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 DeviceStick Coil Removal
Remove the air cleaner housing (see Air Cleaner Housing
Removal in the Fuel System (DFI) chapter).
Disconnect the stick coil connectors [A].
Pull out the stick coils [B] upward.
First, turn the stick coil by 90 degrees, and then pull it out
by twisting the coil head to the left and righ ...
Stem, Stem Bearing Installation
Replace the bearing outer races with new ones.
Drive them into the head pipe at the same time.
Special Tools - Head Pipe Outer Race Press Shaft [A]:
57001-1075
Head Pipe Outer Race Driver,
55 [B]: 57001
-1446 or Bearing Driver Set: 57001-1129
Apply grease to the outer races.
...
Self-Diagnosis Procedures
NOTE
Use a fully charged battery when conducting
self-diagnosis. Otherwise, the light (LED) and symbol
do not light or blink.
Turn the ignition switch to ON.
When a problem occurs with DFI system and ignition system,
the warning indicator light (LED) [A] goes on and
FI warning symbol ...