Cross Technologies 450R Owner's Manual

Operating Controls 5Operating ControlsRead this section carefully before you ride. Itpresents the location of the basic controls on yourCRF. Operati

Adjustments for Competition 95Adjustments for CompetitionThis section tells you how to fine tune your CRFfor maximum competition performance.Initial s

96 Adjustments for CompetitionFront Suspension AdjustmentsThe front suspension can be adjusted for therider’s weight and riding conditions by using on

Adjustments for Competition 97Front Suspension AdjustmentsBoth compression and rebound damping can beincreased by turning the adjuster clockwise. Alwa

Front Suspension Adjustments98 Adjustments for Competition(6)(5)5. Loosen the upper pinch bolts (8). 6. Loosen the fork damper (7), but do notremove t

Front Suspension AdjustmentsAdjustments for Competition 99(28) outer tube (29) oil hole 17.Temporarily install the fork damper to theouter tube. 18.Pl

Front Suspension Adjustments100 Adjustments for Competition22.Apply pressure to the fork damper and insert aspecial tool or mechanic's stopper to

Front Suspension AdjustmentsAdjustments for Competition 101(1) fork damper (2) fork cap assembly4. Empty the fork oil from the oil hole (4) of thefork

Front Suspension Adjustments102 Adjustments for Competition(1) fork damper (5) fork damper piston rod(1) fork damper (10) spring chamber(9) soft jaws

Front Suspension AdjustmentsAdjustments for Competition 103Fork Assembly1. Drain the fork oil from the outer tube/slider(1) by placing it upside down.

Front Suspension Adjustments104 Adjustments for Competition4. Place the lower end (axle holder) of the sliderin a vise with a piece of wood or soft ja

6 Operating ControlsOperation Component Locationsclutch leverhot start leverfront brake leverengine stop buttonthrottle gripchoke knobfuel valveshift

Front Suspension AdjustmentsAdjustments for Competition 10513.Pour the recommended fork oil (11) into theouter tube/slider (1).Recommended Oil: Pro Ho

Front Suspension Adjustments106 Adjustments for Competition14.Check that the O-ring (12) on the fork damperassembly (4) is in good condition. Apply th

Front Suspension AdjustmentsAdjustments for Competition 10721.Clean the threads of the fork protector bolts(18) and axle holder thoroughly. Apply lock

Front Suspension Adjustments108 Adjustments for Competition26.Route the number plate tab (27) around thehandlebar pad (28) as shown.(27) number plate

Rear Suspension AdjustmentsAdjustments for Competition 109Pin spanners should be used for turning the locknut and adjusting nut. See page 148 for opt

Rear Suspension Adjustments110 Adjustments for Competition(3) rebound damping adjusterTo adjust to the standard position:1. Turn the adjuster clockwis

Rear Suspension AdjustmentsAdjustments for Competition 1114. Calculate the race sag dimension.To do this, subtract the loaded with riderdimension (ste

Rear Suspension Adjustments112 Adjustments for CompetitionBecause of the great absorption quality of theshock bumper rubber, it may be difficult for y

Suspension Adjustments for Track ConditionsAdjustments for Competition 113Soft SurfaceOn soft ground, sand, and especially mud,consider increasing com

Suspension Adjustment Guidelines114 Adjustments for CompetitionFollow the procedures described below to accurately adjust your CRF, using the methods

Before Riding 7Before each ride, you need to make sure you andyour Honda are both ready to ride. To help getyou prepared, this section discusses how

Suspension Adjustment GuidelinesAdjustments for Competition 115StiffsuspensionSymptomInitial travel too stiff:•Stiff on small bumps while riding at fu

Suspension Adjustment Guidelines116 Adjustments for CompetitionRear Suspension AdjustmentAdjustments for Type of TrackSymptoms and Adjustment• Always

Carburetor Adjustments & Tuning TipsAdjustments for Competition 117The carburetor on your CRF should performsuitably with the standard recommended

Carburetor Adjustments & Tuning Tips118 Adjustments for CompetitionAccelerator Pump CircuitThe accelerator pump circuit operates when thethrottle

Adjustments for Competition 119Carburetor Adjustments & Tuning TipsCarburetor Circuit FunctionsThe carburetor has several major circuits, eachprov

Carburetor Adjustments & Tuning Tips120 Adjustments for Competition4. Remove the fuel tank (page 30).5. Remove the subframe (page 32).6. Remove th

Carburetor Adjustments & Tuning TipsAdjustments for Competition 121Carburetor Disassembly1. Remove the carbretor top cover bolts (1)clamp (2) and

Carburetor Adjustments & Tuning Tips122 Adjustments for Competition5. Remove the accelerator pump cover screws(10) and accelerator pump cover (11)

Carburetor Adjustments & Tuning TipsAdjustments for Competition 123(1) throttle cables(2) hot start cable(3) throttle position sensor connector(4)

Carburetor Adjustments & Tuning Tips124 Adjustments for CompetitionStandard Tuning RecommendationsFor the following recommendations to beaccurate,

8 Before RidingAre You Ready to Ride?Before riding your CRF for the first time, westrongly recommend that you read this owner’smanual, make sure you u

Carburetor Adjustments & Tuning TipsAdjustments for Competition 125Special Tuning ConditionsThere are some unique atmospheric conditions orsituati

Carburetor Adjustments & Tuning Tips126 Adjustments for CompetitionCarburetor Minor AdjustmentsThe standard carburetor settings are ideal for thef

Carburetor Adjustments & Tuning TipsAdjustments for Competition 1277. Change the main jet (4) and slow jet (5) asrequired.(4) main jet (5) slow je

Carburetor Adjustments & Tuning Tips128 Adjustments for CompetitionSpark Plug ReadingRefer to Spark Plug on page 54.Check any jetting change by re

Chassis AdjustmentsAdjustments for Competition 129The following suggestions may improve aspecific concern. Subtle changes in overallhandling may also

Gearing130 Adjustments for CompetitionYou can “adjust” the power delivery of thestandard engine to suit track conditions bychanging gearing. This all

Tire Selection for Track ConditionsAdjustments for Competition 131Choosing the correct tire tread pattern and rubbercompound can affect your placing i

Personal Fit Adjustments132 Adjustments for CompetitionThe following suggestions may make your rideboth more comfortable and more responsive toyour co

TipsTips 133Here’s helpful advice on how to transport andstore your Honda, as well as threetroubleshooting flow charts.Transporting Your Motorcycle ..

Transporting Your Motorcycle134 TipsIf you use a truck or motorcycle trailer totransport your Honda, we recommend thatyou follow these guidelines:• Us

Before Riding 9Is Your Motorcycle Ready to Ride?Competitive riding can be tough on a motorcycle,so it’s important to inspect your CRF and correctany p

Storing Your HondaTips 135If you won’t be riding for an extended period,such as during the winter, thoroughly inspectyour Honda and correct any proble

You & the Environment136 TipsOwning and riding a motorcycle can beenjoyable, but you must do your part to protectnature. When you show respect for

TroubleshootingTips 137The items that are serviceable using this Manualare followed by the page number reference inparenthesis. The items that require

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Technical InformationTechnical Information 139This section contains dimensions, capacities, andother technical data.Vehicle Identification ...

Vehicle Identification140 Technical InformationSerial NumbersThe VIN and engine serial numbers are requiredwhen you register your CRF. They may also

SpecificationsTechnical Information 141Overall length Overall width Overall height Wheelbase Seat height Footpeg height Ground clearance Item English

Torque Specifications142 Technical InformationNuts, Bolts, FastenersCheck and tighten nuts, bolts, and fasteners before every outing.EngineItem 123456

Torque SpecificationsTechnical Information 143FrameItem 12345678910111213141516171819Steering stem nutFork upper pinch boltsFork lower pinch boltsHand

Torque Specifications144 Technical InformationItem 202122232425262728293031323334353637383940Front brake mastercylinder holder boltsBrake hose boltsFr

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Technical Information 145Oxygenated FuelsSome conventional gasolines are being blendedwith alcohol or an ether compound. Thesegasolines are collectiv

146 Technical InformationCompetition LogbookAny serious competition effort relies heavily onthe knowledge gained and compiled fromprevious racing even

Date Running Location/Event Comments (Jetting, Suspension Settings, Gearing, Chassis Adjustments, Maintenance Time Performed, etc.)(Make several phot

148 Technical InformationFRAME RemarksShock spring StandardStifferOptionalSofterStifferFork spring Standard OptionalSofterThe standard fork spring

Technical Information 149Spare Parts & EquipmentThere are numerous spare parts you can take toan event to help ensure you get in a full day ofridi

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Consumer Information 151Consumer InformationThis section contains information aboutcontacting Honda and how to get an officialHonda service manual.Aut

152 Consumer InformationThe Service Manual used by your authorized Honda dealer is available fromHelm, Inc.Also available but not necessary to service

Consumer Information 153Your owner’s manual was written to cover mostof the questions you might ask about yourHonda. Any questions not answered in th

154 Consumer InformationYour Honda DealerOnce you purchase your new Honda, get familiarwith the organization of your Honda dealer soyou can utilize th

Basic Operating Instructions 11Basic Operating Instructions 11Basic Operating InstructionsThis section gives basic information on how tostart and stop

Consumer Information 155The Honda Rider’s ClubOne of the best ways to get the most enjoymentfrom owning and riding your Honda is throughthe Honda Ride

156 Table of contentsTable of ContentsThe following presents the contents of eachsection of your owner’s manual.MOTORCYCLE SAFETY...

Table of contents 157Table of ContentsTIPS...133Transporting Your Motorcycle ...

158 Indexaccessories...3adjustments,altitude and temperature...124ca

Index 159Indexgap, spark plug ...54gasohol ...

160 IndexIndexsuspension,front...73rear...

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Pro Honda GN4 4-stroke oil or an equivalent motorcycle oil.The maintenance schedule (page 21) lists service frequencies for: each race or about 2.5 ho

12 Basic Operating Instructions12 Basic Operating InstructionsBasic Operating InstructionsSafe Riding PrecautionsBefore riding your CRF for the first

Basic Operating Instructions 13Basic Operating Instructions 13Starting & Stopping the EngineAlways follow the proper starting proceduredescribed b

14 Basic Operating InstructionsStarting & Stopping the Engine14 Basic Operating InstructionsHow to Stop the Engine(1)(2)(1) throttle (2) engine st

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Basic Operating Instructions 15Help assure your CRF’s future reliability andperformance by paying extra attention to howyou ride during the first oper

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Servicing Your Honda 17Servicing Your HondaKeeping your CRF well maintained is absolutelyessential to your safety. It’s also a good way toprotect you

18 Servicing Your HondaWARNINGImproperly maintaining this motorcycle orfailing to correct a problem before youride can cause a crash in which you canb

Servicing Your Honda 19Maintenance SafetyThis section includes instructions on how to perform some important maintenance tasks.Some of the most import

20 Servicing Your HondaMaintenance ScheduleTo maintain the safety and reliability of yourCRF, regular inspection and service is required asshown in th

Servicing Your Honda 21Maintenance ScheduleITEMS THROTTLE OPERATION HOT START SYSTEM AIR FILTER CRANKCASE BREATHER SPARK PLUG RADIATOR COOLANT VALVE C

22 Servicing Your HondaGeneral Competition MaintenancePerform maintenance on firm, level ground usingoptional workstand, or equivalent support.When ti

Servicing Your Honda 23Spark Plug Some non-resistor plugs may cause ignition problems. Refer to the recommendations elsewhere in this manual for spe

24 Servicing Your HondaGeneral Competition MaintenanceHandgripsAlways use Pro Honda Handgrip Cement when replacing handgrips.Refer to the Service Manu

IntroductionCongratulations on choosing your Honda CRFmotocross motorcycle. When you own a Honda, you’re part of a worldwide family of satisfied cust

Suspension Linkage LubricationDisassemble, clean, inspect and lubricate all suspension linkage pivots with grease after each 7.5 hours of running time

26 Servicing Your HondaBefore & After Competition MaintenanceBetween Motos & Practice MaintenanceAfter practice or between motos you have acha

Servicing Your Honda 27Before & After Competition MaintenanceRoutine CleaningIf your CRF is only slightly dirty, it is best toclean it by hand wit

28 Servicing Your HondaMaintenance Component Locationsfront brakecaliperengine oilfilter engine oilfiller capengine oilinspectionwindowengine oildrain

Servicing Your Honda 29Seat RemovalRefer to Safety Precautions on page 19.Removal1. Remove the seat mounting bolts (1).2. Remove the seat (2) by slidi

30 Servicing Your HondaFuel Tank RemovalRefer to Safety Precautions on page 19.Removal1. Turn the fuel valve OFF.2. Remove the seat (page 29).3. Remov

Servicing Your Honda 31Fuel Tank Removal(2)(3)(1)(4)(5)(6)(7)(12)(11)Installation1. Install the fuel tank on the frame.2. Install the fuel valve (1) a

32 Servicing Your Honda(14)(12)(13)Subframe RemovalRefer to Safety Precautions on page 19.Removal1. Remove the seat (page 29).2. Remove the side cover

Servicing Your Honda 33Subframe Removal2. Make sure the carburetor lug (4) align withthe air cleaner connecting tube slot (5).3. Tighten the screw (6)

34 Servicing Your HondaFuel SystemRefer to Safety Precautions on page 19.Fuel RecommendationWe recommend that you use unleaded fuelbecause it produces

A Few Words About SafetyYour safety, and the safety of others, is very important. And operating this motorcycle safely is an important responsibility

Servicing Your Honda 35Fuel SystemFuel FilterThe fuel filter is mounted on the bottom the fueltank. Dirt accumulated in the filter will restrictthe f

36 Servicing Your Honda* Suggested 4-stroke engine oils are equalperformance to SJ oils that are not labeled asenergy conserving on the circular API

Servicing Your Honda 37Engine OilJASO T 903 standardThe JASO T 903 standard is an index for engineoils for 4-stroke motorcycle engines.There are two c

38 Servicing Your HondaEngine Oil8. Remove the left engine guard bolt (4) and leftengine guard (5).12. Apply grease to the filter side of the springe

Refer to Safety Precautions on page 19. Using the proper oil, and regularly checking,adding, and changing oil will help extend theservice life of the

JASO T 903 standardThe JASO T 903 standard is an index for engineoils for 4-stroke motorcycle engines.There are two classes: MA and MB.Oil conforming

Servicing Your Honda 41Your CRF’s liquid cooling system dissipatesengine heat through the coolant jacket thatsurrounds the cylinder and cylinder head.

42 Servicing Your HondaCooling System Inspection1. Check the cooling system for leaks (see theHonda Service Manual for troubleshooting ofleaks). 2. C

Servicing Your Honda 43Air CleanerRefer to Safety Precautions on page 19. The air cleaner uses polyurethane inner and outerpieces which can’t be sepa

44 Servicing Your HondaAir Cleaner(1) air cleaner retaining boltImproper installation of the air cleaner assemblymay allow dirt and dust to enter the

ContentsMOTORCYCLE SAFETY...1Important Safety Information...2Important Safety Precautions...

Servicing Your Honda 45Crankcase BreatherRefer to Safety Precautions on page 19. Service more frequently if your CRF is ridden inthe rain or often at

46 Servicing Your HondaThrottleRefer to Safety Precautions on page 19.Throttle Freeplay(1) freeplayInspectionCheck freeplay (1).Freeplay: 1/8 - 3/16 i

Servicing Your Honda 47ThrottleThrottle Inspection(1) throttle1. Check that the throttle assembly is positionedproperly and the securing bolts are tig

48 Servicing Your HondaEngine Idle SpeedRefer to Safety Precautions on page 19. Remember, idle speed adjustment in not a“cure-all” for other problems

Servicing Your Honda 49Clutch SystemRefer to Safety Precautions on page 19.Clutch Lever AdjustmentThe distance between the tip of the clutch leverand

50 Servicing Your HondaClutch SystemOther Inspections & Lubrication• Check that the clutch lever assembly is positioned properly (by inspecting th

Servicing Your Honda 51Clutch SystemClutch Disc/Plate InspectionReplace the clutch discs (1) if they show signs ofscoring or discoloration.Measure the

52 Servicing Your HondaClutch System(9) O-ring (10) clutch cover12. Apply grease to the rear brake pedal pivot bolt(11) sliding surface.13. Install th

Servicing Your Honda 53Hot Start LeverRefer to Safety Precautions on page 19.Hot Start Lever Freeplayleft handlebar(1) hot start lever(2) hot start le

54 Servicing Your HondaSpark PlugStandard IFR8H11 (NGK) orVK24PRZ11 (DENSO)Optional IFR9H11 (NGK) orVK27PRZ11 (DENSO)Refer to Safety Precautions on pa

Motorcycle SafetyThis section presents some of the most importantinformation and recommendations to help youride your CRF safely. Please take a fewmo

Servicing Your Honda 55Valve ClearanceCylinder Head Cover RemovalBefore inspection, clean the engine thoroughly tokeep dirt from entering the engine.1

Valve Clearance56 Servicing Your HondaValve Clearance Inspection1. Measure the intake valve clearance byinserting a feeler gauge (1) between the valve

Servicing Your Honda 57Valve ClearanceCamshaft Holder Assembly Removal1. Record the intake valve and exhaust valveclearances.Make sure the piston is a

Valve Clearance58 Servicing Your Honda6. Make sure the piston is at TDC (Top DeadCenter) on the compression stroke. Loosen the camshaft holder assembl

Servicing Your Honda 59Valve ClearanceShim Selection1. Clean the valve shim contact area in the valvelifter (1) with compressed air.2. Measure the shi

Valve Clearance60 Servicing Your HondaCamshaft Holder Assembly 1. Install the newly selected shims (1) on thevalve spring retainers (2).Do not let the

(15)(19)(22)(21)(20)(16)(18)(17)Valve ClearanceServicing Your Honda 616. While holding the cam chain, rotate theprimary drive gear bolt (12) (cranksha

Valve Clearance62 Servicing Your Honda13.Rotate the primary drive gear bolt (crankshaft)clockwise two turns and align the punch mark(13) with the inde

Servicing Your Honda 63Valve ClearanceSpark Plug InstallationTighten the spark plug (1):• If the old plug is good:1/8 turn after it seats.• If insta

64 Servicing Your HondaValve Clearance(6) cylinder head cover(8) cylinder head cover A bolt(9) cylinder head cover B bolts(10) spark plug cap(11) brea

Important Safety InformationImportant Safety PrecautionsYour CRF can provide many years of pleasure, ifyou take responsibility for your own safety and

(2) primary wire connector (4) nut(3) bolts (5) ignition coil9. Remove the cylinder head cover (page 55).Servicing Your Honda 65Piston/Piston Rings/Pi

66 Servicing Your HondaPiston/Piston Rings/Piston Pin13.Remove the engine hanger nut (9), enginehanger A bolt (10) and fuel hose guide (11).Remove the

Servicing Your Honda 67Piston/Piston Rings/Piston PinCylinder Removal1. Remove the cylinder bolt (1) and cylinder (2).Do not let the cam chain fall in

68 Servicing Your HondaPiston/Piston Rings/Piston PinPiston Ring Installation 1. Remove the carbon deposits from the pistonhead and piston ring groove

Servicing Your Honda 69Piston/Piston Rings/Piston PinPiston Installation1. Place clean shop towels over the crankcaseopening to keep the piston pin cl

70 Servicing Your Honda(7)(9)(8)Piston/Piston Rings/Piston Pin5. Apply engine oil to the cylinder wall, pistonouter surface and piston rings.Route the

Servicing Your Honda 71Piston/Piston Rings/Piston Pin2. Route the cam chain through the cylinderhead (3).Install the cylinder head.Do not damage matin

72 Servicing Your HondaPiston/Piston Rings/Piston Pin6. Connect the radiator hose (13) to the cylinderhead.(13) radiator hose7. Tighten the radiator

Servicing Your Honda 73SuspensionRefer to Safety Precautions on page 19.Loose, worn, or damaged suspension componentsmay adversely affect the handling

74 Servicing Your HondaSuspensionRear Suspension InspectionThe swingarm is controlled by one hydraulicshock absorber with an aluminum reservoir foroil

Accessories & ModificationsMotorcycle Safety 3Accessories & ModificationsInstalling non-Honda accessories, removingoriginal equipment, or modi

SuspensionServicing Your Honda 75(1) outer tube (3) lock nut wrench(2) fork damper (4) slider, lower end The outer tube (1) can drop on the slider (7

Suspension76 Servicing Your Honda6. Pour the recommended fork oil into the outertube.Fork Oil Capacity: Standard (0.46 kgf/mm) Fork SpringStandard oil

Servicing Your Honda 77BrakesRefer to Safety Precautions on page 19.Both the front and rear brakes are the hydraulicdisc type. As the brake pads wear

78 Servicing Your HondaBrakesFluid Level InspectionFront Brake Fluid Level Check(1) LWR markWith the motorcycle in an upright position, checkthe fluid

Servicing Your Honda 79BrakesAdding Front Brake FluidSpilled brake fluid will severely damageinstrument lenses and painted surfaces. It is alsoharmful

80 Servicing Your HondaBrakesBrake Pad WearBrake pad wear depends on the severity of usageand track conditions. (Generally, the pads willwear faster

Servicing Your Honda 81WheelsRefer to Safety Precautions on page 19.Maintenance of spoke tension and wheel trueness(roundness) is critical to safe mot

82 Servicing Your HondaTires & TubesWARNINGUsing tires that are excessively worn orimproperly inflated can cause a crash inwhich you can be seriou

Servicing Your Honda 83Tires & TubesTire ReplacementThe tires that came on your CRF were designedto provide a good combination of handling,braking

84 Servicing Your HondaDrive ChainRefer to Safety Precautions on page 19.The service life of the chain depends on properlubrication and adjustment. P

4 Motorcycle SafetySafety LabelsRead this label carefully and don’t remove it. If the label comes off or becomes hard to read, contact your Honda dea

Servicing Your Honda 85Replace the roller if necessary as follows.Install the upper drive chain roller (Green) withthe “/” mark (9) facing toward the

86 Servicing Your HondaDrive Chain4. Inspect the sprocket teeth for wear or damage.We recommend replacing the sprocketwhenever a new chain is installe

Servicing Your Honda 87Exhaust Pipe/MufflerExhaust Pipe/Muffler Inspection1. Check the flange bolts and exhaust pipe jointnuts for tightness.2. Check

88 Servicing Your HondaExhaust Pipe/MufflerMuffler Installation1. Remove the gasket (1).2. Install the muffler clamp (2) and new gasketonto the exhaus

Servicing Your Honda 89Exhaust Pipe/MufflerExhaust Pipe Installation1. Install a new exhaust pipe gasket (1), exhaustpipe (2) and exhaust pipe joint

90 Servicing Your HondaAdditional Maintenance ProceduresRefer to Safety Precautions on page 19.Steering Head Bearing Inspection1. With your CRF on a b

Servicing Your Honda 91Additional Maintenance ProceduresNuts, Bolts, FastenersCheck and tighten nuts, bolts, and fastenersbefore every outing.Item 123

92 Servicing Your HondaAppearance CareRefer to Safety Precautions on page 19.Frequent cleaning and polishing will keep yourHonda looking newer longer.

Servicing Your Honda 93Appearance CareCondensation ControlSome condensation can form within thetransmission cavity as well. This is natural andjust o

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