Engine Mechanical:
Complete disassembly, inspection, assembly, and troubleshooting of the 1700cc V-twin engine.
Fuel System:
Fuel injection system (throttle body, injectors, fuel pump, regulator), emissions control system.
Ignition System:
Ignition coil, spark plugs, ECU control, troubleshooting.
Transmission Drivetrain:
Clutch operation, transmission gears, final drive (belt drive system), troubleshooting.
Cooling System:
Radiator, fan, coolant circulation, maintenance.
Electrical System:
Battery, charging system (alternator, rectifier/regulator), starter motor, lighting (headlight, taillight, signals), horn, wiring diagrams.
ABS System:
Hydraulic unit, wheel speed sensors, ABS control unit, troubleshooting and diagnostic procedures.
Suspension:
Front fork (telescopic), rear shock absorbers, adjustment, maintenance, seal replacement.
Braking System:
Front and rear disc brakes, brake pads, calipers, master cylinders, brake fluid replacement, bleeding procedures.
Chassis Frame:
Frame inspection, steering head bearings, wheel bearings, swingarm maintenance.
Bodywork Trim:
Fairing removal and installation, luggage systems (saddlebags, top case), seat, fenders.
Controls:
Throttle controls, clutch lever, brake lever, handlebar removal/installation.
Exhaust System:
Inspection and basic service of the exhaust system.
Instrumentation:
Speedometer, tachometer, fuel gauge, indicator lights, diagnostic codes.
Routine Maintenance:
Oil and filter changes, air filter replacement, spark plug replacement, lubrication points, chain adjustment (if applicable, though belt-driven).
Troubleshooting Diagnostics:
Step-by-step diagnostic flowcharts for common problems and system failures.
Engine Rebuild:
Complete engine disassembly, piston ring replacement, valve adjustments, seal replacements, and reassembly procedures.
Electrical Troubleshooting:
Diagnosis of electrical faults using wiring diagrams, testing of components, and common electrical issues.
Brake System Overhaul:
Complete brake system overhaul, including caliper rebuilds, master cylinder replacement, and brake line service.
Suspension Service:
Fork seal replacement, suspension fluid changes, and rear shock adjustments.
ABS System Diagnosis:
Specific procedures for diagnosing and repairing the Anti-lock Braking System.
Diagnostic Charts:
Detailed fault finding charts based on symptoms.
Timing Adjustment:
Valve lash adjustment procedures and specifications.
Carburetor Adjustment:
While fuel injected, the manual would cover throttle body synchronization and adjustments.
Bearing Service:
Wheel bearing inspection and replacement, steering head bearing service.
Emission Control:
Details on evaporative emission control system and catalytic converter.
Depth:
Comprehensive, covering everything from routine maintenance to complete engine and component rebuilds.
Audience:
Suitable for both DIY enthusiasts with mechanical aptitude and professional motorcycle technicians.
Torque Specifications:
Detailed torque specifications for all critical fasteners.
Clearances:
Specifications for valve clearances, piston-to-cylinder wall clearances, etc.
Wiring Diagrams:
Comprehensive electrical wiring diagrams with component identification.
Engine Oil Change:
Every 3,700 miles (6,000 km) or 6 months
Air Filter Inspection:
Every 3,700 miles (6,000 km)
Spark Plug Replacement:
Every 7,400 miles (12,000 km)
Belt Drive Tension:
Check every 3,700 miles (6,000 km)
Brake Fluid Replacement:
Every 2 years
Engine Oil Type:
SAE 10W-40, API SG or SH
Coolant Type:
Kawasaki Full System Coolant (or equivalent silicate-free, long-life coolant)
Common Wear Items:
Brake pads, tires, clutch plates (under heavy use), front fork seals.
Potential Electrical:
Corrosion on connectors, rectifier/regulator issues (less common on this model).