Kawasaki KZ400 (1981) manual

Kawasaki Motorcycle Service Manual Kawasaki Heavy Industries, Ltd. 1979, 1980, 1981 Revised 2: Feb. 17, 1981 @[...]

Kawasaki Heavy Industries, Ltd. accepts no liability for any inaccuracies or omissions in this publlcation, although every possible care has been taken to make it as complete and accurate as possible. All procedures and specifications subject to change without prior notice, and may not apply to every country.[...]

Foreword This manual is designed primarily for use by motorcycle mechanics in a properly equipped shop, although it contains enough detail and basic information to make it useful to the motorcycle user who desires to carry out his own basic maintenance and repair work. Since a certain basic knowledge of mechanics, the proper use of tools, and works[...]

QUICK REFERENCE GUIDE To use, bend the manual back and match the desired section below against the black spot showing at the edge of these pages. Specifications 1 Adiustment 1 Introduction Disassembly I Chassis Engine r Maintenance & Chassis Theory Electrical Troubleshooting Appendix - Supplement Index[...]

4 MODEL IDENTIFICATION Model ldentif ication KZ500-B1 Left Side View KZ500-B1 Right Side View[...]

SPECIFICATIONS 5 Specifications Table of Contents SPECIFICATIONS .......................................... 6 ENGINE PERFORMANCE CURVES ........................... 8 RUNNING PERFORMANCE CURVES ......................... 9 ........................... PERIODIC MAINTENANCE CHART 10[...]

6 SPECIFICATIONS SPEC1 FICATIONS Dimensions Overall length Overall width Overall height Wheel base Road clearance Dry weight Fuel tank capacity Performance Climbing ability Braking Distance Minimum turning radius Engine TY pe Bore and stroke Displacement Compression ratio Maximum horsepower Maximum torque Valve timing Inlet Open Close Duration Exha[...]

Primary reduction ratio Final reduction ratio Overall drive ratio Electrical Equipment Alternator Regulator/Rectifier Ignition coils Battery Starter Motor Headlight TailIBrake light City light Turn signal lights Meter lights Indicator lights Horn Frame TY pe Steering angle Castor Trail Tire size Suspension Suspension stroke Front fork oil Brakes TY[...]

8 SPECIFICATIONS ENGINE PERFORMANCE CURVES Crankshaft rprn[...]

SPECIFICATIONS 9 RUNNING PERFORMANCE CURVES I:' 1 I I I 4 0 80 120 160 201 Vehicle Speed kph[...]

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ADJUSTMENT.. ENGINE 11 Adjustment-Engine Table of Contents SPARK PLUGS ............................................ 12 IGNITION TIMING ......................................... 12 Point Gap Adjustment (using a thickness gauge) ................. 13 Point Gap Adjustment (using a dwell angle tester) ................ 13 ................................[...]

12 ADJUSTMENT-ENGINE SPARK PLUGS Correct ignition timing is achieved by first obtaining Neglecting the spark plug eventually leads to difficult starting and poor performance. If the spark plug is used for a long period, the electrodes gradually burn away and carbon builds up along the insulator. In accordance with the Periodic Maintenance Chart (Pg[...]

ADJUSTMENT-ENGINE 13 Point Gap Adjustment (using a thickness gauge): .Remove the contact breaker cover and gasket. .Clean the points with a piece of clean paper or cloth, using an oil-free solvent. A business card soaked in trichloroethylene can be used to remove traces of oil. To repair light damage, use emery cloth or an oilstone. If the points a[...]

14 ADJUSTMENT-ENGINE @Turn the crankshaft so that the "1 4" F mark on the timing advancer is aligned with the timing mark as shown. A. Right Contact Breaker B. Base Screws A. Timing Mark B. "1 4" F Mark @Set an ohmmeter to the x 1 L! range and connect it across the left set of points, one lead to the wire coming from the points [...]

ADJUSTMENT-ENGINE 15 .Turn on the ignition switch and engine stop switch. Start the engine and warm it up thoroughly. Then, direct the strobe light at the timing mark. .At idle, the "1 4" F mark must be aligned with the timing mark for correct low rpm ignition timing. If the timing is not correct, adjust it by moving the mounting plate. A[...]

Table B5 Inlet Valve Clearance Adjustment Chart 2.00 2 05 2.10 2.15 2.20 2.25 2.30 2 35 2.40 2 45 2.50 2 55 2.60 2 65 2 70 2.75 2 80 2.85 2 90 2 95 3 00 3.05 2.00 2.05 210 2.15 220 2.25 230 2.35 240 2.45 250 2.55 2.60 265 270 275 2.80 2.85 290 295 300 3.05 3.10 ,/2.00 2.05 210 215 2.20 2.25 2.30 2.35 240 245 250 2.55 2.60 2.65 270 275 2.80 2.85 2.9[...]

Table B6 Exhaust Valve Clearance Adjustment Chart 2.00 2.05 210 2.15 2.20 2.25 2.30 2.35 2.40 2.45 2.50 255 2.60 2.65 2.70 275 2.80 285 2.90 2.95 3.00 2.00 2.05 2.10 2.15 2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60 265 2.70 275 280 2.85 290 295 300 3.05 2.00 2.05 2.10 2.15 2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70 275 2.80 2.85 2.90 2[...]

18 ADJUSTMENT-ENGINE A. Inlet Camshaft B. Thickness Gauge *Turn the crankshaft a half turn until the "2 3" T mark is aligned with the timing mark, and measure the clearance of two exhaust valves (#1 and #3, or #2 and #4). *Turning the crankshaft another a half turn and then another a half turn to measure the valve clearance. *If the valve[...]

ADJUSTMENT-ENGINE 19 To adjust the throttle cables: If any one of the above checks shows to be maladjust- ed, adjust the throttle cable as follows: @Loosen the locknuts, and screw both throttle cable adjusting nuts in completely at the upper end of the throttle cables so as to give the throttle grip plenty of play. @Turn out the decelerator cable a[...]

20 ADJUSTMENT-ENGINE .Back out the idle adjusting screw a couple of turns. Turn the adjusting screw until there is no clearance between the screw and pulley, and then continue for another 1/4 turn from that point. A. Idle Adjusting Screw B. Pulley .Remove the top covers (4), and loosen the throttle adjusting screw locknut. A. Throttle Adjusting Scr[...]

ADJUSTMENT-ENGINE 21 (2)ldle mixture adjustment .For all carburetors, turn in the pilot air screw of each carburetor until it seats lightly, and then back it out 1 'Is turns. A. Pulley Stop Screw C. Carburetor Bore B. Locknut .Install the carburetors (Pg. 50), and adjust the play in the throttle cables (Pg. 18). A. Pilot Air Screws Idling Adju[...]

22 ADJUSTM ENT-ENGINE A. Vacuum Gauge Attachment B. Rubber Cap @Attach the vacuum gauges (special tool) fitting the gauge hoses to the vacuum gauge attachments. A. Vacuum Gauge Set (57001-127) @If the difference in vacuum readings between any two cylinders is greater than 2 cm Hg, synchronize the carburetors according to the following procedure. To[...]

ADJUSTMENT-ENGINE 23 To adjust the clutch: *Turn the adjusting screw in until it becomes hard to *Turn in fully the locknut and adjusting nut at the turn. This is the point where the clutch is just starting center of the clutch cable to give the cable plenty of to release. play. *Back out the adjusting screw % turn from that point, and tighten the [...]

24 ADJUSTMENT-ENGINE ENGINE OIL In order for the engine, transmission, and clutch to function properly, always maintain the engine oil at the proper level and change the oil in accordance with the Periodic Maintenance Chart (Pg. 10). Motorcycle operation with insufficient, 1-1 deteriorated, or contaminated engine oil will cause accelerated wear and[...]

ADJUSTMENT-ENGI NE 25 1. Clean the fuel system in a well- ventilated area, and take ample care that there are no sparks or flame anywhere near the working area. 2. Never clean out the fuel system when the engine is still warm. 3. Wipe any fuel off the engine before starting it. @Turn the fuel tap lever to the "ON" or "RES" posit[...]

ADJUSTMENT-CHASSIS 27 Adjustment-Chassis Table of Contents REAR SHOCK ABSORBERS ...................... .. ........ 28 ............................................ DRIVE CHAIN 28 BRAKES ................................................. 29 FrontBrake ............................................. 29 RearBrake ..........................................[...]

28 ADJUSTMENT-CHASSIS REAR SHOCK ABSORBERS The rear shock absorbers can be adjusted to onc of five positions to suit riding conditions. They can be left soft for average riding but should be adjusted hardcr for high spced riding, or riding with a passenger. Shock absorbers adjusted either too soft or too hard adversely affect riding comfort and sta[...]

ADJUSTMENT-CHASSIS 29 @Remove the cotter pin, and looscn the rear axle nut. *If the chain is too tight, back out the left and right chain adjusting bolts evenly, and kick the wheel for- ward until the chain is too loose. Take care not to damage the brake hose. Damaging the brake line greatly reduces the brake line strength and causes brake fluid le[...]

30 ADJUSTMENT-CHASSIS BRAKE LIGHT SWITCH The front brake light switch, mounted on the front brake master cylinder, is operated simple electrical contact and does not need adjustment. However, the rear brake light switch, activated by a spring attached to the brake pedal, requires periodic adjustment to compensate for any change in spring shape or t[...]

ADJUSTMENT-CHASSIS 31 .Remove the handlebar clamp bolts and lockwashers (4 ea), and take off the clamps. A. Handlebar B. Clamps C. Clamp Bolts .Loosen the steering stem head bolt and head clamp bolt, and back out the steering stem locknut using the stem nut wrench special tool) 1 or 2 turns until it turns without drag. NOTE: Do not back out the ste[...]

32 ADJUSTMENT-CHASSIS .Repeat this procedure several times. If the wheel stops of its own accord in various positions, it is well bal- anced. .However, if the wheel always stops in one position, provisionally attach a balance weight on the rim at the marking using an adhesive tape. .Rotate the wheel % turn, and see whether or not the wheel stops in[...]

ADJUSTMENT-CHASSIS 33 *Loosen the turn signal mounting nuts. A. Turn Signal Mounting Nut Avoid spraying water with any great force near the meter assembly, and under the fuel tank and the seat to prevent damage to electrical components. Exprosed parts that are subject to rust can be treated with a pro- tective polish or a water-displacing oil (bran[...]

A. Grease Clutch and Throttle Cables Lubricate the clutch cable and throttle cables, as shown in the figure. Use a lubricant designed for cable lubrication. Refer to Pg. 134 for cable removal. Cable Lubrication (C24) Left Footpeg, Side Stand Right Footpeg, Brake Pedal, Brake Push Rod Joint Center Stand Swing Arm Pivot Force grease into the nipple u[...]

ADJUSTMENT-CHASSIS 35 A. Grease. Carburetor Choke Link Mechanism Others Lubricate the drive chain, wheel bearings, and steer- ing stem bearing as explained in Maintenance Section. NOTE: A few drops of oil are effective to keep bolts and nuts from rusting and sticking. This makes easy removal at your next work. Badly rusted nuts, bolt, etc. should b[...]

DISASSEMBLY-INTRODUCTION 37 Disassembly-Introduction Table of Contents .......................... INTRODUCTION TO DISASSEMBLY 38 ............................ TORQUE AND LOCKING AGENT 39[...]

38 DISASSEMBLY-INTRODUCTION INTRODUCTION TO DISASSEMBLY Detail has not been spared in this section in order that the motorcycle can not only be taken apart but also put back together properly as well. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been included wherever necessary. Nevertheless, even a detailed acco[...]

DISASSEMBLY-INTRODUCTION 39 (13) Liquid Gasket, Non-permanent Locking Agent Follow manufacturer's directions for cleaning and preparing surfaces where these compounds will be used. Apply sparingly. Excessive amounts may block engine oil passages and cause serious damage. An example of a non-permanent locking agent commonlv available in North A[...]

40 DISASSEMBLY-I NTRODUCTION Part Camshaft chain guide (rear) Allen bolts $6 P1.0 Camshaft chain tensioner cap $ 18 P 1.5 Camshaft sprocket bolts $6 PI .0 Carburetor holder screws $6 PI .0 Clutch hub nut $20 PI .5 Clutch release mounting screws $6 PI .0 Clutch spring bolts $6 PI .0 Connecting rod big end cap nuts $7 P0.75 Crankcase bolts (upper) $6[...]

DISASSEMBLY-INTRODUCTION 41 - -- Part Oil pressure switch PT118 Oil pressure relief valve 4 12 PI .25 Return spring pin (bolt) 48 PI .5 Secondary shaft nut 4 18 P 1.5 Shift drum pin plate screw 46 PI .0 Shift pedal bolt 46 P1.O Spark plugs 4 12 P 1.25 Starter motor clutch Allen bolts $8 PI .25 Studs (cylinder head) 46 PI .0 (crankcase) 46 PI .0 (cr[...]

42 DISASSEMBLY-I NTRODUCTION Part t Rear shock absorber mounting nuts $ 10 PI .25 bolts $ 10 P 1.25 I Rear sprocket nuts $ 10 PI .25 I ?Side stand pivot nut $ 10 P1.25 I ?Steering stem head bolt $ 16 PI .5 I ?Steering stem head clamp bolt 48 P 1.25 I Steering stem locknut $30 P1.O I ?Swing arm pivot shaft nut $14 P1.5 1 ?Torque link nuts (10 PI .25[...]

DISASSEMBLY -INTRODUCTION 43 The table below, relating tightening torque to thread diameter and pitch, lists the basic torque for the bolts and nuts used on Kawasaki Motorcycles. However, the actual torque that is necessary may vary amount bolts and nuts with the same thread diameter and pitch. The bolts and nuts listed on Pg. 39- 42 vary to a grea[...]

DISASSEMBLY.. ENGINE INSTALLED 45 Disassembly- Engine Installed Table of Contents FLOW CHART ............................................ 46 FUEL TANK .............................................. 47 FUEL TAP ................................................ 47 ................................... AIR CLEANER ELEMENT 49 CARBURETORS .................[...]

FLOW CHART Disassembly - Engine Installed The following chart is intended to be aids to proper removal. Select the component you wish to remove and follow the arrows to that point on the chart. Mechanism Cover Shift Motorcycle Left Side I Right Side I Bottom End I Top End I I I P 47 P 68 Left Footpeg [Starter Motor Cover Contact Breaker Cover Clutc[...]

DISASSEMBLY-ENGINE INSTALLED 47 FUEL TANK Removal: .Unlock the seat and swing it open. .Turn the fuel tap to the "ON" or "RES" position, slide the hose clamps down, and pull the fuel hose and vacuum hose off the tap. .Lift the rear end of the fuel tank up about 30 mm and then pull the fuel tank off toward the rear. A. Lift up ab[...]

48 DISASSEMBLY-ENGINE INSTALLED Fuel Tap Disassemblv: *Remove the screws (2)) and remove the washer, and holding plate. . --.-, 0. Holding Plate 3 lever, wave remove 1 Check 2nd clean all the parts (Pg 155). Replace damdged parts with new ones. 2 Install the diaphragm cover in the drcction shown in Fig. E9, making sure that the rpring is compressed[...]

DISASSEMBLY-ENGINE INSTALLED 49 A. Diaphragm Cover AIR CLEANER ELEMENT Removal : .Unlock the seat, and swing it open. .Remove the fuel tank (Pg. 47). .Remove the bolts (2) and baffle plate. A. Baffle Plate B. Air Cleaner Cap .Remove the air cleaner cap screws (2) and flat washers (2), and remove the cap. .Pull out the element. A. Air Cleaner Elemen[...]

50 DISASSEMBLY-ENGINE INSTALLED @Loosen the throttle cable adjuster mounting nuts (2) @Slip the spring band that connects each air cleaner fully, remove the decelerator throttle cable adjuster duct to its carburetor out of place. from its bracket, and slip the tip of its inner cable out @Slip the carburetors out of place. of the pulley. Then do the[...]

DISASSEMBLY-ENGINE INSTALLED 51 Separation of Carburetors: NOTES: 1. The four carburetors look the same, but they are slightly different from each other. Notc the following prior to removal: position of the air screw and drain plug. OPresence of the fuel hose 3-way joint, air vent hose and connecting pipe. 2. All carburetor parts except the linkage[...]

52 DISASSEMBLY-ENGINE INSTALLED Carburetors 1. Screw 27. Mounting Screw 54. Screw 2. Lockwasher 28. Idle Adjusting 55. Lockwasher 3. Set Plate Screw 56. Top Cover 4. Throttle Shaft 29. Flat Washer 57. Gasket 5. Lockwasher 30. Spring 58. Locknut 6. Screw 31. Mounting Screw 59. Flat Washer 7. Bracket 32. Bracket 60. Adjusting Screw 8. Mounting Screw [...]

DISASSEMBLY-ENGINE INSTALLED 53 Remove the throttle valve assemblies (4). .Remove the fast idle cam mounting screw 41 . A. Fast Idle Cam 6. Spring C. Choke Arm 4. Install the throttle shaft so that the notched shaft end is on the right side of the carburetors. 5. Install the throttle shaft set plate so that the projec- tion on the plate is fitted i[...]

54 DISASSEMBLY-ENGINE INSTALLED @Check to see that each choke valve closes the carbu- retor bore completely when the choke lever is pulled up, and that each choke valve opens fully when the choke lever is pushed down. A. Choke Lever B. Choke Valve @If the above check shows improper adjustment, remove the top covers (4). @Loosen the choke arm mounti[...]

DISASSEMBLY-ENGINE INSTALLED 55 .Remove the idle adjusting screw 28, flat washer 29, and .Remove the screws @ and lockwashers@, and remove spring 30. the top covers @ and gaskets @ (4 ea). .Remove the screws @ and lockwashers @, and remove .Remove the choke arm mounting screws @. the top covers @and gaskets @ (4 ea). *Remove the throttle return spr[...]

56 DISASSEMBLY-ENGINE INSTALLED *Remove thc screw5 87 dnd lockwashers 8-t (4 ed), dnd take off the flodt bowl J9' and gasket 7%. .To remove the float valve seat @, fir3t push out the float pin $, remove the flodt @ , dnd pull out the float valve needle 8. A. Connecting Pipe C. Clamps B. Exhaust Pipes .Remove the inner exhaust pipc holder nuts [...]

Installation (each muffler) : @Fit the connecting pipe and gasket to the muffler. @Fit a gasket into the outer exhaust port, and place an exhaust pipe holder on the stud bolts. @Fit the end of the exhaust pipe into the exhaust port, and attach the muffler to the frame with the rear footpeg mounting bolt finger tight. @Fit the split keeper back into[...]

58 DISASSEMBLY-ENGINE INSTALLED A. Timing Mark B. "T" Mark *Remove the Allen bolt, and remove the tachometer pinion holder stops. Pull the tachometer pinion holder and pinion with the tachometer cable off the cylinder head. Attempting to install the camshafts with the tachometer pinion left.in the cylinder head may cause tachometer gear d[...]

DISASSEMBLY--ENGINE INSTALLED 59 *Feed the inlet camshaft through the chain, and align the line adjoining the Z/5 IN mark on the sprocket with the cylinder head surface and pointing to the rear. Find the pin on the link pointed at by the exhaust camshaft sprocket line adjoining the EX mark, starting with this pin as first (I), count to the 43th pin[...]

60 DISASSEMBLY - ENGINE INSTALLED @Remove the 0 ring and clean the other tensioner parts using a high flash-point solvent, and then apply a molybdenum disulfide engine assembly grease to the sliding surfaces of them. The dirt or grime on the sliding surfaces of the tensioner parts could cause the tensioner malfunction. @Install the push rod spring [...]

DISASSEMBLY-ENGINE INSTALLED 61 CAMSHAFT SPROCKETS Removal (on each camshaft): *Rcmovc the camshaft (Pg. 57). *Remove the camshaft sprocket bolts (21, and slide thc sprocket off the camshaft. Installation: *Set the sprockct on the camshaft, aligning thc bolt holes. Use the two of four sprockct bolt holes for installation as shown. The marked side o[...]

62 DISASSEMBLY-ENGINE INSTALLED A. Gasket C. "0" Ring B. "UP" Mark D. Orifice .Install the cylinder head. .Tighten the cylinder head nuts (12) first to about 1.5 kg-m (1 1.0 ft-lbs) and finally to 2.3 kg-m (16.5 ft-lbs) of torque, following the tightening sequence shown in Fig. E61. Each nut has a flat washer. Cylinder Head Nut [...]

DISASSEMBLY-ENGINE INSTALLED 63 Valve and Valve Guide 1. Valve Lifter 2. Shim 3. Split Keeper 4. Spring Retainer 5. Inner Spring 6. Outer Spring 7. Oil Seal 8. Spring Band 9. Circlip 10. Valve Guide 11. Cylinder Head 12. Exhaust Valve 13. Inlet Valve A. Valve Guide Arbor (57001-1021 Installation (each valve and valve guide): NOTE: If a new valve or[...]

64 DISASSEMBLY-ENGINE INSTALLED *Lap the valve to check that it is seating properly. If it is uneven, refer to the hlaintendnce Section (Pg. 168). *Push a new oil seal into place. *Apply a thin coat of a molybdenum disulfide engine assembly grease to the valve stem, insert the valve, and install the outer and inner springs with the con- centrated p[...]

DISASSEMBLY-ENGINE INSTALLED 65 Remove the cloth from under each piston. .Check to see that the oil passage orifices (2) are in place, and that the small hole in each orifice faces up. Install the new orifice 0 rings (2). A. Orifices C. Rear Chain Guide B. "0" Rings Orifice Installation a 1. Orifice 2. Gasket 3. 0 Ring 4. Cvlinde'r B[...]

66 DISASSEMBLY-ENGINE INSTALLED A. Piston Ring Compressor Grip (57001-1095) B. Piston Ring Compressor Adapter (57001-1096) .Check to see that the front chain guide is properly fitted in the cylinder. .Fit the cylinder block on the crankcase studs, inserting the rear chain guide into the cylinder block, and rest the bottom of the cylinders on the pi[...]

DISASSEMBLY-ENGINE INSTALLED 67 2. Apply a non-permanent locking agent to the rear chain guide Allen bolts (2), and tighten them. 3. Install the front chain guide in the cylinder block as shown. Front Camshaft Chain Guide Installation ?I Cylinder Block / Front Cam Chain Guide PISTONS, PISTON RINGS Removal: *Remove the cylinder block (Pg. 64). .Wr[...]

68 DISASSEMBLY-ENGINE INSTALLED A. Oil Ring Expander C. Lower Steel Rail B. Upper Steel Rail Installation: .To install the oil ring, first install the expander so that the expander ends butt together, and then install the upper and lower steel rails. The two steel rails are identical. There is no "up" or "down" to the rails; the[...]

DISASSEMBLY-ENGINE INSTALLED 69 A. Breather Hose C. Clamp B. Breather Cover D. Bolt *Remove the breather cover bolt and cover Installation Notes: 1. Replace the breather cover 0 ring and cover bolt 0 ring with new ones if deteriorated or damaged. 3. Tightening torque for the breather cover boll is 0.60 kg-m (52 in-lbs). ENGINE SPROCKET COVER Remova[...]

70 DISASSEMBLY-ENGINE INSTALLED .Mount the shift pedal so that its end matches the level of the alternator cover lower right bolt. A. Lower Right Bolt B. Shift Pedal .Mount the left footpeg with its bolt and lockwasher. .Adjust the clutch (Pg. 22). CLUTCH RELEASE Removal: .Remove the engine sprocket cover (Pg. 69). .Remove the cotter pin from the c[...]

DISASSEMBLY-ENGINE INSTALLED 71 .Install the engine sprocket cover (Pg. 69). *Adjust the clutch (Pg. 22). ENGINE SPROCKET Removal : .Stand the motorcycle up on its center stand. Check that the transmission is in neutral. *Remove the engine sprocket cover (Pg. 69). .Remove the cdtter pin, and loosen the rear axle nut. A. Engine Sprocket Holding Plat[...]

72 DISASSEMBLY-ENGINE INSTALLED *Remove the chain guard. *Remove the external shift mechanism cover screws (7), and pull off the external shift mechanism cover and gasket. *Move the shift arm and overshift limiter out of their positions on the end of the shift drum, and pull out the external shift mechanism. NOTE: Do not pull the shift rod more tha[...]

DISASSEMBLY-ENGINE INSTALLED 73 .Apply a non-permanent locking agent to the bolts (3), .Fit the lead back on the switch. and install the chain guard. .Install the engine sprocket cover (Pg. 69). A. Lead Clamp B. Apply a non-permanent locking agent. .Fit the neutral switch lead back on the switch. .Apply molybdenum disulfide engine assembly grease t[...]

74 DISASSEMBLY-ENGINE INSTALLED A. "0" Ring 6. Starter Motor Lugs .Place the starter motor back into position fitting the shaft through the idle gear. .Tighten the starter motor retaining bolts (2). .Install the engine sprocket cover (Pg. 69). Disassembly: .Remove the screws 18 (2) and lockwashers 19 (2), and remove the end covers 3, 16 .[...]

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76 DISASSEMBLY-ENGINE INSTALLED oRcmovc the alternator stator Allen bolts (3), and pull out thc alternator stator. Installation: .Install the grommet, and fit the stator into place. Use a non-permanent locking agent on each Allen bolt, and tighten the bolts to 1.0 kg-m (87 in-lbs) of torque. .Install the wiring clamp with its screws (2) and lock- w[...]

DISASSEMBLY-ENGINE INSTALLED 77 Installation Notes: 1. The sequence of installation on the contact breaker bolt is: bolt 14 , flat washer 13 , capacitor lead 6 , contact breaker lead 12, spring 11 , large insulator 5), small insulator 4 (in contact breaker hole), large in- sulator 9, flat washer 8 , lockwasher 7 , and nut I . The green contact brea[...]

78 DISASSEMBLY-ENGINE INSTALLED .With a 17 mm wrench on the crankshaft rotation nut to keep the shaft from turning, remove the advancer mounting bolt, and take off the rotation nut and the timing advancer. Installation: .Fit the timing advancer onto the crankshaft, matching its notch with the pin in the end of the crankshaft, and install the cranks[...]

DISASSEMBLY-ENGINE INSTALLED 79 .Remove the clutch spring bolts ~5 (5), washers 6 (5), .Remove the friction plates 7 (7) and steel plates a and springs il) (5). (6). A. Clutch Spring Bolt C. Spring Plate B. Washer .Pull off the spring plate , pull out the spring plate pusher IL , and tilt the motorcycle so that the steel ball Ll will fall out. Clut[...]

80 DISASSEMBLY-ENGINE INSTALLED *Pull off the clutch hub, clutch housing, needle bearing, drive shaft sleeve, and spacer. There is a thrust washer between the clutch hub and clutch housing. Installation: *Put the clutch housing spacer on the drive shaft. The spacer must be installed with its flat side facing toward the end of the shaft. A. Drive Sh[...]

OIL PRESSURE SWITCH Removal: .Remove the bolt and lockwasher, and free the lead from the oil pressure switch. - A. Oil Pressure Switch *Remove the oil pressure switch. Installation Note: .Tighten the oil pressure switch to 1.5 kg-m (11.0 ft-lbs) of torque. OIL FILTER, BYPASS VALVE Removal: *With the motorcycle up on its center stand, place an oil p[...]

82 DISASSEMBLY--ENGINE INSTALLED A. Mounting Bolt B. Grommet C. Turn. .Install the oil filter, dnd tighten its mounting bolt to 2.0 kg-m (14.5 ft-lbs) of torque. .Check the oil level (Pg. 24), and add more if necessary. OIL PRESSURE RELIEF VALVE Removal: I/ .With the motorcycle on its center stand, place an oil pan beneath the engine, and remove th[...]

ENGINE OIL PUMP Removal : @With the motorcycle on its center stand, place an oil pan beneath the engine, and remove the engine oil drain plug and oil filter to drain out the oil. @After the oil has drained out, install the drain plug and tighten it to 3.8 kg-m (27 ft-lbs) of torquc. @Remove the mufflers (Pg. 56). @Remove the clutch (Pg. 78). *Remov[...]

DISASSEMBLY-ENGINE INSTALLED Tighten the oil pan bolts (1 3) to 1 .O kg-m (87 in-lbs) of torque. Install the oil filter (Pg. 81 ). Install the clutch (Pg. 80). Disassembly: @Remove the circlip 8 and washer 71 on the pump shaft end. @Remove the oil pump cover screws IS (3), and take off the oil pump cover I3 and gasket 12. @Take out the rotors B, ii[...]

DISASSEMBLY-ENGINE INSTALLED 85 *Remove the secondary shaft gear circip. Using the *Put the thrust washer on the secondary shaft, and put bearing puller and adapter (special tools), pull the the secondary shaft into the secondary sprocket and secondary shaft gear off the shaft. starter motor clutch assembly, fitting their splines. A. Bearing Puller[...]

86 DISASSEMBLY-ENGINE INSTALLED *Apply a little oil on the secondary shaft and between the secondary shaft gear and gear pusher (special tool). Using the rotor holder (special tool) to keep the crank- shaft and secondary shaft from turning, push the sec- ondary shaft gear on the shaft by rotating the gear pusher (special tool). A. Gear Pusher (5700[...]

DISASSEMBLY-ENGINE INSTALLED 87 .Install the secondary shatt bearing cap, and tighten its screws (2). The upper screw has a wiring clamp. .Install the alternator cover. .Install the clutch (Pg. 80). .Install the engine sprocket cover (Pg. 69). .Install the mufflers (Pg. 57). .Fill the engine with oil and check the oil level (Pg. 24). Disassembly: .[...]

88 DISASSEMBLY-ENGINE INSTALiED A. Idle Gear C. Shaft B. Circlip D. Left Side Installation Note: *The idle gear must be installed so that the smaller gear side ooints to the left.[...]

DISASSEMBLY-ENGINE REMOVED 89 Disassembly-Engine Removed Table of Contents FLOW CHARTS .......................................... 90 ENGINE REMOVAL ....................................... 92 CRANKCASE SPLIT ....................................... 96 TRANSMISSION .......................................... 104 ........................................[...]

FLOW CHART Engine Removal (D The following charts are intended to be aids to proper removal. Select the O component you wish to remove and follow the arrows to that point on the chart. NOTE: Parts in the broken line are required to loosen its mounting bolts or screws, but not necessary its complete removal. Motorcycle LT' Baffle Plate v Air Cl[...]

FLOW CHART Disassembly - Engine Removed Engine 7 Cylinder Head rYi Alternator Secondary I P 81 * Cylinder Camshaft I Alternator cover] Secondary I Clutch Cover I [oil ~ilter 1 Contact External Head Chain Breaker Shift Shaft Cover Tensioner Bearing $ ~78 Cover Mechanism * I I I i cap I clutch plates j I I Clutch Hub I I Oil Pan 1 Clutch Housing r&qu[...]

92 DISASSEMBLY-ENGINE REMOVED ENGINE REMOVAL Removal: .With the motorcycle up on its center stand, place an oil pan beneath the engine, and remove the engine drain plug and oil filter to drain out the oil. A. Starter Relay C. Rubber Cap B. Starter Motor Lead D. Relay Terminal .Remove the bolts (2) and baffle plate. A. Engine Drain Plug 6. Oil Filte[...]

DISASSEMBLY-ENGINE REMOVED 93 *Remove the carburetors (Pg. 49). .Slide the clip out of place, and remove the breather hose from the breather cover. A. Breather Hose B. Breather Cover .Remove the air cleaner housing. .Remove the left footpeg bolt and lockwasher, and remove the footpeg. .Check to see that the transmission is in neutral, then take out[...]

94 DISASSEMBLY-ENGINE REMOVED .Remove the bolt and lockwasher, and remove the battery negative ground lead from the engine. A. Battery Negative Ground Lead *Free the contact breaker point leads (black and green) from the frame. .Remove the rear master cylinder mounting bolts (2). .Loosen the brake pedal adjusting bolt locknut, and back out the adju[...]

DISASSEMBLY-ENGINE REMOVED 95 .Remove the engine mounting bolts , 2 , 9, '&. .Remove the front upper mounting bracket bolts'9 , nuts, and lockwashers, and remove the bracket. .Remove the rear upper mounting bracket bolts I1 and lockwashers, and remove the bracket with the rear brake light switch. .Pull out the engine mounting bolts 5 [...]

96 DISASSEMBLY-ENGINE REMOVED A. Contact Breaker Leads B. Clamps *Connect the rear brdkc light switch iedds (blue and brown). .Install the battery negative ground lead on the engine right side tightening its bolt. The bolt has a lock- washer. *Adjust the drive chain (Pg. 28). .Install the air cledner housing, and put the mounting brackets into both[...]

DISASSEMBLY-ENGINE REMOVED 97 A. Starter Motor B. Retaining Bolts A. Bearing Cap B. Wiring Clamp .Remove the bolts (3) and drive chain guard. A. Drive Chain Guard C. Clamp B. External Shift Mechanism Cover .Remove the external shift mechanism cover screws (7), and pull off the external shift mechanism cover and gasket. There are two knock pins. One[...]

98 DISASSEMBLY-ENGINE REMOVED *Remove the contact breaker cover and gasket. *Free the contact bredker point leads from the cldmps under the clutch cover. *Take out thc contdct breaker pldte screws, lockwashers, and flat washers (3 ea). A. Clutch Holder (57001-305) A. Contact Breaker Plate Screws B. Crankshaft Rotation Nut C. Timing Advancer Mountin[...]

[...]

[...]

DISASSEMBLY--ENGINE REMOVED 101 A. Bearing Puller (57001-135) B. Bearing Puller Adapter (57001-317) C. Secondary Shaft Gear .Put the thrust washer and star-ter motor clutch into the secondary sprocket and starter motor clutch assembly. @Fit the primary chain on the secondary sprocket. A. Secondary Sprocket B. Primary Chain .Put the bearing collar &[...]

102 DISASSEMBLY-ENGINE REMOVED A. Bearing Stop C. Stop Screws B. Oil Pump Bolt *Put the collar on the secondary shaft. *Apply a little oil on the secondary shaft and between the secondary shaft gear and gear pusher (special tool). Using the holder (special tool) to keep the crankshaft and secondary shaft from turning, push the secondary shaft gear [...]

DISASSEMBLY-ENGINE REMOVED 103 the marked side, "OUT. SIDE", facing out (Fig. F52). If this washer is installed backwards, the hub nut might loosen during operation. This causes clutch disengage- ment, resulting in loss of motorcycle control. A. Lockwasher .Install the friction plates (7) and steel plates (6), start- ing with a friction p[...]

104 DISASSEMBLY-ENGINE REMOVED properly fitted in place, mount the external shift mechanism, and place its arms on the shift drum pins. A. Return Spring B. Pawl Spring *Apply a high temperature grease to the lips of the clutch push rod oil seal and the output shaft collar oil seal. *Check that the external shift mechanism cover knock pins (2) are i[...]

DISASSEMBLY-ENGINE REMOVED 105 .Remove the shift drum positioning bolt, >pring, and pin. A. Positioning Bolt C. Guide Bolt B. Shift Fork Guide Pin D. Cotter Pin .Straighten the side of the lockwasher that is bent over the side of the shift drum guide bolt, and remove the bolt and lockwasher. .Remove the cotter pin, and pull out the 5th/6th shift[...]

L - A. Needle Bearing 6- Bearing Driver (57007-287) Assembly Notes: < -. Drive Shaft Disassemblv: 8. Shift Forks[...]

Transmission DISASSEMBLY-ENGINE REMOVED 107 1. 0 Ring 2. Bearing Outer Race 3. Circlip 4. Needle Bearing 5. Thrust Washer 6. 2nd Gear (D) 7. Circlip 8, Splined Washer 9. 6th Gear (D) 10. Bushing 11. Splined Washer 12. Circlip 13. 3rd/4th Gear (D) 14. Circlip 15. Thrust Washer 16. 5th Gear (D) 17. Cotter Pin 18. Shift Fork Guide Pin 19. Shift Fork ([...]

108 DISASSEMBLY-ENGINE REMOVED *Remove the circlip 7 , and pull off the splined washer 8 , 6th gear 9 , bushing,lo, and splined washerill . .Remove the circlip 12 , and pull oft the 3rdl4th gear 13. *Remove the c~rclip 14 , and pull off the washer I5 and 5th gear 16. .Remove the ball bearing 21 using the bearing puller and addpter (special tools). [...]

DISASSEMBLY-ENGINE REMOVED 109 7. Proper sequence starting with 1st gcar (part of drive shaft) i,: 1st gear, 5th gcar (facc the flat side of the gcar to the right), wdsher, circlip, 3rd/4th gcar (facc 3rd gedr side to the right), circlip, splined wdsher, bushing (face the chamfered side to thc right), 6th gear (face the dog, to the right), splined [...]

110 DISASSEMBLY-ENGINE REMOVED 1L A. Crankshaft C. Primary Chain B. Camshaft Chain *Pull the oil seals off both ends of the crankshaft. @Remove the camshaft chain from the crankshaft. @Remove the primary chain. Installation Notes: 1. If a new crankshaft and/or connecting rod is used, select the proper bearing insert in accordance with the combinati[...]

DISASSEMBLY-ENGINE REMOVED 11 1 .Remove the nuts (2) and pull off the connecting rod big end cap. To prevent damage to the crankshaft journals, do not allow the big end cap bolts to bump against them. .Remove the connecting rod bearing insert halves from the connecting rod big end and the big end cap. A. Big End Cap, B. Nuts A. Bearing Inserts Inst[...]

DISASSEMBLY-CHASSIS 113 Disassembly- Chassis Table of Contents ........................................... FLOW CHART 114 WHEELS. BRAKES FRONT WHEEL .......................................... 115 ................................................. Wheel 115 ................................ Speedometer Gear Housing 116 ................................[...]

FLOW CHART Disassembly - Chassis Motorcycle Lr] Front Calipers Front Brake Housing PI15 9 Front Wheel Ti re & Tube Tachometer Lights Housing Leads 4 4 The following chart is intended to be aids to proper removal. Select the component you wish to remove and follow the arrows to that point on the chart. I Steering Stem Bearing I Starter Lockout S[...]

DISASSEMBLY-CHASSIS 115 FRONT WHEEL Wheel Removal: .Disconnect the lower end of the specdometer cable with pliers. A. Speedometer Cable B. Axle Nut .Unbolt one of the brake calipers, and move it free of the fork leg. Avoid straining the brake lines and fittings. A. Caliper Mounting Bolts B. Axle Clamp Bolt .Remove the axle nut, and loosen the axle [...]

116 DISASSEMBLY-CHASSIS disc. The brakes will not function on the first appli- cation of the lever if this is not done. Speedometer Gear Housing Disassembly: .Pull the speedometer gear housing 20 and collar S off the front wheel 2. .If the speedometer cable bushing 25 or speedometer pinion 24 needs to be removed, first drill the housing through the[...]

DISASSEMBLY-CHASSIS 117 Speedometer Gear Housing Assembly Notes: 1. After inserting a new pin, stake the housing hole to secure the pin in place. A. Pin B. Stake. 2. Install the speedometer gear housing so that it fits in the speedometer gear drive notches. A. Speedometer Gear Housing B. Fit in the gear drive notches. Bearing, Brake Disc Removal: *[...]

118 DISASSEMBLY-CHASSIS A. Holding Plate *After installing the disc, check the disc runout (Pg. 203). *Install the speedometer gear housing so that it fits in the speedometer gear drive notches (Fig. G8). *Install the collar on the right side of the hub. *Completely clean off any grease thdt has gotton on either side of the disc with a high flash-p[...]

DISASSEMBLY-CHASSIS 119 A. Bleed Valve B. Hose @Since some brake fluid was lost when the bleed valve was opened, check the fluid level in the master cylinder and bleed the air from the brake system (Pg. 205). @Push the bleed valve cap onto the valve. @Check the front brake. Do not attempt to drive the motorcycle until a full brake lever is obtained[...]

120 DISASSEMBLY-CHASSIS Caliper Disassembly: *Take out the mounting screw 16 for pad B 13 , and remove the pad A 17 . A lockwasher IS and metal plate 14 also come off. .Remove the caliper holder shaft nuts 6 (2), and pull out the caliper holder shafts 3) (2) and the spacers 5 (2) taking care not to damage the dust covers IZ (4). Remove the holder l[...]

DISASSEMBLY-CHASSIS 121 .Taking care not to damage the cylinder surface, remove the fluid seal 7 with a hook. Caliper Assembly: .Clean the caliper parts with brake fluid or alcohol (See CAUTION - Pg. 11 8). @Fit a new fluid seal in place inside the cylinder. NOTE: It is recommended that the fluid seal, which is removed, bc replaced with a new one. [...]

122 DISASSEMBLY-CHASSIS Front Master Cylinder 1. Front Brake Light Switch 2. Screw 3. Master Cylinder Cap 4. Brake Lever Pivot Bolt 5. Diaphragm 6. Brake Lever 7. Locknut 8. Spring 9. Primary Cup 10. Secondary Cup 11. Piston 12. Piston Stop 13. Dust Seal 14. Liner 15. Dust Covcr 16. Banjo (Fitting) Bolt 17. Flat Washer 18. Hose Fitting 19. Upper Br[...]

DISASSEMBLY-CHASSIS 123 Use a new flat washer on edch side of the brake hose fitting. Tighten the banjo bolt to 3.0 kg-m (22 ft-lbs) of torque. Bleed the brake line after mastcr cylindcr installation (Pg. 205). Master Cylinder Disassembly : *Remove the screws 2 (2), take off the mastcr cylindcr cdp 3 and diaphragm 5 , and empty out the brake fluid.[...]

124 DISASSEMBLY-CHASSIS *Loosen the lcft and right chain adjuster locknuts, and fully loosen both chain adjuster bolts. A. Chain Adjuster D. Axle Nut B. Adjusting Bolt E. Chain Adjuster Stop C. Locknut F. Stop Bolt *Remove the cotter in, loosen the axle nut, and then . , push the wheel forward so that the chain can be easily removed from the rear s[...]

DISASSEMBLY-CHASSIS 125 Rear Wheel 15. Wheel Coupling 1. Brake Disc 16. Bearing 2. Rear Wheel (Hub) 17. Circlip 3. Axle 1 6. Grease Seal 4. Rubber Damper- 19. Coupling Collar 5. Collar 20. Drive Chain 6. Grease Seal 2 1. Rear Sprocket 7. Circlip 22. Axle Nut 8. Bearing 23. Cotter Pin 9. Bolt 24. Double Wa5her 10. Distance Collar 25. Nut DO not atte[...]

126 DISASSEMBLY-CHASSIS .Using the bearing driver and driver holder (special tools) or some other suitable tool, remove the bearing 6 by tapping from the wheel side. A. Bearing Driver Holder (57001-139) B. Bearing Driver (57001-288) Wheel Coupling, Rear Sprocket Installation Notes: 1. Inspect 195). L bearing tools). the bearing, and replace if nece[...]

DISASSEMBLY-CHASSIS 127 .Insert a metal rod into the hub from the coupling side, and remove the right side bearing _s by tapping evenly around the bearing inner race. *Remove the remaining bearing 12 by tapping evenly around the bearing inner race. The distance collar lo come out with the bearing. Bearing, Brake Disc lnstallation Notes: 1. Before i[...]

128 DISASSEMBLY-CHASSIS Pad Installation: *Remove the bleed valvc cap, attach clear plastic hosc to the bleed valve, and run the othcr end of the hosc into a container. *Open (loosen) the valve slightly, push both pistons in by hands as far as they will go using a worn pdd, and then close (tighten) the valve. Wipe LIP any spilled fluid, dnd recap t[...]

DISASSEMBLY-CHASSIS 129 Caliper Installation Notes: 1. Put a new flat washer on edch side of the brake hose fitting, and tighten the banjo bolt to 3.0 kg-m (22 ft-lbs) of torque. 2. Tighten the cdliper Allen bolts to 3.0 kg-m (22 ft-lbs) of torque. 3. Check the fluid level in the master cylinder and bleed the brake line (Pg. 205). 4. Adjust the dri[...]

.Taking care not to damage the cylinder surfaces, re- tm move the fluid seals 5 with a hook. A. Caliper Halves B. Allen Bolts .Remove the 0 ring 12 (2) and the dust seals 7 around the pistons. Caliper Assembly: .Clean the caliper parts with brake fluid or dlcohol (See CAUTION - Pg. 11 8). *Fit a new fluid seal in place inside each cylinder. NOTE: I[...]

DISASSEMBLY-CHASSIS 131 A. Master Cylinder C. Mounting Bolts B. Banjo Bolt *Remove the master cylinder mounting bolts (2), and free the rear master cylinder from the motorcycle. Master Cylinder Installation Notes: 1. Use a new flat washer on each side of the brake hose fitting, and tighten the banjo bolt to 3.0 kg-m (22 ft-lbs) of torque. Be sure t[...]

132 DISASSEMBLY-CHASSIS Rear Master Cylinder *Fit the diaphragm and the master cylinder cap. *Fit the push rod dust cover. Brake Hose Replacement: *Pump the brake fluid out of the line as explained in the Maintenance Section - Changing the brake fluid, Pg. 205. *Remove the banjo bolts at the caliper and the master cylinder, and pull the brake hose [...]

DISASSEMBLY-CHASSIS 133 TIRES, TUBES Removal : .Remove the wheel froln the motorcycle (Pg. 11 5 or 123). Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. .Remove the disc(s). .Mark the valve stem position on the tirc with chalk so that the tire will be reinstalled in the same position to maintain wheel[...]

134 DISASSEMBLY-CHASSIS CLUTCH CABLE *Fasten . . the clutch cable to the frame down tube with Removal: .Remove the engine s~rocket cover (Pg. 69) -. .Remove the cotter pin, and disconnect the tip of the clutch cable from the clutch release lever. A. Clutch Release Lever C. Cotter Pin R. Clutch Cable D. Spring *Loosen the locknut on the clutch lever[...]

DISASSEMBLY-CHASSIS 135 *Loosen both cable elbow nuts, and pull out the cables through the right cable guide on the stem head. *Remove the right switch housing screws (2)) and open the housing. .Slip both throttle cable tips from their catches in the throttle grip. A. Throttle Cable Tips C. Throttle Grip B. Catches *Unscrew the decelerator throttle[...]

136 DISASSEMBLY-CHASSIS .Fit the tip of the decelerator throttle cable into the catch in the right pulley, and install its adjuster into the able bracket. A. Speedometer Cable B. Speedometer .Pull the cable free. A. Decelerator Throttle Cable D. Adjuster Installation: B. Right Pulley E. Mounting Nuts .Run the speedometer cable through its guide at [...]

DISASSEMBLY-CHASSIS 137 There is a gasket between the outer cable and the tachometer pinion holder. HEADLIGHT UNIT Removal: .Take out the retaining screws 6 (2), and swing the unit I_O' from the housing 30. *Disconnect the headlight socket 11 from the rear of the unit. For semi-sealed beam units, the bulb can now be removed. @Remove the pivot [...]

138 DISASSEMBLY-CHASSIS A. Upper Cover 6. Bulb Holder C. Bulb .Pull the indicator light bulb out the bulb holder. .To remove the indicator light bulb, first press the bulb inwards, then holding the bulb in this position, twist it to the left and pull it out. A. Bulb C. Twist. B. Press. D. Pull out. Installation Note: .Use the bulbs shown in Table G[...]

DISASSEMBLY-CHASSIS 139 Table G3 Turn Signal Lead Color Turn Signal Lead -r Main Wiring Harness Lead Green or Gray ., Gray Right I Black/Yellow BlackIYcllow 3. Adjust the headlight vertically. Left Removal (rear, either side): Green or Gray *+ Grcen Black/Ycllow Black/Yellow .Unlock the seat and swing it open. .Remove the rear fender cobcr bolts (2[...]

140 DISASSEMBLY-CHASSIS SPEEDOMETER. TACHOMETER, Table G4 Meter and Indicator Lights - --- - METER LIGHTS, INDICATOR LIGHTS (Oil, Stop Lamp) Removal: .Disconnect thc upper end of the speedomcter cdble and tachometer cable with pliers. .Remove the cap nuts from the bottom of the meter. A. Speedometer C. Cap Nuts B. Tachometer .Pull up thc speedomete[...]

DISASSEMBLY-CHASSIS 141 *Replace a burned-out bulb w~th a new 12 volt bulb of *Initdl the hcadhght unlt (Pg. 117). the correcl wattage (see the wiring diagram). *Adlust the heidlight (Pg. 32). .Fit the rubber garkot in place, rf rcmovcd, and ~nstnll the lens. Be careful not to ovcrt~ghtcn the mounting screws. IGNITION SWITCH Removal: *Open the head[...]

142 DISASSEMBLY-CHASSIS .Remove the right side cover, and disconnect the blue and brown leads from the rear brake light switch. .Loosen the lower mounting nut fully, and remove the rear brake light switch. Installation Note: .Adjust the switch after installation (Pg. 30). A. Adjusting Screw 6. Locknut STARTER LOCKOUT SWITCH Removal : .Loosen the kn[...]

DISASSEMBLY-CHASSIS 143 .Remove the right switch housing screws (2), and open up the housing. .Loosen the master cylinder clamp bolts (2). A. Master Cylinder Clamp Bolts B. Right Switch Housing .Take the starter lockout switch off the clutch holder. .Remove the handlebar clamp bolts and lockwashers (4 ea), remove the clamps (2), and slide the handl[...]

144 DISASSEMBLY-CHASSIS .With the clutch lever mounted at the proper angle, tighten the clutch lever holder bolt. .Install the starter lockout switch onto the clutch holder. .Strap the left switch housing wiring harness, the right switch housing wiring harness, and the front brake light switch leads back onto the handlebar. .Fit the tip of the clut[...]

DISASSEMBLY-CHASSIS 145 @Remove the fork covers. Each fork cover has a ring @Run the inner tube of each front fork leg up through cap at the top, and a stem base cover, damper ring, its clamp in the stem base. Temporarily tighten the and rubber damper at the bottom. lower clamp bolts on each side to hold each fork leg @Remove the front fender bolts[...]

146 DISASSEMBLY-CHASSIS .Install the stem head assembly and the stem hend lock- washer and flat washer (flat side facing down). Screw in the stem head bolt loosely. Be sure the wiring har- nesses and all cables go between the stem head and the front fork legs. .Install one of the calipers on the fork leg. Tighten the caliper mounting bolt, (2) to 3[...]

DISASSEMBLY-CHASSIS 147 .Remove the grease wal under the lower inncr race. Be careful not to damage the grease seal during removal. .Remove thc lower inner race, which is pressed onto the steering stem, with a stem bearing puller and - adapter (spccial tools). A. Bearing Puller (57001-135) B. Adapter (57001-136) C. Lower lnner Race installation: .A[...]

148 DISASSEMBLY-CHASSIS is even with the upper surface of the stem head. Tight- en the clamp bolts to 1.8 kg-m (13.0 ft-lbs) of torque. A. Upper Clamp Bolt C. Stem Head B. Inner Tube Upper End .Install the front fender and hose guides between the front fork legs. Tighten the bolts (4) with iockwashers (Fig. GI 09). *Install the caliper, tightening [...]

Front Fork 1. Piston and Cylindel- Unit 2. Piston Ring 3. Spring 4. Piston Base 5. Dust Seal 6. Retainer 7. Oil Seal 8. Flat Washer 9. Left Outer Tube DISASSEMBLY-CHASSIS 149 Crn) 10. Gasket 11. Allen Bolt 12. Gasket 13. Drdin Bolt 14. Rubbcr Cap 15. Retainer 16. Top Plug 17. 0 Ring 18. Stem Head 19. Upper Clamp Bolt 20. Ring Cap 21. Left Fork Cove[...]

DISASSEMBLY-CHASSIS Replace the oil seal with a new one, apply oil to the outside, and install it with the front fork oil seal driver (special tool). A. Grab Rail C. Mounting Bolt B. Cap Nut A. Front Fork Oil Seal Driver (57001-141) .Remove the cap nut, lockwasher, and flat washer(s). , , The right shock'absorbcr cap nut has two flat washers. [...]

DISASSEMBLY-CHASSIS 151 *Remove the rear wheel (Pg. 123). .Remove the mounting bolt from each shock absorber *Pull the rear brake hose out of the guides on the swing bottom. A lockwasher comes off with the bolt. arm, remove the torque link rear bolt, and rest the rear .Move the swing arm up and down to check for caliper on some kind of stand. abnor[...]

152 DISASSEMBLY-CHASSIS @Pull back the swing arm. A cap on each side of the pivot will also drop off. Installation: @Install the cap on each end of the pivot of the swing arm, and put the left side of the swing arm through the drive chain loop. @Position the pivot of the swing arm into its place in the frame, and slide in the pivot shaft from the r[...]

MAINTENANCE-ENG INE 153 Maintenance- Engine Table of Contents AIR CLEANER ................................... .. ... 154 ................................... FUEL TANK. FUEL TAP 155 CARBURETOR ........................................... 156 Starter System .......................................... 157 Pilot System ...................................[...]

154 MAINTENANCE-ENGINE AIR CLEANER A properly maintained air cleaner ensures that only clean, filtered air is supplied through the carburetor to the engine. If the air is supplied directly without filter- ing, dirt and dust from the air will clog carburetor passages causing the engine to run poorly. The dust that enters the engine will also act lik[...]

MAINTENANCE-ENGINE 155 FUEL TANK, FUEL TAP The fuel tank capacity is 15.0 liter,, 1.5 liters of which forms the reserve supply. A cap is attached to the top of the tank, and a fuel tap to the bottom. An air vent is provided in the cap to prevent an air lock, which would hinder fuel flow to the carburetol-s. Fuel tap construction is shown in Fig. H3[...]

156 MAINTENANCE-ENGINE Clean the air and fuel passages by lightly applying compressed air to the passage openings. Do not use wire for cleaning as this could damage the check valve, 0 ring seat, and diaphragm mating surfaces. CARBURETOR The carburetors perform the function of mixing the fuel and air in the proportions necessary for good engine perf[...]

MAINTENANCE-ENGINE 157 The following explanation of the functioning and maintenance of the carburetors covers the four main systems for fuel regulation and supply. 1. To prevent damage or deterioration of the rubber or plastic parts, remove as Table HZ Carburetor Systems many rubber or plastic parts from the carburetor (Table H3) as possible before[...]

158 MAINTENANCE-ENGINE Fast Idle Mechanism When choke lever is pushed down. pilot jet, main jets, pilot air jet, and main jet bleed pipe will cause insufficient atomization, thus impairing starter efficiency. Fuel mixture trouble results if choke linkage mechanism, pilot and main system is defective. A damaged relief valve will cause insufficient v[...]

MAINTENANCE-ENGINE 159 Pilot System Fuel and Air Supply rn Air Cleaner Air Screw Pilot Jet I I Engine 25 The pilot system determines the operation of the car- buretor from 0 to % throttle opening. At these small throttle openings, almost no fuel is drawn through the main system due to insufficient air flow. Instead, the fuel is drawn through the pi[...]

7. Ma~n ~;r Passage 8. Main Air jet 9. jet Needle 10. Bleed P~pc 11. 0 Ring 12. Main jet Main System Fuel and Air Supply 1m Float Fuel Tank Main Jet Chamber Main Air Main Air Jet Passage Bleed Pipe 1 I V Air Cleaner Engine 25 of this cutaway, which is on the intake side of the throt- tle valve, helps define the size of the air passage directly abov[...]

MAINTENANCE-ENGINE 161 Float System Fig. HI 7 shows the float system which consists of the float 4 , float valve needle 2') float valve seat I , and overflow pipe 5 . The float system serves to keep a relatively constant level of fuel in the carburetor float chamber at all times so that the fuel supply to the engine will be stable. If the fuel[...]

162 MAINTENANCE-ENGINE Table H5 Service Fuel Level 1 - - Standard I 3.5 + 1 mm from the edge of the carburetor body to the fuel level If the fuel level is incorrect, remove the carburetor, and then remove the float bowl and float. Bend the tang on the float a very slight amount to change the fuel level. Bending it up closes the valve sooner and low[...]

MAINTENANCE-ENGINE 163 Cam Height Measurement Journal, bearing wear The journal wear is measured using plastigauge (press gauge), which is inserted into the clearance to be measured. The plastigauge indicates the clearance by the amount it is compressed and widened when the parts are assembled. Remove the camshaft, and wipe each journal and camshaf[...]

164 MAINTENANCE-ENGINE Set the shaft on V blocks at the outside journals as shown in the figure. Measure runout with a dial gauge at the sprocket mounting location, and replace the shaft if the runout exceeds the service limit. A. Camshaft B. Dial Gauge Table HI0 Camshaft Runout I Service Limit I 0.1 mm 1 CAMSHAFT CHAIN, GUIDE, TENSIONER The camsha[...]

MAINTENANCE-ENGINE 165 Table HI1 Camshaft Chain Length Service Limit 1 128.9 mm Chain guide wear Remove all the chain guides, and inspect them visual- ly. Replace them if the rubber or any other portion shows damage. Measure the depth of the grooves where the chain links run. Replace the guide if the wear exceeds the service limit. Chain Guide Rubb[...]

166 MAINTENANCE-ENGINE its center portion. One hole should be dbout 6 mm in diameter, the other about 3 mm in diameter. The plate must be oil resistant, about 120 nlm square, and at ledst 3 mm thick. Measuring Plastic Plate / / ,' about , 35mm I 3. Obtain d burette or syringe which is calibrated at one-cc or smaller graduations. Fi[...]

If the seating surface of the valve is damaged or badly worn, repair the valve with a valve refacer. The angle of the seating surface is 45". If the end of the valve stem is damaged or badly worn, replace the valve with a new one. Do not grind the valve stem end to repair it or to permit additional valve clearance. If the valve end is ground, [...]

168 MAINTENANCE-ENGINE A. Dial Gauge B. New Valve C. Move. Table HI9 ValveIValve Guide Clearance (Wobble Method) Valve seat repair The valve must seat in the valve seat evenly around the circumference over the specified area. If the seat is too wide, the seating pressure per unit of area is re- duced, which may result in compression leakage and car[...]

MAINTENANCE-ENG INE 169 Table H21 Inlet Valve Stem Installed Height Measurement More than 37.03 mm Probable Cause Valve face and valve seat worn out. Table H22 Exhaust Valve Stem Installed Height Measurement More than 36.98 mm Probable Cause - -- Valve face and valve seat worn out. Assembly with this shim: Recommendation After checking valve cleara[...]

170 MAINTENANCE-ENGINE Apply compound to the valve seat, and tap the valvc lightly into place while rotating it with d lapper. Re- peat this until a smooth, matched surface is obtained. A. Lapper B. Valve Valve stem height inspection After grinding the valves or valve seats and before assembling the cylinder head, measure the installed valve height[...]

MAINTENANCE-ENGINE 171 Valve Spring Squareness Table H24 Valve Spring Squareness Service Limit 1 1.5mm Oil Seal The oil seal around each valve stem prevents oil from leaking down into the combustion chamber. If an oil seal is damaged or deteriorated, oil consumption will increase, and carbon may build up in the combustion chambers. This may be indi[...]

172 MAINTENANCE-ENGINE the engine over with the throttle fully open until the compression gauge stops rising; the compression is the highest reading obtainable. Repeat the measurement for the other cvlinder. A. Compression Gauge (57001-221 B. Hose (57001-1018) Table H25 Cylinder CompressionJf 10.9- 16.5 kg/cmZ (1 55-235 psi), or Usable less than 1 [...]

MAINTENANCE-ENG INE 173 Tdble HZ6 applies only to cylinder that has not been bored oversize, and Table HZ7 applies only to the stand- ard size piston. In the case of a rebored cylinder and oversize piston, the service limit for the cylinder is the diameter to which the cylinder was bored plus 0.1 mm, thc servicc limit for thc piston is the uvcrsizc[...]

174 MAINTENANCE-ENGINE A. Piston Ring B. Thickness Gauge Table H29 Piston RingIGroove Clearance I I Service Limit 1 I Top and 2nd 1 0.1 5 mm I Table H30 Piston Ring Thickness I I Service Limit 1 I Oil 1 2.60 mm When new rings are being fitted into a used piston, Table H31 Piston Ring Groove Width check for uneven groove wear by inspecting the ring [...]

MAINTENANCE-ENGINE 175 CRANKSHAFT, CONNECTING ROD The crankshaft changes the reciprocating motion of the pistons into rotating motion, which is transmitted to the rear wheel when the clutch is engaged. The connecting rods connect the pistons to the crankshaft. Crankshaft or connecting rod trouble, such as worn crankshaft journals or a bent connecti[...]

176 MAINTENANCE-ENGINE If the clearance exceeds the service limit, replace the bearing inserts as follows: 1. With a micrometer, measure the diameter of the crankshaft journals on which the connecting rods fit. Mark each flywheel in accordance with the journal diameter (Table H37). If the measurements is less than the service limit, replace the cra[...]

MAINTENANCE-ENGINE 177 A. Crankshaft B. Dial Gauge Table H42 Crankshaft Runout Crankshaft bearing insert/journal wear Remove the crankshaft. Clean off the oil, and install the crdnkshaft. Cut strips of plastigauge to bearing insert width. Place a strip on each journal parallel to the crankshaft so the plastigauge will be compressed between the inse[...]

178 MAINTENANCE-ENGINE A. Markings for Crankcase ("0" or No mark) B. Painted Marks (Brown, Black, or Green) Table H45 Crankshaft Bearing Inside Diameter 1 Markina 1 Standard I 3. Select the proper bearing inserts in accordance with the combination of the crankcase and the crankshaft marks (Table H46). 0 No mark Table H46 Crankshaft Bearin[...]

MAINTENANCE-ENGINE 179 badly damaged. Damaged teeth on the secondary sprocket indicate that the primary chain, by which it is driven, may also be damaged. At the same time that the secondary sprocket is repaired or replaced, the primary chain should be inspected, and then replaced if necessary. A. Secondary Sprocket B. Oilstone PRIMARY CHAIN The po[...]

180 MAINTENANCE-ENGINE The clutch release mechanism is shown in Fig. H72. The clutch release outer release gear 3 and the inner release gear a are made of steel. Balls 4 are installed between the outer and inner release gears to reduce the friction between them. Assembled into the center of the inner release gear is the clutch adjusting screw X , w[...]

MAINTENANCE-ENGINE 181 If any plates show signs of damage, or if they have worn past the service limit, replace them with new ones. Friction plate/clutch housing clearance Measure the clcarancc between the tangs on the fric- tion plates and the fingers of the clutch housing. If this clearance is excessive, the clutch will no noisy. If the clearance[...]

182 MAINTENANCE-ENGINE Clutch housing gear/secondary shaft gear backlash Measure the backlash between the clutch housing gear and secondary shaft gear. To measure the backlash, set a dial gauge against the teeth of one gear. Then move the gear back and forth while holding the other gear steady. The difference between the highest and the lowest gaug[...]

U Shift Mechanism MAINTENANCE-ENGINE 183 Transmission 3rd/4th Gear (D) Drive Shaft Output Shaft 6th Gear (0) 5th Gear (0) Pin Plate Shift Arm Shift Drum Pin Overshift Limiter Shift Drum Shift Fork (5th/6th) Shift Fork (2ndl4th) Shift Fork (1 st/3rd) Operating Plate Shift Pedal[...]

4 MAINTENANCE-ENGINE A. 1st C. 2nd E. 4th G. 6th B. Neutral D. 3rd F. 5th overshift limiter pressed against the shift drum pins to ensure proper pawl and pin contact. When the shift pedal is released after shifting, the return spring 22 returns the shift lever and shift pedal to their original positions. So that the transmission will remain where i[...]

MAINTENANCE-ENGINE 185 shift pedal movement from 1st or 2nd gear required to shift into neutral. The return spring pin 18 on the side of the crankcase passes through a cutout on the shift mechanism lever. This pin engages between the two ends of the shift mechanism return spring. Normally, the return spring pin should not make contact with the cuto[...]

186 MAINTENANCE-ENGINE Gear backlash Split the crankcase. Leaving the transmission in place, measure the backlash between gears 01 and Dl, 02 and D2, 03 and D3, 04 and D4, 05 and D5, 06 and D6. To measure the backlash, set a dial gauge against the teeth on one gear. Then move the gear back and forth while holding the other gear steady. The differen[...]

MAINTENANCE-ENGINE 187 Table H59 Gear Shift Fork Groove Width Table H58 Shift Fork Thickness Service Limit Shift fork guide pinhhi ft drum groove wear Measure the diameter of each shift fork guide pin, and measure the width of each shift drum groove. Re- place any shift fork on which thc guide pin has worn past the service limit. If a shift drum gr[...]

188 MA1 NTENANCE-ENGINE Ball bearing, needle bearing wear, damage Check the ball bearing and needle bearing (Pg. 192). ENGINE LUBRICATION The engine lubrication system includes the oil screen, engine oil pump, oil filter, oil pressure relief valve, oil bypass valve, and oil passages. An oil pressure switch is provided to warn in case of insufficien[...]

Engine Lubrication System MAINTENANCE-ENGINE 189 (m Engine Oil Flow Chart 7 ID Valve I 4 Oil Pan Passage I I- 7 Nozzle 17 Bypass - - - - - - - - - +- 3 Oil Filter Pressure Switch I Oil Screen[...]

190 MAINTENANCE-ENGINE Warm up the engine, and measure the oil pressure at the normal operating temperature. Run the engine at the specified speed (Table H65), and read the oil pressure gauge. Table H65 Oil Pressure Oil Pressure 694,000 rpm, 90"~ (1 94"~) I I 2.0- 2.5 kg/cm2 (28- 36 psi) 1 If the oil pressure is significantly below the st[...]

MAINTENANCE-ENG INE 191 Table H66 Outer Rotor/lnner Rotor Clearance I Service Limit 0.30 mm I Outer iotor/pump body clearance Measure the cleacance between the outer rotor and the pump body with a thickness gauge. If the clearance exceeds the service limit, replace the oil pump assembly. A. Pump Body C. Thickness Gauge B. Outer Rotor Table H67 Oute[...]

192 MAINTENANCE-ENGINE Oil Breather The oil breather is located on the top of the crank- case. The front right side of the breather opens to the crankcase, while the upper part connects through the breather hose to the dir cleaner. Its function is to minimi~e crankcase pressure variations caused by crank- shaft dnd piston movement and to recycle bl[...]

MAINTENANCE-CHASSIS 193 Maintenance- Chassis Table of Contents ................................................. WHEEL 194 .................................................. Tire 194 Rim .................................................. 194 Axle .................................................. 195 ............................................. Gr[...]

194 MAINTENANCE-CHASSIS WHEEL The following sections, Pgs. 194 - 196, cover the tires, rims, spokes, axles, wheel bearings, and grease seals. For thc brakes, see Pgs. 198-206. Tire The tires are designed to provide good traction and power transmission during acceleration and braking even on bad surfaces. To do this, they must be inflated to the cor[...]

MAINTENANCE-CHASSIS 195 Rim Runout 1. Radial Runout 11 2. Axial Runout Rim damage Carefully inspect the wheel for small cracks, dents, bents, or warp. If there is any damage to the wheel, it must be replaced. Never attempt to repair a damaged wheel. If there is any damage besides wheel bear- ings, the wheel must be replaced to insure safe opera- ti[...]

196 MAINTENANCE-CHASSIS If the same bearing is to be used again, re-wash it with a high flash-point solvent, dry it, and pack it with good quality bearing grease before installation. Turn the bearing by hand a few times to make sure the grease is distributed uniformly inside the bearing, and wipe the old grease out of the hub before bearing install[...]

MAINTENANCE-CHASSIS 197 reduced by providing 0 rings to seal in the lubricant between the pin and bushing. The wear between bushing and roller can be minimized by frequent and sufficient lubrication. Table J6 Drive Chain Make 1 Type 1 Link Enuma 1 EK530SH-T30 1 l00link Wear When the chain has worn so much that it is more than 2% longer than when ne[...]

198 MAINTENANCE-CHASSIS Sprocket Teeth (J10) Worn Tooth Worn Tooth (Engine Sprocket) (Rear Sprocket) Direction of rotation A. Rear Sprocket B. Dial Gauge C. Turn. Measure the diameter of the sprocket at the base of the teeth. If the sprocket is worn down to less than the service limit, replace the sprocket. A. Rear Sprocket NOTE: If a sprocket requ[...]

MAINTENANCE-CHASSIS 199 After the brakes are used for a while and the pads wear slightly, the rubber seal will no longer be able to distort the additional amount that the piston travels. Instead, when piston travel forces the seal past its limit, the seal slips on the piston. The seal then returns the piston to a new rest position that is closer to[...]

200 MAINTENANCE-CHASSIS the fluid seal 2 in the cylinder then returns the piston. This leaves no pressure against either pad A or B so that slight friction against the disc pushes them both slightly away from the disc. As the master cylinder piston moves back further, the brake fluid in the line rushes to fill the low pressure area in front of the [...]

NOTE: The cup3 and spring are part of the piston assembly. Replace the piston assembly if any one of the cups or the spring requires replacement. @Inspect the primary and secondary cups. If a cup is worn, damaged, softened (rotted), or swollen, replace it. If fluid leakage is noted at the brake lever, the cups should be replaced. Front A. Primary C[...]

202 MAINTENANCE-CHASSIS The rear wheel has a fixed caliper. The rear caliper assembly consists of two caliper halves 7 , do', bolted together, with each half containing a cylinder; a set of opposed pistons 6 ; and two pads 5 . The pad anti- rattle springs 13 hold the pads in position apart from the disc when the rear brake is not applied. When[...]

MAINTENANCE-CHASSIS 203 A. Fluid Seal B. Dust Seal C. "0" Ring Dust seal, cover, 0 ring damage Check the dust seals, covers, 0 ring, and replace any that are cracked, worn, swollen, or otherwise damaged. Piston, cylinder wear Measure the cylinder inside diameter and piston out- side diameter. Replace the cylinder and piston if they are wo[...]

204 MAINTENANCE-CHASSIS A. Disc Table J13 Disc Thickness Disc cleaning Poor braking can also be caused by oil on the disc. Oil on the disc must bc cleaned off with trichloro- ethylene or a high flash-point solvent. Do not use one which will leave an oily residue. Service Limit Brake Fluid The brake fluid is an extra heavy duty type with a high boil[...]

MAINTENANCE-CHASSIS 205 Brake Fluid Boiling Point Percentage of Moisture Changing the brake fluid The brake fluid should be changed in accordance with the Periodic Maintenance Chart (Pg. 10) and when- ever it becomes contaminated with dirt or water. .Attach a clear plastic hose to the bleed valve on the caliper, and run thc other end of the hose in[...]

206 MAINTENANCE-CHASSIS .With the reservoir cap off, slowly pump the brake lever or pedal several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reservoir. This bleeds the air from the master cylinder end of the line. .Install the reservoir cap, and connect a clear plastic hose to the bleed va[...]

MAINTENANCE-CHASSIS 207 Table J15 Bearing Ball Specifications I I Size I Quantitv I Steering stem warp Examine the steering stem, and replace it if it is bent. Upper Lower Bearing wear, damage Wipe the bearings clean of grease and dirt, and ex- amine the races and balls. If the balls or races are worn, or if either race is dented, replace both race[...]

208 MAINTENANCE-CHASSIS Compression Stroke CJ36) Tent Extension Stroke 1. Dust Scal 2. Retainer 3. Oil Seal 4. Spring 5. Piston Ring 6. Cylinder and Piston Unit 7. lnner Tube 8. Outer Tube 9. Upper Chamber 10. Spring 11. Spring Seat 12. Collar 13. Lower Chamber 14. Cylinder Base 15. Allen Bolt 16. Spring 17. Non-return Valve 1. Dust Scal 2. Retaine[...]

MAINTENANCE-CHASSIS 209 Spring The front fork springs in the inner tube are made of special spring rods, heated and wound in the shape of a special coil, to suspend the vehicle. Front Fork Spring Force 10 5 0 100 150 180 -4.5 Compression (mm) Spring tension Since the spring becomes shorter as it weakens, check its free length to determine its condi[...]

210 MA1 NTENANCE-CHASSIS Rear Shock Absorber A. Drain Bolt Oil level To check the fork oil level, first place a jack or stand under the engine so that the front wheel is raised off the ground. Remove the top plug and fork spring from the inner tube. Insert a rod down into the tube, and measure the distance from the top of the inner tube to the oil [...]

MAINTENANCE-CHASSIS 21 1 Shock Absorber Spring Force (33 Compression (mm) Since the rear shock absorbers are sealed units which cannot be disassembled, only external checks of opcra- tion are necessary. With the shocks removed, compress each one and see that the compression stroke is smooth and that there is damping in addition to spring resistance[...]

21 2 MA1 NTENANCE-CHASSIS end pivots on a shaft connected to the frame. When the rear wheel receives a shock, the swing arm, pivoting on its shaft, allows the wheel to move up and down in relation to the frame within the limits of the shock absorbers. This motorcycle has needle bearings at the swing arm pivot. If bearing wear has progressed such th[...]

MAINTENANCE-ELECTRICAL 213 Maintenance-Electrical Table of Contents BATTERY ............................................... 214 ...................................... CHARGING SYSTEM 216 .............................................. Alternator 217 ...................................... Regulator/Rectifier 218 ......................................[...]

214 MAINTENANCE-ELECTRICAL BATTERY The battery supplies the current to the starter motor and serves as a back-up source of power to operate the electrical equipment whenever the engine is turning over too slowly for the alternator to supply sufficient power. With proper care, the battery can be expected to last several years, but it may be complete[...]

MAINTENANCE-ELECTRICAL 215 Initial charge New batteries for Kawasaki motorcycles are dry charged and can be used directly after adding the electrolyte. However, the effect of the dry charge deteriorates somewhat during storage, especially if any air has entered the battery from imperfect sealing. Therefore, it is best to give the battery an initial[...]

216 MAINTENANCE-ELECTRICAL battery can be restored by charging it with the ordinary charge. If it will take a charge so that the voltage and specific gravity come up to normal, it may be considered good except in the following case: * If the voltage suddenly jumps to over 13 volts just after the start of charging, the plates are probably sul- phate[...]

MAINTENANCE-ELECTRICAL 217 .Start the engine, and run the engine at the rpm in Table K2. Note the voltage reading. Table K2 Charging Voltage I Meter I Connections .If the reading is much higher than the values specified in the table, the regulator/rectifier is defective or its leads are loose or open. If the reading does not rise as the engine spee[...]

218 MAINTENANCE-ELECTRICAL A. Alternator Leads Table K4 Stator Coil Resistance (measured when cold) I Meter Range I MeterReading I .Using the highest resistance range of the multimeter, measure the resistance between each of the yellow leads and chassis ground. Any meter reading less than infinity (00) indicates a short, necessitating stator re- pl[...]

MAINTENANCE-ELECTRICAL 219 Diode Current Flow No current flows c Current flows 111d 2. Thyristor The current of electrons will flow from the cathode to the anode but will not flow in the reverse direction. The thyristor differs from a diode in two respects: (a) even through a voltage of the correct polarity (negative to cathode) may be applied, the[...]

220 MAINTENANCE-ELECTRICAL Rectifier inspection .With the ignition switch turned off, remove the left side cover, open the electrical cover, and remove the electrical panel. Disconnect the regulator/rectifier whitelred lead and white connector. A. Electrical Panel C. WhiteIRed Lead B. RegulatorIRectifier D. White Connector .Using the x 10 or x 100 [...]

MAINTENANCE-ELECTRICAL 221 lgnition Circuit Engine lgnition Stop Switch Switch lgnition Coil . Cdpacitor I I Contact Rd!? A wiring diagram of onc half of the ignition 5ystcm is shown in Fig. K17. Thc othcr half is identicdl, and works as follows. The battery supplie5 the current for the primdry circuit, which includes thc contact breaker points, ca[...]

222 MAINTENANCE-ELECTRICAL @Turn on the tester switches. DO not touch the coil or leads to avoid extremely high voltage shocks. @Gradually slide the arcing distance adjusting knob from left to right (small distance to large distance) carefully watching the arcing. @Stop moving the knob at the point where the arcing begins to fluctuate, and note the[...]

MAINTENANCE-ELECTRICAL 223 Contact breaker inspection When the points become dirty, pitted, or burned, or if the spring weakens, the points will not make the contact necessary to produce a good spark, resulting in unstable idling, misfiring, or the engine not running at all. Inspect the contact breaker in accordance with the Periodic Maintenance Ch[...]

224 MAINTENANCE-ELECTRICAL If the mechanism is damaged, has d weak or broken spring(s), or docs not move smoothly, the ignition timing will not advance smoothly or it may stick in one position. This will result in incorrect timing at certain engine speeds, causing poor engine performance. Failure to advance at all will cause poor high speed perform[...]

MAINTENANCE-ELECTRICAL 225 ELECTRIC STARTER SYSTEM Starter Motor Circuit The starter motor circuit includes the starter button (switch), starter lockout switch, starter relay, battery, and starter motor. The starter lockout switch mounted on the clutch lever holder is designed to prevent starter motor operation unless the clutch is disengaged. When[...]

226 MAINTENANCE-ELECTRICAL If the meter redds battery voltage but the relay does not click, the relay i5 defective. A. 4-pin Connector B. Yellow Lead Starter Motor A. YellowIRed Lead C. Black Lead B. Meter (-1 Lead D. Meter (+) Lead Starter lockout switch test Remove the headlight unit (Pg.l37),and disconnect the two starter lockout switch black le[...]

MAINTENANCE-ELECTRICAL 227 Starter Motor Construction 1. Shaft 2. 0 Ring 3. Grease Seal 4. 0 Ring 5. Field Coil 6. Armature Coil 7. Core 8. Yoke Assembly 9. 0 Ring 10. Spring Brush spring Spring tension should be 560-680 grams but a spring can be considered serviceable if it will snap the brush firmly into place. 11. Brush 12. Commutdtor 13. End Co[...]

228 MA1 NTENANCE-ELECTRICAL Table K9 Commutator Groove Depth Service Limit 1 0.2 mm I Using the x 1 R ohmmeter range, measure the re- sistance between any two commutator segments. If there is a high resistance or no reading between any two segments, a winding is open and the armature must be replaced. A. Armature B. Commutator Segments Using the hi[...]

MAINTENANCE-ELECTRICAL 229 Starter Motor Clutch Operation :KT$ 1. Clutch Body 2. Clutch Gear 3. Crankshaft 4. Roller 5. Spring Cap 6. Spring When the engine starts, friction with the starter clutch gear (and at higher speeds, inertia) moves the rollers back against the tension of their springs so that they no longer serve as wedges locking the clut[...]

230 MAINTENANCE-ELECTRICAL Table K10 Ignition Switch Connections 1 Lead I Ignition I Battery 1 Tail 3 / Tail I / Tail 21 I Color I Yellow I White / Brown I Blue I Red I NEUTRAL SWITCH A neutral indicator light is provided so that the rider can readily determine whether or not the trans- mission is in neutral. The neutral switch, installed in the ex[...]

Headlight Circuit Headlight MAINTENANCE-E LECTRICAL 231 Tail Light Fuse n rl - Regulator/ Br/W U R/Bk High Beam 0 Ih Ignition 9 Indicator i Bk/Y Light Switch r+ - ~ I Battery I i Brown Red Fuse Headlight Switch There is also a passing and horn button. This button is spring loaded and when the button is pushed to pass, the high beam light (but not t[...]

232 MAINTENANCE-ELECTRICAL if the bulb is good, check the fuses, wiring, ignition switch, headlight switch, and battery. Brake Light Circuit The brake light circuit is shown in Fig. K51. When the ignition switch is turned on, the brake light goes on whenever the circuit is closed by either the front or rear brake light switch. The same bulb is used[...]

MAINTENANCE-ELECTRICAL 233 A. lndicator Light Table K13 Brake Light Failure lndicator Switch Test Brake Lever or Pedal A~plied I Released If the brake light failure indicator does not function properly, find out whether the brake light wiring is defective or the failure indicator switch is defective. The easiest way to test the failure indicator sw[...]

234 MAINTENANCE-ELECTRICAL If any one of the meter readings shows an improper value, the brake light failure indicator switch is defective. Turn Signal Circuit A wiring diagram of the turn signal circuit is shown in Fig. K58. When the ignition switch is on and the turn signal switch is turned to R or L, a ground is provided for the circuit so curre[...]

MAINTENANCE-ELECTRICAL 235 A. Meter (+) Lead C. Brown Lead B. Meter (-1 Lead D. Orange Lead (2)Both right or both left turn signal come on and stay on or flash too slowly: *Check that battery voltage is normal. *Check that all wiring connections are good. *Check that the turn signal bulbs and indicator bulbs are of the correct wattage. *If all of t[...]

236 MAINTENANCE-ELECTRICAL @Disconnect the horn black lead; and connect an am- meter in series to the horn circuit. The (+) ammeter lead goes to the horn terminal and the (-) ammeter lead to the black lead. Horn Current Measurement Ammeter rn Horn Button Brown ( 1- 9 7 n 1 1 I I I J Ignition Fuse Horn Switch w + - -0 @Fully loosen the adjusting scr[...]

TROUBLESHOOTING GUIDE 237 Troubleshooting-Guide Engine Doesn't Start, Starting Difficulty Starter motor not rotating Clutch lever not pulled Starter lockout switch trouble Starter motor trouble Battery voltage low Relay not contacting or operating Starter button not contacting Wiring open or shorted lgnition switch trouble Engine stop switch t[...]

238 TROUBLESHOOTING GUIDE Contact breaker point gap maladjusted Capacitor trouble lgnition coil trouble lgnition timing maladjusted and/or timing not ad- vancing Contact breaker spring weak Fuellair mixture incorrect Choke valve closed Main jet clogged or wrong size Jet needle or needle jet worn Air jet clogged Fuel level too high or too low Bleed [...]

TROUBLESHOOTING GUIDE 239 Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Overheating Piston slap Cylinder/piston clearance excessive Cylinder, piston worn Connecting rod bent Piston pin, piston holes worn Valve noise Valve clearance incorrect Valve spring broken or weak Camshaft bearing worn Valve lifter w[...]

240 TROUBLESHOOTING GUIDE Disc warped Contaminated pad Brake fluid deteriorated Primary or secondary cup trouble Master cylinder scratched inside Oil Pressure Indicator Light Goes On Engine oil pump defective Engine oil pump screen clogged Engine oil level too low Engine oil viscosity too low Camshaft bearings worn Crankshaft bearings worn Oil pres[...]

APPENDIX 241 Appendix Table of Contents ADDITIONAL CONSIDERATIONS FOR RACING .............. 242 ............................................. Carburetor 242 ............................................. Spark Plug 242 SPECIAL TOOLS ......................................... 244 WIRING DIAGRAM ....................................... 248[...]

242 APPENDIX ADDITIONAL CONSIDERATIONS FOR RACING This motorcycle has been manufactured for use in a reasonable and prudent manner and as a vehicle only. However, some may wish to subject this motorcycle to abnormal operation, such as would be experienced under racing conditions. KAWASAKI STRONGLY RECOM- MENDS THAT ALL RIDERS RIDE SAFELY AND OBEY A[...]

Spark Plug Condition APPENDIX 243 m Carbon Fouling Oil Fouling A spark plug for higher operating temperatures is used for racing. Such a plug is designed for better cooling efficiency so that it will not overheat and thus is often called a "colder" plug. If a spark plug with too high a heat range is used - that is, a "cold" plug[...]

244 APPENDIX SPECIAL TOOLS REF. NO. 1 2 3 4 5 6 7 8 9 10 11 PART NO. 57001 -1 15 57001 - 1 35 (or PIN 57001-158) 57001-136 57001-31 7 57001-1 37 57001-1 38 57001-139 57001-141 57001 -143 57001-144 57001-149 DESCRIPTION PISTON RING PLIERS BEARING PULLER BEARING PULLER ADAPTER BEARING PULLER ADAPTER STEM BEARING DRIVER STEM CUP DRIVER BEARING DRIVER [...]

APPENDIX 245 @ REF. NO. 12 13 14 15 16 17 18 19 20 21 22 23 24 25 PART NO. 57001-183 57001-101 1 57001 -241 57001-1078 57001 -264 57001 -287 57001 -288 57001 -289 57001 -290 57001 -297 5700 1-305 57001 -308 57001-319 57001 -382 DESCRIPTION FRONT FORK CYLINDER HOLDER HANDLE FRONT FORK CYLINDER HOLDER ADAPTER VALVE SPRING COMPRESSOR ASS'Y VALVE [...]

246 APPENDIX REF. NO. 26 27 2 8 29 30 3 1 32 33 34 35 36 37 PART NO. 57001-900 57001-910 57001 -91 3 57001-1021 57001-1024 57001 - 1063 57001-1079 57001 - 1094 57001-1095 57001 -1 096 57001- 1099 (or PIN 57001-254) 57001-1 100 DESCRIPTION ENGINE STAND PISTON PIN PULLER ASS'Y PISTON PIN PULLER ADAPTER "A" VALVE GUIDE ARBOR SPARK PLUG [...]

APPENDIX 247 @ REF. NO. 38 39 40 41 42 43 44 45 PART NO. 57001 -1 25 57001 -403 57001 -1 27 57001 -22 1 57001-1018 57001 -980 57001 -983 57001-1017 DESCRIPTION OIL PRESSURE GAUGE ASS'Y OIL PRESSURE GAUGE ADAPTER VACUUM GAUGE SET COMPRESSION GAUGE COMPRESSION GAUGE HOSE ELECTROTESTER HAND TESTER FUEL LEVEL GAUGE Q'TY 1 1 1 1 1 1 1 1[...]

[...]

SUPPLEMENT 249 Supplement This Supplement is designed to be used in conjunction with the front part of this Service Manual (up to Pg. 248). The maintenance and repair procedures described in this Supplement are only those that are unique to later year units since the first publication of this Service Manual. Complete and proper servicing of later y[...]

250 SUPPLEMENT FOR 1980 MODEL Supplement for 1980 Model Table of Contents [ALL] ................................... MODEL IDENTIFICATION 252 SPECIFICATIONS .......................... PERIODIC MAINTENANCE CHART 262 ADJUSTMENT .............................. CARBURETORS (on US model) 263 ........................................... FUEL SYSTEM 263 ....[...]

SUPPLEMENT FOR 1980 MODEL 251 ADJUSTMENT CARBURETORS (on KZ400) ................................. 263 DISASSEMBLY CAMSHAFTS (on KZ400) ................................... 271 CAMSHAFT SPROCKETS (on KZ400) ......................... 271 PISTON RINGS (on KZ400) ................................. 272 ENGINE SPROCKET (on KZ400) ..........................[...]

252 SUPPLEMENT FOR 1980 MODEL Model ldentif ication KZ400-J1 (Right Side View) Front disc and rear drum brake KZ400-J1 (Left Side View)[...]

SUPPLEMENT FOR 1980 MODEL 253 KZ550-A1 Front disc and rear drum brake KZ550-C 1 Front disc and rear drum brake Pneumatic front fork and damping adjustable rear shock absorbers Tubeless tires Transistorized ignition system Stepped seat and pullback handlebar[...]

254 SUPPLEMENT FOR 1980 MODEL Specifications SPEC1 FlCATlONS (on KZ400) Dimensions Overall length Overall width Overall height Wheelbase Road clearance Dry weight Fuel tank capacity Performance Climbing ability Braking distance Minimum turning radius Engine TY pe Bore and stroke Displacement Compression ratio Maximum horsepower Maximum torque Valve[...]

SUPPLEMENT FOR 1980 MODEL 255 5th 6th Primary reduction ratio Final reduction ratio Overall drive ratio Electrical Equipment Maximum alternator output Battery Headlight TY pe Bulb TailIBrake light City light Turn signal lights Meter lights l ndicator lights Horn Frame TY pe Steering angle Castor Trail Tire Front Rear Suspension Front Rear 0.96 (251[...]

256 SUPPLEMENT FOR 1980 MODEL SPECIFICATIONS (on KZ550) Dimensions Overall length Overall width Overall height Wheelbase Road clearance Dry weight Fuel tank capacity Performance Climbing ability Braking distance Minimum turning radius Engine TY pe Bore and stroke Displacement Compression ratio Maximum horsepower Maximum torque Valve timing l n let [...]

SUPPLEMENT FOR 1980 MODEL 257 Gear ratio: 1 st 2nd 3 rd 4th 5th 6th Primary reduction ratio Final reduction ratio Overall drive ratio Electrical Equipment Maximum alternator output Battery Headlight TailIBrake light City light Turn signal lights Meter lights l ndicator lights Horn Frame TY pe Steering angle Castor Trail Tire Suspension Wheel travel[...]

258 SUPPLEMENT FOR 1980 MODEL ENGINE PERFORMANCE CURVES (on KZ400) KZ400-J1 (except West German model) Fuel Consumption i Crankshaft rpm[...]

SUPPLEMENT FOR 1980 MODEL 259 ENGINE PERFORMANCE CURVES (on KZ550) KZ550-A1, C1 (US and Canadian models) - :LO Torque --4 - i 40 I I I I I ~ 1 1 I I 2.000 4,000 6,000 8,000 9.000 Crankshaft rpm KZ550-A1, C1 (European model except West German model) Crankshaft rpm[...]

260 SUPPLEMENT FOR 1980 MODEL RUNNING PERFORMANCE CURVES (on KZ400) KZ400-J1 (except West German model) 0 4 0 80 120 160 200 Vehicle Speed kph[...]

SUPPLEMENT FOR 1980 MODEL 261 RUNNING PERFORMANCE CURVES (on KZ550) Vehicle Speed kph KZ550-C1 (except West German model) Vehcle Speed kph[...]

262 SUPPLEMENT FOR 1980 MODEL PERIOD lC MAINTENANCE CHART The maintenance and adjustments must be done in accordance with this chart to keep the motor- cycle in good running condition. The initial maintenance is vitally important and must not be neglected. FREQUENCY OPERATION Drive chain - lubricate Every 300 km 197 Drive chain - adjust Every 800 k[...]

SUPPLEMENT FOR 1980 MODEL 263 Adjustment IGNITION TIMING (on KZ550-C) KZ550-C has a magnetically controlled transistor ignition system which has no moving parts in the elec- trical circuit. Consequently, it is not necessary to check and adjust the ignition timing periodically. However, if there is any doubt as to correct ignition timing, inspect th[...]

264 SUPPLEMENT FOR 1980 MODEL .Loosen the carburetor drain screws, and drain the fuel in the fuel and fuel tank through the overflow tubes. Tighten the drain screws. *If any dirt comes out, clean the following parts in ac- cordance to the procedure in the Maintenance Section. OFuel Tank (Pg. 155) OFuel Tap (Pg. 155) Karburetors (Pg. 1 62) FRONT FOR[...]

SUPPLEMENT FOR 1980 MODEL 265 Table N2 Spring Action To adjust the spring force: Position Spring Action .Tl;rn the adjusting sleeve on each shock absorber to the desired position with a hook spanner. Check to see that both adjusting sleeves are turned to 112131415 Stronger - the same relative position. If both spring adjusting sleeves are not adjus[...]

266 SUPPLEMENT FOR 1980 MODEL If you don't loosen the torque link nut, it may lead to brake panel fracture when the chain adjusters are set. A. Torque Link Nut 6. Safety Clip 2. Before tightening the rear axle nut, center the brake panel assembly in the brake drum. This is done by tightening the axle lightly, spinning the wheel, and depressing[...]

SUPPLEMENT FOR 1980 MODEL 267 @If it does not, remove the cam lever, and then remount Brake Rod Joint it at a new position on the shaft for the proper angle. Since a cam lever angle greater than 90' LWARNINGh reduces braking effectiveness, this adjust- ment should not be neglected. When remounting the cam, be sure that the position of the indi[...]

268 SUPPLEMENT FOR 1980 MODEL Disassembly TORQUE AND LOCKING AGENT The table below shows the tightening torque for the parts which are added to the previous model. Tighten the other parts to the torque listed on Pgs. 39- 43. Part [Engine] Air suction valve cover bolts $6 Pl .O (on US model) Starter motor terminal nut $6 Pl .O (on KZ550) [Chassis] F[...]

SUPPLEMENT FOR 1980 MODEL 269 To remove the air screw: exhaust pipe on KZ400 and KZ550. The marks for *Using an awl or some other suitable tools, punch and KZ400 and KZ550 are shown in the following table. pry off the air screw plug. Table N5 ldentification Marks A. Air Screw Plugs @Turn in the air screw and count the number ot turns until it seats[...]

270 SUPPLEMENT FOR 1980 MODEL .Pull the vacuum switch valve with the hoses attached free off the motorcycle. Installation Note: .Check that all hoses fit in place, and that all clamps are installed. CYLINDER HEAD COVER (on US Model) Removal : .Remove the fuel tank (Pg. 47). .Remove the ignition coils (Pg. 57). .Slide up the hose clamps (2), and pul[...]

SUPPLEMENT FOR 1980 MODEL 271 and the #1 and #4 carburetor holders. Each hose CAMSHAFT SPROCKETS (on KZ400) end should be secured by a hose clamp. Refer to Pg. 61, noting the following: *For KZ400, set the sprocket on the camshaft, aligning the bolt holes. Use the two of the sprocket bolt holes 4. Thoroughly warm up the engine, allow it to cool com[...]

272 SUPPLEMENT FOR 1980 MODEL PISTON RINGS (on KZ400) The pistons on KZ400 use the one-piece type piston oil rings instead of the separate type piston oil rings. Refer to the follows when installing the oil rings: .Install the oil ring so that the correct side (marked "T") faces up. .Turn the rings so that the opening in the top ring and [...]

Starter Motor (KZ550) SUPPLEMENT FOR 1980 MODEL 273 2. There is four carbon brushes on the motor for KZ550, and they are connected to the motor termi- nal the leads. 3. When installing the brush assembly to the yoke, tighten the terminal nut to 1 .I kg-m (95 in-lbs) of torque without the terminal bolt turning. A. Pick-up Coil Cover PICK-UP COl L AS[...]

274 SUPPLEMENT FOR 1980 MODEL *Pull off the right side cover, disconnect the 4-pin connector that joins the pick-up coil leads to the IC igniter, and slide the leads free from the clamps (2) beneath the engine. ENGINE REMOVAL A. Pick-up Coil Lead C. Clamps B. 4-pin Connector *Remove the pick-up coil assembly mounting screws (3), and remove the pick[...]

SUPPLEMENT FOR 1980 MODEL 275 3. For KZ400, remove the clip from the drive chin master link to free the drive chdin from the engine sprocket. FRONT WHEEL (on KZ550-C) Speedometer Gear Housing Disassembly and Assembly Notes: Refer to Pgs. 116-1 17, adding the following: 1. To remove the speedometer gear 14 , pull out the grease seal 15 using a hook,[...]

276 SUPPLEMENT FOR 1980 MODEL Bearings, Brake Disc Removal and Installation: Refer to Pgs. 11 7-1 18, noting the following: To remove the brake disc IO , remove the disc mount- ing Allen bolts 9 (7), and take off the disc. To remove the left side ball bearing I , remove the circlip 6 and speedometer gear driver 7 , and remove the left side ball bea[...]

SUPPLEMENT FOR Front Brake Caliper (KZ550-C) Do not attempt to drive the motorcycle vh until a full brake lever is obtained by pumping the brake lever until the pads are against the disc. The brake will not function on the first applica- tion of the lever if this is not done. Caliper Disassembly: .Remove the caliper holder shaft bolts 1 (2), and pu[...]

SUPPLEMENT FOR 1980 MODEL Apply brake fluid to the outside of the piston dnd the fluid seal, and push the piston into the cylinder by hand. Take care that neither- the cylinder nor the piston skirt get scratched. Install the dust seal around the piston. Check that the dust seal is properly fitted into the grooves in the piston and on the caliper. C[...]

Installation: .Check to see that the coupling collar, coupling sleeve, rubber damper, and brake panel are in place. .Slide the axle through the left chain adjuster, coupling collar, coupling, coupling sleeve, rear hub, brake panel, spacer, and right chain adjuster from the left to right. The chain adjusters should be installed with the notch mark s[...]

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SUPPLEMENT FOR 1980 MODEL 281 Wheel Coupling Disassembly and Assembly: Refer to Pg. 126, noting the following: .Using the bearing driver and driver holder (special tools: PIN 57001 -296, -1 39), install the wheel coupling ball bearing until it stops. TUBELESS TIRES (on KZ550-C) The tubeless tires are mounted on KZ550-C. Damage to the rim flanges an[...]

282 SUPPLEMENT FOR 1980 MODEL .Apply a soap and water solution, or rubber lubricant to the rim flanges, rim protectors, tire beads, and tire Irons. *Check the tire rotation mark on the rear tire and install it on the rim accordingly. NOTE: The direction of the tire rotation is shown by an arrow on the tire sidewall. A. Rim Protectors (57001-1063) B[...]

SUPPLEMENT FOR 1980 MODEL 283 Rim Line A. Handlebar B. Front Fork C. 10" *If the rim lines and tire sidewall lines are not parallel, remove the valve core. Lubricate the rim flanges and tire beads. Install the valve core and inflate the tire again. *After the tire beads seat in the rim flanges, check for air leaks. Inflate the tire slightly ab[...]

284 SUPPLEMENT FOR 1980 MODEL Front Fork (KZ550-C) 1. Piston and Cylinder Unit 2. Piston Ring 3. Spring 4. Piston Base 5. Dust Seal 6. Circlip 7. Oil Seal 8. Oil Seal Seat 9. Guide Bush 1 0. Left Outer Tube 11. Gasket 12. Allen Bolt 13. Gasket 14. Drain Bolt 15. Rubber Cap 16. Retaining Ring 17. Air Valve 1 8. 0 Ring 19. Top Plug 20. 0 Ring 21. Cla[...]

Assembly Notes: Inspect the oil seal and gu~de brushes (Pg. 295), and replace them with new ones if necessary. Also check the 0 ring for damage. Replace them with a new one if damaged. Being careful not to damage the guide bush at the lower end of the inner tube, insert the inner tube. Apply liquid gasket to both sides of the gasket II , apply a no[...]

286 SUPPLEMENT FOR 1980 MODEL Maintenance CARBURETOR Refer to Pgs. 156- 162, noting the following: 1. Table N6 shows the carburetor specifications for KZQOQJ and KZ550. 2. Jet needle on US model carburetor has only one groove in which the clip is set. Table N6 Carburetor Specifications I KZ550 (US) I K22P-2C 1 #92 1 4D92 1 #32 1 - 1 2.5 1 29.5 * 1 [...]

SUPPLEMENT FOR 1980 MODEL 287 Air Suction Valve The air valve is essentially a check valve which allows fresh air to flow only from the air cleaner into the ex- haust port. Any air that has passed the air suction valve is prevented from returning. Remove and inspect the air suction valves periodically (Pg. 262). Also, remove and inspect the air suc[...]

288 SUPPLEMENT FOR 1980 MODEL *Gradually raise the vacuum (lower the pressure) applied to the vacuum switch valve, and check the valve opera- tion. When the vacuum is low enough, the vacuum switch valve should permit air to flow. When the vacuum reaches a certain level between 40 and 46 cmHg, it should stop air flow. When the vacuum is high enough,[...]

SUPPLEMENT FOR 1980 MODEL 289 The indication of "TUBELESS" on the tire sidewall shows that the tire is designed for tubeless use. A. "TUBELESS" The tires are designed to provide good traction and power transmission during acceleration and braking, even on bad surfaces. To do this, they must be inflated to the correct pressure an[...]

290 SUPPLEMENT FOR 1980 MODEL OBefore buffing the tires, thoroughly clean the area around the puncture with a suitable solvent and scrape out all mold lubricants (i.e. silicon, graphite, etc.). Let dry before bufffing. Kenter the COMBl UNlT on the puncture inside of the tire and draw an outline (do not use crayon). buff the area slightly larger tha[...]

SUPPLEMENT FOR 1980 MODEL 291 OPull the end of the stem through the puncture without turning until the base presses against inside of the tire. roll the stitcher cover the patch as hard as possible, keeping strokes close together and working from the center outwards. cut off the protruding rubber tail flush with the tire surface. .Install the tire [...]

292 SUPPLEMENT FOR 1980 MODEL Air Valve I 1. Locknut 2. Nut 3. Washer 4. Cast Wheel 5. Grommet 6. Valve Stem Axle, Grease Seal, Wheel Bearing, and Rear Wheel Coupling Refer to Pgs. 1 95 - 196. Speedometer Gear Housing The speedometer gear housing is mounted on the left side of the front hub. The speedometer gear and pinion are in the housing, trans[...]

SUPPLEMENT FOR 1980 MODEL 293 The force applied by the rider upon braking is trans- mitted to the interior of the brake by a camshaft. The force applied at the brake pedal is transmitted by a rod to the cam lever which then turns the camshaft. When the camshaft rotates, the large portion of the cam is forced between the two brake shoes. Since the s[...]

294 SUPPLEMENT FOR 1980 MODEL Camshaft, shaft hole wear Excessive shaft to hole clearance will increase cam- shaft play and reduce braking efficiency. Measure the shaft diameter with a micrometer, and replace it if it is worn down to less than the service limit. Measure the inside diameter of the camshaft hole, and replace the brake panel if the ho[...]

SUPPLEMENT FOR 1980 MODEL 295 Front Fork Load/Compression Stroke Replacement (per each fork leg) (N91) 200 01 ' 2 Cornprewon jmmj Fork oil change *Put a motorcycle up on its center stand. *Release air through the air valve at the top end of the front fork. *Remove the handlebar off the stem head. .Remove the drain bolt from the lower end of th[...]

296 SUPPLEMENT FOR 1980 MODEL Front Fork Spring Force (per each fork leg) -j2 0 50 100 150 180 Compression (mrn) REAR SHOCK ABSORBER (on KZ550-C) The rear shock absorbers on KZ550-C can be adjusted by the spring force and damping force. Shock absorber spring force can be adjusted to 5 settings, and damping force can be adjusted to 4 settings. Shock[...]

SUPPLEMENT FOR 1980 MODEL 297 IGNITION SYSTEM (on KZ550-C) The ignition system for this model i3 essentially a battery and coil ignition sy5tem where the battery sup- plies the current for the primary circuit in the ignition system. However, this ignition system is transistorized and controls the current for the primary circuit by use of a solid st[...]

298 SUPPLEMENT FOR 1980 MODEL Pick-up Coil Output Voltage at Low and High Speed A. Pick-up Coil Assembly IC Igniter The IC igniter utilizes the voltage pulse sent from the pick-up coil as follows to obtain stable induced high tension voltage from low to high engine speeds. The output voltage of the pick-up coil alternates as shown in Fig. N99. Ootp[...]

Ignition System Troubleshooting Guide SUPPLEMENT FOR 1980 MODEL 299 (Nt02) Beginning -7 rm dYnamlc correct and rotor 'Yo Perform operational inspection of Ignition system 1 Yes l nspect ignition coil 4 Yes Replace Inspect > damaged pick-up coil 4 parts No 5 v Perform ignition v system wiring End check Replace igniter Yes Perform IC > if[...]

300 SUPPLEMENT FOR 1980 MODEL Description of Each Testing Procedure 1. Dynamic lgnition Timing Test Check the ignition timing with a strobe light for both low and high speed operation. Timing advance begins at 1,400- 1,600 rprn and reaches the maximum advance at 3,000 - 3,400 rpm. As a result, the timing must be checked at idle (below 1,400 rpm) an[...]

SUPPLEMENT Operational Inspection of the lgnition System Ignition Engine Switch Stop Switch Fuse nn L Elec .Connect the spark plug leads to the Electrotester in the same way as for measuring the arcing distance. For this test, the Electrotester need not be supplied with electric power. .Slide the adjusting knob to set the arcing distance to 5-8mm. [...]

302 SUPPLEMENT FOR 1980 MODEL - - *Connect the meter (-) lead to ground. Table N21 Wiring Inspection Reading Battery voltage 0.5 - 1 .OV Table N22 IC lgniter out of Circuit Test IGNITION SYSTEM (on KZ400) Timing Advancer Refer to Pgs. 223-224, noting the following: Location At 4-pin connector for the ignition coils At 4-pin connector for the pick-u[...]

SUPPLEMENT FOR 1980 MODEL 303 Yoke assembly inspection Using the highest ohmmeter range, measure the resistance between the carbon brush and the yoke (housing). If there is any meter reading, the brush assembly is shorted to the ground, the terminal insulator must be replaced. LIGHTING SYSTEM (on US, Canadian Model) Headlight Circuit Fig. N111 is U[...]

304 SUPPLEMENT FOR 1980 MODEL SERVICE DATA FOR KZ400 The following tables show the service data applied only on KZ400-J. Refer to the maintenance or supple- ment section for the items not included here. Table N24 Cylinder Inside Diameter 1 52.10 mm, or more than 0.05 rnm difference between anv two measurements I Table N25 Piston Diameter 1 Service [...]

SUPPLEMENT FOR 1980 MODEL 305 Appendix ADDITIONAL CONSIDERATIONS FOR RACING (on US Model) Carburetor jet needle on the carburetor of US model has only one groove in which the clip is set. So a richer mixture cannot be made by changing the position of the needle. SPECIAL TOOLS Refer to Pgs. 244- 247, adding the following: 1. For the motorcycle with [...]

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SUPPLEMENT FOR 1981 MODEL 309 Supplement for 1981 Model Table of Contents [ALL] MODEL IDENTIFICATION ................................. 310 SPECIFICATIONS SPECIFICATIONS ....................................... 312 1981 MODEL MAIN CHANGED ITEMS ...................... 316 PERIODIC MAINTENANCE CHART ........................ 317 ADJUSTMENT FRONT FORK ..[...]

310 SUPPLEMENT FOR 1981 MODEL Model Identification KZ4OO- J2[...]

SUPPLEMENT FOR 1981 MODEL 311[...]

312 SUPPLEMENT FOR 1981 MODEL SPEC1 FlCATlONS l tems Dimensions Overall length Overall width Overall height Wheelbase Road clearance Dry weight Feul tank capacity Performance Climbing ability Braking distance Minimum turning radius Engine Type Bore and stroke Displacement Compression ratio Maximum horsepower Maximum torque Valve timing l nlet Open [...]

SUPPLEMENT FOR 1981 MODEL 313 * : Same as KZ400-J2 8: European model @: West German model ** : Same as KZ500-B3 UK : U.K. model *** : Same as KZ550-A2 : U.S. model KZ550-A2 1 KZ550-B2 1 KZ550-C2 1 KZ550-Dl 2,160 mm, @ 2,190 mm 850 mm, @ 805 mm 1,200 mm, @ 1,205 mm 1,420 mm 140 mm 192 kg, @ 198 kg 12.4 liters * * * * * 188 kg, @ 191 kg * * 740 mm 1,[...]

314 SUPPLEMENT FOR 1981 MODEL SPEC1 FICATIONS (CONT.) l terns Transmission Type Clutch Gear ratio: 1 st 2nd 3rd 4th 5th 6th Primary reduction ratio Final reduction ratio Overall drive ratio Frame Type Steering angle Castor Trail Tire Front Rear Suspension Front Rear Wheel travel Front Rear Front fork oil Type Capacity (per each fork) Brakes Type Fr[...]

SUPPLEMENT FOR 1981 MODEL 315 2.375 (3811 6) 5.937 @Top gear 130190-16 67s (tubeless) b * : Same as KZ400-J2 Q : Italian model @ : Swiss model ** : Same as KZ500-B3 @ : Other than European, US, : U.K. model ***** : Same as KZ550-C2 and Canadian model : West German model[...]

316 SUPPLEMENT FOR 1981 MODEL 1981 MODEL MAIN CHANGED ITEMS 1. Transistor Controlled Breakerless Ignition Motorcycle for 1981 model has a magnetically con- trolled transistor ignition system which is the same system as 1980 KZ550C had. Refer to the following items in 1980 Supplement. [I980 Supplement] olgnition Timing (Pg. 263) OPickup Coil Assy (P[...]

SUPPLEMENT FOR 1981 MODEL 317 PERIODIC MAINTENANCE CHART The maintenance and adjustments for 1981 model must be done in accordance with this chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected. -- ODOMETER READING* km month 1 0 0 1 214 t Brake - check t Brake light switch - [...]

318 SUPPLEMENT FOR 1981 MODEL Adjustment FRONT FORK See the following table to adjust the fork air pressure. Table N34 Front Fork Air Pressure 0.6 kg/cm2 1 0.5- 0.7 kg/cm2 I KZ550C 1 (85 psi, (7.1 - 10.0 psi, I 1 60 kPa) 1 50-70 kPa) A. Arrow Mark C. Damper Adjuster I B. Position Number REAR SHOCK ABSORBERS Refer to 1980 Supplement with the followi[...]

SUPPLEMENT FOR 1981 MODEL 319 Disassembly CLUTCH 2. Removal and Installation Procedures The clutch release is modified as shown in Fig. N120. Removal: Refer to the following exceptions. @Remove the engine sprocket cover (Pg. 69). @Remove the clutch release lever and steel ball assembly. @Remove the clutch adjusting cover screws (2), and take Clutch[...]

320 SUPPLEMENT FOR 1981 MODEL REAR DISC BRAKE The reservoir is separated from the rear master cylinder body, and connected to it with a brake hose. Rear Master Cylinder, Reservoir Removal: .Pull off the right side cover. .Remove the rear brake reservoir mounting bolt, and take the reservoir off the frame. *Remove the banjo bolt to disconnect the br[...]

SUPPLEMENT FOR 1981 MODEL 321 Rear Master Cylinder, Reservoir Assembly Note: When handling the quartz-halogen bulb, 1. Before assembly, clean all parts including the master never touch the glass portion with bare cylinder with brake fluid or alcohol, and apply brake hands. Always use a clean cloth. Oil contamination fluid to the removed parts and t[...]

322 SUPPLEMENT FOR 1981 MODEL FUEL LEVEL SENDER (on KZ550D) OThe shift pedal linkage angles are at 90'. The fuel level sender is attached on the bottom of oThe lower side of the shift pedal end matches the the fuel tank. upper level of the left footpeg. If the pedal is found improperly adjusted by either Fuel Level Sender (on KZ550D) one of th[...]

1. Circlip 2. Flat Washer x 2 3. Shift Pedal 4. Pivot Bolt OIL COOLER (on KZ550D) SUPPLEMENT FOR 1981 MODEL 323 Shift Pedal Linkage (on KZ550D) (-1 A. Mounting Bolts .Keep the oil tube fittings from turning, loosen the oil tube upper mounting nuts, and take off the oil tubes. 5. Pedal Rubber 6. Shift Linkage Rod 7. Shift Lever 8. Bolt A. Oil Tube F[...]

324 SUPPLEMENT FOR 1981 MODEL Table N35 Oil Cooler lnstallation - Part Name Tightening 1 Toraue I To prevent damage to the oil tube fittings, keep them with a wrench from turning during the oil tube upper mounting nuts tightening or loosening. 2. Check the oil level and add more if necessary (Pg. 24). -. 1 2 3 4 5 FAIRING (on KZ550D) A. Fairing Oil[...]

SUPPLEMENT FOR 1981 MODEL 325 Installation Note: 1. If the windshield is replaced with a new one, install it on the fairing as shown in Fig. N137. HEADLIGHT (on KZ550D) Removal: @Remove the fairing (Pg. 324). @Take out the retaining screws. @Swing the outer rim out from the housing. and dis- A. Lower Mounting Bolts connect the headlight socket from[...]

326 SUPPLEMENT FOR 1981 MODEL *Remove the rubber boot. @Push the bulb stop and turn it counterclockwise so that the bulb stop can be removed, and then remove the bulb. When handling the quartz-halogen bulb, never touch the glass portion with bare hands. Always use a clean cloth. Oil contamination from hands or dirty rags can reduce bulb life or cau[...]

SUPPLEMENT FOR 1981 MODEL 327 Maintenance CYLINDER HEAD VALVE Valve seat cutters (special tools) are newly available to repair the valve seat. See the following exceptions. Valve seat inspection The valve must seat in the valve seat evenly around the circumference over the specified area. If the seating area is too wide, the seating pressure per un[...]

328 SUPPLEMENT FOR 1981 MODEL Cutting Valve Seat (m) 1. Original Seating Surface 2. Cut seating surface with following seat cutters to obtain new seating surface: Inlet: Seat Cutter stamped 3 (57001-1 11 5) Exhaust: Seat Cutter stamped '2 (57001 -1 1 14) 3. New Seating Surface 4. Cut this surface to adjust outside diameter of new seating surfa[...]

SUPPLEMENT FOR 1981 MODEL 329 Table N39 Caliper Parts IMeasurGT- 1 Service Limit I I Cylinder Inside Diameter / 42.92 mm I Piston Outside Diameter 1 42.75 mm 1 FRONT FORK For 1981 model except for KZ550C, refer to Pgs. 207 - 21 0, 294 - 296, noting the following. See Pgs. 294 - 296 for KZ550C. Table N40 Fork Oil @ : KZ55OD Table N41 Fork Spring Fre[...]

330 SUPPLEMENT FOR 1981 MODEL Swing arm lubrication If either the high or low beam burns out, the reserve ln order for the swing arm to function safely and lighting system switches over to the remaining filament wear slowly, it be properly lubricated in automatically, and lights the white headlight failure ance with the Periodic Maintenance Chart ([...]

SUPPLEMENT FOR 1981 MODEL 331 *Turn on the headlight and set the dimmer switch to the low beam position. *Disconnect the wire which is connected to the red/ yellow lead to simulate a bad low beam filament. At this time the high beam should go on more dimly than normal, and the white headlight failure indicator light should come on. *Connect the red[...]

332 SUPPLEMENT FOR 1981 MODEL and then inspect the distance sensor and turn signal switch/solenoid assembly. If all these are good, replace the turn signal control unit. Distance sensor inspection .Open the headlight housing, disconnect the 4-pin con- nector from the speedometer, and remove the speed- ometer cable lower end from the speedometer gea[...]

SUPPLEMENT FOR 1981 MODEL 333 Table N45 Wirina lns~ection "Connect the meter negative (-) lead to ground. ., . this time the solenoid should return the turn signal switch to the off position. *If it does not do this for both right and left positions, replace the switch assembly. Do not connect the battery lead to the (CAUTIONI whitelgreen lead[...]

334 SUPPLEMENT FOR 1981 MODEL .Check that the float moves up and down smoothly without binding or hitting the fuel tank. It should go down under its own weight. If the float does not move smoothly, replace the sender. FUEL GAUGE (on KZ550D) The fuel gauge is electrically operated through a sender in the fuel tank. A float in the tank rides up and d[...]

SUPPLEMENT FOR 1981 MODEL 335 *If the voltmeter reading does not correspond to the table, the wiring is bad. Check the leads and connec- tors, and replace or repair any damaged wiring. Table N49 Wiring Check I I - I I Meter (+) -+ I Meter Ranne I 2SV DC I Brown ~ead 1 Battery I Meter (-) + voltage I Black!Yellow Lead I I Connections NOTE: With one [...]

336 SUPPLEMENT FOR 1981 MODEL Appendix SPECIAL TOOLS The following special tools are 1. The valve seat cutters which newly available now. can be used for all 4-stroke engines are manufactured by electrically nickelplating diamond particles on to the cutter body and can grind the valve seat in constant quality, which assures smooth finish of the sea[...]

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INDEX 343 Index Additional Considerations for Racing ............... 242. 305 Air Cleaner ............................................................. 154 Air Cleaner Element ................................................ 49 Air Suction Valve ............................................. 270. 287 Air Valve (Tubeless Tire) .......................[...]

344 INDEX Idle Gear (Starter Motor) ............................................ 87 Idling Adjustment .............................................. 21, 263 Ignition Coil ....................................................... 57. 221 Ignition Switch ................................................. 141. 229 Ignition System ........................[...]

INDEX 345 Oil Pressure .......................................................... 81 Starter Lockout .................................................. 142 Tachometer ...................................................... 140. 236 Tachometer Cable ..................................................... 136 Tail Light .................................[...]