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Kawasaki VERSYS 1000 Manual De Servicio
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Kawasaki VERSYS 1000 Manual De Servicio

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  • Página 1 VERSYS 1000...

  • Página 3: Mantenimiento Periódico

    Guia de referencia rapida Información general Mantenimiento periódico Sistema de combustible (DFI Sistema de enfriamiento Motor superior en Clutc Sistema de lubricación del motor Remoción / instalación del motor Cigüeñal / Transmissio Ruedas / Neumático Conducción final Freno Suspensio Steerin Fram Sistema eléctrico dieciséis...

  • Página 5: Motocicleta

    Quality Assurance Division / Motorcycle & Engine Company / Kawasaki Heavy Industries, Ltd., Japón. No se puede aceptar ninguna responsabilidad por cualquier inexactitud u omisión en esta publicación, aunque se han tomado todas las precauciones posibles para que sea lo más completa y precisa posible.

  • Página 6: Lista De Abreviaciones

    (s) pulgadas) Kilómetros por hora ABDC km / h después del sistema de frenos antibloqueo KTRC Sistema de control de tracción Kawasaki litro (s) abdominales del punto muerto inferior corriente alterna C.A. amperio hora pantalla de cristal líquido ATDC diodo emisor de luz después del punto muerto superior...
  • Página 7 INFORMACIÓN DE CONTROL DE EMISIONES Para proteger el medio ambiente en el que todos vivimos, Kawasaki ha incorporado sistemas de control de emisiones del cárter (1) y emisiones de escape (2) de acuerdo con las regulaciones aplicables de la Agencia de Protección Ambiental de los Estados Unidos y la Junta de Recursos del Aire de California.

  • Página 8: Prohibido El Manejo Del Sistema De Control De Ruido

    PROHIBIDO EL MANEJO DEL SISTEMA DE CONTROL DE RUIDO La ley federal prohíbe los siguientes actos o sus causas. (1) La remoción o inutilización por cualquier persona que no sea para propósitos de mantenimiento, reparación o reemplazo, de cualquier dispositivo o elemento de diseño incorporado en cualquier vehículo nuevo con el propósito de controlar el ruido antes de su venta o entrega al último comprador o mientras está...

  • Página 9: Cómo Usar Este Manual

    Esté alerta a problemas y no programados en la operación o servicio del vehículo. mantenimiento. • Utilice las herramientas adecuadas y los motores Kawasaki originales. Piezas de la motocicleta El Manual de servicio presenta las • Indica un paso de procedimiento o trabajo a ser herramientas especiales, los medidores y los probadores que son hecho.
  • Página 11 INFORMACIÓN GENERAL 1-1 Información general Tabla de contenido Antes de dar servicio ........................Identificación del modelo ........................ Especificaciones generales......................Tabla de conversión de unidades ......................1-11...

  • Página 12: Información General

    1-2 INFORMACIÓN GENERAL Antes de dar servicio Antes de comenzar a realizar un servicio de inspección o realizar una operación de desmontaje y montaje en una motocicleta, lea las precauciones que se indican a continuación. Para facilitar las operaciones reales, en cada capítulo se han incluido notas, ilustraciones, fotografías, precauciones y descripciones detalladas siempre que sea necesario.

  • Página 13: Inspección

    Las piezas de repuesto deben ser originales de KAWASAKI o recomendadas por KAWASAKI. Las juntas, las juntas tóricas, los retenes de aceite, los retenes de grasa, los anillos elásticos, las chavetas o las tuercas autoblocantes deben sustituirse por otros nuevos siempre que se desmonten.

  • Página 14: Secuencia De Apriete

    1-4 INFORMACIÓN GENERAL Antes de dar servicio Secuencia de apriete Por lo general, al instalar una pieza con varios pernos, tuercas o tornillos, inícielos todos en sus orificios y apriételos para que queden bien. A continuación, apriételos de acuerdo con la secuencia especificada para evitar que la carcasa se deforme o que pueda provocar un mal funcionamiento.
  • Página 15 INFORMACIÓN GENERAL 1-5 Antes de dar servicio prensa Para elementos tales como cojinetes o sellos de aceite que deben presionarse en su lugar, aplique una pequeña cantidad de aceite en el área de contacto. Asegúrese de mantener una alineación adecuada y utilice movimientos suaves al instalar. Rodamiento de bolas y rodamiento de agujas No retire la bola o la aguja presionada a menos que sea absolutamente necesario.

  • Página 16: General Information

    1-6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubri- cation points are called out throughout this manual, apply the specific oil or grease as specified. Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment.

  • Página 17: Model Identification

    GENERAL INFORMATION 1-7 Model Identification KLZ1000BF Left Side View KLZ1000BF Right Side View Frame Number Engine Number...

  • Página 18: General Specifications

    1-8 GENERAL INFORMATION General Specifications Items KLZ1000BF Dimensions Overall Length 2 240 mm (88.19 in.) 895 mm Overall Width (35.2 in.) Overall Height/High Position 1 400 mm (55.12 in.)/1 465 mm (57.68 in.) 1 520 mm Wheelbase (59.84 in.) Road Clearance 150 mm (5.91 in.) 840 Seat Height mm (33.1 in.)
  • Página 19 GENERAL INFORMATION 1-9 General Specifications Items KLZ1000BF Ignition Timing From 10° BTDC @1 100 r/min (rpm) to 40.2° BTDC @5 200 r/min (rpm) Spark Plug NGK CR9EIA-9 Cylinder Numbering Method Left to right, 1-2-3-4 1-2-4-3 Firing Order Valve Timing: Intake: Open 24°...
  • Página 20 1-10 GENERAL INFORMATION General Specifications Items KLZ1000BF Front Tire: Type Tubeless Size 120/70 ZR17 M/C (58W) J17M/C Rim Size × MT3.50 Rear Tire: Type Tubeless Size 180/55 ZR17 M/C (73W) J17M/C Rim Size × MT5.50 Front Suspension: Type Telescopic fork (upside-down) Wheel Travel 150 mm (5.91 in.) Rear Suspension:...
  • Página 21 GENERAL INFORMATION 1-11 Unit Conversion Table Prefixes for Units: Units of Length: 0.6214 mile Prefix Symbol Power 3.28 mega × 1 000 000 0.03937 kilo × 1 000 centi × 0.01 Units of Torque: milli × 0.001 N· 0.102 kgf·m micro µ...
  • Página 23 PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....................Torque and Locking Agent..................... Specifications ........................Special Tools 2-13 ......................... Periodic Maintenance 2-15 Procedures..................Fuel System 2-16 (DFI)........................ Air Cleaner Element 2-16 Replacement................... Idle Speed Inspection 2-16 ...................... Idle Speed 2-17 Adjustment.....................

  • Página 24: Periodic Maintenance

    2-2 PERIODIC MAINTENANCE Suspension......................... Suspension System 2-55 Inspection..................Steering 2-55 ..........................Steering Play Inspection 2-57 ....................Steering Play 2-57 Adjustment....................Steering Stem Bearing Lubrication 2-57 .................. Electrical System 2-59 ........................ Lights and Switches Operation 2-60 Inspection............... Headlight Aiming Inspection 2-60 ....................

  • Página 25: Periodic Maintenance Chart

    PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected. Periodic Inspection * A: Service at number of years shown or indicated odometer reading intervals, whichever comes first.
  • Página 26 2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart Odometer Reading (*B) × 1 000 km (× 1 000 mile) See year (*A) Page Items (0.6) (3.8) (7.6) (11.4) (15.2) Wheel bearing damage 2-38 Final Drive Drive chain lubrication condition (*C) 2-39 : every 600 km (400 mile) Drive chain slack (*C) Drive 2-40 : every 1 000 km (600 mile)
  • Página 27 PERIODIC MAINTENANCE 2-5 Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. All of the values are for use with dry solvent - cleaned threads unless otherwise indicated. Letters used in the “Remarks”...
  • Página 28 2-6 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Water Pump Cover Bolts Coolant 97 in·lb Drain Bolt 97 in·lb Engine Top End Air Suction Valve Cover Bolts Spark 87 in·lb Plugs 115 in·lb 89 in·lb Cylinder Head Cover Bolts Camshaft Cap Bolts 106 in·lb...
  • Página 29 PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Oil Pressure Relief Valve Oil Filter G, R Oil Filter Pipe Engine Oil Drain Bolt Lower Fairing Bracket Bolts Oil Pan 106 in·lb Bolts 106 in·lb Engine Removal/Installation Upper Engine Bracket Bolts Lower Engine Bracket Bolts Upper Adjusting Collar...
  • Página 30 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Shift Lever Bolt 0.70 61 in·lb Shift Pedal Mounting Bolt Wheels/Tires Front Axle Clamp Bolt Front Axle 13.3 95.9 Rear Axle Nut 11.2 81.1 Final Drive Engine Sprocket Nut 15.0 Engine Sprocket Cover Bolts 0.71...
  • Página 31 PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Rear Brake Pad Pin Rear Brake Pad Pin Plug Rear 0.25 22 in·lb Caliper Mounting Bolt Rear Wheel Rotation Sensor Lead Bracket Bolt Rear Wheel 0.82 71 in·lb Rotation Sensor Bolt Rear Brake Disc Mounting Bolts Suspension...
  • Página 32 2-10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Socket Cover Screws 0.12 11 in·lb Windshield Adjuster Knob Bolts Windshield 0.46 40 in·lb Bolts 0.43 0.044 38 in·lb Windshield Bracket Nuts 0.82 71 in·lb Middle Fairing Inner Cover Screws Middle 0.12 11 in·lb Fairing Bolts...
  • Página 33 PERIODIC MAINTENANCE 2-11 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Lower Mud Guard Bolts (M5) Reflector 0.50 0.05 4.4 in·lb Bracket Bolts 0.82 71 in·lb Reflector Nuts (US, CA, CAL and CN Models) Center Stand Bracket 0.46 40 in·lb Bolts (Other than CN Model) Center Stand Bolts (Other than CN Model) Center Stand Nuts (Other than CN Model)
  • Página 34 2-12 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Horn Bolt 0.82 71 in·lb Regulator/Rectifier Bolts 0.70 61 in·lb Side Stand Bracket Nut Side 0.82 71 in·lb Stand Switch Bolt Neutral Switch 0.92 80 in·lb The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value.
  • Página 35 PERIODIC MAINTENANCE 2-13 Specifications Item Standard Service Limit Fuel System (DFI) Throttle Grip Free Play Idle 2 "< 3 mm (0.08 "< 0.12 in.) 1 100 – – – Speed ±50 r/min (rpm) – – – Throttle Body Vacuum 40.7 ±1.3 kPa (305 ±10 mmHg) at idle speed –...
  • Página 36 2-14 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Final Drive Drive Chain Slack 25 "< 35 mm (1.0 "< 1.4 in.) – – – Drive Chain Wear (20-link Length) 317.5 "< 318.2 mm (12.50 "< 12.53 in.) 319 mm (12.6 in.) Standard Chain: Make ENUMA...

  • Página 37: Special Tools

    PERIODIC MAINTENANCE 2-15 Special Tools Inside Circlip Pliers: Vacuum Gauge: 57001-143 57001-1369 Jack: Throttle Sensor Setting Adapter: 57001-1538 57001-1238 Pilot Screw Adjuster, A: Extension Tube: 57001-1239 57001-1578 Oil Filter Wrench: Jack Attachment: 57001-1249 57001-1608 Attachment Jack: Socket Wrench, 52: 57001-1252 57001-1828...
  • Página 38 2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System (DFI) Air Cleaner Element Replacement NOTE ○ In dusty areas, the element should be replaced more frequently than the recommended interval. WARNING If dirt or dust is allowed to pass through into the throttle body assy, the throttle may become stuck, possibly causing accident.
  • Página 39 PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures • dle Speed Inspection Start the engine and warm it up thoroughly. [A]. • With the engine idling, turn the handlebars to both sides If handlebars movement changes the idle speed, the throttle cables may be improperly adjusted or incorrectly routed, or damaged Be sure to correct any of these conditions before riding (see Throttle Control System Inspection and Cable, Wire, and Hose Routing section in the Appendix chapter).
  • Página 40 2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures Engine Vacuum Synchronization Inspection NOTE ○ These procedures are explained on the assumption that the intake and exhaust systems of the engine are in good condition. • Situate the motorcycle so that it is vertical. •...
  • Página 41 PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures • Install the air cleaner housing (see Air Cleaner Housing Installation in the Fuel System (DFI) chapter). Connect the • following parts temporarily. Fuel Pump Lead Connector [A] Extension Tube [B] Special Tool - Extension Tube: 57001-1578 •...
  • Página 42 2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures If any vacuum is not within specifications, adjust the by- pass screws [A]. View from Rear [B] Special Tool - Pilot Screw Adjuster, A [C]: 57001-1239 • Adjust the each vacuum (#1 "< #4) to the standard value. ment. •...
  • Página 43 PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures • Back out the same number of turns counted when first turned in. This is to set the screw to its original position. NOTE ○ A throttle body has different “turns out” of the bypass screw for each individual unit.
  • Página 44 2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Check that the fuel hose joints are securely connected. more than two ○ Push and pull [A] the fuel hose joint [B] back and forth times, and make sure it is locked. WARNING Leaking fuel can cause a fire or explosion resulting in serious burns.
  • Página 45 PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures • Remove the vinyl bag on the pipe. foreign materials on • Check that there are no flaws, burrs, and adhesion of the delivery pipe [A]. • Replace the fuel hose with a new one. •...
  • Página 46 2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Evaporative Emission Control System Inspection ( Other than US, CA, ID and SEA-B2 Models) Inspect the canister as follows. ○ Remove the meter cover (see Meter Cover Removal in the Frame chapter). ○ Slide the clamps [A].

  • Página 47: Cooling System

    PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures Cooling System Coolant Level Inspection NOTE ○ Check the level when the engine is cold (room or ambi- ent temperature). • Check the coolant level in the reserve tank [A] with the motorcycle held perpendicular (Do not use the side stand).
  • Página 48 2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove: Left Lower Fairing (see Lower Fairing Removal in the Frame chapter) • Place a container under the drain bolt [A] of the water pump cover. • Remove: Right Fuel Tank Cover (see Fuel Tank Cover Removal in the Frame chapter) •...
  • Página 49 PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures • Fill the radiator up to the filler neck [A] with coolant. NOTE ○ Pour in the coolant slowly so that it can expel the air from the engine and radiator. • Check the cooling system for leaks. •...
  • Página 50 2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures ater Hose and O-ring Replacement • Drain the coolant (see Coolant Change). Oil Passage • Remove: Cover [A] Thermostat Housing Cover [B] (see Thermostat Re- moval in the Cooling System chapter) Water Pump Housing [C] (see Water Pump Removal in the Cooling System chapter) •...