Engine Mechanical:
Complete engine disassembly, assembly, inspection, and overhaul procedures for the 1700cc V-twin engine.
Fuel System:
Fuel injection system (throttle body, injectors, fuel pump, sensors), fuel tank, fuel lines, and emissions control.
Ignition System:
Ignition coil, spark plugs, crankshaft position sensor, ECU control.
Transmission Drivetrain:
Clutch operation, gearbox disassembly and reassembly, final drive (belt drive) inspection and maintenance.
Cooling System:
Radiator, cooling fan, thermostat, coolant circulation, and bleeding procedures.
Electrical System:
Battery, charging system (alternator, regulator/rectifier), starter motor, lighting (headlight, taillight, turn signals), horn, and wiring diagrams.
Braking System:
Front and rear brake caliper service, master cylinder, brake lines, bleeding, and ABS (if equipped).
Suspension:
Front fork service (oil change, seal replacement, spring inspection), rear shock absorber inspection and replacement.
Steering:
Handlebar, steering stem bearings, and related components.
Chassis Frame:
Frame inspection, fork yokes, swingarm maintenance.
Bodywork Trim:
Fender removal/installation, seat, fuel tank, fairings, and other cosmetic components.
Diagnostics Troubleshooting:
Symptom-based troubleshooting guides, diagnostic trouble codes (DTCs) and their interpretations.
Scheduled Maintenance:
Detailed procedures for all scheduled maintenance tasks, including oil changes, filter replacements, and inspections.
Engine Repair:
Complete engine rebuild procedures, piston and ring replacement, valve adjustments, camshaft timing.
Transmission Repair:
Gearbox disassembly, inspection of gears and shift forks, clutch plate replacement, and belt drive adjustment.
Electrical Repair:
Wiring harness diagnosis, component testing (e.g., starter, alternator), switch repair.
Suspension Fork Service:
Front fork seal replacement, oil level and viscosity adjustments, fork spring replacement.
Brake System Overhaul:
Brake caliper piston replacement, master cylinder rebuild, brake line flushing and bleeding.
Fuel System Cleaning:
Throttle body cleaning, injector cleaning/testing, fuel filter replacement.
Troubleshooting Guides:
Step-by-step troubleshooting for common and uncommon issues, diagnostic flowcharts.
Depth:
Comprehensive from basic maintenance to full engine and component rebuilds, including detailed specifications and torque values.
Diagnostic Codes:
Detailed explanations of Diagnostic Trouble Codes (DTCs) and procedures for reading/clearing them.
Wiring Diagrams:
Full electrical system wiring diagrams with component locations and wire color coding.
Torque Specifications:
All critical torque specifications for engine, chassis, and electrical components.
Special Tools:
Listing and description of specialized tools required for specific repair procedures.
Engine Type:
4-stroke, V-twin, SOHC, 4 valves per cylinder
Displacement:
1699 cc (103.7 cu. in.)
Bore X Stroke:
102.0 x 104.0 mm (4.02 x 4.09 in.)
Cooling System:
Liquid-cooled
Horsepower:
Approximately 90-95 hp (estimated, actual may vary)
Torque:
Approximately 100-105 lb-ft (estimated, actual may vary)
Fuel Delivery:
Fuel injection, dual 36mm throttle bodies
Fuel Type:
Unleaded gasoline, minimum 87 octane
Engine Oil Change:
Every 6,000 km (3,700 miles) or 6 months, whichever comes first.
Oil Filter Replacement:
At each oil change.
Air Filter Cleaning Replacement:
Inspect every 6,000 km (3,700 miles), clean or replace as needed. Replace every 12,000 km (7,500 miles).
Spark Plug Replacement:
Every 12,000 km (7,500 miles).
Belt Drive Tension Check:
Every 6,000 km (3,700 miles).
Valve Clearance Check:
Every 24,000 km (15,000 miles).
Engine Oil Type:
SAE 10W-40 API SG, SH, SJ, SL or JASO MA/MA2
Engine Oil Capacity:
3.0 L (3.2 US qt) without filter change, 3.2 L (3.4 US qt) with filter change.
Coolant Type:
Kawasaki Genuine Coolant or equivalent (50/50 mix of ethylene glycol and distilled water)
Fork Oil Type Level:
Showas special fork oil SS-02 or equivalent (160 mm fluid level)
Common Wear Items:
Belt drive, brake pads, clutch plates, fork seals.
Potential Electrical:
Regulator/rectifier failure has been noted on some Kawasaki models of this era.
Performance Tuning:
EFI tuning for aftermarket exhaust/air filter modifications is often recommended for optimal performance and engine health.