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Permanently removing, disconnecting, or rendering inoperative any component or element of design of the emission control systems. They are designed to give optimum performance kawaxaki maintaining a low noise level.

Please do not remove these systems, or alter them in any way which results in an increase in noise level. Use proper tools and genuine Kawasaki Vehi- cle parts.

To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter kawzsaki necessary. Gaskets, O-rings, oil seals, grease seals, circlips, cotter pins or self-locking nuts 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 mznual maintain proper alignment and use smooth movements kawaaski installing. Ball Bearing and Needle Bearing Do not remove pressed kawawaki 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. The gun case is an optional part. Overall Width 1 mm Wheelbase 1 mm Type Belt drive torque converter 3. Type Double Wishbone Wheel Travel mm 7. Torque and Locking Agent The initial maintenance is vitally important and must not be neglected.

Apply a non-permanent locking agent. Use this table for only manua bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads. If the throttle pedal does not return properly, lubricate the throttle cable see Throttle Cable Lubrication in the Fuel System chapter.

-Parts / Manuals

Do not wring the ele- ment or blow it dry; the element can be damaged. If any of the parts of the element are damaged, replace them. In dusty areas, they should be cleaned more fre- quently than the recommended interval.


After riding through muddy terrains, the radiator screen and the radiator should be cleaned immediately. If necessary, replace the belt.

If the upper surface [B] of the drive belt is lowered 1. If the belt deflection is more than 31 mm 1. Special Tool – Oil Filter Wrench: Torque – Wheel Nuts: If the fluid in the reservoir runs completely out any time during fluid changing, air bleeding must be kawaeaki since air will have entered the line.

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Bend and twist the rubber hose while examining Replace it if any cracks [B] or bulges [C] are noticed. Torque – Brake Hose Banjo Bolts: Take care that neither the cylinder nor the piston skirt gets scratched. Front [B] If there is any signs of deterioration, cracks, or damage, replace the steering gear assembly together with these boots.

If the gap is incorrect, carefully bend the side electrode [B] with a suitable tool to obtain the manuxl gap. Spark Plug Gap 0.

If damage, tear or deterioration is found, replace the boots see Front Propeller Shaft section in the Final Drive chap- ter. Also, check to see that each cotter pin is in place and in good condition. Intake Air Pressure Sensor 4. Water Temperature Sensor Main Fuse 30 A 9. Kaqasaki Pump Relay Fuel Pump Relay 3.

Frame Kawaszki 2 6. Intake Air Pressure Sensor: Intake Air Temperature Sensor: Power Supply to Sensors: Inlet Air Pressure Sensor: Inlet Air Temperature Sensor: Throttle Valve Dual throttle valve Bore 34 mm 1. Fuel Pressure Gauge Adapter: Do not use any other battery manuql for a 12 V sealed battery as a power source.

Teryyx sure to install the oil filler cap [A] after teeyx the engine oil. When the repair has been done, the symbol disappears. But the service codes stored in memory of the ECU are not erased to preserve the problem history can be referred using the KDS Kawasaki Diagnostic System when solving unstable problems. Much of the DFI system troubleshooting work consists of confirming continuity of the wiring. In addition, the condition of the problem is stored in the memory of the ECU.

If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Connect the connectors securely. Year of initial registration: Environment when problem occurred.


It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties in DFI system. Throttle sensor trouble Inspect see chapter 3. Fuel pressure too low or too high Inspect see chapter 3. Unstable fuel pressure Fuel pressure regulator trouble Inspect and replace fuel pump or kinked fuel line Inspect and repair fuel line see chapter 3.

Fuel injector trouble Inspect see chapter 3. Intake air temperature sensor trouble Inspect see chapter 3. When repair has been done, yellow engine warning indicator light goes off and the service codes lawasaki not displayed.

Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria If the throttle sensor system manyal the signal mqnual out of the usable range, wiring short or openthe ECU locks ignition timing into the ignition timing at opened throttle position and sets the When the engine load is light like at idling or low speed, the ECU determines the injection quantity by calculating from the throttle vacuum intake air pressure sen- sor output voltage and engine speed crankshaft sensor output voltage.

Never drop the throttle body assy, especially on a hard surface. Waterproof Joint 2 3. Such a shock to the sensor manua damage it.

Vacuum Pressure gauge to Sensor Pl: Local Atmospheric Pressure absolute measured by a barometer Pv: Vacuum Pressure absolute to Sensor Vv: Standard Atmospheric Pressure Absolute Pv: Throttle Full Open Kawasakii Intake Air Pressure Sensor Special Tool – Measuring Adapter: Frame Ground 2 3.

Fuel Pump Relay 7. Fuel Pump Fuse 10 A 4. Fuel Pump Relay 8. Frame Ground 2 9. Ignition Fuse 10 A 4. Service Code 51, 52 Ignition Coil 1: If the input voltage is out of the standard, check the wiring for continuity see Ignition Coil Circuit.

Special Tool – Hand Tester: Spark Plug Front 2. Waterproof Joint 1 3. Water Temperature Sensor 2. Radiator Fan Relay 3. Radiator Fan Breaker 15 A 4. Put the grip end onto your ear, and listen whether the fuel injector is clicking or not. Fuel Injector 1 2.