Description
This KX125 & KX250 1982-1991 & KX500 1983-2004 Repair Manual Kawasaki Clymer provides detailed service information, step-by-step repair instruction and maintenance specifications for 1982-1991 Kawasaki KX125, 1982-1991 Kawasaki KX250 and 1983-2004 Kawasaki KX500 motocross motorcycles.
1982 1983 1984 1985 1986 1987 1988 1989
1990 1991 1992 1993 1994 1995 1996 1997 1998 1999
2000 2001 2002 2003 2004
Includes everything you need to know to perform tune-up and routine maintenance on the engine, clutch and transmission, fuel and exhaust, ignition system, steering and suspension, wheels, brakes and tires, electrical system, frame and body. Features complete wiring diagrams and 572 illustrated pages.
QUICK REFERENCE DATA
CHAPTER ONE, GENERAL INFORMATION
Manual organization, Notes, cautions and warnings, Safety first, Service hints, Engine operation, Washing the motorcycle, 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
INDEX
WIRING DIAGRAMS