Kawasaki ER-5 - Service Manual, Repair Manual - Reparaturanleitung

KAWASAKI ER-5 - WORKSHOP, SERVICE, REPAIR MANUAL - REPARATURANLEITUNG

- English and German Service Manual / Repair Manual, for motorcycles Kawasaki ER-5.
 

CONTENTS:

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: