Special Tools and Sealant

Piston Ring Pliers: 57001 -115

Inside Circlip Pliers: 57001 -143

Outside Circlip Pliers: 57001 -144

Oil Pressure Gauge, 10 kg/cm2: 57001 -164

Valve Spring Compressor Assembly: 57001 -241

Hand Tester: 57001-1394

Fuel Level Gauge: 57001 -1017

Compression Gauge: 57001 -221

Oil Pressure Gauge Adapter. PT %: 57001 -1033

Oil Seal & Bearing Remover: 57001 -1058

Steering Stem Nut Wrench: 57001 -1100

Oil Seal & Bearing Remover: 57001 -1058

Head Pipe Outer Race Drivers: 57001 -1077

Piston Ring Compressor Grip: 57001 -1095

Steering Stem Nut Wrench: 57001 -1100

Head Pipe Outer Race Press Shaft: 57001 -1075 Valve Seat Cutter, 45° - <t>27.5: 57001 -1114

Head Pipe Outer Race Drivers: 57001 -1077

Piston Ring Compressor Grip: 57001 -1095

Piston Ring Compressor Belt, 067 - «>79: 57001 -1097 Valve Seat Cutter, 32° - <l>30: 57001 -1120

Valve Seat Cutter, 60" - <J>30: 57001 -1123 Hexagon Wrench, Hex 8: 57001 -1234

Valve Seat Cutter Holder Bar 57001-1128 Jack: 57001-1238

Bearing Driver Set: 57001 -1129 Clutch Holder 57001 -1243

Valve Spring Compressor Adapter, <P22: 57001 -1202 Oil Filter Wrench: 57001 -1249

Fork Outer Tube Weight: 57001 -1218 Bearing Remover Shaft: 57001 -1265

Carburetor Drain Plug Wrench, Hex 3: 57001 -1269 Fork Piston Rod Puller, M10 x 1.0: 57001 -1298

Carburetor Drain Plug Wrench, Hex 3: 57001 -1269 Fork Piston Rod Puller, M10 x 1.0: 57001 -1298

Valve Seat Cutter Holder, <t>4 5: 57001 -1330

Valve Guide Arbor. <t>4.5: 57001 -1331

Valve Guide Reamer, <D4.5: 57001 -1333

Fork Oil Seal Driver, <P41: 57001 -1288

Compression Gauge Adapter, M10 X 1.0: 57001 -1317

Fork Oil Level Gauge: 57001 -1290

Valve Seat Cutter Holder, <t>4 5: 57001 -1330

Pilot Screw Adjuster, C: 57001 -1292

Valve Guide Arbor. <t>4.5: 57001 -1331

Fork Cylinder Holder 57001 -1297

Valve Guide Reamer, <D4.5: 57001 -1333

Fork Spring Compressor 57001 -1338 Crankcase Splitting Tool Assembly: 57001 -1362

Steering Stem Bearing Driver 57001 -1344 Vacuum Gauge: 57001 -1369

Steering Stem Bearing Driver Adapter: 57001 -1345 Socket Wrench: 57001 -1370

Bearing Remover Head, cj>25 x 4>28: 57001 -1346 Pilot Screw Adjuster Adapter, 05: 57001 -1372

Pilot Screw Adjuster Driver: 57001 -1373

Fork Spring Stopper: 57001 -1374 Kawasaki Bond (Silicone Sealant): 56019-120

Vacuum Gauge Bolt Washer: 92022-304

Spark Plug Wrench, 16mm: 92110-11 54

Vacuum Gauge Bolt: 92150-1161

Pressure Cable Luber k56019-021

Cable, Wire, and Hose Routing

Run the hose between the radiator tank and the fairing bracket.

Meter Unit Air Cleaner Housing Main Harness Rear Frame Nut Seat Lock Cable Air Intake Ducts

7. Resonators

8. Drain Hoses

9. Radiator

10. Lower Fairing Bracket

11. Cross Pipe

12. Starter Motor Cable

Front

13. Battery

14. Battery Positive Lead

15. Tum Signal Relay

16. Starter Relay

17. Speedometer Cable

Position here.)

Clamp-

Position here.)

Run the fuel hose through the bracket.

Main Harness

Clamp-

Straps parallel to the cross pipe.

1. Left Handlebar Switch

2. City Light

3. Right Handlebar Switch

4. Meter Unit

5. Headlight Diode

6. Handlebar Switch Leads

7. Headlight

8. Front Right Turn Signal Light

9. Water Temperature Sensor Leads

10. Radiator Fan Motor

11. Ignition Switch

13. Neutral Switch

14. Side Stand Switch

15. Alternator

16. Pickup Coil

17. Fuel Pump

18. Fuel Level Sensor

19. Main Harness Holder

20. Main Harness Ground

21. Engine Ground Lead

22. Battery Ground Lead

Run the fuel hose through the bracket.

Main Harness

Straps parallel to the cross pipe.

23. Fuel Pump Relay

24. Rear Brake Light Switch

25. Electrical Accessory

26. IC Igniter

27. Rear Right Tum Signal Light

28. Rear Left Turn Signal Light

29. License Light

30. Tail/Brake Lights 31 .Junction Box

32. Starter Relay

33. Turn Signal Relay

34. Battery

35. Battery Positive Lead

36. Fuel Hose (Fuel Filter ~ Fuel Tap)

37. Starter Motor Cable

39. Front Fork

40. Radiator Fan Switch

41. Horn

42. Front Left Turn Signal Light

43. Carburetors

44. Fuel Tap

Clamp (Fan Motor Leads)

(Main Harness and Bracket)

1.

License Light

7.

Battery Negative Lead

12.

Electrical Accessory

2.

Rear Left Turn Signal Light

8.

Engine Ground Lead

13.

Fuel Pump Relay

3.

Tail/Brake Lights

9.

Main Harness

14.

Rear Brake Light Switch

4.

Rear Right Turn

10.

Ignition Coil. Ignition Switch,

15.

Water Temperature Sensor

Signal Light Connectors

Horn, Radiator Fan, and

Leads

5.

IC Igniter

Radiator Fan Switch

16.

Headlight Diode

6.

Rear Frame Nut

11.

Headlight

17.

Front Right Turn Signal Light

Front

Clamp (Fan Motor Leads)

(Main Harness and Bracket)

Run the brake hose inside the left

Front

Front

Run the brake hose inside the left

1. Right Front Fork 4. Front Brake Reservoir

2. Brake Hose Joint 5. Front Brake Caliper

3. Front Brake Master Cylinder 6. Rear Brake Reservoir

7. Rear Brake Caliper

8. Rear Brake Master Cylinder

Run the choke cable on the leftside of the vacuum switch valve hose.

Run the throttle cables over air vent hose.

The clamp screw points downward.

Front

Run the hose inside the frame and outside the rear brake light switch lead.

Run the hose over the rear frame nut.

Run the throttle cables over air vent hose.

Run the choke cable on the leftside of the vacuum switch valve hose.

Front

3. Clutch Hose

4. Front Fork

5. Choke Cable

6. Air Vent Hose

7. Vacuum Switch Valve

8. Throttle Cables

9. Brake Hose

10. Rear Shock Reservoir Hose

11. Clamp Screw

12. Rear Frame Nut

The clamp screw points downward.

Run the hose inside the frame and outside the rear brake light switch lead.

Run the hose over the rear frame nut.

1. Yellow Marks

2. White Mark

3. Water Temperature Sensor

4. Thermostat Housing

5. Coolant Reserve Tank

6. Reserve Tank Hose

7. Reserve Tank Vent Hose

8. Downtube

9. Fairing

10. Fuel Tank Drain Hose

11. Fuel Tank the hose.

the fairing and the downtube.

The yellow mark points upward.

Top View

Front

Front View

Line

Align the yellow mark with the parting line of the thermostat housing.

j 5 i Front

Face the flange of the collar toward the coolant reserve tank. ,

Align the yellow mark with the centerline of the pipe.

aiinn »ho white mark with the parting line of the thermostat housing.

Face the screw head downward. Run the reserve tank vent hose in front of the reserve tank '----

Front View

Place the clamp about 2 mm away from the hose end.

Front

Pickup Coil Cover Elbow

Pickup Coil Leads

Oil Pressure Switch Lead

Oil Pressure Switch

Oil Hose

Lower Crankcase

Clamp

Crankcase Bolt Alternator Alternator Lead Electric Starter Cross Pipe Water Pump Side Stand Switch Lead Neutral Switch

Push the hose onto the elbow until the hose contacts the head of the

Front View

Place the clamp about 2 mm away from the hose end.

Front

California Model these hoses so the white marks face upward.

Run the hose so it touches the hole inside as shown.

California Model

1. Band marked with "R"

2. Air Intake Ducts

3. Frame Holes

4. Air Vent Hoses

5. Air Vent Filters

6. Carburetors

7. Vacuum Switch Valve Hose

8. Band marked with "L"

9. Vacuum Valve (CA)

10. Vacuum Valve Hose (CA)

11. To #2 Inlet Pipe

13. Carburetor Vent Hose (Yellow) CA: California

Front

Run the hoses so they touch the holes inside as shown.

these hoses so the white marks face upward.

the hose under the spark plug leads and the vacuum switch valve hose. Connect the smaller bend of the hose to the vacuum valve.

Run the hose so it touches the hole inside as shown.

Front

Cross these hoses as shown.

Smaller Bend

Smaller Bend

Clamp_J

Install the catch tank near the clamp. Install the clamp horizontally.

the hose over the alternator.

Clamp_J

Evaporative Emission Control System (California)

Install the catch tank near the clamp. Install the clamp horizontally.

Front

Smaller Bend

Cross these hoses as shown.

Smaller Bend

Run these hoses behind the water pipe.

About 15 - 20 mm the hose over the alternator.

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