Kawasaki VERSYS (2006) Инструкция по эксплуатации онлайн
Содержание
- Tables 1
- Quick reference guide 3
- Motorcycle service manual 5
- Versys 5
- Country and area codes 6
- List of abbreviations 6
- Foreword 7
- How to use this manual 7
- General information 9
- General information 1 1 9
- Table of contents 9
- 2 general information 10
- Battery ground 10
- Before servicing 10
- Before starting to perform an inspection service or carry out a 10
- Cleaning vehicle before disassembly 10
- Edges of parts 10
- Solvent 10
- Arrangement and cleaning of removed parts 11
- Assembly order 11
- Before servicing 11
- General information 1 3 11
- Inspection 11
- Replacement parts 11
- Storage of removed parts 11
- 4 general information 12
- Before servicing 12
- Gasket o ring 12
- Liquid gasket non permanent locking agent 12
- Tightening sequence 12
- Tightening torque 12
- Ball bearing and needle bearing 13
- Before servicing 13
- Circlips cotter pins 13
- General information 1 5 13
- Oil seal grease seal 13
- 6 general information 14
- Before servicing 14
- Direction of engine rotation 14
- Electrical wires 14
- Instrument 14
- Lubrication 14
- General information 1 7 15
- Model identification 15
- 8 general information 16
- General specifications 16
- General information 1 9 17
- General specifications 17
- 10 general information 18
- General specifications 18
- General information 1 11 19
- Prefixes for units 19
- Unit conversion table 19
- Units of force 19
- Units of length 19
- Units of mass 19
- Units of power 19
- Units of pressure 19
- Units of speed 19
- Units of temperature 19
- Units of torque 19
- Units of volume 19
- Periodic maintenance 21
- Periodic maintenance 2 1 21
- Table of contents 21
- 2 periodic maintenance 22
- Periodic inspection 23
- Periodic maintenance 2 3 23
- Periodic maintenance chart 23
- 4 periodic maintenance 24
- Periodic maintenance chart 24
- Periodic maintenance 2 5 25
- Periodic maintenance chart 25
- Periodic replacement parts 25
- 6 periodic maintenance 26
- Torque and locking agent 26
- Periodic maintenance 2 7 27
- Torque and locking agent 27
- 8 periodic maintenance 28
- Torque and locking agent 28
- Periodic maintenance 2 9 29
- Torque and locking agent 29
- 10 periodic maintenance 30
- Basic torque for general fasteners 30
- Torque and locking agent 30
- Periodic maintenance 2 11 31
- Specifications 31
- 12 periodic maintenance 32
- Specifications 32
- Periodic maintenance 2 13 33
- Special tools 33
- 14 periodic maintenance 34
- Fuel system dfi 34
- Periodic maintenance procedures 34
- Warning 34
- Periodic maintenance 2 15 35
- Periodic maintenance procedures 35
- Throttle control system inspection 35
- Throttle grip free play 35
- Warning 35
- 16 periodic maintenance 36
- Engine vacuum 36
- Periodic maintenance procedures 36
- Main throttle sensor output voltage 37
- Periodic maintenance 2 17 37
- Periodic maintenance procedures 37
- 18 periodic maintenance 38
- Idle speed 38
- Periodic maintenance procedures 38
- Warning 38
- Cooling system 39
- Periodic maintenance 2 19 39
- Periodic maintenance procedures 39
- Warning 39
- 20 periodic maintenance 40
- Air suction system 40
- Engine top end 40
- Periodic maintenance procedures 40
- Periodic maintenance 2 21 41
- Periodic maintenance procedures 41
- Valve clearance 41
- Valve clearance measuring position 41
- 22 periodic maintenance 42
- Periodic maintenance procedures 42
- Periodic maintenance 2 23 43
- Periodic maintenance procedures 43
- Valve clearance adjustment chart inlet valve 43
- 24 periodic maintenance 44
- Periodic maintenance procedures 44
- Valve clearance adjustment chart exhaust valve 44
- Air pressure inspection 45
- Air pressure when cold 45
- Clutch 45
- Clutch lever free play 45
- Clutch operation inspection 45
- Periodic maintenance 2 25 45
- Periodic maintenance procedures 45
- Warning 45
- Wheels tires 45
- 26 periodic maintenance 46
- Periodic maintenance procedures 46
- Tread depth 46
- Warning 46
- Caution 47
- Drive chain lubrication condition inspection 47
- Drive train 47
- Periodic maintenance 2 27 47
- Periodic maintenance procedures 47
- Wheel bearing damage inspection 47
- 28 periodic maintenance 48
- Chain slack 48
- Periodic maintenance procedures 48
- Warning 48
- Periodic maintenance 2 29 49
- Periodic maintenance procedures 49
- Warning 49
- 30 periodic maintenance 50
- Chain guide inspection 50
- Drive chain 20 link length 50
- Drive chain wear inspection 50
- Periodic maintenance procedures 50
- Standard chain 50
- Warning 50
- Brake system 51
- Periodic maintenance 2 31 51
- Periodic maintenance procedures 51
- 32 periodic maintenance 52
- Periodic maintenance procedures 52
- Recommended disc brake fluid 52
- Warning 52
- Pad lining thickness 53
- Periodic maintenance 2 33 53
- Periodic maintenance procedures 53
- 34 periodic maintenance 54
- Front fork oil leak inspection 54
- Front forks rear shock absorber operation inspection 54
- Periodic maintenance procedures 54
- Rear shock absorber oil leak inspection 54
- Suspensions 54
- Periodic maintenance 2 35 55
- Periodic maintenance procedures 55
- Steering system 55
- 36 periodic maintenance 56
- Periodic maintenance procedures 56
- Steering stem bearing lubrication 56
- Electrical system 57
- Kle650b models 57
- Lights and switches operation inspection 57
- Periodic maintenance 2 37 57
- Periodic maintenance procedures 57
- 38 periodic maintenance 58
- Periodic maintenance procedures 58
- Periodic maintenance 2 39 59
- Periodic maintenance procedures 59
- 40 periodic maintenance 60
- Periodic maintenance procedures 60
- Sidestand switch operation 60
- Engine stop switch operation inspection 61
- Periodic maintenance 2 41 61
- Periodic maintenance procedures 61
- 42 periodic maintenance 62
- Others 62
- Periodic maintenance procedures 62
- Periodic maintenance 2 43 63
- Periodic maintenance procedures 63
- 44 periodic maintenance 64
- Air cleaner element replacement 64
- Caution 64
- Fuel hose replacement 64
- Periodic maintenance procedures 64
- Replacement parts 64
- Warning 64
- Coolant change 65
- Periodic maintenance 2 45 65
- Periodic maintenance procedures 65
- Warning 65
- 46 periodic maintenance 66
- Periodic maintenance procedures 66
- Water and coolant mixture ratio recommended 66
- Periodic maintenance 2 47 67
- Periodic maintenance procedures 67
- 48 periodic maintenance 68
- Periodic maintenance procedures 68
- Recommended engine oil 68
- Periodic maintenance 2 49 69
- Periodic maintenance procedures 69
- 50 periodic maintenance 70
- Periodic maintenance procedures 70
- Periodic maintenance 2 51 71
- Periodic maintenance procedures 71
- 52 periodic maintenance 72
- Periodic maintenance procedures 72
- Periodic maintenance 2 53 73
- Periodic maintenance procedures 73
- Warning 73
- 54 periodic maintenance 74
- Periodic maintenance procedures 74
- Warning 74
- Periodic maintenance 2 55 75
- Periodic maintenance procedures 75
- Standard spark plug 75
- 56 periodic maintenance 76
- Periodic maintenance procedures 76
- Fuel system dfi 77
- Fuel system dfi 3 1 77
- Table of contents 77
- 2 fuel system dfi 78
- Fuel system dfi 3 3 79
- Exploded view 81
- Fuel system dfi 3 5 81
- Exploded view 83
- Fuel system dfi 3 7 83
- Dfi system 85
- Fuel system dfi 3 9 85
- Dfi system 87
- Fuel system dfi 3 11 87
- 12 fuel system dfi 88
- Dfi system 88
- Terminal names 88
- Dfi parts location 89
- Fuel system dfi 3 13 89
- 14 fuel system dfi 90
- Specifications 90
- Fuel system dfi 3 15 91
- Specifications 91
- 16 fuel system dfi 92
- Special tools and sealant 92
- Fuel system dfi 3 17 93
- Special tools and sealant 93
- 18 fuel system dfi 94
- Dfi servicing precautions 94
- Dfi servicing precautions 95
- Fuel system dfi 3 19 95
- 20 fuel system dfi 96
- Outline 96
- Troubleshooting the dfi system 96
- Fuel system dfi 3 21 97
- Troubleshooting the dfi system 97
- 22 fuel system dfi 98
- Troubleshooting the dfi system 98
- Fuel system dfi 3 23 99
- Troubleshooting the dfi system 99
- 24 fuel system dfi 100
- Dfi diagnosis flow chart 100
- Inquiries to rider 100
- Troubleshooting the dfi system 100
- Fuel system dfi 3 25 101
- Sample diagnosis sheet 101
- Troubleshooting the dfi system 101
- 26 fuel system dfi 102
- Troubleshooting the dfi system 102
- Dfi system troubleshooting guide 103
- Engine doesn t start starting difficulty 103
- Fuel system dfi 3 27 103
- 28 fuel system dfi 104
- Dfi system troubleshooting guide 104
- Dfi system troubleshooting guide 105
- Fuel system dfi 3 29 105
- Poor running at low speed 105
- 30 fuel system dfi 106
- Dfi system troubleshooting guide 106
- Dfi system troubleshooting guide 107
- Fuel system dfi 3 31 107
- 32 fuel system dfi 108
- Dfi system troubleshooting guide 108
- Poor running or no power at high speed 108
- Dfi system troubleshooting guide 109
- Fuel system dfi 3 33 109
- 34 fuel system dfi 110
- Dfi system troubleshooting guide 110
- Fuel system dfi 3 35 111
- Self diagnosis 111
- Self diagnosis outline 111
- Self diagnosis procedures 111
- 36 fuel system dfi 112
- Self diagnosis 112
- Service code clearing procedures 112
- 38 fuel system dfi 114
- How to erase service codes 114
- How to read service codes 114
- Self diagnosis 114
- Fuel system dfi 3 39 115
- Self diagnosis 115
- Service code table 115
- 40 fuel system dfi 116
- Backups 116
- Self diagnosis 116
- Fuel system dfi 3 41 117
- Self diagnosis 117
- 42 fuel system dfi 118
- Input voltage at sensor 118
- Main throttle sensor input voltage 118
- Main throttle sensor service code 11 118
- Fuel system dfi 3 43 119
- Idle speed 119
- Main throttle sensor output voltage 119
- Main throttle sensor service code 11 119
- Output voltage at sensor 119
- Wiring connection 119
- 44 fuel system dfi 120
- Main throttle sensor resistance 120
- Main throttle sensor service code 11 120
- Wiring connection 120
- Fuel system dfi 3 45 121
- Main throttle sensor circuit 121
- Main throttle sensor service code 11 121
- 46 fuel system dfi 122
- Inlet air pressure sensor input voltage 122
- Inlet air pressure sensor service code 12 122
- Input voltage at ecu 122
- Fuel system dfi 3 47 123
- Inlet air pressure sensor output voltage 123
- Inlet air pressure sensor service code 12 123
- 48 fuel system dfi 124
- Inlet air pressure sensor service code 12 124
- Pv 24 55 cmhg 124
- Fuel system dfi 3 49 125
- Inlet air pressure sensor service code 12 125
- Pv 55 86 cmhg 125
- 50 fuel system dfi 126
- Inlet air pressure sensor circuit 126
- Inlet air pressure sensor service code 12 126
- Fuel system dfi 3 51 127
- Inlet air temperature sensor output voltage 127
- Inlet air temperature sensor service code 13 127
- Output voltage at ecu 127
- 52 fuel system dfi 128
- Inlet air temperature sensor resistance 128
- Inlet air temperature sensor service code 13 128
- Fuel system dfi 3 53 129
- Water temperature sensor output voltage 129
- Water temperature sensor service code 14 129
- 54 fuel system dfi 130
- Water temperature sensor circuit 130
- Water temperature sensor resistance inspection 130
- Water temperature sensor service code 14 130
- Crankshaft sensor service code 21 131
- Fuel system dfi 3 55 131
- 56 fuel system dfi 132
- Speed sensor input voltage 132
- Speed sensor service code 24 25 132
- Fuel system dfi 3 57 133
- Speed sensor output voltage at sensor 133
- Speed sensor service code 24 25 133
- 58 fuel system dfi 134
- Speed sensor circuit 134
- Speed sensor service code 24 25 134
- Fuel system dfi 3 59 135
- Input voltage at sensor 135
- Vehicle down sensor power source voltage 135
- Vehicle down sensor service code 31 135
- Warning 135
- 60 fuel system dfi 136
- Output voltage at sensor 136
- Vehicle down sensor output voltage 136
- Vehicle down sensor service code 31 136
- Fuel system dfi 3 61 137
- Vehicle down sensor circuit 137
- Vehicle down sensor service code 31 137
- 62 fuel system dfi 138
- Input voltage at sensor 138
- Subthrottle sensor input voltage 138
- Subthrottle sensor service code 32 138
- Fuel system dfi 3 63 139
- Output voltage at sensor 139
- Subthrottle sensor output voltage 139
- Subthrottle sensor service code 32 139
- Wiring connection 139
- 64 fuel system dfi 140
- Subthrottle sensor service code 32 140
- Throttle sensor resistance 140
- Wiring connection 140
- Fuel system dfi 3 65 141
- Subthrottle sensor circuit 141
- Subthrottle sensor service code 32 141
- 66 fuel system dfi 142
- Oxygen sensor inspection 142
- Oxygen sensor not activated service code 33 europe models 142
- Oxygen sensor output voltage 142
- Oxygen sensor output voltage with plugs 142
- Oxygen sensor output voltage without plugs 142
- Oxygen sensor removal installation 142
- Fuel system dfi 3 67 143
- Oxygen sensor circuit 143
- Oxygen sensor not activated service code 33 europe models 143
- 68 fuel system dfi 144
- Input voltage at ecu 144
- Stick coil input voltage at ecu connector 144
- Stick coils 1 2 service code 51 52 144
- Fuel system dfi 3 69 145
- Stick coil circuit 145
- Stick coils 1 2 service code 51 52 145
- 70 fuel system dfi 146
- Radiator fan relay circuit 146
- Radiator fan relay inspection 146
- Radiator fan relay removal installation 146
- Radiator fan relay service code 56 146
- Fuel system dfi 3 71 147
- Subthrottle valve actuator resistance 147
- Subthrottle valve actuator service code 62 147
- 72 fuel system dfi 148
- Input voltage at actuator 148
- Subthrottle valve actuator input voltage 148
- Subthrottle valve actuator service code 62 148
- Air switching valve circuit 149
- Air switching valve inspection 149
- Air switching valve removal installation 149
- Air switching valve service code 64 149
- Fuel system dfi 3 73 149
- 74 fuel system dfi 150
- Oxygen sensor heater inspection 150
- Oxygen sensor heater removal installation 150
- Oxygen sensor heater resistance 150
- Oxygen sensor heater service code 67 europe models 150
- Fuel system dfi 3 75 151
- Oxygen sensor heater service code 67 europe models 151
- Oxygen sensor power source voltage 151
- 76 fuel system dfi 152
- Oxygen sensor circuit 152
- Oxygen sensor heater service code 67 europe models 152
- Fuel system dfi 3 77 153
- Oxygen sensor incorrect output voltage service code 94 europe models 153
- Oxygen sensor inspection 153
- Oxygen sensor output voltage 153
- Oxygen sensor output voltage with plugs 153
- Oxygen sensor output voltage without plugs 153
- Oxygen sensor removal installation 153
- 78 fuel system dfi 154
- Oxygen sensor circuit 154
- Oxygen sensor incorrect output voltage service code 94 europe models 154
- 80 fuel system dfi 156
- Fi indicator light led 156
- Fi indicator light led check 156
- Fi indicator light led circuit 156
- Fi indicator light led inspection 156
- Caution 157
- Ecu removal 157
- Fuel system dfi 3 81 157
- 82 fuel system dfi 158
- Ecu grounding inspection 158
- Ecu installation 158
- Ecu power supply inspection 158
- Ecu power source inspection 159
- Fuel system dfi 3 83 159
- 84 fuel system dfi 160
- Ecu power source circuit 160
- Fuel line 161
- Fuel system dfi 3 85 161
- Warning 161
- 86 fuel system dfi 162
- Fuel line 162
- Fuel pressure idling 162
- Warning 162
- Amount of fuel flow 163
- Fuel line 163
- Fuel system dfi 3 87 163
- Warning 163
- 88 fuel system dfi 164
- Fuel pump 164
- Warning 164
- Fuel pump 165
- Fuel system dfi 3 89 165
- 90 fuel system dfi 166
- Fuel pump 166
- Operating voltage at pump connector 166
- Pump operating voltage at pump 166
- Fuel pump 167
- Fuel pump circuit 167
- Fuel system dfi 3 91 167
- 92 fuel system dfi 168
- Fuel injectors 168
- Injector power source voltage 168
- Power source voltage at injector 168
- Fuel injectors 169
- Fuel system dfi 3 93 169
- Injector output voltage 169
- Injector wiring inspection 169
- Output voltage at injector 169
- 94 fuel system dfi 170
- Fuel injectors 170
- Caution 171
- Fuel injectors 171
- Fuel system dfi 3 95 171
- Injector fuel line inspection 171
- Injector resistance 171
- Injector resistance inspection 171
- Injector unit test 171
- 96 fuel system dfi 172
- Fuel injectors 172
- Injector fuel line maximum pressure 172
- Fuel injector circuit 173
- Fuel injectors 173
- Fuel system dfi 3 97 173
- 98 fuel system dfi 174
- Throttle cable installation 174
- Throttle cable lubrication 174
- Throttle grip and cables 174
- Throttle grip free play adjustment 174
- Throttle grip free play inspection 174
- Warning 174
- Engine vacuum synchronization inspection ad justment 175
- Fuel system dfi 3 99 175
- Idle speed inspection 175
- Throttle body assy 175
- Throttle body assy removal 175
- Warning 175
- 100 fuel system dfi 176
- Throttle body assy 176
- Caution 177
- Fuel system dfi 3 101 177
- Throttle body assy 177
- Throttle body assy disassembly 177
- Warning 177
- 102 fuel system dfi 178
- Throttle body assy 178
- Throttle body assy assembly 178
- Air cleaner 179
- Air cleaner element inspection 179
- Air cleaner element removal installation 179
- Air cleaner housing removal 179
- Air cleaner oil draining 179
- Fuel system dfi 3 103 179
- Warning 179
- 104 fuel system dfi 180
- Air cleaner 180
- Air cleaner housing installation 180
- Fuel system dfi 3 105 181
- Fuel tank 181
- Warning 181
- 106 fuel system dfi 182
- Fuel tank 182
- Warning 182
- Caution 183
- Fuel system dfi 3 107 183
- Fuel tank 183
- Fuel tank installation 183
- Warning 183
- 108 fuel system dfi 184
- Caution 184
- Fuel tank 184
- Fuel tank and cap inspection 184
- Fuel tank cleaning 184
- Warning 184
- Cooling system 185
- Cooling system 4 1 185
- Table of contents 185
- Cooling system 4 3 187
- Exploded view 187
- Coolant flow chart 189
- Cooling system 4 5 189
- 6 cooling system 190
- Specifications 190
- Cooling system 4 7 191
- Special tools 191
- 8 cooling system 192
- Coolant 192
- Caution 193
- Coolant 193
- Coolant reserve tank removal installation 193
- Cooling system 4 9 193
- Cooling system flushing 193
- 10 cooling system 194
- Water pump 194
- Water pump installation 194
- Water pump removal 194
- Cooling system 4 11 195
- Water pump 195
- 12 cooling system 196
- Water pump 196
- Cooling system 4 13 197
- Radiator 197
- 14 cooling system 198
- Radiator 198
- Cooling system 4 15 199
- Radiator 199
- Radiator cap relief pressure 199
- 16 cooling system 200
- Radiator 200
- Radiator filler neck inspection 200
- Cooling system 4 17 201
- Thermostat 201
- Thermostat installation 201
- Thermostat removal 201
- 18 cooling system 202
- Thermostat 202
- Thermostat valve opening temperature 202
- Cooling system 4 19 203
- Hose and pipes 203
- 20 cooling system 204
- Caution 204
- Water temperature sensor 204
- Water temperature sensor inspection 204
- Water temperature sensor removal installation 204
- Engine top end 205
- Engine top end 5 1 205
- Table of contents 205
- 2 engine top end 206
- Engine top end 5 5 209
- Exploded view 209
- Engine top end 5 7 211
- Exploded view 211
- 8 engine top end 212
- Exhaust system identification 212
- Exhaust system kle650a7f kle650b7f 212
- Engine top end 5 9 213
- Exhaust system identification 213
- 10 engine top end 214
- Specifications 214
- Engine top end 5 11 215
- Specifications 215
- 12 engine top end 216
- Special tools and sealant 216
- Engine top end 5 13 217
- Special tools and sealant 217
- 14 engine top end 218
- Air suction valve installation 218
- Air suction valve removal 218
- Clean air system 218
- Air suction valve inspection 219
- Air switching valve installation 219
- Air switching valve operation test 219
- Air switching valve removal 219
- Caution 219
- Clean air system 219
- Engine top end 5 15 219
- 16 engine top end 220
- Air switching valve unit test 220
- Clean air system 220
- Clean air system hose inspection 220
- Cylinder head cover 221
- Cylinder head cover removal 221
- Engine top end 5 17 221
- 18 engine top end 222
- Cylinder head cover 222
- Cylinder head cover installation 222
- Cylinder head cover 223
- Engine top end 5 19 223
- 20 engine top end 224
- Camshaft chain tensioner 224
- Camshaft chain tensioner removal 224
- Caution 224
- Camshaft chain tensioner 225
- Camshaft chain tensioner installation 225
- Engine top end 5 21 225
- 22 engine top end 226
- Camshaft camshaft chain 226
- Camshaft camshaft chain 227
- Caution 227
- Engine top end 5 23 227
- 24 engine top end 228
- Camshaft camshaft chain 228
- Camshaft camshaft chain 229
- Engine top end 5 25 229
- 26 engine top end 230
- Camshaft camshaft chain 230
- Cam height 231
- Camshaft camshaft chain 231
- Camshaft journal camshaft cap clearance 231
- Camshaft journal diameter 231
- Camshaft runout 231
- Engine top end 5 27 231
- 28 engine top end 232
- Camshaft camshaft chain 232
- Camshaft chain removal 232
- Cylinder compression 233
- Cylinder head 233
- Engine top end 5 29 233
- 30 engine top end 234
- Cylinder head 234
- Cylinder head 235
- Engine top end 5 31 235
- 32 engine top end 236
- Cylinder head 236
- Cylinder head warp 236
- Engine top end 5 33 237
- Valves 237
- 34 engine top end 238
- Valve valve guide clearance wobble method 238
- Valves 238
- Engine top end 5 35 239
- Valve seating surface outside diameter 239
- Valve seating surface width 239
- Valves 239
- 36 engine top end 240
- Valves 240
- Engine top end 5 37 241
- Valves 241
- 38 engine top end 242
- Valves 242
- 40 engine top end 244
- Cylinder pistons 244
- Cylinder pistons 245
- Engine top end 5 41 245
- 42 engine top end 246
- Cylinder inside diameter 246
- Cylinder pistons 246
- Piston diameter 246
- Cylinder pistons 247
- Engine top end 5 43 247
- Piston ring groove clearance 247
- Piston ring groove width 247
- Piston ring thickness 247
- 44 engine top end 248
- Cylinder pistons 248
- Piston ring end gap 248
- Engine top end 5 45 249
- Throttle body assy holder 249
- 46 engine top end 250
- Exhaust pipe removal 250
- Muffler 250
- Muffler body removal 250
- Warning 250
- Engine top end 5 47 251
- Muffler 251
- Clutch 253
- Clutch 6 1 253
- Table of contents 253
- Clutch 6 3 255
- Exploded view 255
- 4 clutch 256
- Specifications 256
- Clutch 6 5 257
- Special tool and sealant 257
- 6 clutch 258
- Clutch cable installation 258
- Clutch cable lubrication 258
- Clutch cable removal 258
- Clutch lever and cable 258
- Clutch lever free play adjustment 258
- Clutch lever free play inspection 258
- Clutch 6 7 259
- Clutch lever and cable 259
- 8 clutch 260
- Caution 260
- Clutch cover 260
- Clutch cover installation 260
- Clutch cover removal 260
- Release shaft installation 260
- Release shaft removal 260
- Clutch 6 9 261
- Clutch cover 261
- 10 clutch 262
- Clutch 262
- Clutch 263
- Clutch 6 11 263
- 12 clutch 264
- Clutch 264
- Clutch 265
- Clutch 6 13 265
- Clutch plate warp inspection 265
- Clutch plate wear damage inspection 265
- Clutch spring free length 265
- Clutch spring free length measurement 265
- Friction plate thickness 265
- Friction plate warp 265
- Steel plate warp 265
- 14 clutch 266
- Clutch 266
- Clutch housing finger inspection 266
- Clutch housing spline inspection 266
- Engine lubrication system 267
- Engine lubrication system 7 1 267
- Table of contents 267
- Engine lubrication system 7 3 269
- Exploded view 269
- 6 engine lubrication system 272
- Specifications 272
- Engine lubrication system 7 7 273
- Special tools and sealant 273
- 8 engine lubrication system 274
- Engine oil and oil filter 274
- Warning 274
- Engine lubrication system 7 9 275
- Oil pan 275
- Oil pan removal 275
- 10 engine lubrication system 276
- Oil pan 276
- Oil pan installation 276
- Engine lubrication system 7 11 277
- Oil pressure relief valve 277
- Warning 277
- 12 engine lubrication system 278
- Oil pump 278
- Engine lubrication system 7 13 279
- Oil pump 279
- 14 engine lubrication system 280
- Oil pump 280
- Engine lubrication system 7 15 281
- Oil pressure 281
- Oil pressure measurement 281
- Warning 281
- 16 engine lubrication system 282
- Oil pressure switch 282
- Engine removal installation 283
- Engine removal installation 8 1 283
- Table of contents 283
- Engine removal installation 8 3 285
- Exploded view 285
- 4 engine removal installation 286
- Caution 286
- Engine removal 286
- Engine removal installation 286
- Warning 286
- Engine removal installation 287
- Engine removal installation 8 5 287
- 6 engine removal installation 288
- Engine removal installation 288
- Engine removal installation 289
- Engine removal installation 8 7 289
- Crankshaft transmission 291
- Crankshaft transmission 9 1 291
- Table of contents 291
- Crankshaft transmission 9 3 293
- Exploded view 293
- Crankshaft transmission 9 5 295
- Exploded view 295
- 6 crankshaft transmission 296
- Specifications 296
- Crankshaft transmission 9 7 297
- Specifications 297
- 8 crankshaft transmission 298
- Specifications 298
- Crankshaft transmission 9 9 299
- Special tools and sealants 299
- 10 crankshaft transmission 300
- Crankcase splitting 300
- Crankcase splitting 301
- Crankshaft transmission 9 11 301
- 12 crankshaft transmission 302
- Crankcase splitting 302
- Crankcase splitting 303
- Crankshaft transmission 9 13 303
- 14 crankshaft transmission 304
- Crankcase splitting 304
- Crankcase splitting 305
- Crankshaft transmission 9 15 305
- 16 crankshaft transmission 306
- Crankcase splitting 306
- Crankcase splitting 307
- Crankshaft transmission 9 17 307
- 18 crankshaft transmission 308
- Crankshaft and connecting rods 308
- Crankshaft and connecting rods 309
- Crankshaft transmission 9 19 309
- 20 crankshaft transmission 310
- Crankshaft and connecting rods 310
- Warning 310
- Caution 311
- Crankshaft and connecting rods 311
- Crankshaft transmission 9 21 311
- Warning 311
- 22 crankshaft transmission 312
- Connecting rod bend 312
- Crankshaft and connecting rods 312
- Connecting rod big end bearing insert crankpin clearance 313
- Connecting rod big end side clearance 313
- Connecting rod twist 313
- Crankshaft and connecting rods 313
- Crankshaft transmission 9 23 313
- 24 crankshaft transmission 314
- Connecting rod big end inside diameter marks 314
- Crankpin diameter 314
- Crankpin diameter marks 314
- Crankshaft and connecting rods 314
- Crankshaft and connecting rods 315
- Crankshaft runout 315
- Crankshaft side clearance 315
- Crankshaft transmission 9 25 315
- 26 crankshaft transmission 316
- Crankcase main bearing inside diameter marks 316
- Crankshaft main bearing insert journal clearance 316
- Crankshaft main journal diameter 316
- Crankshaft main journal diameter marks 316
- Crankshaft and connecting rods 317
- Crankshaft transmission 9 27 317
- 28 crankshaft transmission 318
- Balancer 318
- Balancer 319
- Balancer shaft bearing insert journal clearance 319
- Balancer shaft diameter marks 319
- Balancer shaft journal diameter 319
- Crankshaft transmission 9 29 319
- 30 crankshaft transmission 320
- Balancer shaft bearing insert selection 320
- Crankcase bearing bore diameter marks 320
- Crankshaft transmission 9 31 321
- Transmission 321
- 32 crankshaft transmission 322
- Transmission 322
- Crankshaft transmission 9 33 323
- Transmission 323
- 34 crankshaft transmission 324
- Transmission 324
- Crankshaft transmission 9 35 325
- Transmission 325
- Transmission assy removal 325
- 36 crankshaft transmission 326
- Transmission 326
- Crankshaft transmission 9 37 327
- Transmission 327
- 38 crankshaft transmission 328
- Transmission 328
- Crankshaft transmission 9 39 329
- Transmission 329
- 40 crankshaft transmission 330
- Transmission 330
- Crankshaft transmission 9 41 331
- Transmission 331
- 42 crankshaft transmission 332
- Gear groove width 332
- Shift drum and fork installation 332
- Shift drum and fork removal 332
- Shift drum assembly 332
- Shift drum disassembly 332
- Shift drum groove width 332
- Shift fork bending 332
- Shift fork ear thickness 332
- Shift fork gear groove wear 332
- Shift fork guide pin diameter 332
- Shift fork guide pin drum groove wear 332
- Transmission 332
- Crankshaft transmission 9 43 333
- Gear dog and gear dog hole damage 333
- Transmission 333
- 44 crankshaft transmission 334
- Ball bearing needle bearing and oil seal 334
- Table of contents 335
- Wheels tires 335
- Wheels tires 10 1 335
- Exploded view 337
- Wheels tires 10 3 337
- 4 wheels tires 338
- Specifications 338
- Warning 338
- Special tools 339
- Wheels tires 10 5 339
- 6 wheels tires 340
- Wheels rims 340
- Warning 341
- Wheels rims 341
- Wheels tires 10 7 341
- 8 wheels tires 342
- Caution 342
- Rear wheel removal 342
- Wheels rims 342
- Warning 343
- Wheels rims 343
- Wheels tires 10 9 343
- 10 wheels tires 344
- Axle inspection 344
- Axle runout 100 mm 3 4 in 344
- Rim runout with tire installed 344
- Warning 344
- Wheel inspection 344
- Wheels rims 344
- Warning 345
- Wheels rims 345
- Wheels tires 10 11 345
- 12 wheels tires 346
- Balance weight 346
- Wheels rims 346
- Warning 347
- Wheels tires 10 13 347
- 14 wheels tires 348
- Warning 348
- Wheels tires 10 15 349
- 16 wheels tires 350
- Hub bearing 350
- Hub bearing 351
- Wheels tires 10 17 351
- Final drive 353
- Final drive 11 1 353
- Table of contents 353
- Exploded view 355
- Final drive 11 3 355
- 4 final drive 356
- Specifications 356
- Final drive 11 5 357
- Special tools 357
- 6 final drive 358
- Drive chain 358
- Drive chain 359
- Drive chain installation 359
- Final drive 11 7 359
- 8 final drive 360
- Drive chain 360
- Drive chain 361
- Final drive 11 9 361
- Link pin outside diameter 361
- Link plates outside width 361
- 10 final drive 362
- Sprocket coupling 362
- Final drive 11 11 363
- Sprocket coupling 363
- 12 final drive 364
- Coupling bearing installation 364
- Coupling bearing removal 364
- Coupling installation 364
- Sprocket coupling 364
- Final drive 11 13 365
- Sprocket coupling 365
- 14 final drive 366
- Rear sprocket warp 366
- Rear sprocket warp inspection 366
- Sprocket coupling 366
- Brakes 367
- Brakes 12 1 367
- Table of contents 367
- 2 brakes 368
- Brakes 12 5 371
- Exploded view 371
- Brakes 12 7 373
- Exploded view 373
- Brakes 12 9 375
- Exploded view 375
- Brakes 12 11 377
- Exploded view 377
- 12 brakes 378
- Specifications 378
- Brakes 12 13 379
- Special tools 379
- 14 brakes 380
- Brake lever brake pedal 380
- Pedal position 380
- Brake lever brake pedal 381
- Brake pedal installation 381
- Brake pedal removal 381
- Brakes 12 15 381
- 16 brakes 382
- Brake lever brake pedal 382
- Brakes 12 17 383
- Calipers 383
- 18 brakes 384
- Calipers 384
- Warning 384
- Brakes 12 19 385
- Calipers 385
- 20 brakes 386
- Calipers 386
- Rear caliper holder shaft wear 386
- Brake pad wear inspection 387
- Brake pads 387
- Brakes 12 21 387
- Front brake pad installation 387
- Front brake pad removal 387
- Rear brake pad installation 387
- Rear brake pad removal 387
- Warning 387
- 22 brakes 388
- Caution 388
- Front master cylinder installation 388
- Front master cylinder removal 388
- Master cylinder 388
- Brakes 12 23 389
- Master cylinder 389
- 24 brakes 390
- Master cylinder 390
- Brakes 12 25 391
- Master cylinder 391
- Master cylinder inspection 391
- 26 brakes 392
- Brake disc 392
- Brake discs thickness 392
- Disc runout 392
- Brake fluid 393
- Brakes 12 27 393
- Warning 393
- 28 brakes 394
- Brake fluid 394
- Brake fluid 395
- Brakes 12 29 395
- Warning 395
- 30 brakes 396
- Brake hose 396
- Brake hose inspection 396
- Brake hose removal installation 396
- Anti lock brake system equipped models 397
- Brakes 12 31 397
- Parts location 397
- 32 brakes 398
- Abs system wiring diagram 398
- Anti lock brake system equipped models 398
- Anti lock brake system equipped models 399
- Brakes 12 33 399
- Terminal names 399
- 34 brakes 400
- Abs servicing precautions 400
- Anti lock brake system equipped models 400
- Caution 400
- Warning 400
- Anti lock brake system equipped models 401
- Brakes 12 35 401
- Warning 401
- 36 brakes 402
- Anti lock brake system equipped models 402
- Anti lock brake system equipped models 403
- Brakes 12 37 403
- Anti lock brake system equipped models 405
- Brakes 12 39 405
- Sample diagnosis sheet 405
- Anti lock brake system equipped models 407
- Brakes 12 41 407
- Pre diagnosis inspection 2 407
- Self diagnosis outline 407
- Self diagnosis procedures 407
- 42 brakes 408
- Anti lock brake system equipped models 408
- 44 brakes 410
- Anti lock brake system equipped models 410
- How to erase service codes 410
- How to read service codes 410
- Anti lock brake system equipped models 411
- Brakes 12 45 411
- Service code table 411
- 46 brakes 412
- Anti lock brake system equipped models 412
- Terminal voltage 412
- Anti lock brake system equipped models 413
- Brakes 12 47 413
- Terminal voltage 413
- 48 brakes 414
- Anti lock brake system equipped models 414
- Battery terminal voltage 414
- Anti lock brake system equipped models 415
- Brakes 12 49 415
- 50 brakes 416
- Air gap 416
- Anti lock brake system equipped models 416
- Battery terminal voltage 416
- Anti lock brake system equipped models 417
- Brakes 12 51 417
- 52 brakes 418
- Air gap 418
- Anti lock brake system equipped models 418
- Anti lock brake system equipped models 419
- Brakes 12 53 419
- 54 brakes 420
- Anti lock brake system equipped models 420
- Battery terminal voltage 420
- Anti lock brake system equipped models 421
- Brakes 12 55 421
- 56 brakes 422
- Anti lock brake system equipped models 422
- Caution 422
- Anti lock brake system equipped models 423
- Brakes 12 57 423
- 58 brakes 424
- Anti lock brake system equipped models 424
- Anti lock brake system equipped models 425
- Brakes 12 59 425
- 60 brakes 426
- Air gap 426
- Anti lock brake system equipped models 426
- A abs pump motor relay fuse removal 427
- A abs solenoid valve relay fuse removal 427
- Anti lock brake system equipped models 427
- Brake hose and pipe inspection 427
- Brakes 12 61 427
- Fuse installation 427
- 62 brakes 428
- Anti lock brake system equipped models 428
- Caution 428
- Fuse inspection 428
- Suspension 429
- Suspension 13 1 429
- Table of contents 429
- Exploded view 431
- Suspension 13 3 431
- Exploded view 433
- Suspension 13 5 433
- 6 suspension 434
- Specifications 434
- Special tools 435
- Suspension 13 7 435
- 8 suspension 436
- Special tools 436
- Front fork 437
- Rebound damping force adjustment 437
- Spring action 437
- Suspension 13 9 437
- Warning 437
- 10 suspension 438
- Front fork 438
- Front fork 439
- Suspension 13 11 439
- 12 suspension 440
- Fork oil 440
- Front fork 440
- Front fork 441
- Oil level fully compressed without spring 441
- Suspension 13 13 441
- 14 suspension 442
- Front fork 442
- Front fork 443
- Suspension 13 15 443
- 16 suspension 444
- Front fork 444
- Front fork 445
- Suspension 13 17 445
- Warning 445
- 18 suspension 446
- Dust seal inspection 446
- Front fork 446
- Spring free length 446
- Spring tension inspection 446
- Rear shock absorber 447
- Rebound damping force adjustment 447
- Spring preload adjustment 447
- Spring preload setting 447
- Suspension 13 19 447
- 20 suspension 448
- Rear shock absorber 448
- Rear shock absorber installation 448
- Rear shock absorber removal 448
- Warning 448
- Rear shock absorber 449
- Suspension 13 21 449
- 22 suspension 450
- Swingarm 450
- Suspension 13 23 451
- Swingarm 451
- Swingarm bearing installation 451
- Swingarm bearing removal 451
- 24 suspension 452
- Swingarm 452
- Suspension 13 25 453
- Swingarm 453
- Steering 455
- Steering 14 1 455
- Table of contents 455
- Exploded view 457
- Steering 14 3 457
- 4 steering 458
- Special tools 458
- Steering 459
- Steering 14 5 459
- Steering adjustment 459
- Steering inspection 459
- 6 steering 460
- Steering stem 460
- Stem stem bearing removal 460
- Steering 14 7 461
- Steering stem 461
- 8 steering 462
- Steering stem 462
- Steering 14 9 463
- Steering stem 463
- Warning 463
- Handlebar 465
- Handlebar installation 465
- Handlebar removal 465
- Steering 14 11 465
- 12 steering 466
- Handlebar 466
- Frame 15 1 467
- Table of contents 467
- Exploded view 469
- Frame 15 3 469
- Exploded view 471
- Frame 15 5 471
- Exploded view 473
- Frame 15 7 473
- 8 frame 474
- Seat installation 474
- Seat removal 474
- Fairings 475
- Frame 15 9 475
- Lower fairing installation 475
- Lower fairing removal 475
- Middle fairing installation 475
- Middle fairing removal 475
- 10 frame 476
- Fairings 476
- Fairings 477
- Frame 15 11 477
- 12 frame 478
- Side covers 478
- Frame 15 13 479
- Seat covers 479
- 14 frame 480
- Fenders 480
- Fenders 481
- Frame 15 15 481
- 16 frame 482
- Fenders 482
- Frame 15 17 483
- Warning 483
- 18 frame 484
- Windshield 484
- Frame 15 19 485
- Sidestand 485
- Sidestand installation 485
- Sidestand removal 485
- 20 frame 486
- Frame cover 486
- Frame 15 21 487
- Rear view mirrors 487
- Electrical system 489
- Electrical system 16 1 489
- Table of contents 489
- 2 electrical system 490
- Electrical system 16 5 493
- Exploded view 493
- Electrical system 16 7 495
- Exploded view 495
- Electrical system 16 9 497
- Exploded view 497
- 10 electrical system 498
- Specifications 498
- Electrical system 16 11 499
- Special tools and sealant 499
- Electrical system 16 13 501
- Parts location 501
- 20 electrical system 508
- Precautions 508
- Electrical system 16 21 509
- Electrical wiring 509
- 22 electrical system 510
- Battery 510
- Battery activation 510
- Battery installation 510
- Battery removal 510
- Caution 510
- Battery 511
- Electrical system 16 23 511
- 24 electrical system 512
- Battery 512
- Kawasaki recommended chargers 512
- Battery 513
- Caution 513
- Electrical system 16 25 513
- Interchange 513
- Precautions 513
- Warning 513
- 26 electrical system 514
- Battery 514
- Battery terminal voltage 514
- Warning 514
- Battery 515
- Electrical system 16 27 515
- Terminal voltage 11 less than 12 v 515
- Terminal voltage less than 11 v 515
- 28 electrical system 516
- Alternator cover installation 516
- Alternator cover removal 516
- Charging system 516
- Stator coil removal 516
- Charging system 517
- Electrical system 16 29 517
- 30 electrical system 518
- Charging system 518
- Alternator inspection 519
- Charging system 519
- Electrical system 16 31 519
- 32 electrical system 520
- Charging system 520
- Table 1 alternator output voltage 520
- Table 2 stator coil resistance 520
- Charging system 521
- Electrical system 16 33 521
- Regulator rectifier inspection 521
- 34 electrical system 522
- Charging system 522
- Rectifier circuit inspection 522
- Charging system 523
- Electrical system 16 35 523
- 36 electrical system 524
- Charging system 524
- Charging voltage 524
- Charging voltage inspection 524
- Charging system 525
- Charging system circuit 525
- Electrical system 16 37 525
- 38 electrical system 526
- Starter motor clutch 526
- Caution 527
- Crankshaft sensor removal 527
- Electrical system 16 39 527
- Ignition system 527
- Warning 527
- 40 electrical system 528
- Crankshaft sensor inspection 528
- Crankshaft sensor installation 528
- Ignition system 528
- Crankshaft sensor peak voltage 529
- Electrical system 16 41 529
- Ignition system 529
- 42 electrical system 530
- Ignition coil winding resistance 530
- Ignition system 530
- Electrical system 16 43 531
- Ignition system 531
- Primary lead connection 531
- Stick coil primary peak voltage 531
- Warning 531
- 44 electrical system 532
- Condition 532
- Ignition system 532
- Condition 533
- Electrical system 16 45 533
- Ignition system 533
- Electrical system 16 47 535
- Ignition system 535
- Ignition system circuit 535
- 48 electrical system 536
- Caution 536
- Electric starter system 536
- Starter motor installation 536
- Starter motor removal 536
- Electric starter system 537
- Electrical system 16 49 537
- 50 electrical system 538
- Electric starter system 538
- Electric starter system 539
- Electrical system 16 51 539
- Starter motor brush length 539
- 52 electrical system 540
- Electric starter system 540
- Electric starter system 541
- Electrical system 16 53 541
- Testing relay 541
- 54 electrical system 542
- Electric starter circuit 542
- Electric starter system 542
- Electrical system 16 55 543
- Lighting system 543
- 56 electrical system 544
- Lighting system 544
- Electrical system 16 57 545
- Lighting system 545
- 58 electrical system 546
- Lighting system 546
- Electrical system 16 59 547
- Headlight tail light circuit 547
- Lighting system 547
- 60 electrical system 548
- Lighting system 548
- Connect one 12 v battery and turn signal lights as indi cated in the figure and count how may times the lights flash for one minute turn signal relay a turn signal lights b 12 v battery c 549
- Cycle s per minute corrected to one light burned out 549
- Electrical system 16 61 549
- If the lights do not flash as specified replace the turn sig nal relay 549
- Lighting system 549
- Testing turn signal relay 549
- 62 electrical system 550
- Lighting system 550
- Turn signal light circuit 550
- Air switching valve 551
- Air switching valve resistance 551
- Electrical system 16 63 551
- 64 electrical system 552
- Fan motor inspection 552
- Radiator fan circuit 552
- Radiator fan system 552
- Electrical system 16 65 553
- Oil pressure warning system 553
- Oil pressure warning system circuit 553
- 66 electrical system 554
- Oil pressure warning system 554
- Electrical system 16 67 555
- Lighting delay time 555
- Oil pressure warning system 555
- 68 electrical system 556
- Caution 556
- Meter gauge disassembly 556
- Meter gauge indicator unit 556
- Meter unit removal 556
- Electrical system 16 69 557
- Meter gauge indicator unit 557
- 70 electrical system 558
- Meter gauge indicator unit 558
- Electrical system 16 71 559
- Meter gauge indicator unit 559
- 72 electrical system 560
- Meter gauge indicator unit 560
- Electrical system 16 73 561
- Meter gauge indicator unit 561
- 74 electrical system 562
- Meter gauge indicator unit 562
- Electrical system 16 75 563
- Meter gauge indicator unit 563
- 76 electrical system 564
- Meter gauge indicator unit 564
- Electrical system 16 77 565
- Meter circuit 565
- Meter gauge indicator unit 565
- 78 electrical system 566
- Switches and sensors 566
- Electrical system 16 79 567
- Switches and sensors 567
- Water temperature sensor resistance 567
- 80 electrical system 568
- Fuel level sensor resistance 568
- Switches and sensors 568
- Caution 569
- Electrical system 16 81 569
- Oxygen sensor heater inspection europe models 569
- Oxygen sensor inspection europe models 569
- Oxygen sensor installation europe models 569
- Oxygen sensor removal europe models 569
- Switches and sensors 569
- 82 electrical system 570
- Connections 570
- Switches and sensors 570
- Electrical system 16 83 571
- Relay box 571
- Relay box removal 571
- Relay circuit inspection 571
- 84 electrical system 572
- Diode circuit inspection 572
- Relay box 572
- Relay circuit inspection with the battery connected 572
- Relay circuit inspection with the battery disconnected 572
- Electrical system 16 85 573
- Relay box 573
- Relay box internal circuit 573
- 86 electrical system 574
- A main fuse removal 574
- Fuse box fuse removal 574
- A ecu fuse removal 575
- Caution 575
- Electrical system 16 87 575
- Fuse inspection 575
- Fuse installation 575
- Appendix 577
- Appendix 17 1 577
- Table of contents 577
- Appendix 17 3 579
- Cable wire and hose routing 579
- Appendix 17 5 581
- Cable wire and hose routing 581
- Appendix 17 7 583
- Cable wire and hose routing 583
- Appendix 17 9 585
- Cable wire and hose routing 585
- Appendix 17 11 587
- Cable wire and hose routing 587
- Appendix 17 13 589
- Cable wire and hose routing 589
- Appendix 17 15 591
- Cable wire and hose routing 591
- Appendix 17 17 593
- Cable wire and hose routing 593
- Appendix 17 19 595
- Cable wire and hose routing 595
- Appendix 17 21 597
- Cable wire and hose routing 597
- Appendix 17 23 599
- Cable wire and hose routing 599
- Appendix 17 25 601
- Cable wire and hose routing 601
- Appendix 17 27 603
- Cable wire and hose routing 603
- Appendix 17 29 605
- Cable wire and hose routing 605
- Appendix 17 31 607
- Cable wire and hose routing 607
- Appendix 17 33 609
- Cable wire and hose routing 609
- Appendix 17 35 611
- Cable wire and hose routing 611
- Appendix 17 37 613
- Cable wire and hose routing 613
- Appendix 17 39 615
- Cable wire and hose routing 615
- Appendix 17 41 617
- Cable wire and hose routing 617
- Appendix 17 43 619
- Cable wire and hose routing 619
- Appendix 17 45 621
- Cable wire and hose routing 621
- 46 appendix 622
- Engine doesn t start starting difficulty 622
- Poor running at low speed 622
- Troubleshooting guide 622
- Appendix 17 47 623
- Overheating 623
- Poor running or no power at high speed 623
- Troubleshooting guide 623
- 48 appendix 624
- Abnormal engine noise 624
- Clutch operation faulty 624
- Gear shifting faulty 624
- Over cooling 624
- Troubleshooting guide 624
- Abnormal drive train noise 625
- Abnormal frame noise 625
- Appendix 17 49 625
- Exhaust smokes excessively 625
- Handling and or stability unsatisfactory 625
- Oil pressure warning light goes on 625
- Troubleshooting guide 625
- 50 appendix 626
- Battery trouble 626
- Brake doesn t hold 626
- Troubleshooting guide 626
- Model application 627
- Part no 9924 1369 01 627
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