1987 Kawasaki 454 LTD Manual

The 1987 Kawasaki 454 LTD is a mid-size cruiser motorcycle featuring a 454cc liquid-cooled four-stroke parallel-twin engine, 5-speed transmission, shaft drive, electric start, dual exhaust, and cruiser styling with low seat height. Below are key sections for safety, features, maintenance, operation, specifications, and troubleshooting.

1. Features at a Glance 2. Safety Information 3. Controls and Instruments 4. Specifications 5. Routine Maintenance 6. Engine Operation 7. Fuel System 8. Electrical System 9. Brake System 10. Troubleshooting

Features at a Glance

Key components: 454cc parallel-twin engine, 5-speed transmission, shaft final drive, electric start, dual exhaust system, cruiser styling with low seat.

Feature	Description
Engine Type	454cc liquid-cooled 4-stroke parallel twin
Transmission	5-speed constant mesh
Final Drive	Shaft drive
Starting System	Electric start with backup kick starter
Fuel System	Dual CV carburetors
Brakes	Front disc brake, rear drum brake
Suspension	Telescopic front fork, dual rear shocks
Seat Height	Low profile cruiser seat
Fuel Capacity	3.7 gallons (14 liters)
Weight	Approximately 430 lbs (195 kg)

Safety Information

Always wear proper protective gear and follow safe riding practices.

Pre-ride inspection: Check tires, brakes, lights, and fluid levels before each ride.
Protective gear: Always wear DOT-approved helmet, eye protection, gloves, and protective clothing.
Riding skills: Take a motorcycle safety course and practice in safe areas.
Load limits: Do not exceed maximum weight capacity of 400 lbs including rider.

WARNING! Motorcycles offer no crash protection; ride defensively and avoid alcohol/drugs when operating.

Controls and Instruments

Familiarize yourself with all controls before operating the motorcycle.

Handlebar controls: Right side - front brake lever, engine kill switch, starter button; Left side - clutch lever, turn signals, horn, headlight dimmer.
Instrument panel: Speedometer, odometer, trip meter, neutral indicator, high beam indicator, turn signal indicators.
Ignition switch: Located on right side of motorcycle with OFF/ON positions.
Fuel valve: Located under left side of fuel tank with ON/RES/PRIME positions.

CAUTION! Ensure you understand all controls before riding. Practice in safe area.

Specifications

Engine: 454cc liquid-cooled 4-stroke parallel twin
Bore x Stroke: 66.0 x 66.0 mm
Compression Ratio: 9.5:1
Fuel System: Dual 32mm CV carburetors
Ignition: Battery-powered electronic ignition
Transmission: 5-speed constant mesh
Final Drive: Shaft drive
Suspension Front: Telescopic fork, 5.9 in travel
Suspension Rear: Dual shocks, 3.5 in travel
Brakes Front: Single disc, 2-piston caliper
Brakes Rear: Drum brake
Tires Front: 100/90-19
Tires Rear: 140/90-15
Fuel Capacity: 3.7 gal (14 L)
Oil Capacity: 3.2 qt (3.0 L) with filter change

Routine Maintenance

Regular maintenance ensures optimal performance and longevity.

Daily/Pre-ride: Check tire pressure, brake operation, lights, fluid levels, chain tension (if applicable).

Every 600 miles: Change engine oil and filter, check/adjust drive chain, check brake pads, lubricate cables.

Every 3,000 miles: Clean air filter, check valve clearance, inspect spark plugs, check battery fluid.

Every 6,000 miles: Change final drive oil, check wheel bearings, inspect brake system, check steering head bearings.

Seasonal: Winterize if storing, check battery charge, inspect tires for dry rot.

Engine Operation

Starting procedure and normal operation guidelines.

Pre-start check: Ensure motorcycle is in neutral, fuel valve is ON, kill switch is in RUN position.
Cold starting: Pull choke knob, turn ignition ON, press starter button without throttle.
Warm starting: No choke needed, slight throttle opening may be required.
Warm-up: Allow engine to warm up for 1-2 minutes before riding.
Shifting: Use clutch for all gear changes, shift smoothly through gears.

Tip: Avoid high RPM operation until engine reaches normal operating temperature.

Fuel System

Carburetor operation and fuel system maintenance.

Fuel valve positions: ON - normal operation; RES - reserve (0.5 gal); PRIME - for starting after fuel system work.
Carburetor adjustment: Idle speed screw (1200-1400 RPM), fuel mixture screws (factory set).
Fuel filter: Located in fuel line between tank and carburetors.
Fuel recommendations: Use unleaded gasoline with octane rating of 87 or higher.

WARNING! Gasoline is highly flammable. No smoking during refueling. Work in well-ventilated area.

Electrical System

Battery, charging system, and electrical components.

Battery: 12V 14Ah, maintain fluid level, keep terminals clean and tight.

Charging System: AC generator with rectifier/regulator, output approximately 14V at 5000 RPM.

Lights: Headlight (55/60W), brake/tail light (21/5W), turn signals (21W), instrument lights.

Fuses: Main fuse (30A) and accessory fuses located under seat.

Brake System

Front disc brake and rear drum brake maintenance.

Front brake: Hydraulic disc brake with single piston caliper, check fluid level in master cylinder.
Rear brake: Mechanical drum brake, adjust via rear brake pedal linkage.
Brake fluid: Use DOT 4 brake fluid, change every 2 years or 12,000 miles.
Brake pads: Replace when thickness reaches 1mm or less.

CAUTION! Brake fluid damages paint. Clean spills immediately. Test brakes after service.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	Fuel, spark, or compression issue	Check fuel in tank, spark plug condition, battery charge
Poor idle	Dirty carburetor, vacuum leak	Clean carburetor, check intake manifold for leaks
Electrical failure	Battery, fuse, or charging system	Check battery voltage, inspect fuses, test stator output
Brake problems	Worn pads, air in lines, adjustment	Inspect brake pads, bleed hydraulic system, adjust rear brake
Transmission issues	Clutch adjustment, low oil	Adjust clutch cable, check oil level and condition

Service Intervals: Follow maintenance schedule in owner's manual.

Technical Support: Contact authorized Kawasaki dealer for complex repairs.