Kawasaki KVF 750 4x4 manual

BRUTE FORCE 750 4×4i KVF 750 4×4 All T errain V ehicle Service Manual[...]

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This quick refe rence guid e will assis t you in locating a desired topi c or pro- cedure. •Bend the pages back to match the black tab of the desir ed chapter num- ber with t he black tab on the edge at each table of content s page. •Refer to the secti onal table of contents for the exact pages t o locate t he spe- cific topic required. Quick R[...]

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BRUTE FORCE 750 4 ×4i KVF 750 4×4 All T errain V ehicle Service Manual All rights reser ved. No parts of this publi cation may be r eproduced, stored in a retri eval system, or transmitted i n any form or by any means, electroni c mechanical phot ocopying, recordi ng or otherwise, without the prior wri tten permission of Qualit y Assurance Depart[...]

LIST OF A BBREVIA TI ONS A ampere(s) lb pounds(s) ABDC after bottom dead center m meter(s) AC alterna ting cu rrent 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 ce nter psi pound(s) per square inch °C degree(s) Celcius r revo lution DC d[...]

EMISSION CONTROL INFORMA TION T o protect the environme nt in which we all live, Kawasaki has incorpor ated crankcase emission (1) and exhaust emission (2) contr ol systems in compliance with applicabl e regulations of the California Air Resources Board. 1. Crankcase Emission Control System A sealed-type cr ankcase emission cont rol system is us ed[...]

PLEASE DO NOT T AMPER WITH N OISE CONTROL S YSTEM (US MODEL only) T o minimize the nois e emissions fr om this pr oduct, Kawasaki has equipped it with effecti ve intake and exhaust silencing systems. They are designed to giv e optimum perfor mance while maintaining a low nois e level. P lease do not remove these systems, or alter t hem in any which[...]

Foreword This manual is des igned primaril y for use by trained mechanics i n a proper ly equipped s hop. However , it contains enough detai l and basic i n- formation t o make it useful to the owner who de- sires to perfo rm his own basic maintenance and repair work. A basic knowledge of m echanics , the proper use of tools, and workshop proce- du[...]

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GENERAL INFORMA TION 1-1 1 General Information T able of Co ntents Bef ore Serv icing . ..... ...... ...... .... ...... ....... ...... .... ...... ...... .... ....... ...... ...... .... ...... ....... .... ...... ..... ..... 1 -2 Model Identifi cation. .... ...... .... .... ...... .... ..... .... ...... ...... .... ...... ... ...... ...... .... ...[...]

1-2 GENERAL INFORMA TION Before Servicing Before start ing to perform an i nspection servi ce or carry out a di sassembly and reassembly oper - ation on a v ehicle, read the pr ecautions given below . T o facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descript ions have been incl uded in each chapte r wher[...]

GENERAL INFORMA TION 1-3 Before Servic ing Arrang ement an d Cleani ng of Removed Pa rts Disassembled parts are easy to confuse. Arrange t he parts accordi ng to the order the parts were disassemble d and clean the parts i n order pri or to assembly . Stor age of R emo ved Pa rts After all the parts incl uding subassembly pa rts have been cleaned, [...]

1-4 GENERAL INFORMA TION Before Servicing Ti ghteni ng Sequ ence Generally , when installing a part with several bolts , nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified se- quence to pr event case war page or deformat ion which can lead t o malfunction. Conversely wh en loo[...]

GENERAL INFORMA TION 1-5 Before Servic ing Press For items such as bearings or oil seals th at must be pressed into plac e, apply small amount of oil to the con- tact area. Be sure to maintain proper alignment and use smooth movements when instal ling. Ball Bea rin g and Needl e Beari ng Do not remove pressed ball or needle unles s removal is absol[...]

1-6 GENERAL INFORMA TION Before Servicing Lubric ation It is important to lubr icate rot ating or slidi ng parts during assembly to minimize wear durin g initial operation. Lubri - cation poi nts are call ed out thr oughout this manual, apply the specific oi l or grease as specified. Direction of Engine Rota tion When rotati ng the crankshaf t by h[...]

GENERAL INFORMA TION 1-7 Model Ident ification KVF 750-A1 Lef t Side View KVF750-A1 Right Side View The KVF750–B1 is a camouflage-sur face-treated mode l and identica l to the KVF750–A1, the base model, in every other aspect: controls, features, and specifi cations.[...]

1-8 GENERAL INFORMA TION General Speci fications Items KVF750-A1, B1 Dimensions Overall Length 2 192 mm (86.30 in.) Overall Width 1 177 m m (46.34 in .) Overall Height 1 249 mm (49.17 in.) Wheelbase 1 283 mm (50.51 in.) Ground Clearance: 269 mm (10.59 in.) Seat Height 935 mm (36.81 in.) Dry Mass 274 kg (604 lb), (EUR) 27 4.5 kg (605 lb) Curb Mass: [...]

GENERAL INFORMA TION 1-9 General Specific ations Items KVF750-A1, B 1 Engine oil: Ty p e API SF or SG API SH or SJ with JASO MA cl ass Vi sc o si t y SAE 10W-40 Capacity 2.6 L (2.75 US qt) Driv e T rain Primary Reduction System: Ty p e Belt converter Reduction Ratio 3.122 ∼ 0.63 5 T r ansmission: Ty p e 2-speed and reverse Gear Ratios: Forward: H[...]

1-10 GENERAL INFORMA TION General Speci fications Items KVF750-A1, B1 Front ti re: Ty p e Tubel ess Size AT 2 5 × 8 – 1 2 Rear tire: Ty p e Tubel ess Size A T25 × 10 – 12 Suspension: Front: Ty p e D ouble Wishbone Wheel T r avel 171 mm (6.73 in.) Rear: Ty p e D ouble Wishbone Wheel T r avel 200 mm (7.87 in.) Brake: Front Dis c × 2 Rear Enclo[...]

GENERAL INFORMA TION 1-1 1 Unit Convers ion T able Prefixes for Units : Prefix Symbol Power mega M × 1 000 000 kilo k × 1 000 centi c ×0 . 0 1 mill i m × 0.001 mic ro µ × 0.000001 Units of M ass: k g ×2 . 2 0 5 =l b g × 0.03527 = oz Units of V olum e: L × 0.2642 = gal (US) L × 0.2200 = gal (imp) L× 1 . 0 5 7 = qt (US) L × 0.8799 = qt (i[...]

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PERIODIC MAINTE NANCE 2-1 2 Periodic Maintenance T able of Co ntents Periodic Maintenance Chart ....... .... ... 2-3 T orque and Locking Agent .... ...... .... ... 2-5 Spec ifica tions . .... ....... ...... .... ...... ...... .. 2-1 1 Spec ial T o ols .... ....... ...... .... ...... ...... .... 2-13 Periodic Mai ntenance Proc edures..... 2-14 Fuel [...]

2-2 PERIODIC M AINTENANCE Lubricati on ...... ...... ..... ...... ........ .... 2-40 Bolt s and N uts Tightenin g .. ...... .... ... 2- 41 T ightness I nspecti on ...... ..... ........ . 2-41[...]

PERIODIC MAINTENANCE 2-3 Periodic Mainte nance Char t The scheduled maintenance must be done in accordance wit h this chart to keep the vehic le in good running condit ion. The initial m aintenance is vi tally important and must not be neglected. First FREQUENCY Ser vi ce Regular Servi ce OPERA T ION After 10 hrs. or 100 km (60 mi.) of use Every 10[...]

2-4 PERIODIC M AINTENANCE Periodic Maintena nce Chart First FREQUENCY Service Regular Servi ce OPERA TIO N After 10 hrs. or 100 km (60 mi .) of use Every 10 days or 200 km (120 mi.) of use Eve ry 30 days or 600 km (360 mi. ) of use Every 90 days, 1 700 km (1 100 mi.) o r when belt indicator light turns on (100 hrs of use) whichever comes first Ever[...]

PERIODIC MAINTENANCE 2-5 T orque and Lo cking Agent The followi ng tables l ist the tightening torque for the major fas teners, and t he part s requiri ng use of a non-permanent loc king agent or l iquid ga sket. Letters used i n the “Remarks” col umn mean: AL: Tighten t he two clamp bolts alternatel y two times to ensure even tightening tor qu[...]

2-6 PERIODIC M AINTENANCE T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks V alve Adjusting Cap Bolts 8.8 0.90 78 in·lb W ater Pipe Mounting Bolts 8.8 0.90 78 in·lb Rocker Shaft Bolts 20 2.0 14 V alve Adjusting Scr ew Locknuts 12 1.2 104 in·lb Chain T ensioner Mounting Bol ts 8.8 0.90 78 in·lb Chain T ensioner Cap Bolt 22 2[...]

PERIODIC MAINTENANCE 2-7 T orque and Lo cking Agent T orque Fastener N·m kgf·m ft·l b Rem ar ks Engine Mounting Bolt 62 6.3 46 Engine Mounting Nut 62 6.3 46 Crankshaft/T ransm ission Connecting Rod Big End Cap Nuts 34 3.5 25 MO Engine Drain Plug 20 2.0 14 Crankcase Bolts ( M8) 75 mm (2.95 i n.) 20 2.0 14 S Crankcase Bolts ( M8) 1 10 mm (4.33 in.[...]

2-8 PERIODIC M AINTENANCE T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks Front Final Gear Case Lef t Cover Bolts (M6) 9.8 1.0 87 in·lb L Ring Gear Bolts 57 5.8 42 LB Front Final Gear Case Center Cover Bol ts (M6) 9.8 1.0 87 in·lb L Front Final Gear Case Center Cover Bol ts (M8) 24 2.4 17 L Front Final Gear Case Oi l Filler [...]

PERIODIC MAINTENANCE 2-9 T orque and Lo cking Agent T orque Fastener N·m kgf·m ft·l b Rem ar ks Stabilizer Hold er Bolts 23 2.3 17 Stabilizer Joint Nuts 48 4.8 35 Rear Suspension Arm Pivot Nuts 48 4.8 35 Rear Knuckle Mounting Nuts 48 4.8 35 Steering Handlebar Holder Bolts 29 3.0 22 S Stee ring St em Clam p Bolt s 25 2.5 18 T ie-rod End Nuts 42 4[...]

2-10 PERIODIC MAINTENANCE T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks Radiator Fan Switch 18 1.8 13 Coolant T emperature W arning Light Switch 6.9 0.70 61 in·lb SS Oil Pressure Switch 15 1.5 11 SS Oil Pr essu re Sw itch T e rmina l Bolt 1.5 0.15 13 in·lb Regulator/Rect ifier Mounting Bol ts 8.8 0.90 78 in· lb Fuel Level[...]

PERIODIC MAINTENANCE 2-1 1 Specifications Item Standard Se rvice L imit Fuel System Throttle Lever Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) ––– Choke Lever Free P lay about 3 mm (0.12 in.) ––– Idle Speed 1 150 ± 50 r/min (r pm) ––– Air Cleaner Element Oil High-qualit y foam air filter oil ––– Cooling System Coolant: T ype ([...]

2-12 PERIODIC MAINTENANCE Specifications Item Standard Ser vice Limit Final Drive Front Final Gear Case: Gear Case Oil: Ty p e API S F or SG ––– API SH or SJ of JAS O MA class ––– Viscosi ty SAE 10W-40 ––– Oil Level Filler opening bottom ––– Capacity 0.40 L (0.42 US qt) ––– Rear Final Gear Case: Gear Case Oil: Ty p e M[...]

PERIODIC MAINTENANC E 2-13 Special T ools Oil Fil ter W rench: 57001-1 249 Carburetor Drain Plug Wrench , Hex 3: 57001-1 269 Flywheel & Pulley Holder: 57001-1 343 Filler Cap Driver: 57001-14 54 Pulley Hold er Attachment : 57001-14 72[...]

2-14 PERIODIC MAINTENANCE Periodic M aintenance Pro cedures Fuel System Throttl e Lever Fr ee Play Insp ection • Check that the t hrottle l ever [A] moves smoothl y from full open to close, and the thro ttle closes quickly and com- pletely in a ll steerin g positions by the retur n spring. If the throt tle lever does not return properl y , check [...]

PERIODIC MAINTENANC E 2-15 Periodic Maintena nce Procedures Choke Lever Free Play Adju stment • Remo ve : Handlebar Cover Screws [A] • Remo ve : Handlebar Cover Screws [A] Handlebar Cover Front [B] • Loosen the locknut [A] of t he choke cable. • T urn the adjuster [B] until the cable has proper amount of play . • T ighten the locknut secu[...]

2-16 PERIODIC MAINTENANCE Periodic M aintenance Pro cedures Idle Spe ed Adjust ment • Start the engine and warm i t up thoroughly . • T urn the idle adjusting screw [A] until the idle speed is correct. ○ Open and close the thr ottl e a few times t o make sure that the idle speed is withi n the specified ra nge. Fuel System Cleanl iness Inspec[...]

PERIODIC MAINTENANC E 2-17 Periodic Maintena nce Procedures Air Clean er Elemen t Cleani ng and Inspecti on NOTE ○ In dusty areas, the element should be cleaned more frequently than the recommended interval. ○ After riding through rain or muddy terrains, the ele ment should be cleaned immedia tely . ○ Also, if there is a break in the element [...]

2-18 PERIODIC MAINTENANCE Periodic M aintenance Pro cedures Fuel Hose and Conne ction Inspecti on ○ The fuel hoses are designed t o be used throughout the vehicle lif e without any maintenance, however , if the ve- hicle is not properly handled, the pre ssure inside t he fuel line can cause fuel to leak [A] or the hose to burst. Check the fuel ho[...]

PERIODIC MAINTENANC E 2-19 Periodic Maintena nce Procedures • Remo ve : Clamps [A] Fuel Hoses [B] • Replace the fuel hoses with new ones. • When installi ng the fuel hose, route the hose acco rding to Cable, Wire, and Hose Routing section in Appendix chapter . • When installing the fuel hose, avoid sharp bending, ki nk- ing, flattening or t[...]

2-20 PERIODIC MAINTENANCE Periodic M aintenance Pro cedures Radiator Hose and Co nnection Inspe ction ○ The high pressure insi de the radiator h ose can cause coolant to leak [A] or the hose to burst i f the line is not properly maintai ned. Visua lly inspect the hoses for signs of deterior ation. Squeeze the hoses. A hose should not be hard and [...]

PERIODIC MAINTENANC E 2-21 Periodic Maintena nce Procedures • Remo ve : Clamp [A] Rese rve T ank Sc rews [B ] Reserve T ank [C] with H ose • Remove the reserv e tank cap, and pour the c oolant into a container . • Place a container under the dr ain plug [A] at the bot tom of the water pump [B], then remove the drain pl ug. • Remove the radi[...]

2-22 PERIODIC MAINTENANCE Periodic M aintenance Pro cedures • T ighten the drain plug. T o rque - C oolant Drain Plug: 8 .8 N·m (0.90 kgf·m, 78 in·lb) • Support the vehicl e on a stand or the jack so that the fr ont wheels are off the ground. This makes air bleeding easier . • Fill the radi ator up to the radiator f iller neck [A] wi th co[...]

PERIODIC MAINTENANC E 2-23 Periodic Maintena nce Procedures Engine T op E nd V a lve Cle aranc e Inspect ion NOTE ○ Check the valve clearance only when the engine is cold (at room temperatur e). • Remo ve : Left Side Cover (see Frame chapter) Battery Case (see Frame chapt er) V alve Adjusting Caps [A] Recoil Starte r (see Recoil St arter c hapt[...]

2-24 PERIODIC MAINTENANCE Periodic M aintenance Pro cedures • Then, turn the crankshaft counterclockwi se with a wrench on the alter nator rotor bolt unt il “T-R” mark [A] on the alternator rot or aligns with the notch [B] as shown: the end of the compression st roke in the rear cyli nder head. • Measure the clear ance for al l four v alves[...]

PERIODIC MAINTENANC E 2-25 Periodic Maintena nce Procedures Converter Syst em Drive Bel t Inspe ction Inspection of the drive belt is required at least every 90 days of vehicle use (average 12 mil e/day) not to exceed 1 700 km (1 100 mile) or belt indicator light turn on (100 hour s of use) counted by the hour meter . More frequent inspection is ne[...]

2-26 PERIODIC MAINTENANCE Periodic M aintenance Pro cedures • Measure the belt defl ection [ A] as shown: ○ Place a straightedge [B ] on top of the belt between the drive pulley [C] and the dri ven pulley [D]. ○ Use a ruler to push the bel t away from the straight edge. Push hard, but with no more force than 59 N (6 kgf, 13 lb). Belt Deflecti[...]

PERIODIC MAINTENANC E 2-27 Periodic Maintena nce Procedures • Assemble the d riven pull ey (see Converter System chap- ter). • With the transmi ssion in neutr al, rotate the driven pulley to allow the belt to return to the top of t he sheaves before measuring the belt deflecti on. • Measure the belt defl ection again and r epeat the above pro[...]

2-28 PERIODIC MAINTENANCE Periodic M aintenance Pro cedures Oil Fil ter Repl acement • Drain the engine oil. • Remove the oil fil ter [A] with t he oil filt er wrench [B]. Specia l T o ol - Oil Filter Wrench: 5 7001-124 9 • Replace the filt er with a new one. • When install ing the oil filter , be careful of th e following. ○ Apply oil to[...]

PERIODIC MAINTENANC E 2-29 Periodic Maintena nce Procedures Final Drive V ariable Differe ntia l Control Lever Pla y Inspection • Pull the variable di f ferential cont rol lever [A] toward s the handlebar grip [B] wit h a spring scale unti l it reads 30 N (3 kgf, 7 lb) of force. ○ The different ial control in the front fi nal gear case must be [...]

2-30 PERIODIC MAINTENANCE Periodic M aintenance Pro cedures Front Fin al Gear Case Oil Change • W arm up the oil by running the vehicle so that the oil will pick up any sediment and drain easil y . Then stop the vehicle. • Park the vehicl e so that it is level, both side-to-side and front-to-r ear . • Remove the front side cover (see Fr ame c[...]

PERIODIC MAINTENANC E 2-31 Periodic Maintena nce Procedures Rear Final Gear Case Oil Change • W arm up the oi l by runni ng the vehicl e so that t he oil wil l pick up any sediment and drain easil y . Then stop the vehicle. • Park the vehicle so that it is level, both side-to- side and front-to- rear . • Place an oil pan beneath the rear fina[...]

2-32 PERIODIC MAINTENANCE Periodic M aintenance Pro cedures Univers al Joint Lu bri cation • Remove: Rear Propeller Shaft (see Final Drive chapter) • Force grease into t he grease nipples [A] un til the grease comes out from the nipple, and wipe off any excess grease. [B] Grease Gun Brakes Front Br ake Pad W ear Ins pection • Check the lining[...]

PERIODIC MAINTENANC E 2-33 Periodic Maintena nce Procedures Front Brake Hose Replacement • Pump the brake fluid out of the line as explained in t he Brake Fluid Change. • Remove the banjo bolts at both ends of the brake hose, and pull the hose of f the vehicle. • Immediately wipe up any brake flui d that spi lls. CAUTION Brake fluid quickly r[...]

2-34 PERIODIC MAINTENANCE Periodic M aintenance Pro cedures Brake F luid Chan ge • Remove the reservoir cap and the rubber cap on the bleed valve. • Attach a clear plas tic hose to the bleed valve on the caliper , and run the other end of the hose into a con- tainer . • Fill t he reservoir with new brake flui d. • Change the brake fl uid as[...]

PERIODIC MAINTENANC E 2-35 Periodic Maintena nce Procedures Rear Brake Plates Replace ment • Replace the steel plates and friction plates i n accordance with the specif ied interval (see Rear Final Gear Case sec- tion in the Final Drive chapt er). Rear Brake Leve r Free Play I nspecti on • Check the rear brake lever free play [A ]. ○ Pull the[...]

2-36 PERIODIC MAINTENANCE Periodic M aintenance Pro cedures Steering Steerin g Inspection • T urn the handlebar l eft and r ight, and chec k the steer ing action. If the steering a ction is not smooth, or if the stee ring binds or catches before the stop, lubricate the steering st em bearing. NOT E ○ The cables and wires will have some effect o[...]

PERIODIC MAINTENANC E 2-37 Periodic Maintena nce Procedures Brake Light Switch Insp ection • T urn on the ignition switch. • Check the operation of the rear brake light switch by de- pressing the brak e pedal. If it does not as specified, adjust the brake li ght timing. Brake Light Timing Standard: On after about 10 mm (0.4 in .) of pedal trave[...]

2-38 PERIODIC MAINTENANCE Periodic M aintenance Pro cedures[...]

PERIODIC MAINTENANC E 2-39 Periodic Maintena nce Procedures Joint Boots Inspection Front Axle/ Knuckle Joi nt Boot Inspecti on • Visual ly inspect the front axle joint boots [A]. If the joint boot i s torn, worn, deteriorated, or leaks grease, replace the joi nt boot or f ront axle ass embly (see Final Drive chapter). • Visual ly inspect the k [...]

2-40 PERIODIC MAINTENANCE Periodic M aintenance Pro cedures General Lubrication Lubric ation • Before lubri cating each part, clean off any rusty spots with rust remover and wipe off any gr ease, oil, dirt , or grime. • Lubricate the point s listed below with indicat ed lubricant. NOT E ○ Whenever the vehicle has been operated under wet or ra[...]

PERIODIC MAINTENANC E 2-41 Periodic Maintena nce Procedures Slide Points: Lubricat e with Grease. Brake Lever Brake Pedal Pivot Shaft Throttle Lever Shaft Bolts and Nuts Tightening Tigh tnes s Insp ecti on • Check the tightness of the bolts and nuts listed here in accordance with t he Periodi c Maintenance C hart. Also, check to see that each cot[...]

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FUEL SYSTEM 3-1 3 Fuel System T able of Co ntents Exploded V iew .......... ............ ............. 3-2 Spec ifica tions . .... ....... ...... .... ...... ...... .. 3-6 Spec ial T o ols .... ....... ...... .... ...... ...... .... 3-7 Thr ottle L ever an d Cabl e ..... .... ...... .... 3-8 Throttle Lever Free Play Ins pectio n ... ....... ...... [...]

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

FUEL SYSTEM 3-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remar ks 1 Idle Adjusting Screw Bracket Bolt 8.8 0.90 78 in·lb 2. Choke Lever 3. Choke Cable 4. Throttle Cable 5. Throttle Lever 6. Jet Needle 7. Pilot Jet 8. Main Jet 9. Needle Jet 10. Pilot Screw 11 . P r i m i n g P u m p 12. Air T emperature Sensor G: Apply grease. O: Apply [...]

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

FUEL SYSTEM 3-5 Exploded View T orque No. Fastener N·m kgf·m ft·l b Remarks 1 Element Cover Screw 3.5 0.35 31 in·lb 2 Element Holder Screws 3.5 0.35 31 in·l b 3 Clamp Bracket Bolt 9.8 1.0 87 in·lb 4 Fuel Pump Mounting Nuts 7.8 0.80 69 in·l b 5 Fuel T ap P late Screws 0.8 0.08 7i n · l b 6 Fuel T ap Mounting Bolts 4.9 0.50 43 i n·lb 7 Fuel [...]

3-6 FUEL SYSTEM Specifications Item Standard Servi ce Limit Throttle Case and Cable Throttle Lever Fre e Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) ––– Choke Lever and Cable Choke Lever Free Play about 3 mm (0.12 in.) ––– Carburetor Make/T ype KEIHIN, CVKR-34 ––– Main Jet: Front #152 ––– Rear #158 ––– Main Air Jet #70 ––?[...]

FUEL SYSTEM 3-7 Special T ools Fuel Level Gauge: 57001-1 017 Pilo t Scr ew Ad just er , A: 57001-1 239 Carburetor Drain Plug W rench, Hex 3: 57001-12 69 V acuum Gauge: 57001-13 69[...]

3-8 FUEL SYSTEM Throttle Lever a nd Cable Throttl e Lever Fr ee Play Insp ection • Refer to the Thrott le Lever Free Pl ay Inspection i n the Periodic Maintenance chapter . Throttl e Lever Free Play Adj ustment • Refer to the Throttle Lever Free Play Adjustment in the Periodic Maintenance chapter . Throttle Case Removal /Disassembly • Remove [...]

FUEL SYSTEM 3-9 Throttle Leve r and Cabl e • Swing the thr ottle con trol lever so that the carburetor throt- tle valve is full y open. Turn the throt tle l imiter screw [A] until it is spaced about 1 mm (0.04 in.) [B] away from the throttle lever st op [C]. T ighten the locknut [D]. NOTE ○ Refer to the Ow ner ’s Manual for the function of th[...]

3-10 FUEL SYSTEM Choke Lever a nd Cable Choke Lever Free Play Inspect ion • Refer to the Choke Lever Free Play Inspection in the Pe- riodic Maintenanc e chapter . Choke Lever Free Play Adj ustment • Refer to the Choke Lever Free Play Adjustment in the Periodic Maintenance chapter . Choke Lever a nd Cable Removal • Remove the air cleaner housi[...]

FUEL SYSTEM 3-1 1 Choke Leve r and Ca ble • Pu ll off the r etaini ng clip [ A]. • Fit the cable end [A] in the grommet [B], and free the cable from the switch case. • Pull the cable out of the vehicle. Cho ke Lever an d Cable I nstalla tion • Lubricate the choke cabl e before installation. • Install t he wave washer , plane washer and sc[...]

3-12 FUEL SYSTEM Carburetor Idle S peed In specti on • Refer to the I dle Speed Inspect ion in t he Periodic Mai n- tenance chapter . Idle Spe ed Adjust ment • Refer to the Id le Speed Adjustment in t he Periodic Main- tenance chapter . Pilot Screw A djustm ent • Adjust the pilot screw if necessary . • Remove the air cleaner cover (see Fram[...]

FUEL SYSTEM 3-13 Carburetor • Connect two suitable hoses [ A] to the fuel level gauge [B] and the float chamber of the carburetors . Spec ial T o ol - Fuel L evel G auge: 57 001-101 7 • Mark the additional graduation [C] 15 mm (0.59 i n.) higher than the top gr aduation [D]. • Hold the gauge so that the additional graduat ion is placed slight[...]

3-14 FUEL SYSTEM Carburetor Service Fuel Lev el Adju stme nt W ARNING Gasoline is extremely fl ammable and can be ex- plosive under cert ain conditions. T urn the igniti on switch to OFF . Do not smoke. Make sure the ar ea is well-ventilat ed and free from any source of flame or sparks; this includes any appliance with a pilot light. • Remove the[...]

FUEL SYSTEM 3-15 Carburetor • Remove the rear vacuum hose [A] and install the vacuum hose for vacuum gauge. • Connect: V acuum Gauge [A] Spec ial T o ol - V acu um Gau ge: 5700 1-1369 • Connect the fuel hose of a suitable f uel tank [B] to the carburetor . • Start the engine and read the intake vacuum of each car- buretor when idling. If th[...]

3-16 FUEL SYSTEM Carburetor • Remove: Air Cleaner Housing (see Air Cleaner Housi ng Removal) • Drain the f uel from the carburet ors. • Remove: Fuel Hose [A] Heater and Ground Lead Connectors [B] • Remove: Screws [A] and Throttle Link Case Cover [B] • Remove: Locknut [A] Throttle Cable Lower End [B] • Loosen the carburetor clamp screws [...]

FUEL SYSTEM 3-17 Carburetor • Remo ve : Screw [A] Holder Plate [B] Starter Plu nger Carb ureto r Installa tion • Confirm the groove of the carburetor holder [A] fit s on the projection [ B] of the cylinder head. • Check fuel leakage from the carburetors. W A RNING Fuel spilled fr om the carburetors is hazardous. • Adjust the idle speed (see[...]

3-18 FUEL SYSTEM Carburetor • Remove the upper c hamber cover [A], spring [B], and vac- uum piston [C]. CAUTION During carburetor disassembly , be careful not to damage the diaphragm. Never use a sharp edge to remove the diaphr agm. • Remove the jet needle [D] from the vacuum piston. These can be detached together with the spr ing seat [E]. ○[...]

FUEL SYSTEM 3-19 Carburetor • Remo ve : Diaphragm [A] O-ring [B] Carburetor Assembly W A RNING Fuel spilled fr om the carburetors is hazardous. CAUTION Do not apply force to the j et or overti ghten it, or this could damage the jet or the carburetor body , requiring replacement. • Install the float valve needle i n the v alve seat and h ook the[...]

3-20 FUEL SYSTEM Carburetor • Fit the projecti on [A] of the vacuum pist on diaphragm in the recess [B] of the body . • After installi ng the upper chamber cover , check to make sure that the vacuum piston moves smoothly i n the car- buretor body . Carbu retor S epara tion • Remove: Carburetor (see Carburet or Removal) Screws [A] Fuel Hose Fi[...]

FUEL SYSTEM 3-21 Carburetor • Visual ly synchroni ze the throttl e (butterfl y) valves. ○ Check to see that all throttle valves open and close smoothly without bind ing when turning the pull ey . ○ Visually check the clearance [A] between t he throttl e valve and the carburetor bore in each carb uretor . If there i s a dif ference between two[...]

3-22 FUEL SYSTEM Carburetor • Disassemble the car buretor and c lean all t he metal par ts in a carburetor cl eaning solut ion. • Rinse the part s in water and dry them with compressed air . • Blow through the air and fuel passages with compressed air . • Remove the float valve, spray cleaning sol ution from the valve seati ng surface int o[...]

FUEL SYSTEM 3-23 Carburetor • Disassemble the ca rburetors ( see Carburetor D isassem- bly). • Clean the carburetor (see Carburetor Cleani ng). • Check the vacuum pis ton diaphr agm [A], and t he O-rings [B] on the float bowl, pilot screw , coasting enricher , and starter plunger cap. If any of the diaphragm or O-rings ar e not in good condi-[...]

3-24 FUEL SYSTEM Air Cleaner Air C leaner El emen t Remo val • Remove: Seat (see Frame chapter) Clips [A] Air Cleaner Housing Cap [B] • Remove: Element Cover Screw [A] Element Cover [B] Element [C] • After removing the eleme nt, stuff pieces of lint-fr ee, clean cloth into th e air cleaner duc ts to keep dir t out of the car- buretor and engi[...]

FUEL SYSTEM 3-25 Air Cl eaner • Remo ve : Screws [A] Element Holder [B] Spark Arreste r [C] • Remo ve : Screw [A] Air Intake Duct [B] Air Cleaner Housing Bolt [C] • Remo ve : Air Cleaner Housing Bolt [A] • Loosen the clamp screws [A]. • Remo ve : Breather Hose [A][...]

3-26 FUEL SYSTEM Air Cleaner • Remove: Screw [A] Carburetor Breather T ank [B] Air Cleaner Housing [C] Air Cleane r Housing Install ati on • Fit the projec tion [A] of the housing in the groove [B] of the joint duct [C] (front and rear), and tighten t he clamp screws. • Inst all: Dust Seal [A] Air Cleaner Housing Cover [B] [C] Inside • Inst[...]

FUEL SYSTEM 3-27 Air Cl eaner • Apply the soap and water solution over the trim seal [A]. • Install: Element Holder • T ighten: T orque - E lement Holder S crews: 3.5 N·m (0.35 kgf·m, 31 in·lb) • Install: Element (see Air Cleaner Element Ins tallati on)[...]

3-28 FUEL SYSTEM Fuel T ank Fuel T ank Removal • Remove: Electrical Part s Case (see Frame chapter) Rear Fender (see Frame chapter) Storage Case [A] (Optional Par t) Check V alve Hose [B] • Remove: T wo Right Footboard Bolts [A] • Insert a t hin driver [ A] in the clamp [B ] to clear its stopper , and slide the clamp forward. • Move the mai[...]

FUEL SYSTEM 3-29 Fuel T ank Fuel T ank Ins talla tion • Check the insulator s [A] on the tank case. If the insulators are damaged or deteriorated, replace them. • Check the rubber dampers [A] on the frame as shown. If the dampers are damaged or deteriorated, replace them. • Install t he fuel tank with c ase, and tighten the bolt s. • Check [...]

3-30 FUEL SYSTEM Fuel T ank • Inst all: V acuum Hose [A] and Clamp [B] Fuel Level Sensor Lead Connector • Install the r emoved parts. Fuel T ank Cleaning • Remove the fuel tank and drain it (see Fuel T ank Re- moval). • Pour some high-fl ash point sol vent into t he fuel t ank and shake the t ank to remove di rt and f uel deposits . W ARNIN[...]

FUEL SYSTEM 3-31 Fuel T ank • Connect the fuel hoses to the fuel tap as follows. V acuum Hose [A] Fuel Pump Hose [B] • Be sure to cl amps [C] the fuel hoses to pr event leakage. Fuel T ap In spect ion • Check the fuel tap filter screen [A] for any breaks or dete- rioration. If the filter screen has any break or is deteriorat ed, it may allow [...]

3-32 FUEL SYSTEM Fuel T ank Fuel T ap Cleaning • Remove: Fuel T ap (see Fuel T ap Removal) • Clean the f uel tap filt er screen i n a high-fl ash point sol - vent. W ARNING Clean the ta p in a well-ventilate d area, and take car e that there is no spar k or flame anywhere near the working area; this includes any appliance with a pi- lot light. [...]

FUEL SYSTEM 3-33 Fuel Pump Fuel Pump Removal CAUTION Never drop the fuel pump, especially on a hard sur - face. Such a shock to the pump can damage it. W A RNING Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated a nd free from any source of flame or sparks; this includes any appli[...]

3-34 FUEL SYSTEM Fuel Pump Fuel Pump Installation • Inst all: Bracket [A] Fuel Pump [B] W ashers [C] and Nuts [D] • Inst all: V acuum Hose [A] Fuel Hose (Carburetor Side) [ B] Clamps [C] • Inst all: Fuel Hose (Fuel T ap Side) [A] Clamp [B] Bolts [C] Removed Parts Fuel Pump Inspect ion • Remove the fuel pump (see Fuel Pump Removal). If the h[...]

FUEL SYSTEM 3-35 Fuel Pump • Inhale the air to the inl et fitti ng [A], and make sure does not inhale the blown ai r from t he outl et fit ting [B]. If the fuel pump does not operate as desc ribed, replace it with a new one.[...]

[...]

COOLING SYSTEM 4-1 4 Cooling System T able of Co ntents Exploded V iew .......... ............ .............. ......... ............ ........... .......... ............ ......... ............ .... .... . 4-2 Coola nt Fl ow C hart .. ...... ...... .... ...... ....... .... ...... ...... .... ...... ....... .... ...... ...... .... ....... ...... .... [...]

4-2 COOLI NG SYSTEM Exploded View[...]

COOLING SYSTEM 4- 3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Radiator Mounting Bolts 8.8 0.90 78 in·l b 2 Radiator Fan Switch 18 1.8 13 3 Radiator Fan Assembly Bolts 4.9 0.50 43 in·lb 4 Thermostat Housing Cover Bolts 8.8 0.90 78 in·l b 5 Coolant T emperature W arning Light Switch 6.9 0.70 61 in·lb SS 6 Air Bleeder Bolt 8.[...]

4-4 COOLI NG SYSTEM Coolant Flow Ch art Permanent type anti freeze is used as a coolant t o protect the cooling s ystem from rust and corrosion. When the engine star ts, the water pump (coupled with the oil pump) tu rns and the cool ant circulat es. The thermostat is a wax pellet type which opens or closes with coolant temperature changes. The ther[...]

COOLING SYSTEM 4- 5 Coolant Flo w Chart 1. Radiator 2. Radiator Cap 3. Radiator Fan Switch 4. Radiator Fan 5. Coolant T emperature W arning Light Switch 6. Thermostat 7. Cylinder 8. Cylinder Head 9. W ater Pump 10. Reserve T ank Black Painted Arrow: Hot Coolant White Painted Arrow: Cold Coolant[...]

4-6 COOLI NG SYSTEM Specifications Item Standard Service Lim it Coolant Provided when Shippi ng Ty p e Permanent type of antifreez e (soft water and ethylene gl ycol plus corr osion and rust inhibitor chemical s for aluminum engines and radiator s) ––– Color Green ––– Mixed Ratio Soft water 50%, coolant 50% ––– Freezing Point − [...]

COOLING SYSTEM 4-7 Special T ool s & Seal ant Bearing D river Set: 57001-1 129 Bearing Remo ver Shaft, 9: 57001-1 265 Bear in g Remo ver H ead, 10 × 12: 57001-12 66 Kawasaki Bon d (Silicon e Sealant ): 56019-12 0[...]

4-8 COOLI NG SYSTEM Coolant Coolan t Deter ioration I nspection • V isually inspect t he coolant in the reserve t ank [A]. If whitish cotton- like wafts are observed, aluminum parts in the cooli ng system are corroded. If the coolant is brown, iron or steel parts are rustin g. In either case, flush the coo ling syste m. If the coola nt gives of f[...]

COOLING SYSTEM 4- 9 Coolant Pressure T esting • Remove the radiator cap, and instal l a cooli ng system pressure tester [A] on the radiator fi ller neck. NOTE ○ Wet the cap sealing surfaces wit h water or coolant to prevent pressure leakage. • Build up pressure in the system careful ly until the pres- sure reaches 123 kPa ( 1.25 kgf/ cm², 18[...]

4-10 COOLING SYSTEM Wa t e r P u m p W ater Pump Cover Removal • Drain the coolant (see Coolant Change in Periodic Main- tenance chapter). • Remove: Coolant Reserve T ank Wat e r H o se [ A ] W ater Pump Cover Bolts [B] W ater Pump Cover [ C] W ater Pump Cover Install ation • Inst all: K n o c kP i n s[ A ] New Gasket [B] • T ighten: T orqu[...]

COOLING SYSTEM 4-1 1 W ater Pump Water P ump Impell er Inspe ction • Visual ly inspect the impel ler [A]. If the sur face is c orroded or t he blades are damaged, re- place the impeller . Water P ump Leakag e Inspection • Check the drainage catch tank [A] at the bottom of the water pump body for coolant leakage. If there is a coolant leak, the [...]

4-12 COOLING SYSTEM Wa t e r P u m p • Apply heat-resi stance gr ease on the oi l seal l ip. • From outside the alternat or cover , press and insert the oil seal [A] flush [ B] in the directio n as shown. Specia l T ool - B earing Driver S et: 57001 -1 129 • From inside the al ternator cover , press and insert the ball bearing [A] until it is[...]

COOLING SYSTEM 4-1 3 Radiator Radiator Re moval W A RNING The radiator fan is connec ted directly to the bat- tery . The radiator fan may start even if the ignition switch is off . NEVER TOUCH THE RADIA TOR F AN UNTIL THE RADIA TOR F AN CONNECTOR IS DIS- CONNECTED. TOUCHING THE F AN BEFORE THE CONNECTOR IS DISCONNECTED COULD CA USE INJUR Y FROM TH [...]

4-14 COOLING SYSTEM Radiator • Pull the project ions [A] out of from the dampers [B], and remove radiator [C]. CAUTION Do not touch t he radiator cor e. This could damage the ra diato r fins, re sult ing in los s of cool ing ef fi- ciency . Radiato r Installa tion • Insert the pr ojections of the radiator in the dampers. • Inst all: Dampers [[...]

COOLING SYSTEM 4-1 5 Radiator Radiator Insp ection • Check the radiator core. If there are obstr uctions to air fl ow , remove the radiator and remove obstructi ons. If the corrugated fins [A] are deformed, carefully straighten t hem. If the air pas sages of the radiat or core are block ed more than 20% by unremovable obstructions or ir reparably[...]

4-16 COOLING SYSTEM Thermostat Thermosta t Removal • Drain the coolant (see Coolant Change in Periodic Main- tenance chapter). • Remove: Side Cover (see Frame chapter ) Coolant T emperature W arning Light Switch Lead Con- nector [A] Wat e r P i p e B ol t [ B ] • Remove: Thermostat Housing Cover Bolts [A] Thermostat Housing Cover [B] Thermost[...]

COOLING SYSTEM 4-1 7 Thermostat • T o check valve opening temperature, suspend the ther- mostat [A] and an accurate thermometer [B] in a container of water with the heat-sensi tive porti ons [C] in almost t he same depth. NOTE ○ The thermostat must be completely su bmerged and the thermostat and thermometer must not touch the con- tainer sides [...]

4-18 COOLING SYSTEM Radiator Fan Switch Radiato r Fan Switch Removal CAUTION The fan switch should ne ver be allowed to fal l on a hard surface. Such a shock to the part can damage it. • Drain the coolant (see Coolant Change in Periodic Main- tenance chapter). • Remove: Radiator Cover (see Frame chapter) • Disconnect the fa n switch leads. ?[...]

COOLING SYSTEM 4-1 9 Coolant T empera ture W arn ing Light Switch Coo lant T empe rature War ning Lig ht Switc h Remov al CAUTION The coolant t emperature warning light switch should never be allowed to fall on a hard surface. Such a shock to the part can damage it. • Drain the coolant (see Coolant Change i n Periodic Main- tenance chapter). • [...]

[...]

ENGINE T OP END 5-1 5 Engine T op End T able of Co ntents Exploded V iew .......... ............ ............. 5-2 Spec ifica tions . .... ....... ...... .... ...... ...... .. 5-8 Special T ools and Sealant ........ .... ..... 5-1 1 Camshaft Chain T ensioner ......... ....... 5-13 Camshaft Chain T ensioner Re mova l ..... ....... ...... .... ......[...]

5-2 ENG INE T OP END Exploded View[...]

ENGINE TOP END 5-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Rem arks 1 Rocker Case Bolts 55 mm (2. 2 in.) 8.8 0.90 78 in·lb S 2 Rocker Case Bolts 130 mm (5.1 in.) 9. 8 1.0 87 in·lb S 3 Rocker Case Bolts 30 mm (1. 2 in.) 9.8 1.0 87 in·lb S 4 Rocker Case Bolts 25 mm (1. 0 in.) 9.8 1.0 87 in·lb S 5 Cylinder Head Bolts (M10), First T o[...]

5-4 ENG INE T OP END Exploded View[...]

ENGINE TOP END 5-5 Exploded View T orque No. Fastener N·m kgf· m ft·lb Remarks 1 Chain T ensioner Mounting Bolts 8.8 0.90 78 in·lb 2 Chain T ensioner Cap Bolt 22 2.2 16 3 Position Plate B olts 8.8 0.90 78 in·lb 4 Intermediate Shaft Chain Guide Bol ts 8.8 0.90 78 in·lb 5 Intermediate Shaf t Chain T ensioner Bolts 8.8 0.9 0 78 in·lb 6 Camshaft[...]

5-6 ENG INE T OP END Exploded View[...]

ENGINE TOP END 5-7 Exploded View T orque No. Fastener N·m kgf·m ft·lb Rema rks 1 Exhaust Pipe Cover Bolts 8.8 0.90 78 i n·lb 2 Muf fler Cla mp Bolt 8.8 0.90 78 in·lb 3 Muffler C over Bolts 8.8 0.90 78 in·lb 4 Muffler M ounting First Nuts 20 2.0 14 S 5 Muffler Mount ing Second Nuts 31 3.2 23 S L: Apply a non-permanent locking agent. R: Replace[...]

5-8 ENG INE T OP END Specifications Item Standard Servi ce Limit Rocker Case Rocker Arm Inside Diameter 12.000 ∼ 12.018 mm (0.4724 ∼ 0.4731 i n.) 12.05 mm (0.4 74 in.) Rocker Shaft Diameter 1 1.983 ∼ 1 1.994 mm (0.4718 ∼ 0.4722 i n.) 11 . 9 6 m m (0.4 71 in.) Camshafts Cam Height: Exhaust 35.363 ∼ 35.477 mm (1.3922 ∼ 1.3967 i n.) 35.26 [...]

ENGINE TOP END 5-9 Specifications Item Standard Se rvice L imit Va l v e S t e m D i a m e t e r : Exhaust 4.955 ∼ 4.970 mm (0.1951 ∼ 0.1957 in. ) 4.94 mm (0.1945 in.) Inlet 4.975 ∼ 4.990 mm (0.1959 ∼ 0.1965 in. ) 4.96 mm (0.1953 in.) V alve Guide Inside Diameter: Exhaust 5.000 ∼ 5.012 mm (0.1969 ∼ 0.1973 in. ) 5.08 mm (0.20 in.) Inlet [...]

5-10 ENGINE T OP END Specifications Item Standard Servi ce Limit Second 1.02 ∼ 1.04 mm (0.0402 ∼ 0.0409 i n.) 1.12 mm (0.0441 i n.) Piston Ring Thickness: To p 0.97 ∼ 0.99 mm (0.0382 ∼ 0.0390 i n.) 0.90 mm (0.0 35 in.) Second 0.97 ∼ 0.99 mm (0.0382 ∼ 0.0390 i n.) 0.90 mm (0.0 35 in.) Piston Ring End Gap: To p 0.20 ∼ 0.30 mm (0.0079 ?[...]

ENGINE TOP END 5-1 1 Special T ools and Sealan t Outside Circ lip Pliers: 57001-1 44 Compression Ga uge, 20 kgf/c m²: 57001-2 21 V alve Spring Compressor Assembly: 57001-2 41 Piston P in Puller Asse mbly: 57001-9 10 V alve Seat Cutter , 45° - 27.5: 57001-1 1 14 V alve Seat Cutter , 32° - 28: 57001-1 1 19 V alve Seat Cutter , 60° - 30: 57001-1 1[...]

5-12 ENGINE T OP END Special T ools a nd Sealant V alve S pring Compr essor Adapt er , 22: 57001-12 02 V alve Guide Arbor , 5: 57001-12 03 V alve Guide Reamer , 5: 57001-12 04 V alve Seat Cutter Holder , 5: 57001-12 08 Piston Pin Puller Adapter , 14: 57001- 121 1 Filler Ca p Driver: 57001- 1454 Compress ion Gauge Ada pter , M1 0 × 1.0: 57001- 1458[...]

ENGINE T OP END 5-13 Camshaft Chai n T ensione r Camshaft Chain T ensioner Removal CAUTION This is a non-return t ype cam chain tensioner . The push rod does not return to its ori ginal position once it moves out to take up cam chain slack. Ob- serve all the rules li sted below: When removing the tensioner , do not take out the mounting bolts only [...]

5-14 ENGINE T OP END Camshaft Chain T ensioner • T ighten: T o rque - Chain T ensioner Mounting Bolts: 8.8 N·m (0.90 kgf·m, 78 in·l b) • Inst all: Pin [A] and Spring [B] W asher [C] and Chain T ensioner Cap Bolt [D] • T ighten: T orque - Chain T ensioner Cap Bolt: 22 N·m (2.2 kgf·m, 16 ft·lb)[...]

ENGINE T OP END 5-15 Rocker Case Rocker Case Removal Front Rocker Case • Remo ve : Front Fender (see Frame chapt er) Recoil Starte r (see Recoil St arter c hapter) T iming Inspection Plug [A] Special T ool - Fille r Cap Dr iver [B]: 57001-1454 • Remo ve : V alve Adjusting Caps • Using a wrench on the alternator bolt, turn the crankshaft count[...]

5-16 ENGINE T OP END Rocker Case • Insert a suitable bar [A] under the front of the engine. • Lift [A] the front of the engin e to remove the bolt [B] of the front right side on the rocker case. • Lift th e rocker case clear of the dowel pins in the cyli nder head and slide the rocker case out of the frame. Rear Rocker Case • Remove: Front [...]

ENGINE T OP END 5-17 Rocker Case • Apply silicone sealant to the outer surface of the cap [A] and the cylinder head upper surf ace [B] as shown. Sealant - Three B ond: TB121 1F or GE SILICONES TRANSL UCENT RTV 128 • T ighten the rocker c ase bolts fo llowing t he tightening se- quence shown. T orque - Rocker Case Bolts: 8.8 N·m (0.90 kgf·m, 7[...]

5-18 ENGINE T OP END Rocker Case • Using a M8 bol t [A], remove the rocker shaft [B]. • Remove: Rocker Arm [C] W ashers [ D] ○ Mark and record the rocker arm location so it can be in- stalled in the origi nal position. ○ The rocker arms come off with the rocker shafts . Rocker Arm Installation • Apply engine oil: Rocker Shafts [A] Hole in[...]

ENGINE T OP END 5-19 Rocker Case Rocker Shaft Dia meter Measurement • Measure the diameter [A] of the rocker shaft where t he rocker arm piv ots on it with a micr ometer . If the rocker shaft diamet er is smaller tha n the service limit, replace it. Also check the rocker arm insid e diameter (see Rocker Arm Inspection). Rocke r Shaft Diameter Sta[...]

5-20 ENGINE T OP END Camshaft Camshaft Removal • Remove: Camshaft Chain T ensioners (see Camshaft Chain T en- sioner Removal) Rocker Cases (see Rocker Case Removal) Camshafts [A] • Support the chain us ing a suit able tool. Camshaft Installation • Using a wrench on the alternator bol t, turn the cr ankshaft clockwise until “T-R” mark [A] [...]

ENGINE T OP END 5-21 Camshaft • Face the arrow [A] of the front camshaft sprocket upward (right side view). • Engage the front camshaft chain with the front camshaft sprocket. • Align the marks [B] on the wei ghts with the f ront cylinder head upper surface. • Install: Rocker Cases (see Rocker Case Install ation) Camshaft Chain T ensioners [...]

5-22 ENGINE T OP END Camshaft Camshaft Bear ing W ear ○ The journal wear is measured using plasti gage (press gauge), which is insert ed into the clearance to be mea- sured. The plastigage i ndicates the c learance by the amount it is compressed and widened when t he parts are assembled. • Cut stri ps of plasti gage to journal width. Place a st[...]

ENGINE T OP END 5-23 Camshaft KACR Inspection The Kawasaki Automatic Compression Release ( KACR) momentarily opens the exhaust valves on the compression stroke at very low speeds. This allows some of the c om- pression pressure to escape, making it easy to turn over the engine during starting. Due to the simplicity of t he mechanism, no periodic ma[...]

5-24 ENGINE T OP END Camshaft • Remove: Circlips [A] Wei ght s [B ] Spring [C] NOT E ○ Do not remove the shaft [A] and pin [B]. ○ If the parts are removed, they cannot be reinstalled. KACR Installation • Inst all: Wei ght s Circlips Spring [A] ○ Hook the spring fr om the outside wit h the open side of the hook inwards. • Inst all: KACR [...]

ENGINE T OP END 5-25 Camshaft • Remove (right side view): T orque Converter (see Converte r System chapter) • Using a M6 bolt [A], pull out the cover [B]. • Remo ve (left s ide view) : Circ lip [A] Special T ool - Ou tside Circlip Pliers: 5700 1-144 • Remo ve : Intermediate Shaf t Sprocket [B] Intermediat e Shaft Drive Chai n [C] Rear Camsh[...]

5-26 ENGINE T OP END Camshaft Front Camshaft Chain • Install the circli p [A]. Special T ool - Outside Ci rclip Pliers: 57001-144 • Rotate the crankshaft cl ockwise 270°. • Align the key grooves [ B] on the crankshaft w ith the em- bossed line [C] on the cr ankcase. • Move the inter mediate shaft [ A] to the lef t side of t he en- gine. ?[...]

ENGINE T OP END 5-27 Camshaft • Install the inter mediate shaft chain ten sioner [A] as fol- lows: • Release the stopper [B] and push the push rod [C] into the tensioner body . • Insert a wir e [D] int o the rod hole to hold the rod i n place. • Install: Intermediat e Shaft Chain T ensioner [A] • T ighten: T orque - Intermediate Shaft Cha[...]

5-28 ENGINE T OP END Camshaft • Inst all: Rocker Cases (see Rocker Case Installation) Camshaft Chain T ensioners (see Camshaft Chain T en- sioner Inst allation) • Check the valve clearances (see V alve Clearance Inspec- tion). Camshaft Chain Guide W ear • V isually inspect t he rubber on the guides. If the rubber is damaged, cut, or is missin[...]

ENGINE T OP END 5-29 Cylinder Head Cylinder Compression Measurement NOTE ○ Use the battery which is fully charged. • W arm up the engine thoroughly , and stop the engine. • Remove the spark plug (see Electrical System chapter) . • Attach the compression gauge [A] and adapter [B] firmly into the spark pl ug hole. Special T ools - Comp ressio[...]

5-30 ENGINE T OP END Cylinder Head Cylinde r Head Rem oval • Drain the coolant (see Coolant Change in Periodic Main- tenance chapter). • Remove: Carburetor (see Fuel System chapter) Exhaust Pipe (see Engi ne T op End chapter) Thermostat (see Cooling Syst em chapter) Spark Plug Cap [A] Wat e r P i p e B ol t [ B ] Left W ater Pipe [C] • Remove[...]

ENGINE T OP END 5-31 Cylinder Head Cylinder Head Cleaning • Remove the cylinder head (see Cyl inder Head Removal). • Scrape the carbon out of the combustion chamber and exhaust port with a suitable tool. • W ash the head with a high-fl ash point sol vent. • Blow out any parti cles which may obst ruct the oil passage in the cylinder head usi[...]

5-32 ENGINE T OP END Va l v e s V alve Clearance Inspecti on • Refer to the V alve Clearance Inspection i n the Per iodic Maintenance chapter . V alve Clear ance Adj ustmen t • Refer to the V alve Cl earance Adjust ment in the Per iodic Maintenance chapter . V alve Removal • Remove the cylinder head (see Cylinder Head Removal). ○ Mark and r[...]

ENGINE T OP END 5-33 V alves V alve G uide Installation • Lightly oil the valv e guide outer surface. • Using the valve guide arbor [A], drive th e valve guide [B] until its fl ange touches the cylinder head. Special T ool - V alve Guid e Arbor , 5: 57001 -1203 • Ream the valve guide with the valve guide reamer [A] , if may be necessary to re[...]

5-34 ENGINE T OP END Va l v e s V alve Seat Inspecti on • Remove the valve (see V alve Removal). • Check the valve seating surface [A] be tween the valve [B] and valve seat [C]. ○ Coat the valve seat with machini st’ s dye. ○ Push the valve i nto the gui de. ○ Rotate the valve agai nst the seat with a l apping tool. ○ Pull the valve o[...]

ENGINE T OP END 5-35 V alves Seat Cutter Operation Care 1. This valve seat cutter is developed to grind the valve seat for repai r . Therefore the cutter must not be u sed for other purposes than seat repair . 2. Do not drop or shock the val ve seat cutter , or the dia- mond particles may fall off. 3. Do not fail to appl y engine oil to the valve s[...]

5-36 ENGINE T OP END Va l v e s Widened Width [A] of engagement by machining with 45° cutter Ground V olume [B] by 32° cutt er 32° [C] Correct Width [ D] Ground V olume [E] by 60° cutt er 60° [F] • Measure the outside diameter of the seat ing surface with vernier cal ipers. If the outs ide diameter of the seat ing surface i s too small, repe[...]

ENGINE T OP END 5-37 V alves If the seat width is too wide, make the 60° [A] grind de- scribed below . If the seat width is within the specifi ed range, lap the valve to the seat as described below . • Grind the seat at a 60° angle unti l the seat width is within the specified range. ○ T o m ake the 60° grind, fit 60° cutter into the holder[...]

5-38 ENGINE T OP END Va l v e s[...]

ENGINE T OP END 5-39 Cylinder and Pisto n Cylinder Removal • Remo ve : Cylinder Head (see Cylinder Head Removal) Oil Pipe [A] Chain Guide [B] Cylinder Bolts [C] Cylinder [D] Cylinder Base Gasket Piston Removal • Remove the cylinder block (s ee Cylinder Removal). • Place a piece of clean cl oth under t he piston and remove the piston pi n snap[...]

5-40 ENGINE T OP END Cylinder and Piston NOT E ○ The oil ring rail s have no “top” or “bottom”. • Install the oil ring expander [A] in the bottom piston ring groove so the ends [B] butt together . • Install the oil ring steel rai ls, one above the expander and one below it. ○ Spread the rail wi th your thumbs, but only enough to fit[...]

ENGINE T OP END 5-41 Cylinder and Pisto n • Install: Cylinder Clamp [A] (rear only) • T ighten: T o rque - Cylinder Bolts [B]: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Install: Chain Guide [C] • Apply oil to the O-ri ng on the oil pi pe [D], and insert t he pipe. Cylinder W ear • Since there is a di ffer ence in cylinder wear in differ ent di- [...]

5-42 ENGINE T OP END Cylinder and Piston Piston Ring, Piston Ring Groove Wear • Check for uneven groove wear by i nspecting the ring seat - ing. The rings should f it perfect ly parallel to groove surface s. If not, r eplace t he piston and all the pist on rings. • With the piston r ings in their grooves, make sever al mea- surements wit h a th[...]

ENGINE T OP END 5-43 Cylinder and Pisto n Piston Ring End Gap • Place the pisto n ring [A] i nside the cyli nder , using the pis- ton to locate the ring squarel y in place. Set it close to the bottom of the cylinder , where cylinder wear is low . • Measure the gap [B] between the ends of the ring with a thickness gauge. Piston Ring End Gap Stan[...]

5-44 ENGINE T OP END Exhaust System This vehicle i s equipped with a spar k arrester approved for of f-road use by t he U.S. Forest Servi ce. It must be prop- erly maint ained to ensur e its ef ficiency . In accordance with the Periodi c Maintenance Char t, clean t he spark a rrester . Spark A rrest er Cle aning • Refer to the Spark Ar rester Cle[...]

ENGINE T OP END 5-45 Exhaust Syste m • Remo ve : Front Exhaust Pipe Nuts [A] • Move the front exhaust pipe rear end [A] under the fuel tank and remove the pipe forward. Muf fler and Exh aust Pi pe Insta llati on • If the muff ler cover [A] is removed, t ighten them. T orque - Muffler Cover Bolts [B]: 8.8 N·m (0.90 kgf·m, 78 in·lb) • Repl[...]

5-46 ENGINE T OP END Exhaust System Exhaust Syste m Inspection • Before removing the exhaust system, check for signs of leakage at the exhaust pipe gasket in the cylinder head and at the muf fler cl amp. If there are signs of leakage ar ound the exhaust pipe gas- ket, it should be replaced. If the muffler-to- exhaust pipe joint l eaks, tight en t[...]

CONVERTER SYSTEM 6-1 6 Converter System T able of Co ntents Exploded V iew .......... ............ .............. ......... ............ ........... .......... ............ ......... ............ .... .... . 6-2 Spec ifica tion s ..... ....... ...... .... ...... ...... ..... ...... ...... .... ...... ...... ....... .... ...... ...... .... ....... .[...]

6-2 CONVERTE R SYSTEM Exploded View[...]

CONVE RTER SYS TEM 6- 3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Drive Pulley Bol t 93 9.5 69 R, Lh 2 Driv en Pu lley Nut 93 9.5 69 3 Drive Pulley Cover Bolts 13 1. 3 11 3 i n · l b 4 Ramp Weight Nuts 6.9 0.70 61 in·lb 5 Spider 275 28 203 Lh G: Apply grease. Lh: Left-hand Threads R: Replacement Parts WR: Apply grease (WR500[...]

6-4 CONVERTE R SYSTEM Exploded View[...]

CONVE RTER SYS TEM 6- 5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Rema rks 1 Converter Cover Bolt s 8.8 0.90 78 in·lb S 2 Joint Duct Bolts 8.8 0.90 78 in·lb 3 Engine Brake Actuator Mounting Bolts 8.8 0.90 78 in·lb S G: Apply grease. M: Apply molybdenum disulfide grease. R: Replacement Part S: Follow the specific tighteni ng sequence.[...]

6-6 CONVERTE R SYSTEM Specifications Item Standard Se rvice L imit T orque Converter Actuator Lever Guide Shoe ––– 6 mm (0.24 in.) Drive Belt Belt Width 29.7 ∼ 30.3 mm (1.169 ∼ 1.193 in .) 28.0 mm (1.102 i n.) Belt Deflection 22 ∼ 27 mm (0.87 ∼ 1.0 6 in.) ––– Drive Pulley Shoe Side Clearance Up to 0.20 mm (0.008 in.) (in the tex[...]

CONVERTER SYSTEM 6-7 Special T ools Circlip Pliers : 57001-1 54 Flywheel & Pulley Holder: 57001-1 343 Drive & Driven Pulley H older: 57001-1 412 Drive Pulley P uller Bolt: 57001-1 429 Pulley Holder Attachment: 57001-1 472 Drive & Driven Pulley Holder: 57001-14 73 Drive Pulle y Wrench: 57001-14 74 Sprin g Holder Se t: 57001-14 83 Drive P[...]

6-8 CONVERTE R SYSTEM Special T ools Drive Pulley Holder: 57001-15 20[...]

CONVE RTER SYS TEM 6- 9 T orque Conver ter W A RNING Excessive imbalance or operating rpm could cause torque converter pulley failu re resulting in severe injury or death. The pulleys of the belt dr ive torque converter are precision balanced components de- signed to operate within certain rpm limit s. Disas- sembly/assembly and servicing procedure[...]

6-10 CONVERTER SYSTEM T orque Converter T orque Converter Cover Insta llati on • Check the actuator lever ass embly install ation length (see T orque Converter Cover Assembly). • Fit the trim seal into the conv erter cover . ○ Set the trim seal juncture in the area [A] when insert the trim seal in the cover . [B] 10 mm (0.39 in.) • Check: D[...]

CONVERTER SYSTEM 6-1 1 T orque Conver ter Actuator Le ver (En gine Bra ke Cont rol Lever ) Assembly Inspection • Refer to the Actuator Lev er (Engine Brake Contr ol Lever) Assembly Inspection i n the Periodic Maintenance chap- ter . T orque Co nverte r Cove r Asse mbly • Install: New Cir clip Spring Actuator Lever Assembly Engine Brake Act uato[...]

6-12 CONVERTER SYSTEM T orque Converter Actuator Le ver As semblies Part Nu mber Paint C olor [ A] Length [B] 13236-00 46 Ye l l o w 0.4 ±0.1 mm (0.0 16 ±0.004 in.) 13236-00 48 None 1.0 ±0.1 mm (0.039 ±0 .004 in.) 13236-00 47 Green 1.6 ±0.1 mm (0.0 63 ±0.004 in.)[...]

CONVERTER SYSTEM 6-13 Drive Belt Drive Bel t Removal • Remove the drive pulley [A] (see Drive Pulley Removal) . NOTE ○ Before removing, observe the direction the belt’ s printed informatio n [A] (such as manufacturer ’s name) is faci ng so that it may be reinstalled on t he pulleys to r otate i n the same directi on as original ly instal le[...]

6-14 CONVERTER SYSTEM Drive Pulley Drive Pul ley Remova l • Remove the torque conver ter cover (see T orque Con- verter Cover Removal). • Remove the three cover bolts [A] and install the drive pul- ley holder [B]. Specia l T ool - D rive Pulley H older: 570 01-1520 • T ighten the three cover bolts : T orque - Drive Pulley Cover Bolts: 13 N·m[...]

CONVERTER SYSTEM 6-15 Drive Pulley • Remo ve : Spring [A] Spacer • Put the drive pu lley wrench [A] on t he spider [B] and tighten the bolt [C]. Spec ial T o ol - Drive P ulley Wrench: 570 01-1474 • T urn the wrench clockwise and remove the spider with the movable sheave. NOTE ○ The spider has lef t-hand thre ads. T urn the wre nch clockwis[...]

6-16 CONVERTER SYSTEM Drive Pulley If the cover bus hing is damaged or worn, replace the dri ve pulley cover . Cover Bushing Inside Diameter [A] Stan dard: 27. 985 ∼ 28.085 mm (1 .1018 ∼ 1.105 7 in.) Service Limit: 28 .12 mm (1.107 in.) If the sheave bushing is damaged or worn, r eplace it. Sheave Bush ing Inside Diam eter [A] Stan dard: 37.9 8[...]

CONVERTER SYSTEM 6-17 Drive Pulley If the spri ng is worn or damaged, repl ace the spring. Spring Free Lengt h [A] Standar d: 60.4 mm (2.3 8 in.) Spider S hoe Sid e Clear ance Adj ustment • Remo ve : Drive Pul ley (see Drive P ulley Remov al) Drive Pulley Cover and Spring (s ee Drive Pulley Disas- sembly) • T emporarily install the following pa[...]

6-18 CONVERTER SYSTEM Drive Pulley If the clearance is not the specifi ed range after the above shoes are replaced , use the spacer [A] (92026-0038) of the option part . [B] Shoe [C] Spider [D] Post [E] Clearance Drive Pulley A ssembly • Install the ramp weight [A] as shown. • T ighten: T orque - Ramp Weight Nuts [B]: 6.9 N·m (0.70 kgf·m, 61 [...]

CONVERTER SYSTEM 6-19 Drive Pulley • Install the spacer . • Put the spring [A] in the groove of the spi der . • Align the arrows [B] on the drive pulley cover and spider . • Install: Dowel Pins [C] Driv e Pul ley C over • T ighten: T orque - Drive P ulley Cover Bolts : 1 3 N·m (1.3 kgf·m, 1 13 in·lb) • Clean the surface of the s heav[...]

6-20 CONVERTER SYSTEM Drive Pulley • Remove the dri ve pull ey holder and install thr ee drive pul - ley cover bolts to the specifi ed torque. • Adjust the i nstallati on length [A] of the drive pull ey be- tween the surfac e of the crankcase [B] and the collar [C] on the drive pull ey as followi ngs. Drive Pulley Installation Length [A] Stan d[...]

CONVERTER SYSTEM 6-21 Driven Pulley Driven Pulley Removal • Remo ve : T orque Converter Cover (see T orque Converter Cover Removal) Drive Pul ley (see Drive P ulley Remov al) Drive B elt (se e Driv e Belt R emov al) • Using the flywheel & pull ey holder [A] and attachment s [B], remove the driven pull ey nut [C] and washers. (Nut has R/H th[...]

6-22 CONVERTER SYSTEM Driven Pulley • Confirm the paint mark “0” [A] on the m ovable sheave [ B] in alignment with t he point [C] on the fi xed sheave [D] for phase fit of the sheave s. • Wipe off the molybdenum disulfide g rease. • Remove the four pins [A] wit h a thin standard t ip screw- driver [ B]. • Remove the movable sheave fr om[...]

CONVERTER SYSTEM 6-23 Driven Pulley If the sheave bushings [A] are damaged or worn, replace the movable sheave. Sheave Bu shing Inside D iameter Standard: 4 0.000 ∼ 40.039 mm (1 .5748 ∼ 1. 5763 in.) Service Limit: 40.07 mm (1.578 in.) • Inspect seals for damage. If seals are damaged, replac e t he movable sheave. If the spli nes [A] a re dama[...]

6-24 CONVERTER SYSTEM Driven Pulley • Align the paint mark “0” [A] on the movable sheave [B] with the point [ C] on the fixed sheave [ D] for phase fit of the sheaves. ○ In that case the opening [A] and hole [B] will be matched easily . • Apply grease WR500-No.2 ( KYODO YUSHI), POWER LITE WR #2 (KYODO YUSHI), or SERAN-HV (TOT AL FINA) to [...]

CONVERTER SYSTEM 6-25 Driven Pulley • Hold the dri ve & driven pul ley hol der in a vi se. Spec ial T o ol - Drive & Driven P ulley Holder: 5 7001-147 3 • Screw the guide bar into t he holder . Spec ial T o ol - Spring Holder Set: 570 01-1483 • Put the driven pulley [A] onto the guide bar . • Put the thrust plate [B] so that the al [...]

6-26 CONVERTER SYSTEM Driven Pulley • Install t wo washers [A] on the shaft as shown. Crankcase Side [ B] Bolt Head Side [C ] • Using a flywheel & pulley holder [A] and attachments [B], tighten the driven pul ley nut [C]. Specia l T o ols - F lywheel & P ulley Ho lder: 57 001-1343 Pulle y Holder Atta chment: 57001-1472 T orque - Drive n[...]

CONVERTER SYSTEM 6-27 High Altitude Setting Inform ation Specifica tions Alti tude Dri ve Pulley Carburet or m (ft) Ramp Weight s Spring Spacer (q ty) Main Jet (1) Front: #152 (P/No. 92063-1331) (ST D) 0 ∼ 1 200 (0 ∼ 3 900) P/No. 39152-1081 (STD, C) P/No. 92026-1603 t = 1 mm (0. 04 in.) Rear: #158 (P/No. 92063-1344) (ST D) 1 200 ∼ 2 500 (3 90[...]

[...]

RECOIL ST ARTER 7-1 7 Recoil Starter T able of Co ntents Exploded V iew .......... ............ .............. ......... ............ ........... .......... ............ ......... ............ .... .... . 7-2 Reco il Sta rter .... .... ....... ...... .... ...... ...... ..... ...... ...... ...... .... ....... ...... .... ...... ...... .... ....... .[...]

7-2 RECOIL ST ARTER Exploded View[...]

RECOIL ST ARTER 7-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Recoil Starter Mounti ng Bolts 5.9 0.6 0 52 in·lb L L: Apply a non-permanent locking agent.[...]

7-4 RECOIL ST ARTER Recoil Starter Recoil Starter Remova l • Remove: Recoil Starter Mounting Bolt s [A] Recoil Starter [B] Recoil S tarter Install ation • Apply a non-permanent locking agent: Recoil Starter Mounting Bolts • T ighten: T o rque - Recoil Starter Mounting Bolts: 5.9 N·m (0.60 kgf·m, 52 in·l b) Recoil St arter I nspecti on • [...]

ENGINE LUBRICA TION SYSTEM 8-1 8 Engine Lubrication System T able of Co ntents Exploded V iew .......... ............ .............. ......... ............ ........... .......... ............ ......... ............ .... .... . 8-2 Spec ifica tion s ..... ....... ...... .... ...... ...... ..... ...... ...... .... ...... ...... ....... .... ...... ..[...]

8-2 ENGINE LUBRI CA TION SYSTEM Exploded View[...]

ENGINE LUBRICA TION SYSTEM 8- 3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Rem arks 1 Oil Filter 18 1.8 13 R 2 Oil Pressure Switch 15 1.5 11 SS 3 Oil Pipe Bolts 8.8 0.90 78 in·lb 4 Engine Drain Plug 20 2.0 14 5 Oil Pre ssur e Reli ef V alve 15 1.5 11 L 6 Oil Pump Bolts 8. 8 0.90 78 in·lb 7 Chain Guide Bolt s 8.8 0.90 78 in·lb 8 Oil Pu[...]

8-4 ENGINE LUBRI CA TION SYSTEM Specifications Item Standard Engine Oil Ty p e API SF or SG API SH or SJ with JASO MA class Vi sc o si t y SAE 10W-40 Capacity 2.1 L (2. 2 US qt) (when filter is not removed) 2.2 L (2.3 US qt ) (when fil ter is removed) 2.6 L (2.7 US qt) (when engine is completely dry) Oil Pressure Measurement Oil Pre ssure @ 4 000 r[...]

ENGINE LUBRICA TION SYSTEM 8-5 Special T ool s & Seal ant Oil Pressure Gauge, 10 kgf/cm²: 57001-1 64 Oil Press ure Gauge Adapt er , PT 1/8: 57001-1 033 Oil Filter Wrench : 57001-12 49 Kawasaki Bon d (Silicon e Sealant ): 56019-12 0[...]

8-6 ENGINE LUBRI CA TION SYSTEM Engine Oil Flow Chart 1. Front Cam shaft 2. Oil Filter 3. Crankshaft 4. Oil Pressure Switch 5. Oil Pipes 6. Oil Pump 7. Relief V alve 8. Transmissi on Idle Shaft 9. Oil Screen 10. T r ansmission Driven Shaft 1 1. Rear Camshaft 12. Breather H ose 13. T o Air C leaner[...]

ENGINE LUBRICA TION SYSTEM 8- 7 Engine Oil and Oil F ilter W A RNING V ehicle operation with i nsuffici ent, deteriorated, or contaminated engine oil will cause ac celerated wear and m ay result in engine or transmission seizure, accident, and injury . Oil Le vel Insp ection • Park the vehicle so that it is level, both side-to- side and front-to-[...]

8-8 ENGINE LUBRI CA TION SYSTEM Engine Oil and Oil Filter Oil Scre en Cle aning • Clean the oil screen [ A] thoroug hly whenever it is removed for any reason. • Clean the oil scre en w ith a high- flash point solvent and remove any particl es stuck to i t. W ARNING Clean the screen in a w ell-venti lated area, and take care that there is no spa[...]

ENGINE LUBRICA TION SYSTEM 8- 9 Oil Pressure Relief V alve Oil Pressure Relief V alve Removal • Split the crankcase (see Crankcase Disassembly in the Crankshaft/T ransmission chap ter). • Remove the oil pressure reli ef valve [A]. Oil Pre ssure Reli ef V a lve Instal lation • See crankcase assembly (See Crankshaft /T ransmission chapter). •[...]

8-10 ENGINE LUBRICA TION SYSTEM Oil Pump Oil Pum p R emova l • Remove: Alternator Rot or and Starte r Clutch Gear ( see Electric al System chapter) Oil Pump Drive Chain T ensioner Bolt [A] Chain Guide Bolt [B] and Collar Chain Guide [C] • Remove: Oil Pump Bolts [A] Oil Pump Drive Chai n [B] and Oil Pump A ssembly [C] • Remove: Circlip [A] Inn[...]

ENGINE LUBRICA TION SYSTEM 8-1 1 Oil Pump • Install the oil pump drive chain [ A] with t he oil pump as- sembly [B]. • T ighten: T orque - O il Pump Bolts [C]: 8.8 N·m (0.90 kgf·m, 78 in·lb) • Install: Chain Guide [ A] and Coll ar [B] • T ighten: T orque - Chai n Guide Bolt: 8.8 N·m (0.90 kgf·m, 78 in·lb) • Apply grease to the O-rin[...]

8-12 ENGINE LUBRICA TION SYSTEM Oil Pipe Oil Pipe Removal Engine Left Side Oi l Pipe • Remove: Alternator Cover ( see Electri cal System chapt er) Oil Pump (see Oil Pump Removal) Oil Pip e Bolt s [A] Oil Pipes [B] Engine Right Side Oil Pipe • Remove: Drive Pulley (see T orque Converter chapter) Plate Bolts [A] Plate [B] • Remove: Oil Pip e Bo[...]

ENGI NE REMO V AL/I NST ALLA TION 9- 1 9 Engine Removal/Installation T able of Co ntents Exploded V iew .......... ............ .............. ......... ............ ........... .......... ............ ......... ............ .... .... . 9-2 Engin e Remo val/In sta llation .. .... ...... ....... .... ...... ...... .... ...... ....... ...... .... ...[...]

9-2 ENGIN E REMOV AL/INST ALLA TI ON Exploded View[...]

ENGINE REMOV AL/INST ALLA TIO N 9-3 Exploded View T orque No. Fastener N·m kgf ·m ft·lb Rema rks 1 Engine Bracket Mounting Bolts 72 7.3 53 2 Engine Mounting Bolts 62 6.3 46 3 Engine Mounting Nut 62 6.3 46[...]

9-4 ENGIN E REMOV AL/INST ALLA TI ON Engine Removal/In stallation Engin e Removal • Remove: Engine Oil (drain) Coolant (drain) Muffl er and Exhaust Pipe (see Engine T op End chapter) Footboards (see Frame chapte r) Carburetor (see Fuel System chapter) Alternator Lead Connector [ A] Crankshaft Sensor Lead Connector [B] Oil Pressure Swi tch Lead Co[...]

ENGINE REMOV AL/INST ALLA TIO N 9-5 Engine Remova l/Installatio n • Remo ve : Coolant Reserve T ank [A] Neutral Swit ch Lead Connector [B] Reverse Switch Lead Connector [ C] Forward/Reverse Detec ting Sensor Lead Connector [D] Wa t e r H o s e [ E ] • Remo ve : Footboard Bra ckets [A] Engine Mounting Bol ts [B] Engine Mounting Bracket [C] • R[...]

[...]

CRANKSHAFT/TRANSMISSION 10-1 10 Crankshaft/T ransmission T able of Co ntents Exploded V iew .......... ............ .............. ......... ............ ........... .......... ............ ......... ............ .... .... . 10-2 Spec ifica tion s ..... ....... ...... .... ...... ...... ..... ...... ...... .... ...... ...... ....... .... ...... ...[...]

10-2 CRANKSHAFT/TRAN SMISSION Exploded View[...]

CRANKSHAFT/T RANSMISSION 10- 3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Connecting Rod Big End Cap Nuts 34 3.5 25 MO 2 Engine Drain Plug 20 2.0 14 3 Crankcase Bolts (M8) 75 mm (2.95 in.) 20 2.0 14 S 4 Crankcase Bolts (M8) 1 10 mm (4.33 in.) 20 2.0 14 S 5 Crankcase Bolt (M8) 1 10 mm (4.33 in.) 20 2.0 14 S, L (1) 6 Crankcase Bo[...]

10-4 CRANKSHAFT/TRAN SMISSION Exploded View[...]

CRANKSHAFT/T RANSMISSION 10- 5 Exploded View T orque No. Fastener N·m kgf ·m ft·l b Remarks 1 Grip Hold Nut 9.8 1.0 87 in·lb 2 Shift Lever Assembly Bracket Bolts 20 2.0 14 3 T ie-rod End Front Locknut 9.8 1.0 87 in·lb Lh 4 T ie-rod End Rear Locknut 9. 8 1.0 87 in·lb 5 T ie-rod End Nut 20 2.0 14 6 Shift Lever Assembly Nut 20 2.0 14 7 T ie-rod [...]

10-6 CRANKSHAFT/TRAN SMISSION Specifications Item Standard Servic e Limit Crankshaft, Connecting R ods Connecting Rod Bend ––– TIR 0.2/100 mm (0.008/3.94 in .) Connecting Rod T wist ––– TIR 0.2/100 mm (0.008/3.94 in .) Connecting Rod Big End Side Clearance 0.16 ∼ 0.46 mm (0.0063 ∼ 0.0181 i n.) 0.7 mm (0.028 in.) Connecting Rod Big E[...]

CRANKSHAFT/T RANSMISSION 10- 7 Specifications Item Standard Servi ce Limit T ransmission Shift fork Ear Thickness 5.9 ∼ 6.0 mm (0.2322 ∼ 0.2362 in. ) 5.8 mm (0.228 in. ) Sh ift Groo ve Widt h 6.05 ∼ 6.15 mm (0.2382 ∼ 0.2421 in. ) 6.25 mm (0.2460 in.)[...]

10-8 CRANKSHAFT/TRAN SMISSION Special T ools a nd Sealant Ou tsid e Ci rcl ip Plie rs: 57001-14 4 Bearing D river Set : 57001-1 129 Cranks haft Jig: 57001- 1 174[...]

CRANKSHAFT/T RANSMISSION 10- 9 Crankcase Crankcase Disassembly • Remo ve : Engine (see Engine Removal/Inst allation ch apter) Starter Mot or (see E lectrical System chapter) Oil Filte r Recoil Starter Cylinder Blocks and Pistons (see Engine T op End chap- ter) Intermediate Shaft and Chains (see Engi ne T op End chapter) Right Crankcase Bolt ( M6)[...]

10-10 CRANKSHAFT/TRANSMISSION Crankcase • Press and insert the new ball beari ngs until th ey are bot- tomed. Specia l T ool - B earing Driver S et: 57001 -1 129 [A] Ball Bearing [B] Ball Bearing (seal ed side towards crankcase) • Press and insert the new needle bearings so that the bearing surf aces are flush with the end of t he hole. [C] Nee[...]

CRANKSHAFT/TRA NSMISSION 10-1 1 Crankcase • Be sure the f ollowing par ts ar e in place in the r ight crankcase half. Crankshaft T ransmission Shafts and Shift Rod [A] Spacers [B] Oil T ube [C] Oil Screen [D] O-ring (Apply Grease) [E] Dowel Pins [F] • Apply liquid gasket [A] to mating surf ace of the left crankcase half. Sealant - Kawasaki Bond[...]

10-12 CRANKSHAFT/TRANSMISSION Crankcase • Install the br eather tube [A] on t he crankcase fit ting. ○ Align the white li ne on the tube with the mark [B] on the crankcase. ○ Face the open end of the clamp [C] towards the left side [D] as shown. • Apply grease to the steel ball [A] and spring [B]. • Inst all: Steel Ball Spring W asher [C][...]

CRANKSHAFT/TRAN SMISSION 10-13 Crankshaft/Co nnection Rod Crankshaft Removal • Split the crankc ase (see Crankcase Dis assembly). • Remove the crankshaft [A] from the crankcase usi ng a press. Crankshaft Installation • The left shaft [A] of the crankshaf t is longer than the right shaft [B]. • Apply engine oil to the both main journal s. ?[...]

10-14 CRANKSHAFT/TRANSMISSION Crankshaft/Conne ction Rod • Apply molybdenum disulf ide oil: Threads [A] of Connecti ng Rod Big End Cap Bolts Seating Surface [ B] of Connecting R od Big End Cap Nuts [C] • T ighten: T o rque - Connecting Rod Big End Cap N uts: 34 N·m ( 3.5 kgf·m, 25 ft·lb) Crankshaft/Con nect ing Ro d Cleaning • After removi[...]

CRANKSHAFT/TRAN SMISSION 10-15 Crankshaft/Co nnection Rod Connectin g Rod Big End Si de Clear ance • Measure the side clear ance of the connect ing rod big end [A]. ○ Insert a thickness gauge [B] be tween the big end an d ei- ther crank web to det ermine clear ance. Connecting Rod Big End S ide Clearance Standard: 0.16 ∼ 0. 46 mm (0.0063 ∼ [...]

10-16 CRANKSHAFT/TRANSMISSION Crankshaft/Conne ction Rod If the measured crankpin diameter [A] i s not less than the service li mit, but does not coincide with the origi nal diameter marking on the crankshaft , make a new mark on it. Cran kpi n Dia met er Marks Non e: 39.984 ∼ 39 .992 mm (1.5742 ∼ 1.57 449 in.) : 39.993 ∼ 40 .000 mm (1.5745 2[...]

CRANKSHAFT/TRAN SMISSION 10-17 Crankshaft/Co nnection Rod Crankshaft Runout • Measure the crankshaft runout. If the measurement exceeds the serv ice limit, replace t he crankshaft. Crankshaft Runout Standar d: TIR 0.04 mm (0.0016 in.) or less Service Limit: TIR 0.10 mm (0.0039 in.) Cran kshaf t Main Bea ring/Jo urna l Wear • Measure the diamete[...]

10-18 CRANKSHAFT/TRANSMISSION T ran smission Shift Lever Remova l • Set the shift lever in the neut ral position . • Remove: Right Side Cover (see Frame chapter) Shift Shaft Lev er Bolt [A] • Remove the shif t shaft lever [B] from the shift shaft. • Remove: Nut [A] Shift Lever Assembly [B] Front [C] • Remove: T ie-rod End Bolt [A] Ti e - [...]

CRANKSHAFT/TRAN SMISSION 10-19 T ransmissio n Shift Lever Installatio n • T wist the tie-rod end [A] and tie-rod end locknut [ B] to bottom of the screw and then turn back to dimensio n with 77° ±10° [C] as shown. • T ighten the locknut against the ti e-rod end: T orque - T i e-rod End Locknut: 20 N·m (2.0 kgf·m, 14 ft·lb) • Apply molyb[...]

10-20 CRANKSHAFT/TRANSMISSION T ran smission • Inst all: Gui de [ A] • T ighten: T orque - Shift Lever Assembly Bracket Bolts [B]: 20 N·m (2.0 kgf·m, 14 ft·lb) • Set the lever assembly in the neutral position [C] while turning the ti e-rod [D]. NOT E ○ Do not turn the shift shaft [E] w hen sett ing the lever assembly on neutral position [...]

CRANKSHAFT/TRAN SMISSION 10-21 T ransmissio n T ransmission Remova l • Split the crankc ase (see Crankcase Dis assembly). • Remo ve : Shift Shaft Cover Bolts [A] Shift Shaft Cover [B] • Remo ve : Shift Shaft Spring Bolt [A] S h i f tS h a f t[ B ] • Remo ve : Reverse Idle Shaft [A] Spacer [B] Reverse Drive Gear [C], Needle Bearing, and Spac[...]

10-22 CRANKSHAFT/TRANSMISSION T ran smission • Remove: Circlip [A] Special T ool - Outside Ci rclip Pliers: 57001-144 • Remove: Spacer [A] Idle Gear Assembly [B] W ashers and Spacer [C] Low and High Gears [D] • Remove: Needle Bearings [A] • Remove the driven shaft [B] from the crankcase usi ng a press. T ran smissi on Ins tallatio n • Ins[...]

CRANKSHAFT/TRAN SMISSION 10-23 T ransmissio n • Install: Idle Shaft [A] wit h Gear Assembly [B] Spacer [C] Spacer [D] (P/No. 92026-1599, 48.2 × 54.3 × 1.0) • Apply engine oil to the inner surface of the spacer [E]. • Install t he spacer [E] so that the stepped side [F] faces outward. • Install: Spacer T oothed W asher [A] Circ lip Special[...]

10-24 CRANKSHAFT/TRANSMISSION T ran smission • Apply molybdenum disul fide oil to the shi ft shaft [A]. • Inst all: Shift Shaft Spring Bolt [B] Spring [C] Gui de [ D] • Apply a non-permanent locking agent: Shift Shaft Spring Bolt • T ighten: T orque - Shift Shaft Spring Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb) • When a new bushing [ A] and o[...]

CRANKSHAFT/TRAN SMISSION 10-25 T ransmissio n T ransmission an d Shift Mechanism I nspection • Visual ly inspect : Gears Dogs of Gear and Shifter If they are damaged or worn excessively , replace them.[...]

10-26 CRANKSHAFT/TRANSMISSION T ran smission 1. Driven Shaft 2. Spacer (17.3 × 30 × 2.0) 3. Reverse Gear (12T) 4. Spacer (21.2 × 29 × 1.6) 5. Shifter 6. Snap Ring 7. W asher T = 1.5 8. Spacer (28.2 × 34.5 × 1.6) 9. Spacer (Hi and Low) 10. Spacer (48.2 × 54.3 × 1.0) 1 1. Drive Hi Gear (26T) 12. Drive Low Gear (20T) 13. Reverse Idle Shaft 14.[...]

CRANKSHAFT/TRAN SMISSION 10-27 Ball Bearin g, N eedle Bearing, and O il Seal Ball and N eedl e Bearing R eplac ement CAUTION Do not remove the ball or needle bearings unless it is necessary . Removal may dam age them. • Using a press or puller , remove the ball bearing and/or three needle bearings. NOTE ○ In the absence of the a bove mentioned [...]

[...]

WHEELS/TIRES 1 1-1 11 Wheels/T ires T able of Co ntents Exploded V iew .......... ............ .............. ......... ............ ........... .......... ............ ......... ............ .... .... . 1 1-2 Spec ifica tion s ..... ....... ...... .... ...... ...... ..... ...... ...... .... ...... ...... ....... .... ...... ...... .... ....... ...[...]

1 1-2 WHEELS/T IRES Exploded View[...]

WHEELS/TIRES 1 1-3 Exploded View T orque No. Fastener N·m kgf ·m ft·l b Remarks 1 T ie-rod Locknuts 37 3.8 27 2 T ie-rod End Nuts 42 4.3 31 3 Wheel Nuts (First T orque) 15 1.5 11 S 3 Wheel Nuts (Final T orque) 76 78 56 S 4 Front Axle Nuts 197 20 145 5 Rear Axle Nuts 265 27 195 R: Replacement Parts S: Follow the specific tighteni ng sequence. W: [...]

1 1-4 WHEELS/T IRES Specifications Item Standard Service Limit Wheel Alignment T oe-in of front wheels: –10 ∼ 10 mm (–39 ∼ 0.39 in.) at 1G ––– Ti re s Standard tire: Front AT 2 5 × 8 - 1 2 ––– DUNLOP , KT191, Tubel ess Rear A T 25 × 10-12 ––– DUNLOP , KT195, Tubel ess T ire air pressure ( when cold): Front 35 kPa (0.35 k[...]

WHEELS/TIRES 1 1-5 Special T ool Jack: 57001-1 238[...]

1 1-6 WHEELS/T IRES Wheel Alignment T oe-in is the amount that the f ront wheels are cl oser to- gether in f ront than at the rear at the axle height. When there is toe-in, the distance A ( Rear) is the greater than B (Front) a s shown. The purpose of toe-in i s to prevent the f ront wheels fr om getting out of parallel at any t ime, and to prevent[...]

WHEELS/TIRES 1 1-7 Wheel Alignme nt • Repeat the straight edge procedure on the other si de of the vehicle. Now the front wheels are parallel to e ach other and to the center li ne of the vehicle. Front Wheel [A] V ehicle Center Line [B] Parallel eac h other [C] Straightedges [D] Rear Wheels [E] • Go on to the T oe-in Inspection procedure. T oe[...]

1 1-8 WHEELS/T IRES Wheel Alignment NOT E ○ The toe-in will be near the specified v alue, if the t ie-rod length [A] is 393.3 mm (15.48 in.) on each tie- rod. CAUTION Adjust the tie-rod length so that the visible thread length [B] is even on both ends of the tie-r od. Un- even thread length could cause tie-rod damage. • Check the toe-in. • T [...]

WHEELS/TIRES 1 1-9 Wheels (Rims) Wheel Removal • Loosen the wheel nuts [A]. • Support the vehicle on a stand or a j ack so that the wheels are off the ground. Spec ial T o ol - Jack: 5 7001-123 8 • Remo ve : Wheel Nuts Wheel Wheel Installation • Check the tire r otation mark [A] on the t ire, and i nstall t he wheel accordingly . NOTE ○ T[...]

1 1-10 WHEELS/TIRES Wheels (Rims) If the tire is r emoved, inspect the air seali ng surfaces [A] of the r im for scrat ches or nic ks. Smooth the sealing sur- faces wit h fi ne emery clot h if neces sary . Wheel (Rim) Replacement • Remove the wheel (see Wheel Removal). • Disassemble the tire from the ri m (see T ire Removal). ○ Remove the air[...]

WHEELS/TIRES 1 1-1 1 Tire s Tire Removal • Remove the wheel. • Unscrew the valve co re to deflate th e tire. ○ Use a proper valve core tool [A]. • Lubricate the tire beads and rim flanges on both sides of the wheel with a soap and water solution, or water [A]. This helps the tire beads slip of f the rim flanges. CAUTION Do not lubricate the[...]

1 1-12 WHEELS/TIRES Tir e s • Support the wheel rim [A] on a suitabl e stand [B] to pre- vent the t ire fr om slipping of f. • Inflate t he tire until the ti re beads seat on the rim. Maximum Tire Air Pres sure (to seat beads when cold ) Front and Rear: 2 50 kPa (2.5 kgf/cm² , 36 psi) W ARNING Do not inflate t he tire to more than the maximum [...]

WHEELS/TIRES 1 1-13 Front Hub Front Hub Removal • Remo ve : Cap [A] Cotter Pin [B] (cut) • Loosen the axle nut [C]. • Remove the wheel (see Wheel Removal). • Remove the caliper by taking of f t he mounting bolts , and let the caliper hang free. • Remove the axle nut [A] and pull of f the front hub [B] and brake disc. • Separate the brak[...]

1 1-14 WHEELS/TIRES Front Hub Front Hub Disasse mbly/Assembly If any hub bolt [A] is damaged, replace it. • Remove the hub bolt from hub [B] using a press. • Press the hub bolt using a pr ess.[...]

WHEELS/TIRES 1 1-15 Rear Hub Rear Hub Removal • Remo ve : Cap [A] Cotter Pin [B] • Loosen the axle nut [C]. • Remo ve : Wheel (see Wheel Removal) Axle Nut [A] Rear Hub [B] Rear Hub Install ation • Wipe dry the s pline p ortion o f the hub. • Wipe dry the thread s and seating surface of the nuts. • T ighten: T orque - Rear Axle Nuts: 265[...]

1 1-16 WHEELS/TIRES Rear Hub Rear Hub Disassembly/Assembly If any hub bolt [A] is damaged, replace it. • Remove the hub bolt from hub [B] using a press. • Press the hub bolt using a pr ess.[...]

FINAL DRIVE 12-1 12 Final Drive T able of Co ntents Exploded V iew .......... ............ ............. 12-3 Spec ifica tions . .... ....... ...... .... ...... ...... .. 12-1 0 Spec ial T o ols .... ....... ...... .... ...... ...... .... 12-1 1 Out put Beve l G ears . ...... .... ...... ...... .... 1 2-14 Output Drive Bevel Gear Re mova l ..... ..[...]

12-2 FINAL DRIVE Rear Final Gear Case Assembly . 12-65 Rear Final Bevel Gear Adjus tme nt .... ....... ...... ...... .... ..... 12 -68 Pinion Gear Unit Disassembly ..... 12-72 Pinion Gear Unit Assembly .......... 12-72 Bear ing a nd Oil Se al... ...... ....... .... ...... 1 2-73 Ball or Needle Bearing Inspection 12-73 Oil Sea l Inspe ctio n .... ..[...]

FINAL DRIVE 12-3 Exploded View Blank page[...]

12-4 FINAL DRIVE Exploded View[...]

FINAL DRIVE 12-5 Exploded View T orque No. Fastener N·m kgf ·m ft·l b Remarks 1 Output Driven Bevel Gear Housing Bolts 26 2.7 20 2 Output Drive Bevel Gear Housing Bolts 26 2.7 20 3 Bearing Holder 137 14 101 L 4 Bevel Gear Holder Nut 157 16 11 6 L 5 Bearing Holder 11 8 12 87 L 6 Output Shaft Holder Nut 157 16 11 6 L 7 Rotor Mounting Bolts 12 1.2 [...]

12-6 FINAL DRIVE Exploded View[...]

FINAL DRIVE 12-7 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 V ariable Diff erenti al Control Shift Shaft Lever Bolt 8.8 0.90 78 in·lb 2 Front Final Gear Case Left Cove r Bolts (M6) 9. 8 1.0 87 in·l b L(4), S 3 Ring Gear Bolts 57 5.8 42 LB 4 Front Final Gear Case Center Cover Bolts (M6) 9. 8 1.0 87 in·l b L 5 Front Final Gear[...]

12-8 FINAL DRIVE Exploded View[...]

FINAL DRIVE 12-9 Exploded View T orque No. Fastener N·m kgf· m ft·l b Remarks 1 Rear Final Gear Case Front Cover Bol ts 24 2.4 17 2 Gask et Screw s 1.3 0.13 11 i n · l b 3 Pinion Gear Bearing Holder Nut 157 16 11 6 L 4 Pinion Gear Bearing H older 137 14 101 L 5 Rear Final Gear Case Right Cover Bolts (M12) 93 9.5 69 L 6 Rear Final Gear Case Righ[...]

12-10 FINAL DRIVE Specifications Item Standard Servic e Limit Output Bevel Gear Case Output Bevel Gear Backlash 0.05 ∼ 0.1 1 mm (0.0020 ∼ 0.0043 in.) ––– (at output drive shaft spline) Front Final Gear Case Gear Case Oil (same engine oil): Ty p e API SF or SG ––– API SH or SJ with JASO M A class ––– Viscos ity SAE 10W-40 –?[...]

FINAL DRIVE 12-1 1 Special T ools Bearing Pulle r: 57001-1 35 Steeri ng Stem Bea ring Drive r: 57001-1 37 Inside Circl ip Pliers: 57001-1 43 Outside Circ lip Pliers: 57001-1 44 Oil Seal & Beari ng Remover : 57001-1 058 Bear in g Dri ver Se t: 57001-1 129 Rotor Puller , M16/M18 /M20/M2 2 × 1.5: 57001-12 16 Pinion G ear Holder: 57001-12 81 Socke[...]

12-12 FINAL DRIVE Special T ools Socket Wrench , Hex 50: 57001-14 78 Outpu t Shaft Ho lder & Spa cer , m 1.25: 57001-14 79 Nut Holding Bolts: 57001-14 81 Socket Wenc h: 57001-14 82 Socket Wrench , Hex 41: 57001-14 84 Pinion G ear Holder , m 1.0: 57001- 1485 Bearin g Driver , 54.3 : 57001- 1488 Gear H older & Socket Wrench, Hex 24: 57001- 14[...]

FINAL DRIVE 12-13 Special T ools O i lS e a lD r i v e r , 70: 57001-1 506 Output Shaft Holde r: 57001-15 70[...]

12-14 FINAL DRIVE Output Bevel Gears Output Drive Bevel Ge ar Removal • Remove: Oil Pipe [A] (Engine Lef t and Outside, see Engi ne Lubri- cation System chapter) Output Drive Bevel Gear Cover B olts [B] Output Drive Bevel Gear Cover [C] • Remove: Circlip [A] Special T ool - Outside Ci rclip Pliers: 57001-144 • Remove: Output Drive I dle Gear [...]

FINAL DRIVE 12-15 Output Bevel Gear s • Apply grease: O-rings [A] • Install: Output Drive Bevel Gear Cover [B] • T ighten: T orque - Output Drive Bevel Gear Cover Bolt s [C]: 8.8 N·m (0.90 kgf·m, 78 in·lb) • Install: Forward/Reverse Detect ing Sensor [A] • T ighten: T orque - Forward/Reverse Detecting Sensor Mounting Bolt: 15 N·m (1.5[...]

12-16 FINAL DRIVE Output Bevel Gears • Hold the output drive bevel gear housing [A] in a vise. • Loosen the bevel gear [B] using an Allen wrench about four rotat ions. • Remove one nut holding bolt, and look at through the hole. If the groove of the bevel gear holder nut is not seen, loosen the ot her three bol ts. • Drive the gear shaft en[...]

FINAL DRIVE 12-17 Output Bevel Gear s Output Dri ve Bevel Gear Assembl y • Press the new inner ball bear ing until it is bottomed. Spec ial T o ol - Bearing Driver S et [A]: 57 001-1 12 9 • Apply a non-permanent locking agent to the threads of the bearing hol der [A] a nd tighten i t so that the deep side [B] faces outward. T orque - Bearing Ho[...]

12-18 FINAL DRIVE Output Bevel Gears • T ap lightly the fro nt end [A] of the output drive n bevel gear shaft us ing a plas tic malle t. ○ The output driven bevel gear s haft assembly comes of f with the housing. Output Dri ven Bevel Gear Insta lla tion • Apply grease: O-ri ng [A] • Install the out put driven bevel gear shaft assembly . •[...]

FINAL DRIVE 12-19 Output Bevel Gear s • Hold the housing assembly [A] with t he holder [B] in a vise. Spec ial T o ol - Holder & Guide A rbor: 5 7001-14 76 • Remo ve : Bearing Holder [C] Spec ial T o ol - Socket Wrench, He x 50 [D]: 57001- 1478 ○ If the holder seems too dif fic ult to break free, apply heat to softer the l ocking agent . [...]

12-20 FINAL DRIVE Output Bevel Gears • Apply a non-permanent locking agent to the threads of the bearing ho lder [A] and t ighten it . Specia l T ool - S ocket Wrench , Hex 50 [B]: 570 01-1478 T orque - B earing Holder: 13 7 N·m (14 kgf·m, 101 ft·lb) • Hold the holder [A] in a vise, and set the output shaft [ B] on the holder . Special T ool[...]

FINAL DRIVE 12-21 Output Bevel Gear s Output Bevel Gear (Backl ash-related Parts ) 1. Ball Bearings 2. Drive Bevel Gear Shims 3. Output Drive Bevel Gear 4. Bearing Housings 5. Output Driven Bevel G ear 6. Output Driven Shaft 7. Driven Bevel Gear Shims Drive Bevel Gear Shims for T ooth Contact Adjustment Thic kness Par t Number 0.15 mm (0.0 06 in.) [...]

12-22 FINAL DRIVE Output Bevel Gears Bevel Gear Backlash Adjustment ○ The amount of backlash is influenced by driven bevel gear position more than by drive bevel gear position. • Remove the output drive idl e gear (see Output Drive Bevel Gear Removal). • Set up a dial gauge [ A] against t he output dri ve shaft spline gr oove to check gear ba[...]

FINAL DRIVE 12-23 Output Bevel Gear s Example 1: Decrease the thickness of the drive bevel gear shim(s) by 0.1 mm (0.004 in.), and/or increas e the thickness of the driven bevel gear shim(s) by 0.1 mm (0.004 in.) to correct the pattern shown bel ow . Repeat in 0.1 mm (0.004 in.) steps if necessary . Example 2: Increase the t hickness of the dri ve [...]

12-24 FINAL DRIVE Output Bevel Gears Bevel Gears Inspecti on • V isually check the be vel gears [ A] for scoring, chippi ng, or other damage. Replace the bevel gears as a set if either gear is dam- aged.[...]

FINAL DRIVE 12-25 Front Propeller Sha ft Fron t Prop eller S haft Rem ova l • Slip the O-r ing cla mps of f the gr ooves on the smal l rubber boots [A], and then pull the boot. • Push the front prop eller shaft [ A] rearward, and remove the front end [B] from the front final gear case. • Remove the front propeller shaft fr om the vehicle. Fro[...]

12-26 FINAL DRIVE Front Axle Front Axle Remo val • Drain the front fi nal gear case oil (see Fron t Final Gear Case Oil Change in Peri odic Maintenance chapt er). • Remove: Front Wheel (see Wheels/T ires chapter ) Knuckle (see Steering chap ter) • Pull the front axle [A] in a s traight li ne out of the front fi nal gear case. Front Axle Insta[...]

FINAL DRIVE 12-27 Front Axle • T ap the bearing housing [A] straight [B] with a plas tic ham- mer to separate it from the shaf t. CAUTION Do not tap on the cage. Be careful not get hurt when the housing comes out. If the spli ned portion of shaft cracked or damaged during disassembling of outboard joint, do not reuse the shaft . • Remo ve : Cir[...]

12-28 FINAL DRIVE Front Axle ○ T ighten t he boot band [A] and bend the tangs [B ] securely to hold down the end of the band. • Place the special greas e tube nozzle in the bore of the housing and squeeze the tube [A] until the grease comes out from the joint bearing. • T ap the shaft end [A] straight with a plastic hammer until it is lock ed[...]

FINAL DRIVE 12-29 Front Axle Left Front Axle: 178.6 mm (7.03 in.) [A] • Open the edge [A] of the boot in order to equalize the air pressures. • T ighten the large band [A] and bend the tangs securel y to hold down the end of the band. Maximum Outside Diameter of Band: 80.2 mm (3.16 in.) (After tightening the outside diameter ) Inboard Joint Boo[...]

12-30 FINAL DRIVE Front Axle • Rem ove the s teel bal ls [A]. • Slide the cage [B] toward the center of the axle. • Remove: Circlip [A] Specia l T o ol - Out side Cir clip Plie rs [B] : 57001 -144 • Remove the i nner rac e [A] usi ng a suit able beari ng re- mover [B]. • Remove the inboard joint boot [C]. Inboard Joint B oot Installati on[...]

FINAL DRIVE 12-31 Front Axle • Press the inner race [A] using th e cap [B] in the rotor puller set (57001-1216) until it is bott omed. Spec ial T o ol - Rotor Puller , M16/M 18/M20 /M22 × 1.5: 570 01 -1216 • Install: Circ lip [A] Special T ool - Ou tside Circlip Pliers: 5700 1-144 • Slide the cage [B] on the inner race and install the steel [...]

12-32 FINAL DRIVE Front Axle • Install t he new retai ning ring [A] so that the opening [B] is aligned wi th one of the pr ojecti ons [C]. • T ighten the small band. • Squeeze the remaini ng special greas e [A] into t he inboard joint boot [B] . • Compress the axle assembl y to the specifie d length while relievi ng the air pressure ins ide[...]

FINAL DRIVE 12-33 Front Axle • While the band is held at the di ameter above, tap down the tangs [A] of t he clamp.[...]

12-34 FINAL DRIVE Front Final G ear Case Front F inal Ge ar Case Oi l Level In spection • Park the vehicl e so that it is level, both side-to-side and front-to-r ear . • Remove the filler cap. CAUTION Be careful not to allow any dirt or foreign materi als to enter the gear case. • Check the oil l evel. The oil lev el should come to t he bot- [...]

FINAL DRIVE 12-35 Front F inal Gear C ase V ariable Dif ferent ial Contr ol Cable Inst all ation • Lubrication t he variable d if ferenti al contro l cable befor e installat ion. • Route the cable correct ly accor ding to the Appendi x chap- ter . W A RNING Operation with an improperly adjusted, incor rectly routed, or damaged cable could resul[...]

12-36 FINAL DRIVE Front Final G ear Case • Remove: Front Fender (see Fr ame chapter) Front Wheels (see Wheels/T ires chapter) Steering Stem (see Steering chapter ) Front Axles (see Front Axle Removal) Right Upper Suspension Arm (see Suspension chapter) Right Front Shock Absorber (see Suspension ch apter) Front Propeller Shaft (see Front Propeller[...]

FINAL DRIVE 12-37 Front F inal Gear C ase Front Final Gear Case Disassembly • Remo ve : Front Final Gear Case (see Front Final Gear Case Re- moval) V ariable Diff erential Contr ol Shift Shaft Lever Bolt [A] and Nut [B] V ariable Differ ential Control Shift Shaft Lever [C] 2WD/4WD Actuator (see Electrical System chapte r) • Hold the fron t fina[...]

12-38 FINAL DRIVE Front Final G ear Case • Remove: Housing [A] and Dif ferential Dis c Assembly [B] Inner Disc Needle Bearing • Remove: Cam Plate [A] • Remove: Steel Balls [A] Gas ket [ B] Dowel Pins [C] Front Final Gear Case Center Cover Bolts (M6) [D] Front Final Gear Case Center Cover Bolts (M8) [E] Front Final Gear C ase Center Cover [F] [...]

FINAL DRIVE 12-39 Front F inal Gear C ase • Remo ve : Pinion Gear Unit [A] Shim(s) Front Final Gear Case Coupli ng Inspection If the coupling bushing [A] is damaged or worn, replace the front fi nal gear case coupli ng. Front Final Ge ar Case Coupling Bushing Insi de Diameter [B] Stand ard: 13.000 ∼ 13.0 18 mm (0. 51 18 ∼ 0.5125 in.) Servic e[...]

12-40 FINAL DRIVE Front Final G ear Case • Inst all: Ring Gear Assembly • Apply grease to the O-ring [ A] on the front final gear case center cover . • Inst all: Front Final Gear C ase Center Cover [A] • T ighten the cover bolts following the t ightening sequence as shown. T orque - Front Final Gear Case Center Cover Bolts (M8) [1, 3]: 24 N[...]

FINAL DRIVE 12-41 Front F inal Gear C ase • Install: Cam Lever [A] Needle Bearing [B] • Apply engine oil to the needle bearing. • Check the wear of the disc assembly as follows. ○ Measure the thickness of the i nner disc [A]. • Select the widt h [A] of the disc asse mbly [B] in accorda nce with the thickness of the inner disc, refer to th[...]

12-42 FINAL DRIVE Front Final G ear Case • Apply engine oil to the needle bear ing [A]. • Inst all: Needle Bearing Out er Di sc [B] • Apply engine oil to the variable front dif ferential control shaft [A]. • Install the s haft and spring [ B] in the fr ont final gear case left cover [C] as shown. • T urn the shaft counterclockwise and in [...]

FINAL DRIVE 12-43 Front F inal Gear C ase • Apply molybdenum disulfi de grease to t he spline [A] i n the shifter [B] and inner sur face [C] of the coupling. • Install the shift er and coupling on the pinio n gear shaft [D]. • Apply grease to the oil seal li p [E]. • Press the oil seal [F] in the front fi nal gear case so that the oil seal [...]

12-44 FINAL DRIVE Front Final G ear Case Ring Gear Disassembly • Remove: Ring Gear Assembly (see Front Final Gear Case Disas- sembly) Ring Gear Bolts [A] Ring Gear [B] • Remove: Diff erential Gear Case Cover [A] Right Side Gear (16T) [B] Pins [C] Spider Gear Shaft [D] Spider Gears (10T) [E] Left Side Gear ( 16T) [F] Left Diff erential Gear Case[...]

FINAL DRIVE 12-45 Front F inal Gear C ase LSD Clutch T or que In spec tion If the vehicle has the foll owing symptoms, check the LSD (Limited Sl ip Dif ferential) c lutch torq ue. -The handlebar is hard to t urn. -The front fi nal gear cas e overheats. -Abnormal noises come from the front fi nal gear case when rounding a curve. • Ensure 2WD mode.[...]

12-46 FINAL DRIVE Front Final G ear Case Pinion Gear Unit Assembly ○ The pinion gear and ring gear are lapped as a set in the factory to get the best tooth contact. They must be re- placed as a set. • V isually inspect the bearing f or abrasion, color change, or other damage. If there is an y doubt as to the condition of a beari ng, re- place t[...]

FINAL DRIVE 12-47 Front F inal Gear C ase Fron t Fin al Gear C ase (Ba cklas h-re lated P art s) 1. Pinion Gear Shim(s) 2. Ring Gear Right Shim(s) 3. Ring Gear Left Shim(s) 4. Front Final Gear Case Center Cover 5. Front Final Gear Case Right Cover 6. Ball Bearings 7. Ring Gear 8. Ring Gear A ssembly 9. Pinion Gear[...]

12-48 FINAL DRIVE Front Final G ear Case 1. Pinio n Gear Shims for Backl ash Adjust ment Thickn ess Part Num ber 0.15 mm (0.00 6 in.) 92180-1408 0.2 mm ( 0.008 in.) 921 80-1409 0.5 mm ( 0.020 in.) 921 80-1410 0.7 mm ( 0.028 in.) 92180-14 1 1 0.8 mm ( 0.031 in.) 921 80-1412 0.9 mm ( 0.035 in.) 921 80-1413 1.0 mm ( 0.039 in.) 921 80-1414 1.1 mm ( 0.0[...]

FINAL DRIVE 12-49 Front F inal Gear C ase • Mount a dial gauge [A] so t hat the tip of the gauge is against the spli ned portion [B] of the pinion gear shaft. • T o measure the backlash, move the pinion gear shaft back and fort h [C] whil e holding t he front axl e steady . The diffe rence between the highest and the lowest gauge reading is the[...]

12-50 FINAL DRIVE Front Final G ear Case ○ The tooth contact patterns of both (dri ve and coast) si des should be centrally l ocated between the top and bott om of the toot h. The drive pattern can be a little cl oser to the toe and the coast pattern can be a somewhat longer and closer to t he toe. If the tooth contact pattern is i ncorrect, repl[...]

FINAL DRIVE 12-51 Front F inal Gear C ase[...]

12-52 FINAL DRIVE Rear Propelle r Shaft Rear Prop eller Sh aft Removal • Remove: Footboard (see Frame chapter) • Slide the rubber boots [A]. • Push the front universal joi nt [B] rearward, and remove the front end [C] from the engine. • Remove the rear propell er shaft [A] from t he vehicle. Rear Pro peller S haft Insta llati on • Wipe of[...]

FINAL DRIVE 12-53 Rear Propeller Sha ft • Apply molybdenum disulfide grease: Spline [A] on Output Shaft of Engine Spline [B] on Pinio n Gear of Rear Final Gear Case • Install: O-rings [C] Spring [D] Rear Universal Joint [E] • Align the front uni versal join t yoke [F] with t he rear univer- sal joint yoke [G] as shown. • Install t he front [...]

12-54 FINAL DRIVE Rear Axle Rear Axle Removal • Drain the r ear final gear case oil (se e Rear Final Gear Case Oil Change). • Remove: Rear Wheels (see Wheels/T ires chapter) Rear Knuckle (see Suspension chapter) Upper Suspension Arm [A] (see Suspension chapter ) • Pull the rear axle [A] in a str aight line out of the rear fi nal gear case. Re[...]

FINAL DRIVE 12-55 Rear Axle Rear Axle Join t Boot Repl acement Outboard Joint Boot R emoval • Remo ve : Rear Axle (see Rear Axle Removal) Boot Bands [A] • Scrap the removed boot bands. • Slide the joi nt boot [B] toward the inboard j oint. • T ap the bearing housing [A] straight [B] with a plas tic ham- mer to separate it from the shaf t. C[...]

12-56 FINAL DRIVE Rear Axle • Apply the special grease slightl y on the part [A] of the band install ation in orde r to make easy to inst all the boot band. • T ighten the small boot band [B]. ○ T ighten t he boot band [A] and bend the tangs [B ] securely to hold down the end of the band. • Place the special greas e tube nozzle in the bore [...]

FINAL DRIVE 12-57 Rear Axle • Compress the axle assembly to the speci fied lengt h while relieving th e air pressure inside the inboar d boot. • Hold the axle at this set ting. Standard Length of Assembling: Outboard: 216.2 mm (8.51 in.) [A] • Open the edge of the boot in order to equalize the air pressures. • T ighten the large band [A] an[...]

12-58 FINAL DRIVE Rear Axle • Remove: Circlip [A] Specia l T o ol - Out side Cir clip Plie rs [B] : 57001 -144 • Remove: Inner Race [A] Cage [B] Inboard Joint Boot [C] Boot Band [D] Inboard Joint B oot Installati on • Inst all: New Small Band [A] New Inboard Joint Boot [B] Cage [C] • Install the inner r ace [A] so that the flat side [B] fac[...]

FINAL DRIVE 12-59 Rear Axle • Apply the specia l grease [ A] to the st eel balls and cage. • Squeeze about half a tube (30 grams ) of the special grease [A] into the b earing cup [B]. • Insert the balls and cage assembly in the bearing cup strongly . • Install the new retaining ring [A] so that the ope ning [B] is aligned with one of the pr[...]

12-60 FINAL DRIVE Rear Axle • Compress the axle assembl y to the specifie d length while relievi ng the air pressure ins ide the inboard boot. • Hold the axl e at this sett ing. Standard Length of Assembling: Inboard: 174.6 mm (6.87 in.) [A] • Open the edge of the boot i n order to eqaliz e the air pres- sures. • T ighten the large band [A][...]

FINAL DRIVE 12-61 Rear Final Gear Case Rear Final Gear Case Oi l Leve l Inspecti on • Park the vehicle so that it is level, both side-to- side and front-to- rear . • Remo ve the fille r cap. CAUTION Be careful not to allow any dirt or foreign material s to enter the gear case. • Check the oil level . The oil l evel should come to the bot- tom[...]

12-62 FINAL DRIVE Rear Final Gear Case • Remove the rear final gear case [A] as shown. Rear Final Gear Case Install ation • Inst all: Rear Final Gear Case Bracket [A] Collars [B] Bracket Bolts [C] [D] Front [E] Hole W ashers (rear si de) • Apply a non-permanent locki ng agent (Three Bond 1363A, Red) to the rear final gear case nuts. • T igh[...]

FINAL DRIVE 12-63 Rear Final Gear Case • Remo ve : Rear Final Gear Case Front Cover Bolts [A] Rear Final Gear Case Front Cover Assembl y [B] • Remo ve : Gasket Screws [A] Gasket [B] • Remo ve : Set Pins [A] with Steel Plates [B] and Fri ction plates [C] • Remo ve : Brake Cam Plate [A] Brake Camshaft [B] and S pring • Remo ve : Steel Balls[...]

12-64 FINAL DRIVE Rear Final Gear Case • Remove: Pinion Gear Bearing Holder [A] ○ Hold the rear fi nal gear case [A] in a vise, an d remove the bearing holder using the socket wrench [B]. Specia l T ool - So cket Wren ch, Hex 50: 57 001-1478 ○ If the holder seems too dif f icult to break f ree, apply heat to softer the locking ag ent. • Rem[...]

FINAL DRIVE 12-65 Rear Final Gear Case Rear Final Gear Case Right Cover Assembly [A] Rear Final Gear Case Right Cover • Press: Ball Bearing (unti l bottomed) Spec ial T o ol - Bearing Dr iver , 54.3 [B] : 57001-1 488 [A] Rear Final Gear Case Right Cover [B] Ball Bear ing • Press: Oil Seal [C] (until bot tomed) Spec ial T o ol - Bearing Driver S[...]

12-66 FINAL DRIVE Rear Final Gear Case When installing a new pinion gear bearing holder [A], in- stall the holder so tha t the no coating area [B] (one pitch thread) faces gear case [C]. [D] Locking Agent Coating Area • Inst all: Brake Camshaft [A] Spring [B] • Inst all: Steel Balls [A] • Inst all: Brake Cam Plate [A] ○ Fit the cam plate an[...]

FINAL DRIVE 12-67 Rear Final Gear Case • Install (al ternately) : Fricti on Plates [A] Steel Plates (P/ No. 41080-1484, without hol es) • Install: Steel Plate [A] (P/No. 41080-1483, two holes) ○ Insert the pins [B] into the holes of steel pl ate. • Install: Dowel Pins [A] New Gasket [B] • T ighten: T orque - Gasket S crews [C] : 1.3 N· m[...]

12-68 FINAL DRIVE Rear Final Gear Case • Inst all: Shim [A] Rear Final Gear Case Right Cover [B] • Apply a non-permanent locking agent to the rear final gear case right cover bolts. • T ighten: T orque - Rear Final Gear Case Right Cover Bolts (M12) [A]: 93 N·m (9.5 kgf·m, 69 ft·lb) Rear Final Gear Case Right Cover Bolts (M10) [B]: 49 N·m [...]

FINAL DRIVE 12-69 Rear Final Gear Case Rea r Fina l Gea r Ca se (Ba cklas h-re lated P arts) 1. Pinion Gear 2. Pinion Gear Bearing Holder 3. Gear Case R ight Cover 4. Ball Bearings 5. Ring Gear 6. Pinion Gear Shim(s) 7. Ring Gear Shim(s) 8. Ring Gear Shim(s)[...]

12-70 FINAL DRIVE Rear Final Gear Case 6. Pinio n Gear Shims for Backl ash Adjust ment Thickn ess Part Num ber 0.15 mm (0.00 6 in.) 92180-1423 0.2 mm ( 0.008 in.) 921 80-1424 0.5 mm ( 0.020 in.) 921 80-1425 0.8 mm ( 0.031 in.) 921 80-1426 1.0 mm ( 0.039 in.) 921 80-1427 1.2 mm ( 0.047 in.) 921 80-1428 7. Ring Gear Shims for T ooth Contact Adjustmen[...]

FINAL DRIVE 12-71 Rear Final Gear Case If the backl ash is not within the st andard, replace the pinion gear shim (s). T o increase backlas h, increase the thickness of the shim(s). T o decrease backlash, decrease the thickness of the shim(s). Change the thick ness a lit tle at a time. • Recheck the backlash, and readjust as nec essary . T ooth C[...]

12-72 FINAL DRIVE Rear Final Gear Case Pinion Gear Unit Disassembly • Remove: Pinion Gear Unit [A] (see Rear Final Gear Case Disas- sembly) • Hold the pinion gear bearing holde r nut [B] with the socket wrench [C] in a vise, and loosen the pi nion gear shaft using the pinion gear holder [D] . Specia l T ools - S ocket Wrench: 5 7001-136 3 Pinio[...]

FINAL DRIVE 12-73 Bearing an d Oil Seal Ball or Ne edle B earing I nspection Since the bearings are made to extr emely close toler- ances, the clearance cannot normal ly be measured. CAUTION Do not remove any bearings for inspection except the right rear axle bearing. • T urn each bearing in the case or hub back and forth [A] while checking for p[...]

12-74 FINAL DRIVE Bearing and Oil Seal O i lS e a lI n s p e c t i o n • Inspect the oil seals [ A]. Replace any if the l ips are misshapen, discolored ( indicat- ing that the rubber has deteriorated) , hardened, or been otherwise damaged.[...]

BRAKES 13-1 13 Brakes T able of Co ntents Exploded V iew .......... ............ ............. 13-2 Spec ifica tions . .... ....... ...... .... ...... ...... .. 1 3-6 Spec ial T o ol .... ...... ....... .... ...... ...... ...... 13 -7 Bra ke Fluid . ...... .... ....... ...... ...... .... ...... 13-8 Brake Fluid Recommendation..... . 13-8 Brake Flui[...]

13-2 BRAKES Exploded View[...]

BRAKES 13-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Reservoir Cap Screws 1.5 0.15 13 in·lb 2 Brake Lever Pivot Bolt 6.0 0.60 52 in·lb 3 Brake Lever Pivot Bolt Locknut 6.0 0.60 52 in·lb 4 Master Cylinder Clamp Bolts 9.0 0.92 80 in·l b S 5 Brake Hose Banjo Bolts 25 2.5 18 6 Brake Caliper Mounting Bolts 25 2.5 18 7 Bleed V [...]

13-4 BRAKES Exploded View[...]

BRAKES 13-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Rem arks 1 V ariable Dif ferential Control Lever Bolt – – – L 2 Gasket Screws – – – L 3. Bend both hooks after installi ng the spring. G: Apply grease. L: Apply a non-permanent locking agent. MF: Apply MOBIL FLUID 424 or equivalent oil. R: Replacement Parts[...]

13-6 BRAKES Specifications Item Standard Servic e Limit Brake Fluid Ty p e DO T 3 or DOT 4 –– – Front Disc Brake Pad lining thickness 4.0 mm (0.16 in.) 1 mm (0.04 in. ) Disc thickne ss 3.3 ∼ 3.7 mm (0.130 ∼ 0.146 in.) 3 mm (0.12 in. ) Disc runout TIR 0 .4 mm (0.016 in. ) or less TI R 0.5 mm (0.020 in.) Rear Brake Lever , Pedal and Cables [...]

BRAKES 13-7 Special T ool Inside Circl ip Pliers: 57001-1 43[...]

13-8 BRAKES Brake Fluid W ARNING 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 container that has been left unsealed or that has been open f or a long time. 3. Do not mix two types and brands of flui d for use in the brake. This lowers t he brake fluid boi ling [...]

BRAKES 13-9 Brake Fluid Brake Lin e Air Bl eeding • Bleed the air whenever brake parts are replac ed or re- assembled. • Remove the reservoir cap and fill the reservoir with new brake fluid. • Slowly pump the brake l ever several times until no air bubbles can be seen rising up through the fluid from the hose at the bottom of the reservoir . [...]

13-10 BRAKES Master Cylinder Master Cyli nder Remov al • Remove: Brake Hose Banjo Bolt [A] Master Cylinder Clamp Bolts [B] Master Cylinder [C] CAUTION Brake fluid quickly ruins paint ed surface; any spilled fluid should be completel y washed away immediately . Master C ylinde r Installatio n • Align t he punch mark [A] on the handlebar with th [...]

BRAKES 13-1 1 Master Cylind er Master Cylinder Disassembly • Remo ve : Master Cylinder (see Master Cyl inder Removal) Brake Lever Pivot Nut [A] Brake Lever Pivot Bolt [B] Brake Lever [C] Dust Cover [D] Circ lip [E] Piston [F] Spring [G] Special T ool - Insi de Circlip Pliers: 57001 -143 CAUTION Do not remove the secondary cup [H] f rom the pis- t[...]

13-12 BRAKES Master Cylinder Master Cylin der Insp ection (V i sual Inspe ction) • Disassemble the m aster cyl inder (see Mast er Cylinder Disassembly). • Check that there a re no scratches, rust or pi tting on the inner wall of the mast er cylinder [A] and on the outsi de of the p iston [B ]. If the master cylinder or piston shows any damage, [...]

BRAKES 13-13 Calipers Caliper Removal • Remove the front wheel (see Wheels/ T ires chapter). • Loosen the banjo bolt [A] at the brake hose l ower end, and tighten it loosely . • Unscrew the caliper mounting bolts [B], and detac h the caliper [C] from the disc. • Unscrew the banjo bolt and remove the brake hose [D] from the caliper . CAUTION[...]

13-14 BRAKES Calipers Caliper Disassembly • Remove: Caliper (see Caliper Remova l) Pads (see Brake Pad Removal) Anti-ratt le Spring • Using compressed air , remove the piston. ○ Cover the caliper openi ng with a cl ean, heavy cl oth [A]. ○ Remove the piston by lightly applyi ng compressed air [B] to where the brake l ine fits i nto the cali[...]

BRAKES 13-15 Calipers • Apply brake fluid t o the outside of the pi stons [A], and push them into the cylinder by hand. T ake care that nei- ther the cylinder nor the piston skir t gets scratc hed. • Replace the rubber boots [B] if they ar e damaged. • Apply a thin coat of sil icone greas e to the caliper h older shafts [C] [D] (Silicone grea[...]

13-16 BRAKES Calipers Piston and Cyli nder Damag e • V isually inspect the pist on [A] and cylinder su rfaces [B]. Replace the cal iper if th e cylin der and pis ton are badly scored or rust y . Calip er Holder Sha ft We ar Inspect ion The caliper body must slide smoothly on the caliper holder shafts [A]. If the body does not slide smoothly , one[...]

BRAKES 13-17 Brake Pads Brake Pad Re moval • Detach the caliper from the disc (see Caliper Removal). • Remo ve : Pad Mounting Bolts [A] • Remo ve : Br ake P ads [ A] Brake Pad Install ation • Push the caliper piston in by hand as far as it will go. • Be sure that the ant i-ratt le spri ng is in pl ace. • Install: Brake Pads Pad Mounting[...]

13-18 BRAKES Brake Discs Disc Cleaning Poor braking can b e caused by oil on a di sc. Oil on a disc must be cleaned of f w ith an o illess cleani ng fluid such as trichloroet hylene or acetone. W ARNING These cleaning flui ds are usually highly flammabl e and harmful if breat hed for prolonged periods. Be sure to heed the fl uid manufacturer’s wa[...]

BRAKES 13-19 Brake Hoses Brake Hose Inspecti on • Refer to the Front Brake Hose and Connections Inspec- tion in the Periodi c Maintenance chapter . Brake Hose Re placement • Refer to t he Front Brake Hose Replacement in t he Peri- odic Maintenance chapter .[...]

13-20 BRAKES Rear Brake Lever , Pedal and Cables Brake Pedal P osition In spectio n NOT E ○ The position of the brake pedal has been decided by the position of the adjusting bolt [A]. • Check that the adjusti ng bolt is in the cor rect position as shown. Adjusting Bolt Position [B] Stand ard: 5 ∼ 6m m( 0 . 2 0 ∼ 0.24 in.) (betw een Frame an[...]

BRAKES 13-21 Rear Brake L ever , Ped al and Cab les Brake Pedal Instal lation • Apply grease: Brake Pedal Pivot [A] O-ring [B] • Install: Spring [A] Brake Pedal [B] • Apply grease: O-rings [C] • Install: Brake Cable J oint a nd Pin [D ] B r a k eS w i t c hS p r i n g[ E ] W ashers [F] • Replace the cotter pins [ G] with new ones. • Ben[...]

13-22 BRAKES Rear Brake Lever , Pedal and Cables • Remove: Circlip [A] Cotter Pin, W asher and Pin [B] Brake Pedal Cable [C] Brake C able Installatio n • Grease the brake cable f ront ends. • Replace the cotter pin with a new one. • Route the brake cables according to t he Cable, Wire, and Hose Routing secti on in Appendix chapter . • Adj[...]

BRAKES 13-23 Internal Wet Brake Internal Wet Brake Disassembly • Refer to Rear Final Gear Case section in Final Drive chap- ter . Internal W et Brake Assembly • Refer to Rear Final Gear Case section in Final Drive chap- ter .[...]

[...]

SUSPENSION 14-1 14 Suspension T able of Co ntents Exploded V iew .......... ............ .............. ......... ............ ........... .......... ............ ......... ............ .... .... . 14-2 Spec ifica tion s ..... ....... ...... .... ...... ...... ..... ...... ...... .... ...... ...... ....... .... ...... ...... .... ....... ...... ...[...]

14-2 SUSPE NSION Exploded View[...]

SUSPENSION 14-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remar ks 1 Front Shock Absorber Mounting Nuts 34 3.5 25 2 Front Suspension Arm Pivot Nuts 42 4.3 31 3 Front Knuckle Joi nt Nuts 29 3.0 22 G: Apply grease. R: Replacement Parts[...]

14-4 SUSPE NSION Exploded View[...]

SUSPENSION 14-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remar ks 1 Rear Shock Absorber Mounting Nuts 34 3.5 25 2 Stabilizer Holder Bol ts 23 2.3 17 3 Stabilizer Joint N uts 48 4.8 35 4 Rear Suspension Arm Pivot Nuts 48 4.8 35 5 Rear Knuckle Mounti ng Nuts 48 4.8 35 G: Apply grease. R: Replacement Parts RL: Apply rubber lubricant.[...]

14-6 SUSPE NSION Specifications Item S tandard Servi ce Lim it Shock Absorbers (Usable Range) Spring Prelo ad Setting Posit ion (Front and Rear) No.2 1 ∼ 5[...]

SUSPENSION 14-7 Special T ools Inside Circl ip Pliers: 57001-1 43 Outside Circ lip Pliers: 57001-1 44 Spring C ompres sor: 57001-1 087 Steering Ste m Nut Wrench: 57001-1 100 Jack: 57001-12 38[...]

14-8 SUSPE NSION Shock Absorbers Front Shock Abso rber Prel oad Adjus tment The spring adj usting sleeve [ A] on front s hock absorber has 5 positions so that the spring can be adjusted for dif fer- ent terr ain and loadi ng conditions. If the s pring acti on feels too soft or too stif f, adjust it in accordance with the following table. Spri ng Ac[...]

SUSPENSION 14-9 Shock Ab sorbers Fron t Sho ck Ab sorb er In spect ion • Check the bushings [A] i n the upper and lower pi vots. If bushings are worn, cracked, hardened, or otherwise damaged, replace them. Fron t Shoc k Abs orber Scr apping W A RNING Since the front shock absorber contains nitrogen gas, do not incinerat e or disassemble the fr on[...]

14-10 SUS PENSION Shock Absorbers Rear Shock Absorber Inst all ation • Apply grease to the i nside of bushing [ A] and grease s eal lips [ B]. • Inst all: Collar [C] • Inst all: Bushing [A] (press) • T ighten: T orque - Rear Shock Absorber Mounting Nuts [B]: 34 N·m (3.5 kgf·m, 25 ft·lb) Rear Shock Absorber Insp ection • Check the bushi[...]

SUSPENSION 14-1 1 Shock Ab sorbers • Remo ve : Spring Seat Stopper [A] • Remo ve : Spri ng Co mpres sor Spring Guide [A] Spring [B] Spring Adjust ing Sleev e [C] • Install: Spring Adjust ing Sleev e [A] • Install t he replaced spri ng [B] so that the small end faces downwards. • Install: Spring Guide • Use the spring compressor , and in[...]

14-12 SUS PENSION Suspension Arms Front S uspensio n Arm Removal • Remove: Front Wheels (see Wheels/T ires chapter) Wheel Hub [A] Bolt [B] and Brak e Hose [C] (from Suspensi on Arm) Brake Caliper (f rom Brake Disk) Knuckle Joint [D] (see Steer ing chapter) Front Shock Absorber Mounting Bolt [E] (lower) • Remove: Suspension Arm Pivot Bolt [ A] F[...]

SUSPENSION 14-13 Suspension Arm s Fron t Susp ensio n Arm In stallat ion • Clean the taper surface [A] of the suspension arm [B] and shank of the knuckl e joint. • Install: Front Upper Suspension Arm Front Lower Suspension Arm Suspension Arm Pivot Bolts and Nut (temporary) Knuckle Joint (see St eering cha pter) Front Shock Absorber Mounting Bol[...]

14-14 SUS PENSION Suspension Arms Front Susp ension Arm Assembly • Apply grease: Bal l Joint Be aring Needle Bearing • Install the foll owing parts as shown. Front Upper Suspension Arm Front [A] • Press the needl e bearing [ B] until it is stopped. • Press the ball joint bearing [C] unti l it is stopped. • Inst all: New Cir clip Special T[...]

SUSPENSION 14-15 Suspension Arm s Rear Suspension Arm Removal • Remo ve : Rear Wheels (see Wheels/T ires chapter) Mounting Bolts and Nuts [A] Rear Upper Suspension Arm [B] • Remo ve : Stabili zer Joint [A] ○ Hold the joint bolt with an Allen wrench [ B], and remove the nut [C]. • Remo ve : Mounting Bolts and Nuts [A] Rear Lower Suspension A[...]

14-16 SUS PENSION Suspension Arms Rear Suspension Arm Disassembly Rear Upper Suspension Arm • Remove out the bus hings [A] Front Lower Suspension Arm • Remove: Screw [A] Bolts [B] Collars [C] Axle Guard [D] Collars [E] (rear si de) Oil Seals [F] Circlips [G] Special T ool - Outside Ci rclip Pliers: 57001-144 • Remove: Ball Joint Bearing [H] ([...]

SUSPENSION 14-17 Suspension Arm s Rear Lower Suspension Arm • Install t he following parts as shown. Front Side [A]: Needle Bearing [B] 7.5 ±0.1 mm (0.295 ±0.00 4 in.) [C] Rear Side [A]: Circlip [ B] (front si de) Ball J oint B earing [C] Circlip [D ] (rear side) Special T ool - Insi de Circlip Pliers: 57001 -143 • Apply grease: Oil Seal Lips[...]

14-18 SUS PENSION Suspension Arms Stabilizer Insta llation • Inst all: Dampers [A] and Stabilizer [B] Stabilizer Holders [C] and Bolts • T ighten: T orque - Stabilizer Holder Bolts [D]: 23 N·m (2.3 kgf·m, 17 ft·lb) • Inst all: Stabilizer Joint s [E] ○ Hold the joint bolt with an Allen wrench, and t ighten the nut. T orque - Stabilizer Jo[...]

STEE RIN G 15-1 15 Steering T able of Co ntents Exploded V iew .......... ............ .............. ......... ............ ........... .......... ............ ......... ............ .... .... . 15-2 Spec ifica tion s ..... ....... ...... .... ...... ...... ..... ...... ...... .... ...... ...... ....... .... ...... ...... .... ....... ...... .....[...]

15-2 STEERING Exploded View[...]

STEERING 15-3 Exploded View T orque No. Fastener N·m kgf·m ft ·lb Remarks 1 Handlebar Holder Bolts 29 3.0 22 S 2 Steer ing St em C lamp B olts 25 2.5 18 3 T ie-rod End Nuts 42 4.3 31 4 T ie-rod Locknuts 37 3.8 27 5 Steering Stem Beari ng Joint Bolts 23 2.3 17 L 6 Steering Stem B ottom End Nut 62 6.3 46 7 Front Knuckle Joi nt Nuts 29 3.0 22 8 Mas[...]

15-4 STEERING Specifications Item Standard Service L imit Ti e-rods T ie-rod Length 393.3 mm (15.48 in.) –––[...]

STEE RIN G 15-5 Special T ools Inside Circl ip Pliers: 57001-1 43 Bear in g Dri ver Se t: 57001-1 129[...]

15-6 STEERING Steering Steer ing Stem R emova l • Remove: Front Fender (see Fr ame chapter) Handlebar (see Handlebar Removal) Cotter Pins and T ie-rod End Nuts [A] Steering Stem Bearing Joint Bol ts [B] (r ight and left ) CAUTION Do not loosen the locknuts [C] at the ends of the tie-rod adjusti ng sleeve, or the toe-in of the front wheels will be[...]

STEERING 15-7 Steering • Apply a non-permanent l ocking agent: Steering St em Bearing Joint Bolts [A] • T ighten: T orque - Ste ering Stem Bearing Joint Bolts : 23 N·m (2 .3 kgf·m, 17 ft·lb) • Apply Amoco Rykon Premium Grease No.2 EP (Green): Inside of Steering Cla m p [A] Oil Seals [B] • Install: Collars [A] • Apply above grease t o t[...]

15-8 STEERING Steering • Hold the flat surfaces [A] of the tie-r od end with a thin wrench [B], and r emove the tie-r od end nut [C] and wash- ers. • T ap the tie-rod end shaft lightl y and remove the tie-rod end from the knuckle. • Remove: Cotter Pins and Front Knuckle Joint Nuts [A] • Install a suitable nut [A] (M12 ) to the knuckle joint[...]

STEERING 15-9 Steering • Check the joint boo t [A] i s not torn , worn, dete riorated, or is leaking grease. If it is found, replace the knuckle joint. • Clean the shanks [B] of the knuckle joint . • Clean the taper surface [A] in the front suspensi on arm [B]. • Install: W ashers [A] and Knuckle Joint Nuts [B] • T ighten: T orque - Front[...]

15-10 STEERING Steering Front Knu ckle Beari ng Insta llati on • The marked side of the bearing faces outward. • Press in the bearing until it is bottomed. [A] V Block Specia l T ool - B earing Drive r Set [B]: 5 7001-1 129 • Replace the circl ip with a new one. Special T ool - I nside Cir clip P liers: 5700 1-143 Tie- rod Remova l • Remove[...]

STEERING 15-1 1 Steering • Install the tie-r od ends so that the tie-rod has the correct length [A], and both visible thread l engths [B] are equal. Tie-rod Len gth Standar d: 393.3 mm (15 .48 in.) • T ighten: T orque - T i e-rod Locknuts : 37 N·m (3.8 kgf·m, 27 ft·lb)[...]

15-12 STEERING Steering Maintenanc e Steerin g Inspection • Refer to the Steer ing Inspec tion in t he Periodic Maint e- nance chapter . Stee ring Ste m Straight ness • Remove the steering st em (see Steering Stem Removal) . • Check the steering ste m for straightness. ○ Use a straightedge al ong the stem. If the steeri ng stem i s bent, re[...]

STEERING 15-13 Steering Maintena nce Stee ring Knuc kle Be aring Insp ection CAUTION Do not remove any bearings for inspection. • Remove the steering knuckle (see Steering Knuckl e Re- mova l) . • T urn [A] the bearing back and forth while checking for roughness or binding. If roughness or bindi ng is foun d, replace the beari ng. • Examine t[...]

15-14 STEERING Handlebar Handle bar Removal • Remove: Meter Unit (see Electrical System chapter) Throttle Case Front Brake Master Cylinder Left-hand Switch Housing Rear Brake Lever Assembly Handlebar Holder Bolts [A] and Bracket [B] Handlebar Holders [C] Handlebar [D] Handle bar Install ation • Align t he punch mark [A] on the handlebar with th[...]

STEERING 15-15 Handlebar • Install: Left Switch Housing [A] Rear Brake Lever Assembly [B] Punch Mark [C] [D] = 6 mm (0.24 in.)[...]

[...]

FRAME 16-1 16 Frame T able of Co ntents Exploded V iew .......... ............ .............. ......... ............ ........... .......... ............ ......... ............ .... .... . 16-2 Seat .. .... ...... ...... .... ....... ...... ...... .... ...... ....... .... ...... ...... ...... ..... ...... ...... .... ...... ....... .... ..... .... .[...]

16-2 FRAME Exploded View[...]

FRAME 16-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Rem arks 1 Front Guard Bolts 37 3.8 27 2 Front Carrier Bolts, L = 50 mm (2.0 in.) 25 2.5 18 3 Front Bolts, L = 70 mm (2.8 in.) 25 2.5 18 4 Front Carrier Bracket Bolts 32 3.3 24 5 Rear Carrier Bolts , L = 14 mm (0.6 in.) 54 5.5 40 6 Rear Carrier Bolts , L = 41 mm (1.6 in.) 54 5.5 40 7 [...]

16-4 FRAME Exploded View[...]

FRAME 16-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Rem arks 1 Footboard Bracket Bolts 42 4.3 31 2 Hitch Bracket Bolts 82 8.3 60 3. T railer Hitch Bracket OP: Optional Parts[...]

16-6 FRAME Exploded View[...]

FRAME 16-7 Exploded View OP: Optional Parts[...]

16-8 FRAME Seat Seat Removal • Remove the seat [A] by lift the lat ch lever [B] and then pulling the seat up to the rear . Seat Instal lation • Insert the f ront seat hooks [A] int o the recei vers [B] in the bracket. • Insert the rear seat hooks [A] into the dampers [B]. • Push the rear part of the seat down to engage the latches [C].[...]

FRAME 16-9 Carriers Fron t Car rier Re mova l • Remo ve : Front Carrier Bolts [A] Collars Front Carrier [ B] Front Carri er Instal lation • Install: Long Collars, L = 44.6 mm (1.8 in.) [A] Short Collars , L = 21.6 mm (0.9 in.) [B] Front Carrier [ C] • T ighten: T orque - Front Carrier Bolts [D], L = 70 mm (2.8 in.):25 N·m (2.5 kgf·m, 18 ft?[...]

16-10 FRAME Carriers Rear Carrier Bracket Insta llation • Inst all: Rear Carrier B racket [A] • T ighten: T orque - Rear Car rier Brack et Bolts [B] :37 N·m (3.8 k gf·m, 27 ft·lb)[...]

FRAME 16-1 1 Fenders Front Fender Removal • Remo ve : Seat (see Seat Removal) Front Carrier (see Front Carrier Removal) Left and Right Side Covers (see each Side Cover Re- moval) Middle Cover Quick Rivets [A] (both sides) Bolts [B] • Remo ve : Screws [A] and Collars • Remo ve : Screws [A] and Collars Front Fender [B] Front Fender Insta llati [...]

16-12 FRAME Fenders • Remove: Seat (see Seat Removal) Rear Carrier (see Rear Carrier Removal) Screws [A] and C oll ars • Remove: Screws [A] and C oll ars • Remove: Screws [A] and C oll ars Bolts [B] and Collars Fuel T ank Cap [C] Rear Fender [D] • Install the fuel tank ca p after removing the rear f ender . Rear Fender Inst allation • Con[...]

FRAME 16-13 Covers Middle Cover Remova l • Remo ve : Middle Cover Screws [A] and Collars • Remo ve : Middle Cover Scr ew [A] and Coll ar • Disconnect: Reverse Power Assist Switc h Lead Connectors [A] • Remove the middle cover [A] as shown. Middle Co ver Ins tallation • Connect: Reverse Power Assist Switch Lead Connectors • Install: Midd[...]

16-14 FRAME Covers Left S ide Cov er Rem ova l • Remove: Seat (see Seat Removal) Middle Cover Screws Storage Case Screws [A] Storage Case [B] • Remove: Screws [A] and C oll ars • Remove: Screws [A] and C oll ars Left Side Cover [B] Left Si de Co ver Inst allati on • Inst all: Left Side Cover [A] Insulator [B] Screws [C] and Collar s [D] W a[...]

FRAME 16-15 Covers • Remo ve : Shift Knob [A] Screws [B] and Collars • Remo ve : Screws [A] and Collars Left Side Cover [B] Righ t Side C over In stall ation • Install: Right Side Cover [A] Screws [B] and Col lars [C] W asher [D] • Install: Storage Case • Fit the projection [A] on the ignit ion switch into the recess in the storage case. [...]

16-16 FRAME Covers • Remove: Screw [A] Bolts [B] Electrical Parts Case [C] Elect rical P arts C ase Insta llation • Inst all: Removed Parts • Connect the vehicle-down sensor lead connect or . • Route the electric al parts leads accor ding to the Appendix chapter . Radiato r Cover Removal • Remove: Front Fender (see Front Fender Removal) C[...]

FRAME 16-17 Guards Front Guard Removal • Remo ve : Screws [A] and Collars Bolts [B] and Collars Front Guard Cover [C] Bolts [D] and Collars • Remo ve : Front Carrier Br acket Bolts [ A] Radiator Cover Screws [B] and Collars Front Guard Bolts [C] (both sides) • Remove the front guard [D] from the radiator bottom stop- pers [B]. Fron t Gu ard I[...]

16-18 FRAME Guards Front B ottom Guard I nstalla tion • Install the fr ont bottom guard [A] between the fr ame and engine bottom guard [ B]. • Inst all: Bolts [C] and Collars [D] Engin e Bott om Gu ard Re moval • Remove: Bolts [A] and Collars [B] Engine Bottom Guard [C] Engin e Bot tom Guard In stallatio n • Confirm: Damper [D] • Inst all[...]

FRAME 16-19 Flaps and Footboards Left Footboa rd Removal • Remo ve : Screws [A] and Collars Bolts [B] and Collars • Remo ve : Screws [A] and Collars Bolts [B] and Collars Left Footboard [C] Left Footboa rd Installa tion • Install: Left Footboard [A] Bolts [B] and Collars [ C] Screws [D] and Col lars [E] Righ t Footb oard Re mov al • Remo ve[...]

16-20 FRAME Flaps and Fo otboards Right Footboard Installation • Inst all: Right Footboard [A] Bolts [B] and Collars [C] Screws [D] and Coll ars [E] Footbo ard B racket in stallat ion • Inst all: Footboard Bracket [A] • T ighten: T orque - Footboard Bracket Bolts [B]: 42 N·m (4.3 kgf·m, 31 ft·lb)[...]

FRAME 16-21 T railer Hitch Brack et T raile r Hitch Bracke t Rem oval • Remo ve : T railer Hitch Bracket Bolts [A] T railer Hitch Bracket [B] T raile r Hitch Bracket Insta llation • Install the trai ler hitch bracket [A] as shown. • T ighten: T orque - Hitch Bracke t Bolts: 82 N·m (8. 3 kgf·m, 6 0 ft·lb)[...]

[...]

ELECTRICAL SYSTEM 17-1 17 Electrical System T able of Co ntents Par ts Loca tion. .... ....... ...... .... ...... ...... .. 1 7-3 Exploded V iew .......... ............ ............. 17-6 Spec ifica tions . .... ....... ...... .... ...... ...... .. 17-1 2 Wiri ng Di agram . ....... .... ...... ...... .... ...... 17-14 Spec ial T o ols .... ....... [...]

17-2 ELECTRICAL SYSTEM Actuator Control System T roubleshooting ...... .......... ........ 17-74 Drive Bel t Fail ure Detec tion System .. 17-83 Driv e Belt Fa ilure De tectio n Sys tem Insp ect ion .... .... ...... ...... . 17- 83 Carburetor Heater Syst em............. .... 17-84 Air T emperature Sensor Insp ectio n .... ...... ....... .... ......[...]

ELECTRICAL SYSTEM 17-3 Parts Locatio n Light/Dimmer Swit ch [A] Starter Button [ B] Engine Stop Switch [C] Reverse Power Assist Switch (Override) [ D] Rear Brake Light Switch [E] Power Outlet Connector [F] (120 W) 2WD/4WD Shift Switch [A] Front Brake Light Switch [B] Igniti on Switch [C] Battery [A] Igniter [B] Actuator Controller [C] Reset Connect[...]

17-4 ELECTRICAL SYSTEM Parts Location Frame Ground Lead [A] W ater T emperature Switch [B] 2WD/4WD Actuator [C] Engine Brake Actuator [D] Spark Plug [A] Engine Ground Lead [B] Ignition Coi l [C] Frame Ground Lead [D] Rear Brake Light Swit ch [E] Speed Sensor [F] Drive Belt Failure Detect ion Switch [G] Engine Brake Actuator [H] Regulator/Recti fier[...]

ELECTRICAL SYSTEM 17-5 Parts Locatio n Multifuncti on Meter [A] “SET/RESET” Button [B] Belt Check Indicato r Light [C] Neutral Indicator Light [D] Reverse Indicator L ight [E] Oil Pressure W arning Indicato r Light [F] “4WD” Indicator Light [G] “2WD” Indicator Light [H] Coolant T emperature W arning Symbol [I] Fuel Level Gauge [J] “TI[...]

17-6 ELECTRICAL SYSTEM Exploded View[...]

ELECTRICAL SYSTEM 17-7 Exploded View T orque No. Fastener N·m kgf·m ft ·lb Remarks 1 Starter Motor Mounting Bolts 8.8 0.90 78 in·lb 2 Starter Motor T erminal Nut 4.9 0.50 43 in·lb 3 Starter Motor T erminal Locknut 6.9 0.70 61 in·l b 4 Starter Moto r Bolts 4.9 0.50 43 in ·lb 5 Starter Motor Clutch Bolts 34 3.5 25 L 6 Alternator Stator Bol ts [...]

17-8 ELECTRICAL SYSTEM Exploded View[...]

ELECTRICAL SYSTEM 17-9 Exploded View T orque No. Fastener N·m kgf·m ft·lb Rem arks 1 Spark Plugs 13 1.3 11 3 i n · l b 2 2WD/4WD Actuator Mounting Bolts 9.8 1.0 87 in·lb L, S 3 Engine Brake Actuator Mounting Bolts 8.8 0.90 78 in· lb 4 Forward/Reverse Det ecting Sensor M ounting Bol t 15 1.5 11 5 Speed Sensor Mounting Bolt 8.8 0.90 78 in·lb 6[...]

17-10 ELECTRICAL SYSTEM Exploded View[...]

ELECTRICAL SYSTE M 17-1 1 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Radiator Fan Switch 18 1.8 13 2 Coolant T emperature W arning Light Switch 6.9 0.70 61 in·lb SS 3 Oil Pressure Switc h 15 1.5 11 SS 4 Oil Pressure Swit ch T erminal Bolt 1.5 0.15 13 in·l b 5 Regulator/Rect ifier Mounting Bolts 8.8 0.90 78 in ·lb 6 Fuel Leve[...]

17-12 ELECTRICAL SYSTEM Specifications Item Standard Ser vice L imit Battery Ty p e Sealed Battery ––– Capacity 12 V 12 Ah ––– Charging System Alternator T ype Three-phase AC ––– Charging V oltage 14 ∼ 15 V ––– (Regulator/ Rectifier Out put V oltage) Alternator Output V oltage 38 ∼ 58 V @3 000 r /min (rpm) ––– Stat[...]

ELECTRICAL SYSTEM 17-13 Specifications Item Standard Service Limit Radiator Fan Switch Resist ance: Rising T emperature From OFF to O N at 96 ∼ 100°C ––– (205 ∼ 212°F) Falling T emperature From ON to OFF at 91 ∼ 95°C ––– (196 ∼ 203°F) ON: Less than 0.5 Ω OFF: More than 1 M Ω Coolant T emperature W arning Light Switch Res[...]

17-14 ELECTRICAL SYSTEM Wiring Diagram[...]

ELECTRICAL SYSTEM 17-15 Wiring Diagram[...]

17-16 ELECTRICAL SYSTEM Special T ools Ti ming Light: 57001-12 41 Flywheel Hold er: 57001-13 13 Hand T ester: 57001-13 94 Flywheel Pu ller Ass embly , M38 × 1. 5/M35 × 1 .5: 57001-14 05 Peak V olt Adap ter: 57001- 1415 Needle Adap ter Set: 57001- 1457 Drive Pulley Holde r: 57001- 1520[...]

ELECTRICAL SYSTEM 17-17 Precautions There are a number of important precaut ions that should be taken w hen servici ng elect rical s ystems. Learn and ob- s e r v ea l lt h er u l e sb e l o w . ○ Do not reverse the batter y lead connecti ons. This will burn out the diodes in t he electrical parts. ○ Always check battery condition before condem[...]

17-18 ELECTRICAL SYSTEM Precautions ○ Electrical Connecto rs: Female Connectors [A] Male Connectors [B][...]

ELECTRICAL SYSTEM 17-19 Electrical Wiring Wiring Insp ection • Visual ly inspect the wir ing for signs of burni ng, fraying, etc. If any wiring i s defective, replace the damaged wiri ng. • Pull each connector [A] apart and inspect for corrosion, dirt, and damage. If the connector is corroded or dirty , clean it carefully . If it is damaged, re[...]

17-20 ELECTRICAL SYSTEM Battery Battery Removal • T urn off t he ignition switch. • Remove: Seat (see Frame chapter) Battery Holder Bolts [A] and Collars Battery Holder [B] • Disconnect the battery negative (–) cabl e [C] first, and then the positi ve (+) cable [D]. • T ake out the battery [E]. Battery Installation • T urn off t he igni[...]

ELECTRICAL SYSTEM 17-21 Battery CAUTION Do not remove the aluminum sealing sheet [A] from the filler ports [B] until just prior to use. Be sure to use the dedicated electrolyte contai ner for correc t electrolyte volume. • Place the battery on a level surface. • Check to see that the sealing sheet has no peeling, tears, or holes in it. • Remo[...]

17-22 ELECTRICAL SYSTEM Battery • Gently remove t he container f rom the batter y . • Let the battery sit for 60 minutes prior to charging to al low the electrol yte to permeate int o the plates for opti mum performance. NOT E ○ Charging the batter y immediately after filli ng can shorten service lif e. Let the battery sit for at least 60 min[...]

ELECTRICAL SYSTEM 17-23 Battery If an engine will not st art, a horn sounds weak, or lamps are dim, it indicates the b attery has been discharged. Give refres h charge for 5 to 10 hours with c harge current shown in the speci ficati on (see Refreshing Charge). When a fast charge is inevitably required, do it fo llowing prec isely the maximum char g[...]

17-24 ELECTRICAL SYSTEM Battery Chargi ng Condit ion Inspecti on Battery charging condi tion can be checked by measur ing battery te rminal voltage. • Remove the battery ( see Battery Removal) . CAUTION Be sure to disconnect the negative ( − ) lead fi rst. • Measure the battery terminal volt age. NOT E ○ Measure with a digital voltmeter [A][...]

ELECTRICAL SYSTEM 17-25 Battery NOTE ○ Increase the charging voltage to a m aximum voltage of 25 V if the battery will not accept current initially . Charge for no more than 5 minutes at the i ncreased voltage t hen check if the battery is drawing current. If the battery will accept current [D], dec rease the voltage and charge by the standard ch[...]

17-26 ELECTRICAL SYSTEM Charging System Alte rnato r Cove r Rem ova l • Drain: Coolant (see Cooling System chapter ) Oil (see Periodic Maintenance chapt er) • Remove: Recoil Starter (see Recoil Star ter chapter) W ater P ump Impeller (see Cool ing System chapt er) T orque Converter Cove r (see Conver ter System chap- ter) • Remove the three b[...]

ELECTRICAL SYSTEM 17-27 Charging System Alternator Cover I nstallation • Be sure all of the old gasket has been removed from t he alternator cover and the left crankcase seal ing surfaces. • Check that the dowel pins [A] are in place, and fit a new gasket on the crankcase. • Check that the bearing [B] is i n place. • Fit the grommets [A] in[...]

17-28 ELECTRICAL SYSTEM Charging System Alte rnato r Roto r Rem ova l • Remove: Alternator Cover ( see Alterna tor Cover Removal) Ball Bearing [A] • Thread the flywheel puller [A] ont o the alter nator rotor . Specia l T ool - Flywheel Pull er Assembly , M38 × 1.5/M35 × 1.5: 570 01-1405 • Holding the flywheel pull er , turn the rotor puller[...]

ELECTRICAL SYSTEM 17-29 Charging System Altern ator Stator Removal • Remo ve : Alternator Cover (see Alternato r Cover Removal) Crankshaft Sensor [A] (see Crankshaf t Sensor Re- moval) Bolts [B] and Alternator Stator [C] Alternator Stato r Installat ion • T ighten: T orque - Alternator Stator Bolts: 13 N·m (1.3 kgf·m, 1 13 in·lb) • Install[...]

17-30 ELECTRICAL SYSTEM Charging System Alterna tor Inspectio n There are t hree types of alternator f ailures: short, open, or loss in rotor magnetis m. A short or open in one of the coil wires will res ult in either a low output, or no output at all. A loss in rotor magnetism, which may be ca used by dropping or hitt ing the alter nator , by leav[...]

ELECTRICAL SYSTEM 17-31 Charging System Regulator /Rectifier Insp ection • Remo ve : Connectors [A] (disc onnect) Bolts [B] and Regulator/Rectifi er [C] Rectifier Cir cuit Check • Check conductivity of t he following p air of termi nals. Rectifier Circu it Ins pection W-BK1, W- BK2, W-BK 3, T e ster conn ection BK/Y-B K1, BK/Y- BK2, B K/Y- BK3,[...]

17-32 ELECTRICAL SYSTEM Charging System Regulator Circuit T est-2nd Step • Connect the test li ght and a 12 V battery in the s ame man- ner as speci fied in the " Regulator Circuit T est-1st Step". • Apply 12 V to the BR terminal. • Check Y1, Y2, and Y3 terminals. If the test li ght turns on, the regulator /rectif ier is defecti ve.[...]

ELECTRICAL SYSTEM 17-33 Charging System Charging System Circuit 1. Ignition Switch 2. Fuse Box 3. M ain Fuse 30 A 4. Load 5. Alternator 6. Regulator/rec tifire 7. Starter Relay 8. Battery 12 V12 Ah 9. Engine Ground T erminal[...]

17-34 ELECTRICAL SYSTEM Ignition System W ARNING The ignition system produces extremely high volt- age. Do not touch t he spark plug, ignit ion coil, or spark plug lead while the engine is running, or you could receive a severe electrical shock. CAUTION Do not disconnect the battery leads or any other electrical connections when the ignition switch[...]

ELECTRICAL SYSTEM 17-35 Ignition System Spark Plug Cleaning/Inspection • Refer to the Spark Plug Cleaning/Inspec tion in the Peri- odic Maintenance chapter . Spark Plu g Gap Inspecti on • Refer to the Spark Plug Gap I nspection i n the Periodi c Maintenance c hapter . Ignition Coil Removal Front Side • Remo ve : Spark Plug Cap [A] Primary Lea[...]

17-36 ELECTRICAL SYSTEM Ignition System Ignition Coil Inspection • Remove the ignition coi l. • Measure the arcing dis tance with a coi l tester [A] t o check the conditi on of the igni tion coil [B] . • Connect the igniti on coil (with the spar k plug cap left at- tached at the end of the spark plug lead) to the t ester in the manner prescr [...]

ELECTRICAL SYSTEM 17-37 Ignition System Ignit ion Coil Prima ry Pea k V olt age Ins pecti on NOTE ○ Be sure the battery is full y charged. • Remove the spark pl ug cap (see Spar k Plug Removal), but do not remove the spark plug. • Measure the primary peak voltage as fol lows. ○ Connect a commercially peak v oltage adapter [A] to the hand te[...]

17-38 ELECTRICAL SYSTEM Ignition System Cranksha ft Sensor I nstallati on • Inst all: Stator Coil Leads [A] Plate [B] Crankshaft Sensor [C] • T ighten: T orque - Crankshaft Sensor Mounting Bolts: 5.9 N ·m ( 0.60 kgf·m, 52 in·l b) • Fit the lead gr ommets into the notch on the alt ernator cover . Grommets [A] for Alternator Leads Grommets [[...]

ELECTRICAL SYSTEM 17-39 Ignition System Crankshaft Senso r Peak V oltage Inspectio n NOTE ○ Be sure the battery is full y charged. • Remove the spark plug caps, but do not remove the spark plugs. • Disconnect: Crankshaft Sen sor Lead Connector [A] • Set the hand tester [ B] to the 10 V DC range. • Connect the peak voltage adapter [C] to t[...]

17-40 ELECTRICAL SYSTEM Ignition System [A] F or R mark Ignition Timing Engin e speed r/mi n (rpm) Slot [B] ali gned wit h: 1 100 and below Ad vanc ed mark [C ] on alt erna tor roto r 5 000 and above Advanc ed mark [D] on alt erna tor roto r NOT E ○ Do not mix up the timing marks with mark [A]. If the igni tion t iming is i ncorrect, replace the [...]

ELECTRICAL SYSTEM 17-41 Ignition System V e hicle- down Sensor R emo val CAUTION Never drop the vehicle-down sensor , especially on a hard surface. Shock to t he sensor can damage i t. • Remo ve : Rear Fender (see Frame chap ter) V ehicle-down Sensor Lead Connec tor [A] Screws [B] V ehicle-down Sensor [C] V ehicl e-dow n Sens or Ins tallat ion ?[...]

17-42 ELECTRICAL SYSTEM Ignition System II. Connecti ons to Connector (5 V circuit ) V ehicle-down Sensor Lead Connector [A] (harness side) Digital V olt Meter [B] Met er (+ ) → Connector Y/G Le ad [E] Met er (– ) → Connector BK/Y Lead [D] • T urn the ignition switch ON, and measure the power source voltage. V ehicle-down Sensor Power Sourc[...]

ELECTRICAL SYSTEM 17-43 Ignition System Ignition System T roubleshooting[...]

17-44 ELECTRICAL SYSTEM Ignition System Ign ition Sy stem C irc uit 1. Igniti on Switch 2. Reverse S witch 3. Speed Sensor 4. Fuse Box (Main Fuse 30 A) 5. Multifuncti on M eter 6. Belt Failure D etection Swi tch 7. Engine Stop Switch 8. Rever se Power Assist Switch (Over ride) 9. Reset Connector 10. Crankshaft Sensor 1 1. Ignition C oils 12. Spark [...]

ELECTRICAL SYSTEM 17-45 Electric Starter Syste m Star ter M otor R em oval • Remo ve : Air Intak e Rubber Duct [ A] • Remo ve : Join t Duct [A] a nd Colla rs • Remo ve : Starter Motor Cabl e [A] Starter Motor Mounting Bolts [B] Clamp [C] Starter Motor [D] CAUTION Do not tap t he end of the starter motor shaft or the motor may be damaged. Star[...]

17-46 ELECTRICAL SYSTEM Electric S tarter System • Inst all: Starter Motor [A] Clamp [B] (as shown) Starter Motor Cabl e [C] • T ighten: T orque - Starter Motor Mounting Bolts: 8.8 N ·m (0.90 kgf·m, 78 in·lb) Starter Motor T erminal Nut: 4.9 N·m (0.50 kgf·m, 43 in·lb) • Apply grease to the O-ring [D] in the joi nt duct [E]. • Inst all[...]

ELECTRICAL SYSTEM 17-47 Electric Starter Syste m Star ter M otor A sse mbly • Replace the O-rings. • Install t he brush plate assembly t o the right end cover so that the projection [A] on the brush plate fit s into the groove on the right end cover . • Install t he O-ring, insulators [B], and washer [ C] in that order on the terminal bolt. ?[...]

17-48 ELECTRICAL SYSTEM Electric S tarter System • Align the mark [A] on the left end co ver with the mark [B ] on the yoke. • T ighten: T o rque - Starter M otor Bolts: 4.9 N·m (0.50 kgf·m, 43 in·lb) Commutato r Cleaning/I nspecti on • Smooth the commutator surface [A] if necessar y with fine emery cloth [B] , and clean out the grooves . [...]

ELECTRICAL SYSTEM 17-49 Electric Starter Syste m Starter Mo tor Brush Len gth • Measure the overall l ength [A] of each brush. Starter Motor Brush Length Stand ard: 1 2.5 mm (0.49 in .) Service Limit: 5 mm (0.20 in.) If any is worn down to the ser vice li mit, replac e the brush plate assembly . Brush Assembly Insp ection • Usi ng t he × 1 Ω[...]

17-50 ELECTRICAL SYSTEM Electric S tarter System Starter C ircuit Rela y Inspectio n • Remove: Seat (see Frame chapter). Starter Circui t Relay [A] (Brake Swit ch Circuit) Sta rter Cir cuit Rela y [B] ( Neutra l Switch Circ uit) ○ The starter circuit relays f or the brake and neutral switch circuit s are ident ical. • Connect the hand tester [...]

ELECTRICAL SYSTEM 17-51 Electric Starter Syste m Electric Starter Circuit 1. Starter Button 2. Engine Stop Sw itch 3. Parking Brake Light Switch 4. Front Brake Light Switch 5. Rear Brake Light Switch 6. M ain Fuse 30 A 7. Starter Circuit Relay (Brake) 8. Reset Connector 9. Ignition Switch 10. Starter Motor 11 . S t a r t e r R e l a y 12. Battery 1[...]

17-52 ELECTRICAL SYSTEM Electric S tarter System Starter Motor Clutch Removal • Remove the alternat or rotor (see Alt ernator Rotor Re- moval). • Hold the rotor with t he flywheel holder and take out the starter motor cl utch bolts [A] . Specia l T o ol - Fl ywheel Holder: 5 7001-131 3 • T ake out the one-way clutch [A]. Starte r Motor Clut c[...]

ELECTRICAL SYSTEM 17-53 Electric Starter Syste m T orque L imite r Insp ectio n • Remo ve : Alternator Rotor ( see Electrical Syst em chapter) • Remove the torque limiter [A] and visually inspect i t. If the limiter has wear , discolorati on, or other damage, replace it as a unit.[...]

17-54 ELECTRICAL SYSTEM Lighting System Headli ght Beam V ertic al Adjustment • T urn the adjusting screw [A] on each headlight rim in or out to adjust t he headli ght vertical ly . NOT E ○ On high beam, the brightest point should be slightly be- low horizontal wi th the vehicle on its wheels and the rider seated. Adjust both headlights t o the[...]

ELECTRICAL SYSTEM 17-55 Lighting System • T urn the bulb socket [A] counterclockwi se [B], and remove the bulb. • Align the mark [A] of a new bulb socket with the mark [B] of the headlight body . • T urn the bulb socket clockwise until it i s stopped. • Disconnect the position l ight lead connec tor . • T urn the bulb socket [A] countercl[...]

17-56 ELECTRICAL SYSTEM Lighting System T aillight B ulb Repla cem ent • Remove: T aillight Lens Mounting Screws [A] T aillight Lens [B] • Push the bulb [A] in, turn it counterclockwise, and pull it out. • Be sure the soc ket is cl ean. • Insert the new bulb by aligning th e pins [A] with the grooves in the wal ls of the socket. • Push th[...]

ELECTRICAL SYSTEM 17-57 Lighting System Lighting System Circuit 1. Multifuncti on Meter 2. Reverse Switch 3. Reverse Light (EUR and G B models) 4. M ain Fuse 30 A 5. Front Brake Light Switch 6. Parking Brake Light Switch 7. Rear Brake Light Switch 8. Position Light (Right) 9. Headlight (Right) 10. Headlight (Left) 1 1. Position Light (Left) 12. Lig[...]

17-58 ELECTRICAL SYSTEM Radiator Fan System Radiator Fan Circuit Inspection • Remove: Screw [A] Left Lower End of Radiator Cover [B] • Disconnect the leads from the radiator fan switch [A]. • Using an auxili ary wire [B], connect t he radiator fan swi tch leads. If the fan rotat es, inspect t he fan switch. If the fan does not rotate, ins pec[...]

ELECTRICAL SYSTEM 17-59 Radiator Fa n System Radiator Fa n Breaker In stallat i on • Install: Radiator Fan Breaker [A] Holder [B] • Connect: White Lead [C] Blue/White Lea d [D] [E] Electr ical Par ts Case [F] Right Side Radiator Fan Circuit 1. Radiator Fan B reaker 2. Radiator Fan Switch 3. M ain Fuse 30 A 4. Radiator Fan 5. Starter Relay 6. Ba[...]

17-60 ELECTRICAL SYSTEM Fuel Level Sensor Fuel Level Sen sor Removal • Remove: Seat (see Frame chapter) Electrical Part s Case (see frame chapter) Fuel Level Sensor Lead Connector [A] Fuel Level Sensor Mounting Bolts [B ] Fuel Level Sensor [C ] Fuel Level Se nsor Install ation • Inst all: New Gasket Fuel Level Sensor • T ighten: T orque - Fue[...]

ELECTRICAL SYSTEM 17-61 Fuel Level Sens or Fuel Level Sensor Circuit 1. Multifuncti on Meter 2. Fuel Level Sensor 3. Ignition Switch 4. M ain Fuse 30 A 5. Starter Relay 6. Battery 7. Engine Ground T erminal[...]

17-62 ELECTRICAL SYSTEM Meter Multifunction Mete r Unit Removal • Remove: Handle Cover Screws [A] • Remove: Handle Cover Screws [A] Handle Cover Front [B] • Remove: Meter Lead Connectors [A] Handle Cover Screws [B] • Remove: Handle Cover Screw [A] Handle Cover Rear [B] • Remove: Bracket Mounting Screws [A] Meter and Bracket [B] Upper Damp[...]

ELECTRICAL SYSTEM 17-63 Meter • Remo ve : Multifuncti on Meter Mounting Nuts [ A] and W ashers Bracket [B] Multifuncti on Meter Unit [C] CAUTION Do not drop the meter unit. Multifun ction Met er Unit Inspe ction • Remo ve : Multifuncti on Meter Unit (see Multifunction Meter Unit Removal) CAUTION Do not drop the meter unit. [A] Meter Unit Lead C[...]

17-64 ELECTRICAL SYSTEM Meter Check 2: MODE and TIME SET B uttons Operation Check • Connect the wires in the same manner as Check 1. • Check that when the MODE button [A] is pushed and held continuou sly , the display [B] cycl es through the f our modes. ODO → TRIP A → TRIP B → Hour → ODO If this display functi on does not work, r eplac[...]

ELECTRICAL SYSTEM 17-65 Meter Check 4: Odometer Check • Connect the wires in the same manner as Check 3. • Pushing the MODE button [A], cycles the odometer [B]. • Raise the input frequency of the oscillator t o see the res ult of this inspection. If the value indi cated by the odometer does not work, re- place the meter unit. Check 5: T rip M[...]

17-66 ELECTRICAL SYSTEM Meter • Connect terminal [4] to the batter y (–) terminal. ○ The 4WD indicator lig ht (LCD) [A] should appear . If this display functi on does not work, r eplace the meter unit. Check 8: Coolant T emperature W arning Symbol Check • Connect the wires in the same manner as Check 1. • Connect terminal [3] to the batte[...]

ELECTRICAL SYSTEM 17-67 Meter ○ The oil pressure warni ng light (LED) [A] should flash. If the LED light does not flash, replace the meter unit. Check 10: Neutral Indicator Light Check • Connect the wires in the same manner as Check 1. • Connect terminal [8] to the battery (–) termi nal. ○ The neutral indicator l ight (LED) [A] should go [...]

17-68 ELECTRICAL SYSTEM Meter Check 12: Meter Illumination Check • Connect the wires in the same manner as Check 1. • Connect terminal [6] to battery (+) terminal. ○ The meter illumination [A] should go on. If the illuminat ion does not go on, replac e the meter unit. Check 13: B elt Check Indicator Light check • Connect the wires in the sa[...]

ELECTRICAL SYSTEM 17-69 Meter • T urn off the igni tion switch. • Remove the seat (see Frame chapter). • Disconnect both sets of 4 pin connectors [A] in the elec- trical parts ca se. • Reconnect these 4 pi n connectors t o their opposi te gray to black and bl ack to gray as shown. • T urn on the ignition switch. • Observe the belt check[...]

17-70 ELECTRICAL SYSTEM Meter • Connect the belt swit ch 2 pin connec tor [A]. • T urn on the ignition swi tch. • Confirm that no bel t check indic ator light is f lashing. • Put the connectors back and bend the clamps.[...]

ELECTRICAL SYSTEM 17-71 Meter Meter Circuit 1. Multifuncti on Meter 2. Neutral Switch 3. Reverse Switch 4. Coolant T emperature Switch 5. Actuator Controller 6. 2WD/4WD Switch 7. Speed Sensor 8. M ain Fuse 30 A 9. Fuel Level Sensor 10. Igniter 1 1. Belt Failure Detec t ion Swit ch 12. Oil Pressure Switch 13. Frame Ground T erminal (Meter) 14. Light[...]

17-72 ELECTRICAL SYSTEM Actuator Control System 2WD /4WD Ac tuato r Remo val • Drain the front fi nal gear case oil (see Fron t Final Gear Case Oil Change in Peri odic Maintenance chapt er). • Remove: Actuator Lead Connector [A] Clamp [B] • Remove: Actuator Mounting Bolts [A] Actuator [B] 2WD /4WD A ctu ator In stallat ion • When installing[...]

ELECTRICAL SYSTEM 17-73 Actuator Contr ol System Engin e Brake A ctua tor Insta llation • Apply grease and Install : O-ring [A] • Apply molybdenum disulfide grease t o the pin [B]. • Apply grease to the trim seal [A] and install the cover [B]. • Insert the pin int o the collar [A] of the engine bra ke lever assembly [B]. • Wipe off any pr[...]

17-74 ELECTRICAL SYSTEM Actuator Control System Actuator Control System Actuat or Control System T roublesh ooting When the actuator fai ls, the control ler enters fail ure mode and the indicator light illuminates 2WD and 4WD alternately . [A] 2WD Indicator Light ( LCD) [B] 4WD Indicator Light ( LCD)[...]

ELECTRICAL SYSTEM 17-75 Actuator Contr ol System Failure Indication P attern and Failure Pa rt No. Failure Indi cation Pattern Failure Part 1 Selectable 2WD/4WD actuator 2 Engine brake actuator 3 Both the select able 2WD/4WD actuator and the engine brake actuator Malfunction Mod e No. Malfuncti on Mode Probable Faulty Part/Location Check Number 2WD[...]

17-76 ELECTRICAL SYSTEM Actuator Control System Check 1. 2W D/4WD Actuator Inspection • Remove: Actuator Lead Connector [A] Clamp [B] • Measure the r esistance bet ween the foll owing termina l s in the actuator l ead connector [A]. Specia l T ool - H and T e ster: 5 7001-13 94 Actuator In ternal Resist ance 4 (Red) - 6 (Bla ck): 3 ∼ 15 Ω 1[...]

ELECTRICAL SYSTEM 17-77 Actuator Contr ol System Check 3. C ontroller Power Suppl y Inspection NOTE ○ Be sure the battery is full y charged. • Remo ve : Seat (see Frame chapter) • Connect: Controller Connector [A] Hand T ester [B] (range: DC 25 V) Te s t e r ( + ) → Connector (BR) T erminal [9] Te s t e r ( – ) → Connector (BK/Y) T ermi[...]

17-78 ELECTRICAL SYSTEM Actuator Control System Check 5. 2WD/4WD S hift Switch Inspection NOT E ○ Be sure the batter y is full y charged. • Remove: Seat (see Frame chapter) • Connect: Controller Connector [A] Hand T ester [B] (range: DC 10 V) Te s t e r ( + ) → Connector (G) T erminal [7] Te s t e r ( – ) → Connector (BK/Y) T erminal [1[...]

ELECTRICAL SYSTEM 17-79 Actuator Contr ol System • Disconnect the spee d sensor lead connector . • Connect: Controller Connector [A] Hand T ester [B] (range: DC 10 V) Te s t e r ( + ) → Connector (P) T erminal [5] Te s t e r ( – ) → Connector (BK/Y) T erminal [10] ○ Install the needle adapters on the tester leads. Spec ial T ools - Hand[...]

17-80 ELECTRICAL SYSTEM Actuator Control System • Support the v ehicle on a st and or a jack so that the wheels are off the ground. • Connect: Controller Connector [A] Hand T ester [B] (range: DC 25 V) Te s t e r ( + ) → Connector (W/R) T erminal [15] Te s t e r ( – ) → Connector (BK/Y) T erminal [10] ○ Install the needl e adapters on t[...]

ELECTRICAL SYSTEM 17-81 Actuator Contr ol System Check 7. Forward/Reverse Detecting Sensor Inspection • Disconnect forward /reverse detec ting sensor l ead con- nector [A]. • Measure the forward/re verse detecting sensor resi s- tance. ○ Connect the hand tester between the BK lead and the W lead. ○ Set the tester to the × k Ω range. Spec[...]

17-82 ELECTRICAL SYSTEM Actuator Control System Actuator Control System Circuit 1. Speed Sensor 2. Forward/Reverse Detecting Sensor 3. 2WD/4WD A ctuator 4. Engine Brake A ctuator 5. Actuator Controller 6. Igniti on Switch 7. Controller Fuse 10 A 8. Main Fuse 30 A 9. Multifunction Meter 10. 2WD/4WD Shift Switch 1 1. Igniter 12. Belt Failure Detecti [...]

ELECTRICAL SYSTEM 17-83 Drive Belt Fa ilure Detec tion System If the dri ve belt failu re detecti on system activat ed by ab- normal belt, the dr ive belt f ailure det ection swi tch is dam- aged. Make sure replace the torque convert er cover (see Converter System chapter). Drive Belt Failure Detection System Inspection • Refer to t he Drive B el[...]

17-84 ELECTRICAL SYSTEM Carburetor H eater System Air T emperature Sensor I nspection • Remove: Air Cleaner Housing (see Fuel Syst em chapter) Air T emperature Sensor [A] • Connect the ba ttery [A] and hand test er [B] t o the sensor lead connector [C]. Specia l T ool - H and T e ster: 5 7001-13 94 Battery (+) → Red and Y ellow Leads ( − ) [...]

ELECTRICAL SYSTEM 17-85 Carburetor He ater System Carb ureto r Heat er Ins pec tion • Disconnect: Carburetor Heater Lead Connectors [ A] Ground Lead Connector [B] • Using the hand test er , m easure t he resistance of the heater . • Connect the tester bet ween the heater terminal and the ground terminal. If the tester does not read as sp ecif[...]

17-86 ELECTRICAL SYSTEM Switches Brake Light S witch Ad justment • Refer to the Br ake Light Swit ch Inspecti on and Adjust- ment in the Period ic Maintenance chapter . Radiator Fan Swi tch Inspection • Remove: Radiator Fan Switch (see C ooling System chapt er) • Suspend the fan switch [A] in a contai ner of coolant so that the temperature se[...]

ELECTRICAL SYSTEM 17-87 Switches Coolant T emperature W arnin g Light Switch Inspecti on • Remo ve : Coolant T emperature W arning Light Switch (see Cool ing System chapter) • Suspend the switch [A] in a container of coolant so that the temperature sensi ng projection and thr eaded portion are submerged. • Suspend an accurate ther mometer [B][...]

17-88 ELECTRICAL SYSTEM Switches Neutral Switch Connection [A] Neutral Switch Revers e Switc h Connect ions [B] Reverse Switch 2WD/4WD Shi ft Switch Oil Pressure Switch Connections* *: Engine Iubrication system is i n good condition Drive Belt Failure Detection Switch If the drive belt f ailure detect ion system is act ivated by abnormal belt, the [...]

ELECTRICAL SYSTEM 17-89 Fuses Fuse Removal • Remo ve : Seat (see Frame chapter) Lid [A] • Pull the fuses [A] straight out of the fuse bo x with needle nose pliers. Fuse Installation If a fuse fails duri ng operation, ins pect the electrical sys- tem to deter mine the cause, and then replace i t with a new fuse of proper amperage. • Install t [...]

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APPENDIX 18-1 18 Appendix T able of Co ntents T roubleshooting G uide ... ............ ......... ........ ............ .......... ....... ............ .......... ....... ............ ..... 18-2 Cable , Wir e, and Ho se Ro uting . .... ....... ...... ...... .... ...... ...... ..... ...... ...... ...... .... ....... ...... .... ...... .... 18-7[...]

18-2 APPENDIX T roub leshooting Guid e NOTE ○ This is not an exhausti ve list, giving every possible ca use for each problem li sted. It is meant simply as a rough guide to assist the troubleshoot ing for some of the more common difficulties. Engine Doesn’t Start, Starting Difficult y: Starter motor not rotating: Neutral switch troubl e Starter[...]

APPENDIX 18-3 T ro ubleshootin g Guide Cylinder head gasket damaged Cylinder head warped V a l v es p r i n gb r o k e no rw e a k V alve not seating proper ly (valve bent , worn, or carbon accumulation on the seating s urface) Compression rel ease cam (K.A.C.R. ) sticks open (Engine stal ls when moving of f) Oth er: Carburetor vacuum piston doesn?[...]

18-4 APPENDIX T roub leshooting Guid e Fan blade damaged W ater pump not turning W ater pump impeller damaged Over Cooling: Cooling system component incorrect: Radiator fan switch trouble Thermostat trouble Converter Operation Faulty: Belt slippi ng: Belt dirty , worn, or wetted Drive or dri ven pulley sheav e dirty or wor n Drive pulle y spring br[...]

APPENDIX 18-5 T ro ubleshootin g Guide W orn LSD clutch frict ion plate ( Front fina l gear case) Thrust plug maladjusted (Rear final gear case) Damaged side gears or pi nions (Fr ont final gear case) Abnormal Frame Noise: Shock absorber noise: Shock absorber damaged Disc brake noise: Pad installe d incorrectly Pad surface glaze d Disc warped Calip[...]

18-6 APPENDIX T roub leshooting Guid e Battery Discharged: Battery faulty (e.g ., plates sulphated, shorted through sedimentat ion, elec- trolyte l evel too l ow) Battery leads making poor contact Load excessive (e.g. , bulb of excessive wattage) Igniti on switch trouble Regulator/r ectifier trouble Alternator t rouble Wiring f aulty Battery Overch[...]

APPENDIX 18-7 Cable, Wire, and Hose Routing 1. T ube 2. Clamps 3. Align the white paint mark on the tube with the adjustment mark on the crankcase. 4. Starter Motor 5. Install the oil pressure swit ch lead not to interfer e with starter moto r .[...]

18-8 APPENDIX Cable, Wire, and Hose Routing 1. Starter Motor Lead 2. Engine Ground Lead (Instal l the lead so that the flat side of the lower terminal f aces toward the engine.) 3. Install the clamp on the eng ine ground lead. 4. Drive Belt Failure Detecting Switch Lead Connector 5. Engine Brake Actuator Lead Connector 6. Clamps[...]

APPENDIX 18-9 Cable, Wire, and Hose Routing 1. Clamp 2. V acuum Hose 3. Clamps 4. Boot 5. Clamps 6. Choke C able Plunger 7. W ater Hose 8. White P aint 9. Mark 10. W ater Pipe 1 1. Coolant Catch T ank 12. Ignition Coil 13. Ignition Coil Lead[...]

18-10 APPENDIX Cable, Wire, and Hose Routing 1. Air C leaner Cover 2. Breather T ank 3. Breather Hoses 4. Breather Hose 5. Check V alve 6. Duct Screw 7. Air Intake Duct 8. Drain T ube 9. Drain T ube 10. Engine Breather Hose[...]

APPENDIX 18-1 1 Cable, Wire, and Hose Routing 1. Main H arness 2. Bands 3. V acuum Hose (Blue Line) 4. Ignition Coil Lead 5. T orque Converter Air Duct 6. Fuel Hose (Red Line) 7. V acuum Hose 8. Clamps 9. Drain Hose 10. Crankshaft Sensor Lead 1 1. Oil Pressure Switch Lead 12. Alternator Lead 13. 2WD/4WD Actuator Lead 14. Plug 15. Frame Pipe 16. Rea[...]

18-12 APPENDIX Cable, Wire, and Hose Routing 1. Rear Final Gear Case Breather T ube 2. Front Final Gear Case Breather T ube 3. Fuel Breather T ube 4. Radiator Fan Motor Breather T ube 5. Bands 6. Main Harness 7. Outside 8. Fix breather tube to right frame pipe. 9. W ater Hose 10. W ater Hose 1 1. Radiator Mounting Bracket 12. Damper 13. Collar 14. [...]

APPENDIX 18-13 Cable, Wire, and Hose Routing 1. Not crush fan motor breather tube to pull it . 2. Clamps 3. Fan Motor Breather Tube 4. Fan Motor Lead Connector 5. T o Thermostat 6. T o W ater Pump 7. W ater Hose 8. Band 9. Reserve T ank[...]

18-14 APPENDIX Cable, Wire, and Hose Routing 1. W ater Hose 2. W ater Pipe 3. Coolant T em perature W arning Light Switch 4. W ater Hose 5. Thermostat 6. Clamp 7. Reserve T ank 8. Reverse Switch Lead 9. Neutral Switch Lead 10. Clamp 1 1. Forward/Reverse Detecting Sen sor Lead Connector 12. Run the forward/revers e detecting sens or lead outsi de of[...]

APPENDIX 18-15 Cable, Wire, and Hose Routing 1. Clamp 2. 2WD/4WD Actuator Lead 3. Air Intake Duct 4. Band 5. Front Final Gear Case 6. Carburetor Air V ent T ube 7. No Interference[...]

18-16 APPENDIX Cable, Wire, and Hose Routing 1. Maine Harness 2. Drive Belt Failure Dete cting Switch Lead 3. Engine Brake Actuator Lead 4. Starter Motor Cable 5. Clamp 6. Drive Belt Failure Detecting Switch 7. Engine Brake Actuator[...]

APPENDIX 18-17 Cable, Wire, and Hose Routing 1. V acuum Hose (t o rear cyl inder head wi th bl ue line) 2. Connect the thick side of hose to the fuel pump. 3. Fuel Hose (to carburetor with red line) 4. Clamps 5. V acuum Hose (to front cylind er head) 6. Fuel P ump 7. Rubber Cover 8. Air T emperature Sensor[...]

18-18 APPENDIX Cable, Wire, and Hose Routing 1. Rear Brake Lever 2. Parking Brake Lock Lever 3. V ariable Dif ferential Control Cabl e 4. Cable Adjuster 5. V ariable Dif ferential Control Lever 6. Handle Holder Clamp 7. V ariable Dif ferential Operating Lever 8. Fit the dust cap. 9. 27 ∼ 35 mm (1.1 ∼ 1.4 in.)[...]

APPENDIX 18-19 Cable, Wire, and Hose Routing 1. Clamp 2. Bands 3. Radiator Fan Motor Breather T ube 4. Fuel Breather Tube 5. Final G ear Case Breather T ubes 6. Joint 7. T ube 8. Dampers 9. Bands 10. 220 mm (8.66 in.) 1 1. 60 mm (2.36 in.) 12. ”L” Formed S ide[...]

18-20 APPENDIX Cable, Wire, and Hose Routing 1. R ight Headlig ht Lead 2. Radiator Cover 3. Frame Ground Lead 4. H orn Switch Lead (Australia and Europe Models) 5. A lternator , Crankshaft Sensor and Oil Pr essure Switch Leads 6. Rear Brake Light Switch Lead 7. 2WD/4WD Shift Switch Lead 8. Left Handlebar Switch Lead 9. Meter Lead 10. Front Brake Li[...]

APPENDIX 18-21 Cable, Wire, a nd Hose Routing 1. Right Handlebar Switch Lead 2. Throttle Cable 3. Meter Lead 4. V ariable Di ffer ential Contr ol Cable 5. Parking Brake Cable 6. Choke Cable 7. Left Handlebar Switch Lead 8. Bands 9. Front Brake Light Switch Lead 10. Brake Hose 1 1. Tubes 12. Cables 13. Leads 14. Rear Brake Light Switch Lead[...]

18-22 APPENDIX Cable, Wire, and Hose Routing 1. Air Intake Duct 2. Bands 3. Parking Brake Cable 4. Foot Brake Cable 5. Bracket 6. Clamp 7. Foot Brake Light Switch 8. S peed Sensor Lead Connect or 9. R un the lead front side of f rame pipe. 10. Clamps 1 1. Reverse Switch Lead Connector 12. Neutral Switch Lead Connector 13. Forward/Reverse Detecting [...]

APPENDIX 18-23 Cable, Wire, a nd Hose Routing 1. Fuse Box 2. Igniter 3. Main Harness 4. Clamp 5. Actuator Controller 6. Reset Connectors 7. Starter Circuit Relay (Neutral) 8. Electric Parts Case 9. V ehicle Down S ensor 10. Starter Circuit Relay (Brake) 11 . C l a m p 12. Radiator Fan Breaker 13. Starter Relay 14. Battery (+) Cable 15. Run the cabl[...]

18-24 APPENDIX Cable, Wire, and Hose Routing 1. Main Harness 2. Battery ( − ) Cable 3. Bands 4. T o Brake Switch 5. Clamps 6. Fuse Box Lead 7. T o Igniter 8. T o Actuator Controller 9. T o Starter Relay 10. Battery (+) Cable 1 1. Reset Connector 12. T o Starter Circuit Relay (Neutral) 13. T o V ehicle Down Sensor 14. T o Starter Circuit Relay (Br[...]

APPENDIX 18-25 Cable, Wire, a nd Hose Routing 1. T o Left Headlight 2. Run the radiator fan swi tch insid e of frame pipe. 3. Clamps 4. T o Power O utlet Connector 5. Front Ignition Coil 6. T o Air T emperature Sensor 7. Clamps 8. Main Harness 9. Rear Ignition Coil 10. Frame Ground T erminal 1 1. T o Carburetor Heater 12. T o W ater T emperature Sw[...]

18-26 APPENDIX Cable, Wire, and Hose Routing 1. Battery 2. Red Cap 3. From Starter Motor 4. R un the batter y cable under the fr ame pipe. 5. Insert the clamp info the hole of bot tom side.[...]

APPENDIX 18-27 Cable, Wire, a nd Hose Routing 1. Belt Converter Intake Duct 2. Bands 3. Rear Final Gear Case Breather T ube 4. Rear Final Gear Case[...]

MODEL APPLICA TION Y ear Model Beginning Frame No. 2005 KVF750-A1 JKA VFDA1 □ 5B500001 or JKA VF750AAB600001 2005 KVF750-B1 JKA VFDB1 □ 5B500001 □ :This digit in t he frame number changes from one machine to anot her . Part No.99924-1 334- 02 Pri nted in Japan[...]