Engine:
Complete Engine Overhaul and Diagnosis
Transmission:
Gearbox Inspection, Repair, and Clutch Service
Fuel System:
Fuel Injection System, Throttle Bodies, Fuel Pump
Electrical System:
Wiring Diagrams, Ignition, Lighting, Charging System
Chassis:
Frame, Suspension (Front & Rear), Steering, Wheels, Tires
Brakes:
Front & Rear Brake Systems, ABS (if equipped)
Bodywork:
Fairing, Saddlebags, Seats, Body Panels, Ergonomics
Troubleshooting:
Diagnostic Procedures and Common Faults
Type:
Factory Service Manual / Repair Manual
Engine Mechanical:
Cylinder Head, Valve Train, Piston Assembly, Crankshaft, Lubrication System
Engine Management:
ECU, Sensors (TPS, MAP, IAT, Knock), Injectors, Ignition Coils, Fuel Pump Control
Powertrain:
Clutch Assembly, Primary Drive, Transmission Gears, Final Drive (Belt Drive)
Charging System:
Stator, Regulator/Rectifier, Battery
Ignition System:
Spark Plugs, Ignition Timing, CDI Unit
Cooling System:
Radiator, Fan, Thermostat, Coolant Flow
Exhaust System:
Exhaust Pipes, Mufflers, Oxygen Sensors (if applicable)
Suspension Front:
Fork Disassembly, Reassembly, Oil Specifications, Spring Rates
Suspension Rear:
Shock Absorber Adjustment, Linkage Maintenance, Bushings
Brakes Front:
Caliper Service, Rotor Inspection, Pad Replacement, Master Cylinder
Brakes Rear:
Caliper Service, Rotor Inspection, Pad Replacement
Steering Head:
Bearing Service, Adjustment
Wheels Tires:
Wheel Bearing Service, Tire Pressure, Tire Wear Inspection
Lighting System:
Headlight, Taillight, Turn Signals, Dash Lights
Instrumentation:
Speedometer, Tachometer, Gauges, Warning Lights
Accessories:
Saddlebag Latches, Windscreen Mounting, Audio System (if equipped)
Maintenance Tasks:
Oil Changes, Filter Replacements, Spark Plug Replacement, Air Filter Cleaning/Replacement
Tune Up:
Idle Speed Adjustment, Throttle Body Synchronization (if applicable), Ignition Timing Checks
Engine Rebuild:
Top-End Rebuild, Bottom-End Rebuild, Component Torque Specifications
Transmission Repair:
Gearbox Disassembly, Reassembly, Clutch Pack Replacement
Suspension Fork Rebuild:
Fork Seal Replacement, Damper Rod Service, Spring Replacement
Brake System Service:
Brake Pad Replacement, Fluid Bleeding, Caliper Rebuild
Electrical Troubleshooting:
Component Testing, Fault Code Diagnosis, Wiring Harness Repair
Fuel Injection Diagnosis:
Sensor Testing, Injector Flow Rate Checks, ECU Parameter Analysis
Belt Drive Maintenance:
Belt Tension Adjustment, Belt Inspection for Wear
Bodywork Repair:
Panel Removal/Installation, Saddlebag Repair, Windscreen Replacement
Diagnostic Charts:
Symptom-Based Troubleshooting Guides
Torque Specifications:
All Major Component Tightening Specifications
Depth:
Comprehensive Factory-Level Repair and Diagnostic Information
Detail Level:
Step-by-step instructions with diagrams and illustrations
Diagnostic Tools Required:
Specifies specialized tools where necessary (e.g., torque wrench, multimeter)
Engine Oil Change:
Every 3,700 miles (6,000 km) or 6 months
Air Filter Cleaning:
Every 7,500 miles (12,000 km)
Spark Plug Replacement:
Every 7,500 miles (12,000 km)
Belt Tension Check:
Every 7,500 miles (12,000 km)
Coolant Flush:
Every 2 years or 15,000 miles (24,000 km)
Engine Oil Specification:
SAE 10W-40 API SG or higher, JASO MA or MA2
Coolant Type:
Kawasaki Genuine Coolant or equivalent ethylene glycol-based coolant with protection for aluminum alloys
Common Wear Items:
Clutch friction plates, fork seals, belt drive components due to mileage.
Electrical Quirks:
Occasional issues with rectifier/regulator performance under high electrical load (though generally robust).
Engine Performance Notes:
Proper throttle body synchronization is crucial for smooth operation and fuel efficiency.