J300 J300 ABS Motorcycle Service Manual

474 Pages·2014·11.42 MB·English

J300
J300 ABS

Quick Reference Guide
General Information 1 j
Periodic Maintenance 2 j
Fuel System (DFI) 3 j
Cooling System 4 j
Engine Top End 5 j
Converter System 6 j
Engine Lubrication System 7 j
Engine Removal/Installation 8 j
Crankcase/Crankshaft 9 j
Wheels/Tires 10 j
Final Drive 11 j
Brakes 12 j
Suspension 13 j
Steering 14 j
Frame 15 j
Electrical System 16 j
Appendix 17 j
This quick reference guide will assist
you in locating a desired topic or pro-
cedure.
•Bend the pages back to match the
black tab of the desired chapter num-
ber with the black tab on the edge at
each table of contents page.
•Refertothesectionaltableofcontents
for the exact pages to locate the spe-
cific topic required.

J300
J300 ABS
Motorcycle
Service Manual
All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise,
withoutthepriorwrittenpermissionofQualityAssuranceDivision/Motorcycle&EngineCompany/Kawasaki
Heavy Industries, Ltd., Japan.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible
care has been taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time withoutprior notice and without incurring an obligation
to make such changes to products manufactured previously. See your Motorcycle dealer for the latest
information on product improvements incorporated after this publication.
Allinformationcontainedinthispublicationisbasedonthelatestproductinformationavailableatthetime
ofpublication. Illustrationsandphotographsinthispublicationareintendedforreferenceuseonlyandmay
not depict actual model component parts.
© 2013 Kawasaki Heavy Industries, Ltd. 2nd Edition (1) : Jul. 10, 2014
LIST OF ABBREVIATIONS
A ampere(s) kg (mass)
ABDC after bottom dead center kgf (force)
AC alternating current km/h kilometers per hour
Ah ampere hour L liter(s)
ATDC after top dead center lb pound(s)
BBDC before bottom dead center m meter(s)
BDC bottom dead center min minute(s)
BTDC before top dead center N newton(s)
°C degree(s) Celsius oz ounce(s)
CDI capacitive discharge ignition Pa pascal(s)
cmHg centimeters of mercury PS horsepower
cu in. cubic inch(es) psi pound(s) per square inch
DC direct current qt quart(s)
EMI Electro-Magnetic Interference r revolution
F farad(s) r/min, rpm revolution(s) per minute
°F degree(s) Fahrenheit s second(s)
ft foot, feet SOHC single overhead camshaft
g gram(s) (mass) TDC top dead center
gal gallon(s) TIR total indicator reading
h hour(s) V volt(s)
HP horsepower(s) W watt(s)
in. inch(es) Ω ohm(s)
ISC Idle Speed Control
Foreword
This manual is designed primarily for use by Guide shows you all of the product’s system
trainedmechanicsinaproperlyequippedshop. and assists in locating their chapters. Each
However,itcontainsenoughdetailandbasicin- chapter in turn has its own comprehensive Ta-
formationtomakeitusefultotheownerwhode- ble of Contents.
sirestoperformhisownbasicmaintenanceand Forexample,ifyouwantignitioncoilinforma-
repair work. A basic knowledge of mechanics, tion, use the Quick Reference Guide to locate
the proper use of tools, and workshop proce- the Electrical System chapter. Then, use the
dures must be understood in order to carry out TableofContentsonthefirstpageofthechap-
maintenance and repair satisfactorily. When- ter to find the Ignition Coil section.
ever the owner has insufficient experience or Whenever you see symbols, heed their in-
doubts his ability to do the work, all adjust- structions! Always follow safe operating and
ments, maintenance, and repair should be car- maintenance practices.
ried out only by qualified mechanics.
DANGER
In order to perform the work efficiently and
to avoid costly mistakes, read the text, thor- DANGER indicates a hazardous situa-
oughly familiarize yourself with the procedures tion which, if not avoided, will result in
beforestartingwork,andthendotheworkcare- death or serious injury.
fullyinacleanarea. Wheneverspecialtoolsor
WARNING
equipment are specified, do not use makeshift
tools or equipment. Precision measurements WARNING indicates a hazardous situa-
can only be made if the proper instruments are tion which, if not avoided, could result
used, and the use of substitute tools may ad- in death or serious injury.
versely affect safe operation.
For the duration of the warranty period, NOTICE
we recommend that all repairs and scheduled
NOTICEisusedtoaddresspracticesnot
maintenance be performed in accordance with
related to personal injury.
thisservicemanual. Anyownermaintenanceor
repair procedure not performed in accordance
This manual contains four more symbols
with this manual may void the warranty.
which will help you distinguish different types
To get the longest life out of your vehicle.
of information.
•
FollowthePeriodicMaintenanceChartinthe
Service Manual. NOTE
• ○
Be alert for problems and non-scheduled NOTEindicatesinformationthatmayhelp
maintenance. or guide you in the operation or service of
•
Use proper tools and genuine Kawasaki Mo- the vehicle.
torcycle parts. Special tools, gauges, and
•
Indicates a procedural step or work to be
testers that are necessary when servicing
done.
Kawasaki motorcycles are introduced by the
○
Indicates a procedural sub-step or how to do
Service Manual. Genuine parts provided as
the work of the procedural step it follows. It
spare parts are listed in the Parts Catalog.
• also precedes the text of a NOTE.
Follow the procedures in this manual care-
Indicates a conditional step or what action to
fully. Don’t take shortcuts.
• takebasedontheresultsofthetestorinspec-
Remembertokeepcompleterecordsofmain-
tion in the procedural step or sub-step it fol-
tenance and repair with dates and any new
lows.
parts installed.
Inmostchaptersanexplodedviewillustration
How to Use This Manual of the system components follows the Table of
Contents. In these illustrations you will find the
In this manual, the product is divided into instructionsindicatingwhichpartsrequirespec-
its major systems and these systems make up ified tightening torque, oil, grease or a locking
the manual’s chapters. The Quick Reference agent during assembly.

GENERAL INFORMATION 1-1
General Information
Table of Contents
1
Before Servicing..................................................................................................................... 1-2
Model Identification................................................................................................................. 1-7
General Specifications............................................................................................................ 1-9
Unit Conversion Table............................................................................................................ 1-11
1-2 GENERAL INFORMATION
Before Servicing
Before starting to perform an inspection service or carry out a disassembly and reassembly opera-
tiononamotorcycle,readtheprecautionsgivenbelow. Tofacilitateactualoperations,notes,illustra-
tions,photographs,cautions,anddetaileddescriptionshavebeenincludedineachchapterwherever
necessary. This section explains the items that require particular attention during the removal and
reinstallation or disassembly and reassembly of general parts.
Especially note the following.
Battery Ground
Beforecompletinganyserviceonthemotorcycle,discon-
nect the battery cables from the battery to prevent the en-
gine from accidentally turning over. Disconnect the ground
cable (–) first and then the positive (+). When completed
with the service, first connect the positive (+) cable to the
positive(+)terminalofthebatterythenthenegative(–)ca-
ble to the negative terminal.
Edges of Parts
Lift large or heavy parts wearing gloves to prevent injury
from possible sharp edges on the parts.
Solvent
Use a high flash-point solvent when cleaning parts. High
flash-point solvent should be used according to directions
of the solvent manufacturer.
Cleaning Vehicle before Disassembly
Clean the vehicle thoroughly before disassembly. Dirt or
otherforeignmaterialsenteringintosealedareasduringve-
hicledisassemblycancauseexcessivewearanddecrease
performance of the vehicle.