2019 MODEL INFORMATION · 2018-06-26 · 2019 450 3. CONCEPT AND ADVANTAGES. ADVANTAGES . FACTORY-STYLE ENGINE COMPONENTS AND TUNING. 1. The KX450’s engine always been a strength

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2019 MODEL INFORMATION

MODEL NAME

MARKETING CODE

KX450KX450J

CONCEPT AND ADVANTAGES ---- P.2

TECHNICAL DETAILS

ENGINE -------------------------- P.7

CHASSIS ---------------------- P.12

ADDITIONAL FEATURES ----- P.18

COLOUR(S) ------------------------ P.19

SPECIFICATIONS ------------------ P.20

HINTS FOR MARKETING

PROMOTION ----------------------- P.22

CONCEPT AND ADVANTAGES

22 0 1 9 M Y K X 4 5 0 M o d e l I n f o r m a t i o n


STRONGEST MACHINE ON THE TRACK

Designed with mid-level to expert riders in mind, the KX450 motorcycle has always been built with one goal in mind: to put riders on the top step of the podium. And for over 40 years KX brand motocrossers have been extremely successful at doing just that. To maintain its edge in this fiercely competitive class, the 2019 KX450 benefits from a new engine mounted in its leanest chassis to date, enabling it to turn even quicker lap times, and make it the most powerful machine in the paddock. Complementing its already high performance, a number of new features – including finger-follower valve actuation, electric start and a hydraulic clutch, which are all firsts for a Kawasaki motocrosser – further elevate its race-winning potential.



ADVANTAGES

FACTORY-STYLE ENGINE COMPONENTS AND TUNING

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The KX450’s engine always been a strength. With even greater power complementing a host of features proven to give you an advantage on the race track, the new engine is better than ever.

Being able to restart an engine quickly after a spill can mean the difference between keeping your lead, or having to fight your way back through the pack. Kawasaki’s first electric start on a motocrosser makes restarting the engine as easy as pushing a button.

The new engine boasts an increase in peak power of approximately 2.5 kW (3.4 PS), while a flatter torque curve makes it easier to get on the gas. Finger-follower valve actuation (a valve train designed by Kawasaki’s MotoGP & World Superbike engineers) enables larger-diameter valves and more aggressive cams. Downdraft-style intake and reduced friction loss (care of new plain bearings for the connecting rod big-end) further contribute to the power gains.

Even More Powerful Engine

Electric Start

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Kawasaki’s first hydraulic clutch on a motocrosser offers more direct feel and lighter lever action. Less play as the clutch heats up during heavy use results in more consistent feeling.

Using the provided DFI couplers, riders can quickly and easily access their choice of three maps (standard, hard, soft) provided in the ECU.

Works-base bridged-box bottom piston is just one of many features inspired by our factory racers.

Factory-style launch control system increases the chance of getting a good start by helping riders maximise traction when starting on a slippery surface.

Hydraulic Clutch Easy engine tuning: DFI Setting Data Selection

Factory-inspired tuning

Holeshot advantage: Launch Control Mode

KX FI Calibration Controller, a portable handheld calibration tool, enables riders to make changes to engine maps by plugging into the ECU without needing a PC or battery. Comes equipped with seven preset map settings.

KX FI Calibration Kit (Accessory)

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An evolution of the current design, the new frame features revised rigidity and includes the engine as a stressed member. A new swingarm also contributes to the revised rigidity balance and increased rear traction.

Complementing the powerful engine, light, nimble handling contributes to the KX450’s quick lap times. While the addition of electric start and the return to a coil-spring fork add weight, efforts were made to keep the weight gain to a minimum. The result is the KX450’s leanest chassis to date, and a highly-competitive, low overall weight of only 110.0 kg – a gain of only 1.3 kg.

Trimmed of all unnecessary material, this is the leanest KX450 chassis to date. Frame, suspension, brakes and ergonomics have all been improved, making the new KX450 even better equipped to turn quicker lap times.

ADVANTAGES

FACTORY-STYLE CHASSIS COMPONENTS AND TUNING

2 Lightweight Aluminium Perimeter Frame

Light Weight & Light, Nimble Handling

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Large-Diameter Coil-Spring ForkHandling suspension duties up front is a new high-performance ø49 mm inverted coil-spring fork. The large-diameter inner tubes (the same size as on our factory racers) enables the use of large damping pistons, delivering smooth action and firm damping.

A choice of four handlebar positions and two footpeg positions allows riders to tailor their riding position to suit body size and preference.

Increased Front/Rear TractionMatching the KX450’s increased power, increased front and rear traction ensure the bike can put power to the ground and get around corners quickly. A larger-diameter front axle (a hint from our racing teams) helps at the front, while revised rear suspension layout and new linkage ratios benefit the rear.

Stronger Brakes

Slim, Ergonomic Bodywork

A larger-diameter ø250 mm rear disc complements the oversized ø270 mm front disc, delivering stronger stopping power. A new front brake master cylinder offers better initial control, while contributing to overall braking performance.

All-new bodywork (except the front fender and number plate) was designed to facilitate rider movement. Long, smooth surfaces make it easy to slide back and forth. The tank is lower and flatter, making it easier to sit farther forward. Slimmer shrouds are easier to hold on to. Even the engine covers are smooth so that they do not impede rider movement.

Adjustable Ergonomics

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TECHNICAL DETAILS: ENGINE

ENGINEHard-hitting fuel-injected 449 cm3 liquid-cooled, 4-stroke Single with factory-racer engine tuningThe new engine boasts an increase in peak power of approximately 2.5 kW (3.4 PS), while a flatter torque curve makes it easier to get on the gas. Finger-follower valve actuation (a valve train designed by Kawasaki’s MotoGP & World Superbike engineers) enables larger-diameter valves and more aggressive cams. Downdraft-style intake and reduced friction loss (care of new plain bearings for the connecting rod big-end) further contribute to the power gains.

* Possible thanks to the finger-follower valve actuation, an increasedrev-limit (11,500 min-1 >> 11,700 min-1) on US models contributes toincreased high-rpm performance.

* The change to finger-follower valve actuation reduces the valve trainmass (IN is 4.2% lighter; EX is 7.9% lighter) compared to a tappet-stylevalve actuation (even taking into account larger-diameter valves).

* DLC (Diamond-Like Carbon) coating on the finger followers helpsprotect against wear.

* Complementing more aggressive cams, larger-diameter intake (ø36 mm>> ø40 mm) and exhaust valves (ø31 mm >> ø33 mm) with increasedlift (IN: 9.8 mm >> 11.0 mm; EX: 9.0 mm >> 9.5 mm) flow more air,contributing to the increased power.

* The camshafts benefit from a thin and highly durable gas soft-nitridingtreatment for long wear and high-rpm reliability.

* Valves are formed from lightweight titanium, reducing reciprocatingweight and offering high-rpm reliability.

* SCr (chromium steel) valve spring retainers contribute to increasedreliability at high-rpm.

A* Valve train designedby Kawasaki’sMotoGP & WorldSuperbike engineersbring top-level road-racing technology tothe KX450. It usesfinger-follower valveactuation, enablinglarger-diameter valvesand more aggressivecam profiles.(Illustration A)

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* High-performance piston, featuring the same design used on our factoryracers, contributes to strong performance at all rpm. A short skirt,reinforced external ribs and the use of a bridged-box bottom, featuringinternal bracing, contributes to a light, strong piston design. Reviseddesign and strength optimisation results in an even lighter piston(259.8 g >> 243 g), further reducing reciprocating weight andcontributing to the engine’s increased performance.

* A change from needle bearings to plain bearings for the connecting rodbig-end reduces mechanical loss, contributing to overall performance.

* The engine is almost upright (forward lean angle is 3o) to help place thebike’s centre of gravity in the ideal position for maximum traction.

* Cylinder is offset (8.5 mm forward), reducing friction and enabling moreefficient power generation.

* ECU settings include programming that enhances traction by retardingignition when the rear wheel speed increases too quickly (i.e. fromsudden, excess wheel spin).

* Thinner air cleaner element restricts airflow less, contributing toincreased performance at all rpm.

B* Downdraft-styleintake routing allowsan even straighterapproach for intakeair. The intake air’sapproach angle intothe cylinder increasesfrom 10o to 20o,improving cylinder-filling efficiencyand contributing toincreased enginepower. (Illustration B)

* Larger-diameter (ø43 mm >> ø44 mm) throttle with reversed orientation– it turns in the opposite direction to open – flows a greater volume ofair, contributing to increased performance – especially high rpm andover-run – and driveability.

* Fine-atomising injector with 12 holes sprays particles with a droplet sizeof 75 μm (previously 60 μm) and flows over 20% more fuel (391.7 cm3

>> 478.3 cm3), contributing to the engine’s increased power. The finedroplet size contributes to smooth power delivery and superb engineresponse at partial throttle.

* Lightweight flat-bottom aluminium fuel pump is located in the plastic fueltank.

* Revised fuel pump design is more compact, enabling a flatter design forthe top of the tank. (See also Ergonomics below)

* During the cylinder head casting process, the cores for the intake portswere given a special coating to make the intake ports smoother. Theextremely smooth surfaces that result increase intake efficiency atall rpm.

* Longer header pipe (590 mm >> 695 mm) contributes to increased low-end power.

* Kawasaki’s first hydraulic clutch on a motocrosser offers more directfeel and lighter lever action. Less play as the clutch heats up duringheavy use results in more consistent feeling.

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* The combination ofthe smooth-shifting,close-ratio 5-speedtransmission withthe KX450’s low-rpmengine performanceoffers the rider theoption to shift to ahigher gear whentraversing roughsections. Thisreduces the effect ofsudden (unwanted)throttle input, allowing focus to be given to racing rather than carefulthrottle control. (Photo 1)

* Starting is electriconly, via a buttonlocated at the rightgrip. (Photo 2)

* Lightweight, compactLi-ion battery helpskeep weight gain to aminimum. (Photo 3)

* Revisions to the change drum and shift fork save 15 g in weight.

* KX250-style automatic centrifugal decompression system fitted to theexhaust cam lifts one exhaust valve to facilitate starting. The system’ssimple construction ensures light weight and high reliability.

Being able to restart an engine quickly during a race can mean the difference between keeping your lead, or having to fight your way back through the pack. Kawasaki’s first electric start on a motocrosser makes restarting the engine as easy as pushing a button

Electric start

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* The KX450 features a launch control system similar to that on ourfactory racers. With the simple press of a button, riders can activate aseparate engine map designed to ensure efficient race starts in slipperyconditions. (The Launch Control Mode map retards ignition timing,allowing tyres to gain grip in low-traction situations, and allowing ridersto focus on their lines.)

* Launch Control Mode has the greatest effect within the first fewseconds of releasing the clutch off the start. This is the most crucialtime for riders to get ahead of their rivals so they are better positionedgoing into the first corner.

* Even for top-level riders, controlling the massive power of a 450cc-classmotocrosser off the start requires a high degree of throttle control andclutch finesse. By slightly reducing this power, Launch Control Modehelps riders maximise traction, increasing the chance of getting a goodstart.

* To activate Launch Control Mode riders depress the launch controlbutton (for two seconds or more), located at the left handle.

* Launch Control Mode works in 1st and 2nd gear (and Neutral). Oncethe rider shifts into 3rd gear, the system is automatically disengaged,switching back to the normal engine map.

* System designed to the same specifications as that of our AMA factoryracers.

The holeshot advantage: Launch Control Mode

Easy engine tuning: DFI Setting Data Selection (3 map choices)

KX motocrossers have long drawn on works technology to offer riders the best possible performance right out of the box. Launch Control Mode is just one of the factory features that give riders an edge when lining up at the start gate.

Adjusting engine settings to suit conditions has never been easier than with the KX’s DFI couplers. Plug-and-play style system is quick, easy and stress-free.

* Instead of a single engine map, the ECU features three (four, countingthe Launch Control Mode map).



Precision engine tuning: KX FI Calibration Kit (Accessory)

For more detailed information on use and functions of the KX FI Calibration Controller, please refer to the KX FI Calibration Controller User Manual.

The KX FI Calibration Kit features the handheld KX FI Calibration Controller, which enables expert riders to adjust engine characteristics (by rewriting actual data maps) to suit their preference. This simple tool can be used without a PC, simply by plugging into the engine’s ECU.

* The KX FI Calibration Controller is a handheld tool with a built-in colourLCD screen. It comes with transfer and diagnostic cables, SD memorycard, user manual and a carrying case.

* For more advanced setting optimisation, the ECU maps for volumeof fuel injected and ignition timing can be adjusted for given throttleposition and rpm.

* When connected to the ECU, the KX FI Calibration Controller can beused to display the status of a running engine.

* KX FI Calibration Controller can be used with older fuel-injected KXmodels (2015 and earlier).

* While the controller is designed to satisfy racers and expert riders, it issimple and hassle-free to use.- accessing the ECU is accomplished simply by connecting the

controller using the provided cables (no PC or battery necessary)- the kit’s user-interface is simple to understand and easy to use- maps can be stored on a PC: data transfer between the controller and

a PC can be done via SD card

* The KX FI Calibration Controller contains seven preset map settingsthat can be quickly and easily used to adjust the ECU to suit trackconditions. The provided settings are shown below.

SETTING DESCRIPTIONRicher fuel setting fuelling 5% richer than stockLeaner fuel setting fuelling 5% leaner than stockAdvanced ignition setting ignition advanced 3o from stockRetarded ignition setting ignition retarded 3o from stockHard riding surface setting ignition retarded, fuelling richerSoft riding surface setting ignition advanced, fuelling leaner

Low-power setting engine power suppressed: ignition retarded, fuelling richer

* Initial settings for the three maps are: Standard, Hard (conditions) andSoft (conditions). Using provided DFI couplers, riders are able to easilyswitch between the three maps to suit riding conditions. Plugging ineach of the 4-pin couplers activates the corresponding engine map.(Plug is conveniently located on the right side of the head pipe for easyaccess without having to remove any parts.)

* Maps can now be changed while the engine is running.

* Each of the three maps can be reprogrammed using the optional KX FICalibration Kit. (Please see below.)

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TECHNICAL DETAILS: CHASSIS

4* Swingarm rigiditywas also revised tomatch the frame,and contributesto increased reartraction. (Photo 4)

CHASSISLightweight aluminium perimeter frame

* Slim aluminium perimeter frame is a lightweight construction composedof forged, extruded and cast parts.

* An evolution of the current design, the new frame offers a better overallrigidity balance.

* Engine is used as a stressed member, contributing to the frame’s rigiditybalance.

* Chassis balance and settings were all set to suit race-experiencedriders.

* The centre of gravity and key dimensions (swingarm pivot, outputsprocket and rear axle locations) were chosen so that the rear tyrewould drive the bike forward (instead of causing it to squat).

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NEW C* Steering head area with optimised rigidity, main frame rails with revised cross-sections, and a revised line for the swingarm brackets contribute to the overall rigidity balance. Wider lower frame rails also contribute to overall rigidity balance.(Illustration C)



* High-performanceø49 mm inverted coil-spring fork handlessuspension duties upfront. (Photo 5)

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Light handling and weight reduction effortsComplementing the powerful engine, light, nimble handling contributes to the KX450’s quick lap times. While the addition of electric start and the return to a coil-spring fork add weight, efforts were made to keep the weight gain to a minimum. The result is the KX450’s leanest chassis to date, and a highly-competitive, low overall weight of only 110.0 kg – a gain of only 1.3 kg.

CHASSIS- New footpegs and aluminium brackets -260 g- Main frame - 140 g- Change to aluminium brackets for electrical components - 140 g- New brake components (F/R) -100 g- Hollow link bolts + aluminium collars -90 g- Aluminium engine hangers -70 g- Front engine mount (bolt >> stud) -50 g

* Revised design for the top of the fuel tank top allows the tip of the seatto be 20 mm lower. The flatter design greatly facilitates sliding forwardto weight the front wheel, contributing to sharp handling.

* Savings from the engine group (including intake and exhaust systems)amount to approximately 0.93 kg; savings from chassis componentstotal approximately 0.85 kg.

* Some of the major contributing components include:ENGINE- Revised duct, air cleaner construction -390 g- Revised decompressor construction -200 g- Optimised crankshaft design, new connecting rod bearings -177 g- Aluminium silencer cap -60 g- Smaller camshaft bearings -40 g- Smaller fuel pump -34 g- Rubber cooling system fittings -30 g

Race-ready suspension

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* Shifting the shock 5 mm to the right allows room for the new downdraft-style engine intake. Revised rear shock layout also contributes toincreased rear wheel traction.

* The rear shock features dual compression adjustability, allowing high-speed and low-speed damping to be tuned separately.

* A self-lubricating alumite coating on the tank cylinder helps preventwear abrasion, and reduces friction for smoother suspension action.

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* A super-hard titanium coating on the outer surface of the fork innertubes helps prevent wear abrasion. The increased surface hardnessof the dark navy blue coating also helps to prevent scratches anddamage to the tubes. Because the surface remains smooth for a longerperiod, sliding friction (and stiction) is reduced and action is improved,contributing to a smoother ride.

* Kashima Coat creates a hard, low-friction surface on the outer tubes.The hard coating helps prevent wear abrasion on the inside of thetubes, ensuring the sliding surfaces remain smooth for a long time, whilethe outside is protected against corrosion. The lubricating material inthe coat contributes to smoother suspension action (especially at theinitial part of the stroke) and a better ride feel.

* The New Uni-Trak rear suspension system mounts the suspension armbelow the swingarm, allowing a longer rear suspension stroke. Thelonger stroke in turn allows more precise rear suspension tuning.

* Revised linkageratios contribute toincreased rear wheeltraction. (Photo 6)

* The large-diameterinner tubes (the samesize as on our factoryracers) enable theuse of large dampingpistons, deliveringsmooth actionand firm damping.(Illustration D)

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D



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* Revised rear brake master cylinder and hose are lighter.

* Revised front brake master cylinder offers better initial control, whilecontributing to overall braking performance.

* Oversized semi-floating ø270 mmfront disc contributesto strong front brakeforce, as well assuperb controllability.(Photo 7)

* Based on feedbackfrom our factoryrace teams, theKX450 features alarger-diameter frontaxle shaft (20 mm>> 22 mm), whichcontributes to greaterfront-end traction.(Photo 9)

* A larger-diameter reardisc (ø240 mm >>ø250 mm) matchesthe large front discand contributes tostronger stoppingpower. (Photo 8)

* Dunlop tyres

Wheels/Tyres

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* Petal disc brakes are among the KX450’s numerous factory-stylecomponents. The stylish discs contribute to both sporty looks and ahigh-quality appearance.

Strong brakes



* The seat uses a slip-resistant top surface for good grip when seatedand smooth sides for excellent rider mobility. Seat urethane helpsmaintain the original shape longer.

* Slimmer shrouds are positioned closer to the frame. Designed to beslim where they come in contact with the rider’s legs, the new single-piece shrouds are easier to hold on to.

* The frame widens at the ankles to offer the rider better grip and narrowsnear the bend below the seat to allow a slim riding position.

* Smooth engine covers were also designed to not impede ridermovement.

* A factory-style Renthal (standard-type) aluminium handlebar is standardequipment.

* Upper triple clamp with two sets of handle mount slots and reversiblehandle mounts offers riders a choice of four handle positions to choosefrom: 25 mm forward, 15 mm forward, STD and 10 mm back.

* Seams between the shrouds, seat and side covers are very flush, whichfacilitates control as well as moving around on the bike.

* Bodywork designedto facilitate ridermovement featureslong, smooth surfacesthat make it easy toslide back and forth.(Photo 10)

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* Revised design for thetop of the fuel tank topallows an even flatterprogression from theseat to the tank. Theflatter design givesthe rider greaterfreedom of movementwhen changing ridingposition, and facilitatessitting farther forward.(Photo 11)

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ErgonomicsA smoother, flatter rider interface further improves the adjustable racer-friendly ergonomics, helping racers to ride even faster.



Factory styling Complementing the KX450’s sleek new bodywork, factory-style graphics ensure it is the sharpest looking bike in the paddock and further reflect the KX450’s highly tuned performance. Green highlights on the suspension adjusters and engine oil cap and generator cover plugs contribute to a distinctive Kawasaki look.

* In-mould graphics used on the shrouds result in an ultra-smooth surfaceand ensure the racy graphics are not easily damaged.

* Aggressive design of the front fender adds to the racy looks.

* Rims are coated in black alumite1 – just like our factory racers.

* Fork and rear shock adjusters have a high-quality green alumite1 finish.

* Green finish on the oil cap and the two plugs on the generator coverfurther contribute to racy looks.

* Revised footpegdesign is 5 mm wider(front-to-rear) andpositioned 3 mmrearward, offeringexcellent grip, superbfeel, and makingit easier to weightthe pegs. The newdesign is also lighter.(Photo 12)

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* Adjustable footpeg brackets enable riders to lower their footpeg position5 mm. In the lower position, centre of gravity is lowered as is the rider’spoint of view.


TECHNICAL DETAILS: ADDITIONAL FEATURES

ADDITIONAL FEATURESOther

* Optional chassis parts include handlebar holders for a ø28.6 mm bar (STD:ø22.2 mm), aluminium and steel rear sprockets (49-51T; STD: 50T),different springs for the rear shock (49, 51, 53, 55 N/mm; STD: 52 N/mm),plain shrouds (without graphics), and a skid plate.


COLOUR(S)

* Lime Green

1Alumite: an anodic oxidation finishing treatment for aluminium resulting in a coloured, corrosion/scratch-resistant film coating.


SPECIFICATIONS

KX450JKFDIMENSIONS

ENGINE

DRIVETRAIN

Overall length

Overall width

Overall height

Wheelbase

Road clearance

Seat height

Curb mass

Fuel tank capacity

Driving system

Transmission

Gear ratios: 1st

2nd

3rd

4th

5th

Primary reduction ratio

Final reduction ratio

Clutch type (Primary)

Type

Bore x Stroke

Displacement

Compression ratio

Fuel Supply

Lubrication system

Starting system

Ignition system

4st, 1-cyl, DOHC, W/C

96.0 x 62.1 mm

449 cm3

12.5:1

Fuel injection (ø44 x 1)

Forced lubrication, semi-dry sump

Electric

Digital DC-CDI

2,185 mm

830 mm

1,275 mm

1,485 mm

340 mm

955 mm 110.0 kg (EUR/USA/CAN/AUS/JPN)

6.2 litres

Chain

5-speed, return

1.750 (28/16)1.412 (24/17)

1.188 (19/16)

1.000 (19/19)

0.875 (21/24)

2.727 (60/22)

3.846 (50/13)

Wet multi-disc, manual


SPECIFICATIONS

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. Available colours may vary by market.

KX450JKFFRAME

Type

Suspension: Front

Rear

Wheel travel: Front

Rear

Caster (Rake angle)

Trail

Steering angle (left/right)

Tyre: Front

Rear

Brake: Front Type

Effect. dia

Rear Type

Effect. dia

Tubular, semi-double cradle

Telescopic (USD) fork

New Uni-Trak Swingarm

305 mm

307 mm

27.6o

122 mm

42o / 42o

80/100-21 51M 120/80-19 63M (EUR/USA/CAN/AUS/JPN)

Single disc

241 mm

Single disc

225 mm


KAWASAKI TECHNOLOGY

ENGINE

Type

Valve system

Type

Front

Rear

Front: Type

Caliper

Rear: Type

Caliper

Perimeter, aluminium

ø49 mm inverted telescopic fork with adjustable

compression and rebound damping

New Uni-Trak with adjustable dual-range (high/low-

speed) compression damping, adjustable rebound

damping and adjustable preload

Single semi-floating ø270 mm petal disc

Dual-piston

Single ø250 mm petal disc

Single-piston

Liquid-cooled, 4-stroke Single

DOHC, 4 valves

DIMENSIONS

Weight without fuel 105.4 kg (EUR/USA/CAN/AUS/JPN)

FRAME

SUSPENSION

BRAKES

SPECIFICATIONS

Documents

2019 MODEL INFORMATION · 2018-06-26 · 2019 450 3. CONCEPT AND ADVANTAGES. ADVANTAGES . FACTORY-STYLE ENGINE COMPONENTS AND TUNING. 1. The KX450’s engine always been a strength