crf450x2005

Downloadedfrom•••••••••••Downloadedfrom(Sedoon4)recommendationstoensurethatthevehicleis,npea~operahngconditionandtheemIssion1ev€lsarewithi,thestandardssetbytheU.s.EnvironrmmtalProtecTionAglncy(EPA)andCalrlo,maAirResourcesBoard(CARB).Pertorm,ngthe'5\schedUledmaintenance'5veryimiX'ftant.ItcompensalesfortheIniMIWearthatoccursduringthebreak.,nperiod.Sections1and4applytothewholemotorcycle.Section3IllustratesprocedureslorremDVallinstaliatlOnofcomponentsthatmayterequiredtoperlormservicedescribedinIhelolJow,ngsections.Section5through20describeparIsofthemotorcycle,groupedaccord,ngtolocation.FindthesectionyouwantonThispage,thenturntothetable01conlentsonthelirstpage01thesection.MostsectiOilsstartwithanassemblyorsystemillustrahon.5elVlCeinlormationandtroubleshootinglorthesection.Thesubsequentpagesgivedetailedprocedure.ItyouarenotfamiliarwithIhismotorcycle.readTechnicatFeatureinSectron2.Ifyoudon'tknowtilesource01theIrouble,gotosection22TrouOleshootlng.Yoursatety.andthesafetyofothers.Isveryimpol1an1.Tohelpyouma~einformeddecisionswehaWlprovidedsafetymessagesandotherinformationthroughoutthismanual.Ofcourse.ilisnotpracticalorpoSSibletowarnyouaboutallthehazardsassociatedwithservicingthisI'€hicle.YoumustuseyourowngoodjudgementYouwillfindimportantsafetyInformationIna~ariety01tormsinduding:•SafetyLabels-onthevehicle•SafetyMessages-precededbyasafetyalertsymbolLandone01threestgnalwords.DANGER,WARNING.orCAU·TION.Thesesrgn~1wordsmean:,:;•YouWILLbeKILLEDorSERIOUSLYr.'.l.Jdf1:h'HUI'1Tifyoudon'tfollowInstructions.fflZQ;@IUt.lMm[,)?'YouCANbeKILLEDorSERIOUSLYHURTifyoudon'tfollOWonstructions.YouCANbeHURT~youdon'tfollowinstructions•Instructions-howtoser~lcethis~ehiclecorrectlyandsafely,ASyoureadthismanual,youwillfindinformationthatISpl'€cededbyal..NOnrosymbol.ThepurposeofthismessageIStohelpprev!mldamagetoyourI'€hlCle,otherproperty,orIhe(lflVlfOnmentz..a:..wa:cczwzzwJ)iiiJ):I:..J~a:t;w..JWCONTENTSGENERALINFORMATIONMAINTENANCELUBRICATIONSYSTEMFUELSYSTEMCOOLINGSYSTEMENGINEREMOVAUINSTALLATIONCYLINDERHEADNALVESCYLINDER/PISTONALTERNATORFRONTWHEEl/SUSPENSION/STEERINGREARWHEEUSUSPENSIONHYDRAULICBRAKEBATTERY/CHARGINGSYSTEMIGNITIONSYSTEMELECTRICSTARTERLIGHTS/METER/SWITCHESWIRINGDIAGRAMTROUBLESHOOTINGINDEXDownloadedfrom¢l'PReplacethepart(s)withnewone(5)beforeassembly....-78Usetherecommendedengineoil,unlessotherwisespecified.-,Usemolybdenumoilsolution(mixtureoftheengineoilandmolybdenumgreaseinaratioof1:1).•..s;;;m.Usemulti-purposegrease(lithiumbasedmulti-purposegreaseNLGI#2orequivalent).Usemolybdenumdisulfidegrease(containingmorethan3%molybdenumdisulfide,NLGI#2orequivalent).~Example:Moly\oteJ!lBR-2plusmanufacturedbyDowCorningU.S.A.Multi-purposeM-2manufacturedbyMilsubishiOil,JapanUsemolybdenumdisulfidepaste(containingmorethan40%molybdenumdisulfide,NLGI#2orequivalent).Example:Molykote®G-nPastemanufacturedbyDowCorningU.S.A.~HondaMoly60(U.S.A.only)RocolASPmanufacturedbyRacolLimited,U.K.RocolPastemanufacturedbySumicolubricant,Japan...-'iiSitIUsesiliconegrease.DumApplyalockingagent.Useamediumstrengthlockingagentunlessotherwisespecified..,('Illll!Applysealant.UseDOT4brakefluid.UsetherecommendedbrakelIuidunlessotherwisespecified...Useforkorsuspensionfluid.•••Downloadedfrom•1.GENERALINFORMATIONSERVICERULES···..··......········..··················1-2MODELIDENTIFICATION···························1-2GENERALSPECIFICATIONS······················1-5LUBRICATIONSYSTEMSPECiFiCATIONS········································1-7FUELSYSTEMSPECIFICATIONS··············1·7COOLINGSYSTEMSPECIFICATIONS······1·7CYLINDERHEADIVALVESSPECIFICATIONS········································1·8CYLINDER/PISTONSPECIFICATIONS......1·8CLUTCH/STARTERCLUTCH/KICKSTARTER/GEARSHIFTLINKAGESPECiFiCATIONS········································1-9CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCERSPECIFICATIONS(,OS-·07)-······················1-9CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCERSPECIFICATIONSIAfter·07)····················1·10FRONTWHEEL/SUSPENSION/STEERINGSPECIFICATIONS······································1·11REARWHEEL/SUSPENSIONSPECIFICATIONS································....·1·11HYDRAULICBRAKESPECIFICATIONS···1-12BATTERY/CHARGINGSYSTEMSPECIFICATIONS·····································1·12IGNITIONSYSTEMSPECIFICATIONS····1·12ELECTRICSTARTERSPECIFICATION·····1·13LIGHTS/METER/SWITCHESSPECIFICATIONS.....................................1-13STANDARDTORQUEVALUES···············1·14ENGINE&FRAMETORQUEVALUES····1·14LUBRICATION&SEALPOINTS··············1·21CABLE&HARNESSROUTING('OS-·07)·············..····································1·25CABLE&HARNESSROUTINGI