Engine:
Detailed disassembly, assembly, inspection, repair, and troubleshooting of the 903cc SOHC V-twin engine.
Fuel System:
EFI system components (throttle body, injectors, fuel pump, sensors), fuel tank, fuel lines, and filter.
Transmission:
Disassembly, assembly, inspection, and repair of the 5-speed constant mesh transmission.
Drivetrain:
Belt drive system inspection, adjustment, and replacement procedures.
Cooling System:
Radiator, fan, thermostat, coolant, and hose inspection and replacement.
Ignition System:
Ignition coils, spark plugs, ignition control module troubleshooting.
Electrical System:
Wiring diagrams, battery, charging system (alternator, regulator/rectifier), lighting, starting system, switches, and sensors.
Braking System:
Front and rear brake caliper service, master cylinder overhaul, brake lines, brake fluid replacement and bleeding.
Suspension System:
Front fork (telescopic) disassembly, seal replacement, oil changes, and rear shock absorber inspection and adjustment.
Wheel And Tire:
Wheel bearing inspection, tire replacement, and wheel balancing.
Chassis And Frame:
Frame inspection, steering head bearing service.
Bodywork And Trim:
Removal and installation of fenders, fuel tank, seat, exhaust system, and other body panels.
Maintenance:
Routine maintenance, lubrication, inspections, fluid changes, filter replacements.
Troubleshooting:
Diagnostic procedures for common problems, symptom-based troubleshooting guides.
Repair:
Step-by-step instructions for repairing and rebuilding all major components.
Disassembly Assembly:
Detailed procedures for dismantling and reassembling all systems and components.
Adjustments:
Precise instructions for all required adjustments (e.g., throttle cable, clutch cable, idle speed).
Specifications:
Comprehensive listing of factory specifications, including torques, clearances, fluid capacities, and electrical values.
Depth:
Comprehensive: Covers everything from basic maintenance and troubleshooting to complete engine and transmission rebuilds.
Illustrations:
Detailed illustrations, exploded diagrams, drawings, and photos for clarity.
Special Tools:
Identification and usage instructions for required special service tools.
Safety Precautions:
Includes specific safety notes, precautions, DANGER, CAUTION, and NOTE advisories for various procedures.
Engine Type:
4-stroke, SOHC, 8-valve, V-twin
Bore X Stroke:
92.0 x 68.2 mm
Cooling System:
Liquid-cooled
Horsepower:
Approx. 50-53 HP @ 6000 RPM (Varies by model/year, manual provides precise figures)
Torque:
Approx. 78 Nm (57.5 lb-ft) @ 3500 RPM (Varies by model/year, manual provides precise figures)
Fuel Delivery:
Digital Fuel Injection (DFI) with dual 36mm throttle bodies
Fuel Type:
Unleaded gasoline, 91 octane or higher recommended
Oil Type:
SAE 10W-40 API SG or higher, JASO MA certified (Manual specifies exact type and viscosity)
Oil Capacity:
Approx. 3.2 L (3.4 US qt) with filter change (Manual confirms exact capacity)
Length:
Approx. 2385-2415 mm (93.9-95.1 in) depending on model variant
Width:
Approx. 930-935 mm (36.6-36.8 in) depending on model variant
Height:
Approx. 1120-1170 mm (44.1-46.1 in) depending on model variant
Dry Weight:
Approx. 242 kg (533.5 lbs) for Classic, 230 kg (507.1 lbs) for Custom (Manual confirms precise weights)
Curb Weight:
Approx. 260-275 kg (573-606 lbs) depending on model variant and fluids (Manual confirms precise weights)
Wheelbase:
Approx. 1635 mm (64.4 in)
Oil Change Interval:
Every 6,000 km (3,700 miles) or 12 months (Manual provides definitive schedule).
Spark Plug Replacement:
Every 12,000 km (7,500 miles) (Manual provides definitive schedule).
Air Filter Cleaning:
Every 6,000 km (3,700 miles) or as needed based on conditions (Manual provides definitive schedule).
Belt Drive Inspection:
Every 6,000 km (3,700 miles) for tension and wear (Manual provides definitive schedule).
Brake Fluid:
DOT 4 (Manual specifies exact type and replacement interval).
Coolant:
Kawasaki Coolant (or equivalent ethylene glycol-based coolant with anti-corrosion additives) (Manual specifies exact type and capacity).
Common Wear Items:
Clutch plates, brake pads, tires, fork seals, drive belt (if applicable).
Potential Concerns:
Occasional carburetor synchronization issues on pre-EFI models (though this manual is for EFI), potential for minor electrical gremlins if maintenance is neglected.
Chart Availability:
The manual contains a detailed periodic maintenance chart.
