2002-2004 CRF450R Service & Repair Manual

A Few Words About Safety Service Infonnation The servIce and repair information contained in this manual is intended for use by qualified, professional technicians. Anempting service or repairs without the proper training, toots, and equipment could cause injury to you or others. II could also damage the vehicle or create an unsafe condition. This manual describes the proper methods and procedures for performing service, maintenance. and repairs. Some proce- dUres require the use of specially designed tools and dedicated equipment. Anv person who intends to use a replacement Wlrt, service procedure or a laol thai is not recommended by Honda. must determine the risks to their personal safety and the safe operation of the ... ehicle. If you need 10 replace a part , use genu i ne Honda parts with the correct part number or an equ ivalent part. We strongly recommend that you do not use replacement parts of infenor quality . For Your Customer 's Safety Proper service and ma i ntenance are essential to the customer 's safety and the reliabil ity of the vehicle . Any error or oversight while servicing a vehicle can result in faulty operation. damage to the veh icle, or injury to others. For Your Safety Because this manual is intended lor the professional service techni- cian , we do not prov ide warnings about many basic shop safety practices le.g. , hot parts-wear gloves). If you have nOI received shop safety traini ng Of do not feel confident about your knowledge 01 sale 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. Howeve r, we cannot ..... arn 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. Important Safety Precautions AWARNING Improper service or repai rs can create an unsafe cond i tion that can cause your customer or others to be seriously hurt or killed. Follow the procedures and precaut ions in this manual and other service matena !s carefully. AWARNING Failure to properly follow instruct i ons and precautions can cause you to be seriously hurt or killed. Follow the procedures and precautions In this manual carefully . Make sure you have a clear understanding of aU basic shop safety practices and that you wear appropriate clothing and use 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 lools, 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 doub l, 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 vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack, make sure it is always securely supported. Use jack stands. Make sure the engine is turned 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 elChausl system coo l before working in those areas. • Injury from moving parts If the instruct ion tells you to run the engine , be sure your hands , fingers and cloth i ng are out of the way. Gasoline vapors and hydrogen gases from baneries are explosive. To reduce the pOSSibilI ty of a fire or explosion , be care· lu i when working around gasoline or baneries. • Use only a nonflammable solvent, not gasoline , to clean parts. • Never drain or st ore gasoline in an open container. • Keep all cigarenes, sparks and flames away Irom the battery and all fuel-related parts. •

HOW TO USE THIS MANUAL Th,s nrv;ce menual d~scribe. Ille 5e'~IC' procedur.s for the CRF450R Follow Ihe Mlloten.nee Schedule ISeclion 3) re<;ommendnons Ipage 3-3)10 ensure Ihal the motorcycle is atw.y. in ~ak ope,atlng cond,tion. Performing Ih", li~1 SGheduled maintenance II very ImPOrt,nt It compensates lor the inil,al wea. that o«ur, during the b'Nk·ln period Sections 1 and J apply 10 lhll whole motorcvcle. Section 2 illus- ,ralH procedufH lor removallinst.llation of components thai mllV boll requlfed 10 perlarm SflfVice de$Clibed in Ihelollow'ng seetiOIl' . Secllons 4 through 16 d .. ,c,ibe parl. of the ... ehlcle, grouped .oeording 10 10000tion Find Ihe secllon you want on Ihll pag8, then turn to the 'able 01 contents on the fi'$! page of !he . eClion. Molt seellonslI." Wllh lin Hsembly Of SYllem ,IIUSlratlon. service inlo.mittlon and troubleshooting 10. tha section The sub.equent peges give det.lIed p<ocedures II ~ou do not know the sourca 01 the tr ouble. 110 to Section 18. Troubleshoot Ing . Your $iI.ety, .nd the u.aty of othe,s. II very Imponant To halp you make info'med decISIons we have provided safety mess&ges and other info'mation thtoughoUi thil manual, Of course. iIi. nol practical or possible 10 wI.n you about 8111he h&<ards associated with servicIng Ihis vet"cleo You must use you. own good Judgement. You WIll find imponant .. 'ety informalion In I vI"lly 01 forms including; • Safety Labell-on the vehicle . Safely Me,sages-prece ded by. ufety alert symbol .1l. and one of three sign.' words. DANGER. WARNING. or CAUTION These Ilgnal words mean H,fMt!J4i l You WILL be KILLED or SERIOUSLY - ~" .. "--"- HURT if vou don' tl ollow instructions. ew.'iIJilmJ You CAN be KJLLED or SERIOUSLY HURT if you don't follow instruction, t'!t4liitml You CAN be HURT II you don 't lollow _." """ ". - InstructIon •. • Instructlonl-how to service thl' vehICl e correctly ilnd salety As you read thll manual. you will find inform.tlon that .. preceded by • I NOncE I ,ymbol . The purpOse ollh's message is to help pre- vent d.mage to \lour vehicle. other proP8rtv. or the environment Date of Iss ue: July, 2003 z g '" ~ II: C C Z < '" z a z '" CI) ~ :z: u CONTENTS GENERAL INFORMATION FRAME/BODY PANELS/EXHAUST SYSTEM MAINTENANCE LUBRICATION SYSTEM FUEL SYSTEM COOLING SYSTEM ENGINE REMOVAl/INSTALLATION CYLINDER HEADIVALVES CYLINDER/ PISTON CLUTCH / KICKSTARTER / GEARSHIFT LINKAGE BALANCER FRONT WHEEl/SUSPENSION / STEERING REAR WHEEl/SUSPENSION HYDRAULIC BRAKE IGNITION SYSTEM/ ALTERNATOR WIRING DIAGRAM TECHNICAL FEATURES TROUBLESHOOTING INDEX

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. fI Replace the part{sl with new one(s) before assembly. -, 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), ~..ijjjV,. Use multi-purpose grease (lithium based multi -purpose grease NLGI #2 or equivalentJ. Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NlGI #2 or ~ equivalent). Example: MotykolS' BR -2 plus manufactured by Dow Corning, U.S.A. Multi-purpose M-2 manufactured by Mitsubishi 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 60 (U.S.A. only) Rocol ASP manufactured by Rocol Limited, U.K. Rocol Paste manufactured by Sumico Lubricant, Japan .AiSitI Use silicone grease. Da Apply a locking agent. Use a medium strength locking agent unless otherwise specified. ,",'&llilll Apply sealant. I Use DOT 4 brake fluid . Use the recommended brake fluid unless otherwise specified . -- .. Use fork or suspension fluid.

1. GENERAL INFORMATION SERVICE RULES MODEL IDENTIFICATION SPECIFICATIONS TORQUE VALUES SERVICE RULES 1-1 1-2 1-3 1- 10 TOOLS LUBRICATION & SEAL POINTS CABLE & HARNESS ROUTING OPTIONAL PARTS 1-14 1-16 1-18 1-23 1.Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Pans that do not meet Honda 's design specifications may cause damage to the motorcycle . 2. Use the special toots designed for this product to avoid damage and incorrect assembl y. 3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English fasteners. 4. ln5lall new gaskets, O'rings , cotter pins, and lock plates when reassembling. 5. When lightening bolts or nuts, begin with the larger diameter or inner boll first. Then tighten 10 the specified torque diagonally in incremental sleps unless a panicular 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 aU electrical wires as show on pages 1-18 through 1-22, Cable and Harness Routing . 1-1

GENERAL INFORMATION MODEl IDENTIFICATION ' 02 - '03 (1) The frame serial number is stamped on th e tight side of the steering head. (3)The carburetor identification number is stamped on the left side of the carburetor body . 1-2 After '03 I , ENGINE SER"" NUMBER J (2) The engine serial number is stamped on the left side of the lower crankcase.

GENERAL INFORMATION SPECIFICATIONS ~ GENERAL ------------------------~------------------------- DIMENSIONS ITEM Overall length Overall width Overall height Wheelbase Seat height (' 02) (,03) (After '03) ('02-'03) (After '03) (,02) ('03) (After '03) (' 02) ('03) (After '03) ('02) ('03) (After '03) Footpeg h eight ('02) ('03) (After '03) SPECIFICATION 2,187 mm (86.1 in) 2,186 mm (8B.1 in) 2.194 mm (86.4 in) 825 mm (32.5 in) 827 mm (32.6 in) 1,254 mm (49.4 in) 1,257 mm (49.5 in) 1,262 mm (49.7 in) 1,488 mm (58.6 in) 1,486 mm (58.5 in) 1,495 mm (58.9 in) 945 mm (37.2 in) 953 mm (37.5 in) 954 mm (37.6 in) 420 mm (16.5 in) 429 mm (16.9 in) 430 mm (16.9 in) ~ME ---4 ::::::~:"'"'" i~~~~~:; '03) ::-::-:--:-: ____ ilJ! 'O '1L- Frame type Front suspension 331 mm (13.0 in) 337 mm (13.3 in) 338 mm (13.3 in) 102.0 kg (225 Ibs) __ ---l~'0f'3C!.1 kg (227 I bsl Twin tube Telescopic fork 270 mm (10.63 in) 281 mm (1'.06 in) 305 mm (12.0 in) 315 mm (12.4 in) Pro-Link front suspensio n axle travel (,02) (After '02) Front suspensio n cushion stroke ('02) Rear suspension Rear wheel travel Rear damper Front tire size Rear tire size Tire brand (Dunlop) Front brake swept area Rear brake Rear brake swept area Casler angie (,02) ('03) (Afte r '03) Traillength (,02) k (,03) (After '03) cit (After '02) ('02-'03) (After '03) ('02-'03) (After '03) 314 mm (12.36 in) 319 mm (12.56 in) Decarbon type with nitrogen gas filled damper 80/100-21 51M, 80/100-21 M/C 51M 110/90-19 62M, 110190-19 M/C 62M Front: K490G/Rear: K695 Front: D745F/Rear: 0756 Hydraulic single disc 334.5 cm' (51.8 in') Hydraulic single disc 391,1 cm' 160.6 in') 21'50' 27" 1' 26"91 ' 114 mm (4,5 in) 109 mm (4.3 in) 108 mm (4.3 in) 7.4 lite;'/2.0 US "al 1.6 lmn nail 1-3

GENERAL INFORMATION - GENERAL (Cont'd) ITEM SPECIFICATION ENGINE Bore and stroke 96.0 x 62.1 mm (3.78 x 2.44 in ) Displacement 449.4 em' (27. 42 cu·in) Compression ratio ('02 -' 03) 11 .5 : 1 (After '03) 12 .0: 1 Valve train Chain drive and OHC with rocker arm In"', "'v. open' ~ " , mm 15· BTDC doses (0 .04 in) lift 50· ABDC Exhaust valve opens 55 0 BBDC closes ('021 25- ATOe (After '02) 15- ATOC lubrication system Forced pressure and wet sump Oil pump type Trochoid Cooling system liquid cooled Air filtration Oiled polyurethane foam Crankshaft type Assembled type Engine dry weight (' 021 29.5 kg (65.0 Ibs) ('03) 29.4 kg (64.8 Ibs) (After '03) 28.9 kg (63.7 Ibs) Cylinder arrangement Single cylinder inc li ned ff' from vertical CARBURETOR Carburetor type Piston valve type Venturi diameter \1140 mm (1.6 i'~) DRIVE TRAIN Clutch system Multi -plate, wet Clutch operation system Cable operated Transmission Constant mesh, 5-speed Primary reduction 2.739 (63123 ) Final reduction ('02 - '03) 3.846 (50' 13) (After '03) 3.692 (48113) Gear ratio , ,, 1.800 (27/15) 2nd 1.470 (25/17) 3,d 1.235 (21 /17) 4th 1.050 (21 /20) 5th 0.909 (20122 ) Gearshift panern left foot operated return system 1-N-2-3-4-5 ELECTRICAL I nition s stem COl Ca acitive Dischar e I nilion 1-4

GENERAL INFORMATION ,-- FUEL SYSTEM ITEM SPECI FI CATIONS fuel tank caoacl!y 7.4 liner (1.96 US gal l.63~al '-- Carburetor identification number '02 FCROOA '03 FCROOB Aher '03 - I- FeROOC Main jet '02 #115 '03 #170 After '03 #165 Slow jet '02 #45 - After ' 02 #42 - Jet needle '02 OBEKR '03 OBE LR After ' 03 NeYR Jet needle clip position (Standard) '02 After ' 03 I- 4th '03 5th Pilot screw initial opening ' 02 1 - 1/4 1 urns out - After '02 1 - 1/2 turns out Float level 8.0 mrn 10.31 in) __ I~l1e speed 1,700 + 100 rpm Throttle~e~ay: 3 5 mm (1 18 114 in) .- Hot starter lever !reeDis 2 3 mm Ill'S l iB in - LUBRICATION SYSTEM m: , U 't mm Cn) I TEM STANDARD SER VICE LIMIT Engine oil capacity - At draininQ I 0.66 liter (0.70 US qt, 0.58 Imp gt) AI filt er change t 0.69IilerJO.73 US qt, O.61J!!!Q gIl - At disassembl O.85Iite~ :~.90 US~51mp gIl Transmission oil capacity At draining 0.59 liter 0.62 US gt, 0.52 Ime gt) At disassembl 0.67 liter (0.71 US gt, 0.59 Imp gtl Recommended engine oil Pro Honda GN4, HP4 (without mo l ybde· num additives) or HP4M (with mo l ybde· num additives ) 4-stroke oil, or equivalent motor oi l - API service classification: SG or Higher JASO T 903 standard: MA or MB viscosity: SEA 10W·40 Recommended transmission oil Pro Honda HP Trans Oil, Pro Honda GN4 or HP4 (without molybdenum additives) 4- stroke oil an or equivalent API service classification: SG or Higher - JASO T 903 standard: MA Viscosity : SAE 10 W·40 Oil pump rotor Ti clearance 0. 15 (0.006) 0.20 0.008 Body clearance 0.15 0.21 (0.006 0.008) Side clearance 0.05 0.13 (C)'002 0.005) - COOLING SYSTEM ITEM SPECIFICATIONS Coolant capacity , At change 1.03 liter p. 09 US gt, 0.91 Imll' g~ At disassembl 1.1 2 l iter ( 1.1 B US qt, 0.99 Imp gt) _ ~adiator cap relief pressure 108 137kPa 1.1 1 .4~~gf/cm', 16 20 psi Recommended antifreeze Pro Honda HP Coolant or an equivalent high quality ethylene - Standard coolant concentration glyco l antifreeze containing silicate·free cor rosion inhibitors,-- 1 : 1 mixture with distilled water 1-5

GENERAL INFORMATION HEAOIVALVES Uolt mm (0) ITEM S TANDARD S ER VICE LIMIT ..... yli I , - Aii,<'03 539 kPa )5.5 I 78 o,H " 600 com - I Valve and Valve clearance I 0.'6, ).03mm Ii ' ).0012 - valve guide . 'mm (0.0110 ).00 ' '0) - Valv, ",m O.D. I 'l¥oFH '955 - 0.'96 ' ~0:'95) Valv, 9uld, I.D. I 5.000 - 5.' 1 -0. '97 5.052 (0. '989) I - Ex 10- Ol ' 1- Valv, 9uld, . I - abo~'- '-h~~d- Valve seat width I 1-: :04l-~ 2.0 10.08) ~:~~e:;;'~'~9 IN ~ 'tm: ~0 '8 : :: Rocker arm 'DO'" "m .D. J.469) - Rock"~ ~" ~Fm --~ ~~ Cam lo b, h"9hl I ' 37.39 >' 472) EX 35.452 -1[ill ~ >.390) ~ 2~ - 25.99: := '0ill!: ~ ~ CYLINOER/PISTON Unit: mm lin ITEM STANDARD SERVICE LIMIT Cylinder I.D. 9S.000 96.015 (3.7795 3.7801) 96.05 (3.781) Out-af-round 0.010 (0.0004) Taoer 0.010 (0.0004) War a e 0.05 (0.002) Piston, Piston mark direction ~IN" mark faein toward the intake side piston Piston D.D. 95.970 95.980 (3.7783 3.7787) 95.87 (3.774) ring Piston 0.0. 1'02 '03 7.0 mm (0.27 in) from the bottom of skirt measurement noin! After '03 5.0 mm (0.20 in) from the bottom of skirt Pislonoin bore t.D. 19.002 19.008 (0.74Bl 0.74B3) 19.03 (0.749) Piston pin O.D. 18.994 19.000 (0.7478 0.74BO) 18.98 (0.747) Piston-to- iston in clearance 0.002 0.014 (0.0001 0.0006) 0.04 (0.002) Top rina mark "R" mark side facin u Piston ring-Io-ring Top 0.065 - 0.100 (0.0026 - 0.0039) 0.1 15 (0.0045) aroove clearance PiSlon ring end To 0.25 0.31 (0.010 0.012) 0.45 (0.018) gap Oil (s ide rail 0.20 0.70 (0.008 0.028) 0.90 (0.035) Cylinder-to-piston clearance 0.020 0.045 (0.0008 0.0018) 0.18 (0.007) Connecting rod small end I.D. 19.016 19.034 (0.7487 0.7494) 19.04 (0.750) Conneclin rod-IO- iston in clearance 0.016 0.040 (0.0006 0.0016) 0.06 (0.002) 1-6

2002-2004 CRF450R Service & Repair Manual

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