Kawasaki ER-6N - Manuals

Manuals and User Guides for KAWASAKI ER-6N -. We have 5 KAWASAKI ER-6N - manuals available for free PDF download: Service Manual, Owner's Manual, Brochure

Kawasaki ER-6N - Service Manual (629 pages)

Brand: Kawasaki | Category: Motorcycle | Size: 13.62 MB

GENERAL INFORMATION 3

Emission Control Information 7

How To Use This Manual 9

Before Servicing 12

Model Identification 17

General Specifications 19

Unit Conversion Table 22

Table Of Contents 23

Periodic Maintenance Chart 25

Periodic Maintenance 26

Torque And Locking Agent 28

Specifications 34

Special Tools 36

Periodic Maintenance Procedures 37

Fuel System (DFI) 37

Throttle Control System Inspection 37

Engine Vacuum Synchronization Inspection 37

Idle Speed Inspection 40

Idle Speed Adjustment 40

Fuel Hose Inspection (fuel Leak, Damage, Installation Condition) 41

Evaporative Emission Control System Inspection (SEA-B1 And TH Models) 42

Cooling System 42

Coolant Level Inspection 42

Water Hose Damage And Installation Condition Inspection 43

Engine Top End 43

Valve Clearance Inspection 43

Valve Clearance Adjustment 44

Air Suction System Damage Inspection 47

Clutch 47

Clutch Operation Inspection 47

Wheels/Tires 48

Air Pressure Inspection 48

Wheel/Tire Damage Inspection 49

Tire Tread Wear, Abnormal Wear Inspection 49

Wheel Bearing Damage Inspection 50

Final Drive 50

Drive Chain Lubrication Condition Inspection 50

Drive Chain Slack Inspection 51

Drive Chain Slack Adjustment 51

Wheel Alignment Inspection 52

Drive Chain Wear Inspection 53

Chain Guide Inspection 53

Brake System 54

Brake Fluid Leak (Brake Hose And Pipe) Inspection 54

Brake Hose And Pipe Damage And Installation Condition Inspection 54

Brake Fluid Level Inspection 55

Brake Pad Wear Inspection 56

Brake Operation Inspection 56

Brake Light Switch Operation Inspection 56

Suspensions 57

Front Forks/Rear Shock Absorber Operation Inspection 57

Front Fork Oil Leak Inspection 57

Rear Shock Absorber Oil Leak Inspection 58

Steering System 58

Steering Play Inspection 58

Steering Play Adjustment 58

Steering Stem Bearing Lubrication 60

Electrical System 61

Lights And Switches Operation Inspection 61

Headlight Aiming Inspection 63

Sidestand Switch Operation Inspection 64

Engine Stop Switch Operation Inspection 65

Others 66

Chassis Parts Lubrication 66

Bolts, Nuts And Fasteners Tightness Inspection 67

Replacement Parts 68

Air Cleaner Element Replacement 68

Fuel Hose Replacement 70

Coolant Change 71

Radiator Hose And O-ring Replacement 73

Engine Oil Change 73

Oil Filter Replacement 74

Brake Hose And Pipe Replacement 75

Brake Fluid Change 76

Master Cylinder Rubber Parts Replacement 77

Caliper Rubber Parts Replacement 78

Spark Plug Replacement 81

Exploded View 86

DFI System 92

DFI Parts Location 97

Specifications 99

Special Tools And Sealant 101

DFI Servicing Precautions 103

Troubleshooting The DFI System 105

Outline 105

Inquiries To Rider 109

DFI System Troubleshooting Guide 111

Poor Running At Low Speed 111

Poor Running Or No Power At High Speed 114

Self-Diagnosis 116

Self-diagnosis Outline 116

Self-diagnosis Procedures 116

Service Code Reading 119

Service Code Erasing 119

Service Code Table 120

Backups 121

Main Throttle Sensor (Service Code 11) 123

Main Throttle Sensor Removal/Adjustment 123

Main Throttle Sensor Input Voltage Inspection 123

Main Throttle Sensor Output Voltage Inspection 124

Main Throttle Sensor Resistance Inspection 125

Intake Air Pressure Sensor (Service Code 12) 126

Intake Air Pressure Sensor Removal 126

Intake Air Pressure Sensor Installation 126

Intake Air Pressure Sensor Input Voltage Inspection 126

Intake Air Pressure Sensor Output Voltage Inspection 127

Intake Air Temperature Sensor (Service Code 13) 132

Intake Air Temperature Sensor Removal/Installation 132

Intake Air Temperature Sensor Output Voltage Inspection 132

Intake Air Temperature Sensor Resistance Inspection 133

Water Temperature Sensor (Service Code 14) 135

Water Temperature Sensor Removal/Installation 135

Water Temperature Sensor Output Voltage Inspection 135

Water Temperature Sensor Resistance Inspection 136

Crankshaft Sensor (Service Code 21) 137

Crankshaft Sensor Removal/Installation 137

Crankshaft Sensor Resistance Inspection 137

Crankshaft Sensor Peak Voltage Inspection 137

Speed Sensor (Service Code 24, 25) 138

Speed Sensor Removal/Installation 138

Speed Sensor Inspection 138

Speed Sensor Input Voltage Inspection 138

Speed Sensor Output Voltage Inspection 139

Vehicle-down Sensor (Service Code 31) 141

Vehicle-down Sensor Removal/Installation 141

Vehicle-down Sensor Inspection 141

Subthrottle Sensor (Service Code 32) 144

Subthrottle Sensor Removal/Adjustment 144

Subthrottle Sensor Input Voltage Inspection 144

Subthrottle Sensor Output Voltage Inspection 145

Subthrottle Sensor Resistance Inspection 147

Oxygen Sensor-not Activated (Service Code 33) (Equipped Models) 148

Oxygen Sensor Removal/Installation 148

Oxygen Sensor Inspection 148

Stick Coils #1, #2: (Service Code 51, 52) 151

Stick Coil Removal/Installation 151

Stick Coil Primary Winding Resistance Inspection 151

Stick Coil Input Voltage Inspection 151

Radiator Fan Relay (Service Code 56) 153

Radiator Fan Relay Removal/Installation 153

Radiator Fan Relay Inspection 153

Subthrottle Valve Actuator (Service Code 62) 154

Subthrottle Valve Actuator Removal 154

Subthrottle Valve Actuator Inspection 154

Subthrottle Valve Actuator Resistance Inspection 154

Subthrottle Valve Actuator Input Voltage Inspection 155

Air Switching Valve (Service Code 64) 157

Air Switching Valve Removal/Installation 157

Air Switching Valve Inspection 157

Oxygen Sensor Heater (Service Code 67) (Equipped Models) 158

Oxygen Sensor Heater Removal/Installation 158

Oxygen Sensor Heater Inspection 158

Oxygen Sensor Heater Power Source Voltage Inspection 159

Oxygen Sensor-Incorrect Output Voltage (Service Code 94) (Equipped Models) 161

Oxygen Sensor Removal/Installation 161

Oxygen Sensor Inspection 161

Purge Valve (Service Code 3A) (SEA-B1 And TH Models) 164

Purge Valve Removal/Installation 164

Purge Valve Inspection 164

Yellow Engine Warning Indicator Light (LED) 166

Yellow Engine Warning Indicator Light (LED) Inspection 166

ECU 167

ECU Identification 167

ECU Removal 167

ECU Installation 167

DFI Power Source 170

ECU Fuse Removal 170

ECU Fuse Installation 170

ECU Fuse Inspection 170

Fuel Line 171

Fuel Pressure Inspection 171

Fuel Flow Rate Inspection 172

Fuel Pump 174

Fuel Pump Removal 174

Fuel Pump Installation 174

Fuel Pump Operation Inspection 175

Fuel Pump Operating Voltage Inspection 176

Pressure Regulator Removal 177

Fuel Filter Cleaning 177

Fuel Injectors 178

Fuel Injector Removal/Installation 178

Fuel Injector Audible Inspection 178

Fuel Injector Resistance Inspection 178

Fuel Injector Power Source Voltage Inspection 179

Fuel Injector Output Voltage Inspection 180

Fuel Injector Fuel Line Inspection 181

Throttle Grip And Cables 183

Throttle Grip Free Play Inspection 183

Throttle Grip Free Play Adjustment 183

Throttle Cable Installation 183

Throttle Body Assy 184

Idle Speed Inspection/Adjustment 184

Synchronization Inspection/Adjustment 184

Throttle Body Assy Removal 184

Throttle Body Assy Installation 185

Throttle Body Assy Disassembly 186

Throttle Body Assy Assembly 187

Air Cleaner 188

Air Cleaner Element Removal/Installation 188

Air Cleaner Element Inspection 188

Air Cleaner Oil Draining 188

Air Cleaner Housing Installation 189

Fuel Tank 190

Fuel Tank Removal 190

Fuel Tank Installation 192

Fuel Tank And Cap Inspection 193

Fuel Tank Cleaning 194

Evaporative Emission Control System (SEA-B1 And TH Models) 195

Parts Removal/Installation 195

Hose Inspection 195

Purge Valve Inspection 195

Exploded View 198

Coolant Flow Chart 200

Specifications 202

Special Tools 203

Coolant 204

Coolant Deterioration Inspection 204

Coolant Level Inspection 204

Coolant Draining 204

Cooling System Flushing 205

Coolant Reserve Tank Removal/Installation 205

Water Pump 206

Water Pump Removal 206

Water Pump Installation 206

Water Pump Inspection 207

Mechanical Seal Inspection 207

Water Pump Housing Disassembly 208

Water Pump Housing Assembly 208

Impeller Assembly 208

Pump Impeller Inspection 208

Radiator 209

Radiator And Radiator Fan Removal 209

Radiator And Radiator Fan Installation 210

Radiator Inspection 211

Radiator Cap Inspection 211

Radiator Filler Neck Inspection 212

Thermostat 213

Thermostat Removal 213

Thermostat Installation 213

Thermostat Inspection 214

Hose And Pipes 215

Hose Installation 215

Hose Inspection 215

Water Temperature Sensor 216

Water Temperature Sensor Removal/Installation 216

Water Temperature Sensor Inspection 216

Exploded View 218

Exhaust System Identification 222

Specifications 223

Special Tools And Sealant 225

Clean Air System 227

Air Suction Valve Removal 227

Air Suction Valve Installation 227

Air Suction Valve Inspection 228

Air Switching Valve Removal 228

Air Switching Valve Installation 228

Air Switching Valve Operation Test 228

Clean Air System Hose Inspection 229

Cylinder Head Cover 230

Cylinder Head Cover Removal 230

Cylinder Head Cover Installation 231

Camshaft Chain Tensioner 233

Camshaft Chain Tensioner Removal 233

Camshaft Chain Tensioner Installation 233

Camshaft, Camshaft Chain 235

Camshaft Removal 235

Camshaft Installation 237

Camshaft, Camshaft Cap Wear Inspection 240

Camshaft Runout Inspection 240

Cam Wear Inspection 240

Camshaft Chain Removal 241

Cylinder Head 242

Cylinder Compression Measurement 242

Cylinder Head Removal 243

Cylinder Head Installation 243

Cylinder Head Warp Inspection 245

Valves 246

Valve Clearance Inspection 246

Valve Clearance Adjustment 246

Valve Removal 246

Valve Guide Installation 247

Valve-to-Guide Clearance Measurement (Wobble Method) 247

Valve Seat Inspection 248

Valve Seat Repair 248

Cylinder, Pistons 253

Cylinder Removal 253

Cylinder Installation 253

Piston Removal 254

Piston Installation 254

Cylinder Wear Inspection 255

Piston Wear Inspection 256

Piston Ring, Piston Ring Groove Wear Inspection 256

Piston Ring Groove Width Inspection 256

Piston Ring Thickness Inspection 257

Piston Ring End Gap Inspection 257

Throttle Body Assy Holder 258

Throttle Body Assy Holder Removal 258

Throttle Body Assy Holder Installation 258

Muffler 259

Muffler Removal 259

Muffler Installation 260

Exploded View 262

Specifications 264

Special Tools And Sealant 265

Clutch Lever And Cable 266

Clutch Lever Free Play Inspection 266

Clutch Lever Free Play Adjustment 266

Clutch Cable Removal 266

Clutch Lever Installation 267

Clutch Lever Adjustment 267

Clutch Cover 268

Clutch Cover Removal 268

Clutch Cover Installation 268

Release Shaft Removal 269

Release Shaft Installation 269

Clutch Cover Disassembly 269

Clutch Cover Assembly 270

6-10 CLUTCH 270

Clutch Removal 271

Clutch Installation 272

Clutch Plate, Wear, Damage Inspection 274

Clutch Plate Warp Inspection 274

Clutch Spring Free Length Measurement 274

Clutch Housing Finger Inspection 274

Clutch Housing Spline Inspection 275

Exploded View 278

Engine Oil Flow Chart 280

Specifications 282

Special Tools And Sealant 283

Engine Oil And Oil Filter 284

Oil Level Inspection 284

Engine Oil Change 284

Oil Filter Replacement 284

Oil Pan 285

Oil Pan Removal 285

Oil Pan Installation 286

Oil Pressure Relief Valve 288

Oil Pressure Relief Valve Removal 288

Oil Pressure Relief Valve Installation 288

Oil Pressure Relief Valve Inspection 288

Oil Pump 289

Oil Pump Removal 289

Oil Pump Installation 290

Oil Pressure Measurement 292

Oil Pressure Switch 293

Oil Pressure Switch Removal 293

Oil Pressure Switch Installation 293

Exploded View 296

Engine Removal/Installation 298

Engine Removal 298

Engine Installation 300

Specifications 308

Special Tools And Sealants 311

Crankcase Splitting 312

Crankcase Assembly 314

Crankshaft And Connecting Rods 321

Crankshaft Removal 321

Crankshaft Installation 321

Connecting Rod Removal 321

Connecting Rod Installation 322

Crankshaft/Connecting Rod Cleaning 325

Connecting Rod Bend Inspection 325

Connecting Rod Twist Inspection 326

Connecting Rod Big End Side Clearance Inspection 326

Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection 326

Crankshaft Side Clearance Inspection 328

Crankshaft Runout Inspection 328

Crankshaft Main Bearing Insert/Journal Wear Inspection 329

Balancer 331

Balancer Removal 331

Balancer Installation 331

Balancer Shaft Bearing Insert/Journal Clearance Inspection 331

External Shift Mechanism 334

Shift Pedal Removal 334

Shift Pedal Installation 334

External Shift Mechanism Installation 335

External Shift Mechanism Inspection 336

Transmission 337

Transmission Assy Removal 337

Transmission Assy Installation 337

Transmission Assy Disassembly 338

Transmission Assy Assembly 339

Transmission Shaft Removal 341

Transmission Shaft Installation 341

Transmission Shaft Disassembly 342

Transmission Shaft Assembly 342

Shift Drum And Fork Removal 345

Shift Drum And Fork Installation 345

Shift Drum Disassembly 345

Shift Drum Assembly 345

Gear Dog And Gear Dog Hole Damage Inspection 346

Ball Bearing, Needle Bearing, And Oil Seal 347

Ball And Needle Bearing Replacement 347

Ball And Needle Bearing Wear Inspection 347

Oil Seal Inspection 347

Exploded View 350

Specifications 352

Special Tools 353

Wheels (Rims) 354

Front Wheel Removal 354

Front Wheel Installation 354

Rear Wheel Removal 355

Rear Wheel Installation 356

Wheel Inspection 358

Axle Inspection 358

Balance Inspection 359

Balance Adjustment 359

Balance Weight Removal 359

Balance Weight Installation 359

Tires 361

Air Pressure Inspection/Adjustment 361

Tire Inspection 361

Tire Removal 361

Tire Repair 363

Hub Bearing 364

Hub Bearing Removal 364

Hub Bearing Installation 364

Hub Bearing Inspection 364

Hub Bearing Lubrication 365

Exploded View 368

Specifications 370

Special Tools 371

Drive Chain 372

Drive Chain Slack Inspection 372

Drive Chain Slack Adjustment 372

Wheel Alignment Inspection/Adjustment 372

Drive Chain Installation 373

Sprocket, Coupling 376

Engine Sprocket Removal 376

Engine Sprocket Installation 376

Rear Sprocket Removal 377

Rear Sprocket Installation 377

Coupling Installation 377

Coupling Bearing Removal 378

Coupling Bearing Installation 378

Coupling Bearing Inspection 379

Coupling Bearing Lubrication 379

Coupling Damper Inspection 379

Sprocket Wear Inspection 379

Rear Sprocket Warp Inspection 380

Exploded View 383

Specifications 392

Special Tools 393

Brake Lever, Brake Pedal 394

Brake Lever Position Adjustment 394

Brake Pedal Position Inspection 394

Brake Pedal Position Adjustment 394

Brake Pedal Removal 395

Brake Pedal Installation 395

Calipers 396

Front Caliper Removal 396

Caliper Installation 396

Front Caliper Disassembly 397

Front Caliper Assembly 397

Rear Caliper Disassembly 397

Rear Caliper Assembly 397

Caliper Dust Seal Damage Inspection 398

Caliper Dust Boot And Friction Boot Damage Inspection 398

Caliper Piston And Cylinder Damage Inspection 399

Caliper Holder Shaft Wear Inspection 399

Brake Pads 400

Front Brake Pad Removal 400

Front Brake Pad Installation 400

Rear Brake Pad Removal 400

Master Cylinder 401

Front Master Cylinder Removal 401

Front Master Cylinder Installation 401

Rear Master Cylinder Removal 403

Rear Master Cylinder Installation 403

Master Cylinder Disassembly 404

Master Cylinder Assembly 404

Master Cylinder Inspection 405

Brake Disc 406

Brake Disc Removal 406

Brake Disc Installation 406

Brake Disc Wear Inspection 406

Brake Fluid 407

Brake Fluid Level Inspection 407

Brake Fluid Change 407

Brake Line Bleeding 407

Brake Hose 410

Brake Hose Removal/Installation 410

Brake Hose Inspection 410

Anti-Lock Brake System (Equipped Models) 411

Parts Location 411

ABS Servicing Precautions 415

ABS Troubleshooting Outline 417

Self-diagnosis Outline 422

Self-diagnosis Procedures 422

Service Code Clearing Procedures 423

How To Read Service Codes 425

How To Erase Service Codes 425

Yellow ABS Indicator Light (LED) Inspection 427

Yellow ABS Indicator Light (LED) Does Not Go On (When The Ignition Switch Turned To ON) 427

Yellow ABS Indicator Light (LED) Goes On (When The Motorcycle Is Running, - No Service Code) 428

Solenoid Valve Inspection (Service Code 13,14,17,18) 428

ABS Solenoid Valve Relay Inspection (Service Code 19) 428

Front, Rear Wheel Rotation Difference Abnormal (Service Code 25) 430

ABS Motor Relay Inspection (Service Code 35) 430

Front Wheel Rotation Sensor Signal Abnormal (Service Code 42) 431

Front Wheel Rotation Sensor Wiring Inspection (Service Code 43) 432

Rear Wheel Rotation Sensor Signal Abnormal (Service Code 44) 433

Rear Wheel Rotation Sensor Wiring Inspection (Service Code 45) 434

Power Supply Voltage Abnormal (Under-Voltage) (Service Code 52) 434

Power Supply Voltage Abnormal (Over-Voltage) (Service Code 53) 435

ECU Inspection (Service Code 55) 436

ABS Hydraulic Unit Removal 437

ABS Hydraulic Unit Installation 439

ABS Hydraulic Unit Inspection 439

Front Wheel Rotation Sensor Removal 439

Front Wheel Rotation Sensor Installation 440

Rear Wheel Rotation Sensor Removal 440

Rear Wheel Rotation Sensor Installation 441

Wheel Rotation Sensor Inspection 441

Wheel Rotation Sensor Air Gap Inspection 442

Wheel Rotation Sensor Rotor Inspection 442

Brake Hose And Pipe Removal/Installation 442

Brake Hose And Pipe Inspection 442

ABS Motor Relay Fuse 25 A Removal 443

Fuse Installation 443

Fuse Inspection 443

Exploded View 446

Specifications 450

Special Tools 451

Front Fork 452

Front Fork Removal 452

Front Fork Installation 452

Front Fork Oil Change 453

Front Fork Disassembly 454

Front Fork Assembly 456

Inner Tube, Outer Tube Inspection 457

Dust Seal Inspection 457

Spring Tension Inspection 458

Rear Shock Absorber 459

Spring Preload Adjustment 459

Rear Shock Absorber Removal 459

Rear Shock Absorber Installation 460

Rear Shock Absorber Inspection 460

Swingarm 461

Swingarm Removal 461

Swingarm Installation 462

Swingarm Bearing Removal 462

Swingarm Bearing Installation 463

Swingarm Bearing, Sleeve Inspection 464

Swingarm Bearing Lubrication 464

Exploded View 466

Special Tools 468

Steering 468

Steering Inspection 469

Steering Adjustment 469

Steering Stem 470

Stem, Stem Bearing Removal 470

Stem, Stem Bearing Installation 471

Steering Stem Bearing Lubrication 473

Steering Stem Warp Inspection 473

Stem Cap Deterioration, Damage Inspection 473

Handlebar 474

Handlebar Removal 474

Handlebar Installation 474

Exploded View 478

Seats 484

Rear Seat Removal 484

Rear Seat Installation 484

Front Seat Removal 484

Fairings 485

Lower Fairing Removal 485

Lower Fairing Installation 485

Lower Fairing Bracket Installation 485

Center Fairing Removal 486

Center Fairing Installation 486

Upper Fairing Removal 486

Upper Fairing Installation 486

Seat Covers 487

Front Seat Cover Removal 487

Front Seat Cover Installation 487

Rear Seat Cover Removal 487

Rear Seat Cover Installation 488

Fenders 489

Front Fender Removal 489

Front Fender Installation 489

Flap Removal 489

Rear Fender Removal 490

Rear Fender Installation 490

Frame 491

Frame Inspection 491

Battery Case 492

Battery Case Removal 492

Battery Case Installation 492

Footpeg Stay 493

Footpeg Stay Removal 493

Footpeg Stay Installation 493

Sidestand 494

Sidestand Removal 494

Sidestand Installation 494

Frame Cover 495

Frame Cover Removal 495

Frame Cover Installation 495

Side Cover Removal 495

Rear View Mirrors 496

Rear View Mirror Removal 496

Rear View Mirror Installation 496

Exploded View 500

Specifications 506

Special Tools And Sealants 507

Parts Location 509

Wiring Diagram (ER650E Model) 512

Wiring Diagram (ER650F Model) 514

Precautions 516

Electrical Wiring 517

Wiring Inspection 517

Battery 518

Battery Removal 518

Battery Installation 518

Battery Activation 519

Interchange 522

Charging Condition Inspection 523

Refreshing Charge 523

Charging System 525

Alternator Cover Removal 525

Alternator Cover Installation 525

Stator Coil Removal 526

Stator Coil Installation 526

Alternator Rotor Removal 526

Alternator Rotor Installation 527

Alternator Inspection 528

Regulator/Rectifier Inspection 530

Charging Voltage Inspection 532

Starter Motor Clutch 534

Starter Motor Clutch Removal/Installation 534

Starter Motor Clutch Inspection 534

Starter Motor Clutch Disassembly 534

Ignition System 535

Crankshaft Sensor Removal 535

Crankshaft Sensor Installation 535

Crankshaft Sensor Inspection 536

Crankshaft Sensor Peak Voltage Inspection 536

Timing Rotor Removal 537

Timing Rotor Installation 537

Stick Coil Removal 537

Stick Coil Installation 537

Stick Coil Inspection 538

Stick Coil Primary Peak Voltage Inspection 538

Spark Plug Removal 539

Spark Plug Installation 539

Spark Plug Condition Inspection 539

Interlock Operation Inspection 540

IC Igniter Inspection 540

Electric Starter System 543

Starter Motor Removal 543

Starter Motor Installation 543

Starter Motor Disassembly 544

Starter Motor Assembly 544

Brush Inspection 546

Commutator Cleaning And Inspection 547

Armature Inspection 547

Brush Lead Inspection 547

Right-hand End Cover Inspection 548

Starter Relay Inspection 548

Lighting System 550

Headlight Beam Horizontal Adjustment 550

Headlight Beam Vertical Adjustment 550

Headlight Bulb Replacement 550

City Light Bulb Replacement 551

Headlight Unit Removal 551

Headlight Unit Installation 551

Tail/Brake Light (LED) Unit Removal 552

Tail/Brake Light (LED) Unit Installation 552

License Plate Light Bulb Replacement 552

Turn Signal Light Bulb Replacement 554

Turn Signal Relay Inspection 554

Air Switching Valve 557

Air Switching Valve Operation Test 557

Air Switching Valve Unit Test 558

Radiator Fan System 560

Fan Motor Inspection 560

Meter, Gauge, Indicator Unit 561

Meter Unit Removal 561

Meter Unit Installation 561

Meter, Gauge Disassembly 561

Electronic Combination Meter Unit Inspection 562

Switches And Sensors 571

Brake Light Timing Inspection 571

Brake Light Timing Adjustment 571

Switch Inspection 571

Water Temperature Sensor Inspection 572

Speed Sensor Removal 572

Speed Sensor Installation 572

Speed Sensor Inspection 573

Fuel Level Sensor Inspection 573

Oxygen Sensor Removal (Equipped Models) 574

Oxygen Sensor Installation (Equipped Models) 574

Oxygen Sensor Inspection (Equipped Models) 574

Relay Box 575

Relay Box Removal 575

Relay Box Installation 575

Relay Circuit Inspection 575

Diode Circuit Inspection 576

Fuse 578

Main Fuse Removal 578

Fuse Box Fuse Removal 578

Fuse Installation 578

Troubleshooting Guide 624

Gear Shifting Faulty 626

Over Cooling 626

Abnormal Engine Noise 626

Clutch Operation Faulty 626

Exhaust Smokes Excessively 627

Abnormal Drive Train Noise 627

Abnormal Frame Noise 627

Battery Trouble 628

Kawasaki ER-6N - Service Manual (537 pages)

Brand: Kawasaki | Category: Motorcycle | Size: 10.64 MB

GENERAL INFORMATION 3

How To Use This Manual 7

Table Of Contents 9

Before Servicing 10

Model Identification 15

General Specifications 16

Technical Information - Cassette Type Transmission 19

Technical Information - Inlet Air Pressure Sensor 20

Unit Conversion Table 21

Periodic Maintenance 23

Table Of Contents 2 23

Periodic Maintenance Chart 25

Torque And Locking Agent 28

Specifications 33

Special Tools 35

Periodic Maintenance Procedures 36

Fuel System (DFI) 36

Fuel Hose Inspection (fuel Leak, Damage, Installation Condition) 36

Throttle Control System Inspection 36

Idle Speed Inspection 37

Idle Speed Adjustment 37

Air Cleaner Element Cleaning 38

Engine Vacuum Synchronization Inspection 39

Cooling System 41

Coolant Level Inspection 41

Radiator Hose And Pipe Inspection (coolant Leak, Damage, Installation Condition) 42

Air Suction System 42

Air Suction System Damage Inspection 42

Engine Top End 42

Valve Clearance Adjustment 44

VALVE CLEARANCE ADJUSTMENT CHART INLET VALVE 45

Clutch 47

Clutch Operation Inspection 47

Wheels/Tires 47

Air Pressure Inspection 47

Wheel/Tire Damage Inspection 48

Tire Tread Wear, Abnormal Wear Inspection 48

Wheel Bearing Damage Inspection 49

Drive Train 49

Drive Chain Lubrication Condition Inspection 49

Drive Chain Slack Inspection 50

Drive Chain Slack Adjustment 50

Wheel Alignment Inspection 51

Drive Chain Wear Inspection 52

Chain Guide Inspection 52

Brake System 53

Brake Fluid Leak (Brake Hose And Pipe) Inspection 53

Brake Hose Damage And Installation Condition Inspection 53

Brake Operation Inspection 53

Brake Fluid Level Inspection 54

Brake Pad Wear Inspection 55

Brake Light Switch Operation Inspection 55

Suspensions 56

Front Forks/Rear Shock Absorber Operation Inspection 56

Front Fork Oil Leak Inspection 56

Rear Shock Absorber Oil Leak Inspection 56

Steering System 57

Steering Play Inspection 57

Steering Play Adjustment 57

Steering Stem Bearing Lubrication 58

Electrical System 59

Spark Plug Condition Inspection 59

Lights And Switches Operation Inspection 60

Headlight Aiming Inspection 62

Sidestand Switch Operation Inspection 63

Engine Stop Switch Operation Inspection 64

Others 65

Chassis Parts Lubrication 65

Bolts, Nuts And Fasteners Tightness Inspection 66

Replacement Parts 67

Air Cleaner Element Replacement 67

Engine Oil Change 67

Oil Filter Replacement 68

Fuel Hose Replacement 68

Coolant Change 69

Radiator Hose And O-ring Replacement 72

Brake Hose And Pipe Replacement 73

Brake Fluid Change 73

Master Cylinder Rubber Parts Replacement 75

Caliper Rubber Parts Replacement 76

Spark Plug Replacement 78

Exploded View 84

FUEL SYSTEM (DFI) 84

DFI System 88

DFI Parts Location 93

Specifications 94

Special Tools And Sealant 96

DFI Servicing Precautions 98

Troubleshooting The DFI System 100

Outline 100

Inquiries To Rider 104

DFI System Troubleshooting Guide 107

Poor Running At Low Speed 109

Poor Running Or No Power At High Speed 112

Self-Diagnosis 115

Self-diagnosis Outline 115

Self-diagnosis Procedures 115

Service Code Clearing Procedures 116

How To Read Service Codes 118

How To Erase Service Codes 118

Service Code Table 119

Backups 120

Main Throttle Sensor (Service Code 11) 122

Main Throttle Sensor Removal/Adjustment 122

Input Voltage Inspection 122

Output Voltage Inspection 123

Resistance Inspection 124

Inlet Air Pressure Sensor (Service Code 12) 125

Removal 125

Installation 125

Inlet Air Temperature Sensor (Service Code 13) 130

Removal/Installation 130

Sensor Resistance Inspection 131

Water Temperature Sensor (Service Code 14) 132

Water Temperature Sensor Removal/Installation 132

Water Temperature Sensor Output Voltage Inspection 132

Crankshaft Sensor (Service Code 21) 134

Crankshaft Sensor Removal/Installation 134

Crankshaft Sensor Inspection 134

Speed Sensor (Service Code 24, 25) 135

Speed Sensor Removal/Installation 135

Speed Sensor Inspection 135

Speed Sensor Input Voltage Inspection 135

Vehicle-down Sensor (Service Code 31) 137

Vehicle-down Sensor Removal 137

Vehicle-down Sensor Installation 137

Vehicle-down Sensor Inspection 137

Subthrottle Sensor (Service Code 32) 140

Subthrottle Sensor Removal/Adjustment 140

Subthrottle Sensor Input Voltage Inspection 140

Subthrottle Sensor Output Voltage Inspection 141

Subthrottle Sensor Resistance Inspection 142

Oxygen Sensor-not Activated (Service Code 33) - Europe Model 143

Oxygen Sensor Removal/Installation 143

Oxygen Sensor Inspection 143

Stick Coils (#1, #2: Service Code 51, 52) 145

Stick Coil Removal/Installation 145

Stick Coil Input Voltage Inspection 145

Radiator Fan Relay (Service Code 56) 147

Radiator Fan Relay Removal/Installation 147

Radiator Fan Relay Inspection 147

Subthrottle Valve Actuator (Service Code 62) 148

Subthrottle Valve Actuator Removal 148

Subthrottle Valve Actuator Audible Inspection 148

Subthrottle Valve Actuator Visual Inspection 148

Subthrottle Valve Actuator Input Voltage Inspection 149

Air Switching Valve (Service Code 64) 150

Air Switching Valve Removal/Installation 150

Air Switching Valve Inspection 150

Oxygen Sensor Heater (Service Code 67) - Europe Model 151

Oxygen Sensor Heater Removal/Installation 151

Oxygen Sensor Heater Inspection 151

Oxygen Sensor-Incorrect Output Voltage (Service Code 94) - Europe Model 153

FI Indicator Light (LED) 155

FI Indicator Light (LED) Inspection 156

ECU 157

ECU Removal 157

ECU Installation 157

ECU Power Supply Inspection 158

Fuel Line 160

Fuel Pressure Inspection 160

Fuel Flow Rate Inspection 162

Fuel Pump 164

Fuel Pump Removal 164

Fuel Pump Installation 164

Fuel Pump Operation Inspection 165

Fuel Pump Operating Voltage Inspection 165

Pressure Regulator Removal 166

Pump Screen, Fuel Filter Cleaning 166

Fuel Injectors 168

Removal/Installation 168

Audible Inspection 168

Fuel Injector Power Source Voltage Inspection 168

Fuel Injector Output Voltage Inspection 169

Injector Signal Test 169

Injector Resistance Inspection 170

Injector Unit Test 171

Injector Fuel Line Inspection 171

Throttle Grip And Cables 173

Throttle Grip Free Play Inspection 173

Throttle Grip Free Play Adjustment 173

Throttle Cable Installation 173

Throttle Body Assy 174

Idle Speed Inspection 174

Engine Vacuum Synchronization Inspection/Adjustment 174

High Altitude Performance Adjustment 174

Throttle Body Assy Installation 175

Throttle Body Assy Disassembly 176

Throttle Body Assy Assembly 177

Air Cleaner 178

Air Cleaner Element Removal/Installation 178

Air Cleaner Element Inspection 178

Air Cleaner Oil Draining 178

Air Cleaner Housing Installation 179

Fuel Tank 180

Fuel Tank Removal 180

Fuel Tank Installation 181

Fuel Tank And Cap Inspection 182

Fuel Tank Cleaning 183

Exploded View 186

Coolant Flow Chart 188

Specifications 190

Special Tools 191

Coolant 192

Coolant Deterioration Inspection 192

Coolant Level Inspection 192

Coolant Draining 192

Cooling System Flushing 193

Coolant Reserve Tank Removal/Installation 193

Water Pump 194

Water Pump Removal 194

Water Pump Installation 194

Mechanical Seal Inspection 195

Water Pump Housing Disassembly 195

Water Pump Housing Assembly 195

Impeller Assembly 196

Pump Impeller Inspection 196

Radiator 197

Radiator And Radiator Fan Removal 197

Radiator And Radiator Fan Installation 198

Radiator Inspection 198

Radiator Cap Inspection 198

Radiator Filler Neck Inspection 199

Thermostat 200

Thermostat Removal 200

Thermostat Installation 200

Thermostat Inspection 200

Hose And Pipes 202

Hose Installation 202

Hose Inspection 202

Water Temperature Sensor 203

Water Temperature Sensor Removal/Installation 203

Water Temperature Sensor Inspection 203

Exploded View 206

Specifications 211

Special Tools And Sealant 213

Clean Air System 215

Air Suction Valve Removal 215

Air Suction Valve Installation 215

Air Suction Valve Inspection 215

Air Switching Valve Installation 216

Air Switching Valve Operation Test 216

Air Switching Valve Unit Test 216

Clean Air System Hose Inspection 216

Cylinder Head Cover 217

Cylinder Head Cover Removal 217

Cylinder Head Cover Installation 217

Camshaft Chain Tensioner 218

Camshaft Chain Tensioner Removal 218

Camshaft Chain Tensioner Installation 218

Camshaft, Camshaft Chain 219

Camshaft Removal 219

Camshaft Installation 219

Camshaft And Sprocket Assembly 222

Camshaft, Camshaft Cap Wear 222

Camshaft Runout 223

Cam Wear 223

Camshaft Chain Removal 223

Cylinder Head 224

Cylinder Compression Measurement 224

Cylinder Head Removal 225

Cylinder Head Installation 226

Cylinder Head Warp 228

Valves 229

Valve Clearance Inspection 229

Valve Clearance Adjustment 229

Valve Removal 229

Valve Guide Installation 230

Valve-to-Guide Clearance Measurement (Wobble Method) 230

Valve Seat Inspection 231

Valve Seat Repair 231

Cylinder, Pistons 236

Cylinder Removal 236

Cylinder Installation 236

Piston Removal 236

Piston Installation 237

Cylinder Wear 238

Piston Wear 238

Piston Ring, Piston Ring Groove Wear 239

Piston Ring Groove Width 239

Piston Ring Thickness 239

Piston Ring End Gap 240

Throttle Body Holder 241

Throttle Body Holder Installation 241

Muffler 242

Muffler Body Removal 242

Exhaust Pipe Removal 242

Muffler Body And Exhaust Pipe Installation 243

Exploded View 246

Specifications 248

Special Tool And Sealant 249

Clutch Lever And Cable 250

Clutch Lever Free Play Inspection 250

Clutch Lever Free Play Adjustment 250

Clutch Cable Removal 250

Clutch Lever Installation 251

Clutch Lever Adjustment 251

Clutch Cover 252

Clutch Cover Removal 252

Clutch Cover Installation 252

Release Shaft Removal 253

Release Shaft Installation 253

Clutch Cover Disassembly 253

Clutch Cover Assembly 254

6-10 CLUTCH 254

Clutch Removal 255

Clutch Installation 255

Clutch Plate, Wear, Damage Inspection 257

Clutch Plate Warp Inspection 257

Clutch Spring Free Length Measurement 258

Clutch Housing Finger Inspection 258

Clutch Housing Spline Inspection 258

Exploded View 260

Engine Oil Flow Chart 262

Specifications 264

Special Tools And Sealant 265

Engine Oil And Oil Filter 266

Oil Level Inspection 266

Engine Oil Change 266

Oil Filter Replacement 266

Oil Pan 267

Oil Pan Removal 267

Oil Pan Installation 268

Oil Pressure Relief Valve 269

Oil Pressure Relief Valve Removal 269

Oil Pressure Relief Valve Installation 269

Oil Pressure Relief Valve Inspection 269

Oil Pump 270

Oil Pump Removal 270

Oil Pump Installation 271

Oil Pressure Measurement 272

Oil Pressure Switch 273

Oil Pressure Switch Removal 273

Oil Pressure Switch Installation 273

Exploded View 284

Specifications 288

Special Tools And Sealant 291

Crankcase Splitting 292

Crankcase Assembly 293

Crankshaft And Connecting Rods 299

Crankshaft Removal 299

Crankshaft Installation 299

Connecting Rod Removal 299

Connecting Rod Installation 300

Crankshaft/Connecting Rod Cleaning 303

Connecting Rod Bend 303

Connecting Rod Twist 304

Connecting Rod Big End Side Clearance 304

Connecting Rod Big End Bearing Insert/Crankpin Wear 304

Crankshaft Side Clearance 306

Crankshaft Runout 306

Crankshaft Main Bearing Insert/Journal Wear 306

Balancer 309

Balancer Removal 309

Balancer Installation 309

Balancer Shaft Bearing Insert/Journal Clearance 309

Transmission 311

Shift Pedal Removal 311

Shift Pedal Installation 311

External Shift Mechanism Removal 311

External Shift Mechanism Installation 312

External Shift Mechanism Inspection 313

Transmission Assy Removal 314

Transmission Assy Disassembly 315

Transmission Assy Assembly 315

Transmission Assy Installation 316

Transmission Shaft Removal 317

Transmission Shaft Installation 317

Transmission Shaft Disassembly 318

Transmission Shaft Assembly 318

Shift Drum And Fork Removal 321

Shift Drum And Fork Installation 321

Shift Drum Disassembly 321

Shift Drum Assembly 321

Shift Fork Guide Pin/Drum Groove Wear 322

Gear Dog And Gear Dog Hole Damage 322

Ball Bearing, Needle Bearing, And Oil Seal 323

Ball And Needle Bearing Replacement 323

Ball And Needle Bearing Wear 323

Oil Seal Inspection 323

Exploded View 326

Specifications 328

Special Tools 329

Wheels (Rims) 330

Front Wheel Removal 330

Front Wheel Installation 330

Rear Wheel Removal 332

Rear Wheel Installation 332

Wheel Inspection 334

Axle Inspection 334

Balance Inspection 335

Balance Adjustment 335

Balance Weight Removal 335

Balance Weight Installation 335

Tires 337

Air Pressure Inspection/Adjustment 337

Tire Inspection 337

Tire Removal 337

Tire Repair 339

Hub Bearing 340

Hub Bearing Removal 340

Hub Bearing Installation 340

Hub Bearing Inspection 340

Hub Bearing Lubrication 341

Exploded View 344

Specifications 346

Special Tools 347

Drive Chain 348

Drive Chain Slack Inspection 348

Drive Chain Slack Adjustment 348

Wheel Alignment Inspection/Adjustment 348

Drive Chain Installation 349

Sprocket, Coupling 352

Engine Sprocket Removal 352

Engine Sprocket Installation 353

Rear Sprocket Removal 353

Rear Sprocket Installation 353

Coupling Installation 354

Coupling Bearing Removal 354

Coupling Bearing Installation 354

Coupling Bearing Inspection 355

Coupling Bearing Lubrication 355

Coupling Damper Inspection 355

Sprocket Wear Inspection 355

Rear Sprocket Warp Inspection 356

Exploded View 358

Specifications 362

Special Tools 363

Brake Lever, Brake Pedal 364

Brake Lever Position Adjustment 364

Brake Pedal Position Inspection 364

Brake Pedal Position Adjustment 364

Brake Pedal Removal 365

Brake Pedal Installation 365

Calipers 367

Front Caliper Removal 367

Rear Caliper Removal 367

Caliper Installation 367

Front Caliper Disassembly 368

Front Caliper Assembly 368

Rear Caliper Disassembly 368

Rear Caliper Assembly 368

Caliper Piston And Cylinder Damage 369

Rear Caliper Holder Shaft Wear 369

Brake Pads 370

Front Brake Pad Removal 370

Front Brake Pad Installation 370

Rear Brake Pad Removal 370

Master Cylinder 371

Front Master Cylinder Removal 371

Front Master Cylinder Installation 371

Rear Master Cylinder Removal 372

Rear Master Cylinder Installation 372

Front Master Cylinder Disassembly 372

Rear Master Cylinder Disassembly 372

Master Cylinder Inspection 373

Brake Disc 374

Brake Disc Removal 374

Brake Disc Installation 374

Brake Disc Wear 374

Brake Fluid 375

Brake Fluid Level Inspection 375

Brake Fluid Change 375

Brake Line Bleeding 375

Brake Hose 378

Brake Hose Removal/Installation 378

Brake Hose Inspection 378

Exploded View 380

Specifications 384

Special Tools 385

Front Fork 387

Front Fork Removal 387

Front Fork Installation 387

Front Fork Oil Change 387

Front Fork Disassembly 389

Front Fork Assembly 390

Inner Tube Inspection 391

Dust Seal Inspection 391

Fork Spring Inspection 392

Rear Shock Absorber 393

Spring Preload Adjustment 393

Rear Shock Absorber Removal 393

Rear Shock Absorber Installation 394

Rear Shock Absorber Inspection 394

Swingarm 395

Swingarm Removal 395

Swingarm Installation 395

Swingarm Bearing Removal 396

Swingarm Bearing Installation 396

Swingarm Bearing, Sleeve Inspection 397

Swingarm Bearing Lubrication 398

Chain Guide Inspection 398

Exploded View 400

Special Tools 402

14-4 STEERING 402

Steering Inspection 403

Steering Adjustment 403

Steering Stem 404

Stem, Stem Bearing Removal 404

Stem, Stem Bearing Installation 405

Stem Bearing Lubrication 406

Steering Stem Warp 407

Stem Cap Deterioration, Damage 407

Handlebar 408

Handlebar Removal 408

Handlebar Installation 408

Exploded View 412

Seat 418

Seat Removal 418

Seat Installation 418

Fairings 419

Lower Fairing Removal 419

Lower Fairing Installation 419

Center Fairing Removal 419

Upper Fairing Removal 420

Upper Fairing Installation 420

Upper Fairing Bracket Removal 420

Inner Fairing Removal 421

Inner Fairing Installation 421

Side Covers 422

Side Cover Removal 422

Side Cover Installation 422

Seat Covers 423

Seat Cover Removal 423

Seat Cover Installation 423

Fenders 424

Front Fender Removal 424

Front Fender Installation 424

Flap And Rear Fender Rear Removal 424

Rear Fender Front Removal 425

Rear Fender Front Installation 425

Frame 425

Frame Inspection 426

Sidestand 427

Sidestand Removal 427

Sidestand Installation 427

Frame Cover 428

Frame Cover Removal 428

Frame Cover Installation 428

Rear View Mirrors 429

Rear View Mirrors Removal 429

Rear View Mirrors Installation 429

Exploded View 433

Specifications 440

Special Tools And Sealants 441

Parts Location 442

Wiring Diagram 444

Precautions 446

Electrical Wiring 448

Wiring Inspection 448

Battery 449

Battery Removal 449

Battery Installation 449

Battery Activation 449

Interchange 452

Charging Condition Inspection 453

Refreshing Charge 453

Charging System 455

Alternator Cover Removal 455

Alternator Cover Installation 455

Stator Coil Removal 455

Stator Coil Installation 456

Alternator Rotor Removal 456

Alternator Rotor Installation 456

Alternator Inspection 458

Regulator/Rectifier Inspection 459

Charging Voltage Inspection 461

Starter Motor Clutch 463

Starter Motor Clutch Removal/Installation 463

Starter Motor Clutch Inspection 463

Starter Motor Clutch Disassembly 463

Ignition System 464

Crankshaft Sensor Removal 464

Crankshaft Sensor Installation 465

Crankshaft Sensor Inspection 465

Crankshaft Sensor Peak Voltage Inspection 465

Timing Rotor Removal 466

Timing Rotor Installation 466

Stick Coil (Ignition Coil Together With Spark Plug Cap) Removal 466

Stick Coil (Ignition Coil Together With Spark Plug Cap) Installation 466

Stick Coil (Ignition Coil Together With Spark Plug Cap) Inspection 467

Stick Coil Primary Peak Voltage 467

Spark Plug Removal 468

Spark Plug Installation 468

Spark Plug Condition Inspection 468

Interlock Operation Inspection 469

IC Igniter Inspection 470

Electric Starter System 473

Starter Motor Removal 473

Starter Motor Installation 473

Starter Motor Disassembly 473

Starter Motor Assembly 474

Brush Inspection 475

Commutator Cleaning And Inspection 475

Armature Inspection 475

Brush Lead Inspection 476

Brush Plate And Terminal Bolt Inspection 476

Starter Relay Inspection 476

Lighting System 479

Headlight Beam Horizontal Adjustment 479

Headlight Beam Vertical Adjustment 479

Headlight Bulb Replacement 479

City Light Bulb Replacement 480

Headlight Removal/Installation 481

Tail/Brake Light Removal 481

Tail/Brake Light Installation 481

License Plate Light Bulb Replacement 482

Turn Signal Light Bulb Replacement 483

Turn Signal Relay Inspection 484

Air Switching Valve 486

Air Switching Valve Operation Test 486

Air Switching Valve Unit Test 486

Radiator Fan System 488

Fan Motor Inspection 488

Meter, Gauge, Indicator Unit 489

Meter Unit Removal 489

Meter, Gauge Disassembly 489

Electronic Combination Meter Unit Inspection 490

Switches And Sensors 497

Brake Light Timing Inspection 497

Brake Light Timing Adjustment 497

Switch Inspection 497

Water Temperature Sensor Inspection 498

Speed Sensor Removal 498

Speed Sensor Installation 498

Speed Sensor Inspection 499

Oxygen Sensor Removal (Europe Models) 499

Oxygen Sensor Installation (Europe Models) 499

Oxygen Sensor Inspection (Europe Models) 500

Fuel Reserve Switch Inspection 500

Relay Box 501

Relay Box Removal 501

Relay Circuit Inspection 501

Diode Circuit Inspection 502

Fuse 504

30 A Main Fuse Removal 504

Fuse Box Fuse Removal 504

15 A ECU Fuse Removal 504

Fuse Installation 505

Fuse Inspection 505

Troubleshooting Guide 532

Gear Shifting Faulty 534

Over Cooling 534

Abnormal Engine Noise 534

Clutch Operation Faulty 534

Exhaust Smokes Excessively 535

Abnormal Drive Train Noise 535

Abnormal Frame Noise 535

Battery Trouble 536

Kawasaki ER-6N - Owner's Manual (165 pages)

Brand: Kawasaki | Category: Motorcycle | Size: 1.66 MB

Table Of Contents 9

SPECIFICATIONS 11

LOCATION OF PARTS 14

LOADING AND ACCESSORIES INFORMATION 17

GENERAL INFORMATION 20

Meter Instruments 20

Tachometer 21

Multifunction Meter 22

Multifunction Display 24

Warning/Indicator Lights 33

Key 37

Ignition Switch/Steering Lock 37

Right Handlebar Switches 39

Engine Stop Switch 39

Starter Button 40

Left Handlebar Switches 41

Dimmer Switch 41

Turn Signal Switch 42

Horn Button 42

Passing Button 42

Hazard Switch 42

Brake/Clutch Lever Adjusters 43

Fuel Tank Cap 44

Fuel 45

Fuel Requirement 45

Filling The Tank 46

Stand 48

Seats 49

Helmet Hooks 51

Tool Kit 52

Rear View Mirror 53

Tying Hooks 54

BREAK-IN 55

HOW TO RIDE THE MOTORCYCLE 57

Starting The Engine 57

Jump Starting 59

Moving Off 62

Shifting Gears 63

Braking 64

Anti-lock Brake System (ABS) For Models Equipped With ABS 65

Yellow ABS Indicator Light 67

Stopping The Engine 68

Stopping The Motorcycle In An Emergency 69

Parking 70

Catalytic Converter 72

SAFE OPERATION 74

Safe Riding Technique 74

Daily Checks 77

Additional Considerations For High Speed Operation 80

MAINTENANCE AND ADJUSTMENT 82

Periodic Maintenance Chart 83

Engine Oil 93

Cooling System 99

Spark Plugs 105

Kawasaki Clean Air System 106

Valve Clearance 107

Air Cleaner 107

Throttle Control System 109

Engine Vacuum Synchronization 111

Idle Speed 112

Clutch 113

Drive Chain 115

Brakes 124

Brake Light Switches 128

Front Fork 131

Rear Shock Absorber 132

Wheels 135

Battery 140

Headlight Beam 145

Fuses 147

General Lubrication 149

Cleaning Your Motorcycle 151

STORAGE 156

ENVIRONMENTAL PROTECTION 158

LOCATION OF LABELS 159

Kawasaki ER-6N - Brochure (9 pages)

Brand: Kawasaki | Category: Motorcycle | Size: 4.13 MB

Kawasaki ER-6N - Brochure (2 pages)

Brand: Kawasaki | Category: Motorcycle | Size: 0.89 MB

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