Technical Information To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary.
If there is any doubt as to the condition of them, replace them with new ones. Abrasion Crack Hardening Warp Bent Overall Width mm Overall Height 1 mm Rear mm 7.
Specifications are subject to change without notice, and may not apply to every country. Wheelbase 1 mm EUR : Europe Model Page Technical Information [E]. Suppose the 1st gear position is set as shown. Neutral Detent 85610 2. The composite plating includes a nickel-phosphorous alloy, inorganic materials like ce- ramic, silicone carbide and some organic materials.
New Model C. Full Opened Position D. Low Speed Position E. Previous Carburetor B. New Carburetor C. Jet Needle D. Air Baffle E. Main Air F. Needle Jet G. Mikuni TMX carburetor helps boost mid-range and top-end power. Torque and Locking Agent Page 38 Page Specifications 1. Cylinder, Piston KX : KX 2. Steel Plate Thickness: 1. Because of the danger of highly flammable liquids, do not use gasoline or a low flash-point solvent to clean the element.
KX 1. Page 48 Then push down and turn it further in the same direction and remove the cap. KX or KX [A] up from the bottom of the piston at a right angle to the direction of the piston pin. KX 0. Page Piston Ring, Piston Ring Groove Inspection If the ring has worn down to less than the service limit, replace the ring; if the groove width exceeds the service limit, replace the piston.
Standard: Service Limit: 0. Service Limit: KX Page Clutch Plates Inspection Measure the thickness [A] of the friction plates [B] and steel plates with vernier calipers.
If they have worn past the service limit, replace them with new ones. Friction Plate Thickness KX 2. Standard: Service Limit: 2. Page Tires Inspection Check and balance the wheel when a tire is replaced with a new one.
If spoke tightness is uneven or loose, tighten the spoke nipples evenly. Torque - Spoke Nipples: 2. Open the bleed valve [A] 2. If you feel looseness, adjust the steering. If the steering is too tight or too loose, repeat the adjust- ment as mentioned above. The plug may also be cleaned using a high-flash point solvent and a wire brush or other suitable tool. Also, check to see that each cotter pin is in place and in good condition.
Special Tools Throttle Grip and Cable Air Screw Slow Jet Main Jet Needle Jet Main Jet Holder Float Valve Needle Float Carburetor Holder 23a. O: Apply oil. Also, the throttle valve may not open fully at full throttle. Page Carburetor Remove the drain plug from the bottom of the float bowl, and screw a fuel level gauge [A] into the plug hole. KX If the fuel level is incorrect, adjust it.
Page 93 Increasing the float height lowers the fuel level and decreasing the float height raises the fuel level. Float Height Standard: 9. KX 6. After draining, install the drain plug securely. Page Fuel Inspection Install the drain plug on the float bowl, and tighten it se- curely. Idle Adjusting Screw B. Nut C. Air Screw D. Spring E. Always stop the engine and do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; If the slow jet is damaged, replace it with a new one.
If the fuel tap screen have any breaks or is deteriorated, it may allow dirt to reach the carburetor, causing poor run- ning. If there is any doubt as to the condition of a reed, replace the reed valve part with a new one. If a reed becomes wavy, replace the valve part with a new one even if its warp is less than the service limit. Special Tool Coolant Level Inspection Coolant Deterioration Inspection Coolant Draining Coolant Filling Air Bleeding Cooling System Pressure Testing Cooling System Flushing Disassembly and Assembly Precautions Change the coolant in accordance with the Periodic Maintenance Chart see Periodic Maintenance chapter.
WARNING To avoid burns, do not remove the radiator cap or try to inspect the coolant level or change the coolant when the engine is still hot. When this accumulation is suspected or observed, flush the cool- ing system.
If this accumulation is not removed, it will clog up the water passages and considerably reduce the effi- ciency of the cooling system. If the surface is corroded, or if the blades [B] are dam- aged, replace the impeller. If there are obstructions to air flow, remove them.
If the corrugated fins are deformed, carefully straighten them with the thin blade of a screwdriver [A]. If any one of them shows visible damage, replace the cap. Page Main Valve Cover Bolts Governor Shaft Lever Exhaust Valve Right Identification Slot Exhaust Valve Left 34a. Expansion Chamber KXM1 model 34b. Rubber Seals Muffler Body G: Apply grease. L: Apply a non-permanent locking agent. Cylinder, Piston Clutch Cable Clutch Lever Free Play Check Free Play Adjustment Clutch Cable Removal Clutch Cable Installation Clutch Cable Lubrication and Inspection Clutch Cover Page Engine Right Side G: Apply high temperature grease.
L: Apply a non-permanent locking agent to the threads. M: Apply molybdenum disulfide grease O: Apply oil. Si: Apply silicone grease. Page Clutch Cable Line up the slots [C] in the clutch lever, knurled locknut, and adjuster, and then free the cable from the clutch lever. Page Right Engine Cover [B] from the right side of the cylinder.
Page Clutch [B]. Engine Removal Engine Installation Frame 6. Engine Mounting Bracket 7. Special Tools and Sealant Transmission Oil Oil Level Inspection Oil Change Crankcase Splitting Crankcase Disassembly WARNING Motorcycle operation with insufficient, deteri- orated, or contaminated transmission oil will accelerated wear and may result in transmission seizure, and injury.
Be certain to screw the tool in all the way. If any of them has been removed, replace it with a new one. If the crankshaft will not turn, probably the crankshaft is not centered; tap the appropriate end of the crankshaft with a mallet to reposition it. The maximum difference in gauge readings is the crankshaft runout. KX - 8. Page Transmission The drive shaft gears can be identified by size; the smallest diameter gear is 1st gear, and the largest is 5th KX or 6th KX Be sure that all parts are put back in the correct sequence, and facing the proper di- rection, and that all circlips and the washers are properly in place.
Page The output shaft gears can be identified by size; the largest diameter gear is 1st gear, and the smallest is 5th KX or 6th KX Be sure that all parts are put back in the correct sequence and facing the proper direction, and that all circlips are properly in place.
Page Shift Fork Bending Inspection If the thickness of a shift fork ear is less than the service limit, the shift fork must be replaced. KX 4. Repair lightly damaged gear teeth with an oilstone. This clymer shop manual covers all kx and kx and all kx kawasaki motocross bikes.
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