If the coolant is brown, iron or steel parts are rusting. In either case, flush the cooling system. If the surface is corroded or the blades are damaged, re- place the impeller. The radiator fan may start even if the ignition switch is off. This could damage the radiator fins, resulting in loss of cooling effi- ciency. If there are obstructions to air flow, remove the radiator and remove obstructions.
If the corrugated fins [A] are deformed, carefully straighten them. Cylinder Head Cleaning Cylinder Head Warp Page Specifications Camshaft runout TIR 0. Valve Guide Inside Diameter: 5. Piston Ring Thickness: 0. The push rod does not return to its original position once it moves out to take up cam chain slack. Ob- serve all the rules listed below: When removing the tensioner, do not take out the mounting bolts only partway. If the rocker shaft diameter is smaller than the service limit, replace it.
Also check the rocker arm inside diameter see Rocker Arm Inspection. The plastigage indicates the clearance by the amount it is compressed and widened when the parts are assembled.
This allows some of the com- pression pressure to escape, making it easy to turn over the engine during starting. If the rubber is damaged, cut, or is missing pieces, replace the guide. This valve seat cutter is developed to grind the valve seat for repair.
Therefore the cutter must not be used for other purposes than seat repair. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off. If the seat width is within the specified range, lap the valve to the seat as described below. The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings. Set it close to the bottom of the cylinder, where cylinder wear is low.
Forest Service. It must be prop- erly maintained to ensure its efficiency. In accordance with the Periodic Maintenance Chart, clean the spark arrester. Torque - Muffler Cover Bolts [B]: 8. If there are signs of leakage around the exhaust pipe gas- ket, it should be replaced. Special Tools Torque Converter Torque Converter Cover Removal Torque Converter Cover Installation M: Apply molybdenum disulfide grease.
R: Replacement Part S: Follow the specific tightening sequence. Drive Belt Belt Width Belt Deflection — If it is done, the learning control of Kawasaki Engine Brake Control system works and the engine brake actuator works an error operation. Cover Bushing Inside Diameter [A] Standard: Service Limit: If the sheave bushing is damaged or worn, replace it. Sheave Bushing Inside Diameter [A] Spring Free Length [A] Standard: Sheave Bushing Inside Diameter If seals are damaged, replace the movable sheave.
Recoil Starter Recoil Starter Removal Recoil Starter Installation Recoil Starter Inspection Engine Oil Flow Chart Engine Oil and Oil Filter Oil Level Inspection Engine Oil Change Oil Filter Change Oil Screen Removal Oil Screen Cleaning L: Apply a non-permanent locking agent.
O: Apply engine oil. Front Camshaft 8. Transmission Idle Shaft 2. Oil Filter 9. Oil Screen 3. Crankshaft Transmission Driven Shaft 4. Oil Pressure Switch Rear Camshaft 5. Oil Pipes Breather Hose 6. Engine Removal Engine Installation Page Face the seal of the bearing to the left side outward. G: Apply grease. MO: Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1.
Crankpin Diameter Marks None: If the measurement exceeds the service limit, replace the crankshaft. Driven Shaft Drive Low Gear 20T 2.
Spacer Reverse Idle Shaft 3. Reverse Gear 12T Reverse Driven Gear 16T 4. Reverse Driven Output Gear 16T 5. Removal may damage them. W: Apply water or soap and water solution.
When there is toe-in, the distance A Rear is the greater than B Front as shown. The purpose of toe-in is to prevent the front wheels from getting out of parallel at any time, and to prevent any slip- ping or scuffing action between the tires and the ground. Now the front wheels are parallel to each other and to the center line of the vehicle. Un- even thread length could cause tie-rod damage. Smooth the sealing sur- faces with fine emery cloth if necessary.
This helps the tire beads slip off the rim flanges. Page Tire Inspection Deflate the tire to the specified pressure. Tire Air Pressure when cold Front: 35 kPa 0. Ball Bearings 4. Bearing Housings 6. Output Driven Shaft 2.
Drive Bevel Gear Shims 5. Output Driven Bevel Gear 7. Driven Bevel Gear Shims 3. Repeat in 0. Replace the bevel gears as a set if either gear is dam- aged. Be careful not get hurt when the housing comes out. If the splined portion of shaft cracked or damaged during disassembling of outboard joint, do not reuse the shaft.
They must be re- placed as a set. Pinion Gear Shim s 2. Ring Gear Right Shim s 3. Ring Gear Left Shim s 4. The drive pattern can be a little closer to the toe and the coast pattern can be a somewhat longer and closer to the toe. Standard Length of Assembling: Outboard: Standard Length of Assembling: Inboard: Pinion Gear 2.
Pinion Gear Bearing Holder 3. Gear Case Right Cover 4. Ball Bearings 5. Ring Gear 6. Pinion Gear Shim s 7. Ring Gear Shim s 8. To increase backlash, increase the thickness of the shim s. To decrease backlash, decrease the thickness of the shim s.
Change the thickness a little at a time. Replace any if the lips are misshapen, discolored indicat- ing that the rubber has deteriorated , hardened, or been otherwise damaged. Bend both hooks after installing the spring. Disc thickness 3 mm 0. Disc runout Never reuse old brake fluid. Do not use fluid from a container that has been left unsealed or that has been open for a long time.
Take care that nei- ther the cylinder nor the piston skirt gets scratched. Replace the caliper if the cylinder and piston are badly scored or rusty.
Oil on a disc must be cleaned off with an oilless cleaning fluid such as trichloroethylene or acetone. R: Replacement Parts Property of www. If the spring action feels too soft or too stiff, adjust it in accordance with the following table. If bushings are worn, cracked, hardened, or otherwise damaged, replace them. If it is found, replace the knuckle joint. Tie-rod Length Standard: If the steering stem is bent, replace the steering stem.
If roughness or binding is found, replace the bearing. Learn and ob- serve all the rules below. This will burn out the diodes in the electrical parts. If any wiring is defective, replace the damaged wiring. If the connector is corroded or dirty, clean it carefully. Be sure to use the dedicated electrolyte container for correct electrolyte volume.
Page Precautions 1. Give refresh charge for 5 to 10 hours with charge current shown in the specification see Refreshing Charge. Charge for no more than 5 minutes at the increased voltage then check if the battery is drawing current. If the battery will accept current [D], decrease the voltage and charge by the standard charging method described on the battery case.
A short or open in one of the coil wires will result in either a low output, or no output at all. A loss in rotor magnetism, which may be caused by dropping or hitting the alternator, by leaving it near an electromag- netic field, or just by aging, will result in low output. Ignition Switch 2. Fuse Box 3. Please contact Customer Support for assistance.
No accessories found. No two are alike. Each Kawasaki product line has a distinct VIN location. The exact location for these numbers in your particular model is illustrated in your owner's manual near the front of the book. They also appear on your registration documents.
The Vehicle Category field is required. Select a Year. What with its baffling design that keeps getting more complicated each day, the challenge of repairing a Kawasaki ATV is only getting more difficult.
This is where a Kawasaki four-wheeler repair manual comes to the rescue. A Kawasaki repair manual makes life easier for people who own an all-terrine vehicle and are plagued by the machines constant need for attention. Although having a ATV is one of the best things ever, maintaining one can be a real challenge. It contains all the information you need to know about your Kawasaki ATV , its parts and how to fix, repair and even install an engine. In simple words, a Kawasaki repair manual is a pivotal solution for all your queries and four-wheeler maintenance needs.
Unless you have been trained specifically in repairing Kawasaki parts like engines, repairing a Kawasaki all by yourself can not only be challenging, but dangerous as well. Here are a few reasons to use an Kawasaki repair manual. Few things can be as frustrating as finding parts and tools sprawled all over in a jumbled mess, making absolutely no sense as to where each thing goes.
When you avoid making a mess, you are saving on a lot of time and effort.
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