Kawasaki KXF 450 Owner's manual

Quick Reference Guide

GENERAL INFORMATION j

MAINTENANCE AND ADJUSTMENT j

TROUBLESHOOTING GUIDE j

TUNING 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 a competition model only and was not manufactured for use on public streets, roads or

highways.

•

The use of this vehicle should be limited to participation in sanctioned competition events upon a closed

course.

•

This vehicle should not be used for general off-road recreational riding.

•

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 injury.

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

○

Note indicates information that may help or guide

youintheopera

tion or service of the vehicle.

IMPORTANT NOTICE

THIS VEHICLE IS A COMP

ETITION MODEL

ONLY AND WAS NOT MANUFACTURED

FOR, NOR SHOULD IT BE USED ON, PUB-

LIC STREETS, ROADS,

OR HIGHWAYS. THE

USE OF THIS VEHICLE SH OU LD BE LIMITED

TO PARTICIPATION IN SANCTIO NED COMPE-

TITION EVENTS UPON

A CLOSED COURSE.

THIS VEHICLE SHOULD NOT BE USED FOR

GENERAL OFF-ROAD RECREATIONAL RIDING.

READ OWNER’S MANUA

L.

WARNING

THIS VEHICL E SHOULD NOT BE USED FOR

GENERAL OFF-ROAD R

ECREATIONAL RID-

ING.

DISCLAIMER OF WA RRA NTY

This motorcycle is sold AS IS, with all faults,

obvious or conce

aled and there are NO WAR-

RANTIES, expressed or implied. Including war-

ranties of MERCHANTABILITY or FITNES S FOR

PURPOSE.

The purchaser accepts all responsibilities con-

cerning quality, performance, cost of service

and/or necess

ary repairs.

Motorcycle Noise Emi

ssion Control

Information

This motorcycle is designed for closed course

competition use only. It does not conform to

U.S. EPA motorcycle

noise standards.

NOTICE

Off-road motorcycling is a wonderful sport, and

we hope you will enjoy it to the fullest. How-

ever, if improperly conducted, this sport has

the potential to cause environmental problems

as well as conflicts with other people. Respon-

sible use of your off-road motorcycle will en-

sure that these problems and conflicts do not

occur. TO PROTECT THE FUTURE OF YOUR

SPORT, MAKE SURE YOU USE YOUR MOTOR-

CYCLE LEGA LLY, SHOW CONCERN FOR THE

ENVIRONMENT, AND RESPECT THE RIGHTS

OF OTHER PEOPLE.

WARNING

The engine exhaust from this product con-

tains chemicals known to the State of Cali-

fornia to cause cancer, birth defects or other

reproductive harm.

FOREWORD

Congratulations on your choosing this Kawasaki motorcycle. Your new motorcycle is the product of

Kawasaki’s advanced engineering, exhaustive testing, and continuous striving for a superior lightweight,

high-performa n ce machine with superb han dling and stability for rac ing and sporting use .

Your new KX is a highly tuned competition machine for participation in racing events. As with any mechan-

ical device, proper care and maintenance are important for trouble-free operation and top performance. This

manual is written to enable you to keep your KX properly tuned and adjusted.

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

discrepancie s between the actual vehicle and the illustrations and text in this manual.

KAWASAKI HEAVY INDUSTRIES, LTD.

Motorcycle & Engine Company

TABLE OF CONTENTS

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

GENERAL INFORMATION.............................. 12

Location of Labels ......................................... 12

Location of Parts ........................................... 17

Side Stand.............................. ....................... 20

Fuel ............................................................... 21

Fuel Requirem ent:...................................... 22

Kick Pedal .............................. ....................... 24

Starting the Engine........................................ 24

Launch Control Mode

....................................

26

DFI Setting Da ta Selection ....................... ..... 27

Shifting Gears................................................ 28

Stopping the Motor

cycle......... .......................

29

Stopping the Engine ........................ .............. 29

Break-In...................... ................................... 30

Daily Pre-Ride Ch

ecks ..................................

31

After-Race Chec ks ........... ............................. 33

MAINTENANCE AND ADJUSTMENT............. 34

Periodic Mainte

nance Chart ..........................

34

Engine Oil...................................................... 39

Cooling System ............................................. 44

Spark Plug..................................................... 48

Air Cleaner .......................... .......................... 56

Throttle Cable .................................. .............. 6 2

Throttle Body

Assy ........................................

63

Clutch ............................................................ 73

Valve Clearance ............................................ 82

Exhaust Syst

em ............................................

88

Rear Axle Nut ............................ .................... 93

Drive Chain.. .................................................. 94

Adjustable Ergonomics.. ................................ 99

Footpeg ......................................................... 102

Brakes .................. ......................................... 1 04

Steering ......................................................... 107

Front Suspe nsion .......................................... 110

Rear Suspe ns ion (UNI-TR A K

®

)..................... 1 58

Wheels .......................................................... 1 64

Hoses Inspection ........................................... 1 66

Tightening Tor ques of Nuts and Bolts.......... .. 167

Cleaning Your Motorcycle.............................. 1 71

Lubrication ..................................................... 17 3

DFI Self-Diagnosis ............................ ........... 176

TROUBLESHOO TING GUIDE ......................... 183

TUNING................... ......................................... 1 90

Suspension.................................................... 1 90

Gearing.......................................................... 196

Special Care Acc

ording to Track Conditions.

197

OPTIONAL PAR TS .......................................... 1 98

PRE-RACE CHECKS AND AFTER-RACE

MAINTENANCE ............................................ 1 99

STORAGE............ ............................................ 201

Before Storage .............................................. 201

After Storage

.................................................

202

ENVIRONMENTAL PROTECTION.................. 203

WIRING DIAGRAM .......................................... 204

8 SPECIFICATIONS

SPECIFICATIONS

DIMENSIONS

Overall Length 2 195 mm (86.42 in.)

Overall Width 820 mm (32.3 in.)

Overall Height 1 290 mm (50.79 in.)

Wheelbase

1 495 mm (58.86 in.)

Road Clearance 345 mm (13.6 in.)

Curb Mass 108.7 kg (239.7 lb)

Fuel Tank Capacity 6.3 L (1.7 US gal)

ENGINE

Type

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

Bore × Stroke 96.0 × 62.1 mm (3.78 × 2.44 in.)

Displacement

449cm³(27.4cuin.)

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 lubrica tion (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

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 M A, MA1 or MA2

Viscosity

SAE 10W-40

Capacity 1.0 L (1.1 US qt)

FRAME

Type Tubular, semi-double cradle

Steering Angle 42° to either side

Caster 28.0°

Trail

125 mm (4.92 in.)

10 SP ECIFICATIONS

Tire Size/Type:

Front

80/100-21 51M/BRIDGESTONE M403

Rear

120/80-19 63M/BRIDGESTONE M404

Rim Size:

Front 21 × 1.60

Rear 19 × 2.15

Suspension:

Front

Telescopic fork (upside-down)

Rear New U ni-trak

®

swingarm

Front Suspension Travel 310 mm (12.2 in.)

Rear Wheel Travel

315 mm (12.4 in.)

Front Fork 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 50 mL (1.69 US oz.)

Outer Tube 270 mL (9.13 US oz.)

Balance Chamber 5 mL (0.17 US o z .)

SPECIFICATIONS 11

BRAKES

Type:

Front

Single disc

Rear

Single disc

Specifications are subject to change without notice.

12 GENE RAL INFORMATION

j

GENERAL INFORMATION

Location of Lab els

All warning labels which are on your vehicle a re

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 ma y ope

rate your vehicle. There-

fore, it is very important that all warning labels be on

your vehicle in the locations shown. If any label is

missing, damaged, or

worn, get a replacement from

your Kawasak i de aler and install it in the corre ct po-

sition.

NOTE

○

The sam ple warning labe ls in this section have

part numb ers to help

you and your dealer obtain

the correct replacement.

1. Brake Fluid (Front)

GENERAL INFORMATION 13

j

2. Brake Fluid (Rear)

3. Radiator Cap Danger

4. Rear Shock Absorber Warning

14 GENE RAL INFORMATION

j

5. Front Fork Warning

6. Disclaimer of Warranty

7. Important Information

8. Noise Emission Control Information

GENERAL INFORMATION 15

j

1)

2)

3)

4)

16 GENE RAL INFORMATION

j

5)

6)

7)

8)

GENERAL INFORMATION 17

j

Location of Parts

1. Clutch Lever

2. Engine Stop Button

3. Launch Control Mode Button

4. Orange Launch Control Mode/FI Warning

Indicator Light

5. Fuel Tank Cap

6. Front Brake Fluid Reservoir

7. Front Brake Lever

8. T hrottle Grip

18 GENE RAL INFORMATION

j

1. Front For

k

2. Radiator

3. Fuel Tank

4. Throttl

e Body Assy

5. Seat

6. Air Cleaner Element

7. Front B

rake Disc

8. Front Bra

ke Caliper

9. Shift Pedal

10. Footpeg

11. Rear Sho

ck Absorber

12. Drive Chain

13. Chain Guide

14. Swinga

rm

GENERAL INFORMATION 19

j

1. Muffler

2. Rear Brake Fluid Reservoir

3. Rear Shock Absorber Gas Re se rvoir

4. Kick Ped

al

5. DFI Setting Data Selection Connector

6. Rear Brake Disc

7. Re ar Brak

e Caliper

8. Uni-Trak

®

Tie-Rod and Rocker Arm

9. Oil Level Inspection Window

10. Re ar Bra

ke Pedal

11. Exhaust Pipe

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