Segment:
Performance off-road motorcycle (motocross/enduro).
Target Audience:
Enthusiasts, amateur racers, and professional mechanics working on the Kawasaki KLX450R.
Key Competitors Of Vehicle:
Honda CRF450X, Yamaha YZ450F, KTM EXC-F series, Suzuki RM-Z450 (off-road variants).
Engine Type:
Liquid-cooled, four-stroke, DOHC, four-valve single-cylinder (derived from KX450F).
Frame Type:
Perimeter aluminum frame.
Suspension Front:
47mm Kayaba (KYB) upside-down telescopic fork with adjustable compression and rebound damping.
Suspension Rear:
New Uni-Trak linkage system with adjustable spring preload, compression, and rebound damping.
Brakes:
Hydraulic disc brakes front and rear.
General Coverage:
Comprehensive workshop and repair procedures for the Kawasaki KLX450R (2007 onward).
Estimated Page Count:
Typically 300-500 pages for this type of comprehensive workshop manual. Exact count not provided in product name.
Type:
Workshop Manual / Service Manual / Repair Manual
Language:
Likely English. Specific language not explicitly stated in product name.
Format:
Physical book (implied by 'BIKE Workshop Manual'). Could also be available digitally (e.g., PDF).
Engine Systems:
Engine assembly, disassembly, inspection, lubrication, cooling system, fuel system (carburetor), ignition system, exhaust system, starting system.
Drivetrain Systems:
Clutch, transmission (gearbox) overhaul, final drive (chain and sprockets).
Chassis Systems:
Frame, suspension (forks, rear shock absorber), steering system, wheels, hubs, spokes, brakes (front and rear hydraulic disc), controls.
Electrical Systems:
Wiring diagrams, lighting system, battery, charging system (alternator, rectifier/regulator), ignition system components, switches, relays, fuses.
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, spark plug inspection/replacement, air filter cleaning/replacement, brake fluid flush, coolant flush.
Troubleshooting:
Diagnostic procedures for common issues, fault finding charts, symptom-based troubleshooting.
Major Repairs:
Engine rebuilds (top end and bottom end), transmission rebuilds, suspension fork seal replacement, brake caliper overhaul, carburetor tuning and rebuilding.
Component Disassembly Reassembly:
Detailed step-by-step instructions for removing, inspecting, servicing, and reinstalling all major and minor components.
Depth:
Comprehensive. Covers everything from basic fluid checks and adjustments to complete engine and transmission overhauls and advanced electrical system diagnostics.
Diagnostic Capabilities:
Includes information on diagnosing common performance issues, electrical faults, and mechanical wear.
Specification Data:
Provides critical torque specifications, clearances, fluid capacities, and other essential data for accurate repairs.
Digital Format If Applicable:
If digital, typically PDF with searchable text and high-resolution diagrams.
Print Quality If Physical:
High-quality printing on durable paper, designed for workshop use with clear diagrams and text.
Binding Type If Physical:
Often spiral-bound or lay-flat binding for easy use on a workbench.
Paper Type If Physical:
Durable, often glossy or semi-gloss paper to resist grease and dirt in a workshop environment.
Engine Type:
Liquid-cooled, four-stroke, SOHC, four-valve single-cylinder
Bore X Stroke:
92.0 x 67.5 mm
Compression Ratio:
12.0:1
Valve Train:
SOHC, 4 valves
Max Power:
Approx. 46-50 HP (This is an estimate based on similar models; precise figures vary by region and tuning).
Max Torque:
Approx. 40-43 Nm (This is an estimate).
Fuel Delivery:
Keihin FCR39 carburetor
Fuel Tank Capacity:
8.0 Liters (2.1 US gal)
Oil Capacity:
Approx. 1.3 Liters (with filter change)
Coolant Type:
Pre-mixed ethylene glycol coolant (50/50) with distilled water.
Coolant Capacity:
Approx. 1.8 Liters
Crash Test Ratings:
N/A for off-road motorcycles. Safety relies on rider skill and component integrity.
Braking System:
Dual piston front caliper with 250mm petal disc, single piston rear caliper with 240mm petal disc.
Frame Construction:
Rigid aluminum perimeter frame designed for off-road abuse.
Lighting:
Headlight and taillight are standard, but often removed or upgraded for racing.
Infotainment System:
N/A (Performance off-road motorcycle; no standard infotainment features).
Rider Assistance:
N/A (Focus is on rider control and mechanical performance).
Connectivity Features:
N/A (No electronic connectivity features).
Ignition Type:
Digital CDI (Capacitor Discharge Ignition).
Engine Oil Change:
Every 10-15 hours of riding or annually, whichever comes first. More frequent for hard use.
Air Filter Cleaning:
After every ride, or more frequently in dusty conditions.
Spark Plug Inspection:
Every 20-30 hours of riding.
Chain Adjustment Lubrication:
Before every ride.
Brake Fluid Flush:
Annually or every 12 months.
Coolant Flush:
Every 1-2 years or as per manual recommendation.
Engine Oil Specification:
SAE 10W-40, API SG or higher, JASO MA certified motorcycle oil.
Coolant Specification:
Pre-mixed coolant (50% ethylene glycol, 50% distilled water).
Brake Fluid Specification:
DOT 4 hydraulic brake fluid.
Transmission Oil Specification:
SAE 80W-90 API GL-4 gear oil.
Common Wear Items:
Clutch plates, brake pads, chain and sprockets, tires, fork seals, piston rings due to high-performance nature and off-road use.
Carburetor Tuning:
May require re-jetting or adjustment with aftermarket exhaust or air filter modifications.
Suspension Maintenance:
Regular fork oil and seal maintenance is crucial for optimal performance.
Kawasaki Off Road Legacy:
Kawasaki has a long and successful history in motocross and off-road racing with models like the KX series. The KLX line represents their more off-road-oriented, often trail-capable, machines.
Klx450R Development:
The KLX450R was introduced as a purpose-built off-road competition machine, sharing significant DNA with the KX450F motocross bike but with modifications for broader off-road usability (e.g., different gearing, sometimes wider ratios, larger fuel tank, more compliant suspension tuning, lighting).
Manufacturing Location:
Primarily Japan.
Production Period:
Introduced for the 2007 model year, with updates and revisions through subsequent years.
