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This quick reference guide will assist you in locating a desired topic or procedure. Quick Reference Guide. I Fuel System. Engine Top End. Engine Left Side. Engine Right Side. Final Drive. Electrical System. All Terrain Vehicle Service Manual. US Model onlyl. To minimize the noise emissions from this product, Kawasaki has equipped it with. They are designed to give optimum per-. Please do not remove these systems, or alter. This w,arning may apply to any of the following.
Breathing asbestos dust is dangerous. Fol low safety. Brake Shoes or Pads. Clutch Friction Material. Preferably use hand tools or low speed tools equipped, if necessary, with an appropriate dust extraction facility.
If high speed tools are used, they should always be so equipped. This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechan- ics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily.
Whenever the owner has insufficient experience. Precision measurements can only be made if the proper instruments are used,. For the duration of your warranty period, especially, we recommend that all repairs and scheduled maintenance be performed in accord- ance with this service manual.
Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty. To get the longest life out of your vehicle:. Whenever special tools.
Special tools, gauges, and testers that are necessary when servicing Kawasaki vehicles are introduced by the Special Tool. Genuine parts provided as spare parts. Don't take shortcuts. How to Use this Manual. In preparing this manual, we divided the product into its major systems. These systems became the manual 's chapters. All information for a particular system from adjustment through disassembly and inspection is located in a single chapter. The Quick Reference Guide shows you all of the product's systems and assists in locating their chapters.
Each chapter in turn has its own comprehensive Table of Contents. The chart gives a time schedule for required maintenance operations. If you want spark plug information, for example, go to the Periodic Maintenance Chart first. The chart tells you how frequently to clean and gap the plug. Then, use the Table of Contents on the first page of the chapter to find the Spark Plug section. Always follow safe operating and maintenance practices.
In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly.
General Information. Table of Contents. Model Identification. Before Servicing. General Specifications. Torque and. Locking Agent. Periodic Maintenance Chart. Before starting to service a vehicle, careful reading of the applicable section is recommended to eliminate unnecessary work.
Photographs, diagrams, notes, cautions, warnings, and detailed des- criptions have been included wherever necessary. Nevertheless, even a detailed account has limi- tations, a certain amount of basic knowledge is also required for successful work.
Especially note the following:. Dirt Before removal and disassembly, clean the vehicle. Any dirt entering the engine or -other parts will work as an abrasive and shorten the life of the vehicle. For the same reason, before. Battery Ground. Remove the ground - lead from the battery before performing any disassembly operations.
This prevents:. Tighten ing Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them evenly in a cross pattern.
This is to avoid. Conversely when. Where there is a tightening sequence indication in this Service Manual, the bolts, nuts, or screws must be tightened in the order and method indicated. Torque When torque values are given in this Service Manual, use them.
Either too little or too much. Use a good quality , reliable torque wrench. Force Common sense should dictate how much force is necessary in assembly and disassembly. If a part seems especially difficult to remove or install, stop and examine what may be causing the problem. Whenever tapping is necessary, tap lightly using a wooden or plastic -faced mallet. Use an impact driver for screws particularly for the removal of screws held by a locking agent in.
Edges Watch for sharp edges, especially during major engine disassembly and assembly. Protect your. High-Flash Point Solvent A high-flash point solvent is recommended to reduce fire danger. A commercial solvent com-.
Always follow manufac - turer and container directions regarding the use of any solvent. Gasket, O-Ring Do not reuse a gasket or O-ring once it has been in service. The mating surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leaks. Liquid Gasket, Non-Permanent Locking Agent Follow manufacturer's directions for cleaning and preparing surfaces where these compounds will be used. Apply spar ingly. Excessive amounts may block engine oil passages and cause serious damage.
An example of a non-permanent locking agent commonly available in North. Lock ' n Seal. America is Loctite 10 Press A part installed. This prevents severe stress on the balls and races, and prevents races and balls from being dented. Press a ball bearing until it stops at the stop in the hole or on the shaft. When pressing in a seal which has manufacturer's marks, press it in with the marks facing out. Seals should be pressed into place using a suitable driver, which contacts evenly with the side of seal, until the face of the seal is even with the end of the hole.
Before a shaft passes through a seal, apply a little high temperature grease on the lips to reduce rubber to metal friction. When installing circlips and retaining rings, take care to compress or expand them only enough to install them and no more.
During assembly, oil or grease whichever is more suitable should be applied to any rubbing surface which has lost its lubricative film.
Old grease and dirty oil should be cleaned off. Deteriorated grease has lost its lubricative quality and may contain abrasive foreign particles. Don't use just any oil or grease. Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended.
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