Owners Manual
Page 6
... understand the owner's manual provided with any moving vehicle there are possible safety risks; Be sure your child. be familiar with motorcycle controls and maintenance requirements plus be familiar with your child understands the importance of an experienced adult. 2. 3. 4. 5. 6. 7. 8. 9. You, the parent (and most likely "riding instructor/mechanic" as motocross. Review all instructions and warnings with motorcycle controls (location...
... understand the owner's manual provided with any moving vehicle there are possible safety risks; Be sure your child. be familiar with motorcycle controls and maintenance requirements plus be familiar with your child understands the importance of an experienced adult. 2. 3. 4. 5. 6. 7. 8. 9. You, the parent (and most likely "riding instructor/mechanic" as motocross. Review all instructions and warnings with motorcycle controls (location...
Owners Manual
Page 11
... ADJUSTMENT...EMISSION CONTROL INFORMATION ...Periodic Maintenance Chart ...Engine Oil...Spark Plug...Air Cleaner ...Throttle Cable...Choke Knob...Idle Speed ...10 14 14 17 17 18 21 22 22 23 25 26 27 27 28 29 31 31 34 38 42 43 48 51 52 Clutch ...Valve Clearance ...Spark Arrester ...Drive Chain...Handlebar...Brakes ...Steering ...Front Suspension ...Rear Suspension ...Wheels ...Hoses Inspection ...Battery ...Fuse ...Tightening Torques of Nuts and Bolts...Cleaning Your Motorcycle...Lubrication...TROUBLESHOOTING GUIDE...STORAGE ...Before...
... ADJUSTMENT...EMISSION CONTROL INFORMATION ...Periodic Maintenance Chart ...Engine Oil...Spark Plug...Air Cleaner ...Throttle Cable...Choke Knob...Idle Speed ...10 14 14 17 17 18 21 22 22 23 25 26 27 27 28 29 31 31 34 38 42 43 48 51 52 Clutch ...Valve Clearance ...Spark Arrester ...Drive Chain...Handlebar...Brakes ...Steering ...Front Suspension ...Rear Suspension ...Wheels ...Hoses Inspection ...Battery ...Fuse ...Tightening Torques of Nuts and Bolts...Cleaning Your Motorcycle...Lubrication...TROUBLESHOOTING GUIDE...STORAGE ...Before...
Owners Manual
Page 12
10 SPECIFICATIONS SPECIFICATIONS DIMENSIONS Overall length Overall width Overall height Wheelbase Road clearance Dry weight Fuel tank capacity ENGINE Type Bore × stroke Displacement Compression ratio Carburetor Starting system Ignition system Ignition timing Lubrication system Spark plug Spark plug terminal SOHC, 2-valve, single-cylinder, 4-stroke, Air-cooled 58.0 × 54.4 mm (2.3 × 2.1 in.) 144 cm³ (8.8 cu in.) 9.5 : 1 KEIHIN PB20 Electric Starter DC-CDI 10° BTDC @1 400 r/min (rpm) ∼ 30° BTDC @4 000 r/min...
10 SPECIFICATIONS SPECIFICATIONS DIMENSIONS Overall length Overall width Overall height Wheelbase Road clearance Dry weight Fuel tank capacity ENGINE Type Bore × stroke Displacement Compression ratio Carburetor Starting system Ignition system Ignition timing Lubrication system Spark plug Spark plug terminal SOHC, 2-valve, single-cylinder, 4-stroke, Air-cooled 58.0 × 54.4 mm (2.3 × 2.1 in.) 144 cm³ (8.8 cu in.) 9.5 : 1 KEIHIN PB20 Electric Starter DC-CDI 10° BTDC @1 400 r/min (rpm) ∼ 30° BTDC @4 000 r/min...
Owners Manual
Page 21
... sure the fuel tank cap is spilled on service station pumps in the U.S.A. If gasoline is closed securely. Breather Hose Minimum Rating 87 Antiknock Index (RON + MON) 2 WARNING Gasoline is extremely flammable and can lead to severe engine damage. this condition is a measure of a higher octane rating. Fuel Tank Cap B. If this includes any source of a gasoline is allowed to detonation or "knocking". Octane Rating Method...
... sure the fuel tank cap is spilled on service station pumps in the U.S.A. If gasoline is closed securely. Breather Hose Minimum Rating 87 Antiknock Index (RON + MON) 2 WARNING Gasoline is extremely flammable and can lead to severe engine damage. this condition is a measure of a higher octane rating. Fuel Tank Cap B. If this includes any source of a gasoline is allowed to detonation or "knocking". Octane Rating Method...
Owners Manual
Page 23
... battery, if you may be thrown into an unexpected pit resulting in the "ON" position or leave the motorcycle idling after starting the engine for a long time (1 hour or longer). If you turn the ignition switch to the "OFF" position, while driving the motorcycle, all the electrical systems will cease working and you leave the ignition switch in an accident. WARNING Never operate the ignition switch...
... battery, if you may be thrown into an unexpected pit resulting in the "ON" position or leave the motorcycle idling after starting the engine for a long time (1 hour or longer). If you turn the ignition switch to the "OFF" position, while driving the motorcycle, all the electrical systems will cease working and you leave the ignition switch in an accident. WARNING Never operate the ignition switch...
Owners Manual
Page 26
... it cool and the battery power recover. the throttle completely closed, push the • Leaving starter button until the engine starts. CAUTION Do not operate the starter continuously for more than 5 seconds, or the starter will overheat and the battery power will drop temporarily. Ignition Button A. NOTE żWhen the clutch lever is pulled, the motorcycle can be started with the transmission in the ignition button...
... it cool and the battery power recover. the throttle completely closed, push the • Leaving starter button until the engine starts. CAUTION Do not operate the starter continuously for more than 5 seconds, or the starter will overheat and the battery power will drop temporarily. Ignition Button A. NOTE żWhen the clutch lever is pulled, the motorcycle can be started with the transmission in the ignition button...
Owners Manual
Page 28
... a lower gear, do not shift at such a high speed that when shifting up to the next gear, pull in the clutch lever, lift the shift pedal with a 5-speed "return shift" transmission. CAUTION When changing gears, press firmly on the shift pedal, gently release the clutch lever, then release the shift pedal. Not only can cause the transmission to jump out of gear and lead to engine damage. • • • WARNING When shifting down...
... a lower gear, do not shift at such a high speed that when shifting up to the next gear, pull in the clutch lever, lift the shift pedal with a 5-speed "return shift" transmission. CAUTION When changing gears, press firmly on the shift pedal, gently release the clutch lever, then release the shift pedal. Not only can cause the transmission to jump out of gear and lead to engine damage. • • • WARNING When shifting down...
Owners Manual
Page 29
... ignition button (red light is off). • A. OFF Position • Turn the fuel tap lever to ensure good engine response at all speeds. Shift down progressively to the OFF position. GENERAL INFORMATION 27 j Stopping the Motorcycle For maximum deceleration, close the throttle and apply both front and rear brakes. Independent use of the front or rear brake may be advantageous in the clutch...
... ignition button (red light is off). • A. OFF Position • Turn the fuel tap lever to ensure good engine response at all speeds. Shift down progressively to the OFF position. GENERAL INFORMATION 27 j Stopping the Motorcycle For maximum deceleration, close the throttle and apply both front and rear brakes. Independent use of the front or rear brake may be advantageous in the clutch...
Owners Manual
Page 32
... damage Air pressure correct Air valve cap installed Spokes ...No looseness Drive Chain ...Overall condition good Chain slack correct Oil if necessary Front and Rear Brakes ...Function properly Lever and pedal play correct No leakage Throttle ...Functions properly Throttle grip returns smoothly Steering ...Smooth but not loose from lock to lock No binding due to control cables Front Fork ...Functions properly No leakage Rear Shock Absorber ...Functions properly No leakage Fuel Tank ...Mounted...
... damage Air pressure correct Air valve cap installed Spokes ...No looseness Drive Chain ...Overall condition good Chain slack correct Oil if necessary Front and Rear Brakes ...Function properly Lever and pedal play correct No leakage Throttle ...Functions properly Throttle grip returns smoothly Steering ...Smooth but not loose from lock to lock No binding due to control cables Front Fork ...Functions properly No leakage Rear Shock Absorber ...Functions properly No leakage Fuel Tank ...Mounted...
Owners Manual
Page 33
... with the fuel and air supplied by the exhaust of the engine. MAINTENANCE AND ADJUSTMENT 31 MAINTENANCE AND ADJUSTMENT The maintenance and adjustments outlined in this chapter must not be completed by the owner. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in good running condition. While the engine is vitally important and must be able to the intake side of this vehicle. If...
... with the fuel and air supplied by the exhaust of the engine. MAINTENANCE AND ADJUSTMENT 31 MAINTENANCE AND ADJUSTMENT The maintenance and adjustments outlined in this chapter must not be completed by the owner. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in good running condition. While the engine is vitally important and must be able to the intake side of this vehicle. If...
Owners Manual
Page 34
... modification. 32 MAINTENANCE AND ADJUSTMENT High Altitude Performance Adjustment Information To improve the EMISSION CONTROL PERFORMANCE of vehicles operated above 4 000 feet, Kawasaki recommends the following repair recommendations specified in the appropriate Kawasaki Service Manual. This Owner's Manual contains maintenance operations recommended for your own expense. To assist you have the responsibility to the instructions in keeping this Owner's Manual at your vehicle. Warranty This vehicle is carried...
... modification. 32 MAINTENANCE AND ADJUSTMENT High Altitude Performance Adjustment Information To improve the EMISSION CONTROL PERFORMANCE of vehicles operated above 4 000 feet, Kawasaki recommends the following repair recommendations specified in the appropriate Kawasaki Service Manual. This Owner's Manual contains maintenance operations recommended for your own expense. To assist you have the responsibility to the instructions in keeping this Owner's Manual at your vehicle. Warranty This vehicle is carried...
Owners Manual
Page 40
... idle speed. Oil Level Inspection the motorcycle so that it by screwing. the oil has just been changed, start the engine • If and run it for the engine, transmission and clutch to the ground. Oil Filler Cap/Dipstick B. Check the engine oil level on the dipstick. High Level Line C. The oil level should come up between the low and high level lines on the dipstick. A. 38 MAINTENANCE...
... idle speed. Oil Level Inspection the motorcycle so that it by screwing. the oil has just been changed, start the engine • If and run it for the engine, transmission and clutch to the ground. Oil Filler Cap/Dipstick B. Check the engine oil level on the dipstick. High Level Line C. The oil level should come up between the low and high level lines on the dipstick. A. 38 MAINTENANCE...
Owners Manual
Page 41
... type and brand of used oil properly. A. Remove the oil drain plugs and position the vehicle by using a syringe or • some other suitable device. Drain Plug WARNING Motor oil is already in the engine. Warm up the engine thoroughly so that is a toxic substance. MAINTENANCE AND ADJUSTMENT 39 Oil and/or Oil Filter Change The engine oil and/or oil filter should be changed periodically to reach the correct...
... type and brand of used oil properly. A. Remove the oil drain plugs and position the vehicle by using a syringe or • some other suitable device. Drain Plug WARNING Motor oil is already in the engine. Warm up the engine thoroughly so that is a toxic substance. MAINTENANCE AND ADJUSTMENT 39 Oil and/or Oil Filter Change The engine oil and/or oil filter should be changed periodically to reach the correct...
Owners Manual
Page 42
Bolts C. Oil Filter Element B. 40 MAINTENANCE AND ADJUSTMENT the oil filter is replaced, remove the oil filter • When cover and take off the cover with the grommet to- Oil Filter Cover B. j A. Up Mark A. the oil filter cover facing the up mark to up • Install with a new one. • Replace Apply the oil to the specified torque. Grommet CAUTION Inside-Out installation stop oil flow, the causing engine seizure. the oil filter element...
Bolts C. Oil Filter Element B. 40 MAINTENANCE AND ADJUSTMENT the oil filter is replaced, remove the oil filter • When cover and take off the cover with the grommet to- Oil Filter Cover B. j A. Up Mark A. the oil filter cover facing the up mark to up • Install with a new one. • Replace Apply the oil to the specified torque. Grommet CAUTION Inside-Out installation stop oil flow, the causing engine seizure. the oil filter element...
Owners Manual
Page 57
..., which lowers performances, burns the valves and valve seats, and may cause serious engine damage. NOTE żIf the engine is started. The exhaust system becomes very hot soon after the engine is hot, wait until the engine cools. Spark Arrester This vehicle is left unadjusted, wear will eventually cause the valves to ensure its efficiency. It must be done only by an authorized Kawasaki dealer...
..., which lowers performances, burns the valves and valve seats, and may cause serious engine damage. NOTE żIf the engine is started. The exhaust system becomes very hot soon after the engine is hot, wait until the engine cools. Spark Arrester This vehicle is left unadjusted, wear will eventually cause the valves to ensure its efficiency. It must be done only by an authorized Kawasaki dealer...
Owners Manual
Page 68
... operate the motorcycle under such conditions, have the brake checked immediately. Use only heavy-duty brake fluid as follows. Check for brake hose damage. Disc Brake Fluid Inspect the brake fluid level in the front and rear reservoirs and change the brake fluid in the brake lines or the brake may be changed when contaminated with brake fluid DOT4 in the brake system. j WARNING If the brake lever or pedal feels mushy...
... operate the motorcycle under such conditions, have the brake checked immediately. Use only heavy-duty brake fluid as follows. Check for brake hose damage. Disc Brake Fluid Inspect the brake fluid level in the front and rear reservoirs and change the brake fluid in the brake lines or the brake may be changed when contaminated with brake fluid DOT4 in the brake system. j WARNING If the brake lever or pedal feels mushy...
Owners Manual
Page 74
... adjusted easily, making it unnecessary to suit various riding conditions. 72 MAINTENANCE AND ADJUSTMENT Rear Suspension Rear Shock Absorber Inspection the seat down and up by an authorized • If Kawasaki dealer. Rebound Damping Adjuster If the damping feels too soft or too stiff, adjust it does not smoothly or noise is found, inspect • If the oil leak and rear shock absorber mounting.
... adjusted easily, making it unnecessary to suit various riding conditions. 72 MAINTENANCE AND ADJUSTMENT Rear Suspension Rear Shock Absorber Inspection the seat down and up by an authorized • If Kawasaki dealer. Rebound Damping Adjuster If the damping feels too soft or too stiff, adjust it does not smoothly or noise is found, inspect • If the oil leak and rear shock absorber mounting.
Owners Manual
Page 91
... your motorcycle. Be sure the engine and exhaust are cool before washing. using pressure washers; Always use a mild degreaser to wash your motorcycle for motor• Mix cycles or automobiles) and water in air intakes, carburetors, brake components, electrical components, muffler outlets, and fuel tank openings. water can easily be scratched. Do not let the water air dry as ammonia-based window cleaners. Use a soft cloth or...
... your motorcycle. Be sure the engine and exhaust are cool before washing. using pressure washers; Always use a mild degreaser to wash your motorcycle for motor• Mix cycles or automobiles) and water in air intakes, carburetors, brake components, electrical components, muffler outlets, and fuel tank openings. water can easily be scratched. Do not let the water air dry as ammonia-based window cleaners. Use a soft cloth or...
Owners Manual
Page 97
...; Engine overheating - dragging • Brake Clutch slipping • Fuel-air mixture incorrect Air cleaner element clogged Air cleaner duct loose TROUBLESHOOTING GUIDE 95 TROUBLESHOOTING GUIDE NOTE żThis troubleshooting guide is meant simply as a quick guide to OFF • Compression low • Spark plug loose Spark missing or weak plug faulty • Spark Spark plug cap poorly connected or shorted • Fuel does not flow fuel in troubleshooting for each problem listed. not in neutral • Transmission Engine stop switch set...
...; Engine overheating - dragging • Brake Clutch slipping • Fuel-air mixture incorrect Air cleaner element clogged Air cleaner duct loose TROUBLESHOOTING GUIDE 95 TROUBLESHOOTING GUIDE NOTE żThis troubleshooting guide is meant simply as a quick guide to OFF • Compression low • Spark plug loose Spark missing or weak plug faulty • Spark Spark plug cap poorly connected or shorted • Fuel does not flow fuel in troubleshooting for each problem listed. not in neutral • Transmission Engine stop switch set...
Owners Manual
Page 99
... be stored for any length of gasoline properly. Spray oil on all the cables. Always stop it . • • j WARNING Motor oil is a toxic substance. Dispose of time, it should be prepared for approved disposal methods or possible recycling. Clean the entire vehicle thoroughly. Install the spark plug. Lift the motorcycle on the brakes. the spark plug and spray fogging oil, • Remove such as...
... be stored for any length of gasoline properly. Spray oil on all the cables. Always stop it . • • j WARNING Motor oil is a toxic substance. Dispose of time, it should be prepared for approved disposal methods or possible recycling. Clean the entire vehicle thoroughly. Install the spark plug. Lift the motorcycle on the brakes. the spark plug and spray fogging oil, • Remove such as...
