Honda CRF250, CRF450 Repair Manual 2002-2006

The 2002-2006 Honda CFR250, CRF450 repair manual by Haynes covers:

• Honda CRF250R, 2004-2006
• Honda CRF250X, 2004-2006
• Honda CRF450R, 2002-2006
• Honda CRF450X, 2005-2006

Book Excerpt: 2002-2006 Honda CFR250, CRF450 Repair Manual TUNE-UP AND ROUTINE MAINTENANCE

SUSPENSION | CHECK
(Refer to illustration 18.5)

1. The suspension components must be maintained in top operating condition to ensure rider safety and a high level of performance. Loose, worn or damaged suspension parts decrease the motorcycle's stability and control.
2. Lock the front brake and push on the handlebars to compress the front forks several times. See if they move up-and-down smoothly without binding. If binding is felt, the forks should be disassembled and inspected as described in Chapter 6.
3. Check the tightness of all front suspension nuts and bolts to be sure none have worked loose (refer to the Chapter 6 Specifications).
4. Air will heat up and expand during a race (or hard driving), stiffening the front forks. With the forks fully extended (bike set on a pit stand so the front wheel is off the ground), remove the air valve caps from the forks to release built-up air pressure (see illustration).
5. Inspect the rear shock absorber for fluid leakage and tightness of the mounting nuts and bolts. If leakage is found, the shock should be rebuilt or replaced.
6. Support the motorcycle securely upright with its rear wheel off the ground. Grab the swingarm on each side, just ahead of the axle. Rock the swingarm from side to side - there should be no discernible movement at the rear. If there's a little movement or a slight clicking can be heard, make sure the swingarm pivot bolt is tight. If the pivot nut is tight but movement is still noticeable, the swingarm will have to be removed and the bearings replaced as described in Chapter 6.

FUEL, EXHAUST AND EMISSION CONTROL SYSTEMS

AIR FILTER HOUSING | REMOVAL AND INSTALLATION

1. Place the sub-frame in the service position (X-models) or remove sub-frame (R-models) (see Chapter 8).
2. Remove the screws and detach the mud guard from the air filter housing.
3. Remove the rear fender (see Chapter 8).
4. On X-models, disconnect the breather hose from the air filter housing. On California X-models, also detach the air suction hose.
5. Unbolt the air filter housing from the sub-frame.
6. Remove the air filter element from the housing (see Chapter 1, if necessary).
7. If necessary, detach the carburetor connecting tube from the housing.
8. Installation is the reverse of the removal steps. If you removed the connecting tube, apply a ring of silicone sealant to the mating surface of the connecting tube and air cleaner housing.

Subject: 2002, 2003, 2004, 2005, 2006 Honda CRF250, CRF450 motocross and off-road bikes service, maintenance, repair. ISBN-10: 156392630X | ISBN-13: 9781563926303 | Haynes 2630