Kawasaki KX60 & KX80 1983 - 2002 Clymer Owners Service & Repair Manual

By Ron Wright
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Front Cover
Stock image only. Actual cover art may differ.
Kawasaki KX60 & KX80 1983 - 2002 Clymer Owners Service & Repair Manual Covers the following Models:
● KX60 (1983-2002)
● KX80 (1983-1990)

Contents:
QUICK REFERENCE DATA

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

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

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

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

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

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

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

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

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

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

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

REAR SUSPENSION
Rear wheel / Rear hub / Driven sprocket / Drive chain / Tyre changing and Tyre 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

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

WIRING DIAGRAMS

Clymer motorcycle repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from maintenance and troubleshooting, all the way to complete teardown and rebuild.

General information on Repair Manuals

Please note that workshop manuals are usually written for models sold in a specific country. Differences in specification can exist between models sold in different countries and items such as engines can vary. Please check that the manual will cover your model before purchase and if you are unsure please contact us first.

Publisher
Clymer Publications
ISBN
0892878320
ISBN-13
9780892878321
Format
Paperback, 348 pages
Published
January 1991

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