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 16 19 20 21 22 22 23 25 27 28 28 32 34 40 41 43 47 48 49 54 65 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 16 19 20 21 22 22 23 25 27 28 28 32 34 40 41 43 47 48 49 54 65 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 18
... j Fuel The Kawasaki KX is equipped with a pilot light. Fuel Requirements: Fuel Type Use clean, fresh unleaded gasoline with a minimum Antiknock index of flame or sparks; The breather hose has the check valve. Fuel Tank Cap B. Fuel Tank Capacity 5.5 liters (1.46 US gal) WARNING Gasoline is closed securely. Make sure the area is well-ventilated and free from any appliance with a 2-stroke engine that requires a gasoline-oil...
... j Fuel The Kawasaki KX is equipped with a pilot light. Fuel Requirements: Fuel Type Use clean, fresh unleaded gasoline with a minimum Antiknock index of flame or sparks; The breather hose has the check valve. Fuel Tank Cap B. Fuel Tank Capacity 5.5 liters (1.46 US gal) WARNING Gasoline is closed securely. Make sure the area is well-ventilated and free from any appliance with a 2-stroke engine that requires a gasoline-oil...
Owners Manual
Page 20
... warranty and service requirements and can help to lubricate the piston, cylinder, crankshaft, bearings, and connecting rod bearings. 18 GENERAL INFORMATION j NOTICE Never use gasoline with an octane rating lower than 5% methanol. Take time to spill gasoline or gasoline oxygenate blends during refueling. When not operating your Kawasaki for your Kawasaki. Gasoline containing methanol must be blended with "gasohol" in the fuel tank...
... warranty and service requirements and can help to lubricate the piston, cylinder, crankshaft, bearings, and connecting rod bearings. 18 GENERAL INFORMATION j NOTICE Never use gasoline with an octane rating lower than 5% methanol. Take time to spill gasoline or gasoline oxygenate blends during refueling. When not operating your Kawasaki for your Kawasaki. Gasoline containing methanol must be blended with "gasohol" in the fuel tank...
Owners Manual
Page 26
... radiator up . 2. Cylinder: Check and adjust as in step 4. 11. Before putting the motorcycle into operation, bleed the cooling system. 9. A scored piston skirt could lower engine performance or damage the cylinder wall. Using the proper riding skills and techniques and avoiding recklessly high 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...
... radiator up . 2. Cylinder: Check and adjust as in step 4. 11. Before putting the motorcycle into operation, bleed the cooling system. 9. A scored piston skirt could lower engine performance or damage the cylinder wall. Using the proper riding skills and techniques and avoiding recklessly high 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...
Owners Manual
Page 27
... day before operation. Do not run the engine in a well-ventilated area. Engine Transmission Oil ...Coolant ...Radiator Cap ...Spark Plug ...Cylinder Head Nut ...Cylinder Nut ...Clutch ...Carburetor ...Air Cleaner ... Always perform daily safety checks before you ride. No leakage Level correct No leakage Level correct (engine cold) Properly installed Correctly torqued Correctly torqued Correctly torqued Functions properly Properly tuned Clean Properly installed The time required is minimal, and habitual...
... day before operation. Do not run the engine in a well-ventilated area. Engine Transmission Oil ...Coolant ...Radiator Cap ...Spark Plug ...Cylinder Head Nut ...Cylinder Nut ...Clutch ...Carburetor ...Air Cleaner ... Always perform daily safety checks before you ride. No leakage Level correct No leakage Level correct (engine cold) Properly installed Correctly torqued Correctly torqued Correctly torqued Functions properly Properly tuned Clean Properly installed The time required is minimal, and habitual...
Owners Manual
Page 31
... 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 35
... products meets or exceeds warranty and service requirements and can help to extend the life of your local authorities for the engine. the oil filler cap. • Install the oil level after kicking the engine over 3 • Check or 4 times. Recommended Transmission Oil Type: Kawasaki Performance 4-Stroke Motorcycle Oil* Kawasaki Performance 4-Stroke Semi-Synthetic Oil* Kawasaki Performance 4-Stroke Full Synthetic Oil* or other 4-stroke oils with its new gasket and • Install...
... products meets or exceeds warranty and service requirements and can help to extend the life of your local authorities for the engine. the oil filler cap. • Install the oil level after kicking the engine over 3 • Check or 4 times. Recommended Transmission Oil Type: Kawasaki Performance 4-Stroke Motorcycle Oil* Kawasaki Performance 4-Stroke Semi-Synthetic Oil* Kawasaki Performance 4-Stroke Full Synthetic Oil* or other 4-stroke oils with its new gasket and • Install...
Owners Manual
Page 53
... rear. • Turn • Remove the clutch cover and gasket. Bolts B. If the clutch release shaft is removed, the oil seal must be replaced with the pickup coil screw and pickup coil removed. Clutch Pressure Plate NOTE żWhen A. it is hard to remove or install the clutch spring bolts for rotating the clutch, use the flywheel holder (57001-1313) on the magneto flywheel with a new one. the clutch spring bolts, clutch pressure...
... rear. • Turn • Remove the clutch cover and gasket. Bolts B. If the clutch release shaft is removed, the oil seal must be replaced with the pickup coil screw and pickup coil removed. Clutch Pressure Plate NOTE żWhen A. it is hard to remove or install the clutch spring bolts for rotating the clutch, use the flywheel holder (57001-1313) on the magneto flywheel with a new one. the clutch spring bolts, clutch pressure...
Owners Manual
Page 76
... turn the adjuster to overheat, damaging the brake assembly and possibly locking the rear wheel, resulting in the brake lines or the brake may be air in loss of control. A. Have the brake checked immediately by an authorized Kawasaki dealer. After adjustment, tighten the locknut securely. 74 MAINTENANCE AND ADJUSTMENT Brakes Disc and disc pad wear is automatically compensated for and has no • Test brake drag. WARNING Air...
... turn the adjuster to overheat, damaging the brake assembly and possibly locking the rear wheel, resulting in the brake lines or the brake may be air in loss of control. A. Have the brake checked immediately by an authorized Kawasaki dealer. After adjustment, tighten the locknut securely. 74 MAINTENANCE AND ADJUSTMENT Brakes Disc and disc pad wear is automatically compensated for and has no • Test brake drag. WARNING Air...
Owners Manual
Page 83
... brake hose holder. • Remove • Remove the front fork protectors. A. the upper fork clamp bolts. • Loosen • Remove the front fork top plugs. Front Fork Protector the number plate. • Remove the handlebar clamp bolts and the han• Remove dlebar. Fork Oil Level Adjustment the front wheel off the ground using a jack • Raise (special tool). Bolt(s) C. MAINTENANCE...
... brake hose holder. • Remove • Remove the front fork protectors. A. the upper fork clamp bolts. • Loosen • Remove the front fork top plugs. Front Fork Protector the number plate. • Remove the handlebar clamp bolts and the han• Remove dlebar. Fork Oil Level Adjustment the front wheel off the ground using a jack • Raise (special tool). Bolt(s) C. MAINTENANCE...
Owners Manual
Page 98
...MAINTENANCE AND ADJUSTMENT Torque Table Tighten all nuts and bolts to the rider. 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... wrench. An overtightened nut or bolt may become damaged, broken, or fall out, possibly resulting in ·lb) 21 ...
...MAINTENANCE AND ADJUSTMENT Torque Table Tighten all nuts and bolts to the rider. 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... wrench. An overtightened nut or bolt may become damaged, broken, or fall out, possibly resulting in ·lb) 21 ...
Owners Manual
Page 100
... the vehicle, inspect the engine, electrical component and exhaust areas frequently. a mild neutral detergent (designed for build-up . use a mild degreaser to remove any residue (residue • water can penetrate seals and electrical components and damage your motorcycle thoroughly with clean water to inspecting for motor• Mix cycles or automobiles) and water in air intakes, carburetors, brake components, electrical components, muffler outlets, and fuel tank openings...
... the vehicle, inspect the engine, electrical component and exhaust areas frequently. a mild neutral detergent (designed for build-up . use a mild degreaser to remove any residue (residue • water can penetrate seals and electrical components and damage your motorcycle thoroughly with clean water to inspecting for motor• Mix cycles or automobiles) and water in air intakes, carburetors, brake components, electrical components, muffler outlets, and fuel tank openings...
Owners Manual
Page 105
... 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. TROUBLESHOOTING GUIDE 103 TROUBLESHOOTING GUIDE NOTE żThis 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 cap air vent obstructed • Tank tap clogged • Fuel line clogged • Fuel...
... 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. TROUBLESHOOTING GUIDE 103 TROUBLESHOOTING GUIDE NOTE żThis 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 cap air vent obstructed • Tank tap clogged • Fuel line clogged • Fuel...
Owners Manual
Page 106
... deposits) exhaust valves assembled incorrectly • KIPS advancer spring damaged • Exhaust valve operating rod seized • Exhaust KIPS rod seized in cylinder • Other defective • Igniter oil viscosity too high • Transmission • 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 j Fuel-air mixture...
... deposits) exhaust valves assembled incorrectly • KIPS advancer spring damaged • Exhaust valve operating rod seized • Exhaust KIPS rod seized in cylinder • Other defective • Igniter oil viscosity too high • Transmission • 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 j Fuel-air mixture...
Owners Manual
Page 107
... • Throttle cleaner element clogged • Air clogged • Muffler contaminated with water or foreign matter • Fuel exhaust port clogged • Cylinder dragging • Brake slipping • Clutch overheating • Engine oil level too high • Transmission Transmission oil viscosity too high • Crankshaft bearing worn or damaged • KIPS ports stuck closed exhaust valves stuck closed (valve seized or • KIPS contaminated with carbon deposits) exhaust valves assembled incorrectly •...
... • Throttle cleaner element clogged • Air clogged • Muffler contaminated with water or foreign matter • Fuel exhaust port clogged • Cylinder dragging • Brake slipping • Clutch overheating • Engine oil level too high • Transmission Transmission oil viscosity too high • Crankshaft bearing worn or damaged • KIPS ports stuck closed exhaust valves stuck closed (valve seized or • KIPS contaminated with carbon deposits) exhaust valves assembled incorrectly •...
Owners Manual
Page 108
...; Clutch • Clutch release mechanism defective Gear shifting faulty Transmission does not go into gear; 106 TROUBLESHOOTING GUIDE 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 j • • • Fuel-air...
...; Clutch • Clutch release mechanism defective Gear shifting faulty Transmission does not go into gear; 106 TROUBLESHOOTING GUIDE 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 j • • • Fuel-air...
Owners Manual
Page 109
...; Cylinder pipe leaking at cylinder head • Exhaust runout excessive • Crankshaft mounts loose • Engine bearing worn • Crankshaft • 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...
...; Cylinder pipe leaking at cylinder head • Exhaust runout excessive • Crankshaft mounts loose • Engine bearing worn • Crankshaft • 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 110
... 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 j • • Rear shock absorber noise • Shock absorber damaged Disc brake noise installed incorrectly • Pad surface glazed • Pad disc warped • Brake Brake caliper • Brake master defective cylinder damaged • Other noise nut, bolt, etc. 108 TROUBLESHOOTING GUIDE 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 j • • Rear shock absorber noise • Shock absorber damaged Disc brake noise installed incorrectly • Pad surface glazed • Pad disc warped • Brake Brake caliper • Brake master defective cylinder damaged • Other noise nut, bolt, etc. 108 TROUBLESHOOTING GUIDE Frame noise...
Owners Manual
Page 129
... 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...
Owners Manual
Page 131
... and drain the transmission oil. Dispose of used oil properly. the spark plug and spray fogging oil, • Remove such as follows. Install the spark plug. Lift the motorcycle on the brakes. the oil drain plug and fill in fresh transmis• Install sion oil. Clean the entire vehicle thoroughly. Make sure the area is well-ventilated and free from entering. • • WARNING Engine oil is a toxic...
... and drain the transmission oil. Dispose of used oil properly. the spark plug and spray fogging oil, • Remove such as follows. Install the spark plug. Lift the motorcycle on the brakes. the oil drain plug and fill in fresh transmis• Install sion oil. Clean the entire vehicle thoroughly. Make sure the area is well-ventilated and free from entering. • • WARNING Engine oil is a toxic...