Kawasaki GPX250R (1988) [3/253] Quick reference guide

Содержание

• Gpx250r 1
• Kawasaki 1
• Ninja250r 1
• Quick reference guide 3
• Kawasaki 5
• Motorcycle 5
• Ninja250r gpx250r 5
• Service manual 5
• Supplement 5
• Read owner s manual before operating 6
• Emission control information 7
• Tampering with noise control system prohibited 8
• Cautio 9
• Foreword 9
• General information 13
• Table of contents 13
• General information 1 7 19
• 8 general information 20
• General information 1 9 21
• 10 general information 22
• Fuel system 29
• Fuel system 2 1 29
• Table of contents 29
• Fuel system 2 3 31
• A throttle grip free play 32
• Along with common hand tools the following more 32
• Check throttle grip free play by lightly turning the 32
• Fuel system 32
• If the throttle grip free play is incorrect adjust the 32
• Special tools 32
• Specialized tools are required for complete fuel system servicing 32
• Specifications 32
• Throttle cables 32
• Throttle grip and cable 32
• Throttle grip back and forth 32
• Throttle grip play inspection 32
• Air cleaner 33
• Air cleaner element installation 33
• Air cleaner element removal 33
• Cautjon 33
• Fuel system 2 5 33
• Warming 33
• Choke cable 34
• Choke cable free play inspection 34
• Fuel system 2 5 34
• Throttle cable adjustment 34
• Throttle cable inspection 34
• Throttle cable lubrication 34
• Carburetors 35
• Choke cable adjustment 35
• Choke cable inspection 35
• Choke cable lubrication 35
• Fuel system 2 5 35
• Idle speed inspection 35
• Carburetor synchronization 36
• Carburetor synchronization inspection 36
• Fuel system 2 5 36
• Idle speed adjustment 36
• Warnin 36
• Warning 36
• Fuel level adjustment 37
• Fuel level inspection 37
• Fuel system 2 5 37
• Warning 37
• Carburetor assembly removal 38
• Fuel system 2 5 38
• Fuel system cleanliness inspection 38
• Warning 38
• Carbu re tor separa tion 39
• Carburetor assembly installation notes 39
• Carburetor installation 39
• Caution 39
• Fuel system 2 5 39
• Warming i 39
• Warning i 39
• Carburetor disassembly and assembly notes 40
• Caution 40
• Fuel system 2 5 40
• Fuel system 2 5 41
• Carburetor cleaning 42
• Carburetor inspection 42
• Cautiom 42
• Caution 42
• Fuel system 2 5 42
• Warnin 42
• Warning 42
• Fuel system 2 5 43
• Air cleaner 44
• Air cleaner element installation 44
• Air cleaner element removal 44
• Cautjon 44
• Fuel system 2 5 44
• Warning 44
• Air cleaner element cleaning 45
• Air cleaner element inspection 45
• And replacement 45
• Bfeather oh inspection 45
• Caution 45
• Fuel system 2 15 45
• Fuel tank 45
• Fuel tank removal 45
• Warnin 45
• Warning j 45
• Fuel system 2 5 46
• Fuel tank and cap inspection 46
• Fuel tank and tap cleaning 46
• Fuel tap inspection 46
• Warning 46
• Canister inspection 47
• Evaporative emission control system 47
• Fuel system 2 5 47
• Hose inspection 47
• Parts removal installation notes 47
• Separator inspection 47
• Separator operation test 47
• Us california vehicle only 47
• Warning 47
• Fuel system 2 19 48
• Cooling system 49
• Cooling system 3 1 49
• Table of contents 49
• Cooling system 50
• Exploded view 50
• Face the bolt head as down as possible 50
• Coaling system 52
• Coolant 52
• Coolant deterioration 52
• Coolant level inspection 52
• Cooling system 52
• System controls the engine temperature within narrow limits where the engine operates most efficiently in this way the engine performs stably in various riding conditions and is very durable 52
• The water cooling system is a pressurized forced circulation type when the engine load varies this 52
• Cautio 53
• Caution 53
• Coolant draining 53
• Coolant filling 53
• Cooling system 3 5 53
• Warning 53
• 6 cooling system 54
• A drainage outlet passage 54
• A filler neck b coolant level 1 reservoir tank tube 2 radiator hose to engine 3 coolant level 4 radiator hose to radiator 54
• Air bleeding 54
• Any time the system slowly loses water inspect for 54
• At the bottom of the pump body 54
• Before putting the motorcycle into operation any air 54
• Check the coolant level in the reservoir tank after the 54
• Check the cooling system for leaks start the engine warm it up thoroughly and then stop 54
• Coolant 54
• Coolant and install the cap 54
• Coolant leaks 54
• Càütio 54
• Engine cools down 54
• Fill the reservoir tank up to the full mark with 54
• If the coolant level is low add coolant up to the full 54
• If the mechanical seal is damaged the coolant leaks 54
• If there are no apparent leaks pressure test the system 54
• Leaks check the water pump body drainage outlet passage for 54
• Mark through the reservoir tank opening 54
• Through the seal and drains through the passage replace the water pump unit 54
• Trapped in the cooling system must be removed as follows remove the radiator cap fill the radiator up to the radiator filler neck with 54
• Visual leak inspection 54
• Caution 55
• Cooling system 3 7 55
• Disassembly and assembly precautions 55
• Flushing 55
• Pump cover installation note 55
• Pump cover removal 55
• Water pump 55
• 8 cooling system 56
• Pump impeller inspection 56
• Radiator radiator fan 56
• Radiator radiator fan removal 56
• Warning j 56
• Water pump installation notes 56
• Water pump removal 56
• Cooling system 3 9 57
• Radiator inspection 57
• Radiator installation note 57
• 10 cooling system 58
• Caution 58
• Radiator cap inspection 58
• Radiator cleaning 58
• Cooling system 3 11 59
• Radiator hose pipes 59
• Radiator hose reservoir tank tube inspection 59
• Reservoir tank tube installation note 59
• Thermostat 59
• Thermostat housing removal 59
• Thermostat removal 59
• 12 cooling system 60
• C 177 182 f 60
• Cautio 60
• Thermostat inspection 60
• Thermostatic fan switches water temperature sensor 60
• Water temperature sensor removal 60
• Cooling system 3 13 61
• Fan switch removal 61
• Inspection 61
• Installation note 61
• Engine top end 63
• Engine top end 4 1 63
• Table of contents 63
• Engine top end 43 65
• Engine top end 4 5 67
• Refer to the base manual noting the following 67
• Sealant 67
• Special tools 67
• 6 engine top end 68
• Cylinder head cover 68
• Cylinder head cover installation notes 68
• Cylinder head cover removal 68
• Camshaft camshaft chain rocker arm 69
• Camshaft chain tensioner 69
• Camshaft chain tensioner assembly 69
• Camshaft chain tensioner disassembly 69
• Camshaft rocker arm removal 69
• Chain tensioner installation 69
• Chain tensioner removal 69
• Engine top end 4 7 69
• Camshaft installation 70
• Engine top end 4 9 70
• Including chain timing procedure 70
• 10 engine top end 71
• Camshaft and sprocket assembly notes 71
• Camshaft oil clearance inspection 71
• Fcautj0n 71
• Camshaft chain guide wear 72
• Camshaft chain wear 72
• Compression measurement 72
• Cylinder head 72
• Engine top end 4 11 72
• He 1 vol 72
• V zvr v 72
• 12 engine top end 73
• Cylinder head installation notes 73
• Cylinder head removal 73
• Ii kmf 74
• Z xk zir a 74
• 14 engine top end 75
• Cylinder head cleaning 75
• Cylinder head warp 75
• Engine top end 4 7 76
• Valve clearance inspection 76
• Valves 76
• 8 engine top end 77
• Valve clearance adjustment 77
• Engine top end 4 9 78
• Valve seat inspection 78
• After use wash it with washing oil and apply thin 79
• Before grinding the seat surface also wash off ground particles sticking to the cutter with washing oil 79
• Clean the cylinder head thoroughly see cylinder head 79
• Cleaning 79
• Cutter 2 cutter holder 3 bar 79
• Do not drop or shock the valve seat cutter or the dia 79
• Do not fail to apply engine oil to the valve seat cutter 79
• Engine top end 4 17 79
• Good too wide 79
• If the manufacturer s instructions are not available use 79
• If the outside diameter of the valve scaling pattern is 79
• Layer of engine oil before storing 79
• Measure the outside diameter of the seating pattern on 79
• Mond particles may fall off 79
• Operate the cutter in one hand do not apply too much force to the diamond portion 79
• Represent the following 60 cutter angle 37 0 outer diameter of cutter 79
• Seat for repair therefore the cutter must not be used for other purposes than seat repair 79
• Setting the valve seat cutter holder is position 79
• The following procedure 79
• The marks stamped on the back of the cutter 79
• The valve scat 79
• This valve seat cutter is developed to grind the valve 79
• Too large or too small repair the seat see valve scat repair 79
• Too narrow 79
• Use the following procedure and tools to repair the 79
• Valve seat 79
• Valve seat repair 79
• 18 engine top end 80
• Caution 80
• Caution i 80
• Engine top end 4 19 81
• Measuring vaive to guide clearance 81
• Of d n th 81
• Wobble method 81
• Cylinder installation notes 83
• Cylinder piston 83
• Cylinder removal 83
• Engine top end 4 21 83
• Piston removal 83
• 22 engine top end 84
• Caution 84
• Piston installation note 84
• Cylinder inside diameter 85
• Engine top end 4 23 85
• Piston ring end gap 85
• Piston ring piston ring groove wear 85
• 24 engine top end 86
• Boring honing 86
• Carburetor holder 86
• Carburetor holder installation 86
• Piston diameter 86
• Caution 87
• Engine top end 4 25 87
• Muffler 87
• Muffler installation 87
• Muffler removal 87
• Warning i 87
• Clutch 89
• Table of contents 89
• 2 clutch 90
• Exploded view 90
• 4 clutch 92
• Clutch 92
• Clutch adjustment 92
• Clutch adjustment check 92
• Warning 92
• Clutch 5 5 93
• Clutch cover installation note 93
• Clutch cover removal 93
• Clutch release lever shaft installation note 93
• Clutch release lever shaft removal 93
• 6 clutch 94
• Clutch installation notes 94
• Clutch removal 94
• Clutch 5 7 95
• Friction or steel plate warp inspection 95
• Friction plate wear damage inspection 95
• 8 clutch 96
• Clutch housing finger inspection 96
• Clutch hub spline inspection 96
• Clutch spring free length measurement 96
• Engine lubrication system 97
• Table of contents 97
• 2 engine lubrication system 98
• Exploded view 98
• Engine lubrication system 6 3 99
• Engine oil flow chart 99
• Engine lubrication system 100
• Caution 102
• Engine lubrication system 102
• Engine oh level inspection 102
• Engine oil and filter 102
• Engine oit and or fitter change 102
• I caution 102
• Warning 102
• Bypass valve assembly 103
• Bypass valve cleaning and inspection 103
• Bypass valve disassembly 103
• Engine lubrication system 6 7 103
• Oh filter and mounting bolt installation notes 103
• Oil filter and mounting bolt removal 103
• Relief valve removal 103
• Warning 103
• Engine lubrication system 104
• Oh pump installation notes 104
• Oh pump removal 104
• Oil pressure measurement 104
• Oil pump 104
• Oil pump assembly note 104
• Oil pump disassembly 104
• Relief valve installation note 104
• Engine lubrication system 6 9 105
• Oh pump inspection 105
• Relief valve inspection 105
• Warning 105
• Warning j 105
• Engine removal lnstallation 107
• Table of contents 107
• Engine removal installation 108
• Exploded view 108
• Othis tool may be used instead of the common tool 108
• Special tool 108
• Cautiow 109
• Engine removal 109
• Engine removal installation 7 3 109
• Engine removal lnstallation 109
• 4 engine removal installation 110
• Engine installation 110
• Crankshaft transmission 111
• Crankshaft transmission 8 1 111
• Table of contents 111
• Cran kshaft tr ansmission 8 3 113
• 26 00 mm 115
• 29 08 mm 115
• 29 16 mm 115
• Balancer shaft 115
• Balancer shaft bearing bore diameter 29 00 29 16 mm 115
• Balancer shaft bearing insert 115
• Balancer shaft bearing insert selection 115
• Balancer shaft journal diameter 25 84 26 00 mm 25 6 mm 115
• Cran kshaft tr ansmission 8 5 115
• Crankshaft main bearing insert selection 115
• Crankshaft side clearance 0 5 0 0 mm 0 0 mm 115
• Gear backlash 0 0 7 mm 0 5 mm 115
• Gear shift fork groove width 5 5 5 5 mm 5 mm 115
• Item standard service limit 115
• Journal clearance 0 20 0 44 mm 0 8 mm 115
• Marking none 115
• None marking 25 84 25 92 mm 115
• Shift drum groove width 6 5 6 0 mm 6 mm 115
• Shift fork ear thickness 4 5 mm 4 mm 115
• Shift fork guide pin diameter 5 6 mm 5 mm 115
• Special tools 115
• Transmission 115
• 6 crankshaft transmission 116
• Crankcase splitting 116
• A 6 mm bolts b 8 mm bolts 117
• A ply point 117
• Apply liquid gasket to the mating surface of the lower 117
• Assembly is the reverse of splitting be careful of the 117
• Bearings shift drum and crankshaft main bearing inserts 117
• Case set pins must go into the holes in the needle bearing outer races and the set rings must fit into the grooves in the ball bearings 117
• Cautio 117
• Check that the knock pins 2 are in place apply a little engine oil to the transmission gears ball 117
• Crankcase assembly 117
• Crankcase half 117
• Crankshaft transmission 8 7 117
• Following items 117
• I set pins 2 set rings 3 upper crankcase half 117
• Lower crankcase half 117
• Owhen installing the output and drive shafts the crank 117
• Owith a high flash point solvent clean off the mating 117
• Surfaces of the crankcase halves and wipe dry 117
• Crankcase exchange 118
• Crankshaft transmission 118
• Crankshaft connecting rods 119
• Crankshaft installation notes 119
• Crankshaft removal 119
• Crankshaft transmission 8 9 119
• 10 crankshaft transmission 120
• Cautio 120
• Connecting rod bend 120
• Connecting rod installation notes 120
• Connecting rod removal 120
• Crankshaft connecting rod cleaning 120
• Connecting rod big end bearing 121
• Connecting rod big end side clearance 121
• Connecting rod twist 121
• Crankshaft transmission 8 11 121
• Insert crankpin wear 121
• 12 crankshaft transmission 122
• Crankshaft runout 122
• Crankshaft main bearing insert journal wear 123
• Crankshaft transmission 8 13 123
• 14 crankshaf17transmission 124
• Crankshaft side clearance 124
• Balancer 125
• Balancer installation notes 125
• Balancer removal 125
• Balancer shaft bearing insert journa wear 125
• Crankshaft transmission 8 15 125
• 16 crankshaft transmission 126
• Starter motor clutch 126
• Starter motor clutch removal 126
• Crankshaft transmission 8 17 127
• External shift mechanism removal 127
• External shift mechanism removal note 127
• Starter motor clutch assembly note 127
• Starter motor clutch disassembly 127
• Starter motor clutch inspection 127
• Starter motor clutch installation notes 127
• Transmission 127
• 18 crankshaft transmission 128
• External shift mechanism inspection 128
• External shift mechanism installation notes 128
• Crankshaft transmission 8 19 129
• Drive shaft assembly notes 129
• Drive shaft disassembly 129
• Output shaft disassembly 129
• Transmission shaft installation 129
• Transmission shaft removal 129
• 20 crankshaf17transmission 130
• Output shaft assembly notes 130
• Shift drum and fork removal 130
• Cran kshaft tr ansmission 8 21 131
• Shift drum and fork installation 131
• 22 crankshaft transmission 132
• Gear backlash 132
• Shift drum assembly notes 132
• Shift drum disassembly note 132
• Crankshaft transmission 8 23 133
• If a gear shift fork groove is worn over the service limit 133
• If any shift drum groove is worn over the service limit 133
• If the guide pin on any shift fork is less than the service 133
• If the thickness of a shift fork ear is less than the 133
• Limit the fork must be replaced 133
• Measure the diameter of each shift fork guide pin and 133
• Measure the thickness of the shift fork ears and 133
• Measure the width of each shift drum groove 133
• Measure the width of the shift fork grooves on the transmission gears 133
• Move back and forth lightly 2 hold steady 133
• Service limit the shift fork must be replaced 133
• Shift fork bending 133
• Shift fork ears 3 shift fork 2 shift fork guide pin 133
• Shift fork gear groove wear 133
• Shift fork guide pin shift drum groove wear 133
• That is bent a bent fork could cause difficulty in shifting or allow the transmission to jump out of gear when under power 133
• The drum must be replaced 133
• The gear must be replaced 133
• Visually inspect the shift forks and replace any fork 133
• 24 crankshaft transmission 134
• Ball and needle bearing wear 134
• Gear dog gear dog hole damage 134
• Table of contents 135
• Wheels tires 135
• 2 wheels tires 136
• Exploded view 136
• Front wheel installation 138
• Front wheel removal 138
• Rear wheel removal 138
• Warning 138
• Wheels rims 138
• Wheels tires 138
• Caution 139
• Rear wheel installation 139
• Warning 139
• Wheel inspection 139
• Wheels tires 95 139
• 6 wheels tires 140
• Axle inspection 140
• Warning 140
• Wheel balance 140
• Tire removal 141
• Wheels tires 9 7 141
• 8 wheels tires 142
• Cautio 142
• Tire installation 142
• Cautjoi 143
• Warning j 143
• Wheels tires 9 9 143
• 10 wheels tires 144
• Cautio 144
• Front hub bearing removal 144
• Hub bearings 144
• Tire inspection 144
• Tire repair 144
• Warning 144
• Front hub bearing installation 145
• Wheels tires 9 11 145
• Caution 146
• Hub bearing inspection and lubrication 146
• Rear hub bearing installation 146
• Rear hub bearing removal 146
• Wheels tires 146
• Grease seal inspection and lubrication 147
• Speedometer gear housing 147
• Speedometer gear housing assembly 147
• Speedometer gear housing disassembly 147
• Wheels tires 9 13 147
• 14 wheels tires 148
• Speedometer gear housing lubrication 148
• Final drive 151
• Table of contents 151
• 2 final drive 152
• Exploded view 152
• 4 final drive 154
• Drive chain 154
• Drive chain stack adjustment 154
• Drive chain stack inspection 154
• Warning 154
• Final drive 10 5 155
• Warning 155
• Wheel alignment adjustment 155
• Wheel alignment inspection 155
• 6 final drive 156
• A engine sprocket cover 156
• Drive chain lubrication 156
• Drive chain removal 156
• Footpeg bracket 156
• Caution 157
• Drive chain installation 157
• Engine sprocket installation 157
• Engine sprocket removal 157
• Final drive 10 7 157
• Rear sprocket coupling removal 157
• Sprocket coupling 157
• 8 final drive 158
• Rear sprocket coupling installation 158
• Sprocket warp 158
• Sprockets wear 158
• Coupling bearing inspection and lubrication 159
• Coupling bearing installation 159
• Coupling bearing removal 159
• Final drive 10 9 159
• 10 final drive 160
• Damper inspection 160
• Grease seal inspection and lubrication 160
• Base manual 161
• Brakes 161
• Brakes 11 1 161
• Table of contents 161
• Brake adjustment 164
• Brake pedai position adjustment 164
• Brake pedal position inspection 164
• Brakes 164
• Front brake 164
• Rear brake 164
• Brakes 11 5 165
• Caliper assembly notes 165
• Caliper disassembly no tes 165
• Caliper installation notes 165
• Calipers 165
• Front caliper removal 165
• Rear caliper removal 165
• Warning 165
• Brake pad removal 166
• Brake pads 166
• Brakes 166
• Caliper holder shaft wear 166
• Dust seal and cover damage 166
• Fluid seal damage 166
• Piston cylinder damage 166
• Brake pad lining wear 167
• Brakes 11 7 167
• Front master cylinder installation notes 167
• Front master cylinder removal 167
• Master cylinders 167
• Pads installation notes 167
• Warning i 167
• 8 brakes 168
• Front master cylinder disassembly notes 168
• Inspection and adjustment after installation 168
• Rear master cylinder installation notes 168
• Rear master cylinder removal 168
• Brakes 11 9 169
• Front master cylinder assembly notes 169
• Master cylinder inspection 169
• Rear master cylinder assembly notes 169
• Rear master cylinder disassembly notes 169
• Visual inspection 169
• 10 brakes 170
• Disc wear 170
• I 2 3 4 170
• Reservoir installation notes 170
• Reservoir removal 170
• Brake fluid 171
• Brake fluid change 171
• Brakes 11 11 171
• Change the brake fluid the brake fluid should also be changed if it becomes contaminated with dirt or water 171
• Disc cleaning 171
• Disc warp 171
• Fluid level inspection 171
• If the fluid level is lower than the lower level line fill the reservoir to the upper level line of the reservoir 171
• In accordance with the periodic maintenance chart 171
• Inspect the brake fluid level in the front and rear brake fluid reservoirs check the brake fluid level in the reservoir 171
• Jack up the motorcycle so that the front wheel is off 171
• Lower level line 2 upper level line 171
• Poor braking can be caused by oil on the disc oil on 171
• The disc must be cleaned off with an oil less cleaning fluid such as trichloroethylene or acetone 171
• The fluid level must be kept above the lower level lines 171
• The ground and turn the handlebar fully to one side set up a dial gauge against the front disc and measure disc runout remove the jack set the motorcycle up on its center stand and then measure the rear disc runout if runout exceeds the service limit replace the disc 171
• Warning 171
• Warning j 171
• 12 brakes 172
• Bleeding the brake line 172
• Brake hose 173
• Brake hose inspection 173
• Brakes 1113 173
• Warnin 173
• 14 brakes 174
• Brake hose replacement 174
• Suspension 175
• Table of contents 175
• 2 suspension 176
• Caution 177
• Fork oii change 177
• Front fork removal each fork leg 177
• Hiirtriiiriiiihiiiiimiirmiirriiihiiiitriiiariii front fork 177
• Specifications 177
• Suspension 12 3 177
• 4 suspension 178
• Front fork disassembly 178
• Front fork installation each fork leg 178
• Caution 179
• Front fork assembly 179
• Inner tube inspection 179
• Suspension 12 5 179
• 6 suspension 180
• Guide bush inspection 180
• Oh seal and dust seal inspection 180
• Rear shock absorber rear shock absorber adjustment 180
• Rear shock absorber removal 180
• Rear suspension uni trak 180
• Spring tension 180
• Rear shock absorber installation 181
• Rear shock absorber scrapping 181
• Suspension 12 7 181
• Swing arm swing arm removal 181
• Warmimg 181
• 8 suspension 182
• Swing arm installation notes 182
• Swing arm needle bearing inspection 182
• Swing arm needle bearing lubrication 182
• Swing arm sleeve inspection 182
• Tie rod rocker arm tie rod removal 182
• Cautio 183
• Rocker arm installation notes 183
• Rocker arm removal 183
• Suspension 12 9 183
• Tie rod installation note 183
• Tie rod rocker arm bushing inspection 183
• Tie rod rocker arm bushing lubrication 183
• Tie rod rocker arm sleeve inspection 183
• Steering 185
• Table of contents 185
• 2 steering 186
• Exploded view 186
• Handlebar 187
• Handlebar holder installation notes 187
• Special tools 187
• Steering 13 3 187
• 4 steering 188
• Steering adjustment 188
• Steering inspection 188
• Bearing wear damage 189
• Steering 13 5 189
• Steering 190
• Steering maintenance 190
• Steering stem bearing lubrication 190
• Bearing wear damage 191
• Grease seat deterioration damage 191
• Steering 13 7 191
• Steering stem warp 191
• Table of contents 193
• 2 frame 194
• Exploded view 194
• 4 frame 196
• Caution 196
• Sear installation 196
• Sear removal 196
• Seat side covers 196
• Side cover removal 196
• Caution 197
• Fairings 197
• Frame 14 6 197
• Lower fairing removal 197
• Upper fairing installation notes 197
• Upper fairing removal 197
• 6 frame 198
• Fenders 198
• Front part of rear fender removal 198
• Rear part of rear fender removal 198
• Seat cover removal 198
• Upper fairing stay removal 198
• Footpeg bracket 199
• Frame 14 7 199
• Front part of rear fender installation 199
• Left footpeg bracket installation note 199
• Left footpeg bracket removal 199
• Right footpeg bracket removal 199
• Electrical system 201
• Electrical system 15 1 201
• Table of contents 201
• 2 electrical system 202
• Precautions 202
• Electrical system 203
• Exploded view 203
• Electrical system 15 3 204
• Electrical system 205
• Parts locations 205
• Additional tools 206
• C 176 f 42 62 11 206
• C 212 f 22 33 il 206
• Electrical system 15 5 206
• Ousc the coil tester instead of kawasaki elcctrotestcr 206
• Pn 57001 980 206
• Refer to the base manual noting the following 206
• Special tools 206
• Specifications 206
• Water temperature sensor resistance 206
• Battery 207
• Battery charging 207
• Battery condition 207
• Electrical system 15 9 207
• Electrolyte 207
• Electrolyte level inspection 207
• Precautions 207
• Cautio 208
• Fcautton 208
• I caution j 208
• Battery test charging 209
• Caution 209
• Electrical system 15 11 209
• 12 electrical system 210
• Alternator cover installation note 210
• Alternator cover removal 210
• Alternator rotor installation notes 210
• Alternator rotor removal 210
• Cautio 210
• Charging system 210
• Alternator inspection 211
• Electrical system 15 13 211
• Stator coil installation notes 211
• Stator coil removal 211
• Warning 211
• 14 electrical system 212
• Rectifier inspection 212
• Caution 213
• Electrical system 15 15 213
• Regulator inspection 213
• 16 electrical system 214
• Cautio 214
• Ignition system 214
• Regulator rectifter output voltage inspection 214
• Safety instructions 214
• Warning 214
• Electrical system 15 17 215
• Pickup coil installation 215
• Pickup coil removal 215
• Spark plug installation notes 215
• Spark plug removal 215
• Ignition coil removal 216
• Electrical system 15 19 217
• Ignition coil inspection 217
• Ignition coil installation notes 217
• Pickup coit inspection 217
• Warning 217
• 20 electrical system 218
• Fcautlün 218
• Ic igniter removal 218
• Spark plug cleaning inspection 218
• Spark plug gap 218
• C igniter installation note 219
• Caution 219
• Electrical system 15 21 219
• Ic igniter inspection 219
• 22 electrical system 220
• Electric starter system 221
• Electrical system 15 23 221
• Starter motor disassembly 221
• Starter motor installation notes 221
• Starter motor removal 221
• 24 electrical system 222
• Starter motor assembly 222
• Electrical system 15 25 223
• 26 electrical system 224
• Armature inspection 224
• Brush inspection 224
• Brush spring inspection 224
• Commutator cleaning and inspection 224
• Brush leads inspection 225
• Brush plate and terminal bolt inspection 225
• Electrical system 15 27 225
• Fcaurioit 225
• Headlight beam horizontal adjustment 225
• Lighting system 225
• Starter relay inspection 225
• 28 electrical system 226
• A 50 mm 2 in b center of brightest spot c 7 m 25 ft d height of headlight center 226
• A vertical adjuster b guide a horizontal adjuster b guide 226
• Beam points straight ahead 226
• Cautio 226
• Figure 226
• Fit the dust cover onto the bulb firmly as shown in the 226
• Headlight beam vertical adjustment 226
• Healight bulb replacement notes 226
• Horizontal adjuster 3 vertical adjuster 2 adjuster guide 4 adjuster guide 226
• Justed too low neither low nor high beam will illuminate the road far enough ahead if adjusted too high the high beam will fail to illuminate the road close ahead and the low beam will blind oncoming drivers put a phillips screwdriver into the vertical adjuster 226
• The headlight beam is adjustable vertically if ad 226
• The headlight vertically 226
• Turn the adjuster on the headlight in or out to adjust 226
• Turn the adjuster on the headlight in or out until the 226
• Electrical system 15 29 227
• License plate light bulb replacement notes 227
• Removal installation note 227
• Tail brake light bulb replacement notes 227
• Tait brake light lens 227
• Turn signa light bulb replacement note 227
• 30 electrical system 228
• Inspection 228
• Cooling fan system 229
• Electrical system 15 31 229
• Fan inspection 229
• Fan relay inspection 229
• Fan system circuit inspection 229
• 32 electrical system 230
• Cautio 230
• Meters and gauge 230
• Meters and gauge removal 230
• Bulb replacement notes 231
• Electrical system 15 33 231
• Meter and gauge assembly note 231
• Meter or gauge replacement 231
• Meters and gauge disassembly 231
• Tachometer inspection 231
• 34 electrical system 232
• Battery 232
• Caution 232
• Check the water temperature gauge circuit wiring see 232
• If all wiring and components other than the water tem 232
• Lf these readings are not correct the trouble is with 232
• Perature gauge unit check out good the unit is defec tive 232
• Prepare an auxiliary wire and check the operation of 232
• Temperature gauge operation inspection 232
• The gauge 232
• The gauge and or wiring 232
• Wiring inspection 232
• Caution 233
• Electrical system 15 35 233
• Front brake light testing 233
• Rear brake light switch position adjustment 233
• Rear brake light testing 233
• Switch inspection 233
• Switch removal note 233
• Switches and sensors 233
• 36 electrical system 234
• Fan switch inspection 234
• Electrical system 1537 235
• Fuse removal 235
• Junction box 235
• Water temperature sensor inspection 235
• 38 electrical system 236
• Fuse installation notes 236
• Cautio 238
• Diode circuit inspection 238
• Electrical system 15 39 238
• Electrical wiring 238
• Fan starter circuit and 238
• Fuse inspection 238
• Headlight relay inspection 238
• Junction box fuse circuit inspection 238
• Wiring inspection 238
• 40 electrical system 239
• Bk y a b k y j 240
• Bk y ft 8k 240
• Bl h bk v br w y 240
• Br bk y r ei r bk y or w y 240
• Cûo ny fan switch ihaodtorl 240
• Ex250 f2 wiring diagram 240
• Front left turn signal light 12 v23w 240
• Hom 12v2sa 240
• Ignrtl 240
• Ljw bl 240
• R bk r y ok y 240
• Right turn signal indicator 240
• Tac unierer 240
• Us and canada models 240
• Electrical system 15 17 241
• 18 electrical system 242
• Ex25o f2 wiring diagram 242
• Lg gy g or bk y 242
• Morn 12 v 2 a 242
• Spark plum 242
• Twin signal switch 242
• Uk and australia models 242
• Ак v 242
• Иг ç ф x 242
• Ilin uint i 243
• Uk model 243
• Appendix 245
• Table of contents 245
• 2 appendix 246
• Additional considerations for racing 246
• Carburetor 246
• Spark plug 246
• Spark plug inspection 246
• Appendix 16 3 247
• Can be ascertained by noting the condition of the ceramic insulator around the electrode a light brown color indicates the correct plug is being used if the ceramic is white the plug is operating at too high a temperature and it should be replaced with the next colder type 247
• Carbon fouling oil fouling normal operation overheating 247
• Cautio 247
• Engine doesn t start starting difficulty 247
• Starter lockout or neutral switch trouble starter motor trouble battery voltage low relays not contacting or operating starter button not contacting wiring open or shorted ignition switch trouble engine stop switch trouble main fuse blown 247
• Starter motor clutch trouble 247
• Troubleshooting guide 247
• Valve seizure rocker arm seizure cylinder piston seizure crankshaft seizure connecting rod small end seizure connecting rod big end seizure transmission gear or bearing seizure camshaft seizure 247
• Whether or not the right temperature plug is being used 247
• 4 appendix 248
• Poor running at low speed 248
• Poor running or no power at high speed 248
• Abnormal engine noise 249
• Appendix 16 5 249
• Clutch operation faulty 249
• Gear shifting faulty 249
• Over cooling 249
• Overheating 249
• 6 appendix 250
• Abnormal drive train noise 250
• Abnormal frame noise 250
• Brake doesn t hold 250
• Exhaust smokes excessively 250
• Handling and or stability unsatisfactory 250
• Oil pressure warning light goes on 250
• Appendix 16 7 251
• Battery discharged 251
• Battery overcharged 251
• General lubrication 251
• Lubrication 251
• Nut bolt and fastener tightness 251
• Tightness inspection 251
• Heavy industries ltd 253
• Kawasaki 253
• Model application 253
• Part no 99924 1109 51 253
• Printed in japan 253

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Quick Reference Guide General Information Fuel System 2 Cooling System 3 4 Engine Top End Engine Lubrication System 5 6 Engine Removal lnstallation 7 Clutch Crankshaft Transmission Wheels Tires Final Drive Brakes Suspension Steering Frame Electrical System Appendix This quick reference guide will assist you in locating a desired topic or procedure Bend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page Refer to the sectional table of contents for the exact pages to locate the specific topic required bi____ _ 9