Quick Links. Table of Contents. Property of www. Previous Page. Next Page. Page 2 Property of www. Page 4 Property of www. Page 5 Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts.
Second Edition 1 : Jul. Crankcase Emission Control System A sealed-type crankcase emission control system is used to eliminate blow-by gases. They are designed to give optimum performance while maintaining a low noise level. Please do not remove these systems, or alter them in any which results in an increase in noise level.
Page 10 Property of www. Model Identification General Specifications Unit Conversion Table To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. Gaskets, O-rings, Oil seals, Grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled. Then tighten them according to the specified se- quence to prevent case warpage or deformation which can lead to malfunction.
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.
Lubri- cation points are called out throughout this manual, apply the specific oil or grease as specified. Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Overall Width 1 mm Overall Height 1 mm Wheelbase 1 mm Ground Clearance: mm Seat Height mm Dry Mass Page 22 Property of www.
Play Inspection The initial maintenance is vitally important and must not be neglected. Page Torque And Locking Agent R: Replacement Parts S: Follow the specific tightening sequence. SS: Apply silicone sealant Kawasaki Bond: St: Stake the fasteners to prevent loosening. Crankcase Bolts M8 mm 4. Crankcase Bolt M8 mm 4. S, L 1 Crankcase Bolts M6 40 mm 1.
If the throttle lever does not return properly, check the throttle cable routing, lever free play, and cable damage. Visually inspect the hoses for signs of deterioration. Torque - Coolant Drain Plug: 8. This makes air bleeding easier. Push hard, but with no more force than 59 N 6 kgf, 13 lb. Then stop the vehicle. If the steering action is not smooth, or if the steering binds or catches before the stop, lubricate the steering stem bearing.
If it does not as specified, adjust the brake light timing. Brake Light Timing Standard: On after about 10 mm 0. If the joint boot is torn, worn, deteriorated, or leaks grease, replace the joint boot or front axle assembly see Final Drive chapter. Also, check to see that each cotter pin is in place and in good condition. Page 64 Property of www. Carburetor Synchronization Specifications Carburetor Installation Choke Lever 3.
Choke Cable 4. Throttle Cable 5. Throttle Lever 6. Jet Needle 7. Pilot Jet 8. Main Jet 9. Turn the throttle limiter screw [A] until it is spaced about 1 mm 0.
Turn the ignition switch to OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; Never use a sharp edge to remove the diaphragm. These can be detached together with the spring seat [E]. If there is a difference between two carburetors, turn the balance adjusting screw [A] to obtain the same clearance. If any of the diaphragm or O-rings are not in good condi- tion, replace them. If the insulators are damaged or deteriorated, replace them.
If the dampers are damaged or deteriorated, replace them. Such a shock to the pump can damage it. If the fuel pump does not operate as described, replace it with a new one.
Page Property of www. Coolant Flow Chart Coolant Deterioration Inspection Coolant Level Inspection Coolant Draining Coolant Filling Pressure Testing Water Pump Page Water Pump Cover Bolts 0. When the engine starts, the water pump coupled with the oil pump turns and the coolant circulates. The thermostat is a wax pellet type which opens or closes with coolant temperature changes.
Radiator 2. Radiator Cap 3. Radiator Fan Switch 4. Radiator Fan 5. Coolant Temperature Warning Light Switch 6. Thermostat 7. Cylinder 8. Cylinder Head 9.
Water Pump Reserve Tank Property of www. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting.
In either case, flush the cooling system. If the surface is corroded or the blades are damaged, re- place the impeller. The radiator fan may start even if the ignition switch is off. This could damage the radiator fins, resulting in loss of cooling effi- ciency. If there are obstructions to air flow, remove the radiator and remove obstructions. If the corrugated fins [A] are deformed, carefully straighten them.
Cylinder Head Cleaning Cylinder Head Warp Page Specifications Camshaft runout TIR 0. Valve Guide Inside Diameter: 5. Piston Ring Thickness: 0. The push rod does not return to its original position once it moves out to take up cam chain slack. Ob- serve all the rules listed below: When removing the tensioner, do not take out the mounting bolts only partway. If the rocker shaft diameter is smaller than the service limit, replace it.
Also check the rocker arm inside diameter see Rocker Arm Inspection. The plastigage indicates the clearance by the amount it is compressed and widened when the parts are assembled. This allows some of the com- pression pressure to escape, making it easy to turn over the engine during starting.
If the rubber is damaged, cut, or is missing pieces, replace the guide. This valve seat cutter is developed to grind the valve seat for repair. Therefore the cutter must not be used for other purposes than seat repair. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off. If the seat width is within the specified range, lap the valve to the seat as described below. The rings should fit perfectly parallel to groove surfaces.
If not, replace the piston and all the piston rings. Set it close to the bottom of the cylinder, where cylinder wear is low. Forest Service. It must be prop- erly maintained to ensure its efficiency. In accordance with the Periodic Maintenance Chart, clean the spark arrester. Torque - Muffler Cover Bolts [B]: 8. If there are signs of leakage around the exhaust pipe gas- ket, it should be replaced. Special Tools Torque Converter Torque Converter Cover Removal Torque Converter Cover Installation M: Apply molybdenum disulfide grease.
R: Replacement Part S: Follow the specific tightening sequence. Drive Belt Belt Width Belt Deflection — If it is done, the learning control of Kawasaki Engine Brake Control system works and the engine brake actuator works an error operation.
Cover Bushing Inside Diameter [A] Standard: Service Limit: If the sheave bushing is damaged or worn, replace it. Sheave Bushing Inside Diameter [A] Spring Free Length [A] Standard: Sheave Bushing Inside Diameter If seals are damaged, replace the movable sheave. Recoil Starter Recoil Starter Removal Recoil Starter Installation Recoil Starter Inspection Engine Oil Flow Chart Engine Oil and Oil Filter Oil Level Inspection Engine Oil Change Oil Filter Change Oil Screen Removal Oil Screen Cleaning There are many illustrations to aid you during your job and easy to read text throughout the manual.
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