The Junk Man's Adventures
  • Home
  • How To Videos
  • Barn Fresh restoration
  • Toy Restorations
  • About the Junkman
  • The Junk Man's Blog
  • Service manuals
    • Kawasaki Service manuals
    • Suzuki Service Manuals
    • Yamaha Service Manuals
    • Honda Service manuals
    • Chinese clone engines
    • Hodaka
    • Impac Industries
  • JMG Behind the scenes
  • Media apperances
  • Current Sponsors

KAWASAKI Service manual & wiring diagrams

Kawasaki Model Identification Guide
This page is a collection of hard to find information, procedures, tests, and specifications for vintage Kawasaki motorcycles.
Oil Pump Air bleeding & output test
for SuperLube & Injectolube systems.

1. Remove oil pump check valve outlet pipe (the banjo bolt, see Fig 1)

2. Use 20:1 premix in the tank before starting the engine.

3. Remove the cable for the oil pump so it can be opened fully for the test.

4. With some wire open the pump cam to full throttle position.

5. Start engine and run at aprox. 2,000 RPM.

6. With a stopwatch run the engine for 3 minutes while collecting the oil from the oil pipe.

​Specifications are listed for each model in the table.

*For models not listed, use the closest appropriate model displacement (F6 125cc, F7 175cc..) as Kawasaki only made minor revisions over the years but the oil pump output will be similar and should be within a similar output.

Example:  G-Series output specification would be similar for later 80-100cc models such as the KE/KV/KM100, MC1, KD80, ect.. as they share similarities.
Kawasaki oil injection pump test
Oil Pump priming & pump output test & table specifications
Kawasaki Oil pump pipe
Fig 1. Oil pump pipe banjo bolt removed
Kawasaki piston size bore and over size specification chart
Kawasaki Cylinder bore service limit
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.
kawasaki rotary engine piston size chart
Kawasaki cylinder bore size chart & mesurement
Kawasaki piston clearance chart
Kawasaki piston clearance chart
Kawasaki piston ring gap measurement
Kawasaki Piston ring gap measurement
Kawasaki F5 F9 F7 drain pump
Kawasaki F5/F9/F7 drain pump explanation
Kawasaki G2 G3 G4 G5 F6 F7 F8 charging coil table
Kawasaki GA1 GA2 G3 G4 F6 F8 lighting and charging coil test values
Kawasaki G2 G3 G4 G5 F6 F7 F8 F81M F5 carburetor settings
Kawasaki GA1 GA2 G3TR G3SS F6 F7 F8 F81M F5 carburetor settings
Kawasaki F5 F9 F7 drain pump
Kawasaki F5/F9/F7 drain pump explanation
Picture
Lighting & Charging diagnosis
73-75 Kawasaki F11 wiring
73-75 Kawasaki F11 wiring diagram
Kawasaki F5 wiring
70-71 Kawasaki F5 wiring diagram
Kawasaki f7 175 wiring
71-73 Kawasaki F7 wiring
Kawasaki F5 f9 crankcase drain pump
It is good practice to remove and block off this device, it creates a vacuum leak when it fails
Kawasaki B1L-A wiring
Kawasaki B1L-A (125) wiring
Kawasaki G4TR 100 wiring
Kawasaki G4TR 100 wiring
Kawasaki GA1 GA2 wiring
Kawasaki GA1 and GA2 wiring

The Kawasaki "drain pump" F7/F5/F9

Kawasaki KMX 125 wiring diagram
Kawasaki KMX 125 wiring diagram (Euro model not imported to the US)
breaker point timing
Kawasaki G3, G4, F6, F8 ignition timing adjustment proceedure
F11 F11M F12MX carburetor specs
Kawasaki F11 and F12MX carburetor specs
Kawasaki F4, f7, f5, f9, f81m, ke175,ke100,ke125
Carburetor specs for various Rotary Valve Kawasaki models.
Kawasaki Fork oil quantity for the following models.  B1L-A,G-series, G4TR, G31M, F6, F7, F8, F81M, F5 (F9)
Kawasaki fork oil chart G3 G4 G5 F7 F6 F8 F81M F5 F9
Fork oil quantity chart
​Kawasaki F5, F9, F8, F81M cylinder head torque specs:

8mm (small bolts) 18 ft-lbs
10mm (large bolts) 25 ft-lbs
Picture
Kawasaki KE100 carburetor specs
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
Kawasaki KX80 KX60 KDX80 CDI testing
Kawasaki KX80 KX60 KDX80 CDI testing
Kawasaki KX80 wiring diagram
Kawasaki KX80 wiring
Kawasaki KX80 KX60 KDX80 stator coil test
Kawasaki KX80 KX60 KDX80 Stator coil testing
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
KX80 KX60 KDX80 ignition coil
Kawasaki KX80 KX60 KDX80 Ignition coil test
Lighting & charging coil test values for Kawasaki models GA1A, GA2A, G3SSA, G3TR, G4TR, F6, F8
Kawasaki F11 magneto coil test
Kawasaki F11 ignition tests
kawasaki f21m wiring
Kawasaki F21M wiring (other models noted)
Key for Fig K2-5 Diagram of ignition, generator, and starter systems typical of Kawasaki F1, F1TR, F2, F2TR and F3 models. Including F21M
  1. Wire to lights
  2. Wire to brake light
  3. Wire to horn
  4. Wire to tail light
  5. Starter switch
  6. Ignition coil
  7. Spark Plug
  8. Breaker point and condenser
  9. Generator-starter
  10. Regulator and starter relay
  11. Charge regulator light
  12. Main key switch
  13. Fuse
  14. Battery
Kawasaki F1, F2, F3, F4 and F21M wiring diagram (see key)
Kawasaki KH100 wiring
Kawasaki KH100 wiring diagram
1973 Kawasaki KX 125 wiring diagram
1973 Kawasaki KX 125 wiring diagram
Kawasaki F11 250 wiring diagram
Kawasaki CDI unit box testing
Kawasaki CDI unit testing procedure for KE models (may apply to other models)
ke100 magneto coil test
Kawasaki KE100 (KM100) points style magneto coil testing procedure
ke100 ignition test
Kawasaki KE100 (KM100) Ignition coil testing
Picture
KE100 (KM100) charging coil test procedure
Picture
KE100 (KM100) Charging tests
Picture
KZ440 carburetor specifications
Kawasaki KZ400 wiring
Kawasaki KZ400 B1 wiring
Picture
KZ440 float height measurement
ke100 wiring
Kawasaki KE100 (KM100) wiring diagram
KE100 wiring detail
Kawasaki KE100 (KM100) ignition switch wiring detail
Kawasaki KZ400 C1 wiring
Kawasaki KZ400 C1 wiring
ke100 ignition circut
Kawasaki KE100 (KM100) ignition circuit
kawasaki rotary valve singles chain and sprocket specification
Kawasaki rotary valve singles standard chain and sprocket specifications
KE100 KM100 HEADLIGHT WIRING
Kawasaki KE100 (KM100) headlight/battery circuit
Kawasaki big horn ignition test
Kawasaki F5 F9 F7 signal exciter coil testing values
ke175 wiring diagram
Kawasaki KE175 wiring diagram
Kawasaki G3TR G3SS wiring
Kawasaki G3TR and G3SS wiring
Kawasaki G5 wiring
Kawasaki G5 100 wiring
Kawasaki G3 G4 G5 F6 F7 F8 F81M F5 F9 carburetor specifications
Kawasaki G series F series carburetor float level settings
kawasaki G series F6 F8
Kawasaki G series, F6, F8 magneto coil test procedure
Picture
Ke125 Carburetor
Kawasaki F6 125 wiring
71-73 Kawasaki F6 wiring
Kawasaki f8 wiring
Kawasaki F8 wiring
1971 Kawasaki F81M wiring
1971 Kawasaki F81M wiring diagram
Kawasaki spark plug G3 G4 G5 F6 F7 F8 F81M F5 F9
70-73 Kawasaki standard spark plugs, G series, B1L, F series (rotary valve models)
KE175 D Wiring diagram
KE175 Wiring diagram
Kawasaki G5 wiring diagram
Kawasaki G5 wiring
Kawasaki KE100 B models wiring diagram
KE100 B models wiring diagram
F5 F9 control cables
Minor cable differences between F5/F8/F81M and F9 throttle control (oil pump) cables.
Proudly powered by Weebly
  • Home
  • How To Videos
  • Barn Fresh restoration
  • Toy Restorations
  • About the Junkman
  • The Junk Man's Blog
  • Service manuals
    • Kawasaki Service manuals
    • Suzuki Service Manuals
    • Yamaha Service Manuals
    • Honda Service manuals
    • Chinese clone engines
    • Hodaka
    • Impac Industries
  • JMG Behind the scenes
  • Media apperances
  • Current Sponsors