2004-2009 Kawasaki KFX 700 / KFX 700V Force Factory Service Manual
Original 2004-2009 Kawasaki KFX 700 / KFX 700V Force Factory Service Manual.
Manual chapters
EMISSION CONTROL INFORMATION
PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM (US MODEL only)
Foreword
General Information
- Before starting to perform an inspection service or carry out a
- KSV700 A1 Left Side View
- KSV700 A1 Right Side View
- Prefixes for Units:
- Units of Temperature:
Periodic Maintenance
- The scheduled maintenance must be done in accordance with this c
- The following tables list the tightening torque for the major fa
- Oil Filter Wrench : 57001 1249
- Carburetor Drain Plug Wrench, Hex 3 : 57001 1269
- Flywheel & Pulley Holder : 57001 1343
- Pulley Holder Attachment : 57001 1472
- Filler Cap Driver: 57001 1454
- Fuel System
Fuel System
- Fuel Level Gauge : 57001 1017
- Pilot Screw Adjuster, A : 57001 1239
- Carburetor Drain Plug Wrench, Hex 3 : 57001 1269
- Throttle Lever Free Play Inspection
- Choke Lever Free Play Check
- Idling Speed Inspection
- Air Cleaner Element Removal
- Fuel Tank Removal
- Fuel Pump Removal
Cooling System
- Permanent type antifreeze is used as a coolant to protect the co
- Bearing Driver Set : 57001 1129
- Bearing Remover Shaft, x69 : 57001 1265
- Bearing Remover Head, x610 x x612 : 57001 1266
- Kawasaki Bond (Silicone Sealant) : 56019 120
- Coolant Deterioration Inspection
- Water Pump Cover Removal
- Radiator Removal
- Thermostat Removal
- Radiator Fan Switch Removal
- Coolant Temperature Warning Light Switch Removal
- Coolant Filter Cleaning
Engine Top End
- Outside Circlip Pliers : 57001 144
- Compression Gauge : 57001 221
- Valve Spring Compressor Assembly : 57001 241
- Piston Pin Puller Assembly : 57001 910
- Valve Seat Cutter, 45° x627.5 : 57001 1114
- Valve Seat Cutter, 32° x628 : 57001 1119
- Valve Seat Cutter, 60° x630 : 57001 1123
- Valve Seat Cutter Holder Bar : 57001 1128
- Valve Seat Cutter, 45° x630 : 57001 1187
- Valve Seat Cutter, 32° x633 : 57001 1199
- Valve Spring Compressor Adapter, x622 : 57001 1202
- Valve Guide Arbor, x65 : 57001 1203
- Valve Guide Reamer, x65 : 57001 1204
- Valve Seat Cutter Holder, x65 : 57001 1208
- Piston Pin Puller Adapter : 57001 1211
- Filter Cap Driver: 57001 1454
- Compression Gauge Adapter, M10 × 1.0 : 57001 1486
- Kawasaki Bond (Silicone Sealant) : 56019 120
- Camshaft Chain Tensioner Removal
- Rocker Case Removal
- Camshaft Removal
- Cylinder Compression Measurement
- Valve Clearance Inspection
- Cylinder Removal
- This vehicle is equipped with a spark arrester approved for off-
Converter System
- Circlip Pliers : 57001 154
- Flywheel & Pulley Holder : 57001 1343
- Drive & Driven Pulley Holder : 57001 1412
- Drive Pulley Puller Bolt : 57001 1429
- Pulley Holder Attachment : 57001 1472
- Drive Pulley Holder : 57001 1473
- Drive Pulley Wrench : 57001 1474
- Spring Holder Set : 57001 1483
- Drive Pulley Holder : 57001 1520
- Drive Belt Removal
- Drive Pulley Removal
- Driven Pulley Removal
- Specifications
Engine Lubrication System
- Oil Pressure Gauge, 10 kgf/cm : 57001 164
- Oil Pressure Gauge Adapter, PT 1/8 : 57001 1033
- Kawasaki Bond (Silicone Sealant) : 56019 120
- Oil Pressure Relief Valve Removal
- Oil Pump Removal
- Oil Pipe Removal
Engine Removal/Installation
- Engine Removal
- Engine Installation
Crankshaft / Transmission
- Outside Circlip Pliers : 57001 144
- Bearing Driver Set : 57001 1129
- Crankcase Disassembly
- Crankcase Assembly
- Crankshaft Removal
- Shift Lever Removal
- Ball and Needle Bearing Replacement
Wheels / Tires
- Jack : 57001 1238
- Toe-in is the amount that the front wheels are closer together i
- Wheel Removal
- Tire Removal
- Front Hub Removal
- Rear Hub Removal
Final Drive
- Bearing Puller : 57001 135
- Outside Circlip Pliers : 57001 144
- Oil Seal & Bearing Remover : 57001 1058
- Bearing Driver Set : 57001 1129
- Socket Wrench : 57001 1363
- Damper Spring Compressor Set : 57001 1475
- Holder & Guide Arbor : 57001 1476
- Socket Wrench, Hex 50 : 57001 1478
- Output Shaft Holder & Spacer : 57001 1479
- Pinion Gear Holder : 57001 1480
- Nut Holding Bolts : 57001 1481
- Socket Wrench : 57001 1482
- Socket Wrench, Hex 41 : 57001 1484
- Pinion Gear Holder : 57001 1485
- Oil Seal Driver: 57001 1487
- Hexagon Wrench, Hex 41 : 57001 1491
- Output Drive Bevel Gear Removal
- Propeller Shaft Removal
- Rear Axle Removal
- Final Gear Case Oil Level Inspection
- Ball or Needle Bearing Inspection
Brakes
- Inside Circlip Pliers : 57001 143
- Master Cylinder Removal
- Caliper Removal
- Brake Pad Removal
- Disc Cleaning
- Brake Hose Inspection
- Brake Pedal Position Inspection
- Internal Wet Brake Disassembly
Suspension
- Inside Circlip Pliers : 57001 143
- Outside Circlip Pliers : 57001 144
- Oil Seal & Bearing Remover : 57001 1058
- Hook Wrench : 57001 1101
- Bearing Driver Set : 57001 1129
- Jack : 57001 1238
- Front Shock Absorber Inspection
- Suspension Arm Removal
- Swingarm Removal
Steering
- Steering Stem Removal
- Steering Inspection
- Handlebar Removal
Frame
- Seat Removal
- Front Fender Removal
- Side Inner Cover Removal
- Front Guard Removal
- Foot Guard and Stay Removal
Electrical System
- Hook Wrench : 57001 1101
- Timing Light : 57001 1241
- Compression Gauge Gasket : 57001 1314
- Hand Tester : 57001 1394
- Flywheel Puller Assembly : 57001 1405
- Needle Adapter Set : 57001 1457
- Light/Dimmer Switch [A]
- There are a number of important precautions that should be taken
- Wiring Inspection
- Battery Removal
- Alternator Cover Removal
- Starter Motor Removal
- Headlight Beam Vertical Adjustment
- Radiator Fan Circuit Inspection
- Fuel Pump Inspection
- Indicator Unit Removal
- Brake Light Switch Adjustment
- 30 A Main Fuse Removal
Appendix
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Full list of manual chapters:
tables
LIST OF ABBREVIATIONS
Units of Mass:
Units of Volume:
Units of Force:
Units of Length:
Units of Torque:
Units of Pressure:
Units of Speed:
Units of Power:
Basic Torque for General Fasteners of Engine Parts
Basic Torque for General Fasteners of Frame Parts
Throttle Lever Free Play
Choke Lever Free Play [B]
Idle Speed
Water and Coolant Mixture Ratio (when shipping)
Valve Clearance (when cold)
Valve Clearance (when cold)
Belt Height (Paralle Portion)
Belt Deflection
Spacers
Engine Oil
Shift Control Cable Grip Free play [A]
Tire Tread Depth
Standard Tire
Final Gear Case Oil
Pad Lining Thickness
Rear Brake Lever Free Play
Brake Pedal Free Play
Spark Plug Gap
Brake Light Timing
Carburetor Pilot Screw Setting
Service Fuel Level
Float Height
Carburetor Synchronization Vacuum
Radiator Cap Relief Pressure
Thermostat Valve Opening Temperature
Valve Closing Temperature (for reference)
Rocker Arm Inside Diameter
Rocker Shaft Diameter
Cam Height
Camshaft Bearing Clearance (x618)
Camshaft Bearing Clearance (x622)
Camshaft Journal Diameter (x618)
Camshaft Journal Diameter (x622)
Cylinder Compression (Usable Range)
Cylinder Head Warp
Valve/Valve Guide Clearance (Wobble Method)
Valve Seating Surface Outside Diameter
Valve Seating Surface Width
Piston Diameter
Piston/Cylinder Clearance
Piston Ring/Groove Clearance
Piston Ring Groove Width
Piston Ring Thickness
Piston Ring End Gap
Cover Bushing Inside Diameter [A]
Sheave Bushing Inside Diameter [A]
Spring Free Length [A]
Shoe Side Clearance
Sheave Bushing Inside Diameter
Spring Free Length [A]
Oil Pressure
Connecting Rod Bend
Connecting Rod Twist
Connecting Rod Big End Side Clearance
Connecting Rod Big End Bearing, Insert/Crankpin Clearance
Crankpin Diameter
Crankpin Diameter Marks
Connecting Rod Big End Inside Diameter Marks
Big End Bearing Insert Selection
Crankshaft Runout
Crankshaft Main Journal Diameter
Crankcase Main Bearing Bore Diameter
Shift Fork Ear Thickness
Shifter Groove Width
Toe-in of Front Wheels
Maximum Tire Air Pressure (to seat beads when cold)
Tire Air Pressure (when cold)
Drive Bevel Gear Shims for Tooth Contact Adjustment
Driven Bevel Gear Shims for Backlash Adjustment
Output Bevel Gear Backlash
Rear Axle Shaft Runout
6. Pinion Gear Shims for Tooth Contact Adjustment
7. Ring Gear Shims for Backlash Adjustment
Recommended Disc Brake Fluid
Disc Thickness
Disc Runout
Pedal Position [C]
Spring Action
Compression Damping
Spring Preload Setting Position
Spring Action
Tie-Rod Length
Battery Terminal Voltage
Terminal Voltage: 11.5 less than 12.5 V
Terminal Voltage : less than 11.5 V
Regulator/Rectifier Output Voltage
Alternator Output Voltage
Stator Coil Resistance
Rectifier Circuit Inspection
Ignition Coil Arcing Distance
Ignition Coil Winding Resistance
Ignition Coil Primary Peak Voltage
Crankshaft Sensor Resistance
Connections:
Crankshaft Sensor Peak Voltage
Ignition Timing
Vehicle-down Sensor Power Source Voltage
Vehicle-down Sensor Power Source Voltage
Vehicle-down Sensor Power Output Voltage
Vehicle-down Sensor Power Output Voltage
Commutator Diameter
Starter Motor Brush Length
Testing Relay
Testing Relay
Radiator Fan Motor Leads
Fuel Pump Supply Voltage
Fuel Pump Pressure
Fuel Indicator Light [A]:
Neutral Indicator Light (LED) [B]:
Reverse Indicator Light (LED) [C]:
Water Temperature Warning Light (LED) [D]:
Oil Pressure Warning Light (LED) [E]:
Belt Indicator Light (LED) [F]:
Radiator Fan Switch Resistance
Coolant Temperature Warning Light Switch Resistance
Table of Contents
Read OWNER'S MANUAL before operating.
EMISSION CONTROL INFORMATION
1.
2.
PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM (US MODEL only)
Foreword
General Information
Before starting to perform an inspection service or carry out a
Especially note the following:
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
Two-Color Electrical
(19)
(20)
KSV700 A1 Left Side View
KSV700 A1 Right Side View
Prefixes for Units:
Units of Temperature:
Periodic Maintenance
The scheduled maintenance must be done in accordance with this c
The following tables list the tightening torque for the major fa
Oil Filter Wrench : 57001 1249
Carburetor Drain Plug Wrench, Hex 3 : 57001 1269
Flywheel and Pulley Holder : 57001 1343
Pulley Holder Attachment : 57001 1472
Filler Cap Driver: 57001 1454
Fuel System
Throttle Lever Free Play Inspection
Throttle Lever Free Play Adjustment
Choke Lever Free Play Check
Choke Lever Free Play Adjustment
Idle Speed Inspection
Idle Speed Adjustment
Fuel System Cleanliness Inspection
Air Cleaner Element Cleaning and Inspection
Air Cleaner Draining
Fuel Hoses and Connections Inspection
Fuel Hose and Fuel Filter Replacement
Cooling System
Radiator Cleaning
Radiator Hose and Connection Inspection
Coolant Change
Coolant Filter Cleaning
Engine Top End
Valve Clearance Inspection
Valve Clearance Adjustment
Spark Arrester Cleaning
Converter System
Drive Belt Inspection
Drive Belt Deflection Inspection
Drive Belt Deflection Adjustment
Engine Lubrication System
Engine Oil Change
Oil Filter Change
Crankshaft/Transmission
Shift Control Grip Free Play Inspection
Shift Control Grip Free Play Adjustment
Wheels/Tires
Tire Inspection
Final Drive
Final Gear Case Oil Change
Propeller Shaft Joint Boot Inspection
Brakes
Front Brake Pad Wear Inspection
Front Brake Hoses and Connections Inspection
Front Brake Hose Replacement
Brake Fluid Level Inspection
Brake Fluid Change
Brake Line Air Bleeding
Master Cylinder Inspection (Visual Inspection)
Caliper Fluid Seal Replacement
Caliper Dust Seal and Friction Boot Replacement
Rear Brake Plates Replacement
Rear Brake Lever Free Play Inspection
Rear Brake Pedal Free Play Inspection
Rear Brake Lever and Pedal Free Play Adjustment
Suspension
Knuckle Joint Inspection
Steering
Steering Inspection
Tie Rod End Inspection
Electrical System
Spark Plug Cleaning / Inspection
Spark Plug Gap Inspection
Brake Light Switch Inspection
Brake Light Timing Adjustment
General Lubrication
Lubrication
Bolts and Nuts Tightening
Tightness Inspection
Wheels:
Brakes:
Others:
Fuel System
Fuel Level Gauge : 57001 1017
Pilot Screw Adjuster, A : 57001 1239
Carburetor Drain Plug Wrench, Hex 3 : 57001 1269
Throttle Lever Free Play Inspection
Throttle Lever Free Play Adjustment
Throttle Case Removal/Disassembly
Throttle Case Assembly/Installation
Throttle Cable Installation
Throttle Case Inspection
Throttle Cable Lubrication
Throttle Cable Inspection
Choke Lever Free Play Check
Choke Lever Free Play Adjustment
Choke Lever and Cable Removal
Choke Lever and Cable Installation
Choke Cable Lubrication
Choke Cable Inspection
Idling Speed Inspection
Idle Speed Adjustment
Pilot Screw Adjustment
Service Fuel Level Inspection
Service Fuel Level Adjustment
Carburetor Synchronization Inspection
Carburetor Synchronization Adjustment
Fuel System Cleanliness Inspection
Carburetor Removal
Carburetor Installation
Carburetor Disassembly
Carburetor Assembly
Carburetor Separation
Carburetor Joining
Carburetor Cleaning
Carburetor Inspection
Air Cleaner Element Removal
Air Cleaner Element Cleaning and Inspection
Air Cleaner Draining
Air Cleaner Housing Removal
Air Cleaner Housing Installation
Fuel Tank Removal
Fuel Tank Installation
Fuel Tank Cleaning
Fuel Tap Removal
Fuel Tap Installation
Fuel Tap Inspection
Fuel Pump Removal
Pump Filter Cleaning
Fuel Pump Installation
Fuel Pump Inspection
Cooling System
Permanent type antifreeze is used as a coolant to protect the co
Bearing Driver Set : 57001 1129
Bearing Remover Shaft, x69 : 57001 1265
Bearing Remover Head, x610 x x612 : 57001 1266
Kawasaki Bond (Silicone Sealant) : 56019 120
Coolant Deterioration Inspection
Coolant Level Inspection
Coolant Draining
Coolant Filling
Pressure Testing
Water Pump Cover Removal
Water Pump Cover Installation
Impeller Removal
Water Pump Impeller Installation
Water Pump Impeller Inspection
Mechanical Seal Replacement
Radiator Removal
Radiator Fan Removal
Radiator Fan Installation
Radiator Inspection
Radiator Cleaning
Radiator Cap Inspection
Thermostat Removal
Thermostat Installation
Thermostat Inspection
Radiator Fan Switch Removal
Radiator Fan Switch Installation
Radiator Fan Switch Inspection
Coolant Temperature Warning Light Switch Removal
Coolant Temperature Warning Light Switch Installation
Coolant Temperature Warning Light Switch Inspection
Coolant Filter Cleaning
Coolant Valve Inspection
Engine Top End
Outside Circlip Pliers : 57001 144
Compression Gauge : 57001 221
Valve Spring Compressor Assembly : 57001 241
Piston Pin Puller Assembly : 57001 910
Valve Seat Cutter, 45° x627.5 : 57001 1114
Valve Seat Cutter, 32° x628 : 57001 1119
Valve Seat Cutter, 60° x630 : 57001 1123
Valve Seat Cutter Holder Bar : 57001 1128
Valve Seat Cutter, 45° x630 : 57001 1187
Valve Seat Cutter, 32° x633 : 57001 1199
Valve Spring Compressor Adapter, x622 : 57001 1202
Valve Guide Arbor, x65 : 57001 1203
Valve Guide Reamer, x65 : 57001 1204
Valve Seat Cutter Holder, x65 : 57001 1208
Piston Pin Puller Adapter : 57001 1211
Filter Cap Driver: 57001 1454
Compression Gauge Adapter, M10 x 1.0 : 57001 1486
Kawasaki Bond (Silicone Sealant) : 56019 120
Camshaft Chain Tensioner Removal
Camshaft Chain Tensioner Installation
Rocker Case Removal
Rocker Case Installation
Rocker Arm Removal
Rocker Arm Installation
Rocker Arm Inspection
Rocker Shaft Diameter Measurement
Camshaft Removal
Camshaft Installation
Camshaft Assembly
Cam Wear
Camshaft Bearing Wear
KACR Inspection
KACR Removal
KACR Installation
Camshaft Chain Removal
Camshaft Chain Installation
Cylinder Compression Measurement
Cylinder Head Removal
Cylinder Head Installation
Cylinder Head Cleaning
Cylinder Head Warp
Valve Clearance Inspection
Valve Clearance Adjustment
Valve Removal
Valve Installation
Valve Guide Removal
Valve Guide Installation
Valve-to-Guide Clearance Measurement
Valve Seat Inspection
Valve Seat Repair (Valve Lapping)
Cylinder Removal
Piston Removal
Cylinder, Piston Installation
Cylinder Wear
Piston Wear
Piston/Cylinder Clearance
Piston Ring, Piston Ring Groove Wear
Piston Ring Groove Width
Piston Ring Thickness
Piston Ring End Gap
This vehicle is equipped with a spark arrester approved for off-
Spark Arrester Cleaning
Muffler and Exhaust Pipe Removal
Muffler and Exhaust Pipe Installation
Exhaust System Inspection
Converter System
Circlip Pliers : 57001 154
Flywheel and Pulley Holder : 57001 1343
Drive and Driven Pulley Holder : 57001 1412
Drive Pulley Puller Bolt : 57001 1429
Pulley Holder Attachment : 57001 1472
Drive Pulley Holder : 57001 1473
Drive Pulley Wrench : 57001 1474
Spring Holder Set : 57001 1483
Drive Pulley Holder : 57001 1520
WARNING
Torque Converter Cover Removal
Torque Converter Cover Installation
Converter Exhaust Duct Removal
Converter Exhaust Duct Installation
Converter Intake Duct Removal
Converter Intake Duct Installation
Drive Belt Removal
Drive Belt Installation
Drive Belt Inspection
Drive Belt Deflection Inspection
Drive Belt Deflection Adjustment
Drive Pulley Removal
Drive Pulley Disassembly
Drive Pulley Inspection
Spider Shoe Side Clearance Adjustment
Drive Pulley Assembly
Drive Pulley Installation
Driven Pulley Removal
Driven Pulley Disassembly
Driven Pulley Inspection
Driven Pulley Assembly
Driven Pulley Installation
Specifications
Engine Lubrication System
Oil Pressure Gauge, 10 kgf/cm : 57001 164
Oil Pressure Gauge Adapter, PT 1/8 : 57001 1033
Kawasaki Bond (Silicone Sealant) : 56019 120
WARNING
Oil Level Inspection
Engine Oil Change
Oil Filter Change
Oil Screen Removal
Oil Screen Cleaning
Oil Pressure Measurement
Oil Pressure Relief Valve Removal
Oil Pressure Relief Valve Installation
Oil Pressure Relief Valve Inspection
Oil Pump Removal
Oil Pump Installation
Oil Pipe Removal
Oil Pipe Installation
Engine Removal/Installation
Engine Removal
Engine Installation
Crankshaft / Transmission
Outside Circlip Pliers : 57001 144
Bearing Driver Set : 57001 1129
Crankcase Disassembly
Crankcase Assembly
Crankshaft Removal
Crankshaft Installation
Connecting Rod Removal
Connecting Rod Installation
Crankshaft/Connecting Rod Cleaning
Connecting Rod Bend
Connecting Rod Twist
Connecting Rod Big End Side Clearance
Connecting Rod Big End Bearing/Crankpin Wear
Crankshaft Runout
Crankshaft Main Bearing/Journal Wear
Shift Lever Removal
Shift Lever Installation
Shift Control Cables Removal
Shift Control Cables Installation
Reverse Lock Cable Removal
Reverse Lock Cable Installation
Transmission Removal
Transmission Installation
Shift Fork Bending
Shift Fork/Gear and Shifter Groove Wear
Transmission and Shift Mechanism Inspection
Ball and Needle Bearing Replacement
Ball and Needle Bearing Wear
Oil Seal Inspection
Wheels / Tires
Jack : 57001 1238
Toe-in is the amount that the front wheels are closer together i
Toe-in Inspection
Toe-in Adjustment
Wheel Removal
Wheel Installation
Wheel (Rim) Inspection
Wheel (Rim) Replacement
Tire Removal
Tire Installation
Tire Inspection
Front Hub Removal
Front Hub Installation
Front Hub Disassembly/Assembly
Rear Hub Removal
Rear Hub Installation
Rear Hub Disassembly/Assembly
Final Drive
Bearing Puller : 57001 135
Outside Circlip Pliers : 57001 144
Oil Seal and Bearing Remover : 57001 1058
Bearing Driver Set : 57001 1129
Socket Wrench : 57001 1363
Damper Spring Compressor Set : 57001 1475
Holder and Guide Arbor : 57001 1476
Socket Wrench, Hex 50 : 57001 1478
Output Shaft Holder and Spacer : 57001 1479
Pinion Gear Holder : 57001 1480
Nut Holding Bolts : 57001 1481
Socket Wrench : 57001 1482
Socket Wrench, Hex 41 : 57001 1484
Pinion Gear Holder : 57001 1485
Oil Seal Driver: 57001 1487
Hexagon Wrench, Hex 41 : 57001 1491
Output Drive Bevel Gear Removal
Output Drive Bevel Gear Installation
Output Drive Bevel Gear Disassembly
Output Drive Bevel Gear Assembly
Output Driven Bevel Gear Removal
Output Driven Bevel Gear Installation
Output Driven Bevel Gear Disassembly
Output Driven Bevel Gear Assembly
Output Bevel Gears Adjustment
Output Bevel Gear (Backlash-related Parts)
Bevel Gears Inspection
Cam Damper Inspection
Propeller Shaft Removal
Propeller Shaft Installation
Propeller Shaft Joint Boot Inspection
Propeller Shaft Inspection
Rear Axle Removal
Rear Axle Installation
Ball Bearing Wear
Rear Axle Runout Inspection
Final Gear Case Oil Level Inspection
Final Gear Case Oil Change
Final Gear Case Removal
Final Gear Case Installation
Final Gear Case Disassembly
Final Gear Case Assembly
Oil Seal Installation
Final Bevel Gear Adjustment
Final Gear Case (Backlash-related Parts)
Pinion Gear Unit Disassembly
Pinion Gear Unit Assembly
Bevel Gear Inspection
Ball or Needle Bearing Inspection
Oil Seal Inspection
Brakes
Inside Circlip Pliers : 57001 143
WARNING
Brake Fluid Recommendation
Brake Fluid Level Inspection
Brake Fluid Change
Brake Line Air Bleeding
Master Cylinder Removal
Master Cylinder Installation
Master Cylinder Disassembly
Master Cylinder Assembly
Master Cylinder Inspection (Visual Inspection)
Caliper Removal
Caliper Installation
Caliper Disassembly
Caliper Assembly
Piston and Cylinder Damage
Caliper Holder Shaft Wear Inspection
Brake Pad Removal
Brake Pad Installation
Brake Pad Wear Inspection
Disc Cleaning
Disc Removal
Disc Installation
Disc Wear
Disc Runout
Brake Hose Inspection
Brake Hose Replacement
Brake Pedal Position Inspection
Brake Pedal Position Adjustment
Rear Brake Lever Free Play Inspection
Brake Pedal Free Play Inspection
Rear Brake Lever and Pedal Free Play Adjustment
Brake Pedal Removal
Brake Pedal Installation
Brake Cable Removal
Brake Cable Installation
Brake Cable Lubrication
Brake Pedal Shaft Removal
Brake Pedal Shaft Installation
Internal Wet Brake Disassembly
Internal Wet Brake Assembly
Suspension
Inside Circlip Pliers : 57001 143
Outside Circlip Pliers : 57001 144
Oil Seal and Bearing Remover : 57001 1058
Hook Wrench : 57001 1101
Bearing Driver Set : 57001 1129
Jack : 57001 1238
Front Shock Absorber Inspection
Front Shock Absorber Preload Adjustment
Front Shock Absorber Removal
Front Shock Absorber Installation
Rear Shock Absorber:
Compression Damping Adjustment
Rear Shock Absorber Removal
Rear Shock Absorber Installation
Rear Shock Absorber Preload Adjustment
Rear Shock Absorber Inspection
Rear Shock Absorber Scrapping
Suspension Arm Removal
Suspension Arm Installation
Suspension Arm Disassembly
Suspension Arm Assembly
Swingarm Removal
Swingarm Installation
Swingarm Disassembly
Swingarm Assembly
Swingarm Bearing Inspection
Swingarm Bearing Lubrication
Steering
Steering Stem Removal
Steering Stem Installation
Knuckle Removal
Knuckle Installation
Tie-Rod Removal
Tie-Rod Installation
Tie-Rod End Removal
Tie-Rod End Installation
Steering Inspection
Steering Stem Straightness
Steering Lubrication
Steering Stem Clamp Inspection
Steering Stem Bearing Inspection
Steering Knuckle Bearing Inspection
Tie-Rod End and Steering Knuckle Joint Inspection
Handlebar Removal
Handlebar Installation
Frame
Seat Removal
Seat Installation
Front Fender Removal
Front Fender Installation
Rear Fender Removal
Rear Fender Installation
Side Inner Cover Removal
Side Inner Cover Installation
Air Cleaner Cover Removal
Air Cleaner Cover Installation
Radiator Cover Removal
Front Guard Removal
Front Guards Installation
Engine Bottom Guard Removal
Engine Bottom Guard Installation
Rear Bottom Guard Removal
Rear Bottom Guard Installation
Foot Guard and Stay Removal
Foot Guard and Stay Installation
Electrical System
Hook Wrench : 57001 1101
Timing Light : 57001 1241
Compression Gauge Gasket : 57001 1314
Hand Tester : 57001 1394
Flywheel Puller Assembly : 57001 1405
Needle Adapter Set : 57001 1457
Light/Dimmer Switch [A]
There are a number of important precautions that should be taken
Wiring Inspection
Battery Removal
Battery Installation
Electrolyte Filling
Initial Charge
Precautions
1)
2)
3)
4)
Interchange
Charging Condition Inspection
Refreshing Charge
Alternator Cover Removal
Alternator Cover Installation
Alternator Rotor Removal
Alternator Rotor Installation
Alternator Stator Removal
Alternator Stator Installation
Regulator/Rectifier Output Voltage Inspection
Alternator Inspection
Regulator/Rectifier Inspection
Charging System Circuit
WARNING
Spark Plug Removal
Spark Plug Installation
Spark Plug Cleaning/Inspection
Spark Plug Gap Inspection
Ignition Coil Removal
Ignition Coil Installation
Ignition Coil Inspection
Ignition Coil Primary Peak Voltage Inspection
Crankshaft Sensor Removal
Crankshaft Sensor Installation
Crankshaft Sensor Inspection
Crankshaft Sensor Peak Voltage Inspection
Alternator Rotor Inspection
Ignition Timing Test
Vehicle-down Sensor Outline
Vehicle-down Sensor Removal
Vehicle-down Sensor Installation
Vehicle-down Sensor Inspection
Ignition System Troubleshooting
Ignition System Circuit
Starter Motor Removal
Starter Motor Installation
Starter Motor Disassembly
Starter Motor Assembly
Commutator Cleaning/Inspection
Armature Inspection
Starter Motor Brush Length
Brush Assembly Inspection
Brush Plate and Terminal Bolt Inspection
Starter Relay Inspection
Starter Circuit Relay Inspection
Electric Starter Circuit
Starter Motor Clutch Removal
Starter Motor Clutch Installation
Starter Motor Clutch Inspection
Torque Limiter Inspection
Headlight Beam Vertical Adjustment
Headlight Bulb Replacement
Taillight Bulb Replacement
Lighting System Circuit
Radiator Fan Circuit Inspection
Radiator Fan Motor Inspection
Radiator Fan Circuit
Fuel Pump Inspection
Fuel Reserve Switch Inspection (1)
Fuel Reserve Switch Inspection (2)
Fuel Pump/Fuel Reserve Switch Circuit
Indicator Unit Removal
Indicator Unit Installation
Indicator Unit Inspection
Indicator Unit Circuit
Brake Light Switch Adjustment
Radiator Fan Switch Inspection
Coolant Temperature Warning Light Switch Inspection
Switch Inspection
Neutral Switch Connection
Reverse Switch Connections
Oil Pressure Switch Connections*
30 A Main Fuse Removal
Radiator Fan Fuse Removal
Main Fuse Inspection
Radiator Fan Fuse Inspection
Appendix
NOTE
Engine Doesn't Start, Starting Difficulty:
Starter motor not rotating:
Starter motor rotating but engine doesn't turn over:
Engine won't turn over:
No fuel flow:
Engine flooded:
Fuel/air mixture incorrect:
No spark; spark weak:
Compression Low:
Poor Running at Low Speed:
Spark weak:
Fuel/air mixture incorrect:
Compression low:
Other:
Poor Running or No Power at High Speed:
Firing incorrect:
Fuel/air mixture incorrect:
Compression low:
Knocking:
Miscellaneous:
Overheating:
Firing incorrect:
Fuel/air mixture incorrect:
Compression high:
Engine load faulty:
Lubrication inadequate:
Final gear case overheating:
Coolant incorrect:
Cooling system component incorrect:
Over Cooling:
Cooling system component incorrect:
Converter Operation Faulty:
Belt slipping:
Converter engagement speed too low:
Converter engagement speed too high:
Shifting too quickly:
Shifting too slowly:
Gear Shifting Faulty:
Doesn't go into gear:
Jumps out of gear:
Overshifts:
Abnormal Engine Noise:
Knocking:
Piston Slap:
Valve noise:
Other noise:
Abnormal Drive Train Noise:
Converter noise:
Transmission noise:
Final gear case noise:
Abnormal Frame Noise:
Shock absorber noise:
Disc brake noise:
Rear brake noise:
Other noise:
Exhaust Smokes Excessively:
White smoke:
Black Smoke:
Brown smoke:
Handling and/or Stability Unsatisfactory
Handlebar hard to turn:
Handlebar shakes or excessively vibrates:
Handlebar pulls to one side:
Shock absorption unsatisfactory:
Brake Doesn't Hold
Front brake:
Rear Brake:
Battery Discharged:
Battery Overcharged:
