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Manuals
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Kawasaki Manuals
Motorcycle
KX450F -
Service manual
Kawasaki KX450F Service Manual Page 198
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Also See for KX450F
Service manual
-
492 pages
Instruction manual
-
79 pages
Assembly & preparation manual
-
36 pages
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Go
Page 1
Page 2
Page 3 - GENERAL INFORMATION
Page 4
Page 5
Page 6
Page 7 - How to use this manual
Page 8
Page 9
Page 10 - Before Servicing
Page 11 - Replacement parts
Page 12
Page 13
Page 14
Page 15 - Model Identification
Page 16 - General Specifications
Page 17
Page 18 - Unit Conversion Table
Page 19 - Table Of Contents
Page 20
Page 21 - Periodic Maintenance Chart
Page 22
Page 23 - Torque and Locking Agent
Page 24
Page 25
Page 26
Page 27
Page 28
Page 29 - Specifications
Page 30
Page 31
Page 32 - Special Tools and Sealant
Page 33 - Periodic Maintenance Procedures
Page 34 - Throttle Body Cleaning
Page 35 - Idle Speed Inspection
Page 36 - Idle Speed Adjustment
Page 37
Page 38 - Fuel Tank Cleaning
Page 39 - Coolant Level Inspection
Page 40 - Water Hoses and Connections Inspection
Page 41 - Valve Clearance Adjustment
Page 42
Page 43 - Cylinder Head Warp Inspection
Page 44 - Piston/Cylinder Clearance Inspection
Page 45 - Clutch
Page 46 - Clutch Plates Inspection
Page 47 - Engine Lubrication System
Page 48 - Oil Filter Change
Page 49 - Breather Hose Inspection
Page 50 - Wheels/Tires
Page 51 - Tires Inspection
Page 52 - Wheel Bearing Inspection
Page 53 - Drive Chain Slack Inspection
Page 54 - Rear Axle Nut Inspection
Page 55 - Sprocket Wear Inspection
Page 56
Page 57 - Brake Fluid Level Inspection
Page 58 - Brake Fluid Change
Page 59
Page 60
Page 61 - Brake Pad Wear Inspection
Page 62 - Brake Caliper Fluid Seal and Dust Seal R...
Page 63
Page 64
Page 65
Page 66 - Brake Hoses and Connections Inspection
Page 67 - Suspension
Page 68 - Front Fork Oil Change
Page 69
Page 70
Page 71
Page 72
Page 73
Page 74
Page 75
Page 76
Page 77
Page 78
Page 79
Page 80
Page 81
Page 82
Page 83
Page 84
Page 85
Page 86 - Rear Shock Absorber Inspection
Page 87
Page 88
Page 89
Page 90
Page 91 - Swingarm and Uni-Trak Linkage Inspection
Page 92 - Steering Adjustment
Page 93 - Steering Stem Bearing Lubrication
Page 94 - Electrical System
Page 95 - Spark Plug Replacement
Page 96 - Cable Inspection
Page 97
Page 98
Page 99
Page 100
Page 101
Page 102 - Exploded View
Page 103
Page 104
Page 105
Page 106 - Specifications
Page 107 - Special Tools and Sealant
Page 108 - DFI System
Page 109
Page 110
Page 111 - DFI Parts Location
Page 112
Page 113 - DFI Servicing Precautions
Page 114 - Troubleshooting the DFI System
Page 115
Page 116
Page 117 - Inquiries to Rider
Page 118
Page 119 - DFI System Troubleshooting Guide
Page 120
Page 121 - Poor running or no power at high speed
Page 122
Page 123 - Self-Diagnosis
Page 124
Page 125
Page 126 - How to Read Service Codes
Page 127 - Service Code Table
Page 128 - Backups
Page 129 - Throttle Sensor (Service Code 11)
Page 130
Page 131 - Throttle Sensor Input Voltage Inspection
Page 132 - Throttle Sensor Output Voltage Inspectio...
Page 133 - Throttle Sensor Resistance Inspection
Page 134
Page 135 - Intake Air Pressure Sensor (Service Code...
Page 136 - Intake Air Pressure Sensor Input Voltage...
Page 137 - Intake Air Pressure Sensor Output Voltag...
Page 138
Page 139
Page 140
Page 141 - Intake Air Temperature Sensor (Service C...
Page 142 - Intake Air Temperature Sensor Resistance...
Page 143
Page 144 - Water Temperature Sensor (Service Code 1...
Page 145
Page 146 - Water Temperature Sensor Resistance Insp...
Page 147 - Crankshaft Sensor (Service Code 21)
Page 148 - Gear Position Switch (Service Code 25)
Page 149 - Gear Position Switch Inspection
Page 150 - Vehicle-down Sensor (Service Code 31)
Page 151 - Vehicle-down Sensor Input Voltage Inspec...
Page 152 - Vehicle-down Sensor Output Voltage Inspe...
Page 153
Page 154 - Fuel Injector (Service Code 41)
Page 155 - Fuel Injector Audible Inspection
Page 156 - Fuel Injector Power Supply Voltage Inspe...
Page 157 - Fuel Injector Output Voltage Inspection
Page 158
Page 159 - Fuel Pump (Service Code 46)
Page 160 - Fuel Pump Operation Inspection
Page 161 - Pressure Regulator Removal
Page 162
Page 163 - Ignition Coil (Service Code 51)
Page 164 - Orange FI Warning Indicator Light (LED)
Page 165
Page 166 - ECU
Page 167 - ECU Power Supply Inspection
Page 168
Page 169 - Fuel Line
Page 170 - Fuel Flow Rate Inspection
Page 171
Page 172 - Throttle Grip and Cable
Page 173 - Throttle Cable Lubrication
Page 174 - Throttle Cable Inspection
Page 175 - Throttle Body Assy
Page 176 - Throttle Body Assy Installation
Page 177 - Throttle Body Assy Assembly
Page 178
Page 179 - Air Cleaner
Page 180 - Fuel Tank
Page 181
Page 182 - Fuel Tank Installation
Page 183
Page 184 - Exploded View
Page 185
Page 186 - Specifications
Page 187 - Special Tools
Page 188 - Coolant
Page 189 - Coolant Filling
Page 190 - Air Bleeding
Page 191 - Cooling System Flushing
Page 192 - Water Pump
Page 193 - Impeller Installation
Page 194 - Oil Seal and Bearing Installation
Page 195 - Radiator
Page 196 - Radiator Installation
Page 197 - Radiator Cap Inspection
Page 198
Page 199
Page 200 - Exploded View
Page 201
Page 202
Page 203
Page 204 - Specifications
Page 205
Page 206
Page 207 - Special Tools and Sealant
Page 208
Page 209
Page 210 - Cylinder Head Cover
Page 211
Page 212 - Camshaft Chain Tensioner
Page 213
Page 214 - Camshafts
Page 215 - Camshaft Installation
Page 216
Page 217 - Camshaft Chain Removal
Page 218 - Camshaft Chain Installation
Page 219 - Cam Wear Inspection
Page 220 - Cylinder Head
Page 221
Page 222 - Cylinder Head Installation
Page 223 - Cylinder Head Cleaning
Page 224 - Valves
Page 225 - Valve Installation
Page 226 - Valve Guide Installation
Page 227 - Valve/Valve Guide Clearance
Page 228 - Valve Seat Repair
Page 229
Page 230
Page 231
Page 232 - Cylinder and Piston
Page 233
Page 234 - Cylinder Wear Inspection
Page 235 - Piston Ring/Ring Groove Clearance Inspec...
Page 236 - Piston Ring End Gap Measurement
Page 237 - Throttle Body Holder
Page 238 - Muffler
Page 239 - Silencer Wool Replacement
Page 240
Page 241
Page 242 - Exploded View
Page 243
Page 244 - Specifications
Page 245 - Special Tools
Page 246 - Clutch Lever and Cable
Page 247 - Clutch Cable Installation
Page 248 - Clutch Cable Inspection and Lubrication
Page 249 - Clutch Cover and Right Engine Cover
Page 250 - Right Engine Cover Installation
Page 251 - Right Engine Cover Assembly
Page 252 - Clutch Removal
Page 253 - Clutch Installation
Page 254
Page 255
Page 256 - Clutch Plate Assembly Free Play Inspecti...
Page 257 - Release Shaft Installation
Page 258 - Clutch Hub Spline Damage Inspection
Page 259
Page 260 - Exploded View
Page 261
Page 262 - Lubrication System Chart
Page 263
Page 264 - Specifications
Page 265 - Special Tools
Page 266 - Engine Oil and Oil Filter
Page 267 - Oil Filter Replacement
Page 268 - Oil Screen Cleaning
Page 269 - Oil Pump
Page 270 - Oil Pump Installation
Page 271 - Oil Pump Inspection
Page 272 - Oil Pressure
Page 273
Page 274 - Exploded View
Page 275
Page 276 - Special Tools
Page 277 - Engine Removal/Installation
Page 278
Page 279 - Engine Removal
Page 280
Page 281
Page 282 - Exploded View
Page 283
Page 284
Page 285
Page 286 - Specifications
Page 287 - Special Tools and Sealant
Page 288 - Crankcase
Page 289
Page 290 - Crankcase Assembly
Page 291
Page 292
Page 293
Page 294
Page 295
Page 296
Page 297
Page 298
Page 299 - Crankshaft
Page 300 - Crankshaft Inspection
Page 301 - Connecting Rod Bend Inspection
Page 302 - Connecting Rod Twist Inspection
Page 303 - Transmission
Page 304 - Transmission Shaft Assembly
Page 305
Page 306 - Shift Fork Bending Inspection
Page 307 - Balancer
Page 308
Page 309 - Primary Gear
Page 310 - External Shift Mechanism
Page 311 - External Shift Mechanism Installation
Page 312 - External Shift Mechanism Inspection
Page 313
Page 314 - Kickstarter
Page 315 - Idle Gear Removal
Page 316 - Kickshaft Installation
Page 317
Page 318 - Bearings/Oil Seals
Page 319 - Oil Seal Inspection
Page 320
Page 321
Page 322 - Exploded View
Page 323
Page 324 - Specifications
Page 325 - Special Tools
Page 326 - Wheels (Rims)
Page 327 - Rear Wheel Removal
Page 328 - Rear Wheel Installation
Page 329 - Wheels Inspection
Page 330 - Spoke Tightness Inspection
Page 331 - Tires
Page 332 - Tire Installation
Page 333
Page 334 - Hub Bearing
Page 335 - Hub Bearing Installation
Page 336 - Hub Bearing Inspection
Page 337
Page 338 - Exploded View
Page 339
Page 340 - Specifications
Page 341 - Drive Chain Slack Inspection
Page 342
Page 343 - Sprockets
Page 344 - Rear Sprocket Installation
Page 345
Page 346 - Exploded View
Page 347
Page 348
Page 349
Page 350 - Specifications
Page 351 - Special Tools
Page 352 - Brake Lever, Brake Pedal
Page 353
Page 354 - Brake Fluid
Page 355 - Brake Line Bleeding
Page 356
Page 357 - Caliper
Page 358 - Caliper Disassembly
Page 359 - Fluid Seal Damage Inspection
Page 360 - Caliper Piston and Cylinder Damage Inspe...
Page 361 - Brake Pad
Page 362
Page 363 - Brake Pad Installation
Page 364 - Master Cylinder
Page 365 - Rear Master Cylinder Removal
Page 366 - Front Master Cylinder Disassembly
Page 367 - Master Cylinder Inspection (Visual Inspe...
Page 368 - Brake Disk
Page 369 - Brake Hose
Page 370
Page 371
Page 372 - Exploded View
Page 373
Page 374
Page 375
Page 376 - Specifications
Page 377
Page 378 - Special Tools
Page 379 - Front Fork
Page 380 - Compression Damping Adjustment (Left Fro...
Page 381 - Rebound Damping Adjustment (Left Front F...
Page 382 - Front Fork Installation
Page 383 - Front Fork Disassembly
Page 384 - Adjuster Assembly Inspection
Page 385 - Cylinder Unit Inspection
Page 386 - Rear Shock Absorber
Page 387 - Spring Preload Adjustment
Page 388 - Rear Shock Absorber Spring Tension Inspe...
Page 389 - Rear Shock Absorber Installation
Page 390 - Rear Shock Absorber Disassembly
Page 391
Page 392 - Rear Shock Absorber Assembly
Page 393 - Rear Shock Absorber Oil Change
Page 394 - Rear Shock Absorber Inspection
Page 395 - Swingarm
Page 396 - Swingarm Installation
Page 397 - Swingarm Bearing Installation
Page 398 - Swingarm Bearing, Sleeve Inspection
Page 399 - Tie-Rod, Rocker Arm
Page 400 - Rocker Arm Installation
Page 401 - Tie-Rod and Rocker Arm Bearing Installat...
Page 402 - Needle Bearing Inspection
Page 403 - Uni-Trak Maintenance
Page 404
Page 405
Page 406 - Exploded View
Page 407
Page 408 - Special Tools
Page 409 - Steering Inspection
Page 410
Page 411 - Steering Stem, Stem Bearing Installation
Page 412 - Stem Bearing Lubrication
Page 413 - Stem Warp Inspection
Page 414 - Handlebar
Page 415 - Handlebar Installation
Page 416
Page 417 - Handlebar Position Adjustment
Page 418
Page 419
Page 420 - Exploded View
Page 421
Page 422 - Frame Inspection
Page 423 - Engine Guards Removal
Page 424 - Seat
Page 425 - Side Covers
Page 426 - Radiator Shroud
Page 427 - Number Plate
Page 428 - Fender
Page 429 - Footpegs
Page 430 - Footpeg Height Adjustment
Page 431
Page 432 - Exploded View
Page 433
Page 434 - Specifications
Page 435 - Special Tools and Sealant
Page 436 - Wiring Diagram
Page 437
Page 438 - Precautions
Page 439 - Electrical Wiring
Page 440 - Flywheel Magneto
Page 441 - Flywheel Installation
Page 442 - Stator Coil Removal
Page 443 - Flywheel Magneto Inspection
Page 444
Page 445 - Charging System
Page 446 - Regulator/Rectifier Inspection
Page 447
Page 448 - Capacitor Removal
Page 449 - Ignition Timing
Page 450 - Ignition System
Page 451 - Ignition Coil Inspection
Page 452 - Spark Plug Cleaning and Inspection
Page 453 - Ignition Coil Primary Peak Voltage Check
Page 454
Page 455 - Crankshaft Sensor Peak Voltage Check
Page 456 - Engine Stop Switch System Check
Page 457
Page 458 - Switches
Page 459
Page 460
Page 461
Page 462
Page 463
Page 464
Page 465
Page 466
Page 467
Page 468
Page 469
Page 470
Page 471
Page 472
Page 473
Page 474
Page 475
Page 476
Page 477
Page 478 - Troubleshooting guide
Page 479 - Clutch operation faulty
Page 480 - Abnormal frame noise
Page 481
Page 482
/
482
Contents
Table of contents
Troubleshooting
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Periodic Maintenance Chart
Brake Fluid Change
Unit Conversion Table
Before servicing
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Chapters
Table Of Contents
9
Periodic Maintenance
19
Fuel System (dfi)
99
Cooling System
183
Engine Top End
199
Clutch
241
Engine Lubrication System
259
7-14 Engine Lubrication System
273
Crankshaft/transmission
281
Wheels/tires
321
Final Drive
337
Brakes
345
Suspension
371
Steering
405
Frame
419
Electrical System
431
Table of Contents
Troubleshooting
Troubleshooting the DFI System
114
DFI System Troubleshooting Guide
119
troubleshooting guide
478
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