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How To Videos
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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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motorcycle tools
Check out the tools you should have for working on your machine

Downloadable service manual files

Ever wonder what those numbers mean on an NGK brand spark plug?
ngk_spark_plug_number_explanation.pdf
File Size: 210 kb
File Type: pdf
Download File

Carburetor rebuild explained help file
Carb Rebuild Help.pdf
File Size: 49 kb
File Type: pdf
Download File

Honda C72 C77 CA72 CA77 owners manual
honda_c72_c77_ca72_ca77_owners_handbook.pdf
File Size: 7233 kb
File Type: pdf
Download File

Kawasaki KZ400 carburetor specifications (carb specs)
1978-1981 KZ400 carburetor specifications pdf
File Size: 1404 kb
File Type: pdf
Download File

Bridgestone 175 dual twin
Bridgestone 175 dual twin service manual pdf
File Size: 5967 kb
File Type: pdf
Download File

Honda XR50 CRF50 owners manual
xr_50_crf_50_owners_manual.pdf
File Size: 2517 kb
File Type: pdf
Download File

Honda CB750 wiring diagram
honda_cb750_wiring_diagram.pdf
File Size: 1965 kb
File Type: pdf
Download File

HONDA / CHINESE CLONE ENGINES

Honda GY6 (Chinese GY6 clone) top end repair manual, engine used in numerous Chinese scooters and some ATV's
repair_manual_gy6_engine.pdf
File Size: 4398 kb
File Type: pdf
Download File

Chinese 4 pin CDI box pit bike atv scooter
Typical Chinese Pit bike, Atv, Scooter 4 pin CDI box wiring
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GY6 engine
Chinese pit bike atv scooter 6 pin cdi box
Typical Chinese pit bike, ATV, Scooter 6 pin CDI box wiring
Chinese pit bike, atv, scooter 5 pin CDI box wiring
Typical Chinese Pit bike, ATV, Scooter 5 pin CDI box wiring

Click the picture for in depth ignition (spark) problems and diagnosis

timing points type ignition
Typical points type ignition
Hodaka ignition diagram wiring road toad combat wombat
Hodaka Wombat 94 & 94A ignition diagram (may work for other models)
Hodaka ignition stator
Hodaka ignition stator plate (flywheel removed)
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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
dirt bike wiring diagram
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)
chinese pit bike wiring
Typical Chinese pit bike, ATV, Scooter ignition system wiring (represents most models)
Honda CMX 450 Rebel wiring diagram
Honda CMX 450 Rebel wiring
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Honda TRX70 ATV wiring diagram (similar to Chinese ATV)
semi auto clutch
Typical centrifugal clutch parts breakdown, found on most Honda and Chinese Honda clone engines with semi-auto clutches
Honda XL185 wiring diagram
Honda XL185S wiring diagram
honda xl250 wiring
Honda XL250 wiring diagram
Honda XL100 XR100 XR80 XL80 carburetor jets
1981-1984 Honda XL100S 1978-1997 Honda XR100 Carburetor settings
honda xr crf 100 80 carburetor specifications
1985-1997 Honda xr80 xr100 carburetor and valve clearance specs
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Honda TRX125 ATV wiring diagram (similar to Chinese ATV)

KAWASAKI

​Kawasaki F5, F9, F8, F81M cylinder head torque specs:

8mm (small bolts) 18 ft-lbs
10mm (large bolts) 25 ft-lbs
Kawasaki KX80 wiring diagram
Kawasaki KX80 wiring
Kawasaki KX80 KX60 KDX80 CDI testing
Kawasaki KX80 KX60 KDX80 CDI testing
Kawasaki KX80 KX60 KDX80 stator coil test
Kawasaki KX80 KX60 KDX80 Stator coil testing
KX80 KX60 KDX80 ignition coil
Kawasaki KX80 KX60 KDX80 Ignition coil test
Kawasaki F4, f7, f5, f9, f81m, ke175,ke100,ke125
Carburetor specs for various Rotary Valve Kawasaki models.
F11 F11M F12MX carburetor specs
Kawasaki F11 and F12MX carburetor specs
Kawasaki F11 magneto coil test
Kawasaki F11 ignition tests
breaker point timing
Kawasaki G3, G4, F6, F8 ignition timing adjustment proceedure
Kawasaki KMX 125 wiring diagram
Kawasaki KMX 125 wiring diagram (Euro model not imported to the US)
Kawasaki GA1 GA2 wiring
Kawasaki GA1 and GA2 wiring
Kawasaki G4TR 100 wiring
Kawasaki G4TR 100 wiring
Kawasaki B1L-A wiring
Kawasaki B1L-A (125) wiring
Kawasaki f7 175 wiring
71-73 Kawasaki F7 wiring
Kawasaki F5 wiring
70-71 Kawasaki F5 wiring diagram
73-75 Kawasaki F11 wiring
73-75 Kawasaki F11 wiring diagram
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
  • Wire to lights
  • Wire to brake light
  • Wire to horn
  • Wire to tail light
  • Starter switch
  • Ignition coil
  • Spark Plug
  • Breaker point and condenser
  • Generator-starter
  • Regulator and starter relay
  • Charge regulator light
  • Main key switch
  • Fuse
  • Battery
  • Wire to lights
  • Wire to brake light
  • Wire to horn
  • Wire to tail light
  • Starter switch
  • Ignition coil
  • Spark Plug
  • Breaker point and condenser
  • Generator-starter
  • Regulator and starter relay
  • Charge regulator light
  • Main key switch
  • Fuse
  • Battery
  • 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 KZ400 wiring
    Kawasaki KZ400 B1 wiring
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    KZ440 carburetor specifications
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    KZ440 float height measurement
    Kawasaki KZ400 C1 wiring
    Kawasaki KZ400 C1 wiring
    kawasaki rotary valve singles chain and sprocket specification
    Kawasaki rotary valve singles standard chain and sprocket specifications
    Kawasaki big horn ignition test
    Kawasaki F5 F9 F7 signal exciter coil testing values
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    Ke125 Carburetor
    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

    VARIOUS MAKES AND PARTS

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    Click the pic for the magazine test, specifications and performance modifications

    Kawasaki F11 Performance pages

    2014 Yamaha WR450 Supermoto conversion
    1969 Kawasaki Green Streak 238 F21M magazine test
    Boge Mulholland shock rebuild and model specification information
    boge mulholland
    Boge Mulholland shock information (click the image)
    bassani logo
    Vintage Bassani exhaust information (click the image)
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    Vintage Hooker 2 stroke exhaust information (click image)
    motorcycle clutch assembly
    Typical motorcycle clutch assembly/layout found on most manual clutch motorcycles, Kawasaki F7 unit shown

    SUZUKI

    Suzuki TS185 wiring diagram
    Suzuki TS185 wiring diagram
    Suzuki 120 model B100 B100P wiring
    Suzuki 120 Suzuki B100P wiring diagram
    Suzuki 120, B100P wiring dagram

    YAMAHA

    1974 Yamaha DT125 wiring
    1974-1975 Yamaha DT125 wiring diagram
    Yamaha DT125 ignition coil test
    Yamaha DT125 R 1988 pickup and source coil testing specs (for a no spark condition, may apply to other years)
    Yamaha DT175 ignition coil specs
    Yamaha DT175 D 1992 pickup and source coil specs (for a no spark condition, may apply to other years)
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    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 Wiring
    Yamaha SC500 MX360 MX250 wiring diagram
    Yamaha xs11 XS1100 XS Eleven carb specs
    78-79 Yamaha XS1100 Special, Midnight Special carburetor specifications XS Eleven
    xs11 yamaha xs1100sg special carb specs
    80-81 Yamaha XS1100 carburetor specifications XS Eleven Special

    KAWASAKI

    Motorcycle, ATV, Tractor manuals written especially for the DIY enthusiast
    F5 F9 control cables
    Minor cable differences between F5/F8/F81M and F9 throttle control (oil pump) cables.
    1973 Kawasaki KX 125 wiring diagram
    1973 Kawasaki KX 125 wiring diagram

    The Kawasaki "drain pump" F5/F9

    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 F5 F9 F7 drain pump
    Kawasaki F5/F9/F7 drain pump explanation
    Kawasaki F5 F9 F7 drain pump
    Kawasaki F5/F9/F7 drain pump explanation
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    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
    Kawasaki KH100 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
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    KE100 (KM100) charging coil test procedure
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    KE100 (KM100) Charging tests
    ke100 wiring
    Kawasaki KE100 (KM100) wiring diagram
    KE100 wiring detail
    Kawasaki KE100 (KM100) ignition switch wiring detail
    ke100 ignition circut
    Kawasaki KE100 (KM100) ignition circuit
    KE100 KM100 HEADLIGHT WIRING
    Kawasaki KE100 (KM100) headlight/battery circuit
    ke175 wiring diagram
    Kawasaki KE175 wiring diagram
    Kawasaki G3TR G3SS wiring
    Kawasaki G3TR and G3SS wiring
    Kawasaki G5 wiring
    Kawasaki G5 100 wiring
    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
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    • Home
    • How To Videos
    • Barn Fresh restoration
    • Toy Restorations
    • About the Junkman
    • The Junk Man's Blog
    • Service manuals
      • Impac Industries
    • JMG Behind the scenes
    • Media apperances
    • Current Sponsors