Contents
Contents
MOTORCYCLE SAFETY............................. 1
Important Safety Information ........................... 2
Important Safety Precautions ........................ 2
Accessories & Modifications ........................... 3
Accessories & Modifications ........................ 3
Labels ............................................................... 4
INSTRUMENTS & CONTROLS.................. 9
Operation Component Locations .................... 10
Indicator .......................................................... 11
MIL Blink Pattern ....................................... 11
Current DTC/Freeze DTC........................... 11
Circuit Inspection ........................................ 12
DTC Index................................................... 13
BEFORE RIDING......................................... 15
Are You Ready to Ride? ................................ 16
Is Your Motorcycle Ready to Ride? ............... 17
Pre-ride Inspection ...................................... 17
BASIC OPERATING INSTRUCTIONS .... 19
Basic Operating Instructions ........................... 20
Safe Riding Precautions .............................. 20
Starting & Stopping the Engine ...................... 21
Fast Idle Knob ............................................. 21
Preparation .................................................. 21
Starting Procedure....................................... 21
How to Stop the Engine .............................. 22
Break-in Guidelines ........................................ 23
SERVICING YOUR HONDA...................... 25
Before You Service Your Honda
The Importance of Maintenance ..................... 26
Maintenance Safety ........................................ 27
Important Safety Precautions ...................... 27
Maintenance Schedule .................................... 28
General Competition Maintenance ................. 30
Before & After Competition Maintenance ..... 34
Between Heats & Practice Maintenance ..... 34
After Competition Maintenance.................. 34
Service Preparations
Maintenance Component Locations ...............36
Seat ..................................................................37
Fuel Tank ........................................................38
Subframe .........................................................40
Service Procedures
Fluids & Filters
Fuel System .....................................................44
Fuel ..............................................................44
Refueling Procedure ....................................44
Fuel Line......................................................44
Fuel Pressure Relieving ...............................45
Fuel Line Replacement ................................45
Fuel Pump Filter Replacement ....................48
Fuel Pressure Increasing ..............................52
Engine Oil .......................................................53
Oil Recommendation ...................................53
Checking & Adding Oil...............................54
Changing Engine Oil & Filter......................54
Transmission Oil .............................................56
Oil Recommendation ...................................56
Checking & Adding Oil...............................57
Replacing Transmission Oil.........................57
Coolant ............................................................58
Coolant Recommendation............................58
Checking & Adding Coolant .......................58
Cooling System Inspection ..........................59
Coolant Replacement...................................59
Air Cleaner ......................................................60
Cleaning.......................................................60
Crankcase Breather .........................................62
Draining .......................................................62
Engine
Throttle ........................................................... 63
Throttle Freeplay ......................................... 63
Throttle Inspection ...................................... 64
Engine Idle Speed ........................................... 65
Idle Speed Adjustment ................................ 65
Clutch System ................................................. 66
Clutch Lever Adjustment ............................ 66
Clutch Lever Freeplay................................. 66
Other Inspections & Lubrication................. 67
Clutch Operation ......................................... 67
Clutch Disc/Plate Removal ......................... 68
Clutch Disc/Plate Inspection ....................... 69
Clutch Disc/Plate Installation...................... 69
Spark Plug ...................................................... 71
Spark Plug Recommendation ...................... 71
Spark Plug Inspection & Replacement........ 71
Valve Clearance .............................................. 72
Cylinder Head Cover Removal ................... 72
Positioning At TDC On The Compression
Stroke........................................................... 72
Valve Clearance Inspection......................... 73
Camshaft Removal ...................................... 74
Shim Selection............................................. 76
Camshaft Installation................................... 77
Crankshaft Hole Cap Installation ................ 79
Cylinder Head Cover Installation................ 79
Piston/Piston Rings/Piston Pin ....................... 81
Cylinder Head Removal .............................. 81
Cylinder Removal........................................ 83
Piston Removal............................................ 84
Piston Ring Removal................................... 84
Piston/Piston Pin/Piston Ring Inspection.... 84
Piston Ring Installation ............................... 85
Piston Installation........................................ 85
Cylinder Installation.................................... 86
Cylinder Head Installation........................... 87
CRF450R.book Page 6 Thursday, July 8, 2010 9:34 AM
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