1986 kawasaki en450-a2 454 ltd manual free download

The 1986 Kawasaki EN450-A2 454 LTD is a classic cruiser motorcycle featuring a 454cc liquid-cooled DOHC parallel-twin engine, 5-speed transmission, shaft drive, and distinctive cruiser styling. This comprehensive service manual covers maintenance procedures, specifications, troubleshooting, and repair instructions for owners and technicians. Below are key sections covering technical specifications, maintenance schedules, engine service, electrical systems, and troubleshooting.

1. Technical Specifications 2. Maintenance Schedule 3. Engine Service 4. Fuel System 5. Electrical System 6. Chassis & Suspension 7. Brake System 8. Transmission & Drive 9. Troubleshooting 10. Wiring Diagrams 11. Torque Specifications

Technical Specifications

Complete technical data for the 1986 Kawasaki EN450-A2 454 LTD motorcycle.

Specification	Details
Engine Type	454cc liquid-cooled DOHC parallel-twin
Bore x Stroke	70.0 x 59.0 mm
Compression Ratio	9.5:1
Fuel System	Dual CVK34 carburetors
Ignition System	Battery-powered electronic ignition
Transmission	5-speed constant mesh
Final Drive	Shaft drive
Front Suspension	Telescopic fork
Rear Suspension	Dual shocks adjustable preload
Front Brake	Single disc 270mm
Rear Brake	Drum brake 160mm
Wheelbase	1525 mm (60.0 in)
Seat Height	710 mm (28.0 in)
Fuel Capacity	11.5 liters (3.0 gal)
Dry Weight	198 kg (436 lbs)

Maintenance Schedule

Recommended maintenance intervals for optimal performance and longevity.

Every 600 miles/1000 km: Check engine oil level, tire pressure, chain tension, brake fluid
Every 3000 miles/5000 km: Change engine oil and filter, inspect spark plugs
Every 6000 miles/10000 km: Clean air filter, check valve clearance, inspect brakes
Every 12000 miles/20000 km: Replace spark plugs, check carburetor synchronization
Seasonal: Change coolant every 2 years, inspect battery terminals

WARNING! Always use Kawasaki genuine parts for replacement. Follow torque specifications precisely.

Engine Service

Detailed procedures for engine maintenance and repair.

Oil Change: Drain plug torque 30 Nm, capacity 2.7 liters with filter change
Valve Clearance: Intake 0.10-0.15 mm, Exhaust 0.15-0.20 mm
Cylinder Head: Removal procedure and gasket replacement
Piston & Rings: Inspection and replacement specifications
Cooling System: Radiator flush and thermostat replacement

CAUTION! Engine must be cool before servicing. Use proper tools for all procedures.

Fuel System

Carburetor service and fuel system maintenance.

Carburetor Specifications: Main jet #92.5, Pilot jet #35, Float level 17.5mm
Carb Synchronization: Use vacuum gauges for balanced operation
Fuel Filter: Replace every 12000 miles or if clogged
Throttle Cable: Adjustment and lubrication procedure
Idle Speed: Set to 1100 ± 100 rpm when engine is warm

Electrical System

Wiring, charging system, and electrical component service.

Component	Specification
Battery	12V 10Ah, maintenance required
Alternator	Three-phase AC generator 220W
Starter Motor	0.7 kW brush type
Spark Plugs	NGK DR8ES-L, gap 0.7-0.8 mm
Fuses	Main 20A, Headlight 10A, Signal 10A

Tip: Always disconnect battery before electrical work to prevent shorts.

Chassis & Suspension

Frame, suspension, and steering maintenance procedures.

Front Fork: Oil capacity 345ml per leg, oil viscosity SAE 10W
Steering Head Bearings: Adjustment and replacement procedure
Wheel Bearings: Inspection and replacement specifications
Swingarm: Bearing service and lubrication points
Wheel Alignment: Check and adjustment procedure

Brake System

Brake maintenance and service procedures.

Front Disc Brake: Pad thickness minimum 1.5mm, rotor thickness minimum 4.0mm
Rear Drum Brake: Shoe wear limit, adjustment procedure
Brake Fluid: DOT 4, change every 2 years
Brake Lines: Inspection for cracks and wear
Master Cylinder: Rebuild procedure and specifications

WARNING! Always test brakes after service before riding.

Transmission & Drive

Gearbox and shaft drive service procedures.

Transmission Oil: SAE 80W-90, capacity 650ml
Clutch Adjustment: Cable free play 2-3mm at lever
Shaft Drive: Gear oil SAE 80W-90, capacity 180ml
Shift Mechanism: Inspection and adjustment procedure
Final Drive: Universal joint inspection and service

Troubleshooting

Common problems and solutions for the EN450-A2.

Symptom	Possible Cause	Corrective Action
Hard starting	Dirty carburetors, weak battery	Clean carbs, charge/replace battery
Poor idle	Clogged pilot jets, vacuum leaks	Clean jets, check intake boots
Overheating	Low coolant, stuck thermostat	Check coolant level, replace thermostat
Electrical failure	Blown fuse, bad regulator	Check fuses, test charging system
Transmission noise	Low oil, worn gears	Check oil level, inspect transmission
Brake drag	Stuck caliper, worn pads	Clean caliper, replace pads

Wiring Diagrams

Complete electrical schematics for troubleshooting and repair.

Includes main harness diagram, ignition system, charging circuit, lighting system, and switch connections. Color-coded wiring with connector locations and ground points.

Torque Specifications

Critical torque values for proper assembly.

Component	Torque Value
Cylinder head bolts	30 Nm (22 ft-lbs)
Spark plugs	12 Nm (9 ft-lbs)
Oil drain plug	30 Nm (22 ft-lbs)
Front axle nut	65 Nm (48 ft-lbs)
Rear axle nut	90 Nm (66 ft-lbs)
Brake caliper bolts	25 Nm (18 ft-lbs)
Sprocket nuts	65 Nm (48 ft-lbs)

IMPORTANT: Always use a calibrated torque wrench for critical fasteners.