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.
Storage of Removed Parts
Tightening SequenceTroubleshooting guide
Engine Does Not Start
Starter Motor Won’t Turn
Engine stop switch off
Transmission not in neutral
Fuse blown
Battery leads do not make good electrical
contact with battery terminals
Battery discharged
Engine Cranks, But Won’t Start
No fuel in tank
Fuel line clogged
Fuel ...
Rocker Arm/Tie-Rod Bearing, Sleeve Inspection
NOTICE
Do not remove the bearings for inspection. Removal
may damage them.
Visually inspect the rocker arm, or tie-rod sleeves [A] and
needle bearings [B].
The rollers in a needle bearing normally wear very little,
and wear is difficult to measure. Instead of measuring,
inspect the ...
Gear Position Switch Inspection
NOTE
Be sure the transmission and external shift mechanism
are good condition.
Remove the fuel tank (see Fuel Tank Removal in the Fuel
System (DFI) chapter).
Disconnect the connector [A].
Set the hand tester [A] to the × 1 kΩ or × 100 Ω range
and connect i ...