2009 Kawasaki KX450F, KX450 service manual

Table of Contents

General Information

1. General Information
   • Model Identification
   • General Specifications
   • Torque Specifications
   • Special Tools
   • Maintenance Schedule
   • Safety Precautions

Periodic Maintenance

2. Periodic Maintenance
   • Maintenance Schedule
   • Lubrication Points
   • Pre-Ride Inspection
   • Cleaning and Storage

Fuel System (DFI)

3. Fuel System (DFI)
   • Fuel Injection System Overview
   • Fuel Tank and Lines
   • Fuel Pump and Filter
   • Throttle Body and Injector Maintenance

Cooling System

4. Cooling System
   • Radiator and Hoses
   • Water Pump Service
   • Coolant Replacement
   • Thermostat Inspection

Engine Top End

5. Engine Top End
   • Cylinder Head and Valve Service
   • Piston and Cylinder Inspection
   • Camshaft and Timing Chain
   • Compression Testing

Clutch

6. Clutch
   • Clutch Adjustment and Service
   • Clutch Plate Inspection
   • Clutch Cable Replacement

Engine Lubrication System

7. Engine Lubrication System
   • Oil Types and Capacities
   • Oil Change Procedures
   • Oil Pump and Filter Service

Engine Removal/Installation

8. Engine Removal/Installation
   • Engine Removal Procedure
   • Engine Installation Procedure
   • Engine Mounting and Alignment

Crankshaft/Transmission

9. Crankshaft/Transmission
   • Crankshaft Service
   • Transmission Gear Inspection
   • Shift Mechanism
   • Gear Shifter Adjustment

Wheels/Tires

10. Wheels/Tires
    • Wheel Removal and Installation
    • Tire Inspection and Replacement
    • Wheel Balancing
    • Spoke Adjustment

Final Drive

11. Final Drive
    • Chain and Sprocket Maintenance
    • Chain Lubrication and Adjustment
    • Final Drive Inspection

Brakes

12. Brakes
    • Front and Rear Brake Service
    • Brake Pad Replacement
    • Brake Fluid Replacement and Bleeding
    • Brake Lever Adjustment

Suspension

13. Suspension
    • Front Fork Service
    • Rear Shock Absorber Service
    • Suspension Adjustment
    • Steering Head Bearings

Steering

14. Steering
    • Handlebar Adjustment
    • Steering Play Adjustment
    • Steering Damper (if applicable)

Frame

15. Frame
    • Frame Inspection and Repair
    • Body Panels and Fasteners
    • Frame Alignment

Electrical System

16. Electrical System
    • Battery Maintenance
    • Charging System
    • Ignition System
    • Lighting and Switches
    • Wiring Diagrams

Appendix

17. Appendix
    • Technical Data
    • Conversion Tables
    • Troubleshooting Guide
    • Index