Owners Manual
Page 8
...conditions safely allow your child to ride on public roads or paved surfaces. 4. Tell someone where you and your speed. As with any moving vehicle there are not familiar with motorcycle controls and maintenance...suitable protective gear and riding apparel. It is on the good mechanical condition of checking all instructions and warnings with your child with your child to follow the maintenance and adjustment... you are possible safety risks; Never allow your child before riding the motorcycle. Always obey local off -road motorcycle. Be sure to carry a passenger. Do not allow...
...conditions safely allow your child to ride on public roads or paved surfaces. 4. Tell someone where you and your speed. As with any moving vehicle there are not familiar with motorcycle controls and maintenance...suitable protective gear and riding apparel. It is on the good mechanical condition of checking all instructions and warnings with your child with your child to follow the maintenance and adjustment... you are possible safety risks; Never allow your child before riding the motorcycle. Always obey local off -road motorcycle. Be sure to carry a passenger. Do not allow...
Owners Manual
Page 9
......Periodic Maintenance Chart ...Transmission Oil...Cooling System ...Spark Plug ...Ignition Timing ...Air Cleaner ...Throttle Cable...Carburetor ...Clutch ...Piston ...9 15 15 19 22 23 24 27 27 29 30 31 32 34 36 37 37 41 43 48 50 53 58 60 65 72 Exhaust System ...Drive Chain...Handlebar...Brakes ...Steering ...Front Suspension ...Rear Suspension (UNI-TRAK®)...Wheels ...Hoses Inspection ...Tightening Torques of Nuts and Bolts...Cleaning Your Motorcycle...Lubrication...TROUBLESHOOTING GUIDE...TUNING ...Carburetor ...Suspension...Gearing...
......Periodic Maintenance Chart ...Transmission Oil...Cooling System ...Spark Plug ...Ignition Timing ...Air Cleaner ...Throttle Cable...Carburetor ...Clutch ...Piston ...9 15 15 19 22 23 24 27 27 29 30 31 32 34 36 37 37 41 43 48 50 53 58 60 65 72 Exhaust System ...Drive Chain...Handlebar...Brakes ...Steering ...Front Suspension ...Rear Suspension (UNI-TRAK®)...Wheels ...Hoses Inspection ...Tightening Torques of Nuts and Bolts...Cleaning Your Motorcycle...Lubrication...TROUBLESHOOTING GUIDE...TUNING ...Carburetor ...Suspension...Gearing...
Owners Manual
Page 33
... the chain slack and spoke tightness and carry out a general inspection. If so, replace the standard spark plug with a hotter spark plug for performance and reliability. 4. 5. 6. Stop and let the engine cool completely. Stop and let the engine cool completely. 3. Install the removed parts. NOTICE For the first hour or 20 km (12 mile) of operation, run the engine at moderate speed - Start the engine and let it idle...
... the chain slack and spoke tightness and carry out a general inspection. If so, replace the standard spark plug with a hotter spark plug for performance and reliability. 4. 5. 6. Stop and let the engine cool completely. Stop and let the engine cool completely. 3. Install the removed parts. NOTICE For the first hour or 20 km (12 mile) of operation, run the engine at moderate speed - Start the engine and let it idle...
Owners Manual
Page 35
... to return the motorcycle to a safe operating condition. DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Engine Transmission Oil ...No leakage Level correct Coolant ...No leakage Level correct (engine cold) Radiator Cap ...Properly installed Spark Plug ...Correctly torqued Cylinder Head Nut ...Correctly torqued Cylinder Nut ...Correctly torqued Clutch ...Functions properly Carburetor ...Properly tuned Air Cleaner ...Clean Apply oil to perform these checks before operation may result in serious...
... to return the motorcycle to a safe operating condition. DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Engine Transmission Oil ...No leakage Level correct Coolant ...No leakage Level correct (engine cold) Radiator Cap ...Properly installed Spark Plug ...Correctly torqued Cylinder Head Nut ...Correctly torqued Cylinder Nut ...Correctly torqued Clutch ...Functions properly Carburetor ...Properly tuned Air Cleaner ...Clean Apply oil to perform these checks before operation may result in serious...
Owners Manual
Page 36
... damage 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 fluid 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 oil leakage Rear Shock Absorber ...Functions properly No oil leakage Fuel Tank ...Mounted...
... damage 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 fluid 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 oil leakage Rear Shock Absorber ...Functions properly No oil leakage Fuel Tank ...Mounted...
Owners Manual
Page 39
j OPERATION Cylinder head and cylinder - change Connecting rod small end bearing check † Kick and shift pedals - check † K Reed valve - check † • • • 88 96 R 44 43 - check † Radiator hoses, connections - clean/check Silencer - clean Expansion chamber O-rings replace Engine sprocket - 38 MAINTENANCE AND ADJUSTMENT Every 3 FREQUENCY After each race (or 2.5 races (or 7.5 hours) hours) Every 5 Every 10...
j OPERATION Cylinder head and cylinder - change Connecting rod small end bearing check † Kick and shift pedals - check † K Reed valve - check † • • • 88 96 R 44 43 - check † Radiator hoses, connections - clean/check Silencer - clean Expansion chamber O-rings replace Engine sprocket - 38 MAINTENANCE AND ADJUSTMENT Every 3 FREQUENCY After each race (or 2.5 races (or 7.5 hours) hours) Every 5 Every 10...
Owners Manual
Page 43
... authorities for your Kawasaki. Transmission Oil Drain Bolt and Gasket WARNING Transmission oil is a toxic substance. Tightening Torque Transmission Oil Drain Bolt: 20 N·m (2.0 kgf·m, 15 ft·lb) in the specified amount of used oil properly. the transmission oil drain bolt with API SG, SH, SJ, SL, SM and JASO MA, MA1, MA2 rating Viscosity: SAE 10W-40 * Kawasaki Performance Oils and Lubricants have been specifically engineered for approved...
... authorities for your Kawasaki. Transmission Oil Drain Bolt and Gasket WARNING Transmission oil is a toxic substance. Tightening Torque Transmission Oil Drain Bolt: 20 N·m (2.0 kgf·m, 15 ft·lb) in the specified amount of used oil properly. the transmission oil drain bolt with API SG, SH, SJ, SL, SM and JASO MA, MA1, MA2 rating Viscosity: SAE 10W-40 * Kawasaki Performance Oils and Lubricants have been specifically engineered for approved...
Owners Manual
Page 103
... no • Test brake drag. WARNING Air in the brake lines diminish braking performance and can cause an accident resulting in the brake lines or the brake may be changed when contaminated with brake fluid DOT4 in accordance with the Periodic Maintenance Chart. C. The brake fluid should also be defective. the braking power and check that has been unsealed for fluid leakage around the brake system fittings. If...
... no • Test brake drag. WARNING Air in the brake lines diminish braking performance and can cause an accident resulting in the brake lines or the brake may be changed when contaminated with brake fluid DOT4 in accordance with the Periodic Maintenance Chart. C. The brake fluid should also be defective. the braking power and check that has been unsealed for fluid leakage around the brake system fittings. If...
Owners Manual
Page 120
... seat down and up by an authorized Kawasaki • If dealer. *: Between the top end of the outer tube and upper surface of a rear shock absorber unit, a swingarm, two lever rods and a lever. necessary, replace by 4 or 5 times, and • Pump inspect the smooth stroke. However, a linkage system is found, inspect • If the oil leak and rear shock absorber mounting. MAINTENANCE AND...
... seat down and up by an authorized Kawasaki • If dealer. *: Between the top end of the outer tube and upper surface of a rear shock absorber unit, a swingarm, two lever rods and a lever. necessary, replace by 4 or 5 times, and • Pump inspect the smooth stroke. However, a linkage system is found, inspect • If the oil leak and rear shock absorber mounting. MAINTENANCE AND...
Owners Manual
Page 132
... Brake Pad Pins 3. Rear Shock Absorber Mounting Bolts 6. Brake Lever Pivot Bolt Locknut 11. Brake Pedal Bolt 19. Coolant Drain Bolt (Water Pump) 24. Water Hose Clamp Screws 26. Compression Valve Assembly (Both Sides) 28. Front Axle Nut Front Master Cylinder Clamp Bolts 10. Steering Stem Head Nut 14. Tie-Rod Mounting Nuts 18. Transmission Oil Drain Bolt 23. Rear Brake Disc Mounting Bolts 17. Rear Master Cylinder Mounting Bolts 4. Rocker Arm Bracket Bolts 21. Front Brake Reservoir Cap Screws 13. Rear Axle Nut 16. Coolant Drain Bolt (Cylinder) 25. MAINTENANCE...
... Brake Pad Pins 3. Rear Shock Absorber Mounting Bolts 6. Brake Lever Pivot Bolt Locknut 11. Brake Pedal Bolt 19. Coolant Drain Bolt (Water Pump) 24. Water Hose Clamp Screws 26. Compression Valve Assembly (Both Sides) 28. Front Axle Nut Front Master Cylinder Clamp Bolts 10. Steering Stem Head Nut 14. Tie-Rod Mounting Nuts 18. Transmission Oil Drain Bolt 23. Rear Brake Disc Mounting Bolts 17. Rear Master Cylinder Mounting Bolts 4. Rocker Arm Bracket Bolts 21. Front Brake Reservoir Cap Screws 13. Rear Axle Nut 16. Coolant Drain Bolt (Cylinder) 25. MAINTENANCE...
Owners Manual
Page 134
... Rod Nut (Both Sides) Handlebar Holder Nuts Stator Coil Plate Mounting Screws Rear Sprocket Nuts Rear Caliper Mounting Bolts Rear Brake Pad Pins Rear Master Cylinder Mounting Bolts Rear Frame Pipe Nuts Rear Shock Absorber Mounting Bolts Clutch Cover Bolts Clutch Spring Bolts Air Bleeder Bolt Front Master Cylinder Clamp Bolts Brake Lever Pivot Bolt Locknut Brake Lever Pivot Bolt Front Brake Reservoir Cap Screws Steering Stem Head Nut Steering Stem Nut Rear Axle Nut Rear Brake Disc Mounting Bolts Tie-Rod Mounting Nuts Brake Pedal Bolt N·m 15 34 5.2 34 25 17.2 9.8 34 39...
... Rod Nut (Both Sides) Handlebar Holder Nuts Stator Coil Plate Mounting Screws Rear Sprocket Nuts Rear Caliper Mounting Bolts Rear Brake Pad Pins Rear Master Cylinder Mounting Bolts Rear Frame Pipe Nuts Rear Shock Absorber Mounting Bolts Clutch Cover Bolts Clutch Spring Bolts Air Bleeder Bolt Front Master Cylinder Clamp Bolts Brake Lever Pivot Bolt Locknut Brake Lever Pivot Bolt Front Brake Reservoir Cap Screws Steering Stem Head Nut Steering Stem Nut Rear Axle Nut Rear Brake Disc Mounting Bolts Tie-Rod Mounting Nuts Brake Pedal Bolt N·m 15 34 5.2 34 25 17.2 9.8 34 39...
Owners Manual
Page 136
.... a mild neutral detergent (designed for build-up . When operating the vehicle in a bucket. After washing, rinse your motorcycle with clean water to collect in and around the vehicle, inspect the engine, electrical component and exhaust areas frequently. Gasoline, brake fluid, and coolant will help protect its surfaces. Do not park or store the vehicle in air intakes, carburetor, brake components, electrical components, muffler outlets, and fuel tank openings. If...
.... a mild neutral detergent (designed for build-up . When operating the vehicle in a bucket. After washing, rinse your motorcycle with clean water to collect in and around the vehicle, inspect the engine, electrical component and exhaust areas frequently. Gasoline, brake fluid, and coolant will help protect its surfaces. Do not park or store the vehicle in air intakes, carburetor, brake components, electrical components, muffler outlets, and fuel tank openings. If...
Owners Manual
Page 142
... return spring broken • Kick ratchet gear not engaging • Fuel does not flow: fuel in troubleshooting for each problem listed. TROUBLESHOOTING GUIDE 141 TROUBLESHOOTING GUIDE ○This troubleshooting guide is • Wrong flooded, kick with the throttle fully open to allow more common difficulties. It is meant simply as a quick guide to assist you in tank • No tap turned off • Fuel cap air vent obstructed • Tank Fuel...
... return spring broken • Kick ratchet gear not engaging • Fuel does not flow: fuel in troubleshooting for each problem listed. TROUBLESHOOTING GUIDE 141 TROUBLESHOOTING GUIDE ○This troubleshooting guide is • Wrong flooded, kick with the throttle fully open to allow more common difficulties. It is meant simply as a quick guide to assist you in tank • No tap turned off • Fuel cap air vent obstructed • Tank Fuel...
Owners Manual
Page 143
j Fuel/air mixture incorrect: jet clogged or wrong size • Main Jet needle or needle jet worn • 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 142 TROUBLESHOOTING GUIDE head warped • Cylinder base gasket damaged • Cylinder • Reed valve damaged Poor low-speed performance plug dirty, broken...
j Fuel/air mixture incorrect: jet clogged or wrong size • Main Jet needle or needle jet worn • 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 142 TROUBLESHOOTING GUIDE head warped • Cylinder base gasket damaged • Cylinder • Reed valve damaged Poor low-speed performance plug dirty, broken...
Owners Manual
Page 144
... open • Starter Carburetor fuel level too high or too low • Main jet clogged • Throttle valve does not fully open • Air cleaner element clogged • Muffler clogged • Fuel contaminated with water or foreign matter • exhaust port clogged • Cylinder dragging • Brake slipping • Clutch Engine overheating • Transmission oil level too high • Transmission oil viscosity too high • Crankshaft bearing worn or...
... open • Starter Carburetor fuel level too high or too low • Main jet clogged • Throttle valve does not fully open • Air cleaner element clogged • Muffler clogged • Fuel contaminated with water or foreign matter • exhaust port clogged • Cylinder dragging • Brake slipping • Clutch Engine overheating • Transmission oil level too high • Transmission oil viscosity too high • Crankshaft bearing worn or...
Owners Manual
Page 145
...: Clutch not disengaging Shift fork bent or seized Gear stuck on drive shaft • Clutch release mechanism defective • Gear shifting faulty Transmission does not go into gear; 144 TROUBLESHOOTING GUIDE cleaner element clogged, poorly sealed, or not • Air installed • Air intake duct poorly sealed Compression high: • Carbon built up in combustion chamber Engine overloaded: dragging • Brake Clutch slipping • Transmission oil level too high • Transmission oil...
...: Clutch not disengaging Shift fork bent or seized Gear stuck on drive shaft • Clutch release mechanism defective • Gear shifting faulty Transmission does not go into gear; 144 TROUBLESHOOTING GUIDE cleaner element clogged, poorly sealed, or not • Air installed • Air intake duct poorly sealed Compression high: • Carbon built up in combustion chamber Engine overloaded: dragging • Brake Clutch slipping • Transmission oil level too high • Transmission oil...
Owners Manual
Page 146
j • • Rear shock absorber noise: • Shock absorber damaged Front fork noise: Oil level or viscosity too low Spring weak or broken TROUBLESHOOTING GUIDE 145 fork pin worn • Shift • 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 Carbon built up in combustion chamber • Fuel quality poor...
j • • Rear shock absorber noise: • Shock absorber damaged Front fork noise: Oil level or viscosity too low Spring weak or broken TROUBLESHOOTING GUIDE 145 fork pin worn • Shift • 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 Carbon built up in combustion chamber • Fuel quality poor...
Owners Manual
Page 147
146 TROUBLESHOOTING GUIDE Disc brake noise: Pad installed incorrectly Pad surface glazed Brake disc warped Brake caliper defective Brake master cylinder damaged j Other noise: nut, bolt, etc. • Bracket, tightened Exhaust smoke Excessively white: improperly mounted or • Throttle cable improperly adjusted Brownish: cleaner element clogged • Air Main jet too large or fallen out • Starter plunger stuck open • Carburetor fuel level too high • Poor handling and...
146 TROUBLESHOOTING GUIDE Disc brake noise: Pad installed incorrectly Pad surface glazed Brake disc warped Brake caliper defective Brake master cylinder damaged j Other noise: nut, bolt, etc. • Bracket, tightened Exhaust smoke Excessively white: improperly mounted or • Throttle cable improperly adjusted Brownish: cleaner element clogged • Air Main jet too large or fallen out • Starter plunger stuck open • Carburetor fuel level too high • Poor handling and...
Owners Manual
Page 166
... mounting nut torque Engine sprocket installation Shift pedal bolt torque Transmission oil level Carburetor clamp screw torque Carburetor top cap torque Tie-rod mounting nut torque Rocker arm pivot nut torque Rocker arm bracket bolt torque Rear shock absorber mounting bolt torque Swingarm pivot shaft nut torque Rear axle nut torque Rear sprocket nut torque Rear brake pedal operation Seat installation Front and rear wheel spoke nipple torque and rear tire air pressure • Front Front air pressure • Drive...
... mounting nut torque Engine sprocket installation Shift pedal bolt torque Transmission oil level Carburetor clamp screw torque Carburetor top cap torque Tie-rod mounting nut torque Rocker arm pivot nut torque Rocker arm bracket bolt torque Rear shock absorber mounting bolt torque Swingarm pivot shaft nut torque Rear axle nut torque Rear sprocket nut torque Rear brake pedal operation Seat installation Front and rear wheel spoke nipple torque and rear tire air pressure • Front Front air pressure • Drive...
Owners Manual
Page 168
... running the engine at idle speed until the engine stalls (If left in fresh transmission oil. Empty the fuel system by the pump or siphon. Install the spark plug. Lift the motorcycle on a box or stand so that both wheels are raised off the engine before working. STORAGE 167 STORAGE Before Storage When the motorcycle is to prevent moisture from entering. Kick the engine over the muffler...
... running the engine at idle speed until the engine stalls (If left in fresh transmission oil. Empty the fuel system by the pump or siphon. Install the spark plug. Lift the motorcycle on a box or stand so that both wheels are raised off the engine before working. STORAGE 167 STORAGE Before Storage When the motorcycle is to prevent moisture from entering. Kick the engine over the muffler...