Kawasaki Kx85 2015 Manual
. GENERAL INFORMATION Quick Reference Guide MAINTENANCE AND ADJUSTMENT This Quick Reference Guide will assist you in finding the information you’re looking for. TROUBLESHOOTING GUIDE TUNING STORAGE A Table of Contents is included after the Foreword. IMPORTANT INFORMATION. This vehicle is designed for the operator only, no passengers. This vehicle is a competition model only and was not manufactured for use on public streets, roads or highways. The use of this vehicle should be limited to participation in sanctioned competition events upon a closed course.
Whenever you see the symbols shown below, IMPORTANT NOTICE heed their instructions! Always follow safe operat- THIS VEHICLE IS A COMPETITION MODEL ing and maintenance practices. ONLY MANUFACTURED FOR, NOR SHOULD IT BE USED ON, PUB- DANGER LIC STREETS, ROADS, OR HIGHWAYS. THE DANGER indicates a hazardous situation USE OF THIS VEHICLE SHOULD BE LIMITED which, if not avoided, will result in death.
Motorcycle Noise Emission Control Information This motorcycle is designed for closed course competition use only. It does not conform to U.S. EPA motorcycle noise standards. NOTICE Off-road motorcycling is a wonderful sport, and we hope you will enjoy it to the fullest. How- ever, if improperly conducted, this sport has the potential to cause environmental problems as well as conflicts with other people.
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WARNING The engine exhaust from this product con- tains chemicals known to the State of Cali- fornia to cause cancer, birth defects or other reproductive harm. Congratulations on your choosing this Kawasaki motorcycle. Your new motorcycle is the product of Kawasaki’s advanced engineering, exhaustive testing, and continuous striving for a superior lightweight, high-performance machine with superb handling and stability for racing and sporting use. Your new KX is a highly tuned competition machine for participation in racing events. As with any mechan- ical device, proper care and maintenance are important for trouble-free operation and top performance. IMPORTANT NOTE TO PARENTS ABOUT SAFE RIDING This is a high performance off-road motorcycle designed for experienced young riders. It is not suitable for beginners.
Your youngster’s safety will depend on your commitment to always provide a safe riding environment and a properly maintained vehicle. As with any moving vehicle there are possible safety risks. TABLE OF CONTENTS SPECIFICATIONS.Exhaust System.GENERAL INFORMATION.Drive Chain. Location of Labels. Handlebar.Location of Parts.
Brakes.101 Side Stand. Steering.106 Fuel. Front Suspension. 109 ® Fuel Requirement.Rear Suspension (UNI-TRAK ).
SPECIFICATIONS SPECIFICATIONS DIMENSIONS Overall Length: KX85C 1 830 mm (72.05 in.) KX100F 1 920 mm (75.60 in.) Overall Width 765 mm (30.12 in.) Overall Height: KX85C 1 100 mm (43.31 in.) KX100F 1 150 mm (45.28 in.) Wheelbase: KX85C 1 265 mm (49.80 in.) KX100F 1 310 mm (51.57 in.) Road Clearance. SPECIFICATIONS ENGINE Type 2-stroke, single-cylinder, piston reed valve, liquid-cooled Bore × Stroke: KX85C 48.5 × 45.8 mm (1.91 × 1.80 in.) KX100F 52.5 × 45.8 mm (2.07 × 1.80 in.) Displacement: KX85C 84 cm³ (5.1 cu in.) KX100F 99 cm³ (6.04 cu in.) Compression Ratio: Low Speed: KX85C. SPECIFICATIONS Close: KX85C 63.8° ABDC KX100F 62.8° ABDC Exhaust: Open: KX85C (Low speed) 79° BBDC, (High speed) 93.6° BBDC KX100F (Low speed) 81.7° BBDC, (High speed) 93.6° BBDC Close: KX85C (Low speed) 79° ABDC, (High speed) 93.6° ABDC KX100F (Low speed) 81.7° ABDC, (High speed) 93.6° ABDC Fuel System Carburetor, KEIHIN PWK28 Starting System. SPECIFICATIONS Gear Ratio: 2.538 (33/13) 1.875 (30/16) 1.500 (27/18) 1.250 (25/20) 1.090 (24/22) 0.956 (22/23) Primary Reduction Ratio 3.400 (68/20) Final Reduction Ratio: KX85C 3.571 (50/14) KX100F 3.923 (51/13) Overall Drive Ratio: KX85C 11.607 (Top gear) KX100F 12.758 (Top gear) Transmission Oil: Grade API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2. SPECIFICATIONS Trail: KX85C 97 mm (3.82 in.) KX100F 108 mm (4.25 in.) Tire Size/Type: Front: KX85C 70/100-17 40M/DUNLOP MX51F KX100F 70/100-19 42M/DUNLOP MX51F Rear: KX85C 90/100-14 49M/DUNLOP MX51 KX100F 90/100-16 52M/DUNLOP MX51 Rim Size: Front: KX85C 17 × 1.40 KX100F 19 ×. SPECIFICATIONS Front Fork Oil: Type Kawasaki Fork Oil KHL15-10 295 ∼ 325 mL (9.97 ∼ 11.0 US oz.) Amount BRAKES Type: Front Single disc Rear Single disc Brake Fluid Grade: Front DOT3 or DOT4 Rear DOT4 Specifications are subject to change without notice.
If any label is missing, damaged, or worn, get a replacement from your Kawasaki dealer and install it in the correct po- sition. GENERAL INFORMATION 2. Radiator Cap Danger 3.
Rear Shock Absorber Warning 4. Gasoline-Engine Oil Mixing Ratio 5. Disclaimer of Warranty 6. Noise Emission Control Information 7. Important Information. GENERAL INFORMATION.
GENERAL INFORMATION. GENERAL INFORMATION Location of Parts 1. Clutch Lever 4. Engine Stop Button 2. Front Brake Fluid Reservoir 5.
Fuel Tank Cap 3. Front Brake Lever 6.
Throttle Grip. GENERAL INFORMATION 1.
Front Fork 9. Front Brake Caliper 2.
Expansion Chamber 3. Fuel Tank 11. Shift Pedal 4. Carburetor 12. Rear Shock Absorber 5.
Air Cleaner Element 14. Chain Guide 15.
Drive Chain 7. GENERAL INFORMATION 1. Rear Shock Absorber Gas Reservoir 6. Transmission Oil Level Inspection Window 2. Rear Brake Fluid Reservoir 7.
Rear Brake Pedal 3. Kick Pedal 4. Rear Brake Disc 9. Water Pump Cover 5. Rear Brake Caliper. GENERAL INFORMATION NOTE Side Stand ○ Support the motorcycle with a suitable stand to perform maintenance or adjustment procedures. Support the motorcycle with the provided side stand.
Install the upper end of the side stand into the hole at the rear of the left footpeg. Avoid filling the tank in the rain or where heavy dust Fuel is blowing so that the fuel does not get contaminated. The Kawasaki KX is equipped with a 2-stroke en- gine that requires a gasoline-oil mixture. Fuel Tank Capacity 5.0 L (1.3 US gal). GENERAL INFORMATION NOTICE WARNING Gasoline is extremely flammable and can be If engine “knocking” or “pinging” occurs, explosive under certain conditions, creating use a different brand of gasoline of a higher the potential for serious burns. Always stop octane rating. The engine and do not smoke.
Other oxygenates approved for use in unleaded blends during refueling. Gasoline include TAME (up to 16.7%) and ETBE When not operating your Kawasaki for 30 (up to 17.2%). Fuel containing these oxygenates to 60 days, mix a fuel stabilizer (such as can also be used in your Kawasaki.
Take time to ensure a well-blended mixture. ○.Kawasaki Performance Oils and Lubricants have The lubricative quality of the gasoline-oil mixture been specifically engineered for your vehicle. Con- deteriorates rapidly; therefore, prepare a fresh sistent use of these products meets or exceeds ser- mixture for each day of operation.
GENERAL INFORMATION Kick Pedal Starting the Engine. This motorcycle is equipped with a primary kick Turn the fuel tap lever to the “ON” position. Starting system.
When the clutch lever is pulled, the motorcycle can be started with the transmission in any gear. GENERAL INFORMATION NOTICE This motorcycle is designed for competition use only. Therefore, the radiator does not incorporate a coolant reserve tank or cool- ing fan. Prolonged idling of the engine with no airflow through the radiator can cause coolant loss and engine overheating result- ing in possible engine damage. GENERAL INFORMATION NOTE Shifting Gears ○ If the engine fails starting, open the throttle fully ∼ and depress the kick pedal slowly about 4 This motorcycle is equipped with a 6-speed “return times to clear too rich fuel mixtures in the engine. GENERAL INFORMATION Stopping the Motorcycle For maximum deceleration, close the throttle and apply both front and rear brakes. Pull in the clutch lever as the motorcycle comes to a stop.
Indepen- dent use of the front or rear brake may be advanta- geous in certain circumstances. GENERAL INFORMATION Stopping the Engine. Shift the transmission into the neutral position. After racing the engine slightly, close the throttle completely and push the engine stop button. OFF position A.
Engine Stop Button. Turn the fuel tap lever to the “OFF”. GENERAL INFORMATION Stop and let the engine cool completely.
Be Break-In sure to check and adjust the chain slack and spoke tightness and carry out a general inspec- A brief break-in procedure must be carried out to tion. Obtain the proper operating clearances in the engine Start the engine and ride the motorcycle for 20 and transmission, which are necessary for perfor- minutes at moderate speed - NEVER ACCEL. GENERAL INFORMATION Fill the radiator up to the bottom of the radiator operation. Using the proper riding skills and filler neck with coolant. Before putting the mo- techniques and avoiding recklessly high engine torcycle into operation, bleed the cooling sys- speeds will keep the engine trouble-free. GENERAL INFORMATION Daily Pre-Ride Checks Check the following items each day before you ride.
The time required is minimal, and habitual performance of these checks will help ensure a safe, reliable ride. If any irregularities are found during these checks, refer to the appropriate section and take the action required to return the motorcycle to a safe operating condition. GENERAL INFORMATION Properly installed Muffler.
No damage Properly installed Engine Sprocket.No wear or damage Frame Tires.Overall condition good No wear or 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. GENERAL INFORMATION Carry out the general lubrication (see page 137) After-Race Checks and make necessary adjustments.
After racing, first clean the motorcycle (see page 135), then inspect the entire motorcycle with special attention to the air cleaner, carburetor, brakes, etc. Periodic Maintenance Chart to keep the motorcycle in good running condition. †: Replace, add, adjust, clean or torque if necessary. R: Replace K: Should be serviced by referring to the Service Manual or an authorized Kawasaki dealer. Periodic Inspection (Engine Related Item) Every 3. MAINTENANCE AND ADJUSTMENT FREQUENCY After each Every 3 Every 5 Every 10 As re- race (or 2.5 races (or races (or races (or 25 quired Page OPERATION hours) 7.5 hours) 12.5 hours) hours). – Cylinder head and cylinder - inspect.
MAINTENANCE AND ADJUSTMENT 2. Periodic Inspection (Chassis Related Item) FREQUENCY After each Every 3 Every 5 Every 10 As re- race (or 2.5 races (or races (or races (or 25 quired Page OPERATION hours) 7.5 hours) 12.5 hours) hours). Brake adjustment - check †. MAINTENANCE AND ADJUSTMENT FREQUENCY After each Every 3 Every 5 Every 10 As re- race (or 2.5 races (or races (or races (or 25 quired Page OPERATION hours) 7.5 hours) 12.5 hours) hours) – Fuel hose - replace Every 5 years. MAINTENANCE AND ADJUSTMENT NOTE Transmission Oil ○ If the oil level is too high, remove the excess oil using a syringe or other suitable device. ○ In order for the transmission and clutch to function If the oil level is too low, add the correct amount of properly, maintain the transmission oil at the proper oil through the oil filler cap opening. Viscosity: WARNING SAE 10W-40 Transmission oil is a toxic substance.
Dis-. Kawasaki Performance Oils and Lubricants have pose of used oil properly. Contact your lo- been specifically engineered for your vehicle. Con- cal authorities for approved disposal meth- sistent use of these products meets or exceeds ser- ods or possible recycling. MAINTENANCE AND ADJUSTMENT NOTE Cooling System ○ Do not add any chemical additive to the oil. Oils fulfilling the above requirements are fully formu- lated and provide adequate lubrication for both the Water Hoses engine and the clutch. Check the water hoses for cracks or deterioration, and the connections for looseness in accordance Although 10W-40 engine oil is the recommended with the Periodic Maintenance Chart.
MAINTENANCE AND ADJUSTMENT WARNING in order to exhaust the air accumulated in the radiator. The cooling system can get extremely hot. Remove the radiator cap in two steps.
During normal operation and cause serious. First, turn the cap counterclockwise to the first stop burns. MAINTENANCE AND ADJUSTMENT Coolant Total Amount 0.57 L (0.60 US qt). Install the radiator cap in two steps. First, turn the cap clockwise to the first stop. Then, push down and turn the cap further in the same direction.
MAINTENANCE AND ADJUSTMENT NOTICE Immediately wash away any coolant that spills on the frame, engine, or wheel. WARNING Coolant on tires will make them slippery and can cause loss of traction resulting in an accident and injury.
Thoroughly clean any coolant that might have splashed on the tires. MAINTENANCE AND ADJUSTMENT. Tightening Torque Tighten the air bleeder bolt to the specified torque. Coolant Drain Bolt (Water Pump): Tightening Torque 5.2 Nm (0.53 kgfm, 46 inlb) Air Bleeder Bolt: Coolant Drain Bolt (Cylinder): 9.4 Nm (1.0 kgfm, 83 inlb) 8.8 Nm (0.90 kgfm, 78 inlb). MAINTENANCE AND ADJUSTMENT. Start the engine and warm up thoroughly, then Spark Plug stop it. Check the coolant level after the engine has cooled down.
The spark plug should be taken out periodically for. If the coolant level is low, add coolant up to the inspection and regapping.
MAINTENANCE AND ADJUSTMENT If the plug is oily or has carbon built up on it, clean it. The plug may also be cleaned using a high flash -point solvent and a nonmetal brush (nylon etc.). If the spark plug electrodes are corroded, or damaged, or if the insulator is cracked, replace the plug.
MAINTENANCE AND ADJUSTMENT. Check to see if the middle mark of the three-marks Ignition Timing on the stator coil plate is aligned with the straight surface of the projection on the crankcase. Since this motorcycle is equipped with a capacitor discharge ignition (CDI) system, the ignition timing should never require adjustment unless the stator was incorrectly installed during engine reassembly.
MAINTENANCE AND ADJUSTMENT NOTE ○ The ignition timing can be adjusted to change the power band to suit the rider’s preference or ability. If necessary, adjust the timing by shifting the stator coil plate position within the three lines. MAINTENANCE AND ADJUSTMENT. Test ride the motorcycle and readjust the ignition timing if necessary.
Crankshaft Rotation B. Stator Rotation C.
Advance. Tighten the stator coil plate mounting screws to the specified torque.
Tightening Torque Stator Coil Plate Mounting Screws: 5.2 Nm (0.53 kgfm, 46 inlb). MAINTENANCE AND ADJUSTMENT ○ After riding through rain or on muddy roads, the Air Cleaner element should be cleaned immediately. Element Removal and Inspection A clogged air cleaner restricts the air intake, in-. creases fuel consumption, reduces engine power, Remove the seat bolts. MAINTENANCE AND ADJUSTMENT. Remove the wing bolt, and take out the air cleaner element.
Air Cleaner Element B. Element Frame A. Wing Bolt NOTICE B. Air Cleaner Element. Check inside of the intake tract and carburetor for Do not twist or wring the element, as it gets dirt. MAINTENANCE AND ADJUSTMENT WARNING A clogged air cleaner may allow dirt and dust to enter the carburetor and the throttle may stick resulting in a hazardous operating con- dition.
Clean the air cleaner according to the periodic maintenance chart; more often if the motorcycle is used in extremely dusty condi- tions. MAINTENANCE AND ADJUSTMENT. After cleaning, let the element dry completely. Sat- urate the element with a high-quality foam air fil- ter oil and make sure that the oil is evenly ap- plied throughout the element.
Squeeze out the ex- cess oil, but do not wring the element as this could cause tearing. MAINTENANCE AND ADJUSTMENT. Install the air cleaner element so that the projec- Insert the hooks of the seat under the flange collar tion on it fits into the notch in the holder. NOTE ○ Take care not to damage the side covers with the bracket of seat. MAINTENANCE AND ADJUSTMENT.
Loosen the locknut on the upper end of the throttle Throttle Cable cable and turn the adjuster to obtain the specified play. Then, tighten the locknut and reinstall the rubber boot. Throttle Cable Adjustment Inspect the throttle grip for smooth operation in all steering positions. MAINTENANCE AND ADJUSTMENT WARNING Operation with improperly adjusted, incor- rectly routed, or damaged cable could result in an unsafe riding condition. Be sure the control cable is adjusted and routed cor- rectly, and is free from damage. Rubber Boot B. MAINTENANCE AND ADJUSTMENT Carburetor Idle Speed Adjustment Idle speed adjustment is carried out using the air screw and idle adjusting screw.
Start the engine and warm it up thoroughly. First turn the air screw in until it is lightly seated, then back it out 1 1/2 turns (KX85C). MAINTENANCE AND ADJUSTMENT. NOTICE Slide out the cable housing dust cover. Remove the screws and the throttle case cover. This motorcycle’s radiator does not incorpo- rate cooling fan.
Prolonged idling of the en- gine with no airflow through the radiator can cause coolant loss and engine overheating resulting in possible engine damage. MAINTENANCE AND ADJUSTMENT. Loosen the locknut.
Turn the fuel tap lever to the “OFF” position (see. Remove the upper end of the throttle cable. Stopping the Engine section).
Take the adjuster and locknut off the throttle case. Free the carburetor overflow hose from the clamp on the magneto cover. MAINTENANCE AND ADJUSTMENT.
NOTICE Place a container under the fuel drain plug. Remove the fuel drain plug and drain the fuel. Never drop the carburetor, especially on a hard surface.
Such a shock to the carburetor can damage. MAINTENANCE AND ADJUSTMENT. WARNING Rinse the parts in water. After the parts are cleaned, dry them with com- Gasoline and low flash-point solvents can be pressed air. Flammable and/or explosive and cause se-. Blow through the air and fuel passages with com- vere burns.
MAINTENANCE AND ADJUSTMENT Clutch Clutch Lever Adjustment Proper clutch lever free play is 8 ∼ 13 mm (0.3 ∼ 0.5 in.). Lever play increases with cable stretch and friction plate wear, requiring periodic adjustment. When the clutch lever free play is out of specifica- tion, first try adjusting it at the clutch lever as follows. MAINTENANCE AND ADJUSTMENT. If the clutch lever free play cannot be adjusted at Slide the dust cover back into place. The clutch lever, make the adjustment further down WARNING the cable as follows. Loosen the locknut at the clutch lever.
Excess clutch cable play could prevent. MAINTENANCE AND ADJUSTMENT. Take the clutch cable off the cable holder. Take the lower end of the clutch cable off the clutch release lever. Remove the clutch cover bolts. Turn the clutch release lever toward the rear.
NOTICE Do not remove the clutch release shaft un- less it is absolutely necessary. MAINTENANCE AND ADJUSTMENT.
Remove the clutch spring bolts, springs and clutch Remove the friction plates and steel plates. Pressure plate. Friction Plates B. Steel Plates A. Clutch Spring Bolts and Springs B. Clutch Pressure Plate When it is hard to remove the clutch spring bolts, use a flywheel &.
MAINTENANCE AND ADJUSTMENT A. Flywheel & Pulley Holder (Special Tool: B. Friction Plate ) Friction and Steel Plate Warp Inspection. Friction Steel Plates Wear/Damage Place each friction plate and steel plate on a sur- Inspection face plate, and measure the amount of friction. MAINTENANCE AND ADJUSTMENT NOTICE 0.15 mm Standard (0.0059 in.) or less Steel Plate If dry steel plates and friction plates are Service Limit 0.3 mm (0.01 in.) installed, apply transmission oil to the sur- faces of each plate to avoid clutch plate seizure. MAINTENANCE AND ADJUSTMENT. Tighten the clutch cover bolts to the specified torque.
Tightening Torque Clutch Cover Bolts: 9.4 Nm (1.0 kgfm, 83 inlb). Replace the magneto cover gasket with a new one. Install the magneto cover. Check the transmission oil level (see Transmis- sion Oil section). MAINTENANCE AND ADJUSTMENT. Remove the bolts and the shrouds on both sides.
Piston Piston Removal. Turn the fuel tap lever to the “OFF” position (see Stopping the Engine section). Drain the coolant (see Cooling System section).
Remove the fuel tank mounting bolt for easier re- moval of cylinder. MAINTENANCE AND ADJUSTMENT.
Remove the radiator screen bolt. Disconnect the overflow hose. Clear the hook and remove the radiator screen.
Loosen the water hose clamp screws, and discon- nect the water hoses. Radiator Screen Bolt B.
MAINTENANCE AND ADJUSTMENT. Remove the radiator mounting bolts, clamp and Loosen the water hose clamp screws, and discon- radiator. Nect the water hoses. Radiator Mounting Bolts A. Water Hose Clamp Screws B. Water Hoses C. MAINTENANCE AND ADJUSTMENT.
Remove the spark plug cap (see Spark Plug sec- Remove the shroud screen bolt and shroud tion). Remove the muffler (see Exhaust System sec- tion). Remove the expansion chamber mounting springs. Shroud Screen Bolt B.
MAINTENANCE AND ADJUSTMENT. Remove the expansion chamber mounting bolt Remove the engine bracket mounting bolts, nuts and take off the expansion chamber. And the engine brackets. Remove the cylinder head nuts, cylinder head and the gasket. Expansion Chamber Mounting Bolt B. MAINTENANCE AND ADJUSTMENT. Remove the carburetor from the cylinder intake Remove the circlip.
joint (see Carburetor section). Push the shaft lever, and disconnect the link lever. Remove the KIPS cover bolts and the KIPS cover. To the operating rod.
MAINTENANCE AND ADJUSTMENT. Open the alternator lead from the clamp. Stuff a clean cloth into the crankcase opening.
Remove the cylinder nuts. Around the connecting rod so that no parts will fall. Lift off the cylinder, and remove the cylinder base into the crankcase. MAINTENANCE AND ADJUSTMENT. Remove the piston by pushing the piston pin out the side from which the snap ring was removed. Use a piston pin puller assembly (special tool: 57001-910), if the pin is tight. Piston Ring Piston Ring/Ring Groove Clearance Inspection.
MAINTENANCE AND ADJUSTMENT and groove width as follows to decide whether to replace the ring, the piston or both. If the piston ring has worn down to less than the service limit, replace the ring; if the piston ring groove width exceeds the service limit, replace the piston.
MAINTENANCE AND ADJUSTMENT Piston Ring Groove Width Piston Pin Hole Diameter 1.01 ∼ 1.03 mm 14.001 ∼ 14.011 mm KX85C Standard (0.0398 ∼ 0.0406 in.) (0.55122 ∼ 0.55161 in.) Standard KX100F 1.03 ∼ 1.05 mm Service Limit 14.08 mm (0.5543 in.) (0.0406 ∼. Carbon particles can be very abrasive to pis- ton ring. Don’t allow such particles to fall onto the cylinder walls. The ring is identical in KX100 model, but they are different in KX85 model. The piston ring is marked as follow: KX85C A.
MAINTENANCE AND ADJUSTMENT A. Piston Ring A. Marked side. Apply 2–stroke engine oil to the connecting rod. Install the piston ring so that the pin in the piston needle bearing and the piston pin. Ring groove is between the ends of the piston ring.
MAINTENANCE AND ADJUSTMENT A. Piston Pin Snap Ring B. “IN” Mark (KX85C) B.
Snap Ring Ends C. Notch. When installing a piston pin snap ring, compress it only enough to install it and no more. Cylinder Installation. MAINTENANCE AND ADJUSTMENT A.
Dowel Pins B. Mark. Tighten the cylinder nuts to the specified torque in. Tighten the cylinder head nuts to the specified a crisscross pattern. Torque in a crisscross pattern. Tightening Torque Tightening Torque Cylinder Nuts: Cylinder Head Nuts: 25 Nm (2.5 kgfm, 18 ftlb). MAINTENANCE AND ADJUSTMENT.
Link the link lever to the link pin and insert the circlip to the KIPS shaft lever. Replace the exhaust gasket with a new one.
Replace the exhaust O-rings with new ones. Apply molybdenum disulfide grease around the exhaust O-rings. MAINTENANCE AND ADJUSTMENT A. Shroud Screen B.
Projections C. Radiator Screen C. Projections. Install the removed parts.
Holes. Fill the coolant and check the coolant level (see. Install the shroud screen so that the projections fit Cooling System section). MAINTENANCE AND ADJUSTMENT Exhaust System The exhaust system, in particular the muffler body, is designed to reduce exhaust noise and conduct the exhaust gases away from the rider while minimizing power loss. If carbon has built up inside the muffler body, exhaust efficiency is reduced, causing engine performance to drop.
MAINTENANCE AND ADJUSTMENT. Remove the muffler mounting bolts and washer, Remove the liquid gasket on the silencer, tail pipe and pull the muffler off toward the rear.
Remove the muffler body cover bolts, and pull out the tail pipe. MAINTENANCE AND ADJUSTMENT. Remove the O-ring between the silencer wool and Push out the baffle by tapping the inner pipe with tail pipe. A suitable tool.
Pull off the silencer wool. Silencer Wool B.
MAINTENANCE AND ADJUSTMENT. Using a high flash-point solvent, clean off any oil or dirt that may be on the liquid gasket coating area.
Dry them with a clean cloth. Apply liquid gasket to the joint part of the silencer and baffle.
MAINTENANCE AND ADJUSTMENT. Adjust the drive chain if its slack is out of specifi- Drive Chain cation. For safety and to prevent excessive wear, the drive chain must be checked, adjusted, and lubricated in accordance with the Periodic Maintenance Chart. If the chain becomes badly worn or maladjusted - ei- ther too loose or too tight - it could jump off the sprockets or break. MAINTENANCE AND ADJUSTMENT NOTE the chain is too tight, back out the left and right ○ chain adjusting bolts evenly, and kick the wheel Wheel alignment can also be checked using the forward.
If the chain is too loose, turn both chain straightedge or string method. MAINTENANCE AND ADJUSTMENT overly tight chain, which can cause it to break. To prevent this, adjust the chain slack (measured ∼ between the chain and the swingarm) to 64 ∼ mm (2.5 2.9 in.). Chain Wear Inspection When the chain has reached its wear limit (i.e., when it has stretched by 1.7% of its original length), it is no longer safe for use and should be replaced. MAINTENANCE AND ADJUSTMENT KX100F: 124-links).
For maximum stretch resis- tance and safety, a genuine part must be used for replacement. ○ To minimize any chance of the master link coming apart, the master link clip must be installed with the closed end of the “U” pointing in the direction of chain rotation.
MAINTENANCE AND ADJUSTMENT Chain Guide Wear Inspection Chain Slipper Wear Inspection. Visually inspect the drive chain guide and replace Visually inspect the upper and lower of the chain it if excessively worn or damaged. Slipper on the swingarm and replace them if worn or damaged.
MAINTENANCE AND ADJUSTMENT Sprocket Teeth Wear chains following the instructions supplied by the chain cleaner manufacturer. Apply lubricant to the sides of the rollers so that it will penetrate to the rollers and bushings. Wipe off any excess lubricant. MAINTENANCE AND ADJUSTMENT. Install the holders so that the arrow marks on the Handlebar holders point at the front. Align the punch mark on the handlebars with a gap at rear of the handlebar holder. Handlebar Removal.
Unlock the clamp of the number plate (see Steer- ing section). MAINTENANCE AND ADJUSTMENT. Remove the handlebars (see Handlebar Removal in this section). Check the handlebars for bent or crack. Remove the handlebar holder nuts and washers, and the handlebar holders. Handlebar Holders B. Gap Tightening Torque Handlebar Holder Bolts: 25 Nm (2.5 kgfm, 18 ftlb) A.
MAINTENANCE AND ADJUSTMENT Handlebar Position Adjustment To suit various riding positions, the handlebar po- sition can be adjusted by turning the handlebar hold- ers around. Remove the handlebars (see Handlebar Removal in this section). Check the handlebars for bent or crack.
MAINTENANCE AND ADJUSTMENT Tightening Torque Brakes Handlebar Holder Nuts: 34 Nm (3.5 kgfm, 25 ftlb) Disc and disc pad wear is automatically compen-. sated for and has no effect on the brake lever or Install the handlebars (see Handlebar Installation pedal action.
Brake Fluid Level Inspection defective. Have the brake checked immedi- ately by an authorized Kawasaki dealer. Front Brake Reservoir With the front brake reservoir positioned horizon- tally, the brake fluid must always be above the lower. MAINTENANCE AND ADJUSTMENT A.
Front Brake Reservoir A. Front Brake Reservoir Cap Screws B. Lower Level Line B. Front Brake Reservoir Cap. If the brake fluid in the front brake reservoir is be- low the lower level line, check for fluid leaks in the brake line and add brake fluid as follows. MAINTENANCE AND ADJUSTMENT WARNING Mixing brands and types of brake fluid can reduce the brake system’s effectiveness and cause an accident resulting in injury or death. Do not mix two brands of brake fluid.
Change the brake fluid in the brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that is already in the reservoir are unidentified. MAINTENANCE AND ADJUSTMENT NOTE replaced as a set. Pad replacement should be done ○ by an authorized Kawasaki dealer.
First, until slight resistance is felt indicating that the cap is seated on the reservoir body; then, tighten Brake Pads Lining Thickness. MAINTENANCE AND ADJUSTMENT Steering The steering should always be kept adjusted so that the handlebars will turn freely but not have ex- cessive play. Steering Inspection. To check the steering adjustment, raise the front wheel off the ground using a jack (special tool: ) and attachment (special tool: 57001 -1608). MAINTENANCE AND ADJUSTMENT. Loosen the steering stem head nut.
Turn the steering stem nut with a stem nut wrench (special tool: ) to obtain the proper ad- justment. Number Plate C.
Number Plate Mounting Bolt D. MAINTENANCE AND ADJUSTMENT Tightening Torque Steering Stem Head Nut: 64 Nm (6.5 kgfm, 47 ftlb) Steering Stem Nut: 4.9 Nm (0.50 kgfm, 43 inlb) Front Fork Clamp Bolts (Upper): 20 Nm (2.0 kgfm, 15 ftlb). Install the handlebars (see Handlebar section), and check the steering again and readjust it if necessary. NOTICE. If necessary, replace by an authorized Kawasaki dealer. If the inner tube is badly bent or creased, replace it. Excessive bending, followed by subsequent straitening, can weaken the in- ner tube.
MAINTENANCE AND ADJUSTMENT on your KX will get stiffer as the race progresses. Front tire does not touch the fender when the fork Therefore, it is not recommended to increase the air is fully compressed. Make this adjustment in 10 mm pressure for additional springing. MAINTENANCE AND ADJUSTMENT A.
Air Pressure Relief Screw A. Cap (Both Sides) B. Front Fork Top Plug. To adjust the compression damping, turn the ad- juster on the compression valve assembly with a Compression Damping Adjustment. standard tip screwdriver.
Adjust the compression Raise the front wheel off the ground using a jack damping to suit your preference under certain con- (special tool: ) and attachment (spe. MAINTENANCE AND ADJUSTMENT Compression Damper Settings A.
Compression Damping Adjuster B. Compression Valve Assembly A. Seated Position (Adjuster Turned Fully Clockwise) B. Softer (Counterclockwise) C. Harder (Clockwise) D.
Standard Setting (KX85C) E. Standard Setting (KX100F).: Number of turns counterclockwise usable range 20 clicks or more. MAINTENANCE AND ADJUSTMENT. NOTICE Remove the bolts and the front fender. The right and left fork tubes must be adjusted evenly. Install the caps on the bottom of the fork tubes.
Fork Oil Level Adjustment. Thoroughly clean the forks before disassembly.
NOTICE Be careful not to scratch the inner tube and not to damage the dust seal. MAINTENANCE AND ADJUSTMENT A. Front Fork Clamp Bolt (Upper) A. Front Fork Top Plug B. Brake Hose Clamps C.
Bolts (Both Sides). Support the motorcycle using a jack (special tool: D. Front Fork Protectors ) and attachment (special tool: 57001. MAINTENANCE AND ADJUSTMENT A.
Inner Tube (Stepped Portion) A. Suitable Support B. Front Wheel C. Outer Tube. While holding the front fork push rod nut with a. Place a stand or other suitable support under the wrench, remove the front fork top plug from the front wheel. MAINTENANCE AND ADJUSTMENT A.
Front Fork Push Rod Nut A. Push Rod Puller (Special Tool: ) B. Front Fork Top Plug.
Fill the fork cylinder with oil by gently moving the D. Fork Spring Seat push rod puller up and down five times.
MAINTENANCE AND ADJUSTMENT A. Outer Tube Opening A. Push Rod Puller (Special Tool: ) B. Oil Level Gauge (Special Tool: ) B. Fork Spring C.
Fork Spring Seat. Pull up the push rod puller. O-ring. Hold the push rod with your hand and remove the. MAINTENANCE AND ADJUSTMENT.
Assemble the other fork tube in the same way as described above. Tighten the front fork clamp bolts (upper) to the specified torque. Tightening Torque Front Fork Clamp Bolts (Upper): 20 Nm (2.0 kgfm, 15 ftlb).: Between the top end of the outer tube and upper.
Visually inspect the rear shock absorber for oil surface of the steering stem head. If necessary, replace by an authorized Kawasaki dealer. MAINTENANCE AND ADJUSTMENT Rear Shock Absorber Adjustment Rebound Damper Settings The spring preload of the shock absorber can be adjusted or the spring can be replaced with an op- tional one to suit various riding conditions. In addi- tion, the damping force can be adjusted easily, mak- ing it unnecessary to change the oil viscosity.
MAINTENANCE AND ADJUSTMENT NOTE Compression Damper Settings ○ Adjustment of the rebound damping adjuster for the rear suspension will slightly affect the com- pression damping force. Always make any damp- ing adjustments in small steps and test their ef- fects before using them in competition. Compression Damping Adjustment. MAINTENANCE AND ADJUSTMENT NOTICE Do not force the compression damping force adjuster beyond the fully seated position, or the adjusting mechanism may be damaged. NOTE ○ Adjustment of the compression damping adjuster for the rear suspension will slightly affect the re- bound damping force. MAINTENANCE AND ADJUSTMENT A.
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Bolts, Nuts and Washers A. Rear Frame Pipe Bolts and Nuts B. Rear Fender C. Rear Frame Pipe D. Bolts and Collars. Remove the muffler (see Exhaust System sec- E. Rear Flap tion).
MAINTENANCE AND ADJUSTMENT. Using hook wrenches (special tools:, 1580), loosen the rear shock ab- sorber spring locknut on the rear shock absorber. Air Cleaner Duct Clamp Screw B. Air Cleaner Case D. Air Cleaner Duct A. MAINTENANCE AND ADJUSTMENT. Using the hook wrench (special tool: ), turn the spring preload adjusting nut as required.
Turning the adjusting nut down increases the spring preload. Adjusting Nut Position B. Center of Upper Rear Shock Absorber Pivot C.
Always wear eye and face protection when working on the rear shock absorber. Removal and installation of the rear shock absorber spring should be performed by an authorized Kawasaki dealer. Tire Pressure Gauge. Reduce the tire air pressure to increase the tire tread surface on the ground when riding on a wet, muddy, sandy or slippery track. MAINTENANCE AND ADJUSTMENT. Increase the tire air pressure to prevent damage or punctures (though the tires will skid more easily) when riding on a pebbly or hard track. Air Pressure (when cold) 100 ∼ 125 kPa (1.02 ∼ 1.27 kgf/cm², Front 14.5 ∼.
MAINTENANCE AND ADJUSTMENT NOTE ○ The welding spot of the rim may show exces- sive runout. Disregard this when measuring rim runout. Rim Runout A.
Bead Protector Nut Rim Runout. Raise the rear wheel off the ground using a jack (special tool: ) and attachment (spe- cial tool: ). MAINTENANCE AND ADJUSTMENT.: Total Indicator Reading Hoses Inspection Check the brake and fuel hoses for cracks or de- terioration, and the connections for looseness in ac- cordance with the Periodic Maintenance Chart. Inspect the hoses and fittings for deterioration, cracks and signs of leakage by bending or twisting the hoses. MAINTENANCE AND ADJUSTMENT Tightening Torques of Nuts and Bolts Location of nuts and bolts Before the first ride of each day of operation, check the tightness of the nuts and bolts shown below. Check also that all cotter pins are in place and in good condition.
MAINTENANCE AND ADJUSTMENT 1. Rear Caliper Mounting Bolts 11. Brake Lever Pivot Bolt 23. Coolant Drain Bolt (Water 2. Rear Brake Pad Pins 12. Front Brake Reservoir Cap Pump) 3.
Rear Master Cylinder Screws 24. Coolant Drain Bolt Mounting Bolts 13.
MAINTENANCE AND ADJUSTMENT Torque table Tighten all nuts and bolts to the proper torque using an accurate torque wrench. An insufficiently tightened nut or bolt may become damaged or fall out, possibly resulting in damage to the motorcycle and injury to the rider. MAINTENANCE AND ADJUSTMENT Fastener Nm kgfm ftlb Remarks Front Fork Push Rod Nut (Both Sides) Handlebar Holder Nuts Stator Coil Plate Mounting Screws 0.53 46 inlb Rear Sprocket Nuts Rear Caliper Mounting Bolts Rear Brake Pad Pins 17.2 1.75 12.7 Rear Master Cylinder Mounting Bolts 87 inlb Rear Frame Pipe Nuts. MAINTENANCE AND ADJUSTMENT Fastener Nm kgfm ftlb Remarks Rocker Arm Pivot Nut Rocker Arm Bracket Bolts Swingarm Pivot Shaft Nut Transmission Oil Drain Bolt Coolant Drain Bolt (Water Pump) 0.53 46 inlb Coolant Drain Bolt (Cylinder) 0.90 78 inlb Water Hose Clamp Screws 0.31 27 inlb Engine Bracket Mounting Nuts.
General Precautions. Avoid all harsh chemicals, solvents, detergents, Frequent and proper care of your Kawasaki mo- and household cleaning products such as ammo- torcycle will enhance its appearance, optimize over- nia-based window cleaners. All performance, and extend its useful life. The semi-gloss finish effect may be lost when it is part’s finish. Excessively rubbed. If any doubt, consult an authorized Kawasaki Chrome and Aluminum dealer. Chrome and uncoated aluminum parts can be treated with a chrome/aluminum polish.
MAINTENANCE AND ADJUSTMENT aluminum should be washed with a mild neutral de- Lubrication tergent and finished with a spray polish. Aluminum wheels, both painted and unpainted can be cleaned with special non-acid based wheel spray cleaners. Lubricate the areas shown in the illustrations of this section with either motor oil or regular grease, Leather, Vinyl, and Rubber after each race and whenever the vehicle has been. MAINTENANCE AND ADJUSTMENT. Rear Brake Pedal Shift Pedal. Rear Master Cylinder Joint Pin.
Kick Pedal. Footpeg Apply an aerosol cable lubricant with a pressure lubricator on all cables:. Clutch Cable. Throttle Cable. MAINTENANCE AND ADJUSTMENT Cable Lubrication Apply grease to the following points:.
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Clutch Inner Cable Upper End. Throttle Inner Cable Upper End A. MAINTENANCE AND ADJUSTMENT. Drive Chain Lubrication Wipe off any lubricant that gets on the tire surface.
Lubrication is necessary after riding through rain or on wet roads, or any time that the chain appears dry. Use a lubricant for drive chains. If the chain is especially dirty, clean it using a cleaner for drive chains following the instructions supplied by the chain cleaner manufacturer. TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE.
NOTE Wrong starting technique (when the engine is ○ flooded, kick with the throttle fully open to allow This troubleshooting guide is not exhaustive and more air to reach the engine.) does not give every possible cause for each prob- lem listed. TROUBLESHOOTING GUIDE. Cylinder head warped Piston ring side clearance excessive.
Cylinder base gasket damaged Cylinder head gasket damaged. Reed valve damaged Cylinder head warped.
Cylinder base gasket damaged. Reed valve damaged Poor low-speed performance - KIPS ports stuck open:.
TROUBLESHOOTING GUIDE. Jet needle clip in wrong position Cylinder exhaust port clogged. Carburetor fuel level too high or too low Brake dragging. Air jet or air passage clogged Clutch slipping. Air cleaner element clogged, poorly sealed or not Engine overheating.
TROUBLESHOOTING GUIDE. Air cleaner element clogged, poorly sealed, or not Clutch release mechanism defective.
installed Clutch hub or housing unevenly worn. Air intake duct poorly sealed Clutch not disengaging properly:.
Compression high: Clutch lever play excessive. TROUBLESHOOTING GUIDE. Shift fork pin worn Abnormal drive train noise -. Drive shaft, output shaft, and/or gear splines worn Clutch noise: Transmission skips gears:. Clutch housing/friction plate clearance excessive. Gear positioning lever spring weak or broken. TROUBLESHOOTING GUIDE.
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Disc brake noise: Wiring incorrect routed. Pad installed incorrectly Steering stem nut too tight. Pad surface glazed Roller bearing damaged. Brake disc warped Steering bearing race dented or worn. Brake caliper defective Steering stem inadequately lubricated. TROUBLESHOOTING GUIDE Shock absorption unsatisfactory (suspension too hard):. Front fork oil excessive.
Front fork oil viscosity too high. Front fork leg bent. Tire air pressure too high.
Rear shock absorber improperly adjusted Shock absorption unsatisfactory (suspension too soft):. TUNING TUNING tuning. Before attempting any changes, however, Carburetor make sure that everything else is in good shape and properly tuned. Check the condition of the Tuning a carburetor is not the mysterious science spark plug, make sure the ignition timing is correct, many racers believe it to be. TUNING With pinging or rattling, make sure that the gaso- line is fresh and the octane rating sufficient. You might also try a different brand of high-octane gaso- line. Making Adjustments Carburetor tuning is made by replacing or adjust- ing the main jet, jet needle and slow jet, which regu- late the fuel flow, and the air screw, which regulates the air flow.
TUNING There are five grooves in the top of the jet needle in which a clip fits. This clip positions the jet needle in the throttle valve relative to the needle jet. Moving the clip down has the effect of pulling the needle further out of the jet. TUNING Slow Jet and Air Screw The slow jet and air screw control the mixture in the closed-to-1/8–throttle range, but have little effect between that and full throttle. To adjust the mixture in this range, the air screw can be turned to change the air flow, or the slow jet can be replaced to change the fuel flow.
TUNING Test Runs NOTE. ○ With all carburetor settings on standard, warm up If the fuel/air mixture is too lean, the engine tends the engine, run two or three laps of the course to overheat and may seize up. On the other hand, and examine the spark plug condition with varying if the fuel/air mixture is too rich, the spark plug throttle openings.
Temperature °C (°F) B. 3 000 m (9 600 ft) D. 2 000 m (6 400 ft) E. 1 000 m (3 200 ft) F. Correction Factor. TUNING Correction Factor Applied to the Jet Needle and Air Screw Correction Factor 1.06 or above 1.06 – 1.02 1.02 – 0.98 0.98 – 0.94 0.94 or below lower clip one raise clip one same Jet Needle Setting position position same Air Screw Opening one turn in.
TUNING. The front and rear suspension should always be Suspension balanced; when the one is changed, the other one might need to be changed similarly. When evaluating suspension performance, the Introduction rider must make every effort to ride consistently No area of machine adjustment is more critical and to recognize the effects of his input. TUNING Troubleshooting Improper Settings Fork Oil Level Effect on Fork Stroke Listed below are some symptoms of improper sus- pension settings and the most likely means of cor- recting them. The proper settings can be achieved by applying the information given in this chapter in a scientific, methodical manner. TUNING Rear shock absorber improper adjustment much above or below the intermediate level, it is symptoms - likely that a few basic suspension adjustments will be necessary. Too Hard Basic Readjustment of the Suspension Suspension too stiff:.
Suspension Tuning According Ground Compression damping too high. TUNING Front and Rear Suspension Compatibility Suspension Tuning According the Type of Inspection Course Use this procedure to determine if the suspension Lower the front end slightly is balanced reasonably well.
Increase the amount of fork. Hold the motorcycle upright (remove the side tube protrusion above the stand). TUNING NOTE Although this is one of the most effective adjust- ○ ment procedures, suspension settings may vary de- Lighter or less experienced riders may need a pending on the conditions at the track and the rider’s softer spring.
Front End Does Not Respond to Small Bumps in Front and Rear Suspension Troubleshooting Sweeping Turns. TUNING ○ The rear suspension is too soft. Observe the rear end jumps and try lowering the. Increase the rear shock absorber spring preload spring preload and damping if it does not approach or use a harder spring.
TUNING. Since it is difficult to set the machine so it is best Gearing suited for all portions of the circuit, determine which circuit portions will have the greatest ef- fect on lap time, and tune the machine to these Selection of the Secondary Reduction Ratio portions. TUNING. In muddy or sandy conditions, increase chain Special Care According to Track slack as the chain and sprockets will be packed Conditions with mud or sand, which reduces chain slack. Check chain and sprocket wear frequently when. OPTIONAL PARTS OPTIONAL PARTS Optional part KX85C KX100F Jet Needle Richer NRJA NRJA Carburetor NRJB NRJB.NRJC NRJC NRJD NRJD.140 Main Jet Leaner NRJE NRJE Richer NRKA NRKA NRKB NRKB NRKC.NRKC.38 NRKD NRKD Slow Jet Leaner NRKE NRKE NOTE ○. OPTIONAL PARTS Optional part KX85C KX100F Optional part KX85C KX100F Engine Sprocket.13T Disc Plate.14T Front No Holes (For Wet Conditions) Rear Sprocket Rear No Holes (For Wet Conditions) Wheel (Without Tire).50T.51T Front 17 × 1.40 19 × 1.40 Rear 14 ×.
PRE-RACE CHECKS AND AFTER-RACE MAINTENANCE PRE-RACE CHECKS AND AFTER-RACE MAINTENANCE. Pre-Race Checks - Front and rear tire air pressure. Front axle nut torque Front fork air pressure. Front fork clamp bolt torque Drive chain slack. PRE-RACE CHECKS AND AFTER-RACE MAINTENANCE.
Maintenance After Riding in the Rain or on a Carburetor jets. Muddy Course - Air cleaner element. Clean the sliding surface of the front fork and rear Muffler, and related parts. STORAGE STORAGE WARNING Before Storage Gasoline is extremely flammable and can be explosive under certain conditions, creating When the motorcycle is to be stored for any length the potential for serious burns. Always stop of time, it should be prepared for storage as follows.
The engine and never smoke while handling. STORAGE. Fill the fuel tank with fuel. After Storage Check all the points listed in the Daily Pre-Ride Checks section. Remove the plastic bag from the muffler. Perform a lubrication procedure in the Lubrication. Make sure the spark plug is tight.
ENVIRONMENTAL PROTECTION ENVIRONMENTAL PROTECTION Kawasaki subscribes to the guidelines of Tread Lightly! A program dedicated to protecting the great outdoors through education and fostering responsible enjoyment of public lands. When using your Kawasaki motorcycle, please follow these Tread Lightly! Guidelines: Tread Lightly!
Ravel responsibly on designated roads and trails or in permitted areas. WIRING DIAGRAM WIRING DIAGRAM.
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