Contents MOTORCYCLE SAFETY............................. 1 BASIC OPERATING INSTRUCTIONS.....23 Service Procedures Important Safety Information ........................... 2 Basic Operating Instructions ...........................24 Fluids & Filters Important Safety Precautions ........................ 2 Safe Riding Precautions...............................24 Fuel System ....................................................60 Accessories & Modifications ........................... 3 Carbon Monoxide Hazard............................24 Fuel.............................................................. 60 Accessories & Modifications ........................ 3 Starting & Stopping the Engine ......................25 Refueling Procedure.................................... 60 Off-Road Safety ............................................... 4 Fast Idle Knob..............................................25 Fuel Line Inspection.................................... 61 Off-Road Safety ............................................ 4 Preparation...................................................25 Fuel Line Replacement................................ 61 Safety Labels .................................................... 5 Starting Procedure........................................25 Fuel Pump Filter Replacement.................... 63 Bank Angle Sensor Ignition Cut-off System...26 Fuel Pressure Increasing.............................. 68 INSTRUMENTS & CONTROLS.................. 7 How to Stop the Engine...............................26 Engine Oil ....................................................... 69 Operation Component Locations ...................... 8 Shifting Gears .................................................27 Oil Recommendation................................... 69 Indicators & Displays ....................................... 9 Braking ............................................................28 Checking & Adding Oil .............................. 70 Multi-function Display................................ 10 Parking ............................................................29 Changing Engine Oil & Filter ..................... 70 Speedometer................................................ 12 Theft-prevention Tips ..................................29 Coolant ........................................................... 72 Odometer/Tripmeter A & B ........................ 12 Break-in Guidelines ........................................30 Coolant Recommendation ........................... 72 Fuel Mileage Meter ..................................... 12 Checking & Adding Coolant....................... 72 Digital Clock Setting................................... 13 SERVICING YOUR HONDA ......................31 Cooling System Inspection.......................... 73 Backlight Brightness Adjustment................ 13 The Importance of Maintenance .....................32 Coolant Replacement .................................. 73 Changing the Speed and Mileage Unit........ 14 Maintenance Safety .........................................33 Cooling System Bleed Air........................... 74 Changing the Fuel Mileage Unit ................. 14 Important Safety Precautions.......................33 Air Cleaner ..................................................... 75 Controls & Features ........................................ 15 Periodic Maintenance ......................................34 Cleaning....................................................... 75 Ignition Switch ............................................ 15 Maintenance Schedule ....................................35 Crankcase Breather ......................................... 77 Start Button ................................................. 15 Maintenance Record (On-Road Use Only) .....38 Draining....................................................... 77 Engine Stop Switch ..................................... 15 General Competition Maintenance Headlight Dimmer Switch........................... 15 (Off-Road Use Only) ......................................39 Engine Passing Light Control Switch...................... 15 Before & After Competition Maintenance Throttle ........................................................... 78 Turn Signal Switch...................................... 15 (Off-Road Use Only) ......................................43 Throttle Freeplay ......................................... 78 Horn Button................................................. 15 Between Races & Practice Maintenance .....43 Throttle Inspection ...................................... 79 After Competition Maintenance ..................44 Throttle Cable Lubrication .......................... 79 BEFORE RIDING......................................... 17 Engine Idle Speed ........................................... 80 Are You Ready to Ride? ................................ 18 Service Preparations Idle Speed Adjustment ................................ 80 Always carry this manual and tool kit......... 18 Maintenance Component Locations ...............45 Clutch System ................................................. 81 Protective Apparel....................................... 18 Seat ..................................................................46 Clutch Lever Freeplay................................. 81 Rider Training ............................................. 18 Side Cover .......................................................47 Other Inspections......................................... 82 Is Your Motorcycle Ready to Ride? ............... 19 Fuel Tank ........................................................48 Clutch Operation ......................................... 82 Pre-ride Inspection ...................................... 19 Subframe .........................................................52 Clutch Cable Lubrication ............................ 82 Load Limits & Guidelines .............................. 21 Clutch Disc/Plate Removal ......................... 83 Loading........................................................ 21 Clutch Disc/Plate/Spring Inspection ........... 84 Load Limits ................................................. 21 Clutch Disc/Plate Installation...................... 84 Loading Guidelines ..................................... 21 Spark Plug ...................................................... 86 Spark Plug Recommendation ...................... 86 Spark Plug Inspection & Replacement........ 86 Contents 31MKE900 2019 CRF450L MOM 16640 (1803) Contents Valve Clearance ............................................. 87 Wheels ...........................................................126 Electrical Cylinder Head Cover Removal ................... 87 Wheel Rims & Spokes...............................126 Battery .......................................................... 138 Positioning At TDC On The Compression Axles & Wheel Bearings ...........................126 Battery Storage.......................................... 138 Stroke ..........................................................88 Tires & Tubes ...............................................127 Battery Charging ....................................... 139 Valve Clearance Inspection......................... 89 Air Pressure................................................127 Headlight Aim .............................................. 140 Camshaft Removal ...................................... 89 Inspection...................................................127 Headlight Aim Vertical Adjustment.......... 140 Shim Selection............................................. 91 Tube Replacement .....................................127 Appearance Care .......................................... 141 Camshaft Installation................................... 92 Tire Replacement.......................................128 General Recommendations........................ 141 Crankshaft Hole Cap Installation ................ 94 Side Stand .....................................................129 Washing Your Motorcycle with a Mild Cylinder Head Cover Installation................ 95 Drive Chain ...................................................130 Detergent ................................................... 141 Piston/Piston Rings/Piston Pin ....................... 96 Inspection...................................................130 After Cleaning Lubrication ....................... 142 Cylinder Head Removal.............................. 96 Drive Chain Sliders....................................130 Panels......................................................... 142 Cylinder Removal ....................................... 98 Drive Chain Rollers ...................................131 Aluminum Frame Maintenance................. 142 Piston Removal ........................................... 98 Adjustment.................................................131 Titanium Fuel Tank Maintenance ............. 142 Piston Ring Removal................................... 98 Lubrication.................................................131 Exhaust Pipe and Muffler Maintenance .... 142 Piston/Piston Pin/Piston Ring Inspection.... 99 Removal, Cleaning & Replacement...........132 Piston Ring Installation ............................... 99 Exhaust Pipe/Muffler ....................................133 ADJUSTMENTS ......................................... 143 Piston Installation...................................... 100 Exhaust Pipe/Muffler Inspection ...............133 Front Suspension Adjustments ..................... 144 Cylinder Installation.................................