2022 Kawasaki KX450 Air Cleaner Owners Manual

2022 Kawasaki KX450 Air Cleaner

Air Cleaner

A clogged air cleaner restricts the air intake, in- creases fuel consumption, reduces engine power, and can cause spark plug fouling. Inspect the air intake system, which includes the air filter and air duct to the throttle body assy, and the duct clamps and throttles body assy, before each race or practice session.

WARNING

• If dirt or dust is allowed to pass through into the throttle body assembly, the throttle may become stuck, possibly causing an accident.
• Be sure to keep the dust from entering during cleaning.

NOTICE
A clogged air cleaner will affect the fuel mixture to the engine and reduce engine power and cause spark plug fouling.

NOTE

• ln dusty areas, the element should be cleaned more frequently than the recommended interval.
• After riding through rain or on muddy roads, the element should be cleaned immediately.

Element Removal and Inspection

• Remove the seat bolt and side cover bolt.

• • A. Seat Bolt
  • B. Side Cover Bolt (Left Side Cover)
• Open the rear part of the side cover slightly outward.
• Pull the left side cover forward to clear the hooks and remove the left side cover.

• • A. Tab
  • B. Hooks
  • C. Left Side Cover
• Remove the wing bolt, and take out the air cleaner element.

• • A. Wing Bolt
  • B. Air Cleaner Element
• Check inside of the intake tract and throttle body assy for dirt. If dirty, clean the intake tract and throttle body assy thoroughly.
• Stuff a clean, lint-free towel into the throttle body assy to keep dirt from entering the throttle body assy.
• Wipe out the inside of the air cleaner housing with a clean, damp towel.
• Take the element off its frame.
• NOTICE
  Do not twist or wring the element, as it gets easily torn or damaged.
• Inspect the element. If it is dirty, clean it. Also check if the element is in good condition (no tears, hardening or shrinkage). If damaged, replace the element or it will allow dirt into the throttle body assy.

WARNING
A clogged air cleaner may allow dirt and dust to enter the throttle body and the throttle may stick resulting in a hazardous operating condition. Clean the air filter according to the periodic maintenance chart; more often if the vehicle is used in extremely dusty conditions.

NOTICE
A clogged air cleaner may allow dirt and dust to enter the engine, causing it to wear excessively or to become damaged.

• A. Air Cleaner Element
• B. Element Frame

Element Cleaning and Installation

• Clean the element in a bath of a high flash-point solvent or hot soapy water. Rinse the element with clear water to remove all traces of the cleaning solution.
• Squeeze the element dry in a clean towel.
• After cleaning, let the filter dry completely. Saturate the element with a high-quality foam air filter oil and make sure that the oil is evenly applied throughout the element. Squeeze out the excess oil, but do not wring the element as this could cause tearing. In this case, too much oil is better than too little. Finally, pat the inside of the element with a paper towel to remove any excess oil.
• Before installation, check the element for damage such as tears, hardening, or shrinkage. If damaged, replace the element.
• Apply grease to all mating surfaces and to the screw hole in the air cleaner housing and intake tract.
• Remove the towel from the throttle body assy. Align the pins on the element frame with the holes of the air cleaner element to install the element onto its frame.
• Coat the element lip and lip seat with a thick layer of all-purpose grease to assure a complete seal.
• NOTICE
  Do not twist, wring or blow the element dry to avoid damaging it.

• WARNING
  Gasoline and low flash-point solvents can be flammable and/or explosive and cause severe burns. Clean the element in a well-ventilated area: and take care that there is no spark or flame anywhere near the working areas. Do not use gasoline or low flash-point solvents to clean the element.

• • A. Pins
  • B. Apply grease.
• Install the air cleaner element so that align the guide blade of the element holder with the projection of the air cleaner housing, and face the opening of the guide blade outward.

• • A. Guide Blade (Air Cleaner)
  • B. Projection (Air Cleaner Housing)
  • C. Opening
• Tighten the wing bolt.
• Install the hooks of the left side cover to the ribs of the radiator shroud and air cleaner housing..

• • A. Left Side Cover
  • B. Radiator Shroud
  • C. Ribs
  • D. Hooks
• Insert the tab of the left side cover into the slot of the rear fender.

• • A. Tab
  • B. Left Side Cover
  • C. Rear Fender
  • D. Slot
• Tighten the seat bolt and side cover bolt to the specified torque.

• • A. Seat Bolt
  • B. Side Cover Bolt (Left Side Cover)
• Tightening Torque
  • Seat Bolt
    • 25 Nm (2.5 kgfm, 18 ft:lb)
  • Side Cover Bolt:
    • 7.0 N-m (0.71 kgf m, 62 in-lb)
• Pull up the rear end of the seat to make sure it is securely installed.