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2006 Kawasaki KX450F KX450 4-Stroke Service Repair Workshop Manual

pdf download 2006 Kawasaki KX450F KX450 4-Stroke Service Repair Workshop Manual

do it yourself motorcycles repair!This is the most complete Service Repair Manual for the 2006 Kawasaki KX450F Service Repair Manual Download ever compiled by mankind. This DOWNLOAD contains of high quality diagrams and instructions on how to service and repair your motorcycle from the front bumper to the rear. This is a must for the Do-It-Yourselfer! You will not be dissatisfied.

Models Covers: 

2006 Kawasaki KX450-D6F


Kawasaki KX450F KX 450F KX450 Four Stroke

This manual covers

General Information

Battery Ground

Edges of Parts


Cleaning Vehicle before Disassembly

Arrangement and Cleaning of Removed Parts

Storage of Removed Parts


Replacement Parts

Assembly Order

Tightening Sequence

Tightening Torque


Gasket, O-ring

Liquid Gasket, Non-permanent Locking Agent


Ball Bearing and Needle Bearing

Oil Seal, Grease Seal

Circlips, Cotter Pins


Direction of Engine Rotation

Electrical Wires


Periodic Maintenance

Fuel System (DFI)

Throttle Control System Inspection

Engine Vacuum Synchronization Inspection

Idle Speed Inspection

Idle Speed Adjustment

Fuel Hose Inspection (fuel leak, damage, installation condition)

Evaporative Emission Control System Inspection (CAL and SEA Mode

Cooling System

Engine Top End



Final Drive




Electrical System


Replacement Parts

DFI System

DFI System Wiring Diagram

Terminal Numbers of ECU Connectors

Main Throttle Sensor [A]

Oil Pressure Gauge, 5 kgf/cm :

DFI Servicing Precautions

The warning indicator light (LED) [A] is used for the FI indicat

DFI Diagnosis Flow Chart

Inquiries to Rider

Self-diagnosis Outline

Self-diagnosis Procedures

Self-Diagnosis Flow Chart

Main Throttle Sensor Removal/Adjustment

Main Throttle Sensor Input Voltage Inspection

Main Throttle Sensor Output Voltage Inspection

Special Tool –

Main Throttle Sensor Resistance Inspection

Main Throttle Sensor Circuit

Inlet Air Pressure Sensor Removal

Inlet Air Pressure Sensor Installation

Inlet Air Pressure Sensor Input Voltage Inspection

Inlet Air Pressure Sensor Output Voltage Inspection

Inlet Air Temperature Sensor Removal/Installation

Inlet Air Temperature Sensor Output Voltage Inspection

Inlet Air Temperature Sensor Resistance Inspection

Inlet Air Temperature Sensor Circuit

Atmospheric Pressure Sensor Removal

Atmospheric Pressure Sensor Installation

Atmospheric Pressure Sensor Input Voltage Inspection

Atmospheric Pressure Sensor Output Voltage Inspection

Atmospheric Pressure/Altitude Relationship

Atmospheric Pressure Sensor Circuit

Crankshaft Sensor Removal/Installation

Crankshaft Sensor Resistance Inspection

Crankshaft Sensor Peak Voltage Inspection

Crankshaft Sensor Circuit

Camshaft Position Sensor Removal/Installation

Camshaft Position Sensor Resistance Inspection

Camshaft Position Sensor Peak Voltage Inspection

Camshaft Position Sensor Circuit

Speed Sensor Removal/Installation

Speed Sensor Input Voltage Inspection

Speed Sensor Output Voltage Inspection

Speed Sensor Circuit

Gear Position Switch Resistance Inspection

Gear Position Switch Output Voltage Inspection

Gear Position Switch Circuit

Vehicle-down Sensor Removal

Vehicle-down Sensor Installation

The subthrottle sensor is a rotating variable resistor that chan

Oxygen Sensor ##1 Removal/Installation

Exhaust Butterfly Valve Actuator Sensor Removal/Installation

Antenna Resistance Inspection

ECU Communication Line Inspection

Fuel Pump Relay Removal/Installation

Radiator Fan Relay Removal/Installation

Subthrottle Valve Actuator Removal

Exhaust Butterfly Valve Actuator Removal

Air Switching Valve Removal/Installation

Oxygen Sensor Heater Removal/Installation

Light (LED) Inspection

ECU Identification

ECU Fuse Removal

Fuel Pressure Inspection

Fuel Pump Removal

Primary Fuel Injector Removal/Installation

Free Play Inspection

Idle Speed Inspection/Adjustment

Nozzle Assy Removal

Air Cleaner Element Removal/Installation

Air Inlet Duct Removal

Fuel Tank Removal

Cooling System

Coolant Deterioration Inspection

Water Pump Removal

Radiator and Radiator Fan Removal

Thermostat Removal

Hose Installation

Water Temperature Sensor Removal/Installation

Engine Top End

Air Suction Valve Removal

Camshaft Chain Tensioner Removal

Camshaft Removal

Cylinder Compression Measurement

Valve Clearance Inspection

Throttle Body Assy Holder Removal



Clutch Holder:

Clutch Lever Free Play Inspection Clutch Cover Removal Clutch Removal

Engine Lubrication System


Oil Pan Removal

Oil Pressure Relief Valve Removal

Oil Pump Removal

Oil Cooler Removal

Oil Pressure Measurement

Oil Pressure Switch Removal




Final Drive




Electrical System


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