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January 13, In , diagram , sportster , wiring. Leave a Reply Cancel reply Your email address will not be published. Previous post Electric Plug Wiring Colours. Related Post. January 13, January 13, Search Search. Recent Comments No comments to show. Special tools, gauges, and testers that are necessary when servicing Kawasaki motorcycles are introduced by the Service Manual. Genuine parts provided as spare parts are listed in the Parts Catalog. Each chapter in turn has its own comprehensive Table of Contents.
For example, if you want ignition coil informa- tion, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chap- ter to find the ignition coil section.
Always follow safe operating and maintenance practices. WARNING This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in per- sonal injury, or loss of life. CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in dam- age to or destruction of equipment. It also precedes the text of a NOTE. Indicates a conditional step or what action to take based on the results of the test or inspec- tion in the procedural step or sub-step it fol- lows.
In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require spec- ified tightening torque, oil, grease or a locking agent during assembly. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts.
Especially note the following: 1 Dirt Before removal and disassembly, clean the motorcycle. Any dirt entering the engine will shorten the life of the motorcycle.
For the same reason, before installing a new part, clean off any dust or metal filings. This prevents the engine from accidentally turning over while work is being carried out, sparks from being generated while disconnecting the leads from electrical parts, as well as damage to the electrical parts themselves. However, if instal- lation or assembly sequence is given in this Service Manual, follow it. Note parts locations and cable, wire, and hose routing during removal or disassembly so they can be installed or assem- bled in the same way.
It is preferable to mark and record the locations and routing whenever possible. When installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit, thus ensuring that the part has been installed in its proper location.
Then, tighten them to the specified torque in the tightening sequence and method indicated. If tightening sequence instructions are not given, tighten them evenly in a cross pattern. Either too little or too much torque may lead to serious damage. Use a good quality, reliable torque wrench.
If a part seems especially difficult to remove or install, stop and examine what may be causing the problem. Whenever tapping is necessary, tap lightly using a wooden or plastic-faced mallet. Use an impact driver for screws particularly for the removing screws held by non-permanent locking agent in order to avoid damaging the screw heads. Use a clean piece of thick cloth when lifting the engine or turning it over. A commercial solvent com- monly available in North America is standard solvent generic name.
Always follow manufacturer and container directions regarding the use of any solvent. Remove any foreign matter from the mating surface of the gasket or O-ring to ensure a perfectly smooth surface to prevent oil or compression leaks. Apply them sparingly.
Excessive amount may block engine oil passages and cause serious dam- age. Replace any ball or needle bearings that were removed with new ones. Install bearings with the manufacturer and size marks facing out, applying pressure evenly with a suitable driver. Apply force only to the end of the race that contacts the press fit portion, and press it evenly over the base component.
Oil or grease seals should be pressed into place using a suitable driver, applying a force uniformly to the end of seal until the face of the seal is even with the end of the hole, unless instructed otherwise.
Install the circlip with its chamfered side facing load side as well. Replace any circlips, retaining rings, and cotter pins that were removed with new ones, as re- moval weakens and deforms them. If old ones are reused, they could become detached while the motorcycle is driven, leading to a major problem. During assembly, make sure to apply oil to any sliding surface or bearing that has been cleaned.
Old grease or dirty oil could have lost its lubricative quality and may contain foreign particles that act as abrasives; therefore, make sure to wipe it off and apply fresh grease or oil. Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended. Pos- itive rotation is counterclockwise as viewed from the left side of the engine. To carry out proper adjustment, it is furthermore necessary to rotate the engine in the direction of positive rotation as well.
Replacement parts will be damaged or lose their original function once they are removed. There- fore, always replace these parts with new ones every time they are removed. Although the pre- viously mentioned gasket, O-ring, ball bearing, needle bearing, grease seal, oil seal, circlip, and cotter pin have not been so designated in their respective text, they are replacement parts.
A two-color lead is identified first by the primary color and then the stripe color. Unless instructed otherwise, electrical leads must be connected to leads of the same color. Two-Color Electrical If there is any doubt as to the condition of them, replace them with new ones.
If the measurement shows excessive wear or deteri- orated performance, replace the damaged parts. The initial maintenance is vitally important and must not be neglected. CAL: California The secondary air injection system [A] helps Kawasaki keep motorcycle exhaust gases below the established emission regulation limits. This system draws air into the exhaust ports, dilutes and burns harmful ingredients in the exhaust gas in order to reduce them. This allows the carburetor to be set at a reasonable setting position without adjusting it much leaner, so engine performance and actual riding performance are not spoiled.
But, under the trend that the emission regulation becomes more severe, Kawasaki has adopted two catalytic converters [B] in addition to the secondary air injection system. Moreover, a BDSR 36 -type carburetor has been adopted because of its good balance between cost and performance.
As a result, we can reduce the exhaust gas emission below the current standards without hurting the output performance and the actual riding feeling at all. The harmful ingredients in the exhaust gas are reduced considerably under running performance of emission regulation like LA4 or EC mode. Moreover, in order to improve the reliability of the system, we install fuel cut valves [C] as a catalyst protection system.
Exhaust Purification System The burned gas, which goes out from the combustion chamber, is injected with secondary air adding necessary oxygen , and is cleaned up while passing through the small precatalytic converters in the joint pipe and the main catalytic converter in the silencer, and then goes out to the atmosphere.
As original combustion gas has little remaining oxygen, air is injected in the exhaust ports by the sec- ondary air injection system in order to supply enough oxygen to the combustion gas to purify CO, and HC to a certain extent as well as prepare for activation of the catalysts. Exhaust Gas before Purification 2 Precatalytic Converters [A] A small-size three-way catalytic converter precatalytic converter is installed in the pipe ahead at the joint [B] of the silencer.
A precatalytic converter is made of a punched metal pipe [C] of stain- less steel, and its surface is covered with alumina upon which platinum and rhodium as catalysts are applied.
Generally, the temperature of the exhaust gas must be higher than the activation tem- perature, so we set this precatalytic converter at the upper portion of the main catalytic converter where the temperature of exhaust gas is high. Accordingly, the precatalytic converter will be acti- vated even under low load conditions. Activation of the precatalytic converter raises the exhaust gas temperature by the catalyst reaction, which helps the main catalytic converter operate more efficiently.
The main catalytic converter is installed in the first expansion chamber of the silencer. When the exhaust gas passes through the upper portion of the secondary air injection system, the precatalytic converter, and the inside of the honeycomb, the main catalytic converter works efficiently to reduce CO, HC, and NOx. So, we can keep it within regulation. The honeycomb structure is convenient for the catalytic converter because it has a large surface area but small size to react effectively and has low exhaust resistance.
In addition, its inherent strength helps resist vibration, and has simple structure welded directly on the silencer. Catalyst Protection System When excessive unburned gasoline flows more than the allowable amount into the exhaust gas dur- ing running, the temperature of the catalysts rises abnormally because the unburned gasoline reacts with heated catalysts at the activation temperature or higher.
In an excessive case, the problem such as melting-down occurs. Moreover, there is a possibility that the purification performance be- comes poorer when it is cool below the activation temperature. So, the fuel cut valve [A] as a catalyst protection system is installed on each carburetor float bowl [B]. It runs by the IC Igniter and opens and closes the fuel passage toward a main jet [C]. Subscription Preferences. Enter your email address so that we can find your existing information.
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