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CLUTCH/STARTER CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE

"·20

Remove the starter clutch assembly.

Remove the

bolts. gear holder, reduction gear A and

1ii~~~i~

idle

gear

DISASSEMBLY/INSPECTION

Check that the starter driven gear turns counter-

clockwise smoothly and does not turn clockwise.

Remove

the

driven

gear

and

needle bearing

from

starter clutch

outer

Remove the snap ring and one-way clutch from

clutch

outer

NEED

SNAPAING

CLUTCH

",reFR

DRIVEN

GEAR

ONE-WAY CLUTCH

How to Use this Manual3
Contents3
Symbols4
Table of Contents5
General Information Contents5
Service Rules6
Model Identification6
- Vehicle Identification Number7
- Engine Serial Number7
- Carburetor Identification Number7
- Name Plate (U.S.A.) or Safety Certification Label (Canada)7
- Emission Control Information Label8
General Specifications9
Lubrication System Specifications11
Fuel System Specifications11
Cooling System Specifications11
Cylinder Head/Valves Specifications12
Cylinder/Piston Specifications12
Clutch/Starter Clutch/Kickstarter/Gearshift Linkage Specifications13
Crankcase/ Crankshaft/ Transmission / Balancer Specifications (,Os - ·07)13
CRANKCASE/CRANKSHAFT/ TRANSMISSION / BALANCER SPECIFICATIONS Iafter ·07)14
Front Wheel/Suspension/Steering Specifications15
Battery/Charging System Specifications16
Hydraulic Brake Specifications16
Ignition System Specifications16
Electric Starter Specification17
Lights/Meter/Switches Specifications17
Engine and Frame Torque Values18
Standard Torque Values18
- Insulator Band21
- Cylinder Head Side Insulator Band (After'07)21
- Cylinder Stud Bolt21
- Water Hose Clamp21
- Frame22
- Lubrication and Seal Points25
- Cable and Harness Routing (05-07)29
- Secondary Air Supply System (05 and 06 California Type, 07)35
- Cable and Harness Routing (after 07)36
- Optional Parts41
Parts42
- Source of Emissions44
- Exhaust Emission Control System44
- Crankcase Emission Control System44
Emission Control Systems44
- Exhaust Emission Control System (Pulse Secondary Air Injection System): 05 and 06 California Type, after 0645
- Prohibited Actions45
- Servicing the Honda45
- Fuel Permeation Emission Control System (after 07)46
- Noise Emission Control System46
- Rebuilt Engine46
- Technical Feature Contents47
- After the Engine Starts48
- Auto-Decompression System (after 07)48
- During Starting (When Engine Is Off)48
- HPSD: after 0749
- HPSD Characteristics50
- Frame/Body Panels/Exhaust System Contents53
- Service Information54
- Torque Values54
- Troubleshooting54
  - Seat Installation55
  - Seat Removal55
  - Side Cover Removal/Installation55
  - Radiator Shroud Removal/Installation56
  - Center Engine Guard Removal/Installation57
  - Front Visor Removal/Installation57
  - Left/Right Engine Guard Removal/Installation57
  - Front Visor Removal/Installation (after 07)58
  - Sub-Frame Removal58
  - Sub-Frame Installation59
  - Fuel Tank Removal/Installation60
- Exhaust System61
  - Muffler Removal/Installation (05-07)61
  - Muffler Removal/Installation (after 07)63
  - Exhaust Pipe Removal65
  - Exhaust System Installation66
  - Maintenance Contents69
  - Maintenance Service Information70
  - Maintenance Schedule (05, 06)72
  - Maintenance Schedule (after '06)73
- Competition Maintenance Schedule74
- Additional Items Requiring Frequent Replacement75
- Fuel Line76
- Fuel Strainer Screen76
- Throttle Operation77
- Air Cleaner78
- Hot Start78
- Crankcase Breather79
  - Spark Plug Inspection80
  - Spark Plug Removal80
- Radiator Coolant81
- Cooling System82
  - Secondary Air Supply System (05 and 06 California Type, after 06)82
  - Valve Clearance Inspection83
  - Valve Clearance/Decompressor System83
  - Valve Clearance Adjustment84
  - Decompressor Clearance Inspection/Adjustment (05-07)86
  - Decompressor System (after 07)87
  - Engine Oil/Oil Filter87
  - Oil Level Inspection87
  - Engine Oil and Filter Change88
- Engine Idle Speed90
- Oil Level Inspection90
- Transmission Oil90
- Transmission Oil Change91
- Drive Chain92
  - Drive Chain Adjustment92
  - Drive Chain Cleaning and Lubrication92
  - Drive Chain Slack Inspection92
  - Drive Chain Replacement93
- Drive Chain Slider95
- Drive Chain Roller96
- Drive/Driven Sprocket96
- Brake Fluid97
  - Fluid Filling97
  - Fluid Level Inspection97
- Brake Pad Wear98
- Brake System98
  - Lever Position Inspection98
  - Brake Pedal Height99
- Clutch System99
- Headlight Aim99
- Control Cables100
- Exhaust Pipe/Muffler101
  - Exhaust System Inspection101
  - Spark Arrester Inspection/Cleaning101
  - Spark Arrester Removal101
  - Front Suspension Inspection102
  - Sidestand Inspection102
  - Spark Arrester Installation102
  - Rear Suspension Inspection103
- Swingarm/Shock Linkage103
- Nuts, Bolts, Fasteners104
- Wheels/Tires104
- Steering Head Bearings105
  - Lubrication System Contents107
  - Lubrication System Diagram108
  - Lubrication System Service Information109
  - Oil Strainer Removal/Inspection110
  - Oil Strainer Installation111
  - Pressure Relief Valve Removal/Inspection111
  - Oil Jet Removal/Inspection112
  - Pressure Relief Valve Installation112
  - Oil Jet Installation113
  - Oil Pump Disassembly113
  - Oil Pump Inspection113
  - Oil Pump Assembly114
  - Fuel System Contents115
  - Fuel System Component Location116
  - Fuel System Service Information117
  - Carburetor Adjustment120
  - Idle Mixture and Idle Speed120
  - Air Cleaner Housing Removal121
  - Air Cleaner Housing Installation123
  - Carburetor Removal125
  - Carburetor Disassembly127
  - Jet Needle/Throttle Valve127
  - Choke Knob/Throttle Sensor128
  - Accelerator Pump/Float/Jets129
  - Carburetor Assembly132
  - Carburetor Installation138
  - Throttle Position Sensor Replacement140
  - Best Idle (05, 06: 49 States and Canada Type Only)141
  - Pilot Screw Adjustment141
  - Idle Drop Procedure (05 and 06 California Type, 07, after 07)142
  - System Inspection143
  - Pair Check Valve Ispection144
  - Pair Control Valve Removal/Installation144
  - Air Supply Pipe Removal/Installation145
  - Cooling System Contents147
  - System Flow Pattern148
  - Cooling System Service Information149
  - Cooling System Troubleshooting150
  - Coolant (Hydrometer Test)151
  - Coolant Gravity Chart151
  - System Testing151
  - Coolant Replacement Preparation152
  - Radiator Cap/System Pressure Inspection152
  - Replacement/Air Bleeding153
  - Radiator Removal/Installation154
  - Mechanical/Oil Seal Inspection155
  - Radiator Reserve Tank Removal/Installation155
  - Water Pump155
  - Water Pump Removal156
  - Bearing/Mechanial Seal/Oil Seal Replacement158
  - Water Pump Installation159
  - Engine Removal/Installation Contents163
  - Engine Component Location164
- Engine Removal164
  - Engine Service Information165
  - Drive Sprocket Installation166
  - Drive Sprocket Removal166
  - Engine Removal167
- Engine Installation170
- Drive Sprocket171
  - Cylinder Head/Valves Contents173
  - Cylinder Head/Valves Component Location174
  - Cylinder Head/Valves Service Information175
  - Cylinder Compression Test179
  - Cylinder Head Cover Removal179
  - Camshaft Removal (05-07)180
  - Camshaft Disassembly182
  - Camshaft Inspection183
  - Camshaft Assembly186
  - Camshaft Removal (after 07)188
  - Rocker Arm Inspection191
  - Rocker Arm Shaft Inspection191
  - Cam Sprocket/Decompressor Weight/Spring Inspection192
  - Decompressor Shaft/Plunger Inspection192
  - Camshaft Holder Bearing Replacement193
  - Camshaft Holder Inspection193
  - Valve Lifter Inspection193
  - Camshaft Holder Bearing Assembly194
  - Cylinder Head Removal196
  - Cam Chain Tensioner/Cam Chain Guide Removal197
  - Cam Chain Tensioner/Cam Chain Guide Inspection198
  - Cam Chain Tensioner/Cam Chain Guide Installation198
  - Cylinder Head Disassembly199
  - Cylinder Head Inspection200
  - Valve Spring Inspection200
  - Valve/Valve Guide Inspection200
  - Valve Guide Replacement201
  - Valve Seat Inspection/Refacing202
  - Valve Seat Refasing203
  - Cylinder Head Assembly205
  - Cylinder Head Installation208
  - Camshaft Installation (05-07)209
  - Camshaft Installation (after 07)211
  - Cylinder Head Cover Installation214
  - Cylinder/Piston Contents217
  - Cylinder/Piston Component Location218
  - Cylinder/Piston Service Information219
  - Cylinder/Piston Troubleshooting220
  - Cylinder Removal221
  - Cylinder Inspection222
- Piston Removal222
  - Piston Ring Removal222
  - Piston/Piston Ring Inspection223
  - Cam Chain Tensioner Lifter Inspection224
  - Connecting Rod Inspection224
- Piston Installation225
- Piston Ring Installation225
- Cylinder Installation226
  - Clutch/Starter Clutch/Kickstarter/Gearshift Linkage Contents229
  - Clutch/Starter Clutch/Kickstarter/Gearshift Linkage Component Location230
  - Clutch/Starter Clutch/Kickstarter/Gearshift Linkage Service Information231
  - Right Crankcase Cover Removal233
  - Right Crankcase Cover Installation234
  - Clutch Removal235
  - Clutch Spring Inspection237
  - Clutch Center Inspection238
  - Clutch Discs Inspection238
  - Clutch Lifter/Needle Bearing Inspection238
  - Clutch Plates Inspection238
  - Clutch Lifter Lever Inspection239
  - Clutch Outer Guide Inspection239
  - Clutch Outer Inspection239
  - Needle Bearing Inspection239
  - Clutch Installation240
  - Kickstarter Disassembly243
  - Kickstarter Inspection243
  - Kickstarter Removal243
  - Kickstarter Assembly245
  - Kickstarter Installation246
  - Starter Clutch Removal247
  - Starter Clutch Disassembly/Inspection248
  - Starter Clutch Assembly250
  - Starter Clutch Installation251
  - Gearshaft Linkage Removal252
  - Gearshaft Linkage Inspection253
  - Gearshift Spindle Inspection253
  - Ratchet Pawl Inspection253
  - Gearshift Linkage Installation254
  - Alternator Contents257
  - Alternator Component Location258
  - Alternator Service Information259
- Stator259
  - Left Crankcase Cover Removal260
  - Flywheel Removal261
  - Stator Removal261
  - Flywheel Installation262
- Left Crankcase Cover Installation262
  - Crankcase/Crankshaft/Transmission/Balancer Contents265
  - Crankcase/Crankshaft/Transmission/Balancer Component Location266
  - Crankcase/Crankshaft/Transmission/Balancer Component Service Information267
  - Crankcase/Crankshaft/Transmission/Balancer Troubleshooting271
  - Balancer/Gear Balancer Inspection272
  - Balancer/Gear Balancer Installation272
  - Balancer/Gear Balancer Removal272
- Crankcase Separation274
  - Transmission Disassembly275
  - Bushing Inspection276
  - Gear Inspection276
  - Mainshaft/Countershaft Inspection277
  - Shift Fork Inspection277
  - Shift Fork Shaft Inspection277
- Crankshaft Removal278
  - Shift Drum Inspection278
  - Transmission Bearing Inspection278
  - Crankshaft Inspection279
- Crankcase Bearing Replacement280
  - Crankcase Bearing/Oil Seal Location280
  - Crankshaft Bearing280
  - Left Crankcase282
  - Transmission/Balancer Bearings282
  - Right Crankcase284
- Crankshaft Installation285
- Transmission Assembly286
  - Countershaft (05-07)287
  - Mainshaft (after 07)287
  - Countershaft (after 07)288
  - Transmission Installation288
- Crankcase Assembly289
  - Front Wheel/Suspension/Steering Contents291
  - Front Wheel/Suspension/Steering Component Location292
  - Front Wheel/Suspension/Steering Service Information294
  - Front Wheel/Suspension/Steering Troubleshooting297
  - Axle Inspection298
  - Front Wheel Removal298
  - Front Wheel Disassembly299
  - Wheel Bearing Inspection299
  - Wheel Rim Inspection299
  - Front Wheel Assembly300
  - Front Wheel Installation302
  - Fork Removal303
  - Fork Disassembly305
  - Outer Tube and Slider Disassembly307
  - Fork Damper Disassembly308
  - Fork Cap Inspection309
  - Fork Center Bolt Inspection309
  - Slider/Outer Tube Inspection309
  - Bushing/Back-Up Ring Inspection310
  - Fork Damper Inspection310
  - Fork Spring Inspection310
  - Fork Assembly311
  - Outer Tube and Slider Assembly311
  - Fork Damper Refilling/Assembly312
  - Fork Damper Operation Inspection315
  - Fork Damper Instllation/Preparation316
  - Fork Damper Installation317
  - Fork Installation320
  - Oil Capacity Adjustment320
  - Standard Position321
  - Handlebar Removal322
  - Handlebar Installation324
- After '07327
  - HPSD (Honda Progressive Steering Damper): after 07 Removal/Installation328
  - HPSD (Honda Progressive Steering Damper): after 07 Inspection329
  - Spherical Bearing Replacement329
  - HPSD (Honda Progressive Steering Damper): after 07 Disassembly330
  - HPSD Assembly332
  - Steering Stem Removal337
  - Bearing Replacement338
  - Steering Stem Installation340
  - Clutch Lever Removal/Installation342
  - Rear Wheel/Suspension Contents343
  - Rear Wheel/Suspension Component Location344
  - Rear Wheel/Suspension Service Information345
  - Rear Wheel/Suspension Troubleshooting349
  - Rear Wheel Removal350
  - Rear Wheel Disassembly351
  - Rear Wheel Assembly352
  - Rear Wheel Installation355
  - Shock Absorber Removal356
  - Bladder Replacement357
  - Shock Absorber Disassembly357
  - Damper Disassembly360
  - Damper Rod Disassembly362
  - Piston Ring Replacement362
  - Damper Rod Inspection364
  - Rod Guide Case Inspection364
  - Damper Assembly365
  - Shock Absorber Installation371
  - Shock Linkage Removal372
  - Shock Absorber Inspection374
  - Shock Arm Needle Bearing374
  - Shock Link Needle Bearing376
  - Swingarm Removal378
  - Swingarm Disassembly380
  - Swingarm Assembly381
  - Swingarm Installation382
  - Hydraulic Brake Contents385
  - Hydraulic Brake Component Location386
  - Hydraulic Brake Service Information387
  - Hydraulic Brake Troubleshooting389
  - Brake Fluid Replacement/Air Bleeding390
  - Brake Fluid Filling/Air Bleeding391
  - Brake Pad Replacement394
- Brake Pad/Disc394
  - Brake Disc Inspection395
  - Front Master Cylinder Disassembly396
  - Front Master Cylinder Removal396
  - Front Master Cylinder Inspection397
  - Front Master Cylinder Assembly398
  - Front Master Cylinder Installation398
  - Rear Master Cylinder Disassembly399
  - Rear Master Cylinder Removal399
  - Rear Master Cylinder Assembly400
  - Rear Master Cylinder Inspection400
  - Rear Master Cylinder Installation401
  - Front Brake Caliper Disassembly402
  - Front Brake Caliper Removal402
  - Front Brake Caliper Assembly403
  - Front Brake Caliper Inspection403
  - Front Brake Caliper Installation404
  - Rear Brake Caliper Removal404
  - Rear Brake Caliper Disassembly405
  - Rear Brake Caliper Inspection406
  - Rear Brake Caliper Assembly407
  - Rear Brake Caliper Installation407
  - Brake Pedal Installation408
  - Brake Pedal Removal408
  - Battery/Charging System Contents411
  - Battery/Charging System Component Location412
  - Battery/Charging System Diagram412
  - Battery/Charging System Service Information413
  - Battery/Charging System Troubleshooting415
  - Battery Charging (USA Only)416
  - Battery Removal/Installation416
  - Battery Testing416
  - Voltage Inspection416
- Charging System Inspection417
  - Charging Voltage Inspection417
  - Current Leakage Inspection417
  - Alternator Charging Coil Inspection418
  - Regulator/Rectifier Removal/Installation418
  - Regulator/Rectifier System Inspection418
  - Ignition System Contents419
  - Ignition System Component Location420
  - Ignition System System Diagram420
  - Ignition System Service Information421
  - Ignition System Troubleshooting422
  - Ignition Coil Primary Peak Voltage423
  - Ignition System Inspection423
  - Exciter Coil Resistance424
  - Ignition Pulse Generator Peak Voltage424
  - Ignition Coil Inspection425
  - Ignition Control Module (ICM) Removal/Installation425
- Ignition Timing426
- Ignition Coil Removal/Installation (after 07)426
- Ignition Coil Removal/Installation (05-07)426
- Throttle Position Sensor Inspection427
- Electric Starter Contents429
- Electric Starter Component Location430
- Electric Starter System Diagram430
- Electric Starter Service Information431
- Electric Starter Troubleshooting432
- Starter Motor Removal434
- Starter Motor Disassembly/Inspection434
- Starter Motor Assembly438
- Ground Line441
- Starter Relay Switch Inspection441
- Starter Motor Installation441
- Starter Relay Switch Removal/Installation442
- Power Input Line442
- Operation Check442
- Lights/Meter/Switches Contents443
- Lights/Meter/Switches Component Location444
- Lights/Meter/Switches Service Information445
- Headlight Bulb Replacement446
- Headlight Removal/Installation (05-07)447
- Headlight Removal/Installation (after 07)448
- Tail Light Inspection448
- Tail Light Removal/Installationn448
- Engine Stop Button Inspection449
- Clutch Switch Inspection450
- Clutch Switch Removal/Installation450
- Starter Switch Inspection451
- Tripmeter Removal/Installation452
- Wiring Diagram454
- Troubleshooting Contents455
- Engine Does Not Start or Is Hard to Start456
- Engine Lacks Power457
- Poor Performance at Low and Idle Speed459
- Poor Performance at High Speed460
- Poor Handling461
- Index463

Brand	Honda
Model	CRF450X 2008
Category	Motorcycle
Language	English

Honda CRF450X 2008 Service Manual

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