Kawasaki KLX450R 2008-2011 Repair Service Manual

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Art.-Nr: 84165

Stichworte: 2008 2009 2010 2011 Kawasaki KLX450R Misc Motorcycle Motorcycles

Produktvarianten

Beschreibung

The Kawasaki KLX450R is a capable Dual-Sport / Off-Road Motorcycle, produced for the 2008 through 2011 model years. Built in Japan, this model leverages extensive motorsports heritage, particularly its success in off-road racing, to deliver a robust machine designed for challenging terrain. Its engineering emphasizes reliability and performance, featuring a liquid-cooled, 4-stroke, DOHC, single-cylinder engine with a displacement of 449 cc. The motorcycle is equipped with a 5-speed transmission, a wet multi-disc clutch, and hydraulic disc brakes front and rear, contributing to its overall effectiveness in demanding riding conditions. This comprehensive Repair Service Manual provides detailed instructions for the maintenance, servicing, and repair of the KLX450R models from 2008-2011. It covers all essential systems, including the engine, transmission, chassis, suspension, brakes, and electrical components. The manual offers in-depth procedures for engine overhaul, scheduled maintenance, troubleshooting, and diagnostics, along with specific torque values and special tool requirements. Designed for professional motorcycle technicians and experienced DIY mechanics, this manual serves as an authoritative resource for ensuring the optimal performance and longevity of your KLX450R.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KLX450R

Model Year:

2008-2011

Vehicle Type:

Dual-Sport / Off-Road Motorcycle

Codes

Manual Product Code:

Not Specified

👋 Introduction

Market Position

Target Audience:

Professional motorcycle technicians and experienced DIY mechanics seeking in-depth repair and maintenance information.

Competitive Analysis

Manual Value:

Provides factory-level technical data and procedures, superior to generic online guides or basic owner's manuals.

Key Features

Feature 1:

Instant PDF download for immediate access.

Feature 2:

Covers a critical four-year production span of the KLX450R.

Feature 3:

Detailed technical specifications and repair procedures essential for accurate servicing.

📋 Manual Details

Coverage Areas

Coverage Scope:

Comprehensive repair and service for Kawasaki KLX450R models 2008-2011.

Page Count

Page Count:

Not Specified (PDF download)

Manual Type

Manual Type:

Repair Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine overhaul, top-end, bottom-end, lubrication, cooling, fuel injection, ignition, starting system, exhaust.

Transmission Drivetrain:

Clutch, gearbox, gear shifting mechanism, final drive (chain and sprockets).

Chassis Suspension:

Frame inspection, front fork (telescopic, cartridge type), rear suspension (Uni-Trak system), swingarm, bearings.

Brakes:

Front and rear brake system inspection, service, hydraulic components, pad replacement, bleeding procedures.

Electrical System:

Wiring diagrams, battery, charging system (stator, regulator/rectifier), lighting, instrumentation, starter motor, fuses.

Fuel System:

Fuel tank, fuel pump, fuel filter, fuel injector cleaning and testing.

Bodywork Trim:

Body panels, seat, handlebars, controls, footpegs, removal and installation.

Procedures Included

Maintenance Procedures:

Scheduled maintenance, oil changes, filter replacements, chain adjustment, spark plug replacement, valve clearance checks.

Troubleshooting Diagnostics:

Fault finding, diagnostic codes (if applicable), systematic problem diagnosis for all major systems.

Repair Rebuild Procedures:

Detailed step-by-step instructions for engine rebuilds, transmission overhauls, suspension component service, and electrical component repair.

Special Tools Techniques:

Identification and usage of specialized tools required for specific repair and maintenance tasks.

Technical Depth

Depth Of Coverage:

Designed for professional technicians, offering detailed specifications, torque values, diagnostic procedures, and complete overhaul instructions.

📊 Manual Specifications

File Format

File Type:

Portable Document Format (PDF)

Searchability:

Likely text-searchable (typical for professionally produced PDFs), allowing quick access to specific information.

Print Quality

Print Readability:

High-quality digital reproduction of original factory manual content, ensuring clear text and diagrams.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, 4-stroke, DOHC, single-cylinder

Displacement:

449 cc (27.4 cu in)

Bore X Stroke:

96.0 x 62.1 mm (3.8 x 2.4 in)

Compression Ratio:

12.0:1

Performance

Horsepower:

Approximately 45-48 HP (factory figures, subject to model year variations and regulatory compliance)

Torque:

Approximately 31-33 lb-ft (factory figures, subject to model year variations)

Fuel System

Fuel Delivery:

Fuel Injection (Digital Fuel Injection - EFI)

Fuel Type:

Unleaded gasoline, minimum octane rating 87

Throttle Body Size:

43 mm

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh, manual return

Clutch Type:

Wet, multi-disc, manual

Features

Gear Ratios:

Detailed ratios for each gear are covered in the manual.

Final Drive:

Sealed chain, 13/48 or similar (refer to manual for specific ratio).

Transmission Fluid:

Refer to manual for specific type and capacity (e.g., SAE 10W-40 API SG or SH).

📐 Dimensions

Exterior

Overall Length:

Approximately 2,270 mm (89.4 in)

Overall Width:

Approximately 820 mm (32.3 in)

Overall Height:

Approximately 1,270 mm (50.0 in)

Wheelbase:

Approximately 1,480 mm (58.3 in)

Ground Clearance:

Approximately 345 mm (13.6 in)

Seat Height:

Approximately 955 mm (37.6 in)

Weights

Dry Weight:

Approximately 122 kg (269 lbs)

Curb Weight:

Approximately 133 kg (293 lbs)

Fuel Capacity:

10 Liters (2.6 US gal)

🛡️ Safety Features

Ratings

Safety Standard:

As an off-road focused motorcycle, it is not subject to typical automotive safety ratings (e.g., NHTSA, Euro NCAP). Emphasis is on rider control and mechanical integrity.

Active Features

Braking System:

Dual hydraulic disc brakes: Front 270mm petal disc, Rear 240mm petal disc.

Suspension Handling:

Advanced suspension provides excellent handling and stability for off-road conditions.

Passive Features

Frame Construction:

High-tensile steel perimeter frame for rigidity and strength.

💡 Technology Features

Infotainment

Infotainment Features:

N/A (Basic instrumentation: speedometer, odometer, trip meter, neutral indicator, high-beam indicator).

Driver Assistance

Driver Assistance Features:

N/A (No electronic rider aids like ABS or traction control on this model).

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000 km (1,860 miles) or 6 months, whichever comes first (refer to manual for specific conditions).

Air Filter Cleaning:

Regularly, depending on riding conditions (e.g., every 1,000 km or as needed in dusty environments).

Valve Clearance Check:

Every 6,000 km (3,700 miles) or 12 months.

Fluid Specifications

Engine Oil Type:

SAE 10W-40 API SG or SH, or JASO MA certified.

Engine Oil Capacity:

Approximately 1.7 L (1.8 US qt) without filter change; 1.9 L (2.0 US qt) with filter change.

Coolant Type:

Permanent antifreeze coolant (ethylene glycol based) with distilled water.

Brake Fluid Type:

DOT 4

Known Issues

Common Wear Items:

Clutch plates, chain and sprockets, brake pads, fork seals, wheel bearings are typical wear items for this type of motorcycle.

Potential Issues Covered:

Manual will detail procedures for addressing common issues like carburetor/injector cleaning, electrical connector corrosion, and suspension tuning.

📚 Vehicle History

Brand Heritage

Kawasaki Motorsports:

Kawasaki has a long and successful history in motorcycle racing, particularly in off-road and motocross disciplines, lending credibility to the KLX450R's design and performance.

Model Evolution

Klx Series:

The KLX450R is part of Kawasaki's long-standing line of off-road motorcycles, evolving from earlier KX motocross platforms, incorporating street-legal features for dual-sport use.

Production

Manufacturing Location:

Japan

Production Years Covered:

2008, 2009, 2010, 2011 model years.

🏆 Awards & Recognition

Recognitions

Motorcycle Awards:

Specific awards for the 2008-2011 KLX450R are not widely documented as distinct accolades, but the model has been recognized within enthusiast communities for its performance and off-road capability.