Engine Mechanical:
Complete engine disassembly, assembly, timing, valve clearance, lubrication system
Fuel System:
Fuel injection system (FI), throttle body, injectors, fuel pump, pressure regulator
Ignition System:
Ignition coils, spark plugs, ignition control module (ICM), timing
Drivetrain:
Final drive, bevel gear unit, driveshaft, universal joints
Suspension:
Front fork (telescopic, cartridge), rear shock absorbers, swingarm, linkage maintenance
Brakes:
Hydraulic disc brakes (front and rear), calipers, master cylinders, brake lines, bleeding procedures
Electrical System:
Wiring diagrams, battery, charging system (alternator, regulator/rectifier), starter motor, lighting, horn
Bodywork Chassis:
Frame inspection, fairings, body panels, seats, luggage systems, handlebars
Cooling System:
Radiator, coolant, fan, thermostat, hoses
Exhaust System:
Mufflers, exhaust pipes, catalytic converter (if applicable)
Controls:
Throttle control, clutch lever, brake lever, shifter operation
Transmission Gearbox:
Clutch, gearbox operation, gear inspection, shifting mechanism
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, spark plug service, brake fluid replacement
Troubleshooting:
Diagnostic procedures for common malfunctions and fault codes
Repair Procedures:
Detailed step-by-step instructions for component removal, installation, and repair
Major Overhaul:
Engine rebuilding, transmission overhaul, suspension component replacement
Diagnostic Tests:
Procedures for testing electrical components, fuel system pressures, and ignition timing
Diagnostic Capability:
Advanced diagnostics including EFI system analysis and electrical troubleshooting
Rebuild Instructions:
Comprehensive instructions for complete engine and transmission rebuilds
Component Specifications:
Detailed torque specifications, clearances, and measurements for all components
Engine Type:
V-Twin, Four-stroke, SOHC, 8-valve
Displacement:
1,700 cc (103.6 cu in)
Bore X Stroke:
102.0 x 104.0 mm
Cooling System:
Liquid-cooled
Horsepower:
Approximately 80-85 HP (at crankshaft, estimated)
Torque:
Approximately 100-105 lb-ft (at crankshaft, estimated)
Fuel Delivery:
Fuel Injection with Dual Throttle Valves (Kawasaki Twin Throttle System - K-Tronic)
Fuel Type:
Unleaded Gasoline, 87 Octane (or higher)
Oil Type:
SAE 10W-40 API SG or SH, JASO MA
Oil Capacity:
Approximately 4.0 US qt (3.8 L) with filter change
Engine Oil Change:
Every 7,500 km (4,500 miles) or 6 months
Air Filter Inspection:
Every 7,500 km (4,500 miles)
Spark Plug Replacement:
Every 15,000 km (9,000 miles)
Brake Fluid Replacement:
Every 2 years
Coolant Type:
Kawasaki Genuine Coolant or equivalent ethylene glycol-based antifreeze/coolant (50% mixture with distilled water)
Common Wear Items:
Belt drive tension and wear, potential for stator/regulator issues (common in many liquid-cooled bikes of the era)
