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GENERAL INFORMATION 1-3
(12)
Oil Seal
and
Grease
Seal
Replace any
oil or
grease
seals that were
removed
with new ones, as
removal generally damages
seals.
When
pressing
in a seal which
has manufacturer's marks, press
it
in with the marks facing out. Seals
should
be pressed
into
place using
a suitable
driver, which contacts evenly with the side of seal. until the
face
of
the seal
is even with
the
end of
the hole. Before
a shaft
passes through a seal. apply a little high
temperature
grease on the lips to reduce rubber
to
metal friction.
(13)
Circlip, Retaining Ring
Replace any
circlips
and retaining rings that
were
removed with new ones, as removal weakens and
deforms them. When installing circtips
and
retaining rings, take
care
to compress or expand them only
enough to
install
them and
no more.
(14)
Cotter Pin
Replace any cotter pins that
were
removed
with
new ones, as removal deforms and breaks them.
(15)
Lubrication
Engine
wear
is generally at its
maximum while
the
engine
is warming up and before all the rubbing
surfaces have an
adequate
lubricative film. During assembly, oil or grease (whichever is more suitable)
should be applied to any rubbing
surface which
has lost its lubricative film. Old grease and dirty oil should
be
cleaned
off. Deteriorated grease has lost its lubricative quality and may contain abrasive foreign particles.
Don't use just
any oil
or grease. 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. This manual
makes reference to molybdenum disulfide grease
(MOS2 ) in
the assembly of certain engine and chassis
parts. Always
check
manufacturer recommendations before using such special lubricants.
(16)
Electrical Wires
All the electrical wires are either
single-color or
two-color and, with only a few exceptions, must be
connected to wires of the same
color.
On any of the
two-color
wires there is a greater amount of one color
and a lesser amount of
a second color, so a
two-color wire is identified by
first
the primary color and then
the secondary color. For example, a yellow
wire
with thin red stripes is
referred
to as a "yellow/red" wire;
it
would be a
"red/yellow" wire if the colors were
reversed to make red the main
color.
(17)
Replacement Parts
Wire
(cross-section)
Red
Wire
Strands
Yellow
Red
Name of Wire Color
Yellow/Red
When there is a replacement instruction, replace these parts with new ones every time they are removed.
These replacement parts will be damaged or lose their original function once removed.
(18) Inspection
When parts have been disassembled,
visually
inspect these parts
for
the following
conditions
or other
damage. If there is any doubt as to the condition of them, replace them with new ones.
Abrasion
Crack
Hardening
Warp
Bent
Dent
Scratch
Wear
Color
change
Deterioration
Seizure
(19)
Specifications
Specification terms are defined as follows:
"Standards
H
show dimensions or performances which brand-new parts or systems have.
"Service Limits" indicate the usable
limits.
If the measurement shows excessive wear or deteriorated
performance, replace
the
damaged parts.

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   Also See for Kawasaki KDX200

This manual is also suitable for:

Kdx220 1995-2006

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