Мануал для kawasaki klx450r

Detail Specifications:

492/492217-klx450r.pdf file (09 Dec 2022)

[Page 1] Kawasaki KLX450R —

KLX450R Motorcycle Service Manual
…

[Page 2] Kawasaki KLX450R —

…

[Page 3] Kawasaki KLX450R —

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 sectio…

[Page 4] Kawasaki KLX450R —

…

[Page 5] Kawasaki KLX450R —

KLX450R 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 p…

[Page 6] Kawasaki KLX450R —

LIST OF ABBREVIATIONS A ampere(s) lb pound(s) ABDC after bottom dead center m meter(s) AC alternating current min minute(s) ATDC after top dead center N newton(s) BBDC before bottom dead center Pa pascal(s) BDC bottom dead center PS horsepower BTDC b…

[Page 7] Kawasaki KLX450R —

EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emis- sion (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Pro…

[Page 8] Kawasaki KLX450R —

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof. (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or el…

[Page 9] Kawasaki KLX450R —

Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic in- formation to make it useful to the owner who de- sires to perform his own basic maintenance and repa…

[Page 10] Kawasaki KLX450R —

instructions indicating which parts require spec- ified tightening torque, oil, grease or a locking agent during assembly.
…

[Page 11] Kawasaki KLX450R —

GENERAL INFORMATION 1-1 1 General Information Table of Contents Before Servicing ……………………………………………………………………………………………………… 1-2 Model Identification…………………………

[Page 12] Kawasaki KLX450R —

1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions…

[Page 13] Kawasaki KLX450R —

GENERAL INFORMATION 1-3 Before Servicing 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. Storage of…

[Page 14] Kawasaki KLX450R —

1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified se- quence …

[Page 15] Kawasaki KLX450R —

GENERAL INFORMATION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact area. Be sure to maintain proper alignment and use smooth movements when installing. Ba…

[Page 16] Kawasaki KLX450R —

1-6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubri- cation points are called out throughout this manual, apply the specific oil …

[Page 17] Kawasaki KLX450R —

GENERAL INFORMATION 1-7 Model Identification KLX450A8F Left Side View KLX450A8F Right Side View Frame Number Engine Number
…

[Page 18] Kawasaki KLX450R —

1-8 GENERAL INFORMATION General Specifications Items KLX450A8F ∼ ABF Dimensions Overall Length 2 180 mm (85.83 in.), (AU) (EUR) 2 175 mm (85.63 in.) Overall Width 820 mm (32.3 in.) Overall Height 1 255 mm (49.41 in.), (AU) (EUR) 1 250 mm (49.21 in….

[Page 19] Kawasaki KLX450R —

GENERAL INFORMATION 1-9 General Specifications Items KLX450A8F ∼ ABF Transmission: Type 5-speed, constant mesh, return shift Gear ratios: 1st 2.167 (26/12) 2nd 1.533 (23/15) 3rd 1.188 (19/16) 4th 0.950 (19/20) 5th 0.810 (17/21) Final Drive System: …

[Page 20] Kawasaki KLX450R —

1-10 GENERAL INFORMATION General Specifications Items KLX450A8F ∼ ABF Tail Light LED Magneto: Rated Output 2.0A/14V Specifications subject to change without notice, and may not apply to every country.
…

[Page 21] Kawasaki KLX450R —

GENERAL INFORMATION 1-11 Unit Conversion Table Prefixes for Units: Prefix Symbol Power mega M × 1 000 000 kilo k × 1 000 centi c ×0.01 milli m ×0.001 micro µ × 0.000001 Units of Mass: kg ×2.205=lb g × 0.03527 = oz Units of Volume: L × 0.2642…

[Page 22] Kawasaki KLX450R —

…

[Page 23] Kawasaki KLX450R —

PERIODIC MAINTENANCE 2-1 2 Periodic Maintenance Table of Contents Periodic Maintenance Chart ………….. 2-2 Torque and Locking Agent…………….. 2-4 Specifications ……………………………… 2-9 Special Tools …………………….

[Page 24] Kawasaki KLX450R —

2-2 PERIODIC MAINTENANCE Periodic Maintenance Chart The maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. Periodic Inspection FREQUENCY Traveled Distance km (mi) OPERATION Every 100 (60) or 2.5 h…

[Page 25] Kawasaki KLX450R —

PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart FREQUENCY Traveled Distance km (mi) OPERATION Every 100 (60) or 2.5 hr Every 500 (300) or 7.5 hr Every 1000 (600) or 15 hr Every 1 500 (900) or 30 hr Every 2 000 (1 200) or 60 hr See Page Rear sproc…

[Page 26] Kawasaki KLX450R —

2-4 PERIODIC MAINTENANCE Torque and Locking Agent Tighten all bolts and nuts to the proper torque using an accurate torque wrench. If insufficiently tightened, a bolt or nut may become damaged, strip an internal thread, or break and then fall out. Th…

[Page 27] Kawasaki KLX450R —

PERIODIC MAINTENANCE 2-5 Torque and Locking Agent Torque Fastener N·m kgf·m ft·lb Remarks Vacuum Hose Fitting 8.8 0.90 78 in·lb L Cylinder Head Pipe Mounting Bolt 9.8 1.0 87 in·lb Exhaust Pipe Cover Bolts 12 1.2 106 in·lb Rear Muffler Mounting …

[Page 28] Kawasaki KLX450R —

2-6 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener N·m kgf·m ft·lb Remarks Gear Set Lever Nut 8.8 0.90 78 in·lb Engine Oil Drain Plug (M6)(Sub) 7.0 0.71 62 in·lb Engine Oil Drain Plug (M10)(Main) 20 2.0 15 Shift Drum Cam Bolt 24 2…

[Page 29] Kawasaki KLX450R —

PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener N·m kgf·m ft·lb Remarks Locknut/Adjuster Assembly 29 3.0 21 Adjuster Assembly 55 5.6 41 L Front Axle Clamp Bolts 20 2.0 15 AL Swingarm Pivot Shaft Nut 98 10 72 R Rocker Arm Pivot Nu…

[Page 30] Kawasaki KLX450R —

2-8 PERIODIC MAINTENANCE Torque and Locking Agent Basic Torque for General Fasteners Threads dia. Torque (mm) N·m kgf·m ft·lb 5 3.4 ∼ 4.9 0.35 ∼ 0.50 30 ∼ 43 in·lb 6 5.9 ∼ 7.8 0.60 ∼ 0.80 52 ∼ 69 in·lb 8 14 ∼ 19 1.4 ∼ 1.9 10.0 �…

[Page 31] Kawasaki KLX450R —

PERIODIC MAINTENANCE 2-9 Specifications Item Standard Service Limit Fuel System Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) ––– Hot Starter Lever Free Play 0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.) ––– Air Cleaner Element Oil High qua…

[Page 32] Kawasaki KLX450R —

2-10 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Standard Tire: Front: Size 80/100-21 51M ––– (AU) (EUR) 80/100-21 M/C 51P ––– Make BRIDGESTONE ––– Type D401, Tube ––– (AU) (EUR) ED03, Tube ––– Rear: …

[Page 33] Kawasaki KLX450R —

PERIODIC MAINTENANCE 2-11 Special Tools Inside Circlip Pliers: 57001-143 Steering Stem Nut Wrench: 57001-1100 Jack: 57001-1238 Spark Plug Wrench, Hex 16: 57001-1262 Filler Cap Driver: 57001-1454 Top Plug Wrench, 49 mm: 57001-1653
…

[Page 34] Kawasaki KLX450R —

2-12 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System Fuel Hose and Connection Inspection ○ The fuel hoses are designed to be used throughout the motorcycle’s life without any maintenance, however, if the motorcycle is not properl…

[Page 35] Kawasaki KLX450R —

PERIODIC MAINTENANCE 2-13 Periodic Maintenance Procedures WARNING Operation with an improperly adjusted, incorrectly routed or damaged cables could result in an un- safe riding Condition. Follow the service manual to make sure to correct any of these…

[Page 36] Kawasaki KLX450R —

2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Start the engine and warm it up thoroughly. • With the engine idling, turn the handlebar to both sides [A]. If handlebar movement changes the idle speed, the throt- tle cable may be impr…

[Page 37] Kawasaki KLX450R —

PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures 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 fla…

[Page 38] Kawasaki KLX450R —

2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Squeeze it dry in a clean towel [A]. Do not wring the ele- ment or blow it dry; the element can be damaged. • Check all the parts of the element for visible damage. If any of the parts o…

[Page 39] Kawasaki KLX450R —

PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures • Turn the fuel tap to the OFF position. • Place a suitable container beneath the carburetor drain hose [B]. • Loosen the drain plug [A] from the bottom of the float bowl and check for w…

[Page 40] Kawasaki KLX450R —

2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures Coolant Level Inspection NOTE ○ Check the level when the engine is cold (room or ambi- ent temperature). • Lean the motorcycle slightly to the left until the radiator cap is level to the g…

[Page 41] Kawasaki KLX450R —

PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures Radiator Hoses and Connections Inspection ○ The high pressure inside the radiator hoses and water hoses [A] can cause coolant to leak [B] or the hose to burst if the line is not properly mai…

[Page 42] Kawasaki KLX450R —

2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures If the vacuum switch valve does not operate as described, replace it with a new one. NOTE ○ To check air flow through the vacuum switch valve, just blow through the air cleaner hose. Vacuum …

[Page 43] Kawasaki KLX450R —

PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures Valve Clearance Adjustment • Remove the camshaft caps [A] (see Camshaft Removal in the Engine Top End chapter). • Remove the camshafts [B] (see Camshaft Removal in the Engine Top End chapt…

[Page 44] Kawasaki KLX450R —

2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Adjustment shims Thick- ness P/No. Mark Thick- ness P/No. Mark 2.00 92025-1870 0 2.55 92025-1881 55 2.05 92025-1871 5 2.575 92025-1985 58 2.10 92025-1872 10 2.60 92025-1882 60 2.15 92025-1873 …

[Page 45] Kawasaki KLX450R —

PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures Cylinder Head Warp Inspection • Remove the cylinder head (see Cylinder Head Removal in the Engine Top End chapter). • Lay a straightedge [A] across the lower surface of the head at several…

[Page 46] Kawasaki KLX450R —

2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Piston/Cylinder Clearance The piston-to-cylinder clearance is measured whenever a piston or cylinder is replaced with a new one. The standard piston-to-cylinder clearance must be adhered to wh…

[Page 47] Kawasaki KLX450R —

PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures • Remove: Spark Arrester Mounting Bolts [A] Spark Arrester [B] • With a wire brush, remove the carbon off the inside of the spark arrester [A] and muffler. • Inspect the spark arrester. …

[Page 48] Kawasaki KLX450R —

2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Lever Free Play Adjustment • Slide the clutch lever dust cover out of place. • Turn the adjuster [A] so that the clutch lever will have 8 ∼ 13 mm (0.3 ∼ 0.5 in.) of play. NOTE �…

[Page 49] Kawasaki KLX450R —

PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures • Remove the engine oil drain plugs on the bottom of the engine, and let the oil drain completely. Drain Plug (Sub) [A] DrainPlug(Main)[B] NOTE ○ Hold the motorcycle upright so that the oi…

[Page 50] Kawasaki KLX450R —

2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove the Oil Filter [A]. • Install the spring [A] to the right engine cover. • Apply grease to the grommet [B]. • Be sure to install the filter with the grommet facing outside as s…

[Page 51] Kawasaki KLX450R —

PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Crankshaft/Transmission Crankshaft Inspection Connecting Rod Big End Side Clearance • Remove the cylinder head (see Cylinder Head Removal in the Engine Top End chapter). • Remove the cylin…

[Page 52] Kawasaki KLX450R —

2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Tires Inspection As the tire tread wears down, the tire becomes more sus- ceptible the puncture and failure. • Remove any imbedded stones or other foreign particles from the tread. • Visua…

[Page 53] Kawasaki KLX450R —

PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures Rim Runout Inspection • Place the jack under the frame so that the front/rear wheel off the ground. Special Tool — Jack: 57001-1238 • Inspect the rim for small cracks, dents, bending, or w…

[Page 54] Kawasaki KLX450R —

2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Final Drive Drive Chain Slack Inspection • Raise the rear wheel off the ground, rotate the rear wheel to find the place where the chain is tightest (because it wears unevenly). • Check the…

[Page 55] Kawasaki KLX450R —

PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures NOTE ○ When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle shaft, tighten the nut clockwise [A] up to next alignment. ○ It should be wi…

[Page 56] Kawasaki KLX450R —

2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures WARNING A chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock the rear wheel, severely damaging the motorcycle and causing it to go out of control. Inspect t…

[Page 57] Kawasaki KLX450R —

PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures Rear Sprocket Warp Inspection • Using the jack, raise the rear wheel off the ground. Special Tool — Jack: 57001-1238 • Set a dial gauge [A] against the rear sprocket [B] near the teeth as …

[Page 58] Kawasaki KLX450R —

2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures ○ Loosen the push rod locknut [A]. ○ Replace the cotter pin with a new one. ○ Remove: Cotter Pin [B] Washer Joint Pin [C] ○ Turn the bracket [D] to obtain the specified length. ○ Tig…

[Page 59] Kawasaki KLX450R —

PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures Brake Fluid Change In accordance with the Periodic Maintenance Chart, change the brake fluid. The brake fluid should also be changed if it becomes contaminated with dirt or water. Furthermore,…

[Page 60] Kawasaki KLX450R —

2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTE ○ The procedure to change the front brake fluid. Chang- ing the rear brake fluid is the same as for the front brake. • Level the brake fluid reservoir. • Remove the screws [A], rese…

[Page 61] Kawasaki KLX450R —

PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures • Remove the clear plastic hose. • Tighten the bleed valves, and install the rubber caps. Torque — Caliper Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb) Brake Reservoir Cap Screws: 1.5 N�…

[Page 62] Kawasaki KLX450R —

2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTICE Do not remove the secondary cup from the piston since removal will damage it. • Remove the rear master cylinder (see Rear Master Cylin- der Removal in the Brakes chapter). NOTE ○ Do…

[Page 63] Kawasaki KLX450R —

PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures Caliper Piston Seal and Dust Seal Replacement • Loosen the brake pad pin [A] and banjo bolt [B], and tighten them loosely. • Remove: Front Caliper Mounting Bolts [C] Banjo Bolt Brake Hose …

[Page 64] Kawasaki KLX450R —

2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove the rear caliper (see Caliper Removal in the Brakes chapter). • Remove the pads (see Brake Pad Removal in the Brakes chapter). • Separate the caliper holder [B] from the caliper…

[Page 65] Kawasaki KLX450R —

PERIODIC MAINTENANCE 2-43 Periodic Maintenance Procedures • Install the anti-rattle spring [A] in the caliper as shown. • Replace the shaft rubber friction boot [A] and dust boot [B] if they are damaged. • Apply a thin coat of PBC (Poly Butyl C…

[Page 66] Kawasaki KLX450R —

2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose and Connection Check • Inspect the brake hose and fittings for deterioration, cracks and signs of leakage. ○ The high pressure inside the brake line can cause fluid to leak [A] …

[Page 67] Kawasaki KLX450R —

PERIODIC MAINTENANCE 2-45 Periodic Maintenance Procedures For Rear Brake • Remove: Master Cylinder [A] Hose Clamps [B] Caliper Cover [C] • When installing the hoses, avoid sharp bending, kinking, flattening or twisting, and route the hoses accord…

[Page 68] Kawasaki KLX450R —

2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Loosen the fork top plug [A]. Special Tool — Top Plug Wrench, 49 mm [B]: 57001-1653 • Remove: Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Front Brake Caliper (see C…

[Page 69] Kawasaki KLX450R —

PERIODIC MAINTENANCE 2-47 Periodic Maintenance Procedures • Place a drain pan under the front fork and drain fork oil [A]. NOTE ○ Pump the fork tube several times to discharge the fork oil. • Raise the outer tube and temporarily install the for…

[Page 70] Kawasaki KLX450R —

2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Hold the locknut [A] with a wrench [B] and remove the adjuster assembly [C]. • Remove the push rod [A]. • With the outer tube compressed by hands, remove the topplugwrench[A]. NOTICE R…

[Page 71] Kawasaki KLX450R —

PERIODIC MAINTENANCE 2-49 Periodic Maintenance Procedures • Holding the top plug wrench [A] with a vise, loosen the base valve assembly [B] on the subtank [C]. Special Tool — Top Plug Wrench, 49 mm: 57001-1653 • Remove the base valve assembly [A]…

[Page 72] Kawasaki KLX450R —

2-50 PERIODIC MAINTENANCE Periodic Maintenance Procedures • With the piston rod in fully compressed position, pour the specified amount of fork oil [A]. Recommended Oil: KHL15-10 (KAYABA01) or equivalent Recommended Quantity: 189 ml (6.4 US oz.) NO…

[Page 73] Kawasaki KLX450R —

PERIODIC MAINTENANCE 2-51 Periodic Maintenance Procedures • Holdingthetopplugwrench[A]withavise. Special Tool — Top Plug Wrench, 49 mm: 57001-1653 • Holding the subtank [B] with the top plug wrench, torque the base valve assembly [C]. Torque — Ba…

[Page 74] Kawasaki KLX450R —

2-52 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Completely wipe of the fork oil from the spring [A], spacer [B] and cylinder unit [C]. • Insert above-mentioned parts into the fork. • Temporarily tighten the fork top plug [A] (subtan…

[Page 75] Kawasaki KLX450R —

PERIODIC MAINTENANCE 2-53 Periodic Maintenance Procedures • Replace the O-ring and gasket on the adjuster assembly with new ones and apply specified fork oil to the O-ring. • Turn the locknut [A] counterclockwise until it contacts with the adjust…

[Page 76] Kawasaki KLX450R —

2-54 PERIODIC MAINTENANCE Periodic Maintenance Procedures Rear Shock Absorber Inspection • Bounce [A] the rear of the motorcycle up and down and check for smooth suspension stroke. • Remove the rear frame (see Rear Frame Removal in the Frame chap…

[Page 77] Kawasaki KLX450R —

PERIODIC MAINTENANCE 2-55 Periodic Maintenance Procedures • Using the suitable tool [A] and press, push the reservoir cap [B] in 10 mm (0.39 in.). • Remove the circlip [C] from the gas reservoir. • Pull the gas reservoir cap [B] out of the gas …

[Page 78] Kawasaki KLX450R —

2-56 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Using the grinder, shave off the stopper portion [A] of the rod. • Remove: Nut [B] Washer [C] Piston [D] • Install the new piston and tighten the locknut. ○ Discard a washer or two. …

[Page 79] Kawasaki KLX450R —

PERIODIC MAINTENANCE 2-57 Periodic Maintenance Procedures • Mount the circlip [A] in the groove in the gas reservoir. • Pull up the gas reservoir cap [A] against the circlip. The end of the gas reservoir cap must align [B] with the end of the gas…

[Page 80] Kawasaki KLX450R —

2-58 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Insert the piston end [A] of the piston rod assembly into the rear shock body [C] slowly. Do not insert the seal assembly [B] yet. Pump the piston rod until all the air is forced out of th…

[Page 81] Kawasaki KLX450R —

PERIODIC MAINTENANCE 2-59 Periodic Maintenance Procedures Swingarm and Uni-Trak Linkage Inspection • Check the uni-trak component parts for wear periodically, or whenever excessive play is suspected. • Using the jack under the frame, raise the re…

[Page 82] Kawasaki KLX450R —

2-60 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove: Handlebar Pad [A] Headlight [B] (see Headlight Removal/Installation in the Electrical System chapter) • Remove: Handlebar Clamp Bolts [A] Handlebar Clamps [B] Handlebar [C] (from…

[Page 83] Kawasaki KLX450R —

PERIODIC MAINTENANCE 2-61 Periodic Maintenance Procedures • Install the handlebar [B] on the handlebar holder so that the protruded scales of the both side adjust to the same width [A]. • Route the hose according to Cable, Wire, and Hose Rout- in…

[Page 84] Kawasaki KLX450R —

2-62 PERIODIC MAINTENANCE Periodic Maintenance Procedures Electrical System Spark Plug Cleaning and Inspection • Remove: Seat (see Seat Removal in the Frame chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System chapter) Spark Plug Cap • Cl…

[Page 85] Kawasaki KLX450R —

PERIODIC MAINTENANCE 2-63 Periodic Maintenance Procedures Points: Lubricate with Grease. Clutch Inner Cable Upper and Lower Ends [A] Hot Start Inner Cable Upper End Throttle Inner Cable Upper End Cables: Lubricate with Rust Inhibitor. Throttle Cables…

[Page 86] Kawasaki KLX450R —

2-64 PERIODIC MAINTENANCE Periodic Maintenance Procedures If there are loose fasteners, retorque them to the specified torque following the specified tightening sequence. Refer to the Torque and Locking Agent section of the General Information chapte…

[Page 87] Kawasaki KLX450R —

FUEL SYSTEM 3-1 3 Fuel System Table of Contents Exploded View………………………………………………………………………………………………………… 3-2 Specifications …………………………………………….

[Page 88] Kawasaki KLX450R —

3-2 FUEL SYSTEM Exploded View
…

[Page 89] Kawasaki KLX450R —

FUEL SYSTEM 3-3 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Throttle Pulley Cover Bolt 3.4 0.35 30 in·lb 2 Throttle Cable Mounting Bolts 6.9 0.70 61 in·lb 3. Hot Starter Cable 4. Throttle Cables 5. Throttle Grip 6. Carburetor Cap…

[Page 90] Kawasaki KLX450R —

3-4 FUEL SYSTEM Exploded View
…

[Page 91] Kawasaki KLX450R —

FUEL SYSTEM 3-5 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Vacuum Switch Valve Bracket Bolts 9.8 1.0 87 in·lb 2 Fuel Tap Knob Screws 0.80 0.080 7.0 in·lb 3 Rear Frame Mounting Bolts 34 3.5 25 4. Fuel Tank Cap 5. Fuel Tank 6. Fue…

[Page 92] Kawasaki KLX450R —

3-6 FUEL SYSTEM Specifications Item Standard Throttle Grip and Cable Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Hot Starter Lever Free Play 0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.) Carburetor Make/Type KEIHIN FCR-MX40 Starter Jet #55 Leak Jet #…

[Page 93] Kawasaki KLX450R —

FUEL SYSTEM 3-7 Special Tool Fuel Level Gauge, M18 × 1.0: 57001-122
…

[Page 94] Kawasaki KLX450R —

3-8 FUEL SYSTEM Throttle Grip and Cable If the throttle grip has excessive free play due to cable stretch or misadjustment, there will be a delay in throttle re- sponse. Also, the throttle valve may not open fully at full throttle. On the other hand,…

[Page 95] Kawasaki KLX450R —

FUEL SYSTEM 3-9 Throttle Grip and Cable • Remove the exhaust pipe (see Muffler Removal in the Engine Top End chapter). • Unscrew the bolt [A]. • Remove the throttle pulley cover [B]. • Loosen the mounting bolts [A]. • Remove the cables [B] …

[Page 96] Kawasaki KLX450R —

3-10 FUEL SYSTEM Throttle Grip and Cable Hot Starter Cable Removal • Slide the clutch lever dust cover [A] back. • Loosen the locknut [B]. • Turn in the adjuster [C] fully. • Remove the cable end [D] from the hot starter lever [E]. • Remove…

[Page 97] Kawasaki KLX450R —

FUEL SYSTEM 3-11 Throttle Grip and Cable Hot Starter Lever Free Play Adjustment • Refer to the Hot Starter Lever Free Play Inspection in the Periodic Maintenance chapter. Hot Starter Cable Lubrication • Whenever the hot starter cable is removed o…

[Page 98] Kawasaki KLX450R —

3-12 FUEL SYSTEM Carburetor Since the carburetor regulates and mixes the fuel and air going to the engine, there are two general types of carbure- tor trouble: too rich a mixture (too much fuel), and too lean a mixture (too little fuel). Such trouble…

[Page 99] Kawasaki KLX450R —

FUEL SYSTEM 3-13 Carburetor • Read the fuel level in the gauge and compare it to the specification. Service Fuel Level (below the bottom edge of the carb. body) Standard: –6.5 ±1 mm (–0.26 ±0.04 in.) If the fuel level is incorrect, adjust it….

[Page 100] Kawasaki KLX450R —

3-14 FUEL SYSTEM Carburetor NOTE ○ Float height [A] is the distance from the float bowl mat- ing surface [B] of the carburetor body (with the gasket removed) to the top of the float [C]. Measure the height with the carburetor upside down. ○ Do no…