![Kawasaki KLE500 (2004) [393/401] Appendix 17 13](/img/pdf.png)
Kawasaki KLE500 (2004) [393/401] Appendix 17 13
![Kawasaki KLE500 (2004) [393/401] Appendix 17 13](/views2/1121221/page393/bg189.png)
APPENDIX 17-13
Cable, Wire, and Hose Routing
1. Ignition Switch Lead
2. Handlebar Switch Lead (Right)
3. Handlebar Switch Lead (Left)
4. Fix the connector with bracket (5).
5. Bracket
6. Meter Leads
7. Insert the connector to arrow direction.
8. to Headlight
9. Diode Connector
10. Front R ight Turn Signal Light
11. Front Left Turn Signal Light
12. Left handlebar switch terminal shall be connected under the bracket.
A. View from A
B. View from under the upper fairing.
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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