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- Assembly & Preparation Manual
Kawasaki KX450F - Assembly & Preparation Manual
Summary of KX450F -
Page 1
Kx450f motorcycle assembly & preparation manual.
Page 3: Foreword
Foreword in order to ship kawasaki vehicles as effi- ciently as possible, they are partially disassem- bled before crating. Since some of the most commonly removed parts have a direct bear- ing on a vehicle’s reliability and safety, consci- entious pre-sale assembly and preparation be- comes extreme...
Page 4: Table Of Contents
Table of contents uncrating ...................................................................................... 3 opening crate ............................................................................. 3 parts check.................................................................................
Page 5: Uncrating
Uncrating 3 uncrating opening crate warning crates have sharp edges and may have nails or screws that can cause cuts and injury. Always wear protective gloves, boots and eye protection when uncrat- ing to prevent injury. Warning the steel crate panel plates and fasten- ers have sharp edges. Always w...
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4 uncrating a. Rubber plug (dummy) b. Fork top plug • install the air valve adapter (see no.22 part in the parts check section). Note ○ when using the air valve adapter, apply grease to the o-ring. A. Air valve adapter • raise the front wheel off the ground using a jack (special tool: 57001-1238) an...
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Uncrating 5 this page intentionally left blank..
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6 uncrating parts check • open the parts box, and check the parts against the illustrations. There may be minor differences between these illustrations and the actual vehicle parts. In the following charts under remarks, d = diameter in millimeters, and l = length in millimeters..
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Uncrating 7 no. Part name qty remarks 1 dfi setting data selection connector 1 white 2 dfi setting data selection connector 1 black 3 handlebar pad 1 renthal 4 handlebar with grip and wiring band 1 renthal 5 handlebar clamp bolt 4 d = 8, l = 35 6 clamp, front brake master cylinder 1 7 clamp bolt, fr...
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8 uncrating spare parts • these parts and their part numbers are subject to change without prior notice according to the model year. No. Part name qty part number 1 gasket, cylinder head, t = 0.65 2 11004-0088 2 gasket, cylinder head cover 2 11061-0351 3 gasket, cylinder base 2 11061-0768 4 gasket, ...
Page 11: Assembly
Assembly 9 assembly handlebar • apply 2-stroke oil to the edge (slash area) of the handlebar. A. 120 mm (4.72 in.) • install the throttle grip assy on the handlebar and insert the handlebar fully into the grip. A. Throttle grip assy • put the handlebar on the handlebar holders. • mount the handlebar...
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10 assembly a. Forward b. Gap throttle grip assembly • slip the dust cover off the throttle case. • adjust the position of the throttle grip assy so that the joint line of the throttle case is vertical to the handlebar. • tighten the mounting screws (d = 5, l = 20) to the specified torque. Torque : ...
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Assembly 11 clutch lever assembly • install the clutch lever with the clamp and bolts (d = 5, l = 16) on the handlebar. • tighten the clamp bolts. A. Clutch lever assy b. 160.5 mm (6.32 in.) c. Clamp bolts (d = 5, l = 16) d. Horizontal line of frame e. 30° ±5° launch control mode button • remove the...
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12 assembly cables and wiring routing • check that the cables, wiring leads and hoses are routed correctly. (viewed from front) a. Throttle cables b. Wiring band c. Engine stop switch lead d. Launch control mode button lead e. Clutch cable front fender • position the front fender between the fork le...
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Assembly 13 a. Front number plate b. Holes c. Projections • fasten the number plate to the stem head with the flanged bolt (d = 6, l = 12). • fasten the number plate belt to the handlebar pad with a latch. A. Flanged bolt (d = 6, l = 12) b. Number plate belt fuel tank breather hose • fit one end of ...
Page 16: Preparation
14 preparation radiator drain hose • pull the radiator over flow hose end out of the engine guard. Preparation air cleaner air cleaner element inspection the foam cleaner element on off road models is oiled prior to shipping. However, over time the filter will dry and filtration performance will dim...
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Preparation 15 a. Apply grease. • install the air cleaner element so that its tab faces upward and its projections align with the holes in the housing, and tighten the wing bolt, making sure that it is properly seated and sealed. A. Tab b. Projections c. Holes • to install the seat, align the front ...
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16 preparation a. Front brake fluid reservoir b. Upper level line warning when working with the disc brake, ob- serve the precautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3. Do not mix tw...
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Preparation 17 • apply the brake forcefully for a few seconds, and check for fluid leakage around the fittings. Rear brake rear brake fluid level inspection • with the rear brake fluid reservoir positioned horizontally, check that the fluid level is above the lower level line. A. Rear brake fluid re...
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18 preparation • when air bleeding is finished, check the fluid level. • install the diaphragm and reservoir cap. • tighten the bleed valve to the specified torque. Torque : 7.8 n·m (0.80 kgf·m, 69 in·lb) • apply the brake forcefully for a few seconds, and check for fluid leakage around the fittings...
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Preparation 19 a. 52 ∼ 58 mm (2.0 ∼ 2.3 in.) • adjust the drive chain if its slack is out of spec- ification. 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...
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20 preparation a. Cotter pin b. Nut warning a loose axle nut can lead to an acci- dent resulting in serious injury or death. Tighten the axle nut to the proper torque and be sure the cotter pin is installed correctly. • check the rear brake effectiveness. Front fork air pressure adjustment before ri...
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Preparation 21 • after air pressure adjustment, remove the air valve adapter. • reinstall the air valve plug and tighten it to the specified torque. Torque : 0.2 n·m (0.020 kgf·m, 1.8 in·lb) notice be sure to install the air valve plug to prevent dust from entering. • before delivery to the customer...
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22 preparation • to adjust the rebound damping, turn the ad- juster on each front fork cylinder valve with a standard tip screwdriver. Adjust the rebound damping to the standard setting position. Notice the right and left fork tubes must be ad- justed evenly. Notice do not force to turn the rebound ...
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Preparation 23 *: number of turns counterclockwise usable range 2 turns or more. Std low speed compression damping: for european model 11 clicks (counterclockwise from the fully seated position) for australian model 8 clicks (counterclockwise from the fully seated position) • to adjust the low speed...
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24 preparation rebound damping adjuster settings a. Seated position (adjuster turned fully clockwise) b. Softer (counterclockwise) c. Harder (clockwise) d. Standard setting for european model e. Standard setting for australian model *: number of turns counterclockwise usable range 33 clicks or more....
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Preparation 25 a. Radiator cap • check the coolant level in the radiator. The coolant should come up to the bottom of the radiator filler neck. Note ○ check the coolant level when the engine is cold (room or ambient temperature). A. Coolant level b. Filler neck • if the coolant level is low, add coo...
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26 preparation engine oil level inspection • after you have verified that the engine con- tains oil, start the engine, allow it to idle for several minutes then shut it off. Do not rev the engine and shut it off at high rpm. Doing so can leave a significant amount of oil in the crank room and top en...
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Preparation 27 a. Throttle grip b. 2 ∼ 3 mm (0.08 ∼ 0.12 in.) • run the engine at idle speed and turn the handlebar all the way to the right and left to ensure that the idle speed does not change. If the idle speed increases, check the throttle grip free play and the cable routing. Warning operation...
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28 preparation notice this motorcycle is designed for compe- tition use only. Therefore, the radiator does not incorporate a coolant reserve tank or cooling fan. Prolonged idling of the engine with no airflow through the radiator can cause coolant loss and engine overheating resulting in possible en...
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Preparation 29 this page intentionally left blank..
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30 preparation fastener check • the torque values listed are for assembly and preparation items only, see the appropriate service manual for a more comprehensive list. Check tightness of all fasteners that are in the table before retail delivery. Also check to see that each cotter pin or circlip is ...
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Preparation 31 torque no. Fastener n·m kgf·m ft·lb re- marks steering 1 handlebar clamp bolts 25 2.5 18 2t, al brake 2 front master cylinder clamp bolts 8.8 0.90 78 in·lb s 3 front caliper mounting bolts 25 2.5 18 4 front caliper bleed valve 7.8 0.80 69 in·lb 5 rear master cylinder mounting bolts 9....
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32 preparation standard torque table this table relating tightening torque to thread diameter, lists the basic torque for bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent -cleaned threads. General ...
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Model application year model name 2013 kx450fd kx450f part no. 99939-1344-01.