Category:
Off-road, dual-sport, enduro motorcycle
Target Audience:
Owners and technicians of Kawasaki KLX450R motorcycles from 2008-2011 seeking detailed maintenance, repair, and diagnostic information.
Competitors:
Other enduro/off-road motorcycles from brands like Yamaha (WR450F), Honda (CRF450X), KTM (450 EXC), Suzuki (RM-Z450 - though more motocross focused).
Bike Platform:
The KLX450R is based on Kawasaki's successful KX450F motocross platform, adapted for off-road and dual-sport use with features like a larger fuel tank, electric start, and softer suspension settings.
Manual Value Proposition:
Essential resource for DIY maintenance, cost-effective repairs, and understanding the intricate workings of the KLX450R, thereby maximizing its performance and longevity.
Engine Systems:
Engine disassembly, assembly, inspection, repair, troubleshooting, tuning, lubrication, cooling system, fuel system (carburetor, fuel pump, lines), ignition system, exhaust system.
Drivetrain Systems:
Transmission, clutch (operation, maintenance, repair), gearbox, final drive (chain, sprockets), shifting mechanism.
Chassis Systems:
Frame inspection and repair, suspension (front forks, rear shock absorber, linkages), steering system, wheels, hubs, bearings, spokes, braking system (front and rear calipers, master cylinders, lines, pads, rotors), control cables.
Electrical Systems:
Wiring diagrams, lighting system, battery, charging system (stator, regulator/rectifier), ignition switch, starter motor, fuses, relays, instrument panel, troubleshooting electrical faults.
Bodywork And Trim:
Fairings, fenders, seat, fuel tank, graphics, fasteners, trim components.
Maintenance Procedures:
Routine maintenance, oil changes, filter replacements, spark plug service, chain adjustment, brake fluid flush, coolant checks, air filter cleaning/replacement, valve clearance adjustment.
Repair Procedures:
Detailed step-by-step repair instructions for all major mechanical and electrical components, including engine rebuilds, transmission overhauls, suspension work, brake caliper rebuilding, and electrical component replacement.
Troubleshooting Guides:
Systematic diagnostic procedures for identifying and resolving common problems, including engine performance issues, starting problems, electrical gremlins, and braking system faults.
Specifications And Tolerances:
Torque specifications for all fasteners, wear tolerances for engine components, electrical system specifications, fluid capacities, and general setup guidelines.
Depth:
Comprehensive. Covers everything from basic maintenance and adjustments to complete engine and transmission rebuilds, including in-depth electrical system diagnostics and troubleshooting.
Engine Type:
Four-stroke, single-cylinder, DOHC, 4-valve
Bore X Stroke:
96.0 x 62.1 mm
Compression Ratio:
12.0:1
Cooling System:
Liquid-cooled
Horsepower:
Approximately 48-50 HP (as per typical figures for this class of motorcycle, specific figures may vary slightly)
Torque:
Approximately 40-43 Nm (specific figures may vary slightly)
Fuel Delivery:
Keihin FCR40 flat-slide carburetor
Fuel Type:
Unleaded gasoline, minimum 87 octane
Fuel Tank Capacity:
Approximately 7.7 Liters (2.0 US gal)
Ignition System:
Digital CDI
Starter:
Electric starter
Length:
Approx. 2,180 mm (85.8 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. 315 mm (12.4 in)
Seat Height:
Approx. 965 mm (38.0 in)
Curb Weight:
Approx. 123 kg (271.1 lbs)
Dry Weight:
Approx. 116 kg (255.7 lbs)
Safety Features Design:
Built for off-road conditions, prioritizes rider control and durability. Features include robust frame, effective suspension, and reliable braking.
Braking System:
Hydraulic disc brakes front and rear. Specifics on rotor diameter and caliper type would be in manual.
Suspension System:
Front: 48mm inverted cartridge fork with adjustable compression and rebound damping. Rear: New Uni-Trak with adjustable preload, compression, and rebound damping.
Frame Construction:
Perimeter frame made of high-tensile steel, designed for rigidity and impact resistance.
Instrument Cluster:
Digital LCD instrument cluster displaying speedometer, odometer, trip meters, clock, and engine hour meter. Minimalist design focused on essential riding information.
Rider Aids:
No electronic rider aids such as ABS or traction control, typical for off-road focused motorcycles of this era. Rider skill is the primary control.
Connectivity Features:
N/A. This motorcycle is designed for pure off-road performance and does not feature modern connectivity options like Bluetooth or Wi-Fi.
Oil Change Interval:
Typically every 10-15 engine hours or annually, depending on usage. Specific recommendation in manual.
Air Filter Cleaning:
Recommended after every few rides or as conditions dictate (dusty environments require more frequent cleaning). Detailed procedure in manual.
Chain Maintenance:
Regular cleaning, lubrication, and tension adjustment are critical for longevity. Intervals depend on riding conditions.
Valve Clearance Check:
Typically recommended every 100-150 engine hours or annually. Critical for maintaining engine performance and preventing damage.
Engine Oil Type:
API SG or SH, SAE 10W-40 recommended. Specific synthetic or semi-synthetic oils suitable for high-performance motorcycles. Verify in manual.
Engine Oil Capacity:
Approximately 1.6 Liters (1.7 US qt) without filter change, 1.8 Liters (1.9 US qt) with filter change. Exact figures in manual.
Coolant Type:
High-quality ethylene glycol-based coolant with deionized water (50/50 mix). Kawasaki recommends specific coolant types or equivalent. Check manual.
Brake Fluid Type:
DOT 4 hydraulic brake fluid. Always use fresh, sealed fluid.
Common Wear Items:
Clutch plates, chain and sprockets, brake pads, fork seals, wheel bearings, spark plugs, air filter. These are typical for this type of machine and usage.
Potential Problems:
Carburetor jetting sensitivity to altitude and temperature, occasional electrical connector issues if exposed to excessive moisture, normal wear on suspension components with hard use.
Kawasaki Offroad Legacy:
Kawasaki has a strong heritage in motocross and off-road racing with its KX and KDX lines, leveraging this expertise for the KLX series.
Klx Series Development:
The KLX450R was introduced as a dedicated off-road/enduro machine, borrowing heavily from the KX450F motocross platform to offer competitive performance with features suitable for trail riding and competition.
Manufacturing Location:
Primarily Japan. Specific assembly plants may vary.
Production Period:
Model years 2008-2011 represent a specific generation of this platform.
