Motorcycle Assembly & Preparation Manual
Contents
1. 5 MEO7B239 m L A Front Brake Fluid Reservoir B Upper Level Line A WARNING When working with the disc brake ob serve the precautions listed below 1 Never reuse old brake fluid 2 Do not use fluid from a container that has been left unsealed or that has been open for a long time 3 Do not mix two types and brands of fluid for use in the brake This low ers the brake fluid boiling point and could cause the brake to be ineffec tive It may also cause the rubber brake parts to deteriorate 4 Don t leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid 5 Don t change the fluid in the rain or when a strong wind is blowing 6 Brake fluid quickly ruins painted sur faces any spilled fluid should be completely wiped up immediately 7 If any of the brake line fittings or the bleed valve is opened at any time the AIR MUST BE BLED FROM THE BRAKE LINE Install the diaphragm and reservoir e Tighten the reservoir cap screws to the spec ified torque Torque 1 5 N m 0 15 kgf m 13 in lb Operate the brake lever several times elf it feels spongy there might be air in the brake line f necessary bleed the air in the front brake lines e Also check for fluid leakage around the fit tings Brake Line Air Bleeding e Remove the reservoir and diaphragm and check that there is plenty of fluid in the res2. Kawasaki KX450F Motorcycle Assembly amp Preparation Manual Foreword In order to ship Kawasaki vehicles as effi ciently as possible they are partially disassem bled before crating Since some of the most commonly removed parts have a direct bear ing on a vehicle s reliability and safety consci entious pre sale assembly and preparation be comes extremely important Good setup pro cedures can prevent needless warranty claims and give customers a greater sense of confi dence in Kawasaki and their Kawasaki Dealers This Assembly and Preparation Manual ex plains step by step procedures of the following items for the Kawasaki KX450F 1 Uncrating 2 Assembly 3 Preparation The selling dealer assumes sole responsibil ity for any unauthorized modifications prior to sale Refer to your Service Binder for any Ser vice Bulletins specifying Factory Directed Mod ifications Special Claims which must be per formed before the vehicle is ready for sale Whenever you see the following symbols heed their instructions Always follow safe operating and maintenance practices 2012 Kawasaki Heavy Industries Ltd DANGER DANGER indicates a hazardous situa tion which if not avoided will result in death or serious injury WARNING WARNING indicates a hazardous situa tion which if not avoided could result in death or serious injury NOTICE is used to address practices not relate
3. ane 13 Radiator Drain 14 A E cola 14 Ait CIGANGE eevee kaye si 14 Front 15 ave bene Eea 17 Clutch Lever 2 4 18 Drive CHAIN 18 FROME nae eee 20 Rear Shock 22 24 it ka 24 COONAP rin deyo e vie te hia No lab dekad ia en 24 Engine Oil 4 stroke 2 Ske poet na a ei poison 25 Throttle Grip and 4 2 000 0 000000 26 Idle Speed Adjustment 222222211 27 Fastener Check 30 Standard Torque 32 Test Ride the Motorcycle 22020000400 32 ASP Check Li SE tan a e pl ak be aa ap antan 32 Uncrating Opening Crate A WARNING Crates have sharp edges and may have nails or screws that can cause cuts and injury Always wear protective gloves boots and eye protection when uncrat ing to prevent injury MCO3003B 5 A WARNING The steel crate panel plates and fasten e
4. A Idle Adjusting Screw Choke Knob B Tester Open and close the throttle grip a few times to make sure that the idle speed is within the specified range With the engine idling turn the handlebar to each side If handlebar movement changes the idle speed check the throttle cable routing and free play A WARNING Operation with incorrectly routed or damaged throttle cable could result in an unsafe riding condition Be sure the throttle cable is routed correctly prop erly adjusted and is not damaged in any way 28 PREPARATION This motorcycle is designed for compe tition use only Therefore the radiator does not incorporate a coolant reserve tank or cooling fan Prolonged idling of the engine with no airflow through the radiator can cause coolant loss and engine overheating resulting in possible engine damage Any riding conditions that increase engine tem perature will further reduce idling time before coolant loss occurs These con ditions include high ambient tempera ture sandy or muddy terrain or other conditions causing high engine loads at low speeds Furthermore warming the engine up excessively before operation or leaving idling with the hot engine temperature after operation results in the engine overheating too Check for any exhaust leaks and correct if necessary PREPARATION 29 This page intentionally left blank 30 PREPARATION Fastener Check e The torque val
5. attempt to ride the motorcycle when the side stand is installed Brake Disc Cleaning Clean the front and rear brake discs using oilless solvent WARNING An anticorrosive treatment applied to the brake discs will increase braking distance and can cause an accident resulting in serious injury or death Re move the anticorrosive treatment using an oilless solvent 14 PREPARATION D41B069 P Radiator Drain Hose e Pull the radiator over flow hose end out of the engine guard MD16008B 6 Preparation Air Cleaner Air Cleaner Element Inspection The foam cleaner element on off road models is oiled prior to shipping However over time the filter will dry and filtration performance will diminish e Remove the side cover bolts left and right 2 to remove the seat A e ME35B021 P A Bolt D 8 L 16 B Seat Inspect the foam air cleaner element for proper oiling If the foam air cleaner element is dry remove the wing bolt and take out the air cleaner element 5 022 P Wing Bolt B Air Cleaner Element e Take the element off its holder 0090028 2 A Air Cleaner Element B Holder Saturate the element with high quality foam air filter oil and make sure that the oil is evenly applied throughout the element Squeeze out the excess oil but do not wring the element as this could cause tearing In this
6. cable as follows e Turn the adjuster in all the way e Slide the dust cover Loosen the locknut on the middle upper end of the clutch cable and turn the adjuster so that the clutch lever play is 8 13 mm 0 3 0 5 in 0128056 A Dust Cover B Locknut C Adjuster e Tighten the locknut and slide the dust cover back in place NOTE OAfter the adjustment is made start the engine and check that the clutch does not slip and that it releases properly OFor minor corrections use the adjuster at the clutch lever Drive Chain Drive Chain Slack and Wheel Alignment Inspection e Set the motorcycle up on its side stand e Make sure that the drive chain has the speci fied amount of play and that the left and right notches are on the same marks or points on the left and right of the swingarm A WARNING Misalignment of the wheel will result in abnormal tire wear and can cause an un safe riding condition Be sure the wheel is properly aligned e Raise the rear wheel off the ground rotate the rear wheel to find the place where the chain is tightest because it wears unevenly e Push up the drive chain in the middle of the upper chain run to measure the chain slack The distance between the chain and the swingarm at the end of the chain slipper should be 52 58 mm 2 0 2 3 in Drive Chain Slack 52 58 mm 2 0 2 3 in WE13B058 P A 52 58 mm 2 0 2 3 in e
7. next to the oil level inspection window A Oil Level Inspection Window B Upper Level Line C Lower Level Line D Oil Filler Cap elf the oil level is too high open the oil filler cap and remove the excess oil through the oil filler opening using a syringe or some other suitable device f the oil level is too low add oil through the oil filler opening to reach the correct level Use the same type of oil that is already in the en gine e Before reinstalling the cap be sure to replace the O ring in it with a new one Recommended Engine Oil Type Castrol POWER1 R4 Racing SAE 5W 40 or API SG SH SJ SL or SM with JASO MA MA1 or MA2 Viscosity SAE 10W 30 10W 40 10W 50 Capacity 0 96 L 1 01 US qt when filter is not removed 0 98 L 1 04 US at when filter is removed The oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area NOTE ODo not add any chemical additive to the oil Oils fulfilling the above requirements are fully formulated and provide adequate lubrication for both the engine and the clutch SAE 10W 50 ee ae SAE 10W 40 aes es A SAE F 20 10 0 10 20 30 40 C fl ae Se Ten ei 4 14 32 50 68 86 104 F Ld en VDO4006BM2 Throttle Grip and Cable Throttle Grip Free Play Inspection Check the throttle grip free play If the free play is incorrect adjust the throttle cable Throttle G
8. side to side by just a few degrees can drastically alter the oil level indicated in the oil level inspection win dow Be sure the unit is upright when check ing the level Verify Engine Oil Presence If no oil appears in the oil level inspection win dow tip the motorcycle slightly to the right un til oil is visible then return to an upright posi tion If no oil appears even when tipped at an extreme angle remove the drain bolts to empty any oil that may be in the transmission and crankcase reinstall the drain bolts and refill with the specified amount of oil If oil appears in the glass when the machine is tipped but is not visible when perpendicular you must verify the oil level after the engine has been run If the engine is run without oil it will be severely damaged 26 PREPARATION Engine Oil Level Inspection e After you have verified that the engine con tains oil start the engine allow it to idle for several minutes then shut it off DO NOT REV THE ENGINE AND SHUT IT OFF AT HIGH RPM Doing so can leave a significant amount of oil in the crank room and top end leading to a false oil level reading e Allow the oil to settle by keeping the motorcy cle upright on its wheels for several minutes Check the engine oil level with the motorcycle vertical through the oil level inspection win dow on the lower right side ofthe engine The engine oil level should come up between the upper and lower level lines
9. the tightest position and readjust if necessary Install a new cotter pin NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle tighten the nut clockwise up to the next alignment Olt should be within 30 degrees OLoosen once and tighten again when the slot goes past the nearest hole IMO7000BS1 A Cotter Pin B Turning Clockwise Bend the cotter pin over the nut 20 PREPARATION HJO7002BS1 A Cotter Pin B Nut A WARNING A loose axle nut can lead to an acci dent resulting in serious injury or death Tighten the axle nut to the proper torque and be sure the cotter pin is installed correctly Check the rear brake effectiveness Front Fork Air Pressure Adjustment Before riding adjust the air pressure to the specific value e Raise the front wheel off the ground using a jack special tool 57001 1238 and attach ment special tool 57001 1608 e Prepare the commercially available suitable hand air pump and air pressure gauge e Remove the air valve plug from the front fork top plug ME16B037 A Air Valve Plug B Front Fork Top Plug e Install the air valve adapter NOTE OWhen using the air valve adapter apply grease to the O ring ME16B038 A Air Valve Adapter e Using a commercially available suitable hand air pump and air pressure gauge adjust the air p
10. 11061 0082 5 Gasket Clutch Inner Cover 2 11061 0453 6 Gasket Clutch Outer Cover 2 11061 0259 7 Gasket Magneto Cover 2 11061 0452 8 Gasket Muffler D 53 L 32 2 11061 0434 9 O Ring Oil Filter Cap 2 92055 1577 Assembly Handlebar e Apply 2 stroke oil to the edge slash area of the handlebar 8 06071 51 A 120 mm 4 72 in Install the throttle grip assy on the handlebar and insert the handlebar fully into the grip MDO8B436 P A Throttle Grip Assy e Put the handlebar on the handlebar holders e Mount the handlebar clamps e Apply 2 stroke oil to the handlebar clamp bolts and install them ASSEMBLY 9 A Handlebar B Handlebar Holders C Handlebar Clamps D Clamp Bolts D 8 L 35 E Scales F Forward e Before tightening the bolts check the handle bar position 008089 51 A Handlebar Clamps B Align the center of the handlebar bridge with the center of the handlebar holders C D The scales on both sides are the same in width NOTE OThe handlebar angle position can be adjusted to suit your preference using the scales e Tighten the front and rear clamp bolts evenly to the specified torque Torque 25 N m 2 5 kgf m 18 16 e Make sure that the gaps between the handle bar holder and clamp is approximately equal in the front and rear side 10 ASSEMBLY MDO8090BS1 A Forward B Gap Throttle Grip Assembly e S
11. Adjust the drive chain if its slack is out of spec ification A WARNING A chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock the rear wheel severely damaging the motorcycle and causing it to go out of control Inspect the chain for damage and proper adjustment Drive Chain Slack Adjustment e Remove the cotter pin and loosen the rear axle nut Loosen the left and right chain adjuster lock ME13B059 A Rear Axle Nut B Chain Adjusting Bolt C Chain Adjuster Locknut D Marks E Notch F Cotter Pin PREPARATION 19 f the chain is too loose turn out the left and right chain adjusting bolts evenly f the chain is too tight turn in the left and right chain adjusting bolts evenly e Turn out both chain adjusting bolts evenly un til the drive chain has the correct amount of slack To keep the chain and wheel properly aligned the chain adjuster notches should align with the same marks in each side of the swingarm NOTE OWheel alignment also be checked using the straightedge or string method A WARNING Misalignment of the wheel will result in abnormal tire wear and can cause an un safe riding condition Be sure the wheel is properly aligned e Tighten both chain adjuster locknuts e Tighten the rear axle nut to the specified torque Torque 108 N m 11 0 kgf m 80 16 e Rotate the wheel measure the chain slack again at
12. ard Torque Table This table relating tightening torque to thread diameter lists the basic torque for bolts and nuts Use this table for only the bolts and nuts which do not require a specific torque value All of the values are for use with dry solvent cleaned threads General Fasteners Threads Torque dia mm N m kgf m ft lb 5 3 4 4 9 0 35 0 50 30 43 in lb 6 5 9 7 8 0 60 0 80 52 69 in lb 8 14 19 1 4 1 9 10 0 13 5 10 25 34 2 6 3 5 19 0 25 0 12 44 61 4 5 6 2 33 45 14 73 98 74 10 0 54 72 16 115 155 11 5 16 0 83 115 18 165 225 17 0 23 0 125 165 20 225 325 23 0 33 0 165 240 Test Ride the Motorcycle e Complete the test ride check list Control Cables Throttle cable must work without binding in any steering position Steering Action is free from lock to lock Suspension Check operation front and rear Engine Kick starter works properly and engine starts promptly Good throttle response and return Transmission and Clutch Smooth operation Brake Adequate smooth stopping power No drag Engine Stop Switch Works Launch Control Mode Button Works 1 Start the engine 2 Shiftinto neutral 1st or 2nd gear 3 Push the launch control mode button for over two seconds 4 The orange launch control mode indicator light LED will blink to indicate the system is operating 5 When shifting into 3r
13. case too much oil is better than too little Finally pat the inside of the element with a paper towel to remove any excess oil Install the element onto its holder and coat the element lip and lip seat with a thick layer of all purpose grease to assure a complete seal vDog9005BM2 A Apply grease e Install the air cleaner element so that its tab faces upward and its projections align with the holes in the housing and tighten the wing bolt making sure that it is properly seated and sealed 350198 G Projections Holes e To install the seat align the front hook on the seat with front receiver on the fuel tank Slide the seat forward so that center hook engages first followed by the front hook PREPARATION 15 A Seat B Front Hook C Front Receiver D Center Hook E Center Receiver e Tighten the side cover mounting bolts left and right Front Brake Front Brake Fluid Level Inspection With the front brake fluid reservoir held hori zontal check that the fluid level is above the lower level line MEO7B238 A Front Brake Fluid Reservoir B Lower Level Line e f the fluid level in the reservoir is below the lower level line check for fluid leaks in the front brake lines and fill the reservoir e Remove the reservoir cap and diaphragm and fill the reservoir to the upper level line with DOT4 brake fluid 16 PREPARATION
14. d the system is deactivated automatically and the indicator light stops blinking No Unusual Noises No Fuel and Oil Brake Fluid or Coolant Leaks PREPARATION COMPLETE A amp P Check List e Complete the A amp P Check List MODEL APPLICATION Year Model Name 2013 KX450FD KX450F Kawasaki KAWASAKI INDUSTRIES LTD Motorcycle 8 Engine Company Part No 99939 1344 01
15. d position ME17B069 A Rebound Damping Adjuster e To adjust the rear shock absorber rebound damping turn the rebound damping adjuster at the bottom of the rear shock absorber with a standard tip screwdriver Adjust the re bound damping to the standard setting posi tion NOTICE Do not force to turn the rebound damp ing adjuster from the fully seated posi tion or the adjusting mechanism may be damaged 24 PREPARATION Rebound Damping Adjuster Settings Le 333231252423222120191817161514131211102 1 ME16129BS1 A Seated Position Adjuster turned fully clockwise B Softer Counterclockwise C Harder Clockwise D Standard Setting for European Model E Standard Setting for Australian Model Number of turns counterclockwise usable range 33 clicks or more Tire Air Pressures e To prevent flat spotting during shipment the tires are over inflated before crating Adjust the pressures to the specified values in the front and rear and make sure to tighten the caps securely Tire Air Pressure when cold Front 100 kPa 1 0 kgf cm 14 psi Rear 100 kPa 1 0 kgf cm 14 psi Fuel A WARNING Gasoline is extremely flammable and can be explosive under certain condi tions creating the potential for serious burns Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance wi
16. d to personal injury NOTE OThis note symbol indicates points of particular interest for more efficient and convenient op eration Kawasaki Heavy Industries Ltd accepts no liability for any inaccuracies or omissions in this publication although every possible measure has been taken to make it as complete and ac curate as possible All procedures and specifi cations subject to change without notice May 2012 Table of Contents UNnCrating is kitte ke ae pea pak pd a ey ka 3 Opening tye neh eee ae a be aaa 3 Parts CHECK ski ai tite kouti rate anan ka tk pk be 6 bete t bete aa k s hardest eke a e ao as e ason tal ao sab ay ce aac aa tak ans 9 ene 9 Throttle Grip ASSOMDIY asye syon yon il a 10 Front Brake Master Cylinder 10 Clutch Lever ASSOMDIY Pa tid n ek an kay anmede ande aki 11 Launch Control Mode 11 Engine Stop manni pea 11 Cables and Wiring 4000 12 Front FONN 12 Front Number 12 Fuel Tank Breather 13 9196 Stands at elt bek 13 Brake Disc Cleaning icc kk ens k
17. embly Engine Stop Switch e Install the clutch lever with the clamp and bolts D 5 L 16 on the handlebar e Tighten the clamp bolts 008105 51 A Clutch Lever Assy B 160 5 mm 6 32 in C Clamp Bolts D 5 L 16 D Horizontal Line of Frame E 30 5 Launch Control Mode Button e Remove the wiring band temporarily from the handlebar NOTE OWhen installing the removed wiring band re fer to Engine Stop Switch e Attach the clamps to the launch control mode button Install the launch control mode button assy e Tighten the screw D 4 L 14 MDO8B401 A Launch Control Mode Button B Clamps C Screw D 4 L 14 D 5 10 mm 0 20 0 39 in e Attach the clamps to the engine stop switch e Install the engine stop switch assy between the grip and clutch lever and tighten the screw D 3 L 14 Secure the engine stop switch and launch control mode button leads to the handlebar with the wiring band A Engine Stop Switch B Clamps C Screw D 3 L 14 D Launch Control Mode Button E Wiring Band 12 ASSEMBLY Cables and Wiring Routing Check that the cables wiring leads and hoses are routed correctly MDO8117B G Viewed from Front A Throttle Cables B Wiring Band C Engine Stop Switch Lead D Launch Control Mode Button Lead E Clutch Cable Front Fender e Position the front fend
18. er between the fork legs and fasten it to the steering stem base with four bolts D 6 L 18 5 NOTE OTemporarily install the front bolts first and then the rear bolts OTighten all bolts securely A Front Fender B Front Bolts D 6 L 18 5 C Rear Bolts D 6 L 18 5 Front Number Plate Handlebar Pad Installation e Install the handlebar pad onto the handlebar bridge so that the characters on the pad are shown as RENTHAL when viewed from the front of the motorcycle 0128051 A Handlebar Pad Front Number Plate Installation Position the front number plate between the brake hose and front fork and fit the two holes of the number plate to the projections of the steering stem base A Front Number Plate B Holes C Projections eFasten the number plate to the stem head with the flanged bolt D 6 L 12 e Fasten the number plate belt to the handlebar pad with a latch Y A Flanged Bolt 6 L 12 Number Plate Belt Fuel Tank Breather Hose Fit one end of the breather hose into the fuel tank cap and fit the other end into the hole of the steering shaft ASSEMBLY 13 r MD16B031 P A Fuel Tank Cap B Breather Hose L 300 C Hole Side Stand Usage e Fit the flat bar end of the side stand into the rear axle shaft VC03B006 P A Side Stand B Rear Axle Shaft NOTE ODo not start the engine or
19. er turned fully clockwise B Softer Counterclockwise C Harder Clockwise D Standard Setting for European Model E Standard Setting for Australian Model Number of turns counterclockwise usable range 2 turns or more STD Low Speed Compression Damping For European Model 11 clicks Counterclockwise from the fully seated position For Australian Model 8 clicks Counterclockwise from the fully seated position e To adjust the low speed compression damp ing turn the adjuster all the way clockwise with a standard tip screwdriver to make the damping greatest e Turn the adjuster counterclockwise to de crease damping Adjust the low speed com pression damping to the standard position Xp A Low Speed Compression Damping Adjuster B Screwdriver Low Speed Compression Damping Set tings 22212013121110 9 ME16128BS1 A Seated Position Adjuster turned fully clockwise B Softer Counterclockwise C Harder Clockwise D Standard Setting for European Model E Standard Setting for Australian Model PREPARATION 23 Number of turns counterclockwise usable range 22 clicks or more Rebound Damping Adjustment Check the position of the rebound damping adjuster at the bottom of the rear shock ab sorber STD Rebound Damping For European Model 20 clicks Counterclockwise from the fully seated position For Australian Model 19 clicks Counterclockwise from the fully seate
20. ervoir NOTE OThe fluid level must be checked several times during the bleeding operation and replenished as necessary If the fluid in the reservoir runs completely out any time during bleeding the bleeding operation must be done over again from the beginning since air will have entered the line e Attach a clear plastic hose to the bleed valve on the front brake caliper and run the other end of the hose into a container e With the reservoir cap off slowly pump the brake lever 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 brake master cylinder end of the line e Pump the brake lever a few times until it becomes hard and then holding the lever squeezed quickly open turn counterclock wise and close the bleed valve Then release the lever Repeat this operation until no more air can be seen coming out into the plastic hose B Quickly open and close the bleed valve C Release the brake lever e When air bleeding is finished check that the fluid level is between the upper and lower level lines Install the diaphragm and reservoir cap Tighten the bleed valve to the specified torque Torque 7 8 N m 0 80 kgf m 69 in Ib e Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings Rear Brake Rear Brake Fluid Level Inspection e With the rear brake fluid re
21. f slowly pump the brake pedal several times until no air bub bles can be seen rising up through the fluid from the holes at the bottom of the reservoir This bleeds the air from the rear brake master cylinder end of the line Pump the brake pedal a few times until it becomes hard and then holding the pedal pushed down quickly open turn counter clockwise and close the bleed valve Then release the pedal Repeat this operation until no more air can be seen coming up into the plastic hose 6 _ a A Hold the brake pedal applied B Quickly open and close the bleed valve C Release the brake pedal 18 PREPARATION e When air bleeding is finished check the fluid level Install the diaphragm and reservoir e Tighten the bleed valve to the specified torque Torque 7 8 N m 0 80 kgf m 69 in lb e Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings Clutch Lever and Cable Clutch Lever Free Play Inspection e Check that the clutch lever has the specified amount of free play Clutch Lever Free Play 8 13 mm 0 3 0 5 in A Clutch Lever B Adjuster C 8 13 mm 0 3 0 5 in elf the free play is incorrect adjust the free play Clutch Lever Free Play Adjustment e Turn the adjuster so that the clutch lever will have 8 13 mm 0 3 0 5 in of free play f it cannot be done use the adjuster on the middle of the
22. filler neck NOTE OCheck the coolant level when the engine is cold room or ambient temperature VDO5016BM2 A Coolant Level B Filler Neck e f the coolant level is low add coolant through the radiator filler opening to the bottom of the filler neck e Install the radiator cap Engine Oil 4 stroke Because of the semi dry sump lubrication sys tem the engine oil level indicated on the oil level inspection window will fluctuate depending on the motorcycle s position and engine speed when the engine shut off To ensure a proper reading of the engine oil level follow the Engine Oil Level Inspection procedures closely When performing Assembly and Preparation use the following procedures to verify that the engine oil level is correct PREPARATION 25 NOTE OThis vehicle s engine is filled with 10W 40 oil from the factory DO NOT DRAIN and refill the crankcase before use Check oil level and drain bolts tightness Engine Oil Drain Bolts Torque M10 20 N m 2 0 kgf m 15 ft Ib M6 7 0 N m 0 71 kgf m 62 in Ib MEO3BO50 A Engine Oil Drain Bolt M10 B Engine Oil Drain Bolt M6 Check the oil level by placing the motorcycle on its wheels and leveling it from front to back and side to side When level the oil level should be between the upper and lower lines indicated next to the oil level inspection win dow NOTE OTipping the motorcycle from
23. in the Parts Check section NOTE OWhen using the air valve adapter apply grease to the O ring MCO3B145 A Air Valve Adapter e Raise the front wheel off the ground using jack special tool 57001 1238 and attach ment special tool 57001 1608 or chain block e Prepare the commercially available suitable hand air pump and air pressure gauge e Using a commercially available suitable hand air pump and air pressure gauge charge each fork with air 240 kPa 2 4 kgf cm 35 psi alternately beforehand Do not pressurize the fork to more than 500 kPa 5 0 kgf cm 73 psi or the fork may be damaged The air pressure in each fork is different depending on gravity Be sure to check and adjust the air pressure in each fork Aoi W A 4 bo gt MCO3B146 P e Remove the air valve adapter Install the air valve plug see No 25 part in the Parts Check section and tighten it to the specified torque Torque 0 2 N m 0 020 kgf m 1 8 in Ib MCO3B149 P NOTICE Be sure to install the air valve plug to prevent dust from entering e Be sure to remove the styrene foam on the steering stem MCO3B147 A Styrene Foam UNCRATING 5 This page intentionally left blank 6 UNCRATING Parts Check e Open the parts box and check the parts against the illustrations There may be minor differences between these illustrations and the ac
24. lip the dust cover off the throttle case e Adjust the position of the throttle grip assy so that the joint line of the throttle case is vertical to the handlebar e Tighten the mounting screws D 5 L 20 to the specified torque Torque 3 8 0 39 kgf m 34 in lb e Open and close the throttle grip to check if the throttle operates properly e Reinstall the dust cover a MDO8B399 A Dust Cover B Throttle Case C Joint Line D Screws D 5 L 20 E Throttle Grip A WARNING If the throttle grip contacts the end of the handlebar the throttle will be difficult to turn and may not return fully when re leased creating the possiblity of an acci dent resulting in serious injury or death Do not push the throttle grip so far onto the handlebar that the inside of the grip contacts the end of the handlebar Front Brake Master Cylinder Install the master cylinder with the clamp and bolts on the handlebar 008118 51 Front Brake Master Cylinder 176 95 mm 6 97 in Horizontal Line of Frame Align reserve tank cap to the horizontal line of frame GOD gt e Make sure that the master cylinder clamp is installed with the UP mark facing up e Tighten the upper clamp bolt first then the lower bolt to the specified torque Torque 8 8 N m 0 90 kgf m 78 in Ib MDO8B400 A Clamp Bolts B UP Mark ASSEMBLY 11 Clutch Lever Ass
25. m the fully seated position 208258 A Compression Damping Adjuster e To adjust the compression damping turn the adjuster on each front fork base valve assem bly with a standard tip screwdriver Adjust the compression damping to the standard setting position PREPARATION 21 The right and left fork tubes must be ad justed evenly Do not force to turn the compression damping adjuster from the fully seated position or the adjusting mechanism may be damaged Compression Damping Settings 22 2120131211109 8 7 6 5 4 3 2 1 W VD20143BM2 C A Seated Position Adjuster turned fully clockwise B Softer Counterclockwise C Harder Clockwise D Standard Setting Number of turns counterclockwise usable range 22 clicks or more Rebound Damping Adjustment e Clean the bottom of the fork tubes Check the position of the rebound damping adjusters at the bottom of the fork tubes STD Rebound Damping 9 clicks Counterclockwise from the fully seated position 208257 A Rebound Damping Adjuster 22 PREPARATION e To adjust the rebound damping turn the ad juster on each front fork cylinder valve with a standard tip screwdriver Adjust the rebound damping to the standard setting position The right and left fork tubes must be ad justed evenly Do not force to turn the rebound damp ing adjuster from the fully seated posi
26. ressure in each fork leg to the specified value Air Pressure 240 kPa 2 4 kgf cm 35 psi NOTE ODo not use the side stand during air pressure adjustment A WARNING When riding and transporting the motor cycle make sure that the air pressure is within the adjustable range If used out side the adjustable range running sta bility can decrease and cause an acci dent resulting in serious injury or death Be sure to remove the air valve adapter before riding If the air valve adapter is damaged by a stone during riding air leakage can cause loss of control and an accident resulting in serious injury or death Do not pressurize the fork to more than 500 kPa 5 0 kgf cm 73 psi or the fork may be damaged The right and left fork tubes must be ad justed evenly 168039 e After air pressure adjustment remove the air valve adapter e Reinstall the air valve plug and tighten it to the specified torque Torque 0 2 N m 0 020 kgf m 1 8 in lb NOTICE Be sure to install the air valve plug to prevent dust from entering e Before delivery to the customer explain to a customer about the proper use of the air valve adapter while showing the correspond ing page Title Front Suspension in the Owner s Manual Compression Damping Adjustment e Check the position of the compression damp ing adjusters on the top of the fork tubes STD Compression Damping 11 clicks Counterclockwise fro
27. rip Free Play 2 3 mm 0 08 0 12 in Check that the throttle grip moves smoothly from full open to close and the throttle closes quickly and completely in all steering posi tions by the return spring If the throttle grip does not return properly check the throttle ca ble routing grip free play and for possible ca ble damage Then lubricate the throttle cable A ME11B075 A Throttle Grip B 2 3 mm 0 08 0 12 Run the engine at idle speed and turn the handlebar all the way to the right and left to ensure that the idle speed does not change If the idle speed increases check the throttle grip free play and the cable routing A WARNING Operation with improperly adjusted incorrectly routed or damaged cables could result in an unsafe riding condi tion Follow the service manual to make PREPARATION 27 Idle Speed Adjustment sure to correct any of these conditions Throttle Grip Free Play Adjustment Loosen the locknut of the accelerator cable and turn the adjuster to give the throttle grip plenty of play e Tighten the locknut securely A Adjuster B Locknut C Accelerator Cable e Start the engine and warm it up thoroughly Inspect the idle speed using the engine rev olution tester for high accuracy e Adjust the idle speed to following range by turning the idle adjusting screw choke knob Idle Speed 1 950 2 050 r min rpm ME21B031 4
28. rs have sharp edges Always wear pro tective gloves boots and eye protection when uncrating to prevent injury MCO30048 5 Clear a space about 6 m 20 ft square to give yourself plenty of space to work e Place the crate upright on its base e Remove the cardboard cover e Remove the handlebar front fender and the parts box When removing the crate bracket from the motorcycle be careful not to drop any parts or the bracket onto the fuel tank and other components and not to scratch the fuel tank or other compo nents with the crate bracket UNCRATING 3 e Remove the vertical strut mounting bolts D 8 L 12 and the vertical struts at both left and right sides and discard them MCO3B142 P A Top Frame B Vertical Strut C Mounting Bolts D 8 L 12 D Bottom Frame When removing the vertical struts at both left and right sides do not damage the radiator shrouds e Remove the crate bolts D 8 L 12 to take off the crate bracket and discard them A Crate Bolts D 8 L 12 B Crate Bracket Be careful that the motorcycle does not fall over e Take out all the bolts and screws and remove the top frame and front and rear frame of the crate e Remove the rubber plug dummy on each fork top plug and discard them 4 UNCRATING 4 0038148 ki A Rubber Plug Dummy B Fork Top Plug e Install the air valve adapter see No 22 part
29. servoir positioned horizontally check that the fluid level is above the lower level line MEO7B241 A Rear Brake Fluid Reservoir B Lower Level Line e f the fluid level in the reservoir is below the lower level line check for fluid leaks in the rear brake lines and fill the reservoir e Remove the reservoir cap and diaphragm and fill the reservoir to the upper level line with DOT4 brake fluid di 078242 A Rear Brake Fluid Reservoir B Upper Level Line Install the diaphragm and reservoir cap e Tighten the reservoir cap screws to the spec ified torque Torque 1 5 N m 0 15 kgf m 13 in lb PREPARATION 17 e Operate the brake pedal several times f it feels spongy there might be air in the brake line elf necessary bleed the air in the rear brake line e Also check for fluid leakage around the fit tings Brake Line Air Bleeding e Remove the reservoir and diaphragm and check that there is plenty of fluid in the reservoir NOTE OThe fluid level must be checked several times during the bleeding operation and replenished as necessary If the fluid in the reservoir runs completely out any time during bleeding the bleeding operation must be done over again from the beginning since air will have entered the line e Attach a clear plastic hose to the bleed valve on the rear brake caliper and run the other end of the hose into a container e With the reservoir cap of
30. th a pilot light Never fill the tank completely to the top If the tank is filled completely to the top heat may cause the fuel to expand and over flow through the vent in the tank cap After refueling make sure the tank cap is closed securely If gasoline is spilled on the fuel tank wipe it off immediately Open the fuel tank cap and check for debris in the fuel tank Fill the fuel tank with one gallon or four liters of unleaded gasoline Use a gasoline with a minimum octane rating shown below Use clean fresh unleaded gasoline with an octane rating equal to or higher than that shown in the table Fuel Type Unleaded Gasoline Minimum Research Octane Number RON Octane Rating 95 Close the fuel tank cap and check for leaks Coolant NOTE OThe coolant originally filled into the cooling system contains 50 of a permanent ethy lene glycol based antifreeze has a freezing point of 35 C 31 F and a green appear ance Coolant Level Inspection e Lean the motorcycle slightly so that the filler neck is located uppermost e Remove the radiator cap in two steps e First turn the cap counterclockwise to the first stop and wait there for a few seconds e Then push and turn the cap further in the same direction and remove it X A Radiator Cap Check the coolant level in the radiator The coolant should come up to the bottom of the radiator
31. tion or the adjusting mechanism may be damaged Rebound Damping Settings 201918 13 121110 9 8 7 6 5 4 3 2 1 vozo1658W2 A Seated Position Adjuster turned fully clockwise B Softer Counterclockwise C Harder Clockwise D Standard Setting Number of turns counterclockwise usable range 20 clicks or more Rear Shock Absorber Compression Damping Adjustment There are two adjustments you can make to rear shock absorber gas reservoir Check the position of the high and low speed compression damping adjusters on the gas reservoir at the upper end of the rear shock absorber STD High Speed Compression Damping For European Model 1 1 2 turns out Counterclockwise from the fully seated position For Australian Model 1 3 4 turns out Counterclockwise from the fully seated position e To adjust the high speed compression damp ing turn the adjuster all the way clockwise with a wrench to make damping greatest e Turn the adjuster counterclockwise to de crease damping Adjust the high speed compression damping to the standard posi tion A High Speed Compression Damping Adjuster B Wrench Do not force to turn the compression damping adjuster from the fully seated position or the adjusting mechanism may be damaged High Speed Compression Damping Set tings 2 1 ME16127BS1 A Seated Position Adjust
32. tual vehicle parts In the following charts under Remarks D diameter in millimeters and L length in millimeters MCO5251BW4 UNCRATING 7 No Part Name Qty Remarks 1 DFI Setting Data Selection Connector 1 White 2 Setting Data Selection Connector 1 Black 3 Handlebar Pad 1 RENTHAL 4 Handlebar with Grip and Wiring Band 1 RENTHAL 5 Handlebar Clamp Bolt 4 D 8 L 35 6 Front Brake Master Cylinder 1 7 Bolt Front Brake Master Cylinder 2 8 Flanged Bolt Front Fender 4 D 6 L 18 5 9 Front Fender 1 10 Screw Engine Stop Switch 1 D 3 11 Screw Launch Control Mode Button 1 D 4 12 Clamp Clutch Lever 1 13 Handlebar Clamp 2 14 Engine Stop Switch 2 15 Clamp Launch Control Mode Button 2 16 Bolt Clutch Lever 2 D 5 L 16 17 Fuel Tank Breather Hose 1 L 300 18 Front Number Plate 1 19 Flanged Bolt Front Number Plate 1 D 6 L 12 20 Spark Plug Wrench 1 21 Spoke Nipple Wrench 1 22 Air Valve Adapter Front Fork 1 23 Side Stand 1 24 Owner s Manual 1 25 Air Valve Plug Front Fork 2 8 UNCRATING Spare Parts MCO5188BW3 e These parts and their part numbers are subject to change without prior notice according to the model year No Part Name Qty Part Number 1 Gasket Cylinder Head T 0 65 2 11004 0088 2 Gasket Cylinder Head Cover 2 11061 0351 3 Gasket Cylinder Base 2 11061 0768 4 Gasket Exhaust Pipe 2
33. ues listed are for assembly and preparation items only see the appropriate Service Manual for a more comprehensive list Check tightness of all fasteners that are in the table before retail delivery Also check to see that each cotter pin or circlip is in place PREPARATION 31 No Fastener Torque ne kgfm ft lb marks Steering 1 Handlebar clamp bolts 25 25 18 2T AL Brake 2 Front master cylinder clamp bolts 0 90 78 in lb 5 Front caliper mounting bolts Front caliper bleed valve 0 80 69in lb Rear master cylinder mounting bolts 87 in lb 6 Rear caliper bleed valve 0 80 69in lb Wheel Front axle nut 78 8 0 58 5 20 2 0 15 8 Front axle clamp bolts Left and Right Suspension 9 Front fork clamp bolts Front fork clamp bolts Lower Rear shock absorber mounting nut Upper Rear shock absorber mounting nut Lower AL S AL AL 34 3 5 25 Engine Oil Drain Bolt Engine oil drain bolt M10 Engine oil drain bolt M6 Cotter Pin or Circlip 0 71 62 in lb Rear axle nut cotter pin Rear master cylinder cotter pin Footpeg pin Left Right AL Tighten the two clamp bolts alternately two times to ensure even tightening torque S Follow the specified tightening sequence Tighten the upper clamp bolt first and then the lower clamp bolt 2T Apply 2 stroke oil 32 PREPARATION Stand
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