Kawasaki KLX450R 2015 Owner's manual
Quick Reference Guide
GENERAL INFORMATION j
This Quick Reference Guide will assist you in
finding the in
A Table of Contents is included after the
Foreword.
formation you’re looking for.
MAINTENANCE AND ADJUSTMENT j
TROUBLESHOOTING GUIDE j
STORAGE j
IMPORTANT INFORMATION
This vehicle is designed for the operator only, no passengers.
•
This vehicle is an off-road motorcycle only and was not manufactured for use on public streets, roads or
•
highways.
Respect the environment and the rights of other people.
•
Read owner’s manual.
•
Whenever you see the symbols shown below,
heed their instructions! Always follow safe operating and maintenance
practices.
NOTICE
NOTICE is used to address practices not relatedtopersonalin
jury.
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 de ath
or serious injury.
NOTE
NOTE indicates information that may help or guide
○
you in the operation or service of the vehicle.
IMPORTANT
Off-road motorcycling is a wonderful sport,
and we hope you will en
ever, if improperly conducted, this sport has the
potential to cause environmental problems as
well as conflicts wi
Responsible use of your off-road motorcycle
will ensure that these problems and conflicts do
not occur. TO PROTE
SPORT, MAKE SURE YOU USE YOUR MOTORCYCLE LEGALLY, SHOW CONCERN FOR THE
ENVIRONMENT, AND
OF OTHER PE OPLE.
joy it to the fullest. How-
th other people.
CT THE FUTURE OF YOUR
RESPECT THE RIGHTS
WARNING
THIS VEHIC LE IS AN OFF-ROAD VEHICLE
•
ONLY AND WAS NOT MANUFACTURED
FOR USE ON PUBLIC STREETS, ROADS,
OR HIGH-WAYS.
USEYOURBIKELEGALLY.
•
RESPECT THE ENVIRONMENT AND THE
•
RIGHTS OF OTHER REOPLE.
FOREWORD
We wish to thank you for choosing this Kawasaki Motorcycle. It is the end product of Kawasaki’s advanced
engineering, exhaustive testing, and continuous striving for super ior reliability, and performance. By giving your
motorcycle the proper care and maintenance outlined in this manual, you will be helping to ensure it a long,
trouble-free life.
Before starting to ride your motorcycle, please read this manual thoroughly in order to know your motorcycle’s
capabilities, its lim itations, and above all, how to operate it safety.
Due to improvements in design and performance m ade 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 Hea
vy Industries, Ltd.
Feb. 22, 2014. (1)
TABLE OF CONTENTS
SPECIFICATIONS.................. .......................... 7
GENERAL INFORMATION.............................. 10
Location of Labels ......................................... 10
Location of Parts ........................................... 16
Side Stand ..................................................... 19
Fuel ............................................................... 19
Fuel Requirements:.................................... 19
Filling the Tank: .......................................... 20
Fuel Tap:..................................................... 21
Meter Unit ...................................................... 23
Speedometer:........................................... .. 23
Odometer: .................. ................................ 23
Clock: ............................ ............................. 23
Trip Meter: ... ............................................... 24
Engine Stop Button ...................... ................. 25
Kick Pedal ..................................................... 26
Starter Button ................................................ 26
Starting the Engine ........................................ 27
Moving Off ..................................................... 30
Shifting Gears................................................ 30
Stopping the Motorcycle ................................ 31
Stopping the En
Break-In........................................... .............. 32
Daily Pre-Ride Checks .................................. 34
After-Race Ch
MAINTENANCE AND ADJUSTMENT............. 37
Periodic Maintenance Chart .......................... 37
Engine Oil ...................................................... 42
Cooling System ............................................. 47
gine ..................... .................
ecks ........................................
32
36
Spark Plug ..................................................... 52
Air Cleaner .......................................... .......... 54
Throttle Cable ................................................ 59
Carburetor ........................................ ............. 61
Clutch ............................................................ 62
Hot Starter Cable.......................................... . 69
Valve Clearan ce ............................................ 69
Spark Arrester (Brazil mod el only) ... ............. 75
Drive Chain.................. .................................. 77
Handlebar ........ .................................... .......... 83
Brakes .............................................. ............. 85
Steering ................. .................................... .... 89
Front Suspension .......................................... 91
Rear Suspension (UNI-TRA K
Wheels ............... .................................... ....... 123
Hoses Inspection
Headlight ....................................................... 127
Battery ................... .................................... .... 127
Fuse .............................................................. 130
Tightening Torques of Nuts and Bolts............ 132
Cleaning Your Motorcycle..... ......................... 137
Lubrication ....... .................................... .......... 139
TROUBLESHOOTING GUIDE......................... 143
STORAGE................... .................................... . 151
Before Storag
After Storage ................................................. 152
ENVIRONMENTAL PROTECTION .................. 153
WIRING DIAGR
...........................................
e ..............................................
AM ..... .................................... .
®
)..................... 119
126
151
154
SPECIFICATIONS
DIMENSIONS
Overall length 2 175 mm (85.6 in.)
Overall width 820 mm (32.3 in.)
Overall height 1 250 mm (49.2 in.)
Wheelbase
Road clearance
Curb mass 126 kg (278 lb)
Fuel tank capacity
ENGINE
Type
Bore × stroke
Displacement
Compression ratio
Carburetor KEIHIN FCR-MX40
Starting system
Ignition system
Ignition timing
Lubrication system
Spark plug NGK CPR8EB-9
Spark plug terminal Solid-post
1 480 mm (58.3 in.)
315 mm (12.4 in.)
8L(2.1USgal)
DOHC, 4-valve, single-cylinder, 4-stroke, liquid-cooled
96.0 × 62.1 mm (3.8 × 2.4 in.)
449cm³(27.4cuin.)
12.0 : 1
Electric, Primary kick
CDI
10.2° BTDC @1 800 r/min (rpm)
Forced Lubrication (semi dry sump)
SPECIFICATIONS 7
8 SPECIFICATIONS
TRANSMISSION
Transmission type
Clutch type
Drive system
Gear ratios:
1st gear
2nd gear
3rd gear
4th gear
5th gear
Primary reduction ratio
Final reduction ratio
Overall ratio (top gear)
Engine oil:
Capacity 1.3 L (1.4 US qt)
Type
Coolant Capacit
FRAME
Type
Steering angle 42° to either side
Caster 28°
Trail
y
5-speed, constant-mesh, return shift
Wet, multi disc
Chain drive
2.167 (26/12)
1.533 (23/15)
1.188 (19/16)
0.950 (19/20)
0.810 (17/21)
2.727 (60/22)
3.846 (50/13)
8.492
API SG, SH, SJ, SL o
SAE 10W-40
1.1L(1.2USqt)
Semi-double cradle
122 mm (4.8 in.)
r SM with JASO MA, MA1 or MA2
Tire size, type:
Front
Rear
80/100-21 M/C51P, BR
120/90-18 M/C65P, BR
Rim size:
Front 21 × 1.60
Rear 18 × 2.15
Suspension:
Front
Upside-down telesc
Rear New Uni-trak
Front suspension travel
Rear wheel travel
305 mm (12.0 in.)
315 mm (12.4 in.)
Front fork oil:
Type
Kawasaki Fork Oil KHL15-10
Amount (per fork leg) :
Inner Damper
189mL(6.4USoz)
Inner/Outer Tubes 335 mL (11.3 US oz)
BRAKES
Type (Front & Rear)
Disc
ELECTRICAL EQUIPME NT
Battery 12 V 6 Ah
Headlight 12 V 35 W
®
swingarm
SPECIFICATIONS 9
IDGESTONE ED03
IDGESTONE ED04
opic fork
Specifications are subject to change without notice and may not apply to every country.
10 GENERAL INFORMATION
GENERAL INFORMATION
Location of Labels
All warning labels which are on your vehicle are
repeated here. Read lab
derstand them thoroughly. They contain information
which is important for your safety and the safety of
anyone else who may ope
fore, it is very important that all warning labels be on
your vehicle in the locations shown. If any label is
missing, damaged, or
your Kawasaki de a ler and install it in the correct position.
The sample warnin g labels in this section have
○
part numbers to help
the correct replacement.
els on your vehicle and un-
rate your vehicle. There-
worn, get a replacement from
NOTE
you and your dealer obtain
1. Brake Fluid (Front)
GENERAL INFORMATION 11
2. Brake Fluid (Rear)
3. Radiator Cap Danger
4. Rear Shock Absorber Warning
j
12 GENERAL INFORMATION
5. Battery Poison/Danger
6. Important Information
1)
3)
GENERAL INFORMATION 13
j
2)
4)
14 GENERAL INFORMATION
4) Brazil model
5)
5) Brazil model
6)
6) Brazil model
GENERAL INFORMATION 15
j
16 GENERAL INFORMATION
Location of Parts
1. Clutch Lever
2. Engine Stop Button
3. Hot Starter Lever
4. Meter Unit
5. Front Brake Fluid Reservoir
6. Front Brake Lever
7. Throttle Grip
8. Starter Button
9. Fuel Tank Cap
GENERAL INFORMATION 17
j
9. Front For
10. Radiat or
11. Fuel Tank
12. Fuel Tap
13. Carburetor
k
14. Seat
15. Air Cleaner Element
16. Brake Disc
17. Brake Ca
18. Shift Pedal
liper
19. Rear Shoc
20. Swingarm
21. Drive Chain
22. Chain Gu
k Absorber
ide
18 GENERAL INFORMATION
23. Silencer
24. Rear Brake Fluid Res ervo ir
25. Rear Shock Absorber Gas Reservoir
26. Battery
27. Fuse
®
28. Uni-Trak
Tie Rod and Rocker Arm
29. Rear Brake Pedal
30. Kick Pedal
31. Engine O
il Level Inspection Window
32. Exhaust Pipe
GENERAL INFORMATION 19
j
Side Stand
The motorcycle is equ
A. Side Stand
Whenever the side stand is used, make it a practice to kick the fu
cle.
lly up before sitting on the motorcy-
ipped with a side stand.
WARNING
Riding with the side stand down could cause
an accident resulting in serious injury or
death. Always be sure the side stand is fully
raised before riding.
Fuel
Fuel Requirements:
Your Kawasaki engine is designed to use only
unleaded gasoline wit
shown below. Never use gasoline with an octane rating lower than the minimum specified by
Kawasaki to prevent
The octane rating of a gasoline is a measure of
its resistance to detonation or “knocking”. The term
commonly used to des
ing is the Research Octane Number (RON).
h a m inimum octane rating
severe engine damage.
cribe a gasoline’s octane rat-
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 dam-
age. Gasoline quality is important. Fuels of
low quality or not meeting standard industry
specifications may result in unsatisfactory
performance.
Fuel Type and Octane Rating
(Except for Brazil Specification)
Use clean, fresh unleaded gasoline with an octane
rating equal to or higher than that shown in the table.
20 GENERAL INFORMATION
Fuel Type
Ethanol Content
Minimum Octane
Rating
Unleaded Gasoline
E10 o r less
Research Octane Number
(RON)
95
NOTICE
Do not use any fuel that contains more
ethanol or other oxygenates than specified
for E10 fuel* in this vehicle. Damage to the
engine and fuel system, or engine starting
and/or performance problems may result
from the use of improper fuel.
*E10 means fuel containing up to 10% ethanol.
(For Brazil Specification)
clean, fresh unleaded gasoline with an Anti-
Use
knock Index equal to or higher than that shown in
the table.
Antiknock Index is posted on service station
The
pumps. The Antiknock Index is an average of the
Research Octane Number (RON) and the Motor Oc-
ne Number (MON) as shown in the table.
ta
Fuel Type
Ethanol
Content
Minimum
Octane Rating
Unleaded Gasoline
E25
Antiknock
Index
90
(RON + MON)
2
NOTICE
Do not use any fuel that contains more
ethanol or other oxygenates than specified
for E25 fuel* in this vehicle. Damage to the
engine and fuel system, or engine starting
and/or performance problems may result
from the use of improper fuel.
*E25 means fuel containing up to 25% ethanol.
Filling the Tank:
Avoid filling the tank in the rain or where heav y dust
is blowing so that the fuel does not get contaminated.
A. Tank Cap
B. Fuel Tank
C. Top Level
D. Filler Neck
GENERAL INFORMATION 21
WARNING
Gasoline i s 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 th e 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.
NOTICE
Certain ingredients in gasoline may cause
paint fading or damage. Be extra careful
not to spill gas
blends during refueling.
Fuel Tap:
The fuel tap has three position: OFF, ON, and RES
(reserve). Fo
lever to t he ON position. If the fuel runs out with the
tap in the ON position, the last approximately 0.7 L
(0.18 US gal)
turning the tap lever to the RES position.
oline or gasoline oxygenates
r normal operation, turn the fuel tap
of usable fuel remains can be used by
j
22 GENERAL INFORMATION
A. Fuel Tap
B. ON Position
C. OFF Position
D. RES Position
Turn the fuel tap lever to the OFF position when
the fuel tank is removed for maintenance and adjustments or the motorcycle is stored for a long time.
NOTE
Since riding dista n ce is limited when on RES, re-
○
fuel at the earliest opportunity.
Make certain that the fuel tap lever is turned to ON
○
(not RES), after filling up the fuel tank.
WARNING
Practice operating the fuel tap with the motorcycle stopped. To prevent an accident you
should be able to operate the fuel tap while
riding without taking your eyes off the road.
Be careful not to touch the hot engine while
operating the fuel tap.
Meter Unit
In the meter instrume
ter, odometer/clock, and trip meter. Pushing the
odometer/clock (ODO/CLOCK) mode button shifts
the display in the odo
modes; odometer and clock. Pushing the trip meter A/B (Trip A/B) mode button shifts the display in
the trip meter thro
When starting the engine, all segments come on for
three seconds, then the clock or meters operate normally depending on
nts face are the speedome-
meter/clock through the two
ugh the two modes; trip A and B.
the mode selected.
GENERAL INFORMATION 23
Speedometer:
The speedometer shows the speed of the vehicle.
Odometer:
The odometer shows the total distance in the kilometers (mph) that the vehicle has been ridden. The
meter cannot be reset.
NOTE
The date is maintained even if the battery is dis-
○
connected,
When the figures come to 999999, they are
○
stopped and locked.
j
A. Speedometer
B. Trip Meter A/B
C. Clock/Odometer
D. ODO/CLOCK Mode Button
E. TRIP A/B Mode Button
Clock:
To adjust hours and minutes:
Push the ODO/CLOCK mode button to display the
•
clock.
24 GENERAL INFORMATION
Push the ODO/CLOCK mo
•
the TRIP A/B mode button. Both the hour and
minute displays start flashing.
Again push the TRIP A/B mode button. When only
•
the hour display flashes, push the ODO/CLOCK
mode button to advance the hours.
Push the TRIP A/B mode button. The hour dis-
•
play stops flashing and the minute display starts
flashing. Push
advance the minutes.
Push the TRIP A/B mode button. Both the hour
•
and minute displays start flashing again.
Push the ODO/CLOCK mode button. The dis-
•
plays stop flashing and the clock starts working.
the ODO/CLOCK mode button to
de button while holding
NOTE
Pushing the ODO/CLOCK mode button momen-
○
tarily advances the hour or minute step by step.
Pushing and holding the button advance the hour
or minute continuously.
When the battery is disconnected, the clock resets
○
to 1:00, and starts working again when the battery
is connected.
Trip Meter:
The trip meter shows the distance in kilometers
traveled since it w
TRIP A: 0.0 ∼ 999.9
TRIP B: 0 ∼ 9999
To reset the trip meter:
1. Push the TRIP A/B button and hold it in.
2. After two seconds the figure display turns to 0.0
(TRIP A) or 0 (TRIP B), and then starts counting
when the vehicle is operated. The meter counts
until it is next reset.
When th e trip meter is reset while the vehicle is
○
stopped, it starts counting as soon as the vehicle
starts moving.
When the figures come to 999.9 (TRIP A) or 9999
○
(TRIP B) when the vehicle is running, they turn
back to 0.0 or 0 and start counting again.
as last reset to zero.
NOTE
When the battery is di
○
play resets to 0.0 or 0.
sconnected, the meter dis-
GENERAL INFORMATION 25
j
Engine Stop Button
The engine stop butto
of the handlebar. For ordinary engine stoppage and,
if some emergency requires stopping the engine,
press the button unti
A. Engine Stop Button
n is located on the left side
l the engine stops.
26 GENERAL INFORMATION
Kick Pedal
This motorcyc le has a
A. Kick Pedal
kick pedal.
Starter Button
This motorcycle has t
button operates the electric starter when the clutch
lever pulled in.
A. Starter Button
he starter button. The starter
Starting the Engine
Shift the transmissi
•
Turn the fuel tap lever to the ON position.
•
A. Fuel Tap
B. ON Position
on into neutral.
WARNING
Riding with the side stand in the down position can cause a crash resulting in injury. Do
not start the en
torcycle when the side stand is down.
gine or attempt to ride the mo-
GENERAL INFORMATION 27
NOTICE
This motorcycle’s radiator does not incorporate cooling fan. Prolonged idling of the engine with no airflow
cause coolant loss and engine overheating
resulting in possible engine damage. Any
riding conditions
perature will further reduce idling time before coolant loss occurs. These conditions
include high ambi
muddy terrain, or other conditions causing
high engine loads at low speeds. Furthermore, warming th
fore operation, or leaving idling with the hot
engine temperature after operation results in
the engine over
Do not repeatedly operate the throttle with the en-
○
gine starting, stopping and idling. The accelerator
pump may foul t
through the radiator can
that increase engine tem-
ent temperature, sandy or
e engine up excessively be-
heating, too.
NOTE
he spark plugs with excess fuel.
j
28 GENERAL INFORMATION
When engine is cold-
Pull out the choke knob.
•
A. Choke Knob
Leaving the throttle completely closed, push the
•
starter button or kick the engine over until the engine starts.
NOTE
When using the starter button for starting the en-
○
gine, make sure that the clutch lever is pulled in.
When using the kick pedal for starting the engine,
○
find the kick pedal position around the top so that
the resistance to dep
by pushin g down the kick pedal slowly.
When the clutch lever is pulled, the motorcycle can
○
be started with the t
A. Starter Button
B. Kick Pedal
Even after the engine has started, do not push
•
back immediately the choke knob until the engine
is thoroughly warmed up.
ress the kick pedal is fully felt
ransmission in any gear.
When engine is alread
Pull the hot starter lever on the clutch lever.
•
y warm or restarts-
GENERAL INFORMATION 29
Engine
Condition
Already
Warm
Restarting
after falling
Cold No use (OFF) Use (ON)
Hot Starter
Lever
Pull in (ON) Push back (OFF)
Pull in (ON) Push back (OFF)
Choke Knob
j
A. Hot Starter L
Kick the engine over or push the starter button,
•
leaving the throttle closed without using the choke
knob.
Return the hot starter lever back immediately after
•
the engine starts.
ever
NOTE
If the engine fails starting, open the throttle fully
○
and depress the kick pedal slowly about 4
times to c lear too rich fuel mixtures in the engine.
Then, kick the engine over or push the starter button, leaving the throttle closed with the hot starter
lever pulled in.
Hot st arte r lever or choke knob is used as following
•
table.
∼
5
Loading...