Kawasaki KX125, KX250, KX500 Service, Repair & Maintenance Manual
by CLYMER

• KX125 & KX250 1982 - 1991
• KX500 1983 - 2004

Every Clymer contains hundreds of original photographs and illustrations developed from a complete disassembly and assembly of the Motorcycle. This, in addition to extensive research, allows Clymer to achieve an un-matched level of detail, accuracy & clarity.

The step-by-step instructions and two column text with large print are user friendly, bold figure numbers make it easy to quickly match instructions with illustrations and photos. Thumb tabbed chapters, numbered table of contents and extensive index make it possible to locate the desired section quickly.

This manual includes a Quick Reference Data section with frequently used specifications and the following chapters.

• 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

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