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Kawasaki · Two-stroke single, oil injection, chain drive

KE 100

Library entry covers 1975

27 factory 43 guideline

Published source

Kawasaki KE100 Service Manual, Periodic Maintenance Chart (KE100A) p. 119 (km)

Factory workshop manual. Covers 1975- (KE100-A chart; manual also has B1-B15 supplement charts).

Open the source

70 items for a 1975 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Two-stroke
Engine lubrication: Two-stroke oil injection (Autolube, Injectolube, Pilgrim pump...)
Oil filtration: None (no filter)
Valve gear: None (two-stroke porting)
Ignition: Magneto (incl. magdyno, flywheel magneto)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Single carburetor
Cooling: Air / oil cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Separate gearbox oil
Clutch control: Hand lever, cable
Final drive: Chain
Front suspension: Telescopic fork
Rear suspension: Swingarm, twin shocks
Front brake: Drum (or band / stirrup)
Rear brake: Drum (or band / belt rim)
Wheels: Spoked, tubed
Sidecar: No sidecar

Maintenance schedule

1975 Kawasaki KE 100

On the road: every 150 mi

1 item

Check two-stroke oil tank / carry premix oil

Pre-ride / on the road

Guideline

Running a two-stroke out of oil seizes it. Injection bikes: check the tank. Premix: carry oil and a measure.

On the road: every 186 mi

1 item

Lubricate drive chain

Pre-ride / on the road

Factory

Manual: Drive chain - lubricate. Factory: Every 300 +/- 50 km

On the road: every 300 mi

2 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline

On the road: every 497 mi

1 item

Check chain slack and rear wheel alignment

Pre-ride / on the road

Factory

Manual: Drive chain - adjust. Factory: Every 800 +/- 100 km

On the road: every 500 mi

1 item

Walk-around: check nuts and bolts for vibration loosening

Pre-ride / on the road

Guideline

Old machines shake things loose: exhaust nuts, mudguard stays, footrests, tank mounts, battery strap.

On the road: every 1,000 mi

1 item

Check road kit: plugs, points file, master link, tube patches, wire, tape

Pre-ride / on the road

Guideline

Every 1,000 mi or 6 months

2 items

Check gearbox oil level

Primary and gearbox

Guideline
Adjust rear drum brake and rod / cable linkage

Brakes

Guideline

Every 1,500 mi or 6 months

1 item

Clean drive chain thoroughly (remove and soak, re-lube)

Final drive

Guideline

Non O-ring chains on old machines: remove, clean, soak in hot chain grease or lube, refit with the master link clip closed end leading.

Every 2,000 mi or 12 months

2 items

Inspect, clean and gap spark plugs

Engine

Guideline
Grease swingarm pivot

Rear suspension and frame

Guideline

Every 2,485 mi or 1 month

1 item

Check battery electrolyte, top up with distilled water

Ignition and electrics

Factory

Manual: Battery electrolyte level - check. Factory: Monthly and every column from 800 km

Every 2,485 mi

15 items

Check / bleed / adjust oil injection pump cable

Engine

Factory

Manual: Carburetor & oil pump - adjust. Factory: Initial 800 km; then every column
Replace spark plugs (two-stroke)

Engine

Factory

Manual: Spark plug - clean and gap. Factory: Initial 800 km; then every column
Check throttle cable(s) free play and return

Fuel and air

Factory

Manual: Throttle cable - adjust. Factory: Initial 800 km; then every column
Fuel system - clean

Fuel and air

Factory

Factory: Initial 800 km; then every column
Clean and gap contact breaker points, oil cam felt

Ignition and electrics

Factory

Manual: Points, timing - check. Factory: Initial 800 km; then every column
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Factory

Manual: Clutch - adjust. Factory: Initial 800 km; then every column
Inspect chain and sprockets for wear (measure stretch)

Final drive

Factory

Manual: Drive chain wear - check. Factory: Every column from 4,000 km
Check steering head bearing adjustment

Front end

Factory

Manual: Steering play - check. Factory: Initial 800 km; then every column
Inspect fork seals, stanchions and fork boots

Front end

Factory

Manual: Front fork - inspect/clean. Factory: Initial 800 km; then every column
Inspect rear shocks for leaks and damping

Rear suspension and frame

Factory

Manual: Rear shock absorbers - inspect. Factory: Initial 800 km; then every column
Adjust front drum brake

Brakes

Factory

Manual: Brake adjustment - check. Factory: Initial 800 km; then every column (front and rear drum)
Replace brake linings / skim drums (wear based)

Brakes

Factory

Manual: Brake wear - check. Factory: Every column from 4,000 km
Check spoke tension and wheel true

Wheels and tires

Factory

Manual: Spoke tightness and rim runout - check. Factory: Initial 800 km; then every column
Inspect tire tread, sidewalls and date codes

Wheels and tires

Factory

Manual: Tire tread wear - check. Factory: Every column from 4,000 km
Lubricate control cables and lever pivots

Controls and cables

Factory

Manual: General lubrication - perform. Factory: Every column from 4,000 km

Every 3,000 mi or 12 months

9 items

Check engine mounting bolts and plates

Engine

Guideline
Clean fuel tap filter / sediment bowl

Fuel and air

Guideline
Check / set ignition timing

Ignition and electrics

Guideline
Adjust clutch pushrod / clutch adjuster

Primary and gearbox

Guideline
Check chain guard, chain oiler (if fitted), rear chain case

Final drive

Guideline
Check steering damper (friction or hydraulic)

Front end

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Grease and check center / side stand and springs

Rear suspension and frame

Guideline
Check wheel bearings for play

Wheels and tires

Guideline

Every 3,000 mi or 2 years

1 item

Decarbonize exhaust ports, pipes and baffles

Engine

Guideline

Two-strokes coke up the exhaust port and muffler baffles; power falls off gradually.

Every 4,000 mi or 12 months

1 item

Replace spark plugs

Engine

Guideline

Every 4,971 mi or 12 months

1 item

Change gearbox oil

Primary and gearbox

Factory

Manual: Transmission oil - change. Factory: Initial 800 km; then 8,000/16,000/24,000 km or yearly; columns 800/4,000 ... 24,000 km

Every 4,971 mi

4 items

Nuts, bolts, fasteners - check and torque

Engine

Factory

Factory: Initial 800 km; then 8,000/16,000/24,000 km
Clean / inspect air filter

Fuel and air

Factory

Manual: Air cleaner element - clean. Factory: Marked at 4,000, 12,000, 20,000 km
Replace air filter element

Fuel and air

Factory

Manual: Air cleaner element - replace. Factory: Marked at 8,000/16,000/24,000 km, or every 5 cleanings
Change fork oil

Front end

Factory

Manual: Front fork oil - change. Factory: Marked at 8,000/16,000/24,000 km

Every 5,000 mi or 2 years

1 item

Check cylinder head bolt torque

Engine

Guideline

Air-cooled iron and alloy engines can lose head bolt tension; follow your manual's sequence and whether it is done hot or cold.

Every 6,000 mi or 12 months

3 items

Clean carburetor float bowl(s), check float level and jets

Fuel and air

Guideline

Ethanol fuel varnishes old carbs quickly in storage.
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline

Every 6,000 mi or 2 years

2 items

Lubricate and check automatic advance unit

Ignition and electrics

Guideline
Magneto: clean slip ring and pickup brush, check HT lead

Ignition and electrics

Guideline

Every 9,942 mi or 2 years

4 items

Repack / replace steering head bearings

Front end

Factory

Manual: Steering stem bearings - grease. Factory: Marked at 16,000 km or 2 years
Lubricate brake cam spindles, check linings and drums

Brakes

Factory

Manual: Brake camshaft - grease. Factory: Marked at 16,000 km or 2 years
Repack / replace wheel bearings

Wheels and tires

Factory

Manual: Wheel bearings - grease. Factory: Marked at 16,000 km or 2 years
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Factory

Manual: Speedometer gear housing - grease. Factory: Marked at 16,000 km or 2 years

Every 10,000 mi or 2 years

1 item

Compression test (or leak-down)

Engine

Guideline

Every 10,000 mi

1 item

Replace chain and sprockets (wear based)

Final drive

Guideline

Every 12,000 mi or 3 years

1 item

Replace points and condenser

Ignition and electrics

Guideline

Every 15,000 mi or 5 years

1 item

Inspect clutch plates and springs

Primary and gearbox

Guideline

Every 25,000 mi or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 25,000 mi or 10 years

1 item

Magneto overhaul / re-magnetize, replace capacitor

Ignition and electrics

Guideline

Weak spark when hot is the classic symptom. Old capacitors fail with age, not miles.

Every 30,000 mi or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 12 months

1 item

Check speedometer / odometer against a known distance

Controls and cables

Guideline

Old speedos drift with tire size and drive wear. Use phone GPS over a measured 10 miles / km.

Every 2 years

3 items

Inspect fuel tank for rust, sealer failure, leaks

Fuel and air

Guideline
Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline

Every 4 years

2 items

Replace oil injection delivery lines

Engine

Guideline
Replace fuel lines

Fuel and air

Guideline

Old rubber and modern ethanol fuel do not mix well.

Every 6 years

2 items

Replace inner tubes and rim tape with tires

Wheels and tires

Guideline
Replace tires on age (regardless of tread)

Wheels and tires

Guideline

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.