2013 Kawasaki KX100 Owners Manual

2013 Kawasaki KX100 Manual

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  • 2013 Kawasaki KX100 | Owners Manual - Page 1
  • 2013 Kawasaki KX100 | Owners Manual - Page 2
  • 2013 Kawasaki KX100 | Owners Manual - Page 3
    Quick Reference Guide This Quick Reference Guide will assist you in finding the information you're looking for. GENERAL INFORMATION MAINTENANCE AND ADJUSTMENT TROUBLESHOOTING GUIDE ENGINE AND SUSPENSION TUNING STORAGE j j j j j A Table of Contents is included after the Foreword.
  • 2013 Kawasaki KX100 | Owners Manual - Page 4
    IMPORTANT INFORMATION KX models are designed for the operator only, no passengers. • Kawasaki motorcycle is designed for competition only on a closed course. • This intended for use on public streets. • Not • Read your owner's manual, it contains important information.
  • 2013 Kawasaki KX100 | Owners Manual - Page 5
    shown below, heed their instructions! Always follow safe FOR GENERAL OFF-ROAD RECREATIONAL RIDING. READ OWNER'S MANUAL. DANGER DANGER indicates a hazardous situation which, if not all responsibilities concerning quality, performance, cost of service and/or necessary repairs. NOTICE NOTICE is
  • 2013 Kawasaki KX100 | Owners Manual - Page 6
    a wonderful sport, and we hope you will enjoy it to the fullest. However, if improperly conducted, this sport has the potential to cause environmental problems as well as conflicts with other people. TO PROTECT THE FUTURE OF YOUR SPORT, MAKE SURE YOU USE YOUR MOTORCYCLE LEGALLY, SHOW CONCERN FOR THE
  • 2013 Kawasaki KX100 | Owners Manual - Page 7
    tuned competition machine for participation in racing events. As with any mechanical device, proper care and maintenance are important for trouble-free operation and top performance. This manual is written to enable you to keep your KX properly tuned and adjusted. Due to improvements in design and
  • 2013 Kawasaki KX100 | Owners Manual - Page 8
    techniques. Read and understand the owner's manual provided with the motorcycle. Review all instructions and warnings with your child. 6. riding the motorcycle. Also, familiarity with the motorcycle is important should a problem occur far from help. 9. Do not allow your child to ride unsupervised
  • 2013 Kawasaki KX100 | Owners Manual - Page 9
    ...Steering ...Front Fork ...Rear Suspension (UNI-TRAK®)...Wheels ...Tightening Nuts and Bolts ...Cleaning Your Motorcycle...Lubrication...TROUBLESHOOTING GUIDE...ENGINE AND SUSPENSION TUNING...Carburetor Tuning ...Suspension Tuning...Gearing...Special Care According to Track Conditions . OPTIONAL
  • 2013 Kawasaki KX100 | Owners Manual - Page 10
    8 SPECIFICATIONS SPECIFICATIONS DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Road Clearance Curb Mass Fuel Tank Capacity ENGINE Type Bore x Stroke Displacement Compression Ratio Port Timing: Intake: Scavenging: Open Close Open Close 2-stroke, single-cylinder, piston reed valve,
  • 2013 Kawasaki KX100 | Owners Manual - Page 11
    SPECIFICATIONS 9 Exhaust: Carburetor Lubrication System Starting System Ignition System Ignition Timing Spark Plug Spark Plug Terminal TRANSMISSION Transmission Type Clutch Type Driving system Gear Ratios: 1st Gear 2nd Gear 3rd Gear 4th Gear 5th Gear 6th Gear 6-speed, Constant Mesh, Return Shift Wet
  • 2013 Kawasaki KX100 | Owners Manual - Page 12
    10 SPECIFICATIONS Primary Reduction Ratio Final Reduction Ratio Overall Ratio (Top Gear) Transmission Oil: Capacity Grade Viscosity FRAME Type Steering Angle Castor Trail Tire Size, Type: Front Rear Rim Size Front Rear Suspension: Front Suspension Stroke Rear Wheel Travel Front Rear Tubular, SEMI
  • 2013 Kawasaki KX100 | Owners Manual - Page 13
    SPECIFICATIONS 11 Front Fork Oil (Each): KHL15-10 (KAYABA 01) or equivalent, 311 ∼ 319 mL (10.5 ∼ 10.8 US oz) *317 ∼ 325 mL (10.7 ∼ 10.9 US oz) Front Fork Oil Level (Compressed, spring removed) BRAKES Type Effective Disc Diameter (Front & Rear) Disc Brake Front Rear *: KX100D Specifications subject
  • 2013 Kawasaki KX100 | Owners Manual - Page 14
    12 GENERAL INFORMATION j GENERAL INFORMATION Location of Parts 1. Clutch Lever 2. Engine Stop Button 3. Fuel Tank Cap 4. Front Brake Fluid Reservoir 5. Front Brake Lever 6. Throttle Grip
  • 2013 Kawasaki KX100 | Owners Manual - Page 15
    GENERAL INFORMATION 13 j 7. Front Fork 8. Fuel Tank 9. Carburetor 10. Seat 11. Air Cleaner Element 12. Silencer 13. Brake Disc 14. Brake Caliper 15. Shift Pedal 16. Rear Shock Absorber 17. Swingarm 18. Chain Guide 19. Drive Chain
  • 2013 Kawasaki KX100 | Owners Manual - Page 16
    14 GENERAL INFORMATION j 20. 21. 22. 23. 24. 25. 26. 27. 28. Rear Shock Absorber Gas Reservoir Rear Brake Fluid Reservoir Kick Pedal Fuel Tap Radiator Rear Brake Pedal Transmission Oil Level Inspection Window Water Pump Cover Exhaust Pipe
  • 2013 Kawasaki KX100 | Owners Manual - Page 17
    with the provided side stand. Install the upper end of the side stand into the hole at the rear of the left footpeg. NOTE j żSupport the motorcycle by using the suitable stand when performing the maintenance or adjustment. A. Side Stand B. Hole WARNING Riding with the side stand can cause
  • 2013 Kawasaki KX100 | Owners Manual - Page 18
    immediately. Fuel Requirements: Fuel Type Use clean, fresh unleaded gasoline with a minimum Antiknock index of 90. The Antiknock Index is posted on service station pumps in the U.S.A. The octane rating of a gasoline is a measure of its resistance to detonation or "knocking." The Antiknock Index is
  • 2013 Kawasaki KX100 | Owners Manual - Page 19
    unleaded gasoline and methanol (wood alcohol) whenever possible, and never use "gasohol" containing more than 5% methanol. Fuel system damage and performance problems may result. Gasoline/Ether Blends - The most common ether is methyl tertiary butyl ether (MTBE). You may use gasoline containing up
  • 2013 Kawasaki KX100 | Owners Manual - Page 20
    fuel tank and carburetors. See the Storage section in this manual. Recommended Oil Kawasaki Performance 2-Stroke Racing Oil* or equivalent for your vehicle. Consistent use of these products meets or exceeds warranty and service requirements and can help to extend the life of your Kawasaki. Gasoline-
  • 2013 Kawasaki KX100 | Owners Manual - Page 21
    GENERAL INFORMATION 19 żThe lubricative quality of the gasoline-oil mixture deteriorates rapidly; therefore, prepare a fresh mixture for each day of operation. j Kick Pedal This motorcycle starting system is primary kick. When the clutch lever is pulled, the motorcycle can be started with the
  • 2013 Kawasaki KX100 | Owners Manual - Page 22
    20 GENERAL INFORMATION j Starting the Engine • Turn the fuel tap lever to the ON position. A. Choke Knob after the engine has started, do not push • Even down the choke knob until the engine is thoroughly A. Fuel Tap B. OFF position C. ON position warmed up. NOTE sure the transmission is in
  • 2013 Kawasaki KX100 | Owners Manual - Page 23
    GENERAL INFORMATION 21 j Shifting Gears This motorcycle is equipped with a 6-speed "return shift" transmission. The neutral is located halfway between 1st and 2nd gear. "Return shift" means that when shifting up or down, each gear must be engaged before the next higher or lower gear may be selected
  • 2013 Kawasaki KX100 | Owners Manual - Page 24
    22 GENERAL INFORMATION j 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. Independent use of the front or rear brake may be advantageous in certain circumstances. Shift down
  • 2013 Kawasaki KX100 | Owners Manual - Page 25
    GENERAL INFORMATION 23 Break-In A brief break-in procedure must be carried out to obtain the proper operating clearances in the engine and transmission, which are necessary for performance and reliability. NOTE j żThe low-speed operation during the break-in pe- riod may cause carbon to build up
  • 2013 Kawasaki KX100 | Owners Manual - Page 26
    is ready for regular operation. Using the proper riding skills and techniques and avoiding recklessly high engine speeds will keep the engine trouble-free. NOTE Piston: żAfter break-in, install a new standard spark plug, and change the transmission oil. żTo keep optimum engine performance
  • 2013 Kawasaki KX100 | Owners Manual - Page 27
    GENERAL INFORMATION 25 j 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
  • 2013 Kawasaki KX100 | Owners Manual - Page 28
    26 GENERAL INFORMATION Muffler ...Engine Sprocket ...Frame Tires ...Spokes ...Drive Chain ...Front and Rear Brakes ...Throttle ...Steering ...Front Fork ...Rear Shock Absorber ...Fuel Tank ...Rear Sprocket ...Engine Stop Button ...Nuts, Bolts, Fasteners ...Apply oil to air cleaner element No damage
  • 2013 Kawasaki KX100 | Owners Manual - Page 29
    GENERAL INFORMATION 27 j After-Race Checks After racing, first clean the motorcycle (see p. 98), then inspect the entire motorcycle with special attention to the air cleaner, carburetor, brakes, etc. Carry out the general lubrication (see p. 100) and make necessary adjustments.
  • 2013 Kawasaki KX100 | Owners Manual - Page 30
    28 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 accordance with the Periodic Maintenance Chart to keep the motorcycle in good running condition. FREQUENCY After
  • 2013 Kawasaki KX100 | Owners Manual - Page 31
    MAINTENANCE AND ADJUSTMENT 29 FREQUENCY OPERATION Small end bearing-check † Kick pedal and shift pedal-clean Exhaust pipe O-ring-replace Engine sprocket-check † Coolant-check † Radiator hoses/connections-check † *Reed valve-check† Brake adjustment-check † Brake pad wear-check † Brake fluid level-
  • 2013 Kawasaki KX100 | Owners Manual - Page 32
    ) 12.5 hours) hours) hours) j OPERATION Drive chain-adjust Drive chain-lubricate • • • 67 72,102 Drive chain wear-check † Chain slipper and guide-replace Front fork-inspect/clean *Front fork oil-change Nuts, bolts/fasteners-check † Fuel system-clean Fuel hose-replace *Brake hoses, connections
  • 2013 Kawasaki KX100 | Owners Manual - Page 33
    -check *Rear shock oil-change • 1st time after 2 races, then every 5 races 72 100 - - - - †: Replace, add, adjust, clean or torque if necessary. R: Replace *: Should be serviced by referring to the Service Manual or an authorized Kawasaki dealer.
  • 2013 Kawasaki KX100 | Owners Manual - Page 34
    , and injury. Check the oil level before each ride and change the oil according to the periodic maintenance chart in the owner's manual. Oil Level Inspection A. Oil Level Inspection Window B. Oil Filler Cap C. Center of oil inspection window the motorcycle perpendicular to the ground. • Place
  • 2013 Kawasaki KX100 | Owners Manual - Page 35
    -40 *Kawasaki Performance Oils and Lubricants have been specifically engineered for your vehicle. Consistent use of these products meets or exceeds warranty and service requirements and can help to extend the life of your Kawasaki. j NOTE żDo not add any chemical additive to the oil. A. Oil Drain
  • 2013 Kawasaki KX100 | Owners Manual - Page 36
    34 MAINTENANCE AND ADJUSTMENT Cooling System Radiator Hoses Check the radiator hoses for cracks or deterioration, and the connections for looseness in accordance with the Periodic Maintenance Chart. j Radiator Check the radiator fins for obstruction by insects or mud. Clean off any obstructions
  • 2013 Kawasaki KX100 | Owners Manual - Page 37
    MAINTENANCE AND ADJUSTMENT 35 WARNING The cooling system can get extremely hot during normal operation and cause serious burns. Do not touch the radiator when it is hot, nor open the radiator cap. Hot coolant inside will cause severe burns. j NOTE żThe coolant originally filled into the cooling
  • 2013 Kawasaki KX100 | Owners Manual - Page 38
    36 MAINTENANCE AND ADJUSTMENT j A. Radiator Cap A. Coolant Level B. Radiator Filler Neck the coolant level in the radiator. The • Check coolant should come up to the bottom of the radiator filler neck. the coolant level is low, add coolant through the • If radiator filler opening to the bottom
  • 2013 Kawasaki KX100 | Owners Manual - Page 39
    MAINTENANCE AND ADJUSTMENT 37 • Install the right radiator cover Coolant Change The coolant should be changed periodically to ensure long engine life. Wait for the engine to cool completely. Lean the motorcycle slightly to the left until the radiator cap is level to the ground. Remove the right
  • 2013 Kawasaki KX100 | Owners Manual - Page 40
    system are corroded and the NOTICE Use coolant containing corrosion inhibitors made specifically for aluminum engines and radiators in accordance with the instruction of the manufacture. Soft or distilled water must be used with the antifreeze (see below for antifreeze) in the cooling system. If
  • 2013 Kawasaki KX100 | Owners Manual - Page 41
    MAINTENANCE AND ADJUSTMENT 39 j A. Air Bleeder Bolt B. Cylinder Head A. Air Bubbles the air bleeder bolt. • Tighten the engine with the radiator cap removed and • Start run it until no more air bubbles can be seen in the coolant. the cooling hoses to force out any air bubbles • Tap caught
  • 2013 Kawasaki KX100 | Owners Manual - Page 42
    40 MAINTENANCE AND ADJUSTMENT Spark Plug j If the plug is oily or has carbon built up on it, clean it (preferably with a sandblaster) and then clean off any abrasive particles. The plug may also be cleaned using a high-flash-point solvent and a wire brush or other suitable tool. If the spark plug
  • 2013 Kawasaki KX100 | Owners Manual - Page 43
    MAINTENANCE AND ADJUSTMENT 41 Spark Plug Removal and Installation the spark plug cap off the plug before remov• Pull ing the spark plug. a suitable wrench to the spark plug. • Apply and remove the spark plug. • Loosen reinstalling the spark plug, torque it to the • When specification. Spark Plug
  • 2013 Kawasaki KX100 | Owners Manual - Page 44
    42 MAINTENANCE AND ADJUSTMENT Adjust the timing by shifting the stator position within the range offered by the three timing marks on the stator. Remove the magneto cover and gasket. Loosen the stator screws. j • • A. B. C. D. Timing Mark (Crankcase) Timing Marks (Stator) Stator Stator Screw A.
  • 2013 Kawasaki KX100 | Owners Manual - Page 45
    MAINTENANCE AND ADJUSTMENT 43 the breather hose into the bracket on the • Route magneto cover. ride the motorcycle and readjust the ignition • Test timing if necessary. Air Cleaner A clogged air cleaner restricts the air intake, increases fuel consumption, reduces engine power, and can cause spark
  • 2013 Kawasaki KX100 | Owners Manual - Page 46
    44 MAINTENANCE AND ADJUSTMENT Element Removal and Inspection the right side cover. • Remove the wing bolt, and take out the air cleaner • Remove element. When taking out the air cleaner element, do not damage it. • Take the element off its frame. NOTICE Do not twist or wring the element, as it gets
  • 2013 Kawasaki KX100 | Owners Manual - Page 47
    MAINTENANCE AND ADJUSTMENT 45 j A. Air Cleaner Element B. Element Frame Element Cleaning and Installation the element in a bath of a high flash point • Clean solvent or hot soapy water. Rinse the element with • clear water to remove all traces of the cleaning solution. Squeeze the element dry
  • 2013 Kawasaki KX100 | Owners Manual - Page 48
    46 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 condition. Clean the air filter according to the periodic maintenance chart; more often if the vehicle is used in extremely dusty
  • 2013 Kawasaki KX100 | Owners Manual - Page 49
    MAINTENANCE AND ADJUSTMENT 47 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
  • 2013 Kawasaki KX100 | Owners Manual - Page 50
    48 MAINTENANCE AND ADJUSTMENT Carburetor Idling Adjustment Idling adjustment is carried out using the air screw and idling 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 1-3/8 turns. Turn the idling adjusting
  • 2013 Kawasaki KX100 | Owners Manual - Page 51
    MAINTENANCE AND ADJUSTMENT 49 the engine idling, turn the handlebar both • With ways and check if handlebar movement changes the idling speed. If so, the throttle cable may be improperly adjusted, incorrectly routed, or damaged. Be sure to correct any of these conditions before riding. Clutch
  • 2013 Kawasaki KX100 | Owners Manual - Page 52
    50 MAINTENANCE AND ADJUSTMENT If the clutch lever play cannot be adjusted at the clutch lever, make the adjustment further down the cable as follows. Loosen the locknut at the clutch lever. Turn the adjuster in all the way, then tighten the locknut. Loosen the locknut in the middle of the clutch
  • 2013 Kawasaki KX100 | Owners Manual - Page 53
    MAINTENANCE AND ADJUSTMENT 51 NOTICE Do not remove the clutch release shaft unless it is absolutely necessary. If the clutch release shaft is removed, the oil seal must be replaced with a new one. the clutch spring bolts, clutch pressure • Remove plate and springs. j • Remove the clutch cover
  • 2013 Kawasaki KX100 | Owners Manual - Page 54
    Friction Plate Thickness Measurement Standard 2.8 - 2.9 mm (0.110 - 0.115 in.) Service Limit 2.7 mm (0.106 in.) Friction and Steel Plate Warp Inspection each friction plate steel plate). If any plate is warped over the service limit, replace it with a new one. • Friction and Steel Plate Warp Standard Maximum
  • 2013 Kawasaki KX100 | Owners Manual - Page 55
    MAINTENANCE AND ADJUSTMENT 53 j A. Surface Plate B. Friction or Steel Plate C. Thickness Gauge A. Friction and Steel Plates NOTICE If dry steel plates and friction plates are installed, apply transmission oil to the surfaces of each plate to avoid clutch plate seizure. molybdenum disulfide
  • 2013 Kawasaki KX100 | Owners Manual - Page 56
    54 MAINTENANCE AND ADJUSTMENT Piston Piston Removal the fuel tap lever to the OFF position. • Turn the coolant. (See the Cooling System sec• Drain tion) the seat and the left and right side covers. • Remove the fuel tank and left and right radiator • Remove cover, and disconnect the lever ends of
  • 2013 Kawasaki KX100 | Owners Manual - Page 57
    MAINTENANCE AND ADJUSTMENT 55 j A. Springs A. Clamp the clamps, and pull the carburetor out of • Loosen the cylinder intake joint and air cleaner joint. • Remove the KIPS cover. A. KIPS Cover
  • 2013 Kawasaki KX100 | Owners Manual - Page 58
    56 MAINTENANCE AND ADJUSTMENT the E-clip, and separate the link lever • Remove from the link pin by turning the KIPS shaft lever clockwise with the wrench. the two coolant hose ends. • Remove • Disconnect the spark plug cap. j A. E-Clip B. Link Lever A. Engine Bracket B. Coolant Hose End C. Spark
  • 2013 Kawasaki KX100 | Owners Manual - Page 59
    MAINTENANCE AND ADJUSTMENT 57 j A. Cylinder Head Nuts B. Cylinder Head C. Cylinder Head Gasket A. Cylinder Nuts B. Cylinder the cylinder nuts. • Remove off the cylinder, and remove the cylinder base • Lift gasket. If necessary, tap lightly around the base of the cylinder with a plastic mallet,
  • 2013 Kawasaki KX100 | Owners Manual - Page 60
    58 MAINTENANCE AND ADJUSTMENT j A. Piston Pin Puller Assembly: 57001-910 A. Piston Ring Piston Ring Removal to remove it. spread the ring gap with your thumbs • Carefully and then push up on the opposite side of the ring Piston Ring, Piston Ring Groove Inspection inspect the piston rings and
  • 2013 Kawasaki KX100 | Owners Manual - Page 61
    piston. Piston Ring/Groove Clearance Top Ring KX85A Standard KX100D KX85A KX100D 0.020 ∼ 0.060 mm (0.0008 ∼ 0.0024 in.) 0.040 ∼ 0.080 mm (0.0016 ∼ 0.0032 in.) Service Limit 0.16 mm (0.0063 in.) 0.18 mm (0.0071 in.) Piston Ring Thickness (Top and Second) 0.97 ∼ 0.99 mm Standard (0.0382 ∼ 0.0390 in
  • 2013 Kawasaki KX100 | Owners Manual - Page 62
    shows excessive wear, replace the piston. Measure the diameter of the piston pin with a micrometer. If the piston pin diameter is less than the service limit at any point, replace the piston pin. • Check the needle bearing. NOTE Piston Pin Diameter 13.995 ∼ 14.000 mm Standard (0.5510 ∼ 0.5512
  • 2013 Kawasaki KX100 | Owners Manual - Page 63
    MAINTENANCE AND ADJUSTMENT 61 any carbon off of the piston, then lightly • Scrape polish the piston with fine emery cloth. carbon and dirt out of the piston ring • Clean grooves using a suitable tool. j NOTICE Carbon particles can be very abrasive to piston rings. Don't allow such particles to
  • 2013 Kawasaki KX100 | Owners Manual - Page 64
    62 MAINTENANCE AND ADJUSTMENT j A. Top Ring B. Second Ring C. Marked side A. Pin NOTE żInstall the piston ring so that the pin in the piston ring groove is between the ends of the piston ring. 2-stroke engine oil to the connecting rod • Apply needle bearing and the piston pin. the piston so
  • 2013 Kawasaki KX100 | Owners Manual - Page 65
    MAINTENANCE AND ADJUSTMENT 63 j A. Snap Ring B. Snap Ring Ends C. Notch A. Pin the cylinder nuts to the specified torque in • Tighten a crisscross pattern. Cylinder Nut Tightening Torque 25 N·m (2.5 kgf·m, 18 ft·lb) out any carbon and clean the cylinder • Scrape head with a high-flash-point
  • 2013 Kawasaki KX100 | Owners Manual - Page 66
    64 MAINTENANCE AND ADJUSTMENT the parts removed. • Install the radiator up to the bottom of the radiator • Fill filler neck with coolant. (See the "Cooling System" j • chapter) Check the coolant level. A. Gasket the cylinder head nuts to the specified • Tighten torque in a crisscross pattern.
  • 2013 Kawasaki KX100 | Owners Manual - Page 67
    MAINTENANCE AND ADJUSTMENT 65 Exhaust System The exhaust system, in particular the muffler, 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, exhaust efficiency is reduced, causing engine
  • 2013 Kawasaki KX100 | Owners Manual - Page 68
    66 MAINTENANCE AND ADJUSTMENT j A. Bolts B. Tail Pipe the O-ring from the rear end of the si• Remove lencer. out the front inner cover by tapping the inner • Push pipe from the rear by using the suitable tool. off the old silencer packing, and install the new • Pull one. A. Muffler Packing B.
  • 2013 Kawasaki KX100 | Owners Manual - Page 69
    MAINTENANCE AND ADJUSTMENT 67 Drive Chain 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 - either too loose or too tight - it could jump off the
  • 2013 Kawasaki KX100 | Owners Manual - Page 70
    68 MAINTENANCE AND ADJUSTMENT chain adjusting bolts evenly, and kick the wheel forward. If the chain is too loose, turn both chain adjusting bolts evenly until the drive chain has the correct amount of slack. To keep the chain and wheel properly aligned, the notch on the right chain adjuster should
  • 2013 Kawasaki KX100 | Owners Manual - Page 71
    on a straight part of the chain from the center of the 1st pin to the center of the 21st pin. If the length exceeds the service limit, the chain should be replaced. Since overworn sprockets will cause a new chain to wear faster, inspect both the engine and rear sprockets whenever the
  • 2013 Kawasaki KX100 | Owners Manual - Page 72
    20-Link Section Standard Length 254 mm (10.0 in.) Wear Limit 258 mm (10.2 in.) A. Measure Link Clip B. Direction of Rotation NOTE Chain Guide Wear Inspection żThe drive system was designed for use with a DAIDO D.I.D 420DS2 120-link (KX100D : 124-link) chain. For maximum stretch resistance and
  • 2013 Kawasaki KX100 | Owners Manual - Page 73
    MAINTENANCE AND ADJUSTMENT 71 j A. Chain Guide A. Chain Slippers B. Swingarm Chain Slipper Wear Inspection aged. inspect the upper and lower chain slippers • Visually on the swingarm and replace them if worn or
  • 2013 Kawasaki KX100 | Owners Manual - Page 74
    72 MAINTENANCE AND ADJUSTMENT Sprocket Tooth Wear j NOTE żSprocket wear is exaggerated in the illustration. Chain Lubrication Lubrication of the drive chain is necessary after riding in the rain or mud, or any time the chain appears dry. A heavy oil such as SAE90 is preferred to a lighter oil
  • 2013 Kawasaki KX100 | Owners Manual - Page 75
    MAINTENANCE AND ADJUSTMENT 73 Handlebar To keep the handlebar properly secured in place, it is necessary to install the handlebar clamps correctly. j A. Front B. No Gap C. Gap A. Front B. Arrow Mark the clamp bolts to 25 N·m (2.5 kgf·m, 18 • Torque ft·lb), front first, then rear. If the
  • 2013 Kawasaki KX100 | Owners Manual - Page 76
    74 MAINTENANCE AND ADJUSTMENT Brakes Disc and disc pad wear is automatically compensated 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. Brake Lever Position The brake lever position can be adjusted to
  • 2013 Kawasaki KX100 | Owners Manual - Page 77
    MAINTENANCE AND ADJUSTMENT 75 Disc Brake Fluid Inspect the brake fluid level in the front and rear reservoirs and change the brake fluid in accordance with the Periodic Maintenance Chart. The brake fluid should also be changed when contaminated with dirt or water. Use only heavy-duty brake fluid as
  • 2013 Kawasaki KX100 | Owners Manual - Page 78
    76 MAINTENANCE AND ADJUSTMENT j A. Front Reservoir B. Maximum Level Line A. Rear Reservoir Rear Reservoir Positioned horizontally, the rear reservoir must always be more than half full. If the amount of brake fluid is insufficient, check for fluid leaks in the brake line and add brake fluid.
  • 2013 Kawasaki KX100 | Owners Manual - Page 79
    MAINTENANCE AND ADJUSTMENT 77 replaced as a set. Pad replacement should be done by an authorized Kawasaki dealer. Usable Brake Pad Range Steering The steering should always be kept adjusted so that the handlebar will turn freely but not have excessive play. j Steering Inspection check the
  • 2013 Kawasaki KX100 | Owners Manual - Page 80
    78 MAINTENANCE AND ADJUSTMENT Steering Adjustment the strap of the number plate. • Loosen the front wheel off the ground using a jack • Raise (special tool). the handlebar clamps and handlebar. • Remove the steering stem head nut, and the front • Loosen fork lower clamp bolts. j A. Steering Stem
  • 2013 Kawasaki KX100 | Owners Manual - Page 81
    MAINTENANCE AND ADJUSTMENT 79 Front Fork Any of the following front fork adjustments should be made to tune the front suspension to the rider's weight and the condition of the track. Basically, there are five adjustments you can make to the front fork. Air Pressure Air pressure acts as a
  • 2013 Kawasaki KX100 | Owners Manual - Page 82
    80 MAINTENANCE AND ADJUSTMENT j A. Screw A. Compression Damping Adjuster Compression Damping Adjustment the bottom of the fork tubes. • Clean the caps on the bottom of the fork tubes. • Remove adjust the compression damping, turn the • To adjuster on the front fork cylinder valve with a
  • 2013 Kawasaki KX100 | Owners Manual - Page 83
    bolts. • Loosen • Remove the front fork top plugs. WARNING The top plugs are under extreme spring pressure and may eject with great force during service. Use care when removing the top plugs. Wear eye and face protection. compress the front fork fully by pushing up • Slowly the inner tube until
  • 2013 Kawasaki KX100 | Owners Manual - Page 84
    82 MAINTENANCE AND ADJUSTMENT j A. Inner Tube (Stepped Portion) B. Outer Tube C. Dust Cover holding the push rod nut with a 17 mm • While wrench, loosen and remove the front fork top plug from the top of the push rod. a stand or other suitable support under the • Place front wheel.
  • 2013 Kawasaki KX100 | Owners Manual - Page 85
    MAINTENANCE AND ADJUSTMENT 83 j A. B. C. D. Top Plug Spring Seat Wrench (17 mm) Spring A. Push Rod B. Push Rod Puller (P.N. 57001-1289) the fork spring seat and fork spring. • Remove the other fork spring in the same way as • Remove described above. the front fork to the top of the inner tube
  • 2013 Kawasaki KX100 | Owners Manual - Page 86
    84 MAINTENANCE AND ADJUSTMENT Fork Oil Level KX85A Standard Level KX100D Adjustable Range 100 mm (3.94 in.) 90 mm (3.5 in.) 75 ∼ 115 mm (2.95 ∼ 4.53 in.) both top plug O-rings for damage and re• Check place them if necessary. j A. B. C. D. A. Oil Level Gauge (P/No. 57001-1290) Top Plug O-Ring
  • 2013 Kawasaki KX100 | Owners Manual - Page 87
    MAINTENANCE AND ADJUSTMENT 85 Harder springs stiffen the fork action and accelerate the rebound damping. Softer springs soften the fork action and slow down the rebound damping. j Fork Clamp Position Adjustment Steering is greatly affected by the fork clamp position (how much the outer fork tubes
  • 2013 Kawasaki KX100 | Owners Manual - Page 88
    86 MAINTENANCE AND ADJUSTMENT Rear Suspension (UNI-TRAK®) This motorcycle's rear suspension system is called "UNI-TRAK®" and consists of a rear shock absorber unit, a swingarm, two lever rods and a lever. The operating characteristics of the UNI-TRAK® suspension are similar to those of the front
  • 2013 Kawasaki KX100 | Owners Manual - Page 89
    MAINTENANCE AND ADJUSTMENT 87 Rebound Damping Adjuster Settings j A. Rebound Damping Adjuster If the damping feels too soft or too stiff, adjust it in accordance with the following table. A. Seated Position (Adjuster Turned Fully Clockwise) Standard Rebound Damping Adjuster Setting 11 clicks* *
  • 2013 Kawasaki KX100 | Owners Manual - Page 90
    88 MAINTENANCE AND ADJUSTMENT Compression Reservoir) Damping Adjustment (Gas Spring Preload Adjustment the seat and both side covers. • Remove the air intake duct clamp screw. • Loosen the bolts of the rear frame and remove • Remove the rear frame. j To adjust compression damping, turn the
  • 2013 Kawasaki KX100 | Owners Manual - Page 91
    MAINTENANCE AND ADJUSTMENT 89 j A. Bolts B. Rear Fender C. Air Cleaner Case A. Spring Preload Adjusting Nut B. Locknut C. Hook Wrenches (P/No.57001-1101) the rear wheel off the ground using a jack • Raise (special tool). the hook wrenches (special tools: P/No. • Using 57001-1101), loosen the
  • 2013 Kawasaki KX100 | Owners Manual - Page 92
    90 MAINTENANCE AND ADJUSTMENT WARNING Improper removal or installation of the rear shock absorber spring may cause the spring and/or related parts to be ejected at high velocity. Always wear eye and face protection when working on the rear shock absorber. Removal and installation of the rear shock
  • 2013 Kawasaki KX100 | Owners Manual - Page 93
    MAINTENANCE AND ADJUSTMENT 91 Wheels Tire Air Pressure Tire air pressure affects traction, handling, and tire life. Adjust the tire air pressure to suit track conditions and rider preference, but keep it close within the recommended range. Reduce the tire air pressure to increase the tire tread
  • 2013 Kawasaki KX100 | Owners Manual - Page 94
    92 MAINTENANCE AND ADJUSTMENT NOTE żThe welding spot of the rim may show excessive runout. Disregard this when measuring runout. Rim Runout j A. Beed Protector Nut Rim Runout Set up a dial gauge on the side of the rim and rotate the wheel to measure its axial runout. The difference between the
  • 2013 Kawasaki KX100 | Owners Manual - Page 95
    MAINTENANCE AND ADJUSTMENT 93 Rim Runout Maximum Limit Axial 2.0 mm (0.08 in.) Radial j A. Radial Rim Runout Measurement A. Axial Rim Runout Measurement
  • 2013 Kawasaki KX100 | Owners Manual - Page 96
    Fender Bolts 10. Spokes 11. Brake Disc Screws 12. Front Axle Nuts 13. Brake Hose Holder Bolts 14. Brake Caliper Bolts 15. Front Fork Protection Guide Bolt 16. Front Fender Bolts 17. Exhaust Pipe Bolt and Nut 18. Shift Pedal Bolts 19. Side Cover Bolts 20. Chain
  • 2013 Kawasaki KX100 | Owners Manual - Page 97
    MAINTENANCE AND ADJUSTMENT 95 j 24. Rear Axle Nut 25. Rear Frame Bolts 26. Rear Shock Absorber Bolt and Nut 27. Rear Brake Reservoir Bolt or Screw 28. Steering Stem Head Nut 29. Brake Lever Holder Bolt 30. UNI-TRAK® Lever Rod Bolt 31. UNI-TRAK® Lever Bolt 32. Rear Brake Pedal Pivot Bolt 33. Pivot
  • 2013 Kawasaki KX100 | Owners Manual - Page 98
    96 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. An overtightened nut or bolt may
  • 2013 Kawasaki KX100 | Owners Manual - Page 99
    MAINTENANCE AND ADJUSTMENT 97 Part Name Front Fork Top Plug Front Brake Hose Holder Bolts Front Fork Protector Guide Bolt Front Fork Protector Bolts Handlebar Clamp Bolts Pivot Shaft Nut Rear Axle Nut Rear Brake Pedal Pivot Bolt Rear Frame Bolts Rear Shock Absorber
  • 2013 Kawasaki KX100 | Owners Manual - Page 100
    such as ammo- WARNING Build-up of debris or flammable material in and around the vehicle chassis, engine, and exhaust can cause mechanical problems and increase the risk of fire. When operating the vehicle in conditions that allow debris or flammable material to collect in and around the
  • 2013 Kawasaki KX100 | Owners Manual - Page 101
    months or as conditions require. Avoid surfaces with "satin" or "flat" finishes. Always use nonabrasive products and apply them according to the instructions on the container. j Plastic Parts After washing use a soft cloth to gently dry plastic parts. When dry, treat the other non-painted
  • 2013 Kawasaki KX100 | Owners Manual - Page 102
    100 MAINTENANCE AND ADJUSTMENT aluminum should be washed with a mild neutral detergent and finished with a spray polish. Aluminum wheels, both painted and unpainted can be cleaned with special non-acid based wheel spray cleaners. Lubrication Lubricate the areas shown in the illustrations of this
  • 2013 Kawasaki KX100 | Owners Manual - Page 103
    MAINTENANCE AND ADJUSTMENT 101 • Kick pedal Apply an aerosol cable lubricant with a pressure lubricator on all cables: Clutch cable Throttle cable • • j Cable Lubrication • Shift pedal • • Apply grease to the following points: Upper end of clutch cable Upper end of throttle cable
  • 2013 Kawasaki KX100 | Owners Manual - Page 104
    102 MAINTENANCE AND ADJUSTMENT preferred to a lighter oil because it will stay on the chain longer and provide better lubrication. Apply oil to the sides of the rollers so that it will penetrate to the rollers and bushings. Wipe off any excess oil. j • • A. Grease. Drive Chain Lubrication
  • 2013 Kawasaki KX100 | Owners Manual - Page 105
    defective/disconnected Stator damaged Wiring shorted or interrupted does not give every possible cause for each problem listed. It is meant simply as a quick guide to assist you in troubleshooting for some of the more common difficulties. j Starting failure or difficulties Engine does not turn
  • 2013 Kawasaki KX100 | Owners Manual - Page 106
    104 TROUBLESHOOTING GUIDE head warped • Cylinder gasket damaged • Cylinder • Reed valve damaged head gasket damaged • Cylinder head warped • Cylinder gasket damaged • Cylinder • Reed valve damaged KIPS ports stuck
  • 2013 Kawasaki KX100 | Owners Manual - Page 107
    TROUBLESHOOTING GUIDE 105 jet or air passage clogged • Air cleaner element clogged, poorly sealed or not • Air installed plunger stuck open • Starter supply to carburetor insufficient • Fuel
  • 2013 Kawasaki KX100 | Owners Manual - Page 108
    106 TROUBLESHOOTING GUIDE Engine overheating Firing incorrect Spark plug dirty, broken, or gap improperly adjusted Spark plug type incorrect Igniter defective • Water pump not rotating Clutch operation faulty
  • 2013 Kawasaki KX100 | Owners Manual - Page 109
    TROUBLESHOOTING GUIDE 107 mechanism arm broken • Shift • Shift drum broken Transmission jumps out of gear fork worn • Shift groove worn • Gear dogs and/or dog grooves worn •
  • 2013 Kawasaki KX100 | Owners Manual - Page 110
    108 TROUBLESHOOTING GUIDE Frame noise abnormal Front fork noise Oil level or viscosity too low Spring weak or broken Poor handling and/or stability Handlebar hard to turn
  • 2013 Kawasaki KX100 | Owners Manual - Page 111
    TROUBLESHOOTING GUIDE 109 Shock absorption unsatisfactory (suspension too hard) Front fork oil excessive Front fork oil viscosity too high Front fork leg bent Tire air pressure too
  • 2013 Kawasaki KX100 | Owners Manual - Page 112
    of the spark plug, make sure the ignition timing is correct, service the air cleaner element and decarbonize the muffler. If your machine has past and then starts running poorly with the same carburetor settings, the problem is almost certain to be elsewhere; changing the carburetor settings in such
  • 2013 Kawasaki KX100 | Owners Manual - Page 113
    ENGINE AND SUSPENSION TUNING 111 With pinging or rattling, make sure that the gasoline is fresh and the octane rating sufficient. You might also try a different brand of high-octane gasoline. Making Adjustments Carburetor tuning is made by replacing or adjusting the main jet, jet needle and slow
  • 2013 Kawasaki KX100 | Owners Manual - Page 114
    112 ENGINE AND SUSPENSION TUNING Jet Needle The jet needle and needle jet together have their greatest effect in the ¼-to-¾-throttle range. The needle moves in and out of the needle jet. Since the needle is tapered, its position in the needle jet determines the amount of fuel allowed to pass through
  • 2013 Kawasaki KX100 | Owners Manual - Page 115
    ENGINE AND SUSPENSION TUNING 113 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
  • 2013 Kawasaki KX100 | Owners Manual - Page 116
    114 ENGINE AND SUSPENSION TUNING the spark plug insulator is whitish, the fuel-air • If mixture is too lean. Increase the main jet size by • • one step. If the spark plug insulator is wet, the fuel-air mixture is too rich. Reduce the main jet size by one step. Tune the carburetor so that the
  • 2013 Kawasaki KX100 | Owners Manual - Page 117
    ENGINE AND SUSPENSION TUNING 115 j Correction Factor Applied to the Jet Needle and Air Screw 1.06 or above 1.06 - 1.02 1.02 - 0.98 Correction factor Jet needle setting Air screw opening lower clip one position one turn in same ½ turn in same 0.98 - 0.94 0.94 or below raise clip one position ½
  • 2013 Kawasaki KX100 | Owners Manual - Page 118
    116 ENGINE AND SUSPENSION TUNING KX85A: Standard Carburetor Settings Throttle Valve Diameter #3.5 Air Screw Opening Slow Jet Jet Needle Jet Needle Clip Position Main Jet 1-3/8 #45 NAPE 3 #140 Slow Jet Size Selection for a Correction factor of 0.94 #45 x 0.94 = #42 Main Jet Size Selection for a
  • 2013 Kawasaki KX100 | Owners Manual - Page 119
    POSITIONING on the machine. Before changing the suspension settings, test changing your riding posture or position to check whether it is the cause of the problem or not. It is a wise practice to adjust the suspension to suit the rider's strong points. If you are fast in the corners, adjust the
  • 2013 Kawasaki KX100 | Owners Manual - Page 120
    118 ENGINE AND SUSPENSION TUNING Fork Oil Level Effect on Fork Stroke Troubleshooting Improper Settings Listed below are some symptoms of improper suspension settings and the most likely means of correcting them. The proper settings can be achieved
  • 2013 Kawasaki KX100 | Owners Manual - Page 121
    ENGINE AND SUSPENSION TUNING 119 The front fork dives excessively during braking and deceleration: Fork oil level too low Springs too soft Oil viscosity too high Fork oil deteriorated Compression damping improperly adjusted. Determining the Proper Settings Standard Settings From the factory, the
  • 2013 Kawasaki KX100 | Owners Manual - Page 122
    120 ENGINE AND SUSPENSION TUNING Suspension Tuning According the Type of Course Lower the front end slightly. [Increase the amount of fork tube protrusion above the upper fork clamp by 5 mm Many Corners (0.2 in.)]. This accelerates steering and enhances turning ability. Raise the front end slightly.
  • 2013 Kawasaki KX100 | Owners Manual - Page 123
    procedures, suspension settings may vary depending on the conditions at the track and the rider's preferences. Front and Rear Suspension Troubleshooting Front End Surges Downhill or During Acceleration Out of Corner The front suspension is too soft. Increase the compression damping. Increase
  • 2013 Kawasaki KX100 | Owners Manual - Page 124
    122 ENGINE AND SUSPENSION TUNING Front and Rear Ends Bottom Off After a High-speed Jump (harsh bottoming occurs once or twice per lap) The front suspension is too soft. Increase the fork oil level by 10 mm (0.4 in.). Use a harder fork spring. The rear suspension is too soft. Increase the rear shock
  • 2013 Kawasaki KX100 | Owners Manual - Page 125
    ENGINE AND SUSPENSION TUNING 123 Gearing Selection of the Secondary Reduction Ratio (Rear Sprocket) Rear Sprocket Selection According to Course Conditions Fast Course Small Sprocket Many Curves or Hills Sandy or Soft Ground Large Sprocket • course, but care should be taken not to over-rev the
  • 2013 Kawasaki KX100 | Owners Manual - Page 126
    124 ENGINE AND SUSPENSION TUNING Special Care According to Track Conditions • • j • In dry, dusty conditions (such a volcanic ash or fine powdery dust), special care must be given to keeping the air cleaner element clean. When riding on wet, heavy clay, mud adheres to the tires and other parts
  • 2013 Kawasaki KX100 | Owners Manual - Page 127
    OPTIONAL PARTS 125 OPTIONAL PARTS Optional part Carburetor 132 135 138 140 142 145 148 150 40 42 48 50 NAPC NAPD NAPE NAPF NAPG NAPH NAQC NAQD NAQE NAQF NAQG NAQH KX85A, KX100D Optional part Engine Sprocket Rear Sprocket NOTE żNAP* is 0.5 clip position richer than NAQ*. KX85A 13T *14T 48T 49T **
  • 2013 Kawasaki KX100 | Owners Manual - Page 128
    126 OPTIONAL PARTS Optional part Disc Plate Front Rear Front Rear No Holes (For Wet Conditions) No Holes (For Wet Conditions) 1.40-17 1.60-14 1.60-15 **: Standard equipment 1.40-19 1.85-16 KX85A KX100D Wheel (Without Tire)
  • 2013 Kawasaki KX100 | Owners Manual - Page 129
    engine, the crankshaft big end will wear excessively. After riding, inspect the crankshaft big end. If the crankshaft big end is worn past the service limit, replace the crankshaft with a new one. Maintenance After Riding in the Rain or on a Muddy Course Apply grease to swingarm and rear suspension
  • 2013 Kawasaki KX100 | Owners Manual - Page 130
    128 PRE-RACE CHECKS AND AFTER-RACE MAINTENANCE • Grease the throttle grip and control cables. Suggested Spare Parts and rear wheels • Front pedal and brake pedal • Shift lever, clutch lever, and holders • Brake and clutch cables • Throttle • Handlebar and rear fenders, side covers, and number •
  • 2013 Kawasaki KX100 | Owners Manual - Page 131
    STORAGE 129 STORAGE Before Storage When the motorcycle is to be stored for any length of time, it should be prepared for storage as follows. Clean the entire vehicle thoroughly. Run the engine for about five minutes to warm the oil, then stop it and drain the transmission oil. WARNING Gasoline is
  • 2013 Kawasaki KX100 | Owners Manual - Page 132
    130 STORAGE the motorcycle to keep dust and dirt away • Cover from it. After Storage the plastic bag from the muffler. • Remove sure the spark plug is tight. • Make the fuel tank with fuel. • Fill all the points listed in the Daily pre-ride • Check checks section. • Perform a General Lubrication
  • 2013 Kawasaki KX100 | Owners Manual - Page 133
    ENVIRONMENTAL PROTECTION 131 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
  • 2013 Kawasaki KX100 | Owners Manual - Page 134
    132 WIRING DIAGRAM WIRING DIAGRAM 1. Magneto 2. Engine Stop Button 3. Pickup Coil 4. CDI Unit 5. Ignition Coil 6. Noise Suppressor 7. Spark Plug
  • 2013 Kawasaki KX100 | Owners Manual - Page 135
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