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Table of Contents

   Summary of Contents for Kawasaki KX450F 2016

  • Page 2 GENERAL INFORMATION Quick Reference Guide MAINTENANCE AND ADJUSTMENT This Quick Reference Guide will assist you in finding the information you’re looking for. TROUBLESHOOTING GUIDE TUNING STORAGE A Table of Contents is included after the Foreword.
  • Page 3 IMPORTANT INFORMATION • This vehicle is designed for the operator only, no passengers. • This vehicle is a competition model only and was not manufactured for use on public streets, roads or highways. • The use of this vehicle should be limited to participation in sanctioned competition events upon a closed course.
  • Page 4 Whenever you see the symbols shown below, IMPORTANT NOTICE heed their instructions! Always follow safe operat- THIS VEHICLE IS A COMPETITION MODEL ing and maintenance practices. ONLY MANUFACTURED FOR, NOR SHOULD IT BE USED ON, PUB- DANGER LIC STREETS, ROADS, OR HIGHWAYS. THE DANGER indicates a hazardous situation USE OF THIS VEHICLE SHOULD BE LIMITED which, if not avoided, will result in death or...
  • Page 5 Motorcycle Noise Emission Control Information This motorcycle is designed for closed course competition use only. It does not conform to U.S. EPA motorcycle noise standards. NOTICE Off-road motorcycling is a wonderful sport, and we hope you will enjoy it to the fullest. How- ever, if improperly conducted, this sport has the potential to cause environmental problems as well as conflicts with other people.
  • Page 6 WARNING The engine exhaust from this product con- tains chemicals known to the State of Cali- fornia to cause cancer, birth defects or other reproductive harm.
  • Page 7 Congratulations on your choosing this Kawasaki motorcycle. Your new motorcycle is the product of Kawasaki’s advanced engineering, exhaustive testing, and continuous striving for a superior lightweight, high-performance machine with superb handling and stability for racing and sporting use. Your new KX is a highly tuned competition machine for participation in racing events. As with any mechan- ical device, proper care and maintenance are important for trouble-free operation and top performance.
  • Page 8: Table Of Contents

    TABLE OF CONTENTS SPECIFICATIONS..........Rear Axle Nut ..........GENERAL INFORMATION......Drive Chain............ Location of Labels ......... Adjustable Ergonomics........Location of Parts ........... Footpeg ............102 Side Stand............. Brakes ............104 Fuel ............... Steering ............107 Fuel Requirement:........Front Suspension .......... 110 ®...
  • Page 9: Specifications

    SPECIFICATIONS SPECIFICATIONS DIMENSIONS Overall Length 2 195 mm (86.42 in.) Overall Width 820 mm (32.3 in.) Overall Height 1 290 mm (50.79 in.) Wheelbase 1 495 mm (58.86 in.) Road Clearance 345 mm (13.6 in.) Curb Mass 108.7 kg (239.7 lb) Fuel Tank Capacity 6.3 L (1.7 US gal) ENGINE...
  • Page 10 SPECIFICATIONS TRANSMISSION Transmission Type 5-speed, constant mesh, return shift Clutch Type Wet, multi disc Driving System Chain drive Gear Ratio: 1.750 (28/16) 1.412 (24/17) 1.188 (19/16) 1.000 (19/19) 0.875 (21/24) Primary Reduction Ratio 2.727 (60/22) Final Reduction Ratio 3.846 (50/13) Overall Drive Ratio 9.178 @Top gear Engine Oil:...
  • Page 11 Front Suspension Travel 310 mm (12.2 in.) Rear Wheel Travel 315 mm (12.4 in.) Front Fork Oil: Type Kawasaki Fork Oil SS19 Amount: Left Front Fork: Cylinder Unit 310 mL (10.5 US oz.) Outer Tube 345 mL (11.7 US oz.)
  • Page 12 SPECIFICATIONS BRAKES Type: Front Single disc Rear Single disc Specifications are subject to change without notice.
  • Page 13: General Information

    If any label is missing, damaged, or worn, get a replacement from your Kawasaki dealer and install it in the correct po- sition. NOTE 1.
  • Page 14 GENERAL INFORMATION 2. Brake Fluid (Rear) 3. Radiator Cap Danger 4. Rear Shock Absorber Warning...
  • Page 15 GENERAL INFORMATION 5. Front Fork Warning 6. Disclaimer of Warranty 7. Important Information 8. Noise Emission Control Information...
  • Page 16 GENERAL INFORMATION...
  • Page 17 GENERAL INFORMATION...
  • Page 18: Location Of Parts

    GENERAL INFORMATION Location of Parts 1. Clutch Lever 5. Fuel Tank Cap 2. Engine Stop Button 6. Front Brake Fluid Reservoir 3. Launch Control Mode Button 7. Front Brake Lever 4. Orange Launch Control Mode/FI Warning 8. Throttle Grip Indicator Light...
  • Page 19 GENERAL INFORMATION 1. Front Fork 8. Front Brake Caliper 2. Radiator 9. Shift Pedal 3. Fuel Tank 10. Footpeg 4. Throttle Body Assy 11. Rear Shock Absorber 5. Seat 12. Drive Chain 6. Air Cleaner Element 13. Chain Guide 7. Front Brake Disc 14.
  • Page 20 GENERAL INFORMATION 1. Muffler 7. Rear Brake Caliper ® 2. Rear Brake Fluid Reservoir 8. Uni-Trak Tie-Rod and Rocker Arm 3. Rear Shock Absorber Gas Reservoir 9. Oil Level Inspection Window 4. Kick Pedal 10. Rear Brake Pedal 5. DFI Setting Data Selection Connector 11.
  • Page 21: Side Stand

    GENERAL INFORMATION NOTE Side Stand ○ Support the motorcycle with a suitable stand to perform maintenance or adjustment procedures. To install the side stand, insert its flat end into the rear axle as shown. A. Side Stand B. Rear Axle WARNING Riding with the side stand can cause a crash resulting in injury.
  • Page 22: Fuel

    Avoid filling the tank in the rain or where heavy dust Fuel is blowing so that the fuel does not get contaminated. This Kawasaki KX has a 4-stroke engine that re- quires a gasoline. The capacity of the fuel tank is 6.3 L (1.7 US gal).
  • Page 23: Fuel Requirement

    GENERAL INFORMATION WARNING Minimum Octane Rating Method Rating Gasoline is extremely flammable and can be explosive under certain conditions. Always (RON + MON) Antiknock Index stop the engine and do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 24 When not operating your Kawasaki for 30 Gasoline/Ether Blends - The most common ether to 60 days, mix a fuel stabilizer (such as is methyl tertiary butyl ether (MTBE). You may use STA-BIL) with the gasoline in the fuel tank.
  • Page 25: Kick Pedal

    GENERAL INFORMATION Kick Pedal Starting the Engine • This motorcycle is equipped with a primary kick Shift the transmission into neutral. starting system. When the clutch lever is pulled, the WARNING motorcycle can be started with the transmission in any gear. Riding with the side stand can cause a crash resulting in injury.
  • Page 26 GENERAL INFORMATION When engine is cold When engine is already warm or restarts • • Pull out the idle adjusting screw/choke knob. Kick the engine over, leaving the throttle closed without using the idle adjusting screw/choke knob. NOTE ○ If the engine fails starting, open the throttle fully ∼...
  • Page 27: Launch Control Mode

    GENERAL INFORMATION Launch Control Mode The launch control mode can be used to adjust ig- nition timing to help riders get better starts on slip- pery terrain. The system’s effectiveness is dependent on rider skill, technique and terrain conditions. Launch Control Mode Setting •...
  • Page 28: Dfi Setting Data Selection

    GENERAL INFORMATION NOTE DFI Setting Data Selection ○ If the connector is changed while the engine is running, the DFI setting does not change. ○ Three DFI settings are available to suit various The ECU is set to the standard track condition track conditions.
  • Page 29: Shifting Gears

    GENERAL INFORMATION Shifting Gears This motorcycle is equipped with a 5-speed “return shift” transmission. The neutral is located halfway between 1st and 2nd gear. “Return shift” means that when shifting up or down, each gear must be engaged before the next higher or lower gear may be selected.
  • Page 30: Stopping The Motorcycle

    GENERAL INFORMATION Stopping the Motorcycle Stopping the Engine • For maximum deceleration, close the throttle and Shift the transmission into the neutral position. • apply both front and rear brakes. Pull in the clutch Close the throttle completely and push the engine lever as the motorcycle comes to a stop.
  • Page 31: Break-in

    GENERAL INFORMATION Stop and let the engine cool completely. Be Break-In sure to fully check the tightness of nuts and bolts, oil leakage, and any irregularities, espe- A brief break-in procedure must be carried out to cially, each cable elongation, brake play, chain obtain the proper operating clearances in the engine slack and spoke tightness.
  • Page 32: Daily Pre-ride Checks

    GENERAL INFORMATION Daily Pre-Ride Checks Check the following items each day before you ride. The time required is minimal, and habitual performance of these checks will help ensure a safe, reliable ride. If any irregularities are found during these checks, refer to the appropriate section and take the action required to return the motorcycle to a safe operating condition.
  • Page 33 GENERAL INFORMATION Properly installed Engine Sprocket ......No wear or damage Frame Tires ..........Overall condition good No wear or damage Pressure correct Air valve cap installed Spokes ........No looseness Drive Chain ......... Overall condition good Chain slack correct Oil if necessary Front and Rear Brakes ....
  • Page 34: After-race Checks

    GENERAL INFORMATION Carry out the general lubrication and make neces- After-Race Checks sary adjustments. After racing, first clean the motorcycle, then in- spect the entire motorcycle with special attention to the air cleaner, brakes, etc.
  • Page 35: Maintenance And Adjustment

    Periodic Maintenance Chart to keep the motorcycle in good running condition. †: Replace, add, adjust, clean or torque if necessary. K: Should be serviced by referring to the Service Manual or an authorized Kawasaki dealer. 1. Periodic Inspection (Engine Related Item)
  • Page 36 MAINTENANCE AND ADJUSTMENT FREQUENCY After each Every 3 Every 6 Every 12 race (or races (or races (or races (or required Page OPERATION 2.5 hours) 7.5 hours) 15 hours) 30 hours) • – Kick pedal and shift pedal - clean •...
  • Page 37 MAINTENANCE AND ADJUSTMENT 2. Periodic Inspection (Chassis Related Item) FREQUENCY After each Every 3 Every 6 Every 12 race (or races (or races (or races (or required Page OPERATION 2.5 hours) 7.5 hours) 15 hours) 30 hours) • Brake - adjust † •...
  • Page 38 MAINTENANCE AND ADJUSTMENT FREQUENCY After each Every 3 Every 6 Every 12 race (or races (or races (or races (or required Page OPERATION 2.5 hours) 7.5 hours) 15 hours) 30 hours) • – K Wheel bearing - inspect † Swingarm and UNI-TRAK linkage •...
  • Page 39 MAINTENANCE AND ADJUSTMENT 3. Periodic Replacement (Engine and Chassis Related Item) FREQUENCY After each Every 3 Every 6 Every 12 race (or 2.5 races (or 7.5 races (or 15 races (or Page OPERATION hours) hours) hours) 30 hours) • Engine oil - change •...
  • Page 40: Engine Oil

    MAINTENANCE AND ADJUSTMENT Oil Level Inspection • Engine Oil If the oil has just been changed, let the motorcycle sit a few minutes allowing the oil to settle. • In order for the engine, transmission and clutch Start the engine and run it for several minutes at to function properly, maintain the engine oil at the idle speed.
  • Page 41 MAINTENANCE AND ADJUSTMENT A. Oil Level Inspection Window A. Drain Bolt B. High Level Line C. Low Level Line WARNING D. Oil Filler Plug Engine oil is a toxic substance. Dispose of Oil and/or Oil Filter Change used oil properly. Contact your local author- ities for approved disposal methods or pos- The engine oil and/or oil filter should be changed sible recycling.
  • Page 42 MAINTENANCE AND ADJUSTMENT A. Oil Filter Cap Bolts A. Oil Filter Element B. Oil Filter Cap B. Grommet • Replace the oil filter element with a new one. NOTICE • Apply grease to the grommet. • Install the oil filter element with the grommet to- Inside-out installation stop oil flow, causing ward the engine.
  • Page 43 “Kawasaki Performance 4-Stroke Semi-Synthetic Oil*” 10W-40 or “Kawasaki Performance 4-Stroke Motorcycle Oil*” 10W-40 *Kawasaki Performance Oils and Lubricants have been specifically engineered for your vehicle. Con- sistent use of these products meets or exceeds war- A. O-ring ranty and service requirements and can help to ex- B.
  • Page 44 MAINTENANCE AND ADJUSTMENT • Tighten the oil filler plug. Type: API SG, SH, SJ, SL or SM with JASO MA, MA1 Tightening Torque or MA2 Oil Filler Plug: Viscosity: 3.5 N·m (0.36 kgf·m, 31 in·lb) SAE 10W-30, 10W-40, 10W-50 • Start the engine.
  • Page 45: Cooling System

    MAINTENANCE AND ADJUSTMENT WARNING Cooling System The cooling system is pressurized and can get extremely hot during normal operation Water Hoses and cause serious burns. To prevent burns, Check the water hoses for cracks or deterioration, do not touch the radiator when it is hot. Do and the connections for looseness in accordance not attempt to open the radiator cap when hot with the Periodic Maintenance Chart.
  • Page 46 MAINTENANCE AND ADJUSTMENT A. Radiator Cap A. Coolant Level B. Filler Neck • Check the coolant level in the radiator. • If the coolant level is low, add coolant through the coolant should come up to the bottom of the radiator filler opening to the bottom of the filler radiator filler neck.
  • Page 47 MAINTENANCE AND ADJUSTMENT • NOTICE Install the radiator cap. Coolant Change Immediately wash away any coolant that The coolant should be changed to ensure long en- spills on the frame, engine, or wheel. gine life, if necessary. • Wait for the engine to cool completely. •...
  • Page 48 MAINTENANCE AND ADJUSTMENT • Fill the radiator up to the bottom of the radiator filler neck with coolant. • Lean the motorcycle slightly until the radiator filler neck is level to the ground so that the filler neck is located uppermost in order to bleed the air accu- mulated in the radiator.
  • Page 49: Spark Plug

    MAINTENANCE AND ADJUSTMENT • Check the cooling system for leaks. Spark Plug The spark plug should be taken out periodically for inspection and regapping. Measure the gap with a wire-type thickness gauge. If incorrect, adjust the gap to the specified value by bending the outer elec- trode.
  • Page 50 MAINTENANCE AND ADJUSTMENT • the spark plug electrodes are corroded, or damaged, Remove the side cover (see Exhaust System sec- or if the insulator is cracked, replace the plug. The tion). • standard spark plug is shown in the table below. Remove the radiator shroud bolts and take off the radiator shroud on both sides.
  • Page 51 MAINTENANCE AND ADJUSTMENT A. Fuel Tank Bolt A. Cloth B. Band B. Flat Tip Screwdriver C. Joint Lock • Be sure to place a piece of cloth around the fuel hose joint. • WARNING Wipe off the dirt of the surface around the connec- tion using a cloth or a soft brush.
  • Page 52 MAINTENANCE AND ADJUSTMENT A. Turn A. Fuel Pump Lead Connector B. Joint Lock C. Fuel Hose Joint WARNING • Cover the outlet pipe and the fuel hose joint with Gasoline is extremely flammable and can be the vinyl bags to keep them clean. •...
  • Page 53 MAINTENANCE AND ADJUSTMENT • NOTICE Install the spark plug cap so that it is aligned with the line on the cylinder head cover. When removing the spark plug cap, do not • Pull up the plug cap lightly to make sure of the pull the lead.
  • Page 54 MAINTENANCE AND ADJUSTMENT A. Dampers A. Fuel Hose Joint B. Joint Lock • Check the joint lock for deformation and wear. • If the joint lock is deformed, replace the fuel hose NOTICE with a new one. • Apply engine oil to the fuel outlet pipe lightly. When installing the fuel hose joint, do not •...
  • Page 55 MAINTENANCE AND ADJUSTMENT NOTE ○ If it comes off, reinstall the fuel hose joint. • Run the fuel pump lead over the fuel hose. • Before installing the fuel tank, check that both throttle cables run over the main harness. NOTE ○...
  • Page 56 MAINTENANCE AND ADJUSTMENT A. Throttle Cables A. Radiator Shroud B. Fuel Tank B. Radiator Shroud Bolts C. Bottom of the Frame (Right Side) Tightening Torque • Install the radiator shroud. • Radiator Shroud Bolts: Tighten the radiator shroud bolts to the specified 7.0 N·m (0.71 kgf·m, 62 in·lb) torque.
  • Page 57: Air Cleaner

    MAINTENANCE AND ADJUSTMENT ○ After riding through rain or on muddy roads, the Air Cleaner element should be cleaned immediately. Element Removal and Inspection A clogged air cleaner restricts the air intake, in- • creases fuel consumption, reduces engine power, Remove the seat bolts on both sides.
  • Page 58 MAINTENANCE AND ADJUSTMENT A. Side Covers A. Wing Bolt B. Seat B. Air Cleaner Element • • Remove the wing bolt, and take out the air cleaner Check inside of the intake tract and throttle body element. assy for dirt. If dirty, clean the intake tract and throttle body assy thoroughly.
  • Page 59 MAINTENANCE AND ADJUSTMENT hardening or shrinkage). If damaged, replace the element or it will allow dirt into the throttle body assy. WARNING A clogged air cleaner may allow dirt and dust to enter the throttle body and the throttle may stick resulting in a hazardous operating con- dition.
  • Page 60 MAINTENANCE AND ADJUSTMENT WARNING Gasoline and low flash-point solvents can be flammable and/or explosive and cause severe burns. Clean the element in a well-ventilated area, and take care that there is no spark or flame anywhere near the working areas. Do not use gasoline or low flash-point solvents to clean the element.
  • Page 61 MAINTENANCE AND ADJUSTMENT A. Apply grease. A. Tab (Air Cleaner) B. Grooves (Air Cleaner) • Install the air cleaner element so that its tab faces C. Frame (Air Cleaner Housing) upward and its grooves align with the frame on the •...
  • Page 62 MAINTENANCE AND ADJUSTMENT A. Hooks A. Tabs B. Seat B. Seat C. Flange Collar D. Frame Tightening Torque • Seat Bolts: Install the tabs of the side covers into the inside 25 N·m (2.5 kgf·m, 18 ft·lb) of the seat, and tighten the bolts to the specified torque.
  • Page 63: Throttle Cable

    MAINTENANCE AND ADJUSTMENT Throttle Cable Throttle Cable Adjustment Inspect the throttle grip for smooth operation in all steering positions. Check and adjust the throttle cable in accordance with the Periodic Maintenance Chart. • Check that the throttle grip has 2 ∼ 3 mm (0.08 ∼ 0.12 in.) of play and turns smoothly.
  • Page 64: Throttle Body Assy

    MAINTENANCE AND ADJUSTMENT the idle speed. If so, the throttle cable may be im- Throttle Body Assy properly adjusted, incorrectly routed, or damaged. Be sure to correct any of these conditions before riding. Idle Speed Adjustment • Thoroughly warm up the engine. WARNING •...
  • Page 65 MAINTENANCE AND ADJUSTMENT • • Remove the fuel tank (see Spark Plug section). Disconnect the intake air temperature sensor con- • Loosen the muffler clamp bolt. nector. • Remove the muffler mounting bolts, and pull out the muffler body backward. A.
  • Page 66 MAINTENANCE AND ADJUSTMENT A. Rear Frame Mounting Bolts A. Throttle Sensor Connector B. Air Cleaner Housing B. Intake Air Pressure Sensor Connector C. Fuel Injector Connector • Disconnect the throttle sensor connector. • • Be sure to place a piece of cloth around the fuel Disconnect the intake air pressure sensor connec- hose joint.
  • Page 67 MAINTENANCE AND ADJUSTMENT A. Cloth A. Turn B. Flat Tip Screwdriver B. Joint Lock C. Joint Lock C. Fuel Hose Joint • • Turn the driver to disconnect the joint lock. Cover the delivery pipe and the fuel hose joint with •...
  • Page 68 MAINTENANCE AND ADJUSTMENT A. Throttle Body Assy Clamp Screw A. Throttle Pulley Cover Bolt B. Throttle Pulley Cover • Remove the throttle pulley cover bolt and take off • Loosen the decelerator cable bolt locknut, and the throttle pulley cover. free the tip of cable lower end.
  • Page 69 MAINTENANCE AND ADJUSTMENT • If any carbon accumulates, wipe the carbon off the throttle bore and the throttle valve, using a lint-free cloth penetrated with a high flash-point solvent. A. Decelerator Cable Bolt Locknut B. Accelerator Cable Bolt C. Tips of Throttle Cable Lower Ends D.
  • Page 70 MAINTENANCE AND ADJUSTMENT • Tightening Torque Install the throttle pulley cover and tighten its bolt to the specified torque. Accelerator Cable Bolt: 3.0 N·m (0.31 kgf·m, 27 in·lb) Tightening Torque Throttle Pulley Cover Bolt: • Install the tip of decelerator cable lower end to the 4.0 N·m (0.41 kgf·m, 35 in·lb) throttle pulley.
  • Page 71 MAINTENANCE AND ADJUSTMENT • Push the joint lock until the hose joint clicks. A. Groove B. Projection A. Fuel Hose Joint • Tighten the throttle body assy clamp screw to the B. White Paint C. Joint Lock specified torque. Tightening Torque NOTICE Throttle Body Assy Clamp Screw: 2.0 N·m (0.20 kgf·m, 18 in·lb)
  • Page 72 MAINTENANCE AND ADJUSTMENT A. Fuel Hose Joint A. Throttle Sensor Connector B. Push and Pull B. Intake Air Pressure Sensor Connector C. Fuel Injector Connector • WARNING Position the claw on the air cleaner duct clamp between the projections. Leaking fuel can cause a fire or explosion resulting in serious burns.
  • Page 73 MAINTENANCE AND ADJUSTMENT Tightening Torque Rear Frame Mounting Bolts: 35 N·m (3.6 kgf·m, 26 ft·lb) • Install the fuel tank (see Spark Plug section). • Install the muffler (see Exhaust System section). • Install the removed parts. • Open and close the throttle a few times to make sure the grip operates correctly.
  • Page 74: Clutch

    MAINTENANCE AND ADJUSTMENT • Turn the adjusting nuts so that the clutch lever free Clutch play is 8 ∼ 13 mm (0.3 ∼ 0.5 in.). Clutch Lever Adjustment Proper clutch lever free play is 8 ∼ 13 mm (0.3 ∼ 0.5 in.).
  • Page 75 MAINTENANCE AND ADJUSTMENT • NOTE Remove the clutch cover bolts. ○ After the adjustment is made, start the engine and check that the clutch does not slip and that it re- leases properly. Friction and Steel Plates Removal • Drain the engine oil (see Engine Oil section). •...
  • Page 76 MAINTENANCE AND ADJUSTMENT A. Clutch Spring Bolts A. Adjusting Washer B. Clutch Pressure Plate B. Needle Bearing C. Push Rod Holder • Remove the adjusting washer, needle bearing, D. Push Rod push rod holder and push rod. • Remove the friction and steel plates. NOTE ○...
  • Page 77 MAINTENANCE AND ADJUSTMENT • Measure the thickness of the friction plates at sev- eral points with vernier calipers. • If they have worn past the service limit, replace them with new ones. Friction Plate Thickness Measurement 2.92 ∼ 3.08 mm Standard (0.115 ∼...
  • Page 78 MAINTENANCE AND ADJUSTMENT NOTE ○ Do not use the steel plate of 2.0 mm (0.079 in.) and 1.2 mm (0.047 in.) thickness at the same time. A. Clutch Hub B, C. Friction Plates D. Steel Plates E. Clutch Pressure Plate F.
  • Page 79 MAINTENANCE AND ADJUSTMENT • Friction and Steel Plate Warp Install the spacer with the “OUTSIDE” is facing outside. Maximum 0.15 mm Standard Friction (0.0059 in.) or less Plate Service Limit 0.3 mm (0.012 in.) Maximum 0.2 mm Standard (0.008 in.) or less Steel Plate Service Limit 0.3 mm (0.012 in.)
  • Page 80 MAINTENANCE AND ADJUSTMENT A. Friction and Steel Plates A. Apply molybdenum disulfide grease. B. Push Rod C. Oil Passage Holes NOTICE • Apply molybdenum disulfide grease to the contact If dry steel plates and friction plates are in- area of the push rod holder, both surface of the stalled, apply engine oil to the surfaces of needle bearing and adjusting washer.
  • Page 81 MAINTENANCE AND ADJUSTMENT A. Apply molybdenum disulfide grease. A. Release Shaft Lever B. Push Rod B. Push forward C. Push Rod Holder C. Position Distance D. Needle Bearing D. Cable Bracket E. Adjusting Washer Position Distance • Install the clutch pressure plate and springs. •...
  • Page 82 MAINTENANCE AND ADJUSTMENT Release Shaft Lever Position and Adjusting Washer Selection Position Judg- Washers Quan- Distance ment Thickness tity 69.9 ∼ 77.7 mm 1.5 mm Standard (2.75 ∼ 3.06 in.) (0.06 in.) More than 77.7 1.0 mm Too big mm (3.06 in.) (0.04 in.) Less than 69.9 1.0 mm...
  • Page 83: Valve Clearance

    MAINTENANCE AND ADJUSTMENT • Install the clutch cover to the right engine cover Valve Clearance and tighten its bolts to the specified torque. Tightening Torque Valve and valve seat wear decreases valve clear- Clutch Cover Bolts: ance, upsetting valve timing. 12 N·m (1.2 kgf·m, 106 in·lb) NOTICE •...
  • Page 84 MAINTENANCE AND ADJUSTMENT A. Cylinder Head Cover Bolts and Washers A. Head Cover Gasket B. Cylinder Head Cover B. Spark Plug Hole Gasket • • Remove the head cover gasket and spark plug Remove the two caps from the magneto cover. hole gasket.
  • Page 85 MAINTENANCE AND ADJUSTMENT A. Timing Inspection Cap A. Top Mark B. Flywheel Nut Cap B. Grooves on Magneto Cover C. Crankshaft • Bring the piston to the Top Dead Center (TDC) of D. Crankshaft Rotation Direction its compression stroke to inspect the valve clear- •...
  • Page 86 Intake all four valves. • If the valve clearance is not within the specified NOTE range, adjust by an authorized Kawasaki dealer or ○ Record the measured valves clearance. a competent mechanic following the instructions in the Service Manual. •...
  • Page 87 MAINTENANCE AND ADJUSTMENT A. Liquid Gasket A. Head Cover Gasket B. Spark Plug Hole Gasket • Replace the head cover gasket with a new one. • • Make sure that the upper chain guide is bottomed Install the head cover gasket on the cylinder head. •...
  • Page 88 MAINTENANCE AND ADJUSTMENT Tightening Torque Cylinder Head Cover Bolts: 10 N·m (1.0 kgf·m, 89 in·lb) • Install the two caps to the magneto cover. Tightening Torque Timing Inspection Cap: 3.5 N·m (0.36 kgf·m, 31 in·lb) Flywheel Nut Cap: 3.5 N·m (0.36 kgf·m, 31 in·lb) •...
  • Page 89: Exhaust System

    MAINTENANCE AND ADJUSTMENT Exhaust System The exhaust system, in particular the muffler body, is designed to reduce exhaust noise and conduct the exhaust gases away from the rider while minimizing power loss. If carbon has built up inside the muffler body, exhaust efficiency is reduced, causing engine performance to drop.
  • Page 90 MAINTENANCE AND ADJUSTMENT A. Hooks A. Muffler Cover Bolts B. Side Cover B. Muffler Mounting Bolt • • Remove the muffler cover bolts. Remove the muffler cover with the plastic mallet. • Remove the muffler mounting bolt.
  • Page 91 MAINTENANCE AND ADJUSTMENT A. Plastic Mallet A. Silencer Wool B. Muffler Cover B. Muffler Body C. Muffler Cover • Remove the silencer wool. • Remove the liquid gasket attaching on the muffler cover and muffler body. • Using a high flash-point solvent, clean off any oil or dirt that may be on the liquid gasket coating area.
  • Page 92 MAINTENANCE AND ADJUSTMENT A. Muffler Body A. Muffler Cover B. Liquid Gasket B. Muffler Body C. Muffler Cover Bolts • Replace the silencer wool with a new one. • Arrange the shape of the silencer wool and install Tightening Torque the muffler cover to the muffler body.
  • Page 93 MAINTENANCE AND ADJUSTMENT A. Muffler Mounting Bolt (Front) A. Side Cover B. Muffler Mounting Bolt (Rear) B. Radiator Shroud C. Muffler Clamp Bolt C. Ribs D. Hooks Tightening Torque • Tighten the seat bolt, radiator shroud bolt and side Muffler Mounting Bolts: cover bolt to the specified torque.
  • Page 94: Rear Axle Nut

    MAINTENANCE AND ADJUSTMENT Rear Axle Nut • Visually inspect the rear axle nut for deformation or damage at the friction ring and caulking. If it is deformed or damaged, replace the axle nut with a new one. A. Seat Bolt B.
  • Page 95: Drive Chain

    MAINTENANCE AND ADJUSTMENT Drive Chain For safety and to prevent excessive wear, the drive chain must be checked, adjusted, and lubricated be- fore riding. If the chain becomes badly worn or mal- adjusted - either too loose or too tight - it could jump off the sprockets or break.
  • Page 96 MAINTENANCE AND ADJUSTMENT Drive Chain Slack WARNING 52 ∼ 58 mm (2.0 ∼ 2.3 in.) Misalignment of the wheel will result in ab- normal wear, and may result in an unsafe riding condition. Align the rear wheel using the marks on the swingarm or measuring the distance between the center of the axle and swingarm pivot.
  • Page 97 MAINTENANCE AND ADJUSTMENT NOTE ○ When riding in wet and muddy conditions, mud sticks to the chain and sprockets, resulting in an overly tight chain, which can cause it to break. To prevent this, adjust the chain slack (measured ∼ between the chain and the swingarm) to 62 ∼...
  • Page 98 MAINTENANCE AND ADJUSTMENT A. Master Link Clip A. Chain Guide B. Direction of Chain Rotation Chain Slipper Wear Inspection • Chain Guide Wear Inspection Visually inspect the upper and lower of the chain • Visually inspect the drive chain guide and replace slipper on the swingarm and replace them if worn it if excessively worn or damaged.
  • Page 99 MAINTENANCE AND ADJUSTMENT Sprocket Teeth Wear A. Upper and Lower of the Chain Slipper B. Swingarm A. Good Teeth B. Worn Teeth Sprocket Wear Inspection C. Damaged Teeth • Visually inspect the sprocket teeth and replace the sprocket if its teeth are worn or damaged. NOTE ○...
  • Page 100: Adjustable Ergonomics

    MAINTENANCE AND ADJUSTMENT Adjustable Ergonomics To suit various riding positions, the handlebar holder position can be changed and the handlebar can be adjusted by turning the handlebar holders around (180°). The footpeg position can also be changed to suit the rider’s preference. Handlebar Position Adjustment •...
  • Page 101 MAINTENANCE AND ADJUSTMENT A. Handlebar Holder A. Handlebar Holder Nuts B. Handlebar Clamp Bolts B. Washers C. Handlebar Clamps C. Handlebar Holder D. Handlebars • Select the handlebar position and install the upper • Remove the handlebar holder nuts, washers and and lower dampers into the holes of the steering handlebar holders.
  • Page 102 MAINTENANCE AND ADJUSTMENT NOTE should be equal marks showing on each side of ○ the clamps. Install the round washers so that the round part fits • Tighten the front and rear handlebar clamp bolts under the dampers. equally. If the handlebar clamps are correctly in- •...
  • Page 103: Footpeg

    MAINTENANCE AND ADJUSTMENT • Do not disassemble the supporting bar on the han- Footpeg dlebars. • Check the front brake for the proper brake effect, or no brake drag. The right and left footpegs can be mounted onto • Check the clutch lever and throttle for proper op- one of two positions.
  • Page 104 MAINTENANCE AND ADJUSTMENT • Install the washer and new cotter pin. • Bend the longer end of the cotter pin. A. Footpeg Bracket Bolts B. Footpeg Bracket • Apply a non-permanent locking agent to the A. Pivot Pin bracket bolts. B.
  • Page 105: Brakes

    Have the brake checked immedi- the rider’s preference. • ately by an authorized Kawasaki dealer. To adjust the brake lever position, slide the front brake lever dust cover back, and loosen the lock- nut, and turn the adjuster to either side with a Disc Brake Fluid wrench.
  • Page 106 MAINTENANCE AND ADJUSTMENT NOTICE Do not spill brake fluid onto any painted sur- face. Do not use fluid from a container that has been left open or that has been unsealed for a long time. Check for fluid leakage around the brake sys- tem fittings.
  • Page 107 A. Front Brake Reservoir B. Upper Level Line than 1 mm (0.04 in.), have both pads in the caliper replaced as a set. Pad replacement should be done by an authorized Kawasaki dealer. A. Rear Brake Reservoir B. Upper Level Line...
  • Page 108: Steering

    MAINTENANCE AND ADJUSTMENT Usable Brake Pad Range Steering The steering should always be kept adjusted so that the handlebars will turn freely but not have ex- cessive play. Steering Inspection • To check the steering adjustment, raise the front wheel off the ground using a jack (special tool: 57001-1238) and attachment (special tool: 57001 -1608).
  • Page 109 MAINTENANCE AND ADJUSTMENT A. Push and Rock A. Clamp B. Bolt C. Projections Steering Adjustment • D. Number Plate Raise the front wheel off the ground using a jack • (special tool: 57001-1238) and attachment (spe- Remove the handlebars (see Handlebar section). •...
  • Page 110 MAINTENANCE AND ADJUSTMENT A. Front Fork Clamp Bolts (Upper) A. Steering Stem Nut B. Steering Stem Head Nut B. Stem Nut Wrench (Special Tool: 57001-1100) C. Steering Stem Head • Install the steering stem head to the original posi- • Turn the steering stem nut with a stem nut wrench tion.
  • Page 111: Front Suspension

    Visually inspect the front fork for oil leakage, scor- Number Plate Bolt: ing or scratches on the outer surface of the inner 8.0 N·m (0.82 kgf·m, 71 in·lb) tube. • If necessary, repair or replace by an authorized Kawasaki dealer.
  • Page 112 MAINTENANCE AND ADJUSTMENT Front Fork Adjustment Any of the following front fork adjustments can be made to tune the front suspension to the rider’s weight and the condition of the track. Basically, there are five adjustments you can make to the front fork. •...
  • Page 113 MAINTENANCE AND ADJUSTMENT Standard Setting fully seated position (adjuster turned fully clockwise) is the hardest setting. Turning the adjuster 9 clicks 1 200 kPa (12.24 kgf/cm², 174 Inner Chamber counterclockwise from the fully seated position is psi) the standard setting, turning it counterclockwise 22 100 kPa (1.02 kgf/cm², 14.5 clicks (depending on the model) is the softest set- Outer Chamber...
  • Page 114 MAINTENANCE AND ADJUSTMENT Air Pressure Adjustment (Right Front Fork) NOTE ○ Before riding, adjust the air pressure to the specific Do not adjust the air pressure in the wrong order. ○ value. Do not use the side stand during air pressure ad- •...
  • Page 115 Even if the air pressure of the front fork is ad- justed, the performance of the front fork does not change, have the front fork checked by an autho- rized Kawasaki dealer. Rebound Damping Adjustment (Left Fork Only) • A. Rebound Damping Adjuster Clean the bottom of the left fork tube.
  • Page 116 MAINTENANCE AND ADJUSTMENT Compression Damping Adjustment (Left Fork Rebound Damping Adjuster Settings Only) • To adjust the compression damping, turn the ad- juster on the left front fork cylinder base valve with a flat tip screwdriver. Adjust the compression damping to suit your preference and riding condi- tions.
  • Page 117 MAINTENANCE AND ADJUSTMENT NOTICE Compression Damping Adjuster Settings Be careful not to scratch the inner tube and not to damage the dust seal. Avoid scratching or damaging the inner tube or the dust seal. Use a mild detergent and sponge out dirt with plenty of water. •...
  • Page 118 MAINTENANCE AND ADJUSTMENT NOTICE proper position, if the brake lever is squeezed ac- cidentally. Do not lay the wheel on the ground with the • Remove the brake hose clamps and both fork pro- disc facing down. This can damage or warp tectors.
  • Page 119 MAINTENANCE AND ADJUSTMENT NOTE ○ Do not remove the cylinder unit. A. Front Fork Clamp Bolts (Upper) NOTE ○ Set the rebound and compression damping to the A. Cylinder Unit B. Top Plug Wrench, 50 mm (Special Tool: softest settings before disassembly to minimize 57001-1645) damping forces that can hinder disassembly.
  • Page 120 MAINTENANCE AND ADJUSTMENT A. Front Fork Clamp Bolts (Lower) A. Pull down by twisting. B. Front Fork • Remove the front fork by pulling down while twist- ing it. Left Front Fork • Using the top plug wrench, 50 mm (special tool: 57001-1645), remove the cylinder unit from the outer tube and slowly slide down the outer tube.
  • Page 121 MAINTENANCE AND ADJUSTMENT A. Top Plug Wrench, 50 mm (Special Tool: A. Fork Oil 57001-1645) • Temporarily install the cylinder unit to the outer B. Cylinder Unit tube using the top plug wrench, 50 mm (special C. Outer Tube tool: 57001-1645). D.
  • Page 122 MAINTENANCE AND ADJUSTMENT • Loosen the adjuster assembly completely. NOTE ○ When removing the adjuster assembly, do not force to loosen it at once using an impact wrench. A. Cylinder Unit B. Outer Tube C. Top Plug Wrench, 50 mm (Special Tool: 57001-1645) •...
  • Page 123 MAINTENANCE AND ADJUSTMENT • Remove the push rod. A. Locknut B. Wrench A. Push Rod C. Adjuster Assembly • Remove the fork leg from the vise. • NOTICE Remove the cylinder unit with the top plug wrench, 50 mm (special tool: 57001-1645). Removing the locknut and pushing the pis- ton rod thread into the cylinder unit will dam- age the oil seal.
  • Page 124 MAINTENANCE AND ADJUSTMENT A. Cylinder Unit A. Cylinder Unit B. Outer Tube B. Outer Tube C. Top Plug Wrench, 50 mm (Special Tool: • Hold the front fork at the inverted position for more 57001-1645) than 20 minutes to allow the fork oil to fully drain. •...
  • Page 125 MAINTENANCE AND ADJUSTMENT • Holding the top plug wrench, 50 mm (special tool: 57001-1645) with a vise, loosen the base valve as- sembly on the cylinder unit with a top plug wrench, 36 mm (special tool: 57001-1810). A. Base Valve Assembly B.
  • Page 126 MAINTENANCE AND ADJUSTMENT A. Fork Oil A. Threads B. Cylinder Unit • With the piston rod fully stretched, pour 310 mL (10.5 US oz.) of fork oil. NOTICE NOTE Disassembling the cylinder unit can cause ○ Plug the oil hole on the cylinder unit with finger. internal damage.
  • Page 127 MAINTENANCE AND ADJUSTMENT A. Fork Oil A. Pump B. Cylinder Unit B. Piston Rod C. Oil Holes • With the piston rod fully stretched, check the oil level in the cylinder unit. Suspension Oil Oil Level SS-19 (1 L): P/No. 44091-0009 132 ∼...
  • Page 128 MAINTENANCE AND ADJUSTMENT A. 132 ∼ 140 mm (5.20 ∼ 5.51 in.) A. O-rings B. Oil Level B. Bushings • • Replace the O-rings on the base valve assembly With the piston rod appear about 20 mm (0.79 with new ones. in.) from fully compressed, gently install the base •...
  • Page 129 MAINTENANCE AND ADJUSTMENT A. Piston Rod A. Top Plug Wrench, 50 mm (Special Tool: B. Base Valve Assembly 57001-1645) C. Cylinder Unit B. Base Valve Assembly D. Oil Holes C. Cylinder Unit D. Top Plug Wrench, 36 mm (Special Tool: •...
  • Page 130 MAINTENANCE AND ADJUSTMENT • NOTE Hold the cylinder unit at the upright position and ○ slowly pump the piston rod several times about Set the compression damping force setting to the 100 mm (3.94 in.). softest. Check the piston rod sliding surface for •...
  • Page 131 MAINTENANCE AND ADJUSTMENT • Wipe the oil off completely from the cylinder unit. • Compress the piston rod to 200 ∼ 250 mm (7.87 ∼ 9.84 in.) and hold the cylinder unit upright position for 10 minutes. A. Oil Hole •...
  • Page 132 MAINTENANCE AND ADJUSTMENT A. Locknut A. Cylinder Unit B. 10 ∼ 12 mm (0.39 ∼ 0.47 in.) B. Outer Tube • • Completely wipe off the fork oil from the cylinder Temporarily tighten the cylinder unit fully with unit. the top plug wrench, 50 mm (special tool: •...
  • Page 133 MAINTENANCE AND ADJUSTMENT • Insert the push rod into the piston rod. • Replace the O-ring on the adjuster assembly with a new one and apply teflon grease to the O-ring. • Install the adjuster assembly to the push rod. A.
  • Page 134 MAINTENANCE AND ADJUSTMENT NOTICE When tightening the locknut, the threads of the axle holder do not touch the piston rod. If the piston rod is scratched, it is possible to the damage in the cylinder unit. A. Adjuster Assembly B. Locknut C.
  • Page 135 MAINTENANCE AND ADJUSTMENT A. Axle Holder Part A. Top Plug Wrench, 50 mm (Special Tool: B. Adjuster Assembly 57001-1645) B. Cylinder Unit • Using the top plug wrench, 50 mm (special tool: C. Outer Tube 57001-1645), remove the cylinder unit from the D.
  • Page 136 MAINTENANCE AND ADJUSTMENT • Raise the outer tube and temporarily install the left front fork cylinder unit to the outer tube using the top plug wrench, 50 mm (special tool: 57001 -1645). A. Outer Tube B. Fork Oil Suspension Oil SS-19 (1 L): P/No.
  • Page 137 MAINTENANCE AND ADJUSTMENT • Set the front fork upright state. • Bleed air by pushing down the air valves in the or- der of balance chamber, outer chamber and inner chamber. NOTE ○ First, bleed air in a balance chamber. ○...
  • Page 138 MAINTENANCE AND ADJUSTMENT A. Air Valve (Outer) A. Chamber Cap B. Air Valve (Inner) B. Circlip • • Press the chamber cap and remove the circlip. Cover the chamber cap with the clean cloth, and then hold the clean cloth to the outer tube with the tape.
  • Page 139 MAINTENANCE AND ADJUSTMENT A. Clean Cloth A. Fork Oil B. Chamber Cap B. Oil Hole • • Place the a drain pan under the front fork and drain Using the top plug wrench, 50 mm (special tool: fork oil so that the oil hole positions upward for the 57001-1645), remove the cylinder unit from the oil spout from the oil hole.
  • Page 140 MAINTENANCE AND ADJUSTMENT A. Top Plug Wrench, 50 mm (Special Tool: A. Fork Oil 57001-1645) • Temporarily install the cylinder unit to the outer B. Cylinder Unit tube using the top plug wrench, 50 mm (special C. Outer Tube tool: 57001-1645). D.
  • Page 141 MAINTENANCE AND ADJUSTMENT NOTE ○ Protect the axle holder with a heavy cloth when using a vise. A. Top Plug Wrench, 50 mm (Special Tool: 57001-1645) B. Cylinder Unit C. Outer Tube • Hold the axle holder with a vise, remove the plug A.
  • Page 142 MAINTENANCE AND ADJUSTMENT NOTE ○ When loosening the sealing bolt, do not force to loosen it at once using an impact wrench. A. Fork Oil • Hold the axle holder with a vise. WARNING A. Sealing Bolt Clamping the axle holder too tight can dam- •...
  • Page 143 MAINTENANCE AND ADJUSTMENT A. Locknut A. Top Plug Wrench, 50 mm (Special Tool: B. Wrench 57001-1645) C. Sealing Bolt B. Cylinder Unit C. Outer Tube • NOTICE Remove the cylinder unit from the outer tube. Removing the locknut and pushing the pis- NOTICE ton rod thread into the cylinder unit will dam- Do not touch the piston rod to the outer tube.
  • Page 144 MAINTENANCE AND ADJUSTMENT A. Cylinder Unit A. Fork Oil B. Outer Tube • Hold the front fork at the inverted position for more than 20 minutes to allow the fork oil to fully drain. NOTICE Disassembling the cylinder unit can cause internal damage.
  • Page 145 MAINTENANCE AND ADJUSTMENT • With the piston rod fully stretched, pour the fork oil of 50 mL (1.69 US oz.). A. Chamber Cap B. O-rings C. Cylinder Unit A. Fork Oil • Replace the circlip with a new one and install the B.
  • Page 146 MAINTENANCE AND ADJUSTMENT A. Circlip A. Air Pump B. Chamber Cap B. Air Valve (Inner) • With the piston rod fully stretched, inject the air of Inner Chamber Air Pressure specified pressure to the inner chamber by using Air Pressure 1 200 kPa (12.24 kgf/cm², 174 the suitable air pump.
  • Page 147 MAINTENANCE AND ADJUSTMENT A. Length A. Cylinder Unit B. Outer Tube • Insert the cylinder unit to the outer tube. • Temporarily install the cylinder unit to the outer NOTICE tube using the top plug wrench, 50 mm (special tool: 57001-1645 ). Do not touch the piston rod to the outer tube.
  • Page 148 MAINTENANCE AND ADJUSTMENT • Replace the O-rings on the sealing bolt and piston rod with new ones and apply teflon grease to the O-rings. A. Top Plug Wrench, 50 mm (Special Tool: 57001-1645) B. Cylinder Unit C. Outer Tube A. O-rings •...
  • Page 149 MAINTENANCE AND ADJUSTMENT A. Locknut A. Locknut B. Sealing Bolt B. Wrench C. More than 1.5 mm (0.059 in.) C. Sealing Bolt • • Turn the locknut counterclockwise until it contacts Apply a non-permanent locking agent to the with the sealing bolt. threads of the sealing bolt and tighten the sealing •...
  • Page 150 MAINTENANCE AND ADJUSTMENT A. Sealing Bolt A. Top Plug Wrench, 50 mm (Special Tool: 57001-1645) • Remove the cylinder unit with the top plug wrench, B. Cylinder Unit 50 mm (special tool: 57001-1645). C. Outer Tube • Pour the fork oil of 270 mL (9.13 US oz.) into the outer tube.
  • Page 151 MAINTENANCE AND ADJUSTMENT A. Fork Oil A. Top Plug Wrench, 50 mm (Special Tool: B. Outer Tube 57001-1645) B. Cylinder Unit Suspension Oil C. Outer Tube • SS-19 (1 L): P/No. 44091-0009 Inject the air of specified pressure to the outer chamber by using a suitable air pump.
  • Page 152 MAINTENANCE AND ADJUSTMENT A. Air Pump A. Fork Oil B. Air Valve (Outer) B. Balance Chamber Outer Chamber Air Pressure Suspension Oil Air Pressure 100 kPa (1.02 kgf/cm², 14.5 SS-19 (1 L): P/No. 44091-0009 (Standard Setting) psi) • Hold the axle holder with a vise. 0 ∼...
  • Page 153 MAINTENANCE AND ADJUSTMENT • Replace the O-ring on the plug bolt with a new one and apply teflon grease to the O-ring. A. Plug Bolt B. Balance Chamber • Inject the air of specified pressure to the balance A. O-ring chamber by using the suitable air pump.
  • Page 154 MAINTENANCE AND ADJUSTMENT Tightening Torque Front Fork Clamp Bolts (Lower): 23 N·m (2.3 kgf·m, 17 ft·lb) NOTE ○ Tighten the two clamp bolts alternately two times to ensure even tightening torque. • Tighten the front fork top plug using the top plug wrench, 50 mm (special tool: 57001-1645) to the specified torque.
  • Page 155 MAINTENANCE AND ADJUSTMENT Tightening Torque Cylinder Unit: 76 N·m (7.7 kgf·m, 56 ft·lb) NOTE ○ The cylinder unit torque is specified to 76 N·m (7.7 kgf·m, 56 ft·lb) however, when you use the top plug wrench, 50 mm (special tool: 57001-1645), reduce the torque to 90% of the specified value [67 N·m (6.8 kgf·m, 49 ft·lb)] due to the distance between the center of the square hole, where the...
  • Page 156 MAINTENANCE AND ADJUSTMENT Tightening Torque Brake Caliper Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) • Install the fork protector and brake hose clamp, and tighten their bolts to specified torque. Tightening Torque Fork Protector Bolts 4.0 N·m (0.41 kgf·m, 35 in·lb) Brake Hose Clamp Bolts 7.0 N·m (0.71 kgf·m, 62 in·lb) •...
  • Page 157 MAINTENANCE AND ADJUSTMENT • Tightening Torque Before tightening the clamp bolts on the right fork leg, pump the forks up and down 4 or 5 times to Left Front Axle Clamp Bolts: allow the right fork leg to find a neutral position on 23 N·m (2.3 kgf·m, 17 ft·lb) the front axle.
  • Page 158 MAINTENANCE AND ADJUSTMENT NOTICE NOTE ○ Tighten the two clamp bolts alternately two times The right and left fork tubes must be adjusted to ensure even tightening torque. evenly. • Check the front brake for good braking power and no brake drag. WARNING After servicing, it takes several applications of the brake lever before the brake pads con-...
  • Page 159: Rear Suspension (uni-trak ® )

    Visually inspect the rear shock absorber for oil leakage. A. Rebound Damping Adjuster • If necessary, repair or replace by an authorized If the damping feels too soft or too stiff, adjust it in Kawasaki dealer. accordance with the following table.
  • Page 160 MAINTENANCE AND ADJUSTMENT Rebound Damping Adjuster Settings *: Counterclockwise from the fully seated position NOTICE Do not force the rebound damping force ad- juster beyond the fully seated position, or the adjusting mechanism may be damaged. NOTE ○ Adjustment of the rebound damping adjuster for the rear suspension will slightly affect the com- pression damping force.
  • Page 161 MAINTENANCE AND ADJUSTMENT High Speed Compression Damping Adjuster Settings A. Compression Damping Adjuster for High Speed B. Compression Damping Adjuster for Low Speed If the damping feels too soft or too stiff, adjust it in A. Seated Position (Adjuster Turned Fully accordance with the following table.
  • Page 162 MAINTENANCE AND ADJUSTMENT Low Speed Compression Damping Adjuster *: Counterclockwise from the fully seated position Settings NOTICE Do not force the compression damping force adjuster beyond the fully seated position, or the adjusting mechanism may be damaged. NOTE ○ Adjustment of the compression damping adjuster for the rear suspension will slightly affect the re- bound damping force.
  • Page 163 MAINTENANCE AND ADJUSTMENT A. Spring Preload Adjusting Nut A. Hook Wrench (Special Tool: 57001-1539) B. Locknut B. Spring Preload Adjusting Nut C. Hook Wrenches (Special Tools: 57001-1101, • The standard adjusting nut position from the cen- 1539) ter of the upper rear shock absorber pivot point is •...
  • Page 164 Always wear eye and face protection when working on the rear shock absorber. Removal and installation of the rear shock absorber spring should be performed by an authorized Kawasaki dealer. A. Adjusting Nut Position B. Center of Upper Rear Shock Absorber Pivot C. Spring End...
  • Page 165: Wheels

    MAINTENANCE AND ADJUSTMENT rim to warp, the nipples and spokes to fatigue more Wheels quickly, and the spokes to break. Tire Air Pressure Tire air pressure affects traction, handling, and tire life. Adjust the tire air pressure to suit track condi- tions and rider preference, but keep it close within the recommended range.
  • Page 166 MAINTENANCE AND ADJUSTMENT NOTE ○ The welding spot of the rim may show exces- sive runout. Disregard this when measuring rim runout. Rim Runout A. Bead Protector Nut Rim Runout Set up a dial gauge on the side of the rim and rotate the wheel to measure its axial runout.
  • Page 167: Hoses Inspection

    MAINTENANCE AND ADJUSTMENT Hoses Inspection Check the brake and fuel hoses for cracks or de- terioration, and the connections for looseness in ac- cordance with the Periodic Maintenance Chart. • Inspect the brake hose and fittings for deteriora- tion, cracks and signs of leakage by bending or twisting the hoses.
  • Page 168: Tightening Torques Of Nuts And Bolts

    MAINTENANCE AND ADJUSTMENT Tightening Torques of Nuts and Bolts Location of nuts and bolts Before the first ride of each day of operation, check the tightness of the nuts and bolts shown below. Check also that all cotter pins are in place and in good condition. 1.
  • Page 169 MAINTENANCE AND ADJUSTMENT 1. Steering Stem Head Nut 6. Rear Brake Disc Mounting Bolts 2. Front Master Cylinder Clamp Bolts 7. Rear Axle Nut 3. Steering Stem Nut 8. Rocker Arm Pivot Nut 4. Handlebar Holder Nuts 9. Tie-Rod Mounting Nuts 5.
  • Page 170 MAINTENANCE AND ADJUSTMENT Torque table Tighten all nuts and bolts to the proper torque using an accurate torque wrench. An insufficiently tightened nut or bolt may become damaged or fall out, possibly resulting in damage to the motorcycle and injury to the rider.
  • Page 171 MAINTENANCE AND ADJUSTMENT Fastener N·m kgf·m ft·lb Remarks Handlebar Holder Nuts Steering Stem Head Nut 10.2 73.8 Steering Stem Nut 0.51 44 in·lb Rear Frame Mounting Bolt AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease.
  • Page 172: Cleaning Your Motorcycle

    Avoid all harsh chemicals, solvents, detergents, and household cleaning products such as ammo- General Precautions nia-based window cleaners. Frequent and proper care of your Kawasaki mo- • Gasoline, brake fluid, and coolant will damage the torcycle will enhance its appearance, optimize over- finish of painted and plastic surfaces: wash them all performance, and extend its useful life.
  • Page 173 The semi-gloss finish effect may be lost when it is Chrome and Aluminum excessively rubbed. Chrome and uncoated aluminum parts can be • If any doubt, consult an authorized Kawasaki treated with a chrome/aluminum polish. Coated dealer. aluminum should be washed with a mild neutral de- Painted Surfaces tergent and finished with a spray polish.
  • Page 174: Lubrication

    MAINTENANCE AND ADJUSTMENT Leather, Vinyl, and Rubber Lubrication If your motorcycle has leather accessories, special care must be taken. Use a leather cleaner/treatment to clean and care for leather accessories. Washing Lubricate the areas shown in the illustrations of leather parts with detergent and water will damage this section with either motor oil or regular grease, them, shortening their life.
  • Page 175 MAINTENANCE AND ADJUSTMENT • • Rear Brake Pedal Shift Pedal • Rear Master Cylinder Joint Pin • Kick Pedal • Footpeg...
  • Page 176 MAINTENANCE AND ADJUSTMENT Apply an aerosol cable lubricant with a pressure Apply grease to the following points: • lubricator on all cables: Clutch Inner Cable Upper End • • Clutch Cable Throttle Inner Cable Upper End • Throttle Cable Cable Lubrication A.
  • Page 177: Dfi Self-diagnosis

    MAINTENANCE AND ADJUSTMENT Drive Chain Lubrication DFI Self-Diagnosis Lubricate the drive chain after riding through rain or on wet track, or any time that the chain appears dry with a high quality lubricant for drive chains. This motorcycle equips the DFI trouble self •...
  • Page 178 MAINTENANCE AND ADJUSTMENT A. Orange Launch Control Mode/FI Warning A. Capacitor Lead Connector Indicator Light • Connect the power supply harness (optional part: 26011-0246) to the capacitor lead connector of the Self-diagnosis Procedures • main harness. Disconnect the capacitor lead connector. •...
  • Page 179 MAINTENANCE AND ADJUSTMENT • Remove the number plate (see Steering section). • Disconnect the self-diagnosis connector (Y lead). A. Power Supply Harness (Optional Part: 26011-0246) B. Capacitor Lead Connector A. Self-diagnosis Connector (Y Lead) C. 12 V Battery • To enter the self-diagnosis dealer mode, ground NOTE the self-diagnosis terminal for more than 2 sec- ○...
  • Page 180 MAINTENANCE AND ADJUSTMENT A. Orange Launch Control Mode/FI Warning Indicator Light B. Self-diagnosis Terminal...
  • Page 181 MAINTENANCE AND ADJUSTMENT How to Read Service Codes • Service codes are shown by a series of long and short blinks of the orange FI warning indicator light as shown below. • Read 10th digit and unit digit as the orange FI warning indicator light blinks. •...
  • Page 182 MAINTENANCE AND ADJUSTMENT NOTE ○ Even if the battery or the ECU is disconnected, or the problem is solved, all service codes remain in the ECU. Service Code Table Service Orange FI Warning Indicator Light Problems Code Throttle sensor malfunction, wiring open or short Intake air pressure sensor malfunction, wiring open or short Intake air temperature sensor malfunction, wiring open...
  • Page 183 MAINTENANCE AND ADJUSTMENT Service Orange FI Warning Indicator Light Problems Code Fuel pump malfunction, wiring open or short Ignition coil malfunction, wiring open or short NOTE ○ The ECU may be involved in these problems. If all the parts and circuits checked out good, be sure to check the ECU for ground and power supply.
  • Page 184: Troubleshooting Guide

    TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE NOTE Spark missing or weak: • ○ Spark plug dirty, broken, or gap improperly ad- This troubleshooting guide is not exhaustive and justed does not give every possible cause for each prob- • Spark plug cap or high-tension wiring defective lem listed.
  • Page 185 TROUBLESHOOTING GUIDE • • Cylinder head warped Valve not seating properly (valve bent, worn, or • Cylinder gasket damaged carbon accumulation on the seating surface) • • Decompression trouble Piston ring worn, weak, broken, or sticking • Piston ring side clearance excessive Poor low-speed performance - •...
  • Page 186 TROUBLESHOOTING GUIDE • Fuel/air mixture incorrect: Engine oil level too high • • Air cleaner element clogged, poorly sealed, or not Engine oil viscosity too high • installed Crankshaft bearing worn or damaged • • Fuel contaminated with water or foreign matter Drive chain trouble •...
  • Page 187 TROUBLESHOOTING GUIDE • Lubrication inadequate: Clutch hub spline damaged • Engine oil level too low Gear shifting faulty - • Engine oil quality poor or type incorrect Transmission does not go into gear; shift pedal Coolant inadequate: does not return: •...
  • Page 188 TROUBLESHOOTING GUIDE • Fuel quality poor or type incorrect Abnormal drive train noise - • Spark plug type incorrect Clutch noise: • Engine overheating • Clutch housing/friction plate clearance excessive • ECU defective • Clutch housing gear excessive • Metal chip jammed in clutch housing gear teeth Piston slap: •...
  • Page 189 TROUBLESHOOTING GUIDE • Pad surface glazed Handlebar shakes or vibrates excessively: • • Brake disc warped Tire worn • • Brake caliper defective Swingarm sleeve or needle bearing damaged • • Brake cylinder damaged Rim warped or out of balance •...
  • Page 190 TROUBLESHOOTING GUIDE • • Front fork air pressure weak Brake fluid leaking • • Rear shock absorber spring weak Brake disc warped • • Rear shock absorber leaking oil or gas Brake pads contaminated • • Rear shock absorber improperly adjusted Brake fluid deteriorated •...
  • Page 191: Tuning

    TUNING TUNING • The front and rear suspension should always be Suspension balanced; when the one is changed, the other one might need to be changed similarly. • When evaluating suspension performance, the Introduction rider must make every effort to ride consistently No area of machine adjustment is more critical and to recognize the effects of his input.
  • Page 192 TUNING • Troubleshooting Improper Settings When the oil amount is lowered, the air spring be- comes less progressive, and the front fork action Listed below are some symptoms of improper sus- does not feel as “hard” in the later stage of fork pension settings and the most likely means of cor- travel.
  • Page 193 TUNING • Fork oil deteriorated or less, or if his riding experience and ability are • Rebound and/or compression damping improperly much above or below the intermediate level, it is adjusted. likely that a few basic suspension adjustments will be necessary. Rear Shock Absorber Improper Adjustment Basic Readjustment of the Suspension Symptoms -...
  • Page 194 TUNING • Suspension Tuning According the Type of Hold the motorcycle upright (remove the side Course stand.). • While standing next to the machine, lightly pull the Lower the front end slightly brake lever, place one foot on the footpeg closest (Increase the amount of fork tube to you, and push down hard.
  • Page 195 TUNING Front and Rear Suspension Troubleshooting NOTE ○ Lighter or less experienced riders may lower the Front Surges Downhill During air pressure. Acceleration Out of Corner - The front suspension is too soft. • Front End Does Not Respond to Small Bumps in Increase the compression damping or rebound Sweeping Turns - damping.
  • Page 196 TUNING NOTE Front and Rear Ends Bottom Off After a ○ High-speed Jump (harsh bottoming occurs The rear shock absorber behavior on this machine once or twice per lap) - may mislead some riders. ○ The front suspension is too soft. The rear shock absorber bottoms (due to full •...
  • Page 197: Gearing

    TUNING • Since it is difficult to set the machine so it is best Gearing suited for all portions of the circuit, determine which circuit portions will have the greatest ef- fect on lap time, and tune the machine to these Selection of the Secondary Reduction Ratio portions.
  • Page 198: Special Care According To Track Conditions

    TUNING Take care not to overheat the engine in these con- Special Care According to Track ditions. The engine also works very hard when Conditions riding in deep sand. • In muddy or sandy conditions, increase chain • slack as the chain and sprockets will be packed In dry, dusty conditions (such a volcanic ash or fine powdery dust), special care must be given to with mud or sand, which reduces chain slack.
  • Page 199: Optional Parts

    OPTIONAL PARTS OPTIONAL PARTS Rear Sprocket Suspension Spring (N/mm) K = 49 K = 51 Aluminum 50T (Standard) Rear K = 52 (Standard) K = 53 K = 55 Aluminum Nipple Wheel (Without Tire) Front 21 × 1.60 Steel Rear 19 ×...
  • Page 200: Pre-race Checks And After-race Maintenance

    PRE-RACE CHECKS AND AFTER-RACE MAINTENANCE PRE-RACE CHECKS AND AFTER-RACE MAINTENANCE Pre-Race Checks - Maintenance After the First Race - • • Front axle nut, or axle clamp bolt torque Clean the air cleaner element. • • Front fork clamp bolt torque Adjust the drive chain slack.
  • Page 201 PRE-RACE CHECKS AND AFTER-RACE MAINTENANCE • • Apply grease to swingarm and rear suspension Muffler, and related parts • pivots. Chain case • • Inspect the drive chain and rear sprocket for wear. Rear shock absorber springs (for suspension ad- •...
  • Page 202: Storage

    STORAGE STORAGE WARNING Before Storage Gasoline is extremely flammable and can be explosive under certain conditions, creating When the motorcycle is to be stored for any length the potential for serious burns. Always stop of time, it should be prepared for storage as follows. the engine and never smoke while handling •...
  • Page 203: After Storage

    STORAGE • Fill the fuel tank with fuel. • After Storage Check all the points listed in the Daily Pre-Ride Checks section. • • Remove the plastic bag from the muffler. Perform a lubrication procedure in the Lubrication • Make sure the spark plug is tight. section.
  • Page 204: Environmental Protection

    Properly discard used tires, engine oil, other vehicle components, or the entire vehicle that you might dispose of in the future. Consult your authorized Kawasaki dealer or local environmental waste agency for their proper disposal procedure.
  • Page 205: Wiring Diagram

    WIRING DIAGRAM WIRING DIAGRAM...

This manual is also suitable for:

Kx450f 2014Kxf 450

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