![Kawasaki NINJA ZX6RR (2003-2004) [2/514] Foreword](/img/pdf.png)
Kawasaki NINJA ZX6RR (2003-2004) [2/514] Foreword
![Kawasaki NINJA ZX6RR (2003-2004) [2/514] Foreword](/views2/1121195/page2/bg2.png)
Содержание
- Foreword 2
- How to use this manual 2
- Caution 3
- Warning 3
- General information 4
- General information 1 1 4
- Table of contents 4
- 2 general information 5
- Before servicing 5
- Before servicing 6
- General information 1 3 6
- Before servicing 8
- General information 1 5 8
- Before servicing 10
- General information 1 7 10
- 10 general information 13
- General specifications 13
- General information 1 11 14
- General specifications 14
- 12 general information 15
- General specifications 15
- General information 1 13 16
- General specifications 16
- 14 general information 17
- General specifications 17
- General information 1 15 18
- General specifications 18
- 16 general information 19
- Technical information air inlet system 19
- General information 1 17 20
- Technical information air inlet system 20
- 18 general information 21
- Technical information air inlet system 21
- Current ignition interlock sidestand system 22
- General information 1 19 22
- New ignition interlock sidestand system 22
- Technical information new ignition interlock sidestand 22
- 20 general information 23
- Technical information tail brake lights employing led 23
- Technical information tail brake lights employing led 24
- _________________________________________ general information 1 21 24
- 22 general information 25
- Honeycomb type catalytic converter 25
- Technical information kawasaki low exhaust emission system 25
- General information 1 23 26
- Prefixes for units units of length 26
- Unit conversion table 26
- Units of force 26
- Units of mass 26
- Units of power 26
- Units of pressure 26
- Units of speed 26
- Units of torque 26
- Units of volume 26
- Periodic maintenance 27
- Periodic maintenance 2 1 27
- Table of contents 27
- 2 periodic maintenance 28
- Periodic maintenance chart 28
- Periodic maintenance 2 3 29
- Periodic maintenance chart 29
- 4 periodic maintenance 30
- Basic torque for general fasteners 30
- Torque and locking agent 30
- Periodic maintenance 2 5 31
- Torque and locking agent 31
- 6 periodic maintenance 32
- Torque and locking agent 32
- Periodic maintenance 2 7 33
- Torque and locking agent 33
- 8 periodic maintenance 34
- Torque and locking agent 34
- Periodic maintenance 2 9 35
- Specifications 35
- 10 periodic maintenance 36
- Specifications 36
- Periodic maintenance 2 11 37
- Special tools 37
- 12 periodic maintenance 38
- Fuel system dfi 38
- Maintenance procedure 38
- Maintenance procedure 39
- Periodic maintenance 2 13 39
- Warning 39
- 14 periodic maintenance 40
- Caution 40
- Maintenance procedure 40
- Caution 41
- Maintenance procedure 41
- Periodic maintenance 2 15 41
- 16 periodic maintenance 42
- Maintenance procedure 42
- Caution 43
- Maintenance procedure 43
- Periodic maintenance 2 17 43
- 18 periodic maintenance 44
- Caution 44
- Maintenance procedure 44
- Warning 44
- Maintenance procedure 45
- Periodic maintenance 2 19 45
- 20 periodic maintenance 46
- Cooling system 46
- Maintenance procedure 46
- Warning 46
- Caution 47
- Maintenance procedure 47
- Periodic maintenance 2 21 47
- 22 periodic maintenance 48
- Caution 48
- Engine top end 48
- Maintenance procedure 48
- Maintenance procedure 49
- Periodic maintenance 2 23 49
- 24 periodic maintenance 50
- Caution 50
- Maintenance procedure 50
- Example present shim is 3 5 mm 51
- Install the shim specified where the lines intersect this 51
- Maintenance procedure 51
- Measure the clearance when engine is cold 2 check present shim size 3 match clearance in vertical column with present shim 51
- Measured clearance is 0 5 mm 51
- Periodic maintenance 2 25 51
- Remeasure the valve clearance and readjust if neces 51
- Replace 3 5 mm shim with 3 5 mm shim 51
- Shim will give the proper clearance 51
- Size in horizontal column 51
- Valve clearance adjustment chart inlet valve 51
- 26 periodic maintenance 52
- Example present shim is 3 0 mm 52
- Install the shim specified where the lines intersect this 52
- Maintenance procedure 52
- Measure the clearance when engine is cold 2 check present shim size 3 match clearance in vertical column with present shim 52
- Measured clearance is 0 0 mm 52
- Nstall the shim of this thickness mm 52
- Remeasure the valve clearance and readjust if neces 52
- Replace 3 0 mm shim with 3 mm shim 52
- Shim will give the proper clearance 52
- Size in horizontal column 52
- Specified clearance no change required 52
- Valve clearance adjustment chart exhaust valve 52
- Clutch 53
- Maintenance procedure 53
- Periodic maintenance 2 27 53
- Warning 53
- 28 periodic maintenance 54
- Engine lubrication system 54
- Maintenance procedure 54
- Maintenance procedure 55
- Periodic maintenance 2 29 55
- Warning 55
- Wheels tires 55
- 30 periodic maintenance 56
- Final drive 56
- Maintenance procedure 56
- Maintenance procedure 57
- Periodic maintenance 2 31 57
- Warning 57
- 32 periodic maintenance 58
- A warning 58
- Maintenance procedure 58
- Brakes 59
- Caution 59
- Maintenance procedure 59
- Periodic maintenance 2 33 59
- 34 periodic maintenance 60
- Caution 60
- Maintenance procedure 60
- Maintenance procedure 61
- Periodic maintenance 2 35 61
- 36 periodic maintenance 62
- A warning 62
- Maintenance procedure 62
- Maintenance procedure 63
- Periodic maintenance 2 37 63
- 38 periodic maintenance 64
- Maintenance procedure 64
- Warning 64
- Maintenance procedure 65
- Periodic maintenance 2 39 65
- 40 periodic maintenance 66
- A warning 66
- Maintenance procedure 66
- Maintenance procedure 67
- Periodic maintenance 2 41 67
- Suspension 67
- 42 periodic maintenance 68
- Maintenance procedure 68
- Steering 68
- Maintenance procedure 69
- Periodic maintenance 2 43 69
- 44 periodic maintenance 70
- Caution 70
- Electrical system 70
- General lubrication 70
- Maintenance procedure 70
- Maintenance procedure 71
- Periodic maintenance 2 45 71
- 46 periodic maintenance 72
- Maintenance procedure 72
- Nut bolts and fasteners tightness check 72
- Fuel system 73
- Fuel system dfi 73
- Fuel system dfi 3 1 73
- Table of contents 73
- 2 fuel system dfi 74
- Exploded view 77
- Fuel system dfi 3 5 77
- Exploded view 79
- Fuel system dfi 3 7 79
- Exploded view 81
- Fuel system dfi 3 9 81
- 10 fuel system dfi 82
- Specifications 82
- Fuel system dfi 3 11 83
- Specifications 83
- 12 fuel system dfi 84
- Special tools 84
- Fuel system dfi 3 13 85
- Special tools 85
- Dfi system 87
- Fuel system dfi 3 15 87
- Dfi system 89
- Fuel system dfi 3 17 89
- 18 fuel system dfi 90
- Dfi system 90
- Terminal numbers of ecu connectors 90
- Dfi system 91
- Fuel system dfi 3 19 91
- 20 fuel system dfi 92
- Dfi servicing precautions 92
- Dfi servicing precautions 93
- Fuel system dfi 3 21 93
- 22 fuel system dfi 94
- Caution 94
- Outline 94
- Troubleshooting the dfi system 94
- Fuel system dfi 3 23 95
- Troubleshooting the dfi system 95
- 24 fuel system dfi 96
- Troubleshooting the dfi system 96
- Fuel system dfi 3 25 97
- Troubleshooting the dfi system 97
- Fuel system dfi 3 27 99
- Troubleshooting the dfi system 99
- 28 fuel system dfi 100
- Inquiries to rider 100
- Troubleshooting the dfi system 100
- Fuel system dfi 3 29 101
- Sample diagnosis sheet 101
- Troubleshooting the dfi system 101
- 30 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 31 103
- 32 fuel system dfi 104
- Dfi system troubleshooting guide 104
- Dfi system troubleshooting guide 105
- Fuel system dfi 3 33 105
- Poor running at low speed 105
- 34 fuel system dfi 106
- Dfi system troubleshooting guide 106
- Dfi system troubleshooting guide 107
- Fuel system dfi 3 35 107
- 36 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 37 109
- 38 fuel system dfi 110
- Dfi system troubleshooting guide 110
- Caution 111
- Fuel system dfi 3 39 111
- 40 fuel system dfi 112
- Fuel system dfi 3 41 113
- 42 fuel system dfi 114
- Caution 114
- Dfi power source 114
- 44 fuel system dfi 116
- Fl indicator led light 116
- Caution 117
- Fuel line 117
- Fuel system dfi 3 45 117
- Warning 117
- 46 fuel system dfi 118
- Fuel line 118
- Warning 118
- Caution 119
- Fuel line 119
- Fuel system dfi 3 47 119
- Warning 119
- 48 fuel system dfi 120
- Caution 120
- Fuel pump 120
- Warning 120
- Fuel pump 121
- Fuel system dfi 3 49 121
- 50 fuel system dfi 122
- Fuel pump 122
- Caution 123
- Fuel pump relay 123
- Fuel system dfi 3 51 123
- 52 fuel system dfi 124
- Fuel pump relay 124
- Caution 125
- Fuel injectors 125
- Fuel system dfi 3 53 125
- 54 fuel system dfi 126
- Caution 126
- Fuel injectors 126
- Fuel injectors 127
- Fuel system dfi 3 55 127
- 56 fuel system dfi 128
- Caution 128
- Fuel injectors 128
- Fuel injectors 129
- Fuel system dfi 3 57 129
- 58 fuel system dfi 130
- Self diagnosis 130
- Self diagnosis outline 130
- Self diagnosis procedures 130
- Fuel system dfi 3 59 131
- Self diagnosis 131
- Service code clearing procedures 131
- Fuel system dfi 3 61 133
- How to erase service codes 133
- How to read service codes 133
- Self diagnosis 133
- 62 fuel system dfi 134
- Jnnnnjl 134
- Njulfl 134
- Nnnnnrum 134
- Nnnnruwi 134
- Ptljuwl 134
- Self diagnosis 134
- Service code table 134
- Backups 135
- Fuel system dfi 3 63 135
- Self diagnosis 135
- 64 fuel system dfi 136
- Self diagnosis 136
- Caution 137
- Fuel system dfi 3 65 137
- Main throttle sensor service code 11 137
- 66 fuel system dfi 138
- Main throttle sensor service code 11 138
- Caution 139
- Fuel system dfi 3 67 139
- Main throttle sensor service code 11 139
- 68 fuel system dfi 140
- Caution 140
- Main throttle sensor service code 11 140
- Fuel system dfi 3 69 141
- Main throttle sensor service code 11 141
- 70 fuel system dfi 142
- Caution 142
- Inlet air pressure sensor service code 12 142
- Fuel system dfi 3 71 143
- Inlet air pressure sensor service code 12 143
- 72 fuel system dfi 144
- Inlet air pressure sensor service code 12 144
- Fuel system dfi 3 73 145
- Inlet air pressure sensor service code 12 145
- 74 fuel system dfi 146
- Inlet air pressure sensor service code 12 146
- Fuel system dfi 3 75 147
- Inlet air pressure sensor service code 12 147
- 76 fuel system dfi 148
- Caution 148
- Inlet air temperature sensor service code 13 148
- Fuel system dfi 3 77 149
- Inlet air temperature sensor service code 13 149
- Caution 151
- Fuel system dfi 3 79 151
- Water temperature sensor service code 14 151
- 80 fuel system dfi 152
- Water temperature sensor service code 14 152
- Atmospheric pressure sensor service code 15 153
- Caution 153
- Fuel system dfi 3 81 153
- 82 fuel system dfi 154
- Atmospheric pressure sensor service code 15 154
- Atmospheric pressure sensor service code 15 155
- Fuel system dfi 3 83 155
- 84 fuel system dfi 156
- Atmospheric pressure sensor service code 15 156
- Atmospheric pressure sensor service code 15 157
- Fuel system dfi 3 85 157
- 86 fuel system dfi 158
- Atmospheric pressure altitude relationship 158
- Atmospheric pressure sensor service code 15 158
- Crankshaft sensor service code 21 159
- ________________________________________________ fuel system dfi 3 87 159
- 88 fuel system dfi 160
- Camshaft position sensor service code 23 160
- Fuel system dfi 3 89 161
- Speed sensor service code 24 25 161
- 90 fuel system dfi 162
- Speed sensor service code 24 25 162
- Fuel system dfi 3 91 163
- Speed sensor service code 24 25 163
- 92 fuel system dfi 164
- A warning 164
- Caution 164
- Vehicle down sensor service code 31 164
- Fuel system dfi 3 93 165
- Vehicle down sensor service code 31 165
- 94 fuel system dfi ______________________ 166
- Vehicle down sensor service code 31 166
- Fuel system dfi 3 95 167
- Subthrottle sensor service code 32 167
- Zzz caution 167
- 96 fuel system dfi 168
- Subthrottle sensor service code 32 168
- Caution 169
- Fuel system dfi 3 97 169
- Subthrottle sensor service code 32 169
- 98 fuel system dfi 170
- Caution 170
- Subthrottle sensor service code 32 170
- Fuel system dfi 3 99 171
- Subthrottle sensor service code 32 171
- 100 fuel system dfi 172
- Caution 172
- Stick coils 1 2 3 4 service code 51 52 53 54 172
- Fuel system dfi 3 101 173
- Stick coils 1 2 3 4 service code 51 52 53 54 173
- 102 fuel system dfi 174
- Caution 174
- Subthrottle valve actuator service code 62 174
- Fuel system dfi 3 103 175
- Subthrottle valve actuator service code 62 175
- 104 fuel system dfi 176
- A warning 176
- Throttle grip and cables 176
- Choke cable 177
- Fuel system dfi 3 105 177
- Warning 177
- 106 fuel system dfi 178
- A warning 178
- Throttle body assy 178
- Caution 179
- Fuel system dfi 3 107 179
- Throttle body assy 179
- 108 fuel system dfi 180
- Caution 180
- Throttle body assy 180
- Fuel system dfi 3 109 181
- Throttle body assy 181
- 110 fuel system dfi 182
- A warning 182
- Air line 182
- Air line 183
- Fuel system dfi 3 111 183
- 112 fuel system dfi 184
- Caution 184
- Fuel tank 184
- Warning 184
- Fuel system dfi 3 113 185
- Fuel tank 185
- Warning 185
- 114 fuel system dfi 186
- Caution 186
- Fuel tank 186
- Warning 186
- Caution 187
- Evaporative emission control system 187
- Fuel system dfi 3 115 187
- Warning 187
- 116 fuel system dfi 188
- Evaporative emission control system 188
- Warning 188
- Cooling system 189
- Cooling system 4 1 189
- Table of contents 189
- Cooling system 4 3 191
- Exploded view 191
- 4 cooling system 192
- Specifications 192
- 6 cooling system 194
- Coolant flow chart 194
- Coolant flow chart 195
- Coolwg system 4 7 195
- 8 cooling system 196
- Coolant flow chart 196
- Caution 197
- Coolant 197
- Cooling system 4 9 197
- 10 cooling system 198
- Caution 198
- Coolant 198
- Coolant 199
- Cooling system 4 11 199
- 12 cooling system 200
- Water pump 200
- Caution 201
- Cooling system 4 13 201
- Water pump 201
- 14 cooling system 202
- Water pump 202
- Cooling system 4 15 203
- Radiator radiator fan 203
- Warning 203
- 16 cooling system 204
- Caution 204
- Radiator radiator fan 204
- Caution 205
- Cooling system 4 17 205
- Radiator radiator fan 205
- 18 cooling system 206
- Radiator radiator fan 206
- Cooling system 4 19 207
- Thermostat 207
- 20 cooling system 208
- Thermostat 208
- Cooling system 4 21 209
- Hose and pipes 209
- 22 cooling system 210
- Caution 210
- Radiator fan switch water temperature sensor 210
- Engine top 211
- Engine top end 211
- Engine top end 5 1 211
- Table of contents 211
- Engine top end 5 3 213
- Exploded view 213
- Engine top end 5 5 215
- Exhaust system 215
- Exploded view 215
- 6 engine top end 216
- Specifications 216
- Engine top end 5 7 217
- Specifications 217
- 8 engine top end 218
- Special tools and sealant 218
- Engine top end 5 9 219
- Special tools and sealant 219
- 10 engine top end 220
- Clean air system 220
- Clean air system 221
- Engine top end 5 11 221
- 12 engine top end 222
- Cylinder head cover 222
- Cylinder head cover 223
- _________ engine top end 5 13 223
- 14 engine top end 224
- Camshaft chain tensioner 224
- Caution 224
- Camshaft camshaft chain 225
- Caution 225
- Engine top end 5 15 225
- 16 engine top end 226
- Camshaft camshaft chain 226
- Camshaft camshaft chain 227
- Engine top end 5 17 227
- 18 engine top end 228
- Camshaft camshaft chain 228
- Cylinder head 229
- Engine top end 5 19 229
- 20 engine top end 230
- Cylinder head 230
- Cylinder head 231
- Engine top end 5 21 231
- 22 engine top end 232
- Caution 232
- Valves 232
- Engine top end 5 23 233
- Valves 233
- 24 engine top end 234
- Valves 234
- Engine top end 5 25 235
- Valves 235
- 26 engine top end 236
- Caution 236
- Valves 236
- Caution 237
- Engine top end 5 27 237
- Valves 237
- 28 engine top end 238
- Valves 238
- 30 engine top end 240
- Cylinder pistons 240
- Caution 241
- Cylinder pistons 241
- Engine top end 5 31 241
- 32 engine top end 242
- Cylinder pistons 242
- Cylinder pistons 243
- Engine top end 5 33 243
- 34 engine top end 244
- Cylinder pistons 244
- Engine top end 5 35 245
- Throttle valve holder 245
- 36 engine top end 246
- Muffler 246
- Warning 246
- Clutch 247
- Clutch 6 1 247
- Table of contents 247
- Exploded view 249
- ______________ clutch 6 3 249
- 4 clutch 250
- Specifications 250
- Clutch 6 5 251
- Special tool and sealant 251
- 6 clutch 252
- Clutch lever and cable 252
- Caution 253
- Clutch 6 7 253
- Clutch cover 253
- 8 clutch 254
- Caution 254
- Clutch cover 254
- Clutch 255
- Clutch 6 9 255
- 10 clutch 256
- Clutch 256
- Clutch 257
- Clutch 6 11 257
- 12 clutch 258
- Clutch 258
- Caution 259
- Clutch 259
- Clutch 6 13 259
- Clutch 261
- Clutch 6 15 261
- 16 clutch 262
- Clutch 262
- Engine lubrication system 263
- Engine lubrication system 7 1 263
- Table of contents 263
- Engine lubrication system 7 3 265
- Exploded view 265
- 4 engine lubrication system 266
- Engine oil flow chart 266
- Engine lubrication system 7 5 267
- Specifications 267
- 6 engine lubrication system 268
- Special tools and sealant 268
- Caution 269
- Engine lubrication system 7 7 269
- Engine oil and oil filter 269
- Warning 269
- 8 engine lubrication system 270
- Oil pan 270
- Engine lubrication system 7 9 271
- Oil pressure relief valve 271
- Warning 271
- 10 engine lubrication system 272
- Oil pump 272
- Engine lubrication system 7 11 273
- Oil pump 273
- 12 engine lubrication system 274
- Oil pump 274
- Engine lubrication system 7 13 275
- Oil cooler 275
- 14 engine lubrication system 276
- A warning 276
- Oil pressure measurement 276
- Engine lubrication system 7 15 277
- Oil pressure switch 277
- Engine removal installation 278
- Engine removal installation 8 1 278
- Engine removal lnstallation 278
- Table of contents 278
- Engine removal installation 8 3 280
- Exploded view 280
- 4 engine removal installation 281
- Special tools 281
- Caution 282
- Engine removal installation 8 5 282
- Engine removal lnstallation 282
- Warning 282
- 6 engine removal installation 283
- Engine removal lnstallation 283
- Engine removal installation 8 7 284
- Engine removal lnstallation 284
- 8 engine removal installation 285
- Engine removal 1nstallation 8 9 286
- Engine removal lnstallation 286
- Crankshaft transmission 287
- Crankshaft transmission 9 1 287
- Table of contents 287
- Crankshaft transmission 9 3 289
- Exploded view 289
- Crankshaft transmission 9 5 291
- Exploded view 291
- 6 crankshaft transmission 292
- Specifications 292
- Crankshaft transmission 9 7 293
- Specifications 293
- 8 crankshaft transmission 294
- Special tools and sealant 294
- Crankcase splitting 295
- Crankshaft transmission 9 9 295
- 10 crankshaft transmission 296
- Crankcase splitting 296
- Caution 297
- Crankcase splitting 297
- Crankshaft transmission 9 11 297
- 12 crankshaft transmission 298
- Crankcase splitting 298
- Caution 299
- Crankshaft and connecting rods 299
- Crankshaft transmission 9 13 299
- 14 crankshaft transmission 300
- Caution 300
- Crankshaft and connecting rods 300
- Caution 301
- Crankshaft and connecting rods 301
- Crankshaft transmission 9 15 301
- Warning 301
- 16 crankshaft transmission 302
- Caution 302
- Crankshaft and connecting rods 302
- Warning 302
- Crankshaft and connecting rods 303
- Crankshaft transmission 9 17 303
- 18 crankshaft transmission 304
- Crankshaft and connecting rods 304
- Crankshaft and connecting rods 305
- ____ crankshaft transmission 9 19 305
- 20 crankshaft transmission 306
- Crankshaft and connecting rods 306
- Crankshaft and connecting rods 307
- Crankshaft transmission 9 21 307
- 22 crankshaft transmission 308
- Starter motor clutch 308
- Crankshaft transmission 9 23 309
- Transmission 309
- 24 crankshaft transmission 310
- Transmission 310
- Crankshaft transmission 9 25 311
- Transmission 311
- 26 crankshaft transmission 312
- Caution 312
- Transmission 312
- Crankshaft transmission 9 27 313
- Transmission 313
- 28 crankshaft transmission 314
- Transmission 314
- Crankshaft transmission 9 29 315
- Transmission 315
- 30 crankshaft transmission 316
- Transmission 316
- Table of contents 317
- Wheels tires 317
- Wheels tires 10 1 317
- Exploded view 319
- Wheels tires 10 3 319
- 4 wheels tires 320
- Specifications 320
- Warning 320
- 6 wheels tires 322
- Caution 322
- Wheels rims 322
- Warning 323
- Wheels rims 323
- Wheels tires 10 7 323
- 8 wheels tires 324
- A warning 324
- Caution 324
- Wheels rims 324
- A warning 325
- Wheels rims 325
- Wheels tires 10 9 325
- 10 wheels tires 326
- Wheels rims 326
- Caution 327
- Warning 327
- Wheels rims 327
- Wheels tires 10 11 327
- 12 wheels tires 328
- Wheels rims 328
- Caution 329
- Warning 329
- Wheels tires 10 13 329
- 14 wheels tires 330
- A warning 330
- Caution 330
- Wheels tires 10 15 331
- 16 wheels tires 332
- Caution 332
- Hub bearing 332
- Hub bearing 333
- Wheels tires 10 17 333
- Final drive 334
- Final drive 11 1 334
- Table of contents 334
- Exploded view 336
- Final drive 11 3 336
- 4 final drive 337
- Specifications 337
- Final drive 11 5 338
- Special tools 338
- 6 final drive 339
- Drive chain 339
- Final drive 11 7 340
- Sprocket coupling 340
- 8 final drive 341
- Caution 341
- Sprocket coupling 341
- Final drive 11 9 342
- Sprocket coupling 342
- 10 final drive 343
- Sprocket coupling 343
- Final drive 11 11 344
- Sprocket coupling 344
- Brakes 345
- Brakes 12 1 345
- Table of contents 345
- Brakes 12 3 347
- Exploded view 347
- Brakes 12 5 349
- Exploded view 349
- 6 brakes 350
- Specifications 350
- Brakes 12 7 351
- Special tools 351
- 8 brakes 352
- Brake pedal 352
- Brakes 12 9 353
- Calipers 353
- Caution 353
- 10 brakes 354
- Calipers 354
- Warning 354
- Brakes 12 11 355
- Calipers 355
- Caution 355
- Warning 355
- 12 brakes 356
- Calipers 356
- Warning 356
- Brakes 12 13 357
- Calipers 357
- 14 brakes 358
- Calipers 358
- Brake pads 359
- Brakes 12 15 359
- Warning 359
- 16 brakes 360
- A warning 360
- Brake pads 360
- Brakes 12 17 361
- Caution 361
- Master cylinder 361
- 18 brakes 362
- Caution 362
- Master cylinder 362
- Brakes 12 19 363
- Master cylinder 363
- 20 brakes 364
- Brake disc 364
- Brake fluid 365
- Brakes 12 21 365
- 22 brakes 366
- Brake hose 366
- Caution 366
- Suspension 367
- Suspension 13 1 367
- Table of contents 367
- Exploded view 369
- Suspension 13 3 369
- _______________________________ suspension 13 5 exploded view 371
- 6 suspension 372
- Specifications 372
- Special tools 373
- Suspension 13 7 373
- 8 suspension 374
- Special tools 374
- Front fork 375
- Suspension 13 9 375
- Warning 375
- _____i 375
- 10 suspension 376
- Front fork 376
- Warning 376
- Front fork 377
- Suspension 13 11 377
- 12 suspension 378
- Front fork 378
- Front fork 379
- Suspension 13 13 379
- 14 suspension 380
- Front fork 380
- Front fork 381
- Suspension 13 15 381
- 16 suspension 382
- Front fork 382
- Caution 383
- Warning 383
- _____________________________________________________ suspension 13 17 front fork 383
- 18 suspension 384
- Rear shock absorber 384
- A warning 385
- Rear shock absorber 385
- Suspension 13 19 385
- 20 suspension 386
- Rear shock absorber 386
- Warning 386
- Suspension 13 21 387
- Swingarm 387
- 22 suspension 388
- Swingarm 388
- Caution 389
- Suspension 13 23 389
- Swingarm 389
- 24 suspension 390
- Swingarm 390
- Suspension 13 25 391
- Tie rod rocker arm 391
- 26 suspension 392
- Caution 392
- Tie rod rocker arm 392
- Steering 393
- Steering 14 1 393
- Table of contents 393
- Exploded view 395
- Steering 14 3 395
- 4 steering 396
- Special tools 396
- Steering 397
- Steering 14 5 397
- 6 steering 398
- Steering stem 398
- Steering 14 7 399
- Steering stem 399
- 8 steering 400
- A warning 400
- Steering stem 400
- Steering 14 9 401
- Steering stem 401
- 10 steering 402
- Handlebar 402
- Frame 15 1 403
- Table of contents 403
- Exploded view 405
- Frame 15 3 405
- Exploded view 407
- Frame 15 5 407
- Exploded view 409
- 8 frame 410
- Fairings 411
- Frame 15 9 411
- 10 frame 412
- Fairings 412
- Frame 15 11 413
- Seat cover 413
- 12 frame 414
- Fenders 414
- Fenders 415
- Frame 15 13 415
- 14 frame 416
- A warning 416
- Frame 15 15 417
- Storage box 417
- 16 frame 418
- Side stand 418
- Electrical system 419
- Electrical system 16 1 419
- Table of contents 419
- 2 electrical system 420
- Electrical system 16 5 423
- Exploded view 423
- Electrical system 16 7 425
- Exploded view 425
- Electrical system 16 9 427
- Exploded view 427
- Electrical system 16 11 429
- Ignition switch connections 429
- Wiring diagram united states and canada 429
- Electrical system 16 13 431
- I0b2 11sji 431
- R f g h t switch housing connections 431
- W2r1157bw5 c 431
- Wiring diagram australia 431
- 16 electrical system 434
- Specifications 434
- Electrical system 16 17 435
- Special tools and sealant 435
- 18 electrical system 436
- Parts location 436
- Electrical system 16 19 437
- Parts location 437
- 20 electrical system 438
- Precautions 438
- Electrical system 16 21 439
- Precautions 439
- 22 electrical system 440
- Electrical wiring 440
- Battery 441
- Caution 441
- Electrical system 16 23 441
- 24 electrical system 442
- Battery 442
- Caution 442
- A warning 443
- Battery 443
- Caution 443
- Electrical system 16 25 443
- 26 electrical system 444
- Battery 444
- Caution 444
- Warning 444
- Battery 445
- Electrical system 16 27 445
- 28 electrical system 446
- Charging system 446
- Caution 447
- Charging system 447
- Electrical system 16 29 447
- 30 electrical system 448
- Charging system 448
- Charging system 449
- Electrical system 16 31 449
- 32 electrical system 450
- Charging system 450
- Charging system 451
- Electrical system 16 33 451
- 34 electrical system 452
- Caution 452
- Charging system 452
- Charging system 453
- Electrical system 16 35 453
- 36 electrical system 454
- Charging system 454
- Charging system circuit 454
- 38 electrical system 456
- Caution 456
- Ignition system 456
- Warning 456
- Electrical system 16 39 457
- Ignition system 457
- 40 electrical system 458
- Caution 458
- Ignition system 458
- Electrical system 16 41 459
- Ignition system 459
- 42 electrical system 460
- Ignition system 460
- Warning 460
- Electrical system 16 43 461
- Ignition system 461
- 44 electrical system 462
- Ignition system 462
- Electrical system 16 45 463
- Ignition system 463
- 46 electrical system 464
- Ignition system 464
- Electrical system 16 47 465
- Ignition system 465
- Ignition system circuit 465
- 48 electrical system 466
- Caution 466
- Electric starter system 466
- Electric starter system 467
- Electrical system 16 49 467
- 50 electrical system 468
- Electric starter system 468
- Electric starter system 469
- Electrical system 16 51 469
- 52 electrical system 470
- Electric starter system 470
- Electric starter circuit 471
- Electric starter system 471
- Electrical system 16 53 471
- 54 electrical system 472
- Lighting system 472
- Caution 473
- Electrical system 16 55 473
- Lighting system 473
- 56 electrical system 474
- Headlight tail light circuit 474
- Lighting system 474
- Electrical system 16 57 475
- Lighting system 475
- 58 electrical system 476
- Lighting system 476
- Turn signal light circuit 476
- Electrical system 16 59 477
- Radiator fan system 477
- Warning 477
- 60 electrical system 478
- Radiator fan circuit 478
- Radiator fan system 478
- Caution 479
- Electrical system 16 61 479
- 62 electrical system 480
- Caution 480
- Do not short each terminals 480
- Meter gauge indicator unit 480
- Electrical system 16 63 481
- Meter gauge indicator unit 481
- 64 electrical system 482
- Meter gauge indicator unit 482
- Electrical system 16 65 483
- Meter gauge indicator unit 483
- 66 electrical system 484
- Meter gauge indicator unit 484
- Electrical system 16 67 485
- Meter gauge indicator unit 485
- 68 electrical system 486
- Meter gauge indicator unit 486
- Electrical system 16 69 487
- Meter gauge indicator unit 487
- 70 electrical system 488
- Meter circuit 488
- Meter gauge indicator unit 488
- Electrical system 16 71 489
- Switches and sensors 489
- 72 electrical system 490
- Switches and sensors 490
- Electrical system 16 73 491
- Switches and sensors 491
- 74 electrical system 492
- Switches and sensors 492
- Electrical system 16 75 493
- Switches and sensors 493
- 76 electrical system 494
- Junction box 494
- Diode circuit inspection 495
- Electrical system 16 77 495
- Junction box 495
- 78 electrical system 496
- Junction box 496
- Junction box internal circuit 496
- Electrical system 16 79 497
- 80 electrical system 498
- Appendix 499
- 2 appendix 500
- Cable wire and hose routing 500
- Appendix 17 3 501
- Cable wire and hose routing 501
- 4 appendix 502
- Cable wire and hose routing 502
- Appendix 17 5 503
- Cable wire and hose routing 503
- 6 appendix 504
- Cable wire and hose routing 504
- Appendix 17 7 505
- Cable wire and hose routing 505
- 8 appendix 506
- Cable wire and hose routing 506
- Appendix 17 9 507
- Cable wire and hose routing 507
- 10 appendix 508
- Cable wire and hose routing 508
- Appendix 17 11 509
- Cable wire and hose routing 509
- California evaporative emission control system 509
- 12 appendix 510
- Engine doesn t start starting difficulty 510
- Poor running at low speed 510
- Troubleshooting guide 510
- Appendix 17 13 511
- Overheating 511
- Poor running or no power at high speed 511
- Troubleshooting guide 511
- 14 appendix 512
- Clutch operation faulty 512
- Gear shifting faulty 512
- Over cooling 512
- Troubleshooting guide 512
- Abnormal drive train noise 513
- Abnormal engine noise 513
- Abnormal frame noise 513
- Appendix 17 15 513
- Exhaust smokes excessively 513
- Oil pressure warning light goes on 513
- Troubleshooting guide 513
- 16 appendix 514
- Battery trouble 514
- Brake doesn t hold 514
- Handling and or stability unsatisfactory 514
- Troubleshooting guide 514
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Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop However it contains enough detail and basic in formation to make it useful to the owner who de sires to perform his own basic maintenance and repair work A basic knowledge of mechanics the proper use of tools and workshop proce dures must be understood in order to carry out maintenance and repair satisfactorily When ever the owner has insufficient experience or doubts his ability to do the work all adjust ments maintenance and repair should be car ried out only by qualified mechanics In order to perform the work efficiently and to avoid costly mistakes read the text thor oughly familiarize yourself with the procedures before starting work and then do the work care fully in a clean area Whenever special tools or equipment are specified do not use makeshift tools or equipment Precision measurements can only be made if the proper instruments are used and the use of substitute tools may ad versely affect safe operation For the duration of the warranty period we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty To get the longest life out of your vehicle Follow the Periodic Maintenance Chart in the Service Manual Be alert for problems and non scheduled maintenance Use proper tools and genuine Kawasaki Motorcycle parts Special tools gauges and testers that are necessary when servicing Kawasaki motorcycles are introduced by the Special Tool Catalog or Manual Genuine parts provided as spare parts are listed in the Parts Catalog Follow the procedures in this manual care fully Don t take shortcuts Remember to keep complete records of main tenance and repair with dates and any new parts installed How to Use This Manual In this manual the product is divided into its major systems and these systems make up the manual s chapters The Quick Reference Guide shows you all of the product s system and assists in locating their chapters Each chapter in turn has its own comprehensive Table of Contents For example if you want ignition coil informa tion use the Quick Reference Guide to locate the Electrical System chapter Then use the Table of Contents on the first page of the chap ter to find the ignition coil section
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