Download  Print this page

Advertisement

Table of Contents

Advertisement

Table of Contents

   Summary of Contents for Kawasaki KX250F 2012

  • Page 3 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 4 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 5 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 6 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 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..........Drive Chain............ GENERAL INFORMATION......Handlebar............Location of Parts ........... Brakes ............Side Stand............. Steering ............Fuel ............... Front Suspension .......... ® Rear Suspension (UNI-TRAK Fuel Requirement:........)..... 139 Kick Pedal ............. Wheels ............145 Starting the Engine ........Hoses Inspection...........
  • Page 9: Specifications

    SPECIFICATIONS SPECIFICATIONS DIMENSIONS Overall Length 2 170 mm (85.4 in.) Overall Width 820 mm (32.3 in.) Overall Height 1 270 mm (50.0 in.) Wheelbase 1 475 mm (58.1 in.) Road Clearance 330 mm (13.0 in.) Curb Mass 106.1 kg (234 lb) Fuel Tank Capacity 7.2 L (1.9 US gal) ENGINE...
  • Page 10 SPECIFICATIONS TRANSMISSION Transmission Type 5-speed, return shift Clutch Type Wet, multi disc Driving System Chain drive Gear Ratio: 2.142 (30/14) 1.750 (28/16) 1.444 (26/18) 1.235 (21/17) 1.045 (23/22) Primary Reduction Ratio 3.350 (67/20) Final Reduction Ratio 3.846 (50/13) Overall Drive Ratio 13.470 @Top gear Engine Oil: Type...
  • Page 11 SPECIFICATIONS Tire Size/Type: Front 80/100-21 51M/BRIDGESTONE M403 Rear 100/90-19 57M/BRIDGESTONE M404 Rim Size: Front 21 × 1.60 Rear 19 × 1.85 Suspension: Front Telescopic fork (upside-down) ® Rear New Uni-trak swingarm Front Suspension Travel 315 mm (12.4 in.) Rear Wheel Travel 310 mm (12.2 in.) Front Fork Oil: Type...
  • Page 12: General Information

    GENERAL INFORMATION GENERAL INFORMATION Location of Parts 1. Clutch Lever 3. Fuel Tank Cap 5. Front Brake Lever 2. Engine Stop Button 4. Front Brake Fluid Reservoir 6. Throttle Grip...
  • Page 13 GENERAL INFORMATION 1. Front Fork 6. Upstream Injector 11. Shift Pedal 2. Radiator 7. Seat 12. Rear Shock Absorber 3. Fuel Tank 8. Air Cleaner Element 13. Swingarm 4. Throttle Body Assy 9. Brake Disc 14. Drive Chain 5. Downstream Injector 10.
  • Page 14 GENERAL INFORMATION ® 1. Muffler 5. Uni-Trak Tie-Rod and Rocker Arm 2. Rear Brake Fluid Reservoir 6. Oil Level Gauge 3. Rear Shock Absorber Gas Reservoir 7. Rear Brake Pedal 4. Kick Pedal 8. Exhaust Pipe...
  • Page 15: 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 in the figure. A. Side Stand B. Rear Axle WARNING Riding with the side stand can cause a crash resulting in injury.
  • Page 16: Fuel

    Fuel Gasoline is extremely flammable and can be explosive under certain conditions. Always This Kawasaki KX has a 4-stroke engine that re- stop the engine and do not smoke. Make quires a gasoline. sure the area is well-ventilated and free from The capacity of the fuel tank is 7.2 L (1.9 US gal).
  • Page 17 U.S. and (up to 17.2%). Fuel containing these oxygenates Canada which are required to sell such reformu- can also be used in your Kawasaki. lated fuels as part of a strategy to reduce exhaust emissions.
  • Page 18: Kick Pedal

    Be extra careful not to spill gasoline or gasoline oxygenate blends during refueling. When not operating your Kawasaki for 30 to 60 days, mix a fuel stabilizer (such as STA-BIL) with the gasoline in the fuel tank. Fuel stabilizer additives inhibit oxidation of the fuel which minimizes gummy deposits.
  • Page 19: Starting The Engine

    GENERAL INFORMATION When engine is cold - • Starting the Engine Pull out the idle adjusting screw/choke knob. • Shift the transmission into neutral. WARNING Riding with the side stand can cause a crash resulting in injury. Do not start the engine or attempt to ride the motorcycle when the side stand is installed.
  • Page 20: Shifting Gears

    GENERAL INFORMATION NOTE Shifting Gears If the engine fails starting, open the throttle fully and depress the kick pedal slowly about 4 This motorcycle is equipped with a 5-speed “return times to clear too rich fuel mixtures in the engine. shift”...
  • Page 21: Stopping The Motorcycle

    GENERAL INFORMATION Stopping the Motorcycle For maximum deceleration, close the throttle and apply both front and rear brakes. Pull in the clutch lever as the motorcycle comes to a stop. Indepen- dent use of the front or rear brake may be advanta- geous in certain circumstances.
  • Page 22: Stopping The Engine

    GENERAL INFORMATION Stopping the Engine Break-In • Shift the transmission into the neutral position. A brief break-in procedure must be carried out to • Close the throttle completely and push the engine obtain the proper operating clearances in the engine stop button.
  • Page 23 GENERAL INFORMATION NOTICE operation. Using the proper riding skills and techniques and avoiding recklessly high engine When any following parts have been re- speeds will keep the engine trouble-free. placed, the same break-in procedure as the new motorcycle must be carried out for one hour or 20 km (12 mile): Cylinder, Piston, Piston pin, Piston ring, Valve, Valve lifter, Camshaft, Crankshaft,...
  • Page 24: 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 25 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 26: 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 27: Maintenance And Adjustment

    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 accor- dance with the Periodic Maintenance Chart to keep the motorcycle in good running condition. 1.
  • Page 28 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) • Coolant level - inspect • – Breather hose - inspect Water hoses and connections - inspect •...
  • Page 29 MAINTENANCE AND ADJUSTMENT 2. Periodic Inspection (Chassis Related Item) Every 3 Every 6 Every 12 FREQUENCY After each race (or races (or races (or races (or required Page OPERATION 2.5 hours) 7.5 hours) 15 hours) 30 hours) • Brake - adjust † •...
  • Page 30 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) Swingarm and UNI-TRAK linkage • – pivots - inspect † Swingarm and UNI-TRAK linkage •...
  • Page 31 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.
  • Page 32: Engine Oil

    MAINTENANCE AND ADJUSTMENT NOTICE Engine Oil Racing the engine before the oil reaches ev- ery part can cause engine seizure. In order for the engine, transmission and clutch to function properly, maintain the engine oil at the Oil Level Inspection proper level, and change the oil and oil filter period- •...
  • Page 33 MAINTENANCE AND ADJUSTMENT • NOTE Warm up the engine thoroughly so that the oil will pick up any sediment and drain easily. If no oil appears in the oil level gauge, tip the mo- • Stop the engine, and place a container beneath it. torcycle slightly to the right until oil is visible then •...
  • Page 34 MAINTENANCE AND ADJUSTMENT • • When the oil filter is replaced, remove the oil filter Replace the oil filter element with a new one. • cover bolts and take off the cover with O-ring and Apply grease to the grommet. •...
  • Page 35 Semi-Synthetic Oil*” 10W-40 or “Kawasaki Performance 4-Stroke Motorcycle Oil*” 10W-40 A. Spring *Kawasaki Performance Oils and Lubricants have B. O-ring been specifically engineered for your vehicle. Con- C. Oil Filter Cover sistent use of these products meets or exceeds war-...
  • Page 36 MAINTENANCE AND ADJUSTMENT NOTE The oil viscosity may need to be changed to ac- commodate atmospheric conditions in your riding If unavailable, use equivalent engine oil in accor- area. dance 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...
  • Page 37: Cooling System

    MAINTENANCE AND ADJUSTMENT WARNING Cooling System The cooling system can get extremely hot during normal operation and cause serious Water Hoses burns. Do not touch the radiator when it is Check the water hoses for cracks or deterioration, hot, nor open the radiator cap. Hot coolant and the connections for looseness in accordance inside will cause severe burns.
  • Page 38 MAINTENANCE AND ADJUSTMENT • Situate the motorcycle perpendicular to the ground until the radiator cap is level to the ground, so that the radiator cap is located uppermost in order to exhaust the air accumulated in the radiator. • Remove the radiator cap in two steps. •...
  • Page 39 MAINTENANCE AND ADJUSTMENT • Install the radiator cap and right radiator shroud. • Tighten the bolts. Tightening Torque Radiator Shroud Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) Coolant Change The coolant should be changed to ensure long en- gine life, if necessary. •...
  • Page 40 MAINTENANCE AND ADJUSTMENT • NOTICE If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded and the Use coolant containing corrosion inhibitors system must be flushed. made specifically for aluminum engines and • If the coolant is brown, iron or steel parts are rust- radiators in accordance with the instruction ing and the system must be flushed.
  • Page 41: Spark Plug

    MAINTENANCE AND ADJUSTMENT If the plug is oily or has carbon built up on it, clean Spark Plug it (preferably with a sandblaster) and then clean off any abrasive particles. The plug may also be The spark plug should be taken out periodically for cleaned using a high-flash point solvent and a wire inspection and regapping.
  • Page 42 MAINTENANCE AND ADJUSTMENT • Spark Plug Removal and Installation Remove the fuel tank mounting bolt and band. • Remove the seat (see Air Cleaner section). • Remove the bolts and take off the radiator shroud on both sides. A. Fuel Tank Mounting Bolt B.
  • Page 43 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 outlet pipe. • Insert a thin blade screwdriver into the slit on the joint lock.
  • Page 44 MAINTENANCE AND ADJUSTMENT • • Disconnect the fuel pump lead connector. Clean the cylinder head cover around the spark • Remove the fuel tank. plug cap hole before removing the spark plug. • Pull the spark plug cap off the plug before remov- ing the spark plug.
  • Page 45 MAINTENANCE AND ADJUSTMENT • Install the spark plug cap as shown in the figure. not fixed completely, reattach them with an adhe- • Pull up the plug cap lightly to make sure of the sive. If the dampers are damaged, replace them installation of the spark plug cap.
  • Page 46 MAINTENANCE AND ADJUSTMENT • • Insert the fuel hose joint straight onto the fuel out- Push and pull the fuel hose joint back and forth let pipe until the hose joint clicks. more than two times, and make sure it is locked •...
  • Page 47 MAINTENANCE AND ADJUSTMENT • NOTE After installing the fuel tank, make sure that both throttle cables (outer) move slightly by pulling To prevent the bottom of the fuel tank from pushing them back and forth in the upper space of the the throttle cables, run the throttle cables over the right side of the fuel tank.
  • Page 48: Air Cleaner

    MAINTENANCE AND ADJUSTMENT NOTE Air Cleaner In dusty areas, the element should be cleaned more frequently than recommended interval. A clogged air cleaner restricts the air intake, in- After riding through rain or on muddy roads, the creases fuel consumption, reduces engine power, element should be cleaned immediately.
  • Page 49 MAINTENANCE AND ADJUSTMENT • • Open the both side covers slightly outward and Remove the wing bolt, and take out the air cleaner slide the seat rearward. element. A. Side Covers A. Air Cleaner Element B. Seat B. Wing Bolt •...
  • Page 50 MAINTENANCE AND ADJUSTMENT • Inspect the element. If it is dirty, clean it. Also 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.
  • Page 51 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 work- ing areas. Do not use gasoline or low-flash point solvents to clean the element.
  • Page 52 MAINTENANCE AND ADJUSTMENT • Install the air cleaner element so that its tab faces upward and its projections align with the holes in the housing. A. Apply grease. A. Tab B. Projections C. Holes • Tighten the wing bolt.
  • Page 53 MAINTENANCE AND ADJUSTMENT • • Insert the hooks of the seat under the flange collar Install the tabs of the side covers into the inside of and brackets. the seat, and tighten the bolts. A. Hooks A. Tabs B. Seat B.
  • Page 54: Throttle Cable

    MAINTENANCE AND ADJUSTMENT • If the play is incorrect, loosen the locknut on the Throttle Cable upper end of the throttle cable and turn the ad- juster to obtain the specified play. Then, tighten the locknut toward the adjuster. Throttle Cable Adjustment Inspect the throttle grip for smooth operation in all steering positions.
  • Page 55: Throttle Body Assy

    MAINTENANCE AND ADJUSTMENT WARNING Throttle Body Assy Operation with improperly adjusted, incor- rectly routed, or damaged cables could re- Idle Speed Adjustment sult in an unsafe riding condition. Be sure • the control cables are adjusted and routed Thoroughly warm up the engine. •...
  • Page 56 MAINTENANCE AND ADJUSTMENT Cleaning the Throttle Body Assy the idle speed. If so, the throttle cable may be im- • properly adjusted, incorrectly routed, or damaged. Remove the seat (see Air Cleaner section). • Be sure to correct any of these conditions before Remove the fuel tank (see Spark Plug section).
  • Page 57 MAINTENANCE AND ADJUSTMENT • • Loosen the muffler clamp bolt. Loosen the air cleaner duct clamp screw. • Remove the muffler mounting bolts, and pull out the muffler body rearward. A. Air Cleaner Duct Clamp Screw A. Muffler Clamp Bolt B.
  • Page 58 MAINTENANCE AND ADJUSTMENT • • Disconnect the intake air temperature sensor con- Be sure to place a piece of cloth around the fuel nector and upstream injector connector. hose joint. • Open the both tabs of the joint lock outward and slide the joint lock downward.
  • Page 59 MAINTENANCE AND ADJUSTMENT • • Remove the rear frame mounting bolts on the left Be sure to place a piece of cloth around the fuel and right sides. hose joint. • • Pull the rear frame rearward with the air cleaner Insert a thin blade screwdriver into the slit on the housing.
  • Page 60 MAINTENANCE AND ADJUSTMENT • • Turn the driver to disconnect the joint lock. Disconnect the throttle sensor connector. • Pull the fuel hose joint out of the delivery pipe. A. Throttle Sensor Connector A. Turn B. Joint Lock C. Fuel Hose Joint...
  • Page 61 MAINTENANCE AND ADJUSTMENT • • Disconnect the intake air pressure sensor connec- Free the main harness from the clamps. tor. • Disconnect the downstream injector connector. A. Main Harness B. Clamps A. Intake Air Pressure Sensor Connector B. Downstream Injector Connector...
  • Page 62 MAINTENANCE AND ADJUSTMENT • • Loosen the throttle body assy holder clamp screw. Remove the bolts and clamps, and take off the • Pull the throttle body assy from the holder. throttle pulley cover. A. Throttle Body Assy Holder Clamp Screw A.
  • Page 63 MAINTENANCE AND ADJUSTMENT • • Loosen the throttle cable bolts, and free the tips of Clean the throttle body assy (see Cleaning Your throttle cable lower end. Motorcycle section). NOTICE If dirt gets through into the engine, exces- sive engine wear and possibly engine dam- age will occur.
  • Page 64 MAINTENANCE AND ADJUSTMENT • • Install the throttle body assy to the throttle body Hold the main harness to the clamps. assy holder. Align the projection with the groove. • Check the throttle body assy is installed securely. A. Main Harness B.
  • Page 65 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 yellow paint of the hose in the throttle and does not come off.
  • Page 66 MAINTENANCE AND ADJUSTMENT • • Connect the intake air pressure sensor connector, Tighten the rear frame mounting bolts to the spec- upstream injector connector, downstream injector ified torque. connector and throttle sensor connector. Tightening Torque • Install the rear frame with the air cleaner housing Rear Frame Mounting Bolts: to the throttle body assy.
  • Page 67 MAINTENANCE AND ADJUSTMENT NOTICE WARNING When installing the fuel hose joint, do not Leaking fuel can cause a fire or explosion re- apply strong force to the upstream injector sulting in serious burns. Make sure the hose pipe. The pipe made from resin could be joint is installed correctly on the upstream in- damaged.
  • Page 68: Clutch

    MAINTENANCE AND ADJUSTMENT If the clutch lever free play cannot be adjusted at Clutch the clutch lever, make the adjustment further down the cable as follows. • Remove the number plate (see Steering section). Clutch Lever Adjustment • Turn the adjuster in all the way. Proper clutch lever free play is 8 a 13 mm (0.3 a •...
  • Page 69 MAINTENANCE AND ADJUSTMENT WARNING Too much cable play can prevent clutch dis- engagement and cause an accident resulting in serious injury or death. When adjusting the clutch or replacing the cable, be sure the upper end of the clutch outer cable is fully seated in its fitting, or it could slip into place later, creating enough cable play to prevent clutch disengagement.
  • Page 70 MAINTENANCE AND ADJUSTMENT • • Remove the clutch cover bolts. Remove the clutch cover and gasket. • Remove the clutch spring bolts, clutch pressure plate and springs. A. Bolts B. Clutch Cover A. Clutch Spring Bolts B. Clutch Pressure Plate...
  • Page 71 MAINTENANCE AND ADJUSTMENT • Remove the friction and steel plates. Steel Plate Thickness Measurement Standard 1.5 a 1.7 mm (0.059 a 0.067 in.) Service Limit 1.4 mm (0.055 in.) A. Friction Plate B. Steel Plate Friction Steel Plates Wear/Damage A. Thickness Inspection B.
  • Page 72 MAINTENANCE AND ADJUSTMENT Friction and Steel Plate Installation Friction and Steel Plate Warp • Install all parts in the reverse order of removal. 0.15 mm • Standard Install the friction plates and steel plates, alternat- (0.0059 in.) or less Friction Plate ing between the two;...
  • Page 73 MAINTENANCE AND ADJUSTMENT • • Apply molybdenum disulfide grease to the steel Check the release shaft lever position by measur- ball and the contact area of the push rod holder. ing the position distance between the lever and the • Install the steel ball and the push rod holder.
  • Page 74 MAINTENANCE AND ADJUSTMENT Release Shaft Lever Position and Adjusting Washer Selection Position Judg- Washers Quan- Distance ment Thickness tity 49.2 a 56.5 mm 1.5 mm Standard (1.94 a 2.22 in.) (0.06 in.) More than 56.5 1.0 mm Too big mm (2.22 in.) (0.04 in.) Less than 49.2 1.0 mm...
  • Page 75: Valve Clearance

    MAINTENANCE AND ADJUSTMENT Valve Clearance Inspection • Valve Clearance Remove the spark plug cap (see Spark Plug sec- tion). • Valve and valve seat wear decreases valve clear- Remove the cylinder head cover bolts and cylinder ance, upsetting valve timing. head cover.
  • Page 76 MAINTENANCE AND ADJUSTMENT • • Remove the head cover gasket and spark plug Remove the two caps from the magneto cover. hole gasket. A. Timing Inspection Cap B. Flywheel Nut Cap A. Head Cover Gasket B. Spark Plug Hole Gasket...
  • Page 77 MAINTENANCE AND ADJUSTMENT • • Bring the piston to the Top Dead Center (TDC) of At this point, the timing marks on the camshaft its compression stroke to inspect the valve clear- sprockets must be almost aligned with the cylinder ance (the position at the end of the compression head upper surface as shown in the figure.
  • Page 78 Using the thickness gauge, measuring the clear- If the valve clearance is not within the specified ance between each cam lobe and valve lifter, for range, adjust by an authorized Kawasaki dealer or all four valves. a competent mechanic following the instructions in the Service Manual.
  • Page 79 MAINTENANCE AND ADJUSTMENT • • 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. to the cylinder head cover. • Replace the spark plug hole gasket with a new one, and install it.
  • Page 80: Exhaust System

    MAINTENANCE AND ADJUSTMENT Tightening Torque Exhaust System Cylinder Head Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) The exhaust system, in particular the muffler body, • is designed to reduce exhaust noise and conduct the Install the two caps to the magneto cover. exhaust gases away from the rider while minimizing Tightening Torque power loss.
  • Page 81 MAINTENANCE AND ADJUSTMENT • • Remove the muffler cover bolts. Remove the muffler cover with the plastic mallet. • Remove the muffler mounting bolt. A. Plastic Mallet B. Muffler Cover A. Muffler Cover Bolts B. Muffler Mounting Bolt...
  • Page 82 MAINTENANCE AND ADJUSTMENT • • Replace the silencer wool with a new one. Check that the exhaust port of the muffler body • Remove the silicone sealant attaching on the muf- cover align with the muffler pipe. fler cover and muffler body. •...
  • Page 83 MAINTENANCE AND ADJUSTMENT • • Apply a non-permanent locking agent to the muf- Secondly, tighten the muffler mounting bolt (rear). • fler cover bolts. Thirdly, tighten the muffler clamp bolt. • Tighten the muffler cover bolts and apply the sili- cone sealant to the joint part of the muffler cover and muffler body.
  • Page 84: Drive Chain

    MAINTENANCE AND ADJUSTMENT • Insert the tabs of the side cover into the slots of Drive Chain the air cleaner housing, and tighten the bolts. For safety and to prevent excessive wear, the drive chain must be checked, adjusted, and lubricated be- fore riding.
  • Page 85 MAINTENANCE AND ADJUSTMENT • Adjust the drive chain if its slack is out of specifi- For the rear wheel to be properly aligned, the cation. notch of the left chain adjuster should align with the same swingarm mark that the notch of the right chain adjuster aligns with.
  • Page 86 MAINTENANCE AND ADJUSTMENT WARNING 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 87 MAINTENANCE AND ADJUSTMENT 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 mm (2.4 2.7 in.). Chain Wear Inspection When the chain has reached its wear limit (i.e., when it has stretched by 1.7% of its original length), it is no longer safe for use and should be replaced.
  • Page 88 MAINTENANCE AND ADJUSTMENT To minimize any chance of the master link coming apart, the master link clip must be installed with the closed end of the “U” pointing in the direction of chain rotation. A. Weight B. Tape Measure Drive Chain 20-Link Length 317.5 a 318.2 mm (12.50 a 12.53 Standard A.
  • Page 89 MAINTENANCE AND ADJUSTMENT Chain Guide Wear Inspection Chain Slipper Wear Inspection • • Visually inspect the drive chain guide and replace Visually inspect the upper and lower of the chain it if excessively worn or damaged. slipper on the swingarm and replace them if worn or damaged.
  • Page 90 MAINTENANCE AND ADJUSTMENT Sprocket Wear Inspection Chain Lubrication • Visually inspect the sprocket teeth and replace the Lubrication of the drive chain is necessary after rid- sprocket if its teeth are worn or damaged. ing in the rain or mud, or any time the chain appears Sprocket Teeth Wear dry.
  • Page 91: Handlebar

    MAINTENANCE AND ADJUSTMENT Handlebar To suit various riding positions, the handlebar can be adjusted by turning the handlebar holders around. • Remove the handlebar pad. • Check the handlebar for bent or crack. • Remove the handlebar clamp bolts, the clamps and the handlebar.
  • Page 92: Brakes

    MAINTENANCE AND ADJUSTMENT Brakes Disc and disc pad wear is automatically compen- sated for and has no effect on the brake lever or pedal action. There are no parts on the brakes that require adjustment except brake lever position. Brake Lever Position The brake lever position can be adjusted to suit the rider’s preference.
  • Page 93 Check for brake hose damage. defective. Have the brake checked immedi- ately by an authorized Kawasaki dealer. Brake Fluid Level Inspection (Front and Rear Brake Reservoirs) Disc Brake Fluid...
  • Page 94 MAINTENANCE AND ADJUSTMENT A. Rear Brake Reservoir A. Front Brake Reservoir B. Lower Level Line B. Upper Level Line • 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.).
  • Page 95 Do not mix two brands of brake replaced as a set. Pad replacement should be done fluid. Change the brake fluid in the brake line by an authorized Kawasaki dealer. completely if the brake fluid must be refilled Usable Brake Pad Range but the type and brand of the brake fluid that is already in the reservoir are unidentified.
  • Page 96: Steering

    MAINTENANCE AND ADJUSTMENT the figure. If play is felt, the steering is too loose Steering and needs to be adjusted. The steering should always be kept adjusted so that the handlebar will turn freely but not have ex- cessive play. Steering Inspection •...
  • Page 97 MAINTENANCE AND ADJUSTMENT • Steering Adjustment Remove the handlebar (see Handlebar section). • • Raise the front wheel off the ground using a jack Loosen the left and right front fork clamp bolts (up- (special tool: 57001-1238) and attachment (spe- per).
  • Page 98 MAINTENANCE AND ADJUSTMENT • Turn the steering stem locknut with a stem nut Tightening Torque wrench (special tool: 57001-1100) to obtain the Steering Stem Head Nut: proper adjustment. 98 N·m (10.0 kgf·m, 72 ft·lb) Front Fork Clamp Bolts (Upper): 23 N·m (2.3 kgf·m, 17 ft·lb) NOTE Tighten the two clamp bolts alternately two times to ensure even tightening torque.
  • Page 99: Front Suspension

    • If necessary, repair or replace by an authorized weight and the condition of the track. Kawasaki dealer. Basically, there are seven adjustments you can make to the front fork. •...
  • Page 100 MAINTENANCE AND ADJUSTMENT This adjustment affects how quickly the fork com- due to weight biasing. Increasing the amount of fork tube protrusion has opposite effects. Be sure that presses. Depending on the model, the fork com- pression damping adjuster has at least 22 positions. the front tire does not touch the fender when the fork The fully seated position (adjuster turned fully clock- is fully compressed.
  • Page 101 MAINTENANCE AND ADJUSTMENT A. Screw A. Screw B. Front Fork Top Plug B. Front Fork Top Plug C. Front Fork (Left Side) C. Front Fork (Right Side) Rebound Damping Adjustment (Left Fork only) • Clean the bottom of the left fork tube. •...
  • Page 102 MAINTENANCE AND ADJUSTMENT Rebound Damping Adjuster Settings A. Rebound Damping Adjuster B. Left Front Fork Cylinder Valve A. Seated Position (Adjuster Turned Fully Clockwise) B. Softer (Counterclockwise) C. Harder (Clockwise) D. Standard Setting *: Number of turns counterclockwise usable range 20 clicks or more.
  • Page 103 MAINTENANCE AND ADJUSTMENT with a flat-head screwdriver. Adjust the compres- Compression Damping Adjuster Settings sion damping to suit your preference under certain conditions. NOTICE Do not force the compression damping ad- juster beyond the fully seated position, or the adjusting mechanism may be damaged. A.
  • Page 104 MAINTENANCE AND ADJUSTMENT the spring preload to suit your preference under Spring Preload Adjuster Settings certain conditions. NOTICE Do not force the spring preload adjuster be- yond the fully seated position, or the adjust- ing mechanism may be damaged. A. Seated Position (Adjuster Turned Fully Counterclockwise) B.
  • Page 105 MAINTENANCE AND ADJUSTMENT 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. NOTE Set the rebound and compression damping and spring preload setting to the softest settings before...
  • Page 106 MAINTENANCE AND ADJUSTMENT NOTICE Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so the disc does not touch the ground. A. Front Axle Nut B.
  • Page 107 MAINTENANCE AND ADJUSTMENT • Loosen the front fork clamp bolts (lower). Standard 317 a 321 mm (12.48 a 12.64 in.) • Remove the front fork tubes by pulling down while Length twisting it. A. Length A. Front Fork Clamp Bolts (Lower) B.
  • Page 108 MAINTENANCE AND ADJUSTMENT • Left Front Fork Place a drain pan under the front fork and drain • Using the top plug wrench (special tool: 57001 fork oil. -1645), remove the left front fork cylinder unit from NOTE the outer tube and slowly slide down the outer Pump the outer tube several times to discharge tube.
  • Page 109 MAINTENANCE AND ADJUSTMENT • • Temporarily install the left front fork cylinder unit to Loosen the adjuster assembly completely. the outer tube using the top plug wrench (special NOTE tool: 57001-1645). When removing the adjuster assembly, do not force to loosen it at once using an impact wrench. A.
  • Page 110 MAINTENANCE AND ADJUSTMENT • Remove the push rod. A. Locknut B. Wrench A. Push Rod C. Left Front Fork Adjuster Assembly NOTICE Removing the locknut and pushing the pis- ton rod thread into the left front fork cylinder unit will damage the oil seal. Do not remove the locknut from the piston rod.
  • Page 111 MAINTENANCE AND ADJUSTMENT • • Remove the fork leg from the vise. Remove the left front fork cylinder unit from the • Loosen the left front fork cylinder unit with the top outer tube. plug wrench (special tool: 57001-1645). A. Left Front Fork Cylinder Unit B.
  • Page 112 MAINTENANCE AND ADJUSTMENT • Holding the top plug wrench (special tool: 57001 -1645) with a vise, loosen the left front fork base valve assembly on the fork cylinder unit with a hexagon box wrench. A. Left Front Fork Base Valve Assembly B.
  • Page 113 MAINTENANCE AND ADJUSTMENT • • Drain the fork oil from the left front fork cylinder Clean the threads of the left front fork cylinder unit unit by pumping the piston rod several times. and left front fork base valve assembly. •...
  • Page 114 MAINTENANCE AND ADJUSTMENT • • With the piston rod fully stretched, pour 260 mL Pump the piston rod slowly several times to expel (8.79 US oz.) of fork oil. air. A. Pump A. Fork Oil B. Piston Rod B. Left Front Fork Cylinder Unit •...
  • Page 115 MAINTENANCE AND ADJUSTMENT A. 115 a 123 mm (4.53 a 4.84 in.) A. O-rings B. Oil Level B. Bushings • • Replace the O-rings on the left front fork base With the piston rod held immovable fully stretched, valve assembly with new ones. gently install the left front fork base valve assem- •...
  • Page 116 MAINTENANCE AND ADJUSTMENT • Discharge the extra oil off the left front fork cylinder unit by pumping the piston rod to full stroke. NOTICE Be careful not to bend or damage the pis- ton rod when the piston rod is stroked. Ser- vice carefully because oil flies out from the oil hole of the left front fork cylinder unit.
  • Page 117 MAINTENANCE AND ADJUSTMENT • • Drain the extra oil from the left front fork cylinder Protect the piston rod end with a heavy cloth to unit oil hole. prevent damage. • • Blow out the extra oil from the oil hole of the left Pump the piston rod to full stroke by pushing down front fork cylinder unit with the compressed air the left front fork cylinder unit.
  • Page 118 MAINTENANCE AND ADJUSTMENT • • Wipe the oil off completely from the left front fork If oil leaks from the cylinder unit, replace the left cylinder unit. front fork cylinder unit assembly. • • Compress the piston rod to 200 a 250 mm (7.87 Hold the left front fork cylinder unit on level ground a 9.84 in.) and hold the left front fork cylinder unit and release the piston rod then check the piston...
  • Page 119 MAINTENANCE AND ADJUSTMENT • • Completely wipe off the fork oil from the left front Temporarily tighten the left front fork cylinder unit fork cylinder unit. using the top plug wrench (special tool: 57001 • Insert above-mentioned parts into the fork. -1645).
  • Page 120 MAINTENANCE AND ADJUSTMENT • • Replace the O-ring on the left front fork adjuster Slowly turn the left front fork adjuster assembly assembly with a new one and apply specified fork clockwise until resistance is felt and check the oil to the O-ring. clearance between the locknut and left front fork •...
  • Page 121 MAINTENANCE AND ADJUSTMENT A. Locknut A. Axle Holder Part B. Wrench B. Left Front Fork Adjuster Assembly C. Left Front Fork Adjuster Assembly • Compare the length at assembly and at disassem- • Apply a non-permanent locking agent and tighten bly.
  • Page 122 MAINTENANCE AND ADJUSTMENT A. Top Plug Wrench (Special Tool: 57001-1645) A. Left Front Fork Outer Tube B. Left Front Fork Cylinder Unit B. Fork Oil C. Left Front Fork Outer Tube Recommended Fork Oil • Pour the specified amount of fork oil into the left SHOWA SS19 or equivalent front fork outer tube.
  • Page 123 MAINTENANCE AND ADJUSTMENT Right Front Fork • Check the position of the right front fork spring preload adjuster so that it can be installed in the original position. A. Left Front Fork Cylinder Unit B. Left Front Fork Outer Tube C.
  • Page 124 MAINTENANCE AND ADJUSTMENT • • Using the top plug wrench (special tool: 57001 Install the clamps (special tool: 57001-1693) as -1645), remove the top plug from the right front shown in the figure, and tighten the bolts. • fork outer tube and slowly slide down the outer Screw the holders of the fork spring compressor tube.
  • Page 125 MAINTENANCE AND ADJUSTMENT • • Set the right front fork tube on the base (special Insert the compression shaft and screw the exten- tool: 57001-1753) as shown in the figure. sion rod (special tool: 57001-1753). • Set the other side compression shaft same process.
  • Page 126 MAINTENANCE AND ADJUSTMENT • • Screw the extension rods (special tool: 57001 Install the nuts. • -1753) into the base (special tool: 57001-1753). Screw in the nuts until the piston rod nut comes out. A. Extension Rod (Special Tool: 57001-1753) A.
  • Page 127 MAINTENANCE AND ADJUSTMENT • • Holding the piston rod nut with a spanner, loosen Remove the fork spring compressor, clamp and the right front fork spring preload adjuster. base. • Remove the spring collar. A. Piston Rod Nut B. Spanner A.
  • Page 128 MAINTENANCE AND ADJUSTMENT • • Unscrew the piston rod nut. Place a drain pan under the right front fork and • Remove the spring guide and fork spring. drain fork oil. NOTE Pump the right front fork outer tube and piston rod several times to discharge the fork oil.
  • Page 129 MAINTENANCE AND ADJUSTMENT • • Hold the right front fork at the inverted position for Install the fork spring with the smaller end facing more than 30 minutes to allow the fork oil to fully upward. drain. A. Fork Spring B.
  • Page 130 MAINTENANCE AND ADJUSTMENT • • Using the fork piston rod puller (special tool: Install the spring guide. • 57001-1298), pull up the piston rod. Install the piston rod nut with the unthread side down. A. Fork Piston Rod Puller, M10 × 1.0 (Special Tool: A.
  • Page 131 MAINTENANCE AND ADJUSTMENT • • Screw the piston rod nut onto the piston rod as Install the spring collar. shown in the figure. A. Spring Collar A. Piston Rod Nut B. Piston Rod C. 13 mm (0.51 in.) or more...
  • Page 132 MAINTENANCE AND ADJUSTMENT • • Install the clamps (special tool: 57001-1693) as Set the right front fork tube on the base (special shown in the figure, and tighten the bolts. tool: 57001-1753) as shown in the figure. • Screw the holders of the fork spring compressor (special tool: 57001-1587).
  • Page 133 MAINTENANCE AND ADJUSTMENT • • Insert the compression shaft and screw the exten- Screw the extension rod (special tool: 57001 sion rod (special tool: 57001-1753). -1753) into the base (special tool: 57001-1753). • Set the other side compression shaft same process.
  • Page 134 MAINTENANCE AND ADJUSTMENT • Install the nuts. • Screw in the nuts until the piston rod nut comes out. A. Top Plug B. Piston Rod Nut C. Clearance (0.5 mm (0.02 in.) or more) • Turn the piston rod nut counterclockwise until it A.
  • Page 135 MAINTENANCE AND ADJUSTMENT • Push the top plug into the spring collar to make sure that it is securely installed. A. Piston Rod Nut B. Top Plug C. Spanner A. Top Plug D. Right Front Fork Spring Preload Adjuster B. Spring Collar...
  • Page 136 MAINTENANCE AND ADJUSTMENT • Remove the fork spring compressor, clamp and Standard Right Fork Oil Capacity base. Right Fork Spring 9.5 N/mm (0.97 kgf/mm) • Pour the specified amount of fork oil into the right Right Fork Oil front fork outer tube. 205 mL (6.93 US oz.) Capacity •...
  • Page 137 MAINTENANCE AND ADJUSTMENT A. Top Plug A. Left Front Fork Cylinder Unit B. Right Front Fork Outer Tube B. Top Plug Wrench (Special Tool: 57001-1645) C. Top Plug Wrench (Special Tool: 57001-1645) C. Torque Wrench • Install the front fork tubes to the motorcycle. Tightening Torque •...
  • Page 138 MAINTENANCE AND ADJUSTMENT • wrench is fitted, and that of the octagonal hole of Install the front brake caliper to the fork leg, and the wrench. tighten the front caliper mounting bolts to the spec- This torque value (31 N·m (3.1 kgf·m, 23 ft·lb)) is ified torque.
  • Page 139 MAINTENANCE AND ADJUSTMENT NOTE NOTE Tighten the two clamp bolts alternately two times Do not apply the front brake during this process to ensure even tightening torque. to stop the motorcycle from rolling forward. Put a block in front of the wheel to stop it from moving. A.
  • Page 140 MAINTENANCE AND ADJUSTMENT WARNING After servicing, it takes several applications of the brake lever before the brake pads con- tact the disc, which could result in increased stopping distance and cause an accident re- sulting in injury or death. Do not attempt to ride the motorcycle until a firm brake lever is obtained by pumping the lever until the pads are against the disc.
  • Page 141: Rear Suspension (uni-trak ® )

    Visually inspect the rear shock absorber for oil leakage. • If necessary, repair or replace by an authorized Kawasaki dealer. A. Rebound Damping Adjuster Rear Shock Absorber Adjustment If the damping feels too soft or too stiff, adjust it in The spring preload of the shock absorber can be accordance with the following table.
  • Page 142 MAINTENANCE AND ADJUSTMENT NOTICE Rebound Damping Adjuster Settings 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 143 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 144 MAINTENANCE AND ADJUSTMENT NOTICE Low Speed Compression Damping Adjuster Settings 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 145 MAINTENANCE AND ADJUSTMENT • Using the hook wrench (special tool: 57001-1101), turn the spring preload adjusting nut as required. Turning the adjusting nut down increases the spring preload. A. Spring Preload Adjusting Nut B. Locknut C. Hook Wrenches (Special Tools: 57001-1101, 1539) A.
  • Page 146 Always wear eye and face protection when working on the rear shock absorber. Removal and installation of the rear shock A. Adjusting Nut Position absorber spring should be performed by an B. Center of Upper Rear Shock Absorber Pivot authorized Kawasaki dealer. C. Spring End...
  • Page 147: 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 148 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 149: 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 150: 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 151 MAINTENANCE AND ADJUSTMENT 1. Muffler Mounting Bolts 6. Rear Master Cylinder 11. Brake Pedal Bolt 2. Muffler Clamp Bolt Mounting Bolts 12. Kick Pedal Bolt 3. Upper Engine 7. Rear Brake Disc Mounting 13. Clutch Cover Bolts Mounting/Bracket Bolts Bolts 14.
  • Page 152 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 153 MAINTENANCE AND ADJUSTMENT Fastener N·m kgf·m ft·lb Remarks Chassis Air Cleaner Duct Clamp Screw 0.20 18 in·lb Throttle Body Assy Holder Clamp Screw 0.20 18 in·lb Muffler Clamp Bolt 97 in·lb Muffler Mounting Bolts Engine Mounting Nut (Lower) R, S Engine Bracket Nuts (Middle) R, S Engine Mounting Nut (Middle)
  • Page 154 MAINTENANCE AND ADJUSTMENT Fastener N·m kgf·m ft·lb Remarks Front Fork Clamp Bolts (Upper) AL, L Rear Shock Absorber Nut (Lower) Rear Shock Absorber Nut (Upper) Rocker Arm Pivot Nut G, R Swingarm Pivot Shaft Nut 10.0 Tie-Rod Mounting Nuts G, R Handlebar Clamp Bolts Steering Stem Head Nut 10.0...
  • Page 155: 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 156 MAINTENANCE AND ADJUSTMENT • NOTICE Use a soft cloth to dry your motorcycle. As you dry, inspect your motorcycle for chips and scratches. Plastic parts may deteriorate and break if Do not let the water air dry as this can damage they come in contact with chemical sub- the painted surfaces.
  • Page 157: Lubrication

    MAINTENANCE AND ADJUSTMENT 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 WARNING this section with either motor oil or regular grease, after each race and whenever the vehicle has been Rubber protectants can be slippery and, if operated under wet or rainy conditions, especially...
  • Page 158 MAINTENANCE AND ADJUSTMENT • • Rear Brake Pedal Shift Pedal • Rear Master Cylinder Joint Pin • Kick Pedal • Footpeg Apply an aerosol cable lubricant with a pressure lubricator on all cables: • Clutch Cable • Throttle Cable...
  • Page 159 MAINTENANCE AND ADJUSTMENT Cable Lubrication Apply grease to the following points: • Clutch Inner Cable Upper End • Throttle Inner Cable Upper End A. Upper End Drive Chain Lubrication Lubricate the drive chain after riding through rain or on wet track, or any time that the chain appears dry.
  • Page 160: Dfi Self-diagnosis

    MAINTENANCE AND ADJUSTMENT DFI Self-Diagnosis This motorcycle equips the DFI trouble self -diagnosis system. Trouble diagnosis can be con- ducted with the optional parts sold separately as the following procedures. Self-diagnosis Outline The self-diagnosis has two modes and can be switched to another mode by grounding the self-diagnosis terminal.
  • Page 161 MAINTENANCE AND ADJUSTMENT • Connect the power supply harness (optional part: 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. A.
  • Page 162 MAINTENANCE AND ADJUSTMENT • Keep the FI indicator light assy (optional part: 23016-0049) Y lead ground. • Count the blinks of the light to read the service code. Keep the lead ground until you finish read- ing the service code. •...
  • Page 163 MAINTENANCE AND ADJUSTMENT How to Read Service Codes • Service codes are shown by a series of long and short blinks of the FI indicator light as shown below. • Read 10th digit and unit digit as the FI indicator light blinks. •...
  • Page 164 MAINTENANCE AND ADJUSTMENT 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 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...
  • Page 165 MAINTENANCE AND ADJUSTMENT Service FI Indicator Light Problems Code Upstream injector malfunction, wiring open or short 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 166: 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 167 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 168 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 169 TROUBLESHOOTING GUIDE • Clutch hub nut loose • Lubrication inadequate: Clutch plate warped or rough • • Engine oil level too low Clutch hub spline damaged • Engine oil quality poor or type incorrect Gear shifting faulty - Coolant inadequate: Transmission does not go into gear;...
  • Page 170 TROUBLESHOOTING GUIDE • Engine noise abnormal - Camshaft chain, sprocket, chain guide worn • Decompression spring broken Knocking: • Flywheel magneto loose • Carbon built up in combustion chamber • Fuel quality poor or type incorrect Abnormal drive train noise - •...
  • Page 171 TROUBLESHOOTING GUIDE • Rear shock absorber noise: Steering stem bearing damaged • • Shock absorber damaged Steering stem bearing inadequately lubricated • Steering stem bent • Disc brake noise: Tire air pressure too low • Pad installed incorrectly • Pad surface glazed Handlebar shakes or vibrates excessively: •...
  • Page 172 TROUBLESHOOTING GUIDE Shock absorption unsatisfactory (suspension Poor braking performance - too soft): • Air in the brake line • Front fork oil level insufficient and/or front fork • Brake pad or disc worn leaking oil • Brake fluid leaking • Front fork oil viscosity too low •...
  • Page 173: 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 174 TUNING Troubleshooting Improper Settings does not feel as “hard” in the later stage of fork travel. Listed below are some symptoms of improper sus- Fork Oil Capacity Effect on Fork Stroke pension settings and the most likely means of cor- recting them.
  • Page 175 TUNING • Springs too soft Hence, if the actual rider weighs considerably more • 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.
  • Page 176 TUNING Front and Rear Suspension Compatibility Suspension Tuning According the Type of Inspection Course Use this procedure to determine if the suspension Lower the front end slightly is balanced reasonably well. (Increase the amount of fork • Hold the motorcycle upright (remove the side tube protrusion above the stand.).
  • Page 177 TUNING • Although this is one of the most effective adjust- Decrease the fork oil capacity. • ment procedures, suspension settings may vary de- Use a softer spring, or decrease the spring pending on the conditions at the track and the rider’s preload.
  • Page 178 TUNING • Increase the rebound damping. Rear End Bottoms After 3 or 4 Successive • Jumps - Decrease the rear shock absorber spring preload. • • Decrease the compression damping. Decrease the rebound damping. 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) -...
  • Page 179: 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 180: Special Care According To Track Conditions

    TUNING • The engine works hardest in muddy conditions Special Care According to Track and the radiator can become clogged with mud. Conditions Take care not to overheat the engine in these con- ditions. The engine also works very hard when •...
  • Page 181: Optional Parts

    OPTIONAL PARTS OPTIONAL PARTS Engine Sprocket Suspension Spring (N/mm) K = 9.1 13T (Standard) Front K = 9.5 (Standard) K = 9.9 Rear Sprocket K = 49 K = 51 Rear Aluminum 50T (Standard) K = 53 (Standard) K = 55 Disc Plate Front No holes (for wet conditions)
  • Page 182: 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 183 PRE-RACE CHECKS AND AFTER-RACE MAINTENANCE • • Grease the throttle grip and control cables. Rear shock absorber springs (for suspension ad- justment) Suggested Spare Parts - • Rear and engine sprockets with bolts/nuts and cir- • Front and rear wheels clips •...
  • Page 184: 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 185: 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 186: 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 187: Wiring Diagram

    WIRING DIAGRAM WIRING DIAGRAM...

Comments to this Manuals

Symbols: 0
Latest comments: