This KX125 & KX250 1982-1991 & KX500 1983-2004 Repair Manual Kawasaki Clymer provides service, repair and maintenance information for 1982-1991 Kawasaki KX125, 1982-1991 Kawasaki KX250 and 1983-2004 Kawasaki KX500 motocross motorcycles.

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 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

INDEX

WIRING DIAGRAMS