Honda CRF450R 2012 Service Manual

I ND EX
PI STON REMOVAL ........................... .. .. ................. .. ... 10-6
PRESSURE RELIEF VAL VE .. .... .. .. .... . .. . .... .............. .... .. . 5·5
RADIATOR ··········· .. ···· ··· ·· ·· ···· · ··· ·· ···· · ··· · ···· ··················· ·· · 7·8
RADIATOR COOLANT ················································ 4- 13
RADIATOR RESER VE TANK ········································· 7-9
RADIATOR SHROUD .................................................... 3-4
REAR BRAKE CALIPER ························· ··· ················· 16-20
REAR MASTER CyLINDER ················ ·· ··· ·· ············ ·· ·· 16·15
REAR WHEEL ················ · ··················· ·· ·· ··· ········ · ······· .. · 15-8
REAR WHEELJSU$PENSION SPECiFiCATIONS ·· ·· .. · 1- 11
REGULATOR/RECTIFIER ·· .. ··· .. ··· .. · .... ·· .... ··· .. ·· .... ·· ...... · 17-8
RIGHT CRANKCASE COVER ....... .. ............................. 11-5
SEAT ..... .. ............. .. ..................................................... ··· 3-3
SECONDARY AIR SUPPLY SYSTEM
('05
and '06 California type, After '06)
FUEL SYSTEM ··· .. · .. · .. ··· .. ···· .. · .. ··· .. · ·· · .. · ·· .. ·· .... ·· .. ····· 6-29
MAINTENANCE
.. ·· .... · .. .. ·· .... · .. ·· · .. ·· .... ·· .... · .. · .. · .. · .... · 4-14
SER V ICE INFORMATION
ALTERNATOR·
.. ·· .. ··· .. ·· .... ··· .. · ...... · .. · .. ·· ·· .. ·· .... ·· .... · .. 12-3
BAITERY /CHARGING SYSTEM ... .. .................. .. ... 17-3
CLUTCH/STARTER CLUTCHIKICKSTARTER/
GEARSHIFT
LINKAGE ............................................ 11-3
COOLING SYSTEM .................................................. 7-3
CRANKCASEICRANKSHAFTITRANSMISSION/
BALANCER
···· .. · .. ·· .... · .. ····· .. ·· .. ·· .. · .... ·· .... · .... · .. · .. · .. ·· .. 13-3
CYLINDER HEAONALVES ...................... .. ............... 9-3
CYLINDER/PISTON .... .. ................... .. .. .................. .. 10-3
ELECTRIC STARTER .. ··· .. ···· .. · .... · .. ···· .. ·· .... ·· .. ··· .. ··· .. 19-3
ENGINE REMOVALJlNSTALLATION ....................... 8-3
FRAMElBOOY PANELSIEXHAUST SySTEM .......... 3·2
FRONT WHEEUSUSPEN$IONIS
TEER ING ........... 14-4
FUEL SYSTEM .......................... .. ... ........................... 6-3
HYDRAULIC BRAKE . .. ... ...................... .. ............. .. .. 16-3
IGNITION SySTEM··· .... · .... ·· .. ·· .. ··· .. ·· .. ··· .. ··· .. ··· .. ··· .. 18-3
lIGHTSIMETERlSWITCHES .. ·· .. · .... ·· .. ···· .. ·· .... · .. ··· .. 20-3
LUBRICATION SySTEM·
.... · .. ·· .. ··· .. ·· .... · .... · .... · .... ··· .. 5-3
MAINTENANCE ........................................................ 4-2
REAR WHEEUSUSPENSION .............. .. ............... .. 15·3
SERVICE RUlE $· .. · .. ·· .. · ·· .. ···· .. ·· .. · ·· .. ·· .. ·· .... · .... · .. · .. · .. ·· ·· ·· 1·2
SHOCK ABSORBER
.. ... .. ... .. ............ .. ........................ 15·14
SHOCK
LINKAGE .......... · .... ·· .... · .. ·· .... · .. ···· .... · .. · .... · .... 15-30
SIDE
CO V ER .................................................................. 3·3
SI DESTAND ...... ·· .......... ·· .... ·· .. ··· .. ·· .... · .. ··· .. ··· .. ·· .... · ...... 4-34
SPARK ARRESTER .. ·· .... · .... ·· .. ··· .. ···· .. · .. · ·· ········· .... · .. ···· 4-33
SPARK PLUG · .. · ...... · .. .. · .... · .............. · .. · .. .. .. .... · .. ........ · .. 4-12
STANDARD TORQUE
VAlUES .. · .... · ........ · .... · ............ 1-14
STARTER
CLUTCH .. ·· .... · .... ·· .... · .. ·· .... · .. · .. .. · .... ·· .... · .... 11 ·19
STARTER MOTOR·
........ · .. · .. · .... ·· .. · .... · .. · .. · .. ·· .. ·· .... ·· .... · 19-6
STARTER RELAY
SWITCH ·· .... ·• .. ·· .. ··· .... · .. ··· .. ··· .. ·· .. · 19--1 3
STARTER SWiTCH ·
.. ··· .. ··· .. ·· .. ···· .. ·· .. · ·· .. ··· .. ·· · .. ··· .. ·· .... · 20-9
STATOR·
.... ··· .... ········ ··· .. ··· .. ··· .. ·· .... · .. ·· .... ······· .. ··· .. ·· .... · 12·5
23-2
STEERING HEAD BEARINGS .. · .. ·· .. ·· .. ·· .. ···· .. ···· .. · .. ··· ·· 4-37
STEERING STEM ··
.. ·· .. ·· .. ······· .. ·· .. · ·· · ··· · ·· .. · .. · .. ······ .. ··· ·14· 47
SUB-FRAME .. ·· .. ···· .. ······ .. ······ .. ··· .. ·· .. ······ .. · .. · .. ·· ·· ·· .. · ·· · .. ·· 3-6
SUSPENSION ·
.... ·· .. ··· .. · .. ··· .. ·· .... · .. · .. ··· .. · .. ·· .. ·· ...... · .... ··· 4-34
SWINGARM
.. · .... · .... · .. ··· .. · .... · .... ·· .. · .. · .... · .. ·· .... ·· .. ·· .... ·· 15·36
SWINGARM /SHOCK lINKAGE · .... · .. · .. ·· .. ·· .... ··· .. ·· .. ··· .. 4-35
SYSTEM DIAGRAM
BATIERY /CHARGING SySTEM· .. .... ·· .. · .... .. · .... .. .. .. 17·2
ELECTRIC STARTER
.... · .. .. ...... .... · .. · .. .... · .. • .... .. · .. · .. .. 19·2
IGNITION SYSTEM
.... · .. · .... · .... .. .................... · .. .. · .. .. 18·2
SYSTEM FLOW
PATTERN .. ·· .. ·· .. ·· .. ··· .. · .. ·· .. · .. · ........ · .... ·7 -2
SYSTEM TESTING ·· .... · .. ··· .. ··· .. ·· .. · .. ·· .. ·· .. · .. ·· .. · .... · .... · .. ·· 7-5
TAILLIGHT .. · .. ·· .... · .... · .. ···· .. · .. ··· .. ·· .. ·· .. · .. ··· .. · .. ·· .. · .. ·· · .... · 20-6
THROITLE OPERATION .. ··· .. ··· · ··· .. · .. ·· .. ·· ·· ·· .. · .. · .... ·· .. ·· ·· 4-9
THROTTLE
POS ITION SENSOR INSPECTION · .. ·· .. ··· 18·9
THROTILE POSITION SENSOR REPLACEMENT .... ·· 6·26
TRANSMISSION ASSEMBLY
.. ·· .. · .. · .... ·· .. · ...... ·· .. ·· .... 13·22
TRANSMISSION DISASSEMBLY ··
.... · ...... · .. ·· ...... · .... 13- 11
TRANSMISSION OIL ·· .. ·· .... · ...... ·· .............. · .. ·· .. · .... · .... ·4- 22
TRIPMETER .. .... .. .. ... .. .................. .. .. . .. .................... .. .. 20 -10
TROUBLESHOOTING
BAITERY /CHARGING SYSTEM· .. ··· .. · .. · .. ·· .. · .... · .... ·17-5
CLUTCHIST
ARTER CLUTCHIKICKST ARTER!
GEARSHIFT LINKAGE .... · ........ · .. · .. · ·· · .... · .. · .. · .... · .. .. · 11-4
COOLING SYSTEM
.................................... .. ... .. ... .. . .. 7-4
CRANKCASEiCRANKSHAFTITRANSMISSION/
BALANCER
.. ··· .. ··· .. ····· ·· .. ·· .. ·· · .. ·· · ··· .. ·· .. ···· .. ·· .. ·· .. · ·· .. ·13·7
CYLINDER HEADNALVES
................................ ... ..... 9-6
CYLINDERIPISTON · .. · .... · ...... · .... · .... ·· .... · .. ·· .. · .... ·• .. ·· 10-4
ELECTRIC STARTER
.. · .. ···· .. · .. ·· .. ·· .. ·· .. ····· .. · .. ··· .. ··· .. · 19-4
ENGINE DOES NOT START
OR IS HARD TO
START···
.. · ·· .... · .. ··· .. · ·· .. · .... · .. · ·· .. ·· .. · .. ··· .. · .. · .. ·· .. ·· .. ··· .. · 22 ·2
ENGINE LACKS POWER
.... · .. .. .. .. .. .. .. · .. · .. · .... · .. .. · .. · .. 22 -3
FRAME/BODY
PANElSIEXHAUST SYSTEM .. · ...... ·3·2
FRONT WHEEUSUSPENSIONISTEERING
.. ··· ...... · 14-7
FUEL SYSTEM .... ·· .. ·· .... · .. ··· .. ·· .. · ...... · ...... ·· .. · ........ ·· .. ·6-5
HYDRAULIC BRAKE
·· .. ·· .. ·· .. ·· .... · .. ·· .. · .. ·· .... ·· .... · ...... · 16-5
IGNITION SYSTEM
·· · .... · .. ·· .. ·· .. · .. ··· .. ·· .. · .. ·· .. · .. ·· .... ·· ·18-4
LUBRICATION SYSTEM
. .. .. ........... .. .. ........ .. ... .. ... .. ... 5-3
POOR HANDLING ............... .. ...... .. .......................... 22-7
POOR PERFORMANCE AT HIGH SPEED· .. · .. ··· .... ·· 22-6
POOR PERFORMANCE
AT LOW AND IDLE
SPEED ·
.. · .. ··· .... · .... · .. ··· .... · .. ··· .. ·· .. · .... · .. ·· .. · .. · .. ·· .. ·· .... ·· 22 -5
REAR WHEEUSUSPENSION · .... · .. · .. ·· ···· .. · .. ··· .. ··· .. · 15-7
VAL
VE ClEARANCEiDECOMPRESSOR SYSTEM· .. · ·4·15
VALVE GUIDE REPLACEMENT · ...... · ...... · ............ .. .. · .. 9· 29
VALVE SEAT INSPECTIONIREFACING ...................... S- 30
WATER PUMP .. · ........ · ...... · .. · ........ · .... · ...... · .. · .... · ............ 7-S
WHEELSITIRES ·
.. · .... ·· .. ··· .... · .. ·· .. · .... · .. ·· ...... · .. · .. ·· .... · .... ·4- 36
WIRING DIAGRAM ................ .. ............ .. .. .. ............ .... .. 21-2
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Honda CRF450R 2012 Specifications

General

Engine Type	449cc liquid-cooled single-cylinder four-stroke
Bore x Stroke	96.0mm x 62.1mm
Compression Ratio	12.5:1
Induction	Programmed Fuel Injection (PGM-FI), 46mm throttle body
Ignition	CDI
Transmission	Close-ratio five-speed
Final Drive	#520 chain; 13T/48T
Front Brake	Single 240mm disc with twin-piston caliper
Rear Brake	Single 240mm disc
Front Tire	80/100-21
Rear Tire	120/80-19
Seat Height	37.6 inches
Ground Clearance	13.2 inches
Front Suspension	12.2 inches travel
Rear Suspension	Pro-Link Showa single shock with spring preload, rebound and compression damping adjustability; 12.4 inches travel
Rake	27° 04'
Trail	4.6 inches
Wheelbase	58.3 inches
Curb Weight	249 pounds