Owners Manual
Page 9
... unsupervised. Also, familiarity with any moving vehicle there are possible safety risks; Have them practice advanced riding maneuvers under controlled conditions. 11. Never allow . Read and understand the owner's manual provided with your child with motorcycle controls and maintenance requirements plus be necessary to be operated on private property. 5. Your child should a problem occur far from help. 9. Be sure...
... unsupervised. Also, familiarity with any moving vehicle there are possible safety risks; Have them practice advanced riding maneuvers under controlled conditions. 11. Never allow . Read and understand the owner's manual provided with your child with motorcycle controls and maintenance requirements plus be necessary to be operated on private property. 5. Your child should a problem occur far from help. 9. Be sure...
Owners Manual
Page 11
... Maintenance Chart ...Transmission Oil...Cooling System ...Spark Plug...Ignition Timing ...Air Cleaner ...Throttle Cable...Carburetor ...Clutch ...Piston ...Exhaust System ...10 13 13 16 16 19 20 21 22 22 23 25 27 28 28 32 34 39 40 42 45 47 48 58 68 Drive Chain...Handlebar...Brakes ...Steering ...Front Fork ...Rear Suspension (UNI-TRAK®)...Wheels ...Tightening Torques of Nuts and Bolts...Cleaning Your Motorcycle...Lubrication...TROUBLESHOOTING GUIDE...TUNING ...Carburetor Tuning ...Suspension...
... Maintenance Chart ...Transmission Oil...Cooling System ...Spark Plug...Ignition Timing ...Air Cleaner ...Throttle Cable...Carburetor ...Clutch ...Piston ...Exhaust System ...10 13 13 16 16 19 20 21 22 22 23 25 27 28 28 32 34 39 40 42 45 47 48 58 68 Drive Chain...Handlebar...Brakes ...Steering ...Front Fork ...Rear Suspension (UNI-TRAK®)...Wheels ...Tightening Torques of Nuts and Bolts...Cleaning Your Motorcycle...Lubrication...TROUBLESHOOTING GUIDE...TUNING ...Carburetor Tuning ...Suspension...
Owners Manual
Page 17
Transmission Oil Level Inspection Window 27. Water Pump Cover 28. Kick Pedal 25. Exhaust Pipe GENERAL INFORMATION 15 j 21. Muffler 22. Rear Brake Fluid Reservoir 23. Rear Shock Absorber Gas Reservoir 24. Rear Brake Pedal 26.
Transmission Oil Level Inspection Window 27. Water Pump Cover 28. Kick Pedal 25. Exhaust Pipe GENERAL INFORMATION 15 j 21. Muffler 22. Rear Brake Fluid Reservoir 23. Rear Shock Absorber Gas Reservoir 24. Rear Brake Pedal 26.
Owners Manual
Page 18
... performing the maintenance or adjustment. Fuel Tank Capacity 3.8 liters (1.0 US gal) To open the fuel tank cap, pull out the breather hose from flowing out. When installing the breather hose, make sure the arrow on the breather hose prevents fuel from the hole in injury. Fuel The Kawasaki KX is down position can cause a crash resulting in the number plate, and turn the tank cap counterclockwise. The breather hose...
... performing the maintenance or adjustment. Fuel Tank Capacity 3.8 liters (1.0 US gal) To open the fuel tank cap, pull out the breather hose from flowing out. When installing the breather hose, make sure the arrow on the breather hose prevents fuel from the hole in injury. Fuel The Kawasaki KX is down position can cause a crash resulting in the number plate, and turn the tank cap counterclockwise. The breather hose...
Owners Manual
Page 25
... engine cool completely. Scores on the cylinder wall should be smoothed with a hotter spark plug for performance and reliability. 5. 6. j NOTE żThe low-speed operation during the break-in procedure must be carried out to #600 emery cloth. Break in the engine as in period. Stop and let the engine cool completely. Decarbonize the exhaust ports and the upper part of operation, run...
... engine cool completely. Scores on the cylinder wall should be smoothed with a hotter spark plug for performance and reliability. 5. 6. j NOTE żThe low-speed operation during the break-in procedure must be carried out to #600 emery cloth. Break in the engine as in period. Stop and let the engine cool completely. Decarbonize the exhaust ports and the upper part of operation, run...
Owners Manual
Page 27
... in enclosed areas. The time required is minimal, and habitual performance of these checks before operation may result in serious damage or an accident. DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Inhaling carbon monoxide can cause serious brain injury or death. WARNING Failure to a safe operating condition. Engine Transmission oil ...Coolant ...Radiator Cap ...Spark Plug ...Cylinder Head Nut ...Cylinder Nut ...Clutch ...Carburetor ...Air Cleaner ... żNo...
... in enclosed areas. The time required is minimal, and habitual performance of these checks before operation may result in serious damage or an accident. DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Inhaling carbon monoxide can cause serious brain injury or death. WARNING Failure to a safe operating condition. Engine Transmission oil ...Coolant ...Radiator Cap ...Spark Plug ...Cylinder Head Nut ...Cylinder Nut ...Clutch ...Carburetor ...Air Cleaner ... żNo...
Owners Manual
Page 31
.../check † Silencer packing-change Small end bearing-check † Kick pedal and shift pedal-clean Exhaust pipe O-ring-replace Engine sprocket-check † Coolant-check † Radiator hoses/connections-check † *Reed valve-check† Brake adjustment-check † Brake pad wear-check † Brake fluid level-check † *Brake fluid-change *Brake master cylinder cup and dust seal-replace *Brake caliper piston seal and dust seal-replace *Brake hose-replace After each race (or...
.../check † Silencer packing-change Small end bearing-check † Kick pedal and shift pedal-clean Exhaust pipe O-ring-replace Engine sprocket-check † Coolant-check † Radiator hoses/connections-check † *Reed valve-check† Brake adjustment-check † Brake pad wear-check † Brake fluid level-check † *Brake fluid-change *Brake master cylinder cup and dust seal-replace *Brake caliper piston seal and dust seal-replace *Brake hose-replace After each race (or...
Owners Manual
Page 35
... j WARNING Motor oil is a toxic substance. filling the above requirements are fully formulated and provide adequate lubrication for approved disposal methods or possible recycling. Oil Drain Plug Remove the oil filler cap. Contact your local authorities for both the engine and the clutch. in the specified amount of used oil properly. MAINTENANCE AND ADJUSTMENT 33 Oil Change The transmission oil should be changed periodically to the oil...
... j WARNING Motor oil is a toxic substance. filling the above requirements are fully formulated and provide adequate lubrication for approved disposal methods or possible recycling. Oil Drain Plug Remove the oil filler cap. Contact your local authorities for both the engine and the clutch. in the specified amount of used oil properly. MAINTENANCE AND ADJUSTMENT 33 Oil Change The transmission oil should be changed periodically to the oil...
Owners Manual
Page 39
the coolant drain plug along the new gas• Install ket at the water pump cover. inspect the old coolant. • Visually If whitish cotton-like wafts are observed, aluminum • parts in the cooling system are rust• If ing and the system must be flushed. NOTICE Use coolant containing corrosion inhibitors made specifically for aluminum engines and radiators in accordance with...
the coolant drain plug along the new gas• Install ket at the water pump cover. inspect the old coolant. • Visually If whitish cotton-like wafts are observed, aluminum • parts in the cooling system are rust• If ing and the system must be flushed. NOTICE Use coolant containing corrosion inhibitors made specifically for aluminum engines and radiators in accordance with...
Owners Manual
Page 59
... WARNING Air in the brake lines diminish braking performance and can cause an accident resulting in ·lb) the lower end of the rear brake pedal, install the rear brake pedal and attach the return spring onto the frame. If the brake lever or pedal feels mushy when it is no • Test brake drag. the clutch cable. • Adjust Check the transmission oil level and coolant...
... WARNING Air in the brake lines diminish braking performance and can cause an accident resulting in ·lb) the lower end of the rear brake pedal, install the rear brake pedal and attach the return spring onto the frame. If the brake lever or pedal feels mushy when it is no • Test brake drag. the clutch cable. • Adjust Check the transmission oil level and coolant...
Owners Manual
Page 80
... the brake fluid level in the front and rear reservoirs and change the brake fluid in accordance with brake fluid DOT4 in the brake system. Do not use fluid from a container marked DOT3 or DOT4 żThe motorcycle is no • Test brake drag. WARNING Air in the brake lines diminish braking performance and can cause an accident resulting in injury or death. Brake Lever B. Locknut the braking power...
... the brake fluid level in the front and rear reservoirs and change the brake fluid in accordance with brake fluid DOT4 in the brake system. Do not use fluid from a container marked DOT3 or DOT4 żThe motorcycle is no • Test brake drag. WARNING Air in the brake lines diminish braking performance and can cause an accident resulting in injury or death. Brake Lever B. Locknut the braking power...
Owners Manual
Page 101
... prevent rusting. Lubricate the drive chain to seals, brake pads, and tires. water can damage the painted surfaces. a mild neutral detergent (designed for several times. Start the engine and let it idle for motor• Mix cycles or automobiles) and water in • Avoid air intakes, carburetors, brake components, electrical components, muffler outlets, and fuel tank openings. Use a soft cloth to remove any oil or grease build up. MAINTENANCE AND ADJUSTMENT 99 Cleaning...
... prevent rusting. Lubricate the drive chain to seals, brake pads, and tires. water can damage the painted surfaces. a mild neutral detergent (designed for several times. Start the engine and let it idle for motor• Mix cycles or automobiles) and water in • Avoid air intakes, carburetors, brake components, electrical components, muffler outlets, and fuel tank openings. Use a soft cloth to remove any oil or grease build up. MAINTENANCE AND ADJUSTMENT 99 Cleaning...
Owners Manual
Page 106
...;This troubleshooting guide is not exhaustive and starting technique (when the engine is meant simply as a quick guide to assist you in tank • No tap turned off • Fuel Tank cap air vent obstructed • Fuel tap • Fuel line clogged clogged • Float valve clogged • Engine flooded level too high • Fuel Float • valve worn or stuck open to reach the engine). Spark missing or weak Spark plug...
...;This troubleshooting guide is not exhaustive and starting technique (when the engine is meant simply as a quick guide to assist you in tank • No tap turned off • Fuel Tank cap air vent obstructed • Fuel tap • Fuel line clogged clogged • Float valve clogged • Engine flooded level too high • Fuel Float • valve worn or stuck open to reach the engine). Spark missing or weak Spark plug...
Owners Manual
Page 107
... properly Spark plug type incorrect Igniter defective Ignition coil defective Stator damaged head warped • Cylinder Cylinder gasket damaged • Reed valve damaged • Other defective • Igniter Transmission oil viscosity too high • Brake dragging • Poor or no high-speed performance Firing incorrect Spark plug dirty, damaged, or gap improperly adjusted Spark plug cap or high-tension wiring defective Spark plug cap shorted or not contacting properly Spark plug type incorrect Igniter defective Ignition coil defective Stator damaged Fuel-air...
... properly Spark plug type incorrect Igniter defective Ignition coil defective Stator damaged head warped • Cylinder Cylinder gasket damaged • Reed valve damaged • Other defective • Igniter Transmission oil viscosity too high • Brake dragging • Poor or no high-speed performance Firing incorrect Spark plug dirty, damaged, or gap improperly adjusted Spark plug cap or high-tension wiring defective Spark plug cap shorted or not contacting properly Spark plug type incorrect Igniter defective Ignition coil defective Stator damaged Fuel-air...
Owners Manual
Page 108
...; Air cleaner element clogged • Muffler clogged • Fuel contaminated with water or foreign matter • Cylinder exhaust port clogged • Brake dragging • Clutch slipping • Engine overheating • Transmission oil level too high • Transmission oil viscosity too high • Crankshaft bearing worn or damaged • Knocking built up in combustion chamber • Carbon Fuel quality poor or type incorrect • plug type incorrect • Spark Igniter defective...
...; Air cleaner element clogged • Muffler clogged • Fuel contaminated with water or foreign matter • Cylinder exhaust port clogged • Brake dragging • Clutch slipping • Engine overheating • Transmission oil level too high • Transmission oil viscosity too high • Crankshaft bearing worn or damaged • Knocking built up in combustion chamber • Carbon Fuel quality poor or type incorrect • plug type incorrect • Spark Igniter defective...
Owners Manual
Page 109
... worn spring weak or broken • Drive shaft, output shaft, and/or gear splines worn • Transmission skips gears positioning lever spring weak or broken • Gear • Shift mechanism arm spring broken Engine noise abnormal defective • Igniter built up in combustion chamber • Carbon Fuel quality poor or type incorrect • Spark plug type incorrect • Engine overheating • Piston slap clearance excessive • Piston Cylinder or...
... worn spring weak or broken • Drive shaft, output shaft, and/or gear splines worn • Transmission skips gears positioning lever spring weak or broken • Gear • Shift mechanism arm spring broken Engine noise abnormal defective • Igniter built up in combustion chamber • Carbon Fuel quality poor or type incorrect • Spark plug type incorrect • Engine overheating • Piston slap clearance excessive • Piston Cylinder or...
Owners Manual
Page 110
... engine sprocket(s) worn • Drive chain insufficiently • Rear wheel misaligned lubrified • Clutch noise Frame noise abnormal Front fork noise Oil level or viscosity too low Spring weak or broken j • • Rear shock absorber noise • Shock absorber damaged Disc brake noise installed incorrectly • Pad surface glazed • Pad Brake disc warped • Brake caliper • Brake master defective cylinder damaged • Other noise nut, bolt, etc. improperly mounted or • Bracket, tightened Exhaust...
... engine sprocket(s) worn • Drive chain insufficiently • Rear wheel misaligned lubrified • Clutch noise Frame noise abnormal Front fork noise Oil level or viscosity too low Spring weak or broken j • • Rear shock absorber noise • Shock absorber damaged Disc brake noise installed incorrectly • Pad surface glazed • Pad Brake disc warped • Brake caliper • Brake master defective cylinder damaged • Other noise nut, bolt, etc. improperly mounted or • Bracket, tightened Exhaust...
Owners Manual
Page 125
Confirm your settings by recording lap times after each change. The engine also works very hard when riding in these conditions. keeping the air cleaner element clean. The mud can become clogged with mud or sand, which circuit portions will deliver best performance for all portions of the circuit, determine which reduces chain slack. Check chain and sprocket wear frequently when riding...
Confirm your settings by recording lap times after each change. The engine also works very hard when riding in these conditions. keeping the air cleaner element clean. The mud can become clogged with mud or sand, which circuit portions will deliver best performance for all portions of the circuit, determine which reduces chain slack. Check chain and sprocket wear frequently when riding...
Owners Manual
Page 127
... control cable routings Engine mounting bolt torque Engine sprocket installation Shift pedal bolt torque Transmission oil level Carburetor clamp screw tightness Carburetor top cap tightness UNI-TRAK® lever rod bolt tightness UNI-TRAK® lever bolt torque Rear shock absorber bolt torque Swingarm pivot shaft nut torque Rear axle nut torque Rear sprocket bolt or nut torque Rear brake pedal operation Seat installation and rear wheel spoke tightness • Front Front rear tire air pressure • Drive and chain...
... control cable routings Engine mounting bolt torque Engine sprocket installation Shift pedal bolt torque Transmission oil level Carburetor clamp screw tightness Carburetor top cap tightness UNI-TRAK® lever rod bolt tightness UNI-TRAK® lever bolt torque Rear shock absorber bolt torque Swingarm pivot shaft nut torque Rear axle nut torque Rear sprocket bolt or nut torque Rear brake pedal operation Seat installation and rear wheel spoke tightness • Front Front rear tire air pressure • Drive and chain...
Owners Manual
Page 129
... to be stored for any length of time, it and drain the transmission oil. Kick the engine over the muffler to warm the oil, then stop the engine and never smoke while handling fuel. Clean the entire vehicle thoroughly. Always stop it should be prepared for storage as Kawasaki K-Kare Fogging oil (part number K61030002), directly into the cylinder. Run the engine for about five minutes to...
... to be stored for any length of time, it and drain the transmission oil. Kick the engine over the muffler to warm the oil, then stop the engine and never smoke while handling fuel. Clean the entire vehicle thoroughly. Always stop it should be prepared for storage as Kawasaki K-Kare Fogging oil (part number K61030002), directly into the cylinder. Run the engine for about five minutes to...