🏷️ Basic Information

Make:

Kawasaki

Model:

KX450F

Model Years Covered:

2009, 2010

Chassis Code 2009:

KX450D9

Chassis Code 2010:

KX450EAF

👋 Introduction

Segment:

Competition Motocross

Target Audience:

Motocross racers, enthusiasts, mechanics, and owners seeking to maintain and repair their KX450F.

Competitors 2009 2010:

Yamaha YZ450F, Honda CRF450R, Suzuki RM-Z450, KTM 450 SX-F.

Frame Design:

Perimeter frame with advanced rigidity balance for improved handling and cornering.

Engine Design:

Liquid-cooled, DOHC, four-stroke single cylinder with advanced DFI for optimal power delivery.

Suspension Technology:

Separate Function Front Fork (SFF) with adjustable compression and rebound damping, and a fully adjustable rear shock.

Value Proposition:

Provides essential technical information for maintaining peak performance and executing repairs, saving on costly dealership services.

📋 Manual Details

Coverage Type:

Workshop Service Repair

Estimated Page Count:

400+

Manual Type:

Service Manual / Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine:

Complete engine overhaul, including disassembly, inspection, assembly, lubrication, tuning, and component specifications.

Fuel System:

Fuel injection system (DFI - Digital Fuel Injection), throttle body, fuel pump, injectors, pressure regulator, and related components.

Ignition System:

Ignition system, ECU (Engine Control Unit), ignition coil, spark plug, and timing adjustments.

Cooling System:

Radiator, coolant, water pump, hoses, and thermostat.

Exhaust System:

Exhaust pipe, muffler, and related hardware.

Transmission:

Clutch assembly, transmission gears, shift forks, shift drum, and lubrication.

Drivetrain:

Final drive, chain, sprockets, and lubrication.

Suspension Front:

Front fork (SFF - Separate Function Fork type), seals, oil specifications, damping adjustments, and spring rates.

Suspension Rear:

Rear shock absorber, linkage, bushings, oil specifications, and damping adjustments.

Brakes Front:

Front brake caliper, master cylinder, brake lines, brake fluid specifications, and pad replacement.

Brakes Rear:

Rear brake caliper, master cylinder, brake lines, brake fluid specifications, and pad replacement.

Wheels Tires:

Wheel bearing inspection and replacement, tire pressure recommendations, and rim specifications.

Electrical System:

Battery, charging system, lighting, starter motor, wiring diagrams, and troubleshooting.

Bodywork:

Frame, plastics, seat, handlebars, footpegs, and fasteners.

Troubleshooting:

Diagnostic charts and common problem solutions for various systems.

Maintenance:

Regular maintenance procedures, including oil changes, filter replacements, chain lubrication, and general inspection.

Repair:

Detailed step-by-step repair instructions for all major components and systems.

Disassembly Assembly:

Comprehensive instructions for taking apart and reassembling the motorcycle and its sub-systems.

Inspection Adjustment:

Procedures for inspecting wear and tear, and making necessary adjustments to various components.

Tuning:

Engine tuning procedures, including idle speed, fuel mapping adjustments (via DFI coupler), and ignition timing checks.

Torque Specifications:

Detailed torque values for all critical fasteners and bolts.

Lubrication Points:

Identification and specifications for all lubrication points.

Depth:

Comprehensive coverage from basic maintenance and routine checks to advanced diagnostics and complete engine and transmission rebuilds.

Diagnostic Capabilities:

Includes diagnostic flowcharts for common issues, troubleshooting of the DFI system, and electrical system faults.

Component Data:

Provides detailed measurements, tolerances, and wear limits for critical engine and chassis components.

📊 Manual Specifications

File Format:

PDF

Print Quality:

High-resolution scans, suitable for printing.

Binding Type:

N/A (Digital PDF Download)

Paper Type:

N/A (Digital PDF Download)

Searchability:

Searchable text within the PDF document for quick information retrieval.

⚙️ Engine Specifications

Engine Type:

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

Displacement:

449 cc

Bore X Stroke:

96.0 x 62.1 mm

Compression Ratio:

12.0:1

Valve Train:

DOHC, 4 valves

Estimated Horsepower:

Approx. 55-58 HP (at crankshaft, dependent on tuning and exhaust)

Estimated Torque:

Approx. 35-37 lb-ft (at crankshaft, dependent on tuning and exhaust)

Fuel System:

DFI (Digital Fuel Injection) with 43mm Keihin throttle body

Fuel Type:

Unleaded gasoline, minimum 91 octane

Engine Oil Type:

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

Engine Oil Capacity W Filter Change:

1.0 L (1.1 US qt)

Transmission Oil Type:

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

Transmission Oil Capacity:

0.7 L (0.7 US qt)

🔧 Transmission

Transmission Type:

5-speed constant mesh

Optional Gear Ratios:

N/A (Standard fixed gear ratios)

Clutch Type:

Wet, multi-disc

Final Drive:

Sealed O-ring chain

📐 Dimensions

Length:

2,185 mm (86.0 in)

Width:

815 mm (32.1 in)

Height:

1,265 mm (49.8 in)

Wheelbase:

1,480 mm (58.3 in)

Ground Clearance:

330 mm (13.0 in)

Seat Height:

955 mm (37.6 in)

Curb Weight:

114 kg (251.3 lbs) (approximate, depending on fuel and accessories)

Dry Weight:

111 kg (244.7 lbs)

Fuel Capacity:

8.0 L (2.1 US gal)

🛡️ Safety Features

Safety Ratings:

N/A (Motocross bikes are not subject to typical road vehicle safety ratings)

Braking System:

Hydraulic disc brakes front and rear for strong stopping power.

Frame Construction:

High-tensile steel perimeter frame designed for stiffness and impact resistance.

Ergonomics:

Designed for rider control and stability during aggressive riding.

💡 Technology Features

Infotainment System:

N/A (Motocross specific features)

Driver Assistance:

N/A (Motocross specific features)

Connectivity Features:

DFI Couplers: The manual explains the use of optional DFI couplers to easily tune engine performance for different track conditions and rider preferences.

🔧 Maintenance

Engine Oil Change:

Every 5-10 hours of riding or annually.

Air Filter Cleaning:

Before every ride or after dusty conditions.

Spark Plug Inspection:

Every 10-15 hours of riding.

Chain Lubrication Adjustment:

Every 5-10 hours of riding.

Valve Clearance Check:

Every 15-25 hours of riding.

Coolant Type:

High-quality, ethylene glycol-based coolant with distilled water (50/50 mix).

Brake Fluid Type:

DOT 4 hydraulic brake fluid.

Common Wear Items:

Clutch plates, brake pads, wheel bearings, swingarm/linkage bearings, and fork seals due to the demanding nature of motocross.

Potential DFI Issues:

Less common, but check for injector clogging or sensor issues if performance is erratic. The manual details troubleshooting for these.

Suspension Maintenance:

Regular fork oil changes and seal inspections are crucial for maintaining optimal damping performance.

📚 Vehicle History

Kawasaki Motocross Legacy:

Kawasaki has a long and successful history in motocross racing, with a strong lineage of KX models known for performance and durability.

Kx450F Development:

The KX450F has undergone continuous development, with significant updates in the mid-2000s introducing fuel injection and revised chassis designs. The 2009-2010 models represent a refinement of these advancements, focusing on chassis balance and engine tuning.

Manufacturing Location:

Japan

Key Design Changes 2009 2010:

While not a complete redesign, these model years saw refinements in suspension settings, engine mapping, and chassis geometry for improved handling and power delivery.

🏆 Awards & Recognition

Motocross Industry Recognition:

Kawasaki KX models have consistently been highly regarded in the motocross community, often praised for their powerful engines, advanced suspension, and competitive chassis design.