Kawasaki KX65 2013 Owner's manual

Quick Reference Guide
GENERAL INFORMATION j
This Quick Reference Guide will assist you in
A Table of Contents is included after the
Foreword.
formation you’re looking for.
MAINTENANCE AND ADJUSTMENT j
TROUBLESHOOTING GUIDE j
TUNING j
STORAGE j
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. This vehicle should not be used for general off-load recreation riding.
Read owner’s manual.
Whenever you see the symbols shown below, heed their instructions! Always follow safe operat­ing and maintenance
practices.
DANGER
DANGER indicates a hazardous situation
which, if not avoided, will result in death or
serious injury.
WARNING
WARNING indicates a hazardous situation
which, if not avoided, could result in de ath
or serious injury.
NOTICE
NOTICE is used to
latedtopersonalinjury.
NOTE indicates information that may help or guide
youintheopera
address practices not re-
NOTE
tion or service of the vehicle.
IMPORTANT NOTICE
THIS VEHICLE IS A COMP ONLY AND WAS NOT MANUFACTURED FOR, NOR SHOULD IT BE USED ON, PUB­LIC STREETS, R OADS, USE OF THIS VEHICLE SHOULD BE LIMITED TO PARTICIPATION IN SANCTIONED COMPE­TITION EVENTS UPON THIS VEHICLE SHOULD NOT BE USED FOR GENERAL OFF-ROAD RECREATIONAL RID ING. READ OWNER ’S MANUA
ETITION MODEL
OR HIGHWAYS. THE
A CLOSED COURSE.
L.
WARNING
THIS VEHIC LE SHOULD NOT BE USED FOR GENERAL OFF-ROAD R ING.
Disclaimer of Warranty
This motorcycle is sold AS IS, with all faults, obvious or concealed and there are NO WAR­RANTIES, expressed or implied. Including war­ranties of MERCHANTABILITY or FITNESS FOR PURPOSE. The purchaser accepts all responsibilitie s concern­ing quality, performance, cost of service and/or necessary repairs.
ECREATIONAL RID-
Motorcycle Noise Emi Information
This m otorcycle is designed for closed course com­petition use only. It does not conform to U.S. EPA motorcycle noise st
NOTICE
oad motorcycling is a wonderful sport,
Off-r and we hope you will enjoy it to the fullest. How­ever, if improperly conducted, this sport has the
ntial to cause environmental problems as
pote well as conflicts with other people. Responsi­ble use of your off-road motorcycle will ensure
t these problems and conflicts do not occur.
tha TO PROTECT THE FUTURE OF YOUR SPORT, MAKE SUR E YOU USE YOUR MOTORCYCLE
GALLY, SHOW CONCERN FOR THE ENVI-
LE RONMENT, AND RESPECT THE RIGHTS OF OTHER PEOPLE.
ssion Control
andards.
WARNING
The engine exhaust from this product con­tains chemicals known to the State of Cali­fornia to cause cancer, birth defects or other reproductive harm.
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 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 performance made during production, in some cases there may be minor discrepancies between the actual vehicle and the illustrations and text in this manual.
KAWASAKI HEAVY INDUSTRIES, LTD.,
Motorcycle & Engine Company
© 2013 Kawasaki Heavy Industries, Ltd. Mar. 1, 2013. (1)
IMPORTANT NOTE TO PAR
This is a high perform 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; be sure to hee
1. Always equip your child with suitable protective gear and riding apparel. Be sure he or she always wears a helmet, eye protection, gloves, long pants, and a long-sleeved shirt while riding.
2. Never allow your child to carry a passenger. This motorcycle is designed for an OPERATOR ONLY.
3. This motorcycle is designed for off-road riding and should never be operated on public roads or paved surfaces.
4. Always obey local off-road riding laws and regulations. Obtain permission to ride on private property.
5. You, the parent (and most likely “riding instructor/mechanic” as well), must be familiar with motorcycle controls and maintenance requirements plus riding techniques. Read and understand the owner’s manual provided with the motorcycle. Review all instructions and warnings with your child.
6. You must determine your child’s readiness to ride this off-road motorcycle. Your child should already be familiar with motorcycle co ntro ls (location and function) and basic riding techniques. Your child should also be physically large and strong enough to be able to straddle the motorcycle and hold it up,plusbeabletopickitupifitisonitsside.
7. Before allowing your child to enter competition events, you must determine that he or she has the necessary riding skills and physical/emotional maturity.
8. Your child’s safety depends in part on the good mechanical condition of the motorcycle. Be sure to follow the maintenance and adjustment requirements contained in the Periodic Maintenance Chart, Daily Pre-ride Inspection, and After-Race Check Points. Be sure your child understands the importance of checking all items thoroughly before 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. He or she should always ride in the company of an experienced adult.
10. Encourage your child not to ride beyond his or her skill level or faster than conditions safely allow. Have them practice advanced riding maneuvers under controlled conditions.
11. Tell someone where you and your child are planning to ride and when you intend to return. Discuss the ride with your child before you leave so he or she will know in advance what riding techniques may be ne ce ssary to negotiate the terrain safely. If you are not familiar with the area, lead the way and reduce your speed.
ance off-road motorcycle designed for experienced young riders. It is not suitable
d these precautions.
ENTS ABOUT SAFE RIDING
This moto rcycle is de Exceeding this limit could damage the motorcycle.
signed for a rider weighting less than 55 kg (121 ponds).
TABLE OF CONTENTS
SPECIFICATIONS............................................ 10
GENERAL INFORMATION.............................. 13
Location of Labels ......................................... 13
Location of Parts ................. .......................... 17
Side Stand ..................................................... 20
Fuel ............................................................... 20
Kick Pedal ..................................................... 24
Starting the Engine ........................................ 24
Shifting Gears................................................ 25
Stopping the Motorc
Stopping the Engine ............... ....................... 27
Break-In......................................................... 27
Daily Pre-Ride Che
After-Race Ch ecks .......................... .............. 31
MAINTENANCE AND ADJUSTMENT............. 32
Periodic Mainten
Transmission Oil .......................................... .. 36
Cooling Syste m ............................................. 38
Spark Plug ..................................................... 43
Ignition Timing ............................................. .. 44
Air Cleaner ......................................... ........... 46
Throttle Cab le
Carburetor ....................................... .............. 51
Clutch ............................................................ 52
Piston ............................................................ 62
ycle................................
cks ..................................
ance Chart ..........................
................................................
26
29
32
49
Exhaust System ............................................ 72
Drive Chain.................................................... 74
Handlebar ...................................................... 80
Brakes ............................................. .............. 81
Steering ................ ......................................... 85
Front Fork ...................................................... 86
Rear Suspension (UNI
Wheels .............. ............................................ 95
Tightening Tor ques of Nuts and Bolts............ 99
Cleaning Your Motor
Lubrication ....................................... .............. 105
TROUBLESHOOTING GUIDE......................... 108
TUNING............................................................ 114
Carburetor Tuning ............ ............................. 114
Suspension Tuning ........................................ 121
Gearing.......................................................... 126
Special Care According to Track Conditions. 127
OPTIONAL PARTS.......................................... 1 28
PRE-RACE CHECKS
MAINTENANCE .......................................... .. 129
STORAGE ... ..................................................... 131
Before Storage
After Storage ................................................. 132
ENVIRONMENTAL PROTECTION .................. 133
WIRING DIAGRA
..............................................
-TRAK®)....................
cycle................ ..............
AND AFTER-RACE
M ..........................................
92
103
131
134
10 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
Ground Clearance 305 mm (12.0 in.)
Curb Mass 60 kg (132.3 lb)
Fuel Ta nk Capacity 3.8 L (1.0 US gal)
ENGINE
Type 2-stroke, single-cy
Bore × Stroke 44.5 × 41.6 mm (1.75 × 1.64 in.)
Displacement
Compression Ratio:
Timing: Intake port:
Scavenging port: Open 61.8° BBDC
Exhaust port:
Carburetor MIKUNI VM24SS
Open Full Open
Closed
Closed 61.8° ABDC
Open 91.5° BBDC
Closed 91.5° ABDC
1 120 mm (44.1 in.)
linder, piston reed valve,
liquid-cooled
64 cm³ (3.91 cu in.)
8.4 : 1
Lubrication System PETROL M IX (32 : 1)
Starting System
Ignition System CDI
Ignition Timing
Spark Plug NGK BR10EG
Spark Plug Terminal Solid-Post
TRANSMISSION
Transmission Type
Clutch Type
Drive system
Gear Ratios: 1st Gear 2.846 (37/13)
2nd Gear 2.125 (34/16)
3rd Gear 1.722 (31/18)
4th Gear 1.42 8 (3 0/21)
5th Gear 1.21 7 (2 8/23)
6th Gear 1.08 3 (2 6/24)
Primary Reduction Ratio
Final Reduction Ratio
Overall Ratio (Top Gear)
Transmission Oil: Capacity 0.5 L (0.53 US qt)
Type
Primary Kick
20.5° BTDC @7 100 r/min (rpm)
6-speed, Constant Mesh, Return Shift
Wet, Multi Disc
Chain Drive
3.500 (77/22)
3.615 (47/13)
13.703
API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2
SAE 10W-40
SPECIFICATIONS 11
12 SPECIFICATIONS
FRAME
Type Tubular, semi-double cradle
Steering Angle 40° to Either Side
Castor 27°
Trail
Tire Size, Type:
Rim Size:
Front
Rear
Front 14 × 1.40
Rear 12 × 1.60
60 mm (2.36 in.)
60/100-14 30M, DUNLOP D756F
80/100-12 41M, DUNLOP D756
Suspension:
Front
Rear
Telescopic fork
UNI-TRAK
®
Front Suspension Travel 210 mm (8.27 in.)
Rear Wheel Travel
Front Fork Oil
Type
240 mm (9.45 in.)
Kawasaki Fork Oil SS8
Amount (per fork leg) 249.5 254.5 mL (8.44 8.60 US oz)
Level
132 mm (5.2 in.) (fork compressed, spring removed)
BRAKES
Type
Effective Disc Diameter:
(Front & Rear)
Front
Rear
Disc
154.8 mm (6.09 in.)
146 mm (5.75 in.)
Specifications are subject to change without notice.
Swingarm

GENERAL INFORMATION

Location of Labels

All warning labels which are on your vehicle are repeated here. Read lab derstand them thoroughly. They contain information which is important for your safety and the safety of anyone else who may ope fore, it is very important that all warning labels be on your vehicle in the locations shown. If any label is missing, damaged, or your Kawasaki dealer and install it in the correct po­sition.
The sample warning labels in this section have
part numbers to help the correct replacement.
els on your vehicle and un-
rate your vehicle. There-
worn, get a replacement from
NOTE
you and your dealer obtain
GENERAL INFORMATION 13
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1. Brake Fluid (Front)
14 GENERAL INFORMATION
2. Radiator Cap Danger
3. Rear Shock Absorber Warning
4. Disclaimer of Warranty
5. Gasoline-Engine Oil Mixing Ratio
6. Noise Emission Control Information
7. Important Information
1)
3)
GENERAL INFORMATION 15
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2)
4)
16 GENERAL INFORMATION
5)
6)
7)

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 G rip
GENERAL INFORMATION 17
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18 GENERAL INFORMATION
7. Front Fork
8. Radiator
9. Fuel Tank
10. Fuel Tap
11. Carburetor
12. Seat
13. Air Cleaner E
14. Brake Disc
15. Brake Caliper
16. Shift Pedal
17. Rear Shock Absorber
18. Swingarm
19. Chain Gu ide
20. Drive Chain
lement
21. Muffler
22. 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 Co
28. Exhaust Pipe
ver
GENERAL INFORMATION 19
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20 GENERAL INFORMATION

Side Stand

Support the motorcyc
stand as shown.
A. Side Stand B. Longer end
le with the provided side
WARNING
Riding with the side stand in the down posi­tion can cause a c not start the engine or attempt to ride the mo­torcycle when the side stand is down.
rash resulting in injury. Do

Fuel

The Kawasaki KX is equ
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
rom the hole in the num be r plate, and turn the
hose f tank cap counterclockwise.
The breather hose has the check valve. The check
on the breather hose prevents fuel from flow-
valve ing out. When installing the b r eather hose, make sure th e arrow on the valve points toward the fuel
cap.
tank
ipped with a 2-stroke en-
NOTE
Support the mo
when performing the maintenance or adjustment.
torcycle by using the suitable stand
A. Fuel Tank Cap B. Breather Hose
WARNING
Gasoline is extremely flammable and can be
explosive under certain conditions, creating
the potential for serious burns. Always stop
theengineandneversmokewhilehandling
fuel. Make sure the area is well-ventilated
and free from any source of flame or sparks;
this includes any appliance with a pilot light.
Make sure the engine is cold before working.
Wipe any fuel off the engine before starting
it. Gasoline is a toxic substance. Dispose of
gasoline properly. Contact your local author-
ities for approved disposal methods.
GENERAL INFORMATION 21
NOTICE
If engine “knocking” or “pinging” occurs, use a different brand of gasoline of a higher octane rating. If this condition is allowed to continue it can lead to severe engine damage. Gasoline quality is quality or not meeting standard industry specifications may result in unsatisfactory performance. Oper from the use of poor quality or nonrecom­mended fuel may not be covered under your warranty.
important. Fuels of low
ating problems that result
j
Fuel Requirements:
Fuel Type
Use clean, fresh unleaded gasoline with a mini­mum Antiknock index of 90. The Antiknock Index is posted on servi octane rating of a gasoline is a measure of its re­sistance to detonation or “knocking.” The Antiknock Index is an ave ber (RON) and the Motor Octane Number (MON) as shown in the table below.
Octane Rating
Antiknock Index
ce station pumps in the U.S.A. The
rage of the Research Octane Num-
Method
(RON + MON)
2
Minimum
Rating
90
Fuels Containing Oxygenates
Gasoline frequently contains oxgenates (alcohols and ether s) especially in areas of the U.S. and Canada which are required to sell such reformu­lated fuels as part of a strategy to reduce exhaust emissions.
The types and volume of fuel oxygenates ap­proved for use in unleaded gasoline by the U.S. Environmental Protection Agency include a broad range of alcohols and ethers, but only two compo­nents have seen any significant level of commercial use.
Gasoline/Alcohol Blends - Gasoline containing up to 10% ethanol (alcohol produced from agricultural products such as corn), also known as “gasohol” is approved for use.
22 GENERAL INFORMATION
NOTICE
Avoid using blends of unleaded gasoline and methanol (wood alcohol) whenever possible, and never use “gasoh than 5% methanol. Fuel system damage and performance problems m ay result.
Gasoline/Ether Blends - The most common ether is methyl tertiar gasolinecontainingupto15%MTBE.
Other oxygenates approved for use in unleaded
gasolineincludeTAME(upto16.7%)andETBE (upto17.2%). Fu canalsobeusedinyourKawasaki.
y butyl ether (MTBE). You may use
ol” containing more
NOTE
el containing these oxygenates
NOTICE
Never use gasoline with an octane rat­ing lower than the minimum specified by Kawasaki. Never use “gasohol” with more than 10% ethanol, or more than 5% methanol. Gaso­line containing met blended with cosolvents and corrosion inhibitors. Certain ingredien paint fading or damage. Be extra careful not to spill gasoline or gasoline oxygenate blends during ref When not operating your Kawasaki for 30 to 60 days, mix a fuel stabilizer (such as STA
-BIL) with the ga stabilizer additives inhibit oxydation of the fuel which minimizes gummy deposits. Never store this the fuel system. Before storage it is recom­mended that you drain all fuel from the fuel tank and carbur tion in this manual.
Two-Stroke Engine Oil
Oil must be mixe piston, cylinder, cranks haft, bearings, and connect­ing rod bearings.
If unavailable, use an equivalent type of two stroke
racing oil.
d with the gasoline to lubricate the
hanol must also be
ts of gasoline may cause
ueling.
soline in the fuel tank. Fuel
product with “gasohol” in
etors. See the Storage sec-
NOTE
Recommended Oil
KawasakiPerformance2-StrokeRacingOil* or equivalent 2-stroke engine lubricant
*Kawas been specifically engineered for your vehicle. Con­sistent use of these products meets or exceeds war­ranty tend the life of your Kawasaki.
Gasoline-Engine Oil Mixing Ratio
A 32-to-1 mixture is about 31 mL of oil per liter of gasoline or 4 fluid ounces of oil per gallon of gaso­line.
aki Performance Oils and Lubricants have
and service req uirements and can help to ex-
32 : 1 (gasoline: engine oil)
NOTICE
Do not use vegetable and mineral oils.
Too much oil will cause excessive smoking
and spark plug fouling. Too little oil will
cause engine damage or premature wear.
To prepare the gasoline-oil mixture, pour the oil and half of the gasoline into a container first and stir thoroughly. Then, add the rest of the gasoline and stir the mixture well.
GENERAL INFORMATION 23
NOTE
At low te mperature, oil will not easily mix with
gasoline. Take time to ensure a well-blended mixture. The lubricative quality of the gasoline-oil m ixture
deteriorates rapidly; therefore, prepare a fresh mixture f or each day of operation.
j
24 GENERAL INFORMATION

Kick Pedal

This motorcycle star When the clutch lever is pulled, the motorcycle can be started with the transmission in any gear.
A. Kick Pedal
ting system is primary kick.

Starting the Engine

Turn the fuel tap leve
A. Fuel Tap B. OFF position C. ON position
Make sure the transmission is in neutral.
If the engine is cold, pull up the choke knob.
Kick the engine over, leaving the throttle closed.
r to the ON position.
WARNING
Riding with the side stand in the down posi­tion can cause not start the engine or attempt to ride the mo­torcycle when the side stand is down.
a crash resulting in injury. Do

Shifting Gears

GENERAL INFORMATION 25
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A. Choke Knob
Even after the engine has started, do not push
back the choke knob until the engine is thoroughly warmed up.
NOTE
When the engine is already warm or on hot days,
open the throttle part way instead of using the choke knob. If the engine is flooded, kick it over with the throttle
fully open until it starts. When the clutch lever is pulled, the motorcycle can
be started with the transmission in any gear.
This motorcycle is eq shift” transmission. The neutral is located halfway between 1st and 2nd gear. “Return shift” means that when shifting up engaged before the next higher o r lower gear may be selected.
To engage first gea
in the clutch lever and push down on the shift pedal, gently release the clutch lever, then release the shift pedal. To shift up to the next gear, pull in the clutch lever,
lift the shift pedal with your toes, gently release the clutch lever, an To shift down to the next gear, pull in the clutch
lever, push the shift pedal down as far as it will go, gently release t shift pedal.
uipped with a 6-speed “return
or down, each gear must be
r from the neutral position, pull
d then release the shift pedal.
he clutch le ver, then release the
NOTICE
When changing gears, press firmly on the
shift pedal to ensure proper shifting. Care-
less, incomplete shifting can cause the
transmission to jump out of gear and lead to
engine damage.
26 GENERAL INFORMATION

Stopping the Motorcycle

A. Shift Pedal
For maximum decelera apply both front and rear brakes. Pull in the clutch lever as the motorcycle comes to a stop. Indepen­dent use of the front o geous in certain circumstances. Shift down progres­sively to ensure good engine response at all speeds.
tion, close the throttle and
r rear brake may be advanta-
GENERAL INFORMATION 27
j

Stopping the Engine

Shift the transmissi
After racing the engine slightly, close the throttle
completely and push the engine stop button.
A. Engine Stop Button
Turn the fuel tap lever to the OFF position.
on into the neutral position.

Break-In

A brief break-in proc obtain the proper operating clearances in the engine and transmission, which are necessary for perfor­mance and reliabilit
edure must be carried out to
y.
NOTICE
For the first hour or 20 km (12 mi) of opera-
tion, run the engine at low and moderate en-
gine speeds. See details below.
NOTE
The low-speed operation during the break-in pe-
riod may c ause carbon to build up on and foul the spark plug. If so, replace the standard spark plug with a hotter spark plug for the duration of the break-in period.
Recommended Spark Plug
Standard Plug NGK BR10E G
Hotter Plug
Break in the engine as follows.
1. Start the engine and let it idle until it is thor-
oughly warmed up.
2. Stop and let the engine cool completely.
3. Start the engine and ride the motorcycle for 10
minutes at moderate speed - NEVER ACC EL-
ERATE HARD.
NGK BR9EG
28 GENERAL INFORMATION
4. Stop and let the engin sure to check and adjust the chain slack and spoke tightness and carry out a general inspec­tion.
5. Start the engine and ride the motorcycle for 20 minutes at moderate speed -NEVER ACCEL-
ERATE HARD.
6. Stop and let the engine cool completely. Check and adjust as in step 4. Then, drain the coolant, remove and inspec and piston.
Piston: A scored piston s
Cylinder:
Cylinder Head:
e cool completely. Be
t the cylinder head, cylinder
kirt could lower engine performance or damage the cylinder wall. Scores on the cy should be smoothed with a #400 to #600 emery cloth.
Decarbonize th ports and the upper part of the cylinder, taking care not to damage the c Scores on the cylinder wall should be smoothed with a #400 to #600 e
Removethecarboninside the combustion chamber.
linder wall
e exhaust
ylinder w a ll.
mery cloth.
7. Install the parts rem
8. Filltheradiatoruptothebottomoftheradiator filler neck with coolant. Before putting the mo­torcycle into opera tem.
9. Start the engine and ride the motorcycle for 30 minutes at moderat
ERATE HARD.
10. Stop and let the engine cool completely. Check and adjust as in st
11. After the break-in procedure has been properly carried out, the motorcycle is ready for regular operation. Usin techniques and avoiding recklessly high engine speeds will keep the engine trouble-free.
oved.
tion, bleed the cooling sys-
e speed-NEVER ACCEL-
ep 4.
g the proper riding skills and
NOTE
After break-in, install a new standard spark plug,
and change the t To keep optimum engine performance, replace the
piston rings after break-in.
ransmission oil.

Daily Pre-Ride Checks

GENERAL INFORMATION 29
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Check the following i
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 motorcy
tems each day before you ride. The time required is minimal, and habitual performance
cle to a safe operating condition.
WARNING
Failure to perform these checks before operation may result in serious damage or an accident. Al­ways perform daily checks before operation.
DANGER
Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Inhaling carbon monoxide can cause serious brain injury or death. Do not run the engine in enclosed areas. Operate only in a well-ventilated area.
Engine
Transmission oil ...............................
Coolant ............................................
Radiator Cap .......... .........................
Spark Plug .......................... .............
Cylinder Head Nut ...........................
Cylinder Nut ... ..................................
Clutch ..............................................
Carburetor ....................... ................
Air Cleaner ................................ .......
No leakage
Level correct
No leakage
Level correct (engine cold)
Properly installed
Correctly torqued
Correctly torqued
Correctly torqued
Functions
Properly tuned
Clean
Properl
properly
y installed
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