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2009-2012
HOW TO USE THIS MANUAL
A Few Words About Safety
Service Information
The
service
and repair
information contained
In
this manual is
Intended
for use by qualified, professional technicians Attempting
service or
repa
irs
without
the
proper
training, tools, and equipment
could
cause
injury
to
you or others
It
could
also damage
the
vehicle
or create an
unsafe
condition.
This manual
describes
the
proper
methods
and procedures for performing service, maintenance and repa
irs.
Some procedures
require
the
use
of
specially designed
tools
and
dedicated
equipment. Any
persoo
who
intends
to
use
a
replacement
part. service
procedure
or
a
1001
that
Is
not
recommended
by
Honda,
must determtne
the
risks
to
their personal safety and the safe operatIOn 01
the
vehicle
II you
need
1
replace a
part,
use Honda Genuine parts
with
the
correct
part
number or
an eqUIvalent
part.
We strongly
recommend
0
that
you
do
not
use
replacement parts
of
inferior
quality.
For Your Customer's Safety
Proper service and
maintenance afe
essential
to
the
customer's
safety and
the
reliability
of
the
vehicle.
Any error or oversight while
servicing a vehicle can result
in
faulty operation. damage
to
the
vehicle,
or injury to others.
AWARNING
Improper
Service or
repairs
can
create an unsafe
condition
that can cause
your
customer
Of
others to
be
serIOusly hurt
or
killed
Follow
the
procedures
and
precautions
in
thiS
manual
and
other service materials carefully
For Your Safety
Because
this
manual is
intended
for the professional service technician.
we
do
not provide warnings about many basic shop safety
practices
(e.g .•
Hot parts-wear gloves).
If
you have not received shop safety training or do not feel oonfidenl about your knowledge
of safe servicing
practice,
we
recommend thai you do not attempt to perfonn the procedures described
in
thiS
manual
Some of the most
important
general service safety precautions are given below. However, we cannot warn you of every
conceivable
hazard
thai
can arise in performing service and repa
ir
procedures
,
Only you can decide whether or not
you
should
perform a given lask.
AWARNING
Failure to property
follow
instructions and precau-
tions can cause you 10
be
seriously hurt
or
killed
Follow
the
procedures and precaullons in thiS
manual carefully.
Important Safety Precautions
Make sure you
have
a clear understanding of all basic shop safety practices and that you
are
wearing appropriate clothing
and
uSing safety equipment. When performing any service
task,
be especially careful of
the
following:
Read
all
of
the instructions bef()(e you begin, and
make
sure you have
the
tools,
the
replacement or
repair
parts,
and
the
skills
required to perform
the
tasks safely and completely.
Protect your eyes by using proper safety
glasses,
goggles or
face
shields any time you
hammer,
drill, grind
,
pry
Of
work around
pressurized air or liquids. and springs or other stored-energy components. Irthere is any doubt,
put
on eye protecllon.
Use other protective wear when necessary,
for
example gloves or safety shoes.
Handling
hot or sharp parts can cause severe
bums or ruts. Before you grab something thai looks like
it
can hurt you, stop and put on
gloves.
Protect
yourself
and
others whenever you
have
the vehicle up in the air. Any time you lift
the
vehicle, either
with
a hoist or a
jack.
make sure thai it
is
always securely supported.
Use
jack
stands.
Make
~u~e
the engine is off before you begin any servicing procedures,
unless
the instruction lells you to
do
otherwise. This will
help elrmmate several potential hazards:
•
Carbon
monoxide poisoning
from
engine exhaust.
Be
sure there is adequate ventilation whenever you run the engine.
•
Bums
from
hoi
parts
or cootant
lei the
engine and exhaust system cool before working in those areas.
•
InjUry
from
moving parts. If
the
instruction
tefts you
10
run
the
engine, be sure your hands, fingers
and
clothing are out of
the
way.
Gasoline vapors and
hydrogen
gases from batteries are explosive.
To
reduce
the
poSSibility of a fire or explOSion, be careful when
working around gasoline or batteries.
Use
only a nonflammable solvent, not
gasoline, to
clean parts.
Never
drain or store gasoline in an open container.
Keep all cigarettes
,
sparks and flames away from the battery and all
fue~related
parts.
HOW TO USE THIS MANUAL
How To Use This Manual
This manual descnbes the service procedures for the CRF450 R.
Sections 1 and 4 apply to the whole
vehlde.
Section 3 illustrates procedures for removal/installation of components that may
be
required
to
perform service described in
the
following sections.
Section 5
through
17 describe parts of the
motorcycle,
grouped according to location
.
Follow
the
Maintenance
Schedule
recommendations to
ensure that
the
vehicle is in peak operating condition.
Performing
the
first scheduled maintenance
is
very important. II compensates for the
initial
wear
thai
occurs during the break-in
period.
Find the section you want
on
thIs page, then lum to the lable
of
COnlents on the first page of the section
.
Most sections start
with
an assembly
or
system illustration, service information and troubleshooting for the section
.
The subsequent
pages give detailed procedure.
If you are not familiar with this motorcycle. read Technical Features in Section 2.
If
you don't know the source of the trouble, go
to
Troubleshooting Section 19.
Your safety,
and
the safety of others
,
is very important. To help you make
informed
decisions we have provided safety
messages and other
information throughout
this manual. Of course, it is not practical or possible
to
warn you about all the
hazards associated with servicing this vehicle.
You must use your own good Judgement.
You will find important safety
information
in a vanety of fo""s including:
Safety Labels - on the
vehicle
•
Safety Messages
-
preceded by a safety alert symbol
!
and one oflhree signal words, DANGER, WARNING, or CAUTION.
These signal words mean;
w.tnw;;i
You WILL
be
KILLED or SERIOUSLY HURT if you don't follow
instructions.
ffl1"iWidil
You CAN be KILLED or SERIOUSLY
HURT
if you don',
follow
instructions.
ml$iiil,U'
You CAN
be
HURT If you don't follow Instructions
.
•
Instructions - how to service this vehicle correclly and safely.
As you read thiS manual
,
you w
ill
find Information that
Is
preceded by a
HO.TICE...
symbol. The purpose of this message IS to help
prevent damage to your vehicle, other
property,
or the environment.
ALL INFORMATION, ILLUSTRATIONS
,
DIRECTIONS AND SPECIFICATIONS INCLUDED IN
THIS
PUBL1CATION ARE
BASED
ON
THE
LATEST
PRODUCT
INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR
PRINTING
.
Honda
Motor
Co.
,
lid
.
RESERVES
THE
RIGHT TO
MAKE
CHANGES AT ANY
TIME
WITHOUT
NOTICE
AND WITHOUT
INCURRING ANY OBLIGATION WHATSOEVER.
NO
PART OF THIS PUBL1CATION
MAY
BE REPRODUCED WITHOUT
WRIITEN
PERMISSION.
THIS
MANUAL
IS WRIITEN FOR PERSONS WHO
HAVE
ACQUIRED
BASIC
KNOWLEDGE OF
MAINTENANCE ON Honda
MOTORCYCLES
,
MOTOR SCOOTERS OR ATVS.
Date of
Issue:
September, 2010
HOW TO USE THIS MANUAL
SYMBOLS
The symbols used throughout this manual show specific service procedures.
If
supplementary information is required pertaining to
Ihese symbols,
it
would be explained specifically in
Ihe texl
without Ihe
use
of the symbols.
sI
Replace the par1(s) wi
th
new one(s) before
assembly.
,
f-
~
Use the recommended engine oil
,
unless
otherwise
specified.
Use molybdenum oil solution
(mixture
of
the
engine oil and molybdenum grease
in
a ratio
of
1:
1).
,.
~
Use
multi·purpose grease
(lithium
based mUlti-purpose grease
NLGI
#2 or equivalent).
Use molybdenum disulfide grease (containing more Ihan 3% molybdenum disulfide,
NLGI
#2 or
equivalent),
Example:
•
Molykote®
BR-2 plus manufactured by Dow Corning
U.S.A.
I
•
Multi-purpose M-2
manufactured
by
Mitsubishi
011
,
Japan
~
Use molybdenum disulfide paste
(containing
more than 40% molybdenum disulfide,
NlGI
#2 or
equivalent).
Example:
Molykote® G-n Paste manufactured by Dow Corning U.S.A.
Honda
Moly
60
(U.S.A.
only)
Rocol ASP manufactured by
Rocol limited
,
U.K.
Rocol Paste manufactured by Sumico lubricant, Japan
Use silicone grease.
f-
Apply a locking agent. Use a medium strength locking agent unless otherwise specified.
1
Apply sealan\.
Use DOT 4 brake fluid.
Use
the
recommended
brake fluid
unless
otherwise specified.
I
Use fork or suspension fluid
.
CONTENTS
GENERAL INFORMATION
TECHNICAL FEATURE
FRAME/BODY PANELS/EXHAUST SYSTEM
MAINTENANCE
-
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F=~~~~~~~====================
FUEL SYSTEM (PGM-FI)
LUBRICATION SYSTEM
>-
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F=~~~~==~=======================
COOLING SYSTEM
~
F==
~
=
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M O VA L/~
~
T~ L~A
~I=7.
E N G IN E~R
=
~~
~~
IN S~ A~ L
7.T
0 N=================
~
-
~
F=========~===========================
CYLINDER/PISTON
F======================================
CYLINDER HEADNALVES
Z
~
F===~====~==~==~~========~=======
CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE
~
F=~~~~========================
ALTERNATOR
Z
w
F=~====~====~====~~==~~~====~
CRANKCASE/CRANKSHAFTITRANSMISSION/BALANCER
FRONT WHEEUSUSPENSION/STEERING
F=== === =H =E =
S US
=E =S = ======================
R EA R W
=E =U = = =P =N =IO
N
HYDRAULIC BRAKE
ELECTRICAL SYSTEM
WIRING DIAGRAM
TROUBLESHOOTING
INDEX
~
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