2003 KX & Enduro Motorcycles Suspension & Carburetor Tuning Charts

Canadian Kawasaki Motors Inc.

RS03-101
March 24, 2003
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RACE TUNING INFORMATION

The information contained in the following charts is compiled from information obtained from Team Green's experiences working with riders throughout the country. This information is intended as a starting point only - individuals should test all changes in order to obtain maximum performance.

R A C I N G

2003 Team Green KX & Enduro Suspension Chart

FRONTFORKS Rider Weight KX60-B19 50-70 70-90 90+ KX65-A4 55-65 65- 75 75-85 KX85-A3 Up to 75 75-100 100-115 115-125 KXI00-D3 70-85 85-100 100-115 115-125 KX125-M1 120-140 140-165 165 KX250-M1 130-145 145-165 165-180 KX500-E15 145-160 160-175 175+ KDX220-A10 135-150 150-170 170-200 200+ KLX300-A8 All weights Fork Position (height)* Std Std Std 15mm 10mm Flush Std Std Std Std Std Std Std Std I0mm 10mm I0mm I0mm 10mm 10mm Std Std Std Std Std Std Std Std Spring Rate Oil Level Oil Rebound Comp Weight Out Out Spring Rate REAR SHOCK Preload/Sag Rebound Level Out Comp Out Nitrogen Pressure

0.23 0.25 0.27 0.26 0.27 0.28 0.27 0.28 0.29 0.30 0.27 0.28 0.29 0.30 0.41 0.42 0.43 0.43 0.44 0.45 0.39 0.40 0.41 0.34 0.35 0.36 0.37 0.38

Light Stock Heavy Light Stock Heavy Ex Light Light Stock Heavy Ex Light Light Stock Heavy Light Stock Heavy Light Stock Heavy Light Stock Heavy Light Stock Heavy Ex Heavy n/a

130mm 130mm 130mm 130mm 130mm 125mm 90mm 90mm 90mm 80mm 90mm 90mm 90mm 80mm 130mm 120mm 120mm 130mm 120mm 120mm 100mm 100mm 100mm 95mm 95mm 95mm 95mm 95mm

10 10 10 10 10 10 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5

fila n/a n/a 2**** 2**** 3**** n/a n/a n/a n/a n/a n/a n/a n/a 12 10 8 10 8 8 10 10 10 n/a n/a n/a n/a n/a

fila n/a n/a n/a n/a n/a 8 8 8 8 8 8 8 8 9 6 5 8 6 5 6-8 6-8 6-8 8-10 8-10 8-10 8-10 14

3.0 3.3 3.7 4.7 4.9 4.9 4.4 4.6 4.8 5.0 4.4 4.6 4.8 5.0 ***4.5 4.7 4.9 4.7 4.9 5.1 5.3 5.5 5.7 4.8 5.0 5.2 5.4 5.8

Light Stock Heavy Light Stock Stock Ex Light Light Stock Heavy Ex Light Light Stock Heavy

#4 #3 #2 70mm 70mm 70mm 80-85mm 80-85mm 80-85mm 80-85mm 80-85mm 80-85mm 80-85mm 80-85mm

n/a n/a n/a n/a n/a n/a Pull Rods 2**** **Stk 140psi 1.5**** **Stk 140psi 1**** 85.3mm 140psi 9 9 8 8 9 9 8 8 13 13 12 13 12 II 8 8 8 9 9 9 9 9 1 1 1 2 2 2 2 2-3 14-16 14-16 14-16 14-16 14-16 14-16 12 12 12 10 10 10 10 12 150psi 150psi 150psi 150psi 150psi 150psi 150psi 150psi 150psi 150psi 150psi 150psi 150psi 150psi 150psi 150psi 150psi 150psi 150psi 150psi 150psi 150psi

n/a n/a n/a

Ex Light 100-103mm Light 100-103mm Stock 100-103mm Ex Light 100-103mm Light 100-103mm Stock 100-103mm Light Stock Heavy Light Stock Heavy Ex Heavy Stock 100mm 100mm 100mm 100mm 100mm 100mm 100mm 100mm

* Fork Height is measured from top of fork tube to top of fork clamp. ** Stock 86.3mm pull rods on the 2002 KX65 can be exchanged for optional 85.3mm or 87.3mm to raise or lower the seat height by 4.5mm respectively. *** Optional spring from a previous year KX125. P/N: 92144-1501-45. **** Refer to the 2003 KX65 owners manual for position information. FOOTNOTES - Rebound and compression adjustments are the number of clicks out from full seated (all the way in). Front fork oil level is measured in millimeters (mm). Rear shock sag level is measured in millimeters (mm). All optional spring part numbers can be found at your local Kawasaki dealership. SPECIAL NOTE - Team Green recommends that any suspension setting changes be done at normal riding temperatures. Always test new settings before racing. *Team Green Specifications subject to change.

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2003 Team Green KX Carburetor Tuning Chart

KX60 -B19
STOCK MAIN JET P/N: 92063NEEDLE CLIP POSITION P/N: NEEDLE JET P/N: 16017POWER JET P/N: 16159PILOT JET P/N: 92064SLIDE P/N: 16025AIR SCREW TURNS OUT NGK SPARK PLUG FRONT SPROCKET REAR SPROCKET 200 -022 5114 #3 160091220 N-8 -1215 N/A 30 -1030 2.0 -1107 N/A B9EG 13 44 N-6 -1259 N/A 35 -1023 SAME N/A B9EVX SAME SAME SAME T.G. SAME

KX65 -A4
STOCK 190 -021 5GSP-68 #3 161871226 0-0 -1413 N/A 25 - 032 1.5 -1040 1-1/2 B10EG 13 47 SAME N/A SAME SAME SAME B10EVX 14 46 SAME T.G. SAME

KX85 -A3
STOCK 140 -1360 NAPE #3 161871178 N/A N/A 45 -1142 3.5 -1220 1-1/2 N/A N/A 48 -1143 SAME SAME SAME T.G. SAME

KXI00 -D3
STOCK 138 -1359 NAPF #4 161871179 N/A N/A 45 -1142 3.5 -1220 1-1/2 N/A N/A SAME SAME SAME B10EVX SAME SAME SAME T.G. SAME

KX125 -M1
STOCK 420 -1473 6CHJ1182 #3 161870008 N/A N/A 40 -1216 5.75 -0003 1-1/2 BR9EIX 13 51 T.G. 400 -035 SAME #2 SAME

KX250 -M1
STOCK 165 -1370 NAFH #2 161871163 N/A 50 -1053 52 -1130 8.0 -1217 1-1/2 BR8EIX 13 49 N/A SAME SAME SAME SAME SAME SAME SAME SAME T.G. SAME

KX500 -E15
STOCK 168 -1371 N82M #3 160091580 N/A N/A 58 -1146 7.0 -1163 1-1/2 BR8EG 14 47 T.G. 170 -1372 SAME #2 SAME

N/A N/A 37.5 -1215 SAME SAME SAME SAME SAME

N/A N/A 55 -1145 SAME 2 B9EVX SAME SAME

105NGK BR9EVX 105NGK 14 50 14 52 13 51

CAUTION: Team Green specifications are obtained using fuel mixed at a 40:1 mix ratio. Your results will vary with the use of different fuels, oils, temperatures, altitudes or mix ratios. Team Green does not recommend the use of pump gas, aviation fuels or octane boosters. Use of these products may cause engine damage or failure. Recommended for sea level to 3,000 feet above sea level. N/A: Non-applicable

Warranty
Normal warranty procedures apply. Consult the Kawasaki Procedures Manual for complete warranty information.