Kawasaki klx450 Owner's manual

ENGLISH j

Motorcycle

Owner’s Manual

Original instructions

Quick Reference Guide

GENERAL INF OR MATION j

MAINTENANCE A ND ADJUSTMENT j

TROUBLESHOOTING GUIDE j

STORAGE j

This Quick Reference Guide will assist you in

finding the in

formation you’re looking for.

A Table of Contents is included after the

Foreword.

IMPORTANT INFORMATION

•

This vehicle is designed for the operator only, no passengers.

•

This vehicle is an off-road motorcycle only and was not manufactured for use on public streets, roads or

highways.

•

Read owner’s manual.

Whenever you see the symbols shown below,

heed their instructions! Always follow safe operat-

ing and maintenance

practices.

DANGER

DANGER indicates a hazardous situation

which, if not avoided, will result in death or

serious inj ury.

WARNING

WARNING indicates a hazardous situation

which, if not avoided, could result in death

or serious injury.

NOTICE

NOTICE is used to

address practices not re-

latedtopersonalinjury.

NOTE

○

NOTEindicates informationthatmay helporguide

youintheopera

tion or service of the vehicle.

IMPORTANT

Off-road motorcycling is a wonderful sport,

and we hope you will en

joy it to the fullest. Ho w-

ever, if improperly conducted, this sport has the

potential to cause environmental problems as

well as conflicts wi

th other people.

Responsible use of your off-road motorcycle

will ensure that these problems and conflicts do

not occur. TO PROTE

CT THE FUTURE OF YOUR

SPORT, MAKE SURE YOU USE Y OU R MOTOR-

CYCLE LEGALLY, SHOW CONCERN FOR THE

ENVIRONMENT, AND

RESPECT TH E RIGHTS

OF OTHER PEOPLE.

WARNING

•

THIS VEHIC LE IS AN OFF-ROAD VEHICLE

ONLY AND WAS NOT MANUFACTURE D

FOR USE ON PUBLIC STREETS, ROADS ,

OR HIGH-WAYS.

•

USEYOURBIKELEGALLY.

•

RESPECT THE ENVIRONMENT AND THE

RIGHTS OF OTHER REOPLE.

FOREWORD

We wish to thank you for choosing this Kawasaki M otorcycle. It is the end product of Kawasaki’s advanced

engineering, e xh austive testing, and continuous striving for superior reliability, a nd pe rfo rmance. By giving yo ur

motorcycle the proper care and maintenance outlined in this manual, you will be helping to ensure it a long,

trouble-free life.

Beforestartingto ride yourmotorcycle, please read thismanual thoroughly in orderto know your motorcycle’s

capabilities, its limitations, an d above all, ho w to opera te it safety.

Due to improvements in design and performance made during production, in some cases there may be minor discre pancies between

the actual vehicle and the illustrations and text in this manual.

KAWASAKI HEAVY INDUSTRIES, LTD.

Motorcycle & Engine Company

vy Industries, Ltd.

Feb. 14, 2017. (1)

TABLE OF CONTENTS

SPECIFICATIONS..................... ....................... 8

DECLARATION OF CONFORMITY ................ 11

GENERAL INFORMATION....... ....................... 13

Location of Lab els ............ ............................. 13

Location of Parts ........................................... 19

Side Stand...... ............................................... 22

Fuel ............................................................... 22

Fuel Requirements:............. ....................... 22

Filling the Tank: .......................................... 23

Fuel Tap:..................................................... 24

Meter Unit. ..................................................... 25

Speedometer:............................................. 26

Odometer: .................................................. 26

Clock: ......................................................... 26

Trip Meter:... ............................................... 27

Engine Stop Butto

n .......................................

28

Kick Pedal ................................................ ..... 28

Starter Butto n ................................................ 29

Starting the Eng

ine.......................... ..............

29

Moving Off..................................................... 32

Shifting Gear s................................................ 33

Stopping the Mo

torcycle................................

34

Stopping the Engine..................... ................. 34

Break-In. ........................................................ 35

Daily Pre-Rid

e Checks ..................................

36

After-Race Checks........ ................................ 38

MAINTENANCE AND ADJUSTMENT........ ..... 39

Periodic Mai

ntenanc e Chart..........................

39

Engine Oil.... .................................................. 44

Cooling Syste m .......... ................................... 48

Spark Plug... .................................................. 53

Air Cleaner .................................................... 55

Throttle Cable.......... ...................................... 60

Carburetor..................................................... 62

Clutch . ........................................................... 63

Hot Starter Cable........................................... 70

Valve Cle arance ............ ................................ 71

Spark Arrester......... ...................................... 77

Rear Axle Nut....... ......................................... 79

Drive Chain.................................................... 79

Handlebar...................................................... 84

Brakes ........................................................... 86

Steering......................................................... 90

Front Suspension .......................................... 92

Rear Su sp e ns ion (UNI-TRAK

®

)..................... 121

Wheels .......................................................... 125

Hoses Inspect ion........ ................................... 128

Headlight ....................................................... 128

Battery........................................................... 12 9

Fuse .............................................................. 132

Tightening Torques of N uts and Bolts....... ..... 133

Cleaning Your M

otorcycle..............................

138

Lubrication......... ............................................ 140

TROUBLESHOO TING GUIDE......................... 1 44

STORAGE........................................................ 152

Before Storage .............................................. 152

After Storage .............. ................................... 153

ENVIRONMENT

AL PROTECTION..................

154

WIRING D IAGRAM.......................................... 155

8 SPECIFICATIONS

SPECIFICATIONS

DIMENSIONS

Overall length 2 175 mm (85.6 in.)

Overall width 820 mm (32.3 in.)

Overall height 1 250 mm (49.2 in.)

Wheelbase

1 480 mm (58.3 in.)

Road clearance

315 mm (12.4 in.)

Curb Mass 126 kg (278 lb)

Fuel tank capacity

8L(2.1USgal)

ENGINE

Type

DOHC, 4-valve, single-cylinder, 4-stroke, liquid-cooled

Bore × stroke

96.0 × 62.1 mm (3.8 × 2.4 in.)

Displacement

449 cm³ ( 27.4 cu in.)

Compression ratio

12.0 : 1

Carburetor KEIHIN FCR-MX40

Starting system

Electric, Primary kick

Ignition system

CDI

Ignition timing

10.2° BTDC @1 800 r/min (rpm)

Lubrication system

Forced Lubrication (semi dry sump)

Spark plug NGK CPR8EB-9

Spark plug terminal Solid-post

SPECIFICATIONS 9

TRANSMISSION

Transmission type

5-speed, constant-mesh, return shift

Clutch type

Wet, multi disc

Drive system

Chain drive

Gear ratios:

1st gear

2.167 (26/12)

2nd gear

1.533 (23/15)

3rd gear

1.188 (19/16)

4th gear

0.950 (19/20)

5th gear

0.810 (17/21)

Primary reduction ratio

2.727 (60/22)

Final reduction ratio

3.846 (50/13)

Overall ratio (top gear)

8.492

Engine oil:

Capacity 1.3 L (1.4 US qt)

Type

API SG, SH, SJ, SL o

rSMwithJASOMA,MA1orMA2

SAE 10W-40

Coolant Capacit

y

1.1 L (1.2 US qt)

FRAME

Type

Semi-double cradle

Steering angle 42° to either side

Caster 28°

Trail

122 mm (4.8 in.)

10 SP ECIFICATIONS

Tire size, type:

Front

80/100-21 M/C51P, BR

IDGESTONE ED03

Rear

120/90-18 M/C65P, BR

IDGESTONE ED04

Rim size:

Front 21 × 1.60

Rear 18 × 2.15

Suspension:

Front

Upside-down telesc

opic fork

Rear New Uni-trak

®

swingarm

Front suspension travel

305 mm (12.0 in.)

Rear wheel travel

315 mm (12.4 in.)

Front fork oil:

Type

Kawasaki Fork Oil KHL15-10

Amount (per fork leg) :

Inner Damper

189 mL (6.4 US oz)

Inner/Outer Tubes 335 mL (11.3 US oz)

BRAKES

Type (Front & Rear)

Disc

ELECTRICAL EQUIPMENT

Battery

12 V 6 Ah (10 HR)

Headlight 12 V 35 W

Specifications are subject to change without notice and may not apply every country.

DECLARATION OF CONFORMITY 11

DECLARATION OF CONFORMITY

12 DECLAR ATION OF CONFORMITY

GENERAL INF OR MATION 13

j

GENERAL INFORMATION

Location of Labels

All warning labels which are on your vehicle are

repeated here. Read lab

els on your vehicle and un-

derstand them thoroughly. They contain information

which is important for your safety and the safety of

anyone else who may ope

rate your vehicle. There-

fore, it is very importa nt that all w arning labels be on

your vehicle in the locations shown. If any label is

missing, damaged, or

worn, get a replacement from

your Kawasa ki dealer and install it in the correct po-

sition.

NOTE

○

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 GENE RAL INFORMATION

j

2. Brake Fluid (Rear)

3. Radiator Cap Danger

4. Rear Shock Absorber Warning

GENERAL INF OR MATION 15

j

5. Battery Poison/Danger

6. Important Info rmation

7. Fuel Identification

16 GENE RAL INFORMATION

j

1)

2)

3)

4)

GENERAL INF OR MATION 17

j

5) 6)

1. This vehicle is designed for the operator only,

no passengers.

2. This vehicle is an off-road motorcycle o nly

and was not manufactured for use on public

streets, roads or highways.

3. Read owner’s manual

18 GENE RAL INFORMATION

j

7)

Use fuel identified by either of the above symbols.

1. Gasoline conta

iningupto5%ethanolby

volume

2. Gasoline conta

iningupto10%ethanolby

volume

See page 22.

GENERAL INF OR MATION 19

j

Location of Parts

1. Clutch Lever

2. Engine Stop Button

3. Hot Starter Lever

4. Meter Unit

5. FrontBrakeFluidReservoir

6. Front Brake Lever

7. Throttle Grip

8. Starter Button

9. Fuel Tank Cap

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Kawasaki klx450 Owner's manual

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