Valve Clearance Standard: Exhaust 0. If the gap is too wide, the clutch may not release fully. If the gap is too narrow, the clutch may not engage fully. Service Limit: Front 1 mm 0. Rear 2 mm 0. If the chain is too loose, turn in the left and right chain adjuster nuts [D] evenly. If they do not, adjust the chain slack and align the wheel alignment see Drive Chain Slack Adjustment.
Replace the chain guide if it shows any signs of abnormal wear or damage. If the shock absorber does not smoothly stroke or noise is found, inspect the oil leak see Rear Shock Absorber Oil Leak Inspection.
Adjust the headlight to the proper an- gle according to local regulations. Also, check to see that each cotter pin is in place and in good condition. Torque - Drain Bolt: 9. PBC grease. Torque - Bleed Valve: 5. Special Tools Throttle Grip and Cables Throttle Cable accelerator 2. Throttle Cable decelerator 3. Choke Cable 4. Idle Adjusting Screw 5. Air Cut Valve 6. Jet Needle 7. Vacuum Valve 8. Float Valve 9. Needle Jet Needle Jet Holder Canister 3. Separator 4.
Green Hose 5. Blue Hose 6. White Hose 7. Red Hose Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; If the gauge is lowered and then raised again, the fuel level measured shows somewhat higher than the actual fuel level.
Increasing the float height lowers the fuel level and decreasing the float height raises the fuel level. If they are not, loosen the mounting screws and align the carburetors on a flat surface. It will seat against the needle jet, pushing the end of the jet into the carburetor bore. Remove as many rubber or plastic parts from the carburetor as possible before cleaning the carburetor with a cleaning solution.
WARNING If dirt or dust is allowed to pass through into the car- buretors, the butterfly valves may become stuck, possibly causing an accident. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. If the fuel tap screens have any breaks or are deterio- rated, they may allow dirt to reach the carburetor, causing poor running.
Coolant Flow Chart Coolant Deterioration Inspection Coolant Level Inspection Coolant Draining Coolant Filling Pressure Testing Cooling System Flushing Water Pump When the engine starts, the water pump turns and the coolant circulates.
The thermostat is a wax pellet type which opens or closes with coolant temperature changes. The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. When this accumulation is suspected or observed, flush the cool- ing system. If this accumulation is not removed, it will clog up the water passage and considerable reduce the effi- ciency of the cooling system.
If the surface is corroded or if the blades are damaged, replace the water pump unit. The radiator fan may start even if the ignition switch is off. If there are obstructions to air flow, remove them. If the corrugated fins [A] are deformed, carefully straighten them.
They must be smooth and clean for the radiator cap to function properly. If the valve is open, replace the thermostat with a new one. Avoid sharp bending, kinking, flattening or twisting. Torque - Radiator Fan Switch: Cylinder Head Removal Cylinder Head Installation Cylinder Head Warp Inspection Cylinder Head Cleaning Page L: Apply a non-permanent locking agent.
M: Apply molybdenum disulfide grease. MO: Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disufide grease in a weight ratio 10 : 1. Exhaust Cylinder Inside Diameter Piston Diameter The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: When removing the tensioner, do not take out the mounting bolts only halfway. If the runout exceeds the service limit, replace the shaft.
Torque - Cylinder Head Bolts: This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off. The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings. Set it close to the bottom of the cylinder, where cylinder wear is low.
Special Tool and Sealant Clutch Lever and Cable Clutch Lever Free Play Inspection Clutch Lever Free Play Adjustment Clutch Cable Removal Clutch Cable Lubrication Clutch Lever Removal Clutch Cover Starter Lockout Switch 7. Friction Plate Thickness 2.
Friction and Steel Plate Warp Page Clutch Cover [A] of the crankcases. Torque - Clutch Spring Bolts: 8. If they are damaged or if there are groove cuts in the areas that come in contact with the tangs, replace the housing. Replace the friction plates if their tangs are damaged as well. Special Tools and Sealant Engine Oil Flow Chart Engine Oil and Oil Filter Oil Level Inspection Engine Oil Change Oil Filter Replacement Bypass Valve Disassembly Bypass Valve Assembly G: Apply grease.
L: Apply a non-permanent locking agent. Engine Removal Engine Installation Then insert the upper engine mount- ing bolt [B], and tighten the nut loosely. Starter Motor Clutch Assembly.. Balancer Removal LG: Apply liquid gasket Kawasaki Bond: MO: Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio Connecting Rod Twist — — — 0.
Crankshaft Main Bearing Insert Thickness: 1. If the measurement exceeds the service limit, replace the crankshaft. If the measured journal diameter is not less than the ser- vice limit, but does not coincide with the original diameter markings [A] on the balancer shaft, write new marks on it. If the shift shaft [A] is bent, straighten or replace it. The difference between the highest and the lowest gauge readings is the amount of backlash.
Replace any damaged gears or gears with excessively worn dogs or dog holes. Washer 2. Thrust Washer 3. Needle Bearing 4. Ball Bearing 5. Collar 6. Bearing Outer Race 7. Circlip R: Replacement Parts Internet Archive's 25th Anniversary Logo. Search icon An illustration of a magnifying glass. User icon An illustration of a person's head and chest.
Sign up Log in. Web icon An illustration of a computer application window Wayback Machine Texts icon An illustration of an open book. Books Video icon An illustration of two cells of a film strip. Video Audio icon An illustration of an audio speaker. Observe all the rules listed below. Place a strip on each journal parallel to the camshaft installed in the correct position.
If the cams are worn down past the service limit, replace the camshaft. Cam Height Standard: This will warp the cylinder head. Exhaust 0.
Inlet Service Limit: Exhaust This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off.
If the seat width is within the specified range, lap the valve to the seat as described below. The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings. Set it close to the bottom of the cylinder, where cylinder wear is low.
Wait until the muffler cool down. Special Tool and Sealant Clutch Lever and Cable Clutch Lever Free Play Inspection Clutch Lever Free Play Adjustment Clutch Cable Removal Clutch Cable Installation Clutch Cable Lubrication Clutch Lever Free Play — — — Clutch 2. Friction Plate Thickness 2.
Friction and Steel Plate Warp 0. Clutch Spring Free Length Torque - Clutch Spring Bolts: 8. Engine Oil Flow Chart Special Tools and Sealant Engine Oil and Oil Filter Oil Level Inspection Engine Oil Change Oil Filter Replacement Bypass Valve Disassembly Bypass Valve Assembly Engine Removal Engine Installation A: After installation, set the projection in the hole. When inserting the front engine mounting bolt, use the suitable stand under the engine to lift it.
Starter Motor Clutch Assembly.. Balancer Removal Crankshaft Main Bearing Insert Thickness: 1. CAUTION If the crankshaft, bearing inserts, or crankcase halves are replaced with new ones, select the bear- ing inserts and check clearance with a plastigage press gauge before assembling engine to be sure the correct bearing inserts are installed.
If the measurement exceeds the service limit, replace the crankshaft. If the measured journal diameters are not less than the service limit, but do not coincide with the original diameter markings [A] on the balancer shaft, make new marks on Balancer Shaft Journal Diameter Marks None: If it is loose, unscrew it, apply a non-permanent locking agent to the threads, and tighten it. Circlip, 29 mm 1. Ball Bearing 2. Circlip Drive Shaft 3. Thrust Washer, 30 mm 1.
Inside Diameter: Nut Washer 4. Toothed Washer, 30 mm 1. If the thickness of a shift fork ear is less than the service limit, the shift fork must be replaced. Radial TIR 0. TIR 0. Wheel Balance 10 g 0. Page 30 g 1. An imbalance of less than 10 grams 0. Page Tire Repair Also, permanent internal repairs have the advantage of permitting a thorough examination for secondary damage not visible from external inspection of the tire.
For these reasons, Kawasaki does not recommend temporary exter- nal repair. Only appropriate permanent internal repairs are recommended. Repair methods may vary slightly from make to make.
If any bear- ings are removed, they will need to be replaced with new ones. HO: Apply heavy oil. Turn the bearing around by hand a few times to make sure the grease is distributed uniformly inside the bearing. If they show any damage, replace the dust seals with new ones. Replace the caliper if the cylinder and piston are badly scores or rusty.
Removing the rear brake pad is the same as for the front brake pad. Brake Line Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action. Pump the brake lever until it becomes hard, and apply the brake and hold it [A]. Never reuse old brake fluid.
Do not use fluid from a container that has been left unsealed or that has been open for a long time. Holding the inner tube by hand in a vertical position, pull down the outer tube several times to pull out the inner tube. If there is visible damage, replace the sleeve with a new one. G: Apply grease.
If there is any damage to the frame, replace it. If the frame is bent, dented, cracked, or warped, replace it. Meter Unit 2. Ignition Switch 3. Starter Lockout Switch 4. Air Switching Valve 5. Stick Coils 6. Spark Plugs 7. Starter Relay 8. ECU Turn Signal Relay Fuse Box Learn and ob- serve all the rules below. This will burn out the diodes on the electrical parts.
If any wiring is poor, replace the damaged wiring. These names must be the same. Page Newly activated sealed batteries require an initial charge. Standard Charge: 0. When properly installed, the strip of the caps will be level with the top of the battery. Forcibly prying off the seal cap to add water is very dangerous. Never do that. Battery Terminal Voltage Standard: Page Charging System Apply silicone sealant to the crankshaft sensor lead grom- met and crankcase halves mating surface [A] on the front and rear sides of the cover mount.
Striking the rotor can cause the magnets to lose their magnetism. Alternator 2. Frame Ground 4. Main Fuse 30 A 5. Joint Connector 1 6. Load 7. Water-proof Joint 3 8. Ignition Switch 9. Do not touch the spark plugs or stick coils while the engine is running, or you could receive a severe electrical shock.
ECU Fuse 15 A Speed Sensor 2. Joint Connector 2 Oxygen Sensor Heater Sidestand Switch Fuse 10 A Battery 12 V 8 Ah Tapping the shaft or body could damage the motor. Torque - Starter Motor Through Bolts: 3. Special Tool - Hand Tester: If the relay does not work as specified, the relay is defec- tive. Starter Button 4.
Water-proof Joint 3 5. Neutral Switch 6. Sidestand Switch 8. Frame Ground The headlight does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on after the starter button is released and stays on until the ignition switch is turned off. Pull the bulb out to prevent damage to the bulb.
Do not use bulb rated for greater wattage then the specified value. High Beam Indicator 7. Headlight Fuse 10 A Light 12 V 3. Fuse Box 2. Ignition Switch Relay Box 7. ECU Main Relay 8. ECU Fuse 15 A 9. Fan Relay 9. The pointers cannot be reinstalled.
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