Kawasaki 94 klx 650c service manual free download






















Pilot Screw 4. Pilot Jet 5. Needle Jet 6. Needle Jet Holder 7. Main Jet 8. Jet Needle 9. Canister Separator 1 1. Canister Guard Coasting Enricher The device prevents back firing during engine braking by supplying a rich fuel mixture to the engine.

T1: 0. Also, the throttle valve may not open fully at full throttle. On the other hand, if the throttle grip has no play, the throttle will be hard to control, and the idle speed will be erratic. Page Carburetor FUEL SYSTEM Carburetor Since the carburetor regulates and mixes the fuel and air going into the engine, there are two general types of carburetor trouble: too rich a mixture too much fuel , and too lean a mixture too little fuel. Such trouble can be caused by dirt, wear, maladjustment, or improper fuel level in the float chamber.

Turn the ignition switch OFF. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; O Increasing the float height lowers the fuel level and decreasing the float height raises the fuel level.

Float Height Standard: It comes out w i t h a spring seat [ C ]. OTurn in the pilot screw [A] and count the number of turns until it seats fully but not tightly, and then remove the screw. It will seat against the needle jet, pushing the end of the jet into the carburetor bore. The jets or the carburetor body could be damaged requiring replacement.

Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvents to clean the carburetor. It should be smooth, without any grooves, scratches, or tears.

OAfter riding through rain or on muddy roads, the element should be cleaned immediately. Usually water or oil does not collect at the bottom of the housing. In the event that rain water is drawn in through the air cleaner, or if engine oil is blown back, drain the housing.

Always stop the engine and do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Torque - 5. To reserve tank 1. Water Pump When the engine is very hot, the pressure valve in 2. Cylinder Jacket the radiator cap allows air and vapor to escape into 3. Cylinder Head Jacket the reserve tank.

When the engine cools d o w n , the 4. If the coolant is brown, iron or steel parts are rusting. First turn the cap counter- clockwise to the first stop. Then push and turn it further in the same direction and remove the cap. OStart the engine with the radiator cap removed and run it until no more air bubbles [A] can be seen in the coolant. OTap the radiator hoses to force any air bubbles caught inside. OStop the engine and add coolant up to the radiator filler neck.

Carefully follow the instructions supplied by the manufacturer of the cleaning product. Turn the impeller counterclockwise during removal, and clockwise during installation. Squeeze the hose. A hose should not be hard and brittle, nor should it be soft or swollen. Such a shock to the part can damage it. EO: Apply engine oil. Apply a non-permanent locking agent. M: Apply molybdenum disulfide grease.

Replacement Parts Follow the specific tightening sequence. Closed coil end faces d o w n. White paint faces up. This allows some of the compression pressure to escape, making it easy to turn over the engine during starting. Torque - Oil Separator Bolts: 59 N-m 0. OTurn the crankshaft counterclockwise with a wrench on the magneto flywheel bolt and watch the intake valve. Be careful not to mix up these shafts when installing.

The plastigauge indicates the clearance by the amount it is compressed and widened when the parts are assembled. Be sure to time the camshafts properly. Readjust if necessary. This may cause the shim to pop out at high rpm, causing extensive engine damage.

Do not grind the shim. Measure the clearance with engine cold. Check present shim size. O Mark and record the valve location so it can be installed in the original position. Page Valve-To-Guide Clearance Measurement Valve-to-Guide Clearance Measurement If a small bore gauge is not available, inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below.

Seat Cutter Operating Care: 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purpose than seat repair. Grind the seating surface only until it is smooth. OPut a little coarse grinding compound on the face of the valve in a number of places around the valve head.

They could all out and score the cylinder wall. O l f necessary, use the piston pin puller assembly [A] along with a 22 mm washer [ B ]. OWhen installing the piston pin snap ring, compress it only enough to install it and no more. If not, the piston must be replaced. Apply grease. Apply molybdenum disulfide grease.

Apply oil. Replacement Parts Stake the fasteners. Clutch release shaft removal damages the oil seal in the clutch cover, necessitating oil seal replacement. Either side of the bearing may face upward. Also, replace the steel plates if their teeth are damaged.

Torque - Primary Gear Nut: N-m Right Oil Screen 6. Crankshaft 1 1. Breather Hose 2. Crankcase Oil Pump 7. Crankshaft Oil Seal Drive Shaft 3. Relief Valve 8. Oil Pipe Banjo Bolts Output Shaft 4. Clutch Cover Oil Passage 9. Torque - Oil Passage Plug : 25 N-m 2. It could cause an accident and injury. OThe following parts may be removed with the engine in the frame if the crankcase is to be split. Torque - Swingarm Pivot Nut: 88 N-m 9. Page Specifications Shift fork guide pin diameter 5.

Removal may damage them. Crankshaft Installation See Crankcase Assembly. Crankshaft Disassembly CAUTION Since assembly of the crankshaft demands exacting tolerances, the disassembly and reassembly of the crankshaft should only be performed by experienced mechanics with the necessary tools and OThe standard shift pedal position [A] is about 40 mm below the footpeg top. O The output shaft forks [A] are identical.

QBe careful not to confuse the shift forks. OThe machined surfaces [B] of the output shaft forks face to the engine right side. A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear when under power. Follow the specific tightening sequence. Apply soap and water solution or rubber lubricant.

Torque - Axle : 88 N-m 9. Torque - Rear Axle Nut: 98 N-m An imbalance of less than 10 grams will not usually affect running stability. O Do not use four or more balance weight more than 90 gram. O Apply high temperature grease to the grease seal lips. Replacement Part 98 N-m Apply heavy oil. Shake the chain while it is in the oil so that oil will penetrate to the inside of each roller. Torque - Rear Sprocket Nuts : 32 N-m 3.

Replacement Parts Apply silicone grease. Never reuse old brake fluid. Do not use fluid from a container that has been left unsealed or that has been open for a long time. Changing the rear brake fluid is the same as for the front brake. Bleeding the rear brake line is the same as for the front brake. Torque - Caliper Bolts : 25 N-m 2. If you apply compressed air into the caliper, the piston may crush your hand or fingers.

If the seals are not satisfactory, pad wear will increase, and constant pad drag on the disc will raise brake and brake fluid temper- ature. Torque - Banjo Bolt: 25 N-m 2. Blow the ports clean with compressed air. Torque - Front Disc Bolts A 9. The air pressure in the fork legs increases as the fork heats up, so the fork action will get stiffer as the vehicle operation progresses. Special Tool - Fork Spring Holder: O A person should push d o w n the fork spring and another person should insert the fork spring holder.

O Remove the dust seal [D] from the outer tube. O Do not remove the dust seal from the inner tube unless it is absolutely necessary. Excessive bending, followed by subsequent straightening, can weaken the inner tube.

OThe standard adjuster setting for an average-build rider 68 kg 1 50 lb is the 9th click back from the 1st click of the fully clockwise position. Spring Preload Setting Standard adjusting nut position [B] : Slowly release the nitrogen gas pressure from the gas reservoir [A] by pushing d o w n the valve core [ B ] with a screwdriver. OThe bladder [B] comes out with the gas reservoir cap. The end [B] of the gas reservoir cap must be 0. If it is deformed or damaged, replace it with a new one.

O Both damping adjusters must be on the same side. If not, the steering stem bearings may be damaged. O Again back out the stem nut a fraction of a turn until it turns lightly. OTurn the stem nut lightly clockwise until it just becomes hard to turn. Radiator Fan Starter Circuit Relay Fan Relay Neutral Switch TV. Headlight Unit 2. License Light Ignition Coil 4. We presented the full edition of this book in djvu, doc, txt, epub, pdf formats. Stocks clymer kawasaki atv and motorcycle repair manuals, haynes kawasaki atv and motorcycle workshop manuals and a massive selection of both new and used oem kawasaki atv and motorcycle service manuals.

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To protect the future of your sport, make sure you use your vehicle legally, show concern for the environment, and respect the rights of other people. Please provide the username or email address that you used when you signed up for your my kawasaki account.

Disclaimer, this product is intended for closed-course racing only and the parts contained in this kit are not for aircraft er acknowledges that they have the expertise as to the intended use of this product, and therefore assumes all risk and liability resulting from use of the product, whether used singly or in combination with other products.

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