1977-1981 Kawasaki KZ200 Motorcycle Service Manual

Description

This 1977 1978 1979 1980 1981 Kawasaki KZ200 Motorcycle Service Manual is a reproduction of the original, out of print manual. This manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 1977-1981 Kawasaki KZ200 motorcycles.

This repair manual includes wiring diagrams, special tools and troubleshooting information.

Table of Contents

Specifications
Engine Performance Curves
Running Performance Curves
Periodic Maintenance Chart

Adjustment – Engine
Spark Plug
Ignition Timing
Camshaft Chain
Valve Clearance
Throttle Cable
Carburetor
Clutch
Engine Oil
Fuel System

Adjustment – Chassis
Rear Shock Absorbers
Drive Chain
Brakes
Front Brake
Rear Brake
Brake Light Switch
Steering
Wheel Balance
Headlight
Horn
Lubrication

Disassembly – introduction
Introduction To Disassembly
Torque And Locking Agent

Disassembly-engine Installed
Flowchart
Fuel Tank
Air Cleaner Element
Capacitor
Ignition Coil
Carburetor
Muffler
Top End
Contact Breaker
Timing Advancer
Camshaft Sprocket
Camshaft
Rocker Arm
Cylinder Head
Valve Valve Guide
Cylinder Block
Piston, Piston Rings
Left Side
Engine Sprocket
Clutch Release
Left Engine Cover
Dynamo Armature
Dynamo Flywheel Starter Motor Clutch
Sprockets Chain
Starter Motor
Neutral Switch
Camshaft Chain
Right Side
Right Engine Cover, Oil Filter
Bypass Valve
Engine Oil Pump
Clutch
Primary Gear, Oil Pump Drive Gear
External Shift Mechanism
Kickstarter

Disassembly Engine Removed
Flowcharts
Engine Removal
Crankcase Split
Transmission
Shift Drum
Drive Shaft
Output Shaft
Crankshaft
Crankcase

Disassembly – Chassis
Flow Chart
Wheels, Brakes, Drive Chain
Front Wheel
Front Disc Brake
Drive Chain
Rear Wheel Rear Brake
Tire Tube
Rim
Spoke
Cables
Front Brake
Clutch
Throttle
Speedometer
Tachometer
Lights
Headlight Unit
Indicator Lights
Turn Signal Light
Turn Signal Assembly
Speedometer, Tachometer Illuminator Lights
Tail/brake Light
Switches
Ignition
Front Brake Light
Rear Brake Light
Steering
Handlebar
Steering Stem
Steering Stem Bearing
Suspensions
Front Fork
Rear Shock Absorber
Swing Arm

Maintenance – Engine
Engine Perspective
Air Cleaner
Carburetor
Camshaft
Camshaft Chain, Guides, Tensioner
Rocker Arms, Shafts
Cylinder Head, Valves
Cylinder Block, Piston
Crankshaft, Connecting Rod
Clutch
Transmission
Kickstarter
Engine Lubrication
Ball, Roller, Needle Bearings
Oil Seals
Muffler

Maintenance – Chassis
Fuel Tank
Wheels
Tires
Rim, Spokes
Axle
Wheel Bearings, Grease Seals
Rear Wheel Coupling
Drive Chain
Sprockets
Front Brake
Rear Brake
Steering Stem
Front Fork
Rear Shock Absorbers
Swing Arm

Maintenance – Electrical
Battery
Charging System
Dynamo
Regulator/rectifier
Ignition System
Ignition Coil
Contact Breaker
Capacitor
Timing Advancer
Spark Plug
Electric Starter System
Starter Motor Circuit
Starter Motor
Starter Motor Clutch, Chain
Ignition Switch
Neutral Switch
Lighting System
Headlight Circuit
Brake Light Circuit
Turn Signal Circuit
Horn
Speedometer Tachometer

Troubleshooting