KX450E

2010 MODEL INFORMATION
OVERVIEW --------------------- P.2
AT A GLANCE ------------------ P.4
KEY FEATURES ---------------- P.5
HARD-HITTING FUEL-INJECTED POWER ---- P.5
FACTORY-STYLE CHASSIS COMPONENTS
AND TUNING ----------------------------------- P.10
ADDITIONAL FEATURES ---- P.14
COLOUR(S) ------------------- P.15
APPENDIX:
KX FI CALIBRATION KIT ---- P.16
MODEL NAME
KX450F
MARKETING CODE
KX450E
Version: 25 Jun 2009
SPECIFICATIONS ------------ P.19
INTERNAL USE ONLY
Intended as a general reference for the preparation of sales promotion and marketing material,
some of the material contained herein may not apply to your market.
OVERVIEW
FACTORY TUNING TO KEEP
EXPERT RIDERS AT THE
FRONT OF THE PACK
Already ranked at the top of its class in numerous
enthusiast magazine shootouts, for 2010 the KX450F
receives a number of engine and chassis updates to
ensure its winning potential.
The KX450F base package provides an excellent
platform for experienced racers to win races in the top
classes. Design of the highly rigid aluminium frame,
suspension components and settings focused on
delivering superb high-speed stability – especially in
straight lines – to enable race-experienced riders to ride
full out. And to deliver holeshot-winning performance – a
key factor that can mean the difference between running
up front and winning, or getting stuck mid-pack – chassis
geometry and the hard-hitting 4-stroke engine’s wide
powerband were designed to maximise rear wheel
traction. The combination is a proven race-winner, with
Kawasaki racers regular podium finishers.
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2
OVERVIEW
To keep the Lime Green racers out in front, Kawasaki
engineers made a number performance-enhancing updates to
both engine and chassis. Feedback from factory racers
resulted in a number of refinements that deliver increased
high-rpm and over-rev performance. The new engine has
specs on par with Ryan Villopoto’s KX450F racer. Also
inherited from the racing world, a new piston with bridged-box
bottom makes its first appearance in a mass-production
machine. Finally, fine-tuning of the clutch results in improved
clutch feeling.
Chassis updates focus on making the KX450F even easier to
ride fast. Revisions to the frame and suspension components
result in lighter handling, improved suspension action,
increased comfort and greater cushioning when landing jumps.
Already acclaimed as the best looking motocrosser in the
paddock, the KX450F once again sports sharp factory-racer
looks that are more than skin deep. Sleek, functional
bodywork was designed to offer racers a slim rider interface to
further facilitate going faster.
The KX450F – designed to give racers the competitive edge to
run out front.
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3
AT A GLANCE
NEW
Factory-inspired tuning - P.6
Factory-inspired refinements contribute to increased
high-rpm and over-rev performance. Used for the first
time in a mass-production
machine, a new
high-performance piston
with bridged-box bottom
features the same design
as our factory racers.
Factory styling - P.12
Factory-style graphics, black alumite rims and black fork
guards give the KX450F the looks to match its highly
tuned performance.
NEW
Slim rider interface - P.13
Bodywork components and seat designed to offer a slim,
natural riding position making it easier for racers to go
fast. Slimmer shroud design and revised exhaust pipe line
contribute to improved ergonomics.
NEW
Firmer urethane helps seat maintain its original shape
longer.
Lightweight 43 mm throttle body uses two shafts joined
by a progressive link to give sharp response and excellent
power feeling.
Renthal handlebar - P.12
Factory-style handlebar and
pad comes standard.
NEW
Setting-adjustable
motocross ECU - P.8,16
Lightweight ECU was designed specifically to withstand
the rigors of motocross racing. Revisions to programme
and settings offer
improved response at
low-mid rpm. Settings
can be reprogrammed with
an optional KX FI
Calibration Kit.
All-aluminium perimeter frame - P.10
Slim aluminium perimeter frame is a lightweight
construction composed of forged, extruded and cast parts.
NEW
Progressive throttle link - P.8
Seat - P.13
Lighter-handling chassis - P.10
Kayaba AOS fork with DLC coating
and Kashima Coat - P.11
New steering stem and swingarm with revised
cross-section offer lighter handling.
Diamond-Like Carbon
coating reduces sliding
friction for improved fork
action, especially during
cornering. Kashima Coat
and high-precision
machining further reduce
friction.
Rear shock absorber - P.11
Dual compression adjustability offers a wide range of
tuning options. Kashima Coat on the tank cylinder
improves action.
NEW New Uni-Trak rear suspension- P.10
NEW
Linkage mounts below the swingarm for more precise
suspension tuning. Revised linkage ratios contribute to
increased rear wheel traction.
NEW Revised front/rear suspension
spring rates and damping settings - P.11
Revised fork spring rates and damping settings and the
less rigid steering stem offer improved action and
increased comfort. Revised rear shock spring rate and
damping settings add increased stability and increased
cushioning when landing jumps.
NEW
Improved clutch feeling - P.7
Revisions to clutch components result in more direct feel
and increased control.
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Fuel-injected 449 cm3 liquid-cooled,
4-stroke Single - P.5
Fuel-injected engine
offers hard-hitting power
while ensuring stable
fuel-metering in all
conditions
NEW
Shorter exhaust - P.7
Shortened exhaust pipe
offers improved mid-range
performance.
High-precision ACR - P.9
Radiators - P.9
New thicker, wider radiators with
more widely spaced cores/fins
are stronger, offer better
resistance to mud build-up while
maintaining cooling
performance. Also lighter
overall, with reinforcing brackets
unnecessary.
Petal brake discs - P.12
Front and rear petal brake
discs offer efficient
braking performance.
Dual-weight centrifugal decompression system offers
reliable starting.
4
KEY FEATURES
HARD-HITTING FUEL-INJECTED POWER
10MY
09MY
Power (kW)
Torque (N.m)
Fuel-injected 449 cm3 liquid-cooled, 4-stroke Single delivers hard-hitting power
from low- through high-rpm. The broad powerband and responsive throttle offer a
broad spread of torquey response that enables racers to get on the gas and go
even from down low. In addition to the inherent benefits, fuel injection contributes
to the KX450F’s lag-free acceleration, especially after landing jumps. For 2010, a
number of refinements, including the first mass-production use of a
high-performance piston featuring a bridged-box bottom, offer improved
performance in high-rpm and over-rev ranges, and modifications to the clutch
deliver improved clutch feeling.
Engine rpm
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5
KEY FEATURES
Refined power delivery
1
09MY
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10MY
NEW
* New piston, featuring the same design used on our
factory racers, offers improved performance at all rpm.
A revised profile with a shorter skirt, reinforced external
ribs and the first mass-production use of a bridged-box
bottom, featuring fully flush internal bracing, results in a
lighter, stronger piston. (Photo 1)
NEW
* Shorter piston pin has a smaller inner diameter for
increased strength.
NEW
* Intake camshaft with revised sprocket/shaft
arrangement moves intake valve timing 2o forward, to
suit revised engine characteristics.
09MY
10MY
Open
34o BTDC
36o BTDC
Close
70o ABDC
68o ABDC
NEW
* Crankshaft with a slightly higher inertial mass
(47.2 kg-cm2 >> 48.2 cm2) offers increased traction
performance. The balance factor is unchanged.
* Wedge-shaped crank web increases offsetting moment
for high crankshaft balance factor. At close to 60%, the
balance factor of the ’10 KX450F is on par with Ryan
Villopoto’s factory racer. The result is reduced engine
vibration, smoother power delivery and increased
performance – especially at low rpm, where response is
noticeably snappier.
6
KEY FEATURES
* In addition to generating the electrical output necessary to ensure easy
starting, the large-diameter ACG also contributes to engine feeling at
partial throttle.
NEW
NEW
* One-piece stainless steel exhaust pipe is 40 mm shorter, contributing to
improved mid-high range performance. The optimised pipe line
contributes to improved ergonomics, and the new steel construction
offers enhanced durability.
Improved clutch feeling
The following clutch revisions offer more direct feel and increased
control. (Photo 3)
3
* On European models, revised internal construction results in a silencer
approximately 330 g lighter (on par with that of other markets). (Photo 2)
2
09MY
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10MY
NEW
* Material trimmed from the spring holders and outer surface of the
operating plate optimise rigidity and improve oil drainage from the
clutch, contributing to more direct feel.
NEW
* Friction plates feature approximately 75% more friction material,
contributing to a more direct feel (particularly beneficial for hooking up
after landing jumps).
NEW
* Operating plate pusher with increased outer diameter reduces clearance
between the pusher and the hole of the input shaft, improving clutch
operation.
7
KEY FEATURES
Battery-less fuel injection system
Designed specifically for motocrossers the fuel injection system incorporates a small lightweight ECU and operates without a battery to further
eliminate unnecessary weight. And of course, fuel injection eliminates the need to adjust engine settings to suit track and climate conditions.
* Ensuring quick starting without a battery was a prime directive when
developing the KX450F’s fuel injection system. Using only electricity
generated by the kick starter, the engine can be started with only three
rotations of the crankshaft. The system delivers electricity in the
following order: 1) ECU, 2) fuel pump, 3) injector. With a warm engine,
starting can be accomplished in a single kick.
* An optional KX FI Calibration Kit (containing KX Racing software, an ECU
controller, mounting bracket and damper, harness and USB cable) allows racers
to adjust engine characteristics (by rewriting actual data maps) to suit their
preference. (In addition to the kit, a PC and 12 V battery are all that is required.)
Please refer to the Appendix for more details. (Photo 5)
5
* The compact, lightweight ECU, located just in front of the steering head
(behind the number plate), was designed specifically for motocross use.
To help cope with the shocks and vibrations of motocross riding, the fuel
pump relay is built in to the ECU. (Photo 4)
4
* The 43 mm throttle body makes use of a progressive throttle link to deliver
airflow in much the same way as would a FCR carburettor. Using two linked
shafts, the throttle body opens more quickly after the 3/8 open position,
delivering sharp response and excellent power feeling.
* Ultra-fine atomising injector with 12 holes sprays particles with a droplet size of
60μ for smooth power deliver and improved engine at partial throttle.
* The injector was set at 45o, the optimum angle for improved mid-range power.
* Lightweight flat-bottom aluminium fuel pump is located in the plastic fuel tank.
NEW * New ECU operating programme and revised setting data offer improved
response at low-mid rpm.
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* To ensure a stable fuel supply during vigorous motocross riding the fuel pump
features a rubber fuel filter cover that wraps around the inlet port and acts as a
fuel trap. A fuel return hose from the pressure regulator ensures there is always
fuel in the fuel trap.
8
KEY FEATURES
Other performance-enhancing engine
characteristics
6
* The engine was tuned such that the torque curve follows the limit of
running resistance for as long as possible. (Unchecked, engine torque
can exceed this limit, resulting in wheel spin, which does nothing to help
forward momentum.)
* Efforts were made to achieve the widest possible torque band, so that
traction efficiency would be maximised for a greater part of the rev
range.
* The engine is almost upright (forward lean angle is 3o) to help place the
bike’s centre of gravity in the ideal position for maximum traction.
* Asymmetrical high-acceleration cams yield high intake efficiency.
* During the cylinder head casting process, the cores for the intake ports
were given a special coating to make the intake ports smoother. The
extremely smooth surfaces that result increase intake efficiency at
all rpm.
* Lightweight titanium valves (IN: 36 mm; EX: 31 mm) reduce
reciprocating weight and offer high-rpm reliability.
* Aluminium valve spring retainers reduce reciprocating weight for reliable
valve control at high-rpm.
* Double valve springs also help ensure stable valve operation and allow
a short cylinder head height.
NEW
* Cylinder skirt was strengthened to match the increased engine
performance.
NEW
* New thicker (22 mm >> 32 mm), wider (120.2 mm >> 127.8 mm)
radiators with increased fin and tube pitch are stronger, offer better
resistance to mud build-up, and maintain cooling performance. Because
the new radiators are stronger, reinforcing brackets could be eliminated,
resulting in lower overall weight. (Photo 6)
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09MY
10MY
* The screw-type adjuster on the cam chain tensioner is equipped with a
pressure spring. Because the system automatically minimises the vibration
caused by a loose cam chain, it greatly reduces the chance of a mishap during
a race. (Non-automatic systems that are tuned incorrectly can actually
adversely affect valve timing by putting too much pressure on the cam chain.)
* The combination of the smooth-shifting, close-ratio 5-speed transmission with
the KX450F’s low-rpm engine performance offers the rider the option to shift to
a higher gear when traversing rough sections. Since this reduces the effect of
sudden (unwanted) throttle input, allowing focus to be given to racing rather
than careful throttle control.
* In the event of a stalled engine during a race, getting it started again as soon
as possible is a racer’s first priority, so the KX450F is equipped with an
automatic compression release (ACR) system. The dual-weight centrifugal
decompression system fitted to the exhaust cam eases starting in much the
same way as a conventional lever-type system.
* Sprocket-style chain drive roller helps smooth engine braking by reducing the
effect of driveline lash when the rider gets off the gas quickly and play in the
lower side of the chain suddenly tightens. The additional control facilitates
corner entry.
9
KEY FEATURES
FACTORY-STYLE CHASSIS COMPONENTS AND TUNING
The KX450F’s slim aluminium perimeter frame is a lightweight construction composed of forged, extruded and cast parts. Chassis balance and
settings were all set to suit race-experienced riders. The centre of gravity and key dimensions (swingarm pivot, output sprocket and rear axle
locations) were chosen so that the rear tyre would drive the bike forward (instead of causing it to squat). For ’10 revisions to the frame and
suspension components were designed to offer lighter handling, improved suspension action, increased comfort and greater cushioning when
landing jumps.
Superior rear wheel traction
Lighter-handling chassis
* The New Uni-Trak rear suspension system mounts the suspension arm
below the swingarm, allowing a longer rear suspension stroke. The
longer stroke in turn allows more precise rear suspension tuning.
While the frame remains essentially the same as that of the 09MY
model, a revised steering stem shaft and new swingarm offer
improved handling.
NEW
NEW * New steering stem shaft with lower rigidity contributes to lighter handling.
(Photo 7)
* Revised linkage ratios for the New Uni-Trak rear suspension further
increase rear traction performance. (Photo 8)
8
7
NEW * Swingarm with revised cross-section also contributes to lighter handling.
* The alloy swingarm uses a cast front section, tapered hydroformed spars
and forged chain adjusters.
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* Extensive rider testing was conducted to determine the ideal linkage
ratios and rear shock absorber damping settings to achieve maximum
rear wheel traction.
10
KEY FEATURES
Race-oriented suspension
* Kayaba AOS (Air-Oil-Separate) fork keeps oil and air in separate
chambers for stable damping performance during long motos.
Low-friction fork seals contribute to smooth action. (Photo 9)
9
NEW * Revised spring rate, revised damping settings and the less rigid steering
stem offer improved action (especially at the initial part of the stroke)
and increased comfort.
* A super-hard DLC coating (Diamond-Like Carbon) on the outer surface
of the inner fork tubes reduces sliding friction (and stiction) and gives
better action, contributing to the smoother ride. The coating is even
effective when the fork is exposed to lateral forces that would usually
hamper slide action, such as during cornering. The increased surface
hardness also minimises scratches and damage to the tubes.
* Friction-reducing Kashima Coat on the inside of the fork outer tubes
contributes to smoother suspension action (especially at the initial part
of the stroke) and a better ride feel.
NEW * Revised shock spring rate and damping settings contribute to increased
stability and offer improved cushioning when landing jumps.
* The rear shock features dual compression adjustability, allowing
high-speed and low-speed damping to be tuned separately.
* The rear shock also features the Kashima Coat on the tank cylinder.
The reduced friction smoothes suspension action.
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11
KEY FEATURES
Factory-style and other race-oriented components
* The KX450F features petal brake discs front and rear. In addition to
helping reduce unsprung weight, the wave shapes of the petal discs
help clean the brake pads for more efficient braking performance.
(Photos 10-11)
* A factory-style Renthal (standard-type) aluminium handlebar is standard
equipment. (Photo 12)
12
10
* Rib-less rear hub and butted spokes reduced unsprung weight.
11
* Rims are coated in black alumite – just like our factory racers.
* Factory-style graphics complement the KX450F’s highly tuned
performance.
NEW
* Revised rear brake pad material offers stronger braking.
* Rear caliper guard protects the caliper from damage.
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12
KEY FEATURES
Rider interface
Designed with rider ergonomics in mind, bodywork components offer the rider a slim interface, the natural position making it even easier for
racers to go fast.
NEW
* Formed using a double-injection moulding process, 2-tone shrouds
contribute to the slim package. Fine-tuned to accommodate the new
radiators, the shrouds feature a slightly slimmer design. (Photo 13)
* The frame widens at the ankles to offer the rider better grip and narrows
near the bend below the seat to allow a slim riding position.
NEW
* 2-tone side covers are also formed using a double-injection moulding
process. Like the shrouds they contribute to the slim package. A hole in
the right-side cover helps cool the silencer. (Photo 14)
* The optimised pipe line of the exhaust contributes to improved
ergonomics. (Photos 15-16)
16
15
13
09MY
NEW
14
10MY
* Slim seat features firmer urethane which keeps its original shape longer.
* The seat uses a slip-resistant top surface for good grip when seated and
smooth sides for excellent rider mobility.
* Wide (front-to-rear) footpegs designed to offer grip and superb feel at
the pegs.
* The clutch cable boot features a large quick adjuster, making it easier for
riders to adjust play in the clutch cable.
* Throttle grip has a unitised collar. The one-piece unit provides additional
stability during throttle operation.
* Lightweight short-length grips feature a pattern designed to provide
excellent grip.
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13
ADDITIONAL FEATURES
Engine
* Fast-idle knob on the throttle body allows riders to increase engine
speed when first starting a cold engine.
17
* The crankshaft and connecting rod received a carburising and
quenching treatment for additional rigidity.
* The camshaft lobes and tappet surfaces feature a soft-nitriding surface
treatment for long wear and high-rpm reliability.
* A large flap inside the air cleaner case helps prevent the ingress of mud.
* The silencer uses long-fibre packing which is much more resistant to
being blown out of the tail pipe than standard length packing. As a
result, packing needs to be replaced half as often.
NEW
* Rubber damper collar used for the rear silencer mount also contributes
to increased durability.
NEW
* Right-side crankcase is reinforced at the lower engine mount for
increased strength and durability.
18
Chassis
* Designed to accommodate the in-tank fuel pump, the plastic fuel tank is
formed using a rotational moulding (or rotomoulding) process that
reduces weight.
* Large synthetic skid plate offers great protection with minimum weight.
NEW
* Revised front fender is thicker and more rigid. (Photo 17)
NEW
* New chain with thinner inner links offers 20 g in weight savings.
(Photo 18)
NEW * All markets now feature Bridgestone tyres (F: M403; R: M404).
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14
ADDITIONAL FEATURES
Other
* Optional engine parts include magneto rotors with different inertias (8.5, 9.5 kg cm2; STD: 9.0 kg cm2).
* Optional chassis parts include handlebar holder for a ø28.6
mm bar (STD: ø22.2 mm), aluminium and steel rear
sprockets (+/-2T), solid petal brake rotors for wet races, and
different springs for the front fork and rear shock.
20
19
* An FI indicator lamp (available as an option) warns of any
problem with the FI system. (Photos 19-20)
COLOUR(S)
* Lime Green with factory-style graphics
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15
APPENDIX: KX FI CALIBRATION KIT
EASY-TO-USE KIT SAME USED BY WORKS TEAMS
The KX FI Calibration Kit is the same kit
used by Kawasaki’s works teams in Europe
and the U.S. The kit enables expert riders
to adjust engine characteristics (by rewriting
actual data maps) to suit their preference,
record riding data, and analyse their riding
data to further fine-tune their settings.
While the kit is designed to satisfy racers
and expert riders, it is simple and
hassle-free to use: the ECU controller
mounts behind the number plate for easy
access; accessing the ECU is
accomplished simply by connecting to a PC
via the ECU controller using a USB cable
(no additional switches are necessary);
setting adjustments can be prepared in
advance on a PC, or done when connected
to the ECU; the kit’s user-interface is simple
to understand and easy to use; in addition
to the kit, a PC and 12 V battery are all that
is required.
1
4
5
8
6
1
Power supply harness
2 Software CD-ROM
3 Controller sub-harness
4 USB cable
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3
2
5
10
7
Controller bands
6 ECU controller
7 Controller bracket
8 Wire harness clamp
9
9
10
Lower/upper controller dampers
Controller damper
16
APPENDIX: KX FI CALIBRATION KIT
Optimising ECU settings
* The KX FI Calibration Kit contains seven preset settings that can be quickly and
easily used to adjust the ECU to suit track conditions. The provided settings
are shown below.
SETTING
DESCRIPTION
Richer fuel setting
fuelling 5% richer than stock
Leaner fuel setting
fuelling 5% leaner than stock
Advanced ignition setting
ignition advanced 3o from stock
Retarded ignition setting
ignition retarded 3o from stock
Hard riding surface setting
ignition retarded, fuelling richer
Soft riding surface setting
Beginner setting
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* For more advanced setting optimisation, the ECU maps for volume of fuel
injected (via the FI adjustment window) and ignition timing (via the IG
adjustment window) can be adjusted for given throttle position and rpm.
ignition advanced, fuelling leaner
Base settings are shown as a flat graph (left). Settings can be increased or decreased from the
base according to rider preference (right).
engine power suppressed:
ignition retarded, fuelling richer
17
APPENDIX: KX FI CALIBRATION KIT
* Multiple display options are available. Click [3D Graph] or [2D Graph] of the
[3D/2D] to select the 3 or 2-dimensional display. When you use the [3D Graph],
select [Surface Display] or [Frame Display] of the [3D Graph Type] to select the
display type.
Logging and analysing riding data
* The KX FI Calibration Kit can also be used as a data logger, recording up to six
hours of data depending on the number of parameters (engine rpm, angle of
throttle opening, etc) being recorded. After riding, the riding data can be
viewed using the [Analyze] window. Parameters to be recorded and displayed
can be selected independently.
* The logged data can lined up with the course layout to check actual riding. This
also enables before-and-after comparisons and comparisons between riders.
3D Surface Display
3D Frame Display
2D Graph Display
* When connected to the ECU, the KX FI Calibration Kit can be used to display
the status of a running engine. Information can be displayed in numeric form
using the Data Monitor, or in visual form using the various display options
offered by the Data Meter.
Data Monitor Window
Data Meter Window
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For more detailed information on use and functions of the FI
Calibration Kit, please refer to the KX FI Calibration Kit
Instruction Manual.
18
SPECIFICATIONS
KX450EAF
ENGINE
FRAME
Type
Liquid-cooled, 4-stroke Single
3
Type
Perimeter, aluminium
Wheel travel: front
315 mm
rear
315 mm
front
90/100-21 57M
rear
120/80-19 63M
Displacement
449 cm
Bore and Stroke
96.0 x 62.1 mm
Compression ratio
12.5:1
Valve system
DOHC, 4 valves
Fuel system
Fuel injection: ø43 mm x 1 (Keihin)
Caster (rake)
26.7o
Ignition
Digital DC-CDI
Trail
116 mm
Starting
Primary kick
Steering angle (left/right)
42o / 42o
Lubrication
Forced lubrication, semi-dry sump
DRIVETRAIN
Tyre:
SUSPENSION
Transmission
5-speed, return
Final drive
Chain
Primary reduction ratio
2.727 (60/22)
Compression damping
22-way
Gear ratios: 1st
1.750 (28/16)
Rebound damping
20-way
2nd
1.412 (24/17)
3rd
1.188 (19/16)
4th
1.000 (19/19)
5th
0.875 (21/24)
Front: Type
48 mm upside-down AOS-type
telescopic fork
Rear: Type
Compression damping
New Uni-Trak
22-way (low-speed),
2-turns or more (high-speed)
Final reduction ratio
3.846 (50/13)
Rebound damping
22-way
Clutch
Wet multi-disc, manual
Spring preload
Fully adjustable
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19
SPECIFICATIONS
KX450EAF
BRAKES
Front: Type
Rear:
Single semi-floating 250 mm petal disc
Caliper
Dual-piston
Type
Single 240 mm petal disc
Caliper
Single-piston
DIMENSIONS
Overall length
2,185 mm
Overall width
820 mm
Overall height
1,280 mm
Wheelbase
1,480 mm
Ground clearance
340 mm
Seat height
965 mm
Curb mass
113.5 kg (EUR/AUS/JPN)
113.6 kg (USA/CAN)
Fuel capacity
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7 litres
The specifications mentioned here apply to and have been achieved by production models under
standard operating conditions. We intend only to give a fair description of the vehicle and its
performance capabilities but these specifications may not apply to every machine supplied for sale.
Kawasaki Heavy Industries, Ltd. reserves the right to alter specifications without prior notice.
Equipment illustrated and specifications may vary to meet individual markets.
20