![Kawasaki KLE500 (2004) [199/401] Crankshaft transmission 9 13](/img/pdf.png)
Kawasaki KLE500 (2004) [199/401] Crankshaft transmission 9 13
![Kawasaki KLE500 (2004) [199/401] Crankshaft transmission 9 13](/views2/1121221/page199/bgc7.png)
CRANKSHAFT/TRANSMISSION 9-13
Crankcase Splitting
•
Turn the engine over so it is upright.
•
Put the 8 mm bolts [A], and the 6 mm bolts [B] into the
upper crankcase half as shown in the figure, torque the 8
mm bolt first, then the other bolts in the sequence shown.
Torque - Crankcase 8 mm Bolts: 27 N·m (2.8 kgf·m, 20 ft·lb)
Crankcase 6 mm Bolts: 12 N·m (1.2 kgf·m, 104
in·lb)
•
After tightening all crankcase bolts, check the following
items:
○
Drive shaft and output shaft turn freely.
○
While s pinning the output shaft, gears shift smoothly from
the 1st to 6th gear, and 6th to 1st.
○
When the output shaft stays still, the gear can not be
shifted to 2nd gear or other higher gear positions.
Содержание
- Tables 1
- Quick reference guide 2
- Kle500 5
- Motorcycle service manual 5
- List of abbreviations 6
- Read owner s manual before operating 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 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
- 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 torque 19
- Units of volume 19
- Periodic maintenance 21
- Periodic maintenance 2 1 21
- Table of contents 21
- 2 periodic maintenance 22
- 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 34
- Maintenance procedure 34
- Throttle cable inspection 34
- Throttle grip free play 34
- Idle speed 35
- Maintenance procedure 35
- Periodic maintenance 2 15 35
- Warning 35
- 16 periodic maintenance 36
- Maintenance procedure 36
- Maintenance procedure 37
- Periodic maintenance 2 17 37
- Warning 37
- 18 periodic maintenance 38
- Cooling system 38
- Maintenance procedure 38
- Engine top end 39
- Maintenance procedure 39
- Periodic maintenance 2 19 39
- 20 periodic maintenance 40
- Maintenance procedure 40
- Valve clearance measuring position 40
- Clutch 41
- Clutch lever free play 41
- Clutch operation inspection 41
- Maintenance procedure 41
- Periodic maintenance 2 21 41
- Valve clearance when cold 41
- Warning 41
- 22 periodic maintenance 42
- Air pressure inspection adjustment 42
- Air pressure when cold 42
- Maintenance procedure 42
- Tire tread wear inspection 42
- Warning 42
- Wheels tires 42
- Maintenance procedure 43
- Periodic maintenance 2 23 43
- Tread depth 43
- Warning 43
- 24 periodic maintenance 44
- Maintenance procedure 44
- Rim runout with tire installed 44
- Spoke tightness and rim runout inspection 44
- Warning 44
- Wheel bearing damage inspection 44
- Chain slack 45
- Final drive 45
- Maintenance procedure 45
- Periodic maintenance 2 25 45
- Warning 45
- 26 periodic maintenance 46
- Drive chain 20 link length 46
- Maintenance procedure 46
- Warning 46
- Brake fluid leak brake hose and pipe inspection 47
- Brakes 47
- Caution 47
- Drive chain lubrication 47
- Maintenance procedure 47
- Periodic maintenance 2 27 47
- Warning 47
- 28 periodic maintenance 48
- Maintenance procedure 48
- Warning 48
- Maintenance procedure 49
- Pad lining thickness 49
- Periodic maintenance 2 29 49
- Recommended disc brake fluid 49
- Warning 49
- 30 periodic maintenance 50
- Brake light switch operation inspection 50
- Brake light timing 50
- Caution 50
- Front forks rear shock absorber operation inspection 50
- Maintenance procedure 50
- Suspension 50
- Front fork oil leak inspection 51
- Maintenance procedure 51
- Periodic maintenance 2 31 51
- Rear shock absorber oil leak inspection 51
- Rocker arm bearings and sleeves lubrication 51
- Rocker arm operation inspection 51
- 32 periodic maintenance 52
- Maintenance procedure 52
- Steering 52
- Maintenance procedure 53
- Periodic maintenance 2 33 53
- 34 periodic maintenance 54
- Electrical system 54
- Lights and switches operation inspection 54
- Maintenance procedure 54
- Spark plug gap 54
- Spark plug gap inspection 54
- Maintenance procedure 55
- Periodic maintenance 2 35 55
- 36 periodic maintenance 56
- Headlight aiming inspection 56
- Maintenance procedure 56
- Maintenance procedure 57
- Periodic maintenance 2 37 57
- Sidestand switch operation 57
- 38 periodic maintenance 58
- Maintenance procedure 58
- Others 58
- Maintenance procedure 59
- Periodic maintenance 2 39 59
- 40 periodic maintenance 60
- Fuel hose replacement 60
- Maintenance procedure 60
- Replacement parts 60
- Maintenance procedure 61
- Periodic maintenance 2 41 61
- Warning 61
- 42 periodic maintenance 62
- Maintenance procedure 62
- Maintenance procedure 63
- Periodic maintenance 2 43 63
- Water and coolant mixture ratio when shipping 63
- 44 periodic maintenance 64
- Engine oil change 64
- Maintenance procedure 64
- Radiator hoses and o ring replacement 64
- Engine oil 65
- Maintenance procedure 65
- Periodic maintenance 2 45 65
- 46 periodic maintenance 66
- Maintenance procedure 66
- Maintenance procedure 67
- Periodic maintenance 2 47 67
- Warning 67
- 48 periodic maintenance 68
- Maintenance procedure 68
- Maintenance procedure 69
- Periodic maintenance 2 49 69
- Spark plug replacement 69
- Fuel system 71
- Fuel system 3 1 71
- Table of contents 71
- Exploded view 73
- Fuel system 3 3 73
- Exploded view 75
- Fuel system 3 5 75
- 6 fuel system 76
- Specifications 76
- Fuel system 3 7 77
- Special tools 77
- 8 fuel system 78
- Throttle grip and cables 78
- Choke cable 79
- Choke cable free play 79
- Fuel system 3 9 79
- Warning 79
- 10 fuel system 80
- Carburetor installation 80
- Carburetor removal 80
- Carburetors 80
- Warning 80
- Carburetors 81
- Fuel system 3 11 81
- Service fuel level inspection 81
- Warning 81
- 12 fuel system 82
- Carburetors 82
- Fuel level 82
- Warning 82
- Carburetors 83
- Float height 83
- Fuel system 3 13 83
- Warning 83
- 14 fuel system 84
- Carburetors 84
- Carburetor separation assembly 85
- Carburetors 85
- Caution 85
- Fuel system 3 15 85
- 16 fuel system 86
- Carburetors 86
- Carburetors 87
- Fuel system 3 17 87
- Warning 87
- 18 fuel system 88
- Carburetor inspection 88
- Carburetors 88
- Coolant filter cleaning 88
- Warning 88
- Air cleaner 89
- Air cleaner element cleaning and inspection 89
- Air cleaner element installation 89
- Air cleaner element removal 89
- Air cleaner housing removal 89
- Caution 89
- Fuel system 3 19 89
- Warning 89
- 20 fuel system 90
- Air cleaner 90
- Air cleaner draining 90
- Air cleaner housing installation 90
- Warning 90
- Fuel system 3 21 91
- Fuel tank 91
- Warning 91
- 22 fuel system 92
- Fuel tank 92
- Fuel tank and tap cleaning 92
- Fuel tank installation 92
- Fuel tap installation 92
- Fuel tap removal 92
- Warning 92
- Caution 93
- Fuel system 3 23 93
- Fuel tank 93
- Fuel tank and cap inspection 93
- Fuel tap inspection 93
- 24 fuel system 94
- Fuel hose 94
- Fuel hose and connection inspection 94
- Cooling system 95
- Cooling system 4 1 95
- Table of contents 95
- Cooling system 4 3 97
- Exploded view 97
- 4 cooling system 98
- Specifications 98
- Cooling system 4 5 99
- Special tool and sealant 99
- 6 cooling system 100
- Coolant flow chart 100
- Coolant flow chart 101
- Cooling system 4 7 101
- 8 cooling system 102
- Coolant 102
- Coolant 103
- Cooling system 4 9 103
- Valve closing temperature for reference 103
- 10 cooling system 104
- Water pump 104
- Cooling system 4 11 105
- Water pump 105
- 12 cooling system 106
- Impeller assembly 106
- Pump impeller inspection 106
- Water pump 106
- Caution 107
- Cooling system 4 13 107
- Radiator inspection 107
- Radiator radiator fan 107
- Radiator removal 107
- Warning 107
- 14 cooling system 108
- Radiator cap relief pressure 108
- Radiator radiator fan 108
- Cooling system 4 15 109
- Radiator hose and connection inspection 109
- Radiator hose pipe air vent hose reservoir tank hose installation 109
- Radiator radiator fan 109
- 16 cooling system 110
- Thermostat 110
- Thermostat inspection 110
- Thermostat installation 110
- Thermostat removal 110
- Cooling system 4 17 111
- Thermostat 111
- Thermostat valve opening temperature 111
- 18 cooling system 112
- Radiator fan switch water temperature switch 112
- Engine top end 113
- Engine top end 5 1 113
- Table of contents 113
- Engine top end 5 3 115
- Exploded view 115
- Engine top end 5 5 117
- Exploded view 117
- 6 engine top end 118
- Specifications 118
- Engine top end 5 7 119
- Specifications 119
- 8 engine top end 120
- Special tools and sealant 120
- Engine top end 5 9 121
- Special tools and sealant 121
- 10 engine top end 122
- Special tools and sealant 122
- Air suction valve inspection 123
- Air suction valve installation 123
- Air suction valve removal 123
- Clean air system 123
- Clean air system hose inspection 123
- Engine top end 5 11 123
- Vacuum switch valve installation 123
- Vacuum switch valve removal 123
- 12 engine top end 124
- Clean air system 124
- Vacuum switch valve closing pressure open close 124
- Cylinder head cover 125
- Cylinder head cover removal 125
- Engine top end 5 13 125
- 14 engine top end 126
- Cylinder head cover 126
- Cylinder head cover installation 126
- Camshaft chain tensioner 127
- Camshaft chain tensioner installation 127
- Camshaft chain tensioner removal 127
- Caution 127
- Engine top end 5 15 127
- 16 engine top end 128
- Camshaft camshaft chain 128
- Camshaft camshaft chain 129
- Engine top end 5 17 129
- 18 engine top end 130
- Camshaft camshaft chain 130
- Camshaft journal camshaft cap clearance 130
- Engine top end 5 19 131
- Rocker shaft rocker arm 131
- 20 engine top end 132
- Cylinder head oil pipe installation 132
- Cylinder head oil pipe removal 132
- Main oil pipe installation 132
- Main oil pipe removal 132
- Oil pipe 132
- Cylinder compression usable range 133
- Cylinder head 133
- Engine top end 5 21 133
- 22 engine top end 134
- Cylinder head 134
- Cylinder head removal 134
- Cylinder head 135
- Engine top end 5 23 135
- 24 engine top end 136
- Cylinder head 136
- Cylinder head cleaning 136
- Cylinder head warp 136
- Engine top end 5 25 137
- Valves 137
- 26 engine top end 138
- Valve seating surface outside diameter 138
- Valve seating surface width 138
- Valves 138
- Engine top end 5 27 139
- Special tools 139
- Valve valve guide clearance wobble method 139
- Valves 139
- 28 engine top end 140
- Valves 140
- Engine top end 5 29 141
- Valves 141
- 30 engine top end 142
- Valves 142
- 32 engine top end 144
- Cylinder piston 144
- Caution 145
- Cylinder piston 145
- Engine top end 5 33 145
- Piston installation 145
- 34 engine top end 146
- Cylinder inside diameter 146
- Cylinder piston 146
- Piston ring end gap 146
- Piston ring groove clearance 146
- Piston ring piston ring groove wear 146
- Cylinder piston 147
- Engine top end 5 35 147
- Piston diameter 147
- 36 engine top end 148
- Carburetor holder 148
- Carburetor holder installation 148
- Warning 148
- Engine top end 5 37 149
- Muffler 149
- Muffler installation 149
- Muffler removal 149
- Clutch 151
- Clutch 6 1 151
- Table of contents 151
- Clutch 6 3 153
- Exploded view 153
- Clutch 6 5 155
- Exploded view 155
- 6 clutch 156
- Specifications 156
- Clutch 6 7 157
- Special tool and sealant 157
- 8 clutch 158
- Clutch lever and cable 158
- Clutch 6 9 159
- Right engine cover 159
- 10 clutch 160
- Right engine cover 160
- Clutch 161
- Clutch 6 11 161
- 12 clutch 162
- Clutch 162
- Friction and steel plate warp 162
- Friction plate thickness 162
- Clutch 163
- Clutch 6 13 163
- Clutch housing finger inspection 163
- Clutch hub spline inspection 163
- Clutch spring free length 163
- Clutch spring free length measurement 163
- Engine lubrication system 165
- Engine lubrication system 7 1 165
- Table of contents 165
- Engine lubrication system 7 3 167
- Exploded view 167
- Engine lubrication system 7 5 169
- Exploded view 169
- Engine lubrication system 7 7 171
- Specifications 171
- 8 engine lubrication system 172
- Special tools and sealant 172
- Engine lubrication system 7 9 173
- Engine oil and oil filter 173
- Warning 173
- 10 engine lubrication system 174
- Oil pan and relief valve 174
- Engine lubrication system 7 11 175
- Oil pan and relief valve 175
- Warning 175
- 12 engine lubrication system 176
- Oil pump 176
- Oil pump removal 176
- Engine lubrication system 7 13 177
- Oil pump 177
- 14 engine lubrication system 178
- Oil pump 178
- Warning 178
- Engine lubrication system 7 15 179
- Oil pressure 179
- Oil pressure measurement 179
- Warning 179
- Engine removal installation 181
- Engine removal installation 8 1 181
- Table of contents 181
- Engine removal installation 8 3 183
- Exploded view 183
- 4 engine removal installation 184
- Caution 184
- Engine removal 184
- Engine removal installation 184
- Warning 184
- Engine removal installation 185
- Engine removal installation 8 5 185
- 6 engine removal installation 186
- Engine installation 186
- Engine removal installation 186
- Crankshaft transmission 187
- Crankshaft transmission 9 1 187
- Table of contents 187
- Crankshaft transmission 9 3 189
- Exploded view 189
- Crankshaft transmission 9 5 191
- Exploded view 191
- 6 crankshaft transmission 192
- Specifications 192
- Crankshaft transmission 9 7 193
- Specifications 193
- 8 crankshaft transmission 194
- Specifications 194
- Crankshaft transmission 9 9 195
- Special tools and sealant 195
- 10 crankshaft transmission 196
- Crankcase splitting 196
- Crankcase splitting 197
- Crankshaft transmission 9 11 197
- 12 crankshaft transmission 198
- Crankcase splitting 198
- Torque value for 8 mm bolts 198
- Crankcase splitting 199
- Crankshaft transmission 9 13 199
- 14 crankshaft transmission 200
- Clutch housing primary chain 200
- Clutch housing primary chain installation 200
- Clutch housing primary chain removal 200
- Clutch housing primary chain 201
- Crankshaft transmission 9 15 201
- Primary chain guide wear inspection 201
- 16 crankshaft transmission 202
- Crankshaft connecting rods 202
- Caution 203
- Connecting rod installation 203
- Crankshaft connecting rod cleaning 203
- Crankshaft connecting rods 203
- Crankshaft transmission 9 17 203
- 18 crankshaft transmission 204
- Connecting rod bend 204
- Connecting rod big end side clearance 204
- Connecting rod twist 204
- Crankshaft connecting rods 204
- Connecting rod big end bearing insert crankpin clearance 205
- Crankpin diameter 205
- Crankpin diameter marks 205
- Crankshaft connecting rods 205
- Crankshaft transmission 9 19 205
- 20 crankshaft transmission 206
- Connecting rod big end bearing insert selection 206
- Connecting rod big end bore diameter marks 206
- Crankshaft connecting rods 206
- Crankshaft runout 206
- Crankshaft main bearing insert journal clearance 207
- Crankshaft main journal diameter 207
- Crankshaft main journal diameter marks 207
- Crankshaft transmission 9 21 207
- 22 crankshaft transmission 208
- Crankcase main bearing bore diameter marks 208
- Crankshaft main bearing insert selection 208
- Crankshaft side clearance 208
- Balancer 209
- Balancer shaft bearing insert journal clearance 209
- Balancer shaft journal diameter 209
- Crankshaft transmission 9 23 209
- 24 crankshaft transmission 210
- Balancer shaft bearing insert selection 210
- Balancer shaft diameter marks 210
- Crankcase bearing bore diameter marks 210
- Crankshaft transmission 9 25 211
- Transmission 211
- 26 crankshaft transmission 212
- Transmission 212
- Crankshaft transmission 9 27 213
- Transmission 213
- 28 crankshaft transmission 214
- Transmission 214
- Crankshaft transmission 9 29 215
- Transmission 215
- 30 crankshaft transmission 216
- Transmission 216
- Crankshaft transmission 9 31 217
- Shift drum and fork installation 217
- Transmission 217
- 32 crankshaft transmission 218
- Shift drum assembly 218
- Shift drum disassembly 218
- Transmission 218
- Crankshaft transmission 9 33 219
- Transmission 219
- Table of contents 221
- Wheels tires 221
- Wheels tires 10 1 221
- Exploded view 223
- Wheels tires 10 3 223
- 4 wheels tires 224
- Specifications 224
- Special tools 225
- Wheels tires 10 5 225
- 6 wheels tires 226
- Caution 226
- Front wheel installation 226
- Front wheel removal 226
- Warning 226
- Wheels rims 226
- Rear wheel installation 227
- Rear wheel removal 227
- Wheels rims 227
- Wheels tires 10 7 227
- 8 wheels tires 228
- Axle runout 100 mm 3 4 in 228
- Wheels rims 228
- Balance weight 229
- Wheels rims 229
- Wheels tires 10 9 229
- 10 wheels tires 230
- Air pressure inspection adjustment 230
- Caution 230
- Tire removal 230
- Tire wear inspection 230
- Wheels tires 10 11 231
- 12 wheels tires 232
- Hub bearing 232
- Hub bearing 233
- Wheels tires 10 13 233
- 14 wheels tires 234
- Speedometer gear 234
- Final drive 235
- Final drive 11 1 235
- Table of contents 235
- Exploded view 237
- Final drive 11 3 237
- 4 final drive 238
- Specifications 238
- Final drive 11 5 239
- Special tools and sealants 239
- 6 final drive 240
- Drive chain 240
- Drive chain installation 240
- Drive chain lubrication 240
- Drive chain removal 240
- Drive chain slack inspection 240
- Drive chain wear inspection 240
- Wheel alignment inspection adjustment 240
- Drive chain 241
- Final drive 11 7 241
- Recommended tool 241
- 8 final drive 242
- Drive chain 242
- Link pin outside diameter 242
- Link plates outside width 242
- Final drive 11 9 243
- Sprocket coupling 243
- 10 final drive 244
- Rear sprocket warp 244
- Sprocket coupling 244
- Final drive 11 11 245
- Sprocket coupling 245
- 12 final drive 246
- Sprocket coupling 246
- Brakes 247
- Brakes 12 1 247
- Table of contents 247
- Brakes 12 3 249
- Exploded view 249
- Brakes 12 5 251
- Exploded view 251
- 6 brakes 252
- Specifications 252
- Brakes 12 7 253
- Special tool 253
- 8 brakes 254
- Brake lever and brake pedal 254
- Pedal position 254
- Brake lever and brake pedal 255
- Brake pedal and shaft installation 255
- Brakes 12 9 255
- 10 brakes 256
- Caliper 256
- Brakes 12 11 257
- Caliper 257
- Warning 257
- 12 brakes 258
- Caliper 258
- Warning 258
- Brakes 12 13 259
- Caliper 259
- 14 brakes 260
- Caliper 260
- Brakes 12 15 261
- Caliper 261
- Caliper holder shaft wear 261
- 16 brakes 262
- Brake pads 262
- Warning 262
- Brakes 12 17 263
- Caution 263
- Front master cylinder installation 263
- Front master cylinder removal 263
- Master cylinder 263
- Rear master cylinder removal 263
- Warning 263
- 18 brakes 264
- Caution 264
- Front master cylinder disassembly 264
- Master cylinder 264
- Rear master cylinder installation 264
- Warning 264
- Brakes 12 19 265
- Master cylinder 265
- 20 brakes 266
- Master cylinder 266
- Master cylinder inspection visual inspection 266
- Brake disc 267
- Brake disc installation 267
- Brake disc removal 267
- Brake disc warp 267
- Brake disc wear 267
- Brakes 12 21 267
- Disc runout 267
- Disc thickness 267
- 22 brakes 268
- Bleeding the brake line 268
- Brake fluid 268
- Brake fluid change 268
- Brake fluid level inspection 268
- Warning 268
- Brake hose 269
- Brake hose installation note 269
- Brake hose replacement 269
- Brake hoses and connections inspection 269
- Brakes 12 23 269
- Caution 269
- Front brake hose removal 269
- Warning 269
- Suspension 271
- Suspension 13 1 271
- Table of contents 271
- Exploded view 273
- Suspension 13 3 273
- Exploded view 275
- Suspension 13 5 275
- 6 suspension 276
- Specifications 276
- Special tools and sealant 277
- Suspension 13 7 277
- 8 suspension 278
- Front fork 278
- Front fork oil level fully compressed without fork spring 278
- Front fork 279
- Suspension 13 9 279
- Warning 279
- 10 suspension 280
- Front fork 280
- Front fork 281
- Suspension 13 11 281
- 12 suspension 282
- Caution 282
- Dust seal inspection 282
- Front fork 282
- Inner tube outer tube inspection 282
- Spring free length 282
- Spring tension 282
- Warning 282
- Rear shock absorber 283
- Spring preload adjustment 283
- Suspension 13 13 283
- 14 suspension 284
- Bushing wear 284
- Rear shock absorber 284
- Rear shock absorber installation 284
- Rear shock absorber oil leak inspection 284
- Rear shock absorber wear 284
- Suspension 13 15 285
- Swingarm 285
- 16 suspension 286
- Swingarm 286
- Suspension 13 17 287
- Tie rod rocker arm 287
- 18 suspension 288
- Caution 288
- Rocker arm bearing sleeve inspection 288
- Rocker arm installation 288
- Rocker arm lubrication 288
- Tie rod rocker arm 288
- Steering 289
- Steering 14 1 289
- Table of contents 289
- Exploded view 291
- Steering 14 3 291
- 4 steering 292
- Special tools 292
- Special tools 293
- Steering 14 5 293
- 6 steering 294
- Handlebar 294
- Handlebar installation 294
- Handlebar removal 294
- Handlebar 295
- Rear view mirror removal 295
- Rear view mirrors left and right installation 295
- Steering 14 7 295
- 8 steering 296
- Steering 296
- Steering play inspection 296
- Steering 14 9 297
- Steering stem 297
- Steering stem installation 297
- Steering stem removal 297
- 10 steering 298
- Steering stem 298
- Warning 298
- Steering 14 11 299
- Steering stem 299
- Steering stem warp 299
- 12 steering 300
- Steering stem bearing 300
- Steering 14 13 301
- Steering stem bearing 301
- Frame 15 1 303
- Table of contents 303
- Exploded view 305
- Frame 15 3 305
- Frame 15 5 307
- Specifications 307
- 6 frame 308
- Seat installation 308
- Seat removal 308
- Air duct removal 309
- Fairing 309
- Frame 15 7 309
- Lower fairings installation 309
- Lower fairings removal 309
- Upper fairing removal 309
- 8 frame 310
- Left side cover installation 310
- Left side cover removal 310
- Right side cover installation 310
- Right side cover removal 310
- Side covers 310
- Fenders 311
- Frame 15 9 311
- Front fender removal 311
- Rear fender removal 311
- 10 frame 312
- Fender installation note 312
- Fenders 312
- Frame 15 11 313
- Frame inspection 313
- Warning 313
- 12 frame 314
- Carrier installation 314
- Carrier removal 314
- Engine guard removal 314
- Guard carrier 314
- Electrical system 315
- Electrical system 16 1 315
- Table of contents 315
- 2 electrical system 316
- Electrical system 16 3 317
- Parts location 317
- Electrical system 16 5 319
- Exploded view 319
- Electrical system 16 7 321
- Exploded view 321
- Electrical system 16 9 323
- Exploded view 323
- 10 electrical system 324
- Specifications 324
- Electrical system 16 11 325
- Specifications 325
- 12 electrical system 326
- Special tools and sealant 326
- Electrical system 16 13 327
- Special tools and sealant 327
- 16 electrical system 330
- Precautions 330
- 18 electrical system 332
- Electrical wiring 332
- Battery 333
- Battery activation 333
- Battery removal installation 333
- Caution 333
- Electrical system 16 19 333
- 20 electrical system 334
- Battery 334
- Battery 335
- Electrical system 16 21 335
- Kawasaki recommended chargers 335
- 22 electrical system 336
- Battery 336
- Battery terminal voltage 336
- Warning 336
- Battery 337
- Electrical system 16 23 337
- Terminal voltage 11 less than 12 v 337
- Terminal voltage less than 11 v 337
- Warning 337
- 24 electrical system 338
- Charging system 338
- Charging system 339
- Electrical system 16 25 339
- 26 electrical system 340
- Charging system 340
- Charging system 341
- Electrical system 16 27 341
- 28 electrical system 342
- Charging system 342
- Table 2 stator coil resistance 342
- Voltage 342
- Charging system 343
- Electrical system 16 29 343
- Regulator rectifier inspection 343
- Regulator rectifier output voltage 343
- 30 electrical system 344
- Charging system 344
- Rectifier circuit inspection 344
- Caution 345
- Charging system 345
- Electrical system 16 31 345
- 32 electrical system 346
- Charging system 346
- Charging system circuit 346
- Electrical system 16 33 347
- Ignition system 347
- Ignition system circuit 347
- 34 electrical system 348
- Caution 348
- Crankshaft sensor inspection 348
- Crankshaft sensor installation 348
- Crankshaft sensor removal 348
- Crankshaft sensor resistance 348
- Ignition system 348
- Warning 348
- Electrical system 16 35 349
- Ignition coil arcing distance 349
- Ignition system 349
- Warning 349
- 36 electrical system 350
- Ignition coil winding resistance 350
- Ignition system 350
- Ignition timing 350
- Electrical system 16 37 351
- Ignition system 351
- 38 electrical system 352
- Ignition system 352
- Connect 353
- Electrical system 16 39 353
- Ignition coil primary peak voltage 353
- Ignition system 353
- Warning 353
- Connect 355
- Crankshaft sensor peak voltage 355
- Electrical system 16 41 355
- Ignition system 355
- 42 electrical system 356
- Ignition system 356
- Electric starter circuit 357
- Electric starter system 357
- Electrical system 16 43 357
- 44 electrical system 358
- Electric starter system 358
- Starter motor disassembly 358
- Starter motor installation 358
- Starter motor removal 358
- Electric starter system 359
- Electrical system 16 45 359
- Starter motor assembly 359
- 46 electrical system 360
- Brush inspection 360
- Brush spring inspection 360
- Commutator cleaning and inspection 360
- Commutator diameter 360
- Electric starter system 360
- Starter motor brush length 360
- Electric starter system 361
- Electrical system 16 47 361
- 48 electrical system 362
- Electric starter system 362
- Starter relay inspection 362
- Testing relay 362
- Electrical system 16 49 363
- Headlight beam horizontal adjustment 363
- Headlight beam vertical adjustment 363
- Headlight circuit 363
- Lighting system 363
- 50 electrical system 364
- Caution 364
- Headlight bulb replacement 364
- Headlight unit housing removal 364
- Lighting system 364
- City light bulb replacement 365
- Electrical system 16 51 365
- Headlight unit housing installation 365
- Lighting system 365
- Tail brake light bulb replacement 365
- 52 electrical system 366
- Lighting system 366
- Testing turn signal relay 366
- Electrical system 16 53 367
- Lighting system 367
- Turn signal light circuit 367
- 54 electrical system 368
- Fan motor inspection 368
- Fan system circuit inspection 368
- Radiator fan circuit 368
- Radiator fan system 368
- Wire connectors 368
- Caution 369
- Electrical system 16 55 369
- Meter unit 369
- Meter unit disassembly 369
- Meter unit removal 369
- 56 electrical system 370
- Meter unit 370
- Electrical system 16 57 371
- Meter unit 371
- Tachometer circuit 371
- Water temperature warning system inspection 371
- 58 electrical system 372
- Meter unit 372
- Water temperature warning system 372
- Electrical system 16 59 373
- Switches and sensors 373
- 60 electrical system 374
- Radiator fan switch resistance 374
- Switches and sensors 374
- Electrical system 16 61 375
- Switches and sensors 375
- Water temperature switch connections 375
- 62 electrical system 376
- Fuse circuit inspection 376
- Junction box 376
- Junction box fuse circuit inspection 376
- Starter circuit headlight relay inspection 376
- Diode circuit inspection 377
- Electrical system 16 63 377
- Junction box 377
- Relay circuit inspection with the battery connected 377
- Relay circuit inspection with the battery disconnected 377
- 64 electrical system 378
- Junction box 378
- Junction box internal circuit 378
- A main fuse removal 379
- Caution 379
- Electrical system 16 65 379
- Fuse inspection 379
- Junction box fuse installation 379
- Junction box fuse removal 379
- Appendix 381
- Appendix 17 1 381
- Table of contents 381
- Appendix 17 3 383
- Cable wire and hose routing 383
- Appendix 17 5 385
- Cable wire and hose routing 385
- Appendix 17 7 387
- Cable wire and hose routing 387
- Appendix 17 9 389
- Cable wire and hose routing 389
- Appendix 17 11 391
- Cable wire and hose routing 391
- Appendix 17 13 393
- Cable wire and hose routing 393
- Appendix 17 15 395
- Cable wire and hose routing 395
- 16 appendix 396
- Engine doesn t start starting difficulty 396
- Poor running at low speed 396
- Troubleshooting guide 396
- Appendix 17 17 397
- Overheating 397
- Poor running or no power at high speed 397
- Troubleshooting guide 397
- 18 appendix 398
- Abnormal drive train noise 398
- Abnormal engine noise 398
- Clutch operation faulty 398
- Gear shifting faulty 398
- Over cooling 398
- Troubleshooting guide 398
- Abnormal frame noise 399
- Appendix 17 19 399
- Brake doesn t hold 399
- Exhaust smokes excessively 399
- Handling and or stability unsatisfactory 399
- Oil pressure warning light goes on 399
- Troubleshooting guide 399
- 20 appendix 400
- Battery trouble 400
- Troubleshooting guide 400
- Model application 401
- Part no 99 24 1352 01 401
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