MODEL APPLICATION Year
Model
2006
KX450D6F
Beginning Frame No. JKAKXGDC□6A000001 or JKAKX450DDA000001
□:This digit in the frame number changes from one machine to another.
Part No.99924-1355-01
Printed in Japan
KX450F
Motorcycle Service Manual
Quick Reference Guide
This quick reference guide will assist you in locating a desired topic or procedure. •Bend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page. •Refer to the sectional table of contents for the exact pages to locate the specific topic required.
General Information
1 j
Periodic Maintenance
2 j
Fuel System
3 j
Cooling System
4 j
Engine Top End
5 j
Engine Right Side
6 j
Engine Lubrication System
7 j
Engine Removal/Installation
8 j
Crankshaft/Transmission
9 j
Wheels/Tires
10 j
Final Drive
11 j
Brakes
12 j
Suspension
13 j
Steering
14 j
Frame
15 j
Electrical System
16 j
Appendix
17 j
KX450F
Motorcycle Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Division/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan. No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible. The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your Motorcycle dealer for the latest information on product improvements incorporated after this publication. All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts.
© 2005 Kawasaki Heavy Industries, Ltd.
First Edition (1) : Aug. 4, 2005 (M)
LIST OF ABBREVIATIONS A ABDC AC ATDC BBDC BDC BTDC °C DC F °F ft g h kg kgf L
ampere(s) after bottom dead center alternating current after top dead center before bottom dead center bottom dead center before top dead center degree(s) Celsius direct current farad(s) degree(s) Fahrenheit foot, feet gram(s) (mass) hour(s) (mass) (force) liter(s)
lb m min N Pa PS psi r r/min, rpm TDC TIR V W Ω
pound(s) meter(s) minute(s) newton(s) pascal(s) horsepower pound(s) per square inch revolution revolution(s) per minute top dead center total indicator reading volt(s) watt(s) ohm(s)
Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may adversely affect safe operation. To get the longest life out of your vehicle: Follow the Periodic Maintenance Chart in the Service Manual. Be alert for problems and non-scheduled maintenance. Use proper tools and genuine Kawasaki Motorcycle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki motorcycles are introduced by the Service Manual. Genuine parts provided as spare parts are listed in the Parts Catalog. Follow the procedures in this manual carefully. Don’t take shortcuts. Remember to keep complete records of maintenance and repair with dates and any new parts installed.
• • •
• •
How to Use This Manual In this manual, the product is divided into its major systems and these systems make up the manual’s chapters. The Quick Reference Guide shows you all of the product’s system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents.
For example, if you want ignition coil information, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chapter to find the Ignition Coil section. Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices.
WARNING This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life.
CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment. This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information.
NOTE
○This note symbol indicates points of particular interest for more efficient and convenient operation.
a procedural step or work to be • Indicates done.
○Indicates a procedural sub-step or how to do
the work of the procedural step it follows. It also precedes the text of a NOTE. Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows. In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly.
GENERAL INFORMATION 1-1
General Information
1
Table of Contents Before Servicing ..................................................................................................................... Model Identification................................................................................................................. General Specifications............................................................................................................ Unit Conversion Table ............................................................................................................
1-2 1-7 1-8 1-10
1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts. Especially note the following:
Edges of Parts
Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts.
Solvent Use a high-flush point solvent when cleaning parts. High -flush point solvent should be used according to directions of the solvent manufacturer.
Cleaning vehicle before disassembly Clean the vehicle thoroughly before disassembly. Dirt or other foreign materials entering into sealed areas during vehicle disassembly can cause excessive wear and decrease performance of the vehicle.
Arrangement and Cleaning of Removed Parts Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly.
GENERAL INFORMATION 1-3 Before Servicing Storage of Removed Parts After all the parts including subassembly parts have been cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly.
Inspection Reuse of worn or damaged parts may lead to serious accident. Visually inspect removed parts for corrosion, discoloration, or other damage. Refer to the appropriate sections of this manual for service limits on individual parts. Replace the parts if any damage has been found or if the part is beyond its service limit.
Replacement Parts Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, Oil seals, Grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.
Assembly Order In most cases assembly order is the reverse of disassembly, however, if assembly order is provided in this Service Manual, follow the procedures given.
Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quarter turn and them remove them. If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally.
1-4 GENERAL INFORMATION Before Servicing Tightening Torque Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fasteners to the specified torque using a good quality torque wrench. Often, the tightening sequence is followed twice-initial tightening and final tightening with torque wrench.
Force Use common sense during disassembly and assembly, excessive force can cause expensive or hard to repair damage. When necessary, remove screws that have a non -permanent locking agent applied using an impact driver. Use a plastic-faced mallet whenever tapping is necessary.
Gasket, O-ring Hardening, shrinkage, or damage of both gaskets and O-rings after disassembly can reduce sealing performance. Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains. Install new gaskets and replace used O-rings when re-assembling
Liquid Gasket, Non-permanent Locking Agent For applications that require Liquid Gasket or a Non-permanent Locking agent, clean the surfaces so that no oil residue remains before applying liquid gasket or Non-permanent locking agent. Do not apply them excessively. Excessive application can clog oil passages and cause serious damage.
Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and use smooth movements when installing.
GENERAL INFORMATION 1-5 Before Servicing Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary. Replace with new ones whenever removed. Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressure on the correct bearing race as shown. Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage.
Oil Seal, Grease Seal Do not remove pressed oil or grease seals unless removal is necessary. Replace with new ones whenever removed. Press new oil seals with manufacture and size marks facing out. Make sure the seal is aligned properly when installing.
Apply specified grease to the lip of seal before installing the seal.
Circlips, Cotter Pins Replace circlips or cotter pins that were removed with new ones. Take care not to open the clip excessively when installing to prevent deformation.
Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubrication points are called out throughout this manual, apply the specific oil or grease as specified.
1-6 GENERAL INFORMATION Before Servicing Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (clockwise viewed from output side).
Electrical Wires A two-color wire is identified first by the primary color and then the stripe color. Unless instructed otherwise, electrical wires must be connected to those of the same color.
Instrument Use a meter that has enough accuracy for an accurate measurement. Read the manufacture’s instructions thoroughly before using the meter. Incorrect values may lead to improper adjustments.
GENERAL INFORMATION 1-7 Model Identification KX450D6F Left Side View
KX450D6F Right Side View
1-8 GENERAL INFORMATION General Specifications Items Dimensions Overall Length Overall Width Overall Height Wheelbase Road Clearance Seat Height Dry Mass Fuel Tank Capacity Performance Minimum Turning Radius Engine Type Cooling System Bore and Stroke Displacement Compression Ratio Carburetion System Starting System Ignition System Timing Advance Ignition Timing Spark Plug Valve Timing: Inlet: Open Close Duration Exhaust: Open Close Duration Lubrication System Engine Oil: Type Viscosity Capacity Drive Train Primary Reduction System: Type Reduction Ratio Clutch Type Transmission: Type
KX450D6F 2 185 mm (86.02 in.) 820 mm (32.3 in.) 1 280 mm (50.39 in.) 1 485 mm (58.46 in.) 345 mm (13.6 in.) 965 mm (38.0 in.) 99.8 kg (220 lb) 7.2 L (1.9 US gal) – 4-stroke, single cylinder, DOHC 4 valve Liquid-cooled 96.0 × 62.1 mm (3.78 × 2.44 in.) 449 cm³ (27.4 cu in.) 12.0 : 1 Carburetor, KEIHIN FCR40 Primary kick Digital AC-CDI BTDC 10° @1 800 r/min (rpm) NGK CPR8EB-9
BTDC 32° ABDC 72° 284° BBDC 62° ATDC 42° 284° Forced lubrication (semi-dry sump) API SG, SH, SJ or SL with JASO MA SAE 10W-40 1.2 L (1.3 US qt)
Gear 2.727 (60/22) Wet, multi disc 4-speed, constant mesh, return shift
GENERAL INFORMATION 1-9 General Specifications Items Gear ratios: 1st 2nd 3rd 4th Final Drive System: Type Reduction Ratio Overall Drive Ratio Frame Type Steering Angle Caster (rake angle) Trail Front tire: Size Make/Type Rear tire: Size Make/Type Rim size: Front Rear Front suspension: Type Wheel travel Rear suspension: Type Wheel travel Brake type: Front and Rear Effective disc diameter: Front (effect. dia.) Rear (effect. dia.)
KX450D6F 1.800 (27/15) 1.411 (24/17) 1.187 (19/16) 1.000 (19/19) Chain drive 3.4846 (50/13) 10.489 @Top gear Tubular, semi-double cradle 42° to either side 27.1° 117 mm (4.60 in.) 90/100-21 57M DUNLOP D742F, Tube type 120/80-19 63M DUNLOP D756, Tube type 1.60-21 2.15-19 Telescopic fork (up side down) 315 mm (12.4 in.) Swingarm (New Uni-trak) 315 mm (12.4 in.) Single disc 225 mm (8.86 in.) 215 mm (8.46 in.)
Specifications subject to change without notice, and may not apply to every country.
1-10 GENERAL INFORMATION Unit Conversion Table Prefixes for Units: Prefix mega kilo centi milli micro
Symbol M k c m µ
Units of Length: × × × × ×
Power 1 000 000 1 000 0.01 0.001 0.000001
Units of Mass: kg g
× ×
2.205 0.03527
= =
lb oz
= = = = = = = = =
gal (US) gal (imp) qt (US) qt (imp) pint (US) pint (imp) oz (US) oz (imp) cu in
Units of Volume: L L L L L L mL mL mL
× × × × × × × × ×
0.2642 0.2200 1.057 0.8799 2.113 1.816 0.03381 0.02816 0.06102
km m mm
× × ×
0.6214 3.281 0.03937
= = =
mile ft in
= = = = = =
kgf·m ft·lb in·lb N·m ft·lb in·lb
= = = = = =
kgf/cm² psi cm Hg kPa psi kPa
=
mph
= = = =
PS HP kW HP
Units of Torque: N·m N·m N·m kgf·m kgf·m kgf·m
× × × × × ×
0.1020 0.7376 8.851 9.807 7.233 86.80
Units of Pressure: kPa kPa kPa kgf/cm² kgf/cm² cm Hg
× × × × × ×
0.01020 0.1450 0.7501 98.07 14.22 1.333
Units of Speed: km/h
×
0.6214
Units of Force: N N kgf kgf
× × × ×
0.1020 0.2248 9.807 2.205
Units of Temperature:
= = = =
kgf lb N lb
Units of Power: kW kW PS PS
× × × ×
1.360 1.341 0.7355 0.9863
PERIODIC MAINTENANCE 2-1
Periodic Maintenance 2
Table of Contents Periodic Maintenance Chart .............. Torque and Locking Agent................. Specifications .................................... Special Tools ..................................... Periodic Maintenance Procedures..... Fuel System.................................... Fuel Hose and Connection Inspection.................................. Throttle Grip Free Play Inspection Throttle Grip Free Play Adjustment ................................ Hot Starter Lever Free Play Inspection.................................. Idle Speed Inspection .................. Idle Speed Adjustment................. Air Cleaner Element Cleaning and Inspection.................................. Fuel Inspection............................. Fuel Tank, Filter and Tap Cleaning .................................... Fuel Tap and Filter Inspection...... Cooling System............................... Coolant Level Inspection.............. Coolant Deterioration Inspection.. Radiator Hoses and Connections Inspection.................................. Engine Top End .............................. Valve Clearance Inspection ......... Valve Clearance Adjustment........ Cylinder Head Warp Inspection ... Cylinder Wear Inspection............. Piston/Cylinder Clearance ........... Piston, Piston Ring and Piston Pin Replacement....................... Exhaust System Inspection.......... Muffler Baffle Change .................. Engine Right Side ........................... Clutch Lever Free Play Check ..... Clutch Lever Free Play Adjustment ................................ Friction and Steel Plates Inspection.................................. Engine Lubrication System ............. Engine Oil Change....................... Oil Filter Change .......................... Breather Hose Inspection ............
2-3 2-5 2-9 2-11 2-12 2-12 2-12 2-12 2-12 2-13 2-13 2-14 2-14 2-16 2-17 2-17 2-17 2-18 2-18 2-19 2-19 2-19 2-20 2-22 2-22 2-23 2-23 2-23 2-23 2-24 2-25 2-25 2-25 2-26 2-26 2-27 2-27
Crankshaft/Transmission ................ Crankshaft Inspection .................. Wheel/Tires..................................... Air Pressure Inspection/Adjustment .......................................... Tires Inspection............................ Spoke Tightness Inspection......... Rim Runout Inspection................. Wheel Bearing Inspection ............ Final Drive....................................... Drive Chain Slack Inspection ....... Drive Chain Slack Adjustment ..... Drive Chain Wear Inspection ....... Drive Chain Lubrication................ Sprocket Wear Inspection............ Rear Sprocket Warp Inspection ... Brakes............................................. Brake Lever and Pedal Position Adjustment ................................ Brake Fluid Level Inspection........ Brake Fluid Change ..................... Brake Pad Wear Inspection ......... Brake Master Cylinder Cup and Dust Seal Replacement ............ Caliper Piston Seal and Dust Seal Replacement ............................. Brake Hose and Connection Check ........................................ Brake Hose Replacement ............ Suspension ..................................... Front Fork Inspection ................... Front Fork Oil Change (each fork leg) ............................................ Rear Shock Absorber Inspection . Rear Shock Absorber Oil Change Swingarm and Uni-Trak Linkage Inspection.................................. Swingarm and Uni-Track Linkage Pivot Lubricate .......................... Steering .......................................... Steering Inspection ...................... Steering Adjustment .................... Stem Bearing Lubrication............. Frame ............................................. Frame Inspection ......................... Electrical System ............................
2-28 2-28 2-28 2-28 2-29 2-29 2-30 2-30 2-31 2-31 2-31 2-32 2-33 2-33 2-34 2-34 2-34 2-35 2-36 2-38 2-38 2-40 2-43 2-43 2-44 2-44 2-44 2-53 2-53 2-58 2-58 2-58 2-58 2-58 2-60 2-60 2-60 2-61
2-2 PERIODIC MAINTENANCE Spark Plug Cleaning and Inspection.................................. Cable Inspection ............................. Lubrication ...................................
2-61 2-61 2-61
Nut, Bolt, and Fastener Tightness Inspection..................................... Tightness Inspection ....................
2-62 2-62
PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart The maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. FREQUENCY OPERATION Spark plug-clean, gap † Spark plug-replace Clutch cable-adjust Clutch and friction plates-inspect † Throttle cable-adjust Air cleaner element-clean † Air cleaner element-replace Carburetor-inspect and adjust Engine Oil-change E N G I N E
• • • • •
•
2-61 2-25 2-25 2-12 2-14
If damaged
Kick pedal and shift pedal-clean Engine sprocket-inspect † Coolant-check † Radiator hoses and connections-inspect † Crankshaft-inspect Breather hose-inspect Brake adjustment-inspect † Brake pad wear-inspect † Brake fluid level-inspect † Brake fluid-change Brake master cylinder cup and dust seal-replace Brake caliper piston seal and dust seal-replace Brake hoses and pipe-replace Brake hoses, connections-inspect † Spoke tightness and rim runout-inspect † Wheel bearing-inspect † Frame-inspect and clean Drive chain wear-inspect † Drive chain-inspect and adjust
2-26
•
2-22
•
Valve clearance-inspect †
Muffler Baffle-change
•
Every 6 races
Piston pin-replace
Muffler-clean and inspect†
2-14 2-13
Cylinder head, cylinder-inspect
Hot starter cable-adjust
• • • • • • • • • •
• • • • • •
See Page 2-61
•
Piston and piston ring-replace
Oil filter-replace
C H A S S I S
Every Every Each Every 3 races 12 race or 6 races or 7.5 races or 2.5 hr or 15 hr hr 30 hr
2-23
•
2-23 2-19 2-13
•
2-27
•
2-23
2-23 – 2-33 2-18 2-19
•
2-28 2-27 2-34 2-38 2-35
Every Every Every Every
2 2 2 4
years years years years
2-36 2-38 2-40 2-43 2-43 2-29 2-30 2-60 2-32 2-31
2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY OPERATION
Every Every Each Every 3 races 12 race or 6 races or 7.5 races or 2.5 hr or 15 hr hr 30 hr
Drive chain-lubricate Wheels/tires-inspect Rear sprocket-inspect † Front fork-inspect and clean Front fork oil-change
• • • •
2-33 2-28 2-33 2-44
• •
Rear shock oil-replace Cable-inspect Fuel hose-replace Fuel hose, connections-inspect † Fuel system-clean Steering play-inspect † Steering stem bearing-grease
• • •
Swingarm and Uni-Trak linkage pivots-grease Swingarm and Uni-Trak linkage pivots-inspect † Nuts, bolts, fasteners-inspect † Chassis parts-lubricate †: Replace, add, adjust, clean or torque if necessary.
• •
See Page
Every 4 years
2-44 2-53 2-61 2-12 2-12
• • •
2-16 2-58
•
2-60 2-58 2-58 2-62 –
PERIODIC MAINTENANCE 2-5 Torque and Locking Agent Tighten all bolts and nuts to the proper torque using an accurate torque wrench. If insufficiently tightened, a bolt or nut may become damaged, strip an internal thread, or break and then fall out. The following table lists the tightening toque for the major bolts and nuts, and the parts requiring use of a non-permanent locking agent or liquid gasket. When checking the tightening toque of the bolts and nuts, first loosen the bolt or nut by half a turn and then tighten to specified torque. Letters used in the "Remarks" column mean: AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. L: Apply a non-permanent locking agent to the threads. Lh: Left-hand Threads S: Tighten the fasteners following the specified sequence. 2T: Apply 2-stroke oil.
Fastener Fuel System Throttle Pulley Cover Bolt Throttle Cable Locknut Air Cleaner Duct Clamp Screw Air Cleaner Duct Mounting Nuts Air Cleaner Duct Mounting Screw Air Cleaner Housing Bolts Cooling System Water Pump Cover Bolts Water Pump Impeller Bolt Radiator Hose Clamp Screws Coolant Drain Plug Radiator Mounting Bolts Radiator Screen Bolts Radiator Shroud Bolts Engine Top End Cylinder Head Cover Bolts Cylinder Head Bolts (M10) Cylinder Head Bolts (M6) Camshaft Cap Bolts Camsfaft Sprocket Bolts Decompressor Plug Plate Bolt Radiator Hose Fitting Bolts Oil Line Plug Carburetor Holder Clamp Screws Plug Lower Camshaft Chain Guide Bolt Rear Camshaft Chain Guide Bolt Chain Tensioner Mounting Bolts Chain Tensioner Cap Cylinder Bolt Exhaust Pipe Cover Screws
N·m
Torque kgf·m
ft·lb
3.4 6.9 2.0 3.0 3.0 9.8
0.35 0.70 0.20 0.31 0.31 1.0
30 61 18 27 27 87
in·lb in·lb in·lb in·lb in·lb in·lb
9.8 9.8 1.5 6.9 9.8 9.8 9.8
1.0 1.0 0.15 0.70 1.0 1.0 1.0
87 87 13 61 87 87 87
in·lb in·lb in·lb in·lb in·lb in·lb in·lb
9.8 59 12 9.8 12 9.8 9.8 3.0 2.0 20 9.8 15 9.8 5.0 12 12
1.0 6.0 1.2 1.0 1.2 1.0 1.0 0.31 0.20 2.0 1.0 1.5 1.0 0.51 1.2 1.2
87 in·lb 44 106 in·lb 87 in·lb 106 in·lb 87 in·lb 87 in·lb 27 in·lb 18 in·lb 15 87 in·lb 11 87 in·lb 44 in·lb 106 in·lb 106 in·lb
Remarks
S, MO S S, MO L
L L
S
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