Kawasaki KX85 2015 Owner's manual
Quick Reference Guide
GENERAL INFORMATION j
This Quick Reference Guide will assist you in
finding the 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-road recreational 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.
Off-road motorcycling is a wonderful sport, and
we hope you will e
ever, if improperly conducted, this sport has
the potential to cause environmental problems
as well as conf
sible use of your off-road motorcycle will ensure that these problems and conflicts do not
occur. TO PROT
SPORT, MAKE SURE YOU USE YOUR MOTORCYCLE LEGALLY, SHOW CONCERN FOR THE
ENVIRONMENT
OF OTHER PEOPLE.
licts with other people. Respon-
ECT THE FUTURE OF YOUR
, AND RESPECT THE RIGHTS
ECREATIONAL RID-
NOTICE
njoy it to the fullest. How-
FOREWORD
Congratulations on your 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
© 2014 Kawasaki Heavy Industries, Ltd. Feb. 28, 2014. (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 s he 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 in stru cto r/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.
ance off-road motorcycle designed for experienced young riders. It is not suitable
d these precautions.
ENTS ABOUT SAFE RIDING
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 necessary to negotiate the terra in safely. If you are n o t familiar with the area, lead the
way and reduce your speed.
TABLE OF CONTENTS
SPECIFICATIONS............................................ 8
GENERAL INFORMATION.............................. 13
Location of Labels ......................................... 13
Location of Parts ................. .......................... 17
Side Stand ..................................................... 20
Fuel ............................................................... 21
Fuel Requirements:.................................... 22
Kick Pedal ..................................................... 24
Starting the Engine ........................................ 24
Shifting Gears................................................ 26
Stopping the Motorcycle ................................ 27
Stopping the Engine ............... ....................... 27
Break-In......................................................... 28
Daily Pre-Ride Checks .................................. 30
After-Race Ch ecks .......................... .............. 32
MAINTENANCE AND A
Periodic Maint enance Chart .......................... 33
Transmission Oil .......................................... .. 37
Cooling Syste m ............................................. 39
Spark Plug ..................................................... 44
Ignition Timing ............................................. .. 46
Air Cleaner ......................................... ........... 49
Throttle Cab le ................................................ 54
Carburetor ....................................... .............. 56
Clutch ............................................................ 61
Piston ............................................................ 68
DJUSTMENT.............
33
Exhaust System ............................................ 83
Drive Chain.................................................... 87
Handlebar ...................................................... 93
Brakes ............................................. .............. 97
Steering ................ ......................................... 101
Front Suspension .......................................... 104
Rear Suspension (UNI
Wheels .............. ............................................ 121
Hoses Inspect ion ........................................... 125
Tightening Torques
Cleaning Your Motorcycle. ............................. 131
Lubrication ....................................... .............. 133
TROUBLESHOOTING G
TUNING............................................................ 144
Carburetor ....................................... .............. 144
Suspension.................................................... 152
Gearing.......................................................... 157
Special Care According to Track Conditions. 158
OPTIONAL PARTS.......................................... 1 59
PRE-RACE CHECKS AND AFTER-RACE
MAINTENANCE .......................................... .. 161
STORAGE ... ..................................................... 163
Before Storage .................... .......................... 163
After Storage ................................................. 164
ENVIRONMENTA
WIRING DIAGRAM .......................................... 166
-TRAK
of Nuts and Bolts. ...........
L PROTECTION ..................
®
).....................
UIDE.........................
114
126
137
165
8 SPECIFICATIONS
SPECIFICATIONS
DIMENSIONS
Overall Length:
KX85C 1 830 mm (72.05 in.)
KX85D
Overall Width 765 mm (30.12 in.)
Overall Height:
KX85C 1 100 mm (43.31 in.)
KX85D
Wheelbase:
KX85C 1 265 mm (49.80 in.)
KX85D
Road Clearance:
KX85C 290 m m (11.42 in.)
KX85D
Curb Mass:
KX85C 75 kg (165 lb)
KX85D
Fuel Tank Capacity 5.0 L (1.3 US gal)
ENGINE
Type 2-stroke, single-cylinder, piston reed valve, liquid-cooled
Bore × Stroke 48.5 × 45.8 mm (1.91 × 1.80 in.)
1 920 mm (75.59 in.)
1 150 mm (45.28 in.)
1 310 mm (51.57 in.)
330 mm (12.99 in.)
77 kg (170 lb)
SPECIFICATIONS 9
Displacement
Compression Ratio:
Low Speed
High Speed
Port Timing:
Intake:
Open Full Open
Close
Scavenging:
Open 63.8° B BDC
Close 63.8° ABDC
Exhaust:
Open (Low speed) 79° BBDC, (High speed) 93.6° BBDC
Close (Low speed) 79° ABDC, (High speed) 93.6° ABDC
Fuel System Carburetor, KEIHIN PWK28
Starting System
Ignition System CDI
Ignition Timing
Lubrication System PETROL MIX (32:1)
Spark Plug NGK R6252K-105
Spark Plug Terminal Solid-post
TRANSMISSION
Transmission Type
84 cm³ (5.1 cu in.)
10.9:1
9.0:1
–
Primary Kick
12° BTDC @11 320 r/min (rpm)
6-speed, Constant Mesh, Return Shift
10 SPECIFICATIONS
Clutch Type
Driving System Chain Drive
Gear Ratio:
1st
2nd
3rd
4th
5th
6th
Primary Reduction Ratio
Final Reduction Ra
KX85C 3.571 (50/14)
KX85D
Overall Drive Rat
KX85C 11.607 (Top gear)
KX85D
Transmission Oi
Grade API SG, SH, SJ, SL
Viscosity
Amount
FRAME
Type Tubular, semi-double cradle
Steering Angle 45° to either side
tio:
io:
l:
Wet, Multi Disc
2.538 (33/13)
1.875 (30/16)
1.500 (27/18)
1.250 (25/20)
1.090 (24/22)
0.956 (22/23)
3.400 (68/20)
3.923 (51/13)
12.758 (Top gear)
or SM with JASO MA, MA1 or MA2
SAE 10W-40
0.7 L (0.74 US qt)
Caster 29°
Trail:
KX85C 97 mm (3.82 in.)
KX85D
108 mm (4.25 in.)
Tire Size/Type:
Front:
KX85C 70/100-17 40M/DUNLOP MX51F
KX85D
70/100-19 42M/DUNLOP MX51F
Rear:
KX85C 90/100-14 49M/DUNLOP MX51
KX85D
90/100-16 52M/DUNLOP MX51
Rim Size:
Front:
KX85C
17 × 1.40
KX85D 19 × 1.40
Rear:
KX85C
14 × 1.60
KX85D 16 × 1.85
Suspension:
Front
Telescopic fork (u
Rear Uni-trak
®
swingarm
pside-down)
Front Suspension Travel 275 mm (10.83 in.)
Rear Wheel Travel
275mm(10.83in.)
SPECIFICATIONS 11
12 SPECIFICATIONS
Front Fork Oil:
Type
Amount
BRAKES
Type:
Front
Rear
Brake Fluid G rade:
Front
Rear
Specifications are subject to change without notice.
Kawasaki Fork Oil KHL15-10
295 ∼ 325 mL (9.97 ∼ 11.0 US oz.)
Single disc
Single disc
DOT3 or DOT4
DOT4
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
j
1. Brake Fluid (Front)
14 GENERAL INFORMATION
2. Radiator Cap Danger
3. Rear Shock Absorber Warning
4. Gasoline-Engine Oil Mixing Ratio
5. Important Information
1)
3)
GENERAL INFORMATION 15
j
2)
4)
16 GENERAL INFORMATION
5)
Location of Parts
GENERAL INFORMATION 17
j
1. Clutch Lever
2. Front Brake Fluid Reservoir
3. Front Brake Lever
4. Engine Stop Button
5. Fuel Tank Cap
6. Throttle Grip
18 GENERAL INFORMATION
1. Front For
2. Radiator
3. Fuel Tank
4. Carbure
5. Seat
6. Air Cleaner Element
7. Muffle
8. Front Brake Disc
k
tor
r
9. Front Bra
10. Expansion Chamber
11. Shift Pedal
12. Rear Sho
13. Swingarm
14. Chain Guide
15. Drive C
ke Caliper
ck Absorber
hain
GENERAL INFORMATION 19
j
1. Rear Shoc
2. Rear Brake Fluid Reservoir
3. Fuel Tap
4. Rear Bra
5. Rear Brake Caliper
k Absorber Gas Reservoir
ke Disc
6. Transmis
7. Rear Brake Pedal
8. Kick Pedal
9. Water Pu
sion Oil Level Inspection Window
mp Cover
20 GENERAL INFORMATION
Side Stand
Support the motorcyc
stand. Install the upper end of the side stand into
the hole at the rear of the left footpeg.
A. Side Stand
B. Hole
le with the provided side
WARNING
Ridingwiththesidestandcancauseacrash
resulting in injury. Do not start the engine or
attempt to ride
stand is installed.
the motorcycle when the side
NOTE
Support the motorcycle with a suitable stand to
○
perform maintenance or adjustment procedures.
Fuel
GENERAL INFORMATION 21
Avoid filling the tan
k in the rain or where heavy dust
is blowing so that the fuel does not get contaminated.
j
The Kawasaki KX is equ
ipped with a 2-stroke en-
gine that requires a gasoline-oil mix ture.
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.
uel Tank Cap
A. F
B. Breather Hose
A. Fuel Tank Cap
B. Fuel Tank
C. Top Level
D. Filler Neck
22 GENERAL INFORMATION
WARNING
Gasoline i s extremely flammable and can be
explosive under certain conditions, creating
the potential for serious burns. Always stop
the engine and do not smoke. Make sure
theareaiswellventilatedandfreefromany
source of flame or sparks; this includes any
appliance with a pilot light. Never fill the tank
completely to the top. As the fuel expands
in a warm tank, it may overflow through the
vents in the tank cap. After refueling, make
sure the fuel tank cap is closed securely. If
gasoline is spilled on the fuel tank, wipe it off
immediately.
Fuel Requirements:
Your Kawasaki engine is designed to use only
unleaded gasoline with a minimum octane rating
shown below. Never use gasoline with an octane rating lower than the minimum specified by
Kawasaki to prevent severe engine damage.
The octane rating of a gasoline is a measure of
its resistance to detonation or “knocking”. The term
commonly used to describe a gasoline’s octane rating is the Research Octane Number (RON).
NOTICE
If engine “knocking” or “pinging” occurs,
use a different brand of gasoline of a higher
octane rating. If th
continue, it can lead to severe engine damage. Gasoline quality is important. Fuels of
low quality or not m
specifications may result in unsatisfactory
performance.
is condition is allowed to
eeting standard industry
Fuel Type and Octane Rating
Use premium gasoline with an octane rating equal
to or higher than that shown in the table.
Fuel Type
Minimum Octane
Rating
Unleaded Gasoline
Research Octane Number
(RON)
95
NOTICE
Do not use any fuel that contains more
ethanol or other oxygenates than specified
for E10 fuel* in this vehicle. Damage to the
engine and fuel system, or engine starting
and/or performance problems may result
from the use of improper fuel.
*E10 means fuel containing up to 10% ethanol and
is specified by European directive in Europe.
2-Stroke Oil
Oilmustbemixedwiththegasolinetolubricate
the piston, cylinder, crankshaft bearings, and connecting rod bearing
s.
NOTE
If unavailable, use
○
racing oil.
Recommended Oil
Castrol A747
Gasoline-Engine Oil Mixing Ratio
32:1 (Gasoline:Engine Oil)
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.
an equivalent type of 2-stroke
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.
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
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.
24 GENERAL INFORMATION
Kick Pedal
This motorcycle is eq
starting system. When the clutch lever is pulled, the
motorcycle can be started with the transmission in
any gear.
A. Kick Pedal
uippedwithaprimarykick
Starting the Engine
Turn the fuel tap leve
•
A. Fuel Tap
B. ON position
Shift the transmission into neutral.
•
r to the “ON” position.
WARNING
Ridingwiththesidestandcancauseacrash
resulting in injury. Do not start the engine or
attempt to ride the motorcycle when the side
stand is installed.
NOTICE
This motorcycle is designed for competition
use only. Therefore, the radiator does not
incorporate a coola
ing fan. Prolonged idling of the engine with
no airflow through the radiator can cause
coolant loss and en
ing in possible engine damage. Any riding
conditions that increase engine temperature
will further redu
loss occurs. These conditions include high
ambient temperature, sandy or muddy terrain, or other co
loads at low speeds. Furthermore, warming
the engine up excessively before operation,
or leaving idli
ature after operation results in the engine
overheating, too.
When engine is cold -
Pull up the ch
•
ng with the hot engine temper-
oke knob.
nt reserve tank or cool-
gine overheating result-
ce idling time before coolant
nditions causing high engine
GENERAL INFORMATION 25
A. Choke Knob
Kick the engine over, leaving the throttle closed.
•
Even after the engine has started, do not push
•
back immediat
is thoroughly warmed up.
ely the choke knob until the engine
NOTE
If the engine is flooded, kick it over with the throttle
○
fully open until it starts.
When the clut
○
be started with the transmission in any gear.
ch lever is pulled, the motorcycle can
j
When engine is already warm -
When the engine is already warm or on hot days,
•
open the throttle part way instead of using the
choke knob.
26 GENERAL INFORMATION
Shifting Gears
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 1st gear f
•
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
rom 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.
A. Shift Pedal
GENERAL INFORMATION 27
j
Stopping the M oto rcycle
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-
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.
28 GENERAL INFORMATION
Break-In
A. Fuel Tap
B. OFF position
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 mile) of op-
eration, run the engine at low and moderate
engine speeds. See detai ls below.
NOTE
The low-speed operation during the break-in pe-
○
riod may cause 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 R6252K-105
Hotter Plug
Break in the engine as follo ws.
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 - NEVE R ACCEL-
ERATE HARD.
NGK B R9EVX
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: Ascoredpistons
engine performance or damage
the cylinder wall. Scores on the
cylinder wa ll s
with a #400 to #600 emery cloth.
Cylinder:
Cylinder
Head:
Decarbonize the exhaust ports
and the upper pa
taking care not to damage the
cylinder wall. Scores on the
cylinder wa ll
with a #400 to #600 emery cloth.
Remove the carbon inside the
combustion chamber.
e cool completely. Be
t the cylinder head, cylinder
kirt could lower
hould be smoothed
rt of the cylinde r,
should be smoothed
GENERAL INFORMATION 29
7. Install the removed p
8. Fill the radiator up to the bottom of the radiator
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.
arts.
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 ring after break-in.
ransmission oil.
j
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