2005-2006 Honda CRF450R OEM Service & Repair Manual

A Few Words About Safety Service Information The service and repair Ifllormatton contamed In thiS manual IS Intended for use by qualified professionallechniCIans Attemphng service Of repairs WIthout tile proper traming, loois and eqUIpment could cause Injury 10 you or others It could also damage tile vehICle or create an unsale COnditIOn This manual describes the proper methods and procedures fOf pertormlng sen/Ice, maintenance, and reprurs Some procedures require the use of specially designed tools and dedicated equipment AIry pefSOO who Inlends 10 use a replacement part. servICe procedure or a looilhallS not recommended by Honda, must detSfmlne the risks 10 l!lett personal safety and the sale Operation of the vehicle If you need 10 replace a pari use genuine Honda parIS With the correct part number or an equrvalenl part . We strongly recommend that you do not use replacement parts 01 Interior quality. For Your Customer's Safety Proper setYa and maintenance are essen\Jal to the customers safety and the reliability of t he vehicle Any error or oversight while servicmg a vehicle can result In laulty operatIOn, damage to the vehicle Of Injury 10 others. For Your Safety Because this manual IS mtended lor the professional service technician, we do not provide warnings about many baSic shop satety practJCEIS (e.g .. Hot parts-wear glOves). II you have not recewed shop safety traimng or do not lee! conflOent about your knowledge of sale servICing practice. we recommended that you do not attempt to perform the procedures described in thts manual Some of the most Important general servICe safety precautions are given below. However. we cannot warn you of eNety conceivable hazard thai can anse In pertorm.ng serviCe and repair procedures Only you can decide whether or nOl you should perform a given lask . can cause you 10 be senously hurt or killed. Important Safety Precautions AWARNING Improper ser'VIOO or repairs can create an unsafe oond lion lhal can cause your customer or others to be senously hurt or killed FoUow the procedures and precaUlJOns In this manual and olher serviCe malerials carefully. AWARNING Failure to property follow Instructions and precaubons can cause you to be seriously hurt or killed. Follow the procedures and precautJOnS in thiS manual carefully. 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 01 the instructlOflS belore you beQln, and make sure you have the tools, the replacement or repair parts. and the skills required to perform Ina tasks safely and completely. • Protect your eyes by usmg proper safety glasses, goggles or face shields any time you hammer, drill, grind. pry or work around pressurized air or kqUlds. and springs or other stored-energy components. II there IS any doubt. put on eye protectlOO • Use other protective wear when necessary. Jar example Qloves or safely shoes. Handllflg hot Of sharp parts can cause severe burns or cuts. Before you grab something thaI looks like it can hurt you. stop and put on gloves. • Protect yourseH and others whenever yoo have !he vehicle up in the air. Any lime you lift the vehicle, either With a holst 0( a jack. make sure thai it IS always securely supported Use Jack stands. ¥ake sure the engine is off before you beg,n any seMcing procedures unless the instructIOn tells you to do Otherwise. ThIs Will help eliminate several potentIal hazards: • Carnon monoillde poisoning from eng,ne exhaust Be sure there is adequate vent!tabon whenever you run the engine. • Burns from hot parts Of coolant. LeItha engine and exhaust system cool before wooing In those areas. • InJUry from rnc.VlnQ paris lithe InstructIOn tells you 10 run the engine, be sure your hands, fingers and clOthing are Oul of the way Gasoline vapors 3Ild hydrogen gases from banenes are exploSIVe. To reduce the POSSlblhty of a fire or explo$On, be careful when working around gasaine or batteries • Use only a nonflammable solvent. not gaSOline. to clean parts. • Never dratn or $fore gasotine.n an open contau"ler • Keep aN cigarettes, sparks and ~lIJT1es aw~ from the battery and aU fuel-related parts.

HOW TO USE THIS MANUAL ThIe ~ manual IMICrlbe$ ..... MMCe ptOC«lures lor lila CRF45(IR FaIow II\e Mall'ltenan08 ScrwouIe (Secbon J) tecommeoila\lOflS 10 _ 1hal ..... -..hICIe .. 11'1 PNk openobng condI\IoIL 1'*,1011111011 the first scneduled maon_ is 'o9ry important It oompenu* lor 1he moat_that OOCIM durng the break-on perIOd ~ I and 3 ~ to ..... whole moIoteyde. SectIOn 2 illustrates ptOCIIdutM lor ,8ITI!MIlIinstallillOn 01 oompOllents !hal may be leqI.III'ed 10 P'ftfOm1 .. me. ""*=''Ibed in II>e bIIowIng S8CIJDn!L s.ctooo • tnrough , 6 dltscritNI pafl5 01 the moIO<cyde 9fooped acx:ordIng 10 IocabOfl Fll'ld ..... NeIIon ~ wan! on Ihos paga. !hen tum 10 the table 01 contents on !he linu page oIlIIe lectJort Mot! MClIOnt SI,.\ wiIn an ._bIy or syslom mUSlIallOO, service int:lfmabOf1 and tfoobleshoot>ng b, the section The Iljbsequen! P3ge5 ~ delal!&d procedure If '/O'J (IOn'1 know 1M SOUrce oj the trouble. go 10 6&CtIon 17 Troubleahoo\lng Your "'ety. and the utery 01 Dlhers, Is very impoflam. To 00Ip.,cu make inbtmed ~S we ~_ pmvded safety rTlfissages and other IIIiotmallDn Ifl/oughoul this manual 01 courw, iI IS not ~I Of poasbIe 10 walll you about aM the hazards assoaaled WI1h ~!hIt~. You muat La. )'011< own good jUdgement 'Iou WIll hnd 1IIIPOf1aI11 "!ely inIormiIbon on a vanety or Iotms - • Sate1y Labell - on IIMI .....t>ocIe • Saltty MMugM - pt..:edlld by • safely alert syn-boi i .m one oIlhree av-r WOfUII. DANGER WARNING. Of CAUTION The .. tIgRIIl words mean ".nida!;' :'FIT ~~:",~= ..:..!!IOUSlV ffl?dMilml YOu CAN be KIl1.ED or SERIOUSLY HURT ___ .... ",._ ~ you don'tlollow ;nst'UCIIOnS. tIjltJijil.U' :u~:!s be HURT ~ you don' foIow • Insl'uctJ0n5 _ hOw 10 M<VIca thiS vehcIe cooectty and sale~. "" you read thlll manual, you wlH 100 into"n,,"on !hal Is preceded by a l HOTlCl. sy~ The purpose of ttus message is 10 Ile~ Pf'8Wf1t damage to)'OU' "IIhoCle. other prOperty. or!he environment. w ;:; " Z w Ul ~ :z: o CONTENTS GENERAL INFORMATION MAINTENANCE LUBRICATION SYSTEM FUEL SYSTEM COOLING SYSTEM ENGINE REMOVAlilNSTALLATION CYLINDER HEADNALVES CYLINOERlPISTON CLUTCHIKICKSTARTERIGEARSHIFT LINKAGE CRANKCASEfTRANSMISSIONJCRANKSHAFT FRONT WHEEUSUSPENSIONISTEERING REAR WHEEUSUSPENSION HYDRAULIC BRAKE ELECTRICAL SYSTEM WIRING DIAGRAM TROUBLESHOOTING INDEX

SYMBOLS The symbols used throughout this manual show specIfic service procedures. 11 supplementary information is required pertaining to these symbols. it would be explained specifically in the text without the use 01 the symbols. I ~ Replace the parl(S) with new one(s) before assembly. I , Use the recommended engine oil, unless otherwise specified. I -, Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio 01 1: 1) .... Use multi'purpose grease (lithium based multl·purpose grease NLGI #2 or equivalent). - Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or equivalent). ~ Example: MoIykole'l BR·2 plus manufactured by Dow Corning U.S.A. Multi-purpose M·2 manufactured by Milsubishi Oil, Japan Use molybdenum disulfide paste (conlaining more than 40% molybdenum disulfide, NlGI #2 or equivalent). Example: Molykotee G-n Paste manufactured by Dow Corning U.SA ..-'iID 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. L1a Apply a locking agent. Use a medium strength locking agent unless otherwise specified. ,,- Apply sealant. - I Use DOT 4 brake nuid. Use the recommended brake ftuid unless otherwise specified. I - .. Use fork Of suspenslon fluid.

1. GENERAL INFORMATION SERVICE RULES .. .... .. ........................ ............ ' -2 MODEL IDENTIFICATION .. ···························· ' -2 GENERAL SPECiFiCATIONS························· '-4 LUBRICATION SYSTEM SPECiFiCATIONS ········································ .. . ' -5 FUEL SYSTEM SPECiFiCATIONS················· ' -5 COOLING SYSTEM SPECIFICATIONS ......... ' -5 CYLINDER HEADIVALVES SPECiFiCATIONS········································ ... ' -6 CYLINDER / PISTON SPECIFICATIONS ......... ' -6 CLUTCH / KICKSTARTER / GEARSHIFT LINKAGE SPECIFICATIONS ····· ' -7 CRANKCASE/ CRANKSHAFT/ TRANSMISSION SPECIFICATIONS ·············· ' -7 FRONT WHEEL/SUSPENSION/STEERING SPECiFiCATIONS············································ ' -8 REAR WHEEL/SUSPENSION SPECiFiCATIONS···· ················ ·· ·················· ···· ' -8 HYDRAULIC BRAKE SPECIFICATIONS ········· ' -9 ElECTRICAL SYSTEM SPECIFICATIONS ····· ' -9 STANDARD TORQUE VALUES ···················1-10 ENGINE & FRAME TORQUE VALUES ········ , ·,O LUBRICATION & SEAL POINTS ·················· '·'5 CABLE & HARNESS ROUTING ···················' · '8 OPTIONAL PARTS········································' -24 1-1

GENERAL INFORMATION SERVICE RULES 1. Use genuine Honda 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, O-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 1-18). MODEL IDENTIFICATION 1-2

The Vehicle Identification 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 crank.case. The carburetor identification number is stamped on the left side of the carburetor body. GENERAL INFORMATION 1-3

GENERAL INFORMATION GENERAL SPECIFICATIONS 1-4 Overall i Overall height Wheelbase Sea t height Footpeg height type Front suspensi on Front suspension axle travel Front suspension cushion stroke Rear suspension Rear wheel travel Rear damper Fronllire size Rear tire size Tire brand (Du nlop) Front brake Front brake swept area Rear brake Rear brake swept area Caster angle Trail length tank Displacement Compression ratio Valve train Intake valve opens closes Exhaust valve opens closes (05) (After '05) ('05) (After '05) at 1 mm (0.04 in) lift at 1 mm (0.04 in) lift at 1 mm (0.04 in) lift at 1 mm (0.04 in) tift 825 mm (32.5 in) 1,262 mm (49.7 in) 1,492 mm (58.7 in) 955 mm (37.6 in) 432 mm (17.0 in) i Telescopic fork 280 mm (11.0 in) 315 mm (12.4 in) Pro-Link 320 mm (12.6 in) Decarbon type with nitrogen gas filled damper 80/100-21 51M, 80/100-21 M/C 51M 110/90-19 62M, 110/90-19 MIC 62M Front: D742F/Rear: D756 Hydraulic single disc 334.5 cm 2 (51.8 in2) Hydraulic Single disc 391.1 em' (60.6 in 2) 27°47' 26"47' 109.4 mm (4.31 in) 109.3 mm (4.30 in) 7.2 liter US I 449.4 em] (27.41 cu-in) 12.0: 1 Chain drive and OHC with rocker arm 15 Q BTDe 50° ABDC 55° BBDC 15° ATDe 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 28.9 kg (63.7 Ibs) Cyli nder arrangement ('05) Single cylinder, inclined 6° from vertical __________ -'~~~"-________ i_~~~~~~~iO~'"1i~0~e~d~8~ O~f~co~m~v~e~rt~i~'"~I__1 Clutch operation system Transmission Primary reduction Final reduction Gear ratio Gearshift pattern ,,, 20d 3cd 4th 5th Cable operated Constant mesh, 5-speed 2.739 (63/23) 3.692 (48/13) 1. 800 (27/15) 1.470 (25 / 17) 1.235 (2 1/17) 1.050 (2 1/20) 0.909 (20/22) Left foot operated return system, l -N-2-3-4-5 I I I

GENERAL INFORMATION LUBRICATION SYSTEM SPECIFICATIONS Unit· mm (in) I ITEM STANDARD SERVICE LIMIT Engine oil capacity At draining 0.66 liter (0 .70 US qt, 0.58 Imp qt) At oil and fitler 0.69 liter (0.73 US qt, 0.61 Imp qt) - change At disassembly 0.85 liter (0 .90 US qt, 0.75 Imp qt) Transmission oil capacity AI draining O.591iter (0.62 US qt 0.52 Imp qt) ~ .it disassembly 0.67 liter (0.71 US qt, 0.59 Imp qt) Recommended engine oil Pro Honda, GN4, HP4 (without molybdenum additives) or HP4M (with mo l ybdenum additives) 4-stroke oil, or an equivalent motor oil - API service classification: SG or Higher JASO T 903 standard: MA or MB Viscosity: SAE 10W-40 - - Recommended transmission oii Pro Honda HP Trans Oil, Pro Honda GN4 or HP4 (without molybdenum additives) 4-stroke oil or an equivalent - API service classification: SG or Higher JASO T 903 stand ard: MA Viscosity: SAE 10 W-40 011 pump Tip clearance 0.15 (0.006) 0.20 (0 .008) f--iI~dy clearance 0.15 0.21 (0.006 0.008) Side clearance 0.05 0. 13 (0.002 0.005) FUEL SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Fuel tank capacity 7.2 liter (1.90 US gal. 1.58 Imp gal) Carburetor identification number ' 05 FCROOD After '05 FCROOE Main jet #168 Slow jet , #42 - Jet needle '05 NGGO After '05 NCYQ - Jet needle clip position (Standard) 4th from top - Pilot screw initial opening '05 1-7/8 turns out After '05 ,-t /2 turns out Float level 8.0 mm (0.31 in) - Idle speed 1,700 ± 100 rpm Throttle grip free play 3 5 mm (1 /8 3/16 in ) Hot stan lever free play 2 3 mm (1/ 16 118 in) Thronle position sensor resistance (at 20 Q C/68°F) 4 6 k.(! COOLING SYSTEM SPECIFICATIONS ITEM ,~~E~ ,,097 Imp qt l I At I ¥ I ,I I i '". 1 t.i - 1.4 16-: Jp,i) Pm Hond, HP 0' ,n i :::~~ qU"'''yetnyl- ~~~ .g.~ycol antifreeze containing si licate-free corrosion I i I j w,", 1-5

GENERAL INFORMATION CYLINDER HEADIVALVES SPECIFICATIONS , ITEM STANDARD Cylinder compression 539 kPa (5,5 kgf/cm , 78 psi) at 600 rpm Cylinder head warpage - Valve and Valve clearance IN 0.16 ± 0.03 (0.006 ± 0.001) valve guide EX 0.28 ± 0.03 (0.011 ± 0.001) Valve stem 0.0. IN 5.475 5.490 (0.2156 0.2161 ) EX 4.965 4.980 (0.1955 0.1961) Valve guide 1.0. IN S.SOO 5.512 (0.2165 0.2170) EX 5.000 5.012 (0.1969 0.1973) Stem-Ie-guide clear- IN 0.010 0.037 (0.0004 - 0.0015) ance EX 0.020 - 0.047 (0.0008 - 0.0019) Valve guide projection IN 16,' 16.3 (0.63-0.64) above cylinder head EX 17.9 lB.l {G.7D-O."1 Valve seat width IN 1.1 1.3 (0.04 0.05) EX 1.3 1.5 (0.05 0.06 Valve spring free length IN 40.68 1.602) EX 43.16 (1.699) Rocker arm Rocker arm 1.0. 12.000 12.018 (0.4724 0.4731) -': Rocker arm shaft 0.0. 11.967 11.975 (O.4711 0.4715) Rocker arm-fa-shaft clearance 0.025 0.051 (0.0010 0.0020) Camshaft Cam lobe height IN 37.540 37.780 (1.4779 1.4874) EX 35.187 35.427 (1.3853 1.3948) Valve lifter 0.0. 25.978 25.993 (1.0228 1.0233) Valve lifter bore 1.0. 26.0tO 26.026 (1.0240 1.0246) CYLINDER/PISTON SPECIFICA nONS ; ring '-6 9'P I. I. • I. • Top 0.065 - 0.100 (0.0026 - 0.0039) Unit· mm (in) SERVICE LIMIT - 0.05 (0.002) 4.96 (0.195) 5.552 (0.2186) 5.052 (0.1989) - 2.0 (0 .08) 2.0 (0.08) 39.7 (1.56) 42.2 (1.66) 12.05 (0.474) 11.92 (0.469) 0.10 (0.004) 37.39 (1.472) 35.04 (1.380) 25.97 (1.022) 26.04 (1.025) 0.115 (0.0045) 0.90 (0.035) I. •

2005-2006 Honda CRF450R OEM Service & Repair Manual

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