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Manual Details
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Coverage
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Manual Type:
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Digital Service Repair Manual
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Language:
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English
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Format:
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PDF
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Coverage Areas:
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General Information, Fuel System, Cooling System, Engine Top End, Engine Right Side, Engine Removal/Installation, Engine Bottom End Transmission, Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Electrical System, Appendix
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Technical Specs
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File Format Requirements:
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Adobe PDF Reader, WinZip
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Compatibility:
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All Versions of Windows & Mac
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Features
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Zoom Capability:
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Yes
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Manual Coverage
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Systems Covered
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Engine Systems:
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Top End (cylinder, piston, head), Right Side (clutch, gearbox access), Bottom End (crankshaft, connecting rod, bearings, seals), Engine Removal/Installation
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Fuel System:
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Carburetor service, fuel tank, fuel lines, fuel filter
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Cooling System:
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Radiator, coolant, hoses, water pump
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Drivetrain:
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Transmission, final drive (chain and sprockets)
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Wheels Tires:
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Wheel bearing service, tire replacement, spoke tension
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Brakes:
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Front and rear brake system service (hydraulic discs), pad replacement, fluid bleeding
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Suspension:
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Front forks (cartridge service, oil changes), rear shock absorber service
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Steering:
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Handlebar, steering stem bearings, fork triple clamps
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Electrical System:
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Ignition system, lighting, wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier)
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Bodywork Chassis:
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Frame inspection, seat, fenders, fuel tank mounting
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Appendix:
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Torque specifications, fluid capacities, diagnostic charts, general maintenance data
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Procedures Included
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Maintenance Procedures:
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Regular scheduled maintenance, oil changes, filter replacements, chain adjustment, spark plug replacement, brake fluid checks
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Repair Procedures:
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Engine component overhaul, transmission repair, suspension overhaul, brake system overhaul, electrical troubleshooting and repair
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Diagnostic Procedures:
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Troubleshooting common issues, identifying faulty components, electrical diagnostic procedures using wiring diagrams
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Assembly Disassembly:
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Step-by-step instructions for disassembling and reassembling all major motorcycle components
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Technical Depth
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Depth Of Information:
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Comprehensive, covering all workshop procedures from basic maintenance to complete engine rebuilds. Includes detailed diagrams and torque settings.
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Engine Specifications
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Primary Engine
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Engine Type:
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Liquid-cooled, 2-stroke, single-cylinder
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Displacement:
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198 cc
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Bore X Stroke:
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66.0 x 58.0 mm
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Compression Ratio:
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8.5:1 (approx.)
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Ignition:
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CDI (Capacitor Discharge Ignition)
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Lubrication:
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Premix or Auto-lube (Kawasaki's K-PREMIX system)
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Performance
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Horsepower:
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Approx. 35-40 HP (varies with tune and model variation)
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Torque:
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N/A (typically not prominently published for this model in readily available sources, but manual would contain it)
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Fuel System
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Carburetor Model:
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Keihin PWK35 (likely)
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Fuel Type:
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Unleaded gasoline (91 octane or higher recommended)
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Fuel Mixture Ratio:
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50:1 with proper 2-stroke oil if using premix
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Maintenance
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Service Intervals
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Oil Change Interval:
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Refer to manual for specific interval based on usage (e.g., every 20-30 hours of hard riding or annually)
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Air Filter Cleaning:
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Frequent cleaning recommended, especially in dusty conditions (weekly or as needed)
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Spark Plug Replacement:
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Every 3,000-5,000 km or as performance dictates (refer to manual)
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Chain Lubrication Adjustment:
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Check and lubricate chain every 500 km, adjust tension as needed (refer to manual for specific slack)
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Fluid Specifications
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Engine Oil Type Premix:
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High-quality 100% synthetic 2-stroke motorcycle oil (e.g., JASO FD or higher)
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Coolant Type:
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Ethylene glycol based coolant (50% concentration with distilled water)
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Brake Fluid Type:
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DOT 3 or DOT 4 hydraulic brake fluid (Manual will specify exact)
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Known Issues
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Common Wear Items:
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Piston rings, clutch plates, swingarm bearings, steering head bearings, fork seals, chain and sprockets due to off-road use.
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Engine Characteristics:
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Known for strong mid-range power, can be finicky to start when cold if carburetor is not set up correctly. KIPS (Kawasaki Integrated Power Valve System) requires proper maintenance.
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Maintenance Tips
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Carburetor Cleaning:
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Regular cleaning of the carburetor, especially the main jet and pilot jet, is crucial for optimal performance.
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Kips System:
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Kawasaki's KIPS exhaust power valve system can accumulate carbon and requires periodic cleaning and lubrication to function correctly. The manual will detail this.
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