🏷️ Basic Information Identification Make: Kawasaki Model: KLX300R Product Name: Kawasaki KLX300R Service Manual Repair 1997-2005 Generation Covered Years: 1997-2005 (also applicable for 2006-2007) 👋 Introduction Market Position Segment: Off-road motorcycle (Enduro/Dual-Sport) Competitive Analysis Competitors: Honda XR series, Yamaha WR series, KTM EXC series (during its production era) Key Features Vehicle Focus: Durable, reliable off-road performance with a focus on trail riding and general use Manual Value Benefit To Owner: Enables owners to perform comprehensive maintenance, diagnostics, and repairs, reducing reliance on dealerships and extending the life of the vehicle. Vendor Support: Offers free replacement of lost manuals. 📋 Manual Details Coverage Areas Primary Coverage: Factory repair manual for Kawasaki KLX300R Supplementary Coverage: Includes supplement for 1997-2005 KLX300R based on 1993-1996 KLX250R base manual Page Count Total Pages: 305 Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: PDF Digital Features: Clickable chapters, searchable text Usage Rights: No restrictions on printing or saving/burning to disc 📖 Manual Coverage Systems Covered Engine: Complete teardown and rebuild, maintenance, troubleshooting, performance tuning (e.g., carburetor jetting, ignition timing) Transmission: Maintenance, troubleshooting, rebuild procedures, gear ratios, clutch service Chassis: Suspension (forks, rear shock, linkage), steering, frame, swingarm Electrical System: Ignition system, charging system, lighting, starting system, wiring diagrams, troubleshooting no spark conditions Fuel System: Carburetor (KLX300R), fuel pump, fuel tank maintenance, fuel line inspection Brakes: Front and rear brake system maintenance, caliper service, pad replacement, fluid flush Cooling System: Radiator, coolant, fluid replacement intervals Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, chain maintenance, valve adjustments Troubleshooting: Diagnostic procedures for common problems, error code identification (where applicable) Rebuilds: Complete engine and transmission rebuild instructions Installation: Instructions for installing various components and accessories Technical Depth Depth: Comprehensive coverage from basic maintenance to complete overhaul and troubleshooting Detail Level: Includes detailed diagrams, illustrations, torque specifications, and step-by-step procedures 📊 Manual Specifications File Format Format: PDF Print Quality Printability: High-resolution, suitable for printing Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Type: Four-stroke, single-cylinder Displacement: 296 cc (18.07 cu in) Bore X Stroke: 78.0 x 70.0 mm (3.07 x 2.76 in) Cooling System: Liquid-cooled Valve Train: DOHC, 4 valves per cylinder Performance Horsepower: Approx. 26-28 HP (at crankshaft, varies by year and tuning) Torque: Approx. 2.0 kgf·m (14.5 lb-ft) (at crankshaft, varies by year and tuning) Fuel System Carburetor: Keihin CVK34 (for most years) Fuel Capacity: 7.7 L (2.0 US gal) Lubrication Oil Type Specification: SAE 10W-40 API SG or higher, JASO MA certified (refer to manual for exact specifications and viscosity for different temperatures) Oil Capacity: 1.7 L (1.8 US qt) with filter change Ignition System: Digital CDI (Capacitor Discharge Ignition) Starting System Starter: Kick starter Compression Ratio Ratio: 10.0:1 🔧 Transmission Standard Type: Constant mesh, 6-speed return Features Clutch Type: Wet, multi-disc Final Drive: O-ring sealed chain Lubrication Transmission Oil Type: API GL-4 SAE 80 hypoid gear oil (refer to manual for specific viscosity and capacity) 📐 Dimensions Exterior Length: Approx. 2,170 mm (85.4 in) Width: Approx. 810 mm (31.9 in) Height: Approx. 1,235 mm (48.6 in) Wheelbase: Approx. 1,430 mm (56.3 in) Weights Dry Weight: Approx. 117 kg (258 lbs) Curb Weight: Approx. 124 kg (273 lbs) (may vary slightly by year) Suspension Front Suspension Travel: 280 mm (11.0 in) Rear Suspension Travel: 285 mm (11.2 in) Front Fork Type: 43mm inverted cartridge fork Rear Shock Type: Monoshock with adjustable preload and rebound damping (Uni-Trak system) Wheels Tires Front Tire Size: 80/100-21 51M Rear Tire Size: 100/100-18 59M Front Brake: 250mm petal disc Rear Brake: 220mm petal disc 🔧 Maintenance Service Intervals Engine Oil Change: Every 1,000 km (600 miles) or 6 months, whichever comes first (refer to manual for specific conditions). Air Filter Cleaning: Clean every 1,000 km (600 miles), replace as needed. Spark Plug Inspection: Inspect every 2,000 km (1,200 miles). Valve Clearance Adjustment: Every 4,000 km (2,400 miles). Fluid Specifications Engine Oil: SAE 10W-40, API SG, JASO MA (as per engine_specs) Brake Fluid: DOT 3 or DOT 4 (refer to manual for specific recommendations) Coolant: Permanent type antifreeze (ethylene glycol based) mixed with distilled water, typically 50/50 ratio (refer to manual for exact type and capacity). Known Issues Common Wear Items: Clutch plates, chain and sprockets, fork seals, wheel bearings, carburetor diaphragm. Potential Problems: Carburetor jetting may require adjustment for altitude or specific riding conditions; occasional issues with electrical connectors or grounding. 📚 Vehicle History Brand Heritage Manufacturer Focus: Kawasaki Heavy Industries, Ltd. has a long history in motorcycle manufacturing, known for performance and innovation in various classes. Model Evolution Klx Lineage: The KLX line has been a staple for Kawasaki's off-road offerings, evolving from earlier models like the KDX and KL series. The KLX300R specifically filled a niche for a capable, liquid-cooled four-stroke trail bike....