Owners Manual
Page 8
... moving vehicle there are not familiar with motorcycle controls and maintenance requirements plus be operated on your commitment to ride and when you are possible safety risks; As with the motorcycle is designed for an OPERATOR ONLY. 3. Read and understand the owner's manual provided with motorcycle controls (location and function) and basic riding techniques. Your child should a problem...
... moving vehicle there are not familiar with motorcycle controls and maintenance requirements plus be operated on your commitment to ride and when you are possible safety risks; As with the motorcycle is designed for an OPERATOR ONLY. 3. Read and understand the owner's manual provided with motorcycle controls (location and function) and basic riding techniques. Your child should a problem...
Owners Manual
Page 9
......Periodic Maintenance Chart ...Transmission Oil...Cooling System ...Spark Plug...Ignition Timing ...Air Cleaner ...Throttle Cable...Carburetor ...Clutch ...Piston ...Exhaust System ...8 12 12 15 15 19 19 20 21 22 22 24 26 27 27 31 33 38 40 42 45 47 48 53 64 Drive Chain...Handlebar...Brakes ...Steering ...Front Fork ...Rear Suspension (UNI-TRAK®)...Wheels ...Tightening Nuts and Bolts ...Cleaning Your Motorcycle...Lubrication...TROUBLESHOOTING GUIDE...ENGINE AND SUSPENSION TUNING...Carburetor Tuning ...Suspension Tuning...Gearing...
......Periodic Maintenance Chart ...Transmission Oil...Cooling System ...Spark Plug...Ignition Timing ...Air Cleaner ...Throttle Cable...Carburetor ...Clutch ...Piston ...Exhaust System ...8 12 12 15 15 19 19 20 21 22 22 24 26 27 27 31 33 38 40 42 45 47 48 53 64 Drive Chain...Handlebar...Brakes ...Steering ...Front Fork ...Rear Suspension (UNI-TRAK®)...Wheels ...Tightening Nuts and Bolts ...Cleaning Your Motorcycle...Lubrication...TROUBLESHOOTING GUIDE...ENGINE AND SUSPENSION TUNING...Carburetor Tuning ...Suspension Tuning...Gearing...
Owners Manual
Page 17
... rear of the left footpeg. Fuel The Kawasaki KX is installed. Side Stand B. NOTE żSupport the motorcycle by using the suitable stand when performing the maintenance or adjustment. Fuel Tank Capacity 5.5 liters (1.46 US gal) To open the fuel tank cap, pull out the breather hose from flowing out. The breather hose has the check valve. A. The check valve on the valve points toward the fuel tank cap. A. Fuel Tank Cap...
... rear of the left footpeg. Fuel The Kawasaki KX is installed. Side Stand B. NOTE żSupport the motorcycle by using the suitable stand when performing the maintenance or adjustment. Fuel Tank Capacity 5.5 liters (1.46 US gal) To open the fuel tank cap, pull out the breather hose from flowing out. The breather hose has the check valve. A. The check valve on the valve points toward the fuel tank cap. A. Fuel Tank Cap...
Owners Manual
Page 25
...engine speeds will keep optimum engine performance, replace the piston rings after break-in , install a new standard spark plug, and change the transmission oil. żTo keep the engine trouble-free. NEVER ACCELERATE HARD. 4. Decarbonize the exhaust ports and the upper part of the radiator filler neck with coolant. Remove the carbon inside the combustion chamber. Start the engine... Start the engine and let it idle until it is ready for 10 minutes at moderate speed - A scored piston skirt could lower engine performance or damage the cylinder wall. Check and adjust as in the engine ...
...engine speeds will keep optimum engine performance, replace the piston rings after break-in , install a new standard spark plug, and change the transmission oil. żTo keep the engine trouble-free. NEVER ACCELERATE HARD. 4. Decarbonize the exhaust ports and the upper part of the radiator filler neck with coolant. Remove the carbon inside the combustion chamber. Start the engine... Start the engine and let it idle until it is ready for 10 minutes at moderate speed - A scored piston skirt could lower engine performance or damage the cylinder wall. Check and adjust as in the engine ...
Owners Manual
Page 26
... correct No leakage Level correct (engine cold) Properly installed Correctly torqued Correctly torqued Correctly torqued Functions properly Properly tuned Clean Properly installed Apply oil to a safe operating condition. Engine Transmission Oil ...Coolant ...Radiator Cap ...Spark Plug ...Cylinder Head Nut ...Cylinder Nut ...Clutch ...Carburetor ...Air Cleaner ...Muffler ...Engine Sprocket ... WARNING Failure to perform these checks will help ensure a safe, reliable ride. The time required is minimal, and habitual performance of these checks every day...
... correct No leakage Level correct (engine cold) Properly installed Correctly torqued Correctly torqued Correctly torqued Functions properly Properly tuned Clean Properly installed Apply oil to a safe operating condition. Engine Transmission Oil ...Coolant ...Radiator Cap ...Spark Plug ...Cylinder Head Nut ...Cylinder Nut ...Clutch ...Carburetor ...Air Cleaner ...Muffler ...Engine Sprocket ... WARNING Failure to perform these checks will help ensure a safe, reliable ride. The time required is minimal, and habitual performance of these checks every day...
Owners Manual
Page 30
... FREQUENCY OPERATION 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 Spoke tightness and rim runout-check †...
... FREQUENCY OPERATION 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 Spoke tightness and rim runout-check †...
Owners Manual
Page 33
... other suitable device. Oil Level Inspection Window B. Warm up to ensure long engine life. MAINTENANCE AND ADJUSTMENT 31 Transmission Oil In order for all the oil to drain. • • lower right side of oil level gauge Oil Change The transmission oil should come up the engine thoroughly so that is already in transmission seizure, and injury. The oil should be changed periodically to the center of the one...
... other suitable device. Oil Level Inspection Window B. Warm up to ensure long engine life. MAINTENANCE AND ADJUSTMENT 31 Transmission Oil In order for all the oil to drain. • • lower right side of oil level gauge Oil Change The transmission oil should come up the engine thoroughly so that is already in transmission seizure, and injury. The oil should be changed periodically to the center of the one...
Owners Manual
Page 38
... new gasket • Install at the water pump cover and the cylinder, and apply the specified torques. Coolant Drain Plug Tightening Torque Coolant Drain Plug (Water Pump Cover) 4.9 N·m (0.5 kgf·m, 43 in·lb) Coolant Drain Plug (Cylinder) 4.9 N·m (0.5 kgf·m, 43 in·lb) WARNING Wash off any coolant that the filler neck is level to the bottom of coolant on the frame, engine, or wheel. Coolant Drain Plug B. the radiator...
... new gasket • Install at the water pump cover and the cylinder, and apply the specified torques. Coolant Drain Plug Tightening Torque Coolant Drain Plug (Water Pump Cover) 4.9 N·m (0.5 kgf·m, 43 in·lb) Coolant Drain Plug (Cylinder) 4.9 N·m (0.5 kgf·m, 43 in·lb) WARNING Wash off any coolant that the filler neck is level to the bottom of coolant on the frame, engine, or wheel. Coolant Drain Plug B. the radiator...
Owners Manual
Page 75
... brake could damage the brake assembly and possibly lock the wheel, resulting in accordance with a wrench. Disc Brake Fluid Inspect the brake fluid level in the front and rear reservoirs and change the brake fluid in loss of control. j • • WARNING Always maintain proper brake adjustment. Adjuster the braking power and check that require adjustment except brake lever position. The brake fluid MAINTENANCE AND ADJUSTMENT 73 Brakes Disc and disc pad wear is automatically...
... brake could damage the brake assembly and possibly lock the wheel, resulting in accordance with a wrench. Disc Brake Fluid Inspect the brake fluid level in the front and rear reservoirs and change the brake fluid in loss of control. j • • WARNING Always maintain proper brake adjustment. Adjuster the braking power and check that require adjustment except brake lever position. The brake fluid MAINTENANCE AND ADJUSTMENT 73 Brakes Disc and disc pad wear is automatically...
Owners Manual
Page 82
... front wheel off the ground using a jack • Raise (special tool). Brake Hose Holder B. Use care when removing the top plugs. the upper fork clamp bolts. • Loosen Remove the front fork top plugs. • WARNING The top plugs are under extreme spring pressure. Front Fork Protector the number plate. • Remove the handlebar clamp bolts and the han• Remove dlebar. Bolt(s) C. 80 MAINTENANCE...
... front wheel off the ground using a jack • Raise (special tool). Brake Hose Holder B. Use care when removing the top plugs. the upper fork clamp bolts. • Loosen Remove the front fork top plugs. • WARNING The top plugs are under extreme spring pressure. Front Fork Protector the number plate. • Remove the handlebar clamp bolts and the han• Remove dlebar. Bolt(s) C. 80 MAINTENANCE...
Owners Manual
Page 97
An insufficiently tightened nut or bolt may become damaged or fall out. Part Name Cylinder Drain Plug Cylinder Head Nuts Cylinder Nuts Transmission Oil Drain Plug Kick Pedal Pivot Bolt Shift Pedal Bolt Spark Plug Water Pump Cover Drain Plug Air Bleeder Bolt Cooling Hose Clamp Screws Carburetor Mounting Clamp Screws Clutch Spring Bolts Brake Caliper Bolts Brake Disc Screws Engine Mounting Bolts (Bracket Bolts) Front Axle Front Fork Clamp Bolts Front Axle Clamp Bolts Upper Lower N·m 4.9 25 25 20 9 9 25.5 4.9 1.0 1.5 1.5 9.3 25 10 29 79 20 20...
An insufficiently tightened nut or bolt may become damaged or fall out. Part Name Cylinder Drain Plug Cylinder Head Nuts Cylinder Nuts Transmission Oil Drain Plug Kick Pedal Pivot Bolt Shift Pedal Bolt Spark Plug Water Pump Cover Drain Plug Air Bleeder Bolt Cooling Hose Clamp Screws Carburetor Mounting Clamp Screws Clutch Spring Bolts Brake Caliper Bolts Brake Disc Screws Engine Mounting Bolts (Bracket Bolts) Front Axle Front Fork Clamp Bolts Front Axle Clamp Bolts Upper Lower N·m 4.9 25 25 20 9 9 25.5 4.9 1.0 1.5 1.5 9.3 25 10 29 79 20 20...
Owners Manual
Page 99
Avoid using pressure washers; j Washing Your Motorcycle your bike with cold water from a garden • Rinse hose to remove any residue (residue from the detergent can easily be scratched. NOTE żAfter riding in delicate areas such as 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...
Avoid using pressure washers; j Washing Your Motorcycle your bike with cold water from a garden • Rinse hose to remove any residue (residue from the detergent can easily be scratched. NOTE żAfter riding in delicate areas such as 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...
Owners Manual
Page 104
... seized Transmission gear or bearing seized Kick shaft return spring broken Kick ratchet gear not engaging Fuel does not flow fuel in troubleshooting for each problem listed. 102 TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE NOTE żThis troubleshooting guide is not exhaustive and starting technique (when the engine is meant simply as a quick guide to reach the engine.) Spark missing or weak Spark plug dirty, broken, or gap improperly adjusted Spark plug cap or high-tension wiring defective Spark plug cap not...
... seized Transmission gear or bearing seized Kick shaft return spring broken Kick ratchet gear not engaging Fuel does not flow fuel in troubleshooting for each problem listed. 102 TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE NOTE żThis troubleshooting guide is not exhaustive and starting technique (when the engine is meant simply as a quick guide to reach the engine.) Spark missing or weak Spark plug dirty, broken, or gap improperly adjusted Spark plug cap or high-tension wiring defective Spark plug cap not...
Owners Manual
Page 105
... deposits) exhaust valves assembled incorrectly • KIPS Exhaust advancer spring damaged • Exhaust valve operating rod seized • KIPS rod seized in cylinder • Other defective • Igniter Transmission oil viscosity too high • Brake dragging • Poor low-speed performance Spark weak Spark plug dirty, broken, 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 mixture...
... deposits) exhaust valves assembled incorrectly • KIPS Exhaust advancer spring damaged • Exhaust valve operating rod seized • KIPS rod seized in cylinder • Other defective • Igniter Transmission oil viscosity too high • Brake dragging • Poor low-speed performance Spark weak Spark plug dirty, broken, 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 mixture...
Owners Manual
Page 106
... • Cylinder gasket damaged • Reed valve damaged • Improper acceleration plunger stuck open • Starter Carburetor fuel level too high or too low • jet clogged • Main Throttle valve does not fully open • 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...
... • Cylinder gasket damaged • Reed valve damaged • Improper acceleration plunger stuck open • Starter Carburetor fuel level too high or too low • jet clogged • Main Throttle valve does not fully open • 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...
Owners Manual
Page 107
TROUBLESHOOTING GUIDE 105 Engine overheating Firing incorrect Spark plug dirty, broken, or gap improperly adjusted Spark plug type incorrect Igniter defective • Water pump not rotating Clutch operation faulty Clutch slipping No clutch lever play Clutch cable improperly adjusted Clutch cable defective Clutch plate worn or warped Clutch spring broken or weak Clutch release mechanism defective Clutch hub or housing unevenly worn • • • Fuel-air mixture incorrect jet clogged or wrong size • Main fuel level...
TROUBLESHOOTING GUIDE 105 Engine overheating Firing incorrect Spark plug dirty, broken, or gap improperly adjusted Spark plug type incorrect Igniter defective • Water pump not rotating Clutch operation faulty Clutch slipping No clutch lever play Clutch cable improperly adjusted Clutch cable defective Clutch plate worn or warped Clutch spring broken or weak Clutch release mechanism defective Clutch hub or housing unevenly worn • • • Fuel-air mixture incorrect jet clogged or wrong size • Main fuel level...
Owners Manual
Page 108
...; Exhaust pipe leaking at cylinder head • Crankshaft runout excessive • Engine mounts loose • Crankshaft bearing worn • Primary gear worn or chipped • j Abnormal drive train noise Clutch noise Clutch housing/friction plate clearance excessive Clutch housing gear/primary gear backlash excessive Metal chip jammed in clutch housing gear teeth Engine noise abnormal Knocking Igniter defective Carbon built up in combustion chamber Fuel quality poor or type incorrect Spark plug type incorrect Engine overheating...
...; Exhaust pipe leaking at cylinder head • Crankshaft runout excessive • Engine mounts loose • Crankshaft bearing worn • Primary gear worn or chipped • j Abnormal drive train noise Clutch noise Clutch housing/friction plate clearance excessive Clutch housing gear/primary gear backlash excessive Metal chip jammed in clutch housing gear teeth Engine noise abnormal Knocking Igniter defective Carbon built up in combustion chamber Fuel quality poor or type incorrect Spark plug type incorrect Engine overheating...
Owners Manual
Page 109
... to turn Control cable incorrectly routed Wiring incorrect routed Steering stem locknut too tight Roller bearing damaged Steering bearing race dented or worn Steering stem inadequately lubricated Steering stem bent Tire air pressure too low • • Rear shock absorber noise • Shock absorber damaged Disc brake noise installed incorrectly • Pad Pad surface glazed • Brake disc warped • Brake caliper • Brake master defective cylinder damaged • Other noise nut, bolt, etc. TROUBLESHOOTING GUIDE 107 Frame noise...
... to turn Control cable incorrectly routed Wiring incorrect routed Steering stem locknut too tight Roller bearing damaged Steering bearing race dented or worn Steering stem inadequately lubricated Steering stem bent Tire air pressure too low • • Rear shock absorber noise • Shock absorber damaged Disc brake noise installed incorrectly • Pad Pad surface glazed • Brake disc warped • Brake caliper • Brake master defective cylinder damaged • Other noise nut, bolt, etc. TROUBLESHOOTING GUIDE 107 Frame noise...
Owners Manual
Page 125
... therefore reduce performance. The engine also works very hard when riding in muddy conditions and the radiator can add significantly to apply slightly leaner jetting (main jet). The engine works hardest in deep sand. j • The mud can become clogged with mud or sand, which reduces chain slack. ENGINE AND SUSPENSION TUNING 123 Special Care According to Track Conditions dry, dusty conditions (such a volcanic...
... therefore reduce performance. The engine also works very hard when riding in muddy conditions and the radiator can add significantly to apply slightly leaner jetting (main jet). The engine works hardest in deep sand. j • The mud can become clogged with mud or sand, which reduces chain slack. ENGINE AND SUSPENSION TUNING 123 Special Care According to Track Conditions dry, dusty conditions (such a volcanic...
Owners Manual
Page 128
... Fuel tank installation All 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 Front and rear wheel spoke tightness Front and rear tire air pressure Drive chain...
... Fuel tank installation All 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 Front and rear wheel spoke tightness Front and rear tire air pressure Drive chain...