Difficulty
Moderate
Steps
24
Time Required
2 - 5 hours
Sections
1
- 2003 Honda CRF 450 Carburetor Disassembly
- 24 steps
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Back2003 Honda CRF 450
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What you need
Step 1
Turn Fuel Off
- Move the fuel lever from the on position to the off.
Move the fuel lever from the on position to the off.
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Step 2
Drain Pan
- Place a drain pan under the motorcycle to catch any excess fuel.
Place a drain pan under the motorcycle to catch any excess fuel.
Step 3
Remove Seat
- Remove the two bolts from each side of the seat with a 10mm socket.
- Lift up on the rear of the seat to remove.
Remove the two bolts from each side of the seat with a 10mm socket.
Lift up on the rear of the seat to remove.
Step 4
Loosen Air Intake Boot
- Loosen the screw with a phillips head screwdriver so the clamp can move freely.
Loosen the screw with a phillips head screwdriver so the clamp can move freely.
Step 5
Exhaust Bolt
- Loosen the 12mm bolt to separate the exhaust muffler from the exhaust header.
Loosen the 12mm bolt to separate the exhaust muffler from the exhaust header.
Step 6
Lower Sub-Frame Bolts
- Remove the 10mm lower sub-frame bolts on each side of the motorcycle.
Remove the 10mm lower sub-frame bolts on each side of the motorcycle.
Step 7
Upper Sub-Frame Bolt
- Remove the 10mm upper sub-frame bolt from the motorcycle.
Remove the 10mm upper sub-frame bolt from the motorcycle.
Step 8
Sub-Frame Removal
- Remove the sub-frame assembly from the rest of the motorcycle.
Remove the sub-frame assembly from the rest of the motorcycle.
Step 9
Remove Fuel Line
- Using needle-nose pliers, loosen the clamp and slide it forward on the fuel line. Then remove the fuel line.
- The fuel line should contain a small amount of fuel, so beware of spillage.
Using needle-nose pliers, loosen the clamp and slide it forward on the fuel line. Then remove the fuel line.
The fuel line should contain a small amount of fuel, so beware of spillage.
Step 10
Loosen Clamp
- Loosen the clamp on the front of the carburetor with the Phillips head screwdriver.
Loosen the clamp on the front of the carburetor with the Phillips head screwdriver.
Step 11
Remove Shock Bolts
- Remove the top and bottom shock bolts with 17mm socket.
Remove the top and bottom shock bolts with 17mm socket.
Step 12
Remove Shock
- Remove the shock from the motorcycle.
Remove the shock from the motorcycle.
Step 13
Plastic Cover
- Remove this screw with the 4mm hex key
- Now remove the plastic cover, allowing access for the removal of the throttle cables.
Remove this screw with the 4mm hex key
Now remove the plastic cover, allowing access for the removal of the throttle cables.
Step 14
Slack Adjusters
- Loosen the top and bottom slack adjusters. This will allow you to slide the slack adjusters out from the body of the carburetor.
Loosen the top and bottom slack adjusters. This will allow you to slide the slack adjusters out from the body of the carburetor.
Step 15
Side Shrouds
- Remove the side shrouds from the motorcycle by loosening the four 8mm screws. Complete this step for both sides of the bike.
Remove the side shrouds from the motorcycle by loosening the four 8mm screws. Complete this step for both sides of the bike.
Step 16
Fuel Tank Bolts
- Remove the 8mm bolt above the fuel tank.
- Remove the safety clip at the bottom of the fuel tank.
Remove the 8mm bolt above the fuel tank.
Remove the safety clip at the bottom of the fuel tank.
Step 17
Fuel Tank Removal
- Remove the 8mm bolt from the fuel petcock.
- Then remove the fuel tank from the motorcycle.
- Tilting the fuel tank (second picture) will keep it from draining/spilling.
Remove the 8mm bolt from the fuel petcock.
Then remove the fuel tank from the motorcycle.
Tilting the fuel tank (second picture) will keep it from draining/spilling.
Step 18
Wiring Harness
- Gently press on the plastic release on the clip to separate the wiring harness from the carburetor.
- Be careful not to break the plastic clip.
Gently press on the plastic release on the clip to separate the wiring harness from the carburetor.
Be careful not to break the plastic clip.
Step 19
Hot Start Cable
- Un-thread the 13mm plastic hot start cable from the carburetor.
Un-thread the 13mm plastic hot start cable from the carburetor.
Step 20
Remove Carburetor
- At this stage, everything should be disconnected and the carburetor can be removed from the motorcycle.
- The carburetor will more than likely still contain fuel, so be careful transporting it to the area where you will disassemble it.
At this stage, everything should be disconnected and the carburetor can be removed from the motorcycle.
The carburetor will more than likely still contain fuel, so be careful transporting it to the area where you will disassemble it.
Step 21
Clean Carburetor
- Gently brush and blow off any debris from the carburetor.
Gently brush and blow off any debris from the carburetor.
Step 22
Disassemble Carburetor
- Loosen and remove the 5 screws at the bottom of the carburetor, with the Phillips head screwdriver, to detach the bowl. Then remove the bowl.
Loosen and remove the 5 screws at the bottom of the carburetor, with the Phillips head screwdriver, to detach the bowl. Then remove the bowl.
Step 23
Remove Float
- Remove the shaft from the two posts sticking up on the inside of the carburetor.
- Remove the float.
Remove the shaft from the two posts sticking up on the inside of the carburetor.
Remove the float.
Step 24
Remove Jets
- Remove the jets from the body of the carburetor.
- Thoroughly clean all jets and body of carburetor.
Remove the jets from the body of the carburetor.
Thoroughly clean all jets and body of carburetor.
To reassemble your device, follow these instructions in reverse order.
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Author
with 3 other contributors
Tony Rhodes
Member since: 03/31/2022
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