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Инструкция для KAWASAKI ER5 (2004)
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14-4 FRAME
Specifications
Special Tool - Jack: 57001-1238
Страница:
(
252
из 334)
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Оглавление инструкции
Document Outline
tables
LIST OF ABBREVIATIONS
Basic Torque for General Fasteners
Throttle Grip Free Play
Choke Cable Free Play
Idle Speed
Fuel Level
Float Height
Valve Closing Temperature (for reference)
Water and Coolant Mixture Ratio (when shipping)
Radiator Cap Relief Pressure
Thermostat Valve Opening Temperature
Vacuum Switch Valve Closing Pressure (open → close)
Camshaft Journal, Camshaft Cap Clearance
Cylinder Compression (Usable Range)
Cylinder Head Warp
Valve Clearance Measuring Position
Valve Clearance Measuring Position
Valve Clearance (when cold)
Valve Seating Surface Outside Diameter
Valve Seating Surface Width
Valve/Valve Guide Clearance (Wobble Method)
Special Tools -
Piston Ring/Groove Clearance
Piston Ring End Gap
Piston Diameter
Piston Diameter
Clutch Lever Free Play
Friction Plate Thickness
Friction and Steel Plate Warp
Clutch Spring Free Length
Engine Oil
Oil Pressure
Torque Value for 8 mm Bolts
Connecting Rod Bend
Connecting Rod Twist
Connecting Rod Big End Side Clearance
Connecting Rod Big End Bearing Insert/Crankpin Clearance
Crankpin Diameter
Crankpin Diameter Marks
Connecting Rod Big End Bore Diameter Marks
Connecting Rod Big End Bearing Insert Selection
Crankshaft Runout
Crankshaft Main Bearing Insert/Journal Clearance
Crankshaft Main Journal Diameter
Crankshaft Main Journal Diameter Marks
Crankcase Main Bearing Bore Diameter Marks
Crankshaft Main Bearing Insert Selection
Crankshaft Side Clearance
Balancer Shaft Bearing Insert/Journal Clearance
Balancer Shaft Journal Diameter
Balancer Shaft Diameter Marks
Crankcase Bearing Bore Diameter Marks
Balancer Shaft Bearing Insert Selection
Rim Runout
Axle Runout/100 mm (3.94 in.)
Balance Weight
Air Pressure (when cold)
Tread Depth
Chain Slack
Drive Chain 20-link Length
Link Pin Outside Diameter
Link Plates Outside Width
Rear Sprocket Warp
Pad Lining Thickness
Disc Thickness
Disc Runout
Recommended Disc Brake Fluid
Pedal Position
Brake Pedal Free Play
Cam Lever Angle
Shoe Lining Thickness
Camshaft Diameter
Camshaft Hole Diameter
Drum Inside Diameter
Front Fork Oil Level (Fully compressed without fork spring)
Spring Free Length
Spring Preload Adjustment
Battery Terminal Voltage
Terminal Voltage: 11.5 ∼ less than 12.8 V
Terminal Voltage: less than 11.5 V
Voltage
Table 2 Stator Coil Resistance
Regulator/Rectifier Output Voltage
Rectifier Circuit Inspection
Pickup Coil Resistance
Ignition Coil Arcing Distance
Ignition Coil Winding Resistance
Ignition Timing
Spark Plug Gap
Connect
Ignition Coil Primary Peak Voltage
Connect
Pickup Coil Peak Voltage
Starter Chain 20-link Length
Testing Relay
Testing Relay
Starter Motor Brush Length
Commutator Diameter
Testing Relay
Testing Turn Signal Relay
Wire Connectors
Brake Light Timing
Fan Switch Resistance
Water Temperature Switch Connections
Fuel Level Sensor Resistance
Units of Mass:
Units of Volume:
Units of Force:
Units of Length:
Units of Torque:
Units of Pressure:
Units of Speed:
Units of Power:
toc
Read OWNER'S MANUAL before operating.
EMISSION CONTROL INFORMATION
1.
2.
3.
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED
Foreword
General Information
Before starting to perform an inspection service or carry out a
Especially note the following:
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
Two-Color Electrical
(19)
(20)
ER500-C1, D1 Left Side View
ER500-C1, D1 Right Side View
The scheduled maintenance must be done in accordance with this c
Tighten all bolts and nuts to the proper torque using an accurat
Piston Ring Pliers:
Fuel System
Special Tools -
Throttle Cable Inspection
Throttle Cable Lubrication
Free Play Inspection
Free Play Adjustment
Cable Installation
Cable Lubrication
Idle Speed Inspection
Carburetor Synchronization Inspection
Special Tool -
Carburetor Removal
Carburetor Installation
Service Fuel Level Inspection
Special Tool -
Service Fuel Level Adjustment
Fuel System Cleanliness Inspection
Carburetor Disassembly/Assembly
Carburetor Separation/Assembly
Carburetor Cleaning
Carburetor Inspection
Coolant Filter Cleaning
Coolant Valve Inspection
Element Removal
Element Cleaning and Inspection
Housing Removal
Air Cleaner Draining
Fuel Tank Removal
Fuel Tank Installation
Fuel Tap Removal
Fuel Tap Installation
Torque -
Fuel Tank and Tap Cleaning
Fuel Tap Inspection
Fuel Tank and Cap Inspection
Fuel Hose and Connection Inspection
Cooling System
Special Tool -
Sealant -
Permanent type antifreeze is used as a coolant to protect the co
Coolant Deterioration Inspection
Coolant Level Inspection
Coolant Draining
Coolant Filling
Torque -
Visual Leak Inspection
Cooling System Pressure Testing
Flushing
Coolant Filter Cleaning
Water Pump Removal
Water Pump Installation
Sealant -
Torque -
Torque -
Mechanical Seal Inspection
Water Pump Housing Disassembly
Special Tool -
Water Pump Housing Assembly
Special Tool -
Impeller Assembly
Pump Impeller Inspection
WARNING
Radiator Removal
Radiator Inspection
Filler Neck Inspection
Radiator Cap Inspection
Radiator Hose and Connection Inspection
Torque -
Radiator Hose, Pipe, Air Vent Hose, Reservoir Tank Hose Installa
Torque -
Thermostat Removal
Thermostat Installation
Thermostat Inspection
CAUTION
Radiator Fan Switch Removal
Water Temperature Switch Removal
Radiator Fan Switch, Water Temperature Switch Installation
Sealant -
Torque -
Radiator Fan Switch, Water Temperature Switch Inspection
Engine Top End
Special Tools -
Sealant -
Vacuum Switch Valve Removal
Vacuum Switch Valve Installation
Air Suction Valve Installation
Torque -
Air Suction Valve Inspection
Clean Air System Hose Inspection
Vacuum Switch Valve Test
Special Tool -
Cylinder Head Cover Removal
Cylinder Head Cover Installation
Sealant -
Torque -
Camshaft Chain Tensioner Removal
Camshaft Chain Tensioner Installation
Torque -
Torque -
Camshaft Removal
Camshaft Installation
Torque -
Torque -
Camshaft and Sprocket Assembly
Torque -
Camshaft, Camshaft Cap Wear
Torque -
Camshaft Chain Guide Wear
Rocker Shaft, Rocker Arm Removal
Rocker Shaft, Rocker Arm Installation
Torque -
Cylinder Head Oil Pipe Removal
Cylinder Head Oil Pipe Installation
Main Oil Pipe Removal
Main Oil Pipe Installation
Torque -
Compression Measurement
Special Tools -
Cylinder Head Removal
Cylinder Head Installation
Torque -
Cylinder Head Warp
Cylinder Head Cleaning
Valve Clearance Inspection
Torque -
Valve Removal
Special Tools -
Valve Installation
Special Tools -
Valve Guide Removal
Special Tool -
Valve Guide Installation
Special Tool -
Special Tool -
Valve Seat Inspection
Measuring Valve-to-guide Clearance (Wobble method)
Valve Seat Repair
Cylinder Removal
Cylinder Installation
Piston Removal
Special Tool -
Special Tool -
Piston Installation
Piston Ring, Piston Ring Groove Wear
Piston Ring End Gap
Cylinder Inside Diameter
Piston Diameter
Boring, Honing
Carburetor Holder Installation
Muffler Removal
Muffler Installation
Clutch
Special Tool -
Sealant -
Due to friction plate wear and clutch cable stretch over a long
Clutch Adjustment
Clutch Lever Installation
Cable Lubrication
Clutch Cover Removal
Clutch Cover Installation
Sealant -
Torque -
Clutch Release Removal
Clutch Release Installation
Clutch Removal
Special Tool -
Clutch Installation
Special Tool -
Torque -
Torque -
Clutch Plate Wear, Damage Inspection
Clutch Plate Warp Inspection
Clutch Spring Free Length Measurement
Clutch Housing Finger Inspection
Clutch Hub Spline Inspection
Engine Lubrication System
Special Tools -
Sealant -
WARNING
Engine Oil Level Inspection
Engine Oil Change
Torque -
Oil Filter Replacement
Special Tool -
Torque -
Oil Pan Removal
Oil Pan Installation
Torque -
Relief Valve Removal
Relief Valve Installation
Torque -
Relief Valve Inspection
Oil Pump Removal
Oil Pump Installation
Torque -
Torque -
Oil Pump Disassembly
Oil Pump Assembly
Oil Screen Cleaning and Inspection
Oil Pressure Measurement
Special Tools -
Torque -
Engine Removal/Installation
Engine Removal
Engine Installation
Torque -
Crankshaft/Transmission
Special Tools -
Sealant -
Crankcase Splitting
Crankcase Assembly
Sealant -
Torque -
Torque -
Clutch Housing/Primary Chain Removal
Clutch Housing/Primary Chain Installation
Primary Chain Guide Wear
Crankshaft Removal
Crankshaft Installation
Connecting Rod Removal
Connecting Rod Installation
Torque -
Crankshaft/Connecting Rod Cleaning
Connecting Rod Bend/Twist
Connecting Rod Big End Side Clearance
Connecting Rod Big End Bearing Insert/Crankpin Clearance
Torque -
Torque -
Crankshaft Runout
Crankshaft Main Bearing Insert/Journal Clearance
Torque -
Crankshaft Side Clearance
Balancer Removal
Balancer Installation
Balancer Shaft Bearing Insert/Journal Clearance
Torque -
External Shift Mechanism Removal
External Shift Mechanism Installation
Torque -
Torque -
Torque -
External Shift Mechanism Inspection
Torque -
Transmission Shaft Removal
Transmission Shaft Installation
Transmission Shaft Disassembly
Special Tool -
Special Tools -
Drive Shaft Assembly
Special Tool -
Output Shaft Assembly
Special Tool -
Shift Drum and Fork Removal
Shift Drum and Fork Installation
Torque -
Shift Drum Disassembly
Shift Drum Assembly
Ball and Needle Bearing Wear
Shift Pedal Installation
Torque -
Wheels/Tires
Special Tools -
Front Wheel Removal
Special Tool -
Front Wheel Installation
Torque -
Rear Wheel Removal
Rear Wheel Installation
Torque -
Torque -
Wheel Inspection
Special Tool -
Axle Inspection
Wheel Balance
Balance Inspection
Balance Adjustment
Balance Weight Removal
Balance Weight Installation
Air Pressure Inspection/Adjustment
Tire Wear Inspection
Tire Removal
Special Tool -
Special Tools -
Tire Installation
Tire Repair
Hub Bearing Removal
Special Tool -
Special Tools -
Hub Bearing Installation
Special Tool -
Special Tool -
Special Tool -
Special Tool -
Hub Bearing Inspection
Hub Bearing Lubrication
Disassembly and Assembly
Lubrication
Final Drive
Special Tools -
Drive Chain Slack Inspection
Torque -
Torque -
Wheel Alignment Inspection/Adjustment
Drive Chain Wear Inspection
Drive Chain Lubrication
Drive Chain Removal
Drive Chain Installation
Drive Chain Replacement
Recommended Tool -
Engine Sprocket Removal
Engine Sprocket Installation
Torque -
Rear Sprocket Removal
Rear Sprocket Installation
Torque -
Sprocket Wear Inspection
Rear Sprocket Warp Inspection
Coupling Bearing Removal
Special Tool -
Coupling Bearing Installation
Special Tool -
Special Tool -
Special Tool -
Coupling Installation
Coupling Bearing Inspection and Lubrication
Brakes
Special Tool -
Lever Position Adjustment
Caliper Removal
Caliper Installation
Torque -
Caliper Disassembly
Caliper Assembly
Torque -
Caliper Piston Seal and Dust Seal Inspection
Piston and Cylinder Damage
Caliper Holder Shaft Wear
Brake Pad Removal
Brake Pad Installation
Brake Pad Lining Wear
Master Cylinder Removal
Master Cylinder Installation
Torque -
Torque -
Master Cylinder Disassembly
Special Tool -
Master Cylinder Assembly
Torque -
Master Cylinder Inspection (Visual Inspection)
Brake Disc Removal
Brake Disc Installation
Torque -
Brake Disc Wear
Brake Disc Warp
Special Tool -
Level Inspection
Brake Fluid Change
Torque -
Bleeding the Brake Line
Torque -
Brake Hoses and Connections Inspection
Brake Hose Replacement
Torque -
Brake Play Inspection
Brake Pedal Removal
Brake Pedal Installation
Torque -
Brake Lining Wear Inspection
Cam Lever Angle Inspection
Cam Lever Angle Adjustment
Brake Panel Removal
Brake Panel Installation
Brake Panel Disassembly
Brake Panel Assembly
Torque -
Brake Shoe Lining Wear
Brake Shoe Spring Inspection
Brake Camshaft and Camshaft Hole Wear
Brake Drum Wear
Brake Lubrication
Suspension
Special Tools -
Fork Oil Change
Special Tool -
Fork Removal
Fork Installation
Torque -
Fork Disassembly
Special Tools -
Special Tool -
Fork Assembly
Special Tool -
Special Tool -
Special Tools -
Torque -
Fork Oil Leak Inspection
Inner Tube, Outer Tube Inspection
Dust Seal Inspection
Spring Tension
Spring Preload Adjustment
Rear Shock Absorber Removal
Rear Shock Absorber Installation
Torque -
Rear Shock Absorber Wear
Bushing Wear
Rear Shock Absorber Oil Leak Inspection
CAUTION
Swingarm Removal
Swingarm Sleeve and Needle Bearing Wear
Swingarm Installation
Torque -
Torque -
Swingarm Disassembly/Assembly
Special Tool -
Special Tool -
Swingarm Bearing Installation
Special Tool -
Swingarm Needle Bearing Lubrication
Steering
Special Tools -
Handlebar Removal
Handlebar Installation
Torque -
Torque -
Rear View Mirror Removal
Rear View Mirrors (Left and Right) Installation
Steering Inspection
Special Tool -
Special Tool -
Torque -
Torque -
Steering Stem Removal
Special Tool -
Steering Stem Installation
Torque -
Torque -
Steering Stem Warp
Stem Bearing Removal
Special Tools -
Stem Bearing Installation
Special Tools -
Special Tools -
Special Tool -
Torque -
Stem Bearing Lubrication
Stem Bearing Wear, Damage
Frame
Special Tool -
Seat Removal
Seat Installation
Side Cover Removal
Seat Cover Removal
Front Fender Removal
Rear Fender Removal
Frame Inspection
Battery case Removal
Battery Case Installation
Electrical System
1.
Special Tools -
Sealant -
There are a number of important precautions that are musts when
Wiring Inspection
Battery Removal/Installation
Electrolyte Filling
Initial Charge
Precautions
Interchange
Charging Condition Inspection
Refreshing Charge
Alternator Rotor/Starter Clutch Removal
Special Tool -
Special Tool -
Starter Clutch Sprocket Removal
Starter Clutch Sprocket Installation
Alternator Rotor/Starter Clutch Installation
Torque -
Torque -
Special Tool -
Sealant -
Torque -
Alternator Stator Removal
Alternator Stator Installation
Torque -
Alternator Inspection
Special Tool -
Regulator/Rectifier Removal
Regulator/Rectifier Output Voltage Inspection
Regulator/Rectifier Inspection
Charging System Circuit
Ignition System Circuit
Pickup Coil Removal
Pickup Coil Installation
Torque -
Pickup Coil Inspection
Ignition Coil Removal/Installation
Ignition Coil Inspection
Ignition Timing Inspection
Special Tool -
Spark Plug Removal/Installation
Torque -
Spark Plug Gap Inspection
IC Igniter Removal
IC Igniter Inspection
Special Tools -
Special Tool -
Special Tool -
Special Tool -
Troubleshooting
Special Tool -
Diodes Inspection
Electric Starter Circuit
Starter Motor Removal
Starter Motor Installation
Torque -
Starter Motor Disassembly
Starter Motor Assembly
Torque -
Torque -
Starter Chain Wear
Starter Chain Guide Wear
Starter Relay Inspection
Starter Circuit Relay Inspection
Brush Inspection
Brush Spring Inspection
Commutator Cleaning and Inspection
Armature Inspection
Brush Plate Inspection
Headlight Circuit (Australia, ER500-C1 ∼, D1)
Headlight Circuit (Other than Australia, ER500-C1 ∼ C2)
Headlight Circuit (Other than Australia, ER500-C3 ∼)
Headlight Circuit Relay Inspection (Australia)
Special Tool -
Headlight Beam Horizontal Adjustment
Headlight Beam Vertical Adjustment
Headlight Bulb Replacement
Headlight Unit/Housing Removal
Headlight Unit Installation
Tail/Brake Light Bulb Replacement
Tail/Brake Light Lens Removal/Installation
Turn Signal Light Bulb Replacement
Turn Signal Relay Inspection
Turn Signal Light Circuit
Fan System Circuit Inspection
Radiator Fan Circuit
Fan Motor Inspection
Meter Unit Removal
Meter Unit Disassembly
Tachometer Inspection
Bulb Replacement
Tachometer Circuit
Water Temperature Warning System Inspection
Water Temperature Warning System
Brake Light Switch Ispection
Switch Inspection
Special Tool -
Neutral Switch Connections
Rear Brake Light Switch Connections
Oil Pressure Switch Connections*
Side Stand Switch Connections*
Radiator Fan Switch Inspection
Water Temperature Switch Inspection
Fuel Gauge Operation Inspection
Fuel Gauge Circuit
Fuel Level Sensor Inspection
Special Tool -
30 Ampere Fuse Removal
Fuse Box Fuse Removal
Fuse Installation
Fuse Inspection
Appendix
NOTE
Engine Doesn't Start, Starting Difficulty:
Starter motor not rotating:
Starter motor rotating but engine doesn't turn over:
Engine won't turn over:
No fuel flow:
Engine flooded:
No spark; spark weak:
Fuel/air mixture incorrect:
Compression low:
Poor Running at Low Speed:
Spark weak:
Fuel/air mixture incorrect:
Compression low:
Other:
Poor Running or No Power at High Speed:
Firing incorrect:
Fuel/air mixture incorrect:
Compression low:
Knocking:
Miscellaneous:
Overheating:
Firing incorrect:
Fuel/air mixture incorrect:
Compression high:
Engine load faulty:
Lubrication inadequate:
Coolant incorrect:
Cooling system component incorrect:
Over Cooling:
Cooling system component incorrect:
Clutch Operation Faulty:
Clutch slipping:
Clutch not disengaging properly:
Gear Shifting Faulty:
Doesn't go into gear; shift pedal doesn't return:
Jumps out of gear:
Overshifts:
Abnormal Engine Noise:
Knocking:
Piston slap:
Valve noise:
Other noise:
Abnormal Drive Train Noise:
Clutch noise:
Transmission noise:
Drive line noise:
Abnormal Frame Noise:
Front fork noise:
Rear shock absorber noise:
Disc brake noise:
Drum brake noise:
Other noise:
Oil Pressure Warning Light Goes On:
Exhaust Smokes Excessively:
White smoke:
Black smoke:
Brown smoke:
Handling and/or Stability Unsatisfactory:
Handlebar hard to turn:
Handlebar shakes or excessively vibrates:
Handlebar pulls to one side:
Shock absorption unsatisfactory:
Brake Doesn't Hold:
Disc brake:
Drum brake:
Battery Trouble:
Battery discharged:
Battery overcharged:
Lubrication (Periodic Maintenance)
Pivots: Lubricate with Motor Oil.
Points: Lubricate with Grease.
Cables: Lubricate with Cable Lubricant.
Tightness Inspection
Nut, Bolt and Fastener to be checked
Prefixes for Units:
Units of Temperature:
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