Kawasaki KX250F (2005) manual

KX250F Motorcycle Service Manual[...]

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This quick reference guide will assist you in locating a desired topic or pro- cedure. •Bend the pages back to match the black tab of the desired chapter num- ber with the black tab on the edge at each table of contents page. •Refer to the sectional table of contents for the exact pages to locate the spe- cific topic required. Quick Reference G[...]

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KX250F Motorcycle Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Divis ion/Consumer Products & Machinery Company/Kawasaki Heavy[...]

LIST OF ABBREVIA TIONS A ampere(s) lb pound(s) ABDC after bottom dead center m meter(s) AC alternating current min minute(s) AT D C after top dead center N newton(s) BBDC before bottom dead center Pa pascal(s) BDC bottom dead center PS horsepower BTDC before top dead center psi pound(s) per square inch °C degree(s) Celsius r revolution DC direct c[...]

Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However , it contains enough detail and basic in- formation to make it useful to the owner who de- sires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop proce- dures must be[...]

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GENERAL INFORMA TION 1-1 1 General Information T able of Contents Before Servicing ................................................................................................................ ..... 1-2 Model Identification............................................................................................................ ..... 1-7 Gener[...]

1-2 GENERAL INFORMA TION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera - tion on a motorcycle, read the precautions given below . T o facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each c hapter wherever [...]

GENERAL INFORMA TION 1-3 Before Servicing Storage o f Removed P arts After all the parts including subassembly parts have been cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly . Inspection Reuse of worn or damaged parts may lead to s[...]

1-4 GENERAL INFORMA TION Before Servicing Tightening T orque Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fastene rs to the specified torque using a good quality torque wrench. Often, the tightening sequence is followed twice-initial tightening and final tightening with torque wrench. Force Use common sense [...]

GENERAL INFORMA TION 1-5 Before Servicing Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary . Replace with new ones whenever removed. Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressure on the correct bearing race as shown. Pressin[...]

1-6 GENERAL INFORMA TION Before Servicing Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Ro- tate the crankshaft to positive direction (clockwise viewed from output side). Electrical Wires A two-color wire is identified first by the primary color and then the[...]

GENERAL INFORMA TION 1-7 Model Identification KX250T6F Left Side View KX250T6F Right Side View[...]

1-8 GENERAL INFORMA TION General Specifications Items KX250T6F Dimensions Overall Length 2 160 mm (85.04 in.) Overall Width 820 mm (32.3 in.) Overall Height 1 270 mm (50 in.) Wheelbase 1 469 mm (57.83 in. ) Road Clearance 372 mm (14.6 in.) Seat Height 960 mm (37.8 in.) Dry Mass 92.5 kg (204 lb) Curb Mass: Front 4 9 . 9k g( 1 1 0l b ) Rear 5 2 . 6k [...]

GENERAL INFORMA TION 1-9 General Specifications Items KX250T6F Clutch T ype Wet, multi disc, Manual T ransmission: Ty p e 5-speed, constant mesh, return shift Gear ratios: 1st 2.142 (30/14) 2nd 1.785 (25/14) 3rd 1.444 (26/18) 4th 1.200 (24/20) 5th 1.052 (20/19) Final Drive System: Ty p e Chain drive Reduction Ratio 3.692 (48/13) Overall Drive Ratio[...]

1-10 GENERAL INFORMA TION Unit Conversion T able Prefixes for Units: Prefix Symbol Power mega M × 1 000 000 kilo k × 1 000 centi c ×0 . 0 1 milli m ×0 . 0 0 1 micro µ × 0.000001 Units of Mass: k g ×2 . 2 0 5 =l b g × 0.03527 = oz Units of V olume: L × 0.2642 = gal (US) L × 0.2200 = gal (imp) L × 1.057 = qt (US) L × 0.8799 = qt (imp) L×[...]

PERIODIC MAINTENANCE 2-1 2 Periodic Maintenance T able of Contents Periodic Maintenance Chart ............................................................. ...................................... 2-3 T orque and Locking Agent ...................................................................................................... 2-5 Specifications ...[...]

2-2 PERIODIC MAINTENANCE Drive Chain Lubrication..................................................................................................... 2-35 Sprocket Wear Inspection ................................................................................................. 2-36 Rear Sprocket W arp Inspection ....................................[...]

PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart The maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. FREQUENCY OPERA TION Each race or 2.5 hr Every 3 races or 7.5 hr Every 6 races or 15 hr Every 12 races or 30 hr See Page Spark plug - clean, gap † • 2-70 Spark plug - replace • 2-70 C[...]

2-4 PERIODIC MAINTENANCE Periodic Mainten ance Chart FREQUENCY OPERA TION Each race or 2.5 hr Every 3 races or 7.5 hr Every 6 races or 15 hr Every 12 races or 30 hr See Page Wheels/tires - inspect • 2-30 Rear sprocket - inspect † • 2-36 Front fork - inspect and clean • 2-47 Front fork oil - change • 2-47 Rear shock oil - replace • 2-57 [...]

PERIODIC MAINTENANCE 2-5 T orque and Locking Agent T ighten all bolts and nuts to the proper torque using an accurate torque wrench. If insuf ficiently tightened, a bolt or nut may become damaged, strip an internal thread, or break and then fall out. The following table lists the tightening toque for the major bolts and nuts, and the parts requirin[...]

2-6 PERIODIC MAINTENANCE T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks Radiator Mounting Bolts 9.8 1.0 87 in·lb Radiator Shroud Bolts 9.8 1.0 87 in·lb Engine T op End Auto-Decompressor Bolt 12 1.2 104 in·lb Decompressor Plug 9.8 1.0 87 in·lb Cylinder Head Cover Bolts 9.8 1.0 87 in·lb Cylinder Head Bolts: M10 50 5.0 36 S[...]

PERIODIC MAINTENANCE 2-7 T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks Oil Filter Cap Bolts 9.8 1.0 87 in·lb Oil Pump Mounting Bolts 7.0 0.7 61 in·lb L W ater Pump Cover Bolts 9.8 1.0 87 in·lb L( 1 ) W ater Pump C over Bolt (with washer) 9.8 1.0 87 in·lb L( 1 ) Right Engine Cover Bolts 9.8 1.0 87 in·lb Breather Fitting [...]

2-8 PERIODIC MAINTENANCE T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks Brake Reservoir Cap Bolts 1.5 0.15 13 in·lb Brake Disc Mounting Bolts: (Front) 9.8 1.0 87 in·lb L (Rear) 23 2.3 16.6 L Caliper Bleed V alves (Front, Rear) 7.8 0.8 69 in·lb Front Caliper Holder Shaft 22 2.2 16 L Rear Caliper Holder Shaft 27 2.8 20 Calip[...]

PERIODIC MAINTENANCE 2-9 T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks Crankshaft Sensor Bolts 7.0 0.7 61 in·lb Spark Plug 13 1.3 11 5 i n · l b C.D.I. Unit Bolts 9.8 1.0 87 in·lb Magneto Cover Bolts L: 30 9.8 1.0 87 in·lb L: 35 9.8 1.0 87 in·lb L[...]

2-10 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Fuel System T h r o t t l eG r i pF r e eP l a y 2 ∼ 3 m m (0.08 ∼ 0.12 in.) ––– Hot Start Lever Free Play 0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.) ––– Idle Speed 2 000 r/min (rpm) ––– Air Cleaner Element Oil High quality foam air filter oil ––– Cooling Syste[...]

PERIODIC MAINTENANCE 2-1 1 Specifications Item Standard Service Limit Standard T ire: Front: Size 80/100-21 51M ––– Make BRIDESTONE ––– Ty p e M401, Tub e, ––– (EUR) M201, T ube ––– Rear: Size 100/90-19 57M ––– Make BRIDESTONE ––– Ty p e M402, Tub e, ––– (EUR) M202, T ube ––– Final Drive D r i v eC h [...]

2-12 PERIODIC MAINTENANCE Special T ools Inside Ci rclip Pliers: 57001-143 Steering Stem Nut Wrench: 57001-1 100 Jack: 57001-1238 Attachment J ack: 57001-1252 Spark Plug Wrench, Hex 16: 57001-1262 Carburetor Drain Plug W rench, Hex 3: 57001-126 9 Filler Cap Dr iver: 57001-145 4 Pilot Screw Adjust er , D: 57001-158 8 Jack Attachment: 57001-160 8 T o[...]

PERIODIC MAINTENANCE 2-13 Periodic Maintenance Pr ocedures Fuel System Fuel Hose and Connection Inspectio n ○ If the motorcycle is not properly handled, the inside the fuel line can cause fuel to leak [A]. • Check the fuel hose. Replace the fuel hose if any fraying, cracks [B], bulges [C], or ozonic cracks [D] are noticed. • Check that the ho[...]

2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures If the throttle grip free play cannot be adjusted with the adjuster , replace the throttle cables. • T urn the handlebar from side to side while idling the en- gine. If idle speed varies, the throttle c able may be poorly routed or it may be damaged. W ARNING Operation with an improperly a[...]

PERIODIC MAINTENANCE 2-15 Periodic Maintenance Pr ocedures • Start the engine and warm it up thoroughly . • With the engine idling, turn the handlebar to both sides [A]. If handlebar movement changes the idle speed, the throt- tle cable may be improperly adjusted or incorrectly routed, or it may be damaged. Be sure to correct any of these condi[...]

2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Start the engine and warm it up thoroughly . • T urn the idle adjusting screw [A] until the idle speed is correct. T o increase idle speed [B] T o decrease idle speed [C] • Open and close the throttle a few times to make sure that the idle speed is within the specified range. Readjus[...]

PERIODIC MAINTENANCE 2-17 Periodic Maintenance Pr ocedures • Separate the element [A] from the frame [B]. • Clean the element [A] in a bath of a high-flash-point sol- vent using a soft bristle brush. • Squeeze it dry in a clean towel [A]. D o not wring the ele- ment or blow it dry; the element can be damage d. • Check all the parts of the e[...]

2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Install the air cleaner element so that its tab [A] faces upward and its projections [B] align with the holes [C] in the frame. • T ighten the wing bolt [D]. • Install the seat. Fuel System Clean W ARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions[...]

PERIODIC MAINTENANCE 2-19 Periodic Maintenance Pr ocedures Cooling System WA R N I N G T o avoid burns, do not remove the radiator cap or try to change the coolant when the engine is still hot. W ait until it cools down. Coolant on tires will make them slippery and can cause an accident and injury . Immediately wash away any coolant that spills o n[...]

2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures CAUTION For refilling, add the specified mixture of coolant and soft water . Adding water alone dilute s the coolant and degrades its anticorrosion properties. The diluted coolant can attack the aluminum en- gine parts. In an emergency , soft water alone can be added. But the diluted coolant[...]

PERIODIC MAINTENANCE 2-21 Periodic Maintenance Pr ocedures Engine T op End V alve Clearance Inspection NOTE ○ V alve clearance must be checked and adjusted when the engine is cold (at room temperature). • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval in the Engine T op End chapter) T iming Inspection Cap [A] Flywheel Cap [B] Sp[...]

2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTE ○ Mark and record the locations of the valve lifters and shims so that they can be reinstalled in their original positions. • Clean the shim to remove any dust or oil. • Measure the thickness of the removed shim [A]. • Select a new shim thickness calculation as follows. A=( B-C [...]

PERIODIC MAINTENANCE 2-23 Periodic Maintenance Pr ocedures CAUTION Be sure to remeasure the clearance after selecting a shim. The clearance can be out of the specified range because of the shim tolerance. ○ If there is no valve clearance, use a s him that is a few sizes smaller , and remeasure the valve clearance. • When installing the shim, fa[...]

2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cylinder Wear Inspection NOTE ○ Measure the cylinder inside diameter when the cylin der is cold (room or ambient temperature). • Visually Inspect the inside of the cylinder for scratches and abnormal wear . If the cylinder is damaged or badly worn, replace it with a new one. • Since th[...]

PERIODIC MAINTENANCE 2-25 Periodic Maintenance Pr ocedures Exhaust System Inspection • The exhaust system, in particular the silencer , is designed to reduce exhaust noise and conduct the exhaust gases away from the rider while minimizing power loss. If car- bon has built up inside the silencer , exhaust ef ficiency is reduced, causing engine per[...]

2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Install the end [A] of the silencer pipe [B] to the baf fle [C]. • Apply a non-permanent locking agent to the s ilencer pipe cover bolts. • Install the silencer cover . T orque - Silencer Cover Bolts: 12 N·m (1.2 kgf· m, 109 in·lb) • Apply silicone sealant to the circumference [[...]

PERIODIC MAINTENANCE 2-27 Periodic Maintenance Pr ocedures Clutch Lever Free Play Adjustment • T urn the adjuster [A] so that the clutch lever [B] will have 8 ∼ 13 mm (0.3 ∼ 0.5 in. ) of play . NOTE ○ Be sure that the outer cable end at the clutch lever is fully seated in the adjuster at the clutch lever , or it could slip into the place la[...]

2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures Engine Lubrication System W ARNING Motorcycle operation with insufficient, deteri- orated, or contaminated engine oil will cause accelerated wear and may result in engine or trans- mission seizure, and injury . Engine Oil Change • W arm up the engine thoroughly so that the oil will pick up[...]

PERIODIC MAINTENANCE 2-29 Periodic Maintenance Pr ocedures Oil Filter Change • Drain: Engine Oil (see Engine Oil Change) • Remove: Oil Filter Cap Bolt [A] Oil Filter Cap [B] • Remove the Oil Filter [A]. • Replace the oil filter with a new one. • Apply grease [A] to the grommet. • Be sure to install the filter with the grommet [B] facing[...]

2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Crankshaft/T ransmission Crankshaft Inspection • Make sure that the crankshaft rotate smoothy (in the neu- tral position). If the crankshaft will not turn smoothly , check the cranks shaft assembly . Connecting Rod Big End Side Clearance • Remove the cylinder head (see Cylinder Head Remo[...]

PERIODIC MAINTENANCE 2-31 Periodic Maintenance Pr ocedures Tires Inspection As the tire tread wears down, the tire becomes more sus- ceptible the puncture and failure. • Remove any imbedded stones or other foreign particles from the tread. • Visually insp ect the tire for cracks and cuts, replacing the tire in case of bad damage. Swelling or hi[...]

2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Rim Runout Inspection • Place the jack under the frame so that the front/rear wheel off the ground. Special T ools - Jack: 57001-1238 Jack Attachment: 57001-125 2 or 57001 -1608 • Inspect the rim for small cracks, dents, bending, or warp- ing. If there is any damage to th e rim, it must [...]

PERIODIC MAINTENANCE 2-33 Periodic Maintenance Pr ocedures • T urn the handlebar until the handlebar doesn’t move to either side. • The wheel edge is moved to one direction gripping the edge of the wheel by both hands and the play of the wheel bearing is checked. If the play is found, replace the bearing. Final Drive Drive Chain Wear Inspecti[...]

2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Drive Chain Slack Inspection • Raise the rear wheel off the ground, rotate the rear wheel to find the place where the chain is tightest (because it wears unevenly). • Check the wheel alignment (see Wheel Alignment Inspec- tion in the Wheels chapter), and adjust it if necessary (see Wheel[...]

PERIODIC MAINTENANCE 2-35 Periodic Maintenance Pr ocedures NOTE ○ When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle shaft, tighten the nut clockwise [A] up to next alignment. ○ It should be within 30 degree. ○ Loosen one and tighten again when the slot goes past the nearest hole. WA R N I[...]

2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Sprocket Wear Inspection • Visually inspect the front and rear sprocket teeth for wear and damage. If they are worn as illustrated or damaged, replace the sprocket. [A] Worn T ooth (Engine Sprocket) [B] Worn T ooth (Rear Sprocket) [C] Direction of Rotation NOTE ○ If a sprocket requires r[...]

PERIODIC MAINTENANCE 2-37 Periodic Maintenance Pr ocedures NOTE ○ Usually it is not necessary to adjust the pedal position, but always adjust it when the master cylinder is disas- sembled or pedal position is incorrect. • Measure the length indicated in the figure. Length [A] Standard: 68.5 ±1 mm (3.09 ±0.04 in.) If it is not specified length[...]

2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Fluid Level Inspection • Check the brake fluid level in the front or rear brake reser- voir [A]. NOTE ○ Hold the reservoir horizontal when checkin g brake fluid level. • The front or rear reservoir must be kept above the lower level line [B]. ○ If the fluid level in front or re[...]

PERIODIC MAINTENANCE 2-39 Periodic Maintenance Pr ocedures Brake Fluid Ch ange In accordance with the Periodic Maintenance Chart, change the brake fluid. The brake fluid should also be changed if it becomes contaminated with dirt or water . Furthermore, the brake fluid should be changed to bleed the air quickly and completely whenever the brake lin[...]

2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTE ○ The procedure to change the front brake fluid. Chang- ing the rear brake fluid is the same as for the front brake. • Level the brake fluid reservoir . • Remove the screw [A], reservoir cap [B] and diaphragm [C]. • Remove the rubber cap [A] on the bleed valve [B]. • Attach a [...]

PERIODIC MAINTENANCE 2-41 Periodic Maintenance Pr ocedures • Remove the clear plastic hose. • T ighten the bleed valves, and install the rubber caps. T orque - Calip er Bleed V alve: 7.8 N·m (0.8 kgf· m, 69 in·lb) Brake Reservoir Cap Sc rews: 1.5 N·m (0.15 kgf·m, 13 in·lb) • After changing the fluid, check the brake for good braking pow[...]

2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove the reservoir cap and diaphragm, and pour the brake fluid into a container . • Slide the dust cover [A] on the push rod [B] out of place, and remove the circlip [C]. Special T ool - Insid e C irclip Pli ers: 5 7001-143 • Pull out the push rod with th e piston stop [D]. • T a[...]

PERIODIC MAINTENANCE 2-43 Periodic Maintenance Pr ocedures • Separate the caliper holder [A] from the caliper [B] and remove the anti-rattle spring. • Using compressed air , remove the pistons. One way to remove the pistons is as follows. ○ Cover the caliper opening with a clean, heavy cloth [A]. ○ Remove the pistons by lightly applying com[...]

2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Pull out the piston [A] by hand. • Remove the dust seal [B] and fluid seal [C]. • Clean the caliper parts except for the pads. CAUTION For cleaning of the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol. • The bleed valve was removed, install the bleed valve a[...]

PERIODIC MAINTENANCE 2-45 Periodic Maintenance Pr ocedures • Replace the shaft rubber friction boot [A] and dust boot [B] if they are damaged. • Apply a thin coat of PBC (Poly Butyl Cuprysil) grease to the caliper holder shafts [C] and holder holes (PBC is a special high temperature, water-resistance grease). • Install the pads (see Brake Pad[...]

2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove each banjo bolts [A] and washers [B]. • Replace the washers with new one s. For Front Brake Hose • Remove Bolts [A] Brake Hose Clamps [B] For Rear Brake Hose • Remove: Master Cylinder [A] Hose Clamps [B] Caliper Cover [C] • When installing the hoses, avoi d sharp bending, [...]

PERIODIC MAINTENANCE 2-47 Periodic Maintenance Pr ocedures Suspension Front Fork Inspection • Holding the brake lever , pump the front fork back and forth manually to check for smooth operation. • Visually inspect the front fork for oil leakage, scoring or scratches on the outer surface of the inner tube [A]. If necessary , repair any damage. ?[...]

2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Loosen the front fork lower clamp bolts [A]. • Remove the front fork. ○ With a twisting motion, work the fork leg [B] down and out. • Record the position of the damping adjusters [A] and th en turn [B] it to the softest position. • Measure the length [A] between the top surface o[...]

PERIODIC MAINTENANCE 2-49 Periodic Maintenance Pr ocedures • T emporarily install the fork cylinder unit [A] to the outer tube [B]. Special T ool - T op Plug Wrench, 50 mm: 57001-1645 • Hold the axle holder part [A] with a vise [ B]. ○ Protect the axle holder part with a soft jaws [C] or heavy cloth when using a vise. • Unscrew the adjuster[...]

2-50 PERIODIC MAINTENANCE Periodic Maintenance Procedures • With the outer tube compressed by hand, remove the top plug wrench. CAUTION Removing the locknut and pushing the piston rod thread into the cylinder unit will damage the oil seal. Do not remove the locknut from the piston rod. Be careful of reaction force from the fork spring when removi[...]

PERIODIC MAINTENANCE 2-51 Periodic Maintenance Pr ocedures • Hold the fork cylinder unit [A] upside down over a clean container [B] and pump it to drain the oil. NOTE ○ Pump the piston rod up and down to discharge t he fork oil. • Hold the front fork at the inverted position for more than 20 minutes to allow the fork oil to fully dra in. • [...]

2-52 PERIODIC MAINTENANCE Periodic Maintenance Procedures • With the piston rod fully stretched, check the oil level in the fork cylinder unit. ○ Measure the oil level [A] from the step [B] in the cylinder unit using the suitable gauge. Fork Cylinder Unit Oil Level 42 ∼ 49 mm (1.65 ∼ 1. 93 in.) • Replace the O-rings [A] on the base valve [...]

PERIODIC MAINTENANCE 2-53 Periodic Maintenance Pr ocedures • Discharge the extra oil off the cylinder unit [A] by pumping the piston rod [B] to full stroke [C]. CAUTION Be careful not to bend or damage the piston rod when the piston rod is stroked. Service carefully because oil files out from the oil hole of the cylinder unit. • Check the compr[...]

2-54 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Wipe the oil off completely from the cylinder unit [A]. • Compress the piston rod [B] to 200 ∼ 250 mm (7.9 ∼ 9. 8 in.) [C] and hold the cylinder unit upright position for 10 minutes. • There should be no oil leak from the base valve assembly part [A] or bottom of the cylinder . I[...]

PERIODIC MAINTENANCE 2-55 Periodic Maintenance Pr ocedures • Compress the outer tube by hands and insert the top plug wrench [A] between the axle holder part bottom [B] and locknut [C]. Special T ool - T op Plug Wrench, 50 mm: 57001-1645 WA R N I N G Be careful of reaction force in spring and fix surely so that special tool should not come off. D[...]

2-56 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Compare the length [A] at assembly and at disassembly . ○ There should be same length. If the length at assembly is longer than at disassembly , check the adjuster assembly and locknut installation. Axle Holder [B] Outer T ube [C] Length Standard: 317 ±2 mm (125 ±0. 08 in.) • Using[...]

PERIODIC MAINTENANCE 2-57 Periodic Maintenance Pr ocedures The torque of fork cylinder unit is specified to 34 N·m (3.5 kgf·m, 25 ft·lb) however , when you use the top plug wrench [A], reduce the torque to 90% of the specified value [31 N·m (3.1 kgf·m, 23 ft·lb)] due to the distance between the center of the square hole [B], where the torque [...]

2-58 PERIODIC MAINTENANCE Periodic Maintenance Procedures W ARNING Do not to point the reservoir valve toward your face or body when releasing nitrogen gas pressure. An oil mist is often released with the nitrogen. Always release nitrogen gas pressure before disassem- bling the rear shock absorber to prevent explosive separation of parts. • Adjus[...]

PERIODIC MAINTENANCE 2-59 Periodic Maintenance Pr ocedures • Slide the stop up the top of the piston rod then lightly tap around the seal with a suitable rod and mallet, and push the seal assembly 10 mm (0.39 in.) down. • Remove the circlip [A]. • Lightly move the piston rod back and forth, and pull out the piston rod assembly . • Pour the [...]

2-60 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Inspect the slide bushing [A]. If the bushing is damaged, replace it. • Cut the slide bushing [A]. • Remove the O-rings [B]. • Replace the O-rings with new ones. • Install the O-rings and a new bushing on the piston. • Wrap the threads [A] of the piston rod with tape. • Remov[...]

PERIODIC MAINTENANCE 2-61 Periodic Maintenance Pr ocedures • Replace the following with new ones. Oil Seals Rebound Rubber (if damaged) O-ring • Install each parts direction as shown in the figure. Oil Seal [A] Oil Seal [B] Spring Holder [C] Collar [D] Rebound Rubber [E] Spring [F] O-ring [G] • Remove: Stopper [A] Damper [B] Damper Holder [C][...]

2-62 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Install: Damper Holder [A] Damper [B] Stopper [C] • Wrap the threads of the piston rod with tape [A]. • Apply thin coat of shock oil to the sliding surface of the piston rod. • Insert the oil seal assembly [B]. • Install: Wa s h e r [ A ] Stopper [B] • Install: Rebound Side W a[...]

PERIODIC MAINTENANCE 2-63 Periodic Maintenance Pr ocedures ○ Install the piston direction as shown in the figure. Locknut Side Face [A] • Stake [A] the end of the piston rod in three place [B]. • Check the oil seal assembly moving smoothly on the rod. • Check that the bladder [A] on the gas reservoir cap is not partially collapsed. If it is[...]

2-64 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Mount the circlip [A] in the groove in the gas reservoir . • Pull up the gas reservoir cap [A] against the circlip. The end of the gas reservoir cap must align [B] with the end of the gas reservoir [C]. W ARNING If the end of the gas reservoir cap and the end of the gas reservoir are n[...]

PERIODIC MAINTENANCE 2-65 Periodic Maintenance Pr ocedures • Force the stop [A] into the rear shock body by lightly tap- ping around the edge of the stop with a mallet. • Fully extend the piston rod assembly . • Remount the upper portion of the shock absorber in a vise with soft jaws or a heavy cloth. • Fill the specified oil [A] into the d[...]

2-66 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Inject nitrogen gas to a pressure of 50 kPa (0.5 kgf/cm², 7 psi) through the valve on the gas reservoir . • Check the rear shock body and gas reservoir for oil and gas leaks. If there are leaks reassemble the related parts. • Replace the O-rings [A] with new ones and apply shock abs[...]

PERIODIC MAINTENANCE 2-67 Periodic Maintenance Pr ocedures • Push and pull on the swingarm [A] to check for wear . A small amount of play on the swingarm is normal and no corrective action is needed. However , if excessive play is felt, remove the uni-trak parts from the frame and check for wear . Swingarm and Uni-T rack Linkage Pivot Lubricate ?[...]

2-68 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Slide the holder belt [A] out of f. • Remove: Number Plate Bolt [B] Number Plate [C] Handlebar Pad Cover [D] Handlebar Pad [E] • Remove: Handlebar Clamp Bolts [A] Handlebar Clamps [B] Handle Bar [C] V ent T ube [D] • Loosen the front fork upper clamp bolts [A], and remove the steer[...]

PERIODIC MAINTENANCE 2-69 Periodic Maintenance Pr ocedures • Check the steering again. If the steering is too tight or too loose, repeat the adjust- ment as mentioned above. • Install the handlebar [A] on the handlebar holder as shown. Same Length [B] Bridge Bar [C] • Install the handlebar clamps [A]. • T ighten the handlebar clamp bolts [B[...]

2-70 PERIODIC MAINTENANCE Periodic Maintenance Procedures Frame Frame Inspection • Clean the frame with steam cleaner . • Visually inspect the frame and rear frame for cracks, dents, bending, or warp. If there is any damage to the frame, replace it. W ARNING A repaired frame may fail in use, possibly causing an accident. If the frame is bent, d[...]

PERIODIC MAINTENANCE 2-71 Periodic Maintenance Pr ocedures • Measure the gap [A] with a wire-type thickness gauge. If the gap is incorrect, carefully bend the side electrode [B] with a suitable tool to obtain the correct gap. Spark Plug Gap Standard: 0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.) • Insert the spark plug in the plug wrench, and finger-tig[...]

2-72 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cables: Lubricate with Rust Inhibitor . Throttle Cables Clutch Cable Hot Start Cable Pivots: Lubricate with motor oil. Clutch Lever Host Starter Lever Brake Lever Brake Pedal Rear Master Cylinder Joint Pin • With the cable disconnected at the both ends, the cable should move freely [A] wit[...]

PERIODIC MAINTENANCE 2-73 Periodic Maintenance Pr ocedures If there are loose fasteners, retorque them to the specified torque following the specified tightening sequence. Refer to the T orque and Locking Agent section of the General Information chapter for torque specifications. For each fastener , first loosen it by 1/2 turn, then tighten it. If [...]

[...]

FUEL SYSTEM 3-1 3 Fuel System T able of Contents Exploded View ................................................................................................................... ..... 3-2 Specifications ................................................................................................................. ........ 3-6 Special T ools ....[...]

3-2 FUEL SYSTEM Exploded View[...]

FUEL SYSTEM 3-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Throttle Pulley Cover Bolt 3.4 0.3 30 in·lb 2 Throttle Cable Locknut 7.0 0.7 61 in·lb 3 Hot Start Plunger Cap Bolt 1.0 0.1 10 in·lb 4. Hot Start Lever 5. Hot Start Cable 6. Throttle Grip 7. Throttle Cables 8. Carburetor Cap 9. Throttle V alve Plate 10. Jet Needle 1 1[...]

3-4 FUEL SYSTEM Exploded View[...]

FUEL SYSTEM 3-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Rear Frame Mounting Bolts 34 3.5 25 2 Air Cleaner Duct Clamp Screw 3.0 0.3 27 in·lb 3 Air Cleaner Duct Bolt and Nuts 3.0 0.3 27 in·lb 4 Air Cleaner Element Wing Bolt – – – Hand T ighten 5 Air Cleaner Housing Bolts 9.8 7.0 87 in·lb 6. Breather T ube 7. Fuel T an[...]

3-6 FUEL SYSTEM Specifications Item Standard Service Limit Carburetor Make/T ype KEIHIN FCR37 ––– Starter Jet #68 ––– Leak Jet #60 ––– Main Jet #180, (EUR) #175 ––– Throttle V alve Cutaway CA1.5 ––– Jet Needle NCYU, (EUR) NHJU ––– Jet Needle Clip Position 2nd groove from the top (EUR) 3rd groove from the top –?[...]

FUEL SYSTEM 3-7 Special T ools Fuel Level Gauge , M18 × 1.0: 57001-122[...]

3-8 FUEL SYSTEM Throttle Grip and Cable If the throttle grip has excessive free play due to cable stretch or misadjustment, there will be a delay in throttle re- sponse. Also, the throttle valve may not open fully at full throttle. On the other hand, if the throttle grip has no play , the throttle will be hard to control, and the idle speed will be[...]

FUEL SYSTEM 3-9 Throttle Grip and Cable • Unscrew the bolt [A]. • Remove the throttle pulley cover [B]. • Loosen the mounting bolts [A]. • Remove the cables [B] from the carburetor . • Free the tips [C] from the pulley . • Remove the cables from the frame. • Lubricate the cable. • Apply grease to the tips of the cables. • Install [...]

3-10 FUEL SYSTEM Throttle Grip and Cable Throttle Cable Lubricatio n • Whenever the throttle cable is removed or in accordance with the Periodic Maintenance Chart, lubricate the these cables, Refer to General Lubrication in the Periodic Main- tenance Chapter . ○ Apply a thin coating of grease to the cable upper or lower ends. ○ Use a commerci[...]

FUEL SYSTEM 3-1 1 Throttle Grip and Cable • Remove: Fuel T ank (see Fuel T ank Removal) • Pull out the cable [B] from the clamps [A]. Hot Start Cable Installation T orque - Hot Start Plunger Cap Bol t: 1.0 N·m (0.1 kgf ·m, 10 in·lb) • Install the hot start cable in accordance with the Cable, Wire and Hose Routing section in the appendix ch[...]

3-12 FUEL SYSTEM Carburetor Since the carburetor regulates and mixes the fuel and air going to the engine, there are two general types of carbure- tor trouble: too rich a mixture (too much fuel), and too lean a mixture (too little fuel). Such trouble can be caused by dirt, wear , maladjustment, or improper fuel level in the float chamber . A dirty [...]

FUEL SYSTEM 3-13 Carburetor • Read the fuel level in the gauge and compare it to the specification. Service Fuel Lev el (below the bott om edge of the carb. body) Standard : 6.5 ±1 mm (0.256 ±0 .039 in.) If the fuel level is incorrect, adjust it. • T urn the fuel tap to the OFF position and remove the fuel level gauge. • Install the drain p[...]

3-14 FUEL SYSTEM Carburetor NOTE ○ Float height [A] is the distance from the float bowl mat- ing surface [B] of the carburetor body (with the gasket removed) to the top of the float [C]. Measure the height with the carburetor upside down. ○ Do not push the needle rod [D] in during the float height measurement. • Assemble the carburetor , and [...]

FUEL SYSTEM 3-15 Carburetor • Remove: Seat Side Cover Silencer Rear Frame Bolts [B] • Loosen the clamp screws [A] of the air cleaner duct. • Pull out the rear frame [C] with the air cleaner housing. ○ Lift up the rear frame little and then pass the end position [A] of the duct between the frame and shock absorber as shown. • Loosen the cl[...]

3-16 FUEL SYSTEM Carburetor • Loosen the mounting bolts [A]. • Pull out the end of the throttle cables [B]. • Free the tips [C]. • Pull out the air vent tubes and drain tube [A] from the clamp [B]. • Remove the carburetor to the left side of the frame. • Drain the fuel from the float bowl by removing the drain plug. After draining, inst[...]

FUEL SYSTEM 3-17 Carburetor • Fit the claw [A] of the clamp onto the groove [B] of the inlet duct. • Insert the duct end between the frame and shock ab - sorber . • Install the upper bolt temporary . • Insert the duct end onto the carburetor . • T ighten the clamps securely . T orque - Carburetor Holder Clamp Screw : 2.0 N·m (0.2 kgf·m,[...]

3-18 FUEL SYSTEM Carburetor • Unscrew the screw [A]. • Pull out the fuel hose fitting [B]. • Unscrew the carburetor cap bolts [A]. • Remove the carburetor cap [B]. • Unscrew the throttle valve link screw [A]. • Pull out the throttle valve assembly [B]. • Disassemble the throttle valve assembly; jet needle holder [A] (unscrew), spring [...]

FUEL SYSTEM 3-19 Carburetor • Remove the throttle pulley shaft [A] with the spring [B], steel washer [C], plastic washer [D] and throttle valve link [E]. ○ T urn the throttle pulley s haft [A] clockwise while holding down the acceleration pump lever [B] and clear the idle stop screw [C] to the stopper [D] of the pulley . • T urn in the pilot [...]

3-20 FUEL SYSTEM Carburetor • Unscrew the screws [A]. • Remove the acceleration pump cover [B] from the carbu- retor . • Remove the spring [A], diaphragm [B], and the O-rings [C]. • Remove the following parts from the carburetor body . [A] Idle Adjusting Screw [B] Screws [C] Clamps [D] Float Bowl [E] Leak Jet [F] O-ring [G] Pin [H] Float [I[...]

FUEL SYSTEM 3-21 Carburetor • Unscrew the leak jet [A]. • Remove: E-clip [A] W asher [B] • Pull out the acceleration pump lever assembly [C] as a set. • Remove the throttle sensor mounting bolt [A]. • Before removing the throttle sensor [B], mark [C] the car- buretor body and sensor so that it can be installed later in the same position.[...]

3-22 FUEL SYSTEM Carburetor Carburetor Cleaning W ARNING Clean the carburetor in a well-ventilated area, and take care that there is no spark or flame anywhere near the working area; this includes any appliance with a pilot light. Because of the danger of highly flammable liquids, do not use gasoline or low flash -point solvent to clean the carbure[...]

FUEL SYSTEM 3-23 Carburetor • Remove the carburetor . • Before disassembling the carburetor , check the fuel level (see Fuel Level Inspection). If the fuel level is incorrect, inspect the rest of the carbu - retor before correcting it. • T urn the throttle pulley to check that the throttle valve [A] moves smoothly and returns by spring pressu[...]

3-24 FUEL SYSTEM Carburetor • Check the jet needle for wear . A worn jet needle should be replaced. • For the throttle sensor inspection, see Throttle Sensor In- spection in the Electrical System chapter . • Check the valve seat [A] of the choke plunger [B] for dam- age or stepped wear . Replace the choke knob assembly if necessary . • Clea[...]

FUEL SYSTEM 3-25 Carburetor • Install: W asher [A] E-clip [B] • Apply thin coat silicone grease to the shaft. • Fit the hook [A] of the return spring onto the stopper [B] of the throttle cable pulley . • Insert the throttle cable pulley shaft [A] and install the steel washer [D], nylon washer [C] and valve link [B]. ○ Fit the end [A] of t[...]

3-26 FUEL SYSTEM Carburetor • Install the push rod [A] into the push rod holder [B]. • Apply a grease to the O-ring [A]. • Fit the stopper [B] of the throttle sensor onto the projection [C] on the throttle cable pulley shaft. ○ Install the throttle sensor so that the marks aligns and check it position (see Throttle Sensor Inspection in the [...]

FUEL SYSTEM 3-27 Carburetor • Install: Starter Jet [A] Pilot Jet [B] Baffle Plate [C] Needle Jet [D] Main Jet [E] • Replace the O-ring with new one. • Install: Pilot Air Screw [A] Spring [B] W asher [C] O-ring [D] ○ T urn in the pilot air screw fully but not tightly , and the back it out the counted number of turn (see Carburetor Disassembl[...]

3-28 FUEL SYSTEM Carburetor • Replace the O-rings with new ones. • Fit the O-rings [A]. • Install: Diaphragm [B] Spring [C] Acceleration Pump Cover ○ Install the diaphragm so that its mark facing [D] outward. ○ Fit the spring end into the circle groove [E] in the cover . • T ighten the screws. • Install the choke knob/starter plunger [...]

FUEL SYSTEM 3-29 Carburetor • If turn the adjusting screw of the acceleration pump, follow the procedure below . ○ Adjust the acceleration pump timing. ○ Select an arbor [A] of the same diameter as the throttle valve height [B] and insert it under the throttle valve. Throttle V alve Height - 1.25 mm (0.0492 in.) ○ T urn in the adjusting scr[...]

3-30 FUEL SYSTEM Air Cleaner Air Cleaner Housing Removal • Remove: Side Covers (see Side Cover Removal in the Frame chapter) Seat (see Seat Removal in the Frame chapter) Silencer (see Engine T op End chapter) Bolts and Rear Fender [A] Screws and Rear Flap [B] • Loosen the air cleaner duct clamp screw [C]. • Unscrew the rear frame bolts [D]. ?[...]

FUEL SYSTEM 3-31 Air Cleaner Element Installation • When installing the element, coat the lip of the element with a thick layer of all purpose grease [A] to assure a complete seal against the air cleaner element base. Also, coat the base where the lip of the element fits. • Apply grease to all connections and screw holes in the air cleaner hous[...]

3-32 FUEL SYSTEM Fuel T ank Fuel T ank Removal W ARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Always stop the engine and do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. • Remove: Seat (see Seat Removal in the[...]

FUEL SYSTEM 3-33 Fuel T ank • Install the rubber dampers [A] position as shown in the figure. ○ Apply adhesive cement to the contact portion of the damper . • Be sure the fuel hose is clamped to the fuel tap to prevent leaks. • Insert the fuel tank breather hose outlet end into the steer- ing stem hole (see Appendix chapter). Fuel T ap R em[...]

[...]

COOLING SYSTEM 4-1 4 Cooling System T able of Contents Exploded View ................................................................................................................... ..... 4-2 Specifications ................................................................................................................. ........ 4-4 Special T ool[...]

4-2 COOLING SYSTEM Exploded View[...]

COOLING SYSTEM 4-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 W ater Pump Cover Bolts 9.8 1.0 87 in·lb L( 1 ) 2 W ater Pump Cover Bolts (with washer) 9.8 1.0 87 in·lb L( 1 ) 3 Coolant Drain Plug 7.0 0.7 61 in·lb 4 W ater Pump Impeller Bolt 7.0 0.7 61 in·lb 5 Right Engine Cover Bolts 9.8 1.0 87 in·lb 6 Radiator Hose Clamp S[...]

4-4 COOLING SYSTEM Specifications Item Service Limit Coolant Ty p e Permanent type antifreeze for aluminum engines and radiators Color Green Mixed Ratio Soft water 50%, antifreeze 50% Freezing Point –35°C (–31°F) T otal Amount 1.10 L (1.16 US qt.) Radiator Cap Relief Pressure 93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 13 ∼ 18 psi)[...]

COOLING SYSTEM 4-5 Special T ool Bearing Driver Set: 57001-1 129[...]

4-6 COOLING SYSTEM Coolant Check the coolant level each day before riding the motor- cycle, and replenish coolant if the level is low . Change t he coolant in accordance with the Periodic Maintenance Chart (see Coolant Level Inspection in the Periodic Maintenance chapter). W ARNING T o avoid burns, do not remove the radiator cap or try to inspect t[...]

COOLING SYSTEM 4-7 Coolant • Place a container under the coolant drain plug [A], and drain the coolant from the radiator and engine by remov- ing the drain plug on the water pump cover . Immediately wipe or wash out any coolant that spills on the frame, or engine. • Inspect the old coolant for visual evidence of c orrosion and abnormal smell (s[...]

4-8 COOLING SYSTEM Coolant Air Bleeding Before putting the motorcycle into operation, any air trapped in the cooling system must be removed as follows. • Start the engine, warm up the engine thoroughly , and then stop the engine. Wait until the engine cools down. • Remove the radiator cap. • Check the coolant level (see Coolant Level Inspecti[...]

COOLING SYSTEM 4-9 Coolant Cooling System Flushing Over a period of time, the cooling system accumulates rust, scale, and lime in the water jacket and radiator . When this accumulation is suspected or observed, flush the cool- ing system. If this accumulation is not removed, it will clog up the water passages and considerably reduce the ef fi- cien[...]

4-10 COOLING SYSTEM Wa t e r P u m p Water Pump Cover Removal • Drain the engine oil from the water pump cover . ○ Unscrew the bolts [A] and remove the oil filter cap [B]. • Drain the coolant (see Coolant Draining). ○ Unscrew the drain bolt [C]. • Remove: Spring (see Oil Filter Change in the Periodic Mainte- nance chapter) Oil Filter (see[...]

COOLING SYSTEM 4-1 1 W ater P ump • Apply grease to the water pipe O-ring [A]. • Insert the water pipe [B] straightly into the hole of the wa- ter pump cover . • T ighten: T orque - W ater Pipe Bolt: 9.8 N·m (1.0 kgf·m, 87 i n·lb) • Install the oil filter (see Oil Filter Change in the Periodic Maintenance chapter). • Fill the cooling s[...]

4-12 COOLING SYSTEM Wa t e r P u m p • Check the drainage outlet passage [A] a t the bottom of the right engine cover for coolant leaks. If the oil seal is damaged, the coolant leaks through the seal and drains through the passage. Replace the oil seals. Water Pump Gear Removal • Remove: W ater Pump Cover (see Water Pump Cover Removal) Impeller[...]

COOLING SYSTEM 4-13 W ater P ump • Insert a bar [A] into the water pump shaft hole from the inside of the right engine cover , and remove the oil seal [B] by tapping [C] evenly around the seal lips. Oil Seal and Bearing Installatio n CAUTION If the oil seal or ball bearing is removed, replace all of them with new ones at the same time • Be sure[...]

4-14 COOLING SYSTEM Radiator Radiator Removal • Drain the coolant (see Coolant Draining). • Remove: Bolts [A] Radiator Shrouds [B] • Loosen: Clamp Screws [A] • Remove: Radiator Hoses [B] Bolt [C] Right Radiator Screen [D] • Unscrew the bolts [A]. • Loosen: C l a m p[ B ]( S l i d eo u t ) • Remove: Right Radiator [C] with Breather T u[...]

COOLING SYSTEM 4-15 Radiator Radiator Installation • Run the radiator hose [A] between the hot start cable, engine stop switch lead [B] and main harness [C]. • Hold the clutch cable with clamps. • Fit the projections [A] of the screen in the holes [B] of the radiator . T orque - Radiator Hose Clamp Screws: 1.5 N·m (0.15 kgf·m, 13 in·lb) Ra[...]

4-16 COOLING SYSTEM Radiator Radiator Cap Inspection • Check the condition of the valve seals [A], and the top and bottom valve spring [B] of the radiator cap. If any one of them shows visible damage, replace the cap. • Wet the top and bottom valve seals with water or coolant to prevent pressure leaks. • Install the cap [A] on a cooling syste[...]

ENGINE TOP END 5-1 5 Engine T op End T able of Contents Exploded V iew ................................... 5-2 Specifications .................................... 5-6 Special T ools & Sealants ................... 5-9 Cylinder Head Cover ......................... 5-12 Cylinder Head Cover Removal .... 5-12 Cylinder Head Cover Installation . 5-12 [...]

5-2 ENGINE T OP END Exploded View[...]

ENGINE TOP END 5-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Auto-Decompressor Bolt 12 1.2 104 in·lb 2 Cylinder Head Cover Bolts 9.8 1.0 87 in·lb 3 Cylinder Head Bolts M6 12 1.2 104 in·lb S 4 Camshaft Cap Bolts 9.8 1.0 87 in·lb S 5 Carburetor Holder Clamp Screws 2.0 0.2 17 in·lb 6 Plug 20 2.0 14 L 7 Lower Camshaft Chain G[...]

5-4 ENGINE T OP END Exploded View[...]

ENGINE TOP END 5-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Camshaft Chain T ensioner Mounting Bolts 9.8 1.0 87 in·lb 2 Camshaft Chain T ensioner Cap Bolt 20 2.0 14.5 3 Cylinder Bolt M6 12 1.2 104 in·lb S 4 Exhaust Pipe Cover Screws 12 1.2 104 in·lb 5 Exhaust Pipe Holder Nuts 21 2.1 15 S 6 Silencer Mounting Bolts 21 2.1 15[...]

5-6 ENGINE T OP END Specifications Item Standard Service Limit Camshafts Cam Height: Exhaust 33.941 ∼ 34.057 mm 33.84 mm (1.3363 ∼ 1.3408 in.) (1.3322 in.) Inlet 34.642 ∼ 34.758 mm 34.54 mm (1.3639 ∼ 1.3684 in.) (1.3598 in.) Camshaft Bearing Clearance 0.020 ∼ 0.062 mm 0.15 mm (0.0008 ∼ 0.0024 in.) (0.0059 in.) Camshaft Journal Diameter [...]

ENGINE TOP END 5-7 Specifications Item Standard Service Limit V alve Seat Surface Outside Diameter: Exhaust 24.62 ∼ 24.82 mm ––– (0.9693 ∼ 0.9772 in.) Inlet 30.62 ∼ 30.82 mm ––– (1.2055 ∼ 1.2134 in.) V alve Seat Surface Width: Exhaust 0.5 ∼ 1.0 mm ––– (0.0197 ∼ 0.0394 in.) Inlet 0.5 ∼ 1.0 mm ––– (0.0197 ∼ 0.0[...]

5-8 ENGINE T OP END Specifications Cam Height Cam Height [A] Camshaft Runout V alve S tem Diam eter V alve Stem Diameter [A] 45° [B] Va l v e S t e m B e n d Dial Gauge [A][...]

ENGINE TOP END 5-9 Special T ools & Sealants Compression Gauge, 20 kgf/ cm²: 57001-221 V alve Spring Compressor Assembly: 57001-241 Piston Ring Compressor Grip: 57001-1095 Piston Ring Compressor Belt, 67 ∼ 79: 57001-1097 V alve Seat Cutter , 45° - 27.5: 57001-1 1 14 V alve Seat Cutter , 45° - 32: 57001-1 1 15 V alve Seat Cutter , 32° - 28[...]

5-10 ENGINE TOP END Special T ools & Sealants Spark Plug Wrench, Hex 16: 57001-1262 Compression Gauge Adapt er , M10 × 1.0: 57001-1317 V alve Seat Cutter , 60° - 25: 57001-1328 V alve Seat Cutter Holder , 4.5: 57001-1330 V alve Guide Arbor , 4.5: 57001-1331 V alve Guide Reamer , 4.5: 57001-133 3 V alve Seat Cutter , 60° - 33 : 57001-133 4 Fi[...]

ENGINE T OP END 5-1 1 Special T ools & Sealants Kawasaki Bond (Silicone Sealant): 92104-0004[...]

5-12 ENGINE TOP END Cylinder Head Cover Cylinder Head Cover Removal • Remove: Fuel T ank (see Fuel T ank Removal in the Fue l System chapter) Stick Coil (see Spark Plug Cleaning and Inspection in the Periodic Maintenance chapter) • Unscrew the bracket nuts [A] and remove the bolts [B]. • Loosen the mounting nut [C]. • Remove the cylinder he[...]

ENGINE TOP END 5-13 Camshaft Chain T ensioner Camshaft Chain T ensioner Remo val CAUTION This is a non-return type camshaft chain tensioner . The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: When removing the tensioner , do n ot take out the mounting bolts o[...]

5-14 ENGINE TOP END Camshaft Camshaft Removal • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) T iming Inspection Cap [A] Flywheel Cap [B] Special T ool - Filler Cap Driver : 57001-1454 • First, bring the piston to the TDC (of either the compres- sion or exhaust stroke). ○ Place a wrench over the flywheel nut and turn it coun[...]

ENGINE TOP END 5-15 Camshaft • Remove: Bolt [A] Auto-Decompressor [B] Spring [C] Camshaft Installation • Install: Spring [A] Auto-Decompressor [B] Bolt [C] T orque - Auto-Decompressor Bolt: 12 N·m (1.2 kgf·m, 104 in·lb) • Fill the passage of the cylinder head with molybdenum disulfide oil. ○ Pure in the oil from the inlet oil passage hol[...]

5-16 ENGINE TOP END Camshaft 1st Pin [A] Punch Marks (exhaust) [D] 2nd Pin [B] Punch Marks (inlet) [E] 28th Pin [C] Upper Cylinder Head Surface [F] • Be sure to install the dowel pi ns [A] and positioning rings [B]. • Install the camshaft caps in their original positions by fac- ing their triangle marks [A] face to face as shown in the photogra[...]

ENGINE TOP END 5-17 Camshaft • Uniformly tighten all bolts and after the camshaft has set- tled, uniformly tighten all the bolts. ○ Bolts [A] are long. ○ Following the sequence numbers on the camshaft caps, tighten the cap bolts [1 ∼ 4] after applying engin e oil to the seat and thread of them. T orque - Camshaft Cap Bol ts: 9.8 N·m (1.0 k[...]

5-18 ENGINE TOP END Camshaft Camshaft and Camshaft Cap Wear • Measure each clearance between the camshaft journal and camshaft cap using plastigauge (press gauge) [A]. ○ T ighten the camshaft cap bolts after applying engine oil to the seat and thread of them. T orque - Camshaft Cap Bol t: 9.8 N·m (1.0 kgf·m, 87 in·lb) NOTE ○ Do not turn th[...]

ENGINE TOP END 5-19 Cylinder Head Cylinder Compression Measurement • Start the engine. • Thoroughly warm up the engine so that the engine oil be- tween the piston and cylinder wall will help seal compres- sion as it does during normal running. • Stop the engine. • Remove: Fuel T ank (see Fuel T ank Removal in the Fuel System chapter) Stick [...]

5-20 ENGINE TOP END Cylinder Head Cylinder Head Removal • Remove: Fuel T ank (see Fuel T ank Removal in the Fue l System chapter) Carburetor (see Carburetor Removal in the Fuel System chapter) Camshaft Chain T ensioner (see Camshaft Chain T en- sioner Removal) Cylinder Head Cover (see Cylinder Head Cover Re- moval) Camshaft (see Camshaft Removal)[...]

ENGINE TOP END 5-21 Cylinder Head • Pull the cylinder head upward. ○ Do not damage the radiator core. ○ Clear the front [A] and rear [B] chain guides. • Remove the cylinder head gasket. Cylinder Head Installation • Fit the projection [A] of the front camshaft chain guide [B] in the groove [C] of the cylinder [D]. ○ Insert the guide end [...]

5-22 ENGINE TOP END Cylinder Head • T ighten the 6 mm bolts. M6 Cylinder Bolt [A] M6 Cylinder Head Bolt with Clamp [B] M6 Cylinder Head Bolt [C] T orque - 6 mm Cylinder Bolt : 12 N·m (1.2 kgf·m, 104 in·lb) 6 mm Cylinder Head Bolt: 12 N·m (1.2 kgf·m, 104 in·lb) • Install: Camshaft (see Camshaft Installation) Cylinder Head Cover (see Cylind[...]

ENGINE TOP END 5-23 Va l v e s V alve Clearance Inspection ○ Refer to the V alve Clearance Inspection in the Periodic Maintenance chapter . V alve Removal • Remove the cylinder head (see Cylinder Head Removal). • Remove the valve lifter and the shim from the valve. NOTE ○ Use the valve spring compressor assembly [A] and the adapter [B] to p[...]

5-24 ENGINE TOP END Va l v e s V alve G uide Removal • Remove: V a l v e( s e eV a l v eR e m o v a l ) Oil Seal Spring Seat • Heat the area around the valve guide up to 120 ∼ 150°C (248 ∼ 302°F). CAUTION Do not heat the cylinder head with a torch. This will warp the cylinder head. Soak the cylinder head and heat the oil. • Hammer light[...]

ENGINE TOP END 5-25 Va l v e s • Ream the valve guide with valve guide reamer [A], even if the old guide is reused. ○ Always rotate the reamer clockwise. Special T ool - V alve Guide Reamer , 4.5: 57001-1333 V alve/Valve Guide Clearance Measurement (Wobble Method) ○ If a small bore gauge is not available, inspect the valve guide wear by measu[...]

5-26 ENGINE TOP END Va l v e s V alve Seat Inspection • Remove the valve (see V alve Removal). • Check the valve seating surface [A] between the valve [B] and valve seat [C]. • Measure the outside diameter [D] of the seating pat tern on the valve seat. If the outside diameter is too large or too small, repair the seat. (see Seat Repair) V alv[...]

ENGINE TOP END 5-27 Va l v e s Seat Cutter Operation Care: 1. This valve seat cutter is developed to grind the vale for repair . Therefore the cutter must not be used for other purposes than seat repair . 2. Do not drop or shock the valve seat cutter , or the dia- mond particles may fall of f. 3. Do not fail to apply engine oil to the valve seat cu[...]

5-28 ENGINE TOP END Va l v e s • Measure the outside diameter of the seating surface with a vernier caliper . If the outside diameter of the seating surface is too small, repeat the 45° grind until the dia meter is within the spec- ified range. Original Seating Surface [B] ○ Remove all pittings of flaws from 45° ground surface. ○ Alter grin[...]

ENGINE TOP END 5-29 Va l v e s • The seating area should be marked about in the middle of the valve face. If the seat area is not in the right place on the valve, check to be sure the valve is the correct part. If it is, it may have been refaced too much; replace it. • When the engine is assembled, be sure to adjust the valve clearance (see Eng[...]

5-30 ENGINE TOP END Va l v e s V alve Seat Repair[...]

ENGINE TOP END 5-31 Cylinder and Piston Cylinder Removal • Remove: Cylinder Head (see Cylinder Head Removal) Front Camshaft Chain Guide [A] Cylinder Bolt [B] • T ap lightly up with a plastic mallet to separate the cylinder from the crankcase. • Remove the cylinder base gasket. Piston Removal • Remove the cylinder (see Cylinder Removal). •[...]

5-32 ENGINE TOP END Cylinder and Piston • Install the top ring [A] so that the "R" mark [B] faces up. NOTE ○ If a new piston or cylinder is used, check piston to cylin- der clearance (see Piston/Cylinder Clearance), and use new piston rings. • Apply engine oil to the inside wall of the small end of the connecting rod. • Face the c[...]

ENGINE TOP END 5-33 Cylinder and Piston • Apply engine oil to the cylinder bore. • Determine the position of the piston ring ends. • Install the cylinder while compressing the piston rings with your fingers or the special tool [A]. Special T ools - Piston Ring Compressor Grip: 57001-1095 Piston Ring Compressor Belt, 67 to 79: 57001-1097 • D[...]

5-34 ENGINE TOP END Cylinder and Piston Piston Ring Groove Width • Measure the groove width at several points around the piston with a vernier caliper . Piston Ring Groove W idth Standard To p 0.83 ∼ 0.85 mm (0.0327 ∼ 0.335 in.) Service Lim it To p 0.93 mm (0.0366 in.) If any of the groove widths exceeds the service limit, re- place the pisto[...]

ENGINE TOP END 5-35 Cylinder and Piston Piston, Piston Pin, Connecting Rod Wear Inspection • Visually inspect the snap ring [A] still fitted i n place. If the ring shows weakness or deformation, replace the ring. Also if the pin hole groove shows excessive wear , replace the piston. • Measure the diameter of the piston pin [B] with a microm- et[...]

5-36 ENGINE TOP END Carburetor Holder Carburetor Holder Installation • Install the carburetor holder [A] with the marked [B] side facing toward the cylinder head outside. ○ Install the holder clamp [C] with its screw head [D] facing left side. T orque - Carburetor Holder Clamp Screw: 2.0 N·m (0.2 kgf·m, 17 in·lb) • Fit the projection [A] o[...]

ENGINE TOP END 5-37 Muffler WA R N I N G T o avoid a serious burn, do not remove the muffler when the engine is still hot. Wait until the muffler cools down. Muffler Removal • Loosen the silencer clamp bolt [A]. • Remove the exhaust pipe holder nuts [B]. • Remove the exhaust pipe [C]. • Remove Right Side Cover (see Side Cover Removal in the[...]

[...]

ENGINE RIGHT SIDE 6-1 6 Engine Right Side T able of Contents Exploded View ................................................................................................................... ..... 6-2 Specifications ................................................................................................................. ........ 6-6 Special[...]

6-2 ENGINE RIGHT SIDE Exploded View[...]

ENGINE RIGHT SIDE 6-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Primary Gear Nut 98 10 72 LH 2 Clutch Cover Bolts 9.8 1.0 87 in·lb 3 Clutch Cover Bolt (with right engine cover) 9.8 1.0 87 in·lb L( 2 ) 4 Right Engine Cover Bolts 9.8 1.0 87 in·lb 5 Clutch Spring Bolts 9.8 1.0 87 in·lb 6 Clutch Hub N ut 98 10 72 7. Primary Ge[...]

6-4 ENGINE RIGHT SIDE Exploded View[...]

ENGINE RIGHT SIDE 6-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Kick Ratchet Guide Bolt 8.8 0.9 78 in·lb L 2 Kick Pedal Mounting Bolt 25 2.5 18 L 3 Shift Pedal Bolt 9.8 1.0 87 in·lb 4 Ratchet Plate Mounting Bolt 9.8 1.0 87 in·lb L 5 Ratchet Plate Mounting Screw 6.4 0.65 56 in·lb L 6 Gear Set Lever Nut 8.8 0.9 78 in·lb 7 S[...]

6-6 ENGINE RIGHT SIDE Specifications Item Standard Service Limit Clutch Lever Clutch Lever Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) ––– Clutch Friction Plate Thickness 2.72 ∼ 2.88 mm (0.107 ∼ 0.1 13 in.) 2.62 mm (0.1031 in.) Steel Plate Thickness 1.5 ∼ 1.7 mm (0.059 ∼ 0.067 in.) 1.4 mm (0.055 in.) Friction Plate W arp 0.1 5 mm (0.0059[...]

ENGINE RIGHT SIDE 6-7 Special T ools Outside C irclip Pliers: 57001-144 Clutch Holder: 57001-1243 Gear Holder , m2.0: 57001-1557[...]

6-8 ENGINE RIGHT SIDE Clutch Lever and Cable Due to friction plate wear and clutch cable stretch over a long period of use, the clutch must be adjusted in accor- dance with the Periodic Maintenance Chart. W ARNING T o avoid a serious burn, never touch the hot engine or exhaust chamber during clutch adjustment. Clutch Lever Free Pla y Inspection •[...]

ENGINE RIGHT SIDE 6-9 Clutch Lever and Cable • Slide the dust covers [A] out of place. • Line up the slots [A] in the clutch lever [B], and adjuster [C] and then free the cable from the lever . • Free the cable from the cable holder [A]. • Free the clutch inner cable tip [B] from the clutch release lever [C]. CAUTION Do not remove the clutc[...]

6-10 ENGINE RIGHT SIDE Clutch Cover and Right Engine Cover Clutch Cover Removal • Drain the engine oil at the transmission oil sump (see En- gine Oil Change in the Periodic Maintenance chapter). • Set the stand attached. • Remove the clutch cover bolts [A] and remove the clutch cover [B]. Clutch Cover Installation • Apply a non-permanent lo[...]

ENGINE RIGHT SIDE 6-1 1 Clutch Cover and Right Engine Cover • Remove: Wa t e r P i p e B o l t [ A ] Wa t e r P i p e [ B ] W ater Pump Cover [C] • Remove the right engine cover bolts [D] to remove the right engine cover [E]. Right Engine Cover Installation • T wo dowel pins [A] are installed at the mating surface between the crankcase and th[...]

6-12 ENGINE RIGHT SIDE Clutch Cover and Right Engine Cover • Install: W ater Pump Cover (see W ater Pump Cover Installation in the Cooling System chapter) • Apply grease to the water pipe O-ring [A]. • Insert the water pipe [B] straitly into the hole [C] of the water pump cover . T orque - W ater Pump Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in?[...]

ENGINE RIGHT SIDE 6-13 Clutch Cover and Right Engine Cover • Apply plenty of high temperature grease to the oil seal lips. • Press in the oil seals direction as shown. ○ Press in the new oil seal using a press and suitable tools so that the seal surface is flush with the surface of the right engine cover . Flat Side [A] Kickshaft Oil Seal [B][...]

6-14 ENGINE RIGHT SIDE Clutch Clutch Removal • Drain the engine oil at the transmission oil sump (see En- gine Oil Change in the Periodic Maintenance chapter). • Remove the clutch cover (see Clutch Cover Removal). • Remove the clutch spring bolts [A], spring, and clutch pressure plate [B]. • Remove the push rod holder assy [A], friction pla[...]

ENGINE RIGHT SIDE 6-15 Clutch • Install the clutch housing [A]. ○ T urning the oil pump idle gear with the thin blade screw- driver [B] push in the clutch housing and then install the housing to the kick idle gear . ○ Do not forget to install the thrust washer [A] before in - stalling the clutch hu b [B]. • Install the toothed washer [A]. ?[...]

6-16 ENGINE RIGHT SIDE Clutch • If a clutch part was replaced, install the standard adjust- ing washer (1.5 mm thickness) [A] of the push rod holder assy , and check the release lever position as explained later procedure. • T ighten the clutch spring bolts [A] holding the clutch hous- ing with the hand. T o rque - Clutch Spring B olts: 9.8 N·[...]

ENGINE RIGHT SIDE 6-17 Clutch Clutch Spring Free Length Inspection • Measure the free length [A] of the clutch springs. If any clutch spring is shorter than the service limit, it must be replaced. Clutch Spring Free Length Standard: 45. 82 mm (1.804 in.) Service Limit: 43.7 mm (1.720 in. ) Clutch Housing Finger Damage • Visually inspect the clu[...]

6-18 ENGINE RIGHT SIDE Primary Gear Primary Gear Removal • Remove: Right Engine Cover (see Right Engine Cover Removal) Clutch (see Clutch Removal) • T emporarily install the clutch housing [A]. • Using the gear holder [B], secure the p rimary gear . Special T ool - Gear Holder , m2.0: 57001-1557 • Remove the clutch housing. • Remove the p[...]

ENGINE RIGHT SIDE 6-19 External Shift Mechanism External Shift Mechanism Remova l • Remove: Shift Pedal Bolt [A] Shift Pedal [B] • Remove: Right Engine Cover (see Right Engine Cover Removal) Clutch Housing (see Clutch Removal) • Pull out the shift shaft [A]. • Remove the screw [B] and bolt [C], take of f the shift ratchet assembly [D] with [...]

6-20 ENGINE RIGHT SIDE External Shift Mechanism • Set up the shift ratchet assembly as shown in the figure. Ratchet [A] Pawls [B] Pins [C] Springs [D] Crankcase Side [E] • Then install the ratchet assembly [A] to the ratchet plate [B] as shown in the figure. Crankcase Side [C] • Install the ratchet assembly to the shift drum cam. • Apply a [...]

ENGINE RIGHT SIDE 6-21 External Shift Mechanism • Check the ratchet assembly for damage. If ratchet [A], pawls [B], pins [C] or springs [D] are dam- aged in any way , replace them. • Check the gear set lever [A] and its spring [B] for cracks or distortion. If the lever or spring is damaged in any way , replace them. • Visually insp ect the sh[...]

6-22 ENGINE RIGHT SIDE Kickstarter Kick Pedal Assy Removal • Remove: Mounting Bolt [A] Kick Pedal Assy [B] Kick Pedal Assy Installation • Install the kick pedal assy [A] at the angle shown. 10 ∼ 20 mm (0.39 ∼ 0.79 in.) [B] • Apply a non-permanent locking agent to the mounting bolt. • T ighten the mounting bolt. T orque - Kick Pedal Moun[...]

ENGINE RIGHT SIDE 6-23 Kickstarter Idle Gear Installation • Apply engine oil to the inside of the idle gear . • Install the washer [A]. • Fit the idle gear [B] with the bo ss [C] facing toward the engine side. Kickshaft Removal • Remove: Right Engine Cover (see Right Engine Cover Removal) Clutch Housing (see Clutch Removal) • Pull the end[...]

6-24 ENGINE RIGHT SIDE Kickstarter Kickstarter Assembly Disassembly/Assembly • The kickstarter assembly consists of the following parts. • Check the kickstarter assembly parts for damage. A ny damaged parts should be replaced with new ones. A. Kick Gear E. Ratchet Gear B. Circlips F . Kick S haft C. W ashers G. Kick S pring D. Spring H. Spring [...]

ENGINE LUBRICA TION SYSTEM 7-1 7 Engine Lubrication System T able of Contents Exploded View ................................................................................................................... ..... 7-2 Lubrication System Chart ............................................................................................... ........ 7-[...]

7-2 ENGINE LUBRICA TION SYSTEM Exploded View[...]

ENGINE LUBRICA TION SYSTEM 7-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Engine Oil Drain Plug M10 (for transmission room oil sump) 15 1.5 11 2 Engine Oil Drain Bolt M6 (for crank room oil sump) 7.0 0.7 61 in·lb 3 Oil Pump Mounting Bolts 7.0 0.7 61 in·lb L 4 W ater Pump Cover Bolts 9.8 1.0 87 in·lb L( 1 ) 5 W ater Pump Cove[...]

7-4 ENGINE LUBRICA TION SYSTEM Lubrication System Chart[...]

ENGINE LUBRICA TION SYSTEM 7-5 Lubrication System Chart 1. Oil Screen (scavenge) 2. Oil Screen (feed) 3. Oil Pump (scavenge) 4. Oil Pump (feed) 5. Right Crankcase Oil Passage (from Scavenge Oil Pump to T ransmission Oil Shower Passage) 6. Right Engine Cover Oil Passage (from Feed Oil Pump to Oil Filter Oil Chamber) 7. Oil Filter 8. Oil Filter Oil C[...]

7-6 ENGINE LUBRICA TION SYSTEM Specifications Item Standard Engine Oil Grade Castrol “R4 Superbike” 5W-40 or API SG, SH, SJ or SL with JASO MA Vis c os i ty SAE 10W-30, 10W-40, or 10W-50 Capacity Oil Change - when filter is not removed 1 . 3L( 1 . 4U Sq t ) Oil Change - when filter is removed 1.35 L (1.43 US qt) when engine is completely dry 1 [...]

ENGINE LUBRICA TION SYSTEM 7-7 Special T ools Oil Pressure Gauge, 5 kgf/c m²: 57001-125 Outside C irclip Pliers: 57001-144 Gear Holder , m2.0: 57001-1557 Oil Pressure Gauge Adapter , M6 × 1.0: 57001-1664[...]

7-8 ENGINE LUBRICA TION SYSTEM Engine Oil and Oil Filter W ARNING Motorcycle operation with insufficient, deteri- orated, or contaminated engine oil will cause accelerated wear and may result in engine or trans- mission seizure, accident, and injury . The engine oil level indicated in the clutch cover oil level gauge is very sensitive to the motorc[...]

ENGINE LUBRICA TION SYSTEM 7-9 Engine Oil and Oil Filter Oil Filter Change • Refer to the Engine Lubrication System in the Periodic Maintenance chapter . Oil Screen Cleaning • Separate the crankcase (see Crankcase Disassembly in the Crankshaft/T ransmission chapter). • Remove the oil screens [A] from the crankcase. • Clean the oil screens w[...]

7-10 ENGINE LUBRICA TION SYSTEM Oil Pump Oil Pump Removal • Drain: Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) Coolant (see Coolant Draining in the Cooling System chapter) • Remove: Brake Pedal (see Brake Pedal Removal in the Brakes chapter) Kick Pedal (see Kick Pedal Removal in the Engine Right Side chapter) • Re[...]

ENGINE LUBRICA TION SYSTEM 7-1 1 Oil Pump • Remove the inner [A] and outer [B] rotors of the scavenge oil pump. • Disassemble the feed oil pump assembly . Oil Pump Cover [A] Inner Rotor [B] Outer Rotor [C] Pin [D] Oil Pump Body [E] Oil Pump Gear [F] Oil Pump Installation • Apply molybdenum disulfide grease to the shaft of the oil pump gear . [...]

7-12 ENGINE LUBRICA TION SYSTEM Oil Pump • Install the outer rotor [A]. • Install the dowel pin [B] and dowel pin [C]. • Install the scavenge and feed oil pump assembly [D]. • Apply a non-permanent locking agent to the oil pump mounting bolts. • T ighten the oil pump mounting bolts. T orque - Oil Pump Mounting Bolts: 7.0 N· m (0.7 kgf·m[...]

ENGINE LUBRICA TION SYSTEM 7-13 Oil Pressure Oil Pressure Measurement • Start the engine and warm up the engine thoroughly . NOTE ○ Warm up the engine thoroughly before measuring the oil pressure. • Remove: Oil Filter Cap Bolts [A] Oil Filter Cap [B] W ater Pump Cover Bolt [C] • Install the oil pressure gauge adapter [A] to the water pump c[...]

[...]

ENGINE REMOV AL/INST ALLA TION 8-1 8 Engine Removal/Installation T able of Contents Exploded View ................................................................................................................... ..... 8-2 Special T ools ...............................................................................................................[...]

8-2 ENGINE REMOV AL/INST ALLA TION Exploded View[...]

ENGINE REMOV AL/INST ALLA TION 8-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Upper Engine Mounting Bolt, Nut (M10) 49 5.0 36 2 Middle Engine Mounting Bolt, Nut (M10) 49 5.0 36 3 Lower Engine Mounting Bolt, Nut (M10) 49 5.0 36 4 Upper Engine Bracket Bolt, Nuts (M8) 29 3.0 22 5 Middle Engine Bracket Bolts (M8) 29 3.0 22 6 Swinga[...]

8-4 ENGINE REMOV AL/INST ALLA TION Special T ools Jack: 57001-1238 Attachment J ack: 57001-1252 Jack Attachment: 57001-160 8[...]

ENGINE REMOV AL/INST ALLA TION 8-5 Engine Removal/Installation Engine Removal • Place the jack [A] under the frame to support the motor- cycle. Special T ools - Jack: 57001-1 238 Jack Attachmen t :57001-1252 or 57001 -1608 WA R N I N G For engine removal, the swingarm pivot shaft must be pulled out, causing the swingarm and rear wheel assembly to[...]

8-6 ENGINE REMOV AL/INST ALLA TION Engine Removal/Installation • Disconnect: Magneto Lead Connector [A] Neutral Switch Lead Connector [B] • Remove: Stick Coil [C] • Loosen: Carburetor Clamp Screws • Remove: Inlet Duct with Rear Frame [A] (see Rear Frame Re- moval in the Frame chapter) Carburetor [B] (see Carburetor Removal in the Fuel Sys- [...]

ENGINE REMOV AL/INST ALLA TION 8-7 Engine Removal/Installation • Remove: Middle Engine Bracket Bolts [A] Middle Engine Mounting Bolt [B] Middle Engine Brackets [C] Lower Engine Mounting Bolts [D] • Remove the swingarm pivot shaft [A]. ○ Pull out the swingarm pivot shaft half way from right side to free the engine. • Remove the engine from t[...]

8-8 ENGINE REMOV AL/INST ALLA TION Engine Removal/Installation • Install the removed parts. • Run the cables, hoses, and leads according to the Cable, Wire and Hose Routing section of the Appendix chapter . • Fill: Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) Coolant (see Coolant Filling in the Cooling S ystem chap[...]

CRANKSHAFT/TRANSMISSION 9-1 9 Crankshaft/T ransmission T able of Contents Exploded View ................................................................................................................... ..... 9-2 Specifications ................................................................................................................. .......[...]

9-2 CRANKSHAFT/TRANSMISSION Exploded View[...]

CRANKSHAFT/TRANSMISSION 9-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Re- marks 1 Crankcase Bolts 9.8 1.0 87 in·lb S 2 Gear Set Lever Nut 8.8 0.9 78 in·lb 3 Neutral Switch 12 1.2 104 in·lb 4 Engine Oil Drain Bolt (For Crank Room Oil Sump) 7.0 0.7 61 in·lb 5 Engine Oil Drain Bolt (For T ransmission Room Oil Sump) 15 1.5 11 6 Shift Dr[...]

9-4 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Connecting Rods Connecting Rod Big End Radial Clearance 0.002 ∼ 0.014 mm (0.00008 ∼ 0.0006 in.) 0.06 mm (0.0024 in.) Connecting Rod Big End Side Clearance 0.25 ∼ 0.35 mm (0.0098 ∼ 0.0138 in.) 0.55 mm (0.0217 in.) Crankshaft Runout TIR 0.03 mm (0.0012 in.) or less TIR 0.0[...]

CRANKSHAFT/TRANSMISSION 9-5 Special T ools Bearing Pulle r: 57001-135 Outside C irclip Pliers: 57001-144 Crankcase Splitting T ool Assembly: 57001-1098 Bearing Driver Set: 57001-1 129 Crankshaft Ji g: 57001-1 174 Crankcase Splitt ing T ool Assembly: 57001-1362 Kawasaki Bond (Liquid Ga sket - Gray): 92104-1063[...]

9-6 CRANKSHAFT/TRANSMISSION Crankcase Crankcase Disassembly • Remove the engine from the frame (see Engine Re- moval/Installation in the Engine Removal/Installation chapter) • Set the engine on clean surface while pa rts are being re- moved. • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval in the Engine T op End chapter) Camsh[...]

CRANKSHAFT/TRANSMISSION 9-7 Crankcase • Remove the crankcase bolts [A]. • Install the jig [A] between the crankshaft flywheels [B]. Special T ool - Crankshaft Jig: 57001-1 1 74 • Attach the crankcase splitting tool [A] to the left crankcase. ○ Adjust the gap is between the splitting tool arm and adapter , using the collars or nuts [B]. ○ [...]

9-8 CRANKSHAFT/TRANSMISSION Crankcase • Remove: Shift Rods [A] (see T ransmission Shaft Removal) 3 Shift Forks [B] (see Trans mission Shaft R emoval) Shift Drum [C] (see T ransmission Shaft Removal) T ransmission [D] (see Transmission Shaft R emoval) Crankshaft [E] (see Crankshaft Removal) • Remove the reed valve [A] from the left crankcase hal[...]

CRANKSHAFT/TRANSMISSION 9-9 Crankcase • Be sure to replace any oil seal removed with a new one. • Press in the new oil seals using a press and bearing driver so that the seal surface [A] is flush [B] with the surface of the crankcase [C]. • Apply high-temperature grease to the oil seal lips [D]. Right Crankcase Oil Seal [F] Metal Side Face [E[...]

9-10 CRANKSHAFT/TRANSMISSION Crankcase • Press the new output shaft bearings [A] in the left crankcase half [B], so that the stepped side [C] faces inside of the engine. Special T ool - Bearin g Drive r Set: 57001-1 129 • Apply a non-permanent locking agent to the retaining screws [A] and bolts [ B]. • Install the retainers [C]. T orque - Bea[...]

CRANKSHAFT/TRANSMISSION 9-1 1 Crankcase • Install: Shift Drum [A] (see T ransmission Installation) Shift Rods [B] (see T ransmission Installation) Shift Forks [C] (see T ransmission Installation) • Install: Oil Screens [A] ○ Install the oil screen so that the longer pipe side [B] faces in right crankcase. • With the connecting rod positione[...]

9-12 CRANKSHAFT/TRANSMISSION Crankcase • T ighten the crankcase bolts, starting with the periphery of the crankshaft, then outward. ○ T ighten the [8], [12] bolts with the clamp. T orque - C rankcase Bolt: 9.8 N·m (1. 0 kgf·m, 87 in·lb) NOTE ○ After tightening the crankcase bolts, wipe up the liquid gasket seeping out around the mating sur[...]

CRANKSHAFT/TRANSMISSION 9-13 Crankcase • Replace the O-rings [A] on the output shaft with new ones. • Install two O-rings on the grinding faces of the output shaft while expanding the O-ring by the hand. • Apply grease to the inside of the output shaft collar [B]. • Insert the collar with the oil groove end facing [C] in. • Install the ot[...]

9-14 CRANKSHAFT/TRANSMISSION Crankshaft Crankshaft Removal • Disassemble the crankcase (se e Crankcase Disassem- bly). • Remove the transmission shaft (see T ransmission Shaft Removal). • Using the hand press [A], remove the crankshaft [B] from the right crankcase [C]. If the bearing stay on the crankshaft when splitting the crankcase, or rem[...]

CRANKSHAFT/TRANSMISSION 9-15 Crankshaft • Carefully align the oil passage hole in the right flywheel [A] with the one in the crankpin [B] at rebuilding of the crankshaft as shown. • Reassemble the crankshaft according to the standard tol- erances in Specifications. ○ Connecting rod bend, twist (see Connecting Rod Bend, Connecting Rod T wist).[...]

9-16 CRANKSHAFT/TRANSMISSION Crankshaft Crankshaft Runout • Set the crankshaft in a flywheel alignment jig or on V blocks, and place a dial gauge as shown and turn the crankshaft slowly . The maximum difference in gauge reading is the crankshaft runout. Standard: TI R 0.03 mm (0.0012 in.) or less Service Limit: TIR 0.08 m m (0.0031 in .) If the r[...]

CRANKSHAFT/TRANSMISSION 9-17 Crankshaft Connecting Rod Bend • Remove the connecting rod. • Select an arbor [A] of the same diameter as the connect- ing rod big end, and insert the arbor through the connect- ing rod big end. • Select an arbor of the same diameter as the piston pin and more than 105 mm long, and insert the arbor [B] through the[...]

9-18 CRANKSHAFT/TRANSMISSION T ransmission T ransmission Shaf t Removal • Disassemble the crankcase halves (see Crankcase Dis- assembly). • Pull out the oil screens, if fitted the screens at the right crankcase. Crank Room Side Oil Screen [A] T ransmission Room Side Oil Screen [B] • Pull out the shift rods [A] allowing the shift fork guide pi[...]

CRANKSHAFT/TRANSMISSION 9-19 T ransmission • Apply a small amount of engine oil to the shift fork fingers and fit each shift fork into the groove of the proper gear . • The shift forks can be identified by their shape or mark. Install them noting the direction shown. ○ The drive shaft shift fork [A] is the shortest, and install it with its ma[...]

9-20 CRANKSHAFT/TRANSMISSION T ransmission • The output shaft gears can be identified by size; the largest diameter gear is 1st gear , and the smallest is 5th. Be sure that all parts are put back in the correct sequence, facing the proper direction, and that all circlips and washers are properly in place. ○ Install the collar [A] with the flang[...]

CRANKSHAFT/TRANSMISSION 9-21 T ransmission • Check each gear spins or slides freely on the transmission shaft without binding after assembly . Shift Fork Bending • Visually inspect the shift forks, and replace any fork that is bent. A bent fork may cause difficulty in shifting, or allow the transmission to jump out of gear when under power . 90[...]

9-22 CRANKSHAFT/TRANSMISSION Bearings/Oil Seals Bearing Replacement CAUTION Do not remove the ball bearings unless it is neces- sary . Removal may damaged them. • Remove the ball bearing and/or needle bearing outer race using a press or suitable puller [A]. NOTE ○ In the absence of the above mentioned tools, satisfac- tory results may be obtain[...]

CRANKSHAFT/TRANSMISSION 9-23 Bearings/Oil Seals • Check the needle bearing. ○ The rollers in a needle bearing normally wear very little, and wear is difficult to measure. Instead of measuring, inspect the bearing for abrasion, color change, or other damage. If there is any doubt as to the condition of a needle be ar- ing, replace it. Oil Seal I[...]

[...]

WHEELS/TIRES 10-1 10 Wheels/T ires T able of Contents Exploded View ................................................................................................................... ..... 10-2 Specifications ................................................................................................................. ........ 10-4 Special T oo[...]

10-2 WHEELS/TIRES Exploded View[...]

WHEELS/TIRES 10-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Spoke Nipples 2.2 0.22 19 in·lb 2 Front Axle Nut 79 8.0 58 3 Front Axle Clamp Bolts 20 2.0 14.5 AL 4 Rear Axle Nut 11 0 11 . 0 80 5. Spokes 6. Front T ire 7. Rims 8. Front Axle 9. Rear T ire 10. Rear Axle AL: T ighten the two clamp bolts alternately two times to ensu[...]

10-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims) Rim Runout: Axial 1.0 mm (0.039 in.) or less 2m m( 0 . 0 8i n . ) Radial 1.0 mm (0.039 in.) or less 2m m( 0 . 0 8i n . ) Axle Runout/ 100 mm 0.1 mm (0.004 in.) 0.2 mm (0.008 in.) Tires Air Pressure Front and Rear 100 kPa (1.0 kgf/cm², 14 psi) ––– Tir es Standard T ire[...]

WHEELS/TIRES 10-5 Special T ools Inside Circ lip Pliers: 57001-143 Rim Protector: 57001-1063 Bead Breaker Assembly: 57001-1072 Bearing Driver Set: 57001-1 129 Jack: 57001-1238 Attachment Jack : 57001-1252 Jack Attachment : 57001-1608[...]

10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Using the jack [A] under the frame, and stabilize the mo- torcycle. Special T ools - Jack: 57001-1238 Jack Attachment: 57001-125 2 or 57001 -1608 • Loosen the left and right axle clamp bolts [A]. • Unscrew the axle nut [B]. • Place a commercially available jack under the engine to raise [...]

WHEELS/TIRES 10-7 Wheels (Rims) • Remove the jack. • Before tightening the clamp bolts on the right fork leg, pump the forks up and down [A] 4 or 5 times to allow the right fork leg to find a neutral position on the front axle. NOTE ○ Do not apply the front brake during this process to stop the motorcycle from rolling forward. Put a block [B][...]

10-8 WHEELS/TIRES Wheels (Rims) • T ake off t he collars [A] and caps [B] from the each side of the rear hub. CAUTION Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so the disc does not touch the ground. • Insert a wood wedge between the brake pads. This pre- vents th[...]

WHEELS/TIRES 10-9 Wheels (Rims) • Check the drive chain slack (see Final Drive chapter). • T ighten the axle nut. T orque - R ear Axle Nut: 1 10 N·m (1 1.0 kg·m, 80 ft·lb) • Install the new cotter pin [A] and spread its end. NOTE ○ When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle sh[...]

10-10 WHEELS/TIRES Tir e s Tire Removal CAUTION Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so the disc does not touch the ground. • Remove the wheel from the motorcycle (see Wheels Re- moval). • T o maintain front wheel balance, mark [A] the valve stem position on[...]

WHEELS/TIRES 10-1 1 Tir e s • Step on the side of the tire opposite valve stem, pry the tire off the rim with the tire iron [A] of the bead breaker protecting the rim with rim protectors [B]. Special T ools - Rim Protector: 57001-1063 Bead Breaker Assembly: 57001-1072 CAUTION T ake care not to inset the tire irons so deeply that the tube gets dam[...]

10-12 WHEELS/TIRES Tir e s • T ighten the bead protector nut [A] and valve stem nut [B]. • Check and adjust the air pressure after installing. • P u to nt h ev a l v ec a p[ C ] . Air Pressure Inspection/Adjustment • Refer to the Air Pressure Inspection/Adjustment in t he Pe- riodic Maintenance chapter .[...]

WHEELS/TIRES 10-13 Hub Bearings Hub Bearing Removal • Remove the wheel (see Wheel Removal). CAUTION Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground. • Remove the oil seals and circlip (rear wheel only). Special T ool - Inside [...]

[...]

FINAL DRIVE 1 1-1 11 Final Drive T able of Contents Exploded View ................................................................................................................... ..... 1 1-2 Specifications ................................................................................................................. ........ 1 1-4 Special T oo[...]

11 - 2 F I N A L D R I V E Exploded View[...]

FINAL DRIVE 1 1-3 Exploded View T orque No Fastener N·m kgf·m ft·lb Remarks 1 Rear Sprocket Nuts 34 3.5 25 2 Engine Sprocket Cover Bolts 9.8 1. 0 87 in·lb 3. Engine Sprocket 4. Output Shaft 5. Chain Slipper 6. Swingarm 7. Chain Guide 8. Locknut 9. Adjusting Bolt 10. Chain Adjuster 1 1. Drive Chain 12. Rear Sprocket 13. Upper Chain Guide Roller [...]

11 - 4 F I N A L D R I V E Specifications Item Standard Service Limit Drive Chain Chain Slack 52 ∼ 58 mm (2.05 ∼ 2.28 in.) ––– Chain 20-link Length 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.72 in.) Standard Chain: Make: DAIDO ––– T ype: D.I.D 520DMA2 ––– Length: 11 2 L i n k s ––– Sprocket Rear Sprocket W arp U[...]

FINAL DRIVE 1 1-5 Special T ools Outside C irclip Pliers: 57001-144[...]

11 - 6 F I N A L D R I V E Drive Chain Drive Chain Slack Inspection • Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter . Drive Chain Slack Adjustment • Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter . Wheel Alignment Inspection • Check that the rear end [A] of the left chain adjuster[...]

FINAL DRIVE 1 1-7 Drive Chain • Install the clip [A] so that the closed end of the "U" [B] pointed in the direction of chain rotation [C]. • Adjust the drive chain slack (see Drive Chain Slack Ad- justment in the Periodic Maintenance chapter).[...]

11 - 8 F I N A L D R I V E Sprockets Engine Sprocket Removal • Remove: Engine Sprocket Cover Bolts [A] Engine Sprocket Cover [B] Drive Chain Guide [C] • Remove: Drive Chain [A] (free of engine sprocket) • Remove the circlip [B], and pull off the engine sprocket [C]. ○ If remove the circlip difficult, using the thin blade driver [D] as shown[...]

FINAL DRIVE 1 1-9 Sprockets Rear Sprocket Installation • Install the rear sprocket [A] so that the marked side [B] faces out. • Install the rear sprocket bolts an d tighten the nuts. T orque - Rear Sprocket Nu ts: 34 N·m (3.5 kgf·m, 25 ft·lb) Sprocket Wear Inspection • Refer to the Sprocket Wear Inspection in the Periodic Maintenance chapt[...]

[...]

BRAKES 12-1 12 Brakes T able of Contents Exploded View ................................................................................................................... ..... 12-2 Specifications ................................................................................................................. ........ 12-6 Special T ools ..........[...]

12-2 BRAKES Exploded View[...]

BRAKES 12-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Front Master Cylinder Clamp Bolts 8.8 0.9 78 in·lb S 2 Brake Hose Banjo Bolts 34 3.5 25 3 Brake Pad Bolt 17 1.7 12.5 4 Caliper Bleed V alve 7.8 0.8 69 in·lb 5 Caliper Mounting Bolts 25 2.5 18 6 Front Brake Disc Mounting Bolts 9.8 1.0 87 in·lb L 7 Brake Lever Pivot Bolt L[...]

12-4 BRAKES Exploded View[...]

BRAKES 12-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Brake Hose Banjo Bolts 34 3.5 25 2 Rear Master Cylinder Mounting Bolts 10 1.0 87 in ·lb 3 Rear Master Cylinder Push Rod Locknut 17 1.7 12.5 4 Caliper Bleed V alve 7.8 0.8 69 in ·lb 5 Brake Pad Bolt 17 1.7 12.5 6 Rear Brake Pad Bolt Plug 2.5 0.25 22 in·lb 7 Caliper Holder[...]

12-6 BRAKES Specifications Item Standard Service Limit Brake adjustment Lever Play Adjustable (to suit rider) ––– Brake Fluid Recommended Disc Brake Fluid: ––– Ty p e Front DOT3 or DOT4 ––– Rear DOT4 Brake Pads Lining Thickness: Front 4.0 m m (0.157 in.) 1 mm (0.04 in.) Rear 6.4 mm (0.252 in.) 1 mm (0.04 in.) Brake Disc Thickness:[...]

BRAKES 12-7 Special T ools Inside Circ lip Pliers: 57001-143[...]

12-8 BRAKES Brake Lever , B rake Pedal Brake Lever Play Adjustment • Refer to the Brake Lever Play Adjustment in the Periodic Maintenance chapter . Brake Pedal Position/Pedal Pla y Adjustment • Refer to Brake Pedal Position/Pedal Play Adjustment in the Periodic Maintenance chapter . Brake Pedal Removal • Remove the mounting bolt [A] and take [...]

BRAKES 12-9 Brake Fluid WA R N I N G When working with the disc brake, observe the pre- cautions listed below . 1. Never reuse old brake fluid. 2. Do not use fluid from a c ontainer that has been left unsealed or that has been open for a long time. 3. Do not mix two types and brands of fluid for use in the brake. This lowers the brake fluid boiling[...]

12-10 BRAKES Brake Fluid Bleeding the Brake Line The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action. Air , however , is easily compressed. When air enters the brake lines, brake lever or pedal movement will be partially used in [...]

BRAKES 12-1 1 Brake Fluid • Bleed the brake line and the caliper as follows: ○ Repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [A]. 2. Quickly open and close the bleed valve while holding the brake applied [B]. 3. Release the b[...]

12-12 BRAKES Caliper Caliper Removal Front Brake: • Loosen the banjo bolt [A] so as not to spill brake fluid. • Remove the caliper mounting bolts [B]. • Remove the banjo bolt and take of f the brake hose from the caliper [C]. • If the caliper is to be disassembled after removal and if compressed air is not avail able, remove the piston usin[...]

BRAKES 12-13 Caliper • Bleed the brake line (see Bleeding the Brake Line). • Check the brake for good braking power , no brake drag, and no fluid leakage. WA R N I N G Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc. The brakes will not [...]

12-14 BRAKES Caliper Brake Pad Removal For Front Brake Pad • Unscrew the pad bolt [A]. • T ake the piston side pad [B]. • Push the caliper holder toward the piston, and then re- move another pad [C] from the ca liper holder . For Rear Brake Pad • Remove: Pad Bolt Plug [A] • Unscrew the pad bolt [A]. • T ake the piston side pad [B]. • [...]

BRAKES 12-15 Caliper • T ighten the brake pad bolt. T orque - Brak e Pad Bolt: 17 N·m (1.7 kgf·m, 12.5 ft· lb) Brake Pad Bolt Plug: 2.5 N·m (0.25 kgf·m, 22 in·lb) • Check the brake for good braking power , no brake drag, and no fluid leakage. WA R N I N G Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained[...]

12-16 BRAKES Master Cylinder CAUTION Brake fluid quickly ruins painted or plastic sur- faces; any spilled fluid should be completely wished up immediately . Front Master Cylinder Removal • Remove the banjo bolt [A] to disconnect the upper brake hose [B] from the master cylinder [C]. • When removing the brake hose, temporarily secure the end of [...]

BRAKES 12-17 Master Cylinder • The master cylinder clamp must be installed with the ar- row mark [A] upward. ○ T ighten the upper clamp bolt [B] first, and then the lower clamp bolt [C]. There will be a gap at the lower part of the clamp after tightening. T orque - Front Master Cylinder Clamp Bolts: 8.8 N·m (0.9 kgf·m, 78 in·lb) • Replace [...]

12-18 BRAKES Master Cylinder • Replace the cotter pin with a new one. • Install the joint pin, washer and a new cotter pin. • Bend the ends [A] of the cotter pin. • Bleed the brake line (see Bleeding the Brake Line). • Check the brake for good braking power , no brake drag, and no fluid leakage. • Check the brake pedal position (see Bra[...]

BRAKES 12-19 Master Cylinder Master Cylinder Inspection (Visual Inspection) • Disassemble the front and rear master cylinders. • Check that there are no scratches, rust or pitting on the inner wall of each master cylinder [A] and on the outside of each piston [B]. If a master cylinder or piston shows any damage, replace them. • Inspect the pr[...]

12-20 BRAKES Brake Disk Brake Disc Inspection • Visually inspect the disc [A]. If it is scratched or damaged, replace the disc. • Measure the thickness of each disc at the point [B] where it has worn the most. Replace the disc if it has worn past the service limit. Thickness Standard: Front 2.85 ∼ 3.15 mm (0.1 12 ∼ 0.124 in.) Rear 3.85 ∼ [...]

BRAKES 12-21 Brake Hose Brake Hose Removal/Insta llation • Refer to the Brake Hose Replacement in the Periodic Maintenance chapter . Brake Hose Inspection • Refer to the Brake Hose and Connection Check in the Periodic Maintenance chapter .[...]

[...]

SUSPENSION 13-1 13 Suspension T able of Contents Exploded V iew ................................... 13-2 Specifications .................................... 13-6 Special T ools ..................................... 13-7 Front Fork .......................................... 13-9 Air Pressure ................................. 13-9 Rebound Damping Adj[...]

13-2 SUSPENSION Exploded View[...]

SUSPENSION 13-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Front Fork Cylinder 34 3.5 25 2 Front Fork Lower Clamp Bolts 20 2.0 14.5 AL 3 Front Fork Upper Clamp Bolts 20 2.0 14.5 L, AL 4 Steering Stem Head Nut 98 10 72 5 Adjuster Assembly Locknuts 21.6 2.2 16 6 Front Axle Clamp Bolts 20 2.0 14.5 AL 7 Front Fork Base V alve Assem[...]

13-4 SUSPENSION Exploded View[...]

SUSPENSION 13-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Swingarm Pivot Shaft Nut 98 10 72 2 Rocker Arm Pivot Nut 83 8.5 61 3 T ie-rod Mounting N ut (Front, Rear) 83 8.5 61 4 Rear Shock Absorber Mounting Nut (Upper) 39 4.0 29 5 Rear Shock Absorber Mounting Nut (Lower) 34 3.5 25 6 Rear Shock Absorber Spring Locknut 45 4.6 33 7[...]

13-6 SUSPENSION Specifications Item Standard Service Limit Front Fork Air Pressure Atmospheric pressure ––– Rebound Damping Adjustment (Adjustable Range) (from the seated position adjuster turned fully clockwise) 10 clicks counterclockwise (EUR) 14 clicks counterclockwise 20 ±4 clicks Compression Damping Adjustment (Adjustable Range) (from t[...]

SUSPENSION 13-7 Special T ools Oil Seal & Bearing Remover: 57001-1058 Hook Wrench R3 7.5, R42: 57001-1 101 Bearing Driver Set: 57001-1 129 Jack: 57001-1238 Attachment Jack: 57001-1252 Bearing Remover Shaf t, 9: 57001-1265 Bearing Remover Head, 15 × 17: 57001-1267 Hook Wr ench T=3.2 R37: 57001-1539 Jack Attachment : 57001-1608 T o pP l u gW r e[...]

13-8 SUSPENSION Special T ools Fork Oil Seal Driver , 47: 57001-1662[...]

SUSPENSION 13-9 Front Fork Air Pressure The standard air pressure in the front fork legs is atmo- spheric pressure. Air pressure in the fork legs increase with normal use, s o the fork action stif fens during opera- tion. Release air pressure form the fork legs prior to each race through the pressure relief screw located in each cap of the base val[...]

13-10 SUSPENSION Front Fork Compression Damping Adjustment • Place the jack under the frame so that the front wheel off the ground. Special T ools - Jack: 57001-1238 Jack Attachment: 57001-125 2 or 57001 -1608 • Clean the bottom of the fork tubes. • Remove the caps on the bottom of the fork tubes. • T o adjust compression damping, turn the [...]

SUSPENSION 13-1 1 Front Fork • Rest the caliper [B] on some kind of stand [A] so that it doesn’t dangle. • Loosen the upper [A], and lower fork clamp bolts [B]. • Remove the front fork. ○ With a twisting motion [A], work the fork leg [B] down and out. • Remove: Bolts [A] Fork Protector [B] Front Fork Insta llation • If the fork leg wa[...]

13-12 SUSPENSION Front Fork • Route the cables and hose according to the Cable, Har- ness, Hose Routing section in the Appendix chapter . • Unscrew the upper clamp bolts [A]. ○ Apply a non-permanent locking agent to the bolts. • T ighten the fork clamp bolts. T orque - Front Fork Upper Clamp Bolts: 20 N·m (2.0 kgf·m, 14.5 ft·lb ) Front F[...]

SUSPENSION 13-13 Front Fork • Unscrew the fork cylinder unit [A] from the outer tube [B]. • Slowly slide down the outer tube. • Hold the fork tube [A] upside down over a clean container [B] and pump it to drain the oil. NOTE ○ Pump the outer tube up and down to discharge the fork oil. • T emporarily install the fork cylinder unit [A] to t[...]

13-14 SUSPENSION Front Fork • Hold the locknut [A] with a wrench [B] and remove the adjuster assembly [C]. NOTE ○ Do not remove the locknut from the piston rod. The piston rod may slide into the inner tube. • T ake the rebound damping adjuster rod [A] out of the pis- ton rod. • With the outer tube compressed by hand, remove the top plug wre[...]

SUSPENSION 13-15 Front Fork • Holding the top plug wrench [A] with a vise, unscrew the base valve assembly [B] on the fork cylinder unit [C]. ○ Use the hexagon box wrench [D]. • Pull out the base valve assembly [A] from the fork cylinder unit [B]. ○ Slowly compress the piston rod until it stops so that the base valve assembly can be removed[...]

13-16 SUSPENSION Front Fork • Unscrew the locknut [A]. • Wrap the end of the piston rod with a vinyl tape [B]. • Push the piston rod [C] into the cylinder [D] . • Remove the bushing [A] from the cylinder . ○ Carefully remove the bushing by prying the slot [B] with a blade type screwdriver until the bushing can be p ulled off by hand. CAUT[...]

SUSPENSION 13-17 Front Fork • Remove the guide bushes [A], washer [B], oil seal [C], retaining ring [D], and dust seal [E] from the inner tube. • Wipe off the fork oil from the removed parts. Front Fork Assembly • Replace the following with new ones: Dust Seal [A] Retaining Ring [B] Oil Seal [C] Guide Bushes [D] • Place an oil coated plasti[...]

13-18 SUSPENSION Front Fork ○ T u r n i n gi n[ A ]t h ep i s t o nr o dw i t haw r e n c h[ B ] . • Remove a vinyl tape and install the locknut. • Clean the threads [A] of the fork cylinder unit and base valve assembly . • Hold the fork cylinder unit [A] upright with the piston rod fully stretched. • Plug the two oil holes [B]on the cyli[...]

SUSPENSION 13-19 Front Fork • Replace the O-ring [A] on the base valve assembly with new ones. • Apply fork oil to the O-rings and bushings [B]. CAUTION Do not damage the bushings when assembling the base valve. • With the piston rod held immovable fully stretched, gently install the base valve assembly [A] to the fork cylinder unit [B]. NOTE[...]

13-20 SUSPENSION Front Fork • Check the compression damping force setting to the soft- est. • Check the piston rod sliding surface for damage. • Drain the extra oil from the cylinder unit oil hole. • Blow out the extra oil from the oil hole of the cylinder unit with the compressed air [A] blow to the oil hole. • Wipe the oil off completel[...]

SUSPENSION 13-21 Front Fork • There should be no oil leak from the base v alve assembly part [A] or bottom [B] of the cylinder . If oil leaks from the base valve assembly part or bottom of the cylinder . • Hold the cylinder unit on level ground and release the piston rod then check the piston rod extend to maximum. • T ighten the locknut [A] [...]

13-22 SUSPENSION Front Fork • Compress the outer tube by hands and insert the top plug wrench [A] between the axle holder part bottom [B] and locknut [C]. W ARNING Be careful of reaction force in spring and fix surely so that special tool should not come off. Do not place the fingers etc. while serving. • Insert the push rod [A] into the piston[...]

SUSPENSION 13-23 Front Fork • Compare the length [A] at assembly and at disassembly . ○ There should be same length. If the length at assembly is longer than at disassembly , check the adjuster assembly and locknut installation. Axle Holder [B] Outer T ube [C] Length Standard: 317 ±2 mm (125 ±0.08 in. ) • Using the top plug wrench, unscrew [...]

13-24 SUSPENSION Front Fork The torque of fork cylinder unit is specified to 34 N·m (3.5 kgf·m, 25 ft·lb) however , when you use the top plug wrench [A], reduce the torque to 90% of the specified value [31 N·m (3.1 kgf·m, 23 ft·lb)] due to the distance between the center of the square hole [B], where the torque wrench [C] is fitted, and that [...]

SUSPENSION 13-25 Front Fork Slide/Guide Bushing Inspection • Visually inspect the guide bushing [A], and replace them if necessary . Dust Seal/Oil Seal Inspection • Inspect the dust seal [A] for any signs of deterioration or damage. Replace it if necessary . • Replace the oil seal [B] with a n ew one whenever it has been removed. Spring T ens[...]

13-26 SUSPENSION Rear Suspension (Un i-T rak) Rear Shock Absor ber The rear suspension system of this motorcycle is New Uni-trak. It c onsists of a rear shock absorber , swing arm, tie-rod and rocker arm. T o suit to various riding conditions, the spring preload of the shock absorber can be adjusted or the spring can be replaced with an optional on[...]

SUSPENSION 13-27 Rear Suspension (U ni-T rak) • Adjust the high speed compression damping, turn the high speed compression damping adjuster with a 17 mm wrench. If the damping feels too soft or too stiff, adjust it in accor- dance with the following table. Seated position: adjuster turned fully clockwise [A]. High Speed Compression Da mping Adjus[...]

13-28 SUSPENSION Rear Suspension (Un i-T rak) • Using the hook wrenches [A], loosen the locknut [B] on the rear shock absorber . Special T ools - Hook Wrench R37.5, R42: 57001-1 101 Hook Wrenc h T=3.2 R37: 57001-1539 • Using the hook wrench [A], turn the adjusting nut [B] as required. T urning the adjusting nut downward marks the spring action [...]

SUSPENSION 13-29 Rear Suspension (U ni-T rak) Rear Shock Absorber R emoval • Remove: Seat (see Seat Removal in the Frame chapter) Side Covers (see Side Cover Removal in the Frame chapter) Silencer (see Muffler Removal Engine T op End chapter) Rear Frame with Air Cleaner Housing (see Spring Preload Adjustment) • Using the jack under the frame, r[...]

13-30 SUSPENSION Rear Suspension (Un i-T rak) • Hold the upper end of the rear shock absorber in a vise with soft jaws [A] or a heavy cloth. • Using the hook wrenches [B], loosen th e locknut [C] and turn the adjusting nut [D] all way up. Special T ools - Hook Wrench R37.5, R42: 57001-1 101 Hook Wrenc h T=3.2 R37: 57001-1539 • Remove the rear[...]

SUSPENSION 13-31 Swingarm Swingarm Removal • Place the jack [A] under the frame so that the rear wheel is off the ground. Special T ools - Jack: 57001-1 238 Jack Attachmen t: 57001-1252 or 57001 -1608 • Remove Rear Wheel (see Rear Wheel Removal in the Wheels/T ires chapter) Clamps [B] Brake Pedal [C] (see Brake Pedal Removal in the Brakes chapt[...]

13-32 SUSPENSION Swingarm Swingarm Bearing Removal • Remove: Swingarm Collars [A] Grease Seals [B] Sleeves [C] Needle Bearings [D] • Remove the needle bearings [E] using the oil seal & bear- ing remover . Special T ool - Oil Seal & Bearing Remover: 57001-1058 Swingarm Bearing Installation • Replace the needle bearings and, grease seal[...]

SUSPENSION 13-33 Swingarm • Visually inspect the upper and lower chain guide rollers [A] and replace them if excessively worn or damaged. Swingarm Bearing, Sleeve Inspectio n CAUTION Do not remove the bearings for inspection. Re- moval may damage them. • Inspect the needle bearings [A] installed in the swingarm. ○ The rollers in a bearing nor[...]

13-34 SUSPENSION Tie-Rod, Rocker Arm Tie-Rod Removal • Using the jack under the frame, raise the rear wheel off the ground. Special T ools - Jack: 57001-1238 Jack Attachment: 57001-125 2 or 57001 -1608 CAUTION When pulling out the mounting bolts, lift the rear wheel slightly . Forcing or tapping on a bolt could damage the bolt, sleeve, and bearin[...]

SUSPENSION 13-35 Tie-Rod, Rocker Arm • Remove the tie-rod rear mounting bolt [A]. • Remove: Rear Shock Absorber Lower Mounting Bolt [A] Rocker Arm Pivot Shaft [B] Rocker Arm [C] Rocker Arm Installation • Apply plenty of grease to the inside of the rocker arm, needle bearings, oil seals and grease seals outside of the sleeve. • Be sure seate[...]

13-36 SUSPENSION Tie-Rod, Rocker Arm Tie-Rod and Rocker Arm Bearing Removal • Remove: T i e - R o d( s e eT i e - R o dR e m o v a l ) Rocker Arm (see Rocker Arm Removal) Wa s h e r s [ A ] Sleeves [B] Oil Seals [C] Grease Seals [D] • Remove the needle bearings [E], using the bearing re- mover head and bearing remover shaft. • Remove the need[...]

SUSPENSION 13-37 Tie-Rod, Rocker Arm • Install the needle bearings [A], [B], grease seals [C], and oil seals [D] position as shown. ○ The installation procedure is the same as the counter side. Front [E] Right Side [F] Left Side [G] Rear Shock Absorber [H] T ie-rod [I] Rocker Arm [J] Needle Bearing Inspection If there is any doubt as to the con[...]

13-38 SUSPENSION Uni-T rak Maintenance Uni-T rak Linkage Inspection • Refer to the Uni-T rak Linkage Inspection in the Periodic Maintenance chapter . Tie-Rod and Rocker Arm Sleeve Wear • Pull out the sleeves [A] of the tie-rod and rocker arm. • Measure the outside diameter of the sleeve. I ft h es l e e v ei sw o r np a s tt h es e r v i c el[...]

STEERING 14-1 14 Steering T able of Contents Exploded View ................................................................................................................... ..... 14-2 Special T ools ................................................................................................................... ....... 14-4 Steering ...........[...]

14-2 STEERING Exploded View[...]

STEERING 14-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Handlebar Clamp Bolts 25 2.5 18.0 S 2 Steering Stem Head Nut 98 10 72 3 Steering Stem Locknut 4.9 0.5 43 in·lb T 4 Front Fork Upper Clamp Bolts 20 2.0 14.5 AL, L 5 Front Fork Lower Clamp Bolts 20 2.0 14.5 AL 6. Pad Cover with Pad 7. Handlebar Clamp 8. Handlebar 9. Handle[...]

14-4 STEERING Special T ools Bearing Puller Ad apter: 57001-317 Steering Stem Bearin g Driver: 57001-137 Steering Stem Bearing Dri ver Adapter , 34.5: 57001-1074 Head Pipe Outer Race Press Shaft : 57001-1075 Head Pipe Outer R ace Driver , 51.5: 57001-1076 Head Pipe Outer Race Driver , 54.5: 57001-107 7 Steering Stem Nut Wrench: 57001-1 100 Head Pip[...]

STEERING 14-5 Steering Steering Inspection • Refer to the Steering Inspection in the Perio dic Mainte- nance chapter . Steering Adjustment • Refer to the Steering Adjustment in the Periodic Mainte- nance chapter . Steering Stem, Stem B earing Removal • Remove: Front Wheel (see Front Wheel Removal in the Wheels/T ires chapter) Front Fender Bol[...]

14-6 STEERING Steering • Pushing up on the stem base [A], and remove the steering stem nut [B], with the steering stem nut wrench [C], then remove the steering stem [D] and stem base. Special T ool - Steering Stem Nut Wrench: 57001-1 100 • T ake off the upper stem bearing inner race (tapered roller bearing) [A]. • Drive out the bearing outer [...]

STEERING 14-7 Steering • Replace the lower inner races with new ones. ○ Apply grease to the lower tapered roller bearing [A], and drive it onto the stem using the steering stem bearing driver [B] and adapter [C]. Special T ools - Steering Stem Bearing Driver: 57001-137 Steering Stem Bearing Driver Adapte r , 34.5: 57001-1 074 • Apply grease t[...]

14-8 STEERING Steering • Install the parts removed. W ARNING Do not impede the handlebar turning by routing the cables, w ires and hoses improperly (see the Gen- eral Information chapter). • Check and Adjust: Steering Front Brake Clutch Cable Throttle Cable Stem Bearing Lubrication • Refer to the Stem Bearing Lubrication in Pe riodic Mainte- [...]

STEERING 14-9 Handlebar Handlebar Removal • Remove: Band [A] Pad Cover and Pad [B] • Remove: Clutch Lever Holder Assembly [A] Engine Stop Switch [B] Bands [C] Left Handlebar Grip [D] • Remove: Throttle Grip Assy [A] (see Throttle Cable Replacement in the Fuel System chapter) Front Brake Master Cylinder [B] (see Front Master Cylin- der Removal[...]

14-10 STEERING Handlebar • Install the clutch lever holder assembly [A] position as shown in the figure. [B] 170 mm [C] Horizontal Line of Frame [D] Handlebar • Install the engine stop button [E]. • Apply grease to the throttle c able upper end and clutch cable upper end. • Apply a 2 stroke oil to the throttle grip inner wall [A]. • Insta[...]

STEERING 14-1 1 Handlebar ○ Install the master cylinder [A] position as shown in the figure. [B] 185 mm (7.28 in.) [C] Horizontal Line of Frame [D] Handlebar [E] Horizontal Line of Cap Upper Surface T orque - Front Master Cylinder Clamp Bolts: 8.8 N·m (0.9 kgf·m, 78 in·lb) • Install the handlebar clamps [A]. • T ighten the handlebar clamp [...]

[...]

FRAME 15-1 15 Frame T able of Contents Exploded View ................................................................................................................... ..... 15-2 Frame .......................................................................................................................... ........... 15-4 Frame Inspection .......[...]

15-2 FRAME Exploded View[...]

FRAME 15-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Upper Rear Frame Mounting Bolt 34 3.5 25 2 Lower Rear Frame Mounting Bolts 34 3.5 25 3 Footpeg Bracket Upper Bolts 54 5.5 40 L G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts[...]

15-4 FRAME Frame Frame Inspection • Refer to the Frame Inspection in the P eriodic Mainte- nance chapter . Rear Frame Removal • Remove: Seat (see Seat Removal) Right & Left Side Cover (see Side Cover Removal) Silencer (see Muffler Removal in the Engine T op End chapter) Rear Fender (see Rear Fender Removal) Rear Flap (see Rear Flap Removal)[...]

FRAME 15-5 Frame • Insert the duct end [A] slantly between the frame [B] and upper portion [C] of the shock absorber . • Install the rear frame upper mounting bolt [A] through the hook [B] of the band [C]. • T ighten the rear frame mounting bolts. T orque - Rear Frame Mounting Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb) • Install the removal par[...]

15-6 FRAME Seat Seat Removal • Unscrew the bolts [A]. • Pull the seat [B] out from the back. Seat Installation • Fit the hooks [A] of the seat under the flange collar [B] and brackets [C].[...]

FRAME 15-7 Side Cover Side Cover Remo val • Unscrew the bolts [A] and remove the side cover . Side Cover Installation • Stick the pads [A] on the inside of the right side cover [B]. • Install the damper . • Insert the tabs [A] of the cover into the slots [B] of the air cleaner housing.[...]

15-8 FRAME Fender Front Fender Removal • Unscrew the bolts [A] and remove the front fender [B]. Rear Fender Removal • Remove: Seat • Unscrew the bolts [A] and remove the rear fender [B]. Rear Flap Removal • Unscrew the screws [A] and remove the rear flap [B].[...]

ELECTRICAL SYSTEM 16-1 16 Electrical System T able of Contents Exploded View ................................................................................................................... ..... 16-2 Specifications ................................................................................................................. ........ 16-4 Spe[...]

16-2 ELECTRICAL SYSTEM Exploded View[...]

ELECTRICAL SYSTEM 16-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Neutral Switch 12 1.2 104 in·lb 2 Flywheel Nut 49 5. 0 36 3 Stator Bolts 7.0 0.7 61 in·lb 4 Spark Plug 13 1.3 11 5 i n · l b 5 Magneto Cover Bolts L35 9.8 1.0 87 in·lb L 6 Magneto Cover Bolts L30 9.8 1.0 87 in·lb 7 Neutral Lead T erminal Screw 1.3 0.13 12 in[...]

16-4 ELECTRICAL SYSTEM Specifications Item Standard Magneto Crankshaft Sensor Resistance 80 ∼ 120 Ω Magneto Output V oltage in the text Stator Coil Resistance in the text Ignition System Ignition T iming 8° BTDC @2 000 r/min (rpm) Stick Coil: Primary Winding Resistance 0.077 ∼ 0.104 Ω (at 20°C) Secondary Winding Resistance 4.56 ∼ 6.84 k[...]

ELECTRICAL SYSTEM 16-5 Special T ools Timing Li ght: 57001-1241 Hand T ester: 57001-1394 Throttle Sensor Setti ng Adapter #1: 57001-1400 Peak V oltage Adapter: 57001-1415 Lead Wire - Peak V oltage Adapter: 57001-1449 Filler Cap Dri ver: 57001-1454 Needle Adapter Se t: 57001-1457 Rotor Pull er: 57001-1565 Rotor Holder: 57001-1567 Kawasaki Bond (Sil [...]

16-6 ELECTRICAL SYSTEM Wiring Diagram[...]

ELECTRICAL SYSTEM 16-7 Precautions There are numbers of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below . ○ The electrical parts should never be struck sharply , as with a hammer , or allowed to fall on a hard surface. Such a shock to the parts can damage the m. ○ T roubles may inv[...]

16-8 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection • Visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor , replace the damaged wiring. • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty , clean it carefully . If it is damaged, replace it[...]

ELECTRICAL SYSTEM 16-9 Flywheel Magneto Magneto Cover Remo val • Drain the engine oil from the crank room oil sump (see Engine Oil Change in the Periodic Maintenance chapter). • Remove the left radiator shrou d (see Radiator Removal in the Cooling System chapter). • Push down the stopper [A]. • Remove the magneto lead connector [B]. • Dis[...]

16-10 ELECTRICAL SYSTEM Flywheel Magnet o • Hold the flywheel steady , with the rotor holder [A], and remove the nut [B]. Special T ool - Rotor Holder: 57001-1567 • Remove the flywheel holder . • Screw the rotor puller [A] into the flywheel. • Remove the flywheel from the crankshaft by turning in the puller center bolt and tapping the head [...]

ELECTRICAL SYSTEM 16-1 1 Flywheel Magneto Stator Removal • Remove: Magneto Cover (see Magneto Cover Removal) Stator Bolts [A] Crankshaft Sensor Bolts [B] Wiring Holder [C] Wiring Grommet [D] • Remove the stator [E] and crankshaft sensor [F] as a set. Stator Installation • Route the wires according to the Cable, Wiring, and Hose Routing sectio[...]

16-12 ELECTRICAL SYSTEM Flywheel Magnet o ○ Connect the hand tester [A] to the connector [B] as shown in the table 1, using the needle adapter set [C]. ○ Start the engine. ○ Run it at the rpm given in the table 1. ○ Note the voltage readings (total 2 measurements). Special T ool - Needle Adapter Set: 57001-1457 T able 1 Magneto Output V olt[...]

ELECTRICAL SYSTEM 16-13 Ignition Timing Ignition Timing Inspection • Remove the timing inspection cap [A]. Special T ool - Filler Cap Driver: 57001-1454 • Attach the timing light [A] to the ignition coil lead in the manner prescribed by the manufacturer . Special T ool - Timing Light: 57001-1241 • Start the engine and aim the timing light at [...]

16-14 ELECTRICAL SYSTEM Ignition System Safety Instr uctions W ARNING The ignition system produces extremely high volt- age. Do not touch the stick coil while the engine is running, or you could receive a severe electrical shock. Stick Coil Removal • Remove: Fuel T ank (see Fuel T ank Removal in the Fue l System chapter) • Disconnect the stick [...]

ELECTRICAL SYSTEM 16-15 Ignition System Spark Plug Gap Inspection • Refer to the Spark Plug Gap Inspection in the Periodic Maintenance chapter . C.D.I. Unit Removal • Remove: Belt (Open) [A] Bolt [B] Number Plate [C] • Disconnect the main harness connector [A]. • Unscrew the mounting bolts [B] an d remove the C.D.I. Unit [C]. C.D.I. Unit In[...]

16-16 ELECTRICAL SYSTEM Ignition System Stick Coil Primary Peak V oltage Check • Disconnect the stick coil from the spark plug, but do not remove the spark plug. • Connect the good spark plug [A] to the stick coil [B], then touch the engine with it. NOTE ○ Measure the voltage with each lead connected cor - rectly . The correct value may not b[...]

ELECTRICAL SYSTEM 16-17 Ignition System T rouble shooting chart[...]

16-18 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Peak V oltage Check • T o check the peak voltage, do the following procedures. ○ Disconnect the connector of the magneto lead connector from the main harness. NOTE ○ Measure the voltage with each lead connected cor - rectly . The correct value may not be obtained if disconnected. ○ M[...]

ELECTRICAL SYSTEM 16-19 Ignition System Charge Coil Peak V oltage Check • Disconnect the connector of the magneto lead connector from the main harness. • T o check the peak voltage, do the following procedures. NOTE ○ Measure the voltage with each lead connected cor- rectly . The correct value may not be obtained if disconnected. ○ Maintain[...]

16-20 ELECTRICAL SYSTEM Ignition System • T o check the output voltage, do the following procedures. ○ Connect the digital voltmeter as follows. T ester (+) → Y ellow Lead T ester (–) → Black Lead ○ Start the engine. ○ Measure the throttle sensor output voltage with the engine idling speed and with the idle throttle valve opening. Thr[...]

ELECTRICAL SYSTEM 16-21 Throttle Sensor Throttle Sensor Inspection NOTE ○ If the variable rheostat is not available, refer to throttle sensor output/input voltage check in the C.D.I. Unit in- spection. ○ When inspecting the throttle sensor the throttle v alve of the carburetor shall be completely closed and remain the throttle cable connected. [...]

16-22 ELECTRICAL SYSTEM Throttle Sensor Throttle Senso r Position Adj ustment • Remove the carburetor (see Carburetor Removal in t he Fuel System chapter). • Measure the resistance between the blue and black lead terminals of the sensor side connector . Blue Lead T erminal [A] Black Lead T erminal [B] Y ellow Lead T erminal [C] Hand T ester [D][...]

ELECTRICAL SYSTEM 16-23 Neutral Switch Neutral Switch Inspection • Slide out the dust cover [A]. • Disconnect the connector [B]. ○ Unscrew the screw . • Using a hand tester , check to see that only the con- nections shown in the table have continuity (about zero ohms). If the switch has an open or short, repair it or replace it with a new o[...]

[...]

APPENDIX 17-1 17 Appendix T able of Contents Cable, Wire, and Hose Routing .............................................................................................. 17-2 T roubleshooting Guide ....................................... .................................................................... 17-8[...]

17-2 APPENDIX Cable, Wire, a nd Hose Routing 1. Throttle Cables 2. Marked (AAA) cable is accelerator side. 3. Band (Hold t he engine stop switch lead.) 4. Engine Stop Switch Lead 5. Hot Start Cable 6. Clutch Cable 7. Clamp (Run the clutch and hot start c a- ble.) 8. Clamp (Run the throttle cables.)[...]

APPENDIX 17-3 Cable, Wire, and Hose Routing 1. Clutch Cable 2. Engine Stop Switch Lead 3. C.D.I. Unit 4. Main Harness 5. Frame Ground 6. Clamps (Run the clutch cable.) 7. Upper Radiator Hose 8. Clamp (Run the clutch cable.) 9. Hot Start Cable 10. Clamp (Run the hot start cable, clutch ca- ble, and engine stop switch lead.) 1 1. Engine Stop Switch L[...]

17-4 APPENDIX Cable, Wire, a nd Hose Routing 1. C.D.I. Unit 2. Main Harness 3. Clamp (Run the hot start cable and main harness.) 4. Neutral Switch Lead Connector 5. Magneto Lead Connector 6. Stick Coil Connector 7. Magneto Lead 8. Clamps (Hold the Magneto Lead.) 9. Radiator Overflow Tube 10. Stick Coil 1 1. Clamp (Run the hot start cable a nd throt[...]

APPENDIX 17-5 Cable, Wire, and Hose Routing 1. Clumps (Position the clamp claw front.) 2. Install the upper radiator tube so that the yellow painted mark faces upward. 3. Left Radiator 4. Radiator Overflow T ube 5. Joint Pipe (Align the stopper and yellow painted mark.) 6. Right Radiator 7. W ater Pipe 8. Install the screw head of the clamps di- re[...]

17-6 APPENDIX Cable, Wire, a nd Hose Routing 1. Run the fuel hose inside the h ot start cable. 2. Align the end of the net protector with the cam chain tensioner cap. 3. Breather T ube 4. Align the white painted mark of the tube with the rib of the crankcase. 5. Band 6. Clamp (Position the clamp claw front.)[...]

APPENDIX 17-7 Cable, Wire, and Hose Routing 1. Brake Lever 2. Front Brake Master Cylinder 3. Front Brake Hose 4. Clamp 5. Viewed 6. Clamps 7. Front Brake Caliper 8. Front Brake Disc 9. Brake Pedal 10. Rear Brake Master Cylinder 1 1. Rear Brake Hose 12. Clamps 13. Rear Brake Caliper 14. Rear Brake Caliper Guard 15. Rear Brake Disc 16. Rear Brake Dis[...]

17-8 APPENDIX T roubleshooting Guide This is not an exhaustive list, giving every possible cause for each problem listed. it is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. Engine Doesn’t Start, Starting Difficulty: Engine won’t turn over: Va l v e s e i z u r e V alve lifter seizure Cyli[...]

APPENDIX 17-9 T roubleshooting Guide Drive train trouble Engine overheating Clutch slipping Poor Running or No Power at High Speed: Firing incorrect: Spark plug dirty , broken, or gap malad- justed Stick coil not in good contact Spark plug incorrect heat value Faulty CDI unit Crankshaft sensor trouble Flywheel magneto damage Stick coil trouble Wiri[...]

17-10 APPENDIX T roubleshooting Guide Clutch housing seized Clutch release function trouble Clutch hub nut loose Clutch plate warped or rough Clutch hub spline damaged Gear Shifting Faulty: Doesn’t go into gear; shift pedal doesn’t return: Clutch not disengaging Shift fork bent, worn, or seized Shift return spring pin loose Shift return spring [...]

APPENDIX 17 -1 1 T roubleshooting Guide V alve guide worn Engine oil level too high Black smoke: Air cleaner element clogged Main jet too large or fallen of f Starter plunger stuck open Fuel level in carburetor float bowl too high Brown smoke: Main jet too small Fuel level in carburetor float bowl too low Air cleaner duct loose Air cleaner poorly s[...]

MODEL APPLICA TION Ye a r Model Beginning Frame No. 2006 KX250T6F JKAKXMTC □ 6A000001 or JKAKX250TT A000001 □ :This digit in the frame number changes from one machine to another . Part No.99924-1354-01 Printed in Japan[...]