2012-2013 Kawasaki KX450F Service & Repair Manual

KX450F Motorcycle Service Manual

This quick reference guide will assist you in locating a desired topic or pro- cedure. •Bend the pages back to match the black tab of the desired chapter num- ber with the black tab on the edge at each table of contents page. •Refer to the sectional table of contents for the exact pages to locate the spe- cific topic required. Quick Reference Guide General Information 1 Periodic Maintenance 2 Fuel System (DFI) 3 Cooling System 4 Engine Top End 5 Clutch 6 Engine Lubrication System 7 Engine Removal/Installation 8 Crankshaft/Transmission 9 Wheels/Tires 10 Final Drive 11 Brakes 12 Suspension 13 Steering 14 Frame 15 Electrical System 16 Appendix 17

KX450F Motorcycle Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Division/Motorcycle & Engine Company/Kawasaki Heavy Industries, Ltd., Japan. No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible. The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your Motorcycle dealer for the latest information on product improvements incorporated after this publication. All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. © 2011 Kawasaki Heavy Industries, Ltd. Second Edition (0) : Apr. 18, 2012

LIST OF ABBREVIATIONS A ampere(s) in. inch(s) ABDC after bottom dead center KDS Kawasaki Diagnostic System AC alternating current km/h kilometers per hour Ah ampere hour L liter(s) ATDC after top dead center lb pound(s) BBDC before bottom dead center LED Light Emitting Diode BDC bottom dead center m meter(s) BTDC before top dead center min minute(s) °C degree(s) Celsius mph miles per hour cmHg centimeters of mercury N newton(s) CPU Central Processing Unit oz ounce(s) cu in cubic inch(s) Pa pascal(s) DC direct current PS horsepower DFI Digital Fuel Injection psi pound(s) per square inch ECU Electronic Control Unit qt quart(s) F farad(s) r revolution °F degree(s) Fahrenheit rpm revolution(s) perminute ft foot, feet s second(s) g gram(s) TDC top dead center gal gallon(s) V volt(s) h hour(s) W watt(s) HP horsepower(s) Ω ohm(s) COUNTRY AND AREA CODES AU Australia EUR Europe BR Brazil US United States CA Canada

Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who de- sires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. When- ever the owner has insufficient experience or doubts his ability to do the work, all adjust- ments, maintenance, and repair should be car- ried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do the work care- fully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may ad- versely affect safe operation. To get the longest life out of your vehicle: • Follow the Periodic Maintenance Chart in the Service Manual. • Be alert for problems and non-scheduled maintenance. • Use proper tools and genuine Kawasaki Mo- torcycle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki motorcycles are introduced by the Service Manual. Genuine parts provided as spare parts are listed in the Parts Catalog. • Follow the procedures in this manual care- fully. Don’t take shortcuts. • Remember to keep complete records of maintenance and repair with dates and any new parts installed. How to Use This Manual In this manual, the product is divided into its major systems and these systems make up the manual’s chapters. The Quick Reference Guide shows you all of the product’s system and assists in locating their chapters. Each chapter in turn has its own comprehensive Ta- ble of Contents. For example, if you want stick coil information, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chapter to find the Stick Coil section. Whenever you see symbols, heed their instructions! Always follow safe operating and maintenance practices. DANGER DANGER indicates a hazardous situa- tion which, if not avoided, will result in death or serious injury. WARNING WARNING indicates a hazardous situa- tion which, if not avoided, could result in death or serious injury. NOTICE NOTICE is used to address practices not related to personal injury. This manual contains four more symbols which will help you distinguish different types of information. NOTE ○ This note symbol indicates points of particular interest for more efficient and con- venient operation. • Indicates a procedural step or work to be done. ○ Indicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a NOTE. Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows. In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly.

GENERAL INFORMATION 1-1 1 General Information Table of Contents Before Servicing ..................................................................................................................... 1-2 Model Identification................................................................................................................. 1-7 General Specifications............................................................................................................ 1-8 Technical Information - DFI Setting Data Selection ................................................................ 1-11 Technical Information - Launch Control Mode ........................................................................ 1-13 Technical Information - PSF (Pneumatic Spring Fork) Front Fork (KX450FD) ....................... 1-15 Unit Conversion Table ............................................................................................................ 1-20

1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts. Especially note the following: Edges of Parts Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts. Solvent Use a high flash-point solvent when cleaning parts. High flash-point solvent should be used according to directions of the solvent manufacturer. Cleaning Vehicle before Disassembly Clean the vehicle thoroughly before disassembly. Dirt or other foreign materials entering into sealed areas during vehicle disassembly can cause excessive wear and decrease performance of the vehicle. Arrangement and Cleaning of Removed Parts Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly.

2012-2013 Kawasaki KX450F Service & Repair Manual

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