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Kawasaki KX80 (1991 - 2000)

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The original Haynes Repair Manual - Based on a complete stripdown and rebuild of a vehicle

Kawasaki KX80 (1991 - 2000)

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What's Covered
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This Kawasaki Manual is 352 pages.

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Safety / Basic service methods / Serial numbers / Fasteners / Shop supplies / Basic tools / Precision measuring tools / Storage / Specifications

CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Starting the engine / Starting difficulties / Engine performance / Engine / Leak down test / Fuel system / Electrical troubleshooting / Clutch / External shift mechanism ans transmission / Kickstarter / Drive train noise / Front suspension and steering / Rear suspension / Frame noise / Brakes

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Service intervals / Tune-up / Pre-ride inspection / Engine lubrication / Oil level check / Transmission oil / Air filter / Spark plug / Fuel system / Exhaust system / Cooling system / Engine compression test / Ignition timing / Control cable lubrication / Throttle cable operation / Clutch cable / Engine top end inspection / Kick pedal and shift pedal / Brakes / Drive chain and sprockets / Tires and wheels / Wheel bearings / Steering / Front fork / Rear shock absorber / Rear swing arm and linkage / General lubrication / Fasteners / Storage / Specifications

CHAPTER FOUR / ENGINE TOP END
Cleanliness / Exhaust system / Cylinder head / Cylinder / KIPS exhaust valve / Piston, piston pin and piston ring / Reed valve assembly / Engine break-in / Specifications

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

CHAPTER SIX / CLUTCH, KICKSTARTER AND EXTERNAL SHIFT MECHANISM (1989-1997 MODELS)
Right crankcase cover / Clutch / Primary drive pinion gear / Clutch cable / Kickstarter / External shift mechanism / Specifications

CHAPTER SEVEN / CLUTCH, KICKSTARTER AND EXTERNAL SHIFT MECHANISM (1998-ON MODELS)
Clutch cover / Clutch release lever / Right crankcase cover / Exhaust valve governor / Clutch / Clutch inspection / Primary drive pinion gear / Clutch cable / Kickstarter / External shift mechanism / Specifications

CHAPTER EIGHT / TRANSMISSION AND INTERNAL SHIFT MECHANISM
Transmission operation / Transmission troubleshooting / Transmission overhaul / Internal shift mechanism / Transmission gear ratios / Specifications

CHAPTER NINE / FUEL SYSTEM
Air filter / Carburetor identification / Carburetor service / Float height adjustment / Fuel level adjustment / Carburetor rejetting / Fuel tank / Fuel shutoff valve / Throttle cable / Airbox / Specifications

CHAPTER TEN / IGNITION SYSTEM
Electrical component replacement / Capacitor discharge ignition / Flywheel / Stator plate assembly / Pickup coil / Capacitor discharge ignition module / Ignition coil / Engine stop switch / Ignition timing / Specification

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

CHAPTER TWELVE / WHEELS, TIRES AND DRIVE CHAIN
Bike stand / Front wheel / Rear wheel / Wheel service / Front hub / Rear hub / Tire changing / Tire repairs / Sprocket replacement / Drive chain / Specifications

CHAPTER THIRTEEN / FRONT SUSPENSION AND STEERING (CONVENTIONAL FORK)
Handlebar / Steering head / Front fork / Specifications

CHAPTER FOURTEEN / FRONT SUSPENSION AND STEERING (CARTRIDGE FORK)
Handlebar / Steering head / Front fork / Front fork oil refilling / Front fork adjustment / Specifications

CHAPTER FIFTEEN / REAR SUSPENSION
Rear shock absorber / Rear swing arm / Uni-Trak linkage / Specifications

CHAPTER SIXTEEN / BRAKES
Brake fluid selection / Brake service / Brake pad replacement / Front caliper / Rear caliper / Front master cylinder / Rear master cylinder / Brake hose replacement / Brake disc / Draining brake fluid / Brake bleeding / Rear brake pedal / Specifications

INDEX

WIRING DIAGRAMS

Models covered:
1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 Kawasaki KX100 KX 100
1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 Kawasaki KX80 KX 80
2001-2016 Kawasaki KX85 and KX85-II  KX 85

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