1997-2007 Kawasaki KLX300R, KLX300 motorcycle service manual

Table of Contents

General Information

• Model Identification
• Specifications
• Torque Specifications
• Tools and Instruments

Periodic Maintenance

• Maintenance Schedule
• Periodic Maintenance Chart
• Engine Oil and Filter Replacement
• Air Cleaner Servicing
• Spark Plug Inspection

Fuel System

• Carburetor Adjustment
• Fuel Tank and Valve Operation
• Air Suction System Check

Cooling System

• Coolant Replacement/Inspection
• Radiator Cleaning
• Water Pump Inspection

Engine Top End

• Valve Clearance Check
• Cylinder Head Torque
• Piston and Piston Ring Installation

Engine Removal/Installation

• Engine Removal
• Engine Installation
• Engine Mount Inspection

Crankshaft/Transmission

• Crankshaft Inspection
• Transmission Gear Inspection
• Shift Mechanism Inspection

Wheels/Tires

• Wheel Alignment
• Tire Inspection
• Wheel Bearing Inspection

Brakes

• Brake Fluid Change
• Brake Pad Wear Inspection
• Brake Master Cylinder Overhaul

Suspension

• Fork Oil Change
• Fork Spring Inspection
• Rear Shock Absorber Adjustment

Steering

• Steering Adjustment
• Steering Stem Bearings

Frame

• Frame Points Inspection
• Swingarm Bearing Lubrication

Electrical System

• Battery Maintenance
• Ignition System Check
• Lighting System Inspection
• Electric Starter System Check

Appendix

• Troubleshooting
• Wiring Diagrams
• Sealant

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