KAWASAKI KLX450R BIKE 2007 Onward Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Kawasaki Model: KLX450R Year Coverage Start: 2007 Year Coverage End: Onward Vehicle Type: Motorcycle (Off-Road/Motocross) Codes Chassis Code: Likely includes 'KLX450A' or similar prefix, specific to 2007 onward models. Detailed identification would be in the manual. Engine Code: Likely includes 'KLX450A' or similar prefix, specific to the 449cc DOHC engine. Detailed identification would be in the manual. 👋 Introduction Market Position Target Audience: Owners of the Kawasaki KLX450R (2007 onward) seeking to perform maintenance, repairs, and modifications. Also aimed at independent workshops and mechanics. Competitive Analysis Value Proposition: Provides comprehensive, authoritative information for DIY maintenance and repair, saving costs associated with professional servicing. Offers insights comparable to official factory service manuals. Key Features Key Selling Points: Detailed step-by-step instructions, high-quality illustrations, covers all major systems, includes owner's manual and parts catalog, cross-platform compatibility, printable pages. 📋 Manual Details Coverage Areas Primary Coverage: Workshop Service and Repair Included Manuals: Owner's Manual, Parts Catalog Page Count Estimated Page Count: While not explicitly stated, comprehensive workshop manuals for this era and type of motorcycle typically range from 300 to 600+ pages. Manual Type Type: Electronic (PDF) Workshop Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine removal/installation, top end (cylinder head, cylinder, valves, piston), camshaft, crankshaft, flywheel housing, bottom end, lubrication system, cooling system, engine disassembly/assembly. Fuel System: Fuel tank, fuel pump (if applicable), fuel lines, carburetor system, air cleaner system, evaporative emission control. Exhaust System: Exhaust pipes, muffler, heat shields. Drivetrain: Clutch system (operation, maintenance, repair), transmission (gearbox components, shift mechanism), final drive (chain, sprockets), wheels and tires. Brakes: Front and rear brake systems (disassembly, assembly, hydraulic components, pads, rotors). Suspension: Front fork (disassembly, assembly, seals, oil), rear shock absorber, swingarm system, tie-rod and rocker arm linkage. Steering: Handlebar, steering stem, bearings, fork clamps. Frame And Bodywork: Frame structure, body panels, seat, fenders, plastics. Electrical System: Charging system (alternator, regulator/rectifier), starting system (starter motor, battery), ignition system (spark plug, CDI unit, ignition coil), lighting system (headlight, taillight, indicators), wiring diagram. Procedures Included Maintenance: Periodic maintenance schedule, oil changes, filter replacements, chain adjustment, brake pad inspection, valve clearance checks, general lubrication. Troubleshooting: Common issues, diagnostic procedures, symptom-based troubleshooting (implied by comprehensive nature). Repair And Rebuild: Complete disassembly and reassembly instructions for all major components and systems, including engine rebuilds. Technical Data: Tightening torques, fluid capacities, specifications for wear limits, clearances, and adjustments. Special Tools: Identification and usage of specific tools required for certain maintenance and repair tasks. Technical Depth Depth: Comprehensive, covering everything from basic routine maintenance to complete engine and chassis overhauls. Suitable for both DIY enthusiasts and professional mechanics. Illustration Quality: Detailed illustrations, pictures, and diagrams for step-by-step guidance. 📊 Manual Specifications File Format Format: PDF Compatibility: All Windows versions, All Mac versions Required Software: Adobe Acrobat Reader, WinZip/WinRAR for extraction. Print Quality Printability: All pages are printable. Binding Type Binding: Digital (PDF, no physical binding) Paper Type Paper Type: N/A (Digital format) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke Configuration: 1-cylinder Displacement: 449 cc Valve Train: DOHC (Double Overhead Camshaft) Cooling System: Liquid-cooled Performance Horsepower: Specific horsepower figures for the 2007 KLX450R are not provided in the product information, but typically fall in the 45-50 HP range, depending on tuning and emission regulations. Detailed specs would be in the manual. Torque: Specific torque figures are not provided in the product information. The manual would contain this data. Fuel System Fuel Delivery: Carbureted (details covered in 'Fuel System' and 'Carburetor System' sections). 🔧 Transmission Standard Transmission Type: Manual (gearbox) Optional Optional Transmissions: N/A (Typically single transmission option for this model) Features Gear Count: Specific gear count not stated in product info, but typically 5-speed for this class of motorcycle. Covered in manual. Clutch Type: Wet, multi-plate (as per typical Kawasaki motocross designs). Specific details on operation and maintenance covered in manual. 📐 Dimensions Exterior Overall Length: Specific dimensions not provided in product information, but are detailed in the Owner's Manual section of the manual. Overall Width: Specific dimensions not provided in product information, but are detailed in the Owner's Manual section of the manual. Overall Height: Specific dimensions not provided in product information, but are detailed in the Owner's Manual section of the manual. Weights Dry Weight: Specific dry weight not provided in product information, but typically around 250 lbs (113 kg) for this model. Detailed specifications are in the manual. Curb Weight: Specific curb weight not provided in product information. Detailed specifications are in the manual. 🛡️ Safety Features Ratings Safety Ratings: Motorcycles of this type are not typically subjected to crash test ratings like cars. Safety is primarily addressed through design and rider skill. Manual covers brake system safety and maintenance. Active Features Active Safety Features: Front and rear disc brakes, robust suspension, off-road tires....
Likely includes 'KLX450A' or similar prefix, specific to 2007 onward models. Detailed identification would be in the manual.
Engine Code:
Likely includes 'KLX450A' or similar prefix, specific to the 449cc DOHC engine. Detailed identification would be in the manual.
👋 Introduction
Market Position
Target Audience:
Owners of the Kawasaki KLX450R (2007 onward) seeking to perform maintenance, repairs, and modifications. Also aimed at independent workshops and mechanics.
Competitive Analysis
Value Proposition:
Provides comprehensive, authoritative information for DIY maintenance and repair, saving costs associated with professional servicing. Offers insights comparable to official factory service manuals.
Key Features
Key Selling Points:
Detailed step-by-step instructions, high-quality illustrations, covers all major systems, includes owner's manual and parts catalog, cross-platform compatibility, printable pages.
📋 Manual Details
Coverage Areas
Primary Coverage:
Workshop Service and Repair
Included Manuals:
Owner's Manual, Parts Catalog
Page Count
Estimated Page Count:
While not explicitly stated, comprehensive workshop manuals for this era and type of motorcycle typically range from 300 to 600+ pages.
Clutch system (operation, maintenance, repair), transmission (gearbox components, shift mechanism), final drive (chain, sprockets), wheels and tires.
Brakes:
Front and rear brake systems (disassembly, assembly, hydraulic components, pads, rotors).
Suspension:
Front fork (disassembly, assembly, seals, oil), rear shock absorber, swingarm system, tie-rod and rocker arm linkage.
Steering:
Handlebar, steering stem, bearings, fork clamps.
Frame And Bodywork:
Frame structure, body panels, seat, fenders, plastics.
Electrical System:
Charging system (alternator, regulator/rectifier), starting system (starter motor, battery), ignition system (spark plug, CDI unit, ignition coil), lighting system (headlight, taillight, indicators), wiring diagram.
Procedures Included
Maintenance:
Periodic maintenance schedule, oil changes, filter replacements, chain adjustment, brake pad inspection, valve clearance checks, general lubrication.
Troubleshooting:
Common issues, diagnostic procedures, symptom-based troubleshooting (implied by comprehensive nature).
Repair And Rebuild:
Complete disassembly and reassembly instructions for all major components and systems, including engine rebuilds.
Technical Data:
Tightening torques, fluid capacities, specifications for wear limits, clearances, and adjustments.
Special Tools:
Identification and usage of specific tools required for certain maintenance and repair tasks.
Technical Depth
Depth:
Comprehensive, covering everything from basic routine maintenance to complete engine and chassis overhauls. Suitable for both DIY enthusiasts and professional mechanics.
Illustration Quality:
Detailed illustrations, pictures, and diagrams for step-by-step guidance.
📊 Manual Specifications
File Format
Format:
PDF
Compatibility:
All Windows versions, All Mac versions
Required Software:
Adobe Acrobat Reader, WinZip/WinRAR for extraction.
Print Quality
Printability:
All pages are printable.
Binding Type
Binding:
Digital (PDF, no physical binding)
Paper Type
Paper Type:
N/A (Digital format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke
Configuration:
1-cylinder
Displacement:
449 cc
Valve Train:
DOHC (Double Overhead Camshaft)
Cooling System:
Liquid-cooled
Performance
Horsepower:
Specific horsepower figures for the 2007 KLX450R are not provided in the product information, but typically fall in the 45-50 HP range, depending on tuning and emission regulations. Detailed specs would be in the manual.
Torque:
Specific torque figures are not provided in the product information. The manual would contain this data.
Fuel System
Fuel Delivery:
Carbureted (details covered in 'Fuel System' and 'Carburetor System' sections).
🔧 Transmission
Standard
Transmission Type:
Manual (gearbox)
Optional
Optional Transmissions:
N/A (Typically single transmission option for this model)
Features
Gear Count:
Specific gear count not stated in product info, but typically 5-speed for this class of motorcycle. Covered in manual.
Clutch Type:
Wet, multi-plate (as per typical Kawasaki motocross designs). Specific details on operation and maintenance covered in manual.
📐 Dimensions
Exterior
Overall Length:
Specific dimensions not provided in product information, but are detailed in the Owner's Manual section of the manual.
Overall Width:
Specific dimensions not provided in product information, but are detailed in the Owner's Manual section of the manual.
Overall Height:
Specific dimensions not provided in product information, but are detailed in the Owner's Manual section of the manual.
Weights
Dry Weight:
Specific dry weight not provided in product information, but typically around 250 lbs (113 kg) for this model. Detailed specifications are in the manual.
Curb Weight:
Specific curb weight not provided in product information. Detailed specifications are in the manual.
🛡️ Safety Features
Ratings
Safety Ratings:
Motorcycles of this type are not typically subjected to crash test ratings like cars. Safety is primarily addressed through design and rider skill. Manual covers brake system safety and maintenance.
Active Features
Active Safety Features:
Front and rear disc brakes, robust suspension, off-road tires. Manual details proper brake operation and maintenance.
Passive Features
Passive Safety Features:
Frame integrity, ergonomic design for rider control. Manual assists in maintaining structural integrity through proper maintenance.
💡 Technology Features
Infotainment
Infotainment System:
N/A (Motorcycle of this type does not feature infotainment systems).
Driver Assistance
Driver Assistance Systems:
N/A (Motorcycle of this type does not feature driver assistance systems).
Connectivity
Connectivity Features:
N/A (Motorcycle of this type does not feature connectivity features).
Ignition System
Ignition Type:
Electronic ignition (CDI), details covered in the 'Ignition System' section of the manual.
Starting System
Starting Method:
Electric start (typical for KLX450R), details covered in the 'Starting System' section of the manual.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Specific intervals are not listed in the product info but are detailed in the 'Periodic Maintenance' section of the manual, typically every few hundred miles or based on operating hours for off-road use.
Valve Adjustment Interval:
Specific intervals are not listed in the product info but are detailed in the 'Periodic Maintenance' section of the manual, critical for DOHC engines.
Fluid Specifications
Engine Oil Type:
The manual will specify the correct grade and type of engine oil, likely a high-quality motorcycle-specific synthetic or semi-synthetic oil (e.g., SAE 10W-40, meeting JASO MA standards). Exact specifications are in the manual.
Coolant Type:
The manual will specify the correct type of coolant, typically a 50/50 mix of ethylene glycol-based antifreeze and distilled water, or a pre-mixed coolant suitable for liquid-cooled engines.
Brake Fluid Type:
The manual will specify the DOT standard for brake fluid, usually DOT 4. It's critical to use the correct type for proper braking performance and safety.
Known Issues
Common Issues 2007 Klx450R:
While not explicitly listed in product info, common issues for off-road bikes of this era can include carburetor tuning sensitivity, suspension seal wear, chain and sprocket wear, and clutch wear depending on usage. The manual is invaluable for addressing these.
📚 Vehicle History
Brand Heritage
Kawasaki Heritage:
Kawasaki has a long and successful history in motorcycle racing and off-road performance, known for its powerful engines and innovative designs, particularly in the KX and KLX lines.
Model Evolution
Klx450R Evolution:
The KLX450R was introduced as a competitive off-road machine, often leveraging technology from Kawasaki's motocross (KX) series, adapted for enduro and cross-country riding. The 2007 model represents an early iteration of this platform.
Production
Production Location:
Kawasaki motorcycles are manufactured in various global locations, including Japan and other Asian countries. Specific manufacturing location for the 2007 KLX450R would be detailed in its production records.
🏆 Awards & Recognition
Recognitions
Model Awards:
Specific awards for the 2007 Kawasaki KLX450R are not provided in the product information, but the model was generally well-received in the off-road and enduro communities for its performance and capability.
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