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ER-6N -
KAWASAKI ER-6N - Manuals
Manuals and User Guides for KAWASAKI ER-6N -. We have
6
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
Table of Contents
11
General Information
3
General Information
7
Emission Control Information
9
How to Use This Manual
12
Before Servicing
12
General Information
17
Model Identification
19
General Specifications
22
Unit Conversion Table
23
Periodic Maintenance 2-1 Periodic Maintenance
23
Table of Contents
25
Periodic Maintenance Chart
26
Periodic Maintenance
28
Torque and Locking Agent
34
Specifications
36
Special Tools
37
Periodic Maintenance Procedures
37
Fuel System (DFI)
37
Throttle Control System Inspection
37
Engine Vacuum Synchronization Inspection
40
Idle Speed Inspection
40
Idle Speed Adjustment
41
Fuel Hose Inspection (Fuel Leak, Damage, Installation Condition)
42
Evaporative Emission Control System Inspection (SEA-B1 and TH Models)
42
Cooling System
42
Coolant Level Inspection
43
Water Hose Damage and Installation Condition Inspection
43
Engine Top End
43
Valve Clearance Inspection
44
Valve Clearance Adjustment
47
Air Suction System Damage Inspection
47
Clutch
47
Clutch Operation Inspection
48
Wheels/Tires
48
Air Pressure Inspection
49
Wheel/Tire Damage Inspection
49
Tire Tread Wear, Abnormal Wear Inspection
50
Wheel Bearing Damage Inspection
50
Final Drive
50
Drive Chain Lubrication Condition Inspection
51
Drive Chain Slack Inspection
51
Drive Chain Slack Adjustment
52
Wheel Alignment Inspection
53
Drive Chain Wear Inspection
53
Chain Guide Inspection
54
Brake System
54
Brake Fluid Leak (Brake Hose and Pipe) Inspection
54
Brake Hose and Pipe Damage and Installation Condition Inspection
55
Brake Fluid Level Inspection
56
Brake Pad Wear Inspection
56
Brake Operation Inspection
56
Brake Light Switch Operation Inspection
57
Suspensions
57
Front Forks/Rear Shock Absorber Operation Inspection
57
Front Fork Oil Leak Inspection
58
Rear Shock Absorber Oil Leak Inspection
58
Steering System
58
Steering Play Inspection
58
Steering Play Adjustment
60
Steering Stem Bearing Lubrication
61
Electrical System
61
Lights and Switches Operation Inspection
63
Headlight Aiming Inspection
64
Sidestand Switch Operation Inspection
65
Engine Stop Switch Operation Inspection
66
Others
66
Chassis Parts Lubrication
67
Bolts, Nuts and Fasteners Tightness Inspection
68
Replacement Parts
68
Air Cleaner Element Replacement
70
Fuel Hose Replacement
71
Coolant Change
73
Radiator Hose and O-Ring Replacement
73
Engine Oil Change
74
Oil Filter Replacement
75
Brake Hose and Pipe Replacement
76
Brake Fluid Change
77
Master Cylinder Rubber Parts Replacement
78
Caliper Rubber Parts Replacement
81
Spark Plug Replacement
83
Fuel System (Dfi) 3-1 Fuel System (Dfi)
86
Exploded View
87
Exploded View
92
DFI System
97
DFI Parts Location
99
Specifications
101
Special Tools and Sealant
103
DFI Servicing Precautions
105
Troubleshooting the DFI System
105
Outline
109
Inquiries to Rider
111
DFI System Troubleshooting Guide
111
Poor Running at Low Speed
114
Poor Running or No Power at High Speed
116
Self-Diagnosis
116
Self-Diagnosis Outline
116
Self-Diagnosis Procedures
119
Service Code Reading
119
Service Code Erasing
120
Service Code Table
121
Backups
123
Main Throttle Sensor (Service Code 11)
123
Main Throttle Sensor Removal/Adjustment
123
Main Throttle Sensor Input Voltage Inspection
124
Main Throttle Sensor Output Voltage Inspection
125
Main Throttle Sensor Resistance Inspection
126
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
127
Intake Air Pressure Sensor Output Voltage Inspection
132
Intake Air Temperature Sensor (Service Code 13)
132
Intake Air Temperature Sensor Removal/Installation
132
Intake Air Temperature Sensor Output Voltage Inspection
133
Intake Air Temperature Sensor Resistance Inspection
135
Water Temperature Sensor (Service Code 14)
135
Water Temperature Sensor Removal/Installation
135
Water Temperature Sensor Output Voltage Inspection
136
Water Temperature Sensor Resistance Inspection
137
Crankshaft Sensor (Service Code 21)
137
Crankshaft Sensor Removal/Installation
137
Crankshaft Sensor Resistance Inspection
137
Crankshaft Sensor Peak Voltage Inspection
138
Speed Sensor (Service Code 24, 25)
138
Speed Sensor Removal/Installation
138
Speed Sensor Inspection
138
Speed Sensor Input Voltage Inspection
139
Speed Sensor Output Voltage Inspection
141
Vehicle-Down Sensor (Service Code 31)
141
Vehicle-Down Sensor Removal/Installation
141
Vehicle-Down Sensor Inspection
144
Subthrottle Sensor (Service Code 32)
144
Subthrottle Sensor Removal/Adjustment
144
Subthrottle Sensor Input Voltage Inspection
145
Subthrottle Sensor Output Voltage Inspection
147
Subthrottle Sensor Resistance Inspection
148
Oxygen Sensor-Not Activated (Service Code 33) (Equipped Models)
148
Oxygen Sensor Removal/Installation
148
Oxygen Sensor Inspection
151
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
153
Radiator Fan Relay (Service Code 56)
153
Radiator Fan Relay Removal/Installation
153
Radiator Fan Relay Inspection
154
Subthrottle Valve Actuator (Service Code 62)
154
Subthrottle Valve Actuator Removal
154
Subthrottle Valve Actuator Inspection
154
Subthrottle Valve Actuator Resistance Inspection
155
Subthrottle Valve Actuator Input Voltage Inspection
157
Air Switching Valve (Service Code 64)
157
Air Switching Valve Removal/Installation
157
Air Switching Valve Inspection
158
Oxygen Sensor Heater (Service Code 67) (Equipped Models)
158
Oxygen Sensor Heater Removal/Installation
158
Oxygen Sensor Heater Inspection
159
Oxygen Sensor Heater Power Source Voltage Inspection
161
Oxygen Sensor-Incorrect Output Voltage (Service Code 94) (Equipped Models)
161
Oxygen Sensor Removal/Installation
161
Oxygen Sensor Inspection
164
Purge Valve (Service Code 3A) (SEA-B1 and TH Models)
164
Purge Valve Removal/Installation
164
Purge Valve Inspection
166
Yellow Engine Warning Indicator Light (LED)
166
Yellow Engine Warning Indicator Light (LED) Inspection
167
Ecu
167
ECU Identification
167
ECU Removal
167
ECU Installation
167
ECU Power Supply Inspection
170
DFI Power Source
170
ECU Fuse Removal
170
ECU Fuse Installation
170
ECU Fuse Inspection
170
ECU Main Relay Removal/Installation
170
ECU Main Relay Inspection
171
Fuel Line
171
Fuel Pressure Inspection
172
Fuel Flow Rate Inspection
174
Fuel Pump
174
Fuel Pump Removal
174
Fuel Pump Installation
175
Fuel Pump Operation Inspection
176
Fuel Pump Operating Voltage Inspection
177
Pressure Regulator Removal
177
Fuel Filter Cleaning
178
Fuel Injectors
178
Fuel Injector Removal/Installation
178
Fuel Injector Audible Inspection
178
Fuel Injector Resistance Inspection
179
Fuel Injector Power Source Voltage Inspection
180
Fuel Injector Output Voltage Inspection
181
Fuel Injector Fuel Line Inspection
183
Throttle Grip and Cables
183
Throttle Grip Free Play Inspection
183
Throttle Grip Free Play Adjustment
183
Throttle Cable Installation
183
Throttle Cable Lubrication
184
Throttle Body Assy
184
Idle Speed Inspection/Adjustment
184
Synchronization Inspection/Adjustment
184
Throttle Body Assy Removal
185
Throttle Body Assy Installation
186
Throttle Body Assy Disassembly
187
Throttle Body Assy Assembly
188
Air Cleaner
188
Air Cleaner Element Removal/Installation
188
Air Cleaner Element Inspection
188
Air Cleaner Oil Draining
188
Air Cleaner Housing Removal
189
Air Cleaner Housing Installation
190
Fuel Tank
190
Fuel Tank Removal
192
Fuel Tank Installation
193
Fuel Tank and Cap Inspection
194
Fuel Tank Cleaning
195
Evaporative Emission Control System (SEA-B1 and TH Models)
195
Parts Removal/Installation
195
Hose Inspection
195
Purge Valve Inspection
195
Canister Inspection
197
Cooling System 4-1 Cooling System
198
Exploded View
200
Coolant Flow Chart
202
Specifications
203
Special Tools
204
Coolant
204
Coolant Deterioration Inspection
204
Coolant Level Inspection
204
Coolant Draining
204
Coolant Filling
204
Pressure Testing
205
Cooling System Flushing
205
Coolant Reserve Tank Removal/Installation
206
Water Pump
206
Water Pump Removal
206
Water Pump Installation
207
Water Pump Inspection
207
Mechanical Seal Inspection
208
Water Pump Housing Disassembly
208
Water Pump Housing Assembly
208
Impeller Assembly
208
Pump Impeller Inspection
209
Radiator
209
Radiator and Radiator Fan Removal
210
Radiator and Radiator Fan Installation
211
Radiator Inspection
211
Radiator Cap Inspection
212
Radiator Filler Neck Inspection
213
Thermostat
213
Thermostat Removal
213
Thermostat Installation
214
Thermostat Inspection
215
Hose and Pipes
215
Hose Installation
215
Hose Inspection
216
Water Temperature Sensor
216
Water Temperature Sensor Removal/Installation
216
Water Temperature Sensor Inspection
217
Engine Top End 5-1 Engine Top End
218
Exploded View
222
Exhaust System Identification
223
Specifications
225
Special Tools and Sealant
227
Clean Air System
227
Air Suction Valve Removal
227
Air Suction Valve Installation
228
Air Suction Valve Inspection
228
Air Switching Valve Removal
228
Air Switching Valve Installation
228
Air Switching Valve Operation Test
228
Air Switching Valve Unit Test
229
Clean Air System Hose Inspection
230
Cylinder Head Cover
230
Cylinder Head Cover Removal
231
Cylinder Head Cover Installation
233
Camshaft Chain Tensioner
233
Camshaft Chain Tensioner Removal
233
Camshaft Chain Tensioner Installation
235
Camshaft, Camshaft Chain
235
Camshaft Removal
237
Camshaft Installation
240
Camshaft, Camshaft Cap Wear Inspection
240
Camshaft Runout Inspection
240
Cam Wear Inspection
241
Camshaft Chain Removal
242
Cylinder Head
242
Cylinder Compression Measurement
243
Cylinder Head Removal
243
Cylinder Head Installation
245
Cylinder Head Warp Inspection
246
Valves
246
Valve Clearance Inspection
246
Valve Clearance Adjustment
246
Valve Removal
246
Valve Installation
246
Valve Guide Removal
247
Valve Guide Installation
247
Valve-To-Guide Clearance Measurement (Wobble Method)
248
Valve Seat Inspection
248
Valve Seat Repair
253
Cylinder, Pistons
253
Cylinder Removal
253
Cylinder Installation
254
Piston Removal
254
Piston Installation
255
Cylinder Wear Inspection
256
Piston Wear Inspection
256
Piston Ring, Piston Ring Groove Wear Inspection
256
Piston Ring Groove Width Inspection
257
Piston Ring Thickness Inspection
257
Piston Ring End Gap Inspection
258
Throttle Body Assy Holder
258
Throttle Body Assy Holder Removal
258
Throttle Body Assy Holder Installation
259
Muffler
259
Muffler Removal
260
Muffler Installation
261
Clutch 6-1 Clutch
262
Exploded View
264
Specifications
265
Special Tools and Sealant
266
Clutch Lever and Cable
266
Clutch Lever Free Play Inspection
266
Clutch Lever Free Play Adjustment
266
Clutch Cable Removal
266
Clutch Cable Installation
266
Clutch Cable Lubrication
267
Clutch Lever Installation
267
Clutch Lever Adjustment
268
Clutch Cover
268
Clutch Cover Removal
268
Clutch Cover Installation
269
Release Shaft Removal
269
Release Shaft Installation
269
Clutch Cover Disassembly
270
Clutch Cover Assembly
270
6-10 Clutch
271
Clutch Removal
272
Clutch Installation
274
Clutch Plate, Wear, Damage Inspection
274
Clutch Plate Warp Inspection
274
Clutch Spring Free Length Measurement
274
Clutch Housing Finger Inspection
275
Clutch Housing Spline Inspection
277
Engine Lubrication System
278
Exploded View
280
Engine Oil Flow Chart
282
Specifications
283
Special Tools and Sealant
284
Engine Oil and Oil Filter
284
Oil Level Inspection
284
Engine Oil Change
284
Oil Filter Replacement
285
Oil Pan
285
Oil Pan Removal
286
Oil Pan Installation
288
Oil Pressure Relief Valve
288
Oil Pressure Relief Valve Removal
288
Oil Pressure Relief Valve Installation
288
Oil Pressure Relief Valve Inspection
289
Oil Pump
289
Oil Pump Removal
290
Oil Pump Installation
292
Oil Pressure Measurement
293
Oil Pressure Switch
293
Oil Pressure Switch Removal
293
Oil Pressure Switch Installation
295
Engine Removal/Installation
296
Exploded View
298
Engine Removal/Installation
298
Engine Removal
300
Engine Installation
303
Crankshaft/Transmission 9-1 Crankshaft/Transmission
304
Exploded View
308
Specifications
311
Special Tools and Sealants
312
Crankcase Splitting
314
Crankcase Assembly
321
Crankshaft and Connecting Rods
321
Crankshaft Removal
321
Crankshaft Installation
321
Connecting Rod Removal
322
Connecting Rod Installation
325
Crankshaft/Connecting Rod Cleaning
325
Connecting Rod Bend Inspection
326
Connecting Rod Twist Inspection
326
Connecting Rod Big End Side Clearance Inspection
326
Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection
328
Crankshaft Side Clearance Inspection
328
Crankshaft Runout Inspection
329
Crankshaft Main Bearing Insert/Journal Wear Inspection
331
Balancer
331
Balancer Removal
331
Balancer Installation
331
Balancer Shaft Bearing Insert/Journal Clearance Inspection
334
External Shift Mechanism
334
Shift Pedal Removal
334
Shift Pedal Installation
335
External Shift Mechanism Installation
336
External Shift Mechanism Inspection
337
Transmission
337
Transmission Assy Removal
337
Transmission Assy Installation
338
Transmission Assy Disassembly
339
Transmission Assy Assembly
341
Transmission Shaft Removal
341
Transmission Shaft Installation
342
Transmission Shaft Disassembly
342
Transmission Shaft Assembly
345
Shift Drum and Fork Removal
345
Shift Drum and Fork Installation
345
Shift Drum Disassembly
345
Shift Drum Assembly
345
Shift Fork Bending Inspection
345
Shift Fork/Gear Groove Wear Inspection
346
Gear Dog and Gear Dog Hole Damage Inspection
347
Ball Bearing, Needle Bearing, and Oil Seal
347
Ball and Needle Bearing Replacement
347
Ball and Needle Bearing Wear Inspection
347
Oil Seal Inspection
Advertisement
Kawasaki ER-6N - Service Manual (537 pages)
Brand:
Kawasaki
| Category:
Motorcycle
| Size: 10.64 MB
Table of Contents
9
General Information
3
General Information
7
How to Use This Manual
9
Table of Contents
10
Before Servicing
15
Model Identification
16
General Specifications
19
Technical Information - Cassette Type Transmission
20
Technical Information - Inlet Air Pressure Sensor
21
Unit Conversion Table
23
Periodic Maintenance 2-1 Periodic Maintenance
23
Periodic Maintenance
23
Table of Contents 2
25
Periodic Maintenance Chart
27
Periodic Maintenance Chart
28
Torque and Locking Agent
33
Specifications
35
Special Tools
36
Periodic Maintenance Procedures
36
Fuel System (DFI)
36
Fuel Hose Inspection (Fuel Leak, Damage, Installation Condition)
36
Throttle Control System Inspection
37
Idle Speed Inspection
37
Idle Speed Adjustment
38
Air Cleaner Element Cleaning
39
Engine Vacuum Synchronization Inspection
41
Cooling System
41
Coolant Level Inspection
42
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 Inspection
44
Valve Clearance Adjustment
45
Valve Clearance Adjustment Chart Inlet Valve
47
Clutch
47
Clutch Operation Inspection
47
Wheels/Tires
47
Air Pressure Inspection
48
Wheel/Tire Damage Inspection
48
Tire Tread Wear, Abnormal Wear Inspection
49
Wheel Bearing Damage Inspection
49
Drive Train
49
Drive Chain Lubrication Condition Inspection
50
Drive Chain Slack Inspection
50
Drive Chain Slack Adjustment
51
Wheel Alignment Inspection
52
Drive Chain Wear Inspection
52
Chain Guide Inspection
53
Brake System
53
Brake Fluid Leak (Brake Hose and Pipe) Inspection
53
Brake Hose Damage and Installation Condition Inspection
53
Brake Operation Inspection
54
Brake Fluid Level Inspection
55
Brake Pad Wear Inspection
55
Brake Light Switch Operation Inspection
56
Suspensions
56
Front Forks/Rear Shock Absorber Operation Inspection
56
Front Fork Oil Leak Inspection
56
Rear Shock Absorber Oil Leak Inspection
57
Steering System
57
Steering Play Inspection
57
Steering Play Adjustment
58
Steering Stem Bearing Lubrication
59
Electrical System
59
Spark Plug Condition Inspection
60
Lights and Switches Operation Inspection
62
Headlight Aiming Inspection
63
Sidestand Switch Operation Inspection
64
Engine Stop Switch Operation Inspection
65
Others
65
Chassis Parts Lubrication
66
Bolts, Nuts and Fasteners Tightness Inspection
67
Replacement Parts
67
Air Cleaner Element Replacement
67
Engine Oil Change
68
Oil Filter Replacement
68
Fuel Hose Replacement
69
Coolant Change
72
Radiator Hose and O-Ring Replacement
73
Brake Hose and Pipe Replacement
73
Brake Fluid Change
75
Master Cylinder Rubber Parts Replacement
76
Caliper Rubber Parts Replacement
78
Spark Plug Replacement
81
Fuel System (Dfi)
84
Exploded View
84
Fuel System (Dfi)
88
DFI System
93
DFI Parts Location
94
Specifications
96
Special Tools and Sealant
98
DFI Servicing Precautions
100
Troubleshooting the DFI System
100
Outline
104
Inquiries to Rider
107
DFI System Troubleshooting Guide
109
Poor Running at Low Speed
112
Poor Running or No Power at High Speed
115
Self-Diagnosis
115
Self-Diagnosis Outline
115
Self-Diagnosis Procedures
116
Service Code Clearing Procedures
118
How to Read Service Codes
118
How to Erase Service Codes
119
Service Code Table
120
Backups
122
Main Throttle Sensor (Service Code 11)
122
Main Throttle Sensor Removal/Adjustment
122
Input Voltage Inspection
123
Output Voltage Inspection
124
Resistance Inspection
125
Inlet Air Pressure Sensor (Service Code 12)
125
Removal
125
Installation
125
Input Voltage Inspection
126
Output Voltage Inspection
130
Inlet Air Temperature Sensor (Service Code 13)
130
Removal/Installation
130
Output Voltage Inspection
131
Sensor Resistance Inspection
132
Water Temperature Sensor (Service Code 14)
132
Water Temperature Sensor Removal/Installation
132
Water Temperature Sensor Output Voltage Inspection
134
Crankshaft Sensor (Service Code 21)
134
Crankshaft Sensor Removal/Installation
134
Crankshaft Sensor Inspection
135
Speed Sensor (Service Code 24, 25)
135
Speed Sensor Removal/Installation
135
Speed Sensor Inspection
135
Speed Sensor Input Voltage Inspection
135
Speed Sensor Output Voltage Inspection
137
Vehicle-Down Sensor (Service Code 31)
137
Vehicle-Down Sensor Removal
137
Vehicle-Down Sensor Installation
137
Vehicle-Down Sensor Inspection
140
Subthrottle Sensor (Service Code 32)
140
Subthrottle Sensor Removal/Adjustment
140
Subthrottle Sensor Input Voltage Inspection
141
Subthrottle Sensor Output Voltage Inspection
142
Subthrottle Sensor Resistance Inspection
143
Oxygen Sensor-Not Activated (Service Code 33) - Europe Model
143
Oxygen Sensor Removal/Installation
143
Oxygen Sensor Inspection
145
Stick Coils (#1, #2: Service Code 51, 52)
145
Stick Coil Removal/Installation
145
Stick Coil Input Voltage Inspection
147
Radiator Fan Relay (Service Code 56)
147
Radiator Fan Relay Removal/Installation
147
Radiator Fan Relay Inspection
148
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 Resistance Inspection
149
Subthrottle Valve Actuator Input Voltage Inspection
150
Air Switching Valve (Service Code 64)
150
Air Switching Valve Removal/Installation
150
Air Switching Valve Inspection
151
Oxygen Sensor Heater (Service Code 67) - Europe Model
151
Oxygen Sensor Heater Removal/Installation
151
Oxygen Sensor Heater Inspection
153
Oxygen Sensor-Incorrect Output Voltage (Service Code 94) - Europe Model
153
Oxygen Sensor Removal/Installation
153
Oxygen Sensor Inspection
155
FI Indicator Light (LED)
156
FI Indicator Light (LED) Inspection
157
Ecu
157
ECU Removal
157
ECU Installation
158
ECU Power Supply Inspection
160
Fuel Line
160
Fuel Pressure Inspection
162
Fuel Flow Rate Inspection
164
Fuel Pump
164
Fuel Pump Removal
164
Fuel Pump Installation
165
Fuel Pump Operation Inspection
165
Fuel Pump Operating Voltage Inspection
166
Pressure Regulator Removal
166
Pump Screen, Fuel Filter Cleaning
168
Fuel Injectors
168
Removal/Installation
168
Audible Inspection
168
Fuel Injector Power Source Voltage Inspection
169
Fuel Injector Output Voltage Inspection
169
Injector Signal Test
170
Injector Resistance Inspection
171
Injector Unit Test
171
Injector Fuel Line Inspection
173
Throttle Grip and Cables
173
Throttle Grip Free Play Inspection
173
Throttle Grip Free Play Adjustment
173
Throttle Cable Installation
173
Throttle Cable Lubrication
174
Throttle Body Assy
174
Idle Speed Inspection
174
Engine Vacuum Synchronization Inspection/Adjustment
174
High Altitude Performance Adjustment
174
Throttle Body Assy Removal
175
Throttle Body Assy Installation
176
Throttle Body Assy Disassembly
177
Throttle Body Assy Assembly
178
Air Cleaner
178
Air Cleaner Element Removal/Installation
178
Air Cleaner Element Inspection
178
Air Cleaner Oil Draining
178
Air Cleaner Housing Removal
179
Air Cleaner Housing Installation
180
Fuel Tank
180
Fuel Tank Removal
181
Fuel Tank Installation
182
Fuel Tank and Cap Inspection
183
Fuel Tank Cleaning
185
Cooling System 4-1 Cooling System
186
Exploded View
188
Coolant Flow Chart
190
Specifications
191
Special Tools
192
Coolant
192
Coolant Deterioration Inspection
192
Coolant Level Inspection
192
Coolant Draining
192
Coolant Filling
192
Pressure Testing
193
Cooling System Flushing
193
Coolant Reserve Tank Removal/Installation
194
Water Pump
194
Water Pump Removal
194
Water Pump Installation
195
Mechanical Seal Inspection
195
Water Pump Housing Disassembly
195
Water Pump Housing Assembly
196
Impeller Assembly
196
Pump Impeller Inspection
197
Radiator
197
Radiator and Radiator Fan Removal
198
Radiator and Radiator Fan Installation
198
Radiator Inspection
198
Radiator Cap Inspection
199
Radiator Filler Neck Inspection
200
Thermostat
200
Thermostat Removal
200
Thermostat Installation
200
Thermostat Inspection
202
Hose and Pipes
202
Hose Installation
202
Hose Inspection
203
Water Temperature Sensor
203
Water Temperature Sensor Removal/Installation
203
Water Temperature Sensor Inspection
205
Engine Top End 5-1 Engine Top End
206
Exploded View
211
Specifications
213
Special Tools and Sealant
215
Clean Air System
215
Air Suction Valve Removal
215
Air Suction Valve Installation
215
Air Suction Valve Inspection
215
Air Switching Valve Removal
216
Air Switching Valve Installation
216
Air Switching Valve Operation Test
216
Air Switching Valve Unit Test
216
Clean Air System Hose Inspection
217
Cylinder Head Cover
217
Cylinder Head Cover Removal
217
Cylinder Head Cover Installation
218
Camshaft Chain Tensioner
218
Camshaft Chain Tensioner Removal
218
Camshaft Chain Tensioner Installation
219
Camshaft, Camshaft Chain
219
Camshaft Removal
219
Camshaft Installation
222
Camshaft and Sprocket Assembly
222
Camshaft, Camshaft Cap Wear
223
Camshaft Runout
223
Cam Wear
223
Camshaft Chain Removal
224
Cylinder Head
224
Cylinder Compression Measurement
225
Cylinder Head Removal
226
Cylinder Head Installation
228
Cylinder Head Warp
229
Valves
229
Valve Clearance Inspection
229
Valve Clearance Adjustment
229
Valve Removal
229
Valve Installation
229
Valve Guide Removal
230
Valve Guide Installation
230
Valve-To-Guide Clearance Measurement (Wobble Method)
231
Valve Seat Inspection
231
Valve Seat Repair
236
Cylinder, Pistons
236
Cylinder Removal
236
Cylinder Installation
236
Piston Removal
237
Piston Installation
238
Cylinder Wear
238
Piston Wear
239
Piston Ring, Piston Ring Groove Wear
239
Piston Ring Groove Width
239
Piston Ring Thickness
240
Piston Ring End Gap
241
Throttle Body Holder
241
Throttle Body Holder Installation
242
Muffler
242
Muffler Body Removal
242
Exhaust Pipe Removal
243
Muffler Body and Exhaust Pipe Installation
245
Clutch 6-1 Clutch
246
Exploded View
248
Specifications
249
Special Tool and Sealant
250
Clutch Lever and Cable
250
Clutch Lever Free Play Inspection
250
Clutch Lever Free Play Adjustment
250
Clutch Cable Removal
250
Clutch Cable Installation
250
Clutch Cable Lubrication
251
Clutch Lever Installation
251
Clutch Lever Adjustment
252
Clutch Cover
252
Clutch Cover Removal
252
Clutch Cover Installation
253
Release Shaft Removal
253
Release Shaft Installation
253
Clutch Cover Disassembly
254
Clutch Cover Assembly
254
6-10 Clutch
255
Clutch Removal
255
Clutch Installation
257
Clutch Plate, Wear, Damage Inspection
257
Clutch Plate Warp Inspection
258
Clutch Spring Free Length Measurement
258
Clutch Housing Finger Inspection
258
Clutch Housing Spline Inspection
259
Engine Lubrication System
260
Exploded View
262
Engine Oil Flow Chart
264
Specifications
265
Special Tools and Sealant
266
Engine Oil and Oil Filter
266
Oil Level Inspection
266
Engine Oil Change
266
Oil Filter Replacement
267
Oil Pan
267
Oil Pan Removal
268
Oil Pan Installation
269
Oil Pressure Relief Valve
269
Oil Pressure Relief Valve Removal
269
Oil Pressure Relief Valve Installation
269
Oil Pressure Relief Valve Inspection
270
Oil Pump
270
Oil Pump Removal
271
Oil Pump Installation
272
Oil Pressure Measurement
273
Oil Pressure Switch
273
Oil Pressure Switch Removal
273
Oil Pressure Switch Installation
283
Crankshaft/Transmission 9-1 Crankshaft/Transmission
284
Exploded View
288
Specifications
291
Special Tools and Sealant
292
Crankcase Splitting
293
Crankcase Splitting
293
Crankcase Assembly
299
Crankshaft and Connecting Rods
299
Crankshaft Removal
299
Crankshaft Installation
299
Connecting Rod Removal
300
Connecting Rod Installation
303
Crankshaft/Connecting Rod Cleaning
303
Connecting Rod Bend
304
Connecting Rod Twist
304
Connecting Rod Big End Side Clearance
304
Connecting Rod Big End Bearing Insert/Crankpin Wear
306
Crankshaft Side Clearance
306
Crankshaft Runout
306
Crankshaft Main Bearing Insert/Journal Wear
309
Balancer
309
Balancer Removal
309
Balancer Installation
309
Balancer Shaft Bearing Insert/Journal Clearance
311
Transmission
311
Shift Pedal Removal
311
Shift Pedal Installation
311
External Shift Mechanism Removal
312
External Shift Mechanism Installation
313
External Shift Mechanism Inspection
314
Transmission Assy Removal
315
Transmission Assy Disassembly
315
Transmission Assy Assembly
316
Transmission Assy Installation
317
Transmission Shaft Removal
317
Transmission Shaft Installation
318
Transmission Shaft Disassembly
318
Transmission Shaft Assembly
321
Shift Drum and Fork Removal
321
Shift Drum and Fork Installation
321
Shift Drum Disassembly
321
Shift Drum Assembly
321
Shift Fork Bending
321
Shift Fork/Gear Groove Wear
322
Shift Fork Guide Pin/Drum Groove Wear
322
Gear Dog and Gear Dog Hole Damage
323
Ball Bearing, Needle Bearing, and Oil Seal
323
Ball and Needle Bearing Replacement
323
Ball and Needle Bearing Wear
323
Oil Seal Inspection
Kawasaki ER-6N - Owner's Manual (180 pages)
Brand:
Kawasaki
| Category:
Motorcycle
| Size: 1.5 MB
Table of Contents
8
Table of Contents
10
Specifications
14
Serial Number Locations
15
Location of Parts
18
Loading and Accessories Information
21
General Information
21
Meter Instruments
22
Speedometer
22
Digital Meter
30
Warning/Indicator Light
31
Key
32
Ignition Switch/Steering Lock
34
Right Handlebar Switches
34
Engine Stop Switch
35
Starter Button
35
Left Handlebar Switches
35
Dimmer Switch
36
Turn Signal Switch
36
Horn Button
36
Hazard Switch
37
Brake/Clutch Lever Adjusters
38
Fuel Tank Cap
39
Fuel Tank
40
Fuel Requirement
44
Stand
45
Seat
47
Helmet Holding Cable
48
Tool Kit/U-Shaped Lock Compartment
49
Rear View Mirror
50
Tying Hooks
51
Break-In
53
How to Ride the Motorcycle
53
Starting the Engine
55
Jump Starting
58
Moving off
59
Shifting Gears
61
Braking
62
Stopping the Engine
63
Stopping the Motorcycle in an Emergency
64
Parking
66
Catalytic Converter
68
Safe Operation
68
Safe Riding Technique
71
Daily Safety Checks
74
Additional Considerations for High Speed Operation
76
Maintenance and Adjustment
81
Periodic Maintenance Chart
92
Engine Oil
98
Cooling System
104
Spark Plugs
105
Evaporative Emission Control System (California Model Only)
106
Kawasaki Clean Air System
107
Valve Clearance
108
Air Cleaner
109
Throttle Control System
112
Engine Vacuum Synchronization
112
Idle Speed
114
Clutch
116
Drive Chain
125
Brakes
129
Brake Light Switches
131
Front Fork
132
Rear Shock Absorbers
134
Wheels
140
Battery
145
Headlight Beam
147
Fuses
149
General Lubrication
150
Cleaning Your Motorcycle
155
Bolt and Nut Tightening
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Kawasaki ER-6N - Owner's Manual (165 pages)
Brand:
Kawasaki
| Category:
Motorcycle
| Size: 1.66 MB
Table of Contents
9
Table of Contents
11
Specifications
14
Location of Parts
17
Loading and Accessories Information
20
General Information
20
Meter Instruments
21
Tachometer
22
Multifunction Meter
24
Multifunction Display
33
Warning/Indicator Lights
37
Key
37
Ignition Switch/Steering Lock
39
Right Handlebar Switches
39
Engine Stop Switch
40
Starter Button
41
Left Handlebar Switches
41
Dimmer Switch
42
Turn Signal Switch
42
Horn Button
42
Passing Button
42
Hazard Switch
43
Brake/Clutch Lever Adjusters
44
Fuel Tank Cap
45
Fuel
45
Fuel Requirement
46
Filling the Tank
48
Stand
49
Seats
51
Helmet Hooks
52
Tool Kit
53
Rear View Mirror
54
Tying Hooks
55
Break-In
57
How to Ride the Motorcycle
57
Starting the Engine
59
Jump Starting
62
Moving Off
63
Shifting Gears
64
Braking
65
Anti-Lock Brake System (ABS) for Models Equipped with ABS
67
Yellow ABS Indicator Light
68
Stopping the Engine
69
Stopping the Motorcycle in an Emergency
70
Parking
72
Catalytic Converter
74
Safe Operation
74
Safe Riding Technique
77
Daily Checks
80
Additional Considerations for High Speed Operation
82
Maintenance and Adjustment
83
Periodic Maintenance Chart
93
Engine Oil
99
Cooling System
105
Spark Plugs
106
Kawasaki Clean Air System
107
Valve Clearance
107
Air Cleaner
109
Throttle Control System
111
Engine Vacuum Synchronization
112
Idle Speed
113
Clutch
115
Drive Chain
124
Brakes
128
Brake Light Switches
131
Front Fork
132
Rear Shock Absorber
135
Wheels
140
Battery
145
Headlight Beam
147
Fuses
149
General Lubrication
151
Cleaning Your Motorcycle
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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