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Grommets 9. Front Master Cylinder Run the turn signal light lead in front of the upper brake hose [3]. Snap-on Strap [3] and [20] except for throttle cables 3. Throttle Cable decelerator 5. Rear Brake Caliper Brake Pedal 2. Brake Hose Holders View 3. Rear Brake Hose Clevis 4. Brake Hose White Marks Position here. Rear Brake Reservoir Cover 5. Clamps Fuel Return Hose 2.
Fuel Tank Breather Hose 3. Separator Breather Hose 4. Canister Purge Hose 5. Fuel Tank Filler 2. Fuel Tank Breather Pipe 4. Filler Drain Pipe 5. Fuel Tank 6. Separator 7. Canister 8. Clips for [13] and [15] 9. Fuel Tank 2. Left Air Cleaner Base 3. Canister CAL 5. Fuel Breather Hose right, blue 6. Rear View 7. Ignition Coils 4. Ignition Switch 5. Starter Motor 6. Water Temperature Switch 7. Pickup Coils 9. Alternator Sidestand Switch Ignition Coils see preceding page 4.
Ignition Switch see preceding page 5. Starter Motor see preceding page 6. Water Temperature Switch see preceding page 7. Throttle Cable accelerator 2. Throttle Cable decelerator 3. Choke Cable 4. In-tank Fuel Filter 5. To vacuum sensor 6. Atmospheric Pressure Sensor 7.
Vacuum Sensor 8. Fuel Pump Gasket 9. In-tank Fuel Pump electric Page 83 T3: 2. SS: Apply silicone sealant Kawasaki Bond: Pickup Coil 1 3. Pickup Coil 2 4. Pressure Regulator 5. Throttle Sensor front view 6. Engine Stop Switch 1. Do not use any other battery except for a 12 V battery as a power source.
Be sure to install the oil filler cap [A] after filling the engine oil, using the filler cap driver [B]. If the free play is incorrect, adjust the throttle cable. The DFI system has an automatic choke system, using ISC valves, a water temperature sensor, and an atmo- spheric pressure sensor, which provide startability.
Page High Altitude Performance Adjustment Any modification is not necessary in this model since the atmospheric pressure sensor senses atmospheric pres- sure change due to high altitude and the ECU compen- sates the change.
Tampering with the screw could cause malfunction of the choke lever. These nuts and lower air cleaner duct are sold as a unit. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
Part No. If the dampers are damaged or deteriorated, replace them. Replace the gasket if it is damaged. Although no adjustments are required, a thorough visual inspection must be made at the intervals specified by the Periodic Maintenance Chart. If the separator has any cracks or damage, replace it with a new one. In addition, the condition of the problem is stored in the memory of the ECU electronic control unit. Page After measurement, remove the needle adapters and ap- ply silicone sealant to the seals [A] of the connector [B] for waterproofing.
A fully charged battery is a must for conducting accurate tests of the DFI system. This enables to check a long harness for continuity. Inspection starts.
This can be identified by engine sound or vibration. J : Knock A periodic, rattling, thumping or pounding noise caused by spontaneous ignition of the air-fuel mixture in a cylinder, leading to engine damage.
Year of initial registration Model Engine No. Frame No. Date problem occured Mileage Environment when problem occurred. Such a shock to the ECU can damage it. If necessary, disconnect the ECU connectors. If the connector is clogged with mud or dust, blow it off with compressed air. Replace the main harness if the terminals of the main harness connectors are cracked, bent, or otherwise dam- aged.
When the engine is cold, each ISC valve is opened according to the coolant temperature by the ECU, providing good starta- bility in cold weather and allowing the engine to run fast for quick warm up fast idle. Such a shock to the valve can damage it.
This circuit includes parts [D], and wiring [E]. But even if the repair has been done, the ignition switch is turned OFF, or the battery is disconnected, all the fault codes remain in the ECU, which need not be absolutely eraced.
This method is called D-J method. As engine speed increases, and the en- gine load turns middle to heavy, the ECU determines injection quantity by calculating from throttle opening throttle sensor output voltage and engine speed.
The ECU senses this voltage change and determines fuel injection quantity, and ignition timing according to engine rpm, and throttle opening. Page If the reading is out of the standard range, inspect the throttle sensor resistance. Silicone Sealant- Kawasaki Bond: Such a shock to the part can damage it. Page Output Voltage Inspection Turn the ignition switch OFF, remove the needle adapters and apply silicone sealant to the seals of the sensor con- nector for waterproofing.
Page If the output voltage is out of the usable range, replace the sensor. Silicone Sealant- Kawasaki Bond: If the wiring is good, check the sensor resistance. Page If the wiring is good, check the water temperature sensor resistance. Such a shock to the sensor can damage it. Page Output Voltage Inspection Remove the needle adapters. Note the following. If you know the local atmospheric pressure using a barometer, substitude the atmospheric pressure for Pv Throttle Vacuum in the vacuum sensor chart see Vac- uum Sensor section in this chapter.
Page Remove the needle adapters, and apply silicone sealant to the seals of the vehicle-down sensor connector for wa- terproofing. Silicone Sealant- Kawasaki Bond: If the output voltage is normal, the wiring is suspect.
Check the wiring. If the wiring is good, check the ECU for its ground and power supply see this chapter. Such a shock to the pump can damage it.
If the fuel filter is suspected of clogging or being damaged, replace it with the fuel pump as a set. Coolant Flow Chart Coolant Deterioration Inspection Coolant Level Inspection Coolant Draining Coolant Filling Pressure Testing G: Apply grease. When the engine starts, the water pump turns and the coolant circulates. The thermostat is a wax pellet type which opens or closes as coolant temperature changes. The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.
Water Pump 2. Water Jacket 3. Cylinder Head 4. Water Pipe 5. Water Hose 6. Radiator Cap 7. Thermostat 8. Reserve Tank Hose 9. Radiator Radiator Fan Throttle Assy Front If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded.
I'm a happy customer, thanks for the service. Don Davis verified customer July 9, Excellent manual which arrived free of shipping charges within a week of placing order. What's not to like? I would do it again.
Michael McDonough April 6, Tim L Moore verified customer January 19, Manual arrived in perfect condition in a timely manner. This is the second time I have purchased from you and have had excellent service both times. Will definately do business with you again and reccomend others!
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