2003-2006 Kawasaki KFX 50 Service & Repair Manual

KFX50 All Terrain Vehicle Service Manual

Kawwasaki KFX50 All Terrain Vehicle Service Manual Supplement

Foreword This Kawasaki Service manual supplement information provides unique to the Kawasaki KSFSO-A1, which is based on the Suzuki LT-A50K3. It must be used in conjunction with the other chapters of this manual. Read both this supplement and the base manual for complete information on proper service procedures for the model covered by this manual. This manual is designed primarify for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text. thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used. For the duration of the warranty period, we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty. To get the longest life out of your vehicle: • Follow the Periodic Maintenance Chart in the Service Manual. • Be alert for problems and non-scheduled maintenance. • Use proper tools and genuine Kawasaki Vehicle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki vehicle listed in this manual. Genuine parts provided as spare parts are listed in the Parts Catalog. • Follow the procedures in this manual carefully. Don't lake shortcuts. • Remember to keep complete records of maintenance and repair with dates and any new parts installed. How to Use This Manual In preparing this manual, the product was divided into its major systems. and these systems became the manual 'S chapters. All information for a particular system from adjustment through disassembly and inspection is located in a single chapter. The Group Index shows you all of the product's systems and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents . For example, if you want crankshaft information, use the Group Index to locate the Engine chapter. Then, use the Table of Contents on the first page of the chapter to find the Crankshaft section. Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices. A WARNING This warning symbol identified special instructions or procedures which, if not correctly followed, could result in ersonal in 'u ,or loss of life. CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of eauioment. This manual contains the other symbols (in addition to WARNING and CAUTION) which wilt help you distinguish different types of information. NOTE o This note symbol indicates points of particular interest for more efficient and convenient operation. • Indicates a procedural step or work to be done.

Symbol Throughout this manual are symbols indicating instructions and other information necessary for servicing . The meaning of each symbol is included in the table below. Where applicable, comparable Kawasaki products and their part numbers have been included . SYMBOL SUZUKI DEFINITION KAWASAKI DEFINITION ~ Torque control required . Data beside it indicates specified torque . <- - I ndicates service data. <- ~ Apply oil. Use engine oil unless otherwise specified . <- Apply molybdenum oil solution . Apply molybdenum disulfide oil . 1rr (mixture of engine oil and SUZUKI MOLY PASTE (a mixture of engine oil and in a ratio of 1 : 1) molybdenum disulfide grease with a weioht ratio of 1:1) ~ Apply SUZUKI SUPER GREASE "A". Apply grease . 99000-25030 (For USA) 99000-25010 (For the other countries) ~ Apply SUZUKI MOLY PASTE. Apply molybdenum disulfide 99000-25140 grease. - Apply SUZUKI BOND "1207B". Apply THREE BOND "TB1207B". 99104-31140 (For USA) 99000-31140 (For the other countries) I(lffiJ Apply SUZUKI BOND "1215". Apply THREE BOND "TB1215 ". 99000-31110 .. Apply THREAD LOCK SUPER "1303". Apply a non-permanent locking 99000-32030 agent. .. Apply THREAD LOCK "1342". Apply a non-permanent locking 99000-32050 agent. • Apply THREAD LOCK SUPER "1360". Apply a non-permanent locking 99000-32130 agent. ~ Measure in voltage range . <-

SYMBOL SUZUKI DEFINITION KAWASAKI DEFINITION ~ Measure in resistance range . <- ~ Mea su re in current range. <- Measure in diode test range. Use a suitable commercially ~ available digital multi meter for a diode tester and measure in diode test ranQe . ~ Measure in continuity test range . <- .fool. Use special tool. Refer to the special tools in Servicing Information chapter.

GENERAL INFORMATION 1-1 General Information Contents WARNING/CAUTION/NOTE ..................................... .................................................. Base Manual GENERAL PRECAUTIONS ........................................................................................ 1-2 KAWASAKI KSF50- Al ..................................................... ........................................... 1-3 SERIAL NUMBER LOCATION .................................................................................... Base Manual FUEL AND OIL RECOMMENDATIONS ...................................................................... Base Manual FUEL ....................................................................................................................... Base Manual ENGINE OIL ................................................................. .. ......................................... Base Manual TRANSMISSION OIL ........................................................ ....................................... Base Manual BREAK-IN PROCEDURES ......................................................................................... Base Manual INFORMATION LABELS ....................................................................... ...................... Base Manual SPECiFiCATiONS ................................................................ ....................................... 1-4 COUNTRY OR AREA CODES .................................................................................... 1-6 I

GENERAL INFORMATION 1-2 GENERAL PRECAUTIONS CAUTION • If parts replacement is necessary, replace the parts with KAWASAKI Genuine Parts or their equivalent. • When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order. • Be sure to use special tools when instructed. • Make sure that all parts used in reassembly are clean. Lubricate them when specified. • Use the specified lubricants, bands, or sealant. * When tightening the cylinder head nuts and crankcase screws, tighten the larger sizes first. Always tighten the bolts and nuts from the inside working out, in a crisscross pattern and to the specified tightening torque. • Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, self-locking nuts, cotter pins, ci rdips , and certain other parts as specified, be sure to replace them with new ones . Also, before installing these new parts, be sure to remove any teft over material from the mating surfaces. * Never reuse a cirdip . When installing a new circJip, take care not to expand the end gap larger than required to slip the circlip over the shaft. After installing a ciraip , always ensure that it is completely seated in its groove and securely fitted. * Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a thread is smeared with them. • After reassembling, check parts for tightness and proper operation. • To protect the environment, do not unlawfully dispose of used motor oil and tires. • To protect the Earth's natural resources, properly dispose of used vehide and parts.

2003-2006 Kawasaki KFX 50 Service & Repair Manual

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