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

[@ebib5014]

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

[@travisdixon291]

Today is one of those days!

[@brandonrichardson9497]

Yep helped me out on building mine

[@fancy5kitchencateringllcda431]

That time is now for me

[@__Under_Pressure__]

Yessir! Been studying this video this last week

[@CFPNOLES]

My time also..thank you

[@bootturtleproductions7915]

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

[@MichaelSabo]

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]

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

[@robanthony4042]

To the top

[@jesusdenazarette223]

Thank you for sharing this !

[@fuqqbiden1616]

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

[@MichaelSabo]

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

[@NothingTooCrazy]

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

[@sturdyspamsl2277]

Let me know how it goes

[@ononewheel7]

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

[@SJS68]

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]

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]

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!

[@briang4470]

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.

[@SundochStark]

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

[@Frog-AF]

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]

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

[@just_in_time5518]

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

[@RealSuburbanCowboy]

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.

[@smellymala3103]

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.

[@kylehammond2100]

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

[@shonzenert3971]

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

[@braaap5.7]

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]

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.

[@jeremyhackett8613]

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

[@owen8868]

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!

[@fullysurrendered93]

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

[@liamblock1050]

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

[@gamabike_life4105]

You was the only one who gave more details outta everyone on KZbin tho

[@andrewhlubik5335]

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

[@Lupis1437]

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!

[@axelmensch3369]

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.

[@PHILLIPfry2010]

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

[@BradMason2014]

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!

[@haywireredgeil6542]

I would like to see a TRX450ER 07

[@rodrigomillan8483]

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.

[@toast250r6]

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

[@refiii9499]

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

[@hennessyremy4970]

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

[@rileydoner811]

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

[@justinpate796]

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

[@ryanknox3297]

Great video 📹 👍

[@josue24051]

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]

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

[@jimmadonna1436]

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!

[@markbudd2809]

Great video my bud from South Africa

[@jeffsmith6393]

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]

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

[@greasemonkeygarage1896]

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

[@mikeyboost4life69]

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!!

[@rossdarocy3576]

Videos just keep getting better man

[@tonin3615]

Amazing tank you so much

[@jackdaniel5716]

you should do more vids with jst

[@kennethconnors5316]

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

[@tylergress7297]

I really love motor videos 😁😁

[@careysoutherland8291]

been waiting ever since you said that you had to do a full engine build to see the video. great work as always. I think you should try some at home powder coating and cerakoting

[@MichaelSabo]

Thank you Carey 🤘

[@joshbeck289]

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

[@Lupis1437]

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]

Thank you for watching and for the support Lupis1437!

[@edwardwatts4644]

Very good tutorial 👌 clean and informative

[@jeff6732]

Great job dude. I had one of those KFX 450R”s Great on the track too much for most trails.

[@nickklink9125]

I wish you did one of these on that Honda Sportrax 250EX you did awhile back cause I’m building one right now and would love an informative video like this.

[@claudeoconnor4084]

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. ⭐⭐⭐

[@ApexPowerSportsllc]

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]

Thank you for watching and for the feedback man!

[@grandpa-of-3898]

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

[@MichaelSabo]

Thank you Mickey 🤘

[@bryanslittlegarage5724]

Great video man great step by step. ❤️❤️❤️

[@hectorcolon419]

Very good content.alwayslearn something new

[@gavinj.8330]

Great video Michael!

[@dennisbrooks186]

Yo i followed this to a t and my motor grenaded!!! U owe me a motor!!! Chop chop pay up. Lmfao I'm joking dude gotchaaa!!! I already commented when u 1st did this but dude I just bought one for a grand. 2008. They had top end off already. Cranks fine but I'm gonna do a full rebuild so I'm gonna be watching this one alot. Trying to pick up 2 predators for 1200!!! Complete bikes. So these vids r gold for guys like me. Keep it up bro!!! Never see anybody say that to u so I had to get u lol 😆 🤣 💯

[@MichaelSabo]

Lmao! Dude you had me for a moment there. Hoping this is the Kawi you've mentioned recently that is running now 🤘

[@dennisbrooks186]

@@MichaelSabo lmao 🤣 I had to lol. Nah she's sitting for now. Ordering complete top and bottom end kit. Once it gets here I'll get it all done. Have a banshee that's almost built I gotta finish first

[@gpiper23]

You my friend are a legend 🙌 great video

[@dirtcampmx]

Awesome job! All questions answered.

[@daddyrabbitathappyhour9451]

Thank you my friend

[@savage636stuntz3]

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

[@cheto2952]

Hey boss I watched all your videos and with the work and experience you have putting shuff together is truly impressive. But you know you have to let the clutch plates soak for and hour or so. Don't start going down the wrong path on things. It's like in the Marine we look for quality not quantity.

[@davidjurkowski5588]

Been ready for this one!!!!!

[@keithparady2594]

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

[@leehuntley189]

Bro use original chapstick on all ur gaskets they seal better and pull apart clean! Works especially well when working on carbs and intake gaskets

[@greasemonkeygarage1896]

Ps. On the clutch baskets drill small holes to let fluid inside the basket to help with clutch life 1 for every clutch disc rule of thumb.works best on the outer basket *

[@eddiegardner3133]

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!!!...

[@33K3500]

Dang good job, appreciate you sharing your knowledge.

[@jaasoonkkoeeniig]

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]

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

[@DerredmaxTRIAX]

Your videos are killer bro!!

[@MichaelSabo]

Thank you man!

[@AnanusBananus]

Thrust bearing. And not warshers, those are The bearing surfaces. Love The vids.

[@dylanwatrud1409]

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

[@derekmullane231]

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

[@MichaelSabo]

Thank you Derek Mullane!

[@Thewatson77]

Such a service you have done my man 👊🏼

[@franksantarcangelo1950]

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😁👊🏻

[@Bigjameskyboy]

Dude thank you so much for this. My quad is in need of a rebuild and this is perfect. You ever looked at the intimidator front bumper? Clean!!! Also the kfx is know for a shit coil. You can use a ngk jeep coil for improved reliability and durability of your starting system.

[@MOTO_MAVERICK53]

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

[@vernerg436]

perfect! thanks alot couldnt be better

[@cr-yg7rx]

sick build

[@chadriddle3517]

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

[@Frog-AF]

Also please do an LTZ/KFX/DVX build. I have an 06 DVX 400, I don’t have tons of problems with it anymore like I used to but I just need a new swingarm (those weren’t great from factory) and I need new plastics. Great vid as always!

[@MichaelSabo]

Thank you man; if I get a KFX400, LTZ or DVX and it needs a build; I will make a video on it!

[@Wathappn2u]

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

[@cannondxile3180]

Can you do this with a 400ex

[@connersnow298]

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

[@LuvADuc]

Thank you!

[@marcosmachado5989]

Your are awesome super great Job 👌

[@Matthew-re1ke]

me and my dad just got into banshees, he owned one in the past but sold it. we have some questions about motor work and trail builds. we live less then 45 min from you

[@adamfoster7916]

You should buy a YFZ 450!! Great vid!

[@omaralshehhi7830]

As always very nice video 👍

[@dlack387]

everytime i get frustrated i just stop for the night drink beer and start back the next day haha

[@Jgraves2288]

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

[@nellekinggaming9600]

my clutch had 2 spacers and i saw you didnt use any so i was wondering if you need them. if i use 1 it makes it so it sticks a lot

[@davidthorburn9327]

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.

[@jasonhendrie5411]

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

[@joelmaassen7706]

I'm leaving a comment because ur awesome and know how to check ring gap ;)

[@derekbottorff7622]

Great job will definitely help alot of people 👍

[@jakedaly2718]

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

[@zkelly05]

Why’s there no wrist pin bearing? I didn’t see him install one I just didn’t know if it didn’t use one?

[@noway234]

Good job.

[@kevinday4490]

Been slowly buying all the parts for my rebuild and then you hit me with this video. What perfect timing and such a great in depth video too. One question, what's the torque specs on the bearing retainers? I'm gonna blue loctite them but just want to make sure they don't come out. Definitely going to go buy some merch just for this video.