Honda CRF450X (2007) Owner's Manual
IMPORTANT NOTICES
The official Honda Service Manual for your CRF
is available (page 166). It is the same manual
your dealer uses. If you plan to do any service
on your CRF beyond the standard maintenance
procedures in this manual, you will find the
Service Manual a valuable reference.
Read the Warranties Booklet (page 167)
throughly so you understand the coverages that
protect your new Honda and are aware of your
rights and responsibilities.
This motorcycle has no cooling fan. For this
reason, engine overheating and coolant loss will
occur if the engine is kept idling too long when
hot. Additionally, when riding in mud or sand, or
any condition that causes high engine load at low
vehicle speed, the time it takes for the engine to
overheat will be shortened, especially when the
ambient temperature is high. Continuing to
operate the unit in these conditions will result in
engine damage.
Whenever you ride, tread lightly. By staying on
established trails and riding only in approved
areas, you help protect the environment and keep
off-road riding areas open for the future.
If you have any questions, or if you ever need a
special service or repairs, remember that your
Honda dealer knows your CRF best and is
dedicated to your complete satisfaction.
Please report any change of address or ownership
to your Honda dealer so we will be able to
contact you concerning important production
information.
You may also want to visit our website at
www.honda.com
Happy riding!
California Proposition 65 Warning
WARNING: This product contains or emits
chemicals known to the State of California to
cause cancer and birth defects or other
reproductive harm.
A Few Words About Safety
Safety Messages
Service Procedures
Fluids & Filters
Fuel System.......................................................41
Engine Oil .........................................................43
Transmission Oil ...............................................46
Coolant ..............................................................48
Air Cleaner ........................................................51
Crankcase Breather ...........................................53
Engine
Throttle ..............................................................54
Clutch System ...................................................56
Hot Start Lever..................................................60
Spark Plug .........................................................61
Exhaust Pipe/Muffler ........................................62
Spark Arrester....................................................65
Valve Clearance.................................................66
Piston/Piston Rings/Piston Pin..........................75
Chassis
Suspension.........................................................83
Brakes................................................................87
Wheels...............................................................91
Tires & Tubes....................................................92
Side Stand..........................................................94
Drive Chain .......................................................95
Additional Maintenance Procedures .................98
Electrical
Battery .............................................................100
Headlight & Taillight ......................................102
Appearance Care .............................................104
Adjustments for Competition.......................107
Front Suspension Adjustments........................108
Rear Suspension Adjustments.........................122
Suspension Adjustments for Track
Conditions...................................................126
Suspension Adjustment Guidelines.................127
Carburetor Adjustment & Turning Tips ..........130
Chassis Adjustments........................................137
Gearing ............................................................138
Tire Selection for Track Conditions................139
Personal Fit Adjustments ................................140
Tips .................................................................141
Transporting Your Motorcycle ........................142
Storing Your Honda .........................................143
You & the Environment ..................................145
Troubleshooting...............................................146
Taking Care of the Unexpected....................147
If a Fuse Blows ...............................................148
If Your Battery Is Low (or Dead)....................149
Technical Information...................................151
Vehicle Identification ......................................152
Specifications ..................................................153
Torque Specifications......................................154
Emission Control Systems ..............................157
Oxygenated Fuels............................................159
Competition Logbook .....................................160
Optional Parts List...........................................162
Spare Parts & Equipment................................163
Wiring Diagram...............................................164
Consumer Information .................................165
Authorized Manuals ........................................166
Warranty Coverage..........................................167
Warranty Service .............................................168
Contacting Honda............................................169
Your Honda Dealer..........................................170
The Honda Rider’s Club (USA only) .............171
Table of Contents...........................................172
Index ...............................................................174
Quick Reference
Motorcycle Safety
Important Safety Information...............................2
Important Safety Precautions..........................2
Loading.................................................................3
Accessories & Modifications ...............................4
Safety Labels........................................................5
Motorcycle Safety 1
Keep Your Honda in Safe Condition. It’s
important to keep your CRF properly maintained
and in safe riding condition. Having a breakdown
can be difficult, especially if you are stranded
off-road far from your base. To help avoid
problems, inspect your CRF before every ride
and perform all recommended maintenance.
Do not wear loose clothing which could catch on
the control levers, kickstarter, footpegs, drive
chain, or wheels.
Ta ke Time to Learn and Practice. Developing
off-road riding skills is a gradual, step-by-step
process. Start by practicing at low speeds in a
safe area and slowly build your skills.
Personal instruction from an experienced rider
can also be valuable.
If you need assistance, ask your dealer about
riding groups in your area.
Also be sure to read the
Tips & Practice Guide
for the Off-Highway Motorcyclist
booklet that
came with your CRF (USA only).
Be Alert for Off-Road Hazards. The terrain can
present a variety of challenges when you ride
off-road. Continually ‘‘read” the terrain for
unexpected turns, drop-offs, rocks, ruts, and other
hazards. Always keep your speed low enough to
allow time to see and react to hazards.
Ride within Your Limits. Pushing limits is
another major cause of motorcycle accidents.
Never ride beyond your personal abilities or
faster than conditions warrant. Remember that
alcohol, drugs, fatigue, and inattention can
significantly reduce your ability to make good
judgments and ride safely.
Don’t Drink and Ride. Alcohol and riding don’t
mix. Even one drink can reduce your ability to
respond to changing conditions, and your
reaction time gets worse with every additional
drink. So don’t drink and ride, and don’t let your
friends drink and ride either.
Loading
Loading Guidelines
As discussed on this page, we recommended that
you do not carry any cargo on this motorcycle.
However, if you decide to carry cargo, ride at
reduced speeds and follow these commonsense
guidelines:
•Keep cargo small and light. Make sure it
cannot easily be caught on brush or other
objects, and that it does not interfere with
your ability to shift position to maintain
balance and stability.
• Place weight as close to the center of the
motorcycle as possible.
• Do not attach large or heavy items (such as a
sleeping bag or tent) to the handlebar, fork, or
front fender.
• Check that both tires are inflated properly.
Motorcycle Safety 3
Accessories
We strongly recommend that you use only
genuine Honda accessories that have been
specifically designed and tested for your CRF.
Because Honda cannot test all other accessories,
you must be personally responsible for proper
selection, installation, and use of non-Honda
accessories. Check with your Honda dealer for
assistance and always follow this guideline:
• Make sure the accessory does not reduce
ground clearance and lean angle, limit
suspension travel or steering travel, alter your
riding position, or interfere with operating any
controls.
Modifications
We strongly advise you not to remove any
original equipment or modify your CRF in any
way that would change its design or operation.
Such changes could seriously impair your CRF’s
handling, stability, and braking, making it unsafe
to ride.
We also advice you not to make any
modifications or remove any equipment (such as
the USDA qualified spark arrester or emission
control system components) that would make the
motorcycle illegal in your area.
Motorcycle Safety 5
Safety Labels
Operating Controls 7
Operating Controls
Operation Component Locations .........................8
hot start lever
front brake lever
throttle grip
tripmeter
start button
choke knob
shift lever
kickstarter
rear brake pedal
Before Riding 9
Before Riding
Are You Ready to Ride? .....................................10
Is Your Motorcycle Ready to Ride? ...................11
Pre-ride Inspection........................................11
WARNING
Not wearing a helmet increases the
chance of serious injury or death in a
crash.
Be sure you always wear a helmet, eye
protection and other protective apparel
when you ride.
Before Riding 11
Is Your Motorcycle Ready to Ride?
Pre-ride Inspection
Check the following before each ride:
• Engine oil level.............................................44
•Transmission oil level...................................47
• Coolant for proper level................................48
• Cooling system and hoses for condition.......49
• Spark plug for proper heat range, carbon
fouling and high tension cord terminal for
looseness .......................................................61
• Air cleaner for condition and
contamination................................................51
• Clutch operation and freeplay.......................56
• Steering head bearings and related parts
for condition..................................................98
• Carburetor throttle operation ........................55
• Engine idle speed for stable and proper
RPM ............................................................136
•Tires for damage or improper inflation
pressure ........................................................92
• Spokes for looseness.....................................91
• Rim locks for looseness................................91
• Front and rear suspension for proper
operation ..................................................83,84
• Front and rear brakes, check operation ........87
•Drive chain for wear or damage and
adequate lubrication......................................96
•Drive chain guide, sliders and rollers
for damage or wear.......................................97
• Exhaust pipe/Muffler inspection...................62
•Every possible part for looseness (such as
cylinder head nuts, engine mounting bolts,
axle nuts, handlebar holder bolts, fork bridge
pinch bolts, drive chain adjuster, drive chain
guide, wire harness connectors, kickstarter
mounting bolt, etc.) .............................154-156
Basic Operating Instructions 13Basic Operating Instructions 13
Basic Operating Instructions
Safe Riding Precautions................................14
Side Stand .....................................................14
Tripmeter.......................................................14
Starting & Stopping the Engine .........................15
Preparation ....................................................15
Fuel Valve .....................................................15
Starting Procedure ........................................15
Flooded Engine.............................................16
How to Stop the Engine................................16
Shifting Gears.....................................................17
Braking ...............................................................18
Parking................................................................19
Post-ride Inspection............................................20
Break-in Guidelines ...........................................21
Tripmeter
The tripmeter (1) is used to record the distance
traveled (USA: miles, Canada: kilometers) per
trip or section of route.
To operate, pull the tripmeter reset knob (2) out
(OFF) and turn it until the meter shows all zeros
(0), then push the knob in (ON).
(1) side stand
(1) tripmeter
(2) tripmeter reset knob
(1)
OFF
ON
(1)
(2)
Side Stand
The side stand (1) is used to support your CRF
while parked (page 19). To operate, use your foot
to lower the side stand until it is fully extended.
Before riding, raise the side stand.
Starting & Stopping the Engine
Starting Procedure
Always follow the proper starting procedure
described as follow.
5. Warm up the engine; don’t operate the
throttle.
6. About 15 seconds after the engine starts, push
the choke knob back all the way to fully OFF.
If idling is unstable, open the throttle slightly.
Extended use of the choke may impair piston and
cylinder wall lubrication and damage the engine.
High Air Temperature 35°C (95°F) or above
1. Turn the fuel valve ON.
2. Do not use the choke.
3. Keep the throttle fully closed.
4. Start the engine following step 4 under
“Normal Air Temperature.”
Low Air Temperature 10°C (50°F) or below
1. If the temperature is below 0°C (32°F), open
the throttle two or three times. (The engine
requires a richer mixture for starting in cold
weather. When the throttle is so opened, the
accelerator pump will feed extra fuel to the
cylinder, thereby facilitating starting in cold
weather.)
2. Follow steps 1-4 under “Normal Air
Temperature.”
3. Continue warming up the engine until it runs
smoothly and responds to the throttle when
the choke knob is pushed back all the way to
fully OFF.
Extended use of the choke may impair piston and
cylinder wall lubrication and damage the engine.
NOTICE
NOTICE
Basic Operating Instructions 15
(1) fuel valve (2) choke knob
Check the engine oil, transmission oil and
coolant levels before starting the engine (pages
44,47,48).
To restart a warm engine, follow the procedure
for ‘‘High Air Temperature.”
Normal Air Temperature 10°C-35°C (50°F-95°F)
1. Turn the fuel valve (1) ON.
2. Pull the choke knob (2) fully ON, if the
engine is cold.
3. Keep the throttle fully closed.
4. Pull the clutch lever all the way in, and depress
the start button. Or operate the kickstarter to
start the engine. Starting from the top of the
stroke, kick through to the bottom with a rapid,
continuous motion. Do not operate the throttle.
Allowing the kickstarter to snap back freely
against the pedal stop can damage the engine
case.
NOTICE
(1)
(2)
ON
OFF
Flooded Engine
Starting the engine after a stall during riding or
after a fall:
1. Shift the transmission into neutral.
2. Pull the hot start lever all the way in and start
the engine. (Do not open the throttle).
3. As soon as the engine starts, release the hot
start lever.
Starting a flooded engine:
(Using the start button)
1. Do not use the choke.
2. Shift the transmission into neutral with the
throttle fully opened.
3. Pull the clutch and hot start levers all the way
in and depress the start button for 5 seconds.
If the engine starts, quickly close the throttle,
then open it slightly if idling is unstable. If the
engine does not start, wait 10 seconds, and
then follow the regular starting procedure.
4. As soon as the engine starts, release the hot
start lever.
(Using the kickstarter)
1. Do not use the choke.
2. Shift the transmission into neutral with the
throttle fully opened, repeat kickstarter
operation approximately 10 times very slowly
to discharge excessive fuel from the engine.
Close the throttle.
3. Pull the hot start lever all the way in and start
the engine. (Do not open the throttle.)
4. As soon as the engine starts, release the hot
start lever.
How to Stop the Engine
(1)
(2)
(1) throttle (2) engine stop button
Normal Engine Stop
1. Shift the transmission into neutral.
2. Turn the fuel valve OFF.
3. Lightly open the throttle (1) two or three
times, and then close it.
4. Depress the engine stop button (2) until the
engine stops completely.
Failure to close the fuel valve may cause the
carburetor to overflow, result in hard starting.
Emergency Engine Stop
To stop the engine in an emergency, depress the
engine stop button.
Shifting Gears
Remember to close the throttle and pull the
clutch lever in completely before shifting.
Improper shifting may damage the engine,
transmission, and drive train.
Learning when to shift gears comes with
experience. Upshift to a higher gear or reduce
throttle before engine rpm (speed) gets too high.
Downshift to a lower gear before you feel the
engine laboring (lugging) at low rpm.
Downshifting can help slow your motorcycle,
especially on downhills. However, downshifting
when engine rpm is too high can cause engine
damage.
To prevent transmission damage, do not coast or
tow the motorcycle for long distances with the
engine off.
NOTICE
NOTICE
NOTICE
Basic Operating Instructions 17
Parking
Basic Operating Instructions 19
Basic Operating Instructions 21
Break-in Guidelines
Servicing Your Honda 23
Servicing Your Honda
Before You Service Your Honda
The Importance of Maintenance ........................24
Maintenance Safety............................................25
Important Safety Precautions........................25
Maintenance Schedule .......................................26
General Competition Maintenance ....................29
Before & After Competition Maintenance.........33
Between Motos & Practice Maintenance .....33
After Competition Maintenance ...................33
Service Preparations
Maintenance Component Locations...................35
Seat Removal......................................................36
Fuel Tank Removal ............................................37
Subframe Upright Position.................................39
Service Procedures
Fluids & Filters
Fuel System........................................................41
Engine Oil ..........................................................43
Transmission Oil ................................................46
Coolant ...............................................................48
Air Cleaner .........................................................51
Crankcase Breather ............................................53
Engine
Throttle ...............................................................54
Clutch System ....................................................56
Hot Start Lever...................................................60
Spark Plug ..........................................................61
Exhaust Pipe/Muffler .........................................62
Spark Arrester.....................................................65
Valve Clearance ..................................................66
Piston/Piston Rings/Piston Pin...........................75
Chassis
Suspension..........................................................83
Brakes.................................................................87
Wheels................................................................91
Tires & Tubes.....................................................92
Side Stand...........................................................94
Drive Chain ........................................................95
Additional Maintenance Procedures ..................98
Electrical
Battery ..............................................................100
Headlight & Taillight .......................................102
Appearance Care ..............................................104
WARNING
Improperly maintaining this motorcycle or
failing to correct a problem before you
ride can cause a crash in which you can
be seriously hurt or killed.
Always follow the inspection and
maintenance recommendations and
schedules in this owner’s manual.
Servicing Your Honda 25
Maintenance Safety
• Read the instructions before you begin, and
make sure you have the tools and skills
required.
•To help prevent the motorcycle from falling
over, park it on a firm, level surface, using the
side stand or an optional workstand to provide
support.
•To reduce the possibility of a fire or
explosion, be careful when working around
gasoline. Use only a non-flammable (high
flash point) solvent such as kerosene —not
gasoline— to clean parts. Keep cigarettes,
sparks, and flames away from all fuel-related
parts.
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