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1. 3 38 Intake Air Pressure Sensor Output Voltage Inspection 3 39 Intake Air Temperature Sensor Service Code 13 3 43 Intake Air Temperature Sensor Removal Installation 3 43 Intake Air Temperature Sensor Output Voltage Inspection 3 43 Intake Air Temperature Sensor Resistance Inspection 3 44 Water Temperature Sensor Service Code 14 3 46 Water Temperature Sensor Removal Installation ooo ooonoonnoonnoooncoonconcconcnno nono nnnnnnnnnnos 3 46 Water Temperature Sensor Output Voltage Inspection een 3 46 Water Temperature Sensor Resistance Inspection 3 48 Crankshaft Sensor Service Code 27 essaient cid 3 49 Crankshaft Sensor Removal Installation 3 49 Crankshaft Sensor Resistance Inspection 3 49 Crankshaft Sensor Peak Voltage Inspection 3 49 Gear Position Switch Service Code 25 issues 3 50 Gear Position Switch Removal ss 3 50 Gear Position Switch Installation oooooooccncccnnccnnnnnnnnnnnnnnnnnnnnnonnnnnnnnnnnnnnnnnnnnnnnnnnoss 3 50 Gear Position Switch Inspection enssossnennossnoosnerrtertttrtttrtttrtttttttrrtrrtttrtttrrtrrtterttrrrenrnt 3 51 Vehicle down Sensor Service Code 31 3 52 Vehicle down Sensor HRemoval Annn EnEnnnEEnn Ennn EnEn
2. Piston Removal Cylinder and Piston Installation Cylinder Wear Inspection Piston Wear Inspection Piston Cylinder Clearance Inspechon anaoeeeeeeeeeeee Piston Ring Ring Groove Clearance Inspection Piston Ring Groove Width Inspechon naeoeneeeeeeeeeeeeee0 Piston Ring Thickness Inspection Piston Ring End Gap Measurement A Piston Piston Pin Connecting Rod Wear Inspection Throttle Body Holder Throttle Body Assy Holder Hemova Throttle Body Assy Holder Installation Muffler Body Removal Exhaust Pipe Removal Muffler Installation Silencer Wool Replacement 5 28 5 29 5 29 5 30 5 34 5 34 5 34 5 34 5 36 5 36 5 36 5 37 5 37 5 37 5 38 5 38 5 39 5 39 5 39 5 40 5 40 5 40 5 40 5 40 5 2 ENGINE TOP END Exploded View Dee Gem O 0 ENGINE TOP END 5 3 Exploded View Torque Fastener Nom keri ft lb Remarks 2 Cylinder Head Bolts M10 6 0 44 MO S 3 Camshaft Cap Bolts 1 0 87 in lb MO S 4 Camshaft Sprocket Bolts 12 1 2 106 in lb L 5 Plug 20 2 0 15 L 6 Oil Line Plug 3 0 0 31 27 in lb E 7 Cylinder Head Bolts M6 12 1 2 106 in lb S 8 Water Hose Fitting Bolts 9 8 1 0 87 mb
3. sn 12 22 Rear Master Cylinder DisassomD Visca 12 22 Master Cylinder ASS MD et A ENEE Ree 12 22 Master Cylinder Inspection Visual Inspection 12 22 Drake EE 12 23 Brake DISC ROMOVAL cis AA a a es 12 23 Brake Disc Instalacion caridad lidia 12 23 Brake Disc Inspection a 12 23 A e 12 24 Brake Hose Removal Installation ss 12 24 Brake Hose Inspection seccieciivoncianneareautd cay Addi hei deu 12 24 12 2 BRAKES Exploded View do BRAKES 12 3 Exploded View No Fastener Torque Remarks N m kgf m ft Ib 59 0 60 Brake Reservoir Cap Screws 0 15 13 in 1b _ Brake Lever Pivot Bolt oO R o hd ho Brake Hose Banjo Bolts 25 2 5 18 Caliper Bleed Valve 0 80 69 in lb 18 8 Front Caliper Mounting Bolts 25 2 5 18 13 Gm 1 0 87 in lb L O CO Brake Pad Pin Front Brake Disc Mounting Bolts 10 KX450FC B Apply brake fluid L Apply a non permanent locking agent R Replacement Parts S Follow the specified tightening sequence Si Apply silicone grease ex PBC grease Ka 12 4 BRAKES Exploded View OCOD a G Pi W Ka ES W y 7 E zich S E N BRAKES 12 5 Exploded View No Fastener Torgus Remarks ft Ib Brake Reservoir Cap Screws 1 5 0 15 13 in lb 11 KX450FC B Apply brake fluid G Apply grease L Apply a non permanent locking agent R Replacement Part
4. 9 24 Gear Damage Inspection suicid 9 24 Bal NC ua EEN 9 25 Balancer Removal sie 9 25 Balancer Installation cocida een Mr miennes amendement EL 9 25 PHARE GBA ET da nn ee di dE 9 26 Primary Gear REMOVAL nio di ae la ds el tae dns oped dr 9 26 Primary Gear Installation dlls 9 26 External Shift Mechanism ses 9 27 Shift Pedal Removal aia cdo aid are nee entente A An sara tes 9 27 Shift Pedal Installation Sienne 9 27 External Shift Mechanism Hemoval rrrn rr rr ennnen ene 9 27 External Shift Mechanism Installation 9 28 External Shift Mechanism Inspection 9 29 e e let 9 30 Kick Pedal Assy ROMA ui AA A E iki 9 30 Kick EUREN TT 9 30 Kick Pedal Assy Ee E 9 30 Kick Pedal ASSy Assembly escondi enr tennis ee EE TS a de nr ee 9 30 Idle Gear REMOVAl is ss Ps pes ds po d ce cf Lee 9 31 Idle Gear Installation 9 31 leen E EE 9 31 Kickshaft Installation can at iaa a 9 32 Kick Shaft Assembly Disassembly ASSeEMDIy ooooocccccccccccoccococoncccncccnnnannnanncnnnnnnnnnnnnnnnnnn cnn 9 32 A N 9 34 Bearing Replacement inicio ti nena 9 34 Bearing Wear InspeclO srt ti nea lali dia ic ltda ica 9 34 Oil Seal Inspection E T 9 35 9 2 CRANKSHAFT TRANSMISSION Exploded View 61023518W5 C CRANKSHAFT TRANSMISSION 9 3 Exploded View No Fastener Torque
5. WARNING Mixing brands and types of brake fluid can reduce the brake system s effectiveness and cause an ac cident resulting in injury or death Do not mix two brands of brake fluid Change the brake fluid in the brake line completely if the brake fluid must be re filled but the type and brand of the brake fluid that is already in the reservoir are unidentified 6513029 P Periodic Maintenance Procedures PERIODIC MAINTENANCE 2 39 Brake Fluid Change A WARNING When working with the disc brake observe the pre cautions listed below 1 2 Never reuse old brake fluid Do not use fluid from a container that has been left unsealed or that has been open for a long time Do not mix two types and brands of fluid for use in the brake This lowers the brake fluid boiling point and could cause the brake to be ineffec tive It may also cause the rubber brake parts to deteriorate Don t leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid Don t change the fluid in the rain or when a strong wind is blowing Except for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning of the brake parts Do not use any other fluid for cleaning these parts Gasoline engine oil or any other petroleum distillate will cause deterioration of the rubber parts Oil spilled on any part will be difficult to wash off complet
6. e Clean the delivery pipe e Cover the delivery pipe with the vinyl bag to keep it clean e Remove the vinyl bag on each delivery pipe e Check that there are no flaws burrs and adhesion of D foreign materials on each delivery pipe A e Replace the fuel hose with a new one PR e Run the fuel hose correctly see Cable Wire and Hose Routing section in the Appendix chapter GS05265BS1 PERIODIC MAINTENANCE 2 17 Periodic Maintenance Procedures e Apply engine oil to the fuel outlet pipe A lightly GS05265BS1 e Insert the fuel hose A joint straight onto the delivery pipe until the hose joint clicks e Push the joint lock B e Push and pull C the fuel hose joint back and forth more than two times and make sure it is locked and does not come off WARNING Leaking fuel can cause a fire or explosion resulting in severe burns Make sure the fuel hose joint is installed correctly on the delivery pipe and that it doesn t leak x If it comes off reinstall the hose joint e Install the fuel tank see Fuel Tank Installation in the Fuel System DFI chapter e Start the engine and check the fuel hose for leaks Idle Speed Inspection NOTICE This motorcycle is designed for competition use only Therefore the radiator does not incorporate a coolant reserve tank or cooling fan Prolonged idling of the engine with no airflow through the radiator can cause coolant
7. A TNA ao V GM07106BW2 C Needle Bearing Inspection NOTICE Do not remove the bearings for inspection Re moval may damage them e Inspect the needle bearings installed in the tie rod and rocker arm OThe needle bearing normally wear very little and wear is difficult to measure Instead of measuring visually in spect the bearings for abrasion discoloration or other damage x lf there is any doubt as to the condition of either needle bearing replace the bearing and sleeve as a set Uni Trak Maintenance SUSPENSION 13 33 Uni Trak Linkage Inspection e Refer to the Swingarm and Uni Trak Linkage Inspection in the Periodic Maintenance chapter Tie Rod and Rocker Arm Sleeve Wear Inspection e Pull out the sleeves A of the tie rod and rocker arm e Measure the outside diameter of the sleeve Sleeve Outside Diameter Standard Tie Rod 19 987 20 000 mm 0 78689 0 78740 in Rocker Arm Large 19 987 20 000 mm 0 78689 0 78740 in Small 15 950 16 000 mm 0 62795 0 62992 in Service Limit Tie Rod 19 85 mm 0 7815 in Rocker Arm Large 19 85 mm 0 7815 in Small 15 92 mm 0 6268 in lf the sleeve is worn past the service limit replace the sleeve Tie Rod and Rocker Arm Mounting Bolt Bend Inspection A bent bolt causes vibration poor handling and instabil ity e To measure the bolt runout remove the bolt place it in V blocks and set a dial gauge to the
8. ST15712418T ST5714718T Hand Tester Grip 57001 1394 57001 1591 ga d ST5713948T ST5715918T Peak Voltage Adapter Rotor Holder 57001 1415 57001 1730 NES ST5714158T SE ST571730ST 16 6 ELECTRICAL SYSTEM Special Tools and Sealant Liquid Gasket TB1211F 92104 0004 gt ST9200048T ELECTRICAL SYSTEM 16 7 Special Tools and Sealant This page intentionally left blank 16 8 ELECTRICAL SYSTEM Wiring Diagram DFI Setting DFI Setting Data Selection Data Selection Connector White Connector Black xs meee EF EA E A KX Fl Calibration BK W VALL ee Kit Option R W Tics Sree Y R na 55 Y BK E E DFI Setting Data Selection Connector Green IT l Regulator Rectifier Self diagnosis Terminal c xrx SA eS EEER pan Zeen ENEE gt ars gt EPP z Grrr pees oo a a gt Ecu R W BR 6 G R Y G BL TTT RE A E RU BK W e E wY P 6 R Y R W R BL R EMI BL K W BL Di LB W R Y Y R BK BK BK Y BK Y Kawasaki Diagnostic System Connector P BK R W Si H GA Il 2 Ss Se e a sE e SS gt E ba E L e z 2 EE meres gt D Ez o Launch GY o af Magneto Control US Node i Button Engine Stop Capacitor Switch Orange Launch Control Mode Gear Position Crankshaft Orange Fl Indicator
9. Valve Guide Driver 57001 1564 ST5715648T Piston Pin Puller 57001 1568 a ST571568ST Valve Spring Compressor Adapter 24 57001 1586 ST571586ST Valve Guide Driver Attachment D 57001 1659 ST5716598T ENGINE TOP END 5 11 Special Tools and Sealant Valve Guide Driver Attachment G Liquid Gasket TB1216B 57001 1728 92104 1064 gt 8757172897 ST9210648T 5 12 ENGINE TOP END Cylinder Head Cover Cylinder Head Cover Removal e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Fuel Hose see Fuel Hose Replacement in the Periodic Maintenance chapter Spark Plug Cap A Cylinder Head Cover Bolts B and Washers Cylinder Head Cover C Cylinder Head Cover Installation e Using a high flash point solvent clean off any oil or dirt that may be on the liquid gasket coating area Dry them with a clean cloth e Apply liquid gasket A to the cylinder head as shown in the figure Sealant Liquid Gasket TB1216B 92104 1064 NOTE OMake the application finish within 20 minutes when the liquid gasket TB1216B to the mating surface of the cylinder head cover is applied e Replace the cylinder head cover gasket and spark plug hole gasket with new ones e Install the cylinder head cover gasket A and spark plug hole gasket B e Make sure that the upper chain guide A is bottomed NOTICE Unless the upper
10. Poor Running or No Power at High Speed Symptoms or Possible Causes Actions chapter Firing incorrect Ignition coil shorted or not in good contact Inspect or Reinstall see chapter 16 Ignition coil trouble Inspect see chapter 16 Spark plug dirty broken or gap maladjusted Inspect and replace see chapter 2 Spark plug incorrect Replace it with correct plug see chapter 2 ECU trouble Inspect see chapter 3 16 Fuel air mixture incorrect Clean element or inspect sealing see chapter 3 Reinstall see chapter 3 Water or foreign matter in fuel Change fuel Inspect and clean fuel system see chapter 3 Fuel injector O ring damage Replace see chapter 3 Fuel injector clogged Inspect and repair see chapter 3 Fuel line clogged Inspect and repair see chapter 3 Fuel pump trouble Inspect see chapter 3 Intake air pressure sensor trouble Inspect see chapter 3 3 24 FUEL SYSTEM DFI DFI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter Water temperature sensor trouble Inspect see chapter 3 Intake air temperature sensor trouble Inspect see chapter 3 Throttle sensor trouble Inspect see chapter 3 Knocking Fuel poor quality or incorrect Fuel change Use gasoline recommended in the Owner s Manual Spark plug incorrect Replace it with correct plug see chapter 2 Ignition coil trou
11. 14260 0 6 2 6 OIO UE O at HH Ee He rt mH YO GI 0 61135128w3 C 1 2nd Gear 17T 9 Drive Shaft 2 Circlip 10 Output Shaft 3 Toothed Washer 11 1st Gear 28T 4 Bushing 12 Sth Gear 21T 5 4th Gear 19T 13 3rd Gear 19T 6 3rd Gear 16T 14 4th Gear 19T 7 Sth Gear 24T 15 2nd Gear 24T 8 1st Gear 16T 16 Collar e Check that each gear spins or slides freely on the trans mission shaft without binding after assembly 9 24 CRANKSHAFT TRANSMISSION Transmission OOO Shift Fork Bending Inspection e Visually inspect the shift forks and replace any fork that is bent A bent fork could cause difficulty in shifting or allow the transmission to jump out of gear when under power 90 A Shift Fork Gear Groove Wear Inspection e Measure the thickness A of the shift fork ears and mea sure the width B of the gear grooves with which the fork engages Shift Fork Ear Thickness Standard 4 9 5 0 mm 0 193 0 197 in Service Limit 4 8 mm 0 189 in Gear Groove Width Standard 5 05 5 15 mm 0 199 0 203 in Service Limit 5 3 mm 0 209 in x If the thickness of a shift fork ear is less than the service limit the shift fork must be replaced x If the gear groove is worn exceeding the service limit the gear must be replaced Shift Fork Guide Pin Shift Drum Groove Wear Inspection e Measure the diameter A of each shift fork guide
12. Throttle Grip and Cables Throttle Grip Free Play 2 3 mm 0 08 0 12 in Special Tools and Sealant Oil Pressure Gauge 5 kgf cm 57001 125 ST5701258T Fork Oil Level Gauge 57001 1290 ST5712908T Vacuum Gauge 57001 1369 bay A ST5713698T Filler Cap Driver 57001 1454 ST5714548T Needle Adapter Set 57001 1457 ST571457ST C FUEL SYSTEM DFI 3 9 Fuel Pressure Gauge Adapter 57001 1593 Fuel Hose 57001 1607 ST5715938T ST571607ST Measuring Adapter 57001 1700 ST571700ST Liquid Gasket TB1211 56019 120 gt ST560120ST 3 10 FUEL SYSTEM DFI DFI System DFI System GC1796CEW3 C Fuel Tank Pressure Regulator Fuel Pump Intake Air Pressure Sensor Fuel Injector Intake Air Temperature Sensor Air Cleaner Housing Ignition Coil Vehicle down Sensor Crankshaft Sensor Water Temperature Sensor Throttle Sensor Gear Position Switch ECU 15 Capacitor 16 Air Flow 17 Fuel Flow Or 00 NOTES NO AA a BROWN DFI System FUEL SYSTEM DFI 3 11 DFI System Wiring Diagram wn TU fi 1 SN gt n EE a te Se FE HH E BE E m in m SF vi i Part Names 1 ECU 10 Ignition Coil 2 Self diagnosis Terminal 11 Frame Ground 2 3 Throttle Sensor 12 Fuel Pump 4 Intake Air
13. e Fit the spark plug cap A so that it is aligned with the line B on the cylinder head cover e Pull up the plug cap to make sure the installation of the spark plug cap e Install the removed parts see appropriate chapters Spark Plug Replacement e Refer to the Spark Plug Cleaning and Inspection General Lubrication and Cable Inspection Lubrication e Before lubricating each part clean off any rusty spots with rust remover and wipe off any grease oil dirt or grime e Lubricate the points listed below with indicated lubricant NOTE OWhenever the vehicle has been operated under wet or rainy conditions or especially after using a high pressure water spray perform the general lubri cation Points Lubricate with Grease Clutch Inner Cable Upper and Lower Ends A Throttle Inner Cable Upper End Brake Lever Pivot Bolt Clutch Lever Pivot Bolt Brake Pedal Bolt N SODA SS SIS GP100108S1 6c040101S1 2 78 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cables Lubricate with Rust Inhibitor Throttle Inner Cables Clutch Inner Cable Pivots Lubricate with engine oil Rear Master Cylinder Joint Pin Cable Inspection e With the cable disconnected at the both ends the cable should move freely A within the cable housing If cable movement is not free after lubricating if the cable is frayed B or if the cable housing is kinked C replace the cabl
14. Engine Lubrication System WARNING Vehicle operation with insufficient deteriorated or contaminated engine oil will cause accelerated wear and may result in engine seizure accident and injury Check the oil level before each use and change the oil and filter according to the periodic maintenance chart GFO606028S1 6F130107S1 PERIODIC MAINTENANCE 2 29 Periodic Maintenance Procedures Engine Oil Change e Warm up the engine thoroughly so that the oil will pick up any sediment and drain easily Then stop the engine e Place an oil pan beneath the engine e Remove the oil filler plug A Special Tool Filler Cap Driver 57001 1454 e Remove the engine oil drain bolts from the bottom of the engine and let the oil drain completely Drain Bolt M6 A Drain Bolt M10 B NOTE OHold the motorcycle upright so that the oil may drain completely e Replace the drain bolt gaskets with new ones e Install the drain bolts with the gaskets e Tighten Torque Engine Oil Drain Bolt M10 20 N m 2 0 kgf m 15 ft Ib Engine Oil Drain Bolt M6 7 0 N m 0 71 kgf m 62 in Ib e Pour in the specified type and amount of oil z SAE 10W 50 Recommended Engine Oil Se E area Type Castrol POWER1 Racing 4T 5W 40 or API SG SH SJ SL or SM with JASO MA SAE 10W 30 MA1 or MA2 Viscosity SAE 10W 30 10W 40 or 10W 50 200 10 0 10 20 30 4000 Capa
15. Fuel Tank Cleaning WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the tank in a well ventilated area and take care that there are no sparks or flame any where near the working area Do not use gasoline or low flash point solvents to clean the tank e Remove the fuel tank and drain the fuel see Fuel Tank Removal in the Fuel System DFI chapter e Remove the fuel pump see Fuel Pump Removal in the Fuel System DFI chapter e Pour some high flash point solvent into the fuel tank and shake the tank to remove dirt and fuel deposits e Drain the solvent out of the tank e Dry the tank with compressed air e Install the fuel pump see Fuel Pump Installation in the Fuel System DFI chapter e Install the fuel tank see Fuel Tank Installation in the Fuel System DFI chapter Cooling System WARNING Coolant can be extremely hot and cause severe burns is toxic and very slippery Do not remove the radiator cap or attempt to change the coolant when the engine is hot allow it cool completely Immediately wipe any spilled coolant from tires frame engine or other painted parts Do not ingest coolant 6S05027BS1 GSOSCII P L PERIODIC MAINTENANCE 2 21 Periodic Maintenance Procedures Coolant Level Inspection NOTE OCheck the level when the engine is cold room or ambi ent temperature e Lean the motorc
16. NOTE ODo not remove the push rod clevis since removal re quires brake pedal position adjustment e Remove the reservoir cap and diaphragm and pour the brake fluid into a container e Slide the dust cover A on the push rod B out of place and remove the circlip C Special Tool Inside Circlip Pliers 57001 143 e Pull out the push rod e Remove the piston assy D include primary and sec ondary cups Assembly e Before assembly clean all parts including the master cylinder with brake fluid or alcohol NOTICE Except for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning of the brake parts Do not use any other fluid for cleaning of these parts Gasoline engine oil or any other petroleum distillate will cause de terioration of the rubber parts Oil spilled on any part will be difficult to wash off completely and will eventually deteriorate the rubber used in the disc brake GS13298BS1 We 6S13325BS1 GS13299BS1 PERIODIC MAINTENANCE 2 43 Periodic Maintenance Procedures e Apply brake fluid to the removed parts and to the inner wall of the cylinder e Take care not to scratch the piston assy and the inner wall of the cylinder e Apply silicone grease ex PBC grease to the following parts Brake Lever Pivot Bolt Front Brake Lever Contact Front Push Rod Contact Other than KX450FC Front Dust Covers
17. Piston Ring Groove Width Standard Top 0 83 0 85 mm 0 0327 0 0335 in Service Limit Top 0 93 mm 0 037 in x If any of the groove widths exceeds the service limit re place the piston Piston Ring Thickness Inspection e Measure the thickness at several points around the ring with a micrometer Piston Ring Thickness Standard Top 0 77 0 79 mm 0 030 0 031 in Service Limit Top 0 70 mm 0 028 in x If any of the measurements is less than the service limit replace all the rings NOTE OWhen using new rings in a used piston check for un even groove wear The rings should fit perfectly parallel to the groove sides If not replace the piston GE16217BS1 5 38 ENGINE TOP END Cylinder and Piston Piston Ring End Gap Measurement e Place the piston ring A inside the cylinder using the pis ton to locate the ring squarely in place Set it close to the bottom of the cylinder where cylinder wear is low e Measure the gap B between the ends of the ring with a thickness gauge Piston Ring End Gap Standard Top 0 23 0 33 mm 0 0091 0 0130 in Oil 0 15 0 50 mm 0 0059 0 0197 in Service Limit Top 0 6 mm 0 02 in Oil 0 8 mm 0 03 in x lf the ring end gap exceeds the service limit replace all the rings Piston Piston Pin Connecting Rod Wear Inspection e Visually inspect the snap rings A still fitted in place x If the ring shows weakness or deformation r
18. Torque Rear Shock Absorber Mounting Nut Lower 34 N m 3 5 kgf m 25 ft lb Rocker Arm Pivot Nut 59 N m 6 0 kgf m 44 ft lb Tie Rod Mounting Nut 59 N m 6 0 kgf m 44 ft Ib Tie Rod and Rocker Arm Bearing Removal e Remove Tie Rod see Tie Rod Removal Rocker Arm see Rocker Arm Removal Collars A Sleeves B Oil Seals C Grease Seals D e Remove the needle bearing E using the bearing re mover head and bearing remover shaft e Remove the needle bearings F using the oil seal amp bear ing remover Special Tools Bearing Remover Head 420 x 22 57001 1293 Bearing Remover Shaft 613 57001 1377 Oil Seal amp Bearing Remover 57001 1058 Tie Rod and Rocker Arm Bearing Installation e Replace the needle bearings oil seals and grease seals with new ones e Apply plenty of grease to the oil seals grease seals and needle bearings NOTE Olnstall the bearings so that the marked side faces out Olnstall the oil seals so that the deep groove side faces inward Olnstall the grease seals so that the groove side faces outward GM07034BS2 C 13 32 SUSPENSION Tie Rod Rocker Arm e Install the needle bearings A B oil seals C and grease seals D so that their positions are as shown in the figure OThe other side is also the same procedures Front E Right Side F Left Side G Rear Shock Absorber H Tie Rod I Rocker Arm J Deep Groove K Groove L 4 5mm 4 25mm
19. Warning Light LED Sensor Switch W2LO613CW5 C Wiring Diagram ELECTRICAL SYSTEM 16 9 Spark Plug Throttle Sensor Intake Air Pressure Fuel Sensor Injector ras gt r Sas SSC z5 TE 53 H 2 m aas 3 Al o ea a o Frame aX 1 l iti EE Water Intake coil Aie Temperature Air eae Sensor Temperature gonr BK Sensor Sensor Fuel 5 e i e J Pump oilor ode Black 7 Frame Ground 2 7 Brown Green Gray B Light Blue Orange P Pink Red R W White 98052 06136 W2ROGI3CWS C 16 10 ELECTRICAL SYSTEM Precautions There are numbers of important precautions that are musts when servicing electrical systems Learn and ob serve all the rules below OThe electrical parts should never be struck sharply as with a hammer or allowed to fall on a hard surface Such a shock to the parts can damage them OTo prevent damage to electrical parts do not disconnect any electrical connections while the engine is running OTroubles may involve one or in some cases all items Never replace a defective part without determining what CAUSED the failure If the failure was caused by some other item or items they too must be repaired or replaced or the new replacement will soon fail again OMake sure all connectors in the circuit are clean and tight and examine leads for signs of burning fraying etc Poor leads and bad connections will affect electrical
20. e Refer to the Self diagnosis Procedures connect the 12 V battery to the main harness e Measure the intake air pressure sensor output voltage from various vacuum readings while pulling the handle of the fork oil level gauge OCheck the intake air pressure sensor output voltage us ing the following formula and chart Suppose Pg Vacuum Pressure Gauge of Throttle Body PI Local Atmospheric Pressure Absolute measured by a barometer Pv Vacuum Pressure Absolute of Throttle Body Vv Sensor Output Voltage V then Pv PI Pg For example suppose the following data is obtained Pg 8 cmHg Vacuum Gauge Reading PI 70 cmHg Barometer Reading Vv 3 2 V Digital Meter Reading then Pv 70 8 62 cmHg Absolute Plot this Pv 62 cmHg at a point 1 on the chart and draw a vertical line through the point Then you can get the usable range 2 of the sensor output voltage Usable range 3 08 3 48 V Plot Vv 3 2 V on the vertical line Point 3 Results In the chart Vv is within the usable range and the sensor is normal x If the reading is out of the usable range replace the sen sor x If the reading is within the usable range check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation 6017119BS2 C Intake Air Pressure Sensor Service Code 12 FUEL SYSTEM
21. 2 Kawasaki KX450F Motorcycle Service Manual This quick reference guide will assist you in locating a desired topic or pro cedure Bend the pages back to match the black tab of the desired chapter num ber 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 spe cific topic required Quick Reference Guide General Information Periodic Maintenance Fuel System DFI Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal Installation Crankshaft Transmission Wheels Tires Final Drive Brakes Suspension Steering Electrical System 1 sch a ala la NIO BIO IN 6010 Ion BR IIN Appendix Kawasaki 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 Assurance Division Motorcycle amp Engine 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
22. Run the clutch cable inside of the number plate Run the front brake hose outside of the number plate Throttle Cable Accelerator Throttle Cable Decelerator Band Hold the engine stop switch lead and launch control mode button lead Cut the excess of the band into 15 mm length or shorter Launch Control Mode Button Engine Stop Switch Run the throttle cables into the guide Run the engine stop switch lead launch control mode button lead and clutch cable into the guide Run the clutch cable outside of the two leads Regulator Rectifier Clamp Hold the main harness Clamp 17 6 APPENDIX Cable Wire and Hose Routing KX450FC ND CONDON Launch Control Mode Button Lead Engine Stop Switch Lead Main Harness Run the clutch cable outside of the main harness Clutch Cable Clamp Clamp Wind the clamp on the cable Run the clutch cable outside of the mag neto lead and gear position switch lead 10 11 Run the throttle cables over the water 13 14 66097450 G Gear Position Switch Lead Magneto Lead Throttle Cables hose Run the throttle cables through the side of the fuel tank Run the throttle cables over the main har ness When assemble the fuel tank confirm the throttle cables can move forward and backward APPENDIX 17 7 Cable Wire and Hose Routing KX450FD GROSOHIE 6 1 Launch Control Mode But
23. Torque Muffler Mounting Bolts 20 N m 2 0 kgf m 15 ft lb OTighten the front bolt C first and then the rear bolt e Tighten Torque Exhaust Pipe Holder Nuts 20 N m 2 0 kgf m 15 ft Ib Muffler Clamp Bolt D 16 5 N m 1 68 kgf m 12 2 ft Ib OFace the muffler clamp bolt upward OTighten the holder nuts first and then the clamp bolt e Thoroughly warm up the engine wait until the engine cools down and then retighten all the bolts and nuts Silencer Wool Replacement e Refer to the Silencer Wool Replacement in the Periodic Maintenance chapter GE18155BS1 GE18156BS1 CLUTCH 6 1 Clutch Table of Contents Exploded WEE EE 6 2 SPOCIiGAti ONS ste entente M A AAA A A AE 6 4 SM EE 6 5 Clutch Eever and Cable iii Ada 6 6 Clutch Lever Clutch Cable Free Play Inspection 6 6 Clutch Lever Clutch Cable Free Play Adjustment ooooonnonoconcccnnccconcnnancnncnnnnnnnnnnnananonnnos 6 6 Clutch Lever UE e TEE 6 6 Clutch Cable Removal see 6 6 Clutch Cable Installation ii aladas edeteemonenaneds 6 7 Clutch Cable Inspection and Lubrication s s ssessseseseeeeeeerersrtrrrrrrrrrrrrrrrrrrrrrrrrrrrerrrrrrrren Clutch Cover and Right Engine Cover thin nd tit stunecavenusetunteretgenaneatan Clutch Cover Removal sise Clutch Cover Installation siennes den e nn ttes ico Right Engine Cover Removal caceria lod ti din te tres pense Right Engine Cover Installations ra a bt des
24. e Check that the dust seals are not cracked worn swollen or otherwise damaged x If they show any damage replace them Caliper Dust Boot and Friction Boot Damage Inspection e Check that the dust boot A and friction boot B are not cracked worn swollen or other wise damaged x If they show any damage replace it Front Caliper C Rear Caliper D 12 16 BRAKES Caliper Caliper Piston and Cylinder Damage Inspection e Visually inspect the piston s A and cylinder surfaces x Replace the caliper if the cylinder and piston are badly scores or rusty Front Caliper B Rear Caliper C Caliper Holder Shaft Wear Inspection The caliper body must slide smoothly on the caliper holder shafts A If the body does not slide smoothly one pad will wear more than the other pad wear will increase and con stant drag on the disc will raise brake and brake fluid tem perature e Check to see that the caliper holder shafts are not badly worn or stepped and that the friction boots are not dam aged x If the friction boot is damaged replace the friction boot To replace the friction boot remove the pads and caliper bracket x If the caliper holder shaft is damage replace the caliper assembly front caliper caliper bracket or holder shaft rear caliper Torque Rear Caliper Holder Shaft 27 N m 2 8 kgf m 20 ft lb Front Caliper B Rear Caliper C BRAKES 12 17 Brake Pad Brak
25. e Tighten Torque Muffler Mounting Bolt 20 N m 2 0 kgf m 15 ft lb e Using a high flash point solvent clean off any oil or dirt that may be on the silicone sealant coating area Dry them with a clean cloth e Apply silicone sealant to the mating surface A e Install Right Side Cover see Side Cover Installation in the Frame chapter Clutch Clutch Operation Inspection Clutch Lever Clutch Cable Free Play Inspection e Slide the clutch cable adjuster knob A out of place e Check that the clutch cable upper end B is fully seated in the adjusting bolt C e Install the knob to original position e Pull the clutch lever A lightly and check the flee play B Clutch Lever Free Play Standard 8 13 mm 0 3 0 5 in x If the play is too wide the clutch may not release fully If the play is too narrow the clutch may not engage fully In either case adjust it Clutch Lever Clutch Cable Free Play Adjustment e Turn the clutch cable adjuster knob A so that the clutch lever will have 8 13 mm 0 3 0 5 in of play NOTICE Be sure that the outer cable end at the clutch lever is fully seated in the adjuster at the clutch lever or it could slip into the place later creating enough cable play to prevent clutch disengagement x lf the free play can not be adjusted with the clutch cable adjuster use the adjusting nut 2 28 PERIODIC MAINTENANCE Periodic Maintenance Procedures
26. 0 7512 in 19 07 mm 0 7508 in 5 8 ENGINE TOP END Specifications Valve Stem Diameter 6E15049BS1 Valve Stem Diameter A 45 B Valve Stem Bend GE15011281 Dial Gauge A Special Tools and Sealant Compression Gauge 20 kgf cm 57001 221 Valve Spring Compressor Assembly 57001 241 ST5702218T ST5702418T Valve Guide Arbor 5 5 57001 1021 AF 8757102197 Valve Guide Reamer 5 5 57001 1079 N Piston Ring Compressor Grip 57001 1095 ST5710798T ST5710958T ENGINE TOP END 5 9 Valve Seat Cutter 45 p35 57001 1116 Valve Seat Cutter 32 635 57001 1121 ST5711168T ST5711218T Valve Seat Cutter 32 638 5 57001 1122 8757112297 Valve Seat Cutter Holder 5 5 57001 1125 Valve Seat Cutter Holder Bar 57001 1128 ST571125ST ST5711288T 5 10 ENGINE TOP END Special Tools and Sealant Valve Seat Cutter 55 p35 57001 1247 ST571247ST Compression Gauge Adapter M10 x 1 0 57001 1317 ST5713178T Piston Ring Compressor Belt 695 4108 57001 1358 ST571358ST Filler Cap Driver 57001 1454 ST5714548T Valve Seat Cutter 45 40 57001 1496 ST571496ST Valve Seat Cutter 55 438 5 57001 1497 ST571497ST
27. 13 11 Rear Shock Absorber Inspection 13 26 Air Pressure Adjustment Rear Shock Absorber Scrapping 13 26 KX450FD 13 11 Swingarm HE 13 27 Compression Damping Swingarm Removal 13 27 Adjustment 13 12 Swingarm Installation 13 28 Rebound Damping Adjustment 13 13 Swingarm Bearing Removal 13 28 Oil Change each fork leg 13 13 Swingarm Bearing Installation 13 28 Front Fork Removal 13 14 Drive Chain Guide Guide Roller Front Fork Installation 13 15 Chain Slipper Wear Inspection 13 29 Front Fork Disassembly 13 15 Swingarm Bearing Sleeve Front Fork Assembly 13 16 INSpection sin us te 13 29 Adjuster Assembly Inspection 13 17 Tie Rod Rocker Am 13 30 Base Valve Assembly Inspection 13 17 Tie Rod Removal 13 30 Cylinder Unit Inspection 13 17 Tie Rod Installation 13 30 Inner Tube Inspection 13 18 Rocker Arm Removal 13 30 Dust Seal Inspection 13 18 Rocker Arm Installation 13 31 Front Fork Spring Tension Tie Rod and Rocker Arm Bearing Inspection KX450FC 13 18 Removal sas t 13 31 Rear Shock Absorber 13 19 Tie Rod and Rocker Arm Bearing Rebound Damping Adjustment 13 19 Installation aan 13 31 Compression Dampin
28. D S e S ex 7 Ho Oe 6G17978EW1 C 1 ECU 2 Capacitor 3 Fuel Pump 4 Frame Ground 1 FUEL SYSTEM DEI 3 63 Ignition Coil Service Code 51 Ignition Coil Removal Installation e Refer to the Ignition Coil Removal Installation in the Elec trical System chapter Ignition Coil Primary Peak Voltage Inspection e Refer to the Ignition Coil Primary Peak Voltage Check in the Electrical System chapter lf the peak voltage is mach lower than standard check the wiring for continuity see Ignition Coil Circuit lf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation Ignition Coil Circuit O l OR oho 1 ECU 2 Ignition Coil 3 Frame Ground 2 4 Spark Plug 3 64 FUEL SYSTEM DFI Orange FI Warning Indicator Light LED Orange FI Warning Indicator Light LED Inspection NOTE OBe sure the battery is fully charged e Refer to the Self diagnosis Procedures connect the 12 V battery to the main harness e Confirm that the orange Fl warning indicator light LED goes on for 2 seconds when the battery connected to the main harness x lf the orange Fl warning indicator light LED does not go on check the wiring for continuity between the main harness ODisconnect the capacitor and the launch control mode button connectors Wiring Continu
29. Fuel pressure too low Fuel injector trouble Inspect Inspect see chapter 3 see chapter 3 Throttle sensor trouble Inspect see chapter 3 Intake air pressure sensor trouble Water temperature sensor trouble Inspect Inspect see chapter 3 see chapter 3 am LN Le ls Inspect see chapter 3 Intake air temperature sensor trouble FUEL SYSTEM DFI 3 23 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter Surge Unstable fuel pressure Fuel pressure regulator trouble Inspect and replace fuel pump or kinked fuel line Inspect and replace fuel pump see chapter 3 Fuel injector trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Backfiring when deceleration EA eee Spark plug dirty broken or gap maladjusted Inspect and replace see chapter 16 Throttle sensor trouble Inspect see chapter 3 Intake air pressure sensor rouble inspect see chapter 3 inspect Replace see chapter 16 Fuel injector trouble inspect see chapter 3 Intake air pressure sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Intake air temperature sensor trouble Inspect see chapter 3 Other Intermittent any DFI fault and its recovery Check that DFI connectors are clean and tight and examine leads for signs of burning or fraying see chapter 3 see chapter 3
30. L Apply a non permanent locking agent M Apply molybdenum disulfide grease R Replacement Parts 7 4 ENGINE LUBRICATION SYSTEM Lubrication System Chart ETA S AS ei A DA fe NE y g Y AS AY N g Y HA S d K E les L amp W gt z Ue NZ S i Gu 7 CAE a AN A Y LNG d a e ANS UN ENGINE LUBRICATION SYSTEM 7 5 Lubrication System Chart e SE SN e 66041768 G SAA n sch ao 12 13 14 15 Oil Screen Feed Oil Pump Feed Oil Pressure Relief Valve Right Engine Cover Oil Passage from Feed Oil Pump to Oil Filter Crankshaft Right Engine Cover Oil Passage from Oil Filter to Crankshaft Oil Filter Piston Oil Nozzles Left Crankcase Oil Passage from Oil Filter to Transmission Oil Passage Cylinder Oil Passage from Crankcase Oil Passage to Cylinder Head Oil Passage Oil Pipes Oil Screen Scavenge Oil Pump Scavenge Balancer Weight Breather Hose Engine Oil Blowby Gas 7 6 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil Type Viscosity Capacity Oil Level Oil Pressure Measurement Oil Pressure Castrol POWER1 Racing 4T 5W 40 or API SG SH SJ SL or SM with JASO MA MAT or MA2 SAE 10W 30 10W 40 or 10W 50 0 96 L 1 01 US qt when filter is not removed 0 98 L 1 04 US qt when filter is removed 1 20 L 1 27 US qt when engine is completely dry
31. Maintenance chapter Master Cylinder BRAKES 12 19 NOTICE Brake fluid quickly ruins painted or plastic sur faces any spilled fluid should be completely washed up immediately Front Master Cylinder Removal e Remove the banjo bolt A to disconnect the brake hose upper end B from the master cylinder C OWhen removing the brake hose temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum e Remove the clamp bolts A and take off the master cylin der B as an assembly with the brake lever Front Master Cylinder Installation KX450FC e Install the master cylinder A position as shown in the figure 185 mm 7 28 in B Horizontal Line of Frame C Handlebar D Horizontal Line of Cap Surface E GNOGO69BS2 C 12 20 BRAKES Master Cylinder KX450FD e Install the master cylinder A 176 95 mm 6 967 in B Horizontal Line of Frame C Handlebars D Horizontal Line of Cap Surface E e The master cylinder clamp must be installed with the ar row mark A upward e Tighten the upper clamp bolt B first and then the lower clamp bolt C OThere will be a gap at the lower mating surface of the clamp after tightening Torque Front Master Cylinder Clamp Bolts 8 8 N m 0 90 kgf m 78 in Ib e Install the brake hose OReplace the washers A on each side of hose fitting B with new ones e Tighten Torque Brake Ho
32. Make Type Rear Size Make 100 kPa 1 00 kgf cm 14 psi 80 100 21 51M BRIDGESTONE M403 Tube 120 80 19 63M BRIDGESTONE M404 Tube Type Special Tools Inside Circlip Pliers 57001 143 ST5701438T Rim Protector 57001 1063 ST571063ST Bearing Driver Set 57001 1129 ST5711298T Jack 57001 1238 ST5712388ST WHEELS TIRES 10 5 Bearing Remover Head 20 x 22 57001 1293 T5712938T Bearing Remover Head 25 x 428 57001 1346 ST5718468T e Bearing Remover Shaft 13 57001 1377 ST5713778T Jack Attachment ES Jl ST571608ST 10 6 WHEELS TIRES Wheels Rims Front Wheel Removal e Remove the axle nut A e Loosen the axle clamp bolts B on both sides e Raise the front wheel off the ground with jack Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Pull out the axle and remove the wheel e Remove the collars A with caps B on both sides NOTICE Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so the disc does not touch the ground e Insert a wod wedge between the brake pads OThis prevents them from being moved out of their proper position should the brake lever be squeezed accidentally Front Wheel Installation e Apply high temperature grease to the grease
33. OA sound scope can also be used OThe click interval becomes shorter as the engine speed j SUSE rises x lf the injector click at a regular intervals the injector is normal e Stop the engine x If fuel injector dose not click check the fuel injector resis tance see Fuel Injector Resistance Inspection Fuel Injector Service Code 41 FUEL SYSTEM DFI 3 57 Fuel Injector Resistance Inspection e Remove Fuel Tank see Fuel Tank Removal Fuel Hose see Fuel Hose Replacement in the Periodic Maintenance chapter Fuel Injector Connector A e Connect a digital meter A to the injector terminals e Measure the fuel injector resistance Fuel Injector Resistance Connections R W terminal BL R terminal Standard About 11 7 12 3 Q at 20 C 68 F x If the reading is out of the standard replace the injector x If the reading is within the standard check the power sup ply voltage see Fuel Injector Power Supply Voltage In spection Fuel Injector Power Supply Voltage Inspection NOTE OBe sure the battery is fully charged e Disconnect the injector connector and connect the mea suring adapter A between these connectors Main Harness B Fuel Injector C Special Tool Measuring Adapter 57001 1700 e Connect a digital meter D to the measuring adapter lead Fuel Injector Power Supply Voltage Connect the Adapter Digital Meter R injector R W lead Digital Meter Battery Term
34. Olt is able to check with the pads installed 7 j x If either pad is damaged replace both pads in the caliper as a set Brake Pad Lining Thickness Standard Front 4 0 mm 0 16 in Rear 6 4 mm 0 25 in Service Limit Front 1 mm 0 04 in Rear 1 mm 0 04 in GS13255BS2 x lf the lining thickness A of either pad is less than the service limit B replace both pads in the caliper as a set Front Pad C Rear Pad D Brake Master Cylinder Cup and Dust Cover Replacement Front Master Cylinder Disassembly e Remove the front master cylinder see Front Master Cylin der Removal in the Brakes chapter e Remove the reservoir cap and diaphragm and pour the brake fluid into a container e Remove the locknut and pivot bolt and remove the brake lever 2 42 PERIODIC MAINTENANCE Periodic Maintenance Procedures KX450FC e Pull the dust cover A out of place and remove the circlip B Special Tool Inside Circlip Pliers 57001 143 e Remove the washer C e Remove the piston assy D include primary and sec ondary cups KX450FD e Pull the push rod A and dust cover B out of place and remove the circlip C Special Tool Inside Circlip Pliers 57001 143 e Remove the washer D e Remove the piston assy E include primary and sec ondary cups Rear Master Cylinder Disassembly e Remove the rear master cylinder see Rear Master Cylin der Removal in the Brakes chapter
35. Special Tool Measuring Adapter 57001 1700 ORefer to the Self diagnosis Procedures in the Fuel Sys tem DFI chapter connect the 12 V battery to the main harness OStart the engine ORun it at the rpm given in the table 1 ONote the voltage readings total 3 measurements Table 1 Magneto Output Voltage at 4 000 r min rpm Connections Reading Tester to Tester to One yellow lead Another yellow lead AC 37 V or more x If the output voltage shows the value in the table the mag neto operates properly x If the output voltage shows a much lower reading than that given in the table indicates that the magneto is defective e To check the stator coil resistance as follows OStop the engine OConnect the tester as shown in the table 2 ONote the resistance readings total 3 measurements Table 2 Stator Coil Resistance at 20 C 68 F Reading Tester to Tester to One yellow lead Another yellow lead 0 4 1 1 0 GP21011BS1 Flywheel Magneto ELECTRICAL SYSTEM 16 17 x If there is more resistance than shown in the table or no tester reading infinity the stator has an open lead and must be replaced Much less than this resistance means the stator is shorted and must be replaced e Using the highest resistance range of the tester measure the resistance between each leads and chassis ground Any tester reading less than infinity in
36. brake pedal bolt e Apply a non premanent locking agent to the thread of the brake pedal bolt e Install the brake pedal C Olnstall the washer D inside the pedal e Tighten Torque Brake Pedal Bolt 25 N m 2 5 kgf m 18 ft lb BRAKES 12 9 Brake Lever Brake Pedal e Replace the cotter pin with a new one e Install the joint pin washer and new cotter pin OBend the ends A of the cotter pin as shown in the figure e Check the brake pedal position see Brake Lever and Pedal Adjustment in the Periodic Maintenance chapter GLO4023BS1 12 10 BRAKES Brake Fluid A WARNING When working with the disc brake observe the pre cautions listed below eNever reuse old brake fluid eDo not use fluid from a container that has been left unsealed or that has been open for a long time eDo not mix two types and brands of fluid for use in the brake This lowers the brake fluid boiling point and could cause the brake to be ineffective lt may also cause the rubber brake parts to deteriorate eDon t leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid eDon t change the fluid in the rain or when a strong wind is blowing eExcept for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning of the brake parts Do not use any other fluid for cleaning these parts Gasoline engine oil or any other petroleum distillat
37. e Install the primary gear nut D OThe primary gear nut is left hand threads e Temporarily install the clutch housing A e Hold the primary gear B with the gear holder C Special Tool Gear Holder m2 0 57001 1557 e Tighten Torque Primary Gear Nut D 98 N m 10 kgf m 72 ft Ib OThe primary gear nut is left hand threads e Install the removed parts see appropriate chapters CRANKSHAFT TRANSMISSION 9 27 External Shift Mechanism Shift Pedal Removal e Remove Shift Pedal Bolt A Shift Pedal B Shift Pedal Installation e Install the shift pedal so that the slit A on the pedal aligns with the punch mark B on the shift shaft e Tighten Torque Shift Pedal Bolt 9 8 N m 1 0 kgf m 87 in Ib External Shift Mechanism Removal e Remove Right Engine Cover see Right Engine Cover Removal in the Clutch chapter Clutch see Clutch Removal in the Clutch chapter Shift Pedal see Shift Pedal Removal Oil Pump Driven Gear A see Oil Pump Feed Re moval in the Engine Lubrication System chapter e Pull out the shift shaft B e Remove Collar A Ratchet Plate Bolt B Ratchet Plate Screw C e While compressing the pawls D take off the shift ratchet assembly E with ratchet plate F e Remove the shift drum cam bolt A e Push down the gear positioning lever B with the screw driver C and remove the shift drum cam D and pin e Remove Gear Position Lever
38. e Refer to the Swingarm Bearing Installation and Rocker Arm Bearing Installation in the Suspension chapter Steering Steering Inspection e Using the jack raise the front wheel off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e With the front wheel pointing straight ahead alternately nudge each end of the handlebar OThe front wheel should swing fully to left and right from the force of gravity until the fork hits the stop x If the steering binds or catches before the stop check the routing of the cables hoses and harnesses x lf the steering feels tight adjust or lubricate the steering e Feel for steering looseness by pushing and pulling A the forks x If you feel looseness adjust the steering Steering Adjustment e Using the jack raise the front wheel off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 PERIODIC MAINTENANCE 2 75 Periodic Maintenance Procedures e Remove Number Plate see Number Plate Removal in the Frame chapter Handlebar Pad A e Remove Handlebar Clamp Bolts A Handlebar Clamps B Handlebar C e Loosen the front fork clamp bolts upper A on both sides e Remove the steering stem head nut B and washer C e Remove the steering stem head D e Turn the steering stem nut A with the steering stem nut wrench B to obtain the proper adjustment x If the steering is too tight loosen the stem
39. e Remove Handlebar Clamp Bolts A Handlebar Clamps B Handlebar C e Check the handlebar for bends or cracks x If the handlebar was bended or cracked replace it 14 10 STEERING Handlebar Handlebar Installation e Apply adhesive cement to the innermost area of the left handlebar grip and all around inner surface of the left han dlebar grip hole entrance and also apply it to the roulette area on the handlebars e The left handlebar grip must be installed with the projec tion A upward KX450FC KX450FE e The left handlebar grip must be installed with the triangle mark B upward KX450FD OWhen installing the left handlebar grip rotate the grip more than once first and then remove and install the grip alternately more than three times to spread adhesive ce ment Make sure that adhesive cement has been spread evenly OAfter installation hold the left handlebar grip area at more than three points to make the left handlebar grip stick to the handlebars e Install the clutch lever holder assembly A as shown in the figure 25 35 B Horizontal Line of Frame C 170 mm 6 69 in D KX450FC 160 5 mm 6 32 in KX450FD e Install the launch control mode button A as shown in the figure Clutch Lever Holder Assembly B 5 10 mm 0 2 0 4 in C e Install the engine stop switch e Run the launch control mode button lead and engine stop switch lead correctly see Cable Wire and Hose Routing
40. e Tighten Torque Water Hose Clamp Screws 3 0 N m 0 31 kgf m 27 in lb e Install the radiator screens on both sides OFit the projections A and the holes B e Tighten Torque Radiator Screen Bolts 9 8 N m 1 0 kgf m 87 in Ib e Fill the coolant see Coolant Filling e Install the removed parts see appropriate chapters Radiator Inspection e Check the radiator core x If there are obstructions to air flow remove them xlf the corrugated fins A are deformed carefully straighten them with the standard tip screwdriver NOTICE Do not tear the radiator tubes while straightening the fins 6D070104S1 x If the air passages of the radiator core are blocked more than 20 by unremovable obstructions or irreparably de formed fins replace the radiator with a new one NOTICE When cleaning the radiator with steam cleaner be careful of the following to prevent radiator damage Keep the steam gun A away more than 0 5 m 1 64 ft B from the radiator core Hold the steam gun perpendicular to the core surface Run the steam gun following the core fin direction C GDO7093BS1 4 14 COOLING SYSTEM Radiator Radiator Cap Inspection e Check the condition of the valve spring A and the top and bottom valve seals B of the radiator cap x If any one of them shows visible damage replace the cap e Wet the top and bottom valve seals with water or coolant to prevent p
41. exists replace the ECU see ECU Removal Installation ATRAS 6017716DS2 FUEL SYSTEM DEI 3 45 Intake Air Temperature Sensor Service Code 13 Intake Air Temperature Sensor Circuit 10 6 6G17972E 1 C 1 ECU 2 Intake Air Temperature Sensor 3 46 FUEL SYSTEM DFI Water Temperature Sensor Service Code 14 Water Temperature Sensor Removal Installation NOTICE Never drop the water temperature sensor espe cially on a hard surface Such a shock to the sensor can damage it e Drain the coolant see Coolant Draining in the Cooling System chapter e Remove Comnector A Water Temperature Sensor B e Replace the O ring with a new one apply grease to it e Install the new O ring to the water temperature sensor e Tighten Torque Water Temperature Sensor 12 N m 1 2 kgf m 106 in Ib e Fill the engine with coolant and bleed the air from the cooling system see Coolant Filling in the Cooling System chapter Water Temperature Sensor Output Voltage Inspection NOTE OBe sure the battery is fully charged e Disconnect the water temperature sensor connector and connect the measuring adapter A between these con nectors Main Harness B Water Temperature Sensor C Special Tool Measuring Adapter 57001 1700 e Connect a digital meter D to the measuring adapter leads Water Temperature Sensor Output Voltage Connections to Adapter Digital Meter R s
42. faces up ward e Install the spring guide e Adjust the spring preload see Spring Preload Adjust ment e Install the rear shock absorber see Rear Shock Absorber Installation e Install the removed parts see appropriate chapters Rear Shock Absorber Disassembly e Remove Piston Rod Assembly see Rear Shock Absorber Oil Change in the Periodic Maintenance chapter e Visually inspect the piston A lf the piston is badly scored rusty or damage replace them e Using the grinder shave off the stake portion A of the piston rod B NOTE OShaving off is necessary only at the initial disassembly GMO5456BS1 D K ANN GMO5197BS1 A GM05458BS1 13 24 SUSPENSION Rear Shock Absorber e Hold the lower of the piston rod assembly in a vise with soft jaws or a heavy cloth e Remove the piston rod locknut A and washers for the threads length adjustment e Discard the piston rod locknut e Remove the piston assembly A as it is OBe careful not to disassemble it OStick a suitable rod into the piston assembly and leave it until being reinstalled e Remove Oil Seal Assembly A e Remove Stopper A Damper B Damper Holder C e Inspect the piston rod sliding surface A x If the sliding surface is scratches or distortion replace the piston rod assembly Rear Shock Absorber SUSPENSION 13 25 e Make the threads of the pist
43. gradu ally and evenly e While keeping parallel remove the camshaft caps A and oil pipes B OPlug the oil passage and camshaft chain tunnel with a clean cloth for prevent the oil pipe from dropping into the crankcase e Remove Positioning Rings A e Disengage the camshafts B from camshaft chain C e Staff a clean cloth into the camshaft chain tunnel to keep any parts from dropping into the crankcase NOTICE Always strain the camshaft chain while turning the crankshaft when the camshafts removed This avoids kinking the chain on the lower crank shaft sprocket A kinked chain could damage both the chain and the sprocket x fhe P M Camshafts ENGINE TOP END 5 17 e While holding the exhaust camshaft with a vise remove the camshaft sprocket bolts A e Remove Auto Decompressor B with Sprocket e Remove Circlips A Camshaft Installation e Assemble the auto decompressor weights A and spring B to install it to the sprocket C e Replace the circlips D with new ones e Install the circlips so that the opening E face to the out side e Fit the recess F of the weight and projections G of the camshaft e Apply a non permanent locking agent to the threads of the camshaft sprocket bolts H e Tighten Torque Camshaft Sprocket Bolts 12 N m 1 2 kgf m 106 in Ib e Apply molybdenum disulfide oil to the ball bearing all cam and journal surfaces of the c
44. has been adjusted throttle body assy has to be replaced Don t tamper with stop screw e Remove Throttle Sensor Screw A Throttle Sensor B OBO 6017127BS1 3 32 FUEL SYSTEM DFI Throttle Sensor Service Code 11 e Replace Throttle Sensor Screw A Throttle Sensor B O ring C e Apply engine oil to the new O ring and install itto the new throttle sensor e Engage the inner rotor groove A with the throttle shaft B e Insert the throttle sensor A into the throttle body OSet the throttle sensor to the throttle body assy as shown in the figure e Turn the throttle sensor counterclockwise B until the mounting holes align e Tighten the throttle sensor screw lightly e Connect the measuring adapter A between the main har ness B and the throttle sensor C Special Tool Measuring Adapter 57001 1700 e Connect a digital meter D to the measuring adapter leads Throttle Sensor Output Voltage Connections to Adapter Digital Meter W sensor Y lead Digital Meter BK sensor BK lead e Refer to the Self diagnosis Procedures connect the 12 V battery to the main harness FUEL SYSTEM DFI 3 33 Throttle Sensor Service Code 11 e Adjust the sensor position so that the output voltage is within the specified voltage range Throttle Sensor Output Voltage Standard DC 0 58 0 62 V x If the input voltage reading shows o
45. section in the Appendix chapter e Apply grease to the throttle cable upper end and clutch cable upper end e Apply 2 stroke oil to the edge slash area of the handle bar 120 mm 4 72 in A GFO4027BS1 GNO6071BS1 STEERING 14 11 Handlebar e Install the throttle grip assembly so that the grip A is in as far as it will go OPosition the throttle grip assembly so that the cable gate way B of the throttle case is above the handlebar e Install the front master cylinder see Front Master Cylinder Installation in the Brakes chapter e Install the handlebar A on the steering stem head as follows OThe handlebar angle position can be adjusted to suit your preference using the gauge marks B OPosition the handlebar so that the gauge marks is equal positions C Bridge Bar D e Install the handlebar clamps E and handlebar clamp bolts F e Tighten the handlebar clamp bolts A OEqualize the front and rear gaps B NOTE OTighten the two clamp bolts alternately two times to en sure even tightening torque Torque Handlebar Clamp Bolts 25 N m 2 5 kgf m 18 ft Ib e Install Handlebar Pad A Fuel Tank Breather Hose B Number Plate see Number Plate Installation in the Frame chapter Handlebar Position Adjustment The handlebar position can be adjusted in four positions back and forth Front Holes A Rear Holes B Handlebar holders C To suit
46. shaft should be either replaced or disassembled and crankpin needle bearing and connecting rod big end should be examined for wear Connecting Rod Big End Side Clearance Inspection e Refer to the Crankshaft Inspection in the Periodic Main tenance chapter Crankshaft Runout Inspection e Set the crankshaft in a flywheel alignment jig or on V blocks and place a dial gauge as shown and turn the crankshaft slowly The maximum difference in gauge reading is the crankshaft runout 8 5 mm 0 33 in A Crankshaft Runout Standard TIR 0 03 mm 0 001 in or less Service Limit TIR 0 08 mm 0 003 in x If the runout at either point exceeds the service limit re place the crankshaft assembly with a new one or align the crankshaft so that the runout falls within the service limit e First correct the horizontal misalignment by striking the projecting crank half A with a plastic soft lead or brass hammer as shown e Recheck the runout with a dial gauge and repeat the process until the runout falls within the service limit 6105018BS1 G105135BS1 G105136BS1 CRANKSHAFT TRANSMISSION 9 19 Crankshaft e Next correct the vertical misalignment by either driving a wedge A in between the crank halves or by squeezing them in a vise depending on the nature of the misalign ment NOTICE Do not hammer the crank half at the point B x If flywheel misalignment cannot be correct
47. washer and new cotter pin e Bend the ends A of the cotter pin as shown in the figure e Check the brake pedal position see Brake Lever and Pedal Adjustment in the Periodic Maintenance chapter e Bleed the brake line see Brake Line Bleeding e Check the brake for good braking power no brake drag and no fluid leakage A WARNING After servicing it takes several applications of the brake pedal before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the motorcycle until a firm brake pedal is obtained by pumping the pedal until the pads are against the disc GL10000BS1 GLO4023BS1 12 22 BRAKES Master Cylinder Front Master Cylinder Disassembly e Refer to the Brake Master Cylinder Cup and Dust Cover Replacement in the Periodic Maintenance chapter Rear Master Cylinder Disassembly e Refer to the Brake Master Cylinder Cup and Dust Cover Replacement in the Periodic Maintenance chapter Master Cylinder Assembly e Refer to the Brake Master Cylinder Cup and Dust Cover Replacement in the Periodic Maintenance chapter Master Cylinder Inspection Visual Inspection e Disassemble the front and rear master cylinders e Check that there are no scratches rust or pitting on the inner wall of each master cylinder A and on the outside of each piston B If a master cylinde
48. 0 0 71 62 in lb L Oil Pressure Relief Valve 15 1 5 11 L Oil Filter Cap Bolts 9 8 1 0 87 in lb Piston Oil Nozzle 3 0 0 31 27 in lb Engine Oil Drain Bolt M10 20 2 0 15 Engine Oil Drain Bolt M6 7 0 0 71 62 in lb Oil Pump Feed Cover Bolts 9 8 1 0 87 in lb Oil Pump Scavenge Cover Bolts 9 8 1 0 87 in lb Oil Screen Feed Mounting Bolts 9 8 1 0 87 in lb Engine Removal Installation Upper Engine Mounting Bolts 49 5 0 36 S Upper Engine Bracket Bolts 29 3 0 21 S Middle Engine Mounting Nut 49 5 0 36 R S Middle Engine Bracket Nuts 29 3 0 21 R S Lower Engine Mounting Nut 49 5 0 36 R S Swingarm Pivot Shaft Nut 98 10 72 R S Crankshaft Transmission Crankcase Bolts M6 12 1 2 106 ml S Crankcase Bolts M7 15 1 5 11 S Balancer Weight Mounting Nut 52 5 3 38 Crankcase Bearing Retainer Screws 15 1 5 11 L Piston Oil Nozzle 3 0 0 31 27 in lb Piston Oil Nozzle Bolt 7 0 0 71 62 in lb L Primary Gear Nut 98 10 72 Lh PERIODIC MAINTENANCE 2 7 Torque and Locking Agent Fastener a et Rema Kick Pedal Bolt 25 2 5 18 L Ratchet Guide Bolt 8 8 0 90 78 in lb Ratchet Plate Bolt 9 8 1 0 87 in lb S Ratchet Plate Screw 15 1 5 11 L S Shift Drum Cam Bolt 24 2 4 18 L Gear Positioning Lever Nut 8 8 0 90 78 in lb Shift Pedal Bolt 9 8 1 0 87 in lb Wheels Tires Spoke Nipples Not less than Not less than Not less than 2 2 0 22 19 in lb Front Axle Nut 78 8 0 58 S Front Axle Clamp Bolts 20 2 0 15 AL S Rear Axle Nut 108 11 0 79 7 Final Drive
49. 0 02 in Specifications PERIODIC MAINTENANCE 2 11 Item Standard Service Limit Wheels Tires Rim Runout with tire installed Axial Radial Tires Air Pressure Front Rear Standard Tire TIR 1 0 mm 0 04 in or less TIR 1 0 mm 0 04 in or less 100 kPa 1 00 kgf cm 14 psi TIR 2 0 mm 0 08 in TIR 2 0 mm 0 08 in Front Size 80 100 21 51M Make BRIDGESTONE EE Type M403 Tube SE Rear Size 120 80 19 63M Make BRIDGESTONE EE Type M404 Tube SE Final Drive Drive Chain Slack Drive Chain 20 link Length 52 58 mm 2 0 2 3 in 317 5 318 2 mm 12 50 12 53 in 323 mm 12 7 in Rear Sprocket Warp Runout TIR 0 4 mm 0 016 in or less TIR 0 5 mm 0 020 in Brakes Brake Lever Free Play Adjustable to suit rider SS Brake Fluid Type Front DOT3 or DOT4 Rear DOT3 or DOT4 e Brake Pad Lining Thickness Front 4 0 mm 0 16 in 1 mm 0 04 in Rear 6 4 mm 0 25 in 1 mm 0 04 in Suspension Front Fork KX450FC Suspension Oil Kawasaki KHL 15 10 or equivalent SE Amount Cylinder Unit 198 mL 6 69 US oz AS Outer Tube 335 mL 11 3 US oz Adjustable Range EUR BR 345 mL 11 7 US oz 320 380 mL 10 8 12 8 US oz KX450FD Air Pressure Suspension Oil Type 240 kPa 2 4 kgf cm 35 psi Kawasaki Fork Oil KHL 15 11 or equivalent Adjustable Range 220 280 kPa 2 2 2 8 kgf cm 32 41 psi 2 12 PERIODIC MAINTENAN
50. 10 Position the engine stop switch lead connector between the main harness and water hose 11 Viewed A 12 Do not touch the regulator rectifier leads and water hose clamp 17 14 APPENDIX Cable Wire and Hose Routing GBOSOI4E G APPENDIX 17 15 Cable Wire and Hose Routing Frame Ground 2 Lead Tighten the ignition coil mounting bolt together with the frame ground 2 and ignition coil ground Ignition Coil Ground Lead Capacitor Do not touch the radiator Ignition Coil Vehicle down Sensor Do not touch the ground lead and spark plug lead Vehicle down Sensor Connector Do not touch the ignition coil ground lead and vehicle down sensor bracket Joo P ND A 17 16 APPENDIX Cable Wire and Hose Routing KX450FC As 2 LEE P NON 1 Hold the harness at the blue tape por 4 Intake Air Pressure Sensor Connector tions 5 Fuel Injector Connector 2 Intake Air Temperature Sensor Connector 6 Water Temperature Sensor Connector 3 Throttle Sensor Connector APPENDIX 17 17 Cable Wire and Hose Routing KX450FD GBOMOIGE 6 1 Intake Air Pressure Sensor Connector 4 Fuel Injector Connector 2 Main Harness 5 Throttle Sensor Connector 3 Intake Air Temperature Sensor Connector 6 Water Temperature Sensor Connector 17 18 APPENDIX Cable Wire and Hose Routing KX450FD GBO90nE G Cable Wire and Hose Routing OONOARWDN A Clamp
51. 1787 C Special Tools Top Plug Wrench 49 mm 57001 1653 Top Plug Wrench 21 mm 57001 1787 e Remove the base valve assembly A from the cylinder unit B NOTE OSlowly compress the piston rod until it stops so that the base valve assembly can be removed easily NOTICE Disassembling the base valve assembly can lead to trouble Do not disassemble the base valve assembly e Drain the fork oil A from the cylinder unit B by pumping the piston rod several times e Hold the front fork at the inverted position for more than 20 minutes to allow the fork oil to fully drain N 6M04251BS1 PERIODIC MAINTENANCE 2 61 Periodic Maintenance Procedures e Clean the threads A of cylinder unit and base valve as sembly e Replace the O rings A on the base valve assembly and cylinder unit with new ones e Apply specified fork oil to the O rings on the base valve assembly e With the piston rod in fully compressed position pour the specified amount of fork oil A into the cylinder unit C Suspension Oil KHL15 11 1L 44091 0020 KHL15 11 4L 44091 0021 Cylinder Unit Oil Amount 343 ml 11 6 US oz NOTE OPlug the two oil holes B on the cylinder unit with fingers until the base valve assembly is installed e Pump A the piston rod B slowly several times to expel air 2 62 PERIODIC MAINTENANCE Periodic Maintenance Procedures e With the piston rod held i
52. 2 113 pint US kgf cm x 14 22 psi L X 1 816 pint IMP cmHg x 1 333 kPa mL x 0 03381 oz US mL x 0 02816 oz IMP Units of Speed mL x 0 06102 cu in km h x 0 6214 mph Units of Force Units of Power N x 0 1020 kg kW x 1360 PS N x 0 2248 lb kw x 1341 HP kg x 9 807 N PS x 0 7355 kW kg x 2 205 Ib PS x 0 9863 HP Units of Temperature O gee AO a oF oF 32 68 104 248 284 40 20 320 20 40 40 C af wm 267 489 i 400 71 1 93 3 116 120 176 212 80 100 120 140 160 180 200 220 240 260 280 300 440 138 160 C PERIODIC MAINTENANCE 2 1 Periodic Maintenance Table of Contents Periodic Maintenance Chart see 2 3 Torque and Locking Ee alain dette deuce asta AE ea Une nette TASSE 2 5 Specifications EE 2 10 Special TOO ET 2 13 Periodic Maintenance Procedures 2 14 Fuel System DE less ann entiere ana ne Std lle 2 14 Fuel Hose and Connections Inspection 2 14 Throttle Grip Throttle Cable Free Play Inspection seseeeeeeeeeeeeeeeeeeeeressssserrreresssrereene 2 14 Throttle Grip Throttle Cable Free Play Adjustment 2 14 Throttle BOdY Cleaning marin di seal A eed eve 2 15 Fuel Hose Replacement seen 2 15 Idle Speed INSPSCON iietsss seed Sege eege deet sored riences et etes ests 2 17 Idle Speed AdU SENE ee Dern a nee nee Pen re 2 18 Air Cleaner Element
53. 2 32 Rim Runout Inspection 2 32 Kgl Le le GC EE 2 33 Anal DIVE voii dida 2 33 Drive Chain Wear Inspection ssssssssennsernrrnrrtnntnnntnnttnnntnnttnnEAnEEEnEEEnEAnAE Ennn EEEE Ennn Ennn EEEE 2 33 Drive Chain Slack Inspechon 2 34 Drive Chain Slack Adjustment ii ii ARO 2 35 Drive Chain Lubrication ss 2 36 Sprocket Wear Inspection sise 2 36 Rear Sprocket Warp Runout Inspection 2 36 2 2 PERIODIC MAINTENANCE Brake Lever and Pedal Adjustment asus Brake Fluid Level Inspection Brake Fluid Change Brake Pad Wear Inspection Brake Master Cylinder Cup and Dust Cover Replacement Brake Caliper Fluid Seal and Dust Seal Replacement Brake Hoses and Connections Inspection Brake Hose Henlacement ss Suspension Front Fork IISPECI N 000000 RS M Re Ne NA Front Fork Oil Change each fork leg Rear Shock Absorber Inspection ses Rear Shock Absorber Oil Change ses Swingarm and Uni Trak Linkage Inspection oooooooccccncnnccccncccoooncccncncnanananoncncncnnnnnnnnnnnnnnno Swingarm and Uni Trak Linkage Pivot Lubrication nono Steering a e Steering Inspection Steering Adjustment Steering Stem Bearing WEE EE Frame nsss Frame Inspection Electrical System
54. 20 clicks turned fully clockwise Compression Damping Adjustment 11 clicks counterclockwise Adjustable Range from the seated position adjuster 22 clicks turned fully clockwise Suspension Oil Kawasaki KHL15 11 or equivalent SE Amount Cylinder Unit 343 mL 11 6 US oz Outer Tube 235 mL 7 95 US oz Adjustable Range 190 265 mL 6 42 8 96 US oz Rear Suspension Uni Trak Rear Shock Absorber Rebound Damping Adjustment 16 clicks counterclockwise Adjustable Range from the seated position adjuster KX450FC 33 clicks turned fully clockwise 19 clicks counterclockwise KX450FD EUR BR TH 20 clicks counterclockwise KX450FD Spring Preload Adjustment 128 5 mm 5 059 in KX450FC Adjustable Range Lower surface of the adjusting EUR BR 127 5 mm 5 020 in 126 5 138 5 mm nut from the center of the upper KX450FC 4 980 5 453 in mounting hole 127 5 mm 5 020 in KX450FD FE Specifications SUSPENSION 13 9 Item Standard Service Limit Rear Shock Spring Free Length Suspension Oil Amount Gas Reservoir High Speed Compression Damping Adjustment from the seated position adjuster turned fully clockwise Low Speed Compression Damping Adjustment from the seated position adjuster turned fully clockwise Gas Pressure Tie Rod Rocker Arm Sleeve Outside Diameter Tie rod Rocker Arm Large Small Rocker Arm Mounting Bolt Runout 255 mm 10 0 in Kawasa
55. 6 10 Right Engine Gover Assembly esse SL iii ati ita 6 11 O ne a A es An ee 6 12 Clutch Removal ER M codes lamo dida EE 6 12 Glutch Installat EE 6 13 Clutch Plate Assembly Free Play Inspection Adjustment AAA 6 16 Release Shaft Removal ccccceccceccceeeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeeeeeeeeeseeeeeeeeeeeseeeneeess 6 16 Release Shaft Installatton mecena A a a a eaa aara Ea a EA 6 16 Clutch Plates Wear Damage Inspection ooccccccnnccnnncnnnnonnnnnnnonnnnnnnnnnnnnnnnnnnnnnnnnnnnninnnss 6 17 Clutch Plates Warp Inspection ss 6 17 Clutch Spring Free Length Inspection 6 17 Clutch Housing Finger Damage Inspection ooooocoocccccnnccnccccoooncccncncconannnanncnnnnnnnnnnnnnnnn cnn 6 17 Friction Plate Clutch Housing Clearance Inspection 6 17 Clutch Hub Spline Damage Inspection ssesssessseseseeerererrrrrerrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrerrrent 6 17 6 2 CLUTCH Exploded View 6F02195BW5 C CLUTCH 6 3 Exploded View Fastener Torque Remarks N m kgf m 10 R 2 Clutch Spring Bolts 0 90 78 in lb 3 Right Engine Cover Bolts 1 0 87 mb 4 Oil Filter Cap Bolt 9 8 1 0 87 mb 5 Clutch Cover Bolts 9 8 1 0 87 in lb 6 Oil Filler Plug 3 5 0 36 31 in lb CL Apply cable lubricant EO Apply engine oil G Apply grease M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in
56. Axial TIR 1 0 mm 0 04 in or less Radial TIR 1 0 mm 0 04 in or less Service Limit Axial TIR 2 0 mm 0 08 in Radial TIR 2 0 mm 0 08 in x If rim runout exceeds the service limit check the wheel bearings first x If the problem is not due to the bearings loosen some spokes and tighten others within the standard torque Wheel Bearing Inspection e Raise the front rear wheel off the ground using the jack Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Rotate A the wheel lightly and check for roughness binding or noise x If any damage is found replace the hub bearing e Turn the handlebar until the handlebar does not move to either side front wheel e The wheel edge is moved A to one direction gripping the edge of the wheel by both hands and the play of the wheel bearing is checked x lf the play is found replace the bearing Final Drive Drive Chain Wear Inspection e Rotate the rear wheel to inspect the drive chain for dam aged rollers and loose pins and links x If there is any irregularity replace the drive chain x Lubricate the drive chain if it appears dry Bushing A Roller B Pin C Pin Link D Roller Link E 604061081 y 4 Gem EE GKO4011BS1 2 34 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Stretch the chain taut by hanging a 98 N 10 kg 20 Ib weight A on the chain e Measure the length of 20 links
57. Between upper and lower level lines after warm up or driving 20 70 kPa 0 20 0 71 kgf cm 2 9 10 psi at 4 000 r min rpm Oil Temperature 40 C 104 F Special Tools Oil Pressure Gauge 5 kgf cm 57001 125 Outside Circlip Pliers 57001 144 ST5701258T ST5701448T ENGINE LUBRICATION SYSTEM 7 7 Oil Pressure Gauge Adapter M10 x 1 25 57001 1182 8757118297 Oil Pressure Cap 57001 1656 ST5716568T 7 8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter A WARNING Vehicle operation with insufficient deteriorated or contaminated engine oil will cause accelerated wear and may result in engine seizure accident and injury Check the oil level before each use and change the oil and filter according to the periodic maintenance chart The engine oil level indicated in the oil inspection window gauge is very sensitive to the motorcycle s position and en gine rpm at time of shut down Because of the semi dry sump lubrication system with separate oil chambers in the crank room and transmission room under certain condi tions oil can accumulate in the crank room and give a false low reading at the oil level inspection window which indi cates oil volume in the transmission room Engine Oil Level Inspection e Situate the motorcycle so that it is vertical e Check that the engine oil level is between the upper A and lower B levels in the oil
58. Cleaning and Inspection sseseseeeeeeeeeeeiierrresesrirnrnnssssrenrrrressseene 2 18 Fuel TAN Cleaning he nar n TR Te calco 2 20 Cooling Syste Mii ci 2 20 Coolant Level Inspection tica tres a ira te a R EA 2 21 Coolant Deterioration Inspection 2 21 Water Hoses and Connections Inspection 2 22 Engine Top Elia e 2 22 Valve Clearance Inspection Ennen EEEn 2 22 Valve Clearance Ag USUIMONE accio diario idad db dr nt Ee 2 23 Cylinder Head Warp Inspection sise 2 25 Cylinder Wear ee 2 25 Piston Cylinder Clearance Inspection 2 26 Piston Piston Ring and Piston Pin Replacement seennennnennnennrennnnnnnnnnnennnnnnnnnn rennene 2 26 Exhaust System inspeccion ehacdetantadateas 2 26 Silencer Wool Replacement see 2 26 Ee E 2 27 Clutch Operation Inspection ss 2 27 Clutch Plates Inspection Sie 2 28 Engine L brication Syste DEE 2 28 Engine Ol Chane E AEA A T EA AAT 2 29 Oil Filter Change iseten A a tenet esteemed 2 30 Breather Hose Inspection ooocccncccnncnnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnnnnnninnnss 2 31 Crankshaft TransmiSSin a a a aa E a e a ea 2 31 Crankshaft Inspechon 2 31 WORST ia a ee oi adres AAA 2 31 Air Pressure Inspection Adjustment he 2 31 Tires Inspection aan 2 32 Spoke TightnessINSPEctiON vosotras ardor rar ghahaolvenebgnevesweaucersucatousendaadata
59. ECU terminal 24 BK lead E x lf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation Throttle Sensor Resistance Inspection e Disconnect the throttle sensor connector e Connecta digital meter A to the throttle sensor connector B e Measure the throttle sensor resistance Throttle Sensor Resistance Connections BL lead C BK lead D Standard 4 6kQ x lf the reading is out of the standard replace the throttle sensor see Throttle Sensor Replacement x If the reading is within the standard but the problem still exists replace the ECU see ECU Removal Installation GC17708DS1 GC17997ES1 3 36 FUEL SYSTEM DFI Throttle Sensor Service Code 11 Throttle Sensor Circuit o TEO 2 I 1 ECU 2 Throttle Sensor GG17970E 1 C Intake Air Pressure Sensor Service Code 12 FUEL SYSTEM DFI 3 37 Intake Air Pressure Sensor Removal NOTICE Never drop the intake air pressure sensor espe cially on a hard surface Such a shock to the sensor can damage it e Remove Fuel Tank see Fuel Tank Removal Fuel Hose see Fuel Hose Replacement in the Periodic Maintenance chapter Intake Air Pressure Sensor Connector A e Slide the rubber damper B to outside C and remove it with the i
60. Nut E and Washer F Gear Position Lever Collar Spring 9 28 CRANKSHAFT TRANSMISSION External Shift Mechanism External Shift Mechanism Installation e Install the spring A collar and gear positioning lever B OFit each end of the spring to the original positions e Install the washer C e Tighten Torque Gear Positioning Lever Nut D 8 8 N m 0 90 kgf m 78 in Ib e Push down the gear positioning lever A with the screw driver B and install the pin C and shift drum cam D OFit the groove E on the pin e Apply a non permanent locking agent to the threads of the shift drum cam bolt e Tighten Torque Shift Drum Cam Bolt 24 N m 2 4 kgf m 18 ft lb e Align the roller of the gear positioning lever with the slot of the shift drum cam e Set up the shift ratchet assembly as shown in the figure Ratchet A Pawls B Pins C Springs D e Install the shift ratchet assembly A to the ratchet plate B as shown in the figure e While compressing the pawls install the shift ratchet as sembly to the ratchet plate e Apply a non permanent locking agent to the threads of the ratchet plate screw C e Tighten the ratchet plate screw first and then the ratchet plate bolt D Torque Ratchet Plate Screw 15 N m 1 5 kgf m 11 ft lb Ratchet Plate Bolt 9 8 N m 1 0 kgf m 87 in Ib e Install the collar E G116055BS1 CRANKSHAFT TRANSMISSION 9 29 External Shift Me
61. OLoosen the adjuster locknut B and turn the adjuster C to either side e After adjustment tighten the locknut A WARNING An improperly adjusted brake could drag and cause the brake to overheat damaging the brake assem bly and possbily locking the rear wheel resulting in loss of control Always maintain the proper brake adjustment NOTE OUsually it is not necessary to adjust the pedal position but always adjust it when the master cylinder is disas sembled or pedal position is incorrect e Measure the length A indicated in the figure Rear Master Cylinder Push Rod Length Standard 68 5 1 mm 2 70 0 04 in x If it is not within the standard adjust the push rod in the master cylinder as follows OLoosen the push rod locknut A OTurn the adjusting bolt B to obtain the specified length OTighten the locknut Torque Rear Master Cylinder Push Rod Locknut 17 N m 1 7 kgf m 13 ft Ib 2 38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Fluid Level Inspection e Check the brake fluid level in the front or rear brake reser voir A and the front or rear reservoir must be kept above the lower level line B NOTE OHold the reservoir horizontal when checking brake fluid level If the fluid level in front or rear reservoir is lower than the lower level line fill the reservoir to the upper level line e Inside the reservoir is stopped end showing the upper level line C
62. Remove Front Wheel see Front Wheel Removal in the Wheels Tires chapter Front Fender see Front Fender Removal in the Frame chapter Front Forks see Front Fork Removal in the Suspension chapter Steering Stem Head A e Hold the stem base A by hand and remove the steering stem nut B with the steering stem nut wrench C Special Tool Steering Stem Nut Wrench 57001 1100 e Remove the steering stem D and stem base from the head pipe 14 6 STEERING Steering e Remove the upper stem bearing inner race tapered roller bearing A e Drive out the bearing outer races from the head pipe ORemove the outer races pressed into the head pipe using the head pipe outer race remover A and hammer the head pipe outer race remover to drive it out Special Tool Head Pipe Outer Race Remover ID gt 37 mm 57001 1107 NOTE Olf either steering stem bearing is damaged it is recom mended that both the upper and lower bearing includ ing outer races should be replaced with new ones e Remove the lower bearing inner race with tapered roller bearing A with its grease seal from the stem using bear ing pullers Special Tools Bearing Puller 57001 135 Bearing Puller 57001 1575 OAssemble the bearing puller Special Tool 57001 1575 Olnsert the each half split base B under the bottom of bearing inner race and connect the both bases by tight ening the bolts C and nuts D NOTE OTighten even
63. Special Tool Outside Circlip Pliers 57001 144 Kickshaft Removal e Remove Right Engine Cover see Right Engine Cover Removal in the Clutch chapter Clutch see Clutch Removal in the Clutch chapter e Pull the end A of the kick spring B out of the hole in the crankcase e Turn the kickshaft counterclockwise C and pull out the kickstarter assembly D e Remove the bolt A and take off the ratchet guide B 9 32 CRANKSHAFT TRANSMISSION Kickstarter Kickshaft Installation e Install the ratchet guide A pushing itto counterclockwise e Tighten Torque Ratchet Guide Bolt B 8 8 N m 0 90 kgf m 78 in Ib e Apply molybdenum disulfide grease to the end C of the kick shaft e Insert the kick shaft assembly D into the crankcase OSecurely engage the stopper portion E of the ratchet gear with the guide e Insert the spring end F into the hole G e Install the removed parts see appropriate chapter Kick Shaft Assembly Disassembly Assembly e The kick shaft assembly consists of the following parts Circlips A Washer 924 x 18 3 B Spring C Ratchet Gear D Washer 22 x 18 3 E Kick Gear F Kick Shaft G Kick Spring H Spring Guide I Washer 28 x 20 3 J e Check the kick shaft assembly parts for damage Any damaged parts should be replaced with new ones e Apply molybdenum disulfide grease A to the kick gear ratchet gear and kick shaft e Replace the circlips that were remo
64. Valve Guide Clearance Wobble Method Standard Exhaust 0 08 0 15 mm 0 0032 0 0059 in Intake 0 05 0 12 mm 0 0020 0 0047 in Service Limit Exhaust 0 32 mm 0 013 in Intake 0 30 mm 0 012 in Valve Seat Inspection e Remove the valve see Valve Removal e Check the valve seating surface A between the valve B and valve seat C e Measure the outside diameter D of the seating pattern on the valve seat x If the outside diameter is too large or too small repair the seat see Valve Seat Repair Valve Seating Surface Outside Diameter Standard Exhaust 30 4 30 6 mm 1 197 1 205 in Intake 35 4 35 6 mm 1 394 1 402 in OMeasure the seat width E of the portion where there is no build up carbon white portion of the valve seat with a vernier caliper Good F x If the width is too wide G too narrow H or uneven J repair the seat see Valve Seat Repair Valve Seating Surface Width Standard Exhaust 0 8 1 2 mm 0 03 0 05 in Intake 0 5 1 0 mm 0 02 0 04 in 6E15054BS1 GE15011782 C 5 30 ENGINE TOP END Valves Valve Seat Repair e For the instructions on how to use the valve seat cutter A follow the operation manual provided by the tool man ufacturer Special Tools Valve Seat Cutter Holder 5 5 B 57001 1125 Valve Seat Cutter Holder Bar 57001 1128 Exhaust Valve Seat Cutter 45 635 57001 1116 Valve Seat Cutter 32 6
65. Vehicle down Sensor Service Code 31 FUEL SYSTEM DFI 3 53 e Measure the input voltage with the engine stopped and with the connector joined Input Voltage Standard DC 4 75 5 25 V x If the reading is within the standard check the output volt age see Vehicle down Sensor Output Voltage Inspec tion x If the reading is out of the standard remove the ECU and check the wiring for continuity between the main harness connectors ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Vehicle down Sensor Connector B R Y lead C ECU terminal 13 GY lead D ECU terminal 24 lf the wring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation Vehicle down Sensor Output Voltage Inspection e Remove the vehicle down sensor and connect the mea suring adapter A Special Tool Measuring Adapter 57001 1700 Main Harness B Vehicle down Sensor C e Connect a digital meter D to the harness adapter leads Vehicle down Sensor Output Voltage Connections to Adapter Digital Meter W sensor BR lead Digital Meter BK sensor GY lead GC17723D81 GC17710ES1 3 54 FUEL SYSTEM DFI Vehicle down Sensor Service Code 31 e Hold the vehicle down sensor vertically e Refer to the Sel
66. a 100 mm 3 94 in length of the arbor to de termine the amount of connecting rod twist If connecting rod twist exceeds the service limit the con necting rod must be replaced Connecting Rod Twist Service Limit TIR 0 2 100 mm 0 008 3 94 in 6105040781 CRANKSHAFT TRANSMISSION 9 21 Transmission Transmission Shaft Removal e Split the crankcase see Crankcase Disassembly e Pull out the shift rods A allowing the shift fork guide pins to free from the shift drum B e Remove Shift Drum Shift Forks C e Pull out the drive shaft D and output shaft E together with their gears meshed Transmission Shaft Installation e Apply engine oil to the sliding portion of the transmission shaft gears and ball bearings e Install the drive shaft A and output shaft B in the right crankcase half with their gears meshed e Apply a small amount of engine oil to the shift fork fingers and fit each shift fork into the groove of the proper gear Olnstall each shift forks with its marks A facing the engine left side Marks 043 Drive shaft 044 Output shaft e Install the shift drum A e Fit each shift fork guide pin into the corresponding groove in the shift drum e Apply a small amount of engine oil to the shift rods B and slide them into the shift forks e Assembly the crankcase see Crankcase Assembly Transmission Shaft Disassembly e Remove the transmission shafts see Tra
67. a tire is replaced with a new one Standard Tire Front Size 80 100 21 51M Make BRIDGESTONE Type M403 Tube Rear Size 120 80 19 63M Make BRIDGESTONE Type M404 Tube Spoke Tightness Inspection e Check that all the spokes are tightened evenly x If spoke tightness is uneven or loose tighten the spoke nipples evenly Torque Spoke Nipples 2 2 N m 0 22 kgf m 19 in Ib e Check the rim runout see Rim Runout Inspection A WARNING A missing spoke places an additional load on the other spokes which will eventually cause other spokes to break creating the potential for an accident resulting in serious injury or death Immediately replace any broken spoke s Rim Runout Inspection e Place the jack under the frame so that the front rear wheel off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Inspect the rim for cracks dents bending or warping x If there is any damage to the rim it must be replaced i ae 93 Ne 6J05002BS1 GS11047BS1 PERIODIC MAINTENANCE 2 33 Periodic Maintenance Procedures e Set a dial gauge against the side of the rim and rotate the rim to measure the axial runout A OThe difference between the highest and lowest dial read ings is the amount of runout e Set a dial gauge against the outer circumference of the rim and rotate the rim to measure radial runout B Rim Runout with tire installed Standard
68. a weight ratio 10 1 R Replacement Parts 6 4 CLUTCH Specifications Item Standard Service Limit Clutch Lever Clutch Lever Free Play 8 13 mm 0 3 0 5 in Clutch Friction Plate Thickness Friction Plate Warp Steel Plate Warp Clutch Spring Free Length Friction Plate Clutch Housing Clearance 2 92 3 08 mm 0 115 0 121 in 0 15 mm 0 0059 in or less 0 20 mm 0 0079 in or less 46 04 mm 1 813 in 0 20 0 60 mm 0 008 0 024 in 2 7 mm 0 11 in 0 3 mm 0 012 in 0 3 mm 0 012 in 43 9 mm 1 73 in 0 8 mm 0 04 in CLUTCH 6 5 Special Tools Inside Circlip Pliers Clutch Holder 57001 143 57001 1243 C ST5701438T T5712438T Bearing Driver Set 57001 1129 ST5711298T 6 6 CLUTCH Clutch Lever and Cable Due to friction plate wear and clutch cable stretch over a long period of use the clutch must be adjusted in accor dance with the Periodic Maintenance Chart A WARNING The engine and exhaust system get extremely hot during normal operation and can cause serious burns Never touch the engine or exhaust pipe during clutch adjustment Clutch Lever Clutch Cable Free Play Inspection e Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter Clutch Lever Clutch Cable Free Play Adjustment e Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter Clutch Lever Installation
69. as shown in the figure Circle Mark A Front B e Install the piston pin e Fit a new piston pin snap ring into the side of the piston so that the ring opening A does nat coincide with the slit B of the piston pin hole OWhen installing the piston pin snap ring compress it only enough to install it and no more NOTICE Do not reuse snap rings as removal weakens and deforms them They could fall out and score the cylinder wall e Install Dowel Pins A New Cylinder Base Gasket B 6E16042BS1 GE16277BS1 5 36 ENGINE TOP END Cylinder and Piston e The piston ring openings must be positioned as shown in the figure The openings of the oil ring steel rails must be about 20 A of angle from the opening of the oil ring expander Circle Mark B Top Ring C Upper Oil Ring Steel Rail D Oil Ring Expander E Lower Oil Ring Steel Rail F e Apply engine oil to the cylinder bore and the piston side wall e Install the cylinder while compressing the piston rings with your fingers or the special tool A OUpturn the chamfering side of the belt Special Tools Piston Ring Compressor Grip 57001 1095 Piston Ring Compressor Belt 95 4108 57001 1358 e Install Cylinder Bolt Front Camshaft Chain Guide e Install the removed parts see appropriate chapters Cylinder Wear Inspection e Refer to the Cylinder Wear Inspection in the Periodic Maintenance chapter Pi
70. bolt at a point halfway between the blocks e Turn A the bolt to measure the runout OThe amount of dial variation is the amount of runout Rocker Arm Mounting Bolt Runout Standard TIR 0 1 mm 0 004 in or less Service Limit TIR 0 2 mm 0 008 in x If runout exceeds the service limit replace the bolt GMO7036BS1 o GM07038BS1 STEERING 14 1 Steering Table of Contents Elei e WEE 14 2 Special te 14 4 A Le DEE 14 5 Steering Hl e en EEN 14 5 ESTRADA d EE 14 5 Steering Stem Stem Bearing Removal 14 5 Steering Stem Stem Bearing Installation 14 6 Stem Bearing Lubina di 14 8 Stem Bearing Wear Damage Inspection ss 14 8 Stem Warp Inspection sise 14 8 elei Le 14 9 Handlebar Removal see 14 9 Handlebar Installation iis osc niceties etes a telus couse 14 10 Handlebar Position Gebuert ici itinere da did knee ia 14 11 14 2 STEERING Exploded View STONES H TIVHALNZ 6N02214BW5 C STEERING 14 3 Exploded View No Fastener Nm kgm Remarks 2 Steering Stem Head Nut 98 10 72 3 Front Fork Clamp Bolts Upper 20 2 0 15 AL 4 Steering Stem Nut 4 9 0 50 43 in lb T 5 Handle Holder Nuts 34 3 5 25 R 6 Brake Hose Clamp Bolt 2 0 0 20 18 in lb 7 Front Fork Clamp Bolts Lower 20 2 0 15 AL 8 KX450FC AD Apply adhesive AL Tighten the two clamp bolts alternately two ti
71. chapter GM04775BS1 GM04776BS1 13 14 SUSPENSION Front Fork Front Fork Removal e Remove Number Plate see Number Plate Removal in the Frame chapter Bolts A Brake Hose Clamps B e Remove Front Caliper Mounting Bolts A e Remove the caliper B from the fork leg to be removed and rest the caliper on some kind of stand so that it doesn t dangle e Remove Bolts C Fork Protector D Front Wheel see Front Wheel Removal in the Wheels Tires chapter e Loosen Front Fork Clamp Bolts Upper A Front Fork Clamp Bolts Lower B e Remove the front fork OWith a twisting motion A work the fork leg B down and out Front Fork SUSPENSION 13 15 Front Fork Installation e Install the fork so that the distance A between the top end of the outer tube and the upper surface of the steering stem head is specified dimension KX450FC Other than EUR BR 10 mm 0 39 in KX450FC EUR BR 5 mm 0 2 in KX450FD 5 mm 0 2 in e Tighten Torque Front Fork Clamp Bolts Upper 20 N m 2 0 kgf m 15 ft lb Front Fork Clamp Bolts Lower 20 N m 2 0 kgf m 15 ft lb NOTE OTighten the two clamp bolts alternately two times to en sure even tightening torque e Run the cables and hose according to the Cable Wire and Hose Routing section in the Appendix chapter e Install the removed parts see appropriate chapters Front Fork Disa
72. e Install the clutch lever assembly A position as shown in the figure 25 35 B Horizontal Line of Frame C 170 mm 6 69 in D Clutch Cable Removal e Remove Number Plate see Number Plate Removal in the Frame chapter Left Radiator Shroud see Radiator Shroud Removal in the Frame chapter Left Radiator Screen see Radiator Removal in the Cool ing System chapter e Slide the dust cover A e Loosen the locknut B and screw in the adjuster C fully e Slide the dust cover A and the knob B out of place GFO4028BS1 CLUTCH 6 7 Clutch Lever and Cable e Align the slit A of the adjusting nut to the slit B of the clutch lever e Free the clutch cable upper end from the clutch lever e Loosen the adjusting nuts A fully e Free the clutch cable lower end B from the clutch release lever C NOTICE Do not remove the clutch release shaft unless it is absolutely necessary If removed release shaft oil seal must be replaced with a new one KX450FC e Remove Radiator Mounting Bolt A Clamp B Washer e Open the clamp C e Pull the clutch cable out of the frame KX450FD e Open the clamps A e Pull the clutch cable out of the frame Clutch Cable Installation e When installing the adjusting nut apply grease to the lips A of adjusting nut 6 8 CLUTCH Clutch Lever and Cable e Install the clutch cable with the threads width as shown
73. e Tighten Torque Brake Lever Pivot Bolt 5 9 N m 0 60 kgf m 52 in Ib Brake Lever Pivot Bolt Locknut 5 9 N m 0 60 kgf m 52 in lb Brake Caliper Fluid Seal and Dust Seal Replacement Front Caliper Disassembly e Remove Front Caliper see Caliper Removal in the Brakes chap ter Brake Pads see Brake Pad Removal in the Brakes chapter e Separate the caliper holder A from the caliper B e Remove the anti rattle springs C e Using compressed air remove the pistons One way to remove the pistons is as follows OCover the caliper opening with a clean heavy cloth A ORemove the pistons by lightly applying compressed air B to the hose joint opening A WARNING The piston in the brake caliper can crush hands and fingers Never place your hand or fingers in front of the piston 2 44 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Pull out the pistons A by hand e Remove the dust seal B and fluid seal C on each cylin der NOTE Olf compressed air is not available with the brake hose connected to the caliper OPrepare a container for brake fluid and perform the work above it ORemove the spring and pads see Brake Pad Removal in the Brakes chapter OPump the brake lever until the pistons come out of the cylinders Rear Caliper Disassembly e Remove Rear Caliper see Caliper Removal in the Brakes chap ter Brake Pads see Brake Pad Removal in the Brakes chapter e
74. in the figure 5 2 mm 0 2 0 08 in A e Run the clutch cable correctly see Cable Wire and Hose Routing section in the Appendix chapter e Adjust the clutch cable see Clutch Lever Free Play Ad justment in the Periodic Maintenance chapter e Install the removed parts see appropriate chapters Clutch Cable Inspection and Lubrication e During a periodic inspection or when the cable has been removed inspect and lubricate the cable see General Lubrication and Cable Inspection section in the Periodic Maintenance chapter CLUTCH 6 9 Clutch Cover and Right Engine Cover Clutch Cover Removal e Drain the engine oil see Engine Oil Change in the Peri odic Maintenance chapter e Remove Rear Master Cylinder Mounting Bolts A Brake Pedal Bolt B Brake Pedal Return Spring C e Remove Clutch Cover Bolts A Clutch Cover B Clutch Cover Installation e Be sure to install the dowel pins A e Replace the clutch cover gasket B with a new one e Install the clutch cover e Tighten Torque Clutch Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib L 60 mm 2 4 in A L 25 mm 1 0 in B Right Engine Cover Removal e Drain Engine Oil see Engine Oil Change in the Periodic Main tenance chapter Coolant see Coolant Draining in the Cooling System chapter 6 10 CLUTCH Clutch Cover and Right Engine Cover e Remove Kick Pedal see Kick Pedal Removal in the Crank shaft Transmission chapter Rear
75. is a must for conducting accurate tests of the DFI system e Trouble may involve one or in some cases all items Never replace a defective part without determining what CAUSED the problem If the problem was caused by some other item or items they too must be repaired or replaced or the new replacement part will soon fail again e Measure coil winding resistance when the DFI part is cold at room temperature e Make sure all connectors in the circuit are clean and tight and examine leads for signs of burning fraying short etc Deteriorated leads and bad connections can cause reappearance of problems and unstable operation of the DFI system x If any wiring is deteriorated replace the wiring 6017572081 6017037351 3 18 FUEL SYSTEM DFI Troubleshooting the DFI System e Pull each connectors A apart and inspect it for corrosion dirt and damage x If the connector is corroded or dirty clean it carefully If it is damaged replace it Connect them securely e Check the wiring for continuity OUse the wiring diagram to find the ends of the lead which is suspected of being a problem OConnect a digital meter between the ends of the leads OSet the digital meter and read the digital meter x If the tester does not read 0 Q the lead is defective Re place the lead or the main harness Olf both ends of a harness A are far apart ground B the one end C using a jumper lead D and che
76. is normal replace the ECU e Replace the timing inspection cap O ring with a new one e Apply grease to the O ring e Tighten the timing inspection cap Special Tool Filler Cap Driver 57001 1454 Torque Timing Inspection Cap 3 5 N m 0 36 kgf m 31 in Ib Ignition System ELECTRICAL SYSTEM 16 23 Safety Instructions A WARNING The ignition system produces extremely high volt age Do not touch the spark plug ignition coil or ig nition coil lead while the engine is running or you could receive a severe electrical shock Ignition Coil Removal e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Capacitor see Capacitor Removal e Disconnect the primary lead connector A e Pull off the spark plug cap B e Remove Bolts A Capacitor Bracket B e Remove Ignition Coil Bolts A Ignition Coil B Ignition Coil Installation e Run the leads according to the Cable Wire and Hose Routing section in the Appendix chapter e Install Ignition Coil A Ignition Coil Ground Lead B Frame Ground 2 Lead C e Tighten Torque Ignition Coil Bolts D 9 8 N m 1 0 kgf m 87 in Ib e Connect the primary lead connector e Install the capacitor bracket and tighten the bolts EIS P 16 24 ELECTRICAL SYSTEM Ignition System e Install the spark plug cap A so that it is aligned with the line B on the cylinder head cover e Pull up the spark plug cap lightly to
77. is present clean the intake tract and throttle body assy thoroughly You may also need to replace the element and seal the housing and in take tract e Separate the element A from the frame B e Clean the element A in a bath of a high flash point sol vent using a soft bristle brush e Squeeze it dry in a clean towel A Do not wring the ele ment or blow it dry the element can be damaged e Check all parts of the element for visible damage x lf any parts of the element are damaged replace them e After cleaning saturate the element with a high quality foam air filter oil squeeze out the excess then wrap it in a clean towel and squeeze it as dry as possible OBe careful not to tear the sponge filter e Assemble the element e Remove the towel from the air cleaner duct 6S05025BS1 6S05026BS1 2 20 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Apply grease to all connections and screw holes in the air cleaner housing and intake tract e Install the element onto its frame and coat the element lip and lip seat with a thick layer of all purpose grease to assure a complete seal e Install the air cleaner element so that its tab A faces upward and its projections B align with the holes C of the air cleaner housing e Tighten the wing bolt Torque Air Cleaner Element Wing Bolt Hand tighten e Install the seat see Seat Installation in the Frame chap ter
78. is too large make the 32 B grind described below x If the outside diameter of the seating surface is within the specified range measure the seat width as described be low e Grind the seat at a 32 angle until the seat outside diam eter is within the specified range OTo make the 32 grind fit a 32 cutter into the holder and slide it into the valve guide A OTurn the holder one turn at a time while pressing down very lightly Check the seat after each turn GE15012281 5 32 ENGINE TOP END Valves NOTICE The 32 cutter removes material very quickly Check the seat outside diameter frequently to pre vent overgrinding OAfter making the 32 grind return to the seat outside di ameter measurement step above e To measure the seat width use a vernier caliper to mea sure the width of the 45 angle portion of the seat at sev eral places around the seat x If the seat width is too narrow repeat the 45 grind until the seat is slightly too wide and then return to the seat outside diameter measurement step above x If the seat width is too wide make the 55 A grind de scribed below x If the seat width is within the specified range lap the valve to the seat as described below e Grind the seat at a 55 angle until the seat width is within the specified range B OTo make the 55 grind fit a 55 cutter into the holder and slide it into the valve guide OTurn the
79. kPa 5 0 kgf cm 73 psi or the fork may be damaged e Remove the air valve adapter NOTE ODO not ride with the air valve adapter attached to the motorcycle OAlways cap the air valve adapter during storage e Install the front forks to the motorcycle see Front Fork Installation in the Suspension chapter OTemporarily tighten the front fork clamp bolts e After installing the front fork tighten the top plug A Special Tool Top Plug Wrench 49 mm B 57001 1653 PERIODIC MAINTENANCE 2 67 Periodic Maintenance Procedures The torque of fork top plug is specified to 45 N m 4 6 kgf m 33 ft lb however when you use the top plug wrench special tool A reduce the torque to 90 of the spec ified value 41 N m 4 2 kgf m 30 ft Ib due to the dis tance B between the center of the square hole where the torque wrench is fitted and that of the octagonal hole of the wrench This torque value 41 N m 4 2 kgf m 30 ft Ib is appli cable when you use a torque wrench whose length gives leverage of approximately 310 mm between the grip point SE to the center of the coupling square Torque Front Fork Top Plug 45 N m 4 6 kgf m 33 ft Ib Front Fork Clamp Bolts Upper 20 N m 2 0 kgf m 15 ft lb e Install the removed parts see appropriate chapters e Adjust the air pressure see Air Pressure Adjustment KX450FD in the Suspension chapter e Adjust the compression and rebound damping force ad ju
80. meter measure the resistance between the crankshaft sensor leads and chassis ground x Any digital meter reading less than infinity indicates a short necessities replacement of the crankshaft sensor assembly GP10581BS1 GP10582BS1 Ignition System ELECTRICAL SYSTEM 16 29 Engine Stop Switch System Check e Start the engine e Push the engine stop switch A stop the engine x If the engine does not stop check the engine stop switch for continuity see Engine Stop Switch Inspection x If the engine stop switch is good check the wiring see Wiring Inspection x If the wiring is good replace the ECU Launch Control Mode Button System Check e Start the engine e Shift the gear to the neutral 1st or 2nd position e Push the launch control mode button A for more than two seconds OThe orange launch control mode indicator light LED B will blink to indicate the system is operating e Apply the clutch lever and shift the gear to the 3rd position to deactivate the system OThe orange launch control mode indicator light LED should stop blinking lf the launch control mode system does not work as above check the following items Launch Control Mode Button see Launch Control Mode Button Inspection Orange Launch Control Mode Indicator Light LED see Orange FI Warning Indicator Light LED Inspection in the Fuel System DFI chapter Wiring see Wiring Inspection x lf th
81. mm 1 4544 1 4589 in 38 143 38 257 mm 1 5017 1 5062 in 37 743 37 857 mm 1 4859 1 4904 in 0 020 0 062 mm 0 0008 0 0024 in 22 959 22 980 mm 0 9039 0 9047 in 23 000 23 021 mm 0 9055 0 9063 in TIR 0 02 mm 0 0008 in or less 36 84 mm 1 450 in 38 04 mm 1 498 in 37 64 mm 1 482 in 0 15 mm 0 0059 in 22 93 mm 0 9028 in 23 08 mm 0 9087 in TIR 0 1 mm 0 004 in Cylinder Head Cylinder Compression Cylinder Head Warp Usable Range 420 698 kPa 4 3 7 1 kgf cm 61 101 psi at 5 times Valves Valve Clearance Exhaust Intake Valve Stem Bend Valve Stem Diameter Exhaust Intake Valve Guide Inside Diameter Exhaust Intake Valve Valve Guide Clearance Wobble Method Exhaust Intake Valve Seat Cutting Angle 0 17 0 22 mm 0 0067 0 0087 in 0 10 0 15 mm 0 0039 0 0059 in TIR 0 01 mm 0 0004 in or less 5 455 5 470 mm 0 2148 0 2154 in 5 465 5 480 mm 0 2152 0 2157 in 5 500 5 512 mm 0 2165 0 2170 in 5 500 5 512 mm 0 2165 0 2170 in 0 08 0 15 mm 0 0032 0 0059 in 0 05 0 12 mm 0 0020 0 0047 in 32 45 55 TIR 0 05 mm 0 002 in 5 44 mm 0 214 in 5 45 mm 0 215 in 5 58 mm 0 220 in 5 58 mm 0 220 in 0 32 mm 0 013 in 0 30 mm 0 012 in Specifications ENGINE TOP END 5 7 Item Standard Service L
82. oil passage when the gauge adapter is removed e Stop the engine and remove the oil pressure cap oil pres sure gauge adapter and gauge e Replace the O rings with new ones e Apply grease to the O rings and install the O rings to the oil filter cap e Install the oil filter cap e Tighten Torque Oil Filter Cap Bolts 9 8 N m 1 0 kgf m 87 in Ib ENGINE REMOVAL INSTALLATION 8 1 Engine Removal Installation Table of Contents E olle 1o Ee WEE 8 2 lee NEE 8 4 Engine Removalllnstala OM aiii ad iii 8 5 Engine Removal a lis 8 5 Engine Installations ld leidos iros arts 8 7 8 2 ENGINE REMOVAL INSTALLATION Exploded View ENGINE REMOVAL INSTALLATION 8 3 Exploded View Sl e Remarks N m kgf m ft Ib 2 Middle Engine Mounting Nut 49 5 0 36 HS 3 Upper Engine Mounting Bolts 49 5 0 36 S 4 Upper Engine Bracket Bolts 29 3 0 21 S 5 Lower Engine Mounting Nut 49 5 0 36 R S 6 Swingarm Pivot Shaft Nut 98 10 72 R S R Replacement Parts S Follow the specified tightening sequence 8 4 ENGINE REMOVAL INSTALLATION Special Tools Jack Jack Attachment 57001 1238 57001 1608 F J L ST5712388ST ST571608ST ENGINE REMOVAL INSTALLATION 8 5 Engine Removal Installation Engine Removal e Place the jack under the frame to support the motorcycle Special Tools Jack 57001 1238 Jack Attachment 57001 1608 A WARNING When the
83. one and install it e Be sure to install the dowel pins B e Using a high flash point solvent clean off any oil or dirt that may be on the silicone sealant coating area Dry them with a clean cloth e Apply silicone sealant to the area A to the magneto lead grommet Sealant Liquid Gasket TB1211F 92104 0004 e When installing the balancer shaft oil seal A note the following OReplace the balancer shaft oil seal with a new one OPress the balancer shaft oil seal so that the magneto cover end B is flushed as shown in the figure Special Tool Bearing Driver Set 57001 1129 OApply grease to the oil seal lips GP21010BS1 Flywheel Magneto ELECTRICAL SYSTEM 16 13 e When installing the breather fitting A note the following OApply a non permanent locking agent to the threads of the breather fitting OTighten Torque Breather Fitting 15 N m 1 5 kgf m 11 ft Ib e Install Magneto Cover A Holder B Clamps C Magneto Cover Bolts D e Tighten Torque Magneto Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib e Run the magneto lead breather hose and gear position switch lead according to the Cable Wire and Hose Rout ing section in the Appendix chapter e Connect the magneto lead connector e Install the removed parts see appropriate chapters Flywheel Removal e Remove the magneto cover see Magneto Cover Re moval e Hold the flywheel steady with the rotor holder A an
84. pin and measure the width B of each shift drum groove Shift Fork Guide Pin Diameter Standard 5 9 6 0 mm 0 232 0 236 in Service Limit 5 8 mm 0 228 in Shift Drum Groove Width Standard 6 05 6 20 mm 0 238 0 244 in Service Limit 6 3 mm 0 248 in x If the guide pin on any shift fork is less than the service limit the fork must be replaced kl any shift drum groove is worn exceeding the service limit the drum must be replaced Gear Damage Inspection e Visually inspect the gear dogs A and gear dog holes B Replace any damaged gears or gears with excessively worn dogs or dog holes e Visually inspect the gear teeth C on the transmission gears x Replace lightly damaged gear teeth with an oilstone The gear must be replaced if the teeth are badly damaged x When gear is repaired or replaced the driving gear should also be inspected and repaired or replaced if necessary G113235BS1 G113236BS1 G113372BS1 G113238BS1 CRANKSHAFT TRANSMISSION 9 25 Balancer Balancer Removal e Remove Magneto Cover see Magneto Cover Removal in the Electrical System chapter e Hold the flywheel A steady with the rotor holder B and loosen the balancer weight mounting nut C Special Tools Grip D 57001 1591 Rotor Holder 57001 1730 e Remove Right Engine Cover see Right Engine Cover Removal in the Clutch chapter e Remove Flywheel see Flywh
85. pressure is within the adjustable range If used outside the adjustable range run ning stability can decrease and cause an accident resulting in serious injury or death Be sure to remove the air valve adapter before rid ing If the air valve adapter is damaged by a stone during riding air leakage can cause loss of control and an accident resulting in serious injury or death NOTICE Do not pressurize the fork to more than 500 kPa 5 0 kgf cm 73 psi or the fork may be damaged e After air pressure adjustment remove the air valve adapter NOTE ODo not ride with the air valve adapter attached to the motorcycle OAlways cap the air valve adapter during storage e Tighten Torque Air Valve Plug 0 2 N m 0 020 kgf m 18 in Ib NOTICE Be sure to install the air valve plug to prevent dust from entering Compression Damping Adjustment e Place the jack under the frame so that the front wheel off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e To adjust compression damping turn the adjuster A on the front fork top plugs with a standard tip screwdriver until you feel a click Adjust the compression damping to suit you preference under special condition NOTE OThe left and right fork legs must have the same shock damping Front Fork SUSPENSION 13 13 Seated position A adjuster turned fully clockwise NOTICE Do not force the compression da
86. removing the brake hose take care nat to spill the brake fluid on the painted or plastic parts OWhen removing the brake hose temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum ai 65130310 P 6S13256BS1 2 48 PERIODIC MAINTENANCE Periodic Maintenance Procedures e When installing the hoses avoid sharp bending kink ing flattening or twisting and run the hoses according to Cable Wire and Hose Routing section in the Appendix chapter e Tighten Torque Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft Ib e Install the removed parts see appropriate chapters e Bleed the brake line after installing the brake hose see Brake Line Bleeding in the Brakes chapter Suspension Front Fork Inspection e Visually inspect the front fork for oil leakage scoring or scratches on the outer surface of the inner tubes A e Holding the brake lever pump the front fork down and up manually to check for smooth operation x If the fork shown damages or oil leak replace the dam aged parts x If the fork rattles inspect the oil level or tightening torque NOTICE If the inner tube is badly bent or creased replace it Excessive bending followed by subsequent straightening can weaken the inner tube Front Fork Oil Change each fork leg KX450FC e Remove Number Plate see Number Plate Removal in the Frame chapter e Loosen the front fork clamp
87. seal lips e Install the caps and collars to the hub on both sides OFit the projection A and groove B e Install the front wheel e Insert the axle A from right side e Screw the front axle clamp bolts right B temporarily e Tighten Torque Front Axle Nut C 78 N m 8 0 kgf m 58 ft lb Front Axle Clamp Bolts Left D 20 N m 2 0 kgf m 15 ft lb NOTE OTighten the two clamp bolts alternately two times to en sure even tightening torque e Loosen the front axle clamp bolts right e Remove the jack GJ04220BS1 WHEELS TIRES 10 7 Wheels Rims e Pump the front fork up and down A 4 or 5 times to align both fork positions NOTE OPut a block B in front of the wheel to stop moving ODo not apply the front brake e Tighten Torque Front Axle Clamp Bolts Right 20 N m 2 0 kgf m 15 ft lb NOTE OTighten the two clamp bolts alternately two times to en sure even tightening torque e Check the front brake for good braking power and no brake drag WARNING After servicing it takes several applications of the brake lever before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the motorcycle until a firm brake lever is obtained by pumping the lever until the pads are against the disc Rear Wheel Removal e Using the jack under the frame so
88. swingarm pivot shaft is removed the swingarm and rear wheel assembly will become detached and allow the frame to fall to the floor creating the potential for injury Removing the engine requires the swingarm pivot to be removed so support the bottom of the frame with a jack or other appropriate stand e Squeeze the brake lever slowly and hold it with a band A A WARNING Motorcycle may fall over unexpectedly resulting in an accident or injury Be sure to hold the front brake when removing the engine NOTICE Be sure to hold the front brake when removing the engine or the motorcycle may fall over The engine or the motorcycle could be damaged e Drain Engine Oil see Engine Oil Change in the Periodic Main tenance chapter Coolant see Coolant Draining in the Cooling System chapter e Remove Rear Frame see Rear Frame Removal in the Frame chapter Exhaust Pipe see Exhaust Pipe Removal in the Engine Top End chapter Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Throttle Body Assy see Throttle Body Assy Removal in the Fuel System DFI chapter Ignition Coil see Ignition Coil Removal in the Electrical System chapter Shift Pedal see External Shift Mechanism Removal in the Crankshaft Transmission chapter Engine Sprocket see Engine Sprocket Removal in the Final Drive chapter Right Engine Guard see Right Engine Cover Removal in the Clutch chapter Clutch Cable Lower En
89. system operation OMeasure coil and winding resistance when the part is cold at room temperature Electrical Wiring ELECTRICAL SYSTEM 16 11 Wiring Inspection e Visually inspect the wiring for signs of burning fraying etc x If any wiring is poor replace the damaged wiring e Pull each connector A apart and inspect it for corrosion dirt and damage x If the connector is corroded or dirty clean it carefully If it is damaged replace it e Check the wiring for continuity OUse the wiring diagram to find the ends of the lead which is suspected of being a problem OConnect a digital meter between the ends of the leads OSet the digital meter and read the digital meter x If the digital meter does not read 0 Q the lead is defective Replace the lead or the wiring harness if necessary GC17964ES1 16 12 ELECTRICAL SYSTEM Flywheel Magneto Magneto Cover Removal e Drain the engine oil see Engine Oil Change in the Peri odic Maintenance chapter e Remove Left Radiator Shroud see Radiator Shroud Removal in the Frame chapter Shift Pedal see Shift Pedal Removal in the Crank shaft Transmission chapter e Disconnectthe magneto lead connector A from the main harness e Remove the band A e Open the clamps B then free the breather hose C and gear position switch lead D e Remove Magneto Cover Bolts E Magneto Cover F Magneto Cover Installation e Replace the gasket A with a new
90. that the rear wheel is raised off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Squeeze the front brake lever and hold it with a band A to prevent the motorcycle from running forward A WARNING Motorcycle may fall over unexpectedly resulting in an accident or injury Be sure to hold the front brake when removing the rear wheel NOTICE Be sure to hold the front brake when removing the rear wheel or the motorcycle may fall over The rear wheel or the motorcycle could be damaged e Remove Drive Chain see Drive Chain Removal in the Final Drive chapter Disc Guard Bolts A and Washers Disc Guard B Cotter Pin C Rear Axle Nut D e Pull out the axle and remove the chain adjuster on both sides e Remove the rear wheel 10 8 WHEELS TIRES Wheels Rims e Remove the collars A with caps B on both sides NOTICE Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so the disc does not touch the ground e Insert a wod wedge between the brake pads OThis prevents them from being moved out of their proper position should the brake pedal be squeezed acciden tally Rear Wheel Installation e Fit the groove A of the caliper holder and swingarm rib B e Apply high temperature grease to the oil seal lips e Install the caps and collars to the hub on both sides OFit the
91. the ECU see ECU Removal Installation x If the reading is out of the standard remove the ECU and check the wiring for continuity between the main harness connectors ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Intake Air Temperature Sensor Connector B LB lead C ECU terminal 25 6017715DS1 GY lead D ECU terminal 24 x If the wiring is good check the intake air temperature sen sor resistance see Intake Air Temperature Sensor Resis tance Inspection Intake Air Temperature Sensor Resistance Inspection e Remove the intake air temperature sensor see Intake Air Temperature Sensor Removal Installation e Suspend the sensor A in a container of machine oil so that the heat sensitive portion is submerged e Suspend a thermometer B with the heat sensitive por tions C located in almost the same depth NOTE OThe sensor and thermometer must not touch the con tainer side or bottom e Place the container over a source of heat and gradually raise the temperature of the oil while stirring the oil gently for even temperature e Using a digital meter measure the internal resistance of the sensor Intake Air Temperature Sensor Resistance Standard 909 1 363 Q at 40 C 104 F 124 186 O at 100 C 212 F x If the reading is out of the standard replace the sensor x If the reading is within the standard but the problem still
92. the ball bearings are made to extremely close toler ances the wear must be judged by feel rather than mea surement Clean each bearing in a high flash point sol vent dry it do not spin the bearing while it is dry and oil it with engine oil to it OSpin A the bearing by hand to check its condition x If the bearing is noisy does not spin smoothly or has any rough spots replace it 6114060581 6113014981 CRANKSHAFT TRANSMISSION 9 35 Bearings Oil Seals e Inspect the needle bearings OThe rollers in a needle bearing normally wear very little and wear is difficult to measure Instead of measuring inspect the bearing for abrasion color change or other damage x If there is any doubt as to the condition of a needle bear ing replace it Oil Seal Inspection e Inspect the oil seals Replace the oil seal if the lips are deformed discolored indicating that the rubber has deteriorated hardened or otherwise damaged WHEELS TIRES 10 1 Wheels Tires Table of Contents Exploded WEE EE 10 2 Specifications ii AAA ee A a 10 4 Special tee ESA NA A Ain daa oir 10 5 LISTES RIAS EE 10 6 Front Wheel Removal see 10 6 Front Wheel Installation ccc cceccceecceccceecceeeeeeeeeeeeneeeeeeeeeeeeeeeeeeeeseeeeeeeeeeseeeseeeseeeeeeeeseeess 10 6 Rear Wheel Removal eiii sico oros estiment AGS 10 7 Rear Wheel Installation 10 8 Wheels Inspectonsi catenin SS 10 9 Spoke Tightne
93. the connector joined Input Voltage Standard DC 4 75 5 25 V e Disconnect the power supply harness x If the reading is within the standard check the output volt age see Throttle Sensor Output Voltage Inspection x If the reading is out of the standard remove the ECU and check the wiring for continuity between the main harness connectors ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Throttle Sensor Connector B R Y lead C ECU terminal 13 BL lead D GY lead E ECU terminal 5 lt gt BK lead F x If the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU Removal Installation Throttle Sensor Output Voltage Inspection e Measure the throttle sensor output voltage in the same way as input voltage inspection Note the following ODisconnect the throttle sensor connector and connect the measuring adapter A between these connectors Main Harness B Throttle Sensor C Digital Meter D Special Tool Measuring Adapter 57001 1700 Throttle Sensor Output Voltage Connections to Adapter Digital Meter W sensor Y lead Digital Meter BK sensor BK lead e Start the engine and warm it up thoroughly e Check the idle speed to ensure the throttle opening is correct Idle Speed Standard 2 000 50 r min rpm x lf the idle spee
94. the hole B and the projection C e Install the vacuum hose to the fitting D e Tighten the plate mounting screws securely e Install the removed parts see appropriate chapters LEA P Cat Ze Air Cleaner FUEL SYSTEM DFI 3 79 Air Cleaner Housing Removal e Remove the rear frame see Rear Frame Removal in the Frame chapter e Remove the air cleaner housing bolts A e Take the air cleaner housing off the rear frame Air Cleaner Housing Installation e When assembling the air cleaner housing refer to Ex ploded View section Torque Air Cleaner Duct Mounting Bolt 3 0 N m 0 31 kgf m 27 in lb Air Cleaner Duct Mounting Nuts 3 0 N m 0 31 kgf m 27 in lb e Install the air cleaner element see Air Cleaner Element Installation in the Periodic Maintenance chapter e Install the air cleaner housing to the rear frame Olnsert the rear frame ends to the holes A of the guard e Tighten Torque Air Cleaner Housing Bolts B 9 8 N m 1 0 kgf m 87 in lb e Install the rear frame see Rear Frame Installation in the Frame chapter Element Removal Installation e Refer to the Air Cleaner Element Cleaning and Inspection in the Periodic Maintenance chapter Element Cleaning and Inspection e Refer to the Air Cleaner Element Cleaning and Inspection in the Periodic Maintenance chapter 3 80 FUEL SYSTEM DFI Fuel Tank Fuel Tank Removal A WARNING Gasoline is extremely flammable a
95. trouble APPENDIX 17 27 Fuel air mixture incorrect Throttle body assy holder loose Air cleaner duct loose Air cleaner poorly sealed or missing Air cleaner clogged Compression high Carbon built up in combustion chamber Engine load faulty Clutch slipping Engine oil level too high Engine oil viscosity too high Brake dragging Drive train trouble Lubrication inadequate Engine oil level too low Engine oil poor quality or incorrect Coolant incorrect Coolant level too low Coolant deteriorated Cooling system component incorrect Radiator clogged Radiator cap trouble Water pump not rotating Clutch Operation Faulty Clutch slipping No clutch lever play Clutch cable maladjusted Clutch inner cable sticking Friction plate worn or warped Steel plate worn or warped Clutch spring broken or weak Clutch release function trouble Clutch hub or housing unevenly worn Clutch not disengaging properly Clutch lever play excessive Clutch spring compression uneven Engine oil deteriorated Engine oil viscosity too high Engine oil level too high Clutch housing seized Clutch release function trouble Clutch hub nut loose Clutch plate warped or rough Clutch hub spline damaged Gear Shifting Faulty Doesn t go into gear shift pedal doesn t return Clutch not disengaging Shift fork bent worn or seized Shift return spring pin loose Shift return spring weak or broken Shift shaft lever broken Pawl guide plate broken Shift pawl broke
96. valve guide driver press and insert the valve guide in until the valve guide driver surface D touches the head surface e When install the exhaust valve guide using the attached spacer t 2 0 C of the attachment D Exhaust 11 35 11 55 mm 0 437 0 445 in E Intake 13 35 13 55 mm 0 516 0 524 in F Special Tools Valve Guide Driver 57001 1564 Valve Guide Driver Attachment D 57001 1659 Valve Guide Driver Attachment G 57001 1728 e Ream the valve guide with valve guide reamer A even if the old guide is reused Special Tool Valve Guide Reamer 65 5 57001 1079 6E15045BS1 GE15114BS1 6E15046BS1 ENGINE TOP END 5 29 Valves Valve Valve Guide Clearance Measurement Wobble Method If a small bore gauge is not available inspect the valve guide wear by measuring the valve valve guide clearance with the wobble method as indicated below e Insert a new valve A into the guide B and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface e Move the stem back and forth C to measure the valve valve guide clearance e Repeat the measurement in a direction at a 90 angle to the first measurement x If the reading exceeds the service limit replace the guide NOTE OThe reading is greater than the actual valve valve guide clearance because the measurement is taken outside of the guide Valve
97. while spinning the output shaft e Set the shift drum in the neutral position e Replace the O ring A on the output shaft with a new one e Apply grease to the O ring e Install O ring on the output shaft while expanding the O ring e Insert the collar B with the groove C faces inside e Install the balancer drive gear A to the crankshaft so that the wide groove B of the drive gear fits to the wide tooth C on the crankshaft e Replace the circlip with a new one and install it Special Tool Outside Circlip Pliers 57001 144 9 16 CRANKSHAFT TRANSMISSION Crankcase e Replace the circlip A with a new one and install it to the output shaft Special Tool Outside Circlip Pliers 57001 144 e Install the removed parts see appropriate chapters CRANKSHAFT TRANSMISSION 9 17 Crankshaft Crankshaft Removal e Split the crankcase see Crankcase Disassembly e Remove the crankshaft A from the right crankcase half B Crankshaft Installation e Install the crankshaft to the right crankcase half e Apply engine oil to the connecting rod big end bearing Crankshaft Disassembly Since assembly of the crankshaft demands exacting tol erances the disassembly and reassembly of the crankshaft can only be done by a shop having the necessary tools and equipment x If it should be necessary to disassemble the crankshaft use a press to remove the crankpin Crankshaft Assembly Since the assemb
98. yond its service limit Replacement Parts Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI Gaskets O rings oil seals grease seals circlips cotter pins or self locking nuts must be replaced with new ones whenever disassembled Assembly Order In most cases assembly order is the reverse of disassem bly 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 se quence 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 quar ter turn and then remove them If the specified tightening sequence is not indicated tighten the fasteners alternating diagonally ES SCH A 65020088 S 68020048 S 68020108 A PE a SS e ee O pe Es En as 3 ZA Che d 5 ES Sat ka P SS lt L gt S NN 68020118 gt qe Bell ed gt f e aa 5 Es gp Ge En 1 AZ 9 ES y a f A CT re CH FUEGO WS UA gt aes OD E 68020128 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 qua
99. 0 15 e Using a suitable bar A tap the around of the bearing inner race evenly to remove the bearings B Hub Bearing Installation e Before installing the hub bearings blow any dirt or foreign particles out of the hub with compressed air to prevent contamination of the bearings e Replace the bearings with new ones NOTE Olnstall the bearings so that the marked side or sealed side faces out e Install the front hub bearings in the following sequence OPress in the left side bearing A until it is bottomed Special Tool Bearing Driver Set 57001 1129 Olnsert the collar B in the front hub C OPress in the right side bearing D until it is bottomed Special Tool Bearing Driver Set 57001 1129 e Install the rear hub bearings in the following sequence OPress in the right side bearing until it is bottomed Special Tool Bearing Driver Set 57001 1129 Olnsert the collar in the rear hub OPress in the left side bearings until it is bottomed Special Tool Bearing Driver Set 57001 1129 OReplace the circlip with a new one Special Tool Inside Circlip Pliers 57001 143 e Replace the grease seal A with a new one e Press in the grease seal so that the seal surface is flush B with the end of the hole e Apply high temperature grease to the grease seal lip Special Tool Bearing Driver Set C 57001 1129 2 Al ST IG Bs H Y GJ06107BS1
100. 3 9 178 Top gear Tubular semi double cradle 42 to either side 26 9 113 mm 4 45 in 80 100 21 51M BRIDGESTONEM403 Tube type 21 x 1 60 120 80 19 63M BRIDGESTONEM404 Tube type 19 x 2 15 Telescopic fork upside down 314 mm 12 4 in Swingarm New Uni trak 315 mm 12 4 in Single disc 1 10 GENERAL INFORMATION General Specifications Items KX450FC FE Effective Disc Diameter Front 225 mm 8 86 in Rear 215 mm 8 46 in Specifications are subject to change without notice and may not apply to every country GENERAL INFORMATION 1 11 Technical Information DFI Setting Data Selection Overview The DFI setting can be easily selected among three op tions to suit various track conditions without using the KX Fl calibration kit e The setting can be switched by changing the connector A on the right side of the steering stem Track Condition Connector Color Soft White A Standard Green B Js Hard Black C V ah Sept P Switching Procedure e Change the connector with the engine stopped e Remove the connector upward A from the bracket while pushing the connector stopper B e Select the connector suitable for the track condition and install it to the bracket NOTE OThe ignition timing and fuel injection are set to suit each track condition in the DFI setting OThe DFI setting at start up is maintained until the eng
101. 35 57001 1121 Valve Seat Cutter 55 635 57001 1247 Intake Valve Seat Cutter 45 640 57001 1496 Valve Seat Cutter 32 638 5 57001 1122 Valve Seat Cutter 55 638 5 57001 1497 If the tool manufacturer s instructions are not available operate in accordance with the following procedure Seat Cutter Operation Care 1 This valve seat cutter is developed to grind the valve for repair Therefore the cutter must not be used for other purposes than seat repair 2 Do not drop or shock the valve seat cutter or the dia mond particles may fall off 3 Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface Also wash off ground particles sticking to the cutter with washing oil NOTICE Do not use a wire brush to remove the metal par ticles from the cutter It will take off the diamond particles 4 Setting the valve seat cutter holder in position operate the cutter in one hand Do not apply too much force to the diamond portion NOTE OPrior to grinding apply engine oil to the cutter and dur ing the operation wash off any ground particles sticking to the cutter with washing oil 5 After use wash it with washing oil and apply thin layer of engine oil before storing Marks Stamped on the Cutter The marks stamped on the back of the cutter A represent the following GO smilies Cutter Angle B BL DD aii Cutter Outer Diameter C 6E15006B
102. 450FD 1 Overview This model has adopted Pneumatic Spring Fork PSF system Unlike conventional front forks PSF does not have a main spring in each leg and uses air pressure as a spring force A Air Valve Plug 2 New Features Light Weight e In the conventional design the main springs constitute about 12 of the total mass of a front fork Eliminating the main springs has realized a significant reduction in mass 750 g 1 5 Ib Improvement of Operation e The total friction of the front fork has been reduced by about 20 due to elimination of the main springs that mainly cause friction in the latter half of the stroke e The balance spring within the cartridge has a slider that minimizes the friction created during stroke e A new oil seal developed specifically for PFS s air pressurizing system for smooth initial movement 6B06726BW2 C A Slider B Balance Spring C New Oil Seal Improvement of Bottoming Resistance Front Wheel Grip e The larger cylinder diameter 24 32 is possible due to the elimination of the main spring which contributes to double the pressurized area of the main piston e The big piston contributes to increased bottoming resistance near the end of the compression stroke e The larger cylinder and piston generates damping force quickly and can maintain it throughout the extension stroke The pressurized system prevents oil cavitati
103. 5 0391 AU EUR 21175 0392 BR ECU Identification KX450FD Part Number A Specification 21175 0801 US CA 21175 0802 AU EUR TH 21175 0803 BR ECU Identification KX450FE Part Number A Specification 21175 0882 US CA 21175 0883 AU EUR TH 21175 0884 BR ECU Removal NOTICE Never drop the ECU especially on a hard surface Such a shock to the ECU can damage it e Remove Number Plate see Number Plate Removal in the Frame chapter Bolt A Connector Bracket B e Disconnect the ECU connector C e Pull the ECU D together with rubber protector ECU Installation e Install the ECU A to the rubber protector B 6017720ES1 ECU FUEL SYSTEM DFI 3 67 e Insert the slits A of the rubber protector to the ECU bracket e Connect the ECU connector B ECU Power Supply Inspection e Remove the number plate see Number Plate Removal in the Frame chapter e Visually inspect the ECU connector x If the connector is clogged with mud or dust blow it off with compressed air e Remove the ECU see ECU Removal e Visually inspect the terminals A of the ECU connectors x If the terminals of the main harness connector are dam aged replace the main harness x If the terminals of the ECU connector are damaged re place the ECU e Disconnect the capacitor lead connector A e Set a digital meter A and check the following wiring for continui
104. 50FD US CA Models e Installation is the reverse of removal Rear Flap Removal Installation e Remove the screws A and take off the rear flap B e Installation is the reverse of removal Footpegs FRAME 15 11 Footpeg Removal e For the right footpeg removal remove the brake pedal assy see Right Engine Cover Removal in the Clutch chapter e Remove Cotter Pin A Washer B Pivot Pin C Spring D Footpeg E Footpeg Bracket Bolt F Footpeg Bracket G Footpeg Installation NOTE OThe footpeg can be adjusted in two positions refer to the Footpeg Height Adjustment e Replace the cotter pin with a new one e Apply a non permanent locking agent to the footpeg bracket bolts A e Install the footpeg bracket B and tighten the bolts Torque Footpeg Bracket Bolt Upper 34 N m 3 5 kgf m 25 ft lb Footpeg Bracket Bolt Lower 16 5 N m 1 68 kgf m 12 2 ft lb e Apply grease to the pivot pin C e Install the footpeg D spring E and pivot pin Olnsert the pivot pin from upper side e Install the washer F and new cotter pin G e Bend the longer side A of the cotter pin as shown in the figure G014042BS2 G014039BS2 6014016BS1 15 12 FRAME Footpegs Footpeg Height Adjustment OThe footpeg can be adjusted in two positions Footpeg Bracket A Bolts B Bolt Holes C Upper Position D Lower Position E e Remove Footpegs see Footpeg Re
105. 57 9 9 Stator Coil Bolts 9 8 1 0 87 in lb L 10 Crankshaft Sensor Bolts 7 0 0 71 62 in lb 11 Capacitor 12 DFI Setting Data Selection Connectors G Apply grease L Apply a non permanent locking agent R Replacement Parts Si Apply silicone grease SS Apply silicone sealant 16 4 ELECTRICAL SYSTEM Specifications Item Standard Flywheel Magneto Magneto Output Voltage Stator Coil Resistance 37 V or more at 4 000 r min rpm 0 4 1 1 Q at 20 C 68 F Charging System Charging Voltage Regulator Rectifier Output Voltage Capacitor Internal Resistance 14 0 14 5 V see text Ignition System Ignition Timing Ignition Coil 3 Needle Arcing Distance Primary Winding Resistance Secondary Winding Resistance Primary Peak Voltage Crankshaft Sensor Resistance Crankshaft Sensor Peak Voltage Spark Plug Type Gap 10 BTDC at 2 000 r min rpm 7 mm 0 26 in or more 0 28 0 38 Q at 20 C 68 F 7 65 10 4 kQ at 20 C 68 F 120 V or more 180 280 O at 20 C 68 F 3 V or more NGK CPR8EB 9 0 8 0 9 mm 0 03 0 04 in ELECTRICAL SYSTEM 16 5 Special Tools and Sealant Bearing Driver Set Filler Cap Driver 57001 1129 57001 1454 ST5711298T ST5714548T Rotor Puller M16 M18 M20 M22 x 1 5 Needle Adapter Set 57001 1216 57001 1457 T5712168T ST571457ST C Timing Light Flywheel Puller M28 x 1 0 57001 1241 57001 1471
106. 591 Rotor Holder 57001 1730 ORemove the flywheel nut OCheck the tightening torque with rotor puller and a bolt M16 P1 5 L 50 mm 2 0 in or more Special Tool Flywheel Puller M28 x 1 0 57001 1471 x If the flywheel is not pulled out with 20 N m 2 0 kgf m 15 ft lb of drawing torque it is installed correctly x If the flywheel is pulled out with under 20 N m 2 0 kgf m 15 ft lb of drawing torque clean off any oil dirt or flaw of the crankshaft and flywheel tapered portion and dry them with a clean cloth Then confirm that it is not pulled out with above torque e Hold the flywheel steady with the rotor holder and tighten the flywheel nut Special Tools Grip 57001 1591 Rotor Holder 57001 1730 Torque Flywheel Nut 78 5 N m 8 0 kgf m 57 9 ft lb e Install the magneto cover see Magneto Cover Installa tion Stator Coil Removal e Remove Magneto Cover see Magneto Cover Removal Stator Coil Bolts A Crankshaft Sensor Bolts B Holder C Magneto Lead Grommet D e Remove the stator coil E and crankshaft sensor F as a set Flywheel Magneto ELECTRICAL SYSTEM 16 15 Stator Coil Installation e Apply a non permanent locking agent to the threads of the stator coil bolts e Install the stator coil and crankshaft sensor as a set e Tighten Torque Stator Coil Bolts 9 8 N m 1 0 kgf m 87 in Ib e Install the holder A and tighten the crankshaft sensor bolts OHold the
107. 8 1 0 87 in lb 7 KX450FC G Apply grease R Replacement Parts 4 4 COOLING SYSTEM Specifications Item Standard Recommended Coolant Type Color Mixed Ratio Freezing Point Total Amount Radiator Radiator Cap Relief Pressure Permanent type antifreeze soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators Green Soft water 50 coolant 50 35 C 31 F 1 1 L 1 2 US qt 93 123 kPa 0 95 1 25 kgf cm 13 18 psi COOLING SYSTEM 4 5 Special Tools Outside Circlip Pliers Bearing Driver Set 57001 144 57001 1129 ST5701448T ST5711298T 4 6 COOLING SYSTEM Coolant Coolant Level Inspection e Refer to the Coolant Level Inspection in the Periodic Main tenance chapter Coolant Deterioration Inspection e Refer to the Coolant Deterioration Inspection in the Peri odic Maintenance chapter Coolant Draining A WARNING Coolant can be extremely hot and cause severe burns is toxic and very slippery Do not remove the radiator cap or attempt to change the coolant when the engine is hot allow it cool completely Immediately wipe any spilled coolant from tires frame engine or other painted parts Do not ingest coolant NOTICE The coolant should be changed periodically to en sure long engine life e Remove the radiator cap A NOTE ORemove the radiator cap in two steps
108. 9 Oil Pump Scavenge Cover Bolts 9 8 1 0 87 mb 10 Rear Camshaft Chain Guide Bolt 15 1 5 11 11 Cylinder Bolt 12 1 2 106 in lb S 12 Throttle Body Assy Holder Screws 9 8 1 0 87 in lb L 13 Throttle Body Assy Clamp Screw 2 0 0 20 18 in lb 14 Camshaft Chain Tensioner Mounting Bolts 9 8 1 0 87 in lb 15 Camshaft Chain Tensioner Cap Bolt 5 0 0 51 44 in lb 16 Face the round end outward 17 KX450FD EO Apply engine oil G Apply grease L Apply a non permanent locking agent LG Apply liquid gasket M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts S Follow the specified tightening sequence 5 4 ENGINE TOP END Exploded View 6E02523BW5 C ENGINE TOP END 5 5 Exploded View CI eS kgfm SE ET o feo s f 2 Exhaust Pipe Cover Bolts 106 in lb 3 Muffler Clamp Bolt 16 5 1 68 12 2 S 4 Muffler Mounting Bolts 20 2 0 15 S G Apply grease L Apply a non permanent locking agent R Replacement Parts S Follow the specified tightening sequence SS Apply silicone sealant 5 6 ENGINE TOP END Specifications Item Standard Service Limit Camshafts Cam Height Exhaust Intake KX450FC KX450FD Camshaft Journal Camshaft Cap Clearance Camshaft Journal Diameter Camshaft Journal Inside Diameter Camshaft Runout 36 943 37 057
109. A the piston rod B by hand to inspect it if operating smoothly NOTICE Be careful not to bend or damage the piston rod when the piston rod is stroked e Make sure about 16 mm 0 63 in A of push rod thread is exposed from the locknut B e Completely wipe off the fork oil from the cylinder unit A e Insert the cylinder unit to the outer tube B e Temporarily tighten the fork top plug A by using the top plug wrench B Special Tool Top Plug Wrench 49 mm 57001 1653 2 64 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Hold the axle holder with a vise OProtect the axle holder with a soft jaw or heavy cloth when using a vise WARNING Clamping the axle holder too tight can damage it which will affect riding stability Do not clamp the axle holder too tight e Insert the push rod A into the piston rod e Replace the O ring A and gasket B on the adjuster as sembly with new ones and apply specified fork oil to the O ring e Slowly turn the adjuster assembly A clockwise until re sistance is felt and check the clearance between the lock nut B and adjuster assembly for more than 1 mm 0 04 in C e Turn the locknut A counterclockwise until it contacts the adjuster assembly B e Secure the locknut using a wrench tighten the adjuster assembly to the specified torque Torque Adjuster Assembly Locknut 28 N m 2 9 kgf m 21 ft Ib PERIODIC MAINTENAN
110. B on the straight part C of the chain from the pin center of the 1st pin to the pin center of the 21st pin Since the chain may wear unevenly take measurements at several places Chain 20 link Length Standard 317 5 318 2 mm 12 50 12 53 in Service Limit 323 mm 12 7 in x If any measurements exceed the service limit replace the chain Also replace the front and rear sprockets when the drive chain is replaced WARNING A chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock the rear wheel severely damaging the motorcycle and causing it to go out of control Inspect the chain for damage and proper adjustment before each ride If chain wear exceeds the service limit replace it with the standard chain Standard Chain Make DAIDO Type DID 520DMA4 Link 114 Links Drive Chain Slack Inspection e Using the jack raise the rear wheel until the rear shock absorber stretched fully Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Check the wheel alignment see Wheel Alignment Inspec tion in the Final Drive chapter and adjust it if necessary see Wheel Alignment Adjustment in the Final Drive chap ter NOTE OClean the drive chain if it is dirty and lubricate it if it appears dry e Rotate the rear wheel to find the position where the chain is tightest because it wears unevenly e Measure the space chain slack A between the bottom of the chain
111. CE Prying or excessively widening the joint lock ends for fuel hose removal will permanently deform the joint lock resulting in a loose or incomplete lock that may allow fuel to leak and create the potential for a fire explosion To prevent fire or explosion from a damaged joint lock do not pry or excessively widen the joint lock ends when removing the fuel hose The joint lock has a retaining edge that locks around the housing GS05269BS1 e Pull A the fuel hose joint out of the fuel outlet pipe B A WARNING Fuel is flammable and explosive under certain con ditions and can cause severe burns Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is dis connected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with a piece of clean cloth to prevent fuel spillage e Close the fuel tank cap e Remove the fuel tank and place a it on a flat surface ODo not apply the load to the fuel outlet pipe of the fuel pump A WARNING Gasoline is extremely flammable and can be explo sive under certain conditions creating the poten tial for serious burns Store the fuel tank in an area which is well ventilated and free from any source of flame or sparks Do not smoke in this area Place the fuel tank on a flat surface and plug the fuel pipes to prevent fuel leakage 3 82 FUEL
112. CE Specifications Item Standard Service Limit Amount Cylinder Unit 343 mL 11 6 US oz SE Outer Tube 235 mL 7 95 US oz Adjustable Range 190 265 mL 6 42 8 96 US oz Rear Shock Absorber Suspension Oil Kawasaki KHV10 K2C or equivalent Amount Approximately 417 mL 14 1 US oz Electrical System Spark Plug Gap 0 8 0 9 mm 0 03 0 04 in PERIODIC MAINTENANCE 2 13 Special Tools Inside Circlip Pliers Jack Attachment F 7 J L 57001 143 57001 1608 7570143ST ST571608ST Steering Stem Nut Wrench Top Plug Wrench 49 mm 57001 1100 57001 1653 gt Le E SS ST571100ST C ST571653ST Jack Top Plug Wrench 36 mm 57001 1238 57001 1705 ST5712388ST ST571705ST Spark Plug Wrench Hex 16 Top Plug Wrench 21 mm 57001 1262 57001 1787 ST5712628ST ST571787ST Filler Cap Driver 57001 1454 lt a ST5714548T 2 14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System DFI Fuel Hose and Connections Inspection Olf the motorcycle is not properly handled the high pres sure inside the fuel line can cause fuel to leak A or the hose burst Remove the fuel tank see Fuel Tank Re moval in the Fuel System DFI chapter and check the fuel hose Replace the fuel hose if any fraying cracks B or bulges C are noticed e Check that the fuel hose is routed according
113. CE 2 65 Periodic Maintenance Procedures e Tighten the adjuster assembly A Torque Adjuster Assembly 55 N m 5 6 kgf m 41 ft lb e Remove the fork leg from the vise e Using the top plug wrench remove the fork top plug from the outer tube and slowly slide down the outer tube A Special Tool Top Plug Wrench 49 mm 57001 1653 e Pour the specified amount of fork oil B into the outer tube Suspension Oil KHL15 11 1L 44091 0020 KHL15 11 4L 44091 0021 Outer Tube Oil Amount Standard 235 mL 7 95 US oz Adjustable Range 190 265 mL 6 42 8 96 US oz e Raise the outer tube B and temporarily install the fork top plug A to the outer tube with the top plug wrench C Special Tool Top Plug Wrench 49 mm 57001 1653 2 66 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Apply grease to the O ring on the air valve adapter NOTE OWhen using the air valve adapter make sure that there is no dust or foreign material on the threads and O ring e Install the air valve adapter A e Adjust the air pressure in each fork leg within the specified range below Air Pressure Standard setting 240 kPa 2 4 kgf cm 35 psi Adjustable Range 220 280 kPa 2 2 2 8 kgf cm 32 41 psi NOTE ODuring air pressure adjustment be careful that the lower end of the front fork does not contact the ground surface NOTICE Do not pressurize the fork to more than 500
114. D and collar E position as shown in the figure OThe installation procedure is the same as the counter side mm GMO6121BS1 Swingarm SUSPENSION 13 29 Drive Chain Guide Guide Roller Chain Slipper Wear Inspection e Visually inspect the drive chain guide A and replace it if excessively worn or damaged e Visually inspect the upper and lower chain guide rollers A and replace them if excessively worn or damaged e Visually inspect the chain slipper A on the swingarm and replace it if excessively worn or damaged Swingarm Bearing Sleeve Inspection NOTICE Do not remove the bearings for inspection Re moval may damage them e Inspect the needle bearing A installed in the swingarm OThe rollers in a bearing normally wear very little and wear is difficult to measure Instead of measuring visually inspect the bearing for abrasion discoloration or other damage x If the needle bearing and sleeve show any signs of ab normal wear discoloration or damage replace them as a set 13 30 SUSPENSION Tie Rod Rocker Arm Tie Rod Removal e Using the jack under the frame raise the rear wheel off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Remove Nut A Lower Chain Guide Roller B e Remove Rear Tie Rod Mounting Bolt and Nut A Front Tie Rod Mounting Bolt and Nut B Tie Rod C NOTICE When pulling out the m
115. DFI 3 41 7 OM Z E 7 7 1 0 7 7 7 2 ee AY ee ge 7 A 7 10 20 30 40 50 60 70 76 80 90 ene Ps W 1 1 1 1 1 1 20 40 60 80 101 32 120 kPa Ps ID lt gt 10 gt Pr abs 60171208W4 C ID Idling Ps Standard Atmospheric Pressure Absolute Pv Throttle Vacuum Pressure Absolute ST Standard of Sensor Output Voltage V TO Throttle Full Open UR Usable Range of Sensor Output Voltage V Vv Intake Air Pressure Sensor Output Voltage V Digital Meter Reading 3 42 FUEL SYSTEM DFI Intake Air Pressure Sensor Service Code 12 Intake Air Pressure Sensor Circuit BL R Y BL Sr er R Y 6017971Ew1 C 1 ECU 2 Intake Air Pressure Sensor FUEL SYSTEM DFI 3 43 Intake Air Temperature Sensor Service Code 13 Intake Air Temperature Sensor Removal Instal lation NOTICE Never drop the intake air temperature sensor espe cially on a hard surface Such a shock to the sensor can damage it e Remove the seat see Seat Removal in the Frame chap ter e Disconnect the connector A e Remove the bolts A e Pull out the intake air temperature sensor B e Put the intake air temperature sensor A into the air cleaner housing OFace the locks B to front side e Apply a non permanent locking agent to the threads of the intake air temperature sensor bolts C e Tighten Torque Intake Air Temper
116. E Ennn 3 52 Vehicle down Sensor Installation 3 52 Vehicle down Sensor Input Voltage Inspection 3 52 Vehicle down Sensor Output Voltage Inspection 3 53 Fuel Injector Service Code 41 nier A notion 3 55 3 2 FUEL SYSTEM DFI Fuel Injector Removal seen Fuel Injector Installation fin ss A he nee Fuel Injector Audible Inspection Fuel Injector Resistance Inspection ss Fuel Injector Power Fuel Injector Output Injector Fuel Line In Fuel Pump Service Co Fuel Pump Remova Fuel Pump Installati Supply Voltage Inspection Voltage INSpection vos SDOCUOM EEEN E et Sege B ttel dre UT idad ON nr mi M en Te ne Fuel Pump Operation Inspection se Fuel Pump Operating Voltage Inspection oooooooccccnnccccnoccconcconcnonnnnonnnrrnno nono nnornnnnrnnrnnnnnnns Pressure Regulator Fuel Filter Cleaning REMOVAL a eee Malai ae Ignition Coil Service Code Dl iii iii Ignition Coil Removal lnstallation EE Ignition Coil Primary Peak Voltage Inspection sseeseeseeeeeeeeeseerirrirrrrsssrrrirrrresssrrrrrenns Orange FI Warning Indi Orange Fl Warning ECU rein ECU Identification ECU Removal ECU Installation ECU P
117. ED 1 1s 10th digit 0 5s 0 5s a digit i is i is 0 5s D Kl ae d k d a k d k d k A H ns s ON OFF a ees ee ER 2sec 3s 1 5s 5 6617351Fwi C Olf the problem is with the following parts the ECU cannot memorize these problems the orange Fl warning indicator light LED doesn t go on and no service codes can be displayed ECU Power Source Wiring and Ground Wiring see ECU Power Supply Inspection How to Erase Service Codes OEven if the battery or the ECU are disconnected or the problem is solved all service codes remain in the ECU Oln this model the problem history cannot be erased FUEL SYSTEM DEI 3 29 Self Diagnosis Service Code Table Service Orange FI Warning Indicator Codes Light LED aul Throttle sensor malfunction wiring open or short TULA Intake air pressure sensor malfunction wiring open or short TI Dn Intake air temperature sensor malfunction wiring open or short Problems Water temperature sensor malfunction wiring J LIUUUL open or short Crankshaft sensor malfunction wiring open or JULIL Sho SC TTT DD Gear position switch malfunction wiring open or short Vehicle down sensor malfunction wiring open or short AMA Fuel injector malfunction wiring open or short el Fuel pump malfunction wiring open or short 51 Ignition coil malfunction wiring open or short Notes OThe ECU may be involved in these problems If all the part
118. Exploded View o 30 OMID 00 a E E 6M02339BW5 C SUSPENSION 13 7 Exploded View Torque Remarks Va Les fi 1 Rear Shock Absorber Nut Upper 2 Rear Shock Absorber Nut Lower 34 3 5 25 3 Tie rod Mounting Nuts 59 6 0 44 La Rocker Arm PivotNut Jas 60 a rR 5 Swingarm Pivot Shaft Nut Ja lais 6 Piston Rod Lockmat Ja 29 2 R G Apply grease L Apply a non permanent locking agent R Replacement Parts 13 8 SUSPENSION Specifications Item Standard Service Limit Front Fork KX450FC Air Pressure Atmospheric pressure Rebound Damping Adjustment 10 clicks counterclockwise Adjustable Range from the seated position adjuster 20 clicks turned fully clockwise Compression Damping Adjustment 10 clicks counterclockwise Adjustable Range from the seated position adjuster EUR BR 13 clicks 22 clicks turned fully clockwise counterclockwise Suspension Oil Type Kawasaki Fork Oil KHL15 10 or equivalent Amount Cylinder Unit 198 mL 6 69 US oz EE Outer Tube 335 mL 11 3 US oz Adjustable Range EUR BR 345 mL 11 7 US oz 320 380 mL 10 8 12 8 US oz Fork Spring Free Length 470 mm 18 5 in 461 mm 18 1 in KX450FD Air Pressure 240 kPa 2 4 kgf cm 35 psi Adjustable Range 220 280 kPa 2 2 2 8 kgf cm 32 41 psi Rebound Damping Adjustment 9 clicks counterclockwise Adjustable Range from the seated position adjuster
119. FI System FUEL SYSTEM DFI 3 17 e When checking the DFI parts use a digital meter which can be read two decimal place voltage or resistance OThe DFI part connectors A have seals B including the ECU When measuring the input or output voltage with the connector joined use the needle adapter set C Insert the needle adapter inside the seal until the needle adapter reaches the terminal Special Tool Needle Adapter Set 57001 1457 NOTICE Insert the needle adapter straight along the terminal in the connector to prevent short circuit between terminals e Make sure that measuring points are correct in the con nector noting the position of the lock D and the lead color before measurement Do not reverse connections of a digital meter e Be careful not to short circuit the leads of the DFI or elec trical system parts by contact between adapters e Connect the power supply harness option P No 26011 0246 and the battery to the capacitor lead connector and measure the voltage with the connector joined NOTICE Incorrect reverse connection or short circuit by needle adapters could damage the DFI or electrical system parts OAfter measurement remove the needle adapters and ap ply sealant to the seals A of the connector B for water proofing Sealant Liquid Gasket TB1211 56019 120 e Always check the connected battery condition before re placing the DFI parts A fully charged battery
120. First turn the cap counterclockwise to the first stop and wait there for a few seconds Then push down and turn it further in the same direction and remove the cap e Remove Bolt A Right Engine Guard B e Place a container under the coolant drain bolt C e Remove the drain bolt to drain the coolant e Inspect the old coolant see Coolant Deterioration Inspec tion in the Periodic Maintenance chapter COOLING SYSTEM 4 7 Coolant Coolant Filling NOTICE Use coolant containing corrosion inhibitors made specifically for aluminum engines and radiators in accordance with the instruction of the manufac ture s Soft or distilled water must be used with the antifreeze see below for antifreeze in the cooling system If hard water is used in the system it causes scale accumulation in the water passages and considerably reduces the efficiency of the cooling system Recommended Coolant Type Permanent type antifreeze soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators Color Green Mixed Ratio Soft water 50 coolant 50 Freezing Point 35 C 31 F Total Amount 1 1 L 1 2 US qt e Replace the drain bolt gasket with a new one e Tighten Torque Coolant Drain Bolt 7 0 N m 0 71 kgf m 62 in Ib e Fill the radiator up to the bottom of the radiator filler neck A with coolant B and install the cap B A OLean the motorcycle s
121. Frame Engine Guards Removal e Remove the engine guards as shown in the figure Right Engine Guard A Lower Engine Guard B Bolts C Collars D G009051BS2 Engine Guards Installation e Installation is the reverse of removal Note the following OFit the projection A of the right engine guard to the hole B of the frame 15 6 FRAME Seat Seat Removal e Remove the side cover bolt A on both sides e Spread A the side covers lightly e Take off the seat B backward C Seat Installation e Install the seat Olnsert the hooks A of the seat under the flange collar B and brackets C OTake care not to damage the side covers with the bracket of seat e Tighten the side cover bolts FRAME 15 7 Side Covers Side Cover Removal e Remove the bolts A and take off the side cover OClear the side cover tabs B from the air cleaner housing Side Cover Installation e Stick the pad A on the inside of the right side cover e Install the damper B securely e Install the side covers Olnsert the tabs A of the side cover into the slots B of the air cleaner housing Olnsert the side cover rib C between the rear fender D and the rear frame El e Tighten the bolts 15 8 FRAME Radiator Shroud Radiator Shroud Removal e Remove Bolts A Radiator Shroud B OClear the radiator shroud tabs C from the air cleaner housing Radiator Shroud Installation
122. GJ06108BS1 GJ06080BS1 10 16 WHEELS TIRES Hub Bearing Hub Bearing Inspection Since the hub bearings are made to extremely close tol erances the clearance can not normally be measured NOTE ODo not remove any bearings for inspection If any bear ings are removed they will need to be replaced with new ones e Turn each bearing in the hub back and forth A while checking for plays roughness or binding x If bearing play roughness or binding is found replace the bearing e Examine the bearing seal B for tears or leakage x If the seal is torn or is leaking replace the bearing Hub Bearing Lubrication NOTE OSince the hub bearings are packed with grease and sealed lubrication is not required 6J06002BS1 FINAL DRIVE 11 1 Final Drive Table of Contents Exploded VIEW ii A A rt AAA E ae een AA 11 2 eelere TEE 11 4 Drive A ar 11a PAEA A a tendent 11 5 Drive Chain Slack Inspection ss 11 5 Drive Chain Slack Adjustment steam tintin 11 5 Wheel Alignment INSP OCHO seid sde bake d t leede Eet 11 5 Wheel Alignment Adjustment aise 11 5 Drive Chain Wear Inspection ssssesssernrrrrrnntttnrrnnntnnttnnntnnttnnEEAnEEnAEEEEEEAEE Enn EEEE EEEn Ennn EEEE 11 5 Drive Chain L bricati N s enie aaa aaa a ie eaaa ss 11 5 Drive Chain Removal ereenn ai e dido 11 5 Drive Chain Installation 11 5 SPrOCKELS 88 ose A A EA a aea a A 11 7 Engine Sprocket Removal sa ts
123. I system and ignition system parts are faulty In case of serious troubles the ECU stops the injection ignition operation Dealer Mode 1 The orange Fl warning indicator light LED emits service code s to show the problem s which the DFI system and ignition system has at the moment of diagnosis Dealer Mode 2 The orange Fl warning indicator light LED emits service code s to show the problem s which the DFI system and ignition system had in the past Self diagnosis Procedures e Disconnect the capacitor lead connector green A e Connect the power supply harness option P No 26011 0246 A to the capacitor lead connector B of the main harness e Connect the power supply harness option P No 26011 0246 to the 12 V battery C as shown in the figure e The orange Fl warning indicator light LED will go on for 2 seconds for bulb inspection when the ECU activates x If the orange Fl warning indicator light LED does not go on inspect the orange Fl warning indicator light LED see Orange Fl Warning Indicator Light LED Inspection NOTE OUse a fully charged battery when conducting self diagnosis Otherwise the light blinks very slowly or doesn t blink GC17877DS1 3 26 FUEL SYSTEM DFI Self Diagnosis e Disconnect the self diagnosis terminal A from the cover B e Connect an auxiliary lead C for grounding to the self diagnosis terminal NOTE OKeep the self diagnosis terminal g
124. Installation e Suspend the sensor A in a container of machine oil so that the heat sensitive portion and threaded portion are submerged e Suspend a thermometer B with the heat sensitive por tions C located in almost the same depth NOTE OThe sensor and thermometer must not touch the con tainer side or bottom e Place the container over a source of heat and gradually raise the temperature of the oil while stirring the oil gently for even temperature e Using a digital meter measure the internal resistance of the sensor Water Temperature Sensor Resistance Temperature Resistance 20 C 4 F 15 77 22 02 kQ 0 C 32 F about 6 544 kQ 40 C 104 F 0 999 1 281 kO 100 C 212 F 142 4 168 8 O Reference Information x If the reading is out of the range replace the sensor x If the reading is within the standard but the problem still exists replace the ECU see ECU Removal Installation Water Temperature Sensor Circuit GP18055BS2 C MO 6017973Ew1 C 1 ECU 2 Water Temperature Sensor Crankshaft Sensor Service Code 21 FUEL SYSTEM DFI 3 49 The crankshaft sensor has no power source and when the engine stops the crankshaft sensor generates no sig nals Crankshaft Sensor Removal Installation e Refer to the Stator Coil Removal Installation in the Elec trical System chapter Crankshaft Sensor Resistance Inspection e Refer to the Cranks
125. LUBRICATION SYSTEM Oil Pump Oil Pump Feed Removal e Remove Right Engine Cover see Right Engine Cover Removal in the Clutch chapter Clutch see Clutch Removal in the Clutch chapter Circlip A Oil Pump Driven Gear B Shaft C Oil Pump Idle Gear D Special Tool Outside Circlip Pliers 57001 144 e Remove Oil Pump Feed Cover Bolts A Oil Pump Cover B e Remove Inner Rotor Assy A Outer Rotor B Oil Pump Feed Installation e Install the dowel pins A to the crankcase e Apply engine oil to the each oil pump rotor and sliding surface of the oil pump driven gear shaft e Install Outer Rotor B Inner Rotor Assy C OTurn the oil pump driven gear shaft D so that the projec tion in its shaft fits onto the slot of the oil pump shaft e Install the oil pump cover A and tighten the oil pump feed cover bolts L 20 mm 0 8 in B L 16 mm 0 6 in C Torque Oil Pump Feed Cover Bolts 9 8 N m 1 0 kgf m 87 in lb ENGINE LUBRICATION SYSTEM 7 15 Oil Pump e Apply molybdenum disulfide grease to the shaft of the oil pump idle gear e Install the oil pump idle gear A facing the stepped side B to the outside e Install the shaft C and oil pump driven gear D e Turn the oil pump driven gear to check that the oil pump operates smoothly e Replace the circlip E with a new one e Install the new circlip Special Tool Outside Circlip Pliers 57001 144 e Install the removed par
126. Master Cylinder Mounting Bolts A Brake Pedal Bolt B Brake Pedal Return Spring C e Remove Bolt A Right Engine Guard B e Remove Water Pump Cover see Water Pump Cover Removal in the Cooling System chapter Clutch Cover Bolt A Oil Filter Cap Bolt B Right Engine Cover Bolts C Right Engine Cover D Right Engine Cover Installation e Install the dowel pins A e Replace the O rings B with new ones e Replace the right engine cover gasket C with a new one e Wrap the spline D of the kick shaft with the vinyl tape to prevent damage e Apply grease to the O rings and install them to the crankcase Olnstall the lower O ring so that the tapered side facing outside e Apply a grease to the kick shaft oil seal lip e When installing the cover does not go well the cover is installed according to the following procedures Olnstall the cover while turning the impeller A e Tighten Torque Right Engine Cover Bolts 9 8 N m 1 0 kgf m 87 in 1b Clutch Cover Bolt 9 8 N m 1 0 kgf m 87 in Ib Oil Filter Cap Bolt 9 8 N m 1 0 kgf m 87 in Ib CLUTCH 6 11 Clutch Cover and Right Engine Cover e Remove the vinyl tape from the kick shaft e Install Water Pump Cover see Water Pump Cover Installation in the Cooling System chapter Right Engine Guard see Engine Guard Installation in the Frame chapter Rear Master Cylinder see Rear Master Cylinder Instal lation in the Brakes chapter Brake Pe
127. OSS yo Teo HEEN GJ05129BS 1 GJ05130BS1 WHEELS TIRES 10 13 Tires air valve cap C e Adjust the tire air pressure to the specified pressure see Air Pressure Inspection Adjustment in the Periodic Main tenance chapter 10 14 WHEELS TIRES Hub Bearing Front Hub Bearing Removal e Remove Front Wheel see Front Wheel Removal Grease Seals A e Use the bearing remover to remove the hub bearings A NOTICE Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place wooden blocks under the wheel so that the disc does not touch the ground Special Tools Bearing Remover Head 20 x 22 B 57001 1293 Bearing Remover Shaft 13 C 57001 1377 e Remove the collar D Rear Hub Bearing Removal e Remove Rear Wheel see Rear Wheel Removal Grease Seals A Circlip B Special Tool Inside Circlip Pliers 57001 143 e Use the bearing remover to remove the right hub bearing A NOTICE Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place wooden blocks under the wheel so that the disc does not touch the ground Special Tools Bearing Remover Head 425 x 28 B 57001 1346 Bearing Remover Shaft 13 C 57001 1377 e Remove the collar D GJ06074BS1 GJ06104BS1 GJO6076BS1 GJ06106BS1 Hub Bearing WHEELS TIRES 1
128. Pressure Sensor 13 Vehicle down Sensor 5 Fuel Injector 14 Gear Position Switch 6 Intake Air Temperature Sensor 15 Capacitor 7 Water Temperature Sensor 16 Crankshaft Sensor 8 Frame Ground 1 17 Orange Launch Control Mode Fl Warning 9 Spark Plug Indicator Light LED OColor Codes BK Black GY Gray BL Blue LB Light Blue BR Brown LG Light Green CH Chocolate O Orange DG Dark Green P Pink G Green 18 Kawasaki Diagnostic System Connector PU Purple R Red V Violet W White Y Yellow 3 12 FUEL SYSTEM DFI DFI System Terminal Numbers of ECU Connectors Terminal Names Power Supply to ECU Vehicle down Sensor Crankshaft Sensor Gear Position Switch Throttle Sensor Intake Air Pressure Sensor Unused Ground for Control System Crankshaft Sensor 10 External Communication Line KDS 11 Unused 12 Launch Control Mode Button 13 Power Supply to Sensors 14 Fuel Pump Power Supply Voltage 15 Fuel Pump 16 Fuel Injector 17 Unused 18 Ignition Coil 19 Unused OMNAOARWNDN 60176710W2 C Unused Orange Launch Control Model Warning Indicator Light LED Water Temperature Sensor DFI Setting Data Selection 1 Ground for Sensors Intake Air Temperature Sensor DFI Setting Data Selection 2 Unused Unused Self diagnosis Terminal Unused External Communication Line External Communication Line
129. Rear Sprocket Nuts 34 3 5 25 R Engine Sprocket Cover Bolts 9 8 1 0 87 in lb Engine Sprocket Nuts 70 7 1 52 Brakes Brake Reservoir Cap Screws 1 5 0 15 13 in lb Front Master Cylinder Clamp Bolts 8 8 0 90 78 in lb S Brake Lever Pivot Bolt 5 9 0 60 52 in lb Si Brake Lever Pivot Bolt Locknut 5 9 0 60 52 in lb Brake Hose Banjo Bolts 25 2 5 18 Front Brake Disc Mounting Bolts 9 8 1 0 87 in lb L Caliper Bleed Valve 7 8 0 80 69 in lb Brake Pad Pin 17 1 7 13 Front Caliper Mounting Bolts 25 2 5 18 Rear Master Cylinder Mounting Bolts 9 8 1 0 87 in lb Rear Master Cylinder Push Rod Locknut 17 1 7 13 Brake Pedal Bolt 25 2 5 18 L G Rear Brake Disc Mounting Bolts 23 2 3 17 L Rear Brake Pad Pin Plug 2 5 0 25 22 ml Rear Caliper Holder Shaft 27 2 8 20 Si Suspension Front Fork Clamp Bolts Lower 20 2 0 15 AL Front Fork Clamp Bolts Upper 20 2 0 15 AL Adjuster Assembly Locknuts 28 2 9 21 Base Valve Assemblies 30 3 1 22 Adjuster Assemblies KX450FC 55 5 6 41 L Adjuster Assemblies KX450FD 55 5 6 41 Pressure Relief Screws KX450FC 1 2 0 12 11 in lb Air Valve Plug KX450FD 0 2 0 020 18 ml Front Fork Top Plugs KX450FC 30 3 1 22 2 8 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Torgus Remarks N m kgf m ft Ib Front Fork Top Plugs KX450FD 45 4 6 33 Swingarm Pivot Shaft Nut 98 10 72 R Rocker Arm Pivot Nut 59 6 0 44 R Tie Rod Mounting Nuts 59 6 0 44 R Rear Shock Absorber Nut Upper 39 4 0 29 R Rear Shock Abs
130. Remarks N m kgf m ft lb 1 Piston Oil Nozzle Bolt 7 0 0 71 62 mb L 2 Crankcase Bearing Retainer Screws 15 1 5 11 L 3 Primary Gear Nut 98 10 72 Lh 4 Balancer Weight Mounting Nut 52 5 3 38 5 Crankcase Bolts M7 15 1 5 11 S 6 Piston Oil Nozzle 3 0 0 31 27 in lb 7 Crankcase Bolts M6 12 1 2 106 in lb S 8 Washers EO Apply engine oil G Apply grease L Apply a non permanent locking agent Lh Left hand Threads LG Apply liquid gasket R Replacement Parts S Follow the specified tightening sequence 9 4 CRANKSHAFT TRANSMISSION Exploded View Cd SN sv E0 P A 2 ld CRANKSHAFT TRANSMISSION 9 5 Exploded View Torque No Fastener Nem kgm ftlb Remarks 1 Kick Pedal Bolt 25 2 5 18 L 2 Ratchet Guide Bolt 8 8 0 90 78 in lb 3 Ratchet Plate Bolt 9 8 1 0 87 in lb S 4 Shift Drum Cam Bolt 24 2 4 18 L 5 Gear Positioning Lever Nut 8 8 0 90 78 in lb 6 Ratchet Plate Screw 15 1 5 11 L S 7 _ Shift Pedal Bolt 9 8 1 0 87 in lb 8 Face the round end outword EO Apply engine oil G Apply grease L Apply a non permanent locking agent M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts S Follow the specified tightening sequence St Stake the fasteners to prevent loosening 9 6 CRANKSHAFT TRANSMISSION Specifi
131. Run the throttle sensor lead inside of the clamp Intake Air Pressure Sensor Throttle Sensor Connector Fuel Injector Connector Intake Air Temperature Sensor Lead Intake Air Temperature Sensor Throttle Sensor Run the throttle sensor lead to the front side of the throttle body assy Water Temperature Sensor Connector APPENDIX 17 19 17 20 APPENDIX Cable Wire and Hose Routing GROK2SE 6 Intake Air Temperature Sensor Lead Run the intake air temperature sensor lead through the hole of the guide as shown in the figure Bracket Do not show up the intake air temperature sensor lead above the bracket as shown in the figure Do not bend the intake air temperature sensor lead end as shown in the figure Run the intake air temperature sensor lead above and left side of the rear shock absorber upper part Make sure that the intake air temperature sensor lead are not caught between the rear shock absorber upper part and rear shock absorber mounting bracket on the frame OO Om P GO APPENDIX 17 21 Cable Wire and Hose Routing 6899752044 C 1 Viewed A 7 Right Radiator 2 Viewed B 8 Align the rib of the joint pipe to the white 3 Clamp Face the claw portion leftward mark of the hoses 4 Face the white mark of the hoses upward 9 Water Hose Fitting Cylinder Head 5 Clamp Face the claw portion forward and 10 Water Pump Cover downward 11 Run the radiator over
132. S1 ENGINE TOP END 5 31 Valves Repair Operating Procedures e Clean the seat area carefully e Coat the seat with machinist s dye e Fit a 45 cutter into the holder and slide it into the valve guide e Press down lightly on the handle and turn it right or left Grind the seating surface only until it is smooth NOTICE Do not grind the seat too much Overgrinding will reduce valve clearance by sinking the valve into the head If the valve sinks too far into the head it will be impossible to adjust the clearance and the cylin der head must be replaced Widened Width A of engagement by machining with 45 cutter Ground Volume B by 32 cutter 32 C Correct Width D Ground Volume E by 55 cutter 55 F GE15011981 e Measure the outside diameter of the seating surface with a vernier caliper x If the outside diameter of the seating surface is too small repeat the 45 A grind until the diameter is within the specified range Original Seating Surface B O NOTE ORemove all pittings of flaws from 45 ground surface OAfter grinding with 45 cutter apply thin coat of machin amp E15012151 ist s dye to seating surface This makes seating surface distinct and 32 and 55 grinding operation easier OWhen the valve guide is replaced be sure to grind with 45 cutter for centering and good contact x If the outside diameter A of the seating surface
133. SYSTEM DFI Fuel Tank e Clean the pipe A e Cover the pipe and hose joint B with the vinyl bags C to keep them clean Fuel Tank Installation e Note the above WARNING see Fuel Tank Removal e Run the hoses correctly see Cable Wire and Hose Rout ing section in the Appendix chapter e Check that the dampers A are in place on the frame x If the dampers are damaged or deteriorated replace it OUsing a high flash point solvent clean any oil or dirt that may be on the adhesive cement coating area Dry them with a clean cloth x If necessary apply adhesive cement to the underside of the dampers and stick them e Remove the vinyl bags on the pipe and hose joint e Check that there are no flaws burrs and adhesion of foreign materials on fuel outlet pipe A e Check the joint lock for deformation and wear e If the joint lock is deformed replace the fuel hose with a new one e Apply engine oil to the fuel outlet pipe A lightly GS05265BS1 EA ET A GS05265BS1 Fuel Tank FUEL SYSTEM DFI 3 83 e Insert the fuel hose joint A straight onto the fuel outlet pipe until the hose joint clicks e Push the joint lock B e Push and pull C the fuel hose joint back and forth more than two times and make sure it is locked and does not come off A WARNING Leaking fuel can cause a fire or explosion resulting in serious burns Make sure the hose joint is in sta
134. Separate the caliper holder A from the caliper B e Remove the anti rattle springs C e Using compressed air remove the piston OCover the caliper opening with a clean heavy cloth A ORemove the piston by lightly applying compressed air B to the hose joint opening AWARNING The piston in the brake caliper can crush hands and fingers Never place your hand or fingers in front of the piston e Pull out the piston A by hand e Remove the dust seal B and fluid seal C PERIODIC MAINTENANCE 2 45 Periodic Maintenance Procedures Caliper Assembly e Clean the caliper parts except for the pads NOTICE For cleaning of the parts use only disc brake fluid isopropyl alcohol or ethyl alcohol If you removed the bleed valve install the bleed valve and rubber cap Torque Caliper Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib e Replace the fluid seal s A with new ones OApply silicone grease to the fluid seal s and install them into the cylinder s by hand e Replace the dust seal s B with new ones OApply brake fluid to the dust seal s and install them into the cylinder s by hand e Apply brake fluid to the outside of the piston s C and push them into each cylinder by hand e Install the anti rattle springs A as shown in the figure 2 46 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Replace the friction boot A and dust boot B
135. Spark Plug Cleaning and Inspection a te Spark Plug Replacement see General Lubrication and Cable Inspection ss Lubrication Cable Inspection Nut Bolt and Fastener Tightness Inspection Tightness Inspection 2 37 2 37 2 38 2 39 2 41 2 41 2 43 2 46 2 46 2 48 2 48 2 48 2 67 2 67 2 73 2 74 2 74 2 74 2 74 2 76 2 76 2 76 2 76 2 76 2 77 2 77 2 77 2 78 2 78 2 78 PERIODIC MAINTENANCE 2 3 Periodic Maintenance Chart The maintenance must be done in accordance with this chartto keep the motorcycle in good running condition FREQUENCY Each Even 3 Every 6 Every 12 See race or races or races or races or page OPERATION 2 5 hr 7 5 hr 9 Spark plug clean and inspect t 2 76 Spark plug replace 2 77 Clutch inspect 2 27 Clutch plates inspect t 2 28 Throttle cable inspect and adjust Air cleaner element clean Air cleaner element replace Throttle body assy inspect and adjust Engine oil change Piston and piston ring replace Cylinder head cylinder inspect Piston pin replace Valve clearance inspect t i N O E N O Oil filter replace Exhaust system inspect Silencer wool change Kick pedal and shift pedal clean Engine sprocket inspect t Coolant level inspect Water hoses and connections inspect t N 1 Crankshaft inspect Breather hose insp
136. Unused Engine Stop Switch Ground for ECU Ground for ECU KDS Kawasaki Diagnostic System FUEL SYSTEM DEI 3 13 DFI Parts Location Kawasaki Diagnostic System Connector 1 ECU 2 Self diagnosis Terminal 3 Orange Launch Control Mode FI Warning Indicator Light LED 4 Water Temperature Sensor 5 Crankshaft Sensor 6 Capacitor 7 Vehicle down Sensor 8 Ignition Coil 9 Intake Air Pressure Sensor 10 Fuel Pump 11 acne P 3 14 FUEL SYSTEM DFI DFI Parts Location Fuel Injector 12 Throttle Sensor 13 Throttle Body Assy 14 Intake Air Temperature Sensor 15 FUEL SYSTEM DFI 3 15 DFI Servicing Precautions DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system OConnect these connectors until they click A ONever any of the DFI electrical connectors are discon nected The ECU memorizes service codes GC170368S1 ODo not spray water on the electrical parts DFI parts con nectors leads and wiring OWhen the fuel hose is disconnected do not start the en gine The fuel pump will operate and fuel will spout from the fuel hose ODo not operate the fuel pump if it is completely dry This is to prevent pump seizure OBefore removing the fuel system parts blow the outer sur faces of these parts clean with compressed air OWhen the fuel hose is disconnected fuel
137. Visually inspect the inside of the cylinder for scratches and abnormal wear x If the cylinder is damaged or badly worn replace it with a new one e Take a side to side and a front to back measurement shown in the figure total 6 measurements OThe cylinder wear is uneven in different places 10 mm 0 39 in A 30 mm 1 2 in B 50 mm 2 0 in C Cylinder Inside Diameter Standard 96 025 96 037 mm 3 7805 3 7810 in and less than 0 01 mm 0 0004 in difference between any two measurements Service Limit 96 12 mm 3 784 in or more than 0 05 mm 0 002 in difference between any two measurements x lf any of the cylinder inside diameter measurements ex ceeds the service limit the cylinder must be replaced with a new one OSince the PLATING cylinder cannot be bored or honed a GS07215BS1 2 26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Piston Cylinder Clearance Inspection The piston cylinder clearance is measured whenever a piston or cylinder is replaced with a new one The standard piston cylinder clearance must be adhered to whenever the cylinder is replaced If only a piston is replaced the clearance may exceed the standard slightly But it must be within the standard in order to avoid piston seizure The most accurate way to find the piston clearance is by making separate piston and cylinder diameter measure ments and then computing the difference betwe
138. ad side of the main harness and main harness Run the engine stop 4 Clamp switch lead over the main harness 5 Run the main harness over the water 11 Water Hoses hose 12 Magneto Lead Connector 6 Gear Position Switch Lead Connector 13 Capacitor Lead Connector 7 Fuel Pump Lead Connector 14 Gear Position Switch Lead 17 10 APPENDIX Cable Wire and Hose Routing KX450FC APPENDIX 17 11 Cable Wire and Hose Routing Viewed A Frame Pipe Upper Side Regulator Rectifier Lead Main Harness Clamp Hold the PVC tube of the regulator rectifier lead and main harness Do not hold the regulator rectifier leads 7 Front Side 8 Viewed B 9 Do not touch the regulator rectifier leads and water hose clamp 10 Viewed C 11 KX Fl Calibration Kit Lead 12 Clamp Hold the main harness 13 Water Hoses 14 Regulator Rectifier 15 KX FI Calibration Kit Lead Connector 16 Ignition Coil 17 Vehicle down Sensor 18 Capacitor 19 Ignition Coil Lead Connector 20 Fuel Pump Lead Connector 21 Regulator Rectifier Lead Connector 22 Engine Stop Switch Lead Connector OnkWN 17 12 APPENDIX Cable Wire and Hose Routing KX450FD GROSOTSE G APPENDIX 17 13 Cable Wire and Hose Routing 1 Water Hoses 2 Clamp 3 Regulator Rectifier 4 Regulator Rectifier Lead 5 KX FI Calibration Kit Lead Connector 6 Ignition Coil 7 Capacitor 8 Ignition Coil Lead Connector 9 Fuel Pump Lead Connector
139. amount of rotating direction will affect the adjustment Ro tate the crankshaft to positive direction clockwise viewed from output side Electrical Leads A two color lead is identified first by the primary color and then the stripe color Unless instructed otherwise electrical leads 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 thor oughly before using the meter Incorrect values may lead to improper adjustments 68020228 S 68020238 S GBO2062BS1 GENERAL INFORMATION 1 7 Model Identification KX450FC Left Side View 200660 P KX450FC Right Side View 2038610 P 1 8 GENERAL INFORMATION General Specifications ltems KX450FC FE Dimensions Overall Length 2 180 mm 85 83 in Overall Width 820 mm 32 3 in Overall Height 1 275 mm 50 20 in Wheelbase 1 480 mm 58 27 in Road Clearance 330 mm 13 0 in Seat Height 955 mm 37 6 in Curb Mass KX450FC 113 kg 249 Ib KX450FD 112 5 kg 248 Ib Front KX450FC 55 kg 121 Ib KX450FD 54 5 kg 120 Ib Rear 58 kg 128 Ib Fuel Tank Capacity 6 2 L 1 6 US gal Engine Type 4 stroke single cylinder DOHC 4valve Cooling System Bore and Stroke Displacement Compression Ratio Fuel System Fuel Type Minimum Octane Rating Research Octane Number RON Antiknock Index RON MON 2 Starting Syste
140. amshafts e Bring the piston to the TDC of the compression stroke OPlace a wrench over the flywheel nut and turn it counter clockwise to align the TDC mark A with the center of the groove B of the inspection hole GE11372BS1 SEI F 5 18 ENGINE TOP END Camshafts e Engage the camshaft chain with the camshaft sprockets OAlign the timing mark on the sprocket with the cylinder head upper surface as shown in the figure OStarting with the timing mark on the front of the exhaust sprocket count to the 1st pin Feed the exhaust camshaft thought the chain and align the 29th pin with the timing mark on the intake camshaft sprocket NOTE OStrain the exhaust side of the chain while installing the camshaft Oln this figure tension is not applied to the chain 6E113738W2 1st Pin A Timing Mark Exhaust D 2nd Pin B Punch Mark Intake E 29th Pin C Cylinder Head Upper Surface F NOTE OAfter the installation of the camshaft cap and chain tensioner confirm the punch mark of the intake camshaft gear aligns with the cylinder head upper surface e Plug the oil passage and camshaft chain tunnel with a clean cloth for prevent the any parts from dropping in the crankcase e Be sure to install the positioning rings A and dowel pins B e Replace the O ring C with a new one and apply grease it Camshafts ENGINE TOP END 5 19 e Apply grease to the rubber por
141. and the rear of the chain slipper as shown in the figure Chain Slack Standard 52 58 mm 2 0 2 3 in x If the drive chain slack exceeds the standard adjust it ae GKO040606S1 GS12041B82 PERIODIC MAINTENANCE 2 35 Periodic Maintenance Procedures Drive Chain Slack Adjustment e Loosen the left and right chain adjuster locknuts A e Remove the cotter pin B and loosen the rear axle nut C x If the chain is too tight back out the left and right chain adjusting bolts D evenly and push the wheel forward until the chain is too loose x If the chain is too loose turn both chain adjusting bolts evenly until the drive chain has the correct amount of slack To keep the chain and wheel properly aligned the notch on the left chain adjuster should align with the same swingarm mark E as the right chain adjuster notch F e Check the wheel alignment see Wheel Alignment Inspec tion in the Final Drive chapter A WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition Be sure the wheel is properly aligned e Tighten both chain adjuster locknuts securely e Tighten Torque Rear Axle Nut 108 N m 11 0 kgf m 79 7 ft lb e Rotate the wheel measure the chain slack again at the tightest position and readjust if necessary e Insert a new cotter pin A NOTE OWhen inserting the cotter pin if the slots in the n
142. ar suspension will slightly affect the rebound damping force Always make any damping adjust ments in small steps and test their effects before using them in competition Spring Preload Adjustment e Remove Seat see Seat Removal in the Frame chapter Side Covers see Side Cover Removal in the Frame chapter Muffler Body see Muffler Body Removal in the Engine Top End chapter Rear Frame see Rear Frame Removal in the Frame chapter 0 Se dg EEN d d GM05495BS1 aa ot GMO5496BS1 Rear Shock Absorber SUSPENSION 13 21 e Using the jack under the frame raise the rear wheel off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Using the hook wrenches A R42 57001 1103 x 2 loosen the locknut B OThe hook wrench R42 57001 1103 is in the hook wrench R37 5 R42 57001 1101 Special Tools Hook Wrench R37 5 R42 57001 1101 x 2 e Using the hook wrench A R42 57001 1103 turn the adjusting nut B as required Turning the adjusting nut downward marks the spring action harder and upward softer Special Tool Hook Wrench R37 5 R42 57001 1101 Spring Preload Adjustment Lower surface of the adjusting nut from the center of the upper mounting hole A Standard 128 5 mm 5 059 in KX450FC EUR BR 127 5 mm 5 020 in KX450FC 127 5 mm 5 020 in KX450FD Adjustable 126 5 138 5 mm 4 980 5 453 in Range e Tight
143. aring boss with a suitable re tainer A e Using a press and the bearing driver set C install a new bearing B until it bottoms out Special Tool Bearing Driver Set 57001 1129 NOTICE Support the crankcase bearing boss when the bear ing is pressed or the crankcase could be damaged e Press the new drive shaft bearing A and output shaft bearing B in the left crankcase half so that the sealed side C faces outside of the engine Special Tool Bearing Driver Set 57001 1129 G104420BS1 CRANKSHAFT TRANSMISSION 9 11 Crankcase e Press the new drive shaft bearing A in the right crankcase half B so that the stepped side C faces inside of the engine Special Tool Bearing Driver Set 57001 1129 e Press the new crankshaft bearings A in the left and right crankcase halves B so that the stepped side C faces inside of the engine Special Tool Bearing Driver Set 57001 1129 e Press the new shift drum needle bearing A and shift shaft needle bearing B in the left crankcase half so that bear ing surface flush with the crankcase surface C Special Tool Bearing Driver Set 57001 1129 e Press the new shift drum bearing A in the right crankcase half so that the sealed side B faces inside of the engine Special Tool Bearing Driver Set 57001 1129 e First press the new inside release shaft needle bearing A until it bottom out with the bearing driver
144. arm pivot shaft B and remove the swingarm C 13 28 SUSPENSION Swingarm e Remove the screws A e Remove the chain slipper B from the swingarm Swingarm Installation e Apply plenty of grease to the inside of the needle bear ings sleeves and grease seals e Apply a non permanent locking agent to the chain slipper mounting screws e Install the chain slipper and tighten the screws e Replace with new ones Swingarm Pivot Shaft Nut Rocker Arm Pivot Nut e Apply grease to the seating surface ofthe rocker arm pivot nut e Install the swingarm e Tighten Torque Swingarm Pivot Shaft Nut 98 N m 10 kgf m 72 ft lb Rocker Arm Pivot Nut 59 N m 6 0 kgf m 44 ft lb e Install the removed parts see appropriate chapters Swingarm Bearing Removal e Remove Swingarm see Swingarm Removal Collars A Grease Seals B Sleeves C Needle Bearings D e Remove the needle bearings E using the oil seal 8 bear ing remover Special Tool Oil Seal amp Bearing Remover 57001 1058 Swingarm Bearing Installation e Replace the needle bearings and grease seals with new ones e Apply plenty of grease to the grease seals and needle bearings A B NOTE Olnstall the needle bearings so that the manufacturer s marks face out Olnstall the grease seals so that the deep groove side of the rip to the needle bearings Special Tool Bearing Driver Set 57001 1129 e Install the needle bearings grease seals C sleeve
145. art the engine and note the voltage readings at various engine speeds But they must be kept the specified volt age Charging Voltage Connections Reading Tester to Tester to Battery Battery DC 14 0 14 5 V e Stop the engine x If the charging voltage is kept between the values given in the table the charging system is considered to be working normally lf the charging voltage is much higher than the values specified in the table the regulator rectifier is defective or the regulator rectifier leads are loose or open x If the charging voltage does not rise as the engine speed increases then the regulator rectifier is defective or the magneto output is insufficient for the loads Check the magneto and regulator rectifier to determine which part is defective Regulator Rectifier Inspection e Remove Regulator Rectifier see Regulator Rectifier Removal e Set the hand tester to the x 1 KQ range and make the measurements shown in the table Special Tool Hand Tester 57001 1394 e Connect the hand tester to the regulator rectifier x lf the tester readings are not as specified replace the regulator rectifier NOTICE Use only Kawasaki Hand Tester 57001 1394 for this test A tester other than the Kawasaki Hand Tester may show different readings If a megger or a meter with a large capacity battery is used the regulator rectifier will be damaged Regulator Rectifier Resi
146. arts Catalog e Follow the procedures in this manual care fully Don t take shortcuts e Remember to keep complete records of main tenance 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 Ta ble of Contents For example if you want stick 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 Stick Coil section Whenever you see symbols heed their in structions Always follow safe operating and maintenance practices A DANGER DANGER indicates a hazardous situa tion which if not avoided will result in death or serious injury A WARNING WARNING indicates a hazardous situa tion which if not avoided could result in death or serious injury NOTICE NOTICE is used to address practices not related to personal injury This manual contains four more symbols which will help you distinguish different types of information NOTE ONOTE indicates information that may help or guide you in the operation or service of the vehicle e Indicates a procedural step or work to be done Olndicate
147. asket B on the adjuster as sembly with new ones and apply specified fork oil to the O ring e Slowly turn the adjuster assembly A clockwise until re sistance is felt and check the clearance between the lock nut B and adjuster assembly for more than 1 mm 0 04 in C 2 56 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Turn the locknut A counterclockwise until it contacts the adjuster assembly B e With the locknut held immovable using a wrench tighten the adjuster assembly to the specified torque Torque Adjuster Assembly Locknut 28 N m 2 9 kgf m 21 ft lb e With the outer tube compressed by hands remove the top plug wrench e Apply a non permanent locking agent to the threads of adjuster assembly e Tighten the adjuster assembly A Torque Adjuster Assembly 55 N m 5 6 kgf m 41 ft lb e Using the top plug wrench remove the fork top plug from the outer tube and slowly slide down the outer tube Special Tool Top Plug Wrench 49 mm 57001 1653 e Pour the specified amount of fork oil A into the outer tube B Suspension Oil KHL15 10 1L 44091 0004 KHL15 10 4L 44091 0013 Outer Tube Oil Amount Standard 335 mL 11 3 US oz EUR BR 345 mL 11 7 US oz Adjustable Range 320 380 mL 10 8 12 8 US oz e Replace the O ring on the cylinder unit with a new one e Raise the outer tube A and temporarily install the fork top plug B to the outer tube with the t
148. at the crankshaft rotates smoothly after as sembling the engine Wheels Tires Air Pressure Inspection Adjustment e Using an air pressure gauge A measure the air pressure when the tires are cold e Adjust the tire air pressure to suit track conditions and rider preference but do not stray too far from the recom mended pressure Track Condition Tire Pressure When the track is wet muddy sandy 80 kPa 0 8 kgficm or slippery reduce the tire pressure to 12 psi increase the tire tread surface on the e ground When the track is pebbly or hard increase the tire pressure to prevent damage or punctures through the tires will skid more easily 100 kPa 1 0 kgf cm 14 psi e Gun P GJ05010381 2 32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Tires Inspection e Remove any imbedded stones or other foreign particles from the tread x Repair or replace with a new one if necessary e Visually inspect the tire for cracks and cuts x Replace the tire if any damage are noticed OSwelling or high spots indicate internal damage requiring tire replacement A WARNING Some replacement tires may adversely affect han dling and cause an accident resulting in serious in jury or death To ensure proper handling and sta bility use only the recommended standard tires for replacement inflated to the standard pressure NOTE OCheck and balance the wheel when
149. ater Water Temperature 14 Temperature Output Voltage ECU sets the water temperature at 80 C Sensor 0 195 4 902 V Crankshaft sensor must Crankshaft send 18 signals output If the crankshaft sensor generates other than 2l Sensor signal to the ECU at 18 signals the engine stops by itself the one cranking Gear Position Gear Position Sensor If the gear position switch fails the ECU sets 23 Switch pue otage the low 1st gear position 0 469 4 727 V Vehicle down Vehicle down Sensor _ If the vehicle down sensor system fails the 31 Sensor Output Voltage ECU shuts off the fuel system and the ignition 0 195 4 609 V system ECU does not backup Rt A If the injector break down wiring short or open 41 Fuel Injector H the ECU stops the signal input to injector and input to ECU A the fuel delivery to cylinder is stopped 46 Fuel Pump Supply Voltage If the pump fails wiring short or open the ECU 6 15V stops the pump operations Send signals output if the ignition coil fails the ECU shuts off the 51 Ignition Coil voltage continuously to signal to the ignition coil the ECU 9 9 Note 1 D J Method The DFI control method from medium to heavy engine load When the engine load is light like at idling or low speed the ECU determines the injection quantity by calculating from the throttle vacuum intake air pressure sensor output voltage and engine speed crankshaft sensor output voltage Thi
150. ature Sensor Bolts 4 15 N m 0 423 kgf m 37 in Ib e Connect the sensor connector e Install the removed parts see appropriate chapters Intake Air Temperature Sensor Output Voltage Inspection NOTE OBe sure the battery is fully charged e Remove the seat see Seat Removal in the Frame chap ter e Disconnect the intake air temperature sensor connector and connect the measuring adapter A between these connectors Main Harness B Intake Air Temperature Sensor C Special Tool Measuring Adapter 57001 1700 e Connect a digital meter D to the measuring adapter leads Intake Air Temperature Sensor Output Voltage Connections to Adapter Digital Meter R sensor LB lead Digital Meter BK sensor GY lead e Refer to the Self diagnosis Procedures connect the 12 V battery to the main harness CAT P GCITEA2O P ent P L SO gt GC17708ES1 3 44 FUEL SYSTEM DFI Intake Air Temperature Sensor Service Code 13 e Measure the output voltage with the engine stopped and the connector joined Output Voltage Standard About DC 2 28 3 43 V at intake air temperature 20 C 68 F NOTE OThe output voltage changes according to the intake air temperature e Disconnect the power supply harness x lf the reading is within the standard check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace
151. ble Inspect see chapter 16 ECU trouble Inspect see chapter 3 16 Intake air pressure sensor trouble Water temperature sensor trouble Inspect see chapter 3 Inspect see chapter 3 Intake air temperature sensor trouble Miscellaneous Throttle valve will not fully open Inspect see chapter 3 Inspect throttle cables and lever linkage see chapter 3 Engine overheating Water temperature sensor see Overheating of Troubleshooting Guide in or crankshaft sensor trouble Exhaust Smokes Excessively chapter 17 Black smokes Air cleaner element clogged Clean element see chapter 3 Fuel pressure too high Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 Water temperature sensor trouble Intake air temperature sensor trouble Inspect see chapter 3 Inspect see chapter 3 Brown smoke Air cleaner housing loose Reinstall see chapter 3 Fuel pressure too low Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Intake air temperature sensor trouble Inspect see chapter 3 Self Diagnosis FUEL SYSTEM DFI 3 25 Self diagnosis Outline The self diagnosis system has three modes and can be switched to another mode by grounding the self diagnosis terminal User Mode The ECU connected orange Fl warning indicator light LED goes on when DF
152. bolts upper A e Turn the handlebar to one side and loosen the fork top plug A Special Tool Top Plug Wrench 49 mm B 57001 1653 e Remove Front Fork see Front Fork Removal in the Suspension chapter PERIODIC MAINTENANCE 2 49 Periodic Maintenance Procedures NOTE OSet rebound and compression damping setting to the softest settings before disassembling to prevent the needle of adjusters from damaging Record the setting before turning the adjuster e Thoroughly clean the fork before disassembly NOTICE Be careful not scratch the inner tube and not to damage the dust seal Avoid scratching or damaging the inner tube or the dust seal Use a mild detergent and sponge out dirt with plenty of water e Using the top plug wrench A remove the fork top plug B from the outer tube C and slowly slide down the outer tube Special Tool Top Plug Wrench 49 mm 57001 1653 e Place an oil pan under the front fork and drain the fork oil A NOTE OPump the fork tube several times to discharge the fork oil e Raise the outer tube and temporarily install the fork top plug A to the outer tube B with the top plug wrench C Special Tool Top Plug Wrench 49 mm 57001 1653 2 50 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Hold the axle holder A with a vise OProtect the axle holder with a soft jaw or heavy cloth when using a vise e Loosen the adjuster assembl
153. by the number of times the orange Fl warning indicator light LED blinks When due to a malfunction the orange Fl warning indica tor light LED remains lit ask the rider about the conditions B under which the problem occurred and try to determine the cause C e First conduct a self diagnosis inspection and then a non self diagnosis inspection The non self diagnosis items are not indicated by the orange Fl warning indicator light LED Don t rely solely on the DFI self diagnosis function use common sense x If the orange Fl warning indicator light LED goes on by kicking the kick pedal about 10 times these parts are bro ken Even when the DFI system is operating normally the or ange Fl warning indicator light LED may light up under strong electrical interference No repair needed When the orange FI warning indicator light LED goes on and the motorcycle is brought in for repair check the service codes When the repair has been done the light doesn t go on But the service codes stored in memory are not erased to preserve the problem history and the light can display the codes in the self diagnosis mode The problem history is referred when solving unstable problems Much of the DFI system troubleshooting work consists of confirming continuity of the wiring The DFI parts are assembled and adjusted with precision and it is impossible to disassemble or repair them GCITS63E 6 Troubleshooting the D
154. cations Item Standard Service Limit Crankshaft Connection Rod Connecting Rod Big End Radial Clearance 0 002 0 014 mm 0 00008 0 00055 in Side Clearance 0 25 0 35 mm Connecting Rod Bend Se Connecting Rod Twist S Transmission 0 0098 0 0138 in Crankshaft Runout TIR 0 03 mm 0 001 in or less 0 06 mm 0 0024 in 0 6 mm 0 02 in TIR 0 08 mm 0 003 in TIR 0 2 mm 0 008 in 100 mm 3 94 in TIR 0 2 mm 0 008 in 100 mm 3 94 in Shift Fork Ear Thickness 4 9 5 0 mm 0 193 0 197 in 4 8 mm 0 189 in Gear Groove Width 5 05 5 15 mm 0 199 0 203 in 5 3 mm 0 209 in Shift Fork Guide Pin Diameter 5 9 6 0 mm 0 232 0 236 in 5 8 mm 0 228 in Shift Drum Groove Width 6 05 6 20 mm 0 238 0 244 in 6 3 mm 0 248 in CRANKSHAFT TRANSMISSION 9 7 Special Tools and Sealant Inside Circlip Pliers Gear Holder m2 0 57001 143 57001 1557 ST570143ST ST571557ST Outside Circlip Pliers Grip 57001 144 57001 1591 ST570144ST ST571591ST Bearing Driver Set Rotor Holder 57001 1129 57001 1730 ST5711298T Crankshaft Jig Liquid Gasket TB1216 57001 1174 92104 1063 gt ST571730ST ST5711748T ST921063ST Crankcase Splitting Tool Assembly 57001 1362 8757136297 9 8 CRANKSHAFT TRANSMISSION Crankcase Crankcase Disassembly e Remove the engin
155. ce chapter BRAKES 12 1 Brakes Table of Contents Exploded MW iia A ert ee eae A ed ae een ALAS 12 2 A de TED 12 6 Special te EE 12 7 Brake Lever Brake Pedalurmnina o a tn Man Nine 12 8 Brake Lever Play AdjUStMe mts icon nd 12 8 Brake Pedal Position Adjustment issues tentent dead 12 8 Brake Pedal Removal see 12 8 Brake Pedal Installation siccsccsnsrm a a aa O eE EE R 12 8 Braker e RE 12 10 Brake Fluid Level Inspection 12 10 Brake Fluid CONAN tratase dador id dla ios 12 10 Brake Lin Bleeding atras dida 12 11 A A 12 13 Caliper Removal viii A AA A A A E RON e 12 13 RE lee GE UE Le RE 12 14 Caliper Disassembly ss cri scare acenensadess cecteedeesedeesesusaceenieereteueninenst 12 14 Fluid Seal Damage Inspection 12 15 Dust Seal Damage Inspection aa liada 12 15 Caliper Dust Boot and Friction Boot Damage Inspection 12 15 Caliper Piston and Cylinder Damage Inspection cocccconnccoconcccncccnonanonancncnnnnnnnnnnnnnnonnno 12 16 Caliper Holder Shaft Wear Inspection 12 16 Blake A tess tts antenne Menaces sont aan E Mont eser sata era nids een n s Brake P d R mo al ln rai A dE te eu a tarte tee Brake Pad Installation Brake Pad Inspection Master Gylinder EE Front Master Cylinder Removal cocida Hahn 12 19 Front Master Cylinder Installation meine dear elotes 12 19 Rear Master Cylinder Removal sis 12 21 Rear Master Cylinder Installation san 12 21 Front Master Cylinder Disassembly
156. ce chapter Valve Clearance Adjustment e Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter Valve Removal e Remove the cylinder head see Cylinder Head Removal e Remove the valve lifter and shim NOTE OMark and record the locations of the valve lifters and shims so that they can be reinstalled in their original positions e Using the valve spring compressor assembly A and adapter B compress the valve spring and then remove the split keepers Special Tools Valve Spring Compressor Assembly 57001 241 Valve Spring Compressor Adapter 24 57001 1586 e Remove Spring Retainer Inner Valve Spring and Outer Valve Spring Valve Oil Seal Spring Seat 158107 P Valves ENGINE TOP END 5 27 Valve Installation NOTICE Do not lap the valve to the valve seat using the grinding compound It will come off oxide film treated surface of the valve e Visually inspect the valve surface x If the surface is damaged replace the valve e Replace the oil seal A with a new one e Apply a thin coat of molybdenum disulfide grease to the valve stem B and install the valve e Check to make sure that the valve moves up and down smoothly e Check to make sure that the valve and valve seat are making proper contact e Install Oil Seal Spring Seat C e Install the inner valve spring D and outer valve spring E so that the closed coil end faces the spring seat OTurn the painted si
157. ch the crankcase splitting tool B to the left crankcase half Special Tool Crankcase Splitting Tool Assembly 57001 1362 OTighten the center bolt of the crankcase splitting tool to split the crankcase halves e Remove Oil Screen Feed A see Oil Screen Feed Removal in the Engine Lubrication System chapter Shift Rods B see Transmission Shaft Removal Shift Forks C see Transmission Shaft Removal Shift Drum D see Transmission Shaft Removal Transmission Shafts E see Transmission Shaft Re moval Crankshaft F see Crankshaft Removal 9 10 CRANKSHAFT TRANSMISSION Crankcase NOTICE Do not remove the bearings and the oil seals unless it is necessary Removal may damage them Crankcase Assembly NOTICE Right and left crankcase halves are machined at the factory in the assembled state so if replaced they must be replaced as a set e Remove the old gasket from the mating surfaces of the crankcase halves and clean them off with a high flash point solvent e Using compressed air blow out the oil passages in the crankcase halves A WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the engine parts in a well ventilated area and take care that there is no spark or flame anywhere near the working areas Do not use gasoline or low flash point solvents to clean parts e Support the crankcase be
158. chain guide is bottomed the camshaft chain could push the cylinder head cover upward leading to an oil leak e Install the cylinder head cover Cylinder Head Cover ENGINE TOP END 5 13 e Install the cylinder head cover bolt washers with the metal side A upwards e Tighten Torque Cylinder Head Cover Bolts B 9 8 N m 1 0 kgf m 87 in lb e Install the spark plug cap A so that it is aligned with the line B on the cylinder head cover OPull up the spark plug cap lightly to make sure of the in stallation of the spark plug cap 5 14 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal NOTICE This is a non return type camshaft chain tensioner The push rod does not return to its original position once it moves out to take up camshaft chain slack Observe all the rules listed below When removing the tensioner do not take out the mounting bolts only halfway Retightening the mounting bolts from this position could damage the tensioner and the camshaft chain Once the bolts are loosened the tensioner must be removed and reset as described in Camshaft Chain Ten sioner Installation Do not turn over the crankshaft while the tensioner is removed This could upset the camshaft chain timing and damage the valves e Loosen the cap bolt A e Remove the mounting bolts B and take off the camshaft chain tensioner body C Camshaft Chain T
159. chanism e Before installing the shift shaft apply grease to the oil seal lips and shift shaft splines e Insert the shift shaft A OTake care not to damage the oil seal when inserting the shift shaft e Install the removed parts see appropriate chapters External Shift Mechanism Inspection e Remove the shift shaft see External Shift Mechanism Re moval e Check the shift shaft A for bending or damage to the splines x If the shaft is bent straighten or replace it If the splines are damaged replace the shift shaft e Check the return spring B for cracks or distortion x lf the spring is damaged in any way replace it e Check the shift lever C for distortion x If the shift lever is damaged in any way replace the shift shaft e Check the shift ratchet assembly for any damage x lf the ratchet A pawls B pins C or springs D are damaged in any way replace them e Visually inspect the shift drum cam A If it is badly worn or if it shows any damage replace it e Check the gear positioning lever A and its spring B for breaks or distortion x If the lever or spring is damaged in any way replace them 6116629 P G116029BS1 G116056BS1 9 30 CRANKSHAFT TRANSMISSION Kickstarter Kick Pedal Assy Removal s J e Remove Kick Pedal Bolt A and Washer Kick Pedal Assy B Kick Pedal Assy Installation e Install the kick pedal assy OPut the pedal e
160. city 0 96 L 1 01 US qt when filter is not 4 14 32 50 68 86 104 removed __ A 6S09013BS1 0 98 L 1 04 US qt when filter is removed 1 20 L 1 27 US qt when engine is completely dry NOTE ODo not add any chemical additive to the oil Oils fulfilling the above requirements are fully formulated and provide adequate lubrication for both the engine and the clutch OThe oil viscosity may need to be changed to accommo date atmospheric conditions in your riding area e Check the oil level see Oil Level Inspection in the Engine Lubrication System chapter e Replace the oil filler plug O ring with a new one e Apply grease to the O ring e Tighten Special Tool Filler Cap Driver 57001 1454 Torque Oil Filler Plug 3 5 N m 0 36 kgf m 31 in Ib 2 30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Oil Filter Change e Drain Engine Oil see Engine Oil Change e Remove Oil Filter Cap Bolts A Oil Filter Cap B e Remove the oil filter A e Install the spring A e Replace the oil filter with a new one e Apply grease to the grommet A e Install the oil filter to the oil filter cap B so that grommet faces oil filter cap NOTICE Inside out installation stop oil flow causing engine seizure e Replace the oil filter cap O rings A with new ones e Apply grease to the O rings e Install Oil Filter Cap B e Tighten Torque Oil Filter Cap Bolts 9 8 N m 1 0 kgf
161. ck the con tinuity between the end E and the ground F This en ables to check a long harness for continuity If the harness is open repair or replace the harness OWhen checking a harness A for short circuit open one end B and check the continuity between the other end C and ground D If there is continuity the harness has a short circuit to ground and it must be repaired or re placed e Narrow down suspicious locations by repeating the con tinuity tests from the ECU connectors If no abnormality is found in the wiring or connectors the DFI parts are the next likely suspects Check the part starting with input and output voltages However there is no way to check the ECU itself If an abnormality is found replace the affected DFI part If no abnormality is found in the wiring connectors and DFI parts replace the ECU GC17964ES1 6017029281 FUEL SYSTEM DEI 3 19 Troubleshooting the DFI System DFI Diagnosis Flow Chart Problem occurs Confirm problems Gather information from rider Connect the power supply harness option and the 12 V battery to the capacitor lead connector and the state of the orange FI warning indicator light LED is seen Goes on for 2 seconds and then goes off Inspect the orange Fl Goes off for 3 seconds warning indicator light and then goes on LED or harness Kick the kick pedal about 10 times 1 Conduc
162. curate 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 torque for the major bolts and nuts and the parts requiring use of a non permanent locking agent or silicone grease etc When checking the tightening torque 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 G Apply grease L Apply a non permanent locking agent Lh Left hand Threads MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts S Follow the specified tightening sequence Si Apply silicone grease ex PBC grease Fuel System DFI Throttle Pulley Cover Bolts 3 4 0 35 30 in lb Throttle Cable Mounting Bolts 3 5 0 36 31 in lb Air Cleaner Duct Mounting Bolt 3 0 0 31 27 in lb Air Cleaner Duct Mounting Nuts 3 0 0 31 27 in lb Air Cleaner Housing Bolts 9 8 1 0 87 in lb Air Cleaner Duct Clamp Screw 2 0 0 20 18 in lb Intake Air Temperature Sensor Bolts 4 15 0 423 37 in lb L Air Cleaner Element Wing Bolt See Fuel Pump Bolts 9 8 1 0 87 in lb L S Water Temperature Sensor 12 1 2 106 in lb Gear Position Switch Screws 2 9 0 30 26 in lb L Cooling System Water Pump Cover Bo
163. d remove the flywheel nut B Special Tools Grip C 57001 1591 Rotor Holder 57001 1730 e Remove the rotor holder e Install the flywheel puller A to the flywheel e Install the rotor puller B to the flywheel puller e Remove the flywheel from the crankshaft by turning in the rotor puller and tapping the head of the puller lightly with a hammer while holding the puller body steady There is a woodruff key in the crankshaft tapered portion Special Tools Rotor Puller M16 M18 M20 M22 x 1 5 57001 1216 Flywheel Puller M28 x 1 0 57001 1471 NOTICE Never strike the grab bar orthe flywheel itself Strik ing the bar can bond it If the flywheel is struck the magnets may lose their magnetism e Remove Woodruff Key emana P 16 14 ELECTRICAL SYSTEM Flywheel Magneto Flywheel Installation e Using a high flash point solvent clean off any oil or dirt on the following portions and dry them with a clean cloth Crankshaft Tapered Portion A Flywheel Tapered Portion B e Fit the woodruff key C securely in the slot of the crank shaft e Install the flywheel according to the following procedures NOTE OConfirm the flywheel fit or not to the crankshaft before tightening it with specified torque Olnstall the flywheel OHold the flywheel steady with the rotor holder and tighten the flywheel nut with 55 N m 5 6 kgf m 41 ft lb of torque Special Tools Grip 57001 1
164. d see Clutch Cable Removal in the Clutch chapter Rear Master Cylinder Mounting Bolts see Rear Master Cylinder Removal in the Brakes chapter Brake Pedal Bolt and Return Spring see Brake Pedal Removal in the Brakes chapter 8 6 ENGINE REMOVAL INSTALLATION Engine Removal Installation e Disconnect Water Temperature Sensor Connector see Water Tem perature Sensor Removal Installation in the Fuel System DFI chapter Gear Position Switch Lead Connector A Magneto Lead Connector B e Remove Water Hoses A e Remove the following parts on both sides Upper Engine Mounting Bolt A and Nut Upper Engine Bracket Bolts B Upper Engine Bracket C e Remove Middle Engine Bracket Bolts A and Nuts Middle Engine Mounting Bolt B and Nut Middle Engine Bracket C Both Sides Lower Engine Mounting Bolt D and Nut e Remove Swingarm Pivot Shaft Nut A and Washer Swingarm Pivot Shaft e Remove the engine from the motorcycle to right side OClear the engine rear portion from the swingarm and then remove the engine ENGINE REMOVAL INSTALLATION 8 7 Engine Removal Installation Engine Installation e Replace with new ones Upper Engine Mounting Nuts Middle Engine Mounting Nut Middle Engine Bracket Nuts Lower Engine Mounting Nut Swingarm Pivot Shaft Nut e Install the engine OFirst insert the front portion of the engine from the right side and then install the rear portion OSecond fit the rear portion of the
165. d as well Friction Plate Clutch Housing Clearance Inspection e Measure the clearance A between the tangs B on the friction plate and the fingers C of the clutch housing x lf this clearance is excessive the clutch will be noisy x If the clearance exceeds the service limit replace the fric tion plates Friction Plate Clutch Housing Clearance Standard 0 20 0 60 mm 0 008 0 024 in Service Limit 0 8 mm 0 04 in Clutch Hub Spline Damage Inspection e Visually inspect the areas of the clutch hub splines that come in contact with the teeth of the steel plates x If there are notches worn into the clutch hub splines A replace the clutch hub Replace the steel plates if their teeth are damaged as well GFO6O0303S1 GRO5038BS1 GRO5033BS1 ENGINE LUBRICATION SYSTEM 7 1 Engine Lubrication System Table of Contents E olle to Ee WE 7 2 Cubricati n System Chasis a Aira 7 4 Specifications mien nn AS net dr e a A ai 7 6 Special Lee EE 7 7 Engine Oil and OIlPiler tanins tete An one net ube tarte siria 7 8 Engine Oil Level Inspection e aaa 7 8 Engine ON Gg g Bem re a re ear aed ne in de die ia A L 7 8 Oil Filter Replacement eee 7 9 Oil Screen Scav nge REMOVAL te 7 9 Oil Screen Scavenge Installation 7 9 Oil Screen Feed Removal 2ceceavautindd cient Aa Aes 7 9 Oil Screen Feed Install sen neue Mat ee sr nd ie dede sind tete 7 9 Oil Sc
166. d is out of the specified range adjust it see Idle Speed Adjustment in the Periodic Maintenance chapter GC17996ES1 GC17994ES1 Throttle Sensor Service Code 11 FUEL SYSTEM DFI 3 35 e Measure the output voltage with the engine stopped and with the connector joined e Refer to the Self diagnosis Procedures connect the 12 V battery to the main harness Output Voltage Standard DC 0 58 0 62 V at idle throttle opening DC 3 68 3 88 V at full throttle opening for reference NOTE OOpen the throttle confirm the output voltage will be rise OThe standard voltage refers to the value when the volt age reading at the Input Voltage Inspection shows 5 V exactly OWhen the input voltage reading shows other than 5 V derive a voltage range as follows Example In the case of a input voltage of 4 75 V 0 58 x 4 75 5 00 0 55 V 0 62 x 4 75 5 00 0 59 V Thus the valid range is 0 55 0 59 V e Disconnect the power supply harness x If the reading is out of the standard check the throttle sen sor resistance see Throttle Sensor Resistance Inspec tion x If the reading is within the standard remove the ECU and check the wiring for continuity between the main harness connectors ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Throttle Sensor Connector B YIG lead C ECU terminal 5 Y G lead GY lead D
167. dal see Brake Pedal Installation in the Brakes chapter Kick Pedal see Kick Pedal Installation in the Crank shaft Transmission chapter e Pour Engine Oil see Engine Oil Change in the Periodic Main tenance chapter Coolant see Coolant Filling in the Cooling System chap ter e Check the rear brake effectiveness see Brakes section in the Periodic Maintenance chapter Right Engine Cover Assembly e Refer to the Oil Seal and Bearing Installation in the Cool ing System chapter for water pump oil seals and bearings installation e Replace the removed oil seal and circlip with new ones e Press the crankshaft oil seal A until it bottomed as shown in the figure Special Tool Bearing Driver Set 57001 1129 e Install the circlip B Special Tool Inside Circlip Pliers 57001 143 e Press the kick shaft oil seal A so that the bearing surface flush with the right engine cover surface B Special Tool Bearing Driver Set 57001 1129 e Apply grease to the oil seal lips GFO5070BS1 GFO5071BS1 6 12 CLUTCH Clutch Clutch Removal e Drain the engine oil see Engine Oil Change in the Peri odic Maintenance chapter e Remove Clutch Cover see Clutch Cover Removal Clutch Spring Bolts A Clutch Springs Clutch Spring Plate B e Remove Washer A Needle Bearing B Push Rod Holder C Push Rod Friction Plates D Steel Plates E NOTE OThe two plates at both ends are di
168. de of the valve spring to the spring retainer F Exhaust Red Paint Intake Pink Paint e Install the spring retainer e Compress the valve spring to install the split keepers G in order to secure the spring retainer in place Special Tools Valve Spring Compressor Assembly 57001 241 Valve Spring Compressor Adapter 24 57001 1586 e Install the shim to original position OThe shim H must be installed with its thickness indication facing up towards the retainer e Apply engine oil to the valve lifter I surface and install the lifter Valve Guide Removal e Remove Valve see Valve Removal Oil Seal Spring Seat e Heat the area around the valve guide up to 120 150 C 248 302 F NOTICE Do not heat the cylinder head with a torch This will warp the cylinder head Soak the cylinder head in oil and heat the oil LPs D GE15240BS2 5 28 ENGINE TOP END Valves e Hammer lightly on the valve guide arbor A to remove the guide Special Tool Valve Guide Arbor 5 5 57001 1021 Valve Guide Installation e Apply a thin coat of engine oil to the outer surface of the valve guide e Heat the area around the valve guide up to 120 150 C 248 302 F NOTICE Do not heat the cylinder head with a torch This will warp the cylinder head Soak the cylinder head in oil and heat the oil e Assemble the valve guide driver A and valve guide driver attachment G B e Using the
169. der head warped ORefer to the Fuel System DFI chapter for Valve spring broken or weak most of DFI trouble shooting guide Valve not seating properly valve bent de OThis is not an exhaustive list giving every formed worn or carbon accumulation on possible cause for each problem listed It the seating surface is meant simply as a rough guide to assist Decompression trouble the troubleshooting for some of the more common difficulties Engine Doesn t Start Starting Spark weak Difficulty Spark plug dirty broken or gap malad Engine won t turn over justed Poor Running at Low Speed Valve seizure Valve lifter seizure Cylinder piston seizure Crankshaft seizure Connecting rod small end big end seizure Transmission gear or bearing seizure Camshaft seizure Kick shaft return spring broken Kick ratchet gear not engaging Balancer bearing seizure No fuel flow No fuel in fuel tank Fuel tank cap air vent obstructed Fuel line clogged Fuel filter clogged Engine flooded Clean spark plug and adjust plug gap Starting technique faulty When flooded do not crank the engine with the throttle fully opened This promotes engine flood because more fuel is supplied automatically by DFI No spark spark weak Spark plug dirty broken or gap malad justed Spark plug cap or spark plug lead trouble Spark plug cap shorted or not in good con tact Spark plug incorrect heat value ECU trouble Crankshaft se
170. dicates a short necessitating stator replacement x lf the stator coil has normal resistance but the voltage check showed the magneto to be defective then the fly wheel have probably weakened and the flywheel must be replaced 16 18 ELECTRICAL SYSTEM Charging System Regulator Rectifier Removal e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter e Open the clamp A and free the leads e Disconnect the regulator rectifier lead connector B e Remove Regulator Rectifier Bracket Bolts A Regulator Rectifier Nuts B Regulator Rectifier C Bracket D Regulator Rectifier Installation e Replace the regulator rectifier nuts A with new ones e Assemble Bracket B Regulator Rectifier C e Tighten Torque Regulator Rectifier Nuts 10 N m 1 0 kgf m 89 in 1b e Tighten the regulator rectifier bracket bolts D e Run the regulator rectifier lead according to the Cable Wire and Hose Routing section in the Appendix chapter e Connect the regulator rectifier lead connector e Install the fuel tank see Fuel Tank Installation in the Fuel System DFI chapter Regulator Rectifier Output Voltage Inspection NOTE OBe sure the prepared battery is fully charged ELECTRICAL SYSTEM 16 19 Charging System e Connect the 12 V battery to the main harness see Self diagnosis Procedures in the Fuel System DFI chapter e Connect a tester A to the battery terminals B e St
171. dle unless removal is FEEN absolutely necessary Replace with new ones whenever ks ay removed Press bearings with the manufacturer and size KA S E e A marks facing out Press the bearing into place by putting lt J b y pressure on the correct bearing race as shown eT aa Pressing the incorrect race can cause pressure between e the inner and outer race and result in bearing damage E i aon E D 602018 Oil Seal Grease Seal Do not remove pressed oil or grease seals unless removal is necessary Replace with new ones whenever removed d L CES Press new oil seals with manufacture and size marks facing NM x ep kee out Make sure the seal is aligned properly when installing 602018 Apply specified grease to the lip of seal before installing the seal Grease 6B02046BS1 Circlips Cotter Pins Replace circlips or cotter pins that were removed with new ones Take care not to open the clip excessively when in stalling to prevent deformation GB02026B S Lubrication It is important to lubricate rotating or sliding parts during on E assembly to minimize wear during initial operation Lubri ET on d cation points are called out throughout this manual apply NAS A IA the specific oil or grease as specified 7 4 j 68020218 1 6 GENERAL INFORMATION Before Servicing Direction of Engine Rotation When rotating the crankshaft by hand the free play
172. e Nut Bolt and Fastener Tightness Inspection Tightness Inspection e Check the tightness of the bolts and nuts listed here in accordance with the Periodic Maintenance Chart Also check to see that each cotter pin is in place and in good condition NOTE OFor the engine fasteners check the tightness of them when the engine is cold at room temperature 6004011481 6004020152 C PERIODIC MAINTENANCE 2 79 Periodic Maintenance Procedures x lf there are loose fasteners retighten them to the spec ified torque following the specified tightening sequence Refer to the Torque and Locking Agent section in this chapter for torque specifications For each fastener first loosen it by 1 2 turn then tighten it x If cotter pins are damaged replace them with new ones Nut Bolt and Fastener to be checked Wheels Spoke Nipples Front Axle Nut Front Axle Clamp Bolts Rear Axle Nut Cotter Pin Rear Axle Nut Final Drive Chain Adjuster Locknut Rear Sprocket Nuts Brakes Front Master Cylinder Clamp Bolts Brake Lever Pivot Bolt Locknut Front Caliper Mounting Bolts Brake Pedal Bolt Rear Master Cylinder Push Rod Cotter Pin Rear Master Cylinder Mounting Bolts Rear Caliper Holder Shaft Suspension Front Fork Clamp Bolts Rear Shock Absorber Nuts Swingarm Pivot Shaft Nut Uni Trak Link Nuts Steering Steering Stem Head Nut Handlebar Clamp Bolts Engine Throttle Cable Adjuster Locknut s Engine Mo
173. e Table of Contents Exploded Vi Wisin A raed Reaves hee See een eae 15 2 el a e a a E e Een 15 4 Frame Inspection asian da 15 4 Rear Frame Removal erransa n a A sn re TR dE d nk Saunt Samanta shated 15 4 Rear Frame Installation SE Age 15 4 Engine Guardas Removal EE 15 5 Engine Guards Installation a ica 15 5 li ee TAT 15 6 ee l i ne E IEN 15 6 seat Installation A A A A A A ee eS 15 6 SIL EE 15 7 elle eene CIE 15 7 Side Cover Installation oonnonncnnnnninnnccnnnccnnnnccnnnccnnnananonancn anno nan nono n rca nara n nana narnia nana nan 15 7 Radiator Shroud Loi A EE ee Eet EE 15 8 Radiator Shroud R moval sus loci tl lira dat ita lada 15 8 Radiator Shroud InstallatioN oooonnconnccccnncccnnnnnnncnnnncnana nano nano noncnnn nono nonccnonannnncnn nana 15 8 Number Plate css A a A Soli Sal A nn Man Ar Ne 15 9 Number Plate Removal iii 15 9 Number Plate Installation niaan dr ann nent mi bats eden dba 15 9 EAN A ia 15 10 Front Fender Removal lnstallation naci nana no nano nonannn nana nana nano 15 10 Rear Fender Removal lnstallation nana no nanc na nnnnoncc nono nn nn aran 15 10 Rear Flap Removal Installation nnn nnne n nnen nn ennenen nnee 15 10 eege CH 15 11 Fo tpeg ROMA ae 15 11 eelef Be E DU 15 11 Footpeg Height Adjustment se seis shard is distinta betas 15 12 15 2 FRAME Exploded View 6002582845 C FRAME 15 3 Exploded View Fa
174. e disassemble the caliper before brake hose removal see Brake Caliper Fluid Seal and Dust Seal Replacement in the Periodic Main tenance chapter e Remove Caliper Mounting Bolts D Banjo Bolt Caliper NOTICE Immediately wipe up any brake fluid that is spilled Rear Brake e Remove Caliper Guard Bolts A Caliper Guard B Disc Guard Bolts C Disc Guard D e Remove the pad pin plug A and loosen the pad pin B if the caliper C is to be disassembled e Loosen the banjo bolt D so as not to spill brake fluid NOTE Olf the caliper is to be disassembled after removal and compressed air is not available disassemble the caliper before brake hose removal see Brake Caliper Fluid Seal and Dust Seal Replacement in the Periodic Main tenance chapter e Remove Rear Wheel see Rear Wheel Removal in the Wheels Tires chapter Banjo Bolt Caliper NOTICE Immediately wipe up any brake fluid that is spilled 12 14 BRAKES Caliper Caliper Installation e Install the brake pad if it was removed see Brake Pad Installation Front Brake e Install the caliper and tighten the bolts Torque Front Caliper Mounting Bolts 25 N m 2 5 kgf m 18 ft lb Rear Brake e Install the rear wheel and caliper see Rear Wheel Instal lation in the Wheels Tires chapter e Install the brake hose lower end OReplace the washers A on each side of hose fitting B with new ones e Tighten Torque Brake Hose Banjo Bol
175. e Coolant Draining e Loosen the clamp screw A and disconnect the water hose B from the water pump cover e Remove the cover bolts C e Using the pry points A remove the pump cover B Water Pump Cover Installation e Replace the pump cover gasket A with a new one e Check to see that the dowel pins B are in place in the mating surface of the right engine cover e Install the water pump cover A e Replace the drain bolt gasket with a new one e Tighten Torque Water Pump Cover Bolts B 9 8 N m 1 0 kgf m 87 in lb Coolant Drain Bolt C 7 0 N m 0 71 kgf m 62 in Ib e Insert the water hose D into the water pump cover e Tighten Torque Water Hose Clamp Screw E 3 0 N m 0 31 kgf m 27 in lb e Fill the coolant see Coolant Filling e Bleed the air from the coolfing system see Air Bleeding Got P 4 10 COOLING SYSTEM Water Pump Impeller Removal e Remove Water Pump Cover see Water Pump Cover Removal Impeller Bolt A Impeller B Impeller Installation e Install Impeller A e Tighten Torque Water Pump Impeller Bolt B 9 8 N m 1 0 kgf m 87 in lb e Install Water Pump Cover see Water Pump Cover Installation Water Pump Inspection e Visually check the impeller A x If the surface is corroded or if the blades B are dam aged replace the impeller e Check the drainage outlet passage A at the bottom of the right engine cover for coolant leaks x If
176. e Install the radiator shrouds Olnsert the tabs A of the radiator shroud into the slots B of the air cleaner housing e Temporarily install the bolts as shown sequence 1 4 L 13 mm 0 51 in 1 3 L 20 mm 0 79 in 4 e Tighten Torque Radiator Shroud Bolts 9 8 Nm 1 0 kgf m 87 in 1b Number Plate FRAME 15 9 Number Plate Removal e Unlock the band A of the number plate B e Remove the bolt C e Clear the projections D and remove the number plate Number Plate Installation KX450FC e Insert the projections A of the number plate into the holes B of the steering stem base ORun the brake hose through the front of the number plate e Install the band to the handlebar pad and tighten the bolt KX450FD e Fit the holes A of the number plate and projections B of the steering stem base ORun the brake hose through the front of the number plate e Install the band to the handlebar pad and tighten the bolt 15 10 FRAME Fender Front Fender Removal Installation e Remove the bolts A and take off the front fender e Installation is the reverse of removal Rear Fender Removal Installation e Remove the side covers see Side Cover Removal e Remove the bolts A e Remove the bolt A on both sides and take off the rear fender B e When installing the pad A align the edge of the pad with the line B of the rear fender Other than KX450FC and KX4
177. e Pad Removal Front Brake e Loosen the pad pin A e Remove the bolts B e Remove the caliper with the hose installed e Remove Pad Pin A Brake Pads B Rear Brake e Remove Pad Pin Plug A e Remove the pad pin A e Remove the piston side pad B e Push the caliper holder toward the piston and then re move another pad C 12 18 BRAKES Brake Pad Brake Pad Installation e Push the caliper piston s in by hand as far as they will go e Install the piston side pad first and then another pad OFit the pad end into the groove A of the anti rattle spring securely Front Brake B Rear Brake C e Install the front caliper and tighten the bolts Torque Front Caliper Mounting Bolts 25 N m 2 5 kgf m 18 ft lb e Tighten the brake pad pin Torque Brake Pad Pin 17 N m 1 7 kgf m 13 ft lb Rear Brake Pad Pin Plug 2 5 N m 0 25 kgf m 22 in 1b e Check the brake for good braking power no brake drag and no fluid leakage WARNING After servicing it takes several applications of the brake lever or pedal before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the motorcycle until a firm brake lever or pedal is obtained by pumping the lever or pedal until the pads are against the disc Brake Pad Inspection e Refer to the Brake Pad Wear Inspection in the Periodic
178. e Remove the number plate see Number Plate Removal in the Frame chapter e Slide the dust cover A e Loosen the locknut B at the clutch cable and turn the adjusting nut C so that clutch lever has 8 13 mm 0 3 0 5 in of play e Tighten the locknut and start the engine and check that the clutch does not slip and that it release properly Clutch Plates Inspection e Remove the clutch plates see Clutch Removal in the Clutch chapter e Visually inspect the friction and steel plates to see if they show signs of seizure uneven wear or any other damage If any plates show signs of damage replace the friction plates and steel plates as a set e Measure the thickness A of the friction and at several points with vernier calipers Friction Plate Thickness Standard 2 92 3 08 mm 0 115 0 121 in Service Limit 2 7 mm 0 11 in x If they have worn past the service limit replace them with new ones e Place each friction plate or steel plate on a surface plate Al eae the gap between the surface plate and each fric tion plate or steel plate B with a thickness gauge C The gap is the amount of friction or steel plate warp Friction and Steel Plates Warp Standard Friction Plate 0 15 mm 0 0059 in or less Steel Plate 0 20 mm 0 0079 in or less Service Limit Friction Plate 0 3 mm 0 012 in Steel Plate 0 3 mm 0 012 in x If any plate is warped over the service limit replace it with a new one
179. e Speed see Idle Speed Adjustment in the Periodic Maintenance chapter e Check the brake effectiveness A WARNING After servicing it takes several applications of the brake lever before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the motorcycle until a firm brake lever is obtained by pumping the lever until the pads are against the disc CRANKSHAFT TRANSMISSION 9 1 Crankshaft Transmission Table of Contents Exploded WEE EE 9 2 leede iii AA A AA E A Ai 9 6 Special Tools and Sealant ccc ccccccecccecceecceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeeeeeeeeeeeeeseeees 9 7 Elle 9 8 Crankcase DISASSemibl EE 9 8 Crankease e EE 9 10 Crank ET 9 17 Crankshaft Removal see 9 17 CrankshaftInstalation ET 9 17 Crankshaft Disassembly oi aa 9 17 Crankshaft ASSCMDIY routes 9 17 Crankshaft Inspection see 9 18 Connecting Rod Bender t tanie o a 9 19 Connecting Rod Twist Inspeccion diia 9 20 TRANSMISSION A AA AA ne A AA A A a a 9 21 Transmission Shaft Removal ses 9 21 Transmission Shaft Installation ses 9 21 Transmission Shaft Disassembly cocos tia 9 21 Transmission Shaft Assembly dadeh ses dEEEdEeEAR Ee ee Dee tetes es 9 22 Shift Fork Bending INSpectioN EE 9 24 Shift Fork Gear Groove Wear Inspection 9 24 Shift Fork Guide Pin Shift Drum Groove Wear Inspection
180. e all parts are good condition replace the ECU DFI Setting Data Selection Connector Inspection NOTE ORefer to the Technical Information DFI Setting Data Se lection in the General Information chapter for the details of the DFI Setting Data Selection White Connector A for Soft Track Condition Green Connector B for Standard Black Connector C for Hard Track Condition A L V y A B C o P 16 30 ELECTRICAL SYSTEM Ignition System e Check the wiring for continuity between the terminals of each connector referring the connector circuit White Connector A Green Connector B Black Connector C x If a digital meter D does not read 0 Q the connector is defective Replace the connector with a new one GP10719BS2 ELECTRICAL SYSTEM 16 31 Switches Engine Stop Switch Inspection e Using a digital meter check to see that the connections shown in the table have continuity about zero ohms x If the switch has an open or short replace it with a new one Engine Stop Switch Connection BK W BK Push Oo po Launch Control Mode Button Inspection e Using a digital meter check to see that the connections shown in the table have continuity about zero ohms x If the switch has an open or short replace it with a new one Launch Control Mode Button Connection BK W Gear Position Switch Removal e Refer to the Gear Position Switch Removal
181. e common difficulties in DFI system OThe ECU may be involved in the DFI electrical and ignition system troubles If these parts and circuits are checked out good be sure to check the ECU for ground and power supply If the ground and power supply are checked good replace the ECU Engine Won t Turn Over Symptoms or Possible Causes Actions chapter Gear position switch trouble Inspect see chapter 3 Vehicle down sensor OFF Reinstall see chapter 3 Crankshaft sensor trouble Inspect see chapter 16 Ignition coil shorted or not in good contact Inspect or Reinstall see chapter 16 Ignition coil trouble Inspect see chapter 16 Spark plug dirty broken or gap maladjusted Inspect and replace see chapter 2 Spark plug incorrect Replace it with correct plug See chapter 2 ECU ground and power supply trouble Inspect see chapter 3 ECU trouble Inspect see chapter 3 16 No or little fuel in tank Supply fuel See Owner s Manual Fuel Injector trouble Inspect and replace see chapter 3 Fuel pump not operating Inspect see chapter 3 Fuel filter or pump screen clogged Inspect and replace fuel pump see chapter 3 Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump see chapter 3 Fuel line clogged Inspect and repair see chapter 3 Poor Running at Low Speed Symptoms or Possible Causes Actions chapter Spark weak a A Fueliair mixture incorrect Little
182. e from the frame see Engine Removal in the Engine Removal Installation chapter e Set the engine on clean surface while parts are being re moved e Remove Piston see Piston Removal in the Engine Top End chap ter Right Engine Cover see Right Engine Cover Removal in the Clutch chapter Clutch see Clutch Removal in the Clutch chapter Primary Gear see Primary Gear Removal Balancer see Balancer Removal Oil Pumps see Oil Pump Scavenge Feed Removal in the Engine Lubrication System chapter Kick Shaft Assembly see Kick Shaft Removal Kick Shaft Idle Gear see Idle Gear Removal External Shift Mechanism see External Shift Mecha nism Removal Flywheel see Flywheel Removal in the Electrical Sys tem chapter Gear Position Switch see Gear Position Switch Re moval in the Fuel System DFI chapter e Remove the output shaft collar A and the O ring B ODo not reuse the O ring e Remove Circlip A Special Tool Outside Circlip Pliers 57001 144 EU SSP CRANKSHAFT TRANSMISSION 9 9 Crankcase e Remove Circlip A Balancer Drive Gear B Special Tool Outside Circlip Pliers 57001 144 e Remove the crankcase bolts A e Insert a suitable tool to the pry point A and split the crankcase x If the crankcase cannot be split easily split the crankcase according to the following procedures Olnstall the jig A between the crankshaft flywheels Special Tool Crankshaft Jig 57001 1174 OAtta
183. e fuel tank If the fuel pump is driven without fuel it may be damaged e Measure the discharge for 5 seconds ORepeat this operation several times Amount of Fuel Flow Standard 40 mL 1 4 US oz or more for 5 seconds x If the fuel flow is much less than the specified replace the fuel pump see Fuel Pump Removal Installation e Install the fuel tank see Fuel Tank Installation e Start the engine and check for fuel leakage 3 72 FUEL SYSTEM DFI Throttle Grip and Cable If the throttle grip has excessive free play due to cable stretch or misadjustment there will be a delay in throttle re sponse Also the throttle valve may not open fully at full throttle On the other hana if the throttle grip has no play the throttle will be hard to control and the idle speed will be erratic Check the throttle grip play periodically in accor dance with the Periodic Maintenance Chart and adjust the play if necessary The throttle cable routing is shown in Cable Wire and Hose Routing section in the Appendix chapter Throttle Grip Throttle Cable Free Play Inspection e Refer to the Throttle Grip Free Play Inspection in the Pe riodic Maintenance chapter Throttle Grip Throttle Cable Free Play Adjustment e Refer to the Throttle Grip Free Play Adjustment in the Periodic Maintenance chapter Throttle Cable Replacement e Remove the front master cylinder see Front Master Cylin der Removal in the Brakes chapter e Slide o
184. e number changes from one machine to another NX Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Motorcycle amp Engine Company Part No 99924 1448 03 Printed in Japan
185. e small diameter C is toward the shift drum e Replace the O ring D with a new one and apply grease to it e Clean the contact points on the position switch e Apply a non permanent locking agent to the gear position switch screws e Tighten Torque Gear Position Switch Screws 2 9 N m 0 30 kgf m 26 in Ib e Install the removed parts see appropriate chapters GP18462BS1 FUEL SYSTEM DFI 3 51 Gear Position Switch Service Code 25 Gear Position Switch Inspection NOTE OBe sure the transmission mechanism is good condition e Disconnect the gear position switch lead connector A Gray 2 pin e Set a digital meter A and connect it to the terminals in the gear position switch lead connector B and ground C Internal Circuit Gear Position Switch Resistance Gear Connections Position G R Lead D Ground BK Lead E Ground Neutral 1 43 1 58 kO about 0 O 1st 2 23 2 46 KQ about 0 Q 2nd 0 95 1 06 kQ about 0 Q 3rd 644 7110 about 0 Q Ath 410 453 Q about 0 Q 5th 241 266 Q about 0 Q x If the digital meter reading is not as specified replace the gear position switch with a new one ist N 2nd 3rd 4th 5th GC17711ES2 Gear Position Switch Circuit 6017975EW1 C 1 ECU 2 Gear Position Switch 3 Frame Ground 1 3 52 FUEL SYSTEM DFI Vehicle down Sensor Service Code 31 When the motorcycle overturned the engine sto
186. e the circlip C from the gas reservoir e Pour the suspension oil into the rear shock body to 30 mm 1 2 in A from the rear shock body upper end B Push the piston rod assembly and seal downward again into the place where circlip is installed and then fit the circlip C into the rear shock groove securely Suspension Oil KHV10 K2C 1L 45024 0002 e Press the piston rod assembly downward and press out the reservoir cap D from the rear shock by the oil pres sure x If the reservoir cap is pressed out inject the air until the reservoir cap end is flush with the gas reservoir end Then remove the reservoir cap using a suitable tool NOTICE Be careful that if the piston rod assembly is pressed downward mightily the reservoir cap may crush e Remove the circlip A e Wrap a heavy cloth around the rear shock body and piston rod to prevent the oil diffusion e Lightly move the piston rod back and forth and pull out the piston rod assembly e Pour the oil out of the rear shock body into the suitable container e Pour the suspension oil into the gas reservoir to 50 60 mm 2 0 2 4 in A from the gas reservoir upper end Suspension Oil KHV10 K2C 1L 45024 0002 A EN MU Wo e o GS14080BS2 GMO5065BS1 GM05010481 2 70 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Replace the bladder A w
187. e will cause deteri oration of the rubber parts Oil spilled on any part will be difficult to wash off completely and will even tually deteriorate the rubber used in the disc brake eWhen handling the disc pads or disc be careful that no disc brake fluid or any oil gets on them Clean off any fluid or oil that inadvertently gets on the pads or disc with a high flash point solvent Do not use one which will leave an oily residue Replace the pads with new ones if they cannot be cleaned satisfactorily eBrake fluid quickly ruins painted surfaces any spilled fluid should be completely wiped up imme diately elf any of the brake line fittings or the bleed valve is opened at any time the AIR MUST BE BLED FROM THE BRAKE LINE Brake Fluid Level Inspection e Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter Brake Fluid Change e Refer to the Brake Fluid Change in the Periodic Mainte nance chapter Brake Fluid BRAKES 12 11 Brake Line Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action Air however is easily compressed When air enters the brake lines brake lever or pedal movement will be partially used in compressing the air This will make the lever or pedal feel spongy and there will be a loss in braking power A WARNING Air in the brake lines dimin
188. ect Brake adjust T Brake pad wear inspect t N 1 N 1 N Goal oo amp N 1 Brake fluid level inspect t Brake caliper fluid seal and dust seal replace 2 2 Brake hoses connections inspect t N CO co N gt Ay AR wo Spoke tightness and rim runout inspect t Wheel bearing inspect t O Drive chain wear inspect Drive chain inspect and adjust Drive chain lubricate 2 4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY Each Every 3 Every 6 Every 12 See race or races or races or races or Page OPERATION 2 5hr 7 5hr 15 hr 30 hr Wheels tires inspect e 2 32 Rear sprocket inspect 2 36 Front fork clean and inspect 2 48 Front fork oil change e 2 48 Rear shock absorber oil change e 2 67 c Every 5 years 215 A Fuel hose connections inspect t 2 14 S Fuel system clean e 2 20 S Sterna play inset fe 274 s Steering stem bearing lubricate e 2 76 Rear shock absorber inspect 2 67 Swingarm and Uni Trak linkage pivots lubricate e 2 74 Swingarm and Uni Trak linkage pivots inspect e 2 73 Nuts bolts fasteners inspect t 2 78 General lubrication perform 2 77 T Replace add adjust clean or torque if necessary PERIODIC MAINTENANCE 2 5 Torque and Locking Agent Tighten all bolts and nuts to the proper torque using an ac
189. ed by the above method replace the crankpin or the crankshaft itself Connecting Rod Big End Seizure Inspection In case of serious seizure with damaged flywheels the crankshaft must be replaced x In case of less serious damage disassemble the crank shaft and replace the crankpin needle bearing and con necting rod Connecting Rod Bend Inspection e Remove the connecting rod e Select an arbor A of the same diameter as the connect ing rod big end and insert the arbor through the connect ing rod big end e Select an arbor B of the same diameter as the piston pin and more than 105 mm 4 13 in long and insert the arbor through the connecting rod small end e On a surface plate set the big end arbor on a V block C e With the connecting rod held vertically use a height gauge to measure the difference in the height of the arbor above the surface plate over a 100 mm 3 94 in length to determine the amount of connecting rod bend x If connecting rod bend exceeds the service limit the con necting rod must be replaced Connecting Rod Bend Service Limit TIR 0 2 100 mm 0 008 3 94 in 6105004BS2 C 6105040681 9 20 CRANKSHAFT TRANSMISSION Crankshaft Connecting Rod Twist Inspection e With the big end arbor A still on the V block C hold the connecting rod horizontally and measure the amount that the arbor B varies from being parallel with the surface plate over
190. ed valve C 4 Release the brake D WARNING Mixing brands and types of brake fluid can reduce the brake system s effectiveness and cause an ac cident resulting in injury or death Do not mix two brands of brake fluid Change the brake fluid in the brake line completely if the brake fluid must be re filled but the type and brand of the brake fluid that is already in the reservoir are unidentified NOTE OThe fluid level must be checked often during the chang ing operation and replenished with fresh brake fluid If the fluid in the reservoir runs out any time during the changing operation the brakes will need to be bled since air will have entered the brake line GS13257B82 PERIODIC MAINTENANCE 2 41 Periodic Maintenance Procedures e Remove the clear plastic hose e Install the diaphragm and reservoir cap e Tighten Torque Front Brake Reservoir Cap Screws 1 5 N m 0 15 kgf m 13 in lb e Tighten the bleed valve and install the rubber cap Torque Caliper Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib e After changing the fluid check the brake for good braking power no brake drag and no fluid leakage x If necessary bleed the air from the lines see Brake Line Bleeding in the Brakes chapter Brake Pad Wear Inspection e Remove Front Brake Caliper see Caliper Removal in the Brakes chapter e Check the lining thickness and condition of the brake pads in each caliper NOTE
191. edle bearings with grease e Replace Rear Shock Absorber Nut Upper Rear Shock Absorber Nut Lower Rear Tie rod Mounting Nut e Install the rear shock absorber e Tighten Torque Rear Shock Absorber Nut Upper 39 N m 4 0 kgf m 29 ft Ib Rear Shock Absorber Nut Lower 34 N m 3 5 kgf m 25 ft lb Rear Tie rod Mounting Nut 59 N m 6 0 kgf m 44 ft Ib e Install removed parts see appropriate chapters Rear Shock Absorber Spring Replacement In addition to the standard spring heavy and light springs are available If the standard spring is improper for your purpose select a proper one according to the rider s weight or course conditions e Remove Rear Shock Absorber see Rear Shock Absorber Re moval e Clean the threaded portion on the upper of the rear shock absorber Rear Shock Absorber SUSPENSION 13 23 e Hold the lower end of the rear shock absorber in a vise with soft jaws or a heavy cloth e Using the hook wrenches A R42 57001 1103 x 2 loosen the locknut B and turn the adjusting nut C all way Up OThe hook wrench R42 57001 1103 is in the hook wrench R37 5 R42 57001 1101 Special Tools Hook Wrench R37 5 R42 57001 1101 x 2 e Slide the spring seat A e Remove the spring guides B from the shock absorber and lift off the spring C e Remove the rear shock absorber from the vise e Exchange the spring for an optional part Olnstall the spring so that large diameter end A
192. eel Removal in the Electrical Sys tem chapter Balancer Weight Mounting Nut A Balancer Weight B Balancer Gear C e Pull out the balancer shaft from the right crankcase half Balancer Installation e Insert the balancer shaft from the right crankcase half e Install the balancer gear so that the stepped portion A on the balancer shaft is aligned with the short length tooth B on the balancer gear e Align the punch mark A on the balancer drive gear and punch mark B on the balancer gear e Install the balancer weight OAlign the punch mark A on the balancer weight and punch mark B on the balancer gear e Tighten Torque Balancer Weight Mounting Nut 52 N m 5 3 kgf m 38 ft lb 9 26 CRANKSHAFT TRANSMISSION Primary Gear Primary Gear Removal e Remove Right Engine Cover see Right Engine Cover Removal in the Clutch chapter Clutch see Clutch Removal in the Clutch chapter Oil Pump Idle Gear see Oil Pump Feed Removal in the Engine Lubrication System chapter e Temporarily install the clutch housing A e Hold the primary gear B with the gear holder C Special Tool Gear Holder m2 0 57001 1557 e Remove Primary Gear Nut D Washer Clutch Housing Primary Gear Oil Pump Drive Gear OThe primary gear nut is left hand threads Primary Gear Installation e Insert the oil pump drive gear A and primary gear B to the crankshaft e Install the washer C as shown in the figure
193. el Injection System Idle Speed Throttle Body Assy Throttle Valve Bore ECU Make Type Fuel Pressure Fuel Pump Type Discharge Fuel Injector Type Nozzle Type Resistance Throttle Sensor Input Voltage Output Voltage Resistance Intake Air Pressure Sensor Input Voltage Output Voltage Output Voltage Resistance Water Temperature Sensor Output Voltage Resistance Gear Position Switch Resistance Vehicle down Sensor Detection Angle Input Voltage Output Voltage Intake Air Temperature Sensor 2 000 50 r min rpm Single throttle valve p43 mm 1 69 in KEIHIN Digital memory type with built in IC igniter sealed with resin 294 kPa 3 0 kgf cm 43 psi at engine idling Wesco pump 40 mL 1 4 US oz or more for 5 seconds INP 286 Fine atomizing type with 10 holes About 11 7 12 3 Q at 20 C 68 F DC 4 75 5 25 V DC 0 58 0 62 V at idle throttle opening DC 3 68 3 88 V at full throttle opening for reference 4 6kQ DC 4 75 5 25 V DC 3 80 4 20 V at standard atmospheric pressure see text for details About DC 2 28 3 43 V at intake air temperature 20 C 68 F 909 1 363 Q at 40 C 104 F 124 186 Q at 100 C 212 F About DC 2 80 2 97 V at water temperature 20 C 68 F see text see text More than 55 75 for each bank DC 4 75 5 25 V With sensor tilted 55 75 or more right or left DC 3 7 44V With sensor arrow mark pointed up DC 0 4 1 4 V
194. ely and will eventually deteriorate the rubber used in the disc brake When handling the disc pads or disc be careful that no disc brake fluid or any oil gets on them Clean off any fluid or oil that inadvertently gets on the pads or disc with a high flash point sol vent Do not use one which will leave an oily residue Replace the pads with new ones if they cannot be cleaned satisfactorily Brake fluid quickly ruins painted surfaces any spilled fluid should be completely wiped up im mediately If any of the brake line fittings or the bleed valve is opened at any time the AIR MUST BE BLED FROM THE BRAKE LINE Recommended Disc Brake Fluid Type Front and Rear DOT3 or DOT4 2 40 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTE OThe procedure to change the front brake fluid is as fol lows Changing the rear brake fluid is the same as for the front brake e Level the brake fluid reservoir e Remove Screws A Reservoir Cap B Diaphragm C e Remove the rubber cap A from the bleed valve B on the caliper C e Attach a clear plastic hose A to the bleed valve and run the other end of the hose into a container e Fill the reservoir with fresh specified brake fluid e Change the brake fluid as follows ORepeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes 1 Open the bleed valve A 2 Apply the brake and hold it B 3 Close the ble
195. em nut to the specified torque hook the wrench A on the stem nut and pull the wrench at the hole by 22 2 kgf force B in the direction shown Special Tool Steering Stem Nut Wrench 57001 1100 OCheck that there is no play and the steering stem turns smoothly without rattles If not the steering stem bearings may be damaged OAgain back out the stem nut a fraction of a turn until it turns lightly OTurn the stem nut lightly clockwise until it just becomes hard to turn Do not overtighten or the steering will be too tight Torque Steering Stem Nut 4 9 N m 0 50 kgf m 43 in Ib e Install the stem head e Install the washer and temporary the stem head nut e Install the front forks see Front Fork Installation in the Suspension chapter NOTE OTighten the fork clamp bolts upper first next the stem head nut last the fork clamp bolt lower e Tighten Torque Front Fork Clamp Bolts Upper 20 N m 2 0 kgf m 15 ft lb Steering Stem Head Nut 98 N m 10 kgf m 72 ft lb Front Fork Clamp Bolts Lower 20 N m 2 0 kgf m 15 ft lb NOTE OTighten the two clamp bolts alternately two times to en sure even tightening torque GNO50605S1 14 8 STEERING Steering e Install the removed parts see appropriate chapters A WARNING If the handlebar does not turn to the steering stop it may cause an accident resulting in injury or death Be sure the cables harnesses and hoses are routed prope
196. en the locknut securely e After adjusting move the spring up and down to make sure that the spring is seated e Install the removed parts see appropriate chapters Rear Shock Absorber Spring Tension Inspection e Since the spring becomes shorter as it weakens check its free length A to determine its condition Shock Absorber Spring Free Length Standard 255 mm 10 0 in Service Limit 250 mm 9 84 in x If the free length falls below the service limit replace the spring GMO5196BS1 13 22 SUSPENSION Rear Shock Absorber Rear Shock Absorber Removal e Remove Seat see Seat Removal in the Frame chapter Side Covers see Side Cover Removal in the Frame chapter Muffler Body see Muffler Body Removal in the Engine Top End chapter Rear Frame see Rear Frame Removal in the Frame chapter e Using the jack under the frame raise the rear wheel off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 NOTICE When pulling out the mounting bolts lift the rear wheel slightly Forcing or tapping on a bolt could damage the bolt sleeve and bearing e Remove the rear tie rod mounting bolt and nut A and turn the tie rod B downward e Remove the rear shock absorber lower mounting bolt and nut C e Remove the rear shock absorber upper mounting bolt D nut and pull out the rear shock absorber E down and out Rear Shock Absorber Installation e Pack the rocker arm ne
197. en the two values Measure the piston diameter as just described and measure the cylinder diameter at the very bottom of the cylinder Piston Cylinder Clearance Standard 0 045 0 067 mm 0 0018 0 0026 in Piston Piston Ring and Piston Pin Replacement e Refer to the Cylinder and Piston section in the Engine Top End chapter Exhaust System Inspection e The exhaust system in particular the muffler body is de signed to reduce exhaust noise and conduct the exhaust gases away from the rider while minimizing power loss If carbon has built up inside the muffler body exhaust effi ciency is reduced causing engine performance to drop x If the muffler body is badly damaged dented cracked or rusted replace it x If the exhaust noise becomes too loud or engine perfor mance drops replace the silencer wool Silencer Wool Replacement e Remove Right Side Cover see Side Cover Removal in the Frame chapter Muffler Cover Bolts A Muffler Mounting Bolt B e Remove the muffler cover A OTap the bracket B with a plastic hammer C to separate the cover and pipe e Replace the silencer wool with a new one e Clean the adhered silicone sealant PERIODIC MAINTENANCE 2 27 Periodic Maintenance Procedures e Insert the new silencer wool A and muffler cover B OFit the pipe end C and the exhaust hole of the baffle e Apply a non permanent locking agent to the threads of the muffler cover bolts and tighten them
198. engine to the swingarm e Insert the swingarm pivot shaft from the right side e Install all engine brackets bolts and nuts temporarily Olnsert the following bolts from left side Middle Engine Mounting Bolt A Middle Engine Bracket Bolts B Lower Engine Mounting Bolt C e Install the swingarm pivot shaft nut with the washer e Tighten the bolts and nuts in the numbered sequence 1 6 Torque Swingarm Pivot Shaft Nut 1 98 N m 10 kgf m 72 ft lb Lower Engine Mounting Nut 2 49 N m 5 0 kgf m 36 ft lb Middle Engine Mounting Nut 3 49 N m 5 0 kgf m 36 ft lb Middle Engine Bracket Nuts 4 29 N m 3 0 kgf m 21 ft lb Upper Engine Bracket Bolts 5 29 N m 3 0 kgf m 21 ft lb Upper Engine Mounting Bolts 6 49 N m 5 0 kgf m 36 ft lb 8 8 ENGINE REMOVAL INSTALLATION Engine Removal Installation e Install the removed parts see appropriate chapters e Run the cables hoses and leads according to the Cable Wire and Hose Routing section in the Appendix chapter e Pour Engine Oil see Engine Oil Change in the Periodic Main tenance chapter Coolant see Coolant Filling in the Cooling System chap ter e Adjust Throttle Cables see Throttle Grip Throttle Cable Free Play Adjustment in the Periodic Maintenance chapter Clutch Cable see Clutch Operation Inspection in the Pe riodic Maintenance chapter Drive Chain see Drive Chain Slack Adjustment in the Periodic Maintenance chapter Idl
199. ensioner Installation e Remove the cap bolt and O ring e While compressing the push rod A turn it clockwise with a suitable screwdriver B until the rod stops NOTICE Do not turn the rod counterclockwise at installation This could detach the rod and the tensioner cannot be reinstalled e Hold the rod in position with a suitable push rod holder plate A Unit mm 3 5 E GE10014BS1 ENGINE TOP END 5 15 Camshaft Chain Tensioner e Replace the chain tensioner gasket with a new one e Install the chain tensioner body e Tighten Torque Camshaft Chain Tensioner Mounting Bolts A 9 8 N m 1 0 kgf m 87 in Ib e Take out the holder plate B e Replace the O ring with a new one e Apply grease to the O ring e Install the O ring and tighten the cap bolt Torque Camshaft Chain Tensioner Cap Bolt 5 0 N m 0 51 kgf m 44 in Ib 5 16 ENGINE TOP END Camshafts Camshaft Removal e Remove Cylinder Head Cover see Cylinder Head Cover Re moval Timing Inspection Cap A Flywheel Nut Cap B Special Tool Filler Cap Driver 57001 1454 e Bring the piston to the TDC of the compression stroke OPlace a wrench over the flywheel nut and turn it counter clockwise to align the TDC mark A with the center of the groove B of the inspection hole e Remove Camshaft Chain Tensioner see Camshaft Chain Ten sioner Removal Camshaft Cap Bolts 1 8 sequence numbers
200. ensor W lead Digital Meter BK sensor GY lead CA Ge GC17718DS1 Water Temperature Sensor Service Code 14 FUEL SYSTEM DFI 3 47 e Refer to the Self diagnosis Procedures connect the 12 V battery to the main harness e Measure the output voltage with the engine stopped and the connector joined Output Voltage Standard About DC 2 80 2 97 V at water temperature 20 C 68 F NOTE OThe output voltage changes according to the coolant temperature in the engine e Disconnect the power supply harness x lf the reading is within the standard check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation x If the reading is out of the standard remove the ECU and check the wiring for continuity between the main harness connectors ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Water Temperature Sensor Connector B W lead C ECU terminal 22 GY lead D ECU terminal 24 x If the wiring is good check the water temperature sensor resistance see Water Temperature Sensor Resistance Inspection 6017534DS1 3 48 FUEL SYSTEM DFI Water Temperature Sensor Service Code 14 Water Temperature Sensor Resistance Inspection e Remove the water temperature sensor see Water Tem perature Sensor Removal
201. eplace the ring Also if the pin hole groove shows excessive wear replace the piston e Measure the diameter of the piston pin B with a microm eter Piston Pin Diameter Standard 18 991 19 000 mm 0 74768 0 74803 in Service Limit 18 96 mm 0 7465 in x If the piston pin diameter is less than the service limit at any point replace the piston pin e Using a cylinder gauge measure the diameter of both piston pin holes C in the piston and the inside diameter of the connecting rod small end D Piston Pin Hole Diameter Standard 19 004 19 010 mm 0 74819 0 74842 in Service Limit 19 08 mm 0 7512 in Connecting Rod Small End Inside Diameter Standard 19 019 19 030 mm 0 74878 0 74921 in Service Limit 19 07 mm 0 7508 in If either piston pin hole diameter exceeds the service limit replace the piston x If the connecting rod small end inside diameter exceeds the service limit replace the connecting rod GE16218BS1 GE16219BS2 Throttle Body Holder ENGINE TOP END 5 39 Throttle Body Assy Holder Removal e Remove Throttle Body Assy see Throttle Body Assy Removal in the Fuel System DFI chapter Throttle Body Assy Clamp A Throttle Body Assy Holder Screws B Clamp C KX450FD Throttle Body Assy Holder D Throttle Body Assy Holder Installation e Replace the O ring A with a new one e Apply grease to the O ring e Install the O ring to the thro
202. everal minutes at idling above in order to confirm no problem 1 When the engine is rotated there are parts crankshaft sensor fuel injector and ignition coil by which ECU recognizes the fault Kick for that 2 The blink 0 16 seconds cycle is warning of impossible starting The warning of impossible starting displays when connecting the battery and kicked The starting becomes impossible when the crankshaft sensor fuel injector ignition coil fuel pump and vehicle down sensor are fault GC17353F F 3 28 FUEL SYSTEM DFI Self Diagnosis How to Read Service Codes OService codes are shown by a series of long and short blinks of the orange Fl warning indicator light LED as shown below ORead 10th digit and unit digit as the orange Fl warning indicator light LED blinks OWhen there are a number of problems all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical order Then after completing all codes the display is repeated until the self diagnosis terminal is open Olf there is no problem no code and the orange Fl warning indicator light LED blinks with cycle of 0 5 seconds OFor example if two problems occurred in the order of 21 12 the service codes are displayed from the lowest number in the order listed 12 21 12 21 gt repeated Self diagnosis Terminal Grounded Opened 8 Orange Fl Warning Indicator Light L
203. f diagnosis Procedures connect the 12 V battery to the main harness e Measure the output voltage with the engine stopped and with the connector joined OTilt the sensor 55 75 or more A right or left then hold the sensor almost vertical with the arrow mark B pointed up C Output Voltage Standard With sensor tilted 55 75 or more right or left DC 3 7 4 4 V With sensor arrow mark pointed up DC 0 4 1 4V x If the reading is out of the standard replace the sensor x If the reading is within the standard remove the ECU and check the wiring for continuity between the main harness connectors ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Vehicle down Sensor Connector B BR lead C ECU terminal 2 GY lead D ECU terminal 24 x lf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation Vehicle down Sensor Circuit 6017725DS1 GC17726DS1 BR O e 6017976Ew1 C 1 ECU 2 Vehicle down Sensor Fuel Injector Service Code 41 FUEL SYSTEM DFI 3 55 NOTICE Never drop the fuel injector especially on a hard surface Such a shock to the injector can damage it Fuel Injector Removal e Remove Rear Frame see Rear Frame Removal in the Frame c
204. f it is scratched or damaged replace the disc e Measure the thickness of each disc at the point B where it has worn the most Disc Thickness Standard Front 2 85 3 15 mm 0 112 0 124 in Rear 3 85 4 15 mm 0 152 0 163 in Service Limit Front 2 5 mm 0 10 in Rear 3 5 mm 0 14 in Replace the disc if it has worn past the service limit e Place a jack under the motorcycle so that the front rear wheel is raised off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Set up a dial gauge against the disc A as shown OFor the front disc turn the handlebar fully to one side e Measure the disc runout while rotating B the wheel slowly Disc Runout Standard TIR 0 25 mm 0 010 in or less Service Limit TIR 0 3 mm 0 01 in x If the runout exceeds the service limit replace the disc GLO8051BS1 GLO8052BS1 12 24 BRAKES Brake Hose Brake Hose Removal Installation e Refer to the Brake Hose Replacement in the Periodic Maintenance chapter Brake Hose Inspection e Refer to the Brake Hoses and Connections Inspection in the Periodic Maintenance chapter SUSPENSION 13 1 Suspension Table of Contents Exploded View 13 2 Rear Shock Absorber Specifications 4 13 8 DisassemblViainia en tune 13 23 Special TOONS usaran 13 10 Rear Shock Absorber Assembly 13 25 E Ereegnes 13 11 Rear Shock Absorber Oil Change 13 26 Air Pressure KX450FC
205. fferent from the plate installed between these plates However it is impossi ble to identify it on externals OMark and record the locations of the both side friction plates so that they can be reinstalled in their original positions e Hold the clutch hub A with the clutch holder B Special Tool Clutch Holder 57001 1243 e Remove the clutch hub nut C e Remove Washer A Clutch Hub B Clutch CLUTCH 6 13 e Remove Toothed Washer A Clutch Housing B Clutch Installation e Check the clutch plate assembly free play see Clutch Plate Assembly Free Play Inspection Adjustment e Apply molybdenum disulfide oil to the inside A of the clutch housing e Install Clutch Housing B Toothed Washer C e Install the clutch hub A e Install the washer B so that the OUT SIDE mark C faces outward e Replace the clutch hub nut A with a new one e Hold the clutch hub B with the clutch holder C and tighten the clutch hub nut Special Tool Clutch Holder 57001 1243 Torque Clutch Hub Nut 98 N m 10 kgf m 72 ft lb e Install the friction plates and steel plates starting with a friction plate and alternating them Finishing with a friction plate A NOTE Olnstall the both ends of friction plates which are marked when disassembled to the their original position OWhen replace the friction plates with new ones mark the both end two friction plates so that the two kinds of fr
206. flow hose outside of 6 Left Radiator the middle engine bracket Position all clamp screw heads as shown in the figure 17 22 APPENDIX Cable Wire and Hose Routing me _ ng JE d IL SL br S Ee P ef KAN ra SS O 1 o 6B09026EW5 C APPENDIX 17 23 Cable Wire and Hose Routing OMNAOARWND Viewed A 45 Spark Plug Cap Viewed B Run the magneto lead under the claw of the holder Magneto Lead Viewed C Radiator Overflow Hose Run the fuel pump lead over the fuel hose and between the fuel hose and frame Paint Mark Tighten the band with the 5 to 7 notches Face the claw portion leftward Align the white mark on the breather hose and embossed mark Clamp Hold the radiator overflow hose and the gear position switch lead Gear Position Switch Lead Clamp Hold the gear position switch lead Run the magneto lead under the clutch cable 17 24 APPENDIX Cable Wire and Hose Routing GB09754D0W4 C 1 Touch the front brake hose fitting to the stopper 2 Brake Hose 3 Clamp 4 Viewed A 5 Clamps APPENDIX 17 25 Cable Wire and Hose Routing O I Bu Ne O So 6899755044 C 1 Brake Hose 2 Clamps 3 Cotter Pin 4 Touch the rear brake hose fitting to the stopper 5 Viewed A 17 26 APPENDIX Troubleshooting Guide NOTE Cylin
207. fuel in tank Supply fuel see Owner s Manual Air cleaner clogged poorly sealed or missing Clean element or inspect sealing see chapter 3 Air cleaner duct loose Reinstall see chapter 3 Throttle body assy holder loose Reinstall see chapter 3 Fuel injector dust seal damage Replace see chapter 3 Fuel injector O ring damage Replace see chapter 3 Fuel filter or pump screen clogged Inspect and replace fuel pump see chapter 3 Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump see chapter 3 Fuel line clogged Inspect and repair see chapter 3 Intake air pressure sensor trouble Inspect see chapter 3 3 22 FUEL SYSTEM DFI DFI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter Water temperature sensor trouble Inspect see chapter 3 Intake air temperature sensor trouble Inspect see chapter 3 Throttle sensor trouble Inspect see chapter 3 Unstable rough idling Fuel pressure too low or too high Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 Throttle sensor trouble Inspect see chapter 3 Intake air pressure sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Intake air temperature sensor trouble Inspect see chapter 3 Engine stalls easily Spark plug dirty broken or gap maladjusted Ignition coil
208. fuel injector especially on a hard surface Such a shock to the injector can damage it e Separate the injector A and the delivery pipe B NOTE ODo not damage the insertion portion of the fuel injector when it is pulled out from the delivery pipe NOTICE Never drop the fuel injector especially on a hard surface Such a shock to the injector can damage it e Remove Screw A Delivery Pipe B Joint C ves P CCt7E4ST P Throttle Body Assy FUEL SYSTEM DFI 3 77 e Remove Idle Adjusting Screw Assy A NOTE Olf necessary refer to the Throttle Sensor Replacement and remove the throttle sensor B Throttle Body Assy Assembly NOTE Olf necessary refer to the Throttle Sensor Replacement and install the throttle sensor e Install Idle Adjusting Screw Assy A e Replace the O ring A with a new one e Apply engine oil to the new O ring e Install the O ring and the joint B to the delivery pipe C and tighten the screw securely e Replace the fuel injector O ring A and the dust seal B with new ones e Apply engine oil to the O ring and dust seal e Install the fuel injector A to the delivery pipe B enn P enn P 3 78 FUEL SYSTEM DFI Throttle Body Assy e Fit the delivery pipe projections A to the throttle body hollows B e Tighten the delivery pipe mounting screw securely e Install the plate A e Fit
209. g Needle Bearing Inspection 13 32 Adjustment estiment 13 19 Uni Trak Maintenance cocccconcccccccco 13 33 Spring Preload Adjustment 13 20 Uni Trak Linkage Inspection 13 33 Rear Shock Absorber Spring Tie Rod and Rocker Arm Sleeve Tension Inspection 13 21 Wear Inspection 13 33 Rear Shock Absorber Removal 13 22 Tie Rod and Rocker Arm Rear Shock Absorber Installation 13 22 Mounting Bolt Bend Inspection 13 33 Rear Shock Absorber Spring Replacement 13 22 13 2 SUSPENSION Exploded View KX450FC ves 00000 6M02338BW5 C SUSPENSION 13 3 Exploded View RS ue Front Fork Clamp Bolts Upper Copa 15 AL Brake Hose Clamp Bolt 18 in lb Pressure Relief Screws 11 in lb Base Valve Assemblies Front Fork Clamp Bolts Lower AL Front Fork Top Plugs AL Tighten the two clamp bolts alternately two times to ensure even tightening torque L Apply a non permanent locking agent R Replacement Parts 13 4 SUSPENSION Exploded View KX450FD 6M047798W5 C SUSPENSION 13 5 Exploded View Torque ft lb Remarks Front Fork Clamp Bolts Upper 15 AL R Replacement Parts Brake Hose Clamp Bolt 2 0 0 20 18 in lb Air Valve Plug 0 2 0 020 1 8 in Ib AL Tighten the two clamp bolts alternately two times to ensure even tightening torque 13 6 SUSPENSION
210. g is out of the standard remove the ECU and check the wiring for continuity between the main harness connectors ODisconnect the ECU and the fuel injector connector Wiring Continuity Inspection ECU Connector A Fuel Injector Connector B BL R lead C ECU terminal 16 x If the wiring good check the ECU ground and power sup ply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU Removal Installation Injector Fuel Line Inspection e Remove Fuel Tank see Fuel Tank Removal Fuel Hose see Fuel Hose Replacement in the Periodic Maintenance chapter OPlace a piece of cloth around the fuel outlet pipe of fuel pump and the delivery pipe of throttle body assy GC17987ES1 6017732DS1 Fuel Injector Service Code 41 FUEL SYSTEM DFI 3 59 e Check the injector fuel line for leakage as follows OConnect a commercially available vacuum pressure pump A to the delivery pipe B with the fuel hose C OHold both ends with the clamps D e Apply a soap and water solution to the areas E as shown e Watching the pressure gauge squeeze the pump lever F and build up the pressure until the pressure reaches the maximum pressure Fuel Line Maximum Pressure Standard 300 kPa 3 06 kgf cm 44 psi NOTICE During pressure testing do not exceed the maxi mum pressure for which the
211. g it down OCheck that the piston rod A is slowly pushed back B OAgjust the rebound damping adjuster C to the softest po sition By doing that the piston rod is pushed back quickly x lf the rear shock absorber does not work as above change the rear shock absorber oil again e Install the spring and spring guide see Spring Replace ment in the Suspension chapter e Install the rear shock absorber see Rear Shock Absorber Installation in the Suspension chapter e Adjust spring preload see Spring Preload Adjustment in the Suspension chapter e Install the removed parts see appropriate chapters Swingarm and Uni Trak Linkage Inspection e Check the uni trak component parts for wear periodically or whenever excessive play is suspected e Using the jack under the frame raise the rear wheel off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 2 74 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Pump the seat down and up A 4 or 5 times and inspect the smooth stroke x If the uni trak linkage does not smooth stroke or noise is found inspect the uni trak linkage bearings e Push and pull on the swingarm A to check for wear xA small amount of play on the swingarm is normal and no corrective action is needed However if excessive play is felt remove the uni trak parts from the frame and check for wear Swingarm and Uni Trak Linkage Pivot Lubrication
212. ge from the connected portion of the special tools NOTICE Do not drive the fuel pump without the fuel in the fuel tank If the fuel pump is driven without the fuel it may be damaged 3 70 FUEL SYSTEM DFI Fuel Line e Start the engine and let it idle e Measure the fuel pressure with the engine idling Fuel Pressure Standard 294 kPa 3 00 kgf cm 43 psi at engine idling NOTE OThe gauge needle will fluctuate Read the pressure at the average of the maximum and minimum indications e Stop the engine x If the fuel pressure is much higher than specified replace the fuel pump because the fuel pressure regulator in the fuel pump have been clogged or stuck x If the fuel pressure is much lower than specified check the following Fuel Line Leakage see Injector Fuel Line Inspection Amount of Fuel Flow see Fuel Flow Rate Inspection e After above checks measure the fuel pressure again e Remove the fuel pressure gauge hoses and adapter e Install the removed parts see appropriate chapters e Start the engine and check for fuel leakage Fuel Flow Rate Inspection A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Always stop the engine and do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light NOTE OBe sure the battery is fully charged e Wait until the engine c
213. ghten the locknut A e Turn the accelerator cable adjuster D until 2 3 mm 0 08 0 12 in of throttle grip play is obtained e Tighten the locknut B GS05214BS1 65050126 P PERIODIC MAINTENANCE 2 15 Periodic Maintenance Procedures KX450FD e Loosen the locknut A at the upper end of the throttle cable e Screw the throttle cable adjuster B to give the throttle grip plenty of play e Tighten the locknut lf the throttle grip free play cannot be adjusted with the adjuster replace the throttle cables e Turn the handlebar from side to side while idling the en gine If idle speed varies the throttle cable may be poorly routed or it may be damaged WARNING Operation with improperly adjusted incorrectly routed or damaged cables could result in an unsafe riding condition Follow the service manual to make sure to correct any of these conditions Throttle Body Cleaning e Check the throttle bore for cleanliness as follows ORemove the throttle body assy see Throttle Body Assy Removal in the Fuel System DFI chapter OCheck the throttle bore A at the throttle valve for carbon deposits by opening the throttle valve x If any carbon accumulates wipe the carbon off the throt tle bore and the throttle valve using a lint free cloth pen etrated with a high flash point solvent Fuel Hose Replacement e Remove the fuel tank see Fuel Tank Removal in the Fue
214. gt improvement of bottoming resistance 68067308 6 5 Effect of Air Pressure Change e Changing air pressure has the same effect as changing the conventional spring rates and the changes can be made much more easily 1 18 GENERAL INFORMATION Technical Information PSF Pneumatic Spring Fork Front Fork KX450FD Easy to Do Adjustment Adjustable Range of Stroke Conventional Type gaith Oil level adjustment Latter half of stroke main spring Air pressure adjustment Oil level adjustment Whole stroke PSF Type Adjustable Range Only the bottom range can be adjusted Changes in all over the stroke The spring exchange IS necessary 68067318 6 6 Air pressure adjustment e For air pressure adjustment use a commercially available hand air pump and the air valve adapter special tool A P No 57001 0725 supplied with the motorcycle Refer to Air Pressure Adjustment KX450FD in the Suspen sion chapter e Check the air pressure before running Standard Air Pressure 240 kPa 2 4 kgf cm 35 psi Adjustable Range 220 280 kPa 2 2 2 8 kgf cm 32 41 psi Maximum Air Pressure 500 kPa 5 0 kgf cm 73 psi GENERAL INFORMATION 1 19 Technical Information PSF Pneumatic Spring Fork Front Fork KX450FD e Be sure to remove the air valve adapter P No 57001 0725 before running A WARNING When riding and transporting the motorcycle make sure t
215. h a new one Olnstall the O ring to the piston oil nozzle OApply a non parmanent locking agent to the threads of the piston oil nozzle bolt A OTighten Torque Piston Oil Nozzle Bolt 7 0 N m 0 71 kgf m 62 in Ib e Install Crankshaft see Crankshaft Installation Transmission Shafts see Transmission Shaft Installa tion Oil Screen Feed see Oil Screen Feed Installation in the Engine Lubrication System chapter e Replace the O ring A with a new one and apply grease e Install Dowel Pins B O ring 9 14 CRANKSHAFT TRANSMISSION Crankcase e Using a high flash point solvent clean off any oil or dirt that may be on the liquid gasket coating area Dry them with a clean cloth e Apply liquid gasket to the mating surface A of the left crankcase half Sealant Liquid Gasket TB1216 92104 1063 NOTE OEspecially apply liquid gasket so that it shall be filled up on the groove B OMake the application finish within 20 minutes when the liquid gasket to the mating surface of the left crankcase half is applied OMoreover fit the case and tighten the case bolts just after finishing the application of the liquid gasket 61044248W2 C e Using a plastic hammer press the rear portion of the crankcase and tap the area around the crankshaft of the left crankcase half While maintaining the mating sur faces of the right and left crankcase halves constantly par allel mate the crankcase
216. haft Sensor Inspection in the Electrical System chapter x If the reading is within the standard check the peak volt age see Crankshaft Sensor Peak Voltage Inspection Crankshaft Sensor Peak Voltage Inspection e Refer to the Crankshaft Sensor Peak Voltage Inspection in the Electrical System chapter x If the reading is within the standard remove the ECU and check the wiring for continuity between the main harness connectors ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Crankshaft Sensor Connector B G W lead C ECU terminal 3 W Y lead D ECU terminal 9 lf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation Crankshaft Sensor Circuit GC17986ES1 1 ECU 2 Crankshaft Sensor 6017974Ew1 C 3 50 FUEL SYSTEM DFI Gear Position Switch Service Code 25 Gear Position Switch Removal e Remove Shift Pedal External Shift Mechanism Removal in the Crankshaft Transmission chapter Gear Position Switch Connector A Gray 2 pin e Open the clamps A e Remove Screws A Gear Position Switch B e Remove O ring A Gear Position Switch Fingers B Springs C Gear Position Switch Installation e Install the spring A on the switch finger B e Insert the switch finger so that th
217. halves evenly OWhen the left crankcase half can not install easily position the connecting rod at the bottom dead center and install the crankshaft jig A between the crankshaft flywheels Special Tool Crankshaft Jig 57001 1174 NOTE OConstantly check the alignment of the two crankcase halves and the position of the transmission shafts and shift drum The front and rear of the crankcase must be pushed together evenly CRANKSHAFT TRANSMISSION 9 15 Crankcase e Replace the washers A with a new one e Tighten the crankcase bolts starting with the periphery of the crankshaft then outward Torque Crankcase Bolts M6 12 N m 1 2 kgf m 106 in Ib Crankcase Bolts M7 15 N m 1 5 kgf m 11 ft lb NOTE OAfter tightening the crankcase bolts wipe up the liquid gasket seeping out around the mating surface espe cially around the area e Make sure that the crankshaft drive shaft and output shaft rotate smoothy in the neutral position If the crankshaft will not turn probably the crankshaft is not centered install the crankshaft jig at the bottom dead center and tap the appropriate end of the crankshaft with a mallet to reposition it Special Tool Crankshaft Jig 57001 1174 e Install Gear Positioning Lever see External Shift Mechanism Installation Shift Drum Cam see External Shift Mechanism Installa tion e Check to see that gears shift smoothly from 1st to 5th gear and 5th to 1st
218. hapter Fuel Tank see Fuel Tank Removal Fuel Hose see Fuel Hose Replacement in the Periodic Maintenance chapter e Remove the intake air pressure sensor from the plate e Disconnect the fuel injector connector A e Remove the delivery pipe mounting screw A e Remove the delivery pipe B together with the injector NOTE ODo not damage the insertion portions of the injector when they are pulled out from the throttle body e Separate the injector A and the delivery pipe B Fuel Injector Installation e Replace the O ring A and dust seal B with a new one e Apply engine oil to the O ring and dust seal anun P 3 56 FUEL SYSTEM DFI Fuel Injector Service Code 41 e Assemble the delivery pipe A and the fuel injector B reas P e Fit the projections A on the delivery pipe to the hollows B of the throttle body assy e Tighten the delivery pipe mounting screw A e Connect the fuel injector connector e Install Rear Frame see Rear Frame Installation in the Frame chapter Fuel Hose see Fuel Hose Replacement in the Periodic Maintenance chapter Fuel Tank see Fuel Tank Installation Fuel Injector Audible Inspection NOTE OBe sure the battery is fully charged e Start the engine and let it idle e Apply the tip of a screwdriver A to the fuel injector B e Put the grip end into your ear and listen whether the fuel injector is clicking or not
219. hat the air pressure is within the adjustable range If used outside the adjustable range run ning stability can decrease and cause an accident resulting in serious injury or death Be sure to remove the air valve adapter before rid ing If the air valve adapter is damaged by a stone during riding air leakage can cause loss of control and an accident resulting in serious injury or death e Be sure to install the air valve plug A after air pressure adjustment e Be sure to install a plug A and cap B on the air valve adapter C P No 57001 0725 for storage 7 Others elf a oil leak in the front fork or dust seal is found stop running and replace both the dust seal and oil seal with new ones before next riding e Set the air pressure within the adjustable range for trans porting 1 20 GENERAL INFORMATION Unit Conversion Table Prefixes for Units Units of Length Prefix Symbol km x 0 6214 mile mega M 1 000 000 A SE ee kilo k 1 000 mm x 0 03937 in centi c 0 01 milli E 0 001 Units of Torque micro p 0 000001 im me NOLO E CS Mm x 0 7376 Ip Mm x 8 851 in lb Units of Mass kgf m x 9 807 N m kg x 2 205 Ib kgf m x 7233 Ip g x 0 03527 OZ kgf m x 86 80 in lb Units of Volume Units of Pressure L x 0 2642 gal US kPa x 0 01020 kgf cm L x 0 2200 gal IMP kPa x 0 1450 psi L x 1 057 qt US kPa x 0 7501 cmHg L x 0 8799 qt IMP kgf cm x 98 07 kPa L x
220. hips jammed in clutch housing gear teeth Transmission noise Bearings worn Transmission gears worn or chipped Metal chips jammed in gear teeth Engine oil insufficient low viscosity Kick ratchet gear not properly disengaging from kick gear Kick shaft idle gear worn or chipped Drive chain noise Drive chain maladjusted Drive chain worn Rear and or engine sprocket worn Drive chain lubrication insufficient Rear wheel misaligned Abnormal Frame Noise Front fork noise Oil insufficient or too thin Spring weak or broken KX450FC Front fork air pressure incorrect KX450FD Front fork air pressure high KX450FC Rear shock absorber noise Shock absorber trouble Spring weak or broken Disc brake noise Pad surface glazed Disc warped Caliper trouble Pad installed incorrectly Master cylinder damaged Other noise Bracket nut bolt etc not properly mounted or tightened Abnormal Exhaust Color White smoke Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Engine oil level too high Black smoke Air cleaner element clogged Brown smoke Air cleaner duct loose Air cleaner clogged Air cleaner poorly sealed or missing Handling and or Stability Unsatisfactory Handlebar hard to turn Cable hose wire routing incorrect Steering stem nut too tight Troubleshooting Guide Steering stem bearing damaged Steering stem bearing lubrication inade quate Steering stem bent Tire air pressure too low Ha
221. holder while pressing down lightly OAfter making the 55 grind return to the seat width mea surement step above NOTICE Do not lap the valve to the valve seat using the grinding compound It will come off oxide film treated surface of the valve e When the engine is assembled be sure to adjust the valve clearance see Valve Clearance Adjustment in the Peri odic Maintenance chapter GE15012381 ENGINE TOP END 5 33 Valves Valve Seat Repair Machinist s dye on seat 45 Grind Tool 45 Cutter Purpose make seating area smooth and round Measure Seating Area O D Tool Venire Caliper Purpose check seat O D against spec 45 Grind Machinist s dye on seat Tool 45 Cutter Purpose increase O D of seat area to spec 32 Grind Tool 32 Cutter Purpose reduce OD of seat area to spec Measure Seating Width Tool Venire Caliper Purpose check seat width against spec Results 45 Grind Purpose increase width of seat Machinist s dye on seat Tool 45 Cutter area beyond spec to increase O D 55 Grind Tool 55 Cutter Purpose reduce seat width to specification FINISHED GE15117B F 5 34 ENGINE TOP END Cylinder and Piston Cylinder Removal e Remove Cylinder Head see Cylinder Head Removal Front Camshaft Chain Guide A Cylinder Bolt B Water Temperature Sensor Connector C Discon
222. ice Limit Fuel System Throttle Grip Free Play 2 3 mm 0 08 0 12 in Idle Speed 2 000 50 r min rpm Air Cleaner Element Oil High quality foam air filter oil Cooling System Coolant Type Recommended Permanent type antifreeze SE Color Green Mixed Ratio Soft water 50 coolant 50 Freezing Point 35 C 31 F Total Amount 1 1 L 1 2 US qt Engine Top End Valve Clearance Exhaust 0 17 0 22 mm 0 0067 0 0087 in Intake 0 10 0 15 mm 0 0039 0 0059 in Cylinder Head Warp 0 05 mm 0 0020 in Cylinder Inside Diameter see text 96 025 96 037 mm 96 12 mm 3 7805 3 7810 in 3 784 in Piston Cylinder Clearance 0 045 0 067 mm SE 0 0018 0 0026 in Clutch Clutch Lever Free Play 8 13 mm 0 3 0 5 in Friction Plate Thickness 2 92 3 08 mm 0 115 0 121 in 2 7 mm 0 11 in Friction Plate Warp 0 15 mm 0 0059 in or less 0 3 mm 0 012 in Steel Plate Warp 0 20 mm 0 0079 in or less 0 3 mm 0 012 in Engine Lubrication System Engine Oil Type Castrol POWER1 Racing 4T 5W 40 or API SG SH SJ SL or SM with JASO MA MA1 or MA2 Viscosity SAE 10W 30 10W 40 or 10W 50 Capacity 0 96 L 1 01 US qt when filter is not ae removed 0 98 L 1 04 US qt when filter is remove 1 20 L 1 27 US qt when engine is completely dry Crankshaft Transmission Connecting Rod Big End Side 0 25 0 35 mm 0 6 mm Clearance 0 0098 0 0138 in
223. iction plates do not mix up at opening the package NOTICE If new dry steel plates and friction plates are in stalled apply engine oil to the surfaces of each plate to avoid clutch plate seizure 6 14 CLUTCH Clutch e Apply molybdenum disulfide grease to the push rod end A sliding portion B of the push rod holder NOTE ODo not close the oil passage hole on the push rod holder with the molybdenum disulfide grease e Install the push rod and push rod holder e Apply molybdenum disulfide grease to the needle bearing C and washer D and install them e Install the clutch spring plate A and clutch springs e Tighten Torque Clutch Spring Bolts B 8 8 Nm 0 90 kgf m 78 in 1b e Install the clutch cover see Clutch Cover Installation GFO6217BW2 C CLUTCH 6 15 Clutch e Check the release shaft lever position e Pushing A the release shaft lever B lightly forward measure the distance C between the release shaft lever and bracket D Release Shaft Lever Position Standard 68 6 76 4 mm 2 70 3 01 in x If the lever position is not within the standard select the correct thickness of adjusting washer s according to the tables shown Adjusting Washers Thickness Part Number 1 5 mm 0 06 in 92200 1548 1 0 mm 0 04 in 92200 0045 Release Shaft Lever Position and Adjusting Washer Selection Washers Posi
224. iew Specifications oeooaoaaneneoenneneaeneene Special Tools and Sealant Cylinder Head Cover Cylinder Head Cover Removal Cylinder Head Cover Installation Camshaft Chain Tensioner Camshaft Chain Tensioner Hemova Camshaft Chain Tensioner Installation Camshafts areri aih ekai Camshaft Removal Camshaft Installation Camshaft Chain Removal Camshaft Chain Installation Camshaft and Camshaft Cap Wear Inspection Camshaft Runout Inspection Cam Wear Inspection Cylinder Head Cylinder Compression Measurement AA Cylinder Head Removal Cylinder Head Installation Cylinder Head Cleaning Cylinder Head Warp Inspection VI Valve Clearance Inspection Valve Clearance Adjustment Valve Removal Valve Installation Valve Guide Removal 5 14 5 16 5 16 5 17 5 20 5 20 5 20 5 21 5 21 5 22 5 22 5 23 5 24 5 25 5 25 5 26 5 26 5 26 5 26 5 27 5 27 Valve Guide Installation Valve Valve Guide Clearance Measurement Wobble Method Valve Seat Inspection Valve Seat Repair Cylinder and Piston Cylinder Removal
225. if they are damaged e Apply a thin coat of PBC Poly Butyl Cuprysil grease to the caliper holder shafts C and holder holes PBC is a special high temperature water resistance grease e Assemble the caliper and caliper holder e Install the brake pads see Brake Pad Installation in the Brakes chapter e Install the calipers see Caliper Installation in the Brakes chapter e Wipe up any spilled brake fluid on the caliper with wet cloth Brake Hoses and Connections Inspection e Inspect the brake hose and fittings for deterioration cracks and signs of leakage OThe high pressure inside the brake line can cause fluid to leak A or the hose to burst if the line is not properly main tained Bend and twist the rubber hose while examining it x Replace the hose if any cracks B or bulges C are no ticed x Tighten any loose fittings Brake Hose Replacement NOTICE Brake fluid quickly ruins painted surfaces any spilled fluid should be completely washed away immediately GL1001018S1 Periodic Maintenance Procedures PERIODIC MAINTENANCE 2 47 Front Brake Hose e Remove Brake Hose Clamp Bolts A Brake Hose Clamps B Rear Brake Hose e Remove Brake Hose Clamps A e Remove Bolts A Rear Caliper Guard B e Remove Rear Master Cylinder Mounting Bolts A e Remove the front rear brake hose banjo bolts A and washers B e Replace the washers with new ones OWhen
226. imit Valve Seat Surface Outside Diameter Exhaust 30 4 30 6 mm 1 197 1 205 in Intake 35 4 35 6 mm 1 394 1 402 in Width Exhaust 0 8 1 2 mm 0 03 0 05 in Intake 0 5 1 0 mm 0 02 0 04 in Valve Spring Free Length Exhaust Outer Inner Intake Outer Inner 38 92 mm 1 532 in 35 66 mm 1 404 in 39 28 mm 1 546 in 36 05 mm 1 419 in 37 5 mm 1 48 in 34 2 mm 1 35 in 37 8 mm 1 49 in 34 5 mm 1 36 in Cylinder Piston Cylinder Inside Diameter Piston Diameter Piston Cylinder Clearance Piston Ring Ring Groove Clearance Top Piston Ring Groove Width Top Piston Ring Thickness Top Piston Ring End Gap Top Oil Piston Pin Diameter Piston Pin Hole Diameter Connecting Rod Small End Inside Diameter 96 025 96 037 mm 3 7805 3 7810 in 95 970 95 980 mm 3 7783 3 7787 in 0 045 0 067 mm 0 0018 0 0026 in 0 04 0 08 mm 0 002 0 003 in 0 83 0 85 mm 0 0327 0 0335 in 0 77 0 79 mm 0 030 0 031 in 0 23 0 33 mm 0 0091 0 0130 in 0 15 0 50 mm 0 0059 0 0197 in 18 991 19 000 mm 0 74768 0 74803 in 19 004 19 010 mm 0 74819 0 74842 in 19 019 19 030 mm 0 74878 0 74921 in 96 12 mm 3 784 in 95 82 mm 3 772 in 0 18 mm 0 0071 in 0 93 mm 0 037 in 0 70 mm 0 028 in 0 6 mm 0 02 in 0 8 mm 0 03 in 18 96 mm 0 7465 in 19 08 mm
227. in harness Output Voltage Standard DC 3 80 4 20 V at standard atmospheric pressure 101 32 kPa 76 cmHg NOTE OThe output voltage changes according to local atmo spheric pressure e Disconnect the power supply harness x If the reading is out of the usable range replace the sen sor x If the reading is within the usable range remove the ECU and check the wiring for continuity between the main har ness connectors ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Intake Air Pressure Sensor Connector B BL lead C ECU terminal 6 GY lead D ECU terminal 24 GC17984ES1 GC17985ES1 3 40 FUEL SYSTEM DFI Intake Air Pressure Sensor Service Code 12 x If the wiring is good check the sensor for various vacuum e Remove the intake air pressure sensor A and disconnect the vacuum hose from the sensor e Connect an auxiliary hose B to the intake air pressure sensor e Temporarily install the intake air pressure sensor e Connect a digital meter C vacuum gauge D the fork oil level gauge E and the measuring adapter to the intake air pressure sensor Special Tools Fork Oil Level Gauge 57001 1290 Vacuum Gauge 57001 1369 Measuring Adapter 57001 1700 Intake Air Pressure Sensor Output Voltage Connections to Adapter Digital Meter W sensor BL lead Digital Meter BK sensor GY lead
228. in the Wheels Tires chapter Air Valve Plug A e Bleed air by pushing down the air valve NOTE Gre ODo not compress the inner tube GM04531BS1 e Loosen the front fork clamp bolts upper A NOTE OSet rebound and compression damping setting to the softest settings before disassembly to minimize damp ing forces that can hinder disassembly Record the set ting before turning the adjuster 2 58 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Turn the handlebar to one side and loosen the fork top plug A Special Tool Top Plug Wrench 49 mm B 57001 1653 NOTE ODo not remove the top plug e Remove Front Fork see Front Fork Removal in the Suspension chapter e Thoroughly clean the fork before disassembly NOTICE Be careful not scratch the inner tube and not to damage the dust seal Avoid scratching or damaging the inner tube or the dust seal Use a mild detergent and sponge out dirt with plenty of water e Using the top plug wrench A remove the fork top plug B from the outer tube C and slowly slide down D the outer tube Special Tool Top Plug Wrench 49 mm 57001 1653 e Place an oil pan under the front fork and drain the fork oil A NOTE OPump the fork tube several times to discharge the fork oil e Raise the outer tube and temporarily install the fork top plug A to the outer tube B with the top plug wrench C Special Tool Top Plug Wrench 49 m
229. in the Fuel System DFI chapter Gear Position Switch Installation e Refer to the Gear Position Switch Installation in the Fuel System DFI chapter Gear Position Switch Inspection e Refer to the Gear Position Switch Inspection in the Fuel System DFI chapter APPENDIX 17 1 Appendix Table of Contents Cable Wire and Hose Routing EE 17 2 Troubleshooting GUIDE astas iii ida a aa aa Kaana les 17 26 17 2 APPENDIX Cable Wire and Hose Routing KX450FC WN A NOS Throttle Cable Accelerator Run the engine stop switch lead launch Throttle Cable Decelerator Bands Hold the engine stop switch lead and launch control mode button lead Cut the excess of the bands into 15 mm length or shorter Launch Control Mode Button Engine Stop Switch Clutch Cable Run the throttle cables into the guide 12 13 14 68097440 6 control mode button lead and clutch cable into the guide Kawasaki Diagnostic System Connector 10 Launch Control Mode Button Lead Con DFI Setting Data Selection Connector nector ECU Connector Right Side Left Side APPENDIX 17 3 Cable Wire and Hose Routing This page intentionally left blank 17 4 APPENDIX Cable Wire and Hose Routing KX450FD GB09027E 6 APPENDIX 17 5 Cable Wire and Hose Routing OO JO Om P Gab A Front Brake Hose Run the throttle cables inside of the number plate Clutch Cable
230. inal e Refer to the Self diagnosis Procedures connect the 12 V battery to the main harness e Measure the power supply voltage with the engine stopped Power Supply Voltage Standard Battery Voltage x If the voltage is out of the standard check the power sup ply wiring see Fuel Injector Circuit x If the reading is within the standard check the output volt age see Fuel Injector Output Voltage Inspection GC17730DS1 3 58 FUEL SYSTEM DFI Fuel Injector Service Code 41 Fuel Injector Output Voltage Inspection NOTE OBe sure the battery is fully charged e Remove the ECU see ECU Removal ODo not disconnect the ECU connector e Refer to the Self diagnosis Procedures connect the 12 V battery to the main harness e Using the needle adapter set connect a digital meter A to the ECU connector B Special Tool Needle Adapter Set 57001 1457 Fuel Injector Output Voltage Connections to ECU Connector Digital Meter BL R lead ECU Terminal 16 Digital Meter Battery Terminal e Measure the output with the engine stopped with the con nector jointed Output Voltage Standard Battery Voltage e Disconnect the power supply harness x If the reading is within the standard check the ECU for its ground and power supply see ECU Power Supply In spection x If the ground and power supply are good replace the ECU see ECU Removal Installation x If the readin
231. ine stops If the connector is changed during idling the DFI setting does not change OThe DFI setting is fixed to the standard track condi tion when the connector is removed with the engine stopped Always have one of the three connectors at tached when riding to prevent mud and dust from accu mulating in the connector terminal OThe DFI setting can be changed to suit user s prefer ence using the KX FI calibration kit OWhen the connector is not attached the KX Fl calibra tion kit cannot change the DFI setting 1 12 GENERAL INFORMATION Technical Information DFI Setting Data Selection Connector Circuit ane T S A S ze DRAN BL Ed RL W R K DRAN W BL BK W o i as a 1 ECU 2 White Connector 3 Frame Ground 1 4 Green Connector 5 Black Connector DFI Setting Map Image BK w BK W 6B06680Bw1 C G08066316 6 A Correction Value B Throttle Opening C Engine Speed D Ignition Timing Soft E Ignition Timing Hard F Fuel Injection Quantity Soft G Fuel Injection Quantity Hard Technical Information Launch Control Mode GENERAL INFORMATION 1 13 Overview e The launch control mode can be used to adjust ignition timing to reduce rear wheel spin at start up and help riders get better starts on slippery terrain e When the launch control mode is activated the ignition timing is retarded to reduce rear wheel spin e Ho
232. ing force can be adjusted easily so changing oil viscosity unnecessary Rebound Damping Adjustment e Turn the rebound damping adjuster A on the rear shock absorber lower end with a standard tip screwdriver until you feel a click x If the damper setting feels too soft or too stiff adjust it in accordance with the following table Seated position A adjuster turned fully clockwise NOTICE Do not force the rebound damping force adjuster beyond the fully seated position or the adjusting mechanism may be damaged Rebound Damping Adjuster Setting Standard 16 clicks B KX450FC 19 clicks C KX450FD EUR BR TH 20 clicks D KX450FD Softer Counterclockwise E Harder Clockwise F Number of turns counterclockwise usable range 33 clicks or more Counterclockwise from the fully seated position NOTE OAdjustment of the rebound damping adjuster for the rear suspension will slightly affect the compression damping force Always make any damping adjustments in small steps and test their effects before using them in com petition Compression Damping Adjustment There are two adjustments you can make to the rear shock absorber gas reservoir High Speed Compression Damping Adjuster A Low Speed Compression Damping Adjuster B 33 32 3121 20 1918 17 161514 5 fe SA tt DO GM05494BS1 13 20 SUSPENSION Rear Shock Absorber e Adjust the high speed compression damping
233. ing the engine and goes off for 3 seconds and then keeps going on with engine running DFI problem O unlights light ECU or its wiring fault O sometimes lights up probably wiring fault Sino spark O no fuel flow O no fuel in tank O no fuel pump sound O engine flooded do not crank engine with throttle opened which promotes engine flooding O other O right after starting O when moving off O when opening throttle grip O when stopping the motorcycle O when closing throttle grip O when cruising O other O very low fast idle speed O very low idle speed O very high idle speed O rough idle speed O spark plug loose tighten it O spark plug dirty broken or gap maladjusted adjust it D afterring O engine oil viscosity too high E clutch slipping O engine overheating O other Poor running or no power at high speed O spark plug loose tighten it E spark plug incorrect replace it O spark plug dirty broken or gap maladjusted remedy it knocking fuel poor quality or O engine overheating incorrect O brake dragging O engine oil level too high O clutch slipping O engine oil viscosity too high O other FUEL SYSTEM DFI 3 21 DFI System Troubleshooting Guide NOTE OThis is not an exhaustive list giving every possible cause for each problem listed It is meant simply as a rough guide to assist the troubleshooting for some of the mor
234. ir Pressure Sensor Output Voltage In spection x If the reading is out of the standard remove the ECU and check the wiring for continuity between the main harness connectors ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Intake Air Pressure Sensor Connector B R Y lead C ECU terminal 13 GY lead D ECU terminal 24 x lf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation GC17982ES1 GC17983ES1 Intake Air Pressure Sensor Service Code 12 FUEL SYSTEM DFI 3 39 Intake Air Pressure Sensor Output Voltage Inspection e Measure the intake air pressure sensor output voltage in the same way as input voltage inspection Note the fol lowing ODisconnect the intake air pressure sensor connector and connect the measuring adapter A between these con nectors Main Harness B Intake Air Pressure Sensor C Digital Meter D Special Tool Measuring Adapter 57001 1700 Intake Air Pressure Sensor Output Voltage Connections to Adapter Digital Meter W sensor BL lead Digital Meter BK sensor GY lead e Measure the output voltage with the engine stopped and with the connector joined e Refer to the Self diagnosis Procedures connect the 12 V battery to the ma
235. irty broken or gap malad justed Troubleshooting Guide Spark plug cap or spark plug lead trouble Spark plug cap shorted or not in good con tact Spark plug incorrect heat value ECU trouble Crankshaft sensor trouble Flywheel damage Ignition coil trouble Wiring connector not in good contact Fuel air mixture incorrect Air cleaner clogged poorly sealed or miss ing Air cleaner duct loose Water or foreign matter in fuel Throttle body assy holder loose Fuel to injector insufficient Fuel tank air vent obstructed Fuel line clogged Fuel pump trouble Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent de formed worn carbon accumulation on the seating surface Decompression trouble Knocking Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect heat valve ECU trouble Other Throttle valve won t fully open Brake dragging Air cleaner clogged Water or foreign matter in fuel Clutch slipping Overheating Engine oil level too high Engine oil viscosity too high Drive train trouble Crankshaft bearing worn or damage Engine Overheating Firing incorrect Spark plug dirty broken or maladjusted Spark plug incorrect ECU
236. ish braking performance and can cause an accident resulting in injury or death If the brake lever has a soft or spongy feel ing mushy when it is applied there might be air in the brake lines or the brake may be defective Do not operate the vehicle and service the brake sys tem immediately NOTE OThe procedure to bleed the front brake line is as follows Bleeding the rear brake line is the same as for the front brake e Level the brake fluid reservoir e Remove Screws A Reservoir Cap B Diaphragm e Check that there is plenty of fluid in the reservoir e Slowly pump the brake lever several times until no air bubbles rise up from the bottom of the reservoir OBleed the air completely from the master cylinder by this operation e Remove the rubber cap A from the bleed valve on the caliper e Attach a clear plastic hose B to the bleed valve on the caliper and run the other end of the hose into a container 12 12 BRAKES Brake Fluid e Bleed the brake line and caliper as follows ORepeat this operation until no more air can be seen com ing out into the clear plastic hose 1 Pump the brake lever until it becomes hard and apply the brake and hold it A 2 Quickly open and close B the bleed valve while holding the brake applied 3 Release the brake C NOTE OThe fluid level must be checked often during the bleed ing operation and replenished with fresh brake fluid as necessary If the fluid in the
237. iston rod is not extend remove the base valve assembly and perform the air bleeding pour the specified amount fork oil and discharge an excess of oil e Make sure about 16 mm 0 63 in A of push rod thread is exposed from the locknut B e Completely wipe off the fork oil from the spring A and cylinder unit B e Insert the spring and cylinder unit to the outer tube e Temporarily tighten the fork top plug A by using the top plug wrench B Special Tool Top Plug Wrench 49 mm 57001 1653 PERIODIC MAINTENANCE 2 55 Periodic Maintenance Procedures e Hold the axle holder with a vise OProtect the axle holder with a soft jaw or heavy cloth when using a vise A WARNING Clamping the axle holder too tight can damage it which will affect riding stability Do not clamp the axle holder too tight e Compress the outer tube by hands and install the top plug wrench A between the axle holder bottom and locknut Special Tool Top Plug Wrench 49 mm 57001 1653 A WARNING The fork spring applies pressure to the adjuster as sembly and can eject the special tool with substan tial force if the tool is not properly and securely placed Be sure the tool is fully in place as shown in the photo and keep fingers away to avoid getting them pinched between the tool adjuster assembly and axle holder ESHBTIO P e Insert the push rod A into the piston rod e Replace the O ring A and g
238. it replace the axle GJ04022BS1 Tires WHEELS TIRES 10 11 Air Pressure Inspection Adjustment e Refer to the Air Pressure Inspection Adjustment in the Pe riodic Maintenance chapter Tire Removal e Remove the wheel see Front Rear Wheel Removal NOTICE Do not lay the front wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground e To maintain wheel balance mark A the air valve position on the tire with chalk so that the tire can be reinstalled in the same position Align B e Remove the air valve cap C e Take out the valve core A to let out the air e Remove the air valve nut e Loosen the bead protector nut A e Lubricate the tire beads and rim flanges on both sides with a soap and water solution or rubber lubricant This helps the tire beads slip off the rim flanges NOTICE Never lubricate with engine oil or petroleum distil lates because they will deteriorate the tire GJ05126BS1 10 12 WHEELS TIRES Tires e Break the beads away from both sides of the rim with a suitable bead breaker e Lubricate the suitable tire irons A and rim protectors B with soap and water solution or rubber lubricant Special Tool Rim Protector 57001 1063 e Step on the side of the tire opposite air valve and pry the tire off the rim with the tire iron
239. ith a new one NOTICE The bladder is damaged and its performance is re duced noticeably if the bladder is damaged or de formed during reuse e Apply grease to the lip B of the bladder and install the reservoir cap C GMO5066BS1 e Press the reservoir cap assembly A downward slowly into the gas reservoir to 10 mm 0 39 in B from the gas reservoir upper end 4 GS14083BS1 e Incline the rear shock absorber to the gas reservoir side to release the air in the gas reservoir NOTICE Ensure that no air remains in the system e Replace the circlip with a new one A WARNING Pressurized nitrogen gas can explode out of the shock reservoir cap if a weakened deformed or flawed circlip is used allowing oil and internal parts to burst out of the reservoir with great force and cause serious injury To avoid injury always use a new circlip whenever the shock is reassembled e Mount the circlip A in the groove in the gas reservoir GS14081BS1 PERIODIC MAINTENANCE 2 71 Periodic Maintenance Procedures e Pour the suspension oil into the rear shock body to 50 mm 2 0 in A from the lower end of the rear shock body B Suspension Oil KHV10 K2C 1L 45024 0002 e Adjust the gas reservoir damping adjusters A to the hard est position e Insert the piston end A of the piston rod assembly into the rear shock body C slowly Do not inser
240. ity Inspection Capacitor Connector A Launch Control Mode Button Connector B O Y lead C R W lead D ODisconnect the ECU connector Wiring Continuity Inspection ECU Connector A Launch Control Mode Button Connector B BL W lead ECU Terminal 21 C x If the wiring is good check the orange Fl warning indicator light LED e Connect the 12 V battery A to the launch control mode button connector B as shown in the figure x If the orange Fl warning indicator light LED does not go on replace the launch control mode button x lf the orange Fl warning indicator light LED goes on check the ECU for its ground and power supply see ECU Power Supply Inspection GC17990ES1 GC17991ES1 GC17992ES1 FUEL SYSTEM DEI 3 65 Orange FI Warning Indicator Light LED Orange FI Warning Indicator Light LED Circuit BL W z 1 5 z S 5 zt SS Wale a He 1 ECU 2 Orange Fl Warning Indicator Light LED 3 Capacitor 4 Frame Ground 1 GC17980EW1 C 3 66 FUEL SYSTEM DFI ECU ECU Identification OMost countries have their own regulations so each ECU has different characteristic So do not confuse ECU with each other and use only the ECU for your model Other wise the motorcycle cannot clear the regulation ECU Identification KX450FC Part Number A Specification 21175 0390 US CA 2117
241. k under the frame so that the front wheel off the ground and remove the screw A at the top of the front fork top plugs to let the air pressure equalize Special Tools Jack 57001 1238 Jack Attachment 57001 1608 NOTE ODo not use the sidestand when adjusting the air pres sure OAdjust the air pressure when the front forks are cold e Replace the O ring with a new one e Install the screw Air Pressure Adjustment KX450FD Before riding adjust the air pressure to the specific value e Place the jack under the frame so that the front wheel off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 NOTE ODo not use the sidestand when adjusting the air pres sure e Remove Number Plate see Number Plate Removal in the Frame chapter Air Valve Plug e Install the air valve adapter A e Apply grease to the O ring on the air valve adapter 13 12 SUSPENSION Front Fork NOTE OWhen using the air valve adapter make sure that there is no dust or foreign material on the threads and O ring OWhen the handlebar clamps are in the front position in the steering stem head the air valve adapter cannot be installed e Adjust the air pressure in each fork leg within the specified range below Air Pressure Standard setting 240 kPa 2 4 kgf cm 35 psi Adjustable Range 220 280 kPa 2 2 2 8 kgf cm 32 41 psi AWARNING When riding and transporting the motorcycle make sure that the air
242. ki KHV10 K2C or equivalent approx 417 mL 14 1 US oz 1 1 2 turns out KX450FC EUR BR 1 1 4 turns out KX450FC 1 3 4 turns out KX450FD EUR BR TH 1 1 2 turns out KX450FD 10 clicks counterclockwise KX450FC EUR BR 9 clicks counterclock wise KX450FC 8 clicks counterclockwise KX450FD EUR BR TH 11 clicks counterclockwise KX450FD 1 000 kPa 10 2 kgf cm 145 psi 19 987 20 000 mm 0 78689 0 78740 in 19 987 20 000 mm 0 78689 0 78740 in 15 950 16 000 mm 0 62795 0 62992 in TIR 0 1 mm 0 004 in or less 250 mm 9 84 in Adjustable Range 2 turns out Adjustable Range 22 clicks 19 85 mm 0 7815 in 19 85 mm 0 7815 in 15 92 mm 0 6268 in TIR 0 2 mm 0 008 in 13 10 SUSPENSION Special Tools Oil Seal 8 Bearing Remover 57001 1058 Hook Wrench R37 5 R42 57001 1101 ST5710588T ST5711018ST Bearing Remover Head 20 x 22 57001 1293 Bearing Driver Set 57001 1129 ST5711298T Jack 57001 1238 ST5712388ST Bearing Remover Shaft 13 57001 1377 ST571293ST ST5713778T Fork Oil Seal Driver 648 57001 1509 ST5715098T Jack Attachment ES Jl ST571608ST Front Fork SUSPENSION 13 11 Air Pressure KX450FC If you felt that a front fork is strong during a driving place the jac
243. l System DFI chapter e Be sure to place a piece of cloth around each fuel hose joint e Wipe off the dirt of the surface A around the connection using a cloth or a soft brush GS05250BS1 J616153BS1 2 16 PERIODIC MAINTENANCE Periodic Maintenance Procedures When removing with standard tip screwdriver e Insert the standard tip screwdriver A into the slit B on the joint lock C e Turn the driver to disconnect the joint lock When removing with fingers e Open and push up A the joint lock B with your fingers NOTICE Prying or excessively widening the joint lock ends for fuel hose removal will permanently deform the joint lock resulting in a loose or incomplete lock that may allow fuel to leak and create the potential for a fire explosion To prevent fire or explosion from a damaged joint lock do not pry or excessively widen the joint lock ends when removing the fuel hose The joint lock has a retaining edge that locks around the housing GSO5269BS1 e Pull the fuel hose joint A out of the delivery pipe A WARNING Fuel is flammable and explosive under certain con ditions and can cause severe burns Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is dis connected fuel spills out from the hose and the pipe Cover the hose connection with a clean shop towel to prevent fuel spillage
244. l Filter Replacement e Refer to the Oil Filter Replacement in the Periodic Main tenance chapter Oil Screen Scavenge Removal e Remove Oil Pump Scavenge Cover see Oil Pump Scavenge Removal Oil Screen A Oil Screen Scavenge Installation e Clean the oil screen thoroughly whenever it is removed for any reason see Oil Screen Scavenge Cleaning e Apply engine oil to the rubber portion A of the oil screen e Install the oil screen as shown in the figure Carved Line B White Paint Mark C e Install the oil pump scavenge cover see Oil Pump Scavenge Installation Oil Screen Feed Removal e Split the crankcase see Crankcase Disassembly in the Crankshaft Transmission chapter e Remove Bolts A Oil Screen B Oil Screen Feed Installation e Clean the oil screen thoroughly whenever it is removed for any reason see Oil Screen Feed Cleaning e Replace the O ring A with a new one e Apply grease to the O ring and install it 7 10 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter e Install the oil screen A and tighten the bolts B Torque Oil Screen Feed Mounting Bolts 9 8 N m 1 0 kgf m 87 in Ib Oil Screen Scavenge Cleaning e Remove the oil screen see Oil Screen Scavenge Re moval e Clean the oil screen with a high flash point solvent and remove any particles stuck to them WARNING Gasoline and low flash point solvents can be flammable and or e
245. le speed is correct To increase idle speed B To decrease idle speed C e Open and close the throttle a few times to make sure that the idle speed is within the specified range Readjust if necessary Air Cleaner Element Cleaning and Inspection NOTE Oln dusty areas the element should be cleaned more frequently than recommended interval OAfter riding through rain or on muddy roads the element should be cleaned immediately OSince repeated cleaning opens the pores of the ele ment replace it with a new one in accordance with the Periodic Maintenance Chart Also if there is a break in the element material or any other damage to the ele ment replace the element with a new one AWARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the element in a well ventilated area and take care that there is no spark or flame any where near the working areas Do not use gasoline or low flash point solvents to clean the element PERIODIC MAINTENANCE 2 19 Periodic Maintenance Procedures e Remove Seat see Seat Removal in the Frame chapter Wing Bolt A Air Cleaner Element B e Stuff a clean lint free towel into the air cleaner duct so no dirt is allowed to enter the throttle body assy e Wipe out the inside of the air cleaner housing with a clean damp towel NOTICE Check inside of the inlet tract and throttle body assy for dirt If dirt
246. level inspection window NOTE Olf the motorcycle has just been used wait several min utes for all the oil to drain down Olf no oil appears in the oil level inspection window tip the motorcycle slightly to the right until oil is visible then re turn to an upright position If no oil appears even when tipped at an extreme angle remove the drain bolt to empty any oil reinstall the drain bolt and refill with the specified amount of oil Olf the oil has just been changed start the engine and run it for several minutes at idle speed This fills the oil filter with oil ODo not run the engine at high engine speed Stop the engine then wait several minutes until the oil settles NOTICE Racing the engine before the oil reaches every part can cause engine seizure x If the oil level is too high remove the excess oil through the filler opening using a syringe or some other suitable device x lf the oil level is too low add the correct amount of oil through the oil filler opening Use the same type and make of oil that is already in the engine NOTE Olf the engine oil type and make are unknown use any brand of the specified oil to top off the level rather than running the engine with the oil level low Then at your earliest convenience change the oil completely Engine Oil Change e Refer to the Engine Oil Change in the Periodic Mainte nance chapter ENGINE LUBRICATION SYSTEM 7 9 Engine Oil and Oil Filter Oi
247. lightly so that the filler neck is lo cated uppermost in order to exhaust the air accumulated J in the radiator NOTE AS OPour in the coolant slowly so that it can expel the air from the engine and radiator OThe radiator cap must be installed in two steps First 0004146851 turn the cap clockwise to the first stop Then push down on it and turn it the rest of the way e Check the cooling system for leaks Air Bleeding e Start the engine warm up the engine thoroughly and then stop the engine e Wait until the engine cools down e Remove the radiator cap e Check the coolant level see Coolant Level Inspection in the Periodic Maintenance chapter x If the coolant level is low add coolant up to the bottom of the filler neck e Install the radiator cap e Check the cooling system for leaks 4 8 COOLING SYSTEM Coolant Cooling System Pressure Testing NOTICE During pressure testing do not exceed the pres sure for which the system is designed to work The maximum pressure is 123 kPa 1 25 kgf cm 18 psi e Remove the radiator cap and install a cooling system pressure tester A and adapter B on the radiator filler neck C NOTE OWet the adapter cap sealing surfaces with water or coolant to prevent pressure leaks e Build up pressure in the system carefully until the pres sure reaches 123 kPa 1 25 kgf cm 18 psi e Watch the gauge for at least 6 seconds x If
248. lity 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 dam age 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 per formance 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 exces sively 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 con tact area Be sure to maintain proper alignment and use smooth movements when installing 68020138 68020148 68020158 6B02016B_ GENERAL INFORMATION 1 5 Before Servicing Ball Bearing and Needle Bearing Do not remove pressed ball or nee
249. ll ventilated area and take care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Do not use gasoline or a low flash point solvent to clean the oil pressure relief valve If cleaning does not solve the problem replace the oil pressure relief valve as an assembly The oil pressure relief valve is precision made with no allowance for re placement of individual parts 6608060251 ENGINE LUBRICATION SYSTEM 7 13 Oil Pump Oil Pump Scavenge Removal e Remove Flywheel see Flywheel Removal in the Electrical Sys tem chapter Oil Pump Scavenge Cover Bolts A Lower Camshaft Chain Guide B Oil Pump Cover C e Remove Oil Pump Shaft A with Inner Rotor B Outer Rotor C Oil Pump Scavenge Installation e Assemble the following parts as shown in the figure Oil Pump Shaft A Pin B Inner Rotor C OFit the pin into the groove of the inner rotor e Install the dowel pins A to the crankcase e Apply engine oil to the each oil pump rotor and sliding surface of the oil pump shaft e Install Outer Rotor B Inner Rotor Assy C OTurn the oil pump shaft so that the slot in its shaft fits onto the projection of the oil pump driven gear shaft e Install Oil Pump Cover A Lower Camshaft Chain Guide B e Tighten Torque Oil Pump Scavenge Cover Bolts C 9 8 N m 1 0 kgf m 87 in lb 7 14 ENGINE
250. lled correctly on the delivery pipe by sliding the joint x If it comes off reinstall the hose joint e Connect the fuel pump lead connector KX450FC e Before installing the fuel tank check that both throttle ca bles A run over the black connector B OTo prevent the bottom of the fuel tank from pushing the throttle cables run the throttle cables over the black con nector correctly e Hook the band to the fuel tank e Tighten the fuel tank mounting bolt e After installing the fuel tank make sure that both throttle cables A outer move slightly by pulling them back and forth in the upper space of the right side of the fuel tank Check that both throttle cables run under the frame right side B as shown in the figure e Install the removed parts see appropriate chapters Olnsert the fuel tank breather hose into the steering stem hole NOTE OFor easily starting the engine connect the 12 V battery to the main harness see Self diagnosis Procedures OWhen the battery is connected the fuel pump is driven and the pressure of the fuel line increases Fuel Tank Cleaning e Refer to the Fuel Tank Cleaning in the Periodic Mainte nance chapter COOLING SYSTEM 4 1 Cooling System Table of Contents EXPO WEE 4 2 Specifications EE 4 4 Special O Sii A A Aba 4 5 81010 E diria ET 4 6 Coolant Level Inspectiohissif rss een agama caeueenaabunrhorarduahatencgemedawevesnmauenesbuatengenoune
251. loss and engine over heating resulting in possible engine damage Any riding conditions that increase engine temperature will further reduce idling time before coolant loss occurs These conditions include high ambient temperature sandy or muddy terrain or other con ditions causing high engine loads at low speeds Furthermore warming the engine up excessively before operation or leaving idling with the hot engine temperature after operation results in the engine overheating too 2 18 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Start the engine and warm it up thoroughly e With the engine idling turn the handlebar to both sides A x If handlebar movement changes the idle speed the throt tle cable may be improperly adjusted or incorrectly routed or it may be damaged Be sure to correct any of these conditions before riding see Cable Wire and Hose Rout ing section in the Appendix chapter A WARNING Operation with improperly adjusted incorrectly routed or damaged cables could result in an unsafe riding condition Follow the service manual to make sure to correct any of these conditions e Check the idle speed using the engine revolution tester A for high accuracy x lf the idle speed is out of specified range adjust it Idle Speed Standard 2 000 50 r min rpm Idle Speed Adjustment e Start the engine and warm it up thoroughly e Turn the idle adjusting screw A until the id
252. lts 9 8 1 0 87 in lb Coolant Drain Bolt 7 0 0 71 62 in lb Water Pump Impeller Bolt 9 8 1 0 87 in lb Water Hose Clamp Screws 3 0 0 31 27 in lb Radiator Mounting Bolts 9 8 1 0 87 in lb Radiator Screen Bolts 9 8 1 0 87 in lb Engine Top End Camshaft Sprocket Bolts 12 1 2 106 in Ib L Cylinder Head Cover Bolts 9 8 1 0 87 in lb Camshaft Cap Bolts 9 8 1 0 87 in lb MO S Cylinder Head Bolts M10 59 6 0 44 MO S Cylinder Head Bolts M6 12 1 2 106 in 1b S Water Hose Fitting Bolts 9 8 1 0 87 in lb Oil Line Plug 3 0 0 31 27 in lb L Plug 20 2 0 15 L Throttle Body Assy Clamp Screw 2 0 0 20 18 in lb 2 6 PERIODIC MAINTENANCE Torque and Locking Agent Engine Lubrication System Torque Fastener Nem kgfm SO Remarks Throttle Body Assy Holder Screws 9 8 1 0 87 in lb L Cylinder Bolt 12 1 2 106 in Ib S Camshaft Chain Tensioner Cap Bolt 5 0 0 51 44 in Ib Camshaft Chain Tensioner Mounting Bolts 9 8 1 0 87 in lb Oil Pump Scavenge Cover Bolts 9 8 1 0 87 ml Rear Camshaft Chain Guide Bolt 15 1 5 11 Exhaust Pipe Cover Bolts 12 1 2 106 in lb Exhaust Pipe Holder Nuts 20 2 0 15 S Muffler Mounting Bolts 20 2 0 15 S Muffler Clamp Bolt 16 5 1 68 12 2 S Clutch Clutch Cover Bolts 9 8 1 0 87 in lb Right Engine Cover Bolts 9 8 1 0 87 in lb Clutch Spring Bolts 8 8 0 90 78 ml Clutch Hub Nut 98 10 72 R Oil Filter Cap Bolt 9 8 1 0 87 in lb Oil Filler Plug 3 5 0 36 31 ml Breather Fitting 15 1 5 11 L Piston Oil Nozzle Bolt 7
253. ly charged e Remove Radiator Shroud see Radiator Shroud Removal in the Frame chapter Fuel Tank see Fuel Tank Removal Fuel Hose see Fuel Hose Replacement in the Periodic Maintenance chapter OBe sure to place a piece of cloth around the fuel outlet pipe of the fuel pump and the delivery pipe of the throttle body assy A WARNING Fuel is flammable and explosive under certain con ditions and can cause severe burns Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is dis connected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with a piece of clean cloth to prevent fuel spillage e Install the fuel pressure gauge adapter A and fuel hoses Special Tool 57001 1607 B between the fuel pump and the throttle body assy e Secure the fuel hoses with the clamps e Connect the pressure gauge C to the fuel pressure gauge adapter Special Tools Oil Pressure Gauge 5 kgf cm 57001 125 Fuel Pressure Gauge Adapter 57001 1593 Fuel Hose 57001 1607 A WARNING Fuel is extremely flammable and can be explosive under certain conditions resulting in serious injury or death Do not try to start the engine with the fuel hoses disconnected e Connect the fuel pump lead connector e Refer to the Self diagnosis Procedures connect the 12 V battery to the main harness NOTE Olnspect the fuel leaka
254. ly for any damage x If the screen is damaged replace the oil screen with a new one e Install the oil screen see Oil Screen Feed Installation GGO7002BS1 7 12 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Oil Pressure Relief Valve Removal e Remove Right Engine Cover see Right Engine Cover Removal in the Clutch chapter Oil Pressure Relief Valve A Oil Pressure Relief Valve Installation e Apply a non permanent locking agent to the threads of the oil pressure relief valve and tighten it NOTICE Do not apply too much non permanent locking agent to the threads This may block the oil pas sage Torque Oil Pressure Relief Valve 15 N m 1 5 kgf m 11 ft Ib Oil Pressure Relief Valve Inspection e Remove the oil pressure relief valve see Oil Pressure Relief Valve Removal e Check to see if the valve A slides smoothly when push ing it in with a wooden or other soft rod and see if it comes back to its seat by spring B pressure NOTE Olnspect the valve in its assembled state Disassembly and assembly may change the valve performance If any rough spots are found during above inspection wash the valve clean with a high flash point solvent and blow out any foreign particles that may be in the valve with compressed air WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the oil pressure relief valve in a we
255. ly of the crankshaft demands exacting tolerances the disassembly and reassembly of the crank shaft can only be done by a shop having the necessary tools and equipment e Reassemble the crankshaft according to the standard tol erances in Specifications OConnecting rod bend twist see Connecting Rod Bend Inspection Connecting Rod Twist Inspection OConnecting rod big end radial clearance see Crankshaft Inspection OCold fitting tolerance between crankpin and flywheels 0 8 1 2 mm 0 03 0 05 in A 64 3 mm 2 53 in B OSide clearance between the connecting rod big end and one of flywheels see Crankshaft Inspection OCrankshaft runout see Crankshaft Inspection e Carefully align the oil passage hole in the right flywheel A with the one in the crankpin B at rebuilding of the crankshaft as shown G105328BS1 G105144BS1 9 18 CRANKSHAFT TRANSMISSION Crankshaft Crankshaft Inspection Connecting Rod Big End Radial Clearance Inspection e Set the crankshaft on V blocks and place a dial gauge A against the connecting rod big end e Push B the connecting rod first towards the gauge and then in the opposite direction The difference between two gauge readings is the radial clearance Connecting Rod Big End Radial Clearance Standard 0 002 mm 0 014 mm 0 00008 0 00055 in Service Limit 0 06 mm 0 0024 in x If the radial clearance exceeds the service limit crank
256. ly two bases by the two stud bolts OAssemble the parts of the bearing puller Special Tool 57001 135 as shown in the figure Stud Bolts E Arm F Center Bolt G Adapter H OTurn the center bolt by a wrench and pull the bearing inner race Steering Stem Stem Bearing Installation e Replace the bearing outer race with new ones e Apply grease to the outer races e Drive the outer races into the head pipe at the same time with the special tools Special Tools Head Pipe Outer Race Press Shaft A 57001 1075 Head Pipe Outer Race Driver 51 5 B 57001 1076 Head Pipe Outer Race Driver 54 5 C 57001 1077 GNO4015BS1 Guat P GNO4022BS1 Steering STEERING 14 7 e Replace the inner races with new ones e Apply grease to the lower tapered roller bearing A and drive it onto the stem with the steering stem bearing driver B and adapter C Special Tools Steering Stem Bearing Driver 57001 137 Steering Stem Bearing Driver Adapter 34 5 57001 1074 e Apply grease to the upper tapered roller bearing and in stall it in the head pipe e Install the stem through the head pipe and upper bearing and hand tighten the stem nut while pushing up the stem base e Install the stem head and washer and tighten the stem head nut lightly e Settle the bearing in place as follows OTighten the stem nut to 39 N m 4 0 kgf m 29 ft lb of torque To tighten the steering st
257. lywheel see Flywheel Removal in the Electrical Sys tem chapter Oil Pump Scavenge Cover Bolts A Lower Camshaft Chain Guide B e Disengage the camshaft chain from the crankshaft Camshaft Chain Installation e Engage the camshaft chain to the crankshaft e Install the lower camshaft chain guide e Tighten Torque Oil Pump Scavenge Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib e Install Flywheel see Flywheel Installation in the Electrical Sys tem chapter Camshafts see Camshaft Installation Camshaft and Camshaft Cap Wear Inspection e Measure each clearance between the camshaft journal and camshaft cap using plastigage press gauge A OTighten the camshaft cap bolts after applying molybde num disulfide oil to the thread of them Torque Camshaft Cap Bolts 9 8 N m 1 0 kgf m 87 in Ib NOTE ODo not turn the camshaft when the plastigage is be tween the journal and camshaft cap Camshaft Journal Camshaft Cap Clearance Standard 0 020 0 062 mm 0 0008 0 0024 in Service Limit 0 15 mm 0 0059 in If any clearance exceeds the service limit measure the diameter of each camshaft journal with a micrometer Camshaft Journal Diameter Standard 22 959 22 980 mm 0 9039 0 9047 in Service Limit 22 93 mm 0 9028 in x If the camshaft journal diameter is less than the service limit replace the camshaft with a new one and measure the clearance again x If the clearance still remains out of the se
258. m 57001 1653 PERIODIC MAINTENANCE 2 59 Periodic Maintenance Procedures e Hold the axle holder A with a vise OProtect the axle holder with a soft jaw or heavy cloth when using a vise A WARNING Clamping the axle holder too tight can damage it which will affect riding stability Do not clamp the axle holder too tight e Loosen the adjuster assembly B completely NOTE OWhen removing the rebound adjuster assembly do not use an impact wrench e Compress the outer tube by hands and remove the ad juster assembly from the axle holder part so that the lock nut appears about 20 30 mm 0 079 0 12 in e Hold the locknut A with a wrench B and remove the adjuster assembly C e Remove the push rod A NOTICE Removing the locknut and pushing the piston rod thread into the cylinder unit will damage the oil seal Do not remove the locknut from the piston rod e Remove the fork leg from the vise e Remove the fork top plug A with the top plug wrench B Special Tool Top Plug Wrench 49 mm 57001 1653 2 60 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Remove the cylinder unit A from the outer tube B NOTICE Disassembling the cylinder unit can lead to trouble Do not disassemble the cylinder unit e Holding the top plug wrench 57001 1653 A with a vise loosen the base valve assembly B using the top plug wrench 57001
259. m 87 in Ib e Pour the specified engine oil see Engine Oil Change PERIODIC MAINTENANCE 2 31 Periodic Maintenance Procedures Breather Hose Inspection e Be certain that the breather hose A are routed without being flattened or kinked and is connected correctly x If it is not correct it e Inspect the breather hose for damage or signs of deteri oration OThis hose should not be hard and brittle nor should be soft swollen Replace it if any damage is noticed Crankshaft Transmission Crankshaft Inspection e Remove Cylinder Head see Cylinder Head Removal in the En gine Top End chapter Cylinder see Cylinder Removal in the Engine Top End chapter Piston see Piston Removal in the Engine Top End chap ter e Make sure that the crankshaft rotate A smoothly in the neutral position x If the crankshaft will not turn smoothly check the connect ing rod big end side clearance x If the connecting rod big end side clearance is good check the bearings see Bearing Inspection in the Crank shaft Transmission chapter Connecting Rod Big End Side Clearance e Measure the connecting rod big end side clearance at right side of big end using a thickness gauge A Connecting Rod Big End Side Clearance Standard 0 25 0 35 mm 0 0098 0 0138 in Service Limit 0 6 mm 0 02 in x If the clearance exceeds the service limit replace the crankshaft assembly or reassemble the crankshaft e Make sure th
260. m Ignition System Timing Advance Ignition Timing Spark Plug Standard Terminal Option Terminal Valve Timing Intake Open Close Duration Exhaust Open Close Duration Liquid cooled 96 0 x 62 1 mm 3 78 x 2 44 in 449 cm 27 4 cu in 12 5 1 Fl Fuel Injection KEIHIN 443 AU EUR TH 95 US CA BR 90 Primary kick Digital DC CDI Electronically advanced BTDC 10 2 000 r min rpm NGK CPR8EB 9 Solid post NGK CPR9EB 9 Solid post BTDC 36 ABDC 68 284 BBDC 66 ATDC 38 284 General Specifications GENERAL INFORMATION 1 9 Items KX450FC FE Lubrication System Engine Oil Type Viscosity Capacity Forced lubrication semi dry sump API SG SH SJ SL or SM with JASO MA MA1 or MA2 SAE 10W 40 1 2 L 1 3 US qt Drive Train Primary Reduction System Type Reduction Ratio Clutch Type Transmission Type Gear Ratios 1st 2nd 3rd Ath 5th Final Drive System Type Reduction Ratio Overall Drive Ratio Frame Type Steering Angle Caster Rake Angle Trail Front Wheel Tire Size Tire Make Type Rim Size Rear Wheel Tire Size Tire Make Type Rim Size Front Suspension Type Wheel Travel Rear Suspension Type Wheel Travel Brake Type Front and Rear Gear 2 727 60 22 Wet multi disc Manual 5 speed constant mesh return shift 1 750 28 16 1 412 24 17 1 188 19 16 1 000 19 19 0 875 21 24 Chain drive 3 846 50 1
261. magneto lead with the guide B of the wiring holder Torque Crankshaft Sensor Bolts 7 0 N m 0 71 kgf m 62 in Ib e Using a high flash point solvent clean off any oil or dirt that may be on the silicone sealant coating area Dry them with a clean cloth e Apply silicone sealant to the circumference of the mag neto lead grommet C and fit the grommet into the notch of the cover securely Sealant Liquid Gasket TB1211F 92104 0004 e Install the magneto cover see Magneto Cover Installa tion 16 16 ELECTRICAL SYSTEM Flywheel Magneto Flywheel Magneto Inspection There are three types of magneto problems short open lead burned out or loss in flywheel magnetism A short or open in one of the coil leads will result in either a low output or no output at all A loss in flywheel magnetism which may be caused by dropping or hitting the flywheel by leaving it near an electromagnetic field or just by aging will result in low output NOTE OBe sure the prepared battery is fully charged e Check the magneto output voltage do the following pro cedures ORemove the left radiator shroud see Radiator Shroud Re moval in the Frame chapter ODisconnect the magneto lead connector see Magneto Cover Removal OUse the engine revolution tester A for high accuracy OConnect the measuring adapter B between the discon nected connectors OConnect a tester C to the magneto lead connector Main Harness D Flywheel E
262. make sure of the in stallation of the spark plug cap Ignition Coil Inspection Measuring Arcing Distance The most accurate test for determining the condition of the ignition coil is made by measuring arcing distance using the coil tester for the 3 needle method e Remove the ignition coil see Ignition Coil Removal e Measure the arching distance using the coil tester A e Connect the ignition coil with the spark plug cap left in stalled on the spark plug lead B to the tester and mea sure the arcing distance WARNING To avoid extremely high voltage shocks do not touch the coil or lead x lf the distance reading is less than the specified value the ignition coil or spark plug cap is defective 3 Needle Arcing Distance Standard 7 mm 0 26 in or more e To determine which part is defective measure the arcing distance again with the spark plug cap removed from the spark plug lead x If the arcing distance is subnormal as before the trouble is with the ignition coil itself If the arcing distance is now normal the trouble is with the spark plug cap ess P GP10722BS1 Ignition System ELECTRICAL SYSTEM 16 25 Measuring Coil Resistance If the arcing tester is not available the coil can be checked for a broken or badly shorted winding with a digital meter However the digital meter cannot detect layer shorts and shorts resulting from insulation breakdow
263. may spout out by residual pressure in the fuel line Cover the hose joint with a piece of clean cloth to prevent fuel spillage OWhen installing the fuel hose avoid sharp bending kink ing flattening or twisting and run the fuel hose with a minimum of bending so that the fuel flow will not be ob structed ORun the hose according to the Cable Wire and Hose Routing section in the Appendix chapter OTo prevent corrosion and deposition in the fuel system do not add any fuel antifreeze chemicals to fuel Olf the motorcycle is not properly handled the high pres sure inside the fuel line can cause fuel to leak or the hose to burst Remove the fuel tank see Fuel Tank Removal and check the fuel hose A Replace the fuel hose if any fraying cracks or bulges are noticed OTo maintain the correct fuel air mixture F A there must be no intake air leaks in the DFI system Be sure to install the oil filler plug A after filling the engine oil Special Tool Filler Cap Driver 57001 1454 Torque Oil Filler Plug 3 5 N m 0 36 kgf m 31 in Ib 3 16 FUEL SYSTEM DFI Troubleshooting the DFI System Outline When an abnormality in the system occurs the orange Fl warning indicator light LED goes on to alert the rider In addition the condition of the problem is stored in the mem ory of the ECU Electronic Control Unit With the engine stopped and turned in the self diagnosis mode the service code A is indicated
264. mes to ensure even tightening torque G Apply grease 2T Apply 2 stroke oil R Replacement Parts T First tighten the stem locknut with 39 N m 4 0 kgf m 29 ft lb of torque then loosen it and retighten it with 4 9 N m 0 50 kgf m 43 in Ib of torque 14 4 STEERING Special Tools Bearing Puller 57001 135 ST5701358T Steering Stem Bearing Driver 57001 137 Steering Stem Bearing Driver Adapter 34 5 57001 1074 ST5701378T ST5710748T Head Pipe Outer Race Press Shaft 57001 1075 ST5710758T Head Pipe Outer Race Driver 651 5 57001 1076 ST5710768T Head Pipe Outer Race Driver 54 5 57001 1077 ST571077ST Steering Stem Nut Wrench 57001 1100 ST5711008T Head Pipe Outer Race Remover ID gt 37 mm 57001 1107 ST571107ST Bearing Puller 57001 1575 ST5715758T Steering STEERING 14 5 Steering Inspection e Refer to the Steering Inspection in the Periodic Mainte nance chapter Steering Adjustment e Refer to the Steering Adjustment in the Periodic Mainte nance chapter Steering Stem Stem Bearing Removal e Remove Number Plate see Number Plate Removal in the Frame chapter Handlebar Pad A Fuel Tank Breather Hose B e Remove Brake Hose Clamp A Handlebar Clamp Bolts B Handlebar Clamps C Handlebar D Steering Stem Head Nut E and Washer e
265. mmovable in fully compressed position A gently install the base valve assembly B to the cylinder unit NOTE OPlug the two oil holes on the cylinder unit with fingers until the base valve assembly is installed e Screw in the base valve assembly in the cylinder unit when the piston rod extends NOTE OWhen it is hard to screw in the base valve assembly pull down the piston rod a little e Hold the top plug wrench 57001 1653 A with a vise e Holding the cylinder unit B with the top plug wrench 57001 1787 torque the base valve assembly C to the specified torque Special Tools Top Plug Wrench 49 mm 57001 1653 Top Plug Wrench 21 mm 57001 1787 Torque Base Valve Assembly 30 N m 3 1 kgf m 22 ft lb NOTE OCheck if the locknut is completely screwed on to the piston rod e Protect the piston rod end A with a heavy cloth B to prevent fork damage e Discharge the extra oil offthe cylinder unit by pumping C the piston rod to full stroke NOTICE Be careful not to bend or damage the piston rod when the piston rod is stroked Service carefully because oil flows out from the oil hole of the cylin der unit NOTE OCheck the piston rod sliding surface for damage OApply fork oil to the piston rod sliding surface PERIODIC MAINTENANCE 2 63 Periodic Maintenance Procedures e Drain the extra oil from the cylinder unit oil holes A e With the cylinder unit in horizontal position slide
266. moval e Adjust the footpeg height NOTE Olnstall the footpegs with same height on both sides Do not ride the motorcycle with footpegs installed unevenly OAdjust the position of the shift pedal and the brake pedal to suit the rider s preference Olnstalling the footpegs in the lower position will reduce the amount of ground clearance and lean angle e Install Footpegs see Footpeg Installation ELECTRICAL SYSTEM 16 1 Electrical System Table of Contents E leie 530 WEE 16 2 Specifications A dido 16 4 Special Tools and TE EE 16 5 Wiring Di Mba 16 8 O Meet Le A nt Re Tele taunts 16 10 Electrical Wiring BE 16 11 A D a te 16 11 Flywheel Magneto EE 16 12 Magneto Cover Removal viii A net antenne i 16 12 Magneto Cover Installation 25 ne on A EU dl en ideas tgeustadeceedeten nace ad dedacen th 16 12 Flywheel REMOVE Ween ed A pas 16 13 Elywh el ISO nn nr ee a M nn nie eee Sin ae dessein 16 14 el Rn UE 16 14 Stat r e Wl EE EN 16 15 Flywheel Magneto Inspection iran ici ds 16 16 A A 16 18 Regulator Rectifier Removal as 16 18 Regulator Rectifier Installation fssestdeon anna dias raridta altea 16 18 Regulator Rectifier Output Voltage Inspection sssseeeeeeeeseeerrrrreeseeirirrnsssstrntrrnnnsssseenne 16 18 Regulator Rectifier Inspection cs tilde ile ada 16 19 Capacitor Removal een 16 21 Capacitor Installation vicio tete nent lente tte ner tete lan 16 21 Capacitor INSPSCUON EE 16 21 Ignition TIMIN EE 16 22 Igniti
267. mping adjuster beyond the fully seated position or the adjusting mechanism may be damaged Compression Damping Adjuster Setting Standard 10 clicks B KX450FC EUR BR 13 clicks C KX450FC 11 clicks D KX450FD Softer Counterclockwise E Harder Clockwise F Although you can turn the adjuster beyond the ad justable range effecting no changes to damping force use it within the adjustable range Rebound Damping Adjustment e Place the jack under the frame so that the front wheel off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e To adjust rebound damping turn the adjuster A on the front fork cylinder valve with a standard tip screwdriver until you feel a click Adjust the rebound damping to suit your preference under special condition NOTE OThe left and right fork legs must have the same shock damping Seated position A adjuster turned fully clockwise NOTICE Do not force the rebound damping adjuster beyond the fully seated position or the adjusting mecha nism may be damaged Rebound Damping Adjuster Setting Standard 10 clicks B KX450FC 9 clicks C KX450FD Softer Counterclockwise D Harder Clockwise E Although you can turn the adjuster beyond the ad justable range effecting no changes to damping force use it within the adjustable range Oil Change each fork leg e Refer to Front Fork Oil Change in the Periodic Mainte nance
268. n Shift pawl spring tension lose 17 28 APPENDIX Troubleshooting Guide Gear seized Gear positioning lever operation trouble Shift drum broken Jumps out of gear Shift fork ear worn bent Gear groove worn Gear dogs and or dog holes worn Shift drum groove worn Gear positioning lever spring weak or bro ken Shift fork guide pin worn Drive shaft output shaft and or gear splines worn Overshifts Gear positioning lever spring weak or bro ken Pawl guide plate worn Abnormal Engine Noise Knocking ECU trouble Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect heat value Overheating Piston slap Cylinder piston clearance excessive Cylinder piston worn Connecting rod bent Piston pin piston pin hole worn Valve noise Valve clearance incorrect Valve spring broken or weak Camshaft bearing or cam face worn Valve lifter worn Other noise Connecting rod big end small end clear ance excessive Piston ring worn broken or stuck Piston seizure damage Cylinder head gasket leaking Exhaust pipe leaking at cylinder head con nection Crankshaft runout excessive Engine mounts loose Crankshaft bearing worn Camshaft chain tensioner trouble Camshaft chain sprocket chain guide worn Primary gear worn or damaged Decompressor spring broken Magneto flywheel loose Abnormal Drive Train Noise Clutch noise Clutch housing finger and friction plate tang worn Clutch housing gear worn Metal c
269. n System section ECU Power Supply Inspection see ECU Power Supply Inspection in the Fuel System DFI chapter GP10718BS1 ELECTRICAL SYSTEM 16 27 Ignition System Troubleshooting Faulty ignition Malfunctioned engine Wiring and connect portion of the ignition system inspection Repair Replace Spark plug inspection Spark plug cap inspection Ignition coil primary peak voltage inspection E No good Voltage is none No good Voltage is Voltage is specified or almost less than the but faulty ignition specified value No good Replace Defective ignition coil Inspect Inspection 1 Adapter connection is 1 Speed of cranking engine is incorrect or adapter is slow Increase force of kicking directive engine 2 Engine stop switch Lower resistance in the tester 3 Crankshaft sensor peak Lacking of sampling Sampling voltage few times Replace the Crankshaft sensor peak voltage malfunctioned no good parts All good ECU is defective No good All good Replace the malfunctioned parts or inspect in proper way GP10796B F 16 28 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Peak Voltage Check e Disconnect the magneto lead connector see Magneto Cover Removal NOTE OMeasure the voltage with each lead connected cor rectly The correct value may not be obtained if disconnected OMaintain the correct value of compression pressure for the c
270. n rod B slowly several times to expel air e With the piston rod held immovable in fully compressed position A gently install the base valve assembly B to the cylinder unit e Screw in the base valve assembly in the cylinder unit when the piston rod extends NOTE OWhen it is hard to screw in the base valve assembly pull down the piston rod a little e Hold the top plug wrench 57001 1653 A with a vise e Holding the cylinder unit B with the top plug wrench 57001 1653 torque the base valve assembly C using the top plug wrench 57001 1705 D Special Tools Top Plug Wrench 49 mm 57001 1653 Top Plug Wrench 36 mm 57001 1705 Torque Base Valve Assembly 30 N m 3 1 kgf m 22 ft lb e Protect the piston rod end A with a heavy cloth B to prevent fork damage e Discharge the extra oil off the cylinder unit by pumping C the piston rod to full stroke NOTICE Be careful not to bend or damage the piston rod when the piston rod is stroked Service carefully because oil flows out from the oil hole of the cylin der unit NOTE OCheck the piston rod sliding surface for damage OApply fork oil to the piston rod sliding surface Gren P 2 54 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Drain the extra oil from the cylinder unit oil holes A e With the cylinder unit in horizontal position slide A the piston rod B by hand to inspect it if operating smoothly Olf the p
271. n under high volt age e Remove the ignition coil see Ignition Coil Removal e Measure the primary winding resistance A as follows OConnect the digital meter between the coil terminals OSet the digital meter and read the digital meter e Measure the secondary winding resistance B as follows ORemove the spark plug cap from the spark plug lead OConnect the digital meter between the spark plug lead and the ground lead terminal OSet the digital meter and read the digital meter Ignition Coil Winding Resistance Primary Windings 0 28 0 38 Q at 20 C 68 F Secondary Windings 7 65 10 4 kQ at 20 C 68 F x If the digital meter does not read as specified replace the ignition coil x lf the digital meter reads as specified the ignition coil windings are probably good However if the ignition sys tem still does not perform as it should after all other com ponents have been checked test replace the coil with one known to be good e Check the spark plug lead for visible damage x If the spark plug lead is damaged replace the ignition coil Spark Plug Cleaning and Inspection e Refer to the Spark Plug Cleaning and Inspection in the Periodic Maintenance chapter Spark Plug Gap Inspection e Refer to the Spark Plug Cleaning and Inspection in the Periodic Maintenance chapter GP10571BS1 16 26 ELECTRICAL SYSTEM Ignition System Ignition Coil Primary Peak Voltage Check e Remove the spark plug cap from
272. nd A near the cylinder head mating sur face B e Apply a non permanent locking agent to the threads of the kick pedal bolt e Install the washer and tighten the kick pedal bolt Torque Kick Pedal Bolt 25 N m 2 5 kgf m 18 ft lb Kick Pedal Assy Disassembly e Remove the kick pedal assy see Kick Pedal Assy Re moval e Remove Plug Screw A Spring B Steel Ball C Detent Screw D Boss E Oil Seal F Kick Pedal Assy Assembly e Replace the oil seal A plug screw B and detent screw C e Apply grease to the steel ball oil seal lip spring and the sliding portion of the pedal e Install Oil Seal Boss D Detent Screw Steel Ball E Spring F Plug Screw e Tighten the detent screw and plug screw e After tightening the two screws stake them with a punch G119033BS1 G119034BS1 CRANKSHAFT TRANSMISSION 9 31 Kickstarter Idle Gear Removal e Remove Right Engine Cover see Right Engine Cover Removal in the Clutch chapter Clutch see Clutch Removal in the Clutch chapter Circlip A Idle Gear B Special Tool Outside Circlip Pliers 57001 144 Idle Gear Installation e Make sure to position the circlip A in original position Replace it if removed e Apply molybdenum disulfide oil to the inside B of the idle gear e Replace the circlip A with a new one e Install the idle gear B so that the OUT mark C faces outward e Install the circlip
273. nd can be ex plosive under certain conditions Always stop the engine and do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Remove Seat see Seat Removal in the Frame chapter Radiator Shroud see Radiator Shroud Removal in the Frame chapter Fuel Tank Bolt A Band B e Draw the fuel out from the fuel tank with a commercially available pump A OUse a soft plastic hose B as a pump intake hose in order to insert the hose smoothly OPut the hose through the fill opening C into the tank and draw the fuel out WARNING Spilled fuel is flammable and can be explosive un der certain conditions The fuel can not be removed id acososnst 0 completely from the fuel tank Be careful for re mained fuel spillage e Lift up the fuel tank and remove the fuel pump lead con nector A la SNET P e Be sure to place a piece of cloth around the fuel hose joint e Wipe off the dirt of the surface A around the connection using a cloth or a soft brush J616153BS1 FUEL SYSTEM DFI 3 81 Fuel Tank When removing with standard tip screwdriver e Insert the standard tip screwdriver A into the slit B on the joint lock C e Turn the driver to disconnect the joint lock When removing with fingers e Open and push up A the joint lock B with your fingers NOTI
274. nd provide better lubrication e Apply oil to the sides of the rollers so that oil will penetrate into the rollers and bushings e Wipe off any excess oil Oil Applied Area A Sprocket Wear Inspection e Visually inspect the front and rear sprocket teeth for wear and damage x lf they are worn as illustrated or damaged replace the sprocket and inspect the drive chain wear Worn Tooth Engine Sprocket A Worn Tooth Rear Sprocket B Direction of Rotation C NOTE Olf a sprocket requires replacement the chain is proba bly worn also When replacing a sprocket inspect the chain Rear Sprocket Warp Runout Inspection e Using the jack raise the rear wheel off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Set a dial gauge A against the rear sprocket B near the teeth as shown in the figure e Rotate C the rear wheel slowly to measure the sprocket warp runout OThe difference between the highest and lowest dial gauge readings is the amount of warp runout Rear Sprocket Warp Runout Standard TIR 0 4 mm 0 016 in or less Service Limit TIR 0 5 mm 0 020 in x If the runout exceeds the service limit replace the rear sprocket GKO0403038S1 GKO5017BS1 6S12024BS1 PERIODIC MAINTENANCE 2 37 Periodic Maintenance Procedures Brakes Brake Lever and Pedal Adjustment e Slide the dust cover A e Adjust the brake lever to suit you
275. ndlebar shakes or excessively vibrates Tire worn Swingarm pivot bearings worn Rim warped or not balanced Spokes loose Wheel bearing worn Handlebar clamp bolt loose Steering stem head nut loose Front rear axle runout excessive Handlebar pulls to one side Frame bent Rear wheel misalignment Swingarm bent or twisted Swingarm pivot shaft bent Steering maladjusted Steering stem bent Front fork bent Right and left front fork oil level uneven Suspension operation trouble Too hard Tire air pressure too high APPENDIX 17 29 Front fork oil excessive Front fork oil viscosity too high Rear shock absorber adjustment too hard Front fork bent Front fork air pressure too high Too soft Front fork oil insufficient or leaking Front fork oil viscosity too low Rear shock absorber adjusted too soft Front fork air pressure too low KX450FD Front fork rear shock absorber spring weak KX450FC Rear shock absorber spring weak KX450FD Rear shock absorber oil or gas leaking Tire air pressure too low Brake Doesn t Hold Air in brake system Pad disc worn Brake fluid leakage Contaminated pad Brake fluid deteriorated Brake master cylinder cups damaged Master cylinder scratched inside Disc warped MODEL APPLICATION Year Model Beginning Frame No 2012 KXAS0FC IKAKX450FFA000001 2013 1 mam JKAKX450FFA012001 2014 KXASOFE IKAKX450FFA022001 O This digit in the fram
276. nect e Tap lightly up with a plastic mallet to separate the cylinder from the crankcase e Remove the cylinder base gasket Piston Removal e Remove the cylinder see Cylinder Removal e Remove the piston pin snap ring A NOTE OLay a clean cloth under the piston to prevent dropping dirt or parts into the crankcase e Remove the piston pin using a piston pin puller A Special Tool Piston Pin Puller 57001 1568 e Remove the piston e Carefully spread the piston ring opening with your thumbs and then push up on the opposite side of the ring A to remove it e Remove the oil ring in the same procedure GE16212BS1 Cylinder and Piston Installation NOTE Olf a new piston or cylinder is used check piston cylinder clearance see Piston Cylinder Clearance Inspection in the Periodic Maintenance chapter and use new piston rings ENGINE TOP END 5 35 Cylinder and Piston NOTE OThe oil ring rails have no top or bottom e Install the oil ring expander A in the bottom piston ring groove so the ends B butt together e Install the oil ring steel rails one above the expander and one below it OSpread the rail with your thumbs but only enough to fit the rail over the piston ORelease the rail into the bottom piston ring groove e Install the top ring A so that the R mark B faces up e Apply engine oil to the inside wall of the connecting rod small end e Install the piston
277. ngine oil to the valve lifter B surface and install the lifter e Install Camshafts see Camshaft Installation in the Engine Top End chapter Camshaft Caps see Camshaft Installation in the Engine Top End chapter e Recheck the valve clearance and readjust if necessary e Install the removed parts see appropriate chapters 6S07011BS1 PERIODIC MAINTENANCE 2 25 Periodic Maintenance Procedures Cylinder Head Warp Inspection e Remove the cylinder head see Cylinder Head Removal in the Engine Top End chapter e Lay a straightedge A across the lower surface of the head at several different points and measure warp by inserting a thickness gauge B between the straightedge and head Cylinder Head Warp Service Limit 0 05 mm 0 0020 in x If warp exceeds the service limit repair the mating sur face Replace the cylinder head if the mating surface is badly damaged e Remove the valves see Valve Removal in the Engine Top End chapter e Scrape the carbon out of the combustion chamber and exhaust port with a scraper A or a suitable tool e Clean the cylinder head using high flash point solvent e Blow out any particles which may obstruct the oil passage in the cylinder head using compressed air e Install the valves see Valve Installation in the Engine Top End chapter Cylinder Wear Inspection NOTE OMeasure the cylinder inside diameter when the cylinder is cold at room temperature e
278. nnector A Fuel Injector Connector B e Open the clamp C e Loosen the clamp screw A e Open the clamp B NOTE OOpen the two clamps fully along the throttle body assy for easily removing FUEL SYSTEM DFI 3 75 Throttle Body Assy e Disconnect the throttle sensor connector A KX450FD e Disconnect Intake Air Pressure Sensor Connector A Throttle Sensor Connector B Fuel Injector Connector C e Loosen the clamp screw A e Take the throttle body assy A off the engine as shown in the figure e Remove the throttle cable lower ends see Throttle Cable Replacement Throttle Body Assy Installation e Install the throttle body assy OEngage the projection A and the hollow B e Install the removed parts see appropriate chapters NOTE OFor easily starting the engine connect the 12 V battery to the main harness see Self diagnosis Procedures OWhen the battery is connected the fuel pump is driven and the pressure of the fuel line increases 3 76 FUEL SYSTEM DFI Throttle Body Assy Throttle Body Assy Disassembly e Remove Throttle Body Assy see Throttle Body Assy Removal Plate Mounting Screws A Plate B Intake Air Pressure Sensor C e Remove Delivery Pipe Mounting Screw A Delivery Pipe B with Fuel Injector C NOTE ODo not damage the insertion portion of the fuel injector when it is pulled out from the throttle body NOTICE Never drop the
279. nsmission Shaft Removal e Remove the circlips washers collar and gears Special Tool Outside Circlip Pliers 57001 144 NOTE ODO not reuse the removed circlips 9 22 CRANKSHAFT TRANSMISSION Transmission Transmission Shaft Assembly e Apply engine oil liberally to the transmission shaft gears and bearings e Replace any circlips that were removed with new ones OAlways install the circlips A so that the opening B is aligned with a spline groove C and install toothed wash ers To install a circlip without damage first fit the circlip onto the shaft expanding it just enough to install it and then use a suitable gear to push the circlip into place Special Tool Outside Circlip Pliers 57001 144 6113114BS1 e When install the bushing for 4th A to the drive shaft align the oil passage holes B each other G113439BS1 e The drive shaft gears can be identified by size the small est diameter gear is 1st gear and the largest is 5th Be sure that all parts are put back in the correct sequence facing the proper direction and that all circlips and the washers are properly in place e The output shaft gears can be identified by size the largest diameter gear is 1st gear and the smallest is 5th Be sure that all parts are put back in the correct sequence facing the proper direction and that the circlip and collar are properly in place CRANKSHAFT TRANSMISSION 9 23 Transmission
280. nsor trouble Ignition coil trouble Engine stop switch shorted Wiring shorted or open Flywheel damage Compression Low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Spark plug cap or spark plug lead trouble Spark plug cap shorted or not in good con tact Spark plug incorrect heat value ECU trouble Crankshaft sensor trouble Flywheel damaged Ignition coil trouble Wiring connector not in good contact Fuel air mixture incorrect Air cleaner clogged poorly sealed or miss ing Fuel tank air vent obstructed Fuel pump trouble Throttle body assy holder loose Air cleaner duct loose Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent de formed worn or carbon accumulation on the seating surface Decompression trouble Other ECU trouble Engine oil level to high Engine oil viscosity too high Brake dragging Drive train trouble Engine overheating Clutch slipping Poor Running or No Power at High Speed Firing incorrect Spark plug d
281. ntake air pressure sensor D from the plate E e Disconnect the vacuum hose A from the throttle body assy e Remove the intake air pressure sensor B from the rubber damper C Intake Air Pressure Sensor Installation e Assemble the rubber damper A to the intake air pressure sensor B OFit the straight edges C e Install the vacuum hose A e Install the intake air pressure sensor B e Connect the intake air pressure sensor connector C COUPEE P GOrvE4i7 P 3 38 FUEL SYSTEM DFI Intake Air Pressure Sensor Service Code 12 Intake Air Pressure Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged e Disconnect the intake air pressure sensor connector and connect the measuring adapter A between these con nectors Main Harness B Intake Air Pressure Sensor C Special Tool Measuring Adapter 57001 1700 e Connect a digital meter D to the measuring adapter leads Intake Air Pressure Sensor Input Voltage Connections to Adapter Digital Meter R sensor R Y lead Digital Meter BK sensor GY lead e Refer to the Self diagnosis Procedures connect the 12 V battery to the main harness e Measure the input voltage with the engine stopped and with the connector joined Input Voltage Standard DC 4 75 5 25 V e Disconnect the power supply harness x If the reading is within the standard check the output volt age see Intake A
282. ntionally left blank 3 4 FUEL SYSTEM DFI Exploded View 6002565BW5 C FUEL SYSTEM DFI 3 5 Exploded View 2 Throttle Cable Mounting Bolts 3 5 0 36 31 in lb 3 Air Cleaner Duct Mounting Bolt 3 0 0 31 27 in lb 4 Air Cleaner Duct Mounting Nuts 3 0 0 31 27 in lb 5 Air Cleaner Housing Bolts 9 8 1 0 87 in lb 6 Air Cleaner Duct Clamp Screw 2 0 0 20 18 in lb 7 Intake Air Temperature Sensor Bolts 4 15 0 423 37 in lb L 8 Air Cleaner Element Wing Bolt Hand tighten 9 Intake Air Pressure Sensor 10 Fuel Injector 11 Throttle Sensor 12 KX450FC 13 Other than KX450FC and KX450FD US CA Models CL Apply cable lubricant EO Apply engine oil G Apply grease L Apply a non permanent locking agent O Apply high quality foam air filter oil R Replacement Parts 3 6 FUEL SYSTEM DFI Exploded View 6002566BW5 C FUEL SYSTEM DFI 3 7 Exploded View No Fastener tere Tat 1 Fuel Pump Bolts 9 8 1 0 87 in lb 2 Water Temperature Sensor 12 1 2 106 in lb 3 Gear Position Switch Screws 2 9 0 30 26 in lb L 4 ECU 5 Vehicle down Sensor 6 Ignition Coil 7 Capacitor 8 Crankshaft Sensor AD Apply adhesive EO Apply engine oil G Apply grease S Follow the specified tightening sequence L Apply a non permanent locking agent R Replacement Parts 3 8 FUEL SYSTEM DFI Specifications Item Standard Digital Fu
283. nut a fraction of a turn if the steering is too loose tighten the nut a fraction of a turn Special Tool Steering Stem Nut Wrench 57001 1100 NOTE OTurn the nut 1 8 turn at a time maximum e Install the steering stem head and washer e Tighten Torque Steering Stem Head Nut 98 N m 10 kgf m 72 ft Ib Front Fork Clamp Bolts Upper 20 N m 2 0 kgf m 15 ft lb NOTE OTighten the two clamp bolts alternately two times to en sure even tightening torque e Check the steering again x If the steering is too tight or too loose repeat the adjust ment as mentioned above e Install the removed parts see appropriate chapters 2 76 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Stem Bearing Lubrication e Remove the steering stem see Steering Stem Stem Bearing Removal in the Steering chapter e Using a high flash point solvent wash the upper and lower tapered rollers in the cages and wipe the upper and lower outer races which are press fitted into the frame head pipe clean off grease and dirt e Visually inspect the outer races and rollers Replace the bearing assemblies if they show wear or damage e Pack the upper and lower tapered roller bearings A in the cages with grease and apply a light coat of grease to the upper and lower outer races e Install the steering stem see Steering Stem Stem Bear ing Installation in the Steering chapter e Adjust the steering see Steering Adjus
284. o make sure to correct any of these conditions Throttle Cable Lubrication e Whenever the throttle cable is removed or in accordance with the Periodic Maintenance Chart lubricate the these cables see Lubrication in the Periodic Maintenance chapter OApply a thin coating of grease to the cable upper end OUse a commercially available pressure cable lubricator to lubricate these cables Throttle Cable Inspection e Refer to the Cable Inspection in the Periodic Maintenance chapter 3 74 FUEL SYSTEM DFI Throttle Body Assy Idle Speed Inspection e Refer to the Idle Speed Inspection in the Periodic Main tenance chapter Throttle Bore Cleaning e Refer to the Throttle Body Cleaning in the Periodic Main tenance chapter Throttle Body Assy Removal WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Always stop the engine and do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light NOTICE Never drop the throttle body assy especially on a hard surface Such a shock to the throttle body assy can damage it e Remove Fuel Tank see Fuel Tank Removal Fuel Hose see Fuel Hose Replacement in the Periodic Maintenance chapter Air Cleaner Housing with Rear Frame see Rear Frame Removal in the Frame chapter KX450FC e Disconnect Intake Air Pressure Sensor Co
285. o the Wheel Bearing Inspection in the Periodic Maintenance chapter Spoke Tightness Inspection e Refer to the Spoke Tightness Inspection in the Periodic Maintenance chapter Rim Runout Inspection e Refer to the Rim Runout Inspection in the Periodic Main tenance chapter GJ04082BS1 10 10 WHEELS TIRES Wheels Rims Rim Installation Position e When installing the rim set the rim following position OThe distance A from the brake disc seating surface B of the front hub C to left end of the front rim D should be as follows View from Front E Distance 26 5 0 5 mm 1 04 0 020 in OThe distance A from the brake disc seating surface B of the rear hub C to right end of the rear rim D should be as follows View from Rear E Distance 28 5 0 5 mm 1 12 0 020 in e Check the rim runout see Rim Runout Inspection in the Periodic Maintenance chapter Axle Inspection e Visually inspect the front and rear axle for damages x If the axle is damaged or bent replace it e Place the axle on V blocks that are 100 mm 3 94 in A apart and set a dial gauge B on the axle at a point halfway between the blocks e Turn C the axle to measure the runout OThe difference between the highest and lowest dial read ings is the amount of runout Axle Runout 100 mm 3 94 in Standard TIR 0 03 mm 0 001 in or less Service Limit TIR 0 2 mm 0 008 in x If the runout exceeds the service lim
286. of the front camshaft chain guide in the grooves B of the cylinder Olnsert the guide end C into the recess D of the crankcase securely e Install Dowel Pins A New Cylinder Head Gasket B e Install the cylinder head NOTE OThe camshaft caps are machined with the cylinder head therefore if a new cylinder head is installed use the caps that are supplied with the new head e Replace the cylinder head bolt M10 washers with new ones OThese washers could leak oil if reused e Apply molybdenum disulfide oil to the following areas Cylinder Head Bolt M10 Washers Both Sides A Cylinder Head Bolt M10 Threads B e Tighten the cylinder head bolts M10 in the numbered sequence 1 4 Torque Cylinder Head Bolts M10 59 N m 6 0 kgf m 44 ft Ib L 140 mm 5 51 in 1 3 L 127 mm 5 00 in 2 4 GE14071BS1 ENGINE TOP END 5 25 Cylinder Head e Tighten Torque Cylinder Bolt A 12 N m 1 2 kgf m 106 in Ib Cylinder Head Bolts M6 B 12 N m 1 2 kgf m 106 in Ib e Install the removed parts see appropriate chapters Cylinder Head Cleaning e Refer to the Cylinder Head Warp Inspection in the Peri odic Maintenance chapter Cylinder Head Warp Inspection e Refer to the Cylinder Head Warp Inspection in the Peri odic Maintenance chapter 5 26 ENGINE TOP END Valves Valve Clearance Inspection e Refer to the Valve Clearance Inspection in the Periodic Maintenan
287. oil seal and dust seal replace the oil seal and dust seal whenever the inner tube is replaced NOTICE If the inner tube is badly bent or creased replace it Excessive bending followed by subsequent straightening can weaken the inner tube e Temporarily assemble the inner tube A and outer tube B and pump them back and forth manually to check for smooth operation x If you feel binding or catching the inner and outer tubes must be replaced A WARNING A straightened inner or outer fork tube may fall in use possibly causing an accident resulting in seri ous injury or death Replace a badly bent or dam aged inner or outer tube and inspect the other tube carefully before reusing it Dust Seal Inspection e Inspect the dust seal A for any signs of deterioration or damage x Replace it if necessary Front Fork Spring Tension Inspection KX450FC e Since a spring becomes shorter as it weakens check its free length A to determine its condition x lf the spring is shorter than the service limit it must be replaced Fork Spring Free Length Standard 470 mm 18 5 in Service Limit 461 mm 18 1 in 6M04169BS1 6M04168BS1 6M040116S1 SUSPENSION 13 19 Rear Shock Absorber To suit to various riding conditions the spring preload of the shock absorber can be adjusted or the spring can be replaced with an optional one Also the damp
288. on TiMind NS e iOa en a ici 16 22 ele SST acco Sette ah Doct AA D De E AAA AAA EA A 16 23 EE e E 16 23 Ignition Coil Removal iso dira 16 23 Ignition Coil Installation EE 16 23 Ignition Coil Inspeccion oi 16 24 Spark Plug Cleaning Een e EE 16 25 Spark Plug Gap Inspechon 16 25 Ignition Coil Primary Peak Voltage Check 22 cccceeccsseecceeeneeeeeseceeceeeeeeeeeeeeececeneenetenees 16 26 A net te cn dr da en te cn 16 26 Crankshaft Sensor Peak Voltage Check ss 16 28 Crankshaft Sensor Inspection 16 28 Engine Stop Switch System CROCK cuicos iii a eee 16 29 Launch Control Mode Button System Check 16 29 DFI Setting Data Selection Connector Inspection 16 29 EN 16 31 Engine Stop Switch Inspection ooooonciinccnnnnncicnncccncnnccnnncnnnonancnnnnnnn rr nn rr nsn rn rra 16 31 Launch Control Mode Button Inspection 16 31 Gear Position Switch Removal iii da 16 31 Gear Position Switch Installation ista tddi 16 31 Gear Position Switch Inspection ssesssessseseseeeeeeertttrrrttrtrrrrrtrrrrrrttrrrrrirtrrtrertrrrtrrtrtrttrent 16 31 16 2 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 16 3 Exploded View Torque No Fastener Nm kgm SC Remarks 10 10 2 Ignition Coil Bolts 87 in lb 3 Spark Plug 115 in lb 4 Breather Fitting i 11 5 Magneto Cover Bolts 6 Timing Inspection Cap 3 5 0 36 31 in lb 7 Flywheel Nut Cap 3 5 0 36 31 in lb 8 Flywheel Nut 78 5 8 0
289. on rod end using the die A Die 12 x 1 5 mm e Clean all parts with solvent and dry them with compressed air Rear Shock Absorber Assembly e Install Damper Holder A Damper B Stopper C e Wrap the threads of the piston rod with tape A e Apply thin coat of rear shock oil to the sliding surface of the piston rod e Replace the oil seal assembly B and O ring C with new ones e Insert the oil seal assembly e Remove the tape from piston rod e Replace the piston unit in the piston assembly A with a new one OReuse the upper and lower stoppers and valves NOTE OBe careful not to change the original positions e Install the piston assembly so that the thick side of the stopper B faces downward e Reinstall one of the removed washers for the threads length adjustment and discard the rest of them e Install the new piston rod locknut C NOTE OThe piston rod locknut is available with the oil seal as sembly as a set e Tighten Torque Piston Rod Locknut 28 N m 2 9 kgf m 21 ft lb e Check the oil seal assembly moving smoothly on the pis ton rod e Pour the oil and inject the nitrogen gas see Rear Shock Absorber Oil Change in the Periodic Maintenance chap ter 13 26 SUSPENSION Rear Shock Absorber Rear Shock Absorber Oil Change e Refer to the Rear Shock Absorber Oil Change in the Pe riodic Maintenance chapter Rear Shock Absorber Inspection e Remove the rear shock absorber
290. on when the fork is near full extension to maintain consistent and stable damping force e Front wheel grip has been further improved due to softer spring force during the rebound stroke 1 16 GENERAL INFORMATION Technical Information PSF Pneumatic Spring Fork Front Fork KX450FD PSF Type gt Conventional Type 68067278 6 Spring Characteristics Adjustment e Previously changing to an optional spring needed complicated disassembly As for PSF spring characteristics can be changed by simply changing air pressure e Compared to the conventional front fork PSF has a wider adjustable range of spring characteristics 68067288 6 Tool e For air charging a commercially available hand air pump can be used For air pressure adjustment a tire air pressure gauge can be used e Oil change becomes easier since the main spring is eliminated 3 Inner Structure e New oil KHL15 11 is used as operating oil GENERAL INFORMATION 1 17 Technical Information PSF Pneumatic Spring Fork Front Fork KX450FD Conventional F Type 68067298 6 Air Pressure Adjustment Part New Oil KHL 15 11 New Oil Seal Compression Damping Force Adjustment Part Air Chamber Rebound Damping Force Adjustment Part Elimination of Pressure Spring Cylinder Diameter Enlargement 24 gt p32 Elimination of Main Spring 4 Air Flow OOANDAABRWN Compression Effect of air
291. one e Fit the circlip A into the groove in the rear shock body B NOTICE If the circlip is not a certain fit in the groove in the rear shock body the piston rod assembly may come out of the shock absorber when injecting the nitro gen gas or riding the motorcycle e Pull up the piston rod assembly C against the circlip e Force the stopper D into the rear shock body by lightly tapping around the edge of the stopper with a mallet GS14091BS1 GMO5069BS1 PERIODIC MAINTENANCE 2 73 Periodic Maintenance Procedures e Check the rear shock body and gas reservoir for oil and gas leaks x lf there are no leaks inject the nitrogen gas up to the 1 000 kPa 10 2 kgf cm 145 psi pressure A WARNING High pressure gas is dangerous and can explode causing serious injury To avoid injury have a qual ified mechanic pressurize the shock reservoir with nitrogen gas only Do not use air or other gases since they may cause premature wear rust fire haz ard or substandard performance e Remove the suitable tool from the reservoir cap e Check the rear shock absorber as follows OAgjust the rebound damping adjuster A to the hardest position OProtect the piston rod end with a heavy cloth to prevent damage OPush down B the rear shock absorber C to fully com pressed position NOTICE Take care so that the rear shock absorber does not fall over when pushin
292. ons on how to use the tool follow the opera tion manual provided by the manufacturer A WARNING The shock contains high pressure nitrogen gas that when suddenly released can eject oil and internal shock parts at high velocity causing serious injury To avoid injury do not point a suitable tool toward your face or body when releasing nitrogen gas pres sure since an oil mist is often released with the ni trogen Always release nitrogen gas pressure be fore disassembling the rear shock absorber to pre vent explosive separation of parts e Adjust the gas reservoir damping adjusters A to the soft est position e Tap A evenly at the gaps B in the stopper C with suit able tools D to free the stopper from the rear shock body e Slide the stopper up the top of the piston rod then lightly tap around the seal with a suitable rod and mallet and push the seal assembly 10 mm 0 39 in down e Remove the circlip A e Wrap a heavy cloth around the rear shock body and piston rod to prevent the oil diffusion e Lightly move the piston rod back and forth and pull out the piston rod assembly e Pour the oil out of the rear shock body into a suitable container GS14090BS1 GMO5065BS1 PERIODIC MAINTENANCE 2 69 Periodic Maintenance Procedures e Remove the suitable tool from the reservoir cap e Using a suitable tool A and press push the reservoir cap B in 10 mm 0 39 in e Remov
293. ools down e Prepare the fuel hose Special Tool 57001 1607 and a measuring cylinder Special Tool Fuel Hose 57001 1607 e Remove the fuel tank bolt and tank mounting band see Fuel Tank Removal e Remove the left radiator shroud see Radiator Shroud Re moval in the Frame chapter FUEL SYSTEM DFI 3 71 Fuel Line e Open the fuel tank cap A to lower the pressure in the tank e Disconnect the fuel hose from the fuel pump see Fuel Tank Removal OBe sure to place a piece of cloth around the fuel outlet pipe of the fuel pump A WARNING Fuel is flammable and explosive under certain con ditions and can cause severe burns Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is dis connected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with a piece of clean cloth to prevent fuel spillage e Connect the prepared fuel hose A to the fuel outlet pipe e Secure the fuel hose with a clamp e Insert the fuel hose into the measuring cylinder B WARNING Wipe off spilled out fuel immediately Be sure to hold the measuring cylinder vertical e Close the fuel tank cap e Refer to the Self diagnosis Procedures connect the 12 V battery to the main harness OThen the fuel pump operates and fuel is discharged NOTICE Do not operate the fuel pump without fuel in th
294. op plug wrench C Special Tool Top Plug Wrench 49 mm 57001 1653 ESB P PERIODIC MAINTENANCE 2 57 Periodic Maintenance Procedures e Install the front forks to the motorcycle see Front Fork Installation in the Suspension chapter e Loosen the front fork mounting bolts upper e After installing the front fork tighten the top plug A Special Tool Top Plug Wrench 49 mm B 57001 1653 The torque of fork top plug is specified to 30 N m 3 1 kgf m 22 ft lb however when you use the top plug wrench special tool A reduce the torque to 90 of the spec ified value 27 N m 2 8 kgf m 20 ft Ib due to the dis tance B between the center of the square hole where the torque wrench is fitted and that of the octagonal hole of the wrench This torque value 27 N m 2 8 kgf m 20 ft Ib is appli cable when you use a torque wrench whose length gives leverage of approximately 310 mm between the grip point to the center of the coupling square Torque Front Fork Top Plug 30 N m 3 1 kgf m 22 ft lb Front Fork Clamp Bolts Upper 20 N m 2 0 kgf m 15 ft lb e Install the removed parts see appropriate chapters e Adjust the compression and rebound dumping force ad justers see Compression Damping Adjustment and Re bound Damping Adjustment in the Suspension chapter KX450FD e Remove Number Plate see Number Plate Removal in the Frame chapter Front Wheel see Front Wheel Removal
295. orber Nut Lower 34 3 5 25 R Piston Rod Locknut 28 2 9 21 R Brake Hose Clamp Bolt 2 0 0 20 18 in lb Steering Handlebar Clamp Bolts 25 2 5 18 AL Steering Stem Head Nut 98 10 72 Steering Stem Nut 4 9 0 50 43 in lb T Front Fork Clamp Bolts Upper 20 2 0 15 AL Front Fork Clamp Bolts Lower 20 2 0 15 AL Handle Holder Nuts 34 3 5 25 R Brake Hose Clamp Bolt 2 0 0 20 18 in lb Frame Rear Frame Mounting Bolts 34 3 5 25 Footpeg Bracket Bolts Upper 34 3 5 25 L Footpeg Bracket Bolts Lower 16 5 1 68 12 2 L Radiator Shroud Bolts 9 8 1 0 87 in lb Electrical System Flywheel Nut 78 5 8 0 57 9 Stator Coil Bolts 9 8 1 0 87 in lb L Spark Plug 13 1 3 115 in lb Magneto Cover Bolts 9 8 1 0 87 in lb Crankshaft Sensor Bolts 7 0 0 71 62 in lb Breather Fitting 15 1 5 11 L Ignition Coil Bolts 9 8 1 0 87 in lb Regulator Rectifier Nuts 10 1 0 89 in lb R Flywheel Nut Cap 3 5 0 36 31 ml Timing Inspection Cap 3 5 0 36 31 in lb Torque and Locking Agent PERIODIC MAINTENANCE 2 9 Basic Torque for General Fasteners Threads diameter Torque mm N m kgf m ft Ib 5 3 4 4 9 0 35 0 50 30 43 in lb 6 5 9 7 8 0 60 0 80 52 69 in lb 8 14 19 1 4 1 9 10 0 13 5 10 25 34 2 6 3 5 19 0 25 12 44 61 4 5 6 2 33 45 14 73 98 7 4 10 0 54 72 16 115 155 11 5 16 0 83 115 18 165 225 17 0 23 0 125 165 20 225 325 23 33 165 240 2 10 PERIODIC MAINTENANCE Specifications Item Standard Serv
296. ounting bolts lift the rear wheel slightly Forcing or tapping on a bolt could damage the bolt sleeve and bearing Tie Rod Installation e Replace with new ones Tie Rod Mounting Nuts Lower Chain Guide Roller Mounting Nut e Apply plenty of grease to the grease seal lips e Check that collars are in place on the tie rod e Install the tie rod e Apply grease to the seating surface of the tie rod mount ing nuts e Tighten Torque Tie Rod Mounting Nuts 59 N m 6 0 kgf m 44 ft Ib e Install the lower chain guide roller and tighten the nut Rocker Arm Removal e Using the jack under the frame raise the rear wheel off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Remove Rear Tie Rod Mounting Bolt and Nut A Rear Shock Absorber Mounting Bolt and Nut Lower B Rocker Arm Pivot Bolt and Nut C Rocker Arm D NOTICE When pulling out the mounting bolts lift the rear wheel slightly Forcing or tapping on bolt could damage the bolt sleeve and bearing Tie Rod Rocker Arm SUSPENSION 13 31 Rocker Arm Installation e Replace with new ones Rear Shock Absorber Mounting Nut Lower Rocker Arm Pivot Nut Tie Rod Mounting Nut e Apply plenty of grease to the needle bearings and grease seals e Check that collars are in place on the rocker arm e Install the rocker arm e Apply grease to the seating surface of the rocker arm pivot nut and tie rod mounting nut e Tighten
297. ower Supply Fuel Line Gator Light LED a EE TRE tne dag EE Indicator Light LED Inspection elen EE Fuel Pressure Inspection a adar aS Fuel Flow Rate Inspection ss Throttle Grip and Cable Throttle Grip Thrott Throttle Grip Thrott le Cable Free Play Inspection le Cable Free Play Adjustment Throttle Cable Replacement eee Throttle Cable Lubri CA E Ro E Throttle Cable Inspection ss Throttle Body Assy Idle Speed Inspection esis cet ail wave Ee Eege Throttle Bore CIS starts Lie nn Riel dde nee ne far es Throttle Body Assy R mMmoval 2 in tn a etalon a Don ne ine lee Throttle Body Assy Installations fs A eee dedans Throttle Body Assy Disassembly issues Throttle Ee KEN Air Cleaner Air Cleaner Housing Removal ss manu drid Air Cleaner Housing Installation ns Element Removal lnstallation o tdo ne Element Cleaning and Inspection Fuel Tank Fuel Tank Removal Fuel Tank Installation net Eed ANEREN tds ened teens Fuel Tank Cleaning 3 55 3 55 3 56 3 57 3 57 3 58 3 58 3 60 3 60 3 60 3 61 3 61 3 62 3 62 3 63 3 63 3 63 3 64 3 64 3 66 3 66 3 66 3 66 3 67 3 69 3 69 3 70 3 72 3 72 3 72 3 72 3 73 3 73 3 74 3 74 3 74 3 74 3 75 3 76 3 77 3 79 3 79 3 79 3 79 3 79 3 80 3 80 3 82 3 83 FUEL SYSTEM DFI 3 3 This page inte
298. procket washer A e Remove Engine Sprocket Nut B Washer e Remove the engine sprocket C from the drive chain D Engine Sprocket Installation e Install the engine sprocket so that the stepped side A faces inside e Replace the sprocket washer with a new one e Install the sprocket washer and sprocket nut Torque Engine Sprocket Nut 70 N m 7 1 kgf m 52 ft Ib e Bend the one side of the sprocket washer on the nut e Install the drive chain guide and engine sprocket cover Torque Engine Sprocket Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib Rear Sprocket Removal e Remove the rear wheel see Rear Wheel Removal in the Wheels Tires chapter NOTICE Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground e Remove Rear Sprocket Bolts A and Nuts Washers Rear Sprocket B 11 8 FINAL DRIVE Sprockets Rear Sprocket Installation e Replace the rear sprocket nuts with new ones e Install the rear sprocket A so that the marked side B faces out e Install the rear sprocket bolts and washers e Tighten Torque Rear Sprocket Nuts 34 N m 3 5 kgf m 25 ft lb Sprocket Wear Inspection e Refer to the Sprocket Wear Inspection in the Periodic Maintenance chapter Rear Sprocket Warp Runout Inspection e Refer to the Rear Sprocket Warp Runout Inspection in the Periodic Maintenan
299. 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 2011 Kawasaki Heavy Industries Ltd 3rd Edition 1 Mar 15 2013 LIST OF ABBREVIATIONS ABDC AC Ah ATDC BBDC BDC BTDC C cmHg CPU cu in DC DFI ECU AU BR CA ampere s after bottom dead center alternating current ampere hour after top dead center before bottom dead center bottom dead center before top dead center degree s Celsius centimeters of mercury Central Processing Unit cubic inch s direct current Digital Fuel Injection Electronic Control Unit farad s degree s Fahrenheit foot feet gram s gallon s hour s horsepower s in KDS km h rom TDC V Q inch s Kawasaki Diagnostic System kilometers per hour liter s pound s Light Emitting Diode meter s minute s miles per hour newton s ounce s pascal s horsepower pound s per square inch quart s revolution revolution s perminute second s top dead center volt s watt s ohm s COUNTRY AND AREA CODES Australia Brazil Canada Europe Thailand United States Fore
300. projection A and groove B e Install the rear wheel e Install the chain adjusters on the swingarm as shown in the figure Adjuster A Left Side Flat Adjuster B Right Side e Insert the axle from left side and temporarily tighten the axle nut e Install the drive chain see Drive Chain Installation in the Final Drive chapter e Tighten Torque Rear Axle Nut 108 N m 11 0 kgf m 79 7 ft lb GJ04273BS1 Wheels Rims WHEELS TIRES 10 9 e Insert a new cotter pin A NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle tighten the nut clockwise B up to next alignment Olt should be within 30 OLoosen once and tighten again when the slot goes past the nearest hole e Bend the cotter pin A over the nut A WARNING A loose axle nut can lead to an accident resulting in serious injury or death Tighten the axle nut to the proper torque and install a new cotter pin e Check the rear brake for good braking power and no brake drag A WARNING After servicing it takes several applications of the brake pedal before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the motorcycle until a firm brake pedal is obtained by pumping the pedal until the pads are against the disc Wheels Inspection e Refer t
301. ps after 6 seconds if the engine speed is 1 300 r min rpm or more Vehicle down Sensor Removal NOTICE Never drop the vehicle down sensor especially on a hard surface Such a shock to the sensor can damage it e Pull the vehicle down sensor A from the frame bracket e Disconnect the connector B Vehicle down Sensor Installation e The UPPER mark A of the sensor should face upward and install the sensor e Connect the connector A WARNING Incorrect installation of the vehicle down sensor could cause sudden loss of engine power The rider could lose balance during certain riding situ ations like leaning over in a turn with the potential for an accident resulting in injury or death Ensure that the vehicle down sensor is held in place by the sensor bracket Vehicle down Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged e Disconnect the vehicle down sensor connector and con nect the measuring adapter A between these connec tors Main Harness B Vehicle down Sensor C Special Tool Measuring Adapter 57001 1700 e Connect a digital meter D to the measuring adapter leads Vehicle down Sensor Input Voltage Connections to Adapter Digital Meter R sensor R Y lead Digital Meter BK sensor GY lead e Refer to the Self diagnosis Procedures connect the 12 V battery to the main harness eecncas P GC17709ES1
302. r cylinder Inspect the cylinder and piston repair or replace them if necessary Bad condition of piston ring and or piston ring grooves Replace the piston and or the piston rings Auto decompressor do not move smoothly Replace the auto decompressor ENGINE TOP END 5 23 Cylinder Head Cylinder Head Removal e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Cylinder Head Cover see Cylinder Head Cover Re moval Camshafts see Camshaft Removal Exhaust Pipe see Exhaust Pipe Removal Ignition Coil see Ignition Coil Removal in the Electrical System chapter e Remove Upper Engine Bracket A Both Sides Cylinder Head Bolts M6 B e Loosen Cylinder Bolt C Throttle Body Assy Clamp Screw D e Remove Water Hose Clamp Screw A Loosen Water Hose B e Remove the cylinder head bolts M10 A e Pull the throttle body assy off the throttle body assy holder e Remove the cylinder head A NOTE OWhen do not remove the cylinder head easily tap lightly up with a plastic mallet B to separate the cylinder head from the cylinder 5 24 ENGINE TOP END Cylinder Head OTake care not to damage the chain guides A NOTICE Do not touch the radiator core This could damage the radiator fins resulting in loss of cooling effi ciency e Remove the cylinder head gasket B Cylinder Head Installation e Fitthe projections A
303. r or piston shows any damage replace them e Inspect the primary C and secondary D cups If a cup is worn damaged softened rotted or swollen the piston assembly should be replace to renew the cups x If fluid leakage is noted at the brake lever the piston as sembly should be replaced to renew the cup e Check the dust covers E for damage x If they are damaged replace them e Check that the relief F and supply G ports are not plugged x If the small relief port becomes plugged the brake pads will drag on the disc Blow the ports clean with com pressed air e Check the piston return springs H for any damage x If a spring is damaged replace it Front Master Cylinder J KX450FC Front Master Cylinder K KX450FD Rear Master Cylinder L GLO7167BS2 Brake Disk BRAKES 12 23 Brake Disc Removal e Remove the wheels see Front Rear Wheel Removal in the Wheels Tires chapter e Remove the mounting bolts and take off the disc Brake Disc Installation e Install the brake disc on the wheel so that the marked side A faces out Front Brake Disk B Rear Brake Disk C e Apply a non permanent locking agent to the threads of the brake disc mounting bolts e Tighten Torque Front Brake Disc Mounting Bolts D 9 8 N m 1 0 kgf m 87 in lb Rear Brake Disc Mounting Bolts E 23 N m 2 3 kgf m 17 ft lb Brake Disc Inspection e Visually inspect the disc A x I
304. re the compression pressure OWith the throttle fully open turn the engine over sharply with the kickstarter several times until the compression gauge stops rising the compression is the highest read ing obtainable Special Tools Compression Gauge 20 kgf cm 57001 221 Compression Gauge Adapter M10 x 1 0 57001 1317 Cylinder Compression Usable Range 420 698 kPa 4 3 7 1 kgf cm 61 101 psi at 5 times e Install the removed parts see appropriate chapters x If the compression pressure is not within the usable range check the following table Problem Diagnosis Remedy Action The cylinder Carbon accumulation on piston and in Remove the carbon deposits and compression is cylinder head combustion chamber is replace damaged parts if necessary higher than the suspected due to damaged valve stem or usable range piston oil rings Incorrect cylinder head gasket thickness Damaged auto decompressor spring or decompressor do not move smoothly The cylinder Exhaust gas leakage around cylinder head compression is lower than the Incorrect seating surface of valve usable range Valve clearance is too narrow Piston cylinder clearance is too wide Piston seizure Replace the gasket with a standard one Replace the spring or auto decompressor Replace the damaged gasket and inspect cylinder head warp Repair seating surface if possible Adjust the valve clearance Replace the piston and o
305. reen Scavenge Cleaning xsseterenertnn tendent dde rates 7 10 Oil Screen Feed Cleaning EE 7 11 Oil Pressure Relief Valve asset e da EEN 7 12 Oil Pressure Relief Valve Removal unes 7 12 Oil Pressure Relief Valve Installation 7 12 Oil Pressure Relief Valve Inspection 7 12 SUNG Dinde dE 7 13 Oil Pump Scavenge Removal Rues ro tdo ra te eee 7 13 Oil Pump Scavenge Installation pipe Cepagctetsadaasaendse 7 13 Oil Pump Feed Removal E 7 14 Oil Pump Feed Installation ratillo 7 14 Oil PUMP Inspection ainia da 7 15 Ol EE 7 16 Oil Pressure Measurement ccc ceeecceecceecceecceeccecceuccaccueeeseceneceneeeeeseeeeeseeeseeteeseneaeeeneees 7 16 7 2 ENGINE LUBRICATION SYSTEM Exploded View A RTS A 4 N A a PRO Y Ok BOP d k SU KDE 4 TN app AE de Sy Y d Sei 7 AD A ee Da E E AS A TS d S a S Ba Z A ENGINE LUBRICATION SYSTEM 7 3 Exploded View Torque No Fastener kgf m SC Remarks 2 OU Pump Feed Cover Bolts 9 8 10 87inlb 3 Oil Pressure Relief Valve 15 1 5 11 Lo 4 Piston Oil Nozzle 3 0 31 27 imlb 5 Piston Oil Nozzle Bolt 0 71 62 mb 6 Oil Pump Scavenge Cover Bolts oe 1 0 87 in lb 7 Engine Oil Drain Bolt M6 7 0 0 71 62 in lb 8 Oil Screen Feed Mounting Bolts 9 8 1 0 87 in lb 9 Engine Oil Drain Bolt M10 20 2 0 15 10 Oil Filter Cap Bolts 9 8 1 0 87 in lb EO Apply engine oil G Apply grease
306. reservoir runs almost out any time during bleeding operation the bleeding opera tion must be done over again from the beginning since air will have entered the line OTap the brake hose lightly from the caliper to the reser voir for easier bleeding e Remove the clear plastic hose e Tighten the bleed valve and install the rubber cap Torque Caliper Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib e Check the fluid level see Brake Fluid Level Inspection in the Periodic Maintenance chapter e Install the diaphragm and reservoir cap e Tighten Torque Brake Reservoir Cap Screws 1 5 N m 0 15 kgf m 13 in Ib e After bleeding is done check the brake for good braking power no brake drag and no fluid leakage WARNING After servicing it takes several applications of the brake lever before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the motorcycle until a firm brake lever is obtained by pumping the lever until the pads are against the disc GLO9064BS2 C Caliper BRAKES 12 13 Caliper Removal Front Brake e Loosen the brake pad pin A before the caliper B re moval if the caliper is to be disassembled e Loosen the banjo bolt C so as not to spill brake fluid NOTE Olf the caliper is to be disassembled after removal and compressed air is not availabl
307. ression stroke when the cam lobe faces outside of the camshaft OPlace a wrench over the flywheel nut and turn it counter clockwise to align the TDC mark A with the center of the groove B of the inspection hole GS06027BS1 phe F PERIODIC MAINTENANCE 2 23 Periodic Maintenance Procedures e Using a thickness gauge A measure the clearance be tween each cam lobe and valve lifter for all 4 valves OFor the purpose of adjusting the valve clearances record the measured values Valve Clearance Standard Exhaust 0 17 0 22 mm 0 0067 0 0087 in Intake 0 10 0 15 mm 0 0039 0 0059 in lf the valve clearance is not within the specified range adjust it Valve Clearance Adjustment e Remove Camshaft Caps A see Camshaft Removal in the En gine Top End chapter Camshafts B see Camshaft Removal in the Engine Top End chapter e Remove the valve lifters C of the applicable valve e Remove the shims D NOTE OMark and record the locations of the valve lifters and shims so that they can be reinstalled in their original positions e Clean the shim to remove any dust or oil e Measure the thickness of the removed shim A e Select a new shim thickness calculation as follows a tb c d a Present Shim Thickness b Measured Valve Clearance c Specified Valve Clearance Mean Value Exhaust 0 195 mm Intake 0 125 mm d Replace Shim Thickness E
308. ressure leaks e Install the cap A on a cooling system pressure tester B e Watching the pressure gauge slowly pump the pressure tester to build up the pressure The gauge hand must remain within the relief pressure range in the table below at least 6 seconds Continue to pump the tester until the relief valve opens indicated by the gauge hand flicking downward The relief valve must open within the specified range Radiator Cap Relief Pressure Standard 93 123 kPa 0 95 1 25 kgf cm 13 18 psi x If the cap cannot hold the pressure or if the relief pressure is too high or too low replace the cap with a new one Filler Neck Inspection e Check the radiator filler neck for signs of damage e Check the condition of the top and bottom sealing seats A in the filler neck They must be smooth and clean for the radiator cap to function properly Water Hoses and Overflow Hose Inspection e Refer to the Water Hoses and Connections Inspection in the Periodic Maintenance chapter Water Hoses and Overflow Hose Installation e Install the water hoses or overflow hose being careful to follow the performed bends see Cable Wire and Hose Routing section in the Appendix chapter Avoid sharp bending kinking flattening or twisting e Tighten the hose clamps securely Torque Water Hose Clamp Screws 3 0 N m 0 31 kgf m 27 in lb GDO7001BS1 ENGINE TOP END 5 1 Engine Top End Table of Contents Exploded V
309. ridad deidad ia 11 7 Engine Sprocket Installation saint tthe eens Meas a ieee doodles 11 7 Rear Sprocket REMOVAl nusoorioini dias 11 7 Rear Sprocket Installation 11 8 Sprocket Wear Inspection nimes it iranienne etais 11 8 Rear Sprocket Warp Runout Inspection oooooooccinnnnnininnninnnnnccnocccoconnncnn nc renr rn rra nara 11 8 11 2 FINAL DRIVE Exploded View FINAL DRIVE 11 3 Exploded View No Fastener Mm kgfm omen 1 Rear Sprocket Nuts 34 3 5 R 2 Engine Sprocket Nut 70 7 1 52 3 Engine Sprocket Cover Bolts 9 8 1 0 87 in lb 4 KX450FC HO Apply heavy oil L Apply a non permanent locking agent R Replacement Parts 11 4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain Chain Slack Chain 20 link Length Standard Chain 52 58 mm 2 0 2 3 in 317 5 318 2 mm 12 50 12 53 in 323 mm 12 7 in Make DAIDO Type DID 520DMA4 EE Link 114 Links EE Sprocket Rear Sprocket Warp TIR 0 4 mm 0 016 in or less TIR 0 5 mm 0 020 in FINAL DRIVE 11 5 Drive Chain Drive Chain Slack Inspection e Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter Drive Chain Slack Adjustment e Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter Wheel Alignment Inspection e Check that the notch A of the chain adjuster aligns with the same swingarm mark B a
310. rly and do not interfere with handlebar move ment see Cable Wire and Hose Routing section in the Appendix chapter e Check and Adjust Steering Front Brake Clutch Cable Throttle Cable Stem Bearing Lubrication e Refer to the Steering Stem Bearing Lubrication in the Pe riodic Maintenance chapter Stem Bearing Wear Damage Inspection e Using a high flash point solvent wash the upper and lower tapered rollers in the cages and wipe the upper and lower outer races which are press fitted into the head pipe clean off grease and dirt e Visually check the outer race and the rollers Replace the bearing assembly if it show damage Stem Warp Inspection e Whenever the steering stem is removed or if the steering cannot be adjusted for smooth action check the steering stem shaft A for straightness xlf the steering stem shaft is bent replace the steering stem Goss P STEERING 14 9 Handlebar Handlebar Removal e Remove Number Plate see Number Plate Removal in the Frame chapter Handlebar Pad A Fuel Tank Breather Hose B e Remove Clutch Lever Holder Assembly A Engine Stop Switch B Launch Control Mode Button C Band s D Left Handlebar Grip E KX450FC F KX450FD G e Remove Throttle Grip Assy A see Throttle Cable Replacement in the Fuel System DFI chapter Front Master Cylinder B see Front Master Cylinder Re moval in the Brakes chapter
311. rounded during self diagnosis e To enter the self diagnosis dealer mode 1 ground the self diagnosis terminal A for more than 2 seconds B and then keep it grounded continuously C Ground D Open E e Count the blinks of the light to read the service code OKeep the terminal ground until you finish reading the ser vice code e To enter the self diagnosis dealer mode 2 ground the self diagnosis terminal A and open it and then ground the self diagnosis terminal more than 3 times within 3 sec onds B and then keep it grounded continuously C Ground D Open E e Count the blinks of the light to read the service code OKeep the terminal ground until you finish reading the ser vice code gt GC17966ES1 GG17967ES1 FUEL SYSTEM DEI 3 27 Self Diagnosis Self Diagnosis Flow Chart Stop the engine Connect the power supply harness option and the 12 V battery to the capacitor connector Orange Fl warning indicator light LED goes on for 2 seconds and then goes off for 3 seconds Orange Fl warning indicator light LED stays unlit goes on Locate the problem with the service code table and check and repair DFI or ignition system according to inspection procedure on all service codes Make sure the orange Fl warning indicator light LED does not go on Disconnect the connected harness and stop the self diagnosis inspection Run the engine for s
312. rown iron or steel parts are rusting In either case flush the cooling system lf the coolant gives off an abnormal smell check for a cooling system leak It may be caused by exhaust gas leaking into the cooling system A 6 6D04016BS1 6S06008BS1 2 22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Water Hoses and Connections Inspection e Remove the radiator shrouds see Radiator Shroud Re moval in the Frame chapter OThe high pressure inside the water hoses A can cause coolant to leak B or the hose to burst if the line is not properly maintained Visually inspect the hoses for signs of deterioration Squeeze the hoses A hose should not be hard and brittle nor should it be soft or swollen x Replace the hose if any fraying cracks C or bulges D are noticed e Check that the hoses are securely connected and clamps are tightened correctly Torque Water Hose Clamp Screws 3 0 N m 0 31 kgf m 27 in lb Engine Top End Valve Clearance Inspection NOTE OValve clearance must be checked and adjusted when the engine is cold at room temperature e Remove Cylinder Head Cover see Cylinder Head Cover Re moval in the Engine Top End chapter Timing Inspection Cap A Flywheel Nut Cap B Special Tool Filler Cap Driver 57001 1454 e Bring the piston to the TDC of its compression stroke to inspect the valve clearance the position at the end of the comp
313. rvice limit re place the cylinder head unit Camshafts ENGINE TOP END 5 21 Camshaft Runout Inspection e Remove the camshafts see Camshaft Removal e Set the camshaft in a camshaft alignment jig or on V blocks e Measure the runout with a dial gauge A at the specified place as shown in the figure Xlf the runout exceeds the service limit replace the camshaft Camshaft Runout Standard TIR 0 02 mm 0 0008 in or less Service Limit TIR 0 1 mm 0 004 in Cam Wear Inspection e Remove the camshafts see Camshaft Removal e Measure the height A of each cam with a micrometer x If the cams are worn down past the service limit replace the camshaft Cam Height Standard 36 943 37 057 mm 1 4544 1 4589 Exhaust in Intake KX450FC 38 143 38 257 mm 1 5017 1 5062 in KX450FD 37 743 37 857 mm 1 4859 1 4904 in Service Limit Exhaust 36 84 mm 1 450 in Intake KX450FC 38 04 mm 1 498 in KX450FD 37 64 mm 1 482 in GE11374BS1 GE11012281 5 22 ENGINE TOP END Cylinder Head Cylinder Compression Measurement e Warm up the engine thoroughly e Stop the engine e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Spark Plug see Spark Plug Cleaning and Inspection in the Periodic Maintenance chapter e Attach the compression gauge A and compression gauge adapter B firmly into the spark plug hole e Measu
314. s Si Apply silicone grease ex PBC grease O O I NI OD oy R o rmM o 12 6 BRAKES Specifications Item Standard Service Limit Brake Lever Lever Free Play Adjustable to suit rider Brake Fluid Grade Front DOT3 or DOT4 Rear DOT3 or DOT4 Brake Pads Lining Thickness Front 4 0 mm 0 16 in 1 mm 0 04 in Rear 6 4 mm 0 25 in 1 mm 0 04 in Brake Discs Thickness Front 2 85 3 15 mm 0 112 0 124 in 2 5 mm 0 10 in Rear 3 85 4 15 mm 0 152 0 163 in 3 5 mm 0 14 in Runout TIR 0 25 mm 0 010 in or less TIR 0 3 mm 0 01 in BRAKES 12 7 Special Tools Jack Jack Attachment F 7 J L 57001 1238 57001 1608 ST5712388ST ST571608ST 12 8 BRAKES Brake Lever Brake Pedal Brake Lever Play Adjustment e Refer to the Brake Lever and Pedal Adjustment in the Periodic Maintenance chapter Brake Pedal Position Adjustment e Refer to the Brake Lever and Pedal Adjustment in the Periodic Maintenance chapter Brake Pedal Removal e Remove Cotter Pin A Joint Pin B Washer C NOTE OPull off the joint pin while pressing down the brake pedal e Remove Brake Pedal Bolt A Brake Pedal Return Spring B Brake Pedal C and Washer Brake Pedal Installation e Install the return spring A as shown in the figure e Replace the O rings A with new ones e Apply grease to the O rings and shaft portion B of the
315. s a procedural sub step or how to do the work of the procedural step it follows It also precedes the text of a NOTE x Indicates a conditional step or what action to take based on the results of the test or inspec tion in the procedural step or sub step it fol lows 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 spec ified tightening torque oil grease or a locking agent during assembly GENERAL INFORMATION 1 1 General Information Table of Contents Before Se VICIO sata EE 1 2 Model Identification s sise At a AA is 1 7 General Gpechficatons A a r a a a a a aeaa aea Aaa Me na a an Peer E Eae TaRIT 1 8 Technical Information DFI Setting Data Gelecton 1 11 Technical Information Launch Control Mode 1 13 Technical Information PSF Pneumatic Spring Fork Front Fork KX450FD 1 15 dl Reine Te WE Le 1 20 1 2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera tion on a motorcycle read the precautions given below To facilitate actual operations notes illustra tions 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 di
316. s and circuits checked out good be sure to check the ECU for ground and power supply If the ground and power supply are checked good replace the ECU OWhen no service code is displayed the electrical parts of the DFI system has no fault and the mechanical parts of the DFI system and the engine are suspect 3 30 FUEL SYSTEM DFI Self Diagnosis Backups OThe ECU takes the following measures to prevent engine damage when the DFI or the ignition system parts have troubles Service Output Signal Usable Codes Pars Range or Criteria Backups by ECU If the throttle sensor system fails the signal is out of the usable range wiring short or open the ECU locks ignition timing into the closed Throttle Sensor Output throttle position and sets the DFI in the D J 11 Throttle Sensor Voltage method 1 0 391 4 512 V Also the throttle sensor system and intake air pressure fails the ECU locks ignition timing into the closed throttle position and sets the DFI in the a N method 2 If the intake air pressure sensor system fails the signal is out of the usable range wiring short or open the ECU sets the DFI in the a N method Conduct ignition and injection operations whenever crank rotates by 360 degrees Intake Air Intake Air Pressure 12 Pressure Output Voltage Sensor 0 352 4 824 V Intake Air Intake Air Temperature 13 Temperature Output Voltage ECU sets the intake air temperature at 26 C Sensor 0 117 4 922 V W
317. s method is called D J method 2 a N Method As the engine speed increases and the engine load turns middle to heavy the ECU determines the injection quantity by calculating from the throttle opening main throttle sensor output voltage and the engine speed This method is called a N method Throttle Sensor Service Code 11 FUEL SYSTEM DFI 3 31 The throttle sensor is a rotating variable resistor that change output voltage according to throttle operating The ECU senses this voltage change and determines fuel injection quantity and ignition timing according to engine rpm and throttle opening Input Terminal A Output Terminal B Ground Terminal C Throttle Sensor Replacement NOTICE Never drop the throttle sensor A especially on a hard surface Such a shock to the throttle sensor can damage it NOTE OThese procedures are explained on the assumption that the intake and exhaust systems of the engine are in good condition OWhen adjusting the throttle sensor use a digital voltage meter which can be read the third decimal place The DC voltage accuracy must be less than 0 05 reading and 4 digits at DC 1 V ORead the manufacture s instructions thoroughly before using the meter incorrect values may cause improper adjustments e Remove the throttle body assy see Throttle Body Assy Removal e Check the paint on the stop screw A and make sure that the stop screw has not been adjusted If stop screw
318. s of the bead breaker protecting the rim with rim protectors NOTICE Take care not to insert the tire irons so deeply that the tube gets damaged e Remove the tube and bead protector when one side of the tire is pried off e Pry the other side of the tire off the rim Tire Installation NOTE OThe tires should be installed so that the ID serial NO A faces to left side e Inspect the rim and the tire before installing the tire and replace them if necessary e Install the tube band onto the rim e Apply a soap and water solution or rubber lubricant to both the tire bead and the rim flange e Position the tire on the rim so that the air valve A is at the tire balance mark B the chalk mark made during removal OThe new tire is no marked e Insert the valve stem into the rim and screw the nut on loosely e Fit the rim protectors and use suitable tire irons to install the tire bead Special Tool Rim Protector 57001 1063 NOTICE To prevent rim damage be sure to place the rim protectors at any place the tire irons are applied e Install the tire on the rim from the opposite side of the air valve OFit the rim protectors and insert the tire irons so deeply that the tube is not damaged e Install the bead protector onto the rim e Similarly slip the tire bead over the rim on the other side e Check that the tube is not pinched between the tire and rim 6J05010481 DCR
319. s the other side one A WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition Be sure the wheel is properly aligned Wheel Alignment Adjustment e This procedure is the same as Drive Chain Slack Adjust ment see Drive Chain Slack Adjustment in the Periodic Maintenance chapter Drive Chain Wear Inspection e Refer to the Drive Chain Wear Inspection in the Periodic Maintenance chapter Drive Chain Lubrication e Refer to the Drive Chain Lubrication in the Periodic Main tenance chapter Drive Chain Removal e Remove the engine sprocket cover see Engine Sprocket Removal e Remove the clip A from the master link with pliers e Remove Link Plate Master Link Drive Chain Drive Chain Installation e Fit the drive chain onto the sprockets OPlace the drive chain ends on the rear sprocket as shown in the figure e Install the master link A from the wheel side 11 6 FINAL DRIVE Drive Chain e Install the link plate A so that the mark faces out e Install the clip B so that the closed end C of the U pointed in the direction of chain rotation D e Adjust the drive chain slack see Drive Chain Slack Ad justment in the Periodic Maintenance chapter Sprockets FINAL DRIVE 11 7 Engine Sprocket Removal e Remove Engine Sprocket Cover Bolts A Engine Sprocket Cover B Drive Chain Guide C e Flatten the bended s
320. sassembly 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 CB02004B Solvent Use a high flash point solvent when cleaning parts High flash point solvent should be used according to directions of the solvent manufacturer 68020058 Cleaning Vehicle before Disassembly Clean the vehicle thoroughly before disassembly Dirt or H other foreign materials entering into sealed areas during ve hicle 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 Before Servicing GENERAL INFORMATION 1 3 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 ac cident Visually inspect removed parts for corrosion discol oration 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 be
321. se Banjo Bolt 25 N m 2 5 kgf m 18 ft lb e Bleed the brake line see Brake Line Bleeding e Check the brake for good braking power no brake drag and no fluid leakage WARNING After servicing it takes several applications of the brake lever before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the motorcycle until a firm brake lever is obtained by pumping the lever until the pads are against the disc GLO7165BS2 GL10000BS1 BRAKES 12 21 Master Cylinder Rear Master Cylinder Removal e Remove Cotter Pin A Joint Pin B Washer C NOTE OPull off the joint pin while pressing down the brake pedal e Remove the master cylinder mounting bolts A and re move the master cylinder B backward e Remove the brake hose banjo bolt C OWhen removing the brake hose temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum Rear Master Cylinder Installation e Install the brake hose OReplace the washers A on each side of hose fitting B with new ones e Tighten Torque Brake Hose Banjo Bolt 25 N m 2 5 kgf m 18 ft lb e Install the rear master cylinder e Tighten Torque Rear Master Cylinder Mounting Bolts 9 8 N m 1 0 kgf m 87 in lb e Replace the cotter pin with a new one e Install the joint pin
322. see Rear Shock Ab sorber Removal e Visually inspect the following items Oil Leakage Crack or Dent x If there is any damage to the rear shock absorber replace it e Visually inspect the oil seal A x If it show any signs of damage replace it Rear Shock Absorber Scrapping A WARNING Pressurized nitrogen may explode when heated The rear shock contains nitrogen gas To avoid an explosion do not incinerate the shock body without first releasing the nitrogen and removing the shraeder valve e Remove the rear shock absorber see Rear Shock Ab sorber Removal e Insert a suitable tool into the gas reservoir cap hole A to release the nitrogen gas SUSPENSION 13 27 Swingarm Swingarm Removal e Remove Rear Wheel see Rear Wheel Removal in the Wheels Tires chapter Rear Flap see Rear Flap Removal in the Frame chap ter Brake Hose Clamps A e Remove Bolts A and Nuts B Chain Guide Plate C Chain Guide D e Remove the rocker arm pivot nut A and bolt B NOTICE When pulling out the mounting bolts lift the swingarm slightly Forcing or tapping on a bolt could damage the bolt sleeve and bearing e Remove Rear Master Cylinder Mounting Bolts A Brake Pedal Bolt B Brake Pedal Return Spring C e Remove the following parts as a set Brake Pedal Rear Brake Master Cylinder Brake Hose Rear Brake Caliper e Remove the swingarm pivot shaft nut A e Pull out the swing
323. set B Special Tool Bearing Driver Set 57001 1129 G104195BS1 G104196BS1 G104197BS1 G104421BS1 G104422BS1 9 12 CRANKSHAFT TRANSMISSION Crankcase e Next press the new outside release shaft needle bear ing A until the surface of the bearing is even with the crankcase surface B Special Tool Bearing Driver Set 57001 1129 e Replace the oil seals if removed e Press the release shaft oil seal A so that the oil seal lip B faces to the engine outside and the oil seal surface is flush with the left crankcase surface C Special Tool Bearing Driver Set 57001 1129 e Apply grease to the oil seal lip e Install the new circlip D Special Tool Inside Circlip Pliers 57001 143 e Repeat the same procedures for the output shaft and shift shaft oil seals e Install the crankcase bearing retainers so that the cham fered side faces inside of the engine e Apply a non permanent locking agent to the threads of the crankcase bearing retainer screws A e Tighten Torque Crankcase Bearing Retainer Screws 15 N m 1 5 kgf m 11 ft lb e When installing the piston oil nozzle A tighten it se curely Torque Piston Oil Nozzle 3 0 N m 0 31 kgf m 27 in Ib G104199BS1 G104423BS1 CRANKSHAFT TRANSMISSION 9 13 Crankcase e When installing the piston oil nozzle A note the follow ing OReplace the O ring B wit
324. specified loosening sequence 1 5 and remove the fuel pump A NOTICE Do not pull the leads of the fuel pump If they are pulled the lead terminals may be damaged e Discard the fuel pump O ring A Fuel Pump Installation e Remove the dirt or dust from the fuel pump A by lightly applying compressed air e Replace the fuel pump O ring with a new one FUEL SYSTEM DFI 3 61 Fuel Pump Service Code 46 e Install the fuel pump A to the fuel tank e Apply a non permanent locking agent to the threads of the fuel pump bolts e Gradually tighten the fuel pump bolts evenly following the specified tightening sequence 1 6 Torque Fuel Pump Bolts 9 8 N m 1 0 kgf m 87 in Ib e Install the removed parts see appropriate chapters Fuel Pump Operation Inspection NOTE OBe sure the battery is fully charged e Refer to the Self diagnosis Procedures connect the 12 V battery to the main harness e Make sure that the fuel pump operates make light sounds for 5 seconds and then stops e Disconnect the power supply harness x If the pump does not operate as described above check the operating voltage see Fuel Pump Operating Voltage Inspection Fuel Pump Operating Voltage Inspection NOTE OBe sure the battery is fully charged e Remove the left radiator shroud see Radiator Shroud Re moval in the Frame chapter e Disconnect the fuel pump lead connector and connectthe measuring adap
325. ss Inspection ss 10 9 RIMSRUNOUEINSPSCHON estate rend lens les Mn a tt 10 9 Rim Installation Position 10 10 AXIS INSPECCIONES ee 10 10 UE ER EE ee 10 11 Air Pressure Inspection Adjustment ns 10 11 TING ue VUE Tire STAM e A A EP ER TT RE RE EE D batts Front Hub Bearing Removal Rear Hub Bearing Removal Hub Bearing instalation etre dare e Hub Bearing Inspeccion den es Hub Bearing Lubrication ss 10 2 WHEELS TIRES Exploded View 6J022078W5 C WHEELS TIRES 10 3 Exploded View Fastener Remarks 1 Spoke Nipples Not less Not less Not less than 2 2 than 0 22 than 19 in Ib 2 Front Axle Clamp Bolts 20 2 0 15 AL S 3 Front Axle Nut 78 8 0 58 S 4 Rear Axle Nut 108 11 0 79 7 AL Tighten the two clamp bolts alternately two times to ensure even tightening torque HG Apply high temperature grease R Replacement Parts S Follow the specified tightening sequence WL Apply soap and water solution or rubber lubricant 10 4 WHEELS TIRES Specifications Item Standard Service Limit Wheels Rims Rim Size Front 21 x 1 60 SE Rear 19x 2 15 Rim Runout Axial TIR 1 0 mm 0 04 in or less TIR 2 0 mm 0 08 in Radial TIR 1 0 mm 0 04 in or less TIR 2 0 mm 0 08 in Axle Runout 100 mm 3 94 in TIR 0 03 mm 0 001 in or less TIR 0 2 mm 0 008 in Tires Air Pressure when cold Front Rear Standard Tire Front Size
326. ssembly e Drain the folk oil see Front Fork Oil Change in the Peri odic Maintenance chapter e Remove the dust seal A and the retaining ring B NOTICE Be careful not to scratch the inner tube e Grasp the outer tube and stroke A the inner tube several times The shock to fork seal separates the inner tube from the outer tube ower 13 16 SUSPENSION Front Fork e Remove the following parts from the inner tube Guide Bushes A Washer B Collar C Oil Seal D Retaining Ring E Dust Seal F Front Fork Assembly e When the fork tubes are not disassembled hold the fork inverted position for more than 20 minutes to allow the fork oil to fully drain e Replace the following parts with new ones Dust Seal A Retaining Ring B Oil Seal C Guide Bushes D e Place an oil coated plastic bag E over the end of the inner tube to protect the oil seals OThe inner tube guide bush groove has a sharp edge F that cut out the sealing lip of the seals as they are pushed down over the inner tube e Install in order these parts on the inner tube e Tap the washer A with the oil seal driver B to install the outer guide bush KX450FC Special Tool Fork Oil Seal Driver 648 57001 1509 e Tap the oil seal with the oil seal driver to install the outer guide bush KX450FD Special Tool Fork Oil Seal Driver 448 57001 1509 e Install the oil seal by using the fork oil seal dri
327. stance Unit kQ Tester Lead Connection O Terminal A B C D E GPO9332BS1 Tester Lead Connection e Install the regulator rectifier see Regulator Rectifier In stallation 16 20 ELECTRICAL SYSTEM Charging System Charging System Troubleshooting NOTE OBe sure the prepared battery is fully charged 14 0 14 5V End Inspect regulator rectifier leads and harness Inspect charging voltage Too high Replace regulator rectifier Repair or replace damaged part Inspect Magneto output voltage AC at 4 000 r min Less than 37 V Inspect stator coil resistance between yellow leads resistance value lt 0 4 Q or Replace stator coil 1 1 Q lt resistance value 04 11Q Inspect resistance between leads and ground Less than Q Replace stator coil Replace flywheel GPO9374B F Charging System ELECTRICAL SYSTEM 16 21 Capacitor Removal e Disconnect the connector A and pull the capacitor B upward Capacitor Installation e Face the lead of the capacitor downward and insert the capacitor to the bracket e Connect the connector Capacitor Inspection e Remove Capacitor see Capacitor Removal e Setthe hand tester to the x 1 kQ range connect the tester to the leads of the capacitor and check the internal resis
328. stener NES Wee Remarks Radiator Shroud Bolts Footpeg Bracket Bolts Upper Footpeg Bracket Bolts Lower Rear Frame Mounting Bolts 5 KX450FC 6 Other than KX450FC and KX450FD US CA Models G Apply grease L Apply a non permanent locking agent R Replacement Parts S Follow the specified tightening sequence 15 4 FRAME Frame Frame Inspection e Refer to the Frame Inspection in the Periodic Mainte nance chapter Rear Frame Removal e Remove Seat see Seat Removal Side Covers see Side Cover Removal Muffler Body see Muffler Body Removal in the Engine Top End chapter Rear Fender see Rear Fender Removal Rear Flap see Rear Flap Removal Intake Air Temperature Sensor Connector A e Loosen the air cleaner duct clamp screw A e Remove the rear frame mounting bolts A on both sides e Take off the rear frame B together with the air cleaner housing OSeparate the air cleaner duct from the throttle body assy OTake care not to damage the frame and rear shock ab sorber with the air cleaner duct clamp Rear Frame Installation e Fit the claw A of the clamp to the groove B of the air cleaner duct e Install the rear frame Olnsert the duct onto the throttle body assy e Tighten Torque Rear Frame Mounting Bolts 34 N m 3 5 kgf m 25 ft lb e Tighten the air cleaner duct clamp screw e Install the removed parts see appropriate chapters FRAME 15 5
329. sters see Compression Damping Adjustment and Re bound Damping Adjustment in the Suspension chapter A WARNING Improper fork leg adjustment can cause poor han dling and loss of stability which could lead to an accident Always adjust the fork legs on the left and right side to the same setting e Tighten Torque Air Valve Plug 0 2 N m 0 020 kgf m 1 8 in Ib NOTICE Be sure to install the air valve plug to prevent dust from entering Rear Shock Absorber Inspection e Bounce A the rear of the motorcycle up and down and check for smooth suspension stroke e Remove the rear frame see Rear Frame Removal in the Frame chapter e Check for a broken or collapsed spring e Check the shock for a bent shaft or oil leaks x If the shock does not smoothly or damaged replace or repair defective parts Rear Shock Absorber Oil Change The oil should be changed in the rear shock absorber at least once per racing season The frequency for best per formance must be based upon riding conditions and rider ability e Remove the rear shock absorber see Rear Shock Ab sorber Removal in the Suspension chapter e Remove the shock absorber spring see Spring Replace ment in the Suspension chapter 2 68 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Inserta suitable tool to center A of the reservoir cap and release the nitrogen gas completely keep the suitable tool inserted OFor instructi
330. ston Wear Inspection e Using a micrometer measure the outside diameter A of the piston 7 5 mm 0 30 in B up from the bottom of the piston at a right angle to the direction of the piston pin Piston Diameter Standard 95 970 95 980 mm 3 7783 3 7787 in Service Limit 95 82 mm 3 772 in x If the piston outside diameter is smaller than the service limit replace the piston Piston Cylinder Clearance Inspection e Refer to the Piston Cylinder Clearance in the Periodic Maintenance chapter POR Do GE16215BS1 ge Fama men P GE16278BS1 Cylinder and Piston ENGINE TOP END 5 37 Piston Ring Ring Groove Clearance Inspection e Check for uneven groove wear by inspecting the ring seat ing The rings should fit perfectly parallel to groove surfaces If not replace the piston and all the piston rings e With the piston rings in their grooves make several mea surements with a thickness gauge A to determine piston ring groove clearance Piston Ring Ring Groove Clearance Standard Top 0 04 0 08 mm 0 002 0 003 in Service Limit Top 0 18 mm 0 0071 in x If the piston ring groove clearance is greater than the ser vice limit measure the ring thickness and groove width as follows to decide whether to replace the rings the piston or both Piston Ring Groove Width Inspection e Measure the groove width at several points around the piston with a vernier caliper
331. system is designed OWatch the gauge for at least 6 seconds x If the pressure holds steady the fuel line is good x If the pressure drops at once or if bubbles are found in the area the fuel line is leaking Replace the delivery pipe assy injector and related parts ORepeat the leak test and check the fuel line for no leak age e Install Fuel Hose see Fuel Hose Replacement in the Periodic Maintenance chapter Fuel Tank see Fuel Tank Installation e Start the engine check the fuel leakage Fuel Injector Circuit 1 ECU 2 Fuel Injector 3 Capacitor 4 Frame Ground 1 GC17988ES2 6017977EW1 C 3 60 FUEL SYSTEM DFI Fuel Pump Service Code 46 Fuel Pump Removal WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Always stop the engine and do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light NOTICE Never drop the fuel pump especially on a hard sur face Such a shock to the pump can damage it e Draw the fuel out from the fuel tank with a commercially available electric pump e Remove the fuel tank see Fuel Tank Removal OBe careful of fuel spillage from the fuel tank since fuel still remains in the fuel tank and fuel pump Plug the fuel pipe of the fuel tank e Turn the fuel tank upside down e Loosen the fuel pump bolts evenly following the
332. t 25 N m 2 5 kgf m 18 ft lb e Install the removed parts see appropriate chapters e Bleed the brake line see Brake Line Bleeding e Check the brake for good braking power no brake drag and no fluid leakage A WARNING After servicing it takes several applications of the brake lever or pedal before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the motorcycle until a firm brake lever or pedal is obtained by pumping the lever or pedal until the pads are against the disc Caliper Disassembly e Refer to the Brake Caliper Fluid Seal and Dust Seal Re placement in the Periodic Maintenance chapter GL10000BS1 Caliper BRAKES 12 15 Fluid Seal Damage Inspection The fluid seal s A around the piston maintains the proper pad disc clearance If this seal is not in good condi tion pad wear will increase and constant pad drag on the disc will raise brake and brake fluid temperature e Replace the fluid seals under any of the following condi tions OFluid leakage around the pad OBrakes overheat OThere is a large difference in left and right pad wear OThe seal is stuck to the piston x If the fluid seal s is replaced replace the dust seal s B as well Also replace all seals every other time the pads are changed Front Caliper C Rear Caliper D Dust Seal Damage Inspection
333. t non self diagnosis inspection Conduct self diagnosis inspection Conduct general fuel system inspection General fuel system throttle body assy 4 2 Refer to Self Diagnosis Flow Chart GC17352F F Inquiries to Rider OEach rider reacts to problems in different ways so it is important to confirm what kind of symptoms the rider has encountered OTry to find out exactly what problem occurred under exactly what conditions by asking the rider knowing this information may help you reproduce the problem OThe following sample diagnosis sheet will help prevent you from overlooking any areas and will help you decide if it is a DFl system problem or a general engine problem 3 20 FUEL SYSTEM DFI Troubleshooting the DFI System Sample Diagnosis Sheet Rider name Model Engine No Frame No Date problem occurred Environment when problem occurred Weather O fine O cloudy O rain O snow O always O other Temperature O hot O warm O cold O very cold O always H O chronic O often O once frequency Altitude O normal O high about 1 000 m or more Motorcycle conditions when problem occurred Orange Fl O lights up immediately after starting the engine and goes off after 2 seconds warning with engine running normal indicator light LED Starting difficulty Engine stops Poor running at low speed O lights up for 2 seconds immediately after start
334. t the oil seal assembly B yet Pump the piston rod until all the air is forced out of the rear shock body e Adjust the gas reservoir damping adjusters A to the soft est position A EN MU Wi Eh E GS14082BS2 GMO5067BS1 2 72 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Insert the suitable tool to center of the reservoir cap and operate the piston rod assembly after pour 98 kPa 1 0 kgf cm 14 psi nitrogen gas and then push out to the place where the reservoir cap hits the circlip Now check that the edge of the reservoir cap is pushed out to 2 mm 0 08 in deeper than the edge of the gas reservoir A WARNING Oil leaking from the shock or reservoir diminishes shock performance and may cause adverse han dling and or shock performance If the reservoir cap is not pushed out to its specified position oil may spray out during pressurization and or leak during use Be sure the reservoir cap is in its proper position before pressurizing the shock e Pump the piston rod A until all the air is forced out of the rear shock body B e Pull up the piston rod assembly and pour the suspension oil into the rear shock body to upper end of the rear shock body Suspension Oil KHV10 K2C 1L 45024 0002 e Push the oil seal assembly into the rear shock body until it just clears the circlip groove e Replace the circlip with a new
335. tan 4 6 Coolant Deterioration Inspection 4 6 4 OO trie Draining crate ri ela tera li 4 6 Coolant FIG tc ida 4 7 PAUP BIOSCI Gs sd nt nt Te ne mat ied Nees bl et nn ne RS 4 7 Cooling System Pressure Testing Eesen 4 8 Cooling System FUSION it Mees AA Ar ere do A 4 8 WY ALCP TT EE 4 9 Water Pump Cover Removal oooooooococooooooocconononcnnnnnnnononononnnnnnnnnnonnnnnnno nono nono nnnr nono nnnonnnnnnnas 4 9 Water Pump Cover Installation sense 4 9 Impeller ue is aaa ana E dan arts stars dd 4 10 impeller Installation D 4 10 Water SST 4 10 Oil Seal and Bearing Removal se cssccecnssedvoccuPacanpsdacinenteteasunasiaurethendeueheuagsavenaarunueeubhe tenets 4 10 Oil Seal and Bearing Installation 4 11 Ee TEE 4 12 Radiator RTO ER agus daciegueapeadhartoeasiits ia tiCigns leedees 4 12 Radiator Installation a A di 4 13 Radiator Inspection 4 13 Radiator Cap Inspection cias cd 4 14 Filler Neck Inspection eee 4 14 Water Hoses and Overflow Hose Inspection ooooococcccccccococococononononono nono nnnnono no nono nnnonnnnnnos 4 14 Water Hoses and Overflow Hose Installation iii 4 14 4 2 COOLING SYSTEM Exploded View COOLING SYSTEM 4 3 Exploded View Torque No Fastener R k Nm kgfm ftip Radiator Mounting Bolts 9 8 1 0 87 mb Radiator Screen Bolts 1 0 87 in lb 9 8 Water Hose Clamp Screws 3 0 0 31 27 mb Water Pump Cover Bolts 9 8 1 0 87 in lb Coolant Drain Bolt 7 0 0 71 62 in lb Water Pump Impeller Bolt 9
336. tance the following table Special Tool Hand Tester 57001 1394 NOTICE Use only Kawasaki Hand Tester 57001 1394 for this test A tester other than the Kawasaki Hand Tester may show different readings x If the readings do not correspond to the table replace the capacitor unit Capacitor Internal Resistance Tester Positive Lead Connection Color O BK W Tester o a more than 5 kQ Negative 4 Lead Should not be Connection BKIW inspected A 2 1 Check the capacitor after 2 minutes 2 Do not check the resistance because of opposite of the polarity Capacitor Capacity 10 000 F 50 V 16 22 ELECTRICAL SYSTEM Ignition Timing Ignition Timing Inspection e Remove the timing inspection cap A Special Tool Filler Cap Driver 57001 1454 e Attach the timing light A to the ignition coil lead in the manner prescribed by the manufacturer Special Tool Timing Light 57001 1241 e Start the engine and aim the timing light at the TDC mark B on the flywheel e Run the engine at the speeds specified and note the align ment of the TDC mark OCheck the engine speed using the engine revolution tester A for high accuracy Ignition Timing Engine speed r min rpm Hole groove aligns with 2 000 Line mark on flywheel x If the ignition timing is incorrect check the crankshaft sen sor see Crankshaft Sensor Inspection x If the crankshaft sensor
337. ter A between these connectors Main Harness B Fuel Pump C Special Tool Measuring Adapter 57001 1700 e Connect a digital meter D to the measuring adapter R R leads Fuel Pump Operating Voltage sk Ss BK BK Y Connections to Adapter Digital Meter R pump R lead Digital Meter BK pump BK lead slo GC17741DS1 e Refer to the Self diagnosis Procedures connect the 12 V battery to the main harness 3 62 FUEL SYSTEM DFI Fuel Pump Service Code 46 e Measure the operating voltage with engine stopped and with the connector joined Operating Voltage Standard Battery Voltage x If the reading is not battery voltage check the wiring for continuity see Fuel Pump Circuit x If the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation x lf the reading is in specification but the fuel pump does not operate replace the fuel pump see Fuel Pump Re moval Installation Pressure Regulator Removal OThe pressure regulator A is built into the fuel pump and can not be removed ieee P Fuel Filter Cleaning OThe fuel filter A is built into the pump and can not be cleaned or checked x If the fuel filter is suspected of clogging or being damaged replace it with the fuel pump as a set miter P Fuel Pump Circuit Dir
338. the oil seal is damaged the coolant leaks through the seal and drains through the passage Replace the oil seal Oil Seal and Bearing Removal e Remove Impeller see Impeller Removal Right Engine Cover see Right Engine Cover Removal in the Clutch chapter Circlip A Water Pump Shaft B Special Tool Outside Circlip Pliers 57001 144 Water Pump COOLING SYSTEM 4 11 e Insert a bar A into the water pump shaft hole from the outside of the right engine cover and remove the ball bearing B by tapping C evenly around the bearing in ner race e Remove the spacer D e Remove the ball bearing E and oil seal F from the right engine cover in the same way as ball bearing removal e Insert a bar A into the water pump shaft hole from the inside of the right engine cover and remove the oil seal B by tapping C evenly around the seal lips Oil Seal and Bearing Installation NOTICE If the oil seal or ball bearing is removed replace all of them with new ones at the same time e Replace the oil seals with new ones e Apply plenty of grease to the oil seal lips e Press in the new oil seal A using a bearing driver set from the outside of the right engine cover so that the seal bottom surface is flush with the end face B of the right engine cover e Press in the new oil seal C using a bearing driver set from the outside of the right engine cover so that the oil seal surface is flush D with the s
339. the pressure holds steady the cooling system is all right If the pressure drops and no external source is found check for internal leaks Check the cylinder head gasket for leaks e Remove the pressure tester replenish the coolant and install the radiator cap Cooling System Flushing Over a period of time the cooling system accumulates rust scale and lime in the water jacket and radiator When this accumulation is suspected or observed flush the cool ing system If this accumulation is not removed it will clog up the water passages and considerably reduce the effi ciency of the cooling system e Drain the cooling system see Coolant Draining e Fill the cooling system with fresh water mixed with a flush ing compound NOTICE Avoid the use of a flushing compound which is harmful to the aluminum engine and radiators Carefully follow the instructions supplied by the manufacture of the cleaning product e Warm up the engine and run it at normal operating tem perature for about 10 minutes e Stop the engine and drain the cooling system after the coolant cools down e Fill the system with fresh water e Warm up the engine and drain the system after the coolant cools down e Repeat the previous two steps once more e Fill the system with a permanent type coolant and bleed the air from the system see Air Bleeding COOLING SYSTEM 4 9 Water Pump Water Pump Cover Removal e Drain the coolant se
340. the spark plug but do not remove the spark plug e Install the good spark plug A to the spark plug cap then touch the frame with it NOTE OMeasure the voltage with each lead connected cor rectly The correct value may not be obtained if disconnected OMaintain the correct value of compression pressure for the cylinder Be sure to measure the voltage with the spark plug installed to the cylinder head e Connect the peak voltage adapter B to a digital meter Special Tools Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Needle Adapter Set 57001 1457 Hand Tester Range DC 250 V e Connect the peak voltage adapter to the ignition coil ter minal and ground Connections Peak Voltage Digital Adapter Meter Ground C R lead gt Terminal O Lead D BK lead Ignition Coil E ECU F Needle Adapter G e Shift the gear to the neutral position e Crank the engine by kicking the pedal several times to measure the peak voltage of the ignition coil Ignition Coil Primary Peak Voltage Standard 120 V or more WARNING Electrical equipment can cause serious electrical shock To avoid being shocked do not touch the metal portion of the probe when measuring voltage lf the voltage is less than the specified value see the Troubleshooting on next page IC Igniter Inspection OThe IC igniter is built in the ECU e Refer to the following items Ignition System Troubleshooting see Ignitio
341. ther than 5 V calculate a valid output voltage range as follows Example In the case of an input voltage of 4 75 V 0 58 x 4 75 5 00 0 55 V 0 62 x 4 75 5 00 0 59 V Thus the valid range is 0 55 0 59 V e Once the sensor is properly adjusted tighten the throttle sensor screw NOTE OTake care not to vary the output voltage when tightening the throttle sensor screw e Turn the throttle from closed to full open more than 2 times and measure the output voltage x If the output voltage is not within the specified range read just the sensor e Install the throttle body assy see Throttle Body Assy In stallation Throttle Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged e Remove Rear Frame with Air Cleaner Housing see Rear Frame Removal in the Frame chapter e Disconnect the throttle sensor connector and connect the measuring adapter A between these connectors Main Harness B Throttle Sensor C Special Tool Measuring Adapter 57001 1700 e Connect a digital meter D to the measuring adapter leads Throttle Sensor Input Voltage Connections to Adapter Digital Meter R sensor BL lead Digital Meter BK sensor BK lead e Refer to the Self diagnosis Procedures connect the 12 V battery to the main harness GC17995ES1 3 34 FUEL SYSTEM DFI Throttle Sensor Service Code 11 e Measure the input voltage with the engine stopped and with
342. tion Distance Judgment Thickness 68 6 76 4 mm 2 70 3 01 in More than 76 4 mm 3 01 Standard 1 5mm 0 06in 1 Too big 1 0mm 0 04 in 1 in Less than 68 6 mm 2 70 in Too small 1 0mm 0 04 in 2 x If the replacement of the adjusting washer is necessary remove the clutch spring plate again and install the se lected washer A 6 16 CLUTCH Clutch Clutch Plate Assembly Free Play Inspection Ad justment e Assemble the following parts Clutch Hub A Friction Plates B Steel Plates C Friction Plates D Spring Plate E Spring F Bolts G NOTE Olnstall the both ends of friction plates which are marked when disassembled to the their original position e Tighten Torque Clutch Spring Bolts 8 8 N m 0 90 kgf m 78 in Ib e Measure the clutch plate assembly length H Clutch Plate Assembly Length Standard 34 9 35 5 mm 1 37 1 40 in lf length is not within the standard select the correct length of steel plates according to the table shown GRO5034BS2 Thickness Part Number 1 2 mm 0 047 in 13089 1010 1 6 mm 0 063 in STD 13089 1095 2 0 mm 0 079 in 13089 1005 NOTE ODo not use the steel plate of 1 2 mm 0 047 in and 2 0 mm 0 079 in thickness at the same time Release Shaft Removal NOTICE Do not remove the clutch release shaft unless it is absolutely necessary If removed release shaft oil seal must be replaced
343. tions of the oil pipes A e Assemble Camshaft Caps B Oil Pipes e While keeping the camshaft caps in parallel install them to the cylinder head e Apply molybdenum disulfide oil to the threads of the camshaft cap bolts e Tighten all camshaft cap bolts evenly and lightly and then tighten them with specified torque OFollow the numbers 1 8 of tightening sequence on the camshaft cap Torque Camshaft Cap Bolts 9 8 N m 1 0 kgf m 87 in Ib e Install the camshaft chain tensioner see Camshaft Chain Tensioner Installation e Check the camshaft chain timing OConfirm the timing mark and punch mark align with the cylinder head upper surface x lf the timing mark and punch mark do not align with the cylinder head upper surface reinstall the camshafts OTurn the crankshaft slowly x If the crankshaft does not turn smoothly the timing is dif ferent Stop turning immediately NOTICE The improper camshaft chain timing may damage the valves e Install Cylinder Head Cover see Cylinder Head Cover Instal lation e Replace the timing inspection cap and flywheel nut cap O rings with new ones e Apply grease to the O rings e Tighten Torque Timing Inspection Cap 3 5 N m 0 36 kgf m 31 in Ib Flywheel Nut Cap 3 5 N m 0 36 kgf m 31 in Ib Special Tool Filler Cap Driver 57001 1454 5 20 ENGINE TOP END Camshafts Camshaft Chain Removal e Remove Camshafts see Camshaft Removal F
344. tment Frame Frame Inspection e Clean the frame with steam cleaner e Visually inspect the frame and rear frame for cracks dents bending or warp x If there is any damage to the frame replace it WARNING A repaired frame may fail in use possibly causing an accident resulting in injury or death If the frame is bent dented cracked or warped replace it Electrical System Spark Plug Cleaning and Inspection e Remove Seat see Seat Removal in the Frame chapter Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Spark Plug Cap e Clean the plug hole A using the compressed air B e Remove the spark plug A using the spark plug wrench Special Tool Spark Plug Wrench Hex 16 B 57001 1262 e The plug may also be cleaned using a high flash point solvent and a nonmetal brush nylon etc xlf the spark plug electrodes are corroded or damaged or if the insulator is cracked replace the plug Use the standard spark plug PERIODIC MAINTENANCE 2 77 Periodic Maintenance Procedures e Measure the gap A with a wire type thickness gauge x If the gap is incorrect carefully bend the side electrode B with a suitable tool to obtain the correct gap Spark Plug Gap Standard 0 8 0 9 mm 0 03 0 04 in e Install the spark plug using the spark plug wrench Special Tool Spark Plug Wrench Hex 16 57001 1262 e Tighten Torque Spark Plug 13 N m 1 3 kgf m 115 in lb
345. to Cable Wire and Hose Routing section in the Appendix chapter e When installing the fuel hose avoid sharp bending kink ing flattening or twist and run the fuel hose with a mini mum of bending so that fuel flow will not be obstructed Replace the hose if it has been sharply bent or kinked Throttle Grip Throttle Cable Free Play Inspection e Check the throttle grip free play A by lightly turning the throttle grip B back and forth Throttle Grip Free Play Standard 2 3 mm 0 08 0 12 in x If the free play is improper adjust the throttle cable e Check that the throttle grip moves smoothly from full open to close and the throttle closes quickly and completely in all steering positions by the return spring x If the throttle grip does not return properly check the throt tle cable routing grip free play and cable damage Then lubricate the throttle cable e Run the engine at the idle speed and turn the handlebar all the way to the right and left to ensure that the idle speed does not change x If the idle speed increase check the throttle cable free play and the cable routing Throttle Grip Throttle Cable Free Play Adjustment KX450FC e Loosen the locknuts A B at the upper end of the throttle cable e Screw both throttle cable adjuster C D to give the throt tle grip plenty of play e Turn out the decelerator adjuster C until there is no play when the throttle grip is completely closed e Ti
346. ton Lead 11 Throttle Cables 2 Clutch Cable 12 Run the throttle cables over the water 3 Launch Control Mode Button Connector hose 4 Run the clutch cable outside of the main 13 Do not touch the regulator rectifier lead harness and water hose 5 Main Harness 14 Run the throttle cables through the side of 6 Engine Stop Switch Lead the fuel tank 7 Clamps Wind the clamps on the cable 15 Run the throttle cables over the main har 8 Gear Position Switch Lead ness 9 Magneto Lead 10 Run the clutch cable outside of the mag neto lead and gear position switch lead When assemble the fuel tank confirm the throttle cables can move forward and backward 17 8 APPENDIX Cable Wire and Hose Routing KX450FC ND CONDO Launch Control Mode Button Lead Engine Stop Switch Lead Clamp Hold the engine stop switch lead and the main harness Water Hoses Fuel Pump Lead Connector Gear Position Switch Lead Connector Capacitor Lead Connector Magneto Lead Gear Position Switch Lead Magneto Lead Connector Run the main harness over the water hose Self diagnosis Terminal Main Harness Upper Side Frame Pipe APPENDIX 17 9 Cable Wire and Hose Routing KX450FD GBOSOI2E G 1 Launch Control Mode Button Lead 8 Magneto Lead 2 Engine Stop Switch Lead 9 Main Harness 3 Position the self diagnosis terminal out 10 Clamp Hold the engine stop switch le
347. trouble Inspect and replace see chapter 2 Inspect see chapter 16 Throttle sensor trouble Inspect see chapter 3 Intake air pressure sensor trouble Water temperature sensor trouble Inspect Inspect see chapter 3 see chapter 3 Intake air temperature sensor trouble Fuel pump trouble Inspect Inspect see chapter 3 see chapter 3 mla Le jajaja Fuel injector trouble Inspect see chapter 3 Fuel pressure too low or too high Fuel pressure regulator trouble Inspect see chapter 3 Inspect fuel pressure and replace fuel pump see chapter 3 Fuel line clogged Inspect and repair see chapter 3 Poor acceleration Fuel pressure too low Inspect see chapter 3 Water or foreign matter in fuel Change fuel Inspect and clean fuel system see chapter 3 Fuel filter or pump screen clogged Inspect and replace fuel pump see chapter 3 Fuel pump trouble Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 Throttle sensor trouble Inspect see chapter 3 Intake air pressure sensor trouble Inspect see chapter 3 Water temperature sensor trouble nm Le lo lA Inspect see chapter 3 Intake air temperature sensor trouble Inspect see chapter 3 Spark plug dirty broken or gap maladjusted Ignition coil trouble Inspect and replace see chapter 2 Inspect see chapter 16 Stumble
348. ts see appropriate chapters Oil Pump Inspection e Remove each oil pump see Oil Pump Scavenge Feed Removal e Visually inspect the oil pump body outer rotors and the inner rotors x If the oil pump is any damaged or unevenly worn replace the rotors cover or crankcase 7 16 ENGINE LUBRICATION SYSTEM Oil Pressure Oil Pressure Measurement e Remove Oil Filter Cap Bolts A Oil Filter Cap B e Install the O rings of the oil filter cap to the oil pressure cap A Special Tool Oil Pressure Cap 57001 1656 e Install the oil pressure cap and tighten the oil filter cap bolts Torque Oil Filter Cap Bolts 9 8 N m 1 0 kgf m 87 in Ib e Attach the oil pressure gauge adapter B and oil pressure gauge C Special Tools Oil Pressure Gauge 5 kgf cm 57001 125 Oil Pressure Gauge Adapter M10 x 1 25 57001 1182 e Start the engine NOTE OWarm up the engine thoroughly before measuring the oil pressure e Run the engine at the specified speed and read the oil pressure gauge Oil Pressure Standard 20 70 kPa 0 20 0 71 kgf cm 2 9 10 psi at 4 000 r min rpm Oil Temperature 40 C 104 F x If the oil pressure is much lower than the standard check the oil pump feed x If the reading is much higher than the standard check the oil filter first and oil passages for dirt or clogging A WARNING Hot oil can cause severe burns Beware of hot en gine oil that will drain through the
349. ttle body assy holder B e Install the throttle body assy holder so that the groove A faces left side e Apply a non parmanent locking agent to the threads of the throttle body assy holder screws B e Install the clamp C KX450FD e Tighten Torque Throttle Body Assy Holder Screws 9 8 N m 1 0 kgf m 87 in lb e Install Throttle Body Assy Clamp D Throttle Body Assy see Throttle Body Assy Installation in the Fuel System DFI chapter SEI P 5 40 ENGINE TOP END Muffler A WARNING The muffler can become extremely hot during nor mal operation and cause severe burns Do not re move the muffler while it is hot Muffler Body Removal e Remove the right side cover see Side Cover Removal in the Frame chapter e Loosen the muffler clamp bolt A e Remove the mounting bolts B and pull out the muffler body backward Exhaust Pipe Removal e Loosen the muffler clamp bolt A e Remove Exhaust Pipe Holder Nuts B Exhaust Pipe C Muffler Installation e Replace the exhaust pipe gasket A with a new one e Apply grease to the exhaust pipe gasket and install it to engine e Replace the muffler pipe gasket B with a new one Make sure that the gasket is placed securely inside the muffler body e Install the exhaust pipe and muffler body temporary e Temporary tighten the exhaust pipe holder nuts A first and then the muffler mounting bolt rear B e Tighten
350. turn the high speed compression damping adjuster with a 14 mm wrench x If the damping feels too soft or too stiff adjust it in accor dance with the following table Seated position A adjuster turned fully clockwise NOTICE Do not force the compression damping force ad juster beyond the fully seated position or the ad justing mechanism may be damaged High Speed Compression Damping Adjuster Setting Standard 1 1 2 turns out B KX450FC EUR BR 1 1 4 turns out C KX450FC 1 3 4 turns out D KX450FD EUR BR TH 1 1 2 turns out KX450FD Softer counterclockwise E Harder clockwise F Number of turns counterclockwise usable range 2 turns or more Counterclockwise from the fully seated position e Adjust the low speed compression damping turn the low speed compression damping adjuster with a standard tip screwdriver x If the damping feels too soft or too stiff adjust it in accor dance with the following table Seated position A adjuster turned fully clockwise Low Speed Compression Damping Adjuster Setting Standard 10 clicks B KX450FC EUR BR 9 clicks C KX450FC 8 clicks D KX450FD EUR BR TH 11 clicks E KX450FD Softer counterclockwise F Harder clockwise G Number of turns counterclockwise usable range 22 clicks or more Counterclockwise from the fully seated position NOTE OAdjustment of the compression damping adjusters for the re
351. ty ECU Grounding Inspection Capacitor Connector B BK W lead ECU Connector C BK W lead D ECU Terminal 8 BK Y lead E ECU Terminal 35 BK Y lead F ECU Terminal 36 Criteria 0 Q x If no continuity check the connector or main harness and repair or replace them if necessary x lf the wiring is good check the power supply voltage of the ECU NOTE OBe sure the battery is fully charged e Connect the ECU connector e Refer to the Self diagnosis Procedures connect the 12 V battery to the main harness GC17989ES1 3 68 FUEL SYSTEM DFI ECU e Connect a digital meter A to the ECU connector B with the needle adapter set Special Tool Needle Adapter Set 57001 1457 ECU Power Supply Inspection Connections Digital Meter R W lead ECU Terminal 1 Digital Meter Battery Terminal Standard When battery is not connected DC 0 V When battery is connected Battery Voltage GC17736DS1 x If the reading is out of the specification check the follow ing Power Supply Wiring see ECU Power Supply Circuit x lf the wiring is good replace the ECU see ECU Re moval Installation ECU Power Supply Circuit gt BK N 4 D BK Y BK Y T d i SH o 1 ECU 2 Capacitor 3 Frame Ground Fuel Line FUEL SYSTEM DFI 3 69 Fuel Pressure Inspection NOTE OBe sure the battery is ful
352. ug wrench 57001 1653 A with a vise loosen the base valve assembly B using the top plug wrench 57001 1705 C Special Tools Top Plug Wrench 49 mm 57001 1653 Top Plug Wrench 36 mm 57001 1705 e Remove the base valve assembly A from the cylinder unit B NOTE OSlowly compress the piston rod until it stops so that the base valve assembly can be removed easily NOTICE Disassembling the base valve assembly can lead to trouble Do not disassemble the base valve assembly 2 52 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Drain the fork oil A from the cylinder unit B by pumping the piston rod several times e Hold the front fork at the inverted position for more than 20 minutes to allow the fork oil to fully drain Z 6M04251BS1 e Clean the threads A of cylinder unit and base valve as sembly e Replace the O rings A on the base valve assembly with new ones e Apply specified fork oil to the O rings on the base valve assembly e With the piston rod in fully compressed position pour the specified amount of fork oil A into the cylinder unit Suspension Oil KHL15 10 1L 44091 0004 KHL15 10 4L 44091 0013 Cylinder Unit Oil Amount 198 ml 6 69 US oz NOTE OPlug the two oil holes B on the cylinder unit with fingers until the base valve assembly is installed PERIODIC MAINTENANCE 2 53 Periodic Maintenance Procedures e Pump A the pisto
353. unting Bolts Nuts Engine Bracket Bolts Nuts Shift Pedal Bolt Muffler Mounting Bolts Exhaust Pipe Holder Nuts Muffler Pipe Clamp Bolt Clutch Cable Adjuster Locknut Clutch Lever Pivot Bolt Locknut Kick Pedal Bolt Others Footpeg Cotter Pins Rear Frame Mounting Bolts Front Fender Bolts FUEL SYSTEM DFI 3 1 Fuel System DFI Table of Contents E leie 530 WEE 3 4 Specifications iodo 3 8 Special Tools and Sari A iS 3 9 DFI Sym pis 3 10 DEI Parts Loca ON iii A sr A een etat 3 13 DFI Servicing BT EE 3 15 DFI Servicing Pre caos o let ne ed ade ela did 3 15 Troubleshooting the DFI Systems 3 16 QUIN A E 3 16 nie te Ne EE 3 19 DFI System Troubleshooting Guide cocacola 3 21 ele ee EE 3 25 Ee ue Ce le 3 25 Self diagnosis ee E Mi 3 25 How to Read Service Codes 3 28 How to Erase Service Codes a aai 3 28 Service Code Table ici aan dello beac funda za 3 29 A EE 3 30 Throttle Sensor Service Code 11 crec 3 31 Throttle Sensor Replacement ses 3 31 Throttle Sensor Input Voltage Inspection ss 3 33 Throttle Sensor Output Voltage Inspection ss 3 34 Throttle Sensor Resistance Inspection ss 3 35 Intake Air Pressure Sensor Service Code 12 ue 3 37 Intake Air Pressure Sensor Removal renn rne erene 3 37 Intake Air Pressure Sensor Installation 3 37 Intake Air Pressure Sensor Input Voltage Inspection
354. urface of the right engine cover Special Tool Bearing Driver Set 57001 1129 e Press the ball bearings A together with the spacer B into the hole until the face of the bearing is even C with the end of the hole Special Tool Bearing Driver Set 57001 1129 e Install the water pump shaft e Replace the circlip with a new one e Fit the circlip into the groove of the water pump shaft se curely Special Tool Outside Circlip Pliers 57001 144 e Install the removed parts see appropriate chapters GD06108BS1 GDO6109BS1 GDO6110BS1 4 12 COOLING SYSTEM Radiator Radiator Removal e Drain the coolant see Coolant Draining e Remove Radiator Shrouds see Radiator Shroud Removal in the Frame chapter e Loosen Clamp Screws A e Remove Clamp B Water Hoses C Bolt D Left Radiator Screen E e Remove Radiator Mounting Bolts A Clutch Cable Clamps and Washers Left Radiator B e Loosen Clamp Screws A e Remove Water Hoses B Bolt C Right Radiator Screen D e Remove Radiator Mounting Bolts A and Washers Right Radiator B COOLING SYSTEM 4 13 Radiator Radiator Installation e Install Radiators Washers Clutch Cable Clamps A Left Side e Tighten Torque Radiator Mounting Bolts 9 8 N m 1 0 kgf m 87 in Ib e Run the hoses correctly see Cable Wire and Hose Rout ing section in the Appendix chapter
355. ut do not align with the cotter pin hole in the axle tighten the nut clockwise B up to next alignment Olt should be within 30 degrees OLoosen once and tighten again when the slot goes past the nearest hole e Bend the cotter pin A over the nut A WARNING A loose axle nut can lead to an accident resulting in serious injury or death Tighten the axle nut to the proper torque and install a new cotter pin e Check the rear brake effectiveness NOTE Oln wet and muddy conditions mud sticks to the chain and sprockets resulting in an overly tight chain and the chain may break To prevent this adjust the chain to 58 68 mm 2 3 2 7 in of slack whenever necessary GJ04082BS1 2 36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Drive Chain Lubrication OThe chain should be lubricated with a lubricant which will both prevent the exterior from rusting and also absorb shock and reduce friction in the interior of the chain x lf the chain is especially dirty it should be washed in diesel oil or kerosene and afterward soaked in a heavy oil Shake the chain while it is in the oil so that oil will pen etrate into the inside of each roller e An effective good quality lubricant specially formulated for chains is best for regular chain lubrication e If a special lubricant is not available a heavy oil such as SAE9O is preferred to a lighter oil because it will stay on the chain longer a
356. ut the dust covers A e Remove Screws B Throttle Cable Housings C e Free the tips A from the grip B e Remove Throttle Body Assy see Throttle Body Assy Removal Throttle Pulley Cover Bolts A Clamps KX450FC Throttle Pulley Cover B Throttle Grip and Cable FUEL SYSTEM DFI 3 73 e Loosen the throttle cable mounting bolts A e Take the cables B off the throttle body assy e Free the throttle cable tips C from the pulley e Remove the throttle cables e Lubricate the throttle cables see Lubrication in the Peri odic Maintenance chapter e Apply grease to the throttle cable tips e Install Throttle Cable Tips Throttle Cable Holders A OThe bent side B of the holders faces inside as shown in the figure e Tighten Torque Throttle Cable Mounting Bolts 3 5 N m 0 36 kgf m 31 in lb e Install Throttle Pulley Cover Clamps KX450FC e Tighten Torque Throttle Pulley Cover Bolts 3 4 N m 0 35 kgf m 30 in Ib e Install the removed parts see appropriate chapters e Install the throttle cables in accordance with the Cable Wire and Hose Routing section in the Appendix chapter e After the installation adjust each cable properly see Throttle Grip Free Play Adjustment in the Periodic Main tenance chapter A WARNING Operation with an improperly adjusted incorrectly routed or damaged cables could result in an unsafe riding condition Follow the service manual t
357. various riding positions the handlebar holder po sition can be changed and the handlebar can be adjusted by turning the handlebar holders around 180 GNO6029BS1 14 12 STEERING Handlebar e Remove the handlebar pad e Remove the handlebar clamp bolts A handlebar clamps B and handlebar C e Check the handlebar for damage or cracks x If the handlebar is damage or cracks replace it with a new one e Remove Handlebar Holder Nuts A Flat Washers B Round Washers C Handlebar Holders D Dampers E e Select the handlebar position and install the upper and lower dampers A into the hole B of the steering stem head C so that the flat surface D of dampers fit the flat surface E of the steering stem head hole e Install the round washer A and handlebar holder B in the suitable direction Olnstall the round washer so that the round part fits on the damper e Put the handlebar A on the handlebar holders B e Temporarily install the handlebar clamps C and tighten the handlebar clamp bolts D e Replace the handlebar holder nuts E with new ones e Install the round washers F flat washers G and han dlebar holder nuts Olnstall the round washers so that the round part fits under the dampers e Tighten Torque Handlebar Holder Nuts 34 N m 3 5 kgf m 25 ft lb e Install the handlebar see Handlebar Installation FRAME 15 1 Fram
358. ved with new ones Special Tool Outside Circlip Pliers 57001 144 NOTE OWhen assembling the ratchet gear A onto the kick Shaft B align the punch mark C on the ratchet gear with the punch mark D on the kick shaft G119035BS1 G119036BS1 CRANKSHAFT TRANSMISSION 9 33 Kickstarter e Apply grease to the inside of the spring guide A e Fit the spring end B and hollow C on the spring guide 9 34 CRANKSHAFT TRANSMISSION Bearings Oil Seals Bearing Replacement NOTICE Do not remove the ball or needle bearings unless it is necessary Removal may damage them e Using a press or puller remove the ball bearing and or needle bearings NOTE Oln the absence of the above mentioned tools satisfac tory results may be obtained by heating the case to ap proximately 93 C 200 F max and tapping the bearing in or out NOTICE Do not heat the case with a torch This will warp the case Soak the case in oil and heat the oil e Using a press and the bearing driver set A install the new ball bearing until it stops at the bottom of its housing OThe new needle bearings must be pressed into the crankcase so that the end is flush with the end of the hole Special Tool Bearing Driver Set 57001 1129 Bearing Wear Inspection NOTICE Do not remove the bearings for inspection Re moval may damage them e Check the ball bearings OSince
359. ver A KX450FC Special Tool Fork Oil Seal Driver 648 57001 1509 Z 6M04251BS1 GM04777BS1 Front Fork SUSPENSION 13 17 e Install the retaining ring to the outer tube e Push the dust seal into the outer tube and put the spring band on the dust seal e Pour the fork oil see Front Fork Oil Change in the Periodic Maintenance chapter Adjuster Assembly Inspection e Inspect the adjuster assembly A and push rod B for damage x lf they are damaged replace them with new ones e Replace the gasket C and O ring D on the adjuster as sembly with new ones Base Valve Assembly Inspection KX450FC e Inspect the threads portion A and spring B of base valve assembly C for damage x lf they are damaged replace base valve assembly with new one e Replace the O rings D with new ones KX450FD e Inspect the threads portion A of base valve assembly B for damage x If they are damaged replace base valve assembly with a new one e Replace the O rings C with new ones Cylinder Unit Inspection e Inspect the piston rod B of cylinder unit A for scratches or bending x lf it has scratches or is bent replace cylinder unit with a new one 13 18 SUSPENSION Front Fork Inner Tube Inspection e Visually inspect the inner tube A x lf there is any damage replace the inner tube Since damage to the inner tube damages the
360. wever the system s effectiveness is dependent on rider skill technique and terrain conditions e The control map of the launch control mode is fixed and cannot be changed even with the use of the KX Fl cali bration kit Launch Control Mode Setting 1 Start the engine 2 Shift into neutral 1st or 2nd gear 3 Push the launch control mode button A for over two seconds 4 The orange launch control mode indicator light LED B will blink to indicate the system is operating The indicator light keeps blinking until the system is de activated Launch Control Mode Deactivation e When shifting into 3rd the system is deactivated auto matically and the indicator light stops blinking Orange Launch Control Mode Indicator Light LED e Orange lunch control mode indicator light LED also works as the Fl warning light The launch control mode is activated blinks The Fl warning is activated lights up 068111 P 1 14 GENERAL INFORMATION Technical Information Launch Control Mode Launch Control Mode Circuit BK W BL W BK W 0 Y G BK W R W BL W if G BK W R W BL W 62 1G o ET 1 ECU 2 Launch Control Mode Button 3 Orange Launch Control Mode Indicator Light LED 4 Capacitor 5 Frame Ground 1 GENERAL INFORMATION 1 15 Technical Information PSF Pneumatic Spring Fork Front Fork KX
361. with a new one e Remove Clutch see Clutch Removal e Remove the tip A of the clutch cable see Clutch Cable Removal e Pull out the release shaft assembly B Release Shaft Installation e Apply engine oil to the needle bearings in the hole of the crankcase e Apply grease to the release shaft lower end A and oil seal lips e Insert the release shaft straight into the hole of the crankcase NOTICE GFO6218BS1 When inserting the release shaft be careful not to remove the spring of the oil seal e Install the removed parts see appropriate chapters Clutch CLUTCH 6 17 Clutch Plates Wear Damage Inspection e Refer to the Clutch Plates Inspection in the Periodic Main tenance chapter Clutch Plates Warp Inspection e Refer to the Clutch Plates Inspection in the Periodic Main tenance chapter Clutch Spring Free Length Inspection e Measure the free length A of the clutch springs x If any clutch spring is shorter than the service limit it must be replaced Clutch Spring Free Length Standard 46 04 mm 1 813 in Service Limit 43 9 mm 1 73 in Clutch Housing Finger Damage Inspection e Visually inspect the clutch housing fingers A that come in contact with the friction plate tangs x If they are damaged or if there are groove cuts in the areas that come in contact with the tangs replace the housing Replace the friction plates if their tangs are damage
362. word This manual is designed primarily for use by trained mechanics in a properly equipped shop However it contains enough detail and basic in formation to make it useful to the owner who de sires to perform his own basic maintenance and repair work A basic knowledge of mechanics the proper use of tools and workshop proce dures must be understood in order to carry out maintenance and repair satisfactorily When ever the owner has insufficient experience or doubts his ability to do the work all adjust ments maintenance and repair should be car ried out only by qualified mechanics In order to perform the work efficiently and to avoid costly mistakes read the text thor oughly familiarize yourself with the procedures before starting work and then do the work care fully 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 ad versely affect safe operation To get the longest life out of your vehicle e Follow the Periodic Maintenance Chart in the Service Manual eBe alert for problems and non scheduled maintenance e Use proper tools and genuine Kawasaki Mo torcycle 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 P
363. xample Intake 2 60 0 31 0 125 2 785 mm OExchange the shims for the 2 800 size shim NOTICE Do not use the shims for another models This could cause wear of the valve stem end and the valve stem damage 2 24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Adjustment Shims ld PINo Mark hick P No Mark ness ness 2 00 92025 1870 0 2 55 92025 1881 55 2 05 92025 1871 5 2 575 92025 1985 58 2 15 92025 1873 15 2 625 92180 1059 63 2 30 92025 1876 3 2 70 92025 1884 70 3 3 5 8 0 5 0 5 S 2 375 92180 1058 38 2 75 92025 1885 7 2 40 92025 1878 92180 1196 3 2 425 92025 1982 4 92025 1886 8 2 45 92025 1879 45 92025 1887 85 2 475 92025 1983 48 92025 1888 90 2 50 92025 1880 50 2 95 92025 1889 95 NOTE OBe sure to remeasure the clearance after selecting a shim The clearance can be out of the specified range because of the shim tolerance Olf there is no valve clearance use a shim that is a few sizes smaller and remeasure the valve clearance e Install the shim OTurn the marked side A to upside OApply engine oil to the shim to keep the shim in place during camshaft installation NOTICE Do not put shim stock under the shim This may cause the shim to pop out at high rpm causing ex tensive engine damage Do not grind the shim This may cause it to fracture causing extensive engine damage e Apply e
364. xplosive and cause severe burns Clean the screen in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Do not use gasoline or a low flash point solvent to clean the screen NOTE OWhile cleaning the screen check for any metal particles that might indicate internal engine damage e Check the screen A carefully for any damage x If the screen is damaged replace it with a new one e Install the oil screen see Oil Screen Scavenge Installa tion GGO7000BS1 ENGINE LUBRICATION SYSTEM 7 11 Engine Oil and Oil Filter Oil Screen Feed Cleaning e Remove the oil screen see Oil Screen Feed Removal e Clean the oil screen with a high flash point solvent and remove the particles stuck e Blow away the particles by applying compressed air A from the inside to the outside from the clean side to the dirty side A WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the screen in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Do not use gasoline or a low flash point solvent to clean the screen NOTE OWhile cleaning the screen check for any metal particles that might indicate internal engine damage e Check the screen careful
365. y B completely AWARNING Clamping the axle holder too tight can damage it which will affect riding stability Do not clamp the axle holder too tight e Compress the outer tube by hands and install the top plug wrench A between the axle holder bottom B and locknut C Special Tool Top Plug Wrench 49 mm 57001 1653 A WARNING The fork spring applies pressure to the adjuster as sembly and can eject the special tool with substan tial force if the tool is not properly and securely placed Be sure the tool is fully in place as shown in the photo and keep fingers away to avoid getting them pinched between the tool adjuster assembly and axle holder e Hold the locknut A with a wrench B and remove the adjuster assembly C e Remove the push rod A PERIODIC MAINTENANCE 2 51 Periodic Maintenance Procedures e With the outer tube compressed by hands remove the top plug wrench A NOTICE Removing the locknut and pushing the piston rod thread into the cylinder unit will damage the oil seal Do not remove the locknut from the piston rod e Remove the fork leg from the vise 65148710 P e Loosen the fork top plug A with the top plug wrench B Special Tool Top Plug Wrench 49 mm 57001 1653 e Remove Cylinder Unit A Fork Spring B NOTICE Disassembling the cylinder unit can lead to trouble Do not disassemble the cylinder unit e Holding the top pl
366. ycle slightly until the radiator cap is level to the ground so that the radiator cap is located uppermost in order to exhaust the air accumulated in the radiator e Remove the radiator cap A NOTE ORemove the radiator cap in two steps First turn the cap counterclockwise to the first stop and wait there for a few seconds Then push down and turn it further in the same direction and remove the cap e Check the coolant level The coolant level A should be at the bottom of the filler neck B x If the coolant level is low add coolant through the filler opening to the bottom of the filler neck Install the cap Recommended Coolant Permanent type antifreeze soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators Water and Coolant Mixture Ratio Soft Water 50 Coolant 50 Freezing Point 35 C 31 F Total Amount 1 1 L 1 2 US qt NOTICE For refilling add the specified mixture of coolant and soft water Adding water alone dilutes the coolant and degrades its anticorrosion properties The diluted coolant can attack the aluminum en gine parts In an emergency soft water alone can be added But the diluted coolant must be returned to the correct mixture ratio within a few days Coolant Deterioration Inspection e Visually inspect the coolant x If whitish cotton like wafts are observed aluminum parts in the cooling system are corroded If the coolant is b
367. ylinder Be sure to measure the voltage with the spark plug installed to the cylinder head WARNING Electrical equipment can cause serious electrical shock To avoid being shocked do not touch the metal portion of the probe when measuring voltage e Set a digital meter and connect it to the peak voltage adapter A Special Tool Peak Voltage Adapter 57001 1415 Type KEK 54 9 B e Connect the adapter to the terminals of the magneto lead connector B Connections Magneto Lead Peak Voltage SN Connector Adapter Digital Meter G W lead C R lead gt W Y lead D BKlead e Shift the gear to the neutral position e Crank the engine by kicking the pedal several times to measure the peak voltage of the crankshaft sensor Crankshaft Sensor Peak Voltage Standard 3 V or more x If the voltage is less than the specified check the crank shaft sensor see Crankshaft Sensor Inspection Crankshaft Sensor Inspection e Disconnect the magneto lead connector see Magneto Cover Removal e Set a digital meter A and connect it to the Green White B and White Yellow C leads in the connector Crankshaft Sensor Resistance Standard 180 280 Q at 20 C 68 F x If there is more resistance than the specified value the coil has an open lead and must be replaced Much less than this resistance means the coil is shorted and must be replaced e Using the highest resistance range of the digital

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