![Kawasaki Z1000 (2003) [493/515] Appendix 17 3](/img/pdf.png)
Kawasaki Z1000 (2003) [493/515] Appendix 17 3
![Kawasaki Z1000 (2003) [493/515] Appendix 17 3](/views2/1121167/page493/bg1ed.png)
APPENDIX 17-3
Cable, Wire, and Hose Routing
1. Fixes by the left side clamp of the tank.
2. Tank drain hose passes the side cover installation under the bracket.
3. Air cle
aner drain hose
4. Fuel tank drain hose
5. Cooling reserve tank hose
6. Fixes
by the swingarm clamp
7. Fuel level sensor
8. Fixes by the right side clamps two places of the tank.
9. The o
utside of the frame passed
10. Fuel level sensor lead
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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