Description
This 180 page, Kawasaki KE175 Manual is a reproduction of the original, out of print manual. If you are looking for a collectible original, this is NOT it. Photos are blurry, but printed information is useful. If you need repair information though this provides detailed service information, step-by-step repair instruction and maintenance specifications for 1976 Kawasaki KE175B1 two stroke, dual sport motorcycles.
This KE175 Manual is designed primarily for use by Kawasaki motorcycle mechanics in a properly equipped motorcycle shop although it contains enough detail and basic information to make it useful to the Kawasaki KE175 owner who desires to carry out his own basic maintenance and repair work. Since a certain basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily; the adjustments, maintenance, and repair should be carried out only by qualified mechanics whenever the owner has insufficient experience or has doubts as to his ability to do the work so that the motorcycle can be operated safely. In order to perform the work efficiently and to avoid costly mistakes, the mechanic should read the text, thoroughly familiarizing himself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment is specified, makeshift tools or equipment should not be used. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may adversely affect safe operation of the KE175 motorcycle. This KE175 Manual is divided into the following four sections: (1) Adjustment The adjustment section gives the procedure for all adjustments which may become necessary periodically and which do not involve major disassembly. (2) Disassembly , This section shows the best method for the removal, disassembly, assembly, and installation which are necessary for maintenance and repair. Since assembly and installation are usually the reverse of disassembly and removal, assembly and installation are not explained in detail in many cases. Instead, assembly notes and installation notes are provided to explain special points. (3) Maintenance and Theory of Operation The procedures for inspection and repair are described in detail in this section. An explanation on the structure and functioning of each of the major parts and assemblies is given to enable the mechanic to understand better what he is doing. (4) Appendix . The appendix in the back of this KE175 Manual contains miscellaneous information, including special tool list, a torque table, a table for periodic maintenance, and a troubleshooting guide. Since the Shop Manual is based on the first production units of the KE175, there may be minor discrepancies between some vehicles and the illustrations and text in this manual.
KE175 Manual Table of Contents
Foreword
Specifications
Engine Performance Curves
Running Performance Curves
Adjustment
Throttle Control Cable
Throttle Grip Cable
Carburetor Cable
Oil Pump Cable
Carburetor
Choke Cable
Spark Plug
Ignition Timing
Clutch
Steering
Brakes
Brake Light Switch
Drive Chain
Rear Shock Absorbers
Wheel Balance
Headlight
Horn
Disassembly
Introduction To Disassembly
Engine
Engine Oil Tank
Air Cleaner Element
Muffler
Cylinder Head, Cylinder
Piston, Piston Rings
Oil Pump
Carburetor
Right Engine Cover
Clutch
Clutch Release Mechanism
Rotary Disc Valve
Kickstarter
External Shift Mechanism
Drive Chain
Engine Sprocket
Neutral Indicator Switch
Ignition Coil
Cdi Unit
Regulator
Magneto Flywheel
Magneto Stator
Transmission
Crankshaft
Crankcase
Drain Pump
Front Wheel
Rear Wheel
Tire And Tube
Rim
Spoke
Handlebar
Clutch Cable
Throttle Control Cable
Choke Cable
Front Brake Cable
Rear Brake Cable
Speedometer Cable
Tachometer Cable
Headlight Unit
Speedometer
Tachometer
Ignition Switch
Front Brake Light Switch
Rear Brake Light Switch
Front Fork
Steering Stem
Steering Stem Bearings
Rear Shock Absorbers
Swing Arm
Maintenance And Theory Of
Operation
Air Cleaner
Carburetor
Drain Pump
Cylinder And Piston
Cylinder Head
Crankshaft
Clutch
Transmission
Kickstarter
Engine Lubrication System
Rotary Valve
Engine Bearings And Oil Seals
Fuel Tank
Wheels
Tires
Rim And Spokes
Axle
Grease Seals And
Wheel Bearings
Brakes
Drive Chain
Sprockets
Rear Wheel Coupling
Steering Stem
Front Fork
Rear Shock Absorbers
Swing Arm
Muffler
Magneto Flywheel
Ignition System
Lighting/charging System
Rectifier
Regulator
Battery
Spark Plug
Ignition Switch
Headlight Circuit
Brake And Tail Light Circuit
Turn Signals
Horn Circuit
Speedometer And Tachometer
Appendix
Special Tools
Periodic Maintenance
Torque Table
Troubleshooting Guide
Wiring Diagrams
Index
KE175 Manual Index of Subjects Covered
Air cleaner
Axle
Battery
Bearing, engine
Bearing, wheel
Brake
Brake and tail light circuit
Brake cable
Brake light switch
Carburetor
Carburetor cable
CDI unit
Charging system
Choke cable
Clutch
Clutch cable
Clutch release
Coupling
Crankcase
Crankshaft
Cylinder
Cylinder head
Drain pump
Drive chain
Engine
Engine bearings and oil seals
Engine cover, right
Engine lubrication system
Engine performance curves
Engine sprocket
External shift mechanism
Filter, air cleaner
Flywheel magneto
Front fork
Fuel tank
Grease seal
Handlebar
Headlight
Horn
Horn circuit
Idling adjustment
Ignition coil
Ignition switch
Ignition system
Ignition timing
Kickstarter
Lighting/Charging system
Magneto flywheel
Magneto stator
Muffler
Neutral indicator switch
Oil pump
Oil pump cable
Oil seal, engine
Oil tank
Periodic maintenance
Piston
Piston ring
Rear brake cable
Rear shock absorber
Rear sprocket
Rear wheel coupling
Rectifier
Regulator
Right engine cover
Rim
Rotary disc valve
Running performance curves
Shock absorber, front
Shock absorber, rear
Spark plug
Special tool
Speedometer
Speedometer cable
Spoke
Sprocket
Steering
Steering stem
Swing arm
Tachometer
Tachometer cable
Throttle control cable
Throttle grip cable
Tire
Transmission
Torque table
Tube
Turn signal
Wheel
Wheel balance
Wheel bearing
Wiring diagram
