Service Manual

Foreword
m
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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 mechanics, the
proper use of toofs, and workshop procedures must
be understood in order to carry out maintenance and
‘repair satisfactorily.
Whenever the owner has
insufficient experience or has doubts as to his ability
to do the work, all adjustments, maintenance, and
repair should be carried out only by qualified
mechanics.
In order to perform the work efficiently and to
avoid costly mistakes, read the text, thoroughly
familiarize yourself with the procedures before
starting work, and then do the work carefully in a
clean area. Whenever special tools or equipment are
specified, do not use makeshift tools or equipment.
Precision measurements can only be made if the
proper instruments are used, and the use of substi-
tute tools may adversely affect safe operation.
To get the longest life out of your engine:
l Follow the Periodic Maintenance Chart in the
Service Manual.
l Be alert for problems and non-scheduled mainte-
nance.
l Use proper tools and genuine Kawasaki engine
parts. Genuine parts provided as spare parts are
listed in the Parts Catalog.
l FOIIOW the procedures in this manual carefully.
Don’t take shortcuts.
*Remember to keep complete records of mainte-
nance and repair with dates and any new parts
installed.
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 system and assists in locating their
chapters. Each chapter in turn has its own compre-
hensive Table of Contents.
The Periodic Maintenance Chart is located in the
General Information chapter. 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.
Next, use the Quick Reference Guide to locate the
electric System chapter. Then, use the Table of
Contents on the first page of the chapter to find the
Spark Plug section.
Whenever you see these WARNING and
CAUTION symbols, heed their instructions! Always
follow safe operating and maintenance practices.
This warning symbol identifies special
instructions or procedures which, if not
correctly followed, could result in personal
injury, or loss of life.
ACAUTION
This caution symbol identifies special
instructions or procedures which, if not
strictly observed, could result in damage to
or destruction of equipment.