Appendix Table of Contents [Additonal Consdrations for Racing carburetor Spark Plug Spark Plug Inspection “Troubleshooting Guid General Lubes Nut, Blt, ane Fastener Tightnoss Tighness Inspection Standard Torque Table Unit Conversion Table APPENDIX 164 162 162 162 163 164 168 168 168. 168. 169 = 16:10162 APPENDIX ‘ditional Considerations Yor sing “his motorcycle tas Reen munutaeured fr wen a renonble and pen sie ad as. whi ony ‘Shovel oat sh aul be enernced der facing comivon, KAWASAKI STRONGLY RECOM: ENDS THAT ALL RIDERS RIDE SAFELY AND DBEY ALL LAWS AND REGULATICNS CONCERN. ING THEIR MOTORCYCLE. AND ITS OPERATION. “acing hol! be Sone ue spared cons, and coped sanconng bodes oad bs contacted {br fete etin Fortwo sete to priate compete cng er tate sg the falonng thn infrmat may prow wet Hower, {You ae enraly resonable forthe us of your to ce under snoral condenses aac, 26 Reva sal ote Table for any damages ich ghar rom sh os ‘Kava’ Lies Motorcyle Waray ad Lied Emision Cont Systems Warranty ypecaly lode motreydeswhih se ted Ie eorplt o fsluted se.” Pl athe waranty eel Metre racng e ry sophie sort see ‘0 rayvrabler "The folowing Inlrmson Chose ony a Kamas sal tbe abe for ny saa which mie ae frre aerators wl 2g tis ntormation ‘ihen the ovary operate on publ oa it mut be ini gal ae in ee oem sty Sd eamplinc wis spatiale oats carburetors: Sometime an skeaton may be cstale fo tn proved performance under pela endtons when Fe Ben properly uted, aod al ats ead td ‘ound abe fenton prope ‘ne egies ele ajpts uf ova eat carbrtin after maitre and adits ae eer prtarmed helo et an 2 rele Wi ‘only Grr oe Asmar meer et get 2 toner nut and rer runes et rhe xe For the models er thn the US mode a erin amount of aajstment an be mage 8y shang the fusion ofthe nae, There refs roots atthe {Op of the neds Chiping the poston of te clin ‘hicn makes te mixtare riche 2 hen posto Fh ate ae ‘Spark Plug: “The spark pig fnies the fee ice in te “ext fave shown he pg inten he “General Soe tenon econ tothe “Cane Infersatn™ Cap ‘Since spark pg requenants change withthe ignk tin nd erboretion shrines and tg ean fangs i wsed should be determined by removing and inosine re a coment ' casket “ Center Eletrode eewoieSpark lug Condtion —y When a pl of the caret ha ringing, the deevodes wil sy. hot nmap > Key a The fnthon burned out coo ayy to hatp Kom maging the ese and ie sh te Tis em prture abast 400" BOIC (50 1450 and the caries clan and of» fait brown clr the lg is operting hep tmperatre. Asoo plat for Nghe opcaing tempaats i used for dng. Suen ple b dined for beer ‘aingefleney so ati wl rot overex ne ths ipoftenesled'ssoee™ pup t's pr pi wt to al eon wel ~ he pla wi ton coal a Bars ‘ff the carbon, and the eatvn wil elect On te ‘Sera and the ale nate ling hci i tg one baldp on the pg can aso ease thr tals. It fan heat up metho and cause lion and Kock in whieh may every bur shale tn the tp ef te ‘Spark Plug Inspection ‘Remove he stk plug and inspect the eran tne to ‘Whether ar not the right temperate plugs beng aor inates the erect pls boing see tthe ‘rami blk tenes ta the pg rng at {Sri tempers ten ner She pon onertng oo fi sempre ad TUT {hese ted pitch sd ic Cn of thee oro) fd the une ator ty (opr type Protete ype! othe stoned APPENDIX 163, Normal Operon Overeating Teo shat once ech cxbon othe hast range of the ar plug funtion ke 2 hermatt for te gina Unig the wrong typ of {a plug can make the eg rn too hot festng Inamgoecamaz) oro cl wt or performance, mating, 0d sat). he sandr pg ar bean ited to mah te nontal wge 0 thle morro In combined see and hip ing Une ng Senne rare are rh et164 APPENDIX ‘Troubleshooting Guide hie not a0 eae Ist, pig ery posible ‘ae foreach pretend is rant Snel a4 ‘ouh gue toaster te roblesioting er ame of the more common afiutie. Secrest woubie Poot not coved bre ust cane. Far ‘shone! probes, reer ote operate hag crcl System, Engine Doesnt Start; Starting Difieuty ‘hiner, piston eure onmsting al ed cate ‘Fmmicom parr cankae bing sare ‘ics tre sping broken nahh cet ota $Soking othe vale invaein he stoma ap foal up anos closed Tank capa vent bsbuces Fe pclae Fal ine cogs oat ate lopped ng taofos Font Stung tice aly Chen oodd Hk wih he thot aly open toallow mores tarach erp). Nok ut eae Spark pis ey, damaged, of malate Spark pres high elon Wig Samaged Spork pig eap herd o at In ood contact Di ans broken Pekup ot broken or mle Fite magneto daraasd fe dom es Wing sered or open oan mre ieee ‘Arcana ded ot mec sing ‘liner, pion worn tong ba wr, wea, broken, or ng) ton nglng cerns excee rlncr tend at ae se danas yin ead ot it Shinde he warped Spt sus lose Crnishata tl delontedor damage Rotary ave cover ol seal detoroatd or Retry wave cor lage Oving deteriorated or lent tee down Poor Running at Low Speed Shut plug dy, damage, o alse Shure lutea hgh amon wing mage Share pap sorted ont prod eantct Tpon col sarap ut broken petup col broken oF | listed Fes magna damaged Pero dogs uli mere coract “Tree stp screw malchsted Gur nt syceoiing Pet or pasape loge Pile cloged, poeple of msg Starter plunger stick open Flt evel to Right tow Fst an en bused ton bad (wen weak, broken or icing] Pitan ngland cere excsive {yin nnd ake or be putt damaged hiner eng not scent dane done incr ead warped Spuk uglooe Chaka of al detente or damaged Rend ave camaged Roary sve eover of sel dettigated or ‘bagel Rotary vale cover large ving deteorated or ‘haga Poor Running No Power at High Spacd Spur uy exp shared not In good contact Tenon co damaged pion col vet open tut broken Fiekapcol broken or maladjted rusia mort neorece, Wain jet opel or wrong ze Ieineed of neste fe on Jet nee pn won poston Fate to high oto oeFul ine dogged us up lagged Chinde, pon won tn i bale, we, broke, o ekg) Piston sglnd eerie enive Cylinders et obese damaged Red A a vacsesdamaed iw fot ita nearest Tri conre cable mused “amaged Rotary ale cover lag Ovlg éeteoated or “nage Nocilinol tank pu danas i neo eect alec Eni rm wil ot is poet Floste i yore we Tote ds ot open Nich og Ste daging veetng Transeo coy high Cranks bearing worm or aged Eicon sit upin contusion camber Fue poor quay or econct. Overeating ‘Spt lune damage or acted Furl mitre sort APPENDIX 165 Fost eel to ow Arent dogged Ie later det ose (lan oe tre nore “Trt cna eabie mats Nosil inal ark to nas incor etek abe ‘eel poe ie Ccompreien hips ‘Cabon bul pin combustion haber heh sping ‘Taran eel oo igh catia Water wnperate ge broken Wate temperate soso broken costn ener oot deere ate pump impel damaged ed oe cong omens oat tea Thre stop sew maladie ‘hrs como ele etching: poory aested uaa intro en trend ornete worn ‘ner, pon wor Mtn ing bad (vor, ea, broken, o sticking ioe eed ake oe pastel damaged ‘ier head not sunt Tptened down [ine eed wage Starpulse Reed va dimaaed ‘naire Extn obactd Cynder nba port lage166 APPENDIX unc aping “ramen ot oe too igh Srl uraers Clutch Operation Faulty isthe maid ‘th ine cable ching ‘th eae mest teuble hac ab or hewngurevely Wom ‘oh not dienggna ory ‘hatch ter lay exces ‘lute pate warped to cou lath fring eon uneven Franson of detedrated Trannison ol vicsiy to hah Gatch hong ar fozr on vest Guth ese metani vouble Gear Shitting Fully Doran gers etl dos turn "Guten not ene Shi fo ent see ‘Shit etm spring wk orale Shit over broken Shift ret spig la oe SHI pa soring broken Seelve ining Era shit mechani arm pd worn moto of sr ‘hie Yor worn Gear groove worn Seat poe andor eases won Shi gre grote wor Shit dram set lr sing weak orbroken Shit fork plein orca worn Bye sha oupa sat andr tines wor "Sit am steering weak orton Alnormal Engine Noise Tenn ting malfoncion Seon bul up in eombustonchanber Fae goor ual or ncaect ‘ylnderpston clas excesine Connecting bert Peto pin, itn pin bole wom ‘Cometing od sal en race cessive onnsting ed ig en ceane excee Carat uncut excessive hla bering wore ‘Almormal Drive Train Noise Gch pba ape detail {at ening ction pate leans exesive Gotcabeang arprimay eer acto Net chi ammed in cue housing gar tah “Cranes bring worn Neth armed in gear teeth ‘teksae ° ick dpa wor pped ‘Rear andor engi sprocket Cha febaton stent feared misao ) worn Alnor Frame Noise ‘i nue or a0 hin ‘Shock ssrber dha Dh brake na Pruchce ged Calpe damage ‘ined Exhaust Smoke ‘pup cable mated ‘hat controfesble masta Cranks ol sea damaged Roary valve cover eal deter otAPPENDIX 167 Rotary wake cover ge Ove detarontes or Battery Discharged cpp tty. Tay (6g, lat slated, srt Brown snot "hough mani elec 001) “Ar cleaner cogaes Baty ad making poo soa Float let i ae eesie (eg bu of exceive wate) Fyne magneto dined Wing tate Haneling andor Stability Unatstactory Weng roting conte Battery Overcharged Strings oct 0 ah ey ae Seng stam breton dea Steengstem bet Tea rear to low onda sate ar axcenivey irate “ire worn Swingarm ban or vised Shing arm pio shafranast exesve Rigi rant fork ill uneven ‘hoot sion unatisarery (osha Fron fr ol eceve Front fark ol scat oc i Front farsi reste oath Tres penaretoo ih (Toosoh) Front fork of inuicientanertesking Front fk say oc Front fr sr ree tolow Front fr rear snk aber weak Rearsnesbeoer i Rea shock abba seing Brake Doesn't Hold Dic brake air thbak ne fron dae worn rae fl eal Brake png of AVDS dap Die wapee ‘Conard pat Soke fa dota inary cor earn op ap16 APPENDIX General Lubrication Lubrication ‘efre brcating eth pry, cl off any rnty spots nitrate bad wie off any eal i, of serine the pols ted teow wih inetd "aba Talny conten, ot esa ater sng 2 ih ‘rewire ory water, ert te gee weiter, Ren rae Rod Joint “Foie er Cable Lover End Pup ine able Lower Ed Spetcmeta nes cable™ scien prt he ne beso, Fives Convo Cable Pump cabs Nut, Bolt, and FastonerTighteness TightenestInpeciton check th Yohtenes of he Holts ané nas sed hee “Au eek to see tae cater in bin place an Far th oie fatnar, cack the gn of tars hon th ong es it oom empertr). Of thre are fore ater eoxue the 10 the ‘peed Torque tolloving the specified ening Soropate chptr, see the Stands’ Torque Tae Ft lean each fastener by Yt, then ge ut, Bot ana Fartenar be ehh Fre fleNut Front Aale Clamp Bots Chai Austr Cianp Boks rake: Front aster Cyn Clamp Bots Front Calpe Mtg Bais Rear Master Clade Mourtng Bol. Fear ape lr Fixing Bast Rear Calpe Held Cota Bolt Braue Fos Bole Bake Rod Joint Cate in supesion Front Fork Camp ots Front Fender Mounting Bots ana Nuts Fear hock Amber Mounting ts Swing Arm Poe oa ar Units unk ss Sing Arn Holder Mounting Sats seating StomvindNt aneebar ler Bots Engine Meunteg ls . ater Moana ts Gutch Lever Pres Nut Front Feotpor Mounting Bots Rear Fane Maunang BoStandard Torque Table This table rating aheing trae to trad ‘ante isthe bie fore for Dols ante Use fs ale for nly the ats and mute which Jo not ‘or teererce to these features, All of the wakes arb Forase wth ry soventeeanes trends Thal ds, Tae | en | [84-49 | 035-050 [30-9 ni & | $9228 | oso oso [52 —caint & [acts [tects [oon aas 2 45-62 | ‘as “ tat | 4-7 we fuis—ss|115- 160] aus APPENDIX 16916-10 APPENDIX - Units of Lang Unit Conversion Table ~ eee darn km x 0674 = mile m x a2 = tt Prefixes for Unite a ccs Prefix | Symbal_|__Powor rege u % 7/000 000 kilo k ‘1,000 fo i a Units of Torque: rill m 0.001 Nm x 0.1020 = kgm ‘micro Ff ‘0.000001 Nm x 07378 = feb Nm x 8881 = in igm x 8807 = Nm kom x 7.28 Helo Units of ma kom x 8680 Ira 6 x 2205 = tb 8 x 003527 » oz Unite of Preseur kes x 0.01020 = alent Units of Volume: Lc aa ee L x 02842 = gal (US) Pa 0.7501 _omHg t x 0.2200 = gal limp) kalo? x 98.07 Pa L x 1087 = qr(US) kalem? x 1422 psi L x 08790 = quia) emi xX 3.839 = KPa L x 2113 = pine (U5) L x 1818 = pint Gimp) mL x 003881 = ez (US) mu x 0.02818 = oz imp) _ Units of Speed mt x 008102 = euin kmh x 06214 = moh Units of Fore: Units af Power N x 0020 = kg ww x 1380» PS N x 0.228 = kw x 1381 HP tg x 9807 = N Ps x 07355 = kW 3 x 2208 = ib 5 x 09059 = HP Units of Temperatr 800440) yy SE +40) BEEF AO) gga ae i be meat ame + ttt} rte