Kawasaki KX60 (1983-2002) and KX80 (1983-1990) Manual.
Clymer Kawasaki KX60, 1983-2002 and KX80 1983-1990 repair manual is written specifically for the do-it-yourself enthusiast. From basic maintenance to troubleshooting to complete overhaul of your Kawasaki KX60, 1983-2002 and KX80 1983-1990, Clymer manuals provide the information you need. The most important tool in your tool box may be your Clymer manual, get one today.
Models:
KX60 (1983-2002)
KX80 (1983-1990)
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 / Basic hand tools / Precision measureing tools / Special tools / Fabricating tools / Expendable supplies / Mechanic’s tips / Safety / Specifications
CHAPTER TWO / 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
CHAPTER THREE / 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
CHAPTER FOUR / 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
CHAPTER FIVE / ENGINE LOWER END
Servicing engine in frame / Engine / Engine sprocket / Crankcase and crankshaft / Specifications
CHAPTER SIX / CLUTCH, KICKSTARTER AND EXTERNAL SHIFT MECHANISM
Clutch cover / Clutch / Primary drive pinion gear / Clutch cable / Kickstarter / External shift mechanism / Specifications
CHAPTER SEVEN / TRANSMISSION AND INTERNAL SHIFT MECHANISM
Transmission operation / Transmission troubleshooting / Transmission overhaul / Internal shift mechanism / Specifications
CHAPTER EIGHT / 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
CHAPTER NINE / IGNITION SYSTEM
Capacitor discharge ignition / Flywheel / Capacitor discharge ignition unit / Ignition coil / Spark plug / Engine stop switch / Wiring diagrams / Specifications
CHAPTER TEN / LIQUID COOLING SYSTEM
Cooling system inspection / Radiator / Water pump / Hoses / Specifications
CHAPTER ELEVEN / FRONT SUSPENSION AND STEERING
Front wheel / Front hub / Tire changing / Tire repairs / Handlebar / Steering head (KX60 and 1983-1985 KX80) / Steering head (1986-on KX80) / Steering adjustment / Front forks / Specifications
CHAPTER TWELVE / REAR SUSPENSION
Rear wheel / Rear hub / Driven sprocket / Drive chain / Tire changing and tire 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
CHAPTER THIRTEEN / 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
INDEX
WIRING DIAGRAMS
