KAWASAKI KX450F SPARK XCR SYSTEM INSTALLATION INSTRUCTIONS

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Filed Under (Kawasaki) by admin on 02-05-2012

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1. Place the machine on a stable work stand. 2. If you are not familiar with removing the original exhaust refer to the owner’s manual before you start work. 3. Always allow your machine to cool down before attempting to remove the exhaust. 4. Remove the two bolts from the right side panel. Then remove the side panel. 5. Loosen the stock mid-pipe clamp, then remove the stand-off bolt and bracket bolt that supports the muffl er. 6. Remove stock muffl er and clamp from the stock head pipe. 7. Slightly loosen the stock head pipe at the cylinder head to aid in aligning the parts. INSTALLING THE NEW XCR SYSTEM 1. Installer must use supplied hardware. 2. Slide mid-pipe onto head pipe. Rotate the mid-pipe slightly to obtain proper alignment with sub-frame mount. 3. Install the supplied M8x16mm bolt through sub-frame into the stand-off mount on mid-pipe (Finger tight). 4. Slide the muffl er onto mid-pipe, align muffl er mount with the stock muffl er mount hole, and install and fi nger tighten the OEM bolt. 5. Once you have the system fully aligned, install and tighten all the bolts securely to factory specifi cations. 6. Replace the side panel and secure the mounting bolts. 7. Re-tighten stock head pipe at the cylinder head. TEST RIDING 1. When you fi rst ride the bike be aware that the characteristics are often quite different so start out slowly. TUNING 1. On the KX450F, we suggest using stock jetting based on our testing condition. These specifi cations should only be used as a guideline. Riding at different elevations or climates may require using different settings to obtain peak performance. If you need additional assistance, please refer to your Kawasaki owner’s manual. 2. To convert system from Offroad to Competition specifi cations, remove the 5mm Allen bolt and Spark arrestor. Two different Db lowering inserts are also available (see accessories section on page 2). To return the system to Offroad specifi cation re-install the Spark arrestor into the rear of the muffl er using a small amount of blue thread locking compound (Loctite® 243) re-tighten the 5mm Allen bolt (6.5 ft pounds)