This manual covers the motorcycle, produced for the model years 2008 through 2011, including chassis codes KLX450A8F, KLX450A9F, KLX450ABF, and KLX450ACF. The KLX450R is a high-performance, liquid-cooled, four-stroke, DOHC off-road motorcycle designed for motocross and trail riding. It features a perimeter aluminum frame, long-travel adjustable suspension, hydraulic disc brakes, and a 449cc engine with a Keihin FCR39 carburetor, delivering robust power for demanding off-road conditions. Extensive heritage in off-road performance underpins the KLX series' reputation for durability and capability. This comprehensive English-language service manual provides detailed information for maintaining and repairing all KLX450R models from the specified production years. It covers essential areas such as complete engine overhauls, fuel and ignition systems, cooling, transmission, drivetrain, suspension, brakes, electrical systems, and chassis. The manual includes step-by-step disassembly and assembly procedures, rebuilding guides, adjustment instructions, torque specifications, routine maintenance schedules, and troubleshooting diagnostics for common issues. With an estimated 400+ pages, this resource empowers owners and technicians to perform high-quality service, ensuring optimal performance and longevity of the motorcycle. 🏷️ Basic Information Identification Make: Kawasaki Model: KLX450R Year: 2008-2011 Codes Chassis Code Range: KLX450A8F, KLX450A9F, KLX450ABF, KLX450ACF 👋 Introduction Market Position Segment: High-performance off-road/motocross utility motorcycle. Target Audience: Enthusiasts and riders seeking a capable and durable off-road machine for competition or recreational trail riding. Competitive Analysis Key Competitors: Yamaha YZ450F, Honda CRF450R, Suzuki RM-Z450, KTM 450 SX-F. Key Features Engine Type: Liquid-cooled, four-stroke, DOHC, four-valve single. Suspension Type: Long-travel, adjustable upside-down front forks and monoshock rear suspension. Frame Type: Perimeter aluminum frame for rigidity and light weight. Braking System: Hydraulic disc brakes front and rear. Manual Value Proposition Diy Advantage: Empowers owners to perform high-quality repairs and maintenance themselves, saving on labor costs and ensuring proper execution. 📋 Manual Details Coverage Areas Coverage Years: 2008, 2009, 2010, 2011 Model Variants: All KLX450R models Page Count Estimated Page Count: 400+ Manual Type Type: Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine overhaul, including cylinder, piston, crankshaft, connecting rod, valve train, and lubrication system. Fuel System: Carburetor tuning and disassembly, fuel pump, fuel tank, and fuel lines. Ignition System: CDI unit, ignition coil, spark plug, and troubleshooting. Cooling System: Radiator, coolant hoses, water pump, and thermostat. Transmission And Drivetrain: Clutch operation and replacement, gearbox disassembly and assembly, final drive and sprocket inspection. Suspension System: Front fork (USD) service and adjustment, rear shock absorber maintenance and calibration, linkage systems. Brakes: Front and rear brake caliper service, master cylinder overhaul, brake line replacement, bleeding procedures. Electrical System: Wiring diagrams, lighting, battery, charging system, starter motor, fuses, and relays. Chassis And Frame: Frame inspection, swingarm, steering head bearings, and wheel bearings. Bodywork And Plastics: Removal and installation of body panels, seat, fuel tank cover, and fenders. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment and lubrication, air filter cleaning/replacement, spark plug checks. Troubleshooting: Diagnostic procedures for common engine, electrical, and mechanical issues with symptom-based guides. Disassembly And Assembly: Step-by-step instructions for component removal and reinstallation for all major systems. Rebuilding Procedures: Detailed guides for engine, transmission, and suspension component rebuilding. Adjustment Procedures: Valve clearance adjustment, carburetor idle speed and mixture adjustment, suspension sag adjustment. Torque Specifications: Precise torque values for critical fasteners throughout the motorcycle. Technical Depth Depth: Comprehensive, covering everything from basic pre-ride checks to complete engine and transmission rebuilds. Includes detailed schematics and diagnostic flowcharts. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text content for quick access to information. Print Quality Image Resolution: High-resolution images and diagrams suitable for printing. Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 4-stroke, DOHC, 4-valve single Displacement: 449 cc Bore X Stroke: 92.0 x 67.5 mm Compression Ratio: 11.0:1 Valvetrain: DOHC, 4 valves Performance Horsepower Estimated: Approx. 50-55 HP (at crank) Torque Estimated: Approx. 30-33 lb-ft (at crank) Fuel System Carburetor: Keihin FCR39 with accelerator pump Fuel Capacity: 8.0 Liters (2.1 US gal) Lubrication Oil Capacity: 1.7 Liters (with filter change) 🔧 Transmission Standard Type: 5-speed constant mesh Features Clutch: Wet, multi-disc, cable operated Final Drive: O-ring sealed chain, 13/49T (stock) or equivalent aftermarket. 📐 Dimensions Exterior Length: 2,200 mm (86.6 in) Width: 800 mm (31.5 in) Height: 1,275 mm (50.2 in) Wheelbase: 1,475 mm (58.1 in) Ground Clearance: 330 mm (13.0 in) Seat Height: 945 mm (37.2 in) Weights Curb Weight: 123 kg (271.2 lbs) Front Tire Size: 80/100-21 51M Rear Tire Size: 110/100-18 64M Wheel Bolt Pattern: N/A (Spoked wheels, hub specific) 🛡️ Safety Features Ratings Safety Certification: N/A (Designed for off-road use, not street legal by default) Active Features Braking: Large diameter petal disc brakes front and rear for enhanced stopping power and heat dissipation. Passive Features Chassis Design: Rigid perimeter frame and durable...