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.
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 high- ways. • The use of this vehicle should be limited to participation in sanctioned competition events upon a closed course.
Whenever you see the symbols shown below, IMPORTANT NOTICE heed their instructions! Always follow safe operating THIS VEHICLE IS A COMPETITION MODEL ON- and maintenance practices. LY AND WAS NOT MANUFACTURED FOR, NOR DANGER SHOULD IT BE USED ON, PUBLIC STREETS, ROADS, OR HIGHWAYS.
NOTICE Off-road motorcycling is a wonderful sport, and we hope you will enjoy it to the fullest. However, if improperly conducted, this sport has the po- tential to cause environmental problems as well as conflicts with other people. Responsible use of your off-road motorcycle will ensure that these problems and conflicts do not occur.
FOREWORD Congratulations on your choosing this Kawasaki motorcycle. Your new motorcycle is the product of Kawasa- ki's advanced engineering, exhaustive testing, and continuous striving for a superior lightweight, high-perform- ance machine with superb handling and stability for racing and sporting use.
TABLE OF CONTENTS SPECIFICATIONS ..........Steering ............GENERAL INFORMATION ........ Front Suspension ..........Location of Parts ..........Rear Suspension (UNI-TRAK®) ...... Side Stand ............Wheels ............. Fuel ..............Hoses Inspection ..........Fuel Requirement: ......... Tightening Torques of Nuts and Bolts ....Kick Pedal ............
SPECIFICATIONS 7 SPECIFICATIONS DIMENSIONS Overall Length 2 180 mm (85.83 in.) Overall Width 820 mm (32.3 in.) Overall Height 1 275 mm (50.20 in.) Wheelbase 1 480 mm (58.27 in.) Road Clearance 330 mm (13.0 in.) Curb Mass 113 kg (249 lb) Fuel Tank Capacity 6.2 L (1.6 US gal) ENGINE...
8 SPECIFICATIONS 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: Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity...
SPECIFICATIONS 9 Rim Size: Front 21 × 1.60 Rear 19 × 2.15 Suspension: Front Telescopic fork (upside-down) ® Rear New Uni-trak swingarm Front Suspension Travel 314 mm (12.4 in.) Rear Wheel Travel 315 mm (12.4 in.) Front Fork Oil: Type KAYABA 01 Capacity (Per Fork Leg): Inner Damper...
10 GENERAL INFORMATION GENERAL INFORMATION Location of Parts 1. Clutch Lever 6. Front Brake Fluid Reservoir 2. Engine Stop Button 7. Front Brake Lever 3. Launch Control Mode Button 8. Throttle Grip 4. Orange Launch Control Mode/FI Indicator Light 5. Fuel Tank Cap...
GENERAL INFORMATION 11 1. Front Fork 9. Shift Pedal 2. Radiator 10. Footpeg 3. Fuel Tank 11. Rear Shock Absorber 4. Throttle Body Assy 12. Swingarm 5. Seat 13. Drive Chain 6. Air Cleaner Element 14. Chain Guide 7. Brake Disc 8.
12 GENERAL INFORMATION ® 1. Muffler 6. Uni-Trak Tie-Rod and Rocker Arm 2. Rear Brake Fluid Reservoir 7. Rear Brake Pedal 3. Rear Shock Absorber Gas Reservoir 8. Oil Level Gauge 4. Kick Pedal 9. Exhaust Pipe 5. DFI Setting Data Selection Connector...
Side Stand Fuel To install the side stand, insert its flat end into the This Kawasaki KX has a 4-stroke engine that re- rear axle as shown in the figure. quires a gasoline. The capacity of the fuel tank is 6.2 L (1.6 US gal).
14 GENERAL INFORMATION WARNING NOTICE If engine “knocking” or “pinging” occurs, use Gasoline is extremely flammable and can be a different brand of gasoline of a higher oc- explosive under certain conditions. Always tane rating. stop the engine and do not smoke. Make sure If this condition is allowed to continue it can the area is well-ventilated and free from any lead to severe engine damage.
15% MTBE. during refueling. NOTE When not operating your Kawasaki for 30 to 60 days, mix a fuel stabilizer (such as STA- Other oxygenates approved for use in unleaded ○...
16 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.
GENERAL INFORMATION 17 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 ○...
18 GENERAL INFORMATION • When shifting into 3rd, the system is deactivated Launch Control Mode automatically. The launch control mode can be used to adjust ignition timing to help riders get better starts on slip- pery terrain. The system's effectiveness is dependent on rider skill, technique and terrain conditions.
GENERAL INFORMATION 19 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 ○...
20 GENERAL INFORMATION Shifting Gears This motorcycle is equipped with a 5-speed “re- turn shift” transmission. The neutral is located half- way 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.
GENERAL INFORMATION 21 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.
22 GENERAL INFORMATION 7. After the break-in procedure has been properly Break-In carried out, the motorcycle is ready for regular op- eration. Using the proper riding skills and techni- A brief break-in procedure must be carried out to ques and avoiding recklessly high engine speeds obtain the proper operating clearances in the engine will keep the engine trouble-free.
GENERAL INFORMATION 23 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 re- quired to return the motorcycle to a safe operating condition.
24 GENERAL INFORMATION 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 ....
GENERAL INFORMATION 25 After-Race Checks After racing, first clean the motorcycle, then in- spect the entire motorcycle with special attention to the air cleaner, brakes, etc. Carry out the general lubrication and make neces- sary adjustments.
26 MAINTENANCE AND ADJUSTMENT MAINTENANCE AND ADJUSTMENT Periodic Maintenance Chart The maintenance and adjustments outlined in this chapter are easily carried out and must be done in accord- ance with the Periodic Maintenance Chart to keep the motorcycle in good running condition. 1.
MAINTENANCE AND ADJUSTMENT 27 FREQUENCY After each Every 3 Every 6 Every 12 As re- race (or races (or races (or races (or quired Page 2.5 hour) 7.5 hour) 15 hour) 30 hour) OPERATION • Water hoses and connections - inspect †...
28 MAINTENANCE AND ADJUSTMENT 2. Periodic Inspection (Chassis Related Item) FREQUENCY After each Every 3 Every 6 Every 12 As re- race (or races (or races (or races (or quired Page 2.5 hour) 7.5 hour) 15 hour) 30 hour) OPERATION •...
MAINTENANCE AND ADJUSTMENT 29 FREQUENCY After each Every 3 Every 6 Every 12 As re- race (or races (or races (or races (or quired Page 2.5 hour) 7.5 hour) 15 hour) 30 hour) OPERATION Swingarm and UNI-TRAK linkage pivots - •...
K Fuel hose - replace Every 5 years – • K Rear shock absorber oil - change – †: Replace, add, adjust, clean or torque if necessary. K: Should be serviced by referring to the Service Manual or an authorized Kawasaki dealer.
MAINTENANCE AND ADJUSTMENT 31 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 to • Start the engine and run it for several minutes at function properly, maintain the engine oil at the idle speed.
32 MAINTENANCE AND ADJUSTMENT NOTE Oil and/or Oil Filter Change The engine oil and/or oil filter should be changed If no oil appears in the oil level gauge, tip the mo- ○ periodically to ensure long engine life. torcycle slightly to the right until oil is visible then •...
MAINTENANCE AND ADJUSTMENT 33 • Be sure to install the spring on the original posi- WARNING tion. Motor oil is a toxic substance. Dispose of used oil properly. Contact your local author- ities for approved disposal methods or possi- ble recycling. •...
A. Oil Filter Element “Kawasaki Performance 4-Stroke Motorcycle B. Grommet Oil*” 10W-40 C. O-rings *Kawasaki Performance Oils and Lubricants have Tightening Torque been specifically engineered for your vehicle. Con- sistent use of these products meets or exceeds Oil Filter Cap Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
MAINTENANCE AND ADJUSTMENT 35 NOTE The oil viscosity may need to be changed to ac- commodate atmospheric conditions in your riding If unavailable, use equivalent engine oil in accord- ○ area. ance with the following table. Type: API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity: SAE 10W-30, 10W-40, 10W-50...
36 MAINTENANCE AND ADJUSTMENT Cooling System WARNING The cooling system can get extremely hot Water Hoses during normal operation and cause serious Check the water hoses for cracks or deterioration, burns. Do not touch the radiator when it is and the connections for looseness in accordance hot, nor open the radiator cap.
MAINTENANCE AND ADJUSTMENT 37 • Then, push and turn the cap further in the same direction and remove it. A. Coolant Level B. Filler Neck • A. Radiator Cap If the coolant level is low, add coolant through the radiator filler opening to the bottom of the filler •...
38 MAINTENANCE AND ADJUSTMENT Coolant Change WARNING The coolant should be changed to ensure long en- gine life, if necessary. Coolant on tires will make them slippery and • Wait for the engine to cool completely. can cause loss of traction resulting in an acci- •...
MAINTENANCE AND ADJUSTMENT 39 NOTICE Spark Plug Use coolant containing corrosion inhibitors The spark plug should be taken out periodically made specifically for aluminum engines and for inspection and regapping. Measure the gap with radiators in accordance with the instruction a wire-type thickness gauge.
40 MAINTENANCE AND ADJUSTMENT If the plug is oily or has carbon built up on it, clean Spark Plug Removal and Installation • it (preferably with a sandblaster) and then clean off Remove the seat (see Air Cleaner section). • any abrasive particles.
MAINTENANCE AND ADJUSTMENT 41 • • Remove the fuel tank mounting bolt and band. Be sure to place a piece of cloth around the fuel hose joint. • Insert a thin blade screwdriver into the slit on the joint lock. A.
42 MAINTENANCE AND ADJUSTMENT • • Turn the driver to disconnect the joint lock. Disconnect the fuel pump lead connector. • • Pull the fuel hose joint out of the outlet pipe. Remove the fuel tank. A. Turn A. Fuel Pump Lead Connector B.
MAINTENANCE AND ADJUSTMENT 43 • • Clean the cylinder head cover around the spark Install the spark plug cap so that it is aligned with plug cap hole before removing the spark plug. the line on the cylinder head cover. •...
44 MAINTENANCE AND ADJUSTMENT • • Make sure that the dampers are in place on the Insert the fuel hose joint straight onto the fuel out- frame and are not damaged. If the dampers are let pipe until the hose joint clicks. •...
MAINTENANCE AND ADJUSTMENT 45 • • Push and pull the fuel hose joint back and forth Before installing the fuel tank, check that both more than two times, and make sure it is locked throttle cables run over the main harness. and does not come off.
46 MAINTENANCE AND ADJUSTMENT • Install the removed parts. Air Cleaner Tightening Torque A clogged air cleaner restricts the air intake, in- Radiator Shroud Bolts: creases fuel consumption, reduces engine power, 9.8 N·m (1.0 kgf·m, 87 in·lb) and can cause spark plug fouling. Inspect the air in- take system, which includes the air filter and air duct NOTE to the throttle body assy, and the duct clamps and...
MAINTENANCE AND ADJUSTMENT 47 • Element Removal and Inspection Open the both side covers slightly outward and • slide the seat rearward. Remove the bolts on the both sides. A. Side Covers A. Bolt B. Seat...
48 MAINTENANCE AND ADJUSTMENT • • Remove the wing bolt, and take out the air cleaner Inspect the element. If it is dirty, clean it. Also element. check if the element is in good condition (no tears, hardening or shrinkage). If damaged, replace the element or it will allow dirt into the throttle body assy.
MAINTENANCE AND ADJUSTMENT 49 A. Air Cleaner Element B. Element Frame Element Cleaning and Installation • Clean the element in a bath of a high-flash point solvent or hot soapy water. Rinse the element with clear water to remove all traces of the cleaning solution.
50 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.
MAINTENANCE AND ADJUSTMENT 51 • • Install the air cleaner element so that its tab faces Insert the hooks of the seat under the flange collar upward and its projections align with the holes in and brackets. the housing. A. Hooks B.
52 MAINTENANCE AND ADJUSTMENT • Install the tabs of the side covers into the inside of Throttle Cable the seat, and tighten the bolts. Throttle Cable Adjustment Inspect the throttle grip for smooth operation in all steering positions. Check and adjust the throttle ca- ble in accordance with the Periodic Maintenance Chart.
MAINTENANCE AND ADJUSTMENT 53 Throttle Body Assy Idle Speed Adjustment • Remove the left radiator shroud (see Spark Plug section). • Thoroughly warm up the engine. • Turn the idle adjusting screw/choke knob to adjust the idle speed 1 950 ~ 2 050 r/min (rpm) by using the engine revolution tester (The tester should be followed by the method described by the manu- facture.).
54 MAINTENANCE AND ADJUSTMENT • With the engine idling, turn the handlebar both Cleaning the Throttle Body Assy • ways and check if handlebar movement changes Remove the seat (see Air Cleaner section). • the idle speed. If so, the throttle cable may be im- Remove the fuel tank (see Spark Plug section).
MAINTENANCE AND ADJUSTMENT 55 • • Loosen the muffler clamp bolt. Loosen the air cleaner duct clamp screw. • Remove the muffler mounting bolts, and pull out the muffler body backward. A. Air Cleaner Duct Clamp Screw A. Muffler Clamp Bolt B.
56 MAINTENANCE AND ADJUSTMENT • • Disconnect the intake air temperature sensor con- Remove the rear frame mounting bolts on the nector. both sides. • Pull the rear frame rearward with the air cleaner housing. A. Intake Air Temperature Sensor Connector A.
MAINTENANCE AND ADJUSTMENT 57 • • Open the clamp on the throttle pulley cover. Open the clamp on the throttle pulley cover. • • Disconnect the throttle sensor connector. Disconnect the intake air pressure sensor con- nector. • Disconnect the fuel injector connector. A.
58 MAINTENANCE AND ADJUSTMENT • • Be sure to place a piece of cloth around the fuel Turn the driver to disconnect the joint lock. • hose joint. Pull the fuel hose joint out of the delivery pipe. • Insert a thin blade screwdriver into the slit on the joint lock.
MAINTENANCE AND ADJUSTMENT 59 • • Loosen the throttle body assy holder clamp screw. Remove the bolts and clamps, and take off the • Move the clamp forward. throttle pulley cover. • Pull the throttle body assy from the holder. A.
60 MAINTENANCE AND ADJUSTMENT • • Loosen the throttle cable bolts, and free the tips of Lubricate the lower ends of the throttle cables and throttle cable lower ends. reinstall them in reverse order of removal. Tightening Torque Throttle Cable Mounting Bolts: 3.5 N·m (0.36 kgf·m, 31 in·lb) Throttle Pulley Cover Bolts: 3.4 N·m (0.35 kgf·m, 30 in·lb)
MAINTENANCE AND ADJUSTMENT 61 • • Install the throttle body assy to the throttle body Connect the throttle sensor connector. • assy holder. Align the projection with the groove. Hold the main harness with the clamp. • Check the throttle body assy is installed securely. A.
62 MAINTENANCE AND ADJUSTMENT • • Insert the fuel hose joint straight onto the delivery Push and pull the fuel hose joint back and forth pipe. more than two times, and make sure it is locked • Check the white paint of the hose in the throttle and does not come off.
MAINTENANCE AND ADJUSTMENT 63 • • Connect the intake air pressure sensor connector Install the rear frame with the air cleaner housing and fuel injector connector. to the throttle body assy. • • Hold the main harness with the clamp. Check the duct is installed securely.
64 MAINTENANCE AND ADJUSTMENT Tightening Torque Clutch Rear Frame Mounting Bolts: Clutch Lever Adjustment 34 N·m (3.5 kgf·m, 25 ft·lb) Proper clutch lever free play is 8 ~ 13 mm (0.3 ~ • Install the fuel tank (see Spark Plug section). 0.5 in.).
MAINTENANCE AND ADJUSTMENT 65 • Remove the number plate (see Steering section). WARNING • Turn the adjuster in all the way. • Slide the dust cover back. Too much cable play can prevent clutch dis- • Loosen the locknut in the middle of the clutch ca- engagement and cause an accident resulting ble, and turn the adjusting nut so that the clutch in serious injury or death.
66 MAINTENANCE AND ADJUSTMENT • Friction and Steel Plates Removal Remove the clutch cover bolts. • Drain the engine oil (see Engine Oil section). • Remove the rear master cylinder mounting bolts, brake pedal bolt and the rear brake pedal return spring.
MAINTENANCE AND ADJUSTMENT 67 • • Remove the clutch cover and gasket. Remove the adjusting washer, needle bearing, • Remove the clutch spring bolts, clutch pressure push rod holder and push rod. plate and springs. A. Adjusting Washer B. Needle Bearing A.
68 MAINTENANCE AND ADJUSTMENT When replacing the friction plates with new ones, Friction and Steel Plates Wear/Damage In- ○ mark the two end friction plates just after opening spection • the package so that you can distinguish and in- Visually inspect the friction and steel plates to see stall them in the correct location.
MAINTENANCE AND ADJUSTMENT 69 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. Friction Plates C. Steel Plates D. Clutch Pressure Plate E.
70 MAINTENANCE AND ADJUSTMENT Friction and Steel Plate Warp Clutch Hub Installation • Install all parts in the reverse order of removal. Maximum 0.15 mm • Replace the clutch hub nut with a new one. Standard (0.0059 in.) or less Friction Plate •...
MAINTENANCE AND ADJUSTMENT 71 • Friction and Steel Plate Installation Apply molybdenum disulfide grease to the push • rod as shown in the figure. Install all parts in the reverse order of removal. • • Install the push rod so that the oil passage hole Install the friction plates and steel plates, alternat- faces engine right side.
72 MAINTENANCE AND ADJUSTMENT • Apply molybdenum disulfide grease to the contact Tightening Torque area of the push rod holder, both surface of the Clutch Spring Bolts: needle bearing and adjusting washer. 8.8 N·m (0.90 kgf·m, 78 in·lb) • Install the push rod, push rod holder, needle bear- •...
MAINTENANCE AND ADJUSTMENT 73 • If the lever position is not within the standard, se- Release Shaft Lever Position and Adjusting lect the correct thickness of adjusting washer ac- Washer Selection cording to the following table. Position Dis- Judg- Washers Quanti- •...
74 MAINTENANCE AND ADJUSTMENT Tightening Torque Valve Clearance Rear Master Cylinder Mounting Bolts: Valve and valve seat wear decreases valve clear- 9.8 N·m (1.0 kgf·m, 87 in·lb) ance, upsetting valve timing. • Check the engine oil level. NOTICE If valve clearance is left unadjusted, wear will eventually cause the valves to remain partly open, which lowers performances, burns the valves and valve seats, and may cause seri-...
MAINTENANCE AND ADJUSTMENT 75 • Valve Clearance Inspection Remove the head cover gasket and spark plug • hole gasket. Remove the spark plug cap (see Spark Plug sec- tion). • Remove the cylinder head cover bolts and cylin- der head cover. A.
76 MAINTENANCE AND ADJUSTMENT • • Remove the two caps from the magneto cover. Bring the piston to the Top Dead Center (TDC) of its compression stroke to inspect the valve clear- ance (the position at the end of the compression stroke) by aligning the top mark with the groove on the magneto cover while turning the crankshaft counterclockwise.
• If the valve clearance is not within the specified Using the thickness gauge, measuring the clear- range, adjust by an authorized Kawasaki dealer ance between each cam lobe and valve lifter, for or a competent mechanic following the instruc- all four valves.
78 MAINTENANCE AND ADJUSTMENT • • Using a high-flash point solvent, clean off any oil Replace the spark plug hole gasket with a new or dirt that may be on the silicone sealant coating one, and install it. area. Dry them with a clean cloth. •...
MAINTENANCE AND ADJUSTMENT 79 • Make sure that the upper chain guide is bottomed Tightening Torque to the cylinder head cover. Cylinder Head Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Install the two caps to the magneto cover. •...
80 MAINTENANCE AND ADJUSTMENT • Remove the muffler body cover bolts. Exhaust System • Remove the muffler mounting bolt. The exhaust system, in particular the muffler body, is designed to reduce exhaust noise and conduct the exhaust gases away from the rider while mini- mizing power loss.
MAINTENANCE AND ADJUSTMENT 81 • • Remove the muffler body cover with the plastic Replace the muffler baffle with a new one. • mallet. Remove the silicone sealant attaching on the muf- fler body cover and muffler body. • Using a high-flash point solvent, clean off any oil or dirt that may be on the silicone sealant coating area.
82 MAINTENANCE AND ADJUSTMENT • • Check that the exhaust port of the muffler body Apply a non-permanent locking agent to the muf- cover align with the muffler body. fler body cover bolts. • Tighten the muffler body cover bolts and apply the silicone sealant to the joint part of the muffler body cover and muffler body.
MAINTENANCE AND ADJUSTMENT 83 • • Firstly, tighten the muffler mounting bolt (front). Insert the tabs of the side cover into the slots of • Secondly, tighten the muffler mounting bolt (rear). the air cleaner housing, and tighten the bolts. •...
84 MAINTENANCE AND ADJUSTMENT • Adjust the drive chain if its slack is out of specifi- Drive Chain cation. For safety and to prevent excessive wear, the drive chain must be checked, adjusted, and lubri- cated before riding. If the chain becomes badly worn or maladjusted - either too loose or too tight - it could jump off the sprockets or break.
MAINTENANCE AND ADJUSTMENT 85 Chain Slack Adjustment • Remove the cotter pin from the rear axle nut. • Loosen the rear axle nut and both chain adjuster locknuts. • Turn both chain adjusting bolts evenly until the drive chain slack (measured between the chain and the swingarm) is within the standard value.
86 MAINTENANCE AND ADJUSTMENT • Tighten both chain adjuster locknuts. NOTE • Tighten the axle nut to the specified torque. When inserting the cotter pin, if the slots in the nut ○ Tightening Torque do not align with the cotter pin hole in the axle, tighten the nut clockwise up to the next alignment.
MAINTENANCE AND ADJUSTMENT 87 • NOTE Measure the 20-link length on a straight part of the chain from the center of the 1st pin to the cen- When riding in wet and muddy conditions, mud ○ ter of the 21st pin. If the length exceeds the serv- sticks to the chain and sprockets, resulting in an ice limit, the chain should be replaced.
88 MAINTENANCE AND ADJUSTMENT NOTE Chain Guide Wear Inspection • Visually inspect the drive chain guide and replace The drive system was designed for use with a ○ it if excessively worn or damaged. DAIDO DID 520DMA4 114-links chain. For maxi- mum stretch resistance and safety, a genuine part must be used for replacement.
MAINTENANCE AND ADJUSTMENT 89 Chain Slipper Wear Inspection Sprocket Wear Inspection • • Visually inspect the upper and lower of the chain Visually inspect the sprocket teeth and replace slipper on the swingarm and replace them if worn the sprocket if its teeth are worn or damaged. or damaged.
90 MAINTENANCE AND ADJUSTMENT Chain Lubrication Adjustable Ergonomics Lubrication of the drive chain is necessary after riding in the rain or mud, or any time the chain ap- To suit various riding positions, the handlebar pears dry. A heavy oil such as SAE90 is preferred to holder position can be changed and the handlebar a lighter oil because it will stay on the chain longer can be adjusted by turning the handlebar holders...
MAINTENANCE AND ADJUSTMENT 91 • Remove the handlebar holder nuts, washers and Tightening Torque handlebar holders. Handlebar Holder Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb) A. Handlebar Holder Nuts B. Washers C. Handlebar Holder A. Dampers B. Flat Surfaces • Select the handlebar position and install the •...
92 MAINTENANCE AND ADJUSTMENT NOTE Footpeg Tighten the two clamp bolts alternately two times ○ to ensure even tightening torque. The right and left footpegs can be mounted in one of two positions. • Remove the cotter pin, pivot pin, washer, spring and footpeg.
MAINTENANCE AND ADJUSTMENT 93 • • Remove the footpeg bracket bolts and bracket. Position the spring ends as shown in the figure. • (This position is standard.) Install the washer and new cotter pin. • Bend the longer end of the cotter pin. A.
Have the brake checked im- • To adjust the brake lever position, slide the front mediately by an authorized Kawasaki dealer. brake lever dust cover back, and loosen the lock- nut, and turn the adjuster to either side with a wrench.
MAINTENANCE AND ADJUSTMENT 95 Brake Fluid Level Inspection (Front and Rear NOTICE Brake Reservoirs) With the front or rear brake reservoir positioned Do not spill brake fluid onto any painted sur- horizontally, the brake fluid must always be above face. the lower level line.
96 MAINTENANCE AND ADJUSTMENT • If the brake fluid in the front or rear brake reservoir is below the lower level line, check for fluid leaks in the brake line and fill the reservoir to the upper level line (The step inside the front and rear brake reservoirs indicate the upper level.).
(front or rear) brake caliper is less than 1 mm (0.04 in.), have both pads in the cali- per replaced as a set. Pad replacement should be done by an authorized Kawasaki dealer. Usable Brake Pad Range A. Rear Brake Reservoir B.
98 MAINTENANCE AND ADJUSTMENT Steering Inspection Steering • To check the steering adjustment, raise the front wheel off the ground using a jack (special tool: The steering should always be kept adjusted so 57001-1238) and attachment (special tool: 57001- that the handlebar will turn freely but not have ex- 1608).
MAINTENANCE AND ADJUSTMENT 99 • Steering Adjustment Remove the handlebar (see Handlebar section). • • Loosen the left and right front fork clamp bolts Raise the front wheel off the ground using a jack (upper). (special tool: 57001-1238) and attachment (spe- •...
100 MAINTENANCE AND ADJUSTMENT • Turn the steering stem nut with a stem nut wrench NOTE (special tool: 57001-1100) to obtain the proper ad- Tighten the two clamp bolts alternately two times ○ justment. to ensure even tightening torque. • Install the handlebar (see Handlebar section), and check the steering again and readjust it if neces- sary.
• If necessary, repair or replace by an authorized fork legs increases with normal use, the fork action Kawasaki dealer. on your KX will get stiffer as the race progresses. Therefore, it is not recommended to increase the air pressure for additional springing. The KX forks are designed to function without added air.
102 MAINTENANCE AND ADJUSTMENT counterclockwise 22 or more clicks (depending on Air Pressure Adjustment the model) is the softest setting. The standard air pressure in the front fork legs is • Fork Oil Amount Adjustment atmospheric (0 kPa, 0 kgf/cm², 0 psi). Air pressure The fork oil amount affects only the final 100 mm in the fork legs increase with normal use, so the fork (4 in.) of fork travel.
MAINTENANCE AND ADJUSTMENT 103 A. Screw A. Rebound Damping Adjuster Rebound Damping Adjustment • Clean the bottom of the fork tubes. • To adjust the rebound damping, turn the adjuster on each cylinder valve with a standard tip screw- driver. Adjust the rebound damping to suit your preference under certain conditions.
104 MAINTENANCE AND ADJUSTMENT Rebound Damping Adjuster Settings Compression Damping Adjustment • To adjust the compression damping, turn the ad- juster on the each front fork cylinder valve with a standard tip screwdriver. Adjust the compression damping to suit your preference under certain conditions.
MAINTENANCE AND ADJUSTMENT 105 Compression Damping Adjuster Settings NOTICE 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.
106 MAINTENANCE AND ADJUSTMENT • NOTE Support the motorcycle using a jack (special tool: 57001-1238) and attachment (special tool: 57001- Set the rebound and compression damping set- ○ 1608). ting to the softest settings before disassembly to • Unscrew the front axle nut, and then loosen the prevent the needle of adjusters from damping.
MAINTENANCE AND ADJUSTMENT 107 • Remove the brake caliper from the fork leg to be NOTICE removed, and rest the caliper on some kind of stand so that it does not dangle. Do not lay the wheel on the ground with the •...
108 MAINTENANCE AND ADJUSTMENT • • Loosen the front fork clamp bolts (lower). Remove the front fork by pulling down while twist- ing it. A. Front Fork Clamp Bolts (Lower) A. Pull down by twisting. B. Front Fork...
MAINTENANCE AND ADJUSTMENT 109 • Using the top plug wrench, 49 mm (special tool: 57001-1653), remove the fork top plug from the outer tube and slowly slide down the outer tube. A. Fork Oil A. Top Plug Wrench, 49 mm (Special Tool: 57001- 1653) B.
110 MAINTENANCE AND ADJUSTMENT • • Raise the outer tube and temporarily install the Protect the axle holder with a thick rag and secure fork top plug to the outer tube using the top plug it with a vise. wrench, 49 mm (special tool: 57001-1653). A.
MAINTENANCE AND ADJUSTMENT 111 NOTE WARNING When removing the adjuster assembly, do not ○ The fork spring applies pressure to the ad- force to loosen it at once using an impact wrench. juster assembly and can eject the special tool with substantial force if the tool is not prop- erly and securely placed.
112 MAINTENANCE AND ADJUSTMENT • • Hold the locknut with a wrench and remove the Remove the push rod. adjuster assembly. A. Push Rod A. Top Plug Wrench, 49 mm (Special Tool: 57001- • With the outer tube compressed by hand, remove 1653) the top plug wrench, 49 mm (special tool: 57001- B.
MAINTENANCE AND ADJUSTMENT 113 • Remove the fork leg from the vise. • Remove the front fork top plug with the top plug wrench (special tool: 57001-1653). A. Top Plug Wrench, 49 mm (Special Tool: 57001- 1653) A. Front Fork Top Plug B.
114 MAINTENANCE AND ADJUSTMENT • Secure the top plug wrench, 49 mm (special tool: 57001-1653) with a vise and hold the fork cylinder unit with the top plug wrench. • Loosen the base valve assembly completely with the top plug wrench, 36 mm (special tool: 57001- 1705).
MAINTENANCE AND ADJUSTMENT 115 • Drain the fork oil from the cylinder unit by pumping the piston rod several times. A. Base Valve Assembly B. Cylinder Unit A. Fork Oil NOTE B. Cylinder Unit Slowly compress the piston rod until it stops so ○...
116 MAINTENANCE AND ADJUSTMENT • • Hold the front fork at the inverted position for more Clean the threads of cylinder unit and base valve than 20 minutes to allow the fork oil to fully drain. assembly. A. Threads...
MAINTENANCE AND ADJUSTMENT 117 • Replace the O-ring on the base valve assembly and cylinder unit with new ones. • Apply specified fork oil to the O-rings on the base valve assembly. A. Fork Oil B. Oil Holes C. Cylinder Unit Recommended Fork Oil A.
118 MAINTENANCE AND ADJUSTMENT • Pump the piston rod slowly several times to expel air. • Hold the piston rod immovable with the fully com- pressed position. A. Base Valve Assembly B. Cylinder Unit NOTE Put a hand over the two oil holes to prevent oil ○...
MAINTENANCE AND ADJUSTMENT 119 • Hold the top plug wrench, 49 mm (special tool: NOTE 57001-1653) with a vise. Check if the locknut is completely screwed on to ○ • Holding the cylinder unit with the top plug wrench, the piston rod. 36 mm (special tool: 57001-1705), torque the •...
120 MAINTENANCE AND ADJUSTMENT • NOTE With the cylinder unit in horizontal position, slide the piston rod by hand to inspect it if operating Check the piston rod sliding surface for damage. ○ smoothly. Apply fork oil to the piston rod sliding surface. ○...
MAINTENANCE AND ADJUSTMENT 121 • • Make sure about 16 mm (0.63 in.) of push rod Completely wipe off the fork oil from the spring thread is exposed from the locknut. and cylinder unit. • Insert the spring and cylinder unit to the outer tube.
122 MAINTENANCE AND ADJUSTMENT • • Temporarily tighten the fork top plug by using the Compress the outer tube by hands and install the top plug wrench, 49 mm (special tool: 57001- top plug wrench, 49 mm (special tool: 57001- 1653).
MAINTENANCE AND ADJUSTMENT 123 • • Insert the push rod into the piston rod. With the locknut held immovable using a wrench, tighten the adjuster assembly to the specified tor- NOTE que. Check the push rod installation by turning the ○...
124 MAINTENANCE AND ADJUSTMENT • • Tighten the adjuster assembly to the specified tor- Using the top plug wrench, 49 mm (special tool: que. 57001-1653), remove the fork top plug from the outer tube and slowly slide down the outer tube. •...
MAINTENANCE AND ADJUSTMENT 125 • Standard Fork Oil Amount / Fork Spring Tighten the front fork top plug with using the top plug wrench, 49 mm (special tool: 57001-1653) to Fork spring 4.7 N/mm (0.48 kgf/mm) the specified torque. Fork oil amount 335 mL (11.3 US oz.) Adjustable 320 ~ 380 mL (10.8 ~ 12.8 US Range...
126 MAINTENANCE AND ADJUSTMENT NOTE The torque of fork top plug is specified to 30 N·m ○ (3.1 kgf·m, 22 ft·lb) however, when you use the top plug wrench, 49 mm (special tool: 57001- 1653), reduce the torque to 90% of the specified value [27 N·m (2.8 kgf·m, 20 ft·lb)] due to the dis- tance between the center of the square hole, where the torque wrench is fitted, and that of the...
MAINTENANCE AND ADJUSTMENT 127 • Tighten the front axle nut to the specified torque. NOTE Tightening Torque Tighten the two clamp bolts alternately two times ○ to ensure even tightening torque. Front Axle Nut: • Remove the jack and attachment. 79 N·m (8.1 kgf·m, 58 ft·lb) •...
128 MAINTENANCE AND ADJUSTMENT • Tighten the right axle clamp bolts to the specified Optional Fork Springs torque. Various fork springs are available to achieve suit- able front fork action in accordance with the rider's Tightening Torque weight and track condition. Right Front Axle Clamp Bolts: Harder springs stiffen the fork action and acceler- 20 N·m (2.0 kgf·m, 15 ft·lb)
Standard Fork Clamp Position leakage. 10 mm (0.39 in.) * • If necessary, repair or replace by an authorized Kawasaki dealer. * below the surface of the top plug Rear Shock Absorber Adjustment NOTE The spring preload of the shock absorber can be Tighten the two clamp bolts alternately two times ○...
130 MAINTENANCE AND ADJUSTMENT Rebound Damping Adjustment Rebound Damping Adjuster Settings To adjust the rear shock absorber rebound damp- ing, turn the rebound damping adjuster at the bot- tom of the rear shock absorber with a standard tip screwdriver. A. Seated Position (Adjuster Turned Fully Clock- wise) B.
MAINTENANCE AND ADJUSTMENT 131 NOTE If the damping feels too soft or too stiff, adjust it in accordance with the following table. Adjustment of the rebound damping adjuster for ○ the rear suspension will slightly affect the com- pression damping force. Always make any damp- ing adjustments in small steps and test their effects before using them in competition.
132 MAINTENANCE AND ADJUSTMENT High Speed Compression Damping Adjuster Low Speed Compression Damping Adjuster Set- Settings tings A. Seated Position (Adjuster Turned Fully Clock- A. Seated Position (Adjuster Turned Fully Clock- wise) wise) B. Softer (Counterclockwise) B. Softer (Counterclockwise) C. Harder (Clockwise) C.
MAINTENANCE AND ADJUSTMENT 133 • Raise the rear wheel off the ground using a jack NOTICE (special tool: 57001-1238) and attachment (spe- cial tool: 57001-1608). Do not force the compression damping force • Using the hook wrenches (special tools: 57001- adjuster beyond the fully seated position, or 1101 (qt.
134 MAINTENANCE AND ADJUSTMENT • Using the hook wrench (special tool: 57001- Rear Shock Absorber Spring Adjustable Range 1101), turn the spring preload adjusting nut as re- K = 52 N/mm 126.5 ~ 138.5 mm quired. Turning the adjusting nut down increases (K = 5.3 kgf/mm) (4.980 ~ 5.453 in.) the spring preload.
Removal and installation of the rear shock ab- 80 ~ 100 kPa (0.8 ~ 1.0 kgf/cm², 12 ~ 14 psi) sorber spring should be performed by an au- thorized Kawasaki dealer. NOTE Tire air pressure should be checked when the ○...
136 MAINTENANCE AND ADJUSTMENT Spokes and Rims Bead Protector The spokes on both wheels must all be securely There is a bead protector nut on the both wheels. and evenly tightened and not be allowed to loosen. The bead protector nut prevents the tire and tube Unevenly tightened or loose spokes will cause the from slipping on the rim and damaging the valve rim to warp, the nipples and spokes to fatigue more...
MAINTENANCE AND ADJUSTMENT 137 Rim Runout Rim Runout Set up a dial gauge on the side of the rim and ro- tate the wheel to measure its axial runout. The dif- ference between the highest and lowest readings is the amount of runout. •...
138 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.
MAINTENANCE AND ADJUSTMENT 139 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.
MAINTENANCE AND ADJUSTMENT 141 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.
142 MAINTENANCE AND ADJUSTMENT Fastener N·m kgf·m ft·lb Remarks Steering Stem Head Nut Steering Stem Nut 0.50 43 in·lb Rear Frame Mounting Bolts AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease. L: Apply a non-permanent locking agent.
General Precautions • Mix a mild neutral detergent (designed for motor- Frequent and proper care of your Kawasaki mo- cycles or automobiles) and water in a bucket. Use torcycle will enhance its appearance, optimize over- a soft cloth or sponge to wash your motorcycle. If all performance, and extend its useful life.
• If any doubt, consult an authorized Kawasaki locking agents, or other harsh chemicals. If a dealer. plastic part comes in contact with any harsh chemical substance, wash it off immediately...
MAINTENANCE AND ADJUSTMENT 145 The sidewalls of tires and other rubber compo- Lubrication nents should be treated with a rubber protectant to help prolong their useful life. Lubricate the areas shown in the illustrations of this section with either motor oil or regular grease, WARNING after each race and whenever the vehicle has been Rubber protectants can be slippery and, if...
MAINTENANCE AND ADJUSTMENT 147 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.
148 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 This motorcycle equips the DFI trouble self-diag- dry. A heavy oil such as SAE90 is preferred to a nosis system.
MAINTENANCE AND ADJUSTMENT 149 Dealer Mode Self-diagnosis Procedures • The orange FI indicator light emits service code(s) Disconnect the capacitor lead connector. to show the problem(s) which the DFI system, and ignition system has at the moment of diagnosis. A. Capacitor Lead Connector A.
150 MAINTENANCE AND ADJUSTMENT • • Connect the power supply harness (optional part: Disconnect the self-diagnosis connector (Y lead). 26011-0246) to the capacitor lead connector of the main harness. • Connect the power supply harness (optional part: 26011-0246) to the 12 V battery as shown in the figure.
MAINTENANCE AND ADJUSTMENT 151 • To enter the self-diagnosis dealer mode, ground the self-diagnosis terminal for more than 2 sec- onds, and then keep it grounded continuously. • Count the blinks of the orange light to read the service code. Keep the lead ground until you fin- ish reading the service code.
152 MAINTENANCE AND ADJUSTMENT How to Read Service Codes • Service codes are shown by a series of long and short blinks of the orange FI indicator light as shown below. • Read 10th digit and unit digit as the orange FI indicator light blinks. •...
MAINTENANCE AND ADJUSTMENT 153 NOTE Even if the battery or the ECU are disconnected, or the problem is solved, all service codes remain in the ○ ECU. Service Code Table Service Orange FI 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 or short Water temperature sensor malfunction, wiring open or short...
154 MAINTENANCE AND ADJUSTMENT 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. If the ground and power supply are checked good, replace the ECU (see Service Manual).
TROUBLESHOOTING GUIDE 155 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.
156 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 - •...
TROUBLESHOOTING GUIDE 157 • 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 •...
158 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: •...
162 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. Introduction • When evaluating suspension performance, the No area of machine adjustment is more critical rider must make every effort to ride consistently than proper suspension tuning.
TUNING 163 • When the oil capacity is lowered, the air spring Troubleshooting Improper Settings becomes less progressive, and the front fork ac- Listed below are some symptoms of improper tion does not feel as “hard” in the later stage of suspension settings and the most likely means of fork travel.
164 TUNING Too Soft Determining the Proper Settings The front fork dives excessively during braking Standard Settings and deceleration: From the factory, the machine is set up for a me- • Fork oil capacity too low dium-weight rider with intermediate riding ability. •...
TUNING 165 • 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 (In- brake lever, place one foot on the footpeg closest crease the amount of fork tube to you, and push down hard.
166 TUNING Front and Rear Suspension Troubleshooting Front End Does Not Respond to Small Bumps in Sweeping Turns - Front End Surges Downhill or During Accelera- The front suspension is too hard. tion Out of Corner - • Decrease the compression damping or rebound The front suspension is too soft.
TUNING 167 Front and Rear Ends Bottom Off After a High- NOTE speed Jump (harsh bottoming occurs once or The rear shock absorber behavior on this ma- ○ twice per lap) - chine may mislead some riders. The front suspension is too soft. The rear shock absorber bottoms (due to full ○...
168 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 effect Selection of the Secondary Reduction Ratio on lap time, and tune the machine to these por- (Rear Sprocket) tions.
TUNING 169 Special Care According to Track Condi- tions • In dry, dusty conditions (such a volcanic ash or fine powdery dust), special care must be given to keeping the air cleaner element clean. • When riding on wet, heavy clay, mud adheres to the tires and other parts of the vehicle.
170 OPTIONAL PARTS OPTIONAL PARTS Rear Sprocket Suspension Spring (N/mm) K = 4.6 Front K = 4.7 (Standard) Aluminum 50T (Standard) K = 4.8 K = 52 Rear K = 54 (Standard) K = 56 Disc Plate Steel Front No holes (for wet conditions) Rear No holes (for wet conditions) Aluminum Nipple Wheel (Without Tire)
OPTIONAL PARTS 171 KX FI Calibration Kit The KX FI Calibration Kit can change the ECU da- ta setting, and save and analyze the engine opera- tion data in a personal computer (PC). KX FI Calibration Kit: Part No. – 99999-0334 For details, refer to the KX FI Calibration Kit man- ual.
172 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.
PRE-RACE CHECKS AND AFTER-RACE MAINTENANCE 173 • Grease the throttle grip and control cables. Suggested Spare Parts - • Front and rear wheels • Shift pedal and brake pedal • Brake lever, clutch lever, and holders • Throttle and clutch cables •...
174 STORAGE STORAGE Before Storage WARNING Gasoline is extremely flammable and can be When the motorcycle is to be stored for any length explosive under certain conditions, creating of time, it should be prepared for storage as follows. • the potential for serious burns. Always stop Clean the entire vehicle thoroughly.
STORAGE 175 • Cover the motorcycle to keep dust and dirt away After Storage from it. • Remove the plastic bag from the muffler. • Make sure the spark plug is tight. NOTE Fit the plug cap securely onto the spark plug, and ○...
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.