Quick Links. Table of Contents. Page 5 All rights reserved. Use proper tools and genuine Kawasaki Vehi- cle parts.
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Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly. SlideShare Explore Search You. Submit Search. Successfully reported this slideshow. We use your LinkedIn profile and activity data to personalize ads and to show you more relevant ads.
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Embeds 0 No embeds. No notes for slide. Part No. This quick reference guide will assist you in locating a desired topic or pro- cedure. No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your dealer for the latest information on product improvements incorporated after this publication.
All information contained in this publication is based on the latest product information available at the time of publication.
Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. Crankcase Emission Control System A sealed-type crankcase emission control system is used to eliminate blow-by gases. The blow-by gases are led to the breather chamber through the crankcase. Then, it is led to the air cleaner. Oil is separated from the gases while passing through the inside of the breather chamber from the crankcase, and then returned back to the bottom of crankcase.
A maintenance free ignition system provides the most favorable ignition timing and helps maintain a thorough combustion process within the engine which contributes to a reduction of exhaust pollutants entering the atmosphere. Evaporative Emission Control System The evaporative emission control system for this vehicle consists of low permeation fuel hoses and a fuel tank. Tampering does not include the temporary removal or rendering inoperative of de- vices or elements of design in order to perform maintenance.
Tampering could include: a. Maladjustment of vehicle components such that the emission standards are ex- ceeded. Use of replacement parts or accessories which adversely affect the performance or durability of the vehicle. Addition of components or accessories that result in the vehicle exceeding the stan- dards.
Permanently removing, disconnecting, or rendering inoperative any component or element of design of the emission control systems. Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic in- formation to make it useful to the owner who de- sires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop proce- dures must be understood in order to carry out maintenance and repair satisfactorily.
When- ever the owner has insufficient experience or doubts his ability to do the work, all adjust- ments, maintenance, and repair should be car- ried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thor- oughly familiarize yourself with the procedures before starting work, and then do the work care- fully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment.
Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may ad- versely affect safe operation. For the duration of the warranty period, we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual.
Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty. Special tools, gauges, and testers that are necessary when servicing Kawasaki vehicles are introduced by the Service Man- ual. Genuine parts provided as spare parts are listed in the Parts Catalog.
Each chapter in turn has its own comprehensive Ta- ble of Contents. For example, if you want ignition coil informa- tion, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chap- ter to find the Ignition Coil section.
Whenever you see symbols, heed their in- structions! Always follow safe operating and maintenance practices. This manual contains four more symbols which will help you distinguish different types of information. It also precedes the text of a NOTE.
Indicates a conditional step or what action to take based on the results of the test or inspec- tion in the procedural step or sub-step it fol- lows. In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require spec- ified tightening torque, oil, grease or a locking agent during assembly. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary.
This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts. Especially note the following: Battery Ground Before completing any service on the vehicle, disconnect the battery cables from the battery to prevent the engine from accidentally turning over.
Edges of Parts Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts. Solvent Use a high-flush point solvent when cleaning parts. High -flush point solvent should be used according to directions of the solvent manufacturer. Cleaning vehicle before disassembly Clean the vehicle thoroughly before disassembly. Dirt or other foreign materials entering into sealed areas during ve- hicle disassembly can cause excessive wear and decrease performance of the vehicle.
Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly. Storage of Removed Parts After all the parts including subassembly parts have been cleaned, store the parts in a clean area.
Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly. Inspection Reuse of worn or damaged parts may lead to serious ac- cident. Visually inspect removed parts for corrosion, discol- oration, or other damage. Refer to the appropriate sections of this manual for service limits on individual parts. Replace the parts if any damage has been found or if the part is be- yond its service limit.
Gaskets, O-rings, Oil seals, Grease seals, circlips, cotter pins or self-locking nuts must be replaced with new ones whenever disassembled. Assembly Order In most cases assembly order is the reverse of disassem- bly, however, if assembly order is provided in this Service Manual, follow the procedures given. Then tighten them according to the specified se- quence to prevent case warpage or deformation which can lead to malfunction.
Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quar- ter turn and then remove them.
If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally. Tightening Torque Incorrect torque applied to a bolt, nut, or screw may lead to serious damage.
Tighten fasteners to the specified torque using a good quality torque wrench. Often, the tightening sequence is followed twice initial tightening and final tightening with torque wrench. Force Use common sense during disassembly and assembly, excessive force can cause expensive or hard to repair dam- age.
When necessary, remove screws that have a non -permanent locking agent applied using an impact driver. Use a plastic-faced mallet whenever tapping is necessary. Gasket, O-ring Hardening, shrinkage, or damage of both gaskets and O-rings after disassembly can reduce sealing per- formance. Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains.
Install new gaskets and replace used O-rings when re-assembling. Liquid Gasket, Locking Agent For applications that require Liquid Gasket or a Non-Permanent Locking agent, clean the surfaces so that no oil residue remains before applying liquid gasket or non-permanent locking agent.
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