kawasaki KLX 300 - Recent Questions, Troubleshooting & Support


Hi, Anonymous and the usual suspects are:
1. Fuel tank empty.
2. The fuel tank has old dead gas.
3. Fuel tank bottom contaminated with ethanol sludge, dirt, water, rust, etc.
4. Fuel supply valve/petcock turned off.
5. Fouled spark plugs.
6. Engine flooded as a result of overuse of the choke.
7. Vacuum hose to the fuel supply valve/petcock disconnected, broken, cracked, or pinched.
8. Fuel valve/petcock or filter clogged.
9. Fuel line to carburetor or throttle body pinched, kinked or blocked.
10. Carburetor float stuck.
11. Fuel injectors clogged.
12. Fuel injectors stuck open.
13. Quick disconnect check ball stuck.
14. Compression below 75 PSI.
15. A stuck-bent-burnt valve.
16. Severely discharged or a damaged battery should have 12.5 volts or more and be able to pass a proper "LOAD" test if necessary, you may have a cursory reading of 12.5 volts or more but little or zero amperage the battery is faulty and must be replaced, AGM batteries fail in this scenario more so than lead-acid batteries.
17. Check battery terminals for damage or corrosion, check the battery cables at "BOTH" ends for loose, corroded, or broken connectors, "INSIDE" and outside the cable harness, perform connector wiggle test and check cables with an ohmmeter if necessary.
18. Loose or corroded wire connection at the coil or plug between ignition sensor and ECM module.
19. Spark plug cables in bad condition and shorting check for spark leakage in the dark, cable connections are loose or connected to the wrong cylinders.
20. Ignition timing incorrect due to a faulty ignition coil, ignition module or MAP, CMP, CKP, O2, TPS, ETP, IAC sensors.
21. Faulty neutral, clutch, kickstand safety switch.
22. Faulty fuel pump or fuse or relay.
23. Faulty or corroded run/stop switch.
24. Tilt sensor needs a reset.
25. Security system not disarming alarm needs a reset.
26. Check for engine trouble codes.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
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1998 kawasaki... | Answered on Apr 01, 2019


Hi, Edge09dickie for this scenario you will need your service manual that has all fastener torque specs and a wiring diagram on the back pages, parts fiche, and owners manual if you can't find the best tool you ever bought for your Kawasaki, despair not, for a mere $15 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
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1998 kawasaki... | Answered on Sep 17, 2018


Hi, Bevanlock and the usual suspects are:
1. Fuel tank empty.
2. The fuel tank has old dead gas.
3. Fuel tank bottom contaminated with ethanol sludge, dirt, water, rust, etc.
4. Fuel supply valve/petcock turned off.
5. Fouled spark plugs.
6. Engine flooded as a result of overuse of the choke.
7. Vacuum hose to the fuel supply valve/petcock disconnected, broken, cracked, or pinched.
8. Fuel valve/petcock or filter clogged.
9. Fuel line to carburetor or throttle body pinched, kinked or blocked.
10. Carburetor float stuck.
11. Fuel injectors clogged.
12. Fuel injectors stuck open.
13. Quick disconnect check ball stuck.
14. Compression below 75 PSI.
15. A stuck-bent-burnt valve.
16. Severely discharged or a damaged battery should have 12.5 volts or more and be able to pass a proper "LOAD" test if necessary, you may have a cursory reading of 12.5 volts or more but little or zero amperage the battery is faulty and must be replaced, AGM batteries fail in this scenario more so than lead-acid batteries.
17. Check battery terminals for damage or corrosion, check the battery cables at "BOTH" ends for loose, corroded, or broken connectors, "INSIDE" and outside the cable harness, perform connector wiggle test and check cables with an ohmmeter if necessary.
18. Loose or corroded wire connection at the coil or plug between ignition sensor and ECM module.
19. Spark plug cables in bad condition and shorting check for spark leakage in the dark, cable connections are loose or connected to the wrong cylinders.
20. Ignition timing incorrect due to a faulty ignition coil, ignition module or MAP, CMP, CKP, O2, TPS, ETP, IAC sensors.
21. Faulty neutral, clutch, kickstand safety switch.
22. Faulty fuel pump or fuse or relay.
23. Faulty or corroded run/stop switch.
24. Tilt sensor needs a reset.
25. Security system not disarming alarm needs a reset.
26. Check for engine trouble codes.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
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1998 kawasaki... | Answered on Sep 17, 2018


Hi, Anonymous for this scenario you will need your service manual that has all fastener torque specs and a wiring diagram on the back pages, parts fiche, and owners manual if you can't find the best tool you ever bought for your Kawasaki, despair not, for a mere zero $0 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
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1998 kawasaki... | Answered on Jul 16, 2018


Hi, Anonymous for this scenario you will need your service manual that has all fastener torque specs and a wiring diagram on the back pages, parts fiche, and owners manual if you can't find the best tool you ever bought for your Kawasaki, despair not, for a mere $22 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
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1998 kawasaki... | Answered on Jul 11, 2018


Hi, Vineco for this scenario you will need your service manual that has all fastener torque specs and a wiring diagram on the back pages, parts fiche, and owners manual if you can't find the best tool you ever bought for your Kawasaki, despair not, for a mere $15 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
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2001 Kawasaki KLX300R Owner Manual

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e

2001 kawasaki... | Answered on Apr 13, 2018


$Hi, Damien_bug the vast majority of service, parts fiche, and owners manuals on the internet are "FREE" to download and all service manuals contain wiring diagrams in the back pages. The rest usually charge a modest fee of $15 and there is a handful of obscure, rare, obsolete, and very old models that are no longer or never were available and some were never printed in English. The Indian and Philippine markets are usually in E-book format only, for these rare occasions I shall look on eBay and find the cheapest one available. Most of the manuals will cover your exact make, model, and year otherwise one will be provided that comes as close as possible to your bike and will have most of the same info that an exact manual would have. If there is no $ sign after the manual link it is free to download.
To download your manual for viewing or printing please click on the blue links below. Good luck and have a wonderful day
Kawasaki KLX300R service manual repair 1997 2005 KLX300 Download Manuals... $15
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Download Manual 1998 Kawasaki KLX300R Owner Manual
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https://en.wikipedia.org/wiki/List_of_Kawasaki_motorcycles

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e

1998 kawasaki... | Answered on Apr 13, 2018


Hi, Pureredness for this scenario you will need your service manual that has all fastener torque specs and a wiring diagram on the back pages, parts fiche, and owners manual if you can't find the best tool you ever bought for your Kawasaki, despair not, for a mere $15 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
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Kawasaki KLX300R service manual repair 1997 2005 KLX300 Download Manuals... $15
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Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e


1998 kawasaki... | Answered on Apr 13, 2018


Hi, Rpatritti for this scenario you will need your service manual that has all fastener torque specs and a wiring diagram on the back pages, parts fiche, and owners manual if you can't find the best tool you ever bought for your Kawasaki, despair not, for a mere $15 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
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Kawasaki KLX300R service manual repair 1997 2005 KLX300 Download Manuals... $15
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Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e

1998 kawasaki... | Answered on Apr 13, 2018


Hi, Kyle for this scenario you will need your service manual that has all fastener torque specs and a wiring diagram on the back pages, parts fiche, and owners manual if you can't find the best tool you ever bought for your Kawasaki, despair not, for a mere $15 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
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Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e


2001 kawasaki... | Answered on Apr 12, 2018


Hi, Anonymous and the usual suspects are:
1. Damaged or restricted fuel tank venting system.
2. Loose float bowl screws.
3. Damaged float bowl o-ring.
4. improper fuel level in the float bowl.
5. Worn or dirty inlet valve or seat.
6. Damaged or leaking float assembly.
7. Particle contamination in inlet fitting cavity.
8. Damaged petcock diaphragm allowing fuel to flow through the vacuum line into the combustion chamber.
9. Contaminated fuel tank.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
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Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e


1998 kawasaki... | Answered on Apr 12, 2018


Hi, Anonymous and the usual suspects are:
1. Improper clutch adjustment or not disengaging.
2. Bent shift shaft.
3. Shift fork bent or seized.
4. Gear seized on the shaft.
5. Gear positioning lever binding.
6. Shift return springs weak or broken.
7. Shift return spring pin loose
8. Shift mechanism arm spring is broken.
9. Shift mechanism arm is broken.
10. Shift drum is broken.
11. Shift lever loose on the shift shaft.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
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Kawasaki KLX300R service manual repair 1997 2005 KLX300 Download Manuals... $15
OEM Parts for Kawasaki
2000 Kawasaki KLX300R Owner Manual

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e

2000 kawasaki... | Answered on Apr 11, 2018


Hi, Xim1645 a regulator-rectifier on a motorcycle converts alternating current to direct current. The reason you need one on a bike is that the bike is equipped with an alternator, which is just a device that takes power (in the form of rotation) from the engine and converts it into alternating current (AC). Think of the alternator as a type of generator. Now AC is a fine source of power for lights, but you can't feed AC into a battery or into a fuel injection computer and expect it to work.
The rectifier's job is to convert this AC power into Direct Current power so it can be used to charge the bike's battery and otherwise power all the 12 volts (DC) devices on your bike (electronics, tachometer, etc.) It's worth mentioning that generally a rectifier is combined with a voltage regulator, which makes sure the alternator doesn't generate too much (or too little) power/voltage. If your alternator were to generate too much voltage you'd risk overcharging the battery, burning out your bike's electronics, etc. And if it generated too little your battery would slowly drain (this is the most common failure in a voltage regulator) I bring this up because on most bikes they tend to combine these two functions into a single rectifier/regulator. It is also worth mentioning that all rectifier/voltage regulator must be physically or electronically (by wire) grounded in order to function properly.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
Kawasaki KLX300R service manual repair 1997 2005 KLX300 Download Manuals... $15
OEM Parts for Kawasaki
1999 Kawasaki KLX300R Owner Manual
Kawasaki KLX 300R
https://en.wikipedia.org/wiki/List_of_Kawasaki_motorcycles

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e

1998 kawasaki... | Answered on Jan 03, 2018


Hey Bently,
sorry, there is no way to do anything to the transmission without tearing the engine down,,, DO NOT ride this atv again ,,you WILL cause more damage to the engine/transmission... It could/possibly be in the drive train...either way -
take it to a qualified professional...

1998 kawasaki... | Answered on Jul 19, 2017


if your lucks good.
try this. drain your oil. gas may have seep by piston.
and the crank case has to much liquid in it. "BINGO"
might be your lucky day !!!

1998 kawasaki... | Answered on Jun 09, 2017


Hi, Scott I would love to help you but you are not going to believe this the batteries in my crystal ball are dead and my mental telepathy headset is broken. I'm not sure if you are talking about your dirt bike or a gun, you need to be more specific please provide this information in the comment section below and after you post it, a comment alert icon appears on my screen that will allow me to respond to your original question in another comment box below yours. Good luck and have a nice day.

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e

kawasaki KLX 300... | Answered on Dec 13, 2016


You said the motor cut out and popped and backfired when it quit, this is almost always one of two things; either the low speed pulse coil or the actual CDI "black" box. You will almost never lose a main coil. One thing I would also check to make sure did not happen is shearing a flywheel mag key. When the motor backfires you can easily shear a mag key if you have a heavy flywheel, (external). However when this happens you don't usually lose spark but it will certainly cause the backfire.
One other item of importance is that the bike you are in question about does not emit a bright spark when you are checking for fire. Make sure you are using a brand new plug and ground it on the head. Try to make sure you are in a dark environment when you check the spark.

kawasaki KLX 300... | Answered on May 17, 2016


check to see if the choke is stuck or the carb could be dirty (gummed up)

2001 kawasaki... | Answered on Mar 17, 2016


open the clucth cover and check if rod is installed

also how was it packed solid/friction/solid/friction

while open check clutch basket for ruff edges where solids plates ride should be smooth

1998 kawasaki... | Answered on Jan 23, 2016

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