Benutzerhandbuch für Kawasaki Z750

Benutzerhandbuch (English)

Benutzerhandbuch

Inhaltsverzeichnis

tables
1
- LIST OF ABBREVIATIONS
  6
- New Ignition Interlock Sidestand System
  20
- Current Ignition Interlock Sidestand System
  20
- Materials of Semi-Conductor and Emitting Color
  22
- Units of Mass:
  24
- Units of Volume:
  24
- Units of Force:
  24
- Units of Length:
  24
- Units of Torque:
  24
- Units of Pressure:
  24
- Units of Speed:
  24
- Units of Power:
  24
- Periodic Inspection:
  26
- Periodic Replacement Parts:
  28
- Basic Torque for General Fasteners
  29
- Throttle Grip Free Play
  38
- Idle Speed
  39
- Engine Vacuum
  40
- Main Throttle Sensor Output Voltage
  42
- Water and Coolant Mixture Ratio (when shipping)
  45
- Valve Clearance
  46
- Clutch Lever Free Play
  47
- Engine Oil
  48
- Tread Depth
  50
- Air Pressure (when cold)
  50
- Chain Slack
  51
- Drive Chain 20-link Length
  52
- Standard Chain
  52
- Pad Lining Thickness
  53
- Recommended Disc Brake Fluid
  56
- Sample Diagnosis Sheet
  88
- Engine Doesn't Start, Starting Difficulty
  90
- Poor Running at Low Speed
  92
- Poor Running or No Power at High Speed:
  96
- Main Throttle Sensor Input Voltage
  106
- Wiring Connection
  106
- Idle Speed
  107
- Main Throttle Sensor Output Voltage
  107
- Wiring Connection
  107
- Main Throttle Sensor Resistance
  108
- Inlet Air Pressure Sensor Input Voltage
  109
- Inlet Air Pressure Sensor Output Voltage
  110
- Inlet Air Temperature Sensor Output Voltage
  113
- Inlet Air Temperature Sensor Resistance
  114
- Water Temperature Sensor Output Voltage
  115
- Atmospheric Pressure Sensor Input Voltage
  117
- Atmospheric Pressure Sensor Output Voltage
  118
- Speed Sensor Input Voltage
  122
- Speed Sensor Output Voltage at Sensor
  123
- Vehicle-down Sensor Power Source Voltage
  124
- Power Source Voltage at Sensor
  124
- Vehicle-down Sensor Output Voltage
  125
- Output Voltage at Sensor
  125
- Subthrottle Sensor Input Voltage
  127
- Wiring Connection
  127
- Main Throttle Sensor Output Voltage
  128
- Wiring Connection
  128
- Throttle Sensor Resistance
  129
- Stick Coil Input Voltage at ECU
  130
- Input Voltage at ECU
  130
- Subthrottle Valve Actuator Resistance
  132
- Subthrottle Valve Actuator Input Voltage
  133
- Input Voltage at Actuator
  133
- FI Indicator LED Light Check
  135
- ECU Grounding Inspection
  137
- ECU Power Source Inspection
  137
- Testing Relay
  139
- Fuel Pressure
  140
- Fuel Pressure (idling)
  141
- Amount of Fuel Flow
  142
- Pump Operating Voltage at Pump
  145
- Testing Relay
  146
- Injector Power Source Voltage at ECU
  147
- Injector Output Voltage
  148
- Output Voltage at Injector Connector
  148
- Injector Wiring Inspection
  148
- Injector Resistance
  150
- Injector Fuel Line Maximum Pressure
  151
- Choke Lever Free Play
  153
- Radiator Cap Relief Pressure
  176
- Thermostat Valve Opening Temperature
  178
- Vacuum Switch Valve Closing Pressure (Open → Close)
  191
- Camshaft Journal, Camshaft Cap Clearance
  196
- Camshaft Journal Diameter
  197
- Camshaft Runout
  197
- Cam Height
  197
- Cylinder Compression
  198
- Cylinder Head Warp
  200
- Valve/Valve Guide Clearance (Wobble Method)
  202
- Valve Seating Surface Outside Diameter
  203
- Valve Seating Surface Width
  203
- Cylinder Inside Diameter
  210
- Piston Diameter
  210
- Piston Ring/Groove Clearance
  211
- Piston Ring Groove Width
  211
- Piston Ring Thickness
  211
- Piston Ring End Gap
  212
- Clutch Plate Assembly
  228
- Friction Plate Thickness
  229
- Friction and Steel Plate Warp
  229
- Clutch Spring Free Length
  229
- Oil Pressure
  243
- Connecting Rod Bend
  271
- Connecting Rod Twist
  271
- Connecting Rod Big End Side Clearance
  271
- Connecting Rod Big End Bearing Insert/Crankpin Clearance
  272
- Crankpin Diameter
  272
- Crankpin Diameter Marks
  272
- Connecting Rod Big End Inside Diameter Marks
  273
- Crankshaft Side Clearance
  273
- Crankshaft Runout
  274
- Crankshaft Main Bearing Insert/Journal Clearance
  274
- Crankshaft Main Journal Diameter
  274
- Crankshaft Main Journal Diameter Marks
  274
- Crankcase Main Bearing Inside Diameter Marks
  275
- Shift Fork Ear Thickness
  285
- Gear Groove Width
  285
- Shift Fork Guide Pin Diameter
  285
- Shift Drum Groove Width
  285
- Rim Runout
  295
- Axle Runout/100 mm (3.94 in.)
  296
- Balance Weight
  297
- Link Pin Outside Diameter
  311
- Link Plates Outside Width
  311
- Rear Sprocket Warp
  315
- Pedal Position
  324
- Front Disc Thickness
  334
- Rear Disc Thickness
  334
- Disc Runout
  334
- Oil Level (fully compressed, without spring)
  345
- Fork Spring Free Length
  348
- Rebound Damping Adjustment
  349
- Spring Preload Setting
  349
- Spring Preload Adjustment
  349
- Battery Terminal Voltage
  411
- Table 1 Alternator Output Voltage
  416
- Table 2 Stator Coil Resistance
  416
- Rectifier Circuit Inspection
  417
- Charging Voltage
  419
- Crankshaft Sensor Peak Voltage
  423
- Connections:
  425
- Camshaft Position Sensor Peak Voltage
  425
- Ignition Coil Winding Resistance
  427
- Primary Lead Connection
  427
- Stick Coil Primary Peak Voltage
  428
- Connection:
  429
- Condition:
  429
- Interlock Operation Voltage
  429
- Condition:
  429
- Starter Motor Brush Length
  435
- Commutator Diameter
  435
- Testing Relay
  437
- Testing Turn Signal Relay
  444
- Fan Switch Resistance
  459
- Water Temperature Sensor
  460
- Fuel Level Sensor Resistance
  462
- Connections:
  463
- Fuse Circuit Inspection
  464
- Relay Circuit Inspection (with the battery disconnected)
  465
- Relay Circuit Inspection (with the battery connected)
  465
- Diode Circuit Inspection
  466
toc
1
- Read OWNER'S MANUAL before operating.
  6
  - Foreword
    7
  - General Information
    9
    - Before starting to perform an inspection service or carry out a
      10
      - Battery Ground
        10
      - Edges of Parts
        10
      - Solvent
        10
      - Cleaning vehicle before disassembly
        10
      - Arrangement and Cleaning of Removed Parts
        11
      - Storage of Removed Parts
        11
      - Inspection
        11
      - Replacement Parts
        11
      - Assembly Order
        11
      - Tightening Sequence
        12
      - Tightening Torque
        12
      - Force
        12
      - Gasket, O-ring
        12
      - Liquid Gasket, Locking Agent
        12
      - Press
        13
      - Ball Bearing and Needle Bearing
        13
      - Oil Seal, Grease Seal
        13
      - Circlips, Cotter Pins
        13
      - Lubrication
        13
      - Direction of Engine Rotation
        14
      - Electrical Wires
        14
    - ZR750–J1 Left Side View:
      15
    - ZR750–J1 Right Side View:
      15
    - Subthrottle Control System
      18
    - Outline
      20
    - Outline
      21
    - Due Position of LED Installation
      21
    - Since the emission regulations become more severe, Kawasaki has
      23
      - Honeycomb Type Catalytic Converter
        23
    - Prefixes for Units:
      24
    - Units of Temperature:
      24
  - Periodic Maintenance
    25
    - The scheduled maintenance must be done in accordance with this c
      26
    - The following tables list the tightening torque for the major fa
      29
    - Steering Stem Nut Wrench:
      36
    - Fuel System (DFI)
      37
      - Fuel Hose and Connection Inspection
        37
      - Throttle Control System Inspection
        38
      - Idle Speed Inspection
        39
      - Engine Vacuum Synchronization Inspection
        39
        Special Tool -
        40
        Special Tool -
        41
        Torque -
        41
        Torque -
        41
      - Air Cleaner Element Cleaning
        42
        Torque -
        43
      - Cooling System
        44
        Radiator Hose and Connection Inspection
        44
        Torque -
        44
        Coolant Change
        44
        Torque -
        44
        Torque -
        44
      - Engine Top End
        46
        Air Suction Valve Inspection
        46
        Valve Clearance Inspection
        46
      - Clutch
        47
        Clutch Adjust Inspection
        47
      - Engine Lubrication System
        48
        Engine Oil Change
        48
        Torque -
        48
        Oil Filter Change
        49
        Special Tool -
        49
        Torque -
        49
      - Wheels/Tires
        49
        Tire Wear Inspection
        49
        Air Pressure Inspection
        50
        Torque -
        50
      - Final Drive
        51
        Drive Chain Slack Inspection
        51
        Drive Chain Slack Adjustment
        51
        Torque -
        51
        Drive Chain Wear Inspection
        52
        Drive Chain Lubrication
        53
      - Brakes
        53
        Brake Pad Wear Inspection
        53
        Rear Brake Light Switch Inspection/Adjustment
        53
        Special Tool -
        54
        Rear Brake Light Switch Connections:
        54
        Caliper Fluid Seal Damage
        54
        Caliper Dust Seal/Friction Boot Damage
        54
        Master Cylinder Inspection (Visual Inspection)
        55
        Brake Fluid Level Inspection
        56
        Brake Fluid Change
        56
        Torque -
        57
        Torque -
        57
        Brake Line Bleeding
        58
        Torque -
        59
        Torque -
        59
        Brake Hoses and Connections Inspection
        60
      - Suspension
        61
        Front Fork Oil Leak Check
        61
        Rear Shock Absorber Oil Leak Check
        61
      - Steering
        61
        Steering Inspection
        61
        Special Tool -
        61
        Steering Adjustment
        61
        Special Tool -
        62
        Torque -
        62
        Steering Stem Bearing Lubrication
        62
      - Electrical System
        63
        Spark Plug Inspection
        63
        Owner's Tool -
        63
        Owner's Tool -
        64
        Torque -
        64
      - General Lubrication
        65
        Lubrication
        65
      - Nut, Bolt, and Fastener Tightness
        66
        Tightness Inspection
        66
  - Fuel System (DFI)
    67
    - Terminal Names
      77
    - Part Name
      77
    - Oil Pressure Gauge:
      80
    - DFI Servicing Precautions
      81
      - Torque -
        82
    - Outline
      83
      - Outline
        83
        Special Tool -
        84
        Special Tool -
        86
      - DFI Diagnosis Flow Chart
        87
      - Inquiries to Rider
        87
        Inquiries to Rider
        87
    - DFI System Troubleshooting Guide
      90
    - Self-diagnosis Outline
      99
      - Self-diagnosis Outline
        99
      - Self-diagnosis Procedures
        99
        Self-diagnosis Procedures
        99
      - Service Code Clearing Procedures
        100
        Service Code Clearing Procedures
        100
      - How to Read Service Codes
        102
        How to Read Service Codes
        102
      - How to Erase Service Codes
        102
        How to Erase Service Codes
        102
      - Service Code Table
        103
        Service Code Table
        103
        Notes:
        103
      - Backups
        104
        Backups
        104
    - Main Throttle Sensor Removal/Adjustment
      106
      - Input Voltage Inspection
        106
        Special Tool -
        106
      - Output Voltage Inspection
        107
        Special Tool -
        107
      - Resistance Inspection
        108
    - CAUTION
      109
      - Removal
        109
      - Installation
        109
        Torque -
        109
      - Input Voltage Inspection
        109
        Special Tool -
        109
      - Output Voltage Inspection
        110
        Special Tools -
        110
      - Pv = 24 ∼ 55 cmHg
        111
      - Pv = 55 ∼ 86 cmHg
        112
    - Removal/Installation
      113
      - Output Voltage Inspection
        113
        Special Tool -
        113
      - Sensor Resistance Inspection
        114
    - Removal/Installation
      115
      - Torque -
        115
      - Output Voltage Inspection
        115
        Special Tool -
        115
      - Sensor Resistance Inspection
        116
    - CAUTION
      117
      - Removal
        117
      - Input Voltage Inspection
        117
        Special Tool -
        117
      - Output Voltage Inspection
        118
    - Start the engine and switch the diagnosis mode to Dealer 1 mode
      120
      - Crankshaft Sensor Removal/Installation
        120
      - Crankshaft Sensor Inspection
        120
    - Start the engine and switch the diagnosis mode to Dealer 1 mode
      121
      - Camshaft Position Sensor Removal/Installation
        121
      - Camshaft Position Sensor Inspection
        121
    - Speed Sensor Removal/Installation
      122
      - Speed Sensor Inspection
        122
      - Input Voltage Inspection
        122
        Special Tool -
        122
      - Output Voltage Inspection
        122
        Special Tool -
        123
    - Removal
      124
      - Installation
        124
        Torque -
        124
      - Inspection
        124
        Special Tool -
        125
    - Subthrottle Sensor Removal/Adjustment
      127
      - Input Voltage Inspection
        127
        Special Tool -
        127
      - Output Voltage Inspection
        128
        Special Tool -
        128
      - Resistance Inspection
        129
    - Stick Coil ##1: Ignition Coil (Service Code 51)
      130
      - Removal/Installation
        130
      - Input Voltage Inspection
        130
    - Subthrottle Valve Actuator Removal
      132
      - Audible Inspection
        132
      - Visual Inspection
        132
      - Resistance Inspection
        132
        Special Tool -
        132
      - Input Voltage Inspection
        133
        Recommended Tool -
        133
        Special Tool -
        133
    - Inspection Flow Chart
      134
      - LED Light Inspection
        135
    - CAUTION
      136
      - ECU Removal
        136
      - ECU Installation
        136
      - ECU Power Supply Inspection
        136
        Special Tool -
        137
      - ECU Power Source Circuit
        138
    - ECU Fuse Removal
      139
      - ECU Fuse Installation
        139
      - ECU Fuse Inspection
        139
      - ECU Main Relay Removal
        139
      - ECU Main Relay Inspection
        139
        Special Tool -
        139
    - Fuel Pressure Inspection
      140
      - Special Tools -
        140
      - Fuel Flow Rate Inspection
        141
    - Fuel Pump Removal
      143
      - Fuel Pump Installation
        143
        Torque -
        144
      - Operation Inspection
        144
      - Operating Voltage Inspection
        144
        Special Tools -
        145
      - Pressure Regulator Removal
        145
      - Pump Screen, Fuel Filter Cleaning
        145
    - Fuel Pump Relay Removal
      146
      - Fuel Pump Relay Inspection
        146
        Special Tool -
        146
    - Removal/Installation
      147
      - Audible Inspection
        147
      - Power Source Voltage Inspection
        147
        Special Tool -
        147
      - Output Voltage Inspection
        148
        Special Tool -
        148
      - Injector Signal Test
        149
        Special Tool -
        149
      - Injector Resistance Inspection
        150
        Special Tool -
        150
      - Injector Unit Test
        150
      - Injector Fuel Line Inspection
        150
        Torque -
        151
    - Throttle Grip Play Inspection/Adjustment
      153
      - Choke Lever Operation
        153
      - Choke Lever Play Inspection
        153
      - Choke Lever Play Adjustment
        153
      - Cable Removal/Installation
        153
      - Cable Lubrication and Inspection
        153
    - Idle Speed Inspection
      154
      - Engine Vacuum Synchronization Inspection/ Adjustment
        154
      - High Altitude Performance Adjustment
        154
      - Throttle Body Assy Removal
        154
      - Throttle Body Assy Installation
        156
        Torque -
        156
        Torque -
        156
      - Throttle Body Assy Disassembly
        157
      - Throttle Body Assy Assembly
        158
        Torque -
        158
    - Element Removal/Installation
      159
      - Air Cleaner Oil Draining
        159
      - Air Cleaner Housing Removal
        159
    - Fuel Tank Removal
      160
      - Fuel Tank Installation
        161
      - Fuel Tank and Cap Inspection
        162
      - Fuel Tank Cleaning
        162
  - Cooling System
    163
    - Bearing Driver:
      169
    - Coolant Deterioration Inspection
      170
      - Coolant Level Inspection
        170
      - Coolant Draining
        170
      - Coolant Filling
        170
      - Pressure Testing
        171
      - Cooling System Flushing
        171
      - Coolant Reserve Tank Removal/Installation
        171
    - Water Pump Removal
      172
      - Water Pump Installation
        172
      - Water Pump Inspection
        172
      - Water Pump Impeller Disassembly/Assembly
        172
        Torque -
        172
      - Water Pump Impeller Inspection
        172
      - Water Pump Housing Disassembly
        172
      - Water Pump Housing Assembly
        173
        Special Tool -
        173
        Special Tool -
        173
      - Mechanical Seal Inspection
        173
    - Radiator and Radiator Fan Removal
      174
      - Radiator and Radiator Fan Installation
        175
        Torque -
        175
      - Radiator Inspection
        175
      - Radiator Cap Inspection
        175
      - Radiator Filler Neck Inspection
        176
    - Thermostat Removal
      177
      - Thermostat Installation
        177
      - Thermostat Inspection
        177
    - Hose Installation
      179
      - Torque -
        179
      - Hose Inspection
        179
    - CAUTION
      180
      - Radiator Fan Switch Removal
        180
      - Radiator Fan Switch Installation
        180
        Torque -
        180
      - Radiator Fan Switch Inspection
        180
      - Water Temperature Sensor Removal
        180
      - Water Temperature Sensor Inspection
        180
  - Engine Top End
    181
    - Exhaust System
      185
    - Compression Gauge:
      188
    - Air Suction Valve Removal
      190
      - Air Suction Valve Installation
        190
        Torque -
        190
      - Air Suction Valve Inspection
        190
      - Vacuum Switch Valve Removal
        190
      - Vacuum Switch Valve Installation
        190
      - Vacuum Switch Valve Test
        191
        Special Tool -
        191
      - Clean Air System Hose Inspection
        191
    - Cylinder Head Cover Removal
      192
      - Cylinder Head Cover Installation
        192
        Sealant -
        192
        Torque -
        193
    - Camshaft Chain Tensioner Removal
      194
      - Camshaft Chain Tensioner Installation
        194
        Torque -
        194
        Torque -
        194
    - Camshaft Removal
      195
      - Camshaft Installation
        195
        Torque -
        196
      - Camshaft, Camshaft Cap Wear
        196
        Torque -
        196
      - Camshaft Runout
        197
      - Cam Wear
        197
      - Camshaft Chain Removal
        197
    - Cylinder Compression Measurement
      198
      - Owner's Tool -
        198
      - Special Tools -
        198
      - Torque -
        198
      - Cylinder Head Removal
        199
      - Cylinder Head Installation
        199
        Torque -
        199
        Torque -
        200
      - Cylinder Head Warp
        200
    - Valve Clearance Inspection
      201
      - Valve Removal
        201
        Special Tools -
        201
      - Valve Installation
        201
      - Valve Guide Removal
        201
        Special Tool -
        201
      - Valve Guide Installation
        202
        Special Tool -
        202
        Special Tool -
        202
      - Valve-to-Guide Clearance Measurement (Wobble Method)
        202
      - Valve Seat Inspection
        203
      - Valve Seat Repair
        203
        Special Tools -
        203
        Seat Cutter Operation Care:
        204
    - Cylinder Removal
      208
      - Cylinder Installation
        208
      - Piston Removal
        208
        Special Tool -
        209
      - Piston Installation
        209
      - Cylinder Wear
        210
      - Piston Wear
        210
      - Piston Ring, Piston Ring Groove Wear
        211
      - Piston Ring Groove Width
        211
      - Piston Ring Thickness
        211
      - Piston Ring End Gap
        212
    - Throttle Body Holder Installation
      213
      - Torque -
        213
    - WARNING
      214
      - Muffler Body Removal
        214
      - Exhaust Pipe Removal
        214
      - Muffler Body and Exhaust Pipe Installation
        214
        Torque -
        214
  - Clutch
    217
    - Clutch Holder:
      221
    - Clutch Lever Free Play Inspection
      222
      - Clutch Lever Free Play Adjustment
        222
      - Cable Removal
        222
      - Cable Installation
        222
      - Cable Lubrication
        222
      - Clutch Lever Installation
        222
        Torque -
        222
      - Clutch Lever Adjustment
        223
    - Clutch Cover Removal
      224
      - Clutch Cover Installation
        224
        Sealant -
        224
        Torque -
        224
      - Release Shaft Removal
        224
      - Release Shaft Installation
        224
      - Clutch Cover Disassembly
        225
      - Clutch Cover Assembly
        225
    - Clutch Removal
      226
      - Special Tool -
        226
      - Clutch Installation
        226
        Special Tool -
        227
        Torque -
        227
        Torque -
        228
      - Clutch Plate Assembly Inspection
        228
        Torque -
        228
      - Clutch Plate Assembly Adjustment
        228
        Torque -
        228
      - Clutch Plate, Wear, Damage Inspection
        229
      - Clutch Plate Warp Inspection
        229
      - Clutch Spring Free Length Measurement
        229
  - Engine Lubrication System
    231
    - Oil Pressure Gauge, 10 kgf/cm :
      237
    - WARNING
      238
      - Oil Level Inspection
        238
      - Engine Oil Change
        238
      - Oil Filter Replacement
        238
    - Oil Pan Removal
      239
      - Oil Pan Installation
        239
        Torque -
        239
        Torque -
        239
    - Oil Pressure Relief Valve Removal
      240
      - Oil Pressure Relief Valve Installation
        240
      - Oil Pressure Relief Valve Inspection
        240
    - Oil Pump Removal
      241
      - Oil Pump Installation
        241
        Torque -
        242
        Torque -
        242
        Torque -
        242
      - Oil Pump Drive Gear Removal
        242
      - Oil Pump Drive Gear Installation
        242
    - Oil Pressure Measurement
      243
      - Special Tools -
        243
      - Torque -
        243
    - Oil Pressure Switch Removal
      244
      - Oil Pressure Switch Installation
        244
        Sealant -
        244
        Torque -
        244
        Torque -
        244
  - Engine Removal/Installation
    245
    - Engine Mount Nut Wrench:
      248
    - Engine Removal
      249
      - Special Tool -
        251
      - Engine Installation
        251
        Torque -
        251
        Torque -
        252
        Torque -
        252
        Special Tool -
        252
        Torque -
        252
        Torque -
        252
        Torque -
        253
  - Crankshaft/Transmission
    255
    - Bearing Puller:
      263
    - Crankcase Splitting
      264
      - Crankcase Assembly
        264
        Sealant -
        265
        Torque -
        265
        Sealant -
        266
        Torque -
        266
        Torque -
        266
        Torque -
        266
        Torque -
        266
    - Crankshaft Removal
      267
    - Starter Motor Clutch Removal/Installation
      276
      - Starter Motor Clutch Inspection
        276
      - Starter Motor Clutch Disassembly
        276
      - Starter Motor Clutch Assembly
        276
        Torque -
        276
    - Shift Pedal Removal
      277
      - Shift Pedal Installation
        277
        Torque -
        277
        Torque -
        278
        Torque -
        278
        Torque -
        278
      - External Shift Mechanism Removal
        278
      - External Shift Mechanism Installation
        279
        Torque -
        279
        Torque -
        279
      - External Shift Mechanism Inspection
        279
        Torque -
        279
      - Transmission Shaft Removal
        280
      - Transmission Shaft Installation
        280
      - Transmission Shaft Disassembly
        280
        Special Tools -
        281
      - Transmission Shaft Assembly
        281
      - Shift Drum and Fork Removal
        284
      - Shift Drum and Fork Installation
        284
        Torque -
        284
      - Shift Drum Disassembly
        284
      - Shift Drum Assembly
        284
        Torque -
        284
      - Shift Fork Bending
        285
      - Shift Fork/Gear Groove Wear
        285
      - Shift Fork Guide Pin/Drum Groove Wear
        285
      - Gear Dog and Gear Dog Hole Damage
        285
  - Wheels/Tires
    287
    - Bearing Driver Set:
      291
    - Front Wheel Removal
      292
      - Special Tool -
        292
      - Front Wheel Installation
        292
        Torque -
        293
        Torque -
        293
      - Rear Wheel Removal
        293
      - Rear Wheel Installation
        294
        Torque -
        294
      - Wheel Inspection
        295
        Special Tool -
        295
      - Axle Inspection
        296
      - Balance Inspection
        296
      - Balance Adjustment
        296
      - Balance Weight Removal
        296
      - Balance Weight Installation
        297
    - Air Pressure Inspection
      298
      - Tire Inspection
        298
      - Tire Removal
        298
      - Tire Installation
        298
      - Tire Repair
        300
    - Hub Bearing Removal
      301
      - Special Tools -
        301
      - Hub Bearing Installation
        301
        Special Tool -
        301
        Special Tool -
        301
      - Hub Bearing Inspection
        301
  - Final Drive
    303
    - Bearing Driver Set:
      307
    - Drive Chain Slack Inspection
      308
      - Drive Chain Slack Adjustment
        308
      - Drive Chain Wear Inspection
        308
      - Drive Chain Lubrication
        308
      - Drive Chain Removal
        308
      - Drive Chain Installation
        308
      - Drive Chain Replacement
        309
    - Engine Sprocket Removal
      312
      - Special Tool -
        312
      - Engine Sprocket Installation
        312
        Torque -
        312
      - Rear Sprocket Removal
        313
      - Rear Sprocket Installation
        313
        Torque -
        313
      - Coupling Bearing Removal
        313
        Special Tool -
        313
      - Coupling Bearing Installation
        313
        Special Tool -
        313
        Special Tool -
        314
      - Coupling Installation
        314
      - Coupling Bearing Inspection
        314
      - Coupling Bearing Lubrication
        314
      - Coupling Damper Inspection
        314
      - Sprocket Wear Inspection
        315
      - Rear Sprocket Warp Inspection
        315
  - Brakes
    317
    - Jack:
      323
    - Brake Lever Position Adjustment
      324
      - Brake Pedal Position Inspection
        324
      - Brake Pedal Position Adjustment
        324
        Torque -
        324
    - Front Caliper Removal
      325
      - Rear Caliper Removal
        325
      - Caliper Installation
        325
        Torque -
        325
      - Front Caliper Disassembly
        326
      - Front Caliper Assembly
        326
        Torque -
        326
      - Rear Caliper Disassembly
        327
      - Rear Caliper Assembly
        328
        Torque -
        328
      - Caliper Fluid Seal Damage
        328
      - Caliper Dust Seal/Friction Boot Damage
        328
      - Caliper Piston and Cylinder Damage
        329
      - Caliper Holder Shaft Wear
        329
    - Front Brake Pad Removal
      330
      - Front Brake Pad Installation
        330
      - Rear Brake Pad Removal
        330
      - Rear Brake Pad Installation
        330
      - Brake Pad Wear Inspection
        330
    - Front Master Cylinder Removal
      331
      - Front Master Cylinder Installation
        331
        Torque -
        331
        Torque -
        331
      - Rear Master Cylinder Removal
        332
      - Rear Master Cylinder Installation
        332
        Torque -
        332
      - Front Master Cylinder Disassembly
        332
      - Rear Master Cylinder Disassembly
        333
      - Master Cylinder Assembly
        333
        Torque -
        333
      - Master Cylinder Inspection (Visual Inspection)
        333
    - Brake Disc Removal
      334
      - Brake Disc Installation
        334
        Torque -
        334
      - Brake Disc Wear
        334
      - Brake Disc Warp
        334
        Special Tool -
        334
        Special Tool -
        334
    - Brake Fluid Level Inspection
      335
      - Brake Fluid Change
        335
      - Brake Line Bleeding
        335
    - Brake Hose Removal/Installation
      336
      - Torque -
        336
      - Brake Hose Inspection
        336
  - Suspension
    337
    - Fork Cylinder Holder Handle:
      343
    - Front Fork Removal
      344
      - Front Fork Installation
        344
        Torque -
        344
        Torque -
        344
      - Front Fork Oil Change
        344
        Special Tool -
        345
      - Front Fork Disassembly
        345
        Special Tools -
        345
      - Front Fork Assembly
        347
        Special Tool -
        347
        Torque -
        347
        Special Tools -
        347
      - Inner Tube/Outer Tube Inspection
        348
      - Dust Seal Inspection
        348
      - Fork Spring Inspection
        348
    - Rebound Damping Force Adjustment
      349
      - Spring Preload Adjustment
        349
      - Rear Shock Absorber Removal
        349
        Special Tool -
        349
      - Rear Shock Absorber Installation
        350
        Torque -
        350
      - Rear Shock Absorber Inspection
        350
    - Swingarm Removal
      351
      - Special Tool -
        351
      - Special Tool -
        351
      - Swingarm Installation
        352
        Torque -
        352
        Special Tool -
        352
        Torque -
        352
      - Swingarm Bearing Removal
        352
        Special Tool -
        352
      - Swingarm Bearing Installation
        353
        Special Tool -
        353
      - Swingarm Bearing, Sleeve Inspection
        353
      - Chain Guide Inspection
        353
    - Tie-rod Removal
      354
      - Special Tool -
        354
      - Tie-rod Installation
        354
        Torque -
        354
      - Rocker Arm Removal
        354
        Special Tool -
        354
      - Rocker Arm Installation
        354
        Torque -
        354
      - Rocker Arm/Tie-rod Bearing, Sleeve Inspection
        355
  - Steering
    357
    - Steering Stem Nut Wrench:
      360
    - Steering Inspection
      361
      - Steering Adjustment
        361
    - Stem, Stem Bearing Removal
      362
      - Special Tool -
        362
      - Stem, Stem Bearing Installation
        363
        Special Tool -
        363
        Special Tools -
        363
        Special Tool -
        363
        Torque -
        363
        Torque -
        364
      - Stem Bearing Lubrication
        364
      - Steering Stem Warp
        364
    - Handlebar Removal
      365
      - Handlebar Installation
        365
        Torque -
        365
        Torque -
        365
  - Frame
    367
    - Rear Seat Removal
      373
      - Rear Seat Installation
        373
      - Front Seat Removal
        373
      - Front Seat Installation
        373
    - Side Cover Removal
      374
      - Side Cover Installation
        374
    - Inner Cover Removal
      375
      - Inner Cover Installation
        375
      - Fairing Removal
        375
      - Fairing Installation
        375
      - Fairing Bracket Removal
        375
    - Seat Cover Removal
      376
      - Seat Cover Installation
        376
    - Mud Guard Removal
      377
      - Mud Guard Installation
        377
    - Front Fender Removal
      378
      - Front Fender Installation
        378
        Torque -
        378
      - Rear Fender Rear Removal
        378
      - Rear Fender Rear Installation
        379
    - Frame Cover Removal
      380
    - Battery Case Removal
      381
      - Battery Case Installation
        381
    - Side Stand Removal
      382
      - Side Stand Installation
        382
        Torque -
        382
        Torque -
        382
    - Rear View Mirrors Removal
      383
      - Rear View Mirrors Installation
        383
    - Frame Inspection
      384
  - Electrical System
    385
    - Rotor Puller, M16/M18/M20/M22 × 1.5 :
      395
    - There are a number of important precautions that are musts when
      404
    - Wiring Inspection
      406
      - Special Tool -
        406
    - Battery Removal
      407
      - Battery Installation
        407
      - Electrolyte Filling
        407
      - Initial Charge
        409
      - Precautions
        410
        1)
        410
        2)
        410
        3)
        410
        4)
        410
      - Interchange
        411
      - Charging Condition Inspection
        411
      - Refreshing Charge
        411
    - Alternator Cover Removal
      413
      - Alternator Cover Installation
        413
        Sealant -
        413
        Torque -
        413
      - Stator Coil Removal
        413
      - Stator Coil Installation
        414
        Torque -
        414
        Torque -
        414
        Sealant -
        414
      - Alternator Rotor Removal
        414
        Special Tool -
        414
        Special Tools -
        414
      - Alternator Rotor Installation
        414
        Special Tool -
        415
        Torque -
        415
      - Alternator Inspection
        416
        Special Tool -
        417
      - Regulator/Rectifier Inspection
        417
      - Charging Voltage Inspection
        419
        Special Tool -
        419
      - Charging System Circuit
        420
    - WARNING
      421
      - Crankshaft Sensor Removal
        421
      - Crankshaft Sensor Installation
        422
        Torque -
        422
        Sealant -
        422
        Torque -
        422
        Torque -
        422
      - Crankshaft Sensor Inspection
        423
        Special Tool -
        423
      - Crankshaft Sensor Peak Voltage Inspection
        423
        Special Tool -
        423
      - Timing Rotor Removal
        424
        Special Tool -
        424
      - Timing Rotor Installation
        424
        Torque -
        424
      - Camshaft Position Sensor Removal
        424
      - Camshaft Position Sensor Installation
        424
        Torque -
        424
      - Camshaft Position Sensor Inspection
        425
        Special Tool -
        425
      - Camshaft Position Sensor Peak Voltage Inspection
        425
        Special Tool -
        425
      - Stick Coil (Ignition Coil together with Spark Plug Cap) Removal
        426
      - Stick Coil (Ignition Coil together with Spark Plug Cap) Installa
        426
      - Stick Coil (Ignition Coil together with Spark Plug Cap) Inspecti
        427
      - Stick Coil Primary Peak Voltage
        427
        Special Tools -
        427
      - Spark Plug Removal
        428
      - Spark Plug Installation
        428
      - Spark Plug Inspection
        428
      - Spark Plug Gap Inspection
        428
      - Interlock Operation Inspection
        429
        Special Tool -
        429
      - IC Igniter Inspection
        430
      - Ignition System Circuit
        432
    - Starter Motor Removal
      433
      - Starter Motor Installation
        433
        Torque -
        433
      - Starter Motor Disassembly
        433
      - Starter Motor Assembly
        434
      - Brush Inspection
        435
      - Commutator Cleaning and Inspection
        435
      - Armature Inspection
        435
        Special Tool -
        435
      - Brush Lead Inspection
        436
        Special Tool -
        436
      - Brush Plate and Terminal Bolt Inspection
        436
        Special Tool -
        436
      - Starter Relay Inspection
        436
        Special Tool -
        437
      - Electric Starter Circuit
        437
    - This models adopt the daylight system and have a headlight relay
      438
    - Fan System Circuit Inspection
      446
      - Fan Motor Inspection
        446
      - Radiator Fan Circuit
        447
    - Meter Unit Removal
      448
      - Meter, Gauge Disassembly
        448
      - Electronic Combination Meter Unit Inspection
        449
        Special Tool -
        449
      - Meter Circuit
        457
    - Brake Light Timing Inspection
      458
      - Brake Light Timing Adjustment
        458
      - Switch Inspection
        458
        Special Tool -
        458
      - Rear Brake Light Switch Connections
        458
      - Side Stand Switch Connections
        458
      - Neutral Switch Connections
        458
      - Oil Pressure Switch Connections*
        458
      - Radiator Fan Switch Inspection
        458
        Special Tool -
        459
      - Water Temperature Sensor Inspection
        459
      - Speed Sensor Inspection
        460
        Special Tool -
        461
        Torque -
        461
      - Fuel Level Sensor Inspection
        462
        Special Tool -
        462
        Torque -
        462
      - Fuel Reserve Switch Inspection
        462
      - Diode (Rectifier) Inspection
        463
        Special Tool -
        463
    - The junction box [A] has fuses [B], relays, and diodes. The rela
      464
      - Junction Box Fuse Circuit Inspection
        464
        Special Tool -
        464
      - Starter Circuit/Headlight Relay Inspection
        465
        Special Tool -
        465
      - Diode Circuit Inspection
        466
      - Junction Box Internal Circuit
        466
    - 30 A Main Fuse Removal
      467
      - Junction Box Fuse Removal
        467
      - Fuse Installation
        467
      - 15 A ECU Fuse Removal
        467
      - Fuse Inspection
        468
  - Appendix
    469
    - NOTE
      486
      - Engine Doesn't Start, Starting Difficulty:
        486
        Starter motor not rotating:
        486
        Starter motor rotating but engine doesn't turn over:
        486
        Engine won't turn over:
        486
        No fuel flow:
        486
        Engine flooded:
        486
        No spark; spark weak:
        486
        Fuel/air mixture incorrect:
        486
        Compression Low:
        486
      - Poor Running at Low Speed:
        486
        Spark weak:
        486
        Fuel/air mixture incorrect:
        486
        Compression low:
        487
        Other:
        487
      - Poor Running or No Power at High Speed:
        487
        Firing incorrect:
        487
        Fuel/air mixture incorrect:
        487
        Compression low:
        487
        Knocking:
        487
        Miscellaneous:
        487
      - Overheating:
        487
        Firing incorrect:
        487
        Muffler overheating:
        487
        Fuel/air mixture incorrect:
        487
        Compression high:
        487
        Engine load faulty:
        488
        Lubrication inadequate:
        488
        Gauge incorrect:
        488
        Coolant incorrect:
        488
        Cooling system component incorrect:
        488
      - Over Cooling:
        488
        Gauge incorrect:
        488
        Cooling system component incorrect:
        488
      - Clutch Operation Faulty:
        488
        Clutch slipping:
        488
        Clutch not disengaging properly:
        488
      - Gear Shifting Faulty:
        488
        Doesn't go into gear; shift pedal doesn't return:
        488
        Jumps out of gear:
        488
        Overshifts:
        488
      - Abnormal Engine Noise:
        488
        Knocking:
        488
        Piston slap:
        488
        Valve noise:
        488
        Other noise:
        488
      - Abnormal Drive Train Noise:
        489
        Clutch noise:
        489
        Transmission noise:
        489
        Drive line noise:
        489
      - Abnormal Frame Noise:
        489
        Front fork noise:
        489
        Rear shock absorber noise:
        489
        Disc brake noise:
        489
        Other noise:
        489
      - Oil Pressure Warning Light Goes On:
        489
      - Exhaust Smokes Excessively:
        489
        White smoke:
        489
        Black smoke:
        489
        Brown smoke:
        489
      - Handling and/or Stability Unsatisfactory:
        489
        Handlebar hard to turn:
        489
        Handlebar shakes or excessively vibrates:
        489
        Handlebar pulls to one side:
        489
        Shock absorption unsatisfactory:
        489
      - Brake Doesn't Hold:
        490
      - Battery Trouble:
        490
        Battery discharged:
        490
        Battery overcharged:
        490

Benutzerhandbuch

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