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This manual should be considered a permanent part of the motorcycle Honda CRFX Congratulations on choosing your Honda CRF. Service your Honda CRF with a Cyclepedia service manual. Get full-color photographs, color wiring diagrams, specifications and step-by-step procedures. The Service Manual for your CRF is available from your authorized Honda dealer . It is the same manual your dealer uses. If you plan to do any service on your.

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All information in this publication is based on the latest product information available at the time of approval for printing. Shift the transmission into neutral.

Turn the fuel valve OFF. If proper adjustment still cannot be obtained or the adjustment, tighten the lock nut. If the brake lever free play repqir 0. Tighten the lock nut at the desired pedal height. Refer manuual the Honda Service Manual or see your autho- rized Honda dealer for brake bleeding. Apply Honda able to tailor your CRF specifically for your weight, ers or 6 mm by rotating the standard holders Manuao Lock or an equivalent to the threads of these riding style and course conditions.

Drive chain links Shock spring These parts and tools may be ordered from your au- Standard 48 Teeth, Aluminum.

Honda CRF450X 2005 Service Manual

Inspect and Clean, Adjust, Manal or Tepair if necessary. Check spoke tension and rim lock nut security. Lubricate any sliding surface, O- rings. Inspect the cable carefully for shorts or corrosion. Additional corrosion protec- reepair or other damage that may restrict throttle con- tion is offered by using Honda Dielectric Grease on trol in anyway.

Move the handlebar from lock to lock all electrical connections. Refer to the Honda Service Manual. Disconnect the fuel line from the fuel valve. Put the breather tube in the steering stem nut. The fuel line leading to the carburetor must be dis- 1. Install the fuel tank on the frame. Disconnect the crankcase breather tube. Loosen the screw on the air cleaner connecting tube 1.

Loosely attach the upper and lower ends of the Subframe Removal clamp. Remove the seat page Install the side covers, side cover bolts and collars. Tighten the screw on the air cleaner connecting tube 7.

Install the muffler clamp by aligning the tab of the clamp. Remove the left engine guard bolt and left engine guard. Repaif and Adding Engine Oil 2.

Support the CRF in an upright position on xrf level 1. Install the engine oil filler cap. Recommended Transmission Oil 1. Run the engine for three minutes, then shut if off.


Support the CRF in an upright position on a level without molybdenum additives 4-stroke oil, or an 1.


A ity ethylene glycol based anti-freeze containing corro- coolant loss of 0. Remove the fuel tank page Disconnect the spark plug cap. Remove the spark plug. If you want to check the igni- Coast to a stop, then remove and inspect the spark the same number of turns. The porcelain insulator around the center elec- trode should appear tan or medium gray.

Allow the air cleaner to dry thoroughly. After dry- ing, soak the air cleaner in clean Pro Honda Foam Filter Oil or an equivalent air cleaner oil.

Apply air cleaner oil to the entire surface, inner and outer, and rub it with both repiar to saturate the air cleaner with oil. The clutch springs have sky blue paint. Coat the clutch plates with transmission oil. Install the six clutch springs and bolts.

Install the six clutch discs which has yellow paint on Tighten the bolts in a crisscross pattern in 2 or 3 steps. Cylinder Head Cover Removal Remove the crankshaft hole cap. Lubricate the rear brake pedal pivot and pivot bolt and NOTE: Remove the cam sprocket bolt. Remove the camshaft holder assembly bolts, camshaft Rotate the primary drive gear lock bolt crankshaft maual assembly, intake valve lifters and shims.

Then attach a piece of wire to the As you remove the camshaft holder assembly, the in- cam chain to prevent it from falling into the crankcase. Install the newly selected shims on the valve retainers. Install the cam shaft holder assembly onto the cylinder Insert the feeler gauge between the intake valve lifter Place the cam sprocket and align mahual timing mark on head manuual the intake cam lobes facing up as illustrated and cam lobe.

Measure the intake valve clearance and exhaust valve Measure the decompressor arm clearance by inserting Decompressor Arm Clearance Adjustment clearance. Spark Plug Installation Cylinder Head Cover Installation Insert the feeler gauge right exhaust valve clearance Install the spark plug by hand until finger tight, then Remove the spark plug hole packing from the cylinder 0. Remove the engine hanger nut, engine hanger A bolt, sion stroke page Loosen the cylinder bolt.

Remove the cam shaft holder assembly page Remove the dowel pins, cylinder head gasket and cam Piston Removal Cylinder Removal chain guide. Place clean shop towels in the crankcase to keep the Remove the cylinder bolt and cylinder. Apply engine oil to the piston rings and install the pis- We recommended you consult the 40 Manual or ton rings. Piston Installation Cylinder Installation Clean off repwir gasket material from the gasket surface Place manuql shop towels in the crankcase to keep the of the crankcase, being careful not to let any material piston pin clips from falling into the crankcase.

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Install the dowel pins and new cylinder head gasket.

Route the cam chain though the cylinder. Route the cam chain through the cylinder head. Install the cylinder bolt and cylinder head bolts to the Install the cylinder head. Install a new exhaust pipe gasket, exhaust pipe and tighten the radiator hose clamp securely.

Install the cylinder head cover page If any roughness or play is felt, refer to the Honda Service Manual for replacement or ad- justment procedures. Reassemble the fuel filter in the reverse order of re- moval.

Make sure the O-ring is in place. Check the fuel valve and fuel filter for msnual The fuel filter is mounted on the bottom of the fuel tank. Install the fuel filter in the fuel tank.

Check the axle for runout. Do not attempt to disassemble, disconnect or replacement. Rein- is probably air in the brake system and it must be bled. Refer to the Honda Service Manual or see your autho- Tighten the screws. If either pad is worn anywhere per to determine the pad wear. Adjustment Removal, Cleaning and Inspection 1. Loosen the rear axle nut. For maximum service life, the drive chain should be 2.

Loosen the lock nuts and turn the adjusting bolt cleaned, lubricated, and adjusted before each outing. Lubrication Commercially prepared drive chain lubricants may be purchased at most motorcycle shops and should be used in preference to motor oil.

Loosen the muffler clamp bolt. Check the flange bolts for tightness. Tighten the muffler B bolt and muffler A bolt. Remove the muffler page Install a new exhaust pipe gasket, exhaust pipe and Lubrication exhaust pipe joint nuts and tighten to the specified Periodically, disconnect the throttle, clutch and hot start torque. Apply Honda Thread Lock or an equivalent to the threads. Apply oil to the threads and flange surface. Rear brake reservoir cap bolts 0. When the hot start lever is is opened.

Fuel is metered by the main jet, jet needle and needle Fuel is metered by the slow jet and mixed with air from 2. Drain the remaining fuel in the float bowl by remov- jet. Disconnect the fuel line. Remove the hot start cable holder. Remove the throttle drum cover bolt and throttle 5. Remove the sub frame page