This workshop service manual provides comprehensive repair and overhaul instructions for the KE175 Dual-Sport Motorcycle, covering model years 1979 through 1983. The KE175, a versatile motorcycle known for its lightweight design and manageable power, was a popular choice for riders seeking capability in both on-road and light off-road conditions. Built upon a legacy of producing reliable and performance-oriented machines, the KE175 offered a balanced riding experience, making it a respected model within the dual-sport segment. This manual aims to support the longevity and optimal performance of these classic motorcycles.
This 174-page English-language workshop service manual is meticulously designed to guide mechanical technicians and owners with mechanical aptitude through all aspects of KE175 maintenance and repair. It covers essential systems including the engine, transmission, fuel, ignition, lubrication, electrical, and bodywork, with detailed procedures for disassembly, assembly, removal, and installation. The manual also includes troubleshooting guidance, tune-up instructions, and information on proprietary components, aiming to provide information comparable to that of an authorized service department. By utilizing this manual, owners and technicians can ensure informed ownership, efficient maintenance, and professional-level repairs, ultimately saving time and resources.
Model Years Covered:
1979, 1980, 1981, 1982, 1983
Vehicle Type:
Dual-Sport Motorcycle
Target Audience:
Mechanical technicians and owners with mechanical aptitude.
Value Proposition:
Enables informed ownership, efficient DIY maintenance, and professional-level repairs, saving time and money.
Content Parity:
Provides similar information and procedures to an authorized Kawasaki dealer service department.
Accuracy Statement:
Endeavored to ensure accuracy, presenting reliable information for comprehensive repairs.
Primary Coverage:
Repair and overhaul of Kawasaki KE175 models from 1979-1983.
Secondary Coverage:
Includes instructions for proprietary components manufactured for the KE175.
Type:
Workshop Service Manual
Engine And Transmission:
Comprehensive disassembly and assembly for engine and transmission.
Fuel System:
Detailed information on the fuel system components and operation.
Ignition System:
Procedures for ignition system maintenance and repair.
Lubrication System:
Coverage of the lubrication system, including oil flow and components.
Exhaust System:
Information pertaining to the exhaust system.
Electrical System:
Detailed explanation of the electrical system and its components.
Bodywork And Chassis:
Procedures related to body and chassis components.
Routine Maintenance:
Instructions for routine maintenance and servicing tasks.
Troubleshooting Diagnostics:
Diagnostic and repair procedures for common and uncommon issues.
Removal Installation:
Step-by-step procedures for component removal and installation.
Assembly Disassembly:
Detailed instructions for the assembly and disassembly of various components.
Tune Ups:
Guidance on performing tune-up procedures.
Depth Of Coverage:
Assumes technician familiarity with general automotive practices, emphasizing product-specific aspects.
Proprietary Components:
Incorporates instructions for proprietary components and their manufacturers.
Special Tools:
References and illustrations for recommended or required special tools with Kawasaki part numbers.
Warning And Cautionary Information:
Highlights important safety information through WARNING, CAUTION, and NOTE notations.
Delivery Method:
Electronic delivery via Email
Binding Type:
N/A (Digital Download)
Paper Type:
N/A (Digital Download)
Engine Type:
Two-stroke, Single-cylinder (Inferred from model name 'KE175')
Displacement:
Approximately 170-175cc (Inferred from model name 'KE175')
Horsepower:
Typically in the 16-20 HP range (Inferred for the era and displacement)
Torque:
Specific torque figures not provided in product info, but consistent with a small-displacement two-stroke.
Fuel Delivery:
Carburetor (Standard for this type of motorcycle)
Fuel Type:
Unleaded gasoline with two-stroke oil mixture (Standard for two-stroke engines)
Transmission Type:
6-Speed Manual (Common for this class of Kawasaki motorcycle)
Optional Transmissions:
N/A
Clutch Type:
Wet, multi-plate (Standard for Kawasaki motorcycles of this era)
Seat Height:
Specific figures not provided in product data, but typical for a dual-sport of this size.
Dry Weight:
Approximately 110-120 kg (Inferred)
Wet Weight:
Approximately 120-130 kg (Inferred, with fluids)
Safety Ratings:
No specific safety ratings (e.g., NHTSA, IIHS) are applicable to this vintage motorcycle. Emphasis on manual's safety notations (WARNING, CAUTION).
Braking System Front:
Drum brake (Likely, common for the era)
Braking System Rear:
Drum brake (Likely, common for the era)
Lighting:
Headlight, taillight, turn signals (Standard)
Infotainment Features:
N/A (This is a vintage motorcycle, no electronic infotainment systems).
Assistance Features:
N/A (No electronic driver assistance features).
Connectivity Options:
N/A (No electronic connectivity options).
Oil Change:
Specific intervals not detailed in product info, but typically every 1,000-2,000 miles or annually for two-stroke pre-mix. Manual would specify exact interval.
Spark Plug Check:
Regular checks and cleaning/replacement as per manual recommendations. Likely every few thousand miles.
Air Filter Cleaning:
Frequent cleaning or replacement recommended, especially if used off-road. Manual will provide specific intervals.
Two Stroke Oil:
High-quality two-stroke motorcycle oil, specifically recommended by Kawasaki for pre-mix applications. Manual would list exact specifications and ratios.
Gearbox Oil:
Specific gear oil type and viscosity would be detailed in the manual (e.g., SAE 80 or 90 gear oil).
Common Wear Items:
Clutch wear, carburetor jetting issues due to age/ethanol in fuel, suspension seals, and ignition components (e.g., CDI unit, spark plug).
Typical Repairs:
Carburetor overhaul, top-end engine rebuild (piston, rings), swingarm bearing replacement, and electrical system troubleshooting.
Kawasaki Legacy:
Kawasaki has a long-standing reputation for producing reliable and performance-oriented motorcycles across various segments, including off-road and dual-sport.
Ke175 Positioning:
The KE175 was part of Kawasaki's successful line of dual-sport motorcycles, offering versatility for both on-road and light off-road use. It was known for its lightweight and manageable power delivery.
Manufacturing Period:
Produced from the late 1970s into the mid-1980s, with the manual specifically covering 1979-1983.
Industry Recognition:
While specific awards for the KE175 might not be readily available, Kawasaki's dual-sport motorcycles of this era were generally well-regarded for their reliability and performance in their class.
