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- Apr 29, 2012 HOW TO GET ((FREE)) TECHNICAL CAR REPAIR DATA TO FIX YOUR CAR LIKE THE PROS (MITCHELL PRO DEMAND) - Duration: 25:07. Oldskool funk Recommended for you.
- I get emails from readers quite regularly looking for service manuals for their bike. I always try and help as best as I can. Over the years I’ve amassed quite a large collection of motorcycle service manuals for all sorts of bikes. I have factory repair manuals, part microfiche manuals, setup and tuning documentation, owners manuals, etc, etc.
Before working on your machine, check out the TOOL Basics page (click here)
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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.
Motorcycle, ATV, Tractor manuals written especially for the DIY enthusiast Buy your service manuals here and support the site! 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?
Kawasaki KZ400 carburetor specifications (carb specs)
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 diagnosisHodaka Wombat 94 & 94A ignition diagram (may work for other models) 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 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 1981-1984 Honda XL100S 1978-1997 Honda XR100 Carburetor settings 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 Carburetor specs for various Rotary Valve Kawasaki models. Kawasaki G3, G4, F6, F8 ignition timing adjustment proceedure Kawasaki KMX 125 wiring diagram (Euro model not imported to the US) 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 rotary valve singles standard chain and sprocket specifications Kawasaki F5 F9 F7 signal exciter coil testing values Kawasaki G series F series carburetor float level settings Kawasaki G series, F6, F8 magneto coil test procedure | VARIOUS MAKES AND PARTSClick the pic for the magazine test, specifications and performance modifications Kawasaki F11 Performance pagesBoge 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 SUZUKIYAMAHAYamaha 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. 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. The Kawasaki 'drain pump' F5/F9It is good practice to remove and block off this device, it creates a vacuum leak when it fails 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 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 switch wiring detail 70-73 Kawasaki standard spark plugs, G series, B1L, F series (rotary valve models) | ||||||||||||||||||||||||||||||||||||||||||||||||||
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