Kawasaki KX60 & KX80 1983-2002 Service & Repair Manual (Clymer M444-2)

Kawasaki KX60 & KX80 1983-2002 Service & Repair Manual (Clymer M444-2)
Brand:Clymer
Product Code:Clymer M444-2
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This Kawasaki Motorcycle Manual is 360 pages.

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 / Basic hand tools / Precision measureing tools / Special tools / Fabricating tools / Expendable supplies / Mechanic's tips / Safety / Specifications

CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Troubleshooting instruments / Starting the engine / Starting difficulties / Engine starting trouble / Engine / Engine performance / Engine noises / Excessive vibration / Fuel system / Two-stroke pressure testing / Clutch /Transmission / Ignition system / Front suspension and steering / Brakes

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Pre-checks / Engine lubrication / Periodic lubrication / Periodic maintenance / Maintenance Schedule Intervals / Engine oil and filter change / Fork oil change / Drive chain adjustment / Engine tune-up / Front fork air pressure measurement / Storage / Specifications

CHAPTER FOUR / ENGINE TOP END
Engine lubrication / Engine cooling / Cleanliness / Servicing engine in frame / Cylinder head / Cylinder / Piston, piston pin and piston rings / Break-in procedure / Reed valve assembly / Specifications

CHAPTER FIVE / ENGINE LOWER END
Servicing engine in frame / Engine / Engine sprocket / Crankcase and crankshaft / Specifications

CHAPTER SIX / CLUTCH, KICKSTARTER AND EXTERNAL SHIFT MECHANISM
Clutch cover / Clutch / Primary drive pinion gear / Clutch cable / Kickstarter / External shift mechanism / Specifications

CHAPTER SEVEN / TRANSMISSION AND INTERNAL SHIFT MECHANISM
Transmission operation / Transmission troubleshooting / Transmission overhaul / Internal shift mechanism / Specifications

CHAPTER EIGHT / FUEL AND EXHAUST SYSTEMS
Air filter / Carburetor operation / Carburetor service (1983-1987) / Carburetor service (1988-on) / Carburetor adjustment / Carburetor rejetting / Fuel tank / Fuel shutoff valve / Exhaust system / Exhaust system decarbonizing / Exhaust system repair / Specifications

CHAPTER NINE / IGNITION SYSTEM
Capacitor discharge ignition / Flywheel / Capacitor discharge ignition unit / Ignition coil / Spark plug / Engine stop switch / Wiring diagrams / Specifications

CHAPTER TEN / LIQUID COOLING SYSTEM
Cooling system inspection / Radiator / Water pump / Hoses / Specifications

CHAPTER ELEVEN / FRONT SUSPENSION AND STEERING
Front wheel / Front hub / Tire changing / Tire repairs / Handlebar / Steering head (KX60 and 1983-1985 KX80) / Steering head (1986-on KX80) / Steering adjustment / Front forks / Specifications

CHAPTER TWELVE / REAR SUSPENSION
Rear wheel / Rear hub / Driven sprocket / Drive chain / Tire changing and tire repairs / Uni-Trak linkage / Rear swing arm / Rear suspension bearing replacement / Uni-Trak rear suspension / Rear shock absorber (KX60) / Rear shock absorber (1983-1985 KX80) / Rear shock absorber (1986-1987 KX80) / Shock absorber (1988-on) / Specifications

CHAPTER THIRTEEN / BRAKES
Drum brakes / Front brake cable / Disc brake (1984-on) / Brake pad replacement / Front caliper / Rear caliper (1988-on KX80) / Front master cylinder / Rear master cylinder (1988-on KX80) / Brake hose replacement / Brake disc / Brake bleeding / Specifications

INDEX

WIRING DIAGRAMS


 

Models covered:


1983 1984 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 Kawasaki KX60

1983 1984 1985 1986 1987 1988 1989 1990 Kawasaki KX80

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