They must be re- placed as a set. Pinion Gear Shim s 2. Ring Gear Right Shim s 3. Ring Gear Left Shim s 4. The drive pattern can be a little closer to the toe and the coast pattern can be a somewhat longer and closer to the toe.
Standard Length of Assembling: Outboard: Standard Length of Assembling: Inboard: Pinion Gear 2. Pinion Gear Bearing Holder 3. Gear Case Right Cover 4.
Ball Bearings 5. Ring Gear 6. Pinion Gear Shim s 7. Ring Gear Shim s 8. To increase backlash, increase the thickness of the shim s. To decrease backlash, decrease the thickness of the shim s. Change the thickness a little at a time. Replace any if the lips are misshapen, discolored indicat- ing that the rubber has deteriorated , hardened, or been otherwise damaged. Bend both hooks after installing the spring. Disc thickness 3 mm 0. Disc runout Never reuse old brake fluid.
Do not use fluid from a container that has been left unsealed or that has been open for a long time. Take care that nei- ther the cylinder nor the piston skirt gets scratched. Replace the caliper if the cylinder and piston are badly scored or rusty. Oil on a disc must be cleaned off with an oilless cleaning fluid such as trichloroethylene or acetone.
R: Replacement Parts Property of www. If the spring action feels too soft or too stiff, adjust it in accordance with the following table. If bushings are worn, cracked, hardened, or otherwise damaged, replace them. If it is found, replace the knuckle joint.
Tie-rod Length Standard: If the steering stem is bent, replace the steering stem. If roughness or binding is found, replace the bearing. Learn and ob- serve all the rules below. This will burn out the diodes in the electrical parts. If any wiring is defective, replace the damaged wiring. If the connector is corroded or dirty, clean it carefully. Be sure to use the dedicated electrolyte container for correct electrolyte volume.
Page Precautions 1. Give refresh charge for 5 to 10 hours with charge current shown in the specification see Refreshing Charge. Charge for no more than 5 minutes at the increased voltage then check if the battery is drawing current.
If the battery will accept current [D], decrease the voltage and charge by the standard charging method described on the battery case. A short or open in one of the coil wires will result in either a low output, or no output at all. A loss in rotor magnetism, which may be caused by dropping or hitting the alternator, by leaving it near an electromag- netic field, or just by aging, will result in low output.
Ignition Switch 2. Fuse Box 3. Main Fuse 30 A 4. Load 5. Alternator 6. Starter Relay 8. Battery 12 V12 Ah 9. Engine Ground Terminal Property of www. Do not touch the spark plug, ignition coil, or spark plug lead while the engine is running, or you could receive a severe electrical shock. CAUTION Do not disconnect the battery leads or any other electrical connections when the ignition switch is on, or while the engine is running.
Shock to the sensor can damage it. Ignition Switch 9. Reset Connector 2. Reverse Switch Crankshaft Sensor 3. Speed Sensor Ignition Coils 4. Fuse Box Main Fuse 30 A Spark Plugs 5. Multifunction Meter Battery 6. Starter Motor Brush Length Standard: Service Limit: 5 mm 0.
If any is worn down to the service limit, replace the brush plate assembly. Starter Button 2. Engine Stop Switch 3. Parking Brake Light Switch 4. Front Brake Light Switch 5. Rear Brake Light Switch 6. Main Fuse 30 A 7. Starter Circuit Relay Brake 8.
If the limiter has wear, discoloration, or other damage, replace it as a unit. Headlight Left 2. Position Light Left 3. Main Fuse 30 A Reset Connector 5. Front Brake Light Switch Radiator Fan Breaker 2.
Multifunction Meter 2. Fuel Level Sensor 3. Ignition Switch 4. Main Fuse 30 A 5. Starter Relay 6. Battery 7. If this display function does not work, replace the meter unit. If the LED light does not flash, replace the meter unit. If the illumination does not go on, replace the meter unit. Neutral Switch 3. Reverse Switch 4. Coolant Temperature Switch 5. Actuator Controller 6. Speed Sensor 8. Main Fuse 30 A 9. Fuel Level Sensor Igniter Belt Failure Detection Switch Speed Sensor 9.
Igniter 4. Engine Brake Actuator Belt Failure Detection Switch 5. Actuator Controller Make sure replace the torque converter cover see Converter System chapter. Fuse Installation If a fuse fails during operation, inspect the electrical sys- tem to determine the cause, and then replace it with a new fuse of proper amperage. It Crankshaft sensor trouble is meant simply as a rough guide to assist Igniter trouble the troubleshooting for some of the more Ignition coil trouble Valve not seating properly valve bent, Compression release cam K.
Tube 2. Clamps 3. Align the white paint mark on the tube with the adjustment mark on the crankcase. Starter Motor 5. Install the oil pressure switch lead not to interfere with starter motor. Starter Motor Lead 2. Engine Ground Lead Install the lead so that the flat side of the lower terminal faces toward the engine. Install the clamp on the engine ground lead. Clamp 2. Vacuum Hose 3.
Clamps 4. Boot 5. Clamps 6. Choke Cable Plunger 7. Water Hose 8. White Paint 9. Mark Water Pipe Coolant Catch Tank Property of www. Air Cleaner Cover 2. Breather Tank 3. Breather Hoses 4. Breather Hose 5. Check Valve 6. Duct Screw 7. Air Intake Duct 8. Drain Tube 9. Drain Tube Engine Breather Hose Property of www. Main Harness Alternator Lead 2. Bands Vacuum Hose Blue Line Plug 4. Ignition Coil Lead Frame Pipe 5.
Torque Converter Air Duct Radiator Mounting Bracket 2. Damper 3. Fuel Breather Tube Collar 4. Radiator Fan Motor Breather Tube Radiator Screen 5. Not crush fan motor breather tube to pull it. Fan Motor Breather Tube 4. Fan Motor Lead Connector 5.
To Thermostat 6. To Water Pump 7. Band 9. Water Hose 2. Water Pipe 3. Coolant Temperature Warning Light Switch 4. Water Hose 5. Thermostat 6. Clamp 7. Reserve Tank 8. Reverse Switch Lead 9. Neutral Switch Lead Clamp Air Intake Duct 4. Band 5. Front Final Gear Case 6. Carburetor Air Vent Tube 7. No Interference Property of www.
Maine Harness 2. Engine Brake Actuator Lead 4. Starter Motor Cable 5. Clamp 6. Drive Belt Failure Detecting Switch 7. Engine Brake Actuator Property of www. Vacuum Hose to rear cylinder head with blue line 2. Connect the thick side of hose to the fuel pump. Fuel Hose to carburetor with red line 4. Clamps 5. Vacuum Hose to front cylinder head 6. Rear Brake Lever 2. Parking Brake Lock Lever 3. Variable Differential Control Cable 4.
Cable Adjuster 5. Variable Differential Control Lever 6. Handle Holder Clamp 7. Variable Differential Operating Lever 8. Fit the dust cap. Bands 3. Radiator Fan Motor Breather Tube 4. Fuel Breather Tube 5. Final Gear Case Breather Tubes 6. Joint 7. Tube 8. Dampers 9. Right Headlight Lead 2.
Radiator Cover 3. Frame Ground Lead 4. Rear Brake Light Switch Lead 7. Right Handlebar Switch Lead 2. Throttle Cable 3. Meter Lead 4. Variable Differential Control Cable 5.
Parking Brake Cable 6. Choke Cable 7. Left Handlebar Switch Lead 8. Bands 9. Front Brake Light Switch Lead Air Intake Duct 2. Parking Brake Cable 4.
Foot Brake Cable 5. Bracket 6. Foot Brake Light Switch 8. Speed Sensor Lead Connector 9. Run the lead front side of frame pipe. Fuse Box 2. Igniter 3. Main Harness 4. Clamp 5. Reset Connectors 7. Starter Circuit Relay Neutral 8. Electric Parts Case 9. Vehicle Down Sensor Starter Circuit Relay Brake Accessory Connector 2. To Reverse Light Europe Model 4. To Brake Switch Book file PDF easily for everyone and every device.
You can download and. Visit Kawasaki Motor Corps. Parking Brake Lock Lever 3. If the seat width is within the specified range, lap the valve to the seat as described below. The radiator fan may start even if the ignition switch is off.
Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off. Decrease the thickness of the drive bevel gear shim s by 0. If the insulators are damaged or deteriorated, replace them. If the splined portion of shaft cracked or damaged during disassembling of mxnual joint, do not reuse the shaft.
Sealant — Kawasaki Bond: Deflate the tire to the specified pressure. Radiator Mounting Bracket 2. Transmission Driven Shaft 4. Removal may damage them. Pinion Gear Shim fore 7. Special Tool — Hand Tester: Page 5 Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. Fan Motor Breather Tube 4. Variable Differential Control Lever 6.
Turn the throttle limiter screw [A] until it is spaced about 1 mm 0.
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