Engine Mechanical:
Complete disassembly, inspection, repair, and reassembly of all engine components including cylinder head, valves, piston, crankshaft, connecting rods, camshafts, and oil pump.
Engine Electrical:
Ignition system (spark plugs, coils, timing), fuel injection system (ECU, injectors, sensors), charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), wiring diagrams.
Fuel System:
Fuel tank, fuel pump, fuel filter, fuel injectors, fuel pressure regulator, throttle body assembly.
Transmission:
Clutch operation, gearshift mechanism, internal transmission components, lubrication, removal and installation.
Suspension:
Front forks (disassembly, seal replacement, oil level and type, adjustment), rear shock absorber (removal, installation, adjustment), linkage system.
Brakes:
Front and rear brake system components (calipers, master cylinders, brake lines, pads, discs), hydraulic system bleeding, ABS system (if equipped - diagnostics and bleeding procedures).
Cooling System:
Radiator, coolant hoses, water pump, thermostat, fan operation, coolant type and capacity.
Exhaust System:
Exhaust pipes, muffler, catalytic converter, exhaust gasket replacement.
Frame And Bodywork:
Frame inspection, body panel removal and installation, fairings, seat, fuel tank mounting.
Electrical System And Lighting:
Headlight, taillight, turn signals, brake lights, dashboard instrumentation, horn, battery maintenance, fuses, relays.
Wheels And Tires:
Tire pressure, wheel bearing inspection, tire replacement, wheel balancing.
Routine Maintenance:
Oil and filter changes, air filter cleaning/replacement, spark plug checks and replacement, chain lubrication and adjustment, brake fluid checks, coolant level checks.
Troubleshooting:
Diagnostic flowcharts for common starting issues, running problems, electrical faults, and performance degradation.
Major Repairs:
Engine rebuilds, transmission overhaul, suspension fork rebuilds, brake system servicing.
Component Removal And Installation:
Detailed steps for removing and reinstalling all major and minor components.
Wiring Diagrams:
Complete, high-resolution wiring schematics for all electrical systems.
Torque Specifications:
Essential torque values for all fasteners to ensure correct assembly and prevent damage.
Diagnostic Capability:
Advanced diagnostic procedures, fault code interpretation (if applicable for ECU), sensor testing.
Rebuild Procedures:
Detailed, step-by-step instructions for complete engine and component rebuilds.
Measurement And Calibration:
Specifications for critical measurements (e.g., piston ring gap, bearing clearances) and calibration procedures.
First Service:
1,000 km (600 miles) or 6 months (whichever comes first) - includes oil and filter change, chain adjustment, inspection of all critical fasteners and systems.
Subsequent Service:
Every 6,000 km (3,750 miles) or 12 months - includes standard checks, oil and filter, air filter, spark plugs at specific intervals (e.g., 12,000 km), coolant change (e.g., every 24,000 km).
Engine Oil:
SAE 10W-40, API SG or SH (refer to manual for exact specifications and alternatives).
Coolant:
Kawasaki Genuine Coolant or equivalent ethylene glycol-based coolant with demineralized water (50:50 mix).
Fork Oil:
Typically Showa SS-01 or equivalent SAE 5W fork oil. Exact type and quantity per leg specified in manual.
Common Wear Items:
Clutch plates, brake pads, chain and sprockets, fork seals, wheel bearings.
Potential Electrical:
Less common, but regulator/rectifier failure can occur under sustained high electrical load or due to heat buildup. Wiring loom connections should be checked for corrosion.
Engine Performance Notes:
Some owners report a slightly snatchy throttle response at low RPMs, often mitigated by fuel management adjustments or ECU remapping. Regular maintenance of the fuel injection system is key.
Suspension Tuning:
The stock suspension is often considered adequate but can be improved with aftermarket components or precise tuning of the existing adjusters for aggressive riding styles.
