Kawasaki KX450F 2014 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.

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

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

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

DFI Setting Data Selection ............................ 27

Shifting Gears................................................ 28

Stopping the Motor

Stopping the Engine ............... ....................... 29

Break-In......................................................... 30

Daily Pre-Ride Ch

After-Race Ch ecks .......................... .............. 33

MAINTENANCE AND ADJUSTMENT............. 34

Periodic Mainte

Engine Oil ...................................................... 39

Cooling Syste m ............................................. 44

Spark Plug ..................................................... 48

Air Cleaner ......................................... ........... 55

Throttle Cab le ................................................ 61

Throttle Bod y

Clutch ............................................................ 72

Valve Clearance .................. .......................... 82

Exhaust Syst

Assy ........................................

em ............................................

....................................

cycle................................

ecks ..................................

nance Chart ..........................

Rear Axle Nut ............................... ................. 92

Drive Chain.................................................... 92

Adjustable Ergon omics.................................. 98

Footpeg ......................................................... 100

Brakes ............................................. .............. 102

Steering ................ .................................... ..... 105

Front Suspension .......................................... 108

Rear Suspension (UNI-TRAK

Wheels .............. .................................... ........ 161

Hoses Inspect ion ........................................... 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 Acc

OPTIONAL PARTS.......................................... 196

PRE-RACE CHECKS AND AFTER-RACE

MAINTENANCE ......... ................................... 197

STORAGE ... .................................... ................. 199

Before Storage .................... .......................... 199

After Storage

ENVIRONMENTAL PROTECTION . ................. 201

WIRING DIAGRAM .......................................... 202

ording to Track Conditions .

.................................................

)..................... 155

195

200

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

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

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

1 495 mm (58.86 in.)

4-stroke, DOHC, single-cylinder, liquid-cooled

449cm³(27.4cuin.)

12.8:1

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 27.9°

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

120 mm (4.72 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:

Left Front F ork:

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.)

80/100-21 51M/BRIDGESTONE M403

120/80-19 63M/BRIDGESTONE M404

Telescopic fork (upside-down)

315 mm (12.4 in.)

Kawasaki Fork Oil SS19

swingarm

)

BRAKES

Type:

Front

Rear

Specifications are subject to change without notice.

SPECIFICATIONS 11

Single disc

12 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 13

2. Brake Fluid (Rear)

3. Radiator Cap Danger

4. Rear Shock Absorber Warning

14 GENERAL INFORMATION

5. Noise Emission Control Information

6. Important Information

7. Disclaimer of Warranty

8. Front Fork Warning

GENERAL INFORMATION 15

16 GENERAL INFORMATION

Location of Parts

GENERAL INFORMATION 17

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

18 GENERAL INFORMATION

1. Front For

2. Radiator

3. Fuel Tank

4. Throttl

5. Seat

6. Air Cleaner Element

7. Brake D

eBodyAssy

isc

8. Brake Cal

9. Shift Pedal

10. Footpeg

11. Rear Sho

12. Drive Chain

13. Chain Guide

14. Swinga

iper

ck Absorber

1. Muffler

2. Rear Brake Fluid Reservoir

3. Rear Shock Absorb er Gas Reservoir

4. Kick Ped

5. DFI S etting Data Selection Connector

GENERAL INFORMATION 19

6. Uni-Trak

Tie-Rod and Rocker Arm

7. Rear Brake Pedal

8. Oil Level Inspection Window

9. Exhaust

Pipe

20 GENERAL INFORMATION

Side Stand

To install the side st

rear axle as shown in the figu re.

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 the motorcycle when the side stand is instal

ide stand can cause a crash

led.

NOTE

Support the motorcycle with a suitable stand to

○

perform maintenance or adjustment procedures.

Fuel

GENERAL INFORMATION 21

Avoid filling the tan

k in the rain or where heavy dust

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 c

ap, pull out the breather hose from the hole in the steering stem, and turn the tank cap c ounterclockwise.

A. Fuel Tank Cap B. Breather Hose

A. Tank Cap B. Fuel Tank C. Top Level D. Filler Neck

22 GENERAL INFORMATION

WARNING

Gasoline i s extremely flammable and can be explosive under certain conditions. Always stop the engine and do not smoke. Make suretheareaiswell-ventilatedandfreefrom 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.

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

Octane Rating Method

Antiknock Index

(RON + MON)

Minimum

Rating

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.

The types and volume o proved for use in unleaded gasoline by the Canadian 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 (MTBE). 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 can also be used in your Kawasaki.

GENERAL INFORMATION 23

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-

24 GENERAL INFORMATION

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 theengineupe or leaving idling with the hot engine temperature after operation results in the engine overheating

, too.

e, the radiator does not

gh the radiator can cause

increase engine temperature

ature, sandy or muddy ter-

xcessively before operation,

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

GENERAL INFORMATION 25

When engine is alread

Kick the engine over, leaving the throttle 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

∼

26 GENERAL INFORMATION

Launch Control Mode

The launch control mo nition timing to help riders get better starts on slippery terrain.

The system’s effecti skill, tech niq ue and terrain conditions.

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 will blink to indicate the system is operating.

decanbeusedtoadjustig-

veness is dependent on rider

the orange launch control m ode

When shifting into 3r

•

automatically.

A. Launch Control Mode Button B. Orange Launch Control Mode/FI Warning

Indicator Light

d, the system is deactivated

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

GENERAL INFORMATION 27

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

28 GENERAL INFORMATION

Shifting Gears

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 o r lower gear may be selected.

To engage first gea

•

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,

•

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 le ver, 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

GENERAL INFORMATION 29

Stopping the M oto rcycle

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 circumstances. 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 co mpletely and push the engine

•

stop button.

A. Engine Stop Button

on into the neutral position.

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