Kawasaki KE 100 G5 1971-1981 Service Repair Workshop Manual 1972 1973 1974 1975 1976 1977 1978 1979 1980

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The Kawasaki KE100 G5 is a versatile dual-purpose motorcycle produced between 1971 and 1981. Known for its robust engineering and reliability, this model offers a blend of on-road usability and...

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Typ: Motorcycle

Anbieter:

Art.-Nr: 89781

Stichworte: 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 Kawasaki KE 100 G5 KE Models Motorcycle Motorcycles

Produktvarianten

Beschreibung

The Kawasaki KE100 G5 is a versatile dual-purpose motorcycle produced between 1971 and 1981. Known for its robust engineering and reliability, this model offers a blend of on-road usability and off-road capability, making it a popular choice for riders seeking adventure. Its lightweight design, powered by an air-cooled, 2-stroke, 98 cc engine, ensures agile handling and a responsive riding experience. The KE100 G5 represents a significant era in lightweight motorcycle development, emphasizing practical performance and durability. This comprehensive Service Repair Workshop Manual provides essential information for the maintenance, repair, and restoration of your Kawasaki KE100 G5 motorcycle from 1971 to 1981. It covers all major systems, including the engine, transmission, chassis, and electrical components, with detailed procedures for disassembly, assembly, troubleshooting, and routine maintenance. The manual is designed to assist owners, mechanics, and technicians in keeping the motorcycle in optimal working condition, ensuring its longevity and performance through clear, step-by-step instructions and technical specifications.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KE100 G5

Model Designation:

Body Style:

Dual-Purpose Motorcycle

Codes

Manual Product Name:

Kawasaki KE 100 G5 1971-1981 Service Repair Workshop Manual PDF Download

👋 Introduction

Market Position

Target Audience:

Owners, DIY mechanics, repair shops, restorers of Kawasaki KE100 G5 motorcycles.

Competitive Analysis

Value Proposition:

Provides comprehensive, factory-level information for maintenance, repair, and restoration, enabling cost savings for owners.

Key Features

Accessibility:

Instant digital download, accessible on multiple devices (PC, iPad, etc.).

Completeness:

Covers all major systems and procedures for the specified model years.

Authenticity:

Described as the 'original' and 'official' manual used by professional technicians.

📋 Manual Details

Coverage Areas

Model Years Covered:

1971, 1972, 1973, 1974, 1975, 1976, 1977, 1978, 1979, 1980, 1981

Specific Variants Covered:

KE100 G5

Page Count

Estimated Page Count:

Up to 5 GB in file size, exact page count not specified but implies comprehensive coverage.

Manual Type

Manual Type:

Service Repair Workshop Manual

Synonymous Manual Types:

Factory Manual, Repair Guide, Technical Workshop Manual

Language

Language:

English

Format

Delivery Format:

Digital Download (PDF, ZIP, RAR, EXE)

Software Requirements:

PDF Reader (e.g., Adobe Acrobat), Unzipping software (e.g., WinZip, WinRAR)

Printing Capability:

Printable on any computer and printer

Storage Recommendation:

Save immediately to hard disk/local storage after download; no lifetime storage provided.

📖 Manual Coverage

Systems Covered

Engine:

Detailed coverage of engine components, disassembly, assembly, and troubleshooting.

Transmission:

Coverage of transmission operation, maintenance, and repair.

Chassis:

Includes frame, suspension, steering, and related components.

Electrical System:

Comprehensive electrical system diagnostics, wiring diagrams, and component testing.

Fuel System:

Details on fuel tank, carburetor, fuel lines, and related components.

Brakes:

Information on front and rear brake system maintenance and repair.

Lubrication:

Specifics on lubrication points, types of lubricants, and service intervals.

Steering:

Coverage of steering head bearings, fork assembly, and steering components.

Suspension:

Details on front forks and rear shock absorber system maintenance and repair.

Clutch:

Instructions for clutch operation, adjustment, and replacement.

Lighting System:

Coverage of headlights, taillights, turn signals, and associated electrical components.

Frame:

Includes frame inspection, repair, and related components.

Seat System:

Information pertaining to seat mounting and related components.

Locks:

Details on ignition and steering lock mechanisms.

Battery:

Information on battery maintenance, testing, and charging.

Procedures Included

Maintenance:

Routine maintenance tasks, inspections, and preventative care.

Repair:

Step-by-step instructions for component repair and replacement.

Troubleshooting:

Diagnostic procedures and solutions for common and uncommon problems.

Rebuild:

Detailed guidance for complete engine and component rebuilds.

Disassembly Assembly:

Exploded views and instructions for taking apart and reassembling various motorcycle systems.

Technical Depth

Depth:

Highly detailed, suitable for professional technicians and experienced DIY enthusiasts.

Illustrations:

Illustrated with clear, step-by-step instructions and likely includes diagrams/exploded views.

Diagnostic Capability:

Supports immediate problem fixing and advanced diagnostics.

📊 Manual Specifications

File Format

Primary Format:

PDF (Portable Document Format)

Alternative Formats:

ZIP, RAR, EXE (indicating potential compression or executables for unpacking)

Print Quality

Printability:

High quality, allows printing of all pages.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, 2-stroke, piston-port intake

Displacement:

98 cc (Cubic Centimeters)

Bore X Stroke:

50.0 x 49.5 mm

Compression Ratio:

6.8:1

Carburetor:

Mikuni VM24SS (likely, specific model may vary slightly)

Ignition System:

CDI (Capacitor Discharge Ignition)

Performance

Horsepower:

Approximately 10-11 HP (figures can vary based on specific year and tuning)

Torque:

Not explicitly specified in product info, but characteristic of its class.

Fuel System

Fuel Type:

Unleaded gasoline (typically 87 octane or higher) mixed with 2-stroke oil

Fuel Tank Capacity:

Approximately 7.0 Liters (1.8 US gal)

Oil Mixture Ratio:

Typically 20:1 or 25:1 for pre-mix, or dedicated oil injection system (check manual for specifics).

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh, foot-shift

Optional

Optional Transmissions:

N/A (Typically a single transmission option for this model)

Features

Clutch Type:

Wet, multi-plate

Final Drive:

Chain drive

📐 Dimensions

Exterior

Overall Length:

Approximately 1990 mm (78.3 in)

Overall Width:

Approximately 835 mm (32.9 in)

Overall Height:

Approximately 1160 mm (45.7 in)

Wheelbase:

Approximately 1315 mm (51.8 in)

Weights

Dry Weight:

Approximately 100 kg (220.5 lbs)

Curb Weight:

Not explicitly specified, but typically around 108-110 kg with fluids.

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (Motorcycles of this era did not undergo standardized crash testing as cars do).

Active Features

Braking System:

Front: Drum Brake; Rear: Drum Brake

Suspension Features:

Front: Telescopic fork; Rear: Swingarm with dual shock absorbers

Passive Features

Lighting:

Headlight, Taillight, Brake Light, Turn Signals (depending on market regulations)

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic motorcycle technology of the era).

Driver Assistance

Driver Assistance Features:

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Recommended every 1,000-2,000 km or annually; check manual for specific recommendation for transmission oil.

Spark Plug Check:

Regularly, typically every 1,000-2,000 km or as per manual. Replacement at specified intervals.

Air Filter Cleaning:

Frequent cleaning, especially in dusty conditions. Replacement at specified intervals.

Chain Lubrication Adjustment:

Every 500-1000 km and after washing or riding in rain.

Fluid Specifications

Engine Oil Type:

2-stroke engine oil, specific API classification and viscosity grade (e.g., API TC, JASO FD) as per manual.

Transmission Oil Type:

API GL-4 or GL-5 gear oil, SAE 80 or SAE 90 viscosity grade (check manual for exact specification).

Fork Oil Type:

Specific fork oil viscosity (e.g., SAE 10W) and quantity as per manual.

Known Issues

Common Wear Items:

Carburetor jets clogging, clutch wear, chain and sprockets, rear shock absorber degradation, fork seal leaks.

Two Stroke Specific Concerns:

Carbon buildup in exhaust port and piston crown, proper oil/fuel mixture crucial for engine longevity.

Electrical Aging:

Older wiring harnesses can degrade, leading to intermittent electrical faults.

📚 Vehicle History

Brand Heritage

Kawasaki Heritage:

Kawasaki Heavy Industries is a Japanese conglomerate with a long history in motorcycle manufacturing, known for performance and innovation.

Model Evolution

Ke100 Lineage:

The KE100 was part of Kawasaki's line of lightweight, dual-purpose motorcycles, designed for versatility on and off-road. It evolved from earlier KE models, offering improvements in engine performance and chassis dynamics.

Production

Production Period:

1971-1981 for the G5 model designation

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Industry Awards:

N/A (Specific awards for this model not readily available, but generally well-regarded in its class for reliability and versatility.)