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Kawasaki just announced its entire 2016 model line of dirt bikes, and the big news is a new KX450F.
Kawasaki’s already powerful flagship motocross bike is even stronger for 2016, with the KX450F motorcycle boasting a more powerful and lighter engine. The cylinder head updates include revisions to the intake ports, which are less curved than before, improving mid-high RPM performance and over-rev.
The single cylinder is offset (8.5mm forward) to reduce mechanical loss through friction from the piston movement, enabling more efficient power generation.
Another addition for 2016 is the redesigned air box, which does away with any steel parts, resulting in a weight savings of 8.8oz. Another weight saving measure saw 9.2oz trimmed from the transmission gears and shafts, which retain their overall strength while contributing to the motorcycle’s dynamic performance. With all these engine changes, the revolutionary and popular DFI® couplers are again available for the Digital Fuel Injection system. The KX450F motorcycle’s Launch Control System is another popular feature that helps obtain holeshot supremacy for the amateur and pro rider alike. As a further benefit of owning a KX450F motorcycle, the engine ECU remains fully programmable thanks to the new handheld Kawasaki Accessory KX FI Calibration Kit.
Kawasaki’s engineers worked tirelessly to improve handling and chassis feedback with a new aluminum perimeter frame. The alloy swingarm has a cast front section and twin tapered hydro-formed spars in a raw aluminum finish.Forged chain adjusters are also fitted with a self-locking rear axle nut.
The original goal was to create the lightest motorcycle in its class, increasing the bike’s agility and helping to reduce rider fatigue, making the KX450F more potent than ever before. The 2016 KX450F motorcycle receives all-new bodywork with aggressive styling to suit its heightened performance.
The top of the fuel tank is lower than before, allowing easier progression from the seat to the tank. Aggressive styling for the new front fender adds to the motorcycle’s overall racy appearance and alsosaves 1.8oz in weight overall the previous model year. The appearance is further highlighted by green engine plugs, oil cap and generator cover plugs, as well as green alumite suspension adjusters and black alumite wheels.
To protect the 2016 Kawasaki KX450F motorcycle from general wear and tear encountered during a typical day at the track, a large synthetic skid plate offers great protection with minimum weight.
With Kawasaki engineers creating a lighter motorcycle, its agility was increased, allowing the suspension and brakes to work more efficiently and effectively.
The fork has traditional 22-position compression and 20-position rebound damping adjustment.Furthermore, the rider can adjust the internal air pressure with the Kawasaki Genuine Accessories 0-300psi Digital Air Pump that is supplied with the KX450F motorcycle. New linkage ratios for the Kawasaki Uni-Trak® suspension system were designed to suit the new aluminum frame and swingarm.
Riders looking for an extra edge over the competition can use the optional Kawasaki rear suspension tie rod.
Kawasaki’s commitment to the rider continues with an adjustable handlebar and footpegs to fit various sizes and riding styles. Equipped with a flat seat, adjustable footpegs and handlebar as well as fully adjustable suspension, the 2016 Kawasaki KX450F motorcycle can be tailored to suit a large range of riders. Receiving several upgrades for Model Year 2016, the KX250F motorcycle continues to be a popular choice for amateur riders as well as the professionals – with more riders winning races on a Kawasaki KX250F than any other 250cc four-stroke in its class.
It comes with a host of technology to help the rider succeed, including a Launch Control mode thatenhances traction off the line by temporarily retarding ignition to help riders get the holeshot. To exploit the powerful engine, the KX250F motorcycle has a 48mm Showa Separate Function Fork (SFF), which utilizes the left fork tube to carry the damping assembly, with the spring contained in the right tube.
As an industry first in the 250 class, the KX250F has two-position, adjustable footpeg brackets that allow the rider to lower the position by 5mm, thereby lowering the center of gravity.
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The engine might not look radically different, but almost all of it is new, with a different angle on the top end, a new head, piston, cam and throttle body. The revisions are extensive and start with new engine cases to save weight while optimizing the design to increase strength and rigidity. The intake port cores are also given a special coating during the head casting process to make the ports smoother.

The new design, with slimmer throat angle and reduced recess (similar to valves on Kawasaki supersport engines) contributes to increased high-RPM performance. This necessitated a revised crankshaft shape, corresponding to the revised crankshaft housing. It starts with a new header design that features a resonator to improve low RPM power and help reduce the sound level. And when combined with a lighter overall curb weight, the 2016 Kawasaki KX450F motorcycle has an improved power-to-weight ratio that provides improved acceleration response. Three are supplied with each motorcycle and allow the riders to quickly change the fuel injection mapping to suit any riding condition.
The push-button activation retards ignition timing in first and second gears, helping to maximize traction off the line. This portable device allows custom maps to be created giving riders precise adjustment of fuel and ignition settings. The perimeter spars are 6mm slimmer than the previous frame, allowing easier rider movement.
The axle nut holds the 80 lb-ft torque setting without the need of a cotter pin for ease of maintenance at the track. The minimalist bodywork is light and features angular styling for the new number plates, shrouds, fenders, skid plate and water pump guard.
The flatter design gives the rider greater freedom of movement when changing riding position, while also allowingthe rider to sit further forward. Another neat detail is the embossing?on the clutch cover, which was designed to gradually appear as contact from the rider’s boots wears away the paint.A new generator cover has also been incorporated to fit the new crankcase. The revised designhas oval holes that facilitates easy mud removal and reduces the weight further.
This is especially true of its state-of-the-art Showa SFF-Air TAC (Separate Function front Fork, Triple Air Chamber) fork technology, which separates the damping and shock absorption duties into the individual fork legs. Changing the air pressure covers a range of settings offered by optional springs in a standard fork, including quick changes of ride height, without needing to disassemble the fork tubes.
Mounting the link below the swingarm allows a longer rear suspension stroke, while maintaining a low seat height. It is 1mm longer than stock and can be used to reduce seat height by 4mm to give the rider greater control and adjustment.
The 2016 KawasakiKX450F motorcycle uses an oversized 270mm, petal-shaped front brake rotor (largest in class) from the renowned manufacturer, Braking.
The footpegs feature dual-position mounting points, with a lower position, which reduces the height from the standard position by an additional 5mm.
With 35mm of range, the multi-position handlebars feature two mounting holes, and the 180-degree offset clamps provide four individual settings to suit different sizeriders. This perfectly complements the wide range of damping settings as well as the DFI couplers and optional handheld Kawasaki AccessoryKX FI Calibration Kit, allowing the rider to find the ideal engine characteristics to suit a particular track or conditions. The system features dual injectors for the Digital Fuel Injection (DFI®), with a downstream injector for smooth response and the upstream injector for hard-hitting power. This combination allows a balance of precision movement, smooth action and firm damping to deal with small bumps or giant jumps. It also has a four-way adjustable upper triple clamp with two mounting holes for the 180-degree rotatable handlebar clamps. The location of the oil scavenger pump was also changed, swapping from the left case to the right case. The extremely smooth surfaces and revised port shape increase the intake efficiency and performance at?all RPM.
Revised intake cam timing (advanced 2-degrees) contributes to better low-RPM performance, while the camshaft is 0.5oz lighter than before. The crankshaft balancer shape was also changed – reducing its size and lightening it by 1.9oz.
These and the revise shape of the air box help to ensure clean airflow, improving engine response and reducing intake sound to meet local market requirements.
The outer part of the fuel pump was also revised, changing the flange position in order to lower the fuel tank position, contributing to the motorcycle’s overall lower center of gravity. Once the rider shifts into third, normal ignition mapping is resumed and full power returns. It is also lighter by 1 lb, while the subframe (seat rails) has thicker walls for increased strength.

The new bodywork unifies the radiator shroud and side covers for a smoother, seamless rider interface that is 1.2” slimmer at the widest point, and allows unimpaired movement around the motorcycle.
The left fork tube contains the damping assembly and the right fork tube contains the air spring.
The low friction design contributes to an extremely smooth fork action, while precise settings are possible merely by changing air pressure. The pump’s digital display offers precise air pressure setting, and its casing stores the engine’s DFI couplers for the fuel injection system, allowing better organization on practice or race days.
Dual compression adjustability from the Showa shock allows high-speed and low-speed damping rates to be set separately. It helps provide powerful stopping forces, good lever feel and consistency in all conditions.
The lower position effectively lowers the center of gravity when standing, and reduces knee angle when seated. So while the base settings on the KX450F motorcycle are based on extensive testing, including racing, the motorcycle provides a huge range of technology and adjustment to help ensure every rider can fully exploit the incredible ability of this extremely capable motocross bike. These offer the rider the choice of four bar positions, including 25mm forward, 15mm forward, standard or 10mm back. Caiman Urban ‘n Dirt are dead set on building motorcycles that thrive in this environment. The 250 didn’t get as much attention, although Kawasaki is rolling out a new handheld FI Calibration Kit that will make customization of the fuel injection easier at the track. Further updates were made to the crankshaft balancer drive gear and driven gear, resulting in a combined reduction of 1.4oz.
The rider simply connects the appropriate coupler cap to suit the track conditions and the DFI couplers immediately activate an ignition mode to match.
Overall rigidity has been improved with a new swingarm (while losing 7.8oz in the process), helping rear-wheel traction and rider feel. The radiator was reshaped in order to achieve this, creating a vee-shapeand allowing the shrouds to be slimmer.
Instead of the steel coil springs found in conventional forks, the SFF-Air TAC’s right fork tube has three chambers filled with pressurized air that act as a “spring”. The shock reservoir has a friction-reducing internal Kashima Coat for improved suspension action. Additionally, the KX250F uses an oversized 270mm petal-shape front brake rotor, giving the rider powerful but controllable braking.
Eliminating the steel coil springs reduces friction by approximately 20% and creates an extremely smooth action throughout the fork’s stroke. This race-oriented suspension offers class-leading action and adjustability on par with the Showa SFF-Air TAC fork. And these can be further tuned with the optional handheld Kawasaki KX FI Calibration Kit that is new for the 2016 Model Year. This has the added benefit of greatly reducing weight and allowing a larger damper piston to be used, providing smoother action.
The fully adjustable unit allows for precise settings to help keep the rear wheel planted and the rider out front. This device allows users to create engine maps, or use the stored maps, allowing the rider to find the best setting for their favorite tracks. New low-friction fork seals and revised valve settings for reduced damping deliver easier fork movement, matching the pitching characteristics to the lighter chassis.
They’ve been replaced by a mono conversion, using a Yamaha YZ250 shock with an upgraded spring. The front suspension has been left alone, but treated to a new set of fork gaiters to help keep muck out.
A pair of blacked-out reverse cone mufflers has been installed too.Up front are a set of tracker bars, an Acewell speedo and a smaller headlight.
The wheels were powder coated black—along with a select few other parts—but the engine cases were left raw to maintain character.

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