1986 Kawasaki LTD 454 Shop Manual

The 1986 Kawasaki LTD 454 is a compact cruiser motorcycle featuring a 454cc parallel-twin engine, 5-speed transmission, shaft drive system, and classic cruiser styling. This comprehensive shop manual covers complete service procedures, maintenance schedules, troubleshooting guides, and technical specifications for proper maintenance and repair. Below are key sections for general information, periodic maintenance, engine, fuel system, electrical, chassis, and troubleshooting.

1. General Information 2. Periodic Maintenance 3. Engine Service 4. Fuel System 5. Electrical System 6. Chassis & Suspension 7. Drive System 8. Brake System 9. Technical Specifications 10. Troubleshooting

General Information

Key components: 454cc air-cooled parallel-twin engine, 5-speed transmission, shaft final drive, hydraulic disc brakes front and rear.

Component	Description
Engine Type	454cc air-cooled 4-stroke parallel twin
Bore x Stroke	70.0 x 59.0 mm
Compression Ratio	9.5:1
Fuel System	Dual Mikuni CV carburetors
Ignition System	Battery-powered CDI
Transmission	5-speed constant mesh
Final Drive	Shaft drive
Front Suspension	Telescopic fork
Rear Suspension	Dual shocks adjustable preload
Brakes	Hydraulic disc front and rear

Periodic Maintenance

Regular maintenance schedule for optimal performance and longevity.

Engine Oil Change: Every 3,000 miles or 6 months
Oil Filter Replacement: Every other oil change
Spark Plugs: Replace every 7,500 miles
Air Filter: Clean every 3,000 miles, replace every 12,000 miles
Valve Clearance: Check every 6,000 miles
Brake Fluid: Replace every 2 years
Drive Shaft Lubrication: Every 12,000 miles

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

Engine Service

Complete engine disassembly, inspection, and reassembly procedures.

Cylinder Head Removal: Remove cam cover, camshafts, cylinder head bolts
Valve Adjustment: Intake 0.10-0.15mm, Exhaust 0.15-0.20mm
Piston and Cylinder: Inspect for wear, measure cylinder bore
Crankshaft and Connecting Rods: Check bearing clearance and end play
Clutch: Inspect plates, springs, and basket for wear
Oil Pump: Check for proper pressure and flow

CAUTION! Engine components are precision parts; handle with care and use proper tools.

Fuel System

Carburetors: Dual Mikuni CV34 carburetors
Fuel Capacity: 3.4 gallons (12.8 liters)
Main Jet: #92.5
Pilot Jet: #35
Float Level: 17.5mm
Idle Speed: 1,100 ± 100 rpm
Fuel Filter: Replace every 12,000 miles
Throttle Cable: Check for smooth operation and proper free play

Electrical System

Complete wiring diagrams and component testing procedures.

Battery: 12V 10Ah, specific gravity 1.280 at 20°C

Charging System: Three-phase AC generator, output 280W at 5,000 rpm

Starter Motor: 0.7kW, brush length service limit 8.5mm

Ignition System: CDI electronic ignition, advance curve 10° at 1,500 rpm to 35° at 3,500 rpm

Lights: Headlight 60/55W, brake light 21/5W, turn signals 21W

Chassis & Suspension

Frame inspection, suspension service, and steering maintenance.

Frame Inspection: Check for cracks, bends, or damage
Steering Head Bearings: Adjust and lubricate every 12,000 miles
Front Fork: Oil capacity 335ml per leg, oil level 135mm
Rear Shocks: Preload adjustment 5 positions
Wheel Bearings: Check for play and smooth rotation
Tire Pressure: Front 28 psi, Rear 32 psi (cold)

Tip: Always use a motorcycle stand when working on wheels or suspension.

Drive System

Shaft drive maintenance and service procedures.

Drive Shaft: Remove rear wheel and final drive unit
Universal Joint: Check for play and wear
Final Drive Gear Oil: Capacity 180ml, SAE 80W-90 gear oil
Drive Splines: Lubricate with molybdenum disulfide grease
Wheel Alignment: Check and adjust if necessary

WARNING! Do not operate motorcycle with damaged drive components. Replace worn parts immediately.

Brake System

Hydraulic disc brake service and maintenance.

Front Brake: Single disc 275mm, caliper single piston

Rear Brake: Single disc 275mm, caliper single piston

Brake Fluid: DOT 4, replace every 2 years

Brake Pad Wear Limit: 1.0mm minimum thickness

Brake Disc Thickness: 4.0mm service limit, 3.5mm discard limit

Technical Specifications

Overall Length: 2,230 mm
Overall Width: 800 mm
Overall Height: 1,120 mm
Wheelbase: 1,510 mm
Seat Height: 710 mm
Ground Clearance: 145 mm
Dry Weight: 194 kg
Fuel Consumption: 45-50 mpg
Maximum Speed: 95 mph

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	Fuel, spark, compression	Check fuel flow, spark plugs, compression test
Poor idle	Carburetor sync, vacuum leaks	Synchronize carburetors, check intake boots
Electrical failure	Battery, charging system	Test battery voltage, check stator output
Brake drag	Stuck caliper, contaminated fluid	Clean calipers, replace brake fluid
Vibration	Wheel balance, engine mounts	Balance wheels, check engine mount bolts

Service Intervals: Refer to periodic maintenance chart for specific mileage-based services.

Technical Support: Contact authorized Kawasaki dealer for complex repairs