2017 Kawasaki kx250f 72423
2017 Kawasaki kx250f 72423
2017 Kawasaki kx250f 72423
TUNING j
STORAGE j
• The use of this vehicle should be limited to participation in sanctioned competition events upon a closed
course.
• This vehicle should not be used for general off-road recreational riding.
• Read owner’s manual.
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 AND WAS NOT 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 TO PARTICIPATION IN SANCTIONED COMPE-
serious injury. TITION EVENTS UPON A CLOSED COURSE.
THIS VEHICLE SHOULD NOT BE USED FOR
GENERAL OFF-ROAD RECREATIONAL RIDING.
WARNING READ OWNER’S MANUAL.
WARNING indicates a hazardous situation
which, if not avoided, could result in death
or serious injury. WARNING
THIS VEHICLE SHOULD NOT BE USED FOR
GENERAL OFF-ROAD RECREATIONAL RID-
NOTICE ING.
NOTICE is used to address practices not re-
lated to personal injury. DISCLAIMER OF WARRANTY
This motorcycle is sold AS IS, with all faults,
NOTE obvious or concealed and there are NO WAR-
○NOTE indicates information that may help or guide RANTIES, expressed or implied. Including war-
ranties of MERCHANTABILITY or FITNESS FOR
you in the operation or service of the vehicle.
PURPOSE.
The purchaser accepts all responsibilities con-
cerning quality, performance, cost of service
and/or necessary repairs.
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. Respon-
sible use of your off-road motorcycle will en-
sure that these problems and conflicts do not
occur. TO PROTECT THE FUTURE OF YOUR
SPORT, MAKE SURE YOU USE YOUR MOTOR-
CYCLE LEGALLY, SHOW CONCERN FOR THE
ENVIRONMENT, AND RESPECT THE RIGHTS
OF OTHER PEOPLE.
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.
FOREWORD
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. This
manual is written to enable you to keep your KX properly tuned and adjusted.
Due to improvements in design and performance made during production, in some cases there may be minor
discrepancies between the actual vehicle and the illustrations and text in this manual.
SPECIFICATIONS
DIMENSIONS
Overall Length 2 170 mm (85.43 in.)
Overall Width 820 mm (32.3 in.)
Overall Height 1 265 mm (49.80 in.)
Wheelbase 1 475 mm (58.07 in.)
Road Clearance 320 mm (12.6 in.)
Curb Mass 104.3 kg (230.0 lb)
Fuel Tank Capacity 6.4 L (1.7 US gal)
ENGINE
Type 4-stroke, DOHC, single-cylinder, liquid-cooled
Bore × Stroke 77.0 × 53.6 mm (3.03 × 2.11 in.)
Displacement 249 cm³ (15.2 cu in.)
Compression Ratio 13.7:1
Fuel System FI (Fuel Injection)
Starting System Primary kick
Ignition System Digital DC-CDI
Ignition Timing 4° BTDC @2 000 r/min (rpm)
Lubrication System Forced lubrication (semi-dry sump)
Spark Plug NGK CPR8EB-9
Spark Plug Terminal Solid-post
SPECIFICATIONS 9
TRANSMISSION
Transmission Type 5-speed, constant mesh, return shift
Clutch Type Wet, multi disc
Driving System Chain drive
Gear Ratio:
1st 2.142 (30/14)
2nd 1.750 (28/16)
3rd 1.444 (26/18)
4th 1.235 (21/17)
5th 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 API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2
Viscosity SAE 10W-40
Capacity 1.0 L (1.1 US qt)
FRAME
Type Tubular, semi-double cradle
Steering Angle 42° to either side
Caster 28.5°
Trail 126 mm (4.96 in.)
Tire Size/Type:
10 SPECIFICATIONS
Rim Size:
Front 21 × 1.60
Rear 19 × 1.85
Suspension:
Front Telescopic fork (upside-down)
Rear New Uni-trak® swingarm
Front Suspension Travel 310 mm (12.2 in.)
Rear Wheel Travel 310 mm (12.2 in.)
Front Fork Oil:
Type Kawasaki Fork Oil SS19
Amount (Left Front Fork):
Cylinder Unit 330 mL (11.2 US oz.)
Outer Tube 300 mL (10.1 US oz.)
Amount (Right Front Fork) 223 mL (7.54 US oz.)
BRAKES
Type:
Front Single disc
Rear Single disc
Location of Labels
All warning labels which are on your vehicle are
repeated here. Read labels on your vehicle and un-
derstand them thoroughly. They contain information
which is important for your safety and the safety of
anyone else who may operate your vehicle. There-
fore, it is very important that all warning labels be on
your vehicle in the locations shown. If any label is
missing, damaged, or worn, get a replacement from
your Kawasaki dealer and install it in the correct po-
sition.
NOTE
1. Brake Fluid (Front)
○The sample warning labels in this section have
part numbers to help you and your dealer obtain
the correct replacement.
12 GENERAL INFORMATION
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2) 4)
14 GENERAL INFORMATION
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5) 7)
6)
GENERAL INFORMATION 15
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Location of Parts
1. Clutch Lever
2. Engine Stop Button
3. Launch Control Mode Button
4. Orange Launch Control Mode/FI Warning
Indicator Light
5. Front Brake Fluid Reservoir
6. Front Brake Lever
7. Throttle Grip
8. Fuel Tank Cap
9. Radiator Cap
10. Radiator
16 GENERAL INFORMATION
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A. Side Stand
B. Rear Axle
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.
GENERAL INFORMATION 19
j
Avoid filling the tank in the rain or where heavy dust
Fuel is blowing so that the fuel does not get contaminated.
A. Tank Cap
B. Fuel Tank
C. Top Level
D. Filler Neck
NOTICE
This motorcycle is designed for competition
use only. Therefore, the radiator does not
incorporate a coolant reserve tank or cool-
ing fan. Prolonged idling of the engine with
no airflow through the radiator can cause
coolant loss and engine overheating result-
ing in possible engine damage. Any riding
conditions that increase engine temperature
A. Kick Pedal will further reduce idling time before coolant
loss occurs. These conditions include high
ambient temperature, sandy or muddy ter-
rain, or other conditions causing high engine
loads at low speeds. Furthermore, warming
the engine up excessively before operation,
or leaving idling with the hot engine temper-
ature after operation results in the engine
overheating, too.
GENERAL INFORMATION 23
j
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
and depress the kick pedal slowly about 4 ∼ 5
times to clear too rich fuel mixtures in the engine.
Then, kick the engine over, leaving the throttle
closed.
A. Connector
26 GENERAL INFORMATION
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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.
• To engage first gear from the neutral position, pull
in the clutch lever and push down on the shift
pedal, gently release the clutch lever, then release
the shift pedal.
• To shift up to the next gear, pull in the clutch lever,
lift the shift pedal with your toes, gently release the A. Shift Pedal
clutch lever, and then release the shift pedal.
• To shift down to the next gear, pull in the clutch
lever, push the shift pedal down as far as it will go,
gently release the clutch lever, then release the
shift pedal.
NOTICE
When changing gears, press firmly on the
shift pedal to ensure proper shifting. Care-
less, incomplete shifting can cause the
transmission to jump out of gear and lead to
engine damage.
GENERAL INFORMATION 27
j
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
lever as the motorcycle comes to a stop. Indepen-
• Close the throttle completely and push the engine
stop button.
dent use of the front or rear brake may be advanta-
geous in certain circumstances. Shift down progres-
sively to ensure good engine response at all speeds.
WARNING
Failure to perform these checks before operation may result in serious damage or an accident. Al-
ways perform daily checks before operation.
DANGER
Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Inhaling carbon
monoxide can cause serious brain injury or death. DO NOT run the engine in enclosed areas. Op-
erate only in a well-ventilated area.
Engine
Engine Oil ........................................ No leakage
Level correct
Coolant ............................................ No leakage
Level correct (engine cold)
Radiator Cap ................................... Properly installed
Spark Plug ....................................... Correctly torqued
Cylinder Head Cover ....................... Correctly torqued
Clutch .............................................. Functions properly
Air Cleaner ....................................... Clean
Apply oil to air cleaner element
Properly installed
30 GENERAL INFORMATION
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Frame - inspect • –
Wheels/tires - inspect • 166
Rear shock absorber - inspect • 160
Cable - inspect • –
36 MAINTENANCE AND ADJUSTMENT
3. Periodic Replacement (Engine and Chassis Related Item)
FREQUENCY After each Every 3 Every 6 Every 12
See
j race (or 2.5 races (or 7.5 races (or 15 races (or
Page
OPERATION hours) hours) hours) 30 hours)
Engine oil - change • 38
Oil filter - replace • 38
K Piston and piston ring - replace • –
K Piston pin - replace • –
Silencer wool - replace • 86
Spark plug - replace • 46
K Brake fluid - change Every 2 years –
Brake master cylinder cup and dust cover –
K Every 2 years
- replace
Brake caliper fluid seal and dust seal - –
K Every 2 years
replace
K Brake hoses - replace Every 4 years –
Front fork oil - change • 115
K Fuel hose - replace Every 5 years –
K Rear shock absorber oil - change • –
Air cleaner element - replace If damaged 55
MAINTENANCE AND ADJUSTMENT 37
Type:
API SG, SH, SJ, SL or SM with JASO MA, MA1
• Tighten the oil filler plug.
Tightening Torque
or MA2 j
Viscosity: Oil Filler Plug:
SAE 10W-30, 10W-40, 10W-50 3.5 N·m (0.36 kgf·m, 31 in·lb)
WARNING
Cooling System The cooling system is pressurized and can
j get extremely hot during normal operation
Water Hoses and cause serious burns. To prevent burns,
Check the water hoses for cracks or deterioration, do not touch the radiator when it is hot. Do
and the connections for looseness in accordance not attempt to open the radiator cap when hot
with the Periodic Maintenance Chart. since steam and hot coolant can forcefully
erupt when the cap is even loosened slightly.
Radiator
Check the radiator fins for obstruction by insects or
mud. Clean off any obstructions with a low-pressure NOTE
stream of water. ○The coolant originally filled into the cooling sys-
tem contains 50% of a permanent, ethylene-glycol
NOTICE -based antifreeze, has a freezing point of –35°C
Using high-pressure water, as from a car (–31°F) and a green appearance.
wash facility, could damage the radiator fins
and impair the radiator’s effectiveness. Coolant Level Inspection
Do not obstruct or deflect airflow by in-
stalling unauthorized accessories in front of
• Situate the motorcycle perpendicular to the
ground until the radiator cap is level to the ground,
the radiator. so that the radiator cap is located uppermost
Interference with the cooling airflow can lead in order to exhaust the air accumulated in the
to overheating and consequent engine dam- radiator.
age. • Remove the radiator cap in two steps.
• First, turn the cap counterclockwise to the first stop
and wait there for a few seconds.
Coolant
Coolant absorbs excessive heat from the engine • Then, push and turn the cap further in the same
direction and remove it.
and transfers it to the air through the radiator. If
the coolant level becomes low, the engine overheats
and may suffer severe damage. Check the coolant
level each day before riding the motorcycle, and re-
plenish coolant if the level is low.
MAINTENANCE AND ADJUSTMENT 43
Recommended Antifreeze
Permanent type of antifreeze (ethylene glycol
plus corrosion and rust inhibitor chemicals for
aluminum engines and radiators)
• Remove the radiator cap in two steps. • Visually inspect the old coolant.
• Drain the coolant from the engine and radiator with • parts in the
If whitish cotton-like wafts are observed, aluminum
cooling system are corroded and the
the following procedures.
• Place a container under the coolant drain bolt on
the water pump cover and remove the drain bolt.
system must be flushed.
• Ifingtheandcoolant is brown, iron or steel parts are rust-
the system must be flushed.
• Check the cooling system for damage, loose con-
nections, and leaks.
• Install the coolant drain bolt with its new gasket
at the water pump cover and apply the specified
torque.
NOTE
○Always replace a gasket with a new one.
Tightening Torque
Coolant Drain Bolt:
7.0 N·m (0.71 kgf·m, 62 in·lb)
NOTICE
• Lean the motorcycle slightly until the radiator filler
neck is level to the ground so that the filler neck
is located uppermost in order to exhaust the air
Immediately wash away any coolant that accumulated in the radiator.
spills on the frame, engine, or wheel.
MAINTENANCE AND ADJUSTMENT 45
NOTICE
Use coolant containing corrosion inhibitors
made specifically for aluminum engines and j
radiators in accordance with the instruction
of the manufacture. Soft or distilled water
must be used with the antifreeze in the cool-
ing system. If hard water is used in the sys-
tem, it causes scale accumulation in the wa-
ter passages, and considerably reduces the
efficiency of the cooling system.
NOTE
○Pour in the coolant slowly so that it can expel the
air from the engine and radiator. A. Air Bleeder Screw
• Loosen the air bleeder screw on the top of the left • Replace
new one.
the O-ring of the air bleeder screw with a
radiator until the coolant begins to flow out from
the air bleeder screw hole. • Tighten the air bleeder screw to specified torque.
Tightening Torque
Air Bleeder Screw:
1.6 N·m (0.16 kgf·m, 14 in·lb)
A. Gap
B. Outer Electrode
If the plug is oily or has carbon built up on it, clean
it. The plug may also be cleaned using a high flash
-point solvent and a nonmetal brush (nylon etc.). If
MAINTENANCE AND ADJUSTMENT 47
standard spark plug is shown in the table below. • Remove the radiator screen bolts. j
Standard Spark Plug
NGK CPR8EB-9
• Disconnect the fuel pump lead connector. • Be sure to place a piece of cloth around the fuel
hose joint.
• Wipe off the dirt on the surface around the con-
nection using a cloth or a soft brush.
j
• Insert
lock.
a flat tip screwdriver into the slit on the joint
A. Cloth
B. Flat Tip Screwdriver
C. Joint Lock
50 MAINTENANCE AND ADJUSTMENT
A. Turn
B. Joint Lock
C. Fuel Hose Joint
• Cover the pipe and the fuel hose joint with the vinyl
bags to keep them clean.
• Remove the fuel tank.
WARNING
Gasoline is extremely flammable and can be
explosive under certain conditions. Always
stop the engine and do not smoke. Make
sure the area is well ventilated and free from
any source of flame or sparks; this includes
any appliance with a pilot light.
MAINTENANCE AND ADJUSTMENT 51
• Make sure that the dampers are in place on the • Check the joint lock for deformation and wear.
frame and are not damaged. If the dampers are
not fixed completely, reattach them with an adhe-
• with a newlock
If the joint
one.
is deformed, replace the fuel hose
j sive. If the dampers are damaged, replace them • Apply engine oil to the fuel outlet pipe lightly.
with new ones. • Insert the fuel hose joint straight onto the fuel out-
let pipe until the hose joint clicks.
• Push the joint lock until the hose joint clicks.
A. Dampers
NOTICE
When installing the fuel hose joint, do not
apply strong force to the outlet pipe on the
fuel pump. The pipe made from resin could
be damaged.
MAINTENANCE AND ADJUSTMENT 53
• Push and pull the fuel hose joint back and forth
more than two times, and make sure it is locked
• Tighten the fuel tank bolt.
Tightening Torque
and does not come off.
Fuel Tank Bolt: j
8.0 N·m (0.82 kgf·m, 71 in·lb)
WARNING
Leaking fuel can cause a fire or explosion
resulting in serious burns. Make sure the
hose joint is installed correctly on the deliv-
ery pipe by sliding the joint.
○If it comes off, reinstall the fuel hose joint. • Install the radiator shroud.
54 MAINTENANCE AND ADJUSTMENT
• Tighten
torque.
the radiator shroud bolts to the specified
Tightening Torque
A. Radiator Shroud
B. Radiator Shroud Bolts Radiator Screen Bolts:
7.0 N·m (0.71 kgf·m, 62 in·lb)
Tightening Torque
Radiator Shroud Bolts: • Install the removed parts.
7.0 N·m (0.71 kgf·m, 62 in·lb) NOTE
○After installation, insert the fuel tank breather hose
• Tighten
torque.
the radiator screen bolts to the specified outlet end into the steering stem hole.
MAINTENANCE AND ADJUSTMENT 55
NOTE
Air Cleaner ○In dusty areas, the element should be cleaned
more frequently than recommended interval. j
A clogged air cleaner restricts the air intake, in-
creases fuel consumption, reduces engine power,
○After riding through rain or on muddy roads, the
element should be cleaned immediately.
and can cause spark plug fouling. Inspect the air
intake system, which includes the air filter and air Element Removal and Inspection
duct to the throttle body assy, and the duct clamps
and throttle body assy, before each race or practice • Remove the seat bolt on both sides.
session.
WARNING
If dirt or dust is allowed to pass through into
the throttle body assembly, the throttle may
become stuck, possibly causing accident.
Be sure to keep the dust from entering dur-
ing cleaning.
NOTICE
A clogged air cleaner will affect fuel mixture
to the engine and reduce engine power and
cause spark plug fouling. A. Seat Bolt
56 MAINTENANCE AND ADJUSTMENT
• Lift the rear part of the seat upward and slide the
seat rearward.
• Remove
element.
the wing bolt, and take out the air cleaner
WARNING
A clogged air cleaner may allow dirt and dust
to enter the throttle body assembly and the
throttle may stick resulting in a hazardous
operating condition. Clean the air cleaner ac-
cording to the periodic maintenance chart;
more often if the motorcycle is used in ex-
tremely dusty conditions.
A. Air Cleaner Element
B. Element Frame
NOTICE
Element Cleaning and Installation
A clogged air cleaner may allow dirt and dust
to enter the engine, causing it to wear exces- • Clean the element in a bath of a high flash-point
solvent or hot soapy water. Rinse the element with
sively or to become damaged. clear water to remove all traces of the cleaning
solution.
• Squeeze the element dry in a clean towel.
NOTICE
Do not twist, wring or blow the element dry
to avoid damaging it.
58 MAINTENANCE AND ADJUSTMENT
WARNING
Gasoline and low flash-point solvents can
j 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.
A. Apply grease.
A. Hooks A. Tabs
B. Seat B. Seat
C. Flange Collar
D. Frame • Tighten the seat bolts to the specified torque.
Tightening Torque
Seat Bolts:
25 N·m (2.5 kgf·m, 18 ft·lb)
Throttle Cable
j
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.
A. Adjuster
B. Locknut
WARNING
A. Throttle Grip Operation with improperly adjusted, incor-
B. 2 ∼ 3 mm (0.08 ∼ 0.12 in.) rectly routed, or damaged cables could re-
sult in an unsafe riding condition. Be sure
• Ifupper
the play is incorrect, loosen the locknut on the
end of the accelerator cable and turn the
the control cables are adjusted and routed
correctly, and are free from damage.
adjuster to obtain the specified play. Then, tighten
the locknut toward the adjuster.
62 MAINTENANCE AND ADJUSTMENT
the idle speed. If so, the throttle cable may be im-
Throttle Body Assy properly adjusted, incorrectly routed, or damaged.
Be sure to correct any of these conditions before
j riding.
Idle Speed Adjustment
• Thoroughly warm up the engine.
WARNING
• the
Turn the idle adjusting screw/choke knob to adjust
idle speed 2 000 ∼ 2 100 r/min (rpm) by using Operation with damaged cables could result
the engine revolution tester (The tester should be in an unsafe riding condition. Replace dam-
followed by the method described by the manufac- aged control cables before operation.
ture.).
NOTICE
This motorcycle’s radiator does not incorpo-
rate cooling fan. Prolonged idling of the en-
gine with no airflow through the radiator can
cause coolant loss and engine overheating
resulting in possible engine damage. Any
riding conditions that increase engine tem-
perature will further reduce idling time be-
fore coolant loss occurs. These conditions
include high ambient temperature, sandy or
muddy terrain, or other conditions causing
high engine loads at low speeds. Further-
more, warming the engine up excessively be-
A. Idle Adjusting Screw/Choke Knob fore operation, or leaving idling with the hot
B. Tester engine temperature after operation results in
the engine overheating, too.
• Open and close the throttle a few times to make
sure the idle speed does not change, and readjust
if necessary. Cleaning the Throttle Body Assy
• With the engine idling, turn the handlebars both • Remove the seat (see Air Cleaner section).
ways and check if handlebars movement changes • section). the side covers (see Exhaust System
Remove
MAINTENANCE AND ADJUSTMENT 63
• Remove the fuel tank (see Spark Plug section). • Remove the muffler mounting bolts, and pull out
• pipe holder nuts.
Loosen the muffler clamp bolt and the exhaust the muffler body rearward.
j
• Be sure to place a piece of cloth around the fuel • Turn the screwdriver to disconnect the joint lock.
hose joint. • pipe.
Disconnect the fuel hose joint from the delivery
j • Wipe off the dirt on the surface around the con-
nection using a cloth or a soft brush.
• Insert
lock.
a flat tip screwdriver into the slit on the joint
A. Turn
B. Joint Lock
C. Fuel Hose Joint
A. Cloth
B. Flat Tip Screwdriver • Cover the delivery pipe and the fuel hose joint with
the vinyl bags to keep them clean.
C. Joint Lock
MAINTENANCE AND ADJUSTMENT 65
• Disconnect the upstream injector connector. • Disconnect the intake air temperature sensor con-
• hose joint.
Be sure to place a piece of cloth around the fuel nector.
• Loosen the air cleaner duct clamp bolt.
j
• Wipe off the dirt on the surface around the con-
nection using a cloth or a soft brush.
• Remove
sides.
the rear frame mounting bolts on both
NOTICE
Never drop the throttle body assy especially
on a hard surface. Such a shock to the body
assy can damage it.
68 MAINTENANCE AND ADJUSTMENT
• Ifthrottle
any carbon accumulates, wipe the carbon off the
bore and the throttle valve, using a lint-free
cloth penetrated with a high flash-point solvent.
Tightening Torque
NOTICE
Accelerator Cable Bolt:
If dirt gets through into the engine, exces- 3.0 N·m (0.31 kgf·m, 27 in·lb)
sive engine wear and possibly engine dam-
age will occur. • Install the tip of decelerator cable lower end to the
throttle pulley.
• Lubricate the lower ends of the throttle cables.
MAINTENANCE AND ADJUSTMENT 69
• Place
head.
the throttle body assy in rear of the cylinder
Tightening Torque
Throttle Body Assy Clamp Bolt:
1.1 N·m (0.11 kgf·m, 10 in·lb)
MAINTENANCE AND ADJUSTMENT 71
•
sure sensor and the downstream injector.
• Check the air cleaner duct is installed securely.
Connect the downstream injector connector, throt-
tle sensor connector, intake air pressure sensor • ified torque.
Tighten the air cleaner duct clamp bolt to the spec-
connector and regulator/rectifier lead connector.
• Hold the regulator/rectifier lead with the clamp. Tightening Torque
Air Cleaner Duct Clamp Bolt:
1.1 N·m (0.11 kgf·m, 10 in·lb)
WARNING
Leaking fuel can cause a fire or explosion
A. Fuel Hose Joints resulting in serious burns. Make sure the
B. Joint Locks hose joint is installed correctly on the deliv-
ery pipe by sliding the joint.
MAINTENANCE AND ADJUSTMENT 73
NOTE
○If it comes off, reinstall the fuel hose joint. Clutch
j
• Install the muffler (see Exhaust System section).
• Install the
Install fuel tank (see Spark Plug section). Clutch Lever Adjustment
• Open andthe removed parts. Proper clutch lever free play is 8 ∼ 13 mm (0.3 ∼
• sure the gripclose the throttle a few times to make
operates correctly.
0.5 in.). Lever play increases with cable stretch and
friction plate wear, requiring periodic adjustment.
• Check
justment.
the throttle cable play and idle speed ad- When the clutch lever free play is out of specifica-
tion, first try adjusting it at the clutch lever as follows.
• Turn the adjuster to obtain the proper amount of
clutch lever free play.
A. Clutch Lever
B. Adjuster
C. 8 ∼ 13 mm (0.3 ∼ 0.5 in.)
If the clutch lever free play cannot be adjusted at
the clutch lever, make the adjustment further down
the cable as follows.
74 MAINTENANCE AND ADJUSTMENT
NOTE
○After the adjustment is made, start the engine and
check that the clutch does not slip and that it re-
leases properly.
A. Friction Plate
A. Clutch Spring Bolts B. Steel Plate
B. Clutch Pressure Plate
Friction and Steel Plates Wear/Damage
Inspection
• Visually inspect the friction and steel plates to see
if they show any signs of seizure, or uneven wear.
• Iffriction
any plates show signs of damage, replace all
plates and steel plates as a set.
• plates at several
Measure the thickness of the friction and steel
points with vernier calipers.
• them with new ones.past the service limit, replace
If they have worn
A. Thickness
B. Friction Plate
NOTICE
If dry steel plates and friction plates are in-
stalled, apply engine oil to the surfaces of A. Apply molybdenum disulfide grease.
B. Push Rod Holder
each plate to avoid clutch plate seizure.
• Install the clutch pressure plate and springs.
• torque. the clutch spring bolts to the specified
Tighten
Tightening Torque
Clutch Spring Bolts:
9.0 N·m (0.92 kgf·m, 80 in·lb)
• 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
j stroke) by aligning the top mark with the groove
on the magneto cover while turning the crankshaft
counterclockwise.
A. Top Mark
B. Groove on Magneto Cover
C. Crankshaft
D. Crankshaft Rotation Direction
MAINTENANCE AND ADJUSTMENT 83
• Atsprockets
this point, the timing marks on the camshaft
must be almost aligned with the cylinder
• Using the thickness gauge, measuring the clear-
ance between each cam lobe and valve lifter, for
head upper surface as shown. all four valves.
j
NOTE
○Record the measured valves clearance.
A. Timing Marks
B. Camshaft Sprockets
C. Cylinder Head Upper Surface
A. Thickness Gauge
• Ifrange,
the valve clearance is not within the specified
adjust by an authorized Kawasaki dealer or
a competent mechanic following the instructions in
the Service Manual.
• Replace the spark plug hole gasket with a new
one.
84 MAINTENANCE AND ADJUSTMENT
• Install the new gasket. • Apply liquid gasket to the cylinder head as shown.
j
NOTICE
Unless the upper chain guide is bottomed,
the camshaft chain could push the cylinder
head cover upward, leading to an oil leak.
Exhaust System
j The exhaust system, in particular the muffler body,
is designed to reduce exhaust noise and conduct the
exhaust gases away from the rider while minimizing
power loss. If carbon has built up inside the muffler
body, exhaust efficiency is reduced, causing engine
performance to drop.
If the muffler body is badly damaged, dented,
cracked or rusted, replace it. Replace the silencer
wool if the exhaust noise becomes too loud or en-
gine performance drops.
Silencer Wool Replacement
• Remove the seat bolt, radiator shroud bolt and
side cover bolt.
A. Seat Bolt
B. Radiator Shroud Bolt
C. Side Cover Bolt
MAINTENANCE AND ADJUSTMENT 87
• Pull the right side cover upward to clear the hooks. • Remove the muffler cover bolts.
• Remove the right side cover. • Remove the muffler mounting bolt (rear).
j
A. Plastic Mallet
• Apply a non-permanent locking agent to the muf-
fler cover bolts.
B. Muffler Cover
C. Silencer Wool • Tighten
torque.
the muffler cover bolts to the specified
Tightening Torque • Insert the hooks of the side cover to the ribs of the
radiator shroud.
Exhaust Pipe Holder Nuts:
15 N·m (1.5 kgf·m, 11 ft·lb)
A. Side Cover
B. Radiator Shroud
C. Ribs
D. Hooks
A. Seat Bolt
B. Radiator Shroud Bolt
C. Side Cover Bolt
Tightening Torque
Seat Bolt:
25 N·m (2.5 kgf·m, 18 ft·lb)
Radiator Shroud Bolt: A. Friction Ring
7.0 N·m (0.71 kgf·m, 62 in·lb) B. Caulking
Side Cover Bolt:
7.0 N·m (0.71 kgf·m, 62 in·lb)
92 MAINTENANCE AND ADJUSTMENT
Drive Chain
j 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.
WARNING
A chain that breaks or jumps off the sprock-
ets could snag on the engine sprocket or lock
the rear wheel, severely damaging the motor-
cycle and causing it to go out of control. In-
spect the chain for damage and proper ad- A. Chain Slack
justment before each ride.
• Inwheel
addition to checking the slack, rotate the rear
to inspect the drive chain for damaged
Chain Slack Inspection rollers, loose pins and links and the sprockets
• Raise the rear wheel off the ground, then rotate
the rear wheel to find the place where the chain is
for unevenly or excessively worn and damaged
teeth.
tightest (because it wears unevenly). • If there are any such defects, replace the drive
• Push up the drive chain in the middle of the upper
chain run to measure the chain slack. The dis-
chain and/or the sprockets.
Chain Slack Adjustment
tance between the bottom-line of the chain and the
swingarm should be within the standard value.
• Loosen the rear axle nut and both chain adjuster
locknuts.
Drive Chain Slack • Turn both chain adjusting bolts evenly until the
drive chain slack (measured between the chain
Standard 52 ∼ 58 mm (2.0 ∼ 2.3 in.)
and the swingarm) is within the standard value.
• Adjust the drive chain if its slack is out of specifi-
cation.
For the rear wheel to be properly aligned, the
notch of the left chain adjuster should align with
the same swingarm mark that the notch of the
right chain adjuster aligns with.
MAINTENANCE AND ADJUSTMENT 93
• Inspect
tion).
the rear axle nut (see Rear Axle Nut sec-
A. Rear Axle Nut • Tighten the axle nut to the specified torque.
B. Adjusting Bolt Tightening Torque
C. Locknut Rear Axle Nut:
D. Marks
E. Notch
110 N·m (11.2 kgf·m, 81.1 ft·lb)
A. Chain Guide
96 MAINTENANCE AND ADJUSTMENT
Chain Slipper Wear Inspection Sprocket Wear Inspection
• Visually inspect the upper and lower of the chain
slipper on the swingarm and replace them if worn
• Visually inspect the sprocket teeth and replace the
sprocket if its teeth are worn or damaged.
j or damaged. Sprocket Teeth Wear
NOTE
○Sprocket wear is exaggerated in the illustration.
MAINTENANCE AND ADJUSTMENT 97
Chain Lubrication
Lubrication is necessary after riding through rain Adjustable Ergonomics
or on wet roads, or any time that the chain appears
dry. To suit various riding positions, the handlebar
j
Use a lubricant for drive chains. If the chain is holder position can be changed and the handlebars
especially dirty, clean it using a cleaner for drive can be adjusted by turning the handlebar holders
chains following the instructions supplied by the around (180°).
chain cleaner manufacturer. The footpeg position can also be changed to suit
• Apply lubricant to the sides of the rollers so that it
will penetrate to the rollers and bushings. Wipe off
the rider’s preference.
A. Dampers
Handlebar Holder
Handlebar Position B. Steering Stem Head
Direction Position C. Flat Surfaces
A C Far • Install
holders.
the rounded washers and the handlebar
B C ↑
A D ↓ NOTE
B D Near ○Install the rounded washer so that the round part
fits on the damper.
• Install the upper and lower dampers into the steer-
• Replace the handlebar holder nuts with new ones.
ing stem head with aligning the flat surfaces.
• Put the handlebars
Apply 2-stroke oil to the handlebar clamp bolts.
• Temporarily install the
onto the handlebar holders.
• Hand tighten the handlebar
handlebar clamps.
• Tighten the handlebar holderclamp bolts.
• torque. nuts to the specified
100 MAINTENANCE AND ADJUSTMENT
Tightening Torque
Handlebar Holder Nuts:
j 35 N·m (3.6 kgf·m, 26 ft·lb)
Footpeg
• Remove the footpeg bracket bolts and bracket.
The right and left footpegs can be mounted onto
j
one of two positions.
• Remove the cotter pin, pivot pin, washer, spring
and footpeg.
A. Standard Position
B. Lower Position
A. Pivot Pin
• Tighten the footpeg bracket bolts to the specified
torque.
B.
C.
Spring Ends
Washer
D. Cotter Pin
Tightening Torque
Footpeg Bracket Bolts (M10): NOTE
35 N·m (3.6 kgf·m, 26 ft·lb)
○Install the footpegs with same height on both
Footpeg Bracket Bolts (M8): sides. Do not ride the motorcycle with footpegs
17 N·m (1.7 kgf·m, 13 ft·lb) installed unevenly.
○Adjust the positions of the shift pedal and the
• Apply grease to the pivot pin. brake pedal to suit the rider’s preference.
• pivot pinthefrom
Install footpeg, spring and pivot pin. Insert the
the front.
○Installing the footpegs in the lower position will re-
duce the amount of ground clearance and lean an-
• Install the washer and
Position the spring ends as shown. gle.
• new cotter pin.
MAINTENANCE AND ADJUSTMENT 103
Brakes
Disc and disc pad wear is automatically compen-
j
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.
• 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
wrench.
• After adjustment, tighten the locknut securely.
A.
B.
Dust Cover
Brake Lever
C. Adjuster
D. Locknut
WARNING
Air in the brake lines diminish braking perfor-
mance and can cause an accident resulting
in injury or death. If the brake lever or pedal
feels mushy when it is applied, there might
be air in the brake lines or the brake may be
defective. Have the brake checked immedi-
ately by an authorized Kawasaki dealer.
104 MAINTENANCE AND ADJUSTMENT
Disc Brake Fluid
Inspect the brake fluid level in the front and rear
brake reservoirs and change the brake fluid in ac-
j cordance with the Periodic Maintenance Chart. The
brake fluid should also be changed when contami-
nated with dirt or water.
NOTE
○The motorcycle is shipped with brake fluid DOT4
in the brake system. A. Front Brake Reservoir
B. Lower Level Line
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.
Check for brake hose damage.
WARNING
Mixing brands and types of brake fluid can
A. Front Brake Reservoir reduce the brake system’s effectiveness
B. Upper Level Line and cause an accident resulting in injury
or death. Do not mix two brands of brake
fluid. Change the brake fluid in the brake line
completely if the brake fluid must be refilled
but the type and brand of the brake fluid that
is already in the reservoir are unidentified.
106 MAINTENANCE AND ADJUSTMENT
Brake Pad Wear Inspection
Inspect the brake pads for wear in accordance with Steering
the Periodic Maintenance Chart. If the thickness of
j any pad in any (front or rear) brake caliper is less The steering should always be kept adjusted so
than 1 mm (0.04 in.), have both pads in the caliper that the handlebars 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
Steering Inspection
• To check the steering adjustment, raise the front
wheel off the ground using a jack (special tool:
57001-1238) and attachment (special tool: 57001
-1608).
• Push the handlebars lightly to both side. If the
handlebars continues moving under its own mo-
mentum, the steering is normal.
• Squatting in front of the motorcycle, grasp the
lower ends of the front fork at the axle, and push
and pull the front fork back and forth. If play is
felt, the steering is too loose and needs to be
adjusted.
A. Lining Thickness
B. 1 mm (0.04 in.)
C. Front
D. Rear
MAINTENANCE AND ADJUSTMENT 107
Steering Adjustment
• Raise the front wheel off the ground using a jack
(special tool: 57001-1238) and attachment (spe-
cial tool: 57001-1608).
j
• Unlock the clamp of the number plate.
• Remove the bolt.
• Clear the projections and remove the number
plate.
A. Clamp
B. Bolt
C. Projections
D. Number Plate
108 MAINTENANCE AND ADJUSTMENT
• Remove
tion).
the handlebars (see Handlebars sec- • Turn the steering stem nut with a stem nut wrench
(special tool: 57001-1100) to obtain the proper ad-
j • Loosen
per).
the left and right front fork clamp bolts (up- justment.
NOTE
○Tighten the two clamp bolts alternately two times Front Suspension
to ensure even tightening torque. j
• Install the handlebars (see Handlebars section),
and check the steering again and readjust it if nec-
Front Fork Inspection
essary. NOTICE
• Check the front brake for the proper brake effect,
or no brake drag.
Sticking muds or dusts on the sliding surface
of the front fork could damage the oil seal,
• Check the clutch lever and throttle for the proper
operations.
leading to an oil leak. Clean the sliding sur-
face after each ride.
• Install the number plate, and tighten the bolt.
Tightening Torque • Holding the brake lever, pump the front fork up and
down manually to check for smooth operation.
Number Plate Bolt:
8.0 N·m (0.82 kgf·m, 71 in·lb) • Visually inspect the front fork for oil leakage, scor-
ing or scratches on the outer surface of the inner
tube.
• If necessary, replace by an authorized Kawasaki
dealer.
110 MAINTENANCE AND ADJUSTMENT
on your KX will get stiffer as the race progresses.
Therefore, it is not recommended to increase the air
pressure for additional springing. The KX forks are
j designed to function without added air.
• Rebound Damping Adjustment (Left Fork only)
This adjustment affects how quickly the fork re-
bounds. Depending on the model, the fork rebound
damping adjuster has 20 positions. The fully seated
position (adjuster turned fully clockwise) is the hard-
est setting. Turning the adjuster 16 clicks counter-
clockwise from the fully seated position is the stan-
dard setting, turning it counterclockwise 20 clicks
(depending on the model) is the softest setting.
A. Inner Tubes
• Compression Damping Adjustment (Left Fork
only)
This adjustment affects how quickly the fork com-
NOTICE presses. Depending on the model, the fork com-
pression damping adjuster has 22 positions. The
If the inner tube is badly bent or creased, fully seated position (adjuster turned fully clockwise)
replace it. Excessive bending, followed by is the hardest setting. Turning the adjuster 8 clicks
subsequent straitening, can weaken the in- counterclockwise from the fully seated position is
ner tube. the standard setting, turning it counterclockwise 22
clicks (depending on the model) is the softest set-
Front Fork Adjustment ting.
Any of the following front fork adjustments should
be made to tune the front suspension to the rider’s
• Spring Preload Adjustment (Right Fork only)
This adjustment affects the driving position. De-
weight and the condition of the track. pending on the model, the fork spring preload ad-
Basically, there are seven adjustments you can juster has 40 positions. The fully seated position
make to the front fork. (adjuster turned fully counterclockwise) is the softest
• Air Pressure
Air pressure acts as a progressive spring over the
setting. Turning the adjuster 8 clicks clockwise from
the fully seated position is the standard setting, turn-
entire fork travel range. Since the air pressure in the ing it clockwise 40 clicks (depending on the model)
fork legs increases with normal use, the fork action is the hardest setting.
MAINTENANCE AND ADJUSTMENT 111
• The
Fork Oil Amount Adjustment
fork oil amount affects the front fork action.
Air Pressure Adjustment
The standard air pressure in the front fork legs is
When the oil amount is raised, the air spring be- atmospheric (0 kPa, 0 kgf/cm², 0 psi). Air pressure
comes more progressive, and the front fork action in the fork legs increase with normal use, so the fork
j
feels “harder” in the later stage of fork travel, near action stiffens during operation. Release air pres-
the bottom. When the oil amount is lowered, the air sure from the fork legs prior to each race through the
spring becomes less progressive, and the front fork air pressure relief screw located in left front fork base
action does not feel as “hard” in the later stage of valve assembly and right front fork top plug. Make
fork travel. sure the front forks are fully extended with the front
• Fork Springs wheel off the ground when releasing the pressure.
Optional springs, softer and stiffer than standard,
are available.
• Raise the front wheel off the ground using a jack
(special tool: 57001-1238) and attachment (spe-
• Fork Height cial tool: 57001-1608).
Steering is greatly affected by the fork height (how
much the outer fork tubes protrude above the steer-
• Remove the screw on each front fork top plug to
let the air pressure equalize. Then, tighten the
ing stem head). The less the fork tube protrudes, screws.
the lighter the front end becomes and the greater Tightening Torque
the tendency for understeering and washout due to
weight biasing. Increasing the amount of fork tube Air Pressure Relief Screws:
protrusion has opposite effects. Be sure that the 1.3 N·m (0.13 kgf·m, 12 in·lb)
front tire does not touch the fender when the fork is
fully compressed.
NOTICE
The right and left fork tubes must be adjusted
evenly.
112 MAINTENANCE AND ADJUSTMENT
A. Screw A. Screw
B. Left Front Fork Base Valve Assembly B. Right Front Fork Top Plug
C. Front Fork (Left Side) C. Front Fork (Right Side)
NOTICE
Do not force the rebound damping adjuster
beyond the fully seated position, or the ad-
justing mechanism may be damaged.
MAINTENANCE AND ADJUSTMENT 113
Spring Preload Adjustment (Right Fork only) Spring Preload Adjuster Settings
• Raise the front wheel off the ground using a jack
(special tool: 57001-1238) and attachment (spe-
cial tool: 57001-1608).
j
• To adjust the spring preload, turn the adjuster on
the right front fork top plug with a wrench. Adjust
the spring preload to suit your preference under
certain conditions.
NOTICE
Do not force the spring preload adjuster be-
yond the fully seated position, or the adjust-
ing mechanism may be damaged.
NOTE
○Record the rebound, compression and spring
preload setting before disassembling.
○Set the rebound and compression damping to the
softest settings before disassembly to prevent the
needle of adjusters from damping.
A. Front Fork Clamp Bolts (Upper)
• Remove the number plate (see Steering section). B. Top Plug Wrench (Special Tool: 57001-1645)
• Loosen the front
Loosen the fork clamp bolts (upper).
• Unscrew
• wrench (special
front fork top plug with the top plug
tool: 57001-1645).
the front axle nut, and then loosen the
left front axle clamp bolts.
NOTE
• Remove the brake caliper from the fork leg, and
rest the caliper on some kind of stand so that it
○Do not take off the base valve assembly (left fork does not dangle.
only). • Insert the wood wedge between the disc brake
pads. This prevents them from being moved out of
their proper position, if the brake lever is squeezed
accidentally.
• Remove the brake hose clamps and fork protector.
MAINTENANCE AND ADJUSTMENT 117
NOTICE
Do not lay the wheel on the ground with the
disc facing down. This can damage or warp j
the disc. Place blocks under the wheel so the
disc does not touch the ground.
• Remove the front axle, and pull out the front wheel.
C. Collar
Take off the collar from each side of the front hub. • Loosen the front fork clamp bolts (lower).
• Remove the front fork tubes by pulling down while
twisting it.
118 MAINTENANCE AND ADJUSTMENT
Standard
312 ∼ 316 mm (12.3 ∼ 12.4 in.)
Length
j
A. Fork Oil
A. Top Plug Wrench (Special Tool: 57001-1645)
B. Left Front Fork Cylinder Unit • Temporarily install the left front fork cylinder unit to
the outer tube using the top plug wrench (special
C. Left Front Fork Outer Tube
tool: 57001-1645).
• Place a drain pan under the front fork and drain
fork oil.
120 MAINTENANCE AND ADJUSTMENT
WARNING
If the axle holder is not securely clamped, the
j front fork assembly may come out of the vise
when compressed, which could cause an ac-
cident resulting in injury. However, clamp-
ing the axle holder too tightly can damage it
which will affect riding stability. Use protec-
tive aluminum covers on the jaws of the vise
and do not tighten the vise excessively.
• Remove the push rod. • Remove the fork leg from the vise.
• plug wrench
Unscrew the left front fork cylinder unit with the top
(special tool: 57001-1645).
j
A. Push Rod
NOTE
A. Top Plug Wrench (Special Tool: 57001-1645) ○Slowly compress the piston rod until it stops so
B. Left Front Fork Base Valve Assembly that the left front fork base valve assembly can be
C. Left Front Fork Cylinder Unit removed easily.
D. Box Wrench
A. Fork Oil
B. Left Front Fork Cylinder Unit
A. Threads
A. Fork Oil
B. Left Front Fork Cylinder Unit
C. Oil Hole
A. Pump
Suspension Oil B. Piston Rod
SS-19 (1 L): P/No. 44091-0009 • With the piston rod fully stretched, check the oil
level in the left front fork cylinder unit.
Oil Level
115 ∼ 123 mm (4.53 ∼ 4.84 in.)
NOTE
○Measure the oil level from the top surface in the
left front fork cylinder unit using a gauge.
MAINTENANCE AND ADJUSTMENT 127
NOTICE NOTE
Do not damage the bushings when assem-
○Plug the oil hole on the left fork cylinder unit with
finger.
bling the left front fork base valve.
○While pulling the piston rod, install the base valve
assembly slowly and pushing down it fully.
○If there is difficulty in assembling the base valve,
it may be because the oil level is too high. Check
the oil level in the left front fork cylinder unit.
128 MAINTENANCE AND ADJUSTMENT
• Discharge the extra oil off the left front fork cylinder NOTE
unit by pumping the piston rod to full stroke. ○Check the piston rod sliding surface for damage.
NOTICE ○Apply specified fork oil to the piston rod sliding j
surface.
Be careful not to bend or damage the piston
rod when the piston rod is stroked. • Drain the extra oil from the left front fork cylinder
unit oil hole.
NOTE
• Blow out the extra oil from the oil hole of the left
front fork cylinder unit with the compressed air
○Service carefully because oil flies out from the oil blow to the oil hole.
hole of the left front fork cylinder unit. • Wipe the oil off completely from the left front fork
cylinder unit.
• If you cannot use compressed air, remove the air
pressure relief screw of the left front fork base
valve assembly. Up side down the fork damper for
more than 10 minutes and drain the oil from the left
front fork cylinder unit. Reinstall and tighten the air
pressure relief screw.
Tightening Torque
Air Pressure Relief Screw:
1.3 N·m (0.13 kgf·m, 12 in·lb)
A. Piston Rod
B. Heavy Cloth
C. Pump the piston.
130 MAINTENANCE AND ADJUSTMENT
• Wipe the oil off completely from the left front fork
cylinder unit.
j • Compress the piston rod to 200 ∼ 250 mm (7.87
∼ 9.84 in.) and hold the left front fork cylinder unit
upright position for 10 minutes.
A. Oil Hole
A. Locknut
B. 10 ∼ 12 mm (0.39 ∼ 0.47 in.) A. Left Front Fork Cylinder Unit
WARNING
If the axle holder is not securely clamped, the
j front fork assembly may come out of the vise
when compressed, which could cause an ac-
cident resulting in injury. However, clamp-
ing the axle holder too tightly can damage it
which will affect riding stability. Use protec-
tive aluminum covers on the jaws of the vise
and do not tighten the vise excessively.
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
Suspension Oil
• Pour the specified amount of fork oil into the left
front fork outer tube. SS-19 (1 L): P/No. 44091-0009
A. Fork Oil
A. Fork Spring Compressor (Special Tool: A. Holder Bar of Fork Spring Compressor (Special
57001-1771) Tool: 57001-1587)
B. Heavy Cloth B. Holder of Fork Spring Compressor (Special Tool:
57001-1771)
• Insert the holder bar of the fork spring compressor
(special tool: 57001-1587) to the axle hole and se-
cure it with the holder of the fork spring compres-
• Compress the outer tube with a suitable jack while
keeping the front fork upright, and install the top
sor (special tool: 57001-1771). plug wrench (special tool: 57001-1645) between
the axle holder bottom and locknut.
WARNING
The fork spring applies pressure to the ad-
juster assembly and can eject the special
tool with substantial force if the tool is not
properly and securely placed. Be sure the
tool is fully in place as shown in the photo,
and keep fingers away to avoid getting them
pinched between the tool, adjuster assembly
and axle holder.
142 MAINTENANCE AND ADJUSTMENT
WARNING
If the axle holder is not securely clamped, the
j front fork assembly may come out of the vise
when compressed, which could cause an ac-
cident resulting in injury. However, clamp-
ing the axle holder too tightly can damage it
which will affect riding stability. Use protec-
tive aluminum covers on the jaws of the vise
and do not tighten the vise excessively.
A. Wrench
B. Right Front Fork Bottom Plug
• Tighten the locknut fully. A. Fork Piston Rod Puller Adapter (Special Tool:
57001-1791)
B. Fork Piston Rod Puller (Special Tool:
57001-1289)
A. Locknut
MAINTENANCE AND ADJUSTMENT 145
WARNING
The fork spring applies pressure to the ad-
juster assembly and can eject the special
A. Right Front Fork Spring Adjuster Unit tool with substantial force if the tool is not
B. Right Front Fork Outer Tube properly and securely placed. Be sure the
C. Top Plug Wrench (Special Tool: 57001-1645) tool is fully in place as shown in the photo,
and keep fingers away to avoid getting them
When not using the Fork Spring Compressor pinched between the tool, adjuster assembly
(Special Tool: 57001-1771): and axle holder.
• Hold the axle holder with a vise.
NOTE When using the Fork Spring Compressor
○Protect the axle holder with a soft jaw or heavy (Special Tool: 57001-1771):
cloth when using a vise. • Set the fork spring compressor (special tool:
57001-1771) and a suitable jack as shown.
MAINTENANCE AND ADJUSTMENT 147
A. Fork Spring Compressor (Special Tool: A. Fork Spring Compressor (Special Tool:
57001-1771) 57001-1771)
B. Suitable Jack B. Heavy Cloth
A. Holder Bar of Fork Spring Compressor (Special A. Top Plug Wrench (Special Tool: 57001-1645)
Tool: 57001-1587) B. Axle Holder Bottom
B. Holder of Fork Spring Compressor (Special Tool: C. Locknut
57001-1771)
• Remove the front fork from the fork spring com-
• Compress the outer tube with a suitable jack while
keeping the front fork upright, and install the top
pressor (special tool: 57001-1771) with care not
to drop the top plug wrench (special tool: 57001
plug wrench (special tool: 57001-1645) between -1645), and hold the axle holder with a vise.
the axle holder bottom and locknut.
NOTE
WARNING ○Protect the axle holder with a soft jaw or heavy
The fork spring applies pressure to the ad- cloth when using a vise.
juster assembly and can eject the special
tool with substantial force if the tool is not
properly and securely placed. Be sure the
tool is fully in place as shown in the photo,
and keep fingers away to avoid getting them
pinched between the tool, adjuster assembly
and axle holder.
MAINTENANCE AND ADJUSTMENT 149
NOTICE
When tightening the locknut, the threads of
the axle holder do not touch the piston rod.
If the piston rod is scratched, it is possible to
the damage in the cylinder unit.
A. Threads
B. Right Front Fork Bottom Plug
C. Top Plug Wrench (Special Tool: 57001-1645)
A. Threads
B. Right Front Fork Bottom Plug
C. Top Plug Wrench (Special Tool: 57001-1645)
juster.
MAINTENANCE AND ADJUSTMENT 153
A. Projections
B. Holes A. Top Plug Wrench (Special Tool: 57001-1645)
C. Right Front Fork Spring Adjuster Unit B. Right Front Fork Spring Preload Adjuster
C. Right Front Fork Spring Adjuster Unit
• Holding the top plug wrench (special tool: 57001
-1645) with a vise, tighten the right front fork spring
D. Top Plug Wrench (Special Tool: 57001-1705)
preload adjuster on the fork spring adjuster unit
with a top plug wrench (special tool: 57001-1705).
154 MAINTENANCE AND ADJUSTMENT
Tightening Torque
Front Fork Clamp Bolts (Lower):
23 N·m (2.3 kgf·m, 17 ft·lb) j
NOTE
○Tighten the two clamp bolts alternately two times
to ensure even tightening torque.
• Install the front fork tubes to the motorcycle. A. Left Front Fork Cylinder Unit
• Adjust the fork height (see Fork Height Adjustment
section).
B. Top Plug Wrench (Special Tool: 57001-1645)
C. Torque Wrench
• Tighten the front fork clamp bolts (lower) to the
specified torque.
156 MAINTENANCE AND ADJUSTMENT
Tightening Torque For an example:
Left Front Fork Cylinder Unit: 34 N·m × 310 ÷ (310 + 44) = 30 N·m
j 34 N·m (3.5 kgf·m, 25 ft·lb)
Right Front Fork Spring Adjuster Unit:
34 N·m (3.5 kgf·m, 25 ft·lb)
NOTE
○The left front fork cylinder unit and right front fork
spring adjuster unit torque are specified to 34 N·m
(3.5 kgf·m, 25 ft·lb) however, when you use the top
plug wrench (special tool: 57001-1645), reduce
the torque to 90% of the specified value [30 N·m
(3.1 kgf·m, 22 ft·lb)] due to the distance between
the center of the square hole, where the torque
wrench is fitted, and that of the octagonal hole of
the wrench.
A. Top Plug Wrench
○This torque value [30 N·m (3.1 kgf·m, 22 ft·lb)] is B. Distance
applicable when you use a torque wrench whose C. Torque Wrench Length
length gives leverage of approximately 310 mm D. Grip Point
(12.2 in.) between the grip point to the center of
the coupling square. • Apply a non-permanent locking agent to the
○To obtain the correct tightening torque with your threads of the front fork clamp bolts (upper).
torque wrench, you need to calculate as follows. • Tighten the front fork clamp bolts (upper) to the
specified torque.
Formula:
a × b ÷ (b + c) = d Tightening Torque
Front Fork Clamp Bolts (Upper):
[a] Specified torque
23 N·m (2.3 kgf·m, 17 ft·lb)
[b] Length from center of square hole to grip
point
[c] Offset = 44 mm • Install the front brake caliper to the fork leg, and
tighten the front caliper mounting bolts to the spec-
[d] Tightening torque ified torque.
MAINTENANCE AND ADJUSTMENT 157
Tightening Torque
Front Caliper Mounting Bolts:
25 N·m (2.5 kgf·m, 18 ft·lb) j
• Install the fork protectors so that they do not touch
the front fork outer tube, and tighten the bolts to
specified torque.
Tightening Torque
Fork Protector Bolts:
4.0 N·m (0.41 kgf·m, 35 in·lb)
• Take
pads.
out wood wedge between the disc brake
NOTE
• Apply high-temperature grease to the grease ○Do not apply grease to the threads of the axle.
seals of the wheel.
• Install the collars on the left and right side of the • Insert the front axle from the right side of the mo-
torcycle.
hub.
• Put • Tighten the right front axle clamp bolts temporary.
the front wheel assembly between the fork
legs, and insert the front brake disc into the front • Tighten the front axle nut to the specified torque.
brake pads. Tightening Torque
• Apply a thin coat of grease to the front axle for rust
prevention.
Front Axle Nut:
80 N·m (8.2 kgf·m, 59 ft·lb)
A. Collars
B. Caps
C. Front Axle A. Pump the forks up and down.
D. Right Front Axle Clamp Bolts B. Block
E. Front Axle Nut
F. Left Front Axle Clamp Bolts • Tighten the right front axle clamp bolts to the spec-
ified torque.
G. Grease Seals
• Remove
cycle.
the jack and stand supporting the motor-
MAINTENANCE AND ADJUSTMENT 159
Tightening Torque Softer springs soften the fork action and slow down
Right Front Axle Clamp Bolts: the rebound damping.
23 N·m (2.3 kgf·m, 17 ft·lb) Fork Height Adjustment j
Steering is greatly affected by the fork height (how
NOTE much the outer fork tubes protrude above the steer-
ing stem head). The less the fork tube protrudes,
○Tighten the two clamp bolts alternately two times the lighter the front end becomes and the greater
to ensure even tightening torque.
the tendency for understeering and washout due to
• Check the front brake for good braking power and
no brake drag.
weight biasing. Increasing the amount of fork tube
protrusion has opposite effects.
Be sure that the front tire does not touch the fender
WARNING when the fork is fully compressed.
After servicing, it takes several applications
of the brake lever before the brake pads con-
NOTICE
tact the disc, which could result in increased The right and left fork tubes must be adjusted
stopping distance and cause an accident re- evenly.
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.
NOTE
○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.
High Speed Compression Damping Adjuster Low Speed Compression Damping Adjuster
Settings Settings
j
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. Standard Setting D. Standard Setting
*: Number of turns counterclockwise usable range *: Number of turns counterclockwise usable range
4 turns or less. Although you can turn the adjuster 19 clicks or less. Although you can turn the adjuster
beyond the adjustable range, effecting no changes beyond the adjustable range, effecting no changes
to damping force, use it within the adjustable range. to damping force, use it within the adjustable range.
Standard High Speed Compression Damping Standard Low Speed Compression Damping
Adjuster Setting Adjuster Setting
2 1/2 turns out* 11 clicks*
*: Counterclockwise from the fully seated position *: Counterclockwise from the fully seated position
164 MAINTENANCE AND ADJUSTMENT
NOTICE
Do not force the compression damping force
j 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. Always make any damping
adjustments in small steps and test their effects
before using them in competition.
*: Standard
A. Rim
B. Axial Runout
C. Radial Runout
Hoses Inspection
Check the brake and fuel hoses for cracks or de-
j
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.
• If damaged, replace the hoses.
A. Leak
B. Cracks
C. Bulges
AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
S: Follow the specified tightening sequence.
2T: Apply 2-stroke oil.
174 MAINTENANCE AND ADJUSTMENT
• Shift Pedal
178 MAINTENANCE AND ADJUSTMENT
Cable Lubrication Apply grease to the following points:
• Clutch Inner Cable Upper End
j • Throttle Inner Cable Upper End
A. Upper End
DFI Self-Diagnosis
This motorcycle equips the DFI trouble self
j
-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.
User Mode -
The ECU connected orange FI warning indicator
• Wipe off any lubricant that gets on the tire surface. light goes on when DFI system and ignition system
and ignition system parts are faulty. In case of se-
rious troubles, the ECU stops the injection/ignition
operation.
Dealer Mode -
The orange FI warning indicator light emits service
code(s) to show the problem(s) which the DFI sys-
tem, and ignition system has at the moment of diag-
nosis.
180 MAINTENANCE AND ADJUSTMENT
Self-diagnosis Procedures
•Disconnect the capacitor lead connector.
j
• Service codes are shown by a series of long and short blinks of the orange FI warning indicator light
as shown below.
j
• Read 10th digit and unit digit as the orange FI warning indicator light blinks.
• startingthere
When are a number of problems, all the service codes can be stored and the display will begin
from the lowest number service codes in the numerical order. Then after completing all codes, the
display is repeated until the self-diagnosis terminal is open.
• If there is no problem, no code and unlight.
• For example, if two problems occurred in the order of 21, 12, the service codes are displayed from
the lowest number in the order listed.
(12 → 21) → (12 → 21) → ··· (repeated)
• Ifindicator
the problem is with the following parts, the ECU cannot memorize these problems, the orange FI warning
light doesn’t go on, and no service codes can be displayed.
ECU Power Source Wiring and Ground Wiring (see Service Manual)
184 MAINTENANCE AND ADJUSTMENT
NOTE
○Even if the battery or the ECU is disconnected, or the problem is solved, all service codes remain in the ECU.
j
Service Code Table
Service
Orange FI Warning Indicator Light Problems
Code
Service
Orange FI Warning Indicator Light Problems
Code
j
46 Fuel pump 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. If the ground and power supply are checked good, replace the ECU
(see Service Manual).
○When no service code is displayed, the electrical parts of the DFI system has no fault, and the mechanical
parts of the DFI system and the engine are suspect.
186 TROUBLESHOOTING GUIDE
TROUBLESHOOTING GUIDE
NOTE Spark missing or weak:
○This troubleshooting guide is not exhaustive and •Spark plug dirty, broken, or gap improperly ad-
justed
j does not give every possible cause for each prob-
lem listed. It is meant simply as a quick guide to •Spark plug cap or high-tension wiring defective
assist you in troubleshooting for some of the more •Spark plug cap not contacting properly
common difficulties. •Spark plug type incorrect
•Crankshaft sensor defective
Starting failure or difficulties - •ECU defective
•Ignition coil defective
Engine does not turn over:
• Valve •Engine stop button wiring defective
seized
• Cylinder or seized •Flywheel magneto damaged
Valve lifter
• Crankshaft seized
piston seized
•Wiring shorted or interrupted
•
No fuel in tank
•Crankshaft oil seal leak
•
Fuel tank cap air vent obstructed
•Valve spring broken or weak
•
Fuel line clogged
Break down of a fuel pump
•Valve not seating properly (valve bent, worn, or
carbon accumulation on the seating surface)
• Break down of upstream injector and/or down-
•Piston ring worn, weak, broken, or sticking
stream injector
•Piston ring/groove clearance excessive
•Cylinder head gasket damaged
TROUBLESHOOTING GUIDE 187
• Cylinder head warped • Valve not seating properly (valve bent, worn, or
• Decompression damaged
Cylinder gasket carbon accumulation on the seating surface)
• trouble • Piston ring worn, weak, broken, or sticking
Poor low-speed performance - • Piston ring/groove clearance excessive
• Cylinder head gasket damaged
Spark weak: • Cylinder gasket
Cylinder head warped
j
•Spark plug dirty, broken, or gap improperly ad- • Decompression damaged
justed • trouble
•Spark plug cap or high-tension wiring defective
•Spark plug cap shorted or not contacting properly Other:
•Spark plug type incorrect •ECU defective
•Crankshaft sensor defective •Brake dragging
•ECU defective •Clutch slipping
•Ignition coil defective •Engine overheating
•Flywheel magneto defective •Engine oil level too high
•Wiring connector not in good contact •Engine oil viscosity too high
Compression low:
•ECU defective
Engine overheating -
• Spark plug loose
• Cylinder head insufficiently tightened Firing incorrect:
• Cylinder orboltpiston
Cylinder loose • Spark plug dirty, broken, or gap improperly ad-
• No valve clearanceworn justed
• Valve spring broken or weak • Spark plug type incorrect
• Valve not seating properly (valve bent, worn, or • ECU defective
• carbon accumulation on the seating surface) Fuel/air mixture incorrect:
• Piston ring worn, weak, broken, or sticking • Throttle body assy holder loose
• Piston ring/groove clearance excessive • Air cleaner element clogged, poorly sealed, or not
• Cylinder head
Cylinder gasket damaged installed
• Cylinder gasketwarped
head • Air cleaner duct poorly sealed
• Decompression damaged
• trouble Compression high:
Improper acceleration:
•Carbon built up in combustion chamber
Piston slap:
• Metal chip jammed in clutch housing gear teeth
• Brake fluid
Brake pad or disc worn
• Master cylinder scratched
• Brake disc warped
leaking
• Brake maladjusted (lever or pedal play excessive)
• Brake pads contaminated
j •
TUNING 193
TUNING
Suspension
• The front and rear suspension should always be
balanced; when the one is changed, the other one
might need to be changed similarly.
Introduction • When evaluating suspension performance, the
rider must make every effort to ride consistently
No area of machine adjustment is more critical
and to recognize the effects of his input. Such
than proper suspension tuning. An improperly tuned
things as changes in rider position and increasing j
suspension will keep even the best rider from attain-
fatigue may lead to incorrect judgments about
ing the full benefit of his machine’s ability. Match the
necessary adjustments.
suspension to the rider and the course conditions.
• When the proper settings have been determined
for a particular track, they should be written down
WHILE TUNING THE SUSPENSION, KEEP THE
for reference when returning to the same track.
FOLLOWING IMPORTANT POINTS IN MIND:
•If the machine is new, “break-in” the suspension • Lubricate the bearings in the swingarm and UNI
-TRAK® linkage after break-in and after every 3
with at least one hour of riding before making any
races to prevent friction from affecting suspension
setting evaluations or changes.
performance.
•The three major factors which must be considered
in suspension tuning are RIDER WEIGHT, RIDER Front Fork
ABILITY, and TRACK CONDITIONS. Additional
Front Fork Oil Amount-
influences include the RIDER’S STYLE and PO-
The fork oil amount in the fork tube is adjustable.
SITIONING on the machine.
A change in the fork oil level will not affect the spring
•Before changing the suspension settings, test
changing your riding posture or position to check
force much at the top of fork travel, but it will have a
great effect at the bottom of it.
whether it is the cause of the problem or not.
•It is a wise practice to adjust the suspension to • When the oil amount is raised, the air spring be-
comes more progressive, and the front fork action
suit the rider’s strong points. If you are fast in
feels “harder” in the later stage of fork travel, near
the corners, adjust the suspension to allow fast
the bottom.
cornering.
•Make setting changes in small increments. A little • When the oil amount is lowered, the air spring be-
comes less progressive, and the front fork action
bit goes a long way, and a setting is easily over
adjusted.
194 TUNING
does not feel as “hard” in the later stage of fork Troubleshooting Improper Settings
travel. Listed below are some symptoms of improper sus-
Fork Oil Amount Effect on Fork Stroke pension settings and the most likely means of cor-
recting them. The proper settings can be achieved
by applying the information given in this chapter in a
scientific, methodical manner. This does not mean,
however, that you must be a scientist or trained tech-
nician to succeed. Simply take time to think about
the changes you believe are necessary, check them
j against the symptoms and cures described here,
make the changes in small increments, and take
note of the changes and their effects.
Front Fork Improper Adjustment Symptoms -
Too Hard
Spring too stiff:
• Rebound or compression damping improperly ad-
justed.
A. Weight
• Spring too hard
B. Fork Stroke
C. Increase Amount • Fork oil amount too high
D. Standard Oil Amount Suspension stiffens at the end of the fork stroke:
E. Decrease Amount • Fork oil amount too high
Changing the fork oil amount works effectively at • air pressure high
Fork
the end of fork travel. If fork bottoming is experi- Spring OK, but suspension too hard:
enced, raise the fork oil amount. This will change • Fork oil deteriorated
the secondary spring rate. • Springairpreload
Fork pressure high
Front Fork Oil Amount Adjustment - • too hard
• Springs too soft Hence, if the actual rider weighs considerably more
• Rebound and/or compression damping improperly
Fork oil deteriorated or less, or if his riding experience and ability are
• adjusted. much above or below the intermediate level, it is
likely that a few basic suspension adjustments will
• Spring preload too soft be necessary.
Rear shock absorber improper adjustment Basic Readjustment of the Suspension
symptoms - Suspension Tuning According to Ground
Too Hard Surface
Suspension too stiff: j
• Compression damping too high Smooth Terrain Softer spring
• Spring too hard Rough Terrain Harder spring
Spring OK but suspension too hard:
• Unbalance between the spring and the rebound
damping (rebound damping too hard)
Suspension
Experience
Tuning According to Riding
Although this is one of the most effective adjust- • Decrease the fork oil amount.
ment procedures, suspension settings may vary de-
pending on the conditions at the track and the rider’s
• preload.
Use a softer spring, or decrease the spring
preferences.
NOTE
Front and Rear Suspension Troubleshooting ○Lighter or less experienced riders may need a
Front End Surges Downhill or During softer spring, or decrease the spring preload.
Acceleration Out of Corner -
The front suspension is too soft. Front End Does Not Respond to Small Bumps in
j
• Increase the compression damping or rebound
damping.
Sweeping Turns -
The front suspension is too hard.
• Increase the fork oil amount. • Decrease the compression damping or rebound
• Use an optional harder spring, or increase the
spring preload. •
damping.
Decrease the fork oil amount.
Front End “Knifes” or Oversteers in Turns • Use a softer spring, or decrease the spring
preload.
(Tends to Turn Inward) -
The front suspension is too soft. Rear End “Kicks” When Braking on Bumps -
• Increase the compression damping or rebound
damping.
The rear shock absorber rebound damping may be
too low.
• Increase the fork oil amount. • Increase the rebound damping.
NOTE Rear Tire Does Not “Hook Up” Out of Corners
(Lack of Traction Coming Out of Turns) -
○Heavier or expert riders may need a harder spring, The rear shock absorber may be too stiff.
or increase the spring preload.
• Decrease the rear shock absorber spring preload.
Front End Pushes or “Washes Out” in Turns • Decrease the high speed/low speed compression
damping.
(Front Wheel Tends to Push Outward Rather
than “Bite” in a Turn) - • Use a softer spring (lightweight rider only).
The front suspension is too stiff. Fork Bottoms Off After a High-speed Jump (may
• Decrease the compression damping or rebound
damping.
be due to improper riding posture) -
The rebound damping is too soft or the spring is
• Release some air from the fork tubes. too hard.
198 TUNING
Gearing
• Since it is difficult to set the machine so it is best
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. Confirm your settings by recording lap
(Rear Sprocket) times after each change. In this way the machine
Rear Sprocket Selection According to Course will deliver best performance for the entire circuit.
Conditions
Fast Course Small sprocket
j
Many Curves or Hills
Large sprocket
Sandy or Soft Ground
• Ifondary
the course has long straight portions, the sec-
reduction ratio should be reduced so that
the machine speed can be increased.
• If then the course has many corners or uphills or
is wet, the secondary reduction ratio should be
increased so that gear shifting and acceleration
are smooth.
• Since the speed must be changed depending on
the ground condition on the day of the race, be
sure to run through the circuit prior to a race and
tune the machine accordingly.
• If there is a long straight portion of the course on
which the machine can be run at maximum speed,
the machine should be set so that the maximum
speed is developed toward the end of the straight
course, but care should be taken not to over-rev
the engine.
200 TUNING
Take care not to overheat the engine in these con-
Special Care According to Track ditions. The engine also works very hard when
Conditions riding in deep sand.
• In muddy or sandy conditions, increase chain
• Infinedry,powdery
dusty conditions (such a volcanic ash or
dust), special care must be given to
slack as the chain and sprockets will be packed
with mud or sand, which reduces chain slack.
keeping the air cleaner element clean. • Check chain and sprocket wear frequently when
• When riding on wet, heavy clay, mud adheres to
the tires and other parts of the vehicle. The mud
riding in mud or sand, since wear is increased in
these conditions.
j can add significantly to the weight of the vehicle
and therefore reduce performance. Take care to
• Sticking muds or dusts on the front fork inner tube
and rear shock absorber rod could damage to the
remove built-up mud from the tires and chassis oil seal, leading to an oil leak. Clean the sticking
after each ride, before drying occurs. muds or dusts from the front fork inner tube and
• The engine works hardest in muddy conditions
and the radiator can become clogged with mud.
rear shock absorber rod after each ride.
OPTIONAL PARTS 201
OPTIONAL PARTS
Engine Sprocket Suspension Spring (N/mm)
12T K = 9.4
13T (Standard) Front K = 9.8 (Standard)
Rear Sprocket K = 10.2
48T K = 50
49T K = 52 (Standard)
Aluminum 50T (Standard) K = 54
51T Aluminum Nipple Wheel (Without Tire)
52T Front 21 × 1.60
48T Rear 19 × 1.85
49T Spoke Nipple
Steel 50T Front and Rear Steel
51T
52T KX FI Calibration Kit
The KX FI Calibration Kit can change the ECU data
Handlebar Holder and Clamp setting.
Clamp (Upper) Size 28.6
KX FI Calibration Kit: Part No. – 99999-0527
28.6 For details, refer to the KX FI Calibration Kit man-
Holder (Lower) Size
22.2 ual.
202 PRE-RACE CHECKS AND AFTER-RACE MAINTENANCE
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
• Clean the entire vehicle thoroughly. fuel. Make sure the area is well ventilated
• Run the engine for about five minutes to warm the
oil, then stop it and drain the engine oil.
and free from any source of flame or sparks;
this includes any appliance with a pilot light.
Make sure the engine is cold before working.
j WARNING Wipe any fuel off the engine before starting
Engine oil is a toxic substance. Dispose of it. Gasoline is a toxic substance. Dispose of
used oil properly. Contact your local author- gasoline properly. Contact your local author-
ities for approved disposal methods or pos- ities for approved disposal methods.
sible recycling.
• Remove the spark plug and spray fogging oil di-
• Install the oil drain bolt and fill in fresh engine oil. rectly into the cylinder. Kick the engine over slowly
• siphon.the fuel from the fuel tank by the pump or
Empty a few times to coat the cylinder wall. Install the
spark plug.
• Empty the fuel system by running the engine at • Lubricate the drive chain and all the cables.
idle speed until the engine stalls (If left in for a long
time, the fuel will break down and could clog the
• Spray oil on all unpainted metal surfaces to pre-
vent rusting. Avoid getting oil on rubber parts and
fuel system). on the brakes.
• Lift the motorcycle on a box or stand so that both
wheels are raised off the ground (If this cannot be
done, put boards under the front and rear wheels
to keep dampness away from the tire rubber.).
• Tie a plastic bag over the muffler to prevent mois-
ture from entering.
• Cover the motorcycle to keep dust and dirt away
from it.
STORAGE 205
• Remove the plastic bag from the muffler. • Perform a lubrication procedure in the Lubrication
• Make sure the spark plug is tight. section.
NOTE
○Fit the plug cap securely onto the spark plug, and
pull the cap lightly to make sure that it is properly
installed.
j
206 ENVIRONMENTAL PROTECTION
ENVIRONMENTAL PROTECTION
Kawasaki subscribes to the guidelines of Tread Lightly! a program dedicated to protecting the great outdoors
through education and fostering responsible enjoyment of public lands. When using your Kawasaki motorcycle,
please follow these Tread Lightly! guidelines:
Tread Lightly!
Travel responsibly on designated roads and trails or in permitted areas.
Respect the rights of others including private property owners and all recreational trail users, campers and
others to allow them to enjoy their recreational activities undisturbed.
Educate yourself by obtaining travel maps and regulations from public agencies, planning for your trip, taking
recreation skills classes, and knowing how to use and operate your equipment safely.
Avoid sensitive areas such as meadows, lakeshores, wetlands and streams, unless on designated routes.
This protects wildlife habitat and sensitive soils from damage.
D o your part by leaving the area better than you found it, properly disposing of waste, minimizing the use of
fire, avoiding the spread of invasive species, restoring degraded areas, and joining a local enthusiast organi-
zation.
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.
WIRING DIAGRAM 207
WIRING DIAGRAM