Like this Manual?SAFETY FIRST: Protective gloves and eyewear are recommended at this point.
Remove the rear fender. See the Rear Fender topic for more information.
Looking at the fuel pump disconnect the fuel line from the fuel valve on the left side and then disconnect the vacuum and fuel lines from the right side.
Remove the fuel valve bracket bolts with a 10 mm socket.
Remove the fuel tank mounting bolts with a 10 mm socket. Slide the front portion of the tank out of the frame enough to access the fuel valve mounting bolts.
Remove the fuel valve mounting bolts with a 10 mm socket.
Remove the fuel valve from the tank.
Inspect the fuel valve and tube for any damage. Kawasaki only sells the fuel valve assembly but at the time of writing rebuild kits were available.
Check that the screen filter is in good condition.
Remove the old O-ring.
Remove the plate screws with a #2 screwdriver.
Remove the plate.
Remove the wave spring.
Remove the fuel knob.
Remove the O-ring.
Remove the inner rubber.
Remove the diaphragm cover screws with a #2 Screwdriver.
Remove the diaphragm cover.
Remove the spring.
Use a small flat blade to pry open the diaphragm assembly.
Remove the diaphragm noting the direction.
Fit a new diaphragm into the assembly and then align it with the fuel valve body.
Fit the spring into place and then align the cover with the fuel valve.
Install the cover screws and tighten securely with the #2 screwdriver.
Install a new inner rubber piece and O-ring.
Lightly coat the rubber parts in multi-purpose grease before assembly.
Install the knob.
Install the wave spring.
Install the cover and tighten the screws with a #2 screwdriver.
Fit a new O-ring lightly coated with multi-purpose grease into place.
Install the fuel valve into the tank and tighten the bolts with a 10 mm socket.
Fit the fuel tank back into place and tighten the bolts.
Install and tighten the fuel valve bracket bolts.
Connect the fuel and vacuum lines.
Check for any leaks.