• Nissan Altima 2017 Service Manual

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. GENERAL INFORMATION Quick Reference Guide MAINTENANCE AND ADJUSTMENT This Quick Reference Guide will assist you in finding the information you’re looking for. TROUBLESHOOTING GUIDE TUNING STORAGE A Table of Contents is included after the Foreword. IMPORTANT INFORMATION.

This vehicle is designed for the operator only, no passengers. This vehicle is a competition model only and was not manufactured for use on public streets, roads or highways. The use of this vehicle should be limited to participation in sanctioned competition events upon a closed course.

Whenever you see the symbols shown below, IMPORTANT NOTICE heed their instructions! Always follow safe operat- THIS VEHICLE IS A COMPETITION MODEL ing and maintenance practices. ONLY MANUFACTURED FOR, NOR SHOULD IT BE USED ON, PUB- DANGER LIC STREETS, ROADS, OR HIGHWAYS. THE DANGER indicates a hazardous situation USE OF THIS VEHICLE SHOULD BE LIMITED which, if not avoided, will result in death. FOREWORD Congratulations on choosing this Kawasaki motorcycle. Your new motorcycle is the product of Kawasaki’s advanced engineering, exhaustive testing, and continuous striving for a superior lightweight, high-performance machine with superb handling and stability for racing and sporting use. Your new KX is a highly tuned competition machine for participation in racing events.

As with any mechan- ical device, proper care and maintenance are important for trouble-free operation and top performance. IMPORTANT NOTE TO PARENTS ABOUT SAFE RIDING This is a high performance off-road motorcycle designed for experienced young riders.

It is not suitable for beginners. Your youngster’s safety will depend on your commitment to always provide a safe riding environment and a properly maintained vehicle. As with any moving vehicle there are possible safety risks. This motorcycle is designed for a rider weighting less than 55 kg (121 ponds). Exceeding this limit could damage the motorcycle. TABLE OF CONTENTS SPECIFICATIONS.Exhaust System.GENERAL INFORMATION.Drive Chain.

Location of Labels. Handlebar.Location of Parts. Brakes.Side Stand. Front Fork.Kick Pedal. Rear Suspension (UNI-TRAK®).Starting the Engine.Wheels. SPECIFICATIONS SPECIFICATIONS DIMENSIONS Overall Length 1 590 mm (62.6 in.) Overall Width 760 mm (29.9 in.) Overall Height 955 mm (37.6 in.) Wheelbase 1 120 mm (44.1 in.) Ground Clearance 305 mm (12.0 in.) Curb Mass 60 kg (132.3 lb) Fuel Tank Capacity 3.8 L (1.0 US gal) ENGINE.

SPECIFICATIONS Lubrication System PETROL MIX (32: 1) Starting System Primary Kick Ignition System Ignition Timing 20.5° BTDC @7 100 r/min (rpm) Spark Plug NGK BR10EG Spark Plug Terminal Solid-Post TRANSMISSION Transmission Type 6-speed, Constant Mesh, Return Shift Clutch Type Wet, Multi Disc Drive system Chain Drive. Front Suspension Travel 210 mm (8.27 in.) Rear Wheel Travel 240 mm (9.45 in.) Front Fork Oil Type Kawasaki Fork Oil SS8 249.5 ∼ 254.5 mL (8.44 ∼ 8.60 US oz) Amount (per fork leg) Level 132 mm (5.2 in.) (fork compressed. If any label is missing, damaged, or worn, get a replacement from your Kawasaki dealer and install it in the correct po- sition. GENERAL INFORMATION 2. Radiator Cap Danger 3.

Rear Shock Absorber Warning 4. Important Information 5. Gasoline-Engine Oil Mixing Ratio. GENERAL INFORMATION.

GENERAL INFORMATION. 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.

GENERAL INFORMATION 7. Front Fork 8. Fuel Tank 10.

Carburetor 12. Air Cleaner Element 14.

Brake Disc 15. Brake Caliper 16. Shift Pedal 17. Rear Shock Absorber 18. Chain Guide 20.

GENERAL INFORMATION 21. Rear Brake Fluid Reservoir 23.

Rear Shock Absorber Gas Reservoir 24. Kick Pedal 25. Rear Brake Pedal 26. Transmission Oil Level Inspection Window 27. Water Pump Cover 28. Exhaust Pipe.

GENERAL INFORMATION Side Stand Fuel Support the motorcycle with the provided side The Kawasaki KX is equipped with a 2-stroke en- stand as shown. Gine that requires a gasoline-oil mixture. Fuel Tank Capacity 3.8 liters (1.0 US gal) To open the fuel tank cap, disconnect the breather hose from the hole in the number plate, and turn the tank cap counterclockwise. GENERAL INFORMATION NOTICE Recommended Fuel Use premium gasoline with an octane rating equal Do not use any fuel that contains more to or higher than that shown in the table. Ethanol or other oxygenates than specified Fuel Type Unleaded Gasoline for E10 fuel. in this vehicle.

GENERAL INFORMATION NOTICE Kick Pedal Do not use vegetable and mineral oils. Too much oil will cause excessive smoking This motorcycle starting system is primary kick. And spark plug fouling. Too little oil will When the clutch lever is pulled, the motorcycle can cause engine damage or premature wear. GENERAL INFORMATION Starting the Engine. Turn the fuel tap lever to the ON position.

Choke Knob. Even after the engine has started, do not push back the choke knob until the engine is thoroughly warmed up. Fuel Tap NOTE B. GENERAL INFORMATION 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. GENERAL INFORMATION Stopping the Motorcycle Stopping the Engine.

For maximum deceleration, close the throttle and Shift the transmission into the neutral position. apply both front and rear brakes. Pull in the clutch After racing the engine slightly, close the throttle lever as the motorcycle comes to a stop. GENERAL INFORMATION Stop and let the engine cool completely. Be Break-In sure to check and adjust the chain slack and spoke tightness and carry out a general inspec- A brief break-in procedure must be carried out to tion.

Obtain the proper operating clearances in the engine Start the engine and ride the motorcycle for 20 and transmission, which are necessary for perfor- minutes at moderate speed -NEVER ACCEL. GENERAL INFORMATION Fill the radiator up to the bottom of the radiator 11. After the break-in procedure has been properly filler neck with coolant. Before putting the mo- carried out, the motorcycle is ready for regular torcycle into operation, bleed the cooling sys- operation.

GENERAL INFORMATION Daily Pre-Ride Checks Check the following items each day before you ride. The time required is minimal, and habitual performance of these checks will help ensure a safe, reliable ride.

If any irregularities are found during these checks, refer to the appropriate section and take the action required to return the motorcycle to a safe operating condition. GENERAL INFORMATION. Air Cleaner.Clean. Properly installed. Apply oil to air cleaner element. Muffler.No damage. Engine Sprocket.No wear or damage Frame.

Tires.Overall condition good. No wear or damage. GENERAL INFORMATION After-Race Checks After racing, first clean the motorcycle (see p.100), then inspect the entire motorcycle with special atten- tion to the air cleaner, carburetor, brakes, etc.

Carry out the general lubrication (see p.102) and make necessary adjustments. MAINTENANCE AND ADJUSTMENT MAINTENANCE AND ADJUSTMENT Periodic Maintenance Chart The maintenance and adjustments outlined in this chapter are easily carried out and must be done in accor- dance with the Periodic Maintenance Chart to keep the motorcycle in good running condition. FREQUENCY Every Every. MAINTENANCE AND ADJUSTMENT FREQUENCY Every Every After each Every 10 3 races 5 races race (or races (or (or 7.5 (or 12.5 required ref.

2.5 hours) 25 hours) hours) hours). Silencer-clean/check †. Silencer packing-change. Small end bearing-check †. MAINTENANCE AND ADJUSTMENT FREQUENCY Every Every After each Every 10 3 races 5 races race (or races (or (or 7.5 (or 12.5 required ref. 2.5 hours) 25 hours) hours) hours).

Spoke tightness and rim runout-check † 92, 93. Drive chain-adjust. –.Rear shock oil-change 1st time after 2 races, then every 5 races †: Replace, add, adjust, clean or torque if necessary. R: Replace.: Should be serviced by referring to the Service Manual or an authorized Kawasaki dealer. MAINTENANCE AND ADJUSTMENT level is too high, remove the excess oil using a sy- Transmission Oil ringe or other suitable device. If the oil level is low, add the correct amount of oil through the oil filler In order for the transmission and clutch to function opening.

MAINTENANCE AND ADJUSTMENT. Oil Change Install the oil drain plug with its new gasket and The transmission oil should be changed periodi- torque it to 20 Nm (2.0 kgfm, 14 ftlb). cally to ensure long engine life.

Pour in the specified amount of fresh transmission. MAINTENANCE AND ADJUSTMENT Cooling System Radiator Hoses Check the radiator hoses for cracks or deteriora- tion, and the connections for looseness in accor- dance with the Periodic Maintenance Chart.

Radiator Check the radiator fins for obstruction by insects or mud. Clean off any obstructions with a low-pressure stream of water. MAINTENANCE AND ADJUSTMENT 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. MAINTENANCE AND ADJUSTMENT. Install the radiator cap. Coolant Change The coolant should be changed periodically to en- sure long engine life. Wait for the engine to cool completely. Lean the motorcycle slightly to the right until the radiator cap is level to the ground.

MAINTENANCE AND ADJUSTMENT NOTICE. Fill the radiator up to the bottom of the radiator filler Immediately wash away any coolant that neck with coolant. Spills on the frame, engine, or wheel. Lean the motorcycle slightly to the right until the radiator filler neck is level to the ground so that the WARNING filler neck is located uppermost in order to exhaust. MAINTENANCE AND ADJUSTMENT A. Air Bleeder Bolt A.

Air Bubbles. Tighten the air bleeder bolt to the specified torque. Check the coolant level. If the coolant level is low, add coolant up to the Air Bleeder Bolt Tightening Torque bottom of the radiator filler neck. MAINTENANCE AND ADJUSTMENT If the plug is oily or has carbon built up on it, clean Spark Plug it. The plug may also be cleaned using a high flash -point solvent and a nonmetal brush (nylon etc.). If the spark plug electrodes are corroded, or damaged, or if the insulator is cracked, replace the plug.

MAINTENANCE AND ADJUSTMENT. Fit the plug cap securely onto the spark plug, and Ignition Timing pull the cap lightly to make sure that it is properly installed. Since this motorcycle is equipped with a capacitor NOTE discharge ignition (CDI) system, the ignition timing ○. MAINTENANCE AND ADJUSTMENT. NOTE Install the magneto cover and the gasket. ○ The ignition timing can be adjusted to suit the For best engine performance, it is very important rider’s preference and ability. To adjust the ignition timing within the adjustable.

MAINTENANCE AND ADJUSTMENT. Remove the wing bolt, and take out the air cleaner Air Cleaner element. A clogged air cleaner restricts the air intake, in- creases fuel consumption, reduces engine power, and can cause spark plug fouling.

Inspect the air in- take system, which includes the air filter and air duct to the carburetor, and the duct clamps and carbure- tor, before each race or practice session. MAINTENANCE AND ADJUSTMENT. Inspect the element. If it is dirty, clean it.

Also check if the element is in good condition (no tears, hardening or shrinkage). If damaged, replace the element or it will allow dirt into the carburetor. WARNING A clogged air cleaner may allow dirt and dust to enter the carburetor and the throttle may. MAINTENANCE AND ADJUSTMENT WARNING Gasoline and low flash-point solvents can be flammable and/or explosive and cause severe burns. Clean the element in a well-ventilated area, and take care that there is no spark or flame anywhere near the working areas. Do not use gasoline or low flash-point solvents to clean the element.

MAINTENANCE AND ADJUSTMENT Throttle Cable Throttle Cable Adjustment Inspect the throttle grip for smooth operation in all steering positions. Check and adjust the throttle cable in accordance with the Periodic Maintenance Chart.

Check that the throttle grip has 2 ∼ 3 mm (0.08 ∼ 0.12 in.) of play and turns smoothly. MAINTENANCE AND ADJUSTMENT. If the play is incorrect, pull the rubber boot off the upper end of the throttle cable, loosen the locknut on the upper end of the throttle cable and turn the adjuster to obtain the specified play. Then, tighten the locknut. MAINTENANCE AND ADJUSTMENT. Open and close the throttle a few times to make Carburetor sure the idling speed does not change, and read- just if necessary.

With the engine idling, turn the handlebar both Idling Adjustment ways and check if handlebar movement changes Idling adjustment is carried out using the air screw the idling speed. MAINTENANCE AND ADJUSTMENT. Slide back the clutch lever dust cover. Clutch If the clutch lever play cannot be adjusted at the clutch lever, make the adjustment further down the cable as follows. Clutch Lever Adjustment. Loosen the locknut at the clutch lever. Proper clutch lever play is 8 ∼.

MAINTENANCE AND ADJUSTMENT NOTICE Friction Plate Removal. Drain the transmission oil and coolant (see the Do not remove the clutch release shaft un- Transmission Oil section and Cooling System sec- less it is absolutely necessary.

Nissan Altima 2017 Service Manual

If the clutch tion). Release shaft is removed, the oil seal must be. MAINTENANCE AND ADJUSTMENT. Remove the cotter pin, pivot pin and washer from Remove the brake pedal mounting bolt and take the rear brake pedal. Off the brake pedal and return spring. Rear Brake Pedal Pivot Pin A.

Brake Pedal Mounting Bolt B. MAINTENANCE AND ADJUSTMENT. Loosen the water pump hose clamp, and discon- Remove the impeller bolt, and take out the im- nect the lower end of the water pump hose. Peller and washer. Unscrew the water pump cover bolts, and remove the water pump cover and gasket. MAINTENANCE AND ADJUSTMENT. Remove the right engine cover mounting bolt after Remove the clutch pusher, and clutch spring plate pulling off the lower end of the coolant hose.

Turn the clutch release lever toward the rear, and remove the right engine cover and gasket. MAINTENANCE AND ADJUSTMENT. Remove the magneto cover. Remove the clutch hub bolt, clutch spring bolts,.

Hold the magneto flywheel steady with the fly- clutch spring holder, springs and clutch hub. Wheel holder to prevent clutch from rotating. MAINTENANCE AND ADJUSTMENT Friction Plate Thickness Measurement (i.e., the gap between the surface plate and each friction plate or steel plate).

3.1 ∼ 3.3 mm (0.122 ∼ 0.130 in.) Standard. If any plate is warped over the service limit, re- Service Limit 2.9 mm (0.114 in.) place it with a new one. MAINTENANCE AND ADJUSTMENT. Friction and Steel Plate Installation Install the clutch hub, springs and clutch spring. Install all parts in the reverse order of removal. Install the friction plates and steel plates, alternat- Tighten the clutch hub bolt and clutch spring bolts.

Ing between the two. MAINTENANCE AND ADJUSTMENT A.

Apply grease. Dowel Pins B. Breather Hose. Turn the clutch release lever toward the rear.

Clamp. Place a new right engine cover gasket in position. Tighten the right engine cover mounting bolts.

With a thin layer of grease. defective. Have the brake checked immedi- Connect the lower end of the water pump hose, ately by an authorized Kawasaki dealer. And tighten the clamp screw securely. Check the brake pedal O-ring for damage, and if.

MAINTENANCE AND ADJUSTMENT. Remove the muffler (See the Exhaust System sec- Piston tion). Remove the springs holding the exhaust pipe. Piston Removal. Turn the fuel tap lever to the OFF position. Drain the coolant (See the Cooling System sec- tion). MAINTENANCE AND ADJUSTMENT.

Remove the exhaust pipe damper mounting bolts, Loosen the clamp screws and pull the carburetor and pull the exhaust pipe off toward the front. Out of the cylinder intake joint and air cleaner joint. Exhaust Pipe Damper Mounting Bolts A. MAINTENANCE AND ADJUSTMENT. Remove the cylinder head nuts, and take off the Lift off the cylinder, and remove the cylinder base cylinder head and gasket. If necessary, tap lightly around the base of the cylinder with a plastic mallet, taking care not to damage the cylinder. MAINTENANCE AND ADJUSTMENT A.

Piston Pin Puller Assembly: 57001-910 A. Piston Ring Piston Ring Removal Piston Ring, Piston Ring Groove Inspection. Carefully spread the ring gap with your thumbs Visually inspect the piston rings and the piston ring and then push up on the opposite side of the ring grooves. MAINTENANCE AND ADJUSTMENT Piston Ring Thickness (Top and Second) 0.97 ∼ 0.99 mm Standard (0.0382 ∼ 0.0390 in.) Service Limit 0.90 mm (0.0354 in.) Piston Ring Groove Width (Top and Second) 1.01 ∼ 1.03 mm Standard (0.0398 ∼ 0.0406 in.) Service Limit 1.11 mm (0.0437 in.) Piston, Piston Pin, Connecting Rod Wear. MAINTENANCE AND ADJUSTMENT Piston Pin Hole Diameter 12.001 ∼ 12.011 mm Standard (0.4725 ∼ 0.4729 in.) Service Limit 12.08 mm (0.4756 in.).

If the connecting rod small end inside diameter exceeds the service limit, replace the crankshaft assembly. Connecting Rod Small End Inside Diameter 16.002 ∼. MAINTENANCE AND ADJUSTMENT NOTICE NOTE ○ Install the piston ring so that the pin in the piston Carbon particles can be very abrasive to pis- ring groove is between the ends of the piston ring. Don’t allow such particles to fall onto the cylinder walls. MAINTENANCE AND ADJUSTMENT A.

Snap Ring Ends C. Notch.

When installing a piston pin snap ring, compress it only enough to install it and no more. Cylinder, Cylinder Head Installation. Scrape any carbon out of the exhaust port. MAINTENANCE AND ADJUSTMENT A. Cylinder Head Gasket B. “UP” Mark.

Tighten the cylinder nuts to the specified torque in C. Exhaust Side a crisscross pattern. Cylinder Head. Cylinder Nut Tightening Torque Tighten the cylinder head nuts to the specified 25 Nm (2.5 kgfm, 18 ftlb) torque in a crisscross pattern.

MAINTENANCE AND ADJUSTMENT. When installing the carburetor, note the following: Fit the ridge on the carburetor body into the notch.

Being careful not to bend or otherwise damage the on the carburetor holder. Jet needle, align the groove in the throttle valve with the guide pin in the carburetor body. MAINTENANCE AND ADJUSTMENT. Turn the fuel tap lever to the ON position, and Exhaust System check for fuel leakage from the carburetor.

Install the parts removed. Fill the radiator up to the bottom of the radiator The exhaust system, in particular the muffler, is filler neck with coolant (See the “Cooling System”. MAINTENANCE AND ADJUSTMENT A. Muffler Pipe.

Remove the inner pipe bolts of the front end and rear end of the muffler, and pull out the tail pipe. MAINTENANCE AND ADJUSTMENT.

Pull off the old silencer wool, and install the new Drive Chain one. 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 sprockets or break. MAINTENANCE AND ADJUSTMENT For the rear wheel to be properly aligned, the rear end of the left chain adjuster should align with the same swingarm mark that the rear end of the right chain adjuster aligns with. 45 ∼ 55 mm (1.8 ∼ 2.2 in.).

MAINTENANCE AND ADJUSTMENT WARNING NOTE ○ When inserting the cotter pin, if the slots in the Misalignment of the wheel will result in ab- nut do not align with the cotter pin hole in the normal wear, and may result in an unsafe axle shaft, tighten the nut clockwise up to the next riding condition. MAINTENANCE AND ADJUSTMENT NOTE ○ When riding in wet and muddy conditions, mud sticks to the chain and sprockets, resulting in an overly tight chain, which can cause it to break. To prevent this, adjust the chain slack (measured ∼ between the chain and the swingarm) to 55 ∼. MAINTENANCE AND ADJUSTMENT Chain Guide Wear Inspection.

Visually inspect the drive chain guide and replace it if excessively worn or damaged. Master Link Clip B. Direction of Rotation A.

MAINTENANCE AND ADJUSTMENT Chain Slipper Wear Inspection Sprocket Wear Inspection. Visually inspect the upper and lower chain slippers Visually inspect the sprocket teeth and replace the on the swingarm and replace them if worn or dam- sprocket if its teeth are worn or damaged. MAINTENANCE AND ADJUSTMENT Chain Lubrication Handlebar Lubrication of the drive chain is necessary after rid- ing in the rain or mud, or any time the chain appears dry with a high quality lubricant for drive chains. To keep the handlebar properly secured in place,. MAINTENANCE AND ADJUSTMENT Brakes Disc and disc pad wear is automatically compen- sated for and has no effect on the brake lever or pedal action. There are no parts on the brakes that require adjustment except brake lever position. Brake Lever Position The brake lever position can be adjusted to suit the rider’s preference.

Check for brake hose damage. Be air in the brake lines or the brake may be defective. Have the brake checked immedi- ately by an authorized Kawasaki dealer. Brake Fluid Level Inspection Front Reservoir With the front reservoir positioned horizontally, the brake fluid must always be above the minimum level line.

MAINTENANCE AND ADJUSTMENT A. Front Reservoir A. Front Reservoir B.

Minimum Level Line B. Maximum Level Line.

If the brake fluid in the front reservoir is below the Rear Reservoir minimum level line, check for fluid leaks in the Positioned horizontally, the rear reservoir must al- brake line and fill the reservoir to the maximum ways be more than half full. (front or rear) brake caliper is less than 1 mm (0.04 in.), have both pads in the caliper replaced as a set. Pad replacement should be done by an authorized Kawasaki dealer. Usable Brake Pad Range A.

Rear Reservoir. MAINTENANCE AND ADJUSTMENT Steering Adjustment. Steering Loosen the number plate. Raise the front wheel off the ground using a jack The steering should always be kept adjusted so (special tool). that the handlebar will turn freely but not have ex- Remove the handlebar clamps and handlebar.

MAINTENANCE AND ADJUSTMENT Steering Stem Head Nut Tightening Torque Front Fork 44 Nm (4.5 kgfm, 33 ftlb) NOTICE Lower Clamp Bolt Tightening Torque 29 Nm (3.0 kgfm, 22 ftlb) Sticking muds or dusts on the sliding surface of the front fork could damage to the oil seal,. MAINTENANCE AND ADJUSTMENT is fully compressed. Make this adjustment in 10 mm (0.4 in.) steps. Rebound Damping Adjustment This adjustment affects how quickly the fork re- bounds. Depending on the model, the fork rebound damping adjuster has 4 positions. The fully seated position (adjuster turned fully clockwise) is the hard- est setting. MAINTENANCE AND ADJUSTMENT.

Standard Rebound Damping Adjuster Setting Check both top plug O-rings for damage and re- place them if necessary. 3 clicks.Out from the fully seated position (Adjuster Turned Fully Counterclockwise) NOTICE The right and left fork tubes must be adjusted evenly. MAINTENANCE AND ADJUSTMENT A. Oil Level Gauge (P/No. Outer Tube B. Stand.

Adjust the fork oil level as required within the ad-. With the fork in this position, attach the oil level justable range using one of the following springs.

Gauge (special tool) to the top of the fork tube, and measure the distance from the top of the inner tube to the oil level. MAINTENANCE AND ADJUSTMENT Fork Oil Level Standard Adjustable Fork Spring Level Range 106 ∼ 150 mm 140 mm K = 2.45 N/mm (4.17 ∼ 5.9 in.) (5.50 in.) 101 ∼ 145 mm 135 mm K = 2.55 N/mm (3.98 ∼ 5.71 in.) (5.30 in.) 98 ∼. MAINTENANCE AND ADJUSTMENT Softer springs soften the fork action and slow down the rebound damping. Fork Height Adjustment Steering is greatly affected by the fork height (how much the outer fork tubes protrude above the up- per fork clamp). The less the fork tube protrudes, the lighter the front end becomes and the greater the tendency for understeering and washout due to weight biasing. MAINTENANCE AND ADJUSTMENT Rebound Damping Adjustment Rear Suspension (UNI-TRAK®) To adjust the rear shock absorber rebound damp- ing, turn the rebound damping adjuster at the bottom of the rear shock absorber with a flat-head screw- NOTICE driver. Sticking muds or dusts on the sliding surface of the rear shock absorber could damage to the oil seal, leading to an oil leak.

MAINTENANCE AND ADJUSTMENT. Rebound Damping Adjuster Settings Remove the seat and both side covers. Loosen the air intake duct clamp screw. Remove the air cleaner case bolts. Remove the rear frame and air cleaner case.

Seated Position (Adjuster Turned Fully Clockwise) B. MAINTENANCE AND ADJUSTMENT A. Adjusting Nut A. Adjusting Nut Position B. Hook Wrenches (P/No.) C.

Adjusting Nut. The standard adjusting nut position from the cen- Tighten the locknut securely.

ter of the upper mounting hole and the adjustable After making the adjustment, move the spring up range is as follows: and down to make sure that it is properly seated. authorized Kawasaki dealer. Reduce the tire air pressure to increase the tire tread surface on the ground when riding on a wet, muddy, sandy or slippery track. MAINTENANCE AND ADJUSTMENT A. Spoke and Spark Plug Wrench A.

Bead Protector Nut Bead Protector Rim Runout There is a bead protector on the rear wheel. The Set up a dial gauge on the side of the rim and bead protector prevents the tire and tube from slip- rotate the wheel to measure its axial runout.

MAINTENANCE AND ADJUSTMENT NOTE Rim Runout Maximum Limit ○ The welding spot of the rim may show excessive Axial 2.0 mm (0.08 in.) runout. Disregard this when measuring runout. Radial Rim Runout A. Axial Rim Runout Measurement. MAINTENANCE AND ADJUSTMENT A. Radial Rim Runout Measurement.

MAINTENANCE AND ADJUSTMENT Tightening Torques of Nuts and Bolts Location of nuts and Bolts Before the first ride of each day of operation, check the tightness of the nuts and bolts listed below. Check also that all cotter pins are in place and in good condition. MAINTENANCE AND ADJUSTMENT 22. Rear Axle Nut 23. Muffler Bolts 24. Rear Shock Absorber Bolt and Nut 25.

Rear Brake Reservoir Bolt or Screw 26. Expansion Chamber Damper Mounting Bolt and Nut 27. Steering Stem Head Nut 28. Brake Lever Holder Bolt 29.

MAINTENANCE AND ADJUSTMENT Torque Table Tighten all nuts and bolts to the proper torque using an accurate torque wrench. An insufficiently tightened nut or bolt may become damaged or fall out, possibly resulting in damage to the motorcycle and injury to the rider. MAINTENANCE AND ADJUSTMENT Part Name Nm kgfm ftlb Handlebar Clamp Bolts Swingarm Pivot Shaft Nut Rear Axle Nut Rear Brake Pedal Mounting Bolt Rear Frame Bolts Rear Shock Absorber Bolt (Top) Rear Shock Absorber Nut (Bottom) Spokes 0.15 (13 inlb) Steering Stem Head Nut Steering Stem Locknut (26 inlb). General Precautions. Avoid all harsh chemicals, solvents, detergents, Frequent and proper care of your Kawasaki mo- and household cleaning products such as ammo- torcycle will enhance its appearance, optimize over- nia-based window cleaners. All performance, and extend its useful life. When washing the motorcycle, always use a mild clean plastic parts, as they will damage the neutral detergent and water.

Part’s finish. The semi-gloss finish effect may be lost when the finish is excessively rubbed. If any doubt, consult an authorized Kawasaki dealer. MAINTENANCE AND ADJUSTMENT Chrome and Aluminum Lubrication Chrome and uncoated aluminum parts can be treated with a chrome/aluminum polish. Coated aluminum should be washed with mild neutral de- Lubricate the areas shown in the illustrations of tergent and finished with a spray polish.

Aluminum this section, with either motor oil or regular grease, wheels, both painted and unpainted can be cleaned in accordance with the Periodic Maintenance Chart. MAINTENANCE AND ADJUSTMENT. Rear brake pedal Apply an aerosol cable lubricant with a pressure.

Rear brake rod joints lubricator on all cables:. Kick pedal Clutch cable. Throttle cable Cable Lubrication. MAINTENANCE AND ADJUSTMENT. Apply grease to the following points: Apply lubricant to the sides of the rollers so that it. Upper end of clutch cable will penetrate to the rollers and bushings. Upper end of throttle cable Wipe off any excess lubricant.

TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE. NOTE Float valve worn or stuck open.

○ Wrong starting technique (when the engine is This troubleshooting guide is not exhaustive and flooded, kick with the throttle fully open to allow does not give every possible cause for each prob- more air to reach the engine). TROUBLESHOOTING GUIDE. Cylinder or piston worn Cylinder head insufficiently tightened.

Piston ring worn, weak, broken, or sticking Cylinder nut loose. Piston ring side clearance excessive Cylinder or piston worn. Cylinder head gasket damaged Piston ring worn, weak, broken, or sticking. TROUBLESHOOTING GUIDE. Air cleaner element clogged, poorly sealed or not Engine overheating. installed Transmission oil level too high. Starter plunger stuck open Transmission oil viscosity too high.

Fuel supply to carburetor insufficient Crankshaft bearing worn or damaged. TROUBLESHOOTING GUIDE. Transmission oil viscosity too high Lubrication inadequate Gear shifting faulty. Transmission oil level too low Transmission does not go into gear; shift pedal. Transmission oil quality poor or type incorrect does not return.

Coolant inadequate Clutch not disengaging. TROUBLESHOOTING GUIDE.

Engine overheating Clutch housing gear/primary gear backlash exces- sive Piston slap. Metal chip jammed in clutch housing gear teeth. Piston clearance excessive. Cylinder or piston worn Transmission noise. Connecting rod bent Crankcase bearing worn or damaged. TROUBLESHOOTING GUIDE.

Frame noise abnormal Steering bearing race dented or worn. Steering stem inadequately lubricated Front fork noise. Steering stem bent. Oil level or viscosity too low. Tire air pressure too low.

Spring weak or broken Handlebar shakes or vibrates excessively Rear shock absorber noise. TROUBLESHOOTING GUIDE Shock absorption unsatisfactory (suspension too soft). Front fork oil level insufficient and/or front fork leaking oil.

Front fork oil viscosity too low. Front fork and/or rear shock absorber spring weak. Rear shock absorber leaking gas. TUNING TUNING tuning. Before attempting any changes, however, Carburetor Tuning make sure that everything else is in good shape and properly tuned. Check the condition of the Tuning a carburetor is not the mysterious science spark plug, make sure the ignition timing is correct, many racers believe it to be. TUNING With pinging or ratting, make sure that the gasoline is fresh and the octane rattling sufficient.

You might also try a different brand of high-octane gasoline. Making Adjustments Carburetor tuning is made by replacing or adjust- ing the main jet, jet needle and pilot jet, which regu- late the fuel flow, and the air screw, which regulates the air flow. TUNING There are five grooves in the top of the jet needle in which a clip fits. This clip positions the jet needle in the throttle valve relative to the needle jet.

Moving the clip down has the effect of pulling the needle further out of the jet. TUNING On the side of the needle jet two figures are Pilot Jet and Air Screw stamped: a letter followed by an even number; The pilot jet and air screw control the mixture in these figures indicate the relative size of the needle the closed-to-1/8-throttle range, but have little effect jet. TUNING. If the spark plug insulator is whitish, the fuel-air mixture is too lean.

Increase the main jet size by one step. If the spark plug insulator is wet, the fuel-air mix- ture is too rich. Reduce the main jet size by one step. TUNING Correction Factor Applied to the Jet Needle and Air Screw 1.06 ∼ 1.02 1.02 ∼ 0.98 0.98 ∼ 0.94 Correction factor 1.06 or above 0.94 or below Jet needle setting lower clip one position same raise clip one position one size one size same. TUNING. Standard Carburetor Settings Change the jet needle clip position, needle jet and air screw opening according to the appropriate Throttle Valve Cutaway #1.5 chart on the previous page.

Air Screw Opening 1 1/2 EXAMPLE: For a correction factor of 0.94, raise the needle clip one position and turn out the air screw Pilot Jet one extra turn. TUNING. The front and rear suspension should always be Suspension Tuning balanced; when the one is changed, the other one might need to be changed similarly. When evaluating suspension performance, the Introduction rider must make every effort to ride consistently No area of machine adjustment is more critical and to recognize the effects of his input.

TUNING Troubleshooting Improper Settings Fork Oil Level Effect on Fork Stroke Listed below are some symptoms of improper sus- pension settings and the most likely means of cor- recting them. The proper settings can be achieved by applying the information given in this chapter in a scientific, methodical manner. TUNING Too Soft Too Soft The front fork dives excessively during braking Bottoming occurs on landing after a high jump and deceleration: (otherwise OK). Fork oil level too low Spring preload too soft. Springs too soft Spring too soft. TUNING. Suspension Tuning According to Rider Weight A change in the front suspension might require one in the rear suspension, and vise versa.

Heavy Rider Harder Spring Front and Rear Suspension Compatibility Light Rider Softer Spring Inspection Use this procedure to determine if the suspension Suspension Tuning According the Type of is balanced reasonably well. TUNING NOTE ○ Although this is one of the most effective adjust- Lighter or less experienced riders may need a ment procedures, suspension settings may vary de- softer spring. Pending on the conditions at the track and the rider’s preferences. Front and Rear Suspension Troubleshooting Front End Does Not Respond to Small Bumps in Sweeping Turns.

TUNING ○ Front and Rear Ends Bottom Off After a A bottoming sensation (even though the machine High-speed Jump (harsh bottoming occurs is actually not bottoming) may be caused by ma- once or twice per lap) chine weight and the inability of the rider to over- The front suspension is too soft. TUNING. Since it is difficult to set the machine so it is best Gearing suited for all portions of the circuit, determine which circuit portions will have the greatest ef- fect on lap time, and tune the machine to these Selection of the Secondary Reduction Ratio portions. TUNING. In muddy or sandy conditions, increase chain Special Care According to Track slack as the chain and sprockets will be packed Conditions with mud or sand, which reduces chain slack. Check chain and sprocket wear frequently when. OPTIONAL PARTS OPTIONAL PARTS Carburetor Jets Rear Sprocket Main Jet 47T (Standard) Suspension Spring Pilot Jet 22.5 K = 0.25 kgf/mm 27.5 K = 0.26 kgf/mm Front K = 0.27 kgf/mm (Standard) Needle Jet K = 0.28 kgf/mm Richer K = 0.29 kgf/mm K = 4.5 kgf/mm K = 4.7 kgf/mm Leaner.

Pi af user guide. The PI Server: • receives data from many disparate sources and consolidates it into a single system • transforms raw data into actionable information and makes it accessible to users at all levels • proactively monitors data to deliver real-time alerts when critical events occur • stores and secures data so information is both accessible to users and protected With the PI Server, differences in data types, delivery speeds, formats and sources no longer matter - information is instantly and uniformly available to users and applications whenever and wherever needed. Store, Organize and Contextualize Data The PI Server uses two components, the Data Archive and Asset Framework to collect, consolidate, organize and contextualize sensor-based data. The Data Archive can store millions of tags and thousands of values per second while preserving data at its original fidelity.

PRE-RACE CHECKS AND AFTER-RACE MAINTENANCE PRE-RACE CHECKS AND AFTER-RACE MAINTENANCE. Drive chain slack. Coolant level Pre-race Checks. Front axle nut, or axle clamp nut tightness. Front fork clamp bolt tightness Maintenance After the First Race. PRE-RACE CHECKS AND AFTER-RACE MAINTENANCE. Maintenance After Riding in the Rain or on a Throttle grip assembly.

Muddy Course Carburetor jets. Clean the sliding surface of the front fork and rear Air cleaner element. shock absorber. Muffler, silencer, and related parts. STORAGE STORAGE WARNING Before Storage Gasoline is extremely flammable and can be explosive under certain conditions, creating When the motorcycle is to be stored for any length the potential for serious burns. Always stop of time, it should be prepared for storage as follows.

The engine and never smoke while handling. STORAGE. Cover the motorcycle to keep dust and dirt away After Storage from it. Remove the plastic bag from the muffler. Make sure the spark plug is tight.

Fill the fuel tank with fuel. Check all the points listed in the Daily pre-ride checks section. To help preserve the environment, properly discard used batteries, tires, oils and fluids, or other vehicle compo- nents that you might dispose of in the future.

Consult your authorized Kawasaki dealer or local environmental waste agency for their proper disposal procedure. This also applies to disposal of the entire vehicle at the end of its life. WIRING DIAGRAM WIRING DIAGRAM.

The straight section of the jet needle affects the throttle response at smaller throttle openings. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.

Begin the actual on-track testing and evaluation after making these preliminary adjustments. The mud can add significantly to the weight of the vehicle and therefore reduce performance. Clean the sticking muds or dusts from the front fork inner tube and rear shock absorber rod after each ride.