2014 Kawasaki KX100 Owners Manual

2014 Kawasaki KX100 Manual

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  • 2014 Kawasaki KX100 | Owners Manual - Page 1
  • 2014 Kawasaki KX100 | Owners Manual - Page 2
    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 TUNING STORAGE j j j j j A Table of Contents is included after the Foreword.
  • 2014 Kawasaki KX100 | Owners Manual - Page 3
    limited to participation in sanctioned competition events upon a closed • The course. vehicle should not be used for general off-road recreational riding. • This • Read owner's manual.
  • 2014 Kawasaki KX100 | Owners Manual - Page 4
    shown below, heed their instructions! Always follow safe operating FOR GENERAL OFF-ROAD RECREATIONAL RIDING. READ OWNER'S MANUAL. DANGER DANGER indicates a hazardous situation which, if not responsibilities concerning quality, performance, cost of service and/or necessary repairs. NOTICE NOTICE is
  • 2014 Kawasaki KX100 | Owners Manual - Page 5
    conducted, this sport has the potential to cause environmental problems as well as conflicts with other people. Responsible use of your off-road motorcycle will ensure that these problems and conflicts do not occur. TO PROTECT THE FUTURE OF YOUR
  • 2014 Kawasaki KX100 | Owners Manual - Page 6
    WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
  • 2014 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
  • 2014 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
  • 2014 Kawasaki KX100 | Owners Manual - Page 9
    Rear Suspension (UNI-TRAK®)...Wheels ...Hoses Inspection ...Tightening Torques of Nuts and Bolts...Cleaning Your Motorcycle...Lubrication...TROUBLESHOOTING GUIDE...TUNING ...Carburetor ...Suspension...Gearing...Special Care According to Track Conditions . OPTIONAL PARTS ...PRE-RACE CHECKS AND AFTER
  • 2014 Kawasaki KX100 | Owners Manual - Page 10
    SPECIFICATIONS 9 SPECIFICATIONS DIMENSIONS Overall Length: KX85C KX100F Overall Width Overall Height: KX85C KX100F Wheelbase: KX85C KX100F Road Clearance: KX85C KX100F Curb Mass: KX85C KX100F Fuel Tank Capacity 75 kg (165 lb) 77 kg (170 lb) 5.0 L (1.3 US gal) 290 mm (11.42 in.) 330 mm (12.99 in.) 1
  • 2014 Kawasaki KX100 | Owners Manual - Page 11
    10 SPECIFICATIONS ENGINE Type Bore × Stroke: KX85C KX100F Displacement: KX85C KX100F Compression Ratio: Low Speed: KX85C KX100F High Speed: KX85C KX100F Port Timing: Intake: Open Close Scavenging: Open: KX85C KX100F 63.8° BBDC 62.8° BBDC Full Open - 9.0:1 8.7:1 10.9:1 10.2:1 84 cm³ (5.1 cu in.) 99
  • 2014 Kawasaki KX100 | Owners Manual - Page 12
    SPECIFICATIONS 11 Close: KX85C KX100F Exhaust: Open: KX85C KX100F Close: KX85C KX100F Fuel System Starting System Ignition System Ignition Timing: KX85C KX100F Lubrication System Spark Plug Spark Plug Terminal TRANSMISSION Transmission Type Clutch Type Driving System 6-speed, Constant Mesh, Return
  • 2014 Kawasaki KX100 | Owners Manual - Page 13
    12 SPECIFICATIONS Gear Ratio: 1st 2nd 3rd 4th 5th 6th Primary Reduction Ratio Final Reduction Ratio: KX85C KX100F Overall Drive Ratio: KX85C KX100F Transmission Oil: Grade Viscosity Amount FRAME Type Steering Angle Caster Tubular, semi-double cradle 45° to either side 29° API SG, SH, SJ, SL or SM
  • 2014 Kawasaki KX100 | Owners Manual - Page 14
    SPECIFICATIONS 13 Trail: KX85C KX100F Tire Size/Type: Front: KX85C KX100F Rear: KX85C KX100F Rim Size: Front: KX85C KX100F Rear: KX85C KX100F Suspension: Front Rear Front Suspension Travel Rear Wheel Travel Telescopic fork (upside-down) Uni-trak® swingarm 275 mm (10.83 in.) 275 mm (10.83 in.) 14 ×
  • 2014 Kawasaki KX100 | Owners Manual - Page 15
    14 SPECIFICATIONS Front Fork Oil: Type Amount BRAKES Type: Front Rear Brake Fluid Grade: Front Rear DOT3 or DOT4 DOT4 Single disc Single disc Kawasaki Fork Oil KHL15-10 295 ∼ 325 mL (9.97 ∼ 11.0 US oz.) Specifications are subject to change without notice.
  • 2014 Kawasaki KX100 | Owners Manual - Page 16
    GENERAL INFORMATION 15 GENERAL INFORMATION Location of Labels All warning labels which are on your vehicle are repeated here. Read labels on your vehicle and understand them thoroughly. They contain information which is important for your safety and the safety of anyone else who may operate your
  • 2014 Kawasaki KX100 | Owners Manual - Page 17
    16 GENERAL INFORMATION j 2. 3. 4. 5. 6. 7. Radiator Cap Danger Rear Shock Absorber Warning Gasoline-Engine Oil Mixing Ratio Disclaimer of Warranty Noise Emission Control Information Important Information
  • 2014 Kawasaki KX100 | Owners Manual - Page 18
    GENERAL INFORMATION 17 1) 3) j 2) 4)
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    18 GENERAL INFORMATION 5) 7) j 6)
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    GENERAL INFORMATION 19 j Location of Parts 1. Clutch Lever 2. Front Brake Fluid Reservoir 3. Front Brake Lever 4. Engine Stop Button 5. Fuel Tank Cap 6. Throttle Grip
  • 2014 Kawasaki KX100 | Owners Manual - Page 21
    20 GENERAL INFORMATION j 1. Front Fork 2. Radiator 3. Fuel Tank 4. Carburetor 5. Seat 6. Air Cleaner Element 7. Muffler 8. Front Brake Disc 9. Front Brake Caliper 10. Expansion Chamber 11. Shift Pedal 12. Rear Shock Absorber 13. Swingarm 14. Chain Guide 15. Drive Chain
  • 2014 Kawasaki KX100 | Owners Manual - Page 22
    GENERAL INFORMATION 21 j 1. Rear Shock Absorber Gas Reservoir 2. Rear Brake Fluid Reservoir 3. Fuel Tap 4. Rear Brake Disc 5. Rear Brake Caliper 6. Transmission Oil Level Inspection Window 7. Rear Brake Pedal 8. Kick Pedal 9. Water Pump Cover
  • 2014 Kawasaki KX100 | Owners Manual - Page 23
    motorcycle with the provided side stand. Install the upper end of the side stand into the hole at the rear of the left footpeg. ○Support the motorcycle with a suitable stand to perform maintenance or adjustment procedures. NOTE A. Side Stand B. Hole WARNING Riding with the side stand can cause
  • 2014 Kawasaki KX100 | Owners Manual - Page 24
    GENERAL INFORMATION 23 Fuel The Kawasaki KX is equipped with a 2-stroke engine that requires a gasoline-oil mixture. Fuel Tank Capacity 5.0 L (1.3 US gal) To open the fuel tank cap, pull out the breather hose from the hole in the steering shaft, and turn the tank cap counterclockwise. Avoid
  • 2014 Kawasaki KX100 | Owners Manual - Page 25
    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 standard industry specifications may result in unsatisfactory performance. Operating problems that result from the use of poor quality or nonrecommended
  • 2014 Kawasaki KX100 | Owners Manual - Page 26
    " containing more than 5% methanol. Fuel system damage and performance problems may result. Gasoline/Ether Blends - The most common ether is you drain all fuel from the fuel system. See the Storage section in this manual. j ○Other oxygenates approved for use in unleaded gasoline include TAME (up to
  • 2014 Kawasaki KX100 | Owners Manual - Page 27
    engine lubricant *Kawasaki Performance Oils and Lubricants have been specifically engineered for your vehicle. Consistent use of these products meets or exceeds service requirements and can help to extend the life of your Kawasaki. Gasoline-Engine Oil Mixing Ratio 32:1 (Gasoline:Engine Oil) A 32-to
  • 2014 Kawasaki KX100 | Owners Manual - Page 28
    GENERAL INFORMATION 27 j Kick Pedal This motorcycle is equipped with a primary kick starting system. When the clutch lever is pulled, the motorcycle can be started with the transmission in any gear. Starting the Engine • Turn the fuel tap lever to the "ON" position. A. Fuel Tap B. ON position A.
  • 2014 Kawasaki KX100 | Owners Manual - Page 29
    28 GENERAL INFORMATION j NOTICE This motorcycle is designed for competition use only. Therefore, the radiator does not incorporate a coolant reserve tank or cooling fan. Prolonged idling of the engine with no airflow through the radiator can cause coolant loss and engine overheating resulting in
  • 2014 Kawasaki KX100 | Owners Manual - Page 30
    GENERAL INFORMATION 29 ○If the engine fails starting, open the throttle fully NOTE 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
  • 2014 Kawasaki KX100 | Owners Manual - Page 31
    30 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
  • 2014 Kawasaki KX100 | Owners Manual - Page 32
    GENERAL INFORMATION 31 j Stopping the Engine the transmission into the neutral position. • Shift After racing the engine slightly, close the throttle • completely and push the engine stop button. A. Fuel Tap B. OFF position A. Engine Stop Button • Turn the fuel tap lever to the "OFF" position.
  • 2014 Kawasaki KX100 | Owners Manual - Page 33
    32 GENERAL INFORMATION j 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. 4. 5. 6. NOTICE For the first hour or 20 km (12 mile) of operation, run the engine at
  • 2014 Kawasaki KX100 | Owners Manual - Page 34
    is ready for regular operation. Using the proper riding skills and techniques and avoiding recklessly high engine speeds will keep the engine trouble-free. j ○After break-in, install a new standard spark plug, and change the transmission oil. ○To keep optimum engine performance, replace the piston
  • 2014 Kawasaki KX100 | Owners Manual - Page 35
    34 GENERAL INFORMATION 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
  • 2014 Kawasaki KX100 | Owners Manual - Page 36
    GENERAL INFORMATION 35 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
  • 2014 Kawasaki KX100 | Owners Manual - Page 37
    36 GENERAL INFORMATION j After-Race Checks After racing, first clean the motorcycle (see page 135), then inspect the entire motorcycle with special attention to the air cleaner, carburetor, brakes, etc. Carry out the general lubrication (see page 137) and make necessary adjustments.
  • 2014 Kawasaki KX100 | Owners Manual - Page 38
    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. 1. Periodic Inspection (Engine Related Item) Every 3 FREQUENCY After each race (or 2.5 races (or
  • 2014 Kawasaki KX100 | Owners Manual - Page 39
    38 MAINTENANCE AND ADJUSTMENT Every 3 FREQUENCY After each race (or 2.5 races (or 7.5 hours) hours) Every 5 Every 10 races (or races (or 25 12.5 hours) hours) As re- See quired Page - - 88 88 R 81 - j OPERATION Cylinder head and cylinder - inspect K Exhaust valves - clean/check Silencer - clean/
  • 2014 Kawasaki KX100 | Owners Manual - Page 40
    dust seals - replace Spokes tightness and rim runout check † Drive chain - adjust Drive chain - lubricate Drive chain wear - check † Chain slipper and guide - replace Front forks - inspect/clean K Front fork oil - change Nuts, bolts, fasteners - check † Fuel system - clean Every 5 Every 10 races (or
  • 2014 Kawasaki KX100 | Owners Manual - Page 41
    40 MAINTENANCE AND ADJUSTMENT Every 3 FREQUENCY After each race (or 2.5 races (or 7.5 hours) hours) Every 5 Every 10 races (or races (or 25 12.5 hours) hours) As re- See quired Page - - - 106 j OPERATION Fuel hose - replace Every 5 years K Brake hoses, connections - check † K Fuel hose,
  • 2014 Kawasaki KX100 | Owners Manual - Page 42
    accident, 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 the motorcycle perpendicular to the ground. • Place If the oil just been changed, let the motorcycle • sit a fewhas minutes allowing
  • 2014 Kawasaki KX100 | Owners Manual - Page 43
    -40 * Kawasaki Performance Oils and Lubricants have been specifically engineered for your vehicle. Consistent use of these products meets or exceeds service requirements and can help to extend the life of your Kawasaki. Transmission Oil Total Amount 0.7 L (0.74 US qt) j A. Transmission Oil Drain
  • 2014 Kawasaki KX100 | Owners Manual - Page 44
    MAINTENANCE AND ADJUSTMENT 43 ○Do not add any chemical additive to the oil. NOTE Oils fulfilling the above requirements are fully formulated and provide adequate lubrication for both the engine and the clutch. Cooling System Check the water hoses for cracks or deterioration, and the connections
  • 2014 Kawasaki KX100 | Owners Manual - Page 45
    the same direction and remove it. 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 in the cooling system. If hard water is used in
  • 2014 Kawasaki KX100 | Owners Manual - Page 46
    MAINTENANCE AND ADJUSTMENT 45 Coolant Total Amount 0.57 L (0.60 US qt) the radiator cap in two steps. • Install turn the cap clockwise to the first stop. First, • Then, push down and turn the cap further in the • same direction. The coolant should be changed periodically to ensure long engine life.
  • 2014 Kawasaki KX100 | Owners Manual - Page 47
    46 MAINTENANCE AND ADJUSTMENT NOTICE Immediately wash away any coolant that spills on the frame, engine, or wheel. j 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
  • 2014 Kawasaki KX100 | Owners Manual - Page 48
    MAINTENANCE AND ADJUSTMENT 47 Tightening Torque Coolant Drain Bolt (Water Pump): 5.2 N·m (0.53 kgf·m, 46 in·lb) Coolant Drain Bolt (Cylinder): 8.8 N·m (0.90 kgf·m, 78 in·lb) the radiator up to the bottom of the radiator filler • Fill neck with coolant. • Tighten the air bleeder bolt to the
  • 2014 Kawasaki KX100 | Owners Manual - Page 49
    48 MAINTENANCE AND ADJUSTMENT the engine and warm up thoroughly, then • Start stop it. the coolant level after the engine has • Check cooled down. the coolant level is low, add coolant up to the • If bottom of the radiator filler neck. the radiator cap. • Install Check the cooling system for leaks.
  • 2014 Kawasaki KX100 | Owners Manual - Page 50
    MAINTENANCE AND ADJUSTMENT 49 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. The
  • 2014 Kawasaki KX100 | Owners Manual - Page 51
    50 MAINTENANCE AND ADJUSTMENT Ignition Timing 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. If there is any doubt as to the timing, inspect
  • 2014 Kawasaki KX100 | Owners Manual - Page 52
    MAINTENANCE AND ADJUSTMENT 51 ○The ignition timing can be adjusted to change the power band to suit the rider's preference or ability. NOTE • j If necessary, adjust the timing by shifting the stator coil plate position within the three lines. A. Stator Coil Plate Mounting Screws B. Stator Coil
  • 2014 Kawasaki KX100 | Owners Manual - Page 53
    52 MAINTENANCE AND ADJUSTMENT ride the motorcycle and readjust the ignition • Test timing if necessary. j A. B. C. D. Crankshaft Rotation Stator Rotation Retard Advance the stator coil plate mounting screws to the • Tighten specified torque. Tightening Torque Stator Coil Plate Mounting Screws:
  • 2014 Kawasaki KX100 | Owners Manual - Page 54
    MAINTENANCE AND ADJUSTMENT 53 Air Cleaner A clogged air cleaner restricts the air intake, increases fuel consumption, reduces engine power, and can cause spark plug fouling. Inspect the air intake system, which includes the air cleaner element and air duct to the carburetor, and the duct clamps and
  • 2014 Kawasaki KX100 | Owners Manual - Page 55
    54 MAINTENANCE AND ADJUSTMENT the wing bolt, and take out the air cleaner • Remove element. j A. Air Cleaner Element B. Element Frame A. Wing Bolt B. Air Cleaner Element NOTICE Do not twist or wring the element, as it gets easily torn or damaged. the air cleaner element. If it is dirty, clean •
  • 2014 Kawasaki KX100 | Owners Manual - Page 56
    MAINTENANCE AND ADJUSTMENT 55 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 cleaner according to the periodic maintenance chart; more often if the motorcycle is used in extremely
  • 2014 Kawasaki KX100 | Owners Manual - Page 57
    56 MAINTENANCE AND ADJUSTMENT cleaning, let the element dry completely. Sat• After urate the element with a high-quality foam air filter oil and make sure that the oil is evenly applied throughout the element. Squeeze out the excess oil, but do not wring the element as this could cause tearing. In
  • 2014 Kawasaki KX100 | Owners Manual - Page 58
    MAINTENANCE AND ADJUSTMENT 57 the air cleaner element so that the projec• Install tion on it fits into the notch in the holder. the hooks of the seat under the flange collar • Insert and bracket. ○Take care not to damage the side covers with the bracket of seat. NOTE j A. Air Cleaner Element B.
  • 2014 Kawasaki KX100 | Owners Manual - Page 59
    58 MAINTENANCE AND ADJUSTMENT Throttle Cable 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. the
  • 2014 Kawasaki KX100 | Owners Manual - Page 60
    MAINTENANCE AND ADJUSTMENT 59 WARNING Operation with improperly adjusted, incorrectly routed, or damaged cable could result in an unsafe riding condition. Be sure the control cable is adjusted and routed correctly, and is free from damage. j A. Rubber Boot B. Locknut C. Adjuster the engine
  • 2014 Kawasaki KX100 | Owners Manual - Page 61
    60 MAINTENANCE AND ADJUSTMENT Carburetor 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). First turn the air screw in until it
  • 2014 Kawasaki KX100 | Owners Manual - Page 62
    MAINTENANCE AND ADJUSTMENT 61 NOTICE This motorcycle's radiator does not incorporate cooling fan. Prolonged idling of the engine with no airflow through the radiator can cause coolant loss and engine overheating resulting in possible engine damage. Any riding conditions that increase engine
  • 2014 Kawasaki KX100 | Owners Manual - Page 63
    62 MAINTENANCE AND ADJUSTMENT the locknut. • Loosen the upper end of the throttle cable. • Remove Take the adjuster and locknut off the throttle case. • the fuel tap lever to the "OFF" position (see • Turn Stopping the Engine section). the carburetor overflow hose from the clamp • Free on the
  • 2014 Kawasaki KX100 | Owners Manual - Page 64
    MAINTENANCE AND ADJUSTMENT 63 a container under the fuel drain plug. • Place • Remove the fuel drain plug and drain the fuel. NOTICE Never drop the carburetor, especially on a hard surface. Such a shock to the carburetor can damage it. the screws and take off the carburetor • Remove body. j A.
  • 2014 Kawasaki KX100 | Owners Manual - Page 65
    64 MAINTENANCE AND ADJUSTMENT WARNING Gasoline and low flash-point solvents can be flammable and/or explosive and cause severe burns. Clean the carburetor in a well -ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a
  • 2014 Kawasaki KX100 | Owners Manual - Page 66
    MAINTENANCE AND ADJUSTMENT 65 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 specification, first try adjusting it at
  • 2014 Kawasaki KX100 | Owners Manual - Page 67
    66 MAINTENANCE AND ADJUSTMENT If the clutch lever free 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
  • 2014 Kawasaki KX100 | Owners Manual - Page 68
    MAINTENANCE AND ADJUSTMENT 67 the clutch cable off the cable holder. • Take the lower end of the clutch cable off the clutch • Take release lever. the clutch cover bolts. • Remove Turn the clutch release lever toward the rear. • j NOTICE Do not remove the clutch release shaft unless it is
  • 2014 Kawasaki KX100 | Owners Manual - Page 69
    68 MAINTENANCE AND ADJUSTMENT the clutch spring bolts, springs and clutch • Remove pressure plate. • Remove the friction plates and steel plates. j A. Clutch Spring Bolts and Springs B. Clutch Pressure Plate A. Friction Plates B. Steel Plates When it is hard to remove the clutch spring bolts,
  • 2014 Kawasaki KX100 | Owners Manual - Page 70
    plates with • Measure vernier calipers. they have worn past the service limit, replace • If them with new ones. Friction Plate Thickness Standard 2.92 ∼ 3.08 plate or steel plate). If any plate is warped over the service limit, replace it with a new one. Friction and Steel Plate Warp 0.15 mm
  • 2014 Kawasaki KX100 | Owners Manual - Page 71
    disulfide grease to the swollen • Apply areas of the clutch spring push rod. • Install the clutch spring push rod and the washer. j Service Limit 0.3 mm (0.01 in.) A. Surface Plate B. Friction or Steel Plate C. Thickness Gauge Friction and Steel Plate Installation all parts in the reverse
  • 2014 Kawasaki KX100 | Owners Manual - Page 72
    MAINTENANCE AND ADJUSTMENT 71 the clutch cover bolts to the specified • Tighten torque. Tightening Torque Clutch Cover Bolts: 9.4 N·m (1.0 kgf·m, 83 in·lb) the magneto cover gasket with a new • Replace one. the magneto cover. • Install Check transmission oil level (see Transmis• sion Oilthe section
  • 2014 Kawasaki KX100 | Owners Manual - Page 73
    72 MAINTENANCE AND ADJUSTMENT Piston Piston Removal the fuel tap lever to the "OFF" position (see • Turn Stopping the Engine section). the coolant (see Cooling System section). • Drain the fuel tank mounting bolt for easier re• Remove moval of cylinder. • Remove the bolts and the shrouds on both
  • 2014 Kawasaki KX100 | Owners Manual - Page 74
    MAINTENANCE AND ADJUSTMENT 73 the radiator screen bolt. • Remove • Clear the hook and remove the radiator screen. the overflow hose. • Disconnect the water hose clamp screws, and discon• Loosen nect the water hoses. j A. Radiator Screen Bolt B. Hook C. Radiator Screen A. Overflow Hose B. Water
  • 2014 Kawasaki KX100 | Owners Manual - Page 75
    74 MAINTENANCE AND ADJUSTMENT the radiator mounting bolts, clamp and • Remove radiator. the water hose clamp screws, and discon• Loosen nect the water hoses. j A. Radiator Mounting Bolts B. Clamp C. Radiator A. Water Hose Clamp Screws B. Water Hoses
  • 2014 Kawasaki KX100 | Owners Manual - Page 76
    MAINTENANCE AND ADJUSTMENT 75 the spark plug cap (see Spark Plug sec• Remove tion). the muffler (see Exhaust System sec• Remove tion). the expansion chamber mounting • Remove springs. • Remove screen. the shroud screen bolt and shroud j A. Shroud Screen Bolt B. Shroud Screen A. Expansion
  • 2014 Kawasaki KX100 | Owners Manual - Page 77
    76 MAINTENANCE AND ADJUSTMENT the expansion chamber mounting bolt • Remove and take off the expansion chamber. the engine bracket mounting bolts, nuts • Remove and the engine brackets. the cylinder head nuts, cylinder head and • Remove the gasket. j A. Expansion Chamber Mounting Bolt B. Expansion
  • 2014 Kawasaki KX100 | Owners Manual - Page 78
    MAINTENANCE AND ADJUSTMENT 77 the carburetor from the cylinder intake • Remove joint (see Carburetor section). the KIPS cover bolts and the KIPS cover. • Remove Remove the KIPS cover gasket. • the circlip. • Remove the shaft lever, and disconnect the link lever • Push to the operating rod. • Push
  • 2014 Kawasaki KX100 | Owners Manual - Page 79
    78 MAINTENANCE AND ADJUSTMENT the alternator lead from the clamp. • Open the cylinder nuts. • Remove Lift off the and remove the cylinder base • gasket. If cylinder, necessary, tap lightly around the base of the cylinder with a plastic mallet, taking care not to damage the cylinder. a clean cloth
  • 2014 Kawasaki KX100 | Owners Manual - Page 80
    MAINTENANCE AND ADJUSTMENT 79 the piston by pushing the piston pin out • Remove the side from which the snap ring was removed. Use a piston pin puller assembly (special tool: 57001-910), if the pin is tight. j A. Piston Ring Piston Ring/Ring Groove Clearance Inspection A. Piston Pin Puller
  • 2014 Kawasaki KX100 | Owners Manual - Page 81
    at several points around • Measure the ring with a micrometer. Piston Ring Thickness 0.97 ∼ 0.99 mm Standard (0.038 ∼ 0.039 in.) A. Thickness Gauge Service Limit 0.90 mm (0.035 in.) Piston Ring/Ring Groove Clearance KX85C 0.02 ∼ 0.06 mm Standard (0.0008 ∼ 0.0024 in.) KX100F KX85C KX100F 0.04
  • 2014 Kawasaki KX100 | Owners Manual - Page 82
    pin hole diameter exceeds the ser• If vice limit, replace the piston. the inside diameter of the connecting rod small • If end exceeds the service limit, replace the crank- Piston, Piston Pin, and Connecting Rod Wear Inspection inspect the snap rings still fitted in place. • Visually If the snap
  • 2014 Kawasaki KX100 | Owners Manual - Page 83
    82 MAINTENANCE AND ADJUSTMENT off 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 ring. Don't allow such particles to
  • 2014 Kawasaki KX100 | Owners Manual - Page 84
    MAINTENANCE AND ADJUSTMENT 83 j A. Piston Ring B. Marked side A. Pin the piston ring so that the pin in the piston • Install 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. ○Install the piston with its
  • 2014 Kawasaki KX100 | Owners Manual - Page 85
    84 MAINTENANCE AND ADJUSTMENT j A. Mark B. "IN" Mark (KX85C) installing a piston pin snap ring, compress • When it only enough to install it and no more. A. Piston Pin Snap Ring B. Snap Ring Ends C. Notch NOTICE Do not reuse snap rings, as removal weakens and deforms them. They could fall out
  • 2014 Kawasaki KX100 | Owners Manual - Page 86
    MAINTENANCE AND ADJUSTMENT 85 j A. Pin the cylinder nuts to the specified torque in • Tighten a crisscross pattern. Tightening Torque Cylinder Nuts: 25 N·m (2.5 kgf·m, 18 ft·lb) Cylinder Head Installation Replace the cylinder head gasket with a new one. Scrape out any carbon and clean the
  • 2014 Kawasaki KX100 | Owners Manual - Page 87
    86 MAINTENANCE AND ADJUSTMENT the link lever to the link pin and insert the • Link circlip to the KIPS shaft lever. the exhaust gasket with a new one. • Replace Replace the exhaust O-rings with new ones. • Apply molybdenum • exhaust O-rings. disulfide grease around the j A. Expansion Chamber
  • 2014 Kawasaki KX100 | Owners Manual - Page 88
    MAINTENANCE AND ADJUSTMENT 87 j A. Radiator B. Clamp C. Radiator Screen D. Projections E. Holes A. Shroud Screen B. Projections C. Holes the shroud screen so that the projections fit • Install into the holes. the removed parts. • Install the coolant and check the coolant level (see • Fill
  • 2014 Kawasaki KX100 | Owners Manual - Page 89
    88 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
  • 2014 Kawasaki KX100 | Owners Manual - Page 90
    MAINTENANCE AND ADJUSTMENT 89 the muffler mounting bolts and washer, • Remove and pull the muffler off toward the rear. the liquid gasket on the silencer, tail pipe • Remove and baffle. the muffler body cover bolts, and pull out • Remove the tail pipe. j A. Muffler Mounting Bolts B. Washer C.
  • 2014 Kawasaki KX100 | Owners Manual - Page 91
    90 MAINTENANCE AND ADJUSTMENT the O-ring between the silencer wool and • Remove tail pipe. out the baffle by tapping the inner pipe with • Push a suitable tool. • Pull off the silencer wool. j A. O-ring B. Silencer Wool A. Baffle B. Silencer Wool C. Push Out the silencer wool and O-ring with new
  • 2014 Kawasaki KX100 | Owners Manual - Page 92
    MAINTENANCE AND ADJUSTMENT 91 a high flash-point solvent, clean off any oil or • Using 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. j A. B. C. D. O-ring Liquid Gasket Silencer Tail Pipe A.
  • 2014 Kawasaki KX100 | Owners Manual - Page 93
    92 MAINTENANCE AND ADJUSTMENT 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
  • 2014 Kawasaki KX100 | Owners Manual - Page 94
    MAINTENANCE AND ADJUSTMENT 93 the chain is too tight, back out the left and right 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
  • 2014 Kawasaki KX100 | Owners Manual - Page 95
    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
  • 2014 Kawasaki KX100 | Owners Manual - Page 96
    in the direction of chain rotation. j A. Weight B. Tape Measure Drive Chain 20-link Length 254.0 ∼ 254.6 mm (10.00 ∼ 10.02 Standard in.) Service Limit 259 mm (10.2 in.) A. Master Link Clip B. Direction of Chain Rotation ○The NOTE drive system was designed for use with a DAIDO DID 420DS2 chain
  • 2014 Kawasaki KX100 | Owners Manual - Page 97
    or damaged. j inspect the upper and lower of the chain • Visually slipper on the swingarm and replace them if worn A. Drive Chain Guide A. Upper and Lower of the Chain Slipper B. Swingarm Sprocket Wear Inspection inspect the sprocket teeth and replace the • Visually sprocket if its teeth
  • 2014 Kawasaki KX100 | Owners Manual - Page 98
    MAINTENANCE AND ADJUSTMENT 97 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
  • 2014 Kawasaki KX100 | Owners Manual - Page 99
    98 MAINTENANCE AND ADJUSTMENT Handlebar Handlebar Removal the clamp of the number plate (see Steer• Unlock ing section). the handlebar holder bolts, the handlebar • Remove holders and the handlebars. j the holders so that the arrow marks on the • Install holders point at the front. the punch mark
  • 2014 Kawasaki KX100 | Owners Manual - Page 100
    MAINTENANCE AND ADJUSTMENT 99 the handlebars (see Handlebar Removal • Remove in this section). the handlebars for bent or crack. • Check Remove the handlebar holder nuts and washers, • and the handlebar holders. j A. Handlebar Holders B. Gap Tightening Torque Handlebar Holder Bolts: 25 N·m (2.5
  • 2014 Kawasaki KX100 | Owners Manual - Page 101
    100 MAINTENANCE AND ADJUSTMENT To suit various riding positions, the handlebar position can be adjusted by turning the handlebar holders around. Remove the handlebars (see Handlebar Removal in this section). Check the handlebars for bent or crack. Remove the handlebar holder nuts and washers, and
  • 2014 Kawasaki KX100 | Owners Manual - Page 102
    MAINTENANCE AND ADJUSTMENT 101 Tightening Torque Handlebar Holder Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb) the handlebars (see Handlebar Installation • Install in this section). Brakes Disc and disc pad wear is automatically compensated for and has no effect on the brake lever or pedal action. There are
  • 2014 Kawasaki KX100 | Owners Manual - Page 103
    102 MAINTENANCE AND ADJUSTMENT Inspect the brake fluid level in the front and rear brake 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 follows.
  • 2014 Kawasaki KX100 | Owners Manual - Page 104
    MAINTENANCE AND ADJUSTMENT 103 j A. Front Brake Reservoir B. Lower Level Line A. Front Brake Reservoir Cap Screws B. Front Brake Reservoir Cap the brake fluid in the front brake reservoir is be• If low the lower level line, check for fluid leaks in the the screws and the front brake reservoir •
  • 2014 Kawasaki KX100 | Owners Manual - Page 105
    104 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
  • 2014 Kawasaki KX100 | Owners Manual - Page 106
    as a set. Pad replacement should be done by an authorized Kawasaki dealer. Brake Pads Lining Thickness Standard 4.0 mm (0.16 in.) Service Limit 1 mm (0.04 in.) j Usable Brake Pad Range A. B. C. D. Reservoir Cap Clockwise 1/6 turn A. Lining Thickness B. 1 mm (0.04 in.) Inspect the brake
  • 2014 Kawasaki KX100 | Owners Manual - Page 107
    106 MAINTENANCE AND ADJUSTMENT Steering The steering should always be kept adjusted so that the handlebars will turn freely but not have excessive play. j Steering Inspection check the steering adjustment, raise the front • To wheel off the ground using a jack (special tool: • • 57001-1238)
  • 2014 Kawasaki KX100 | Owners Manual - Page 108
    MAINTENANCE AND ADJUSTMENT 107 the steering stem head nut. • Loosen the steering stem nut with a stem nut wrench • Turn (special tool: 57001-1100) to obtain the proper adjustment. j A. B. C. D. Clamp Number Plate Number Plate Mounting Bolt Projections A. Steering Stem Head Nut B. Steering Stem
  • 2014 Kawasaki KX100 | Owners Manual - Page 109
    108 MAINTENANCE AND ADJUSTMENT Tightening Torque Steering Stem Head Nut: 64 N·m (6.5 kgf·m, 47 ft·lb) Steering Stem Nut: 4.9 N·m (0.50 kgf·m, 43 in·lb) Front Fork Clamp Bolts (Upper): 20 N·m (2.0 kgf·m, 15 ft·lb) the handlebars (see Handlebar section), • Install and check the steering again and
  • 2014 Kawasaki KX100 | Owners Manual - Page 110
    oil seal, leading to an oil leak. Clean the sliding surface after each ride. the brake lever, pump the front fork back • Holding and forth manually to check for smooth operation. inspect the front fork for oil leakage, scor• Visually ing or scratches on the outer surface of the inner necessary
  • 2014 Kawasaki KX100 | Owners Manual - Page 111
    110 MAINTENANCE AND ADJUSTMENT on your KX will get stiffer as the race progresses. Therefore, it is not recommended to increase the air pressure for additional springing. The KX forks are designed to function without added air. Compression Damping Adjustment This adjustment affects how quickly the
  • 2014 Kawasaki KX100 | Owners Manual - Page 112
    MAINTENANCE AND ADJUSTMENT 111 j A. Air Pressure Relief Screw B. Front Fork Top Plug A. Cap (Both Sides) Compression Damping Adjustment cial tool: 57001-1608). adjust the compression damping, turn the ad• To juster on the compression valve assembly with a standard tip screwdriver. Adjust the
  • 2014 Kawasaki KX100 | Owners Manual - Page 113
    112 MAINTENANCE AND ADJUSTMENT Compression Damper Settings j 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
  • 2014 Kawasaki KX100 | Owners Manual - Page 114
    MAINTENANCE AND ADJUSTMENT 113 NOTICE The right and left fork tubes must be adjusted evenly. • Remove the bolts and the front fender. j • 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
  • 2014 Kawasaki KX100 | Owners Manual - Page 115
    Front Fork Top Plug the motorcycle using a jack (special tool: • Support 57001-1238) and attachment (special tool: 57001 A. B. C. D. Bolts 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.
  • 2014 Kawasaki KX100 | Owners Manual - Page 116
    MAINTENANCE AND ADJUSTMENT 115 j A. Inner Tube (Stepped Portion) B. Dust Seal C. Outer Tube A. Suitable Support B. Front Wheel a stand or other suitable support under the • Place front wheel. holding the front fork push rod nut with a • While wrench, remove the front fork top plug from the •
  • 2014 Kawasaki KX100 | Owners Manual - Page 117
    116 MAINTENANCE AND ADJUSTMENT j A. Front Fork Push Rod Nut B. Wrench C. Front Fork Top Plug D. Fork Spring Seat E. Fork Spring A. Push Rod Puller (Special Tool: 57001-1298) B. Push Rod the other fork spring in the same way as • Remove described above. the front fork to the top of the inner tube
  • 2014 Kawasaki KX100 | Owners Manual - Page 118
    MAINTENANCE AND ADJUSTMENT 117 j A. Outer Tube Opening B. Oil Level Gauge (Special Tool: 57001-1290) up the push rod puller. • Pull Hold push rod with your hand and remove the • push the rod puller. the fork spring and the fork spring seat on • Install the fork spring. • Replace both top plug O-
  • 2014 Kawasaki KX100 | Owners Manual - Page 119
    Rod Nut Front Fork Top Plug Push Rod Wrench j Tightening Torque Front Fork Push Rod Nuts: 15 N·m (1.5 kgf·m, 11 ft·lb) the stand and support to apply load to the • Remove vehicle. the front fork top plug to the specified • Tighten torque. Tightening Torque Front Fork Top Plugs: 28 N·m (2.9 kgf
  • 2014 Kawasaki KX100 | Owners Manual - Page 120
    MAINTENANCE AND ADJUSTMENT 119 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
  • 2014 Kawasaki KX100 | Owners Manual - Page 121
    120 MAINTENANCE AND ADJUSTMENT The spring preload of the shock absorber can be adjusted or the spring can be replaced with an optional one to suit various riding conditions. In addition, the damping force can be adjusted easily, making it unnecessary to change the oil viscosity. To adjust the rear
  • 2014 Kawasaki KX100 | Owners Manual - Page 122
    MAINTENANCE AND ADJUSTMENT 121 ○Adjustment of the rebound damping adjuster for NOTE Compression Damper Settings the rear suspension will slightly affect the compression damping force. Always make any damping adjustments in small steps and test their effects before using them in competition. j
  • 2014 Kawasaki KX100 | Owners Manual - Page 123
    122 MAINTENANCE AND ADJUSTMENT NOTICE Do not force the compression damping force adjuster beyond the fully seated position, or the adjusting mechanism may be damaged. j ○Adjustment of the compression damping adjuster NOTE for the rear suspension will slightly affect the rebound damping force.
  • 2014 Kawasaki KX100 | Owners Manual - Page 124
    MAINTENANCE AND ADJUSTMENT 123 j A. Bolts, Nuts and Washers B. Bolts C. Rear Fender D. Bolts and Collars E. Rear Flap A. Rear Frame Pipe Bolts and Nuts B. Bolt C. Rear Frame Pipe the rear frame pipe bolts and nuts, and • Remove remove the rear frame pipe. the muffler (see Exhaust System sec•
  • 2014 Kawasaki KX100 | Owners Manual - Page 125
    124 MAINTENANCE AND ADJUSTMENT the • Using 57001-1101, hook wrenches (special tools: 1580), loosen the rear shock absorber spring locknut on the rear shock absorber. j A. B. C. D. Air Cleaner Duct Clamp Screw Bolts Air Cleaner Case Air Cleaner Duct a clean cloth into the carburetor opening to •
  • 2014 Kawasaki KX100 | Owners Manual - Page 126
    MAINTENANCE AND ADJUSTMENT 125 the hook wrench (special tool: 57001-1101), • Using turn the spring preload adjusting nut as required. Turning the adjusting nut down increases the spring preload. j A. Adjusting Nut Position B. Center of Upper Rear Shock Absorber Pivot C. Spring End A. Hook Wrench
  • 2014 Kawasaki KX100 | Owners Manual - Page 127
    126 MAINTENANCE AND ADJUSTMENT Various rear shock absorber springs are available to achieve suitable rear shock absorber action in accordance with the rider's weight and track condition. A harder spring stiffens the shock absorber action and accelerates the rebound damping. A softer spring softens
  • 2014 Kawasaki KX100 | Owners Manual - Page 128
    MAINTENANCE AND ADJUSTMENT 127 the tire air pressure to prevent damage • Increase 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 ∼ 18.1 psi) Rear 100 ∼ 125 kPa (1.02 ∼ 1.27 kgf/cm²,
  • 2014 Kawasaki KX100 | Owners Manual - Page 129
    badly bent, however, it should be replaced. A. Rim B. Axial Runout C. Radial Runout Rim Runout (with tire installed) *TIR 1.0 mm (0.04 in.) or Standard less Axial Service Limit *TIR 2.0 mm (0.08 in.) Radial Standard *TIR 1.0 mm (0.04 in.) or less
  • 2014 Kawasaki KX100 | Owners Manual - Page 130
    MAINTENANCE AND ADJUSTMENT 129 *: Total Indicator Reading Hoses Inspection Check the brake and fuel hoses for cracks or deterioration, and the connections for looseness in accordance with the Periodic Maintenance Chart. Inspect the hoses and fittings for deterioration, cracks and signs of leakage
  • 2014 Kawasaki KX100 | Owners Manual - Page 131
    130 MAINTENANCE AND ADJUSTMENT Tightening Torques 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. j Location of nuts and bolts 1. Front Fork Clamp Bolts (
  • 2014 Kawasaki KX100 | Owners Manual - Page 132
    MAINTENANCE AND ADJUSTMENT 131 j 1. Rear Caliper Mounting Bolts 2. Rear Brake Pad Pins 3. Rear Master Cylinder Mounting Bolts 4. Rear Frame Pipe Nuts 5. Rear Shock Absorber Mounting Bolts 6. Clutch Cover Bolts 7. Clutch Spring Bolts 8. Air Bleeder Bolt 9. Front Master Cylinder Clamp Bolts 10.
  • 2014 Kawasaki KX100 | Owners Manual - Page 133
    132 MAINTENANCE AND ADJUSTMENT 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 become
  • 2014 Kawasaki KX100 | Owners Manual - Page 134
    MAINTENANCE AND ADJUSTMENT 133 Fastener Front Fork Push Rod Nut (Both Sides) Handlebar Holder Nuts Stator Coil Plate Mounting Screws Rear Sprocket Nuts Rear Caliper Mounting Bolts Rear Brake Pad Pins Rear Master Cylinder Mounting Bolts Rear Frame Pipe Nuts Rear Shock Absorber Mounting Bolts Clutch
  • 2014 Kawasaki KX100 | Owners Manual - Page 135
    134 MAINTENANCE AND ADJUSTMENT Fastener Rocker Arm Pivot Nut Rocker Arm Bracket Bolts Swingarm Pivot Shaft Nut Transmission Oil Drain Bolt Coolant Drain Bolt (Water Pump) Coolant Drain Bolt (Cylinder) Water Hose Clamp Screws Engine Bracket Mounting Nuts Compression Valve Assembly (Both Sides) Front
  • 2014 Kawasaki KX100 | Owners Manual - Page 136
    such as ammo- j 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
  • 2014 Kawasaki KX100 | Owners Manual - Page 137
    months or as conditions require. Avoid surfaces with "satin" or "flat" finishes. Always use non-abrasive products and apply them according to the instructions on the container. After washing use a soft cloth to gently dry plastic parts. When dry, treat the non-painted plastic parts with an approved
  • 2014 Kawasaki KX100 | Owners Manual - Page 138
    MAINTENANCE AND ADJUSTMENT 137 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. If your motorcycle has leather accessories, special care must be taken
  • 2014 Kawasaki KX100 | Owners Manual - Page 139
    138 MAINTENANCE AND ADJUSTMENT Brake Pedal • Rear Master Cylinder Joint Pin • Rear Pedal • Kick Footpeg • • Shift Pedal j Apply an aerosol cable lubricant with a pressure lubricator on all cables: Clutch Cable Throttle Cable • •
  • 2014 Kawasaki KX100 | Owners Manual - Page 140
    MAINTENANCE AND ADJUSTMENT 139 Cable Lubrication Inner Cable Upper End • Clutch Throttle Inner Cable Upper End • Apply grease to the following points: j A. Upper End
  • 2014 Kawasaki KX100 | Owners Manual - Page 141
    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. Apply lubricant to the sides of the rollers so that it will penetrate to the rollers and bushings
  • 2014 Kawasaki KX100 | Owners Manual - Page 142
    TROUBLESHOOTING GUIDE 141 TROUBLESHOOTING GUIDE ○This troubleshooting guide is not exhaustive and 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. Starting failure or
  • 2014 Kawasaki KX100 | Owners Manual - Page 143
    142 TROUBLESHOOTING GUIDE head warped • Cylinder base gasket damaged • Cylinder • Reed valve damaged Poor low-speed performance plug dirty, broken, or gap improperly ad• Spark justed plug cap
  • 2014 Kawasaki KX100 | Owners Manual - Page 144
    TROUBLESHOOTING GUIDE 143 needle clip in wrong position • Jet fuel level too high or too low • Carburetor Air jet or air passage clogged • Air cleaner element clogged,
  • 2014 Kawasaki KX100 | Owners Manual - Page 145
    144 TROUBLESHOOTING GUIDE cleaner element clogged, poorly sealed, or not • Air installed • Air intake duct poorly sealed Compression high: • Carbon built up in combustion chamber Engine overloaded: dragging •
  • 2014 Kawasaki KX100 | Owners Manual - Page 146
    TROUBLESHOOTING GUIDE 145 fork pin worn • Shift • Drive shaft, output shaft, and/or gear splines worn Transmission skips gears: positioning lever spring weak or broken • Gear Shift
  • 2014 Kawasaki KX100 | Owners Manual - Page 147
    146 TROUBLESHOOTING GUIDE Disc brake noise: Pad installed incorrectly Pad surface glazed Brake disc warped Brake caliper defective Brake master cylinder damaged j Other noise: nut, bolt, etc. • Bracket,
  • 2014 Kawasaki KX100 | Owners Manual - Page 148
    TROUBLESHOOTING GUIDE 147 Shock absorption unsatisfactory (suspension too hard): Front fork oil excessive Front fork oil viscosity too high Front fork leg bent Tire air pressure too
  • 2014 Kawasaki KX100 | Owners Manual - Page 149
    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
  • 2014 Kawasaki KX100 | Owners Manual - Page 150
    TUNING 149 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. Carburetor tuning is made by replacing or adjusting the main jet, jet needle and slow jet, which regulate the fuel flow, and the
  • 2014 Kawasaki KX100 | Owners Manual - Page 151
    150 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; the mixture is thereby enrichened. Moving the
  • 2014 Kawasaki KX100 | Owners Manual - Page 152
    TUNING 151 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
  • 2014 Kawasaki KX100 | Owners Manual - Page 153
    152 TUNING Test Runs all carburetor settings on standard, warm up • With the engine, run two or three laps of the course and examine the spark plug condition with varying throttle openings. Mixture Correct Too lean Too rich ○If the fuel/air mixture is too lean, the engine tends to overheat and may
  • 2014 Kawasaki KX100 | Owners Manual - Page 154
    TUNING 153 j A. Temperature °C (°F) B. Altitude C. 3 000 m (9 600 ft) D. 2 000 m (6 400 ft) E. 1 000 m (3 200 ft) F. Sea Level G. Correction Factor
  • 2014 Kawasaki KX100 | Owners Manual - Page 155
    154 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 Jet Needle Setting Air Screw Opening lower clip one position one turn in same 1/2 turn in same 1/2 turn out 0.98 - 0.94 0.94 or below raise clip one position one turn out j
  • 2014 Kawasaki KX100 | Owners Manual - Page 156
    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
  • 2014 Kawasaki KX100 | Owners Manual - Page 157
    Front Fork Improper Adjustment Symptoms A. Weight B. Fork Stroke C. EX: 300 mm (11.8 in.) D. Increase Level E. Standard Oil Level F. Decrease Level Troubleshooting Improper Settings j Too Hard Spring too stiff: Compression damping improperly adjusted. Spring too hard Fork oil level too high Fork
  • 2014 Kawasaki KX100 | Owners Manual - Page 158
    TUNING 157 Rear shock absorber improper adjustment symptoms Too Hard Suspension too stiff: Compression damping too high Spring too hard Rebound damping too high Spring preload too hard much above or below the intermediate level, it is likely that a few basic suspension adjustments will be necessary.
  • 2014 Kawasaki KX100 | Owners Manual - Page 159
    158 TUNING Suspension Tuning According the Type of Course Lower the front end slightly [Increase the amount of fork tube protrusion above the steering stem head by 5 mm Many Corners (0.2 in.)]. This accelerates steering and enhances turning ability. Raise the front end slightly [Decrease the amount
  • 2014 Kawasaki KX100 | Owners Manual - Page 160
    at the track and the rider's preferences. ○Lighter NOTE or less experienced riders may need a softer spring. Front and Rear Suspension Troubleshooting Front End Surges Downhill or Acceleration Out of Corner The front suspension is too soft. Increase the compression damping. Increase the fork oil
  • 2014 Kawasaki KX100 | Owners Manual - Page 161
    160 TUNING the rear shock absorber spring preload • Increase or use a harder spring. the rear shock absorber compression • Increase damping or use a harder spring. The rear suspension is too soft. ○Observe the rear end jumps and try lowering the spring preload and damping if it does not approach
  • 2014 Kawasaki KX100 | Owners Manual - Page 162
    TUNING 161 Gearing Selection of the Secondary Reduction Ratio (Rear Sprocket) Rear Sprocket Selection According to Course Conditions Fast Course Small Sprocket Many Corners or Hills Sandy or Soft Ground Large Sprocket it is difficult to set the machine so it is best • Since suited for all portions
  • 2014 Kawasaki KX100 | Owners Manual - Page 163
    162 TUNING Special Care According to Track Conditions dry, dusty conditions (such a volcanic ash or • In fine powdery dust), special care must be given to muddy or sandy conditions, increase chain • In slack as the chain and sprockets will be packed • • • j • • keeping the air cleaner element
  • 2014 Kawasaki KX100 | Owners Manual - Page 164
    OPTIONAL PARTS 163 OPTIONAL PARTS Optional part Carburetor 135 138 Main Jet **140 142 145 150 35 Slow Jet **38 40 42 Leaner Leaner Richer KX85C KX100F Jet Needle Richer NRJA NRJB **NRJC NRJD NRJE NRKA NRKB NRKC NRKD NRKE NRJA NRJB NRJC NRJD NRJE NRKA NRKB **NRKC NRKD NRKE ○NRJ* is 0.5 clip
  • 2014 Kawasaki KX100 | Owners Manual - Page 165
    164 OPTIONAL PARTS Optional part Engine Sprocket Rear Sprocket KX85C 13T **14T 48T 49T **50T 51T 52T Suspension Spring [N/mm (kgf/mm)] K = 2.65 (0.27) K = 2.75 (0.28) Front **K = 2.84 (0.29) K = 2.94 (0.30) K = 43 (4.4) K = 45 (4.6) Rear **K = 47 (4.8) K = 49 (5.0) KX100F **13T 14T 49T 50T **51T 52T
  • 2014 Kawasaki KX100 | Owners Manual - Page 166
    , cylinder, piston • If and crankshaft bearings will be damaged. 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. Clean the sliding surface of the front fork and rear shock absorber.
  • 2014 Kawasaki KX100 | Owners Manual - Page 167
    166 PRE-RACE CHECKS AND AFTER-RACE MAINTENANCE Maintenance After Riding in the Rain or on a Muddy Course Clean the sliding surface of the front fork and rear shock absorber. Apply grease to swingarm and rear suspension pivots. Inspect the drive chain and rear sprocket for wear. Clean the air cleaner
  • 2014 Kawasaki KX100 | Owners Manual - Page 168
    STORAGE 167 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
  • 2014 Kawasaki KX100 | Owners Manual - Page 169
    168 STORAGE After Storage the plastic bag from the muffler. • Remove Make sure the spark plug is tight. • the fuel tank with fuel. • Fill all the points listed in the Daily Pre-Ride • Check Checks section. a lubrication procedure in the Lubrication • Perform section. ○Fit the plug cap securely
  • 2014 Kawasaki KX100 | Owners Manual - Page 170
    ENVIRONMENTAL PROTECTION 169 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
  • 2014 Kawasaki KX100 | Owners Manual - Page 171
    170 WIRING DIAGRAM WIRING DIAGRAM
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