2015 Kawasaki KX450F Owners Manual

2015 Kawasaki KX450F Manual

Get 2015 Kawasaki KX450F PDF manuals and user guides View all 2015 Kawasaki KX450F manuals

2015 Kawasaki KX450F manual content summary:

  • 2015 Kawasaki KX450F | Owners Manual - Page 1
  • 2015 Kawasaki KX450F | Owners Manual - Page 2
    Quick Reference Guide This Quick Reference Guide will assist you in finding the information you're looking for. GENERAL INFORMATION MAINTENANCE AND ADJUSTMENT TROUBLESHOOTING GUIDE TUNING STORAGE j j j j j A Table of Contents is included after the Foreword.
  • 2015 Kawasaki KX450F | Owners Manual - Page 3
    limited to participation in sanctioned competition events upon a closed • The course. vehicle should not be used for general off-road recreational riding. • This • Read owner's manual.
  • 2015 Kawasaki KX450F | Owners Manual - Page 4
    the symbols shown below, heed their instructions! Always follow safe operating and NOT BE USED FOR GENERAL OFF-ROAD RECREATIONAL RIDING. READ OWNER'S MANUAL. DANGER DANGER indicates a hazardous situation which, if not avoided, help or guide you in the operation or service of the vehicle. NOTE
  • 2015 Kawasaki KX450F | Owners Manual - Page 5
    The purchaser accepts all responsibilities concerning quality, performance, cost of service and/or necessary repairs. NOTICE Off-road motorcycling is a , this sport has the potential to cause environmental problems as well as conflicts with other people. Responsible use of your off-road
  • 2015 Kawasaki KX450F | Owners Manual - Page 6
    WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
  • 2015 Kawasaki KX450F | Owners Manual - Page 7
    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 performance. This manual is written to enable you to keep your KX properly tuned and adjusted. Due to improvements in design and
  • 2015 Kawasaki KX450F | Owners Manual - Page 8
    (UNI-TRAK®)...Wheels ...Hoses Inspection ...Tightening Torques of Nuts and Bolts...Cleaning Your Motorcycle...Lubrication ...DFI Self-Diagnosis ...TROUBLESHOOTING GUIDE...TUNING ...Suspension...Gearing...Special Care According to Track Conditions . OPTIONAL PARTS ...PRE-RACE CHECKS AND AFTER-RACE
  • 2015 Kawasaki KX450F | Owners Manual - Page 9
    8 SPECIFICATIONS SPECIFICATIONS DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Road Clearance Curb Mass Fuel Tank Capacity ENGINE Type Bore × Stroke Displacement Compression Ratio Fuel System Starting System Ignition System Ignition Timing Lubrication System Spark Plug Spark Plug
  • 2015 Kawasaki KX450F | Owners Manual - Page 10
    SPECIFICATIONS 9 TRANSMISSION Transmission Type Clutch Type Driving System Gear Ratio: 1st 2nd 3rd 4th 5th Primary Reduction Ratio Final Reduction Ratio Overall Drive Ratio Engine Oil: Type Viscosity Capacity FRAME Type Steering Angle Caster Trail Tubular, semi-double cradle 42° to either side 27.9°
  • 2015 Kawasaki KX450F | Owners Manual - Page 11
    10 SPECIFICATIONS Tire Size/Type: Front Rear Rim Size: Front Rear Suspension: Front Rear Front Suspension Travel Rear Wheel Travel Front Fork Oil: Type Amount: Left Front Fork: Cylinder Unit Outer Tube Right Front Fork: Cylinder Unit Outer Tube Balance Chamber 100 mL (3.38 US oz.) 300 mL (10.1 US oz
  • 2015 Kawasaki KX450F | Owners Manual - Page 12
    SPECIFICATIONS 11 BRAKES Type: Front Rear Single disc Single disc Specifications are subject to change without notice.
  • 2015 Kawasaki KX450F | Owners Manual - Page 13
    12 GENERAL INFORMATION j 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 information which is important for your safety and the safety of anyone else who may operate your
  • 2015 Kawasaki KX450F | Owners Manual - Page 14
    GENERAL INFORMATION 13 j 2. Brake Fluid (Rear) 3. Radiator Cap Danger 4. Rear Shock Absorber Warning
  • 2015 Kawasaki KX450F | Owners Manual - Page 15
    14 GENERAL INFORMATION j 5. 6. 7. 8. Noise Emission Control Information Important Information Disclaimer of Warranty Front Fork Warning
  • 2015 Kawasaki KX450F | Owners Manual - Page 16
    GENERAL INFORMATION 15 1) 3) j 2) 4)
  • 2015 Kawasaki KX450F | Owners Manual - Page 17
    16 GENERAL INFORMATION 5) 7) j 6) 8)
  • 2015 Kawasaki KX450F | Owners Manual - Page 18
    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. Throttle Grip
  • 2015 Kawasaki KX450F | Owners Manual - Page 19
    18 GENERAL INFORMATION j 1. Front Fork 2. Radiator 3. Fuel Tank 4. Throttle Body Assy 5. Seat 6. Air Cleaner Element 7. Brake Disc 8. Brake Caliper 9. Shift Pedal 10. Footpeg 11. Rear Shock Absorber 12. Drive Chain 13. Chain Guide 14. Swingarm
  • 2015 Kawasaki KX450F | Owners Manual - Page 20
    GENERAL INFORMATION 19 j 1. Muffler 2. Rear Brake Fluid Reservoir 3. Rear Shock Absorber Gas Reservoir 4. Kick Pedal 5. DFI Setting Data Selection Connector 6. Uni-Trak® Tie-Rod and Rocker Arm 7. Rear Brake Pedal 8. Oil Level Inspection Window 9. Exhaust Pipe
  • 2015 Kawasaki KX450F | Owners Manual - Page 21
    20 GENERAL INFORMATION j Side Stand To install the side stand, insert its flat end into the rear axle as shown in the figure. ○Support the motorcycle with a suitable stand to perform maintenance or adjustment procedures. NOTE A. Side Stand B. Rear Axle WARNING Riding with the side stand can
  • 2015 Kawasaki KX450F | Owners Manual - Page 22
    GENERAL INFORMATION 21 Fuel This Kawasaki KX has a 4-stroke engine that requires a gasoline. The capacity of the fuel tank is 6.2 L (1.6 US gal). To open the fuel tank cap, pull out the breather hose from the hole in the steering stem, and turn the tank cap counterclockwise. Avoid filling the tank
  • 2015 Kawasaki KX450F | Owners Manual - Page 23
    higher than that shown in the table. The Antiknock Index is posted on service station pumps in Canada and the U.S.A. The octane rating of a gasoline is standard industry specifications may result in unsatisfactory performance. Operating problems that result from the use of poor quality or
  • 2015 Kawasaki KX450F | Owners Manual - Page 24
    drain all fuel from the fuel system. See the Storage section in this manual. j NOTICE Avoid using blends of unleaded gasoline and methanol (wood alcohol) " containing more than 5% methanol. Fuel system damage and performance problems may result. Gasoline/Ether Blends - The most common ether is
  • 2015 Kawasaki KX450F | Owners Manual - Page 25
    24 GENERAL INFORMATION j Kick Pedal This motorcycle is equipped with a primary kick starting system. When the clutch lever is pulled, the motorcycle can be started with the transmission in any gear. Starting the Engine • Shift the transmission into neutral. WARNING Riding with the side stand can
  • 2015 Kawasaki KX450F | Owners Manual - Page 26
    GENERAL INFORMATION 25 When engine is cold Pull out the idle adjusting screw/choke knob. • When engine is already warm or restarts Kick the engine over, leaving the throttle closed without using the idle adjusting screw/choke knob. j • ○If the engine fails starting, open the throttle fully
  • 2015 Kawasaki KX450F | Owners Manual - Page 27
    26 GENERAL INFORMATION j Launch Control Mode The launch control mode can be used to adjust ignition timing to help riders get better starts on slippery terrain. The system's effectiveness is dependent on rider skill, technique and terrain conditions. shifting into 3rd, the system is deactivated •
  • 2015 Kawasaki KX450F | Owners Manual - Page 28
    GENERAL INFORMATION 27 DFI Setting Data Selection Three DFI settings are available to suit various track conditions. They are easily activated by changing the wiring connector on the side of the frame when the engine is stopped. Track Condition Soft Standard Hard Connector Color White Green Black
  • 2015 Kawasaki KX450F | Owners Manual - Page 29
    28 GENERAL INFORMATION j Shifting Gears This motorcycle is equipped with a 5-speed "return shift" transmission. The neutral is located halfway between 1st and 2nd gear. "Return shift" means that when shifting up or down, each gear must be engaged before the next higher or lower gear may be selected
  • 2015 Kawasaki KX450F | Owners Manual - Page 30
    GENERAL INFORMATION 29 j Stopping the Motorcycle For maximum deceleration, close the throttle and apply both front and rear brakes. Pull in the clutch lever as the motorcycle comes to a stop. Independent use of the front or rear brake may be advantageous in certain circumstances. Shift down
  • 2015 Kawasaki KX450F | Owners Manual - Page 31
    , the motorcycle is ready for regular operation. Using the proper riding skills and techniques and avoiding recklessly high engine speeds will keep the engine trouble-free. NOTICE When any following parts have been replaced, the same break-in procedure as the new motorcycle must be carried out for
  • 2015 Kawasaki KX450F | Owners Manual - Page 32
    GENERAL INFORMATION 31 j Daily Pre-Ride Checks Check the following items each day before you ride. The time required is minimal, and habitual performance of these checks will help ensure a safe, reliable ride. If any irregularities are found during these checks, refer to the appropriate section and
  • 2015 Kawasaki KX450F | Owners Manual - Page 33
    32 GENERAL INFORMATION Properly installed Engine Sprocket ...No wear or damage Frame Tires ...Overall condition good No wear or damage Pressure correct Air valve cap installed Spokes ...No looseness Drive Chain ...Overall condition good Chain slack correct Oil if necessary Front and Rear Brakes ...
  • 2015 Kawasaki KX450F | Owners Manual - Page 34
    GENERAL INFORMATION 33 j After-Race Checks After racing, first clean the motorcycle, then inspect the entire motorcycle with special attention to the air cleaner, brakes, etc. Carry out the general lubrication and make necessary adjustments.
  • 2015 Kawasaki KX450F | Owners Manual - Page 35
    34 MAINTENANCE AND ADJUSTMENT MAINTENANCE AND ADJUSTMENT Periodic Maintenance Chart The maintenance and adjustments outlined in this chapter are easily carried out and must be done in accordance with the Periodic Maintenance Chart to keep the motorcycle in good running condition. 1. Periodic
  • 2015 Kawasaki KX450F | Owners Manual - Page 36
    MAINTENANCE AND ADJUSTMENT 35 Every 6 Every 12 FREQUENCY After each Every 3 As See races (or races (or races (or race (or required Page 2.5 hours) 7.5 hours) 15 hours) 30 hours) OPERATION Coolant level - inspect Breather hose - inspect Water hoses and connections - inspect † • • • j 44 - 44
  • 2015 Kawasaki KX450F | Owners Manual - Page 37
    36 MAINTENANCE AND ADJUSTMENT 2. Periodic Inspection (Chassis Related Item) FREQUENCY After each Every 3 Every 6 Every 12 As See races (or races (or races (or race (or required Page 2.5 hours) 7.5 hours) 15 hours) 30 hours) OPERATION Brake - adjust † Brake pad wear - inspect † Brake fluid level -
  • 2015 Kawasaki KX450F | Owners Manual - Page 38
    MAINTENANCE AND ADJUSTMENT 37 Every 6 Every 12 FREQUENCY After each Every 3 As See races (or races (or races (or race (or required Page 2.5 hours) 7.5 hours) 15 hours) 30 hours) OPERATION K Wheel bearing - inspect † Swingarm and UNI-TRAK linkage pivots K - inspect † K Swingarm and UNI-TRAK linkage
  • 2015 Kawasaki KX450F | Owners Manual - Page 39
    K Brake hoses - replace Front fork oil - change K Fuel hose - replace K Rear shock absorber oil - change • • †: Replace, add, adjust, clean or torque if necessary. K: Should be serviced by referring to the Service Manual or an authorized Kawasaki dealer.
  • 2015 Kawasaki KX450F | Owners Manual - Page 40
    seizure, accident, and injury. Check the oil level before each ride and change the oil according to the periodic maintenance chart in the Owner's Manual. Because of the semi-dry sump lubrication system, the engine oil level indicated on the oil level inspection window will fluctuate depending on the
  • 2015 Kawasaki KX450F | Owners Manual - Page 41
    40 MAINTENANCE AND ADJUSTMENT j ○If no oil appears in the oil level inspection window, NOTE tip the motorcycle slightly to the right until oil is visible then return to an upright position. If no oil appears even when tipped at an extreme angle, remove the drain bolts to empty any oil that may
  • 2015 Kawasaki KX450F | Owners Manual - Page 42
    MAINTENANCE AND ADJUSTMENT 41 WARNING Engine oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved disposal methods or possible recycling. the oil filter is replaced, remove the oil filter • When cap bolts and take off the cap with O-rings. • Be sure
  • 2015 Kawasaki KX450F | Owners Manual - Page 43
    40 *Kawasaki Performance Oils and Lubricants have been specifically engineered for your vehicle. Consistent use of these products meets or exceeds warranty and service requirements and can help to extend the life of your Kawasaki. Engine Oil Capacity Capacity: 0.96 L (1.01 US qt) (When filter is not
  • 2015 Kawasaki KX450F | Owners Manual - Page 44
    MAINTENANCE AND ADJUSTMENT 43 ○If unavailable, use equivalent engine oil in accordance with the following table. Type: API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity: SAE 10W-30, 10W-40, 10W-50 NOTE The oil viscosity may need to be changed to accommodate atmospheric conditions in
  • 2015 Kawasaki KX450F | Owners Manual - Page 45
    44 MAINTENANCE AND ADJUSTMENT Cooling System Check the water hoses for cracks or deterioration, and the connections for looseness in accordance with the Periodic Maintenance Chart. Check the radiator fins for obstruction by insects or mud. Clean off any obstructions with a low-pressure stream of
  • 2015 Kawasaki KX450F | Owners Manual - Page 46
    MAINTENANCE AND ADJUSTMENT 45 push and turn the cap further in the same • Then, direction and remove it. j A. Coolant Level B. Filler Neck A. Radiator Cap the coolant level in the radiator. The • Check coolant should come up to the bottom of the radiator filler neck. the coolant level is low,
  • 2015 Kawasaki KX450F | Owners Manual - Page 47
    46 MAINTENANCE AND ADJUSTMENT • Install the radiator cap. The coolant should be changed to ensure long engine life, if necessary. Wait for the engine to cool completely. Situate the motorcycle perpendicular to the ground until the radiator cap is level to the ground. Remove the radiator cap in two
  • 2015 Kawasaki KX450F | Owners Manual - Page 48
    the cooling system for leaks. • j NOTICE Use coolant containing corrosion inhibitors made specifically for aluminum engines and radiators in accordance with the instruction of the manufacture. Soft or distilled water must be used with the antifreeze in the cooling system. If hard water is used in
  • 2015 Kawasaki KX450F | Owners Manual - Page 49
    48 MAINTENANCE AND ADJUSTMENT Spark Plug The spark plug should be taken out periodically for inspection and regapping. Measure the gap with a wire-type thickness gauge. If incorrect, adjust the gap to the specified value by bending the outer electrode. Spark Plug Gap CPR8EB-9 CPR9EB-9 j If the
  • 2015 Kawasaki KX450F | Owners Manual - Page 50
    MAINTENANCE AND ADJUSTMENT 49 Spark Plug Removal and Installation the seat (see Air Cleaner section). • Remove the bolts and take off the radiator shroud • Remove on both sides. • Remove the fuel tank mounting bolt and band. j A. Fuel Tank Mounting Bolt B. Band A. Bolts B. Radiator Shroud
  • 2015 Kawasaki KX450F | Owners Manual - Page 51
    50 MAINTENANCE AND ADJUSTMENT sure to place a piece of cloth around the fuel • Be hose joint. off the dirt of the surface around the connec• Wipe tion using a cloth or a soft brush. a thin blade screwdriver into the slit on the • Insert joint lock. WARNING Fuel is flammable and explosive under
  • 2015 Kawasaki KX450F | Owners Manual - Page 52
    MAINTENANCE AND ADJUSTMENT 51 the pipe and the fuel hose joint with the vinyl • Cover bags to keep them clean. the fuel pump lead connector. • Disconnect Remove the fuel tank. • the cylinder head cover around the spark • Clean plug cap hole before removing the spark plug. the spark plug cap off the
  • 2015 Kawasaki KX450F | Owners Manual - Page 53
    52 MAINTENANCE AND ADJUSTMENT the spark plug cap so that it is aligned with • Install the line on the cylinder head cover. up the plug cap lightly to make sure of the • Pull installation of the spark plug cap. sure that the dampers are in place on the • Make frame and are not damaged. If the dampers
  • 2015 Kawasaki KX450F | Owners Manual - Page 54
    MAINTENANCE AND ADJUSTMENT 53 the fuel hose joint straight onto the fuel out• Insert let pipe until the hose joint clicks. • Push the joint lock until the hose joint clicks. and pull the fuel hose joint back and forth • Push more than two times, and make sure it is locked and does not come off. j
  • 2015 Kawasaki KX450F | Owners Manual - Page 55
    54 MAINTENANCE AND ADJUSTMENT installing the fuel tank, check that both • Before throttle cables run over the main harness. tighten the radiator shroud bolts fol• Temporarily lowing the tightening sequence. j ○To prevent the bottom of the fuel tank from pushing the throttle cables, run the
  • 2015 Kawasaki KX450F | Owners Manual - Page 56
    MAINTENANCE AND ADJUSTMENT 55 Air Cleaner A clogged air cleaner restricts the air intake, increases fuel consumption, reduces engine power, and can cause spark plug fouling. Inspect the air intake system, which includes the air filter and air duct to the throttle body assy, and the duct clamps and
  • 2015 Kawasaki KX450F | Owners Manual - Page 57
    56 MAINTENANCE AND ADJUSTMENT the both side covers slightly outward and • Open slide the seat rearward. the wing bolt, and take out the air cleaner • Remove element. j A. Side Covers B. Seat A. Wing Bolt B. Air Cleaner Element inside of the intake tract and throttle body • Check assy for dirt.
  • 2015 Kawasaki KX450F | Owners Manual - Page 58
    MAINTENANCE AND ADJUSTMENT 57 the element. If it is dirty, clean it. Also • Inspect check if the element is in good condition (no tears, hardening or shrinkage). If damaged, replace the element or it will allow dirt into the throttle body assy. j WARNING A clogged air cleaner may allow dirt and
  • 2015 Kawasaki KX450F | Owners Manual - Page 59
    58 MAINTENANCE AND ADJUSTMENT WARNING Gasoline and low flash-point solvents can be flammable and/or explosive and cause severe burns. Clean the element in a well-ventilated area, and take care that there is no spark or flame anywhere near the working areas. Do not use gasoline or low flash-point
  • 2015 Kawasaki KX450F | Owners Manual - Page 60
    MAINTENANCE AND ADJUSTMENT 59 the air cleaner element so that its tab faces • Install upward and its projections align with the holes in the housing. j A. Apply grease. A. Tab B. Projections C. Holes • Tighten the wing bolt.
  • 2015 Kawasaki KX450F | Owners Manual - Page 61
    60 MAINTENANCE AND ADJUSTMENT the hooks of the seat under the flange collar • Insert and brackets. the tabs of the side covers into the inside of • Install the seat, and tighten the bolts. j A. B. C. D. Hooks Seat Flange Collar Brackets A. Tabs B. Seat up the rear end of the seat to make sure
  • 2015 Kawasaki KX450F | Owners Manual - Page 62
    MAINTENANCE AND ADJUSTMENT 61 Throttle Cable Inspect the throttle grip for smooth operation in all steering positions. Check and adjust the throttle cable in accordance with the Periodic Maintenance Chart. Check that the throttle grip has 2 ∼ 3 mm (0.08 ∼ 0.12 in.) of play and turns smoothly.
  • 2015 Kawasaki KX450F | Owners Manual - Page 63
    62 MAINTENANCE AND ADJUSTMENT Throttle Body Assy Idle Speed Adjustment the left radiator shroud (see Spark Plug • Remove section). warm up the engine. • Thoroughly the idle adjusting screw/choke knob to adjust • Turn the idle speed 1 950 ∼ 2 050 r/min (rpm) by using the engine idling, turn the
  • 2015 Kawasaki KX450F | Owners Manual - Page 64
    MAINTENANCE AND ADJUSTMENT 63 the fuel tank (see Spark Plug section). • Remove the bolt and take off the side cover on • Remove both sides. the muffler clamp bolt. • Loosen the muffler mounting bolts, and pull out • Remove the muffler body backward. j A. Bolt B. Side Cover A. Muffler Clamp Bolt
  • 2015 Kawasaki KX450F | Owners Manual - Page 65
    64 MAINTENANCE AND ADJUSTMENT • Loosen the air cleaner duct clamp screw. the intake air temperature sensor con• Disconnect nector. j A. Air Cleaner Duct Clamp Screw A. Intake Air Temperature Sensor Connector
  • 2015 Kawasaki KX450F | Owners Manual - Page 66
    MAINTENANCE AND ADJUSTMENT 65 the rear frame mounting bolts on the both • Remove sides. the rear frame rearward with the air cleaner • Pull housing. the throttle sensor connector. • Disconnect the intake air pressure sensor connec• Disconnect tor. • Disconnect the fuel injector connector. j A.
  • 2015 Kawasaki KX450F | Owners Manual - Page 67
    66 MAINTENANCE AND ADJUSTMENT sure to place a piece of cloth around the fuel • Be hose joint. off the dirt of the surface around the connec• Wipe tion using a cloth or a soft brush. a thin blade screwdriver into the slit on the • Insert joint lock. the driver to disconnect the joint lock. • Turn the
  • 2015 Kawasaki KX450F | Owners Manual - Page 68
    MAINTENANCE AND ADJUSTMENT 67 the throttle body assy holder clamp screw. • Loosen • Pull the throttle body assy from the holder. the bolts, and take off the throttle pulley • Remove cover. j A. Throttle Body Assy Holder Clamp Screw A. Throttle Pulley Cover Bolts B. Throttle Pulley Cover the
  • 2015 Kawasaki KX450F | Owners Manual - Page 69
    68 MAINTENANCE AND ADJUSTMENT any carbon accumulates, wipe the carbon off the • If throttle bore and the throttle valve, using a lint-free cloth penerated with a high flash-point solvent. j A. Decelerator Cable Bolt Locknut B. Accelerator Cable Bolt C. Tips of Throttle Cable Lower Ends D. Throttle
  • 2015 Kawasaki KX450F | Owners Manual - Page 70
    MAINTENANCE AND ADJUSTMENT 69 holding the decelerator cable bolt, tighten • While the cable bolt locknut. Tightening Torque Throttle Cable Mounting Bolts: 3.0 N·m (0.31 kgf·m, 27 in·lb) Throttle Pulley Cover Bolts: 3.4 N·m (0.35 kgf·m, 30 in·lb) WARNING Operation with improperly adjusted,
  • 2015 Kawasaki KX450F | Owners Manual - Page 71
    70 MAINTENANCE AND ADJUSTMENT the fuel hose joint straight onto the delivery • Insert pipe. the white paint of the hose in the throttle • Check body assy side. • Push the joint lock until the hose joint clicks. and pull the fuel hose joint back and forth • Push more than two times, and make sure it
  • 2015 Kawasaki KX450F | Owners Manual - Page 72
    MAINTENANCE AND ADJUSTMENT 71 the intake air pressure sensor connector, • Connect fuel injector connector and throttle sensor connector. the rear frame with the air cleaner housing • Install to the throttle body assy. the duct is installed securely. • Check Check the clamp position as shown in the
  • 2015 Kawasaki KX450F | Owners Manual - Page 73
    72 MAINTENANCE AND ADJUSTMENT Tightening Torque Rear Frame Mounting Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb) the fuel tank (see Spark Plug section). • Install Install the (see Exhaust System section). • Install the muffler removed • Open and close theparts. throttle a few times to make • sure the grip
  • 2015 Kawasaki KX450F | Owners Manual - Page 74
    MAINTENANCE AND ADJUSTMENT 73 the number plate (see Steering section). • Remove the adjuster in all the way. • Turn the dust cover back. • Slide Loosen locknut in the middle of the clutch ca• ble, andthe turn the adjusting nut so that the clutch lever free play is 8 ∼ 13 mm (0.3 ∼ 0.5 in.). •
  • 2015 Kawasaki KX450F | Owners Manual - Page 75
    74 MAINTENANCE AND ADJUSTMENT Friction and Steel Plates Removal the engine oil (see Engine Oil section). • Drain Remove the rear master cylinder mounting bolts, • brake pedal bolt and the rear brake pedal return spring. • Remove the clutch cover bolts. j A. Clutch Cover Bolts B. Clutch Cover A.
  • 2015 Kawasaki KX450F | Owners Manual - Page 76
    each end are different from the plates installed between these plates. However, it is impossible to identify the difference by external view. ○When servicing the clutch, use a permanent marker to identify the two end friction plates before removing them so that they can be reinstalled in the correct
  • 2015 Kawasaki KX450F | Owners Manual - Page 77
    friction plates with vernier calipers. If they have worn past the service limit, replace them with new ones. Friction Plate Thickness Measurement Standard 2.92 ∼ 3.08 mm (0.115 ∼ 0.121 in.) Service Limit 2.7 mm (0.11 in.) If the steel plates are replaced, measure
  • 2015 Kawasaki KX450F | Owners Manual - Page 78
    plate warp with a thickness gauge (i.e., the gap between the surface plate and each friction plate or steel plate). If any plate is warped over the service limit, replace it with a new one.
  • 2015 Kawasaki KX450F | Owners Manual - Page 79
    . • Install Replace clutch hub nut with a new one. • Install thethe clutch • Install the spacerhub. while "OUTSIDE" is faced to the • nut. Service Limit 0.3 mm (0.012 in.) A. Spacer B. "OUTSIDE" A. Surface Plate B. Friction or Steel Plate C. Thickness Gauge the clutch hub nut with using the
  • 2015 Kawasaki KX450F | Owners Manual - Page 80
    MAINTENANCE AND ADJUSTMENT 79 Friction and Steel Plate Installation all parts in the reverse order of removal. • Install Install the friction plates and steel plates, alternat• ing between the two; be sure to start and finish with a friction plate. molybdenum disulfide grease to the push • Apply
  • 2015 Kawasaki KX450F | Owners Manual - Page 81
    80 MAINTENANCE AND ADJUSTMENT molybdenum disulfide grease to the contact • Apply area of the push rod holder, both surface of the Tightening Torque Clutch Spring Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) the release shaft lever position by measur• Check ing the position distance between the lever and
  • 2015 Kawasaki KX450F | Owners Manual - Page 82
    MAINTENANCE AND ADJUSTMENT 81 the lever position is not within the standard, se• If lect the correct thickness of adjusting washer acRelease Shaft Lever Position and Adjusting Washer Selection Position JudgWashers QuanDistance ment Thickness tity 68.6 ∼ 76.4 mm Standard (2.70 ∼ 3.01 in.) More than
  • 2015 Kawasaki KX450F | Owners Manual - Page 83
    82 MAINTENANCE AND ADJUSTMENT pushing down the brake pedal, tighten the • While rear master cylinder mounting bolts. Tightening Torque Rear Master Cylinder Mounting Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) Valve Clearance Valve and valve seat wear decreases valve clearance, upsetting valve timing. j
  • 2015 Kawasaki KX450F | Owners Manual - Page 84
    MAINTENANCE AND ADJUSTMENT 83 Valve Clearance Inspection the spark plug cap (see Spark Plug sec• Remove tion). the cylinder head cover bolts and cylinder • Remove head cover. the head cover gasket and spark plug • Remove hole gasket. j A. Head Cover Gasket B. Spark Plug Hole Gasket A. Cylinder
  • 2015 Kawasaki KX450F | Owners Manual - Page 85
    84 MAINTENANCE AND ADJUSTMENT • Remove the two caps from the magneto cover. the piston to the Top Dead Center (TDC) of • Bring its compression stroke to inspect the valve clear- j ance (the position at the end of the compression stroke) by aligning the top mark with the groove on the magneto
  • 2015 Kawasaki KX450F | Owners Manual - Page 86
    .) the valve clearance is not within the specified • If range, adjust by an authorized Kawasaki dealer or a competent mechanic following the instructions in the Service Manual. the thickness gauge, measuring the clear• Using ance between each cam lobe and valve lifter, for all four valves. ○Record
  • 2015 Kawasaki KX450F | Owners Manual - Page 87
    86 MAINTENANCE AND ADJUSTMENT a high flash-point solvent, clean off any oil • Using or dirt that may be on the silicone sealant coating the spark plug hole gasket with a new • Replace one, and install it. j • area. Dry them with a clean cloth. Apply silicone sealant to the cylinder head as shown
  • 2015 Kawasaki KX450F | Owners Manual - Page 88
    (0.36 kgf·m, 31 in·lb) Flywheel Nut Cap: 3.5 N·m (0.36 kgf·m, 31 in·lb) • Install the removed parts. A. Upper Chain Guide B. Cylinder Head Cover NOTICE Unless the upper chain guide is bottomed, the camshaft chain could push the cylinder head cover upward, leading to an oil leak. the cylinder head
  • 2015 Kawasaki KX450F | Owners Manual - Page 89
    88 MAINTENANCE AND ADJUSTMENT Exhaust System The exhaust system, in particular the muffler body, is designed to reduce exhaust noise and conduct the exhaust gases away from the rider while minimizing power loss. If carbon has built up inside the muffler body, exhaust efficiency is reduced, causing
  • 2015 Kawasaki KX450F | Owners Manual - Page 90
    MAINTENANCE AND ADJUSTMENT 89 • Remove the muffler cover with the plastic mallet. the silencer wool with a new one. • Replace the silicone sealant attaching on the muf• Remove fler cover and muffler body. a high flash-point solvent, clean off any oil • Using or dirt that may be on the silicone
  • 2015 Kawasaki KX450F | Owners Manual - Page 91
    90 MAINTENANCE AND ADJUSTMENT that the exhaust port of the muffler cover • Check align with the muffler body. a non-permanent locking agent to the muf• Apply fler body cover bolts. the muffler cover bolts and apply the sili• Tighten cone sealant to the joint part of the muffler cover and muffler
  • 2015 Kawasaki KX450F | Owners Manual - Page 92
    MAINTENANCE AND ADJUSTMENT 91 tighten the muffler mounting bolt (front). • Firstly, tighten the muffler mounting bolt (rear). • Secondly, Thirdly, tighten the muffler clamp bolt. • the tabs of the side cover into the slots of • Insert the air cleaner housing. the side cover rib between the rear
  • 2015 Kawasaki KX450F | Owners Manual - Page 93
    92 MAINTENANCE AND ADJUSTMENT Rear Axle Nut inspect the rear axle nut for deformation • Visually or damage at the friction ring and caulking. If it is deformed or damaged, replace the axle nut with a new one. Drive Chain For safety and to prevent excessive wear, the drive chain must be checked,
  • 2015 Kawasaki KX450F | Owners Manual - Page 94
    MAINTENANCE AND ADJUSTMENT 93 the drive chain if its slack is out of specifi• Adjust cation. For the rear wheel to be properly aligned, the notch of the left chain adjuster should align with the same swingarm mark that the notch of the right chain adjuster aligns with. Drive Chain Slack 52 ∼ 58 mm
  • 2015 Kawasaki KX450F | Owners Manual - Page 95
    94 MAINTENANCE AND ADJUSTMENT WARNING Misalignment of the wheel will result in abnormal wear, and may result in an unsafe riding condition. Align the rear wheel using the marks on the swingarm or measuring the distance between the center of the axle and swingarm pivot. the rear axle nut (see Rear
  • 2015 Kawasaki KX450F | Owners Manual - Page 96
    a straight part of the • Measure chain from the center of the 1st pin to the center of the 21st pin. If the length exceeds the service limit, the chain should be replaced. Since overworn sprockets will cause a new chain to wear faster, inspect both the engine and rear sprockets whenever the
  • 2015 Kawasaki KX450F | Owners Manual - Page 97
    Wear Inspection inspect the drive chain guide and replace • Visually it if excessively worn or damaged. Chain Slipper Wear Inspection or damaged. j inspect the upper and lower of the chain • Visually slipper on the swingarm and replace them if worn A. Chain Guide A. Upper and Lower of the Chain
  • 2015 Kawasaki KX450F | Owners Manual - Page 98
    MAINTENANCE AND ADJUSTMENT 97 Sprocket Wear Inspection Sprocket Teeth Wear inspect the sprocket teeth and replace the • Visually sprocket if its teeth are worn or damaged. Lubrication of the drive chain is necessary after riding in the rain or mud, or any time the chain appears dry with a high
  • 2015 Kawasaki KX450F | Owners Manual - Page 99
    98 MAINTENANCE AND ADJUSTMENT Adjustable Ergonomics To suit various riding positions, the handlebar holder position can be changed and the handlebar can be adjusted by turning the handlebar holders around (180°). The footpeg position can also be changed to suit the rider's preference. the
  • 2015 Kawasaki KX450F | Owners Manual - Page 100
    are correctly installed, there will be even gaps on the front and rear sides of the clamp after the bolts are torqued. not disassemble the supporting bar on the han• Do dlebar. the front brake for the proper brake effect, • Check or no brake drag. Tightening Torque Handlebar Clamp Bolts: 25
  • 2015 Kawasaki KX450F | Owners Manual - Page 101
    100 MAINTENANCE AND ADJUSTMENT Footpeg The right and left footpegs can be mounted in one of two positions. Remove the cotter pin, pivot pin, washer, spring and footpeg. the footpeg bracket bolts and bracket. • Remove (This position is standard.) j • A. Footpeg Bracket Bolts B. Footpeg Bracket
  • 2015 Kawasaki KX450F | Owners Manual - Page 102
    MAINTENANCE AND ADJUSTMENT 101 the spring ends as shown in the figure. • Position the washer and new cotter pin. • Install • Bend the longer end of the cotter pin. ○Installing the footpegs in the lower position will re- duce the amount of ground clearance and lean angle. j A. B. C. D. Pivot Pin
  • 2015 Kawasaki KX450F | Owners Manual - Page 103
    102 MAINTENANCE AND ADJUSTMENT Brakes Disc and disc pad wear is automatically compensated for and has no effect on the brake lever or pedal action. There are no parts on the brakes that require adjustment except brake lever position. The brake lever position can be adjusted to suit the rider's
  • 2015 Kawasaki KX450F | Owners Manual - Page 104
    MAINTENANCE AND ADJUSTMENT 103 NOTICE Do not spill brake fluid onto any painted surface. Do not use fluid from a container that has been left open or that has been unsealed for a long time. Check for fluid leakage around the brake system fittings. Check for brake hose damage. j With the front or
  • 2015 Kawasaki KX450F | Owners Manual - Page 105
    104 MAINTENANCE AND ADJUSTMENT the brake fluid in the front or rear brake reservoir • If is below the lower level line, check for fluid leaks j in the brake line and fill the reservoir to the upper level line (The step inside the front and rear brake reservoirs indicate the upper level.). A. Rear
  • 2015 Kawasaki KX450F | Owners Manual - Page 106
    MAINTENANCE AND ADJUSTMENT 105 Inspect the brake pads for wear in accordance with the Periodic Maintenance Chart. If the thickness of any pad in any (front or rear) brake caliper is less than 1 mm (0.04 in.), have both pads in the caliper replaced as a set. Pad replacement should be done by an
  • 2015 Kawasaki KX450F | Owners Manual - Page 107
    106 MAINTENANCE AND ADJUSTMENT Steering Inspection check the steering adjustment, raise the front • To wheel off the ground using a jack (special tool: Steering Adjustment j • • 57001-1238) and attachment (special tool: 57001 -1608). Push the handlebar lightly to either side. If the handlebar
  • 2015 Kawasaki KX450F | Owners Manual - Page 108
    MAINTENANCE AND ADJUSTMENT 107 the handlebar (see Handlebar section). • Remove the left and right front fork clamp bolts (up• Loosen per). the steering stem head nut, and raise the • Remove steering stem head. the steering stem nut with a stem nut wrench • Turn (special tool: 57001-1100) to obtain
  • 2015 Kawasaki KX450F | Owners Manual - Page 109
    oil seal, leading to an oil leak. Clean the sliding surface after each ride. the brake lever, pump the front fork back • Holding and forth manually to check for smooth operation. inspect the front fork for oil leakage, scor• Visually ing or scratches on the outer surface of the inner necessary
  • 2015 Kawasaki KX450F | Owners Manual - Page 110
    MAINTENANCE AND ADJUSTMENT 109 Any of the following front fork adjustments can be made to tune the front suspension to the rider's weight and the condition of the track. Basically, there are five adjustments you can make to the front fork. Air Pressure (Right Front Fork) Air pressure adjustment
  • 2015 Kawasaki KX450F | Owners Manual - Page 111
    110 MAINTENANCE AND ADJUSTMENT Standard Setting Inner Chamber Outer Chamber Balance Chamber 1 000 kPa (10.20 kgf/cm², 145 psi) 50 kPa (0.51 kgf/cm², 7.25 psi) 900 kPa (9.18 kgf/cm², 131 psi) j Recommended Hard Setting 1 100 kPa (11.22 kgf/cm², 160 Inner Chamber psi) Outer Chamber Balance Chamber
  • 2015 Kawasaki KX450F | Owners Manual - Page 112
    MAINTENANCE AND ADJUSTMENT 111 WARNING Improper fork leg adjustment can cause poor handling and loss of stability, which could lead to an accident. Always adjust the fork legs height on the left and right side to the same setting. Outer Chamber Air Pressure Air Pressure 50 kPa (0.51 kgf/cm², 7.25
  • 2015 Kawasaki KX450F | Owners Manual - Page 113
    112 MAINTENANCE AND ADJUSTMENT NOTICE Do not pressurize the fork to more than the adjustable range or the fork may be damaged. if the air pressure of the front fork is ad• Even justed, the performance of the front fork does not change, have the front fork checked by an authorized Kawasaki dealer.
  • 2015 Kawasaki KX450F | Owners Manual - Page 114
    MAINTENANCE AND ADJUSTMENT 113 Rebound Damping Adjuster Settings Compression Damping Adjustment adjust the compression damping, turn the • To adjuster on each front fork cylinder valve with a standard tip screwdriver. Adjust the compression damping to suit your preference and riding conditions.
  • 2015 Kawasaki KX450F | Owners Manual - Page 115
    114 MAINTENANCE AND ADJUSTMENT Compression Damping Adjuster Settings NOTICE Be careful not to scratch the inner tube and not to damage the dust seal. Avoid scratching or damaging the inner tube or the dust seal. Use a mild detergent and sponge out dirt with plenty of water. the motorcycle on a
  • 2015 Kawasaki KX450F | Owners Manual - Page 116
    MAINTENANCE AND ADJUSTMENT 115 the brake caliper from the fork leg, and • Remove rest the caliper on some kind of stand so that it the axle, and pull out the wheel. Take off • Remove the collar from each side of the front hub. • • does not dangle. Insert a wood wedge between the disc brake pads.
  • 2015 Kawasaki KX450F | Owners Manual - Page 117
    116 MAINTENANCE AND ADJUSTMENT j ○Do not remove the cylinder unit. NOTE A. Front Fork Clamp Bolts (Upper) ○Set the rebound and compression damping to the softest settings before disassembly to minimize damping forces that can hinder disassembly. Record the setting before turning the adjuster.
  • 2015 Kawasaki KX450F | Owners Manual - Page 118
    MAINTENANCE AND ADJUSTMENT 117 • Loosen the front fork clamp bolts (lower). the front fork by pulling down while twist• Remove ing it. j A. Front Fork Clamp Bolts (Lower) A. Pull down by twisting. B. Front Fork
  • 2015 Kawasaki KX450F | Owners Manual - Page 119
    118 MAINTENANCE AND ADJUSTMENT Left Front Fork Using the top plug wrench, 50 mm (special tool: 57001-1645), remove the cylinder unit from the outer tube and slowly slide down the outer tube. j • ○Pump the outer tube several times to drain the fork oil. NOTE A. Top Plug Wrench, 50 mm (Special
  • 2015 Kawasaki KX450F | Owners Manual - Page 120
    MAINTENANCE AND ADJUSTMENT 119 • Loosen the adjuster assembly completely. ○When removing the adjuster assembly, do not force to loosen it at once using an impact wrench. NOTE j A. Cylinder Unit B. Outer Tube C. Top Plug Wrench, 50 mm (Special Tool: 57001-1645) • Hold the axle holder with a vise.
  • 2015 Kawasaki KX450F | Owners Manual - Page 121
    120 MAINTENANCE AND ADJUSTMENT • Remove the push rod. j A. Locknut B. Wrench C. Adjuster Assembly A. Push Rod NOTICE Removing the locknut and pushing the piston rod thread into the cylinder unit will damage the oil seal. Do not remove the locknut from the piston rod.
  • 2015 Kawasaki KX450F | Owners Manual - Page 122
    MAINTENANCE AND ADJUSTMENT 121 the fork leg from the vise. • Remove the cylinder unit with the top plug wrench, • Remove 50 mm (special tool: 57001-1645). j A. Cylinder B. Outer Tube A. Cylinder Unit B. Outer Tube C. Top Plug Wrench, 50 mm (Special Tool: 57001-1645) NOTICE Disassembling the
  • 2015 Kawasaki KX450F | Owners Manual - Page 123
    122 MAINTENANCE AND ADJUSTMENT the top plug wrench, 50 mm (special tool: • Holding 57001-1645) with a vise, loosen the base valve assembly on the cylinder unit with a top plug wrench, 36 mm (special tool: 57001-1810). j A. Top Plug Wrench, 50 mm (Special Tool: 57001-1645) B. Base Valve Assembly C.
  • 2015 Kawasaki KX450F | Owners Manual - Page 124
    MAINTENANCE AND ADJUSTMENT 123 NOTICE Disassembling the base valve assembly can lead to trouble. Do not disassemble the base valve assembly. the fork oil from the cylinder unit by pumping • Drain the piston rod several times. j A. Base Valve Assembly B.
  • 2015 Kawasaki KX450F | Owners Manual - Page 125
    124 MAINTENANCE AND ADJUSTMENT the threads of the cylinder unit and base • Clean valve assembly. j A. Threads A. Fork Oil B. Cylinder Unit C. Oil Holes the piston rod fully stretched, pour 310 mL • With (10.5 US oz.) of fork oil. Suspension Oil SS-19 (1 L): P/No. 44091-0009 ○Plug the oil hole
  • 2015 Kawasaki KX450F | Owners Manual - Page 126
    MAINTENANCE AND ADJUSTMENT 125 the piston rod slowly several times to expel • Pump air with plugged the oil hole by finger. j A. 132 ∼ 140 mm (5.20 ∼ 5.51 in.) B. Oil Level A. Pump B. Piston Rod the piston rod fully stretched, check the oil • With level in the cylinder unit. Oil Level 132 ∼ 140
  • 2015 Kawasaki KX450F | Owners Manual - Page 127
    126 MAINTENANCE AND ADJUSTMENT j A. O-rings B. Bushings the piston rod appear about 20 mm (0.79 • With in.) from fully compressed, gently install the base valve assembly slowly to the cylinder unit. A. B. C. D. Piston Rod Base Valve Assembly Cylinder Unit Oil Holes ○Plug the oil hole on the
  • 2015 Kawasaki KX450F | Owners Manual - Page 128
    by pumping the piston rod to full stroke. j NOTICE Be careful not to bend or damage the piston rod when the piston rod is stroked. Service carefully because oil flies out from the oil holes of the cylinder unit. A. Top Plug Wrench, 50 mm (Special Tool: 57001-1645) B. Base Valve Assembly
  • 2015 Kawasaki KX450F | Owners Manual - Page 129
    128 MAINTENANCE AND ADJUSTMENT j ○Set the compression damping force setting to the softest. Check the piston rod sliding surface for damage. Apply specified fork oil to the piston rod sliding surface. the extra oil from the cylinder unit oil hole. • Drain out the extra oil from the oil hole of the
  • 2015 Kawasaki KX450F | Owners Manual - Page 130
    MAINTENANCE AND ADJUSTMENT 129 the oil off completely from the cylinder unit. • Wipe Compress the piston rod to 200 ∼ 250 mm (7.87 ∼ • 9.84 in.) and hold the cylinder unit upright position for 10 minutes. the cylinder unit on level ground and release • Hold the piston rod then check the piston rod
  • 2015 Kawasaki KX450F | Owners Manual - Page 131
    130 MAINTENANCE AND ADJUSTMENT wipe off the fork oil from the cylinder • Completely unit. • Insert the cylinder unit into the fork. j NOTICE Do not touch the piston rod to the outer tube. The piston rod could be damage. A. Cylinder Unit B. Outer Tube C. Top Plug Wrench, 50 mm (Special Tool: 57001
  • 2015 Kawasaki KX450F | Owners Manual - Page 132
    MAINTENANCE AND ADJUSTMENT 131 • Install the adjuster assembly to the push rod. j A. Push Rod B. Adjuster Assembly C. O-ring A. Adjuster Assembly B. Locknut C. More Than 1 mm (0.04 in.) turn the adjuster assembly clockwise until • Slowly resistance is felt and check the clearance between the
  • 2015 Kawasaki KX450F | Owners Manual - Page 133
    132 MAINTENANCE AND ADJUSTMENT NOTICE When tightening the locknut, the threads of the axle holder do not touch the piston rod. If the piston rod is scratched, it is possible to the damage in the cylinder unit. j Tightening Torque Adjuster Assembly (to Axle Holder): 69 N·m (7.0 kgf·m, 51 ft·lb)
  • 2015 Kawasaki KX450F | Owners Manual - Page 134
    MAINTENANCE AND ADJUSTMENT 133 j A. Top Plug Wrench, 50 mm (Special Tool: 57001-1645) B. Cylinder Unit C. Outer Tube D. Slide Down A. Outer Tube B. Fork Oil the specified amount of fork oil into the outer • Pour tube. Suspension Oil SS-19 (1 L): P/No. 44091-0009 Standard Fork Oil Amount Fork
  • 2015 Kawasaki KX450F | Owners Manual - Page 135
    134 MAINTENANCE AND ADJUSTMENT j A. Cylinder Unit B. Outer Tube C. Top Plug Wrench, 50 mm (Special Tool: 57001-1645) A. Air Valve Cap (Outer) B. Air Valve Cap (Inner) Right Front Fork Remove the air valve caps. • A. Air Valve Cap (Balance)
  • 2015 Kawasaki KX450F | Owners Manual - Page 136
    MAINTENANCE AND ADJUSTMENT 135 the front fork upright state. • Set air by pushing down the air valves in the or• Bleed der of balance chamber, outer chamber and inner chamber. j ○First, bleed air in a balance chamber. ○The oil may spout from the air valve. NOTE A. Air Valve (Outer) B. Air Valve
  • 2015 Kawasaki KX450F | Owners Manual - Page 137
    136 MAINTENANCE AND ADJUSTMENT j A. Chamber Cap B. Circlip A. Clean Cloth B. Chamber Cap the chamber cap with the clean cloth, and • Cover then hold the clean cloth to the outer tube with the the outer tube several times to remove • Pumping the chamber cap. tape. the a drain pan under the front
  • 2015 Kawasaki KX450F | Owners Manual - Page 138
    MAINTENANCE AND ADJUSTMENT 137 the top plug wrench, 50 mm (Special tool: • Using 57001-1645), remove the cylinder unit from the outer tube and slowly slide down the outer tube. j A. Oil Hole A. Top Plug Wrench, 50 mm (Special Tool: 57001-1645) B. Cylinder Unit C. Outer Tube D. Slide Down the
  • 2015 Kawasaki KX450F | Owners Manual - Page 139
    138 MAINTENANCE AND ADJUSTMENT j A. Fork Oil install the cylinder unit to the outer • Temporarily tube using the top plug wrench, 50 mm (Special tool: 57001-1645). A. Top Plug Wrench, 50 mm (Special Tool: 57001-1645) B. Cylinder Unit C. Outer Tube the axle holder with a vise, remove the plug •
  • 2015 Kawasaki KX450F | Owners Manual - Page 140
    MAINTENANCE AND ADJUSTMENT 139 • Hold the axle holder with a vise. WARNING Clamping the axle holder too tight can damage it which will affect riding stability. Do not clamp the axle holder too tight. j ○Protect the axle holder with a heavy cloth when using a vice. NOTE • Loosen the sealing bolt
  • 2015 Kawasaki KX450F | Owners Manual - Page 141
    140 MAINTENANCE AND ADJUSTMENT the outer tube by hand and remove the • Compress sealing bolt from the axle holder part so that the the fork leg with a vise. • Remove the cylinder unit with the top plug wrench, • Remove 50 mm (special tool: 57001-1645). j • locknut appears about 20 ∼ 30 mm (0.79 ∼
  • 2015 Kawasaki KX450F | Owners Manual - Page 142
    than 10 times. the front fork at the inverted position for more • Hold than 20 minutes to allow the fork oil to fully drain. NOTICE Service carefully because oil flies out from the oil hole of the cylinder unit.
  • 2015 Kawasaki KX450F | Owners Manual - Page 143
    142 MAINTENANCE AND ADJUSTMENT the piston rod fully stretched, pour the fork oil • With of 100 mL (3.38 US oz.). j A. Fork Oil B. Cylinder Unit A. Chamber Cap B. O-rings C. Cylinder Unit Recommended Fork Oil SS-19 (1 L): P/No. 44091-0009 the O-rings on the chamber cap and • Replace cylinder unit
  • 2015 Kawasaki KX450F | Owners Manual - Page 144
    creating the potential for injury. To avoid injury and damaging the piston rod, do not pressurize the cylinder unit quickly with compressed air; use a manually operated air pump. • Measure the cylinder unit length. Standard Length 950.5 ∼ 952.5 mm (37.42 ∼ 37.50 in.) it is not within the standard
  • 2015 Kawasaki KX450F | Owners Manual - Page 145
    144 MAINTENANCE AND ADJUSTMENT j A. Length • Insert the cylinder unit to the outer tube. NOTICE Do not touch the piston rod to the outer tube. The piston rod could be damage. A. Cylinder Unit B. Outer Tube install the cylinder unit to the outer • Temporarily tube using the top plug wrench, 50
  • 2015 Kawasaki KX450F | Owners Manual - Page 146
    MAINTENANCE AND ADJUSTMENT 145 the O-rings on the sealing bolt and piston • Replace rod with new ones and apply teflon grease to the O-rings. j A. Top Plug Wrench B. Cylinder Unit C. Outer Tube • Hold the axle holder with a vise. WARNING Clamping the axle holder too tight can damage it which will
  • 2015 Kawasaki KX450F | Owners Manual - Page 147
    146 MAINTENANCE AND ADJUSTMENT j A. Locknut B. Sealing Bolt C. More than 1.5 mm (0.059 in.) A. Locknut B. Wrench C. Sealing Bolt the locknut counterclockwise until it contacts • Turn with the sealing bolt. the locknut held immovable using a wrench, • With tighten the sealing bolt to the
  • 2015 Kawasaki KX450F | Owners Manual - Page 148
    MAINTENANCE AND ADJUSTMENT 147 j A. Sealing Bolt the cylinder unit with the top plug wrench, • Remove 50 mm (special tool: 57001-1645). A. Top Plug Wrench, 50 mm (Special Tool: 57001-1645) B. Cylinder Unit C. Outer Tube the fork oil of 300 mL (10.1 US oz.) into the • Pour outer tube.
  • 2015 Kawasaki KX450F | Owners Manual - Page 149
    pressurization of the front fork can damage it. To avoid damaging the front fork, do not pressurize the front fork quickly with compressed air; use a manually operated air pump.
  • 2015 Kawasaki KX450F | Owners Manual - Page 150
    MAINTENANCE AND ADJUSTMENT 149 j A. Air Pump B. Air Valve (Outer) A. Fork Oil B. Balance Chamber Outer Chamber Air Pressure Air Pressure 50 kPa (0.51 kgf/cm², 7.3 psi) (Standard Setting) Adjustable Range 0 ∼ 130 kPa (0 ∼ 1.33 kgf/cm², 0 ∼ 18.9 psi) Suspension Oil SS-19 (1 L): P/No. 44091-0009
  • 2015 Kawasaki KX450F | Owners Manual - Page 151
    of the front fork can damage it. To avoid damaging the front fork, do not pressurize the front fork quickly with compressed air; use a manually operated air pump. the Air valve cap. • Install Confirm the stroke of the front fork. • Install the front forks to the motorcycle. • Tighten the
  • 2015 Kawasaki KX450F | Owners Manual - Page 152
    MAINTENANCE AND ADJUSTMENT 151 the front fork top plug using the top plug • Tighten wrench, 50 mm (special tool: 57001-1645) to the specified torque. plug wrench, 50 mm (special tool: 57001-1645), reduce the torque to 90% of the specified value [67 N·m (6.8 kgf·m, 49 ft·lb)] due to the distance
  • 2015 Kawasaki KX450F | Owners Manual - Page 153
    152 MAINTENANCE AND ADJUSTMENT out wood wedge between the disc brake • Take pads. high-temperature grease to the oil seals of • Apply the wheel. the collars on the left and right side of the • Install hub. the front wheel assembly between the fork • Put legs, and insert the front brake disc into the
  • 2015 Kawasaki KX450F | Owners Manual - Page 154
    MAINTENANCE AND ADJUSTMENT 153 ○Do not apply the front brake during this process to stop the motorcycle from rolling forward. Put a block in front of the wheel to stop it from moving. NOTE j A. Collars B. Caps C. Axle D. Right Front Axle Clamp Bolts E. Axle Nut F. Left Front Axle Clamp Bolts G.
  • 2015 Kawasaki KX450F | Owners Manual - Page 155
    154 MAINTENANCE AND ADJUSTMENT the front brake for good braking power and • Check no brake drag. j WARNING After servicing, it takes several applications of the brake lever before the brake pads contact the disc, which could result in increased stopping distance and cause an
  • 2015 Kawasaki KX450F | Owners Manual - Page 156
    MAINTENANCE AND ADJUSTMENT 155 Rear Suspension (UNI-TRAK®) This motorcycle's rear suspension system is called "UNI-TRAK®" and consists of a rear shock absorber unit, a swingarm, two lever rods and a lever. The operating characteristics of the UNI-TRAK® suspension are similar to those of the front
  • 2015 Kawasaki KX450F | Owners Manual - Page 157
    156 MAINTENANCE AND ADJUSTMENT Rebound Damping Adjuster Settings *: Counterclockwise from the fully seated position j NOTICE Do not force the rebound damping force adjuster beyond the fully seated position, or the adjusting mechanism may be damaged. ○Adjustment of the rebound damping adjuster for
  • 2015 Kawasaki KX450F | Owners Manual - Page 158
    MAINTENANCE AND ADJUSTMENT 157 If the damping feels too soft or too stiff, adjust it in accordance with the following table. High Speed Compression Damping Adjuster Settings j A. Compression Damping Adjuster for High Speed B. Compression Damping Adjuster for Low Speed If the damping feels too
  • 2015 Kawasaki KX450F | Owners Manual - Page 159
    158 MAINTENANCE AND ADJUSTMENT Low Speed Compression Damping Adjuster Settings *: Counterclockwise from the fully seated position j NOTICE Do not force the compression damping force adjuster beyond the fully seated position, or the adjusting mechanism may be damaged. ○Adjustment of the
  • 2015 Kawasaki KX450F | Owners Manual - Page 160
    MAINTENANCE AND ADJUSTMENT 159 the rear wheel off the ground using a jack • Raise (special tool: 57001-1238) and attachment (spethe hook wrench (special tool: 57001 • Using -1539), turn the spring preload adjusting nut as required. Turning the adjusting nut down increases the spring preload. •
  • 2015 Kawasaki KX450F | Owners Manual - Page 161
    160 MAINTENANCE AND ADJUSTMENT Rear Shock Absorber Spring K = 49 N/mm (K = 5.0 kgf/mm) K = 51 N/mm (K = 5.2 kgf/mm) K = 53 N/mm* (K = 5.4 kgf/mm) K = 55 N/mm (K = 5.6 kgf/mm) *: Standard Adjustable Range 125.8 ∼ 135.8 mm (4.953 ∼ 5.346 in.) 125.8 ∼ 133.8 mm (4.953 ∼ 5.268 in.) 124.8 ∼ 139.5 mm (4.
  • 2015 Kawasaki KX450F | Owners Manual - Page 162
    MAINTENANCE AND ADJUSTMENT 161 Wheels Tire air pressure affects traction, handling, and tire life. Adjust the tire air pressure to suit track conditions and rider preference, but keep it close within the recommended range. To check the tire air pressure, remove the air valve cap, and make sure to
  • 2015 Kawasaki KX450F | Owners Manual - Page 163
    162 MAINTENANCE AND ADJUSTMENT There is a bead protector nut on the both wheels. The bead protector nut prevents the tire and tube from slipping on the rim and damaging the valve stem. Valve stem damage may cause the tube to leak, necessitating tube replacement. In order to keep the tire and tube in
  • 2015 Kawasaki KX450F | Owners Manual - Page 164
    MAINTENANCE AND ADJUSTMENT 163 Rim Runout Maximum Limit Axial *TIR 2.0 mm (0.08 in.) Radial *: Total Indicator Reading j A. Radial Rim Runout Measurement A. Axial Rim Runout Measurement
  • 2015 Kawasaki KX450F | Owners Manual - Page 165
    164 MAINTENANCE AND ADJUSTMENT Hoses Inspection Check the brake and fuel hoses for cracks or deterioration, and the connections for looseness in accordance with the Periodic Maintenance Chart. Inspect the brake hose and fittings for deterioration, cracks and signs of leakage by bending or twisting
  • 2015 Kawasaki KX450F | Owners Manual - Page 166
    MAINTENANCE AND ADJUSTMENT 165 Tightening Torques of Nuts and Bolts Before the first ride of each day of operation, check the tightness of the nuts and bolts shown below. Check also that all cotter pins are in place and in good condition. Location of nuts and bolts j 1. 2. 3. 4. 5. 6. Front
  • 2015 Kawasaki KX450F | Owners Manual - Page 167
    166 MAINTENANCE AND ADJUSTMENT j 1. 2. 3. 4. 5. Steering Stem Head Nut Front Master Cylinder Clamp Bolts Steering Stem Nut Handlebar Holder Nuts Rear Master Cylinder Mounting Bolts 6. 7. 8. 9. 10. Rear Brake Disc Mounting Bolts Rear Axle Nut Rocker Arm Pivot Nut Tie-Rod Mounting Nuts Brake
  • 2015 Kawasaki KX450F | Owners Manual - Page 168
    MAINTENANCE AND ADJUSTMENT 167 Tighten all nuts and bolts to the proper torque using an accurate torque wrench. An insufficiently tightened nut or bolt may become damaged or fall out, possibly resulting in damage to the motorcycle and injury to the rider. An overtightened nut or bolt may become
  • 2015 Kawasaki KX450F | Owners Manual - Page 169
    168 MAINTENANCE AND ADJUSTMENT Fastener Handlebar Holder Nuts Steering Stem Head Nut Steering Stem Nut Rear Frame Mounting Bolts N·m 34 98 4.9 34 kgf·m 3.5 10 0.50 3.5 ft·lb 25 72 43 in·lb 25 Remarks R j AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G:
  • 2015 Kawasaki KX450F | Owners Manual - Page 170
    -based window cleaners. j WARNING Build-up of debris or flammable material in and around the vehicle chassis, engine, and exhaust can cause mechanical problems and increase the risk of fire. When operating the vehicle in conditions that allow debris or flammable material to collect in and around
  • 2015 Kawasaki KX450F | Owners Manual - Page 171
    months or as conditions require. Avoid surfaces with "satin" or "flat" finishes. Always use non-abrasive products and apply them according to the instructions on the container. After washing use a soft cloth to gently dry plastic parts. When dry, treat the non-painted plastic parts with an approved
  • 2015 Kawasaki KX450F | Owners Manual - Page 172
    MAINTENANCE AND ADJUSTMENT 171 Chrome and uncoated aluminum parts can be treated with a chrome/aluminum polish. Coated aluminum should be washed with a mild neutral detergent and finished with a spray polish. Aluminum wheels, both painted and unpainted can be cleaned with special non-acid based
  • 2015 Kawasaki KX450F | Owners Manual - Page 173
    172 MAINTENANCE AND ADJUSTMENT Brake Pedal • Rear Master Cylinder Joint Pin • Rear Pedal • Kick Footpeg • • Shift Pedal j
  • 2015 Kawasaki KX450F | Owners Manual - Page 174
    MAINTENANCE AND ADJUSTMENT 173 Apply an aerosol cable lubricant with a pressure lubricator on all cables: Clutch Cable Throttle Cable Cable Lubrication Inner Cable Upper End • Clutch Throttle Inner Cable Upper End • Apply grease to the following points: • • j A. Upper End
  • 2015 Kawasaki KX450F | Owners Manual - Page 175
    to the rollers and bushings. Wipe off any excess lubricant. Drive Chain Lubrication DFI Self-Diagnosis This motorcycle equips the DFI trouble self -diagnosis system. Trouble diagnosis can be conducted as the following procedures. Self-diagnosis Outline The self-diagnosis has two modes and can be
  • 2015 Kawasaki KX450F | Owners Manual - Page 176
    MAINTENANCE AND ADJUSTMENT 175 Dealer Mode The orange FI warning indicator light emits service code(s) to show the problem(s) which the DFI system, and ignition system has at the moment of diagnosis. Self-diagnosis Procedures Disconnect the capacitor lead connector. • j A. Capacitor Lead
  • 2015 Kawasaki KX450F | Owners Manual - Page 177
    176 MAINTENANCE AND ADJUSTMENT the power supply harness (optional part: • Connect 26011-0246) to the capacitor lead connector of the j • • main harness. Connect the power supply harness (optional part: 26011-0246) to the 12 V battery as shown in the figure. Connect the O/Y lead (red cap) to the
  • 2015 Kawasaki KX450F | Owners Manual - Page 178
    terminal for more than 2 sec- • onds, and then keep it grounded continuously. Count the blinks of the orange light to read the service code. Keep the lead ground until you finish reading the service code. j A. Orange Launch Control Mode/FI Warning Indicator Light B. Self-diagnosis Terminal
  • 2015 Kawasaki KX450F | Owners Manual - Page 179
    a number of problems, all the service codes can be stored and the display will begin • startingthere from the lowest number service codes in the , the there is no problem, no code and unlight. • If For example, if two problems occurred in the order of 21, 12, the service codes are displayed from •
  • 2015 Kawasaki KX450F | Owners Manual - Page 180
    ○Even if the battery or the ECU is disconnected, or the problem is solved, all service codes remain in the ECU. Service Code Table Service Code 11 12 13 14 21 25 31 41 Orange FI Warning Indicator Light Problems Throttle sensor malfunction, wiring open or short Intake air pressure sensor malfunction
  • 2015 Kawasaki KX450F | Owners Manual - Page 181
    j ○The ECU may be involved in these problems. If all the parts and circuits checked out good, be sure to check the ECU for ground and power supply. If the ground and power supply are checked good, replace the ECU (see Service Manual). ○When no service code is displayed, the electrical parts of the
  • 2015 Kawasaki KX450F | Owners Manual - Page 182
    is not exhaustive and does not give every possible cause for each problem listed. It is meant simply as a quick guide to assist you in troubleshooting for some of the more common difficulties. Starting failure or difficulties - NOTE Engine does not turn over: Valve seized Valve lifter seized
  • 2015 Kawasaki KX450F | Owners Manual - Page 183
    182 TROUBLESHOOTING GUIDE head warped • Cylinder gasket damaged • Cylinder • Decompression trouble Poor low-speed performance plug damaged • Cylinder head head warped • Cylinder gasket • Decompression damaged trouble • defective • ECU Brake • Clutch dragging • Engineslipping overheating • Engine
  • 2015 Kawasaki KX450F | Owners Manual - Page 184
    TROUBLESHOOTING GUIDE 183 Fuel/air mixture incorrect: Air cleaner element clogged, poorly clearance excessive Cylinder head gasket damaged Cylinder head warped Cylinder gasket damaged Decompression trouble Improper acceleration: Throttle valve does not fully open Air cleaner element clogged Fuel
  • 2015 Kawasaki KX450F | Owners Manual - Page 185
    184 TROUBLESHOOTING GUIDE Lubrication inadequate: Engine oil level too low Engine oil quality poor Clutch not disengaging Shift fork bent or seized Gear stuck on the shaft Shift lever broken Pawl guide plate broken Shift return spring broken or weak Shift return spring pin loose Shift pawl broken
  • 2015 Kawasaki KX450F | Owners Manual - Page 186
    TROUBLESHOOTING GUIDE 185 quality poor or type incorrect • Fuel plug type incorrect • Spark Engine worn or chipped Camshaft chain tensioner defective Camshaft chain, sprocket, chain guide worn Decompression spring broken Flywheel magneto loose Transmission noise: Crankcase bearing worn
  • 2015 Kawasaki KX450F | Owners Manual - Page 187
    186 TROUBLESHOOTING GUIDE surface glazed • Pad disc warped • Brake Brake caliper • Brake Exhaust smoke Excessively white: Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Engine oil level too high Black smoke: • Air cleaner element clogged Brownish: Air
  • 2015 Kawasaki KX450F | Owners Manual - Page 188
    TROUBLESHOOTING GUIDE 187 fork air pressure weak • Front shock absorber spring weak • Rear shock absorber leaking oil or gas • Rear Rear shock absorber improperly adjusted • Tire air
  • 2015 Kawasaki KX450F | Owners Manual - Page 189
    POSITIONING on the machine. Before changing the suspension settings, test changing your riding posture or position to check whether it is the cause of the problem or not. It is a wise practice to adjust the suspension to suit the rider's strong points. If you are fast in the corners, adjust the
  • 2015 Kawasaki KX450F | Owners Manual - Page 190
    Too Hard Spring too stiff: Rebound or compression damping improperly adjusted. Fork air pressure high Fork oil amount too high Troubleshooting Improper Settings j A. Weight B. Fork Stroke C. Increase Amount D. Standard Oil Amount E. Decrease Amount Changing the fork oil amount works effectively
  • 2015 Kawasaki KX450F | Owners Manual - Page 191
    190 TUNING Too Soft The front fork dives excessively during braking and deceleration: Fork oil amount too low Fork air pressure low Fork oil deteriorated Rebound and/or compression damping improperly adjusted. Hence, if the actual rider weighs considerably more or less, or if his riding experience
  • 2015 Kawasaki KX450F | Owners Manual - Page 192
    TUNING 191 Suspension Tuning According the Type of Course Lower the front end slightly (Increase the amount of fork tube protrusion above the steering Many Corners stem head by 5 mm (0.20 in.).). This accelerates steering and enhances turning ability. Raise the front end slightly (Decrease the
  • 2015 Kawasaki KX450F | Owners Manual - Page 193
    192 TUNING Front and Rear Suspension Troubleshooting Front End Surges Downhill or During Acceleration Out of Corner The front suspension is too soft. Increase the compression damping or rebound damping. Increase the
  • 2015 Kawasaki KX450F | Owners Manual - Page 194
    TUNING 193 Front and Rear Ends Bottom Off After a High-speed Jump (harsh bottoming occurs once or twice per lap) The front suspension is too soft. Increase the air pressure (right front fork inner chamber). Increase the fork oil amount (left front fork). • • ○The rear shock absorber behavior on
  • 2015 Kawasaki KX450F | Owners Manual - Page 195
    194 TUNING Gearing Selection of the Secondary Reduction Ratio (Rear Sprocket) Rear Sprocket Selection According to Course Conditions Fast Course Small sprocket Many Curves or Hills Sandy or Soft Ground Large sprocket it is difficult to set the machine so it is best • Since suited for all portions
  • 2015 Kawasaki KX450F | Owners Manual - Page 196
    TUNING 195 Special Care According to Track Conditions dry, dusty conditions (such a volcanic ash or • In fine powdery dust), special care must be given to muddy or sandy conditions, increase chain • In slack as the chain and sprockets will be packed • • • • keeping the air cleaner element clean
  • 2015 Kawasaki KX450F | Owners Manual - Page 197
    the engine operation data in a personal computer (PC). KX FI Calibration Kit: Part No. - 99999-0394 For details, refer to the KX FI Calibration Kit manual.
  • 2015 Kawasaki KX450F | Owners Manual - Page 198
    • If and crankshaft bearings will be damaged. After • • riding, inspect the crankshaft big end. If the crankshaft big end is worn past the service limit, replace the crankshaft with a new one. Clean the sliding surface of the front fork and rear shock absorber. Maintenance After Riding in the Rain
  • 2015 Kawasaki KX450F | Owners Manual - Page 199
    198 PRE-RACE CHECKS AND AFTER-RACE MAINTENANCE grease to swingarm and rear suspension • Apply pivots. the drive chain and rear sprocket for wear. • Inspect Clean the cleaner element. • Check the air cylinder crankshaft big end. • Grease the throttle and grip and control cables. • Suggested Spare
  • 2015 Kawasaki KX450F | Owners Manual - Page 200
    STORAGE 199 STORAGE Before Storage When the motorcycle is to be stored for any length of time, it should be prepared for storage as follows. Clean the entire vehicle thoroughly. Run the engine for about five minutes to warm the oil, then stop it and drain the engine oil. WARNING Gasoline is
  • 2015 Kawasaki KX450F | Owners Manual - Page 201
    200 STORAGE After Storage the plastic bag from the muffler. • Remove Make sure the spark plug is tight. • the fuel tank with fuel. • Fill all the points listed in the Daily Pre-Ride • Check Checks section. a lubrication procedure in the Lubrication • Perform section. ○Fit the plug cap securely
  • 2015 Kawasaki KX450F | Owners Manual - Page 202
    ENVIRONMENTAL PROTECTION 201 ENVIRONMENTAL PROTECTION Kawasaki subscribes to the guidelines of Tread Lightly! a program dedicated to protecting the great outdoors through education and fostering responsible enjoyment of public lands. When using your Kawasaki motorcycle, please follow these Tread
  • 2015 Kawasaki KX450F | Owners Manual - Page 203
    202 WIRING DIAGRAM WIRING DIAGRAM
  • 2015 Kawasaki KX450F | Owners Manual - Page 204
  • 1
  • 2
  • 3
  • 4
  • 5
  • 6
  • 7
  • 8
  • 9
  • 10
  • 11
  • 12
  • 13
  • 14
  • 15
  • 16
  • 17
  • 18
  • 19
  • 20
  • 21
  • 22
  • 23
  • 24
  • 25
  • 26
  • 27
  • 28
  • 29
  • 30
  • 31
  • 32
  • 33
  • 34
  • 35
  • 36
  • 37
  • 38
  • 39
  • 40
  • 41
  • 42
  • 43
  • 44
  • 45
  • 46
  • 47
  • 48
  • 49
  • 50
  • 51
  • 52
  • 53
  • 54
  • 55
  • 56
  • 57
  • 58
  • 59
  • 60
  • 61
  • 62
  • 63
  • 64
  • 65
  • 66
  • 67
  • 68
  • 69
  • 70
  • 71
  • 72
  • 73
  • 74
  • 75
  • 76
  • 77
  • 78
  • 79
  • 80
  • 81
  • 82
  • 83
  • 84
  • 85
  • 86
  • 87
  • 88
  • 89
  • 90
  • 91
  • 92
  • 93
  • 94
  • 95
  • 96
  • 97
  • 98
  • 99
  • 100
  • 101
  • 102
  • 103
  • 104
  • 105
  • 106
  • 107
  • 108
  • 109
  • 110
  • 111
  • 112
  • 113
  • 114
  • 115
  • 116
  • 117
  • 118
  • 119
  • 120
  • 121
  • 122
  • 123
  • 124
  • 125
  • 126
  • 127
  • 128
  • 129
  • 130
  • 131
  • 132
  • 133
  • 134
  • 135
  • 136
  • 137
  • 138
  • 139
  • 140
  • 141
  • 142
  • 143
  • 144
  • 145
  • 146
  • 147
  • 148
  • 149
  • 150
  • 151
  • 152
  • 153
  • 154
  • 155
  • 156
  • 157
  • 158
  • 159
  • 160
  • 161
  • 162
  • 163
  • 164
  • 165
  • 166
  • 167
  • 168
  • 169
  • 170
  • 171
  • 172
  • 173
  • 174
  • 175
  • 176
  • 177
  • 178
  • 179
  • 180
  • 181
  • 182
  • 183
  • 184
  • 185
  • 186
  • 187
  • 188
  • 189
  • 190
  • 191
  • 192
  • 193
  • 194
  • 195
  • 196
  • 197
  • 198
  • 199
  • 200
  • 201
  • 202
  • 203
  • 204