• 04 Crf450r Service Manual

. 2007 Honda CRF450R OWNER’S MANUAL & COMPETITION HANDBOOK. CRF and how it works. 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.

A Few Words About Safety Your safety, and the safety of others, is very important. And operating this motorcycle safely is an important responsibility.

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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. Break-in Guidelines.15 Authorized Manuals.152 Chassis Contacting Honda.153 SERVICING YOUR HONDA.17 Suspension.73 Your Honda Dealer.154 Before You Service Your Honda Brakes.77 The Honda Rider’s Club.155 The Importance of Maintenance.18 Wheels.81 Maintenance Safety.19 Tires & Tubes.82 TABLE OF CONTENTS.156 Important Safety Precautions.19. Motorcycle Safety This section presents some of the most important Important Safety Information.2 information and recommendations to help you Important Safety Precautions.2 ride your CRF safely. Please take a few Accessories & Modifications.3 moments to read these pages. This section also Safety Labels.4 includes information about the location of the safety labels on your CRF. As an experienced rider, you know there is much Keep your Honda in Safe Condition.

Maintaining your CRF properly is critical to your you can do to protect yourself when you ride. A loose bolt, for example, can cause a. Accessories & Modifications Accessories & Modifications Installing non-Honda accessories, removing original equipment, or modifying your CRF in any way that would change its design or operation, could seriously impair your CRF’s handling, stability, and braking, making it unsafe to ride. Safety Labels Read this label carefully and don’t remove it.

If the label comes off or becomes hard to read, contact your Honda dealer for replacement. Motorcycle Safety. Operating Controls Read this section carefully before you ride.

It Operation Component Locations.6 presents the location of the basic controls on your CRF. Operating Controls. Operation Component Locations hot start lever front brake lever clutch lever engine stop button throttle grip choke knob kickstarter fuel valve shift lever rear brake pedal Operating Controls. Before Riding Before each ride, you need to make sure you and Are You Ready to Ride?.8 your Honda are both ready to ride. To help get Is Your Motorcycle Ready to Ride?.9 you prepared, this section discusses how to Pre-ride Inspection.9. Are You Ready to Ride? Before riding your CRF for the first time, we WARNING strongly recommend that you read this owner’s manual, make sure you understand the safety Not wearing a helmet increases the messages, and know how to operate the controls.

Chance of serious injury or death in a crash. Is Your Motorcycle Ready to Ride?

Competitive riding can be tough on a motorcycle, Pre-ride Inspection so it’s important to inspect your CRF and correct any problems you find before each ride. Check the following items (page numbers are at the Check the following before each ride: right):.

Before Riding. Basic Operating Instructions This section gives basic information on how to Safe Riding Precautions.12 start and stop your engine as well as break-in Starting & Stopping the Engine.13 guidelines. Preparation.13 Starting Procedure.13 Flooded Engine.13 How to Stop the Engine.14 Break-in Guidelines.15 Basic Operating Instructions Basic Operating Instructions. Basic Operating Instructions Safe Riding Precautions 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. Starting & Stopping the Engine Always follow the proper starting procedure Check the engine oil, transmission oil and coolant Warm Engine Starting described below.

Levels before starting the engine (pages 37,40,41). Turn the fuel valve ON. Shift the transmission into neutral. Starting & Stopping the Engine How to Stop the Engine (1) throttle (2) engine stop button Normal Engine Stop 1.

Shift the transmission into neutral. Turn the fuel valve OFF. Lightly open the throttle (1) two or three times, and then close it. 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:. Basic Operating Instructions.

You’ll also find Drive Chain.84 important safety precautions, information on oils, Service Preparations Exhaust Pipe/Muffler.87 and tips for keeping your Honda looking good. Maintenance Component Locations.28 Additional Maintenance Procedures.90 Seat Removal.29 An ICM (Ignition Control Module) system is Fuel Tank Removal.30. Improperly maintaining this motorcycle or failing to correct a problem before you ride can cause a crash in which you can be seriously hurt or killed. Always follow the inspection and maintenance recommendations and schedules in this owner’s manual. Servicing Your Honda.

Be sure there is adequate ventilation whenever you operate the engine. Burns from hot motorcycle parts. Let the engine and exhaust system cool before touching. Injury from moving parts. Do not run the engine unless instructed to do so.

Servicing Your Honda. 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 genuine. 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. Servicing Your Honda. Use genuine Honda parts or their equivalent when servicing your CRF.

Clean parts in non-flammable (high flash point) cleaning solvent (such as kerosene) when disassembling. Follow the servicing instructions in the Maintenance section. Use Pro Honda Foam Filter Oil or an equivalent.

Be sure to grease the air cleaner flange where it contacts the air cleaner housing. Pro Honda White.

Make certain the throttle operation is to the proper torque specification. For added peace of mind, perfect after servicing and inspecting. Remove the nuts, clean the threads, and apply Pro Honda Hondalock or an equivalent prior to torquing the nuts. Servicing Your Honda. If replacement is necessary, both seals offers added assurance and security. Remove the nuts, clean should be replaced.

The threads of both the nuts and bolts, apply Pro Honda Hondalock or an equivalent and tighten to the specified torque. (1) are in the same position on (2) pressure release screws 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 wear.

Servicing Your Honda. 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 92).

Servicing Your Honda. Servicing Your Honda. Install and tighten the seat mounting bolts to the specified torque: 19 lbfft (26 Nm, 2.7 kgfm) (1) seat mounting bolts (2) seat (3) seat front prong (4) seat bracket (5) seat rear prong (6) frame Servicing Your Honda.

(10) (4) breather tube (5) fuel tank band (6) air cleaner case cover (1) shroud A bolts/collars (7) fuel tank bolt/collar (2) shroud B bolts (3) shrouds (8) fuel line (10) fuel valve bolt (9) fuel valve Servicing Your Honda. Install and hook the fuel tank band (5). Hook the air cleaner case cover (6). (10) (8) shrouds (10) subframe (9) tab (4) fuel tank bolt/collar (5) fuel tank band (6) air cleaner case cover Servicing Your Honda.

(2) subframe mounting upper bolts (3) subframe mounting lower bolts straight backward. (13) (14) (12) (3) muffler clamp bolt (4) muffler A bolt (12) subframe mounting lower bolts (5) muffler B bolt/washers (13) subframe mounting upper bolts (6) muffler (14) subframe Servicing Your Honda. Remove the old gasket from exhaust pipe. Install the muffler clamp (11) and new gasket (17) (18) (19) (12) to the exhaust pipe. (12) (11) (17) muffler B bolt/washers (18) muffler A bolt (19) muffler clamp bolt (11) muffler clamp (12) gasket Servicing Your Honda. If pinging or spark knock persists, WARNING 1. Check for leaks.

Consult your Honda dealer. Check the fuel line (1) for cracks, Gasoline is highly flammable and deterioration, damage or leakage. Replace the Never use stale or contaminated gasoline.

Drain the fuel from the fuel tank into an approved gasoline container. Disconnect the fuel valve and fuel line. Remove the fuel joint (1) from fuel tank by removing the bolts (2). (3) fuel filter (4) O-ring (1) fuel joint (2) bolts Servicing Your Honda. (weight) the engine.

JASO T 903 standard MA NOT RECOMMENDED suggested oil. Pro Honda GN4 4-stroke oil or an equivalent motorcycle oil. Other viscosities shown in the following chart may be used when the average temperature in. Suggested 4-stroke engine oils are equal your riding area is within the indicated range. Repeat steps 1–4. Every 6 races or about every 15.0 hours. Reinsert the engine oil filler cap.

However, if you replace only the oil before 7. Check for oil leaks.

The recommended interval, see page 21. (cont’d) Servicing Your Honda. (11) facing out, away from the engine. You should see the “OUT-SIDE” mark (12) on the filter body, near the seal. 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.

NOT RECOMMENDED suggested oil. Pro Honda GN4 4-stroke oil or an equivalent motorcycle Other viscosities shown in the following chart oil. may be used when the average temperature in your riding area is within the indicated range. (1) transmission oil filler cap steps 1–4. (2) transmission oil drain bolt 5. After inspecting the oil level or adding oil, (3) sealing washer tighten the oil check bolt to the specified torque: 7 lbfft (10 Nm, 1.0 kgfm) Servicing Your Honda. Checking & Adding Coolant 2.

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. Refer to Safety Precautions on page 19. 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 radiator hose clamp for service data and are mechanically qualified. Service the air cleaner more frequently if you ride in unusually wet or dusty areas. Your Honda dealer can help you determine the correct service interval for your riding conditions. Your CRF’s air cleaner has very specific (1) air cleaner retaining bolt performance requirements.

Air Cleaner 5. Remove the air cleaner element (5) out from 9. Apply a thin coat of Pro Honda White 14. Install and tighten the air cleaner retaining the air cleaner holder (6). Lithium Grease or equivalent to the sealing bolt (1) securely. Service the breather if you can see deposits in the transparent section of the drain tube. Remove the crankcase breather tube plug (1) from the tube (2) and drain deposits.

Reinstall the crankcase breather tube plug. (1) crankcase breather tube plug (2) tube Servicing Your Honda. Operate the throttle grip to ensure that it functions smoothly and returns completely. Install the fuel tank (page 31). If you can’t get the freeplay within the specified (–) range, contact your Honda dealer. (2) dust cover (+) increase (3) lock nut (–) decrease. If the cable is kinked or chafed, have it replaced.

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. Servicing Your Honda. Shift the transmission into neutral. Start the engine. Keep the motorcycle in an upright position.

Adjust idle speed with the throttle stop screw (1). Idle speed: 1,700 ± 100 rpm (1) throttle stop screw Servicing Your Honda. To position the brake lever closer to the handgrip, turn the adjuster (–) clockwise.

Tighten the lock nut. (4) lock nut (5) integral cable adjuster (+) increase freeplay (–) decrease freeplay 6.

Adjust the cable end adjuster for minor adjustement. Servicing Your Honda. Check the clutch cable for deterioration, your Honda dealer or refer to the Honda Service kinks, or damage.

Manual (page 152). Servicing Your Honda. Remove the six clutch spring bolts and springs (5). (7) washer (10) clutch lifter rod Loosen the bolts in a crisscross pattern in 2 or 3 (8) needle bearing (11) clutch discs and plates progressive steps. (9) clutch lifter (2) clutch plate Servicing Your Honda.

(11) pivot bolt (13) rear brake pedal (7) clutch pressure plate (12) dust seals (14) return spring (1) seven clutch plates (8) clutch springs and bolts (2) eight clutch discs 15. Add the transmission oil (page 40). Servicing Your Honda. (–) (1) hot start lever (2) hot start lever freeplay Inspection (3) lock nut (+) increase Check freeplay: (4) adjuster (–) decrease 1/16 – 1/8 in (2 – 3 mm) If necessary, adjust to the specified range. Servicing Your Honda. Connect the spark plug cap.

Take care to with a new one. Avoid pinching any cables or wires. Install the fuel tank and seat (pages 29, 31). (3) sealing gasket (4) spark plug gap Servicing Your Honda. Remove the cylinder head cover A bolt/rubber seal (3), cylinder head cover B bolts/rubber seals (4) and cylinder head cover (5).

(2) spark plug (3) cylinder head cover A bolt/rubber seal (4) cylinder head cover B bolts/rubber seals (cont’d) (5) cylinder head cover Servicing Your Honda. If intake valve clearance and exhaust valve clearance need adjustment, see Camshaft Holder Assembly Removal (page 57) and select the correct shim for each valve. (3) primary drive gear bolt (5) “∆” mark (4) punch mark (6) exhaust rocker arm Servicing Your Honda. Do not let the bolts, sprocket and cam chain fall into the crankcase. (3) stopper tool (1) cam chain tensioner lifter cover bolt (2) sealing washer (4) cam sprocket bolts (5) cam sprocket (6) cam chain (cont’d) Servicing Your Honda. (10) (9) intake valve lifters (10) decompressor shaft (11) plunger (7) camshaft holder assembly bolts (8) camshaft holder assembly NOTICE Do not let the valve lifters, shims, decompressor shaft (10) and plunger (11) fall into the crankcase.

Servicing Your Honda. Reface the intake valve seat if carbon deposits result in a calculated dimension of over 2.450 Reface the exhaust valve seat if carbon deposits result in a calculated dimension of over 3.000 mm.

(1) valve lifter (2) shim Servicing Your Honda. – camshaft cam lobes (10) – each valve lifter outer surface – plunger whole surface – decompressor shaft sliding area (9) camshaft holder assembly (8) valve lifters (10) intake cam lobes (9) camshaft holder assembly (11) camshaft holder assembly bolts Servicing Your Honda. (1.0 – 2.0 mm) assembly. When installing the cam sprocket with (16) cam sprocket decompressor weight pin (19) toward the front (25) cam sprocket bolts side. (25) (23) coating width (24) no coating width (25) cam sprocket bolt (cont’d) Servicing Your Honda.

Chain tensioner lifter. (13) punch mark (14) index mark (17) timing mark (18) “∆” mark (29) (28) (26) (28) sealing washer (26) stopper tool (29) cam chain tensioner lifter cover bolt Servicing Your Honda.

(2) spark plug hole (2) crankshaft hole cap 2. Install the cylinder head cover packing (3) into the groove of the cylinder head cover (4). (1) spark plug (3) cylinder head cover packing (4) cylinder head cover (cont’d) Servicing Your Honda. Tighten the cylinder head cover A bolt (8) and cylinder head cover B bolts (9) to the specified torque: 7 lbfft (10 Nm, 1.0 kgfm) (6) cylinder head cover (8) cylinder head cover A bolt (9) cylinder head cover B bolts Servicing Your Honda. (4) nut (3) bolts (5) ignition coil 9. Remove the cylinder head cover (page 55).

(7) radiator hose clamp screw 10. Remove the spark plug (6). (8) radiator hose (1) spark plug cap (6) spark plug (cont’d) Servicing Your Honda. (9) engine hanger nut (10) engine hanger A bolt (11) fuel hose guide (17) (12) engine hanger B bolts (13) left engine hanger plate (14) right engine hanger plate (17) (18) (17) cylinder head nuts/washers (18) cylinder head Servicing Your Honda. Remove the A dowel pins (3), B dowel pin (4) and cylinder gasket (5). NOTICE (1) piston pin clips (3) piston (2) piston pin Do not let the dowel pins fall into the crankcase.

(3) A dowel pins (5) cylinder gasket (4) B dowel pin Servicing Your Honda. Remove the carbon deposits from the piston We recommend you consult the Service Manual head and piston ring grooves with the or your authorized Honda dealer for correct removed ring (1).

After installing the rings they should rotate Service Limit measurements. (1) cylinder gasket (3) B dowel pin (2) A dowel pins 4. Clean any gasket material off the cylinder.

(1) piston (4) piston pin (2) “IN” mark (5) piston pin clips (3) large valve recesses (6) cut-out (cont’d) Servicing Your Honda. Do not let the dowel pins fall into the crankcase. Do not damage the piston rings and cylinder walls. (7) cam chain guide (8) cam chain guide tabs (9) cylinder cut-outs (1) dowel pins (2) cylinder head gasket (4) cam chain (6) piston rings (5) cylinder Servicing Your Honda.

(11) fuel hose guide 19 lbfft (26 Nm, 2.7 kgfm) (12) engine hanger nut Tighten the engine hanger nut to the specified torque: 40 lbfft (54 Nm, 5.5 kgfm) (3) cylinder head (4) cylinder head nuts/washers (cont’d) Servicing Your Honda. 13.Install the spark plug cap (20). (20) 0 – 0.04 in (0 – 1.0 mm) (14) radiator hose clamp screw 8. Install the camshaft holder assembly (page 60).

Install the spark plug (page 63). (20) spark plug cap Servicing Your Honda. See page 100 for damper locking the front brake and pushing down on fork oil replacement. The handlebar several times. Use Pro Honda HP Fork Oil 5W or an equivalent which contains special additives to assure maximum performance of your CRF's front suspension. (pages 109-113). Do not attempt to disassemble, service, or dispose of the damper; see your Honda dealer.

Remove the subframe (page 32). The instructions found in this owner’s manual are 3. (5) and guide bushing viscosity (weight) 5 W (6) when the fork damper is removed.

To avoid suggested oil Pro Honda HP Fork Oil or damage hold both the outer tube and slider when equivalent removing the fork damper. (412 cm it nears full 25 lbfft (34 Nm, 3.5 kgfm) compression. Minimum oil 10.7 US oz Slightly softer as capacity (316 cm it nears full compression. (10) (1) outer tube (2) fork damper (10) O-ring Servicing Your Honda. (3) knocker arm 80), there is probably air in the brake system. (–) (2) adjuster Refer to the Honda Service Manual or see your Honda dealer to have the air bled from the 1.

Loosen the lock nut (1). Worn brake pads should be replaced. 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 13/16 in dealer for brake bleeding.

The recommended brake fluid is Pro Honda. The recommended brake fluid is Pro Honda DOT 4 brake fluid or an equivalent.

DOT 4 brake fluid or an equivalent. Make sure there are no fluid leaks. Check for wear indicator grooves deterioration or cracks in the hoses and fittings.

(1) brake pads (3) brake disc (2) front brake caliper Servicing Your Honda. Excessively loose spokes may result in 3. Check wheel rim runout. If runout is instability at high speeds and the possible loss of noticeable, see the Honda Service Manual for control. It’s also important that the rim locks are inspection instructions. Overinflated tires make your CRF ride harshly, are more prone to damage from surface hazards, and wear unevenly.

(1) tire tread depth Make sure the valve stem caps are secure. If necessary, install a new cap. Servicing Your Honda. Use a replacement tire equivalent to 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.

Servicing Your Honda. Adjust chain slack if needed. Upper roller: 1.5 in (39 mm) lower roller: 1.4 in (35 mm) 5. Check the chain slider (4) for wear. If the wear is 0.2 in (5 mm) or more, replace it. Servicing Your Honda. Pro Align the index marks (4) of the axle plates otherwise appears unserviceable.

Honda Chain Lube or an equivalent, or SAE 80 (5) with the same reference marks (6) on both or 90 gear oil is recommended. Install the master link retaining clip so that the closed end of the clip will face the direction of forward wheel rotation. Recheck chain slack and adjust as necessary. Servicing Your Honda. Remove the seat mounting bolt (1), side cover bolt (2) and right side cover (3). (4) muffler clamp bolt (6) muffler B bolt/washers (5) muffler A bolt (7) muffler (1) seat mounting bolt (3) right side cover (2) side cover bolt Servicing Your Honda.

(12) side cover bolt 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. (4) muffler (6) tab (5) muffler clamp (7) cut-out Servicing Your Honda. 15 lbfft (21 Nm, 2.1 kgfm) (1) exhaust pipe joint nuts (2) exhaust pipe (1) exhaust pipe gasket (3) exhaust pipe gasket (2) exhaust pipe (3) exhaust pipe joint nuts 2.

Install the muffler (page 88). Servicing Your Honda. Control Cables the fork bushings may be worn. Refer to the Honda Service Manual for replacement or Periodically, disconnect the throttle, clutch and adjustment procedures, or see your Honda hot start cables at their upper ends. Thoroughly dealer. (7) cylinder bolt (8) cylinder head bolts (10) drive sprocket bolt (1) cylinder head cover bolts (2) clutch cover bolts (3) water pump cover bolts (4) transmission oil check bolt (5) crankshaft hole cap (9) exhaust pipe joint nuts Servicing Your Honda. Wet any heavy deposits with water first.

Then spray on the Pro Honda Hondabrite and rinse with a garden hose at full pressure. Stubborn deposits may require a quick wipe with a sponge.

#7447-maroon) is for removing stains on the non-coated aluminum frame only. 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.

Servicing Your Honda. Servicing Your Honda. Adjustments for Competition This section tells you how to fine tune your CRF Front Suspension Adjustments.96 for maximum competition performance. Front Suspension Air Pressure.96 Front Suspension Damping.96 Initial suspension adjustments should be Fork Springs.97 performed after a minimum of two hours of easy Front Suspension Disassembly.97 break-in time.

Front Suspension Adjustments The front suspension can be adjusted for the Front Suspension Air Pressure Front Suspension Damping rider’s weight and riding conditions by using one or more of the following methods: Air is an unstable gas which builds up pressure Rebound Damping Adjustment as it is worked (such as in a fork). See the Service Manual or adjusters are firmly located in a detent, and not the fork is too hard on big bumps, turn the your Honda dealer for this service. Between positions. Damping adjuster counterclockwise 1-turn and.

Front Suspension Adjustments 1. Place your CRF on the optional workstand or 5. Loosen the upper pinch bolts (8). Remove the front axle nut (11) and loosen the equivalent support with the front wheel off the 6.

Loosen the fork damper (7), but do not front axle pinch bolts (12) on both forks. Front Suspension Adjustments 15.Hold the outer tube, then remove the fork 16.Drain the fork oil from the outer tube (28). 11.Loosen the fork leg lower pinch bolts (19), damper (23) from the outer tube using a lock Drain the fork oil from the oil hole (29) of the then pull the fork legs down and out. Front Suspension Adjustments 20.Push out the fork center bolt from the axle 24.Remove the push rod (33) from the fork Damper Oil Change holder of the slider by pushing the fork damper. 25.Remove the special tool or mechanic's stopper 21.Make the mechanic's stopper tool out of a thin tool (31) between the axle holder (25) and 1. Recommended Oil: Be careful not to damage the fork cap bushing. Oil Level: 1.65 – 1.85 in (42 – 47 mm) Pro Honda HP Fork Oil 5 W or equivalent Do not disassemble the fork cap assembly.

Recommended Amount: Replace the fork cap as an assembly if it is 6.5 US oz (192 cc, 6.8 Imp oz). Front Suspension Adjustments 10. Tighten the fork cap assembly (2) while 12.

Screw in the lock nut (8) to the fork damper 14. Drain the extra oil from the oil hole (5) of the piston rod (5) fully. Holding the cut out of the fork damper (1) fork damper (1). Front Suspension Adjustments 2. Tighten the lock nut (2) fully and measure the Fork Assembly thread length (A) as shown. Standard: 0.43 – 0.51 in (11 – 13 mm) 1. Drain the fork oil from the outer tube/slider (1) by placing it upside down.

(About 7 cc of fork oil will be left in the outer Wipe the oil completely off the fork damper. Front Suspension Adjustments 4.

Place the lower end (axle holder) of the slider 8. Measure the length of the lock nut (2) and 10. Remove the special tool or mechanic's stopper in a vise with a piece of wood or soft jaws to fork center bolt (8) clearance. Fork Oil Capacity: outer tube/slider (1). Standard (0.46 kgf/mm) Fork Spring No mark Recommended Oil: 4 scribe marks (factory products) Pro Honda HP Fork Oil 5 W or equivalent. 2 scribe marks (aftermarket parts) (11) Standard oil 12.8 US oz capacity.

Front Suspension Adjustments 14.Check that the O-ring (12) on the fork damper 17.Tighten the fork damper assembly (4) to the assembly (4) is in good condition. Apply the specified torque using the lock nut wrench recommended fork oil to the O-ring. Front Suspension Adjustments 21.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. Clamps contact each other. Washers and handlebar holder nuts (26) and Apply locking agent to the bolt threads. Front Suspension Adjustments 26.Route the number plate tab (27) around the 28.While keeping the forks parallel, alternately 30.Turn the rebound damping (32) and handlebar pad (28) as shown.

Tighten the right axle pinch bolts (29) to the compression damping (33) adjuster screws specified torque: back to their original settings. Do not attempt to disassemble, service, or 4. After adjustment, hold the adjusting nut and dispose of the damper; see your Honda dealer. Tighten the lock nut to the specified torque: Spring pre-load length (Optional spring) The instructions found in this owner’s manual are 32 lbfft (44 Nm, 4.5 kgfm).

Rear Suspension Adjustments High Speed Damping: Rear Suspension Damping The high speed damping can be adjusted by turning the hexagonal portion of the compression adjuster. Compression Damping Compression damping may be adjusted in two stages with separate adjusters. To adjust to the standard position: 1.

Rear Suspension Adjustments 4. 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: 3.9 in (100 mm) important for competition use.

Rear Suspension Adjustments 6. Calculate the free sag dimension.

Because of the great absorption quality of the To do this, subtract the loaded without rider shock bumper rubber, it may be difficult for you dimension (step 5) from the unloaded to notice when your CRF’s suspension is dimension (step 2). Suspension Adjustments for Track Conditions Soft Surface On soft ground, sand, and especially mud, consider increasing compression damping front and rear. Sand often requires a bit more rebound damping to minimize rear end kick. Although sand bumps are usually larger, there’s more distance between them, giving the shock more time to recover. Suspension Adjustment Guidelines Follow the procedures described below to accurately adjust your CRF, using the methods described on pages 96 – 113. 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. Suspension Adjustment Guidelines Symptom Action Stiff Initial travel too stiff: – Test softer compression damping adjustments in one-click increments.

Suspension. Stiff on small bumps while riding at full throttle in a straight line. – Reduce the rebound damping adjustments in one-click increments. Suspension Adjustment Guidelines Rear Suspension Adjustment Adjustments for Type of Track Hard-surfaced track Begin with the standard settings. If the suspension is too stiff/soft, adjust according to the chart below. Sand track Lower the rear end (to improve front wheel stability) by increasing Race Sag (reduce spring pre-load). (2) and is mixed with circuit resulting in a lean condition.

Available for your CRF. See your Honda dealer. Air from the air passage (3) (located above the throttle valve (4)) to provide a rich mixture for Any engine or air cleaner modifications or the starting. Carburetor Adjustments & Tuning Tips Accelerator Pump Circuit Slow Circuit Main Circuit The accelerator pump circuit operates when the Fuel is metered by the slow jet (1) and mixed Fuel is metered by the main jet (1), jet needle (2) throttle is opened. Honda carburetor jet sizes are numbered in increments of 2 or 3.

When changing the main jet The minimum to maximum range of pilot screw size, increase or decrease it gradually until the adjustment is 1 1/4 to 2 turns out from the lightly desired jetting is obtained. Carburetor Adjustments & Tuning Tips 4. Remove the fuel tank (page 30). Remove the hot start cable holder (6). Loosen the throttle cable lock nut (9), adjuster 5.

Remove the subframe (page 32). (10), throttle cable bolt (11) and disconnect 6. Carburetor Adjustments & Tuning Tips 3. Remove the link arm set torx screw (6). When installing the floating valve (8) onto the Carburetor Disassembly When installing the link arm set torx screw, throttle valve (5) make sure the floating apply a locking agent to the link arm set torx valve’s flat side faces out and the hole (9) screw threads. Carburetor Adjustments & Tuning Tips 5.

Remove the accelerator pump cover screws 7. Remove the holder screw (17), throttle stop 9. Measure the float level (24) with the float (10) and accelerator pump cover (11). Screw holder (18), float bowl screws (19), level gauge (25) while the float tab is just tube guides (20) and float bowl (16).

Carburetor Adjustments & Tuning Tips Carburetor Assembly To assemble, reverse the disassembly procedures. To install the carburetor, reverse the removal procedures. Tighten the following parts to the specified torque.

Float bowl screws: 1.5 lbfft (2.1 Nm, 0.2 kgfm) accelerator pump cover screws: 1.5 lbfft (2.1 Nm, 0.2 kgfm) carburetor top cover bolts: 1.5 lbfft (2.1 Nm, 0.2 kgfm). Carburetor Adjustments & Tuning Tips Standard Tuning Recommendations For the following recommendations to be accurate, you must use the standard settings as a baseline. Also, don’t change any of the settings until you’ve determined what changes are necessary.

Adjustment Standard settings Pilot screw opening 1 3/4 turns out Slow jet. Carburetor Adjustments & Tuning Tips Once you’ve adjusted the carburetor for Special Tuning Conditions Pre-Adjustment Checks temperature and altitude, it shouldn’t need major readjustment unless race conditions change drastically. 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.

Carburetor Adjustments & Tuning Tips WARNING Carburetor Minor Adjustments Gasoline is highly flammable and explosive. You can be burned or The standard carburetor settings are ideal for the following conditions: sea level altitude, and 68°F seriously injured when handling fuel. (20°C ) air temperature. Carburetor Adjustments & Tuning Tips 7. Change the main jet (4) and slow jet (5) as 10. Remove the fuel tank (page 30).

Change the clip position of jet needle or jet required. Remove the carburetor top cover bolts (9), needle as required. Carburetor Adjustments & Tuning Tips NOTICE NOTICE Spark Plug Reading Using spark plugs with an improper heat range An improperly tightened spark plug can damage or incorrect reach can cause engine damage. If a plug is too loose, a piston may Refer to Spark Plug on page 54. Chassis Adjustments The following suggestions may improve a Fork Height/Angle Wheelbase specific concern. Subtle changes in overall handling may also be noted. The position of the fork tubes in the clamps is Adjusting your CRF’s wheelbase can offer subtle adjustable.

Changes in overall handling. Unless you have the required mechanical. Wet and slippery or sandy conditions: use a (before and after the change) to get an accurate knowhow, tools, and an official Honda Service higher gear (less teeth) to keep engine rpm appraisal of the change. Tire Selection for Track Conditions Choosing the correct tire tread pattern and rubber If you choose a tire with a sticky compound for compound can affect your placing in competition.

Added traction, remember that it may transfer The tires on your CRF offer a “happy medium” additional loads to the transmission because it for the variety of soil conditions the majority of grips so well, especially when riding in situations. Handlebar Position, Width & Shape Apply Pro Honda Hondalock or an equivalent to the threads of these bolts prior to adjustment to help ensure the correct torque is retained. Tips Here’s helpful advice on how to transport and store your Honda, as well as three troubleshooting flow charts. Transporting Your Motorcycle.134 Storing Your Honda.135 Preparation for Storage.135 Removal from Storage.135 You & the Environment.136 Troubleshooting.137 Tips. Transporting Your Motorcycle If you use a truck or motorcycle trailer to To secure your CRF, brace the front wheel transport your Honda, we recommend that against the front of the truck bed or trailer rail. You follow these guidelines: Attach the lower ends of two straps to the tie-down.

Drain gasoline into an approved If the coolant level lowers, add coolant and 9. Place your CRF on the optional Honda container. Retighten the drain screw. Repeat the above procedure. Workstand or equivalent to raise both tires off Install the radiator cap securely.

04 Crf450r Service Manual

You & the Environment Owning and riding a motorcycle can be NOTICE enjoyable, but you must do your part to protect nature. 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. The items that require use of the. Lack of fuel in tank 1. Disconnect fuel FUEL FLOW CHECK POSSIBLE CAUSES Honda Service Manual are followed by an (P.34) line at carburetor RESTRICTED. Over-oiled air cleaner. Check if air INCORRECT.

Technical Information This section contains dimensions, capacities, and Vehicle Identification.140 other technical data. Specifications.141 Torque Specifications.142 Oxygenated Fuels.145 Competition Logbook.146 Optional Parts List.148 Spare Parts & Equipment.149 Wiring Diagram.150 Technical Information. Vehicle Identification The engine number (2) is stamped on the left Serial Numbers crankcase. The VIN and engine serial numbers 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. Specifications Item English Metric Item English Metric Item English Metric Dimension Engine Drive train Overall length Type Liquid cooled, 4-stroke Clutch type Wet, multi-plate type 86.3 in 2,191 mm Single 8˚ inclined from Overall width 32.5 in Transmission 5-speed, constant mesh 825 mm Cylinder arrangement vertical.

Torque Specifications Nuts, Bolts, Fasteners ENGINE Check and tighten nuts, bolts, and fasteners before every outing. Torque Remarks Item lbf.ft N.m kgf.m Engine Cylinder head cover bolts Clutch cover bolts Water pump cover bolts Transmission oil check bolt Crankshaft hole cap NOTE 1 Oil filter cover bolts Cylinder bolt.

Torque Specifications Frame FRAME Torque Remarks Item lbf.ft N.m kgf.m Steering stem nut 11.0 Fork upper pinch bolts Fork lower pinch bolts (12) (13) Handlebar upper holder bolts Handlebar holder nuts Front axle nut Front axle pinch bolts Rear axle nut 13.1 NOTE 1 Chain adjuster lock nuts. Torque Specifications Frame FRAME Torque Remarks Item (39) lbf.ft N.m kgf.m Front brake master cylinder holder bolts (36) Brake hose bolts (29) Front brake caliper mounting bolts NOTE 6 Front brake disc nuts NOTE 1 Rear brake disc nuts NOTE 1 (32) (35) Brake pedal pivot bolt.

Oxygenated Fuels Some conventional gasolines are being blended If you notice any undesirable operating with alcohol or an ether compound. These symptoms, try another service station or switch gasolines are collectively referred to as to another brand of gasoline. Oxygenated fuels. To meet clean air standards, some areas of the United States use oxygenated Fuel system damage or performance problems fuels to help reduce emissions.

Competition Logbook Any serious competition effort relies heavily on Tuning & Adjustment Records Racing Records the knowledge gained and compiled from Keep track of the settings and adjustments that Information worth recording for this section of previous racing events. The best way to organize worked best at a particular location. Competition Logbook Date Running Location/Event Comments (Jetting, Suspension Settings, Gearing, Chassis Adjustments, Maintenance Time Performed, etc.) (Make several photocopies of this page for future use) Technical Information. Optional Parts List These parts and tools may be ordered from your FRAME Remarks FRAME Remarks authorized Honda dealer. Driven sprocket: Drive chain links Shock spring 308.0 lbf/in (5.50 kgf/mm) Standard 48 Teeth, Aluminum. Standard CARBURETOR Remarks. Spare Parts & Equipment There are numerous spare parts you can take to ignition components Pro Honda DOT 4 Brake Fluid an event to help ensure you get in a full day of radiator hoses Pro Honda Chain Lube riding.

In addition to the usual nuts and bolts, radiator shrouds (L &. Wiring Diagram Technical Information. Consumer Information This section contains information about Authorized Manuals.152 contacting Honda and how to get an official Contacting Honda.153 Honda service manual.

Your Honda Dealer.154 The Honda Rider’s Club.155 Consumer Information. For purchases outside U.S.A., please write to the address shown below for a quotation. Also available but not necessary to service your model is the Honda Common Service Manual which explains theory of operation and basic service.

If you wish to comment on your experiences with your Honda or with your dealer, please send your comments to the following address: Motorcycle Division, American Honda Motor Co., Inc., P.O. Your Honda Dealer Once you purchase your new Honda, get familiar Your dealer can inform you about competition with the organization of your Honda dealer so events in your area. You’ll also find that your you can utilize the full range of services dealer is a source of information the Honda available. 24-hour, toll-free roadside assistance for your new Honda (includes roadside assistance for your transport vehicle up to one ton as long as your Honda is aboard or in tow). For street-legal motrcycles and scooters only. An exclusive HRCA website complete with.

Table of Contents The following presents the contents of each SERVICING YOUR HONDA.17 Chassis section of your owner’s manual. Before You Service Your Honda Suspension.73 The Importance of Maintenance.18 Front Suspension Inspection.73 MOTORCYCLE SAFETY.1 Maintenance Safety.19 Rear Suspension Inspection.74 Important Safety Information.2. Authorized Manuals.152 Carburetor Assembly.123 Contacting Honda.153 Standard Tuning Recommendations.124 Your Honda Dealer.154 Adjustments for Altitude & Temperature.124 The Honda Rider’s Club.155 Special Tuning Conditions.125 Pre-Adjustment Checks.125 Carburetor Minor Adjustments.126 Spark Plug Reading.128 Chassis Adjustments.129 Rear End.129.96 refueling.34 fluid level.78 rear.110 system.34 lever, front adjustment.77 dealer, your Honda.154 oxygenated.145 pad wear.80 diagram, wiring.150 tank capacity.34 pedal height.77 drive chain.84 valve.13 break-in guidelines.15.

Index gap, spark plug.54 maintenance, rear suspension maintenance.109 gasohol.145 after competition.26 Rider’s Club Honda.155 gasoline.34 before & after competition.26 riding, gearing.130 between motos & practice.26 apparel.2 guidelines, suspension adjustment.114 component locations.28 basic operation.11 general competition.22. Index suspension, front.73 rear.74 suspension adjustment, front.96 rear.109 for track conditions.113 guidelines.114 transmission oil.39 tuning tips.117 throttle, freeplay.46 inspection.47 tires, air pressure.82 flat.82 selection.83 tools.149 torque specifications.142-144 transporting.134 troubleshooting.137 tubes, replacing.82 valve, fuel.13 vehicle identification no.

Fuel/Tank Capacity unleaded gasoline, pump octane number of 91 or higher tank: 1.90 US gal (7.2R) Engine oil Pro Honda GN4 4-stroke oil or an equivalent motorcycle oil. Transmission oil Pro Honda GN4 4-stroke oil or an equivalent motorcycle oil. Tires 80/100 –.

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