![Kawasaki VULCAN 2000 (2003) [503/633] Electrical system 16 25](/img/pdf.png)
Kawasaki VULCAN 2000 (2003) [503/633] Electrical system 16 25
![Kawasaki VN2000 (2003) [503/633] Electrical system 16 25](/views2/1121171/page503/bg1f7.png)
ELECTRICAL SYSTEM 16-25
Servicing Precautions
There are a number of important precautions that should
be followed servicing electrical systems.
○
Do not reverse the battery cable connections. This will
burn out the diodes on the electrical parts.
○
Always check battery condition before condemning other
parts of an electrical system. A fully charged battery is a
must for conducting accurate electrical system tests.
○
The electrical parts should never be struck sharply, as
with a hammer, or allowed to fall on a hard surface. Such
a shock to the parts can damage them.
○
To prevent damage to electrical parts, do not disconnect
the battery leads or any other electrical connections when
the ignition switch is on, or while the engine is running.
○
Because of the large amount of current, never keep the
starter button pushed when the starter motor will not turn
over, or the current may burn out the starter m otor wind-
ings.
○
Do not use a meter illumination bulb rated for other than
voltage or wattage specified in the wiring diagram, as the
meter or gauge panel could be warped by excessive heat
radiated from the bulb.
○
Take care not to short the leads that are directly con-
nected to the battery positive (+) terminal to the chassis
ground.
○
Troubles may involve one or in some cases all items.
Never replace a defective part without determining what
CAUSED the failure. If the failure was caused by some
other item or items, they too must be r epaired or replaced,
or the new replacement will soon fail again.
○
Make sure all connectors in the circuit are clean and tight,
and examine wires for signs of burning, fraying, etc. Poor
wires and bad connections will affect electrical system op-
eration.
○
Measure coil and winding resistance when the part is cold
(at room temperature).
○
Wire Color Codes:
BK: Black
G: Green
P: Pink
BL: Blue
GY: Gray
PU: Purple
BR: Brown LB: Light blue R: Red
CH: Chocolate LG: Light green
W: White
DG: Dark g reen O: Orange
Y: Yellow
○
Electrical Connectors
Female Connectors [A]
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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