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 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 as to his ability to do the work, all ad-
justments, 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, thor-
oughly familiarize yourself with the procedures
before starting work, and then do the work ca
re-
fully in a clean area. Whenever special tools or
equipment are specified, do not use makeshift
tools or equipment. Precision measurem
ents
can only be made if the proper instruments are
used, and the use of substitute tools may ad-
versely 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 genu
ine Kawasaki en-
gine parts. Genuine parts provided as spare
parts are listed in the Parts Catalog.
•
Follow the procedure
s 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 WA
RNING, CAU-
TION, or NOTE.
Indicates a conditional step or what action to
take based on the results o
f the test or inspec-
tion in the procedural step or sub-step it fol-
lows.
In most chapters an e
xploded view illustration
of the system components follows the Table of
Contents. In these illustrations you will find the
instructions ind
icating which parts require spec-
ified tightening torque, oil, grease or a locking
agent during assembly.