Kawasaki KX450 F 2013 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
TUNING j
STORAGE j
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 de ath
or serious injury.
NOTICE
NOTICE is used to
latedtopersonalinjury.
NOTE indicates information that may help or guide
○
youintheopera
address practices not re-
NOTE
tion or service of the vehicle.
IMPORTANT NOTICE
THIS VEHICLE IS A COMP
ONLY AND WAS NOT MANUFACTURED
FOR, NOR SHOULD IT BE USED ON, PUBLIC STREETS, R OADS,
USE OF THIS VEHICLE SHOULD BE LIMITED
TO PARTICIPATION IN SANCTIONED COMPETITION EVENTS UPON
THIS VEHICLE SHOULD NOT BE USED FOR
GENERAL OFF-ROAD RECREATIONAL RID ING.
READ OWNER ’S MANUA
ETITION MODEL
OR HIGHWAYS. THE
A CLOSED COURSE.
L.
WARNING
THIS VEHIC LE SHOULD NOT BE USED FOR
GENERAL OFF-ROAD R
ING.
ECREATIONAL RID-
DISCLAIMER OF WARRAN
This motorcycle is so
obvious or concealed and there are NO WARRANTIES, expressed or implied. Including warranties of MERCHANT
PURPOSE.
The purchaser accepts all responsibilities concerning quality, p
and/or necessary repairs.
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.
ld AS IS, with all faults,
ABILITY or FITNESS FOR
erformance, cost of service
NOTICE
TY
WARNING
The engine exhaust from this product con-
tains chemicals known to the State of Cali-
fornia 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
© 2013 Kawasaki Heavy Industries, Ltd. Feb. 22, 2013. (1)
TABLE OF CONTENTS
SPECIFICATIONS............................................ 8
GENERAL INFORMATION.............................. 11
Location of Labels ......................................... 11
Location of Parts ................. .......................... 16
Side Stand ..................................................... 19
Fuel ............................................................... 20
Fuel Requirement:...................................... 21
Kick Pedal ..................................................... 23
Starting the Engine ........................................ 23
Launch Control Mode
DFI Setting Data Selection ............................ 26
Shifting Gears................................................ 27
Stopping the Motor
Stopping the Engine ............... ....................... 28
Break-In......................................................... 29
Daily Pre-Ride Ch
After-Race Ch ecks .......................... .............. 32
MAINTENANCE AND ADJUSTMENT............. 33
Periodic Mainte
Engine Oil ...................................................... 38
Cooling Syste m ............................................. 43
Spark Plug ..................................................... 47
Air Cleaner ......................................... ........... 54
Throttle Cab le ................................................ 60
Throttle Bod y
Clutch ............................................................ 71
Valve Clearance .................. .......................... 81
Assy ........................................
....................................
cycle................................
ecks ..................................
nance Chart ..........................
25
28
30
33
61
Exhaust System ............................................ 87
Drive Chain.................................................... 91
Adjustable Ergon omics.................................. 9 7
Footpeg ......................................................... 99
Brakes ............................................. .............. 101
Steering ................ .................................... ..... 104
Front Suspension .......................................... 107
Rear Suspension (UNI-TRAK
Wheels .............. .................................... ........ 142
Hoses Inspect ion ........................................... 145
Tightening Torques of Nuts and Bolts............ 146
Cleaning Your Motorcycle. ............................. 150
Lubrication ..................................................... 152
DFI Self-Diagnosis ....................................... 155
TROUBLESHOOTING GUIDE......................... 162
TUNING............................................................ 169
Suspension................................... ................. 169
Gearing...................................... .................... 175
Special Care Acc
OPTIONAL PARTS.......................................... 177
PRE-RACE CHECKS AND AFTER-RACE
MAINTENANCE ......... ................................... 178
STORAGE ... .................................... ................. 180
Before Storage .................... .......................... 180
After Storage
ENVIRONMENTAL PROTECTION . ................. 182
WIRING DIAGRAM .......................................... 183
ording to Track Conditions .
.................................................
®
)..................... 136
176
181
8 SPECIFICATIONS
SPECIFICATIONS
DIMENSIONS
Overall Length 2 180 mm (85.83 in.)
Overall Width 820 mm (32.3 in.)
Overall Height 1 275 mm (50.20 in.)
Wheelbase
Road Clearance 330 mm (13.0 in.)
Curb Mass 112.5 kg (248 lb)
Fuel Tank Capacity 6.2 L (1.6 US gal)
ENGINE
Type
Bore × Stroke 96.0 × 62.1 mm (3.78 × 2.44 in.)
Displacement
Compression Ratio
Fuel System FI (Fuel Injection)
Starting System
Ignition System Digital DC-CDI
Ignition Timing
Lubrication System Forced lubrication (semi-dry sump)
Spark Plug NGK CPR8EB-9
Spark Plug Terminal Solid-post
1 480 mm (58.27 in.)
4-stroke, DOHC, single-cylinder, liquid-cooled
449cm³(27.4cuin.)
12.5:1
Primary kick
10° BTDC @2 000 r/min (rpm)
TRANSMISSION
Transmission Type
Clutch Type
Driving System Chain drive
Gear Ratio:
1st
2nd
3rd
4th
5th
Primary Reduction Ratio
Final Reduction Ratio
Overall Drive Ratio 9.178 @Top gear
Engine Oil:
Type
Viscosity
Capacity 1.2 L (1.3 US qt)
FRAME
Type Tubular, semi-double cradle
Steering Angle 42° to either side
Caster 26.9°
Trail
5-speed, constant-mesh, return shift
Wet, multi disc
1.750 (28/16)
1.412 (24/17)
1.188 (19/16)
1.000 (19/19)
0.875 (21/24)
2.727 (60/22)
3.846 (50/13)
API SG, SH , SJ, SL or SM with JASO MA, MA1 or MA2
SAE 10W-40
113 mm (4.45 in.)
SPECIFICATIONS 9
10 SPECIFICATIONS
Tire Size/Type:
Front
Rear
Rim Size:
Front 21 × 1.60
Rear 19 × 2.15
Suspension:
Front
Rear New U ni-trak
Front Suspension Travel 314 mm (12.4 in.)
Rear Wheel Travel
Front Fork Oil:
Type
Amount (Per Fork Leg):
Inner Damper
Inner/Outer Tubes 190 ∼ 265mL(6.42∼ 8.96 US oz.)
BRAKES
Type:
Front
Rear
80/100-21 51M/BRIDGESTONE M403
120/80-19 63M/BRIDGESTONE M404
Telescopic fork (upside-down)
315 mm (12.4 in.)
Kawasaki Fork Oil KHL15-11
333mL(11.3USoz.)
Single disc
Single disc
®
swingarm
Specifications are subject to change without notice.
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 dealer and install it in the correct position.
The sample warning 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
GENERAL INFORMATION 11
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1. Brake Fluid (Front)
12 GENERAL INFORMATION
2. Brake Fluid (Rear)
3. Radiator Cap Danger
4. Rear Shock Absorber Warning
5. Noise Emission Control Information
6. Important Information
7. Disclaimer of Warranty
GENERAL INFORMATION 13
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14 GENERAL INFORMATION
1)
2)
3)
4)
5)
6)
7)
GENERAL INFORMATION 15
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16 GENERAL INFORMATION
Location of Parts
1. Clutch Lever
2. Engine Stop Button
3. Launch Control Mode Button
4. Orange Launch Control Mode/FI Warning
Indicator Light
5. Fuel Tank Cap
6. Front Brake Fluid Reservoir
7. Front Brake Lever
8. Throttle Grip
GENERAL INFORMATION 17
j
1. Front For
2. Radiator
3. Fuel Tank
4. Throttl
5. Seat
6. Air Cleaner Element
7. Brake D
k
e Body Assy
isc
8. Brake Cal
9. Shift Pedal
10. Footpeg
11. Re a r Sho
12. Swingarm
13. Drive Chain
14. Chain G
iper
ck Absorber
uide
18 GENERAL INFORMATION
1. Muffler
2. Rear Brake Fluid Reservoir
3. Rear Shock Absorber Gas Reservoir
4. Kick Ped
5. DFI Setting Data Selection Connector
al
®
6. Uni-Trak
Tie-Rod and Ro cker Arm
7. Rear Brake Pedal
8. Oil Level Inspection Window
9. Exhaust
Pipe
Side Stand
To install the side st
rear axle as shown in the figure.
A. Side Stand
B. Rear Axle
and, insert its flat end into the
WARNING
Riding with the s
resulting in injury. Do not start the engine or
attempt to ride th e motorcycle when the side
stand is instal
idestandcancauseacrash
led.
GENERAL INFORMATION 19
NOTE
Support the motorcycle with a suitable stand to
○
perform maintenance or adjustment procedures.
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20 GENERAL INFORMATION
Fuel
This Kawasaki KX has a
quires a gasoline.
The capacity of the fuel tank is 6.2 L (1.6 US gal).
To open the fuel tank c
from the hole in the steering stem, and turn the tank
cap c ounterclockwise.
A. Fuel Tank Cap
B. Breather Hose
4-stroke engine that re-
ap, pull out the breather hose
Avoid filling the tan
k in the rain or where heavy dust
is blowing so that the fuel does not get contaminated.
A. Tank Cap
B. Fuel Tank
C. Top Level
D. Filler Neck
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 equ
the table. The Antiknock Index is posted on service
station pumps in Canada and the U.S.A. The octane
rating of a gas
to detonation or “knocking”. The Antiknock Index is
an average of the Research Octane Number (RON)
and the Motor
the table below.
al to or higher than that shown in
oline is a measure of its resistance
Octane Number (MON) as shown in
GENERAL INFORMATION 21
Octane Rating Method
Antiknock Index
(RON + MON)
2
Minimum
Rating
90
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 (alco-
ls and ethers) especially in areas of Canada and
ho
the U.S. which are required to sell such reformulated fuels as part of a strategy to reduce exhaust
issions.
em
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22 GENERAL INFORMATION
The types and volume o
proved for use in unleaded gasolin e by the C an adian Environmental Protection Agency include a
broad range of alcoh
components have seen any significant level of commercial use.
Gasoline/Alcohol
to 10% ethanol (alcohol produced from agricultural
products such as corn), also known as “gasohol” is
approved for use.
ols and ethers, but only two
Blends - Gasoline containing up
f fuel oxygenates ap-
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 m ay result.
Gasoline/Ether Blends - The most common ether
is methyl tertiary butyl ether (MTB E). You may use
gasolinecontainingupto15%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
canalsobeusedinyourKawasaki.
NOTICE
Never use gasoline with an octane rating lower than the minimum specified by
Kawasaki.
Never use “gasohol” with more than 10%
ethanol, or more than 5% methanol. Gasoline containing met
blended with cosolvents and corrosion
inhibitors.
Certain ingredien
paint fading or damage. Be extra careful
not to spill gasoline or gasoline oxygenate
blends during ref
When not operating your Kawasaki for 30
to 60 days, mix a fuel stabilizer (such as
STA-BIL) with th
Fuel stabilizer additives inhibit oxidation of
the fuel which minimizes gummy deposits.
Never store this
the fuel system. Before storage it is recommended that you drain all fuel from the fuel
system. See the
ual.
hanol must also be
ts of gasoline may cause
ueling.
e gasoline in the fuel tank.
product with “gasohol” in
Storage section in this man-
GENERAL INFORMATION 23
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Kick Pedal
This motorcycle is eq
starting system. When the clutch lever is pulled, the
motorcycle can be started with the transmission in
any gear.
A. Kick Pedal
uippedwithaprimarykick
Starting the Engine
Shift the transmissi
•
on into neutral.
WARNING
Ridingwiththesidestandcancauseacrash
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. Therefor
incorporate a coolant reserve tank or cooling fan. Prolonged idling of the engine with
no airflow throu
coolant loss and engine overheating resulting in possible engine damage. Any riding
conditions that
will further reduce idling time before coolant
loss occurs. These conditions include high
ambient temper
rain, or other conditions causing high engine
loads at low speeds. Furthermore, warming
the engine up e
or leaving idling with the hot engine temperature after operation results in the engine
overheating
,too.
e, the r adiator does not
gh the radiator can cause
increase engine temperature
ature, sandy or muddy ter-
xcessively before operation,
24 GENERAL INFORMATION
When engine is cold
Pull out the idle adjusting screw/choke knob.
•
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 engi
•
When the clut
○
be started with the transmission in any gear.
Even after t
•
back immediately the idle adjusting screw/choke
knob until the engine is thoroughly warmed up.
ne over, leaving the throttle closed.
NOTE
ch lever is pulled, the motorcycle can
he engine has started, do not push
When engine is alread
Kick the engine over, leaving the thro ttle closed
•
without using the idle adjusting screw/choke knob.
If the engine fails starting, open the throttle fully
○
and depress the kick pedal slowly about 4
times to clear too rich fuel mixtures in the engine.
Then, kick the engine over, leaving the throttle
closed.
y warm or restarts
NOTE
∼
5
Launch Control Mode
When shifting into 3r
•
automatically.
GENERAL INFORMATION 25
d, the system is deactivated
j
The launch control mo
nition timing to help riders get better starts on slippery terrain.
The system’s effecti
skill, technique and terrain conditions.
decanbeusedtoadjustig-
veness is dependent on rider
Launch Control Mode Setting
The launch control mode can be set when the en-
•
gine 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,
indicator light w ill blink to indicate the system is
operating.
the orange launch control mode
A. Launch Control Mode Button
B. Orange Launch Control Mode/FI Warning
Indicator Light
26 GENERAL INFORMATION
DFI Setting Data Selection
Three DFI settings ar
track conditions. They are easily activated by changing the wiring connector on the side of the frame
when the engine is sto
Track Condition Connector Color
Soft
Standard Green
Hard Black
Change the connector on the right front of the
•
e to suit the track condition with the engine
fram
stopped.
e available to suit various
pped.
White
NOTE
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
Shifting Gears
GENERAL INFORMATION 27
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This motorcycle is eq
shift” transmission. The neutral is located halfway
between 1st and 2nd gear. “Return shift” means
that when shifting up
engaged before the next higher or lower gear may
be selected.
To engage first gea
•
intheclutchleverandpushdownontheshift
pedal, gently release the clutch lever, then release
the shift pedal.
To shift up to the next gear, pull in the clutch lever,
•
lift the shift pedal with your toes, gently release the
clutch lever, an
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 t
shift pedal.
uipped with a 5-speed “return
or down, each gear must be
r from the neutral position, pull
d then release the shift pedal.
he clutch lever, then release the
NOTICE
When changing gears, press firmly on the
shift pedal to ensure proper shifting. Care-
less, incomplete shifting can cause the
transmission to jump out of gear and lead to
engine damage.
A. Shift Pedal
28 GENERAL INFORMATION
Stopping the Motorcycle
For maximum decelera
apply both front and rear brakes. Pull in the clutch
lever as the motorcycle comes to a stop. Independent use of the front o
geous in certain circu ms ta nc es . Shift down progressively to ensure good engine response at all speeds.
tion, close the throttle and
r rear brake may be advanta-
Stopping the Engine
Shift the transmissi
•
Close the throttle completely and push the engine
•
stop button.
A. Engine Stop Button
on into the neutral position.
Break-In
A brief break-in proc
obtain the proper operating clearances in the engin e
and transmission, which are necessary for performance and reliabilit
edure must be carried out to
y.
NOTICE
For the first hour or 20 km (12 mile) of op-
eration, run the engine at low and moderate
engine speeds. See details below.
Break in the engine as follows.
1. Start the engine and let it idle until it is thor-
oughly warmed up.
2. Ride the motorcycle for about 20 minutes within
1/2 throttle opening.
3. Stop and let the engine cool completely. Be
sure to check the tightness of nuts and bolts,
oil leakage, and any irregularities.
4. Start the engine and ride the motorcycle for
about 40 minutes within 3/4 throttle opening.
GENERAL INFORMATION 29
5. Stop and let the engin
sure to fully check the tightness of nuts and
bolts, oil leakage, coolant leakage and any irregularities, espe
brake play, chain sla ck and sp oke tightness.
6. Change the engine oil, oil filter and front
fork/rear shock ab
7. After the break-in procedure has been properly
carried out, the motorcycle is ready for regular
operation. Using
techniques and avoiding recklessly high engine
speeds will keep the engine trouble-free.
e cool completely. Be
cially, each cable elongation,
sorber oil to the new one.
the proper riding skills an d
NOTICE
When any following parts have been replaced, the same break-in procedure as the
new motorcycle must be carried out for one
hour or 20 km (12 mile):
Cylinder, Piston, Piston pin, Piston ring,
Valve, Valve lifter, Camshaft, Crankshaft,
Mission gear, etc.
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