Positioning:
The Kawasaki KLX450R is a potent off-road motorcycle designed for competitive motocross and enduro riding, blending powerful performance with robust chassis components. It's positioned as a no-nonsense, race-ready machine.
Competitors:
Primarily competes with models like the Yamaha YZ450F, Honda CRF450X, KTM 450 EXC, and Suzuki RM-Z450 (off-road variants).
Features:
Liquid-cooled 4-stroke engine, electric start, long-travel suspension, aggressive styling, durable build for off-road abuse.
Primary Coverage:
Complete Workshop and Service
Model Years Covered:
2007, 2008, 2009, 2010, 2011, 2012, 2013, 2014, 2015, 2016, 2017, 2018, 2019, 2020, 2021, 2022, 2023, 2024
Engine Variants Covered:
KLX450A
Type:
Factory Service Manual / Workshop Manual
Engine:
Complete teardown, assembly, specifications, troubleshooting, tuning
Fuel System:
Carburetor (Keihin FCR40), fuel pump, fuel tank, fuel lines
Ignition System:
CDI, spark plug, ignition coil, timing
Cooling System:
Liquid-cooled, radiator, fan, coolant specifications
Transmission:
5-speed gearbox, clutch operation, lubrication, disassembly
Drivetrain:
Chain drive, sprockets, rear hub
Suspension Front:
Upside-down telescopic forks (Showa), oil type, level, damping adjustments, rebuild
Suspension Rear:
Uni-Trak single shock system (Showa), shock absorber specifications, linkage maintenance, rebuild
Brakes Front:
Hydraulic disc, caliper, master cylinder, pad replacement, fluid type, bleeding procedure
Brakes Rear:
Hydraulic disc, caliper, master cylinder, pad replacement, fluid type, bleeding procedure
Electrical System:
Wiring diagrams, battery, lighting, charging system, starter motor, switches, fuses
Frame And Bodywork:
Frame structure, subframe, plastic panels, seat, fuel tank removal/installation
Wheels And Tires:
Rim specifications, spoke tension, tire sizes, pressure, wheel bearing maintenance
Maintenance:
Scheduled maintenance, oil changes, filter replacements, chain adjustment, brake service, valve clearance checks
Troubleshooting:
Diagnostic charts for common problems, electrical issues, engine performance issues
Repair:
Component-level repair procedures, engine rebuilds, transmission overhauls, suspension servicing
Disassembly Assembly:
Detailed step-by-step instructions for all major components and systems
Specifications:
Torque values, clearances, fluid capacities, electrical values
Depth:
Comprehensive: Covers everything from basic rider maintenance to full engine and transmission rebuilds, including advanced diagnostics and electrical system repairs.
Engine Type:
4-stroke, DOHC, single-cylinder
Bore X Stroke:
96.0 x 62.1 mm
Compression Ratio:
12.0:1
Valve Train:
DOHC, 4 valves
Horsepower Estimated:
Approx. 53 HP (at crank, varies by region/tuning)
Torque Estimated:
Approx. 33 lb-ft (at crank, varies by region/tuning)
Carburetor Type:
Keihin FCR40 (Flat CR)
Fuel Capacity:
8.0 Liters (2.1 US gallons)
Fuel Type Recommended:
Unleaded gasoline, 91 octane or higher
Engine Oil Change:
Every 1,000 km (600 miles) or 6 months, whichever comes first.
Oil Filter Replacement:
At every oil change.
Air Filter Cleaning:
Every 500 km (300 miles) or as needed based on riding conditions.
Valve Clearance Check:
Every 3,000 km (1,800 miles) or 12 months.
Chain Lubrication:
Every 500 km (300 miles) and after washing or riding in wet conditions.
Chain Adjustment:
Every 1,000 km (600 miles) or as needed for proper slack.
Engine Oil Type:
SAE 10W-40, API SG or higher, JASO MA certified.
Engine Oil Capacity:
1.9 L (2.0 US qt) without filter change; 2.1 L (2.2 US qt) with filter change.
Coolant Type:
High-quality ethylene glycol-based coolant, 50/50 mix with distilled water.
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Fork Oil Type:
Showa SS-02 or equivalent, SAE 0W-20 (check specific model year for exact recommendation).
Fork Oil Level:
130 mm (5.1 in) from top of inner tube with spring removed.
Common Wear Items:
Clutch plates, brake pads, chain and sprockets, wheel bearings, suspension seals, air filter degradation.
Carburetor Tuning:
Can be sensitive to altitude and temperature changes, requiring periodic adjustment.
Cam Chain Tensioner:
Some early models may benefit from aftermarket cam chain tensioner upgrades to prevent potential slack.
Radiator Fan Switch:
Infrequent reports of fan switch failures; regular testing is advised.
