1986 Kawasaki KX80 Manual

The 1986 Kawasaki KX80 is a high-performance 80cc two-stroke motocross bike designed for young riders. Featuring a liquid-cooled engine, 6-speed transmission, front and rear suspension systems, and lightweight frame construction. Below are key sections for safety, specifications, maintenance, operation, and troubleshooting.

Features at a Glance

Key components: Liquid-cooled 80cc two-stroke engine, 6-speed transmission, Uni-Trak rear suspension, telescopic front forks, disc brakes.

Installation & Assembly

Unpack and inspect contents. Assemble on stable surface.

1. Install handlebars: Position and tighten clamp bolts to specification.
2. Mount front wheel: Insert axle and tighten to proper torque.
3. Install controls: Attach throttle, clutch, and brake levers.
4. Add fluids: Fill with recommended 2-stroke oil and fuel mixture.

WARNING! Motorcycle is heavy; lift with care to avoid injury. Ensure all fasteners are properly torqued.

First-Time Setup

Complete pre-ride inspection and adjustments.

1. Check tire pressure: Front 12 psi, Rear 12 psi.
2. Adjust suspension: Set sag and compression for rider weight.
3. Lubricate chain: Apply chain lube to drive chain.
4. Fuel mixture: Prepare 32:1 gas/oil mixture.
5. Start engine: Use choke for cold starts.

CAUTION! Always wear proper safety gear. Check all systems before operation.

Specifications

• Engine: 80cc liquid-cooled two-stroke single
• Bore x Stroke: 47.0 x 45.8mm
• Compression Ratio: 8.4:1
• Carburetor: Mikuni VM24SS
• Ignition: CDI
• Transmission: 6-speed, wet multi-disc clutch
• Final Drive: Chain
• Frame: Semi-double cradle, steel
• Wheelbase: 49.0 inches
• Ground Clearance: 11.4 inches

Controls and Operation

Familiarize yourself with all controls before riding.

Left Handlebar: Clutch lever, horn button, choke knob

Right Handlebar: Front brake lever, throttle grip, kill switch

Foot Controls: Gear shift lever (left), rear brake pedal (right)

Starting Procedure: Turn fuel on, set choke, kick start firmly. Allow warm-up before riding.

Shifting: Use clutch for smooth gear changes. Pattern: 1-down, 5-up.

Maintenance Procedures

Regular maintenance ensures optimal performance and safety.

1. Daily: Check tire pressure, chain tension, fluid levels
2. Weekly: Clean air filter, inspect brakes, check spokes
3. Monthly: Change transmission oil, inspect suspension
4. Seasonal: Top end rebuild, bearing inspection

Tip: Keep detailed maintenance records for service intervals.

Engine Service

Two-stroke engine requires specific maintenance procedures.

1. Spark Plug: NGK BR9ES, gap 0.024-0.028 inches
2. Fuel Mix: 32:1 premium gasoline with 2-stroke oil
3. Top End: Rebuild every 20-30 hours of operation
4. Carburetor: Clean jets regularly, adjust air/fuel mixture
5. Cooling System: Check coolant level, inspect hoses
6. Exhaust: Repack silencer periodically

WARNING! Engine components get extremely hot. Allow cooling before service.

Safety Features

Kill Switch: Emergency engine shut-off. Brake Lights: Activate with brake application. Throttle: Spring-loaded return.

Care & Cleaning

Clean after each ride. Use mild soap and water; avoid high-pressure spray near bearings and seals.

CAUTION! Do not spray water directly at air filter or electrical components. Dry thoroughly after washing.

Regulatory Information

Designed for closed-course competition use only. Not legal for street operation. Always obey local riding area regulations. For support, contact Kawasaki Motors Corp., U.S.A. or visit authorized Kawasaki dealership.

Troubleshooting

Reset: Return carburetor to factory settings if available.

Service: Contact authorized Kawasaki dealership for technical support.