Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips, cotter pins or self-locking nuts must be replaced with new ones whenever disassembled.
Assembly Order
In most cases assembly order is the reverse of disassembly, however, if assembly order is provided in this Service Manual, follow the procedures given.
Subthrottle Valve Actuator Inspection
NOTE
Be sure the battery is fully charged.
Remove the air cleaner housing (see Air Cleaner Housing
Removal in the Fuel System (DFI) chapter).
Turn the ignition switch to ON.
Check to see that all the subthrottle valves [A] open and
close smoothly.
Turn the ignition switch to OFF.
I ...
Crankcase Assembly
NOTICE
The upper and lower crankcase halves are machined
at the factory in the assembled state, so the
crankcase halves must be replaced as a set.
With a high flash-point solvent, clean off the mating surfaces
of the crankcase halves and wipe dry
WARNINGGasoline and low flash-poin ...
Fuel Tank Cleaning
WARNINGGasoline and low flash-point solvents can
be
flammable and/or explosive and cause severe
burns. Clean the tank in a well-ventilated area, and
take care that there are no sparks or flame anywhere
near the working area. Do not use gasoline
or low flash-point solvents t ...