M451-3 Kawasaki KZ 1000 Z 1100 Fours 1981 – 2002 Service Manual

This Kawasaki motorcycle manual is 376 pages.

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Service hints / Safety first / Expendable supplies / Shop tools / Emergency tool kit / Troubleshooting and tune-up equipment / Specifications

CHAPTER TWO / TROUBLESHOOTING
Starting difficulties / Poor performance / Clutch and transmission / Drive train / Chassis / Brakes / Electrical system / Charging system / Lighting / Fuses / Wiring / Specifications

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Model identification / Scheduled maintenance / Engine oil and filter / Drive chain lubrication / Swing arm lubrication / Steering head lubrication / Wheel bearing lubrication / Shaft drive lubrication / General lubrication / Battery / Air filter / Clutch adjustment / Drive chain adjustment / Steering play inspection / Front forks / Rear shock absorbers (dual shock models) / Rear shock absorbers (uni-track models / Tires / Wire wheels / Cast wheels / Disc brake / Nuts, bolts and fasteners / Engine tune-up / Fuel system / Spark plugs / Air suction valves / Valve clearance / Ignition timing / Carburation or fuel injection / Cylinder compression / Storage / Specifications

CHAPTER FOUR / ENGINE
Break-in / Cam chain and tensioner / Valve cover / Camshafts / Cylinder head / Valves and valve components / Cylinder block / Pistons and rings / Oil cooler / removal installation / Oil pump / Crankcase / Crankshaft and cam chain / Crankcase assembly / Specifications

CHAPTER FIVE / CLUTCH
Operation / Clutch release / Overhaul / Specifications

CHAPTER SIX / TRANSMISSION
Sprocket cover / Engine sprocket / Neutral switch / Shift linkage / Shift drum and forks / Transmission gears / Front bevel drive / Specifications

CHAPTER SEVEN / CARBURETION AND EXHAUST SYSTEMS
Carburetor operation service troubleshooting / Rejetting / Fuel level inspection / Idle mixture adjustment / Crankcase breather / Air suction system / Fuel tank / Fuel tap / Fuel level sending unit / Exhaust system / Specifications

CHAPTER EIGHT / FUEL INJECTION SYSTEM
Fuel injection operation / Fuel injection precautions / Fuel injection scheduled maintenance / Fuel injection testing / Quick diagnosis / Fuel system tests / Control unit system tests / Sensor tests / Signal test / Last chance / Fuel injection disassembly / Control unit / Specifications

CHAPTER NINE / ELECTRICAL SYSTEM
Fuses / Battery / Ignition system / Spark plugs / Ignition coils / Pickup coils / Ignition advance mechanism / IC igniter / Charging system / Alternator / Starting system / Starter motor / Starter clutch / Starter solenoid / Starter lockout switch / Lighting system / Turn signal cancelling system / Fuel gauge / Fuel level sensor / Electric instruments / Tachometer/voltmeter / Electronic warning unit / Horn / Voltmeter / Specifications

CHAPTER TEN / WHEELS, TIRES AND BRAKES
Wire wheels / Cast wheels / Front rear wheel / Wheel bearings and seals / Axle / Brakes / Brake system bleeding / Brake fluid change / Brake hose / Brake pads and calipers / Front rear master cylinder / Brake discs / Specifications

CHAPTER ELEVEN / CHASSIS
Fairing / Handlebars / Front forks / Steering / Shock absorbers / Swing arm / Uni-track rear suspension / Drive chain / Final gear case / Swing arm / Drive shaft / Specifications

SUPPLEMENT / 1982-2002 POLICE MODEL SERVICE INFORMATION

INDEX

WIRING DIAGRAMS

Models covered:
1981-1982 Kawasaki KZ1000 KZ 1000 J1, J2 Standard (US and Canada)
1981-1982 Kawasaki KZ1000 KZ 1000 K1, K2 LTD (US and Canada)
1981-1982 Kawasaki KZ1000 KZ 1000 M1, M2 CSR (US and Canada)
1982-1983 Kawasaki KZ1000 KZ 1000 R1, R2 Replica (US and Canada)
1981-1983 Kawasaki KZ1100 KZ 1100 A1, A2, A3 Standard (US and Canada)
1981-1982 Kawasaki KZ1100 KZ 1100 B1, B2 GP (US and Canada)
1982-1983 Kawasaki KZ1100 KZ 1100 D1, D2 Spectre (US and Canada)
1983 Kawasaki KZ1100 KZ 1100 L1 LTD-shaft (US and Canada)
1981 1982 Kawasaki Z1000 Z 1000 J1, J2 (Other than US and Canada)
1981 1982 Kawasaki Z1000 Z 1000 K1, K2 (Other than US and Canada)
1982 1983 1984 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 Kawasaki Z1000 Z 1000 Police Model P1-P21 (US and Canada)
1983 Kawasaki Z1000 Z 1000 R2 (Other than US and Canada)
1983 Kawasaki Z1000J3 Z 1000 J3(Other than US and Canada)
1981 1982 Kawasaki Z1100 Z 1100 A1, A2 (Other than US and Canada)
1983 1984 Kawasaki Z1100 Z 1100 A1, A2 (Other than US and Canada)
1985 Kawasaki Z1100 Z 1100 A3 (Other than US and Canada)
1981 1982 Kawasaki Z1100 Z 1100 B1, B2 (Other than US and Canada)
1983 Kawasaki Z1100 Z 1100 D2 (Other than US and Canada)
1984 1985 Kawasaki ZN1100 Z 1100 B1, B2 (US and Canada)
1983 1984 Kawasaki ZX1100 Z 1100 A1, A2 (US and Canada)

45134513b4513p

M448-2 Clymer Kawasaki KX80 1991-2000 KX85 2001-2010 and KX100 1989-2009

This Kawasaki Manual is 352 pages.

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Safety / Basic service methods / Serial numbers / Fasteners / Shop supplies / Basic tools / Precision measuring tools / Storage / Specifications

CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Starting the engine / Starting difficulties / Engine performance / Engine / Leak down test / Fuel system / Electrical troubleshooting / Clutch / External shift mechanism ans transmission / Kickstarter / Drive train noise / Front suspension and steering / Rear suspension / Frame noise / Brakes

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Service intervals / Tune-up / Pre-ride inspection / Engine lubrication / Oil level check / Transmission oil / Air filter / Spark plug / Fuel system / Exhaust system / Cooling system / Engine compression test / Ignition timing / Control cable lubrication / Throttle cable operation / Clutch cable / Engine top end inspection / Kick pedal and shift pedal / Brakes / Drive chain and sprockets / Tires and wheels / Wheel bearings / Steering / Front fork / Rear shock absorber / Rear swing arm and linkage / General lubrication / Fasteners / Storage / Specifications

CHAPTER FOUR / ENGINE TOP END
Cleanliness / Exhaust system / Cylinder head / Cylinder / KIPS exhaust valve / Piston, piston pin and piston ring / Reed valve assembly / Engine break-in / Specifications

CHAPTER FIVE / ENGINE LOWER END
Servicing engine in frame / Engine / Crankcase and crankshaft / Specifications

CHAPTER SIX / CLUTCH, KICKSTARTER AND EXTERNAL SHIFT MECHANISM (1989-1997 MODELS)
Right crankcase cover / Clutch / Primary drive pinion gear / Clutch cable / Kickstarter / External shift mechanism / Specifications

CHAPTER SEVEN / CLUTCH, KICKSTARTER AND EXTERNAL SHIFT MECHANISM (1998-ON MODELS)
Clutch cover / Clutch release lever / Right crankcase cover / Exhaust valve governor / Clutch / Clutch inspection / Primary drive pinion gear / Clutch cable / Kickstarter / External shift mechanism / Specifications

CHAPTER EIGHT / TRANSMISSION AND INTERNAL SHIFT MECHANISM
Transmission operation / Transmission troubleshooting / Transmission overhaul / Internal shift mechanism / Transmission gear ratios / Specifications

CHAPTER NINE / FUEL SYSTEM
Air filter / Carburetor identification / Carburetor service / Float height adjustment / Fuel level adjustment / Carburetor rejetting / Fuel tank / Fuel shutoff valve / Throttle cable / Airbox / Specifications

CHAPTER TEN / IGNITION SYSTEM
Electrical component replacement / Capacitor discharge ignition / Flywheel / Stator plate assembly / Pickup coil / Capacitor discharge ignition module / Ignition coil / Engine stop switch / Ignition timing / Specification

CHAPTER ELEVEN / COOLING SYSTEM
Cooling system inspection / Radiator / Water pump / Hoses / Specifications

CHAPTER TWELVE / WHEELS, TIRES AND DRIVE CHAIN
Bike stand / Front wheel / Rear wheel / Wheel service / Front hub / Rear hub / Tire changing / Tire repairs / Sprocket replacement / Drive chain / Specifications

CHAPTER THIRTEEN / FRONT SUSPENSION AND STEERING (CONVENTIONAL FORK)
Handlebar / Steering head / Front fork / Specifications

CHAPTER FOURTEEN / FRONT SUSPENSION AND STEERING (CARTRIDGE FORK)
Handlebar / Steering head / Front fork / Front fork oil refilling / Front fork adjustment / Specifications

CHAPTER FIFTEEN / REAR SUSPENSION
Rear shock absorber / Rear swing arm / Uni-Trak linkage / Specifications

CHAPTER SIXTEEN / BRAKES
Brake fluid selection / Brake service / Brake pad replacement / Front caliper / Rear caliper / Front master cylinder / Rear master cylinder / Brake hose replacement / Brake disc / Draining brake fluid / Brake bleeding / Rear brake pedal / Specifications

INDEX

WIRING DIAGRAMS

Models covered:
1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 Kawasaki KX100 KX 100
1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 Kawasaki KX80 KX 80
2001-2010 Kawasaki KX85 and KX85-II KX 85

44824482b

Kawasaki ZG1000 GTR1000 Concours 1986-2006 Service Manual M409-2

ZG1000 Concours / GTR1000 (1986-2006)

This Kawasaki Concours Manuals is 464 pages.

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Safety / Serial numbers / Fasteners / Shop supplies / Basic tools / Precision measuring tools / Electrical system fundamentals / Basic service methods / Storage / Specifications

CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Starting the engine / Starting difficulties / Engine performance / Engine noises / Engine lubrication / Engine leakdown test / Clutch / Fuel system / Gearshift linkage / Transmission / Final drive / Electrical testing / Charging system / Ignition system / Starting system / Cooling system / Front suspension and steering / Brakes

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Maintenance schedule intervals / Spark plugs / Engine compression test / Ignition timing / Valve clearance / Engine oil and filter / Air filter / Throttle and choke cable / General lubrication / Emission control system / Specifications

CHAPTER FOUR / ENGINE TOP END
Servicing engine in the frame / Cylinder head cover / Cam chain tensioner / Camshaft / Cam chain and chain guides / Rocker arm assembly / Cylinder head / Valves and valve components / Cylinder block / Pistons / Specifications

CHAPTER FIVE / ENGINE LOWER END
Engine removal and installation / Alternator chain assembly / Starter clutch and alternator shaft / Oil cooler / Oil pan / Oil pump / Oil pressure switch / Crankcase / Crankshaft / Connecting rods / Balancer / Specifications

CHAPTER SIX / CLUTCH
Clutch system bleeding and draining / Clutch cover / Clutch master cylinder / Clutch slave cylinder / Clutch hose / Specifications

CHAPTER SEVEN / TRANSMISSION, BEVEL GEARCASE AND SHIFT MECHANISM
Shift pedal / Shift pedal bracket / External shift mechanism / Internal shift mechanism / Bevel gear assembly / Specifications

CHAPTER EIGHT / AIR/FUEL, EMISSION AND EXHAUST SYSTEM
Fuel tank / Fuel level sensor / Fuel valve / Air filter housing / Secondary air system / Evaporative emission control system / Carburetor / Throttle cable / Exhaust system / Specification

CHAPTER NINE / ELECTRICAL SYSTEM
Battery terminal / Charging system / Alternator / Ignition system / Starting system / Lighting system / Meter assembly / Gauges / Wiring and connectors / Switches / Junction box / Fuses / Specifications

CHAPTER TEN / COOLING SYSTEM
Hose clamps / Flushing the system / Water pump / Thermostat assembly / Coolant temperature sensor / Coolant reservoir / Coolant manifold / Radiator / Cooling fan motor / Fan switch / Radiator bracket / Specifications

CHAPTER ELEVEN / WHEELS AND TIRES
Bike stand / Brake rotor protection / Front wheel / Front hub / Rear wheel / Rear hub / Wheel balance / Tire repairs / Tire changing / Specifications

CHAPTER TWELVE / FRONT SUSPENSION AND STEERING
Front fork / Handlebars / Handlebar left grip replacement / Steering head / Lower bearing replacement / Specifications

CHAPTER THIRTEEN / REAR SUSPENSION AND FINAL DRIVE
Shock absorber / Rear suspension linkage / Swing arm / Driveshaft / Final gearcase / Specifications

CHAPTER FOURTEEN / BRAKES
Bleeding and draining brake fluid / Brake pads / Front rear brake calipers / Front rear brake master cylinder / Brake pedal footpeg assembly / Brake disc / Brake hose replacement / Specifications

CHAPTER FIFTEEN / BODY AND FRAME
Side covers / Footpegs / Lower fairing / Middle fairing / Front fairing / Fairing bracket / Tail cover / Front fender / Rear fender / Seat / Tool box / Rear frame

INDEX

COLOR WIRING DIAGRAMS

Models covered:
1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 GTR1000 GTR 1000
1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 ZG1000 ZG 1000 Concours
GTR 1000 ZG
40924092b4092p

Clymer 409 Kawasaki Concours ZG1000 GTR1000 Service Manual 1986 2004

ZG1000 Concours / GTR1000 (1986-2004)

This Kawasaki Concours Manual is over 450 pages.

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Safety / Serial numbers / Fasteners / Shop supplies / Basic tools / Precision measuring tools / Electrical system fundamentals / Basic service methods / Storage / Specifications

CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Starting the engine / Starting difficulties / Engine performance / Engine noises / Engine lubrication / Engine leakdown test / Clutch / Fuel system / Gearshift linkage / Transmission / Final drive / Electrical testing / Charging system / Ignition system / Starting system / Cooling system / Front suspension and steering / Brakes

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Maintenance schedule intervals / Spark plugs / Engine compression test / Ignition timing / Valve clearance / Engine oil and filter / Air filter / Throttle and choke cable / General lubrication / Emission control system / Specifications

CHAPTER FOUR / ENGINE TOP END
Servicing engine in the frame / Cylinder head cover / Cam chain tensioner / Camshaft / Cam chain and chain guides / Rocker arm assembly / Cylinder head / Valves and valve components / Cylinder block / Pistons / Specifications

CHAPTER FIVE / ENGINE LOWER END
Engine removal and installation / Alternator chain assembly / Starter clutch and alternator shaft / Oil cooler / Oil pan / Oil pump / Oil pressure switch / Crankcase / Crankshaft / Connecting rods / Balancer / Specifications

CHAPTER SIX / CLUTCH
Clutch system bleeding and draining / Clutch cover / Clutch master cylinder / Clutch slave cylinder / Clutch hose / Specifications

CHAPTER SEVEN / TRANSMISSION, BEVEL GEARCASE AND SHIFT MECHANISM
Shift pedal / Shift pedal bracket / External shift mechanism / Internal shift mechanism / Bevel gear assembly / Specifications

CHAPTER EIGHT / AIR/FUEL, EMISSION AND EXHAUST SYSTEM
Fuel tank / Fuel level sensor / Fuel valve / Air filter housing / Secondary air system / Evaporative emission control system / Carburetor / Throttle cable / Exhaust system / Specification

CHAPTER NINE / ELECTRICAL SYSTEM
Battery terminal / Charging system / Alternator / Ignition system / Starting system / Lighting system / Meter assembly / Gauges / Wiring and connectors / Switches / Junction box / Fuses / Specifications

CHAPTER TEN / COOLING SYSTEM
Hose clamps / Flushing the system / Water pump / Thermostat assembly / Coolant temperature sensor / Coolant reservoir / Coolant manifold / Radiator / Cooling fan motor / Fan switch / Radiator bracket / Specifications

CHAPTER ELEVEN / WHEELS AND TIRES
Bike stand / Brake rotor protection / Front wheel / Front hub / Rear wheel / Rear hub / Wheel balance / Tire repairs / Tire changing / Specifications

CHAPTER TWELVE / FRONT SUSPENSION AND STEERING
Front fork / Handlebars / Handlebar left grip replacement / Steering head / Lower bearing replacement / Specifications

CHAPTER THIRTEEN / REAR SUSPENSION AND FINAL DRIVE
Shock absorber / Rear suspension linkage / Swing arm / Driveshaft / Final gearcase / Specifications

CHAPTER FOURTEEN / BRAKES
Bleeding and draining brake fluid / Brake pads / Front rear brake calipers / Front rear brake master cylinder / Brake pedal footpeg assembly / Brake disc / Brake hose replacement / Specifications

CHAPTER FIFTEEN / BODY AND FRAME
Side covers / Footpegs / Lower fairing / Middle fairing / Front fairing / Fairing bracket / Tail cover / Front fender / Rear fender / Seat / Tool box / Rear frame

INDEX

COLOR WIRING DIAGRAMS

Models covered:
1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 GTR1000 GTR 1000
1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 ZG1000 ZG 1000 Concours
GTR 1000 ZG
409409b

Kawasaki Z KZ 900 1000 Chain Shaft Drive 1973-1981 Service Manual M359-3

This vintage Kawasaki motorcycle manual is 384 pages.

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Service hints / Safety first / Expendable supplies / Shop tools / Emergency tool kit /Troubleshooting and tune-up equipment / Specifications

CHAPTER TWO / TROUBLESHOOTING
Starting difficulties / Poor performance / Clutch and transmission / Drive train / Chassis / Electrical system / Charging system / Lighting / Fuses / Wiring

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Scheduled maintenance / Weekly maintenance / Drive chain adjustment / Throttle adjustment/ Chain oil pump adjustment / Monthly maintenance / Six month maintenance / Tune-up / Air cleaner / Fuel system cleaning / Spark plugs / Cam chain adjustment / Air suction valves / Valve clearance / Contact points / Ignition timing / Throttle cable adjustment / Carburetors / Cylinder compression / Lubrication / Engine oil and filter / Chassis maintenance / Specifications

CHAPTER FOUR / ENGINE
Engine design / Break-in / Cam chain and tensioner / Camshafts / Valves / Cylinder block and pistons / Engine removal/installation / Oil pump / Crankcase / Crankshaft and cam chain / Specifications

CHAPTER FIVE / CLUTCH
Operation / Cable replacement / Release / Plates and hub / Specifications

CHAPTER SIX / TRANSMISSION
Transmission outer parts / Drive sprocket cover / Chain oil pump / Drive sprocket / Shift linkage / Front bevel drive / Transmission internal parts / Shift drum and forks / Input shaft / Output shaft / Kickstarter / Specifications

CHAPTER SEVEN / FUEL AND EXHAUST SYSTEMS
Fuel tank / fuel tap / Carburetors / Carburetor adjustment / Carburetor service / Accelerator pump / Air suction system / Crankcase breather / Exhaust system / Specifications

CHAPTER EIGHT / BRAKES
Brake fluid bleeding / Brake fluid change / Front brake pads / Front brake caliper / Rear brake pads / Rear brake caliper / Brake discs / Master cylinders / Rear drum brake / Specifications

CHAPTER NINE / WHEELS AND TIRES
Front wheel / Rear wheel / Wheel inspection / Tire changing / Inner tube repair / Tubeless tires / Specifications

CHAPTER TEN / CHASSIS
Front fork / Steering play / Steering head / Rear shock absorbers / Swing arm / Drive chain / Rear bevel drive / Drive shaft / Specifications

CHAPTER ELEVEN / ELECRICAL SYSTEM
Fuses / Battery / Charging system / Charging system test / Alternator / Ignition system / Spark plugs / Ignition advance / Condenser / Ignition coil / Pickup coils / IC igniter / Starting system / Starter clutch / Starter solenoid / Lighting system / Fuel gauge / Z1R circuits / Horn / Specifications

SUPPLEMENT / 1980-1981 SERVICE INFORMATION

INDEX

WIRING DIAGRAMS

Z1 (1973-1974)
KZ900 (1975-1976)
KZ1000 (1977-1978)
KZ1000 Standard (1979-1980)
KZ1000 Classic (1980)
KZ1000 Limited (1977-1980)
Z1R (1978-1980)
KZ1000 C Series Police (1978-1981)
35933593b3593p

Clymer Kawasaki KZ650 1977-1983 Service Repair Manual M358

This Kawasaki KZ650 Manual is 320 pages.

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Service hints / Safety first / Parts replacement / Expendable supplies / Tools / Serial numbers / General specifications

CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Emergency troubleshooting / Starter / Charging system / Engine / Engine noises / Excessive vibration / Lubrication troubles / Fuel system / Clutch / Transmission / Brakes / Lighting system / Fuses / Wiring / Front suspension and steering / Specifications

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Routine checks / Service intervals / Tires / Battery / Periodic lubrication / Engine oil and filter / Fork oil change / Drive chain lubrication / Contact breaker points lubrication / Periodic maintenance / Drive chain cleaning and lubrication / Clutch adjustment / Camshaft chain tensioner adjustment / Fuel system cleaning / Fuel shut off valve / Air filter / Tune-up / Valve clearance measurement and adjustment / Spark plugs / Breaker point inspection and cleaning / Contact breaker points gap / Ignition timing / Initial carburetor mechanical synchronization / Carburetor idle speed lubrication / Carburetor final synchronization Storage / Specifications

CHAPTER FOUR / ENGINE
Engine principles / Servicing engine in frame / Engine / Cylinder head / Valve and valve components / Camshaft / Camshaft chain / Cylinder / Pistons and connecting rods / Piston rings / Ignition advance mechanism / Alternator / Oil pump / Oil pressure relief valve / Secondary shaft and starter motor clutch / Crankcase / Crankshaft / Kickstarter / Break-in / Specifications

CHAPTER FIVE / CLUTCH AND TRANSMISSION
Clutch / Clutch release mechanism / Clutch cable / Drive sprocket / Shifting mechanism (external) / Transmission / Gearshift drum and forks / Specifications

CHAPTER SIX / FUEL AND EXHAUST SYSTEMS
Air cleaner / Carburetors / Fuel shutoff valve / Fuel tank / Exhaust system / Air injection system / Specifications

CHAPTER SEVEN / ELECTRICAL SYSTEM
Charging system / Battery / Alternator / Voltage regulator (1977) / Rectifier (1977) / Voltage regulator/rectifier (1978 and later) / Ignition system / Ignition coil / Ignition advance mechanism / Spark plugs / Starting system / Lighting system / Horn / Fuses / Specifications

CHAPTER EIGHT / FRONT SUSPENSION AND STEERING
Front wheel / Front hub / Wheels / Tire changing / Tire repairs / Handlebar / Steering head / Front fork / Specifications

CHAPTER NINE / REAR SUSPENSION
Rear wheel / Rear hub / Sprocket assembly / Drive chain / Rear swing arm / Shock absorbers / Specifications

CHAPTER TEN / BRAKES
Front disc brakes / Front brake pad replacement / Front calipers / Front brake hose replacement / Rear drum brake (Model B) / Rear disc brake (Models C and D) / Rear master cylinder / Rear brake pad replacement (Model D) / Rear caliper (Models C and D) / Brake disc (front and rear) / Bleeding the system / Specifications

CHAPTER ELEVEN / FRAME
Kickstand (sidestand) / Footpegs / Centerstand / Frame / Specifications

SUPPLEMENT / 1980 AND LATER SERVICE INFORMATION

INDEX

WIRING DIAGRAMS

Models covered:
1977 1978 1979 1980 1981 1982 1983 Kawasaki KZ650B KZ650 KZ 650 B
1977 1978 1979 1980 1981 1982 1983 Kawasaki KZ650C KZ650 KZ 650 C (Custom) KZ650C 650C
1977 1978 1979 1980 1981 1982 1983 Kawasaki KZ650D KZ650 KZ 650 D (SR) KZ650SR 650SR
1977 1978 1979 1980 1981 1982 19833 Kawasaki KZ650E KZ650 KZ 650 E (LTD) KZ650LTD 650LTD
1977 1978 1979 1980 1981 1982 1983 Kawasaki KZ650F KZ650 KZ 650 F
1977 1978 1979 1980 1981 1982 1983 Kawasaki KZ650H KZ650 KZ 650 H (CSR)

358358b358p

Kawasaki VN1500 Vulcan 1987-1999 Service and Repair Manual M357-2

This Kawasaki Vulcan 1500 Manual is 456 pages.

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Notes / cautions and warnings / Safety first / Service hints / Washing the bike / Torque specifications / Special tips / Fasteners / Lubricants / Threadlocking compound / Expendable supplies / Serial numbers / Warning and information labels / Basic hand tools / Precision measuring tools / Special tools / Fabricating tools / Mechanic’s tips / Ball bearing replacement / Seals / Riding safety / Storage

CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Troubleshooting instruments / Starting the engine / Starting difficulties / Poor idle speed performance / Engine starting system / Charging system / Ignition system / Fuel system / Engine overheating / Engine / Engine noises / Cylinder leakage test / Clutch / Transmission / Final drive / Handling / Frame noise / Brakes

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Routine checks / Pre-ride inspection / Service intervals / Tires and wheels / Battery / Battery electrical cable connectors / Periodic lubrication / Engine oil and filter change / Oil pump screen / Final drive oil change / Front fork oil change / Periodic maintenance / Throttle adjustment / Air filter element / Unscheduled maintenance / Coolant change / Vacuum line inspection / Fuel line inspection / Tune-up / Compression test / Spark plug / Ignition timing / Carburetor idle speed adjustment / Carburetor synchronization / Specifications

CHAPTER FOUR / ENGINE UPPER END
Engine principles / Engine / Rocker arm case / Rocker arm assemblies / Hydraulic lash adjusters / Camshafts / Camshaft chain tensioner / Camshaft chain and guides / External oil line / Cylinder head / Valves and valve components / Cylinder block / Pistons and piston rings / Specifications

CHAPTER FIVE / ENGINE LOWER END
Right-hand crankcase cover / Left-hand crankcase outer cover / Front bevel gear case / Primary drive gear and water pump drive mechanism / Starter motor gears / Oil pump / Balancer weights and shaft / Crankcase / Crankshaft and connecting rods / Break-in / Specifications

CHAPTER SIX / CLUTCH AND EXTERNAL SHIFT MECHANISM
External gearshift mechanism / Clutch / Clutch hydraulic system / Master cylinder / Slave cylinder / Bleeding the system / Specifications

CHAPTER SEVEN / TRANSMISSION AND INTERNAL SHIFT MECHANISM
Transmission / Internal gearshift mechanism / Specifications

CHAPTER EIGHT / FUEL / EMISSION CONTROL AND EXHAUST SYSTEMS
Fuel system identification / Air filter surge tank / Carburetor operation / Carburetor / Carburetor adjustments / Throttle cable replacement / Fuel tank / Fuel shutoff valve / Fuel pump / Fuel filter and hoses / Crankcase breather system (U.S. only) / Evaporative emission control system (California models only) / Exhaust system / Specifications

CHAPTER NINE / ELECTRICAL SYSTEMS
Basic information / Electrical connectors / Charging system / Voltage regulator/rectifier / Alternator / Transistorized ignition system / Starting system / Lighting system / Switches / Electrical components / Horn / Fuel pump / Cooling fan circuit / Thermostatic fan switch / Fuel level system (A models only) / Junction box and fuses / Wiring and connectors / Wiring diagrams / Specifications

CHAPTER TEN / COOLING SYSTEM
Hoses and hose clamps / Cooling system inspection / Coolant reservoir / Radiator and radiator fan / Cooling fan / Thermostat / Water pump impeller and mechanical seal / Specifications

CHAPTER ELEVEN / FRONT SUSPENSION AND STEERING
Front wheel / Front hub / Wheels / Tires / Tire changing / Tire repairs / Handlebar / Steering head and stem / Steering head bearing races / Front fork / Specifications

CHAPTER TWELVE / REAR SUSPENSION AND FINAL DRIVE
Rear wheel / Rear hub / Final drive unit / Swing arm and drive shaft / Shock absorbers / Specifications

CHAPTER THIRTEEN / BRAKE SYSTEM
Disc brakes / Front brake pad replacement / Front brake caliper / Front master cylinder / Rear brake pad replacement / Rear brake caliper / Brake caliper disassembly/inspection assembly (all models) / Rear master cylinder / Brake hose replacement / Brake disc / Bleeding the system / Rear brake pedal / Specifications

CHAPTER FOURTEEN / BODY AND FRAME
Seats / Frame side covers / Frame head side covers / Footpegs / Sidestand / Front fender / Specifications

INDEX

WIRING DIAGRAMS

Models covered:
1987 1988 1989 1990 1991 1992 1993 1994 1995 KAWASAKI VN-15 A1-A9 (Except US and Canada)
1994 1995 1996 1997 KAWASAKI VN-15 C1-C4 (Except US and Canada)
1987 1988 1989 1990 1991 1992 KAWASAKI VN-15SE B1-B4 (Except US and Canada)
1996 1997 1998 1999 KAWASAKI Vulcan 1500 A10-A13 (US and Canada)
1996 1997 KAWASAKI Vulcan 1500 C3-C4 (US and Canada)
1987 1988 1989 1990 1991 1992 1993 1994 1995 KAWASAKI Vulcan 88 A1-A9 (US and Canada)
1987 1988 1989 1990 1991 1992 KAWASAKI Vulcan 88 B1-B4 (US and Canada)

357-2357-2b

Kawasaki KZ Z EN 400 440 450 500 454 LTD 1974 1995 Service Manual Clymer M355

Save money on repair and maintenance jobs. This manual covers the KZ400A, S, KZ400B, KZ400C, KZ400G, KZ400H, KZ400A, D, KZ440B, KZ440C, KZ440G, KZ440H, Z440A, C, D,EN450A 454 LTD, EN500A and Vulcan 500 Kawasaki made from 1974 to 1995. It has chapters on troubleshooting , fuel system overhaul and adjustment , plus brakes and every other system onboard. As with all Clymer publications this manual has step by step instructions for each repair procedure , complete with multiple illustrations. There are wiring diagrams and specification charts , plus many great tips on types of tools , fasteners , and specialty chemicals used in motorcycle maintenance. Not only save money on repairs , but know that it was done correctly. It is all in this manual.
This Kawasaki Motorcycle Manual is 392 pages.

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Notes, cautions and warnings / Safety first / Service hints / Torque specifications / Fasteners / Lubricants / Parts replacement / Basic hand tools / Test equipment / Mechanic’s tips / Specifications

CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Troubleshooting instruments / Engine starting / Engine performance / Engine noises / Engine lubrication / Clutch / Transmission / Charging system / Starting system / Electrical problems / Ignition system / Breaker point ignition troubleshooting / Breakerless ignition troubleshooting / Excessive vibration / Front suspension and steering / Brake problems / Carburetor troubleshooting

CHAPTER THREE / PERIODIC LUBRICATION, MAINTENANCE AND TUNE-UP
Routine checks / Maintenance intervals / Tires / Battery / Periodic lubrication / Engine oil and filter / Fork oil change / Periodic maintenance / Drive chain inspection and adjustment / Final drive belt inspection and adjustment / Clutch adjustment / Throttle adjustment / Front fork air adjustment / Coolant change / Tune-up / Air filter element / Cam chain tension / Valve clearance adjustment / Compression test / Spark plugs / Breaker point ignition / Contact point inspection / Contact point gap / Ignition timing / Electronic ignition / Carburetor / idle aped / Carburetor synchronization / Specifications

CHAPTER FOUR / ENGINE KZ400 AND KZ440
Engine / Cylinder head and cylinder head cover / Automatic cam chain tensioner / Valves and valve components / Cylinder / Pistons and piston rings / Oil pump / Oil pressure relief valve / Alternator and starter / Engine sprocket cover / Engine sprocket or pulley / Crankcase / Kickstarter / Balancer / Crankshaft and connecting rods / Specifications

CHAPTER FIVE / ENGINE 1985-ON
Engine removal installation / Cylinder head and camshafts / Rocker arm assemblies / Cam chain tensioner / Valves and valve components / Cylinder / Pistons and piston rings / Oil pump / Oil pressure relief valve / Oil level switch / Neutral switch / Alternator / starter drive mechanism and starter / Crankcase / Crankshaft and connecting rods / Balancer shaft / Specifications

CHAPTER SIX / CLUTCH AND PRIMARY CHAIN
Clutch and primary chain / Specifications

CHAPTER SEVEN / TRANSMISSION
Shift mechanism / 5-speed transmission / 6-speed transmission / Specifications

CHAPTER EIGHT / FUEL AND EMISSION CONTROL SYSTEMS
Carburetor / Carburetor adjustment / Emission control / Specifications

CHAPTER NINE / ELECTRICAL SYSTEM
Charging system / Breaker point ignition / Transistorized ignition / Transistorized ignition / Electric starter / Lighting system / Switches / Horn / Fuses / Specifications

CHAPTER TEN / COOLING SYSTEM
Cooling system inspection / Radiator and fan / Thermostat / Water pump / Hoses / Thermostatic fan switch and water temperature sensor / Specifications

CHAPTER ELEVEN / FRONT SUSPENSION AND STEERING
Front wheel / Front hub / Wheel balance / Tire changing / Tire repairs / Steering head / Front fork / Specifications

CHAPTER TWELVE / REAR SUSPENSION
Rear wheel / Rear hub / Rear wheel coupling / Drive chain / Wheel balancing / Tire changing / Drive belt and pulleys / Rear swing arm / Shock absorbers / Specifications

CHAPTER THIRTEEN / BRAKES
Front disc brakes / Front brake pad / Front caliper / Master cylinder / Front brake hose / Front brake disc / Drum brakes / Bleeding the system / Specifications

SUPPLEMENT / EN500 SERVICE INFORMATION

Models covered:
KZ400A, S (U.S.) (1974-1978)
KZ400B (U.S.) (1978-1980)
KZ400B (Canada) (1978-1980)
KZ400B (Europe) (1978-1980)
KZ400C (U.S.) (1978)
KZ400G (U.S.) (1980-1981)
KZ400G (Canada) (1980-1981)
KZ400G (Europe ) (1980-1981)
KZ400H (U.S.) (1979-1981)
KZ400H (Canada) (1979-1981)
KZ400H (Europe) (1979-1981)
KZ400A, D (U.S.) (1980-1983)
KZ400A, D (Canada) (1980-1983)
KZ440B (U.S.) (1980-1981)
KZ440B (Canada) (1980-1981)
KZ440C (Canada) (1981)
KZ440G (U.S.) (1982-1983)
KZ440G (Canada) (1982-1983)
KZ440H (Europe) (1982-1983)
Z440A, C, D (Europe) (1980-1983)
EN450A (1985-1990)
EN500A (1990-1995)

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Kawasaki VN800 Vulcan Classic 1995-2005 Service Repair Manual M354-3

This Kawasaki Vulcan Manual is 408 pages.

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Notes, cautions and warnings / Safety first / Service hints / Washing the bike / Special tips / Torque specifications / Fasteners / Lubricants / RTV gasket sealant / Gasket remover / Threadlocking compound / Expendable supplies / Serial numbers / Warning and information labels / Basic hand tools / Precision measuring tools / Special tools / Fabricating tools / Mechanic’s tips / Ball bearing replacement / Seals / Riding safety / Storage / Specifications

CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Troubleshooting instruments / Starting the engine / Emergency troubleshooting / Engine starting troubleshooting / Engine performance / Engine noises / Engine lubrication / Clutch / Gearshift linkage / Transmission / Electrical troubleshooting / Test equipment / Basic test procedures / Electrical problems / Charging system troubleshooting / Ignition system troubleshooting / Starter system troubleshooting / Carburetor troubleshooting / Excessive vibration / Front suspension and steering / Brake problems

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Routine checks / Pre-checks / Service intervals / Tires and wheels / Battery / New battery installation / Battery electrical cable connectors / Periodic lubrication / Engine oil and filter change / Engine oil pressure test / Fork oil change / Periodic maintenance / Drive chain cleaning and lubrication / Drive chain adjustment / Throttle adjustment / Air filter replacement / Coolant change / Tune-up / Valve clearance adjustment / Compression test / Spark plugs / Ignition timing / Carburetor idle mixture / Specifications

CHAPTER FOUR / ENGINE UPPER END
Engine principles / Servicing engine in frame / Cylinder head cover / Camshaft / Rocker arms/rocker shaft / Cam chain and chain guides / Cylinder head / Cylinder head inspection / Cam chain tensioner body inspection / Cylinder block / Valves and valve components / Pistons and piston rings / Break-in / Specifications Specs

CHAPTER FIVE / ENGINE LOWER END
Engine / Oil pump / Primary drive gear / Balancer assembly and starter gears / Crankcase / Crankshaft and connecting rods / Break-in / Specifications Specs

CHAPTER SIX / CLUTCH
Clutch cable / Clutch cover / Clutch / Clutch release assembly / Specifications Specs

CHAPTER SEVEN / TRANSMISSION AND GEARSHIFT MECHANISMS
Shift pedal/lever assembly / External shift mechanism / Transmission and internal shift mechanism / Specifications Specs

CHAPTER EIGHT / FUEL / EMISSION CONTROL AND EXHAUST SYSTEMS
Carburetor operation / Carburetor service / Carburetor / Carburetor service / Carburetor adjustments / Fuel system cleanliness inspection / Throttle cable replacement / Choke cable replacement / Air filter / Fuel tank / Fuel shutoff valve and filter / Crankcase breather system (U.S. only) / Evaporative emission control system (California models only) / Vacuum switch valve / Air suction valve / Exhaust system / Specifications Specs

CHAPTER NINE / ELECTRICAL SYSTEM
Electrical connectors / Battery negative terminal / Charging system / Voltage regulator/rectifier / Alternator / Transistorized ignition system / Starter system / Electric starter / Starter relay / Lighting system / Switches / Electrical components / Junction box / Main fuse / Wiring diagrams / Specifications Specs

CHAPTER TEN / COOLING SYSTEM
Hoses and hose clamps / Cooling system inspection / Coolant reservoir / Radiator and radiator fan / Radiator fan / Thermostat / Water pump / Specifications Specs

CHAPTER ELEVEN / FRONT SUSPENSION AND STEERING
Front wheel / Front hub / Wheels / Tires / Tire changing / Tire repairs / Handlebar / Steering head and stem / Steering head bearing races / Front fork / Specifications Specs

CHAPTER TWELVE / REAR SUSPENSION
Rear wheel / Rear hub / Rear wheel coupling and rear sprocket / Drive chain / Tire changing and tire repair / Shock absorber / Swing arm and shock linkage / Specifications Specs

CHAPTER THIRTEEN / BRAKES
Front disc brakes / Front brake pad replacement / Front brake caliper / Front master cylinder / Front brake hose replacement / Front brake disc / Bleeding the system / Rear drum brake / Rear brake pedal / Rear brake cable/rod assembly / Specifications Specs

CHAPTER FOURTEEN / FRAME
Seat / Frame side covers / Storage box / Tool box / Footpegs / Sidestand / Front fender / Rear fender / Frame / Specifications Specs

INDEX

WIRING DIAGRAMS

Models covered:
1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 KAWASAKI VN800A Vulcan
1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 KAWASAKI VN800B Vulcan Classic
VN 800 A B

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Kawasaki C D F G J M KD KE KH KM KV KX 1966 – 2001 Service Manual M350-9

This Kawasaki vintage motorcycle manual is 256 pages.

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Service hints / Tools / Expendable supplies / Mechanic’s tips

CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Starting difficulties / Poor idling / Misfiring / Flat spots / Power loss / Overheating / Backfiring / Engine noises / Piston seizure / Excessive vibration / clutch drag and slip / Poor handling / Brake problems / Lighting problems / Troubleshooting guide

CHAPTER THREE / PERIODIC MAINTENANCE
Regular maintenance / Racing maintenance / Engine tune-up / Battery service / Transmission / Clutch adjustment / Electrical equipment / Drive chain / Brakes / Wheels and tires / Fork oil / Steering head bearings / Swinging arm / Specifications Specs

CHAPTER FOUR / ENGINE, TRANSMISSION AND CLUTCH
Rotary valve engines / Engine lubrication / Preparation for engine disassembly / Engine removal / Cylinder and cylinder head / Piston, piston pin and piston rings / Left crankcase cover / Flywheel magneto and starter-generator / Engine sprocket / Right crankcase cover / Primary drive gear / Clutch / Rotary valve / Gearshift mechanism / Crankcase / Kickstarter / Crankshaft / Transmission / Drain pipe / Specifications Specs

CHAPTER FIVE / FUEL SYSTEM
Carburetion operation / Carburetor overhaul / Carburetor adjustment / Carburetor components / Miscellaneous carburetor problems / Specifications Specs

CHAPTER SIX / ELECTRICAL SYSTEM
Flywheel magneto / Magneto troubleshooting / Starter-generator / Starter-generator troubleshooting / Rectifier / High voltage cable / Capacitor discharge ignition system operation / Solid state voltage regulator / Solid state regulator/rectifier (1979 and later) / Charging system test (1979 and later) / Lights / Horn / Main switch / Battery / Specifications Specs

CHAPTER SEVEN / FRAME, SUSPENSION AND STEERING
Handlebars / Wheels and tires / Brakes / Front fork / Steering system / Shock absorbers / Fenders / Swinging arm / Rear sprocket / Fuel and oil tank / Seat / Stands and footrests / Exhaust pipe and muffler / Drive chain / Specifications Specs

INDEX

WIRING DIAGRAMS for KE100 and KE125 only

Models covered:
1967 1986 1969 KAWASAKI C2 SERIES
1966 KAWASAKI D1
1967 KAWASAKI F2
1968 1969 1970 KAWASAKI F3
1969 1970 KAWASAKI F4
1970 1971 KAWASAKI F5
1971 1972 1973 KAWASAKI F6
1971 1972 1973 1974 1975 KAWASAKI F7
1971 1972 KAWASAKI F8
1972 1973 1974 1975 KAWASAKI F9
1969 1970 1971 1972 1973 1974 1975 KAWASAKI G SERIES
1965 1966 1967 KAWASAKI J1 SERIES
1976 1977 1978 1979 KAWASAKI KD100
1975 1976 1977 1978 1979 KAWASAKI KD125
1976 1977 1978 1979 KAWASAKI KD175
1975 1976, 1980 1981 1982 1983 1984 1985 1986 1987 KAWASAKI KD80
1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1888 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 KAWASAKI KE100
1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 KAWASAKI KE125
1976 1977 1978, 1980 1981 1982 KAWASAKI KE175
1976 KAWASAKI KH100
1976 1977 1978 1979 1980 1981 KAWASAKI KM100
1974 1975 KAWASAKI KS125
1976 KAWASAKI KV100
1974 1975 1976 KAWASAKI KX125
1973 1974 1975 KAWASAKI M SERIES
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