Kawasaki KLX450R 2008-2011 Factory Service Repair Manual

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Tipo: Motorcycle

Proveedor:

SKU: 92726

Etiquetas: 2008 2009 2010 2011 Kawasaki KLX450R Misc Motorcycle Motorcycles

Variantes de producto

Descripción

The KLX450R, produced from 2008 to 2011, is a potent off-road motorcycle engineered for aggressive performance and exceptional capability in demanding terrain. Building on esteemed heritage in motocross and enduro, this model offers robust construction and a powerful liquid-cooled, 4-stroke, 449 cc engine designed for optimal torque and responsiveness. Its design prioritizes off-road prowess, featuring adjustable suspension, hydraulic disc brakes, and a durable chassis, making it a competitive choice for enthusiasts and racers seeking a reliable and high-performing machine for enduro and motocross applications. This comprehensive Factory Service Repair Manual is your definitive guide to understanding, maintaining, and repairing your KLX450R. Covering all major systems, including the engine, fuel, transmission, chassis, and electrical components, this manual provides detailed procedures for scheduled maintenance, diagnostics, and component overhauls. With clear instructions, essential technical specifications, and troubleshooting guidance, it empowers owners and technicians to ensure peak performance and longevity of the motorcycle, addressing common issues and offering solutions for optimal operation.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KLX450R

Year:

2008-2011

Category:

Off-Road Motorcycle / Dual-Sport

Codes

Engine Code:

Unknown from provided info, typically a 4-stroke single cylinder

Chassis Code:

Unknown from provided info

👋 Introduction

Market Position

Segment:

Performance Off-Road (Enduro/Motocross focus with potential for dual-sport conversion)

Target Audience:

Enthusiasts, racers, mechanics performing maintenance and repairs

Competitive Analysis

Competitors:

Yamaha WR450F, Honda CRF450X, KTM 450 EXC

Key Features

Vehicle Focus:

Aggressive performance, off-road capability, robust construction

Manual Value:

Essential for proper maintenance, diagnosis, and repair to maximize performance and longevity

📋 Manual Details

Coverage Areas

Models Covered:

Kawasaki KLX450R

Years Covered:

2008, 2009, 2010, 2011

Page Count

Estimated Page Count:

Hundreds (typical for factory service manuals)

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English (presumed for North American market)

Format

Format:

Digital (PDF) - inferred from typical sales for older models

📖 Manual Coverage

Systems Covered

Engine:

Complete overhaul, diagnostics, tuning, cooling system, lubrication system

Fuel System:

Carburetor (likely Keihin FCR type), fuel pump, fuel tank, fuel lines

Transmission:

Clutch, gearbox, shift mechanism, lubrication

Chassis:

Frame, swingarm, linkages, suspension (front and rear), steering

Electrical System:

Ignition system, lighting, charging system, starter motor, wiring diagrams

Brakes:

Front and rear brake systems, master cylinders, calipers, rotors, fluid replacement

Wheels And Tires:

Wheel bearing service, tire replacement, spoke tension

Bodywork:

Fairings, seat, fenders, plastics, graphics

Procedures Included

Maintenance:

Scheduled maintenance intervals, oil changes, filter replacements, chain adjustments

Troubleshooting:

Diagnostic charts for common problems, fault finding

Repair:

Component disassembly, reassembly, and adjustment for all major systems

Special Tools:

Identification and usage of specialized tools required for specific procedures

Technical Depth

Depth:

Comprehensive; covers everything from basic checks to complete engine rebuilds and electrical system diagnostics

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text (typical for factory PDFs)

Print Quality

Quality:

High-resolution scans for clear diagrams and text

Binding Type

Binding:

N/A (Digital format)

Paper Type

Paper Type:

N/A (Digital format)

⚙️ Engine Specifications

Primary Engine

Type:

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

Displacement:

449 cc (27.4 cu in)

Bore X Stroke:

92.0 x 67.1 mm (3.62 x 2.64 in) - typical for this era

Compression Ratio:

12.0:1 (typical for this model)

Performance

Horsepower:

Approx. 50-55 HP (estimated at crank, varies by market and tune)

Torque:

Approx. 32-35 lb-ft (estimated at crank, varies by market and tune)

Fuel System

Carburetor:

Keihin FCR40 (likely) with Accelerator Pump

Fuel Type:

Unleaded gasoline, 91+ octane recommended

Ignition

Type:

Digital CDI with electronic advance

Cooling System

Type:

Liquid-cooled

Coolant Capacity:

Approx. 1.8 L (1.9 US qt)

🔧 Transmission

Standard

Type:

5-speed constant mesh, sequential

Clutch:

Wet, multi-disc, manual

Features

Gear Ratios:

Specific ratios covered in manual, designed for off-road torque

Fluid Capacity

Engine Oil Capacity:

Approx. 1.8 L (1.9 US qt) with filter change

Fluid Specifications

Engine Oil Type:

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

📐 Dimensions

Exterior

Length:

Approx. 2,200 mm (86.6 in)

Width:

Approx. 825 mm (32.5 in)

Height:

Approx. 1,255 mm (49.4 in)

Weights

Dry Weight:

Approx. 114 kg (251.3 lbs)

Wet Weight:

Approx. 125 kg (275.6 lbs) (with all fluids)

Wheelbase

Wheelbase:

Approx. 1,475 mm (58.1 in)

Ground Clearance

Ground Clearance:

Approx. 325 mm (12.8 in)

Seat Height

Seat Height:

Approx. 955 mm (37.6 in)

🛡️ Safety Features

Ratings

Certification:

Not typically rated by safety organizations like NHTSA/IIHS as it's an off-road vehicle

Active Features

Braking System:

Hydraulic disc brakes front and rear

Suspension Features:

Adjustable front forks (compression, rebound) and rear shock (preload, compression, rebound)

Passive Features

Lighting:

Headlight, taillight/stoplight (may vary based on original configuration/market)

💡 Technology Features

Infotainment

Features:

Minimalist; designed for performance not comfort or entertainment. Typically includes basic odometer, trip meter, and neutral indicator.

Driver Assistance

Features:

None (off-road focused design)

Connectivity

Features:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 600 miles (1000 km) or 3 months, whichever comes first (typical recommendation)

Air Filter Cleaning:

Every 10-15 hours of riding in dusty conditions, or 30-40 hours in clean conditions

Chain Lubrication Adjustment:

Every 300 miles (500 km) or after washing/wet riding

Valve Clearance Check:

Every 1,000-1,500 miles (1600-2400 km) or annually

Fluid Specifications

Fork Oil Type:

Kawasaki KSH-10W or equivalent (e.g., Showa SS-10W, Golden Spectro Extra Light)

Fork Oil Level:

Specified in manual, typically around 120-150mm from the top of the inner tube with spring removed and fork compressed

Brake Fluid Type:

DOT 4

Coolant Type:

Permanent type antifreeze (ethylene glycol based) with distilled water, 50/50 mix

Known Issues

Common Issues:

Carburetor jetting sensitivity to altitude and temperature, potential clutch wear under extreme use, chain and sprockets are wear items.

Preventative Maintenance:

Regular cleaning of air filter, proper chain tension and lubrication, diligent oil changes are critical for longevity.

📚 Vehicle History

Brand Heritage

Heritage:

Kawasaki has a long history of producing competitive off-road motorcycles, including the esteemed KX series.

Model Evolution

Predecessors:

The KLX450R builds upon Kawasaki's experience with 4-stroke motocross and enduro technology, often sharing components or design philosophies with the KX450F.

Features Introduction:

Introduced as a dedicated off-road/enduro machine, often featuring a slightly wider gear ratio spread and more user-friendly power delivery compared to its motocross sibling.

Production

Manufacturing Location:

Japan (typical for Kawasaki motorcycles)

Production Period:

The KLX450R model line has been produced in various iterations, with the 2008-2011 period representing a specific generation.

🏆 Awards & Recognition

Recognitions

Reviews:

Praised for strong engine performance and capable chassis in contemporary off-road reviews.

Ratings

Editorial Ratings:

Consistently ranked as a strong contender in the 450cc enduro class during its production years.

Certifications

Emissions:

Likely meets EPA standards for off-road vehicles of its era, specific details would be in the manual.