KX450F

Motorcycle
Assembly & Preparation
Manual
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 Foreword
In order to ship Kawasaki vehicles as effi- DANGER
ciently as possible, they are partially disassem- DANGER indicates a hazardous situa-
bled before crating. Since some of the most tion which, if not avoided, will result in
commonly removed parts have a direct bear- death or serious injury.
ing on a vehicle’s reliability and safety, consci-
entious pre-sale assembly and preparation be-
comes extremely important. Good setup pro-
WARNING
cedures can prevent needless warranty claims WARNING indicates a hazardous situa-
and give customers a greater sense of confi- tion which, if not avoided, could result
dence in Kawasaki and their Kawasaki Dealers. in death or serious injury.
This Assembly and Preparation Manual ex-
plains step by step procedures of the following NOTICE
items for the Kawasaki KX450F.
NOTICE is used to address practices not
related to personal injury.
1. Uncrating
2. Assembly
3. Preparation NOTE
○This note symbol indicates points of particular
The selling dealer assumes sole responsibil- interest for more efficient and convenient op-
ity for any unauthorized modifications prior to eration.
sale. Refer to your Service Binder for any Ser-
vice Bulletins specifying Factory Directed Mod-
ifications (Special Claims) which must be per- Kawasaki Heavy Industries, Ltd. accepts no
formed before the vehicle is ready for sale. liability for any inaccuracies or omissions in this
Whenever you see the following symbols publication, although every possible measure
heed their instructions! Always follow safe has been taken to make it as complete and ac-
operating and maintenance practices. curate as possible. All procedures and specifi-
cations subject to change without notice.

© 2012 Kawasaki Heavy Industries, Ltd. May, 2012

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 Table of Contents

Uncrating ...................................................................................... 3
Opening Crate ............................................................................. 3
Parts Check ................................................................................. 6
Assembly ...................................................................................... 9
Handlebar.................................................................................... 9
Throttle Grip Assembly ................................................................ 10
Front Brake Master Cylinder ....................................................... 10
Clutch Lever Assembly................................................................ 11
Launch Control Mode Button....................................................... 11
Engine Stop Switch ..................................................................... 11
Cables and Wiring Routing.......................................................... 12
Front Fender................................................................................ 12
Front Number Plate ..................................................................... 12
Fuel Tank Breather Hose............................................................. 13
Side Stand................................................................................... 13
Brake Disc Cleaning .................................................................... 13
Radiator Drain Hose .................................................................... 14
Preparation ................................................................................... 14
Air Cleaner ................................................................................. 14
Front Brake.................................................................................. 15
Rear Brake .................................................................................. 17
Clutch Lever and Cable ............................................................... 18
Drive Chain.................................................................................. 18
Front Fork .................................................................................... 20
Rear Shock Absorber .................................................................. 22
Tire Air Pressures........................................................................ 24
Fuel ............................................................................................. 24
Coolant ........................................................................................ 24
Engine Oil (4-stroke) ................................................................... 25
Throttle Grip and Cable ............................................................... 26
Idle Speed Adjustment ................................................................ 27
Fastener Check ........................................................................... 30
Standard Torque Table ................................................................ 32
Test Ride the Motorcycle ............................................................. 32
A&P Check List ........................................................................... 32

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 UNCRATING 3

Uncrating • Remove the vertical strut mounting bolts (D =

8, L = 12) and the vertical struts at both left
Opening Crate and right sides, and discard them.

WARNING
Crates have sharp edges and may have
nails or screws that can cause cuts and
injury. Always wear protective gloves,
boots and eye protection when uncrat-
ing to prevent injury.

A. Top Frame
B. Vertical Strut
C. Mounting Bolts (D = 8, L = 12)
D. Bottom Frame

NOTICE
When removing the vertical struts at
WARNING both left and right sides, do not damage
the radiator shrouds.
The steel crate panel plates and fasten-
ers have sharp edges. Always wear pro- • Remove the crate bolts (D = 8, L = 12) to take
off the crate bracket and discard them.
tective gloves, boots and eye protection
when uncrating to prevent injury.

A. Crate Bolts (D = 8, L = 12)

B. Crate Bracket
• Clear a space about 6 m (20 ft) square to give
yourself plenty of space to work.
NOTICE
• Place the crate upright on its base.
• Remove the
Remove cardboard cover. Be careful that the motorcycle does not
• parts box.the handlebar, front fender, and the fall over.

NOTICE • Take out all the bolts and screws and remove
the top frame, and front and rear frame of the
When removing the crate bracket from crate.
the motorcycle, be careful not to drop • Remove the rubber plug (dummy) on each
fork top plug and discard them.
any parts or the bracket onto the fuel
tank and other components, and not to
scratch the fuel tank or other compo-
nents with the crate bracket.

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 4 UNCRATING

A. Rubber Plug (Dummy) • Remove the air valve adapter.

B. Fork Top Plug • the Parts Check
Install the air valve plug (see No.25 part in
section) and tighten it to the
• Install the air valve adapter (see No.22 part in
the Parts Check section).
specified torque.
Torque : 0.2 N·m (0.020 kgf·m, 1.8 in·lb)

NOTE
○When using the air valve adapter, apply
grease to the O-ring.

A. Air Valve Plug

NOTICE
Be sure to install the air valve plug to
A. Air Valve Adapter
prevent dust from entering.
• Raise the front wheel off the ground using a
jack (special tool: 57001-1238) and attach- • Be sure to remove the styrene foam on the
steering stem.
ment (special tool: 57001-1608) or chain
block.
• Prepare the commercially available suitable
hand air pump and air pressure gauge.
• Using a commercially available suitable hand
air pump and air pressure gauge, charge
each fork with air [240 kPa (2.4 kgf/cm², 35
psi)] alternately beforehand.
NOTICE
Do not pressurize the fork to more than
500 kPa (5.0 kgf/cm², 73 psi) or the fork
may be damaged.
The air pressure in each fork is different A. Styrene Foam
depending on gravity. Be sure to check
and adjust the air pressure in each fork.

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 UNCRATING 5

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 6 UNCRATING

Parts Check
• Open the parts box, and check the parts against the illustrations. There may be minor differences
between these illustrations and the actual vehicle parts. In the following charts under Remarks, D
= diameter in millimeters, and L = length in millimeters.

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 UNCRATING 7

No. Part Name Qty Remarks

1 DFI Setting Data Selection Connector 1 White
2 DFI Setting Data Selection Connector 1 Black
3 Handlebar Pad 1 RENTHAL
4 Handlebar with Grip and Wiring Band 1 RENTHAL
5 Handlebar Clamp Bolt 4 D = 8, L = 35
6 Clamp, Front Brake Master Cylinder 1
7 Clamp Bolt, Front Brake Master Cylinder 2
8 Flanged Bolt, Front Fender 4 D = 6, L = 18.5
9 Front Fender 1
10 Screw, Engine Stop Switch 1 D=3
11 Screw, Launch Control Mode Button 1 D=4
12 Clamp, Clutch Lever 1
13 Handlebar Clamp 2
14 Clamp, Engine Stop Switch 2
15 Clamp, Launch Control Mode Button 2
16 Clamp Bolt, Clutch Lever 2 D = 5, L = 16
17 Fuel Tank Breather Hose 1 L = 300
18 Front Number Plate 1
19 Flanged Bolt, Front Number Plate 1 D = 6, L = 12
20 Spark Plug Wrench 1
21 Spoke Nipple Wrench 1
22 Air Valve Adapter, Front Fork 1
23 Side Stand 1
24 Owner’s Manual 1
25 Air Valve Plug, Front Fork 2

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 8 UNCRATING

Spare Parts

• These
year.
parts and their part numbers are subject to change without prior notice according to the model

No. Part Name Qty Part Number

1 Gasket, Cylinder Head, T = 0.65 2 11004-0088
2 Gasket, Cylinder Head Cover 2 11061-0351
3 Gasket, Cylinder Base 2 11061-0768
4 Gasket, Exhaust Pipe 2 11061-0082
5 Gasket, Clutch Inner Cover 2 11061-0453
6 Gasket, Clutch Outer Cover 2 11061-0259
7 Gasket, Magneto Cover 2 11061-0452
8 Gasket, Muffler, D = 53, L = 32 2 11061-0434
9 O-Ring, Oil Filter Cap 2 92055-1577

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 ASSEMBLY 9

Assembly
Handlebar
• Apply 2-stroke oil to the edge (slash area) of
the handlebar.

A. Handlebar
B. Handlebar Holders
C. Handlebar Clamps
D. Clamp Bolts (D = 8, L = 35)
E. Scales
A. 120 mm (4.72 in.)
F. Forward
• Install the throttle grip assy on the handlebar
and insert the handlebar fully into the grip. • Before tightening the bolts, check the handle-
bar position.

A. Throttle Grip Assy A. Handlebar Clamps

• Put the handlebar on the handlebar holders. B. Align the center of the handlebar
• Apply 2-stroke
Mount the handlebar clamps. bridge with the center of the
• bolts, and installoilthem.
to the handlebar clamp handlebar holders.
C=D The scales on both sides are the
same in width.

NOTE
○The handlebar angle position can be adjusted
to suit your preference using the scales.

• Tighten the front and rear clamp bolts evenly

to the specified torque.
Torque : 25 N·m (2.5 kgf·m, 18 ft·lb)
• Make sure that the gaps between the handle-
bar holder and clamp is approximately equal
in the front and rear side.

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 10 ASSEMBLY

WARNING
If the throttle grip contacts the end of the
handlebar, the throttle will be difficult to
turn and may not return fully when re-
leased, creating the possiblity of an acci-
dent resulting in serious injury or death.
Do not push the throttle grip so far onto
the handlebar that the inside of the grip
contacts the end of the handlebar.

A. Forward
Front Brake Master Cylinder
B. Gap • Install the master cylinder with the clamp and
bolts on the handlebar.

Throttle Grip Assembly

• Slip the dust cover off the throttle case.
• that thethejointposition
Adjust of the throttle grip assy so
line of the throttle case is vertical
to the handlebar.
• Tighten the mounting screws (D = 5, L = 20)
to the specified torque.
Torque : 3.8 N·m (0.39 kgf·m, 34 in·lb)
• Open and close the throttle grip to check if the
throttle operates properly.
• Reinstall the dust cover. A.
B.
Front Brake Master Cylinder
176.95 mm (6.97 in.)
C. Horizontal Line of Frame
D. Align reserve tank cap to the horizontal
line of frame

• Make sure that the master cylinder clamp is

installed with the “UP” mark facing up.
• Tighten the upper clamp bolt first, then the
lower bolt to the specified torque.
Torque : 8.8 N·m (0.90 kgf·m, 78 in·lb)

A. Dust Cover
B. Throttle Case
C. Joint Line
D. Screws (D = 5, L = 20)
E. Throttle Grip

A. Clamp Bolts
B. UP Mark

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 ASSEMBLY 11

Clutch Lever Assembly Engine Stop Switch

• Install the clutch lever with the clamp and • Attach the clamps to the engine stop switch.
bolts (D = 5, L = 16) on the handlebar. • Install the engine stop switch assy between
• Tighten the clamp bolts. the grip and clutch lever and tighten the screw
(D = 3, L = 14).
• Secure the engine stop switch and launch
control mode button leads to the handlebar
with the wiring band.

A. Clutch Lever Assy

B. 160.5 mm (6.32 in.)
C. Clamp Bolts (D = 5, L = 16)
D. Horizontal Line of Frame A. Engine Stop Switch
E. 30° ±5° B. Clamps
C. Screw (D = 3, L = 14)
D. Launch Control Mode Button
Launch Control Mode Button
E. Wiring Band
• Remove the wiring band temporarily from the
handlebar.
NOTE
○When installing the removed wiring band, re-
fer to “Engine Stop Switch”.

• Attach
button.
the clamps to the launch control mode

• Install the launch control mode button assy.

• Tighten the screw (D = 4, L = 14).

A. Launch Control Mode Button

B. Clamps
C. Screw (D = 4, L = 14)
D. 5 ∼ 10 mm (0.20 ∼ 0.39 in.)

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 12 ASSEMBLY

Cables and Wiring Routing

• Check that the cables, wiring leads and hoses
are routed correctly.

A. Front Fender
B. Front Bolts (D = 6, L = 18.5)
C. Rear Bolts (D = 6, L = 18.5)

Front Number Plate

Handlebar Pad Installation
• Install the handlebar pad onto the handlebar
bridge so that the characters on the pad are
shown as “RENTHAL” when viewed from the
front of the motorcycle.

(Viewed from Front)

A. Throttle Cables
B. Wiring Band
C. Engine Stop Switch Lead
D. Launch Control Mode Button Lead
E. Clutch Cable
A. Handlebar Pad

Front Fender Front Number Plate Installation

• Position the front fender between the fork legs • Position the front number plate between the
brake hose and front fork, and fit the two holes
and fasten it to the steering stem base with of the number plate to the projections of the
four bolts (D = 6, L = 18.5). steering stem base.
NOTE
○Temporarily install the front bolts first, and
then the rear bolts.
○Tighten all bolts securely.

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 ASSEMBLY 13

A. Front Number Plate A. Fuel Tank Cap

B. Holes B. Breather Hose (L = 300)
C. Projections C. Hole

• Fasten the number plate to the stem head

with the flanged bolt (D = 6, L = 12).
Side Stand
• Fasten the number plate belt to the handlebar
pad with a latch. Usage:
• Fit the flat bar end of the side stand into the
rear axle shaft.

A. Flanged Bolt (D = 6, L = 12)

B. Number Plate Belt
A. Side Stand
B. Rear Axle Shaft
Fuel Tank Breather Hose
• Fit one end of the breather hose into the fuel
tank cap, and fit the other end into the hole of
NOTE
○Do not start the engine or attempt to ride the
the steering shaft. motorcycle when the side stand is installed.

Brake Disc Cleaning

• Clean the front and rear brake discs using
oilless solvent.
WARNING
An anticorrosive treatment applied to
the brake discs will increase braking
distance and can cause an accident
resulting in serious injury or death. Re-
move the anticorrosive treatment using
an oilless solvent.

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 14 PREPARATION

• Inspect the foam air cleaner element for

proper oiling.
• Ifthethewing
foam air cleaner element is dry, remove
bolt, and take out the air cleaner
element.

Radiator Drain Hose

• Pull the radiator over flow hose end out of the
engine guard.
A. Wing Bolt
B. Air Cleaner Element

• Take the element off its holder.

Preparation
Air Cleaner A. Air Cleaner Element
Air Cleaner Element Inspection B. Holder
The foam cleaner element on off road models
is oiled prior to shipping. However, over time • Saturate the element with high-quality foam
air filter oil and make sure that the oil is evenly
the filter will dry and filtration performance will
diminish. applied throughout the element. Squeeze out
• Remove the side cover bolts (left and right)
(2) to remove the seat.
the excess oil, but do not wring the element
as this could cause tearing. In this case, too
much oil is better than too little. Finally pat
the inside of the element with a paper towel
to remove any excess oil.
• Install the element onto its holder, and coat
the element lip and lip seat with a thick layer of
all-purpose grease to assure a complete seal.

A. Bolt (D = 8, L = 16)
B. Seat

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 PREPARATION 15

A. Apply grease. A. Seat

B. Front Hook
• Install the air cleaner element so that its tab
faces upward and its projections align with C. Front Receiver
the holes in the housing, and tighten the wing D. Center Hook
bolt, making sure that it is properly seated and E. Center Receiver
sealed.
• Tighten
right).
the side cover mounting bolts (left and

Front Brake
Front Brake Fluid Level Inspection
• With the front brake fluid reservoir held hori-
zontal, check that the fluid level is above the
lower level line.

A. Tab
B. Projections
C. Holes

• To install the seat, align the front hook on the

seat with front receiver on the fuel tank. Slide
the seat forward so that center hook engages
first followed by the front hook.

A. Front Brake Fluid Reservoir

B. Lower Level Line

• Iflower
the fluid level in the reservoir is below the
level line, check for fluid leaks in the
front brake lines, and fill the reservoir.
• Remove the reservoir cap and diaphragm,
and fill the reservoir to the upper level line with
DOT4 brake fluid.

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 16 PREPARATION

Brake Line Air Bleeding

• Remove the reservoir cap and diaphragm,
and check that there is plenty of fluid in the
reservoir.
NOTE
○The fluid level must be checked several times
during the bleeding operation and replenished
as necessary. If the fluid in the reservoir runs
completely out any time during bleeding, the
bleeding operation must be done over again
from the beginning since air will have entered
A. Front Brake Fluid Reservoir the line.
B. Upper Level Line • Attach a clear plastic hose to the bleed valve
on the front brake caliper and run the other
end of the hose into a container.
WARNING
When working with the disc brake, ob-
• With the reservoir cap off, slowly pump the
brake lever several times until no air bubbles
serve the precautions listed below. can be seen rising up through the fluid from
1. Never reuse old brake fluid. the holes at the bottom of the reservoir. This
2. Do not use fluid from a container that bleeds the air from the brake master cylinder
has been left unsealed or that has end of the line.
been open for a long time.
3. Do not mix two types and brands of
• Pump the brake lever a few times until it
becomes hard and then, holding the lever
fluid for use in the brake. This low- squeezed, quickly open (turn counterclock-
ers the brake fluid boiling point and wise) and close the bleed valve. Then release
could cause the brake to be ineffec- the lever. Repeat this operation until no more
tive. It may also cause the rubber air can be seen coming out into the plastic
brake parts to deteriorate. hose.
4. Don’t leave the reservoir cap off for
any length of time to avoid moisture
contamination of the fluid.
5. Don’t change the fluid in the rain or
when a strong wind is blowing.
6. Brake fluid quickly ruins painted sur-
faces; any spilled fluid should be
completely wiped up immediately.
7. If any of the brake line fittings or the
bleed valve is opened at any time,
the AIR MUST BE BLED FROM THE
BRAKE LINE.

• Install the diaphragm and reservoir cap. A. Hold the brake lever applied.
• ified torque.
Tighten the reservoir cap screws to the spec- B. Quickly open and close the bleed valve.
C. Release the brake lever.
Torque : 1.5 N·m (0.15 kgf·m, 13 in·lb)
• Operate the brake lever several times. • When air bleeding is finished, check that the
• brake line.spongy, there might be air in the
If it feels fluid level is between the upper and lower
level lines.
• Iflines.
necessary, bleed the air in the front brake • Install the diaphragm and reservoir cap.
• Tighten the bleed valve to the specified
• Also
tings.
check for fluid leakage around the fit- torque.
Torque : 7.8 N·m (0.80 kgf·m, 69 in·lb)

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 PREPARATION 17

• Apply the brake forcefully for a few seconds, • Operate the brake pedal several times.
and check for fluid leakage around the fittings. • brake line.spongy, there might be air in the
If it feels

Rear Brake • Ifline.necessary, bleed the air in the rear brake

Rear Brake Fluid Level Inspection • Also check for fluid leakage around the fit-
• With the rear brake fluid reservoir positioned
horizontally, check that the fluid level is above
tings.
Brake Line Air Bleeding
the lower level line. • Remove the reservoir cap and diaphragm,
and check that there is plenty of fluid in the
reservoir.
NOTE
○The fluid level must be checked several times
during the bleeding operation and replenished
as necessary. If the fluid in the reservoir runs
completely out any time during bleeding, the
bleeding operation must be done over again
from the beginning since air will have entered
the line.

A. Rear Brake Fluid Reservoir

• Attach a clear plastic hose to the bleed valve
on the rear brake caliper and run the other
B. Lower Level Line end of the hose into a container.
• With the reservoir cap off, slowly pump the
• Iflower
the fluid level in the reservoir is below the
level line, check for fluid leaks in the
brake pedal several times until no air bub-
bles can be seen rising up through the fluid
rear brake lines, and fill the reservoir. from the holes at the bottom of the reservoir.
• Remove the reservoir cap and diaphragm,
and fill the reservoir to the upper level line with
This bleeds the air from the rear brake master
cylinder end of the line.
DOT4 brake fluid. • Pump the brake pedal a few times until it
becomes hard and then, holding the pedal
pushed down, quickly open (turn counter-
clockwise) and close the bleed valve. Then
release the pedal. Repeat this operation until
no more air can be seen coming up into the
plastic hose.

A. Rear Brake Fluid Reservoir

B. Upper Level Line

• Install the diaphragm and reservoir cap.

• ified torque.
Tighten the reservoir cap screws to the spec-

Torque : 1.5 N·m (0.15 kgf·m, 13 in·lb) A. Hold the brake pedal applied.
B. Quickly open and close the bleed valve.
C. Release the brake pedal.

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 18 PREPARATION

• When
level.
air bleeding is finished, check the fluid

• Install the diaphragm and reservoir cap.

• torque. the bleed valve to the specified
Tighten

Torque : 7.8 N·m (0.80 kgf·m, 69 in·lb)

• Apply the brake forcefully for a few seconds,
and check for fluid leakage around the fittings.

Clutch Lever and Cable

Clutch Lever Free Play Inspection A. Dust Cover
• Check that the clutch lever has the specified
amount of free play. B. Locknut
Clutch Lever Free Play: C. Adjuster
8 ∼ 13 mm (0.3 ∼ 0.5 in.)
• Tighten the locknut and slide the dust cover
back in place.
NOTE
○After the adjustment is made, start the engine
and check that the clutch does not slip and
that it releases properly.
○For minor corrections, use the adjuster at the
clutch lever.

Drive Chain
Drive Chain Slack and Wheel Alignment
A. Clutch Lever Inspection
B. Adjuster • Set the motorcycle up on its side stand.

C. 8 ∼ 13 mm (0.3 ∼ 0.5 in.)

• fied amount
Make sure that the drive chain has the speci-
of play, and that the left and right
notches are on the same marks or points on
• Ifplay.
the free play is incorrect, adjust the free
the left and right of the swingarm.

Clutch Lever Free Play Adjustment WARNING

• Turn the adjuster so that the clutch lever will
have 8 ∼ 13 mm (0.3 ∼ 0.5 in.) of free play.
Misalignment of the wheel will result in
abnormal tire wear and can cause an un-
• Ifmiddle
it cannot be done, use the adjuster on the
of the cable as follows.
safe riding condition. Be sure the wheel
is properly aligned.
• Slide the adjuster
Turn the in all the way.
• Loosen the locknut on the middle (upper end)
dust cover. • Raise the rear wheel off the ground, rotate the
• of the clutch cable, and turn the adjuster so rear wheel to find the place where the chain
is tightest (because it wears unevenly).
that the clutch lever play is 8 ∼ 13 mm (0.3 ∼
0.5 in.).
• Push up the drive chain in the middle of the
upper chain run to measure the chain slack.
The distance between the chain and the
swingarm (at the end of the chain slipper)
should be 52 ∼ 58 mm (2.0 ∼ 2.3 in.).
Drive Chain Slack:
52 ∼ 58 mm (2.0 ∼ 2.3 in.)

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 PREPARATION 19

• Ifright
the chain is too loose, turn out the left and
chain adjusting bolts evenly.
• chainchain
If the is too tight, turn in the left and right
adjusting bolts evenly.
• Turn out both chain adjusting bolts evenly un-
til the drive chain has the correct amount of
slack. To keep the chain and wheel properly
aligned, the chain adjuster notches should
align with the same marks in each side of the
swingarm.
NOTE
A. 52 ∼ 58 mm (2.0 ∼ 2.3 in.) ○Wheel alignment can also be checked using
the straightedge or string method.
• Adjust the drive chain if its slack is out of spec-
ification. WARNING
WARNING Misalignment of the wheel will result in
abnormal tire wear and can cause an un-
A chain that breaks or jumps off the
safe riding condition. Be sure the wheel
sprockets could snag on the engine
is properly aligned.
sprocket or lock the rear wheel, severely
damaging the motorcycle and causing
• Tighten both chain adjuster locknuts.
it to go out of control. Inspect the chain
for damage and proper adjustment.
• Tighten
torque.
the rear axle nut to the specified

Torque : 108 N·m (11.0 kgf·m, 80 ft·lb)

Drive Chain Slack Adjustment
• Remove the cotter pin, and loosen the rear • Rotate the wheel, measure the chain slack
again at the tightest position, and readjust if
axle nut.
necessary.
• Loosen
nuts.
the left and right chain adjuster lock-
• Install a new cotter pin.
NOTE
○When inserting the cotter pin, if the slots in the
nut do not align with the cotter pin hole in the
axle, tighten the nut clockwise up to the next
alignment.
○It should be within 30 degrees.
○Loosen once and tighten again when the slot
goes past the nearest hole.

A. Rear Axle Nut

B. Chain Adjusting Bolt
C. Chain Adjuster Locknut
D. Marks
E. Notch
F. Cotter Pin

A. Cotter Pin
B. Turning Clockwise

• Bend the cotter pin over the nut.

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 20 PREPARATION

NOTE
○When using the air valve adapter, apply
grease to the O-ring.

A. Cotter Pin
B. Nut

WARNING A. Air Valve Adapter

A loose axle nut can lead to an acci-
dent resulting in serious injury or death. • Using a commercially available suitable hand
air pump and air pressure gauge, adjust the
Tighten the axle nut to the proper torque
and be sure the cotter pin is installed air pressure in each fork leg to the specified
correctly. value.
Air Pressure: 240 kPa (2.4 kgf/cm², 35 psi)
• Check the rear brake effectiveness.
NOTE
Front Fork ○Do not use the side stand during air pressure
adjustment.
Air Pressure Adjustment
Before riding, adjust the air pressure to the
specific value. WARNING
• Raise the front wheel off the ground using a
jack (special tool: 57001-1238) and attach-
When riding and transporting the motor-
cycle, make sure that the air pressure is
ment (special tool: 57001-1608). within the adjustable range. If used out-
• Prepare the commercially available suitable
hand air pump and air pressure gauge.
side the adjustable range, running sta-
bility can decrease and cause an acci-
• Remove the air valve plug from the front fork
top plug.
dent resulting in serious injury or death.
Be sure to remove the air valve adapter
before riding. If the air valve adapter is
damaged by a stone during riding, air
leakage can cause loss of control and
an accident resulting in serious injury or
death.

NOTICE
Do not pressurize the fork to more than
500 kPa (5.0 kgf/cm², 73 psi) or the fork
may be damaged.
The right and left fork tubes must be ad-
justed evenly.
A. Air Valve Plug
B. Front Fork Top Plug

• Install the air valve adapter.

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 PREPARATION 21

NOTICE
The right and left fork tubes must be ad-
justed evenly.

NOTICE
Do not force to turn the compression
damping adjuster from the fully seated
position or the adjusting mechanism
may be damaged.

Compression Damping Settings

• After air pressure adjustment, remove the air
valve adapter.
• Reinstall the air valve plug and tighten it to the
specified torque.
Torque : 0.2 N·m (0.020 kgf·m, 1.8 in·lb)

NOTICE
Be sure to install the air valve plug to
prevent dust from entering.

• Before delivery to the customer, explain to

a customer about the proper use of the air
valve adapter while showing the correspond-
A. Seated Position
ing page (Title: Front Suspension) in the
Owner’s Manual. (Adjuster turned fully clockwise)
Compression Damping Adjustment B. Softer (Counterclockwise)
• Check the position of the compression damp-
ing adjusters on the top of the fork tubes.
C. Harder (Clockwise)
D. Standard Setting
STD Compression Damping:
*: Number of turns counterclockwise usable
11 clicks (Counterclockwise from the fully
range 22 clicks or more.
seated position)
Rebound Damping Adjustment
• Clean the bottom of the fork tubes.
• adjusterstheatposition
Check of the rebound damping
the bottom of the fork tubes.
STD Rebound Damping:
9 clicks (Counterclockwise from the fully
seated position)

A. Compression Damping Adjuster

• To adjust the compression damping, turn the

adjuster on each front fork base valve assem-
bly with a standard tip screwdriver. Adjust the
compression damping to the standard setting
position.
A. Rebound Damping Adjuster

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 22 PREPARATION

• To adjust the rebound damping, turn the ad-

juster on each front fork cylinder valve with a
• To adjust the high speed compression damp-
ing, turn the adjuster all the way clockwise
standard tip screwdriver. Adjust the rebound with a wrench to make damping greatest.
damping to the standard setting position. • Turn the adjuster counterclockwise to de-
crease damping. Adjust the high speed
NOTICE
compression damping to the standard posi-
The right and left fork tubes must be ad- tion.
justed evenly.

NOTICE
Do not force to turn the rebound damp-
ing adjuster from the fully seated posi-
tion or the adjusting mechanism may be
damaged.

Rebound Damping Settings

A. High Speed Compression Damping

Adjuster
B. Wrench

NOTICE
Do not force to turn the compression
damping adjuster from the fully seated
position or the adjusting mechanism
may be damaged.
A. Seated Position
(Adjuster turned fully clockwise) High Speed Compression Damping Set-
B. Softer (Counterclockwise) tings
C. Harder (Clockwise)
D. Standard Setting

*: Number of turns counterclockwise usable

range 20 clicks or more.

Rear Shock Absorber

Compression Damping Adjustment
There are two adjustments you can make to
rear shock absorber gas reservoir.
• Check the position of the high and low speed
compression damping adjusters on the gas A. Seated Position
reservoir at the upper end of the rear shock (Adjuster turned fully clockwise)
absorber. B. Softer (Counterclockwise)
STD High Speed Compression Damping: C. Harder (Clockwise)
For European Model D. Standard Setting for European Model
1 1/2 turns out (Counterclockwise from E. Standard Setting for Australian Model
the fully seated position)
For Australian Model
1 3/4 turns out (Counterclockwise from
the fully seated position)

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 PREPARATION 23

*: Number of turns counterclockwise usable *: Number of turns counterclockwise usable

range 2 turns or more. range 22 clicks or more.
STD Low Speed Compression Damping: Rebound Damping Adjustment
For European Model • Check the position of the rebound damping
adjuster at the bottom of the rear shock ab-
11 clicks (Counterclockwise from the
fully seated position) sorber.
For Australian Model STD Rebound Damping:
For European Model
8 clicks (Counterclockwise from the fully
seated position) 20 clicks (Counterclockwise from the
fully seated position)
• To adjust the low speed compression damp-
ing, turn the adjuster all the way clockwise
For Australian Model
19 clicks (Counterclockwise from the
with a standard tip screwdriver to make the
fully seated position)
damping greatest.
• Turn the adjuster counterclockwise to de-
crease damping. Adjust the low speed com-
pression damping to the standard position.

A. Rebound Damping Adjuster

A. Low Speed Compression Damping

• To adjust the rear shock absorber rebound
damping, turn the rebound damping adjuster
Adjuster at the bottom of the rear shock absorber with
B. Screwdriver a standard tip screwdriver. Adjust the re-
bound damping to the standard setting posi-
tion.
Low Speed Compression Damping Set-
tings NOTICE
Do not force to turn the rebound damp-
ing adjuster from the fully seated posi-
tion or the adjusting mechanism may be
damaged.

A. Seated Position
(Adjuster turned fully clockwise)
B. Softer (Counterclockwise)
C. Harder (Clockwise)
D. Standard Setting for European Model
E. Standard Setting for Australian Model

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 24 PREPARATION

Rebound Damping Adjuster Settings

Fuel
WARNING
Gasoline is extremely flammable and
can be explosive under certain condi-
tions, creating the potential for serious
burns. 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 completely to the top. If the
tank is filled completely to the top, heat
A. Seated Position may cause the fuel to expand and over-
(Adjuster turned fully clockwise) flow through the vent in the tank cap.
After refueling, make sure the tank cap
B. Softer (Counterclockwise)
is closed securely. If gasoline is spilled
C. Harder (Clockwise) on the fuel tank, wipe it off immediately.
D. Standard Setting for European Model
E. Standard Setting for Australian Model • Open the fuel tank cap, and check for debris
in the fuel tank.
*: Number of turns counterclockwise usable • Fill the fuel tank with one gallon or four liters
of unleaded gasoline. Use a gasoline with a
range 33 clicks or more.
minimum octane rating shown below.

Tire Air Pressures Use clean, fresh unleaded gasoline with an

• To prevent flat-spotting during shipment, the
tires are over-inflated before crating. Adjust
octane rating equal to or higher than that shown
in the table.
the pressures to the specified values in the Fuel Type Unleaded Gasoline
front and rear, and make sure to tighten the Minimum Research Octane Number (RON)
caps securely. Octane
Tire Air Pressure [when cold]: Rating 95
Front: 100 kPa
(1.0 kgf/cm², 14 psi)
• Close
leaks.
the fuel tank cap, and check for any

Rear: 100 kPa

(1.0 kgf/cm², 14 psi) Coolant
NOTE
○The coolant originally filled into the cooling
system contains 50% of a permanent, ethy-
lene-glycol-based antifreeze, has a freezing
point of –35°C (–31°F) and a green appear-
ance.

Coolant Level Inspection

• Lean the motorcycle slightly so that the filler
neck is located uppermost.
• Remove the radiator cap in two steps.
• stop and wait
First, turn the cap counterclockwise to the first
there for a few seconds.
• same direction andturnremove
Then, push and the cap further in the
it.

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 PREPARATION 25

NOTE
○This vehicle’s engine is filled with 10W-40 oil
from the factory. DO NOT DRAIN and refill
the crankcase before use. Check oil level and
drain bolts tightness.
Engine Oil Drain Bolts Torque:
(M10) 20 N·m (2.0 kgf·m, 15 ft·lb)
(M6) 7.0 N·m (0.71 kgf·m, 62 in·lb)

A. Radiator Cap

• Check the coolant level in the radiator. The

coolant should come up to the bottom of the
radiator filler neck.
NOTE
○Check the coolant level when the engine is
cold (room or ambient temperature).

A. Engine Oil Drain Bolt (M10)

B. Engine Oil Drain Bolt (M6)

• Check the oil level by placing the motorcycle

on its wheels and leveling it from front to back
and side to side. When level, the oil level
should be between the upper and lower lines
indicated next to the oil level inspection win-
dow.
NOTE
A. Coolant Level
○Tipping the motorcycle from side to side by
just a few degrees can drastically alter the oil
B. Filler Neck level indicated in the oil level inspection win-
dow. Be sure the unit is upright when check-
• Ifthetheradiator
coolant level is low, add coolant through
filler opening to the bottom of the
ing the level.
filler neck. Verify Engine Oil Presence
• Install the radiator cap. • Ifdow,
no oil appears in the oil level inspection win-
tip the motorcycle slightly to the right un-
Engine Oil (4-stroke) til oil is visible then return to an upright posi-
tion. If no oil appears even when tipped at
Because of the semi-dry sump lubrication sys- an extreme angle, remove the drain bolts to
tem, the engine oil level indicated on the oil empty any oil that may be in the transmission
level inspection window will fluctuate depending and crankcase, reinstall the drain bolts and
on the motorcycle’s position and engine speed refill with the specified amount of oil.
when the engine shut off. To ensure a proper
reading of the engine oil level, follow the Engine
• If oil appears in the glass when the machine
is tipped but is not visible when perpendicular,
Oil Level Inspection procedures closely. you must verify the oil level after the engine
When performing Assembly and Preparation, has been run.
use the following procedures to verify that the
engine oil level is correct. NOTICE
If the engine is run without oil, it will be
severely damaged.

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 26 PREPARATION

Engine Oil Level Inspection Recommended Engine Oil

• After you have verified that the engine con-
tains oil, start the engine, allow it to idle for
Type: Castrol “POWER1 R4 Racing”
SAE 5W-40 or API SG, SH, SJ,
several minutes then shut it off. DO NOT REV SL or SM with JASO MA, MA1
THE ENGINE AND SHUT IT OFF AT HIGH or MA2
RPM. Doing so can leave a significant amount
Viscosity: SAE 10W-30, 10W-40, 10W-50
of oil in the crank room and top end, leading
to a false oil level reading. Capacity: 0.96 L (1.01 US qt)
• Allow the oil to settle by keeping the motorcy-
cle upright on its wheels for several minutes.
[when filter is not removed]
0.98 L (1.04 US qt)
Check the engine oil level with the motorcycle
[when filter is removed]
vertical through the oil level inspection win-
dow on the lower right side of the engine. The The oil viscosity may need to be changed to
engine oil level should come up between the accommodate atmospheric conditions in your
upper and lower level lines next to the oil level riding area.
inspection window.
NOTE
○Do not add any chemical additive to the oil.
Oils fulfilling the above requirements are fully
formulated and provide adequate lubrication
for both the engine and the clutch.

A. Oil Level Inspection Window

B. Upper Level Line
C. Lower Level Line
D. Oil Filler Cap

• Ifcaptheandoilremove
level is too high, open the oil filler
the excess oil through the oil
filler opening, using a syringe or some other
suitable device.
Throttle Grip and Cable
• If the oil level is too low, add oil through the oil Throttle Grip Free Play Inspection
filler opening to reach the correct level. Use
the same type of oil that is already in the en-
• Check the throttle grip free play. If the free
play is incorrect, adjust the throttle cable.
gine.
Throttle Grip Free Play:
• Before reinstalling the cap, be sure to replace
the O-ring in it with a new one. 2 ∼ 3 mm (0.08 ∼ 0.12 in.)
• Check that the throttle grip moves smoothly
from full open to close, and the throttle closes
quickly and completely in all steering posi-
tions by the return spring. If the throttle grip
does not return properly, check the throttle ca-
ble routing, grip free play, and for possible ca-
ble damage. Then lubricate the throttle cable.

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 PREPARATION 27

Idle Speed Adjustment

• Start the engine and warm it up thoroughly.
• Inspect the idle speed, using the engine rev-
olution tester for high accuracy.
• Adjust the idle speed to following range by
turning the idle adjusting screw/choke knob.
Idle Speed: 1 950 ∼ 2 050 r/min (rpm)

A. Throttle Grip
B. 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

• Run the engine at idle speed and turn the

handlebar all the way to the right and left to
ensure that the idle speed does not change.
If the idle speed increases, check the throttle
grip free play and the cable routing.
WARNING
A. Idle Adjusting Screw/Choke Knob
Operation with improperly adjusted,
B. Tester
incorrectly routed or damaged cables
could result in an unsafe riding condi-
tion. Follow the service manual to make
• Open and close the throttle grip a few times
to make sure that the idle speed is within the
sure to correct any of these conditions. specified range.
• With the engine idling, turn the handlebar to
each side. If handlebar movement changes
Throttle Grip Free Play Adjustment
• Loosen the locknut of the accelerator cable
and turn the adjuster to give the throttle grip
the idle speed, check the throttle cable routing
and free play.
plenty of play.
WARNING
• Tighten the locknut securely.
Operation with incorrectly routed or
damaged throttle cable could result in
an unsafe riding condition. Be sure the
throttle cable is routed correctly, prop-
erly adjusted and is not damaged in any
way.

A. Adjuster
B. Locknut
C. Accelerator Cable

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 28 PREPARATION

NOTICE
This motorcycle is designed for compe-
tition use only. Therefore, the radiator
does not incorporate a coolant reserve
tank or cooling fan. Prolonged idling
of the engine with no airflow through
the radiator can cause coolant loss
and engine overheating resulting in
possible engine damage. Any riding
conditions that increase engine tem-
perature will further reduce idling time
before coolant loss occurs. These con-
ditions include high ambient tempera-
ture, sandy or muddy terrain, or other
conditions causing high engine loads at
low speeds. Furthermore, warming the
engine up excessively before operation,
or leaving idling with the hot engine
temperature after operation results in
the engine overheating, too.

• Check for any exhaust leaks and correct if

necessary.

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 PREPARATION 29

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 30 PREPARATION

Fastener Check
• The torque values listed are for assembly and preparation items only, see the appropriate Service
Manual for a more comprehensive list. Check tightness of all fasteners that are in the table before
retail delivery. Also check to see that each cotter pin or circlip is in place.

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 PREPARATION 31

Torque Re-
No. Fastener
N·m kgf·m ft·lb marks
Steering
1 Handlebar clamp bolts 25 2.5 18 2T, AL
Brake
2 Front master cylinder clamp bolts 8.8 0.90 78 in·lb S
3 Front caliper mounting bolts 25 2.5 18
4 Front caliper bleed valve 7.8 0.80 69 in·lb
5 Rear master cylinder mounting bolts 9.8 1.0 87 in·lb
6 Rear caliper bleed valve 7.8 0.80 69 in·lb
Wheel
7 Front axle nut 78 8.0 58 S
8 Front axle clamp bolts (Left and Right) 20 2.0 15 AL, S
Suspension
9 Front fork clamp bolts (Upper) 20 2.0 15 AL
10 Front fork clamp bolts (Lower) 20 2.0 15 AL
11 Rear shock absorber mounting nut (Upper) 39 4.0 29
12 Rear shock absorber mounting nut (Lower) 34 3.5 25
13 Swingarm pivot shaft nut 98 10 72
14 Tie-rod mounting nuts 59 6.0 43
15 Rocker arm pivot nut 59 6.0 43
Engine Oil Drain Bolt
16 Engine oil drain bolt (M10) 20 2.0 15
17 Engine oil drain bolt (M6) 7.0 0.71 62 in·lb
Cotter Pin or Circlip
18 Rear axle nut cotter pin – – –
19 Rear master cylinder cotter pin – – –
20 Footpeg cotter pin (Left and Right) – – –

AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.
S: Follow the specified tightening sequence.
(Tighten the upper clamp bolt first, and then the lower clamp bolt.)
2T: Apply 2-stroke oil.

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 32 PREPARATION

Launch Control Mode Button Works:

Standard Torque Table 1. Start the engine.
This table relating tightening torque to thread 2. Shift into neutral, 1st, or 2nd gear.
diameter, lists the basic torque for bolts and 3. Push the launch control mode button
nuts. Use this table for only the bolts and nuts for over two seconds.
which do not require a specific torque value. 4. The orange launch control mode
All of the values are for use with dry solvent indicator light (LED) will blink to
-cleaned threads. indicate the system is operating.
General Fasteners: 5. When shifting into 3rd, the system
is deactivated automatically and the
Threads Torque
indicator light stops blinking.
dia. mm N·m kgf·m ft·lb
No Unusual Noises:
5 3.4 ∼ 4.9 0.35 ∼ 0.50 30 ∼ 43 in·lb
No Fuel and Oil, Brake Fluid, or Coolant
6 5.9 ∼ 7.8 0.60 ∼ 0.80 52 ∼ 69 in·lb
Leaks:
8 14 ∼ 19 1.4 ∼ 1.9 10.0 ∼ 13.5
PREPARATION COMPLETE.
10 25 ∼ 34 2.6 ∼ 3.5 19.0 ∼ 25.0
12 44 ∼ 61 4.5 ∼ 6.2 33 ∼ 45
14 73 ∼ 98 7.4 ∼ 10.0 54 ∼ 72
A&P Check List
16 115 ∼ 155 11.5 ∼ 16.0 83 ∼ 115
18 165 ∼ 225 17.0 ∼ 23.0 125 ∼ 165 • Complete the A&P Check List.
20 225 ∼ 325 23.0 ∼ 33.0 165 ∼ 240

Test Ride the Motorcycle

• Complete the test ride check list.
Control Cables:
Throttle cable must work without binding
in any steering position.
Steering:
Action is free from lock–to–lock.
Suspension:
Check operation front and rear.
Engine:
Kick starter works properly and engine
starts promptly. Good throttle response
and return.
Transmission and Clutch:
Smooth operation.
Brake:
Adequate, smooth stopping power, No
drag.
Engine Stop Switch Works:

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 MODEL APPLICATION
Year Model Name
2013 KX450FD KX450F

Part No. 99939-1344-01

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