gx200 honda troubleshooting guide
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gx200 honda troubleshooting guideMAINTENANCE AND ADJUSTMENT STORAGE TROUBLESHOOTING GUIDE A Table of Contents is included after the Foreword. Your new mo- torcycle is the product of Kawasaki’s advanced engineering, exhaustive testing, and continuous striving for superior reliability, safety and performance. Please read this Owner’s Manual carefully before riding so that you will be thoroughly familiar with the proper operation of your motorcycle’s controls, its fea-. All products are subject to change without prior notice or obligation.They are the only means of identifying your particular machine from others of the same model type. These serial numbers may be needed by your dealer when ordering parts. Right Handlebar Switches 5. Brake Lever Adjuster 11. Turn Signal Light 24. Side Stand Switch 15. Horn 25. Side Stand 16. Spark Plugs 26. Fuse Box 17. Battery 27. Coolant Reserve Tank 18. Rear Brake Pedal 34. Air Cleaner Element 40. Rear Brake Light Switch 35. Fuel Tank 41. Brake Fluid Reservoir (Rear) 36. Avoid carrying baggage oughly familiar with motorcycle op- that extends beyond the rear of the eration. Kawasaki does not manu- wheel travel, front fork movement, facture sidecars or trailers for mo- or any other aspect of the motorcy- torcycles and cannot predict the ef- cle’s operation. Both the hour and of the vehicle.Digital Display The digital display located in the speedometer face is used to display the odometer, trip meter, and clock. Push the tarily advances the hour or minute MODE button to advance the min- step by step. Pushing and hold- utes. This meter can- last reset to zero. When the nee- dle comes near the E (empty) posi- tion, refuel at the earliest opportunity. When vehicle stands with side stand, fuel gauge cannot show the amount of fuel in the fuel tank exactly. Re- thorized Kawasaki dealer.Re- switch, steering lock, and fuel tank fuel at the earliest opportunity when the cap. Contact your Kawasaki dealer to pur- A. Ignition Key chase additional spare keys either us- B.http://analogsys.com/uploaded/6166754085f514239c0e13.xml
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Tag ing your original key as a master or us- C. All electrical The ignition switch is located at circuits off.When the headlight is on high beam ( ), the high beam indicator light is lit. High beam.( Low beam.( Turn Signal Switch: When the turn signal switch is turned to the left ( ) or right (. The adjuster has 5 positions so that the released lever position can be adjusted to suit the operator’s hands. Push the lever forward and turn the ad- juster to align the number with the ar- row mark on the lever holder. To close the cap, push it down into place with the key inserted. The key can be removed by turning it to the left to the original position. The octane rating California models only: Never of a gasoline is a measure of its resis- fill the tank so the fuel level rises tance to detonation or “knocking”. The into the filler neck. Before storage it is recom- mended that you drain all fuel from the fuel system. See the Storage section in this manual. This switch is de- To remove the seat, insert the ignition signed so that the engine does not key into the seat lock, and turn the start if the transmission is in gear and key to the right. The kit contains tools that can be helpful in making roadside repairs, adjustments, and some maintenance procedures explained in this manual.The hel- met hook is located under the seat. WARNING Riding with helmet attached to the hook could cause an acci- dent by distracting the operator or interfering with normal vehi- cle operation. Always moving only the mirror portion of the install a fuse 10 A or less in the assembly. If the motorcycle is not used carefully during this period, you may very well end up with a “broken down” instead of a “broken in” motorcycle after a few thousand kilometers. Af- ter righting the motorcycle, first turn the ignition key to “OFF”. This switch is than five minutes, or engine designed so that the engine does not overheating and damage may start if the transmission is in gear and occur.http://cornwallstaffagency.com/userfiles/canon-ixy-manual-download.xml If this is not practical, a 12 explosive under certain con- volt booster battery and jumper cables ditions. NOTICE DANGER Do not operate the starter con- tinuously for more than 5 sec- Batteries contain sulfuric acid onds or the starter will overheat that can cause burns and pro-. For smooth riding, shift up or The transmission is equipped with a down when the motorcycle is oper- positive neutral finder. The converter reacts with car- cause a fire, and can result in bon monoxide, hydorocarbons and ni- property damage or severe per- trogen oxides to convert them into car-. Leaded gaso- excessively accelerates reaction in line significantly reduces the capabil- the converter allowing the converter ity of the catalytic converter.For safety, eye protection and a When riding always keep both helmet are strongly recommended.The time required is minimal, and habitual performance of these checks will help ensure you a safe, reliable ride. If any irregularities are found during these checks, refer to the Maintenance and Adjustment chapter or see your dealer for the action required to return the motor- cycle to a safe operating condition. Return spring not weak or not damaged. Do not attempt high speed operation unless you have received sufficient training and have the required skills. Additionally, Kawasaki has incorporated. The Kawasaki Limited Emission Control System Warranty requires that you re- turn your motorcycle to an authorized Kawasaki dealer for remedy under warranty. Please read the warranty carefully, and keep it valid by complying with the owner’s obligations it contains. Clean off spheric conditions in your riding area. If the coolant level be- damage the radiator fins and im- comes low, the engine overheats and pair the radiator’s effectiveness. This will clog If hard water is used in the sys- up the coolant passages, and con- tem, it causes scale accumula- siderably reduce the efficiency of the tion in the water passages, and cooling system.http://eco-region31.ru/bosch-k-jetronic-fuel-injection-manual-2000 When it coolant level gauge. Have the cooling system inspected by your authorized Kawasaki dealer. Coolant Change A. Projections Have the coolant changed by an au- B. Belt check and adjustment should Spark plug removal should be done be done by an authorized Kawasaki by a competent mechanic following the dealer.Although no ad- justments are required, a thorough vi- sual inspection must be made at the in- tervals specified by the Periodic Main- tenance Chart. NOTICE If valve clearance is left un- adjusted, wear will eventually cause the valves to remain partly open;. Inspect the air suction valves (KCA) is a secondary air suction sys- in accordance with the Periodic Main- tem that helps the exhaust gases to tenance Chart. If any part of the ele- If dirt or dust is allowed to pass ment is damaged, the element must through into the fuel injection be replaced.Replace damaged dance with the Periodic Maintenance control cables before operation. Pad replace- ment should be done by an authorized Kawasaki dealer. A. Lining Thickness B. 1 mm (0.04 in.) Inside the front brake fluid reser- voir is a stepped line showing the up- per level line. The brake light should go on move the switch up or down by turn- after about 10 mm (0.4 in.) of pedal ing the adjusting nut. The indica- tions of TUBELESS on the tire side wall and the rim show that the tire and rim are specially designed for tubeless use. A. Hook Wrench B. The tires, rims, and air valves on this motorcycle are designed only for tubeless type wheels. An accepted estimate is torcycle has not been ridden more that 90 of all tire failures occur during than a mile during the past 3 hours). Days from Days from 100 Dis- Electrical accessories, such as digi- 100 Charged Charged charging tal clocks and computer memory, also to 50 to 100 Ampere draw current from the battery even Discharged. For more details, ask your Kawasaki Do not install a conventional bat- dealer.http://complexitycafe.com/images/building-operation-and-maintenance-manual-example.pdfIf adjusted too low, neither low The headlight beam is adjustable nor high beam will illuminate the road horizontally. If not properly adjusted far enough ahead. If adjusted too high, horizontally, the beam will point to one the high beam will fail to illuminate the side rather than straight ahead. The main fuse is mounted on the starter relay behind right side cover. If a fuse fails during operation, inspect the electrical system to determine the cause, and then replace it with a new fuse of proper amperage. Do not use any sub- stitute for the standard fuse. Replace the blown fuse with a new one of the correct capacity, as specified on the junction box and main fuse. If the boot is not po- system, brake components, electri- sitioned in the groove correctly, re- cal components, muffler outlets, and place it in the correct position. This helps dry the signed for motorcycles or automo- brakes and restores them to normal biles) and water in bucket.When dry, treat Kawasaki dealer.Aluminum wheels, both painted and break if they come in con- and unpainted can be cleaned with tact with chemical substances special non-acid based wheel spray or household cleaning products. Do not apply rub- ber protectant to any tread area. Also, check to see that each cotter pin is in place and in good condition. Please ask your authorized Kawasaki dealer for torque values. Brake Lever Holder Clamp Bolts 16. Pivot Shaft Bolt 17. Brake Pedal Mounting Bolts 18. Rear Shock Absorber Mounting Nuts. WARNING Engine oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved disposal methods or possible recy- cling. Turn the ignition key to “OFF”. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. The warranty does not cover the cost of regularly-scheduled maintenance.https://www.stallionreadymix.co.za/wp-content/plugins/formcraft/file-upload/server/content/files/162938682a5777---Colt-m4-carbine-airsoft-manual.pdf The warranty also does not apply to the normal wear of items such as tires, brake pads, transmission drive belts, chains, sprockets, etc. See your Kawasaki dealer or go to Kawasaki.com for more information if you don’t already have the GTPP. What Am I Responsible For. You are responsible for maintaining your vehicle according to the maintenance schedule shown in this owner’s manual. The dealership will also file all necessary paperwork. The dealership is responsible for correctly completing any necessary repairs, whether they are covered by the lim- ited warranty or not. No autho- rization for warranty work can be given until your vehicle has been inspected by a Kawasaki dealer. What if I am not Satisfied With My Warranty Service. If you aren’t satisfied with your dealership’s repair work or operations, it is best to. This owner’s manual should answer most of your questions about your Kawasaki. Your Kawasaki dealer should either be able to answer any other questions you might have immediately or be able to find the answer for you. This also applies to disposal of the entire vehicle at the. Odometer Date Maintenance Performed Dealer Name. Service manual contains step by step instructions for troubleshoot and maintenance, that allows to detect and eliminate problems and inaccuracies. This service manual is a file PDF, which contains 623 pages, any one of which we can be printed easily.To purchase a catalog online, please add the product to your cart, fill in the contact form online. Our managers proceed your order the same day. The scan tool is available with worldwide shipping. Order the latest version with worldwide shipping or Download! 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CAT Caterpillar Operation and Maintenance Manual C-9 1J-1008-B11, Mf 39 Manual, Barrons Sat Chemistry Study Guide, Mh 65C Flight Manual, Trane Voyager Troubleshooting Manual Ych, Repair Manual For New Holland Model 1630 Reload to refresh your session. Reload to refresh your session. Always follow safe operating and maintenance practices.However, there may be minor differences between the actual product and illustrations and text in this manual. All products are subject to change without prior notice or obligation.They are the only means of identifying your particular machine from others of the same model type. These serial numbers may be needed by your dealer when ordering parts.Rear Brake PedalWeight and Manufacture. Before you ride the motorcycle, make sure it is not overloaded and that you have followed these instructions. With the exception of genuine Kawasaki Parts and Accessories, Kawasaki has no control over the design or application of accessories. Do not carry animals on your motorcycle. 2. You should instruct any passenger before riding to keep his feet on the passenger footpegs and hold on to the operator or seat strap.Speedometer: The speedometer shows the speed of the vehicle. Digital Display The digital display located in the speedometer face is used to display the odometer, trip meter, and clock.Push the MODE button to advance the minutes.This meter cannot be reset.Fuel Gauge: The fuel gauge shows the amount of fuel in the fuel tank. When the needle comes near the E (empty) position, refuel at the earliest opportunity. When vehicle stands with side stand, fuel gauge cannot show the amount of fuel in the fuel tank exactly. The warning indicator light also goes on whenever the troubles occur in digital fuel injection system (DFI). Keys. This motorcycle has a combination key, which is used for the ignition switch, steering lock, and fuel tank cap. Included with the key is a key number, which is stamped on the separate tag.If the key number is lost completely, you will need to replace the ignition switch and all other locks operated by that key. All electrical circuits off. Engine on. All electrical equipment can be used.Engine off. Taillight and P (Park) licence plate light on.Dimmer Switch: High or low beam can be selected with the dimmer switch. When the ), the headlight is on high beam ( high beam indicator light is lit. ) High beam.( ) Low beam.(. Brake Lever Adjusters. There is an adjuster on the brake lever. The adjuster has 5 positions so that the released lever position can be adjusted to suit the operator's hands. Fuel Tank Cap. To open the fuel tank cap, insert the ignition key into the fuel tank cap and turn the key to the right. To close the cap, push it down into place with the key inserted. The key can be removed by turning it to the left to the original position. Fuel Tank. Avoid filling the tank in the rain or where heavy dust is blowing so that the fuel does not get contaminated.Fuel Requirement: Fuel Type Use clean, fresh unleaded gasoline with a minimum Antiknock Index of 87. The Antiknock Index is posted on service station pumps. Gasoline quality is important. Fuels of low quality or not meeting standard industry specifications may result in unsatisfactory performance. Operating problems that result from the use of poor quality or nonrecommended fuel may not be covered under your warranty. Fuel system damage and performance problems may result. Before storage it is recommended that you drain all fuel from the fuel system. See the Storage section in this manual. Side Stand. The motorcycle is equipped with a side stand. A. Side StandSeat Removal To remove the seat, insert the ignition key into the seat lock, and turn the key to the right.Seat Installation To install the seat, insert the projection of the front on the seat into the receptacle on the frame. A. Hook B. Holder. A. Projection B. ReceptacleThe kit contains tools that can be helpful in making roadside repairs, adjustments, and some maintenance procedures explained in this manual. Keep the tool kit in this case. Remove the seat. Open the tool kit case cover by pulling the knob. Helmet-Hook. Windshield. The windshield can be adjusted within 50 mm (1.9 in.) in height to suit the rider's preference. Loosen both the upper and lower bolts on each lower side of the windshield and move it up or down. After adjusting, tighten all the bolts securely. A. Helmet-Hook. Special Warning on the Use of Saddlebags. When preparing to ride this motorcycle, always check the saddlebags for secure mounting in their respective brackets. Be certain the saddlebags are securely bolted on their brackets by attempting to pull them from the brackets.Saddlebags. The saddlebags are provided at both sides of the rear wheel to carry baggage. To remove the saddlebag: Open the saddlebag and take off the bolts inside the saddlebag.Failure to adjust the speed to compensate for added weight and other conditions may result in a loss of control and subsequent accident. Steering LockUnlock the steering before starting the engine. Electric Accessory ConnectorsAlways install a fuse 10 A or less in the electrical accessory circuit.Jump Starting. If this is not practical, a 12 volt booster battery and jumper cables may be used to start the engine.A. Seat Lock Cable B. GuideThis switch is designed so that the engine does not start if the transmission is in gear and the side stand is down.When the motorcycle is standing still, the transmission cannot be shifted past neutral from 1st gear. Braking. Close the throttle completely, leaving the clutch engaged (except when shifting gears) so that the engine will help slow down the motorcycle. Shift down one gear at a time so that you are in 1st gear when you come to a complete stop. Stopping the EngineImproper maintenance can create a dangerous situation known as throttle failure. Two of the most common causes of throttle failure are: 1. An improperly serviced or clogged air cleaner may allow dirt and dust to enter the throttle body and stick the throttle open.This motorcycle is equipped with a catalytic converter in the exhaust system.Leaded gaso-Do not operate the vehicle with the engine or any one cylinder misfiring. Under these conditions unburnedThe points given below are applicable for everyday motorcycle use and should be carefully observed for safe and effective vehicle operation. For safety, eye protection and a helmet are strongly recommended. In general your actions should be smooth as sudden acceleration, braking or turning may cause loss of control, especially when riding in wet conditions or on loose roadway surfaces, when the ability to maneuver will be reduced. Daily Safety Checks. Check the following items each day before you ride. The time required is minimal, and habitual performance of these checks will help ensure you a safe, reliable ride. Front Rear. Install the air valve cap. Nuts, bolts, fasteners. Side stand.Returns to its fully up position by spring tension. Return spring not weak or not damaged. Additional Considerations for High Speed OperationCoolant:To avoid overheating, check that the coolant level is at the upper level line.To assist you in keeping this record, we have provided space on pages 164 through 169 of this manual where an authorized Kawasaki dealer, or someone equally competent, can record the maintenance.See Page. Frequency Whichever comes first. See Page. See Page. Operation (Engine Items) Air suction system damage - inspect Evaporative emission control system function (California model only). EverySee Page. See Page. Frequency Whichever comes first. See Page. See Page. Frequency Whichever comes first. See Page. Operation (Chassis Items) K K Uni-trak rocker arm bearings - lubricate Uni-trak tie rods bearings - lubricate. Every. See Page. Operation (Chassis Items) Side stand switch operation - inspect Engine stop switch operation - inspect Chassis: Chassis parts lubricate Bolts and nuts tightness - inspectOperation (Chassis Items) K Rubber parts of master cylinder and caliper - replace. Every 4 years. K Spark plug - replacePlace an oil pan beneath the engine. Remove the engine oil drain plug.Dispose of used oil properly. A. Bracket B. BoltA. Packing. A. CartridgeRadiator and Cooling Fin Check the radiator fins for obstruction by insects or mud. Clean off any obstructions with a stream of low-pressure water.Use coolant in accordance with the instructions of the manufacturer. Soft or distilled water must be used with the antifreeze (see below for antifreeze) in the cooling system. When it is diluted excessively, it loses its anti-corrosion property. Dilute a permanent type of antifreeze in accordance with the instructions of the manufacturer.A. Reserve Tank B. Reserve Tank CapDrive Belt. In order for the belt and belt pulleys to function properly, check the drive belt in accordance with the Periodic Maintenance Chart. Spark plug removal should be done by a competent mechanic following the instructions in the Service Manual. Evaporative Emission Control System (California model only). This system routes fuel vapors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. In dusty, rainy, or on muddy conditions, the air cleaner element should be serviced more frequently than the recommended interval. If any part of the element is damaged, the element must be replaced.Check the throttle grip play, in accordance with the Periodic Maintenance Chart, and adjust the throttle grip play. Throttle Grip The throttle grip controls the butterfly valves in the throttle body.Idle Speed. The idle adjustment should be performed in accordance with the Periodic Maintenance Chart or whenever the idle speed is disturbed. Adjustment Start the engine, and warm it up thoroughly. Clutch. Due to friction plate wear and clutch cable stretch over a long period of use, the clutch must be adjusted in accordance with the Periodic Maintenance Chart.Brake Wear Inspection Inspect the brakes for wear. For each front and rear disc brake caliper, if the thickness of either pad is less than 1 mm (0.04 in), replace both pads in the caliper as a set. Inside the front brake fluid reservoir is a stepped line showing the upper level line. Fluid Change Have the brake fluid changed by an authorized Kawasaki dealer. Front and Rear Brakes Disc and disc pad wear is automatically compensated for and has no effect on the brake lever or pedal action. Brake Light Switches. When either the front or rear brake is applied, the brake light goes on. The front brake light switch requires no adjustment, but the rear brake light switch should be adjusted in accordance with the Periodic Maintenance Chart. Adjustment To adjust the rear brake light switch, move the switch up or down by turning the adjusting nut.The rear shock absorber can be adjusted by changing the spring preload for various riding and loading conditions. Spring Preload Adjustment The rear shock absorber spring preload adjuster has 7 positions.A. Spring Preload Adjuster B. Wrench. Position Spring Action. A. Under Part of Reserve Tank B. HolderTires Payload and Tire Pressure Failure to maintain proper inflation pressures or observe payload limits for your tires may adversely affect handling and performance of your motorcycle and can result in loss of control.An accepted estimate is that 90 of all tire failures occur during the last 10 of tread life (90 worn).It is not necessary to check the battery electrolyte level or add distilled water. Self-discharge Approx.