l
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)
recomme
nda
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
nsta
liatlO
n
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 impol1an
1.
To
help
you
ma
~e
in
fo
rmed decisions
we
haWl
provided
sa
fe
ty
messages and other information throughout this manual. Of
course.
il
is not practical or
poSS
ible
to
warn
yo
u about all the
ha
za
rds associated with servicing
th
is
I'€hicle.
You
must
use
your own good judge
ment
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. DANG
ER
, 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
Ins
tructions.
fflZQ;@IUt.
"lMm[,)?'
You
CAN be KILLED or SERIOUSLY
HURT if you don't
fo
ll
OW
onstructions.
You
CAN
be
HURT
~
you
don't follow
instructions
• Instructions
-
how
to
ser~
lc
e
this
~ehi
c
le
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
z
..
a:
..
w
>
a:
c
c
z
"
w
z
"
z
w
<J)
iii
<J)
"
:I:
"
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w
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W
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
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