Kawasaki KDX200 (1989-1994) [7/174] 2 general information
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Kawasaki KDX200 (1989-1994) [7/174] 2 general information

Kawasaki KDX200 (1989-1994) [7/174] 2 general information

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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 detailed des criptions 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 engine 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 Tightening Sequence Generally when installing a part with several bolts nuts or screws they should all be started in their holes and tightened to a snug fit Then tighten them evenly in a cross pattern 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 of 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 3 Torque The torque values given in this Service Manual should always be adahered to Either too little or too much torque may lead to serious damage Use a good quality reliable torque wrench 4 Force Common sense should dictate how much force is necessary in assembly and disassemly 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 5 Edges Watch for sharp edges especially during major engine disassembly and assembly Pro tect your hands with gloves or a piece of thick cloth when lifting the engine or turning it over 6 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 regarding the use of any solvent 7 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 matter and perfectly smooth to avoid oil or com pression leaks 8 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 Blue 9 Press A part installed using a press or driver such as a wheel bearing should first be coated with oil on its outer or inner circumference so that it will go into place smoothly 10 Ball Bearing When installing a ball bearing the bearing race which is affected by friction should be pushed by a suitable driver This prevents severe stress on the balls and races and prevents races and balls from being dented Press a ball bearing until it stops at the stop in the hole or on the shaft

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