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2003 honda crf450r service manual free download |
- 2003 honda crf450r service manual free download
Table Of Contents. Quick Links. Honda CRFR. All information in this publication is based on the latest product information available at the time of. Honda Motor Co. No part of this publication may be reproduced without written permission. Table of Contents. Previous Page. Next Page.
American honda motor co. Summary of Contents for Honda CRFR Page 1 All information in this publication is based on the latest product information available at the time of approval for printing.
Page 4: Operating Instructions 1. Shift the transmission into neutral. Turn the fuel valve OFF. Page 6: Contotls 1. Page 7: Control Adjustment 3.
Page 8: Hot Start If proper adjustment still cannot be obtained or the adjustment, tighten the lock nut. Page 9: Front Brake Lever If the brake lever free play exceeds 0. Tighten the lock nut at the desired pedal height. Refer to the Honda Service Manual or see your autho- rized Honda dealer for brake bleeding. Page Adjustment For Personal Fit 3 mm using optional handlebar lower hold- stiffer and softer, rear: stiffer and softer are avail- rather than bending or breaking.
Apply Honda able to tailor your CRF specifically for your weight, ers or 6 mm by rotating the standard holders Thread Lock or an equivalent to the threads of these riding style and course conditions.
Page Specifications 2. Standard Page Service And Maintenance 4. C: Clean. R: Replace. L: Lubricate. Page General Service Information Check spoke tension and rim lock nut security. Lubricate any sliding surface, O- rings. Page General Maintenance page 27 Use the Honda genuine air cleaner or an equivalent air cleaner specified for your model. Page 17 Inspect the cable carefully for shorts or corrosion. Additional corrosion protec- kinks or other damage that may restrict throttle con- tion is offered by using Honda Dielectric Grease on trol in anyway.
Move the handlebar from lock to lock all electrical connections. Page 18 containing more suspension. Refer to the Honda Service Manual. Seat Removal 2. Page 20 4. Disconnect the fuel line from the fuel valve. Put the breather tube in the steering stem nut. The fuel line leading to the carburetor must be dis- 1. Install the fuel tank on the frame. Page Subframe 5. Disconnect the crankcase breather tube. Loosen the screw on the air cleaner connecting tube 1. Loosely attach the upper and lower ends of the Subframe Removal clamp.
Remove the seat page Page 22 4. Install the muffler. Install the side covers, side cover bolts and collars. Tighten the screw on the air cleaner connecting tube 7. Install the muffler clamp by aligning the tab of the clamp. Remove the left engine guard bolt and left engine guard. Inspecting and Adding Engine Oil 2. Support the CRF in an upright position on a level 1. Page 24 0. Install the engine oil filler cap. Run the engine for three minutes, then shut if off.
Support the CRF in an upright position on a level without molybdenum additives 4-stroke oil, or an 1. A ity ethylene glycol based anti-freeze containing corro- coolant loss of 0. Remove the fuel tank page Disconnect the spark plug cap. Standard: 3. Remove the spark plug. Page Ignition If you want to check the igni- Coast to a stop, then remove and inspect the spark the same number of turns. The porcelain insulator around the center elec- trode should appear tan or medium gray. Page Crankcase Breather 8.
Allow the air cleaner to dry thoroughly. After dry- ing, soak the air cleaner in clean Pro Honda Foam Filter Oil or an equivalent air cleaner oil. Apply air cleaner oil to the entire surface, inner and outer, and rub it with both hands to saturate the air cleaner with oil. Page Clutch 4. NOTE: Operation The clutch springs have sky blue paint. Coat the clutch plates with transmission oil. Install the six clutch springs and bolts. Install the six clutch discs which has yellow paint on Tighten the bolts in a crisscross pattern in 2 or 3 steps.
Page Valve 4. Cylinder Head Cover Removal Remove the crankshaft hole cap. Lubricate the rear brake pedal pivot and pivot bolt and NOTE: tighten the pivot bolt. Page 34 4. Page 35 Remove the cam sprocket bolt. Remove the camshaft holder assembly bolts, camshaft Rotate the primary drive gear lock bolt crankshaft holder assembly, intake valve lifters and shims. Then attach a piece of wire to the As you remove the camshaft holder assembly, the in- cam chain to prevent it from falling into the crankcase.
Page 36 4. Install the newly selected shims on the valve retainers. Page 37 Install the cam shaft holder assembly onto the cylinder Insert the feeler gauge between the intake valve lifter Place the cam sprocket and align the timing mark on head with the intake cam lobes facing up as illustrated and cam lobe.
Page 38 4. Page 39 Measure the intake valve clearance and exhaust valve Measure the decompressor arm clearance by inserting Decompressor Arm Clearance Adjustment clearance. Page 40 4. Spark Plug Installation Cylinder Head Cover Installation Insert the feeler gauge right exhaust valve clearance Install the spark plug by hand until finger tight, then Remove the spark plug hole packing from the cylinder 0.
Page 42 4. Remove the engine hanger nut, engine hanger A bolt, sion stroke page Loosen the cylinder bolt. Remove the cam shaft holder assembly page Page 43 Remove the dowel pins, cylinder head gasket and cam Piston Removal Cylinder Removal chain guide. Place clean shop towels in the crankcase to keep the Remove the cylinder bolt and cylinder. Page 44 Apply engine oil to the piston rings and install the pis- We recommended you consult the Service Manual or ton rings.
Page 45 Piston Installation Cylinder Installation Clean off any gasket material from the gasket surface Place clean shop towels in the crankcase to keep the of the crankcase, being careful not to let any material piston pin clips from falling into the crankcase. Page Cylinder Head Installation 4.
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