Tampering with noise control System prohibited

 

 

Federal law prohibits the following acts or the causing thereof. (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

Among those acts presumed to constitute tampering are the acts listed below.

 

• Replacement of the original exhaust system or muffler with a component not in compliance with Federal regulations.

• Removal of the muffler(s) or any internal portion of the muffler(s).

• Removal of the air box or air box cover.

• Modifications to the muffler(s) or air inlet system by cutting, drilling, or other means if such modifications result in increased noise levels.

 

Foreword

 

This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic in-formation to make it useful to the owner who de-sires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop proce-dures must be understood in order to carry out maintenance and repair satisfactorily. When-ever the owner has insufficient experience or doubts his ability to do the work, all adjust-ments, maintenance, and repair should be car-ried out only by qualified mechanics.

In order to perform the work efficiently and to avoid costly mistakes, read the text, thor-oughly familiarize yourself with the procedures before starting work, and then do the work care-fully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may ad-versely affect safe operation.

 

For the duration of the warranty period, we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty.

To get the longest life out of your vehicle.

 

• Follow the Periodic Maintenance Chart in the Service Manual.

• Be alert for problems and non-scheduled maintenance.

 

• Use proper tools and genuine Kawasaki Mo-torcycle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki motorcycles are introduced by the Service Manual. Genuine parts provided as spare parts are listed in the Parts Catalog.

 

• Follow the procedures in this manual care-fully. Don’t take shortcuts.

• Remember to keep complete records of main-tenance and repair with dates and any new parts installed.

 

How to Use This Manual

 

In this manual, the product is divided into its major systems and these systems make up the manual’s chapters. The Quick Reference

 

 

Guide shows you all of the product’s system and assists in locating their chapters. Each chapter in turn has its own comprehensive Ta-ble of Contents.

 

For example, if you want ignition coil informa-tion, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chap-ter to find the Ignition Coil section.

 

Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices.

WARNING

 

This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in per-sonal injury, or loss of life.

 

CAUTION

 

This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in dam-age to or destruction of equipment.

 

This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of informa-tion.

 

NOTE

○This note symbol indicates points of par-ticular interest for more efficient and con-venient operation.

 

•Indicates a procedural step or work to be done. ○Indicates a procedural sub- step or how to do the work of the procedural step it follows. It

 

also precedes the text of a NOTE.

 

Indicates a conditional step or what action to take based on the results of the test or inspec-tion in the procedural step or sub-step it fol-lows.

 

In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require spec-ified tightening torque, oil, grease or a locking agent during assembly.

 

 

LIST OF ABBREVIATIONS

 

A	ampere(s)	lb	pound(s)
ABDC	after bottom dead center	m	meter(s)
AC	alternating current	min	minute(s)
ATDC	after top dead center	N	newton(s)
BBDC	before bottom dead center	Pa	pascal(s)
BDC	bottom dead center	PS	horsepower
BTDC	before top dead center	psi	pound(s) per square inch
°C	degree(s) Celsius	r	revolution
DC	direct current	rpm	revolution(s) per minute
F	farad(s)	TDC	top dead center
°F	degree(s) Fahrenheit	TIR	total indicator reading
ft	foot, feet	V	volt(s)
g	gram(s)	W	watt(s)
h	hour(s)	Ω	ohm(s)
L	liter(s)

 

COUNTRY AND AREA CODES

 

AT	Austria	DE	Germany
CA	Canada	GB	United Kingdom
CAL	California	US	United States
CH	Switzerland	WVTA	Whole Vehicle Type Approval

 

GENERAL INFORMATION 1-1

 

 

.....................................................................................................................

General Information
Table of Contents
Before Servicing	1-2
Model Identification.................................................................................................................	1-7
General Specifications............................................................................................................	1-10
Technical Information - Cassette Type Transmission.............................................................	1-13
Technical Information - Inlet Air Pressure Sensor.................................................................	1-14
Technical Information – ABS (Anti – Lock Brake System)......................................................	1-15
Unit Conversion Table............................................................................................................	1-27

 

GENERAL INFORMATION

 

Before Servicing

 

Before starting to perform an inspection service or carry out a disassembly and reassembly opera-tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra-tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts.

 

Especially note the following:

Battery Ground

 

Before completing any service on the motorcycle, discon-nect the battery cables from the battery to prevent the en-gine from accidentally turning over. Disconnect the ground cable (–) first and then the positive (+). When completed with the service, first connect the positive (+) cable to the positive (+) terminal of the battery then the negative (–) ca-ble to the negative terminal.

 

Edges of Parts

 

Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts.

 

 

Solvent

 

Use a high-flush point solvent when cleaning parts. High -flush point solvent should be used according to directions of the solvent manufacturer.