2003 Honda CRF 450 Carburetor Disassembly

Step 1

Turn Fuel Off

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• Move the fuel lever from the on position to the off.

Step 2

Drain Pan

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• Place a drain pan under the motorcycle to catch any excess fuel.

Step 3

Remove Seat

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• 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

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TOOL USED ON THIS STEP Phillips #2 Screwdriver Referenced by the iFixit guide

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• Loosen the screw with a phillips head screwdriver so the clamp can move freely.

Step 5

Exhaust Bolt

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• Loosen the 12mm bolt to separate the exhaust muffler from the exhaust header.

Step 6

Lower Sub-Frame Bolts

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• Remove the 10mm lower sub-frame bolts on each side of the motorcycle.

Step 7

Upper Sub-Frame Bolt

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• Remove the 10mm upper sub-frame bolt from the motorcycle.

Step 8

Sub-Frame Removal

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• Remove the sub-frame assembly from the rest of the motorcycle.

Step 9

Remove Fuel Line

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• 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

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TOOL USED ON THIS STEP Phillips #2 Screwdriver Referenced by the iFixit guide

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• Loosen the clamp on the front of the carburetor with the Phillips head screwdriver.

Step 11

Remove Shock Bolts

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• Remove the top and bottom shock bolts with 17mm socket.

Step 12

Remove Shock

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• Remove the shock from the motorcycle.

Step 13

Plastic Cover

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TOOL USED ON THIS STEP Phillips #2 Screwdriver Referenced by the iFixit guide

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• 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

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• 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

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TOOL USED ON THIS STEP Phillips #2 Screwdriver Referenced by the iFixit guide

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• 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

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• Remove the 8mm bolt above the fuel tank.
• Remove the safety clip at the bottom of the fuel tank.

Step 17

Fuel Tank Removal

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• 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

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• 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

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• Un-thread the 13mm plastic hot start cable from the carburetor.

Step 20

Remove Carburetor

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• 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

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• Gently brush and blow off any debris from the carburetor.

Step 22

Disassemble Carburetor

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TOOL USED ON THIS STEP Phillips #2 Screwdriver Referenced by the iFixit guide

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• 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

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• Remove the shaft from the two posts sticking up on the inside of the carburetor.
• Remove the float.

Step 24

Remove Jets

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• Remove the jets from the body of the carburetor.
• Thoroughly clean all jets and body of carburetor.