Fury 125 Ensamblaje

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Despiece y Ensaamblaje de Fury 125 kawasaki Motors.

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<ul><li><p>FURY 125FURY 125R</p><p>MotorcycleAssembly &amp; Preparation</p><p>Manual</p></li><li><p>Foreword</p><p>In order to ship Kawasaki vehicles asefficiently as possible, they are partiallydisassembled before crating. Since some of themost commonly removed parts have a directbearing on a vehicle's reliability and safety,conscientious pre-sale assembly andpreparation becomes extremely important. Goodsetup procedures can prevent needles warrantyclaims and give customers a greater sense ofconfidence in Kawasaki and their KawasakiDealers.</p><p>This Assembly and Preparation Manualexplain step by step procedures of the followingitem for all Kawasaki Fury125.</p><p>1. Uncrating2. Assembly3. Preparation</p><p>CAUTIONCAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.</p><p>NOTE</p><p>This note symbol indicates points ofti l i t t f ffi i t d</p><p>WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.</p><p>WARNING!</p><p>NOTICENOTICE is used to address practices not ralated to personal injury.</p><p>!</p><p>The selling dealers assumes soleresponsibility for any unauthorized modificationsprior to sale. Refer to your Service Binder forany Service Bulletins specifying FactoryDirected Modifications (Special Claims) whichmust be performed before the vehicle is readyfor sale.</p><p>Whenever you see the following symbols needtheir instruction! Always follow safe operatingand maintenance practice.</p><p>Kawasaki Motor Philippines Corporation acceptsno liability for any inaccuracies or omissions in thispublication, although every possible measure hasbeen taken to make it as complete and accurate aspossible. All procedures and specifications subjectto change without notice.</p><p>particular interest for more efficient andconvenient operation.</p></li><li><p>Table of Contents</p><p>Uncrating ..........................................................................................4Opening Crate....................................................................................4 Parts Check ......................................................................................5-6</p><p>Assembly ............................................................................................7Handlebar .........................................................................................7 Front Fender .....................................................................................7 Front wheel Installation.......................................................................8 Brake Disc Cleaning ...........................................................................8 Rear View Mirrors ( Left and Right) ....................................................9 </p><p>Preparation ........................................................................................10 Battery Service .................................................................................10 Battery Activation .................................................................................11-12 Front Brake Fluid ................................................................................13Rear Brake Fluid. .................................................................................14 Drive Chain ........................................................................................15Rear Shock Absorber ..........................................................................17 Tire Air Pressures ...............................................................................17 Fuel .................................................................................................17 Engine Oil (4-Stroke) ..................................................................................18 Throtle Grip and Cable ...............................................................................19 Idle Speed Adjustment ...............................................................................19 Choke Lever and Cable ..............................................................................20Rear Brake Light Switch 20Rear Brake Light Switch ..............................................................................20 Headlight Aim .............................................................................................20 Fastener Check .............................................................................................21-22 Standard Torque Table ................................................................................23 Test Ride the Motorcycle .............................................................................23A &amp; P Check List ...........................................................................................23</p></li><li><p>UNCRATING 4</p><p>Uncrating NOTICEWhen you remove the crate bracket from the motorcycle, be careful not to drop any parts and bracket onto the fuel tank and other components, and not to scratch the fuel tank by the crate bracket. This could dama-ge the fuel tank or components.</p><p>Remove first the two lower flange bolts (D= 8, L=25) at the steering stem and discard it.</p><p>Remove the two upper bolts (D= 8, L=60 ) and washer (D=24.5) to take off the crate bracket and foam pad and discard them.</p><p>DA</p><p>Opening Crate</p><p>Crates have sharp edges and may have nails or screws that can cause cuts and injury. Always wear protective gloves, boots and eye protection when uncrating to prevent injury.</p><p>WARNING!</p><p>Clear a space about 6m (20ft) square to give your self plenty of space to work.</p><p>Place the crate upright on its base.Remove the parts box.</p><p>A. Upper FlangeBolt (D= 8 , L=60 )B. Lower FlangeBolt (D= 8 , L=25 )C. Crate BracketD. Washer (D=24.5 )Remove the top and sides of the crate.</p><p>B</p><p>C</p><p>The steel crate panel plates and fasteners have sharp edges. Always wear protective gloves, boots and eye protection when uncrating to prevent injury.</p><p>WARNING!</p></li><li><p> UNCRATING 5</p><p>Open the parts box, and check the parts against the illustrations. There may be minor differences between these illustrations and the actual vehicle parts. In the following charts under Remarks, D = diameter in millimeters, and L = length in millimeters.</p><p>1</p><p>Prats Check</p><p>23</p></li><li><p>UNCRATING 6</p><p>4224</p><p>2 111</p><p>3 154112</p><p>4 15 1</p><p>1</p><p>No. Part Name Qty. Remarks</p><p>1</p><p>HANDLEBAR MOUNTING BOLTS D = 8 , L = 50SPACERPLUGS D = 30PLUGS D = 14.5FRONT WHEEL PIN-COTTERCOLLAR D = 24 , L = 24.5FRONT FENDERCOLLAR D = 16SCREW D = 6 , L = 14CLAMPCLAMP L = 78.8BOLT-FLANGED D = 6 , L = 16BATTERY ELCTROLYTE, 12 V 3 AhOWNERS MANUAL</p><p>TOOL KIT</p></li><li><p> ASSEMBLY 7</p><p>AssemblyHandlebar Installation</p><p>Install the right handlebar with the mounting bolts (D = 8 , L = 50) (2) in place.</p><p>I t ll fi t th d th th l ft</p><p>A. Plastic Plugs (D=14) (4) , (D=30) (2)B. Socket Bolt (D = 8 , L = 50) (4)C. Left and Right HandlebarD. Spacers</p><p>Install the front fender on the fork legs, and install the collar (D=16)(4) with screw(D=6, L=14) (4) at the left and right of the fork legs.</p><p>A. Boltflange (D=6,L=16)B. Collar (D=16) and Screw (D=6,L=14)C. Front FenderD. Clamp</p><p>Install the flange bolt (D=6,L=16)at the right side with collar (D=16) inside of front fender, and install the clamp cable guide holder at the right i t ll d t bl</p><p>D</p><p>B</p><p>C</p><p>A</p><p>Handlebar</p><p>A. Brake HoseB. Clamp</p><p>A. Speedometer CableB. Clamp</p><p>Install first the spacer and then the left handlebar in the same manner as the right handlebar.Tighten the left and right handlebar mounting bolts to the specified torque.</p><p>Torque: 23 Nm (2.3 kgfm, 17 ftlb)Push the plastic plugs (D=14)(4) into the </p><p>handlebar mounting bolts and Install the platic plug (D=30)(2) to left and right handlebar.</p><p>Install the front brake hose clamp on the left side(L = 78.8) with flangebolt (D=6, L=16) inside of the front fender and then tighten it.</p><p>Front Fender InstallationInstall the front fender with its facing forward.</p><p>install speedometer cable.</p><p>A. Front FenderB. ForwardC. Back</p><p>A</p><p>B C</p><p>A</p><p>B</p><p>A</p><p>B</p><p>Front Fender</p></li><li><p>ASSEMBLY 8</p><p>Lift the motorcycle off the crate base and support the motorcycle with a suitable stand or jack to install the front wheel.</p><p>Check the wheel rotation mark on the front tire.</p><p>A. Axle NutB. Front AxleC. Pin-Cotter</p><p>Discard the crate base.</p><p>C B</p><p>A</p><p>A. Front AxleB. Case-Assy-MeterC. Axle NutD. CollarE. Pin-Cotter</p><p>Torque: 48 Nm (4.9 kgfm , 35 ftlb)</p><p>E</p><p>D</p><p>ABC</p><p>It may take several application of the brake lever before the brake pads contack the disc, </p><p>WARNING </p><p>Tigten the front axle nut (D= 17) to the spe-cified torque and install the pin-cotter.</p><p>Loosen the left axle nut and remove the front axle. </p><p>Front Wheel Installation</p><p>!</p><p>A. Front WheelB. ArrowC. Rotation</p><p>NOTE</p><p>Fit the axle collar on the left sides of the front wheel hud. The collar are identical.</p><p>The direction of the wheel is shown by an arrow on the front tire. Install the wheel so that the ratation mark coincides with wheel ratational direction.</p><p>A</p><p>B C</p><p>Position the front wheel assembly between the fork leg.</p><p>Insert the front brake disk between the brake pads of the caliper.</p><p>p ,which could result in increased stopping distance and cause an accident resulting in injury or death. Do not attempt to ride the motorcycle until a firm brake lever is obtained by pumping the lever unit the pads are against the disc.</p><p>Clean the front brake disc using oilless solvent.</p><p>An anticorrosive treatment applied to the brake discs will increase braking distance and can cause an accident resulting in se-rious injury or death. Remove the anticor-rosive treatment using an oilless solvent.</p><p>WARNING</p><p>Brake Disc Cleaning</p><p>!</p><p>Insert the front axle from the right side of the wheel and push it completely through.</p></li><li><p> ASSEMBLY 9</p><p>Turn the stay to assure visibility to the rear with the operator sitting on the motorcycle.</p><p>Adjust the rear view mirror by slightly moving only the mirror portion of the assembly.</p><p>Conventional Type (Single Nut)Loosen the lucknut completely.Screw the rear view morror in completely, and </p><p>then back it two turns out.Turn the mirror stay to assure visibility to the </p><p>rear with the operator sitting on the motorcycle and tighten the locknut securely.</p><p>Adjust the rear view mirror by slightly moving only the mirror portion of the assembly.</p><p>NOTICEDo not force to tighten and / or loosen the upper hexagonal area (adapter) with a span-ner or wrench. Disassembly of this area is not possible. Non-permanent locking agent is already applied to the threads of this inner area. Forcible loose- ning may damage the adapter and/or the turning mecha-nism of the stay.</p><p>B</p><p>A</p><p>B</p><p>A</p><p>Rear View Mirror (Left and Rigth)</p><p>A. LocknutB. Rear View Mirror (Right)</p><p>Installation and adjustment of the left side mirror is common with the right side. Follow the procedure specified for the right side.</p><p>Turning Stay TypeScrew the mounting area of the right rear view </p><p>mirror into the holder all the way, and tighten the lower hexagonal area securely.</p><p>A. Lower Hexagonal Area for TighteningB. Upper Hexagonal Area (Adapter)C. Rear View Mirror (Right)</p><p>A. StayB. Mirror</p><p>Installation and adjustment of the left side mirror is common with the right side. Follow the procedure specified for the right side.</p><p>B</p><p>C</p><p>B</p><p>A</p></li><li><p>PREPARATION 10</p><p>Preparation</p><p>The battery used in this motorcycle is a sealed type and never needs to be refilled. Follow the procedure for activating a new battery to ensure the best possible battery performance.</p><p>Activating the battery requires two steps, filling the battery with electrolyte , and charging. Read the electrolyte safety label and the following procedure carefully before activation.</p><p>Make sure to use the electrolyte packed in the </p><p>NOTICEIncorrect Battery Activation will reduce battery performance and service life. Be sure to strictly follow the Battery Service instructions in this Manual.</p><p>Insert the ignition key into the switch ignition and turn counterclockwise to open the seat. </p><p>Seat Unlock</p><p>Battery RemovalTake the battery out of the battery case.</p><p>A</p><p>B</p><p>A. SeatB. Seat Lock</p><p>Battery Service</p><p>y pcrate with the unit.Make sure that the model name of the elec-trolyte container matches the model name of the battery. These names must be the same.Battery Model Name for:AX125A/B: YTX4L-BS</p><p>A. Model Name of the ElectrolyteB. Model Name of the Battery</p><p>NOTICE</p><p>Sealed battery electrolyte has a higher cancentration of sulfuric acid. Each con-tainer contains the proper amount of electrolyte for its specific battery. Insu- fficient or incorrect electrolytre will reduce battery performance and service life. Electrolyte over capacity can lead to battery cracking or leaking and result in corrosion damage to the vehicle.</p><p>A. Rubber BandB. Negative (-) CableC. Terminal CapD. Positive (+) CableE. BatteryClean the terminals.</p><p>NOTICEBe sure to disconnect the negative (-) cable first.</p><p>Battery Specification</p><p>E</p><p>Make YuasaBattery Type YTX4L-BS</p><p>Battery Capacity 12 V 3 Ah</p></li><li><p> PREPARATION 11</p><p>Filling the Battery with Electrolyte</p><p>NOTICEDo not remove the alluminum sealing sheet [A] from the filler ports [B] until just prior to use. Be sure to used the dedica-ted eloctrolyte container for correct elec-trolyte volume.</p><p>Place the batterry on the a level surface.Check to see that the sealing sheet [A] has no </p><p>peeling, tears, or holes in it.Remove the sealing sheet [A].</p><p>NOTEThe battery is vacuum sealed. If the sea-</p><p>ling sheet has leaked air into the battery,it may required longer initial charge.</p><p>Place the electrolyte container upside down with the six sealed cells into the filler ports of the battery. Hold the container level, push down the break the seals of all six cells. You will see air bubbles rising into each cell as the port fill.</p><p>NOTEDo not tilt the electrolyte container.</p><p>Check the elctrolyte flow.If no air bubbles [A] are coming up from the filler </p><p>ports, or if the container cells have not emptied completely, tap [B] the container a few times.</p><p>Battery Activation</p><p>Remove the electrolyte container from the vinyl bag.Detach the strip of caps [A] from the con- tainer </p><p>and set asidem, these will be used later to seal the battery. </p><p>NOTEDo not pierce or otherwise open the sea-led </p><p>cells [B] of the electrolyte container. Donot attemp to separate individual cells.</p><p>p y p [ ]</p><p>Keep the container in a place for 20 minutes or more. Don't remove the container from the battery untill it's empty, the battery requires all the electrolyte from the container for proper operation.</p><p>NOTICERemoval of the container before it is completely empty can shorten the sevice life of the battery. Do not remove the elec trolyte container until it is completely empty and 20 minutes have elapsed.</p><p>Gently remove the container from the battery.Let the battery sit for 30 minutes prior to </p><p>charging to allow the electrolyte to permeate into the plate optimum performance.</p></li><li><p>PREPARATION 12</p><p>NOTECharging the battery immediately after filling </p><p>can shorten service life. Let the battery sit for at least 30 minutes after filling.</p><p>Place the strip of caps [A] loosely over the filler ports.</p><p>Newly activated sealed batteries requred an initial charge.Standard Charge 0.4 A x 5 ~ 10 hours</p><p>If using a recommended battery charger, follow th h ' i t ti f l ti t d</p><p>Initial Charge</p><p>NOTICEOnce the strip of caps [A]...</p></li></ul>