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Kawasaki Z750s 2005 – 2006 Workshop Repair Service Manual – PDF DOWNLOAD
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Description
Kawasaki Z750s 2005 – 2006 Workshop Repair Service Manual
FILE DETAILS:
LANGUAGE:ENGLISH
PAGES:567
DOWNLOADABLE:YES
FILE TYPE:PDF
KAWASAKI Z750S 2005 – 2006 WORKSHOP REPAIR SERVICE MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Kawasaki Z750s 2005 – 2006 Workshop Repair Service Manual
FOREWORD:
This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics.
- In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment.
- Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may adversely affect safe operation. For the duration of the warranty period, we recommend that all repairs and scheduled maintenance be performed in accordance with this servicemanual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty.
To get the longest life out of your vehicle:
- Follow the Periodic Maintenance Chart in the Service Manual.
- Be alert for problems and non-scheduled maintenance.
- Use proper tools and genuine Kawasaki Motorcycle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki motorcycles are introduced by the Special Tool Catalog or Manual. Genuine parts provided as spare parts are listed in the Parts Catalog.
- Follow the procedures in this manual carefully. Don’t take shortcuts.
- Remember to keep complete records of maintenance and repair with dates and any new parts installed.
How to Use This Manual:
In preparing this manual, we divided the product into its major systems. These systems became the manual’s chapters. All information for a particular system from adjustment through disassembly and inspection is located in a single chapter.
- The Quick Reference Guide shows you all of the product’s system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents. The Periodic Maintenance Chart is located in the Periodic Maintenance chapter.
- The chart gives a time schedule for required maintenance operations. If you want spark plug information, for example, go to the Periodic Maintenance Chart first. The chart tells you how frequently to clean and gap the plug. Next, use the Quick Reference Guide to locate the Periodic Maintenance chapter. Then, use the Table of Contents on the first page of the chapter to find the Spark Plug section.
TABLE OF CONTENTS:
Kawasaki Z750s 2005 – 2006 Workshop Repair Service Manual
tables.................................................................................. 1 LIST OF ABBREVIATIONS............................................................... 3 New Ignition Interlock Side Stand System............................................ 21 Current Ignition Interlock Side Stand System........................................ 21 Materials of Semi-Conductor and Emitting Color...................................... 23 Units of Mass:...................................................................... 28 Units of Volume:.................................................................... 28 Units of Force:..................................................................... 28 Units of Length:.................................................................... 28 Units of Torque:.................................................................... 28 Units of Pressure:.................................................................. 28 Units of Speed:..................................................................... 28 Units of Power:..................................................................... 28 Periodic Inspection................................................................. 32 Periodic Replacement Parts.......................................................... 34 Basic Torque for General Fasteners.................................................. 39 Throttle Grip Free Play............................................................. 45 Idle Speed ......................................................................... 46 Choke Lever Free Play [C]........................................................... 46 Engine Vacuum....................................................................... 49 Main Throttle Sensor Output Voltage................................................. 50 Valve Clearance..................................................................... 54 Clutch Lever Free Play.............................................................. 58 Air Pressure (When Cold)............................................................ 59 Tread Depth......................................................................... 60 Chain Slack......................................................................... 61 Drive Chain 20-link Length.......................................................... 63 Standard Chain...................................................................... 63 Recommended Disc Brake Fluid........................................................ 65 Pad Lining Thickness................................................................ 66 Side Stand Switch Operation......................................................... 73 Recommended Engine Oil.............................................................. 77 Water and Coolant Mixture Ratio (Recommended)....................................... 80 Sample Diagnosis Sheet..............................................................117 Engine Doesn't Start, Starting Difficulty...........................................119 Poor Running at Low Speed...........................................................121 Poor Running or No Power at High Speed:.............................................124 Main Throttle Sensor Input Voltage..................................................134 Wiring Connection...................................................................134 Idle Speed..........................................................................135 Main Throttle Sensor Output Voltage.................................................135 Wiring Connection...................................................................135 Main Throttle Sensor Resistance.....................................................136 Inlet Air Pressure Sensor Input Voltage.............................................138 Inlet Air Pressure Sensor Output Voltage............................................138 Inlet Air Temperature Sensor Output Voltage.........................................143 Inlet Air Temperature Sensor Resistance.............................................144 Water Temperature Sensor Output Voltage.............................................145 Atmospheric Pressure Sensor Input Voltage...........................................147 Atmospheric Pressure Sensor Output Voltage..........................................148 Speed Sensor Input Voltage..........................................................153 Speed Sensor Output Voltage at Sensor...............................................154 Vehicle-down Sensor Power Source Voltage............................................155 Power Source Voltage at Sensor......................................................155 Vehicle-down Sensor Output Voltage..................................................156 Output Voltage at Sensor............................................................156 Subthrottle Sensor Input Voltage....................................................158 Wiring Connection...................................................................158 Main Throttle Sensor Output Voltage.................................................159 Wiring Connection...................................................................159 Throttle Sensor Resistance..........................................................160 Antenna Resistance..................................................................161 Amplifier Input Voltage.............................................................161 Input Voltage.......................................................................161 Stick Coil Input Voltage at ECU.....................................................163 Input Voltage at ECU................................................................163 Subthrottle Valve Actuator Resistance...............................................165 Subthrottle Valve Actuator Input Voltage............................................166 Input Voltage at Actuator...........................................................166 FI Indicator Light (LED) Check......................................................168 ECU Grounding Inspection............................................................170 ECU Power Source Inspection.........................................................170 Testing Relay.......................................................................172 Fuel Pressure.......................................................................173 Fuel Pressure (Idling)..............................................................174 Amount of Fuel Flow.................................................................175 Pump Operating Voltage at Pump......................................................178 Testing Relay.......................................................................179 Injector Power Source Voltage at ECU................................................181 Injector Output Voltage.............................................................182 Output Voltage at Injector Connector................................................182 Injector Wiring Inspection..........................................................182 Injector Resistance.................................................................184 Injector Fuel Line Maximum Pressure.................................................185 Radiator Cap Relief Pressure........................................................214 Thermostat Valve Opening Temperature................................................216 Vacuum Switch Valve Closing Pressure (Open → Close).................................230 Camshaft Journal, Camshaft Cap Clearance............................................235 Camshaft Journal Diameter...........................................................236 Camshaft Runout.....................................................................236 Cam Height..........................................................................236 Cylinder Compression................................................................237 Torque - Cylinder Head Bolts (M10):.................................................238 Cylinder Head Warp..................................................................239 Valve/Valve Guide Clearance (Wobble Method).........................................241 Valve Seating Surface Outside Diameter..............................................242 Valve Seating Surface Width.........................................................242 Cylinder Inside Diameter............................................................249 Piston Diameter.....................................................................249 Piston Ring/Groove Clearance........................................................250 Piston Ring Groove Width............................................................250 Piston Ring Thickness...............................................................250 Piston Ring End Gap.................................................................251 Clutch Plate Assembly...............................................................267 Friction Plate Thickness............................................................267 Friction and Steel Plate Warp.......................................................268 Clutch Spring Free Length...........................................................268 Oil Pressure........................................................................283 Connecting Rod Bend.................................................................311 Connecting Rod Twist................................................................312 Connecting Rod Big End Side Clearance...............................................312 Connecting Rod Big End Bearing Insert/Crankpin Clearance............................312 Crankpin Diameter...................................................................312 Crankpin Diameter Marks.............................................................313 Connecting Rod Big End Inside Diameter Marks........................................313 Crankshaft Side Clearance...........................................................314 Crankshaft Runout...................................................................314 Crankshaft Main Bearing Insert/Journal Clearance....................................314 Crankshaft Main Journal Diameter....................................................315 Crankshaft Main Journal Diameter Marks..............................................315 Crankcase Main Bearing Inside Diameter Marks........................................315 Shift Fork Ear Thickness............................................................324 Gear Groove Width...................................................................324 Shift Fork Guide Pin Diameter.......................................................324 Shift Drum Groove Width.............................................................324 Rim Runout..........................................................................334 Axle Runout/100 mm (3.94 in.).......................................................335 Balance Weight......................................................................336 Link Pin Outside Diameter...........................................................351 Link Plates Outside Width...........................................................351 Rear Sprocket Warp..................................................................355 Pedal Position......................................................................363 Front Disc Thickness................................................................372 Rear Disc Thickness.................................................................372 Disc Runout.........................................................................372 Oil Level (fully compressed, without spring)........................................387 Fork Spring Free Length.............................................................391 Rebound Damping Adjustment..........................................................392 Spring Preload Setting..............................................................392 Spring Preload Adjustment...........................................................392 Kawasaki-recommended chargers:......................................................458 Battery Terminal Voltage............................................................460 Terminal Voltage: 11.5 ∼ less than 12.8 V...........................................461 Terminal Voltage: less than 11.5 V..................................................461 Table 1 Alternator Output Voltage...................................................466 Table 2 Stator Coil Resistance......................................................466 Rectifier Circuit Inspection........................................................467 Charging Voltage....................................................................469 Crankshaft Sensor Peak Voltage......................................................473 Connections:........................................................................475 Camshaft Position Sensor Peak Voltage...............................................475 Ignition Coil Winding Resistance....................................................477 Primary Lead Connection.............................................................478 Stick Coil Primary Peak Voltage.....................................................478 Connection:.........................................................................479 Condition:..........................................................................479 Interlock Operation Voltage.........................................................479 Condition:..........................................................................480 Starter Motor Brush Length..........................................................485 Commutator Diameter.................................................................485 Testing Relay.......................................................................487 Testing Turn Signal Relay...........................................................493 Fan Switch Resistance...............................................................495 Water Temperature Sensor............................................................496 User Key Indicator Flashes..........................................................512 Fuel Level Sensor Resistance........................................................530 Connections:........................................................................531 Fuse Circuit Inspection.............................................................532 Relay Circuit Inspection (with the battery disconnected)............................533 Relay Circuit Inspection (with the battery connected)...............................533 Diode Circuit Inspection............................................................534 toc..................................................................................... 1 Read OWNER'S MANUAL before operating................................................ 3 EMISSION CONTROL INFORMATION.................................................... 4 1........................................................................... 4 2........................................................................... 4 3........................................................................... 4 TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED.................................. 5 Foreword........................................................................ 6 General Information............................................................. 8 Before starting to perform an inspection service or carry out a ............ 9 Battery Ground.......................................................... 9 Edges of Parts.......................................................... 9 Solvent................................................................. 9 Cleaning vehicle before disassembly..................................... 9 Arrangement and Cleaning of Removed Parts............................... 10 Storage of Removed Parts................................................ 10 Inspection.............................................................. 10 Replacement Parts....................................................... 10 Assembly Order.......................................................... 10 Tightening Sequence..................................................... 11 Tightening Torque....................................................... 11 Force................................................................... 11 Gasket, O-ring.......................................................... 11 Liquid Gasket, Non-permanent Locking Agent.............................. 11 Press................................................................... 12 Ball Bearing and Needle Bearing......................................... 12 Oil Seal, Grease Seal................................................... 12 Circlips, Cotter Pins................................................... 12 Lubrication............................................................. 13 Direction of Engine Rotation............................................ 13 Electrical Wires........................................................ 13 ZR750-K1 (United States and Canada) Left Side View.......................... 14 ZR750-K1 (United States and Canada) Right Side View......................... 14 ZR750-K1 (Europe) Left Side View............................................ 15 ZR750-K1 (Europe) Right Side View........................................... 15 Subthrottle Control System.................................................. 19 Outline..................................................................... 21 Outline..................................................................... 22 Due Position of LED Installation............................................ 22 Since the emission regulations become more severe, Kawasaki has ............ 24 Honeycomb Type Catalytic Converter...................................... 24 Overview.................................................................... 25 Related Parts and Function.............................................. 25 Sequence of Operation................................................... 26 Immobilizer System Circuit.............................................. 27 Prefixes for Units:......................................................... 28 Units of Temperature:....................................................... 28 Periodic Maintenance............................................................ 30 The scheduled maintenance must be done in accordance with this c............ 32 The following tables list the tightening torque for the major fa............ 35 Inside Circlip Pliers:...................................................... 43 Fuel System (DFI)........................................................... 44 Fuel Hose Inspection (fuel leak, damage, installation condition)........ 44 Throttle Control System Inspection...................................... 45 Idle Speed Inspection................................................... 46 Idle Speed Adjustment................................................... 46 Choke Operation Inspection.............................................. 46 Air Cleaner Element Cleaning............................................ 47 Torque -............................................................ 48 Engine Vacuum Synchronization Inspection................................ 48 Special Tool -...................................................... 49 Torque -............................................................ 50 Torque -............................................................ 50 Evaporative Emission Control System Inspection (CAL).................... 51 Cooling System.......................................................... 52 Coolant Level Inspection............................................ 52 Radiator Hose and Pipe Inspection (coolant leak, damage, install.... 53 Torque -........................................................ 53 Air Suction System...................................................... 53 Air Suction System Damage Inspection................................ 53 Engine Top End.......................................................... 53 Valve Clearance Inspection.......................................... 53 Valve Clearance Adjustment.......................................... 54 VALVE CLEARANCE ADJUSTMENT CHART INLET VALVE........................ 56 VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE...................... 57 Clutch.................................................................. 58 Clutch Operation Inspection......................................... 58 Wheels/Tires............................................................ 59 Air Pressure Inspection............................................. 59 Torque -........................................................ 59 Wheel/Tire Damage Inspection........................................ 59 Tire Tread Wear, Abnormal Wear Inspection........................... 59 Wheel Bearing Damage Inspection..................................... 60 Drive Train............................................................. 61 Drive Chain Lubrication Condition Inspection........................ 61 Drive Chain Slack Inspection........................................ 61 Drive Chain Slack Adjustment........................................ 62 Torque -........................................................ 62 Wheel Alignment Inspection.......................................... 63 Drive Chain Wear Inspection......................................... 63 Chain Guide Inspection.............................................. 64 Brake System............................................................ 64 Brake Fluid Leak (Brake Hose and Pipe) Inspection................... 64 Brake Hose Damage and Installation Condition Inspection............. 64 Torque -........................................................ 64 Brake Operation Inspection.......................................... 65 Brake Fluid Level Inspection........................................ 65 Brake Pad Wear Inspection........................................... 66 Brake Light Switch Operation Inspection............................. 66 Suspensions............................................................. 67 Front Forks/Rear Shock Absorber Operation Inspection................ 67 Front Forks/Rear Shock Absorber Oil Leak Inspection................. 67 Rocker Arm Operation Inspection..................................... 68 Tie-rod Operation Inspection........................................ 68 Steering System......................................................... 68 Steering Play Inspection............................................ 68 Special Tool -.................................................. 68 Steering Play Adjustment............................................ 69 Special Tool -.................................................. 69 Torque -........................................................ 69 Steering Stem Bearing Lubrication................................... 70 Electrical System....................................................... 70 Lights and Switches Operation Inspection............................ 70 Headlight Aiming Inspection......................................... 72 Side Stand Switch Operation Inspection.............................. 73 Engine Stop Switch Operation Inspection............................. 74 Others.................................................................. 74 Chassis Parts Lubrication........................................... 74 Bolts, Nuts and Fasteners Tightness Inspection...................... 76 Replacement Parts....................................................... 77 Air Cleaner Element Replacement..................................... 77 Engine Oil Change................................................... 77 Torque -........................................................ 77 Oil Filter Replacement.............................................. 78 Special Tool -.................................................. 78 Torque -........................................................ 78 Fuel Hose Replacement............................................... 78 Coolant Change...................................................... 79 Torque -........................................................ 80 Torque -........................................................ 80 Radiator Hose and O-ring Replacement................................ 81 Brake Hose and Pipe Replacement..................................... 81 Torque -........................................................ 81 Brake Fluid Change.................................................. 82 Torque -........................................................ 83 Master Cylinder Rubber Parts Replacement............................ 83 Special Tool -.................................................. 83 Special Tool -.................................................. 84 Torque -........................................................ 84 Caliper Rubber Parts Replacement.................................... 85 Torque -........................................................ 85 Torque -........................................................ 86 Spark Plug Replacement.............................................. 87 Owner's Tool -.................................................. 88 Owner's Tool -.................................................. 88 Torque -........................................................ 88 Fuel System (DFI)............................................................... 90 DFI System.................................................................. 97 DFI System Wiring Diagram................................................... 99 DFI System Wiring Diagram (Immobilizer Equipped Models).....................101 Oil Pressure Gauge, 5 kgf/cm :..............................................108 DFI Servicing Precautions...................................................110 Torque -................................................................111 Outline.....................................................................112 Outline.................................................................112 Special Tool -......................................................113 Special Tool -......................................................115 DFI Diagnosis Flow Chart................................................116 Inquiries to Rider......................................................116 Inquiries to Rider..................................................116 NOTE........................................................................119 Self-diagnosis Outline......................................................127 Self-diagnosis Outline..................................................127 Self-diagnosis Procedures...............................................127 Self-diagnosis Procedures...........................................127 Service Code Clearing Procedures........................................128 Service Code Clearing Procedures....................................128 How to Read Service Codes...............................................130 How to Read Service Codes...........................................130 How to Erase Service Codes..............................................130 How to Erase Service Codes..........................................130 Service Code Table......................................................131 Service Code Table..................................................131 Notes:..........................................................131 Backups.................................................................132 Backups.............................................................132 Main Throttle Sensor Removal/Adjustment.....................................134 Input Voltage Inspection................................................134 Special Tool -......................................................134 Output Voltage Inspection...............................................135 Special Tool -......................................................135 Resistance Inspection...................................................136 Main Throttle Sensor Circuit............................................136 Main Throttle Sensor Circuit (immobilizer Equipped Models)..............136 CAUTION.....................................................................137 Removal.................................................................137 Installation............................................................137 Torque -............................................................137 Input Voltage Inspection................................................137 Special Tool -......................................................138 Output Voltage Inspection...............................................138 Special Tools -.....................................................139 Pv = 24 ∼ 55 cmHg.......................................................140 Pv = 55 ∼ 86 cmHg.......................................................141 Inlet Air Pressure Sensor Circuit.......................................142 Inlet Air Pressure Sensor Circuit (Immobilizer Equipped Models).........142 Removal/Installation........................................................143 Output Voltage Inspection...............................................143 Special Tool -......................................................143 Sensor Resistance Inspection............................................144 Inlet Air Temperature Sensor Circuit....................................144 Inlet Air Temperature Sensor Circuit (Immobilizer Equipped Model........144 Removal/Installation........................................................145 Torque -................................................................145 Output Voltage Inspection...............................................145 Special Tool -......................................................145 Water Temperature Sensor Circuit........................................146 Water Temperature Sensor Circuit (Immobilizer Models)...................146 Sensor Resistance Inspection........................................146 CAUTION.....................................................................147 Removal.................................................................147 Input Voltage Inspection................................................147 Special Tool -......................................................147 Output Voltage Inspection...............................................148 Atmospheric Pressure Sensor Circuit.....................................150 Atmospheric Pressure Sensor Circuit (Immobilizer Equipped Models........150 Start the engine and switch the diagnosis mode to Dealer 1 mode ............151 Crankshaft Sensor Removal/Installation..................................151 Crankshaft Sensor Inspection............................................151 Crankshaft Sensor Circuit...............................................151 Crankshaft Sensor Circuit (Immobilizer Equipped Models).................151 Start the engine and switch the diagnosis mode to Dealer 1 mode ............152 Camshaft Position Sensor Removal/Installation...........................152 Camshaft Position Sensor Inspection.....................................152 Speed Sensor Removal/Installation...........................................153 Speed Sensor Inspection.................................................153 Input Voltage Inspection................................................153 Special Tool -......................................................153 Output Voltage Inspection...............................................153 Special Tool -......................................................154 Speed Sensor Circuit....................................................154 Speed Sensor Circuit (Immobilizer Equipped Models)......................154 Removal.....................................................................155 Installation............................................................155 Torque -............................................................155 Inspection..............................................................155 Special Tool -......................................................156 Vehicle-down Sensor Circuit.............................................157 Vehicle-down Sensor Circuit (Immobilizer Equipped Models)...............157 Subthrottle Sensor Removal/Adjustment.......................................158 Input Voltage Inspection................................................158 Special Tool -......................................................158 Output Voltage Inspection...............................................159 Special Tool -......................................................159 Resistance Inspection...................................................160 Subthrottle Sensor Circuit..............................................160 Subthrottle Sensor Circuit (Immobilizer Wquipped Models)................160 Antenna Resistance Inspection...............................................161 Amplifier Input Voltage Inspection......................................161 Special Tool -......................................................161 This code appears in the following conditions. .............................162 User Key Inspection.....................................................162 Stick Coil ##1: Ignition Coil (Service Code 51).............................163 Removal/Installation....................................................163 Input Voltage Inspection................................................163 Stick Coil Circuit......................................................164 Subthrottle Valve Actuator Removal..........................................165 Audible Inspection......................................................165 Visual Inspection.......................................................165 Resistance Inspection...................................................165 Special Tool -......................................................165 Input Voltage Inspection................................................166 Special Tools -.....................................................166 Subthrottle Sensor Circuit..............................................166 Subthrottle Sensor Circuit (Immobilizer Equipped Models)................166 Inspection Flow Chart.......................................................167 FI Indicator Light (LED) Inspection.....................................168 FI Indicator light (LED) Circuit........................................168 CAUTION.....................................................................169 ECU Removal.............................................................169 ECU Installation........................................................169 ECU Power Supply Inspection.............................................169 Special Tool -......................................................170 ECU Power Source Circuit................................................171 ECU Power Source Circuit (Immobilizer Equipped Models)..................171 ECU Fuse Removal............................................................172 ECU Fuse Installation...................................................172 ECU Fuse Inspection.....................................................172 ECU Main Relay Removal..................................................172 ECU Main Relay Inspection...............................................172 Special Tool -......................................................172 Fuel Pressure Inspection....................................................173 Special Tools -.........................................................173 Fuel Flow Rate Inspection...............................................174 Fuel Pump Removal...........................................................176 Fuel Pump Installation..................................................176 Torque -............................................................177 Operation Inspection....................................................177 Operating Voltage Inspection............................................177 Special Tools -.....................................................178 Pressure Regulator Removal..............................................178 Pump Screen, Fuel Filter Cleaning.......................................178 Fuel Pump Relay Removal.....................................................179 Fuel Pump Relay Inspection..............................................179 Special Tool -......................................................179 Fuel Pump Circuit.......................................................180 Removal/Installation........................................................181 Audible Inspection......................................................181 Power Source Voltage Inspection.........................................181 Special Tool -......................................................181 Output Voltage Inspection...............................................182 Special Tool -......................................................182 Injector Signal Test....................................................183 Special Tool -......................................................183 Injector Resistance Inspection..........................................184 Special Tool -......................................................184 Injector Unit Test......................................................184 Injector Fuel Line Inspection...........................................184 Torque -............................................................185 Free Play Inspection........................................................187 Free Play Adjustment....................................................187 Cable Installation......................................................187 Cable Lubrication.......................................................187 Free Play Inspection........................................................188 Free Play Adjustment....................................................188 Choke Cable Installation................................................188 Cable Lubrication.......................................................188 Idle Speed Inspection.......................................................189 Engine Vacuum Synchronization Inspection/ Adjustment....................189 High Altitude Performance Adjustment....................................189 Throttle Body Assy Removal..............................................189 Throttle Body Assy Installation.........................................191 Torque -............................................................191 Torque -............................................................192 Torque -............................................................192 Throttle Body Assy Disassembly..........................................193 Throttle Body Assy Assembly.............................................193 Torque -............................................................193 Element Removal/Installation................................................194 Air Cleaner Element Inspection..........................................194 Air Cleaner Oil Draining................................................194 Air Cleaner Housing Removal.............................................194 Fuel Tank Removal...........................................................195 Fuel Tank Installation..................................................196 Fuel Tank and Cap Inspection............................................198 Fuel Tank Cleaning......................................................198 The Evaporative Emission Control System routes fuel vapors from ............199 Parts Removal/Installation..............................................199 Hose Inspection.........................................................199 Separator Inspection....................................................199 Separator Operation Test................................................200 Canister Inspection ....................................................200 Cooling System..................................................................202 Bearing Driver, 32:.........................................................207 Coolant Deterioration Inspection............................................208 Coolant Level Inspection................................................208 Coolant Draining........................................................208 Coolant Filling.........................................................208 Pressure Testing........................................................208 Cooling System Flushing.................................................209 Coolant Reserve Tank Removal/Installation...............................209 Water Pump Removal..........................................................210 Water Pump Installation.................................................210 Water Pump Inspection...................................................210 Water Pump Impeller Disassembly/Assembly................................210 Torque -............................................................210 Water Pump Impeller Inspection..........................................210 Water Pump Housing Disassembly..........................................210 Water Pump Housing Assembly.............................................211 Special Tool -......................................................211 Special Tool -......................................................211 Mechanical Seal Inspection..............................................211 Radiator and Radiator Fan Removal...........................................212 Radiator and Radiator Fan Installation..................................213 Torque -............................................................213 Radiator Inspection.....................................................213 Radiator Cap Inspection.................................................214 Radiator Filler Neck Inspection.........................................214 Thermostat Removal..........................................................215 Thermostat Installation.................................................215 Thermostat Inspection...................................................215 Hose Installation...........................................................217 Torque -................................................................217 Hose Inspection.........................................................217 CAUTION.....................................................................218 Radiator Fan Switch Removal.............................................218 Radiator Fan Switch Installation........................................218 Torque -............................................................218 Radiator Fan Switch Inspection..........................................218 Water Temperature Sensor Removal/Installation...........................218 Water Temperature Sensor Inspection.....................................218 Engine Top End..................................................................220 Exhaust System ZR750-K1.....................................................224 Compression Gauge, 20 kgf/cm :..............................................227 Air Suction Valve Removal...................................................229 Air Suction Valve Installation..........................................229 Torque -............................................................229 Air Suction Valve Inspection............................................229 Vacuum Switch Valve Removal.............................................229 Vacuum Switch Valve Installation........................................230 Vacuum Switch Valve Test................................................230 Special Tool -......................................................230 Clean Air System Hose Inspection........................................230 Cylinder Head Cover Removal.................................................231 Cylinder Head Cover Installation........................................231 Sealant -...........................................................231 Torque -............................................................232 Camshaft Chain Tensioner Removal............................................233 Camshaft Chain Tensioner Installation...................................233 Torque -............................................................233 Torque -............................................................233 Camshaft Removal............................................................234 Camshaft Installation...................................................234 Torque -............................................................235 Camshaft, Camshaft Cap Wear.............................................235 Torque -............................................................235 Camshaft Runout.........................................................236 Cam Wear................................................................236 Camshaft Chain Removal..................................................236 Cylinder Compression Measurement............................................237 Owner's Tool -..........................................................237 Special Tools -.........................................................237 Torque -................................................................237 Cylinder Head Removal...................................................238 Cylinder Head Installation..............................................238 Torque -............................................................238 Torque -............................................................239 Cylinder Head Warp......................................................239 Valve Clearance Inspection..................................................240 Valve Clearance Adjustment..............................................240 Valve Removal...........................................................240 Special Tools -.....................................................240 Valve Installation......................................................240 Valve Guide Removal.....................................................240 Special Tool -......................................................240 Valve Guide Installation................................................241 Special Tool -......................................................241 Special Tool -......................................................241 Valve-to-Guide Clearance Measurement (Wobble Method)....................241 Valve Seat Inspection...................................................242 Valve Seat Repair.......................................................242 Special Tools -.....................................................242 Cylinder Removal............................................................247 Cylinder Installation...................................................247 Piston Removal..........................................................248 Special Tool -......................................................248 Piston Installation.....................................................248 Cylinder Wear...........................................................249 Piston Wear.............................................................249 Piston Ring, Piston Ring Groove Wear....................................250 Piston Ring Groove Width................................................250 Piston Ring Thickness...................................................250 Piston Ring End Gap.....................................................251 Throttle Body Holder Installation...........................................252 Torque -................................................................252 WARNING.....................................................................253 Muffler Body Removal....................................................253 Exhaust Pipe Removal....................................................253 Muffler Body and Exhaust Pipe Installation..............................253 Torque -............................................................253 Clutch..........................................................................256 Clutch Holder:..............................................................260 Clutch Lever Free Play Inspection...........................................261 Clutch Lever Free Play Adjustment.......................................261 Cable Removal...........................................................261 Cable Installation......................................................261 Cable Lubrication.......................................................261 Clutch Lever Installation...............................................261 Torque -............................................................261 Clutch Lever Adjustment.................................................262 Clutch Cover Removal........................................................263 Clutch Cover Installation...............................................263 Sealant -...........................................................263 Torque -............................................................263 Release Shaft Removal...................................................263 Release Shaft Installation..............................................263 Clutch Cover Disassembly................................................264 Clutch Cover Assembly...................................................264 Clutch Removal..............................................................265 Special Tool -..........................................................265 Clutch Installation.....................................................265 Special Tool -......................................................266 Torque -............................................................266 Torque -............................................................266 Clutch Plate Assembly Inspection........................................267 Torque -............................................................267 Clutch Plate Assembly Adjustment........................................267 Torque -............................................................267 Clutch Plate, Wear, Damage Inspection...................................267 Clutch Plate Warp Inspection............................................268 Clutch Spring Free Length Measurement...................................268 Clutch Housing Finger Inspection........................................268 Clutch Housing Spline Inspection........................................268 Engine Lubrication System.......................................................270 Outside Circlip Pliers:.....................................................276 WARNING.....................................................................277 Oil Level Inspection....................................................277 Engine Oil Change.......................................................277 Oil Filter Replacement..................................................277 Oil Pan Removal.............................................................278 Oil Pan Installation....................................................278 Torque -............................................................278 Torque -............................................................278 Oil Pressure Relief Valve Removal...........................................279 Oil Pressure Relief Valve Installation..................................279 Oil Pressure Relief Valve Inspection....................................279 Oil Pump Removal............................................................280 Oil Pump Installation...................................................280 Torque -............................................................281 Torque -............................................................281 Torque -............................................................281 Oil Pump Drive Gear Removal.............................................282 Special Tool -......................................................282 Oil Pump Drive Gear Installation........................................282 Special Tool -......................................................282 Oil Pressure Measurement....................................................283 Special Tools -.........................................................283 Torque -................................................................283 Oil Pressure Switch Removal.................................................284 Oil Pressure Switch Installation........................................284 Sealant -...........................................................284 Torque -............................................................284 Torque -............................................................284 Engine Removal/Installation.....................................................286 Engine Mount Nut Wrench:....................................................289 Engine Removal..............................................................290 Special Tool -..........................................................292 Engine Installation.....................................................292 Torque -............................................................292 Torque -............................................................293 Torque -............................................................293 Special Tool -......................................................293 Torque -............................................................293 Torque -............................................................293 Torque -............................................................294 Crankshaft/Transmission.........................................................296 Bearing Puller:.............................................................303 Crankcase Splitting.........................................................304 Crankcase Assembly......................................................304 Sealant -...........................................................305 Torque -............................................................305 Sealant -...........................................................305 Torque -............................................................306 Torque -............................................................306 Torque -............................................................306 Torque -............................................................306 Crankshaft Removal..........................................................307 Crankshaft Installation.................................................307 Connecting Rod Removal..................................................307 Connecting Rod Installation.............................................307 Crankshaft/Connecting Rod Cleaning......................................311 Connecting Rod Bend.....................................................311 Connecting Rod Twist....................................................312 Connecting Rod Big End Side Clearance...................................312 Connecting Rod Big End Bearing Insert/Crankpin Wear.....................312 Crankshaft Side Clearance...............................................314 Crankshaft Runout.......................................................314 Crankshaft Main Bearing Insert/Journal Wear.............................314 Shift Pedal Removal.........................................................316 Shift Pedal Installation................................................316 Torque -............................................................316 Torque -............................................................317 Torque -............................................................317 Torque -............................................................317 External Shift Mechanism Removal........................................317 External Shift Mechanism Installation...................................318 Torque -............................................................318 Torque -............................................................318 External Shift Mechanism Inspection.....................................318 Torque -............................................................318 Transmission Shaft Removal..............................................319 Transmission Shaft Installation.........................................319 Transmission Shaft Disassembly..........................................319 Special Tool -......................................................319 Special Tools -.....................................................320 Transmission Shaft Assembly.............................................320 Shift Drum and Fork Removal.............................................323 Shift Drum and Fork Installation........................................323 Torque -............................................................323 Shift Drum Disassembly..................................................323 Shift Drum Assembly.....................................................323 Torque -............................................................323 Shift Fork Bending......................................................324 Shift Fork/Gear Groove Wear.............................................324 Shift Fork Guide Pin/Drum Groove Wear...................................324 Gear Dog and Gear Dog Hole Damage.......................................324 Wheels/Tires....................................................................326 Bearing Driver Set:.........................................................330 Front Wheel Removal.........................................................331 Special Tool -..........................................................331 Front Wheel Installation................................................331 Torque -............................................................332 Torque -............................................................332 Rear Wheel Removal......................................................332 Rear Wheel Installation.................................................333 Torque -............................................................333 Wheel Inspection........................................................334 Special Tool -......................................................334 Axle Inspection.........................................................335 Balance Inspection......................................................335 Balance Adjustment......................................................335 Balance Weight Removal..................................................335 Balance Weight Installation.............................................336 Air Pressure Inspection.....................................................338 Tire Inspection.........................................................338 Tire Removal............................................................338 Tire Installation.......................................................338 Tire Repair.............................................................340 Hub Bearing Removal.........................................................341 Special Tools -.........................................................341 Hub Bearing Installation................................................341 Special Tool -......................................................341 Special Tool -......................................................341 Hub Bearing Inspection..................................................341 Final Drive.....................................................................342 Inside Circlip Pliers:......................................................346 Drive Chain Slack Inspection................................................347 Drive Chain Slack Adjustment............................................347 Wheel Alignment Inspection/Adjustment...................................347 Drive Chain Wear Inspection.............................................347 Drive Chain Lubrication.................................................347 Drive Chain Removal.....................................................347 Drive Chain Installation................................................347 Drive Chain Replacement.................................................348 Engine Sprocket Removal.....................................................352 Engine Sprocket Installation............................................352 Torque -............................................................352 Rear Sprocket Removal...................................................353 Rear Sprocket Installation..............................................353 Torque -............................................................353 Coupling Bearing Removal................................................353 Special Tool -......................................................353 Special Tool -......................................................353 Coupling Bearing Installation...........................................353 Special Tool -......................................................353 Special Tool -......................................................353 Special Tool -......................................................354 Coupling Installation...................................................354 Coupling Bearing Inspection.............................................354 Coupling Bearing Lubrication............................................354 Coupling Damper Inspection..............................................354 Sprocket Wear Inspection................................................355 Rear Sprocket Warp Inspection...........................................355 Brakes..........................................................................356 Inside Circlip Pliers:......................................................362 Brake Lever Position Adjustment.............................................363 Brake Pedal Position Inspection.........................................363 Brake Pedal Position Adjustment.........................................363 Torque -............................................................363 Brake Pedal Removal.....................................................363 Brake Pedal Installation................................................364 Torque -............................................................364 Front Caliper Removal.......................................................365 Rear Caliper Removal....................................................365 Caliper Installation....................................................365 Torque -............................................................365 Front Caliper Disassembly...............................................366 Front Caliper Assembly..................................................366 Rear Caliper Disassembly................................................366 Rear Caliper Assembly...................................................366 Caliper Fluid Seal Damage...............................................366 Rear Caliper Dust Boot and Friction Boot Damage.........................366 Caliper Piston and Cylinder Damage......................................367 Caliper Holder Shaft Wear...............................................367 Front Brake Pad Removal.....................................................368 Front Brake Pad Installation............................................368 Rear Brake Pad Removal..................................................368 Rear Brake Pad Installation.............................................368 Brake Pad Wear Inspection...............................................368 Front Master Cylinder Removal...............................................369 Front Master Cylinder Installation......................................369 Torque -............................................................369 Torque -............................................................369 Rear Master Cylinder Removal............................................370 Rear Master Cylinder Installation.......................................370 Torque -............................................................370 Front Master Cylinder Disassembly.......................................370 Rear Master Cylinder Disassembly........................................371 Master Cylinder Assembly................................................371 Master Cylinder Inspection..............................................371 Brake Disc Removal..........................................................372 Brake Disc Installation.................................................372 Torque -............................................................372 Brake Disc Wear.........................................................372 Brake Disc Warp.........................................................372 Special Tool -......................................................372 Brake Fluid Level Inspection................................................373 Brake Fluid Change......................................................373 Brake Line Bleeding.....................................................373 Torque -............................................................374 Torque -............................................................374 Brake Hose Removal/Installation.............................................376 Brake Hose Inspection...................................................376 Suspension......................................................................378 Inside Circlip Pliers:......................................................384 Front Fork Removal..........................................................386 Front Fork Installation.................................................386 Torque -............................................................386 Torque -............................................................386 Front Fork Oil Change...................................................386 Special Tool -......................................................387 Front Fork Disassembly..................................................388 Special Tools -.....................................................388 Front Fork Assembly.....................................................389 Special Tool -......................................................389 Torque -............................................................390 Special Tools -.....................................................390 Inner Tube/Outer Tube Inspection........................................390 Dust Seal Inspection....................................................390 Fork Spring Inspection..................................................391 Rebound Damping Force Adjustment............................................392 Spring Preload Adjustment...............................................392 Rear Shock Absorber Removal.............................................393 Special Tool -......................................................393 Rear Shock Absorber Installation........................................394 Torque -............................................................394 Rear Shock Absorber Inspection..........................................394 Swingarm Removal............................................................395 Special Tool -..........................................................395 Special Tool -..........................................................395 Swingarm Installation...................................................396 Torque -............................................................396 Special Tool -......................................................396 Torque -............................................................396 Swingarm Bearing Removal................................................396 Special Tool -......................................................396 Special Tool -......................................................396 Swingarm Bearing Installation...........................................397 Special Tool -......................................................397 Swingarm Bearing, Sleeve Inspection.....................................397 Chain Guide Inspection..................................................397 Swingarm Bearing Lubrication............................................398 Tie-rod Removal.............................................................399 Special Tool -..........................................................399 Tie-rod Installation....................................................399 Torque -............................................................399 Rocker Arm Removal......................................................399 Special Tool -......................................................399 Rocker Arm Installation.................................................400 Torque -............................................................400 Tie-rod and Rocker Arm Bearing Removal..................................400 Tie-rod and Rocker Arm Bearing Installation.............................400 Special Tools -.....................................................401 Rocker Arm/Tie-rod Bearing, Sleeve Inspection...........................402 Rocker Arm/Tie-rod Bearing Lubrication..................................402 Steering........................................................................404 Steering Stem Nut Wrench:...................................................407 Steering Inspection.........................................................408 Steering Adjustment.....................................................408 Stem, Stem Bearing Removal..................................................409 Special Tool -..........................................................409 Stem, Stem Bearing Installation.........................................410 Special Tool -......................................................410 Special Tools -.....................................................410 Special Tool -......................................................411 Torque -............................................................411 Torque -............................................................411 Stem Bearing Lubrication................................................411 Steering Stem Warp......................................................412 Stem Cap Deterioration, Damage..........................................412 Handlebar Removal...........................................................413 Handlebar Installation..................................................414 Torque -............................................................414 Torque -............................................................414 Torque -............................................................414 Torque -............................................................415 Frame...........................................................................416 Seat Removal................................................................422 Seat Installation.......................................................422 Side Cover Removal..........................................................423 Side Cover Installation.................................................423 Frame Cover Removal.....................................................423 Inner Cover Removal.........................................................424 Inner Cover Installation................................................424 Inner Cover Installation................................................424 Meter Cover Removal.....................................................424 Meter Cover Installation................................................425 Windshield Removal......................................................425 Windshield Installation.................................................425 Torque -............................................................425 Fairing Removal.........................................................425 Fairing Installation....................................................426 Fairing Disassembly.....................................................426 Fairing Assembly........................................................427 Fairing Bracket Removal.................................................427 Seat Cover Removal..........................................................429 Seat Cover Installation.................................................429 Front Fender Removal........................................................430 Front Fender Installation...............................................430 Torque -............................................................430 Rear Fender Flap Removal................................................430 Rear Fender Removal.....................................................431 Rear Fender installation................................................431 Battery Case Removal....................................................432 Battery Case Installation...............................................432 Side Stand Removal..........................................................433 Side Stand Installation.................................................433 Torque -............................................................433 Torque -............................................................433 Frame Inspection............................................................434 Electrical System...............................................................436 Hand Tester:................................................................446 There are a number of important precautions that are musts when ............453 Wiring Inspection...........................................................455 Special Tool -..........................................................455 Battery Removal.............................................................456 Battery Installation....................................................456 Battery Activation......................................................456 Precautions.............................................................459 1)..................................................................459 2)..................................................................459 3)..................................................................459 4)..................................................................459 Interchange.............................................................459 Charging Condition Inspection.......................................460 Refreshing Charge...................................................460 Alternator Cover Removal....................................................462 Alternator Cover Installation...........................................462 Sealant -...........................................................462 Torque -............................................................462 Stator Coil Removal.....................................................462 Stator Coil Installation................................................463 Torque -............................................................463 Torque -............................................................463 Sealant -...........................................................463 Alternator Rotor Removal................................................463 Special Tool -......................................................463 Special Tools -.....................................................463 Alternator Rotor Installation...........................................463 Special Tool -......................................................464 Torque -............................................................464 Starter Motor Clutch Removal/Installation...............................465 Starter Motor Clutch Inspection.........................................465 Starter Motor Clutch Disassembly........................................465 Starter Motor Clutch Assembly...........................................465 Torque -............................................................465 Alternator Inspection...................................................466 Special Tool -......................................................467 Regulator/Rectifier Inspection..........................................467 Charging Voltage Inspection.............................................469 Special Tool -......................................................469 Charging System Circuit.................................................470 WARNING.....................................................................471 Crankshaft Sensor Removal...............................................471 Crankshaft Sensor Installation..........................................472 Torque -............................................................472 Sealant -...........................................................472 Torque -............................................................472 Torque -............................................................472 Crankshaft Sensor Inspection............................................473 Special Tool -......................................................473 Crankshaft Sensor Peak Voltage Inspection...............................473 Special Tools -.....................................................473 Timing Rotor Removal....................................................474 Special Tool -......................................................474 Timing Rotor Installation...............................................474 Torque -............................................................474 Camshaft Position Sensor Removal........................................474 Camshaft Position Sensor Installation...................................474 Torque -............................................................474 Camshaft Position Sensor Inspection.....................................475 Special Tool -......................................................475 Camshaft Position Sensor Peak Voltage Inspection........................475 Special Tools -.....................................................475 Stick Coil (Ignition Coil together with Spark Plug Cap) Removal.........476 Stick Coil (Ignition Coil together with Spark Plug Cap) Installa........476 Stick Coil (Ignition Coil together with Spark Plug Cap) Inspecti........477 Stick Coil Primary Peak Voltage.........................................477 Special Tools -.....................................................478 Spark Plug Removal......................................................478 Spark Plug Installation.................................................478 Spark Plug Cleaning and Inspection......................................479 Interlock Operation Inspection..........................................479 IC Igniter Inspection...................................................480 Ignition System Circuit.................................................482 Starter Motor Removal.......................................................483 Starter Motor Installation..............................................483 Torque -............................................................483 Starter Motor Disassembly...............................................483 Starter Motor Assembly..................................................484 Brush Inspection........................................................485 Commutator Cleaning and Inspection......................................485 Armature Inspection.....................................................485 Special Tool -......................................................485 Brush Lead Inspection...................................................486 Special Tool -......................................................486 Brush Plate and Terminal Bolt Inspection................................486 Special Tool -......................................................486 Starter Relay Inspection................................................486 Special Tool -......................................................487 Electric Starter Circuit................................................487 This models adopt the daylight system and have a headlight relay............488 Headlight Beam Horizontal Adjustment....................................488 Headlight Beam Vertical Adjustment......................................488 Headlight Bulb Replacement..............................................488 Headlight Removal/Installation..........................................489 City Light Bulb Replacement.............................................489 Tail/Brake Light (LED) Removal..........................................490 Tail/Brake Light (LED) Installation.....................................490 Torque -............................................................490 Headlight/Tail Light Circuit............................................491 Turn Signal Light Circuit...............................................492 Turn Signal Light Bulb Replacement..................................492 Turn Signal Relay Inspection........................................493 Fan System Circuit Inspection...............................................494 Fan Motor Inspection....................................................494 Radiator Fan Switch Inspection..........................................494 Special Tool -......................................................495 Water Temperature Sensor Inspection.....................................495 Radiator Fan Circuit....................................................497 Meter Unit Removal..........................................................498 Meter Unit Disassembly..................................................498 Bulb Replacement........................................................499 Electronic Combination Meter Unit Inspection............................499 Special Tool -......................................................499 Meter Circuit...........................................................507 This motorcycle is equipped with an immobilizer system to protec............508 Operational Cautions....................................................508 Key Registration....................................................508 Special Tool -..................................................509 Spare User Key Registration Flow Chart..................................513 Special Tool -......................................................514 All Keys Initial Registration Flow Chart................................523 Immobilizer System Parts Replacement................................524 Immobilizer System Inspection.......................................526 Immobilizer System Circuit..............................................527 Brake Light Timing Inspection...............................................528 Brake Light Timing Adjustment...........................................528 Switch Inspection.......................................................528 Special Tool -......................................................528 Rear Brake Light Switch Connections.....................................528 Side Stand Switch Connections...........................................528 Neutral Switch Connections..............................................528 Oil Pressure Switch Connections*........................................528 Speed Sensor Inspection.................................................528 Special Tool -......................................................529 Torque -............................................................529 Fuel Level Sensor Inspection............................................530 Special Tool -......................................................530 Torque -............................................................530 Fuel Reserve Switch Inspection..........................................530 Diode (Rectifier) Inspection............................................531 Special Tool -......................................................531 The junction box [A] has fuses [B], relays, and diodes. The rela............532 Junction Box Fuse Circuit Inspection....................................532 Special Tool -......................................................532 Starter Circuit/Headlight Relay Inspection..............................533 Special Tool -......................................................533 Diode Circuit Inspection................................................534 Junction Box Internal Circuit...........................................534 30 A Main Fuse Removal......................................................535 Junction Box Fuse Removal...............................................535 15 A ECU Fuse Removal...................................................535 Fuse Installation.......................................................535 Fuse Inspection.........................................................536 Appendix........................................................................538 NOTE........................................................................563 Engine Doesn't Start, Starting Difficulty:..............................563 Starter motor not rotating:.........................................563 Starter motor rotating but engine doesn't turn over:................563 Engine won't turn over:.............................................563 No fuel flow:.......................................................563 Engine flooded:.....................................................563 No spark; spark weak:...............................................563 Fuel/air mixture incorrect:.........................................563 Compression Low:....................................................563 Poor Running at Low Speed:..............................................563 Spark weak:.........................................................563 Fuel/air mixture incorrect:.........................................563 Compression low:....................................................564 Other:..............................................................564 Poor Running or No Power at High Speed:.................................564 Firing incorrect:...................................................564 Fuel/air mixture incorrect:.........................................564 Compression low:....................................................564 Knocking:...........................................................564 Miscellaneous:......................................................564 Overheating:............................................................564 Firing incorrect:...................................................564 Muffler overheating:................................................564 Fuel/air mixture incorrect:.........................................564 Compression high:...................................................565 Engine load faulty:.................................................565 Lubrication inadequate:.............................................565 Gauge incorrect:....................................................565 Coolant incorrect:..................................................565 Cooling system component incorrect:.................................565 Over Cooling:...........................................................565 Gauge incorrect:....................................................565 Cooling system component incorrect:.................................565 Clutch Operation Faulty:................................................565 Clutch slipping:....................................................565 Clutch not disengaging properly:....................................565 Gear Shifting Faulty:...................................................565 Doesn't go into gear; shift pedal doesn't return:...................565 Jumps out of gear:..................................................565 Overshifts:.........................................................565 Abnormal Engine Noise:..................................................565 Knocking:...........................................................565 Piston slap:........................................................565 Valve noise:........................................................565 Other noise:........................................................565 Abnormal Drive Train Noise:.............................................566 Clutch noise:.......................................................566 Transmission noise:.................................................566 Drive line noise:...................................................566 Abnormal Frame Noise:...................................................566 Front fork noise:...................................................566 Rear shock absorber noise:..........................................566 Disc brake noise:...................................................566 Other noise:........................................................566 Oil Pressure Warning Light Goes On:.....................................566 Exhaust Smokes Excessively:.............................................566 White smoke:........................................................566 Black smoke:........................................................566 Brown smoke:........................................................566 Handling and/or Stability Unsatisfactory:...............................566 Handlebar hard to turn:.............................................566 Handlebar shakes or excessively vibrates:...........................566 Handlebar pulls to one side:........................................566 Shock absorption unsatisfactory:....................................566 Brake Doesn't Hold:.....................................................567 Battery Trouble:........................................................567 Battery discharged:.................................................567 Battery overcharged:................................................567
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