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HOW TO USE THIS MANUAL
ThtS service manual descnbes th e servi ce procedures tor the
CRF450X.
Follow Ihe Ma in tenance Schedule (Sedoon 4) recommenda tions to
ensure that the ve hicle is ,n pea~ operahng condition and the emIssion
1ev€ls are withi", the standards set by the U.s. Environrmmtal
ProtecTion Ag<lncy (EPA) and Calrlo,ma Air Resources Board (CARB).
Pertorm,ng the '"5\ schedUled maintenance '5 very imiX'ftant. It
compensales for the IniMI W ear that occurs during the break.,n
period.
Sections 1 and 4 apply to the whole motorcycle. Section 3 Il lustrates
procedures lor remDValli nstaliatlOn of components that may t>e
required to perlorm service described in Ihe l olJow ,ng sections.
Section 5 through 20 describe parIs of the motorcycle, grouped
accord,ng to location.
Find the section you wa nt on This page, then tu rn to the table 01
conlents on the lirst page 01 the section.
Most sectiOils start wit h an assembly or system illustrahon. 5elVlCe
inlormation and troubleshooting lor the section. The subsequent
pages gi ve detailed procedu re .
It you are not fam il iar with Ihis motorcycle. read Technicat Featu re in
Sectron 2.
If you don't know tile source 01 the Irouble, go to section 22
TrouOleshootlng.
Your satety. and the safety of others. Is very impol1an1. To he lp
you ma~e informed decisions we haWl provided safety
messages and other information throughout this manual. Of
course. il is not practical or poSSible to warn yo u about all the
haza rds associated with servicing th is I'€hicle.
You must use your own good judgement
You will find important safety Information In a ~ariety 01 torms
induding:
• Safety Labe ls - on the vehicle
• Safety Messages - preceded by a safety alert symbol Land
one 01 three stgnal words. DANGER, WARNING. or CAU·
TION .
These srgn~1 words mean:
,:; • You WI LL be KILLED or SERIOUSLY
r.'.l.Jdf1:h' HUI'1T if you don't fol low Inst ructions.
fflZQ;@IUt.
"lMm[,)?'
You CAN be KILLED or SERIOUSLY
HURT if you don't foll OW onstructions.
You CAN be HURT ~ you don't follow
instructions
• Instructions - how to ser~lce this ~ehicle correctly and safely,
AS you read this manual, you will find information that IS pl'€ceded by a
l..NOnro symbol. The purpose of this message IS to help prev!ml
damage to your I'€hlCle, other property, or Ihe (lflVlfOnment
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CONTENTS
GENERAL INFORMATION
MAINTENANCE
LUBRICATION SYSTEM
FUEL SYSTEM
COOLING SYSTEM
ENGINE REMOVAUINSTALLATION
CYLINDER HEADNALVES
CYLINDER/PISTON
ALTERNATOR
FRONT WHEEl/SUSPENSION/STEERING
REAR WHEEUSUSPENSION
HYDRAULIC BRAKE
BATTERY/CHARGING SYSTEM
IGNITION SYSTEM
ELECTRIC STARTER
LIGHTS/METER/SWITCHES
WIRING DIAGRAM
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.
¢l'P
Replace the part(s) with new one(5) before assembly.
...-
""78
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).
• ..s;;;m.
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: Moly\<ot eJ!l BR-2 plus manufactured by Dow Corning U.S.A.
Multi-purpose M-2 manufactured by Milsubishi 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 Racol Limited, U.K.
Rocol Paste manufactured by Sumico lubricant , Japan
...-'iiSitI
Use silicone grease.
Dum
Apply a locking agent. Use a medium strength locking agent unless otherwise specified .
.,('Illll!
Apply sealant.
Use DOT 4 brake fluid. Use the recommended brake lIuid unless otherwise specified .
..
Use fork or suspension fluid.
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1. GENERAL INFORMATION
SERVICE RULES ··· .. ·· ...... ········ .. ·················· 1-2
MODEL IDENTIFICATION··························· 1-2
GENERAL SPECIFICATIONS ··········· ··· ······· · 1-5
LUBRICATION SYSTEM
SPECiFiCATIONS ··· ·· ·· ·· ···· ·· ··· ··· ···· ·· ··· ······ ·· ··1-7
FUEL SYSTEM SPECIFICATIONS······· ······· 1·7
COOLING SYSTEM SPECIFICATIONS ······1·7
CYLINDER HEADIVALVES
SPECIFICATIONS ··· ····································· 1·8
CYLINDER/ PISTON SPECIFICATIONS .. .... 1·8
CLUTCH/STARTER CLUTCH/
KICKSTARTER/ GEARSHIFT LINKAGE
SPECiFiCATIONS ····· ·· ································· 1-9
CRANKCASE/CRANKSHAFT/
TRANSMISSION/ BALANCER
SPECIFICATIONS (,OS - ·07)-······················ 1-9
CRANKCASE/CRANKSHAFT/
TRANSMISSION/ BALANCER
SPECIFICATIONS IAfter ·07) ······· ········· ·· ·· 1· 10
FRONT WHEEL/ SUSPENSION/ STEERING
SPECIFICATIONS ······································ 1· 11
REAR WHEEL/SUSPENSION
SPECIFICATIONS ································ .. .. ·1 · 11
HYDRAULIC BRAKE SPECIFICATIONS··· 1- 12
BATTERY/ CHARGING SYSTEM
SPECIFICATIONS ············· ·· ····· ················· 1· 12
IGNITION SYSTEM SPECIFICATIONS ·· ·· 1· 12
ELECTRIC STARTER SPECIFICATION ····· 1· 13
LIGHTS/ METER/SWITCHES
SPECIFICATIONS .................................. .. . 1- 13
STANDARD TORQUE VALUES··············· 1· 14
ENGINE & FRAME TORQUE VALUES···· 1·14
LUBRICATION & SEAL POINTS ···· ·· ··· ·· · ·· 1·21
CABLE & HARNESS ROUTING
('OS - ·07) ············· .. ···································· 1·25
CABLE & HARNESS ROUTING
IAfter '07) .. .. ...... ... ... ... .. .. ... ........................ 1· 32
OPTIONAL PARTS··· .. ····························· ·· 1·37
EMISSION CONTROL SYSTEMS ............ 1-40
1-1
GENERAL INFORMATION
SERVICE RULES
1. Use genuine Honda or Honda- re commended 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 sc r ews 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 pans for proper installation and operation.
8. Route all electrical wires as shown in the Cable and Harness Routing.
- '05 - '07: (page 1-25)
- After '07: (page 1-32)
MODEL IDENTIFICATION
'05 - '07 shown:
1-2
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The Vehicle Id entification Number IV.I.N.) is stamped on the right side
of the steering head.
GENERAL INFORMATION
The engine serial number is stamped on the left sid e of the lower ~~=~~~~~~~~~~~~~~---,
crankcase.
The carburetor identification number is stamped on the left side of the
ca rburetor body.
The name plate (U.S.A.) or Safety Certification Label (Canada) is
attached on the right side of the frame.
ENGINE SERIAL NUMBER
1-3
GENERAL INFORMATION
The Vehicle Emission Control Information label is attached on the rear
'05 - '06 California type, '07 U.S. A. :
fender (' 05 - '06 California type, ' 07 U.S.A.!.
/'
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EMISSION CDNTROllNFORMATION LABEL
The Vehicle Emission Control Information label is attached on the rear
After '07 U.S.A. and Canada :
fender (After '07 U.S.A. and Canada ).
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/ada type only
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EMISSION CONTRO~NFORMATION LABEL
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1-4
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GENERAL INFORMATION
GENERAL SPECIFICATIONS
ITEM S PECIA C ATION
DIMENSIONS Overall length ('05 - '07) 2,180 mm (85.8 in)
(After ' 07) 2,179 mm (85.8 in)
Overall width 821 mm (32.3 in)
Overall height 1,273 mm (50 .1 in)
Wheelbase 1'05 - '07) 1,483 mm (58.4 in)
(After '07) 1,480 mm (58.3 in)
Seat height 963 mm (37.9 in)
Footpeg height 431 mm (17.0 in)
Gr ound clearance 345 mm (13.6 in)
FRAME Frame type Twin tube
Front susp ension Telescopic fork
Front suspensio n axle travel 279 mm (" .0 i n)
Front suspensio n cushi on stroke 315 mm (12.4 in )
Rear suspension Pro-link
Rear w heel tr avel 313 mm (12.3 in)
Rear damper Decarbon type with nitrogen gas filled
damper
Front tire size 80/100· 21 5 1 M
Rear tire size ,,0/100· 1884M
Tire brand (Dunlop ) ('05- '07) Front: D742F
(After '07) Front: D742FA
Rear: 0756
Fr ont brake Hydrauli c single disc
Front brake swe pt area 334.5 cm
2
(51.8 in
1
)
Rear brake Hydraulic sing le disc
Rear brake swept area 391 .1 cm! (60.6 1n2)
Caster angle ('05 - '07) 27" 10'
(After '07) 27 °03'
Trail length ('05 - '07) 110 mm (4.3 in )
(After '07) 114.7 mm (4.52 in )
Fu el tank capacity ('05 - ' 07) 8.6 liter (2.27 US gal, 1.89 Imp gal)
(After '07) 7.2 liter (1.90 US gal, 1.58 I mp gal )
Fu el tank reserve capacity ('05 - '07) 1.4 liter (0.37 US gal, 0.31 Imp gat)
(After '07) 1.6 liter (0.42 US gal, 0.35 Imp gat)
ENGINE Bore and s1roke 96.0 x 62.1 mm (3. 78 x 2.44 in )
Dis placement 449 cm' ( 27.4 cu· in)
Co mpressi on ratio 12.0 : 1
Valve train Chain drive and OHC with rocker arm
Intake valve opens at 1.0 mm (0.04 in) lift 10" BTOC
closes at 1.0 mm (0.04 in) lift 45 " ABDC
Exhaust valve opens at 1.0 mm (0.04 in) lift 50 " BBOC
closes at 1.0 mm (0.04 in) lift 15" ATOC
Lubrication system Forced pressure and wet sump
Oil p ump type Tr ochoid
Cool ing system Liquid cooled
Air filtration Oiled polyu ret hane foam
Crankshaft type Assembled type
Engine dry weight 32.3 kg (71.2 IbsJ
Cylinder arr angement Single cylinder, inclined 6" from ve rtical
CARBURETOR Ca r bu r etor type Piston valve type
Venturi d iamete r 40 mm (1.6 in)
1-5
GENERAL INFORMATION
ITEM SPECIFICATION
DRI VE TRAIN Clutch system Multi -plate, wet
Clutch operation system Cable ope rated
Transmissi on Constant mesh, 5-speed
Primary reduction 2.739 (63123 )
Final reduction 3.923 (51 /13)
Gea r ratio
, ,,
2.230 (29/13)
2nd 1.625 (26116)
3,d 1.235 (2 1/17)
. th lOOO (1 9119 )
5th 0.826 ( 19123)
Gearshift panern Left foot operated return system,
l -N-2 -3-4-5
ELECTRICAL Ignition system leM (Ignition Control Module )
Starting system Electric starter motor and kickstarter
Charging system Single phase output al tern ator
Regu lato r/r ectifier SeR shorted/Single pha se , ha lf wave
rectification
lighting system Alternator
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2005-2013 CRF450X Service & Repair Manual
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Description
Get your hands on the comprehensive repair manual for the 2005-2013 Honda CRF450X four-stroke bike. This manual covers everything from complete tear down and rebuild, to pictures and part diagrams, torque specs, maintenance, troubleshooting, and more. With 464 pages, it provides all the essential information you need.
This manual features clickable chapters and is searchable, making it easy to find the information you're looking for. There are no restrictions on printing or saving/burning to disc, giving you the flexibility to use the manual as needed.
- Complete tear down and rebuild
- Pictures and part diagrams
- Torque specs
- Maintenance procedures
- Troubleshooting guidance
- 464 pages
Whether you're a professional mechanic or a DIY enthusiast, this manual is an invaluable resource for maintaining and repairing your Honda CRF450X. It covers a wide range of topics including pump, strut, primary reduction gear, switches, troubleshooting, over, kickstart, idle, valves, stator, linkage, cooler, fender, frame, specs, tank, diagram, cover, conrod, cams, line, displacement, viscosity, carb, switchs, camshaft, trouble, shaft, switch, psi, plastics, instruction, adjust, forks, diy, system, transmission, axle, piston, fuel injection, size, drive train, swinger, panels, brakes, data, lights, problem, online, rotor, plug, light, air, head, chart, crankshaft, gearshift, starter, brake, valve clearance, bars, throttle cable, trees, mixture screw, weight, electronic, specifications, fuse, tree, cylinder, cables, rod, main jet, coolant, carburetor, coil, clutch, fuel pump, carburettor, handle, four, motor, schedule, speed, clutch, electric, pads, illustration, exhaust, width, problems, boot, boots, rotors, triple, fuel, hydraulic, parts, schematic, flywheel, struts, information, instructions, kicker, front, cam, oversized, operation, fix, slow jet, tire, rebuild, start, jug, change coolant, error codes, kick, fix, bar, starting, reference, efi, rectifier, plate, radiator, compression ratio, crank, regulator, muffler, guides, guide, stroke, oversize, swingarm, plastic, battery, troubleshoot, fenders, tires, charging, installation, gas, pgm-fi, skis, length, shop, bore, workshop, able, magneto, spring, which engine oil, drive, connecting rod, charge, pilot jet, no spark, seat, torque specs, body, suspension, tork, fluid, ignition, rear, error code, ski, performance, side, overhaul, wheel, carburetor, intake, install, lubrication, track, bogey.
