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FRAME/ BODY PANELS/EXHAUST SYSTEM

ENGINE GUARD

LEFT/RIGHT ENGINE GUARD

REMOVAL/INSTALLATION

Remove

the

bolt,

colia

r and

engine

guard.

Install

the

engine

guard,

collar

and

tighten

the

bolt

securely.

CENTER ENGINE GUARD

REMOVAL/INSTALLATION

Remove

the

bolts

and collars.

Remove

the

center

engine

guard

from

the

reserve

tank.

Install

the

center

engine

guard

aligning

its

tabs

with

the

reserve tank

groove

Install

the

collars

and bolts.

Tighten

the

bolts

securely.

FRONT VISOR

REMOVAL/INSTALLATION ('05 - '07)

Remove the bolts and front visor.

BOl

TS/COLLARS

3-5

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 2009
Category	Motorcycle
Language	English

Honda CRF450X 2009 User Manual

Table of Contents

Questions and Answers:

Honda CRF450X 2009 Specifications

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