2009-2010 Honda CRF450R 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 lor use by qualified professional technicians. Attempting service or repairs without Ihe proper trainrng, tools, and equipment could cause Injury to you or others. It could also damage the vehlde or create an unsafe condition This manual descnbes the proper methods and procedures fOf performing service, maintenance and repairs. Some procedures require Ihe use of spedally designed tools and dedicated equipment. Any person who inlends to use a replacement part, service procedure or a tool that IS nol recommended by Honda, must determine the nsks to their personal safety and the safe operabon of the vehicle. [fyou need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend thai you do not use replacement parts of inferior quality. For Your Customer 's Safety Proper service and maintenance are essential 10 Ihe customer's safety and the reliability of the vehicle. Any error or oversight whi le servicing a vehl de can result in faulty operation. damage to the vehicle, or Injury to others. For Your Safety AWARNING Improper service or repairs can creale an unsafe condition thai can cause your customer or others to be seriously hurt or killed Follow the procedures and precautions in thiS manual and other service materials care ~f~ U~ ff' ~ . __ _ 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 Iraining Of do not feel confident about your knowledge of safe servicing practice, we recommend 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 wam you of every conceIVable hazard that can aose in perforrmng service and repair procedures Only you can decide whether Of not you should perform a given task AWARNING Failure to property follow instructioos and precautions can cause you to be senously hurt Of killed. Follow the procedures and precautions in thiS manual carefully. Important Safety Precautions Make sure you have a dear understanding of all baSIC shOp safety practices and thai you are weanng appropnate clothing and USing safety equipment. When perfonning any service task, be especially careful of Ihe following Read all of the instructions before you begin, and make sure you have the lools, Ihe replacemenl or repair parts, and the skills required to perfonn the tasks safety 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 spnngs or other stored-energy components. If there is any doubt, put on eye protection Use olher protective wear when necessary, for example gloves or safety shoes. Handling hoi or sharp parts can cause severe bums or cuts. Before you grab something that looks like it can hurt you, slop and put on gloves. Proled yourself and others whenever you have the vehide up in Ihe air. Any time you lift the vehicle, either With a hoist or a jack, make sure that it IS always securely supported. Use jack stands Make sure the engi ne is off before you begin any seNiclng procedures unless the InstructlOO tells you to do otherwise. This will help eliminate several potential hazards: , Carbon monoxide poisonmg from engine exhaust Be sure there IS adequate ventilation whenever you run the engine. • Bums from hot parts or coolant. Lei the engine and exhaust system cool before wor1o:ing in those areas. • Injury from moving parts If the instruction tells you to run the engine. be sure your hands, fingers and doth ing are out of the way Gasoline vapors and ~ydrogen gases from batteries are explosive. To reduce the POSSibility of a fire or explOS ion, be careful when wonting around gasolme or battenes. Use only a nonflammable solvent. not gasoline, to clean parts. Neller drain or store gasoline In an open conlainer. Keep art cigarettes, sparks and flames away from the battery and all fuel-related parts.

HOW TO USE THIS MANUAL How To Use This Manual This manual describes the service procedures for the CRF450R. Sections 1 and 4 apply to the whole vehicle. 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. It compensates for the initial wear that occurs dunng the break·in penod. 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. 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 variety of forms including Safety Labels - on the vehicle • Safety Messages - preceded by a safety alert symbol ! and one of three signal words. DANGER, WARNING , or CAUTION. These signal words mean: I!j.MN33;' You WILL be KILLED or SERIOUSLY HURT If you don't follow instructions. fflWfiilWdfl You CAN be KILLED or SERIQUSL Y HURT if you don't follow instructions. "MiW.g. You CAN be HURT if you don't follow instructions • Instructions - how to service thiS vehicle correctly and safely. As you read this manual, you will find Information thai IS preceded by a ]iOtlCE symbol. The purpose of thiS message IS to help prevent damage to your vehicle, other property, or the enVifonmenl.

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. t Replace the partes) with new ooe(s) before assembly. Use the recommended engine 011. unless otherwise specified. I Use molybdenum 011 solullon Im,, 'ur. o rthe engine oil .nd molybdenum gre.se In. r.,lo of "'). 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: • M04ykote® BR·2 plus manufactured by Dow Coming U.S.A. • Multi-purpose M-2 manufactured by Mltsubishj Oil, 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 Paste M77 (U.S.A. only) Rocol ASP manufactured by Rocol Limited, U.K. Rocol Paste manufactured by Sumlco Lubricant, Japan ___________ _ Use silicone grease . Apply a locking agent. Use a medium strength locking agent unless otherwise specified. Apply sealant. Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified. Use fork or suspension fluid. I j

CONTENTS GENERAL INFORMATION TECHNICAL FEATURE FRAME/BODY PANELS/EXHAUST SYSTEM MAINTENANCE LUBRICATION SYSTEM z FUEL SYSTEM (PGM-FI) ~ F=C ~O ~ O~ LI ~ N ~ G ~ S = y 7. S = T = E =M ~========================== ~ ~====================================== UJ ENGINE REMOVAL/INSTALLATION ~ F=====~================================ CYLINDER HEADNALVES ~ F=====~~~==========================~ CYLINDER/PISTON ~ F===~==~~==~~~~~======~======~ ," CLUTCH/KICKSTARTERIGEARSHIFT LINKAGE Z F===~==~============================= UJ ALTERNATOR CRANKCASE/CRANKSHAFTITRANSMISSION/BALANCER '" FRONT WHEEL/SUSPENSION/STEERING '" ~ REAR WHEEL/SUSPENSION G HYDRAULIC BRAKE ELECTRICAL SYSTEM WIRING DIAGRAM TROUBLESHOOTING INDEX

SERVICE RULES ··· ....... .............. ........... 1·2 MODEL IDENTIFICATION ············· ········ ·· 1·3 GENERAL SPECIFICATIONS ····· ··· ·········· 1·5 LUBRICATION SYSTEM SPECiFiCATIONS ······ ............. ... , . .......... 1·8 FUEL SYSTEM (PGM·FI) SPECIFICATIONS ", .. ............................. 1·8 COOLING SYSTEM SPECIFICATIONS "'''' 1·8 CYLINDER HEADNALVES SPECIFICATIONS·············· ·· ···· ·· · ········ · ·· 1·9 CYLINDER/PISTON SPECIFICATIONS ····· 1·9 CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE SPECiFiCATIONS ··· ···· . ....... .. 1·10 1. GENERAL INFORMATION CRANKCASEICRANKSHAFTI TRANSMISSION/ BALANCER SPECIFICATIONS" . ... .......................... 1·10 FRONT WHEEL/SUSPENSION/ STEERING SPECIFICATIONS ....... ........ 1·11 REAR WHEEL/SUSPENSION SPECiFiCATiONS····· · ·· ··· ·········· · ·········· 1·12 HYDRAULIC BRAKE SPECiFiCATIONS···· ··· ········ ·· · ·· ·········· ·· 1·13 ELECTRICAL SYSTEM SPECiFiCATIONS··· · ············· ······ .. ······· 1·13 TORQUE VALUES ............................... 1·13 LUBRICATION & SEAL POINTS .... ........ 1·20 CABLE & HARNESS ROUTING ............. 1·23 OPTIONAL PARTS .............................. 146 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 nol interchangeable with English fastener. 4. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling. 5. When lightening bolts or nuts, begin with the larger diameter or inner bolt first. Then lighten 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 1-23). g. 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. l 1 DESTINATION CODE Throughout this manual, the following codes are used to identify individual types for each region. DESTINATION CO >I: D"E--1=::::;:=:-::::;;:::;;=:::;" R~ EGION ~A~C~ _______ -+-i 50- ~ S~late, meels California .~=======- 1 -' C"M"--______ -'- Canada _ ~ 1·2

GENERAL INFORMATION MODEL IDENTIFICATION '09 shown: After '15 shown; 1-3

GENERAL INFORMATION SERIAL NUMBERS The Vehicle Identiffcation Number (VIN) is stamped on the right side of the steering head. The engine serial number is stamped on the left side of the lower 0;;;';;'- .. crankcase. The throttle body identification number is stamped on the right side of the !~~~iiI!I!~~~~~~~~~~~ throttle body. NUMBER LABEL The name plate is located on the right side of the frame. 1-4

2009-2010 Honda CRF450R Service Repair Manual

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