Engine Overhaul:
Complete engine disassembly, inspection, repair, and reassembly
Transmission Repair:
Gearbox removal, inspection, replacement of worn components, clutch service
Suspension Servicing:
Fork seal replacement, damper rod service, shock absorber rebuild, spring rate specifications
Electrical System:
Wiring diagrams, ignition system troubleshooting, lighting, CDI unit service
Cooling System:
Radiator maintenance, coolant specifications, water pump inspection
Fuel System:
Carburetor tuning, jetting specifications, fuel line inspection
Brake System:
Hydraulic brake bleeding, pad replacement, caliper service, master cylinder maintenance
Chassis And Bodywork:
Frame inspection, seat removal, plastic panel replacement, handlebar setup
Troubleshooting Guide:
Common starting problems, performance issues, and diagnostic procedures
Type:
Factory Service Manual / Repair Manual
Format:
Digital (PDF, printable)
Engine Mechanical:
Cylinder, piston, crankshaft, connecting rod, valves, seals, gaskets
Engine Tuning:
Carburetor jetting, ignition timing, power valve operation
Transmission Gearbox:
Gear sets, shift drum, shift forks, clutch assembly, primary drive
Suspension Forks:
Cartridge types, oil levels, damping adjustments, spring preload
Suspension Rear Shock:
Rebuild procedures, seal head replacement, nitrogen charging, damping settings
Electrical Charging System:
Stator, rectifier/regulator, battery maintenance
Electrical Ignition System:
CDI unit, ignition coil, spark plug, wiring harness
Fuel Delivery:
Keihin PWK carburetor specifications, fuel pump (if applicable, though typically not for this model), fuel tank and lines
Exhaust System:
Pipe and silencer maintenance, packing replacement
Wheel And Tire:
Hub bearing replacement, spoke tensioning, tire selection guidance
Cooling System Radiator:
Radiator core cleaning, coolant replacement intervals
Engine Rebuild:
Full bottom-end and top-end rebuild procedures
Carburetor Rebuild And Tuning:
Step-by-step instructions for cleaning, reassembly, and jetting
Suspension Fork Rebuild:
Detailed fork oil change and seal replacement
Rear Shock Rebuild:
Disassembly, component replacement, and charging instructions
Clutch Adjustment And Replacement:
Friction plate replacement, spring replacement, cable adjustment
Brake Bleeding:
Front and rear hydraulic brake system bleeding
Electrical Troubleshooting:
Fault finding for ignition, lighting, and charging systems
Chain And Sprocket Maintenance:
Lubrication, adjustment, and replacement guidelines
Wheel Bearing Replacement:
Front and rear wheel bearing service
Depth:
Comprehensive factory-level repair and maintenance
Diagnostic Capabilities:
Detailed diagnostic procedures for all major systems
Torque Specifications:
All critical engine, chassis, and suspension torque values included
Clearances And Tolerances:
Specific measurements for piston-to-cylinder, ring gap, bearing play, etc.
Illustrations:
High-quality, clear diagrams and photographs of procedures and components
Engine Type:
2-stroke, single-cylinder
Displacement:
124 cc (7.58 cu in)
Bore X Stroke:
54.0 x 54.5 mm (2.13 x 2.15 in)
Cooling System:
Liquid-cooled
Compression Ratio:
8.9:1 (Typical, check manual for exact spec)
Horsepower:
Approx. 38-40 HP (at crankshaft, typical for this era)
Torque:
Not commonly published in HP figures for MX bikes, but power delivery is optimized for mid-to-top range
Carburetor Model:
Keihin PWK38 Air Stripper
Fuel Type:
Unleaded gasoline with appropriate 2-stroke oil mix
Oil Type:
Kawasaki specific 2-stroke premix oil (e.g., Kasei 2-stroke oil) or equivalent high-performance 2-stroke racing oil
Premix Ratio:
Typically 32:1 or 40:1, refer to manual for specific factory recommendation
Oil Change Transmission:
Every 10-15 hours of riding or annually
Air Filter Cleaning:
After every few rides, or as conditions demand
Spark Plug Inspection Replacement:
Every 20-30 hours of riding, or when fouled/worn
Top End Rebuild:
Every 30-50 hours of racing for optimal performance
Suspension Service:
Every 20-40 hours of riding for fork oil and seal service; full rebuild as needed
Engine Oil Premix:
As per manual, typically a high-quality JASO FD certified 2-stroke oil
Transmission Oil:
API GL-4 SAE 80W
Coolant:
Ethylene glycol-based coolant with corrosion inhibitors, 50/50 mix with distilled water recommended
Brake Fluid:
DOT 4 hydraulic brake fluid
Common Wear Items:
Piston rings, clutch plates, wheel bearings, fork seals, power valve components
Performance Tuning:
Proper carburetor jetting and power valve adjustment are critical for optimal engine performance and longevity
Suspension Tuning:
Suspension settings need to be adapted to rider weight and track conditions; manual provides baseline
