Kawasaki J300 User manual

Category
Motorcycles
Type
User manual

This manual is also suitable for

J300
J300 ABS
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.
•Refer to the sectional table of contents
for the exact pages to locate the spe-
cific topic required.
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
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,
without the prior written permission of Quality Assurance Division/Motorcycle & Engine Company/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 without prior 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.
All information contained in this publication is based on the latest product information available at the time
of publication. Illustrations and photographs in this publication are intended for reference use only and may
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) ohm(s)
ISC Idle Speed Control
Foreword
This manual is designed primarily for use by
trained mechanics in a properly equipped shop.
However, it contains enough detail and basic in-
formation to m ake it useful to the owner who de-
sires to perform his own basic maintenance and
repair work. A basic knowledge of mechanics,
the proper use of tools, and workshop proce-
dures must be understood in order to carry out
maintenance and repair satisfactorily. When-
ever the owner has insufficient experience or
doubts his ability to do the work, all adjust-
ments, maintenance, and repair should be car-
ried out only by qualified mechanics.
In order to perform the work efficiently and
to avoid costly m istakes, read the text, thor-
oughly familiarize yourself with the procedures
before starting work, and then do the work care-
fully in a clean area. Whenever special tools or
equipment are specified, do not use makeshift
tools or equipment. Precision measurements
can only be made if the proper instruments are
used, and the use of substitute tools may ad-
versely affect safe operation.
For the duration of the warranty period,
we recommend that all repairs and scheduled
maintenance be performed in accordance with
this service manual. Any owner maintenance or
repair procedure not performed in accordance
with this manual may void the warranty.
To get the longest life out of your vehicle.
Follow the Periodic Maintenance Chart in the
Service Manual.
Be alert for problems and non-scheduled
maintenance.
Use proper tools and genuine Kawasaki Mo-
torcycle parts. Special tools, gauges, and
testers that are necessary when servicing
Kawasaki motorcycles are introduced by the
Service Manual. Genuine parts provided as
spare parts are listed in the Parts Catalog.
Follow the procedures in this manual care-
fully. Don’t take shortcuts.
Remember to keep complete records of main-
tenance and repair with dates and any new
parts installed.
How to Use This Manual
In this manual, the product is divided into
its major systems and these systems make up
the m anual’s chapters. The Quick Reference
Guide s hows y ou all of the product’s system
and assists in locating their chapters. Each
chapter in turn has its own comprehensive Ta-
ble of Contents.
For example, if you want ignition coil informa-
tion, use the Quick Reference Guide to locate
the Electrical System chapter. Then, use the
Table of Contents on the first page of the chap-
ter to find the Ignition Coil section.
Whenever you see symbols, heed their in-
structions! Always follow safe operating and
maintenance practices.
DANGER
DANGER indicates a hazardous situa-
tion which, if not avoided, will result in
death or serious injury.
WARNING
WARNING indicates a hazardous situa-
tion which, if not avoided, could result
in death or serious injury.
NOTICE
NOTICE is used to address practices not
related to personal injury.
This manual contains four more symbols
which will help you distinguish different types
of information.
NOTE
NOTE indicates information that may help
or guide you in the operation or service of
the vehicle.
Indicates a procedural step or work to be
done.
Indicates a procedural sub-step or how to do
the work of the procedural step it follows. It
also precedes the text of a NOTE.
Indicates a conditional step or what action to
take based on the results of the test or inspec-
tion in the procedural step or sub-step it fol-
lows.
In most chapters an exploded view illustration
of the system components follows the Table of
Contents. In these illustrations you will find the
instructions indicating which parts require spec-
ified tightening torque, oil, grease or a locking
agent during assembly.
GENERAL INFORMATION 1-1
1
General Information
Table of Contents
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-
tion on a motorcycle, read the p recautions given below. To facilitate actual operations, notes, illustra-
tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever
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
Before completing any service on the motorcycle, 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 (+) terminal of the battery then the negative (–) 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
other foreign materials entering into sealed areas during ve-
hicle disassembly can cause excessive wear and decrease
performance of the vehicle.
GENERAL INFORMATION 1-3
Before Servicing
Arrangement and Clea ning of Removed Parts
Disassembled parts are easy to confuse. Arrange the
parts according to the order the parts were disassembled
and clean the parts in order prior to assembly.
Storage of Remov ed Parts
After all the parts including subassembly parts have been
cleaned, store the parts in a clean area. Put a clean cloth
or plastic sheet over the parts to protect from any foreign
materials that may collect before re-assembly.
Inspection
Reuse of worn or damaged parts may lead to serious ac-
cident. Visually inspect removed parts for corrosion, discol-
oration, or other damage. Refer to the appropriate sections
of this manual for service limits on individual parts. Replace
the parts if any damage has been found or if the part is be-
yond its service limit.
Replacement Parts
Replacement Parts must be KAWASAKI genuine or
recommended by KAWASAKI. Gaskets, O-rings, oil seals,
grease seals, circlips, cotter pins or self-locking nuts must
be replaced with new ones whenever disassembled.
Assembly Order
In most cases assembly order is the reverse of disassem-
bly, however, if assembly order is provided in this Service
Manual, follow the procedures given.
1-4 GENERAL INFORMATION
Before Servicing
Tightening Sequence
Generally, when installing a part with several bolts, nuts,
or screws, start them all in their holes and tighten them to
a snug fit. Then tighten them according to the specified se-
quence to prevent case warpage or deformation which can
lead to malfunction. Conversely when loosening the bolts,
nuts, or screws, first loosen all of them by about a quar-
ter turn and then remove them. If the specified tightening
sequence is not indicated, tighten the fasteners alternating
diagonally.
Tightening Torque
Incorrect torque applied to a bolt, nut, or screw may
lead to serious damage. Tighten fasteners to the specified
torque using a good quality torque wrench. Often, the
tightening sequence is followed twice-initial tightening and
final tightening with torque wrench.
All of the tightening torque values are for use with dry,
solvent - cleaned threads unless otherwise indicated. If a
fastener which should have dry, clean threads gets contami-
nated with lubricant, etc., applying even the specified torque
could damage it.
Force
Use common sense during disassembly and assembly,
excessive force can cause expensive or hard to repair dam-
age. When necessary, remove screws that have a non
-permanent locking agent applied using an impact driver.
Use a plastic-faced mallet whenever tapping is necessary.
Gasket, O-ring
Hardening, shrinkage, or damage of both gaskets and
O-rings after disassembly can reduce sealing performance.
Remove old gaskets and clean the sealing surfaces thor-
oughly so that no gasket material or other material remains.
Install the new gaskets and replace the used O-rings when
re-assembling.
Liquid Gasket, Non-permanent Locking Agent
For applications that require Liquid Gasket or a
Non-permanent Locking Agent, clean the s urfaces so
that no oil residue remains before applying liquid gasket or
non-permanent locking agent. Do not apply them exces-
sively. Excessive application can clog oil passages and
cause serious damage.
GENERAL INFORMATION 1-5
Before Servicing
Press
For items such as bearings or oil seals that must be
pressed into place, apply small amount of oil to the con-
tact area. Be sure to maintain proper alignment and use
smooth movements when installing.
Ball Bearing and Needle Bearing
Do not remove pressed ball or needle unless removal is
absolutely necessary. Replace with new ones whenever
removed. Press bearings with the manufacturer and size
marks facing out. Press the bearing into place by putting
pressure on the correct bearing race as shown.
Pressing the incorrect race can cause pressure between
the inner and outer race and result in bearing damage.
Oil Seal, Grease Seal
Do not remove pressed oil or grease seals unless removal
is necessary. Replace w ith new ones whenever removed.
Press new oil seals with manufacture and size marks facing
out. Make sure the seal is aligned properly when installing.
Apply specified grease to the lip of seal before installing
the seal.
Circlips, Cotter Pins
Replace the circlips or cotter pins that were removed with
new ones. Take care not to open the clip excessively when
installing to prevent deformation.
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. Ro-
tate the crankshaft to positive direction (clockwise viewed
from output side).
Electrical Leads
A two-color lead is identified first by the primary color and
then the stripe color. Unless instructed otherwise, electrical
leads must be connected to those o f the same color.
Instrument
Use a meter that has enough accuracy for an accurate
measurement. Read the manufacture’s instructions thor-
oughly before using the meter. Incorrect values may lead
to improper adjustments.
GENERAL INFORMATION 1-7
Model Identification
SC300AE Left Side View
SC300AE Right Side View
1-8 GENERAL INFORMATION
Model Identification
SC300BE Left Side View
SC300BE Right Side View
Frame Number Engine Number
GENERAL INFORMATION 1-9
General Specifications
Items SC300AE AF/BE BF
Dimensions
Overall Length 2 235 mm (87.99 in.)
Overall Width 775 mm (30.51 in.)
Overall Height 1 260 mm (49.61 in.)
Wheelbase 1 555 mm (61.22 in.)
Road Clearance 145 mm (5.71 in.)
Seat Height 775 mm (30.5 in.)
Curb Mass: 191 kg (421 lb)
Front
78 kg (172 lb)
Rear 113kg(249lb)
Fuel Tank Capacity 13 L (3.4 US gal)
Performance
Minimum Turning Radius
2.6 m (8.5 ft)
Engine
Type 4-stroke, SOHC, single cylinder
Cooling S ystem
Liquid-cooled
Bore and Stroke 72.7 × 72.0 mm (2.86 × 2.83 in.)
Displacement 299 cm³ (18.2 cu in.)
Compression Ratio 10.8:1
Maximum Horsepower 20.3 kW (28 PS) @7 750 r/min (rpm)
Maximum Torque 28.7 N·m (2.9 kgf·m, 21 ft·lb) @6 250 r/min (rpm)
Fuel System: FI (Fuel Injection) KEIHIN 34 × 1
Minimum Octane Rating:
Research Octane
Number (RON)
91
Starting System
Electric starter
Ignition System ECU control (full transistor)
Timing Advance Electronically advanced
Ignition Timing
10.0° BTDC @1 600 r/min (rpm) to 30.0° BTDC @7 750 r/min
(rpm)
Spark Plug NGK CR7E
Valve Timing:
Intake:
Open (BTDC)
Close 37° (ABDC)
Duration 226°
Exhaust:
Open 39° (BTDC)
Close 10° (ATDC)
Duration
229°
Lubrication System Forced lubrication (wet sump)
1-10 GENERAL INFORMATION
General Specifications
Items SC300AE AF/BE BF
Engine Oil:
Type
API S J, SL or SM with JASO MA, MA1 or MA2
Viscosity SAE 5W-50
Capacity 1.5L(1.6USqt)
Drive Train
Driving System V-Matic continuously variable
Primary Reduction Ratio 2.220 0.790
Final Reduction Ratio 7.222
Over Drive Ratio 16.030 5.700
Clutch Type Automatic, centrifugal
Frame
Type Tubular diamond
Caster (Rake Angle) 28°
Trail 113 mm (4.45 in.)
Front Tire:
Type MAXXIS, i PRO, Tubeless
Size 120/80-14 M/C 58S
Rear Tire:
Type MAXXIS, PRO, Tubeless
Size 150/70-13 M/C 64S
Rim Size:
Front J14×3.0
Rear J13×4.0
Front Suspension:
Type Telescopic fork
Wheel Travel 110 mm (4.33 in.)
Rear Suspension:
Type
Swingarm
Wheel Travel 100 mm (3.94 in.)
Brake Type:
Front
Single disc
Rear
Single disc
Electrical Equipment
Battery
12V10Ah(10HR)
Headlight:
Type Semi-sealed beam
Bulb:
High 12 V 35 W × 2
Low 12 V 35 W × 2
Tail/Brake Light
LED
Alternator:
Type Three-phase AC
Maximum Output 25.0 A/14 V @10 000 r/min (rpm)
Specifications are subject to change without notice, and may not apply to every country.
GENERAL INFORMATION 1-11
Unit Conversion Table
Prefixes for Units:
Prefix Symbol Power
mega M × 1 000 000
kilo k ×1000
centi c ×0.01
milli m × 0.001
micro µ × 0.000001
Units of Mass:
kg ×2.205=lb
g × 0.03527 = oz
Units of Volume:
L × 0.2642 = gal (US)
L × 0.2200 = gal (IMP)
L × 1.057 =
qt (US)
L × 0.8799 =
qt (IMP)
L × 2.113 = pint (US)
L × 1.816 = pint (IMP)
mL × 0.03381 = oz (US)
mL × 0.02816 = oz (IMP)
mL × 0.06102 = cu in.
Units of Force:
N × 0.1020 = kg
N × 0.2248 = lb
kg ×9.807=N
kg ×2.205=lb
Units of Length:
km × 0.6214 = mile
m × 3.281 = ft
mm × 0.03937 = in.
Units of Torque:
N·m × 0.1020 = kgf·m
N·m × 0.7376 = ft·lb
N·m × 8.851 = in·lb
kgf·m × 9.807 = N·m
kgf·m × 7.233 = ft·lb
kgf·m × 86.80 = in·lb
Units of Pressure:
kPa × 0.01020 = kgf/cm²
kPa × 0.1450 = psi
kPa × 0.7501 = cmHg
kgf/cm² × 98.07 = kPa
kgf/cm² × 14.22 = psi
cmHg×1.333=kPa
Units of Speed:
km/h
× 0.6214 = mph
Units of Power:
kW ×1.360=PS
kW ×1.341=HP
PS
× 0.7355 = kW
PS × 0.9863 = HP
Units of Temperature:
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Kawasaki J300 User manual

Category
Motorcycles
Type
User manual
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