Kawasaki H1-D 1972 Assembly & Preparation Manual

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KAWASAKI |,IOTOHS

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19i-2PF,li'.lTFD lhj

&.

âtænaeræ§

Lj.S.A

KAWASAKI MODEL

ASSEMBLY

There

are ihree maior

ASSEMBTY INSTRIJCTIONS

PREPARATION

SERVICE SPECIFICATION

SERVICING

seclions

AND

PREPARATION MANUAT

in this manual:

-Work

-Detailing

-Handy

performed during

specs for

and inspection

possible

HI.D

uncrating

performed

trou ble-shooting.

and assembly.

before

delivery.

PAGE

I

Clear a 20' x 20'area,

cut

on

the

its

base. Pry

banding

upright

then

crate.

and then

off

wires

at the corners

posilion

The crate

the Iop panel,

of

%

'#

and

the

BÂSE I.EGS

Fold

back the

panels

plastic

and The

covering

front fender,
the

strap holding

the

of

Do

f rom the f

crate,

not

remove the protective

uel Tank

top panel

Two

and

and the

end

lift

two

and pull

panels.

Ihe front

out

parts

the handlebar

and remove the

at this time.

down

Remove

wheel, the

côrtons.

to

the

handlebar.

packing

The

side

ihe

Pry up

bottorn

NOTE:

maierial

FRONT

Ë€

W}IEEI.

Ë

(Ross

lE

§,'

:l i

BRÂ(E

..:15

With

a helper, lift

the

of

crate base, and then lift

the cross

CAUTION: Peen

puncturing

or

Ihe center stand.

brace.

the tires.

the rear

Roll

over any nails to

of the moTorcycle

the front

the

uniT

ouf of

Park the moïorcycle

by

The

prevent

out

using

craTe.

iniury

on

**,

,§

u3"

t,É

É\

!-t

'.:::' ':::l

§

1ÿ

-/

Open

A.

B.
C.
D.

E.
F.

G. Front

É

§:

l.

Êl

1

\

I

t

\

\

K

the parts

Seat backrest

Grab rail.

Front fender
Froni wheel

Seat backrest

ers, 4 washers.

Grab rail hardware:

2 washers.

washers.

carTons and check the

assembly.

ôssembly.

hardware: 4 bolts,

fender

§

§*

\J

,*

re !&

w

§=

''F:

i

I

t

I

I
t

I

I
I

I

I

I

i

I

Ê*

2 bolts, 2 lockwashers,

hardware'

4 bolts, 4 lock-

conïents

4 lockwash-

"...,'",,."-."#..t

;_----*

against

â

this

-.-.----._"&

"*

*Ër

ü

*

tmhffi

§

\

nt

rLt

phoio.

H.

Front

axle with

4lockwashers.

l. Speedometer

J.

Shift lever with pin,

K. Rear view

L. Handlebar

M.

Steering damper

discs,

torque

and

cotter

N.

STeering damper detent

O. Mirror mount plug.

spacer, 2

drive

mirror.

assembly.

plate,

pin.

clamps, 4

gearbox.

washer,

assembly with 2 friction

plate,

steel

spring and nut.

nuts,

and circlip.

spring,

and

nut,

t

m

rt

PAGE

3

the inside

Check
assembly

hub. Be sure

wheel

assembly

parts

Loose

gears

wilh resulting

the speedometer

of

for loose

parts

to

align

to the recesses

can

wedge

into the speedometer

damage.

fit it to the

and

tangs in

the

in

the

gear

drive

front

drive

the

hub. CAUTION:

drive

THESE PARTS

lnsert the axle spacer
shown and

thread in the axle.

inio the hub

Tighten rhe axle securely,

speedometer

drive assembly

grease

then turn

and

to check

for

seaL as

the

binding.

!&

'j;

Mount the front

bolts

fender
brake

and the fork
bend

tion,

squeal.

lockwashers,

and

toward

hose

bracket between

sliders,

the hydraulic

it

or

may cause

fender

with four

with the

the front.

brake

Be sure

as shown. CAUTION:

pipe

the disc

14 mm

short end

of the

to mount

the fender

during

brake linings to

this

brace

Do

opera-

long

the

not

Remove

caliper pads.

with The

axle

the

ers,

each nuT

Turn

cable

insure

end

nut

each to

several times

right-hand

rear, to

the

disc

ends

between the

axle mounting

but do not

with

the speedometer

axis points

lhat there

of the

speedometer

of the left-hand

l4 lb.-ft.

clamp

l4 lb.-ft.

carboard

Lift

between the

the f lat

spacer from

the front

caps

tighten them

side facing

drive

to

the left

are no

clamp

of torque.

to

center

cap

nuts, front

the

wheel into position

caliper pads,

axle

mounting

with nuts

sharp

cable. Tighten

and lockwash-

yet.

NOTE:

the lockwasher.

assembly

sparkplug.

bends in

and then

Depress ihe

axle

and tighten

first

between

and the

studs. Fit

lnstall

so that the

This

the lower

the front

the

forks

and then

the

paosT#,1

will

rear,

the

F RONT

WRONG

Remove

discard

dlebar holders
the

fwo clamps

do not lighten

packing material f rom

the handiebar clamp bolls; take

for

plate

beni

ihe metal

handlebar in the holders as

with four bolts and

them. Remove the

and bolt. Check

studs, and then

shown. lnstall the

lockwashers, but

the fuel tank.

and

off

the han-

position

prolective

lnverT

grip

lever.
and

head

are

i-.r-J

the hand

assembiy,

Rotale the handlebar io

tighten Ihe clamps.

screws

poiniing

gr p

ebar

laking care Io center the slarter

throttle

in the

downward. Be sure

does noT draq

i'ai'd e::a:

Mounl

grip.

clamp cap will space

Ihe
:he

the

The nipple on the side of

proper

bolts to aboul

môsTer cylinder

brake

distance

from

4.5 lb.-ft. of torque.

and siide on

the proper position

Tighten Ihe two Phillips

case

on

lhe master cylinder ôssembly

twist

the

the throttle

The

Ihat

so

thaT

ihe

next to the twist

The handlebar

ir.e

=-:

grip.

cab es

rubber

:t

Tighten

-'=

PAGE

7