2004 KX250F SALES GUIDE

©Kawasaki Motors Pty Ltd 2003No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible. All information contained in this publication is based on the latest product information available at the time of publication. E & OE.

Due to improvements in design and performance prior to and during production, in some cases there may be minor discrepancies between the actual vehicle and the information presented in this publication. Illustrations in this publication are intended for reference use only and may not depict actual model components. Model colour availability and graphics may vary between different regions.

2004 KX250F SALES GUIDE

Dear Kawasaki Dealer

Here is your copy of the 2004 KX250F sales guide.

This sales guide is designed to be a useful selling tool as well as a training guide for your staff. Our off-road product line continues to provide consumers with a variety of models aimed at every facet of the market. Every year our product line becomes more focused and directed toward specific consumer wants and needs. Therefore, it is more important than ever that you match your customers with the products that fit their requirements and skill levels.

You must know about product features and understand how they work to explain the benefits to your customers. Please study this product sales guide and encourage your sales staff to increase their knowledge of Kawasaki products. Knowledge of Kawasaki products and their key features is an effective tool for selling them.

All Kawasaki KX models come with a free spares kit.

Thank you for your time.

Sincerely

Kawasaki Motors Pty LtdTechnical Services Division

Kawasaki 2004 2

OFF-ROAD MOTORCYCLE MODELS

Kawasaki is seen by its customers and dealers as a performance brand. Nothing does more to reinforce this image than the outstanding range of off-road competition models produced each season for both professional and amateur competitors and enthusiasts.

The KX range of motocross machines from the KX65 all the way to the mighty KX250 are famous for innovation, durability and performance, a combination that our competitors find hard to match.

Every weekend tracks echo to the sound of countless KX machines carving turns with accuracy and performing complex manoeuvres with ease at the hands of riders that demand a quality product.

For 2004, the familiar two stroke KX crackle will be joined by the distinctive sound of Kawasaki’s latest innovative off-road competitor, the KX250F four stroke.

Designed to win “straight from the box”, the new four stroke has been produced as a direct result of customer and dealer demand and includes many of the features that Kawasaki riders want and need from a Kawasaki competition machine.

Knowing that in some situations - or for some riders - the two stroke is still King, the mighty KX250 is thoroughly updated for the 2004 season and is partnered once more by a re-specified and re-engineered KX125, based on the World Championship winning machine of Kawasaki’s own Michael Maschio.

With such a resurgence of interest in off-road sport, and an underlying demand from customers for performance, quality and, above all, durability, there has never been a better time to be part of Kawasaki’s “Green Machine”.

KX250F – new model K

3

EY POINTS The first Kawasaki 4-stroke MX bikeCompact and lightweight 249 cc DOHC, liquid cooled engineVery low engine heightTitanium valvesTitanium exhaust pipeNew D-section tubing perimeter frame, very narrow profile and rider friendly riding positionNew Uni-Trak rear suspensionEasy hot starting

SPECIFICATIONS KX250-N1 Engine type............................ 4-stroke, liquid cooled, single cylinder, primary kick-start

with Automatic Compression Release (ACR)Displacement......................... 249 cc Bore & stroke......................... 77.0 x 53.6 mmValve system ......................... 4-valve, DOHCCompression ratio. ............... 12.6:1Maximum power .................... 31.6kW (43.0PS) / 11,000rpmMaximum torque ................... 28.7 N•m (2.93 kgf•m) / 8,500 rpmFuel System........................... 37mm Keihin FCR carburettorIgnition ................................... Acceleration Compensating Capacitor Discharge Ignition

(AC-CDI) Transmission......................... 5-speedFrame type ............................. High tensile steel perimeter frameRake / trail .............................. 26.5º / 110 mmSuspension, front.................. 48 mm inverted cartridge forkSuspension, rear ................... New Uni-Trak®Wheel travel, front / rear ....... 300/310mmTyre size, front / rear............. 80/100-21 51M / 100/90-19 57M, BridgestoneBrakes, front .......................... 250 mm single semi-floating disc with dual piston caliperBrakes, rear ........................... 240 mm single disc with single piston caliperL x W x H ................................ 2,170 x 840 x 1,270Wheelbase ............................. 1,475 mmSeat height............................. 960 mmFuel tank capacity ................. 7.5 litres Ground clearance.................. 340 mmDry weight.............................. 92.5 kg

NOTE: Specifications subject to change without notice.

Kawasaki 2004

KX250F (KX250-N1)FEATURES AND BENEFITS

ENGINEHigh performance 4-stroke engine

DOHC with 4 titanium valves produces a wide powerband with high torque and rpm. Thin wall engine construction, no engine balancer and magnesium generator and clutch covers help make this the lightest engine in its class. Internal oil lines reduce complexity, weight and make the unit more compact. Semi dry sump allows the engine to be mounted lower in the frame reducing the centre of gravity and eliminates the need for an external oil tank.New Automatic Compression Release (ACR) design aids starting.A reed valve between the crankcase and transmission reduces pumping losses resulting in excellent engine response.Aluminium engine mounts are strong, reliable and reduce weight.

Digital Acceleration Compensating Capacitor Discharge Ignition (AC-CDI)

A separate ignition map for neutral gives quick starting and a stable idle when in neutral. A second map is selected when a gear is selected to increase the idle speed and reduce the engine braking effect.

Fuel system37 mm Keihin FCR carburettor provides quick starting, good response and a wide powerband. Hot start lever on the left handlebar leans off the fuel mixture making starting a hot engine quick and easy.

Exhaust systemStepped titanium exhaust pipe is lightweight and has that ‘factory’ look about it.Bolt on silencer is easy to re-pack reducing maintenance time.Aluminium end cap is angled to reduce the risk of clogging.

TRANSMISSION5-speed transmission

Lightweight, compact and reliable 5 speed transmission.Gear type ratchet shifting mechanism with phased shift holder for excellent shift response and feel.‘Daido’ super steel gears for improved reliability.

CHASSISFrame

D section tubing used on main perimeter frame reduces width and improves riding position.High footpegs and a narrow frame width allow a high angle of lean for excellent cornering.Aluminium skid plate fitted as standard increases crankcase protection.

Inverted 48 mm front fork48 mm inverted cartridge type front forks provide excellent performance.New front axle clamping method and rigidly held handlebars reduce weight and improve performance.New front fork guard design improves fork protection.

Uni-Trak® rear suspension The superb new Uni-Trak rear suspension is shared with the KX250-M2 and features:New linkage, revised swingarm, suspension arms and layout of the Uni-Trak improve traction, lower weight and make a more compact suspension while reducing side load on the rear shock absorber.Revised settings on the rear shock absorber to suit the new layout.Added drain bolt to the rear shock absorber to ease maintenace.Swingarm plug prevents water, mud and sand from entering the swingarm.

Front and rear disc brakesA 250 mm semi floating front disc with twin piston caliper and 240 mm rear disc with single piston caliper ensure excellent stopping power and feel.Single layer kevlar front brake hose with revised routing gives excellent feel and response while reducing weight.

Wheels New front and rear rims feature an extremely light weight design.Stepped front spokes and revised axle reduce weight.New lightweight mould Bridgestone tyres.

Detail featuresSeat shape and cover improve riding position and reduce slipping.7.5 litre fuel tank improves the riding position.New engine covers provides more protection and improve riding position.Refer to the technical summary for a comprehensive guide on the KX250-N1.

Kawasaki 2004 4

KX250F TECHNICAL SUMMARY

Kawasaki enters the 4-stroke motocross market with the KX250F. The engine is designed to be the lightest in its class and uses automatic compression release, a hot start lever and specialised ignition timing to make starting the 4-stroke easy. The chassis is based on the proven KX125 design yet is narrower and features an all-new Uni-Trak linkage. With its technically advanced engine and refined chassis, the new KX250F is destined for success.MAJOR FEATURES

ENGINE CYLINDER

Chrome composite plated aluminium cylinder is short and compact for light weight and high rigidity.

Lightweight titanium valves require less force to close so that smaller and lighter valve springs can be utilised. Each valve is coated with an oxidised membrane treatment to resist wear. Intake valves are 31mm in diameter and the exhaust valves 25mm.

CYLINDER HEADVariable cylinder head wall thickness uses more material in higher stress areas and less material in low stress areas so that weight is reduced without sacrificing durability.

Dual overhead camshafts have narrow lobes to reduce weight and are made of case hardened steel for durability. The cam profiles help provide a wide power spread.

5 Kawasaki 2004

KX250F TECHNICAL SUMMARY

The cylinder head mounting stud holes are slightly larger than the studs to create oil passages to the head which eliminate external oil lines to reduce weight and add reliability.

PISTONThe forged piston is lighter and stronger than a cast version. The skirt is “streaked” with a fine, spiral-cut groove that increases oil retention for better lubrication and durability.

Single compression and oil rings keep friction low for quick throttle response.

KEIHIN FCR CARBURETTOR Equipped with a hot start lever for easy starting when the engine is hot. When the hot start lever, located on the clutch perch, is pulled, a small plunger at the front of the carburettor opens a passage that draws additional air into the intake tract. More air leans out the fuel mixture to make starting a hot engine easier.

EXHAUST PIPE Titanium head pipe provides the ultimate in light weight. Aluminium silencer with removable end cap provides easy access for changing the packing.

Kawasaki 2004 6

KX250F TECHNICAL SUMMARY

DIGITAL CDI

Ignition timing is optimised through the use of a throttle position sensor for quick acceleration, superb engine performance and to minimise engine braking effect. A neutral sensor provides easy starting and stabilises idle speed. A digital microcomputer monitors throttle position and engine rpm and adjusts ignition timing to maintain maximum power.

CRANKSHAFT The big-end bearing features loose needle bearings in a cage for high reliability.

CRANKCASESA semi-dry sump engine stores oil in the transmission. The crankshaft, piston and cylinder head are lubricated via the oil pump and oil passages within the engine cases. A scavenge pump moves oil from the crankcase to the transmission.

Crankcase pressure is reduced by way of a reed valve between the crankcase and transmission. Engine cases are vented through the kickstart mechanism. Holes in the kickstart idler gear are matched to holes in the kickstart shaft. As the idler gear spins on the shaft, centrifugal force prevents oil from going through the gear, into the shaft and out of the engine while allowing excess pressure to escape.

MAGNESIUM ENGINE COVERS Magnesium generator, clutch and cylinder head covers are lightweight and provide a “factory” look.

7 Kawasaki 2004

KX250F TECHNICAL SUMMARY

COOLING SYSTEM

The radiator side plate is rigid to reduce radiator and shroud deformation caused by riders’ knees and crashes.

CHASSIS FRAME

Based on the KX125 frame, but redesigned with larger and longer front downtube to suit the 4-stroke engine.

Rake is steeper for quicker handling. Footpegs are located higher than KX125-M2 for increased cornering clearance, and the frame is 40mm narrower at the peg mounts for improved riding position and cornering clearance. D-shaped upper frame rails are 3mm wider than the KX125 and the rounded outside edge provides a smooth transition between the bodywork. An aluminium steering stem nut and thin stainless steel washer are utilised to shave weight.

UNI-TRAK® REAR SUSPENSION All-new linkage system anchors the Uni-Trak link in the swingarm and utilises a single, forged aluminium wishbone-style pull rod. There is less

front-to-back movement as the suspension is compressed for better traction and shock action when landing from jumps. Suspension loads are now mainly absorbed by the swingarm, allowing a lighter frame construction.The linkage bushings are all collared sleeves for easier maintenance.

SWINGARM Hydroformed extruded aluminium swingarm has cast brackets for the Uni-Trak linkage mounting points.

The rear axle brackets are forged aluminium for better reliability.

REAR SHOCK Shock settings match the new linkage system. A drain bolt on the piggyback reservoir makes shock oil changes easier.

Kawasaki 2004 8

KX250F TECHNICAL SUMMARY

FRONT FORK

New Kayaba semi-sealed cartridge fork has check valves within the fork located at the top of the lower cartridge tube. The check valve forms a seal within the fork and allows oil to flow into the lower portion of the fork pressurising the lower portion of the fork where the cartridge is located. The check valve holds pressure in the lower portion of the fork and helps prevent cavitation, resulting in improved damping and better fork action throughout the stroke.Compact axle collars allow a shorter axle to be used, which helps reduce weight.

BRAKES The front brake line is routed directly to the caliper instead of wrapping under the bottom of the fork. The shorter line helps reduce weight.

Rear brake lever pivot and pedal shape designed to provide maximum ground clearance when leaned over in a turn. The rear brake caliper has a smaller piston than that of the KX125 (25.4mm vs. 27mm) and a redesigned carrier that lowers the overall caliper height in order to provide adequate clearance for the 4-stroke muffler.

9 Kawasaki 2004

KX250F TECHNICAL SUMMARY

STYLING/ERGONOMICS

The seat is shaped to create a flat, comfortable riding position and has a textured surface to help provide grip for the rider.

Revised bodywork distinguishes the KX250F from the KX125/250. Aluminium skid plate and plastic guards help protect the engine.

Kawasaki 2004 10

OFF-ROAD FEATURE LIST

EN

GINE

& T

RANS

MISS

ION

Liquid cooledk

Kawasaki Integrated Powervalve Systemk

4 stroke, DOHC, 4 valve, single cylinder

Chrome composite plated cylinder

Electrofusion cylinderk

Reed valvek

Magnesium engine covers

Aluminium rebuildable silencer

5-speed transmission

6-speed transmission

Aluminium kick-starter pedal

ELEC

TRIC

AL

AC-CDIk

CDI with electronic timing advancek

Digital CDIk

Kawasaki Integrated Powervalve Systemk

CHAS

SIS

Detachable rear sub framek

Perimeter framek

Recessed chain adjusters

Straight pull spokesk

Aluminium rims

BRAK

ES

Hydraulic front disc brake

Hydraulic rear disc brake

Dual piston front caliper

Aluminium brake pedal

CONT

ROLS Straight pull throttle

Folding aluminium shift pedal

Folding steel shift pedal

KX65

-A5

KX85

-A4

KX85

-B4

KX12

5-M

2

KX25

0-M

2

KX25

0-N1

11 Kawasaki 2004

OFF-ROAD FEATURE LIST

k For further information on these features, please refer to the Kaw-Pedia

REAR

SUS

PENS

ION

Uni-Trak rear suspensionk

Aluminium body shock

Gas rear shock with reservoir

Rebound damping adjustmentk

Compression damping adjustmentk

Aluminium Uni-Trak linkage

Threaded preload adjuster

Hydroformed tapered aluminium swingarm

Box-section aluminium swingarm

Box section steel swingarm

Needle bearing swingarm pivot

FRON

TSU

SPEN

SION

Inverted front cartridge fork

Adjustable front fork compression damping

Leading axle forks

Aluminium triple clamps

Tapered roller bearing steering

FUEL

SY

STEM

Power jet carburettork

Crescent shape slide carburettork

Hot start systemk

KX65

-A5

KX85

-A4

KX85

-B4

KX12

5-M

2

KX25

0-M

2

KX25

0-N1

Kawasaki 2004 12

13 Kawasaki 2004

FUEL SYSTEM 35CARBURETTOR . . . . . . . . . . . . . . . . . . . . . . . 35CRESCENT SLIDE CARBURETTOR . . . . . . . 35POWER JET CARBURETTOR . . . . . . . . . . . . 35HOT START SYSTEM. . . . . . . . . . . . . . . . . . . 35REED VALVES . . . . . . . . . . . . . . . . . . . . . . . . 35CRANKCASE REED VALVES . . . . . . . . . . . . 36CARBON FIBRE REED VALVE . . . . . . . . . . . 36

COOLING SYSTEM 36LIQUID COOLING . . . . . . . . . . . . . . . . . . . . . . 36

ENGINE TOP END 36DUAL-OVERHEAD CAMS . . . . . . . . . . . . . . . 36DIRECT ACTUATION VALVES . . . . . . . . . . . 36FOUR-VALVE HEADS. . . . . . . . . . . . . . . . . . . 37VALVE INCLUDED ANGLE. . . . . . . . . . . . . . . 37KAWASAKI AUTOMATIC COMPRESSION RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37AUTOMATIC CAM CHAIN TENSIONER. . . . . 37ELECTROFUSION . . . . . . . . . . . . . . . . . . . . . 37KAWASAKI INTEGRATED POWERVALVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38COMPRESSION RATIO - VARIABLE . . . . . . . 38

ENGINE RIGHT SIDE 38PAPER-BASED FRICTION PLATES. . . . . . . . 38

WHEELS/TYRES 38STRAIGHT-PULL SPOKES. . . . . . . . . . . . . . . 38

BRAKES 38SEMI FLOATING DISC . . . . . . . . . . . . . . . . . . 38

SUSPENSION 39CARTRIDGE FORKS . . . . . . . . . . . . . . . . . . . 39INVERTED FORKS. . . . . . . . . . . . . . . . . . . . . 39COMPRESSION DAMPING . . . . . . . . . . . . . . 39ADJUSTABLE COMPRESSION DAMPING . . 39REBOUND DAMPING. . . . . . . . . . . . . . . . . . . 39SPRING PRELOAD . . . . . . . . . . . . . . . . . . . . 40UNI-TRAK®. . . . . . . . . . . . . . . . . . . . . . . . . . . 40

FRAME 40PERIMETER FRAME . . . . . . . . . . . . . . . . . . . 40DETACHABLE SUB-FRAME . . . . . . . . . . . . . 40

ELECTRICAL SYSTEM 41KAWASAKI THROTTLE RESPONSIVE IGNITION CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . 41CAPACITOR DISCHARGE IGNITION (CDI) . 41DIGITAL CAPACITOR DISCHARGE IGNITION41ACCELERATION COMPENSATING CAPACITOR DISCHARGE IGNITION . . . . . . 41FEATURES: . . . . . . . . . . . . . . . . . . . . . . . . . . 41IGNITION TIMING MAP . . . . . . . . . . . . . . . . . 41

KAW-PEDIA CONTENTS

OFF-ROAD MOTORCYCLE KAW-PEDIA

The Kaw-Pedia is a guide to the benefits of the many technical features of the 2004 Kawasaki products shown in this book. The Kaw-Pedia is divided into sections to ease comparison.

FUEL SYSTEMCARBURETTORFeatures:Carburettors create an air/fuel mixture for the engine to burn. The carburettor controls (or throttles) the amount of air/fuel mixture that reaches the engine and changes the air/fuel ratio for different operating conditions such as starting or abrupt slowing of the vehicle. Carburettors have an air valve called a slide connected to a fuel valve called a jet needle and needle jet. As the slide is raised, letting more air flow into the engine, the needle also rises letting fuel flow out the needle jet to mix with the air. The shape of the slide and size of the jet needle and needle jet control the air/fuel ratio at mid-throttle rpm. At low throttle openings when little air flows past the jet needle and needle jet, fuel does not mix efficiently. A smaller jet and several passages, together called the pilot circuit, control the fuel at low throttle openings. During full throttle, the main jet controls fuel delivery.CRESCENT SLIDE CARBURETTORFeatures:The shape of the Keihin crescent slide improves air velocity through the carburettor creating more vacuum draw around the atomising tower, improving fuel atomisation. The crescent shape of the slide also allows the main and pilot circuit passages to be closely spaced for smoother transitions as different fuel circuits come into effect.

Benefits:The crescent slide carburettor provides accurate air/ fuel mixtures at all throttle openings allowing the engine to pull smoothly.

POWER JET CARBURETTORFeatures:The Keihin power jet carburettor uses an electronic solenoid to open and close a fuel passage in the carburettor to provide a wider range of power. The solenoid is controlled by the digital igniter. The igniter uses rpm and throttle position data to open and close the solenoid at pre-set points. Typically, the fuel passage is closed under a specified throttle position. Once the specified throttle position point is reached, the solenoid opens the fuel passage allowing fuel into the engine intake. Once the rpm reach a second specified point, the solenoid closes off the fuel passage leaning out the engine at high rpm.Benefits:This carburettor provides more accurate fuel delivery to better meet the demands of the 2-stroke engine. The result is a wider powerband, cleaner running at lower rpm, and increased top end power.HOT START SYSTEMFeatures:Without a hot start system, restarting a 4-stroke motocross machine after a fall often takes many kicks losing valuable time. When the motorcycle tips over, fuel flows from the carburettor and floods the intake tract, creating an overly rich mixture that makes starting a hot engine difficult. With this system a rider pulls the hot start lever mounted on the left handlebar, a plunger at the front of the carburettor opens an additional air passage which allows air to enter the intake and lean the mixture.Benefits:Combined with the KX250F’s special “neutral” ignition map, the hot start system allows riders to quickly restart their machine.REED VALVESFeatures:Reed valves, used on 2-stroke engines, act as one-way valves in the intake port. As the piston moves up creating low pressure in the crankcase, the reeds open and allow the fuel/air mixture to fill the crankcase. As the piston starts to pass top dead centre (TDC) and pressurises the crankcase, the reeds close preventing the air/fuel mixture from being pushed out through the carburettor. Benefits:The reeds provide variable intake timing depending on intake pressures to give the engine strong low rpm power while maintaining high rpm power.

Kawasaki 2004 14

OFF-ROAD MOTORCYCLE KAW-PEDIA

CRANKCASE REED VALVES Features:The intake and reed assembly is mounted into the crankcase instead of the cylinder. Intake flow directly into the crankcase reduces the number of bends and shortens the path the intake mixture must travel to get to the combustion chamber. More fuel stays suspended in the air and more mixture flows when the piston clears the transfer ports. Benefits:The shortened intake path produces better throttle response and improved cylinder filling for increased torque for the entire rpm range.CARBON FIBRE REED VALVE Features:The reed valve petals are made of carbon fibre reinforced plastic. The lightweight carbon fibre reeds seal better against the reed cage and the reeds maintain their form better at high rpm).Benefits:The light, flexible reeds respond better at low flow rates for excellent throttle response and low rpm torque. At high engine speeds, the reeds maintain their form better to improve high rpm power. The result is a broader power band, better throttle response and increased high rpm power.

COOLING SYSTEMLIQUID COOLINGFeatures:A pump circulates coolant through a water jacket surrounding the cylinder(s) and combustion chamber(s), absorbing engine heat. The coolant continues on to the radiator. Air flowing by the radiator tubes carries the engine heat away. Consistent engine temperatures result, allowing closer-fitting pistons, minimal mechanical noise, and reduced emissions.

Benefits:Liquid cooling is used to maintain more consistent engine temperatures. Liquid-cooled engines can sustain more horsepower during hard use, have longer engine life, and lower exhaust emissions due to constant temperatures. Liquid-cooled engines are also quieter than air-cooled engines.

ENGINE TOP ENDDUAL-OVERHEAD CAMS Features:Individual camshafts are placed in the cylinder head and operate the intake and exhaust valves. One cam opens the intake valves and the second cam opens the exhaust valves. Placing the cams in the head allows for optimum placement of the valves for more efficient combustion. Dual camshafts simplify valve actuation, allow for a lightweight compact valve actuation system and are suited for high rpm use.Benefits:Dual-overhead cams are light and compact for less valve train inertial mass and provide consistent valve timing at high rpm. Dual-overhead camshaft heads remain the standard for efficient power and torque production.DIRECT ACTUATION VALVES Features:The camshaft is located directly over the valve. A tappet carrying the valve clearance adjustment shim slides in a bore in the cylinder head and fits over the end of the valve stem. The rotating cam pushes on the tappet which opens the valve.Benefits:Direct actuation lowers inertial mass and provides consistent valve timing. Valve sealing and valve guide oil sealing are improved by eliminating the rocking motion from the valve stem.

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OFF-ROAD MOTORCYCLE KAW-PEDIA

FOUR-VALVE HEADSFeatures:

Putting the most air and fuel into the cylinder possible produces the best power and torque. One way to do this is to open many large valves letting the air and fuel fill the

cylinder. Improvements in metallurgy have allowed the use of very large valve openings with very small (4mm diameter) and light weight valve stems.Benefits:Air and fuel enter the combustion chamber with less restriction improving torque and power.VALVE INCLUDED ANGLEFeatures:Valve included angle is the angle between the intake and exhaust valve stems. As the angle is reduced, the roof of the combustion chamber can be brought down closer to the top of the piston. Combined with straight-shot intake ports, the narrow valve included angle permits compression ratios to exceed 12:1.

Benefits:High compression ratios and improved thermal efficiency deliver more horsepower per litre.

KAWASAKI AUTOMATIC COMPRESSION RELEASEFeatures:When the engine is rotated during starting, Kawasaki Automatic Compression Release (KACR) automatically holds the exhaust valve(s) slightly open as the piston nears TDC (Top Dead Centre). Once the piston passes TDC, the exhaust valve(s) closes. This releases some of the cylinder compression that causes resistance during starting. Once the engine begins to run the valves operate normally. KACR is used on both kick-start and electric start 4-stroke models.Benefits:KACR makes the engine easier to start for both kick-start and electric start models, and eliminates the need for a manual compression release.AUTOMATIC CAM CHAIN TENSIONERFeatures:Cam chains require tension at all times to maintain correct valve timing. The automatic cam chain tensioner maintains the correct tension and compensates for the increased chain length due to gradual wear. This is accomplished by a spring that pushes the tensioner plunger out against the cam chain guide, keeping the chain tension correct. A pawl and ratchet prevent the tensioner plunger from being pushed in when chain loads are high.Benefits:The cam chain maintains correct tension at all times to provide consistent performance without any maintenance expense. The chain operates quietly for increased riding comfort.ELECTROFUSIONFeatures:The electrofusion treatment starts with placing the aluminium cylinder in a heated vacuum chamber. Fine wires of molybdenum and steel are suspended in the bore and a high voltage is passed through them. The resulting metal particles bond to the cylinder in a hard, porous film. Being porous, the electrofusion cylinder holds oil so the piston always rides on a film of oil for better sealing and less wear.Benefits:Electrofusion resists wear and seizure. Rapid heat transfer permits higher compression ratios for increased power. It allows the use of closer tolerances and leaner carburation for better fuel economy and lower exhaust emissions.

Kawasaki 2004 16

OFF-ROAD MOTORCYCLE KAW-PEDIA

KAWASAKI INTEGRATED POWERVALVE SYSTEMFeatures:Two-stroke engines with Kawasaki Integrated Powervalve System (KIPS) have an rpm sensing governor that opens and closes as many as three exhaust port valves. At low rpm, the valves close off part of the exhaust port, shortening exhaust duration and improving low end power. At high rpm, the valves open and increase exhaust duration, improving top end power. Changing exhaust port timing allows for the engine to produce maximum torque at low rpm and maximum horsepower at high rpm.

Benefits:KIPS-equipped 2-stroke engine has a broader power band making the vehicle easier to ride for a variety of track conditions.COMPRESSION RATIO - VARIABLEFeatures:Two stroke models with KIPS list variable compression ratios. The variable compression ratio is a result of KIPS altering the exhaust port height. The compression ratio of 2-stroke engines is figured by calculating the volume of the cylinder above the exhaust port. Since KIPS alters exhaust port height, the compression ratio will be higher when the valve is closed and the exhaust port height is lower. The compression ratio will be lower at high rpm when the valve is open and the exhaust port height is higher.Benefits:Engineers set the compression ratio based on the design of the engine and type of fuel available to provide the best performance for the conditions.

ENGINE RIGHT SIDEPAPER-BASED FRICTION PLATESFeatures:The friction qualities of paper-based clutch friction material are more uniform under hard use. It better resists deformation in extreme heat from hard use when compared to cork compounds.Benefits:The paper-based clutch friction plates retain smooth operating qualities under hard use and last longer.

WHEELS/TYRESSTRAIGHT-PULL SPOKESFeatures:The spokes have little or no bend at the head where the spoke exits the wheel hub, thus eliminating a critical weak spot.Benefits:The wheels are stronger for their weight than ever before.

BRAKESSEMI FLOATING DISCFeatures:Disc brake calipers must be aligned with the disc to provide effective braking and have a small amount of clearance from the disc to prevent the brakes from dragging. Some disc brakes have pins on which the calipers float back and forth to maintain alignment and clearance. Letting the disc float on the hub is a simpler and lighter way to maintain the caliper to disc alignment and clearance. Small spring washers between the hub and the disc dampen disc noise when the brakes are not applied.Benefits:Semi floating discs ensure correct brake pad to disc alignment for good brake performance and feel while reducing weight and complexity.

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OFF-ROAD MOTORCYCLE KAW-PEDIA

SUSPENSIONCARTRIDGE FORKSFeatures:The fork inner cylinder and piston rod form a damping chamber inside the fork to prevent the mixture of oil and air. Air mixed into the oil results in inconsistent damping. The design of the cartridge allows for minimal oil and air mixture, and allows for adjusters to control damping. Depending on the model application, cartridge forks may have compression damping adjustment or both compression and rebound damping adjustment. (see REBOUND DAMPING, COMPRESSION DAMPING)Benefits:The cartridge design provides damping control necessary for high performance motorcycles and allows for the addition of damping adjustment.INVERTED FORKSFeatures:The large diameter fork outer-tube is held in the triple-clamps and the inner tube holds the front axle. The forces put on the fork during turning, braking and suspension travel are more evenly applied to the length of the fork assembly so the fork flexes less.

Benefits:The more rigid inverted fork produces very precise handling with less suspension weight. Off-road motorcycles with inverted forks have no overhang below the axle. The fork does not drag in ruts for better control and acceleration out of corners.COMPRESSION DAMPING Features:Shock absorbers and front forks control spring compression with compression damping. Compression damping slows the speed of the spring as it compresses when the wheel strikes a bump. Compression damping also helps limit the compression/extension cycles (bounce) after the spring has extended. Compression damping is achieved with oil being pushed through a small opening of a fixed size. (see REBOUND DAMPING)Benefits:Compression damping keeps the chassis level and less affected by bumps and holes in the riding surface, improving tyre contact.ADJUSTABLE COMPRESSION DAMPINGSome models allow the rider to adjust the speed of spring compression with a needle valve.Benefits:Allows the rider to tune the suspension to suit their riding style and different tracks.REBOUND DAMPINGFeatures:Shock absorbers and front forks control spring extension with rebound damping. Rebound damping slows the speed of the suspension as it tries to extend after striking a bump in the riding surface. Rebound damping also helps limit the compression/extension cycles (bounce) after the spring has extended. Oil pushed through a small opening of a fixed size is the most common method of damping. If more damping is required for a vehicle, the factory makes the opening smaller which slows the spring more and increases the damping rate.Benefits:Rebound damping helps keep the vehicle stable and tyres in contact with the surface when riding over irregularities.

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OFF-ROAD MOTORCYCLE KAW-PEDIA

SPRING PRELOADFeatures:Motorcycle suspension is set up to not only provide a comfortable ride for the rider, but also to maintain proper geometry and ride height of the motorcycle. Spring preload refers to the amount the spring is initially compressed to maintain proper ride height. To compensate for different rider weights or changing loads, the amount of spring preload can be adjusted. Benefits:Adjustable spring preload offers more flexibility in fine tuning the suspension to the rider's needs. UNI-TRAK®Features:Uni-Trak® transfers the movement of the rear wheel and swingarm to a link arm which acts upon one large shock absorber and spring. The shock absorber is centrally located low in the frame, improving mass centralisation and lowering the machine's centre of gravity. The shock linkage decreases leverage on the shock as the suspension is compressed. Bumps are damped progressively with small bumps receiving light damping and large bumps receiving heavy damping.

Benefits:Uni-Trak® with its single shock and spring offers a smoother ride with more comfort, better steering and high speed handling control. It also puts more power to the ground. For high-performance machines, this is what it's all about.

FRAMEPERIMETER FRAMEFeatures:From the steering head two upper frame tubes sweep around the sides of the cylinder head to the Uni-Trak® shock mount then down to the swingarm pivot. The direct path between the two load points makes the frame very rigid and light at the same time. Benefits:The perimeter frame is very rigid and low in weight while allowing space for the easy breathing engine intake and exhaust systems. The result is phenomenal handling and the feel of solid control.DETACHABLE SUB-FRAMEFeatures:The portion of the frame holding the seat, airbox, and rear fender removes for easy access to the Uni-Trak® shock and spring. Benefits:The removable portion of the frame allows easy access to the suspension components. If the frame is damaged, only the bent portion of the frame need be replaced for lower repair costs.

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OFF-ROAD MOTORCYCLE KAW-PEDIA

ELECTRICAL SYSTEMKAWASAKI THROTTLE RESPONSIVE IGNITION CONTROLFeatures:Kawasaki Throttle Responsive Ignition Control (K-TRIC) identifies throttle position and relays this input to the igniter. The igniter adjusts the ignition timing according to a pre-set ignition timing map for efficient combustion, without detonation, based on how much load is on the engine.Benefits:K-TRIC allows the engine to use optimum ignition advance in all conditions resulting in better response and power throughout the rpm range.CAPACITOR DISCHARGE IGNITION (CDI)Features:CDI is a self-powered ignition that relies on the quick discharge of a capacitor to fire the spark plug(s). An exciter coil and the magnets in the engine's rotating flywheel generate a voltage charging the capacitor in the CDI unit. A pickup coil senses the position of the flywheel and times the discharge of the capacitor. At the correct moment, the capacitor voltage is discharged through the ignition coil firing the spark plug.In 2-stroke engines the rich air/fuel mixture laden with oil can easily foul spark plugs if the voltage rises too slowly. CDI spark voltage rises immediately, firing the mixture before plug fouling can occur.

Benefits:CDI helps the engine start easily and ensures firing under adverse conditions. CDI requires no battery so the ignition weighs less and requires no maintenance. Spark plugs last longer.

DIGITAL CAPACITOR DISCHARGE IGNITIONFeatures:Digital CDI features a computer chip that dictates spark advance. Kawasaki engineers program the chip to change spark advance to match the exact demands of each model. The engineer considers port timing, powervalve operation, expansion chamber design, and more before plotting the timing map. Extensive testing under actual operating conditions finalises the timing map. Kawasaki's digital CDI system uses a pickup coil instead of a pulser coil because it is more accurate.Benefits:Digital CDI helps the engine make maximum power at all engine speeds. It responds more quickly to rpm changes for better response and power when you need it.ACCELERATION COMPENSATING CAPACITOR DISCHARGE IGNITIONFeatures:AC-CDI features seperate ignition maps for in gear operation and neutral. When the gears are engaged the ignition timing raises the idle speed to minimise the 4-stroke engine braking effect. A neutral sensor engages another ignition map that reduces idle speed to a normal level.Benefits:AC-CDI reduces the 4-stroke engine braking effect making the bike more stable when shifting down and when entering corners and making the bike easier to start when hot (in conjunction with the hot start system).IGNITION TIMING MAPFeatures:Most motorcycle ignitions use an electronic advance that varies the ignition timing depending on rpm. Using two sources of data, rpm and throttle position, allows for multiple ignition advance points to maximise ignition timing in all conditions without detonation. These pre-set advance points form a three-dimensional "map" with peaks and plateaus to correspond with the amount of load on the engine.Benefits:The ignition timing map allows for maximum ignition advance in all conditions for efficient combustion. This results in better engine performance from idle to wide open throttle.

Exciter coil Ignition coil

Pulse coil CDI

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Kawasaki Motors Pty Ltd, Technical Service Division