Kawasaki NINJA ZX6RR (2003-2004) [4/514] General information 1 1

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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GENERAL INFORMATION 1 1 General Information TABLE OF CONTENTS Before Servicing 1 2 Model Identification i g General Specifications 1 10 Technical Information Air Inlet System 1 16 Technical Information New Ignition Interlock Sidestand 1 19 Technical Information Tail Brake Lights Employing LED 1 20 Technical Information KAWASAKI LOW EXHAUST EMISSION SYSTEM 1 22 Unit Conversion Table 1 23