Kawasaki KX450F 2014 Owner's manual

Quick Reference Guide

This Quick Reference Guide will assist you in finding the information you’re looking for.

GENERAL INFORMATION	j
MAINTENANCE AND ADJUSTMENT	j
TROUBLESHOOTING GUIDE	j
TUNING	j
STORAGE	j

A Table of Contents is included after the Foreword.

IMPORTANT INFORMATION

•This vehicle is designed for the operator only, no passengers.

•This vehicle is a competition model only and was not manufactured for use on public streets, roads or highways.

•The use of this vehicle should be limited to participation in sanctioned competition events upon a closed course.

•This vehicle should not be used for general off-road recreational riding.

•Read owner’s manual.

Whenever you see the symbols shown below, heed their instructions! Always follow safe operating and maintenance practices.

DANGER

DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

NOTICE

NOTICE is used to address practices not related to personal injury.

NOTE

○NOTE indicates information that may help or guide you in the operation or service of the vehicle.

IMPORTANT NOTICE

THIS VEHICLE IS A COMPETITION MODEL ONLY AND WAS NOT MANUFACTURED FOR, NOR SHOULD IT BE USED ON, PUBLIC STREETS, ROADS, OR HIGHWAYS. THE USE OF THIS VEHICLE SHOULD BE LIMITED TO PARTICIPATION IN SANCTIONED COMPETITION EVENTS UPON A CLOSED COURSE. THIS VEHICLE SHOULD NOT BE USED FOR GENERAL OFF-ROAD RECREATIONAL RIDING. READ OWNER’S MANUAL.

WARNING

THIS VEHICLE SHOULD NOT BE USED FOR GENERAL OFF-ROAD RECREATIONAL RIDING.

DISCLAIMER OF WARRANTY

This motorcycle is sold AS IS, with all faults, obvious or concealed and there are NO WARRANTIES, expressed or implied. Including warranties of MERCHANTABILITY or FITNESS FOR PURPOSE.

The purchaser accepts all responsibilities concerning quality, performance, cost of service and/or necessary repairs.

NOTICE

Off-road motorcycling is a wonderful sport, and we hope you will enjoy it to the fullest. However, if improperly conducted, this sport has the potential to cause environmental problems as well as conflicts with other people. Responsible use of your off-road motorcycle will ensure that these problems and conflicts do not occur. TO PROTECT THE FUTURE OF YOUR SPORT, MAKE SURE YOU USE YOUR MOTORCYCLE LEGALLY, SHOW CONCERN FOR THE ENVIRONMENT, AND RESPECT THE RIGHTS OF OTHER PEOPLE.

WARNING

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

FOREWORD

Congratulations on your choosing this Kawasaki motorcycle. Your new motorcycle is the product of Kawasaki’s advanced engineering, exhaustive testing, and continuous striving for a superior lightweight, high-performance machine with superb handling and stability for racing and sporting use.

Your new KX is a highly tuned competition machine for participation in racing events. As with any mechanical device, proper care and maintenance are important for trouble-free operation and top performance. This manual is written to enable you to keep your KX properly tuned and adjusted.

Due to improvements in design and performance made during production, in some cases there may be minor discrepancies between the actual vehicle and the illustrations and text in this manual.

KAWASAKI HEAVY INDUSTRIES, LTD.

Motorcycle & Engine Company

© 2014 Kawasaki Heavy Industries, Ltd.

Mar. 17, 2014. (3)

TABLE OF CONTENTS

SPECIFICATIONS............................................	8
GENERAL INFORMATION..............................	12
Location of Labels .........................................	12
Location of Parts ...........................................	17
Side Stand.....................................................	20
Fuel ...............................................................	21
Fuel Requirement:......................................	22
Kick Pedal .....................................................	24
Starting the Engine........................................	24
Launch Control Mode ....................................	26
DFI Setting Data Selection ............................	27
Shifting Gears................................................	28
Stopping the Motorcycle................................	29
Stopping the Engine ......................................	29
Break-In.........................................................	30
Daily Pre-Ride Checks ..................................	31
After-Race Checks ........................................	33
MAINTENANCE AND ADJUSTMENT.............	34
Periodic Maintenance Chart ..........................	34
Engine Oil......................................................	39
Cooling System .............................................	44
Spark Plug.....................................................	48
Air Cleaner ....................................................	55
Throttle Cable................................................	61
Throttle Body Assy ........................................	62
Clutch ............................................................	72
Valve Clearance ............................................	82
Exhaust System ............................................	88

Rear Axle Nut ................................................	92
Drive Chain....................................................	92
Adjustable Ergonomics..................................	98
Footpeg .........................................................	100
Brakes ...........................................................	102
Steering .........................................................	105
Front Suspension ..........................................	108
Rear Suspension (UNI-TRAK®).....................	155
Wheels ..........................................................	161
Hoses Inspection...........................................	164
Tightening Torques of Nuts and Bolts............	165
Cleaning Your Motorcycle..............................	169
Lubrication.....................................................	171
DFI Self-Diagnosis .......................................	174
TROUBLESHOOTING GUIDE.........................	181
TUNING............................................................	188
Suspension....................................................	188
Gearing..........................................................	194
Special Care According to Track Conditions . 195
OPTIONAL PARTS ..........................................	196
PRE-RACE CHECKS AND AFTER-RACE
MAINTENANCE............................................	197
STORAGE........................................................	199
Before Storage ..............................................	199
After Storage .................................................	200
ENVIRONMENTAL PROTECTION..................	201
WIRING DIAGRAM..........................................	202

8 SPECIFICATIONS

	SPECIFICATIONS
DIMENSIONS
Overall Length	2 195 mm (86.42 in.)
Overall Width	820 mm (32.3 in.)
Overall Height	1 275 mm (50.20 in.)
Wheelbase	1 495 mm (58.86 in.)
Road Clearance	340 mm (13.4 in.)
Curb Mass	112.1 kg (247 lb)
Fuel Tank Capacity	6.2 L (1.6 US gal)
ENGINE
Type	4-stroke, DOHC, single-cylinder, liquid-cooled
Bore × Stroke	96.0 × 62.1 mm (3.78 × 2.44 in.)
Displacement	449 cm³ (27.4 cu in.)
Compression Ratio	12.8:1
Fuel System	FI (Fuel Injection)
Starting System	Primary kick
Ignition System	Digital DC-CDI
Ignition Timing	10° BTDC @2 000 r/min (rpm)
Lubrication System	Forced lubrication (semi-dry sump)
Spark Plug	NGK CPR8EB-9
Spark Plug Terminal	Solid-post

		SPECIFICATIONS 9
TRANSMISSION
Transmission Type	5-speed, constant-mesh, return shift
Clutch Type	Wet, multi disc
Driving System	Chain drive
Gear Ratio:
1st	1.750	(28/16)
2nd	1.412	(24/17)
3rd	1.188	(19/16)
4th	1.000	(19/19)
5th	0.875	(21/24)
Primary Reduction Ratio	2.727	(60/22)
Final Reduction Ratio	3.846	(50/13)
Overall Drive Ratio	9.178	@Top gear
Engine Oil:
Type	API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2
Viscosity	SAE 10W-40
Capacity	1.2 L (1.3 US qt)
FRAME
Type	Tubular, semi-double cradle
Steering Angle	42° to either side
Caster	27.9°
Trail	120 mm (4.72 in.)

10 SPECIFICATIONS
Tire Size/Type:
Front	80/100-21 51M/BRIDGESTONE M403
Rear	120/80-19 63M/BRIDGESTONE M404
Rim Size:
Front	21 × 1.60
Rear	19 × 2.15
Suspension:
Front	Telescopic fork (upside-down)
Rear	New Uni-trak® swingarm
Front Suspension Travel	314 mm (12.4 in.)
Rear Wheel Travel	315 mm (12.4 in.)
Front Fork Oil:
Type	Kawasaki Fork Oil SS19
Amount:
Left Front Fork:
Cylinder Unit	310 mL (10.5 US oz.)
Outer Tube	340 mL (11.5 US oz.)
Right Front Fork:
Cylinder Unit	100 mL (3.38 US oz.)
Outer Tube	300 mL (10.1 US oz.)
Balance Chamber	10 mL (0.34 US oz.)

SPECIFICATIONS 11

BRAKES
Type:
Front	Single disc
Rear	Single disc

Specifications are subject to change without notice.

12 GENERAL INFORMATION

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			GENERAL INFORMATION
		Location of Labels
		All warning labels which are on your vehicle are
		repeated here. Read labels on your vehicle and un-
		derstand them thoroughly. They contain information
		which is important for your safety and the safety of
		anyone else who may operate your vehicle. There-
		fore, it is very important that all warning labels be on
		your vehicle in the locations shown. If any label is
		missing, damaged, or worn, get a replacement from
		your Kawasaki dealer and install it in the correct po-
		sition.
		NOTE
					1. Brake Fluid (Front)
		○The sample warning labels in this section have
		part numbers to help you and your dealer obtain
		the correct replacement.

GENERAL INFORMATION 13

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2.Brake Fluid (Rear)

3.Radiator Cap Danger

4.Rear Shock Absorber Warning

14 GENERAL INFORMATION

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5. Noise Emission Control Information

6. Important Information

7. Disclaimer of Warranty

8. Front Fork Warning

GENERAL INFORMATION 15

1)	3)	j

2)	4)

16 GENERAL INFORMATION

j	5)	7)

6)	8)

GENERAL INFORMATION 17

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Location of Parts

1.	Clutch Lever	5.	Fuel Tank Cap
2.	Engine Stop Button	6.	Front Brake Fluid Reservoir
3.	Launch Control Mode Button	7.	Front Brake Lever
4.	Orange Launch Control Mode/FI Warning	8.	Throttle Grip
	Indicator Light

18 GENERAL INFORMATION

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1.	Front Fork	8.	Brake Caliper
2.	Radiator	9.	Shift Pedal
3.	Fuel Tank	10.	Footpeg
4.	Throttle Body Assy	11.	Rear Shock Absorber
5.	Seat	12.	Drive Chain
6.	Air Cleaner Element	13.	Chain Guide
7.	Brake Disc	14.	Swingarm

GENERAL INFORMATION 19

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1.	Muffler	6.	Uni-Trak® Tie-Rod and Rocker Arm
2.	Rear Brake Fluid Reservoir	7.	Rear Brake Pedal
3.	Rear Shock Absorber Gas Reservoir	8.	Oil Level Inspection Window
4.	Kick Pedal	9.	Exhaust Pipe
5.	DFI Setting Data Selection Connector

20 GENERAL INFORMATION

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Side Stand

To install the side stand, insert its flat end into the rear axle as shown in the figure.

NOTE

○Support the motorcycle with a suitable stand to perform maintenance or adjustment procedures.

A.Side Stand

B.Rear Axle

WARNING

Riding with the side stand can cause a crash resulting in injury. Do not start the engine or attempt to ride the motorcycle when the side stand is installed.

		GENERAL INFORMATION 21
		Avoid filling the tank in the rain or where heavy dust		j
Fuel
		is blowing so that the fuel does not get contaminated.
This Kawasaki KX has a 4-stroke engine that re-
quires a gasoline.
The capacity of the fuel tank is 6.2 L (1.6 US gal).
To open the fuel tank cap, pull out the breather hose
from the hole in the steering stem, and turn the tank
cap counterclockwise.

A. Tank Cap

B. Fuel Tank

C. Top Level

D. Filler Neck

A.Fuel Tank Cap

B.Breather Hose

22 GENERAL INFORMATION

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WARNING

Gasoline is extremely flammable and can be explosive 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. Never fill the tank so the fuel level rises into the filler neck. If the tank is overfilled, heat may cause the fuel to expand and overflow through the vents in the tank cap. After refueling, make sure the fuel tank cap is closed securely. If gasoline is spilled on the fuel tank, wipe it off immediately.

Fuel Requirement:

Fuel Type

Use clean, fresh unleaded gasoline with an Antiknock index equal to or higher than that shown in the table. The Antiknock Index is posted on service station pumps in Canada and the U.S.A. The octane rating of a gasoline is a measure of its resistance to detonation or “knocking”. The Antiknock Index is an average of the Research Octane Number (RON) and the Motor Octane Number (MON) as shown in the table below.

	Octane Rating Method		Minimum
			Rating
	Antiknock Index	(RON + MON)	90
		2

NOTICE

If engine “knocking” or “pinging” occurs, use a different brand of gasoline of a higher octane rating.

If this condition is allowed to continue it can lead to severe engine damage.

Gasoline quality is important. Fuels of low quality or not meeting standard industry specifications may result in unsatisfactory performance. Operating problems that result from the use of poor quality or nonrecommended fuel may not be covered under your warranty.

Fuels Containing Oxygenates

Gasoline frequently contains oxygenates (alcohols and ethers) especially in areas of Canada and the U.S. which are required to sell such reformulated fuels as part of a strategy to reduce exhaust emissions.

The types and volume of fuel oxygenates approved for use in unleaded gasoline by the Canadian Environmental Protection Agency include a broad range of alcohols and ethers, but only two components have seen any significant level of commercial use.

Gasoline/Alcohol Blends - Gasoline containing up to 10% ethanol (alcohol produced from agricultural products such as corn), also known as “gasohol” is approved for use.

NOTICE

Avoid using blends of unleaded gasoline and methanol (wood alcohol) whenever possible, and never use “gasohol” containing more than 5% methanol. Fuel system damage and performance problems may result.

Gasoline/Ether Blends - The most common ether is methyl tertiary butyl ether (MTBE). You may use gasoline containing up to 15% MTBE.

NOTE

○Other oxygenates approved for use in unleaded gasoline include TAME (up to 16.7%) and ETBE (up to 17.2%). Fuel containing these oxygenates can also be used in your Kawasaki.

GENERAL INFORMATION 23

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NOTICE
Never use gasoline with an octane rat-
ing lower than the minimum specified by
Kawasaki.
Never use “gasohol” with more than 10%
ethanol, or more than 5% methanol. Gaso-
line containing methanol must also be
blended with cosolvents and corrosion
inhibitors.
Certain ingredients of gasoline may cause
paint fading or damage. Be extra careful
not to spill gasoline or gasoline oxygenate
blends during refueling.
When not operating your Kawasaki for 30
to 60 days, mix a fuel stabilizer (such as
STA-BIL) with the gasoline in the fuel tank.
Fuel stabilizer additives inhibit oxidation of
the fuel which minimizes gummy deposits.
Never store this product with “gasohol” in
the fuel system. Before storage it is recom-
mended that you drain all fuel from the fuel
system. See the Storage section in this man-
ual.

24 GENERAL INFORMATION

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Kick Pedal

This motorcycle is equipped with a primary kick starting system. When the clutch lever is pulled, the motorcycle can be started with the transmission in any gear.

A. Kick Pedal

Starting the Engine

• Shift the transmission into neutral.

WARNING

Riding with the side stand can cause a crash resulting in injury. Do not start the engine or attempt to ride the motorcycle when the side stand is installed.

NOTICE

This motorcycle is designed for competition use only. Therefore, the radiator does not incorporate a coolant reserve tank or cooling fan. Prolonged idling of the engine with no airflow through the radiator can cause coolant loss and engine overheating 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 conditions 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.

	GENERAL INFORMATION 25
When engine is cold	When engine is already warm or restarts	j
• Pull out the idle adjusting screw/choke knob.	• Kick the engine over, leaving the throttle closed
	without using the idle adjusting screw/choke knob.

NOTE

○If the engine fails starting, open the throttle fully and depress the kick pedal slowly about 4 5 times to clear too rich fuel mixtures in the engine. Then, kick the engine over, leaving the throttle closed.

A.Idle Adjusting Screw/Choke Knob

•Find the kick pedal position around the top so that the resistance to depress the kick pedal is fully felt by pushing down the kick pedal slowly.

•Kick the engine over, leaving the throttle closed.

NOTE

○When the clutch lever is pulled, the motorcycle can be started with the transmission in any gear.

•Even after the engine has started, do not push back immediately the idle adjusting screw/choke knob until the engine is thoroughly warmed up.

26 GENERAL INFORMATION

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Launch Control Mode

The launch control mode can be used to adjust ignition timing to help riders get better starts on slippery terrain.

The system’s effectiveness is dependent on rider skill, technique and terrain conditions.

Launch Control Mode Setting

•The launch control mode can be set when the engine is running and in neutral, 1st or 2nd gear. When activated, it only functions in 1st and 2nd gear.

•When pushing the launch control mode button for over two seconds, the orange launch control mode indicator light will blink to indicate the system is operating.

•When shifting into 3rd, the system is deactivated automatically.

A.Launch Control Mode Button

B.Orange Launch Control Mode/FI Warning Indicator Light

DFI Setting Data Selection

Three DFI settings are available to suit various track conditions. They are easily activated by changing the wiring connector on the side of the frame when the engine is stopped.

Track Condition	Connector Color
Soft	White
Standard	Green
Hard	Black

•Change the connector on the right front of the frame to suit the track condition with the engine stopped.

GENERAL INFORMATION 27

NOTE	j

○If the connector is changed while the engine is running, the DFI setting does not change.

○The ECU is set to the standard track condition when operated without a connector. However, always have one of the three connectors attached when riding to prevent dust and mud from accumulating in the connector harness.

○The KX FI calibration kit (Part/No.: 99999-0394) can be used for changing the DFI setting.

A. Connector

28 GENERAL INFORMATION

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Shifting Gears
This motorcycle is equipped with a 5-speed “return
shift” transmission. The neutral is located halfway
between 1st and 2nd gear. “Return shift” means
that when shifting up or down, each gear must be
engaged before the next higher or lower gear may
be selected.
• To engage first gear from the neutral position, pull
in the clutch lever and push down on the shift
pedal, gently release the clutch lever, then release
the shift pedal.
• To shift up to the next gear, pull in the clutch lever,	A. Shift Pedal
lift the shift pedal with your toes, gently release the

clutch lever, and then release the shift pedal.

•To shift down to the next gear, pull in the clutch lever, push the shift pedal down as far as it will go, gently release the clutch lever, then release the shift pedal.

NOTICE

When changing gears, press firmly on the shift pedal to ensure proper shifting. Careless, incomplete shifting can cause the transmission to jump out of gear and lead to engine damage.

Stopping the Motorcycle

For maximum deceleration, close the throttle and apply both front and rear brakes. Pull in the clutch lever as the motorcycle comes to a stop. Independent use of the front or rear brake may be advantageous in certain circumstances. Shift down progressively to ensure good engine response at all speeds.

GENERAL INFORMATION 29

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Stopping the Engine

•Shift the transmission into the neutral position.

•Close the throttle completely and push the engine stop button.

A. Engine Stop Button