How to Build a Kawasaki KFX450R Engine | 2008 - 2014 Full Build Step by Step

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How to Build a Kawasaki KFX450R Engine | 2008 - 2014 Full Build Step by Step
Chapters
0:00 - Intro
CRANKCASE
2:09 - Bearing and Seal Install Method (9-11)
3:24 - Transmission (9-22)
4:10 - Crankshaft (9-18)
4:30 - Shift drum and Forks (9-22)
5:57 - Crankcase Oil Tubes
6:53 - Reverse Gear (9-15)
7:58 - Applying Gasket Sealer (9-15)
9:13 - Assembling Case Halves (9-15)
LEFT AND RIGHT SIDE ENGINE
10:28 - Shift Detent Assembly (9-16)
11:31 - Shift Cam (9-16)
12:17 - Testing Transmission (9-16)
12:47 - Countershaft O-Ring and Collar (9-17)
13:36 - Balancer Drive Gear (9-17)
13:52 - Oil Scavenge System (7-12)
15:03 - Cam Chain (7-13)
15:33 - Oil Feed System (7-13)
16:38 - Oil Pressure Relief Valve (7-11)
17:08 - Oil Pump Gears (7-14)
17:46 -Clutch Side Oil Pipe (7-15)
18:18 - Oil Pump and Primary Drive Gear (6-19)
18:52 - Shift Rachet Assembly (6-21)
20:04 - Shift Shaft (6-21)
20:23 - Counter Balancer (9-26)
22:15 - Clutch Basket and Inner Hub (6-13)
23:22 - Explaining Full Fiber Clutch Mod
25:36 - Prepping and Assembling The Clutch Pack (6-14)
27:41 - Clutch Actuator and Pushrod/Pressure Plate (6-15)
29:01 - Tightening Primary Drive Gear (6-19)
29:27 - Right Side Engine Cover (6-11)
30:46 - Clutch Cover (6-10)
31:25 - Water pump and Cover (4-13)
32:09 - Oil Filter and Cover (2-26)
STATOR SIDE/STARTER
33:07 - Starter Motor (16-39)
34:00 - Cam Chain Slider (5-18)
34:23 - Flywheel and Starter Gears (16-26)-(16-48)
35:27 - Stator and Cover (16-25)
36:45 - Torque Limiter Gear and Cover (16-47)
TOP END
38:41 - Checking and Adjusting Ring Gap (5-36)
40:57 - Installing Rings and Piston (5-34)
45:01 - Installing Cylinder (5-36)
46:15 - Upper Cam Chain Slide (5-22)
47:20 - Installing Head (5-22)
50:22 - Installing Cams and Shims (5-15)
52:40 - Camshaft Caps and Oil Tubes (5-18)
54:17 - Checking Timing (5-17)
55:24 - Cam Chain Tensioner (5-13)
56:35 - Last Engine Check (5-13)
57:21 - Installing Cam Cover (5-12)
58:33 - Installing the Temperature Sensor (16-55)
58:50 - Throttle Body Holder (5-38)
SHOWCASING AND FIRST START
59:15 - Showcasing and First Start/Riding Footage
TOOLS AND PRODUCTS IN THIS VIDEO
All OEM Parts - www.rockymountainatvmc.com/?r...
Assembly Lube - bit.ly/3rXYKje
Case Sealer (Yamabond 6b) - bit.ly/393wIdp
Blue Thread locker (Loctite) - bit.ly/3odjEIK
Anti-Seize - bit.ly/2JNlEsn
Engine Oil (Klotz MX4) - bit.ly/3ni8YqQ
Small Impact Driver & Drill (M12) - amzn.to/35bXI9v
Large Impact Driver (M18) - amzn.to/3nd4emp
Small Torque Wrench (3/8”) - bit.ly/3pVUfnx
Large Torque Wrench (1/2”) - bit.ly/2LocVxe
Tusk Clutch Kit - bit.ly/3pM9zTm
Kawasaki OEM Clutch Fiber (13088) - bit.ly/2Lnao6i
Athena Cylinder - ebay.us/ClSk8s
Wiseco Piston (Standard) - bit.ly/2XgzHcM
Wiseco Piston (High Comp) - ebay.us/s2jegs
Hot Cams Stage 3 (Intake) - bit.ly/3pRX1Kp
Hot Cams Stage 3 (Exhaust) - bit.ly/392nPAN
Gasket Kit - bit.ly/35bYkfm
Valve Shim Kit (9.48mm) - bit.ly/3rPUNwO
If you enjoyed, please comment, like, share and subscribe!
Add me on Instagram @michaelsabo350 for Channel Updates!
Thank you for watching!
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25 июл 2024

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Комментарии : 251

@ebib5014 3 года назад

youre a legend for this. someone somewhere anywhere from 1 year to 15 in the future will find this and feel blessed

@travisdixon291 Год назад

Today is one of those days!

@brandonrichardson9497 Год назад

Yep helped me out on building mine

@fancy5kitchencateringllcda431 Год назад

That time is now for me

@__Under_Pressure__ Год назад

Yessir! Been studying this video this last week

@CFPNOLES 8 месяцев назад

My time also..thank you

@bootturtleproductions7915 3 года назад

You Need to do more motor builds like this. Very informative

@NothingTooCrazy 3 года назад

I’m gonna attempt to rebuild the engine of my KFX450r after watching this video. I will be referring back to it later 👍🏽

@sturdyspamsl2277 3 года назад

Let me know how it goes

@ononewheel7 3 года назад

Just grab a manual as well the kfx engine is not bad at all!

@MichaelSabo 3 года назад

If this video helped you or you enjoyed it please leave a comment (that helps me a lot! 😊) You Guys ROOOCK! 🤘 Chapters (They're clickable in the description of this video) 0:00 - Intro CRANKCASE 2:09 - Bearing and Seal Install Method (9-11) 3:24 - Transmission (9-22) 4:10 - Crankshaft (9-18) 4:30 - Shift drum and Forks (9-22) 5:57 - Crankcase Oil Tubes 6:53 - Reverse Gear (9-15) 7:58 - Applying Gasket Sealer (9-15) 9:13 - Assembling Case Halves (9-15) LEFT AND RIGHT SIDE ENGINE 10:28 - Shift Detent Assembly (9-16) 11:31 - Shift Cam (9-16) 12:17 - Testing Transmission (9-16) 12:47 - Countershaft O-Ring and Collar (9-17) 13:36 - Balancer Drive Gear (9-17) 13:52 - Oil Scavenge System (7-12) 15:03 - Cam Chain (7-13) 15:33 - Oil Feed System (7-13) 16:38 - Oil Pressure Relief Valve (7-11) 17:08 - Oil Pump Gears (7-14) 17:46 -Clutch Side Oil Pipe (7-15) 18:18 - Oil Pump and Primary Drive Gear (6-19) 18:52 - Shift Ratchet Assembly (6-21) 20:04 - Shift Shaft (6-21) 20:23 - Counter Balancer (9-26) 22:15 - Clutch Basket and Inner Hub (6-13) 23:22 - Explaining Full Fiber Clutch Mod 25:36 - Prepping and Assembling The Clutch Pack (6-14) 27:41 - Clutch Actuator and Pushrod/Pressure Plate (6-15) 29:01 - Tightening Primary Drive Gear (6-19) 29:27 - Right Side Engine Cover (6-11) 30:46 - Clutch Cover (6-10) 31:25 - Water pump and Cover (4-13) 32:09 - Oil Filter and Cover (2-26) STATOR SIDE/STARTER 33:07 - Starter Motor (16-39) 34:00 - Cam Chain Slider (5-18) 34:23 - Flywheel and Starter Gears (16-26)-(16-48) 35:27 - Stator and Cover (16-25) 36:45 - Torque Limiter Gear and Cover (16-47) TOP END 38:41 - Checking and Adjusting Ring Gap (5-36) 40:57 - Installing Rings and Piston (5-34) 45:01 - Installing Cylinder (5-36) 46:15 - Upper Cam Chain Slide (5-22) 47:20 - Installing Head (5-22) 50:22 - Installing Cams and Shims (5-15) 52:40 - Camshaft Caps and Oil Tubes (5-18) 54:17 - Checking Timing (5-17) 55:24 - Cam Chain Tensioner (5-13) 56:35 - Last Engine Check (5-13) 57:21 - Installing Cam Cover (5-12) 58:33 - Installing the Temperature Sensor (16-55) 58:50 - Throttle Body Holder (5-38) SHOWCASING AND FIRST START 59:15 - Showcasing and First Start/Riding Footage TOOLS AND PRODUCTS IN THIS VIDEO All OEM Parts - www.rockymountainatvmc.com/?r... Assembly Lube - bit.ly/3rXYKje Case Sealer (Yamabond 6b) - bit.ly/393wIdp Blue Thread locker (Loctite) - bit.ly/3odjEIK Anti-Seize - bit.ly/2JNlEsn Engine Oil (Klotz MX4) - bit.ly/3ni8YqQ Small Impact Driver & Drill (M12) - amzn.to/35bXI9v Large Impact Driver (M18) - amzn.to/3nd4emp Small Torque Wrench (3/8”) - bit.ly/3pVUfnx Large Torque Wrench (1/2”) - bit.ly/2LocVxe Tusk Clutch Kit - bit.ly/3pM9zTm Kawasaki OEM Clutch Fiber (13088) - bit.ly/2Lnao6i Athena Cylinder - ebay.us/ClSk8s Wiseco Piston (Standard) - bit.ly/2XgzHcM Wiseco Piston (High Comp) - ebay.us/s2jegs Hot Cams Stage 3 (Intake) - bit.ly/3pRX1Kp Hot Cams Stage 3 (Exhaust) - bit.ly/392nPAN Gasket Kit - bit.ly/35bYkfm Valve Shim Kit (9.48mm) - bit.ly/3rPUNwO

@slowdirtyboyz670 3 года назад

love the content from you man thanks for the effort in the vidoes keep it up

@robanthony4042 3 года назад

To the top

@jesusdenazarette223 3 года назад

Thank you for sharing this !

@fuqqbiden1616 Год назад

If I'm just replacing the crank and piston/rod do I need to take the right side cover off?

@MichaelSabo Год назад

@@fuqqbiden1616 If just piston you can do it but for crank replacement you will have to do both sides to replace.

@SJS68 4 месяца назад

Thank you for this video, It took over 8 months , always finding gaskets and seals i didnt have that I needed to order, was doing a top end and realized it needed a bottom end. Thanks to this video Was able to get it completely rebuilt while adding tons of goodies along the way. Wouldnt have been able to do it without this video!

@bencameron4153 Месяц назад

Michael, I’ve watched a ton of YT videos on quad repairs and yours, by far is the best I have seen. Your videos have helped me out immensely. I’ve never seen a more detailed and organized how-to video before. Your step-by-step guide has been so helpful for me! Thank you brother! Keep making these gold videos sir!

@joenewberry5912 3 года назад

Fantastic video. I couldnt have done any better myself. Im glad this machine went to you. I knew when i sold it. It was going to a great home. Keep up the awesome videos Mike!

@SundochStark Год назад

Saved my life, mine didnt run and i re assmpled it with no knowledge about 4 strokes. And it runs now!

@jimmadonna1436 3 года назад

I'll probably never own a four stroke but at least I'll be able to refer to this and rebuild one. That's MIKE!

@shonzenert3971 Год назад

Absolute savior! This video was perfect, step by step for every little aspect, help me tons!

@briang4470 3 года назад

Dont take this as me complaining but be careful using large amounts of thick assembly lubes and grease because that stuff will clog an oil filter in a heart beat. If you ever use grease on a camshaft in a car engine and pull the oil filter out after the cambreak in(roughly 20 min of running) it will be completely full of thick oil and grease and if not caught right away can plug the filter and lose oil pressure and blow the motor up. I personally just like to use what ever oil the engine will be run with or if you do use assembly lubes use it sparingly.

@Frog-AF 3 года назад

Great video! Very detailed! I don’t even own a Kfx 450 but I’m just watching for a better general knowledge on rebuilding motors. Thank you!!

@MichaelSabo 3 года назад

I'm glad you liked it man; thank you for watching!

@just_in_time5518 3 года назад

Kawasaki should pay you for making this video! Amazing job!

@RealSuburbanCowboy 3 года назад

Your videos are by far the best out there for this type of thing. I followed your Raptor series and re-assembled an engine I got completely disassembled, it was so easy to do with your videos. Thank you for taking the time to do this and do it RIGHT! A child could do this following your instructions.

@kylehammond2100 Год назад

Doing valve clearances and shims, this video is great info for building and knowledge

@toast250r6 3 года назад

Your so underrated man! This stuff is top-notch quality and informative. Love the content!

@smellymala3103 2 года назад

Rebuilding three of these with my dad when I visit next week and I’m handy but not a mechanic, thank you a million times for this video. I feel like I will be a lot more helpful after watching a few times.

@davidjurkowski5588 3 года назад

Been ready for this one!!!!!

@andrewhlubik5335 2 года назад

I enjoyed your video. I have the same hobby. I buy bikes make them right ride them for a while then move on. It was cool to watch someone else doing it for a change. Keep it up

@fullysurrendered93 Год назад

Just built a KFX 511 stroker. This video was monumental to my build. Thanks a lot Mike!

@rodrigomillan8483 3 года назад

Great Video Man, your the Man, one way of pre lubing the engine with out assembly grease is to put oil in it let it sit with the cap off , the manual calls it crank case breath time , arctic cat manual says 15 minutes , I leave it over night, than put cap back on , you spin the engine with the starter with out start to prime the engine oil lines with out start or ignition , pre pressurize power plant oil system , before first start, and even oil changes , my DVX 400 lasted me 16 years with out rebuild . Thanks again for the reference and help.

@liamblock1050 3 года назад

Definetly looks better with the lime green plastics... awsome job love the step by step videos!

@Thewatson77 3 года назад

Such a service you have done my man 👊🏼

@jeremyhackett8613 3 года назад

I dont even have a 450 and im gonna still watch till the end, knowledge is power

@PHILLIPfry2010 3 месяца назад

Lot of small parts in this motor compared to seeing the yfz rebuild videos. Nice work!!

@owen8868 3 года назад

this reminds me of when i completely rebuilt my crf250r until 1:30am for a few days but now its running good and has great power and the engine is solid surprisingly because that is the first engine ive ever rebuilt and im 14 but it runs so im happy and its my first dirtbike!

@chadriddle3517 3 года назад

Mike , you always do such a precise job building engines! Great tutorial bro

@axelmensch3369 2 года назад

I'm wondering how someone can give you thumbs down for this video. So far the best video I ever have seen. Thank you for all your work.

@Jgraves2288 3 года назад

This was a good detailed video I’m definitely gonna use this video in the future good job mike keep up the good work!👍🏽

@braaap5.7 3 года назад

Me just now realizing I just sat and did nothing but watch this video which is an hour long. Felt like it was only 15 minutes long, rebuild vids are the best. Also too bad u don’t live further up north. To get snow. It would be awesome if u were into snowmobiles. I got a 2001 skidoo summit 800 and just put twin pipes on it. They vibrate my ear drums at wot 😂

@MichaelSabo 3 года назад

Thank you for watching man! Yea if we got more snow I'd probably get into sleds but here in the Philly area it would barely get used.

@mikeyboost4life69 3 года назад

Mike thank you so much for another awesome video I actually bought a brand new white and black 2008 kfx450r in 2007 when it first came out and man that was one hell of a quad I remember all my buddies with their Raptor 700 and their TRX450R brand new at the time trying to do any upgrade they could like computer chips exhaust everything and no matter what they did my stock kfx450r always smoked them one hell of a quad can't wait to see more content on it keep up the great uploads!!

@charliepapa5835 3 года назад

Amazing job on the videos and great clean work!

@gavinj.8330 3 года назад

Great video Michael!

@sember_1183 3 года назад

Great video man, super detailed.

@gamabike_life4105 3 года назад

You was the only one who gave more details outta everyone on RU-vid tho

@markbudd2809 2 года назад

Great video my bud from South Africa

@cr-yg7rx 3 года назад

sick build

@staceycampbell2171 3 года назад

Awesome video Mike. You do good work man!!!

@dubbedmodz7253 3 года назад

Loved the video bro! Great job

@dannysheppard2882 3 года назад

Great job mike!!

@dirtcampmx 6 месяцев назад

Awesome job! All questions answered.

@savage636stuntz3 2 года назад

Awesome video u really put the information into all the videos bro so sick!

@bryanslittlegarage5724 2 года назад

Great video man great step by step. ❤️❤️❤️

@AM-kv4zl 5 месяцев назад

Great vid 🤙🏽

@33K3500 2 года назад

Dang good job, appreciate you sharing your knowledge.

@rossdarocy3576 3 года назад

Videos just keep getting better man

@justinpate796 3 года назад

I don’t have a 450r but these videos are so detailed and interesting I have to watch them, keep them coming👍

@Lupis1437 3 года назад

Thank you so much! I’ve got the manual for this bike but this video is gonna help a ton when I do a full rebuild. Will get some merch from ya and show some support.

@MichaelSabo 3 года назад

Thank you for watching and for the support Lupis1437!

@MOTO_MAVERICK53 3 года назад

I respect you for the step by step of the rebuild awesome video and I’ve always been a 2stroke fan but damn she rips alright

@DJAUDI0 3 года назад

Fantastic video!!

@kennethconnors5316 2 года назад

got me hooked ,, enjoy your stuff some of the best editing I have ever scene on youtube

@jakedaly2718 3 года назад

awesome video dude been following your builds for bit ,great work dude keep it up

@jeffsmith6393 3 года назад

Great video man keep up the work I love watching your videos they have taught me so much and helped me in so many ways I can’t wait to see a dirtbike build one day

@MichaelSabo 3 года назад

Thank you for watching bro! I will be doing a build series on a YZ125 soon!

@Wathappn2u 3 года назад

well done. wish more ppl would do videos at this level.

@kernelbadness 3 года назад

Awesome content, MS!

@derekmullane231 3 года назад

Awesome video all around, Love to see some more in the future !

@MichaelSabo 3 года назад

Thank you Derek Mullane!

@ApexPowerSportsllc 3 года назад

Nice vid man, very detailed and I'm glad your into the laquer thinner for cleaning +1. Whoever finds this video during a build will definitely use this for atleast orientations, very informative

@MichaelSabo 3 года назад

Thank you for watching and for the feedback man!

@claudeoconnor4084 3 года назад

Man, I've been watching your videos since the nightmare raptor. I appreciate your camera angles, even tone, cool demeanor. I can't recommend anything. In my opinion you're doing awesome and I love all your videos. ⭐⭐⭐

@refiii9499 3 года назад

I like that torque Gun with those settings. That’s a slick feature

@davidthorburn9327 3 года назад

You are amazing at engines: can’t wait for the next top quad series. My favorite though is your Trx250r. Wish I had one of those.

@ryanknox3297 3 года назад

Great video 📹 👍

@gpiper23 2 года назад

You my friend are a legend 🙌 great video

@hectorcolon419 2 года назад

Very good content.alwayslearn something new

@bert4452 3 года назад

Awesome vid! I will def be using this on mine the future, not many vids on this quad. This will help a lot, keep up the great work!🤙 can’t wait to see you rip this thing

@robdajuiceman1328 3 года назад

Awesome video

@greasemonkeygarage1896 3 года назад

You should have wayy more followers ... contents golden!!!!

@jasonhendrie5411 3 года назад

Good vid bother learned some good pointers from ya🤟🤟🤟

@derekbottorff7622 3 года назад

Great job will definitely help alot of people 👍

@edwardwatts4644 2 года назад

Very good tutorial 👌 clean and informative

@jamesBGgarner 2 года назад

Another banger!!

@NickW90 3 года назад

Great video

@franksantarcangelo1950 3 года назад

I really enjoyed this video it was awesom good camera work perfectly explaining everything not too much to talk just enough I like it you da man Sabo😁👊🏻

@omaralshehhi7830 3 года назад

As always very nice video 👍

@eddiegardner3133 2 года назад

Great video... I'm gonna say easily the most informative atv engine build out there... I'm getting ready to do a kfx450r as well so this is huge to have this video right there to help ... I've been all about race Quads since I was knee high and love Workin on them... It would be great to meet ya some day and go for a rip or two!!!!.. great job man!... Plus I'd love to show ya my trx450r build from the ground up!!.. waited my whole life to be able to do that and it's done and I'm loving it racin it In the local XC series!!!...

@hennessyremy4970 3 года назад

Thanks bro!! Who needs a dealership when u can watch mike do it and save a ton of money broski lol great vid. Great angles. And every time I wanted say y didn’t mentioned this or show that. U would b in the process of talking about it or about to show it on camera

@outerlimits583 Год назад

Awsome work thanks heaps

@stephanelanglois6140 3 года назад

pretty good job......solid 💪🏻💪🏻👍👍👍

@josue24051 3 года назад

Man you are the freaking best man this video is so informative, so in depth great video man. You are definitely inspiring i work on my quad and pretty much always fix all my friends quads. I really enjoy working on quads and you definitely inspired me to start my own channel. Your awesome man thank you for all your great content. I hope i can meet you one day 🤘🤘

@MichaelSabo 3 года назад

Hell yea man! I'm glad you enjoyed this and it inspires you to work on your friends bikes; thats what its all about man! Good luck on your channel and one day maybe we will meet

@jamescameron7633 2 года назад

Good work bro

@grandpa-of-3898 3 года назад

Now thats how you put a engine together great job hope to see more like this but great video 📹

@MichaelSabo 3 года назад

Thank you Mickey 🤘

@dylanwatrud1409 3 года назад

Very very good video, good walkthrough and will help so many people now and in the future

@vernerg436 3 года назад

perfect! thanks alot couldnt be better

@Lupis1437 3 года назад

Helpful tip for the tensioner if you are doing with the motor in the bike: use the screwdriver to turn and then thread a longer 6mm bolt where the cover with o-ring goes and that will lock it down. Just got done doing this and didn’t see in the manual or on forums!

@keithparady2594 3 года назад

Definitely a good job lots of good info lots of people on here don’t give the good details

@rileydoner811 3 года назад

Do I own a Kfx 450? NOPE, Im still gonna watch the whole thing though because your videos are so entertaining and informative, good to watch. I have never watched one video from you that I disliked

@LuvADuc Год назад

Thank you!

@jaasoonkkoeeniig 3 года назад

Awesome video, been looking for sometime like this for a long time. It’s going to save me a lot of money at the dealer!

@MichaelSabo 3 года назад

I'm glad it will help; thank you for watching Jason!

@joshbeck289 3 года назад

I like a lot of the design on that engine Kawasaki did some great work on the design especially the oil screens on the outer case easy access

@tonin3615 2 года назад

Amazing tank you so much

@noway234 3 года назад

Good job.

@DerredmaxTRIAX 2 года назад

Your videos are killer bro!!

@MichaelSabo 2 года назад

Thank you man!

@connersnow298 2 года назад

Awesome vid and edits and filming and shop and bike and knowledge and motor

@BradMason2014 3 года назад

Personally would LOVE to see an 04/05 TRX450R full motor build. This is pretty close so thanks for doing it! Appreciate your channel sir. Great content!