2007–2008 Honda CRF450R Service & Repair Manual (P/N 07SM2-MBN)

Honda service manual for the 2007–2008 CRF450R, covering engine, drivetrain, suspension, chassis, and electrical repair, with separate procedures where the two configurations differ.

• Engine repair: Engine removal and installation, cylinder-head disassembly, valve-clearance adjustment, piston inspection, cam timing, and auto-decompression system checks.

• Clutch and transmission: Clutch overhaul, kickstarter and gearshift-linkage service, crankcase separation, transmission inspection, and balancer removal and installation.

• Fuel system: FCR carburetor disassembly and assembly, accelerator-pump inspection, jetting adjustments, hot-start service, and throttle-position sensor replacement.

• Lubrication and cooling: Oil-pump inspection, strainer and relief-valve service, cooling-system pressure testing, coolant bleeding, and water-pump seal replacement.

• Suspension and brakes: Telescopic-fork and rear-shock overhaul, Pro-Link linkage service, HPSD repair, and hydraulic brake master-cylinder and caliper service.

• Electrical diagnosis: Ignition peak-voltage testing, wiring diagrams, connector checks, and troubleshooting for starting problems, poor running, and loss of power.

Written for qualified professional technicians with the training, tools, and equipment required for the documented service procedures.

Engine, Clutch, and Transmission Repair

Cylinder-head and piston chapters cover shim selection, valve-guide replacement, valve-seat refacing, and camshaft inspection. The auto-decompression section explains how the mechanism affects starting. Honda warns that lapping the titanium intake valves damages their oxide coating.

Clutch, kickstarter, gearshift-linkage, and balancer service can be performed with the engine installed. Crankshaft and transmission work requires engine removal and crankcase separation, with inspection limits for gears, shafts, bearings, and shift forks.

Torque tables cover the primary drive gear bolt, cylinder-head nuts, and suspension-linkage fasteners.

FCR Carburetor Service and Tuning

The fuel-system chapter distinguishes FCR00F carburetors for 2007 from FCR00G carburetors for the later configuration. Separate temperature/altitude tuning charts accompany jet and needle selection, pilot-screw adjustment, and accelerator-pump service.

An exploded carburetor view shows component relationships. Float inspection references gauge 07401-0010000, while throttle-position sensor replacement includes resistance-based adjustment.

Cooling Tests and Lubrication Service

Cooling-system coverage includes radiator-cap and system pressure tests, a coolant flow diagram, air bleeding, and water-pump shaft, bearing, and seal replacement.

The lubrication diagram and oil-pump clearance tables accompany strainer, pressure relief valve, and pump inspection. Oil-pump service requires crankcase separation; the maintenance chapter also warns that installing the oil filter backward can cause severe engine damage.

Forks, HPSD, Rear Suspension, and Brakes

Fork procedures distinguish the fork-cap bushing and piston-ring arrangements used across the two configurations. Suspension assembly drawings support damper disassembly, filling, bleeding, and operation checks.

Honda Progressive Steering Damper coverage includes HPSD characteristics charts, spherical-bearing replacement, air bleeding, and free-piston depth checks. The damper rod/piston assembly itself is nonserviceable and is replaced as a unit.

Rear-shock procedures cover bladder replacement, damper overhaul, and nitrogen charging. Follow the manual's pressure-release precautions when servicing the nitrogen-charged shock.

Chassis instructions cover Pro-Link linkage bearings, steering-head and wheel bearings, and sub-frame, body-panel, and exhaust removal. Hydraulic-brake chapters detail master-cylinder and caliper overhaul, with bleeding procedures and inspection limits.

Ignition Testing and Fault Isolation

Electrical sections combine component-location views with ignition peak-voltage tables, TP-sensor checks, and engine-stop-button tests. The later configuration also includes gear-position-switch diagnosis.

Comparing peak voltage at the ICM and component connectors helps distinguish harness faults from exciter-coil or ignition-pulse-generator faults. Separate cable-routing drawings and wiring diagrams show the configuration differences. Ignition timing is factory-set and nonadjustable.

Troubleshooting charts also address poor handling and running faults at low and high speeds.

Examples of Valve, Compression, and Coolant Specifications

These examples represent a small selection of the manual's engine-check and cooling-service specifications.

Intake valve clearance is 0.16 ± 0.03 mm with the engine cold, below 35°C (95°F). The compression-test specification is 539 kPa (78 psi) at 600 rpm, with the engine warm and throttle fully open.

Cooling-system capacity at a coolant change is 1.03 liters (1.09 US qt).

Text Search, Bookmarks, and PDF Contents

Search and diagram detail: OCR text search is available, but recognition errors affect some tables and wiring labels. Embedded bookmarks cover the chapters and both wiring diagrams; small connector and wire-color labels are readable when enlarged.

Supplied as a single printable, English-language 404-page PDF. The total comprises 390 chapter and index pages, one cover, three introductory pages, and ten blank memo pages, all already included.