2019-2022 Honda CRF450L Service & Repair Manual

,.. .• - 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 repairs without the proper training, tools and equipment could cause injury to you or others. It could also damage the motorcycle or create an unsafe condition. This manual describes the proper methods and procedures for performing service, maintenance and repairs. Some procedures require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of the motorcycle. If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend that you do not use replacement parts of inferior quality. For Your Customer's Safety Proper service and maintenance are essential to the customer's safety and the reliability of the motorcycle. Any error or oversight while servicing a motorcycle can result in faulty operation, damage to the motorcycle, or injury to others. For Your Safety AWARNING Improper service or repairs can create an unsafe condition that can cause your customer or others to be seriously hurt or killed. Follow the procedures and precautions in this manual and other service materials carefully. 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 confident about your knowledge of safe servicing practice, we recommended that you do not attempt to perform 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 that can arise in performing service and repair procedures. Only you can decide whether or not you should perform a given task. AWARNING Failure to properly follow instructions and precautions can cause you to be seriously hurt or killed. Follow the procedures and precautions 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 before 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 or work around pressurized air or liquids and springs or other stored-energy components. If there is any doubt, put on eye protection. • Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves. • Protect yourself and others whenever you have the motorcycle up in the air. Any time you lift the motorcycle, either with a hoist or a jack, make sure that it is always securely supported. Use jack stands. Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will help eliminate several potential hazards: • Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine. • Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas. • Injury from moving parts. If the instruction tells you to 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 fuel-related parts. 61MKE53

HOW TO USE THIS MANUAL How To Use This Manual This manual describes the service procedures for the CRF450URL. Follow the Maintenance Schedule (Section 3) recommendations to ensure that the motorcycle is in peak operating condition and the emission levels are within the standards set by the U.S. Environmental Protection Agency (EPA) and California Air Resources Board (GARB) and Environment and Climate Change Canada (ECCC). Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in period. Sections 1 and 3 apply to the whole motorcycle. Section 2 illustrates procedures for removal/installation of components that may be required to perform service described in the following sections. Section 4 through 20 describe parts of the motorcycle, grouped according to location. Find the section you want on this page, then turn to the table of contents 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. Refer to the troubleshooting in each section according to the malfunction or symptom. In case of an engine trouble, refer to PGM-FI section troubleshooting first. 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 motorcycle. You must use your own good judgment. You will find important safety information in a variety of forms including: • Safety Labels - on the motorcycle • Safety Messages- preceded by a safety alert symbol /!' , and one of three signal words, DANGER, WARNING, or CAUTION. These signal words mean: jj-(;WM§;• You WILL be KILLED or SERIOUSLY HURT if you don't follow instructions. ffl','M;Wlml You CAN be KILLED or SERIOUSLY HURT if you don't follow instructions. t1M•nMa You CAN be HURT if you don't follow instructions. • Instructions - how to service this motorcycle correctly and safely. As you read this manual, you will find information that is preceded by a []MICE] symbol. The purpose of this message is to help prevent damage to your motorcycle, other property, or the environment. ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITIEN PERMISSION. THIS MANUAL IS WRITIEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON Honda MOTORCYCLES, MOTOR SCOOTERS OR ATVS. © Honda Motor Co., Ltd. SERVICE PUBLICATION OFFICE Date of Issue: May, 2020

HOW TO USE THIS MANUAL SYMBOLS The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols. :ti Replace the part(s) with new one(s) before assembly. -, Use the recommend engine oil, unless otherwise specified. 71 Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1) . .,-UM Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent). Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or ,,. equivalent). Example: • Molykote® BR-2 plus manufactured by Dow Corning U.S.A. 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. • Pro Honda M-77 Assembly Paste (Moly) (U .S.A. only) • Rocol ASP manufactured by Rocol Limited, U.K. • Moly Paste 500 manufactured by Sumico Lubricant, Japan Use silicone grease. c=. Apply a locking agent. Use a medium strength locking agent unless otherwise specified. J'Ciru Apply sealant. :I, Use Honda DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified. I Use fork or suspension fluid.

CONTENTS GENERAL INFORMATION FRAME/BODY PANELS/EXHAUST SYSTEM MAINTENANCE PGM-FI SYSTEM IGNITION SYSTEM ELECTRIC STARTER ....1 FUEL SYSTEM ~!======================: a: LUBRICATION SYSTEM I-I========================; O COOLING SYSTEM w .... 11===================== CYLINDER HEADNALVES zi===================== CYLINDER/PISTON/CAM CHAIN TENSIONER CJI===================== ffi CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE ALTERNATOR CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER ENGINE REMOVAL/INSTALLATION Cl) FRONT WHEEL/SUSPENSION/STEERING C/)1===================== REAR WHEEL/SUSPENSION :I: o HYDRAULIC BRAKE ..J w c3 BATTERY/CHARGING SYSTEM :.- I===================== ... LIGHTS/METERS/SWITCHES w WIRING DIAGRAM INDEX

1. GENERAL INFORMATION • SERVICE RULES····· ....... · ....... · .......... ···· 1-2 LUBRICATION & SEAL POINTS ............ 1-17 MODEL IDENTIFICATION .... · · ............ · ·· .. 1-3 CABLE & HARNESS ROUTING ............. 1-20 SPECIFICATIONS,·· ............................... 1-4 EMISSION CONTROL SYSTEMS .... · · · · · ·· 1-38 TORQUE VALUEs ............................... 1-10 TECHNICAL FEATURE ........................ 1-41 1-1

GENERAL INFORMATION SERVICE RULES 1. Use Honda genuine or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda's design specifications may cause damage to the motorcycle. 2. Use the special tools designed for this product to avoid damage and incorrect assembly. 3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English fastener. 4. Install new gaskets, 0-rings, cotter pins and lock plates when reassembling. 5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified. 6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly. 7. After reassembly, check all parts for proper installation and operation. 8. Route all electrical wires as shown in the Cable and Harness Routing (page 1-20). 9. Do not bend or twist control cables. Damaged control cables will not operate smoothly and may stick or bind. ABBREVIATION Throughout this manual, the following abbreviations are used to identify the respective parts or systems. Abbrev. term Full term CDI Capacitive Discharge Ignition CKP sensor Crankshaft Position sensor DLC Data Link Connector DTC Diagnostic Trouble Code ECM Engine Control Module ECT sensor Engine Coolant Temperature sensor EEPROM Electrically Erasable Programmable Read Only Memory EVAP Evaporative Emission IAT sensor Intake Air Temperature sensor MAP sensor Manifold Absolute Pressure sensor MCS Motorcycle Communication System MIL Malfunction Indicator Lamp PAIR Pulse Secondary Air Injection PGM-FI Programmed Fuel Injection SGS Service Check Signal TP sensor Throttle Position sensor DESTINATION CODES Throughout this manual, the following codes are used to identify individual types for each region. '19 - '20 model (CRF450L): DESTINATION CODE REGION AC 50-State, meets California CM Canada After '20 model (CRF450RL): DESTINATION CODE REGION AC 50-State, meets California CM Canada 1-2 -

d ,, MODEL IDENTIFICATION '19 - '20 model shown: SERIAL NUMBERS/LABELS The motorcycle Identification Number (V.1.N) [1] is stamped on the right side of the steering head. The throttle body identification number [1] is stamped on the right side of the throttle body. [1] GENERAL INFORMATION The engine serial number [1] is stamped on the upper side of the right crankcase. The emission information label [1] and CM type only emission information label [2] are attached on the left side of the frame and rear fender A. ... Frame side: Rear fender A side: 1-3

2019-2022 Honda CRF450L Service & Repair Manual

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