Kawasaki KX450F - Owner's manual

Category
Motorcycles
Type
Owner's manual

This manual is also suitable for

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ENGLISH
Motorcycle
Owner's Manual
Original instructions
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Quick Reference Guide
This Quick Reference Guide will assist you in
finding the information you're looking for.
A Table of Contents is included after the Foreword.
DECLARATION OF CONFORMITY
GENERAL INFORMATION
MAINTENANCE AND ADJUSTMENT
TROUBLESHOOTING GUIDE
TUNING
STORAGE
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IMPORTANT INFORMATION
•
This vehicle is designed for the operator only, no passengers.
•
This vehicle is a competition model only and was not manufacture d for use on public streets, roads or high-
ways.
•
The use of this vehicle should be limited to participation in sanctioned competition eve nts upon a closed
course.
•
This vehicle should not be used for general off-road recreational riding.
•
Read owner's manual.
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Whenever you see the symbols shown below,
heed their instructions! Always follow safe operating
and maintenance practices.
DANGER
DANGER indicates a hazardous situation
which, if not avoided, will result in death or
serious injury.
WARNING
WARNING indicates a hazardous situation
which, if not avoi ded, could result in death or
serious injury.
NOTICE
NOTICE is used to address practices not re-
lated to personal injury.
NOTE
â—‹
Note indicates information that may help or guide
you in the operation or service of the vehicle.
IMPORTANT NOTICE
THIS VEHICLE IS A COMPETITION MODEL ON-
LY AND WAS NOT MANUFACTURED FOR, NOR
SHOULD IT BE USED ON, PUBLIC STREETS,
ROADS, OR HIGHWAYS. THE USE OF THIS VE-
HICLE SHOULD BE LIMITED TO PARTICIPATION
IN SANCTIONED COMPETITION EVENTS UPON
A CLOSED COURSE. THIS VEHICLE SHOULD
NOT BE USED FOR GENERAL OFF-ROAD REC-
REATIONAL RIDING.
READ OWNER'S MANUAL.
WARNING
THIS VEHICLE SHOULD NOT BE USED FOR
GENERAL OFF-ROAD RECREATIONAL RID-
ING.
MANUFACTURER'S WARRANTY
This motorcycle is sold as a Competition Racing
Machine and as such there is no manufacturer's
warranty expressed or implied. You should also be
aware that any accidental damage and/or damage
caused by alteration of the standard sp ecification
(tuning or modification) is entirely the owner's re-
sponsibility. Nothing in this statement affects your
statutory rights.
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NOTICE
Off-road motorcycling is a wonderful sport, and
we hope you will enjoy it to the fullest. However,
if improperly conducted, this sport has the po-
tential to cause environmental problems as well
as conflicts with other people. Resp onsible use
of your off-road motorcycle will ensure that
these problems and conflicts do not occur. TO
PROTECT THE FUTURE OF YOUR SPORT,
MAKE SURE YOU USE YOUR MOTORCYCLE
LEGALLY, SHOW CONCERN FOR THE ENVI-
RONMENT, AND RESPECT THE RIGHTS OF
OTHER PEOPLE.
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FOREWORD
Congratulations on your choosing this Kawasaki motorcycle. Your new motorcycle is the product of Kawasa-
ki's advanced engineering, exhaustive testing, and continuous striving for a superior lightweight, high-perform-
ance machine with superb handling and stability for racing and sporting use.
Your new KX is a high ly tuned competition machine for participation in racing events. As with any mechanical
device, proper care and maintenance are important for trouble-free operation and top performanc e. This man-
ual is written to enable you to keep your KX prope rly tuned and adjusted.
Due to improvements in design and performance made during production, in some cases there may be minor
discrepancies between the actual vehicle and the illustrations and text in this manual.
KAWASAKI HEAVY INDUSTRIES, LTD.
Motorcycle & Engine Company
© 2014 Kawasaki Heavy Industries, Ltd. Mar. 31, 2014. (5)
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TABLE OF CONTENTS
SPECIFICATIONS .............................................. 9
DECLARATION OF CONFORMITY ................... 12
GENERAL INFORMATION ................................ 14
Location of Labels ............................................ 14
Location of Parts .............................................. 19
Side Sta nd ........................................................ 22
Fuel ................................................................... 22
Fuel Requi rements: ....................................... 22
Filling the Tank: ............................................. 23
Kick Pedal ........................................................ 25
Starting the Engine ........................................... 25
Launch Control Mode ....................................... 27
DFI Setting Data Selection ............................... 28
Shifting Gears ................................................... 29
Stopping the Motorcycle ................................... 30
Stopping the Engine ..... .................................... 30
Break-In ............................................................ 31
Daily Pre-Ride Checks ..................................... 32
After-Race Checks ........................................... 34
MAINTENANCE AND ADJUSTMENT ............... 35
Periodic Maintenance Chart ............................. 35
Engine Oil ......................................................... 40
Cooling System ................................................ 44
Spark Plug .......... .............................................. 48
Air Cleaner ........................................................ 55
Throttle Cable ................................................... 61
Throttle Body Assy ........................................... 62
Clutch ............................................................... 73
Valve Clearance ............................................... 83
Exhaust System ............................................... 88
Rear Axle Nut ................................................... 92
Drive Chain ....................................................... 93
Adjustable Ergonomics .................................... 98
Footpeg ............................................................100
Brakes ..............................................................102
Steering ............................................................106
Front Suspension .............................................109
Rear Suspension (UNI-TRAK
®
) .......................155
Wheels .............................................................161
Hoses Inspection ..............................................164
Tightening Torques of Nuts and Bolts ..............165
Cleaning Your Motorcycle ................................169
Lubrication ........................................................171
DFI Self-Diagnosis ..........................................174
TROUBLESHOOTING GUIDE ...........................181
TUNING ..... ..........................................................188
Suspension .......................................................188
Gearing .............................................................194
Special Care According to Track Conditions ...195
OPTIONAL PARTS .............................................196
PRE-RACE CHECKS AND AFTER-RACE
MAINTENANCE ..............................................
197
STORAGE ...........................................................199
Before Storage .................................................199
After Storage .......... ..........................................200
ENVIRONMENTAL PROTECTION ....................201
WIRING DIAGRAM .............................................202
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SPECIFICATIONS
DIMENSIONS
Overall Length 2 195 mm (86.42 in.)
Overall Width 820 mm (32.3 in.)
Overall Height 1 275 mm (50.20 in.)
Wheelbase 1 495 mm (58.86 in.)
Road Clearance 340 mm (13.4 in.)
Curb Mass 112.1 kg (247 lb)
Fuel Tank Capacity 6.2 L (1.6 US gal)
ENGINE
Type 4-stroke, DOHC, single-cylinder, liquid-cooled
Bore × Stroke 96.0 × 62.1 mm (3.78 × 2.44 in.)
Displacement 449 cm³ (27.4 cu in.)
Compression Ratio 12.8:1
Fuel System FI (Fuel Injection)
Starting System Primary kick
Ignition System Digital DC-CDI
Ignition Timing 10° BTDC @2 000 r/min (rpm)
Lubrication System Forced lubrication (semi-dry sump)
Spark Plug NGK CPR8EB-9
Spark Plug Terminal Solid-post
TRANSMISSION
Transmission Type 5-speed, constant mesh, return shift
SPECIFICATIONS 9
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Clutch Type Wet, multi disc
Driving System Chain drive
Gear Ratio:
1st 1.750 (28/16)
2nd 1.412 (24/17)
3rd 1.188 (19/16)
4th 1.000 (19/19)
5th 0.875 (21/24)
Primary Reduction Ratio 2.727 (60/22)
Final Reduction Ratio 3.846 (50/13)
Overall Drive Ratio 9.178 @Top gear
Engine Oil:
Type
API SG , SH, SJ, SL or SM with JASO MA, MA1 or MA2
Viscosity SAE 10W-40
Capacity 1.2 L (1.3 US qt)
FRAME
Type Tubular, semi-do uble cradle
Steering Angle 42° to either side
Caster 27.9°
Trail 120 mm (4.72 in.)
Tire Size/Type:
Front 80/100-21 51M/BRIDGESTONE M403
Rear 120/80-19 63M/BRIDGESTONE M404
10 SPECIFICATIONS
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Rim Size:
Front 21 × 1.60
Rear 19 × 2.15
Suspension:
Front Telescopic fork (upside-down)
Rear New Uni-trak
®
swingarm
Front Suspension Travel 314 mm (12.4 in.)
Rear Wheel Travel 315 mm (12.4 in.)
Front For k Oil:
Type Kawasaki Fork Oil SS19
Amount:
Left Front Fork:
Cylinder Unit 310 mL (10.5 US oz.)
Outer Tube 345 mL (11.7 US oz.)
Right Front Fork:
Cylinder Unit 100 mL (3.38 US oz.)
Outer Tube 300 mL (10.1 US oz.)
Balance Chamber 10 mL (0.34 US oz.)
BRAKES
Type:
Front Single disc
Rear Single disc
Specifications are subject to change without notice, and may not apply to every co untry.
SPECIFICATIONS 11
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DECLARATION OF CONFORMITY
12 DECLARATION OF CONFORMITY
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DECLARATION OF CONFORMITY 13
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GENERAL INFORMATION
Location of Labels
All warning labels which are on your vehicle are
repeated here. Read labels on your vehicle and
understand them thoroughly. They contain informa-
tion which is important for your safety and the safety
of anyone else who may operate your vehicle.
Therefore, it is very important that all warning labels
be on your vehicle in the locations shown. If any la-
bel is missing, damaged, or worn, get a replacement
from your Kawasaki dealer and install it in the cor-
rect position.
NOTE
â—‹
The sample warning labels in this section have
part numbers to help you and your dealer obtain
the correct replacement.
1. Brake Fluid (Front)
14 GENERAL INFORMATION
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2. Brake Fluid (Rear)
3. Radiator Cap Danger
4. Rear Shock Absorber Warning
GENERAL INFORMATION 15
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5. Important Information
6. Front Fork Warning
16 GENERAL INFORMATION
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1)
2)
3)
4)
GENERAL INFORMATION 17
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5)
1. This vehicle is designed for the operator only,
no passengers.
2. This vehicle is a competition model only and
was not manufactured for use on public
streets, roads or highways.
3. The use of this vehicle should be limited to par-
ticipation in sanctioned competition events
upon a closed course.This vehicle should not
be used for general off-road recreational rid-
ing.
4. Read owner's manual
6)
18 GENERAL INFORMATION
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Location of Parts
1. Clutch Lever
2. Engine Stop Button
3. Launch Control Mode Button
4. Orange Launch Control Mode/FI Warning Indi-
cator Light
5. Fuel Tank Cap
6. Front Brake Fluid Reservoir
7. Front Brake Lever
8. Throttle Grip
GENERAL INFORMATION 19
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Kawasaki KX450F - Owner's manual

Category
Motorcycles
Type
Owner's manual
This manual is also suitable for

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