No photo of this model in the library yet.

Kawasaki · Modern air-cooled single (2000-)

KLX 300

Library entry covers 1999-2025

32 factory 27 guideline

Published source

Kawasaki KLX300 / KLX300SM (KLX300D/E) Service Manual, 1st edition Oct. 2020, Periodic Maintenance Chart pp. 2-3 to 2-4

Factory workshop manual. Covers 2021- (KLX300 dual-sport, KLX300D/E service manual).

Open the source

59 items for a 2004 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: Four-stroke
Engine lubrication: Wet sump (oil in crankcase)
Oil filtration: Replaceable cartridge or spin-on filter
Valve gear: Overhead cam, screw/locknut adjusters
Ignition: Electronic (CDI / transistor / ECU)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Fuel injection
Cooling: Air / oil cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Shares engine oil
Clutch control: Hand lever, cable
Final drive: Chain
Front suspension: Telescopic fork
Rear suspension: Swingarm, twin shocks
Front brake: Disc, hydraulic
Rear brake: Drum (or band / belt rim)
Wheels: Spoked, tubed
Sidecar: No sidecar

Maintenance schedule

2004 Kawasaki KLX 300

On the road: every 200 mi

1 item

Check engine oil level

Pre-ride / on the road

Guideline

Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

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 400 mi

1 item

Lubricate drive chain

Pre-ride / on the road

Factory

Manual: Drive chain - lubricate. Factory: Daily check list: every 600 km (400 mile)

On the road: every 600 mi

1 item

Check chain slack and rear wheel alignment

Pre-ride / on the road

Factory

Manual: Drive chain slack - check. Factory: Daily check list: every 1 000 km (600 mile)

Every 1,000 mi or 6 months

2 items

Adjust rear drum brake and rod / cable linkage

Brakes

Guideline
Inspect tire tread, sidewalls and date codes

Wheels and tires

Guideline

Every 3,000 mi or 12 months

4 items

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.
Inspect fork seals, stanchions and fork boots

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

Every 3,800 mi

2 items

Spark arrester - inspect

Engine

Factory

Factory: Every 6 000 km (3 800 mile)
Check spoke tension and wheel true

Wheels and tires

Factory

Manual: Spoke tightness and rim runout - inspect. Factory: Initial 1,000 km; then every 6 000 km (3 800 mile)

Every 4,000 mi or 12 months

2 items

Inspect, clean and gap spark plugs

Engine

Guideline
Lubricate brake cam spindles, check linings and drums

Brakes

Guideline

Every 6,000 mi or 12 months

3 items

Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 7,600 mi or 12 months

12 items

Change engine oil

Engine

Factory

Manual: Engine oil and oil filter - change. Factory: Initial 1 (0.6) x1000 km; columns 1/12/24/36/48 x1000 km; repeat beyond chart
Inspect coolant hoses and clamps

Engine

Factory

Manual: Cooling system - inspect. Factory: Initial 1,000 km; then every column or yearly
Replace oil filter

Engine

Factory

Manual: Engine oil and oil filter - change. Factory: Changed with engine oil; initial 1,000 km (600 mi)
Check throttle cable(s) free play and return

Fuel and air

Factory

Manual: Throttle control system (play, smooth return, no drag) - inspect. Factory: Initial 1,000 km; then every column or yearly
Fuel system - inspect

Fuel and air

Factory

Factory: Initial 1,000 km; then every column or yearly
Inspect wiring, bullet connectors and ground points

Ignition and electrics

Factory

Manual: Electrical system - inspect. Factory: Marked at 12-48 x1000 km or yearly
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Factory

Manual: Clutch operation (play, engagement, disengagement) - inspect. Factory: Initial 1,000 km; then every column or yearly
Check steering head bearing adjustment

Front end

Factory

Manual: Steering play - inspect. Factory: Initial 1,000 km; then every column or yearly
Inspect rear shocks for leaks and damping

Rear suspension and frame

Factory

Manual: Suspension system - inspect. Factory: Marked at 12-48 x1000 km or yearly
Check brake pads and discs

Brakes

Factory

Manual: Brake system - inspect. Factory: Initial 1,000 km; then every column or yearly
Check wheel bearings for play

Wheels and tires

Factory

Manual: Wheel bearing damage - inspect. Factory: Marked at 12-48 x1000 km or yearly
Lubricate control cables and lever pivots

Controls and cables

Factory

Manual: Chassis parts - lubricate. Factory: Marked at 12-48 x1000 km or yearly

Every 7,600 mi

7 items

Air suction system - inspect

Engine

Factory

Factory: Marked at 12/24/36/48 x1000 km
Check and adjust valve clearances

Engine

Factory

Manual: Valve clearance - inspect. Factory: Marked at 12/24/36/48 x1000 km
Condition of bolts, nuts and fasteners - inspect

Engine

Factory

Factory: Initial 1,000 km; then every column
Idle speed - inspect

Engine

Factory

Factory: Initial 1,000 km; then every column
Replace spark plugs

Engine

Factory

Manual: Spark plug - change. Factory: Marked at 12/24/36/48 x1000 km
Clean / inspect air filter

Fuel and air

Factory

Manual: Air cleaner element - inspect. Factory: Marked at 12/24/36/48 x1000 km; more often in severe conditions
Inspect chain and sprockets for wear (measure stretch)

Final drive

Factory

Manual: Drive chain wear - inspect. Factory: Marked at 12-48 x1000 km; drive chain guide wear same

Every 10,000 mi or 2 years

1 item

Compression test (or leak-down)

Engine

Guideline

Every 12,000 mi or 2 years

2 items

Synchronize throttle bodies

Fuel and air

Guideline
Grease swingarm pivot

Rear suspension and frame

Guideline

Every 15,000 mi or 3 years

1 item

Change fork oil

Front end

Guideline

Some early telescopic forks are grease filled or use very small oil quantities. Check your manual.

Every 15,000 mi

1 item

Replace brake linings / skim drums (wear based)

Brakes

Guideline

Every 15,200 mi or 2 years

2 items

Repack / replace steering head bearings

Front end

Factory

Manual: Steering stem bearing - lubricate. Factory: Marked at 24 and 48 x1000 km or 2 years
Replace brake fluid

Brakes

Factory

Manual: Brake fluid (front and rear) - change. Factory: Marked at 24 and 48 x1000 km or 2 years

Every 15,200 mi

2 items

Replace fuel filter

Fuel and air

Factory

Manual: Fuel filter - change. Factory: Marked at 24 and 48 x1000 km
Clean and grease rear suspension linkage

Rear suspension and frame

Factory

Manual: Lubrication of rear suspension. Factory: Marked at 24 and 48 x1000 km

Every 18,000 mi

1 item

Replace chain and sprockets (wear based)

Final drive

Guideline

Every 20,000 mi or 4 years

1 item

Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 22,800 mi or 3 years

1 item

Replace coolant

Engine

Factory

Manual: Coolant, water hose and O-ring - change. Factory: Marked at 36 (22.8) x1000 km or 3 years

Every 25,000 mi or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 30,000 mi or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 30,400 mi or 4 years

1 item

Rebuild calipers and master cylinders (seals)

Brakes

Factory

Manual: Rubber parts of brake master cylinder and caliper - change. Factory: Marked at 48 (30.4) x1000 km or 4 years

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 2 years

2 items

Replace air filter element

Fuel and air

Factory

Manual: Air cleaner element - change. Factory: Every 2 years
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline

Every 4 years

1 item

Inspect brake hoses; replace old rubber

Brakes

Factory

Manual: Brake hose - change. Factory: Every 4 years

Every 5 years

1 item

Replace fuel lines

Fuel and air

Factory

Manual: Fuel hose - change. Factory: Every 5 years

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.