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 highways. • 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 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...
DISCLAIMER OF WARRANTY This motorcycle is sold AS IS, with all faults, obvious or concealed and there are NO WAR- RANTIES, expressed or implied. Including war- ranties of MERCHANTABILITY or FITNESS FOR PURPOSE. The purchaser accepts all responsibilities con- cerning quality, performance, cost of service and/or necessary repairs.
WARNING The engine exhaust from this product con- tains chemicals known to the State of Cali- fornia to cause cancer, birth defects or other reproductive harm.
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.
SPECIFICATIONS 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 112.5 kg (248 lb) Fuel Tank Capacity 6.2 L (1.6 US gal) ENGINE...
SPECIFICATIONS TRANSMISSION Transmission Type 5-speed, constant-mesh, return shift Clutch Type Wet, multi disc Driving System Chain drive Gear Ratio: 1.750 (28/16) 1.412 (24/17) 1.188 (19/16) 1.000 (19/19) 0.875 (21/24) Primary Reduction Ratio 2.727 (60/22) Final Reduction Ratio 3.846 (50/13) Overall Drive Ratio 9.178 @Top gear Engine Oil: Type...
314 mm (12.4 in.) Rear Wheel Travel 315 mm (12.4 in.) Front Fork Oil: Type Kawasaki Fork Oil KHL15-11 Amount (Per Fork Leg): Inner Damper 333 mL (11.3 US oz.) 190 ∼ 265 mL (6.42 ∼ 8.96 US oz.) Inner/Outer Tubes...
GENERAL INFORMATION Location of Parts 1. Clutch Lever 5. Fuel Tank Cap 2. Engine Stop Button 6. Front Brake Fluid Reservoir 3. Launch Control Mode Button 7. Front Brake Lever 4. Orange Launch Control Mode/FI Warning 8. Throttle Grip Indicator Light...
GENERAL INFORMATION 1. Front Fork 8. Brake Caliper 2. Radiator 9. Shift Pedal 3. Fuel Tank 10. Footpeg 4. Throttle Body Assy 11. Rear Shock Absorber 5. Seat 12. Swingarm 6. Air Cleaner Element 13. Drive Chain 14. Chain Guide 7.
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 Inspection Window 4. Kick Pedal 9. Exhaust Pipe 5. DFI Setting Data Selection Connector...
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.
Avoid filling the tank in the rain or where heavy dust Fuel is blowing so that the fuel does not get contaminated. This Kawasaki KX has a 4-stroke engine that re- quires a gasoline. The capacity of the fuel tank is 6.2 L (1.6 US gal).
GENERAL INFORMATION WARNING Minimum Octane Rating Method Rating Gasoline is extremely flammable and can be explosive under certain conditions. Always (RON + MON) Antiknock Index stop the engine and do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;...
Avoid using blends of unleaded gasoline and blends during refueling. methanol (wood alcohol) whenever possible, When not operating your Kawasaki for 30 and never use “gasohol” containing more to 60 days, mix a fuel stabilizer (such as than 5% methanol. Fuel system damage and STA-BIL) with the gasoline in the fuel tank.
GENERAL INFORMATION Kick Pedal Starting the Engine • This motorcycle is equipped with a primary kick Shift the transmission into neutral. starting system. When the clutch lever is pulled, the WARNING motorcycle can be started with the transmission in any gear. Riding with the side stand can cause a crash resulting in injury.
GENERAL INFORMATION When engine is cold When engine is already warm or restarts • • Pull out the idle adjusting screw/choke knob. Kick the engine over, leaving the throttle closed without using the idle adjusting screw/choke knob. NOTE ○ If the engine fails starting, open the throttle fully ∼...
GENERAL INFORMATION • When shifting into 3rd, the system is deactivated Launch Control Mode automatically. The launch control mode can be used to adjust ig- nition timing to help riders get better starts on slip- pery terrain. The system’s effectiveness is dependent on rider skill, technique and terrain conditions.
GENERAL INFORMATION NOTE DFI Setting Data Selection ○ If the connector is changed while the engine is running, the DFI setting does not change. ○ Three DFI settings are available to suit various The ECU is set to the standard track condition track conditions.
GENERAL INFORMATION Shifting Gears This motorcycle is equipped with a 5-speed “return shift” transmission. The neutral is located halfway between 1st and 2nd gear. “Return shift” means that when shifting up or down, each gear must be engaged before the next higher or lower gear may be selected.
GENERAL INFORMATION Stopping the Motorcycle Stopping the Engine • For maximum deceleration, close the throttle and Shift the transmission into the neutral position. • apply both front and rear brakes. Pull in the clutch Close the throttle completely and push the engine lever as the motorcycle comes to a stop.
GENERAL INFORMATION Stop and let the engine cool completely. Be Break-In sure to fully check the tightness of nuts and bolts, oil leakage, coolant leakage and any ir- A brief break-in procedure must be carried out to regularities, especially, each cable elongation, obtain the proper operating clearances in the engine brake play, chain slack and spoke tightness.
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.
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 ....
GENERAL INFORMATION 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.
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.
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 •...
MAINTENANCE AND ADJUSTMENT 2. Periodic Inspection (Chassis Related Item) FREQUENCY After each Every 3 Every 6 Every 12 race (or races (or races (or races (or required Page OPERATION 2.5 hours) 7.5 hours) 15 hours) 30 hours) • Brake - adjust † •...
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 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 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- •...
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 inspection window, periodically to ensure long engine life. tip the motorcycle slightly to the right until oil is •...
MAINTENANCE AND ADJUSTMENT • WARNING Be sure to install the spring on the original position. Engine oil is a toxic substance. Dispose of used oil properly. Contact your local author- ities for approved disposal methods or pos- sible recycling. • When the oil filter is replaced, remove the oil filter cap bolts and take off the cap with O-rings.
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- Oil Filter Cap Bolts: sistent use of these products meets or exceeds war- 9.8 N·m (1.0 kgf·m, 87 in·lb)
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...
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.
MAINTENANCE AND ADJUSTMENT • 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 Check the coolant level in the radiator.
MAINTENANCE AND ADJUSTMENT • NOTICE Install the radiator cap. Coolant Change Immediately wash away any coolant that The coolant should be changed to ensure long en- spills on the frame, engine, or wheel. gine life, if necessary. • Wait for the engine to cool completely. WARNING •...
MAINTENANCE AND ADJUSTMENT • • Fill the radiator up to the bottom of the radiator filler If the coolant level is low, add coolant up to the neck with coolant. bottom of the radiator filler neck. • • Lean the motorcycle slightly until the radiator filler Install the radiator cap.
MAINTENANCE AND ADJUSTMENT If the plug is oily or has carbon built up on it, clean Spark Plug it. The plug may also be cleaned using a high flash -point solvent and a nonmetal brush (nylon etc.). If The spark plug should be taken out periodically for the spark plug electrodes are corroded, or damaged, inspection and regapping.
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.
MAINTENANCE AND ADJUSTMENT • WARNING Be sure to place a piece of cloth around the fuel hose joint. Fuel is flammable and explosive under cer- • Wipe off the dirt of the surface around the connec- tain conditions and can cause severe burns. tion using a cloth or a soft brush.
MAINTENANCE AND ADJUSTMENT • • Cover the pipe and the fuel hose joint with the vinyl Clean the cylinder head cover around the spark bags to keep them clean. plug cap hole before removing the spark plug. • • Disconnect the fuel pump lead connector. Pull the spark plug cap off the plug before remov- •...
MAINTENANCE AND ADJUSTMENT • • Install the spark plug cap so that it is aligned with Make sure that the dampers are in place on the the line on the cylinder head cover. frame and are not damaged. If the dampers are •...
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 •...
MAINTENANCE AND ADJUSTMENT • • Before installing the fuel tank, check that both Temporarily tighten the radiator shroud bolts fol- throttle cables run over the main harness. lowing the tightening sequence. NOTE ○ To prevent the bottom of the fuel tank from pushing the throttle cables, run the throttle cables over the main harness correctly.
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.
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. Wing Bolt B. Seat B. Air Cleaner Element •...
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.
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 • 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.
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.
MAINTENANCE AND ADJUSTMENT Throttle Cable Throttle Cable Adjustment Inspect the throttle grip for smooth operation in all steering positions. Check and adjust the throttle cable in accordance with the Periodic Maintenance Chart. • Check that the throttle grip has 2 ∼ 3 mm (0.08 ∼ 0.12 in.) of play and turns smoothly.
MAINTENANCE AND ADJUSTMENT • With the engine idling, turn the handlebar both Throttle Body Assy ways and check if handlebar movement changes the idle speed. If so, the throttle cable may be im- properly adjusted, incorrectly routed, or damaged. Idle Speed Adjustment Be sure to correct any of these conditions before •...
MAINTENANCE AND ADJUSTMENT • • Remove the fuel tank (see Spark Plug section). Loosen the muffler clamp bolt. • • Remove the bolt and take off the side cover on Remove the muffler mounting bolts, and pull out both sides. the muffler body backward.
MAINTENANCE AND ADJUSTMENT • • Loosen the air cleaner duct clamp screw. Disconnect the intake air temperature sensor con- nector. A. Air Cleaner Duct Clamp Screw A. Intake Air Temperature Sensor Connector...
MAINTENANCE AND ADJUSTMENT • • Remove the rear frame mounting bolts on the both Disconnect the throttle sensor connector. • sides. Disconnect the intake air pressure sensor connec- • Pull the rear frame rearward with the air cleaner tor. • housing.
MAINTENANCE AND ADJUSTMENT • • Be sure to place a piece of cloth around the fuel Turn the driver to disconnect the joint lock. • hose joint. Disconnect the fuel hose joint from the delivery • Wipe off the dirt of the surface around the connec- pipe.
MAINTENANCE AND ADJUSTMENT • • Loosen the throttle body assy holder clamp screw. Remove the bolts, and take off the throttle pulley • Pull the throttle body assy from the holder. cover. A. Throttle Pulley Cover Bolts A. Throttle Body Assy Holder Clamp Screw B.
MAINTENANCE AND ADJUSTMENT • If any carbon accumulates, wipe the carbon off the throttle bore and the throttle valve, using a lint-free cloth penerated with a high flash-point solvent. A. Decelerator Cable Bolt Locknut B. Accelerator Cable Bolt C. Tips of Throttle Cable Lower Ends D.
MAINTENANCE AND ADJUSTMENT • WARNING While holding the decelerator cable bolt, tighten the cable bolt locknut. Operation with improperly adjusted, incor- Tightening Torque rectly routed, or damaged cables could re- sult in an unsafe riding condition. Be sure Throttle Cable Mounting Bolts: the control cables are adjusted and routed 3.0 N·m (0.31 kgf·m, 27 in·lb) correctly, and are free from damage.
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 • • Connect the intake air pressure sensor connector, Install the rear frame with the air cleaner housing fuel injector connector and throttle sensor connec- to the throttle body assy. • tor. Check the duct is installed securely. •...
MAINTENANCE AND ADJUSTMENT Tightening Torque Clutch Rear Frame Mounting Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb) Clutch Lever Adjustment • Install the fuel tank (see Spark Plug section). Proper clutch lever free play is 8 ∼ 13 mm (0.3 ∼ •...
MAINTENANCE AND ADJUSTMENT • • Remove the number plate (see Steering section). Tighten the locknut. • Turn the adjuster in all the way. • WARNING Slide the dust cover back. • Loosen the locknut in the middle of the clutch ca- Too much cable play can prevent clutch dis- ble, and turn the adjusting nut so that the clutch engagement and cause an accident resulting...
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 • • 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.
MAINTENANCE AND ADJUSTMENT ○ Friction Steel Plates Wear/Damage When replacing the friction plates with new ones, Inspection mark the two end friction plates just after opening • the package so that you can distinguish and install Visually inspect the friction and steel plates to see them in the correct location.
MAINTENANCE AND ADJUSTMENT NOTE ○ Do not use the steel plate of 2.0 mm (0.079 in.) and 1.2 mm (0.047 in.) thickness at the same time. A. Clutch Hub B. Friction Plates C. Steel Plates D. Clutch Pressure Plate E. Clutch Spring Bolt A.
MAINTENANCE AND ADJUSTMENT Clutch Hub Installation Friction and Steel Plate Warp • Install all parts in the reverse order of removal. Maximum 0.15 mm • Standard Friction Replace the clutch hub nut with a new one. (0.0059 in.) or less •...
MAINTENANCE AND ADJUSTMENT • Friction and Steel Plate Installation Apply molybdenum disulfide grease to the push • Install all parts in the reverse order of removal. rod as shown in the figure. • • Install the friction plates and steel plates, alternat- Install the push rod so that the oil passage hole ing between the two;...
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 • 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 Judg- Washers Quan- • Remove the clutch pressure plate as necessary Distance ment...
MAINTENANCE AND ADJUSTMENT • While pushing down the brake pedal, tighten the Valve Clearance rear master cylinder mounting bolts. Tightening Torque Valve and valve seat wear decreases valve clear- Rear Master Cylinder Mounting Bolts: ance, upsetting valve timing. 9.8 N·m (1.0 kgf·m, 87 in·lb) NOTICE •...
MAINTENANCE AND ADJUSTMENT • Valve Clearance Inspection Remove the head cover gasket and spark plug • Remove the spark plug cap (see Spark Plug sec- hole gasket. tion). • Remove the cylinder head cover bolts and cylinder head cover. A. Head Cover Gasket B.
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 or ance between each cam lobe and valve lifter, for a competent mechanic following the instructions in all four valves.
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 • 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. Tightening Torque Timing Inspection Cap: 3.5 N·m (0.36 kgf·m, 31 in·lb) Flywheel Nut Cap:...
MAINTENANCE AND ADJUSTMENT • Remove the muffler 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 minimizing power loss.
MAINTENANCE AND ADJUSTMENT • • Remove the muffler cover with the plastic mallet. Replace the silencer wool with a new one. • Remove the silicone sealant attaching on the muf- fler 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.
MAINTENANCE AND ADJUSTMENT • • Check that the exhaust port of the muffler cover Apply a non-permanent locking agent to the muf- align with the muffler body. fler body cover bolts. • Tighten the muffler cover bolts and apply the sili- cone sealant to the joint part of the muffler cover and muffler body.
MAINTENANCE AND ADJUSTMENT • • 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. • Thirdly, tighten the muffler clamp bolt.
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 lubricated be- fore riding. If the chain becomes badly worn or mal- adjusted - either too loose or too tight - it could jump off the sprockets or break.
MAINTENANCE AND ADJUSTMENT 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.
MAINTENANCE AND ADJUSTMENT • NOTE Tighten both chain adjuster locknuts. • ○ Tighten the axle nut to the specified torque. When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, Tightening Torque tighten the nut clockwise up to the next alignment.
MAINTENANCE AND ADJUSTMENT • NOTE Measure the 20-link length on a straight part of the ○ chain from the center of the 1st pin to the center When riding in wet and muddy conditions, mud of the 21st pin. If the length exceeds the service sticks to the chain and sprockets, resulting in an limit, the chain should be replaced.
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 Chain Slipper Wear Inspection Sprocket Wear Inspection • • Visually inspect the upper and lower of the chain Visually inspect the sprocket teeth and replace the slipper on the swingarm and replace them if worn sprocket if its teeth are worn or damaged. or damaged.
MAINTENANCE AND ADJUSTMENT Chain Lubrication Adjustable Ergonomics Lubrication of the drive chain is necessary after rid- ing in the rain or mud, or any time the chain appears dry with a high quality lubricant for drive chains. To suit various riding positions, the handlebar •...
MAINTENANCE AND ADJUSTMENT • 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 •...
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 • • 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 immedi- the rider’s preference. • ately by an authorized Kawasaki dealer. To adjust the brake lever position, slide the front brake lever dust cover back, and loosen the lock- nut, and turn the adjuster to either side with a Disc Brake Fluid wrench.
MAINTENANCE AND ADJUSTMENT NOTICE Do not spill brake fluid onto any painted sur- face. Do not use fluid from a container that has been left open or that has been unsealed for a long time. Check for fluid leakage around the brake sys- tem fittings.
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.).
1 mm (0.04 in.), have both pads in the caliper that the handlebar will turn freely but not have ex- replaced as a set. Pad replacement should be done cessive play. by an authorized Kawasaki dealer. Usable Brake Pad Range A. Lining Thickness B. 1 mm (0.04 in.)
MAINTENANCE AND ADJUSTMENT Steering Inspection Steering Adjustment • • To check the steering adjustment, raise the front Raise the front wheel off the ground using a jack wheel off the ground using a jack (special tool: (special tool: 57001-1238) and attachment (spe- 57001-1238) and attachment (special tool: 57001 cial tool: 57001-1608).
MAINTENANCE AND ADJUSTMENT • • Remove the handlebar (see Handlebar section). Turn the steering stem nut with a stem nut wrench • Loosen the left and right front fork clamp bolts (up- (special tool: 57001-1100) to obtain the proper ad- per).
• Visually inspect the front fork for oil leakage, scor- ing or scratches on the outer surface of the inner tube. • If necessary, repair or replace by an authorized Kawasaki dealer.
MAINTENANCE AND ADJUSTMENT Front Fork Adjustment Any of the following front fork adjustments can be made to tune the front suspension to the rider’s weight and the condition of the track. Basically, there are five adjustments you can make to the front fork. •...
MAINTENANCE AND ADJUSTMENT • WARNING Compression Damping Adjustment This adjustment affects how quickly the fork com- Improper fork leg adjustment can cause poor presses. Depending on the model, the fork com- handling and loss of stability, which could pression damping adjuster has at least 22 positions. lead to an accident.
MAINTENANCE AND ADJUSTMENT WARNING When riding and transporting the motor- cycle, make sure that the air pressure is within the adjustable range. If used outside the adjustable range, running stability can decrease and cause an accident resulting in serious injury or death. Be sure to remove the air valve adapter be- fore riding.
MAINTENANCE AND ADJUSTMENT NOTICE Rebound Damping Adjuster Settings Be sure to install the air valve plug to prevent dust from entering. 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.
MAINTENANCE AND ADJUSTMENT Compression Damping Adjustment Compression Damping Adjuster Settings • To adjust the compression damping, turn the adjuster on each front fork cylinder valve with a standard tip screwdriver. Adjust the compression damping to suit your preference and riding condi- tions.
MAINTENANCE AND ADJUSTMENT • NOTICE Remove the brake caliper from the fork leg, and rest the caliper on some kind of stand so that it Be careful not to scratch the inner tube and does not dangle. not to damage the dust seal. •...
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. Air Valve Plug •...
MAINTENANCE AND ADJUSTMENT • NOTE Loosen the front fork clamp bolts (lower). ○ Set the rebound and compression damping to the softest settings before disassembly to minimize damping forces that can hinder disassembly. Record the setting before turning the adjuster. •...
MAINTENANCE AND ADJUSTMENT • • Remove the front fork by pulling down while twist- Using the top plug wrench, 49 mm (special tool: ing it. 57001-1653), remove the fork top plug from the outer tube and slowly slide down the outer tube. A.
MAINTENANCE AND ADJUSTMENT • Raise the outer tube and temporarily install the fork top plug to the outer tube using the top plug wrench, 49 mm (special tool: 57001-1653). A. Fork Oil A. Front Fork Top Plug B. Outer Tube C.
MAINTENANCE AND ADJUSTMENT • NOTE Compress the outer tube by hand and remove the ○ rebound adjuster assembly from the axle holder Protect the axle holder with a soft jaw or heavy part so that the locknut appears about 20 ∼ 30 mm cloth when using a vise.
MAINTENANCE AND ADJUSTMENT • • Remove the push rod. Remove the fork leg from the vise. • Remove the front fork top plug with the top plug wrench (special tool: 57001-1653). A. Push Rod NOTICE A. Front Fork Top Plug B.
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, 21 mm (special tool: 57001 -1787).
MAINTENANCE AND ADJUSTMENT NOTICE Disassembling the base valve assembly can cause internal damage. Do not disassemble the base valve assembly. • Drain the fork oil from the cylinder unit by pumping the piston rod several times. A. Base Valve Assembly B.
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 • Replace the O-rings 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.
MAINTENANCE AND ADJUSTMENT • Pump the piston rod slowly several times to expel air. • Secure the piston rod in the fully compressed po- sition. A. Base Valve Assembly B. Cylinder Unit NOTE ○ Put a hand over the two oil holes to prevent oil A.
MAINTENANCE AND ADJUSTMENT • NOTE Hold the top plug wrench, 49 mm (special tool: ○ 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. 21 mm (special tool: 57001-1787), torque the •...
MAINTENANCE AND ADJUSTMENT • NOTE With the cylinder unit in a horizontal position, slide ○ the piston rod by hand to be sure it is operating Check the piston rod sliding surface for damage. ○ smoothly. Apply fork oil to the piston rod sliding surface. •...
MAINTENANCE AND ADJUSTMENT • • Make sure about 16 mm (0.63 in.) of push rod Completely wipe off the fork oil from the cylinder thread is exposed from the locknut. unit. • Insert the cylinder unit to the outer tube. A.
MAINTENANCE AND ADJUSTMENT • WARNING Temporarily tighten the fork top plug by us- ing the top plug wrench, 49 mm (special tool: Clamping the axle holder too tight can dam- 57001-1653). age it which will affect riding stability. Do not clamp the axle holder too tight. •...
MAINTENANCE AND ADJUSTMENT • With the outer tube compressed by hand, remove the top plug wrench, 49 mm (special tool: 57001 -1653). • Apply a non-permanent locking agent to the threads of rebound adjuster assembly. • Tighten the rebound adjuster assembly to the specified torque.
MAINTENANCE AND ADJUSTMENT • Using the top plug wrench, 49 mm (special tool: Recommended Fork Oil 57001-1653), remove the fork top plug from the KHL15-11 (1 L): P/No. 44091-0020 outer tube and slowly slide down the outer tube. KHL15-11 (4 L): P/No. 44091-0021 •...
MAINTENANCE AND ADJUSTMENT NOTE ○ During air pressure adjustment, be careful that the lower end of the front fork does not contact the ground surface. NOTICE Do not pressurize the fork to more than 500 kPa (5.0 kgf/cm², 73 psi) or the fork may be damaged.
MAINTENANCE AND ADJUSTMENT • NOTE Tighten the front fork top plug using the top plug ○ wrench, 49 mm (special tool: 57001-1653) to the The fork top plug torque is specified to 45 N·m (4.6 specified torque. kgf·m, 33 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 [41 N·m (4.2 kgf·m, 30 ft·lb)] due to the distance...
MAINTENANCE AND ADJUSTMENT • Take out wood wedge between the disc brake pads. • Apply high-temperature grease to the oil seals of the wheel. • Install the collars on the left and right side of the hub. • Put the front wheel assembly between the fork legs, and insert the front brake disc into the front brake pads.
MAINTENANCE AND ADJUSTMENT NOTE ○ Do not apply the front brake during this process to stop the motorcycle from rolling forward. Put a block in front of the wheel to stop it from moving. A. Collars B. Caps C. Axle D.
MAINTENANCE AND ADJUSTMENT • Check the front brake for good braking power and Tightening Torque no brake drag. Air Valve Plug: 0.2 N·m (0.020 kgf·m, 1.8 in·lb) WARNING After servicing, it takes several applications NOTICE of the brake lever before the brake pads con- tact the disc, which could result in increased Be sure to install the air valve plug to prevent stopping distance and cause an accident re-...
Tighten the two clamp bolts alternately two times • Visually inspect the rear shock absorber for oil to ensure even tightening torque. leakage. • If necessary, repair or replace by an authorized Kawasaki dealer.
MAINTENANCE AND ADJUSTMENT Rear Shock Absorber Adjustment Rebound Damping Adjuster Settings The spring preload of the shock absorber can be adjusted or the spring can be replaced with an op- tional one to suit various riding conditions. In addi- tion, the damping force can be adjusted easily, mak- ing it unnecessary to change the oil viscosity.
MAINTENANCE AND ADJUSTMENT 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 ef- fects before using them in competition.
MAINTENANCE AND ADJUSTMENT High Speed Compression Damping Adjuster Low Speed Compression Damping Adjuster Settings Settings A. Seated Position (Adjuster Turned Fully A. Seated Position (Adjuster Turned Fully Clockwise) Clockwise) B. Softer (Counterclockwise) B. Softer (Counterclockwise) C. Harder (Clockwise) C. Harder (Clockwise) D.
MAINTENANCE AND ADJUSTMENT • NOTICE Raise the rear wheel off the ground using a jack (special tool: 57001-1238) and attachment (spe- Do not force the compression damping force cial tool: 57001-1608). adjuster beyond the fully seated position, or • Using the hook wrenches (special tools: 57001 the adjusting mechanism may be damaged.
MAINTENANCE AND ADJUSTMENT • Using the hook wrench (special tool: 57001-1101), Rear Shock Absorber Spring Adjustable Range turn the spring preload adjusting nut as required. 126.5 ∼ 138.5 mm K = 52 N/mm Turning the adjusting nut down increases the (4.980 ∼...
Removal and installation of the rear shock Tire Air Pressure Adjustable Range absorber spring should be performed by an 80 ∼ 100 kPa (0.8 ∼ 1.0 kgf/cm², 12 ∼ 14 psi) authorized Kawasaki dealer. NOTE ○ Tire air pressure should be checked when the tires...
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 • Set up the dial gauge on the inner circumference Rim Runout Maximum Limit of the rim and rotate the wheel to measure its ra- Axial dial runout. The difference between the highest *TIR 2.0 mm (0.08 in.) Radial and lowest readings is the amount of runout.
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 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 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.
MAINTENANCE AND ADJUSTMENT Fastener N·m kgf·m ft·lb Remarks Handlebar Holder Nuts 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.
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.
• The semi-gloss finish effect may be lost when it is Avoid using abrasive pads or brushes to excessively rubbed. clean plastic parts, as they will damage the • If any doubt, consult an authorized Kawasaki part’s finish. dealer.
MAINTENANCE AND ADJUSTMENT Chrome and Aluminum Lubrication Chrome and uncoated aluminum parts can be treated with a chrome/aluminum polish. Coated aluminum should be washed with a mild neutral de- Lubricate the areas shown in the illustrations of tergent and finished with a spray polish. Aluminum this section with either motor oil or regular grease, wheels, both painted and unpainted can be cleaned after each race and whenever the vehicle has been...
MAINTENANCE AND ADJUSTMENT Apply an aerosol cable lubricant with a pressure Apply grease to the following points: • lubricator on all cables: Clutch Inner Cable Upper End • • Clutch Cable Throttle Inner Cable Upper End • Throttle Cable Cable Lubrication A.
MAINTENANCE AND ADJUSTMENT Drive Chain Lubrication DFI Self-Diagnosis Lubricate the drive chain after riding through rain or on wet track, or any time that the chain appears dry with a high quality lubricant for drive chains. This motorcycle equips the DFI trouble self •...
MAINTENANCE AND ADJUSTMENT Dealer Mode Self-diagnosis Procedures • The orange FI warning indicator light emits service Disconnect the capacitor lead connector. code(s) to show the problem(s) which the DFI sys- tem, and ignition system has at the moment of diag- nosis.
MAINTENANCE AND ADJUSTMENT • NOTE Connect the power supply harness (optional part: ○ 26011-0246) to the capacitor lead connector of the Use a fully charged battery when conducting self main harness. -diagnosis. Otherwise, the light blinks very slowly • Connect the power supply harness (optional part: or doesn’t blink.
MAINTENANCE AND ADJUSTMENT • 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 finish reading the service code.
MAINTENANCE AND ADJUSTMENT How to Read Service Codes • Service codes are shown by a series of long and short blinks of the orange FI warning indicator light as shown below. • Read 10th digit and unit digit as the orange FI warning indicator light blinks. •...
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 Orange FI Warning Problems Code Indicator Light 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...
MAINTENANCE AND ADJUSTMENT Service Orange FI Warning Problems Code Indicator Light 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.
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.
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 • 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 •...
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: •...
TROUBLESHOOTING GUIDE • Pad surface glazed Handlebar shakes or vibrates excessively: • • Brake disc warped Tire worn • • Brake caliper defective Swingarm sleeve or needle bearing damaged • • Brake cylinder damaged Rim warped or out of balance •...
TROUBLESHOOTING GUIDE • Front fork air pressure weak Poor braking performance - • Rear shock absorber spring weak • Air in the brake line • Rear shock absorber leaking oil or gas • Brake pad or disc worn • Rear shock absorber improperly adjusted •...
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.
TUNING • Troubleshooting Improper Settings When the oil amount is lowered, the air spring be- comes less progressive, and the front fork action Listed below are some symptoms of improper sus- does not feel as “hard” in the later stage of fork pension settings and the most likely means of cor- travel.
TUNING Determining the Proper Settings Too Soft Standard Settings The front fork dives excessively during braking From the factory, the machine is set up for a and deceleration: medium-weight rider with intermediate riding ability. • Fork oil amount too low Hence, if the actual rider weighs considerably more •...
TUNING Suspension Tuning According to Rider Weight Begin the actual on-track testing and evaluation after making these preliminary adjustments. Front Higher air pressure Heavy Rider Bear in mind the following points when readjusting Rear Harder spring the suspension. • Always make changes in small steps. Front Lower air pressure •...
TUNING Front End “Knifes” or Oversteers in Turns (Tends to Turn Inward) - The front suspension is too soft. • Increase the compression damping or rebound damping. • Increase the fork oil amount. NOTE ○ Heavier or expert riders may heighten the air pres- sure.
TUNING NOTE Rear End “Kicks” When Braking on Bumps - ○ The rear shock absorber rebound damping may be Check the front and rear suspension compatibility too low. after making any adjustment. • Increase the rebound damping. Rear End Feels Soft at Small Jump - Rear Tire Does Not “Hook Up”...
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.
TUNING • In muddy or sandy conditions, increase chain Special Care According to Track slack as the chain and sprockets will be packed Conditions with mud or sand, which reduces chain slack. • Check chain and sprocket wear frequently when •...
OPTIONAL PARTS OPTIONAL PARTS Rear Sprocket Suspension Spring (N/mm) K = 52 Rear K = 54 (Standard) Aluminum 50T (Standard) K = 56 Disc Plate Front No holes (for wet conditions) Rear No holes (for wet conditions) Aluminum Nipple Wheel (Without Tire) Steel Front 21 ×...
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 • • Apply grease to swingarm and rear suspension Rear shock absorber springs (for suspension ad- pivots. justment) • • Inspect the drive chain and rear sprocket for wear. Rear and engine sprockets with bolts/nuts and cir- •...
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 •...
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.
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.