Positioning:
The Honda CRF450R is a top-tier motocross machine renowned for its power, handling, and reliability. This manual serves the owners and mechanics of these performance-oriented dirt bikes, providing essential information for maintaining and repairing them to factory standards.
Competitors:
Competes directly with other premium 450cc motocross bikes from manufacturers like Yamaha (YZ450F), Kawasaki (KX450F), KTM (450 SX-F), and Suzuki (RM-Z450).
Manual Benefits:
Comprehensive coverage, detailed illustrations, clear step-by-step instructions, essential technical data (torque specs, clearances), troubleshooting guides, and explicit instructions for model year updates (especially for 2016 models, distinguishing it from a mere rehash of earlier year manuals).
Guarantee:
Free replacement of the manual if lost by the purchaser.
Years Covered:
2009, 2010, 2011, 2012, 2013, 2014, 2015, 2016
Type:
Service Manual / Repair Manual
Accessibility Features:
Clickable chapters, Searchable text
Permissions:
No restrictions on printing or saving
Engine:
Complete tear down, rebuild, maintenance, troubleshooting, PGM-FI (Fuel Injection) system, ignition, lubrication, fuel system (carburetor/fuel pump details depending on specific year sub-model variations), exhaust system.
Drivetrain:
Transmission, clutch (including primary reduction gear), drive shaft, kickstarter system, crankshaft, connecting rod, wheel axle, swingarm, linkage.
Suspension And Wheels:
Front forks (including internal components and adjustments), rear suspension struts/shocks, wheel bearing maintenance, tire specifications.
Brakes:
Front and rear brake system maintenance, pad replacement, fluid specifications, rotor inspection.
Electrical System:
Battery, charging system (stator, regulator/rectifier), ignition coil, lighting (if applicable to model variants), starter system.
Bodywork And Chassis:
Panel removal and installation, fenders, fuel tank, seat, frame inspection, triple tree maintenance.
Maintenance:
Regular scheduled maintenance, oil changes, filter replacements, chain adjustment, valve clearance checks and adjustments, spark plug replacement, coolant changes, brake fluid flushes.
Repair And Rebuild:
Complete engine tear down and rebuild, transmission overhaul, suspension servicing, electrical component repair, brake system overhaul.
Troubleshooting:
Diagnosis of common problems, no-spark conditions, starting issues, performance complaints, error code interpretation (if applicable to PGM-FI models).
Technical Data And Specs:
Torque specifications for all fasteners, component dimensions, clearances, electrical specifications, PGM-FI settings.
Depth:
Comprehensive, covering all aspects from basic rider maintenance to full engine and chassis rebuilds, suitable for both novice DIY enthusiasts and experienced technicians.
Engine Type:
4-Stroke, Liquid-Cooled, Single-Cylinder, Unicam OHC
Displacement:
Approx. 449cc (specific bore and stroke vary slightly across model years, e.g., 96mm x 62.1mm for some 2009-2016 models, but manual covers these variations).
Bore X Stroke:
Refer to manual for specific year data (typical range: 96.0 mm x 62.1 mm)
Compression Ratio:
Refer to manual for specific year data (typical range: 12.5:1 or higher)
Horsepower:
Not explicitly stated in product description, but typically in the 50-60 HP range for this class.
Torque:
Not explicitly stated in product description.
Fuel Delivery:
Fuel Injection (PGM-FI) for most models in this range, with specific injector types, pump specifications, and ECU mapping details covered. Some earlier models within the range might have featured carburetors, and the manual addresses these variations if applicable.
Fuel Type:
Unleaded gasoline
Recommended Oil Viscosity:
Refer to manual for specific year and climate recommendations. Typically SAE 10W-30 or 10W-40 motorcycle-specific oil with JASO MA/MA2 certification.
Oil Capacity:
Refer to manual for specific year data (typically around 1.5-1.7 liters when filter is changed).
Overall Length:
Refer to manual for specific year data (typical range: approx. 2180-2200 mm)
Overall Width:
Refer to manual for specific year data (typical range: approx. 800-820 mm excluding handlebars)
Overall Height:
Refer to manual for specific year data (typical range: approx. 1270-1290 mm)
Wheelbase:
Refer to manual for specific year data (typical range: approx. 1480-1495 mm)
Dry Weight:
Refer to manual for specific year data (typical range: approx. 105-107 kg)
Curb Weight:
Not explicitly stated in product description, but significantly higher than dry weight due to fluids.
Fuel Capacity:
Refer to manual for specific year data (typical range: approx. 6.3 - 7.0 liters)
Safety Ratings:
N/A (Off-road vehicles are not subject to the same regulatory safety ratings as street-legal vehicles).
Braking System:
Hydraulic disc brakes front and rear for strong stopping power.
Engine Management:
PGM-FI system offers precise fuel delivery for consistent power and throttle response, contributing to rider control.
Frame Construction:
Aluminum twin-spar frame provides a balance of rigidity and light weight for stable handling and impact absorption.
Infotainment System:
N/A (Motocross bike, no infotainment system).
Driver Assistance Features:
N/A (Motocross bike, no driver assistance features).
Connectivity Features:
N/A (Motocross bike, no connectivity features).
Electronic Fuel Injection:
PGM-FI is a key technology, offering adjustable mapping (via optional tuning tools not covered in this manual, but diagnostic interfaces are), throttle position sensors, and fuel injectors. The manual details its operation and maintenance.
Oil Change Interval:
Refer to manual for specific recommendations based on usage. Typically every 10-15 hours of riding or more frequently under severe conditions.
Air Filter Cleaning:
Recommended after every few rides, or more often in dusty conditions.
Valve Clearance Check:
Refer to manual for specific interval, typically every 100-200 hours or as needed based on performance.
Spark Plug Replacement:
Refer to manual. Generally checked during major service intervals and replaced as needed.
Coolant:
High-quality motorcycle coolant (ethylene glycol based) mixed with distilled water. Manual specifies exact mixture ratio and capacity.
Brake Fluid:
DOT 4 brake fluid for hydraulic clutch and brake systems.
Common Wear Items:
Clutch plates, brake pads and rotors, tires, chain and sprockets, wheel bearings, fork seals, and engine top-end components (piston, rings, valves) due to the high-performance nature of motocross riding.
Engine Performance:
Can include issues with piston wear, valve seat wear, and potential issues with the fuel injection system's sensors or injectors if not properly maintained or subjected to contaminants. The manual provides diagnostic procedures for these.
Honda Motorsports:
Honda has a long and storied history in motorsports, particularly in motocross, with a continuous development of the CRF line for decades.
Crf450R Development:
The CRF450R has seen significant evolution, with key changes in engine tuning, suspension components, chassis design, and electronic systems (like PGM-FI) throughout its production run. This manual covers a period of substantial development, including updates specific to the 2016 model year.
Manufacturing Location:
Primarily Japan.
Motocross Awards:
The CRF450R has historically received numerous awards and accolades from motocross publications and industry bodies for its performance, handling, and engineering across various model years.
Editorial Reviews:
Consistently praised for its powerful engine, agile chassis, and sophisticated suspension, making it a perennial contender in head-to-head comparisons.
Technical Compliance:
The manual adheres to Honda's internal technical specifications and standards for the CRF450R.
