Category:
High-performance off-road/motocross motorcycle.
Competitors:
Honda CRF450R, Yamaha YZ450F, Suzuki RM-Z450, KTM 450 SX-F.
Off Road Focus:
Designed for competitive off-road riding, emphasizing power, suspension, and agility. Not street legal in most configurations.
Manual Purpose:
Essential resource for owners and mechanics to maintain, troubleshoot, and repair the KLX450R to factory specifications.
Engine:
Complete overhaul, diagnostics, tuning, internal components (piston, rings, valves, camshafts, crankshaft), lubrication system.
Fuel System:
Carburetor (Keihin FCR MX series), fuel tank, fuel pump (if applicable), fuel lines, cleaning, adjustment, and troubleshooting.
Ignition System:
CDI unit, ignition coil, spark plug, wiring, timing adjustments.
Transmission:
Clutch operation and adjustment, gearbox disassembly and reassembly, gear ratios, shift mechanism, transmission oil specifications and change intervals.
Cooling System:
Radiator, cooling fan, coolant hoses, thermostat, coolant type and capacity, bleeding the system.
Suspension:
Front fork (Kayaba USD, adjustable compression and rebound), rear shock absorber (Kayaba, adjustable preload, compression, and rebound), seal replacement, oil levels and types, spring rates, linkage maintenance.
Brakes:
Front and rear hydraulic disc brakes, brake fluid type (DOT 4), bleeding procedures, pad replacement, caliper maintenance, master cylinder service.
Electrical System:
Wiring diagrams, battery maintenance, charging system (stator, rectifier/regulator), lighting system, starter motor, fuses, troubleshooting electrical faults.
Chassis And Frame:
Frame inspection, steering head bearing maintenance, swingarm bearing service, wheel bearings.
Exhaust System:
Muffler, header pipe inspection and replacement.
Bodywork And Trim:
Seat removal, fuel tank removal, body panel removal and installation.
Routine Maintenance:
Oil changes, filter replacements (oil, air), chain adjustment and lubrication, brake inspection, tire pressure checks, spark plug checks.
Troubleshooting:
Diagnostic flowcharts for common problems, symptom-based repair guidance.
Disassembly And Reassembly:
Step-by-step instructions for major component overhauls and replacements.
Torque Specifications:
Essential torque values for all critical fasteners.
Special Tools:
Identification and usage of specialized tools required for certain procedures.
Depth:
Comprehensive, covering basic maintenance to full engine and transmission rebuilds. Includes detailed diagnostic information and component specifications.
Quality:
High-resolution PDF, ensuring clarity of diagrams and text. Searchable text for efficient information retrieval.
Printability:
Designed to be printable, allowing users to create physical copies for workshop use.
Digital Format Advantage:
No physical binding limitations; accessible on multiple devices.
Digital Content Advantage:
Richly illustrated with diagrams, schematics, and photographs (typical for factory service manuals).
Type:
4-stroke, Liquid-cooled, DOHC, 4-valve Single Cylinder
Bore X Stroke:
96.0 x 62.1 mm
Compression Ratio:
12.0:1
Valve Train:
DOHC, 4 valves (2 intake, 2 exhaust)
Horsepower:
Approx. 50-55 HP (at crankshaft, model dependent)
Torque:
Approx. 40-45 Nm (at crankshaft, model dependent)
Carburetor:
Keihin FCR40MX (flat slide, accelerator pump)
System:
Semi-dry sump with oil cooler
Engine Oil Change:
Recommended every 10-15 hours of riding or annually, whichever comes first. Refer to manual for precise intervals based on riding conditions.
Air Filter Cleaning:
Clean after every few rides, or more frequently in dusty conditions.
Spark Plug Check:
Check at 10-15 hour intervals, replace as needed.
Chain Lubrication Adjustment:
Lubricate before every ride; adjust tension every 5-10 hours of riding.
Engine Oil Type:
SAE 10W-40, API SG or higher, JASO MA certified (e.g., Kawasaki Genuine Oil, Motul 3000 10W-40).
Engine Oil Capacity:
1.7 Liters (1.8 US qt) without filter change, 1.9 Liters (2.0 US qt) with filter change.
Transmission Oil Type:
Refer to engine oil specifications (same oil is used for engine and transmission in this model).
Coolant Type:
Permanent type antifreeze (ethylene glycol based), 50/50 mixture with distilled water. (e.g., Kawasaki Coolant).
Carburetor Tuning:
The Keihin FCR MX carburetor can require precise tuning for optimal performance at different altitudes and temperatures. The manual provides detailed jetting and adjustment procedures.
Suspension Maintenance:
Off-road riding places significant stress on suspension. Regular seal and oil changes are crucial to maintain performance and prevent leaks.
Clutch Wear:
Aggressive riding can lead to clutch wear. The manual details clutch inspection, component replacement, and adjustment.
