Kawasaki · Kawasaki two-stroke triple (S1/S2/S3, H1, H2, KH 1969-1980)

S1 / S2 / S3 / KH250-400

Library entry covers 1972-1980

17 factory 51 guideline

Published source

1972 Kawasaki S2 350cc Rider's Handbook (Owner's Manual)

Factory owner's handbook. Covers 1972 (S2 350 Rider's Handbook).

Open the source

68 items for a 1972 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: Battery and coil with contact points
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Two or more carburetors
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

1972 Kawasaki S1 / S2 / S3 / KH250-400

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 300 mi

3 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline
Lubricate drive chain

Pre-ride / on the road

Guideline

Lube warm, ideally at the end of the riding day so it soaks in overnight. Sooner after rain.

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

On the road: every 2,000 mi

2 items

Check chain slack and rear wheel alignment

Pre-ride / on the road

Factory

Manual: Adjust drive chain. Factory: Chart p.48: initial 500 and 2,000 mi, then every 2,000 mi
Walk-around: check nuts and bolts for vibration loosening

Pre-ride / on the road

Factory

Manual: Tighten bolts and nuts. Factory: Chart p.48: initial 500 and 2,000 mi, then every 2,000 mi

Every 1,000 mi or 6 months

3 items

Check gearbox oil level

Primary and gearbox

Guideline
Adjust front drum brake

Brakes

Guideline
Inspect tire tread, sidewalls and date codes

Wheels and tires

Guideline

Every 2,000 mi or 12 months

2 items

Replace spark plugs (two-stroke)

Engine

Guideline
Grease swingarm pivot

Rear suspension and frame

Guideline

Every 2,000 mi

12 items

Check / bleed / adjust oil injection pump cable

Engine

Factory

Manual: Check, adjust carburetor and oil pump. Factory: Chart p.48: initial 500 and 2,000 mi, then every 2,000 mi
Inspect, clean and gap spark plugs

Engine

Factory

Manual: Clean, set spark plugs. Factory: Chart p.48: initial 500 and 2,000 mi, then every 2,000 mi
Clean / inspect air filter

Fuel and air

Factory

Manual: Clean air cleaner. Factory: Chart p.48: every 2,000 mi
Clean fuel tap filter / sediment bowl

Fuel and air

Factory

Manual: Clean fuel tap screen. Factory: Chart p.48: every 2,000 mi
Check battery electrolyte, top up with distilled water

Ignition and electrics

Factory

Manual: Add battery water. Factory: Chart p.48: initial 500 and 2,000 mi, then every 2,000 mi
Clean and gap contact breaker points, oil cam felt

Ignition and electrics

Factory

Manual: Clean points, check ignition timing. Factory: Chart p.48: initial 500 and 2,000 mi, then every 2,000 mi
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Factory

Manual: Check, adjust clutch release. Factory: Chart p.48: initial 500 and 2,000 mi, then every 2,000 mi
Change gearbox oil

Primary and gearbox

Factory

Manual: Change transmission oil. Factory: Chart p.48: initial 500 and 2,000 mi, then every 2,000 mi
Clean drive chain thoroughly (remove and soak, re-lube)

Final drive

Factory

Manual: Clean, lubricate drive chain. Factory: Chart p.48: initial 500 and 2,000 mi, then every 2,000 mi
Check fork oil level

Front end

Factory

Factory: Chart p.48: every 2,000 mi
Adjust rear drum brake and rod / cable linkage

Brakes

Factory

Manual: Check, adjust brakes. Factory: Chart p.48: initial 500 and 2,000 mi, then every 2,000 mi
Check spoke tension and wheel true

Wheels and tires

Factory

Manual: Check, tighten spokes. Factory: Chart p.48: initial 500 and 2,000 mi, then every 2,000 mi

Every 3,000 mi or 12 months

13 items

Check engine mounting bolts and plates

Engine

Guideline
Check throttle cable(s) free play and return

Fuel and air

Guideline
Synchronize carburetors

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
Inspect chain and sprockets for wear (measure stretch)

Final drive

Guideline
Check steering damper (friction or hydraulic)

Front end

Guideline
Check steering head bearing adjustment

Front end

Guideline
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
Check wheel bearings for play

Wheels and tires

Guideline

Every 4,000 mi or 12 months

2 items

Replace spark plugs

Engine

Guideline
Lubricate brake cam spindles, check linings and drums

Brakes

Guideline

Every 4,000 mi

3 items

Decarbonize exhaust ports, pipes and baffles

Engine

Factory

Manual: Decarbon heads and exhaust system. Factory: Chart p.48: every 4,000 mi (H2 is 2,000)
Change fork oil

Front end

Factory

Manual: Change front fork oil. Factory: Chart p.48: every 4,000 mi
Lubricate control cables and lever pivots

Controls and cables

Factory

Manual: Lubricate cables. Factory: Chart p.48: every 4,000 mi

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

5 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
Inspect rear shocks for leaks and damping

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 6,000 mi or 2 years

1 item

Lubricate and check automatic advance unit

Ignition and electrics

Guideline

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 2 years

1 item

Replace air filter element

Fuel and air

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 15,000 mi

1 item

Replace brake linings / skim drums (wear based)

Brakes

Guideline

Every 20,000 mi or 4 years

2 items

Repack / replace steering head bearings

Front end

Guideline

Many old machines use loose balls in cups and cones. Taper roller conversions are common.
Repack / replace wheel bearings

Wheels and tires

Guideline

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

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 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.