accessory application publication no. installation...

Issue Date

February 2017

INSTALLATIONINSTRUCTIONS

Accessory Application Publication No.

MII 16169

© 2017 Honda Motor Co., Ltd. - All Rights Reserved.

PARTS LIST

87940-MKE-A001 of 16

Honda Dealer: Please give a copy of these instructions to your customer.

ELECTRIC STARTERSold separately

ELECTRIC START WIRE HARNESS

P/N 08Z70-MKE-A00After '16 CRF450R

BATTERY (YTX4L-BS)Sold separately

CAP, 28 mmP/N 11332-HP1-601Sold separately

(1)

No. Description Qty

(1) Installation Instructions URL 1

(2) Electric start wire harness 1

No. Description Qty

(1) Battery (YTX4L-BS) 1

No. Description Qty

(1) Cap 1

(1)

(2)

(43)

(1)

(40)

(2)

(19)(17)

(47)(44)

(13)

(8) (7)

(32)(34)

(33)(31)

(24)(25)

(35)

(22)

(27)

(15)

(14)

(37)

(20)

(12)

(9)(4)

(10)

(39)

(18)

(6)(5)

(28)

(30)

(29)

(16)

(11)

(41)

(42)

(38)

(46)

(45)

(26)

(23)

(21)

(36)

(3)

(1)

Install when this accessory is used with the kick starter removed.

SCREW

SCREW

BAND A

BAND A

BAND B

BAND B

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INSTALLATION CAUTION

• To prevent burns, allow the engine, exhaust system, radiator, etc., to cool before installing the accessory.

• Be sure to observe all safety messages and precautions described in the Service Manual while removing and installing the fuel tank.

NOTE:

• Reinstall the removed parts on the motorcycle and make sure that the wires and harnesses are not pinched.

• Trim the excess ends off the wire ties after attaching them to the wire harnesses. Do not allow the cut part of the wire tie to interfere with another harness or brake hose.

1. Remove the under guard.

2. Refer to the Service Manual for the motorcycle and drain the coolant and the engine oil.

3. Remove the seat, right and left side cover, number plate, right and left radiator shroud and left radiator grill.

4. Remove the fuel tank.

5. Remove the ECM, ECM stay and regulator.

6. Remove the brake pedal.

TORQUE CHARTTighten all screws, bolts and nuts to their specified torque values. Refer to the Service Manual for the torque values of the removed parts and installation parts.

• Refer to the CRF450RX parts catalog for the part numbers.

TOOLS AND SUPPLIES REQUIREDSocket (8, 10 and 27 mm)

Ratchet

Hex wrench (5 mm)

Phillips ® screwdriver

Side cutters

Ruler

Thread lock

Isopropyl alcohol

Shop towel

Torque wrench

Refer to the Service Manual for the tools required to remove or install the motorcycle’s parts.

No. Description Qty

(1) Starter motor 1

(2) 6 mm flange nut 1

(3) 6 mm SH flange bolt (long) 2

(4) Starter motor cable 1

(5) Wire tie (middle) 2

(6) Wire tie (long) 2

(7) Harness clip 1

(8) Clip 1

(9) Battery positive (+) cable 1

(10) Battery negative (-) cable 1

(11) 6 mm SH flange bolt (short) 1

(12) Engine stop & mode indicator switch 1

(13) Start switch 1

(14) Wire tie (short) 2

(15) Clip band 1

(16) Stop switch 1

(17) Starter relay switch 1

(18) 6 mm washer bolt 2

(19) Starter relay switch cover 1

(20) Relay 1

(21) Gasket 1

(22) Decompressor plunger 1

(23) O-ring 1

(24) 18 mm nut 1

(25) Lock washer 1

(26) Starter driven gear 1

(27) Starting clutch outer 1

(28) Starter reduction gear A 1

(29) Starter reduction shaft 2

(30) Starter reduction gear B 1

(31) Starter idle gear 1

(32) Starter idle shaft 1

(33) Starter gear collar 1

(34) 6 mm socket bolt 1

(35) Bearing 1

(36) Battery band 1

(37) Starter relay switch stay 1

(38) Battery box 1

(39) Battery cushion 1

(40) 6 mm flange bolt 1

(41) 6 mm SH flange bolt (middle) 3

(42) Flange collar 3

(43) Clutch cable 1

(44) Left lever bracket 1

(45) Switch plate 1

(46) Lever cover 1

(47) 5 mm screw 1

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7. Remove the kick starter pedal.• Be sure to keep the kick start pedal after

removal.<Right side>

8. Remove the clutch cable stay and disconnect the clutch cable from the clutch lifter lever.

KICK STARTER PEDAL

BOLT

9. Remove the clutch cable stay from the clutch cable as shown.

10. Remove the pulse generator stay as shown.<Left side>

NOTE: Steps 11 through 18 will require using the Service Manual

11. Disconnect each connector and remove the wire ties and remove the motorcycle’s wire harness.• Keep the motorcycle’s wire harness.

12. Remove the cylinder head cover, camshaf t, decompressor weight and spring.

13. Replace the decompressor plunger as shown.

PULSE GENERATOR STAY

CLUTCH CABLE

CLUTCH CABLE STAY

BOLT

ACCESSORY DECOMPRESSOR PLUNGER (22.67 mm)

DECOMPRESSOR PLUNGER (22.91 mm, Save)

CAMSHAFT

14. Install the spring, decompressor weight, camshaft and cylinder head cover in the reverse order of removal.

15. Remove the right crankcase cover, clutch discs, clutch plates, clutch center, clutch outer, needle bearing and clutch outer guide.

16. Remove the primary drive gear as shown.<Right side>

WASHER

BOLT

PRIMARY DRIVE GEAR

STARTER DRIVEN COLLAR (Save)

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17. Remove the starter motor cap, O-ring, dowel pins and gasket as shown.

STARTER MOTOR CAP (Save)

GASKET (Discard)

O-RING (Discard)

DOWEL PIN

DOWEL PIN

22. Install the starter driven gear, bearing and starting clutch outer as shown.

<Right side>

STARTER DRIVEN GEAR

BEARING

STARTING CLUTCH OUTER

21. Install the starter motor as shown.<Left side>

STARTER MOTOR

6 mm SH FLANGE BOLT (long)

18. Remove the oil pump driven gear and balancer driven gear.

19. Remove the kick starter spindle assembly and kick starter idle gear as shown.

• Perform this step when using this accessory with the kick starter removed.

20. Remove the oil seal and install the cap as shown.• Perform this step when using this accessory

with the kick starter removed.

COLLAR (Save)

BOLT (Save)

KICK STARTER IDLE GEAR (Save)

IDLE GEAR COLLAR (Save)

KICK STARTER SPINDLE ASSEMBLY (Save)

CAP

OIL SEAL (Save)

RIGHT CRANK CASE COVER

5 of 16

25. Install the balancer driven gear, oil pump driven gear, primary drive gear, needle bearing and clutch outer guide in the reverse order of removal.

NOTE: Align the punch marks on the balancer driven gear and primary drive gear.

26. Install the clutch outer and clutch center as shown.

23. Install the starter idle gear as shown.• Clean with isopropyl alcohol before applying

thread lock.• Be sure to apply to the threads of the bolt.

24. Install the starter reduction gear A and starter reduction gear B as shown.

6 mm SOCKET BOLT

STARTER IDLE SHAFT

STARTER REDUCTION GEAR A

STARTER REDUCTION GEAR B

STARTER REDUCTION SHAFT

STARTER IDLE GEAR

STARTER GEAR COLLAR

CLUTCH OUTER (Reuse)

CLUTCH CENTER (Reuse)

WASHER (Reuse)

LOCK WASHER

18 mm NUT

THREAD LOCK

ACCESSORY GASKET

ACCESSORY O-RING

29. Install the right crankcase cover in the reverse order of removal.

28. Install the accessory O-ring, dowel pins and accessory gasket as shown.

30. Remove the engine stop & mode indicator switch as shown.• Disconnect the connector and remove the clip

and wire ties.<Left side>

ENGINE STOP & MODE INDICATOR SWITCH (Save)

BAND (Save)

SCREW (Save)

DOWEL PIN (Reuse)

DOWEL PIN (Reuse)

27. Install the clutch discs and clutch plates in the reverse order of removal.

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31. Remove the bolts as shown.<Left side>

BOLT

CLUTCH CABLE

ADJUSTING DIAL

COVER (Save)

32. Remove the clutch lever.

33. Remove the clutch cable, adjusting dial and cover as shown.

<Left side>

Remove the cable clips from the clutch cable.

34. Remove the clutch cable as shown.

CLUTCH CABLE (Save)

CLUTCH CABLE

CABLE CLIP

CABLE CLIP

CLUTCH CABLE

CLAMPRemove the clutch cable.

7 of 16

ACCESSORY ENGINE STOP & MODE INDICATOR SWITCH

35. Remove the lever bracket and adjusting bolt as shown.

ADJUSTING BOLT

LEVER BRACKET (Save)

HOLDER

BOLT

36. Connect the accessory engine stop & mode indicator switch to the stop switch as shown.

37. Install the stop switch to the left lever bracket as shown.

STOP SWITCH

STOP SWITCH

SWITCH PLATE

5 mm SCREW

LEFT LEVER BRACKET

39. Pass the adjusting dial and lever cover over the accessory clutch cable as shown.

40. Install the adjusting dial and lever cover to the left lever bracket in the reverse order of removal.

41. Install the clutch lever.

38. Install the adjusting bolt and assembled left lever bracket as shown.• Install the assembled left lever bracket and

holder with the punch mark on the holder facing up.

• Align the holder mating surface with the paint mark.

• Tighten the upper bolt first, then tighten the lower bolt.

ACCESSORYCLUTCH CABLE

ADJUSTING DIAL (Reuse)

ADJUSTING BOLT (Reuse)

ASSEMBLED LEFT LEVER BRACKET

LEVER COVER

BOLT (Reuse)HOLDER (Reuse)

PAINT MARK

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Install the cable clips to the accessory clutch cable.

CABLE CLIP

CABLE CLIP (Reuse)

ACCESSORYCLUTCH CABLE

ACCESSORY CLUTCH CABLE

42. Route the accessory clutch cable in the reverse order of removal and secure it using the cable clips.

CLAMPSecure the accessory clutch cable.

BOLT (Reuse)

43. Install the clutch cable stay to the accessory clutch cable as shown.

46. Install the accessory engine stop & mode indicator switch as shown.• Install the engine stop & mode indicator switch

with care not to interfere with the holder.

ACCESSORY ENGINE STOP & MODE INDICATOR SWITCH

BAND B

BAND A

SCREW

HOLDER

CLUTCH CABLE STAY (Reuse)

44. Install the pulse generator stay in the reverse order of removal.

45. Install the accessory clutch cable to the clutch lifter lever and secure the clutch cable stay in the reverse order of removal.



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BAND B

BAND A

47. Route the engine stop & mode indicator switch harness and secure it with the wire ties as shown.

ENGINE STOP & MODE INDICATOR SWITCH HARNESS

ENGINE STOP & MODE INDICATOR SWITCH

WIRE TIE (Reuse)Secure the engine stop & mode indicator switch harness to the handlebar.


WIRE TIE (short)Secure the start switch harness to the handlebar.

START SWITCH

49. Route the start switch harness and secure it with the wire ties as shown.• Do not cut the excess wire tie ends.

START SWITCH HARNESS

SCREW

48. Install the start switch as shown.<Right side>

START SWITCH

20 - 40 mm

30 - 40 mm

WIRE TIE (Reuse)


HOLDER

5 -10 mm

START SWITCH

10 - 20 mm30 - 40 mm

WIRE TIE (short)


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50. Route the electric start wire harness as shown.



51. Route and connect the start switch harness and electric start wire harness as shown.



2-PIN WATERPROOF CONNECTOR (Black)


Secure the connected 2-pin waterproof connector to the stay.

Install the clip band.

52. Secure each harness as shown.



CLIP BAND

CLAMPPass the electric start wire harness and engine stop & mode indicator switch harness.







CLIP BANDInstall around the rubber cushions of both harnesses.


STAY

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53. Secure each harness with the clip as shown.

CLIPInstall to the engine stop & mode indicator switch harness and electric start wire harness and secure to the radiator.



RADIATOR



54. Install the battery band to the battery box as shown.

55. Route and install the battery positive (+)cable as shown.

BATTERY BAND

BATTERY BOX

BATTERY BOX

BATTERY POSITIVE (+) CABLE

CLIP

CLIP

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56. Route the battery positive (+) cable as shown.<Right side>

57. Install the battery box as shown.

6 mm SH FLANGE BOLT (middle)

FLANGE COLLAR

BATTERY BOX


58. Install the battery negative (-) cable and battery cushion as shown.

6 mm SH FLANGE BOLT (short)

BATTERY NEGATIVE (-) CABLE

BATTERY CUSHION

BATTERY BOX

59. Install the starter relay switch stay to the starter relay as shown.

STARTER RELAYSWITCH STAY

STARTER RELAY SWITCH

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60. Route the starter motor cable as shown.

STARTER MOTOR CABLE

STARTER MOTOR CABLE

61. Route the electric start wire harness as shown.



8-PIN WATERPROOF CONNECTOR (Gray)

After connecting, install the starter relay switch cover.

62. Connect the battery positive (+)cable and starter motor cable as shown.

STARTER MOTOR CABLE

STARTER MOTOR CABLE

ASSEMBLED STARTER RELAY SWITCH


STARTER RELAY SWITCH COVER

BATTERY POSITIVE (+)CABLE


6 mm WASHER BOLT

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STARTER MOTOR CABLE TAPE (Blue)

63. Connect the electric start wire harness and install the assembled starter relay switch as shown.

64. Secure the starter motor cable with the wire tie as shown.• Secure it to the curved surface of the frame to

prevent the starter motor cable from rubbing against the throttle body.

6 mm FLANGE BOLT


30 mm




Secure the battery cable.

WIRE TIE (long)Secure the taped part (Blue) of the starter motor cable to the frame.


STARTER MOTOR CABLE

65. Secure the starter motor cable with the wire tie as shown.• Secure it to the curved surface of the frame to

prevent the starter motor cable from rubbing against the throttle body.

• Do not cut the excess wire tie ends.

66. Secure the starter motor cable with the wire tie as shown.• Confirm that the wire tie lock is below the

lower edge of the frame and inside the motorcycle’s body.

STARTER MOTOR CABLE

WIRE TIE (middle)Secure the starter motor cable to the frame.

30 mm

WIRE TIE (long)Secure the rubber part of the starter motor cable to the frame.


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67. Secure the battery cable with the wire tie as shown.• Confirm that the locked part of wire tie is

below the upper edge of the frame and inside the motorcycle’s body.

• Do not cut the excess wire tie ends.

68. Connect the starter motor cable to the starter motor as shown.

STARTER MOTOR CABLE

COVERCover the connected terminal.

STARTER MOTOR6 mm FLANGE NUT

70. Connect the engine stop & mode indicator switch harness to the electric start wire harness as shown.

<Left side>


HARNESS BOOTStore the connected connectors.


2-PIN WATERPROOF CONNECTOR (Black)CONDENSER

HARNESS


69. Secure the starter motor cable and pulse generator harness with the harness clip as shown.

PULSE GENERATOR HARNESS

STARTER MOTOR CABLE

HARNESS CLIP

WIRE TIE (middle)Secure the battery cable to the frame.

BOLT

40 - 70 mm


Connect the electric start wire harness to the relay.


8-PIN WATERPROOF CONNECTOR (Gray)

RELAY

RELAY

71. Install the relay as shown.

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72. Secure all electric start wire harness connectors and install the wire ties.

73. Install the battery as shown.• Connect the positive (+) cable first.

74. Hook the battery band on the battery box as shown.

75. Install the motorcycle’s parts in the reverse order of removal.• Confirm that no wire harness is caught or too

tight.76. Fill the coolant and the engine oil.77. Check that the engine starts while pulling the clutch

lever and pushing the start switch.• Refer to the Genuine Accessory User’s Guide

for operating instructions.

BATTERY BOX

BATTERY BOX

BATTERY

BATTERY BAND

accessory application publication no. installation...

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