• Kawasaki Kx450f Horsepower
• Kawasaki Kx450f For Sale

. 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 ENGINE AND SUSPENSION 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- WARNING LIC STREETS, ROADS, OR HIGHWAYS. THE This warning symbol identifies special in- USE OF THIS VEHICLE SHOULD BE LIMITED structions or procedures which, if not cor. 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. 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. TABLE OF CONTENTS SPECIFICATIONS.Drive Chain.

GENERAL INFORMATION.Handlebar.Location of Parts. Brakes.Side Stand. Front Suspension. ® Kick Pedal. Rear Suspension (UNI-TRAK ). 111 Starting the Engine.Wheels.117 Shifting Gears. SPECIFICATIONS SPECIFICATIONS DIMENSIONS Overall length 2 170 mm (85 in.) Overall width 820 mm (32.3 in.) Overall height 1 270 mm (50 in.) Wheelbase 1 470 mm (57.9 in.) Road clearance 340 mm (13.4 in.) Curb Mass 104.3 kg (230 lb) Fuel tank capacity 8.0 L (2.1 US gal) ENGINE.

SPECIFICATIONS TRANSMISSION Transmission type 5-speed, constant-mesh, return shift Clutch type Wet, multi disc Drive system Chain drive Gear ratios: 1st gear 2.142 (30/14 ) 2nd gear 1.769 (23/13) 3rd gear 1.444 (26/18) 4th gear 1.200 (24/20) 5th gear 1.045 (23/22) Primary reduction ratio 3.350 (67/20) Final reduction ratio. SPECIFICATIONS FRAME Type Tubular, semi-double cradle Steering angle 42° to either side Castor 27.7° Trail 122.3 mm (4.8 in.) Tire size, type: Front 80/100-21 51M, BRIDGESTONE M403 Rear 100/90-19 57M, BRIDGESTONE M404 Rim size: Front 21 × 1.60 Rear 19 × 1.85 Front Suspension: Upside-down telescopic fork. SPECIFICATIONS BRAKES Type (Front & Rear) Disc Effective disc diameter: Front 225 mm (8.9 in.) Rear 215 mm (8.4 in.) Specifications are subject to change without notice. GENERAL INFORMATION GENERAL INFORMATION Location of Parts 1. Clutch Lever 4. Fuel Tank Cap 7.

Throttle Grip 2. Engine Stop Button 5. Front Brake Fluid Reservoir 3. Hot Starter Lever 6. Front Brake Lever. GENERAL INFORMATION 8.

Front Fork 13. Rear Shock Absorber 9. Air Cleaner Element 19.

Fuel Tank 15. Brake Disc 20. Drive Chain 11.

Brake Caliper 21. Chain Guide 12. Carburetor 17. GENERAL INFORMATION 22. Kick Pedal 23.

Rear Brake Fluid Reservoir 27. Engine Oil Level Inspection Window 24. Rear Shock Absorber Gas Reservoir 28.

Rear Brake Pedal ® 25. Uni-Trak Tie Rod and Rocker Arm 29. Exhaust Pipe.

GENERAL INFORMATION NOTE Side Stand Support the motorcycle with a suitable stand to perform maintenance or adjustment procedures. To install the side stand, insert its flat end into the rear axle shaft as shown.

Side Stand B. Rear Axle Shaft WARNING Do not start the engine or attempt to ride the motorcycle when the side stand is installed.

Fuel Gasoline is extremely flammable and can be explosive under certain conditions. Always This Kawasaki KX has a 4-stroke engine that re- stop the engine and do not smoke. Make quires a gasoline. Sure the area is well ventilated and free from The capacity of the fuel tank is 8.0 L (2.1 US gal). And (up to 17.2%).

Fuel containing these oxygenates Canada which are required to sell such reformu- can also be used in your Kawasaki. Lated fuels as part of a strategy to reduce exhaust emissions. Be extra careful not to spill gasoline or gasoline oxygenate blends during refueling. When not operating your Kawasaki for 30 to 60 days, mix a fuel stabilizer (such as STA-BIL) with the gasoline in the fuel tank.

Fuel stabilizer additives inhibit oxidation of the fuel which minimizes gummy deposits. GENERAL INFORMATION CAUTION Starting the Engine This motorcycle is designed for competition use only. Therefore, the radiator does not. Shift the transmission into neutral. Incorporate a coolant reserve tank or cool-. Turn the fuel tap lever to the ON position. GENERAL INFORMATION A.

Choke Knob A. Hot Starter Lever. Find the kick pedal position around the top so that Kick the engine over, leaving the throttle closed the resistance to depress the kick pedal is fully felt without using the choke knob. GENERAL INFORMATION Engine Hot Starter Choke Knob Shifting Gears Condition Lever Already This motorcycle is equipped with a 5-speed 'return Pull in (ON) Push back (OFF) shift' transmission.

The neutral is located halfway Warm between 1st and 2nd gear. “Return shift' means Restarting that when shifting up or down, each gear must be Pull in (ON). 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 Break-In. Shift the transmission into the neutral position.

A brief break-in procedure must be carried out to. Close the throttle completely and push the engine obtain the proper operating clearances in the engine stop button.

GENERAL INFORMATION CAUTION operation. Using the proper riding skills and techniques and avoiding recklessly high engine When any following parts have been re- speeds will keep the engine trouble-free. Placed, the same break-in procedure as the new motorcycle must be carried out for one hour or 20 km (12 mi): Cylinder, Piston, Piston pin, Piston ring, Valve, Valve lifter, Camshaft, Crankshaft. 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 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.Function properly Lever and pedal play correct No fluid leakage Throttle. GENERAL INFORMATION After-Race Checks After racing, first clean the motorcycle (see p. 126), then inspect the entire motorcycle with special attention to the air cleaner, carburetor, brakes, etc. Carry out the general lubrication (see p. 128) and make necessary adjustments. MAINTENANCE AND ADJUSTMENT MAINTENANCE AND ADJUSTMENT Periodic Maintenance Chart The maintenance and adjustments outlined in this chapter are easily carried out and must be done in accor- dance with the Periodic Maintenance Chart to keep the motorcycle in good running condition.

MAINTENANCE AND ADJUSTMENT FREQUENCY After each Every 3 Every 6 Every 12 race (or races (or races (or races (or required Page OPERATION 2.5 hour) 7.5 hour) 15 hour) 30 hour). – Kick pedal and shift pedal - clean. MAINTENANCE AND ADJUSTMENT 2. Periodic Inspection (Chassis Related Item) FREQUENCY After each Every 3 Every 6 Every 12 race (or races (or races (or races (or required Page OPERATION 2.5 hour) 7.5 hour) 15 hour) 30 hour). Brake adjustment - inspect †. MAINTENANCE AND ADJUSTMENT FREQUENCY After each Every 3 Every 6 Every 12 race (or races (or races (or races (or required Page OPERATION 2.5 hour) 7.5 hour) 15 hour) 30 hour).Swingarm and UNI-TRAK linkage.

– pivots - inspect.Swingarm and UNI-TRAK linkage.Fuel hose - replace † Every 4 years –.Rear shock absorber oil - replace †: Replace, add, adjust, clean or torque if necessary.: Should be serviced by referring to the Service Manual or an authorized Kawasaki dealer. MAINTENANCE AND ADJUSTMENT NOTE Engine Oil To achieve better engine performance and less weight, the engine oil capacity of this model is 0.5 In order for the engine, transmission and clutch L less than the previous model. To function properly, maintain the engine oil at the In order to keep the engine in good condition, proper level, and change the oil and oil filter period- maintain the proper engine oil level and change. MAINTENANCE AND ADJUSTMENT. visible then return to an upright position.

If no oil Remove the oil filler cap. appears even when tipped at an extreme angle, Remove the oil drain plugs and position the vehi- remove drain plugs to empty any oil that may be in cle perpendicular to the ground to allow all the oil the transmission and crankcase, reinstall the drain to drain. MAINTENANCE AND ADJUSTMENT A. Oil Filter Cover A. Oil Filter Element B. Grommet. Replace the oil filter element with a new one.

Apply a little engine oil to the grommet. Install the oil filter element with the grommet to- ward the engine. MAINTENANCE AND ADJUSTMENT NOTE Engine Oil Drain Plug Tightening Torque Do not add any chemical additive to the oil. Oils Drain Plug 20 Nm (2.0 kgfm, 15 ftlb) fulfilling the above requirements are fully formu- lated and provide adequate lubrication for both the NOTE engine and the clutch. MAINTENANCE AND ADJUSTMENT and may suffer severe damage.

Check the coolant Cooling System level each day before riding the motorcycle, and re- plenish coolant if the level is low. Cooling Hoses WARNING Check the cooling hoses for cracks or deteriora- To avoid burns, do not remove the radiator tion, and the connections for looseness in accor- cap or change the coolant when the engine. MAINTENANCE AND ADJUSTMENT A. Radiator Cap A Coolant Level B. Filler Neck. Check the coolant level in the radiator. If the coolant level is low, add coolant through the coolant should come up to the bottom of the radiator filler opening to the bottom of the filler radiator filler neck.

MAINTENANCE AND ADJUSTMENT. CAUTION Install the radiator cap. Coolant Change Immediately wash away any coolant that The coolant should be changed to ensure long en- spills on the frame, engine, or wheel. Gine life, if necessary.

Wait for the engine to cool completely. MAINTENANCE AND ADJUSTMENT. Lean the motorcycle slightly to the right until the Spark Plug radiator filler neck is level to the ground so that the filler neck is located uppermost in order to exhaust the air accumulated in the radiator. CAUTION Use coolant containing corrosion inhibitors made specifically for aluminum engines.

MAINTENANCE AND ADJUSTMENT. If the plug is oily or has carbon built up on it, clean Apply a suitable wrench to the spark plug. it (preferably with a sandblaster) and then clean Loosen and remove the spark plug. 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 bolt and seat.

And can cause spark plug fouling. MAINTENANCE AND ADJUSTMENT hardening or shrinkage). If damaged, replace the element or it will allow dirt into the carburetor. WARNING A clogged air cleaner may allow dirt and dust to enter the carburetor and jam the throttle, which could cause an accident and injury. CAUTION A clogged air cleaner may allow dirt and dust to enter the engine, causing it to wear exces.

MAINTENANCE AND ADJUSTMENT Element Cleaning and Installation. Clean the element in a bath of a high flash point solvent or hot soapy water.

Rinse the element with clear water to remove all traces of the cleaning solution. Squeeze the element dry in a clean towel. CAUTION Do not twist, wring or blow the element dry to avoid damaging it. MAINTENANCE AND ADJUSTMENT. Before installation, check the element for damage such as tears, hardening, or shrinkage.

If dam- aged, replace the element. Apply grease to all mating surfaces and to the screw hole in the air cleaner housing and intake tract. MAINTENANCE AND ADJUSTMENT Throttle Cable Throttle Cable Adjustment Inspect the throttle grip for smooth operation in all steering positions. Check and adjust the throttle cable in accordance with the Periodic Maintenance Chart. Check that the throttle grip has 2 ∼ 3 mm (0.08 ∼ 0.12 in.) of play and turns smoothly. MAINTENANCE AND ADJUSTMENT.

Thoroughly warm up the engine. Carburetor Turn the idling adjusting screw to adjust the idling speed 1 900 ∼ 2 000 r/min (rpm) by using the en- gine revolution tester (The tester should be fol- Idling Adjustment lowed by the method described by the manufac- Idling adjustment is carried out using the pilot. MAINTENANCE AND ADJUSTMENT WARNING Carburetor Removal Operation with a damaged throttle cable WARNING could result in an unsafe riding condition. Gasoline is extremely flammable and can be explosive under certain conditions.

CAUTION Always stop the engine and do not smoke. Make sure the area is well-ventilated and free This motorcycle is designed for competition from any source of flame or sparks. MAINTENANCE AND ADJUSTMENT A. Side Covers B. Carburetor.

Remove the fuel tank together with left and right Remove the silencer (see the “Exhaust System' radiator covers (see the “Valve Clearance” sec- section). MAINTENANCE AND ADJUSTMENT. Remove the cable holder cover by removing the bolt. Rear Frame.

A. Bolt After removing the air cleaner housing, push a B. Cable Holder Cover clean, lint-free towel into the carburetor inlet and outlet to keep dirt or other foreign material from. MAINTENANCE AND ADJUSTMENT. Disconnect the throttle sensor connector. Throttle Cable Lower Ends B. Carburetor Pulley A.

Throttle Sensor Connector C. Accelerator Cable. D. Decelerator Cable Loosen the carburetor clamp screw.

MAINTENANCE AND ADJUSTMENT A. Float Bowl B.

Drain Plug C. Carburetor. Detach the carburetor from the carburetor clamp. Drain the fuel from the float bowl by removing the and hold it up above the vehicle. MAINTENANCE AND ADJUSTMENT WARNING Operation with an improperly adjusted, in- correctly routed, or damaged cable could re- sult in an unsafe riding condition. When installing the carburetor into the carburetor clamp, align the projection of the carburetor with groove in the carburetor clamp. MAINTENANCE AND ADJUSTMENT A.

Carburetor Projection A. Duct Groove B. Side Cover. Route the carburetor air vent and overflow hoses Turn the fuel tap lever to the ON position, and properly. Check for fuel leakage from the carburetor. MAINTENANCE AND ADJUSTMENT If the clutch lever play cannot be adjusted at the Clutch clutch lever, make the adjustment further down the cable as follows.

Turn the adjuster in all the way. Clutch Lever Adjustment. Loosen the locknut in the middle of the clutch ca- Proper clutch lever play is 8 ∼. MAINTENANCE AND ADJUSTMENT. NOTE Remove the clutch spring bolts, clutch pressure plate and springs. After the adjustment is made, start the engine and check that the clutch does not slip and that it re- leases properly.

Friction Plate Removal. MAINTENANCE AND ADJUSTMENT Friction Plate Thickness Measurement plate and steel plate warp with a thickness gauge (i.e., the gap between the surface plate and each 2.72 ∼ 2.88 mm Standard friction plate or steel plate). (0.1071 ∼ 0.1134 in.). If any plate is warped over the service limit, re- Service Limit 2.6 mm (0.102 in.). MAINTENANCE AND ADJUSTMENT Friction and Steel Plate Installation. Install all parts in the reverse order of removal.

Install the friction plates and steel plates, alternat- ing between the two; be sure to start and finish with a friction plate. MAINTENANCE AND ADJUSTMENT A. Release Shaft Lever A. Adjusting Washer B. Push forward B. Needle Bearing C. Position Distance C.

Push Rod Holder Assembly D. Cable Bracket Adjusting Washer. If the lever position is not within the standard, se- Thickness Part Number lect the correct thickness of adjusting washer ac. MAINTENANCE AND ADJUSTMENT Release Shaft Lever Position and adjusting Hot Starter Cable Washer Selection Wash- Position Judg- Proper hot starter lever play between the hot ers Thick- Quantity Distance ment starter lever and holder is 0.5 ∼ 1 mm (0.02 ∼ 0.04 ness in.). MAINTENANCE AND ADJUSTMENT. Unhook the rubber band, and disconnect the fuel Valve Clearance hose from the fuel tap. Remove the fuel tank together with left and right Valve and valve seat wear decreases valve clear- radiator covers.

Ance, upsetting valve timing. CAUTION If valve clearance is left unadjusted, wear will eventually cause the valves to remain partly. MAINTENANCE AND ADJUSTMENT A. Spark Plug Cap A. Cylinder Head Cover Bolts B. Cylinder Head Cover. Remove the cylinder head cover bolts and take off.

Remove the head cover gasket. The cylinder head cover. Head Cover Gasket. MAINTENANCE AND ADJUSTMENT. Remove the two caps from the generator cover. Ignition Timing Mark B.

Groove on Alternator Cover. Bring the piston to the Top Dead Center (TDC) of NOTE its compression stroke to inspect the valve clear- ance (the position at the end of the compression Do not mistake the top mark for ignition timing stroke) by aligning the top mark with the groove. 0.10 ∼ 0.15 mm (0.0039 ∼ 0.0059 in.) NOTE. If the valve clearance is not within the specified Record the measured valves clearance.

Range, adjust by an authorized Kawasaki dealer or a competent mechanic following the instructions in the Service Manual. Cylinder Head Cover Installation.

MAINTENANCE AND ADJUSTMENT A. Apply Silicone Sealant. Upper Chain Guide B. Cylinder Head Cover Gasket B. Cylinder Head Cover. Make sure that the upper chain guide is bottomed CAUTION to the cylinder head cover. Unless the upper chain guide is bottomed, the camshaft chain could push the cylinder head cover upward, leading to an oil leak.

MAINTENANCE AND ADJUSTMENT Exhaust System The exhaust system, in particular the silencer, 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 silencer, exhaust efficiency is reduced, causing engine per- formance to drop. MAINTENANCE AND ADJUSTMENT A. Silencer Pipe A.

Silencer Pipe B. Silencer Cover B. Silencer Packing C. Silencer Packing. Install the silencer pipe into the silencer cover.

Put new silencer packing over the silencer pipe. Apply silicone sealant so that no gaps are left be- tween the silencer pipe and silencer cover. MAINTENANCE AND ADJUSTMENT Drive Chain For safety and to prevent excessive wear, the drive chain must be checked, adjusted, and lubricated be- fore riding.

If the chain becomes badly worn or mal- adjusted - either too loose or too tight - it could jump off the sprockets or break. MAINTENANCE AND ADJUSTMENT notch of the right chain adjuster should align with the same swingarm mark that the notch of the left chain adjuster aligns with.

Drive Chain Slack 52 ∼ 58 mm (2.0 ∼ 2.3 in.) A. Chain Slack. MAINTENANCE AND ADJUSTMENT WARNING NOTE When inserting the cotter pin, if the slots in the Misalignment of the wheel will result in ab- nut do not align with the cotter pin hole in the normal wear and possibly in an unsafe riding axle shaft, tighten the nut clockwise up to the next condition.

MAINTENANCE AND ADJUSTMENT NOTE When riding in wet and muddy conditions, mud sticks to the chain and sprockets, resulting in an overly tight chain, which can cause it to break. To prevent this, adjust the chain slack (measured between the chain and the swingarm) to 62 ∼. MAINTENANCE AND ADJUSTMENT A. Master Link Clip A.

Chain Guide B. Direction of Rotation Chain Slipper Wear Inspection. Chain Guide Wear Inspection Visually inspect the upper and lower chain slippers. Visually inspect the drive chain guide and replace on the swingarm and replace them if worn or dam- it if excessively worn or damaged. MAINTENANCE AND ADJUSTMENT Sprocket Tooth Wear A.

Chain Slippers B. Good Teeth B. Worn Teeth Sprocket Wear Inspection C. Damaged Teeth. Visually inspect the sprocket teeth and replace the sprocket if its teeth are worn or damaged.

NOTE Sprocket wear is exaggerated in the illustration. MAINTENANCE AND ADJUSTMENT Handlebar To suit various riding positions, the handlebar can be adjusted by turning the handlebar holders around. Remove the handlebar pad. Check the handlebar for bent or crack.

Remove the handlebar clamp bolts, the clamps and the handlebar. MAINTENANCE AND ADJUSTMENT A. Handlebar Holders A. Handlebar Clamps B. Handlebar Holder Nuts B. Clamp Bolts C. Gap.

Put the handlebar on the handlebar holders. Torque the front and rear bolts of the handlebar Mount the handlebar clamps. MAINTENANCE AND ADJUSTMENT NOTE Brakes Tighten the two clamp bolts alternately two times to ensure even tightening torque.

Disc and disc pad wear is automatically compen- sated for and has no effect on the brake lever or pedal action. There are no parts on the brakes that require adjustment except brake lever position. MAINTENANCE AND ADJUSTMENT. CAUTION Test the braking power and check that there is no brake drag. Do not spill brake fluid onto any painted sur- face. WARNING Do not use fluid from a container that has If the brake lever or pedal feels mushy, there been left open or that has been unsealed for might be air in the brake lines or the brake a long time.

MAINTENANCE AND ADJUSTMENT A. Rear Reservoir A. Front Reservoir B. Minimum Level Line B. Maximum Level Line.

If the brake fluid in the front or rear reservoir is be- low the minimum level line, check for fluid leaks in the brake line and fill the reservoir to the maxi- mum level line. (front or rear) brake caliper is less than 1 mm (0.04 in.), have both pads in the caliper replaced as a set. Pad replacement should be done by an authorized Kawasaki dealer. Lining Thickness B. 1 mm (0.04 in.). MAINTENANCE AND ADJUSTMENT Steering Adjustment. Steering Raise the front wheel off the ground using a jack (special tool).

The steering should always be kept adjusted so Remove the number plate. that the handlebar will turn freely but not have ex- Remove the handlebar. MAINTENANCE AND ADJUSTMENT NOTE Tighten the two clamp bolts alternately two times to ensure even tightening torque.

Install the handlebar, check the steering again and readjust it if necessary. Stem Nut Wrench (P/N. Steering Stem Locknut. Basically, there are six adjustments you can make If necessary, repair or replace by an authorized to the front fork. Kawasaki dealer.

Air Pressure Air pressure acts as a progressive spring over the entire fork travel range. Since the air pressure in the fork legs increases with normal use, the fork action on your KX will get stiffer as the race progresses. MAINTENANCE AND ADJUSTMENT Air Pressure Adjustment This adjustment affects how quickly the fork com- presses.

Depending on the model, the fork com- The standard air pressure in the front fork legs is pression damping adjuster has at least 22 positions. Atmospheric (0 kPa, 0 kgf/cm², 0 ftlb). MAINTENANCE AND ADJUSTMENT Compression Damping Adjustment Compression Damping Adjuster Settings. To adjust the compression damping, turn the ad- juster on each front fork base valve assembly with a flat-head screwdriver. Adjust the compression damping to suit your preference under certain con- ditions.

MAINTENANCE AND ADJUSTMENT Rebound Damping Adjustment Rebound Damping Adjuster Settings. Clean the bottom of the fork tubes. To adjust the rebound damping, turn the adjuster on the each front fork cylinder valve with a flat -head screwdriver. Adjust the rebound damping to suit your preference under certain conditions. MAINTENANCE AND ADJUSTMENT. Install the caps on the bottom of the fork tubes. Loosen the front fork cylinder unit with the top plug wrench (special tool).

Front Fork Oil Change. NOTE Thoroughly clean the fork before disassembly. Do not take off the base valve assembly. MAINTENANCE AND ADJUSTMENT. Support the motorcycle using a jack (special tool). Loosen the right front axle clamp bolts. Unscrew the front axle nut, and then loosen the Place a suitable stand under the engine to raise left front axle clamp bolts.

MAINTENANCE AND ADJUSTMENT A. Upper Front Fork Clamp Bolts A. Pull down by twisting. Lower Front Fork Clamp Bolts B. Front Fork. Remove the front fork by pulling down while twist- Measure the length between the axle holder and ing it. MAINTENANCE AND ADJUSTMENT A.

Measure the length A. Top Plug Wrench (P.N.

Fork Cylinder Unit. Using the top plug wrench (special tool), remove C. Outer Tube the fork cylinder unit from the outer tube and slowly. Place a drain pan under the front fork and drain slide down the outer tube. MAINTENANCE AND ADJUSTMENT A. Fork Cylinder Unit B. Outer Tube.

Raise the outer tube and temporarily install the C. Top Plug Wrench (P.N. ) fork cylinder unit to the outer tube using the top.

Hold the axle holder with a vise. Plug wrench (special tool). MAINTENANCE AND ADJUSTMENT NOTE When removing the adjuster assembly, do not force to loosen it at once using an impact wrench. Top Plug Wrench (P.N. Axle Holder Bottom C. Locknut. Hold the locknut with a wrench and remove the A.

MAINTENANCE AND ADJUSTMENT A. Wrench. With the outer tube compressed by hand, remove C. Adjuster Assembly the top plug wrench (special tool). Remove the push rod. CAUTION Removing the locknut and pushing the pis- ton rod thread into the cylinder unit will dam- age the oil seal. MAINTENANCE AND ADJUSTMENT A.

Top Plug Wrench (P.N. Fork Cylinder Unit B.

Outer Tube. Remove the fork leg from the vise. Top Plug Wrench (P.N. ). Loosen the fork cylinder unit with the top plug. MAINTENANCE AND ADJUSTMENT A.

Cylinder Unit A. Top Plug Wrench (P.N.

Fork Spring B. Base Valve Assembly C. Piston Rod C. Fork Cylinder Unit. Holding the top plug wrench (special tool) with a Remove the base valve assembly from the fork vise, loosen the base valve assembly on the fork cylinder unit.

MAINTENANCE AND ADJUSTMENT A. Base Valve Assembly A.

Fork Cylinder Unit B. Fork Cylinder Unit. Hold the front fork at the inverted position for more NOTE than 20 minutes to allow the fork oil to fully drain. Slowly compress the piston rod until it stops so that the base valve assembly can be removed easily. MAINTENANCE AND ADJUSTMENT. Clean the threads of fork cylinder unit and base valve assembly. Fork Cylinder Unit A.

Piston Rod. With the piston rod fully stretched, pour 180 mL Recommended Fork Oil (6.19 US oz.) of fork oil. MAINTENANCE AND ADJUSTMENT A. Pump the Piston.

42 ∼ 49 mm (1.65 ∼ 1.93 in.) B. Piston Rod B. Oil Level. With the piston rod fully stretched, check the oil Replace the O-ring on the base valve assembly level in the fork cylinder unit. MAINTENANCE AND ADJUSTMENT A. Base Valve Assembly B.

Bushings. Hold the top plug wrench (special tool) with a vise.

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With the piston rod held immovable fully stretched, Holding the fork cylinder unit with the top plug gently install the base valve assembly to the fork wrench (special tool), torque the base valve as- cylinder unit. MAINTENANCE AND ADJUSTMENT CAUTION Be careful not to bend or damage the pis- ton rod when the piston rod is stroked. Ser- vice carefully because oil flies out from the oil hole of the cylinder unit. Top Plug Wrench (P.N. MAINTENANCE AND ADJUSTMENT.

Blow out the extra oil from the oil hole of the cylin- Hold the fork cylinder unit on level ground while der unit with the compressed air blow to the oil piston rod is full stroked by your hand. MAINTENANCE AND ADJUSTMENT. There should be no oil leak from the cylinder unit. Completely wipe off the fork oil from the spring and.

If oil leaks from the cylinder unit, replace the cylin- fork cylinder unit. der unit assembly. MAINTENANCE AND ADJUSTMENT WARNING Be careful of reaction force in spring and fix surely so that special tool should not come off. Do not place the fingers etc. While serving.

Fork Cylinder Unit B. Outer Tube C.

Top Plug Wrench (P.N. MAINTENANCE AND ADJUSTMENT A. Adjuster Assembly B.

Locknut. Replace the O-ring on the adjuster assembly with C. More Than 1 mm (0.04 in.) new ones and apply specified fork oil to the O-ring. Turn the locknut counterclockwise until it contacts Slowly turn the adjuster assembly clockwise until with the adjuster assembly. MAINTENANCE AND ADJUSTMENT A. Axle Holder Part B. Adjuster Assembly C.

Adjuster Assembly C. Torque Wrench D. Torque Wrench. Compare the length at assembly and at disassem-.

With the outer tube compressed by hands, remove bly. MAINTENANCE AND ADJUSTMENT A. Top Plug Wrench (P.N. Outer Tube B. Fork Cylinder Unit B. Outer Tube CAUTION. Pour the specified amount of fork oil into the outer tube.

Be sure the oil capacity is the same in both fork legs. MAINTENANCE AND ADJUSTMENT.

When changing the fork spring, the oil quantity is as shown in the table. Standard Oil 371 ml Quantity (12.5 US oz.) SOFT 316 ∼ 412 ml (K = 4.3 Nmm) Adjustable (10.7 ∼ 13.9 US Range oz.) Standard Oil. MAINTENANCE AND ADJUSTMENT (12.2 in.) between the grip point to the center of the coupling square. Tighten the front fork upper clamp bolts to the specified torque. Front Fork Upper Clamp Bolts Tightening Torque 20 Nm (2.0 kgfm, 15 ftlb) A. MAINTENANCE AND ADJUSTMENT.

Apply grease to the oil seals of the wheel. Install the caps and collars on the left and right side of the hub. Put the front wheel assembly between the fork legs, and insert the front brake disc into the front brake pads. MAINTENANCE AND ADJUSTMENT the right fork leg to find a neutral position on the Right Front Axle Clamp Bolt Tightening Torque front axle. 20 Nm (2.0 kgfm, 15 ftlb) NOTE Do not apply the front brake during this process WARNING to stop the motorcycle from rolling forward. Standard Fork Clamp Position leakage. 7 mm (0.28 in.).

If necessary, repair or replace by an authorized Kawasaki dealer. below the surface of the top plug Rear Shock Absorber Adjustment NOTE The spring preload of the shock absorber can be. MAINTENANCE AND ADJUSTMENT Rebound Damping Adjuster Settings A.

Rebound Damping Adjuster If the damping feels too soft or too stiff, adjust it in A. Seated Position (Adjuster Turned Fully Clockwise) accordance with the following table. Softer (Counterclockwise) C. Harder (Clockwise) D. MAINTENANCE AND ADJUSTMENT CAUTION Do not force the rebound and compression damping force adjusters beyond the fully seated position, or the adjusting mechanism may be damaged. NOTE Adjustment of the rebound damping adjuster for the rear suspension will slightly affect the com- pression damping force. MAINTENANCE AND ADJUSTMENT CAUTION Low Speed Compression Damping Adjuster Settings Do not force the rebound and compression damping force adjusters beyond the fully seated position, or the adjusting mechanism may be damaged.

NOTE Adjustment of the rebound damping adjuster for the rear suspension will slightly affect the com- pression damping force. MAINTENANCE AND ADJUSTMENT A. Spring Preload Adjusting Nut A. Hook Wrench (P.N. Spring Preload Adjusting Nut C. Hook Wrenches (P.N.

). The standard adjusting nut position from the cen-. Using the hook wrench (special tool), turn the ter of the upper rear shock absorber pivot point is spring preload adjusting nut as required.

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. Adjusting Nut Position B. Spring Preload Adjusting Nut. MAINTENANCE AND ADJUSTMENT WARNING Wheels This unit contains high pressure nitrogen gas.

Mishandling can cause explosion. Tire Air Pressure Adjustable Range Read Service Manual for instructions. Tire air pressure affects traction, handling, and tire Do not incinerate, puncture or open.

MAINTENANCE AND ADJUSTMENT Spokes and Rims The spokes on both wheels must all be securely and evenly tightened and not be allowed to loosen. Unevenly tightened or loose spokes will cause the rim to warp, the nipples and spokes to fatigue more quickly, and the spokes to break. MAINTENANCE AND ADJUSTMENT NOTE The welding spot of the rim may show exces- sive runout. Disregard this when measuring rim runout.

Rim Runout A. Axial Rim Runout Measurement A.

Radial Runout C. Axial Runout Rim Runout Maximum Limit Axial 1.0 mm (0.04 in.) Radial. MAINTENANCE AND ADJUSTMENT 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 brake hose and fittings for deteriora- tion, 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 19.

Silencer Pipe Mounting 28. Uni-Trak Arm Bolt 24. Front Master Cylinder Bolts Mounting Bolts 29. Kick Pedal Pivot Bolt 20.

Silencer Cover Mounting 25. Rear Axle Nut 30. Engine Oil Drain Plugs ® Bolts 26. UNI-TRAK Lever Rod Bolt 31. 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 Part Name Nm kgfm ftlb Brake Caliper Bolts (Front) Brake Disc Mounting Bolts (Front) (89 inlb) (Rear) Engine Mounting Bolts Front Axle Nut Front Axle Clamp Bolts Front Fork Clamp Bolts (Upper) (Lower) Silencer Bolts Silencer Cover Bolts (106 inlb) Fork Cylinder Unit Handlebar Clamp Bolts. MAINTENANCE AND ADJUSTMENT Part Name Nm kgfm ftlb Rear Shock Absorber Lower Nut Spokes (19 inlb) Steering Head Nut 10.0 Steering Stem Locknut (43 inlb) ® UNI-TRAK Arm Bolt.

® UNI-TRAK Rod Bolts. Rear Sprocket Nuts Front Brake Master Cylinder Clamp Bolts (78 inlb) Rear Brake Master Cylinder Mounting Bolts (89 inlb).

General Precautions Washing Your Motorcycle Frequent and proper care of your Kawasaki mo-. torcycle will enhance its appearance, optimize over- Rinse your bike with cold water from a garden all performance, and extend its useful life. Covering hose to remove any loose dirt.

MAINTENANCE AND ADJUSTMENT Chrome and Aluminum accelerates the chemical reaction of the salt. Af- ter drying, apply a corrosion protection spray on all Chrome and uncoated aluminum parts can be metal and chrome surfaces to prevent corrosion. Treated with a chrome/aluminum polish. Coated aluminum should be washed with a mild neutral de- Painted Surfaces.

MAINTENANCE AND ADJUSTMENT. Foot peg Lubrication Lubricate the areas shown in the illustrations of this section with either motor oil or regular grease, after each race and whenever the vehicle has been operated under wet or rainy conditions, especially after using a high-pressure spray washer. MAINTENANCE AND ADJUSTMENT Apply an aerosol cable lubricant with a pressure Apply grease to the following points:. lubricator on all cables: Upper end of clutch cable. Clutch cable Upper end of throttle cable. Throttle cable Upper end of hot starter cable.

MAINTENANCE AND ADJUSTMENT Drive Chain Lubrication Lubricate the drive chain after riding through rain or on wet track, or any time that the chain appears dry. A heavy oil such as SAE 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication. TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE NOTE Engine flooded. Fuel level too high This troubleshooting guide is not exhaustive and. Float valve worn or stuck open does not give every possible cause for each prob-.

Wrong starting technique (when the engine is lem listed. TROUBLESHOOTING GUIDE Compression low Fuel-air mixture incorrect. Spark plug loose Idling adjusting/pilot screw improperly adjusted. Cylinder head insufficiently tightened Slow jet, Needle jet or air passage clogged. Cylinder nut loose Air cleaner element clogged, poorly sealed, or not. TROUBLESHOOTING GUIDE. Other Fuel supply to carburetor insufficient.

Engine oil viscosity too high Fuel contaminated with water or foreign matter. Brake dragging Fuel tank air vent obstructed. Ignition timing incorrect Carburetor holder loose. TROUBLESHOOTING GUIDE. Fuel contaminated with water or foreign matter Compression high. Brake dragging Carbon built up in combustion chamber.

Clutch slipping. Engine overheating Engine overloaded. Brake dragging Engine oil level too high.

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TROUBLESHOOTING GUIDE. Clutch not disengaging properly Gear dogs and/or dog grooves worn. Clutch lever play excessive Shift drum groove worn. Clutch plate warped or too rough Gear positioning lever spring weak or broken.

Clutch spring tension uneven Shift fork pin worn. TROUBLESHOOTING GUIDE. Other noise Output shaft idle gear worn or chipped. Connecting rod small end clearance excessive. Connecting rod big end clearance excessive Drive chain noise. Piston ring worn, broken or stuck Drive chain slack improperly adjusted.

TROUBLESHOOTING GUIDE. Exhaust smoke – Tire air pressure too low Excessively white Handlebar shakes or vibrates excessively. Piston oil ring worn. Tire worn. Cylinder worn. Swingarm sleeve or needle bearing damaged.

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Valve oil seal damaged. TROUBLESHOOTING GUIDE Shock absorption unsatisfactory (suspension too soft). Front fork oil level insufficient and/or front fork leaking oil. Front fork oil viscosity too low. Front fork and/or rear shock absorber spring weak. Rear shock absorber leaking gas.

ENGINE AND SUSPENSION TUNING ENGINE AND SUSPENSION TUNING Symptoms of Improper Mixture Carburetor Tuning If your machine exhibits one or several of the symptoms listed below, it may need carburetor Tuning a carburetor is not the mysterious science tuning. Before attempting any changes, however, many racers believe it to be.

ENGINE AND SUSPENSION TUNING Symptoms when the mixture is too lean Pinging or rattling Erratic acceleration Same as when running out of fuel High engine temperature 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. ENGINE AND SUSPENSION TUNING If you note a particular symptom of too rich or lean A. Slow Jet mixture in a specific operating range, use the chart to C. Jet Needle determine which components need adjusting. ENGINE AND SUSPENSION TUNING allowed to pass through.

There are seven grooves Slow Jet and Pilot Screw – in the top of the jet needle in which a clip fits. This The slow jet and pilot screw control the mixture clip positions the jet needle in the throttle valve rel- in the closed-to-1/8-throttle range, but have little ef- ative to the needle jet. ENGINE AND SUSPENSION TUNING If the spark plug insulator is whitish, the fuel-air mixture is too lean. Increase the main jet size by one step.

If the spark plug insulator is wet, the fuel-air mix- ture is too rich. Reduce the main jet size by one step. ENGINE AND SUSPENSION TUNING Correction Factor Applied to the Jet Needle and Pilot 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 Jet needle setting same position position. ENGINE AND SUSPENSION TUNING. Standard Carburetor Settings Change the jet needle clip position and pilot screw opening according to the appropriate chart on the Pilot screw opening 2-1/8 previous page. Throttle valve diameter EXAMPLE: For a correction factor of 0.94, raise the Slow jet needle clip one position and turn in the pilot screw one turn.

ENGINE AND SUSPENSION TUNING. When evaluating suspension performance, the Suspension Tuning rider must make every effort to ride consistently and to recognize the effects of his input.

Such things as changes in rider position and increasing Introduction fatigue may lead to incorrect judgments about No area of machine adjustment is more critical necessary adjustments. ENGINE AND SUSPENSION TUNING Troubleshooting Improper Settings Fork Oil Quantity 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. ENGINE AND SUSPENSION TUNING. Fork oil deteriorated Hence, if the actual rider weighs considerably more.

Rebound and/or compression damping improperly or less, or if his riding experience and ability are adjusted. Much above or below the intermediate level, it is likely that a few basic suspension adjustments will Rear shock absorber improper adjustment be necessary.

ENGINE AND SUSPENSION 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). ENGINE AND SUSPENSION TUNING. Although this is one of the most effective adjust- Use a softer spring.

Ment procedures, suspension settings may vary de- NOTE pending on the conditions at the track and the rider’s Lighter or less experienced riders may need a preferences. ENGINE AND SUSPENSION TUNING NOTE Front and Rear Ends Bottom Off After a High-speed Jump (harsh bottoming occurs The rear shock absorber behavior on this machine once or twice per lap) – may mislead some riders. The front suspension is too soft. The rear shock absorber bottoms (due to full.

ENGINE AND SUSPENSION 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.

ENGINE AND SUSPENSION TUNING Take care not to overheat the engine in these con- Special Care According to Track ditions. The engine also works very hard when Conditions riding in deep sand. In muddy or sandy conditions, increase chain. OPTIONAL PARTS OPTIONAL PARTS Carburetor Carburetor Main Jet #172 Jet needle #175 Richer NHJR #178 NHJS #180 NHJT (Standard) NHJU #182 (Standard) #185 Leaner NHJV Richer NHKR #188 #190 NHKS NHKT #192 NHKU Slow jet Leaner NHKV #40 (Standard) NOTE NHJ. is 0.5 clip position leaner than NHK.

OPTIONAL PARTS Engine Sprocket Suspension Spring (Nmm) Front K = 4.3 13T (Standard) K = 4.5 (Standard) Rear Sprocket K = 4.7 Aluminum Rear K = 47 K = 49 48T (Standard) K = 51 (Standard) K = 53 Disc plate Steel Front no holes (for wet conditions). PRE-RACE CHECKS AND AFTER-RACE MAINTENANCE PRE-RACE CHECKS AND AFTER-RACE MAINTENANCE.

Pre-race Checks – Coolant level. Front axle nut, or axle clamp nut tightness Oil applied to air cleaner element.

Front fork clamp bolt tightness Maintenance After the First Race –. PRE-RACE CHECKS AND AFTER-RACE MAINTENANCE. Clean the air cleaner element. Chain case. Check the cylinder and crankshaft big end. Front springs (for suspension adjustment).

Grease the throttle grip and control cables. Rear shock absorber spring (for suspension ad- justment) Suggested Spare Parts –. STORAGE STORAGE WARNING Before Storage Gasoline is extremely flammable and can be explosive under certain conditions. Always When the motorcycle is to be stored for any length stop the engine and never smoke while han- of time, it should be prepared for storage as follows. STORAGE After Storage. Remove the plastic bag from the muffler. Make sure the spark plug is tight.

NOTE Fit the plug cap securely onto the spark plug, and pull the cap lightly to make sure that it is properly installed. ENVIRONMENTAL PROTECTION To protect our environment, properly discard used tires, engine oil, or other vehicle components that you might dispose of in the future. Consult your authorized Kawasaki dealer or local environmental waste agency for the proper disposal pro- cedure. WIRING DIAGRAM WIRING DIAGRAM.