Kawasaki KX450 D8F User Manual

This catalog covers:

GRID NO.

’08 KX450 D8F A-1

This grid covers:

Title

’08 KX450 D8F

(KX450F)

Publications......................................................A-2

Model Identiﬁcation..........................................A-4

Engine..............................................................B-1

Chassis.............................................................E-1

Engine No. Location: LH crankcase, lower rear

Year & Model Color VIN No. Range

Engine No. Range

’08 KX450D8F

1. Lime Green (777) JKAKX450DDA021001 JKAKXGDC√8A021001 (Australia only) KX450DE000001

’08 KX450 D8F(AL) 99912-1505-01

This catalog covers:

GRID NO.

’08 KX450 D8F A-2

This grid covers:

Publications

Year & Model Owner’s Manual

2008 KX450D8F

99976-1393(EN/FR/DE) 99976-1394(IT/ES/NL) 99986-1420(Australia only)

A&P Manual

General Supplement Basic Supplement

99939-1315-03 99924-1355-03 99912-1505-01

Service Manual

Microﬁche

This catalog covers:

GRID NO.

’08 KX450 D8F A-3

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Parts List Infomation

This parts catalog lists parts and sub-assemblies provided as spare parts.

PARTS LIST INFORMATION

When it becomes necessary to replace parts always use KAWASAKI GENUINE PARTS. Strict inspection assures quality and performance of KAWASAKI GENUINE PARTS.

1. HOW TO ODER PARTS

When ordering parts be sure to use the catalog for the correct model and year of the vehicle. Include the following items exactly as listed in this catalog on your parts order.

Part Number Part Name Color Code Specify the color using both color code (which is part of the part number) and name when ordering painted parts.

Example: 51001-5074-H Parts not shown disassembled in the illustrations of this parts catalog are not sold separately; only the complete units or next higher assemblies illustrated, are supplied, as spare parts.

2. EXPLANATION OF PARTS CATALOG FORMAT

A. Year & Model Title

This title describes the year(s) and model(s) contained in this catalog.

B. Part Group Title

A representative name for the group of parts illustrated on this page.

C. Referernce Number

The reference number is listed on the illustration and parts list. It is the link between the illustration and the parts list.

D. Part Number

The number assigned to a part for the purpose of parts ordering.

TANK-COMP-FUEL,E

BONY

E. Description

Describes the main function of the part and includes data such as size, number of teeth, color,etc.

(+)..................................................Plus HEX.....................................Hexagonal REF......................................Reference

(-)................................................Minus ID =.............................Inside Diameter RH......................................Right Hand

&.....................................................And KPH.....................Killometers Per Hour RPM................Revolutions Per Minute

2ND..........................................Second L.....................................................Link RR................................................Rear

3RD..............................................Third L =.............................................Length STD........................................Standard

4TH............................................Fourth L/...................................................Less T..................................................Teeth

AR....................................As Required LH.........................................Left Hand T =........................................Thickness

ASSY....................................Assembly LWR............................................Lower U/S......................................Under Size

CA.........................................Cut Away MM........................................Millimeter UPP............................................Upper

CNT...........................................Center MPH.............................Miles Per Hour V.....................................................Volt

COMP...................................Complete NA...................................Not Available W...................................................Watt

D...............................................Degree O/S.......................................Over Size W/..................................................With

FR................................................Front OD =.........................Outside Diameter WD......................................With Decal

G..................................................Gram PR........................................Ply Rating WOD..............................Without Decal

F. Quantity

Speciﬁes how many of a part are required at the indicated position on the illustration.

G. Year & Model

Indicates which parts are used for a speciﬁc vehicle year and model.

H. Additional Information

Additional Information is shown as follows:

1) (OPTION) Part is not installed as original equipment, but is available separately.

2) (RACING USE ONLY) Part is to be used for closed course racing only on this vehicle.

3) (OFF-ROAD USE ONLY) Part is for off-road use only this vehicle.

4) (LOCAL PROCUREMENT ITEM) Part is obtainable from a local source. No part number is listed.

5) Technical relationships between old part numbers and new part numbers are shown as follows: INTERCHANGE - Old part or new part can be used. SUBSTITUTE - New part replaces old part. Old part cannot be used in place of new part.

6) Mid-Year part number changes on a vehicle are noted by engine or frame number references. ( - KZ400DE001181) Affected units are from beginning of model year production up to

(KZ400D-008111 - ) Affected units are from this frame number to the end of model

(KZ400DE008181 - KZ400DE018888) Affected units are in this engine number range.

I. Speciﬁcation Code

Identiﬁes the speciﬁcation of the vehicle for which the part applies. If no spec code is listed, that means the part is used for all speciﬁcations.

Spec Code Speciﬁcation

AS Australia O EU Europe(General) O

List of Abbreviations

and including this engine number.

year production.

’08

D8F

This catalog covers:

GRID NO.

’08 KX450 D8F A-4

KX450D8F

Left Side View

This grid covers:

Model I.D. ’08 KX450D8F

Right Side View

This catalog covers:

GRID NO.

’08 KX450D8F A-5

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Color Combination Parts List

’08 KX450D8F

O : Applicable : Not applicable

Color: Lime Green (777 ) (1)

Part No. Description

11011-0055-6Z CASE-AIR FILTER,F.BLACK OO 14037-0036-RZ SCREEN,LH,WHITE OO 14037-0037-RZ SCREEN,RH,WHITE OO 14091-1523-RZ COVER,REAR DISC,WHITE OO 34024-1396-458 STAND-SIDE,P.SILVER OO

35004-0078-290 FENDER-FRONT,L.GREEN OO 35023-0100-290 FENDER-REAR,L.GREEN OO 36001-0084-266 COVER-SIDE,LH,S.WHITE OO 36001-0088-266 COVER-SIDE,RH,S.WHITE OO 41025-0094-WC RIM,FR,1.60X21,BLACK OO

41025-0095-WC RIM,RR,2.15X19,BLACK OO 41034-0035-10Y DRUM-ASSY,REAR BRAKE,M.M.GOLD OO 41034-0037-10Y DRUM-ASSY,FRONT BRAKE,M.M.GOLD OO 44037-0075-10Y HOLDER-FORK UNDER,M.M.GOLD OO 44039-0035-10Y HOLDER-FORK UPPER,M.M.GOLD OO

45014-0188-8V SHOCKABSORBER,I.SILVER O 45014-0217-8V SHOCKABSORBER,I.SILVER O 46012-0013-10Y HOLDER-HANDLE,LWR,M.M.GOLD OO 46012-0020-10Y HOLDER-HANDLE,UPP,FAT BAR,GOLD OO 46012-0021-10Y HOLDER-HANDLE,LWR,FAT BAR,GOLD OO

AS EU

Spec.Code

46012-0023-10Y HOLDER-HANDLE,UPP,M.M.GOLD OO 49089-0038-290 SHROUD-ENGINE,LH,L.GREEN OO 49089-0039-290 SHROUD-ENGINE,RH,L.GREEN OO 51001-0095-6Z TANK-COMP-FUEL,F.BLACK OO 53066-0131-MA SEAT-ASSY,BLACK OO

55020-0172-RZ GUARD,FORK,LH,WHITE OO

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GRID NO.

’08 KX450D8F A-6

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Color Combination Parts List

’08 KX450D8F

O : Applicable : Not applicable

Color: Lime Green (777 ) (2)

Part No. Description

55020-0179-RZ GUARD,ENGINE,RH,WHITE OO 55020-0334-RZ GUARD,FORK,RH,WHITE OO 58029-0003-266 PLATE-NUMBER,S.WHITE OO 92145-0016-8V SPRING,SHOCK,K=52N/MM,I.SILVER OO 92145-0244-8V SPRING,SHOCK,K=54N/MM,I.SILVER OO

92145-0383-8V SPRING,SHOCK,K=56N/MM,I.SILVER OO

AS EU

Spec.Code

This catalog covers:

’08 KX450D8F Engine B-1

GRID NO.

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Pictorial Index

B-3 Cylinder Head B-4 Cylinder Head Cover B-5 Cylinder/Piston(s)

B-6 Air Cleaner B-7 Mufﬂer(s)(AS) B-8 Mufﬂer(s)(EU)

This catalog covers:

’08 KX450D8F Engine B-2

GRID NO.

This grid covers:

Pictorial Index

B-9 Valve(s) B-10 Camshaft(s)/Tensioner B-11 Crankshaft

B-12 Kickstarter Mechanism B-13 Clutch B-14 Transmission

This catalog covers:

’08 KX450D8F Engine C-1

GRID NO.

This grid covers:

Pictorial Index

C-3 Gear Change Drum/Shift Fork(s) C-4 Gear Change Mechanism C-5 Crankcase

C-6 Engine Cover(s) C-7 Carburetor(1/3) C-8 Carburetor(2/3)

This catalog covers:

’08 KX450D8F Engine C-2

GRID NO.

This grid covers:

Pictorial Index

C-9 Carburetor(3/3) C-10 Oil Pump C-11 Oil Filter

C-12 Generator C-13 Ignition System C-14 Water Pump

This catalog covers:

’08 KX450D8F Engine D-1

GRID NO.

This grid covers:

Pictorial Index

D-3 Radiator D-4 Engine Shrouds D-5 Water Pipe

This catalog covers:

GRID NO.

’08 KX450D8F Engine D-2

This grid covers:

Pictorial Index

This catalog covers:

GRID NO.

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’08 KX450D8F Chassis E-1 Pictorial Index

E-3

Frame

E-4 Frame Fittings E-5 Swingarm

E-6 Suspension E-7 Footrests E-8 Fenders

This catalog covers:

GRID NO.

This grid covers:

’08 KX450D8F Chassis E-2 Pictorial Index

E-9

Stand(s)

E-10 Tires E-11 Front Hub

E-12 Rear Hub E-13 Brake Pedal E-14 Shock Absorber(s)

This catalog covers:

GRID NO.

This grid covers:

’08 KX450D8F Chassis F-1 Pictorial Index

F-3

Front Master Cylinder

F-4 Front Brake F-5 Rear Master Cylinder

F-6 Rear Brake F-7 Handlebar(1/2) F-8 Handlebar(2/2)

This catalog covers:

GRID NO.

This grid covers:

’08 KX450D8F Chassis F-2 Pictorial Index

F-9

Front Fork(1/2)

F-10 Front Fork(2/2) F-11 Fuel Tank

F-12 Seat F-13 Cables F-14 Side Covers

This catalog covers:

GRID NO.

This grid covers:

’08 KX450D8F Chassis G-1 Pictorial Index

G-3

Chassis Electrical Equipment

G-4 Owner’s Tools G-5 Labels

G-6 Decals G-7 Accessory G-8 Manual(EU)

This catalog covers:

GRID NO.

This grid covers:

’08 KX450D8F Chassis G-2 Pictorial Index

This catalog covers:

GRID NO.

’08 KX450D8F Engine B-3

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Cylinder Head

Ref.

Part No. Description Spec Code

No.

11004 11004-0045 GASKET-HEAD 1 11008 11008-0143 HEAD-COMP-CYLINDER 1 11060 11060-1300 GASKET,THERMOSTAT 1 13234 13234-0009 SHAFT-COMP,DECOMP 1

13271 13271-0675 PLATE 1 13280 13280-0038 HOLDER,DECOMP 1 16065 16065-0050 HOLDER-CARBURETOR 1

39193 39193-0027 PIPE-OIL 2 49002 49002-0007 GUIDE-VALVE AR 92004 92004-0025 STUD,8X22 2

92005 92005-0018 FITTING 1 92022 92022-161 WASHER,25.3X30X1 1 92042 92042-007 PIN,DOWEL,6.3X8X14 4 92043 92043-4009 PIN,10.1X12X14 2 92049 92049-1196 SEAL-OIL 1

92055 92055-0046 RING-O,23.5X2.0 1 92066 92066-0002 PLUG,PT1/2X12.5 1 92066A 92066-0024 PLUG,4X18 1 92066B 92066-0068 PLUG,6X6 1 92145 92145-0048 SPRING 1

(OPTION)

Quantity-KX450

’08

D8F

92150 92150-1935 BOLT,L=140 2 92153 92153-0338 BOLT,6X38 4 92153A 92153-0339 BOLT,6X45 4 92153B 92153-0695 BOLT,6X16 2 92153C 92153-0810 BOLT,6X35 2

92153D 92153-1001 BOLT,FLANGED-SMALL,10X127 2 92170 92170-1448 CLAMP 2 92200 92200-0114 WASHER,10.5X19X2.3 4 99999 99999-0023 KIT.,MANUAL DECOMP 1

120 120CA0612 BOLT-SOCKET,6X12 1

132 132BB0612 BOLT-FLANGED-SMALL,6X12 1

1 MAY 29,2007

(OPTION) (OPTION)

This catalog covers:

GRID NO.

’08 KX450D8F Engine B-4

This grid covers:

Cylinder Head Cover

Ref.

Part No. Description Spec Code

No.

11061 11061-0079 GASKET,PLUG HOLE 1 11061A 11061-0185 GASKET,CYLINDER HEAD COVER 1 14091 14091-0796 COVER,CYLINDER HEAD 1 92002 92002-1327 BOLT,FLANGED,6X22.5 3 92055 92055-1352 RING-O,HEAD COVER BOLT 3

Quantity-KX450

’08

D8F

2 MAY 29,2007

This catalog covers:

GRID NO.

’08 KX450D8F Engine B-5

This grid covers:

Cylinder/Piston(s)

Ref.

Part No. Description Spec Code

No.

11005 11005-0088 CYLINDER-ENGINE 1 11061 11061-0160 GASKET,CYLINDER BASE 1 13001 13001-0073 PISTON-ENGINE 1 13002 13002-0016 PIN-PISTON 1 13008 13008-0018 RING-SET-PISTON 1

92036 92036-008 RING-SNAP,PISTON PIN 2 92043 92043-4009 PIN,10.1X12X14 2 92153 92153-0844 BOLT,6X30 1

Quantity-KX450

’08

D8F

3 MAY 29,2007

This catalog covers:

GRID NO.

’08 KX450D8F Engine B-6

This grid covers:

Air Cleaner

Ref.

Part No. Description Spec Code

No.

11011 11011-0055-6Z CASE-AIR FILTER,F.BLACK 1 11013 11013-0011 ELEMENT-AIR FILTER 1 13271 13271-0730 PLATE,DUCT FITTING 1 13280 13280-0108 HOLDER,ELEMENT 1 13280A 13280-0170 HOLDER 1

14073 14073-0085 DUCT,AIR FILTER 1 59006 59006-0011 ARRESTER-FLAME 1 92015 92015-1259 NUT,FLANGED,5MM 5 92152 92152-0275 COLLAR 2 92153 92153-0623 BOLT,6X75 1

92153A 92153-0863 BOLT,6X16 2 92161 92161-0213 DAMPER 2 92161A 92161-0350 DAMPER 1 92171 92171-0651 CLAMP,DUCT,62MM 1

130 130G0512 BOLT-FLANGED,5X12 1

Quantity-KX450

’08

D8F

4 MAY 29,2007

This catalog covers:

GRID NO.

’08 KX450D8F Engine B-7

This grid covers:

Mufﬂer(s)(AS)

Ref.

Part No. Description Spec Code

No.

11061 11061-0082 GASKET,38.9X46.4X3.0 11061A 11061-0226 GASKET,41.0X48.7X32.0 18046 18046-0081 WOOL 18088 18088-0356 PIPE-EXHAUST 18100 18100-0077 BODY-ASSY-MUFFLER

31064 31064-0128 PIPE-COMP 49107 49107-0077 COVER-EXHAUST PIPE 92015 92015-1402 NUT,8MM 92151 92151-1449 BOLT,SOCKET,6X10 92151A 92151-1822 BOLT,FLANGED,6X10

92153 92153-1963 BOLT,FLANGED-SMALL,8X18 92171 92171-0653 CLAMP

132 132L0818 BOLT-FLANGED-SMALL,8X18 411 411AB0800 WASHER-PLAIN,8.5X18X1.6 411A 411S0600 WASHER-PLAIN,6MM

L------------------------------------AS 1 L------------------------------------AS 1 L------------------------------------AS 1 L------------------------------------AS 1 L------------------------------------AS 1

L------------------------------------AS 1 L------------------------------------AS 1 L------------------------------------AS 2 L------------------------------------AS 2 L------------------------------------AS 4

Quantity-KX450

’08

D8F

461 461S0600 WASHER-SPRING,6MM

5 MAY 29,2007

L------------------------------------AS 2

This catalog covers:

GRID NO.

’08 KX450D8F Engine B-8

This grid covers:

Mufﬂer(s)(EU)

Ref.

Part No. Description Spec Code

No.

11061 11061-0082 GASKET,38.9X46.4X3.0 11061A 11061-0226 GASKET,41.0X48.7X32.0 18046 18046-0097 WOOL 18088 18088-0356 PIPE-EXHAUST 18100 18100-0076 BODY-ASSY-MUFFLER

31064 31064-0127 PIPE-COMP 49107 49107-0077 COVER-EXHAUST PIPE 92015 92015-1402 NUT,8MM 92151 92151-1449 BOLT,SOCKET,6X10 92151A 92151-1822 BOLT,FLANGED,6X10

92153 92153-1963 BOLT,FLANGED-SMALL,8X18 92171 92171-0653 CLAMP

132 132L0818 BOLT-FLANGED-SMALL,8X18 411 411AB0800 WASHER-PLAIN,8.5X18X1.6 411A 411S0600 WASHER-PLAIN,6MM

L------------------------------------EU 1 L------------------------------------EU 1 L------------------------------------EU 1 L------------------------------------EU 1 L------------------------------------EU 1

L------------------------------------EU 1 L------------------------------------EU 1 L------------------------------------EU 2 L------------------------------------EU 2 L------------------------------------EU 6

Quantity-KX450

’08

D8F

461 461S0600 WASHER-SPRING,6MM

6 MAY 29,2007

L------------------------------------EU 2

This catalog covers:

GRID NO.

’08 KX450D8F Engine B-9

This grid covers:

Valve(s)

Ref.

Part No. Description Spec Code

No.

12004 12004-0018 VALVE-INTAKE 2 12005 12005-0036 VALVE-EXHAUST 2 12009 12009-0008 RETAINER-VALVE SPRING 4 12011 12011-1003 COLLET 8 12032 12032-0004 TAPPET 4

16007 16007-0022 SEAT-SPRING,11.6X25.5X1.0 4 49078 49078-0018 SPRING-ENGINE VALVE,EXHAUST 2 49078A 49078-0043 SPRING-ENGINE VALVE,INTAKE 2 92025 92025-1870 SHIM,T=2.00 4 92025A 92025-1871 SHIM,T=2.05 AR

92025B 92025-1872 SHIM,T=2.10 AR 92025C 92025-1873 SHIM,T=2.15 AR 92025D 92025-1874 SHIM,T=2.20 AR 92025E 92025-1875 SHIM,T=2.25 AR 92025F 92025-1876 SHIM,T=2.30 AR

92025G 92025-1877 SHIM,T=2.35 AR 92025H 92025-1878 SHIM,T=2.40 AR 92025I 92025-1879 SHIM,T=2.45 AR 92025J 92025-1880 SHIM,T=2.50 AR 92025K 92025-1881 SHIM,T=2.55 AR

92025L 92025-1882 SHIM,T=2.60 AR 92025M 92025-1883 SHIM,T=2.65 AR 92025N 92025-1884 SHIM,T=2.70 AR 92025O 92025-1885 SHIM,T=2.75 AR 92025P 92025-1886 SHIM,T=2.80 AR

Quantity-KX450

’08

D8F

92025Q 92025-1887 SHIM,T=2.85 AR 92025R 92025-1888 SHIM,T=2.90 AR 92025S 92025-1889 SHIM,T=2.95 AR 92025T 92025-1890 SHIM,T=3.00 AR 92025U 92025-1982 SHIM,T=2.425 AR

92025V 92025-1983 SHIM,T=2.475 AR 92025W 92025-1984 SHIM,T=2.525 AR 92025X 92025-1985 SHIM,T=2.575 AR 92049 92049-1062 SEAL-OIL,RVC2-5.5X8.5X8.3 4 92180 92180-1058 SHIM,T=2.375 AR

92180A 92180-1059 SHIM,T=2.625 AR 92180B 92180-1194 SHIM,T=2.675 AR 92180C 92180-1195 SHIM,T=2.725 AR 92180D 92180-1196 SHIM,T=2.775 AR

7 MAY 29,2007

This catalog covers:

GRID NO.

’08 KX450D8F Engine B-10

This grid covers:

Camshaft(s)/Tensioner

Ref.

Part No. Description Spec Code

No.

11061 11061-0260 GASKET 1 12046 12046-0043 SPROCKET,34T 1 12048 12048-0021 TENSIONER-ASSY 1 12053 12053-0031 GUIDE-CHAIN,CAM CHAIN STOPPER 1 12053A 12053-0051 GUIDE-CHAIN,UPP 1

12053B 12053-0064 GUIDE-CHAIN,FR 1 12053C 12053-0065 GUIDE-CHAIN,RR 1 13042 13042-0005 WEIGHT 2 14013 14013-0001 RING-POSITION 2 49118 49118-0087 CAMSHAFT-COMP,INTAKE 1

49118A 49118-0088 CAMSHAFT-COMP,EXHAUST 1 92057 92057-0035 CHAIN,98XRH2010-124M 1 92145 92145-0390 SPRING 1 92150 92150-1650 BOLT,SOCKET,6X10 2 92151 92151-1930 BOLT,FLANGED-SMALL,6X25 2

92153 92153-0717 BOLT,8X29.5 1 92153A 92153-1380 BOLT,6X6 1

482 482J5000 CIRCLIP-TYPE-E 2 670 670D2010 O RING 1

Quantity-KX450

’08

D8F

8 MAY 29,2007

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