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klix 450 manualFourth Edition (0): March 12, 2010. Addi- tionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance with applicable regulations of the United States Environmental Protection Agency. General Specifications.Unit Conversion Table.1-11. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. Gaskets, O-rings, Oil seals, Grease seals, circlips, cotter pins or self-locking nuts must be replaced with new ones whenever disassembled. Then tighten them according to the specified se- quence to prevent case warpage or deformation which can lead to malfunction. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary. Lubri- cation points are called out throughout this manual, apply the specific oil or grease as specified. Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Periodic Inspection FREQUENCY Traveled Distance km (mi) Every Every Every Every Every 1 000 1 500 2 000 (60) (300) If insufficiently tightened, a bolt or nut may become damaged, strip an internal thread, or break and then fall out. The following table lists the tightening toque for the major bolts and nuts, and the parts requiring use of a non-permanent locking agent or liquid gasket. Follow the service manual to make sure to correct any of these conditions.If handlebar movement changes the idle speed, the throt- tle cable may be improperly adjusted or incorrectly routed, or it may be damaged. Clean the element in a well ventilated area, and take care that there is no spark or flame any- where near the working areas. If any of the parts of the element are damaged, replace them.
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If any water or dirt comes out, clean the carburetor, fuel filter, fuel tap and fuel tank. Visually inspect the hoses for signs of deterioration. If only a piston is replaced, the clearance may exceed the standard slightly. If the spark arrester is damaged, replace it with a new one. Inspect the chain for damage and proper adjustment before each ride. The brake fluid should also be changed if it becomes contaminated with dirt or water. Furthermore, the brake fluid should be changed to bleed the air quickly and completely whenever the brake line parts are removed. NOTICE Removing the locknut and pushing the piston rod thread into the cylinder unit will damage the oil seal. Pump the piston rod until all the air is forced out of the rear shock body. Refer to the Torque and Locking Agent section of the General Information chapter for torque specifications.Throttle Cable Lubrication.Throttle Cable Inspection.Hot Starter Cable Removal.3-10 Hot Starter Cable Installation. Also, the throttle valve may not open fully at full throttle. Such trouble can be caused by dirt, wear, maladjustment, or improper fuel level in the float chamber. Service Fuel Level (below the bottom edge of the carb.If the rod does not come out fully by spring tension, re- place the valve needle. Always stop the engine and do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;. When the engine starts, the water pump turns and the coolant circulates. Change the coolant in accordance with the Periodic Maintenance Chart (see Periodic Maintenance chapter). WARNING Hot engine coolant can cause serious burns. To avoid burns, do not remove the radiator cap or try to inspect the coolant level or change the coolant when the engine is still hot. Immediately wipe or wash out any coolant that spills on the frame, or engine. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: When removing the tensioner, do not take out the mounting bolts only halfway. NOTICE Do not heat the cylinder head with a torch. This will warp the cylinder head. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off. If the seat area is not in the right place on the valve, check to be sure the valve is the correct part. If it is, it may have been refaced too much;. If the rings show weakness or deformation, replace the rings. Also if the pin hole groove shows excessive wear, replace the piston. Do not re- move the muffler while it is hot.If car- bon has built up inside the silencer, exhaust efficiency is reduced, causing engine performance to drop. Clutch Lever Installation.Clutch Cable Removal. Clutch Cable Installation. WARNING The engine and exhaust system get extremely hot during normal operation and can cause serious burns. NOTICE Do not remove the clutch release shaft unless it is absolutely necessary.If they are damaged or if there are groove cuts in the areas that come in contact with the tangs, replace the housing. Replace the friction plates if their tangs are damaged as well. Specifications. Special Tools. Engine Oil and Oil Filter.Engine Oil Level Inspection.Engine Oil Change.Oil Filter Change. Oil Screen.7-10 Oil Screen (Scavenge) Removal. Check the oil level before each use and change the oil and filter according to the periodic maintenance chart. Do not attempt to ride the motorcycle until a firm brake pedal is obtained by pumping the pedal until the pads are against the disc. Special Tool - Bearing Driver Set: 57001-1129 NOTICE Support the crankcase bearing boss when the bear- ing is pressed, or the crankcase could be damaged. If flywheel misalignment cannot be corrected by the above method, replace the crank pin or the crankshaft itself.http://superbia.lgbt/flotaganis/1654921768 Instead of measuring, inspect the bearing for abrasion, color change, or other damage. If there is any doubt as to the condition of a needle bear- ing, replace it. If the roughness or binding is found, replace the hub bear- ings. This can damage or warp the disc.Special Tools - Rim Protector: 57001-1063 Bead Breaker Assembly: 57001-1072 NOTICE Take care not to inset the tire irons so deeply that. NOTICE Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground. Air, however, is easily compressed. When air enters the brake lines, brake lever or pedal movement will be partially used in compressing the air. WARNING After servicing, it takes several applications of the brake lever or pedal before the brake pads contact the disc, which could result in increased stopping distance and cause an accident resulting in injury or death. WARNING After servicing, it takes several applications of the brake lever or pedal before the brake pads contact the disc, which could result in increased stopping distance and cause an accident resulting in injury or death. Air pressure in the fork legs increase with normal use, so the fork action stiffens during opera- tion. Release air pressure form the fork legs prior to each race through the pressure relief screw located in each front fork cap. NOTICE Removing the locknut and pushing the piston rod thread into the cylinder unit will damage the oil seal. The shock to fork seal separates the inner tube from the outer tube. Special Tool - Top Plug Wrench, 49 mm: 57001-1653 WARNING The fork spring applies pressure to the adjuster as- sembly and can eject the special tool with substan- tial force if the tool is not properly and securely placed. If it has scratches or is bent, replace cylinder unit with a new one.If the spring of either fork leg is shorter than the service limit, it must be replaced.http://curabona.com/images/connect-direct-manual-for-windows.pdf If the length of a replacement spring and that of the remaining spring vary greatly, the remaining spring should also be replaced in order to keep the fork legs balanced from motorcycle stability. It consists of a rear shock absorber, swing arm, tie-rod and rocker arm. To suit to various riding conditions, the spring preload of the shock absorber can be adjusted or the spring can be replaced with an optional one. If the damping feels too soft or too stiff, adjust it in accor- dance with the following table.NOTICE When pulling out the mounting bolts, lift the rear wheel slightly. L: Apply a non-permanent locking agent. R: Replacement Parts. Such a shock to the parts can damage them. If the connector is corroded or dirty, clean it carefully. Keep the battery away from sparks and open flames during charging. When using a battery charger, connect the battery to the charger before turning on the charger. WARNING This battery is sealed type. Charge with current and time as stated below.There is a woodruff key in the crankshaft tapered portion. Safety Instructions WARNING The ignition system produces extremely high volt- age. Do not touch the spark plug, ignition coil or high tension lead while the engine is running, or you could receive a severe electrical shock. Ignition Coil Primary Peak Voltage Standard: 128 V or above (Kick starter) Starter Motor Installation NOTICE Do not tap the starter motor shaft or body. Replace the starter motor with a new one if the commu- tator diameter is less than the service limit. If the headlight beam points too low or high, adjust the vertical beam.If the tester indicator does not flick, replace the speed sensor. TROUBLESHOOTING GUIDE STORAGE A Table of Contents is included after the Foreword. Always follow safe operat- Off-road motorcycling is a wonderful sport, ing and maintenance practices.How- ever, if improperly conducted, this sport has the DANGER potential to cause environmental problems as well as conflicts with other people. It is the end product of Kawasaki’s advanced engineering, exhaustive testing, and continuous striving for superior reliability, and performance. By giving your motorcycle the proper care and maintenance outlined in this manual, you will be helping to ensure it a long, trouble-free life. Radiator 16. Air Cleaner Element 21. Swingarm 12. Fuel Tank 17. Brake Disc 22. Drive Chain 13. Fuel Tap 18. Brake Caliper 23. Chain Guide 14. Carburetor 19. Shift Pedal. Silencer 29. Uni-Trak Tie Rod and Rocker Arm 25. Rear Brake Fluid Reservoir 30. Rear Brake Pedal 26. Rear Shock Absorber Gas Reservoir 31. Kick Pedal 27. Battery 32. Engine Oil Level Inspection Window 28. Fuse 33. Fuel Requirements: Your Kawasaki engine is designed to use only unleaded gasoline with a minimum octane rating shown below. Never use gasoline with an oc- tane rating lower than the minimum specified by Kawasaki to prevent severe engine damage. For normal operation, turn the fuel tap explosive under certain conditions. Always lever to the ON position. If the fuel runs out with the stop the engine and do not smoke. Both the hour and The speedometer shows the speed of the vehicle.Odometer: The odometer shows the total distance in the kilo- meters (mph) that the vehicle has been ridden. This motorcycle’s radiator does not incorpo- rate cooling fan. Prolonged idling of the en- gine with no airflow through the radiator can cause coolant loss and engine overheating resulting in possible engine damage. Pull in (ON) Push back (OFF) after falling Cold. 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. Pull in the clutch Close the throttle completely and push the engine lever as the motorcycle comes to a stop. Be Break-In sure to fully check the tightness of nuts and bolts, oil leakage, and any irregularities, espe- A brief break-in procedure must be carried out to cially, each cable elongation, brake play, chain obtain the proper operating clearances in the engine slack and spoke tightness. 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 take the action required to return the motorcycle to a safe operating condition. Carry out the general lubrication (see p. 140) and make necessary adjustments. Engine oil is a toxic substance. Dispose of used oil properly.After the oil has completely drained out, install the drain plugs with their new gaskets. Proper torque for them is shown in the table.Cooling Hoses Type: API SG, SH, SJ, SL or SM with JASO Check the cooling hoses for cracks or deteriora- MA, MA1 or MA2 tion, and the connections for looseness in accor- dance with the Periodic Maintenance Chart. Permanent type of antifreeze (ethylene glycol base plus corrosion and rust inhibitors for aluminum engines and radiators) If it is dirty, clean it. Also check if the element is in good condition (no tears, hardening or shrinkage). NOTICE Do not twist, wring or blow the element dry to avoid damaging it. In this case, too much oil is better than too little.Throttle Cable Adjustment Inspect the throttle grip for smooth operation in all steering positions. Check and adjust the throttle cable in accordance with the Periodic Maintenance Chart. Then, tighten rectly routed, or damaged cables could re- the locknut toward the adjuster. If so, the throttle cable may be improperly adjusted, incorrectly routed, or dam- Idling Adjustment aged. Be sure to correct any of these conditions Idling adjustment is carried out using the idling ad- before riding. Inspection and adjustment should be done only by an authorized Kawasaki dealer.Remove the two caps from the generator cover. A. Head Cover Gaskets A. Caps. Spark Arrester This vehicle is equipped with a spark arrester. It must be properly maintained to ensure its efficiency. In accordance with the Periodic Maintenance Chart, clean the spark arrester. NOTICE The spark arrester must be installed cor- rectly and functioning properly to provide. If it is chain must be checked, adjusted, and lubricated be- deformed or damaged, replace the axle nut with a fore riding. WARNING A loose axle nut can lead to an accident re- sulting in serious injury or death. Ap- ply lubricant to the seals so that the seals will be coated with lubricant. Wipe off any excess lubri- To suit various riding positions, the handlebar cant. Disc and disc pad wear is automatically compen- sated for and has no effect on the brake lever or NOTE pedal action. Brake Fluid Level Inspection (Front and Rear Reservoirs) Disc Brake Fluid. Pad replacement should be done by an authorized Kawasaki dealer. Usable Brake Pad Range A. Rear Reservoir B. If the inner tube is badly bent or creased, replace it. Excessive bending, followed by subsequent straitening, can weaken the in- ner tube. Fork Oil Amount Adjustment Therefore, it is not recommended to increase the air The fork oil amount affects only the final 100 mm pressure for additional springing. The KLX forks are (4 in.) of fork travel. Adjust the compression damping to suit your preference under certain con- ditions. NOTICE Be careful not to scratch the inner tube and A. Take off the speedometer gear case assy from right side of the front hub and collar and cap from the left side. Loosen the front fork top plug with the top plug wrench (special tool). NOTICE Removing the lock nut and pushing the pis- ton rod thread into the cylinder unit will dam-. NOTICE Disassembling the cylinder unit can lead to trouble. Disassembling the base valve assembly can NOTICE lead to trouble. Do not disassemble the base valve assembly.Do not damage the bushings when assem- bling the base valve. Discharge the extra oil off the cylinder unit by pumping the piston rod to full stroke. WARNING The fork spring applies pressure to the ad- juster assembly and can eject the special. Replace the O-ring on the adjuster assembly with new ones and apply specified fork oil to the O-ring.If the projections fit in the notches correctly, the machined surface is not seen after putting the front wheel between the fork legs. A. Softer springs soften the fork action and slow down the rebound damping. Fork Height Adjustment Steering is greatly affected by the fork height (how much the outer fork tubes protrude above the up- per fork clamp). There are two adjustments you can make to the Low Speed Compression Damping Adjuster rear shock absorber gas reservoir. Always make any damp- ing adjustments in small steps and test their ef- fects before using them in competition. Unevenly tightened or loose spokes will cause the Tire Air Pressure rim to warp, the nipples and spokes to fatigue more Tire air pressure affects traction, handling, and tire quickly, and the spokes to break. The of the rim and rotate the wheel to measure its ra- bead protector prevents the tire and tube from slip- dial runout. Turning the adjusting screw clockwise cordance with the Periodic Maintenance Chart.Number of Days From 100 Charged to 100 The battery installed in this motorcycle is a sealed discharged Temperature type, so it is not necessary to check the battery elec- Lead-Antimony Lead-Calcium trolyte level or add distilled water. However, in order to maximize battery life and en- Battery Battery. If you will not be using the The charger will keep the battery fully charged un- motorcycle for longer than two weeks, the battery til you are ready to reinstall the battery in the mo- should be charged using an appropriate charger. Be sure that the cable connections are If you charge the sealed battery, never fail to ob- clean.Do not use any The main fuse is mounted on the starter relay un- substitute for the standard fuse. Replace the der the seat. If a fuse fails during operation, inspect blown fuse with a new one of the correct ca- the electrical system to determine the cause, and pacity, as specified on the junction box and. Check also that all cotter pins are in place and in good condition. 1. Rear Brake Pedal Pivot Bolt 21. Spark Arrester Mounting Bolts 28. Rear Shock Absorber Bolt and Nut 22. Rear Master Cylinder Mounting Bolts 29. UNI-TRAK Arm Bolt 23. Steering Head Nut 30. An insufficiently tightened nut or bolt may become damaged or fall out, possibly resulting in damage to the motorcycle and injury to the rider. Coated aluminum should be washed with a mild neutral de- Lubricate the areas shown in the illustrations of tergent and finished with a spray polish. Aluminum this section with either motor oil or regular grease, wheels, both painted and unpainted can be cleaned after each race and whenever the vehicle has been. Use a lubricant for sealed chains to prevent deteri- oration of chain seals. If the chain is especially dirty, clean it using a cleaner for sealed chains following the instructions supplied by the chain cleaner man- ufacturer. Always stop of time, it should be prepared for storage as follows.Consult your authorized Kawasaki dealer or local environmental waste agency for their proper disposal procedure. This also applies to disposal of the entire vehicle at the end of its life. 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Discover everything Scribd has to offer, including books and audiobooks from major publishers. Start Free Trial Cancel anytime. Report this Document Download now Save Save Manual del propietario KLX 450.pdf For Later 0 (1) 0 found this document useful (1 vote) 662 views 164 pages Manual del propietario KLX 450.pdf Uploaded by pablo Description: Full description Save Save Manual del propietario KLX 450.pdf For Later 0 0 found this document useful, Mark this document as useful 100 100 found this document not useful, Mark this document as not useful Embed Share Print Download now Jump to Page You are on page 1 of 164 Search inside document Browse Books Site Directory Site Language: English Change Language English Change Language Quick navigation Home Books Audiobooks Documents, active. Le frizioni Rekluse hanno un sistema a 6 molle realizzate in acciaio indurito a caldo, che garantisce una migliore durata delle prestazioni della molla stessa anche dopo innumerevoli cicli di riscaldamento. Proseguendo nella navigazione si accetta l’uso dei cookie. Impostazioni Informativa Accetta Rifiuto Politica Privacy e Cookies Out of these cookies, the cookies that are categorized as necessary are stored on your browser as they are essential for the working of basic functionalities of the website. We also use third-party cookies that help us analyze and understand how you use this website. These cookies will be stored in your browser only with your consent. You also have the option to opt-out of these cookies. But opting out of some of these cookies may have an effect on your browsing experience. This category only includes cookies that ensures basic functionalities and security features of the website. These cookies do not store any personal information. It is mandatory to procure user consent prior to running these cookies on your website. Writing On Front Cover At Top. Tag Stapled To Inside Front Cover., Model: KLX 450R 450 09 2009 KLX450 KLX450R, Modified Item: No, Non-Domestic Product: No, Brand: Kawasaki, Manufacturer Part Number: 99987-1536 You are the light of the world. I also use valve saver in my petrol, mobil or BP 98 octane unleaded and clean the oil filter each ride with No-Toil. Ive followed that and have checked the clearences every now and then and it hasnt moved after 3 yrs LOL, still goes well and sometime starts on the first kick cold, but very rarely takes more than 5. i guess some ppl have good luck with their bikes, but if you look after it then it should give you some hours back.You're buying a race bike, not a cab though ??They were both extreem cases and im yet to see any klx450 with engine problems. Rock solid Motors.You're buying a race bike, not a cab though ?? I currently have over 130 race hours on the hour meter. I check the valves every 15 hours and the first time I had to reshim to centre the clearances was at 53 hours. I also changed out the piston at the same time. The piston showed no sign of wear or blow by with only very slight wear marks on the intake side of the teflon coated skirt. At 113 hours the exhaust valves had'nt moved at all and the intake valves had closed.002mm. Still well within the correct specs. I have since replaced the piston for the upcoming MX season and have no doubt about the reliability of the motor and valve train. I do change the air filter after each ride and replace gearbox oil (motul 5100) and oil filter every 4 hours which might help with the reliabilty. I imagine the KLX motor with different valves, cams and ignition timing the bike would be even more reliable than higher strung KXF unit.