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2005
Honda CRF450R
OWNER’S MANUAL & COMPETITION HANDBOOK
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Introduction
Congratulations on choosing your Honda CRF
motocross motorcycle.
As you read this manual, you will find
information that is preceded by a
symbol. This information is intended to help you
avoid damage to your Honda, other property, or
the environment.
NOTICE
When you own a Honda, you’re part of a
worldwide family of satisfied customers – people
who appreciate Honda’s reputation for building
quality into every product.
Unless you are mechanically qualified and have
the proper tools, you should see your Honda
dealer for the service and adjustment procedures
discussed in this manual.
Your CRF is a high performance racing
motorcycle that utilizes the latest motocross
technology and is intended for competition use in
sanctioned, closed-course events by experienced
riders only.
The official Honda Service Manual for your CRF
is available (page 156). 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.
Be aware that motocross is a physically
demanding sport that requires more than just a
fine motorcycle. To do well, you must be
excellent physical condition and be a skillful
rider. For the best results, work diligently on
your physical conditioning and practice
frequently.
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.
Before riding, take time to get acquainted with
your CRF and how it works. To protect your
investment, we urge you to take responsibility for
keeping your CRF well maintained. Scheduled
service is a must, of course. But it’s just as
important to observe the break-in guidelines, and
perform all the pre-ride and other periodic checks
detailed in this manual.
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
You should also read the owner’s manual before
you ride. It’s full of facts, instructions, safety
information, and helpful tips. To make it easy to
use, the manual contains a table of contents, a
detailed list of topics at the beginning of each
section, and an index at the back of the book.
Happy riding!
Introduction
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A Few Words About Safety
Your safety, and the safety of others, is very important. And operating this motorcycle safely is an important responsibility.
To help you make informed decisions about safety, this manual contains a section devoted to Motorcycle Safety, as well as a number of Safety Messages
throughout the manual.
Safety Messages are preceded by a safety alert symbol and one of three signal words: DANGER , WARNING , or CAUTION .
These signal words mean:
DANGER
You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.
WARNING
You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.
CAUTION
You CAN be HURT if you don’t follow instructions.
Of course, it is not practical or possible to warn you about all hazards associated with operating or maintaining a motorcycle. You must use your own good
judgement.
Safety Messages
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Contents
MOTORCYCLE SAFETY...............................1
Important Safety Information..............................2
Important Safety Precautions..........................2
Accessories & Modifications ..............................3
Safety Labels .......................................................4
Service Procedures
Fluids & Filters
Fuel System .......................................................34
Engine Oil .........................................................36
Transmission Oil ...............................................39
Coolant ..............................................................41
Air Cleaner ........................................................43
Crankcase Breather ...........................................45
TIPS ................................................................135
Transporting Your Motorcycle ........................136
Storing Your Honda.........................................137
You & the Envionment....................................138
Troubleshooting...............................................139
OPERATING CONTROLS .............................5
Component Locations .........................................6
TECHNICAL INFORMATION ..................141
Vehicle Identification ......................................142
Specifications ..................................................143
Torque Specifications ......................................144
High Altitude Carburetor Adjustment .............147
Oxygenated Fuels............................................148
Competition Logbook .....................................149
Optional Parts List ..........................................151
Spare Parts & Equipment................................152
Wiring Diagram...............................................153
BEFORE RIDING ............................................7
Are You Ready to Ride? .....................................8
Is Your Motorcycle Ready to Ride?....................9
Pre-ride Inspection..........................................9
Engine
Throttle ..............................................................46
Engine Idle Speed .............................................48
Clutch System ...................................................49
Hot Start Lever..................................................53
Spark Plug .........................................................54
Valve Clearance.................................................55
Piston/Piston Rings/Piston Pin..........................66
BASIC OPERATING INSTRUCTIONS ......11
Safe Riding Precautions................................12
Starting & Stopping the Engine ........................13
Break-in Guidelines ..........................................15
CONSUMER INFORMATION ...................155
Authorized Manuals ........................................156
Contacting Honda............................................157
Your Honda Dealer..........................................158
The Honda Rider’s Club (USA only) .............159
Chassis
Suspension.........................................................74
Brakes................................................................79
Wheels ...............................................................83
Tires & Tubes ....................................................84
Drive Chain .......................................................86
Exhaust Pipe/Muffler ........................................89
Additional Maintenance Procedures .................92
Appearance Care ...............................................94
SERVICING YOUR HONDA........................17
Before You Service Your Honda
The Importance of Maintenance .......................18
Maintenance Safety ...........................................19
Important Safety Precautions........................19
Maintenance Schedule ......................................20
General Competition Maintenance ...................22
Before & After Competition Maintenance........26
Between Motos & Practice Maintenance .....26
After Competition Maintenance ...................26
TABLE OF CONTENTS ..............................160
INDEX ............................................................162
QUICK REFERENCE
ADJUSTMENTS FOR COMPETITION .....97
Front Suspension Adjustments..........................98
Rear Suspension Adjustments .........................111
Suspension Adjustments for Track
Conditions ...................................................115
Suspension Adjustment Guidelines.................116
Carburetor Adjustments & Tuning Tips ..........119
Chassis Adjustments........................................131
Gearing ............................................................132
Tire Selection for Track Conditions................133
Personal Fit Adjustments ................................134
Service Preparations
Component Locations .......................................28
Seat Removal ....................................................29
Fuel Tank Removal ...........................................30
Subframe Removal............................................32
Contents
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Motorcycle Safety
This section presents some of the most important
information and recommendations to help you
ride your CRF safely. Please take a few
moments to read these pages. This section also
includes information about the location of safety
labels on your CRF.
Important Safety Information...............................2
Important Safety Precautions..........................2
Accessories & Modifications ...............................3
Safety Labels ........................................................4
Motorcycle Safety
1
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