Kawasaki AE50, AE80, AR50, AR80 Repair & Service Manual 1981-1995
The 1981-1995 Kawasaki AE/AR50, AE/AR80 repair manual by Haynes, covers the following models:
United States:
Kawasaki AR50A, 1981-1982
Kawasaki AR80A, 1981-1982
United Kingdom:
Kawasaki AE50A, 1981-1995
Kawasaki AR50A, 1981-1983
Kawasaki AR50C, 1983-on
Kawasaki AE80A, 1981-1983
Kawasaki AE80B, 1983-1987
Kawasaki AR80A, 1981-1983
Kawasaki AR80C, 1983-1992
Book Excerpt: 1981-1995 Kawasaki AE50, AE80, AR50, AR80 Repair Manual
ENGINE, CLUTCH AND TRANSMISSION
EXAMINATION AND RENOVATION: CYLINDER HEAD
Check that the cylinder head fins are not clogged with oil or road dirt, otherwise the engine will overheat. If necessary, use a degreasing agent and brush to clean between the fins.
Check that no cracks are evident, especially in the vicinity of the spark plug or stud holes.
Check the condition of the thread in the spark plug hole. If it is damaged an effective repair can be made using a Helicoil thread insert.
This service is available from most Kawasaki dealers. Always use the correct plug and do not overtighten, see Routine Maintenance.
Leakage between the head and barrel will indicate distortion. Check the head by placing a straight-edge across several places on its mating surface and attempting to insert a 0.10 mm (0.004 in) feeler gauge between the two.
This applies to all except US and later UK 80 models, for which see accompanying figure.
Remove excessive distortion by rubbing the head mating surface in a slow, circular motion against emery paper placed on plate glass.
Do not remove an excessive amount of metal. If in doubt consult a Kawasaki dealer.
Note that most cases of cylinder head distortion can be traced to unequal tensioning of the cylinder head securing nuts or by tightening them in the incorrect sequence.
FRAME AND FORKS
SWINGING ARM | REMOVAL, EXAMINATION, RENOVATION AND REFITTING
Wear in the arm pivot will cause imprecise handling with a tendency for the rear of the machine to twitch or hop.
Support the machine with its rear wheel clear of the ground. Hold onto the main frame and pull and push the rear of the arm. Play in the pivot will be magnified by the leverage effect produced.
Wear will necessitate replacement of the pivot bushes. Refer to Chapter 5 and remove the rear wheel. Move the drive chain clear of the arm.
Detach the arm from the suspension linkage and main frame by removing the necessary bolts. Maneuver the arm rearwards and down to clear the machine.
Thoroughly clean the arm and pivot components. Examine the arm for distortion and cracking. If repair is expensive, look around for a good secondhand item.
Remove corrosion with a wire brush and de-rusting agents and replace the paint finish.
Replace the pivot shaft if its shank is stepped, badly scored or bent beyond the specified limit. No wear should exist between the shaft, sleeve and pivot brushes.
Refer to Specifications for wear limits.
Do not attempt to remove the pivot brushes unless they are to be replaced; they will be destroyed upon removal.
Make sure new bushes are obtainable. Drift each bush from the arm by using a long drift passed through the opposite end of the housing.
Ensure the housing is well supported and each bush leaves it squarely.
Clean and lightly grease the housing before fitting new bushes. Support the housing and drift each bush home, using a short length of metal tube of the same outer diameter as the bush. Check that tube ends are square to its length.
Replace the chain deflector fitted over the left-hand end of the bush housing, if perished or worn. Replace any flattened spring washers. Grease and fit the pivot sleeve.
TABLE of CONTENTS:
Introduction to the Kawasaki AE/AR50 and 80 models
