Kawasaki KLX450R 2008-2011 Repair PDF Service Manual Download

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Basic Information Identification Make: Kawasaki Model: KLX450R Years Covered: 2008, 2009, 2010, 2011 Codes Platform Code: KLX450A Introduction Market Position Market Segment: Competition/Off-Road/Enduro motorcycle Competitive Analysis Competitors: Honda CRF450X, Yamaha...

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Type: Motorcycle

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Sku: 87173

Tags: 2008 2009 2010 2011 Kawasaki KLX450R Misc Motorcycle Motorcycles

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Description

Basic Information
Identification
Make:	Kawasaki
Model:	KLX450R
Years Covered:	2008, 2009, 2010, 2011
Codes
Platform Code:	KLX450A

Introduction
Market Position
Market Segment:	Competition/Off-Road/Enduro motorcycle
Competitive Analysis
Competitors:	Honda CRF450X, Yamaha WR450F, KTM EXC series
Key Features
Klx450R Design:	Purpose-built for off-road competition and trail riding, derived from Kawasaki's KX450F motocross platform
Manual Value:	Essential tool for owners and technicians to maintain, diagnose, and repair the KLX450R efficiently

Manual Details
Coverage Areas
Primary Coverage:	Comprehensive service and repair for the Kawasaki KLX450R
Page Count
Estimated Page Count:	Varies by specific model year variant, typically 300-400 pages
Manual Type
Manual Type:	Repair Service Manual
Language
Language:	English
Format
File Format:	PDF

Manual Coverage
Systems Covered
Engine:	Detailed engine disassembly, assembly, tuning, and troubleshooting including fuel system, ignition, lubrication, and cooling
Transmission:	Clutch, gearbox, shift mechanism, and lubrication system service
Chassis:	Frame, suspension (front fork and rear shock absorber), steering, and swingarm
Brakes:	Front and rear hydraulic brake systems, including caliper, master cylinder, and fluid service
Electrical System:	Wiring diagrams, lighting, ignition system, battery, charging system, and troubleshooting
Fuel System:	Carburetor (Keihin FCR40), fuel pump, fuel lines, and maintenance
Cooling System:	Radiator, fan, hoses, and coolant specifications
Exhaust System:	Muffler, header pipe inspection and maintenance
Wheels And Tires:	Wheel bearing service, tire pressure, and replacement
Procedures Included
Maintenance:	Regular scheduled maintenance, oil changes, filter replacements, and lubrication points
Troubleshooting:	Diagnostic procedures for common problems, fault codes (if applicable), and systematic problem-solving
Repair:	Step-by-step instructions for component replacement, overhaul, and adjustment
Rebuilds:	Engine and transmission component rebuild procedures
Specifications:	Torque specifications, clearances, and measurements for all components
Wiring Diagrams:	Detailed electrical system schematics
Technical Depth
Depth:	Comprehensive, covering basic maintenance to complete engine and chassis rebuilds

Manual Specifications
File Format
File Format Details:	Searchable PDF, allowing for easy navigation and keyword searching
Print Quality
Print Quality:	High-resolution, suitable for printing individual pages or the entire manual
Binding Type
Binding Type:	N/A (Digital Download)
Paper Type
Paper Type:	N/A (Digital Download)

Engine Specifications
Primary Engine
Engine Type:	4-stroke, DOHC, liquid-cooled, single cylinder
Displacement:	449 cc (27.4 cu in)
Bore X Stroke:	96.0 x 62.1 mm (3.78 x 2.44 in)
Compression Ratio:	12.0:1 (typical)
Performance
Horsepower:	Approx. 52 hp @ 8,500 rpm (specifications may vary slightly by year and tuning)
Torque:	Approx. 47 Nm (34.5 lb-ft) @ 6,500 rpm (specifications may vary slightly by year and tuning)
Fuel System
Carburetor:	Keihin FCR40 (Flat CR) with Acceleration Pump
Fuel Type:	Unleaded gasoline (91 octane or higher recommended)
Lubrication
Oil Type:	SAE 10W-40 API SG or higher motorcycle specific oil
Oil Capacity:	Approx. 1.2 L (1.3 US qt) with filter change
Cooling System
Coolant Type:	High-quality ethylene glycol based coolant with distilled water (50:50 mix)
Ignition
Ignition System:	Digital CDI

Transmission
Standard
Transmission Type:	5-speed constant mesh, sequential manual
Clutch Type:	Wet, multi-plate
Features
Gear Ratios:	Typically: 1st: 2.923 (38/13), 2nd: 2.063 (33/16), 3rd: 1.579 (30/19), 4th: 1.294 (22/17), 5th: 1.050 (21/20)
Final Drive:	O-ring sealed chain, 520 size
Transmission Oil Type:	API SG, SAE 10W-40 motorcycle oil (shared with engine)

Dimensions
Exterior
Length:	Approx. 2,200 mm (86.6 in)
Width:	Approx. 800 mm (31.5 in)
Height:	Approx. 1,230 mm (48.4 in)
Wheelbase:	Approx. 1,480 mm (58.3 in)
Ground Clearance:	Approx. 345 mm (13.6 in)
Weights
Dry Weight:	Approx. 121 kg (267 lbs)
Wet Weight:	Approx. 132 kg (291 lbs) (with all fluids)
Wheels And Tires
Front Tire Size:	80/100-21 51M
Rear Tire Size:	110/100-18 64M
Front Wheel Type:	Spoked, 21-inch
Rear Wheel Type:	Spoked, 18-inch

Safety Features
Ratings
Safety Standards:	Designed for off-road use; not intended for highway use, therefore no DOT safety ratings apply
Active Features
Brakes:	Front: 250mm petal disc with 2-piston caliper; Rear: 240mm petal disc with 1-piston caliper
Passive Features
Frame Construction:	Perimeter frame with high-tensile steel construction for rigidity and durability

Technology Features
Infotainment
Infotainment System:	N/A (Performance off-road motorcycle, basic instrumentation)
Driver Assistance
Assistance Features:	N/A
Connectivity
Connectivity Features:	N/A
Instrumentation
Display:	Digital odometer, trip meter, clock, and basic indicator lights (neutral, oil pressure, high beam)

Maintenance
Service Intervals
Oil Change Interval:	Every 1,000 km (600 miles) or 6 months, whichever comes first, or more frequently under severe use.
Air Filter Cleaning:	Cleaned every 500 km (300 miles) or more often in dusty conditions.
Spark Plug Replacement:	Recommended every 6,000 km (3,700 miles) or as needed based on inspection.
Valve Clearance Check:	Every 6,000 km (3,700 miles) or 12 months.
Fluid Specifications
Brake Fluid:	DOT 4
Coolant Capacity:	Approx. 1.1 L (1.2 US qt)
Known Issues
Common Wear Items:	Clutch plates, chain and sprockets, fork seals, and wheel bearings are common wear items for this type of motorcycle.
Carburetor Tuning:	Keihin FCR carburetors may require occasional fine-tuning based on altitude, temperature, and modifications.
Common Issues
Engine Starting:	Intermittent starting issues can sometimes be related to the starter clutch or battery condition, detailed in the manual.

Vehicle History
Brand Heritage
Kawasaki Off Road:	Kawasaki has a long and successful history in off-road racing and recreational riding with its KDX and KX lines.
Model Evolution
Klx450R Lineage:	The KLX450R builds upon the motocross-proven KX450F, adapting it for enduro and cross-country racing with features like a larger fuel tank, electric start, and a softer suspension tune.
Production
Production Period:	The KLX450R was produced for a limited run, with these specific years covering a key generation.

Awards & Recognition
Recognitions
Motorcycle Press:	While specific awards for the 2008-2011 KLX450R are not widely documented, it was generally well-regarded by off-road publications for its potent engine and competitive chassis.
Ratings
Durability Reputation:	Known for its robust construction, typical of Kawasaki off-road machines.
Certifications
Emissions:	Designed for off-road use and competition, not street-legal in most jurisdictions, therefore not subject to typical street emissions certifications.