KAWASAKI Service manual & wiring diagrams
This page is a collection of hard to find information, procedures, tests, and specifications for vintage Kawasaki motorcycles.
CLICK graphic for oil injection pump testing, adjustment, and air bleeding procedures
CLICK (Tap) For Oil pump adjustment & testing
Kawasaki piston size bore and over size specification chart
Kawasaki cylinder bore service limit
Measurement of the cylinder (see chart below for specific model). If any measurement deviates more than 0.05mm between any measured point OR if the of of the points exceeds 0.15mm over the STANDARD bore the cylinder needs to be bored to the next .5mm size. If the initial measurement is already over the 1mm (commonly referred as 2nd over)" service limit of the cylinder. The cylinder needs to be replaced.
Example: F5 standard bore is 80.5mm. If measurements at points A-D in the cylinder measure 80.66. The cylinder needs to be bored .5mm (1st over) or 81mm and a .5mm over piston & ring combo must be used.
Example: F5 standard bore is 80.5mm. If measurements at points A-D in the cylinder measure 80.66. The cylinder needs to be bored .5mm (1st over) or 81mm and a .5mm over piston & ring combo must be used.
Kawasaki cylinder bore size chart & mesurement
Kawasaki piston clearance chart
Kawasaki GA1 GA2 G3 G4 F6 F8 lighting and charging coil test values
Kawasaki Piston ring gap measurement
CLICK for Kawasaki F5/F9/F7 drain pump explanation
Kawasaki GA1 GA2 G3TR G3SS F6 F7 F8 F81M F5 carburetor settings
Kawasaki F5/F9/F7 drain pump explanation
73-75 Kawasaki F11 wiring diagram
Lighting & Charging diagnosis
70-71 Kawasaki F5 wiring diagram
71-73 Kawasaki F7 wiring
Kawasaki B1L-A (125) wiring
It is good practice to remove and block off this device, it creates a vacuum leak when it fails
Kawasaki G4TR 100 wiring
Kawasaki GA1 and GA2 wiring
Kawasaki KMX 125 wiring diagram (Euro model not imported to the US)
The Kawasaki "drain pump" F7/F5/F9
Kawasaki G3, G4, F6, F8 ignition timing adjustment proceedure
Kawasaki F11 and F12MX carburetor specs
Carburetor specs for various Rotary Valve Kawasaki models.
Kawasaki F5, F9, F8, F81M cylinder head torque specs:
8mm (small bolts) 18 ft-lbs
10mm (large bolts) 25 ft-lbs
8mm (small bolts) 18 ft-lbs
10mm (large bolts) 25 ft-lbs
Kawasaki Fork oil quantity for the following models. B1L-A,G-series, G4TR, G31M, F6, F7, F8, F81M, F5 (F9)
Kawasaki KE100 carburetor specs
Fork oil quantity chart
1974-1976 Kawasaki KX125 wiring diagram
Kawasaki KE100 Carburetor specs
Carb type Main Jet Air jet pilot jet Air screw Fuel level
VM19SC 75 .05 17.5 1 1/2 turns 27-29mm
Carb type Main Jet Air jet pilot jet Air screw Fuel level
VM19SC 75 .05 17.5 1 1/2 turns 27-29mm
Kawasaki KX80 KX60 KDX80 CDI testing
Kawasaki KX80 wiring
Kawasaki KX80 KX60 KDX80 Stator coil testing
Kawasaki KX80 KX60 KDX80 Ignition coil test
Carburetor settings chart (specs also found on the appropriate model pages as well) covers these models. GA1A, GA2A, G3SSA, G3TRA, G4TR, G31M, B1LA, F6, F7, F8, F81M, F5
Kawasaki F11 ignition tests
Lighting & charging coil test values for Kawasaki models GA1A, GA2A, G3SSA, G3TR, G4TR, F6, F8
Kawasaki KH100 wiring diagram
Kawasaki F21M wiring (other models noted)
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Key for Fig K2-5 Diagram of ignition, generator, and starter systems typical of Kawasaki F1, F1TR, F2, F2TR and F3 models. Including F21M
Kawasaki F1, F2, F3, F4 and F21M wiring diagram (see key)
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Kawasaki CDI unit testing procedure for KE models (may apply to other models)
1973 Kawasaki KX 125 wiring diagram
Kawasaki F11 250 wiring diagram
Kawasaki KE100 (KM100) points style magneto coil testing procedure
Kawasaki KE100 (KM100) Ignition coil testing
KE100 (KM100) charging coil test procedure
KE100 (KM100) Charging tests
KZ440 carburetor specifications
KE125 Wiring diagram (Euro model)
Kawasaki KZ400 B1 wiring
KZ440 float height measurement
Kawasaki KE100 (KM100) wiring diagram
Kawasaki KE100 (KM100) ignition switch wiring detail
Kawasaki KZ400 C1 wiring
Kawasaki KE100 (KM100) ignition circuit
Kawasaki rotary valve singles standard chain and sprocket specifications
Kawasaki KE100 (KM100) headlight/battery circuit
Kawasaki F5 F9 F7 signal exciter coil testing values
Kawasaki KE175 wiring diagram
Kawasaki G3TR and G3SS wiring
Kawasaki G5 100 wiring
Kawasaki G series F series carburetor float level settings
Kawasaki G series, F6, F8 magneto coil test procedure
Ke125 Carburetor
71-73 Kawasaki F6 wiring
Kawasaki F8 wiring
1971 Kawasaki F81M wiring diagram
70-73 Kawasaki standard spark plugs, G series, B1L, F series (rotary valve models)
KE175 Wiring diagram
Kawasaki G5 wiring
KE100 B models wiring diagram
Minor cable differences between F5/F8/F81M and F9 throttle control (oil pump) cables.