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Kawasaki KFX90 - User Manual

Kawasaki KFX90
241 pages
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KFX90
All Terrain Vehicle
Service Manual

Table of Contents

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Summary

General Information

Specifications

Detailed technical specifications for the vehicle, including dimensions, engine, and electrical systems.

Service Precautions

Essential safety guidelines and procedural recommendations for servicing the vehicle.

Torque Values

Specified torque values for critical engine and frame fasteners during assembly and maintenance.

Troubleshooting

Diagnostic procedures for common engine starting and running problems.

Frame Covers;Exhaust Muffler;Bulb

Frame Covers

Procedures for the removal and installation of the vehicle's frame covers.

Exhaust Muffler

Instructions for the removal, inspection, and installation of the exhaust muffler.

Inspection;Adjustment

Maintenance Schedule

Overview of recommended periodic inspections and adjustments for the vehicle.

Fuel System

Procedures for inspecting and adjusting fuel lines, throttle, and air cleaner.

Engine Oil

Guidelines for checking and replacing engine oil and filter.

Brakes

Inspection and adjustment procedures for brake shoes, pads, and fluid.

Wheels;Tires

Inspection and maintenance procedures for wheels, tires, and tire pressure.

Lubrication System

Service Information

General instructions and specifications for the vehicle's lubrication system.

Oil Pump

Procedures for the removal, disassembly, inspection, and assembly of the oil pump.

Fuel System

Service Information

General instructions and specifications for the fuel system components.

Carburetor

Detailed procedures for carburetor removal, disassembly, inspection, and assembly.

Engine Removal

Engine Removal

Step-by-step instructions for safely removing the engine assembly from the frame.

Engine Installation

Procedures and torque values for reinstalling the engine assembly.

Cylinder Head;Valves

Service Information

General instructions and specifications for servicing the cylinder head and valves.

Cylinder Head

Procedures for removing and inspecting the cylinder head assembly.

Cylinder;Piston

Service Information

General instructions and specifications for cylinder and piston service.

Piston Inspection

Detailed inspection procedures for piston, rings, and pin.

Drive and Driven Pulleys

Service Information

General instructions and specifications for the drive and driven pulley systems.

Drive Pulley

Procedures for the removal, disassembly, and inspection of the drive pulley.

Clutch;Driven Pulley

Service procedures for the clutch and driven pulley assembly.

Transmission System

Service Information

General instructions and specifications for the transmission system.

Transmission Removal

Step-by-step guide for removing the transmission components.

Crankcase;Crankshaft

Service Information

General instructions and specifications for servicing the crankcase and crankshaft.

Crankshaft Inspection

Procedures for inspecting crankshaft runout, clearances, and bearing play.

Front Wheel;Front Brake;Front Suspension;Steering System

Service Information

General instructions and specifications for front end components.

Front Wheel

Procedures for front wheel removal, inspection, and installation.

Front Brake

Service procedures for the front brake pads, disk, and caliper.

Front Suspension

Procedures for removing and inspecting front suspension components.

Steering System

Maintenance and inspection of the handlebar and steering column.

Tie-Rod

Procedures for tie-rod removal, inspection, adjustment, and installation.

Rear Wheel;Swing Arm;Hydraulic Brake

Service Information

General instructions and specifications for rear wheel, swing arm, and brake systems.

Troubleshooting

Diagnostic guide for common problems related to the rear wheel and brake system.

Rear Wheel

Procedures for rear wheel and hub removal, inspection, and installation.

Swing Arm

Procedures for removing, inspecting, and installing the swing arm and shock absorber.

Hydraulic Brake

Service procedures for the hydraulic brake fluid, pads, disk, master cylinder, and caliper.

Battery;Charging System;A.C. Generator

Service Information

General instructions and specifications for the battery and charging systems.

Battery

Procedures for battery removal, installation, and voltage inspection.

Charging System

Testing procedures for the charging system's short circuit and voltage.

Regulator;Rectifier

Inspection and testing of the regulator/rectifier for proper operation.

Ignition System

Service Information

General instructions and specifications for the ignition system.

Troubleshooting

Diagnostic guide for common ignition system problems like no spark or low voltage.

CDI Unit Inspection

Procedures for testing the resistance of the CDI unit.

Ignition Coil

Removal and resistance testing procedures for the ignition coil.

Starting System

Service Information

General instructions for servicing the vehicle's starting system.

Troubleshooting

Diagnostic guide for common starting system issues like motor not turning.

Starter Motor

Procedures for starter motor removal, disassembly, and inspection.

Starter Relay

Inspection and voltage testing procedures for the starter relay.

Starter One-way Clutch;Starter Pinion

Procedures for removing and inspecting the starter one-way clutch and pinion.

Summary

General Information

Specifications

Detailed technical specifications for the vehicle, including dimensions, engine, and electrical systems.

Service Precautions

Essential safety guidelines and procedural recommendations for servicing the vehicle.

Torque Values

Specified torque values for critical engine and frame fasteners during assembly and maintenance.

Troubleshooting

Diagnostic procedures for common engine starting and running problems.

Frame Covers;Exhaust Muffler;Bulb

Frame Covers

Procedures for the removal and installation of the vehicle's frame covers.

Exhaust Muffler

Instructions for the removal, inspection, and installation of the exhaust muffler.

Inspection;Adjustment

Maintenance Schedule

Overview of recommended periodic inspections and adjustments for the vehicle.

Fuel System

Procedures for inspecting and adjusting fuel lines, throttle, and air cleaner.

Engine Oil

Guidelines for checking and replacing engine oil and filter.

Brakes

Inspection and adjustment procedures for brake shoes, pads, and fluid.

Wheels;Tires

Inspection and maintenance procedures for wheels, tires, and tire pressure.

Lubrication System

Service Information

General instructions and specifications for the vehicle's lubrication system.

Oil Pump

Procedures for the removal, disassembly, inspection, and assembly of the oil pump.

Fuel System

Service Information

General instructions and specifications for the fuel system components.

Carburetor

Detailed procedures for carburetor removal, disassembly, inspection, and assembly.

Engine Removal

Engine Removal

Step-by-step instructions for safely removing the engine assembly from the frame.

Engine Installation

Procedures and torque values for reinstalling the engine assembly.

Cylinder Head;Valves

Service Information

General instructions and specifications for servicing the cylinder head and valves.

Cylinder Head

Procedures for removing and inspecting the cylinder head assembly.

Cylinder;Piston

Service Information

General instructions and specifications for cylinder and piston service.

Piston Inspection

Detailed inspection procedures for piston, rings, and pin.

Drive and Driven Pulleys

Service Information

General instructions and specifications for the drive and driven pulley systems.

Drive Pulley

Procedures for the removal, disassembly, and inspection of the drive pulley.

Clutch;Driven Pulley

Service procedures for the clutch and driven pulley assembly.

Transmission System

Service Information

General instructions and specifications for the transmission system.

Transmission Removal

Step-by-step guide for removing the transmission components.

Crankcase;Crankshaft

Service Information

General instructions and specifications for servicing the crankcase and crankshaft.

Crankshaft Inspection

Procedures for inspecting crankshaft runout, clearances, and bearing play.

Front Wheel;Front Brake;Front Suspension;Steering System

Service Information

General instructions and specifications for front end components.

Front Wheel

Procedures for front wheel removal, inspection, and installation.

Front Brake

Service procedures for the front brake pads, disk, and caliper.

Front Suspension

Procedures for removing and inspecting front suspension components.

Steering System

Maintenance and inspection of the handlebar and steering column.

Tie-Rod

Procedures for tie-rod removal, inspection, adjustment, and installation.

Rear Wheel;Swing Arm;Hydraulic Brake

Service Information

General instructions and specifications for rear wheel, swing arm, and brake systems.

Troubleshooting

Diagnostic guide for common problems related to the rear wheel and brake system.

Rear Wheel

Procedures for rear wheel and hub removal, inspection, and installation.

Swing Arm

Procedures for removing, inspecting, and installing the swing arm and shock absorber.

Hydraulic Brake

Service procedures for the hydraulic brake fluid, pads, disk, master cylinder, and caliper.

Battery;Charging System;A.C. Generator

Service Information

General instructions and specifications for the battery and charging systems.

Battery

Procedures for battery removal, installation, and voltage inspection.

Charging System

Testing procedures for the charging system's short circuit and voltage.

Regulator;Rectifier

Inspection and testing of the regulator/rectifier for proper operation.

Ignition System

Service Information

General instructions and specifications for the ignition system.

Troubleshooting

Diagnostic guide for common ignition system problems like no spark or low voltage.

CDI Unit Inspection

Procedures for testing the resistance of the CDI unit.

Ignition Coil

Removal and resistance testing procedures for the ignition coil.

Starting System

Service Information

General instructions for servicing the vehicle's starting system.

Troubleshooting

Diagnostic guide for common starting system issues like motor not turning.

Starter Motor

Procedures for starter motor removal, disassembly, and inspection.

Starter Relay

Inspection and voltage testing procedures for the starter relay.

Starter One-way Clutch;Starter Pinion

Procedures for removing and inspecting the starter one-way clutch and pinion.

Kawasaki KFX90 Specifications

General IconGeneral
BrandKawasaki
ModelKFX90
CategoryOffroad Vehicle
LanguageEnglish

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