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A Few Words About Safety
Service Information
The service and repair information contained in this manual is intended for use by qualified, professional technicians.
Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also
damage the vehicle or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures
require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service
procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of
the vehicle.
If you need to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We strongly recommend
that you do not use replacement parts of inferior quality.
For Your Customer’s Safety
Proper service and maintenance are essential to the customer’s safety and
the reliability of the vehicle. Any error or oversight while servicing a vehicle
can result in faulty operation, damage to the vehicle, or injury to others.
For Your Safety
Because this manual is intended for the professional service technician, we
do not provide warnings about many basic shop safety practices (e.g., Hot
parts–wear gloves). If you have not received shop safety training or do not
feel confident about your knowledge of safe servicing practice, we
recommended that you do not attempt to perform the procedures described
in this manual.
Some of the most important general service safety precautions are given
below. However, we cannot warn you of every conceivable hazard that can
arise in performing service and repair procedures. Only you can decide
whether or not you should perform a given task.
Important Safety Precautions
Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
using safety equipment. When performing any service task, be especially careful of the following:
• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
required to perform the tasks safely and completely.
• Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around
pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack,
make sure that it is always securely supported. Use jack stands.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise.
This will help eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine.
• Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas.
• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.
Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries.
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never drain or store gasoline in an open container.
• Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts.
Improper service or repairs can create an
unsafe condition that can cause your customer
or others to be seriously hurt or killed.
Follow the procedures and precautions in this
manual and other service materials carefully.
Failure to properly follow instructions and
precautions can cause you to be seriously hurt
or killed.
Follow the procedures and precautions in this
manual carefully.
HOW TO USE THIS MANUAL
This service manual describes the service procedures for the
CRF450X.
Follow the Maintenance Schedule (Section 4) recommendations to
ensure that the vehicle is in peak operating condition and the emission
levels are within the standards set by the U.S. Environmental
Protection Agency (EPA) and California Air Resources Board (CARB).
Performing the first scheduled maintenance is very important. It
compensates for the initial wear that occurs during the break-in
period.
Sections 1 and 4 apply to the whole motorcycle. Section 3 illustrates
procedures for removal/installation of components that may be
required to perform service described in the following sections.
Section 5 through 20 describe parts of the motorcycle, grouped
according to location.
Find the section you want on this page, then turn to the table of
contents on the first page of the section.
Most sections start with an assembly or system illustration, service
information and troubleshooting for the section. The subsequent
pages give detailed procedure.
If you are not familiar with this motorcycle, read Technical Feature in
Section 2.
If you don't know the source of the trouble, go to section 22
Troubleshooting.
Your safety, and the safety of others, is very important. To help
you make informed decisions we have provided safety
messages and other information throughout this manual. Of
course, it is not practical or possible to warn you about all the
hazards associated with servicing this vehicle.
You must use your own good judgement.
You will find important safety information in a variety of forms
including:
• Safety Labels – on the vehicle
• Safety Messages – preceded by a safety alert symbol and
one of three signal words, DANGER, WARNING, or CAU-
TION.
These signal words mean:
You WILL be KILLED or SERIOUSLY
HURT if you don’t follow instructions.
You CAN be KILLED or SERIOUSLY
HURT if you don’t follow instructions.
You CAN be HURT if you don’t follow
instructions.
• Instructions – how to service this vehicle correctly and safely.
As you read this manual, you will find information that is preceded by a
symbol. The purpose of this message is to help prevent
damage to your vehicle, other property, or the environment.
ALL INFORMATION, ILLUSTRATIONS, DIREC-
TIONS AND SPECIFICATIONS INCLUDED IN
THIS PUBLICATION ARE BASED ON THE LAT-
EST PRODUCT INFORMATION AVAILABLE AT
THE TIME OF APPROVAL FOR PRINTING.
Honda Motor Co., Ltd. RESERVES THE RIGHT
TO MAKE CHANGES AT ANY TIME WITHOUT
NOTICE AND WITHOUT INCURRING ANY
OBLIGATION WHATSOEVER. NO PART OF
THIS PUBLICATION MAY BE REPRODUCED
WITHOUT WRITTEN PERMISSION. THIS MAN-
UAL IS WRITTEN FOR PERSONS WHO HAVE
ACQUIRED BASIC KNOWLEDGE OF MAINTE-
NANCE ON Honda MOTORCYCLES, MOTOR
SCOOTERS OR ATVS.
Honda Motor Co., Ltd.
SERVICE PUBLICATION OFFICE
CONTENTS
GENERAL INFORMATION
FRAME/BODY PANELS/EXHAUST
SYSTEM
MAINTENANCE
LUBRICATION SYSTEM
FUEL SYSTEM
COOLING SYSTEM
ENGINE REMOVAL/INSTALLATION
CYLINDER HEAD/VALVES
CYLINDER/PISTON
CLUTCH/STARTER CLUTCH/KICKSTARTER/
GEARSHIFT LINKAGE
ALTERNATOR
CRANKCASE/CRANKSHAFT/TRANSMISSION/
BALANCER
FRONT WHEEL/SUSPENSION/STEERING
REAR WHEEL/SUSPENSION
14
13
12
11
10
9
8
7
6
5
4
2
3
1
HYDRAULIC BRAKE
BATTERY/CHARGING SYSTEM
IGNITION SYSTEM
ELECTRIC STARTER
18
17
16
15
ENGINE AND DRIVE TRAIN
CHASSIS
ELECTRICAL
LIGHTS/METER/SWITCHES
WIRING DIAGRAM
TROUBLESHOOTING
INDEX
19
20
21
22
Date of Issue: November, 2007
©Honda Motor Co., Ltd.
2
23
TECHNICAL FEATURE
SYMBOLS
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to
these symbols, it would be explained specifically in the text without the use of the symbols.
Replace the part(s) with new one(s) before assembly.
Use the recommended engine oil, unless otherwise specified.
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1).
Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent).
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent).
Example: Molykote
®
BR-2 plus manufactured by Dow Corning U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or
equivalent).
Example: Molykote
®
G-n Paste manufactured by Dow Corning U.S.A.
Honda Moly 60 (U.S.A. only)
Rocol ASP manufactured by Rocol Limited, U.K.
Rocol Paste manufactured by Sumico Lubricant, Japan
Use silicone grease.
Apply a locking agent. Use a medium strength locking agent unless otherwise specified.
Apply sealant.
Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified.
Use fork or suspension fluid.
1-1
1
1. GENERAL INFORMATION
SERVICE RULES ········································· 1-2
MODEL IDENTIFICATION··························· 1-2
GENERAL SPECIFICATIONS······················ 1-5
LUBRICATION SYSTEM
SPECIFICATIONS········································ 1-7
FUEL SYSTEM SPECIFICATIONS·············· 1-7
COOLING SYSTEM SPECIFICATIONS ······ 1-7
CYLINDER HEAD/VALVES
SPECIFICATIONS········································ 1-8
CYLINDER/PISTON SPECIFICATIONS ······ 1-8
CLUTCH/STARTER CLUTCH/
KICKSTARTER/GEARSHIFT LINKAGE
SPECIFICATIONS········································ 1-9
CRANKCASE/CRANKSHAFT/
TRANSMISSION/BALANCER
SPECIFICATIONS (’05 – ’07)······················· 1-9
CRANKCASE/CRANKSHAFT/
TRANSMISSION/BALANCER
SPECIFICATIONS (After ’07)···················· 1-10
FRONT WHEEL/SUSPENSION/STEERING
SPECIFICATIONS······································ 1-11
REAR WHEEL/SUSPENSION
SPECIFICATIONS ····································· 1-11
HYDRAULIC BRAKE SPECIFICATIONS··· 1-12
BATTERY/CHARGING SYSTEM
SPECIFICATIONS ····································· 1-12
IGNITION SYSTEM SPECIFICATIONS ···· 1-12
ELECTRIC STARTER SPECIFICATION····· 1-13
LIGHTS/METER/SWITCHES
SPECIFICATIONS ····································· 1-13
STANDARD TORQUE VALUES ··············· 1-14
ENGINE & FRAME TORQUE VALUES ···· 1-14
LUBRICATION & SEAL POINTS ·············· 1-21
CABLE & HARNESS ROUTING
(’05 – ’07)··················································· 1-25
CABLE & HARNESS ROUTING
(After ’07)·················································· 1-32
OPTIONAL PARTS···································· 1-37
EMISSION CONTROL SYSTEMS ············ 1-40
GENERAL INFORMATION
1-2
GENERAL INFORMATION
SERVICE RULES
1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet
Honda's design specifications may cause damage to the motorcycle.
2. Use the special tools designed for this product to avoid damage and incorrect assembly.
3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with
English fastener.
4. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling.
5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque
diagonally in incremental steps unless a particular sequence is specified.
6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.
7. After reassembly, check all parts for proper installation and operation.
8. Route all electrical wires as shown in the Cable and Harness Routing.
– ’05 – ’07: (page 1-25)
– After ’07: (page 1-32)
MODEL IDENTIFICATION
’05 – ’07 shown:
GENERAL INFORMATION
1-3
The Vehicle Identification Number (V.I.N.) is stamped on the right side
of the steering head.
The engine serial number is stamped on the left side of the lower
crankcase.
The carburetor identification number is stamped on the left side of the
carburetor body.
The name plate (U.S.A.) or Safety Certification Label (Canada) is
attached on the right side of the frame.
VEHICLE IDENTIFICATION NUMBER (VIN)
ENGINE SERIAL NUMBER
CARBURETOR IDENTIFICATION NUMBER
NAME PLATE (U.S.A.) OR SAFETY
CERTIFICATION LABEL (Canada)
U.S.A. type shown:
GENERAL INFORMATION
1-4
The Vehicle Emission Control Information Label is attached on the rear
fender (’05 – ’06 California type, ’07 U.S.A.).
The Vehicle Emission Control Information Label is attached on the rear
fender (After ’07 U.S.A. and Canada).
EMISSION CONTROL INFORMATION LABEL
’05 – ’06 California type, ’07 U.S.A.:
After ’07 U.S.A. and Canada:
Canada type only
EMISSION CONTROL INFORMATION LABEL
GENERAL INFORMATION
1-5
GENERAL SPECIFICATIONS
ITEM SPECIFICATION
DIMENSIONS Overall length (’05 – ’07) 2,180 mm (85.8 in)
(After ’07) 2,179 mm (85.8 in)
Overall width 821 mm (32.3 in)
Overall height 1,273 mm (50.1 in)
Wheelbase (’05 – ’07) 1,483 mm (58.4 in)
(After ’07) 1,480 mm (58.3 in)
Seat height 963 mm (37.9 in)
Footpeg height 431 mm (17.0 in)
Ground clearance 345 mm (13.6 in)
FRAME Frame type Twin tube
Front suspension Telescopic fork
Front suspension axle travel 279 mm (11.0 in)
Front suspension cushion stroke 315 mm (12.4 in)
Rear suspension Pro-Link
Rear wheel travel 313 mm (12.3 in)
Rear damper Decarbon type with nitrogen gas filled
damper
Front tire size 80/100-21 51M
Rear tire size 110/100-18 64M
Tire brand (Dunlop) (’05 – ’07) Front: D742F
(After ’07) Front: D742FA
Rear: D756
Front brake Hydraulic single disc
Front brake swept area 334.5 cm
2
(51.8 in
2
)
Rear brake Hydraulic single disc
Rear brake swept area 391.1 cm
2
(60.6 in
2
)
Caster angle (’05 – ’07) 27°10’
(After ’07) 27°03’
Trail length (’05 – ’07) 110 mm (4.3 in)
(After ’07) 114.7 mm (4.52 in)
Fuel tank capacity (’05 – ’07) 8.6 liter (2.27 US gal, 1.89 lmp gal)
(After ’07) 7.2 liter (1.90 US gal, 1.58 Imp gal)
Fuel tank reserve capacity (’05 – ’07) 1.4 liter (0.37 US gal, 0.31 lmp gal)
(After ’07) 1.6 liter (0.42 US gal, 0.35 lmp gal)
ENGINE Bore and stroke 96.0 x 62.1 mm (3.78 x 2.44 in)
Displacement 449 cm
3
(27.4 cu-in)
Compression ratio 12.0 : 1
Valve train Chain drive and OHC with rocker arm
Intake valve opens at 1.0 mm (0.04 in) lift 10° BTDC
closes at 1.0 mm (0.04 in) lift 45° ABDC
Exhaust valve opens at 1.0 mm (0.04 in) lift 50° BBDC
closes at 1.0 mm (0.04 in) lift 15° ATDC
Lubrication system Forced pressure and wet sump
Oil pump type Trochoid
Cooling system Liquid cooled
Air filtration Oiled polyurethane foam
Crankshaft type Assembled type
Engine dry weight 32.3 kg (71.2 lbs)
Cylinder arrangement Single cylinder, inclined 6° from vertical
CARBURETOR Carburetor type Piston valve type
Venturi diameter 40 mm (1.6 in)
GENERAL INFORMATION
1-6
DRIVE TRAIN Clutch system Multi-plate, wet
Clutch operation system Cable operated
Transmission Constant mesh, 5-speed
Primary reduction 2.739 (63/23)
Final reduction 3.923 (51/13)
Gear ratio 1st 2.230 (29/13)
2nd 1.625 (26/16)
3rd 1.235 (21/17)
4th 1.000 (19/19)
5th 0.826 (19/23)
Gearshift pattern Left foot operated return system,
1 - N - 2 - 3 - 4 - 5
ELECTRICAL Ignition system ICM (Ignition Control Module)
Starting system Electric starter motor and kickstarter
Charging system Single phase output alternator
Regulator/rectifier SCR shorted/Single phase, half wave
rectification
Lighting system Alternator
ITEM SPECIFICATION
GENERAL INFORMATION
1-7
LUBRICATION SYSTEM SPECIFICATIONS
Unit: mm (in)
FUEL SYSTEM SPECIFICATIONS
COOLING SYSTEM SPECIFICATIONS
ITEM STANDARD SERVICE LIMIT
Engine oil capacity At draining 0.67 liter (0.71 US qt, 0.59 lmp qt) –
At filter change 0.70 liter (0.74 US qt, 0.62 Imp qt) –
At disassembly 0.87 liter (0.92 US qt, 0.77 lmp qt) –
Transmission oil capacity At draining 0.65 liter (0.69 US qt, 0.57 Imp qt) –
At disassembly 0.75 liter (0.79 US qt, 0.66 Imp qt) –
Recommended engine oil Pro Honda GN4 4-stroke oil (U.S.A. and
Canada) or equivalent motor oil
API service classification: SG or Higher
JASO T 903 standard: MA
Viscosity: SAE 10W-30
–
Recommended transmission oil Pro Honda GN4 4-stroke oil (U.S.A. and
Canada) or equivalent motor oil
API service classification: SG or Higher
JASO T 903 standard: MA
Viscosity: SAE 10W-30
–
Oil pump rotor Tip clearance 0.15 (0.006) 0.20 (0.008)
Body clearance 0.15 – 0.21 (0.006 – 0.008) –
Side clearance 0.05 – 0.13 (0.002 – 0.005) –
ITEM SPECIFICATIONS
Fuel tank capacity ’05 – ’07 8.6 liter (2.27 US gal, 1.89 Imp gal)
After ’07 7.2 liter (1.90 US gal, 1.58 Imp gal)
Carburetor identification number ’05, ’06 FCR04A
’07 FCR13A
After ’07 FCR13B
Main jet ’05 – ’07 #142
After ’07 #145
Slow jet #45
Jet needle ’05, ’06 NCVU
’07 NHTU
After ’07 NNEU
Jet needle clip position (Standard) ’05, ’06 2nd position from the top
After ’06 Fixed position
Pilot screw initial opening ’05 – ’07 1-1/4 turns out
After ’07 1-1/8 turns out
Float level 8.0 mm (0.31 in)
Idle speed 1,700 ± 100 rpm
Throttle grip freeplay 3 – 5 mm (1/8 – 3/16 in)
Hot starter lever freeplay 2 – 3 mm (1/16 – 1/8 in)
PAIR control valve specified vacuum
(’05 and ’06 California type, After ’06)
56 kPa (420 mmHg)
Throttle position sensor (Blue – Black) resistance
(at 20°C/68°F)
4 – 6 kΩ
ITEM SPECIFICATIONS
Coolant capacity At change 1.21 liter (1.28 US qt, 1.06 lmp qt)
At disassembly 1.45 liter (1.53 US qt, 1.28 lmp qt)
Radiator cap relief pressure 108 – 137 kPa (1.1 – 1.4 kgf/cm
2
, 16 – 20 psi)
Recommended antifreeze Pro Honda HP Coolant or an equivalent high quality ethyl-
ene glycol antifreeze containing silicate-free corrosion
inhibitors
Standard coolant concentration 1 : 1 mixture with distilled water
GENERAL INFORMATION
1-8
CYLINDER HEAD/VALVES SPECIFICATIONS
Unit: mm (in)
CYLINDER/PISTON SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Cylinder compression 402 kPa (4.1 kgf/cm
2
, 58 psi)
at 360 rpm
–
Cylinder head warpage – 0.05 (0.002)
Decompressor clearance ’05 – ’07 Ex valve clearance + 0.35 mm (0.014) –
Valve and
valve guide
Valve clearance IN 0.16 ± 0.03 (0.006 ± 0.001) –
EX 0.28 ± 0.03 (0.011 ± 0.001) –
Valve stem O.D. IN 5.475 – 5.490 (0.2156 – 0.2161) –
EX 4.965 – 4.980 (0.1955 – 0.1961) 4.96 (0.195)
Valve guide I.D. IN 5.500 – 5.512 (0.2165 – 0.2170) 5.552 (0.2186)
EX 5.000 – 5.012 (0.1969 – 0.1973) 5.052 (0.1989)
Stem-to-guide clear-
ance
IN 0.010 – 0.037 (0.0004 – 0.0015) –
EX 0.020 – 0.047 (0.0008 – 0.0019) –
Valve guide projec-
tion above cylinder
head
IN 16.1 – 16.3 (0.63 – 0.64) –
EX 17.9 – 18.1 (0.70 – 0.71) –
Valve seat width IN 1.1 – 1.3 (0.04 – 0.05) 2.0 (0.08)
EX 1.3 – 1.5 (0.05 – 0.06) 2.0 (0.08)
Valve spring free length IN 40.68 (1.602) 39.7 (1.56)
EX 42.82 (1.686) 41.9 (1.65)
Rocker arm Rocker arm I.D. 12.000 – 12.018 (0.4724 – 0.4731) 12.05 (0.474)
Rocker arm shaft O.D. 11.967 – 11.975 (0.4711 – 0.4715) 11.92 (0.469)
Rocker arm-to-shaft clearance 0.025 – 0.051 (0.0010 – 0.0020) 0.10 (0.004)
Camshaft Cam lobe height IN 36.890 – 37.130 (1.4524 – 1.4618) 36.890 (1.4524)
EX 35.063 – 35.303 (1.3804 – 1.3899) 35.063 (1.3804)
Valve lifter O.D. 25.978 – 25.993 (1.0228 – 1.0233) 25.97 (1.022)
Valve lifter bore I.D. 26.010 – 26.026 (1.0240 – 1.0246) 26.04 (1.025)
ITEM STANDARD SERVICE LIMIT
Cylinder I.D. 96.000 – 96.015 (3.7795 – 3.7801) 96.025 (3.7805)
Out of round – 0.010 (0.0004)
Taper – 0.010 (0.0004)
Warpage – 0.05 (0.002)
Piston, piston
ring
Piston mark direction "IN" mark facing toward the intake side –
Piston O.D. 95.970 – 95.980 (3.7783 – 3.7787) 95.94 (3.777)
Piston O.D. measurement point 5.0 mm (0.20 in) from the bottom of
skirt
–
Piston pin bore I.D. 19.002 – 19.008 (0.7481 – 0.7483) 19.03 (0.749)
Piston pin O.D. 18.994 – 19.000 (0.7478 – 0.7480) 18.98 (0.747)
Piston-to-piston pin clearance 0.002 – 0.014 (0.0001 – 0.0006) 0.04 (0.002)
Top ring mark "R" mark side facing up –
Piston ring-to-ring
groove clearance
Top 0.065 – 0.100 (0.0026 – 0.0039) 0.115 (0.0045)
Piston ring end gap Top ring 0.25 – 0.31 (0.010 – 0.012) 0.45 (0.018)
Oil ring
(side rail)
0.20 – 0.70 (0.008 – 0.028) 0.90 (0.035)
Cylinder-to-piston clearance 0.020 – 0.045 (0.0008 – 0.0018) 0.085 (0.0033)
Connecting rod small end I.D. ’05 – ’07 19.016 – 19.034 (0.7487 – 0.7494) 19.04 (0.750)
After ’07 19.016 – 19.038 (0.7487 – 0.7495) 19.04 (0.750)
Connecting rod-to-piston pin clearance ’05 – ’07 0.016 – 0.040 (0.0006 – 0.0016) 0.06 (0.002)
After ’07 0.016 – 0.044 (0.0006 – 0.0017) 0.06 (0.002)
GENERAL INFORMATION
1-9
CLUTCH/STARTER CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE
SPECIFICATIONS
Unit: mm (in)
CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER
SPECIFICATIONS (’05 – ’07)
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Clutch lever freeplay 10 – 20 (3/8 – 13/16) –
Clutch spring free length 44.7 (1.76) 43.7 (1.72)
Clutch disc thickness 2.92 – 3.08 (0.115 – 0.121) 2.85 (0.112)
Clutch plate warpage – 0.15 (0.006)
Kickstarter pinion gear I.D. 22.007 – 22.028 (0.8664 – 0.8672) 22.05 (0.868)
Kickstarter pinion gear bushing I.D. 20.000 – 20.021 (0.7874 – 0.7882) 20.04 (0.789)
O.D. 21.979 – 22.000 (0.8653 – 0.8661) 21.96 (0.865)
Kickstarter spindle O.D. 19.980 – 19.993 (0.7866 – 0.7871) 19.97 (0.786)
Kickstarter idle gear I.D. 20.020 – 20.041 (0.7882 – 0.7890) 20.07 (0.790)
Kickstarter idle gear bushing I.D. 17.000 – 17.018 (0.6693 – 0.6700) 17.04 (0.671)
O.D. 19.979 – 20.000 (0.7866 – 0.7874) 19.96 (0.786)
Countershaft O.D. at kickstarter idle gear 16.966 – 16.984 (0.6680 – 0.6687) 16.95 (0.667)
Starter driven gear boss I.D. 36.009 – 36.034 (1.4177 – 1.4187) 36.034 (1.4187)
O.D. 45.660 – 45.673 (1.7976 – 1.7981) 45.660 (1.7976)
Reduction gear A I.D. 12.010 – 12.050 (0.4728 – 0.4744) 12.050 (0.4744)
Reduction gear B I.D. 10.045 – 10.085 (0.3955 – 0.3970) 10.085 (0.3970)
Idle gear I.D. 12.010 – 12.050 (0.4728 – 0.4744) 12.050 (0.4744)
Gear holder shafts O.D. 11.989 – 12.000 (0.4720 – 0.4724) 11.989 (0.4720)
Reduction gear shaft O.D. 9.980 – 9.995 (0.3929 – 0.3935) 9.980 (0.3929)
ITEM STANDARD SERVICE LIMIT
Crankshaft Side clearance 0.30 – 0.75 (0.012 – 0.030) 0.75 (0.030)
Radial clearance 0.006 – 0.018 (0.0002 – 0.0007) 0.05 (0.002)
Runout R – 0.03 (0.001)
L – 0.05 (0.002)
Transmission Gear I.D. M4 28.007 – 28.028 (1.1026 – 1.1035) 28.05 (1.104)
M5 25.020 – 25.041 (0.9850 – 0.9859) 25.07 (0.987)
C1 22.007 – 22.028 (0.8664 – 0.8672) 22.04 (0.868)
C2 30.020 – 30.041 (1.1819 – 1.1827) 30.07 (1.184)
C3 25.020 – 25.041 (0.9850 – 0.9859) 25.07 (0.987)
Bushing O.D. M4 27.959 – 27.980 (1.1007 – 1.1016) 27.94 (1.100)
C2 29.979 – 30.000 (1.1803 – 1.1811) 29.95 (1.179)
Bushing I.D. C2 27.000 – 27.021 (1.0630 – 1.0638) 27.04 (1.065)
Gear-to-bushing
clearance
M4 0.027 – 0.069 (0.0011 – 0.0027) 0.11 (0.004)
C2 0.020 – 0.062 (0.0008 – 0.0024) 0.12 (0.005)
Mainshaft O.D. M5 24.959 – 24.980 (0.9826 – 0.9835) 24.94 (0.982)
Countershaft O.D. C1 bearing 18.987 – 19.000 (0.7475 – 0.7480) 18.94 (0.746)
C2 bushing 26.959 – 26.980 (1.0614 – 1.0622) 26.94 (1.061)
C3 24.959 – 24.980 (0.9826 – 0.9835) 24.96 (0.983)
Gear-to-shaft
clearance
M5 0.040 – 0.082 (0.0016 – 0.0032) 0.13 (0.005)
C3 0.040 – 0.082 (0.0016 – 0.0032) 0.082 (0.0032)
Bushing-to-shaft
clearance
C2 0.020 – 0.062 (0.0008 – 0.0024) 0.12 (0.005)
Shift fork, shift
fork shaft
Fork claw thickness 4.93 – 5.00 (0.194 – 0.197) 4.8 (0.19)
Shift fork I.D. C 10.989 – 11.011 (0.4326 – 0.4335) 11.011 (0.4335)
R, L 12.035 – 12.056 (0.4738 – 0.4746) 12.070 (0.4752)
Fork shaft O.D. C 10.969 – 10.980 (0.4319 – 0.4323) 10.969 (0.4318)
R, L 11.966 – 11.984 (0.4711 – 0.4718) 11.950 (0.4705)
GENERAL INFORMATION
1-10
CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER
SPECIFICATIONS (After ’07)
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Crankshaft Side clearance 0.30 – 0.75 (0.012 – 0.030) 0.75 (0.030)
Radial clearance 0.006 – 0.018 (0.0002 – 0.0007) 0.05 (0.002)
Runout R – 0.03 (0.001)
L – 0.05 (0.002)
Transmission Gear I.D. M4 28.007 – 28.028 (1.1026 – 1.1035) 28.05 (1.104)
M5 28.020 – 28.033 (1.1031 – 1.1037) 28.07 (1.105)
C1 22.007 – 22.028 (0.8664 – 0.8672) 22.04 (0.868)
C2 30.020 – 30.041 (1.1819 – 1.1827) 30.07 (1.184)
C3 28.020 – 28.041 (1.1031 – 1.1040) 28.07 (1.105)
Bushing O.D. M4 27.959 – 27.980 (1.1007 – 1.1016) 27.94 (1.100)
M5 27.959 – 27.980 (1.1007 – 1.1016) 27.94 (1.100)
C2 29.979 – 30.000 (1.1803 – 1.1811) 29.95 (1.179)
C3 27.979 – 28.000 (1.1015 – 1.1024) 27.95 (1.100)
Bushing I.D. M5 25.000 – 25.021 (0.9843 – 0.9851) 25.04 (0.9858)
C2 27.000 – 27.021 (1.0630 – 1.0638) 27.04 (1.065)
C3 25.000 – 25.021 (0.9843 – 0.9851) 25.04 (0.9858)
Gear-to-bushing
clearance
M4 0.027 – 0.069 (0.0011 – 0.0027) 0.11 (0.004)
M5 0.040 – 0.074 (0.0016 – 0.0029) 0.12 (0.005)
C3 0.020 – 0.062 (0.0008 – 0.0024) 0.12 (0.005)
C2 0.020 – 0.062 (0.0008 – 0.0024) 0.12 (0.005)
Mainshaft O.D. M5 24.959 – 24.980 (0.9826 – 0.9835) 24.94 (0.982)
Countershaft O.D. C1 bearing 18.987 – 19.000 (0.7475 – 0.7480) 18.94 (0.746)
C2 bushing 26.959 – 26.980 (1.0614 – 1.0622) 26.94 (1.061)
C3 bushing 24.959 – 24.980 (0.9826 – 0.9835) 24.96 (0.983)
Bushing-to-shaft
clearance
M5, C2, C3 0.020 – 0.062 (0.0008 – 0.0024) 0.12 (0.005)
Shift fork, shift
fork shaft
Fork claw thickness 4.93 – 5.00 (0.194 – 0.197) 4.8 (0.19)
Shift fork I.D. C 10.989 – 11.011 (0.4326 – 0.4335) 11.011 (0.4335)
R, L 12.035 – 12.056 (0.4738 – 0.4746) 12.070 (0.4752)
Fork shaft O.D. C 10.969 – 10.980 (0.4319 – 0.4323) 10.969 (0.4318)
R, L 11.966 – 11.984 (0.4711 – 0.4718) 11.950 (0.4705)
GENERAL INFORMATION
1-11
FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS
Unit: mm (in)
REAR WHEEL/SUSPENSION SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Cold tire pressure 98 kPa (1.0 kgf/cm
2
, 14 psi) –
Axle runout – 0.20 (0.008)
Wheel rim runout Radial – 2.0 (0.08)
Axial – 2.0 (0.08)
Wheel hub-to-rim distance See page 14-10 –
Fork Spring free length 500 (19.7) 493 (19.4)
Slider runout – 0.20 (0.008)
Recommended fork oil Pro Honda HP Fork Oil 5W or
equivalent
–
Oil level 42 – 47 (1.65 – 1.85) –
Fluid capacity
(’05 – ’07)
Outer tube 332 cm
3
(11.2 US oz, 11.7 lmp oz) –
Fork damper 192 cm
3
(6.5 US oz, 6.8 lmp oz) –
Fluid capacity
(After ’07)
Outer tube 324 cm
3
(11.0 US oz, 11.4 lmp oz) –
Fork damper 192 cm
3
(6.5 US oz, 6.8 lmp oz) –
Compression damping adjuster
standard position
’05 – ’07 14 clicks out from full in –
After ’07 11 clicks out from full in –
Rebound damping adjuster
standard position
’05 – ’07 7 clicks out from full in –
After ’07 6 clicks out from full in –
Steering damper
(After ’07)
Recommended damper oil Pro Honda HP Fork Oil 5W or
equivalent
–
Free piston depth at 20°C (68°F) 27.3 – 27.9 (1.07 – 1.10) –
Damping force adjuster
standard position
9 clicks out from full in –
ITEM STANDARD SERVICE LIMIT
Cold tire pressure 98 kPa (1.0 kgf/cm
2
, 14 psi) –
Axle runout – 0.20 (0.008)
Wheel rim runout Radial – 2.0 (0.08)
Axial – 2.0 (0.08)
Wheel hub-to-rim distance See page 15-11 –
Drive chain slack 25 – 35 (1.0 – 1.4) 60 (2.4)
Drive chain width – 13.4 (0.53)
Drive chain size/link DID 520MXV/114 –
Drive chain slider thickness – 5.0 (0.20)
Drive chain roller O.D. Upper – 39 (1.5)
Lower – 35 (1.4)
Shock
absorber
Damper gas pressure 980 kPa (10.0 kg/cm
2
, 142 psi) –
Damper compressed gas Nitrogen gas –
Recommended shock oil Pro Honda HP Fork Oil 5W or
equivalent
–
Damper rod compressed force at 12 mm
compressed
20.0 – 24.0 kgf (44.1 – 52.9 lbf) –
Standard oil capacity 395 cm
3
(13.4 US oz, 13.9 Imp oz) –
Spring installed length
(standard)
’05 – ’07 258.5 (10.18) –
After ’07 258.0 (10.16) –
High speed side compression
damping adjuster standard position
’05 – ’07 3/4 – 1-1/4 turns out from full in –
After ’07 7/12 – 1-1/12 turns out from full in –
Low speed side compression
damping adjuster standard position
10 clicks out from full in –
Rebound damping adjuster standard
position
’05 – ’07 11 – 14 clicks out from full in –
After ’07 10 – 13 clicks out from full in –
GENERAL INFORMATION
1-12
HYDRAULIC BRAKE SPECIFICATIONS
Unit: mm (in)
BATTERY/CHARGING SYSTEM SPECIFICATIONS
IGNITION SYSTEM SPECIFICATIONS
ITEM STANDARD SERVICE LIMIT
Front Brake fluid DOT 4 –
Brake disc thickness 3.0 (0.12) 2.5 (0.10)
Brake disc warpage – 0.15 (0.006)
Master cylinder I.D. 11.000 (0.4331) 11.050 (0.4350)
Master piston O.D. 10.971 (0.4319) 10.840 (0.4268)
Caliper cylinder I.D. 27.025 (1.0640) 27.060 (1.0654)
Caliper piston O.D. 26.968 (1.0617) 26.853 (1.0572)
Rear Brake fluid DOT 4 –
Brake disc thickness 4.0 (0.16) 3.5 (0.14)
Brake disc warpage – 0.15 (0.006)
Master cylinder I.D. 9.547 (0.3759) 9.575 (0.3770)
Master piston O.D. 9.491 (0.3737) 9.465 (0.3726)
Caliper cylinder I.D. 22.650 (0.8917) 22.712 (0.8942)
Caliper piston O.D. 22.620 (0.8905) 22.573 (0.8887)
Brake pedal push rod standard
length
79.6 mm (3.13 in) –
ITEM SPECIFICATIONS
Battery Capacity 12 V – 6 Ah
Current leakage 0.1 mA max.
Voltage
(20°C/68°F)
Fully charged 13.0 – 13.2 V
Needs
charging
Below 12.4 V
Charging cur-
rent
Normal 0.6 A/5 – 10 h
Quick 3.0 A/1.0h
Alternator Capacity 78 W/5,000 rpm
ITEM SPECIFICATION
Spark plug Standard (NGK) IFR8H11
(DENSO) VK24PRZ11
Optional (NGK) IFR9H11
(DENSO) VK27PRZ11
Spark plug gap 1.0 – 1.1 mm (0.039 – 0.043 in)
Ignition coil
resistance
(at 20°C/68°F)
Primary 0.1 – 0.3 Ω
Secondary with plug cap 9 – 16 kΩ
Secondary without plug cap 4 – 8 kΩ
Ignition coil peak voltage 100 V minimum
Ignition pulse generator resistance (at 20°C/68°F) 180 – 280 Ω
Ignition pulse generator peak voltage 0.7 V minimum
Alternator exciter coil resistance (at 20°C/68°F) 9 – 28 Ω
Ignition timing ("F" mark) 8° BTDC/1,800 rpm
Throttle position sensor (Blue – Black) resistance
(at 20°C/68°F)
4 – 6 kΩ
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