The 1975-1999 Kawasaki KC100, KE100, KH100 repair manual by Haynes covers:
Book Excerpt: 1975-1999 Kawasaki KC100, KE100, KH100 Repair Manual
- Kawasaki KC100 (Companion), U.K. 1979-1986
- Kawasaki KE100A, U.K. 1978-1981, U.S.A. 1975-1981
- Kawasaki KE100B, U.K., U.S.A. 1981-1999
- Kawasaki KH100A (KH100, KH100EL), U.K. 1977-1980
- Kawasaki KH100G (KH100EX), U.K. 1981-1992
FUEL SYSTEM AND LUBRICATION
AIR FILTER | GENERAL
ROTARY DISC VALVE | REMOVAL, EXAMINATION AND REFITTING
- The care and maintenance of the filter element(s) is described in Routine Maintenance. Never run the engine with the air filter disconnected or the element removed.
Apart from the risk of increased engine wear due to unfiltered air being allowed to enter, the carburetor is jetted to compensate for the presence of the filter and a dangerously weak mixture will results if the filter is omitted.
- US owners should note that the air filter is subject to the anti-tampering legislation currently in force, which means the machine must never be run with the filter element removed or rendered inoperative, or with the assembly altered in any way.
Furthermore, only genuine Kawasaki replacement parts may be used if the replacement of any component is necessary.
Since the valve forms such an integral part of the engine/transmission unit its removal and refitting is outlined only here.
FRAME | EXAMINATION AND RENOVATION
Refer to this Chapter, Chapter 1, and Routine Maintenance for full details of the individual operations. The procedure is as follows:
- Drain the transmission oil.
- Remove the kickstart lever.
- Remove the carburetor and withdraw both the fuel feed pipe and the oil pump control cable from their respective sealing grommets.
On early KE100 models remove the metal carburetor overflow drain cover from underneath the carburetor chamber.
- Disconnect the clutch cable.
- Remove the oil pump.
- On early KE100 models, it may be necessary to remove the right-hand footrest assembly (three bolts). Similarly, on the KH1200 models, it may be necessary to remove the exhaust system.
- Remove the crankcase right-hand cover; take care not to lose the oil transfer pipe or the clutch release piece.
- Remove the clutch assembly and primary drive gear. (continued).
- The frame is unlikely to require attention unless accident damage has occurred. In some case, replacement of the frame is the only satisfactory remedy if it is badly out of alignment; repairs are a task for a specialist only.
- At regular intervals, examine the frame closely for signs of cracking or splitting at the welded joints. Rust can also cause weakness at these joints. Minor damage can be repaired by welding or brazing depending on the extent and nature of the damage.
- Remember that a frame which is out of alignment will cause handling problems and may even promote a "speed wobble." If misalignment is suspected, it will be necessary to strip the machine completely so that the frame can be checked, and if necessary, replaced.
Subject: 1975, 1976, 1977, 1978, 1979, 1980, 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999 Kawasaki KC100, KE100, KH100 service, maintenance, repair. ISBN-10: 1859607071 | ISBN-13: 9781859607077 | Haynes 1371