![Kawasaki VULCAN 2000 (2003) [275/633] Clutch](/img/pdf.png)
Kawasaki VULCAN 2000 (2003) [275/633] Clutch
![Kawasaki VN2000 (2003) [275/633] Clutch](/views2/1121171/page275/bg113.png)
CLUTCH 6-1
6
Clutch
Table of Contents
Exploded View........................................................................................................................ 6-2
Specifications ......................................................................................................................... 6-4
Special Tools and Sealant ...................................................................................................... 6-5
Clutch Lever and Cable .......................................................................................................... 6-6
Lever Free Play Inspection ............................................................................................... 6-6
Clutch Cable Removal ...................................................................................................... 6-6
Clutch Cable Installation ................................................................................................... 6-6
Clutch Cable Lubrication................................................................................................... 6-6
Clutch Lever Installation.................................................................................................... 6-6
Clutch ..................................................................................................................................... 6-7
Outer Clutch Cover Removal ............................................................................................ 6-7
Outer Clutch Cover Installation ......................................................................................... 6-7
Release Shaft Removal .................................................................................................... 6-8
Release Shaft Installation ................................................................................................. 6-8
Clutch Removal................................................................................................................. 6-9
Clutch Installation..............................................................................................................6-12
Starter Clutch Disassembly............................................................................................... 6-17
Starter Clutch Assembly ................................................................................................... 6-17
Starter Clutch Inspection................................................................................................... 6-17
Starter Torque Limiter Check ............................................................................................ 6-18
Primary Chain Wear.......................................................................................................... 6-18
Clutch Plate Assembly Inspection..................................................................................... 6-18
Clutch Plate Assembly Adjustment ................................................................................... 6-19
Friction and Steel Plate Wear, and Damage Inspection ................................................... 6-19
Friction or Steel Plate Warp .............................................................................................. 6-19
Clutch Housing Finger Inspection ..................................................................................... 6-20
Outer Clutch Hub Spline Inspection.................................................................................. 6-20
Cam Damper Inspection ................................................................................................... 6-20
Clutch Spring Free Length Measurement......................................................................... 6-20
Содержание
- Tables 1
- Quick reference guide 3
- Vulcan 2000 vn2000 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
- Before starting to perform an inspection service or carry out a 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
- Model identification 18
- General information 1 9 19
- General specifications 19
- 10 general information 20
- General specifications 20
- General information 1 11 21
- Overview 21
- Technical information oxygen sensor 21
- 12 general information 22
- Construction and operation 22
- Technical information oxygen sensor 22
- Air fuel ratio control by oxygen sensor 23
- General information 1 13 23
- Technical information oxygen sensor 23
- 14 general information 24
- Technical information oxygen sensor 24
- General information 1 15 25
- Maintenance 25
- Technical information oxygen sensor 25
- 16 general information 26
- Technical information electric solenoid operated decompressor 26
- General information 1 17 27
- Technical information dual balancer shaft system 27
- 18 general information 28
- Technical information dual balancer shaft system 28
- General information 1 19 29
- Prefixes for units 29
- Unit conversion table 29
- Units of force 29
- Units of length 29
- Units of mass 29
- Units of power 29
- Units of pressure 29
- Units of speed 29
- Units of torque 29
- Units of volume 29
- Periodic maintenance 31
- Periodic maintenance 2 1 31
- Table of contents 31
- Periodic inspection 32
- Periodic maintenance 2 3 33
- Periodic maintenance chart 33
- 4 periodic maintenance 34
- Periodic maintenance chart 34
- Periodic replacement parts 34
- Basic torque for general fasteners 35
- Periodic maintenance 2 5 35
- Torque and locking agent 35
- 6 periodic maintenance 36
- Torque and locking agent 36
- Periodic maintenance 2 7 37
- Torque and locking agent 37
- 8 periodic maintenance 38
- Torque and locking agent 38
- Periodic maintenance 2 9 39
- Torque and locking agent 39
- 10 periodic maintenance 40
- Torque and locking agent 40
- Periodic maintenance 2 11 41
- Specifications 41
- 12 periodic maintenance 42
- Specifications 42
- Periodic maintenance 2 13 43
- Special tools 43
- 14 periodic maintenance 44
- Periodic maintenance procedures 44
- Steering system 44
- Brake system 45
- Periodic maintenance 2 15 45
- Periodic maintenance procedures 45
- Warning 45
- 16 periodic maintenance 46
- Periodic maintenance procedures 46
- Warning 46
- Pad lining thickness 47
- Periodic maintenance 2 17 47
- Periodic maintenance procedures 47
- Warning 47
- 18 periodic maintenance 48
- Air pressure when cold 48
- Periodic maintenance procedures 48
- Warning 48
- Wheel and tires 48
- Front forks rear shock absorber operation inspection 49
- Periodic maintenance 2 19 49
- Periodic maintenance procedures 49
- Suspensions 49
- Tread depth 49
- Wheel bearing damage inspection 49
- 20 periodic maintenance 50
- Front fork oil leak inspection 50
- Periodic maintenance procedures 50
- Rear shock absorber oil leak inspection 50
- Swingarm pivot lubrication 50
- Clutch and drive train 51
- Clutch lever free play 51
- Periodic maintenance 2 21 51
- Periodic maintenance procedures 51
- Warning 51
- 22 periodic maintenance 52
- Periodic maintenance procedures 52
- Periodic maintenance 2 23 53
- Periodic maintenance procedures 53
- 24 periodic maintenance 54
- Periodic maintenance procedures 54
- Warning 54
- Belt wear and damage inspection 55
- Periodic maintenance 2 25 55
- Periodic maintenance procedures 55
- Warning 55
- 26 periodic maintenance 56
- Drive belt tooth wear and damage patterns 56
- Periodic maintenance procedures 56
- Drive belt wear and damage analysis 57
- Electrical system 57
- Periodic maintenance 2 27 57
- Periodic maintenance procedures 57
- Spark plug condition inspection 57
- 28 periodic maintenance 58
- Lights and switches operation 58
- Periodic maintenance procedures 58
- Periodic maintenance 2 29 59
- Periodic maintenance procedures 59
- 30 periodic maintenance 60
- Periodic maintenance procedures 60
- Periodic maintenance 2 31 61
- Periodic maintenance procedures 61
- Sidestand switch operation 61
- 32 periodic maintenance 62
- Fuel system dfi 62
- Periodic maintenance procedures 62
- Throttle grip free play 62
- Idle speed 63
- Periodic maintenance 2 33 63
- Periodic maintenance procedures 63
- Warning 63
- 34 periodic maintenance 64
- Cooling system 64
- Periodic maintenance procedures 64
- Evaporative emission control system inspection cal 65
- Periodic maintenance 2 35 65
- Periodic maintenance procedures 65
- 36 periodic maintenance 66
- Air suction system 66
- Others 66
- Periodic maintenance procedures 66
- Periodic maintenance 2 37 67
- Periodic maintenance procedures 67
- 38 periodic maintenance 68
- Periodic maintenance procedures 68
- Periodic maintenance 2 39 69
- Periodic maintenance procedures 69
- Replacement parts 69
- 40 periodic maintenance 70
- Periodic maintenance procedures 70
- Periodic maintenance 2 41 71
- Periodic maintenance procedures 71
- 42 periodic maintenance 72
- Periodic maintenance procedures 72
- Periodic maintenance 2 43 73
- Periodic maintenance procedures 73
- Warning 73
- 44 periodic maintenance 74
- Periodic maintenance procedures 74
- Warning 74
- Periodic maintenance 2 45 75
- Periodic maintenance procedures 75
- 46 periodic maintenance 76
- Periodic maintenance procedures 76
- Warning 76
- Periodic maintenance 2 47 77
- Periodic maintenance procedures 77
- 48 periodic maintenance 78
- Engine oil 78
- Periodic maintenance procedures 78
- Periodic maintenance 2 49 79
- Periodic maintenance procedures 79
- Warning 79
- 50 periodic maintenance 80
- Coolant change 80
- Periodic maintenance procedures 80
- Warning 80
- Periodic maintenance 2 51 81
- Periodic maintenance procedures 81
- Water and coolant mixture ratio when shipping 81
- 52 periodic maintenance 82
- Caution 82
- Periodic maintenance procedures 82
- Periodic maintenance 2 53 83
- Periodic maintenance procedures 83
- Fuel system dfi 85
- Fuel system dfi 3 1 85
- Table of contents 85
- 2 fuel system dfi 86
- Fuel system dfi 3 3 87
- Exploded view 89
- Fuel system dfi 3 5 89
- Exploded view 91
- Fuel system dfi 3 7 91
- 8 fuel system dfi 92
- Dfi parts location 92
- Fuel system dfi 3 11 95
- Specifications 95
- 12 fuel system dfi 96
- Specifications 96
- Fuel system dfi 3 13 97
- Special tools and sealant 97
- Dfi system 99
- Fuel system dfi 3 15 99
- Dfi system 101
- Fuel system dfi 3 17 101
- 18 fuel system dfi 102
- Dfi servicing precautions 102
- Fuel system dfi 3 19 103
- Outline 103
- Troubleshooting the dfi system 103
- 20 fuel system dfi 104
- Troubleshooting the dfi system 104
- Fuel system dfi 3 21 105
- Troubleshooting the dfi system 105
- 22 fuel system dfi 106
- Troubleshooting the dfi system 106
- Fuel system dfi 3 23 107
- Inquiries to rider 107
- Troubleshooting the dfi system 107
- 24 fuel system dfi 108
- Sample diagnosis sheet 108
- Troubleshooting the dfi system 108
- Fuel system dfi 3 25 109
- Troubleshooting the dfi system 109
- 26 fuel system dfi 110
- Dfi system troubleshooting guide 110
- Engine doesn t start starting difficulty 110
- Dfi system troubleshooting guide 111
- Fuel system dfi 3 27 111
- 28 fuel system dfi 112
- Dfi system troubleshooting guide 112
- Poor running at low speed 112
- Dfi system troubleshooting guide 113
- Fuel system dfi 3 29 113
- 30 fuel system dfi 114
- Dfi system troubleshooting guide 114
- Dfi system troubleshooting guide 115
- Fuel system dfi 3 31 115
- 32 fuel system dfi 116
- Dfi system troubleshooting guide 116
- Dfi system troubleshooting guide 117
- Fuel system dfi 3 33 117
- Poor running or no power at high speed 117
- 34 fuel system dfi 118
- Dfi system troubleshooting guide 118
- Dfi system troubleshooting guide 119
- Fuel system dfi 3 35 119
- 36 fuel system dfi 120
- Self diagnosis 120
- Self diagnosis outline 120
- Self diagnosis procedures 120
- Fuel system dfi 3 37 121
- Self diagnosis 121
- Service code clearing procedures 121
- 38 fuel system dfi 122
- Self diagnosis 122
- Fuel system dfi 3 39 123
- 40 fuel system dfi 124
- How to erase service codes 124
- Self diagnosis 124
- Fuel system dfi 3 41 125
- Self diagnosis 125
- Service code table 125
- 42 fuel system dfi 126
- Self diagnosis 126
- Backups 127
- Fuel system dfi 3 43 127
- Self diagnosis 127
- 44 fuel system dfi 128
- Self diagnosis 128
- Fuel system dfi 3 45 129
- Input voltage at ecu connector 129
- Main throttle sensor input voltage 129
- Main throttle sensor service code 11 129
- 46 fuel system dfi 130
- Idle speed 130
- Main throttle sensor output voltage 130
- Main throttle sensor service code 11 130
- Output voltage at ecu 130
- Fuel system dfi 3 47 131
- Main throttle sensor resistance 131
- Main throttle sensor service code 11 131
- Resistance inspection 131
- 48 fuel system dfi 132
- Inlet air pressure sensor input voltage 132
- Inlet air pressure sensor service code 12 132
- Input voltage at ecu 132
- Fuel system dfi 3 49 133
- Inlet air pressure sensor output voltage 133
- Inlet air pressure sensor service code 12 133
- Output voltage at ecu 133
- 50 fuel system dfi 134
- Inlet air pressure sensor output voltage connection to sensor 134
- Inlet air pressure sensor service code 12 134
- Fuel system dfi 3 51 135
- Inlet air pressure sensor service code 12 135
- 52 fuel system dfi 136
- Inlet air pressure sensor service code 12 136
- Fuel system dfi 3 53 137
- Inlet air temperature sensor output voltage 137
- Inlet air temperature sensor service code 13 137
- Output voltage at ecu 137
- 54 fuel system dfi 138
- Inlet air temperature sensor resistance 138
- Inlet air temperature sensor service code 13 138
- Fuel system dfi 3 55 139
- Water temperature sensor output voltage 139
- Water temperature sensor service code 14 139
- 56 fuel system dfi 140
- Water temperature sensor resistance 140
- Water temperature sensor service code 14 140
- Atmospheric pressure sensor input voltage 141
- Atmospheric pressure sensor service code 15 141
- Fuel system dfi 3 57 141
- Input voltage at ecu 141
- 58 fuel system dfi 142
- Atmospheric pressure sensor output voltage 142
- Atmospheric pressure sensor service code 15 142
- Output voltage 142
- Atmospheric pressure sensor service code 15 143
- Fuel system dfi 3 59 143
- Crankshaft sensor service code 21 145
- Fuel system dfi 3 61 145
- 62 fuel system dfi 146
- Camshaft position sensor service code 23 146
- Input voltage at sensor 146
- Speed sensor input voltage 146
- Camshaft position sensor service code 23 147
- Fuel system dfi 3 63 147
- 64 fuel system dfi 148
- Input voltage at sensor 148
- Speed sensor input voltage 148
- Speed sensor service code 24 148
- Fuel system dfi 3 65 149
- Output voltage at sensor 149
- Speed sensor service code 24 149
- Throttle sensor output voltage 149
- 66 fuel system dfi 150
- Gear position switch input voltage at neutral position 150
- Gear position switch input voltage at other gear positions 150
- Gear position switch service code 25 150
- Input voltage at neutral position 150
- Input voltage at other gear positions 150
- Fuel system dfi 3 67 151
- Gear position switch service code 25 151
- 68 fuel system dfi 152
- Vehicle down sensor power source voltage 152
- Vehicle down sensor service code 31 152
- Warning 152
- Fuel system dfi 3 69 153
- Vehicle down sensor output voltage 153
- Vehicle down sensor service code 31 153
- 70 fuel system dfi 154
- Input voltage at ecu connector 154
- Subthrottle sensor input voltage 154
- Subthrottle sensor service code 32 154
- Fuel system dfi 3 71 155
- Output voltage at ecu 155
- Subthrottle sensor output voltage 155
- Subthrottle sensor service code 32 155
- 72 fuel system dfi 156
- Resistance inspection 156
- Subthrottle sensor service code 32 156
- Throttle sensor resistance 156
- Fuel system dfi 3 73 157
- Oxygen sensor inspection 157
- Oxygen sensor not activated service code 33 157
- Oxygen sensor output voltage 157
- Oxygen sensor output voltage with plugs 157
- Oxygen sensor output voltage without plugs 157
- Oxygen sensor removal installation 157
- 74 fuel system dfi 158
- Oxygen sensor heater inspection 158
- Oxygen sensor not activated service code 33 158
- Oxygen sensor resistance 158
- Fuel injectors 1 2 service code 41 42 159
- Fuel system dfi 3 75 159
- Warning 159
- 76 fuel system dfi 160
- Fuel injectors 1 2 service code 41 42 160
- Fuel injectors 1 2 service code 41 42 161
- Fuel system dfi 3 77 161
- Injector fuel line maximum pressure 161
- 78 fuel system dfi 162
- Fuel injectors 1 2 service code 41 42 162
- Injector power source voltage at ecu main relay 162
- Caution 163
- Fuel injectors 1 2 service code 41 42 163
- Fuel system dfi 3 79 163
- Injector output voltage at ecu 163
- Injector signal test 163
- Injector wiring inspection 163
- Output voltage inspection 163
- 80 fuel system dfi 164
- Fuel injectors 1 2 service code 41 42 164
- Injector resistance 164
- Caution 165
- Fuel injectors 1 2 service code 41 42 165
- Fuel system dfi 3 81 165
- Injector unit test 165
- 82 fuel system dfi 166
- Fuel pump service code 45 166
- Warning 166
- Fuel pump service code 45 167
- Fuel system dfi 3 83 167
- 84 fuel system dfi 168
- Fuel pump service code 45 168
- Pump operating voltage at pump 168
- Fuel pump service code 45 169
- Fuel system dfi 3 85 169
- Pump operating voltage at pump connector 169
- Pump power source voltage 169
- 86 fuel system dfi 170
- Fuel pump service code 45 170
- Fuel system dfi 3 87 171
- Ignition coil input voltage at ecu 171
- Ignition coils 1 2 service code 51 52 171
- 88 fuel system dfi 172
- Starter control relay inspection 172
- Starter control relay removal and installation 172
- Starter control relay service code 55 172
- Fuel system dfi 3 89 173
- Radiator fan relay inspection 173
- Radiator fan relay removal installation 173
- Radiator fan relay service code 56 173
- 90 fuel system dfi 174
- Caution 174
- Resistance inspection 174
- Subthrottle valve actuator inspection 174
- Subthrottle valve actuator removal 174
- Subthrottle valve actuator resistance 174
- Subthrottle valve actuator service code 62 174
- Fuel system dfi 3 91 175
- Input voltage at sensor 175
- Subthrottle valve actuator input voltage 175
- Subthrottle valve actuator service code 62 175
- 92 fuel system dfi 176
- Subthrottle valve actuator service code 62 176
- Air switching valve inspection 177
- Air switching valve removal instalation 177
- Air switching valve service code 64 177
- Fuel system dfi 3 93 177
- 94 fuel system dfi 178
- Decompression solenoid service code 66 178
- Fuel system dfi 3 95 179
- Oxygen sensor heater service code 67 179
- Oxygen sensor power source voltage 179
- Oxygen sensor resistance 179
- 96 fuel system dfi 180
- Oxygen sensor heater inspection 180
- Oxygen sensor heater service code 67 180
- Oxygen sensor resistance 180
- Fuel system dfi 3 97 181
- Subthrottle motor driver inspection 181
- Subthrottle motor driver removal installation 181
- Subthrottle motor driver service code 85 181
- 98 fuel system dfi 182
- Oxygen sensor incorrect output voltage service code 94 182
- Oxygen sensor inspection 182
- Oxygen sensor output voltage 182
- Oxygen sensor output voltage with plugs 182
- Oxygen sensor output voltage without plugs 182
- Oxygen sensor removal installation 182
- Fuel system dfi 3 99 183
- Oxygen sensor heater inspection 183
- Oxygen sensor incorrect output voltage service code 94 183
- Oxygen sensor resistance 183
- Fi indicator led light 185
- Fuel system dfi 3 101 185
- Led light inspection 185
- Warning 185
- 102 fuel system dfi 186
- Caution 186
- Ecu grounding inspection 186
- Ecu installation 186
- Ecu power supply inspection 186
- Ecu removal 186
- Ecu power source inspection 187
- Fuel system dfi 3 103 187
- 104 fuel system dfi 188
- Fuel line 188
- Warning 188
- Fuel line 189
- Fuel pressure 189
- Fuel system dfi 3 105 189
- Warning 189
- 106 fuel system dfi 190
- Fuel line 190
- Fuel pressure idling 190
- Fuel line 191
- Fuel system dfi 3 107 191
- Warning 191
- 108 fuel system dfi 192
- Amount of fuel flow 192
- Fuel line 192
- Warning 192
- Fuel system dfi 3 109 193
- Throttle grip and cables 193
- Warning 193
- 110 fuel system dfi 194
- Throttle body assy 194
- Warning 194
- Fuel system dfi 3 111 195
- Throttle body assy 195
- 112 fuel system dfi 196
- Throttle body assy 196
- Warning 196
- Fuel system dfi 3 113 197
- Throttle body assy 197
- 114 fuel system dfi 198
- Throttle body assy 198
- Warning 198
- Air cleaner 199
- Air cleaner housing removal 199
- Caution 199
- Element removal 199
- Fuel system dfi 3 115 199
- Warning 199
- 116 fuel system dfi 200
- Air cleaner 200
- Fuel system dfi 3 117 201
- Fuel tank 201
- Fuel tank removal 201
- Warning 201
- 118 fuel system dfi 202
- Fuel tank 202
- Warning 202
- Fuel system dfi 3 119 203
- Fuel tank 203
- Warning 203
- 120 fuel system dfi 204
- Fuel tank 204
- Caution 205
- Fuel system dfi 3 121 205
- Fuel tank 205
- Fuel tank and cap inspection 205
- Fuel tank cleaning 205
- Warning 205
- 122 fuel system dfi 206
- Canister inspection periodic inspection 206
- Canister installation 206
- Caution 206
- Evaporative emission control system 206
- Hose inspection periodic inspection 206
- Parts removal installation 206
- Separator inspection periodic inspection 206
- Warning 206
- Evaporative emission control system 207
- Fuel system dfi 3 123 207
- Separator operation test 207
- Warning 207
- Cooling system 209
- Cooling system 4 1 209
- Table of contents 209
- Cooling system 4 3 211
- Exploded view 211
- 4 cooling system 212
- Coolant flow chart 212
- Coolant flow chart 213
- Cooling system 4 5 213
- 6 cooling system 214
- Specifications 214
- Cooling system 4 7 215
- Special tools and sealant 215
- 8 cooling system 216
- Coolant 216
- Caution 217
- Coolant 217
- Cooling system 4 9 217
- Cooling system flushing 217
- 10 cooling system 218
- Water pump 218
- Cooling system 4 11 219
- Water pump 219
- 12 cooling system 220
- Water pump 220
- Cooling system 4 13 221
- Radiator 221
- Radiator removal 221
- Warning 221
- 14 cooling system 222
- Caution 222
- Radiator 222
- Radiator inspection 222
- Radiator installation 222
- Cooling system 4 15 223
- Radiator 223
- Radiator cap relief pressure 223
- 16 cooling system 224
- Thermostat 224
- Thermostat installation 224
- Thermostat removal 224
- Cooling system 4 17 225
- Thermostat 225
- Thermostat valve opening temperature 225
- 18 cooling system 226
- Hoses and pipes 226
- Engine top end 227
- Engine top end 5 1 227
- Table of contents 227
- Engine top end 5 3 229
- Exploded view 229
- Engine top end 5 5 231
- Exploded view 231
- Engine top end 5 7 233
- Exploded view 233
- 8 engine top end 234
- Specifications 234
- Engine top end 5 9 235
- Specifications 235
- 10 engine top end 236
- Specifications 236
- Engine top end 5 11 237
- Special tools and sealant 237
- 12 engine top end 238
- Special tools and sealant 238
- Air suction valve inspection 239
- Air suction valve installation 239
- Air suction valve removal 239
- Air switching valve inspection 239
- Air switching valve installation 239
- Air switching valve operation test 239
- Air switching valve removal 239
- Clean air system 239
- Engine top end 5 13 239
- 14 engine top end 240
- Clean air system 240
- Clean air system hose inspection 240
- Engine top end 5 15 241
- Rocker case cover 241
- 16 engine top end 242
- Rocker case 242
- Engine top end 5 17 243
- Rocker case 243
- 18 engine top end 244
- Rocker case 244
- Engine top end 5 19 245
- Rocker case 245
- 20 engine top end 246
- Rocker case 246
- Engine top end 5 21 247
- Rocker case 247
- 22 engine top end 248
- Rocker case 248
- Decompression mechanism 249
- Engine top end 5 23 249
- 24 engine top end 250
- Decompression mechanism 250
- Decompression mechanism 251
- Decompression solenoid inspection 251
- Engine top end 5 25 251
- Oil seal inspection 251
- Spring free length 251
- Spring tension 251
- 26 engine top end 252
- Camshaft removal 252
- Camshafts 252
- Camshaft installation 253
- Camshafts 253
- Caution 253
- Engine top end 5 27 253
- 28 engine top end 254
- Camshafts 254
- Camshafts 255
- Engine top end 5 29 255
- 30 engine top end 256
- Cam height 256
- Cam wear 256
- Camshaft chain 20 link length 256
- Camshaft chain wear 256
- Camshafts 256
- Cylinder compression usable range 257
- Cylinder head 257
- Engine top end 5 31 257
- 32 engine top end 258
- Cylinder head 258
- Cylinder head removal 258
- Caution 259
- Cylinder head 259
- Cylinder head installation 259
- Engine top end 5 33 259
- 34 engine top end 260
- Cylinder head 260
- Cylinder head warp 260
- Temporary torque 260
- Cylinder head 261
- Engine top end 5 35 261
- 36 engine top end 262
- Cylinder head 262
- For exhaust valve seat 262
- For inlet valve seat 262
- Valve seat surface outside diameter seat o d 262
- Valve seat surface width or seat width 262
- Valve to guide clearance wobble method 262
- Cylinder head 263
- Engine top end 5 37 263
- 38 engine top end 264
- Cylinder head 264
- Cylinder head 265
- Engine top end 5 39 265
- Caution 267
- Cylinder removal 267
- Cylinders piston 267
- Engine top end 5 41 267
- Piston removal 267
- 42 engine top end 268
- Cylinders piston 268
- Cylinders piston 269
- Engine top end 5 43 269
- 44 engine top end 270
- Cylinder inside diameter 270
- Cylinder wear 270
- Cylinders piston 270
- Piston diameter 270
- Piston ring groove clearance 270
- Piston ring piston ring groove wear 270
- Piston wear 270
- Cylinders piston 271
- Engine top end 5 45 271
- Piston ring end gap 271
- Piston ring groove width 271
- Piston ring thickness 271
- 46 engine top end 272
- Exhaust manifold removal 272
- Lower muffler removal 272
- Mufflers 272
- Upper muffler removal 272
- Engine top end 5 47 273
- Muffler exhaust pipe installation 273
- Mufflers 273
- 48 engine top end 274
- Mufflers 274
- Clutch 275
- Clutch 6 1 275
- Table of contents 275
- Clutch 6 3 277
- Exploded view 277
- 4 clutch 278
- Specifications 278
- Clutch 6 5 279
- Special tools and sealant 279
- 6 clutch 280
- Clutch cable installation 280
- Clutch cable lubrication 280
- Clutch cable removal 280
- Clutch lever and cable 280
- Clutch lever installation 280
- Lever free play inspection 280
- Clutch 281
- Clutch 6 7 281
- 8 clutch 282
- Clutch 282
- Clutch 283
- Clutch 6 9 283
- Clutch removal 283
- 10 clutch 284
- Clutch 284
- Clutch 285
- Clutch 6 11 285
- 12 clutch 286
- Clutch 286
- Clutch 287
- Clutch 6 13 287
- 14 clutch 288
- Clutch 288
- Clutch 289
- Clutch 6 15 289
- 16 clutch 290
- Clutch 290
- Clutch 291
- Clutch 6 17 291
- 18 clutch 292
- Clutch 292
- Clutch plate assembly 292
- Primary chain 20 link length 292
- Clutch 293
- Clutch 6 19 293
- Friction or steel plate warp 293
- Friction plate thickness 293
- 20 clutch 294
- Cam damper inspection 294
- Clutch 294
- Clutch housing finger inspection 294
- Clutch spring free length 294
- Clutch spring free length measurement 294
- Outer clutch hub spline inspection 294
- Engine lubrication system 295
- Engine lubrication system 7 1 295
- Table of contents 295
- Engine lubrication system 7 3 297
- Engine oil flow chart 297
- Engine lubrication system 7 5 299
- Exploded view 299
- 6 engine lubrication system 300
- Specifications 300
- Engine lubrication system 7 7 301
- Special tools and sealant 301
- 8 engine lubrication system 302
- Engine oil and oil filter 302
- Warning 302
- Engine lubrication system 7 9 303
- Engine oil and oil filter 303
- Oil filter replacement 303
- 10 engine lubrication system 304
- Oil pump and oil line 304
- Engine lubrication system 7 11 305
- Oil pump and oil line 305
- 12 engine lubrication system 306
- Oil pan 306
- Warning 306
- Engine lubrication system 7 13 307
- Oil pan 307
- 14 engine lubrication system 308
- Oil pan 308
- Engine lubrication system 7 15 309
- Oil pressure 309
- Warning 309
- 16 engine lubrication system 310
- Oil pressure 310
- Engine removal installation 311
- Engine removal installation 8 1 311
- Table of contents 311
- Engine removal installation 8 3 313
- Exploded view 313
- 4 engine removal installation 314
- Specifications 314
- Caution 315
- Engine removal 315
- Engine removal installation 315
- Engine removal installation 8 5 315
- Warning 315
- 6 engine removal installation 316
- Engine removal installation 316
- Engine removal installation 317
- Engine removal installation 8 7 317
- 8 engine removal installation 318
- Engine removal installation 318
- Engine removal installation 319
- Engine removal installation 8 9 319
- 10 engine removal installation 320
- Engine removal installation 320
- Engine removal installation 321
- Engine removal installation 8 11 321
- Warning 321
- Crankshaft transmission 323
- Crankshaft transmission 9 1 323
- Table of contents 323
- Crankshaft transmission 9 3 325
- Exploded view 325
- Crankshaft transmission 9 5 327
- Exploded view 327
- 6 crankshaft transmission 328
- Specifications 328
- Crankshaft transmission 9 7 329
- Specifications 329
- 8 crankshaft transmission 330
- Special tools and sealants 330
- Crankcase 331
- Crankshaft transmission 9 9 331
- 10 crankshaft transmission 332
- Crankcase 332
- Caution 333
- Crankcase 333
- Crankcase assembly 333
- Crankshaft transmission 9 11 333
- 12 crankshaft transmission 334
- Crankcase 334
- Crankcase 335
- Crankshaft transmission 9 13 335
- 14 crankshaft transmission 336
- Crankcase 336
- Crankcase 337
- Crankshaft transmission 9 15 337
- 16 crankshaft transmission 338
- Crankcase 338
- Crankcase 339
- Crankshaft transmission 9 17 339
- 18 crankshaft transmission 340
- Crankcase 340
- Starter clutch assembly 340
- Starter clutch disassembly 340
- Starter clutch inspection 340
- Starter torque limiter check 340
- Crankshaft connecting rods 341
- Crankshaft transmission 9 19 341
- 20 crankshaft transmission 342
- Crankshaft connecting rods 342
- Connecting rod bend 343
- Connecting rod big end side clearance 343
- Connecting rod twist 343
- Crankshaft connecting rods 343
- Crankshaft transmission 9 21 343
- 22 crankshaft transmission 344
- Connecting rod big end bearing crankpin clearance 344
- Crankpin diameter 344
- Crankpin diameter marks 344
- Crankshaft connecting rods 344
- Big end bearing insert selection 345
- Connecting rod big end bore diameter marks 345
- Crankshaft connecting rods 345
- Crankshaft runout 345
- Crankshaft transmission 9 23 345
- 24 crankshaft transmission 346
- Caution 346
- Crankcase main bearing bore diameter 346
- Crankshaft connecting rods 346
- Crankshaft main bearing journal wear 346
- Crankshaft main journal diameter 346
- Crankshaft side clearance 346
- Crankshaft web length 346
- Balancer mechanism 347
- Balancer mechanism removal 347
- Crankshaft transmission 9 25 347
- 26 crankshaft transmission 348
- Balancer mechanism 348
- Balancer mechanism installation 348
- Balancer mechanism 349
- Crankshaft transmission 9 27 349
- 28 crankshaft transmission 350
- Apply molybdenum disulfide oil to the threads and flange portion of balancer chain sprocket nut 350
- Balancer mechanism 350
- Be sure the roller a is on the camshaft chain sprocket b and torque the camshaft chain sprocket bolt 350
- Install chain guides a chain tensioner b 350
- Pull the stopper pin e out of the chain tensioner body 350
- Torque 350
- Balancer mechanism 351
- Crankshaft transmission 9 29 351
- 30 crankshaft transmission 352
- Shift pedal installation 352
- Shift pedal removal 352
- Transmission 352
- Crankshaft transmission 9 31 353
- Transmission 353
- 32 crankshaft transmission 354
- External shift mechanism installation 354
- Transmission 354
- Crankshaft transmission 9 33 355
- Transmission 355
- 34 crankshaft transmission 356
- Transmission 356
- Crankshaft transmission 9 35 357
- External shift mechanism inspection 357
- Transmission 357
- Transmission installation 357
- Transmission removal 357
- 36 crankshaft transmission 358
- Transmission 358
- Crankshaft transmission 9 37 359
- Transmission 359
- 38 crankshaft transmission 360
- Gear dog and gear dog hole damage 360
- Gear groove width 360
- Shift drum groove width 360
- Shift fork ear thickness 360
- Shift fork gear groove wear 360
- Shift fork guide pin diameter 360
- Shift fork guide pin drum groove wear 360
- Transmission 360
- Crankshaft transmission 9 39 361
- Transmission 361
- 40 crankshaft transmission 362
- Ball bearing needle bearing and oil seal 362
- Ball bearing needle bearing and oil seal 363
- Crankshaft transmission 9 41 363
- Oil seal inspection 363
- Table of contents 365
- Wheels tires 365
- Wheels tires 10 1 365
- Exploded view 367
- Wheels tires 10 3 367
- 4 wheels tires 368
- Specifications 368
- Warning 368
- Special tools 369
- Wheels tires 10 5 369
- 6 wheels tires 370
- Warning 370
- Wheels rims 370
- Warning 371
- Wheels rims 371
- Wheels tires 10 7 371
- 8 wheels tires 372
- Caution 372
- Rear wheel removal 372
- Warning 372
- Wheels rims 372
- Warning 373
- Wheels rims 373
- Wheels tires 10 9 373
- 10 wheels tires 374
- Warning 374
- Wheel inspection 374
- Wheels rims 374
- Axle runout 100 mm 3 4 in 375
- Rim runout 375
- Warning 375
- Wheels rims 375
- Wheels tires 10 11 375
- 12 wheels tires 376
- Balance adjustment 376
- Balance weight removal 376
- Caution 376
- Warning 376
- Wheels rims 376
- Balance weight 377
- Warning 377
- Wheels rims 377
- Wheels tires 10 13 377
- 14 wheels tires 378
- Warning 378
- Wheels tires 10 15 379
- 16 wheels tires 380
- Warning 380
- Tire repair 381
- Warning 381
- Wheels tires 10 17 381
- 18 wheels tires 382
- Hub bearings wheel bearings 382
- Hub bearings wheel bearings 383
- Wheels tires 10 19 383
- Final drive 385
- Final drive 11 1 385
- Table of contents 385
- Exploded view 387
- Final drive 11 3 387
- 4 final drive 388
- Specifications 388
- Final drive 11 5 389
- Special tools 389
- 6 final drive 390
- Drive belt 390
- Drive belt 391
- Final drive 11 7 391
- 8 final drive 392
- Drive belt 392
- Final drive 11 9 393
- Pulley and coupling 393
- 10 final drive 394
- Pulley and coupling 394
- Engine pulley installation 395
- Final drive 11 11 395
- Pulley and coupling 395
- Rear pulley installation 395
- Rear pulley removal 395
- 12 final drive 396
- Pulley and coupling 396
- Rear pulley coupling installation 396
- Rear pulley coupling removal 396
- Final drive 11 13 397
- Pulley and coupling 397
- 14 final drive 398
- Coupling bearing inspection and lubrication 398
- Coupling bearing installation 398
- Pulley and coupling 398
- Rubber damper inspection 398
- Brakes 399
- Brakes 12 1 399
- Table of contents 399
- Brakes 12 3 401
- Exploded view 401
- Brakes 12 5 403
- Exploded view 403
- 6 brakes 404
- Specifications 404
- Brakes 12 7 405
- Special tool 405
- 8 brakes 406
- Brake lever brake pedal 406
- Pedal position 406
- Brake lever brake pedal 407
- Brake pedal installation 407
- Brakes 12 9 407
- Warning 407
- 10 brakes 408
- Calipers 408
- Warning 408
- Brakes 12 11 409
- Calipers 409
- 12 brakes 410
- Brake pads 410
- Front brake pad installation 410
- Front brake pad removal 410
- Warning 410
- Brake pad wear inspection 411
- Brake pads 411
- Brakes 12 13 411
- Rear brake pad installation 411
- Rear brake pad removal 411
- Warning 411
- 14 brakes 412
- Caution 412
- Front master cylinder installation 412
- Front master cylinder removal 412
- Master cylinder 412
- Brakes 12 15 413
- Master cylinder 413
- Rear master cylinder removal 413
- 16 brakes 414
- Front master cylinder disassembly 414
- Master cylinder 414
- Master cylinder assembly 414
- Rear master cylinder disassembly 414
- Rear master cylinder installation 414
- Warning 414
- Brakes 12 17 415
- Master cylinder 415
- Master cylinder inspection 415
- 18 brakes 416
- Brake discs 416
- Disc runout 416
- Front disc thickness 416
- Rear disk thickness 416
- Brake fluid 417
- Brakes 12 19 417
- Warning 417
- 20 brakes 418
- Brake fluid 418
- Brake fluid 419
- Brakes 12 21 419
- Warning 419
- 22 brakes 420
- Brake hose removal installation 420
- Brake hoses 420
- Caution 420
- Suspension 421
- Suspension 13 1 421
- Table of contents 421
- Exploded view 423
- Suspension 13 3 423
- Exploded view 425
- Suspension 13 5 425
- 6 suspension 426
- Specifications 426
- Special tools 427
- Suspension 13 7 427
- 8 suspension 428
- Fork oil change 428
- Front fork 428
- Front fork 429
- Front fork oil level fully compressed without fork spring 429
- Suspension 13 9 429
- 10 suspension 430
- Front fork 430
- Front fork 431
- Suspension 13 11 431
- Warning 431
- 12 suspension 432
- Front fork 432
- Warning 432
- Front fork 433
- Suspension 13 13 433
- 14 suspension 434
- Front fork 434
- Caution 435
- Dust seal inspection 435
- Front fork 435
- Inner tube outer tube inspection 435
- Spring free length 435
- Spring tension 435
- Suspension 13 15 435
- Warning 435
- 16 suspension 436
- Rear shock absorber 436
- Rebound damping force adjustment 436
- Spring preload setting length 436
- Caution 437
- Rear shock absorber 437
- Rear shock absorber removal 437
- Spring adjustment 437
- Suspension 13 17 437
- Warning 437
- 18 suspension 438
- Rear shock absorber 438
- Suspension 13 19 439
- Swingarm 439
- Swingarm installation 439
- Swingarm removal 439
- 20 suspension 440
- Swingarm 440
- Swingarm bearing removal 440
- Suspension 13 21 441
- Swingarm 441
- Swingarm bearing installation 441
- 22 suspension 442
- Caution 442
- Grease seal and needle bearing lubrication 442
- Swingarm 442
- Swingarm bearing sleeve inspection 442
- Steering 443
- Steering 14 1 443
- Table of contents 443
- Exploded view 445
- Steering 14 3 445
- 4 steering 446
- Special tools 446
- Handlebar 447
- Steering 14 5 447
- 6 steering 448
- Handlebar 448
- Steering 449
- Steering 14 7 449
- Steering adjustment 449
- Steering check 449
- 8 steering 450
- Caution 450
- Steering stem 450
- Steering stem removal 450
- Warning 450
- Steering 14 9 451
- Steering stem 451
- 10 steering 452
- Steering stem 452
- Warning 452
- Steering 14 11 453
- Steering stem bearing 453
- 12 steering 454
- Steering stem bearing 454
- Stem cap deterioration damage 454
- Frame 15 1 455
- Table of contents 455
- Exploded view 457
- Frame 15 3 457
- Exploded view 459
- Frame 15 5 459
- Exploded view 461
- Frame 15 7 461
- 10 frame 464
- Special tools 464
- Frame 15 11 465
- Front seat installation 465
- Front seat removal 465
- Rear seat installation 465
- Rear seat removal 465
- 12 frame 466
- Left side cover installation 466
- Left side cover removal 466
- Right side cover installation 466
- Right side cover removal 466
- Side covers 466
- Frame 15 13 467
- Ignition coil bracket cover installation 467
- Ignition coil bracket cover removal 467
- Side covers 467
- 14 frame 468
- Caution 468
- Fenders 468
- Front fender removal 468
- Rear fender installation 468
- Rear fender removal 468
- Battery case tool case 469
- Frame 15 15 469
- Tool case removal 469
- 16 frame 470
- Battery case removal 470
- Battery case tool case 470
- Battery case tool case 471
- Frame 15 17 471
- 18 frame 472
- Footboard and sidestand 472
- Right footboard assembly 472
- Right footboard disassembly 472
- Right footboard installation 472
- Right footboard removal 472
- Footboard and sidestand 473
- Frame 15 19 473
- Left footboard assembly 473
- Left footboard disassembly 473
- Left footboard installation 473
- Left footboard removal 473
- 20 frame 474
- Footboard and sidestand 474
- Side stand installation 474
- Downtube 475
- Downtube removal 475
- Frame 15 21 475
- 22 frame 476
- Downtube 476
- Frame 15 23 477
- Headlight cover 477
- Headlight cover installation 477
- Headlight cover removal 477
- 24 frame 478
- Frame inspection 478
- Warning 478
- Electrical system 479
- Electrical system 16 1 479
- Table of contents 479
- 2 electrical system 480
- Electrical system 16 5 483
- Exploded view 483
- Electrical system 16 7 485
- Exploded view 485
- Electrical system 16 9 487
- Exploded view 487
- Electrical system 16 11 489
- Exploded view 489
- 12 electrical system 490
- Specifications 490
- Electrical system 16 13 491
- Special tools 491
- 22 electrical system 500
- Electrical parts location 500
- Electrical parts location 501
- Electrical system 16 23 501
- 24 electrical system 502
- Electrical parts location 502
- Electrical system 16 25 503
- Servicing precautions 503
- Electrical system 16 27 505
- Electrical wiring 505
- 28 electrical system 506
- Battery 506
- Battery installation 506
- Battery removal 506
- Caution 506
- Battery 507
- Electrical system 16 29 507
- 30 electrical system 508
- Battery 508
- Kawasaki recommended chargers 508
- Battery 509
- Electrical system 16 31 509
- Warning 509
- 32 electrical system 510
- Battery 510
- Battery terminal voltage 510
- Warning 510
- Battery 511
- Electrical system 16 33 511
- Terminal voltage 11 less than 12 v 511
- Terminal voltage less than 11 v 511
- 34 electrical system 512
- Alternator rotor installation 512
- Alternator rotor removal 512
- Alternator stator removal 512
- Charging system 512
- Alternator stator installation 513
- Battery charging voltage 513
- Charging system 513
- Charging voltage inspection 513
- Electrical system 16 35 513
- 36 electrical system 514
- Alternator output voltage 514
- Charging system 514
- Charging system 515
- Electrical system 16 37 515
- Stator coil resistance 515
- 38 electrical system 516
- Caution 516
- Charging system 516
- Regulator rectifier inspection 516
- Regulator rectifier resistance unit kω 516
- Charging system 517
- Charging system circuit 517
- Electrical system 16 39 517
- Caution 519
- Electrical system 16 41 519
- Ignition coil removal 519
- Ignition system 519
- Warning 519
- 42 electrical system 520
- Ignition coil inspection 520
- Ignition coil installation 520
- Ignition system 520
- Needle arcing distance 520
- Warning 520
- Electrical system 16 43 521
- Ignition coil winding resistance 521
- Ignition system 521
- 44 electrical system 522
- Ignition system 522
- Primary lead connections 522
- Recommended tool peak voltage adapter 522
- Crankshaft sensor inspection 523
- Crankshaft sensor installation 523
- Crankshaft sensor removal 523
- Electrical system 16 45 523
- Ignition coil primary peak voltage 523
- Ignition system 523
- Warning 523
- 46 electrical system 524
- Connections 524
- Crankshaft sensor peak voltage 524
- Crankshaft sensor resistance 524
- Ignition system 524
- Recommended tool peak voltage adapter 524
- Electrical system 16 47 525
- Ignition system 525
- 48 electrical system 526
- Condition 526
- Ignition system 526
- Electrical system 16 49 527
- Ignition system 527
- Ignition system circuit 527
- 50 electrical system 528
- Caution 528
- Starter motor 528
- Starter motor disassembly 528
- Starter motor installation 528
- Starter motor removal 528
- Electrical system 16 51 529
- Starter motor 529
- 52 electrical system 530
- Starter motor 530
- Starter motor brush length 530
- Commutator diameter 531
- Electrical system 16 53 531
- Starter motor 531
- 54 electrical system 532
- Starter control relay inspection 532
- Starter motor 532
- Starter relay inspection 532
- Testing relay 532
- Electric starter circuit 533
- Electrical system 16 55 533
- Starter motor 533
- 56 electrical system 534
- Headlight beam horizontal adjustment 534
- Headlight beam vertical adjustment 534
- Headlight bulb replacement 534
- Lighting system 534
- Electrical system 16 57 535
- Lighting system 535
- 58 electrical system 536
- Caution 536
- City light bulb replacement europe model 536
- Lighting system 536
- Tail brake light bulb replacement 536
- Caution 537
- Electrical system 16 59 537
- Lighting system 537
- 60 electrical system 538
- Headlight tail light circuit 538
- Lighting system 538
- Automatic turn signal canceling system 539
- Connections 539
- Electrical system 16 61 539
- 62 electrical system 540
- Automatic turn signal canceling system 540
- Caution 540
- Turn signal control relay inspection 540
- Turn signal switch inspection 540
- Automatic turn signal canceling system 541
- Electrical system 16 63 541
- Testing turn signal control relay inspection 541
- 64 electrical system 542
- Automatic turn signal canceling system 542
- Automatic turn signal canceling system 543
- Electrical system 16 65 543
- Turn signal cancelling system circuit 543
- 66 electrical system 544
- Fan motor inspection 544
- Radiator fan system 544
- Electrical system 16 67 545
- Radiator fan circuit 545
- Radiator fan system 545
- 68 electrical system 546
- Caution 546
- Meter gauge 546
- Meter unit disassembly 546
- Meter unit installation 546
- Meter unit removal 546
- Electrical system 16 69 547
- Meter gauge 547
- 70 electrical system 548
- Connections 548
- Meter gauge 548
- Electrical system 16 71 549
- Meter gauge 549
- 72 electrical system 550
- Meter gauge 550
- Electrical system 16 73 551
- Example 551
- Meter gauge 551
- 74 electrical system 552
- Connections 552
- Meter gauge 552
- Electrical system 16 75 553
- Fuel level warning indicator led light connections 553
- Meter gauge 553
- Oil pressure warning indicator led light connections 553
- 76 electrical system 554
- Fi indicator led light connections 554
- Meter gauge 554
- Water temperature warning indicator led light connections 554
- Electrical system 16 77 555
- Meter gauge 555
- Neutral indicator light connections 555
- 78 electrical system 556
- High beam indicator light connections 556
- Meter gauge 556
- Electrical system 16 79 557
- Meter gauge 557
- Meter unit circuit 557
- 80 electrical system 558
- Air switching valve 558
- Air switching valve operation test 558
- Air switching valve resistance 558
- Air switching valve unit test 558
- Air switching valve 559
- Electrical system 16 81 559
- 82 electrical system 560
- Decompression solenoid 560
- Decompression solenoid inspection 560
- Decompression solenoid resistance 560
- Electrical system 16 83 561
- Fuel level sensor inspection 561
- Fuel level sensor resistance 561
- Switch and sensors 561
- 84 electrical system 562
- Switch and sensors 562
- Electrical system 16 85 563
- Switch and sensors 563
- 86 electrical system 564
- Switch and sensors 564
- Electrical system 16 87 565
- Switch and sensors 565
- Water temperature sensor resistance 565
- 88 electrical system 566
- Switch and sensors 566
- Electrical system 16 89 567
- Gear position switch resistance 567
- Switch and sensors 567
- 90 electrical system 568
- Relay box 568
- Relay box removal 568
- Relay circuit inspection 568
- Diode circuit inspection 569
- Electrical system 16 91 569
- Relay box 569
- Relay circuit inspection with the battery connected 569
- Relay circuit inspection with the battery disconnected 569
- 92 electrical system 570
- Relay box 570
- Relay box internal circuit 570
- Caution 571
- Ecu fuse removal 571
- Electrical system 16 93 571
- Fuse box fuse removal 571
- Fuse inspection 571
- Fuse installation 571
- Main fuse removal 571
- Appendix 573
- Appendix 17 1 573
- Table of contents 573
- Appendix 17 3 575
- Cable wire and hose routing 575
- Appendix 17 5 577
- Cable wire and hose routing 577
- Appendix 17 7 579
- Cable wire and hose routing 579
- Appendix 17 9 581
- Cable wire and hose routing 581
- Appendix 17 11 583
- Cable wire and hose routing 583
- Appendix 17 13 585
- Cable wire and hose routing 585
- Appendix 17 15 587
- Cable wire and hose routing 587
- Appendix 17 17 589
- Cable wire and hose routing 589
- Appendix 17 19 591
- Cable wire and hose routing 591
- Appendix 17 21 593
- Cable wire and hose routing 593
- Appendix 17 23 595
- Cable wire and hose routing 595
- Appendix 17 25 597
- Cable wire and hose routing 597
- Appendix 17 27 599
- Cable wire and hose routing 599
- Appendix 17 29 601
- Cable wire and hose routing 601
- Appendix 17 31 603
- Cable wire and hose routing 603
- Appendix 17 33 605
- Cable wire and hose routing 605
- Appendix 17 35 607
- Cable wire and hose routing 607
- Appendix 17 37 609
- Cable wire and hose routing 609
- Appendix 17 39 611
- Cable wire and hose routing 611
- Appendix 17 41 613
- Cable wire and hose routing 613
- Appendix 17 43 615
- Cable wire and hose routing 615
- Appendix 17 45 617
- Cable wire and hose routing 617
- Appendix 17 47 619
- Cable wire and hose routing 619
- Appendix 17 49 621
- Cable wire and hose routing 621
- Appendix 17 51 623
- Cable wire and hose routing 623
- Appendix 17 53 625
- Cable wire and hose routing 625
- Appendix 17 55 627
- Cable wire and hose routing 627
- 56 appendix 628
- Engine doesn t start starting difficulty 628
- Poor running at low speed 628
- Troubleshooting guide except dfi 628
- Appendix 17 57 629
- Overheating 629
- Poor running or no power at high speed 629
- Troubleshooting guide except dfi 629
- 58 appendix 630
- Abnormal engine noise 630
- Clutch operation faulty 630
- Gear shifting faulty 630
- Over cooling 630
- Troubleshooting guide except dfi 630
- Abnormal drive train noise 631
- Abnormal frame noise 631
- Appendix 17 59 631
- Exhaust smokes excessively 631
- Handling and or stability unsatisfactory 631
- Oil pressure warning light goes on 631
- Troubleshooting guide except dfi 631
- 60 appendix 632
- Battery trouble 632
- Brake doesn t hold 632
- Troubleshooting guide except dfi 632
- Model application 633
- Part no 9924 1320 02 633
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