting nut (4) spring length
(2)
(4)
(1)
(3)
Adjustments for Competition 147
Rear Suspension Adjustments
To decrease spring pre-load
Loosen the shock spring lock nut using the
optional pin spanners (3) and turn the adjusting nut
to increase the spring length (4). Do not increase to
more than
9.41 in (239.0 mm)
Each turn of the adjusting nut changes spring
length and spring pre-load. One turn equals: spring
length/spring pre-load:
Standard: 0.06 in (1.5 mm)/18 lbf (78 N)
Pin spanners should be used for turning the shock
spring lock nut and adjusting nut. See page 181 for
optional pin spanners.
(CRF450RX)
Spring pre-load length (Standard (medium) spring)
(CRF450R/RWE)
Spring pre-load length (Standard (medium) spring)
Compression Damping
Compression damping may be adjusted in two
stages with separate adjusters.
The high speed compression damping adjuster (1)
is effective when damping adjustment is desired
for high speed operation. The low speed
compression damping adjuster (2) should be used
when damping adjustment is desired at relatively
low speeds.
• When adjusting the compression damping
adjusters, make sure to use the proper size tool
to avoid damage.
• Both the high and low speed compression
damping can be increased by turning the
appropriate adjuster clockwise.
• Adjust the high speed compression damping
adjuster in 1/4 turn increments.
• Be sure the high speed compression adjuster is
firmly located in a detent, and not between
positions.
High Speed Damping:
The high speed damping can be adjusted by
turning the hexagonal portion of the compression
damping adjuster.
The high speed compression damping adjuster has
3 1/2 turns or more.
To adjust to the standard position:
1. Turn the adjuster clockwise (harder) until it
will no longer turn (lightly seats).
2. (CRF450RX)
Turn the adjuster counterclockwise (softer)
3 1/2 turns. Further turn it by ± 1/4, align the
punch mark (3) on the adjuster and the punch
mark (4) on the adjuster body.
(CRF450R/RWE)
Turn the adjuster counterclockwise (softer)
3 1/3 turns. Further turn it by ± 1/4, align the
punch mark (3) on the adjuster and the punch
mark (4) on the adjuster body.
Standard: 9.19 in (233.5 mm)
Max. : 9.41 in (239.0 mm)
Min. : 8.88 in (225.5 mm)
Standard: 9.37 in (238.0 mm)
Max. : 9.41 in (239.0 mm)
Min. : 9.02 in (229.0 mm)
Rear Suspension Damping
(1) high speed compression damping adjuster
(2) low speed compression damping adjuster
(1)
(2)
(3) high speed compression damping adjuster punch
mark
(4) adjuster body punch mark
(3)
(4)
148 Adjustments for Competition
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.
To adjust to the standard position:
1. Turn the adjuster clockwise (harder) until it
will no longer turn (lightly seat). Turn the
adjuster counterclockwise (softer) until it
clicks. This click is position 1.
2. Set the adjuster 10 clicks and adjust it until the
punch mark (5) on the adjuster and the punch
mark (4) on the adjuster body are aligned.
Rebound Damping
The rebound damping adjuster (6) is located at the
lower end of the rear shock absorber.
It has 17 clicks or more. Turning the adjuster one
full turn changes the adjuster 8 clicks.
• Rotate adjuster gently to prevent damage to the
rear shock absorber.
• When adjusting the rebound damping adjuster,
make sure to use the proper size tool to avoid
damage.
• Rebound damping can be increased by turning
the adjuster clockwise.
• Be sure that the rebound adjuster is firmly
located in a detent, and not between positions.
To adjust to the standard position:
1. Turn the adjuster clockwise (harder) until it
will no longer turn (lightly seat). Turn the
adjuster counterclockwise (softer) until it
clicks. This click is position 1.
2. Set the adjuster 7 to 10 clicks and adjust it until
the punch marks (7) on the adjuster and the rear
shock absorber are aligned.
(4) adjuster body punch mark
(5) low speed compression damping adjuster punch
mark
(5)
(4)
(6) rebound damping adjuster (7) punch marks
(7)
(6)
Adjustments for Competition 149
Rear Suspension Adjustments
Setting the proper race sag (ride height) is very
important for competition use.
Race sag refers to the amount of rear wheel travel
used by your CRF at rest, ready to ride, with you
on the seat. As a general rule of thumb, the race sag
dimension should be about one-third of the
maximum travel.
On your CRF, ride height is changed by adjusting
the rear suspension spring pre-load.
Spring Pre-load & Race Sag Adjustment
The following adjustment procedure establishes
the correct starting point for any suspension tuning
— the proper rear suspension spring preload
adjustment for your specific needs.
Your CRF should be at normal racing weight,
including fuel, oil and coolant. You should be
wearing all your normal protective apparel. You
will need two helpers.
To calculate the proper adjustment, it is necessary
to measure between two fixed points — from the
center of the seat mounting bolt to the center of the
chain adjuster lock nut as illustrated here — for
two different situations:
unloaded: motorcycle on an optional workstand
with rear suspension fully extended, no rider.
loaded with rider: motorcycle on ground, with
rider.
1. Support your CRF on an optional workstand
with the rear wheel off the ground.
2. Measure the unloaded dimension.
3. Measure the loaded with rider dimension.
Remove the workstand. With two helpers
available, sit as far forward as possible on your
CRF’s seat, wearing your riding apparel.
Ask one helper to steady your CRF perfectly
upright so you can put both feet on the pegs.
Bounce your weight on the seat a couple of
times to help the suspension overcome any
situation and settle to a good reference point.
Ask the other helper to measure the loaded
with rider dimension.
Example:
4. Calculate the race sag dimension.
To do this, subtract the loaded with rider
dimension (step 3) from the unloaded
dimension (step 2).
Standard Race Sag: 4.1 in (105 mm)
Adjust spring pre-load as necessary to obtain
the desired handling results.
Decreasing the race sag dimension (example:
3.7 in, 95 mm) improves turning ability for
tight terrain at the cost of slightly reduced
straight line stability.
Increasing the race sag dimension (example:
4.5 in, 115 mm) may improve stability on
faster terrain with less turns, but will reduce
turning performance slightly and may upset the
balance between the front and rear suspension,
producing a harsher ride. This will happen if
the adjustment shifts the effective wheel travel
toward the more progressive end of its range.
Rear Suspension Race Sag
UNLOADED MEASUREMENT
(without rider)
EXAMPLE: 24.6 in (625 mm)
SEAT MOUNTING BOLT
CHAIN ADJUSTER LOCK NUT
Unloaded = 24.6 in (625 mm)
– Loaded = 20.7 in (525 mm)
Race Sag = 3.9 in (100 mm)
LOADED MEASUREMENT
(with rider)
EXAMPLE: 20.7 in (525 mm)
SEAT MOUNTING BOLT
CHAIN ADJUSTER LOCK NUT
150 Adjustments for Competition
Rear Suspension Adjustments
Spring Rates
If you are lighter or heavier than the average rider
and cannot set the proper ride height with altering
the correct spring pre-load, consider an optional
rear shock spring.
A spring that is too soft for your weight forces you
to add excessive spring pre-load to get the right
race sag and, as a result, the rear end of the
motorcycle is raised. This can cause the rear wheel
to unload too much in the air and top out as travel
rebounds. The rear end may top out from light
braking, or kick sideways over lips and square-
edged terrain. It may even top-out when you
dismount your CRF.
Because of the great absorption quality of the
shock bumper rubber, it may be difficult for you to
notice when your CRF’s suspension is bottoming.
Some riders may think the damping or perhaps the
leverage ratio is too harsh. In reality, the problem
is most likely insufficient spring pre-load or a
spring that is too soft. Either situation prevents
utilizing the full travel.
Keep in mind that a properly adjusted suspension
system may bottom slightly every few minutes at
full speed. Adjusting the suspension to avoid this
occasional bottoming may cost more in overall
suspension performance than it is worth.
A spring that is too stiff for your weight will not
allow the rear tire to hook up under acceleration
and will pass more bumps on to you.
Suspension Adjustments for Track Conditions
Adjustments for Competition 151
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.
You may want a little bit stiffer front suspension
for sand tracks to help keep the front end up and
improve straight-line stability.
In a muddy event, stiffer optional springs front and
rear may help, especially if you are heavier than
the average rider. Your CRF may be under-sprung
because of the added weight of the clinging mud.
This additional weight may compress the
suspension too much and affect traction.
Hard Surface
For a fast, hard track with no large jumps, you can
probably run the same spring as normal, but run
softer damping both ways-compression and
rebound. If you run softer rebound damping, the
wheel will follow the rough ground and small
bumps much better, and you will hook up better.
With a lot of rebound damping, the wheel returns
very slowly and doesn’t contact the ground quickly
enough after each bump. The result is a loss of
traction and slower lap times.
Suspension Adjustment Guidelines
152 Adjustments for Competition
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 Begin with the standard setting. If the suspension is too stiff/soft, adjust according to the chart below.
Sand track Adjust to a stiffer position.
Example: – Turn the compression damping adjuster to a stiffer position.
– Install the optional stiff spring. (Adjust compression damping to a softer position and rebound damping to a stiffer position at this
time.)
Mud track Adjust to a stiffer position because mud build-up increases your CRF’s weight.
Example: – Turn the compression damping adjuster to a stiffer setting.
– Install the optional stiff spring
.
Adjustments for Too Soft/Stiff Damping
Symptom Action
Soft
suspension
Initial travel too soft:
• Steering is too quick.
• Front end darts while cornering or riding in a straight line.
– Test stiffer compression damping adjustments in one-click increments.
– Test stiffer rebound damping in one-click increments.
Middle travel too soft:
• Front end dives when cornering.
If suspension isn’t stiff in initial travel:
– Test stiffer compression damping adjustments in one-click increments.
If initial travel becomes stiff because of the above adjustment:
– Reduce the rebound damping in one-click increments.
– Test softer compression damping adjustments in one-click increments.
If that doesn’t solve the problem, install the optional stiff spring.
Final travel too soft:
• Bottoms on landings.
• Bottoms on large bumps, especially downhill bumps.
If initial and middle travel aren’t stiff:
– Test stiffer compression damping adjustments in one-click increments.
If initial and middle travel are stiff:
– Install the optional stiff spring.
If initial travel is stiff after installing the optional stiff spring:
– Test softer compression damping adjustments in one-click increments.
If initial travel is still soft after installing the optional stiff spring:
– Test stiffer compression damping adjustments in one-click increments.
If final travel is still soft after installing the optional stiff spring:
– Increase the fork oil capacity in increments of 0.2 US oz (5 cm
3
).
Entire travel too soft:
• Front end shakes.
• Fork bottoms over any type of terrain.
– Install the optional stiff spring.
– Test stiffer compression damping adjustments in one-click increments.
– Increase rebound damping in one-click increments.
Suspension Adjustment Guidelines
Adjustments for Competition 153
Symptom Action
Stiff
suspension
Initial travel too stiff:
• Stiff on small bumps while riding at full throttle in a straight line.
• Stiff on small cornering bumps.
• Front end wanders while riding at full throttle in a straight line.
– Test softer compression damping adjustments in one-click increments.
– Reduce the rebound damping adjustments in one-click increments.
– Check for dirt in the dust seals. Check the fork oil for any contamination.
If the front end dives while cornering after the above adjustment:
Reduce the rebound damping in one-click increments. If that doesn’t solve the
problem, install the optional stiff spring.
If the stiff spring makes the suspension too stiff over the full range of travel:
test softer compression damping adjustments in one-click increments until the
desired compression damping for initial travel is obtained.
Middle travel too stiff:
• Stiff on bumps when cornering.
• Front end wanders when cornering.
• Stiff suspension on bumps, especially downhill bumps.
• While braking, front end dives during initial travel, then feels stiff.
If initial travel isn’t stiff:
– Test stiffer compression damping adjustments in one-click increments. (This
should produce smooth fork action from initial to middle travel.)
If initial and middle travel is stiff:
– Test softer compression damping adjustments in one-click increments.
– Reduce the rebound damping in one-click increments.
Final travel too stiff:
• Doesn’t bottom on landings, but feels stiff.
• Stiff on large bumps, especially downhill bumps.
• Stiff on large bumps when cornering.
If initial and middle travel aren’t stiff:
– Test stiffer compression damping adjustments in one-click increments. (This
should produce smooth fork action from initial to middle travel.)
If final travel is still stiff after the above adjustment, or
If initial and middle travel becomes stiff:
– Install the optional soft spring.
– Test softer compression damping adjustments in one-click increments.
If the entire travel feels stiff after the above adjustment:
– Test softer compression damping adjustments in one-click increments until the
desired initial travel compression damping is obtained.
– Lower the oil capacity by 0.2 US oz (5 cm
3
).
Entire travel too stiff:
• Stiff suspension on any type of terrain.
– Test softer compression damping adjustments in one-click increments.
– Reduce the rebound damping in one-click increments.
– Lower the oil capacity by 0.2 US oz (5 cm
3
).
Suspension Adjustment Guidelines
154 Adjustments for Competition
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: – Turn the compression damping adjuster and, especially, rebound damping adjuster to a stiffer setting.
– Increase standard Race Sag (+0.2 to 0.4 in/5 to 10 mm).
Mud track Adjust to a stiffer position because mud build-up increases your CRF’s weight.
Example: – Adjust the compression and rebound damping adjusters to stiffer settings.
– Install an optional stiff spring.
– Reduce standard Race Sag (–0.2 to –0.4 in/–5 to –10 mm).
Symptoms and Adjustment
• Always begin with the standard settings.
• Turn the low speed compression and rebound adjusters in one-click increments, and the high speed compression adjuster in 1/12 turn increments at a time. Adjusting two or
more clicks or turns at a time may cause you to pass over the best adjustment. Test ride after each adjustment.
• If, after setting, the suspension feels unusual, find the corresponding symptom in the table and test stiffer or softer compression and/or rebound damping adjustments until the
correct settings are obtained as described.
Symptom Action
Stiff suspension Suspension feels stiff on small bumps 1. Test softer low speed compression adjustment.
2. If it still feels stiff, further test softer low and high speed compression adjustments simultaneously.
Suspension feels stiff on large bumps 1. Test softer high speed compression adjustment.
2. If it still feels stiff, further test softer low and high speed compression adjustments simultaneously.
Entire travel too stiff 1. Test softer high and low speed compression adjustments and rebound adjustment simultaneously.
2. If it still feels stiff, replace the spring with an optional soft spring and begin with the standard settings to softer
settings.
Soft suspension Entire travel too soft 1. Test stiffer high and low speed compression adjustments simultaneously.
2. If it still feels soft, replace the spring with an optional stiff spring and begin with the standard settings to stiffer
setting.
Rear end sways 1. Test stiffer high and low speed compression adjustments and rebound adjustment to stiffer settings
simultaneously.
Suspension
bottoms
Suspension bottoms at landing after
jumping
1. Test stiffer high speed compression adjustment.
2. If it still bottoms, test stiffer high and low speed compression adjustments, and replace the spring with a stiff
spring (optional) if necessary.
Suspension bottoms after landing 1. Test stiffer low speed compression adjustment.
2. If it still bottoms, test stiffer high and low speed compression adjustments, and replace the spring with a stiff
spring (optional) if necessary.
Suspension bottoms after end of
continuous bumps
1. Test softer rebound damping adjustment.
2. If it still bottoms, test stiffer high and low speed compression adjustments and softer rebound damping
adjustment, and replace the spring with an optional stiff spring if necessary.
Tuning Tips
Adjustments for Competition 155
Refer to Spark Plug on pa
ge 78.
The following procedure is recommended.
You may not get an accurate reading if you simply
turn off the engine and pull the plug for inspection.
Use a new spark plug. Inspect the plug before
installing it.
Using spark plugs with an improper heat range or
incorrect reach can cause engine damage.
Ride for 10 – 15 minutes before taking a plug
reading. A new plug will not color immediately.
Before removing the spark plug, clean the spark
plug area thoroughly to prevent dirt from entering
the cylinder.
To obtain an accurate reading of a new spark plug:
1. Accelerate at full throttle on a straight.
2. Depress and hold the engine stop button and
pull the clutch lever in.
3. Coast to a stop.
4. Remove the spark plug.
5. Use a magnifying glass to inspect the spark
plug. The porcelain insulator (1) around the
center electrode (2) should appear clean and
colorless with a gray ring around the center
electrode where it exits the porcelain.
Light gray or white color streaks the porcelain
insulator and center electrode indicate lean air-
fuel mixture. Wet or black sooty streaks on the
porcelain indicate rich air-fuel mixture.
An improperly tightened spark plug can damage
the engine. If a plug is too loose, the piston may be
damaged. If a plug is too tight, the threads may be
damaged.
Spark Plug Coloring Guidelines
Remember that in addition to improper air-fuel
mixture:
• A lean condition can be caused by air leaks in
the inlet tract or exhaust system, the passage of
too much air because of the use of the wrong
air cleaner, or use of a less-restrictive
aftermarket exhaust system.
• A rich condition can be caused by a plugged or
dirty air cleaner, use of a more-restrictive
aftermarket exhaust system, or excessive oil on
the air cleaner.
Excessive smoking will occur.
Spark Plug Reading
(1) porcelain insulator (2) center electrode
Condition Spark Plug Appearance Mixture
Normal Dark brown to light tan
color with dry electrode
correct
Overheating
(Lean)
Light gray or white color lean
Wet (Rich) Wet or sooty rich
(2)
(1)
Chassis Adjustments
156 Adjustments for Competition
Chassis Adjustments
The following suggestions may improve a specific
concern. Subtle changes in overall handling may
also be noted.
If you have a problem with rear wheel traction,
raise the rear end of your CRF by increasing the
rear suspension spring pre-load. Instead of running
3.9 in (100 mm) of sag, you can run 3.5 in (90 mm)
so the rear of the motorcycle will sit a little higher.
This should produce more traction because of the
change to the swingarm and location of your
CRF’s center of gravity.
If you have a problem with the steering head
shaking when you use the front brake hard or if
your CRF wants to turn too quickly, lower the rear
of the motorcycle by reducing the rear suspension
spring pre-load. This will increase fork rake and
trail and should improve stability in a straight line.
The effective suspension travel will be transferred
toward the firmer end of wheel travel.
Keep the race sag adjustment (page 149) in the 3.7
– 4.5 in (95 – 115 mm) range.
The position of the fork in the clamp is not
adjustable.
Standard Position
The groove (1) in the outer tube is aligned with the
top surface of the upper fork bridge (2).
Adjusting your CRF’s wheelbase can offer subtle
changes in overall handling. You may adjust
wheelbase by adding or removing links on the
drive chain. If you change the wheelbase, be sure
to recheck race sag and adjust, if necessary.
In the past, a general rule was lengthen the
wheelbase to add straight line stability, shorten the
wheelbase to improve turning. However, we
suggest you do not lengthen the wheelbase of your
CRF unless you are racing on a track with more
fast sections than normal.
As a general recommendation, keep the wheelbase
as short as possible. This positions the wheels
closer together, improves turning response,
increases weighting (traction) on the rear wheel,
and lightens weighting on the front wheel.
With your CRF, you will probably find that the
standard setting or a shorter wheelbase will offer
more overall benefits.
Rear End
Fork Height/Angle
(1) groove
(2) upper fork bridge
(2)
(1)
Wheelbase
Gearing
Adjustments for Competition 157
You can “adjust” the power delivery of the
standard engine to suit track conditions by
changing gearing. This allows you to utilize a
different portion of the
engine’s power range at a
given throttle setting. New gearing may provide
the change you are looking for without the need to
consider further modifications.
The portion of your engine’s power range you use
can be adjusted by changing the final drive ratio
with different sized driven sprockets. Gearing
changes allow you to more closely match the type
of terrain and the available traction.
Normally, a change of one tooth on the driven
sprocket will be sufficient.
There is a choice of both higher and lower final
drive ratios with two optional driven sprockets.
Like the optional springs, these sprockets are listed
in the Optional Parts List section of this manual
(page 181).
Unless you have the required mechanical know-
how, tools, and an official Honda Service Manual,
sprocket changing should be done by your dealer.
Higher Gearing (less driven sprocket teeth)
• increases top speed in each gear (provided the
engine will pull the higher gearing)
• reduces frequency of shifting (wider gear
ratios)
• reduces engine rpm at a given throttle setting
or ground speed (which may allow better rear
wheel traction on slippery or loose terrain)
However:
• the engine may not pull the higher gearing
• the spacing between gears may be too wide
• engine rpm may be too low
Lower Gearing (more driven sprocket teeth)
• decreases top speed in each gear
• increases frequency of shifting (narrower gear
ratios)
• increases engine rpm at a given throttle setting
or ground speed (which may provide more
power-to-the-ground on good traction surfaces)
However:
• spacing between gears may be too narrow
• engine rpm may be too high
Some tracks may be watered heavily prior to the
first race (CRF450RX)/moto (CRF450R/RWE),
then lightly or not at all during the day. This results
in a track surface that is slippery during the first
few races (CRF450RX)/motos (CRF450R/RWE),
then changes from good to great and back to good
and possibly ends the day with a slick rock-hard
consistency.
Ideally, your gearing should be adjusted to suit all
these conditions.
• Wet and slippery or sandy conditions: use a
higher gear (less teeth) to keep engine rpm
down, and avoid unwanted wheelspin. The
engine may bog in certain corners so you’ll
need to slip the clutch to compensate;
downshifting may be too drastic a change in
speed.
• Average conditions: use the standard sprocket.
• Hard (but not slippery) track conditions: use
lower gearing (more teeth) to keep the engine
rpm high where the engine produces the most
power. This may require an extra upshift on
certain sections or perhaps you can just rev it
out a bit longer.
For tight tracks, consider lower gearing to avoid
having to slip the clutch frequently. Repeated
fanning or pulling of the clutch lever in a turn to
raise engine rpm may eventually damage the
clutch system.
A gearing change may help for riding in sand,
where you want to keep the front end light so it can
float from the peak of one sand whoop to the next.
Generally, with higher gearing, it is easier to
maintain that perfect attitude (maximum rear
wheel traction and a light front end) because you
remain in the powerband longer in each gear.
The higher gearing allows you to steer more
efficiently with throttle control and body English.
If you are riding a track with sections where you
choose to over-rev the engine temporarily rather
than shifting up, higher gearing might help.
Sometimes you have to sacrifice performance on
one section of the track to gain a better overall
time. Your goal is the fastest overall lap time, even
if the cost is some sections where the gearing feels
wrong.
If you decide to try a gearing change, have
someone check your times with a stopwatch
(before and after the change) to get an accurate
appraisal of the change. “Seat-of-the-pants”
feelings can’t be trusted. Eliminating wheelspin
with a gearing change can make you feel like
you’re going slower when, in reality, you’ve
decreased your time by increasing your speed with
better traction.
These gearing recommendations should be
evaluated by considering your ability, your riding
style, and the track.
Tire Selection for Track Conditions
158 Adjustments for Competition
Tire Selection for Track Conditions
Choosing the correct tire tread pattern and rubber
compound can affect your placing in competition.
The tires on your CRF offer a “happy medium” for
the variety of soil conditions the majority of riders
are likely to encounter.
Experienced competitors often switch to tires
developed for specific terrain conditions. If you do
switch, stay with the factory recommended sizes.
Other tires may affect handling or acceleration.
Be aware that tire sizes (width and aspect ratio) do
vary from manufacturer to manufacturer or even
among tires made by the same manufacturer.
Variations in tires, especially the sidewall profile,
can change the attitude of your CRF and its
handling. Tire variations that raise or lower the
rear of your CRF have a more significant effect on
handling than variations in front tires which,
generally, don’t vary as much.
Often, you can see or feel the change in tire size.
Another way to check is to measure the rolling
circumference of the old and new tires. A higher
profile tire will have a larger rolling
circumference.
If you do switch to tires designed for special terrain
use, remember they will be less acceptable in other
circumstances. For example, an aggressive mud
tire will give excellent grip on wet, loamy terrain,
but less impressive grip on a hard surface.
If you choose a tire with a sticky compound for
added traction, remember that it may transfer
additional loads to the transmission because it
grips so well, especially when riding in situations
that normally place unusual demands on the
transmission.
Complete consumer information can be obtained
from the various tire manufacturer representatives
and dealers.
Some general recommendations for specific
terrain follow:
Hard, Slick Soil
Use tires with many relatively short knobs that are
close together in order to obtain the largest
possible contact patch on the surface. The rubber
compound needs to be softer for hard ground in
order to hook up, but not so soft that the knobs roll
over easily and affect holding a straight line.
These tires tend to wear more quickly than
standard tires because of the combination of soft
rubber and hard terrain.
Muddy Soil
Use a more open tread pattern to avoid clogging.
For these conditions, the relatively long knobs will
probably be made from a harder rubber compound
to reduce any tendency to bend back under
acceleration or wear quickly.
Loose, Sandy Soil
Use a tire that is similar in construction to those
needed for tacky soil and mud, but with a few more
knobs.
Personal Fit Adjustments
Adjustments for Competition 159
The following suggestions may make your ride
both more comfortable
and more responsive to
your control input.
• Position the control levers so that you can use
them comfortably when seated and standing.
• Adjust the mounting bolt (1) torque of the
clutch and front brake lever assemblies so that
they can rotate on the handlebar in a fall. If an
assembly does not rotate, it may bend or break
a control lever. 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.
Tighten the top bolts first.
As an alternative, consider wrapping the handlebar
area under the control assemblies with Teflon tape.
Then tighten the assemblies to their normal torque.
Upon impact, the fully-tightened assemblies
should rotate on the Teflon tape.
• Position the shift lever and rear brake pedal so
they are close to your boot for rapid access, but
not so close that either is depressed when
sitting or standing comfortably on your CRF.
• Position the handlebar so that both gripping the
bar and operating the controls are comfortable
while both seated and standing, while riding
straight ahead and turning.
• The handlebar position may be moved
backward 0.4 in (10 mm) by rotating the
handlebar lower holders 180 degrees.
• The handlebar position may be moved forward
1 in (26 mm) by changing the position where
the handlebar under holder bolts is inserted
into the fork bridge holes.
Control Positioning
(1) control lever mounting bolts
(1) (1)
Handlebar Position, Width & Shape
Handlebar standard position
160 Adjustments for Competition
Personal Fit Adjustments
Refer to an official Honda Service Manual for installation instructions. Be sure to check control cable and
wiring harness routing after the adjustment.
Position chart
Handlebar position Handlebar lower holders position Handlebar lower holders
Forward 1 in (26 mm) Front holes of fork bridge No change
Forward 0.6 in (16 mm) Front holes of fork bridge Rotating 180 degrees
Standard Rear holes of fork bridge No change
Backward 0.4 in (10 mm) Rear holes of fork bridge Rotating 180 degrees
• Handlebar width can be trimmed with a
hacksaw to better suit your particular shoulder
width and riding preference. Think this
through carefully and cut off just a small
amount at a time from both sides equally. It is
obviously much easier to make the handlebar
narrower than it is to add material.
• Chamfer the edges to remove burrs and other
irregularities or roughness after sawing the
handlebar.
• An alternate handlebar shape, through varying
rise or rearward sweep dimensions, will
provide further adjustment to riding position
and may better suit your particular body size or
riding style. Each of the ergonomic dimensions
of the machine was determined to suit the
greatest possible number of riders based on an
average size rider.
Tips
Tips 161
Here’s h
elpful advice on how to transport and store
your CRF, as well as three troubleshooting flow
charts.
Transporting Your Motorcycle ......................162
Storing Your Honda.......................................163
Preparation for Storage ..............................163
Removal from Storage ...............................163
You & the Environment.................................164
Troubleshooting .............................................165
Transporting Your Motorcycle
162 Tips
Transporting Your Motorcycle
If you use a truck or motorcycle trailer to transport
your CRF, we recommend that you follow these
guidelines:
• Use a loading ramp.
• Relieve the fuel pressure (pages 43, 53) and
drain the fuel from the fuel tank into an
approved gasoline container.
• Secure the motorcycle in an upright position,
using motorcycle tie-down straps. Avoid using
rope, which can loosen and allow the
motorcycle to fall over.
To secure your CRF, brace the front wheel against
the front of the truck bed or trailer rail.
Attach the lower ends of two straps to the tie-down
hooks on truck bed or trailer rail. Attach the upper
ends of the straps to the handlebar (one on the right
side, the other on the left), close to the fork.
Check that the tie-down straps do not contact any
control cables or electrical wiring.
Tighten both straps until the front suspension is
compressed about half-way. Too much pressure is
unnecessary and could damage the fork seals.
Use another tie-down strap to keep the rear of the
motorcycle from moving.
We recommend that you do not transport your
CRF on its side. This can damage the motorcycle,
and leaking gasoline could be a hazard.
Storing Your Honda
Tips 163
If you
won’t be riding for an extended period, such
as during the winter, thoroughly inspect your CRF
and correct any problem before storing it. That
way, needed repairs won’t be forgotten and it will
be easier to get your CRF running again.
To reduce or prevent deterioration that can occur
during storage, also follow the following
procedures.
1. Completely clean all parts of your CRF. If your
CRF has been exposed to sea air or salt water,
wash it down with fresh water and wipe dry.
2.
Remove the engine guard A bolts/washers (1), B
bolt/washer (2) and engine guard (3).
3. Change the engine oil and filter (page 63).
4. Remove the radiator cap and coolant drain bolt
(4) and sealing washer (5) at the water pump
cover (6) to drain coolant.
After the coolant has been completely drained,
reinstall the drain bolt with a new sealing
washer and radiator cap.
Tighten the drain bolt to the specified torque:
7 lbf·ft (10 N·m, 1.0 kgf·m)
5. Install the engine guard (3), then tighten the
engine guard A bolts/washers (1), B bolt/
washer (2) to the specified torque:
7 lbf·ft (10 N·m, 1.0 kgf·m)
6. Lubricate the drive chain.
7. Relieve the fuel pressure (pages 43, 53) and
drain the fuel from the fuel tank into an
approved gasoline container.
8. Remove the battery.
Store in an area protected from freezing
temperatures and direct sunlight. Slow charge
the battery (page 135) once a month.
9. Inflate the tires to their recommended
pressures.
10. Place your CRF on an optional workstand or
equivalent to raise both tires off the ground.
11. Stuff a rag into the muffler outlet. Then tie a
plastic bag over the end of the muffler to
prevent moisture from entering.
12. Store your CRF in an unheated area, free of
dampness, away from sunlight, with a
minimum of daily temperature variation.
13. Cover your CRF with a porous material.
Avoid using plastic or similar non-breathing,
coated materials that restrict air flow and allow
heat and moisture to accumulate.
1. Uncover and clean your CRF.
Change the engine oil if more than 4 months
have passed since the start of storage.
2. Uncover the end of the muffler and remove the
rag from the muffler outlet.
3. Fill the fuel tank with the recommended fuel
(pages 42, 52).
4. Charge the battery (page 135) as required.
Install the battery.
5. Pour a fresh recommended coolant mixture
slowly into the radiator fill hole up to the filler
neck (page 65).
Capacity:
(CRF450RX)
1.22 US qt (1.15 ℓ) after disassembly
1.13 US qt (1.07 ℓ) after draining
(CRF450R/RWE)
1.19 US qt (1.13 ℓ) after disassembly
1.13 US qt (1.07 ℓ) after draining
Lean your CRF slightly right and left several
times to bleed trapped air in the cooling
system.
If the coolant level lowers, add coolant and
repeat the above procedure.
Install the radiator cap securely.
6. Increase the fuel pressure (page 51).
7. Perform all maintenance checks (page 13).
Preparation for Storage
(1) engine guard A bolts/washers
(2) engine guard B bolt/washer
(3) engine guard
(1)
(2)
(3)
(4) coolant drain bolt
(5) sealing washer (new)
(6) water pump cover
(6)
(5)
(4)
Removal from Storage
You & the Environment
164 Tips
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
people, you also help preserve the sport of off-road
riding.
Following are tips on how you can be an
environmentally responsible motorcycle owner.
• Choose Sensible Cleaners. Use a
biodegradable detergent when you wash your
CRF. Avoid aerosol spray cleaners that contain
chlorofluorocarbons (CFCs) which damage the
atmosphere’s protective ozone layer. Don’t
throw cleaning solvents away; see the following
guidelines for proper disposal.
• Recycle Wastes. It’s illegal and thoughtless to
put used engine oil in the trash, down a drain, or
on the ground. Used oil, gasoline, coolant, and
cleaning solvents contain poisons that can hurt
refuse workers and contaminate our drinking
water, lakes, rivers, and oceans.
Before changing your oil, make sure you have
the proper containers. Put oil and other toxic
wastes in separate sealed containers and take
them to a recycling center. Call your local or
state office of public works or environmental
services to find a recycling center in your area
and get instructions on how to dispose of non
recyclable wastes.
Improper disposal of drained fluids is harmful to
the environment.
Troubleshooting
(cont’d)
Tips 165
The items that are
serviceable using this Manual
are followed by the page number reference in
parenthesis. The items that require use of the
official Honda Service Manual are followed by an
asterisk (*).
ENGINE DOES NOT START OR IS HARD TO START
Operate the start button with the throttle grip in
fully closed position (page 17).
CHECK POSSIBLE CAUSES
1. Check the starter
motor*
• Loose or disconnected
battery terminals (P.135)
• Blown main fuse (P.168)
• Weak battery (P.135, 169)
• Faulty starter relay switch
or starter motor*
• Faulty start button*
• Faulty clutch switch
• Faulty CKP sensor*
2. Check the starter/
ignition relay*
• Faulty starter/ignition
relay
3. Check the spark
plug condition
(P.78)
• Incorrect spark plug heat
range
• Incorrect spark plug gap
• Dirty air cleaner element
4. Try spark test* • Faulty spark plug (P.78)
• Fouled spark plug (P.78)
• Faulty ECM*
• Broken or shorted spark
plug wire
• Faulty alternator*
• Faulty ignition coil*
• Faulty engine stop
button*
• Loose or disconnected
ignition system wires
• Faulty CKP sensor*
• Faulty regulator/rectifier*
5. Check the PGM-FI
system (P.7)
• Faulty PGM-FI system
(P.9)
6. Check the fuel
pump operation
and inspect the fuel
flow*
• Faulty fuel pump*
• Clogged fuel pump filter
TURN
DOES NOT
TURN
CORRECT
INCORRECT
CORRECT
INCORRECT
GOOD SPARK
WEAK OR
NO SPARK
CORRECT
INCORRECT
CORRECT
INCORRECT
7. Check the fuel
injector operating
sound
• Faulty PGM-FI system
(P.9)
• Faulty fuel injector
8. Test cylinder
compression*
• Valve clearance too small
• Valve stuck open
• Worn cylinder and piston
ring*
• Damaged cylinder head
gasket
• Improper valve timing*
• Seized valve
9. Start by following
normal starting
procedure
• Insulator leaking
• Improper ignition timing
(Faulty ECM or CKP
sensor)*
• Fast idle knob stuck open
or damaged
• Fuel contaminated
ENGINE LACKS POWER
CHECK POSSIBLE CAUSES
1. Check the wheel
spin smoothness
• Brake dragging
• Worn or damaged wheel
bearings
• Bent axle shaft
• Drive chain too tight
2. Check the tire
pressure (P.119)
• Faulty valve core
• Punctured tire
3. Check the engine
speed change
accordingly when
clutch is engaged*
• Clutch slipping
• Improperly adjusted
clutch lever freeplay
(P.73)
• Worn clutch discs/plates
(P.76)
• Warped clutch discs/
plates (P.76)
• Weak clutch springs*
• Sticking clutch lifter
• Additive in engine oil
4. Check the engine
speed increase
• Dirty air cleaner element
• Clogged muffler
• Fast idle knob stuck open
or damaged
• Restricted fuel fill cap
breather tube
• Restricted fuel flow
CORRECT
INCORRECT
CORRECT
LOW
ENGINE
STARTS BUT
SOON STOPS
CORRECT
INCORRECT
CORRECT
INCORRECT
GOOD
NO GOOD
GOOD
NO GOOD
5. Check the engine
knocking when
accelerate or run
the engine at high
speed
• Worn piston and cylinder*
• Use of poor quality fuel
• Excessive carbon build-
up in combustion
chamber
• Ignition timing too
advance (Faulty ECM)*
• Lean fuel mixture
6. Check the ignition
timing*
• Faulty ECM*
• Faulty CKP sensor*
7. Test cylinder
compression*
• Valve clearance too small
• Valve stuck open
• Worn cylinder and piston
ring*
• Damaged cylinder head
gasket
• Improper valve timing*
• Faulty decompressor
system*
8. Check the PGM-FI
system (P.7)
• Faulty PGM-FI system
(P.9)
9. Check the fuel
pump operation
and inspect the fuel
flow*
• Faulty fuel pump unit*
• Clogged fuel pump filter
10.Check the spark
plug condition
(P.78)
• Incorrect spark plug
• Incorrect spark plug gap
• Dirty air cleaner element
11.Check the engine
oil level and
condition (P.63)
• Engine oil level too high
• Engine oil level too low
• Contaminated engine oil
12.Remove the
cylinder head cover
and inspect
lubrication
• Faulty oil pump*
• Faulty pressure relief
valve*
• Clogged oil passage*
• Clogged oil strainer
screen*
NO
YES
CORRECT
INCORRECT
CORRECT
LOW
CORRECT
INCORRECT
CORRECT
INCORRECT
CORRECT
INCORRECT
CORRECT
INCORRECT
INCORRECT
166 Tips
Troubleshooting
POOR HANDLING
Steering is heavy
• Steering stem adjusting nut too tight*
• Damaged steering head bearings
Either wheel is wobbling
• Excessive wheel bearing play
•Bent rim
• Improperly installed wheel hub
• Excessively worn swingarm pivot bearings
• Bent frame
The motorcycle pulls to one side
• Front and rear wheels not aligned
• Bent fork
• Bent swingarm
• Bent axle shaft
• Bent frame
POOR PERFORMANCE AT LOW AND IDLE SPEED
CHECK POSSIBLE CAUSES
1. Check the spark
plug condition
(P.78)
• Incorrect spark plug heat
range
• Incorrect spark plug gap
• Plug not serviced
frequently enough
2. Check the ignition
timing*
• Faulty ECM*
• Faulty CKP sensor*
3. Check the PGM-FI
system (P.7)
• Faulty PGM-FI system
(P.9)
4. Check the fuel
pump operation
and inspect the fuel
flow*
• Faulty fuel pump unit*
• Clogged fuel pump filter
5. Check the insulator
for leaks
• Loose insulator
• Damaged insulator
6. Check the valve
clearance (P.79)
• Faulty valve clearance
• Faulty valve*
• Faulty valve seat*
• Faulty camshaft*
7. Try spark test* • Faulty, carbon or wet
fouled spark plug (P.78)
• Faulty ECM*
• Faulty alternator*
• Faulty ignition coil*
• Broken or shorted spark
plug wire.
• Faulty CKP sensor*
• Loose or disconnected
ignition system wires
• Faulty engine stop
button*
• Faulty regulator/rectifier*
CORRECT
INCORRECT
CORRECT
INCORRECT
CORRECT
INCORRECT
CORRECT
INCORRECT
CORRECT
INCORRECT
CORRECT
INCORRECT
WEAK OR
INTERMITTENT
SPARK
POOR PERFORMANCE AT HIGH SPEED
CHECK POSSIBLE CAUSES
1. Check the ignition
timing*
• Faulty ECM*
• Faulty CKP sensor*
2. Check the air
cleaner (P.67)
• Not cleaned frequently
enough
3. Check the PGM-FI
system (P.7)
• Faulty PGM-FI system
(P.9)
4. Check the fuel pump
operation and
inspect the fuel flow*
• Faulty fuel pump unit*
• Clogged fuel pump filter
5. Check the valve
timing
• Camshaft not installed
properly (P.84)
6. Check the valve
clearance (P.79)
• Faulty valve clearance
• Faulty valve*
• Faulty valve seat*
• Faulty camshaft*
7. Check the valve
springs*
• Faulty valve springs*
8. Try spark test* • Faulty, carbon or wet
fouled spark plug (P.78)
• Faulty ECM*
• Faulty alternator*
• Faulty ignition coil*
• Broken or shorted spark
plug wire.
• Faulty CKP sensor*
• Loose or disconnected
ignition system wires
• Faulty engine stop
button*
• Faulty regulator/rectifier*
9. Remove and
inspect the cam
lobe height*
• Faulty camshaft*
CORRECT
INCORRECT
AIR CLEANER
NOT DIRTY
DIRTY
CORRECT
INCORRECT
CORRECT
INCORRECT
CORRECT
INCORRECT
CORRECT
INCORRECT
GOOD
WEAR
GOOD SPARK
WEAK OR
INTERMITTENT
SPARK
CORRECT
WORN
If a Fuse Blows
168 Taking Care of the Unexpected
If a Fuse Blows
All of the electrical circuits on your CRF have a
fuse to protect them from damage caused by excess
current flow (short circuit or overload).
If something electrical on your CRF stops
working, the first thing you should check for is a
blown fuse. Check the fuse before looking
elsewhere for another possible cause of the
problem. Replace a blown fuse and check
component operation.
• The main fuse (and spare) are located on the
starter magnetic switch behind the right side
cover.
Recommended Main Fuse: 10A
1. To prevent an accidental short circuit, stop the
engine.
2. Remove the seat (page 34).
3. Disconnect the negative (–) terminal
(page 134).
4. Remove the right side cover and right air
cleaner housing cover (page 126).
5. Remove the start magnetic switch stay bolt (1)
and plastic wire band (2).
6. Pull out the start magnetic switch (3).
7. Remove the start magnetic switch cover (4).
8. Pull out the main fuse (5). If it is blown (6),
install the spare main fuse (7).
9. Install the start magnetic switch cover (4).
10. Install the start magnetic switch (3).
Install and tighten the start magnetic switch
stay bolt (1) to the specified torque:
9 lbf·ft (12 N·m, 1.2 kgf·m)
11. Install the plastic wire band (2).
12. Connect the negative (–) terminal (page 135).
If you do not have a replacement fuse with the
proper rating for the circuit, install one with a
lower rating.
Replacing a fuse with one that has a higher rating
greatly increases the chance of damage to the
electrical system.
If you replace a blown fuse with a spare fuse that
has a lower rating, replace the fuse with the correct
rating as soon as you can. Also remember to
replace the spare fuse that was installed.
If the replacement fuse of the same rating burns out
in a short time, there is probably a serious electrical
problem on your CRF.
Leave the blown fuse in that circuit and have your
CRF checked by your dealer.
13. Install the right side cover, right air cleaner
housing cover and bolts.
14. Install the seat (page 34).
(1) start magnetic switch stay bolt
(2) wire band
(3) start magnetic switch
(4) start magnetic switch cover
(5) main fuse
(6) blown fuse
(7) spare main fuse
(3) (2)
(4)
(5)
(7)
(1)
(6)
If Your Battery Is Low (or Dead)
Taking Care of the Unexpected 169
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.
Check the battery voltage using a digital multi
meter with the cable connected.
Below 1V: The battery has failed; replace the
battery.
Between1V and 8V: The battery may have
failed; charge the battery and then recheck. If
you can’t charge the battery or it appears
unable to hold a charge, see your dealer.
170 Taking Care of the Unexpected
BLANK PAGE
Technical Information
Technical Information 171
This section contains dimensions, capacities, and
other te
chnical data.
Vehicle Identification.....................................172
Serial Numbers ..........................................172
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
Vehicle Identification
172 Technical Information
Vehicle Identification
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.
The VIN (vehicle identification number) (1) is
stamped on the right side of the steering head.
The engine number (2) is stamped on the right
crankcase.
Serial Numbers
(1) VIN
(1)
(2) engine number
(2)
Specifications
(cont d)
echnical Infor ation
Item English Metric
Dimension
Overall length
CRF450RX:
85.6 in
CRF450R/RWE:
85.9 in
CRF450RX:
2,175 mm
CRF450R/RWE:
2,183 mm
Overall width 32.6 in 827 mm
Overall height 49.6 in
CRF450RX:
1,259 mm
CRF450R/RWE:
1,260 mm
Wheelbase
CRF450RX:
58.1 in
CRF450R/RWE:
58.3 in
CRF450RX:
1,477 mm
CRF450R/RWE:
1,482 mm
Seat height 37.8 in
CRF450RX:
959 mm
CRF450R/RWE:
960 mm
Footpeg height
CRF450RX:
16.4 in
CRF450R/RWE:
16.5 in
CRF450RX:
417 mm
CRF450R/RWE:
418 mm
Ground clearance 12.9 in 328 mm
Frame
Type Twin tube
F. suspension
Telescopic fork,
travel 10.55 in (268 mm)
stroke 12.01 in (305 mm)
R. suspension
Pro-link,
CRF450RX:
travel 12.28 in (312 mm)
CRF450R/RWE:
travel 12.36 in (314 mm)
Tire size, front
CRF450RX: 90/90-21 54M
CRF450R/RWE: 80/100-21 51M
DUNLOP
CRF450RX:
AT81F
CRF450R/RWE:
MX3SF
Tire size, rear
CRF450RX: 120/90-18 65M
CRF450R/RWE: 120/80-19 63M
DUNLOP
CRF450RX:
AT81
CRF450R/RWE:
MX3S
Tire type bias-ply, tube
Tire pressure, front
(cold)
15 psi (100 kPa, 1.0 kgf/cm
2
)
Tire pressure, rear
(cold)
15 psi (100 kPa, 1.0 kgf/cm
2
)
F. brake, swept area
Single disc brake
56.0 in
2
(361.0
cm
2
)
R. brake, swept
area
Single disc brake
60.5 in
2
(390.3
cm
2
)
Fuel
unleaded gasoline, pump octane
number of 91 or higher
Fuel tank capacity
CRF450RX:
2.25 US gal
CRF450R/RWE:
1.66 US gal
CRF450RX:
8.5 ℓ
CRF450R/RWE:
6.3 ℓ
Caster angle
CRF450RX: 27°26’
CRF450R/RWE: 27°22’
Trail length 4.6 in 116 mm
Fork oil capacity
(except damper)
CRF450RX:
12.2 US oz
CRF450R/RWE:
12.0 US oz
CRF450RX:
360 cm
3
CRF450R/RWE:
356 cm
3
Fork oil capacity
(damper)
8.2 US oz 243 cm
3
Item English Metric
Engine
Type Liquid cooled, 4-stroke
Cylinder
arrangement
Single 10° inclined
from vertical
Bore and stroke
3.7795 x
2.4464 in
96.000 x
62.138 mm
Displacement 27.436 cu-in 449.77 cm
3
Compression ratio 13.5 : 1
Valve clearance
(cold)
Intake: 0.005 ± 0.001 in
(0.13 ± 0.03 mm)
Exhaust:0.011 ± 0.001 in
(0.28 ± 0.03 mm)
Engine oil capacity
after draining 1.06 US qt 1.00 ℓ
after draining and
oil filter change
1.10 US qt 1.04 ℓ
after
disassembly
1.43 US qt 1.35 ℓ
Throttle body
Identification
number
GQ2DA
Idle speed 2,000 ± 100 rpm
Cooling system
Cooling capacity
after draining 1.13 US qt 1.07 ℓ
after
disassembly
CRF450RX:
1.22 US qt
CRF450R/RWE:
1.19 US qt
CRF450RX:
1.15 ℓ
CRF450R/RWE:
1.13 ℓ
174 Technical Information
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
Final reduction
CRF450RX: 3.846
CRF450R/RWE: 3.769
Gear shift pattern
Left foot-operated return
system 1-N-2-3-4-5
Electrical
Battery
HY85S lithium-ion (li-ion)
12 V-2.0 Ah (20 HR)
Ignition ECM
Starting system Electric
Spark plug NGK
Standard SILMAR9A-9S
For extended high
speed riding
NGK
SILMAR10A-9S
Spark plug gap
0.031 – 0.035 in
(0.8 – 0.9 mm)
Fuse
Main fuse 10 A
Torque Specifications
Technical Information 175
(cont’d)
Ch
eck and tighten nuts, bolts, and fasteners before every outing.
Nuts, Bolts, Fasteners
LEFT SIDE
(8)
(1)
(6)
(5)
(9)
RIGHT SIDE
(10)
(1)
(2)
(6)
(7)
(4)
(3)
ENGINE
Item
Torque
Remarks
lbf·ft N·m kgf·m
1 Cylinder head cover
socket bolts 7 10 1.0
2 Clutch cover bolts 7 10 1.0
3 Water pump cover bolts 7 10 1.0
4 Crankshaft hole cap 11 15 1.5 NOTE 1
5 Oil filter cover bolts 7 10 1.0
6 Cylinder head bolts 37 50 5.1 NOTE 2
7 Exhaust pipe joint nuts 15 20 2.0
8 Drive sprocket bolt 23 31 3.2
9 Engine oil drain bolt 13 18 1.8 NOTE 2
10 Coolant drain bolt 7 10 1.0
NOTES: 1. Apply grease to the threads.
2. Apply engine oil to the threads and seating surface.
Torque Specifications
176 Technical Information
LEFT SIDE
(16)
(4)
(13)
(14)
(9)
(14)
(12)
(17)
(6)
(3)
(7)
(5)
(2)
(1)
(21)
(17)
(18)
(23)
(CRF450R/RWE)
RIGHT SIDE
(12)
(16)
(2)
(3)
(7)
(19)
(9)
(8)
(11)
(22)
(10)(18) (15)
(23)
(23)
(CRF450R/RWE)
(20)
(13)
FRAME
Item
Torque
Remarks
lbf·ft N·m kgf·m
1 Steering stem nut 80 108 11.0
2
Fork bridge upper pinch bolts
16 22 2.2
3
Fork bridge lower pinch bolts
15 20 2.0
4 Handlebar upper holder
bolts 16 22 2.2
5
Handlebar lower holder nuts
32 44 4.5 NOTE 1
6 Front axle nut 65 88 9.0
7 Axle pinch bolts 15 20 2.0
8 Rear axle nut 94 128 13.1 NOTE 1
9 Chain adjuster lock nuts 20 27 2.8 NOTE 2
10 Front engine hanger nuts 40 54 5.5
Front engine hanger plate
nuts 19 26 2.7
11 Lower engine hanger nut 40 54 5.5
12
Cylinder head hanger bolts
40 54 5.5
13 Cylinder head hanger
plate bolts 24 32 3.3
14 Rear suspension (upper) 32 44 4.5 NOTE 1
(lower) 32 44 4.5 NOTE 1
15 Swingarm pivot nut 65 88 9.0 NOTE 1
16 Fork
(fork damper assembly)
56 76 7.7
(fork bolt assembly) 22 30 3.1
17 Rear shock arm nuts
(swingarm side) 38 52 5.3 NOTE 1, 5
(shock link side) 38 52 5.3 NOTE 1, 5
18 Rear shock link bolts 27 37 3.8 NOTE 1, 5
19
Rear shock spring lock nut
32 44 4.5
20 Battery terminal bolts 1.5 2.0 0.2
21 Fuel pump mounting bolts
(CRF450RX)
8111.1
Fuel pump mounting nuts/
cap nut (CRF450R/RWE)
22 Front brake master cylinder
holder bolts 7.3 9.9 1.0
23 Fuel tank bolt (CRF450RX)
7101.0
Fuel tank bolts
(CRF450R/RWE)
NOTES: 1. U-nut
2. UBS nut
5. Apply molybdenum oil to the threads and flange surface.
Torque Specifications
Technical Information 177
LEFT SIDE
(31)
(29)
(50)(29)
(46)
(42)
(54)
(47)
(56)
(39)
(38)
(43)
(52)
(36)
(35) (51)
(48)
(32)
(49)
(37)
(CRF450R/RWE)
(48)
(25)
(53)
(26)
RIGHT SIDE
(30)
(33)(34)
(50)
(44)
(37)
(28)(45)
(41)
(30)
(27)
(43)
(39)
(52)
(53)
(47)
(42)
(54)
(46)
(36)
(55)
(48)
(40)
(32)
(24)
(49)
(57) (58)
(CRF450R/RWE)
(48)
(56)
FRAME
Item
Torque
Remarks
lbf·ft N·m kgf·m
24 Brake hose oil bolts 25 34 3.5
25 Front brake caliper
mounting bolts 22 30 3.1 NOTE 4
26 Front brake disc nuts 12 16 1.6 NOTE 1
27 Rear brake disc nuts 12 16 1.6 NOTE 1
28 Brake pedal pivot bolt 27 36 3.7 NOTE 4
29 Spokes (front) 2.7 3.7 0.4
(rear) 2.7 3.7 0.4
30 Rim locks 9 12 1.2
31 Drive chain roller (upper) 9 12 1.2 NOTE 4
(lower) 9 12 1.2 NOTE 1
32
Subframe bolts
(upper) 24 32 3.3
(lower) 36 49 5.0
33 Fork center bolt 51 69 7.0
34 Fork center bolt lock nut 21 28 2.9
35 Disc cover bolts 10 13 1.3
36 Fork protector socket bolts 5.2 7.0 0.7 NOTE 4
37
Left/right muffler clamp bolt
(CRF450R/RX)
15 20 2.0
Left/right muffler joint pipe
clamp bolt (CRF450RWE)
6.3 8.5 0.9
38 Driven sprocket nuts 24 32 3.3 NOTE 1
39 Seat mounting bolts 19 26 2.7
40 Front brake reservoir cap
screws 0.7 1.0 0.1
41
Rear brake reservoir cap bolts
0.7 1.0 0.1
42 Fork air pressure release
screw 1.0 1.3 0.1
43 Right/left muffler mounting
bolt A 19 26 2.7
Right/left muffler mounting
bolt B 19 26 2.7
44
Throttle cable adjuster lock nuts
3.0 4.0 0.4
45 Rear master cylinder push
rod lock nut 4.4 5.9 0.6
46 Shroud A bolts 7 10 1.0
47 Shroud B bolts 7 10 1.0
48 Shroud C bolts 3.8 5.2 0.5
49 Shroud D bolts 3.8 5.2 0.5
50
Engine guard A bolts/washers
7101.0
51 Engine guard B bolt/washer 7 10 1.0
52 Side cover bolts 7 10 1.0
53 Air cleaner housing cover
bolts 7 10 1.0
54 Number plate bolts 7 10 1.0
55 Air cleaner retaining bolt 1.8 2.4 0.2
56 Seat support base
mounting bolts 7 10 1.0
57 Battery cable terminal bolt 5.2 7 0.7
58
Start magnetic switch stay bolt
9121.2
NOTES: 1. U-nut
4. Alock bolt: replace with a new one.
Oxygenated Fuels
178 Technical Information
Oxygenated Fuels
Some conventional gasolines are being blended
with alcohol or an ether compound. These
gasolines are collectively referred to as oxygenated
fuels. To meet clean air standards, some areas of
the United States and Canada use oxygenated fuels
to help reduce emissions.
If you use an oxygenated fuel, be sure it is
unleaded and meets the minimum octane rating
requirement.
Before using an oxygenated fuel, try to confirm the
fuel’s contents. Some states/province require this
information to be posted on the pump.
The following fuel blends are EPA-approved and
have been approved for use in your motorcycle:
ETHANOL (ethyl or grain alcohol) up to 10% by
Volume
You may use gasoline containing up to 10%
ethanol by volume. Gasoline containing ethanol
may be marketed under the name “Gasohol”.
METHANOL (methyl or wood alcohol) up to 5%
by Volume
You may use gasoline containing up to 5%
methanol by volume as long as it also contains
cosolvents and corrosion inhibitors to protect the
fuel system. Gasoline containing more than 5%
methanol by volume may cause starting and/or
performance problems.
It may also damage metal, rubber, and plastic parts
of your fuel system.
If you notice any undesirable operating symptoms,
try another service station or switch to another
brand of gasoline.
Fuel system damage or performance problems
resulting from the use of an oxygenated fuel
containing more than the percentages of
oxygenates mentioned above are not covered
under warranty.
Oxygenated fuels can damage paint and plastic.
Be careful not to spill fuel when filling the fuel
tank. Wipe up any spills immediately.
Oxygenated fuels can damage paint and plastic.
Competition Logbook
Technical Information 179
Any serious competition effort rel
ies heavily on
the knowledge gained and compiled from previous
racing events. The best way to organize the many
bits of information is to record them in a logbook.
Your logbook can include such information as
suspension adjustments, gearing, and tire
selection. This detailed information, along with
your comments, can prove valuable when you
compete at the same track or on similar terrain.
Your logbook can also tell you when maintenance
was performed and when it will be necessary
again. Your logbook also lets you record any
repairs and lets you keep track of the running time
on the engine and suspension components.
If you choose to sell your CRF, the accurate
maintenance records in your logbook might be the
deciding deal-maker for a potential buyer.
Consider using different color pens or pencils to
record important information on specific subjects.
For example, record results in black, suspension/
chassis settings in blue, and gearing selections in
green.
Color codes will help you identify the information
you want with a glance.
Tuning & Adjustment Records
Keep track of the settings and adjustments that
worked best at a particular location. These items
include:
• PGM-FI mode
• HRC-launch control system
• basic track conditions, altitude, and
temperature
• suspension settings
• chassis adjustments tested and selected
•gearing
• tire selection
• air pressure
Competition Records
• your placings
• thoughts to improve performance next time:
both yours and your CRF’s
• strategy notes
Maintenance Records
• regular interval maintenance
• repairs
• running time on engine
• running time on suspension components
Timekeeping
This Manual lists maintenance intervals for every-
so-many races (CRF450RX)/motos (CRF450R/
RWE) or every-so-many hours of running.
Because all races (CRF450RX)/motos (CRF450R/
RWE) are not the same, the most effective way to
schedule maintenance is by the hours you have run
your CRF.
An official “guesstimate” is close enough for our
timekeeping purposes. You may choose to record
your time the same way aircraft operators do (but
without the benefit of an electrical hourmeter).
All running time is broken down into hours and
tenths of an hour (each 6 minutes represents one
tenth of an hour).
Racing Records
Information worth recording for this section of
your logbook may include:
• Your placing in each race (CRF450RX)/moto
(CRF450R/RWE) and overall finishing
position.
• Thoughts on what you could do to improve
your performance next time.
• Notes on any patterns noted in choice of
starting gate positions or in riding portions of
the course as the day progressed that may
prove helpful in future events.
• Any places on the course where you chose the
wrong line and were passed too easily.
• Notes on strategy used by your competition or
by riders in another event that are worth
remembering.
Maintenance Records
Regular maintenance items you’ll want to record
in your logbook should include:
• Dates and results of cylinder, piston and ring
examinations
• Patterns for frequency of need for
decarbonization with a particular oil
• When you last performed shock linkage and
swingarm pivot bearing maintenance
• Engine and suspension oil changes
• Chain, sprocket, chain roller and slider
replacements
• Coolant changes and related component
replacements
• Spark plug, brake pad and control cable
replacements
In addition, you should record any irregularities
noted in component wear so you’ll remember to
keep a close eye on these areas in the future.
Competition Logbook
180 Technical Information
Date Running
Time
Location/Event Comments (Suspension Settings, Gearing, Chassis Adjustments, Maintenance Performed, etc.)
(Make several photocopies of this page for future use)
Optional Parts List
Technical Information 181
These parts and
tools may be ordered from your
authorized dealer.
The standard fork spring and shock spring
mounted on the motorcycle when it leaves the
factory are not marked. Before replacing the
springs, be sure to mark them so they can be
distinguished other optional springs.
FRAME Remarks
Driven sprocket < >: Drive chain links
CRF450RX: 50 Teeth, Aluminum
CRF450R/RWE: 49 Teeth,
Aluminum
<114>
Standard
Optional
CRF450RX: 49 Teeth, Aluminum
CRF450R/RWE: 48 Teeth,
Aluminum
CRF450RX: 51 Teeth, Aluminum
CRF450R/RWE: 50 Teeth,
Aluminum
Drive chain
size/link
CRF450RX: RK520EXU/120LJFZ
CRF450R: RK520TXZ/120RJ
TOOLS Remarks
Pin spanner A To adjust spring preload.
(two spanners required)
Workstand For maintenance
Air gauge For checking tire air pressure
FRAME Remarks
Fork spring
CRF450RX:
27.4 lbf/in (4.8 N/mm)
Standard
(Medium)
CRF450R/RWE: 28.6 Ibf/in
(5.0 N/mm)
Optional
Soft
CRF450RX: 26.3 lbf/in (4.6 N/mm)
CRF450R/RWE: 27.4 Ibf/in
(4.8 N/mm)
Stiff
CRF450RX: 28.6 lbf/in (5.0 N/mm)
CRF450R/RWE:
29.7 Ibf/in
(5.2 N/mm)
1 scribe mark or
no mark
(factory products)
2 scribe marks or
no mark
(factory products)
1 scribe mark
1 scribe mark
2 scribe marks
3 scribe marks
FRAME Remarks
Shock spring C
RF450RX: 296.9 lbf/in (52 N/mm)
CRF450R/RWE: 319.8 lbf/in
(56 N/mm)
Standard
(Medium)
Optional
Soft
CRF450RX: 285.5 lbf/in (50 N/mm)
CRF450R/RWE: 308.3 lbf/in
(54 N/mm)
Stiff
CRF450RX: 308.3 lbf/in (54 N/mm)
CRF450R/RWE: 331.2 lbf/in
(58 N/mm)
CRF450RX:
Red paint or
no mark
(factory products)
CRF450R/RWE:
Blue paint or
no mark
(factory products)
CRF450RX:
Pink paint
CRF450R/RWE:
White paint
CRF450RX:
White paint
CRF450R/RWE:
Yellow paint
Spare Parts & Equipment
182 Technical Information
Spare Parts & Equipment
There are numerous spare parts you can take to an
event to help ensure you get in a full day of riding.
In addition to the usual nuts and bolts, consider the
following:
spark plugs
air cleaner (clean & oiled, sealed in a plastic bag)
chain & masterlinks
chain guide slider
chain guide
chain rollers
tire tubes (front & rear)
fenders
footpegs
fuel feed hose
fuel pump filter
number plate & side covers
handlebar
grips
levers (brake & clutch)
clutch lever handlebar mount
clutch cable
throttle assembly
throttle cable
shift lever
brake pedal
spokes (front & rear, each side)
sprockets (larger & smaller than standard)
assorted nuts, bolts, washers, screws, cotter pins
Additional Spares
fuel pump
front brake master cylinder
rear brake assembly
wheels & tires (front & rear, mounted)
clutch discs and plates
engine oil
seat
ignition components
radiator hoses
radiator shrouds (L & R)
brake hoses (front & rear)
sockets (3/8 in drive)
screwdrivers: blade & Phillips No. 1, 2, 3
wrench, large adjustable
wrenches: open end & box
wrenches: hex (Allen)
wrench, spoke
torque wrench (metric scale, click-stop style)
pliers: standard, needle-nose, channel-lock set
hammer, plastic head
syringe with adjustable stop
air pressure gauge
tire irons
tire pump or air tank
feeler gauge set
Vernier caliper (metric)
pressure/vacuum testing equipment
Any special tools for your CRF purchased from
your dealer.
• Tensioner stopper 07AMG-001A100
• Lock Nut Wrench 07WMA-KZ30100
• Spoke Wrench 07JMA-MR60100
• Spoke Wrench 070MA-KZ30100
• Piston Base 07958-2500001
• Fork Rod Holder 07AMB-KZ3A100
(USA only)
Pro Honda GN4 4-stroke Oil
(Engine Oil)
Pro Honda HP Fork Oil, A15-00
Honda DOT 4 Brake Fluid
Pro Honda HP Chain Lube
Pro Honda Foam Air Filter Oil
Pro Honda Hondabrite
Pro Honda Dielectric Grease
Pro Honda Handgrip Cement
Pro Honda Hondalock
Molybdenum disulfide grease (containing more
than 3% molybdenum disulfide additive Moly
Paste 77)
Pro Honda Foam Air Filter Sealer
Multi-Purpose Grease
Rust-inhibiting oil
Cable lubricant
Pro Honda HP Coolant
Urea based multi-purpose grease designed for high
temperature, high pressure performance
(example: EXCELITE EP2 manufactured by
KYODO YUSHI, Japan or equivalent)
pliers-safety wire
safety wire
mechanic’s wire
duct tape
plastic wire bands
hose clamps
drop light
electrical tape
Scotch-Brite Hand Pad #7447 (maroon)
Teflon tape
Spare Parts
General Tools
Honda Special Tools
Chemical Products
Other Products
Wiring Diagram
Technical Information 183
WPC
24P
A-33
A-32
A-31
A-30
A-29
A-28
A-27
A-26
A-25
A-24
A-23
A-22
A-21
A-20
A-19
A-18
A-17
A-16
A-15
A-14
A-13
A-12
A-11
A-10
A-9
A-8
A-7
A-6
A-5
A-4
A-3
A-2
A-1
LG
SCS
PCP
PCM
PG2
TW
TA
SG
GPAD
TH
VCC
IG
FLP
STARTER RLY
START SW
PG
MAP MODE LED
INJ MAIN
IGP
PRC
WARN
PB
K-LINE
ENG STOP
MAP MODE SW
ST MODE SW
WPC
33P
Bl
WPC
4P
Bl
10A
CHARGE
CHARGE
CHARGE
-
+
6P
WPC
3P
Bu
WPC
2P
Bl
WPC
2P
Bl
VCC
GND
V OUT
WPC
3P
Bl
WPC
2P
Gr
EIGEIG
WPC
8P
Gr
WPC
6P
Bl
WPC
2P
Bl
+-
WPC
5P
WPC
4P
R
E
IG
E
IG
WPC
6P
Bl
1
N
2
3
4
5
WPC
2P
Bl
FREE
EIG
PUSH
COLOR Bl Bl/Y
FREE
EIG
PUSH
COLOR G Bl
FREE
EIG
PUSH
COLOR W G
FREE
EIG
PUSH
COLOR Lg G
COLOR COMB : GROUND/MARKING
Be Beige
Bl Black
Y Yellow
V Violet
Bu Blue
G Green
R Red
Sb Sky blue
WhiteW
Br Brown
O Orange
Lg Light Green
PPink
Gr Gray
JUNCTION CONNECTOR
CHANGE SWITCH
RESISTOR
RESISTOR
LED
ORANGE
LED
BLUE
ENGINE MODE
SELECT SWITCH
ENGINE STOP
SWITCH
STARTER
SWITCH
CLUTCH
SWITCH
DLC
FUEL
PUMP
ECM
FUEL
INJECTOR
GROUND
IGNITION COIL
SPARK PLUG
ALTERNATOR
CKP SENSOR
IAT
SENSOR
ECT
SENSOR
MAP
SENSOR
TP
SENSOR
REGULATOR/
RECTIFIER
STARTER
RELAY
SWITCH
STARTER
RELAY
DIODE
STARTER
MOTOR
MAIN
RELAY
RESISTOR
RESISTOR
ENGINE MODE
SELECT SWITCH
ENGINE STOP
SWITCHSTARTER SWITCH CLUTCH SWITCH
BATTERY
Bl/G
Y/Bl
G/Bl
R/W
W/Bl
Bl/Y
Bl
Y
Y
Y
G
G
R/W
Bl/G
G
Sb
R
G
Y
R
G
Gr
G
P
G/R
W/Y
Bu/Y
Y/Bu
Bu/Y
G
G
G
G
G
G
WW
Be BeW
Lg
G
Lg
Bu Bu
Bl
W
Be
G
Lg
Bu
Bl
G
G/W
Y
Y
Y
W/Y
Bu/Y
Y
Y
Y
P
Bl
Bl
Bl
Bl
G
Bl
Bl
G
Bl
W
Br
O/Bl
W
G/W
Bl
G/Bl
Br
Sb
O/Bl
W/Y
Bu/Y
G
P
Gr
Br
G
Y/Bu
W
Y/Bl
Y
R
G
Bu
P
W/Bl
Bl
Be
Lg
Bl
Bl/Y
Bl
Bl/Y
Bl
Bl/G
G/R
G
G
G
R
R
R
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Br
G
V
V
G
184 Technical Information
BLANK PAGE
Consumer Information
Consumer Information 185
This sect
ion contains information about contacting
Honda and how to get an official Honda Service
Manual.
Authorized Manuals.......................................186
Contacting Honda ..........................................187
Your Honda Dealer ........................................188
Authorized Manuals
186 Consumer Information
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.
The Winter Storage Guide in conjunction with the Owner's Manual and
Service Manual can help you prepare your Honda motorcycle, scooter, ATV,
and SxS for winter storage.
These Honda manuals are written for the professional technician, but most
mechanically-capable owners should find them helpful if they have the proper
tools and skills. Special Honda tools are necessary for some procedures.
Order On-Line: www.helminc.com
Order Toll Free: 1-888-CYCLE93 (1-888-292-5393)
(NOTE: For Credit Card Orders Only)
Monday - Friday 8:00 AM - 6:00 PM EST
Publication Item No. Description
61MKE02 2019 CRF450R/RX/RWE Service Manual
61CSM00 Common Service Manual
S9507 Winter Storage Guide
31MKE620 2019 CRF450RX/R/RWE Owner’s Manual
Contacting Honda
Consumer Information 187
Your owner’s
manual was written to cover most of
the questions you might ask about your CRF.
Any questions not answered in the owner’s manual
can be answered by your dealer. If your dealer
doesn’t have the answer right away, they will get it
for you.
If you have a difference of opinion with your
dealer, please remember that each dealership is
independently owned and operated. That’s why
it’s important to work to resolve any differences at
the dealership level.
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.
Canada: Honda Canada Inc., Customer Relations
Dept, 180 Honda Boulevard, Markham, Ontario
L6C 0H9, telephone: (888) 946 – 6329,
facsimile: (877) 939 – 0909.
E-mail: [email protected]
Please include the following information in your
letter:
• name, address, and telephone number
• product model, year, and VIN
• date of purchase
• dealer name and address
We will likely ask your dealer to respond, or
possibly acknowledge your comments directly.
Your Honda Dealer
188 Consumer Information
Your Honda Dealer
Once you purchase your new Honda, get familiar
with the organization of your Honda dealer so you
can utilize the full range of services available.
The service department is there to perform regular
maintenance and unexpected repairs. It has the
latest available service information from Honda.
The parts department offers Honda Genuine Parts,
Pro Honda products, Honda Genuine Accessories
(USA only), and Honda accessories and products
(Canada only). The same quality that went into
your Honda can be found in Honda Genuine
replacement parts. You’ll also find comparable
quality in the accessories and products available
from the parts department.
Your Honda dealer can inform you about
competition events in your area.
We’re sure you’ll be as pleased with the service
your Honda dealer continues to provide after the
sale as you are with the quality and dependability
of your Honda.
Consumer Information 189
BLANK PAGE
Index
190 Index
accessories
.....................................................3
adjustments,
chassis
..................................................156
control freeplay .........................70, 73, 114
for competition......................................139
gearing..................................................157
personal fit ............................................159
suspension, front....................................143
suspension, rear .....................................146
suspension, track conditions ...................151
tire selection, track condition..................158
after competition maintenance.......................32
air cleaner ....................................................67
air pressure,
front suspension
....................................143
tires ......................................................119
apparel, protective ..........................................2
appearance care..........................................136
authorized manuals.....................................186
basic operation .............................................15
battery .......................................................134
before riding ................................................11
between races (CRF450RX)/
motos (CRF450R/RWE) &
practice maintenance
....................................31
brakes,
fluid level
..............................................115
lever, front adjustment ...........................114
pad wear ...............................................117
pedal height...........................................114
break-in guidelines .......................................20
capacity, fuel..........................................42, 52
care, appearance.........................................136
chain drive.................................................122
chassis adjustments ....................................156
cleaner, air ...................................................67
cleaning, appearance care............................136
competition logbook...................................179
consumer information.................................185
contacting Honda .......................................187
controls .........................................................5
coolant.........................................................65
customer service.........................................188
cylinder system ............................................90
damping adjustments,
front
.....................................................144
rear.......................................................147
dealer, your Honda .....................................188
diagram, wiring..........................................183
drive chain .................................................122
Engine Mode &
Launch Control System Indicator
..................10
engine,
does not start
.........................................165
flooded ...................................................18
idle speed................................................72
lacks power ...........................................165
mode indicator ........................................10
mode select button.................................140
number .................................................172
oil...........................................................62
pinging .............................................42, 52
starting....................................................17
stop button ..............................................18
stopping ..................................................18
environment, protecting ..............................164
A
B
C
D
E
(cont’d)
Index 191
Index
filter,
air
...........................................................67
fuel pump..........................................46, 56
oil...........................................................63
flooded engine, starting.................................18
fork,
front suspension adjustment
...................143
front suspension inspection ......................97
oil recommendation ...............................100
front brake lever adjustment........................114
front suspension maintenance......................143
fuel........................................................42, 52
fuel,
line inspection
...................................42, 52
line replacement ................................43, 53
oxygenated............................................178
pump filter ........................................46, 56
refueling ...........................................42, 52
system ..............................................42, 52
tank capacity .....................................42, 52
gap, spark plug.............................................78
gasohol......................................................178
gasoline .................................................42, 52
gearing ......................................................157
guidelines,
suspension adjustment
............................152
handlebar inspection...................................132
Honda,
contacting
.............................................187
service manual.......................................186
your dealer ............................................188
HRC-Launch Control System......................141
identification, vehicle .................................172
idle knob, fast ........................................17, 72
idle speed, engine .........................................72
indicator,
circuit inspection
.......................................8
DTC index ................................................9
engine mode....................................10, 140
launch control system ..............................10
MIL blink .................................................7
inspection, pre-ride.......................................13
instruments ....................................................5
labels, safety ..................................................4
launch control system indicator .....................10
logbook, competition..................................179
maintenance,
after competition
.....................................32
before & after competition .......................31
between races (CRF450RX)/
motos (CRF450R/RWE) & practice
..........31
component locations ................................33
general competition .................................27
importance ..............................................22
safety......................................................23
schedule..................................................24
manual, service ..........................................186
mode indicator ...........................................140
modifications .................................................3
oil,
engine
.....................................................62
fork ......................................................100
operating instructions ...................................15
operation component locations ........................6
optional,
parts list
................................................181
sprockets...............................................157
oxygenated fuels ........................................178
pads, brake.................................................117
parts, optional ............................................181
personal fit adjustments ..............................159
pinging, engine ......................................42, 52
plug, spark ...................................................78
pre-load, rear suspension.............................146
pre-ride inspection........................................13
protective apparel...........................................2
rear suspension adjustment..........................146
riding,
apparel
......................................................2
basic operation ........................................15
before .....................................................11
important safety information ......................2
safety precautions ......................................2
F
G
H
I
L
M
O
P
R
192 Index
Index
safety,
a few words about
.............Safety Messages
important information ................................2
important precautions.................................2
labels ........................................................4
maintenance ............................................23
riding precautions ....................................16
schedule, maintenance ..................................24
seat..............................................................34
serial numbers............................................172
service,
customer
...............................................188
manuals ................................................186
side stand (CRF450RX) ..............................121
spare parts..................................................182
spark knock............................................42, 52
spark plug,
maintenance
............................................78
reading..................................................155
specifications .............................................173
spring pre-load, rear suspension...................146
starting,
engine
.....................................................17
troubleshooting......................................165
steering stem inspection..............................132
stopping engine ............................................18
storage.......................................................163
subframe......................................................39
suspension adjustment,
for track conditions
................................151
front .....................................................143
guidelines..............................................152
rear .......................................................146
suspension,
front
.......................................................97
rear .......................................................113
throttle,
freeplay
...................................................70
inspection................................................71
lubrication...............................................71
tires,
air pressure
............................................119
flat........................................................119
selection................................................120
tools ..........................................................182
torque specifications,
engine
...................................................175
frame ............................................176, 177
transporting................................................162
troubleshooting ..........................................165
tubes, replacing ..........................................119
tuning tips..................................................155
valve clearance.............................................79
vehicle identification no. (VIN)...................172
washing your motorcycle ............................136
wheels .......................................................118
wiring diagram...........................................183
S T
V
W
Quick Reference
Quick Reference
The following is a brief, but important collection
of
information you need to know about your CRF.
You'll also find space to record important notes.
The engine of your CRF can be the most expensive
component to repair. Proper maintenance,
especially the use of the recommended fluids and
filters, prevents premature wear and damage.
Frequent causes of costly engine repairs are:
• Transmission oil & engine oil: insufficient
quantity, improper oil.
• Air cleaner: dirty, leaking because of improper
installation (poor seal)
How To Avoid Costly Repairs
Record important information here:
VIN
Engine No.
Owner's:
Name
Address
City/State
Phone
Dealer's:
Name
Address
City/State
Phone
Service Mgr.
Maintenance CRF450RX:
The maintenance schedule (page 25) lists service frequencies for:
each race or about 3.5 hours, every 2 races or about 7.5 hours, every 4 races or about 15.0
hours, every 6 races or about 22.5 hours and every 8 races or about 30.0 hours
CRF450R/RWE:
The maintenance schedule (page 26) lists service frequencies for:
each race or about 2.5 hours, every 3 races or about 7.5 hours, every 6 races or about 15.0
hours, every 9 races or about 22.5 hours and every 12 races or about 30.0 hours
Pre-ride Inspection Check the items listed on the Pre-ride Inspection checklist each time before you ride
(page 13)
Fuel/Tank Capacity CRF450RX:
unleaded gasoline, pump octane number of 91 or higher
tank: 2.25 US gal (8.5 ℓ)
CRF450R/RWE:
unleaded gasoline, pump octane number of 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
Tires Front CRF450RX: 90/90-21 54M
CRF450R/RWE: 80/100-21 51M
Rear CRF450RX: 120/90-18 65M
CRF450R/RWE: 120/80-19 63M
DUNLOP CRF450RX: AT81F
CRF450R/RWE: MX3SF
DUNLOP CRF450RX: AT81
CRF450R/RWE: MX3S
Type bias-ply, tube
Tire Pressure (cold) Front: 15 psi (100 kPa, 1.0 kgf/cm
2
)
Rear: 15 psi (100 kPa, 1.0 kgf/cm
2
)
Spark Plug standard: SILMAR9A-9S (NGK)
optional: SILMAR10A-9S (NGK)
Coolant ethylene glycol antifreeze (silicate-free) for aluminum engines in 50/50 solution with
Pro Honda HP Coolant or an equivalent distilled water.
Fuse main: 10 A
Drive Chain Size/Link CRF450RX: RK520EXU/114LE
CRF450R: RK520TXZ/114RJ
CRF450RWE: GB520TXZ/114RJ
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. For more
information go to www.P65Warnings.ca.gov/passenger-vehicle.
