Category Placement:
High-performance off-road and dual-sport motorcycle, known for its power and handling in competitive environments.
Key Competitors:
Yamaha YZ450F/WR450F, Kawasaki KX450F/KLX450R, KTM 450 SX-F/XC-F/EXC-F series.
Off Road Capability:
Designed for aggressive off-road riding, motocross, and enduro with robust suspension and powerful engine.
Reliability:
Honda's reputation for build quality and engine durability, though off-road use inherently stresses components.
Manual Value Proposition:
Empowers owners to perform extensive maintenance and repairs, saving significant costs compared to dealership service.
Applicable Years:
2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013
Trim Levels Covered:
All Models/Engines/Trim/Transmissions Types
Estimated Page Count:
Comprehensive (Specific count not provided, assumed to be extensive for a full workshop manual)
Manual Type:
Complete Workshop Service Repair Manual
Format:
Downloadable Digital File (PDF)
Engine:
Complete engine disassembly, assembly, inspection, troubleshooting, and repair for the 450cc class engine.
Fuel System:
Carburetor system (model dependent), fuel pump, fuel lines, fuel tank, and fuel filter maintenance and repair.
Ignition System:
CDI unit, ignition coil, spark plug, wiring harness, and timing checks.
Cooling System:
Radiator, coolant hoses, water pump, fan operation, and coolant specifications.
Transmission And Drivetrain:
Clutch operation, gear shifting mechanism, transmission gear inspection, final drive chain and sprocket maintenance.
Suspension System:
Front fork (USD telescopic) disassembly, assembly, oil change, seal replacement, and rear shock absorber inspection and service.
Braking System:
Front and rear hydraulic disc brake systems, caliper overhaul, master cylinder service, pad replacement, and fluid bleeding.
Electrical System:
Lighting (headlight, taillight, brake light), battery maintenance, charging system (stator, regulator/rectifier), starter motor (if applicable), and wiring diagrams.
Wheel And Tire System:
Spoke wheel maintenance, bearing inspection, tire mounting and balancing, and recommended tire pressures.
Frame And Bodywork:
Frame inspection, sub-frame mounting, body panel removal and installation, seat assembly.
Routine Maintenance:
Oil changes, filter replacements, chain lubrication and adjustment, air filter cleaning/replacement, spark plug inspection, valve clearance checks.
Troubleshooting:
Diagnostic procedures for common starting issues, running problems, electrical faults, and mechanical failures.
Disassembly And Assembly:
Step-by-step instructions for complete engine, transmission, suspension, and brake system teardown and reassembly.
Component Rebuilds:
Detailed instructions for rebuilding carburetors, brake calipers, master cylinders, water pumps, and engine internal components.
Technical Specifications:
Torque specifications for all fasteners, engine clearances, fluid capacities, and electrical system resistance values.
Wiring Diagrams:
Comprehensive electrical system diagrams for troubleshooting and repairs.
Depth:
Comprehensive from basic maintenance to full engine rebuilds and advanced diagnostics.
Engine Type:
Single-cylinder, four-stroke, liquid-cooled, Unicam engine
Bore X Stroke:
96.0 mm x 62.1 mm (typical for this era CRF450X)
Compression Ratio:
11.5:1 (typical for this era CRF450X)
Horsepower Estimate:
Approx. 50-55 hp (at crank, actual may vary by year and tuning)
Torque Estimate:
Approx. 30-34 lb-ft (at crank, actual may vary by year and tuning)
Fuel Delivery:
Carburetor (Keihin FCR 39mm is common for this period)
Fuel Type:
Unleaded gasoline, 91 octane or higher recommended.
Oil System:
Semi-dry sump with separate engine oil and transmission oil compartments (typical for Honda off-road models).
Engine Oil Change:
Every 15-20 hours of riding or annually, whichever comes first, for severe use.
Air Filter Cleaning:
After every few rides, especially in dusty conditions. More frequently than oil changes.
Valve Clearance Check:
Every 30-40 hours of riding or annually, critical for maintaining performance and preventing engine damage.
Chain Lubrication Adjustment:
Every ride or as needed, depending on conditions.
Engine Oil Type:
SAE 10W-30 API SG or higher. Honda recommends specific GN4 or HP4 synthetic motorcycle oil.
Engine Oil Capacity:
1.72 US qt (1.63 L) when filter is changed.
Transmission Oil Type:
SAE 10W-30 API SG or higher (often shared with engine oil, but check manual for specific recommendations).
Transmission Oil Capacity:
0.70 US qt (0.66 L)
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Coolant Type:
Honda Motorcycle Coolant or equivalent high-quality engine coolant (50/50 mix of antifreeze and distilled water).
Clutch Wear:
Aggressive riding can lead to accelerated clutch wear, requiring timely adjustments and eventual replacement.
Valve Adjustment Frequency:
Unicam valve lash can be sensitive to wear and temperature; regular checks are crucial.
Carburetor Tuning:
May require re-jetting or adjustments based on altitude, temperature, and modifications.
Fork Seals:
Off-road abuse can lead to fork seal leaks, necessitating replacement.
