Honda CRF450X 2005 User Manual

ADDITIONAL ITEMS REQUIRING FREOUENT
REPLACEMENT ··················· ··· ·· ······························ ·· ·· ··· ·4·7
AIR CLEANER·········· ·· ·· ·· ···· ·· ············ ·· ·············· ·· ·· ·· ·······4·10
AIR CLEANER HO USING ··············· ·· · ·· ···· ·· ··· ·· ·········· ·· ··· 6·7
ALTERNATOR CHARGING CQll · ·· .. ·· .. ·· .. ·· ·· .. ··· ··· .. · .. .. 17·8
AUTO-DECOMPRESSION SYSTEM ( After '07) ·· ··· ·· ····2·2
BALANCER GEAR/BALANCER ··································· 13 ·8
BATTERy ····· · ······················ · ······ ··· ·········· · ··········· · ········· 17 -6
BATTERY/CHARGING SYSTEM SPEC1FICATIONS · .. 1· 12
BRAKE FLUiD······················· ·· ······································ 4-29
BRAKE FLUID REPLACEMENT/AIR BLEEDING ···· ·· ··· 16-6
BRAKE PAD WEAR ··· .... · .. ··· · ··· .. · .. ·· .... ·· .. · .. · ··· .. ····· .. ··· .. ·4-30
BRAKE PAD/DISC · .. ·· .... ··· ··· .. ··· .. ·· ·· · .. · ·· · .. · .. ··· .. ····· .... ··16-10
BRAKE PEDAL· .. ····· .. ······ .. ·· ·· .. ·· .. · .. ··· .. ··· ...... ··· .. ··· ·· .. · ·· 16-24
BRAKE
SYSTEM · .. ·· .... ·· .. · .. ···· .. · .. · .. ··· .. ·· .. ·· .. ··· .... · .. ··· .. ··4-30
CABLE
& HARNESS ROUTING ('05 - '07) · .. · .. · .... ··· .. ·· 1-25
CABLE
& HARNESS ROUTING ( After ·07}··· .... ····· .. · .. 1-32
CAM CHAIN TENSIONERICAM CHAIN GUIDE · .. ...... 9-25
CAMSHAFT INSTALLATION .. ·· .. · .. · .... ·· .. · .. ·· ·· .. · ·· ···· .. · ·· 9-39
CAMSHAFT INSTALLATION ('05
- ·07)· .. .. · .... .. ...... · .. ·9 -37
CAMSHAFT REMOVAL ('05
- '07)· .... · .. ...... .. .. .... · .... · .... ·9-S
CAMSHAFT REMOVAL
( After '07) ···· ...... ··· .. ·· .. ·· .... · .. ·9 - '6
CARSURETOR ADJUSTMENT ····· .. ··· ...... ··· .. ····· .... ·· .. ···6-6
CARBURETOR
ASSEMBLY ···· .. ····· .. ··· ...... ··· .. ·· .. ·· .. ·· .. ·· 6-1S
CARBURETOR DISASSEMBLY
.... · .... ··· .. · .... · .. · .. ·· .... · .. ·6-13
CARBURETOR INSTALLATION
...... · ...... · .. · .......... · ...... 6-24
CARBURETOR REMOVAL .. ·· ·· .. ·· ·· .... ·· .. ··· ···· .. ·· .. · .. .. ·· .. ·6 - 11
CHARGING SYSTEM INSPECTION · ·· .. ····· ·· .. ·· .. · .... ·· .. ·17-7
CLUTCH
.. · .. · ·· .... ·· · ·· .. ·· .. ······· .. ··· .. · ·· ·· · .. ·· ...... · ·· ········ .. ··· .. ·1 1-7
CLUTCH
LEVER ··· .... ·· .... ·· .. · ·· ··· .. ·· ·· · .. ··· .... · .. ·· ···· ·· .... ····14-52
CLUTCH SWITCH
......................................................... 20-S
CLUTCH SYSTEM ·
.. ·· .... ····· .... ·· .. · .. ·· .. ·· .... · .. ·· .. ···· .. · .. ·· .. ·4- 31
CLUTCHISTARTER CLUTCH/KICKSTARTER/
GEARSHIFT
LINKAGE SPECIFICATIONS · .. ·· .... ·· ··· .. ·· .. · ' ·9
COMPETlnON MAINTENANCE SCHEDULE .. ······ .. ·· .. ·4·6
COMPONENT LOCATION
ALTERNATOR .... .. .... · .... .. .. .... · .. · .. .. · .. .. .... · .. · .... · .... · .. ·12·2
BAnERY /CHARGING SYSTEM · .... · .... · .. · ............ · .. 17·2
CLUTCH/STARTER CLUTCH/KICKSTARTER/
GEARSHIFT LINKAGE·
.. ·· .. ··· .... ··· .. ··· .. · .... ·· .... ··· .... · .. 1 1·2
CRANKCASEICRANKSHAFTfTRANSMISSIONI
BALANCER ·
.. ······ .. ···· .... ··· .. ··· .. · .. · .... ··· ...... ·· .. ······· .. ···13·2
CYLINDER HEADN ALVES··
...... · .... ··· .. · .. ··· .... · ·· .... ·· .. ·9-2
CYLINDERIPISTON ·
.. .... ·· · .. ··· .... ···· .. ··· ·· .. ··· .. ···· ··· .. · .. 10-2
ELECTRIC
STARTER · .. ·· .. ·········· .. ··· .. ······ .. ··· .. ······ .. ·· 19-2
ENGINE REMOVAUINSTALLATION .. .. .. · .. .. · ...... · .. · .. 8-2
FRONT WHEEUSUSPENS ION /STEERING .. ........ .. 14-2
FUEL SYSTEM ·· .. · .... ·· .. ·· .. · ·· .. ·· .. · .... · .... · .. · .... · ...... ·· .. · ·· ·6-2
HYDRAULIC BRAKE
·· .. · .. ··· .. ······· .. · .... ····· .. ·· .... ·· .. · .. ·· 16-2
IGNITION SYSTEM ···
.. · .. · .. · .. ···· .... ·· .. ····· .... ·· .. ······ .. ·· 18-2
LlGHTSIMETERISWITCHES
.. ···· .. ··· .. ··· ··· .. ···· .... ··· .. ·20-2
REAR WHEEUSUSPENSION .... · .... .. .. .... · .... .. .. · .... · .. 1 5-2
CONTROL CAB LE S ·· .... ·· .. · .. · ·· .. ····· .... ·· .. · ·· ··· .. ·· · .. ······ .. ··4-32
COOLANT REPLACEMENT
... .. ..... .. ................ .. ...... .. .. ... 7-6
COOLING SYSTEM··· .... ····· .. ·· .. ·· ···· .. ··· .. ····· .... ·· .. ··· .... ···4-14
COOLING SYSTEM SPECIFICATIONS
.. · .. ··· .. ··· ...... · .. ··· ' -7
CRANKCASE
ASSEMBLY .... · ...... · .. .. · ........ · .. · ........ · .. ·13-25
CRANKCASE
BEARING REPLACEMENT ···· .. ··· ...... ·· '3 ·16
CRANKCASE
BREATHER ·· .... ·· .. ·· ·· .... ·· .... ···· .. ·· ...... ·· .. · ·4 - 11
CRANKCASE SEPARATION .. ··· .. · .. · .. ·· ·· .. · .... · .. ··· ...... ··13- 'O
CRANKCASE/CRANKSHAFTfTRANSMISSIONI
BALANCER SPECIFICATIONS ('05
. ·07) ...... · ...... · .. .... .. 1·9
CRANKCASEICRANKSHAFTfTRANSMISSIONI
BALANCER SPECIFICATIONS
( After '07} .. · .. .. · .. · .. ...... 1· 10
CRANKSHAFT INSTALLATION
.... · .... · ...... ··· .. ··· .. · .. · .. 13- 21
CRANKSHAFT REMOVAL· ·· .. ·· .. ····· .. ···· .. ·· .. · ........ · .. · ·· 13-14
CYLINDER COMPRESSION TEST·· .. ···· .. ········· .... · .. ·· .. ···9-7
CYLINDER
HEAD ASSEMBLY·· .. ···· .... ·· .. ·· .. ·· .. ··· .. · .. ·· .. ·9-33
CYLINDER
HEAD COVER INSTALLATlON·· .. ··· .. · .. ·· .. ·9 -42
23. INDEX
CY LI NDER HEAD COVER REMOVAL ...... .... .. .. · .. ...... · .. · 9-7
CYLIN DER HEAD DiSASSEMBLy .. · .. ·· .. ···· .. ·· .... ·· .. ·· .. · 9·27
CYLINDER
HEAD INSPECTION .... .. . .. ...................... .. . 9-2S
CYLIN
DER HEAD INSTALLATION· .. ·· .. · .. ·· ·· .. ··· .... .. ····· 9-36
CYLINDER HEAD REMOVAL . .. .................... .. .......... .. . 9-24
CYLINDER HEADN ALVES SPECIFICATIONS· .......... · .. 1-S
CYLINDER
INSTALLATION ········ .... ·· .. · .. ··· .. · .... · ........ · 10-10
CYLINDER
REMOVAL·· .. · .... ·· .... · .... · .. ·· .. ···· .. ··· .. ······ .. ··· 10-5
CYUNDERIPISTON SPECIFICATIONS
........ · .... · .... · ...... 1-8
DRIVE CHAIN ·· .... ····· .. ·· .. ·· .... ··· .. ·· .. ··· .. ·· .. ·· .. · ··· .. · .. · .. · .... · 4·24
DRIVE CHAIN
ROL LER .. ..... .. .. ................... .... .............. 4-28
DRIVE CHAIN SLIDER ........ .. ... .. ....... .. .................... .... . 4-27
DRIVE SPROCKET · .. ··· .. ·· .... ·· .. ············ .. ·· .... ······ ...... ··· .. ·· 8-4
DRIVE/DRIVEN SPROCKET
...... · .......... .. · .... · .... · .... .. .... · 4·28
ELECTRIC STARTER SPECIFICATION·
.... · ...... · ...... · .... 1-13
EMISSION CONTROL SYSTEMS ·· .. ·· .. · .. · .. · .. ··· ...... ·· .. · 1-40
ENGINE & FRAME TORQUE VALUES ...... · .... .. ...... · .. · 1-14
ENGINE
GUARD· .. · .. ··· .. ·· .. ··· .. ···· .. ··· .. ·· .. ·· .... ······ .... · .. ·· .. ·· 3-5
ENGINE
IDLE SPEED··· .. ·· .. · ·· · .. ··· .. ···· .. ····· .... ·· .. ·· ·· ...... ·· 4-22
ENGINE
INSTALLA TION· .. ····· ·· ·· .. ···· .. · ·· ·· .... ··· .. ··· .. · .. ·· .. · S-S
ENGINE OIUOIL FILTER·· .... ·· .. ·· · .. ·· · .. ·· .. ·· .... ·· .. ···· ...... ·· 4-19
ENGINE REMOVAL·
.. ·· .. ·· .... ·· .... · .. ···· .. ·· .. · .... ·· .. · ··· ...... ·· .. 8-5
ENGINE
STOP BUnON · .... · .. · ...... · .. · ............ .. ............ 20-7
EXHAUST PIPEIMUFFLER .......................................... 4-33
EXHAUST SYSTEM ............................................ .. ........ 3·9
FLYWHEEL .... """"" " ", ,, ,, ,,,,,,,,,,,,,,,,,,,, ,, ,, ,,,, ,,,, ,,,, ,, ,,,,,, 12-5
FORK .. .. .... .. ... .. .. .. . .. ....... .. .. .. .. ... .. ......... .. ......... .. .... ······ 14-13
FRONT BRAKE CALIPER······ .. ·· .. ·· ·· ···· .. ·· .. ·· ·· .. ·· .. · ·· ·· ·· 16-18
FRONT
MASTER CyLINDER .. .... .. · .. · ...................... · .. 16-12
FRONT
VISOR .............. ... ........................... ... .. ... ........... 3-5
FRONT
WHEEL··· .. · .. · .... · ...... · .. ·· .. ···· .. ·· .. · .. ···· .. ·· .... ······ .. 14-S
FRONT WHEEUSUSPENSION/STEERING
SPECIFICATIONS
................................ .. ...................... 1-11
FUEL
LINE··· .. · .... ·· .. • .. · .. ·· .... .. · .. ·· .. ··· · .. ·· ·· ··· .. · ··· .. · .... · .. · ·· .. · 4-8
FUEL
STRAINER SCREEN ... .. .................. .. ........ .. ......... 4-8
FUEL
SYSTEM SPECIFICATIONS .. ......................... .. ... 1-7
FUEL
TANK .. ·· .. ·· · .. · .. ············· .. ·· ·· ·· ····· ·· · ·· .. ········ .... ·· .. · .. ·· 3-8
GEARSHIFT LINKAGE·····
.. · ·· .. ···· .. ···· .. · .. ·· .... ·· .. ···· ...... 11 ·24
GENERAL SPECIFICATIONS · .. ·· .. ···· .. · .. ···· .. · ·· .. ··· .. · .. ··· .. 1-5
HANDLEBAR ·· .... ··· .... ··· .. ·· .. •··· .. ··· .. ···· .. · .. ·· .... ·· · .. ··· .. · .. · 14-33
HEADLIGHT
.. ........................... .. .............. .. .... .. ............ 20·4
HEADLIGHT AIM ...... ... .. .. .... ... .. ........... .. .. .. ....... .. ......... 4- 31
HOT START .. · .... ·· .. · .. ··· .. ·· .. ·· ··· ··· .. ·· ·· .. ·· .. ·· ·· .. ··· · ···· .. · .. ··· 4-10
HPSD
(Honda P ro gressive Steering Damper) : After '07
FRONT WHEEUSUSPENSION/STEERING .... ······ 14-38
TECHNICAL FEATURE····· .. · .. ·· ······ .. ·· .. ···· .. ·· .. ······· .. ··· 2-3
HYDRAULIC BRAKE SPEC IFICATIONS· .. ···· .. ·· .... ····· .. 1·12
IGNITION COIL
...... ·· .... · .. ···· .. ··· .. ·· .. ···· .. ·· .. · .. · .. · .... ·· ...... · 18·7
IGNITION CONTROL
MODULE (ICM) .. · .... .... · .. · ...... · .. 18-7
IGNITION SYSTEM INSPECTION···· .. ·· ........ ·· .... ·· ...... · 18-5
IGNITION SYSTEM SPECIFICATIONS .. · .... · .... .. · .. · .. .. · 1-12
IGNITION TIMING ....... .. . .. .. ......................... .... ..... .. ... .. 18-8
KICKSTARTER .. .. .. ...... · ...... · .... .. ...... · .. .. .... .. · .... .. · .. .. · .. · 11 ·15
lEFT CRANKCASE COVER INSTALLAT ION· .. · .......... 12·6
LEFT CRANKCASE COVER REMOVAL .. · .. · .. · .. · .. · ...... · 12·4
LIGHTS/METER/SWITCHES SPECiFiCATIONS ·······
.. '-13
LUBRICATION & SEAL POINTS · .. · ........................ · .... 1- 21
LUBRICATION SYSTEM DIAGRAM .............. .. ............. 5-2
LUBRICATION SYSTEM SPECiFiCATIONS· ........ · ...... · 1-7
MAINTENANCE SCHEDULE ('05. '06 ) ...... .. .. .... ........... 4-4
MAINTENANCE SCHEDULE (Aft er ·06) .. ........ .. · .. ·· .. · .. · 4-5
MODEL IDENTIFICATION
.............. · .... · .......... .. .. · .. · ...... · 1-2
NUTS . BOLTS. FASTENERS .. · ...... · ........ .. .. .. ............ · .. 4-36
Oil JET .......................................................................... 5·6
OIL
PUMp ··· .. · .... · ...... ·· .. · ·· .. ··· .. ··· .. ···· .. ·· .... · .. · .... · .. · .. · .... · .. 5-7
Oil STRAINER .. ·· .. · ·· ·· .... ·· .. ··· .. ··· .. ···· .. ·· .. ·· · .. · .. · .. ··· .. · .. ··· .. 5·4
OPTIONAL PARTS··
.. · .. · ··· .. ··· .. ·· · .. ···· .. ·· .. ·· .. ··· ·· .... · .. · .. ··· 1-37
PilOT SCREW ADJUSTMENT .. .. ..... .. ............ .... ........ 6-27
PISTON INSTALLATION· .. ···· .. ··· .. ···· .. ·· .. ·· .. · ···· ·· · ·· ···· .. · 10-9
23-1

Honda CRF450X 2005 Specifications

General

Engine Type	449cc liquid-cooled single-cylinder four-stroke
Bore x Stroke	96.0mm x 62.1mm
Compression Ratio	12.0:1
Valve Train	Unicam, four-valve
Transmission	Wide-ratio five-speed
Front Brake	Single 240mm disc with twin-piston caliper
Rear Brake	Single 240mm disc
Front Tire	80/100-21
Rear Tire	110/100-18
Wheelbase	58.3 inches
Seat Height	37.6 inches
Fuel Capacity	1.9 gallons
Ignition	Solid-state CD with electronic advance
Final Drive	520 O-ring-sealed chain
Front Suspension	47mm inverted Showa cartridge fork with 16-position rebound and 16-position compression damping adjustability; 12.4 inches travel
Rear Suspension	Pro-Link Showa single shock with spring preload, 17-position rebound damping adjustability, and compression damping adjustment separated into low-speed (13 positions) and high-speed (3.5 turns); 12.4 inches travel
Induction	Keihin 40mm flat-slide carburetor