The Kawasaki Clean Air System (KCA) is a secondary air suction system that helps the exhaust gases to burn more completely. When the spent fuel charge is released into the exhaust system, it is still hot enough to burn. The KCA System allows extra air into the exhaust system so that the spent fuel charge can continue to burn.
This continued burning action tends to burn up a great deal of the normally unburned gases, as well as changing a significant portion of the carbon monoxide into carbon dioxide.
Air Suction Valves
The air suction valve is essentially a check valve which allows fresh air to flow only from the air cleaner into the exhaust port. Any air that has passed the air suction valve is prevented from returning. Inspect the air suction valves in accordance with the Periodic Maintenance Chart. Also, inspect the air suction valves whenever stable idling cannot be obtained, engine power is greatly reduced, or there are abnormal engine noises.
Air suction valve removal and inspection should be carried out only by a competent mechanic following the instructions in the Service Manual.
Valve Clearance
Exhaust DeviceBalancer Removal
Remove:
Engine (see Engine Removal in the Engine Removal/Installation
chapter)
Oil Pan (see Oil Pan Removal in the Engine Lubrication
System chapter)
Remove:
Balancer Shaft Clamp Lever Bolt [A]
Balancer Shaft Clamp Bolt [B]
Balancer Shaft Clamp Lever [C]
Balancer Shaft [D]
Bal ...
Exploded View
EO: Apply engine oil.
G: Apply grease.
L: Apply a non-permanent locking agent.
M: Apply molybdenum disulfide grease.
MO: Apply molybdenum disulfide oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio
10:1)
R: Replacement Parts
S: Follow the s ...
Fuel Tank Installation
Note the above WARNING (see Fuel Tank Removal).
Run the hoses correctly (see Cable, Wire, and Hose Routing
section in the Appendix chapter).
Check that the dampers [A] are in place on the fuel tank.
If the dampers are damaged or deteriorated, replace
them.
If the fuel tank brack ...