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Kawasaki KX450 2009-2011 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Kawasaki Model: KX450 Model Variant: Motocross Production Years Covered: 2009, 2010, 2011 Codes Engine Code Prefix: KZT450 Chassis Code Prefix: KX450N 👋 Introduction Market Position...
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Type: Motorcycle
Vendor:
Kawasaki
Sku: 399764
Tags: 2009 2010 2011 Kawasaki KX Series KX450 Motorcycle Motorcycles
Kawasaki KX450 2009-2011 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
KX450
Model Variant:
Motocross
Production Years Covered:
2009, 2010, 2011
Codes
Engine Code Prefix:
KZT450
Chassis Code Prefix:
KX450N
👋 Introduction
Market Position
Market Segment:
High-performance Motocross Competition
Competitive Analysis
Competitors:
Yamaha YZ450F, Honda CRF450R, Suzuki RM-Z450, KTM 450 SX-F
Key Features Vehicle
Engine Type:
Liquid-cooled, four-stroke, DOHC, single cylinder
Fuel Delivery:
Digital Fuel Injection (DFI) with dual injectors
Suspension Front:
48mm inverted telescopic cartridge fork with adjustable compression and rebound damping
Suspension Rear:
New Uni-Trak linkage system with gas-oil separate type shock absorber, adjustable for pre-load, compression, and rebound damping
Manual Value Proposition
Value For Mechanics:
Provides dealer-level expertise for comprehensive servicing and repair
📋 Manual Details
Coverage Areas
Primary Coverage:
Full Factory Service Repair
Target Audience:
Kawasaki Dealer Technicians and Professional Mechanics
Page Count
Total Pages:
440
Manual Type
Type:
Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Internal:
Top End Rebuild, Crankshaft, Transmission
Fuel System:
DFI (Digital Fuel Injection) System Diagnostics and Servicing
Lubrication System:
Engine Lubrication System, Oil Pump, Oil Passages
Cooling System:
Radiator, Coolant Circulation, Thermostat
Drivetrain:
Clutch, Final Drive (Chain and Sprockets)
Chassis Components:
Wheels, Tires, Brakes (Front and Rear), Suspension (Front and Rear), Steering, Frame
Electrical System:
Ignition, Lighting, Battery, Wiring Diagrams
Procedures Included
Disassembly Assembly:
Complete Strip Down and Reassembly Procedures
Diagnostics:
Comprehensive Troubleshooting and Diagnostic Procedures
Maintenance:
Periodic Maintenance Schedules and Procedures
Rebuilding:
Engine Top End and Crankshaft/Transmission Rebuilds
Adjustments:
Clutch Adjustment, Suspension Adjustment, Steering Head Adjustment
Technical Depth
Depth:
Factory Level Detail for All Repair and Maintenance Tasks
Torque Specifications:
Included for all critical fasteners
Special Tools:
Identification of required special tools
📊 Manual Specifications
File Format
PDF Quality:
High-resolution, searchable text
Printability:
Printable pages
Binding Type
Binding:
N/A (PDF Format)
Paper Type
Paper:
N/A (PDF Format)
⚙️ Engine Specifications
Primary Engine
Displacement:
449 cm³
Bore X Stroke:
96.0 x 62.1 mm
Compression Ratio:
12.0:1 (typical)
Valve Train:
DOHC, 4 valves per cylinder
Ignition:
Digital CDI
Performance
Horsepower:
Approx. 55-58 HP (at crank, varies by tune and testing)
Torque:
Approx. 45-47 Nm (at crank, varies by tune and testing)
Fuel System
Fuel Delivery Type:
Digital Fuel Injection (DFI)
Throttle Body Size:
43 mm (typical)
Injectors:
Dual Injectors (Primary and Secondary)
Fuel Type:
Unleaded gasoline, premium (91+ octane recommended)
🔧 Transmission
Standard
Type:
5-speed, constant mesh
Clutch:
Wet, multi-disc, manual
Features
Gear Ratios:
Detailed in manual (e.g., 1st: 2.615, 2nd: 1.941, 3rd: 1.550, 4th: 1.294, 5th: 1.130)
Final Drive Ratio:
3.900 (typically 13T front, 51T rear sprocket)
📐 Dimensions
Exterior
Length:
Approx. 2185 mm
Width:
Approx. 820 mm
Height:
Approx. 1270 mm
Wheelbase:
Approx. 1475 mm
Weights
Dry Weight:
Approx. 102 kg (typically without fluids)
Curb Weight:
Approx. 110 kg (typically with all fluids)
Front Tire Size:
80/100-21 51M
Rear Tire Size:
110/90-19 62M
Wheel Bolt Pattern:
N/A (Spoked wheels with hubs)
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Off-road competition vehicle)
Active Features
Brakes Front:
270mm petal disc, dual-piston caliper
Brakes Rear:
240mm petal disc, single-piston caliper
Passive Features
Frame Construction:
Perimeter aluminum frame
💡 Technology Features
Infotainment
Infotainment System:
N/A (Competition Motocross Bike)
Driver Assistance
Driver Assistance Features:
N/A (Competition Motocross Bike)
Connectivity
Connectivity Options:
N/A (Competition Motocross Bike)
Engine Management
Engine Management System:
Digital Fuel Injection (DFI) with ECU control for ignition timing and fuel delivery
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual (typically after every few races or 10-20 hours of use for competition)
Air Filter Cleaning:
Frequent cleaning recommended, especially in dusty conditions
Valve Clearance Check:
Refer to manual (typically at 10-20 hours or major rebuilds)
Fluid Specifications
Engine Oil Type:
Refer to manual; typically SAE 10W-40, JASO MA specification motorcycle oil (e.g., Kawasaki Genuine Oil)
Engine Oil Capacity:
Approx. 0.7-0.8 Liters (without filter change), 0.8-0.9 Liters (with filter change)
Coolant Type:
Permanent type antifreeze coolant (50/50 mix with distilled water)
Brake Fluid Type:
DOT 4
Fork Oil Type:
Refer to manual for specific grade (e.g., Showa SS-05 or equivalent)
Known Issues
Clutch Wear:
Can experience accelerated wear under hard use; manual details inspection and replacement.
DFI Tuning:
May benefit from ECU remapping or ignition timing adjustments for optimal performance; manual covers base DFI parameters.
Suspension Seals:
Fork and shock seals can wear over time; manual provides seal replacement procedures.
📚 Vehicle History
Brand Heritage
Manufacturer History:
Kawasaki Heavy Industries, Ltd. is a Japanese multinational corporation founded in 1896, known for motorcycles, heavy equipment, aerospace, and defense.
Model Evolution
Kx Series Heritage:
The KX line has a long-standing racing pedigree, with significant design advancements over its generations, particularly in chassis and engine technology.
Kx450 Generation 2009-2011:
This generation represented an evolution of the KX450F, building on previous successes with refined DFI and chassis updates for improved handling and power delivery.
Production
Manufacturing Location:
Japan (typical for Kawasaki motorcycles)
🏆 Awards & Recognition
Recognitions
Motocross Awards:
The KX450 platform has historically been a strong performer and recipient of various magazine shoot-out wins and professional racer endorsements.
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