Honda 450r service manual free download

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Be sure to grease the air cleaner flange where it contacts the air cleaner housing. Pro Honda White Lithium Page 35 Always use new gaskets when reassembling components.

Refer to Fuel Line Inspection on page Check the fuel line for deterioration, damage, or leakage. Page 36 A small amount of coolant offers added assurance and security. Remove the nuts, weeping from the bleed hole is normal. See an official Honda clean the threads of both the nuts and bolts, apply Pro Service Manual or consult your dealer for replacing the Honda Hondalock or an equivalent and tighten to the mechanical seal or oil seal.

Be sure the chain is wiped clean and is dry before lubricating the chain. Page Seat 2. Page Fuel Tank 7 hose clamp 8 breather tube 12 fuel feed hose 13 clamp 8. Pull the breather tube 8 out of steering stem nut. Unhook the fuel tank band 9 and air cleaner rubber Page 42 4. Hook the air cleaner rubber 5 and the fuel tank band 6. Page 43 14 shroud tabs 15 air cleaner housing cover tabs 10 16 shroud B bolts 13 17 collars and shroud A bolts 11 Install the seat page Page Subframe Right side: 4.

Remove the air cleaner box 3 from the subframe 4. Page 45 7. Install the left and right mufflers page Page Fuel System Never use stale or contaminated gasoline.

Avoid getting dirt, dust or water in the fuel tank. Install the fuel quick connect fitting cover. Install the fuel tank page Page 47 1 fuel quick connect fitting cover 2 fuel pump 3 fuel quick connect fitting 5. Remove the bolt 4 , clamp and setting rubber 5. Page 49 16 rubber cover by aligning the clamp tab 11 with the groove 12 of the stay. Increase the fuel pressure page Page 51 Remove the fuel pump filter from the fuel pump assembly Page 52 4.

Install a new damper rubber 11 to the fuel 14 fuel pump base pump filter as shown. Page 53 20 black wire terminal 21 fuel pump base terminals 22 O-ring new 23 fuel pump unit 27 27 fuel pump plate 28 identification mark Connect the fuel line page Remove the battery harness and battery harness adaptor. Page 57 12 facing out, away from the engine. Use a new Honda Genuine oil filter or a filter of equal quality specified for your model.

Page 59 1 transmission oil fill cap 3 sealing washer 2 oil check bolt 5. Position your CRF on an optional workstand or Page 61 A small amount of coolant weeping from the 4.

See an official Honda and not clogged. Service Manual or consult your dealer for Removing the radiator cap while the 5. Use a new Honda Genuine air cleaner specified for your model or an 1 air cleaner retaining bolt air cleaner of equal quality.

Page 63 Install the holder tabs in the holes of the air 1 air cleaner retaining bolt cleaner element. Apply 0. Page Crankcase Breather 1. Remove the crankcase breather tube plugs 1 from the crankcase breather tubes 2 and drain deposits into a suitable container. Reinstall the crankcase breather tube plugs. Page Throttle Tighten the lock nut 3 to the specified torque: 3.

Page 66 1 throttle housing 2 paint mark 2. Check for smooth rotation of the throttle 3 from fully open to fully closed in all steering positions. If there is a problem, see your dealer. Page Engine Idle Speed 3. Start the engine. Keep the motorcycle in an upright position. Adjust idle speed with the fast idle knob 1. Page Clutch System Make sure to adjust the clutch lever freeplay after the clutch cable is disconnected. Adjust the cable end adjuster for minor adjustment page Page 69 2.

Check the clutch cable for deterioration, kinks, worn, or the clutch discs may be worn. Inspect the clutch discs and plates page Page 70 4 clutch cover bolts 5 clutch cover 14 clutch discs, clutch plates, judder spring and spring 4. Remove the six clutch spring bolts and springs seat 6. Loosen the bolts in a crisscross pattern in two or three progressive steps. Page 72 page Apply locking agent to the brake pedal pivot 13 bolt threads.

Install the dust seals into the rear brake pedal Page Spark Plug Connect the spark plug cap. Take care to avoid pinching any cables or wires. Install the fuel tank and seat pages 33, Page Valve Clearance 2 spark plug cap 3. Remove the cylinder head cover socket bolts 3 , rubber seals 4 and cylinder head cover 5.

Page 76 3. Remove the cam chain tensioner lifter cover clearance need adjustment, see Camshaft Removal bolt 2 and sealing washer 3. If the set rings are remained on the camshaft holder, remove the set rings carefully. Page 78 2. Page 79 4 cylinder head 10 cam sprocket If the operation is not smooth, refer to an official 7 camshaft 11 left camshaft bearing Honda Service Manual page for 9 cam chain decompressor disassembly or see your dealer.

Page 81 Install a new sealing washer 24 and tighten the cam chain tensioner lifter cover bolt Page 82 4. Page 85 23 cylinder head bolts and washers Do not let the cam chain fall into the crankcase. Page 86 6 races or about every Replace the piston pin every 12 races or about every Page 87 Piston Ring Installation rotate freely, without sticking.

Space the ring end gaps degrees apart We recommend you consult an official Honda 1. Remove the carbon deposits from the piston between top ring and upper side rail.

Service Manual or your dealer for correct Service head and piston ring grooves. Page 88 Install the piston pin and new piston pin clips 7. Never reuse old clips. Do not let the clips fall into the crankcase. Do not align the piston pin clip end gap with the piston cutout 8. Page 89 3. Install a new cylinder gasket 1 and dowel pins 2.

Page 91 19 air cleaner connecting tube 20 throttle body 9 left cylinder head hanger plate 21 air cleaner connecting tube band screw 10 right cylinder head hanger plate 11 cylinder head hanger plate bolts 12 cylinder head hanger bolts Servicing Your Honda Page 92 Check for the following: 25 28 ECT sensor connector — compression leaks 26 — abnormal engine noise — secondary air leaks 25 radiator hose — exhaust gas leaks 26 water hose joint — coolant leaks — oil leaks Servicing Your Honda DIY is the top-rated supplier of printed dealership factory manuals.

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