Service Manual

Foreword
This manual is designed primarily for use by trained
mechanics in a properly equipped shop. However, it
contains enough detail and basic information to make
it useful to the owner who desires to perform his own
basic maintenance and repair work. A basic knowledge
of mechanics, the proper use of tools, and workshop
procedures must be understood in order to carry out
maintenance and repair satisfactorily. Whenever the
owner has insufficient experience or doubts as to his
ability to do the work, all adjustments, maintenance, and
repair should be carried out only by qualified mechanics.
In order to perform the work efficiently and to avoid
costly mistakes, read the text, thoroughly familiarize
yourself with the procedures before starting work, and
then do the work carefully 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 adversely affect safe
operation.
To get the longest life out of your engine:
•
Follow the Periodic Maintenance Chart in the Service
Manual.
•
Be alert for problems and non-scheduled maintenance.
•
Use proper tools and genuine Kawasaki engine parts.
Genuine parts provided as spare parts are listed in the
Parts Catalog.
•
Follow the procedures in this manual carefully. Don’t
take shortcuts.
•
Remember to keep complete records of maintenance
and repair with dates and any new parts installed.
How to Use This Manual
In this manual, the product is divided into its major sys-
tems 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 chap-
ter in turn has its own comprehensive Table of Contents.
For example, if you want ignition coil information, use
the Quick Reference Guide to locate the Electr ical System
chapter. Then, use the Table of Contents on the first page
of the chapter to find the Ignition coil section.
Whenever you see these WARNING and CAUTION
symbols, heed their instructions! Always follow safe
operating and maintenance practices.
This warning symbol identifies special instruc-
tions or procedures which, if not correctly fol-
lowed, could result in personal injury, or loss of
life.
CAUTION
This caution symbol identifies special instruc-
tions or procedures which, if not strictly ob-
served, could result in damage 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 information.
NOTE
This note symbol indicates points of particular in-
terest for more efficient and convenient 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 WARNING, CAUTION, or NOTE.
Indicates a conditional step or what action to take based
on the results of the test or inspection in the procedural
step or sub-step it follows.
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 specified tightening torque, oil, grease
or a locking agent during assembly.
engine parts.