Kawasaki KX125, KX250 1982-1991, KX500 1983-2004 Repair Manual

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Item # M447-3  ISBN: 0892979602




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This repair & service manual covers Kawasaki KX125 1982-1991, KX250 1982-1991, and KX500 1983-2004 dirt bikes. Note: see item M472-2 for 1992-on KX125, and item M473 for 1992-on KX250.

Table of Contents

QUICK REFERENCE DATA

CHAPTER ONE: GENERAL INFORMATION
Manual organization | Notes, cautions and warnings | Safety first | Service hints | Engine operation | Washing the bike | Torque specifications | Fasteners | Lubricants | RTV gasket sealant | Threadlock | Parts replacement | Optional parts | Precision measuring tools | Special tools | Fabricating tools | Expendable supplies | Mechanic's tips | Ball bearing replacement | Oil seals | Safety

CHAPTER TWO: TROUBLESHOOTING
Operating requirements | Troubleshooting instruments | Starting the engine | Starting difficulties | Engine starting troubles | Engine performance | Engine | Engine noises | Two-stroke pressure testing | Fuel system | Ignition system | Clutch | Transmission | Drive train noise | Front suspension and steering | Rear suspension | Frame noise | Brakes

CHAPTER THREE: LUBRICATION, MAINTENANCE and TUNE-UP
Pre-ride checklist | Maintenance schedule | Lubricants | Cleaning solvent | Engine lubrication | Periodic lubrication | Engine tune-up | Storage

CHAPTER FOUR: ENGINE TOP END
Engine principles | Engine lubrication | Cleanliness | Servicing engine in frame | Cylinder head | Cylinder and exhaust valve | Cylinder inspection | Exhaust valve decarbonizing | Piston, wrist pin and piston rings | Reed valve assembly | Engine break-in

CHAPTER FIVE: ENGINE LOWER END
Servicing engine in frame | Engine | Engine sprocket | Countershaft oil seal replacement | Crankcase and crankshaft

CHAPTER SIX: CLUTCH, KICKSTARTER and EXTERNAL SHIFT MECHANISM
Clutch cover | Clutch release arm | Exhaust advancer assembly | Clutch | Clutch service | Clutch inspection | Primary drive pinion gear | Clutch cable | Kickstarter | External shift mechanism | Clutch release adjustment

CHAPTER SEVEN: TRANSMISSION and INTERNAL SHIFT MECHANISM
Transmission operation | Transmission troubleshooting | Transmission | Transmission overhaul | Transmission inspection | Internal shift mechanism

CHAPTER EIGHT: FUEL and EXHAUST SYSTEMS
Air cleaner | Carburetor operation | Carburetor service | Carburetor cleaning and inspection | Carburetor fuel level and float height adjustment | Carburetor rejetting | Carburetor variables | Exhaust system | Exhaust system repair

CHAPTER NINE: IGNITION SYSTEM
Component testing | Capacitor discharge ignition | Flywheel rotor | I.C. igniter unit | Ignition coil | Spark plug | Engine stop switch | Ignition timing

CHAPTER TEN: LIQUID COOLING SYSTEM
Safety precautions | Cooling system inspection | Radiator(s) | Water pump | Hoses

CHAPTER ELEVEN: FRONT SUSPENSION and STEERING
Front wheel | Front hub | Rim and spoke service | Tire changing | Tire repairs | Handlebar | Steering head | Front fork | Fork service

CHAPTER TWELVE: REAR SUSPENSION
Rear wheel | Rear hub | Driven sprocket | Drive chain | Tire changing and tire repairs | Shock absorber | Uni-trak linkage | Rear swing arm | Shock absorber brackets | Sub-frame

CHAPTER THIRTEEN: BRAKES
Rear drum brakes | Disc brakes | Front brake pad replacement | Front caliper | Front master cylinder | Rear brake pad replacement | Rear brake caliper | Rear master cylinder | Brake hose replacement | Brake disc | Brake bleeding

WIRING DIAGRAMS

Clymer motorcycle repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from maintenance and troubleshooting, all the way to complete teardown and rebuild.

Kawasaki KX125, KX250 1982-1991, KX500 1983-2004 Repair Manual