2005 Honda CRF450R OWNER’S MANUAL & COMPETITION HANDBOOK
2005Honda CRF450ROWNER’S MANUAL & COMPETITION HANDBOOK
IntroductionCongratulations on choosing your Honda CRFmotocross motorcycle.When you own a Honda, you’re part of aworldwide family of satisfied customers – peoplewho appreciate Honda’s reputation for buildingquality into every product.Your CRF is a high performance racingmotorcycle that utilizes the latest motocrosstechnology and is intended for competition use insanctioned, closed-course events by experiencedriders only.Be aware that motocross is a physicallydemanding sport that requires more than just afine motorcycle. To do well, you must beexcellent physical condition and be a skillfulrider. For the best results, work diligently onyour physical conditioning and practicefrequently.Before riding, take time to get acquainted withyour CRF and how it works. To protect yourinvestment, we urge you to take responsibility forkeeping your CRF well maintained. Scheduledservice is a must, of course. But it’s just asimportant to observe the break-in guidelines, andperform all the pre-ride and other periodic checksdetailed in this manual.You should also read the owner’s manual beforeyou ride. It’s full of facts, instructions, safetyinformation, and helpful tips. To make it easy touse, the manual contains a table of contents, adetailed list of topics at the beginning of eachsection, and an index at the back of the book.IntroductionAs you read this manual, you will findinformation that is preceded by a NOTICEsymbol. This information is intended to help youavoid damage to your Honda, other property, orthe environment.Unless you are mechanically qualified and havethe proper tools, you should see your Hondadealer for the service and adjustment proceduresdiscussed in this manual.The official Honda Service Manual for your CRFis available (page 156). It is the same manualyour dealer uses. If you plan to do any serviceon your CRF beyond the standard maintenanceprocedures in this manual, you will find theService Manual a valuable reference.If you have any questions, or if you ever need aspecial service or repairs, remember that yourHonda dealer knows your CRF best and isdedicated to your complete satisfaction.Please report any change of address or ownershipto your Honda dealer so we will be able tocontact you concerning important productioninformation.You may also want to visit our website atwww.honda.comHappy riding!
A Few Words About SafetyYour 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 Messagesthroughout the manual.Safety Messages are preceded by a safety alert symboland one of three signal words: DANGER, WARNING, or CAUTION.These signal words mean:DANGERYou WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.WARNINGYou CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.CAUTIONYou 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 goodjudgement.Safety Messages
ContentsMOTORCYCLE SAFETY.1Important Safety Information.2Important Safety Precautions.2Accessories & Modifications .3Safety Labels.4OPERATING CONTROLS .5Component Locations .6BEFORE RIDING .7Are You Ready to Ride? .8Is Your Motorcycle Ready to Ride?.9Pre-ride Inspection.9BASIC OPERATING INSTRUCTIONS .11Safe Riding Precautions.12Starting & Stopping the Engine .13Break-in Guidelines .15SERVICING YOUR HONDA.17Before You Service Your HondaThe Importance of Maintenance .18Maintenance Safety.19Important Safety Precautions.19Maintenance Schedule .20General Competition Maintenance .22Before & After Competition Maintenance.26Between Motos & Practice Maintenance .26After Competition Maintenance .26Service PreparationsComponent Locations .28Seat Removal .29Fuel Tank Removal .30Subframe Removal.32ContentsService ProceduresFluids & FiltersFuel System.34Engine Oil .36Transmission Oil .39Coolant .41Air Cleaner .43Crankcase Breather .45EngineThrottle .46Engine Idle Speed .48Clutch System .49Hot Start Lever.53Spark Plug .54Valve Clearance.55Piston/Piston Rings/Piston Pin.66ChassisSuspension.74Brakes.79Wheels.83Tires & Tubes .84Drive Chain .86Exhaust Pipe/Muffler .89Additional Maintenance Procedures .92Appearance Care .94TIPS .135Transporting Your Motorcycle .136Storing Your Honda.137You & the Envionment.138Troubleshooting.139TECHNICAL INFORMATION .141Vehicle Identification .142Specifications .143Torque Specifications.144High Altitude Carburetor Adjustment .147Oxygenated Fuels.148Competition Logbook .149Optional Parts List .151Spare Parts & Equipment.152Wiring Diagram.153CONSUMER INFORMATION .155Authorized Manuals .156Contacting Honda.157Your Honda Dealer.158The Honda Rider’s Club (USA only) .159TABLE OF CONTENTS .160INDEX .162QUICK REFERENCEADJUSTMENTS FOR COMPETITION .97Front Suspension Adjustments.98Rear Suspension Adjustments .111Suspension Adjustments for TrackConditions .115Suspension Adjustment Guidelines.116Carburetor Adjustments & Tuning Tips .119Chassis Adjustments.131Gearing .132Tire Selection for Track Conditions.133Personal Fit Adjustments .134
Motorcycle SafetyThis section presents some of the most importantinformation and recommendations to help youride your CRF safely. Please take a fewmoments to read these pages. This section alsoincludes information about the location of safetylabels on your CRF.Important Safety Information.2Important Safety Precautions.2Accessories & Modifications .3Safety Labels .4Motorcycle Safety1
Important Safety InformationImportant Safety PrecautionsYour CRF can provide many years of pleasure, ifyou take responsibility for your own safety andunderstand the challenges you can meet incompetitive racing.As an experienced rider, you know there is muchyou can do to protect yourself when you ride.The following are a few precautions we considermost important.Never Carry a Passenger.Your CRF is designed for one operator only.Carring a passenger can cause an accident inwhich you and others can be hurt.Wear Protective Gear.Whether you’re practicing to improve your skills,or riding in competition, always wear anapproved helmet, eye protection, and properprotective gear.Take Time to Get to Know Your CRF.Because every motorcycle is unique, take time tobecome thoroughly familiar with how this oneoperates and responds to your commands beforeplacing your machine, and yourself, incompetition.Learn and Respect Your Limits.Never ride beyond your personal abilites or fasterthan conditions warrant. Remember that alcohol,drugs, illness and fatigue can reduce your abilityto perform well and ride safety.2Motorcycle SafetyDon’t Drink and Ride.Alcohol and riding don’t mix. Even one drinkcan reduce your ability to respond to changingconditions, and your reaction time gets worsewith every additional drink. So don’t drink andride, and don’t let your friends drink and rideeither.Keep your Honda in Safe Condition.Maintaining your CRF properly is critical to yoursafety. A loose bolt, for example, can cause abreakdown in which you can be seriouslyinjured.
Accessories & ModificationsAccessories & ModificationsInstalling non-Honda accessories, removingoriginal equipment, or modifying your CRF inany way that would change its design oroperation, could seriously impair your CRF’shandling, stability, and braking, making it unsafeto ride.WARNINGImproper accessories or modificationscan cause a crash in which you can beseriously hurt or killed.Follow all instructions in this owner’smanual regarding modifications andaccessories.Motorcycle Safety3
Safety LabelsRead this label carefully and don’t remove it.If the label comes off or becomes hard to read, contact your Honda dealer for replacement.4Motorcycle Safety
Operating ControlsRead this section carefully before you ride. Itpresents the location of the basic controls on yourCRF.Component Locations .6Operating Controls5
Component Locationshot start leverfront brake leverclutch leverengine stop buttonthrottle gripfuel fill capchoke knobfuel valvekickstartershift leverrear brake pedal6Operating Controls
Before RidingBefore each ride, you need to make sure you andyour Honda are both ready to ride. To help getyou prepared, this section discusses how toevaluate your riding readiness, and what itemsyou should check on your CRF.Are You Ready to Ride?.8Is Your Motorcycle Ready to Ride?.9Pre-ride Inspection .9For information about suspension, carburetor,and other adjustment for competition, see page97.Before Riding7
Are You Ready to Ride?Before riding your CRF for the first time, westrongly recommend that you read this owner’smanual, make sure you understand the safetymessages, and know how to operate the controls.Before each ride, it’s also important to make sureyou and your CRF are both ready to ride.For information about suspension, carburetor,and other adjustments, see page 97.Whether you’re preparing for competition or forpractice, always make sure you are: In good physical and mental condition Free of alcohol and drugs Wearing an approved helmet, eye protection,and other appropriate riding gearAlthough complete protection is not possible,wearing the proper gear can reduce the chance orseverity of injury when you ride.8Before RidingWARNINGNot wearing a helmet increases thechance of serious injury or death in acrash.Be sure you always wear a helmet, eyeprotection and other protective apparelwhen you ride.
Is Your Motorcycle Ready to Ride?Competitive riding can be tough on a motorcycle,so it’s important to inspect your CRF and correctany problems you find before each ride. Checkthe following items (page numbers are at theright):WARNINGImproperly maintaining this motorcycle orfailing to correct a problem before ridingcan cause a crash in which you can beseriously hurt or killed.Always perform a pre-ride inspectionbefore every ride and correct anyproblems.Pre-ride InspectionCheck the following before each ride: Engine oil level .37 Transmission oil level.40 Coolant for proper level. 41 Cooling system and hoses for condition.42 Spark plug for proper heat range, carbonfouling and high tension cord terminal forlooseness .54 Air cleaner for condition andcontamination.43 Clutch lever adjustment and freeplay .49 Hot starter operation and freeplay .53 Breather drain for cleaning .45 Steering head bearing and related partsfor condition.92 Carburetor throttle operation .46 Tires for damage or improper inflationpressure .84 Spokes for looseness.83 Rim locks for looseness.83 Front and rear suspension for properoperation .74,75 Front and rear brakes, check operation .79 Drive chain for correct slack and adequatelubrication .86 Drive chain guide, sliders and guide rollersfor damage or wear .86,87 Exhaust pipe/Muffler inspection,removal and installation.89,90,91 Every possible part for looseness (such ascylinder head nuts, engine mounting bolts,axle nuts, handlebar holder bolts, fork tripleclamp bolts, drive chain adjuster, drive chainguide, wire harness connectors, kickstartermounting bolt) .92,93Before Riding9
10Before Riding
Basic Operating InstructionsThis section gives basic information on how tostart and stop your engine as well as break-inguidelines.Safe Riding Precautions .12Starting & Stopping the Engine .13Preparation .13Starting Procedure .13Flooded Engine .13How to Stop the Engine.14Break-in Guidelines .15Basic Operating Instructions11
Basic Operating InstructionsSafe Riding PrecautionsBefore riding your CRF for the first time, pleasereview the Important Safety Precautionbeginning on page 7 and the previous section,titled Before Riding.For your safety, avoid starting or operating theengine in an enclosed area such as a garage.Your CRF’s exhaust contains poisonous carbonmonoxide gas which can collect rapidly in anenclosed area and cause illness or death.12Basic Operating Instructions
Starting & Stopping the EngineAlways follow the proper starting proceduredescribed below.Check the engine oil, transmission oil and coolantlevels before starting the engine (pages 37,40,41).Your CRF can be kickstarted with thetransmission in gear by pulling in the clutch leverbefore operating the kickstarter.Cold Engine Starting1. Turn the fuel valve (1) ON.2. Shift the transmission into neutral.3. If the temperature is 95 F (35 C) or below,pull the choke knob (2) fully out.4. If the temperature is below 32 F (0 C), openthe throttle two or three times. (The enginerequires a richer mixture for starting in coldweather. When the throttle is so opened, theaccelerator pump will feed extra fuel to thecylinder, thereby facilitating starting in coldweather.)5. With the throttle closed, operate thekickstarter starting from the top of thekickstarter stroke, kick through to the bottomwith a rapid, continuous motion. (Do not openthe throttle, As the carburetor is equipped withan accelerator pump, excessive fuel will becharged into the engine, and the spark plugwill be fouled if the throttle is opened andclosed repeatedly. Excessive fuel in the enginemakes kickstarting difficult.)6. About a minute after the engine starts, pushthe choke knob back all the way to fully OFF.If idling is unstable, open the throttle slightly.PreparationMake sure that the transmission is in neutral.Turn the fuel valve ON.Starting ProcedureAlways follow the proper starting proceduredescribed as follow.ONOFF(2)Warm Engine Starting1. Turn the fuel valve ON.2. Shift the transmission into neutral.3. Pull the hot start lever (3) and kick-start theengine. (Do not open the throttle.)4. As soon as the engine starts, release the hotstart lever.(3)(3) hot start leverStarting the engine after a stall during riding orafter a fall:1. Shift the transmission into neutral.2. Pull the hot start lever and kick-start theengine. (Do not open the throttle).3. As soon as the engine starts, release the hotstart lever.Flooded Engine(1)(1) fuel valve(2) choke knobIf the engine fails to start after repeated attempts,it may be flooded with excess fuel. To clear aflooded engine:1. Shift the transmission into neutral.2. With the throttle fully opened, repeatkickstarter operation approximately 10 timesvery slowly to discharge excessive fuel fromthe engine.3. Pull the hot start lever and kick-start theengine (Do not open the throttle.)4. As soon as the engine starts, release the hotstart lever.Basic Operating Instructions13
Starting & Stopping the EngineHow to Stop the Engine(1)(2)(1) throttle grip(2) engine stop buttonNormal Engine Stop1. Shift the transmission into neutral.2. Turn the fuel valve OFF.3. Lightly open the throttle (1) 2 – 3 times, andthen close it.4. Depress and hold the engine stop button (2)until the engine stops completely.Failure to close the fuel valve may cause thecarburetor to overflow, result in hard starting.Emergency Engine StopTo stop the engine in an emergency, press theengine stop button.14Basic Operating Instructions
Break-in GuidelinesHelp assure your CRF’s future reliability andperformance by paying extra attention to howyou ride during the first operating day or 15miles (25 km).During this period, avoid full-throttle starts andrapid acceleration.This same procedure should be followed eachtime when: piston is replacedpiston rings are replacedcylinder is replacedcrankshaft or crank bearings are replacedBasic Operating Instructions15
16Basic Operating Instructions
Servicing Your HondaKeeping your CRF well maintained is absolutelyessential to your safety. It’s also a good way toprotect your investment, get maximumperformance, avoid breakdowns, and have morefun.To help keep your
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. If you have any questions, or if you ever need a special service or repairs, remember that your Honda dealer knows your CRF best .
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