2009 Kawasaki KFX450R Owners Manual

2009 Kawasaki KFX450R Manual

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  • 2009 Kawasaki KFX450R | Owners Manual - Page 1
  • 2009 Kawasaki KFX450R | Owners Manual - Page 2
  • 2009 Kawasaki KFX450R | Owners Manual - Page 3
    Quick Reference Guide This Quick Reference Guide will assist you in finding the information you're looking for. GENERAL INFORMATION BREAK-IN HOW TO RIDE SAFE OPERATION MAINTENANCE AND ADJUSTMENT STORAGE TROUBLESHOOTING GUIDE j j j j j j j A Table of Contents is included after the Foreword.
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    not avoided, will result in death or serious injury. HOW TO AVOID THE DANGER Read all DANGERS in this manual carefully and for your safety be sure to follow their instructions. NOTICE NOTICE is used to address practices not related to personal injury. WARNING HAZARD Failure to heed WARNING. WHAT
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    this manual carefully and completely before starting your new Kawasaki. It contains important safety information. Never operate an ATV without proper instruction. , the sport has the potential to cause environmental problems as well as conflicts with other people. Responsible use of your off-
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    to take proper precautions. SEVERE INJURY OR DEATH can result if you do not follow these instructions: żRead this manual and all labels carefully and follow the operating procedures described. żThe Owner's Manual should be kept in the waterproof plastic bag and stored in the storage case provided
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    sharply to one side. Go straight down the hill where possible. żAlways follow proper procedures for crossing the side of a hill as described in this manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around
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    installation or use of accessories. Installation of accessory items may affect vehicle handling. Refer to the Loading Information chapter in this manual. żPreserve the environment, ride responsibly and always know and obey laws and regulations governing ATV operation. żRefueling: Shut engine off and
  • 2009 Kawasaki KFX450R | Owners Manual - Page 10
    and limitations. This manual offers many safe riding tips, but its purpose is not to provide instruction in all the trouble-free life for your ATV, give it the proper care and maintenance described in this manual. For those who would like more detailed information on their ATVs, a Service Manual
  • 2009 Kawasaki KFX450R | Owners Manual - Page 11
    the Engine ...Parking the ATV...Stopping the ATV in an Emergency...In case of Vehicle Overturn ...SAFE OPERATION ...Read the Owner's Manual...Obey Local Laws ...Adult Supervision ...Beginning Riders ...Off-Road Use Only ...Dress Properly...Operator Only...Ride Carefully and with Good Judgement
  • 2009 Kawasaki KFX450R | Owners Manual - Page 12
    126 130 General Lubrication ...Cleaning ...Bolt and Nut Tightening ...STORAGE ...Preparation for Storage ...Removal from Storage ...TRANSPORTING THE ATV ...TROUBLESHOOTING GUIDE...OWNER SATISFACTION ...ENVIRONMENTAL PROTECTION ...MAINTENANCE RECORD ... 132 133 134 136 136 138 139 140 142 143 144
  • 2009 Kawasaki KFX450R | Owners Manual - Page 13
    SPECIFICATIONS 11 SPECIFICATIONS PERFORMANCE Maximum Torque Minimum Turning Radius DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Tread: 41.9 N·m (4.3 kgf·m, 31 ft·lb) @7 000 r/min (rpm) 3.6 m (11.81 ft) 1 806 mm (71.10 in.) 1 170 mm (46.06 in.) 1 064 mm (41.89 in.) 1 255 mm (49.
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    12 SPECIFICATIONS Lubrication System Engine Oil: Forced lubrication (semi-dry sump) API SF or SG API SH, SJ, SL, or SM with JASO MA, MA1 or MA2 SAE 10W-40 1.35 L (1.43 US qt) 1.4 L (1.48 US qt) Chain 2WD 5-speed return & reverse 2.952 2.714 8.395 2.230 1.800 1.529 1.278 1.048 2.364 Wet Multi Disc
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    SPECIFICATIONS 13 Tire Size: Front Rear Front Rear Front & Rear AT21 × 7-10 AT20 × 10-9 10 × 5.5 9×8 Disc (Hydraulic) Disc (Mechanical) 10 L (2.6 US gal) 12 V 6 Ah 12 V 30 W × 2 LED Rim Size: Brake: Parking Brake Fuel Tank Capacity ELECTRICAL EQUIPMENT Battery Headlight Tail/Brake Light
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    14 SERIAL NUMBER LOCATIONS SERIAL NUMBER LOCATIONS The frame and engine serial numbers are used to register the vehicle. They are the only means of identifying your particular machine from others of the same model type. These serial numbers may be needed by your dealer when ordering parts. In the
  • 2009 Kawasaki KFX450R | Owners Manual - Page 17
    LOCATION OF LABELS 15 LOCATION OF LABELS All warning labels which are on your ATV are repeated here. Read them and understand them thoroughly. They contain information which is important for your safety and the safety of anyone else who may operate your ATV. Therefore, it is very important that all
  • 2009 Kawasaki KFX450R | Owners Manual - Page 18
    16 LOCATION OF LABELS 8. Shock Absorber Warning 10. Radiator Cap Danger 11. Battery Danger/Poison 9. Specification Label
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    LOCATION OF LABELS 17 (1) (2) (3)
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    18 LOCATION OF LABELS (4) (6) (5) (7)
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    LOCATION OF LABELS 19 (8) (10) (9) (11)
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    20 LOCATION OF LABELS (12) (14) (13) (15)
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    LOCATION OF PARTS 21 LOCATION OF PARTS 1. Clutch Lever 2. Parking Brake 3. Indicator Lights 4. Front Brake Reservoir 5. Front Brake Lever 6. Throttle Lever 7. Reverse Lock Release Lever 8. Fuel Filler Cap 9. Starter Button 10. Engine Stop Switch 11. Light Switch
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    22 LOCATION OF PARTS 12. Radiator 13. Battery 14. Shift Pedal 15. Drive Chain 16. Air Cleaner Box 17. Fuse 18. Coolant Reserve Tank 19. Shock Absorber
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    LOCATION OF PARTS 23 20. Rear Brake Pedal 21. Spark Plug 22. Fuel Tank 23. Engine Oil Filler Port 24. Muffler 25. Brake Light Switch
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    this vehicle should be genuine Kawasaki or equivalent components designed for use on this ATV and should be installed and used according to instructions. If you have questions, consult an authorized ATV dealer. NOTE żKawasaki Parts and Accessories have been specially designed for use on Kawasaki
  • 2009 Kawasaki KFX450R | Owners Manual - Page 27
    LOADING INFORMATION 25 Because an all terrain vehicle is sensitive to increases in weight, changes in weight distribution, and aerodynamic forces, you must take extreme care in the fitting of accessories. The following general guidelines have been prepared to help you make your determinations. not
  • 2009 Kawasaki KFX450R | Owners Manual - Page 28
    and check the following items after the engine cools down. Radiator grill Coolant level and its quality Cooling fan Refer to the TROUBLESHOOTING chapter and Cooling System section in the MAINTENANCE AND ADJUSTMENT chapter for more details. A. Fuel Warning Light B. Reverse Indicator Light C. Neutral
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    handlebars operates the front brake. FI System Failure This warning light also functions as FI warning light. If the light still stays on after the trouble sources for the cooling system are removed, there is a possibility of ECU malfunction or other reasons. See an authorized Kawasaki dealer for
  • 2009 Kawasaki KFX450R | Owners Manual - Page 30
    28 GENERAL INFORMATION The foot pedal on the right side operates the rear brake. j WARNING HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN Could result in ATV overturning. HOW TO AVOID THE HAZARD Use low gearing and maintain steady speed when
  • 2009 Kawasaki KFX450R | Owners Manual - Page 31
    GENERAL INFORMATION 29 j Parking Brake The rear brake is used as the parking brake. When the parking brake lever is flipped to the "PARK ON" position, the parking brake is on. To release the parking brake, flip the lever to the "PARK OFF" side. A. "ON" Position B. "OFF" Position
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    30 GENERAL INFORMATION j Clutch Lever The clutch lever on the left side of the handlebar disengages the clutch when pulled in. Always pull in the clutch lever before starting the engine. If the clutch lever has too much free paly, it may not properly disengage the clutch. Refer to the MAINTENANCE
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    GENERAL INFORMATION 31 WARNING HAZARD Improperly operating in reverse. WHAT CAN HAPPEN You could hit an obstacle or person behind you, resulting in serious injury or death. HOW TO AVOID THE HAZARD When you select reverse gear, make sure there are no obstacles or people behind you. When it is safe
  • 2009 Kawasaki KFX450R | Owners Manual - Page 34
    into reverse gear. Release the reverse lock release lever and shift pedal. Refer to the "Reverse Lock Release Lever" section for detailed instructions. If the engine is stopped, releasing the clutch lever and rolling the vehicle slightly while shifting will help shifting back to neutral. WARNING
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    GENERAL INFORMATION 33 WARNING HAZARD Inattentive operation in "R" (Reverse). Backing up without looking where you are going. WHAT CAN HAPPEN Inattentive operation in "R" (Reverse) could cause you to hit a person or obstacle behind you, resulting in severe personal injury or death. HOW TO AVOID THE
  • 2009 Kawasaki KFX450R | Owners Manual - Page 36
    : A. Fuel Tank B. Filler Neck C. Top Level Fuel Type Use clean, fresh unleaded gasoline with a minimum Antiknock Index of 91. The Antiknock Index is posted on service station pumps in the U.S.A. The
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    damage. Gasoline quality is important. Fuels of low quality or not meeting standard industry specifications may result in unsatisfactory performance. Operating problems that result from the use of poor quality or nonrecommended fuel may not be covered under your warranty. NOTICE Avoid using blends
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    the fuel system. Before storage it is recommended that you drain all fuel from the fuel tank and carburetors. See the Storage section in this manual. Ignition Switch The ignition switch is located on the right front fender. It is a 2-position, key-operated switch. The key can be removed only when
  • 2009 Kawasaki KFX450R | Owners Manual - Page 39
    GENERAL INFORMATION 37 make a new key in the event that your original keys are lost. j Left Handlebar Switches Light/Dimmer Switch: The switch positions are identified on the housing. Headlight and taillight come on by turning the switch to "LO" (low beam) or "HI" (high beam) with the ignition key
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    "N" (neutral). A. Engine Stop Button B. "RUN" position C. "OFF" position Starter Button: Refer to the "Starting the Engine" section of the "How to Ride" chapter for starting instructions.
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    GENERAL INFORMATION 39 j Idle Adjusting/Choke Knob This vehicle is equipped with an idle adjusting/choke knob which operates as a choke knob in addition to the idle adjuster. Throttle Lever The throttle lever is located on the right side of the handlebars. Pushing the lever forward increases
  • 2009 Kawasaki KFX450R | Owners Manual - Page 42
    increases the maximum engine power. WARNING HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if and the operating techniques described in the Owner's Manual. For more information about the training course, contact an authorized ATV
  • 2009 Kawasaki KFX450R | Owners Manual - Page 43
    GENERAL INFORMATION 41 j Seat To remove the seat, push the latch lever located at the left rear end of the vehicle and lift the seat up. A. Locknut B. Screw C. Throttle Lever NOTICE If the throttle limiter is adjusted, verify the changes in throttle in an open, non-traffic area. Never try to
  • 2009 Kawasaki KFX450R | Owners Manual - Page 44
    42 GENERAL INFORMATION To attach the seat, insert the front and center hooks of the seat into the front stopper and the center slot and slide it all the way forward pushing the seat end. Make sure the rear projections of the seat enter into the dampers. j A. Seat B. Front Hook C. Front Stopper D.
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    of the seat to make sure it is securely locked. j Storage Case & Tool Kit The storage case is located under the seat. Keep this Owner's Manual in the storage case. Here is where you will find a tool kit. The minor adjustments and replacement of parts explained in this
  • 2009 Kawasaki KFX450R | Owners Manual - Page 46
    the engine while the transmission is in neutral. żIt is important to perform the initial service after the first 10 hours (100 km, 60 mi) of operation as described in this manual and the service manual for this vehicle. See the Periodic Maintenance Chart in the MAINTENANCE AND ADJUSTMENT chapter.
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    . If any irregularities are found during these checks, refer to the MAINTENANCE AND ADJUSTMENT chapter, see your dealer, or refer to the Service Manual for the action required to return the vehicle to a safe operating condition. DANGER HAZARD Running the engine without ventilation. WHAT CAN HAPPEN
  • 2009 Kawasaki KFX450R | Owners Manual - Page 48
    46 HOW TO RIDE Fuel ...Engine Oil ...Coolant ...Tires ...Enough fuel in tank, no leaks. Oil level between "H" (High) and "L" (Low) lines, no leaks. Coolant level between level lines (when engine is cold), no leaks. Air Pressure (when cold): Front: 30 kPa (0.30 kgf/cm², 4.3 psi) Rear: 27 kPa (0.27
  • 2009 Kawasaki KFX450R | Owners Manual - Page 49
    HOW TO RIDE 47 Starting the Engine has warmed, push the idle adjusting/choke knob back. Idle Adjusting/Choke Knob DANGER HAZARD Running the engine without ventilation. WHAT CAN HAPPEN Breathing exhaust gas leads to carbon monoxide poisoning, asphyxiation, and death. Exhaust gases contain carbon
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    48 HOW TO RIDE the starter button. • Push starts. Repeat until the engine Moving Off sure the transmission is in neutral. • Make Apply the front and rear brakes. • Release the parking brake. • With the clutch pulled in, press down on the • shift pedal with lever your toe to engage 1st gear. the
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    HOW TO RIDE 49 Shifting Gears the throttle and pull in the clutch lever at • Release the same time. to the next higher or lower gear by pulling up • Shift once or pushing down once on the shift pedal. the throttle lever forward part way to in• Push crease engine speed while gently releasing the
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    50 HOW TO RIDE Braking the throttle completely. Leave the clutch • Close engaged (except when shifting gears) so that the WARNING HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN Could result in ATV overturning. HOW TO AVOID THE HAZARD Use low
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    HOW TO RIDE 51 Stopping the Engine the throttle completely. • Close Put the transmission into the "N" (Neutral) position. • Apply the parking brake to help prevent the vehicle • from rolling. • Turn the ignition key to "OFF". Parking the ATV • Stop the vehicle on a level surface. WARNING HAZARD
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    operation. Improper maintenance can create a dangerous situation known as throttle failure. Two of the most common causes of throttle failure are: An improperly serviced or clogged air cleaner may allow dirt and dust to enter the throttle body and stick the throttle open. 2. During removal of the
  • 2009 Kawasaki KFX450R | Owners Manual - Page 55
    HOW TO RIDE 53 In case of Vehicle Overturn If the vehicle is overturned, engine oil can flow from the engine into the intake tract and air cleaner housing resulting in lack of lubrication and possible engine damage. To avoid engine damage caused by vehicle's overturn, operate the vehicle at a slow
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    there without the express written permission of the owner. Always try to preserve nature and the environment. j Read the Owner's Manual Read and understand this Owner's Manual, and carry it with you when you ride. This is especially important for younger riders and beginners. Refer to this Owner
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    to reach to put their feet on the footboards and their hands on the handlebars. Study this manual with your child to be sure he or she fully understands all of the special safety instructions. WARNING HAZARD Failure to follow the age recommendations for this ATV. Failure to supervise children 16
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    are designed for off-road use only. WARNING HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if the and the operating techniques described in the Owner's Manual. For more information about the training course, contact an authorized ATV
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    SAFE OPERATION 57 Off-Road Use Only This vehicle is designed for off-road use only. Operation on public streets, roads, and highways is not recommended and is not safe. ATV tires are not designed to operate on paved or concrete surfaces. The tires will not slip as necessary which may seriously
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    58 SAFE OPERATION Dress Properly Always wear an approved helmet, eye protection, and protective clothing. The proper clothing can make riding more comfortable and reduce the chance of injury If you take a spill. Long pants will also protect your legs from the hot exhaust system. j
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    SAFE OPERATION 59 WARNING HAZARD Operating this ATV without wearing an approved motorcycle helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident. Operating
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    60 SAFE OPERATION WARNING HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Passengers affect balance and steering and increase risk of losing control. Carrying a passenger could cause an accident, resulting in harm to you and/or your passenger. HOW TO AVOID THE HAZARD Never carry a
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    SAFE OPERATION 61 WARNING HAZARD Attempting wheelies, stunts. jumps, and other Never Drink and Drive Alcohol and drugs impair your judgement and slow your reactions. Even drugs prescribed by a physician can be dangerous. Check with your doctor. WHAT CAN HAPPEN Increases the chance of an accident,
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    62 SAFE OPERATION Keep Your Feet on the Footboards and Hands on the Handlebars Always ride with your feet on the footboards. If your feet touch the ground while you are moving, you could be injured. It is possible to have the rear wheel run over your foot. If you have a lot of motorcycle experience
  • 2009 Kawasaki KFX450R | Owners Manual - Page 65
    SAFE OPERATION 63 Before Starting the Engine Three "musts" before starting the engine are: 1) Set the parking brake, 2) Put the transmission in neutral, Use the Parking Brake Always apply the parking brake before getting off your vehicle. If it should roll, it might be damaged or cause injury.
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    may affect the handling of your ATV. See the Loading Information chapter of this manual for more detailed information. Kawasaki does not recommend that you modify your ATV in ATV and should be installed and used according to instructions. If you have questions, consult an authorized ATV dealer. j
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    use it to make sure the ATV is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner's Manual. j
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    loss of control, increasing your risk of an accident. HOW TO AVOID THE HAZARD Always use the size and type tires specified in the Owner's Manual for this vehicle. Always maintain proper tire pressure as described in the Owner
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    SAFE OPERATION 67 Riding Terrain Before riding in a new area be sure to check for hidden obstacles or hazards. Keep your speed down until you know the area well. You must know the land you intend to ride on and be familiar with your machine and its handling characteristics to have a safe and
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    large obstacles, such as large rocks or fallen trees. When you go over obstacles, always follow proper procedures as described in the Owner's Manual. WARNING HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction
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    SAFE OPERATION 69 Riding in Reverse Start the engine following the procedure in the "Starting the Engine" section. Before shifting into reverse, engage 1st gear. Then with the clutch lever pulled in push the reverse lock release lever and press down the shift pedal into reverse gear. Release the
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    70 SAFE OPERATION WARNING HAZARD Inattentive operation in "R" (Reverse). Backing up without looking where you are going. WHAT CAN HAPPEN Inattentive operation in "R" (Reverse) could cause you to hit a person or obstacle behind you, resulting in severe personal injury or death. HOW TO AVOID THE
  • 2009 Kawasaki KFX450R | Owners Manual - Page 73
    SAFE OPERATION 71 seat and shifting body weight onto the outside footboard, helps the rear wheels turn easier and improve front wheel steering. WARNING HAZARD Removing hands from handlebars or feet from footboards during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce your
  • 2009 Kawasaki KFX450R | Owners Manual - Page 74
    loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the Owner's Manual. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight
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    SAFE OPERATION 73 Don't attempt to climb hills that are too steep for the ATV or for your abilities. When climbing a hill, lean forward to keep the front wheels from lifting. On steeper hills you may need to stand and lean forward for even more weight transfer. The front wheels must be kept on the
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    TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in this manual on level ground. Be very careful when turning on any hill. Rear brake application will brake the downhill wheels when climbing hills and so will
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    parking brake. Dismount on uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in this manual.
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    76 SAFE OPERATION Antenna Flag In hilly country, use an antenna flag so others can see you coming from the other side of a hill or sand dune. Take extra care when approaching blind hill tops and corners. Traversing Hillsides When riding across the side of a hill, keep your body weight toward the
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    loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described in this manual. Note: a special technique is required when braking as you go down a hill. Always check the terrain carefully before you start down any hill. Shift your
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    78 SAFE OPERATION WARNING HAZARD Applying brakes improperly. WHAT CAN HAPPEN Could cause ATV to overturn. HOW TO AVOID THE HAZARD Apply both front and rear breaks gradually. Be careful if the surface is loose; the tires may skid and braking effectiveness will be reduced. Turning while descending a
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    SAFE OPERATION 79 Remember: żStop and look for obstacles before descending a hill. żGo straight downhill. żShift your weight to the rear. żGo slowly. żAvoid excessive use front brake. żIf you must turn, do so carefully and gradually, keeping your weight toward the top of the hill. Sliding and
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    80 SAFE OPERATION WARNING HAZARD Skidding or sliding improperly. WHAT CAN HAPPEN You may lose control of this ATV. You may also regain traction unexpectedly, which may cause the ATV to overturn. HOW TO AVOID THE HAZARD Learn to safely control skidding or sliding by practicing at low speeds and on
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    SAFE OPERATION 81 Riding in Water Choose a location to enter and exit the water where the banks are not too steep or slippery. Check the water before entering for rocks, holes or other obstacles which may cause you to overturn or become stuck or submerged. Observe the following rules for operating
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    82 SAFE OPERATION WARNING HAZARD Operating this ATV through deep or fast flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident. HOW TO AVOID THE HAZARD Never operate this ATV in fast flowing water or in water deeper than the
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    MAINTENANCE AND ADJUSTMENT 83 MAINTENANCE AND ADJUSTMENT The maintenance and adjustments outlined in this chapter must be carried out in accordance with the Periodic Maintenance Chart to keep the vehicle in good running condition. The initial maintenance is vitally important and must not be
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    make sure that the recommended maintenance is carried out according to the instructions in this Owner's Manual at your own expense. You should keep a maintenance record for Owner's Manual carefully and keep it valid by complying with the owner's obligations it contains. To obtain warranty service,
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    MAINTENANCE AND ADJUSTMENT 85 Among those acts presumed to constitute tampering are the acts listed below: Do not tamper with the original emission related parts: Throttle body or internal parts Fuel pump/Fuel injector Spark plug Air cleaner element Magneto ignition system Electronic control unit (
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    addition to the following items, always perform the Daily Safety Checks listed in the HOW TO RIDE chapter. = Clean, adjust, lubricate, replace parts as necessary. D = Service to be performed by an authorized Kawasaki dealer or someone equally competent. ż = Emission related parts. FREQUENCY First
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    10 hrs. or 100 km (60 mi) of use OPERATION Every 10 days or 200 km (120 mi) of use Regular Service Every 30 days or 600 km (360 mi) of use Every 90 days of vehicle use or Every 1,700 km (1 100 year of ml) whichever
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    -inspect General lubrication* Bolts and nuts-tighten Drive chain lubrication condition-inspect* Drive chain slack-inspect* Drive chain wear-inspect* Drive chain guide wear-inspect* * Regular Service Every 10 days or 200 km (120 mi) of use Every 30 days or 600 km (360 mi) of use Every 90 days
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    MAINTENANCE AND ADJUSTMENT 89 Engine Oil In order for the engine, transmission and clutch to function properly, maintain the engine oil at the proper level, and change the oil and oil filter periodically. Not only do dirt and metal particles collect in the oil, but the oil itself loses its
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    90 MAINTENANCE AND ADJUSTMENT crankcase, reinstall the drain plugs and refill with the specified amount of oil. Oil and/or Oil Filter Change The engine oil and/or oil filter should be changed periodically to ensure long engine life. Warm up the engine thoroughly so that the oil will pick up any
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    MAINTENANCE AND ADJUSTMENT 91 WARNING HAZARD Improper disposal of used motor oil. WHAT CAN HAPPEN Used motor oil is a toxic substance, which can pollute the environment. HOW TO AVOID THE HAZARD Contact your local authorities for approved disposal methods and follow those methods at all times. the
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    92 MAINTENANCE AND ADJUSTMENT • Replace the oil filter element with a new one. the oil has completely drained out, install the • After drain plugs with their new gaskets. Proper torque for them is shown in the table. Engine Oil Drain Plugs Tightening Torque Drain Plug (M6) 7.0 N·m (0.7 kgf·m, 5.2
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    MAINTENANCE AND ADJUSTMENT 93 NOTE żDo not add any chemical additive to the oil. Oils fulfilling the above requirements are fully formulated and provide adequate lubrication for both the engine and the clutch. Cooling System Radiator and Cooling Fan: Although 10W-40 engine oil is the
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    94 MAINTENANCE AND ADJUSTMENT Coolant: Coolant absorbs heat from the engine and transfers it to the air at the radiator. If the coolant level becomes low, the engine overheats and may suffer damage. Check the coolant level each day before operating the vehicle, and replenish coolant if the level is
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    MAINTENANCE AND ADJUSTMENT 95 NOTE żIn an emergency you can add water alone to the coolant reserve tank, however it must be returned to the correct mixture ratio by the addition of antifreeze concentrate as soon as possible. żA permanent type of antifreeze is installed in the cooling system when
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    fuel tank, you need to remove the fuel tank to gain access for maintaining the spark plug. Ask your authorized dealer to have the plug serviced in accordance with the Maintenance Chart.
  • 2009 Kawasaki KFX450R | Owners Manual - Page 99
    MAINTENANCE AND ADJUSTMENT 97 Spark Plug Standard Plug NGK CPR8EB-9 or CPR9EB-9 Solid Post Type Plug Gap Tightening Torque 0.8 ∼ 0.9 mm (0.032 ∼ 0.035 in.) 13 N·m (1.3 kgf·m, 9.4 ft·lb) Valve Clearance Valve and valve seat wear decrease valve clearance, upsetting valve timing. NOTICE If valve
  • 2009 Kawasaki KFX450R | Owners Manual - Page 100
    and stick the throttle open. This could cause an accident. HOW TO AVOID THE HAZARD Clean the air cleaner regularly and according to the instructions in this section. A. Mud Guard Plate B. Air Cleaner Cover C. Snaps j NOTICE A clogged air cleaner may allow dirt and dust to enter the engine causing
  • 2009 Kawasaki KFX450R | Owners Manual - Page 101
    MAINTENANCE AND ADJUSTMENT 99 WARNING HAZARD Dirt or dust allowed into the throttle body. WHAT CAN HAPPEN Can cause the throttle to stick open. This could cause an accident. HOW TO AVOID THE HAZARD Be sure to cover the air cleaner opening to the throttle body after removing the element. Clean the
  • 2009 Kawasaki KFX450R | Owners Manual - Page 102
    100 MAINTENANCE AND ADJUSTMENT the element frame to clean the element • Remove in a bath of biodegradable foam air filter cleaner using a soft bristle brush. WARNING HAZARD Cleaning the air cleaner element with gasoline or low flash-point solvent. WHAT CAN HAPPEN Gasoline or low flash-point
  • 2009 Kawasaki KFX450R | Owners Manual - Page 103
    MAINTENANCE AND ADJUSTMENT 101 cleaning, saturate the element with a • After biodegradable foam air filter oil, squeeze out the excess, then wrap it in a clean rag and squeeze it as dry as possible. Be careful not to tear the element. Remove the towel from the inlet tract. Install the element in the
  • 2009 Kawasaki KFX450R | Owners Manual - Page 104
    102 MAINTENANCE AND ADJUSTMENT Spark Arrester This vehicle is equipped with a spark arrester approved for off-road use by the U.S. Forest Service. It must be properly maintained to ensure its efficiency. In accordance with the Periodic Maintenance Chart, clean the spark arrester. Spark Arrester
  • 2009 Kawasaki KFX450R | Owners Manual - Page 105
    MAINTENANCE AND ADJUSTMENT 103 the spark arrester and clean in a bath of • Remove high-flash point solvent and if necessary use a fine wire brush to gently remove any particles in the screen. j A. B. C. D. Muffler Rear Cap Bolts Spark Arrester A. Spark Arrester an open area away from combustible
  • 2009 Kawasaki KFX450R | Owners Manual - Page 106
    104 MAINTENANCE AND ADJUSTMENT WARNING HAZARD Cleaning the spark arrester near combustible materials. WHAT CAN HAPPEN Can cause a fire resulting in burns. HOW TO AVOID THE HAZARD Never run the engine with the spark arrester disassembled near combustible materials. Hot carbon particles are emitted
  • 2009 Kawasaki KFX450R | Owners Manual - Page 107
    MAINTENANCE AND ADJUSTMENT 105 Throttle Cable There must be free play in the throttle mechanism. Measure the distance the throttle lever moves before the engine begins to pick up speed. Free play should be 2 ∼ 3 mm (0.08 ∼ 0.12 in.). j A. Adjuster B. Locknut If the free play cannot be set by
  • 2009 Kawasaki KFX450R | Owners Manual - Page 108
    106 MAINTENANCE AND ADJUSTMENT Reverse Lock Release Cable There must be free play in the reverse lock release system. Determine the amount of the release cable play at the release lever. Push the lever until resistance is felt; the amount of the lever is equivalent to that of cable play. The proper
  • 2009 Kawasaki KFX450R | Owners Manual - Page 109
    MAINTENANCE AND ADJUSTMENT 107 Clutch Due to friction plate wear and clutch cable stretch over a long period of use, the clutch must be adjusted in accordance with the Periodic Maintenance Chart. WARNING HAZARD Malfunctioning controls. WHAT CAN HAPPEN Can result in an unsafe riding condition and
  • 2009 Kawasaki KFX450R | Owners Manual - Page 110
    108 MAINTENANCE AND ADJUSTMENT j A. Knurled Adjuster B. Adjusting Nut C. Locknut A. Knurled Adjuster B. Rubber Cover (removed) C. Turning-out distance of knurled adjuster Be careful that the knurled adjuster has its limit in turning out, or the outer cable may come off the adjuster. Remove the
  • 2009 Kawasaki KFX450R | Owners Manual - Page 111
    the engine sprocket and lock the rear wheels. This can cause the vehicle to go out of control. HOW TO AVOID THE HAZARD Inspect and service the chain regularly and according to the instructions in this section. j Chain Slack Inspection • Stop the engine.
  • 2009 Kawasaki KFX450R | Owners Manual - Page 112
    110 MAINTENANCE AND ADJUSTMENT WARNING HAZARD Trying to measure chain slack when the engine is running or the rear wheels are turning. WHAT CAN HAPPEN Your hands can get caught in the chain and be severely injured. HOW TO AVOID THE HAZARD Before inspecting chain slack, stop the engine and apply the
  • 2009 Kawasaki KFX450R | Owners Manual - Page 113
    MAINTENANCE AND ADJUSTMENT 111 j A. Axle Shaft Housing B. Clamp Bolts C. Wrench Tightening Torque Clamp Bolts: 32 N·m (3.3 kgf·m, 24 ft·b) NOTICE Do not overtighten the chain. Overtightening will cause accelerated wear to engine and drive line components. the clamp bolts to the specified torque
  • 2009 Kawasaki KFX450R | Owners Manual - Page 114
    the 21st pin. Since the chain may wear unevenly, take measurements at several places. If the length exceeds the service limit, the chain should be replaced. j NOTE żSprocket wear is exaggerated for illustration. See Service Manual for wear limits. A. Measure B. Weight Drive Chain 20-Link Length
  • 2009 Kawasaki KFX450R | Owners Manual - Page 115
    Cover Do not operate this vehicle without the sprocket cover installed and in good condition. Lubrication the rear of the vehicle on a stable stand • Support with both rear wheels off the ground. Turn the • wheels slowly while oiling the chain. Use a heavy oil, such as SAE90 gear oil, to
  • 2009 Kawasaki KFX450R | Owners Manual - Page 116
    114 MAINTENANCE AND ADJUSTMENT Idle Adjustment Idle adjustment is done with the idle adjusting/choke knob. j A. Sprocket Cover B. Engine Sprocket A. Idle Adjusting/Choke knob B. Engine Cylinder (left side)
  • 2009 Kawasaki KFX450R | Owners Manual - Page 117
    MAINTENANCE AND ADJUSTMENT 115 Adjustment żThe idle adjusting/choke knob also functions as WARNING the choke knob. When adjusting the idle, be sure to have the knob fully pushed-in. With the knob pulled-out, you cannot adjust the idling. HAZARD Hot engine. WHAT CAN HAPPEN Can burn your hands. HOW
  • 2009 Kawasaki KFX450R | Owners Manual - Page 118
    116 MAINTENANCE AND ADJUSTMENT Fuel Tank Vent The fuel tank vent hose must be routed as specified. The engine may stall or lose power if the fuel tank vent is plugged or if the vent hose is pinched. Inspect the vent hose before riding and whenever the engine seems to lose power. If the fuel tank is
  • 2009 Kawasaki KFX450R | Owners Manual - Page 119
    MAINTENANCE AND ADJUSTMENT 117 WARNING HAZARD Contaminated brake fluid. WHAT CAN HAPPEN Can reduce braking performance or cause brake failure, resulting in an accident. HOW TO AVOID THE HAZARD Do not use brake fluid from a container that has been left open or that has been unsealed for a long time.
  • 2009 Kawasaki KFX450R | Owners Manual - Page 120
    118 MAINTENANCE AND ADJUSTMENT Fluid Level Inspection held horizontal). brake fluid levels in the brake fluid reservoirs • The must be kept above the lower level line (reservoir j A. Rear Reservoir B. Lower Level Line the level is low, fill the reservoir to the upper level • If line with the same
  • 2009 Kawasaki KFX450R | Owners Manual - Page 121
    MAINTENANCE AND ADJUSTMENT 119 Fluid Change Have the brake fluid changed by an authorized Kawasaki dealer. j A. Front Reservoir B. Upper Level Line A. Rear Reservoir B. Upper Level Line
  • 2009 Kawasaki KFX450R | Owners Manual - Page 122
    120 MAINTENANCE AND ADJUSTMENT Parking Brake The parking brake needs proper tension on the cable to hold the vehicle from rolling while parked. In accordance with the Periodic Maintenance Chart, check the cable tension as follows. it moves more than 2 mm (0.08 in.), adjust the • If cable tension
  • 2009 Kawasaki KFX450R | Owners Manual - Page 123
    MAINTENANCE AND ADJUSTMENT 121 Brake Light Switch Only the switch at the rear brake pedal can be adjusted. When the brake pedal is depressed, the brake light goes on. The brake light switch should be inspected in accordance with the Periodic Maintenance Chart. The brake light switch of the front
  • 2009 Kawasaki KFX450R | Owners Manual - Page 124
    vehicle and possibly result in a loss of control. żInstallation of tubeless tires on rims requires compressed air and is normally recommended as a dealer service operation. However, a tube can be inserted into the tire by the operator as an emergency repair. j Maximum Tire Air Pressure for Seating
  • 2009 Kawasaki KFX450R | Owners Manual - Page 125
    accident. HOW TO AVOID THE HAZARD Always use the size and type tires specified in the Owner's Manual for this vehicle. Always maintain proper tire pressure as described in this Owner's Manual. A. Tire Depth Gauge j Minimum Tread Depth Front Tire 3 mm (0.12 in.) Rear Tire 3 mm (0.12 in.) Tightening
  • 2009 Kawasaki KFX450R | Owners Manual - Page 126
    boots on the front suspension arms (4 pieces), and tie rod ends (4 pieces), for cracks, holes, damage or deterioration. If there is any indication of these troubles in one of them, have the joint boot replaced by an authorized Kawasaki dealer. j A. Joint Boots B. Tie Rod
  • 2009 Kawasaki KFX450R | Owners Manual - Page 127
    MAINTENANCE AND ADJUSTMENT 125 Suspension The front and rear shock absorbers can be adjusted by changing the spring preload for various riding and loading conditions. If the spring action feels too soft or too stiff, have it adjusted by an authorized Kawasaki dealer. Headlight Beam • The
  • 2009 Kawasaki KFX450R | Owners Manual - Page 128
    126 MAINTENANCE AND ADJUSTMENT Battery The battery is located below the radiator. DANGER HAZARD Batteries contain sulfuric acid. Batteries produce hydrogen gas. WHAT CAN HAPPEN Sulfuric acid can cause burns. Hydrogen gas can cause an explosion. HOW TO AVOID THE HAZARD Read and understand the
  • 2009 Kawasaki KFX450R | Owners Manual - Page 129
    type, and the sealing strip should not be removed at any time after the specified electrolyte has been installed in the battery for initial service. It is not necessary to check the battery electrolyte level or add distilled water. Battery Installation the battery in place. • Put connect the cable
  • 2009 Kawasaki KFX450R | Owners Manual - Page 130
    128 MAINTENANCE AND ADJUSTMENT However, in order to maximize battery life and ensure that it will provide the power needed to start your vehicle you must properly maintain the battery's charge. When used regularly, the charging system in your vehicle helps keep the battery fully charged. If your
  • 2009 Kawasaki KFX450R | Owners Manual - Page 131
    install a conventional battery on this vehicle, or the electrical system cannot work properly. j NOTE żIf you charge the sealed battery, never fail to observe the instructions shown on the label on the battery.
  • 2009 Kawasaki KFX450R | Owners Manual - Page 132
    130 MAINTENANCE AND ADJUSTMENT WARNING HAZARD Handling battery parts that contain lead and lead compounds WHAT CAN HAPPEN Could cause health problem. HOW TO AVOID THE HAZARD Wash hands after handling battery. Fuse The main fuse and the fuses for the radiator fan and fuel pump are
  • 2009 Kawasaki KFX450R | Owners Manual - Page 133
    MAINTENANCE AND ADJUSTMENT 131 j A. Front Cover B. Screws A. B. C. D. Radiator Fuse Fuel Pump Fuse Main Fuse Vinyl Bag and remove the fuse case to inspect each • Pull fuse.
  • 2009 Kawasaki KFX450R | Owners Manual - Page 134
    132 MAINTENANCE AND ADJUSTMENT General Lubrication Lubricate the points shown below, with either motor oil or regular grease, in accordance with the Periodic Maintenance Chart or whenever the vehicle has been operated under wet or rainy conditions, and especially after using a high-pressure spray
  • 2009 Kawasaki KFX450R | Owners Manual - Page 135
    MAINTENANCE AND ADJUSTMENT 133 Cleaning For the prolonged life of your vehicle, wash it down immediately after it has been splashed with seawater or exposed to the sea breeze, or operated on rainy days, rough terrain, or in dusty areas. • Swingarm pivot NOTE żCoin operated, high pressure spray
  • 2009 Kawasaki KFX450R | Owners Manual - Page 136
    Bolt and Nut Tightening Every day before riding, check the tightness of the nuts and bolts listed here. Please refer to the Service Manual or ask your authorized dealer for the torque values. j 1. Front Shock Absorber Mounting Bolts and Nuts 2. Handlebar Clamp Bolts 3. Clutch Lever Pivot
  • 2009 Kawasaki KFX450R | Owners Manual - Page 137
    MAINTENANCE AND ADJUSTMENT 135 j 17. 18. 19. 20. 21. Chain Adjuster Clamp Bolts Muffler Mounting Bolts Rear Shock Absorber Mounting Bolts and Nuts Exhaust Pipe Holder Nuts Throttle Case Screws 22. 23. 24. 25. Brake Lever Pivot Nut Brake Pedal Bolt Swing Arm Pivot Nuts Rear Frame Bolts and Nuts
  • 2009 Kawasaki KFX450R | Owners Manual - Page 138
    136 STORAGE STORAGE Preparation for Storage • Empty the fuel tank. WARNING HAZARD Draining the fuel system without following proper precautions. WHAT CAN HAPPEN Gasoline is extremely flammable and can be explosive under certain conditions. A fire or explosion can cause severe injury or death. HOW
  • 2009 Kawasaki KFX450R | Owners Manual - Page 139
    on all unpainted metal surfaces to pre• Spray vent rusting. Avoid getting oil on rubber parts or in j NOTE żAsk an authorized dealer for this service since the fuel tank needs to be removed as an access. • • the brakes. Lubricate all the cables. Remove the battery, and store it where it
  • 2009 Kawasaki KFX450R | Owners Manual - Page 140
    138 STORAGE NOTICE Keep the battery well charged during cold weather so that the electrolyte does not freeze and crack open the battery. The more discharged a battery becomes, the more easily it freezes. a plastic bag over the muffler to prevent mois• Tie ture from entering. a cover over the
  • 2009 Kawasaki KFX450R | Owners Manual - Page 141
    TRANSPORTING THE ATV 139 TRANSPORTING THE ATV Note the following points for transporting the vehicle. Check that the vent hose for the fuel tank is properly routed. • WARNING A. Filler Cap B. Fuel Tank Vent Hose HAZARD Transporting this ATV tipped up on its rear end. WHAT CAN HAPPEN Can cause
  • 2009 Kawasaki KFX450R | Owners Manual - Page 142
    140 TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE Starter Motor Not Rotating Engine stop switch "OFF" Fuse failed Battery leads do not make good electrical contact with battery terminals. Battery discharged Engine Cranks,
  • 2009 Kawasaki KFX450R | Owners Manual - Page 143
    TROUBLESHOOTING GUIDE 141 oil incorrect • Engine Water in fuel • j
  • 2009 Kawasaki KFX450R | Owners Manual - Page 144
    receipt of your correspondence we will contact the dealership and work with them in resolving your problem. In order to provide a permanent record, all warranty and service resolutions take place only through written correspondence. Please send your correspondence to:. CONSUMER RELATIONS KAWASAKI
  • 2009 Kawasaki KFX450R | Owners Manual - Page 145
    ENVIRONMENTAL PROTECTION 143 ENVIRONMENTAL PROTECTION To protect our environment, properly discard used tire, engine oil, or other vehicle components that you might dispose of in the future. Consult your authorized Kawasaki dealer or local environmental waste agency for their proper disposal
  • 2009 Kawasaki KFX450R | Owners Manual - Page 146
    144 MAINTENANCE RECORD MAINTENANCE RECORD Owner Name...Address ...Phone Number ...Engine Number ...Vehicle Number...Selling Dealer Name ...Address ...Phone Number ...Warranty Start Date ...Note: Keep this information and a spare key in a secure location. Date Traveled Distance Maintenance Performed
  • 2009 Kawasaki KFX450R | Owners Manual - Page 147
    MAINTENANCE RECORD 145 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2009 Kawasaki KFX450R | Owners Manual - Page 148
    146 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2009 Kawasaki KFX450R | Owners Manual - Page 149
    MAINTENANCE RECORD 147 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2009 Kawasaki KFX450R | Owners Manual - Page 150
    148 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2009 Kawasaki KFX450R | Owners Manual - Page 151
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