2009 Kawasaki KLX450R Motorcycle Service Manual

Shop manual for the KLX450R providing in-depth service and repair procedures. Includes engine, chassis, and electrical system diagnostics. PN 99969-0059-02

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Document Details

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Document Number / Seller:
27293 / Lisa Murphy
File Size:
8.27 MB
File Type:
ZIP
Language:
English
Printable:
Yes
Category:
Bike
Last updated / verified
Jan 3, 2025

Models Covered & Key Technical Specifications

2009 Kawasaki KLX450R Motorcycle Service Manual

Shop manual for the KLX450R providing in-depth service and repair procedures. Includes engine, chassis, and electrical system diagnostics. PN 99969-0059-02 | Binder Edition.

  • Factory Component Weight: 115 kg represents the standard dry mass Framework.
  • Essential Precision Specs: For engine tuning, 449 cm³ defines the displacement Benchmark.
  • Key Bolt Torques: 12 N·m signifies the camshaft sprocket bolt torque Sequences.
  • Primary Displacement Data: The engine displacement requires 449 cm³ Requirements.
  • General Circuit Specs: The ignition system utilizes Digital AC-CDI Threshold.
  • Integral Size Parameters: Brake pad lining thickness for the front measures 3.8 mm Parameters.

Professional Workshop Service Manual & Technical Specifications

Enhanced Technical Calibration Manual: Bike Kawasaki KLX450R manual, 2009 edition Hydraulic-Guide

Subsystem-Focus: Engine // Documentation-Type: Service Manual // Subsystem-Focus: Fuel System.

Performance-Element Technical-Path Validation-Data
Engine Type 4-stroke, single cylinder, DOHC 4 valve Liquid-cooled
Bore and Stroke 96.0 × 62.1 mm (3.78 × 2.44 in.) 449 cm³ (27.4 cu in.)
Ignition System Digital AC-CDI BTDC 10.2° @1 800 r/min (rpm)
Front Tire Size 80/100-21 51M BRIDGESTONE M401, Tube type
Rear Tire Size 110/100-18 64M BRIDGESTONE M402, Tube type
Front Brake Disc Diameter 225 mm (8.86 in.) Rear Brake Disc Diameter 215 mm (8.46 in.)

Technical chapters are organized around the following systems:

Engine Lubrication System

This manual covers essential engine lubrication procedures, including oil changes and filter replacements, ensuring optimal engine performance and longevity. Configuration is key to consistent operation.

Fuel System

Detailed procedures for fuel system maintenance are included, covering the carburetor, fuel tank, and fuel filter. Proper fuel delivery is crucial for engine health.

Brakes

Comprehensive brake system documentation is provided, detailing inspection and adjustment of levers, pads, fluid levels, and lines for safe operation.

Suspension

Information on front and rear suspension maintenance, including fork oil changes and shock absorber inspection, is covered to ensure proper handling and stability.

Electrical System

This section addresses the motorcycle's electrical components, including spark plug maintenance, cable inspection, and wiring diagrams for troubleshooting and repair.

Torque specifications for critical engine components are documented for proper assembly to ensure optimal corrosion joint prevention.

FAQ

Check the **standard** throttle grip free play? keyboard_arrow_down

2-3 mm (0.08-0.12 in.) is the standard specification for throttle grip free play.

What does the **necessary** valve clearance adjustment involve? keyboard_arrow_down

Valve clearance adjustment involves removing camshafts, lifters, and shims to replace with new ones based on specified measurements.

Reference the **recommended** coolant pressure specifications? keyboard_arrow_down

112.3–141.7 kPa (1.145–1.445 kgf/cm², 16.28–20.55 psi) is the standard radiator cap relief pressure range.

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Reviews (4)

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New
The service manual for my KLX 450R was incredibly detailed and easy to follow. Downloading was a breeze!
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New
This manual covers everything from engine removal to brake servicing. Very professional support when I had questions—highly recommend!
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Rated 5 out of 5 stars
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New
Received my download link quickly and the manual is laid out perfectly. It’s a must-have for any KLX owner!