![Kawasaki Z1000 (2003) [3/515] Quick reference guide](/img/pdf.png)
Kawasaki Z1000 (2003) [3/515] Quick reference guide
![Kawasaki Z1000 (2003) [3/515] Quick reference guide](/views2/1121167/page3/bg3.png)
This quick reference guide will assist
you in locating a desired topic or pro-
cedure.
•Bend the pages back to match the
black tab of the desired chapter num-
ber with the black tab on the edge at
each table of contents page.
•Refer to the sectional table of contents
for the exact pages to locate the spe-
cific topic required.
Quick Reference Guide
General Information 1
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Periodic Mainte nance 2
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Fuel System (DFI) 3
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Cooling System 4
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Engine Top End 5
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Clutch 6
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Engine Lubrication System 7
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Engine Removal/Installation 8
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Crankshaft/Transmission 9
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Wheels/Tires 10
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Final Drive 11
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Brakes 12
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Suspension 13
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Steering 14
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Frame 15
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Electrical System 16
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Appendix 17
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Содержание
- Quick reference guide 3
- Motorcycle service manual 5
- List of abbreviations 6
- Read owner s manual before operating 6
- Emission control information 7
- The phrase remove or render inoperative any device or element of design has been generally interpreted as follows 1 tampering does not include the temporary removal or rendering inoperative of de vices or elements of design in order to perform maintenance 2 tampering could include a maladjustment of vehicle components such that the emission standards are ex ceeded b use of replacement parts or accessories which adversely affect the performance or durability of the motorcycle c addition of components or accessories that result in the vehicle exceeding the stan dards d permanently removing disconnecting or rendering inoperative any component or element of design of the emission control systems 7
- Tampering with noise control system prohibited 8
- Foreword 9
- How to use this manual 9
- Warning 9
- This note symbol indicates points of par ticular interest for more efficient and con venient operation 10
- General information 11
- General information 1 1 11
- Table of contents 11
- 2 general information 12
- Battery ground 12
- Before servicing 12
- Cleaning vehicle before disassembly 12
- Edges of parts 12
- Solvent 12
- Arrangement and cleaning of removed parts 13
- Assembly order 13
- Before servicing 13
- General information 1 3 13
- Inspection 13
- Replacement parts 13
- Storage of removed parts 13
- 4 general information 14
- Before servicing 14
- Gasket oring 14
- Liquid gasket locking agent 14
- Tightening sequence 14
- Tightening torque 14
- Ball bearing and needle bearing 15
- Before servicing 15
- Circlips cotter pins 15
- General information 1 5 15
- Lubrication 15
- Oil seal grease seal 15
- 6 general information 16
- Before servicing 16
- Direction of engine rotation 16
- Electrical wires 16
- General information 1 7 17
- Model identification 17
- 8 general information 18
- General specifications 18
- General information 1 9 19
- General specifications 19
- 10 general information 20
- General specifications 20
- General information 1 11 21
- Technical information air inlet system 21
- 12 general information 22
- Technical information air inlet system 22
- Current ignition interlock sidestand system 23
- General information 1 13 23
- New ignition interlock sidestand system 23
- Technical information new ignition interlock sidestand 23
- 14 general information 24
- Technical information tail brake lights employing led 24
- Ga gallium as arsenic p phosphorus n nitrogen al aluminum 25
- General information 1 15 25
- Technical information tail brake lights employing led 25
- The emitting color differs according to the materials of semi conductors 25
- 16 general information 26
- Honeycomb type catalytic converter 26
- Technical information kleen kawasaki low exhaust emission system 26
- General information 1 17 27
- Prefixes for units 27
- Unit conversion table 27
- Units of force 27
- Units of length 27
- Units of mass 27
- Units of power 27
- Units of pressure 27
- Units of speed 27
- Units of torque 27
- Units of volume 27
- Periodic maintenance 29
- Periodic maintenance 2 1 29
- Table of contents 29
- 2 periodic maintenance 30
- Periodic maintenance chart 30
- Periodic maintenance 2 3 31
- Periodic maintenance chart 31
- 4 periodic maintenance 32
- Basic torque for general fasteners 32
- Torque and locking agent 32
- Periodic maintenance 2 5 33
- Torque and locking agent 33
- 6 periodic maintenance 34
- Torque and locking agent 34
- Periodic maintenance 2 7 35
- Torque and locking agent 35
- 8 periodic maintenance 36
- Torque and locking agent 36
- Periodic maintenance 2 9 37
- Specifications 37
- 10 periodic maintenance 38
- Specifications 38
- Periodic maintenance 2 11 39
- Special tools 39
- 12 periodic maintenance 40
- Fuel system dfi 40
- Periodic maintenance procedures 40
- Warning 40
- Periodic maintenance 2 13 41
- Periodic maintenance procedures 41
- Throttle control system inspection 41
- 14 periodic maintenance 42
- Periodic maintenance procedures 42
- Warning 42
- Periodic maintenance 2 15 43
- Periodic maintenance procedures 43
- 16 periodic maintenance 44
- Periodic maintenance procedures 44
- Periodic maintenance 2 17 45
- Periodic maintenance procedures 45
- 18 periodic maintenance 46
- Periodic maintenance procedures 46
- Periodic maintenance 2 19 47
- Periodic maintenance procedures 47
- Warning 47
- 20 periodic maintenance 48
- Periodic maintenance procedures 48
- Cooling system 49
- Periodic maintenance 2 21 49
- Periodic maintenance procedures 49
- Warning 49
- 22 periodic maintenance 50
- Periodic maintenance procedures 50
- Air suction valve inspection 51
- Caution 51
- Engine top end 51
- Periodic maintenance 2 23 51
- Periodic maintenance procedures 51
- 24 periodic maintenance 52
- Periodic maintenance procedures 52
- Periodic maintenance 2 25 53
- Periodic maintenance procedures 53
- 26 periodic maintenance 54
- Periodic maintenance procedures 54
- Valve clearance adjustment chart inlet valve 54
- Periodic maintenance 2 27 55
- Periodic maintenance procedures 55
- Valve clearance adjustment chart exhaust valve 55
- 28 periodic maintenance 56
- Clutch 56
- Periodic maintenance procedures 56
- Warning 56
- Engine lubrication system 57
- Periodic maintenance 2 29 57
- Periodic maintenance procedures 57
- 30 periodic maintenance 58
- Periodic maintenance procedures 58
- Warning 58
- Wheels tires 58
- Final drive 59
- Periodic maintenance 2 31 59
- Periodic maintenance procedures 59
- Warning 59
- 32 periodic maintenance 60
- Periodic maintenance procedures 60
- Warning 60
- Caution 61
- Drive chain lubrication 61
- Periodic maintenance 2 33 61
- Periodic maintenance procedures 61
- Warning 61
- 34 periodic maintenance 62
- Brake pad wear inspection 62
- Brakes 62
- Periodic maintenance procedures 62
- Rear brake light switch inspection adjustment 62
- Caliper dust seal friction boot damage 63
- Caliper fluid seal damage 63
- Caution 63
- Periodic maintenance 2 35 63
- Periodic maintenance procedures 63
- 36 periodic maintenance 64
- Master cylinder inspection visual inspection 64
- Periodic maintenance procedures 64
- Periodic maintenance 2 37 65
- Periodic maintenance procedures 65
- Warning 65
- 38 periodic maintenance 66
- Periodic maintenance procedures 66
- Periodic maintenance 2 39 67
- Periodic maintenance procedures 67
- Warning 67
- 40 periodic maintenance 68
- Periodic maintenance procedures 68
- Periodic maintenance 2 41 69
- Periodic maintenance procedures 69
- Warning 69
- 42 periodic maintenance 70
- Front fork oil leak check 70
- Periodic maintenance procedures 70
- Rear shock absorber oil leak check 70
- Suspension 70
- Swingarm pivot lubrication 70
- Uni trak linkage lubrication 70
- Periodic maintenance 2 43 71
- Periodic maintenance procedures 71
- Steering 71
- 44 periodic maintenance 72
- Electrical system 72
- Periodic maintenance procedures 72
- Periodic maintenance 2 45 73
- Periodic maintenance procedures 73
- 46 periodic maintenance 74
- Periodic maintenance procedures 74
- General lubrication 75
- Periodic maintenance 2 47 75
- Periodic maintenance procedures 75
- 48 periodic maintenance 76
- Nut bolt and fastener tightness 76
- Periodic maintenance procedures 76
- Fuel system dfi 77
- Fuel system dfi 3 1 77
- Table of contents 77
- 2 fuel system dfi 78
- Clifornia evaporative emission control system 79
- Exploded view 79
- Fuel system dfi 3 3 79
- Exploded view 81
- Fuel system dfi 3 5 81
- Exploded view 83
- Fuel system dfi 3 7 83
- 8 fuel system dfi 84
- Dfi parts location 84
- Dfi wiring diagram 87
- Fuel system dfi 3 11 87
- 12 fuel system dfi 88
- Specifications 88
- Fuel system dfi 3 13 89
- Specifications 89
- 14 fuel system dfi 90
- Special tools 90
- Dfi servicing precautions 91
- Fuel system dfi 3 15 91
- 16 fuel system dfi 92
- Dfi servicing precautions 92
- Fuel system dfi 3 17 93
- Outline 93
- Troubleshooting the dfi system 93
- 18 fuel system dfi 94
- Troubleshooting the dfi system 94
- Fuel system dfi 3 19 95
- Troubleshooting the dfi system 95
- 20 fuel system dfi 96
- Troubleshooting the dfi system 96
- Dfi diagnosis flow chart 97
- Fuel system dfi 3 21 97
- Inquiries to rider 97
- Troubleshooting the dfi system 97
- 22 fuel system dfi 98
- Sample diagnosis sheet 98
- Troubleshooting the dfi system 98
- Fuel system dfi 3 23 99
- Troubleshooting the dfi system 99
- 24 fuel system dfi 100
- Dfi system troubleshooting guide 100
- Engine doesn t start starting difficulty 100
- Dfi system troubleshooting guide 101
- Fuel system dfi 3 25 101
- 26 fuel system dfi 102
- Dfi system troubleshooting guide 102
- Poor running at low speed 102
- Dfi system troubleshooting guide 103
- Fuel system dfi 3 27 103
- 28 fuel system dfi 104
- Dfi system troubleshooting guide 104
- Dfi system troubleshooting guide 105
- Fuel system dfi 3 29 105
- 30 fuel system dfi 106
- Dfi system troubleshooting guide 106
- Poor running or no power at high speed 106
- Dfi system troubleshooting guide 107
- Fuel system dfi 3 31 107
- 32 fuel system dfi 108
- Dfi system troubleshooting guide 108
- Fuel system dfi 3 33 109
- Self diagnosis 109
- Self diagnosis outline 109
- Self diagnosis procedures 109
- 34 fuel system dfi 110
- Self diagnosis 110
- Service code clearing procedures 110
- 36 fuel system dfi 112
- How to erase service codes 112
- How to read service codes 112
- Self diagnosis 112
- Fuel system dfi 3 37 113
- Self diagnosis 113
- Service code table 113
- 38 fuel system dfi 114
- Backups 114
- Self diagnosis 114
- Fuel system dfi 3 39 115
- Self diagnosis 115
- 40 fuel system dfi 116
- Main throttle sensor service code 11 116
- Fuel system dfi 3 41 117
- Main throttle sensor service code 11 117
- Output voltage inspection 117
- 42 fuel system dfi 118
- Main throttle sensor service code 11 118
- Resistance inspection 118
- Fuel system dfi 3 43 119
- Inlet air pressure sensor service code 12 119
- 44 fuel system dfi 120
- Inlet air pressure sensor service code 12 120
- Fuel system dfi 3 45 121
- Inlet air pressure sensor service code 12 121
- 46 fuel system dfi 122
- Inlet air pressure sensor service code 12 122
- Fuel system dfi 3 47 123
- Inlet air pressure sensor service code 12 123
- Pv 55 86 cmhg 123
- 48 fuel system dfi 124
- Inlet air temperature sensor service code 13 124
- Fuel system dfi 3 49 125
- Inlet air temperature sensor service code 13 125
- 50 fuel system dfi 126
- Water temperature sensor service code 14 126
- Fuel system dfi 3 51 127
- Sensor resistance inspection 127
- Water temperature sensor service code 14 127
- 52 fuel system dfi 128
- Atmospheric pressure sensor service code 15 128
- Atmospheric pressure sensor service code 15 129
- Fuel system dfi 3 53 129
- 54 fuel system dfi 130
- Atmospheric pressure sensor service code 15 130
- Crankshaft sensor service code 21 131
- Fuel system dfi 3 55 131
- 56 fuel system dfi 132
- Camshaft position sensor service code 23 132
- Fuel system dfi 3 57 133
- Speed sensor service code 24 25 133
- 58 fuel system dfi 134
- Speed sensor service code 24 25 134
- Fuel system dfi 3 59 135
- Vehicle down sensor service code 31 135
- Warning 135
- 60 fuel system dfi 136
- Vehicle down sensor service code 31 136
- Fuel system dfi 3 61 137
- Vehicle down sensor service code 31 137
- 62 fuel system dfi 138
- Subthrottle sensor service code 32 138
- Fuel system dfi 3 63 139
- Output voltage inspection 139
- Subthrottle sensor service code 32 139
- 64 fuel system dfi 140
- Resistance inspection 140
- Subthrottle sensor service code 32 140
- Fuel system dfi 3 65 141
- Stick coils 1 2 3 4 service code 51 52 53 54 141
- 66 fuel system dfi 142
- Stick coils 1 2 3 4 service code 51 52 53 54 142
- Fuel system dfi 3 67 143
- Subthrottle valve actuator service code 62 143
- 68 fuel system dfi 144
- Subthrottle valve actuator service code 62 144
- 70 fuel system dfi 146
- Fi indicator led light 146
- Led light inspection 146
- Fuel system dfi 3 71 147
- 72 fuel system dfi 148
- Ecu power supply inspection 148
- Fuel system dfi 3 73 149
- 74 fuel system dfi 150
- Caution 150
- Dfi power source 150
- Ecu fuse inspection 150
- Ecu fuse installation 150
- Ecu fuse removal 150
- Ecu main relay inspection 150
- Ecu main relay removal 150
- Fuel line 151
- Fuel system dfi 3 75 151
- Warning 151
- 76 fuel system dfi 152
- Fuel line 152
- Warning 152
- Fuel line 153
- Fuel system dfi 3 77 153
- Warning 153
- 78 fuel system dfi 154
- Fuel pump 154
- Warning 154
- Fuel pump 155
- Fuel system dfi 3 79 155
- 80 fuel system dfi 156
- Fuel pump 156
- Caution 157
- Fuel pump 157
- Fuel pump relay inspection 157
- Fuel pump relay removal 157
- Fuel system dfi 3 81 157
- 82 fuel system dfi 158
- Fuel injectors 158
- Fuel injectors 159
- Fuel system dfi 3 83 159
- Output voltage inspection 159
- 84 fuel system dfi 160
- Fuel injectors 160
- Caution 161
- Fuel injectors 161
- Fuel system dfi 3 85 161
- Injector fuel line inspection 161
- Injector resistance inspection 161
- Injector unit test 161
- 86 fuel system dfi 162
- Fuel injectors 162
- Fuel injectors 163
- Fuel system dfi 3 87 163
- 88 fuel system dfi 164
- Throttle grip and cables 164
- Engine vacuum synchronization inspection adjustment 165
- Fuel system dfi 3 89 165
- High altitude performance adjustment 165
- Idle speed inspection adjustment 165
- Throttle body assy 165
- Throttle body assy removal 165
- Throttle bore cleaning 165
- Warning 165
- 90 fuel system dfi 166
- Throttle body assy 166
- Caution 167
- Fuel system dfi 3 91 167
- Throttle body assy 167
- Throttle body assy installation 167
- Warning 167
- 92 fuel system dfi 168
- Caution 168
- Throttle body assy 168
- Throttle body assy disassembly 168
- Warning 168
- Fuel system dfi 3 93 169
- Throttle body assy 169
- 94 fuel system dfi 170
- Air cleaner 170
- Warning 170
- Fuel system dfi 3 95 171
- Fuel tank 171
- Warning 171
- 96 fuel system dfi 172
- Fuel tank 172
- Warning 172
- Fuel system dfi 3 97 173
- Fuel tank 173
- Warning 173
- 98 fuel system dfi 174
- Caution 174
- Fuel tank 174
- Fuel tank and cap inspection 174
- Fuel tank cleaning 174
- Warning 174
- Canister installation 175
- Caution 175
- Evaporative emission control system 175
- Fuel system dfi 3 99 175
- Hose inspection 175
- Parts removal installation 175
- Separator inspection 175
- Warning 175
- 100 fuel system dfi 176
- Evaporative emission control system 176
- Separator operation test 176
- Warning 176
- Cooling system 177
- Cooling system 4 1 177
- Table of contents 177
- Cooling system 4 3 179
- Exploded view 179
- Coolant flow chart 181
- Cooling system 4 5 181
- 6 cooling system 182
- Specifications 182
- Cooling system 4 7 183
- Special tool 183
- 8 cooling system 184
- Coolant 184
- Coolant 185
- Cooling system 4 9 185
- 10 cooling system 186
- Mechanical seal replacement 186
- Water pump 186
- Water pump inspection 186
- Water pump installation 186
- Water pump removal 186
- Cooling system 4 11 187
- Water pump 187
- 12 cooling system 188
- Caution 188
- Radiator 188
- Radiator removal 188
- Warning 188
- Caution 189
- Cooling system 4 13 189
- Radiator 189
- Radiator cap inspection 189
- Radiator inspection 189
- 14 cooling system 190
- Radiator 190
- Cooling system 4 15 191
- Thermostat 191
- Thermostat inspection 191
- Thermostat installation 191
- Thermostat removal 191
- 16 cooling system 192
- Thermostat 192
- Cooling system 4 17 193
- Hose and pipes 193
- 18 cooling system 194
- Caution 194
- Radiator fan switch inspection 194
- Radiator fan switch installation 194
- Radiator fan switch removal 194
- Radiator fan switch water temperature sensor 194
- Water temperature sensor inspection 194
- Water temperature sensor removal 194
- Engine top end 195
- Engine top end 5 1 195
- Table of contents 195
- Engine top end 5 3 197
- Exploded view 197
- Engine top end 5 5 199
- Exhaust system 199
- Exploded view 199
- 6 engine top end 200
- Specifications 200
- Engine top end 5 7 201
- Specifications 201
- 8 engine top end 202
- Special tools and sealant 202
- Engine top end 5 9 203
- Special tools and sealant 203
- 10 engine top end 204
- Air suction valve inspection 204
- Air suction valve installation 204
- Air suction valve removal 204
- Clean air system 204
- Vacuum switch valve installation 204
- Vacuum switch valve removal 204
- Clean air system 205
- Engine top end 5 11 205
- 12 engine top end 206
- Cylinder head cover 206
- Cylinder head cover installation 206
- Cylinder head cover removal 206
- Cylinder head cover 207
- Engine top end 5 13 207
- 14 engine top end 208
- Camshaft chain tensioner 208
- Camshaft chain tensioner installation 208
- Camshaft chain tensioner removal 208
- Caution 208
- Camshaft camshaft chain 209
- Camshaft installation 209
- Camshaft removal 209
- Caution 209
- Engine top end 5 15 209
- 16 engine top end 210
- Camshaft camshaft chain 210
- Camshaft camshaft chain 211
- Engine top end 5 17 211
- 18 engine top end 212
- Camshaft camshaft chain 212
- Camshaft chain removal 212
- Cylinder head 213
- Engine top end 5 19 213
- 20 engine top end 214
- Cylinder head 214
- Cylinder head 215
- Cylinder head warp 215
- Engine top end 5 21 215
- 22 engine top end 216
- Valves 216
- Engine top end 5 23 217
- Valves 217
- 24 engine top end 218
- Valves 218
- Engine top end 5 25 219
- Valves 219
- 26 engine top end 220
- Valves 220
- Engine top end 5 27 221
- Valves 221
- Cylinder pistons 223
- Engine top end 5 29 223
- 30 engine top end 224
- Cylinder pistons 224
- Cylinder pistons 225
- Engine top end 5 31 225
- 32 engine top end 226
- Cylinder pistons 226
- Engine top end 5 33 227
- Throttle body holder 227
- Throttle body holder installation 227
- 34 engine top end 228
- Muffler 228
- Warning 228
- Engine top end 5 35 229
- Muffler 229
- Clutch 231
- Clutch 6 1 231
- Table of contents 231
- Clutch 6 3 233
- Exploded view 233
- 4 clutch 234
- Specifications 234
- Clutch 6 5 235
- Special tools and sealant 235
- 6 clutch 236
- Cable installation 236
- Cable lubrication 236
- Cable removal 236
- Clutch lever and cable 236
- Clutch lever free play adjustment 236
- Clutch lever free play inspection 236
- Clutch lever installation 236
- Caution 237
- Clutch 6 7 237
- Clutch cover 237
- Clutch cover installation 237
- Clutch cover removal 237
- Release shaft installation 237
- Release shaft removal 237
- 8 clutch 238
- Clutch cover 238
- Clutch 239
- Clutch 6 9 239
- 10 clutch 240
- Clutch 240
- Clutch 241
- Clutch 6 11 241
- 12 clutch 242
- Clutch 242
- Engine lubrication system 243
- Engine lubrication system 7 1 243
- Table of contents 243
- Engine lubrication system 7 3 245
- Exploded view 245
- Engine lubrication system 7 5 247
- Engine oil flow chart 247
- 6 engine lubrication system 248
- Specifications 248
- Engine lubrication system 7 7 249
- Special tools and sealant 249
- 8 engine lubrication system 250
- Engine oil and oil filter 250
- Warning 250
- Engine lubrication system 7 9 251
- Oil pan 251
- 10 engine lubrication system 252
- Oil pressure relief valve 252
- Warning 252
- Engine lubrication system 7 11 253
- Oil pump 253
- 12 engine lubrication system 254
- Oil pump 254
- Engine lubrication system 7 13 255
- Oil pump 255
- Oil pump drive gear installation 255
- Oil pump drive gear removal 255
- 14 engine lubrication system 256
- Oil cooler 256
- Oil cooler installation 256
- Oil cooler removal 256
- Engine lubrication system 7 15 257
- Oil pressure measurement 257
- Warning 257
- 16 engine lubrication system 258
- Oil pressure switch 258
- Oil pressure switch installation 258
- Oil pressure switch removal 258
- Engine removal installation 259
- Engine removal installation 8 1 259
- Table of contents 259
- Engine removal installation 8 3 261
- Exploded view 261
- 4 engine removal installation 262
- Special tools 262
- Caution 263
- Engine removal 263
- Engine removal installation 263
- Engine removal installation 8 5 263
- Warning 263
- 6 engine removal installation 264
- Engine removal installation 264
- Engine removal installation 265
- Engine removal installation 8 7 265
- 8 engine removal installation 266
- Engine removal installation 266
- Engine removal installation 267
- Engine removal installation 8 9 267
- 10 engine removal installation 268
- Engine removal installation 268
- Engine removal installation 269
- Engine removal installation 8 11 269
- Crankshaft transmission 271
- Crankshaft transmission 9 1 271
- Table of contents 271
- Crankshaft transmission 9 3 273
- Exploded view 273
- Crankshaft transmission 9 5 275
- Exploded view 275
- 6 crankshaft transmission 276
- Specifications 276
- Crankshaft transmission 9 7 277
- Specifications 277
- 8 crankshaft transmission 278
- Special tools and sealant 278
- Crankcase splitting 279
- Crankshaft transmission 9 9 279
- 10 crankshaft transmission 280
- Crankcase splitting 280
- Crankcase splitting 281
- Crankshaft transmission 9 11 281
- 12 crankshaft transmission 282
- Crankshaft and connecting rods 282
- Crankshaft and connecting rods 283
- Crankshaft transmission 9 13 283
- 14 crankshaft transmission 284
- Caution 284
- Crankshaft and connecting rods 284
- Warning 284
- Crankshaft and connecting rods 285
- Crankshaft transmission 9 15 285
- Warning 285
- 16 crankshaft transmission 286
- Crankshaft and connecting rods 286
- Crankshaft and connecting rods 287
- Crankshaft transmission 9 17 287
- 18 crankshaft transmission 288
- Crankshaft and connecting rods 288
- Crankshaft and connecting rods 289
- Crankshaft transmission 9 19 289
- 20 crankshaft transmission 290
- Crankshaft and connecting rods 290
- Crankshaft transmission 9 21 291
- Starter motor clutch 291
- 22 crankshaft transmission 292
- Shift pedal installation 292
- Shift pedal removal 292
- Transmission 292
- Crankshaft transmission 9 23 293
- Transmission 293
- 24 crankshaft transmission 294
- External shift mechanism inspection 294
- External shift mechanism installation 294
- Transmission 294
- Crankshaft transmission 9 25 295
- Transmission 295
- 26 crankshaft transmission 296
- Transmission 296
- Crankshaft transmission 9 27 297
- Transmission 297
- 28 crankshaft transmission 298
- Shift drum and fork removal 298
- Transmission 298
- Crankshaft transmission 9 29 299
- Transmission 299
- 30 crankshaft transmission 300
- Gear dog and gear dog hole damage 300
- Shift fork gear groove wear 300
- Shift fork guide pin drum groove wear 300
- Transmission 300
- Table of contents 301
- Wheels tires 301
- Wheels tires 10 1 301
- Exploded view 303
- Wheels tires 10 3 303
- 4 wheels tires 304
- Specifications 304
- Warning 304
- Special tools 305
- Wheels tires 10 5 305
- 6 wheels tires 306
- Wheels rims 306
- Warning 307
- Wheels rims 307
- Wheels tires 10 7 307
- 8 wheels tires 308
- Wheels rims 308
- Warning 309
- Wheel inspection 309
- Wheels rims 309
- Wheels tires 10 9 309
- 10 wheels tires 310
- Wheels rims 310
- Warning 311
- Wheels rims 311
- Wheels tires 10 11 311
- 12 wheels tires 312
- Wheels rims 312
- Warning 313
- Wheels tires 10 13 313
- 14 wheels tires 314
- Warning 314
- Wheels tires 10 15 315
- 16 wheels tires 316
- Hub bearing 316
- Final drive 317
- Final drive 11 1 317
- Table of contents 317
- Exploded view 319
- Final drive 11 3 319
- 4 final drive 320
- Specifications 320
- Final drive 11 5 321
- Special tools 321
- 6 final drive 322
- Drive chain 322
- Drive chain installation 322
- Drive chain lubrication 322
- Drive chain removal 322
- Drive chain replacement 322
- Drive chain slack adjustment 322
- Drive chain slack inspection 322
- Drive chain wear inspection 322
- Wheel alignment inspection adjustment 322
- Drive chain 323
- Final drive 11 7 323
- 8 final drive 324
- Drive chain 324
- Drive chain 325
- Final drive 11 9 325
- 10 final drive 326
- Sprocket coupling 326
- Caution 327
- Coupling bearing installation 327
- Coupling bearing removal 327
- Final drive 11 11 327
- Rear sprocket installation 327
- Rear sprocket removal 327
- Sprocket coupling 327
- 12 final drive 328
- Sprocket coupling 328
- Final drive 11 13 329
- Sprocket coupling 329
- Brakes 331
- Brakes 12 1 331
- Table of contents 331
- Brakes 12 3 333
- Exploded view 333
- Brakes 12 5 335
- Exploded view 335
- 6 brakes 336
- Specifications 336
- Brakes 12 7 337
- Special tool 337
- 8 brakes 338
- Brake lever brake pedal 338
- Brakes 12 9 339
- Calipers 339
- 10 brakes 340
- Calipers 340
- Warning 340
- Brakes 12 11 341
- Calipers 341
- Warning 341
- 12 brakes 342
- Calipers 342
- Warning 342
- Brakes 12 13 343
- Calipers 343
- 14 brakes 344
- Caliper holder shaft wear 344
- Caliper piston and cylinder damage 344
- Calipers 344
- Brake pads 345
- Brakes 12 15 345
- Front brake pad installation 345
- Front brake pad removal 345
- Rear brake pad removal 345
- Warning 345
- 16 brakes 346
- Brake pad wear inspection 346
- Brake pads 346
- Rear brake pad installation 346
- Warning 346
- Brakes 12 17 347
- Front master cylinder installation 347
- Front master cylinder removal 347
- Master cylinder 347
- 18 brakes 348
- Master cylinder 348
- Brakes 12 19 349
- Master cylinder 349
- 20 brakes 350
- Brake disc 350
- Brake fluid 351
- Brake fluid change 351
- Brake fluid level inspection 351
- Brake line bleeding 351
- Brakes 12 21 351
- 22 brakes 352
- Brake hose 352
- Brake hose inspection 352
- Brake hose removal installation 352
- Caution 352
- Suspension 353
- Suspension 13 1 353
- Table of contents 353
- Exploded view 355
- Suspension 13 3 355
- Exploded view 357
- Suspension 13 5 357
- 6 suspension 358
- Specifications 358
- Special tools 359
- Suspension 13 7 359
- 8 suspension 360
- Front fork 360
- Warning 360
- Front fork 361
- Suspension 13 9 361
- 10 suspension 362
- Front fork 362
- Front fork 363
- Suspension 13 11 363
- 12 suspension 364
- Front fork 364
- Front fork 365
- Suspension 13 13 365
- 14 suspension 366
- Front fork 366
- Caution 367
- Dust seal inspection 367
- Front fork 367
- Inner tube outer tube inspection 367
- Suspension 13 15 367
- Warning 367
- 16 suspension 368
- Front fork 368
- Spring tension 368
- Rear shock absorber 369
- Suspension 13 17 369
- 18 suspension 370
- Rear shock absorber 370
- Rear shock absorber removal 370
- Warning 370
- Rear shock absorber 371
- Rear shock absorber inspection 371
- Rear shock absorber installation 371
- Rear shock absorber scrapping 371
- Suspension 13 19 371
- Warning 371
- 20 suspension 372
- Swingarm 372
- Swingarm removal 372
- Suspension 13 21 373
- Swingarm 373
- 22 suspension 374
- Swingarm 374
- Rocker arm removal 375
- Suspension 13 23 375
- Tie rod installation 375
- Tie rod removal 375
- Tie rod rocker arm 375
- 24 suspension 376
- Rocker arm installation 376
- Rocker arm tie rod bearing sleeve inspection 376
- Tie rod rocker arm 376
- Unit track linkage lubrication 376
- Steering 377
- Steering 14 1 377
- Table of contents 377
- Exploded view 379
- Steering 14 3 379
- 4 steering 380
- Special tools 380
- Steering 381
- Steering 14 5 381
- Steering adjustment 381
- Steering inspection 381
- 6 steering 382
- Steering stem 382
- Stem stem bearing removal 382
- Steering 14 7 383
- Steering stem 383
- 8 steering 384
- Steering stem 384
- Steering 14 9 385
- Steering stem 385
- Warning 385
- 10 steering 386
- Handlebar 386
- Handlebar installation 386
- Handlebar removal 386
- Caution 387
- Handlebar 387
- Rear view mirrors installation 387
- Rear view mirrors removal 387
- Steering 14 11 387
- Frame 15 1 389
- Table of contents 389
- Exploded view 391
- Frame 15 3 391
- Exploded view 393
- Frame 15 5 393
- Frame 15 7 395
- Warning 395
- 8 frame 396
- Side cover installation 396
- Side cover removal 396
- Side covers 396
- Fairing removal 397
- Fairings 397
- Frame 15 9 397
- Inner cover installation 397
- Inner cover removal 397
- Windshield installation 397
- Windshield removal 397
- 10 frame 398
- Fairing installation 398
- Fairings 398
- Faring bracket removal 398
- Frame 15 11 399
- Seat cover installation 399
- Seat cover removal 399
- Seat covers 399
- 12 frame 400
- Mud guard 400
- Mud guard installation 400
- Mud guard removal 400
- Fenders 401
- Frame 15 13 401
- Front fender installation 401
- Front fender removal 401
- Rear fender rear removal 401
- 14 frame 402
- Fenders 402
- Rear fender rear installation 402
- Frame 15 15 403
- Frame cover 403
- Frame cover removal 403
- 16 frame 404
- Battery case 404
- Battery case installation 404
- Battery case removal 404
- Frame 15 17 405
- Side stand 405
- 18 frame 406
- Warning 406
- Electrical system 407
- Electrical system 16 1 407
- Table of contents 407
- 2 electrical system 408
- Electrical system 16 3 409
- Parts location 409
- Electrical system 16 5 411
- Exploded view 411
- Electrical system 16 7 413
- Exploded view 413
- Electrical system 16 9 415
- Exploded view 415
- 10 electrical system 416
- Specifications 416
- Electrical system 16 11 417
- Special tools and sealant 417
- 20 electrical system 426
- Precautions 426
- 22 electrical system 428
- Electrical wiring 428
- Battery 429
- Battery installation 429
- Battery removal 429
- Caution 429
- Electrical system 16 23 429
- Electrolyte filling 429
- 24 electrical system 430
- Battery 430
- Battery 431
- Electrical system 16 25 431
- 26 electrical system 432
- Battery 432
- Caution 432
- Precautions 432
- Warning 432
- Battery 433
- Electrical system 16 27 433
- Warning 433
- 28 electrical system 434
- Battery 434
- Charging system 435
- Electrical system 16 29 435
- 30 electrical system 436
- Charging system 436
- Charging system 437
- Electrical system 16 31 437
- 32 electrical system 438
- Charging system 438
- Charging system 439
- Electrical system 16 33 439
- 34 electrical system 440
- Charging system 440
- Charging system 441
- Charging voltage inspection 441
- Electrical system 16 35 441
- 36 electrical system 442
- Charging system 442
- Charging system circuit 442
- Caution 443
- Crankshaft sensor removal 443
- Electrical system 16 37 443
- Ignition system 443
- Warning 443
- 38 electrical system 444
- Ignition system 444
- Electrical system 16 39 445
- Ignition system 445
- 40 electrical system 446
- Ignition system 446
- Electrical system 16 41 447
- Ignition system 447
- 42 electrical system 448
- Ignition system 448
- Electrical system 16 43 449
- Ignition system 449
- 44 electrical system 450
- Ignition system 450
- Spark plug cleaning and inspection 450
- Spark plug gap inspection 450
- Spark plug installation 450
- Spark plug removal 450
- Warning 450
- Electrical system 16 45 451
- Ignition system 451
- 46 electrical system 452
- Ignition system 452
- 48 electrical system 454
- Ignition system 454
- Ignition system circuit 454
- Caution 455
- Electric starter system 455
- Electrical system 16 49 455
- Starter motor disassembly 455
- Starter motor installation 455
- Starter motor removal 455
- 50 electrical system 456
- Electric starter system 456
- Armature inspection 457
- Brush inspection 457
- Commutator cleaning and inspection 457
- Electric starter system 457
- Electrical system 16 51 457
- 52 electrical system 458
- Electric starter system 458
- Electric starter circuit 459
- Electric starter system 459
- Electrical system 16 53 459
- 54 electrical system 460
- Lighting system 460
- Electrical system 16 55 461
- Lighting system 461
- 56 electrical system 462
- Lighting system 462
- Caution 463
- Electrical system 16 57 463
- Lighting system 463
- 58 electrical system 464
- Headlight tail light circuit other than us ca as 464
- Headlight tail light circuit us ca as 464
- Lighting system 464
- Electrical system 16 59 465
- Lighting system 465
- Turn signal light bulb replacement 465
- Turn signal light circuit 465
- 60 electrical system 466
- Lighting system 466
- Caution 467
- Electrical system 16 61 467
- Lighting system 467
- Tail brake light led removal 467
- Turn signal relay inspection 467
- 62 electrical system 468
- Lighting system 468
- Electrical system 16 63 469
- Radiator fan system 469
- 64 electrical system 470
- Radiator fan circuit 470
- Radiator fan system 470
- Caution 471
- Electrical system 16 65 471
- Meter gauge disassembly 471
- Meter gauge indicator unit 471
- Meter unit removal 471
- 66 electrical system 472
- Meter gauge indicator unit 472
- Electrical system 16 67 473
- Meter gauge indicator unit 473
- 68 electrical system 474
- Meter gauge indicator unit 474
- Electrical system 16 69 475
- Meter gauge indicator unit 475
- 70 electrical system 476
- Check that the number of segments matches the resis tance value of the variable rheostat 476
- Connect the 12 v battery and terminals in the same man ner as specified in the liquid crystal display lcd seg ments check 476
- Connect the variable rheostat a to the terminal 8 as shown 476
- If any display function does not work replace the meter unit 476
- Meter gauge indicator unit 476
- Water temperature meter check 476
- Electrical system 16 71 477
- Meter gauge indicator unit 477
- 72 electrical system 478
- Meter gauge indicator unit 478
- Electrical system 16 73 479
- Meter gauge indicator unit 479
- 74 electrical system 480
- Meter circuit 480
- Meter gauge indicator unit 480
- Electrical system 16 75 481
- Switches and sensors 481
- 76 electrical system 482
- Switches and sensors 482
- Electrical system 16 77 483
- Switches and sensors 483
- 78 electrical system 484
- Switches and sensors 484
- Electrical system 16 79 485
- Fuel level sensor inspection 485
- Fuel reserve switch inspection 485
- Switches and sensors 485
- 80 electrical system 486
- Switches and sensors 486
- Electrical system 16 81 487
- Junction box 487
- 82 electrical system 488
- Junction box 488
- Electrical system 16 83 489
- Junction box 489
- 84 electrical system 490
- A ecu fuse removal 490
- A main fuse removal 490
- Caution 490
- Fuse inspection 490
- Fuse installation 490
- Junction box fuse removal 490
- Appendix 491
- Appendix 17 1 491
- Table of contents 491
- Appendix 17 3 493
- Cable wire and hose routing 493
- Appendix 17 5 495
- Cable wire and hose routing 495
- Appendix 17 7 497
- Cable wire and hose routing 497
- Appendix 17 9 499
- Cable wire and hose routing 499
- Appendix 17 11 501
- Cable wire and hose routing 501
- Appendix 17 13 503
- Cable wire and hose routing 503
- Appendix 17 15 505
- Cable wire and hose routing 505
- Appendix 17 17 507
- Cable wire and hose routing 507
- Appendix 17 19 509
- Cable wire and hose routing 509
- 20 appendix 510
- Engine doesn t start starting difficulty 510
- Poor running at low speed 510
- Troubleshooting guide 510
- Appendix 17 21 511
- Overheating 511
- Poor running or no power at high speed 511
- Troubleshooting guide 511
- 22 appendix 512
- Clutch operation faulty 512
- Gear shifting faulty 512
- Over cooling 512
- Troubleshooting guide 512
- Abnormal drive train noise 513
- Abnormal engine noise 513
- Abnormal frame noise 513
- Appendix 17 23 513
- Exhaust smokes excessively 513
- Oil pressure warning light goes on 513
- Troubleshooting guide 513
- 24 appendix 514
- Battery trouble 514
- Brake doesn t hold 514
- Handling and or stability unsatisfactory 514
- Troubleshooting guide 514
- Model application 515
- Part no 9924 1310 03 515
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