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Repair, Service manuals, wiring diagrams, caruburetor specifications
and other helpful documents
This page will be dedicated to any service or repair info I have in my library. This page will always be changing as I add or update more information to it. Most information will be images or scans of documents, service manuals and other repair literature that I find helpful. I have gotten a lot of requests for certain things like wiring diagrams, tuning procedures, carburetor specifications that can only be reliably found in printed documents. The service specifications listed here covers many popular and obscure Honda, Yamaha, Suzuki, and Kawasaki motorcycles. Also some information can apply to Chinese "clone" engines from ATVs, pit bikes and scooters that use the popular Honda horizontal and vertical engines. As I come across common questions or requests I may posts visual documents here. Use this information as you wish and I accept no liability for it's use. Captions below describe the information or models it covers. The information posted here is at random and with no cataloging. Click to view a larger image. Scroll down for some downloadable files. If you have a request please leave a comment at the bottom of the page and I will do my best to find and post it, but no guarantees ;) Use the search bar to aid in finding information.
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Motorcycle, ATV, Tractor manuals written especially for the DIY enthusiast
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Check out the tools you should have for working on your machine
Downloadable service manual filesEver wonder what those numbers mean on an NGK brand spark plug?
Carburetor rebuild explained help file
Honda C72 C77 CA72 CA77 owners manual
Kawasaki KZ400 carburetor specifications (carb specs)
Bridgestone 175 dual twin
Honda XR50 CRF50 owners manual
Honda CB750 wiring diagram
HONDA / CHINESE CLONE ENGINES
Typical Chinese Pit bike, ATV, Scooter 5 pin CDI box wiring
Click the picture for in depth ignition (spark) problems and diagnosis
Typical points type ignition
Another typical points type ignition system #8 is the contact breaker (points) #9 is the condenser #4 source or primary coil (for generating the spark) #5 lighting/charging coli
Typical layout of a dirt bike wiring system (CDI) this relates more specifically to Honda CRF50/XR50 pit bike clone engines (sometimes found in ATV's as well. This also simply displays the layout of most motorcycle ignition systems (ignore colors)
Typical Chinese pit bike, ATV, Scooter ignition system wiring (represents most models)
Honda CMX 450 Rebel wiring
Honda TRX70 ATV wiring diagram (similar to Chinese ATV)
Typical centrifugal clutch parts breakdown, found on most Honda and Chinese Honda clone engines with semi-auto clutches
Honda XL185S wiring diagram
Honda XL250 wiring diagram
1985-1997 Honda xr80 xr100 carburetor and valve clearance specs
Honda TRX125 ATV wiring diagram (similar to Chinese ATV)
KAWASAKIKawasaki F5, F9, F8, F81M cylinder head torque specs:
8mm (small bolts) 18 ft-lbs 10mm (large bolts) 25 ft-lbs 
Kawasaki KX80 wiring
Kawasaki KX80 KX60 KDX80 CDI testing
Kawasaki KX80 KX60 KDX80 Stator coil testing
Kawasaki KX80 KX60 KDX80 Ignition coil test
Carburetor specs for various Rotary Valve Kawasaki models.
Kawasaki F11 and F12MX carburetor specs
Kawasaki F11 ignition tests
Kawasaki G3, G4, F6, F8 ignition timing adjustment proceedure
Kawasaki KMX 125 wiring diagram (Euro model not imported to the US)
Kawasaki GA1 and GA2 wiring
Kawasaki G4TR 100 wiring
Kawasaki B1L-A (125) wiring
71-73 Kawasaki F7 wiring
70-71 Kawasaki F5 wiring diagram
73-75 Kawasaki F11 wiring diagram
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
Kawasaki GA1 GA2 G3 G4 F6 F8 lighting and charging coil test values
Kawasaki GA1 GA2 G3TR G3SS F6 F7 F8 F81M F5 carburetor settings
Kawasaki KZ400 B1 wiring
KZ440 carburetor specifications
KZ440 float height measurement
Kawasaki KZ400 C1 wiring
Kawasaki rotary valve singles standard chain and sprocket specifications
Kawasaki F5 F9 F7 signal exciter coil testing values
Ke125 Carburetor
Kawasaki G series F series carburetor float level settings
Kawasaki G series, F6, F8 magneto coil test procedure
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VARIOUS MAKES AND PARTS
Click the pic for the magazine test, specifications and performance modifications
Kawasaki F11 Performance pages
Boge Mulholland shock information (click the image)
Vintage Bassani exhaust information (click the image)
Vintage Hooker 2 stroke exhaust information (click image)
Typical motorcycle clutch assembly/layout found on most manual clutch motorcycles, Kawasaki F7 unit shown
SUZUKI
Suzuki TS185 wiring diagram
Suzuki 120, B100P wiring dagram
YAMAHA
1974-1975 Yamaha DT125 wiring diagram
Yamaha DT125 R 1988 pickup and source coil testing specs (for a no spark condition, may apply to other years)
Yamaha DT175 D 1992 pickup and source coil specs (for a no spark condition, may apply to other years)
Yamaha MX360 MX250 (M100-08) and SC500 (F145-01) Magneto Coil resistance testing specifications. Readings should be within 5% +/- outside of this range could result in a "no spark" situation coils must be replaced.
Yamaha SC500 MX360 MX250 wiring diagram
78-79 Yamaha XS1100 Special, Midnight Special carburetor specifications XS Eleven
80-81 Yamaha XS1100 carburetor specifications XS Eleven Special
KAWASAKIMotorcycle, ATV, Tractor manuals written especially for the DIY enthusiast
Minor cable differences between F5/F8/F81M and F9 throttle control (oil pump) cables.
1973 Kawasaki KX 125 wiring diagram
The Kawasaki "drain pump" F5/F9
It is good practice to remove and block off this device, it creates a vacuum leak when it fails
Kawasaki F5/F9/F7 drain pump explanation
Kawasaki F5/F9/F7 drain pump explanation
Kawasaki KE100 carburetor specs
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 KH100 wiring diagram
Kawasaki CDI unit testing procedure for KE models (may apply to other models)
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
Kawasaki KE100 (KM100) wiring diagram
Kawasaki KE100 (KM100) ignition switch wiring detail
Kawasaki KE100 (KM100) ignition circuit
Kawasaki KE100 (KM100) headlight/battery circuit
Kawasaki KE175 wiring diagram
Kawasaki G3TR and G3SS wiring
Kawasaki G5 100 wiring
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
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