FD671D/FD711DFD750DFD791D (DFI)4–stroke liquid-cooled v-twin gasoline engineService ManualAll rights reserved. No parts of this publication may be rep
1-6 GENERAL INFORMATIONGeneral SpecificationsItemsFD791D (DFI)Type of engineLiquid-cooled, Horizontal shaft, OHV, 4-stroke, 90V-twin, Gasoline en-gine.
LUBRICATION SYSTEM 5-1Lubrication SystemTable of Contents5Exploded View...
5-2 LUBRICATION SYSTEMExploded ViewEO: Apply engine oil.G: Apply grease.L: Apply a non-permanent locking agent.T1: 6 Nm (0.6 kg m, 52 in lb)T2: 15 Nm
LUBRICATION SYSTEM 5-3Engine Oil Flow Chart
5-4 LUBRICATION SYSTEMSpecificationsItemStandardEngine Oil:Grade API service classification; SF, SG, SH, or SJ classViscosity SAE40, SAE30, SAE10W-30 /
LUBRICATION SYSTEM 5-5Engine Oil and Oil FilterCAUTIONEngine operation with insufficient, deteriorated, or contami-nated engine oil will cause accelera
5-6 LUBRICATION SYSTEMEngine Oil and Oil Filter•Remove the oil filler cap and pour in the specified type and amountof oil.Engine Oil :Grade: API Service
LUBRICATION SYSTEM 5-7Pressurized Lubrication SystemThe engine lubrication circuit is a pressurized system consistingof a positive displacement pump w
5-8 LUBRICATION SYSTEMOil Pump and Relief ValveOil Pump, Relief Valve Removal•Remove the crankcase cover (see Camshaft/Crankshaft chapter).•Unscrew th
LUBRICATION SYSTEM 5-9Oil Pump and Relief Valve•Measure the inside diameter [A] of the pump housing with a insidemicrometer at several points.If the i
GENERAL INFORMATION 1-7Periodic Maintenance ChartTo ensure satisfactory operation over an extended period of time, any engine requires normal maintena
5-10 LUBRICATION SYSTEMOil Pump and Relief ValveIf cleaning does not solve the problem, replace the relief valve parts.If necessary, put the ball in p
LUBRICATION SYSTEM 5-11Oil Screen FilterThe oil screen filter cannot be disassembled, if any damage for theoil screen filter is noticed replace it with
CAMSHAFT/CRANKSHAFT 6-1Camshaft/CrankshaftTable of Contents6Exploded View...
6-2 CAMSHAFT/CRANKSHAFTExploded ViewEO: Apply engine oil.G: Apply grease.S: Follow the specific tightening sequence.SS: Apply silicone sealant.T1: 22 N
CAMSHAFT/CRANKSHAFT 6-3SpecificationsItemService LimitCamshaft, Tappet:Cam lobe height Intake33.594 mm (1.3226 in.)Exhaust 33.594 mm (1.3226 in.)Camsha
6-4 CAMSHAFT/CRANKSHAFTCrankcaseCrankcase Cover Removal•Set the engine on a clean surface while parts are being removed.•Drain the oil (see Lubricatio
CAMSHAFT/CRANKSHAFT 6-5Crankcase(Crankcase installation)•Check to see that the crankcase dowel pins [A] are in place on thecrankcase as shown in the fi
6-6 CAMSHAFT/CRANKSHAFTCrankcase•A coolant leaks into the engine through:A loose cylinder headA cracked or porous castingThe push rod compartment•Give
CAMSHAFT/CRANKSHAFT 6-7Crankcase•The service bushing is to be reinstalled using a bushing tool as shown.•Coat the bushing and flange surface with light
1-8 GENERAL INFORMATIONTorque and Locking AgentThe following tables lists the tightening torque for the major fasteners, and the parts requiring use o
6-8 CAMSHAFT/CRANKSHAFTBreatherThe function of the breather is to create a vacuum in the crankcasewhich prevents oil from being forced out of the engi
CAMSHAFT/CRANKSHAFT 6-9Camshaft, TappetCamshaft, Tappet Removal•Remove the crankcase cover (see Crankcase Cover Removal).•Turn the crankcase up side d
6-10 CAMSHAFT/CRANKSHAFTCamshaft, Tappet•Measure the inside diameter [A] of the camshaft bearing on thecrankcase at several points. This bearing is no
CAMSHAFT/CRANKSHAFT 6-11Crankshaft, Connecting RodConnecting Rod Removal•Remove:Piston (see Engine Top End Chapter)Connecting Rod Installation•Install
6-12 CAMSHAFT/CRANKSHAFTCrankshaft, Connecting Rod•Measure connection rod twist.With the big-end arbor still on the V blocks, hold the connection rodh
CAMSHAFT/CRANKSHAFT 6-13Crankshaft, Connecting RodCrankshaft Runout•Measure the crankshaft runout.Set the crankshaft in a flywheel alignment jig or on
ELECTRICAL SYSTEM 7-1Electrical SystemTable of Contents7Exploded View...
7-2 ELECTRICAL SYSTEMExploded ViewG: Apply grease.L: Apply a non-permanent locking agent.T1: 15 Nm (1.5 kg m, 11 ft lb)T2: 20 Nm (2.0 kg m, 15 ft lb)T
ELECTRICAL SYSTEM 7-3SpecificationsItemStandard Service LimitCharging System:Regulated output voltage Battery voltage to 15 V DC –––Alternator stator c
GENERAL INFORMATION 1-9Special ToolsCompression Gauge: 57001–221Piston Ring Pliers: 57001–115Piston Ring Compression Grip: 57001–1095Piston Ring Compr
7-4 ELECTRICAL SYSTEMWiring DiagramNOTEPortion surrounded by shows KHI procurement parts.
ELECTRICAL SYSTEM 7-5Wiring DiagramFD791D (DFI Model)NOTEPortion surrounded byshows KHI procurement parts.
7-6 ELECTRICAL SYSTEMWire Harness
ELECTRICAL SYSTEM 7-7PrecautionsThere are a number of important precautions that are musts whenservicing electrical systems. Learn and observe all the
7-8 ELECTRICAL SYSTEMCharging SystemFlywheel, Stator Coil Removal•Remove:RadiatorCooling FanStarter MotorFan Drive Sheave/Hub•Hold the flywheel [A] wit
ELECTRICAL SYSTEM 7-9Charging SystemCharging System Operational Inspection•Check battery condition.NOTEAlways check battery condition before condemnin
7-10 ELECTRICAL SYSTEMCharging SystemUnregulated Stator Output•Disconnect the stator coil connector.•Connect AC voltmeter to the stator pins.•Start th
ELECTRICAL SYSTEM 7-11Ignition SystemIgnition SystemThis engine ignition is controlled by a solid state ignition assemblyand requires no periodic main
7-12 ELECTRICAL SYSTEMIgnition SystemIgnition Coil Inspection•Remove the ignition coils (see Ignition Coil Removal).•Measure the primary winding resis
ELECTRICAL SYSTEM 7-13Electric Starter SystemStarter Motor Removal•Disconnect the wires shown [A].•Remove the mounting bolts [C] and pull the starter
1-10 GENERAL INFORMATIONSpecial ToolsOil Filter Wrench : 57001–1249Hand Tester: 57001–1394Kawasaki Bond (Silicone Sealant) : 56019–120Read Wire ECU Ad
7-14 ELECTRICAL SYSTEMElectric Starter System•Set the hand tester to the R x 1 position and connect the leads asshown.If the tester does not read clos
ELECTRICAL SYSTEM 7-15Electric Starter System•Connect the starter motor, battery and ammeter as shown.[A] Ammeter[B] Voltmeter[C] Battery[D] Switch[E]
7-16 ELECTRICAL SYSTEMElectric Starter System•Pull the armature [A] from the yoke [B].•Separate the front and rear stoppers each other using a screw d
ELECTRICAL SYSTEM 7-17Electric Starter System•Inspect the rubber insert [B] and/or boot [A] for visible damage.If they are damaged, replace them.•Fit
7-18 ELECTRICAL SYSTEMElectric Starter SystemStarter Motor Brush Inspection•Measure the overall length of each brush [A].If the brushes are shorter th
ELECTRICAL SYSTEM 7-19Electric Starter System•Support the armature in an alignment jig at each end of the shaft asshown. Position a dial indicator per
7-20 ELECTRICAL SYSTEMElectric Starter System•Set the multimeter selector switch to the R 1 position andmeasure the resistance between the negative br
TROUBLESHOOTING 8-1TroubleshootingTable of Contents8Engine Troubleshooting Guide...
8-2 TROUBLESHOOTINGEngine Troubleshooting GuideIf the engine malfunctions, check if the way the engine is used is correct. If engine malfunctions even
TROUBLESHOOTING 8-3Engine Troubleshooting Guide
FUEL SYSTEM 2-1Fuel SystemTable of Contents2Exploded View...2-3Specifications...
8-4 TROUBLESHOOTINGEngine Troubleshooting Guide
TROUBLESHOOTING 8-5Engine Troubleshooting Guide
8-6 TROUBLESHOOTINGEngine Troubleshooting Guide
TROUBLESHOOTING 8-7Engine Troubleshooting GuideFD791D (DFI Model) Trouble shootingTrouble shooting guide shows the relationship between systams and in
8-8 TROUBLESHOOTINGStarter Motor Troubleshooting Guide1. Disconnect spark plug cap, and ground the cap terminal.2. Turn engine switch to “START” posit
2-2 FUEL SYSTEMSensor Resistance inspection...2-39Water Temperature Sensor (Fault Code 13)...2-39Removal/Installation...
FUEL SYSTEM 2-3Exploded View1. Pilot Screw Assy2. Pilot Jet3. Main Jet (#105)4. Main Jet (#105)T1: 0.7 N m (0.07 kg m, 6 in lb)T2: 2.0 N m (0.2 kg m,
2-4 FUEL SYSTEMExploded ViewFD791D (DFI Model)1. Throttle Body Assy2. Electrical Control Unit (ECU)3. Fuel Injectors4. Fuel Pressure Regulator5. Inlet
FUEL SYSTEM 2-5Exploded View1. Other than DFI ModelT1: 8 N m (0.8 kg m, 69 in lb)
LIST OF ABBREVIATIONSA ampere(s) lb pound(s)ABDC after bottom dead center m meter(s)AC alternating current min minute(s)ATDC after top dead center N n
2-6 FUEL SYSTEMSpecificationsItemStandardFD671D FD711D FD750DCaburetors Specifications:Make/ type MIKUNI BW26Throttle bore diameter 26 mm (1.02 in.)Vent
FUEL SYSTEM 2-7SpecificationsItemStandardFD791D (DFI Model)Digital Fuel Injection SystemIdle SpeedLow idle speed 1550 rpmHigh idle speed 3600 rpmThrott
2-8 FUEL SYSTEMGovernor Link MechanismControl Panel Assembly Removal•Remove:Air Cleaner (see Air Cleaner Body Removal)Muffler (see Muffler Assembly Remo
FUEL SYSTEM 2-9Governor Link MechanismGovernor Arm Installation•Insert the bracket [A] onto the governor shaft [B] thoroughly to thebottom of the wood
2-10 FUEL SYSTEMGovernor Link MechanismGovernor Shaft Removal•Remove:Camshaft (see Camshaft/Crankshaft chapter)•Unscrew the governor arm clamp nut, an
FUEL SYSTEM 2-11CarburetorFuel and Air FlowThe main system of the carburetor consists of the main jet [A], mainnozzle [B], and the main air passage (m
2-12 FUEL SYSTEMCarburetorLow Idle Speed Adjustment•Disconnect all possible external loads from the engine.•Start the engine and warm it up thoroughly
FUEL SYSTEM 2-13CarburetorHigh Altitude OperationAt high altitude, the standard carburetor air-fuel mixture will beexcessively rich. Performance will
2-14 FUEL SYSTEMCarburetor•Remove:Air Cleaner and Related Parts (see Air Cleaner Removal)Radiator (see Radiator Removal)Cooling Fan and Fan Belt (see
FUEL SYSTEM 2-15CarburetorCarburetor Disassembly/Assembly•Refer to the illustration shown for disassembly and assembly.•There are several passage plug
EMISSION CONTROL INFORMATIONTo protect the environment in which we live, Kawasaki has incorporated crankcase emission (1) and exhaust emission(2) cont
2-16 FUEL SYSTEMCarburetorCarburetor CleaningClean the carburetor in a well-ventilated area, and take carethat there is no spark or flame anywhere near
FUEL SYSTEM 2-17Carburetor•With the float [A] assembly installed onto the carburetor body [B], holdthe carburetor upside down at an eye level. Gently s
2-18 FUEL SYSTEMIntake ManifoldIntake Manifold Removal•Remove:Air Cleaner (see Cleaner Body Removal)CarburetorControl Panel Assembly•Drain the coolant
FUEL SYSTEM 2-19Fuel PumpThe fuel pump cannot be disassembled, if any damage for the pumpis appeared replace it with a new one.[A] Fuel Pump[B] Inlet
2-20 FUEL SYSTEMAir CleanerElement Removal•Remove:Air Cleaner Case Nut [A]Upper-case [B]Cleaner Case [C]•Remove:Wing Nut [A]Foam Element [B]Paper Elem
FUEL SYSTEM 2-21Air CleanerCleaner Body Removal•Remove the elements. (see Element Removal)•Remove the cleaner body mounting bolts [A] and take off the
2-22 FUEL SYSTEMDigital Fuel Injection (DFI) SystemGovernor Link MechanismControl Panel Assembly Removal•Remove:Air Cleaner (see Air Cleaner Body Remo
FUEL SYSTEM 2-23Digital Fuel Injection (DFI) SystemGovernor Arm Installation•Insert the bracket [A] onto the governor shaft [B] thoroughly to thebotto
2-24 FUEL SYSTEMDigital Fuel Injection (DFI) SystemThrottle Body Assy DisassemblyNOTEDo not attempt to remove the throttle valve and shaft unless they
FUEL SYSTEM 2-25Digital Fuel Injection (DFI) SystemHigh Idle Speed AdjustmentNOTEHigh idle speed adjustment should be made after the idle speedadjustm
ForewordThis manual is designed primarily for use by trainedmechanics in a properly equipped shop. However, itcontains enough detail and basic informa
2-26 FUEL SYSTEMDigital Fuel Injection (DFI) SystemIntake Manifold (DFI) Installation•Before assembling the manifold, install the cylinder heads on ea
FUEL SYSTEM 2-27Digital Fuel Injection (DFI) SystemDFI System
2-28 FUEL SYSTEMDigital Fuel Injection (DFI) SystemDFI System Wiring DiagramNOTEPortion surrounded by shows KHI procurement pars.1.ECU (Electronic Con
FUEL SYSTEM 2-29Digital Fuel Injection (DFI) SystemTerminal Numbers of ECU Connectors(View from wire side)#11.#1 Injector Signal#21.#2 Injector Signal
2-30 FUEL SYSTEMDigital Fuel Injection (DFI) SystemElectrical Control Unit (ECU)CAUTIONNever drop the ECU, especially on a hard surface. Such ashock t
FUEL SYSTEM 2-31Digital Fuel Injection (DFI) SystemECU Power Source Inspection•Set the tester [A] to the DC25 V range and connect it to the adapter[B]
2-32 FUEL SYSTEMDigital Fuel Injection (DFI) SystemMeasure the operating voltage with the engine stopped, and with theconnector joined.•Turn the ignit
FUEL SYSTEM 2-33Digital Fuel Injection (DFI) SystemFuel Injectors (#1, #2)CAUTIONNever drop the injector, especially on a hard surface. Such ashock to
2-34 FUEL SYSTEMDigital Fuel Injection (DFI) SystemAudible Inspection•Start the engine.•Apply the tip of a screwdriver [A] to the injector [C]. Put th
FUEL SYSTEM 2-35Digital Fuel Injection (DFI) SystemInjector Resistance Inspection•Disconnect the connector from the injector [A] (see Injector Removal
GENERAL INFORMATION 1-1General InformationTable of Contents1Before Servicing...
2-36 FUEL SYSTEMDigital Fuel Injection (DFI) SystemFuel Pressure Regulator InspectionNOTEBe sure the battery is fully charged.•Loosen the fuel pressur
FUEL SYSTEM 2-37Digital Fuel Injection (DFI) SystemHow to Read Fault CodesFault codes are shown by a series of long and short blinks of the Self Diagn
2-38 FUEL SYSTEMDigital Fuel Injection (DFI) SystemInstallation•Push the sensor [A] into the grommet [B] until the flange of sensor[C] touches the grom
FUEL SYSTEM 2-39Digital Fuel Injection (DFI) SystemSensor Resistance inspection•Remove the inlet air temperature sensor (see this section).•Suspend th
2-40 FUEL SYSTEMDigital Fuel Injection (DFI) SystemNOTEThe output voltage changes according to the coolant temperaturein the engine.If the output volt
FUEL SYSTEM 2-41Digital Fuel Injection (DFI) SystemSpecial Tool - ECU Adapter: 57001–1400•Set the tester [A] to the DC 10 V range, and connect it to t
COOLING SYSTEM 3-1Cooling SystemTable of Contents3Exploded View...
3-2 COOLING SYSTEMExploded ViewG: Apply grease.T1: 6 Nm (0.6 kg m, 52 in lb)T3: 20 Nm (2.0 kg m, 15 ft lb)T5: 1.2 Nm (0.12 kg m, 11 in lb)
COOLING SYSTEM 3-3Exploded View1. Thermo Switch2. Thermostat3. Drain PlugEO: Apply engine oil.G: Apply grease.L: Apply a non-permanent locking agent.S
1-2 GENERAL INFORMATIONBefore ServicingBefore starting to service the engine, carefully read the applicable section to eliminate unnecessary work. Pho
3-4 COOLING SYSTEMSpecificationsItemStandard*Coolant:Type Permanent type of antifreeze for aluminum engine and radiatorColor GreenMixed ratio 50% solut
COOLING SYSTEM 3-5Cooling SystemThis engine is equipped with a highly efficient pressurized coolingsystem using a thermostat to maintain an optimum ope
3-6 COOLING SYSTEMCoolantCoolant Deterioration•Visually inspect the coolant in the radiator.If whitish cotton-like wafts are observed, aluminum parts
COOLING SYSTEM 3-7CoolantTo avoid burns do not remove the radiator cap or try to changethe coolant when the engine is still hot. Wait until it coolsdo
3-8 COOLING SYSTEMCoolantVisual Leak InspectionAny time the system slowly loses water, inspect for leaks. Small leaksmay appear only a rust, corrosion
COOLING SYSTEM 3-9CoolantFlushingOver a period of time, the cooling system accumulates rust, scale,and lime in the water jacket and radiator. When thi
3-10 COOLING SYSTEMWater PumpWater Pump Removal•Remove:Muffler (see Muffler Assembly Removal)•Loosen the hose clamp [A] and disconnect the water hose [B
COOLING SYSTEM 3-11Water Pump•Install the mounting bolts and tighten them in the order shown.Torque - Water Pump and Cover Mounting Bolts: 20 N m (2.0
3-12 COOLING SYSTEMWater PumpPumps Parts Inspection•Clean all parts except plastic and rubber parts in a bath of high flash-point solvent and dry them
COOLING SYSTEM 3-13RadiatorRadiator RemovalAlways allow the engine to cool before removing the radiatorcap. Then remove the cap slowly and carefully t
GENERAL INFORMATION 1-3Before Servicing(15) Cotter PinReplace any cotter pins that were removed with new ones, as removal deforms and breaks them.(16)
3-14 COOLING SYSTEMRadiator•Check the radiator filler neck for signs of damage.•Check the condition of the top [A] and bottom [B] sealing seats in thefi
COOLING SYSTEM 3-15RadiatorRadiator Hose Installation Notes•Install the radiator hoses being careful to follow bending direction (seeExploded View). A
3-16 COOLING SYSTEMCooling Fan, Fan BeltThe only service on the cooling fan is to be srue the fan blades arenot deformed, and the blade tips are far e
COOLING SYSTEM 3-17Cooling Fan, Fan BeltCooling Fan, Fan Belt Removal•Remove:Radiator (see Radiator Removal)•Remove the radiator guide.Unscrew the mou
3-18 COOLING SYSTEMCooling Fan, Fan BeltCooling Fan, Fan Belt Installation•Install the cooling fan as “AISHIN” raised lettering [A] on the fan bossfac
COOLING SYSTEM 3-19ThermostatThermostat Removal and Installation•Drain the coolant (see Coolant Draining).•Loosen the hose clamps [A], and pull off th
3-20 COOLING SYSTEMThermo SwitchWhen coolant temperature rises above 111 C (232 F), the thermoswitch detects this and turns on a warning light on dash
ENGINE TOP END 4-1Engine Top EndTable of Contents4Exploded View...
4-2 ENGINE TOP ENDExploded ViewEO: Apply engine oil.G: Apply grease.T1: 22 Nm (2.2 kg m, 16 ft lb)T2: 21 Nm (2.1 kg m, 15 ft lb)T5: 11 Nm (1.1 kg m, 9
ENGINE TOP END 4-3Exploded ViewS: Follow the specific tightening sequence.T3: 27 N m (2.8 kg m, 20 ft lb)T4: 20 Nm (2.0 kg m, 15 ft lb)
1-4 GENERAL INFORMATIONModel IdentificationCylinder Number Designation:No.1 Cyl. is on the oil filter side.No.2 Cyl. is on the electric starter side.
4-4 ENGINE TOP ENDSpecificationsItemService LimitCylinder Head:Cylinder compression (MIN) [1171 kPa (170 psi)] (MIN)Cylinder head warp 0.06 mm (0.002 i
ENGINE TOP END 4-5Cylinder HeadCompression Measurement•Before measuring compression, do the following.Be sure the battery is fully charged.Thoroughly
4-6 ENGINE TOP ENDCylinder Head•When removing the cylinder head, set the flywheel at top dead center(T.D.C) of power stroke each cylinder.When setting
ENGINE TOP END 4-7Cylinder Head•Install the head bolts noting the position of different length bolts.•Then tighten the head bolts to the specification
4-8 ENGINE TOP ENDCylinder HeadValve Mechanism Removal/Installation•Remove the cylinder head assembly. (see Cylinder Head AssemblyRemoval)NOTEWhen rem
ENGINE TOP END 4-9Cylinder Head•Valve Installation.Apply engine oil to the valve stem to avoid damaging the stem seal.Check to see that the valve move
4-10 ENGINE TOP ENDCylinder Head•Check the cylinder head for cracks or other damage.•Cracks not visible to the eye may be detected by coating thesuspe
ENGINE TOP END 4-11ValvesValve Clearance InspectionNOTEValve clearance must be checked when the engine is cold (at roomtemperature).•Remove the rocker
4-12 ENGINE TOP ENDValvesValve Seat Inspection•Remove the valve. (see Valve Mechanism Removal/Installation)•Inspect the valve seats for damage.If the
ENGINE TOP END 4-13Valves•Setting the valve seat cutter holder [A] in position, operate the cutter[B] with one hand. Do not apply too much force to th
GENERAL INFORMATION 1-5General SpecificationsItemsFD671D, FD711D, FD750DType of engineLiquid-cooled, Horizontal shaft, OHV, 4-stroke, 90V-twin, Gasolin
4-14 ENGINE TOP ENDValves•Use a 30 seat cutter [A] to narrow the seat width to the STD width.Turn the seat cutter one turn at a time while pressing do
ENGINE TOP END 4-15ValvesValve Stem Runout•Support the valve in V blocks at each end of the stem.•Position a dial gauge perpendicular to the stem.•Tur
4-16 ENGINE TOP ENDCylinder, PistonPiston Removal•Split the crankcase (see Camshaft/Crankshaft chapter).•Remove the camshaft (see Camshaft/Crankshaft
ENGINE TOP END 4-17Cylinder, PistonPiston Installation•Install the expander [A] in the piston oil ring groove so that theexpander ends [B] touch toget
4-18 ENGINE TOP ENDCylinder, PistonUsing the piston ring compressor grip [A] and the belt [B], insert thepiston and connecting rod into the cylinder.L
ENGINE TOP END 4-19Cylinder, PistonPiston Cleaning•Remove the piston and piston rings (see Piston and Ring Removal).CAUTIONNever clean the piston head
4-20 ENGINE TOP ENDCylinder, PistonPiston Ring End Gap•Remove the piston rings.•Push each ring (one at a time) in the cylinder bore to a point closeto
ENGINE TOP END 4-21Cylinder, PistonPiston Diameter•Measure the outside diameter of the piston 11 mm (0.43 in.) up fromthe bottom of the piston at a ri
4-22 ENGINE TOP ENDCylinder, PistonChange to a honing stone for finishing, the final bore diameter shouldbe as shown in the table.Be sure the correct st
ENGINE TOP END 4-23MufflerMuffler Assembly Removal•Unscrew the flange nuts [A], and remove the spring washers andengine hook [B] (Only No.1 Cylinder side
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