Crf 450 repair manual pdf
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Clean parts in non-flammable high flash point cleaning solvent such as kerosene when disassembling. And operating this motorcycle safely is an important responsibility. Be sure to grease the air cleaner flange where it contacts the air cleaner housing. Remove the seat bolt 1 , side cover bolt 2 and right side cover 3. Calculate the race sag dimension. Check the fuel valve 1 and fuel filter 2 for Gasoline is highly flammable and contamination. Check for oil leaks.
To protect your Please report any change of address or ownership investment, we urge you to take responsibility for to your Honda dealer so we will be able to keeping your CRF well maintained. Scheduled contact you concerning important production service is a must, of course. 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. This section also Safety Labels............ As an experienced rider, you know there is much Maintaining your CRF properly is critical to your you can do to protect yourself when you ride. If the label comes off or becomes hard to read, contact your Honda dealer for replacement. It Operation Component Locations...... To help get Is Your Motorcycle Ready to Ride?..... For your safety, avoid starting or operating the engine in an enclosed area such as a garage. Turn the fuel valve ON. Shift the transmission into neutral. Shift the transmission into neutral. Turn the fuel valve OFF. Lightly open the throttle 1 2 — 3 times, and then close it. During this period, avoid full-throttle starts and rapid acceleration. 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. If you decide to do your own maintenance, use only genuine... Machine subjected to severe use require more frequent servicing. Clean after every moto for dusty riding condition. Replace every 2 years. Replacement requires mechanical skill. Replace after the first break-in ride. Inspect after the first break-in ride. Clean parts in non-flammable high flash point cleaning solvent such as kerosene when disassembling. Use Pro Honda Foam Filter Oil or an equivalent. Be sure to grease the air cleaner flange where it contacts the air cleaner housing. Make certain the throttle remove the nuts, clean the threads, and apply Honda Thread operation is perfect after servicing and inspecting. Lock or an equivalent prior to torquing the nuts. Remove the nuts, clean should be replaced. 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 wear. If you decide to wash your CRF or use cleaners, refer to Appearance Care page 94. Remove the seat 2 by sliding it backward. Install and tighten the seat bolts to the specified torque: 19 lbf·ft 26 N·m, 2. Hook the air cleaner case cover 5. Install and hook the fuel tank band 6. Install the muffler clamp 9 and new gasket specified torque: 10 to the exhaust pipe. If pinging or spark knock persists, WARNING consult your Honda dealer. Check the fuel valve 1 and fuel filter 2 for Gasoline is highly flammable and contamination. Refill the fuel tank. Attach the fuel valve and fuel line, and turn the fuel valve to ON; check for leaks. Reinsert the engine oil filler cap. However, if you replace only the oil before 7. Check for oil leaks. Use a new genuine Honda oil filter or a filter of equal quality specified for your model. NOTICE If the oil filter is not installed properly, it will cause serious engine damage. After inspecting the oil level or adding oil, 3 sealing washer tighten the oil check bolt to the specified torque:. Add coolant up to the filler neck if the level is low. Use Pro Honda HP Coolant or an equivalent high Refer to Safety Precautions on page 19. Inspect the coolant level before each outing. Honda Service Manual for troubleshooting of leaks. Coolant should be replaced by your Honda 2. Check the water hoses 1 for cracks, dealer, unless you have the proper tools and deterioration, and clamp bands for looseness. Your Honda dealer can help you determine the correct service interval for your riding conditions. Remove the air cleaner 3 from the air 9. Apply a thin coat of Honda White Lithium NOTICE cleaner holder 5. Grease to the sealing surface. Assemble the air cleaner and holder. Improper installation of the air cleaner assembly... Remove the crankcase breather tube plug 1 from the tube 2 and drain deposits. Reinstall the crankcase breather tube plug. Operate the throttle grip to ensure that it functions smoothly and returns completely. Install the fuel tank page 31. Check the cables for tension or stress in all steering positions. Lubricate the cables with a commercially-available cable lubricant to prevent premature rust and corrosion. Connect a tachometer to the engine. Shift the transmission into neutral. Keep the motorcycle in an upright position. Adjust idle speed with the throttle stop screw 2. Idle speed: 1,700 ± 100 rpm Servicing Your Honda... Tighten the lock nut. Adjust the cable end adjuster for minor adjustement. See your Honda dealer or refer to the Honda Service Manual page 156. Remove the six clutch spring bolts and springs 5. Install the clutch pressure plate 7. If the gap is out of specification, replace the spark plug with a new one. Remove the cylinder head cover A bolt 3 , cylinder head cover B bolts 4 and cylinder head cover 5. Remove the valve shims. Then realign the valve timing. Install the cylinder head cover packing 3 into the groove of the cylinder head cover 4. Remove the cylinder head cover page 55. Remove the spark plug 8. Remove the A dowel pins 3 , B dowel pin 4 and cylinder gasket 5. NOTICE 1 piston pin clip 3 piston 2 piston pin Do not let the dowel pins fall into the crankcase. Remove the carbon deposits from the piston oil ring We recommend you consult the Service Manual head and piston ring grooves with the or your authorized Honda dealer for correct removed ring. Apply engine oil to the piston rings and install the piston rings. Clean the any gasket material off the cylinder. Install the fuel tank and the seat page 31. Add the coolant up to the filler neck page 41. Do not attempt to disassemble, service, or dispose of the damper; see your Honda dealer. Remove the subframe page 32. To avoid suggested oil Pro Honda HP Fork Oil or damage hold both the outer tube and slider when equivalent removing the fork damper. After installing the fork leg page 119 tighten the fork damper to the specified torque: 25 lbf·ft 34 N·m, 3. Loosen the lock nut 1. If the pads 20 mm , there is probably air in the brake are not worn, have your brake system inspected system and it must be bled. Refer to the Honda for leaks. Service Manual or see your Honda motorcycle If the front brake lever freeplay exceeds 0. Check for grooves deterioration or cracks in the hoses and fittings. Check wheel rim runout. If runout is instability at high speeds and the possible loss of noticeable, see the Honda Service Manual for control. If necessary, install a new cap. The old tube will probably be stretched and, if installed in a new tire, could fail. Check the chain slider 4 for wear. If the wear is 0. Honda Chain Lube or an equivalent, or SAE 80 5 with the same reference marks 6 on both or 90 gear oil is recommended. Recheck chain slack and adjust as necessary. Remove the seat bolt 1 , side cover bolt 2 and right side cover 3. Install the muffler 4. Install the muffler clamp 5 by aligning the tab 6 of the muffler clamp with the cut-out 7 of the muffler. Install the muffler page 90. Thoroughly adjustment procedures, or see your Honda lubricate the cable pivot points with a dealer. 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. Front Suspension Air Pressure...... Remove the handlebar holder nuts 3 , 7. Remove the disc cover 7 by removing the Do not support the brake caliper by the brake washers, mounting rubbers and handlebar 4. Do not operate the brake lever after the front wheel is removed. Clean the fork assembly, especially the sliding 17. Temporarily install the fork damper to the NOTICE surface of the slider 18 and dust seal 19. Record the rebound damping adjuster position The outer tube can drop on the slider and 18. Set the lower end axle holder 27 of the and turn the adjuster counterclockwise until it slider in a vise with a piece of wood or soft... Apply pressure to the fork damper and insert a Damper Oil Change 27 special tool or mechanic's stopper tool 29 see below between the axle holder 27 and 29 lock nut 30. Set the fork damper 1 in a vise with a piece 23. Hold the lock nut and remove the fork center of wood or soft jaws to avoid damage. Recommended Amount: Replace the fork cap as an assembly if it is 6. Tighten the fork cap 1 while holding the cut 12. Screw in the lock nut 9 to the fork damper 14. Drain the extra oil from the fork damper piston rod 6 fully. Tighten the lock nut 2 fully and measure the Fork Assembly thread length A as shown. About 7 cc of fork oil will be left in the outer Wipe the oil completely off the fork damper. Set the lower end axle holder of the slider in 8. Measure the length of the lock nut 2 and 10. Apply fork oil to the center bolt 8 O-ring. Check that the O-ring 12 on the fork damper 17. Tighten the fork damper 4 to the specified assembly 4 is in good condition. Apply the torque using the lock nut wrench 14. Pull up the outer tube 1 slowly and install 25 lbf·ft 34 N·m, 3. Clean the threads of the fork protector bolts 24. Clean the surfaces where the axle and axle 25. Install the handlebar 25 , mounting rubbers 18 and axle holder thoroughly. Install and tighten the number plate bolt 30. Install the handlebar pad 31. With the front brake applied, pump the fork left fork leg clamp inner surface. Do not attempt to disassemble, service, or dispose of the damper; see your Honda dealer. Compression Damping Compression damping may be adjusted in two stages with separate adjusters. To adjust to the standard position: 1. Calculate the race sag dimension. REAR FENDER MOUNTING BOLT Rear Suspension Race Sag To do this, subtract the loaded with rider dimension step 3 from the unloaded dimension step 2. Setting the proper race sag ride height is very UNLOADED MEASUREMENT Standard Race Sag: 3. Calculate the free sag dimension. Sand often requires a bit more rebound damping to minimize rear end kick. Remember to make all adjustments in one-click increments. Test ride after each adjustment. Front Suspension Adjustment Adjustments for Type of Track Hard-surfaced track Begin with the standard setting. Sand track Lower the rear end to improve front wheel stability by increasing Race Sag reduce spring preload. See your Honda dealer. Tighten the drain screw. Honda carburetor jet sizes are numbered in The minimum to maximum range of pilot screw increments of 2 or 3. Disconnect the fuel line 2 from the fuel 10. Remove the hot start cable holder 6. Remove the throttle cables 9 by loosening valve 3. Remove the fuel tank page 30. Remove the link arm set screw 6. When installing the floating valve 8 onto the Carburetor Disassembly When installing the link arm set screw, apply a throttle valve 5 make sure the floating locking agent to the link arm set screw threads. Remove the accelerator pump cover screws 7. Remove the holder screw 15 , throttle stop 9. Measure the float level 23 with the float 10 and accelerator pump cover 11. To install the carburetor, reverse the removal procedures. Tighten the following parts to the specified torque. However, there are some unique There are some unique atmospheric conditions or Before adjusting carburetor settings, check the atmospheric conditions or race day situations that situations that may require additional... You can be burned or The standard carburetor settings are ideal for the seriously injured when handing fuel. Change the main jet 4 and slow jet 5 as 9. Rotate the carburetor and align the lug 6 on 13. Remove the jet needle holder 10 and jet required. If a plug is too loose, a piston may Refer to Spark Plug on page 54. Subtle changes in overall handling may also be noted. The appraisal of the change. Eliminating wheelspin Manual, sprocket changing should be done by need to slip the clutch to compensate;... Place your CRF on the optional Honda container. Retighten the drain screw. When you show respect for the land, Improper disposal of drained fluids is harmful to wildlife, and other people, you also help preserve the environment. RIGHT SIDE The frame, VIN, and engine serial numbers are required when you register your CRF. They may also be required when ordering replacement parts. See your Honda dealer for high altitude modification. NOTICE Sustained operation at altitudes below 5,000 feet... These symptoms, try another service station or switch gasolines are collectively referred to as to another brand of gasoline. To meet clean air standards, some areas of the United States and Canada use Fuel system damage or performance problems oxygenated fuels to help reduce emissions. The best way to organize worked best at a particular location. Make several photocopies of this page for future use Technical Information... Driven sprocket : Drive chain links Shock spring 308. Also available but not necessary to service your model is the Honda Common Service Manual which explains theory of operation and basic service... Separate free training from the Specialty Vehicle Institute of America for ATV owners. Before You Service Your Honda Suspension............ Transmission oil Pro Honda HP Trans oil, Pro Honda GN4 or HP4 without molybdem additives 4-stroke engine oil, or an equivalent.
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