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Tighten the two clamp bolts alternately two times to en

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1. GMO7038BS1 STEERING 14 1 Steering Table of Contents Exploded Vie Weoo A A 14 2 A MEET 14 4 ne DEE A ete 14 5 Ss E See trade te En di 14 5 lte Be EE ME A E 14 5 Steering Stem Stem Bearing Removal ss 14 5 Steering Stem Stem Bearing Installation 14 7 Stem Bearing LUCA O EE 14 8 Stem Bearing Wear Damage Inspection ss 14 8 Stem Warp INSPSCUON EEN 14 8 PAIN EE 14 9 Handlebar Removal EE 14 9 Handl bar N DEIER BEEN 14 9 14 2 STEERING Exploded View TIRER PE e VILLANI GNO2097BWS C STEERING 14 3 Exploded View 1 Handlebar Holder Bolts 25 2 5 18 2T 2 Steering Stem Head Nut 3 Steering Stem Nut K in T 4 Front Fork Clamp Bolts Upper 4 Front Fork Clamp Bolts Lower 20 2 0 15 AL 5 6 Handlebar Holder Upper 7 Handlebar 8 Handlebar Holder Lower 9 Steering Stem Head Bracket 10 Upper Tapered Roller Bearing 11 Head Pipe 12 Lower Tapered Roller Bearing 13 Steering Stem AD Apply adhesive cement AL Tighten the two clamp bolts alternately two times to ensure even tightening torque G Apply grease O Apply 2 stroke oil 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
2. 6608060251 ENGINE LUBRICATION SYSTEM 7 13 Oil Pump Oil Pump Scavenge Removal e Drain Engine Oil see Engine Oil Change in the Periodic Main tenance chapter Coolant see Coolant Draining in the Coolant System chapter e Remove Shift Pedal see External Shift Mechanism in the Engine Right Side chapter Flywheel see Flywheel Removal in the Electrical Sys tem chapter e Remove Oil Pump Cover Bolts A Lower Camshaft Chain Guide B Oil Pump Cover C e Remove Inner Rotor A Outer Rotor B Oil Pump Scavenge Installation e Install the dowel pin 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 C OWhile turn the oil pump shaft install the oil pump so that the left and right oil pump shaft may mesh in the crankcase e Install Oil Pump Cover A Lower Camshaft Chain Guide B e While pushing the oil pump cover tighten the oil pump cover bolts following the sequence number as shown Torque Oil Pump Scavenge Cover Bolts 9 8 N m 1 0 kgf m 87 in lb 7 14 ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump Feed Removal e Remove Clutch Clutch Removal in the Engine Right Side chap ter 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 Cover Bolts A Oil Pump Cover B C KX450D6F
3. 6J06008BS1 6J06002BS1 FINAL DRIVE 11 1 Final Drive Table of Contents EXPO BEE 11 2 eelere TEE 11 4 O OS 11 5 Drive Chain Slack Inspection nsnnnnnnsnnnrrnrrrnertrrrnrtrntttntttnttttttttttttttrnttnnnttnntnnnnnen nnen nenn 11 5 Drive Chain Slack AdIUStinent Le cr Eege ae 11 5 Wheel Alignment Inspection luso e dc 11 5 Wheel Alignment AG E 11 5 Drive Chain Wear Inspection ococcccccncccnccnnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnninnnnnnnnnnnnnnnnnneninnns 11 5 Drive Chain Lubricationi ssssssins nt th San REENEN AE 11 5 Drive Chain HRemoval sie 11 5 Drive Chain Installationiys css seit dE tm hant edd Modan aies 11 5 SPOCK StS EE 11 7 Engine sprocket REMOVAL oil triste al Dd i E aide tac 11 7 Engine Sprocket Installation E 11 7 Rear Sprocket Removal seen 11 7 Rear Sprocket Installation 11 8 Sprocket Wear Inspechon a E a e a adete 11 8 Rear Sprocket Warp Inspection 11 8 11 2 FINAL DRIVE Exploded View NG FINAL DRIVE 11 3 Exploded View No Fastener Remarks _ Rear Sprocket Nuts Engine Sprocket Nut 127 13 94 Engine Sprocket Cover Bolts 9 8 1 0 87 in lb Engine Sprocket Output Shaft Chain Slipper Swingarm Chain Guide Locknut 10 Adjusting Bolt 11 Chain Adjuster 12 Drive Chain 13 Rear Sprocket 14 Upper Chain Guide Roller 15
4. 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 Be careful of reaction force in spring and fix surely so that special tool should not come off Do not place the fingers etc while serving Front Fork KX450D8F SUSPENSION 13 37 e Insert the push rod A into the piston rod e Replace the O ring and gasket on the adjuster assembly 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 A to provide more than 1 mm 0 04 in C e Turn the locknut A counterclockwise until it contacts with the adjuster assembly B e With the locknut held immovable using a wrench tighten the adjuster assembly to the specified torque Torque Locknut Adjuster Assembly 29 N m 3 0 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 Torque the adjuster assembly A Torque Adjuster Assembly 58 N m 5 9 kgf m 43 ft lb e Loosen and remove the fork top plug subtank from the outer tube and slowly slide down the outer tube Special Tool Top Plug Wrench 49 mm 57001 1653 e Pour A the specified amount of fork oil into the
5. WARNING To avoid a serious burn never touch the hot engine or exhaust chamber during clutch adjustment Clutch Lever Clutch Cable Free Play Inspection e Refer to the Clutch Lever Clutch Cable Free Play Check in the Periodic Maintenance chapter Clutch Lever Clutch Cable Free Play Adjustment e Refer to the Clutch Lever Free Clutch Cable Play Ad justment in the Periodic Maintenance chapter Clutch Lever Installation e Install the clutch lever A so that itincline 20 5 B more than the horizontal line C and position it from the edge of the grip to 170 mm 6 69 in D Clutch Cable Removal e Turn in the adjuster fully A e Slide the dust cover A out of place e Screw the adjuster B at the clutch lever fully e Line up the slots C in the clutch lever and adjuster and then free the cable from the lever ENGINE RIGHT SIDE 6 9 Clutch Lever and Cable e Loosen the adjusting nuts A fully e Free the clutch inner cable tip B from the clutch release lever C CAUTION 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 e Pull the clutch cable out of the frame Clutch Cable Installation 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 Clutch Cable Free Play Adjustment in t
6. 14 8 STEERING Steering e Install the front fork see Front Fork Installation in the Sus pension chapter NOTE OTighten the fork upper clamp bolts first next the stem head nut last the fork lower clamp bolt 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 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 Install the parts removed see the appropriate chapter WARNING Do not impede the handlebar turning by routing the cables wires and hoses improperly see the Ap pendix chapter e Check and Adjust Steering Front Brake Clutch Cable Throttle Cable Stem Bearing Lubrication e Refer to the Stem Bearing Lubrication in the Periodic 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 frame head pipe clean off grease and dirt e Visually check the outer rase 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 for straightness x If the steering stem shaft is bent A replace the steering
7. GDO06062BS1 4 12 COOLING SYSTEM Radiator Radiator Removal e Drain the coolant see Coolant Draining e Remove Radiator Shrouds e Loosen Clamp Screws A Clamp B e Remove Water Hoses C Bolts D Left Radiator Screen E e Unscrew the radiator mounting bolts A e Remove the left radiator B e Loosen Clamp Screws A e Remove Radiator Hoses B Bolt C Right Radiator Screen D e Remove Radiator Mounting Bolts A Right Radiator B COOLING SYSTEM 4 13 Radiator Radiator Installation e Fit the projections A of the screen in the holes B of the radiator Torque Water Hose Clamp Screws 1 5 N m 0 15 kgf m 13 in Ib Radiator Mounting Bolts 9 8 N m 1 0 kgf m 87 in Ib Radiator Screen Bolts 9 8 N m 1 0 kgf m 87 in Ib Radiator Shroud Bolts 9 8 Nm 1 0 kgf m 87 in Ib e Route the water and breather hoses correctly see Cable Wire and Hose Routing section in the Appendix chapter e Fill the cooling system with a permanent type coolant Radiator Inspection e Check the radiator core x If there are obstructions to air flow remove them x lf the corrugated fins are deformed carefully straighten them with the thin blade of a screwdriver A CAUTION Do not tear the radiator tubes while straightening the fins NS NS SS SS ISS SR x If the air passages of the radiator core are blocked more than 20 by unremovable obstr
8. Brake pad lining thickness Front 3 8 mm 0 15 in 1 mm 0 04 in Rear 6 4 mm 0 25 in 1 mm 0 04 in Suspension Fork Oil Oil Viscosity KHL15 10 KAYABA 01 or equivalent Oil Quantity Adjustable range 345 mL 11 7 US oz KX450D6F 355 mL 12 0 US oz KX450D7F 350 mL 11 8 US oz KX450D8F EUR 350 mL 11 8 US oz KX450D6F 170 mL 5 75 US oz KX450D6F 191 mL 6 46 US oz KX450D7F K2 C KAYABA or equivalent 11 2 12 8 US oz EUR 330 370 mL 11 2 12 5 US oz 325 365 mL 11 0 12 3 US oz KX450D6F 330 380 mL KX450D7F KX450D6F Electrical System Spark Plug Gap 0 8 0 9 mm 0 03 0 04 in TIR Total Indicator Readings EUR Europe Model Special Tools Inside Circlip Pliers 57001 143 ST5701438T Steering Stem Nut Wrench 57001 1100 ST5711008T Jack 57001 1238 ST5712388ST Spark Plug Wrench Hex 16 57001 1262 ST15712628T Pilot Screw Adjuster C 57001 1292 8757129297 PERIODIC MAINTENANCE 2 11 Pilot Screw Adjuster Adapter 4 57001 1371 A 8757137197 Filler Cap Driver 57001 1454 ST5714548T Pilot Screw Adjust D 57001 1588 ST571588ST Top Plug Wrench 49 mm 57001 1653 ST571653ST Top Plug Wrench 36 mm 57001 1705 ST15717058T 2 12 PERIODIC MAINTENANCE Pe
9. 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 GE16139BS2 Carburetor Holder ENGINE TOP END 5 37 Carburetor Holder Installation e Fit the recess A of the holder on the projection B of the cylinder head OThe marked side A of the carburetor holder B face to the carburetor e When installing the clamp screws refer to the Cable Wire and Hose Routing in the Appendix chapter Torque Carburetor Holder Clamp Screw 2 0 N m 0 20 kgf m 17 in lb GE17013BS1 o GE17035BS1 5 38 ENGINE TOP END Muffler A WARNING To avoid a serious burn do not remove the muffler when the engine is still hot Wait until the muffler cools down Muffler Removal e Loosen the muffler clamp bolt A e Remove the exhaust pipe holder nut B e Remove the exhaust pipe C e Remove Seat see Seat Removal in the Frame chapter Right Side Cover see Side Cover Removal in the Frame chapter e Remove the muffler mounting bolts A e Remove the muffler B from the back Muffler Installation e Replace the holder gasket A with a new one e Check the gasket B at the clamp and replace it if it is damaged Make sure that the gasket is placed securely outside the exhaust pipe e Tighten the following bolts and nut according to the spe cific tightening sequence 1 Exhaust Pipe Holder Nuts A Te
10. x If the voltage is less than the specified value see the next page GP10284BS1 16 18 ELECTRICAL SYSTEM Ignition System Troubleshooting Faulty ignition Malfunctioned engine Wiring and connect portion of the ignition No good system inspection Repair Good Spark plug inspection Replace Replace Spark plug cap inspection d Good Ignition coil primary peak voltage inspection No good Voltage is less than the specified value Good No good Voltage is Voltage is specified none or almost none but faulty ignition 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 Use KAWASAKI Hand Tester voltage Lacking of sampling Sampling few times EE Crankshaft sensor peak voltage malfunctioned no good parts All good All good C D I Unit is defective No good Replace the malfunctioned parts or inspect in proper way GP10286B F Ignition System ELECTRICAL SYSTEM 16 19 Crankshaft Sensor Peak Voltage Check e To check the peak voltage do the following procedures ODisconnect the connector of the magneto lead connector from the main harness NOTE OMeasure the voltage with each lead connected cor rec
11. 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 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 KX450D6F Left Side View KX450D6F Right Side View 1
12. Crankcase Disassembly e Remove the engine 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 Magneto Cover see Magneto Cover Removal in the Electrical System chapter Cylinder Head Cover see Cylinder Head Cover Re moval in the Engine Top End chapter 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 Right Engine Cover see Right Engine Cover Removal in the Engine Right Side chapter Clutch see Clutch Removal in the Engine Right Side chapter Primary Gear see Primary Gear Removal in the Engine Right Side chapter 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 in the En gine Right Side chapter Kick Shaft Idle Gear see Idle Gear Removal in the En gine Right Side chapter External Shift Mechanism see External Shift Mecha nism Removal in the Engine Right Side chapter Flywheel see Flywheel Removal in the Electrical Sys tem chapter e Remove the output shaft sleeve A and the O rings B ODo not reuse the O rings e Remove Gear Position Switch Screws A Gear Position Switch B CRANKSHAFT TRANSMISSION 9 7 Crankcase e Remove Gear Position
13. Fuel Tank 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 e Turn the fuel tap lever A to the OFF position e Slide out the clamp B and pull the fuel hose C off the fuel tap D e Remove the bolt E e Remove Seat see Seat Removal in the Frame chapter Bolts A e Remove the fuel tank mounting bolt B and band C e Pull out the fuel tank breather hose D from the steering stem e Remove the fuel tank E together with the radiator shrouds e Drain the fuel Fuel Tank Installation e Check the rubber dampers A on the frame xlf the dampers are damaged or deteriorated replace them e Be sure the fuel hose is clamped to the fuel tap to prevent leaks e Insert the fuel tank breather hose outlet end into the steer ing stem hole Fuel Filter Removal e Remove the fuel tank and drain it see Fuel Tank Re moval e Remove the mounting bolts A and take out the fuel filter B Fuel Filter Installation e Be sure the O ring is in good condition to prevent leaks e Be sure to clamp the fuel hose to the tap and fuel filter to prevent leaks Fuel Tank FUEL SYSTEM 3 31 Fuel Tank Filter and Tap Cleaning e Refer to the Fuel Tank Filter and Tap Cleaning in the Per
14. 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 Belore SEMVICING ideada aabt 1 2 Model dentttcatton eee 1 7 General Specific Le ET 1 8 Unit Conversion Table vieron id dada 1 10 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 disassembly and reassembly of general parts Especially note the following Edges of Parts Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts 68020048 Solvent Use a high flush point solvent when cleaning parts High flush 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 enterin
15. Rear Frame Removal e Remove Seat see Seat Removal Right amp Left Side Cover see Side Cover Removal Muffler see Muffler Removal in the Engine Top End chapter Rear Fender see Rear Fender Removal e Loosen the air cleaner duct clamp screw see Air Cleaner Housing Removal in the Fuel System chapter e Unscrew the rear frame mounting bolts A KX450D6F D7F e Remove the rear frame mounting bolts A and the washer at right lower frame KX450D8F e Remove the rear frame B with air cleaner housing C e Remove Bolts A Air Cleaner Housing B Rear Frame Installation e Install the air cleaner housing e Tighten Torque Rear Frame Mounting Bolts 34 N m 3 5 kgf m 25 ft lb e Install the removed parts FRAME 15 5 Frame Engine Guard Installation e Install the engine guard as shown Right Engine Guard A Collar B Bolt C Engine Guard D Bolts E G009021BS2 15 6 FRAME Seat Seat Removal e Remove the bolts A ue e Pull the seat B out from the back Seat Installation e Insert the hooks A of the seat under the flange collar B and brackets C e Tighten the seat mounting bolts FRAME 15 7 Side Cover Side Cover Removal e Remove Bolts A Side Cover B e Remove the other side according to similar procedure Side Cover Installation e Stick the pads A on the inside of the right side cover B e Install the dampers C e Insert the ta
16. 0 15 mm 0 0059 in or less 0 2 mm 0 008 in or less 0 05 mm 0 002 in 96 10 mm 3 783 in 2 6 mm 0 10 in 0 3 mm 0 01 in 0 3 mm 0 01 in Engine Lubrication System Engine oil Grade Viscosity Capacity Castrol R4 superbike 5W 40 KX450D6F D7F Castrol POWER1 R4 Racing 5W 40 KX450D8F or API SG SH SJ or SL with JASO MA SAE 10W 30 10W 40 or 10W 50 1 2 L 1 3 US qt Crankshaft Transmission Connecting Rod Big End Side Clearance 0 25 0 35 mm 0 0098 0 014 in 0 6 mm 0 02 in Wheels Tires Rim Runout with tire installed Axial Radial Front and Rear Tires Air Pressure TIR 1 0 mm 0 039 in or less TIR 1 0 mm 0 039 in or less 100 kPa 1 0 kgf cm 14 psi TIR 2 mm 0 08 in TIR 2 mm 0 08 in 2 10 PERIODIC MAINTENANCE Specifications Drive Chain Slack Drive Chain 20 Link Length Item Standard Service Limit Standard Tire Front Size 90 100 21 57M EE Make DUNLOP Type D742F Tube Rear Size 120 80 19 63M Make DUNLOP Type D756 Tube Final Drive 52 58 mm 2 0 2 3 in 317 5 318 2 mm 12 50 12 53 in 323 mm 12 7 in Outer Outer Inner Tubes Inner Subtank Rear Shock Absorber Oil Oil Viscosily 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 to suit rider a Brake Fluid Type Front DOT3 or DOT4 gt Rear DOT4
17. 1 03 1 05 mm 0 0406 0 0413 in 0 970 0 990 mm 0 0381 0 0390 in 0 25 0 35 mm 0 0098 0 014 in 0 15 0 50 mm 0 0059 0 020 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 10 mm 3 783 in 95 82 mm 3 772 in 0 17 mm 0 0067 in 1 1 mm 0 043 in 0 90 mm 0 035 in 0 6 mm 0 8 mm 18 95 mm 19 08 mm 0 02 in 0 03 in 0 7461 in 0 7512 in PRO PRO AA 19 07 mm 0 7508 in TIR Total Indicator Readings 5 8 ENGINE TOP END Specifications Cam Height GE11012281 Cam Height A Valve Stem Diameter 6E15049BS1 C Valve Stem Diameter A 45 B Camshaft Runout GE11077BS1 C Valve Stem Bend Dial Gauge A GE15011281 C 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 38 5 57001 1122 8757112297 Valve
18. 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 Gear Shifting Faulty Primary gear worn or damaged Doesn t go into gear shift pedal doesn t Decompressor spring broken return Magneto flywheel loose Clutch not disengaging Shift fork bent worn or seized Shift return spring pin loose Abnormal Drive Train Noise Clutch noise Shift return spring weak or broken Shift shaft lever broken Pawl guide plate broken Shift pawl broken Shift pawl spring tension lose Gear seized Gear set 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 set lever spring weak or broken Shift fork guide pin worn Drive shaft output shaft and or gear splines worn Overshifts Gear set lever spring weak or broken Pawl guide plate worn Clutch housing finger and friction plate tang worn Clutch housing gear worn Metal chips 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 ge
19. D7F D KX450D8F e Remove Inner Rotor 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 shaft e Install Outer Rotor B Inner Rotor C e While turn the oil pump shaft install the oil pump so that the left and right oil pump shaft may mesh in the crankcase ENGINE LUBRICATION SYSTEM 7 15 Oil Pump e Install the oil pump cover A e While pushing the oil pump cover tighten the oil pump cover bolts following the sequence number as shown OThread length of the bolt is 16 mm 0 63 in only in the bolt installed thirdly KX450D6F D7F OThread length of the bolts is 16 mm 0 63 in in the bolts installed thirdly and fifthly KX450D8F B KX450D6F D7F C KX450D8F Torque Oil Pump Feed Cover Bolts 9 8 N m 1 0 kgf m 87 in lb e Install the oil pump idle gear A facing the stepped side B to the outside e Replace the circlip C with a new one e Install the oil pump driven gear D and circlip Oil Pump Inspection e Remove the oil pump 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 body or the crankcase 7 16 ENGINE LUBRICATION SYSTEM Oil Pressure Oil Pressure Measurement e Remove the oil filter cover A e Install the O rings to the oil p
20. Ri 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 Cooling System Engine Top End Engine Right Side Engine Lubrication System Engine Removal Installation Crankshaft Transmission Wheels Tires Final Drive Brakes Suspension Steering Electrical System a ala la NIO BIO IN 6010 Ion B 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 Consumer Products 8 Machinery Company Kawasaki Heavy Industries Ltd Japan No liability can be accepted for any inaccuracies or omissions in this publication although every possible care has been taken to make it as complete and accurate as possible The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such chang
21. 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 Jack 57001 1238 ST5712388ST Bearing Puller 57001 1575 ST5715758T STEERING 14 5 Steering 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 Front Wheel see Front Wheel Removal in the Wheels Tires chapter Front Fender Bolts A Front Fender B e Remove Handlebar Pad A Number Plate B Breather Hose C Pull out e Remove the bolts A to remove the brake hose C from the holder B e Remove Handlebar Holder Bolts A Handlebar Holder Upper B Handlebar C see Handlebar Removal e Remove the front fork upper clamp bolts D e Remove the steering stem head nut E and washer e Remove the steering stem head F 14 6 STEERING Steering e Remove Front Fork Lower Clamp Bolts
22. 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 an ohmmeter between the ends of the leads OSet the meter to the x 1 Q range and read the meter x If the meter does not read 0 Q the lead is defective Re place the lead or the wiring harness if necessary GPO7019BS1 ELECTRICAL SYSTEM 16 9 Flywheel Magneto Magneto Cover Removal e Remove the left radiator shroud e Drain the engine oil from the crank room oil sump see Engine Oil Change in the Periodic Maintenance chapter e Pull the stopper A to this side to remove the magneto lead connector B AD E SAR K KC AS Sr e Disconnect the magneto lead connector from the main harness A KZ Ss e Remove the shift pedal see External Shift Mechanism Removal in the Engine Right Side chapter e Open the clamp A then free the breather hose B e Remove Magneto Cover Mounting Bolts C Magneto Cover D Magneto Cover Installation e Replace the gasket with a new one e Be sure to install the dowel pins A e Apply silicone sealant to the area A to the magneto lead grommet Sealant Kawasaki Bond Silicone Sealant 92104 0004 e Put in the magneto lead to the lead holder A e Tighten Torque Magneto Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib e Run the breather hose B and magneto lead according the Cable Wire and Hose R
23. e Check to see that gears shift smoothly from 1st to 5th gear and 5th to 1st while spinning the output shaft e Set the shift drum in the neutral position e Replace the O rings A on the output shaft with new ones e Install two O rings on the grinding faces of the output shaft while expanding the O ring by the hand e Apply grease to the inside of the output shaft collar B e Insert the collar with the oil groove end facing C in e Install the balancer drive gear C so that the punch mark A of the balancer drive gear and groove B of the crank shaft align e Replace the circlip with a new one and install it e Replace the circlip A with a new one and install it to the output shaft 9 14 CRANKSHAFT TRANSMISSION Crankshaft Crankshaft Removal e Disassemble the crankcase see Crankcase Disassem bly e Using the hand pull out the crankshaft A from the right crankcase half B Crankshaft Installation e Apply high temperature grease to the outer side of the crankshaft bearings and use the bearing driver set C to face the stepped side A to the engine inside and drive the bearing to the bottom of the crankcase B While driving the bearing in make sure to use a holder to support the boss area Special Tool Bearing Driver Set 57001 1129 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
24. sistance is felt and check the clearance between the lock nut B and adjuster assembly A to provide more than 1 mm 0 04 in C e Turn the locknut A counterclockwise until it contacts with the adjuster assembly B e With the locknut held immovable using a wrench tighten the adjuster assembly to the specified torque Torque Locknut Adjuster Assembly 29 N m 3 0 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 Torque the adjuster assembly A Torque Adjuster Assembly 58 N m 5 9 kgf m 43 ft lb e Loosen and remove the fork top plug subtank from the outer tube and slowly slide down the outer tube Special Tool Top Plug Wrench 49 mm 57001 1653 e Pour A the specified amount of fork oil into the outer tube Recommended Oil KHL15 10 KAYABAO1 or equivalent 345 mL 11 7 US oz KX450D6F Recommended Europe Model 350 mL 11 8 US Quantity oz KX450D6F 355 ml 12 00 US oz KX450D7F SUSPENSION 13 23 Front Fork KX450D6F D7F e Raise the outer tube and temporarily tighten the fork top plug subtank Special Tool Top Plug Wrench 49 mm 57001 1653 e After installing the front fork torque the top plug A Special Tool Top Plug Wrench 49 mm 57001 1653 B The torque of fork top plug is specified to 30 N m 3 1 kgf m 22 ft lb however when you us
25. 2 52 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Completely wipe of the fork oil from the spring A spacer B and cylinder unit C e Insert above mentioned parts into the fork e Temporarily tighten the fork top plug A subtank using the top plug wrench Special Tool Top Plug Wrench 49 mm 57001 1653 B e Clamp the axle holder with a vise OProtect the axle holder with a rag 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 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 Be careful of reaction force in spring and fix surely so that special tool should not come off Do not place the fingers etc while serving e Insert the push rod A into the piston rod PERIODIC MAINTENANCE 2 53 Periodic Maintenance Procedures e Replace the O ring and gasket on the adjuster assembly 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 to provide more than 1 mm 0 04 in C e Turn the locknut A counterclockwise until it contacts with the adjuster assembly B e With the locknut held immovable using a wrenc
26. 8757012297 3 8 FUEL SYSTEM 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 A see Front Master Cylinder Removal in the Brakes chapter e Slide out the dust cover B and cable housing dust cover C e Unscrew the screws A e Separate the throttle cable housing B e Free the tips A from the grip B FUEL SYSTEM 3 9 Throttle Grip and Cable e Remove the rear frame assy see Rear Frame Removal in the Frame chapter e Remove the carburetor e Unscrew the bolt A e Remove the throttle pulley cover B e Loosen the mounting bolts A e Remov
27. Counterclockwise C Harder Clockwise D Number of turns counterclockwise usable range 20 clicks or more Counterclockwise from the fully seated position e Put the caps into the bottom of the fork tubes GM04493BS1 Front Fork KX450D8F SUSPENSION 13 27 Compression Damping Adjustment e Place the jack under the frame so that the front wheel off the ground Special Tool Jack 57001 1238 e To adjust compression damping turn the adjuster A on the front fork top plugs with the blade of a 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 Seated positions adjuster turned fully clockwise A Compression Damping Adjuster Setting Standard 10 clicks B Softer Counterclockwise C Harder Clockwise D Number of turns counterclockwise usable range 22 clicks or more Counterclockwise from the fully seated position Oil Change each fork leg e Refer to Front Fork Oil Change in the Periodic Mainte nance chapter Front Fork Removal e Remove Number Plate e Unscrew the bolts A and remove the front brake hose clamps B e Remove Front wheel see Front Wheel Removal in the Wheels Tires chapter 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 dangl
28. e Clean the oil screens with a high flash point solvent and remove any particles stuck to them A WARNING Clean the screen in a well ventilated area and take care that there is no spark or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvent ENGINE LUBRICATION SYSTEM 7 11 Engine Oil and Oil Filter e Check the screen A carefully for any damage holes broken wires gasket pulling off x If the screen is damaged replace it e Install the oil screen see Oil Screen Scavenge Installa tion 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 Clean the screen in a well ventilated area and take care that there is no spark or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents NOTE OWhile cleaning the screens check for any metal parti cles that might indicate internal engine damage e Check the screens carefully for any damage holes and broken wires x If the screen is damaged replace the oil screen GGO7000BS1 GGO7002BS1 7 12 ENGINE LUBRICATION SYS
29. new one e Replace the O rings F with new ones 6M04254BS1 Front Fork KX450D8F SUSPENSION 13 39 Cylinder Unit Inspection e Inspect the piston rod B of cylinder unit A for scratches or bending x If it has scratches or is bent replace cylinder unit with a new one Inner Tube Inspection e Visually inspect the inner tube A repair any damage e Nick or rust damage can sometimes be repaired by using a wet stone to remove sharp edges or raised areas which cause seal damage sl the damage is not repairable replace the inner tube Since damage to the inner tube damages the oil seal replace the oil seal whenever the inner tube is repaired or replaced e Temporarily assemble the inner A and outer tubes B and pump them back and forth manually to check for smooth operation CAUTION If the inner tube is badly bent or creased replace it Excessive bending followed by subsequent straightening can weaken the inner tube Guide Bush Inspection e Visually inspect the guide bushes A and replace them if necessary Dust Seal Oil Seal Inspection e Inspect the dust seal A for any signs of deterioration or damage Replace it if necessary e Replace the oil seal B with a new one whenever it has been removed 6M04169BS1 6M04168BS1 6M040119S1 GM040120S1 13 40 SUSPENSION Front Fork KX450D8F Spring
30. s dr te en ARE ne 9 19 Shift Fork Bending Inspeccion de EELER 9 22 Shift Fork Gear Groove Wear Inspection 9 22 Shift Fork Guide Pin Shift Drum Groove Wear Inspection 9 22 Gear Damage Inspection theme al insti estres 9 22 EE Ile EE 9 23 Balancer Removal Ada AE 9 23 Balancer Installations EE 9 23 Beano S Oth SOAS tea da leads une betas al tn Shoes ee doctrina 9 24 Bearing Replacement sy siccccssen ced ecnceses EENEG ci 9 24 B aring INS PO CUO BEE 9 24 Oil Seal Inspection seen 9 25 9 2 CRANKSHAFT TRANSMISSION Exploded View CRANKSHAFT TRANSMISSION 9 3 Exploded View Piston Oil Nozzle KX450D8F Balancer Weight Mounting Nut o Gear Position Switch Screws 1 Copper Washer i KX450D6F 13 KX450D6F D7F EO Apply engine oil G Apply grease L Apply a non permanent locking agent MO Apply molybdenum disulfide oil LG Apply liquid gasket R Replacement parts S Tighten the fasteners following the specified sequence 52 2 9 0 30 26 in lb 0 41 35 in lb Bearing Retaining Screws 1 5 11 5 3 38 Fastener E Re kgf m ft lb marks 1 Crankcase Bolts M6 1 2 104 in lb S 2 Crankcase Bolts M7 1 5 11 S 3 Gear Set Lever Nut 0 90 78 in lb Engine Oil Drain Bolt M10 For Transmission Room Oil 4 S
31. stem GNO4013BS1 STEERING 14 9 Handlebar Handlebar Removal e Remove Number Plate A Clutch Holder B Engine Stop Switch C Clamps D Left Handlebar Grip E e Remove Throttle Grip Assy A see Throttle Cable Replacement in the Fuel System chapter Master Cylinder B see Front Master Cylinder Removal in the Brakes chapter e Remove Handlebar Holder Bolts A Handlebar Holder Upper B Handlebar C Handlebar Installation e Apply adhesive cement to the inside of the left handlebar grip e Install the left handlebar grip so that the arrow A on the grip face to the forward e Install the clutch lever A so that it incline 20 5 B more than the horizontal line C and position it from the edge of the grip to 170 mm 6 69 in D GR11004081 14 10 STEERING Handlebar e Apply grease to the throttle cable upper end and clutch cable upper end e Apply a 2 stroke oil to the throttle grip inner wall A e Install the throttle grip assy so that the grip A is in as far as it will go e Position the throttle grip assy so that the parting line B of the throttle case vertically and tighten the screws e Install the front master cylinder see Front Master Cylinder Installation in the Brakes chapter e Install the handlebar B on the handlebar holder lower so that the protruded scales of the both side adjust to the same width A e Apply 2 stroke oil to the thr
32. 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 carburetor 6S05025BS1 6S05026BS1 2 16 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 faces A upward and its projections B align with the holes C in the housing e Tighten the wing bolt D e Install the seat see Seat Installation in the Frame chap ter Fuel System Cleaning 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 e Turn the fuel tap to the OFF position e Remove the carburetor see Carburetor Removal in the Fuel System chapter e Place a suitable container beneath the carburetor e Remove the drain plug A from the bottom of the float bowl and check for water or dirt in the fuel If any water or dirt comes out clean the carburetor fuel filter fuel tap and fuel tank e Install the dr
33. 0 02 0 039 in E15011782 x If the width is too wide G too narrow H or uneven J repair the seat see Valve Seat Repair Valve Seat Repair e For the instructions on how to use the valve seat cutter A follow the operation manual provided by the to man ufacturer Special Tools Valve Seat Cutter Holder 95 5 57001 1125 B Valve Seat Cutter Holder Bar 57001 1128 Exhaust Valve Seat Cutter 45 635 57001 1116 Valve Seat Cutter 32 635 57001 1121 Valve Seat Cutter 55 635 57001 1247 Inlet 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 5 28 ENGINE TOP END Valves Seat Cutter Operation Care 1 This valve seat cutter is developed to grind the vale 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 NOTE ODO not use a wire brush to remove the metal particles 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 to
34. 11 8 US oz Quantity e Raise the outer tube and temporarily tighten the fork top plug subtank Special Tool Top Plug Wrench 49 mm 57001 1653 B e After installing the front fork torque the top plug A Special Tool Top Plug Wrench 49 mm 57001 1653 The torque of fork top plug is specified to 30 N m 3 1 kgf m 22 ft 1b 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 e Install Front Wheel see Front Wheel Installation in the Wheels Tires chapter Front Brake see Caliper Installation in the Brakes chap ter Brake Hose Clamps see Brake Hose Replacement 6M04254BS1 PERIODIC MAINTENANCE 2 63 Periodic Maintenance Procedures 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 sh
35. 1238 e With the front wheel pointing straight ahead alternately nudge each end of the handlebar The front wheel should swing fully 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 If the steering feels tight adjust or lubricate the steering e Feel for steering looseness by pushing and pulling the forks x If you feel looseness adjust the steering Steering Adjustment e Using the jack raise the front wheel off the ground Special Tool Jack 57001 1238 L ps P PERIODIC MAINTENANCE 2 69 Periodic Maintenance Procedures e Slide the holder belt A out off e Remove number plate bolt B and number plate C e Remove the handlebar pad D e Remove Handlebar Holder Bolts A Handlebar Holders upper B Handlebar C e Loosen the front fork upper clamp bolts A and remove the steering stem head nut B and steering stem head C 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 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 stem nut 1 8 turn at a time maximum e Install the steering stem head e Tighten the following Torque Steering Stem Head
36. 5 19 Camshaft and Camshaft Cap Wear Inspection e Measure each clearance between the camshaft journal and camshaft cap using plastigauge press gauge A e Install the camshaft caps see Camshaft Installation NOTE ODo not turn the camshaft when the plastigauge is be tween the journal and camshaft cap x lf any clearance exceeds the service limit measure the diameter of each camshaft journal with a micrometer Camshaft Bearing Clearance Standard 0 020 0 062 mm 0 00079 0 0024 in Service Limit 0 15 mm 0 0059 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 Camshaft Journal Diameter Standard 22 959 22 980 mm 0 90390 0 90472 in Service Limit 22 93 mm 0 9027 in If the clearance still remains out of the service limit re place the cylinder head unit Camshaft Runout Inspection e Remove the camshaft see Camshaft Removal e Set the camshaft in a camshaft alignment jig or on V blocks e Measure the runout with a dial gauge at the specified place as shown x lf 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 camshaft 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
37. 57001 1653 Top Plug Wrench 36 mm 57001 1705 e Remove the base valve assembly A from the subtank B NOTE OSlowly compress the piston rod until it stops so that the base valve assembly can be removed easily CAUTION 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 SUSPENSION 13 33 Front Fork KX450D8F 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 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 When assembling the new outer tube guide bush A hold the used guide bush B against the new one and tap the used guide bush with the fork oil seal driver C until it stops Special Tool Fork Oil Seal Driver 648 57001 1509 e After installing the washer install the oil seal by using the fork oil seal driver Special Tool Fork Oil Seal Driver 448 57001 1509 e Install the retaining ring to th
38. 8 GENERAL INFORMATION General Specifications Items KX450D6F D8F Dimensions Overall Length 2 185 mm 86 02 in Overall Width 820 mm 32 3 in Overall Height 1 280 mm 50 39 in Wheelbase 1 485 mm 58 46 in Road Clearance 345 mm 13 6 in Seat Height 965 mm 38 0 in Dry Mass 99 8 kg 220 Ib Fuel Tank Capacity 7 2 L 1 9 US gal Performance Minimum Turning Radius Engine Type 4 stroke single cylinder DOHC 4 valve Cooling System Liquid cooled Bore and Stroke 96 0 x 62 1 mm 3 78 x 2 44 in Displacement 449 cm 27 4 cu in Compression Ratio 12 0 1 Carburetion System Carburetor KEIHIN FCR40 Starting System Primary kick Ignition System Digital AC CDI Timing Advance Ignition Timing BTDC 10 1 800 r min rpm Spark Plug NGK CPR8EB 9 Valve Timing Inlet Open BTDC 32 KX450D6F BTDC 36 KX450D7F Close ABDC 72 KX450D6F ABDC 68 KX450D7F Duration 284 Exhaust Open BBDC 62 KX450D6F BBDC 66 KX450D7F Close ATDC 42 KX450D6F ATDC 38 KX450D7F Duration 284 Lubrication System Forced lubrication semi dry sump Engine Oil Grade API SG SH SJ or SL with JASO MA Viscosity SAE 10W 40 Capacity 1 2 L 1 3 US qt Drive Train Primary Reduction System Type Gear Reduction Ratio 2 727 60 22 Clutch Type Wet multi disc GENERAL INFORMATION 1 9 General Specifications Items KX450D6F D8F Transmission Type 4 speed constant wesh return shift KX450D6F
39. 92025 1985 58 92025 1873 92025 1882 60 92025 1874 92025 1883 65 EE 92025 1875 92025 1884 70 92025 1876 92025 1885 75 92025 1877 92025 1886 80 2 40 92025 1878 2 85 92025 1887 85 2 425 92025 1982 2 90 92025 1888 90 2 45 92025 1879 2 95 92025 1889 95 2 475 92025 1983 3 00 92025 1890 00 CAUTION Be sure to remeasure the clearance after selecting a shim The clearance can be out of the specified range because of the shim tolerance OH there is no valve clearance use a shim that is a few sizes smaller and remeasure the valve clearance 2 22 PERIODIC MAINTENANCE Periodic Maintenance Procedures e When installing the shim face the marked side A toward the valve lifter B At this time apply engine oil to the shim or the valve lifter to keep the shim in place during camshaft installation CAUTION 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 engine oil to the valve lifter surface and install the lifter e Install the camshaft see Camshaft Installation in the En gine Top End chapter e Recheck the valve clearance and readjust if necessary e Install the cylinder head cover see Engine Top End chap ter timing inspection plug and the balancer weight plug Cylinder Head Warp Inspection e Remove the cy
40. A Shift Pedal B e Remove Right Engine Cover see Right Engine Cover Removal Clutch Housing see Clutch Removal Circlip A Oil Pump Driven Gear B e Pull out the shift shaft C e Remove the bolt D and screw E take off the shift ratchet assembly F with ratchet plate G e Remove the bolt A and shift dram cam B e Remove the nut C and take off the gear set lever D External Shift Mechanism Installation e Install the gear set lever A OFit each end of the spring B or original positions ODo nat forget to install the color and washer C e Tighten the gear set lever nut D Torque Gear Set Lever Nut 8 8 N m 0 90 kgf m 78 in Ib e Holding the gear set lever A with the driver B and install the shift dram cam C OApply a non permanent locking agent to the shift dram cam bolt OFit the groove D on the pin E e Align the roller of the gear set lever with the slot of the shift dram cam ENGINE RIGHT SIDE 6 19 External Shift Mechanism e Set up the shift ratchet assembly as shown in the figure Ratchet A Pawls B Pins C Springs D OAssembly the shift ratchet so that groove E of the pawl faces the crankcase side F e Then install the ratchet assembly A to the ratchet plate B as shown in the figure e Install the ratchet assembly to the shift drum cam e Apply a non permanent locking agent to the ratchet plate mounting screw e Tighten the screw
41. A Front Fork B e Pushing up on the stem base A and remove the steering stem nut B with the steering stem nut wrench C then remove the steering stem D and stem base Special Tool Steering Stem Nut Wrench 57001 1100 e Take off 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 stem bearing inner rase tapered roller bearing A with its grease seal from the stem using bear ing puller Special Tools Bearing Puller 57001 1575 Bearing Puller 57001 135 GNO4002BS1 GNO70106S1 GNO4011BS1 Steering STEERING 14 7 Steering Stem Stem Bearing Installation e Replace the bearing outer race with new ones OApply grease to the outer races and drive them into the head pipe at the same time using the head pipe outer race press shaft A and the head pipe outer race drivers Special Tools Head Pipe Outer Race Press Shaft 57001 1075 Head Pipe Outer Race Driver 654 5 57001 1077 B Head P
42. A to the tester and the terminals of the magneto lead connector B Special Tools Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Connection Adapter Positive White Lead C Adapter Negative Red Lead D OCrank the engine by kicking the pedal several time to measure the peak voltage of the charge coil Peak Voltage 20 V or Above x If the voltage is less than the specified check the charge coil Throttle Sensor Output Input Voltage Check e Remove the carburetor transiently see Carburetor Re moval in the Fuel System chapter e Remove the throttle sensor lead connector A e Connect the throttle sensor setting adapter A between throttle sensor lead connector B and main harness con nector C Special Tools Hand Tester 57001 1394 Throttle Sensor Setting Adapter 1 57001 1400 e Set the Hand tester D to the DC 10 V range and connect it to the adapter leads Hand Tester Yellow White Lead Hand Tester Black Blue Lead e Temporary install the fuel tank e Start the engine e Check the sensor input voltage with the engine running Throttle Sensor Input Voltage Standard around 5 V x If it is not within the specified voltage range check the magneto output voltage If it has normal functions re place the C D I Unit GP10287BS1 GP10289BS1 Ignition System ELECTRICAL SYSTEM 16 21 e To check the output voltag
43. Bolts 9 8 N m 1 0 kgf m 87 in 1b Rear Frame Mounting Bolts 34 N m 3 5 kgf m 25 ft Ib Element Removal e Remove Seat see Seat Removal in the Frame chapter Wing Bolt A Element B e Stuff a clean lint free towel into the carburetor so no dirt is allowed to enter the carburetor e Wipe out the inside of the air cleaner housing with a clean damp towel CAUTION Check inside of the inlet tract and carburetor for dirt If dirt is present clean the intake tract and car buretor thoroughly You may also need to replace the element and seal the housing and inlet tract Air Cleaner FUEL SYSTEM 3 29 Element Installation e When installing the element coat the lip of the element with a thick layer of all purpose grease A to assure a complete seal against the air cleaner element base Also coat the base where the lip of the element fits e Apply grease to all connections and screw holes in the air cleaner housing and intake tract e Take out the towel from the carburetor securely e Install the element so that its tab A faces upward and fit the frame projections B to the holes of the holder C e Tighten the wing bolt D e Install the seat see Seat Installation in the Frame chap ter Element Cleaning and Inspection e Refer to the Air Cleaner Element Cleaning and Inspection in the Periodic Maintenance chapter GCO7033BS1 GCO7034BS1 3 30 FUEL SYSTEM Fuel Tank
44. Cap Bolts 1 8 Sequence numbers Camshaft Caps A together with the oil pipe B OPlug the oil passage and camshaft chain tunnel with a clean cloth for prevent the oil pipe from dropping into the crankcase OWhile keeping parallel remove the camshaft caps and oil pipes 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 CAUTION The crankshaft may be turned while the camshafts are removed Always pull the chain taut while turning the crank shaft This avoids kinking the chain on the lower crankshaft sprocket A kinked chain could dam age both the chain and the sprocket 5 16 ENGINE TOP END Camshaft e Remove Bolt A Auto Decompressor B with the 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 and install them e Apply a non permanent locking agent to camshaft sprocket bolts e Fit the recess E of the weight and projection F of the camshaft and install it Torque Camshaft Sprocket Bolt G 12 N m 1 2 kgf m 104 in Ib e Apply molybdenum disulfide oil to the ball bearing all cam and journal surfaces of the camshaft elt the camshaft is replaced with a new part apply a thin coat of molybdenu
45. 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 ignition coil informa tion use the Quick Reference Guide to locate the Electrical System chapter Then use the Table of Contents on the first page of the chap ter to find the Ignition Coil section Whenever you see these WARNING and CAUTION symbols heed their instructions Always follow safe operating and maintenance practices A WARNING This warning symbol identifies special instructions or procedures which if not correctly followed could result in per sonal injury or loss of life CAUTION This caution symbol identifies special instructions or procedures which if not strictly observed could result in dam age to or destruction of equipment This manual contains four more symbols in addition to WARNING and CAUTION which will help you distinguish different types of informa tion NOTE OThis note symbol indicates points of par ticular interest for more efficient and con venient operation e Indicates a procedural step or work to be done Olndicates 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
46. Install the collars A on the left and right side of the hub OThe collars are identical e Install the drive chain Install the master link clip A so that the closed end B of the U points in the direction of chain rotation C GKO4060BS1 Wheels Rims WHEELS TIRES 10 9 e Check the drive chain slack see Drive Chain Slack In spection in the Periodic Maintenance chapter e Tighten the axle nut Torque Rear Axle Nut 108 N m 11 kg m 80 ft Ib e Install the new cotter pin A and spread its end NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle shaft tighten the nut clockwise A up to next alignment Olt should be within 30 degree OLoosen one and tighten again when the slot goes past the nearest hole A WARNING If the axle nut is not securely tightened or the cotter pin is not installed an unsafe riding condition may result e Install the disc cover e Check the rear brake for good braking power and no brake drag WARNING Do not attempt to drive the motorcycle until a full brake pedal is obtained by pumping the brake pedal until the pads are against the disc The brake will not function on the first application of the pedal if this is not done Wheels Inspection e Place the jack under the frame so that the front rear wheel is raised off the ground Special Tool Jack 57001 1238 e Spin the wheel lightl
47. Lower Chain Guide Roller 16 KX450D6F G Apply grease L Apply a non permanent locking agent O Apply oil R Replacement Parts ocoxnoWaa O N 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 a Type D I D 520DMA2 Dan Length 114 Links SE Sprocket Rear Sprocket Warp Under 0 4 mm 0 016 in 0 5 mm 0 020 in Drive Chain FINAL DRIVE 11 5 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 rear end A of the left chain adjuster aligns with the same swing arm mark B as the right chain ad juster WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition Wheel Alignment Adjustment 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 cha
48. Mounting Bolts Front 25 N m 2 5 kgf m 18 ft lb Rear Brake e Before install the caliper install the rear wheel see Rear Wheel Installation in the Wheels Tires chapter e Install the caliper Torque Caliper Holder Shaft Rear 27 N m 2 8 kgf m 20 ft lb e Install the brake hose lower end OReplace the washers that are on each side of hose fitting with new ones Torque Brake Hose Banjo Bolt 25 N m 2 5 kgf m 18 ft lb e Bleed the brake line see Bleeding the Brake Line e Check the brake for good braking power no brake drag and no fluid leakage A WARNING Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc The brakes will not function on the first appli cation of the lever or pedal if this is not done Caliper Disassembly e Refer to the Caliper Piston Seal and Dust Seal Replace ment in the Periodic Maintenance chapter Fluid Seal Damage Inspection The fluid seal around the piston maintains the proper pad disc clearance lf this seal is not in good condition 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 a fluid leakage around the pad b brakes over heat c there is a large difference in left and right pad wear d the seal is stuck to the piston If the fluid seal is re
49. PUMP Ee EE 7 15 Oil PROS SU AA A A AA a th ee eee AA aon 7 16 Oil Pressure Measurement iii iii a aar a a a aaa Aaaa a aaan E a nasaha ah ii 7 16 7 2 ENGINE LUBRICATION SYSTEM Exploded View AS NE VE LNG e 6802112845 C ENGINE LUBRICATION SYSTEM 7 3 Exploded View Engine Oil Drain Bolt M10 for transmission room oil sump Engine Oil Drain Bolt M6 for crank room oil sump 62 in lb Oil Pump Scavenge Cover Bolts 87 in lb Oil Pump Feed Cover Bolts 87 in lb Right Engine Cover Bolts f 87 in lb Piston Oil Nozzle KX450D6F D7F E 26 in lb Piston Oil Nozzle KX450D8F y 35 in lb Oil Filter Cover Bolt 87 in lb Oil Screen Feed Mounting Bolts f 87 in lb Oil Pressure Relief Valve 11 10 Breather Fitting 15 1 5 11 L 11 Oil Filter Cover 12 Inner Rotor feed 13 Outer Rotor feed 14 Oil Filler Plug 15 Oil Screen Feed 16 Oil Screen Scavenge 17 Oil Pump Idle Gear 18 Oil Pump Gear 19 Oil Level Gauge 20 Breather Hose 21 Inner Rotor Scavenge 22 Outer Rotor Scavenge EO Apply engine oil G Apply high temperature grease L Apply a non permanent locking agent M Apply molybdenum disulfide grease R Replacement Parts 7 4 ENGINE LUBRICATION SYSTEM Lubrication System Chart d Lo oa SS e d SE 4 4 SO CH d S N REY pe Y Le i ei A KS BN JAY Ge S
50. REMOVAL INSTALLATION 8 3 we Fastener Upper Engine Mounting Bolts M10 Remarks 2 Middle Engine Mounting Bolt Nut M10 49 5 0 36 3 Lower Engine Mounting Bolt Nut M10 49 5 0 36 4 Upper Engine Bracket Bolts M8 29 3 0 21 5 Middle Engine Bracket Bolts Nuts M8 29 3 0 21 6 Swingarm Pivot Shaft Nut 98 10 72 7 KX450D6F D7F 8 4 ENGINE REMOVAL INSTALLATION Special Tool Jack 57001 1238 o E a E Ei N ba e Di ENGINE REMOVAL INSTALLATION 8 5 Engine Removal Installation Engine Removal e Place the jack A under the frame to support the motor cycle Special Tool Jack 57001 1238 WARNING For engine removal the swingarm pivot shaft must be pulled out causing the swingarm and rear wheel assembly to become detached To prevent the motorcycle from falling make sure to support the frame with a jack e Squeeze the brake lever slowly and hold it with a band A WARNING Be sure to hold the front brake when removing the engine or the motorcycle may fall over It could cause an accident and injury CAUTION GHO4056BS1 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
51. Switch Finger Spring A e Remove Circlip A Special Tool Outside Circlip Pliers 57001 144 e Remove the crankcase bolts A e Install the jig A between the crankshaft flywheels Special Tool Crankshaft Jig 57001 1174 e Attach the crankcase splitting tool A to the left crankcase half Special Tool Crankcase Splitting Tool Assembly 57001 1362 e Tighten the center bolt of the crankcase splitting tool to split the crankcase halves ORemove the left crankcase half 9 8 CRANKSHAFT TRANSMISSION Crankcase e Remove Oil Screen Feed A see Oil Screen Feed Removal in the Engine Lubrication System chapter Shift rods B see Transmission Shaft Removal 2 shift forks C see Transmission Shaft Removal Shift drum D see Transmission Shaft Removal Transmission E see Transmission Shaft Removal e Remove the crankshaft from the right crankcase half see Crankshaft Removal CAUTION Do not remove the bearings and the oil seals unless it is necessary Removal may damage them Crankcase Assembly CAUTION 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 WARNING Clean the engine parts in a well
52. Tension Inspection e Since a spring becomes shorter as it weakens check its free length A to determine its condition x If the spring of either fork leg is shorter than the service limit it must be replaced If the length of a replacement spring and that of the remaining spring vary greatly the remaining spring should also be replaced in order to keep the fork legs balanced from motorcycle stability Fork Spring Free Length Standard 470 mm 18 5 in Service Limit 461 mm 18 1 in 6M040116S1 Rear Shock Absorber SUSPENSION 13 41 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 damping 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 the blade of a 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 adjuster turned fully clockwise A Rebound Damping Adjuster Setting Standard 11 clicks B KX450D6F 8 clicks EUR 10 clicks KX450D7F 8 clicks KX450D8F Softer Counterclockwise C Harder Clockwise D Number of turns counterclockwise usable range 16 or more KX450D6F 22 clicks or more KX450D7F D8F Counterclockwise from the fully seated po
53. aa a aaa aia 6 10 Clutch Cover Installation 6 10 Right Engine Cover e EE 6 10 Right Engine Cover EU EE 6 10 Release Shaft Removal se 6 11 Release Shaft Installation 6 11 Clica o NA AAA 6 12 GCIUTCH I REMOVAl ra oso dci diia eee 6 12 Glutch Installations ea sececctsts detest coeds dd 6 12 Clutch Plate Assembly Free Play Inspection Adjustment 6 15 Friction and Steel Plates Wear Damage Inspechon 6 15 Friction and Steel Plate Warp Inspection 6 15 Clutch Spring Free Length Inspection 6 15 Clutch Housing Finger Damage Inspection cc cccceeeeeeeeeeneeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeaaaes 6 16 Friction Plate Clutch Housing Clearance Inspection 6 16 Clutch Hub Spline Damage Inspection 6 16 RATER GOA fits foes tice cOnctaceces EE 6 17 Primary Gear Removal nn ef Eug Eege eege ege dee 6 17 Lulu ee e E Ee Te E 6 17 External Shift Mechanisme 6 18 External Shift Mechanism Hemoval nro rra nn nan rr rn rr rnr rra 6 18 External Shift Mechanism Installation 6 18 External Shift Mechanism Inspection 6 20 lee ln 6 21 Kick Pedal ASSY E 6 21 Kick Pedal Assy Stalin s Ot 6 21 Kick Pedal Assy DISISSO MDI a e e t 6 21 Kick ER e E 6 21 Idle Gear Removal A A deier EE dee 6 21 Idle Gear Installation 6 22 KiCKShaATTREMOVA Lines A t dead ees a ENEE Ee 6 22 Kickshaft Installation sacssecsscsudverncoeactacedsabactheat
54. bleed valve A 2 Apply the brake and hold it B 3 Close the bleed valve C 4 Release the brake D OFill the reservoir with fresh specified brake fluid 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 GS13119BS1 GS13121B82 C PERIODIC MAINTENANCE 2 39 Periodic Maintenance Procedures e Remove the clear plastic hose e Tighten the bleed valves and install the rubber caps Torque Caliper Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib Brake Reservoir Cap Screws 1 5 N m 0 15 kgf m 13 in Ib e After changing the fluid check the brake for good braking power no brake drag and no fluid leakage lf necessary bleed the air from the lines see Bleeding the Brake Line in the Brakes chapter WARNING Do not mix two brands of fluid Change the brake fluid in the brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that is already in the reservoir are unidentified Brake Pad Wear Inspection e Remove the brake pad see Brake Pad Removal in the Brakes chapter e Check the lining thickness and condition of the pads in each caliper x If either pad is damaged replace both pads in the caliper as a set x If the lining thick
55. chain is replaced GJ04034BS1 gh GKO406068S1 2 34 PERIODIC MAINTENANCE Periodic Maintenance Procedures WARNING If the drive chain wear exceeds the service limit re place the chain or an unsafe riding condition may result A chain that breaks or jumps off the sprock ets could snag on the engine sprocket or lock the rear wheel severely damaging the motorcycle and causing it to go out of control Standard Chain Make DAIDO Type D I D 520DMA2 Link 114 Links 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 to 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 SAE90 is preferred to a lighter oil because it will stay on the chain longer and 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
56. e Check the rear shock body and gas reservoir for oil and gas leaks x If there are no leaks inject the nitrogen gas up to the 980 kPa 10 kgf cm 142 psi pressure A WARNING Pressurize the gas reservoir with nitrogen gas only Do not use air or other gases since they may cause premature wear rust fire hazard or substandard performance High pressure gas is dangerous Have a qualified mechanic perform this procedure e Install the spring and spring guide e Adjust spring preload Reinstall the rear shock absorber e Install the parts removed GMO5069BS1 6M05105BS1 2 68 PERIODIC MAINTENANCE Periodic Maintenance Procedures 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 Tool Jack 57001 1238 e Push and pull on the swingarm A up and down to check for wear A 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 Track Linkage Pivot Lubrication e Refer to the Swingarm Bearing Installation and Rocker Arm Bearing Installation in Suspension chapter Steering Steering Inspection e Using the jack raise the front wheel off the ground Special Tool Jack 57001
57. e Next correct the vertical misalignment by either driving a wedge A in between the crank halves or by squeezing them in a vice depending on the nature of the misalign ment CAUTION Do not hammer the crank half at the point B x If flywheel misalignment cannot be corrected by the above method replace the crank pin or the crankshaft itself Connecting Rod Big End Seizure Inspection In case of serious seizure with damaged flywheels the crankshaft must be replaced 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 of the same diameter as the piston pin and more than 105 mm long and insert the arbor B 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 length to determine the amount of connecting rod bend 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 08 3 94 in 6105004BS2 C 6105040681
58. e With the piston rod in fully compressed position pour the specified amount of fork oil A Recommended Oil KHL15 10 KAYABA01 or equivalent Recommended Quantity 191 ml 6 46 US oz NOTE OPlug the two oil holes on the subtank B with fingers e Pump A the piston rod B slowly several times to expel air 6M04251BS1 PERIODIC MAINTENANCE 2 59 Periodic Maintenance Procedures e Replace the O rings A on the base valve assembly with new ones e Apply specified fork oil to the O rings A B and bushings C on the base valve assembly e With the piston rod held immovable in fully compressed position A gently install the base valve assembly B to the subtank e Screw in the base valve assembly in the subtank 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 Holding the top plug wrench 57001 1653 A with a vise Special Tool Top Plug Wrench 49 mm 57001 1653 Top Plug Wrench 36 mm 57001 1705 e Holding the subtank B with the top plug wrench torque the base valve assembly C using the top plug wrench 57001 1705 D Torque Base Valve Assembly 28 N m 2 9 kgf m 21 ft lb e Protect the piston rod end A with a rag B to prevent fork damage e Discharge the extra oil off the cylinder unit by pumping C the piston rod to full stroke CAUTION Be careful not to bend or damage the pis
59. in KX450D6F 461 mm 18 1 in KX450D7F GM040116S1 13 26 SUSPENSION Front Fork KX450D8F Air Pressure The standard air pressure in the front fork legs is atmo spheric pressure Air pressure in the fork legs increase with normal use so the fork action stiffens during opera tion Release air pressure form the fork legs prior to each race through the pressure relief screw located in each front fork cap e Place the jack under the frame so that the front wheel off the ground Special Tool Jack 57001 1238 e Remove the screws A atthe top of the front fork top plugs to let the air pressure equalize 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 Rebound Damping Adjustment e Place the jack under the frame so that the front wheel off the ground Special Tool Jack 57001 1238 e Clean the bottom of the fork tubes e Remove the caps on the bottom of the fork tubes e To adjust rebound damping turn the adjuster A on the front fork cylinder valve with the blade of a 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 positions adjuster turned fully clockwise A Rebound Damping Adjuster Setting Standard 10 clicks B Softer
60. in lb Oil Pump Scavenge Cover Bolts 87 in lb S Oil Pump Feed Cover Bolts 87 in lb S Oil Filter Cover Bolt 87 in lb Oil Screen Feed Mounting Bolts 87 in lb Oil Pressure Relief Valve 11 L Piston Oil Nozzle 26 in lb Breather Fitting 11 L Engine Removal Installation Engine Mounting Bolt Nuts 49 Engine Bracket Bolt Nuts 29 Swingarm Pivot Shaft Nut 98 Crankshaft Transmission Piston Oil Nozzle KX450D6F D7F 2 9 26 in lb Piston Oil Nozzle KX450D8F 4 0 35 in lb Crankcase Bolts M6 12 104 in Ib S Crankcase Bolts M7 15 11 S Torque and Locking Agent PERIODIC MAINTENANCE 2 7 Fastener Remarks Engine Oil Drain Bolt M10 Brakes Brake Lever Pivot Bolt Locknut Brake Reservoir Cap Screws Front Brake Lever Pivot Bolt Caliper Mounting Bolts Front Brake Hose Banjo Bolts Front Master Cylinder Clamp Bolts Rear Master Cylinder Mounting Bolts Rear Master Cylinder Push Rod Locknut Brake Reservoir Cap Bolts Rear Brake Disc Mounting Bolts Front Rear Caliper Bleed Valves Front Rear Caliper Holder Shaft Rear Brake Pad Bolt Rear Brake Pad Bolt Plug Brake Pedal Mounting Bolt Suspension Front Fork Clamp Bolts Upper Lower Front Fork Top Plug Adjuster Assembly 5 9 1 5 5 9 25 25 8 8 9 8 17 1 5 9 8 23 7 8 27 17 2 5 25 20 20 30 58 0 60 0 15 0 60 2 5 2 5 0 90 1 0 1 7 0 15 1 0 2 3 0 80 2 8 1 7 0 25 2 5 2 0 2 0 3 1 5 9 52 in lb 13 in l
61. in the Engine Top End chapter Engine Right Side WARNING To avoid a serious burn never touch the hot engine or exhaust chamber during clutch adjustment Clutch Lever Clutch Cable Free Play Inspection e Slide the clutch lever dust covers A out of place e Check that the clutch cable upper end is fully seated in the adjusting bolt B e Check that the clutch lever C has 8 13 mm 0 3 0 5 in of play D x If it does not adjust the lever play Clutch Lever Clutch Cable Free Play Adjustment e Slide the clutch lever dust cover out of place e Turn the adjuster A so that the clutch lever will have 8 13 mm 0 3 0 5 in of play NOTE OBe sure that the outer cable end at the clutch lever is fully seated in the adjusting bolt at the clutch lever or it could slip into the place later creating enough cable play to prevent clutch disengagement esoo P 2 26 PERIODIC MAINTENANCE Periodic Maintenance Procedures e f it cannot be done loosen the locknut A at the middle of the clutch cable and turn the adjusting nut B so that the clutch lever has 8 13 mm 0 3 0 5 in of play e After the adjustment is made 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 En gine Right Side chapter e Visually inspect the friction and steel plates to se
62. m 6 0 kgf m 44 ft Ib e Tighten Torque Cylinder Bolt A 12 N m 1 2 kgf m 104 in 1b Cylinder Head Bolts M6 B 12 N m 1 2 kgf m 104 in 1b e Install Camshaft see Camshaft Installation Cylinder Head Cover see Cylinder Head Cover Instal lation Engine Bracket see Engine Installation in the Engine Removal Installation chapter e Connect the water hose and tighten the hose clamp screw e Install Carburetor see Carburetor Installation in the Fuel Sys tem chapter Exhaust Pipe see Muffler Installation Fuel Tank see Fuel Tank Installation in the Fuel System chapter 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 24 ENGINE TOP END Valves Valve Clearance Inspection e Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter Valve Removal e Remove the cylinder head see Cylinder Head Removal e Remove the valve lifter and the shim from the valve NOTE OUse the valve spring compressor assembly and the adapter to press down the valve spring retainer Special Tools Valve Spring Compressor Assembly 57001 241 A Valve Spring Compressor Adapter 24 57001 1586 B Valve Installation CAUTION Do not lap the valve to the valve seat using the grinding compound It will come off oxide film treat
63. of the hose into a con tainer e Bleed the brake line and the caliper as follows ORepeat this operation until no more air can be seen com ing out into the plastic hose 1 Pump the brake lever until it becomes hard and apply the brake and hold it A 2 Quickly open and close the bleed valve while holding the brake applied B 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 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 valves and install the rubber caps Torque Caliper Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib GLO9034BS2 Brake Fluid BRAKES 12 11 e Check the fluid level e After bleeding is done check the brake for good braking power no brake drag and no fluid leakage WARNING Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc The brake will not function on the first appli cation of the lever or pedal if this in not done 12 12 BRAKES Caliper Caliper Removal Front Brake e Lo
64. opening with a clean heavy cloth A ORemove the piston by lightly applying compressed air B to where the brake line fits into the caliper WARNING To avoid serious injury never place your fingers or palm inside the caliper opening If you apply com pressed air into the caliper in such condition the piston may crush your hand or finger e Pull out the piston A by hand e Remove the dust seal B and fluid seal C e Clean the caliper parts except for the pads CAUTION For cleaning of the parts use only disc brake fluid isopropyl alcohol or ethyl alcohol e The bleed valve was removed install the bleed valve and rubber cap Torque Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib e Replace the fluid seal s A with new ones OApply brake fluid to the fluid seal s and install them into the cylinders 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 by hand e Apply brake fluid to the outside of the pistons C and push them into each cylinder by hand PERIODIC MAINTENANCE 2 43 Periodic Maintenance Procedures e Install the anti rattle spring A in the caliper as shown e Replace the shaft rubber boot A and dust boot B 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 temperatu
65. outer tube Recommended Oil KHL15 10 KAYABAO1 or equivalent Recommended Quantity 350 mL 11 8 US oz 13 38 SUSPENSION Front Fork KX450D8F e Raise the outer tube and temporarily tighten the fork top plug subtank Special Tool Top Plug Wrench 49 mm 57001 1653 e After installing the front fork torque the top plug A Special Tool Top Plug Wrench 49 mm 57001 1653 B 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 specified value 27 N m 2 8 kgf m 20 ft lb due to the distance 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 Adjuster Assembly Inspection e Inspect the adjuster assembly A and push rod B for damage x If 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 e Inspectthe threads portion A bushing B O ring C and spring D of base valve assembly E for damage xlf they are damaged replace base valve assembly with
66. piston ring groove clearance Piston Ring Ring Groove Clearance Standard Top 0 04 0 07 mm 0 002 0 003 in Service Limit Top 0 17 mm 0 0067 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 168129 M GE16135BS1 GE16136BS1 Cylinder and Piston ENGINE TOP END 5 35 Piston Ring Groove Width Inspection e Measure the groove width at several points around the piston with a vernier caliper Piston Ring Groove Width Standard Top 1 03 1 05 mm 0 0406 0 0413 in Service Limit Top 1 1 mm 0 043 in lf 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 ring with a micrometer Piston Ring Thickness Standard Top 0 970 0 990 mm 0 0381 0 0390 in Service Limit Top 0 90 mm 0 035 in x If any of the measurements is less than the service limit on either of the rings replace the rings as a set 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 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 Place the p
67. piston stop D e Take off the piston E secondary cup F primary cup G and return spring H CAUTION Do not remove the secondary cup from the piston since removal will damage it e Before assembly clean all parts including the master cylinder with brake fluid or alcohol CAUTION 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 e Apply brake fluid to the removed parts and to the inner wall of the cylinder e Take care not to scratch the piston or the inner wall of the cylinder e Apply silicone grease ex PBC grease Brake Lever Pivot Bolt Brake Lever Pivot Contact Push Rod Contact Rear Dust Covers 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 Ib 6L07057BS2 C PERIODIC MAINTENANCE 2 41 Periodic Maintenance Procedures Brake Caliper Fluid Seal and Dust Seal Replacement e Loosen the brake pad pin A and banjo bolt B and tighten them loosely e Remove Front Caliper Mounting Bolts C Banjo Bolt Brake Hose E Front Ca
68. plug cap shorted or not in good con tact Spark plug incorrect heat value Faulty CDI unit Crankshaft sensor trouble Flywheel damaged Ignition coil trouble Wiring connector not in good contact Fuel air mixture incorrect Pilot screw maladjusted Pilot jet or air passage clogged Needle Jet or air passage clogged Air cleaner clogged poorly sealed or miss ing Choke plunger stuck open Hot starter plunger stuck open Fuel level in carburetor float bowl too high or too low Fuel tank cap air vent obstructed Fuel tap clogged Carburetor 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 Troubleshooting Guide Valve not seating properly valve bent de formed worn or carbon accumulation on the seating surface Decompression trouble Other Faulty CDI unit 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 dirty broken or gap malad justed Spark plug cap or high tension wiring trou ble Spark plug cap shorted or not in good con tact Spark plug incorrect heat value Faulty CDI unit Crankshaft sensor tr
69. rings A with the new ones e Install the fuel hose fitting B e Tighten the screws e Install all hoses A e Install the carburetor see Carburetor Installation x If turn the adjusting screw of the acceleration pump follow the procedure below OPrepare an arbor A with the outside diameter of D5 4 OOpen the throttle valve and insert the arbor at the bottom of the bore of the air cleaner side and slowly close the throttle valve throttle Valve Height Air Cleaner Side 5 4 mm 0 213 in Reference Engine Side 3 4 mm 0 134 in OPush the link lever A in the direction of the arrow B and adjust the timing with the adjusting screw C so it be comes no free play and the condition of no pushing down of the push rod D Tightening the adjusting screw makes more free play and loosening makes less free play GC06121BS1 3 28 FUEL SYSTEM Air Cleaner Air Cleaner Housing Removal e Remove Side Covers see Side Cover Removal in the Frame chapter Seat see Seat Removal in the Frame chapter Muffler see Muffler Removal in the Engine Top End chapter Rear Fender A see Rear Fender Removal in the Frame chapter d EN Rear Frame Bolts B DAA E e Loosen the air cleaner duct clamp C e Remove the rear frame e Unscrew the bolts A e Remove the air cleaner housing B Air Cleaner Housing Installation e Installation is the reverse of the removal e Tighten Torque Air Cleaner Housing
70. stalling the clutch hub C ENGINE RIGHT SIDE 6 13 Clutch e Install the washer so that stamp mark A facing the out side e Tighten the clutch hub nut A using the clutch holder B 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 A and alternating them Finishing with a friction plate Olnstall the friction plates which the lining blocks B on the plates installed to both end are more than the one of the other plates OApply engine oil to the new friction plates when it shall be installed CAUTION If dry steel plates and friction plates are installed apply engine oil to the surfaces of each plate to avoid clutch plate seizure e Apply molybdenum disulfide grease to the rubbing portion A of the push rod holder e Install the push rod B and push rod holder e Apply molybdenum disulfide grease to the needle bearing C and washer D and install them 6 14 ENGINE RIGHT SIDE Clutch e Tighten Torque Clutch Spring Bolts A 8 8 Nm 0 90 kgf m 78 in 1b e Install the clutch cover see Clutch Cover Installation e Check the release shaft lever positions OPushing B the release shaft lever C lightly frontward measure the distance A between the lever and cable bracket D Release Shaft Lever Position Standard 68 6 76 4 mm 2 70 3 01 in x If t
71. the outside e Install the circlip Kickshaft Removal e Remove Right Engine Cover see Right Engine Cover Removal Clutch Housing see Clutch Removal 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 Kickshaft Installation e Apply a non permanent locking agent to the ratchet guide bolt e Install the ratchet guide A Torque Ratchet Guide Bolt 8 8 N m 0 90 kgf m 78 in Ib e Apply molybdenum disulfide grease to the end of the kick shaft e Insert the kick shaft assembly B into the crankcase OSecurely engage the stopper portion C of the ratchet gear with the guide e Insert the spring end D into the hole E e Install Idle Gear see Idle Gear Installation Clutch Housing see Clutch Installation Right Engine Cover see Right Engine Cover Installa tion Kickstarter ENGINE RIGHT SIDE 6 23 Kick Shaft Assembly Disassembly Assembly e The kick shaft assembly consists of the following parts A Kick Gear E Ratchet Gear B Circlip F Kick Shaft C Washer G Kick Spring D Spring H Spring Guide e Check the kick shaft assembly parts for damage Any damaged parts should be replaced with new ones e Apply molybdenum disulfide grease to the inside of the kick gear and ratchet gear e Apply grease to the inside o
72. the camshaft Cam Height Standard Exhaust 36 943 37 057 mm 1 4544 1 4589 in Inlet 37 743 37 857 mm 1 4859 1 4904 in Service Limit Exhaust 36 84 mm 1 450 in Inlet 37 64 mm 1 482 in 6E11077BS1 GE11012281 5 20 ENGINE TOP END Cylinder Head Cylinder Compression Measurement e Start the engine e Thoroughly warm up the engine so that the engine oil be tween the piston and cylinder wall will help seal compres sion as it does during normal running e Stop the engine e Remove Fuel Tank see Fuel Tank Removal in the Fuel System chapter e Remove the spark plug A with spark plug wrench B or owner s tool Special Tool Spark Plug Wrench Hex 16 57001 1262 Owner s Tool Spark Plug Wrench 92110 1172 e Attach the compression gauge A and the adapter hose B firmly into the spark plug hole e With 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 57001 221 Compression Gauge Adapter M10 x 1 0 57001 1317 Cylinder Compression Service Range 450 750 kPa 4 59 7 65 kg cm 65 2 109 psi 5 kicks e Install the spark plug Torque Spark Plug 13 N m 1 3 kgf m 113 in Ib e Pull the spark plug cap lightly to make sure the installation of the spark plug cap ENGINE TO
73. the fuel tap e Check the fuel tap for fuel leaks e f the fuel tap leaks or allows fuel to flow when it is at OFF position replace the fuel tap Cooling System WARNING To avoid burns do not remove the radiator cap or try to change the coolant when the engine is still hot Wait until it cools down Coolant on tires will make them slippery and can cause an accident and injury Immediately wash away any coolant that spills on the wheels Since coolant is harmful to the human body do not use for drinking 2 18 PERIODIC MAINTENANCE Periodic Maintenance Procedures Coolant Level Inspection NOTE OCheck the level when the engine is cold room or ambi ent temperature e Lean the motorcycle slightly to the left 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 lf 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 of antifreeze soft water and ethylene glycol plus corrosion
74. the right engine cover e Install the water pump cover OReplace the drain bolt washer with a new ones e Tighten Torque Water Pump Cover Bolts A 9 8 N m 1 0 kgf m 87 in lb Coolant Drain Bolt B 6 9 N m 0 70 kgf m 61 in lb e Insert the water hose C into the water pump cover e Tighten Torque Water Hose Clamp Screw D 1 5 N m 0 15 kgf m 13 in Ib e Fill the cooling system see Coolant Filling e Bleed the air from the coolfing system e Check the engine oil level and add the engine oil 4 10 COOLING SYSTEM Water Pump Impeller Removal e Drain Coolant see Coolant Draining 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 the oil seal is damaged the coolant leaks through the seal and drains through the passage Replace the oil seals Oil Seal and Bearing Removal e Remove Impeller see Impeller Removal Right Engine Cover see Right Engine Cover Removal in the Engine Right Side chapter Circlip A Water Pump Sh
75. 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 Replace the muffler baffle if the exhaust noise becomes too loud or engine performance drops Muffler Baffle Change e Remove the muffler see Muffler Removal in the Engine Top End chapter e Remove the muffler pipe mounting bolts A e Tap the bracket A of the muffler body with a plastic mallet B to separate from the inner pipe e Pull off the old muffler baffle assembly A e Install the new muffler baffle assembly A into the muffler body B NOTE OWhen replacing the muffler baffle assembly first insert the muffler baffle assembly into the muffler body and align the exhaust hole of the muffler body with the muf fler baffle assembly hole while turning the muffler baffle assembly Then install the inner pipe by pushing the inner pipe into the muffler body with aligning the inner pipe with the exhaust hole e Apply a non permanent locking agent to the muffler pipe mounting bolts e Tighten the muffler pipe mounting bolts PERIODIC MAINTENANCE 2 25 Periodic Maintenance Procedures e Apply silicone sealant to the circumference A of the inner pipe e Install the muffler see Muffler Installation
76. valve assembly B on the subtank C Special Tool Top Plug Wrench 49 mm 57001 1653 PERIODIC MAINTENANCE 2 49 Periodic Maintenance Procedures e Remove the base valve assembly A from the subtank B NOTE OSlowly compress the piston rod until it stops so that the base valve assembly can be removed easily CAUTION 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 inverted position for more than 20 min utes to allow the fork oil to fully drain e Clean the threads A of subtank and base valve assem bly e With the piston rod in fully compressed position pour the specified amount of fork oil A Recommended Oil KHL15 10 KAYABA01 or equivalent Recommended 170 ml 5 75 US oz KX450D6F Quantity 191 ml 6 46 US oz NOTE OPlug the two oil holes on the subtank B with fingers Z 6M04251BS1 OA IS Fd 2 50 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Pump A the piston rod B slowly several times to expel air e Replace the O rings A on the base valve assembly with new ones e Apply specified fork oil to the O rings A B and bushings C on the base valve assembly e With the piston rod held immovable in fully compressed position A gently install the base valve assembl
77. while the engine is running This may damage the C D I unit Ignition System ELECTRICAL SYSTEM 16 17 Ignition Coil Primary Peak Voltage Check e Disconnect the spark plug cap from the spark plug but do not remove the spark plug e Connect the good spark plug A to the spark plug cap then touch the engine 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 the hand tester and connect the black lead of adapter to the terminal of primary lead orange red lead ofit to the ground connec tion of the ignition coil C OSet the tester to DC 250 V range Special Tools Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Needle Adapter Set 57001 1457 Connection Adapter Positive Ground Lead D Adapter Negative Orange Lead E C D I Unit F Needle Adapter G e Shift the gear to the neutral position then free the engine stop switch e Crank the engine by kicking the pedal several times to measure the peak voltage of the primary ignition coil Peak Voltage 128 V or above Do not touch the metal portion of the probe in case of measuring the voltage or you may receive a se rious electric shock
78. with a rag B to prevent fork damage e Discharge the extra oil off the cylinder unit by pumping C the piston rod to full stroke CAUTION Be careful not to bend or damage the piston rod when the piston rod is stroked Service carefully because oil flies out from the oil hole of the cylinder unit NOTE OSet the compression damper setting to the softest OCheck the piston rod sliding surface for damage OApply fork oil to the piston rod sliding surface e Drain the extra oil from the subtank oil hole A e With the cylinder unit in horizontal position move A the piston rod B by hand to inspect it if operating smoothly Olf the piston 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 13 36 SUSPENSION Front Fork KX450D8F 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 collar B and cylinder unit C e Insert above mentioned parts into the fork e Temporarily tighten the fork top plug A subtank using the top plug wrench Special Tool Top Plug Wrench 49 mm 57001 1653 B e Clamp the axle holder with a vise OProtect the axle holder with a rag 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
79. 0D6F 10 clicks KX450D7F 8 clicks KX450D8F Softer counterclockwise C Harder clockwise D Number of turns counterclockwise usable range 16 clicks or more KX450D6F 19 clicks or more KX450D7F 22 clicks or more KX450D8F 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 Spring Preload Adjustment e Remove Seat see Seat Removal in the Frame chapter Side Covers see Side Cover Removal in the Frame chapter Carburetor Holder Clamp Screw loosen Muffler see Muffler Removal in the Engine Top End chapter Rear Frame Mounting Bolts A Rear Frame B with Air Cleaner Housing e Using the jack under the frame raise the rear wheel off the ground Special Tool Jack 57001 1238 2 GMO5206BS1 D 16151418121110 9 8 7 6 5 4 3 2 ES D D DS E i drt d GM05207BS1 Rear Shock Absorber SUSPENSION 13 43 e Using the hook wrenches A loosen the locknut B on the rear shock absorber Special Tool Hook Wrench R37 5 R42 57001 1101 e Using the stem nut wrench A turn the adjusting nut B as required Turning the adjusting nut downward marks the spring action harder and upward softer Spec
80. 1 2 104 ml S Muffler Pipe Mounting Bolts L z S Top Ring Oil Ring Circle Mark KX450D6F D7F Apply engine oil Apply high temperature grease Apply non permanent locking agent Replacement Parts Follow the specific tightening sequence Apply silicone sealant m G Ow Co oy ON Kg cen a DO Dr 5 6 ENGINE TOP END Specifications Item Standard Service Limit Camshafts Cam Height Exhaust 36 943 37 057 mm 1 4544 1 4589 in 36 84 mm 1 450 in Inlet 37 743 37 857 mm 1 4859 1 4904 in 37 64 mm 1 482 in Camshaft Journal Clearance Camshaft Journal Diameter Camshaft Journal Inside Diameter Camshaft Runout Cylinder Head Cylinder Compression Cylinder Head Warp 0 020 0 062 mm 0 00079 0 0024 in 22 959 22 980 mm 0 90390 0 90472 in 23 000 23 021 mm 0 90551 0 90634 in TIR 0 02 mm 0 0008 in or less Usable range 450 750 kPa 4 59 7 65 kg cm 65 2 109 psi 5 kicks 0 15 mm 0 0059 in 22 93 mm 0 9072 in 23 08 mm 0 9087 in TIR 0 1 mm 0 004 in Valve Valve Clearance Exhaust Inlet Valve Stem Bend Valve Stem Diameter Exhaust Inlet Valve Guide Inside Diameter Exhaust Inlet Valve valve Guide Clearance wobble method Exhaust Inlet Valve Seat Cutting Angle Valve Seat Surface Outside Diameter Exhaust Inlet Valve Seat Surface Width Exhaust Inlet Valve
81. 42BS1 GE16132BS1 GE16134BS1 5 34 ENGINE TOP END Cylinder and Piston e Apply engine oil to the cylinder bore e Determine the position of the piston ring ends e Install the cylinder while compressing the piston rings with your fingers or the special tool A Special Tools Piston Ring Compressor Grip 57001 1095 Piston Ring Compressor Belt 695 4108 57001 1358 e Drive the front chain guide in e Install the removed parts Cylinder Wear Inspection e Refer to the Cylinder Wear Inspection in the Periodic Maintenance chapter Piston Wear Inspection e Using a micrometer measure the outside diameter A of each piston 8 5 mm 0 33 in B up from the bottom of the piston at a right angle to the direction of the piston pin x If the pistons outside diameter is smaller than the service limit replace the piston Piston Diameter Standard 95 970 95 980 mm 3 7783 3 7787 in Service Limit 95 82 mm 3 772 in Piston Cylinder Clearance Inspection e Refer to the Piston Cylinder Clearance Inspection in the Periodic Maintenance chapter 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
82. 5 speed constant mesh return shift KX450D7F Gear ratios 1st 1 800 27 15 KX450D6F 1 750 28 16 KX450D7F 2nd 1 411 24 17 3rd 1 187 19 16 4th 1 000 19 19 Sth 0 875 21 24 Final Drive System Type Chain drive Reduction Ratio 3 4846 50 13 10 489 Top gear KX450D6F 9 178 Top gear KX450D7F Overall Drive Ratio Frame Type Tubular semi double cradle Steering Angle 42 to either side Caster rake angle 27 1 Trail 117 mm 4 60 in Front tire Size 90 100 21 57M Make Type DUNLOP D742F Tube type Rear tire Size 120 80 19 63M Make Type DUNLOP D756 Tube type Rim size Front 21 x 1 60 Rear 19 x 2 15 Front suspension Type Telescopic fork up side down Wheel travel 315 mm 12 4 in Rear suspension Type Swingarm New Uni trak Wheel travel 315 mm 12 4 in Brake type Front and Rear Single disc Effective disc diameter Front effect dia 225 mm 8 86 in Rear effect dia 215 mm 8 46 in Specifications subject to change without notice and may not apply to every country 1 10 GENERAL INFORMATION Unit Conversion Table Prefixes for Units Prefix mega kilo centi milli micro Units of Mass kg g x x 2 205 0 03527 Units of Volume FE Fi mL mL x x x x 0 2642 0 2200 1 057 0 8799 2 113 1 816 0 03381 0 02816 0 06102 Units of Force N N kgf kgf x x x x 0 1020 0 2248 9 807 2 205 Units of Te
83. 63 in 3 5 mm 0 14 in Runout TIR 0 25 mm 0 0098 in or less TIR 0 3 mm 0 01 in BRAKES 12 7 Special Tools Inside Circlip Pliers Jack 57001 143 57001 1238 ST5701438T ST5712388ST 12 8 BRAKES Brake Lever Brake Pedal Brake Lever Adjustment e Refer to the Brake Lever and Pedal Position Adjustment in the Periodic Maintenance chapter Brake Pedal Position Adjustment e Refer to the Brake Lever and Pedal Position Adjustment in the Periodic Maintenance chapter Brake Pedal Removal e Remove Cotter Pin A Joint Pin B Washer C e Remove the mounting bolt D and take off the brake pedal E and return spring Brake Pedal Installation e Replace the O rings with new one and apply high temper ature grease to the O rings e Apply high temperature grease to the shaft portion and a non premanent locking agent to the thread of the brake pedal mounting bolt and install the pedal with return spring onto the frame Olnstall the return spring direction A as shown Torque Brake Pedal Mounting Bolt 25 N m 2 5 kgf m 18 ft Ib e Check the brake pedal position e Install the joint pin washer and a new cotter pin OBend the ends A of the cotter pin GLO4020BS1 GLO4008BS1 BRAKES 12 9 Brake Fluid A WARNING When working with the disc brake observe the pre cautions listed below 1 Never reuse old brake fluid 2 Do not use fluid from
84. 70 61 in lb Radiator Mounting Bolts 9 8 1 0 87 in lb Radiator Screen Bolts 9 8 1 0 87 in lb Radiator Shroud Bolts 9 8 1 0 87 in lb Engine Top End Cylinder Head Cover Bolts 87 in lb Cylinder Head Bolts M10 f 44 Cylinder Head Bolts M6 104 in Ib Camshaft Cap Bolts 87 in lb Camshaft Sprocket Bolts 104 in lb Decompressor Plug Plate Bolt 87 in lb Water Hose Fitting Bolts 2 87 ml Oil Line Plug d 27 in lb Carburetor Holder Clamp Screws 17 in lb Plug E 15 Lower Camshaft Chain Guide Bolt 87 in lb Rear Camshaft Chain Guide Bolt 11 Chain Tensioner Mounting Bolts 87 in lb Chain Tensioner Cap Bolt d 44 in lb 2 6 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Torgue Remarks Cylinder Bolt 104 in lb S Exhaust Pipe Cover Screws 104 in lb Exhaust Pipe Holder Nuts 15 Muffler Mounting Bolts 15 Muffler Pipe Mounting Bolts L Engine Right Side Primary Gear Nut 72 Lh Shift Drum Cam Bolt 17 L Clutch Spring Bolts 78 in lb Clutch Hub Nut 72 Gear Set Lever Nut 78 in lb Ratchet Plate Mounting Bolt 87 in lb S Ratchet Plate Mounting Screw KX450D6F 57 in lb S L Ratchet Plate Mounting Bolt KX450D7F 11 S L Ratchet Guide Bolt 78 in lb Kick Pedal Bolt 18 L Shift Pedal Bolt 87 in lb Clutch Cover Bolts 87 in lb Right Engine Cover Bolts 87 in lb Engine Lubrication System Engine Oil Drain Bolt M10 for transmission room oil sump 15 Engine Oil Drain Bolt M6 for crank room oil sump 62
85. Brake Master Cylinder Cup and INSPECtION cceeeeeeeeeeeeeeeees 2 19 Dust Cover Replacemert 2 39 Engine Top End 2 19 Brake Caliper Fluid Seal and Dust Valve Clearance Inspection 2 19 Seal Replacement 05 2 41 Valve Clearance Adjustment 2 20 Brake Hoses and Connections Cylinder Head Warp Inspection 2 22 Inspection 2 44 Cylinder Wear Inspection 2 23 Brake Hose Replacement 2 44 Piston Cylinder Clearance SUSPENSION D 2 45 Inspection 2 23 Front Fork Inspection 2 45 Piston Piston Ring and Piston Front Fork Oil Change each fork Pin HReplacement 2 23 leg KX450D6F D7F 2 45 Exhaust System Inspection 2 24 Front Fork Oil Change each fork Muffler Baffle Change 2 24 leg KX450D8F 2 54 Engine Right Side 2 25 Rear Shock Absorber Inspection 2 63 Clutch Lever Clutch Cable Free Rear Shock Absorber Oil Change 2 63 Play Inspechon 2 25 Swingarm and Uni Trak Linkage Clutch Lever Clutch Cable Free NSpECt On acicate ina icons 2 68 Play Adjustment oooooooccccnnccccnn 2 25 Swingarm and Uni Track Linkage Clutch Plates Inspection 2 26 Pivot Lubricati0n 2 68 Engine Lubrication System 2 26 Steering E 2 68 Engine Oil Change 2 26 Steering Inspection 2 68 2 2 PERIODIC
86. CRANKSHAFT TRANSMISSION 9 17 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 a 100 mm length of the arbor to determine the amount of connecting rod twist x 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 08 3 94 in 6105040751 9 18 CRANKSHAFT TRANSMISSION Transmission Transmission Shaft Removal e Disassemble the crankcase see Crankcase Disassem bly e Pull out the shift rods A allowing the shift fork guide pins to free from the shift drum B e Remove the shift fork C e Remove the shift drum e Pull out the drive shaft A and output shaft B 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 C with their gears meshed e Install the shift drum 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 e The shift forks can be identified by their shape or mark Install them noting the direction shown Olnstall each shift forks with its mark A facing the
87. E 12 12 Caliper Installation EE 12 13 Caliper DISASSEMOIY EE EE 12 13 Fluid Seal Damage Inspection tn bd ti 12 13 Dust Seal and Cover Damage Inspection 12 13 Piston Cylinder Damage Inspection 12 13 Caliper Holder Shaft Wear Inspection 12 14 112 Brake Pad tb 12 15 Brake e Rn Le EE E 12 15 Brake Pad Installation E 12 15 BrakKe Pad Min Geet TEE 12 15 Master C ylinG r un EE 12 16 Front Master Cylinder Removal sio ti e nine da cb 12 16 Front Master Cylinder Installation 12 16 Rear Master Cylinder REMOVAL it ed Si a ant 12 17 Rear Master Cylinder Installation 12 17 Front Master Cylinder Disassembly sens 12 17 Rear Master Cylinder Disassembly sisi 12 17 Master Cylinder Assembly ea 12 17 Master Cylinder Inspection Visual Inspechon 12 18 Brake RE 12 19 Brake DISC Inspection EE 12 19 Brake HOSC tases svess Wea tehas Eeer eege ves sates 12 20 Brake Hose Removal lnstallationinc cccacce sce eege herd tears tend Meet das 12 20 Brake Hose Inspechon see 12 20 12 2 BRAKES Exploded View BRAKES 12 3 Exploded View No B 0O N Fastener Front Master Cylinder Clamp Bolts Brake Hose Banjo Bolts Brake Pad Bolt Nm 8 8 Torque kgf m 0 90 25 2 5 17 1 7 Remarks ft lb Caliper Bleed Valve 0 80 69 in lb O O1 00 Brake Lever Pivot Bolt Front Brake Reservoir Brake Lever Brake Lever Adjuster Locknut Brake Hose Clamps Front Calipe
88. Engine Stop Switch Lead Hot Starter Cable C D I Unit Clamps Clamp the clutch cable Main Harness Gear Position Sensor Lead Flywheel Lead Clamp Clamp the gear position sensor lead and magneto lead Clamp Clamp the main harness gear po sition sensor lead and magneto lead Ignition Coil Ground Lead 13 14 15 16 17 Throttle Cables 19 20 Ignition Coil Ground Lead Clamp Clamp the hot starter cable en gine stop switch lead and main harness Clamp Clamp the hot starter cable and main harness Clamp Clamp the hot starter cable main harness and fuel hose Fuel Hose Run the hot starter cable engine stop switch lead and main harness above the water hose Do not clamp the engine stop switch lead 17 4 APPENDIX Cable Wire and Hose Routing OA Ze Le 0 Y 4 Spark Plug Cap Clamp Clamp the carburetor drain and air vent hoses Clamp Clamp the gear position sensor lead Gear Position Sensor Lead Clamp Clamp the gear position sensor lead radiator overflow hose and breather hose Na Oy Ze ONO 10 12 ee 6B09192CW4 C Breather Hose Flywheel Lead Align the clamp claw and white mark on the breather hose Align the white mark on the breather hose and embossed mark Radiator Overflow Hose Fuel Hose High Tension Lead APPENDIX 17 5 Cable Wire and Hose Routing Vie
89. F D7F e Place a drain pan under the front fork and drain 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 subtank to the outer tube B with the top plug wrench C Special Tool Top Plug Wrench 49 mm 57001 1653 e Hold the axle holder A with a vise OProtect the axle holder with a rag when using a vise e Loosen the adjuster assembly B completely 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 B and locknut C Special Tool Top Plug Wrench 49 mm 57001 1653 WARNING Be careful of reaction force in spring and fix surely so that the special tool should not come off Do not place the finger etc while servicing e Hold the locknut A with a wrench B and remove the adjuster assembly C 13 16 SUSPENSION Front Fork KX450D6F D7F e Remove the push rod A e With the outer tube compressed by hands remove the top plug wrench A CAUTION 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 Loos
90. Front Fork Clamp Bolts Rear Shock Absorber Mounting Bolts Nuts Swingarm Pivot Shaft Nut Steering Steering Stem Head Nut Handlebar Holder Bolts Engine Throttle Cable Adjuster Locknuts Engine Mounting Bolts Nuts Shift Pedal Bolt Muffler Mounting Bolts Exhaust Pipe Holder Nuts Muffler Pipe Clamp Bolt Clutch Cable Adjuster Locknut Clutch Lever Pivot Nut Others Footpeg Cotter Pins Rear Frame Mounting Bolts Front Fender Bolts FUEL SYSTEM 3 1 Fuel System Table of Contents Exploded EE A LOIN EE 3 6 Special te EE 3 7 Throttle Grip and Cable Sienne 3 8 Throttle Grip Throttle Cable Free Play Inspection eee eeeeeeee tree eeeeeenaeeeeeeeeeeeeeeea 3 8 Throttle Grip Throttle Cable Free Play Adjustment 3 8 Throttle Cable Replacement esse 3 8 Lhrottle CablesLuBricatlon EE 3 9 Throttle Cable Inspechon ses 3 9 Hot Starter Cable HRemoval ron a ran rn 3 10 Hot Starter Cable Installation 3 10 Hot Starter Lever Hot Starter Cable Free Play Inspecthon 3 10 Hot Starter Lever Hot Starter Cable Free Play Adiustmment 3 11 Hot Starter Cable Lubrtcaton nr nenn nenn rennene 3 11 Hot Starter Cable Inspection 3 11 Carburetor EE 3 12 Idle Speed Inspection ss 3 12 Idle Speed AdjUSIM asistan A 3 12 Service Fuel Level Inspection see 3 12 Service Fuel Level Adjustment iii 3 13 Carburetor steig e aa a ra ete d i the th an 3 14 Carburetor Jnstallaton see 3 16 Fuel System Cle
91. Grip Throttle Cable Free Play Adjustment in the Periodic Maintenance chapter Clutch Cable see Clutch Lever Clutch Cable Free Play Adjustment in the Periodic Maintenance chapter Drive Chain see Drive Chain Slack Adjustment in the Periodic Maintenance chapter e Adjust the idling see Idle Speed Adjustment in the Peri odic Maintenance chapter e Check the operation of the clutch lever e Check the brake effectiveness A WARNING Do no attempt to drive the motorcycle until you pump the brake pedal until the pads are against the disc The brake will not function on the first application of the pedal if this is not done CRANKSHAFT TRANSMISSION 9 1 Crankshaft Transmission Table of Contents EXplOded ET 9 2 eelere EE 9 4 Special Tools and Sealant arroa ea er en a A A Ea aa A E 9 5 RE a L ee ETS ERP doer due dedcaghhdbgea ch geavdeads convaanesiaenesedens 9 6 Crankcase Disassembly ess rentes ta de do de a tu de 9 6 Ee Oe EEN 9 8 Gra ankshaft eng a a AE Pai O 9 14 Crankshaft Removal seen 9 14 Crankshaft Installation siens 9 14 Crankshaft Disassembly gereest dere 9 14 Crankshaft Assembly coo ds 9 14 Grankshaft Inspection Ra 9 15 Connecting Rod Bend Inspection sise 9 16 Connecting Rod Twist INSPECHOM cada Eet eben 9 17 TransMISSION E 9 18 Transmission Shaft Removal esse 9 18 Transmission Shaft Installation ses 9 18 Transmission Shaft Dis ssemblyisss nest di 9 18 Transmission Shaft Assembly accio den een
92. HAFT TRANSMISSION 9 11 Crankcase e Install Shift Drum A see Transmission Installation Shift Rods B see Transmission Installation Shift Forks C see Transmission Installation e Install Crankshaft A Dowel Pins B e Replace the O ring A with a new one e Install the Oil Screen Feed Torque Oil Screen Feed Mounting Bolts 9 8 N m 1 0 kgf m 87 in lb e With the connecting rod positioned at the bottom dead center install the crankshaft jig A Special Tool Crankshaft Jig 57001 1174 e Apply liquid gasket to the mating surface A of the left crankshaft half Sealant Kawasaki Bond Liquid Gasket Gray 92104 1063 NOTE OMake the application finish within 30 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 9 12 CRANKSHAFT TRANSMISSION Crankcase e Using a plastic hammer A press B the rear portion of the crankcase and tap the area around the crankshaft of the left crankcase half While maintaining the mating surfaces of the right and left crankcase halves constantly parallel mate the crankcase halves evenly 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 e Remove the crankshaft
93. ION 9 25 Bearings Oil Seals e Check the needle bearing 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 seal 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 ET e A A en dieser nee Special lolita A ai E Wheels RIMS EE Front Wheel Eu EE Air Pressure Inspection Adjustment albo eSt ALL EE AT Hub Bearing e ue LEE Hub Bearing Installation ccc cc cccccccecceccccceceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeneeeeseeeeeeeeeeeneees Hub Bearing Inspection 10 2 WHEELS TIRES Exploded View 6J02068BW5 C WHEELS TIRES 10 3 Exploded View No Fastener S Remarks 1 Spoke Nipples Front Axle Nut Front Axle Clamp Bolts Rear Axle Nut 2 3 4 5 Spokes 6 Front Tire 7 Rims 8 Front Axle 9 Swingarm 10 Rear Tire 11 Rear Axle AL Tighten the two clamp bolts alternately two times to ensure even tightening torque HG Apply high temperature grease WL Apply soap and water solution or rubber lubricant 10 4 WHEELS TIRES Specifications Item Standard Service L
94. MAINTENANCE Steering Adjustment o Steering Stem Bearing A A nantaise Frame Inspection Electrical System oooonnnnnniccnnnnnn Spark Plug Cleaning and Inspection 2 68 2 70 2 70 2 70 2 71 2 71 Spark Plug Replacement General Lubrication and Cable Inspection General Lubrication Cable Inspection Nut Bolt and Fastener Tightness Inspection Tightness Inspection 2 71 2 72 2 72 2 73 2 73 2 73 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 OPERATION Spark plug clean inspect e E N E S Spark plug replace Each race or 2 5 hr Every 12 races or 30 hr Clutch cable inspect and adjust Clutch plates inspect t Throttle cable inspect and adjust Air cleaner element clean t Air cleaner element replace Carburetor inspect and adjust Engine Oil change e Piston and piston ring replace Every 6 races 2 23 Cylinder head cylinder inspect e 2 22 e 2 23 S Piston pin replace N Valve clearance inspect e Hot starter cable inspect 2 13 Oil filter replace 2 27 Exhaust System inspect t Muffler Baffle change e Kick pedal and shift pedal clean 2 24 Engine sprocket inspect t Coolant level in
95. N Y d DA H Si 7 ENGINE LUBRICATION SYSTEM 7 5 Lubrication System Chart GG04066BH3 C Joo ND Oil Screen feed Oil Pump feed Oil Pressure Relief Valve Right Engine Cover Oil Passage from Feed Oil Pump to Oil filter Oil Filter Right Engine Cover Oil Passage from Oil filter to Crankshaft Crankshaft Piston Oil Nozzle 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 Fitting Breather Hose Crank Room Oil Transmission Room Oil Blowby Gas 7 6 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil Grade Viscosity Capacity Oil Change when filter is not removed Oil Change when filter is removed when engine is completely dry Oil Level after warm up or driving Castrol R4 Superbike 5W 40 KX450D6F D7F Castrol POWER1 R4 Racing 5W 40 KX450D8F or API SG SH SJ or SL with JASO MA SAE 10W 30 10W 40 or 10W 50 0 96 L 1 01 US at 0 98 L 1 03 US qt 1 2 L 1 3 US qt Upper level Oil Pressure Measurement oil temperature 90 C engine speed 4 000 rpm 39 98 kPa 0 4 1 0 kgf cm 5 6 14 psi Special Tools Oil Pressure Gauge 5 kgf cm 57001 125 ST5701258T Outsi
96. NCE 2 5 Torque and Locking Agent Tighten all bolts and nuts to the proper torque using an accurate torque wrench If insufficiently tightened a bolt or nut may become damaged strip an internal thread or break and then fall out The following table lists the tightening toque for the major bolts and nuts and the parts requiring use of a non permanent locking agent or liquid gasket When checking the tightening toque of the bolts and nuts first loosen the bolt or nut by half a turn and then tighten to specified torque Letters used in the Remarks column mean AL Tighten the two clamp bolts alternately two times to ensure even tightening torque G Apply grease L Apply a non permanent locking agent to the threads MO Apply molybdenum disulfide oil mixture of engine oil and molybdenum disulfide grease with a weight ratio 10 1 Lh Left hand Threads S Tighten the fasteners following the specified sequence O Apply 2 stroke oil Torque Fastener es Karn ftlb Remarks Fuel System Throttle Pulley Cover Bolt 3 4 0 35 30 in lb Throttle Cable Mounting Bolts 6 9 0 70 61 in lb Air Cleaner Duct Clamp Screw 2 0 0 20 17 in lb Air Cleaner Duct Mounting Nuts 3 0 0 31 27 in lb Air Cleaner Duct Mounting Bolt 3 0 0 31 27 in lb Air Cleaner Housing Bolts 9 8 1 0 87 in lb Cooling System Water Pump Cover Bolts 9 8 1 0 87 in lb Water Pump Impeller Bolt 9 8 1 0 87 in lb Water Hose Clamp Screws 1 5 0 15 13 in lb Coolant Drain Bolt 6 9 0
97. NSION 13 45 e Using the hook wrenches C loosen the locknut B and turn the adjusting nut A all way up Special Tool Hook Wrench R37 5 R42 57001 1101 e Remove the rear shock absorber from the vise e Slide down the rubber bumper A e Remove the spring guides B from the shock absorber and lift off the spring C e Exchange the spring for an optional part Install the spring so that closed coil large diameter end A faces upward e Install the spring guide e Adjust the spring preload see Spring Preload Adjust ment e Install the rear shock absorber e Install the parts removed Rear Shock Absorber Disassembly Oil Change e Refer to the Rear Shock Absorber Oil Change in the Pe riodic Maintenance chapter Rear Shock Absorber Assembly e Refer to the Rear Shock Absorber Oil Change in the Pe riodic Maintenance chapter Rear Shock Absorber Scrapping A WARNING Since the reserve tank of the rear shock absorber contains nitrogen gas do not incinerate the reserve tank without first releasing the gas or it may ex plode e Remove the shock absorber see Rear Shock Absorber Removal e Remove the valve cap A and release the nitrogen gas completely from the gas reservoir e Remove the valve A WARNING Since the high pressure gas is dangerous do not point the valve toward your face or body GMO5195BS1 GMO5055BS1 13 46 SUSPENSION Swinga
98. 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 2 70 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Install the handlebar B on the handlebar holder lower so that the protruded scales of the both side adjust to the same width A e Apply 2 stroke oil to the threads of the handlebar holder bolts e Install the handlebar holder upper so that center D of the handlebar holder upper C and handlebar bridge E align Torque Handlebar Holder Bolts 25 N m 2 5 kgf m 18 ft lb Front F e After tighten make sure space A B of the ahead and back are same width e Install the handlebar pad and number plate 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 check the outer races and the 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
99. P END 5 21 Cylinder Head Problem Diagnosis Remedy Action The cylinder Carbon accumulation on piston and in Remove the carbon deposits and replace compression is cylinder head combustion chamber is damaged parts if necessary higher than the suspected due to damaged valve stem usable range or piston oil rings Incorrect cylinder head gasket Replace the gasket with a standard one thickness Damaged auto decompressor spring or Replace the spring or auto decompressor do not move smoothly decompressor The cylinder Exhaust gas leakage around cylinder Replace the damaged gasket and compression is head inspect cylinder head warp lower than the incorrect seating surface of valve Repair seating surface if possible SES eebe Valve clearance is too narrow Adjust the valve clearance Piston cylinder clearance is too wide Replace the piston and or cylinder Piston seizure Inspect the cylinder and piston repair or replace them if necessary Bad condition of piston ring and or Replace the piston and or the piston piston ring grooves rings Auto decompressor do not move Replace the auto decompressor smoothly Cylinder Head Removal e Remove Fuel Tank see Fuel Tank Removal in the Fuel System chapter Camshaft Chain Tensioner see Camshaft Chain Ten sioner Removal Cylinder Head Cover see Cylinder Head Cover Re moval Camshaft see Camshaft Removal Carburetor see Carburetor Removal in the F
100. Rocker Arm Sleeve Inner Tube Inspection 13 39 Wear Inspection 13 52 Guide Bush Inspection 13 39 Tie Rod and Rocker Arm Dust Seal Oil Seal Inspection 13 39 Mounting Bolt Bend Inspection 13 52 Spring Tension Inspection 13 40 13 2 SUSPENSION Exploded View KX450D6F ND odo OG 6M021408W5 C SUSPENSION 13 3 Exploded View Torque Ve kgfm teo meri Le 9 Screw 10 O ring 11 Piston Rod 12 Rebound Damping Adjuster Rod 13 Subtank 14 Cylinder Unit 15 Outer Tube 16 Washer 17 Spacer 18 Spring Seat 19 Fork Spring 20 Bushings 21 Washer 22 Oil Seal 23 Retaining Ring 24 Dust Seal 25 Inner Tube 26 O ring 27 Gasket 28 Steering Stem Head 29 Steering Stem AL Tighten the two clamp bolts alternately two times to ensure even tightening torque L Apply a non permanent locking agent to the threads R Replacement Parts 13 4 SUSPENSION Exploded View KX450D7F D8F d OG de DC Goo o 0 o 6M02216BW5 C SUSPENSION 13 5 Exploded View Torque Ve kgfm teo meri Le Screw O ring Piston Rod Rebound Damping Adjuster Rod Subtank Cylinder Unit Outer Tube Spacer Fork Spring Bushings Washer Oil Seal Retaining Ring Dust Seal Inner Tube O ring Gasket Steering Stem H
101. Rod Locknut 17 N m 1 7 kgf m 13 ft lb e Bleed the brake line see Bleeding the Brake Line e Check the brake for good braking power no brake drag and no fluid leakage e Check the brake pedal position see Brake Lever and Pedal Position Adjustment in the Periodic Maintenance chapter 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 GLO7068BS1 12 18 BRAKES Master Cylinder Master Cylinder Inspection Visual Inspection e Disassemble the front and rear master cylinders Ge gt AAA e Check that there are no scratches rust or pitting on the O gt I inner wall of each master cylinder A and on the outside NA E NEO of each piston B If a master cylinder or piston shows any damage replace be ie them DBA er e Inspect the primary C and secondary D cups PA AAA If a cup is worn damaged softened rotted or swollen the piston assembly should be replace to renew the cups WW D E x If fluid leakage is noted at the brake lever the piston as sembly should be replaced to renew the cup O e Check the dust covers E for da
102. Seat Cutter Holder 5 5 57001 1125 Valve Seat Cutter Holder Bar 57001 1128 ST571125ST ST5711288ST 5 10 ENGINE TOP END Special Tools and Sealant Valve Seat Cutter 55 p35 57001 1247 ST571247ST Spark Plug Wrench Hex 16 57001 1262 T5712628T 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 55 938 5 57001 1497 ST571497ST Valve Guide Driver 57001 1564 ST5715648T Piston Pin Puller 57001 1568 ST571568ST Valve Spring Compressor Adapter 24 57001 1586 ST571586ST ENGINE TOP END 5 11 Special Tools and Sealant Valve Guide Driver Attachment D Kawasaki Bond Silicone Sealant 57001 1659 92104 0004 ST5716598T ST9200048T 5 12 ENGINE TOP END Cylinder Head Cover Cylinder Head Cover Removal e Remove Fuel Tank see Fuel Tank Removal in the Fuel System chapter Spark Plug Cap e Remove the cylinder head cover bolts A and remove the cylinder head cover B Cylinder Head Cover Installation e Apply silicon sealant A to the cylinder head as shown Sealant Kawasaki Bond Silicone Sealant 92104 0004 e Rep
103. Sos SN YN 68020118 Tightening Sequence z Generally when installing a part with several bolts nuts A or screws start them all in their holes and tighten them to AK e a snug fit Then tighten them according to the specified se AS quence to prevent case warpage or deformation which can lod Ge a lead to malfunction Conversely when loosening the bolts fF SI nuts or screws first loosen all of them by about a quar el LE A ter turn and them remove them If the specified tightening Orce gt sequence is not indicated tighten the fasteners alternating 68020128 diagonally 1 4 GENERAL INFORMATION Before Servicing Tightening Torque Incorrect torque applied to a bolt nut or screw may lead to serious damage Tighten fasteners to the specified torque using a good quality torque wrench Often the tightening sequence is followed twice initial tightening and final tightening with torque wrench Force Use common sense during disassembly and assembly excessive force can cause expensive or hard to repair 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 remain
104. Spring Free Length Exhaust Outer Inner Inlet Outer Inner 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 09 0 16 mm 0 0035 0 0063 in 0 06 0 14 mm 0 0024 0 0055 in 45 32 60 30 4 30 6 mm 1 197 1 205 in 35 4 35 6 mm 1 39 1 40 in 0 8 1 2 mm 0 03 0 047 in 0 5 1 0 mm 0 02 0 039 in 38 92 mm 1 532 in 35 67 mm 1 404 in 39 28 mm 1 546 in 36 04 mm 1 419 in 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 36 mm 0 014 in 0 33 mm 0 013 in 37 5 mm 1 48 in 34 2 mm 1 35 in 37 8 mm 1 49 in 35 7 mm 1 40 in Specifications ENGINE TOP END 5 7 Item Standard Service Limit Cylinder and Pistons 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 96 000 96 012 mm 3 7795 3 7800 in 95 970 95 980 mm 3 7783 3 7787 in 0 020 0 042 mm 0 00079 0 0016 in 0 04 0 07 mm 0 002 0 003 in
105. TEM Oil Pressure Relief Valve Oil Pressure Relief Valve Removal e Remove Clutch see Clutch Removal in the Engine Right Side chapter Right Engine cover see Right Engine Cover Removal in the Engine Right Side chapter e Remove the oil pressure relief valve A Oil Pressure Relief Valve Installation e Apply a non permanent locking agent to the threads of oil pressure relief valve and tighten it Torque Oil Pressure Relief Valve 15 N m 1 5 kgf m 11 ft Ib Oil Pressure Relief Valve Inspection e Remove the relief valve see Oil Pressure Relief Valve Removal e Using a wooden stick push the inner valve to make sure that the valve A moves smoothly and that it returns to its original position by the force of the spring B NOTE OThe relief valve cannot be disassembled and it must be inspected in the assembled state x If the valve movement is not smooth wash the relief valve with high flash point solvent and use compressed air to remove any foreign particles from it A WARNING Clean the oil pressure relief valve in a well ventilated area and take care that there is no spark or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents x If the valve does not move smoothly even after washing it replace the relief valve The oil pressure relief valve is precision made with no allowance for replacement of individual parts
106. a container that has been left unsealed or that has been open for a long time 3 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 ineffective It may also cause the rubber brake parts to deteriorate 4 Don t leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid 5 Don t change the fluid in the rain or when a strong wind is blowing 6 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 deterio ration 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 7 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 solvent Do not use one which will leave an oily residue Replace the pads with new ones if they cannot be cleaned satisfacto rily 8 Brake fluid quickly ruins painted surfaces any spilled fluid should be completely wiped up imme diately 9 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 Flui
107. able 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 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 Tighten 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 A WARNING Operation with an improperly adjusted incorrectly routed or damaged cable could result in an unsafe riding condition GSO5080BS1 PERIODIC MAINTENANCE 2 13 Periodic Maintenance Procedures Hot Starter Lever Hot Starter Cable Free Play Inspection e Slide the clutch lever dust cover A back e Check the hot starter lever play B when pulling the start lever C lightly Hot Starter Lever Free Play Standard 0 5 1 0 mm 0 02 0 04 in x lf the free play is improper adjust the hot starter cable Slide the adjuster cover A back e Loosen the locknut B and turn the adjuster C to obtain the proper lever free play e Tighten the locknut securel
108. ackets Left and Right H Collars Left and Right KX450D8F Lower Engine Mounting Bolts and Nuts I e Remove the swingarm pivot shaft nut A to pull out the swingarm pivot shaft B OPull out the swingarm pivot shaft half way from right side to free the engine e Remove the engine from the vehicle to right side OClear the engine rear portion from the swingarm and then remove the engine Engine Installation e Install the engine OFirst insert the front portion of the engine and then install the rear portion e Install the swingarm pivot shaft all engine bracket and mounting bolts temporarily Olnstall the collars at the left and right brackets KX450D8F OSwingarm pivot shaft insert from the right side Olnsert the middle and lower engine mounting bolts from the left side e Tighten the pivot shaft engine mounting bolts and engine bracket bolts Torque Swingarm Pivot Shaft Nut 98 N m 10 kgf m 72 ft Ib Engine Mounting Bolts 49 N m 5 0 kgf m 36 ft Ib Engine Bracket Bolt 29 N m 3 0 kgf m 21 ft Ib 8 8 ENGINE REMOVAL INSTALLATION Engine Removal Installation e Install the removed parts see Appropriate chapter e Run the cables hoses and leads according to the Cable Wire and Hose Routing section in the Appendix chapter e Fill Engine Oil see Engine Oil Change in the Periodic Main tenance chapter Coolant see Coolant Draining in the Cooling System chapter e Adjust Throttle Cable see Throttle
109. aft B 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 Installation CAUTION If the oil seal or ball bearing is removed replace all of them with new ones at the same time e Be sure to replace the oil seals e Apply plenty of high temperature 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 surface of the right engine cover Special Tool Bearing Driver Set 57001 1129 e Press the ball bearing 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 GDO6060BS1 GD06061BS1
110. aft 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 from the frame see Rear Shock Absorber Removal in the Suspension chap ter e Remove the shock absorber spring see Spring Replace ment in the Suspension chapter e Point the valve A away from you Slowly release nitro gen gas pressure from the gas reservoir by pushing down the valve core with a screw driver Do not point the reservoir valve toward your face or body when releasing nitrogen gas pressure An oil mist is often released with the nitrogen Always re lease nitrogen gas pressure before disassembling the rear shock absorber to prevent explosive sepa ration of parts e Adjust the gas reservoir damping adjusters A to the soft est position e Remove the air bleed bolt B and pump the rear shock to drain the oil out the rear shock body e Install the air bleed bolt 2 64 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Using the suitable tool A and press push the reservoir cap B in 10 mm 0 39 in e Remove the circlip C from the gas reservoir e Pull the gas reservoir cap B out ofthe gas reservoir using the pliers A e Pry or tap A a
111. ain tenance chapter Coolant Deterioration Inspection e Refer to the Coolant Deterioration Inspection in the Peri odic Maintenance chapter Coolant Draining e The coolant should be changed periodically to ensure long engine life WARNING To avoid burns do not remove the radiator cap or try to change the coolant when the engine is still hot Wait until it cools down Coolant on tires will make them slippery and can cause an accident and injury Immediately wipe up or wash away any coolant that spills on the frame engine or other painted parts Since coolant is harmful to the human body do not use for drinking 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 Place a container under the coolant drain bolt A and drain the coolant from the radiator and engine by remov ing the drain bolt on the water pump cover Immediately wipe or wash out any coolant that spills on the frame or engine e Inspect the old coolant for visual evidence of corrosion and abnormal smell see Coolant Deterioration Inspection in the Periodic Maintenance chapter COOLING SYSTEM 4 7 Coolant Coolant Filling CAUTION Use coolant containing corrosion inhibitors made specifically for aluminum engines and radiators in accordance
112. ain plug on the float bowl and tighten it se curely e Install the carburetor see Carburetor Installation in the Fuel System chapter 6S05027BS1 GS05078BS1 PERIODIC MAINTENANCE 2 17 Periodic Maintenance Procedures Fuel Tank Filter and Tap Cleaning A WARNING Clean the fuel tank in a well ventilated area and take care that there is no sparks or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvent to clean the tank e Remove the fuel tank and drain it see Fuel Tank Removal in the Fuel System 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 Remove the fuel filter from the tank by taking out the bolts e Clean the fuel filter screen in a high flash point solvent After cleaning install the fuel filter e Pour high flash point solvent through the tap in all lever positions e Dry the tank filter and tap with compressed air e Install the filter in the fuel tank e Install the tap and fuel tank Fuel Tap and Filter Inspection e Remove the fuel filter from the fuel tank e Check the fuel filter screen A for any breaks or deterio ration x If the fuel filter screen have any breaks or is deteriorated it may allow dirt to reach the carburetor causing poor run ning Replace the fuel filter e Remove
113. alues Valve clearance between cam and valve lifter Standard Exhaust 0 17 0 22 mm 0 0067 0 0087 in Inlet 0 10 0 15 mm 0 0039 0 0059 in xlf the valve clearance is not within the specified range adjust it Valve Clearance Adjustment e Remove the camshaft caps A see Camshaft Removal in the Engine Top End chapter e Remove the camshafts B see Camshaft Removal in the Engine Top End chapter e Remove the valve lifters C of the applicable valve e Remove the shim D from the top of the spring retainer NOTE OMark and record the locations of the valve lifters and shims so that they can be reinstalled in their original positions 6S07008BS1 PERIODIC MAINTENANCE 2 21 Periodic Maintenance Procedures 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 B C D A Replace Shim Thickness B Measured Valve Clearance C Specified Valve Clearance D Present Shim Thickness Example 0 31 mm 0 10 0 15 mm 2 60 mm 2 81 2 76 mm OExchange the shims for the 2 775 or 2 800 size shim CAUTION Don t use the shims for another models This could cause wear of the valve stem end and valve stem damage Adjustment shims ee P No Mark es P No Mark 92025 1870 92025 1984 53 92025 1871 92025 1881 55 92025 1872
114. and rust inhibitor chemicals for aluminum engines and radiators Water and coolant mixture ratio 1 1 water 50 Coolant 50 Total amount 1 05 L 1 11 US qt CAUTION 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 If coolant must be added often or the reserve tank has run completely dry there is probably leakage in the cooling system Check the system for leaks Coolant ruins painted surfaces Immediately wash away any coolant that spills on the frame engine wheels or other painted parts A B 6D04016BS1 6S06008BS1 PERIODIC MAINTENANCE 2 19 Periodic Maintenance Procedures 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 brown 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 Water Hoses and Connections Inspection OThe high pressure inside the water ho
115. aniNg EE 3 17 Carburetor Disassembly saciedad 3 17 RE leie Le DEE 3 21 Carburetor Inspection ss 3 21 ele e EE 3 23 AIR Cleaner en Corrido E ane n die ta test isa iens tnt s cena sean EE 3 28 Air Cleaner Housing R movalisssusun dd lement 3 28 Air Cleaner Housing Installation sm 3 28 Element HRemoval see 3 28 Element Installation tii limitant eke ah nn latte 3 29 Element Cleaning and Inspection 44044444 hessiesienenines 3 29 Fuel E in etienne iranienne entres 3 30 Fuel Tank Removal sise 3 30 Fuel Tank Instala EE 3 30 Fuel Filter Removal sise 3 30 Fuel Filter Installation sere ooo ii a A A A aL eu ds 3 30 Fuel Tank Filter and Tap Cleaning reen rene 3 31 Fuel Tap and Filter Inspechon cnn rr rar rra 3 31 3 2 FUEL SYSTEM Exploded View FUEL SYSTEM 3 3 Exploded View im ite Put Cover Bot ner Throttle Cable Mounting Bolts 0 70 61 in Ib 3 Hot Starter Cable 4 Throttle Cables 5 Throttle Grip 6 Carburetor Cap 7 Throttle Valve Plate 8 Throttle Valve 9 Jet Needle 10 Throttle Pulley Shaft 11 Choke Knob 12 Idle Adjusting Screw 13 Pilot Air Screw 14 Slow Jet 15 Main Jet 16 Needle Jet 17 Starter Jet 18 Float 19 Leak Jet 20 Throttle Sensor 21 Hot Starter Plunger 22 Acceleration Pump Diaphragm 23 Slow Air Jet CL Apply cable lubricant G Apply grease L Apply a non permanent locki
116. ankcase and the right engine cover e Apply grease to the O rings B and install them to the crankcase Olnstall the lower O ring so that the tapered side facing outside e Replace the engine cover gasket with a new one e Apply a high temperature grease to the kick shaft oil seal lips and kick shaft spline Clutch Cover and Right Engine Cover ENGINE RIGHT SIDE 6 11 e When installing the cover doesn t go well the cover is installed according to the following procedures OFit the water pump shaft A and groove B of the balancer shaft while turning the water pump shaft e Tighten Torque Right Engine Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib e Insert the water hose A into the water pump cover B and tighten it with the clamp C Torque Water Hose Clamp Screw 1 5 N m 0 15 kgf m e Install the kick pedal see Kick Pedal Installation in the Periodic Maintenance chapter e Install the engine oil drain bolts surely see Periodic Main tenance chapter e Pour in the specified type and amount of oil see Engine Oil Change in the Periodic Maintenance chapter e Pour in the specified type and amount of coolant see Coolant Filling in the Cooling System chapter e Check the rear brake for good braking power and no brake drag Release Shaft Removal e Remove the clutch see Clutch Removal e Remove the clutch cable upper end see Clutch Cable Removal e Remove the tips A of the cl
117. ar 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 Abnormal Engine Noise Knocking Faulty CDI unit 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 Spring weak or broken Front fork air pressure high Rear shock absorber noise Shock absorber trouble Spring weak or broken Disc brake noise Pad surface glazed Disc warped Caliper trouble Pad installed incorrectly APPENDIX 17 11 Troubleshooting Guide 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 Main jet too large or fallen off Choke plunger stuck open Fuel level in carburetor float bowl too high Brown smoke Main jet too small Fuel level in carburetor float bowl too low Air cleaner duct loose Air cleaner poorly sealed or missing Handling and or Stability Unsatisfactory Handl
118. argest 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 all circlips and washers are properly in place 9 20 CRANKSHAFT TRANSMISSION Transmission KX450D6F O 000 e o d bit bech RE DID G113234BW3 C 1 Circlip small 11 Collar 2 Circlip middle 12 O rings 2 3 Circlip large 13 Oil Seal 4 Ball Bearing one side sealed 14 Ball Bearing one side sealed 5 2nd Gear 17T 15 2nd Gear 24T 6 3rd Gear 16T 16 3rd Gear 19T 7 4th Gear 19T 17 4th Gear 19T 8 1st Gear 15T 18 1st Gear 27T 9 Ball Bearing 19 Ball Bearing 10 Drive Shaft 20 Output Shaft e Check each gear spins or slides freely on the transmission shaft without binding after assembly CRANKSHAFT TRANSMISSION 9 21 Transmission KX450D7F GJ 14 10 52 D 6 OM 8 y D Te mile E O STEHE Jee Bis al ML eg YM 3 249069 D D Y We ey ea es 1 Circlip 13 Oil Seal 2 Toothed Washer 14 O rings 3 Ball Bearing one side sealed 15 Ball Bearing one side sealed 4 2nd Gear 17T 16 Collar 5 4th Gear 19T 17 2nd Gear 24T 6 3rd Gear 16T 18 4th Gear 19T 7 5th Gear 24T 19 3rd Gear 19T 8 1st Gear 16T 20 5th Gear 21T 9 Bushing 21 1st Gear 28T 10 Ball Bearing 22 Ball Bearing 11 Drive Shaft 23 Output Shaft 12 Collar e C
119. as far as they will go e Install the piston side pad first and then another pad OFit the pad end A into the groove B of the anti rattle spring securely e Tighten the brake pad bolt Torque Brake Pad Bolt 17 N m 1 7 kgf m 13 ft Ib Rear Brake Pad Bolt Plug 2 5 N m 0 25 kgf m 22 in Ib e Check the brake for good braking power no brake drag and no fluid leakage WARNING Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc The brake will not function on the first appli cation of the lever or pedal if this is not done Brake Pad Inspection e Refer to the Brake Pad Wear Inspection in the Periodic Maintenance chapter 12 16 BRAKES Master Cylinder CAUTION Brake fluid quickly ruins painted or plastic sur faces any spilled fluid should be completely wiped up immediately Front Master Cylinder Removal e Remove the banjo bolt A to disconnect the upper brake hose B from the master cylinder C e When removing the brake hose temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum e Unscrew the clamp bolts A and take off the master cylin der B as an assembly with the reservoir and brake lever Front Master Cylinder Installation e Install the master cylinder so that the reservoir cap B is horizontally and position it from edge of
120. b 52 in lb 18 18 78 in lb 87 in lb 13 13 in lb 87 in lb 17 69 in lb 20 13 22 in lb 18 15 19 22 43 for transmission room oil sump 20 2 0 15 Engine Oil Drain Bolt M6 for crank room oil sump 7 0 0 71 62 in lb Bearing Retaining Screw 15 1 5 11 L Gear Set Lever Nut 8 8 0 90 78 in lb Shift Drum Cam Bolt 24 2 4 17 L Balancer Weight Mounting Nut 52 5 3 38 Gear Position Switch Screws 2 9 0 30 26 in lb L Wheels Tires Front Axle 78 80 58 Front Axle Clamp Bolts 20 2 0 15 AL Rear Axle Nut 108 11 80 Spoke Nipples Not less Not less Not less than 2 2 than 0 22 than 19 mb Final Drive Rear Sprocket Nuts 34 3 5 25 Engine Sprocket Nut 127 13 94 Engine Sprocket Cover Bolts 9 8 1 0 87 in lb L G AL AL 2 8 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Remarks Base Valve Assembly Locknut Adjuster Assembly Swingarm Pivot Shaft Nut Rear Shock Absorber Mounting Nuts Upper Lower 25 Air Bleed Bolt 56 in lb Tie Rod Mounting Nut Front Rear 61 KX450D6F Tie Rod Mounting Nut Front Rear 43 KX450D7F Rocker Arm Pivot Nut KX450D6F 61 Rocker Arm Pivot Nut KX450D7F 43 Steering Steering Stem Head Nut 72 Steering Stem Nut 43 in lb Handlebar Holder Bolts 18 O Frame Rear Frame Mounting Bolts 25 Upper Footpeg Bracket Bolts 40 L Electrical System Gear Position Switch Screws 26 in lb E Flywheel Nut 58 Stator Bolts 35 in lb L Crankshaft Sensor Bolts 62 in lb Spa
121. be Rear Size 120 80 19 63M Make DUNLOP Type D756 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 A WARNING If any spoke breaks it should be replaced immedi ately A missing spoke places an additional load on the other spokes which will eventually cause other spokes to break ae 93 Ne 6J05002BS1 GS11041BS1 PERIODIC MAINTENANCE 2 31 Periodic Maintenance Procedures Rim Runout Inspection e Place the jack under the frame so that the front rear wheel off the ground Special Tool Jack 57001 1238 e Inspect the rim for small cracks dents bending or warp ing x If there is any damage to the rim it must be replaced e Set a dial gauge against the side of the rim and rotate the rim to measure the axial runout A The difference be tween the highest and lowest dial readings 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 The difference between the highest and lowest dial readings is the amount of runout x If rim runout exceeds the service limit check the wheel bearings first Replace them if they are damaged If the problem is not due to the bearings correct the rim warp runout A certain am
122. ble disconnected at the both ends the cable should move freely A within the cable housing x If cable movement is not free after lubricating if the cable is frayed B or if the cable housing is kinked C replace the cable 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 x If there are loose fasteners retorque them to the specified torque following the specified tightening sequence Refer to the Torque and Locking Agent section of the General Information 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 6004020152 C 2 74 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brakes Front Master Cylinder Clamp Bolts Brake Lever Pivot Nut Front Caliper Mounting Bolts Brake Pedal Mounting Bolt Rear Master Cylinder Push Rod Cotter Pin Rear Master Cylinder Mounting Bolts Rear Caliper Holder Shaft Suspension
123. bly Inspection 13 23 Swingarm Installation 0 13 47 Cylinder Unit Inspection 13 24 Swingarm Bearing Removal 13 47 Inner Tube Inspection 13 24 Swingarm Bearing Installation 13 47 Guide Bush Inspection 13 24 Swingarm Bearing Sleeve Dust Seal Oil Seal Inspection 13 24 INSPECtION ccceeeeeeeteeeeeeees 13 48 Spring Tension Inspection 13 25 Drive Chain Guide Guide Roller Front Fork KX450D8F 13 26 Chain Slipper Wear Inspection Air Pressure ccecce 13 26 Tie Rod Rocker Arm 13 49 Rebound Damping Adjustment 13 26 Tie Rod Removal 13 49 Compression Damping Tie Rod Installation 13 49 Adjustment cocociaconccncnncnrncianoniannos 13 27 Rocker Arm Removal 13 49 Oil Change each fork leg 13 27 Rocker Arm Installation 13 50 Front Fork Removal se 13 27 Tie Rod and Rocker Arm Bearing Front Fork Installation 13 28 Removal spiraia 13 50 Front Fork Disassembly each Tie Rod and Rocker Arm Bearing elt e EE 13 29 Installation coat cal da 13 51 Front Fork Assembly 13 33 Needle Bearing Inspection 13 51 Adjuster Assembly Inspection 13 38 Uni Trak Maintenance 13 52 Base Valve Assembly Inspection 13 38 Uni Trak Linkage Inspection 13 52 Cylinder Unit Inspection 13 39 Tie Rod and
124. bs A of the cover into the air cleaner housing B 15 8 FRAME Fender Front Fender Removal e Unscrew the bolts A and remove the front fender B Rear Fender Removal e Remove Seat see Seat Removal e Unscrew the bolts A and remove the rear fender B Rear Flap Removal e Unscrew the screws A and remove the rear flap B ELECTRICAL SYSTEM 16 1 Electrical System Table of Contents Exploded Vi We iii A A 16 2 A de TEE 16 4 Special Tools and Sealant ccc cece n e d ea aa ee reaa eet 16 5 MU A E 16 6 Precautions iii AS A AAA Riedie eh ar ane 16 7 EE VII EE 16 8 Wiring INSPOCUON avion is 16 8 Flywheel Magneto ist corel dieta dd 16 9 Magneto Cover ue EE 16 9 Magneto Cover installation cia enee 16 9 Flywheel Removal iaa oia oie 16 9 Flywheel Install LEET 16 10 LAO ReMOVal iodo ct cad E des 16 11 Stator installation A A men Dia Eta 16 11 le E Me uscar ln it bicis 16 11 Ignition MiNi EE 16 13 Ignition Timing De e RE 16 13 Ignition AE e a Ei E a a Locate 16 14 Safety Instructions eee aa EE o dedos 16 14 Ignition Coil E EE 16 14 Ignition Col Installation cia teen Te SAA ARRAT SANEA Terana 16 14 Ignition Coil INSpection E 16 15 Spark Plug Cleaning and Aspects ill 16 15 Spark Plug Gap Inspection C D EUnt Removal viii akn eee a AAA Tek AA age Pade a CADH Unit Installation RE C DEUnitInspection aeree ea a e ile A a as Crankshaft Sensor Inspection u tele Throttle Sensor Ins
125. completely e Replace the gaskets at the drain plugs with a new one e After the oil has completely drained out install the drain plugs with the gaskets and tighten them Torque Engine Oil Drain Bolts Transmission Room Oil Sump 20 N m 2 0 kgf m 15 ft lb Crank Room Oil Sump 7 0 N m 0 71 kgf m 62 in Ib e Fill the engine with a good quality motor oil specified be low Recommended Engine Type Castrol R4 Superbike 5W 40 YP KX450D6F D7F Castrol POWER1 R4 Racing 5W 40 KX450D8F or API SG SH SJ or SL with JASO MA Viscosity SAE 10W 30 10W 40 10W 50 Capacity 0 96 L 1 01 US qt when filter is not removed 0 98 L 1 03 US qt when filter is remove 1 2 L 1 3 US qt when engine is completely dry NOTE OThe oil viscosity may need to be changed to accommo date atmospheric conditions in your riding area e Check the oil level see Engine Oil Level Inspection in the Engine Lubrication System chapter Oil Filter Change e Drain Engine Oil see Engine Oil Change e Remove Oil Filter Cover Bolts A Oil Filter Cover B E A SAE 10W 40 40 C 104 F 6S09013BS1 2 28 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Remove the Oil Filter A e Install the spring A to the right engine cover e Apply grease to the grommet B e Be sure to install the filter with the grommet facing outside as shown CAUTION Inside out installat
126. correct Faulty CDI unit Fuel air mixture incorrect Main jet clogged or wrong size Fuel level in carburetor float bowl too low Carburetor holder loose Air cleaner clogged poorly sealed or miss ing Air cleaner duct loose Hot starter plunger stuck open 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 17 10 APPENDIX Troubleshooting Guide Clutch inner cable sticking Valve noise 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 Valve clearance incorrect Valve spring broken or weak Camshaft bearing or cam face worn Valve lifter worn Other noise
127. d Level Inspection e Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter Fluid Change e Refer to the Brake Fluid Change in the Periodic Mainte nance chapter 12 10 BRAKES Brake Fluid Bleeding the Brake Line 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 Be sure to bleed the air from the brake whenever brake lever or pedal action feels soft or spongy af ter the brake fluid is changed or whenever a brake line fitting has been loosened for any reason 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 Remove the reservoir cap and check that there is plenty of fluid in the reservoir e With the reservoir cap off slowly pump the brake lever several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reser voir OBleed the air completely from the master cylinder by this operation e Install the reservoir cap e Attach a clear plastic hose to the bleed valve on the caliper and run the other end
128. damage lf the damage is not repairable replace the inner tube Since damage to the inner tube damages the oil seal replace the oil seal whenever the inner tube is repaired or replaced e Temporarily assemble the inner A and outer tubes B and pump them back and forth manually to check for smooth operation CAUTION If the inner tube is badly bent or creased replace it Excessive bending followed by subsequent straightening can weaken the inner tube Guide Bush Inspection e Visually inspect the guide bushes A and replace them if necessary Dust Seal Oil Seal Inspection e Inspect the dust seal A for any signs of deterioration or damage x Replace it if necessary e Replace the oil seal B with a new one whenever it has been removed 6M04168BS1 6M040119S1 GM040120S1 Front Fork KX450D6F D7F SUSPENSION 13 25 Spring Tension Inspection e Since a spring becomes shorter as it weakens check its free length A to determine its condition x lf the spring of either fork leg is shorter than the service limit it must be replaced If the length of a replacement spring and that of the remaining spring vary greatly the remaining spring should also be replaced in order to keep the fork legs balanced from motorcycle stability Fork Spring Free Length Standard 480 mm 18 9 in KX450D6F 470 mm 18 5 in KX450D7F Service Limit 470 mm 18 5
129. de Circlip Pliers 57001 144 ST5701448T ENGINE LUBRICATION SYSTEM 7 7 Oil Pressure Gauge Adapter M10 x 1 25 57001 1182 8757118297 Oil Pressure Cap 57001 1656 ST5701448T 7 8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter A WARNING Motorcycle operation with insufficient deteri orated or contaminated engine oil will cause accelerated wear and may result in engine or trans mission seizure accident and injury The engine oil level indicated in the right engine cover oil level gauge is very sensitive to the motorcycle s posi tion and engine rpm at time of shut down Because of the semi dry sump lubrication system with separate oil cham bers in the crank room and transmission room under cer tain conditions oil can accumulate in the crank room and give a false low reading at the oil level gauge 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 levels B in the gauge NOTE OSituate the motorcycle so that it is perpendicular to the ground Olf no oil appears in the gauge tip the motorcycle slightly to the right until oil is visible then return to an upright po sition If no oil appears even when tipped at an extreme angle remove both drain bolts to empty any oil that may be in the transmission and crankcase reinstal
130. dures 2 12 Wieelfires eects 2 29 Fuel Systemes 2 12 Air Pressure Inspection Adjust Fuel Hose and Connections MSN SE and sus re qu 2 29 Inspection 2 12 Tires Inspection 2 30 Throttle Grip Throttle Cable Free Spoke Tightness Inspection 2 30 Play Inspection 2 12 Rim Runout Inspection 2 31 Throttle Grip Throttle Cable Free Wheel Bearing Inspection 2 31 Play Adjustment oooooooccccnnncccnn 2 12 Final Drive 2 32 Hot Starter Lever Hot Starter Drive Chain Slack Inspection 2 32 Cable Free Play Inspection 2 13 Drive Chain Slack Adjustment 2 32 Idle Speed Inspection 2 13 Drive Chain Wear Inspection 2 33 Idle Speed Adjustment 2 14 Drive Chain Lubrication 2 34 Air Cleaner Element Cleaning and Sprocket Wear Inspection 2 34 Inspection 2 14 Rear Sprocket Warp Runout Fuel System Cleaning 2 16 Inspection eee 2 35 Fuel Tank Filter and Tap Ee 2 35 Gleaningi ssss servent 2 17 Brake Lever and Pedal Position Fuel Tap and Filter Inspection 2 17 Adjustment c ccccceeeceeeees 2 35 Cooling System 2 17 Brake Fluid Level Inspection 2 36 Coolant Level Inspection 2 18 Brake Fluid Change 2 37 Coolant Deterioration Inspection 2 19 Brake Pad Wear Inspection 2 39 Water Hoses and Connections
131. e Friction and Steel Plates Wear Damage Inspection e Refer to the Friction and Steel Plates Inspection in the Periodic Maintenance chapter Friction and Steel Plate Warp Inspection e Refer to the Friction and Steel Plate Inspection in the Pe riodic Maintenance 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 49 2 mm 1 94 in Service Limit 46 7 mm 1 84 in GRO5034BS2 C GFO6O0303S1 6 16 ENGINE RIGHT SIDE Clutch 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 damaged as well Friction Plate Clutch Housing Clearance Inspection e Measure the clearance between the tangs A on the fric tion plate and the fingers B of the clutch housing x If 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 0079 0 024 in Service Limit 0 8 mm 0 03 in Clutch Hub Spline Damage Inspection e Visually inspect the areas of the clutch
132. e e Remove Bolts C Fork Protector D GM04494BS1 13 28 SUSPENSION Front Fork KX450D8F e Loosen the upper A and lower B fork clamp bolts e Remove the front fork OWith a twisting motion A work the fork leg B down and out Front Fork Installation e Install the fork so thatthe distance between the top end of the outer tube and the upper surface of the steering stem head is specified dimension A 8 mm 0 31 in e Route the cables and hose according to the Cable Wire and Hose Routing section in the Appendix chapter e Install the front wheel see Front Wheel Installation in the Wheels Tires chapter e Tighten the fork clamp bolts 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 Tighten Torque Front Caliper Mounting Bolts 25 N m 2 5 kgf m 18 ft lb e Check the front brake operation after installation SUSPENSION 13 29 Front Fork KX450D8F Front Fork Disassembly each fork leg e Loosen the front fork upper camp bolts A e Loosen the fork top plug subtank A with the top plug wrench B Special Tool Top Plug Wrench 49 mm 57001 1653 B e Remove the front fork see Front Fork Removal NOTE OSet rebound and compression damping setting to the
133. e C of the carburetor body e Turn the fuel tap to the ON position to feed fuel to the carburetor e Wait until the fuel level in the gauge settles e Keeping the gauge vertical slowly lower the gauge until the Zero line is even with the bottom edge of the carbu retor body NOTE ODO not lower the zero line below the bottom edge of the carburetor body If the gauge is lowered and then raised again the fuel level measure shows somewhat higher than the actual fuel level If the gauge is lowered too far dump the fuel out of it into a suitable container and start the procedure over again GCo6138BS2 C Carburetor FUEL SYSTEM 3 13 e Read the fuel level D in the gauge and compare it to the specification Service Fuel Level below the bottom edge of the carb body Standard 6 5 1 mm 0 256 10 039 in x lf the fuel level is incorrect adjust it e Turn the fuel tap to the OFF position and remove the fuel level gauge e Install the drain plug on the bottom of the float bowl Service Fuel Level Adjustment 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 e Remove the carburetor and drain the fuel into a suitable container e Remove the float bowl see Carburetor Disassembly e D
134. e do the following procedures OConnect the digital voltmeter A as follows Tester Blue Lead Tester Black Blue Lead OStart the engine OMeasure the throttle sensor output voltage with the engine idling speed and with the idle throttle valve opening Throttle Sensor Output Voltage Standard 0 68 10 1 V when engine is idle speed xlfitis not within the specified voltage range adjust the throttle sensor position see Throttle Sensor Position Ad justment Engine Stop Switch Electric Current Check e Remove the fuel tank transiently see Fuel Tank Removal in the Fuel System chapter e Disconnect the engine stop switch lead connector A e Temporarily install the fuel tank e Start the engine e Ground the stop switch black white lead of the main har ness side while the engine is running x If the engine does not stop replace the C D I Unit Crankshaft Sensor Inspection e Remove Magneto Lead Connector see Magneto Cover Re moval e Set the hand tester A to the x 100 Q range and connect it to the Green White B and White Yellow C Leads in the connector Special Tool Hand Tester 57001 1394 Alf 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 Crankshaft Sensor Resistance Standard 180 280 Q at 20 C 68 EH e Using the highest resistance range of the test
135. e After adjustment tighten the locknut 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 indicated in the figure Length A Standard 68 5 1 mm 3 09 0 04 in x lf it is not specified length the brake pedal may be de formed or incorrectly installed x If it is not within the specified length adjust the push rod in the master cylinder as follows 2 36 PERIODIC MAINTENANCE Periodic Maintenance Procedures OLoosen the push rod locknut A OReplace the cotter pin with a new one ORemove Cotter Pin B Washer Joint Pin C OTurn the U link D 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 Brake Fluid Level Inspection e Check the brake fluid level in the front or rear brake reser voir A NOTE OHold the reservoir horizontal when checking brake fluid level e The front or rear reservoir must be kept above the lower level line B Olf the fluid level in front or rear reservoir is lower than the lower level line fill the reservoir to the upper level line In side the reservoir is stopped end showing the upper level line C Torque Reservoir Cap Screws 1 5 N m 0 15 kgf m 13 in 1b WARNING Do not mix two brands of fluid Change the brake fluid in the brake line completely if
136. e Clean the oil screens thoroughly whenever it is removed for any reason e Clean the oil screens with a high flash point solvent and remove any particles stuck to them WARNING Clean the screen in a well ventilated area and take care that there is no spark or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents NOTE OWhile cleaning the screens check for any metal parti cles that might indicate internal engine damage e Check the screens A carefully for any damage holes broken wires gasket pulling off x If the screen is damaged replace it GGO7000BS1 e Apply engine oil to the rubber portion A on the oil screen e Install the oil screen facing the carved line B to the out side e Install the oil pump scavenge cover GGO7001BS1 7 10 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter 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 Replace the O ring A with a new one e Apply grease to the O ring and install it 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
137. e Hot Starter Cable Installation e Tighten Torque Throttle Pulley Cover Bolt 3 4 N m 0 35 kgf m 30 in 1b Throttle Cable Mounting Bolts 6 9 Nm 0 70 kgf m 61 in lb e When installing the carburetor into the carburetor holder fit the projection A of the carburetor with the groove B on the holder OFit the claw A of the clamp onto the groove B of the inlet duct e Tighten the clamps securely Torque Air Cleaner Duct Clamp Screw 2 0 N m 0 20 kgf m 17 in Ib e Route the air vent and overflow hoses properly see Ca ble Wire and Hose Routing Section in the Appendix chap ter CAUTION Always keep the hoses free of obstruction and make sure they do not get pinched by the chain or shock absorber e Connect the throttle sensor connector e After installing the carburetor do the following OTurn the fuel tap to the ON position and check for fuel leakage from the carburetor A WARNING Fuel spilled from the carburetor is hazardous GC06124BS1 FUEL SYSTEM 3 17 Carburetor OAdjust the following items if necessary Throttle Cable see Throttle Grip Throttle Cable Free Play Adjustment in the Periodic Maintenance chapter Idle Speed see Idle Speed Adjustment in the Periodic Maintenance chapter Fuel System Cleaning e Refer to the Fuel System Cleaning in the Periodic Main tenance chapter Carburetor Disassembly e Remove the carburetor e Remove all vent hoses A and fue
138. e Mounting Bolt KX450D7F 15 1 5 11 LS 6 Gear Set Lever Nut 8 8 0 90 78 in lb 7 Shift Drum Cam Bolt 24 2 4 17 L 8 Kick Pedal 9 Kickshaft Idle Gear 10 Ratchet Gear 11 Kick Gear 12 Shift Pedal 13 Ratchet Plate 14 Ratchet Assembly 15 Gear Set Lever 16 Shift Drum Cam 17 Shift Shaft 18 KX450D6F EO Apply engine oil G Apply grease L Apply a non permanent locking agent M Apply molybdenum disulfide grease R Replacement Parts St Stake the fasteners 6 6 ENGINE RIGHT SIDE Specifications Item Standard Service Limit Clutch Lever Clutch Lever Free Play 8 13 mm 0 3 0 5 in Clutch Friction Plate Thickness 2 92 3 08 mm 0 115 0 121 in 2 6 mm 0 10 in Friction Plate Warp 0 15 mm 0 0059 in or less 0 3 mm 0 01 in Steel Plate Warp 0 2 mm 0 008 in or less 0 3 mm 0 01 in Clutch Spring Free Length 49 2 mm 1 94 in 46 7 mm 1 84 in Ee SE 0 20 0 60 mm 0 0079 0 024 in 0 8 mm 0 03 in Clutch Plate Assembly Length 34 9 35 5 mm 1 37 1 40 in ENGINE RIGHT SIDE 6 7 Special Tools Outside Circlip Pliers Gear Holder m2 0 57001 144 57001 1557 ST5701448T ST571557ST Clutch Holder 57001 1243 C ST5712488T 6 8 ENGINE RIGHT SIDE 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
139. e element material or any other damage to the ele ment replace the element with a new one A WARNING Clean the element 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 Because of the danger of highly flammable liquids do not use gasoline or a low flash point solvent to clean the element PERIODIC MAINTENANCE 2 15 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 carburetor so no dirt is allowed to enter the carburetor e Wipe out the inside of the air cleaner housing with a clean damp towel CAUTION Check inside of the inlet tract and carburetor for dirt If dirt is present clean the intake tract and car buretor thoroughly You may also need to replace the element and seal the housing and inlet 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 the parts of the element for visible damage x If any of the 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
140. e if they show any signs of seizure or uneven wear x lf any plates show signs of damage replace the friction plates and steel plates as a set e Measure the thickness A ofthe friction plates with vernier calipers x If they have worn past the service limit replace them with new ones Friction Plate Thickness Standard 2 92 3 08 mm 0 115 0 121 in Service Limit 2 6 mm 0 10 in e Place each friction plate or steel plate on a surface plate and measure the gap between the surface plate A and each friction plate or steel plate B with a thickness gauge C The gap is the amount of friction or steel plate warp x If any plate is warped over the service limit replace it with a new one Friction and Steel Plates Warp Standard Friction Plate Not more than 0 15 mm 0 0059 in Steel Plate Not more than 0 2 mm 0 008 in Service Limit Friction Plate 0 3 mm 0 01 in Steel Plate 0 3 mm 0 01 in Engine Lubrication System 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 GFO606028S1 GF13010781 PERIODIC MAINTENANCE 2 27 Periodic Maintenance Procedures e Remove the engine oil drain plugs on the bottom of the engine and let the oil drain completely Drain Plug for transmissionroom oil sump A Drain Plug for crank oil sump B NOTE OHold the motorcycle upright so that the oil may drain
141. e outer tube e Push the dust seal into the outer tube and put the spring band on the dust seal e Clean the threads A of subtank and base valve assem bly GM04399BS1 13 34 SUSPENSION Front Fork KX450D8F e With the piston rod in fully compressed position pour the specified amount of fork oil A Recommended Oil KHL15 10 KAYABAO1 or equivalent Recommended Quantity 191 ml 6 46 US oz NOTE OPlug the two oil holes on the subtank B with fingers e Pump A the piston rod B slowly several times to expel air e Replace the O rings A on the base valve assembly with new ones e Apply specified fork oil to the O rings A B and bushings C on the base valve assembly e With the piston rod held immovable in fully compressed position A gently install the base valve assembly B to the subtank e Screw in the base valve assembly in the subtank when the piston rod extends NOTE OWhen it is hard to screw in the base valve assembly pull down the piston rod a little SUSPENSION 13 35 Front Fork KX450D8F e Holding the top plug wrench 57001 1653 A with a vise e Holding the subtank B with the top plug wrench torque the base valve assembly C using the top plug wrench 57001 1705 D Special Tool Top Plug Wrench 49 mm 57001 1653 Top Plug Wrench 36 mm 57001 1705 Torque Base Valve Assembly 28 N m 2 9 kgf m 21 ft lb e Protect the piston rod end A
142. e 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 6113235BS1 G113236BS1 A G113237BS1 G113238BS1 CRANKSHAFT TRANSMISSION 9 23 Balancer Balancer Removal e Remove Right Engine Cover see Right Engine Cover Removal in the Engine Right Side chapter Magneto Cover see Magneto Cover Removal in the Electrical System chapter Flywheel see Flywheel 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 and punch mark B on the balancer gear align e Align the punch mark A on the balancer drive gear and punch mark B on the balancer gear e Install the balancer weight so that the punch mark A on the balancer and punch mark B on the balance
143. e the cables B from the carburetor e Free the tips C from the pulley e Pull out the cables from the frame e Lubricate the cable e Apply grease to the tips of the cables e Install the throttle cable tips A e Install the mounting bolts B to the holder as shown e Install the throttle pulley cover Torque Throttle Cable Mounting Bolts 6 9 N m 0 70 kgf m 61 in lb Throttle Pulley Cover Bolt 3 4 N m 0 35 kgf m 30 in Ib e Install the throttle cable in accordance with the Cable Wire and Hose Routing section in the Appendix chapter e After the installation adjust each cable properly Operation with an incorrectly routed or improperly adjusted cable could result in an unsafe riding con dition 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 GCO4019BS1 3 10 FUEL SYSTEM Throttle Grip and Cable Hot Starter Cable Removal e Remove Dust Cover A Slide out Locknut B Loosen e Turn in the adjuster C fully e Remove the cable end D from the hot starter lever E e Remove Ca
144. e the tensioner mounting bolts B and remove the chain tensioner body C Camshaft Chain Tensioner Installation e Remove the tensioner cap bolt and O ring e While compressing the push rod A turn it clockwise with a suitable screwdriver until the rod stopped CAUTION Do not turn the rod counterclockwise at installation This could detach the rod and the tensioner cannot be reinstalled e While holding the rod in position with a suitable push rod holder plate A install the tensioner on the cylinder block GE10014BS1 5 14 ENGINE TOP END Camshaft Chain Tensioner e Replace the chain tensioner gasket with a new one e Tighten Torque Chain Tensioner Mounting Bolts A 9 8 N m 1 0 kgf m 87 in Ib e Take out the holder plate B e Install the O ring and tighten the cap bolt Torque Chain Tensioner Cap Bolt 5 0 N m 0 51 kgf m 44 in 1b Camshaft ENGINE TOP END 5 15 Camshaft Removal e Remove Cylinder Head Cover see Cylinder Head Cover Re moval Timing Inspection Plug A Balancer Shaft Plug B Special Tool Filler Cap Driver 57001 1454 e First bring the piston to the TDC of either the compres sion or exhaust stroke OPlace a wrench over the balancer weight nut and turn it counterclockwise 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
145. e the top plug wrench special tool A reduce the torque to 90 of the specified value 27 N m 2 8 kgf m 20 ft lb due to the distance 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 6M04254BS1 Adjuster Assembly Inspection e Inspect the adjuster assembly A and push rod B for damage x If 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 e Inspect the threads portion A bushing B and spring C of base valve assembly D for damage lf they are damaged replace base valve assembly with new one e Replace the O rings E with new ones 13 24 SUSPENSION Front Fork KX450D6F D7F Cylinder Unit Inspection e Inspect the piston rod B of cylinder unit A for scratches or bending x If it has scratches or is bent replace cylinder unit with a new one Inner Tube Inspection e Visually inspect the inner tube A repair any damage e Nick or rust damage can sometimes be repaired by using a wet stone to remove sharp edges or raised areas which cause seal
146. e will cause deterioration of the rubber parts Oil spilled on any part will be diffi cult to wash off completely and will eventually dete riorate the rubber used in the disc brake 7 When handing 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 satisfacto rily 8 Brake fluid quickly ruins painted surfaces any spilled fluid should be completely wiped up imme diately 9 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 DOT3 or DOT4 Rear DOT4 2 38 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 the screws A reservoir cap B and diaphragm C e Remove the rubber cap A on the bleed valve B e Attach a clear plastic hose A to the bleed valve on the caliper and run the other end of the hose into a container B 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
147. ead Steering Stem KX450D7F Tighten the two clamp bolts alternately two times to ensure even tightening torque Apply a non permanent locking agent to the threads Replacement Parts 13 6 SUSPENSION Exploded View SUSPENSION 13 7 Exploded View eO e ene C Nm Lee feb sopresa a Po fre Rocker Arm Pivot Nut KX450D6F 61 Rocker Arm Pivot Nut KX450D7F a 43 3 Tie rod Mounting Nut Front Rear KX450D6F 83 8 5 61 Tie rod Mounting Nut Front Rear KX450D7F 59 6 0 43 4 Rear Shock Absorber Mounting Nut Upper 39 4 0 29 5 Rear Shock Absorber Mounting Nut Lower 34 3 5 25 6 Air Bleed Bolt 6 4 0 65 56 in lb 7 8 Swingarm Pivot Shaft Swingarm 9 Rocker Arm 10 Tie Rod 11 Rear Shock Absorber Cylinder 12 O ring 13 Bladder 14 Cap 15 Circlip 16 Valve Cap 17 Locknut 18 Adjusting Nut 19 Spring 20 Spring Guides 21 Circlip 22 Piston Rod Assembly 23 Piston 24 O ring 25 Oil Seal 26 Stopper 27 Rear Shock Absorber G Apply grease L Apply a non permanent locking agent R Replacement Parts 13 8 SUSPENSION Specifications Item Standard Service Limit Front Fork Air Pressure Rebound Damping Adjustment from the seated position adjuster turned fully clockwise Compression Damping Adjustment from the seated position adjuster turned fully clockwise Oil Viscosity Oil Quantity Outer Outer Inner Tube
148. ead of the handlebar holder bolts e Install the handlebar holder upper so that center D of the handlebar holder upper C and handlebar bridge E align Torque Handlebar Holder Bolts 25 N m 2 5 kgf m 18 ft lb Front F e After tighten make sure the gap A B of the front and rear are same width GNO6034BS1 GNOGO36BS1 FRAME 15 1 Frame Table of Contents EXploded WE 15 2 Ile 15 4 Frame Inspection 15 4 Rear Frame REMOVal Luisiana id aN a ae Seca dd H 15 4 Rear Frame Installeten edd nd RARE canne diiniita ida 15 4 Engine Guara Installation ada 15 5 EE o e ege 15 6 SOARES Ah de ia sites 15 6 SEAL MSTAMAOM 2 ges to ebe EE ee ee 15 6 EN EE 15 7 Side Cover Remolino No aad 15 7 ele ee EC UE e Te EE 15 7 A A eh ee 15 8 Front Fender Removal a a a a ds ls 15 8 Rear Fender Removal iii eme en A A ates Poh ERA dot tte tst 15 8 Rear Flap Removal ii 15 8 15 2 FRAME Exploded View 6002286BW5 C Exploded View FRAME 15 3 Torque No Fast R k o astener NS SEN tib emarks Rear Frame Mounting Bolt 3 5 25 EA Upper Footpeg Bracket Bolts 5 5 40 L 3 Front Fender Bolts 4 KX450D6F D7F 4 KX450D8F G Apply grease L Apply a non permanent locking agent R Replacement Parts 15 4 FRAME Frame Frame Inspection e Refer to the Frame Inspection in the Periodic Mainte nance chapter
149. eaner Housing e Using the jack under the frame raise the rear wheel off the ground Special Tool Jack 57001 1238 CAUTION 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 tie rod mounting bolt and nut Front and turn it downward e Remove the rear shock absorber lower mounting bolt A and nut e Remove the rear shock absorber upper mounting bolt B nut and pull out the rear shock absorber C down and out Rear Shock Absorber Installation e Pack the rocker arm needle bearings with grease e Tighten the following Torque Rear Shock Absorber Mounting Nut Upper 39 N m 4 0 kgf m 29 ft lb Rear Shock Absorber Mounting Nut Lower 34 N m 3 5 kgf m 25 ft lb Rear Frame Mounting Bolts 34 N m 3 5 kgf m 25 ft Ib Tie Rod Mounting Nut Front 83 N m 8 5 kgf m 61 ft lb KX450D6F Tie Rod Mounting Nut Front 59 N m 6 0 kgf m 43 ft lb KX450D7F 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 the rear shock absorber see Rear Shock Ab sorber Removal e Clean the threaded portion on the upper of the rear shock absorber e Hold the lower of the rear shock absorber with a vise Rear Shock Absorber SUSPE
150. ebar hard to turn Cable hose wire routing incorrect Steering stem nut too tight Steering stem bearing damaged Steering stem bearing lubrication inade quate Steering stem bent Tire air pressure too low Handlebar 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 bolt 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 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 rear shock absorber spring weak 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 amo mmm BS 2007 mmm kakxas00DA012001 2008 mmm kakxas00DA021001 O T
151. ed surface of the valve e Visually inspect the valve surface x If the surface is damaged replace it e Replace the oil seal C with a new part e Apply a thin coat of molybdenum disulfide grease to the valve stem A before installing the valve e Check to make sure that the valve moves up and down smoothly e Check to make sure that the valve and the valve seat are making proper contact e Install the inner valve spring D and outer valve spring E so that the closed coil end faces the spring seat B e Compress the valve spring to install the split keepers G in order to secure the spring retainer F in place Special Tools Valve Spring Compressor Assembly 57001 241 Valve Spring Compressor Adapter 24 57001 1586 e The shim H must be installed with its thickness indication facing up towards the retainer OApply high temperature grease to the shim or to the retainer to prevent the shim from falling off when the camshaft is being installed e Apply engine oil to the valve lifter I surface then install the lifter d cm ei GE15113BS2 ENGINE TOP END 5 25 Valves 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 CAUTION Do not heat the cylinder head with a torch This will warp the cylinder head Soak the cylinder head and heat the oil e Hamme
152. en the fork top plug subtank A with the top plug wrench B Special Tool Top Plug Wrench 49 mm 57001 1653 B e Remove Cylinder Unit A Spring Seat B Spacer C Washer D Fork Spring E CAUTION Disassembling the cylinder unit can lead to trouble Do not disassemble the cylinder unit e Remove the dust seal A and the retaining ring B CAUTION Be careful not to scratch the inner tube SUSPENSION 13 17 Front Fork KX450D6F D7F 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 e Remove the following parts from the inner tube A Guide Bushes B Washer C Oil Seal D Retaining Ring E Dust Seal e Holding the top plug wrench A with a vise loosen the base assembly B on the subtank C Special Tool Top Plug Wrench 49 mm 57001 1653 e Remove the base valve assembly A from the subtank B NOTE OSlowly compress the piston rod until it stops so that the base valve assembly can be removed easily CAUTION 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 13 18 SUSPENSION Front Fork KX450D6F D7F Front Fork Assembly e When the fork tubes are not disassembled hold the fork inverted position fo
153. enesdatescanenesh tisser teen E AEA 6 22 Kick Shaft Assembly Disassembly Assembly oooooccccccccccccccococoncccncccnnnananan cnc ncnnnnnnnannn nn nnnno 6 23 6 2 ENGINE RIGHT SIDE Exploded View GRO2036BWS C ENGINE RIGHT SIDE 6 3 Exploded View No Fastener Forque Remarks N m kgf m ft lb 1 Primary Gear Nut 98 10 72 Lh 2 Clutch Cover Bolts 9 8 1 0 87 in lb 3 Right Engine Cover Bolts 9 8 1 0 87 in lb 4 Clutch Spring Bolts 8 8 0 90 78 in lb D Clutch Hub Nut 98 10 72 6 Primary Gear 7 Push Rod Holder 8 Release Lever Shaft 9 Clutch Lever 10 Clutch Cable 11 Clutch Hub 12 Clutch Housing Clutch Pressure Plate Friction Plates Number of the lining blocks are many Friction Plates Number of the lining blocks are little Steel Plates KX450D6F D7F Apply cable lubricant Apply engine oil Apply grease Left hand threads Apply molybdenum disulfide grease Apply molybdenum disulfide oil Replacement Parts Apply silicone grease 6 4 ENGINE RIGHT SIDE Exploded View ENGINE RIGHT SIDE 6 5 Exploded View Torque No Fastener SC kaim ftIb Remarks 1 Ratchet Guide Bolt 8 8 0 90 78 in lb L 2 Kick Pedal Bolt 25 2 5 18 L 3 Shift Pedal Bolt 9 8 1 0 87 in lb 4 Ratchet Plate Mounting Bolt 9 8 1 0 87 in lb S 5 Ratchet Plate Mounting Screw KX450D6F 6 4 0 65 56 in lb L S Ratchet Plat
154. engine left side Marks 020 Drive shaft 021 Output shaft e Assembly the crankcase see Crankcase Assembly OFit each shift fork guide pin into the corresponding groove in the shift drum OApply a small amount of engine oil to the shift rods and slide them into the shift forks OAssembly the crankcase see Crankcase Assembly Transmission Shaft Disassembly e Remove the transmission shafts e Remove the circlips washers then gears Special Tool Outside Circlip Pliers 57001 144 e Do not reuse the removed circlips CRANKSHAFT TRANSMISSION 9 19 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 The drive shaft gears can be identified by size the small est diameter gear is 1st gear and the largest is 4th 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 l
155. ent 5 38 5 2 ENGINE TOP END Exploded View ENGINE TOP END 5 3 Exploded View No Fastener E Remarks N m kgf m ft Ib 1 Cylinder Head Cover Bolts 9 8 1 0 87 in lb 2 Cylinder Head Bolts M10 59 6 0 44 S MO 3 Cylinder Head Bolts M6 12 1 2 104 in lb S 4 Cylinder Bolt 12 1 2 104 in lb 5 Camshaft Cap Bolts 9 8 1 0 87 in lb S MO 6 Camshaft Sprocket Bolts 12 1 2 104 in lb L 7 Carburetor Holder Clamp Screws 2 0 0 20 17 in lb 8 Plug 20 2 0 15 L 9 Rear Camshaft Chain Guide Bolt 15 1 5 11 10 Lower Camshaft Chain Guide Bolts 9 8 1 0 87 in lb 11 Chain Tensioner Mounting Bolts 9 8 1 0 87 in lb 12 Chain Tensioner Cap Bolt 5 0 0 51 44 in lb 13 Water Hose Fitting Bolts 9 8 1 0 87 in lb 14 Oil Line Plug 3 0 0 31 27 in lb L 15 Decompressor Plug Plate Bolt 9 8 1 0 87 in lb 16 Closed coil end faces down n I m NANO OO Apply engine oil Apply grease Apply high temperature grease Apply non permanent locking agent Apply molybdenum disulfide grease Apply molybdenum disulfide oil Replacement Parts Follow the specific tightening sequence Apply silicon sealant 5 4 ENGINE TOP END Exploded View ENGINE TOP END 5 5 Exploded View Torque Fastener Nem kgfm ftlb Remarks Exhaust Pipe Cover Bolts 12 1 2 104 ml Exhaust Pipe Holder Nuts 21 2 1 15 Muffler Mounting Bolts 21 2 1 15 Cylinder Bolt 12
156. er measure the resistance between the crankshaft sensor leads and chassis ground x Any tester reading less than infinity indicates a short necessities replacement of the crankshaft sensor assem bly GP10290BS1 GP10276BS1 16 22 ELECTRICAL SYSTEM Throttle Sensor Throttle Sensor Inspection NOTE Olf the variable rheostat is not available refer to throttle sensor output input voltage check in the C D I Unit in spection OWhen inspecting the throttle sensor the throttle valve of the carburetor shall be completely closed and remain the throttle cable connected e Remove the carburetor see Carburetor Removal in the Fuel System chapter e Connect the throttle sensor lead connector A with the battery B variable rheostat C and hand testers D as shown Variable Rheostat Blue Lead Terminal E Hand Tester Yellow Lead terminal F Hand Tester Black Lead terminal G e Check the sensor input voltage Throttle Sensor Input Voltage Standard around 5 V e Check the sensor output voltage with the throttle valve is completely closed Throttle Sensor Output Voltage Standard 0 68 0 1 V when the engine speed is idle x If it is not within the specified voltage adjust the throt tle sensor position see Throttle Sensor Position Adjust ment x If it is within specified voltage go to next test e Check the sensor output voltage with the throttle ful
157. er removed parts Gear Position Switch Inspection NOTE OBe sure the transmission mechanism is good condition e Disconnect the gear position switch lead connector A e Set the hand tester A to the x1 kQ or x100 Q range and connect it to the terminals in the gear position switch lead connector B and ground C Internal Circuit D Green Red Lead E Black Lead Special Tool Hand Tester 57001 1394 Gear Position Switch Resistance Connections Ze D Terminal Ground E Terminal Ground z 3 00 3 32 kQ 11 63 12 87 kQ 2nd 1 70 1 89 KQ 10 33 11 44 KQ 1 07 1 19 KQ 9 70 10 74 KQ 4th 0 695 0 769 KQ 9 32 10 32 kQ x If the tester reading is not as specified replace the gear position switch with a new one GP18318BS1 GP18189BS2 APPENDIX 17 1 Appendix Table of Contents Cable Wire and Hose Routing acciona 17 2 Troubleshooting GUIAS EE 17 8 17 2 APPENDIX Cable Wire and Hose Routing GB09849BW4 C 1 Throttle Cables 6 Clutch Cable 2 Marked AAA cable is accelerator side 7 Clamp Clamp the clutch and hot starter 3 Band Hold the engine stop switch lead cable 4 Engine Stop Switch Lead 8 Clamp Clamp the throttle cables 5 Hot Starter Cable 9 Clamp Clamp the throttle cables Cable Wire and Hose Routing APPENDIX 17 3 GB09442CW4 C 10 11 12 OMNMAOARWND Clutch Cable
158. erpendicular to it as close as possible to the cylinder head mating surface e Move the stem back and forth C to measure the valve wobble 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 Valve Guide Clearance Measurement Wobble Method Standard Exhaust 0 09 0 16 mm 0 0035 0 0063 in Inlet 0 06 0 14 mm 0 0024 0 0055 in Service Limit Exhaust 0 36 mm 0 014 in Inlet 0 33 mm 0 013 in GE15010481 ENGINE TOP END 5 27 Valves 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 Seat Repair Valve Seating Surface Outside Diameter Exhaust 30 4 30 6 mm 1 197 1 205 in Inlet 35 4 35 6 mm 1 39 1 40 in e Check the seating surface width of the valve seat 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 Valve Seating Surface Width Standard Exhaust 0 8 1 2 mm 0 03 0 047 in Inlet 0 5 1 0 mm
159. es to products manufactured previously See your Motorcycle dealer for the latest information on product improvements incorporated after this publication All information contained in this publication is based on the latest product information available at the time of publication Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts O 2005 Kawasaki Heavy Industries Ltd Third Edition 1 Jul 1 2007 K LIST OF ABBREVIATIONS A ampere s Ib pound s ABDC after bottom dead center m meter s AC alternating current min minute s ATDC after top dead center N newton s BBDC before bottom dead center Pa pascal s BDC bottom dead center PS horsepower BTDC before top dead center psi pound s per square inch C degree s Celsius r revolution DC direct current r min rpm revolution s per minute F farad s TDC top dead center F degree s Fahrenheit TIR total indicator reading ft foot feet V volt s g gram s mass W watt s h hour s Q ohm s kg mass kgf force L liter s Foreword 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 understo
160. f both carburetor holder and air cleaner duct fully e Remove Engine Mounting Bracket Bolts B Engine Mounting Bracket C e Remove Seat see Seat Removal in the Frame chapter Side Covers see Side Cover Removal in the Frame chapter Muffler see Muffler Removal in the Engine Top End chapter Rear Frame Bolts A e Pull out the rear frame B with the air cleaner housing and remove the carburetor e Unscrew the hot starter plunger cap bolt A e Remove the hot starter plunger e Unscrew the throttle pulley cover bolt A e Remove the throttle pulley cover B 3 16 FUEL SYSTEM Carburetor e Loosen the throttle cable mounting bolts A e Pull out the end of the throttle cables B e Free the tips C e Remove the carburetor to the right side of the frame e Drain the fuel from the float bowl by removing the drain plug After draining install the drain plug securely e After removing the carburetor push a clean lint free towel into the carburetor holder and the air cleaner duct to keep dirt or other foreign material from entering A WARNING If dirt or dust is allowed to pass through into the carburetor the throttle may become stuck possibly causing an accident CAUTION If dirt gets through into the engine excessive en gine wear and possibly engine damage will occur Carburetor Installation e Install Throttle Cables see Throttle Cable Replacement Hot Starter Plunger se
161. f operating smoothly Olf the piston 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 Front Fork KX450D6F D7F SUSPENSION 13 21 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 collar B and cylinder unit C e Insert above mentioned parts into the fork e Temporarily tighten the fork top plug A subtank using the top plug wrench Special Tool Top Plug Wrench 49 mm 57001 1653 B e Clamp the axle holder with a vise OProtect the axle holder with a rag 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 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 WARNING Be careful of reaction force in spring and fix surely so that special tool should not come off Do not place the fingers etc while serving 13 22 SUSPENSION Front Fork KX450D6F D7F e Insert the push rod A into the piston rod e Replace the O ring and gasket on the adjuster assembly with new ones and apply specified fork oil to the O ring e Slowly turn the adjuster assembly A clockwise until re
162. f the spring guide e When assembling the ratchet gear A onto the kick shaft B align the punch mark C on the ratchet gear with the punch mark C on the kick shaft e Replace the circlips that were removed with new ones Special Tool Outside Circlip Pliers 57001 144 ENGINE LUBRICATION SYSTEM 7 1 Engine Lubrication System Table of Contents Exploded Vi Wei A Aa 7 2 elei En EE 7 4 Specifications cia a A A A A aa 7 6 A A T E ane Tee ra ta sets tete n Ste Pa ts DA 7 7 Engine E Oilkand Oil EE 7 8 Engine Oil Level Inspection EE 7 8 Engine Oil Change suisses ent skere eien ait eih aaa n AANO mn th re ds 7 8 Oil Filter Chang CEET ed ra 7 9 Oil Screen Scavenge Removal s nnen 7 9 Oil Screen Scavenge Installations nan nome sen ed 7 9 Oil Screen Feed Removal insistent di 7 10 Oil Screen Feed Installation eiee fanion Adel Anse 7 10 Oil Screen Scavenge Cleaning e 7 10 Oil Screen Feed Cleaning EE 7 11 Oil Pressure TE 7 12 Oil Pressure Relief Valve Removal see 7 12 Oil Pressure Relief Valve Installation 7 12 Oil Pressure Relief Valve Inspechon 7 12 A E odes ebetsetha T 7 13 Oil Pump Scavenge Remowall cs coin 7 13 Oil Pump REN Ga EE EE 7 13 Oil Pump Feed Removal wie comica Nee de antee dees EEGEN 7 14 Oil Pump Feed Installation Sis tt oeste nee 7 14 Oil
163. first and tighten the bolt e Tighten Torque Ratchet Plate Mounting Screw 6 4 N m 0 65 kgf m 56 in Ib KX450D6F Ratchet Plate Mounting Bolt 15 N m 1 5 kgf m 11 ft lb KX450D7F Ratchet Plate Mounting Bolt 9 8 N m 1 0 kgf m 87 in lb e Install the collar C e Before installing the shift shaft apply high temperature grease to the oil seal lips and shift shaft splines e Insert the shift shaft A e Replace the circlip B with a new one e Install Oil Pump Driven Gear C Circlip Clutch see Clutch Installation Right Engine Cover see Right Engine Cover Installa tion e Install the shift pedal so that the split portion A on the pedal align 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 GRO7018BS1 GRO7020BS1 6 20 ENGINE RIGHT SIDE External Shift Mechanism External Shift Mechanism Inspection 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 mechanism 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 lf the shift lever is damaged in any way replace the shift shaft e Check the ratchet assembly for damage x If ratchet A pawls B pins C or springs D are dam aged in any way
164. g and fix surely so that the special tool should not come off Do not place the finger etc while servicing e Hold the locknut A with a wrench B and remove the adjuster assembly C Front Fork KX450D8F SUSPENSION 13 31 e Remove the push rod A e With the outer tube compressed by hands remove the top plug wrench A CAUTION 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 Loosen the fork top plug subtank A with the top plug wrench B Special Tool Top Plug Wrench 49 mm 57001 1653 B e Remove Cylinder Unit A Spacer B Fork Spring C CAUTION Disassembling the cylinder unit can lead to trouble Do not disassemble the cylinder unit e Remove the dust seal A and the retaining ring B CAUTION Be careful not to scratch the inner tube 13 32 SUSPENSION Front Fork KX450D8F 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 e Remove the following parts from the inner tube A Guide Bushes B Washer C Oil Seal D Retaining Ring E Dust Seal e Holding the top plug wrench 57001 1653 A with a vise loosen the base assembly B using the top plug wrench 57001 1653 C Special Tool Top Plug Wrench 49 mm
165. g 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 GENERAL INFORMATION 1 3 Before Servicing Storage of Removed Parts After all the parts including subassembly parts have been cleaned store the parts in a clean area Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re assembly 65020088 S Inspection Reuse of worn or damaged parts may lead to serious ac cident Visually inspect removed parts for corrosion discol mE 8 oration or other damage Refer to the appropriate sections q ES of this manual for service limits on individual parts Replace YS A the parts if any damage has been found or if the part is be i yond its service limit A 68020048 S Replacement Parts Replacement Parts must be KAWASAKI genuine or rhe es recommended by KAWASAKI Gaskets O rings Oil seals A at Grease seals circlips or cotter pins must be replaced with new ones whenever disassembled 68020108 Assembly Order In most cases assembly order is the reverse of disassem a in bly however if assembly order is provided in this Service PE OS Manual follow the procedures given lt oe
166. grease to the upper and lower outer races e Install the steering stem and adjust the steering see Steering Adjustment 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 If the frame is bent dented cracked or warped replace it GS15024BS1 GS16003BS1 PERIODIC MAINTENANCE 2 71 Periodic Maintenance Procedures 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 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 B Special Tool Spark Plug Wrench 57001 1262 Owner s Tool Spark Plug Wrench 16 mm 92110 0005 e Clean the spark plug preferably in a sandblasting device and then clean off any abrasive particles The plug may also be cleaned using a high flash point solvent and a wire brush or other suitable tool lf the spark plug electrodes are corroded or damaged or if the insulator is cracked replace the plug Use the standard spark plug e Measure the gap A with a wire type thickness gauge x If the gap is incorrect carefu
167. h tighten the adjuster assembly to the specified torque Torque Locknut Adjuster Assembly 29 N m 3 0 kgf m 22 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 a adjuster assembly e Torque the adjuster assembly A Torque Adjuster Assembly 58 N m 5 9 kgf m 43 ft lb e Loosen and remove the fork top plug subtank from the outer tube and slowly slide down the outer tube Special Tool Top Plug Wrench 49 mm 57001 1653 e Pour A the specified amount of fork oil into the outer tube Recommended KHL15 10 KAYABA01 or Oil equivalent Recommended 345 mL 11 7 US oz KX450D6F Quantity EUR 350 mL 11 8 US oz KX450D6F 355 mL 12 0 US oz KX450D7F 2 54 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Raise the outer tube and temporarily tighten the fork top plug subtank Special Tool Top Plug Wrench 49 mm 57001 1653 B e After installing the front fork torque the top plug A Special Tool Top Plug Wrench 49 mm 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
168. h flash point cleaning solution safe for plastic parts Do not use wire or any other hard instrument to clean carburetor parts especially jets as they may be damaged e Immerse all the metal parts in a carburetor cleaning solu tion e Rinse the parts in water e After the parts are cleaned dry them with compressed air e Blow through the air and fuel passages with compressed air A e Assemble the carburetor and install it on the motorcycle Carburetor 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 3 22 FUEL SYSTEM Carburetor e Remove the carburetor see Carburetor Removal e Before disassembling the carburetor check the fuel level see Service Fuel Level Inspection If the fuel level is incorrect inspect the rest of the carbu retor before correcting it e Turn the throttle pulley to check that the throttle valve A moves smoothly and returns by spring pressure x If the throttle valve does not move smoothly Replace the throttle valve or pulley spring e Disassemble the carburetor see Carburetor Disassem bly e Clean the carburetor see Carburetor Cleaning e Check the tapered portion A of the pilot air screw B for wear or damage x If the pilot air scre
169. h 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 OTo make the 55 grind fit a 55 cutter into the holder and slide it into the valve guide OTurn the holder while pressing down lightly OAfter making the 55 grind return to the seat width mea surement step above Correct Width B GE15012181 A GE15012281 GE15012381 5 30 ENGINE TOP END Valves e The seating area should be marked about in the middle of the valve face x If the seat area is not in the right place on the valve check to be sure the valve is the correct part If itis it may have been refaced too much replace it e When the engine is assembled be sure to adjust the valve clearance see Valve Clearance Adjustment in the Peri odic Maintenance chapter ENGINE TOP END 5 31 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 Wid
170. he Periodic Maintenance chap ter 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 in the Periodic Mainte nance chapter 6 10 ENGINE RIGHT SIDE 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 the brake pedal see Brake Pedal Removal in the Brakes chapter e Remove the clutch cover bolts A and remove the clutch cover B Clutch Cover Installation e Replace the clutch cover gasket with a new one e Be sure to install the dowel pins e Apply a non permanent locking agent to the brake pedal bolt e Install the clutch cover A Torque Clutch Cover Bolts B 9 8 N m 1 0 kgf m 87 ft lb Right Engine Cover Bolts C 9 8 N m 1 0 kgf m 87 in lb Brake Pedal Bolt 25 N m 2 5 kgf m 18 ft lb 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 e Remove Kick Pedal A see Kick Pedal Removal Brake Pedal B see Brake Pedal Removal in the Brakes chapter e Remove Engine Guard Water Hose A Right Engine Cover Bolts B Right Engine Cover C Right Engine Cover Installation e Three dowel pins A are installed at the mating surface between the cr
171. he 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 subtank from the outer tube and slowly slide down the outer tube C Special Tool Top Plug Wrench 49 mm 57001 1653 e Place a oil pan under the front fork and drain fork oil A NOTE OPump the fork tube several times to discharge the fork oil 2 56 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Raise the outer tube and temporarily install the fork top plug A subtank to the outer tube B with the top plug C wrench C Special Tool Top Plug Wrench 49 mm 57001 1653 e Hold the axle holder A with a vise OProtect the axle holder with a rag when using a vise e Loosen the adjuster assembly B completely 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 B and locknut C Special Tool Top Plug Wrench 49 mm 57001 1653 WARNING Be careful of reaction force in spring and fix surely so that the special tool should not come off Do not place the finger etc while servicing e Hold the locknut A with a wrench B and remove the adjuster assembly C e Remove the push rod A PERIODIC MAINTENANCE 2 57 Periodic Main
172. he 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 92200 1548 1 0 mm 92200 0045 Release Shaft Lever Position and Adjusting Washer Selection Position Distance Judgment EE 68 6 mm to 76 4 mm Standard 1 5 mm More than 76 4 mm Too big 1 0 mm Less than 68 6 mm Too small 1 0 mm 2 Remove the push rod holder assy as necessary and re install the clutch a ON o a OSDI P Clutch ENGINE RIGHT SIDE 6 15 Clutch Plate Assembly Free Play Inspection Adjust ment e Assemble the following parts Clutch Hub A Friction Plates B Steel Plates C Friction Plates D Spring Plates E Spring F Bolts G OThe friction plates B have many lining blocks than other plates D These plates are installed to both end of the all plates Torque Clutch Spring Bolts 8 8 N m 0 90 kgf m 78 in Ib e Measure the clutch plate assembly H Clutch Plate Length Standard 34 9 35 5 mm 1 37 1 40 in x If clutch plate length is not within the standard select the correct length of steel plates according to the table shown 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 ODo not use the steel plate of 1 2 mm 0 047 in and 2 0 mm 0 079 in thickness at the same tim
173. heck each gear spins or slides freely on the transmission shaft without binding after assembly 9 22 CRANKSHAFT TRANSMISSION Transmission OOO Shift Fork Bending Inspection e Visually inspect the shift forks and replace any fork that is bent A bent fork may 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 19 in Gear Groove Width Standard 5 05 5 15 mm 0 199 0 203 in Service Limit 5 25 mm 0 207 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 of each shift fork guide pin A 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 25 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 th
174. heck the stator coil resistance as follows OStop the engine ODisconnect the auxiliary leads OConnect the hand tester as shown in the table 2 ONote the readings total 2 measurement Table 2 Stator Coil Resistance Se Ee Range Tester to Tester to Red lead White lead 30 600 Green White lead Yellow lead 180 280 Q x If there is more resistance than shown in the table or no hand 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 hand tester measure the resistance between each leads and chas sis ground Any hand tester reading less than infinity indicates a short necessitating stator replacement x If the stator coils have 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 Special Tool Hand Tester 57001 1394 Ignition Timing ELECTRICAL SYSTEM 16 13 Ignition Timing Inspection e Remove the timing inspection plug 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 ignition timing mark B on the flywheel e Run the engine at the speeds spec
175. his digit in the frame number changes from one machine to another BE amp Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Consumer Products amp Machinery Company Part No 99924 1355 03 Printed in Japan
176. 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 GRO5038BS1 GRO5033BS1 ENGINE RIGHT SIDE 6 17 Primary Gear Primary Gear Removal e Remove Right Engine Cover Clutch see Clutch Removal e Temporarily install the clutch housing A e Using the gear holder B secure the primary gear Special Tool Gear Holder m2 0 57001 1557 e Remove the clutch housing e Remove the primary gear nut C washer primary gear D and oil pump drive gear OPrimary gear nut is left hand threads Primary Gear Installation e Apply high temperature grease to the oil seal lip e Insert the oil pump drive gear A and primary gear B to the crankshaft e Install the washer C as shown e Temporarily install the clutch housing e Using the gear holder A secure the clutch gear and the bottom of the primary gear then tighten the primary gear nut B OPrimary gear nut is left hand threads Torque Primary Gear Nut 98 N m 10 kgf m 72 ft lb Special Tool Gear Holder m2 0 57001 1557 e Install Clutch see Clutch Installation Right Engine Cover see Right Engine Cover Installa tion GROGOO7BS1 6 18 ENGINE RIGHT SIDE External Shift Mechanism External Shift Mechanism Removal e Remove Shift Pedal Bolt
177. ial Tool Steering Stem Nut Wrench 57001 1100 Spring Preload Adjustment Adjusting nut position at the lower surface A from the center of the mounting hole Standard 127 5 mm 5 020 in KX450D6F D7F 128 5 mm 5 059 in KX450D8F Adjustable 121 5 138 5 mm 4 783 5 453 in Range KX450D6F D8F 122 1 131 6 mm 4 807 5 181 in KX450D7F e Tighten the locknut securely e After adjusting move the spring up and down to make sure that the spring is seated e Install the parts removed e Tighten the rear frame mounting bolts Torque Rear Frame Mounting Bolts 34 N m 3 5 kgf m 25 ft Ib Spring Tension Inspection e Since the spring becomes shorter as it weakens check its free length A to determine its condition x If the spring of either rear shock absorber is shorter than the service limit it must be replaced If the length of re placement spring and that of the remaining spring vary greatly the remaing spring should also be replaced in or der to keep the rear shock absorbers balanced of motor cycle stability Shock Absorber Spring Free Length Standard 260 mm 10 2 in Service Limit 255 mm 10 0 in GM040116S1 13 44 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 see Muffler Removal in the Engine Top End chapter Rear Frame with Air Cl
178. ice Limit 0 06 mm 0 002 in x If the radial clearance exceeds the service limit crank 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 Measure the connecting rod big end side clearance A Connecting Rod Big End Side Clearance Standard 0 25 0 35 mm 0 0098 0 014 in Service Limit 0 6 mm 0 02 in x If the clearance exceeds the service limit replace the crankshaft assembly 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 Standard TIR 0 03 mm 0 0012 in or less Service Limit TIR 0 08 mm 0 0031 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 8 5 mm 0 33 in A 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 G105134BS1 G105135BS1 G105136BS1 9 16 CRANKSHAFT TRANSMISSION Crankshaft
179. ified and note the align ment of the ignition timing marks OCheck the engine speed using the engine revolution tester A for high accuracy Ignition Timing Engine speed r min rpm Hole groove aligns with 1 800 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 are normal check the C D I unit see C D I Unit Inspection e Install the timing inspection plug 16 14 ELECTRICAL SYSTEM Ignition System Safety Instructions The ignition system produces extremely high volt age Do not touch the spark plug ignition coil or high tension lead while the engine is running or you could receive a severe electrical shock Ignition Coil Removal e Remove Fuel Tank Fuel Tank Removal in the Fuel System chap ter Bolt A Left Radiator Screen B Left Radiator Mounting Bolts C e Push the left radiator forward D e Pry open the clamps A e Disconnect the ignition coil primary lead connector A e Pull the plug cap off the spark plug e Unscrew the mounting bolts B and remove the ignition coil C Ignition Coil Installation e Ignition coil installation is the reverse of removal Torque Ignition Coil Bolts 7 0 N m 0 71 kgf m 62 in Ib Ignition System ELECTRICAL SYSTEM 16 15 Ignition Coil Inspection Measuring arcing distance The most accurate test for de
180. imit Wheels Rims Axial Radial Rim Size Front Rear Rim Runout with tire installted Axle Runout 100 mm 3 94 in TIR 1 0 mm 0 039 in or less TIR 1 0 mm 0 039 in or less TIR 0 1 mm 0 004 in or less 21 x 1 60 19 x 2 15 TIR 2 mm 0 08 in TIR 2 mm 0 08 in TIR 0 2 mm 0 008 in Tires Air Pressure Front and Rear 100 kPa 1 0 kgf cm 14 psi Tires Standard Tire Front Size Make Type Rear Size Make Type 90 100 21 57M DUNLOP D742F Tube 120 80 19 63M DUNLOP D756 Tube Special Tools Inside Circlip Pliers 57001 143 Rim Protector 57001 1063 ST5701438T ST5710638T Bead Breaker Assembly 57001 1072 T5710728T WHEELS TIRES 10 5 Bearing Driver Set 57001 1129 ST5711298T Jack 57001 1238 ST5712388ST 10 6 WHEELS TIRES Wheels Rims Front Wheel Removal e Using the jack A under the frame and stabilize the mo torcycle Special Tool Jack 57001 1238 e Apply the rear brake to rear wheel so that it does not turn e Unscrew the axle nut A e Loosen the left and right axle camp bolts B e Place a commercially available jack under the engine to raise the front wheel off the ground e Remove the axle C and pull out the wheel Take off the collars and caps D from each side of the front hub CAUTION Do not lay the wheel on the ground with the disc facing dow
181. imit TIR 0 3 mm 0 01 in GLO8024BS1 GLO8025BS1 12 20 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 13 41 Specifications 13 8 Rebound Damping Adjustment 13 41 Special Tools 13 10 Compression Damping Front Fork KX450D6F D7F 13 11 Adjustment 13 41 Air Pressure x ions de 13 11 Spring Preload Adjustment 13 42 Rebound Damping Adjustment 13 11 Spring Tension Inspection 13 43 Compression Damping Rear Shock Absorber Removal 13 44 Adjustment 13 12 Rear Shock Absorber Installation 13 44 Oil Change each fork leg 13 12 Spring Replacement 13 44 Front Fork Removal 13 12 Rear Shock Absorber Front Fork Installation 13 13 Disassembly Oil Change 13 45 Front Fork Disassembly each Rear Shock Absorber Assembly 13 45 A 13 14 Rear Shock Absorber Scrapping 13 45 Front Fork Assemblv 13 18 EE 13 46 Adjuster Assembly Inspection 13 23 Swingarm Removal 13 46 Base Valve Assem
182. ing 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 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 system operation OMeasure coil and winding resistance when the part is cold at room temperature OElectrical Connectors Connectors A Connectors B Safety Instructions A WARNING The ignition system produces extremely high volt age Do not touch the spark plug ignition coil or high tension lead while the engine is running or you could receive a severe electrical shock GPO60101S1 GPO06010281 16 8 ELECTRICAL SYSTEM Electrical Wiring 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
183. ing to the engine there are two general types of carbure tor trouble too rich a mixture too much fuel and too lean a mixture too little fuel Such trouble can be caused by dirt wear maladjustment or improper fuel level in the float chamber A dirty or damaged air cleaner can also alter the fuel to air ratio Idle Speed Inspection e Refer to the Idle Speed Inspection in the Periodic Main tenance chapter Idle Speed Adjustment e Refer to the Idle Speed Adjustment in the Periodic Main tenance chapter Service Fuel Level Inspection 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 e Turn the fuel tap to the OFF position e Remove the fuel tank e Remove the carburetor and hold it in true vertical position on a stand The fuel hose and carburetor cable do not have to be removed to inspect the fuel level e Put the fuel tank on a bench and connect the fuel tap to the carburetor using a suitable hose e Remove the drain plug from the bottom of the float bowl and screw a fuel level gauge A into the plug hole Special Tools Fuel Level Gauge 57001 122 e Hold the gauge vertically against the side of the carbure tor body so that the zero line B is several millimeters higher than the bottom edg
184. iodic Maintenance chapter Fuel Tap and Filter Inspection e Refer to the Fuel Tap and Filter Inspection in the Periodic Maintenance chapter COOLING SYSTEM 4 1 Cooling System Table of Contents Exploded EE 4 2 MPSCINGALIONS EE 4 4 Special Tool aun A nn ds A AA A AE 4 5 A A O NT 4 6 Coolant Level Inspection aaa eiii 4 6 Coolant Deterioration Inspechon 4 6 Coolant Draining EE 4 6 COO ANI A 4 7 Air Ee Le ME 4 7 Cooling System Pressure Testing TEE 4 8 Cooling System FUSIL ple 4 8 Water PUMP EE 4 9 Water Pump Cover Removal ooooooooococooooooocconcnonnnnnnnnnnnononnnnonnnnnnnonnnnnnnonnnnnn non nnrnnnnnnnrnnnnnnnns 4 9 Water Pump Cover Installation sise 4 9 Impeller Hemoval seen 4 10 Impeller Installato M mrien a a ls 4 10 Water Pump Inspection 4 10 Oil Seal and Bearing ne EE 4 10 BIR UN EE ue WT 4 11 Radiador RE iosashanh ieee diawsuama se ined a Matheedendeas 4 12 Radiator REMOVAl EE 4 12 Radiator Installation 4 13 Radiator le Dee BEE 4 13 Radiator Cap Inspection ss 4 13 Filler Neck Inspection eege dee a A A at da ds 4 14 Water Hoses Breather Hose Jnspechon ss 4 14 Water Hoses Breather Hose Installation nino nanaconacinnanas 4 14 4 2 COOLING SYSTEM Exploded View ON S Exploded View COOLING SYSTEM 4 3 Fastener N m Torque kgf m ft lb Remarks Water Pump Cover Bolts 9 8 1 0 87 in lb Coolant Drain Bolt 6 9 0 70 61 in lb 2 3 Water Pu
185. ion stop oil flow causing engine seizure e Replace the oil filter cover O ring A with a new one e Replace the oil filter with a new one e Apply grease to the O rings e Install the oil filter cover Torque Oil Filter Cover Bolt 9 8 N m 1 0 kgf m 87 in lb e Pour in the specified type and amount of oil see Engine Oil Change Breather Hose Inspection e Be certain that the breather hose are routed without being flattened or kinked and is connected correctly x If it is not correct it e Inspect the breather hose A for damage or sings of de terioration OThis hose should not be hard and brittle nor should be soft swollen x Replace it if any cracks or swelling is noticed PERIODIC MAINTENANCE 2 29 Periodic Maintenance Procedures Crankshaft Transmission Crankshaft Inspection Connecting Rod Big End Side Clearance e Remove the cylinder head see Cylinder Head Removal in the Engine Top End chapter e Remove the cylinder see Cylinder Removal in the Engine Top End chapter e Remove the piston see Piston Removal in the Engine Top End chapter 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 0 014 in Service Limit 0 6 mm 0 02 in x If the clearance exceeds the service limit replace the crankshaft assembly e Make sure that the crankshaft rotates smoo
186. ipe Outer Race Driver 651 5 57001 1076 C e Replace the lower inner races with new ones OApply grease to the lower tapered roller bearing A and drive it onto the stem using 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 inner race and install it in the head pipe e Install the stem through the head pipe and upper bearing install the stem cap and hand tighten the stem nut while pushing up on 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 stem nut to the specified torque hook the wrench A on the stem nut and pull the wrench at the hole by 22 2 kg 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 GN05040281 GN04012BS1 o 6N05060581 o
187. ipper A on the swingarm B and replace it if worn or damaged SUSPENSION 13 49 Tie Rod Rocker Arm Tie Rod Removal e Using the jack under the frame raise the rear wheel off the ground Special Tool Jack 57001 1238 e Unscrew the nut A and remove the guide roller B CAUTION 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 tie rod rear mounting bolt A e Remove the tie rod front mounting bolt B and then take off the tie rod C Tie Rod Installation e Apply plenty of grease to the inside of the oil seals e Tighten the tie rod front and rear mounting nuts Torque Tie Rod Mounting Nuts 83 N m 8 5 kgf m 61 ft 1b KX450D6F Tie Rod Mounting Nuts 59 N m 6 0 kgf m 43 ft Ib KX450D7F Rocker Arm Removal e Using the jack under the frame raise the rear wheel off the ground Special Tool Jack 57001 1238 CAUTION When pulling out the mounting bolts lift the rear wheel slightly Forcing or tapping on bolt could damage the bolt sleeve and bearing e Remove the rear shock absorber lower mounting bolt A e Remove the tie rod rear mounting bolt B e Remove the rocker arm pivot bolt C e Remove the rocker arm D 13 50 SUSPENSION Tie Rod Rocker Arm Rocker Arm Installation e Apply plenty of grease to the inside of the rocker arm needle bearings
188. is within the spec ified range Original Seating Surface B ORemove all pittings of flaws from 45 ground surface OAlter grinding with 45 cutter apply thin coat of machin ists dye to 45 A seating surface This makes seating surface distinct and 32 and 55 grinding operation eas ier 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 is too large make the 32 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 B until the seat O D is within the specified range OTo make the 32 grind fit a 32 cutter into the holder and slide it into the valve guide OTurn the holder one turn at a time while pressing down very lightly Check the seat after each turn CAUTION 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 O D mea surement 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 O D measurement step above x If the seat widt
189. istance Primary Winding Resistance Secondary Winding Resistance Spark Plug Type Gap C D I Unit Throttle Sensor Input Voltage Output Voltage when the Throttle Valve Completely Closed when the Throttle Fully Opened 10 BTDC 1 800 r min rpm 7 mm 0 26 in or more 0 28 0 38 Q at 20 C 68 F 7 65 10 35 kQ at 20 C 68 F NGK CPR8EB 9 0 8 0 9 mm 0 03 0 04 in in the text around 5 V 0 58 0 78 V 3 5 3 7 V Special Tools and Sealant Timing Light 57001 1241 Spark Plug Wrench Hex 16 57001 1262 ST5712418ST ST5712628ST Hand Tester 57001 1394 ST5713948T Throttle Sensor Setting Adapter 1 57001 1400 Peak Voltage Adapter 57001 1415 ST5714008T ST5714158T ELECTRICAL SYSTEM 16 5 Filler Cap Driver 57001 1454 ST5714548T Needle Adapter Set 57001 1457 ST571457ST C Rotor Puller 57001 1565 Az Rotor Holder 57001 1654 ST5715658T ST5716548T Kawasaki Bond Silicone Sealant 92104 0004 ST9200048T 16 6 ELECTRICAL SYSTEM Wiring Diagram Engine Stop Switch BK N R G W BK Y a gt as Se a gt S welt H E dh get 7 7 Throttle Gear SE Ground Sensor Position Ve Sensor GP05097BW3 C Precautions ELECTRICAL SYSTEM 16 7 There are numbers of important precautions that are musts when servic
190. iston ring close to the bottom of the cylinder where cylinder wear is minimal e Measure the gap B between the ends of the ring using a thickness gauge x If the ring end gap exceeds the service limit replace the ring Piston Ring End Gap Standard Top 0 25 0 35 mm 0 0098 0 014 in Oil 0 15 0 50 mm 0 0059 0 020 in Service Limit Top 0 6 mm 0 02 in Oil 0 8 mm 0 03 in GE16055BS1 5 36 ENGINE TOP END Cylinder and Piston Piston Piston Pin Connecting Rod Wear Inspection e Visually inspect the snap ring A still fitted in place x lf the ring shows weakness or deformation replace 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 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 of piston pin holes C in the piston and the inside diameter of the connecting rod small end D x 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 Piston Pin Diameter Standard 18 991 19 000 mm 0 74768 0 74803 in Service Limit 18 95 mm 0 7461 in Piston Pin Hole Diameter Standard 19 004 19 010 mm 0 74819 0 74842 in Service Limit 19 08 mm 0 7512 in
191. ition 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 Breather Hose Inspection e Refer to the Water Hoses and Connections Inspection in the Periodic Maintenance chapter Water Hoses Breather Hose Installation e Install the water hoses or breather 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 1 5 N m 0 15 kgf m 13 in Ib 6D07001BS1 ENGINE TOP END 5 1 Engine Top End Table of Contents Exploded View 5 2 Valve Installation 5 24 Specifications ccceeeeeeceeeeeeeeeeees 5 6 Valve Guide Removal 5 25 Special Tools and Sealant 5 9 Valve Guide Installation 5 25 Cylinder Head Cover 5 12 Valve Valve Guide Clearance Cylinder Head Cover Removal 5 12 Measurement Wobble Method 5 26 Cylinder Head Cover Installation 5 12 Valve Seat Inspection 5 27 Camshaft Chain Tensioner 5 13 Valve Seat Repair 5 27 Camshaft Chain Tensioner Cylinder and Piston 5 32 R moval ss haha 5 13 Cylinder Removal 5 32 Camshaft Chain Tensioner Pi
192. jig C e Tighten the crankcase bolts starting with the periphery of the crankshaft then outward e Replace the copper washer installed to the bolt B with a new one OTighten the bolt A with the clamp and the bolt B with the copper washer Torque Crankcase Bolts M6 12 N m 1 2 kgf m 104 in Ib Crankcase Bolts M7 15 N m 1 5 kgf m 11 ft Ib 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 driveshaft and the output shaft rotate smoothy in the neutral position x lf the crankshaft will not turn probably the crankshaft is not centered tap the appropriate end of the crankshaft with a mallet A to reposition it e Install the gear set lever A OFit each end B of the spring to original positions ODo not forget to install the collar and washer C e Tighten the gear set lever nut D Torque Gear Set Lever Nut 8 8 N m 0 90 kgf m 78 in Ib CRANKSHAFT TRANSMISSION 9 13 Crankcase e To install the shift drum cam A use the driver B to bring the gear set lever C to the bottom of the crankcase e Mate the shift drum pin D into the shift drum hole OFit the groove E of the shift drum cam on the shift drum pin e Apply non permanent locking agent to the shift drum cam bolt and tighten it Torque Shift Drum Cam Bolt 24 N m 2 4 kgf m 17 ft lb
193. k performance GMO5066BS1 e Apply grease to the lip B of the bladder and install the reservoir cap C e Push the bladder into the gas reservoir slowly until it just clears the circlip groove Wipe out any spilled oil CAUTION Ensure that no air remains in the system e Check the circlip for weakening deformity and flaws x If necessary replace it with a new one CAUTION If weakened deformed or flawed circlip is used the gas reservoir cap may not hold when injecting the nitrogen gas This would allow oil and internal parts to explode out of the reservoir 2 66 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Mount the circlip A in the groove in the gas reservoir e Pull up the gas reservoir cap A against the circlip The end of the gas reservoir cap must align B with the end of the gas reservoir C WARNING If the end of the gas reservoir cap and the end of the gas reservoir are not aligned the circlip is not correctly fitting in the groove in the gas reservoir or is deformed In this case the oil and internal parts could explode out of the reservoir when injecting the nitrogen gas or while riding the motorcycle e Pour KYB K2 C SAE 5W or Bel Ray SE2 40 oil into the rear shock body to 55 mm 1 77 in A from the lower end of the rear shock body B Recommended Oil K2 C KAYABA or equivalent e Insert the piston end A of the piston rod assembly into
194. l hose B e Unscrew the screw A e Pull out the fuel hose fitting B e Unscrew the carburetor cap bolts A e Remove the carburetor cap B e Unscrew the throttle valve link screw A e Pull out the throttle valve assembly B 3 18 FUEL SYSTEM Carburetor e Disassemble the throttle valve assembly jet needle holder A unscrew spring B retainer C jet needle with circlip D O ring with throttle valve plate E and throttle valve F e Remove the choke knob starter plunger assembly A from the carburetor e Remove the throttle pulley shaft A with the spring B steel washer C plastic washer D and throttle valve link E OTurn the throttle pulley shaft A clockwise while holding down the acceleration pump lever B and clear the idle stop screw C to the stopper D of the pulley e Turn in the pilot air screw A fully but not tightly and count the number of turns ORecord this number as the manufacture set number of turns out to put back to the original position e Unscrew the pilot air screw FUEL SYSTEM 3 19 Carburetor e Unscrew the screws A e Remove the acceleration pump cover B from the carbu retor e Remove the spring A diaphragm B and the O rings C e Remove the following parts from the carburetor body A Idle Adjusting Screw B Screws C Clamps D Float Bowl E Leak Jet F O ring G Pin H Float I Main Jet J Need
195. l the drain bolts and refill with the specified amount of oil Olf the motorcycle has just been used wait several min utes for all the oil to drain down 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 CAUTION 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 Oil Filter Change e Refer to the Oil Filter Change in the Periodic Maintenance chapter Oil Screen Scavenge Removal e Remove the oil pump scavenge cover see Oil Pump Scavenge Cover Removal e Pull out the oil screen A from the crankcase Oil Screen Scavenge Installation
196. l to find the position where the chain is tightest e Measure the space chain slack A between the chain and the swingarm at the rear of the chain slipper as shown x If the drive chain slack exceeds the standard adjust it Chain Slack Standard 52 58 mm 2 0 2 3 in Drive Chain Slack Adjustment e Loosen the left and right chain adjuster locknuts A e Remove the cotter pin B and loosen the axle nut C x lf 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 lf 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 Check the wheel alignment A WARNING Misalignment of the wheel result in abnormal wear and may result in an unsafe riding condition e Tighten both chain adjuster locknuts securely e Tighten the axle nut Torque Rear Axle Nut 108 N m 11 kgf m 80 ft Ib e Rotate the wheel measure the chain slack again at the tightest position and readjust if necessary e Install a new cotter pin A through the axle nut and axle and spread its ends GKO4001BS1 PERIODIC MAINTENANCE 2 33 Periodic Maintenance Procedures NOTE OWhen inserting the cotte
197. lace the head cover gasket e Install the head cover gasket A on the cylinder head e Install the spark plug hole gasket e Make sure that the upper chain guide A is bottomed CAUTION Unless the upper chain guide is bottomed the camshaft chain could push the cylinder head cover upward leading to an oil leak e Install the head cover from the motorcycle left side e Install the head cover bolt washers A with the metal side upwards e Tighten the cover bolt B Torque Cylinder Head Cover Bolt 9 8 N m 1 0 kgf m 87 in 1b e Install the spark plug cap OPull up the spark plug cap lightly to make sure of the in stallation of the spark plug cap ENGINE TOP END 5 13 Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION 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 Remov
198. lamps B Caliper Cover C e When installing the hoses avoid sharp bending kinking flattening or twisting and route the hoses according to Cable Wire and Hose Routing section in the Appendix chapter e Tighten the banjo bolts on the hose fittings Torque Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft Ib e Fill the brake line after installing the brake hose see Brake Fluid Changing Suspension Front Fork Inspection e Holding the brake lever pump the front fork back and forth manually to check for smooth operation e Visually inspect the front fork for oil leakage scoring or scratches on the outer surface of the inner tube A x If necessary repair any damage e Nick or rust damage can sometimes be repaired by using a wet stone to remove sharp edges or raised areas which cause seal damage lf the damage is not repairable replace the inner tube Since damage to the inner tube damages the oil seal replace the oil seal whenever the inner tube is repaired or replaced e f the fork is not smooth confirm the cause CAUTION 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 KX450D6F D7F e Loosen the front fork upper clamp bolts A csta8777 P 2 46 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Loosen the fork top plug A Special Tool Top Plug W
199. le Jet K Starter Jet L Pilot Jet M Pilot Air Jet e Pull out the push rod A of the acceleration pump 3 20 FUEL SYSTEM Carburetor e Unscrew the leak jet A e Remove E clip A Washer B e Pull out the acceleration pump lever assembly C as a set e Remove the throttle sensor mounting bolt A e Before removing the throttle sensor B mark C the car buretor body and sensor so that it can be installed later in the same position FUEL SYSTEM 3 21 Carburetor Carburetor Cleaning WARNING Clean the carburetor in a well ventilated area and take care that there is no spark or flame anywhere near the working area this includes any appliance with a pilot light Because of the danger of highly flammable liquids do not use gasoline or low flash point solvent to clean the carburetor e Make sure the fuel tap is in the OFF position e Remove the carburetor see Carburetor Removal e Drain the fuel in the carburetor e Disassemble the carburetor see Carburetor Disassem bly CAUTION Do not use compressed air on an assembled carbu retor the float may be deformed by the pressure Remove as many rubber or plastic parts from the carburetor as possible before cleaning the carbu retor with a cleaning solution This will prevent damage or deterioration of the parts Do not use a strong carburetor cleaning solution which could at tack the plastic parts instead use a mild hig
200. 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 e Fill the cooling system with fresh water mixed with a flush ing compound CAUTION Avoid the use of a flushing compound which is harmful to the aluminum engine and radiator 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 ten 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 Water Pump COOLING SYSTEM 4 9 Water Pump Cover Removal e Unscrew the drain bolt A and drain the coolant see Coolant Draining e Loosen the clamp screw B and remove the water hose C from the water pump cover e Unscrew the cover bolts D 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 dowel pins B are in place in the mating surfaces of
201. linder 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 between the straightedge and the head If warp exceeds the service limit repair the mating sur face Replace the cylinder head if the mating surface is badly damaged Cylinder Head Warp Service Limit 0 05 mm 0 002 in 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 PERIODIC MAINTENANCE 2 23 Periodic Maintenance Procedures Cylinder Wear Inspection NOTE OMeasure the cylinder inside diameter when the cylinder is cold room or ambient temperature e 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 Since there is a difference in cylinder wear in different di SE rections take a side to side and a front to back measure ment shown in the figure lf any of the cylinder inside diameter measurements ex ceeds the service limit the cylinder mu
202. liper D see Front Caliper Removal in the Brakes chapter Brake Pads see Brake Pad Removal in the Brakes chapter e Separate the caliper holder A from the caliper B and remove the anti rattle spring 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 To avoid serious injury never place your fingers or palm in front of the piston If you apply compressed air into the caliper the piston may crush your hand or fingers OPull out the piston A by hand e Remove the dust seals B and fluid seals C NOTE Olf compressed air is not available do as follows for both calipers coincidentally 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 and then disassemble the caliper 2 42 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Remove the rear caliper see Caliper Removal in the Brakes chapter e Remove the pads see Brake Pad Removal in the Brakes chapter e Separate the caliper holder B from the caliper A e Using compressed air remove the piston OCover the caliper
203. lly 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 Torque Spark Plug 13 N m 1 3 kgf m 113 in Ib SDS WK e Fit the plug cap securely OPull the spark plug cap A to make sure the installation of the spark plug cap Spark Plug Replacement e Refer to the Spark Plug Cleaning and Inspection 2 72 PERIODIC MAINTENANCE Periodic Maintenance Procedures General Lubrication and Cable Inspection General 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 Hot Starter Inner Cable Upper End Throttle Inner Cable Upper End Brake Lever Pivot Bolt Clutch Lever Pivot Bolt Brake Pedal Mounting Bolt Cables Lubricate with Rust Inhibitor Throttle Inner Cables Clutch Inner Cable Hot Starter Inner Cable Pivot Lubricate with Engine Oil Hot Starter Lever Rear Master Cylinder Joint Pin 6004010151 6004011481 PERIODIC MAINTENANCE 2 73 Periodic Maintenance Procedures Cable Inspection e With the ca
204. ly opened Throttle sensor Output Voltage Standard 3 5 3 7 V When throttle fully opened x If it is not within the specified voltage replace the sensor GP25003BS2 C Throttle Sensor ELECTRICAL SYSTEM 16 23 Throttle Sensor Position Adjustment e Remove the carburetor see Carburetor Removal in the Fuel System chapter e Measure the resistance between the blue and black lead terminals of the sensor side connector Blue Lead Terminal A Black Lead Terminal B Yellow Lead Terminal C Hand Tester D Special Tool Hand Tester 57001 1394 e Calculated the throttle sensor resistance at idle speed us ing the equation 0 58 0 78 V A x B 5 V A Blue and Black lead terminal resistance B Throttle sensor resistance at idle speed Example elf the blue and black lead terminals resistance is 5 KQ then the throttle sensor resistance at idle speed is 0 58 0 78 V 5kQ x 580 7800 5V e Adjust the throttle sensor position so the resistance be tween yellow and black lead terminals is as calculated example 580 780 Q e Loosen the throttle sensor mounting bolt A e Adjust the position of the sensor B until the resistance is within the specified resistance range x If it is not within the specified resistance range replace the sensor e Install the carburetor see carburetor Installation in the Fuel System chapter e Start the engine and warm it up thoroughl
205. m I ek L of SES A AM ET ET kcal E al E e E GM07035BW2 C Needle Bearing Inspection x If there is any doubt as to the condition of either needle bearing replace the bearing and sleeve as a set 13 52 SUSPENSION Uni Trak Maintenance Uni Trak Linkage Inspection e Refer to the 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 x If the sleeve is worn past the service limit replace the sleeve Sleeve Outside Diameter Standard Tie rod 19 987 20 000 mm 0 7888 0 78740 in Rocker Arm Large 19 987 20 000 mm 0 78688 0 78740 in Small 15 950 16 000 mm 0 62795 0 62992 in Service Limit Tie rod 19 85 mm 0 781 in Rocker Arm Large 19 85 mm 0 781 in Small 15 92 mm 0 627 in 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 bolt at a point halfway between the blocks Turn A the bolt to measure the runout The amount of dial variation is the amount of runout If runout exceeds the service limit replace the bolt Bolt Runout Standard TIR 0 1 mm 0 004 in or less Service Limit TIR 0 2 mm 0 008 in GMO7036BS1
206. m disulfide grease to the cam and jour nal surfaces e First bring the crankshaft to the TDC of either the com pression or exhaust stroke OPlace a wrench over the balancer weight nut and turn it counterclockwise to align the TDC mark A with the center of the groove B of the inspection hole GE11151BS1 ENGINE TOP END 5 17 Camshaft e Engage the camshaft chain with the camshaft sprockets OPull the tension side exhaust side of the chain taut to install the chain OThe timing marks on the sprocket must be aligned with the cylinder head upper surface e Pull the chain taut and fit it onto the camshaft sprocket e Starting 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 inlet camshaft sprocket 6E111528W2 1st Pin A Mark exhaust D 2nd Pin B Punch Mark inlet E 29th Pin C Upper Cylinder Head Surface F 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 5 18 ENGINE TOP END Camshaft e Apply grease to the rubber portions of the oil pipes e Assemble Camshaft Caps A Oil Pipes B e While keeping the camshaft caps parallel install them e Uniformly tighten all bolts and after the camshaft has set
207. mage 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 If a spring is damaged replace it J Front Master Cylinder K Rear Master Cylinder GLO7021B S Gs GLO7022B S Brake Disk BRAKES 12 19 Brake Disc Inspection e Visually inspect the disc A x If 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 Replace the disc if it has worn past the service limit 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 Torque Brake Disc Mounting Bolts Front 9 8 N m 1 0 kgf m 87 in lb Brake Disc Mounting Bolts Rear 23 N m 2 3 kgf m 17 ft lb e Place a jack under the motorcycle so that the front rear wheel is raised off the ground Special Tool Jack 57001 1238 e Set up a dial gauge against the disc A as illustrated OFor the front disc turn the handlebar fully to one side e Measure the disc runout while rotating the wheel slowly B x If the runout exceeds the service limit replace the disc Runout Standard TIR 0 25 mm 0 098 in or less Service L
208. mover 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 sleeves D grease seals C 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 in ward Special Tool Bearing Driver Set 57001 1129 e Install the needle bearings and grease seals position as shown OThe installation procedure is the same as the counter side mm GMO6121BS1 13 48 SUSPENSION Swingarm Swingarm Bearing Sleeve Inspection CAUTION Do not remove the bearings for inspection Re moval may damage them e Inspect the needle bearings 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 sings of ab normal wear discoloration or damage replace them as a set 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 sl
209. mover 57001 1058 Steering Stem Nut Wrench 57001 1100 Bearing Remover Shaft 9 57001 1265 ST5710588T ST5711008T Hook Wrench R37 5 R42 57001 1101 ST5711018ST Bearing Driver Set 57001 1129 Jack 57001 1238 ST5711298T ST5712388ST Bearing Remover Head 915 x 17 57001 1267 ST5712658T ST571267ST Fork Oil Seal Driver 648 57001 1509 ST5715098T Top Plug Wrench 49 mm 57001 1653 Top Plug Wrench 36 mm 57001 1705 ST571653ST ST571705ST Front Fork KX450D6F D7F SUSPENSION 13 11 Air Pressure The standard air pressure in the front fork legs is atmo spheric pressure Air pressure in the fork legs increase with normal use so the fork action stiffens during opera tion Release air pressure form the fork legs prior to each race through the pressure relief screw located in each front fork cap e Place the jack under the frame so that the front wheel off the ground Special Tool Jack 57001 1238 e Remove the screws A at the top of the front fork top plugs to let the air pressure equalize 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 Rebound Damping Adjustment e Place the jack under the frame so tha
210. mp Impeller Bolt 9 8 1 0 87 in lb Right Engine Cover Bolts 98 1 0 87 in lb Water Hose Clamp Screws 1 5 0 15 13 in lb 5 6 8 Radiator Mounting Bolts Radiator Shroud Bolts Radiator Screen Bolts 9 8 9 8 9 8 1 0 87 in lb 1 87 in lb 0 1 0 87 in lb Water Pump Cover Impeller Right Engine Cover Right Radiator Left Radiator Radiator Cap Radiator Overflow Hose Apply grease Replacement Parts 4 4 COOLING SYSTEM Specifications Item Service Limit Coolant Type Permanent type antifreeze for aluminum engines and radiators Color Green Mixed Ratio Soft water 50 antifreeze 50 Freezing Point Total Amount 35 C 31 F 1 05 L 1 11 US at Radiator Cap Relief Pressure 112 142 kPa 1 14 1 45 kgf cm 16 2 20 6 psi COOLING SYSTEM 4 5 Special Tool Bearing Driver Set 57001 1129 ST5711298T 4 6 COOLING SYSTEM Coolant Check the coolant level each day before riding the motor cycle and replenish coolant if the level is low Change the coolant in accordance with the Periodic Maintenance Chart see Periodic Maintenance chapter WARNING To avoid burns do not remove the radiator cap or try to inspect the coolant level or change the coolant when the engine is still hot Wait until it cools down Coolant Level Inspection e Refer to the Coolant Level Inspection in the Periodic M
211. mperature 9 C 40 F 40 20 32 20 40 40 60 x 1 000 000 1 000 0 01 0 001 0 000001 OZ gal US S gal imp qt US S at imp pint US pint imp oz US oz imp cu in kof Ib 68 Units of Length 212 248 284 104 176 80 100 120 140 160 180 200 220 240 260 280 300 km x 0 6214 mile m x 3 281 ft mm x 0 03937 in Units of Torque N m x 0 1020 kgf m N m x 0 7376 ft lb N m x 8 851 in Ib kgf m x 9 807 N m kgf m x 7 233 ft lb kgf m x 86 80 in Ib Units of Pressure kPa x 0 01020 kgf cm kPa x 0 1450 psi kPa x 0 7501 cm Hg kgf cm x 98 07 kPa kgf cm x 14 22 psi cm Hg x 1 333 kPa Units of Speed km h x 0 6214 mph Units of Power kW x 1 360 PS kW x 1 341 HP PS x 0 7355 kW PS x 0 9863 HP 5 F 40 ee 40 C 9 F 320 40 Se ATSB 44 20 40 26 7 48 9 i 400 71 1 93 3 116 420 440 138 160 C PERIODIC MAINTENANCE 2 1 Periodic Maintenance Table of Contents Periodic Maintenance Chart 2 3 Oil Filter Change ee 2 27 Torque and Locking Agent 2 5 Breather Hose Inspection 2 28 Specifications oooconcoccnnnnncnno 2 9 Crankshaft Transmission 2 29 Special Tools 2 11 Crankshaft Inspection 2 29 Periodic Maintenance Proce
212. mporary 2 Muffler Mounting Bolts B Temporary 3 Muffler Mounting Bolts C Torque Muffler Mounting Bolts 21 N m 2 1 kgf m 15 ft Ib 4 Muffler Mounting Bolts B Torque Muffler Mounting Bolts 21 N m 2 1 kgf m 15 ft Ib 5 Exhaust Pipe Holder Nuts A Torque Exhaust Pipe Holder Nuts 21 N m 2 1 kgf m 15 ft Ib 6 Muffler Clamp Bolt D e Thoroughly warm up the engine wait until the engine cools down and then retighten the exhaust pipe holder nuts and the clamp bolt securely Muffler Baffle Replacement e Refer to the Muffler Baffle Change in the Periodic Main tenance chapter GE18033BS1 GE18084BS1 ENGINE RIGHT SIDE 6 1 Engine Right Side Table of Contents Exploded EE 6 2 A A rs tes srenchressscorenaseste aa teee cles Sach ahaadads aa eaa nent i nest ess ttes sata dde dada states ds 6 6 Special te EE 6 7 Clutch Lever and Cable nnneneeeneeesee eener neer nen rnent nenn n nennen rnent nennnnn nananana nanan nenna nann nn Ennan nannaa 6 8 Clutch Lever Clutch Cable Free Play Inspechon 6 8 Clutch Lever Clutch Cable Free Play Adjustment A 6 8 Clutch Lever Installaton ses 6 8 Clutch GableRermmpevat a e aaa codo aa EAR 6 8 Clutch Cable Installation 6 9 Clutch Cable Inspection and Lubrication ccocccccccnnnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnoneninnnos 6 9 Clutch Cover and Right Engine Cover seen 6 10 Clutch Cover Removal irainetan a aa aa a A aaa e
213. n This can damage or warp the disc Place blocks under the wheel so the disc does not touch the ground e Insert a wood wedge between the disc brake pads this prevents them from being moved out of their proper posi tion should the brake lever be squeezed accidentally Front Wheel Installation e Apply grease to the seals e Fit the projection A on the cap to the groove B on the collar e Install the caps and collars on the left and right side of the hub GJ04136BS1 Wheels Rims WHEELS TIRES 10 7 e Insert the axle A from right side e Tighten the right B axle clamp bolts temporally e Tighten the axle nuts C e Tighten the left axle clamp bolts D Torque Front Axle 78 N m 8 0 kgf m 58 ft lb Left Axle Clamp Bolts 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 Remove the jack e Before tightening the right clamp bolts on the right fork leg pump the forks up and down A 4 or 5 times to allow the right fork leg to find a neutral position on the front axle NOTE ODo not apply the front brake during this process to stop the motorcycle from rolling forward Put a block B in front of the wheel to stop it from moving e Tighten the right axle clamp bolts Torque Right Axle Clamp Bolts 20 N m 2 0 kgf m 15 ft Ib NOTE OTighten the two clamp bolts alternately two times to en sure even tightening
214. nd and tube e Apply a soap and water solution or rubber lubricant to the rim flange and tire beads e Position the front tire on the rim so that the valve A is at the tire balance mark B the chalk mark made during removal or the white paint mark on a new tire see Re moval e Insert the valve stem into the rim and screw the nut on loosely e Fit the rim protectors and use tire irons to install the tire bead NOTE OTo prevent rim damage be sure to place the rim protec tors at any place the tire irons are applied e Pry one side of the tire back onto the rim Fit the bead protector into the tire e Pry the other side of the tire onto the rim starting at the side opposite the valve OTake care not to insert the tire irons so deeply that the tube is damaged e Install the other side of the tire bead onto the rim in the same manner e Check that the tube is not pinched between the tire and rim 6J05010481 WHEELS TIRES 10 13 Tires e Tighten the bead protector nut A and valve stem nut B and put on the valve cap C e Check and adjust the air pressure after installing Air Pressure Inspection Adjustment e Refer to the Air Pressure Inspection Adjustment in the Pe riodic Maintenance chapter 10 14 WHEELS TIRES Hub Bearings Hub Bearing Removal e Remove the wheel see Wheel Removal CAUTION Do not lay the wheel on the ground with the disc facing down This can damage o
215. ne 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 GE16131BS1 VAVAVAVAVAYYAYAYAVAVATAWE NY 6E16044BS1 ENGINE TOP END 5 33 Cylinder and Piston e Install the top ring A so that the R mark B faces up NOTE Olf a new piston or cylinder is used check piston to cylin der clearance see Piston Cylinder Clearance and use new piston rings e Apply engine oil to the inside wall of the small end of the connecting rod e Face the circle mark A on the top of the piston must point toward the front B of the engine e Fit a new piston pin snap ring into the side of the piston so that the ring opening A does not 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 CAUTION 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 e The piston ring openings must be positioned as shown in the figure The openings of the oil ring steel rails must be 20 of angle from the opening of the oil ring expander Circle Mark A Top Ring B Upper Oil Ring Steel Rails C Oil Ring Expander D Lower Oil Ring Steel Rail E 6E160
216. ness A of either pad is less than the service limit B replace both pads in the caliper as a set Lining Thickness Standard Front 3 8 mm 0 15 in Rear 6 4 mm 0 25 in Service Limit Front 1 mm 0 04 in Rear 1 mm 0 04 in Brake Master Cylinder Cup and Dust Cover Replacement 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 Unscrew the locknut and pivot bolt and remove the brake lever 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 Pull out the piston D secondary cup E primary cup F and return spring G 6S13042BS1 2 40 PERIODIC MAINTENANCE Periodic Maintenance Procedures CAUTION Do not remove the secondary cup from the piston since removal will damage it e Remove the rear master cylinder see Rear Master Cylin der Removal in the Brakes chapter NOTE ODo not remove the push rod clevis for master cylinder disassembly since removal requires brake pedal posi tion 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 with the
217. ng agent O Apply 2 stroke oil 3 4 FUEL SYSTEM Exploded View FUEL SYSTEM 3 5 Exploded View Torque No Fastener q Remarks ft lb 1 Rear Frame Mounting Bois 2 Air Cleaner Duct Clamp Screw 2 0 20 17 in lb 34 0 3 Air Cleaner Duct Mounting Nuts 3 0 0 31 27 in lb 3 0 4 Air Cleaner Duct Mounting Bolt 0 31 27 in lb Air Cleaner Housing Bolts 9 8 1 0 87 in lb 5 6 Fuel Tank Cap 7 Fuel Tank 8 Fuel Tap 9 Element 10 Frame 11 12 13 14 Holder Air Cleaner Duct Air Cleaner Housing Rear Frame AD Apply adhesive cement G Apply grease O High quality foam air filter oil R Replacement Parts 3 6 FUEL SYSTEM Specifications Item Standard Throttle Grip and Cable Throttle Grip Free Play 2 3 mm 0 08 0 12 in Hot Starter Lever Free Play 0 5 1 0 mm 0 02 0 04 in Carburetor Make Type KEIHIN FCR40 Starter Jet 72 Leak Jet 70 Main Jet 175 Throttle Valve Cutaway CA1 5 Jet Needle NCVR Jet Needle Clip Position 4th groove from the top Slow Jet 42 EUR 40 KX450D6F Slow Air Jet 100 PE Sen EUR 1 KX450D7F Reference Service Fuel Level 6 5 1 mm 0 256 0 039 in below the bottom edge of the carb body Float Height 8 1 mm 0 315 0 039 in Air Cleaner Air Cleaner Element Oil EUR Europe Model High quality form air filter oil FUEL SYSTEM 3 7 Special Tool Fuel Level Gauge M18 x 1 0 57001 122
218. nstallation in the Wheels Tires chapter e Tighten the fork clamp bolts 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 Tighten Torque Front Caliper Mounting Bolts 25 N m 2 5 kgf m 18 ft lb e Check the front brake operation after installation 13 14 SUSPENSION Front Fork KX450D6F D7F Front Fork Disassembly each fork leg e Loosen the front fork upper clamp bolts A e Loosen the fork top plug subtank A with the top plug wrench B Special Tool Top Plug Wrench 49 mm 57001 1653 B e Remove the front fork see Front Fork Removal 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 CAUTION 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 subtank from the outer tube and slowly slide down the outer tube C Special Tool Top Plug Wrench 49 mm 57001 1653 SUSPENSION 13 15 Front Fork KX450D6
219. o 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 Oct is Cutter Angle B IND da Cutter Outer Diameter C 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 CAUTION 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 GE15011881 GE15011981 Valves ENGINE TOP END 5 29 e Measure the outside diameter O D of the seating sur face with a vernier caliper x If the outside diameter of the seating surface is too small repeat the 45 grind until the diameter
220. od 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 Parts 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
221. oil seals and grease seals outside of the sleeve e Tighten Torque Rear Shock Absorber Mounting Nut Lower 34 N m 3 5 kgf m 25 ft Ib Rocker Arm Pivot Nut 83 N m 8 5 kgf m 61 ft lb KX450D6F Rocker Arm Pivot Nut 59 N m 6 0 kgf m 43 ft lb KX450D7F Tie Rod Mounting Nuts 83 N m 8 5 kgf m 61 ft lb KX450D6F Tie Rod Mounting Nuts 59 N m 6 0 kgf m 43 ft lb KX450D7F 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 bearings E using the bearing re mover head and bearing remover shaft e Remove the needle bearing F using the oil seal amp bear ing remover Special Tools Bearing Remover Head 57001 1267 Bearing Remover Shaft 57001 1265 Oil Seal amp Bearing Remover 57001 1058 GM07034BS2 C SUSPENSION 13 51 Tie Rod Rocker Arm Tie Rod and Rocker Arm Bearing Installation e Replace the needle bearing grease seals and oil seals with new ones e Apply plenty of grease to the oil seal and needle bearings A NOTE Olnstall the grease seals so that the deep groove side of the rip out ward e Install the needle bearings A B and grease seals C position as shown OThe installation procedure is the same as the counter side 1 mm 0 04 in D Rear Shock Absorber G 4 5 mm 0 18 in E Tie rod H 4 25 mm 0 167 in F Rocker Ar
222. om and locknut Special Tool Top Plug Wrench 49 mm 57001 1653 WARNING Be careful of reaction force in spring and fix surely so that special tool should not come off Do not place the fingers etc while serving e Insert the push rod A into the piston rod e Replace the O ring and gasket on the adjuster assembly 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 to provide more than 1 mm 0 04 in C e Turn the locknut A counterclockwise until it contacts with the adjuster assembly B e With the locknut held immovable using a wrench tighten the adjuster assembly to the specified torque Torque Locknut Adjuster Assembly 29 N m 3 0 kgf m 22 ft lb e With the outer tube compressed by hands remove the top plug wrench 2 62 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Apply a non permanent locking agent to the threads of a adjuster assembly e Torque the adjuster assembly A Torque Adjuster Assembly 58 N m 5 9 kgf m 43 ft Ib e Loosen and remove the fork top plug subtank from the outer tube and slowly slide down the outer tube Special Tool Top Plug Wrench 49 mm 57001 1653 e Pour A the specified amount of fork oil into the outer tube Recommended KHL15 10 KAYABA01 or Oil equivalent Recommended 350 mL
223. osen the banjo bolt A so as not to spill brake fluid e Remove the caliper mounting bolts B e Remove the banjo bolt and take off the brake hose from the caliper C e f the caliper is to be disassembled after removal and if compressed air is not available remove the piston using the following steps before disconnecting the brake hose from the caliper ORemove the pads OPump the brake lever to remove the piston Rear Brake e Unbolt the caliper guard bolts A and remove the caliper guard B e Unbolt the disc guard bolts C and remove the disc guard D e Loosen the banjo bolt A so as not to spill brake fluid e Loosen the brake pad bolt plug B and pad bolt C before the caliper removal if the caliper is to be disassembled NOTE Olf the caliper is to be disassembled after removal and compressed air is not available disassemble the caliper before brake hose removal see Caliper Disassembly e Remove the rear wheel see Rear Wheel Removal in the Wheels Tires chapter e Unscrew the banjo bolt and remove the brake hose D from the caliper see Brake Hose Replacement in the Pe riodic Maintenance chapter CAUTION Immediately wipe up any brake fluid that is spilled Caliper BRAKES 12 13 Caliper Installation e Tighten the brake pad bolts if it was removed Torque Brake Pad Bolts 17 N m 1 7 kgf m 13 ft lb Front Brake e Install the caliper and tighten the bolts Torque Caliper
224. ouble Flywheel damage Ignition coil trouble Wiring connector not in good contact Fuel air mixture incorrect Choke plunger stuck open Hot starter plunger stuck open Main jet clogged or wrong size Jet needle or needle jet worn Air jet clogged Fuel level in carburetor float bowl too high or too low Needle Jet or air passage clogged Air cleaner clogged poorly sealed or miss ing Air cleaner duct loose Water or foreign matter in fuel Carburetor holder loose Fuel tank cap air vent obstructed Fuel tap clogged Fuel line clogged 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 APPENDIX 17 9 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 Faulty CDI unit 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 in
225. ount of rim warp can be corrected by recentering the rim Loosen some spokes and tighten others within the standard torque to change the position of different parts of the rim If the rim is badly bent however it must be replaced 604061081 Rim Runout with tire installed Standard Axial TIR 1 0 mm 0 039 in or less Radial TIR 1 0 mm 0 039 in or less Service Limit Axial TIR 2 mm 0 08 in Radial TIR 2 mm 0 08 in Wheel Bearing Inspection e Raise the front rear wheel off the ground Special Tool Jack 57001 1238 e Spin the wheel lightly and check for roughness binding or noise x lf roughness binding abnormal noise is found replace the hub bearing e Turn the handlebar until the handlebar doesn t move to either side e The wheel edge is moved to one direction gripping the edge of the wheel by both hands and the play of the wheel bearing is checked x If the play is found replace the bearing 2 32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Final Drive Drive Chain Slack Inspection e Raise the rear wheel off the ground rotate the rear wheel to find the place where the chain is tightest because it wears unevenly e Checkthe wheel alignment see Wheel Alignment Inspec tion in the Final Drive chapter and adjust it if necessary see Drive Chain Slack Adjustment NOTE OClean the drive chain if it is dirty and lubricate it if it appears dry e Rotate the rear whee
226. out with 20 N m 2 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 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 Tool Rotor Holder 57001 1654 Torque Flywheel Nut 78 N m 8 0 kgf m 58 ft Ib e Install the magneto cover see Magneto Cover Installa tion Flywheel Magneto ELECTRICAL SYSTEM 16 11 Stator Removal e Remove Magneto Cover see Magneto Cover Removal Stator Bolts A Crankshaft Sensor Bolts B Wiring Holder C Wiring Grommet D e Remove the stator E and crankshaft sensor F as a set Stator Installation e Route the leads according to the Cable Wire and Hose Routing section in the Appendix chapter e Apply a non permanent locking agent to the stator bolts e Install the stator and tighten the stator bolts Torque Stator Bolts 4 0 N m 0 41 kgf m 35 in Ib e Install the crankshaft sensor and wiring holder A ORun the magneto leads under the holder and sensor Torque Crankshaft Sensor Bolts 7 0 N m 0 71 kgf m 61 in Ib e Apply silicone sealant around the circumference of the wiring grommet Sealant Kawasaki Bond Silicone Sealant 92104 0004 e Set the stator wiring g
227. outing section in the Appen dix chapter e Connect the lead connector Flywheel Removal e Remove the magneto cover see Magneto Cover Re moval 16 10 ELECTRICAL SYSTEM Flywheel Magneto e Hold the flywheel steady with the rotor holder A and remove the flywheel nut B Special Tool Rotor Holder 57001 1654 e Remove the rotor holder e Screw the rotor puller A into the flywheel e Remove the flywheel from the crankshaft by turning in the puller center bolt and tapping the head of the bolt lightly with a hammer while holding the puller body steady There is a woodruff key in the crankshaft tapered portion Special Tool Rotor Puller 57001 1565 CAUTION 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 Flywheel Installation e Using a high flash point solvent clean off any oil or dirt that may be on the crankshaft taper A or in the hole B of the flywheel Dry them with a clean cloth 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 and tighten it with 45 N m 4 5 kgf m 33 ft lb of torque ORemove the flywheel nut OCheck the tightening torque with rotor puller x If the flywheel is not pulled
228. p air vent obstructed Fuel tap clogged Fuel tap turned off Fuel line clogged Carburetor float valve clogged Engine flooded Fuel level in carburetor float bowl too high Float valve worn or jammed with foreign matter Starting technique faulty When flooded crank the engine with the hot start opened to allow more air to reach the engine Fuel air mixture incorrect Pilot screw and or idle adjusting screw mal adjusted Pilot jet or air passage clogged Air cleaner clogged poorly sealed or miss ing Starter jet clogged No spark spark weak Spark plug dirty broken or gap malad justed Spark plug cap or high tension wiring trou ble Spark plug cap shorted or not in good con tact Spark plug incorrect heat value Faulty CDI unit Crankshaft sensor trouble Ignition coil trouble Engine stop switch shorted Neutral switch trouble 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 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 Poor Running at Low Speed Spark weak Spark plug dirty broken or gap malad justed Spark plug cap or high tension wiring trou ble Spark
229. pection Throttle Sensor Position Adjustment 16 23 ele 16 24 Engine Stop Switch Inspection ooocoociinccnnnnnnccnncccncnoncnancnanonancrnn cnn nn rrn nr rn rra 16 24 Gear Position Switch Removal sisi 16 24 Gear Position Switch Installation 16 25 Gear Position Switch Inspection ccoocccnnccnnccnnnonnnonnnnnnnonnnonnnnnnnnnnnnnnnnnnnninnninnnnnnnoss 16 25 16 2 ELECTRICAL SYSTEM Exploded View Exploded View ELECTRICAL SYSTEM 16 3 mef Faster mr N Flywheel Nut Stator Bolts oO 78 4 0 R k ftlb emarks 26 in lb L 35 in lb L 5 Magneto Cover Bolts 9 8 1 0 87 in lb 6 Crankshaft Sensor Bolts 7 0 0 71 62 in lb 7 C D Unit Bolts 9 8 1 0 87 in lb 8 Ignition Coil Bolts 7 0 0 71 62 in lb 9 Breather Fitting 15 1 5 11 L 10 Magneto Cover 11 Flywheel 12 Stator 13 Ignition Coil 14 C D I Unit 15 Spark Plug Cap 16 Main Harness 17 Crankshaft Sensor 18 Throttle Sensor 19 Engine Stop Switch 20 Breather Hose G Apply grease L Apply a non permanent locking agent R Replacement Parts SS Apply silicon sealant 16 4 ELECTRICAL SYSTEM Specifications Item Standard Magneto Crankshaft Sensor Resistance Magneto Output Voltage Stator Coil Resistance 180 280 Q at 20 C 68 F in the text in the text Ignition System Ignition Timing Ignition Coil 3 Needle Arcing D
230. placed replace the dust seal as well Also replace all seals every other time the pads are changed Dust Seal and Cover Damage Inspection e Check that the dust seals and covers are not cracked worn swollen or otherwise damaged x If they show any damage replace them Piston Cylinder Damage Inspection e Visually inspect the piston and cylinder surfaces Replace the cylinder and piston if they are badly scored or rusty 12 14 BRAKES Caliper Caliper Holder Shaft Wear Inspection The caliper body must slide smoothly on the caliper holder shafts 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 if the caliper holder shafts are not badly worn or stepped or the rubber boot is not damaged xlf the shafts or rubber boot are damaged replace the shafts rubber boot and the caliper holder Brake Pad BRAKES 12 15 Brake Pad Removal For Front Brake Pad e Unscrew the pad bolt A e Take the piston side pad B e Push the caliper holder toward the piston and then re move another pad C from the caliper holder For Rear Brake Pad e Remove Plug A e Unscrew the pad bolt A e Take the piston side pad B e Push the caliper hold toward the piston and then remove another pad C from the caliper holder Brake Pad Installation e Push the caliper pistons in by hand
231. position on the tire with chalk so that the tire can be rein stalled in the same position e Remove the valve cap B 6J05029BS1 e Take out the valve core A to let out the air e Remove the valve stem nut B OWhen handling the rim be careful not to damage the rim flanges 6y05030BS1 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 CAUTION Never lubricate with mineral oil engine oil or gaso line because they will cause deterioration of the tire e Break the beads away from both sides of the rim with the bead breaker A Special Tool Bead Breaker Assembly 57001 1072 6J05031BS1 10 12 WHEELS TIRES Tires e Step on the side of the tire opposite valve stem pry the tire off the rim with the tire iron A of the bead breaker protecting the rim with rim protectors B Special Tools Rim Protector 57001 1063 Bead Breaker Assembly 57001 1072 CAUTION Take care not to inset the tire irons so deeply that the tube gets damaged e Remove the bead protector and tube when one side of the tire is pried off e Pry 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 tire and replace them if necessary e Install the tube ba
232. pter Drive Chain Removal e Remove the engine sprocket cover see Engine Sprocket Removal e Remove the clip A from the master link using pliers and free the drive chain from the rear sprocket e Remove the drive chain from the chassis Drive Chain Installation e Fitthe drive chain back onto the sprockets with the ends at the rear sprocket e Install the master link A from the frame side e Install the link plate B so that the mark faces out Clip C 11 6 FINAL DRIVE Drive Chain e Install the clip A so that the closed end B of the U pointed in the direction of chain rotation C e Adjust the drive chain slack see Drive Chain Slack Ad justment e Check the rear brake 6K04060BS1 C Sprockets FINAL DRIVE 11 7 Engine Sprocket Removal e Remove Engine Sprocket Cover Bolts A Engine Sprocket Cover B Drive Chain Guide C e Remove Drive Chain B free of engine sprocket e Flatten the bended sprocket washer A e Remove the engine sprocket nut C and sprocket washer and pull off the engine sprocket D Engine Sprocket Installation e Install the engine sprocket so that the flatten side faces A inside e Replace the sprocket washer with a new one e Install the sprocket washer and sprocket nut Torque Engine Sprocket Nut 127 N m 13 kgf m 94 ft lb e Bend the one side of the sprocket washer on the nut e Install the engine sprocket cover Torque Engine Sprocke
233. r Brake Pad Piston Front Disc Apply brake fluid Apply a non permanent locking agent Replacement Parts i Apply Silicone grease Brake Reservoir Cap Screws Front 5 9 1 5 7 8 Caliper Mounting Bolts Front 25 2 5 Brake Disc Mounting Bolts Front 9 8 1 0 5 9 Brake Lever Pivot Bolt Locknut 0 60 0 60 0 15 18 18 78 inlb S E Ce 12 4 BRAKES Exploded View BRAKES 12 5 Exploded View No Fastener N m w 17 B 0O N Caliper Holder Shaft Rear 27 Brake Pedal Mounting Bolt f Brake Disc Mounting Bolts Rear 2 3 Brake Reservoir Cap Bolts Rear 0 15 11 Brake Hose 12 Rear Master Cylinder 13 Brake Pedal 14 Rear Caliper Cover 15 Rear Caliper 16 Piston 17 Brake Pads 18 Rear Disc BF Apply brake fluid G Apply high temperature grease L Apply a non permanent locking agent R Replacement Parts Si Apply Silicone grease O O1 N N 00 N al N oO _ al 12 6 BRAKES Specifications Item Standard Service Limit Brake adjustment Lever Play Adjustable to suit rider Brake Fluid Recommended Disc Brake Fluid Type Front DOT3 or DOT4 Rear DOT4 Brake Pads Lining thickness Front 3 8 mm 0 15 in 1 mm 0 04 in Rear 6 4 mm 0 25 in 1 mm 0 04 in Brake Disc 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 1
234. r gear e Tighten Torque Balancer Weight Mounting Nut 52 N m 5 3 kgf m 38 ft lb 9 24 CRANKSHAFT TRANSMISSION Bearings Oil Seals Bearing Replacement CAUTION Do not remove the ball bearings unless it is neces sary Removal may damaged them e Remove the ball bearing and or needle bearing outer race using a press or puller 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 CAUTION Do not heat the case with a torch This will warp the case Soak the case in oil and heat the oil e Install the new bearing until its outer race stops at the bottom of the case using a press and the bearing driver set A Special Tool Bearing Driver Set 57001 1129 Bearing Inspection CAUTION Do not remove the bearings for inspection Re moval may damage them e Inspect the ball bearings OSince 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 TRANSMISS
235. r lightly on the valve guide arbor A to remove the guide Special Tool Valve Guide Arbor bb 57001 1021 Valve Guide Installation e Apply a thin coat of 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 CAUTION Do not heat the cylinder head with a torch This will warp the cylinder head Soak the cylinder head and heat the oil e Assemble the valve guide driver A and valve guide driver attachment D B Special Tools Valve Guide Driver 64 5 57001 1564 Valve Guide Driver Attachment D 57001 1659 e When install the exhaust valve guide using the attached washer t 2 0 C e Using the valve guide driver press and insert the valve guide in until the valve guide driver surface D touches the head surface E Exhaust 11 1 11 3 mm 0 437 0 445 in F Inlet 13 1 13 3 mm 0 516 0 524 in GE15070681 SA Ga PRADO 19 GE15114BS1 5 26 ENGINE TOP END Valves 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 Valve Valve Guide Clearance Measurement Wobble Method OH 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 p
236. r more than 20 minutes to allow the fork oil to fully drain e Replace the following 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 When assembling the new outer tube guide bush A hold the used guide bush B against the new one and tap the used guide bush with the fork oil seal driver C until it stops Special Tool Fork Oil Seal Driver 448 57001 1509 e After installing the washer install the oil seal by using the fork oil seal driver Special Tool Fork Oil Seal Driver 448 57001 1509 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 Clean the threads A of subtank and base valve assem bly GM04399BS1 SUSPENSION 13 19 Front Fork KX450D6F D7F e With the piston rod in fully compressed position pour the specified amount of fork oil A Recommended Oil KHL15 10 KAYABA01 or equivalent Recommended 170 ml 5 75 US oz KX450D6F Quantity 191 ml 6 46 US oz KX450D7F NOTE OPlug the two oil holes on the subtank B with fingers e Pump A the piston rod B slowly several
237. r pin if the slots in the nut do not align with the cotter pin hole in the axle shaft tighten the nut clockwise A up to next alignment Olt should be within 30 degree OLoosen once and tighten again when the slot goes past the nearest hole A WARNING If the axle nut is not securely tightened or the cotter pin is not installed an unsafe riding condition may result e Check the rear brake 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 28 2 68 in of slack whenever necessary 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 A Bushing B Roller C Pin D Pin Link E Roller Link e Stretch the chain taut by hanging a 98 N 10 kgf 20 Ib weight A on the chain e Measure the length of 20 links 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
238. r warp the disc Place blocks under the wheel so that the disc does not touch the ground e Remove the oil seals and circlips Special Tool Inside Circlip Pliers 57001 143 e Remove the hub bearing by tapping evenly around the bearing inner race as shown A Bar B Distance Collar C Hub Bearing Hub Bearing Installation e Before installing the wheel bearings blow any dirt or for eign particles out of the hub A with compressed air to prevent contamination of the bearings e Replace the bearings with new ones e Lubricate them and install them using the bearing driver set B so that the marked or shielded sides face out OPress in the bearings until they are bottomed Special Tool Bearing Driver Set 57001 1129 e Replace the circlips and oil seals with new ones e Press in the oil seals A so that the seal surface is flush B with the end of the hole e Apply high temperature grease to the oil seal lips Special Tool Bearing Driver set 57001 1129 C Hub Bearing Inspection NOTE Olt is not necessary to remove any bearings for inspec tion If any bearings are removed they will need to be replaced with new ones e Spin A it by hand to check its condition x If it is noisy does not spin smoothly or has any rough spots it must be replaced e Examine the bearing seal B for tears or leakage x If the seal is torn or is leaking replace the bearing 6J06013BS1 6J06009BS1
239. rburetor see Carburetor Removal e Unscrew the plunger cap bolt A and remove the cable end e Disassemble the cable end from the plunger A Spring B Plunger Cap Assy C e Remove Left Radiator Shroud Clamps A Open Hot Starter Cable B Hot Starter Cable Installation e Install the hot starter cable in accordance with the Cable Wire and Hose Routing section in the appendix chapter e After the installation adjust the cable properly WARNING Operation with an incorrectly routed or improperly adjusted cable could result in an unsafe riding con dition Hot Starter Lever Hot Starter Cable Free Play Inspection e Refer to the Hot Starter Lever Hot Starter Cable Free Play Inspection in the Periodic Maintenance chapter Throttle Grip and Cable FUEL SYSTEM 3 11 Hot Starter Lever Hot Starter Cable Free Play Adjustment e Refer to the Hot Starter Lever Hot Starter Cable Free Play Inspection in the Periodic Maintenance chapter Hot Starter Cable Lubrication e Whenever the hot starter cable is removed or in accor dance with the Periodic Maintenance Chart lubricate the these cable see General Lubrication and Cable Inspec tion in the Periodic Maintenance chapter Hot Starter Cable Inspection e Refer to the General Lubrication and Cable Inspection in the Periodic Maintenance chapter 3 12 FUEL SYSTEM Carburetor Since the carburetor regulates and mixes the fuel and air go
240. re water resistance grease e Install the pads see Brake Pad Installation in the Brakes chapter e Install the caliper see Caliper Installation in the Brakes chapter e Wipe up any spilled brake fluid on the caliper with wet cloth 2 44 PERIODIC MAINTENANCE Periodic Maintenance Procedures 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 Tighten any loose fittings Brake Hose Replacement CAUTION Brake fluid quickly ruins painted surfaces any spilled fluid should be completely washed away immediately e When removing the brake hose take care not to spill the brake fluid on the painted or plastic parts e When removing the brake hose temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum e Immediately wash away any brake fluid that spills e Remove each banjo bolts A and washers B e Replace the washers with new ones For Front Brake e Remove Bolts A Brake Hose Clamps B 6L100101S1 PERIODIC MAINTENANCE 2 45 Periodic Maintenance Procedures For Rear Brake e Remove Master Cylinder A Hose C
241. rench 49 mm 57001 1653 B e Remove Front Wheel see Front Wheel Removal in the Wheels Tires chapter Front Brake Caliper see Caliper Removal in the Brakes chapter Brake Hose Clamps see Brake Hose Replacement e Loosen the front fork lower clamp bolts A e Remove the front fork OWith a twisting motion work the fork leg B down and out 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 CAUTION 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 subtank from the outer tube and slowly slide down the outer tube C Special Tool Top Plug Wrench 49 mm 57001 1653 PERIODIC MAINTENANCE 2 47 Periodic Maintenance Procedures e Place a oil pan under the front fork and drain 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 subtank to the outer tube B with the top plug wrench C Special Tool Top Plug Wrench 49 mm 57001 1653 e Hold the axle holder A with a vise OProtec
242. replace them e Check the gear set lever A and its spring B for cracks or distortion x If the lever or spring is damaged in any way replace them e Visually inspect the shift drum cam A x If it is badly worn or if it shows any damage replace it GRO7021BS1 8 8 A GRO7023BS1 GRO7022BS1 ENGINE RIGHT SIDE 6 21 Kickstarter Kick Pedal Assy Removal e Remove Mounting Bolt A Kick Pedal Assy B Kick Pedal Assy Installation e Install the kick pedal assy A at the angle shown 17 27 mm 0 67 1 1 in B e Apply a non permanent locking agent to the kick pedal bolt e Tighten Torque Kick Pedal Bolt 25 Nm 2 5 kgf m 18 ft lb Kick Pedal Assy Disassembly e Remove the kick pedal assy e Remove Plug Screw A Spring B Steel Ball C Detent Screw D Oil Seal E GRO8017BS1 Kick Pedal Assy Assembly e Apply high temperature grease to the steel ball oil seal lip spring and the sliding portion of the lever e After tightening the screws stake it with a punch Idle Gear Removal e Remove Right Engine Cover see Right Engine Cover Removal Clutch Housing see Clutch Removal Circlip A Idle Gear B 6 22 ENGINE RIGHT SIDE Kickstarter Idle Gear Installation e Apply engine oil to the inside of the idle gear e Replace the circlip A with a new one e Install the idle gear C facing embossed letter B to
243. ressure cap Special Tool Oil Pressure Cap 57001 1656 e Install the oil pressure cap e Attach the oil pressure gauge adapter A and oil pressure gauge B Special Tools Oil Pressure Gauge Adapter M10 x 1 0 57001 1182 Oil Pressure Gauge 5 kgf cm 57001 125 e Start the engine and warm up the engine thoroughly e Run the engine at the specified speed and read the oil pressure gauge x If the oil pressure is much lower than the standard check the feed oil pump x If the reading is much higher than the standard check the oil filter first and oil passages for dirt or clogging Oil Pump Pressure oil temperature 90 C 4 000 rpm Standard 39 98 kPa 0 4 1 0 kgf cm 5 6 14 psi NOTE OWarm up the engine thoroughly before measuring the oil pressure e Stop the engine and remove the oil pressure cap oil pres sure gauge adapter and gauge A WARNING Take care against burns from hot engine oil that will drain through the oil passage when the oil pressure gauge adapter is removed e Install the oil filter cover Torque Oil Filter Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib ENGINE REMOVAL INSTALLATION 8 1 Engine Removal Installation Table of Contents Exploded WEE 8 2 SR EE 8 4 Engine Removal starlet isis ss siege AR Abe eae a terne En re das 8 5 A A A deat 8 5 Engine Instala it Ai 8 7 8 2 ENGINE REMOVAL INSTALLATION Exploded View A Exploded View ENGINE
244. riodic Maintenance Procedures Fuel System Fuel Hose and Connections Inspection OThe fuel hoses are designed to be used throughout the motorcycle s life without any maintenance however if the motorcycle is not properly handled the inside the fuel line can cause fuel to leak A or the hose to burst e Check the fuel hose Replace the fuel hose if any fraying cracks B bulges C or ozone cracks D are noticed e Check that the hose A are securely connected and clamps B are tightened correctly e When installing route the hose according to Cable Wire and Hose Routing section in the Appendix chapter e When installing the fuel hose avoid sharp bending kink ing flattening or twisting and route the fuel hose with a minimum of bending so that the fuel flow will not be ob structed Replace the hose if it has been sharply bent or kinked Throttle Grip Throttle Cable Free Play Inspection e Check throttle grip free play B by lightly turning the throt tle grip A back and forth x If the free play is improper adjust the throttle cable Throttle Grip Free Play Standard 2 3 mm 0 08 0 12 in 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 c
245. rive out the pivot pin A and remove the float B with valve needle C GCOGI39BS2 C 6068417 p 3 14 FUEL SYSTEM Carburetor e Bend the tang A on the float arm very slightly to change the float height Increasing the float height lowers the fuel level and decreasing the float height raises the fuel level Float Height Standard 8 1 mm 0 315 0 039 in NOTE OFloat height A is the distance from the float bowl mat ing surface B of the carburetor body with the gasket removed to the top of the float C Measure the height with the carburetor upside down ODo not push the needle rod D in during the float height measurement e Assemble the carburetor and recheck the fuel level x If the fuel level cannot be adjusted by this method the float or the float valve is damaged Carburetor Removal 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 e Turn the fuel tap lever A to the OFF position OSlide off the clamp B and pull the fuel hose C off the tap 6C006088BS1 FUEL SYSTEM 3 15 Carburetor e Remove the fuel tank see Fuel Tank Removal e Disconnect the throttle sensor connector A e Loosen the clamp screws A o
246. rk Plug 113 in lb C D I Unit Bolts 87 in lb Magneto Cover Bolts 87 in lb Breather Fitting 11 L Ignition Coil Bolts 62 in lb Basic Torque for General Fasteners Threads dia 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 PERIODIC MAINTENANCE 2 9 Specifications Item Standard Service Limit Fuel System Throttle Grip Free Play Hot Starter Lever Free Play Air Cleaner Element Oil 2 3 mm 0 08 0 12 in 0 5 1 0 mm 0 02 0 04 in High quality foam air filter oil Cooling System Coolant Type recommended Color Mixed Ratio Freezing Point Total Amount Permanent type antifreeze Green Soft water 50 and coolant 50 35 C 31 F 1 05 L 1 11 US qt Engine Top End Valve Clearance Exhaust Inlet Cylinder Head Warp Cylinder Inside Diameter see text Piston cylinder Clearance Engine Right Side Clutch Lever Free Play Friction Plate Thickness Friction Plate Warp Steel Plate Warp 0 17 0 22 mm 0 0067 0 0087 in 0 10 0 15 mm 0 0039 0 0059 in 96 000 96 012 mm 3 7795 3 7800 in 0 020 0 042 mm 0 00079 0 0016 in 8 13 mm 0 3 0 5 in 2 92 3 08 mm 0 115 0 121 in
247. rm Swingarm Removal e Place the jack A under the frame so that the rear wheel y is off the ground Special Tool Jack 57001 1238 e Remove Rear Wheel see Rear Wheel Removal in the Wheels Tires chapter Clamps B Brake Pedal C see Brake Pedal Removal in the Brakes chapter Disc Protector D e Remove Bolts A and Nuts B Chain Guide Plate C Chain Guide D e Unscrew the rocker arm pivot nut A and pull out the rocker arm pivot bolt B CAUTION When pulling out the mounting bolts lift the swingarm slightly Forcing or tapping on a bolt could damage the bolt sleeve and bearing e Unscrew the nut A e Pull out the swingarm pivot shaft B and remove the swingarm C Swingarm SUSPENSION 13 47 e Unscrew the screws A e Separate the chain slipper B from the swingarm Swingarm Installation e Apply plenty of grease to the inside of the needle bear ings sleeves and oil seals e Tighten the following Torque Swingarm Pivot Shaft Nut 98 N m 10 kgf m 72 ft lb Rocker Arm Pivot Nut 83 N m 8 5 kgf m 61 ft lb KX450D6F Rocker Arm Pivot Nut 59 N m 6 0 kgf m 42 ft lb KX450D7F e Refer to the Wheels Tires Final Drive and Brakes chap ters for wheel installing 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 amp bear ing re
248. rned fully clockwise A O a Compression Damping Adjuster Setting Standard 12 clicks B KX450D6F 9 clicks EUR 10 clicks KX450D7F Softer Counterclockwise C 161514131211 10 9 8 7 6 5 4 3 2 1 Harder Clockwise D 4 Number of turns counterclockwise usable range O 16 clicks or more KX450D6F GM04322BS1 22 clicks or more KX450D7F Counterclockwise from the fully seated position Oil Change each fork leg e Refer to Front Fork Oil Change in the Periodic Mainte nance chapter Front Fork Removal e Unscrew the bolts A and remove the front brake hose clamps B e Remove Front wheel see Front Wheel Removal in the Wheels Tires chapter 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 Fork KX450D6F D7F SUSPENSION 13 13 e Loosen the upper A and lower B fork clamp bolts e Remove the front fork OWith a twisting motion A work the fork leg B down and out Front Fork Installation e Install the fork so that the distance between the top end of the outer tube and the upper surface of the steering stem head is specified dimension A 7 mm 0 28 in KX450D6F 8 mm 0 31 in KX450D7F e Route the cables and hose according to the Cable Wire and Hose Routing section in the Appendix chapter e Install the front wheel see Front Wheel I
249. rommet B securely in the notch C e Install the magneto cover see Magneto Cover Installa tion Flywheel Inspection e There are three types of magneto problems short open lead burned out or loss in flywheel 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 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 e Check the magneto output voltage do the following pro cedures ORemove the left radiator shroud OPull the stopper A to this side and remove the magneto lead connector B RCE VK AEN W USAR SES No RE A EC 16 12 ELECTRICAL SYSTEM Flywheel Magneto OConnect the hand tester A to the connector B as shown in the table 1 using the needle adapter set C OStart the engine ORun it at the rpm given in the table 1 ONote the voltage readings total 2 measurements Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 Table 1 Magneto Output Voltage Tester Connections Reading Range Tester to Tester to 4 000 rpm 50 V AC White lead Red lead 20 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 it indicates that the magneto is defective e To c
250. s Inner subtank Fork Spring Free Length Rear Shock Absorber Rebound Damping Adjustment from the seated position adjuster turned fully clockwise Atmospheric pressure 13 clicks counterclockwise KX450D6F 9 clicks counterclockwise EUR 10 clicks conterclockwise KX450D7F 10 clicks counterclockwise KX450D8F 12 clicks counterclockwise KX450D6F 9 clicks counterclockwise EUR 10 clicks conterclockwise KX450D7F 10 clicks counterclockwise KX450D8F KHL15 10 KAYABA 01 or equivalent 345 mL 11 7 US oz KX450D6F 355 mL 12 00 US oz KX450D7F 350 mL 11 8 US oz KX450D8F EUR 350 mL 11 8 US oz KX450D6F 170 mL 5 75 US oz KX450D6F 191 mL 6 46 US oz KX450D7F 480 mm 18 9 in KX450D6F 470 mm 18 5 in KX450D7F 11 clicks counterclockwise KX450D6F 8 clicks counterclockwise EUR 10 clicks counterclockwise KX450D7F Adjustable Range 16 clicks KX450D6F 20 clicks KX450D7F Adjustable Range 16 clicks KX450D6F 22 clicks KX450D7F Adjustable Range 325 365 mL 11 0 12 3 US oz KX450D6F 330 380 mL 11 2 12 8 US oz KX450D7F 330 370 mL 11 2 12 5 US oz KX450D6F 470 mm 18 5 in KX450D6F 461 mm 18 1 in KX450D7F Adjustable Range 16 clicks KX450D6F 22 clicks KX450D7F Specifications SUSPENSION 13 9 Item Standard Service Limit Spring Preload Adjustmen
251. s 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 GENERAL INFORMATION 1 5 Before Servicing Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is FEEN absolutely necessary Replace with new ones whenever removed Press bearings with the manufacturer and size cr P E K 7 marks facing out Press the bearing into place by putting mice J Y pressure on the correct bearing race as shown KS Te Ah Pressing the incorrect race can cause pressure between S i e x 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 Le out Make sure the seal is aligned properly when installing
252. se 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 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 1 5 N m 0 15 kgf m 13 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 Balancer Shaft Plug A Timing Inspection Plug B Special Tool Filler Cap Driver 57001 1454 GS06027BS1 2 20 PERIODIC MAINTENANCE Periodic Maintenance Procedures e First bring the piston to the top dead center of its com pression stroke to inspect the valve clearance the posi tion at the end of the compression stroke when the cam lobe faces outside of the camshaft OPlace a wrench over the balancer weight nut and turn it counterclockwise to align the TDC mark A with the center of the groove B of the inspection hole e Using a thickness gauge A measure the clearance be tween each cam lob and valve lifter for all four valves OFor the purpose of adjusting the valve clearances record the measured v
253. sition 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 1615 1413121110 9 dria oO wN o a C N GMO5205BS1 13 42 SUSPENSION Rear Shock Absorber e Adjust the high speed compression damping turn the high speed compression damping adjuster with a 17 mm wrench x If the damping feels too soft or too stiff adjust it in accor dance with the following table High Speed Compression Damping Standard 1 1 6 turns out B KX450D6F 1 1 2 turns out KX450D7F 1 turn out KX450D8F Softer counterclockwise C Harder clockwise D Number of turns counterclockwise usable range 2 turns or more KX450D6F D8F 4 turns or more KX450D7F Counterclockwise from the fully seated position e Adjust the low speed compression damping turn the low speed compression damping adjuster with a flat head screwdriver x If the damping feels too soft or too stiff adjust it in accor dance with the following table Low Speed Compression Damping Standard 11 clicks B KX45
254. 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 CAUTION 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 subtank from the outer tube and slowly slide down the outer tube C Special Tool Top Plug Wrench 49 mm 57001 1653 13 30 SUSPENSION Front Fork KX450D8F e Place a drain pan under the front fork and drain 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 subtank to the outer tube B with the top plug wrench C Special Tool Top Plug Wrench 49 mm 57001 1653 e Hold the axle holder A with a vise OProtect the axle holder with a rag when using a vise e Loosen the adjuster assembly B completely 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 B and locknut C Special Tool Top Plug Wrench 49 mm 57001 1653 Be careful of reaction force in sprin
255. spectt e Water hoses and connections inspect t 2 19 Crankshaft inspect 2 29 Breather hose inspect Brake adjustment inspect t 2 28 2 35 Brake adjust t 2 39 Brake fluid level inspect t Brake fluid change Brake master cylinder cup and dust cover replace Brake caliper fluid seal and dust seal replace Brake hoses and pipe replace Brake hoses connections inspect t Spoke tightness and rim runout inspect t Every 2 years Every 2 years Every 2 years Every 4 years 2 36 2 37 2 39 2 41 2 44 2 30 Wheel bearing inspect t Frame inspect and clean Drive chain wear inspect t 2 31 2 33 Drive chain inspect and adjust 2 32 2 4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY OPERATION Each race or 2 5 hr Every 3 races or 7 5 Every 6 races or 15 hr Drive chain lubricate Wheels tires inspect Rear sprocket inspect t Front fork inspect and clean Front fork oil change Rear shock absorber oil change Cable inspect Fuel hose replace Fuel hose connections inspect t Fuel system clean Steering play inspect t Steering stem bearing lubricate Swingarm and Uni Trak linkage pivots lubricate Swingarm and Uni Trak linkage pivots inspect t Nuts bolts fasteners inspect t General Lubrication perform T Replace add adjust clean or torque if necessary PERIODIC MAINTENA
256. ss the inside release shaft needle bearing A until it bottom out with the bearing driver set B Special Tool Bearing driver Set 57001 1129 G104194BS1 G104195BS1 G104196BS1 G104197BS1 G104198BS1 9 10 CRANKSHAFT TRANSMISSION Crankcase e Next press the outside release shaft needle bearing 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 output shaft and release shaft oil seals C so that oil seal lip A face to the engine outside and oil seal surface flush with the left crankcase surface B e Press the shift shaft oil seal until it bottom out so that oil seal lip face the engine outside e Apply high temperature grease to the oil seal lip e Install the new circlip D to the output shaft and release shaft oil seal Special Tool Bearing driver Set 57001 1129 e Apply a non permanent locking agent to the bearing re taining screw e Tighten the bearing retaining screws A Torque Bearing Retaining Screws 15 N m 1 5 kgf m 11 ft Ib Piston Oil Nozzle B 2 9 N m 0 30 kgf m 26 in Ib e Apply engine oil to the transmission gears bearings shift forks shift drum and crankshaft bearing e Install the drive shaft A and output shaft B in the right crankcase half C as a set G104199BS1 CRANKS
257. st be replaced with a new one since the PLATING cylinder cannot be bored or honed A 10 mm 0 39 in B 30 mm 1 2 in C 50 mm 2 0 in Cylinder Inside Diameter Standard 96 000 96 012 mm 3 7795 3 7800 in and less than 0 01 mm 0 0004 in difference between any two measurements Service Limit 96 10 mm 3 783 in or more than 0 05 mm 0 020 in difference between any two measurements Piston Cylinder Clearance Inspection The piston to cylinder clearance is measured whenever a piston or cylinder is replaced with a new one The standard piston to 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 not be less than the minimum 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 between 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 0 020 0 042 mm 0 00079 0 0016 in Piston Piston Ring and Piston Pin Replacement e Refer to the Cylinder and Piston Section in Engine Top End chapter 2 24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Exhaust System Inspection e The exhaust system in particular the muffler body is de signed
258. ston Removal 5 32 Installations 5 13 Cylinder and Piston Installation 5 32 CALS MAMA cies coctelera 5 15 Cylinder Wear Inspection 5 34 Camshaft Removal 5 15 Piston Wear Inspection 5 34 Camshaft Installation 5 16 Piston Cylinder Clearance Camshaft Chain Removal 5 18 Inspection 5 34 Camshaft Chain Installation 5 18 Piston Ring Ring Groove Camshaft and Camshaft Cap Clearance Inspection 5 34 Wear Inspection 5 19 Piston Ring Groove Width Camshaft Runout Inspection 5 19 Inspection 5 35 Cam Wear Inspection 5 19 Piston Ring Thickness Inspection 5 35 Cylinder Head 5 20 Piston Ring End Gap Cylinder Compression Measurement 5 35 Measurement 5 20 Piston Piston Pin Connecting Cylinder Head Removal 5 21 Rod Wear Inspection 5 36 Cylinder Head Installation 5 22 Carburetor Holder 5 37 Cylinder Head Cleaning 5 23 Carburetor Holder Installation 5 37 Cylinder Head Warp Inspection 5 23 Muller tesina 5 38 Wai ais 5 24 Muffler HRemoval 5 38 Valve Clearance Inspection 5 24 Muffler Installation 5 38 Valve Removal 5 24 Muffler Baffle Replacem
259. t Adjusting nut position from the center of the mounting hole upper Rear Shock Spring Free Length High Speed Compression Damping Adjustment Low 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 EUR Europe Model TIR Total Indicator Reading 127 5 mm 5 020 in KX450D6F D7F 128 5 mm 5 059 in KX450D8F 260 mm 10 2 in 1 1 6 turns out KX450D6F 1 1 2 turns out KX450D7F 1 turn out EUR 1 1 2 turns out KX450D8F 11 clicks counterclockwise KX450D6F 10 clicks counterclockwise KX450D7F 8 clicks counterclockwise EUR 10 clicks counterclockwise KX450D8F 980 kPa 10 kgf cm 142 psi 19 987 20 000 mm 0 78688 0 78740 in 19 987 20 000 mm 0 78688 0 78740 in 15 950 16 000 mm 0 62795 0 62992 in TIR 0 1 mm 0 004 in or less Adjustable Range 121 5 138 5 mm 4 783 5 453 in KX450D6F D8F 122 1 131 6 mm 4 8075 5 181 in KX450D7F 255 mm 10 0 in Adjustable Range 2 0 5 turns out KX450D6F 4 turns out KX450D7F Adjustable Range 16 clicks KX450D6F 19 clicks KX450D7F 22 clicks KX450D8F 19 85 mm 0 781 in 19 85 mm 0 781 in 15 92 mm 0 627 in TIR 0 2 mm 0 008 in 13 10 SUSPENSION Special Tools Oil Seal 8 Bearing Re
260. t Cover Bolts 9 8 N m 1 0 kgf m 87 in lb Rear Sprocket Removal e Remove the rear wheel see Rear wheel Removal in the Wheels Tires chapter CAUTION 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 Unscrew the rear sprocket bolts A and remove the rear sprocket B 6K05003BS1 11 8 FINAL DRIVE Sprockets Rear Sprocket Installation e Install the rear sprocket A so that the marked side B faces out e Install the rear sprocket bolts and tighten the nuts Torque Rear Sprocket Nuts 34 N m 3 5 kgf m 25 lb Sprocket Wear Inspection e Refer to the Sprocket Wear Inspection in the Periodic Maintenance chapter Rear Sprocket Warp Inspection e Refer to the Rear Sprocket Warp Inspection in the Peri odic Maintenance chapter EE OC 6K05004BS1 BRAKES 12 1 Brakes Table of Contents EXDIOded VIEWS STARS M AR RE ARS DT A nha en Re 12 2 Specifications EE 12 6 MPSClal MEET 12 7 Brake Lever Brake Pedal A E dt de 12 8 Brake Lever AGiuSUMOM Eerad 12 8 Brake Pedal Position Adjusiment ssssssseean metiers 12 8 Brake eg Removal A Re dur Means idl al cain atari Anne 12 8 Brake Pedal Installation cias 12 8 Brake Fluid EE 12 9 Fluid Level Inspection ss 12 9 Ge Ke Le EE EE 12 9 Bleeding the Brake LIO amic ri 12 10 A D cite ener dees 12 12 Caliper ne R
261. t the axle holder with a rag when using a vise e Loosen the adjuster assembly B completely 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 B and locknut C Special Tool Top Plug Wrench 49 mm 57001 1653 WARNING Be careful of reaction force in spring and fix surely so that the special tool should not come off Do not place the finger etc while servicing e Hold the locknut A with a wrench B and remove the adjuster assembly C 2 48 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Remove the push rod A e With the outer tube compressed by hands remove the top plug wrench A CAUTION 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 Loosen the fork top plug subtank A with the top plug wrench B Special Tool Top Plug Wrench 49 mm 57001 1653 B e Remove Cylinder Unit A Spring Seat B Spacer C Washer D Fork Spring E CAUTION Disassembling the cylinder unit can lead to trouble Do not disassemble the cylinder unit e Holding the top plug wrench A with a vise loosen the base
262. t the front wheel off the ground Special Tool Jack 57001 1238 e Clean the bottom of the fork tubes e Remove the caps on the bottom of the fork tubes e To adjust rebound damping turn the adjuster A on the front fork cylinder valve with the blade of a 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 positions adjuster turned fully clockwise A Rebound Damping Adjuster Setting Standard 13 clicks B KX450D6F 9 clicks EUR 10 clicks KX450D7F Softer Counterclockwise C Harder Clockwise D Number of turns counterclockwise usable range 16 clicks or more KX450D6F 20 clicks or more KX450D7F Counterclockwise from the fully seated position e Put the caps into the bottom of the fork tubes 161514131211 10 9 8 7 6 5 4 3 2 1 d GM04321BS1 13 12 SUSPENSION Front Fork KX450D6F D7F Compression Damping Adjustment e Place the jack under the frame so that the front wheel off the ground Special Tool Jack 57001 1238 e To adjust compression damping turn the adjuster A on the front fork top plugs with the blade of a 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 Seated positions adjuster tu
263. t the gaps B in the stop C with suitable tools to free the stop from the rear shock body D e Slide the stop 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 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 GMO5065BS1 e Visually inspect the piston A O ring B and oil seal assy C elt the piston O ring and oil seal assy are badly scored rusty or damaged replace them PERIODIC MAINTENANCE 2 65 Periodic Maintenance Procedures e Using the grinder shave off the stop portion A of the rod e Remove Nut B Washer C Piston D e Install the new piston and tighten the locknut ODiscard a washer or two e Pour KYB K2 C SAE 5W or Bel Ray SE2 40 oil into the gas reservoir to 60 70 mm 2 63 2 76 in A from the gas reservoir upper end Recommended Oil K2 C KAYABA or equivalent GM05010481 e Check that the bladder A on the gas reservoir cap is not partially collapsed x If it is push down the valve core with a screwdriver e Check the bladder for sign of damage or crack x f necessary replace it with a new one CAUTION Do not use a damaged or partially collapsed blad der because it may burst gently reducing rear shoc
264. teeth for wear and damage lf they are worn as illustrated or damaged replace the sprocket A Worn Tooth Engine Sprocket B Worn Tooth Rear Sprocket C Direction of Rotation NOTE Olf a sprocket requires replacement the chain is proba bly worn also When replacing a sprocket inspect the chain 6K04030351 6K05017BS1 PERIODIC MAINTENANCE 2 35 Periodic Maintenance Procedures Rear Sprocket Warp Runout Inspection e Using the jack raise the rear wheel off the ground Special Tool Jack 57001 1238 e Set a dial gauge A against the rear sprocket B near the teeth as shown and rotate C the rear wheel to measure the sprocket runout warp The difference between the highest and lowest dial gauge readings is the amount of runout warp Alf the runout exceeds the service limit replace the rear sprocket 6S12024BS1 Rear Sprocket Warp Runout Standard TIR 0 4 mm 0 016 in or less Service Limit TIR 0 5 mm 0 02 in Brakes Brake Lever and Pedal Position Adjustment A WARNING Always maintain proper brake adjustment If ad justment is improper the brake could drag and overheat This could damage the brake assembly and possibly lock the wheel resulting in loss of control e Adjust the front brake lever A to suit you e Slide the brake lever dust cover B out of place e Loosen the adjuster locknut C and turn the adjuster D to either side
265. tenance Procedures e With the outer tube compressed by hands remove the top plug wrench A CAUTION 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 Loosen the fork top plug subtank A with the top plug wrench B Special Tool Top Plug Wrench 49 mm 57001 1653 B e Remove Cylinder Unit A Spacer B Fork Spring C CAUTION 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 1705 C Special Tool Top Plug Wrench 49 mm 57001 1653 Top Plug Wrench 36 mm 57001 1705 e Remove the base valve assembly A from the subtank B NOTE OSlowly compress the piston rod until it stops so that the base valve assembly can be removed easily CAUTION Disassembling the base valve assembly can lead to trouble Do not disassemble the base valve assembly 2 58 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 inverted position for more than 20 min utes to allow the fork oil to fully drain e Clean the threads A of subtank and base valve assem bly
266. ter A WARNING Operation with an improperly adjusted incorrectly routed or damaged cable could result in an unsafe riding condition 2 14 PERIODIC MAINTENANCE Periodic Maintenance Procedures 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 1 800 50 r min rpm Idle Speed Adjustment e First turn in the air screw using the pilot screw adjuster A until it seats lightly and back it out the specified num ber of turns see Specifications Section in the Fuel Sys tem chapter Special Tools Pilot Screw Adjuster C 57001 1292 or Pilot Screw Adjuster D 57001 1588 Pilot Screw Adjuster Adapter 4 57001 1371 e Start the engine and warm it up thoroughly e Turn the idle adjusting screw B until the idle speed is correct To increase idle speed C To decrease idle speed D 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 th
267. termining 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 e Connect the ignition coil with the spark plug cap left in stalled on the spark plug lead A to the tester B and measure the arcing distance WARNING To avoid extremely high voltage shocks do not touch the coil or lead x If 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 ignition coil 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 Measuring Coil Resistance If the arcing tester is not available the coil can be checked for a broken or badly shorted winding with an ohmmeter However an ohmmeter cannot detect layer shorts and shorts resulting from insulation breakdown under high voltage e Remove the ignition coil see Ignition Coil Removal e Measure the primary winding resistance A OConnect an ohmmeter between the coil terminals OSet the meter to the x 1 Q range and read the meter e Measure the secondary winding resistance B OPull the spark plug cap off the lead OConnect an ohmmeter between
268. th 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 32 ENGINE TOP END Cylinder and Piston Cylinder Removal e Remove Cylinder Head see Cylinder Head Removal Front Camshaft Chain Guide A Cylinder Bolt B 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 Place a clean cloth under the piston and remove the pis ton snap ring A from one end of the piston pin CAUTION Do not reuse snap rings as removal weakens and deforms them They could fall out and score the cylinder wall e Remove the piston pin using a piston pin puller Special Tool Piston Pin Puller Assembly 57001 1568 A e Remove the piston e Carefully spread the ring opening with your thumbs and then push up on the opposite side ofthe ring A to remove it e Remove the oil ring in the same procedure Cylinder and Piston Installation 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 o
269. the brake fluid must be refilled but the type and brand of the brake fluid that is already in the reservoir are unidentified After changing the fluid use only the same type and brand of fluid thereafter PERIODIC MAINTENANCE 2 37 Periodic Maintenance Procedures Brake Fluid Change In accordance with the Periodic Maintenance Chart change the brake fluid The brake fluid should also be changed if it becomes contaminated with dirt or water Furthermore the brake fluid should be changed to bleed the air quickly and completely whenever the brake line parts are removed A WARNING When working with the disc brake observe the pre cautions listed below 1 Never reuse old brake fluid 2 Do not use fluid from a container that has been left unsealed or that has been open for a long time 3 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 ineffective It may also cause the rubber brake parts to deteriorate 4 Don t leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid 5 Don t change the fluid in the rain or when a strong wind is blowing 6 Except for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning brake parts Do not use any other fluid for cleaning these parts Gasoline engine oil or any other petroleum distillat
270. 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 e If it should be necessary to disassemble the crankshaft use a press to remove the crankpin Crankshaft Assembly Since the assembly 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 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 e Reassemble the crankshaft according to the standard tol erances in Specifications OConnecting rod bend twist OConnecting rod big end radial clearance OCold fitting tolerance between crankpin and flywheels OSide clearance between the connecting rod big end and one of flywheels OCrankshaft runout G105137BS1 G105144BS1 CRANKSHAFT TRANSMISSION 9 15 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 0006 in Serv
271. the grip to 185 mm 7 28 in A e The master cylinder clamp must be installed with the ar row mark A upward OTighten the upper clamp bolt B first and then the lower clamp bolt C There will be a gap at the lower part of the clamp after tightening Torque Master Cylinder Clamp Bolts 8 8 N m 0 90 kgf m 78 in lb e Replace the washers that are on each side of hose fitting with new ones e Tighten the brake hose banjo bolt Torque Brake Hose Banjo Bolt 25 N m 2 5 kgf m 18 ft lb e Bleed the brake line see Bleeding the Brake Line e Check the brake for good braking power no brake drag and no fluid leakage aowi P BRAKES 12 17 Master Cylinder Rear Master Cylinder Removal e Remove the cotter pin A e Pull off the joint pin B with washer NOTE OPull off the joint pin while pressing down the brake pedal e Unscrew the master cylinder mounting bolts C and re move the master cylinder D e Unscrew the brake hose banjo bolt E e When 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 Replace the cotter pin with a new one e Replace the washers are on each side of hose fitting with new ones e Tighten the following Torque Brake Hose Banjo Bolt 25 N m 2 5 kgf m 18 ft lb Rear Master Cylinder Mounting Bolts 9 8 N m 1 0 kgf m 87 in lb Rear Master Cylinder Push
272. the high tension lead and the ground lead terminal OSet the meter to the x 1 kQ range and read the meter Ignition Coil Winding Resistance Primary windings 0 28 0 38 Q at 20 C 68 F Secondary windings 7 65 10 35 kQ at 20 C 68 F x If the meter does not read as specified replace the coil x If the meter reads as specified the ignition coil windings are probably good However if the ignition system still does not perform as it should after all other components have been checked test replace the coil with one known to be good e Check the high tension lead for visible damage lf the high tension 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 CG 6P10199BS1 GP10274BS1 16 16 ELECTRICAL SYSTEM Ignition System Spark Plug Gap Inspection e Refer to the Spark Plug Cleaning and Inspection in the Periodic Maintenance chapter C D I Unit Removal e Remove Belt Open A Bolt B Number Plate C e Disconnect the main harness connector A e Unscrew the mounting bolts B and remove the C D I Unit C C D I Unit Installation Torque CDI Unit Bolts 9 8 N m 1 0 kgf m 87 in Ib C D I Unit Inspection CAUTION When inspecting the C D I unit observe the follow ing to avoid damage to the C D I unit Do not disconnect the C D I unit
273. the mounting bolt A and remove the engine guard B e Remove Seat see Seat Removal in the Frame chapter Side Covers see Side Cover Removal in the Frame chapter Fuel Tank see Fuel Tank Removal in the Fuel System chapter e Remove Water Hoses A Bolt B Radiator Screen C 8 6 ENGINE REMOVAL INSTALLATION Engine Removal Installation e Remove Radiator Mounting Bolts A Radiator B e Remove Muffler see Muffler Removal in the Engine Top End chapter Water Hoses B Bolt C Radiator Screen D e Remove Radiator Mounting Bolts A Radiator B e Loosen Carburetor Clamp Bolts A e Remove Air Cleaner Duct B with Rear Frame see Rear Frame Removal in the Frame chapter Carburetor C see Carburetor Removal in the Fuel Sys tem chapter Clutch Cable Lower End D see Engine Right Side chapter Drive Chain E cut out e Remove Bolts A Rear Brake Pedal B Master Cylinder C ENGINE REMOVAL INSTALLATION 8 7 Engine Removal Installation e Pry open the clamps A e Disconnect Magnet Lead Connector B Gear Position Switch Connector C Ignition Coil Lead Connector D Spark Plug Cap e Remove Ignition Coil A Upper Engine Bracket Bolts Left and Right B Upper Engine Mounting Bolt and Nut Left and Right C Upper Engine Brackets Left and Right D Engine Guard E Middle Engine Bracket Bolts and Nuts F Middle Engine Mounting Bolt and Nut G Middle Engine Br
274. the rear shock body C slowly Do not insert the seal assembly B yet Pump the piston rod until all the air is forced out of the rear shock body GMO5011BS1 GMO5068BS2 C tpg GM05067BS1 PERIODIC MAINTENANCE 2 67 Periodic Maintenance Procedures e Push the seal assembly into the rear shock body until it just clears the circlip groove e Check the circlip x If it is deformed or damaged replace it with a new one e Fit the circlip A into the groove in the rear shock body B CAUTION 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 stop D into the rear shock body by lightly tap ping around the edge of the stop with a mallet e Fully extend the piston rod assembly e Install the suitable oil cup A to the air bleed bolt hole and fill the specified oil into the cup e Purge the air from between the gas reservoir B and rear shock body C by slowly pumping the piston rod D in and out e Install the air bleed bolt securely Torque Air Bleed Bolt 6 4 N m 0 65 kgf m 57 in lb e Fully extend the push rod assembly e Inject nitrogen gas to a pressure of 50 kPa 0 5 kgf cm 7 psi through the valve on the gas reservoir
275. the throttle link into the slits B of the throttle valve e Tighten the screw e Apply a grease to the O ring A e Fit the stopper B of the throttle sensor onto the projection C on the throttle cable pulley shaft Olnstall the throttle sensor so that the marks aligns and check it position see Throttle Sensor Inspection in the Electrical System chapter e Install O ring A Carburetor Cap B Bolts tighten e Install Starter Jet A Pilot Jet B Baffle Plate C Needle Jet D Main Jet E 3 26 FUEL SYSTEM Carburetor e Replace the O ring with new one e Install Pilot Air Screw A Spring B Washer C O ring D OTurn in the pilot air screw fully but not tightly and the back it out the counted number of turn see Carburetor Disassembly e Hang the float valve A on the tang B of the float C e Fit the float valve into the valve seat e Insert the pin D e Install Leak Jet A e Replace the O ring with new one e Fit the O ring B onto the groove of the float chamber e Install Float Bowl e Tighten the screws with hose clamps A and cable holder B as shown e Replace the O rings with new ones e Fit the O rings A e Install Diaphragm B Spring C Acceleration Pump Cover Olnstall the diaphragm so that its mark facing D outward e Tighten the bolts Carburetor FUEL SYSTEM 3 27 e Install the choke knob starter plunger A e Replace the O
276. thly after as sembling the engine Wheel Tires Air Pressure Inspection Adjustment e Using tire air pressure gauge A measure the tire pres sure when the tires are cold 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 kgf em or slippery reduce the tire pressure 11 psi to increase the tire tread surface on H A the ground When the track is pebbly or hard increase the tire pressure to prevent damage or punctures through the tires will skid more easily y 100 kPa 1 0 kgf cm 14 psi f ESIOBOO P GJ05010381 2 30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Tires Inspection As the tire tread wears down the tire becomes more sus ceptible the puncture and failure e Remove any imbedded stones or other foreign particles from the tread e Visually inspect the tire for cracks and cuts replacing the tire in case of bad damage Swelling or high spots indi cate internal damage requiring tire replacement WARNING To ensure safe handling and stability use only the recommended standard tires for replacement in flated to the standard pressure NOTE OCheck and balance the wheel when a tire is replaced with a new one Standard Tire Front Size 90 100 21 57M Make DUNLOP Type D742F Tu
277. times to expel air e Replace the O rings A on the base valve assembly with new ones e Apply specified fork oil to the O rings A B and bushings C on the base valve assembly e With the piston rod held immovable in fully compressed position A gently install the base valve assembly B to the subtank e Screw in the base valve assembly in the subtank when the piston rod extends NOTE OWhen it is hard to screw in the base valve assembly pull down the piston rod a little 13 20 SUSPENSION Front Fork KX450D6F D7F e Holding the top plug wrench A with a vise e Holding the subtank B with the top plug wrench torque the base valve assembly C Special Tool Top Plug Wrench 49 mm 57001 1653 Torque Base Valve Assembly 28 N m 2 9 kgf m 21 ft lb e Protect the piston rod end A with a rag B to prevent fork damage e Discharge the extra oil offthe cylinder unit by pumping C the piston rod to full stroke CAUTION Be careful not to bend or damage the piston rod when the piston rod is stroked Service carefully because oil flies out from the oil hole of the cylinder unit NOTE OSet the compression damper setting to the softest OCheck the piston rod sliding surface for damage OApply fork oil to the piston rod sliding surface e Drain the extra oil from the subtank oil hole A e With the cylinder unit in horizontal position move A the piston rod B by hand to inspect it i
278. tion pump lever A Spring B Push Rod Holder C Adjusting Screw with Spring D OFit the spring end on the stopper E of the push rod holder e Install the return spring A to the acceleration pump lever B e Install the acceleration pump lever assembly to the car buretor body OFit the end B of the return spring into the recess A on the carburetor body e Install Washer A E clip B 3 24 FUEL SYSTEM Carburetor e Apply thin coat silicone grease to the shaft e Fit the hook A of the return spring onto the stopper B f of the throttle cable pulley A ENT eus Y LR d Ox i i A e Insert the throttle cable pulley shaft A and install the steel washer B nylon washer C and valve link D OFit the end A of the return spring into the recess B of the carburetor body e Turn the pulley counterclockwise A while holding down the acceleration pump lever B and clear the stopper C of the pulley from the throttle stop screw head D e Install the push rod A into the push rod holder B FUEL SYSTEM 3 25 Carburetor e Assembly Throttle Valve A Jet Needle B Circlip C Retainer D Spring E Jet Needle Holder F O ring G Throttle Valve Plate H OAssemble the valve plate so that the hole side downward 1 e Apply a non permanent locking agent to the link screw e Insert the throttle valve assembly Olnsert the link rollers A on
279. tled uniformly tighten all the bolts OFollowing the sequence numbers on the camshaft caps Tighten the cap bolts 1 8 after applying molybdenum disulfide oil to the thread of them 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 then check the camshaft chain timing CAUTION After this procedure if any resistance is felt while turning over the crankshaft stop immediately and check the camshaft chain timing Valves will be bent if the timing is not properly set e Install the cylinder head cover see Cylinder Head Cover Installation timing inspection cap and the balancer shaft cap Special Tool Filler Cap Driver 57001 1454 Camshaft Chain Removal e Remove Camshaft see Camshaft Removal Flywheel see Flywheel Removal in the Electrical Sys tem Lower Camshaft Chain Guide Bolt A Lower Chain Guide B Front Chain Guide C e Remove the camshaft chain D from the crankshaft sprocket Camshaft Chain Installation e Hang the camshaft chain A to the crankshaft sprocket e Install Front Chain Guide B Lower Chain Guide C e Tighten Torque Lower Camshaft Chain Guide Bolts D Oil Pump Scavenge Cover Bolts 9 8 Nm 1 0 kgf m 87 in lb e Install Flywheel see Flywheel Installation in the Electrical Sys tem chapter Camshaft see Camshaft Installation Camshaft ENGINE TOP END
280. tly 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 OSet the hand tester to DC 2 5 V range OConnect the peak voltage adapter A to the tester and the terminals of the magneto lead connector B Special Tools Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Connection Adapter Positive Green White Lead C Adapter Negative White Yellow Lead D OCrank the engine by kicking the pedal several times to measure the peak voltage of the crankshaft sensor Peak Voltage 1 1 V or above WARNING Do not touch the metal portion of the probe in case of measuring the voltage or you may receive a se rious electric shock x If the voltage is less than the specified check the crank shaft sensor GP10275BS1 16 20 ELECTRICAL SYSTEM Ignition System Charge Coil Peak Voltage Check e Disconnect the connector of the magneto lead connector from the main harness e To check the peak voltage do the following procedures 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 OConnect the peak voltage adapter
281. ton rod when the piston rod is stroked Service carefully because oil files out from the oil hole of the cylinder unit NOTE OSet the compression damper setting to the softest OCheck the piston rod sliding surface for damage OApply fork oil to the piston rod sliding surface 2 60 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Drain the extra oil from the subtank oil hole A e With the cylinder unit in horizontal position move A the piston rod B by hand to inspect it if operating smoothly Olf the piston 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 of the fork oil from the spring A spacer B and cylinder unit C e Insert above mentioned parts into the fork e Temporarily tighten the fork top plug A subtank using the top plug wrench Special Tool Top Plug Wrench 49 mm 57001 1653 B PERIODIC MAINTENANCE 2 61 Periodic Maintenance Procedures e Clamp the axle holder with a vise OProtect the axle holder with a rag 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 Compress the outer tube by hands and install the top plug wrench A between the axle holder bott
282. torque e Check the front brake for good braking power and no brake drag A WARNING Do not attempt to drive the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc The brake will not function on the first application of the lever if this is not done Rear Wheel Removal e Using the jack under the frame so that the rear wheel is raised off the ground Special Tool Jack 57001 1238 e Remove the clip A from the master link using pliers and free the drive chain B from the rear sprocket 2 DEJEN NECIO Et F Qp e COR Zo 6J04006BS1 10 8 WHEELS TIRES Wheels Rims e Remove Cotter Pin A Axle Nut B e Pull out the axle C e Move the rear wheel back with the rear caliper installed e Take off the collar and cap from the each side of the rear hub CAUTION 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 wood wedge between the brake pads This pre vents them from being moved out of their proper position should the brake pedal be squeezed accidentally Rear Wheel Installation e Fit the brake holder stop A with the stop grooves B against the swingarm stop space C with the stop pro jection D e Fit the projection on the cap to the groove on the collar e
283. tting the motorcycle into operation any air trapped in the cooling system must be removed as follows e Start the engine warm up the engine thoroughly and then stop the engine 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 CAUTION 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 If the pressure holds steady the cooling system is all right e Remove the pressure tester replenish the coolant and install the radiator cap xlf the pressure drops and no external source is found check for internal leaks Check the cylinder head gasket for leaks Cooling System Flushing Over a period of time the cooling system accumulates rust scale and
284. uctions or irreparably de formed fins replace the radiator with a new one CAUTION 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 Radiator Cap Inspection e Check the condition of the valve spring B and the top and bottom valve seals A of the radiator cap x If any one of them shows visible damage replace the cap 6D07000BS1 4 14 COOLING SYSTEM Radiator e Wet the top and bottom valve seals with water or coolant to prevent pressure 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 112 142 kPa 1 14 1 45 kgf lcm 16 2 20 6 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 cond
285. ued from Left Side 1 Install the clamps as shown in the figure 3 Carburetor 2 Clamps Install the clamp screws as shown in the figure 17 6 APPENDIX Cable Wire and Hose Routing 1 Left Radiator 6 Joint Pipe 2 Right Radiator 7 Clamp Position the clamp claw to left 3 Water Hose to cylinder head side 4 Water Hose to water pump 8 Clamp Position the clamp claw down 5 Radiator Overflow Hose ward APPENDIX 17 7 Cable Wire and Hose Routing GB098538W4 C 1 Brake Lever 10 Rear Brake Master Cylinder 2 Front Brake Master Cylinder 11 Rear Brake Hose 3 Front Brake Hose 12 Clamps 4 Clamp 13 Rear Brake Caliper 5 Viewed 14 Rear Brake Caliper Guard 6 Clamps 15 Rear Brake Disc 7 Front Brake Caliper 16 Rear Brake Disc Guard 8 Front Brake Disc 17 Cotter Pin 9 Brake Pedal 17 8 APPENDIX Troubleshooting Guide This 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 more common difficulties Engine Doesn t Start Starting Difficulty Engine won t turn over 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 No fuel flow No fuel in tank Fuel tank ca
286. uel System chapter Exhaust Pipe A see Muffler Removal Clamp Screw B Water Hose C Engine Bracket Bolts D Engine Bracket E e Remove the 6 mm cylinder head bolts A and loosen the cylinder bolt B OThis prevents the 6 mm bolts from becoming damaged 5 22 ENGINE TOP END Cylinder Head e Remove the 10 mm cylinder head bolts following the tight ening sequence as shown e Tap lightly up with a plastic mallet A to separate the cylin der head B from the cylinder e Remove the cylinder head gasket Cylinder Head Installation e Fit the projection A of the front camshaft chain guide B in the groove C of the cylinder Olnsert the guide end D into the recess E of the crankcase securely e Install Dowel Pins A New Cylinder Head Gasket B e Install the cylinder head 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 all the 10 mm cylinder head bolt washers with new ones OThe 10 mm cylinder head bolt washers are copper plated and they could leak oil if reused e Apply molybdenum disulfide oil to the both sides A of the 10 mm cylinder head bolt washer and thread B of the 10 mm cylinder head bolts GE14072BS1 Cylinder Head ENGINE TOP END 5 23 e Tighten the 10 mm cylinder head bolts in the numbered sequence 1 4 Torque Cylinder Head Bolts M10 59 N
287. ump 2 0 15 5 Engine Oil Drain Bolt M6 For Crank Room Oil Sump 0 71 62 in lb 6 Shift Drum Cam Bolt 2 4 17 L 7 Piston Oil Nozzle KX450D6F D7F 0 30 26 in lb 9 4 CRANKSHAFT TRANSMISSION Specifications Item Standard Service Limit Connecting Rods Connecting Rod Big End Radial 0 002 0 014 mm 0 06 mm 0 002 in Clearance 0 00008 0 0006 in Connecting Rod Big End Side 0 25 0 35 mm 0 6 mm 0 02 in Clearance 0 0098 0 014 in Crankshaft Runout TIR 0 03 mm 0 0012 in or less TIR 0 08 mm 0 0031 in Connecting Rod Bend TIR 0 2 mm 0 08 in 100 mm 3 94 in Connecting Rod Twist EE TIR 0 2 mm 0 08 in 100 mm 3 94 in Transmission Shift Fork Ear Thickness 4 9 5 0 mm 0 193 0 197 in 4 8 mm 0 19 in Gear Shift Fork Groove Width 5 05 5 15 mm 0 199 0 203 in 5 25 mm 0 207 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 25 in TIR Total Indicator Readings Special Tools and Sealant Outside Circlip Pliers 57001 144 ST5701448T Bearing Driver Set 57001 1129 ST5711298T Crankshaft Jig 57001 1174 ST5711748T CRANKSHAFT TRANSMISSION 9 5 Crankcase Splitting Tool Assembly 57001 1362 8757136297 Kawasaki Bond Liquid Gasket Gray 92104 1063 9 6 CRANKSHAFT TRANSMISSION Crankcase
288. utch cable see Clutch Cable Removal e Pull the lever and shaft assembly B out of the crankcase Release Sha t Installation e Apply high temperature grease to the oil seal lips e Apply engine oil to the bearing in the hole of the crankcase e Apply grease to the part where the push rod comes in contact e Insert the release shaft straight into the upper hole of the crankcase CAUTION When inserting the release shaft be careful not to remove the spring of the oil seal e Install the clutch cable see Clutch Cable Installation 6 12 ENGINE RIGHT SIDE Clutch Clutch Removal e Drain the engine oil see Engine Oil Change in the Peri odic Maintenance chapter e Remove the clutch cover see Clutch Cover Removal e Remove Clutch Spring Bolts A Clutch Spring Clutch Pressure Plate B e Remove Washer A Needle Bearing B Push Rod Holder C Push Rod Friction Plates D Steel Plates E e Fix the clutch hub A with the clutch holder B Special Tool Clutch Holder 57001 1243 e Loosen the clutch hub nut C counterclockwise e Remove Washer Clutch Hub 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 of the clutch housing gear e Install the clutch housing A e Do not forget to install the toothed washer B before in
289. 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 e Install Front Wheel see Front Wheel Installation in the Wheels Tires chapter Front Brake see Caliper Installation in the Brakes chap ter Brake Hose Clamps see Brake Hose Replacement Front Fork Oil Change each fork leg KX450D8F e Remove Number Plate e Loosen the front fork upper camp bolts A e Loosen the fork top plug A Special Tool Top Plug Wrench 49 mm 57001 1653 B e Remove Front Wheel see Front Wheel Removal in the Wheels Tires chapter Front Brake Caliper see Caliper Removal in the Brakes chapter Brake Hose Clamps see Brake Hose Replacement 6M04254BS1 PERIODIC MAINTENANCE 2 55 Periodic Maintenance Procedures e Loosen the front fork lower clamp bolts A e Remove the front fork OWith a twisting motion work the fork leg B down and out GSi48374 P 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 CAUTION Be careful not scratch the inner tube and not to damage the dust seal Avoid scratching or damaging t
290. ventilated area and take care that there are no sparks or flame any where near the working area this includes any ap pliance with a pilot light Do not use gasoline or a low flash point solvent to clean parts A fire or ex plosions could result e Support the crankcase bearing 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 CAUTION Support the crankcase bearing boss when the bear ing is pressed or the crankcase could be damaged 6104000BS1 CRANKSHAFT TRANSMISSION 9 9 Crankcase e Press the new transmission shaft bearing A in the left crankcase half so that the sealed side B faces outside of the engine Special Tool Bearing Driver Set 57001 1129 e Press the new drive shaft bearing A in the right crankcase B half 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 shift drum needle bearing A and shift shaft needle B bearing in the left crankcase half so that bear ing surface flush with the crankcase surface C Special Tool Bearing driver Set 57001 1129 e First pre
291. w is worn or damaged on the tapered portion it will prevent the engine from idling smoothly Replace it e Remove the float valve needle e Check the plastic tip A of the float valve needle B for wear x If the needle is worn as shown right C replace the valve needle e Push the rod D in the valve needle then release it x lf the rod does not come out fully by spring tension re place the valve needle Push and release E e Remove the starter jet e Check the slow jet for any damage x If the slow jet is damaged replace it with a new one e Remove the throttle valve and jet needle e Inspect the outside of the throttle valve and plate for scratches and abnormal wear x If it is badly scratched or worn replace the throttle valve or plate e Inspect the inside of the carburetor body for these same faults x lf it is badly scratched or worn replace the entire carbu retor e Check the jet needle for wear e For the throttle sensor inspection see the Electrical Sys tem chapter A worn jet needle should be replaced e Clean the fuel and air passages with a high flash point solvent and compressed air 6006014451 C 6006014351 C FUEL SYSTEM 3 23 Carburetor Carburetor Assembly e Clean the disassembly parts before assembling OClean the fuel and air passages with a high flash point solvent and compressed air A e Set up the acceleration pump lever assembly as shown Accelera
292. 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 05 L 1 11 US qt e Install the drain bolt OReplace the gasket with a new one Torque Coolant Drain Bolt 6 9 N m 0 70 kgf m 61 in Ib e Fill the radiator up to the bottom of the radiator filler neck B with coolant A and install the cap turning it clockwise A B about 1 4 turn OLean the motorcycle slightly to the right until the radiator r filler neck is level to the ground so that the filler neck is lo cated uppermost in order to exhaust the air accumulated SJ in the radiator NOTE OPour in the coolant slowly so that it can expel the air eposo1ensi from the engine and radiator The radiator cap must be installed in two steps First 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 Before pu
293. y e Check that the hot starter lever moves smoothly from full open to close and the lever closes quickly and completely in all steering positions by the return spring x If the hot starter lever does not return properly check the hot starter cable routing free play and cable damage Then lubricate the hot starter cable Idle Speed Inspection CAUTION 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 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 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 chap
294. y e Check the idle speed lf the idle speed is out of the specified range adjust it see Idle speed Adjustment in the Periodic Maintenance chapter GP18196BS2 GP25006BS1 16 24 ELECTRICAL SYSTEM Switches Engine Stop Switch Inspection e Using the hand tester check to see that only the con nections shown in the table have continuity about zero ohms Special Tool Hand Tester 57001 1394 x If the switch has an open or short repair it or replace it with a new one Engine Stop Switch Connection Gear Position Switch Removal e Remove Bolt A Left Radiator Screen B Left Radiator Mounting Bolts C e Push the left radiator forward D e Pry open the clamps A e Disconnect the gear position switch connector e Remove Shift Pedal External Shift Mechanism Removal in the Engine Right Side chapter Screws A Gear Position Switch B Switches ELECTRICAL SYSTEM 16 25 e Remove O ring A Gear Position Switch Finger B Spring C Gear Position Switch Installation e Insert the spring into the hole in the shift drum e Insert the switch finger A so that the small diameter B is toward hole side e Apply grease to the O ring e Clean the contact points on the position switch e Apply a non parmanent 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 lb e Install the oth
295. y B to the subtank e Screw in the base valve assembly in the subtank 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 Holding the top plug wrench A with a vise Special Tool Top Plug Wrench 49 mm 57001 1653 e Holding the subtank B with the top plug wrench torque the base valve assembly C Torque Base Valve Assembly 28 N m 2 9 kgf m 21 ft lb PERIODIC MAINTENANCE 2 51 Periodic Maintenance Procedures e Protect the piston rod end A with a rag B to prevent fork damage e Discharge the extra oil off the cylinder unit by pumping C the piston rod to full stroke CAUTION Be careful not to bend or damage the piston rod when the piston rod is stroked Service carefully because oil files out from the oil hole of the cylinder unit NOTE OSet the compression damper setting to the softest OCheck the piston rod sliding surface for damage OApply fork oil to the piston rod sliding surface e Drain the extra oil from the subtank oil hole A e With the cylinder unit in horizontal position move A the piston rod B by hand to inspect it if operating smoothly Olf the piston 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
296. y and check for roughness or binding x If the roughness or binding is found replace the hub bear ings e Visually inspect the front and rear axles for damage x If the axle is damaged or bent replace it 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 GKO4001BS1 GJ04034BS1 10 10 WHEELS TIRES Wheels Rims 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 in V blocks that are 100 mm 3 937 in A apart and set a dial gauge on the axle at a point halfway between the blocks Turn the axle to measure the runout The difference between the highest and lowest dial read ings is the amount of runout x If the runout exceeds the service limit replace the axle Axle Runout 100 mm 3 94 in Standard TIR 0 1 mm 0 004 in or less Service Limit TIR 0 2 mm 0 008 in GJ04139BS1 WHEELS TIRES 10 11 Tires Tire Removal CAUTION 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 Remove the wheel from the motorcycle see Wheels Re moval e To maintain front wheel balance mark A the valve stem

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