Engine:
Detailed engine overhaul, diagnosis, and tuning procedures for the 1352cc inline-four engine.
Fuel System:
Fuel injection system (EFI), fuel pump, injectors, throttle bodies, and evaporative emissions control system.
Ignition System:
Ignition timing, spark plugs, coils, ECU control, and troubleshooting.
Cooling System:
Radiator, fan, thermostat, coolant flow, and pressure testing.
Exhaust System:
Catalytic converter, mufflers, lambda sensors (oxygen sensors), and emissions control.
Transmission:
Clutch operation, gear shifting mechanisms, internal transmission components, and lubrication.
Drivetrain:
Final drive chain and sprockets, rear wheel hub, and related components.
Brakes:
Hydraulic brake system, front and rear calipers, master cylinders, brake lines, ABS (if equipped), and pad replacement.
Suspension:
Front forks (spring rate, damping adjustments, oil levels), rear shock absorber, linkages, and bearings.
Steering:
Handlebar assembly, steering stem bearings, and front fork alignment.
Electrical System:
Battery, charging system (stator, regulator/rectifier), starter motor, lighting, horn, and wiring diagrams.
Electronics:
ECU (Engine Control Unit) functions, sensor diagnostics, fuel mapping, and self-diagnostic codes.
Bodywork And Frame:
Fairings, seat, fuel tank removal, frame inspection, and body panel alignment.
Wheels And Tires:
Wheel bearing inspection, tire pressure recommendations, and tire replacement.
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, spark plug checks, and general inspections.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon faults, including electrical and mechanical issues.
Engine Repair:
Complete engine rebuilds, piston and ring replacement, valve adjustments, and gasket services.
Transmission Repair:
Clutch replacement, gearbox component inspection, and seal replacements.
Brake Service:
Brake fluid flush and bleed, caliper rebuild, and ABS system diagnostics.
Suspension Service:
Fork seal replacement, shock absorber rebuild, and linkage maintenance.
Electrical Diagnostics:
Wiring harness inspection, component testing, and troubleshooting using wiring diagrams.
Special Tools:
Identification and usage instructions for specialized tools required for specific repair procedures.
Depth:
Comprehensive from basic maintenance to full engine and chassis rebuilds, suitable for professional mechanics and advanced DIY enthusiasts.
Diagnostic Codes:
Coverage of diagnostic trouble codes (DTCs) and troubleshooting strategies.
Torque Specifications:
Precise torque values for all critical fasteners throughout the motorcycle.
Clearances And Tolerances:
Specifications for valve clearances, bearing clearances, and piston-to-cylinder wall clearances.
Type:
Liquid-cooled, 4-stroke, DOHC, 16-valve inline-four
Bore X Stroke:
84.0 x 61.0 mm
Compression Ratio:
12.0:1
Horsepower Est:
~187 hp (139.4 kW) @ 9500 rpm (claimed, without ram air)
Torque Est:
~117.5 lb-ft (159 Nm) @ 7000 rpm (claimed)
Type:
Digital fuel injection with sub-throttles
Fuel Capacity:
22 Liters (5.8 US gallons)
Oil Type:
API SG, SH, SJ, SL or SMA SAE 10W-40 or SAE 20W-50
Oil Capacity:
3.6 L (3.8 US qt) with filter change
Oil And Filter Change:
Every 6,000 km (3,700 miles) or 6 months, whichever comes first.
Air Filter Inspection:
Every 6,000 km (3,700 miles).
Spark Plug Replacement:
Every 12,000 km (7,500 miles) or 12 months.
Valve Clearance Check:
Every 24,000 km (15,000 miles).
Coolant Replacement:
Every 24,000 km (15,000 miles) or 24 months.
Brake Fluid Replacement:
Every 24,000 km (15,000 miles) or 24 months.
Engine Oil Grade:
SAE 10W-40 or 20W-50 (API SG or higher)
Coolant:
Kawasaki Motorcycle Coolant or equivalent ethylene glycol based antifreeze mixture (50/50 with distilled water).
Brake Fluid:
DOT 4 Hydraulic Brake Fluid
Clutch Fluid:
DOT 4 Hydraulic Clutch Fluid (if hydraulic clutch)
Clutch Slippage:
Can occur under extreme use, often due to worn plates or improper adjustment/fluid.
Stator Failure:
Occasional reports of stator failure leading to charging system issues.
Fueling Hesitation:
Some early models might exhibit slight hesitation; ECU re-flashing or aftermarket tuning can address this.
Regulator Rectifier Overheating:
A potential failure point on many Japanese motorcycles of this era, can lead to battery drain.