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Before Servicing - Kawasaki KDX200 Service Manual

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1-2 GENERAL INFORMATION
Before Servicing
Before
starting to service a motorcycle, careful reading of the applicable section is recommended to eliminate
unnecessary work.
Photographs. diagrams, notes, cautions, warnings,
and detaJled descriptions
have
been
included
wherever necessary. Nevertheless, even a detailed account has limitations. a certain
amount
of basic
knowledge is also
required
for successful work.
Especially note the following
;
(1)
Dirt
Before
removal and
disassembly,
clean the motorcycle
,
Any dirt entering the engme or other
parts
will
work as an abrasive and shorten the life of the
motorcycle.
For the same
reason,
before Installing
a new
part
clean
off
any dust or metal
filings.
(2)
Installation, Assembly
Generally,
installation or assembly is
the
reverse of removal or
disassembly.
But
if this Service
Manual
has
installation
or assembly
procedures,
follow them
.
(3)
Tightening Sequence
Generally,
when installing a part with several bolts, nuts, or screws, start
them
an in
their holes and
tighten
them
to
a snug
fit.
Then tighten them evenly in a cross panern.
This
is to avoid distortion of the
part and/or causing gas or oil
leakage.
Conversely when
loosening
the bolts, nuts, or screws,
first
loosen
all
of
them
by
about a
quarter turn
and
then
remove them_ Where there is a tightening sequence indication
in
this
Service Manual, the bolts,
nuts,
or screws must be tightened in the order and method indicated.
(4)
Torque
When
torque
values are given in this Service Manual, use
them.
Either too linle or too much torque may
lead
to
serious damage. Use a good quality, reliable tOfque
wrench.
(5)
Force
Common sense should dictate how much
force
is necessary in assembly and
disassembly. If a part
seems
especially
difficult to remove
or install, stop and examine what may
be
causing
the problem.
Whenever
tapping is
necessary, tap
lightly using a wooden or plastic
-faced mallet. Use
an
impact driver for
screws
(particularly
for the removal
of screws held by a
locking
agent) in order to avoid damaging the screw
heads.
(6)
Edges
Watch for
sharp edges, especially during major engine disassembly and
assembly.
Protect
your
hands
with gloves
or a
piece
of thick cloth when lifting the engine or turning it
over.
(7) High-Flash
Point
Solvent
A
high-flash point
solvent
is recommended
to reduce
fire
danger. A
commercial solvent
commonly
available in North
America is Stoddard solvent (generic name)
.
Always follow manufacturer
and container
directions
regard
ing
the use
of any solvent.
(8)
Gasket, O-Ring
Do
not reuse a
gasket
or
O-ring
once it
has
been in service.
The
mating surfaces around the gasket
should
be
free
of
foreign
maner and perfectly smooth to avoid oil or compression leaks.
(9)
Liquid Gasket. Non-Permanent Locking
Agent
Follow manufacturer's
directions
for
cleaning and preparing surfaces where these compounds
will
be
used. Apply
sparingly.
Excessive amounts may block. engine oil passages and cause serious
damage. An
example of
a non-permanent
locking agent commonly available in
North
America is
Loctite
Lock'n
Seal
(B lue).
(10) Press
A part installed using
a press or
driver,
such as a wheel bearing (hub
bearing),
should first
be
coated
with oil on
its
outer
or
inner circumference so that it will go
into place
smoothly.
(11) Bait
Bearing and Needle Bearing
Do not
remove
a ball bearing or a needle bearing unless it
is
absolutely necessary.
Replace
any
ball
or
needle bearings that
were
removed
with
new
ones,
as removal
generally damages
bearing.
Install bearings
with the marked side facing out applying pressure evenly with a suitable
driver. Only
press
on the
race that forms
the press
fit
with the base component to avoid
damaging the
bearings.
This
prevents
severe stress on the balls or needles and
races,
and prevent races and balls or
needles
from
being
dented.
Press a
ball
bearing until
it
stops at
the
stop in the
hole
or on the shaft.

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   Also See for Kawasaki KDX200

This manual is also suitable for:

Kdx220 1995-2006

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