2003 Kawasaki ER500-C3 ( ER 500 C3 ) Complete Service Manual

 The ER-5 Motorcycle Service Manual covers the following model years:

•    2001: ER500-C1, ER500-D1

•   2002: ER500-C2

•    2003: ER500-C3

•    2004: ER500-C4

•    2005: ER500-C5

Each model is identified by a specific frame number range.

The document is a Kawasaki ER-5 Motorcycle Service Manual covering maintenance, repair, and troubleshooting procedures. It includes sections on the fuel system, cooling system, engine, clutch, lubrication, transmission, wheels, brakes, suspension, steering, frame, and electrical system. It provides detailed instructions, safety warnings, and specifications for servicing the motorcycle.

Summary of the Document
General Information

•    Quick reference guide for locating topics and procedures.

•    Follow safe operating and maintenance practices; heed WARNING and CAUTION symbols.

•    Disconnect battery ground before disassembly to prevent accidental engine turnover.
Fuel System

•    Inspect and adjust idle speed and carburetor synchronization.

•    Ensure fuel hoses are securely connected and routed properly.
Cooling System

•    Perform coolant level inspection, draining, and filling.

•    Inspect and replace radiator fan switch and water temperature switch.
Engine Top End

•    Inspect and adjust valve clearance and compression measurement.

•    Remove and install cylinder head and camshaft.
Clutch

•    Adjust and lubricate clutch lever and cable.

•    Inspect and replace friction plates if damaged.
Engine Lubrication System

•    Check and change engine oil and oil filter.

•    Inspect and clean oil screen and relief valve.
Crankshaft/Transmission

•    Remove and install crankshaft and connecting rods.

•    Inspect crankshaft runout and bearing clearance.
Final Drive

•    Inspect and adjust drive chain slack and alignment.

•    Remove and replace engine and rear sprockets.
Brakes

•    Inspect and lubricate brake drum and brake shoe components.

•    Ensure proper brake pedal pivot lubrication.
Suspension & Steering

•    Change fork oil and inspect for leaks.

•    Remove and install steering stem and bearings.
Electrical System

•    Inspect and replace battery, starter motor, and alternator rotor.

•    Adjust headlight beam and replace bulbs.

•    Quick Reference Guide: Helps locate topics and procedures efficiently.

•    Emission Control Systems: Includes crankcase, exhaust, and evaporative emission controls.

•    Tampering Prohibited: Federal law restricts modification of emission and noise control systems.

•    Maintenance Guidelines: Follow manual procedures, use proper tools, and keep records.

•    Engine and Mechanical Maintenance: Covers lubrication, cooling, crankshaft, and transmission.

•    Electrical System: Includes wiring diagrams, starter system, and lighting.

•    Safety Warnings: Symbols indicate warnings, cautions, and important notes.

•    Torque and Assembly Instructions: Follow specified tightening sequences and torque values.

Here is the full chapters index based on the available information:

1.    General Information
    
•    Model Identification
    
•    General Specifications
    
•    Periodic Maintenance Chart
    
•    Torque and Locking Agent
    
•    Special Tools and Sealants
    
•    Cable, Wire, and Hose Routing

2.    Fuel System
    
•    Free Play Adjustment
    
•    Cable Installation and Lubrication
    
•    Carburetors (Idle Speed, Synchronization, Removal, Installation)
    
•    Service Fuel Level Inspection and Adjustment
    
•    Fuel System Cleanliness Inspection
    
•    Carburetor Disassembly, Cleaning, and Inspection
    
•    Air Cleaner Maintenance

3.    Cooling System
    
•    Coolant Specifications and Inspection
    
•    Coolant Draining and Filling
    
•    Cooling System Pressure Testing
    
•    Radiator, Radiator Fan, and Thermostat Maintenance
    
•    Water Pump Removal, Installation, and Inspection

4.    Engine Top End
    
•    Clean Air System
    
•    Cylinder Head and Valves
    
•    Valve Clearance Inspection
    
•    Camshaft Chain Tensioner
    
•    Cylinder and Piston Maintenance

5.    Clutch
    
•    Clutch Adjustment and Lubrication
    
•    Clutch Hub Spline Inspection
    
•    Friction Plate Inspection and Replacement

6.    Engine Lubrication System
    
•    Engine Oil Flow Chart
    
•    Engine Oil Level Inspection and Change
    
•    Oil Filter Replacement
    
•    Oil Pump and Relief Valve Maintenance

7.    Engine Removal/Installation
    
•    Engine Mounting Bolts and Torque Specifications
    
•    Cable, Wire, and Hose Routing
    
•    Drive Chain and Throttle Cable Adjustments

8.    Crankshaft/Transmission
    
•    Crankcase Splitting and Assembly
    
•    Clutch Housing and Primary Chain
    
•    Crankshaft and Connecting Rods
    
•    Transmission Shafts and Shift Mechanism

9.    Wheels/Tires
    
•    Front and Rear Wheel Removal/Installation
    
•    Wheel Inspection and Balance
    
•    Tire Wear Inspection and Replacement
    
•    Hub Bearing Maintenance

10.    Final Drive
    
•    Drive Chain Slack Adjustment
    
•    Engine and Rear Sprocket Replacement

11.    Brakes
    
•    Brake Play and Fluid Level Inspection
    
•    Brake Hoses and Connections
    
•    Brake Pad Wear Inspection

12.    Suspension
    
•    Front Fork Oil Leak Inspection
    
•    Rear Shock Absorber Maintenance
    
•    Swingarm and Needle Bearing Lubrication

13.    Steering
    
•    Handlebar and Rear View Mirror Installation
    
•    Steering Stem and Bearing Inspection

14.    Frame
    
•    Side Stand and Footpeg Bracket Maintenance
    
•    Rear Frame Mounting Bolts

15.    Electrical System
    
•    Parts Location and Wiring Inspection
    
•    Battery and Charging System
    
•    Starter Motor and Relay Inspection
    
•    Lighting System and Headlight Adjustment
    
•    Ignition System and Spark Plug Maintenance
    
•    Fuses and Switches Inspection

16.    Appendix
    
•    Unit Conversion Table
    
•    Abbreviations
    
•    Special Tools and Sealants
This index provides a structured overview of the chapters and major topics covered.

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