The CRF450R was the moment to the largest member of Honda's new-for-2002 CRF motocross-based off-road motorcycles, shadowed by oneself by the CRF650. The CRF's four-stroke 449 cc single-cylinder engine was cooled by a dual-radiator cooling method, powered by a diminutive douse pump on the correctly side of the engine. While the physical demands of off-road racing could return a toll on the moisten pump, much valuable to visible damage to the douse pump's aluminium involve. On the contrary, less than conclusive damage can eventuate to the dilute pump's internal seal that could decision in failure of the douse pump.9. Spin the impeller shaft bearing pursuit, located in the condign engine crankcase contain, by fist. Ideally, the bearing should roll smoothly without binding. The bearings must be replaced whether the bearings bind or mood notchy.
Mount the CRF450R on a overhaul stand and let it nipping for at least two hours.
2. Unscrew the filler cap from the top of the fair radiator.
3. District a extract pan below the imbue pump on the deserved side of the engine, identified by the coolant hose running from the top of the pump to the CRF450R's radiator. Loosen the filter bolt, located at the backside of the H2O pump, using a 10 mm socket and a socket wrench. Unscrew the empty bolt and interchange its copper crush washer. Seal the container and shake thoroughly to blend the antifreeze solution.16. Fill the right radiator through its filler neck with the antifreeze solution. Remove the CRF450R from the service stand, then slowly lean the motorcycle from side to side to remove any air bubbles trapped in the radiators.
Pull the coolant hose off the imbue pump inlet. Unscrew the remaining three H2O pump bolts, using a 10 mm socket. Pull the H2O pump involve and O-ring off the ethical engine crankcase contain by plam.
5. Unscrew all 11 bolts from the boundary of the correctly engine crankcase encompass, using a 10 mm socket. Pull the crankcase comprehend and gasket off the engine. Pull the bypass cylinder off the coolant inlet on the honest side of the engine, located at the upper border of the crankcase encompass's mating surface, by plam.
6. Pull the O-ring off the bypass conduit. Observe the bypass drainpipe for signs of damage, such as beneath scoring, cracking or corrosion. Convert the bypass cylinder whether it is damaged in any design. Slide a original O-ring onto the bypass channel, then push the bypass pipe into the crankcase.
7. Unscrew the bathe pump impeller from the condign engine crankcase contain, using a 10 mm socket. Slide the impeller washer off the impeller shaft, then pull the impeller shaft elsewhere from the inside face of the involve. Contemplate the shaft for signs of damage, such as any bending or wear. Moderate the shaft, provided needed.
8. Probation the imbue pump seal, located directly under the impeller's mounting speck on the right crankcase comprehend, for tears or puncture marks. The seal must be replaced whether it is damaged in any system.
Internal damage is much displayed as a slender antifreeze leak emanating from a slender gap -- called a telltale gap -- at the backside of the damp pump. Provided a leak has occurred, the water pump must be replaced.
Instructions
1. Additionally, the contest should not enjoy any side-to-side or up-and-down play.10. Incorporate a 12 mm bearing remover -- Honda department No. 07936-166010A -- into the impeller bearing from the inside of the equitable crankcase cover. Connect the bearing remover handle and bearing removal weight -- Honda part Nos. 07936-3710100 and 07936-3710120 -- to the bearing removal. Slide the bearing weight backward forcefully against the handle until the impeller bearing is removed completely from the crankcase cover. Pull the oil seal out of the crankcase cover.
11. Drive the water seal out from the outside of the crankcase cover, using a water seal driver -- Honda part No. 07965-415000A.
12. Drive a new bearing into the right crankcase cover, using a bearing driver and a 12 mm pilot -- Honda part Nos. 07749-001000 and 07746-0040200. Push the new oil seal into place through the front of the crankcase cover. Drive a new water seal into place over the oil seal, using the water seal driver.
13. Push the impeller shaft through the inside of the crankcase cover. Hold the shaft in place with a 17 mm open-end wrench. Slide the impeller washer over the shaft, then screw the impeller into place by hand. Tighten the impeller to 9 foot-pounds, using a torque wrench.
14. Reinstall the right crankcase cover and gasket onto the engine. Tighten the crankcase cover bolts to 7.6 foot-pounds. Reinstall the water pump cover and a new O-ring onto the right crankcase cover. Tighten the cover mounting bolts to 9 foot-pounds and the coolant drain bolt to 7 foot-pounds. Push the coolant hose over the inlet at the top of the water pump cover, then tighten the hose clamp.
15. Pour a half-quart of Pro Honda HP coolant or a similar silicate-free ethylene glycol antifreeze into a one-quart resealable plastic container, followed by a half-quart of distilled water. Let the coolant withdraw completely into the withdraw pan.4. Loosen the coolant hose clamp at the top of the soak pump, using a flat-head screwdriver.
Add more antifreeze if the antifreeze level decreases after bleeding out the air bubbles from the radiator. Screw the filler cap into place.
17.Mount the CRF450R on a triangular side stand for storage.
18. Transfer the old antifreeze from the drain pan to the container used to mix the new antifreeze solution. Take the antifreeze to an automotive fluid recycling center for disposal.
