Kawasaki ER-5
KAWASAKI ER-5 - WORKSHOP, SERVICE, REPAIR MANUAL - REPARATURANLEITUNG
KAWASAKI ER-5 - WORKSHOP, SERVICE, REPAIR MANUAL - REPARATURANLEITUNG - English and German Workshop Manual / Repair Manual, for motorcycles Kawasaki ER-5. INDEX: Foreword General Information - Before starting to perform an inspection service or carry out a - Especially note the following: - Two-Color Electrical - 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:
Kawasaki ER-5 - Workshop Manual, Repair Manual - Reparaturanleitung
inicio - index
coche - car
moto
4x4
quad - buggy
cami?n - truck
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