Engine Mechanical:
Complete overhaul, diagnosis, specifications, torque values, timing, valve clearances, piston/cylinder assembly, crankshaft, connecting rods, lubrication system.
Fuel System:
Fuel injection system (EFI), injectors, throttle body, fuel pump, fuel pressure regulator, fuel tank, lines, troubleshooting.
Ignition System:
Ignition coils, spark plugs, ECU control, timing, troubleshooting.
Cooling System:
Radiator, fan, coolant, water pump, thermostat, hoses, diagnosis.
Exhaust System:
Catalytic converter, mufflers, pipes, mounting.
Transmission Drivetrain:
Clutch operation, gear shifting mechanism, gearbox components, lubrication, troubleshooting.
Chassis Frame:
Frame inspection, rigidity, component mounting points, welding integrity.
Suspension Front:
Front fork (telescopic), oil type and level, seals, springs, damping adjustments, disassembly, reassembly.
Suspension Rear:
Monoshock rear suspension, linkage, swingarm, adjustment, bearing service, lubrication.
Braking System Front:
Dual disc brakes, calipers, pads, rotors, master cylinder, fluid type and bleeding, troubleshooting.
Braking System Rear:
Single disc brake, caliper, pad, rotor, master cylinder, fluid type and bleeding, troubleshooting.
Wheels Tires:
Wheel bearing service, tire pressure, rim specifications, balancing.
Steering System:
Handlebar, steering stem bearings, lubrication, adjustment, geometry.
Electrical System Components:
Wiring diagrams, battery, charging system (alternator, regulator/rectifier), starter motor, lighting (headlight, taillight, indicators), horn, fuses, relays.
Electronics ECU:
ECU diagnosis, sensor inputs (MAP, TPS, IAT, Crankshaft Position), output control.
Bodywork Fairings:
Fairing removal and installation, seat, fuel tank cover, fenders, trim pieces, fasteners.
Preventative Maintenance:
Scheduled maintenance checks, lubrication points, fluid changes, filter replacements.
Troubleshooting Diagnostics:
Step-by-step diagnostic procedures for common and uncommon issues, fault code interpretation (if applicable).
Engine Rebuild:
Complete engine disassembly, inspection, repair, and reassembly instructions.
Suspension Service:
Front fork oil change, seal replacement, rear shock absorber inspection.
Brake System Service:
Brake pad replacement, rotor inspection, caliper service, brake fluid flush and bleeding.
Electrical Component Testing:
Testing of stator, regulator/rectifier, starter, battery, lights, switches, and sensors using multimeters.
Fuel System Cleaning:
Injector cleaning, throttle body cleaning procedures.
Wiring Diagram Interpretation:
Detailed electrical schematics for all systems.
Depth Level:
Comprehensive, covering everything from basic maintenance to complete engine and component overhauls.
Diagnostic Capability:
Advanced diagnostic procedures, including electrical system testing and potential fault finding for EFI components.
Repair Procedures:
Detailed, step-by-step instructions for virtually all repair and replacement operations.
Specifications Data:
Includes critical torque specifications, clearances, fluid capacities, and performance data.
Oil Filter Change:
Every 6,000 km (3,700 miles) or 6 months, whichever comes first.
Engine Oil Change:
Every 6,000 km (3,700 miles) or 6 months, whichever comes first.
Air Filter Inspection Cleaning:
Every 6,000 km (3,700 miles), replace as needed.
Spark Plug Replacement:
Every 12,000 km (7,500 miles) or annually.
Valve Clearance Check:
Every 12,000 km (7,500 miles) or annually.
Brake Fluid Change:
Every 24,000 km (15,000 miles) or 2 years, whichever comes first.
Coolant:
Kawasaki Motorcycle Antifreeze (or equivalent ethyl glycol based, phosphate-free coolant) mixed 50/50 with distilled water.
Common Wear Items:
Clutch plates, brake pads, chain and sprockets, fork seals.
Electrical Potential Issues:
Regulator/rectifier failure (can lead to battery charging issues) is a known potential issue on many Japanese bikes of this era. Inspect wiring for corrosion.
