Service Manual (KLZ1000C) — page 23 of 762

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PERIODIC MAINTENANCE 2-1

                           Periodic Maintenance
                                                      Table of Contents
Periodic Maintenance Chart ...................................................................................................                2-3
Torque and Locking Agent......................................................................................................                2-5   2
Specifications .........................................................................................................................     2-11
Special Tools ..........................................................................................................................     2-13
Periodic Maintenance Procedures..........................................................................................                    2-14
 Fuel System (DFI)................................................................................................................           2-14
   Air Cleaner Element Replacement....................................................................................                       2-14
   Idle Speed Inspection .......................................................................................................             2-14
   Idle Speed Adjustment......................................................................................................               2-15
   Throttle Control System Inspection...................................................................................                     2-15
   Engine Vacuum Synchronization Inspection.....................................................................                             2-15
   Fuel System Inspection.....................................................................................................               2-16
   Fuel Filter Replacement....................................................................................................               2-17
   Fuel Hose Replacement ...................................................................................................                 2-19
   Evaporative Emission Control System Inspection (Other than CA Model) .......................                                              2-21
 Cooling System....................................................................................................................          2-22
   Coolant Level Inspection...................................................................................................               2-22
   Cooling System Inspection ...............................................................................................                 2-22
   Coolant Change ................................................................................................................           2-22
   Water Hose and O-ring Replacement ...............................................................................                         2-25
 Engine Top End ...................................................................................................................          2-26
   Valve Clearance Inspection ..............................................................................................                 2-26
   Valve Clearance Adjustment.............................................................................................                   2-27
   Air Suction System Damage Inspection............................................................................                          2-31
 Clutch...................................................................................................................................   2-32
   Clutch Operation Inspection .............................................................................................                 2-32
 Engine Lubrication System ..................................................................................................                2-33
   Engine Oil Change............................................................................................................             2-33
   Oil Filter Replacement ......................................................................................................             2-34
 Wheels/Tires ........................................................................................................................       2-35
   Air Pressure Inspection.....................................................................................................              2-35
   Wheels and Tires Inspection.............................................................................................                  2-35
   Wheel Bearing Damage Inspection ..................................................................................                        2-36
 Final Drive............................................................................................................................     2-37
   Drive Chain Lubrication Condition Inspection ...................................................................                          2-37
   Drive Chain Slack Inspection ............................................................................................                 2-37
   Drive Chain Slack Adjustment ..........................................................................................                   2-38
   Wheel Alignment Inspection .............................................................................................                  2-39
   Drive Chain Wear Inspection ............................................................................................                  2-39
   Chain Guide Wear Inspection ...........................................................................................                   2-40
 Brakes..................................................................................................................................    2-40
   Brake System Inspection ..................................................................................................                2-40
   Brake Operation Inspection ..............................................................................................                 2-41
   Brake Fluid Level Inspection.............................................................................................                 2-41
   Brake Fluid Change ..........................................................................................................             2-42
   Brake Hose and Pipe Replacement..................................................................................                         2-44
   Master Cylinder Rubber Parts Replacement ....................................................................                             2-46
   Caliper Rubber Parts Replacement ..................................................................................                       2-47
   Brake Pad Wear Inspection ..............................................................................................                  2-50
   Brake Light Switch Operation Inspection ..........................................................................                        2-51