Kawasaki KX450F (2007) manual

KX450F Motorcycle Service Manual[...]

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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 G[...]

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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 Assu rance Division/Consumer Products & Machinery Company/Kawa[...]

LIST OF ABBREVIA TIONS A ampere(s) lb pound(s) ABDC after bottom dead center m meter(s) AC alternating current min minute(s) AT D C after top dead center N newton(s) BBDC before bottom dead center Pa pascal(s) BDC bottom dead center PS horsepower BTDC before top dead center psi pound(s) per square inch °C degree(s) Celsius r revolution DC direct c[...]

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 repair work. A basic knowledge of mechanics, the proper use of tools, and workshop proce- dures must be[...]

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GENERAL INFORMA TION 1-1 1 General Information T able of Contents Before Servicing ................................................................................................................ ..... 1-2 Model Identification............................................................................................................ ..... 1-7 Gener[...]

1-2 GENERAL INFORMA TION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the preca utions given below . T o facilitate ac tual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever [...]

GENERAL INFORMA TION 1-3 Before Servicing Storage of Removed Parts After all the parts including subassembly parts have been cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly . Inspection Reuse of worn or damaged parts may lead to ser[...]

1-4 GENERAL INFORMA TION Before Servicing Tightening T orq ue Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fasteners to the specified torque using a good quality torque wrench. Often, the tightening sequence is followed twice-initial tightening and final tightening with torque wrench. Force Use common sense [...]

GENERAL INFORMA TION 1-5 Before Servicing Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary . Replace with new ones whenever removed. Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressure on the correct bearing race as shown. Pressin[...]

1-6 GENERAL INFORMA TION Before Servicing Direction of Engine Rota tion When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Ro- tate the crankshaft to positive direction (clockwise viewed from output side). Electrical Leads A two-color lead is identified first by the primary color and then th[...]

GENERAL INFORMA TION 1-7 Model Identification KX450D6F Left Side View KX450D6F Right Side View[...]

1-8 GENERAL INFORMA TION General Specifications Items KX450D6F ∼ D8F Dimensions Overall Length 2 185 mm (86.02 in.) Overall Width 820 mm (32.3 in.) Overall Height 1 280 mm (50.39 in.) Wheelbase 1 485 mm (58.46 in.) Road Clearance 345 mm (13.6 in.) Seat Height 965 mm (38.0 in.) Dry Mass 99.8 kg (220 lb) Fuel T ank Capacity 7.2 L (1.9 US gal) Perfo[...]

GENERAL INFORMA TION 1-9 General Specifications Items KX450D6F ∼ D8F T ransmission: Ty p e 4-speed, constant wesh, return shift (KX450D6F) 5-speed, constant mesh, return shift (KX450D7F ∼ ) Gear ratios: 1st 1.800 (27/15) (KX450D6F), 1.750 (28/16) (KX450D7F ∼ ) 2nd 1.41 1 (24/17) 3rd 1.187 (19/16) 4th 1.000 (19/19) 5th 0.875 (21/24) Final Driv[...]

1-10 GENERAL INFORMA TION Unit Conversion T able Prefixes for Units: Prefix Symbol Power mega M × 1 000 000 kilo k × 1 000 centi c ×0 . 0 1 milli m × 0.001 micro µ × 0.000001 Units of Mass: kg × 2.205 = lb g × 0.03527 = oz Units of V olume: L × 0.2642 = gal (US) L × 0.2200 = gal (imp) L × 1.057 = qt (US) L × 0.8799 = qt (imp) L × 2.1 1[...]

PERIODIC MAINTENANCE 2-1 2 Periodic Maintenance T able of Contents Periodic Maintenance Chart .............. 2-3 T orque and Locking Agent ................. 2-5 Specifications .................................... 2-9 Special T ools ..................................... 2-1 1 Periodic Maintenance Procedures..... 2-12 Fuel System ....................[...]

2-2 PERIODIC MAINTENANCE Steering Adjustment .................... 2-68 Steering Stem Bearing Lubrication................................. 2-70 Frame ............................................. 2-70 Frame Inspection ......................... 2-70 Electrical System ............................ 2-71 Spark Plug Cleaning and Inspection ...............[...]

PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart The maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. FREQUENCY OPERA TIO N Each race or 2.5 hr Every 3 races or 7.5 hr Every 6 races or 15 hr Every 12 races or 30 hr See Page Spark plug-clean, inspect † • 2-71 Spark plug-replace • 2-71 [...]

2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY OPERA TION Each race or 2.5 hr Every 3 races or 7.5 hr Every 6 races or 15 hr Every 12 races or 30 hr See Page Drive chain-lubricate • 2-34 Wheels/tires-inspect • 2-29 Rear sprocket-inspect † • 2-35 Front fork-inspect and clean • 2-45 Front fork oil-change • 2-45 Rear shock a[...]

PERIODIC MAINTENANCE 2-5 T orque and Locking Agent T ighten 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. The following table lists the tightening to que for the major bolts and nuts, and the parts requirin[...]

2-6 PERIODIC MAINTENANCE T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks Cylinder Bolt 12 1.2 104 in·lb S Exhaust Pipe Cover Screws 12 1.2 104 in·lb Exhaust Pipe Holder Nuts 21 2.1 15 Muffler Mounting Bolts 21 2.1 15 Muffler Pipe Mounting Bolts – – – L Engine Right Side Primary Gear Nut 98 10 72 Lh Shift Drum Cam Bolt [...]

PERIODIC MAINTENANCE 2-7 T orque and Locking Agent To r q u e Fastener N·m kgf·m ft·lb Remarks Engine Oil Drain Bolt (M10) (for transmission room oil sump) 20 2.0 15 Engine Oil Drain Bolt (M6) (for crank room oil sump) 7.0 0.71 62 in·lb Bearing Retaining Screw 15 1.5 11 L Gear Set Lever Nut 8.8 0.90 78 in·lb Shift Drum Cam Bol t 24 2.4 17 L Ba[...]

2-8 PERIODIC MAINTENANCE T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks Base V alve Assembly 28 2.9 21 Locknut/Adjuster Assembly 29 3.0 21 Swingarm Pivot Shaft Nut 98 10 72 Rear Shock Absorber Mounting Nuts: (Upper) 39 4.0 29 (Lower) 34 3.5 25 Air Bleed Bolt 6.4 0.65 56 in·lb T ie-Rod Mounting Nut (Front, R ear) (KX450D6F) 8[...]

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 quality foam air filter oil ––– Cooling System Coolant: T ype (recommended) Permanent type antifr[...]

2-10 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Standard T ire: Front : Size 90/100-21 5 7M ––– Make DUNLOP Ty p e D742F , T ube Rear: Size 120/80-19 6 3M ––– Make DUNLOP Ty p e D756, T ube Final Drive Drive Chain Slack 52 ∼ 58 mm (2.0 ∼ 2.3 in.) ––– Drive Chain 20 Link Length 317.5 ∼ 318.2 mm (12.50 ∼[...]

PERIODIC MAINTENANCE 2-1 1 Special T ools Inside Circlip Pl iers: 57001-143 Steering Stem Nu t Wrench: 57001-1 100 Jack: 57001-1238 Spark Plug W rench, Hex 16: 57001-1262 Pilot Screw Adj uster , C: 57001-1292 Pilot Screw Adjus ter Adapter , 4: 57001-1371 Filler Cap Driver: 57001-1454 Pilot Screw Adjust, D: 57001-1588 T o pP l u gW r e n c h ,4 9m m[...]

2-12 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System Fuel Hose and Connections Inspection ○ The fuel hoses are designed to be used throughout the motorcycle’s life without any maintenance, however , if the motorcycle is not properly handled, the inside the fuel line can cause fuel to leak [A] or the hose to burst. • Check the[...]

PERIODIC MAINTENANCE 2-13 Periodic Maintenance Procedures Hot Starter Lever (Hot Starter Cable) Free Play Inspection • Slide the clutch lever dust cover [A] back. • Check the hot starter lever play [B] when pulling the start lever [C] lightly . Hot Starter Lever Free Pl ay Standard: 0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.) If the free play is imprope[...]

2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Check the idle speed, using the engine revolution tester [A] for high accuracy . If the idle speed is out of specified range, adjust it. Idle Speed: Standard: 1 800 ±50 r/min (rpm) Idle Speed Adjustment • First, turn in the air screw using the pilot screw adjuster [A], until it seats [...]

PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures • Remove: Seat (see Seat Removal in the Frame chapter) Wing Bolt [A] Air Cleaner Element [B] • Stuff a clean, lint-free towel into the carburetor so no dirt is allowed to enter the carburetor . • Wipe out the inside of the air cleaner ho using with a clean damp towel. CAUTION Check ins[...]

2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Apply grease to all connections and screw holes in the air cleaner housing and intake tract. • Install the element onto its frame, and coat the element lip and lip seat with a thick layer of all-purpose grease to assure a complete seal. • Install the air cleaner element so that its t[...]

PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures Fuel T ank, Filter and T ap Cleaning WA R N I N G Clean the fuel tank in a well-ventilated area, and take care that there is no sparks or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or low flash-point solvent to clean the tank.[...]

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 ground so that the radiator cap is located uppermost in order to exhaust the air accumulated in the r[...]

PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures Coolant Deterioration Inspection • Visually inspect the coolant. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. In either case, flush the cooling system. If the coolant gives off an abn[...]

2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures • First, bring the piston to the top-dead-center of its com- pression stroke to inspect the valve clearance (the posi- tion at the end of the compression stroke), when the cam lobe faces outside of the camshaft. ○ Place a wrench over the balancer weight nut and turn it counterclockwise t[...]

PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures • Clean the shim to remove any dust or oil. • Measure the thickness of the removed shim [A]. • Select a new shim thickness calculation as follows. A=( B–C )+D [A] Replace Shim Thickness [B] Measured V alve Clearance [C] Specified V alve Clearance [D] Present Shim Thickness Example (0[...]

2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures • When installing the shim, face the marked side [A] toward the valve lifter [B]. At this time, apply engine oil to the shim or the valve lifter to keep the shim in place during camshaft installation. CAUTION Do not put shim stock under the shim. This may cause the shim to pop out at high [...]

PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures Cylinder Wear Inspection NOTE ○ Measure the cylinder inside diameter when the cylinder is cold (room or ambient temperature). • Visually Inspect the inside of the cylinder for scratches and abnormal wear . If the cylinder is damaged or badly worn, replace it with a new one. • Since the[...]

2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Exhaust System Inspection • The exhaust system, in particular the muffler body , is de- signed to reduce exhaust noise and conduct the exhaust gases away from the rider while minimizing power loss. If carbon has built up inside the muffler body , exhaust effi- ciency is reduced, causing en[...]

PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures • Apply silicone sealant to the circumference [A] of the inner pipe. • Install the muffler (see Muffler Installatio n in the Engine T op End chapter). Engine Right Side WA R N I N G T o avoid a serious burn, never touch the hot engine or exhaust chamber during clutch adjustment. Clutch L[...]

2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures • If it cannot be done, loosen the locknut [A] at the middle of the clutch cable, and turn the adjusting nut [B] so that the clutch lever has 8 ∼ 13 mm (0.3 ∼ 0.5 in.) of play . • After the adjustment is made, tighten the locknut, and start the engine and check that the clutch does n[...]

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 (for transmission room oil sump) [A] Drain Plug (for crank oil sump) [B] NOTE ○ Hold the motorcycle upright so that the oil may drain completely . • Replace the gaskets at the[...]

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 shown. CAUTION Inside out installation stop oil flow , causing engine seizure. • Replace the oil f[...]

PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Crankshaft/T ransmission Crankshaft Inspection Connecting Rod Big End Side Clearance • Remove the cylinder head (see Cylinder Head Removal in the Engine T op End chapter). • Remove the cylinder (see Cylinder Removal in the Engine T op End chapter). • Remove the piston (see Piston Remov[...]

2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Tire s In sp ec ti on 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. • Visually inspect the tire for cracks and cuts, replacing the tire in case of bad damage. Swelling or[...]

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 T ool - Jack: 57001-1238 • Inspect the rim for small cracks, dents, bending, or warp- ing. If there is any damage to the rim, it must be rep laced. • Set a dial gauge against the[...]

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 wheel alignment (see Wheel Alignment In spec- tion in the Final Drive chapter), and adjust it if ne[...]

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 within 30 degree. ○ Loosen once and tighten again when the slot goes past the nearest hole. WA R N I[...]

2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures WA R N I N G If the drive chain wear exceeds the service limit, re- place the chain or an unsafe riding condition may result. A chain that breaks or jumps off the sprock- ets could snag on the engine sprocket or lock the rear wheel, severely damaging the motorcycle and causing it to go out o[...]

PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures Rear Sprocket Warp (Runout) Inspection • Using the jack, raise the rear wheel off the ground. Special T ool - Jack: 57001-1238 • Set a dial gauge [A] against the rear sprocket [B] near the teeth as shown and rotate [C] the rear wheel to measure the sprocket runout (warp). The difference [...]

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] W asher Joint Pin [C] ○ T urn the U link [D] to obtain the specified length. ○ T ighten the locknut. T orque - Rear Ma ster Cylinde r Push Rod Locknut: 17 N·m (1.7 kgf·m, 13 ft·l[...]

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, the brake fluid should be changed to bleed the air quickly and completely whenever the brake line [...]

2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTE ○ The procedure to change the front brake fluid is as fol- lows.Changing the rear brake fluid is the same as for the front brake. • Level the brake fluid reservoir . • Remove the screws [A], reservoir cap [B] and diaphragm [C]. • Remove the rubber cap [A] on the bleed valve [B].[...]

PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures • Remove the clear plastic hose. • T ighten the bleed valves, and install the rubber caps. T orque - Cal iper Bleed V alve: 7.8 N·m (0. 80 kgf·m, 69 in·l b) Brake Reservoir Cap Screws: 1.5 N·m (0.15 kgf·m, 13 in·lb) • After changing the fluid, check the brake for good braking pow[...]

2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures CAUTION 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 not remove the push rod clevis for master cylinder disassembly since removal requires brake pedal [...]

PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures Brake Caliper Fluid 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 [E] Front Caliper [D] (see Front Caliper Removal in the Brakes chapter) Brake Pads (see Brake [...]

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 [A]. • Using compressed air , remove the piston. ○ Cover the caliper opening with a clean, heav[...]

PERIODIC MAINTENANCE 2-43 Periodic Maintenance Procedures • Install the anti-rattle spring [A] in the caliper as shown. • Replace the shaft rubber boot [A] and dust boot [B] if they are damaged. • Apply a thin coat of PBC (Poly Butyl Cuprysil) grease to the caliper holder shafts [C] and holder holes (PBC is a special high temperature, water-r[...]

2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hoses and Connections Inspec tion • 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] or the hose to burst if the line is not properly main- tained. Bend and twist the rubber hos[...]

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 according to Cable, Wire, and Hose Routing section in the Appendix chapter . • T ighten the banjo bolts [...]

2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Loosen the fork top plug [A]. Special T ool - T op Plug Wrench, 49 mm: 57001-1653 [B] • Remove: Front Wheel (see Front Wheel Removal in the Wheels/T ires chapter) Front Brake Caliper (see Caliper Removal in the Brakes chapter) Brake Hose Clamps (see Brake Hose Replacement) • Loosen t[...]

PERIODIC MAINTENANCE 2-47 Periodic Maintenance Procedures • Place a oil 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 t emporarily install the fork top plug [A] (subtank) to the outer tube [B] with the top plug wrench [C]. Special T ool - T op Plu[...]

2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove the push rod [A]. • With the outer tube compressed by hands, remove the t o pp l u gw r e n c h[ A ] . CAUTION Removing the locknut and pushing the piston rod thread into the cylinder unit will damage the oil seal. Do not remove the locknut from the piston rod. • Remove the fo[...]

PERIODIC MAINTENANCE 2-49 Periodic Maintenance Procedures • Remove the base valve assembly [A] from the subtank [B]. NOTE ○ Slowly compress the piston rod until it stops so that the base valve assembly can be removed easily . CAUTION Disassembling the base valve assembly can lea d to trouble. Do not disassemble the base valve assembly . • Dra[...]

2-50 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Pump [A] the piston rod [B] slowly several times to expel air . • Replace the O-rings [A] on the base valve assembly with new ones. • Apply specified fork oil to the O-rings [A] [B] and bushings [C] on the base valve assembly . • With the piston rod held immovable in fully compress[...]

PERIODIC MAINTENANCE 2-51 Periodic Maintenance Procedures • Protect the piston rod end [A] with a rag [B] to prevent fork damage. • Discharge the extra oil of f the cylinder unit by pumping [C] the piston rod to full stroke. CAUTION Be careful not to bend or damage the piston rod when the piston rod is stroked. Service carefully because oil fil[...]

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. • T emporarily tighten the fork top plug [A] (subtank) using the top plug wrench. Special T ool - T op Plug Wrench, 49 mm: 57001-1653 [B] • Clamp the[...]

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. • Slowly turn the adjuster assembly [A] clockwise until re- sistance is felt and check the clearance betwee n the lock- nut [B] and adjuster assembly to provide more than 1 [...]

2-54 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Raise the outer tube and tempo rarily tighten the fork top plug (subtank). Special T ool - T op Plug Wrench, 49 mm: 57001-1653 [B] • After installing the front fork, torque the top plug [A]. Special T ool - T op Plug Wrench, 49 mm: 57001-1653 The torque of fork top plug is specified to[...]

PERIODIC MAINTENANCE 2-55 Periodic Maintenance Procedures • Loosen the front fork lower clamp bolts [A]. • Remove the front fork. ○ With a twisting motion, work the fork leg [B] down and out. NOTE ○ Set rebound and compression damping setting to the softest settings before disassembling to prevent the needle of adjusters from damaging. Reco[...]

2-56 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Raise the outer tube and temporarily install the fork top plug [A] (subtank) to the outer tube [B] with the top plug wrench [C]. Special T ool - T op Plug Wrench, 49 mm: 57001-1653 • Hold the axle holder [A] with a vise. ○ Protect the axle holder with a rag when using a vise. • Loo[...]

PERIODIC MAINTENANCE 2-57 Periodic Maintenance Procedures • With the outer tube compressed by hands, remove the t o pp l u gw r e n c h[ A ] . CAUTION Removing the locknut and pushing the piston rod thread into the cylinder unit will damage the oil seal. Do not remove the locknut from the piston rod. • Remove the fork leg from the vise. • Loo[...]

2-58 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Drain the fork oil [A] from the cylinder unit [B] by pumping the piston rod several times. • Hold the front fork inverted position for more than 20 min- utes to allow the fork oil to fully drain. • Clean the threads [A] of subtank and base valve assem- bly . • With the piston rod i[...]

PERIODIC MAINTENANCE 2-59 Periodic Maintenance Procedures • Replace the O-rings [A] on the base valve assembly with new ones. • Apply specified fork oil to the O-rings [A] [B] and bushings [C] on the base valve assembly . • With the piston rod held immovable in fully compressed position [A], gently install the base valve assembly [B] to the s[...]

2-60 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Drain the extra oil from the subtank oil hole [A]. • With the cylinder unit in horizontal position, move [A] the piston rod [B] by hand to inspect it if operating smoothly . ○ If the piston rod is not extend, remove the b ase valve assembly and perform the air bleeding (pour the spec[...]

PERIODIC MAINTENANCE 2-61 Periodic Maintenance Procedures • Clamp the axle holder with a vise. ○ Protect the axle holder with a rag when using a vise. WA R N I N G Clamping the axle holder too tight can damage it which will affect riding stability . Do not clamp the axle holder too tight. • Compress the outer tube by hands and install the top[...]

2-62 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Apply a non-permanent locking agent to the threads of a adjuster assembly . • T orque the adjuster assembly [A]. T orque - Adjuste r Assembly: 58 N·m (5.9 kgf·m, 43 ft·lb) • Loosen and remove the fork top plug (subtank) from the outer tube and slowly slide down the outer tube. Spe[...]

PERIODIC MAINTENANCE 2-63 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 chapter). • Check for a broken or collapsed spring. • Check the shock for a bent shaft or oil leaks.[...]

2-64 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Using the suitable tool [A] and press, push the reservoir c a p[ B ]i n1 0m m( 0 . 3 9i n . ) . • Remove the circlip [C] from the gas reservoir . • Pull the gas reservoir cap [B] out of the gas reservoir using the pliers [A]. • Pry or tap [A] at the gaps [B] in the stop [C] with su[...]

PERIODIC MAINTENANCE 2-65 Periodic Maintenance Procedures • Using the grinder , shave of f the stop portion [A] of the rod. • Remove: Nut [B] W asher [C] Piston [D] • Install the new piston and tighten the locknut. ○ Discard a washer or two. • Pour KYB K2-C (SAE 5W or Bel-Ray SE2 #40) oil into the gas reservoir to 60 ∼ 70 mm (2.63 ∼ 2[...]

2-66 PERIODIC MAINTENANCE 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 reservoir [C]. WA R N I N G If the end of the gas reservoir cap and the end of the gas reservoir a[...]

PERIODIC MAINTENANCE 2-67 Periodic Maintenance Procedures • Push the seal assembly into the rear shock body until it just clears the circlip groove. • Check the circlip. If it is deformed or damaged, replace it with a new one. • Fit the circlip [A] into the groove in the rear shock body [B]. CAUTION If the circlip is not a certain fit in the [...]

2-68 PERIODIC MAINTENANCE Periodic Maintenance Procedures Swingarm and Uni-T rak 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 rear wheel off the ground. Special T ool - Jack: 57001-1238 • Push and pull on the swingarm [A], u[...]

PERIODIC MAINTENANCE 2-69 Periodic Maintenance Procedures • Slide the holder belt [A] out of f. • Remove number plate bolt [B] and number plate [C]. • Remove the handlebar p ad [D]. • Remove: Handlebar Holder Bolts [A] Handlebar Holders (upper) [B] Handlebar [C] • Loosen the front fork upper clamp bolts [A], and remove the steering stem h[...]

2-70 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Install the handlebar [B] on the handlebar holder (lower) so that the protruded scales of the both side adjust to the same width [A]. • Apply 2-stroke oil to the threads of the handle bar holder bolts. • Install the handlebar holder (upper) so that center [D] of the handlebar holder [...]

PERIODIC MAINTENANCE 2-71 Periodic Maintenance Procedures Electrical System Spark Plug Cleaning and Insp ection • Remove: Seat (see Seat Removal in the Frame chapter) Fuel T ank (see Fuel T ank Removal in the Fuel System chapter) Spark Plug Cap • Clean the plug hole [A], using the compressed air [B]. • Remove the spark plug [A], using the spa[...]

2-72 PERIODIC MAINTENANCE Periodic Maintenance Procedures General Lubrication and Cable Inspection General Lubrication • Before lubricating each part, clean off any rusty spots with rust remover and wipe of f any grease, oil, dirt, or grime. • Lubricate the points listed below with indicated lubricant. NOTE ○ Whenever the vehicle has been ope[...]

PERIODIC MAINTENANCE 2-73 Periodic Maintenance Procedures Cable Inspection • With the cable disconnected at the both ends, the cable should move freely [A] within the cable housing. If cable movement is not free after lubricating, if the cable is frayed [B], or if the cable housing is kinked [C], replace the cable. Nut, Bolt, and F astener Tightn[...]

2-74 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brakes: Front Master Cylinder Clamp Bolts Brake Lever Pivot Nut Front Caliper Mounting Bolts Brake Pedal Mounting Bolt Rear Master Cylinder Push Rod Cotter Pin Rear Master Cylinder Mounting Bolts Rear Caliper Holder Shaft Suspension: Front Fork Clamp Bolts Rear Shock Absorber Mounting Bolts,[...]

FUEL SYSTEM 3-1 3 Fuel System T able of Contents Exploded View ................................................................................................................... ..... 3-2 Specifications ................................................................................................................. ........ 3-6 Special T ool .....[...]

3-2 FUEL SYST EM Exploded View[...]

FUEL SYSTEM 3-3 Exploded View T orque 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 S tarter Cable 4. Throttle Cables 5. Throttle Grip 6. Carburetor Cap 7. Throttle V alve Plate 8. Throttle V alve 9. Jet Needle 10. Throttle P ulley Shaft 1 1. Choke K[...]

3-4 FUEL SYST EM Exploded View[...]

FUEL SYSTEM 3-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Rear Frame Mounting Bolts 34 3.5 25 2 Air Cleaner Duct Clamp Screw 2.0 0.20 17 in·lb 3 Air Cleaner Duct Mounting Nuts 3.0 0.31 27 in·lb 4 Air Cleaner Duct Mounting Bolt 3.0 0.31 27 in·lb 5 Air Cleaner Housing Bolts 9.8 1.0 87 in·lb 6. Fuel T ank Cap 7. Fuel T ank 8.[...]

3-6 FUEL SYST EM 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/T ype KEIHIN FCR40 Starter Jet #72 Leak Jet #70 Main Jet #175 Throttle V alve Cutaway CA1.5 Jet Needle NCVR Jet Needle Clip Position 4th groove fr[...]

FUEL SYSTEM 3-7 Special T ool Fuel Level Gauge, M18 × 1.0: 57001-122[...]

3-8 FUEL SYST EM 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, if the throttle grip has no play , the throttle will be hard to control, and the idle speed will b[...]

FUEL SYSTEM 3-9 Throttle Grip and Cable • Remove the rear frame assy (see Rear Frame R emoval in the Frame chapter). • Remove the carburetor . • Unscrew the bolt [A]. • Remove the throttle pulley cover [B]. • Loosen the mounting bolts [A]. • Remove the cables [B] from the carburetor . • Free the tips [C] from the pulley . • Pull out[...]

3-10 FUEL SYSTEM Throttle Grip and Cable Hot Starter Cable Removal • Remove: Dust Cover [A] (Slide out) Locknut [B] (Loosen) • T urn in the adjuster [C] fully . • Remove the cable end [D] from the hot starter lever [E]. • Remove: Carburetor (see Carburetor Removal) • Unscrew the plunger cap bolt [A] and remove the cable end. • Disassemb[...]

FUEL SYSTEM 3-1 1 Throttle Grip and Cable Hot Starter Lever (Hot Starter Cable) Free Play Adjustment • Refer to the Hot Starter Lever (Hot Starter Cable) Free Play Inspection in the Periodic Maintenance chapter . Hot Starter Cable Lubrication • Whenever the hot starter cable is removed or in accor- dance with the Periodic Maintenance Chart, lub[...]

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 can be caused by dirt, wear , maladjustment, or improper fuel level in the float chamber . A dirty [...]

FUEL SYSTEM 3-13 Carburetor • Read the fuel level [D] in the gauge and compare it to the specification. Service Fuel Level (below the botto m edge of the carb. body) Standard: 6 .5 ±1 mm (0.256 ±0 .039 in.) If the fuel level is incorrect, adjust it. • T u rn the fuel tap to the OFF position and remove the fuel level gauge. • Install the dra[...]

3-14 FUEL SYSTEM Carburetor • Bend the tang [A] on the float arm very slightly to change the float height. Increasing the float height lowers the fuel level and decreasing the float height raises the fuel level. Float Height Standard: 8 ±1 mm (0.315 ±0.039 in.) NOTE ○ Float height [A] is the distance from the float bowl mat- ing surface [B] o[...]

FUEL SYSTEM 3-15 Carburetor • Remove the fuel tank (see Fuel T ank Removal). • Disconnect the throttle sensor connector [A]. • Loosen the clamp screws [A] of both carbu retor holder and air cleaner duct fully . • Remove: Engine Mounting Bracket Bolts [B] Engine Mounting Bracket [C] • Remove: Seat (see Seat Removal in the Frame chapter) Si[...]

3-16 FUEL SYSTEM Carburetor • Loosen the throttle cable mounting bolts [A]. • Pull out the end of the throt tle cables [B]. • Free the tips [C]. • Remove the carburetor to the right side of the frame. • Drain the fuel from the float bowl by removing the drain plug. After draining, install the drain plug securely . • After removing the c[...]

FUEL SYSTEM 3-17 Carburetor ○ Adjust the following items if necessary: Throttle Cable (see Throttle Grip (Throttle Cable) Free Play Adjustment in the Periodic Maintenance chapter) Idle Speed (see Idle Speed Adjustment in the Periodic Maintenance chapter) Fuel System Cleaning • Refer to the Fuel System Cleaning in the Periodic Main- tenance chap[...]

3-18 FUEL SYSTEM Carburetor • Disassemble the throttle valve assembly; jet needle holder [A] (unscrew), spring [B], retainer [C], jet needle with circlip [D], O-ring with throttle valve plate [E], and throttle valve [F]. • Remove the choke knob/starter plunger assembly [A] from the carburetor . • Remove the throttle pulley shaft [A] with the [...]

FUEL SYSTEM 3-19 Carburetor • Unscrew the screws [A]. • Remove the acceleration pump cover [B] from the carbu- retor . • Remove the spring [A], diaphragm [B], and the O-rings [C]. • Remove the following parts from the carburetor body . [A] Idle Adjusting Screw [B] Screws [C] Clamps [D] Float Bowl [E] Leak Jet [F] O-ring [G] Pin [H] Float [I[...]

3-20 FUEL SYSTEM Carburetor • Unscrew the leak jet [A]. • Remove: E-clip [A] W asher [B] • Pull out the acceleration pump lever assembly [C] as a set. • Remove the throttle sensor mounting bolt [A]. • Before removing the throttle sensor [B], mark [C] the car- buretor body and sensor so that it can be installed later in the same position.[...]

FUEL SYSTEM 3-21 Carburetor Carburetor Cleaning WA R N I N G Clean the carburetor in a well-ventilated area, and take care that there is no spark or flame anywhere near the working area; this includes any appliance with a pilot light. Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvent to clean the carb[...]

3-22 FUEL SYSTEM Carburetor • Remove the carburetor (see Carburetor Removal). • Before disassembling the carburetor , check the fuel level (see Service Fuel Level Inspection). If the fuel level is incorrect, inspect th e rest of the carbu- retor before correcting it. • T urn the throttle pulley to check that the throttle valve [A] moves smoot[...]

FUEL SYSTEM 3-23 Carburetor Carburetor Assembly • Clean the disassembly parts before assembling. ○ Clean the fuel and air passages with a high-flash point solvent and compressed air [A]. • Set up the acceleration pump lever assembly as shown. Acceleration pump lever [A] Spring [B] Push Rod Holder [C] Adjusting Screw with Spring [D] ○ Fit th[...]

3-24 FUEL SYSTEM Carburetor • Apply thin coat silicone grease to the shaft. • Fit the hook [A] of the return spring onto the stopper [B] of the throttle cable pulley . • Insert the throttle cable pulley shaft [A] and install the steel washer [B], nylon washer [C] and valve link [D]. ○ Fit the end [A] of the return spring into the recess [B][...]

FUEL SYSTEM 3-25 Carburetor • Assembly: Throttle V alve [A] Jet Needle [B] Circlip [C] Retainer [D] Spring [E] Jet Needle Holder [F] O-ring [G] Throttle V alve Plate [H] ○ Assemble the valve plate so that the hole side downward [I]. • Apply a non-permanent locking agent to the link screw . • Insert the throttle valve assembly . ○ Insert t[...]

3-26 FUEL SYSTEM Carburetor • Replace the O-ring with new one. • Install: Pilot Air Screw [A] Spring [B] W asher [C] O-ring [D] ○ T urn in the pilot air screw fully but not tightly , and the back it out the counted number of turn (see Carburetor Disassembly). • Hang the float valve [A] on the tang [B] of the float [C]. • Fit the float val[...]

FUEL SYSTEM 3-27 Carburetor • Install the choke knob/starter plunger [A]. • Replace the O-rings [A] with th e new ones. • Install the fuel hose fitting [B]. • T ighten the screws. • Install all hoses [A]. • Install the carburetor (see Carburetor Installation). If turn the adjusting screw of the acceleration pump, follow the procedure be[...]

3-28 FUEL SYSTEM Air Cleaner Air Cleaner Housin g Removal • Remove: Side Covers (see Side Cover Removal in the Frame chapter) Seat (see Seat Removal in the Frame chapter) Muffler (see Muffler Removal in the Engine T op End chapter) Rear Fender [A] (see Rear Fender Removal in the Frame chapter) Rear Frame Bolts [B] • Loosen the air cleaner duct [...]

FUEL SYSTEM 3-29 Air Cleaner Element Installation • When installing the element, coat the lip of the element with a thick layer of all purpose grease [A] to assure a complete seal against the air cleaner element base. Also, coat the base where the lip of the element fits. • Apply grease to all connections and screw hole s in the air cleaner hou[...]

3-30 FUEL SYSTEM Fuel T ank Fuel T ank Removal WA R N I N G Gasoline is extremely flammable and can be ex- plosive under certain conditions. Always stop the engine and do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. • T urn the fuel tap l ever [A] to [...]

FUEL SYSTEM 3-31 Fuel T ank Fuel T ank, Filter and T ap Cleaning • Refer to the Fuel T ank, Filter and T ap Cleaning in the Periodic Maintenance chapter . Fuel T ap an d Filter Inspection • Refer to the Fuel T ap and Filter Inspection in the Periodic Maintenance chapter .[...]

[...]

COOLING SYSTEM 4-1 4 Cooling System T able of Contents Exploded View ................................................................................................................... ..... 4-2 Specifications ................................................................................................................. ........ 4-4 Special T ool[...]

4-2 COOLING SYSTEM Exploded View[...]

COOLING SYSTEM 4-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 W ater Pump Cover Bolts 9.8 1.0 87 in·lb 2 Coolant Drain Bolt 6.9 0.70 61 in·lb 3 W a t e rP u m pI m p e l l e rB o l t 9.8 1.0 87 in·lb 4 Right Engine Cover Bolts 9.8 1.0 87 in·lb 5 Wa t e r H o s e C l a m p S c r e w s 1.5 0.15 13 in·lb 6 Radiator Mounting B[...]

4-4 COOLING SYSTEM Specifications Item Service Limit Coolant Ty p e Permanent type antifreeze for aluminum engines and radiators Color Green Mixed Ratio Soft water 50%, antifreeze 50% Freezing Point -35°C (-31°F) T otal Amount 1.05 L (1.1 1 US qt.) Radiator Cap Relief Pressure 11 2 ∼ 142 kPa (1.14 ∼ 1.45 kgf/cm², 16.2 ∼ 20.6 psi)[...]

COOLING SYSTEM 4-5 Special T ool Bearing Driv er Set: 57001-1 129[...]

4-6 COOLING SYSTEM Coolant Check the coolant level each day before riding the motor- cycle, and replenish coolant if the level is low . Change the coolant in accordance with the Periodic Maintenance C hart (see Periodic Maintenance chapter). WA R N I N G T o avoid burns, do not remove the radiator cap or try to inspect the coolant level or change t[...]

COOLING SYSTEM 4-7 Coolant Coolant Filling CAUTION Use coolant containing corrosion inhibitors made specifically for aluminum engines and radiators in accordance with the instruction of the manufac- ture’ s. Soft or distilled water must be used with the antifreeze (see below for antifreeze) in the cooling system. If hard water is used in the syst[...]

4-8 COOLING SYSTEM Coolant Cooling System Pressure T esting CAUTION During pressure testing, do not exceed the pres- sure for which the system is designed to work. The maximum pressure is 123 kPa (1.25 kgf/cm², 18 psi). • Remove the radiator cap, and install a cooling system pressure tester [A] and adapter [B] on the radiator filler neck [C]. NO[...]

COOLING SYSTEM 4-9 Wa t e r P u m p Water Pump Cover Removal • Unscrew the drain bolt [A], and d rain the coolant (see Coolant Draining). • Loosen the clamp screw [B], and remove the water hose [C] from the water pump cover . • Unscrew the cover bolts [D]. • Using the pry points [A], remove the pump cover [B]. Water Pump Cover Installation [...]

4-10 COOLING SYSTEM Wa t e r P u m p Impeller Removal • Drain: Coolant (see Coolant Draining) • Remove: W ater Pump Cover (see Water Pump Cover Removal) Impeller Bolt [A] Impeller [B] Impeller Installation • Install: Impeller [A] • T ighten: T o rque - Water Pump Im peller Bolt [B]: 9 .8 N·m (1.0 kgf ·m, 87 in·lb) • Install: W ater Pum[...]

COOLING SYSTEM 4-1 1 Wa t e r P u m p • Insert a bar [A] into the water pump shaft hole from the outside of the right engine cove r , and remove the ball bearing [B] by tapping [C] evenly around the bearing in- ner race. • Remove the spacer [D]. • Remove the ball bearing [E] and oil seal [F] from the right engine cover in the same way as ball[...]

4-12 COOLING SYSTEM Radiator Radiator Removal • Drain the coolant (see Coolant Draining) • Remove: Radiator Shrouds • Loosen: Clamp Screws [A] Clamp [B] • Remove: W ater Hoses [C] Bolts [D] Left Radiator Screen [E] • Unscrew the radiator mounting bolts [A]. • Remove the left radiator [B]. • Loosen: Clamp Screws [A] • Remove: Radiato[...]

COOLING SYSTEM 4-13 Radiator Radiator Installation • Fit the projections [A] of the screen in the holes [B] of the radiator . T o rque - Water Hose Clamp Scre ws: 1.5 N·m (0.1 5 kgf·m, 13 in·lb) Radiator Mounting Bolts: 9.8 N·m (1.0 kgf·m, 8 7 in·lb) Radiator Scre en Bolts: 9 .8 N·m (1.0 kgf ·m, 8 7 in·lb) Radiator Shroud Bolts: 9.8 N·m[...]

4-14 COOLING SYSTEM Radiator • Wet the top and bottom valve seals with water or coolant to prevent pressure leaks. • Install the cap [A] on a cooling system pressure tester [B]. • W atching the pressure gauge, slowly pump the pressure tester to build up the pressure. The gauge hand must remain within the relief pressure range in the table bel[...]

ENGINE TOP END 5-1 5 Engine T op End T able of Contents Exploded View ................................... 5-2 Specifications .................................... 5-6 Special T ools and Sealant ................. 5-9 Cylinder Head Cover ......................... 5-12 Cylinder Head Cover Removal .... 5-12 Cylinder Head Cover Installation . 5-12 Camsha[...]

5-2 ENGINE TOP END Exploded View[...]

ENGINE TOP END 5-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Cylinder Head Cover Bolts 9.8 1.0 87 in·lb 2 Cylinder Head Bolts (M10) 59 6.0 44 S, MO 3 Cylinder Head Bolts (M6) 12 1.2 104 in·lb S 4 Cylinder Bolt 12 1.2 104 in·lb 5 Camshaft Cap Bolts 9.8 1.0 87 in·lb S, MO 6 Camshaft Sprocket Bolts 12 1.2 104 in·lb L 7 Carbu[...]

5-4 ENGINE TOP END Exploded View[...]

ENGINE TOP END 5-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Exhaust Pipe Cover Bolts 12 1.2 104 in·lb 2 Exhaust Pipe Holder Nuts 21 2.1 15 3 Muffler Mounting Bolts 21 2.1 15 4 Cylinder Bolt 12 1.2 104 in·lb S 5 Muffler Pipe Mounting Bolts – – – L 6. T op Ring 7. Oil Ring 8. Circle Mark 9. KX450D6F ∼ D7F EO: Apply en[...]

5-6 ENGINE TOP END Specifications Item Standard Service Limit Camshafts Cam Height: Exhaust 36.943 ∼ 37.057 mm (1.4544 ∼ 1.4589 in.) 36.84 mm (1.450 in.) Inlet 37.743 ∼ 37.857 mm (1.4859 ∼ 1.4904 in.) 37.64 mm (1.482 in.) Camshaft Journal Clearance 0.020 ∼ 0.062 mm (0.00079 ∼ 0.0024 in.) 0.15 mm (0.0059 in.) Camshaft Journal Diameter 22[...]

ENGINE TOP END 5-7 Specifications Item Standard Service Limit Cylinder and Pistons Cylinder Inside Diameter 96.000 ∼ 96.012 mm (3.7795 ∼ 3.7800 in.) 96.10 mm (3.783 in.) Piston Diameter 95.970 ∼ 95.980 mm (3.7783 ∼ 3.7787 in.) 95.82 mm (3.772 in.) Piston/Cylinder Clearance 0.020 ∼ 0.042 mm (0.00079 ∼ 0.0016 in.) ––– Piston Ring/Ri[...]

5-8 ENGINE TOP END Specifications Cam Height Cam Height [A] Camshaft Runout V alve Stem Diameter V alve Stem Diameter [A] 45° [B] Va l v e S t e m B e n d Dial Gauge [A][...]

ENGINE TOP END 5-9 Special T ools and Sealant Compression Gauge, 20 kgf/c m²: 57001-221 V alve Spring Compressor Assembly: 57001-241 V alve Guide Arbor , 5.5: 57001-1021 V alve Guide Reamer , 5.5: 57001-1079 Piston Ring Co mpressor Grip: 57001-1095 V alve S eat Cu tter , 45 ° - 35: 57001-1 1 16 V alve S eat Cu tter , 32 ° - 35: 57001-1 121 V alv[...]

5-10 ENGINE TOP END Special T ools and Sealant V alve Seat Cutter , 55° - 35 : 57001-124 7 S p a r kP l u gW r e n c h ,H e x1 6 : 57001-126 2 Compression Gauge Adapter , M10 × 1.0: 57001-131 7 Piston Ring Compresso r Belt, 95 ∼ 108: 57001-135 8 Filler Cap Dr iver: 57001-145 4 Va l v e S e a t C u t t e r, 4 5 ° - 40: 57001-1496 V alve Seat Cu[...]

ENGINE T OP END 5-1 1 Special T ools and Sealant V alve Guide Driver At tachment D: 57001-1659 Kawasaki Bond (Silicone Seal ant): 92104-0004[...]

5-12 ENGINE TOP END Cylinder Head Cover Cylinder Head Cover Re moval • Remove: Fuel T ank (see Fuel T ank Removal in the Fuel System chapter) Spark Plug Cap • Remove the cylinder head cover bolts [A] and remove the cylinder head cover [B]. Cylinder Head Cover Installation • Apply silicon sealant [A] to th e cylinder head as shown. Sealant - K[...]

ENGINE T OP END 5-13 Camshaft Chain T ensioner Camshaft Chain T ensioner Removal CAUTION This is a non-return type camshaft chain tensioner . 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 on[...]

5-14 ENGINE TOP END Camshaft Chain T ensioner • Replace the chain tensioner gasket with a new one. • T ighten: T orque - Chain T ensioner Mounting Bolts [A]: 9.8 N·m (1.0 kgf·m, 87 in·lb) • T ake out the holder plate [B]. • Install the O-ring and tighten the cap bolt. T orque - Chain T ensioner Cap Bolt: 5.0 N·m (0.51 kgf·m, 44 in·lb)[...]

ENGINE T OP END 5-15 Camshaft Camshaft Removal • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) T iming Inspection Plug [A] Balancer Shaft Plug [B] Special T ool - Filler Cap Driver: 57001-1454 • First, bring the piston to the TDC (of either the compres- sion or exhaust stroke). ○ Place a wrench over the balancer weight nut a[...]

5-16 ENGINE TOP END Camshaft • Remove: Bolt [A] Auto-Decompressor [B] (with the sprocket) • Remove: Circlips [A] Camshaft Installation • Assemble the auto-decompressor weights [A] and spring [B] to install it to the sprocket [C]. • Replace the circlips [D] with new ones, and install them. • Apply a non-permanent locking agent to camshaft [...]

ENGINE T OP END 5-17 Camshaft • Engage the camshaft chain with the camshaft sprockets. ○ Pull the tension side (exhaust side) of the chain taut to install the chain. ○ The timing marks on the sprocket must be aligned with the cylinder head upper surface. • Pull the chain taut and fit it onto the camshaft sprocket. • Starting with the timi[...]

5-18 ENGINE TOP END Camshaft • Apply grease to the rubber portions of the oil pipes. • Assemble: Camshaft Caps [A] Oil Pipes [B] • While keeping the camshaft caps parallel, install them. • Uniformly tighten all bolts and after the camshaft has set- tled, uniformly tighten all the bolts. ○ Following the sequence numbers on the camsh aft ca[...]

ENGINE T OP END 5-19 Camshaft Camshaft and Camshaft Cap Wear Inspection • Measure each clearance between the camshaft journal and camshaft cap using plastigauge (press gauge) [A]. • Install the camshaft caps (see Camshaft Installation) NOTE ○ Do not turn the camshaft when the plastigauge is be- tween the journal and camshaft cap. If any clear[...]

5-20 ENGINE TOP END Cylinder Head Cylinder Compression Measurement • Start the engine. • Thoroughly warm up the engine so that the engine oil be- tween the piston and cylinder wall will help seal compres- sion as it does during normal running. • Stop the engine. • Remove: Fuel T ank (see Fuel T ank Removal in the Fuel System chapter) • Re[...]

ENGINE T OP END 5-21 Cylinder Head Problem Diagnosis Remedy (Action) Carbon accumulation on piston and in cylinder head (combustion chamber) is suspected due to damaged valve stem or piston oil rings. Remove the carbon deposits and replace damaged parts if necessary . The cylinder compression is higher than the usable range Incorrect cylinder head [...]

5-22 ENGINE TOP END Cylinder Head • Remove the 10 mm cylinder head bolts following the tight- ening sequence as shown. • T ap lightly up with a plastic mallet [A] to separate the cylin- der head [B] from the cylinder . • Remove the cylinder head gasket. Cylinder Head Installation • Fit the projection [A] of the front camshaft chain guide [B[...]

ENGINE T OP END 5-23 Cylinder Head • T ighten the 10 mm cylinder head bolts in the numbered sequence [1 ∼ 4]. T orque - Cylinder Head Bol ts (M10): 59 N·m (6.0 kgf· m, 44 ft·lb) • T ighten: T orque - Cylind er Bolt [A]: 12 N·m (1.2 kgf·m, 104 in·lb) Cylinder H ead Bolts (M6) [B ]: 12 N·m (1 .2 kgf·m, 104 in·l b) • Install: Camshaft[...]

5-24 ENGINE TOP END Va l v e s V alve Clearance I nspection • Refer to the V alve Clearance Inspection in the Periodic Maintenance chapter . V alve Remo val • Remove the cylinder head (see Cylinder Head Removal). • Remove the valve lifter and the shim from the valve. NOTE ○ Use the valve spring compressor assembly and the adapter to press d[...]

ENGINE T OP END 5-25 Va l v e s V alve Guide Re moval • Remove: V a l v e( s e eV a l v eR e m o v a l ) Oil Seal Spring Seat • Heat the area around the valve guide up to 120 ∼ 150°C (248 ∼ 302°F). CAUTION Do not heat the cylinder head with a torch. This will warp the cylinder head. Soak the cylinder head and heat the oil. • Hammer ligh[...]

5-26 ENGINE TOP END Va l v e s • Ream the valve guide with valve guide reamer [A], even if the old guide is reused. Special T ool - V alve Guide Reamer , 5.5: 5700 1-1079 V alve/Valve Guide Clearance Measurement (Wobble Method) ○ If a small bore gauge is not available, inspect the valve guide wear by measuring the valve/valve guide clearance wi[...]

ENGINE T OP END 5-27 Va l v e s V alve Seat In spection • Remove the valve (see V alve Removal). • Check the valve seating surface [A] b etween the valve [B] and valve seat [C]. • Measure the outside diameter [D] of the seating pattern on the valve seat. If the outside diameter is too large or too small, repair the seat. (see Seat Repair) V a[...]

5-28 ENGINE TOP END Va l v e s Seat Cutter Operation Care 1. This valve seat cutter is developed to grind the vale for repair . 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. 3. Do not fail to apply engine oil to the valve seat cutt[...]

ENGINE T OP END 5-29 Va l v e s • Measure the outside diameter [O.D.] of the seating sur- face with a vernier caliper . If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is with in the spec- ified range. Original Seating Surface [B] ○ Remove all pittings of flaws from 45° ground surface. ○ [...]

5-30 ENGINE TOP END Va l v e s • The seating area should be marked about in the middle of the valve face. 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; replace it. • When the engine is assembled, be sure to adjust the valve clearance (see V a[...]

ENGINE T OP END 5-31 Va l v e s V alve Seat Repair[...]

5-32 ENGINE TOP END Cylinder and Piston Cylinder Removal • Remove: Cylinder Head (see Cylinder Head Removal) Front Camshaft Chain Guide [A] Cylinder Bolt [B] • T ap lightly up with a plastic mallet to separate the cylinder from the crankcase. • Remove the cylinder base gasket. Piston Removal • Remove the cylinder (see Cylinder Removal). •[...]

ENGINE T OP END 5-33 Cylinder and Piston • Install the top ring [A] so that the "R" mark [B] faces up. NOTE ○ If a new piston or cylinder is used, check piston to c ylin- der clearance (see Piston/Cylinder Clearance), and use new piston rings. • Apply engine oil to the inside wall of the small end of the connecting rod. • Face the[...]

5-34 ENGINE TOP END Cylinder and Piston • Apply engine oil to the cylinder bore. • Determine the position of the piston ring ends. • Install the cylinder while compressing the piston rings with your fingers or the special tool [A]. Special T ools - Piston Ring Compressor Grip: 57001-1095 Piston Ring Compressor Belt, 95 ∼ 108: 57001-1358 •[...]

ENGINE T OP END 5-35 Cylinder and Piston Piston Ring Groove Width Inspection • Measure the groove width at several points around the piston with a vernier caliper . Piston Ring Groove Width Standard: To p 1.03 ∼ 1.05 mm (0.0406 ∼ 0.0413 in.) Service Limit: To p 1.1 mm (0.04 3 in.) If any of the groove widths exceeds the service limit, re- pla[...]

5-36 ENGINE TOP END Cylinder and Piston Piston, Piston Pin, Connecting Rod Wear Inspection • Visually inspect the snap ring [A] still fitted in place. If the ring shows weakness or deformation, replace the ring. Also if the pin hole groove shows excessive wear , replace the piston. • Measure the diameter of the piston pin [B] with a microm- ete[...]

ENGINE T OP END 5-37 Carburetor Holder Carburetor Holder Installation • Fit the recess [A] of the holder on the projection [B] of the cylinder head. ○ The marked side [A] of the carburetor holder [B] face to the carburetor . • When installing the clamp screws refer to the Cable, Wire, and Hose Routing in the Appendix chapter . T orque - Carbu[...]

5-38 ENGINE TOP END Muffler WA R N I N G T o avoid a serious burn, do not remove the muffler when the engine is still hot. Wait until the muffler cools down. Muffler Removal • Loosen the muffle r clamp bolt [A]. • Remove the exhaust pipe holder nut [B]. • Remove the exhaust pipe [C]. • Remove Seat (see Seat Removal in the Frame chapter) Rig[...]

ENGINE RIGHT SIDE 6-1 6 Engine Right Side T able of Contents Exploded View ................................................................................................................... ..... 6-2 Specifications ................................................................................................................. ........ 6-6 Special[...]

6-2 ENGINE RIGHT SIDE Exploded View[...]

ENGINE RIGHT SIDE 6-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Primary Gear Nut 98 10 72 Lh 2 Clutch Cover Bolts 9.8 1.0 87 in·lb 3 Right Engine Cover Bolts 9.8 1.0 87 in·lb 4 Clutch Spring Bolts 8.8 0.90 78 in· lb 5 Clutch Hub Nut 98 10 72 6. Primary Gear 7. Push Rod H older 8. Release Lever Shaft 9. Clutch Lever 10. Clut[...]

6-4 ENGINE RIGHT SIDE Exploded View[...]

ENGINE RIGHT SIDE 6-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Ratchet Guide Bolt 8.8 0.90 78 in·lb L 2 Kick Pedal Bolt 25 2.5 18 L 3 Shift Pedal Bolt 9.8 1.0 87 in·lb 4 Ratchet Plate Mounting Bolt 9.8 1.0 87 in·lb S 5 Ratchet Plate Mounting Screw (KX450D6F) 6.4 0.65 56 in·lb L, S Ratchet Plate Mounting Bolt (KX450D7F ∼[...]

6-6 ENGINE RIGHT SIDE Specifications Item Standard Service Limit Clutch Lever Clutch Lever Free Play 8 ∼ 13 mm (0.3 ∼ 0.5 in.) ––– Clutch Friction Plate Thickness 2.92 ∼ 3.08 mm (0.1 15 ∼ 0.121 in.) 2.6 mm (0.10 in.) Friction Plate W arp 0.15 mm (0.0059 in.) or less 0.3 mm (0.01 in.) Steel Plate W arp 0.2 mm (0.008 in.) or less 0.3 mm[...]

ENGINE RIGHT SIDE 6-7 Special T ools Outside C irclip Pliers : 57001-144 Clutch Holde r: 57001-1243 Gear Holder , m2.0: 57001-1557[...]

6-8 ENGINE RIGHT SIDE Clutch Lever and Cable Due to friction plate wear and clutch cable stretch over a long period of use, the clutch must be adjusted in accor- dance with the Periodic Maintenance Chart. WA R N I N G T o avoid a serious burn, never touch the hot engine or exhaust chamber during clutch adjustment. Clutch Lever (Clutch Cable) Free P[...]

ENGINE RIGHT SIDE 6-9 Clutch Lever and Cable • Loosen the adjusting nuts [A] fully . • Free the clutch inner cable tip [B] from the clutch release lever [C]. CAUTION Do not remove the clutch release shaft unless it is absolutely necessary . If removed, release shaft oil seal must be replaced with a new one. • Pull the clutch cable out of the [...]

6-10 ENGINE RIGHT SIDE Clutch Cover and Right Engine Cover Clutch Cover Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove the brake pedal (see Brake Pedal Removal in the Brakes chapter). • Remove the clutch cover bolts [A] and remove the clutch cover [B]. Clutch Cover Installation • Repla[...]

ENGINE RIGHT SIDE 6-1 1 Clutch Cover and Right Engine Cover • When installing the cover doesn’t go well, the cover is installed according to the following procedures. ○ Fit the water pump shaft [A] and groove [B] of the balancer shaft while turning the water pump shaft. • T ighten: T orque - Right Engine Cover Bolts : 9.8 N·m (1.0 kgf·m, [...]

6-12 ENGINE RIGHT SIDE Clutch Clutch Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove the clutch cover (see Clutch Cover Removal). • Remove: Clutch Spring Bolts [A] Clutch Spring Clutch Pressure Plate [B] • Remove: W asher [A] Needle Bearing [B] Push Rod Holder [C] Push Rod Friction Plat[...]

ENGINE RIGHT SIDE 6-13 Clutch • Install the washer so that stamp mark [A] facing the out- side. • T ighten the clutch hub nut [A] using the clutch holder [B]. Special T ool - Clutch Holder: 57001-1243 T o rque - Clu tch Hub Nut: 98 N·m ( 10 kgf·m , 72 ft·lb) • Install the friction plates and steel plates, starting with a friction plate [A][...]

6-14 ENGINE RIGHT SIDE Clutch • T ighten: T o rque - Cl utch Sp ring B olts [A]: 8. 8 N·m (0.9 0 kgf·m , 7 8 in·lb) • Install the clutch cover (see Clutch Cover Installation). • Check the release shaft lever positions. ○ Pushing [B] the release shaft lever [C] lightly frontward measure the distance [A] between the lever and cable bracket[...]

ENGINE RIGHT SIDE 6-15 Clutch Clutch Plate Assembly Free Play Insp ection/Adjust- ment • Assemble the following parts. Clutch Hub [A] Friction Plates [B] Steel Plates [C] Friction Plates [D] Spring Plates [E] Spring [F] Bolts [G] ○ The friction plates [B] have many lining blocks than other plates [D]. These plates are installed to both end of t[...]

6-16 ENGINE RIGHT SIDE Clutch Clutch Housing Finger Damage Inspection • Visually inspect the clutch housing fingers [A] that come in contact with the friction plate tangs. 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[...]

ENGINE RIGHT SIDE 6-17 Primary Gear Primary Gear Removal • Remove: Right Engine Cover Clutch (see Clutch Removal) • T emporarily install the clutch housing [A]. • Using the gear holder [B], secure the primary gear . Special T ool - Gear Holder , m2.0: 57001-1557 • Remove the clutch housing. • Remove the primary gear nut [C], washer , prim[...]

6-18 ENGINE RIGHT SIDE External Shift Mechanism External Shift Mechanism Remo val • Remove: Shift Pedal Bolt [A] Shift Pedal [B] • Remove: Right Engine Cover (see Right Engine Cover Removal) Clutch Housing (see Clutch Removal) Circlip [A] Oil Pump Driven Gear [B] • P u l lo u tt h es h i f ts h a f t[ C ] . • Remove the bolt [D] and screw [[...]

ENGINE RIGHT SIDE 6-19 External Shift Mechanism • Set up the shift ratchet assembly as shown in the figure. Ratchet [A] Pawls [B] Pins [C] Springs [D] ○ Assembly the shift ratchet so that groove [E] of the pawl faces the crankcase side [F]. • Then install the ratchet assembly [A] to the ratchet plate [B] as shown in the figure. • Install th[...]

6-20 ENGINE RIGHT SIDE External Shift Mechanism External Shift Mechanism Inspectio n • Check the shift shaft [A] for bending or damage to the splines. If the shaft is bent, straighten or replace it. If the splines are damaged, replace the shift mechanism. • Check the return spring [B] for cracks or distortion. If the spring is damaged in any wa[...]

ENGINE RIGHT SIDE 6-21 Kickstarter Kick Pedal Assy Removal • Remove: Mounting Bolt [A] Kick Pedal Assy [B] Kick Pedal Assy Installation • Install the kick pedal assy [A] at the angle shown. 17 ∼ 27 mm (0.67 ∼ 1.1 in.) [B] • Apply a non-permanent locking agent to the kick pedal bolt. • T ighten: T o rque - Kick Pedal Bolt : 25 N ·m (2.5[...]

6-22 ENGINE RIGHT SIDE Kickstarter Idle Gear Installation • Apply engine oil to the inside of the idle gear . • Replace the circlip [A] with a new one. • Install the idle gear [C] facing embossed letter [B] to the outside. • Install the circlip. Kickshaft Removal • Remove: Right Engine Cover (see Right Engine Cover Removal) Clutch Housing[...]

ENGINE RIGHT SIDE 6-23 Kickstarter Kick Shaft Assembly Disassembly/Assembly • The kick shaft assembly consists of the following parts. [A] Kick Gear [E] Ratchet Gear [B] Circlip [F] Kic k Shaft [C] W asher [G] Kick Spring [D] Spring [H] Spring Gu ide • Check the kick shaft assembly parts for damage. Any damaged parts should be replaced with new[...]

[...]

ENGINE LUBRICA TION SYSTEM 7-1 7 Engine Lubrication System T able of Contents Exploded View ................................................................................................................... ..... 7-2 Lubrication System Chart ....................................................................................................... 7- [...]

7-2 ENGINE LUBRICA TION SYSTEM Exploded View[...]

ENGINE LUBRICA TION SYSTEM 7-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Engine Oil Drain Bolt M10 (for transmission room oil sump) 20 2.0 15 2 Engine Oil Drain Bolt M6 (for crank room oil sump) 7.0 0.71 62 in·lb 3 Oil Pump (Scavenge) Cover Bolts 9.8 1.0 87 in·lb S 4 Oil Pump (Feed) Cover Bolts 9.8 1.0 87 in ·lb S 5 Right E[...]

7-4 ENGINE LUBRICA TION SYSTEM Lubrication System Chart[...]

ENGINE LUBRICA TION SYSTEM 7-5 Lubrication System Chart 1. Oil S creen (feed) 2. Oil P ump (feed) 3. Oil Pressure Relief V alve 4. Right Engine Cover Oil Passage (from Feed Oil Pump to Oil filter) 5. Oil Filter 6. Right Engine Cover Oil Passage (from Oil filter to Crankshaft) 7. Crankshaft 8. Piston Oil Nozzle 9. Left Crankcase Oil Passage (from Oi[...]

7-6 ENGINE LUBRICA TION SYSTEM Specifications Item Standard Engine Oil Grade Castrol “R4 Superbike” 5W-40 (KX450D6F ∼ D7F), Castrol “POWER1 R4 Racing” 5W-40 (KX450D8F) or A P IS G ,S H ,S Jo rS Lw i t hJ A S OM A Vis c o si t y SAE 10W-30, 10W-40, or 10W-50 Capacity Oil Change - when filter is not removed 0.96 L (1.01 US qt) Oil Change - [...]

ENGINE LUBRICA TION SYSTEM 7-7 Special T ools Oil Pressure Gauge, 5 kgf/cm² : 57001-125 Outside C irclip Pliers : 57001-144 Oil Pressure Gau ge Adapter , M10 × 1.25: 57001-1 182 Oil Pressure Cap: 57001-1656[...]

7-8 ENGINE LUBRICA TION SYSTEM Engine Oil and Oil Filter WA R N I N G Motorcycle operation with insufficient, deteri- orated, or contaminated engine oil will cause accelerated wear and may result in engine or trans- mission seizure, accident, and injury . The engine oil level indicated in the right engine cover oil level gauge is very sensitive to [...]

ENGINE LUBRICA TION SYSTEM 7-9 Engine Oil and Oil Filter Oil Filter Change • Refer to the Oil Filter Change in the Periodic Maintenance chapter . Oil Screen (Scavenge) Removal • Remove the oil pump (scavenge) cover (see Oil Pump (Scavenge) Cover Removal). • Pull out the oil screen [A] from the crankcase. Oil Screen (Scavenge) Installation •[...]

7-10 ENGINE LUBRICA TION SYSTEM Engine Oil and Oil Filter Oil Screen (Feed) Removal • Split the crankcase (see Crankcase Disassembly in the Crankshaft/T ransmission chapter). • Remove: Bolts [A] Oil Screen [B] Oil Screen (Feed) Insta llation • Replace the O-ring [A] with a new one. • Apply grease to the O-ring, and install it. • Install t[...]

ENGINE LUBRICA TION SYSTEM 7-1 1 Engine Oil and Oil Filter • Check the screen [A] carefully for any damage, holes, broken wires gasket pulling off. If the screen is damaged, replace it. • Install the oil screen (see Oil Screen (Scavenge) Installa- tion). Oil Screen (Feed) Cleaning • Remove the oil screen (see Oil Screen (Feed) Removal) • Cl[...]

7-12 ENGINE LUBRICA TION SYSTEM Oil Pressure Relief V alve Oil Pressure Relief V alve Removal • Remove: Clutch (see Clutch Removal in the Engine Right Side chapter) Right Engine cover (see Right Engine Cover Removal in the Engine Right Side chapter) • Remove the oil pressure relief valve [A]. Oil Pressure Relief V alve Installation • Apply a [...]

ENGINE LUBRICA T ION SYSTEM 7-13 Oil Pump Oil Pump (Scavenge) Removal • Drain: Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) Coolant (see Coolant Draining in t he Coolant System chapter) • Remove: Shift Pedal (see External Shift Mechanism in the Engine Right Side chapter) Flywheel (see Flywheel Removal in the Electric[...]

7-14 ENGINE LUBRICA TION SYSTEM Oil Pump Oil Pump (Feed) Removal • Remove: Clutch (Clutch Removal in the Engine Right Side chap- ter) Circlip [A] Oil Pump Driven Gear [B] Shaft [C] Oil Pump Idle Gear [D] Special T ool - Outside Circlip Pliers: 57001-144 • Remove: Oil Pump Cover Bolts [A] Oil Pump Cover [B] [C] KX450D6F ∼ D7F [D] KX450D8F • [...]

ENGINE LUBRICA T ION SYSTEM 7-15 Oil Pump • Install the oil pump cover [A]. • While pushing the oil pump cover , tighten the oil pump cover bolts following the sequence number as shown. ○ Thread length of the bolt is 16 mm (0.63 in.) only in the bolt installed thirdly . (KX450D6F ∼ D7F) ○ Thread length of the bolts is 16 mm (0.63 in.) in [...]

7-16 ENGINE LUBRICA TION SYSTEM Oil Pressure Oil Pressure Measurement • Remove the oil filter cover [A]. • Install the O-rings to the oil pressure cap. Special T ool - Oil Pressure Cap: 57001–1656 • Install the oil pressure cap. • Attach the oil pressure gauge adapter [A] and oil pressure gauge [B]. Special T ools - Oil Pressure Gauge Ada[...]

ENGINE REMOV AL/INST ALLA TION 8-1 8 Engine Removal/Installation T able of Contents Exploded View ................................................................................................................... ..... 8-2 Special T ool ................................................................................................................[...]

8-2 ENGINE REMOV AL/INST ALLA TION Exploded View[...]

ENGINE REMOV AL/INST ALLA TION 8-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Upper Engine Mounting Bolts (M10) 49 5.0 36 2 Middle Engine Mounting Bolt, Nut (M10) 49 5.0 36 3 Lower Engine Mounting Bolt, Nut (M10) 49 5.0 36 4 Upper Engine Bracket Bolts (M8) 29 3.0 21 5 Middle Engine Bracket Bolts, Nuts (M8) 29 3.0 21 6 Swingarm [...]

8-4 ENGINE REMOV AL/INST ALLA TION Special T ool Jack: 57001-123 8[...]

ENGINE REMOV AL/INST ALLA TION 8-5 Engine Removal/Installation Engine Removal • Place the jack [A] under the frame to support the motor- cycle. Special T ool - Jack: 57001-1238 WA R N I N G For engine removal, the swingarm pivot shaft must be pulled out, causing the swingarm and rear wheel assembly to become detached. T o prevent the motorcycle f[...]

8-6 ENGINE REMOV AL/INST ALLA TION Engine Removal/Installation • Remove: Radiator Mounting Bolts [A] Radiator [B] • Remove: Muffler (see Muffler Removal in the Engine T op End chapter) W ater Hoses [B] Bolt [C] Radiator Screen [D] • Remove: Radiator Mounting Bolts [A] Radiator [B] • Loosen: Carburetor Clamp Bolts [A] • Remove: Air Cleaner[...]

ENGINE REMOV AL/INST ALLA TION 8-7 Engine Removal/Installation • Pry open the clamps [A]. • Disconnect: Magnet Lead Connector [B] Gear Position Switch Connector [C] Ignition Coil Lead Connector [D] Spark Plug Cap • Remove: Ignition Coil [A] Upper Engine Bracket Bolts (Left and Right) [B] Upper Engine Mounting Bolt and Nut (Left and Right) [C][...]

8-8 ENGINE REMOV AL/INST ALLA TION Engine Removal/Installation • Install the removed parts (see Appropriate chapter). • Run the cables, hoses, and leads according to the Cable, Wire and Hose Routing section in the Appendix chapter . • Fill: Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) Coolant (see Coolant Draining [...]

CRANKSHAFT/TRANSMISSION 9-1 9 Crankshaft/T ransmission T able of Contents Exploded View ................................................................................................................... ..... 9-2 Specifications ................................................................................................................. .......[...]

9-2 CRANKSHAFT/TRANSMISSION Exploded View[...]

CRANKSHAFT/TRANSMISSION 9-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Re- marks 1 Crankcase Bolts (M6) 12 1.2 104 in·lb S 2 Crankcase Bolts (M7) 15 1.5 11 S 3 Gear Set Lever Nut 8.8 0.90 78 in·lb 4 Engine Oil Drain Bolt (M10)(For T ransmission Room Oil Sump) 20 2.0 15 5 Engine Oil Drain Bolt (M6)(For Crank Room Oil Sump) 7.0 0.71 62 i[...]

9-4 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Connecting Rods Connecting Rod Big End Radial Clearance 0.002 ∼ 0.014 mm (0.00008 ∼ 0.0006 in.) 0.06 mm (0.002 in.) Connecting Rod Big End Side Clearance 0.25 ∼ 0.35 mm (0.0098 ∼ 0.014 in.) 0.6 mm (0.02 in.) Crankshaft Runout TIR 0.03 mm (0.0012 in.) or less TIR 0.08 mm [...]

CRANKSHAFT/TRANSMISSION 9-5 Special T ools and Sealant Outside C irclip Pliers : 57001-144 Bearing Driv er Set: 57001-1 129 Crankshaft Ji g: 57001-1 174 Crankcase Splitti ng T ool Assembly: 57001-1362 Kawasaki Bond (Liquid Gasket - Gray ): 92104-1063[...]

9-6 CRANKSHAFT/TRANSMISSION Crankcase Crankcase Disassembly • Remove the engine from the frame (see Engine Remo val in the Engine Removal/Installation chapter). • Set the engine on clean surface while parts are being re- moved. • Remove: Magneto Cover (see Magneto Cover Removal in the Electrical System chapter) Cylinder Head Cover (see Cylind[...]

CRANKSHAFT/TRANSMISSION 9-7 Crankcase • Remove: Gear Position Switch Finger Spring [A] • Remove: Circlip [A] Special T ool - Outside Circlip Pliers: 57001-144 • Remove the crankcase bolts [A]. • Install the jig [A] between the crankshaft flywheels. Special T ool - Crankshaft Jig: 57001-1 174 • Attach the crankcase splitting tool [A] to th[...]

9-8 CRANKSHAFT/TRANSMISSION Crankcase • Remove: Oil Screen (Feed) [A] (see Oil Screen (Feed) Removal in the Engine Lubrication System chapter) Shift rods [B] (see T ransmission Shaft Removal) 2 shift forks [C] (see T ransmission Shaft Removal) Shift drum [D] (see T ransmission Shaft Removal) T ransmission [E] (see Transmission Shaft Removal) • [...]

CRANKSHAFT/TRANSMISSION 9-9 Crankcase • Press the new transmission shaft bearing [A] in the left crankcase half, so that the sealed side [B] faces outside of the engine. Special T ool - Bearing Driver Set: 57001-1 129 • Press the new drive shaft bearing [A] in the right crankcase [B] half, so that the stepped side [C] faces inside of the engine[...]

9-10 CRANKSHAFT/TRANSMISSION Crankcase • Next, press the outside release shaft needle bearing [A] until the surface of the bearing is e ven with the crankcase surface [B]. Special T ool - Bearing driver Set: 57001-1 129 • Replace the oil seals, if removed. • Press the output shaft and release shaft oil seals [C] so that oil seal lip [A] face [...]

CRANKSHAFT/TRANSMISSION 9-1 1 Crankcase • Install: Shift Drum [A] (see T ransmission Installation) Shift Rods [B] (see T ransmission Installation) Shift Forks [C] (see T ransmission Installation) • Install: Crankshaft [A] Dowel Pins [B] • Replace the O-ring [A] with a new one. • Install the Oil Screen (Feed). T orque - Oil Screen (Fee d) Mo[...]

9-12 CRANKSHAFT/TRANSMISSION Crankcase • Using a plastic hammer [A], press [B] the rear portion of the crankcase, and tap the area around the crankshaft of the left crankcase half. While maintaining the mating surfaces of the right and left crankcase halves constantly parallel, mate the crankcase halves evenly . NOTE ○ Constantly check the alig[...]

CRANKSHAFT/TRANSMISSION 9-13 Crankcase • T o install the shift drum cam [A], use the driver [B] to bring the gear set lever [C] to the bottom of the crankcase. • Mate the shift drum pin [D] into the shift drum hole. ○ Fit the groove [E] of the shift drum cam on the shift drum pin. • Apply non-permanent locking agent to the shift drum cam bo[...]

9-14 CRANKSHAFT/TRANSMISSION Crankshaft Crankshaft Removal • Disassemble the crankcase (see Crankcase Disassem- bly). • Using the hand pull out the crankshaft [A] from the right crankcase half [B]. Crankshaft Installation • Apply high-temperature grease to the outer side of the crankshaft bearings and use the bearing driver set [C] to face th[...]

CRANKSHAFT/TRANSMISSION 9-15 Crankshaft Crankshaft Inspection Connecting Rod Big End Radial Clearance Inspection • Set the crankshaft on V blocks, and place a dial gauge [A] against the connecting rod big end. • Push [B] the connecting rod first towards the gauge and then in the opposite direction. The difference between two gauge readings is t[...]

9-16 CRANKSHAFT/TRANSMISSION Crankshaft • Next, correct the vertical misalignment by either driving a wedge [A] in between the crank halves or by squeezing them in a vice, depending on the nature of the misalign- ment. CAUTION Do not hammer the crank half at the point [B]. If flywheel misalignment cannot be corrected by the above method, replace [...]

CRANKSHAFT/TRANSMISSION 9-17 Crankshaft Connecting Rod T wist Inspection • With the big-end arbor [A] still on the V block [C], hold the connecting rod horizontally and measure the amount that the arbor [B] varies from being parallel with the surface plate over a 100 mm length of the arbor to determine the amount of connecting rod twist. If conne[...]

9-18 CRANKSHAFT/TRANSMISSION T ransmission T ransmission Shaft Removal • Disassemble the crankcase (see Crankcase Disassem- bly). • Pull out the shift rods [A] allowing the shift fork guide pins to free from the shift drum [B]. • Remove the shift fork [C]. • Remove the shift drum. • Pull out the drive shaft [A] and output shaft [B] togeth[...]

CRANKSHAFT/TRANSMISSION 9-19 T ransmission T ransmission Shaft Assembly • Apply engine oil liberally to the transmission shaft, gears and bearings. • Replace any circlips that were removed with new ones. ○ Always install the circlips [A] so that the opening [B] is aligned with a spline groove [C], and install toothed wash- ers. T o install a [...]

9-20 CRANKSHAFT/TRANSMISSION T ransmission KX450D6F 1. Circlip (small) 2. Circlip (middle ) 3. Circlip (large) 4. Ball Bearing (one side sealed) 5. 2nd Gear (17T) 6. 3rd Gear (16T) 7. 4th Gear (19T) 8. 1st Gear (15T) 9. Ball Bearing 10. Drive Shaft 1 1. Collar 12. O-rings (2) 13. Oil S eal 14. Ball Bearing (one side sealed) 15. 2nd Gear (24T) 16. 3[...]

CRANKSHAFT/TRANSMISSION 9-21 T ransmission KX450D7F ∼ 1. Circlip 2. T oothed Washer 3. Ball Bearing (one side sealed) 4. 2nd Gear (17T) 5. 4th Gear (19T) 6. 3rd Gear (16T) 7. 5th Gear (24T) 8. 1st Gear (16T) 9. Bushing 10. Ball Bearing 1 1. Drive Shaft 12. Collar 13. Oil S eal 14. O-rings 15. Ball Bearing (one side sealed) 16. Collar 17. 2nd Gear[...]

9-22 CRANKSHAFT/TRANSMISSION T ransmission Shift Fork Bending Inspection • Visually inspect the shift forks, and replace any fork that is bent. A bent fork may cause difficulty in shifting, or allow the transmission to jump out of gear when under power . 90° [A] Shift Fork/Gear Groove Wear Inspection • Measure the thickness [A] of the s hift f[...]

CRANKSHAFT/TRANSMISSION 9-23 Balancer Balancer Removal • Remove: Right Engine Cover (see Right Engine Cover Removal in the Engine Right Side chapter) Magneto Cover (see Magneto Cover Removal in the Electrical System chapter) Flywheel (see Flywheel Removal in the Electrical Sys- tem chapter) Balancer Weight Mounting Nut [A] Balancer Weight [B] Bal[...]

9-24 CRANKSHAFT/TRANSMISSION Bearings/Oil Seals Bearing Replacement CAUTION Do not remove the ball bearings unless it is neces- sary . Removal may damaged them. • Remove the ball bearing and/or needle bearing outer race using a press or puller . NOTE ○ In the absence of the above mentioned tools, satisfac- tory results may be obtained by heatin[...]

CRANKSHAFT/TRANSMISSION 9-25 Bearings/Oil Seals • Check the needle bearing. ○ The rollers in a needle bearing normally wear very little, and wear is difficult to m easure. 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. Oil Seal I[...]

[...]

WHEELS/TIRES 10-1 10 Wheels/T ires T able of Contents Exploded View ................................................................................................................... ..... 10-2 Specifications ................................................................................................................. ........ 10-4 Special T oo[...]

10-2 WHEELS/TIRES Exploded View[...]

WHEELS/TIRES 10-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Spoke Nipples Not less than 2.2 Not less than 0.22 Not less than 19 in·lb 2 Front Axle Nut 78 8.0 58 3 Front Axle Clamp Bolts 20 2.0 15 AL 4 Rear Axle Nut 108 11 80 5. Spokes 6. Front T ire 7. Rims 8. Front Axle 9. Swingarm 10. Rear T ire 1 1. Rear Axle AL: T ighten [...]

10-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims) Rim Runout (with tire installted): Axial TIR 1.0 mm (0.039 in.) or less TIR 2 mm (0.08 in.) Radial TIR 1.0 mm (0.039 in.) or less TIR 2 mm (0.08 in.) Axle Runout/100 mm (3.94 in.) TIR 0.1 mm (0.004 in.) or less TIR 0.2 mm (0.008 in.) Rim Size: Front 21 × 1.60 ––– Rear[...]

WHEELS/TIRES 10-5 Special T ools Inside Circlip Pl iers: 57001-143 Rim Protec tor: 57001-1063 Bead Breaker Assembly: 57001-1072 Bearing Driver Set: 57001-1 129 Jack: 57001-1238[...]

10-6 WHEELS/TIRES Wheels (Rims) Front Wheel R emoval • Using the jack [A] under the frame, and stabilize the mo- torcycle. Special T ool - Jack: 57001-1238 • Apply the rear brake to rear wheel so that it does not turn. • Unscrew the axle nut [A]. • Loosen the left and right axle clamp bolts [B]. • Place a commercially ava ilable jack unde[...]

WHEELS/TIRES 10-7 Wheels (Rims) • Insert the axle [A] from right side. • T ighten the right [B] axle clamp bolts temporally . • T ighten the axle nuts [C]. • T ighten the left axle clamp bolts [D]. T orque - Front Axle: 78 N·m (8.0 kgf·m, 58 ft·lb) Left Axle Cla mp Bo lts: 20 N·m (2 .0 kgf·m , 15 ft·lb) NOTE ○ Tighten the two clamp [...]

10-8 WHEELS/TIRES Wheels (Rims) • Remove Cotter Pin [A] Axle Nut [B] • P u l lo u tt h ea x l e[ C ] . • Move the rear wheel back with the rear caliper installed. • T ake off the collar and cap from the each side of the rear hub. CAUTION Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place bl[...]

WHEELS/TIRES 10-9 Wheels (Rims) • Check the drive chain slack (see Drive Chain Slack In- spection in the Periodic Maintenance chapter). • T ighten the axle nut. T orque - Rear Axle Nut: 108 N·m (1 1 kg·m, 80 ft·lb) • Install the new cotter pin [A] and spread its end. NOTE ○ When inserting the cotter pin, if the slots in the nut do not al[...]

10-10 WHEELS/TIRES Wheels (Rims) Axle Inspection • Visua lly inspect the front and rear axle for damages. If the axle is damaged or bent, replace it. • Place the axle in V blocks that are 100 mm (3.937 in.) [A] apart, and set a dial gauge on the axle at a point halfway between the blocks. T urn the axle to me asure the runout. The difference be[...]

WHEELS/TIRES 10-1 1 Ti r e s Tire R em o va l CAUTION 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 the disc does not touch the ground. • Remove the wheel from the motorcycle (see Wheels Re- moval). • T o maintain front wheel balance, mark [A] the valve stem posit[...]

10-12 WHEELS/TIRES Ti r e s • Step on the side of the tire opposite valve stem, pry the tire off the rim with the tire iron [A] of the bead breaker protecting the rim with rim protectors [B]. Special T ools - Rim Protector: 57001-1063 Bead Breaker Assembly: 57001-1072 CAUTION T ake care not to inset the tire irons so deeply that the tube gets dam[...]

WHEELS/TIRES 10-13 Ti r e s • T ighten the bead protector nut [A] and valve stem nut [B], and put on the valve cap [C]. • Check and adjust the air pressure after installing. Air Pressure Inspection/Adjustment • Refer to the Air Pressure Inspection/Adjustment in the Pe- riodic Maintenance chapter .[...]

10-14 WHEELS/TIRES Hub Bearings Hub Bearing Removal • Remove the wheel (see Wheel Removal). CAUTION 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. • Remove the oil seals and circlips. Special T ool - Inside Circlip Pliers: 5[...]

FINAL DRIVE 1 1-1 11 Final Drive T able of Contents Exploded View ................................................................................................................... ..... 1 1-2 Specifications ................................................................................................................. ........ 1 1-4 Drive Chain [...]

1 1-2 FINAL DRIVE Exploded View[...]

FINAL DRIVE 1 1-3 Exploded View T orque No Fastener N·m kgf·m ft·lb Remarks 1 Rear Sprocket Nuts 34 3.5 25 2 Engine Sprocket Nut 127 13 94 3 Engine Sprocket Cover Bolts 9.8 1.0 87 in·lb 4. Engine Sprocket 5. Output Shaft 6. Chain Slipper 7. Swingarm 8. Chain Guide 9. Locknut 10. Adjusting Bolt 1 1. Chain Adjuster 12. Drive Chain 13. Rear Sprock[...]

1 1-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain Chain Slack 52 ∼ 58 mm (2.0 ∼ 2. 3 in.) ––– Chain 20-link Length 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.) Standard Chain: Make DAIDO ––– Ty p e D.I.D 520DMA2 ––– Length 11 4 L i n k s –– – Sprocket Rear Sprocket W arp Under 0.4 mm [...]

FINAL DRIVE 1 1-5 Drive Chain Drive Chain Slack Inspection • Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter . Drive Chain Slack Adjustment • Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter . Wheel Alignment Inspection • Check that the rear end [A] of the left chain adjuster aligns w[...]

1 1-6 FINAL DRIVE Drive Chain • Install the clip [A] so that the closed end [B] of the "U" pointed in the direction of chain rotation [C]. • Adjust the drive chain slack (see Drive Chain Slack Ad- justment). • Check the rear brake.[...]

FINAL DRIVE 1 1-7 Sprockets Engine Sprocket Removal • Remove: Engine Sprocket Cover Bolts [A] Engine Sprocket Cover [B] Drive Chain Guide [C] • Remove: Drive Chain [B] (free of engine sprocket) • Flatten the bended sprocket washer [A]. • Remove the engine sprocket nut [C] and sprocket washer , and pull off the engine sprocket [D]. Engine Sp[...]

1 1-8 FINAL DRIVE Sprockets Rear Sprocket Insta llation • Install the rear sprocket [A] so that the marked side [B] faces out. • Install the rear sprocket bolts and tighten the nuts. T orque - Rear Sp rocket Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb) Sprocket Wear Inspection • Refer to the Sprocket Wear Inspection in the Periodic Maintenance chapt[...]

BRAKES 12-1 12 Brakes T able of Contents Exploded View ................................................................................................................... ..... 12-2 Specifications ................................................................................................................. ........ 12-6 Special T ools ..........[...]

12-2 BRAKES Exploded View[...]

BRAKES 12-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Front Master Cylinder Clamp Bolts 8.8 0.90 78 in·lb S 2 Brake Hose Banjo Bolts 25 2.5 18 3 Brake Pad Bolt 17 1.7 13 4 Caliper Bleed V alve 7.8 0.80 69 in·lb 5 Caliper Mounting Bolts (Front) 25 2.5 18 6 Brake Disc Mounting Bolts (Front) 9.8 1.0 87 in·lb L 7 Brake Lever Pi[...]

12-4 BRAKES Exploded View[...]

BRAKES 12-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Re- marks 1 Brake Hose Banjo Bolts 25 2.5 18 2 Rear Master Cylinder Mounting Bolts 9.8 1.0 87 in·lb 3 Rear Master Cylinder Push Rod Locknut 17 1.7 13 4 Caliper Bleed V alve 7.8 0.80 69 in·lb 5 Brake Pad Bolt 17 1.7 13 6 Rear Brake Pad Bolt Plug 2.5 0.25 22 in·lb 7 Caliper Holder S[...]

12-6 BRAKES Specifications Item Standard Service Limit Brake adjustment Lever Play Adjustable (to suit rider) ––– Brake Fluid Recommended Disc Brake Fluid: ––– Ty p e Front DOT3 or DOT4 ––– Rear DOT4 Brake Pads Lining thickness: Front 3.8 mm (0.15 in.) 1 mm (0.04 in.) Rear 6.4 mm (0.25 in.) 1 mm (0.04 in.) Brake Disc Thickness: Fr[...]

BRAKES 12-7 Special T ools Inside Circlip Pl iers: 57001-143 Jack: 57001-1238[...]

12-8 BRAKES Brake Lever , Brake Pedal Brake Lever Adjustment • Refer to the Brake Lever and Pedal Position Adjustment in the Periodic Maintenance chapter . Brake Pedal Position Adjustmen t • Refer to the Brake Lever and Pedal Position Adjustment in the Periodic Maintenance chapter . Brake Pedal Removal • Remove: Cotter Pin [A] Joint Pin [B] W[...]

BRAKES 12-9 Brake Fluid WA R N I N G When working with the disc brake, observe the pre- cautions 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 two types and brands of fluid for use in the brake. This lowers the brake fluid boiling [...]

12-10 BRAKES Brake Fluid Bleeding the Brake Line The brake fluid has a very low compression c oefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action. Air , however , is easily compressed. When air enters the brake lines, brake lever or pedal movement will be partially used in[...]

BRAKES 12-1 1 Brake Fluid • Check the fluid level. • After bleeding is done, check the brake for good braking power , no brake drag, and no fluid leakage. WA R N I N G Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc. The brake will not f[...]

12-12 BRAKES Caliper Caliper Removal Front Brake: • Loosen the banjo bolt [A] so as not to spill brake fluid. • Remove the caliper mounting bolts [B]. • Remove the banjo bolt and take off the brake hose from the caliper [C]. • If the caliper is to be disassembled after removal and if compressed air is not available, remove the piston using [...]

BRAKES 12-13 Caliper Caliper Installation • T ighten the brake pad bolts if it was removed. T orque - Brake Pad Bolts: 17 N·m (1.7 kgf·m, 13 ft·l b) Front Brake: • Install the caliper and tighten the bolts. T orque - Caliper Mounting Bolts (Front): 25 N·m (2.5 kgf· m, 18 ft·lb) Rear Brake: • Before install the caliper , install the rear[...]

12-14 BRAKES Caliper Caliper Holder Shaft Wear Inspection The caliper body must slide smoothly on the caliper holder shafts. If the body does not slide smoothly , one pad will wear more than the other , pad wear will increase, and con- stant drag on the disc will raise brake and brake fluid tem- perature. • Check to see if the caliper holder shaf[...]

BRAKES 12-15 Brake Pad Brake Pad Removal For Front Brake Pad • Unscrew the pad bolt [A]. • T ake the piston side pad [B]. • Push the caliper holder toward the piston, and then re- move another pad [C] from the caliper holder . For Rear Brake Pad • Remove: Plug [A] • Unscrew the pad bolt [A]. • T ake the piston side pad [B]. • Push the[...]

12-16 BRAKES Master Cylinder CAUTION Brake fluid quickly ruins painted or plastic sur- faces; any spilled fluid should be completely wiped up immediately . Front Mast er Cylinder Rem oval • Remove the banjo bolt [A] to disconnect the upper brake hose [B] from the master cylinder [C]. • When removing the brake hose, temporarily secure the end of[...]

BRAKES 12-17 Master Cylinder Rear Master Cylinder Removal • Remove the cotter pin [A]. • Pull off the joint pin [B] with washer . NOTE ○ Pull off the joint pin while pressing down the brake pedal. • Unscrew the master cylinder mounting bolts [C], and re- move the master cylinder [D]. • Unscrew the brake hose banjo bolt [E]. • When remov[...]

12-18 BRAKES Master Cylinder Master Cylinder Inspection (Visual Inspection) • Disassemble the front and rear master cylinders. • Check that there are no scratches, rust or pitting on the inner wall of each master cylinder [A] and on the outside of eac h pist on [B]. If a master cylinder or piston shows any damage, replace them. • Inspect the [...]

BRAKES 12-19 Brake Disk Brake Disc Inspection • Visually inspect the disc [A]. If it is scratched or damaged, replace the disc. • Measure the thickness of each disc at the point [B] where it has worn the most. Replace the disc if it has worn past the service l imit. Thickness Standard: Front 2.85 ∼ 3.15 mm (0.1 1 2 ∼ 0.124 in.) Rear 3.85 ?[...]

12-20 BRAKES Brake Hose Brake Hose Removal/Installation • Refer to the Brake Hose Replacement in the Periodic Maintenance chapter . Brake Hose Inspection • Refer to the Brake Hoses and Connections Inspection in the Periodic Maintenance chapter .[...]

SUSPENSION 13-1 13 Suspension T able of Contents Exploded View ................................... 13-2 Specifications .................................... 13-8 Special T ools ..................................... 13-10 Front Fork (KX450D6F ∼ D7F) .......... 13-1 1 Air Pressure ................................. 13-1 1 Rebound Damping Adjustment .[...]

13-2 SUSPENSION Exploded View KX450D6F[...]

SUSPENSION 13-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Base V alve Assembly 28 2.9 21 2 Front Fork T op Plug 30 3.1 22 3 Front Fork Clamp Bolts (Upper) 20 2.0 15 AL 4 Front Fork Clamp Bolts (Lower) 20 2.0 15 AL 5 Steering Stem Head Nut 98 10 72 6 Locknut/Adjuster Assembly 29 3.0 21 7 Adjuster Assembly 58 5.9 43 L 8 Front Ax[...]

13-4 SUSPENSION Exploded View KX450D7F ∼ D8F[...]

SUSPENSION 13-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Base V alve Assembly 28 2.9 21 2 Front Fork T op Plug 30 3.1 22 3 Front Fork Clamp Bolts (Upper) 20 2.0 15 AL 4 Front Fork Clamp Bolts (Lower) 20 2.0 15 AL 5 Steering Stem Head Nut 98 10 72 6 Locknut/Adjuster Assembly 29 3.0 21 7 Adjuster Assembly 58 5.9 43 L 8 Front Ax[...]

13-6 SUSPENSION Exploded View[...]

SUSPENSION 13-7 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Swingarm Pivot Shaft Nut 98 10 72 2 Rocker Arm Pivot Nut (KX450D6F) 83 8.5 61 Rocker Arm Pivot Nut (KX450D7F ∼ ) 59 6.0 43 3 T ie-rod Mounting Nut (Front, Rear) (KX450D6F) 83 8.5 61 T ie-rod Mounting Nut (Front, Rear) (KX450D7F ∼ ) 59 6.0 43 4 Rear Shock Absorber Mo[...]

13-8 SUSPENSION Specifications Item Standard Service Limit Front Fork Air Pressure Atmospheric pressure ––– (Adjustable Range) Rebound Damping Adjustment (from the seated position adjuster turned fully clockwise) 13 clicks counterclockwise (KX450D6F) 9 clicks counterclockwise, (EUR) 10 clicks conterclockwise (KX450D7F) 10 clicks counterclockw[...]

SUSPENSION 13-9 Specifications Item Standard Service Limit (Adjustable Range) Spring Preload Adjustment (Adjusting nut position from the center of the mounting hole upper) 127.5 mm (5.020 in.) (KX450D6F ∼ D7F) 128.5 mm (5.059 in.) (KX450D8F) 121.5 ∼ 138.5 mm (4.783 ∼ 5.453 in.) (KX450D6F , D8F) 122.1 ∼ 131.6 mm (4.8075 ∼ 5.181 in.) (KX450[...]

13-10 SUSPENSION Special T ools Oil Seal & Bearing Remover: 57001-105 8 Steering Stem Nut Wrench: 57001-1 100 Hook Wrenc h R37.5, R42: 57001-1 101 Bearing Driver Set: 57001-1 129 Jack: 57001-123 8 Bearing Remover Shaft, 9: 57001-1265 Bearing Remover Head, 15 × 17: 57001-1267 Fork Oil Seal Driv er , 48: 57001-1509 T o pP l u gW r e n c h ,4 9m [...]

SUSPENSION 13-1 1 Front Fork (KX450D6 F ∼ D7F) Air Pressure The standard air pressure in the front fork legs is atmo- spheric pressure. 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[...]

13-12 SUSPENSION Front Fork (KX450D 6F ∼ D7F) Compression Damping Adjustment • Place the jack under the frame so that the front wheel off the ground. Special T ool - Jack: 57001-1238 • T o adjust compression damping, turn the adjuster [A] on the front fork top plugs with the blade of a screwdriver until you feel a click. Adjust the compressio[...]

SUSPENSION 13-13 Front Fork (KX450D6 F ∼ D7F) • Loosen the upper [A], and lower [B] fork clamp bolts. • Remove the front fork. ○ W i t hat w i s t i n gm o t i o n[ A ] ,w o r kt h ef o r kl e g[ B ]d o w na n d out. Front Fork Installation • Install the fork so that the distance between the top end of the outer tube and the upper surface[...]

13-14 SUSPENSION Front Fork (KX450D 6F ∼ D7F) Front Fork Di sassembly (each fork leg) • Loosen the front fork upper clamp bolts [A]. • Loosen the fork top plug (subtank) [A] with the top plug wrench [B]. Special T ool - T op Plug Wrench, 49 mm: 57001-1653 [B] • Remove the front fork (see Front Fork Remova l). NOTE ○ Set rebound and compre[...]

SUSPENSION 13-15 Front Fork (KX450D6 F ∼ D7F) • 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 t emporarily install the fork top plug [A] (subtank) to the outer tube [B] with the top plug wrench [C]. Special T ool - T op Plug Wrench[...]

13-16 SUSPENSION Front Fork (KX450D 6F ∼ D7F) • Remove the push rod [A]. • With the outer tube compressed by hands, remove the t o pp l u gw r e n c h[ A ] . CAUTION Removing the locknut and pushing the piston rod thread into the cylinder unit will damage the oil seal. Do not remove the locknut from the piston rod. • Remove the fork leg fro[...]

SUSPENSION 13-17 Front Fork (KX450D6 F ∼ D7F) • Grasp the outer tube and stroke [A] the inner tube several times. The shock to fork seal separates the inner tube from the outer tube. • Remove the following part s from the inner tube. [A] Guide Bushes [B] W asher [C] Oil Seal [D] Retaining Ring [E] Dust Seal • Holding the top plug wrench [A][...]

13-18 SUSPENSION Front Fork (KX450D 6F ∼ D7F) Front Fork Assembly • When the fork tubes are not disassembled, hold the fork inverted position for more than 20 minutes to allow the fork oil to fully drain. • Replace the following with new ones: Dust Seal [A] Retaining Ring [B] Oil Seal [C] Guide Bushes [D] • Place an oil coated plastic bag [[...]

SUSPENSION 13-19 Front Fork (KX450D6 F ∼ D7F) • With the piston rod in fully compressed position, pour the specified amount of fork oil [A]. Recomme nded Oil: KHL15-10 (KA Y ABA01) or equivalent Recommended Quantity: 170 ml (5.75 US oz) ( KX450D6F) 191 ml (6.46 US oz) (KX450D7F) NOTE ○ Plug the two oil holes on the subtank [B] with fingers. ?[...]

13-20 SUSPENSION Front Fork (KX450D 6F ∼ D7F) • H o l d i n gt h et o pp l u gw r e n c h[ A ]w i t hav i s e . • Holding the subtank [B] with the top plug wrench, torque the base valve assembly [C]. Special T ool - T op Plug Wrench, 49 mm: 57001-1653 T orque - Base V alve Assembly: 28 N·m (2.9 kgf·m, 21 ft·lb) • Protect the piston rod e[...]

SUSPENSION 13-21 Front Fork (KX450D6 F ∼ D7F) • Make sure about 16 mm (0.63 in.) [A] of push rod thread is exposed from the locknut [B]. • Completely wipe off the fork oil from the spring [A], collar [B] and cylinder unit [C]. • Insert above-mentioned parts into the fork. • T emporarily tighten the fork top plug [A] (subtank) using the to[...]

13-22 SUSPENSION Front Fork (KX450D 6F ∼ D7F) • Insert the push rod [A] into the piston rod. • Replace the O-ring and gasket on the adjuster assembly with new ones and apply specified fork oil to the O-ring. • Slowly turn the adjuster assembly [A] clockwise until re- sistance is felt and check the clearance between the lock- nut [B] and adj[...]

SUSPENSION 13-23 Front Fork (KX450D6 F ∼ D7F) • Raise the outer tube and temporarily tighten the fork top plug (subtank). Special T ool - T op Plug Wrench, 49 mm: 57001-1653 • After installing the front fork, torque the top plug [A]. Special T ool - T op Plug Wrench, 49 mm: 57001-1653 [B] The torque of fork top plug is specified to 30 N·m (3[...]

13-24 SUSPENSION Front Fork (KX450D 6F ∼ D7F) Cylinder Unit Inspection • Inspect the piston rod [B] of cylinder unit [A] for scratches or bending. If it has scratches or is bent, replace cylinder unit with a new one. Inner T ube Inspection • Visually inspect the inner tube [A], repair any damage. • Nick or rust damage can sometimes be repai[...]

SUSPENSION 13-25 Front Fork (KX450D6 F ∼ D7F) Spring T ension Inspection • Since a spring becomes shorter as it weakens, check its free length [A] to determine its condition. If the spring of either fork leg is shorter than the service limit, it must be replaced. If the length of a replacement spring and that of the remaining spring vary greatl[...]

13-26 SUSPENSION Front Fork (KX450D8F) Air Pressure The standard air pressure in the front fork legs is atmo- spheric pressure. 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 for[...]

SUSPENSION 13-27 Front Fork (KX450D8F) Compression Damping Adjustment • Place the jack under the frame so that the front wheel off the ground. Special T ool - Jack: 57001-1238 • T o adjust compression damping, turn the adjuster [A] on the front fork top plugs with the blade of a screwdriver until you feel a click. Adjust the compression damping[...]

13-28 SUSPENSION Front Fork (KX450D8F) • Loosen the upper [A], and lower [B] fork clamp bolts. • Remove the front fork. ○ W i t hat w i s t i n gm o t i o n[ A ] ,w o r kt h ef o r kl e g[ B ]d o w na n d out. Front Fork Insta llation • Install the fork so that the distance between the top end of the outer tube and the upper surface of the [...]

SUSPENSION 13-29 Front Fork (KX450D8F) Front Fork Di sassembly (each f ork leg) • Loosen the front fork upper clamp bolts [A]. • Loosen the fork top plug (subtank) [A] with the top plug wrench [B]. Special T ool - T op Plug Wrench, 49 mm: 57001-1653 [B] • Remove the front fork (see Front Fork Removal). NOTE ○ Set rebound and compression dam[...]

13-30 SUSPENSION Front Fork (KX450D8F) • Place a drain pan under the front fork and drain f ork oil [A]. NOTE ○ Pump the fork tube several times to discharge the fork oil. • Raise the outer tube and temporarily install the fork top plug [A] (subtank) to the outer tube [B] with the top plug wrench [C]. Special T ool - T op Plug Wrench, 49 mm: [...]

SUSPENSION 13-31 Front Fork (KX450D8F) • Remove the push rod [A]. • With the outer tube compressed by hands, remove the t o pp l u gw r e n c h[ A ] . CAUTION Removing the locknut and pushing the piston rod thread into the cylinder unit will damage the oil seal. Do not remove the locknut from the piston rod. • Remove the fork leg from the vis[...]

13-32 SUSPENSION Front Fork (KX450D8F) • Grasp the outer tube and stroke [A] the inner tube several times. The shock to fork seal separates the inner tube from the outer tube. • Remove the following parts from the inner tube. [A] Guide Bushes [B] W asher [C] Oil Seal [D] Retaining Ring [E] Dust Seal • Holding the top plug wrench (57001-1653) [...]

SUSPENSION 13-33 Front Fork (KX450D8F) Front Fork Assembly • When the fork tubes are not disassembled, hold the fork inverted position for more than 20 minutes to allow the fork oil to fully drain. • Replace the following with new ones: Dust Seal [A] Retaining Ring [B] Oil Seal [C] Guide Bushes [D] • Place an oil coated plastic bag [E] over t[...]

13-34 SUSPENSION Front Fork (KX450D8F) • With the piston rod in fully compressed position, pour the specified amount of fork oil [A]. Recomme nded Oil: KHL15-10 (KA Y ABA01) or equivalent Recommended Quantity: 191 ml ( 6.46 US oz) NOTE ○ Plug the two oil holes on the subtank [B] with fingers. • Pump [A] the piston rod [B] slowly several times[...]

SUSPENSION 13-35 Front Fork (KX450D8F) • Holding the top plug wrench (57001-1653) [A] with a vise. • Holding the subtank [B] with the top plug wrench, torque the base valve assembly [C] using the top plug wrench (57001-1705) [D]. Special T ool - T op Plug Wrench, 49 mm: 57001-1653 T op Plug Wrench, 36 mm: 57001-1705 T orque - Base V alve Assemb[...]

13-36 SUSPENSION Front Fork (KX450D8F) • Make sure about 16 mm (0.63 in.) [A] of push rod thread is exposed from the locknut [B]. • Completely wipe off the fork oil from the spring [A], collar [B] and cylinder unit [C]. • Insert above-mentioned parts into the fork. • T emporarily tighten the fork top plug [A] (subtank) using the top plug wr[...]

SUSPENSION 13-37 Front Fork (KX450D8F) • Insert the push rod [A] into the piston rod. • Replace the O-ring and gasket on the adjuster assembly with new ones and apply specified fork oil to the O-ring. • Slowly turn the adjuster assembly [A] clockwise until re- sistance is felt and check the clearance betwee n the lock- nut [B] and adjuster as[...]

13-38 SUSPENSION Front Fork (KX450D8F) • Raise the outer tube and tempo rarily tighten the fork top plug (subtank). Special T ool - T op Plug Wrench, 49 mm: 57001-1653 • After installing the front fork, torque the top plug [A]. Special T ool - T op Plug Wrench, 49 mm: 57001-1653 [B] The torque of fork top plug is specified to 30 N·m (3.1 kgf·[...]

SUSPENSION 13-39 Front Fork (KX450D8F) Cylinder Unit Inspection • Inspect the piston rod [B] of cylinder unit [A] for scratches or bending. If it has scratches or is bent, replace cylinder unit with a new one. Inner T ube Inspection • Visually inspect the inner tube [A], repair any damage. • Nick or rust damage can sometimes be repaired by us[...]

13-40 SUSPENSION Front Fork (KX450D8F) Spring T ension Inspection • Since a spring becomes shorter as it weakens, check its free length [A] to determine its condition. If the spring of either fork leg is shorter than the service limit, it must be replaced. If the length of a replacement spring and that of the remaining spring vary greatly , the r[...]

SUSPENSION 13-41 Rear Shock Absorber T o 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. Also the damping force can be adjusted easily so changing oil viscosity unnecessary . Rebound Damping Adjustment • T urn the rebound damping adjuster [A] on the re[...]

13-42 SUSPENSION Rear Shock Absorber • Adjust the high speed compression damping, turn the high speed compression damping adjuster with a 17 mm wrench. If the damping feels too soft or too stiff, adjust it in accor- dance with the following table. High Speed Compression Damping Standard: 1 1/6 turns out [B] (KX450D6F) 1 1/2 turns out (KX450D7F) 1[...]

SUSPENSION 13-43 Rear Shock Absorber • Using the hook wrenches [A], loosen the locknut [B] on the rear shock absorber . Special T ool - Hook Wrench R37.5, R42: 57001-1 101 • Using the stem nut wrench [A], turn the adjusting nut [B] as required. T urning the adjusting nut downward marks the spring action harder and upward softer . Special T ool [...]

13-44 SUSPENSION Rear Shock Absorber Rear Shock Absorber Removal • Remove: Seat (see Seat Removal in the Frame chapter) Side Covers (see Side Cover Removal in the Frame chapter) Muffler (see Muffler Removal in the Engine T op End chapter) Rear Frame with Air Cleaner Housing • Using the jack under the frame, raise the rear wheel off the ground. [...]

SUSPENSION 13-45 Rear Shock Absorber • Using the hook wrenches [C], loosen the locknut [B] and turn the adjusting nut [A] all way up. Special T ool - Hook Wrench R37.5, R42: 57001-1 101 • Remove the rear shock absorber from the vise. • Slide down the rubber bumper [A]. • Remove the spring guides [B] from the shock absorber and lift off the [...]

13-46 SUSPENSION Swingarm Swingarm Removal • Place the jack [A] under the frame so that the rear wheel is off the ground. Special T ool - Jack: 57001-1238 • Remove Rear Wheel (see Rear Wheel Removal in the Wheels/T ires chapter) Clamps [B] Brake Pedal [C] (see Brake Peda l Removal in the Brakes chapter) Disc Protector [D] • Remove: Bolts [A] [...]

SUSPENSION 13-47 Swingarm • Unscrew the screws [A] • Separate the chain slipper [B] from the swingarm. Swingarm Installation • Apply plenty of grease to the inside of the needle bear- ings, sleeves, and oil seals. • T ighten the following: T orque - Swingarm Pivot Shaf t Nut: 98 N·m (10 kgf·m, 72 ft·lb) Rocker Arm Pivot Nut: 83 N·m (8.5[...]

13-48 SUSPENSION Swingarm Swingarm Bearing, Sleeve Inspe ction CAUTION Do not remove the bearings for inspection. Re- moval may damage them. • Inspect the needle bearings installed in the swingarm. ○ The rollers in a bearing normally wear very little, and wear is difficult to m easure. Instead of measuring, visually inspect the bearing for abra[...]

SUSPENSION 13-49 T ie-Rod, Rocker Arm Tie-Rod Removal • Using the jack under the frame, raise the rear wheel off the ground. Special T ool - Jack: 57001-1238 • Unscrew the nut [A] and remove the guide roller [B]. CAUTION When pulling out the mounting bolts, lift the rear wheel slightly . Forcing or tapping on a bolt could damage the bolt, sleev[...]

13-50 SUSPENSION T ie-Rod, Rocker Arm Rocker Arm Installation • Apply plenty of grease to the inside of the rocker arm, needle bearings, oil seals and grease seals outside of the sleeve. • T ighten: T orque - Rear Shock Absorber Mounting Nut (Lowe r): 34 N·m (3.5 kgf·m, 25 ft· lb) Rocker Arm Pivot Nut: 83 N·m (8.5 kgf·m, 61 ft·l b) (KX450[...]

SUSPENSION 13-51 T ie-Rod, Rocker Arm Tie-Rod and Rocker Arm Bearing Installation • Replace the needle bearing, grease seals and oil seals with new ones. • Apply plenty of grease to the oil seal and needle bearings [A]. NOTE ○ Install the grease seals so that the deep groove side of the rip out-ward. • Install the needle bearings [A], [B] a[...]

13-52 SUSPENSION Uni-T rak Maintenance Uni-T rak Linkage Inspection • Refer to the Uni-T rak Linkage Inspection in the Periodic Maintenance chapter . Tie-Rod and Rocker Arm Sleeve W ear Inspection • Pull out the sleeves [A] of the tie-rod and rocker arm. • Measure the outside diameter of the sleeve. If the sleeve is worn past the service limi[...]

STEERING 14-1 14 Steering T able of Contents Exploded View ................................................................................................................... ..... 14-2 Special T ools .......................................................................................................................... 14-4 Steering ............[...]

14-2 STEERI NG Exploded View[...]

STEERING 14-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Handlebar Holder Bolts 25 2.5 18 2T 2 Steering Stem Head Nut 98 10 72 3 Steering Stem Nut 4.9 0.50 43 in· lb T 4 Front Fork Clamp Bolts (Upper) 20 2.0 15 AL 5 Front Fork Clamp Bolts (Lower) 20 2.0 15 AL 6. Handlebar Holder (Upper) 7. Handlebar 8. Handlebar Holder (Lower)[...]

14-4 STEERI NG Special T ools Bearing Pulle r: 57001-135 Steering Stem Bearing Dr iver: 57001-137 Steering Stem Bearing Drive r Adapter , 34.5: 57001-107 4 Head Pipe Outer Race Press Shaft: 57001-107 5 Head Pipe Outer Race Driver , 51.5: 57001-107 6 Head Pipe Outer Race Driver , 54.5: 57001-1077 Steering Stem Nut Wrenc h: 57001-1 100 Head Pipe Oute[...]

STEERING 14-5 Steering Steering Inspection • Refer to the Steering Inspection in the Periodic Mainte- nance chapter . Steering Adjustment • Refer to the Steering Adjustment in the Periodic Mainte- nance chapter . Steering Stem, Stem Bearing Removal • Remove: Front Wheel (see Front Wheel Removal i n the Wheels/T ires chapter) Front Fender Bolt[...]

14-6 STEERI NG Steering • Remove: Front Fork Lower Clamp Bolts [A] Front Fork [B] • Pushing up on the stem base [A], and remove the steering stem nut [B], with the steering stem nut wrench [C], then remove the steering stem [D] and stem base. Special T ool - Steering Stem Nut Wrench: 57001-1 100 • T ake off the upper stem bearing inner race ([...]

STEERING 14-7 Steering Steering Stem, Stem Bearing Installation • Replace the bearing outer race with new ones. ○ Apply grease to the outer races, and drive them into the head pipe at the same time using the head pipe outer race press shaft [A] and the head pipe outer race drivers. Special T ools - Head Pipe Outer Race Press Shaft: 57001 -1075 [...]

14-8 STEERI NG Steering • Install the front fork (see Front Fork Installation in the Sus- pension chapter). NOTE ○ Tighten the fork upper clamp bolts first, next the stem head nut, last the fork lower clamp bolt. • T ighten: T orque - Steering Stem Head Nut: 98 N·m (10 kgf·m, 72 ft·lb) Front Fork Clamp Bolts (Up per): 20 N·m (2.0 kgf·m, [...]

STEERING 14-9 Handlebar Handlebar Removal • Remove: Number Plate [A] Clutch Holder [B] Engine Stop Switch [C] Clamps [D] Left Handlebar Grip [E] • Remove: Throttle Grip Assy [A] (see Throttle Cable Replacement in the Fuel System chapter) Master Cylinder [B] (see Front Master Cylinder Removal in the Brakes chapter) • Remove: Handlebar Holder B[...]

14-10 STEERING Handlebar • Apply grease to the throttle cable upper end and clutch cable upper end. • Apply a 2-stroke oil to the throttle grip inner wall [A]. • Install the throttle grip assy so that the grip [A] is in as far as it will go. • Position the throttle grip assy so that the parting line [B] of the throttle case vertically , and[...]

FRAME 15-1 15 Frame T able of Contents Exploded View ................................................................................................................... ..... 15-2 Frame .......................................................................................................................... ........... 15-4 Frame Inspection .......[...]

15-2 FRAME Exploded View[...]

FRAME 15-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Rear Frame Mounting Bolt 34 3.5 25 2 Upper Footpeg Bracket Bolts 54 5.5 40 L 3. Front Fender Bolts 4. KX450D6F ∼ D7F 4. KX450D8F G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts[...]

15-4 FRAME Frame Frame Inspection • Refer to the Frame Inspection in the Periodic Mainte- nance chapter . Rear Frame Removal • Remove: Seat (see Seat Removal) Right & Left Side Cover (see Side Cover Removal) Muffler (see Muffler Removal in the Engine T op End chapter) Rear Fender (see Rear Fender Removal) • Loosen the air cleaner duct cla[...]

FRAME 15-5 Frame Engine Guard Installation • Install the engine guard as shown. Right Engine Guard [A] Collar [B] Bolt [C] Engine Guard [D] Bolts [E][...]

15-6 FRAME Seat Seat Removal • Remove the bolts [A]. • Pull the seat [B] out from the back. Seat Installation • Insert the hooks [A] of the seat under the flange collar [B] and brackets [C]. • T ighten the seat mounting bolts.[...]

FRAME 15-7 Side Cover Side Cover Removal • Remove: Bolts [A] Side Cover [B] • Remove the other side according to similar procedure. Side Cover Installation • Stick the pads [A] on the inside o f the right side cover [B]. • Install the dampers [C]. • Insert the tabs [A] of the cover into the air cleaner housing [B].[...]

15-8 FRAME Fender Front Fender Removal • Unscrew the bolts [A] and remove the front fender [B]. Rear Fender Removal • Remove: Seat (see Seat Removal) • Unscrew the bolts [A] and remove the rear fender [B]. Rear Flap Removal • Unscrew the screws [A] and remove the rear flap [B].[...]

ELECTRICAL SYSTEM 16-1 16 Electrical System T able of Contents Exploded View ................................................................................................................... ..... 16-2 Specifications ................................................................................................................. ........ 16-4 Spe[...]

16-2 ELECTRICAL SYSTEM Exploded View[...]

ELECTRICAL SYSTEM 16-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Gear Position Switch Screws 2.9 0.30 26 in·lb L 2 Flywheel Nut 78 8.0 58 3 Stator Bolts 4.0 0.41 35 in·lb L 4 Spark Plug 13 1.3 11 3 i n · l b 5 Magneto Cover Bolts 9.8 1.0 87 in·lb 6 Crankshaft Sensor Bolts 7.0 0.71 62 in·lb 7 C.D.I. Unit Bolts 9.8 1.0 87 i[...]

16-4 ELECTRICAL SYSTEM Specifications Item Standard Magneto Crankshaft Sensor Resistance 180 ∼ 280 Ω (at 20°C (68°F)) Magneto Output V oltage in the text Stator Coil Resistance in the text Ignition System Ignition T iming 10° BTDC @1 800 r/min (rpm) Ignition Coil: 3 Needle Arcing Distance 7 mm (0.26 in.) or more Primary Winding Resistance 0.[...]

ELECTRICAL SYSTEM 16-5 Special T ools and Sealant Timing L ight: 57001-1241 Spark Plug W rench, Hex 16: 57001-1262 Hand T ester: 57001-1394 Throttle Se nsor Setti ng Adapter # 1: 57001-1400 Peak V oltage Adapter: 57001-1415 Filler Cap Driver: 57001-1454 Needle Adapter Set : 57001-1457 Rotor Puller: 57001-1565 Rotor Holder: 57001-1654 Kawasaki Bond [...]

16-6 ELECTRICAL SYSTEM Wiring Diagram[...]

ELECTRICAL SYSTEM 16-7 Precautions There are numbers of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below . ○ The electrical parts should never be struck sharply , as with a hammer , or allowed to fall on a hard surface. Such a shock to the parts can damage them. ○ T roubles may invo[...]

16-8 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection • Visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor , replace the damaged wiring. • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty , clean it carefully . If it is damaged, replace it[...]

ELECTRICAL SYSTEM 16-9 Flywheel Magneto Magneto Cover Removal • Remove the left radiator shroud. • Drain the engine oil from the crank room oil sump (see Engine Oil Change in the Periodic Maintenance chapter). • Pull the stopper [A] to this side to remove the magneto lead connector [B]. • Disconnect the magneto lead connector from the main [...]

16-10 ELECTRICAL SYSTEM Flywheel Magneto • Hold the flywheel steady with the rotor holder [A], and remove the flywheel nut [B]. Special T ool - Rotor Holder: 57001-1654 • Remove the rotor holder . • Screw the rotor puller [A] into the flywheel. • Remove the flywheel from the crankshaft by turning in the puller center bolt and tapping the he[...]

ELECTRICAL SYSTEM 16-1 1 Flywheel Magneto Stator Removal • Remove: Magneto Cover (see Magneto Cover Removal) Stator Bolts [A] Crankshaft Sensor Bolts [B] Wiring Holder [C] Wiring Grommet [D] • Remove the stator [E] and crankshaft sensor [F] as a set. Stator Installation • Route the leads according to the Cable, Wire, and Hose Routing section [...]

16-12 ELECTRICAL SYSTEM Flywheel Magneto ○ Connect the hand tester [A] to the connector [B] as shown in the table 1, using the needle adapter set [C]. ○ Start the engine. ○ Run it at the rpm given in the table 1. ○ Note the voltage readings (total 2 measurements). Special T ools - Hand T ester: 57001-1394 Needle Adapt er Set: 57001-14 57 T [...]

ELECTRICAL SYSTEM 16-13 Ignition Timing Ignition Timing Inspection • Remove the timing inspection plug [A]. Special T ool - Filler Cap Driver: 57001-1454 • Attach the timing light [A] to the ignition coil lead in the manner prescribed by the manufacturer . Special T ool - Timing Light: 57001-1241 • Start the engine and aim the timing light at[...]

16-14 ELECTRICAL SYSTEM Ignition System Safety Instructions WA R N I N G 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 electric al shock. Ignition Coil Removal • Remove: Fuel T ank (Fuel T ank Removal in the Fuel Sy[...]

ELECTRICAL SYSTEM 16-15 Ignition System Ignition Coil Inspection Measuring arcing distance The most accurate test for determining the condition of the ignition coil is made by measuring arcing distance using the coil tester for the 3-needle method. • Remove the ignition coil. • Connect the ignition coil (with the spark plug cap left in- stalled[...]

16-16 ELECTRICAL SYSTEM Ignition System Spark Plug Gap Inspection • Refer to the Spark Plug Cleaning and Inspection in the Periodic Maintenance chapter . C.D.I. Unit Removal • Remove: Belt (Open) [A] Bolt [B] Number Plate [C] • Disconnect the main harness connector [A]. • Unscrew the mounting bolts [B] and remove the C.D.I. Unit [C]. C.D.I.[...]

ELECTRICAL SYSTEM 16-17 Ignition System Ignition Coil Primary Peak V oltage Check • Disconnect the spark plug cap from the spark plug, but do not remove the spark plug. • Connect the good spark plug [A] to the spark plug cap, then touch the engine with it. NOTE ○ Measure the voltage with each lead connected cor - rectly . The correct value ma[...]

16-18 ELECTRICAL SYSTEM Ignition System[...]

ELECTRICAL SYSTEM 16-19 Ignition System Crankshaft Sensor Peak V oltage Check • T o check the peak voltage, do the following procedures. ○ Disconnect the connector of the magneto lead connector from the main harness. NOTE ○ Measure the voltage with each lead connected cor - rectly . The correct value may not be obtained if disconnected. ○ M[...]

16-20 ELECTRICAL SYSTEM Ignition System Charge Coil Peak V oltage Check • Disconnect the connector of the magneto l ead connector from the main harness. • T o check the peak voltage, do the following procedures. NOTE ○ Measure the voltage with each lead connected cor- rectly . The correct value may not be obtained if disconnected. ○ Maintai[...]

ELECTRICAL SYSTEM 16-21 Ignition System • T o check the output voltage, do the following procedures. ○ Connect the digital voltmeter [A] as follows. Te s t e r ( + ) → Blue Lead Te s t e r ( – ) → Black/Blue Lead ○ Start the engine. ○ Measure the throttle sensor output voltage with the engine idling speed and with the idle throttle va[...]

16-22 ELECTRICAL SYSTEM Throttle Sensor Throttle Sensor Inspection NOTE ○ If the variable rheostat is not available, refer to throttle sensor output/input voltage check in the C.D.I. Unit in- spection. ○ When inspecting the throttle sensor the throttle v alve of the carburetor shall be completely closed and remain the throttle cable connected. [...]

ELECTRICAL SYSTEM 16-23 Throttle Sensor Throttle Sensor Position Adjustment • Remove the carburetor (see Carburetor Removal in the Fuel System chapter). • Measure the resistance between the blue and black lead terminals of the sensor side connector . Blue Lead T erminal [A] Black Lead T erminal [B] Y ellow Lead T erminal [C] Hand T ester [D] Sp[...]

16-24 ELECTRICAL SYSTEM Switches Engine Stop Switch Inspection • Using the hand tester , check to see that only th e con- nections shown in the table have continuity (about zero ohms). Special T ool - Hand T ester: 57001-1394 If the switch has an open or short, repair it or replace it with a new one. Engine Stop Swi tch Connection Gear Position S[...]

ELECTRICAL SYSTEM 16-25 Switches • Remove: O-ring [A] Gear Position Switch Finger [B] Spring [C] Gear Position Switch Installation • I n s e r tt h es p r i n gi n t ot h eh o l ei nt h es h i f td r u m . • Insert the switch finger [A] so that the small diameter [B] is toward hole side. • Apply grease to the O-ring. • Clean the contact p[...]

[...]

APPENDIX 17-1 17 Appendix T able of Contents Cable, Wire, and Hose Routing .............................................................................................. 17-2 T roubleshooting Guide ........................................................................................................... 17-8[...]

17-2 APPENDIX Cable, Wire, and Hose Routing 1. Throttle Cables 2. Marked (AAA) cable is accelerator side. 3. Band (Hold the engine stop switch lead.) 4. Engine Stop Switch Lead 5. Hot S tarter Cable 6. Clutch Cable 7. Clamp (Clamp the clutch and hot starter cable.) 8. Clamp (Clamp the throttle cables.) 9. Clamp (Clamp the throttle cables.)[...]

APPENDIX 17-3 Cable, Wire , and Hose Routing 1. Clutch Cable 2. Engine Stop Switch Lead 3. Hot Starter Cable 4. C.D.I. Unit 5. Clamps (Clamp the clutch cable.) 6. Main Harness 7. Gear Position Sensor Lead 8. Flywheel Lead 9. Clamp (Clamp the gear position sensor lead and magneto lead.) 10. Clamp (Clamp the main harness, gear po- sition sensor lead [...]

17-4 APPENDIX Cable, Wire, and Hose Routing 1. Spark Plug Cap 2. Clamp (Clamp the carburetor drain and air vent hoses.) 3. Clamp (Clamp the gear position sensor lead.) 4. Gear Position Sensor Lead 5. Clamp (Clamp the gear position sensor lead, radiator overflow hose and breather hose.) 6. Breather Hose 7. Flywheel Lead 8. Align the clamp claw and w[...]

APPENDIX 17-5 Cable, Wire , and Hose Routing 1. Install the clamps as shown in the figure. 2. Clamps (Install the clamp screws as shown in the figure.) 3. Carburetor[...]

17-6 APPENDIX Cable, Wire, and Hose Routing 1. Left Radi ator 2. Right Radiator 3. W ater Hose (to cylinder head) 4. W ater Hose (to water pump) 5. Radiator Overflow Hose 6. Joint Pipe 7. Clamp (Position the clamp claw to left side.) 8. Clamp (Position the clamp claw down- ward.)[...]

APPENDIX 17-7 Cable, Wire , and Hose Routing 1. Brake Lever 2. Front Brake Master Cylinder 3. Front Brake Hose 4. Clamp 5. Vi ewed 6. Clamps 7. Front Brake Caliper 8. Front Brake Disc 9. Brake Pedal 10. Rear Brake Master Cylinder 1 1. Rear Brake Hose 12. Clamps 13. Rear Brake C aliper 14. Rear Brake Caliper Guard 15. Rear Brake Disc 16. Rear Brake [...]

17-8 APPENDIX T roubleshooting Guide This is not an exhaustive list, giving every possible cause for each problem listed. it is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. Engine Doesn’t Start, Starting Difficulty: Engine won’t turn over: Va l v e s e i z u r e V alve lifter seizure Cyli[...]

APPENDIX 17-9 T roubleshooting Guide V alve not seating properly (valve bent, de- formed, worn, or carbon accumulation on the seating surface) Decompression trouble Other: Faulty CDI unit Engine oil level to high Engine oil viscosity too high Brake dragging Drive train trouble Engine overheating Clutch slipping Poor Running or No Power at High Spee[...]

17-10 APPENDIX T roubleshooting Guide Clutch inner cable sticking Friction plate worn or warped Steel plate worn or warped Clutch spring broken or weak Clutch release function trouble Clutch hub or housing unevenly worn Clutch not disengaging properly: Clutch lever play excessive Clutch spring compression uneven Engine oil deteriorated Engine oil v[...]

APPENDIX 17-1 1 T roubleshooting Guide Master cylinder damaged Other noise: Bracket, nut, bolt, etc., not properly mounted or tightened Abnormal Exhaust Color: White smoke: Piston oil ring worn Cylinder worn V alve oil seal damaged V alve guide worn Engine oil level too high Black smoke: Air cleaner element clogged Main jet too large or fallen of f[...]

MODEL APPLICA TION Ye a r Model Beginning Frame No. 2006 KX450D6F JKAKXGDC □ 6A000001 or JKAKX450DDA000001 2007 KX450D7F JKAKXGDC □ 7A012001 or JKAKX450DDA012001 2008 KX450D8F JKAKXGDC □ 8A021001 or JKAKX450DDA021001 □ :This digit in the frame number changes from one machine to another . Part No.99924-1355-03 Printed in Japan[...]