Cleaning Vehicle before Disassembly

 

Clean the vehicle thoroughly before disassembly. Dirt or other foreign materials entering into sealed areas during ve-hicle disassembly can cause excessive wear and decrease performance of the vehicle.

 

GENERAL INFORMATION 1-3

 

Before Servicing

 

Arrangement and Cleaning of Removed Parts

Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly.

 

Storage of Removed Parts

 

After all the parts including subassembly parts have been cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly.

 

Inspection

 

Reuse of worn or damaged parts may lead to serious ac-cident. Visually inspect removed parts for corrosion, discol-oration, or other damage. Refer to the appropriate sections of this manual for service limits on individual parts. Replace the parts if any damage has been found or if the part is be-yond its service limit.

 

Replacement Parts

 

Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.

 

Assembly Order

 

In most cases assembly order is the reverse of disassem-bly, however, if assembly order is provided in this Service Manual, follow the procedures given.

 

GENERAL INFORMATION

 

Before Servicing

 

Tightening Sequence

Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified se-quence to prevent case warpage or deformation which can lead to malfunction. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quar-ter turn and then remove them. If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally.

Tightening Torque

 

Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fasteners to the specified torque using a good quality torque wrench. Often, the tightening sequence is followed twice-initial tightening and final tightening with torque wrench.

 

 

Force

 

Use common sense during disassembly and assembly, excessive force can cause expensive or hard to repair dam-age. When necessary, remove screws that have a non -permanent locking agent applied using an impact driver. Use a plastic-faced mallet whenever tapping is necessary.

 

 

Gasket, O-ring

 

Hardening, shrinkage, or damage of both gaskets and O-rings after disassembly can reduce sealing per-formance. Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains. Install new gaskets and replace used O-rings when re-assembling

 

Liquid Gasket, Non-permanent Locking Agent

 

For applications that require Liquid Gasket or a Non-permanent Locking Agent, clean the surfaces so that no oil residue remains before applying liquid gasket or non-permanent locking agent. Do not apply them exces-sively. Excessive application can clog oil passages and cause serious damage.

 

GENERAL INFORMATION 1-5

 

Before Servicing

 

Press

For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con-tact area. Be sure to maintain proper alignment and use smooth movements when installing.

 

 

Ball Bearing and Needle Bearing

 

Do not remove pressed ball or needle unless removal is absolutely necessary. Replace with new ones whenever removed. Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressure on the correct bearing race as shown.

 

Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage.

 

Oil Seal, Grease Seal

 

Do not remove pressed oil or grease seals unless removal is necessary. Replace with new ones whenever removed. Press new oil seals with manufacture and size marks facing out. Make sure the seal is aligned properly when installing.

 

Apply specified grease to the lip of seal before installing the seal.

 

Circlips, Cotter Pins

 

Replace circlips or cotter pins that were removed with new ones. Take care not to open the clip excessively when in-stalling to prevent deformation.

 

GENERAL INFORMATION

 

Before Servicing

 

Lubrication

It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubri-cation points are called out throughout this manual, apply the specific oil or grease as specified.