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1. 3 12 Inspection 3 6 Carburetor Installation 3 13 Throttle Lever Free Play Carburetor Disassembly 3 13 Adjustment res cavasscesatnaletee dti 3 6 Carburetor Assembly 3 14 Throttle Case Removal Disas Carburetor Cleaning 3 15 SEMI ns 3 6 Carburetor Inspection 3 15 Throttle Case Assembly Installa Air Cleaner 3 17 A eataneatiees 3 7 Air Cleaner Element Removal 3 17 Throttle Cable Installation 3 7 Air Cleaner Element Installation 3 17 Throttle Case Inspection and Air Cleaner Element Cleaning and Lubrication 3 7 Inspecti0N ccooccccccccccccncccncos 3 18 Throttle Cable Lubrication and Air Cleaner Draining 3 18 pl AA 3 8 Air Cleaner Housing Removal 3 18 Choke Lever and Cable 3 9 Fuel Taka 3 19 Choke Lever Removal 3 9 Fuel Tank Removal 3 19 Choke Lever and Cable Fuel Tank Installation 3 19 Installation 3 9 Fuel Tap Removal 3 20 Choke Lever Lubrication 3 9 Fuel Tap Installation 3 20 Choke Cable Lubrication and Fuel Tank and Fuel Tap Cleaning 3 20 Inspection 3 9 Fuel Tap Inspection 3 21 Carburetor s
2. A WARNING Clean the engine parts in a well ventilated area and take care that there are no sparks or flame any where near the working area this includes any ap pliance with a pilot light Do not use gasoline or a low flash point solvent to clean parts A fire or ex plosion could result e Apply a small amount of engine oil to the transmission gears bearings and shift forks e Be sure the mating surfaces of the crankcase halves are clean and dry eBe sure the following parts are in place in the right crankcase half Crankshaft and Balancer Shaft Transmission Shafts Shift Forks and Shift Drum see Transmission Installation Washer A Oil Pressure Relief Valve Dowel Pins B e Apply liquid gasket A to the mating surface of the left crankcase half Sealant Kawasaki Bond Liquid Gasket Silver 92104 002 9 10 CRANKSHAFT TRANSMISSION Crankcase e Insert crankshaft jig A between the crankshaft halves opposite the crankpin to prevent crankshaft distortion during installation Special Tool Crankshaft Jig 57001 1174 e Install Clamp A e Tighten Torque Crankcase Bolts 8 8 N m 0 9 kgf m 78 in Ib B L 40 mm 1 57 in Bolts C L 60 mm 2 36 in Bolts D L 75 mm 2 95 in Bolts e Check Shift of transmission is neutral position Crankshaft drive shaft and output shaft turn freely If any of the shaft do not turn freely split the crankcase to locate the pro
3. NOTE OThere should be no spring tension on the reel when removing the reel Lift the reel slightly If tension is felt push the reel back into place and gently wiggle it until the reel may be easily removed e f necessary remove the recoil spring A as follows OPlace the starter housing facing down on a bench OStrike the bench sharply so safely remove the spring Recoil Starter Assembly e f the recoil spring was removed install it as shown If itis not installed correctly the starter will not operate properly The recoil spring must be put under great pressure during installation Wear gloves to avoid injury e Hook the outer end A of the recoil spring onto the hous ing tab B Reel the recoil spring clockwise into the housing from out side to inside NOTE OPush the recoil spring against the housing securely to prevent the spring from slipping off during installation e Lightly grease the spring 6 6 RECOIL STARTER Recoil Starter e f the rope was unwound from the reel it must be wound clockwise for correct starter operation e Wind the rope around the smaller diameter of the reel NOTE OTurn the reel counterclockwise A to wind the rope clockwise This prevents the rope from twisting e Set the reel into the place so that the hook A on the spring catches on the tab B in the reel e Install Pin A Pawl B Recoil Shaft C Friction Plate Spring D Collar E Re
4. 9 8 CRANKSHAFT TRANSMISSION Crankcase Crankcase Disassembly e Remove Engine see Engine Removal Installation chapter e Set the engine on a clean surface and hold the engine steady while parts are being removed e Remove Starter Motor see Electrical System chapter Output Bevel Gear Case and Output Drive Bevel Gear see Final Drive chapter Clutches and Balancer Gear see Engine Right Side chapter Oil Pump see Engine Lubrication System chapter External Shift Mechanism see External Shift Mecha nism Removal Cylinder Head Cylinder and Piston see Engine Top End chapter Alternator and Starter Clutch Gear see Electrical Sys tem chapter Camshaft Chain and Guide see Engine Top End chap ter Reverse Shift Mechanism see Reverse Shift Mecha nism Removal e Remove Crankcase Bolts A e Using the pry points A split the crankcase halves e Lift off the left crankcase half NOTE Olfthe crankcase is very tight use the crankcase splitting tool Special Tool Crankcase Splitting Tool 57001 1098 CRANKSHAFT TRANSMISSION 9 9 Crankcase Crankcase Assembly CAUTION Right and left crankcase halves are machined at the factory in the assembled state so the crankcase halves must be replaced as a set NOTE OBe certain that all parts are cleaned thoroughly before assembly OBlow through all oil passages with compressed air A to clear any blockage in the crankcase halves and crank shaft
5. Battery Installation Electrolyte Level Inspection Electrolyte Specific Gravity INSpecti0N ooococcccccccnccconcccnnos Initial Charging ccceeeeeeeee Ordinary Charging Battery Test Charging 00000 Charging System Alternator Cover Removal Alternator Cover Installation Alternator Rotor Removal Alternator Rotor Installation Alternator Stator Removal Alternator Stator Installation Regulator Rectifier Output Voltage Inspection Alternator Inspection Regulator Rectifier Inspection Ignition System Spark Plug Removal Installation Spark Plug Cleaning Inspection Spark Plug Gap Inspection Ignition Coil Removal Ignition Coil Installation Ignition Coil Inspection Ignition Coil Primary Peak Voltage Inspection Crankshaft Sensor Removal Crankshaft Sensor Inspection Crankshaft Sensor Peak Voltage INSpecti0N oooooccccccccnccccnccnncos 16 2 16 6 16 7 16 8 16 9 16 11 Alternator Rotor Inspection Ignition Timing Test 16 31 Electric Starter System 0000aaeeeeeee 16 34 Starter Motor Removal 16 34 Starter Motor Installation 16 34 Starter Motor Di
6. 4 23 Camshaft Chain Tensioner Wear 4 11 Valve Installation 4 24 Camshaft Sprocket 4 12 Valve Visual Inspection 4 24 Camshaft Sprocket Removal 4 12 Valve Guide Removal 000000 4 24 Camshaft Sprocket Installation 4 12 Valve Guide Installation 4 25 Rocker Arms and hatte 4 14 Valve to Guide Clearance Compression Releasing Lever Measurement 4 25 Hemova 4 14 Valve Seat Inspection 4 26 Compression Releasing Lever Valve Seat Repair Valve Installation 4 14 Lapping micos ocio ci n sites 4 26 Rocker Arm and Shaft Removal 4 15 Cylinder and Piston 4 31 Rocker Arm and Shaft Installation 4 15 Cylinder Removal 4 31 Rocker Arm and Shaft Inspection 4 16 Cylinder Installation 4 31 Camshaft s r eehed eataa 4 17 Piston Removal 4 32 Camshaft Removal 4 17 Piston Installation 4 32 Camshaft Installation 4 17 Cylinder Piston Wear 0000ssann 4 33 Cam Wear Inspection 4 17 Piston Cylinder Clearance 4 34 Camshaft Bearing Inspection 4 17 Piston Ring and Ring Groove Camshaft Chain and Guides 4 18 ET 4 34 Camshaft Chain Removal 4 18 Piston Ring Groove Width
7. SLO OV ON Speedometer Washers Damper Meter Brackets Collar Handlebar Clamp the meter bracket at the portion indicated in the figure Bracket Mounting Bolt Speedometer Cable Other than US GA and UK Models HB09026BW4 Bands Meter Harness Rear Parking Brake Cable Choke Cable Horn Harness Handlebar Switch Leads U S A Model Canada Model United Kingdom Model APPENDIX 17 11 Cable Wire and Hose Routing QO Front O AU EU UK HB09027BW4 1 Bands US U S A Model 2 Horn Leads CA Canada Model 3 To Igniter AU Australia Model 4 To Left Headlight EU Europe Model 5 Main Harness UK United Kingdom Model 6 35 mm 1 378 in 7 Horn 17 12 APPENDIX Troubleshooting Guide NOTE OThis is not an exhaustive list giving every possible cause for each problem listed It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties Engine Doesn t Start Starting Difficulty Starter motor not rotating Neutral switch trouble Starter motor trouble Battery voltage low Relays not contacting or operating Starter button not contacting Wiring open or shorted Ignition switch trouble Engine stop switch trouble Fuse blown Starter motor rotating but engine doesn t turn over Starter motor clutch trouble Recoil starter not operating Recoil starter spring broken Recoil starter pawl not eng
8. 5 480 5 495 mm 0 2157 0 2163 in 5 495 5 510 mm 0 2163 0 2169 in 5 520 5 532 mm 0 2173 0 2178 in 5 520 5 532 mm 0 2173 0 2178 in 0 05 mm 0 002 in 0 5 mm 0 020 in 0 4 mm 0 016 in TIR 0 05 mm 0 002 in 5 47 mm 0 2154 in 5 48 mm 0 2157 in 5 60 mm 0 220 in 5 60 mm 0 220 in Specifications ENGINE TOP END 4 7 Item Standard Service Limit Valve Guide Clearance wobble method Exhaust 0 05 0 11 mm 0 27 mm 0 0020 0 0043 in 0 0106 in Inlet 0 02 0 08 mm 0 23 mm 0 0008 0 0032 in 0 0091 in Valve Seat Cutting Angle 45 32 60 EE Valve Stem Bend TIR 0 05 mm Valve Seat Surface Width Exhaust Inlet Outside Diameter Exhaust Inlet Valve spring free length Inner Outer 0 5 1 0 mm 0 02 0 04 in 0 5 1 0 mm 0 02 0 04 in 26 9 27 1 mm 1 059 1 067 in 30 9 31 1 mm 1 217 1 224 in 37 8 mm 1 488 in 40 4 mm 1 591 in 36 2 mm 1 425 in 38 7 mm 1 524 in Cylinder Piston Cylinder Inside Diameter Piston Diameter Piston Cylinder Clearance Piston Ring Groove Clearance Top Second Piston Ring Groove Width Top Second Oil Piston Ring Thickness Top Second 68 995 69 007 mm 2 7163 2 7168 in 68 960 68 975 mm 2 7150 2 7155 in 0 020 0 047 mm 0 0008 0 0019 in 0 02 0 06 mm 0 0008 0 0024 in 0 02 0 06 mm 0 0008 0 002
9. Cylinder Piston Wear e Since there is a difference in cylinder wear in different di rection take a side to side and a front to back measure ment at each of the 3 locations total of 6 measurements shown in the figure Alf any of the cylinder inside diameter measurements ex ceeds the service limit replace the cylinder 20 mm 0 79 in A 40 mm 1 57 in B 10 mm 0 39 in C rie Cylinder Inside Diameter Standard 68 995 69 007 mm 2 7163 2 7168 in and less than 0 01 mm 0 0004 in difference between any two measurements Service Limit 69 10 mm 2 720 in or more than 0 05 mm 0 0020 in difference between any two measurements e Measure the piston diameter A of each piston 5 mm 0 20 in B up from the bottom of the piston at a right angle to the direction of the piston pin Piston Diameter Standard 68 960 68 975 mm 2 7150 2 7155 in Service Limit 68 81 mm 2 709 in x lf the piston diameter is less than the service limit replace it HE14004BS1 4 34 ENGINE TOP END Cylinder and Piston Piston Cylinder Clearance e Subtract the piston diameter from the cylinder inside di ameter to get the piston cylinder clearance Piston Cylinder Clearance Standard 0 020 0 047 mm 0 0008 0 0019 in Piston Ring and Ring Groove Wear e Check for uneven groove wear by inspecting the ring seat ing The rings should fit perfectly
10. 4 34 Camshaft Chain Installation 4 18 Piston Ring Thickness 00020 4 35 Camshaft Chain Guide Removal 4 18 Piston Ring End Gap Camshaft Chain Guide Installation Measurement 4 35 SE Jee tees ste ne moe 4 18 ExhaustSyStem issues 4 36 Camshaft Chain Guide Wear 4 18 Spark Arrester Cleaning 4 36 Cylinder Head 4 19 Muffler Removal 4 36 Cylinder Compression Exhaust Pipe Removal 4 36 Measurement 4 19 Exhaust Pipe Installation 4 37 Cylinder Head Removal 4 20 Exhaust System Inspection 4 37 Cylinder Head Installation 4 21 4 2 ENGINE TOP END Exploded View ENGINE TOP END 4 3 Exploded View No Fastener pores SN kgf m ft 2 1 Cylinder Head Bolts M10 final toque S 2 Cylinder Head Bolts M6 first torque gt 52 T MO S 2 Cylinder Head Bolts M6 final torque 9 8 1 0 87 in lb S 3 Valve Adjusting Cap Bolts 8 8 0 9 78 in lb 4 Retaining Bolt 4 4 0 45 39 in lb 5 Compression Releasing Lever Bolt 8 8 0 9 78 mb G Apply grease for oil seal and O ring L Apply a non permanent locking agent MO Apply molybdenum disulfide oil R Replacement Parts S Follow the specific tightening sequence 4 4 ENGINE TOP END Exploded View Explo
11. Alf any of the measurements is less than the service limit on either of the rings replace all the rings NOTE OWhen using new rings in a used piston check for un even groove wear The rings should fit perfect parallel to the groove sides If not replace the piston Piston Ring End Gap Measurement e Place the piston ring inside the cylinder using the piston to locate the ring squarely in place Set it close to the bottom of the cylinder where cylinder wear is low e Measure the gap A between the ends of the ring with a thickness gauge where cylinder wear is low Piston Ring End Gap Standard Service Limit Top 0 15 0 30 mm 0 6 mm a HE14013B51 0 0059 0 0118 in 0 0236 in Second 0 30 0 45 mm 0 8 mm 0 0118 0 0177 in 0 0315 in Oil 0 20 0 70 mm 1 0 mm 0 0079 0 0276 in 0 0394 in Alf the end gap of either ring is greater than the service limit replace all the rings 4 36 ENGINE TOP END Exhaust System This vehicle is equipped with a spark arrester approved for off road use by the U S Forest Service It must be prop erly maintained to ensure its efficiency In accordance with the Periodic Maintenance Chart clean the spark arrester CAUTION The spark arrester must be installed correctly and functioning properly to provide adequate fire pro tection Spark Arrester Cleaning e Refer to the Spark Arrester Cleaning in the Periodic Main tenance chapter Muffle
12. Wheel Removal e Loosen the wheel nuts A e Support the vehicle on a stand or the jack so that the wheels are off the ground Special Tool Jack 57001 1238 e Remove Wheel Nuts Wheel Wheel Installation e Check the tire rotation mark A on the tire and install the wheel accordingly NOTE OThe direction of the tire rotation B is shown by an arrow on the tire sidewall e Position the wheel so that the air valve A is toward the outside of the vehicle e Tighten the wheel nuts in a criss cross pattern Torque Wheel Nuts 34 N m 3 5 kgf m 25 ft lb Wheel Rim Inspection e Examine both sides of the rim for dents A If the rim is dented replace it x lf the tire is removed inspect the air sealing surfaces A of the rim for scratches or nicks Smooth the sealing sur faces with fine emery cloth if necessary HJ050101S1 HJO5003BS1 HJO5013BS1 10 10 WHEELS TIRES Wheels Rims Wheel Rim Replacement e Remove the wheel see Wheel Removal e Disassemble the tire from the rim see Tire Removal ORemove the air valve and discard it CAUTION Replace the air valve whenever the tire is replaced Do not reuse the air valve Air Valve Cap A Valve Core B Stem Seal C Valve Stem D Valve Seat E Valve Opened F e Install a new air valve in the new rim ORemove the valve cap lubricate the stem with a soap and water solution and pull the stem A
13. e Remove Float Valve Seat A Main Jet B Needle Jet Holder C Pilot Jet D e Remove Needle Jet A Carburetor Assembly e Turn the carburetor body upside down and drop the nee dle jet into place so that the long end A of the jet goes in first CAUTION Do not force the needle jet holder and main jet or overtighten them The needle jet or the carburetor body could be damaged requiring replacement e Drop the float valve needle into the valve seat and hold the float in place with the tang A hooked into the needle hanger e Slip the float pivot pin B through the pivot posts and the float C as shown A WARNING If the float is improperly installed the specified fuel level cannot be maintained Fuel spilled from the carburetor is hazardous e Set the float height as specified Carburetor FUEL SYSTEM 3 15 Carburetor Cleaning WARNING Clean the carburetor in a well ventilated area and take care that there is no spark or flame anywhere near the working area this includes any appliance With a pilot light Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents to clean the carburetor A fire or ex plosion could result CAUTION Do not use compressed air on an assembled carbu retor the float may be crushed by the pressure and the vacuum piston diaphragm may be damaged Remove as many rubber or plastic parts from th
14. 2 Spark Plug 14 1 4 10 3 Starter Motor Clutch Bolts 34 3 5 25 L 4 Ignition Switch Nut 2 9 0 3 26 in lb 5 Alternator Rotor Bolt 59 6 0 43 6 Other than U S A Model 7 U S A Model 8 U S A Canada and Australia Models 9 Europe and United Kingdom Models A KLF250 A1 B KLF250 A2 Gr Apply grease L Apply a non permanent locking agent MO Apply molybdenum disulfide oil SS Apply silicone sealant Kawasaki Bond 56019 120 16 4 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 16 5 Exploded View Remarks F astener ftlb 78 in 1b Starter Motor Mounting Bolts 1 2 Starter Motor Terminal Nut 4 9 0 5 43 in lb 0 7 61 in lb 6 9 Starter Motor Terminal Locknut 3 4 0 3 30 in lb 3 4 Starter Motor Bolts 5 Other than U S A and Canada Models 6 Europe and United Kingdom Models A KLF250 A1 B KLF250 A2 16 6 ELECTRICAL SYSTEM Specifications Item Standard Service Limit Battery Capacity Electrolyte Level Specific Gravity of Electrolyte Charging System Alternator Type Charging Voltage Regulator Rectifier Output Voltage Alternator Output Voltage Stator Coil Resistance Ignition System Spark Plug Spark Plug Gap Spark Plug Cap Resistance Ignition Coil 3 needle Arcing Distance Primary Winding Resistance Secondary Winding Resistance Primary Peak Voltage Crankshaft Sensor Crankshaft Sensor Resistance Crankshaft Sensor Pea
15. 2 mm 0 04 0 08 in 2 3 mm 0 08 0 12 in 25 35 mm 1 0 1 4 in 80 90 0 6 0 7 mm 0 024 0 028 in On after 10 mm 0 4 in of pedal travel 4 mm 0 16 in 4 mm 0 16 in Periodic Maintenance Procedures PERIODIC MAINTENANCE 2 7 Fuel System Throttle Lever Free Play Inspection e Check that the throttle lever moves smoothly from full open to close and the throttle closes quickly and com pletely in all steering positions by the return spring Alf the throttle lever does not return properly check the throttle cable routing lever free play and cable damage Then lubricate the throttle cable e Run the engine at the idle speed and turn the handlebar all the way to the right and left to ensure that the idle speed does not change x lf the idle speed increases check the throttle lever free play and the cable routing e Stop the engine and check the throttle lever free play A x lf the free play is not within the specified range adjust the cable Throttle Lever Free Play Standard 2 3 mm 0 08 0 12 in Throttle Lever Free Play Adjustment e Slide the rubber cover off the adjuster at the throttle case e Loosen the locknut A and turn the throttle cable upper adjuster B until the cable has proper amount of play e Tighten the locknut and reinstall the rubber cover x lf the free play cannot be adjusted by using the upper ca ble adjuster pull up the rubber cover A at the ca
16. BAYOU 250 Kawasaki Workhorse 250 All Terrain Vehicle Service Manual This quick reference guide will assist you in locating a desired topic or pro cedure Bend the pages back to match the black tab of the desired chapter num ber with the black tab on the edge at each table of contents page Refer to the sectional table of contents for the exact pages to locate the spe cific topic required Quick Reference Guide General Information Periodic Maintenance Fuel System Engine Top End Engine Right Side Recoil Starter Engine Lubrication System Engine Removal Installation Crankshaft Transmission Wheels Tires Final Drive Brakes Suspension Steering Electrical System sch NIO BIO IN e0 O0 ol Ion B OIN Appendix KLF 250 BAYOU 250 Workhorse 250 Kawasaki All Terrain Vehicle Service Manual All rights reserved No parts of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Quality Division Consumer Products amp Machinery Company Kawasaki Heavy Industries Ltd Japan No liability can be accepted for any inaccuracies or omissions in this publication although every possible care has been taken to make it as complete and accurate as possible The right is reserved to make changes at any time without prior noti
17. OUse aluminum vise jaw plate to prevent damage to the housing Special Tool Bearing Retainer Wrench Hex 40 57001 1256 e To remove the ball bearing press fitted into the output bevel gear case A use the oil seal amp bearing remover B Special Tool Oil Seal amp Bearing Remover 57001 1058 Output Bevel Gear Case Assembly e Press and insert the new ball bearing A until it is bot tomed Special Tool Bearing Driver Set 57001 1129 e Apply a non permanent locking agent Bearing Retainer B e Tighten Torque Bearing Retainer 108 N m 11 kgf m 80 ft Ib HK08003BS1 11 10 FINAL DRIVE Output Bevel Gear Case e Install Bearing Housing A Driven Gear Shaft B Collar C Toothed Washer D Washer E Driven Gear Shaft Nut F e Apply a non permanent locking agent Driven Gear Shaft Nut A e Install the driven gear shaft nut so that the flat side B faces upward e Tighten Torque Driven Gear Shaft Nut 147 N m 15 kgf m 108 ft lb Special Tools Bevel Gear Holder 57001 1618 Socket Wrench 57001 1354 e Bend a toothed washer tab into the groove of the driven gear shaft nut e Apply molybdenum disulfide oil to the spline cam damper and driven gear shaft A e Install Spring B Cam Damper C Driven Gear D Washer E Cam Damper Mounting Nut F e Apply molybdenum disulfide oil to the threads of cam damper mounting nut e Tighten Torque Cam Damper Mounting Nut 78 N m 8 0
18. 1 Never blow brake lining dust with compressed air 2 If any components are to be cleaned wash them with detergent then immediately discard the clean ing solution and wash your hands 3 Do not grind any brake lining material unless a ventilation hood is available and properly used e Loosen the right rear axle nut e Remove Right Rear Wheel see Wheels Tires chapter Axle Nut Brake Drum A e Remove Brake Adjuster A Breather Hose B e Remove Brake Panel Bolts A and Washers Position Plate B Brake Panel C Brake Shoes D Brake Drum and Panel BRAKES 12 11 e Remove Cam Lever Bolt A Cam Lever B NOTE OBefore removing the brake cam lever mark the position of the cam lever so that it can be installed later in the same position e Remove Indicator C O ring D Brake Cam E Rear Brake Panel Assembly Installation e Apply grease to the brake cam A e Install the following parts to the brake panel B Brake Cam O ring C Indicator D e Fit the brake cam lever E so that the marks align e Install Cam Lever Bolt F and Nut Brake Shoes G e Apply grease Amoco rykon premium grease No 2 EP Green to the O ring A and install it e Install Brake Panel Assembly e Apply a non permanent locking agent to the brake panel bolts and tighten them Torque Rear Brake Panel Bolts 29 N m 3 0 kgf m 22 ft lb e Apply grease Amoco rykon premium grease No 2 EP Green to
19. A e Push and turn the bulb holder B counterclockwise and remove the bulb holder from the headlight unit e Remove Bulb A e Install the new bulb by aligning the tang A with the notch in the headlight unit e Fit the tangs A to the notches in the headlight unit and then push and turn the bulb holder clockwise 16 44 ELECTRICAL SYSTEM Lighting System OFace the TOP mark A on the dust cover upward and fit it completely Taillight Bulb Replacement e Remove Taillight Lead Connectors A Taillight Housing Holder Nuts B and Washers Taillight Assembly C e Remove Taillight Lens Mounting Screws A and Nuts Taillight Lens B e Push the bulb in turn it counterclockwise and pull it out e Be sure the socket is clean e Insert the new bulb by aligning the pins A with the grooves in the walls of the sprocket e Push the bulb in turn it clockwise and release it It should lock in position Neutral and Reverse Indicator Light Bulb Replacement e Remove Handlebar Cover A e Remove the socket B with the bulb attached e Pull the bulb C out of the socket CAUTION Do not turn the bulb to prevent damage to the bulb The indicator bulbs are of a wedge base type Do not use the bulb rated for greater wattage than the specified value ELECTRICAL SYSTEM 16 45 Lighting System Lighting System Circuit SO i i E A RAR BK YH FE BK Y R BK R B
20. Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Turn the fuel tap to the OFF position e Remove Fuel Hose Starter Plunger Clamps A e Pull out the carburetor e Remove the carburetor cap A a HCO6011BS1 Carburetor FUEL SYSTEM 3 13 Carburetor Installation e Align the slit A on the side of the throttle valve with the guide pin B in the carburetor body e Route the carburetor hoses according to Appendix chap ter e Check fuel leakage from the carburetor Fuel spilled from the carburetor is hazardous Alf the carburetor has been disassembled or if there is some other reason that the fuel level may be incorrect inspect the fuel level see Carburetor Fuel Level Inspec tion e Adjust the idle speed see Idle Speed Adjustment e Check the throttle cable see Throttle Lever Free Play In spection in Periodic Maintenance chapter Carburetor Disassembly e Remove Carburetor see Carburetor Removal Float Bowl Screws A Float Bowl B Slide out the float pivot pin A remove the float B and drop out the float valve needle with its hanger e Remove Main Jet Fence A Plate Screw B Plate C 3 14 FUEL SYSTEM Carburetor
21. Olf necessary use the piston ring pliers Special Tool Piston Ring Pliers 57001 115 e Remove the oil ring upper and lower steel rails e Spread the rail open with your thumbs OPush up on the opposite side with your fingers e Remove the oil ring expander GE16011381 Piston Installation B NOTE Olf a new piston is used check piston to cylinder clear ance see Piston Cylinder Clearance and use new pis ton rings OThe oil ring rails have no top or bottom e Install the oil ring expander A in the bottom piston ring groove so the ends B butt together e Install the oil ring steel rails one above the expander and one below it OSpread the rail with your thumbs but only enough to fit the rail over the piston ORelease the rail into the bottom piston ring groove GE16040481 ENGINE TOP END 4 33 Cylinder and Piston e Install the second ring A so that the RN mark B faces up e Install the top ring C so that the R mark D faces up e Install the piston pin OOil the piston pin lightly and slide it through the side of the piston without a snap ring OHold the piston in position over the connecting rod with the arrow A pointing forward and slide the piston pin the rest of the way through the connecting rod and piston e Fit a new piston pin snap ring into the side of the piston so that the ring opening does not coincide with the slit of the piston pin hole
22. PERIODIC MAINTENANCE 2 15 Periodic Maintenance Procedures Brakes Front Brake Adjustment e Loosen the locknut A at the brake lever B and turn in the adjuster C as far as it will go to make the brake lever loose e Turn each adjuster A at both lower ends of the cable so that each brake cam lever B will have 2 3 mm 0 08 0 12 in C of free play e Turn the adjuster A at the brake lever until the brake lever has the specified amount of free play B Front Brake Lever Free Play Standard 1 2 mm 0 04 0 08 in e Tighten the locknut C NOTE OOnce the adjustment has been made following the above procedures ordinarily adjust the free play by using the adjusters at both lower ends of the cable OMake sure that the equalizer A is lifted parallel to the bottom of the case B when brake lever is pulled in to prevent the brakes from pulling to either side 2 16 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Check that the brake lining wear indicator A points within the USABLE RANGE B when the brake is fully applied x lf does not replace the brake shoes e Check the cam lever angle A when the brake is fully applied Cam Lever Angle Standard 80 90 x If the cam lever angle is not within the specified range adjust it see Cam Lever Angle Adjustment A WARNING Since a cam lever angle greater than 90 reduces braking effectiveness cam lever angle
23. aged Ball Bearing Inspection e Since the ball bearings are made to extremely close toler ances the wear must be judged by feel rather than mea surement Clean each bearing in a high flash point sol vent dry it do not spin the bearing while it is dry and oil it with engine oil e Spin the bearing by hand to check its condition x If the bearing is noisy does not spin smoothly or has any rough spots replace it Oil Seal Inspection e Inspect the oil seal A Replace it if the lips are misshapen discolored indicat ing that the rubber had deteriorated hardened or been otherwise damaged BRAKES 12 1 Brakes Table of Contents Elei e WE 12 2 eelere TEE 12 4 Brake Adjustment an anna A nec de hatin dr nc ee ahs 12 5 Front Brake Adj stment n comi an da di nine Rod eines re cl eden a eat 12 5 Brake Pedal Position Inspection 12 5 Brake Pedal Position Adjusiment cios Ao 12 5 Rear Parking Brake Lever Free Play Inspection ccccceceeeeeeeeeenneeeeeeeeeeeteneeneeeeeeeeeees 12 5 Brake Pedal Free Play Inspection ss 12 5 Rear Parking Brake Lever and Brake Pedal Free Play Adjustment 12 5 Cam Lever Angle Adjustment Front and Rear 12 5 Brake Drum and Panele taste is crater nt MR tend Ee eng 12 7 Front Brake Panel Removal DisassemMbly 0ooooooccccc cccocooccooccccconononananononcncnonanan nn ncncnnnnnnns 12 7 Front Brake Panel Assem
24. and the gaskets on the carburetor cap and float bowl C are in good condition x If any of the O rings or gaskets are not in good condition replace them e Check the plastic tip A of the float valve needle B It should be smooth without any grooves scratches or tears x lf the plastic tip is damaged C replace the needle e Push the rod D in the other end of the float valve needle and then release it E x lf it does not spring out replace the float valve needle e Check the tapered portion A of the pilot screw B for wear or damage x If the pilot screw is worn or damaged on the tapered por tion it will prevent the engine from idling smoothly Re place it 6006014351 C 6006014451 C Air Cleaner FUEL SYSTEM 3 17 Air Cleaner Element Removal e Remove Seat see Frame chapter Clips A Air Cleaner Housing Cap B e Remove Element Mounting Screw A Element Clamp Screw B Element C e After removing the element stuff pieces of lint free clean cloth into the air cleaner duct to keep dirt out of the car buretor and engine A WARNING If dirt or dust is allowed to pass through into the carburetor the throttle may become stuck possibly causing an accident CAUTION If dirt gets through into the engine excessive en gine wear and possibly engine damage will occur e Remove Screw A and Washer Stopper B Element C Air Cleaner Element Ins
25. e f the exhaust pipe covers H were removed install them Exhaust System Inspection e Before removing the exhaust system check for signs of leakage at the exhaust pipe gasket in the cylinder head and at the muffler clamp x If there are signs of leakage around the exhaust pipe gas ket it should be replaced If the muffler to exhaust pipe joint leaks tighten the clamp e Remove the exhaust pipe and muffler see Exhaust Pipe and Muffler Removal e Inspect the gasket for damage and signs of leakage Alf the gasket is damaged or has been leaking replace it e Check the exhaust pipe and muffler for dents cracks rust and holes x If the exhaust pipe or muffler is damaged or has holes it should be replaced for best performance and least noise HE15005BS2 C ENGINE RIGHT SIDE 5 1 Engine Right Side Table of Contents Exploded EE 5 2 A EE 5 4 Special Tools and Sealant inisiasie n a a a a a e aa e reae 5 5 Engine Right Side EE Re A aAA E 5 6 Engine Right Side RE E 5 6 Engine Right Side ASSOMmply EE 5 7 CluttheS eebe di Are teen eessen 5 10 Clutch AdjuStMeE Nt ara e A EEEE Ea Na EA 5 10 Clutch Release Removal cccceceecsdecceeeeeteceseseceteceeneesuseaccecneceebeeeeesesenneceeteteenndennnecense 5 10 Clutch Release Wear ass nn e Dene Aiea Sat nr latinas 5 10 Primary Clutch Housing Wear d 5 10 Primary Clutch Shoe Lining Wear lasagnes TEE 5 10 One way Clutch Inspection ete serial dt dre Meter ete nee 5
26. e Install the O ring insulators B and washer C in that order to the terminal bolt e Tighten Torque Starter Motor Terminal Locknut D 6 9 N m 0 7 kgf m 61 in Ib e Install the washers A e Install the armature B between the brushes 16 36 ELECTRICAL SYSTEM Electric Starter System e Install the yoke A onto the right end cover B aligning the marks C on the yoke and right end cover e Install the washers A e Install the plate A on the left end cover B e Align the mark A on the left end cover with the mark B on the yoke e Tighten Torque Starter Motor Bolts 3 4 N m 0 3 kgf m 30 in Ib Commutator Cleaning Inspection e Smooth the commutator surface A if necessary with fine emery cloth B and clean out the grooves GP110610S1 Electric Starter System ELECTRICAL SYSTEM 16 37 e Measure the diameter A of the commutator B Replace the starter motor with a new one if the commu tator diameter is less than the service limit Commutator Diameter Standard 28 mm 1 10 in Service Limit 27 mm 1 06 in Armature Inspection e Using the x 1 Q range of the hand tester measure the resistance between any two commutator segments A x lf there is a high resistance or no reading between any two segments a winding is open Replace the starter motor e Using the highest range of the hand tester measure the resistance between the segments and th
27. e Remove Valve see Valve Removal Valve Stem Oil Seal e Hammer lightly on the valve guide arbor A to remove the guide from the top of the head Special Tool Valve Guide Arbor 5 5 57001 1021 HE13007BS2 C HE13010681 HE13010781 Valves Guides Seats Springs Oil Seals ENGINE TOP END 4 25 Valve Guide Installation e Clean the valve guide hole in the cylinder head e Lightly oil the valve guide e Set the O ring under the valve guide flange e Use the valve guide arbor and a hammer to drive the guide into the head from the outside until the flange on the guide seats against the head e Ream the valve guide with the valve guide reamer A even if the old guide is reused Special Tool Valve Guide Reamer 5 5 57001 1020 Valve to Guide Clearance Measurement If a small bore gauge is not available inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below e Insert a new valve A into the guide B and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface e Move C the stem back and forth to measure valve valve guide clearance e Repeat the measurement in a direction at a right angle to the first x If the reading exceeds the service limit replace the guide NOTE OThe reading is not actual valve valve guide clearance because the measurin
28. plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Install the fuel level gauge so that the 1 2 scale A faces the front B e Push the new gauge cap over the gauge so that the notch C aligns with the 1 2 scale e Check that the gauge cap nails fit securely in the grooves in the fuel tank boss Fuel Level Gauge Check e Remove the fuel level gauge from the fuel tank see Fuel Level Gauge Removal e Check that the float A moves up and down B smoothly without binding It should go down under its own weight x If the float does not move smoothly or has visual damage replace the gauge HC080107S1 HCO8004BS1 ENGINE TOP END 4 1 Engine Top End Table of Contents Exploded View 4 2 Cylinder Head Assembly 4 21 Specifications 4 6 Cylinder Head Cleaning 4 22 Special Tools and Sealant 4 9 Cylinder Head Warm 4 22 Camshaft Chain Tensioner 4 11 Valves Guides Seats Springs Oil Camshaft Chain Tensioner Seals seine AE ees 4 23 Hemova 4 11 Valve Clearance Inspection 4 23 Camshaft Chain Tensioner Valve Clearance Adjustment 4 23 Installation 4 11 Valve Removal
29. 11 Friction H SEA 5 11 Friction and Steel Plate Warp ccccccccccecceecceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeneeeeeeess 5 11 Clutch Spring Free Length Measurement 5 12 dic A A E NS 5 13 Gear Baca ad Elo EN 5 13 Primary Gear Crankshaft Wear pei la 5 13 Secondary Gear Collar Wear see 5 13 5 2 ENGINE RIGHT SIDE Exploded View HRO2000B 5 ENGINE RIGHT SIDE 5 3 Exploded View No Fastener Torque Remarks N m kgf m ft Ib 2 Clutch Spring Bolts 12 1 2 104 mb 3 Primary Clutch Hub Nut 127 13 94 MO 4 Secondary Clutch Hub Nut 78 8 0 58 MO 5 Balancer Drive Gear Nut 83 8 5 61 MO 6 Balancer Gear Nut 118 12 87 MO 7 Clutch Adjusting Screw Locknut 11 1 1 95 in lb G Apply grease for oil seal and O ring MO Apply molybdenum disulfide oil O Apply engine oil 5 4 ENGINE RIGHT SIDE Specifications Item Standard Service Limit Primary Clutch Primary Clutch Housing Inside Diameter Primary Clutch Shoe Groove Depth Secondary Clutch Friction Plate Thickness Friction Plate Warp Steel Plate Warp Clutch Spring Free Length Primary Reduction Gear Backlash Primary Gear Inside Diameter Crankshaft Diameter Secondary Gear Inside Diameter Secondary Gear Collar Diameter 116 0 116 2 mm 4 567 4 575 in 1 0 1 3 mm 0 04 0 05 in 2 9 3 1 mm 0 11 0 12 in less than 0 2 mm 0 008 in less than 0 1 mm 0 004 i
30. AS CN ee A 9 20 Shift Fork Men estas nine Ae e AA AA tee dons 9 20 Shift Rief geed EE 9 20 Transmission Gear Inspection seen 9 20 Ball Bearing Needle Bearing and Oil Seal 9 23 Ball and Needle Bearing Replacement rn 9 23 Ball and Needle Bearing Werner ds te eee ne De 9 23 Oil Seal Inspection r r a cet sntenmeneeteibnnsssnee esse E aED nest 9 23 9 2 CRANKSHAFT TRANSMISSION Exploded View Le as PAS AR CRANKSHAFT TRANSMISSION 9 3 Exploded View No Fastener Engine Drain Plug Crankcase Bolts 8 8 0 9 25 2 5 N m 29 Torque kgf m ft lb Remarks 30 78 in lb 5 Output Shaft Bearing Position Plate Screws 8 8 0 9 78 in lb L 6 Relief Valve 15 1 5 11 L 7 9 8 1 0 87 in lb Bearing Stopper Screws L Apply a non permanent locking agent LG Apply liquid gasket Kawasaki Bond 92104 002 MO Apply molybdenum disulfide oil O Apply engine oil 9 4 CRANKSHAFT TRANSMISSION Exploded View CRANKSHAFT TRANSMISSION 9 5 Exploded View Torque No Fastener q Remarks N m 1 Positioning Lever Bolt 8 8 12 ft lb 78 in lb reit os 72 NeutralReverse Switch Screws 1 3 Shift Drum Pin Plate Bolt L Apply a non permanent locking agent O Apply engine oil SS Apply silicone sealant
31. Bearing and Oil Seal Ball and Needle Bearing Replacement CAUTION Do not remove the ball or needle bearings unless it is necessary Removal may damage them e Using a press or puller remove the ball bearing and or needle bearing NOTE Oln the absence of the above mentioned tools satisfac tory results may be obtained by heating the case to ap proximately 93 C 200 F max and tapping the bearing in or out CAUTION Do not heat the case with a torch This will warp the case Soak the case in oil and heat the oil e Using a press and the bearing driver set A install the new bearing or outer race until it stops at the bottom of its housing Special Tool Bearing Driver Set 57001 1129 Ball and Needle Bearing Wear CAUTION Do not remove the bearings for inspection Re moval may damage them e Check the ball bearings OSince the ball bearings are made to extremely close toler ances the wear must be judged by feel rather than mea surement Clean each bearing in a high flash point sol vent dry it do not spin the bearing while it is dry and oil it with engine oil OSpin A the bearing by hand to check its condition x If the bearing is noisy does not spin smoothly or has any rough spots replace it e Check the needle bearings OThe rollers in a needle bearing normally wear very little and wear is difficult to measure Instead of measuring inspect the bearing for abrasion colo
32. ENGINE TOP END Cylinder Head Compression Too High Possible Problems Solutions References Remove carbon Piston Cleaning and Cylinder Head Cleaning Carbon build up on piston Valve Stem Oil Seal Inspection Check possible oil leaks head and cylinder head to combustion chamber Valve Stem Diameter Valve Guide Inside Diameter and check piston oil ring for visible damage Cylinder head or base Cylinder Head Removal Cylinder Head Installation Replace gaskets gasket too thin S Cylinder Removal and Cylinder Installation Wet Compression No Change Possible Problems Solutions References Valve Clearance Check and Valve Clearance Improper valve clearance Check clearance Adjustment Worn valve seats Check seats Valve Seat Inspection and Valve Seat Repair Burned valve Check valves Valve Visual Inspection and Valve Head Thickness Cylinder Head Removal and Cylinder Head Check head gasket Cylinder head leak Installation Check head flatness Cylinder Head Warp Wet Compression Increase Possible Problems Solutions References Too much piston to Check clearance Cylinder Piston Wear Piston Cylinder Clearance cylinder clearance Worn piston rings and Piston Ring and Ring Groove Wear Check piston and rings ring grooves and Piston Ring End Gap top and second only Cylinder Head Removal e Remove Front Fender see Frame chapter Fuel Tank Carburetor see Fuel System chapter Exhau
33. Head ENGINE TOP END 4 19 Cylinder Compression Measurement e Before measuring compression do the following OBe sure the battery is fully charged OWarm up the engine if the engine will run ODuring warm up check for leaks around the cylinder head gasket e Remove the spark plug e Set the compression gauge A and adapter B into the spark plug hole Special Tools Compression Gauge 57001 221 Compression Gauge Adapter M12 x 1 25 57001 1183 e Hold the throttle wide open and crank the engine with the recoil starter or the electric starter e When the gauge stops rising stop cranking and read the gauge Cylinder Compression Usable Range Recoil Starter 750 1 180 kPa 7 7 12 kgf cm 5 times 110 171 psi 450 r min rpm Electric Starter 930 1 435 kPa 9 5 14 6 kgf cm 135 208 psi 600 r min rpm x If the compression is within the specified range the piston rings cylinder and valves are probably in good condition x If the compression is higher than the specified range see the Compression Too High table Alf the compression is below the specified range squirt a little oil into the spark plug hole and repeat the compres sion measurement x If the compression does not change very much the piston rings are probably OK See the Wet Compression No Change table x If the compression increases the piston rings are not sealing properly See the Wet Compression Increase table 4 20
34. Kawasaki Bond 56019 120 104 in lb 9 6 CRANKSHAFT TRANSMISSION Specifications Item Standard Service Limit Crankshaft Connecting Rod Connecting Rod Big End Radial Clearance Connecting Rod Big End Side Clearance Crankshaft Runout Connecting Rod Bend Connecting Rod Twist Transmission Reverse Knob Free Play Shift Fork Ear Thickness Shift Fork Guide Pin Diameter Shift Drum Groove Width Gear Shift Fork Groove Width 0 008 0 020 mm 0 0003 0 0008 in 0 4 0 5 mm 0 016 0 020 in TIR 0 04 mm 0 0016 in or less under 0 05 100 mm 0 002 3 94 in under 0 15 100 mm 0 006 3 94 in 2 3 mm 0 08 0 12 in 4 9 5 0 mm 0 193 0 197 in 5 9 6 0 mm 0 232 0 236 in 6 05 6 20 mm 0 238 0 244 in 5 05 5 15 mm 0 199 0 203 in 0 07 mm 0 003 in 0 7 mm 0 028 in TIR 0 1 mm 0 0039 in 0 2 100 mm 0 008 3 94 in 0 2 100 mm 0 008 3 94 in 4 8 mm 0 189 in 5 8 mm 0 228 in 6 3 mm 0 248 in 5 3 mm 0 209 in CRANKSHAFT TRANSMISSION 9 7 Special Tools and Sealant Outside Circlip Pliers Crankshaft Jig 57001 144 57001 1174 p ST5701448T ST5711748T Crankcase Splitting Tool Assembly Kawasaki Bond Silicone Sealant 57001 1098 56019 120 ST5601208ST Bearing Driver Set Kawasaki Bond Liquid Gasket Silver 57001 1129 92104 002 ST571129ST ST9200028T
35. Lead Engine A Starter Motor Lead B Engine Breather Hose C e Loosen the propeller shaft dust cover clamp A e Remove Engine Mounting Bolts and Nuts A Engine Mounting Brackets B e Free the engine from the propeller shaft and remove the engine ENGINE REMOVAL INSTALLATION 8 5 Engine Removal Installation Engine Installation e Be sure the damper A is in place e Apply grease the splines at the driven gear shaft A and front end of the propeller shaft B e Support the vehicle so that the rear wheels are off the ground e Fit the driven gear shaft to the propeller shaft while rotat ing one rear wheel slowly e Tighten Torque Engine Bracket Bolts and Nuts 26 N m 2 7 kgf m 20 ft lb Engine Mounting Nut M8 29 N m 3 0 kgf m 22 ft lb Engine Mounting Nuts M10 39 N m 4 0 kgf m 29 ft lb e Route the hoses cables and leads properly see Appen dix chapter e Adjust Reverse Cable see Crankshaft Transmission chapter Throttle Lever Free Play see Periodic Maintenance chapter Engine Oil see Engine Lubrication System chapter Idle Speed see Fuel System chapter CRANKSHAFT TRANSMISSION 9 1 Crankshaft Transmission Table of Contents EXploded ET 9 2 eelere EE 9 6 Special Tools and Sealant rres anei e ear en a Ae aA a a Aa E a 9 7 GA EE a LU ETS a A E E E E E E E E ENNER gek dE er 9 8 Crankcase Disassembly ss rennais ant tent Patent edie dot de a td ee 9 8 Ee E 9 9 Cr
36. Lead 23 Ignition Switch Leads 16 Charging Coil Leads 24 Headlight Lead 7 Accessory Leads 17 To Regulator Rectifier 25 Coupler Cover 8 Indicator Light Leads 18 Route the taillight leads 9 Headlight Leads through this hole 10 To Igniter 19 Tail Brake Light Leads 17 4 APPENDIX Cable Wire and Hose Routing Viewed from Top HB09020BW4 1 Bands 7 Air Cleaner 2 To Igniter 8 Main Harness Battery Ground Cable and 3 Horn Lead Starter Motor Cable 4 Cross Pipe 9 Route the harness under the plate shown 5 To Left Headlight 10 Rear Fender 6 Main Harness APPENDIX 17 5 Cable Wire and Hose Routing HB09024BW4 Battery Breather Hose 6 CH C O g 2 a Pou oe FEO oar IN ODO Handlebar Front Brake Light Switch Leads Rear Brake Light Switch Leads 1 3 4 5 17 6 APPENDIX Cable Wire and Hose Routing _ Throttle Cable Front Brake Cable Rear Parking Brake Ca ble Choke Cable Front Brake Cable Equal izer Reverse Cable Rear Brake Cable Handlebar Frame Route the choke and parking cables behind this frame peg Clamp the choke cable and switch leads to the handlebar with the band Adjuster HB09021BW4 13 Pin 14 Washer 15 Spring 16 Lever 17 Knuckle 18 Tie Rod 19 Circlip APPENDIX 17 7 Cable Wire and Hose Routing HB
37. OWith the crankshaft still in the alignment jig hold the con necting rod horizontally and measure the amount that the 100mm arbor varies from being parallel with the crankshaft over a 100 mm 3 94 in length of the arbor to determine the amount of connecting rod twist Mi Alf connecting rod twist exceeds the service limit the con necting rod must be replaced Connecting Rod Twist H105007BS1 Standard Under 0 15 100 mm 0 006 3 94 in Service Limit 0 2 100 mm 0 008 3 94 in 9 16 CRANKSHAFT TRANSMISSION Transmission External Shift Mechanism Removal Ka e Remove Shift Pedal Clutches see Engine Right Side chapter Clutch Release Cams A Ball Assembly B e Remove Shift Mechanism Shaft A NOTE OMove the shift mechanism arm B out of its position on the end of the shift drum and pull out the shift mecha nism shaft e Remove Positioning Lever Bolt A Positioning Lever B and Spring Return Spring Pin C Clutch Release Cam Pin D External Shift Mechanism Installation e Apply a non permanent locking agent to the threads of the return spring pin and cam pin and tighten them Torque Return Spring Pin 25 N m 2 5 kgf m 18 ft lb Clutch Release Cam Pin 25 N m 2 5 kgf m 18 ft lb e Be sure the shift mechanism arm collar A and clutch release inner cam B are in place e Install Ball Assembly A Clutch Release Outer Cam B CRANKSHAFT TRANSMISSION 9 17 Transmissi
38. Remove the brake lever cable from the frame e Remove Rear Brake Lever Cable Rear End A Cotter Pin Washer and Pin B Brake Pedal Cable Mount C Brake Cable Installation e Grease the brake cable e Replace the cotter pin with a new one e Run the brake cables according to the Cable Wire and Hose Routing section in Appendix chapter e Adjust the brake pedal and rear brake lever Brake Cable Lubrication Whenever the brake cable is removed lubricate the cable as follows e Lubricate the cable with a penetrating rust inhibitor Brake Pedal Installation e Bend both side hooks A of switch spring B after in stalling the spring C Brake Pedal HL11002BS1 HL11004BS1 SUSPENSION 13 1 Suspension Table of Contents EXpDlOd d EE 13 2 Shock AbsorD rs sisi aia 13 4 Shock Absorber Removal ecc orion llanta colacao 13 4 Rear Shock Absorber Installation ennenen 13 4 Rear Shock Absorber Inspection nennen nnee 13 4 SUSPENSION AMS EE 13 5 Front Suspension Arm Removal 13 5 Front Suspension Arm Installation tenn reen teen ne n 13 5 Rear Suspension Arm Removal nnee 13 5 Rear Suspension Arm Installati
39. SUS STING as ea A de ce Sal cates Acree Aeon Ra TA a ne AN in ainda AA 14 5 Steering Stem e EE 14 5 Steering Stem Installations san ent ee ar a Sade 14 6 Steering Knuckle E e 14 6 Steering Knuckle Installation ONSE dd 14 7 RRC Nun Le lisse net ue A E 14 7 Tie rod Installation 22535 rhone a Ee Ae 14 7 Te rod Nee Bn Le EE 14 7 Tie rod End Installation eet dr lid 14 8 As A O A tnt time tee 14 9 Si AR 14 9 Steerng Stem WA ne EE 14 9 EIDEN En RE rada 14 9 Steering Stem Clamp Inspection see 14 9 Steering Stem Bearing Inspection su 14 9 Tiesrod End Inspection EE 14 10 Steering Knuckle Pivot EISE geed deg 14 10 FIANGIOD AR eet Abee ek eebe a os 14 11 ele Neger 14 11 Handlebar Installation cccocccocccnccnnccnncnnncnnncnonononcnoncnononnncnnnnonnnoncnnnrnnnrnnncnnnrnnncnnncnnn 14 11 14 2 STEERING Exploded View HN92012845 C STEERING 14 3 Exploded View Torque No Fast O astener kaim ftlb Steering Stem Clamp Bolts 2 7 Remarks Steering Stem Bottom End Nut 22 Tie rod End Nuts 30 Tie rod Adjusting Sleeve Locknuts 2 7 Steering Knuckle Arm Pivot Nuts 29 Handlebar Holder Bolts 20 14 S 7 Europe and Australia Models 8 Optional Parts for U S A Canada and United Kingdom Models A KLF250 A1 A3 Model AD Apply adhesive agent AG Apply grease Amoco rykon premium grease No 2 EP Green Gr Apply grease S Follow the specific tightening sequence O O1
40. Tester Bule Red gt Black Black gt e Turn the ignition switch on and rotate the engine for 4 5 seconds with the transmission gear in neutral to measure the crankshaft sensor peak voltage e Repeat the measurement 5 or more times Crankshaft Sensor Peak Voltage Standard 3 6 V or more x If the peak voltage is lower than the standard inspect the crankshaft sensor Alternator Rotor Inspection e Check the timing projection A for damage such as chip ping or grooving x lf the timing projection on the rotor is visibly damaged replace the alternator rotor Ignition System ELECTRICAL SYSTEM 16 31 Ignition Timing Test e Remove the ignition timing inspection plug e Attach the timing light A and a tachometer in the manner prescribed by the manufacturer Special Tool Timing Light 57001 1241 e Start the engine and aim the timing light at the timing mark on the alternator rotor e Run the engine at the speeds specified and note the align ment of the timing marks Ignition Timing Engine speed r min rpm Slot B aligned with 1 800 and below Advanced mark C on alternator rotor 4 600 and above Advanced mark D on alternator rotor NOTE ODo not mix up the timing marks with the top mark T lf the ignition timing is incorrect replace the igniter and the Crankshaft Sensor ion d le T J HP10010BS1 16 32 ELECTRICAL SYSTEM
41. Tool Hexagon Wrench Hex 32 57001 1194 Pinion Gear Assembly e The pinion gear and ring gear are lapped as a set by the factory to get the best tooth contact They must be re placed as a set e Apply grease to the oil seal lips e Install the bearing A and oil seal B using the bearing driver set Special Tool Bearing Driver 57001 1129 e Apply a non permanent locking agent to the bearing re HK140078S1 tainer C and tighten it Torque Bearing Retainer 108 N m 11 kgf m 80 ft lb e Install Pinion Gear D Pinion Gear Joint E e Apply grease to the O ring F e Install O ring Washer G e Replace the pinion gear nut H with a new one 11 30 FINAL DRIVE Final Gear Case e Apply molybdenum disulfide oil the threads and seated surface of the pinion gear nut and tighten it Torque Pinion Gear Nut 69 N m 7 0 kgf m 51 ft lb e Stake the head of the pinion gear nut with a punch to secure the pinion gear nut in place CAUTION When staking the nut be careful not to apply shock to the pinion and bearing Such a shock could dam age the pinion and or bearing e Be sure to check and adjust the bevel gear backlash and tooth contact when any of the parts which influence these items are replaced see Final Bevel Gear Adjustment Bevel Gear Inspection e Visually check the bevel gears A for scoring chipping or other damage x Replace the bevel gears as a set if either gear is dam
42. US CA 1 020 mm 40 16 in Overall Height 1 040 mm 40 94 in Wheelbase 1 115 mm 43 90 in Ground Clearance 155 mm 6 10 in Seat Height 730 mm 28 74 in Dry Mass 185 kg 408 Ib US 183 kg 404 Ib CA 183 5 kg 405 Ib Curb Mass Front 89 kg 196 Ib US CA 88 5 195 Ib Rear 106 kg 234 Ib US 104 5 kg 230 Ib CA 105 kg 232 Ib 10 L 2 6 US gal 2 7 m 8 86 ft 4 stroke SOHC 1 cylinder Air cooled 69 0 x 61 0 mm 2 72 x 2 40 in 228 cm 13 9 cu in 8 9 12 5 kW 17 PS 7 000 r min rpm US 17 9 N m 1 83 kgf m 13 24 ft lb 5 500 r min rpm Carburetor MIKUNI VM24SS Electric starter amp Recoil starter CDI Electronically advanced From 10 BTDC 1 800 r min rpm to 35 BTDC 4 600 r min rpm NGK DR8ES 35 BTDC 57 ABDC 272 54 BBDC 26 ATDC 260 Forced lubrication wet sump General Specifications GENERAL INFORMATION 1 7 Engine Oil Type API SF or SG API SH or SJ with JASO MA Viscosity SAE 10W 40 Capacity 2 0 L 2 11 US qt Drive Train Primary Reduction System Type Reduction Ratio Clutch Type Transmission Type Gear Ratio 1st 2nd 3rd 4th 5th Reverse Final Drive System Type Reduction Ratio Overall Drive Ratio Top Gear Final Gear Case Oil Type Capacity Gear 3 450 69 20 Wet multi disc and centrifugal 5 speed plus reverse constant mesh return shift 2 923 1 684 1 173 0 923 0 785 3 115 38 1
43. adjustment should not be neglected Reduced braking effec tiveness could lead to a crash Rear Parking Brake Lever Free Play Inspection e Check the rear parking brakelever free play A OPull the rear brake lever lightly until the brake is applied x If the play is incorrect adjust it Rear Parking Brake Lever Free Play Standard 2 3 mm 0 08 0 12 in Brake Pedal Free Play Inspection e Check the brake pedal free play A ODepress the brake pedal B lightly by hand until the brake is applied x If the free play is incorrect adjust it Brake Pedal Free Play Standard 25 35 mm 1 0 1 4 in PERIODIC MAINTENANCE 2 17 Periodic Maintenance Procedures Rear Parking Brake Lever and Pedal Free Play Adjustment e Loosen the locknut A and turn in the adjuster B at the rear brake parking lever as far as it will go e Turn in or out the adjuster A at the rear end of the brake cable so that the brake pedal will have 25 35 mm 1 0 1 4 in of free play before the brake starts to take hold e Turn out the adjuster at the rear brake lever until brake lever has 2 3 mm 0 08 0 12 in of free play Tighten the locknut e Check the cam lever angle A when the brake is fully applied Cam Lever Angle Standard 80 90 x If the cam lever angle is not within the range specified adjust it see Cam Lever Angle Adjustment A WARNING Since a cam lever angle greater than 90 reduc
44. bolt B and then tighten the locknut Now adjust the brake pedal free play e After adjusting the pedal position check the operation of the rear brake light switch see Electrical System chap ter Then adjust the brake pedal free play Rear Parking Brake Lever Free Play Inspection e Refer to the Rear Parking Brake Lever Free Play Inspec tion in the Periodic Maintenance chapter Brake Pedal Free Play Inspection e Refer to the Brake Pedal Free Play Inspection in the Pe riodic Maintenance chapter Rear Parking Brake Lever and Brake Pedal Free Play Adjustment e Refer to the Rear Parking Brake Lever and Brake Pedal Free Play Adjustment in the Periodic Maintenance chap ter Cam Lever Angle Adjustment Front and Rear e Remove Cam Lever Bolt A Cam Lever B 12 6 BRAKES Brake Adjustment e Mount the cam lever at a new position so that the cam lever has the proper angle when the brake is fully applied Cam Lever Angle front and rear Standard 80 90 A WARNING When remounting the cam be sure that the position of the indicator on the serrated shaft is not altered A change in cam lever angle is caused by wear of internal brake parts Whenever the cam lever angle is adjusted also check for drag and proper opera tion taking particular note of the brake lining wear indicator position In case of doubt as to braking effectiveness disas semble and inspect all internal brake parts Wo
45. contact First adjust the backlash and then tooth contact by replac ing shims These two adjustments are of critical importance and must be carried out in the correct sequence using the procedures shown Output Bevel Gear Adjustment Procedure Adjust gear backlash Adjust tooth contact pattern Assemble the output bevel gear case completely 11 12 FINAL DRIVE Output Bevel Gear Case Backlash Related Parts Ar ALTA a L p a en CT O AQ KT CT OZIZIZIZITIZZ pe A Gg VX 2 A HKO8006B 3 1 Output Bevel Gear Case 2 Ball Bearing 3 Output Driven Gear 4 Drive Gear Shims 5 Transmission Output 8 Bearing Housing Shaft 9 Driven Gear Shaft 6 Output Drive Gear 7 Driven Gear Shims Output Bevel Gear Case Drive Gear Shims FINAL DRIVE 11 13 Thickness Part Number 0 15 mm 0 006 in 92025 1573 0 20 mm 0 008 in 92025 1574 0 7 mm 0 028 in 92025 1534 0 8 mm 0 031 in 92025 1535 0 9 mm 0 035 in 92025 1536 1 0 mm 0 039 in primary 92025 1537 1 1 mm 0 043 in 92025 1575 1 2 mm 0 047 in 92025 1538 1 3 mm 0 051 in 92025 1533 Driven Bevel Gear Shims Thickness mm Part Number 0 10 mm 0 004 in 92025 1859 0 15 mm 0 006 in 92025 1860 0 50 mm 0 020 in 92025 1861 0 80 mm 0 031 in 92025 1862 1 00 mm 0 039 in primary 92025 1858 1 20 mm 0 047 in 92025 1863 Bevel Gear Backlash Adjus
46. e Measure the diameter of the rocker shaft where the rocker arm pivots on it with a micrometer x lf the rocker shaft diameter is smaller than the service limit replace it Rocker Shaft Diameter Standard 12 976 12 994 mm 0 5109 0 5116 in Service Limit 12 95 mm 0 510 in Camshaft ENGINE TOP END 4 17 Camshaft Removal e Remove Camshaft Sprocket see Camshaft Sprocket Removal Rocker Shaft Retainer see Rocker Arm and Shaft Re moval e Pull the camshaft A straight out of the head Camshatt Installation e Blow the oil passage with compressed air A e Apply molybdenum disulfide oil to the cam lobes A e Carefully push the camshaft into the cylinder head with the cam lobes down Cam Wear Inspection e Measure the height A of each cam lobe with a microm eter Alf the cam height is less than the service limit for either lobe replace the camshaft Cam Height Standard Service Limit Exhaust 39 720 39 828 mm 39 62 mm 1 5638 1 5680 in 1 560 in Inlet 40 395 40 503 mm 40 30 mm 1 5904 1 5946 in 1 587 in Camshaft Bearing Inspection e Check the ball bearing which is press fitted on the camshaft OSince the ball bearing is made to extremely close toler ances the wear must be judged by feel rather than mea surement Clean the bearing in a high flash point solvent dry it do not spin the bearing while it is dry and oil it with engine oil OSpin the bearing by hand to c
47. install a new valve guide e Check the valve seating e After proper valve seating has been confirmed replace the valve stem oil seal A e Smear the valve stem end with a thin coat of molybdenum disulfide engine assembly grease and push the valve B into the guide e Put the spring seat C and the inner and outer springs D in place OPlace the springs so that the closed coil end E of each spring faces down e Set the spring retainer F on the springs e Use the valve spring compressor to press down the valve spring retainer e Install the split keepers G and slowly remove the spring compressor Be sure the keepers stay in place holding the retainer down e Repeat the procedure for the other valve e Install the removed parts to the cylinder head e Install the cylinder head see Cylinder Head Installation e Adjust the valve clearance see Valve Clearance Inspec tion Valve Visual Inspection e Inspect the valve head seating area A for erosion nicks and warpage xlf the valve head seating area is warped replace the valve x If the valve head seating area is eroded or nicked it may be possible to repair the valve on a valve refacing ma chine e Inspect the stem B for obvious wear discoloration and stem end C damage x lf the stem is obviously worn or discolored replace the valve x lf the stem end is damaged it may be possible to repair it on a valve refacing machine Valve Guide Removal
48. is removed or in accordance with the Periodic Maintenance Chart in the Periodic Main tenance chapter lubricate the cable e Refer to the General Lubrication in the Periodic Mainte nance chapter for the cable lubrication and inspection 3 10 FUEL SYSTEM Carburetor Idle Speed Adjustment e Start the engine and warm it up thoroughly e With the engine idling turn the handlebar to both sides to check for any changes in the idle speed If handlebar movement changes the idle speed the throt tle cable may be improperly adjusted incorrectly routed or damaged Be sure to correct any of these conditions before riding A WARNING Operation with an improperly adjusted incorrectly routed or damaged cable could result in an unsafe riding condition e Check idle speed with a suitable tachometer x If the idle speed is out of the specified range adjust it Idle Speed Standard 1 300 1 400 r min rpm Idle Speed Adjustment e Start the engine and warm it up thoroughly e Turn the idle adjusting screw A until the idle speed is correct OOpen and close the throttle a few times to make sure that the idle speed is within the specified range Carburetor Pilot Screw Adjustment e Adjust the pilot screw if necessary e Turn the carburetor pilot screw A all the way in until it seats lightly Special Tool Pilot Screw Adjuster A 57001 1239 B CAUTION Do not overtighten the pilot screw or th
49. kgf m micro p x 0 000001 Wm E im AED N m x 8 851 in lb kgf m x 9 807 N m kgf m x 7 233 ft lb Units of Mass kgf m x 86 80 in Ib kg x 2 205 Ib cs E 5 Units of Pressure kPa x 0 01020 kg cm Units of Volume kPa x 0 1450 psi L x 0 2642 gal US kPa x 0 7501 cmHg L x 0 2200 gal imp kg cm x 98 07 kPa L x 1 057 qt US kg cm x 14 22 psi L x 0 8799 qt imp cmHg x 1 333 kPa L x 2 113 pint US L x 1 816 int im mL x 003381 s US UniS Of Speed mL x 0 02816 oz imp km h x 0 6214 mph mL x 0 06102 cu in Units of Power Units of Force kW x 1 360 PS N x 0 1020 kg kW x 1 341 HP N x 0 2248 Ib PS x 0 7355 kW kg x 9807 N PS x 0 9863 HP kg x 2 205 Ib Units of Temperature ERA es AA 2 pace tin oF oF 32 68 104 248 284 40 20 320 40 20 40 60 20i 267 489 i 400 71 1 93 3 116 120 176 212 80 100 120 140 160 180 200 220 240 260 280 300 440 138 160 PERIODIC MAINTENANCE 2 1 Periodic Maintenance Table of Contents Periodic Maintenance Chart 2 2 Wheels Tires 2 13 Torque and Locking Agent 2 3 Tire Inspection 2 13 Specifications 2 6 Final Drive 2 14 Periodic Maintenance Procedures 2 7 Final Gear Case Oil Change 2 14 Fuel System 2 7 Propeller Shaft Joint Boot Throttle Lever Free Play INSpec
50. leads Special Tool Hand Tester 57001 1394 OSet the tester to the x 1 Q range x If the tester does not read 0 Q the lead is defective Re place the lead or the wiring harness B if necessary S HPO7OO1ES1 16 12 ELECTRICAL SYSTEM Battery Battery Removal e Remove Seat see Frame chapter Battery Holder A e Disconnect the battery negative cable B first and then the positive cable C e Take out the battery D Battery Installation e Connect the positive cable first and then the negative ca ble e Put a light coat of grease on the terminals to prevent cor rosion e Route the battery vent hose according to the Cable Wire and Hose Routing section in Appendix chapter Electrolyte Level Inspection e The electrolyte level should be between the upper and lower level lines A x If the level of electrolyte in any cell is below the lower level line add only distilled water to the cell until the level is at the upper level line CAUTION Ordinary tap water is not a substitute for distilled water and will shorten the life of the battery Electrolyte Specific Gravity Inspection e Check battery condition by testing the specific gravity of the electrolyte in each cell with a hydrometer ORead the level of the electrolyte B on the floating scale A x If the specific gravity is below 1 200 the battery needs to be charged NOTE OThe specific gravity of the electrolyte varies wit
51. rod End Nuts 41 N m 4 2 kgf m 30 ft lb e Inspect the following and adjust them if necessary Toe in see Wheels Tires chapter Front Brake Cable see Brakes chapter Steering Knuckle Removal e Remove Front Brake Panel see Brakes chapter Brake Cable Cotter Pin A Tie rod End Nut B and Tie rod End C CAUTION Do not loosen the locknuts at the ends of the tie rod adjusting sleeve or the toe in of the front wheels will be changed e Remove Steering Knuckle Pivot Bolt D and Nut Steering Knuckle E HNO4011BS1 STEERING 14 7 Steering e Remove Grease Seals A Sleeve B Steering Knuckle Installation e Tighten Torque Steering Knuckle Pivot Nut 39 N m 4 0 kgf m 29 ft Ib Tie rod End Nut 41 N m 4 2 kgf m 30 ft Ib Tie rod Removal e Remove Cotter Pin and Tie rod End Nuts A Tie rod B CAUTION When removing the tie rod be careful not to bend it Do not loosen the locknuts C at the end of the tie rod adjusting sleeve or the toe in of the front wheels will be changed Tie rod Installation e The right and left tie rods are identical e Install the tie rod with the flattened area A located in board e Tighten Torque Tie rod End Nuts 41 N m 4 2 kgf m 30 ft lb e Inspect the toe in if necessary see Wheels Tires chap ter Tie rod End Removal e Remove the tie rod see Tie rod Removal e Holding the tie rod flattened area A l
52. side e Remove Alternator Cover Bolts A Alternator Cover B Alternator Cover Installation e Apply silicone sealant to the circumference of the Crank shaft Sensor lead grommet A and fit the grommet into the notch of the crankcase e Check the dowel pins B are in place and fit a new gasket on the crankcase e Check the ball bearing C is in place 16 18 ELECTRICAL SYSTEM Charging System e Apply silicone sealant A to the circumference of the sta tor coil lead grommet and fit the grommet into the notch of the cover securely Sealant Kawasaki Bond Silicone Sealant 56019 120 e Tighten Torque Alternator Cover Bolts 8 8 N m 0 9 kgf m 78 in 1b e Grease the alternator cover oil seal e Check that the pulley O ring A is in good condition e Clean the pulley boss and apply oil to the O ring and the boss HPO9010281 e Push the pulley A into the left engine cover oil seal e Fit the key B in the groove between the pulley and the crankshaft e Tighten Torque Alternator Rotor Bolt 59 N m 6 0 kgf m 43 ft Ib e Add engine oil Alternator Rotor Removal e Remove Alternator Cover see Alternator Cover Removal Ball Bearing A Crankshaft Sensor B Torque Limiter C e Thread the flywheel puller A and rotor puller B onto the alternator rotor Special Tools Flywheel Puller M30 x 1 5 57001 1191 Rotor Puller M16 M18 M20 M22 x 1 5 57001 1216 e Hol
53. stator coil resistance as follows OStop the engine ODisconnect the alternator connector OConnect a hand tester as shown in the table ONote the readings total 3 measurement Stator Coil Tester Comnections Reading Range Tester t Tester 4 000 r min to rpm One yellow lead a 0 4 1 10 x If there is more resistance than shown in the table or no reading infinity for any two leads the stator has an open and must be replaced Much less resistance means the stator is shorted and must be replaced e Using the highest resistance range of the hand tester measure the resistance between each of the yellow leads and chassis ground x Any reading less than infinity indicates a short neces sitating stator replacement x lf the stator coils have normal resistance but the voltage check shows the alternator to be defective then the rotor magnetism has probably weakened and the rotor must be replaced Special Tool Hand Tester 57001 1394 Charging System ELECTRICAL SYSTEM 16 23 Regulator Rectifier Inspection e Remove Regulator Bracket Bolts A Connector B disconnect Regulator Rectifier C Rectifier Circuit Check e Check conductivity of the following pair of terminals Rectifier Circuit Inspection W Y1 W Y2 W Y3 BK Y Y1 BK Y Y2 BK Y Y3 x The resistance should be low in one direction and more than ten times as much in the other direction If any two leads are low or h
54. the center of the chalk coating while turning the wheel e With the front wheels on the ground set the handlebar straight ahead e At the level of the axle height measure the distance be tween the scribed or painted lines for both front and rear of the front tires e Subtract the measurement of the front from the measure ment of the rear to get the toe in x If the toe in is not in the specified range go on to the Toe in Adjustment procedure Toe in of Front Wheels Standard 15 35 mm 0 59 1 38 in at 1G HJ04002B S HJ04008B S R P 10 8 WHEELS TIRES Wheel Alignment Toe in Adjustment e Loosen the locknuts A B and turn the adjusting sleeves C the same number of turns on both sides to achieve the specified toe in NOTE OThe locknut A on the opposite side of the flattened area D on the tie rod has left hand threads Turn the locknut clockwise for loosening NOTE OThe toe in will be near the specified value if the tie rod length A is 288 mm 11 3 in on each tie rod CAUTION Adjust the tie rod length so that the visible thread length B is even on both ends of the tie rod Un even thread length could cause tie rod damage e Check the toe in see Toe in Inspection e Tighten Torque Tie rod Adjusting Sleeve Locknuts 26 N m 2 7 kgf m 20 ft lb e Test ride the vehicle HJ04003B S Wheels Rims WHEELS TIRES 10 9
55. the rocker arm with a thickness gauge A x If the valve clearance is not correct adjust it Valve Clearance when cold Exhaust 0 18 0 23 mm 0 0071 0 0091 in Inlet 0 15 0 20 mm 0 0059 0 0079 in Spark Arrester Cleaning WARNING To avoid burns wear gloves while cleaning the spark arrester Since the engine must be run dur ing this procedure the muffler will become hot HUO5000BS1 PERIODIC MAINTENANCE 2 11 Periodic Maintenance Procedures e Remove the drain plug A on the muffler e In an open area away from combustible materials start the engine with the transmission in neutral e Raise and lower engine speed while tapping on the muf fler with a rubber mallet until carbon particles are purged from the muffler WARNING Do not run the engine in a closed area Exhaust gases contain carbon monoxide a colorless odor less poisonous gas Breathing exhaust gas leads to carbon monoxide poisoning asphyxiation and death e Stop the engine e Remove Bolt A Spark Arrester B Muffler C e Scrape carbon deposits off the spark arrester and slide it back into the muffler WARNING Never run the engine with the spark arrester re HE15004BS1 moved near combustible materials Hot carbon particles may start a fire e Install the drain plug Clutches Clutch Adjustment e Remove Screws A Adjusting Screw Cover B e Loosen t
56. the seal lips A in the drum seal e Install Brake Drum Washer e Tighten Torque Rear Axle Nut 147 N m 15 kgf m 108 ft lb HL14002BS1 HL14003BS1 HL14004B S 12 12 BRAKES Brake Drum and Panel e Insert a new cotter pin A NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle shaft tighten the nut clockwise B up to next alignment Olt should be within 30 degree OLoosen once and tighten again when the slot goes past the nearest hole HJO7007BS1 e Bend the cotter pin A over the nut B HJO7008BS1 Brake Drum Seal Wear Whenever the braking efficiency of the rear brake panel has decreased perform the following Remove the drain bolt A at the bottom of the rear brake panel and check to see if any water comes out x If any water drains the rear brake drum seal is damaged and must be immediately replace Also inspect the other brake parts e Tighten Torque Rear Brake Drum Drain Bolt 29 N m 3 0 kgf m 22 ft Ib Brake Maintenance BRAKES 12 13 Brake Drum Wear e Measure the inside diameter A of the drum at several points Front Brake Drum Inside Diameter Standard 140 000 140 160 mm 5 512 5 518 in Service Limit 140 75 mm 5 541 in Rear Brake Drum Inside Diameter Standard ec 160 160 mm 6 299 6 305 Service Limit 160 65 mm 6 325 in Alf
57. water to lubricate the tire beads and rim because it may cause tire separation e Check the tire rotation mark A on the tire and install the tire on the rim accordingly OThe tires should be installed on the rims so that each air valve is toward the outside of the vehicle NOTE OThe direction of the tire rotation B is shown by an arrow on the tire sidewall e Install the tire on the rim using a suitable commercially available tire changer e Lubricate the tire beads again and center the tire on the rim HJO5006B S HJO5007B S HJO5001B S 10 12 WHEELS TIRES Tires e Support the wheel rim A on a suitable stand B to pre vent the tire from slipping off e Inflate the tire until the tire beads seat on the rim Maximum Tire Air Pressure to seat beads when cold Front and Rear 250 kPa 2 5 kg cm 36 psi A WARNING Do not inflate the tire to more than the maximum tire air pressure Overinflation can explode the tire with possibility of injury and loss of line e Check to see that rim lines A on both sides of the tire are parallel with the rim flanges B x lf the rim lines and the rim flanges are not parallel deflate the tire lubricate the sealing surfaces again and reinflate the tire e After the beads are properly seated check for air leaks OApply a soap and water solution around the tire bead and check for bubbles e Deflate the tire to the specified p
58. 0 r min rpm 5 1 mm 0 20 5 8 1 mm 0 22 0 04 in 0 04 in below bottom edge of carburetor body 22 6 2 mm 0 89 0 04 in 115 92063 1109 112 5 92063 1110 110 92063 1038 107 5 92063 073 102 5 92063 1028 120 92063 1106 117 5 92063 1107 115 92063 1109 112 5 92063 1110 110 92063 1038 High quality foam air filter oil FUEL SYSTEM 3 5 Special Tools and Sealant Fuel Level Gauge Pilot Screw Adjuster A 57001 1017 57001 1239 ST571017ST ST571239ST 3 6 FUEL SYSTEM Throttle Lever and Cable Throttle Lever Free Play Inspection e Refer to the Throttle Lever Free Play Inspection in the Periodic Maintenance chapter Throttle Lever Free Play Adjustment e Refer to the Throttle Lever Free Play Adjustment in the Periodic Maintenance chapter Throttle Case Removal Disassembly e Remove the throttle case screws A and separate the case halves e Pull the cable tip A out of the throttle lever catch with the throttle lever opened e Loosen the locknut B and unscrew the adjuster C e Remove Throttle Lever Bolt A Spring Washer B and Washer gt C Arm D and Spring E y Collars F Throttle Lever G Oo e Loosen the locknut H and unscrew the throttle limiter C screw I D DS HCO4000BS2 C FUEL SYSTEM 3 7 Throttle Lever and Cable Throttle Case Assembly Installation e Lubricate the thrott
59. 001 1125 Valve Seat Cutter Holder Bar 57001 1128 If the manufacturer s instructions are not available use the following procedure HE13009BS2 C Valves Guides Seats Springs Oil Seals ENGINE TOP END 4 27 Seat Cutter Operating Care 1 This valve seat cutter is developed to grind the valve for repair Therefore the cutter must not be used for other purposes than seat repair 2 Do not drop or shock the valve seat cutter or the dia mond particles may fall off 3 Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface Also wash off ground particles sticking to the cutter with washing oil CAUTION Do not use a wire brush to remove the metal par ticles from the cutter It will take off the diamond particles 4 Setting the valve seat cutter holder in position operate the cutter in one hand Do not apply too much force to the diamond portion NOTE OPrior to grinding apply engine oil to the cutter and dur ing the operation wash off any ground particles sticking to the cutter with washing oil 5 After use wash it with washing oil and apply thin layer of engine oil before storing Marks Stamped on the Cutter The marks stamped on the back ofthe cutter A represent the following O Saisons Cutter angle B ST OD Outer diameter of cutter C Operating Procedures e Clean the seat area carefully e Coat the s
60. 001BS1 11 16 FINAL DRIVE Output Bevel Gear Case Cam Damper Inspection e Visually inspect Bevel Gear Cam A Cam Follower B Spring C Shaft D Replace any part if it appears damaged Ball Bearing Inspection e Since the ball bearings are made to extremely close toler ances the wear must be judged by feel rather than mea surement Clean each bearing in a high flash point sol vent dry it do not spin the bearing while it is dry and oil it with engine oil e Spin the bearing by hand to check its condition x If the bearing is noisy does not spin smoothly or has any rough spots replace it Oil Seal Inspection e Inspect the oil seals x Replace it if the lips are misshapen discolored indicat ing that the rubber has deteriorated hardened or been otherwise damaged FINAL DRIVE 11 17 Propeller Shaft Propeller Shaft Removal e Support the vehicle on a stand or the jack so that the rear wheels are off the ground Special Tool Jack 57001 1238 e Loosen the propeller shaft housing mounting nuts e Remove Rear Wheels see Wheels Tires chapter Center Arm see Suspension chapter e Support the final gear case on a stand or jack e Remove Rear Suspension Arms A Propeller Shaft Housing Mounting Nuts B Rear Shock Absorber Lower Bolts C e Move back the final gear case D and rear axle assembly e Loosen the clamp A and remove the propeller shaft housing B e Remove Spr
61. 018B F 16 34 ELECTRICAL SYSTEM Electric Starter System Starter Motor Removal e Remove Exhaust Pipe see Engine Top End chapter Oil Pipes A e Remove Starter Motor Lead A Starter Motor Mounting Bolt B Starter Motor C CAUTION Do not tap the end of the starter motor shaft or the motor may be damaged Starter Motor Installation e When installing the starter motor clean the starter mo tor lugs A and crankcase B where the starter motor is grounded elf the O ring A shows any damage or if it is hardened replace it with a new one e Apply a small amount of engine oil to the O ring e Attach the stater motor lead A at the angle as shown B 30 C Starter Motor e Tighten Torque Starter Motor Mounting Bolts 8 8 N m 0 9 kgf m 78 in Ib Starter Motor Terminal Nut 4 9 N m 0 5 kgf m 43 S in Ib Cn HP11004BS1 ELECTRICAL SYSTEM 16 35 Electric Starter System Starter Motor Disassembly e Remove Starter Motor Through Bolts A Left End Cover B Right End Cover C Yoke D e To remove the brush plate assembly A remove the ter minal locknut B e Hold the brush spring A with needle nose pliers and pull the brush B off the holder Starter Motor Assembly e Replace the O rings with new ones e Install the brush plate assembly to the right end cover so that the projection A on the brush plate fits into the groove on the right end cover
62. 0642 in Crankshaft Diameter A Standard 26 959 26 980 mm 1 0614 1 0622 in Service Limit 26 94 mm 1 0606 in Secondary Gear Collar Wear x If the inside diameter of the secondary gear is greater than the service limit replace it x If the outside diameter of the collar is less than the service limit replace it Secondary Gear Inside Diameter A Standard 25 000 25 021 mm 0 9842 0 9851 in Service Limit 25 03 mm 0 9854 in Secondary Gear Collar Diameter B Standard 24 970 24 985 mm 0 9831 0 9837 in Service Limit 24 95 mm 0 9823 in Exploded View Recoil Starter Recoil Starter Removal RECOIL STARTER 6 1 Recoil Starter Table of Contents Recoil Starter Installation non cnnnc nan cnn rr nnrrnncnnnnns Recoil Starter DIS ISSO EE Recoil Starter Assembly Recoil Starter Cleaning Recoil Starter Inspection 6 2 6 4 6 2 RECOIL STARTER Exploded View AY RE JE RECOIL STARTER 6 3 Exploded View Ka kom Rib EE 88 f os re 2 Recoil Starter Flange Nut 2 104 in lb Gr Apply grease 6 4 RECOIL STARTER Recoil Starter Recoil Starter Removal e Remove Recoil Starter Mounting Bolts A Recoil Starter B OPush down the shift pedal C when removing the recoil starter Recoil Starter Installation e Tighten Torque Recoi
63. 09022BW4 1 Handlebar Cover 8 Frame 2 Indicator Light Leads 9 Cross Pipe 3 Handlebar 10 Choke Cable 4 Clamp the choke cable and handlebar 11 Band switch leads 12 Rear Parking Brake Cable 5 Install the throttle cable only in the clamp 13 Engine Bracket 6 Bracket 14 Clamp 7 Throttle Cable 15 Reverse Cable 17 8 APPENDIX Cable Wire and Hose Routing O O1 P N A CON Breather Hose for Engine Parking Cable Rear Brake Cable Breather Hose for Final Gear Case Breather Hose for Rear Brake Carburetor Vent Hose Make sure the carburetor vent hose is not kinked 70 mm 2 8 in Clamp the breather hoses and parking cable with the band Clamp the breather hoses and rear brake cable with the bands HB09023BW4 Clamp Fuel Tank It is important to position three hoses as shown Carburetor Vent Hose End Frame Gusset Upper Surface 3 9 mm 0 12 0 35 in Install the vent hoses in the slots at the back of the fuel tank APPENDIX 17 9 Cable Wire and Hose Routing HB09025BW4 1 Clamp 7 Clamp on Starter Motor Mounting Bolt 2 Engine Breather Hose 8 Clamp on Crankcase Bolt 3 Camshaft Cover 9 Carburetor Drain Hose 4 Valve Adjusting Cap 10 Carburetor Overflow Hose 5 Clamp on Valve Adjsuting Cap Bolt 11 Assemble the clamp in this line 6 Air Cleaner 17 10 APPENDIX Cable Wire and Hose Routing SE
64. 1 B00480193 P 3 8 FUEL SYSTEM Throttle Lever and Cable e Apply a thin coating of multi purpose grease to the throttle lever pivot area A and throttle cable end B Throttle Cable Lubrication and Inspection e Whenever the throttle cable is removed or in accordance with the Periodic Maintenance Chart in the Periodic Main tenance chapter lubricate the cable e Refer to the General Lubrication in the Periodic Mainte nance chapter for the cable lubrication and inspection Choke Lever and Cable FUEL SYSTEM 3 9 Choke Lever Removal e Unscrew the choke lever mounting screw A and take off the plane washer and the wave washer e Remove the choke lever B and free the choke cable up per end from the lever e Pull off the retaining ring A and free the choke cable B from the switch case e Pull the cable out of the vehicle Choke Lever and Cable Installation e Lubricate the choke cable before installation e Install the wave washer plane washer and screw in that order e Route the choke cable according to the General Informa tion chapter A WARNING Operation with an incorrectly routed or damaged cable could result in an unsafe riding condition Choke Lever Lubrication Whenever the choke cable is removed lubricate the choke lever as follows e Apply a thin coating of multi purpose grease to the wave washer A Choke Cable Lubrication and Inspection e Whenever the choke cable
65. 14 4 STEERING Specifications Item Standard Service Limit Tie rods Tie rod Lengths 288 mm 11 3 in STEERING 14 5 Steering Steering Stem Removal e Remove Front Fender see Frame chapter Fuel Tank see Fuel System chapter Front Brake Cable Equalizer A Handlebar see Handlebar Removal e Remove Tie rod End Nuts A CAUTION Do not loosen the locknuts B at the ends of the tie rod adjusting sleeve or the toe in of the front wheels will be changed e Remove Bearing Housing Mounting Bolts A e Remove Steering Clamp Bolts A Steering Clamps B e Pull the steering stem out of the frame e Remove Cotter Pin A Stem Bottom End Nut B Collar Steering Stem Bearing C 14 6 STEERING Steering Steering Stem Installation e Lubricate the stem bearing A see Steering Lubrication e Install Steering Stem Bearing Collar B Stem Bottom End Nut C e Tighten Torque Stem Bottom End Nut 29 N m 3 0 kgf m 22 ft lb e Install Cotter Pin D e Lubricate the steering stem clamps A and grease seal B see Steering Lubrication e Install the grease seals e Install the steering stem clamps so that the ribs on both grease seals fit into the grooves C on the steering stem clamps e Align the marks A on the steering stem clamps at right side e Tighten Torque Steering Stem Clamp Bolts 26 N m 2 7 kgf m 20 ft lb Tie
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67. 3 32 19 27 23 24 26 22 28 27 13 x 33 22 Le AR AR AAA Shaft 4 680 18 15 x 39 10 12 686 Hypoid gear oil SAE90 above 5 C 41 F or SAE80 below 5 C 41 F 0 2 L 0 21 US qt Frame Type Caster Rake Angle Camber King Pin Angle Trail Tread Front Rear Front Tire Type Size Rear Tire Type Size Double tubular 4 0 3 0 10 17 mm 0 67 in 764 mm 30 08 in 776 mm 30 55 in Tubeless AT21 x 8 9 Tubeless AT22 x 10 10 1 8 GENERAL INFORMATION General Specifications Rated Output Item KLF250 A1 A6F Rim size Front 9 x 6 0 Rear 10 x 8 5 Suspension Front Type Independent swing axle Wheel Travel 115 mm 4 53 in Rear Type Torque tube link Wheel Travel 125 mm 4 92 in Brake type Front Drum Mechanical Rear Drum Mechanical Electrical Equipment Battery 12 V 14 Ah US 12 V 11 Ah Headlight Type Semi sealed beam Bulb 12 V 25 25 W x 2 Tail brake light 12 V 8 27 W x 2 Alternator Type Three phase AC 13 A 14 V 8 000 r min rpm Specifications are subject to change without notice and may not apply to every country CA Canada Model US U S A Model Unit Conversion Table Prefixes for Units GENERAL INFORMATION 1 9 Units of Length km x 0 6214 mile Prefix Symbol Power m x 3 281 ft mega M x 1000 000 mm x 0 03937 in kilo k x 1000 centi c x 0 01 Units of Torque milli m x 0 001 N m x 0 1020
68. 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 12 44 61 4 5 6 2 33 45 14 73 98 7 4 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 33 165 240 2 6 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Fuel System Throttle Lever Free Play Idle Speed Air Cleaner Element Oil 2 3 mm 0 08 0 12 in 1 300 1 400 r min rpm High quality foam air filter oil Engine Top End Valve Clearance Exhaust Inlet 0 18 0 23 mm 0 0071 0 0091 in 0 15 0 20 mm 0 0059 0 0079 in Engine Lubrication System Engine Oil Type Viscosity Capacity Wheels Tires Tire Tread Depth Front Rear Standard Tire Front Rear Final Drive Final Gear Case Gear Case Oil Type Viscosity Capacity Brakes Front Brake Lever Free Play Rear Parking Brake Lever Free Play Brake Pedal Free Play Cam Lever angle Electrical System Spark Plug Gap Rear Brake Light Switch Timing API SF or SG API SH or SJ with JASO MA SAE10W40 2 0 L 2 11 US qt When filter is not removed 2 1 L 2 22 US qt When filter is removed 2 75 L 2 91 US qt When engine is completely dry AT 21 X 8 9 Dunlop KT856 Tubeless AT 22 x 10 10 Dunlop KT857 Tubeless API GL 5 Hypoid gear oil SAE90 above 5 C 41 F SAE80 below 5 C 41 F 0 2 L 0 21 US qt 1
69. 4 in 0 81 0 83 mm 0 0319 0 0327 in 1 21 1 23 mm 0 0476 0 0484 in 2 51 2 53 mm 0 0988 0 0996 in 0 77 0 79 mm 0 0303 0 0311 in 1 17 1 19 mm 0 0461 0 0469 in 69 10 mm 2 720 in 68 81 mm 2 709 in 0 16 mm 0 0063 in 0 16 mm 0 0063 in 0 91 mm 0 0358 in 1 31 mm 0 0516 in 2 61 mm 0 1028 in 0 70 mm 0 028 in 1 10 mm 0 043 in 4 8 ENGINE TOP END Specifications Item Standard Service Limit Piston Ring End Gap Top 0 15 0 30 mm 0 6 mm 0 0059 0 0118 in 0 0236 in Second 0 30 0 45 mm 0 8 mm 0 0118 0 0177 in 0 0315 in Oil 0 20 0 70 mm 1 0 mm 0 0079 0 0276 in 0 0394 in ENGINE TOP END 4 9 Special Tools and Sealant Piston Ring Pliers 57001 115 ST5701158ST Compression Gauge 20 kgf cm 57001 221 T5702218T Valve Spring Compressor Assembly 57001 241 T5702418T Piston Pin Puller Assembly 57001 910 ST5709108ST Valve Spring Compressor Adapter 25 57001 1019 ST571019ST Valve Guide Reamer 65 5 57001 1020 ST5710208T Valve Guide Arbor 65 5 57001 1021 ST5710218T Valve Seat Cutter 45 435 57001 1116 Valve Seat Cutter 32 635 57001 1121 ST5711168T ST5711218T Valve Seat Cutter 60 430 57001 1123 Q ST571123ST 4 10 ENGINE TOP E
70. 9 1 2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera tion on a motorcycle read the precautions given below To facilitate actual operations notes illustra tions photographs cautions and detailed descriptions have been included in each chapter wherever necessary This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts Especially note the following 1 2 4 6 7 8 Dirt Before removal and disassembly clean the motorcycle Any dirt entering the engine will shorten the life of the motorcycle For the same reason before installing a new part clean off any dust or metal filings Battery Ground Disconnect the ground wire from the battery before performing any disassembly operations on the vehicle This prevents the engine from accidentally turning over while work is being carried out sparks from being generated while disconnecting the wires from electrical parts as well as damage to the electrical parts themselves For reinstallation first connect the positive wire to the positive terminal of the battery Installation Assembly Generally installation or assembly is the reverse of removal or disassembly However if instal lation or assembly sequence is given in this Service Manual follow it Note parts locations and cab
71. A it g i i 1914878 EL A E E nae EE 2 eL l E E Eaa AS IES 2 O 1034838 ZX MLT 8 AZI gt Rs S 34317 9449 1181 Or ze D ir GL ce ep o S 7 a peuruJsa Se CAER 2 pois MN y ADMITA A lt gt sue gt 14 14 lt w w e w o w A M8 E Ka Ka ar r Br La gt RAS RD H A7 3894A 9 A AA H a eege Jo awopeads e143naN tH 148 17 4011841 LV 05247Y yo tas 9S19ADY i i Lyg x x19 8 HY s euluda Joss3o0y 14317 eyeug LIJ A a A 8 MSZ GTAZL yoring guoa A 14 A M8 43 PeoH 14317 04218 axe Ae Ea VERSET MAKE 14317 J403e91pul UoYIAS usoy uojyiu3 APPENDIX 17 1 Appendix Table of Contents Cable Wire and Hose Routing acciona 17 2 Troubleshooting GUIAS EE 17 12 17 2 APPENDIX Cable Wire and Hose Routing BANDING LOCATIONS 4 Outward 1 Frame 2 Bands 5 Coupler Cover 6 Front Guard 3 Turn outward the cutting portion of the band away from the frame center APPENDIX 17 3 Cable Wire and Hose Routing HB09019BW4 1 Bands 11 To Ignition Coil 20 Starter Circuit Relay 2 Clamps 12 To Starter Motor Leads 3 Main Harness 13 To Engine Ground 21 Starter Relay Leads 4 Ignition Switch Leads Terminal 22 To Battery Ground 5 Handlebar Switch Leads 14 Reverse Switch lead Terminal 6 Front Brake Light Switch 15 Neutral Switch
72. Before Servicing Two Color Electrical Wire Wire cross section Color Indicated on the Wire Color Indicated on the Wiring Diagram Red Wire Strands Yellow Red Y Rass Yellow Red 19 Inspection When parts have been disassembled visually inspect these parts for the following conditions or other damage If there is any doubt as to the condition of them replace them with new ones Abrasion Crack Hardening Warp Bent Dent Scratch Wear Color change Deterioration Seizure 20 Specifications Specification terms are defined as follows Standards show dimensions or performances which brand new parts or systems have Service Limits indicate the usable limits If the measurement shows excessive wear or dete riorated performance replace the damaged parts GENERAL INFORMATION 1 5 Model Identification KLF250 A1 Left Side View KLF250 A1 Right Side View 1 6 GENERAL INFORMATION General Specifications Fuel Tank Capacity Performance Minimum Turning Radius Engine Type Cooling System Bore and Stroke Displacement Compression Ratio Maximum Horsepower Maximum Torque Carburetion System Starting System Ignition System Timing Advance Ignition Timing Spark Plug Valve Timing Inlet Open Close Duration Exhaust Open Close Duration Lubrication System Item KLF250 A1 A6F Dimensions Overall Length 1 780 mm 70 08 in Overall Width 1 120 mm 44 09 in
73. DRIVE 11 23 Final Gear Case Oil Level Inspection e Park the vehicle so that it is level both side to side and front to rear e Unscrew the oil level inspection bolt A OThe oil level is correct if a small amount of oil comes out of the bolt hole x If no oil comes out first check the final gear case for oil leakage remedy it if necessary and add oil through the filler opening Use the same type and brand of oil that is already in the final gear case see Final Gear Case Oil Change e Install the oil level inspection bolt e Tighten Torque Oil Level Inspection Bolt 7 8 N m 0 8 kgf m 69 in Ib Final Gear Case Oil Change e Refer to the Final Gear Oil Change in the Periodic Main tenance chapter Final Gear Case Removal e Remove Rear Axles see Rear Axle Removal Skid Plate A Speedometer Cable Lower End if installed Propeller Shaft Housing Mounting Nuts B e Remove the final gear case C Final Gear Case Installation e Apply molybdenum disulfide grease to the spline A of the pinion gear e Tighten Torque Propeller Shaft Housing Nuts 25 N m 2 5 kgf m 18 ft lb e Install Rear Axles see Rear Axle Installation e Fill the final gear case with the specified oil see Final Gear Case Oil Change Final Gear Case Disassembly e Remove the final gear case see Final Gear Case Re moval e Remove Pinion Gear Assembly A and Pinion Gear Housing B Shim s 11 24 FINAL DRIVE Fi
74. EET a 7 D am Rye COCO a ww 2 Z Do E lt 1109 EDEN a a Se Za eo lt SE lt tt bp Dees LG bp ho bp pp bp gt pb A A bp po O y A um 5 lt lt D EB DA g wa noag wedy es Zs EI ma EES Es non 251949 CLV 062471Y TX ME AZI yorlms 463821pul uolz usl uozng uJOH H1 MSZ GTAZL u311Ppe2H RATE A Y A 18 8 19 8 191414098 403e n30y ya gt l fresa ly inaJ1o yg Wi 19114818 Es DROE ETATS H 4317 Rte LR jezyswuopeeds L__cispon_ an _ 49 ADA DA Klak ed X 8 LKA Ar 34311 Ei Aeyowoposdg 19 8 19 84 HY A Y A Y MS2 SZAZL A M4 A M8 43 PeoH HPO5007BW5 o Ce L 9S18A0 1843n5N 0 HPOSOOSBHS 16 50 ELECTRICAL SYSTEM Wiring Diagram Australia Model wozing 1934838 yoYIAg dog au u YORIAS 40uwIq 94217 suolzoeuuog YOLIMS JEqe pUeH 4407 KE A a pures ar suoljzoauuog Suoryoeuuog Vaiieg LO 1 UB uong u410H uoring iin yoring 191835 gang aewwtg eurzuz 434817 BE 1 1 l 1 1 l l 4sosuas ENTERED J 1991431 A M8 Aug HT PL X Y k 4 AGZ GZAZL a Po 8 8 EI EEGEN lt lt lt lt lt lt EEES 8S1SA9Y 8413N9N gt 10384183 u5919 yseg 93e 090y9 a 4 O Ke ko IAs E apog 40109 1109 uorziusl 191414098 403e n30y M 59 A 59 O EI ES ww lt RA M UC KIA A 9151
75. ES positions e Dry the tank fuel filter with compressed air e Install the fuel filter in the tank see Fuel Tap Fuel Filter Installation e Install the fuel tank see Fuel Tank Installation FUEL SYSTEM 3 21 Fuel Tank Fuel Tap Inspection e Check the fuel filter screens A for any breaks or deteri oration x lf the fuel filter screens have any breaks or are deterio rated it may allow dirt to reach the carburetor causing poor running Replace the fuel tap x If the fuel tap leaks or allows fuel to flow when it is OFF replace the damaged gasket A or O rings B HCO8003BS1 Fuel Level Gauge Removal e Remove the fuel tank cap Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Remove the fuel tank cover see Fuel Tank Removal e Install the fuel tank cap immediately 0 e Pry off the gauge cap A and discard the cap e Check the grooves B in the fuel tank boss If the grooves are damaged by removing the cap or can not hold the cap nails the fuel tank must be replaced e Pull out the fuel level gauge C A a act HCO8010681 3 22 FUEL SYSTEM Fuel Tank Fuel Level Gauge Installation WARNING Gasoline is extremely flammable and can be ex
76. Ignition System Ignition System Circuit Oo Pe TOM l l l l aa aol ea run l l l lt I l I e a ae eee BK Y _ xc BK Y H h ess F A KLF250 A1 B KLF250 A2 1 Starter Button 2 Engine Stop Switch 3 Ignition Switch 4 Main Fuse 20 A 5 Igniter 6 Crankshaft Sensor 7 Ignition Coil 8 Spark Plug 9 Battery ELECTRICAL SYSTEM 16 33 Ignition System Faulty ignition No spark Battery Inspection No good Charge or replace battery Good Ignition system wiring and connector inspection No SS Repair or replace damaged part Good Spark plug inspection No goog Replace spark plug Good Plug cap inspection No goog Replace plug cap Ignition coil primary peak voltage inspection No good Voltage is less than the specified value d Good No good Ignition coil is defective Voltage is zero or Replace ignition coil almost zero Inspect 1 Lower resistance in a No good hand tester Use KAWASAKI Hand Tester 2 Crankshaft sensor peak voltage Inspect 1 Adapter connection is incorrect or adapter is defective 2 Ignition switch and engine stop switch 3 Crankshaft sensor peak voltage No good Good Good Igniter is defective Replace igniter Replace bad parts or inspect them with KAWASAKI Hand Tester Replace bad parts HP10
77. K R Y R Y BK Y BK Y R BK R BK R Y R Y BK Y BK Y R t gt L Rk BYE BY 4 BL CSC BL BK Y gt Bk y oe oG HP12009BW4 A KLF250 A1 B KLF250 A2 1 Front Brake Light Switch 6 Reverse Indicator Light 10 Headlight Left 2 Rear Brake Light Switch 7 Ignition Switch 11 Light Dimmer Switch 3 Reverse Light Europe 8 Speedometer Light Aus 12 Tail Brake Light Right and U K models tralia and Europe mod 13 Tail Brake Light Left 4 Neutral Reverse Switch els 14 Battery 5 Neutral Indicator Light 9 Headlight Right 15 Main Fuse 20 A 16 46 ELECTRICAL SYSTEM Switches Brake Light Switch Adjustment e Refer to the Brake Light Switch Adjustment in the Periodic Maintenance chapter Switch Inspection e Using the hand tester check to see that only the con nections shown in the table have continuity about zero ohms OFor the handlebar switches and ignition switch refer to tables in the Wiring Diagram x lf the switch has an open or short repair or replace it with a new one Front Brake Light Switch Connections BL BR Brake lever pulled in C O Brake lever released HP14005BN3 C Rear Brake Light Switch Connections BL BR Brake pedal pushed down Brake pedal released HP14006BN3 C ELECTRICAL SYSTEM 16 47 Fuses 20 Main Fuse Removal e Remove Seat see Frame chapter Fuse Connector A e Pu
78. LUBRICATION SYSTEM Specifications Item Standard Engine Oil Type API SF or SG API SH or SJ with JASO MA Viscosity SAE 10W 40 Capacity 2 0 L 2 11 US qt when filter is not removed 2 1 L 2 22 US qt when filter is removed 2 75 L 2 91 US qt when engine is completely dry ENGINE LUBRICATION SYSTEM 7 5 Engine Oil Flow Chart 3 HG04002B 4 1 Oil Screen 6 Crankshaft 11 Drive Shaft 2 Oil Pump 7 Oil Pipe 12 Engine Breather 3 Relief Valve 8 Camshaft 13 Blow by Gas 4 Oil Filter 9 Reverse Shaft to Air Cleaner 5 Bypass Valve 10 Input Shaft 7 6 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter A WARNING Vehicle operation with insufficient deteriorated or contaminated engine oil will cause accelerated wear and may result in engine or transmission seizure accident and injury Oil Level Inspection e Park the vehicle so that it is level both side to side and front to rear e Check that the engine oil level is between the upper A and lower B lines in the gauge C NOTE Olf the oil has just been changed start the engine and run it for several minutes at idle speed This fills the oil filter with oil Stop the engine then wait several minutes until the oil settles CAUTION Racing the engine before the oil reaches every part can cause engine seizure x lf the level is too high suck the excess oil out the filler hol
79. ND Special Tools and Sealant Valve Seat Cutter 60 641 57001 1124 ST5711248T Valve Seat Cutter Holder 45 5 57001 1125 ST571125ST Valve Seat Cutter Holder Bar 57001 1128 Compression Gauge Adapter M12 x 1 25 57001 1183 ST571183ST Valve Seat Cutter 45 430 57001 1187 ST571187ST ST5711288ST Filler Cap Driver 57001 1454 ST5714548T ENGINE TOP END 4 11 Camshaft Chain Tensioner Camshaft Chain Tensioner Removal e Loosen the lock bolt A in the top of the camshaft chain tensioner Do not remove it yet e Remove Tensioner Mounting Bolts B and Clamp C Camshaft Chain Tensioner D CAUTION Do not turn the engine while the camshaft chain ten sioner is removed Engine damage could result e Remove the lock bolt e Carefully pull the push rod out of the tensioner body Do not drop the ball and retainer assembly or the spring e Slide the retainer and the spring off the push rod Camshaft Chain Tensioner Installation e Slip the spring A over the push rod B and compress it down past the hole e Insert a piece of wire C in the hole to hold the spring in place e Drop the retainer D onto the push rod e Insert the push rod A into the tensioner body OThe flat side of the push rod must face up as shown e When the push rod is in as far as it will go screw in the lock bolt B with its washer
80. Surface Plate A Friction or Steel Plate B Thickness Gauge C Friction Plate Warp Standard less than 0 2 mm 0 008 in Service Limit 0 3 mm 0 012 in F13010781 Steel Plate Warp Standard less than 0 1 mm 0 004 in Service Limit 0 3 mm 0 012 in 5 12 ENGINE RIGHT SIDE Clutches Clutch Spring Free Length Measurement x If any of the springs A is shorter than the service limit it must be replaced Clutch Spring Free length Standard 37 2 mm 1 46 in Service Limit 35 7 mm 1 41 in GFO6O0603S1 ENGINE RIGHT SIDE 5 13 Primary Reduction Gear Backlash e Remove the right engine cover see Right Engine Cover Removal e Set a dial gauge A against the teeth on one gear and move the gear B back and forth while holding the other gear C steady The difference between the highest and the lowest gauge readings is the amount of backlash Gear Backlash Standard 0 02 0 11 mm 0 0008 0 0043 in Service Limit 0 14 mm 0 0055 in If the amount of backlash exceeds the service limit re place both gears Primary Gear Crankshaft Wear x lf the inside diameter of the primary gear is greater than the service limit replace it Alf the outside diameter of the crankshaft is less than the service limit replace it see Crankshaft Transmission chapter Primary Gear Inside Diameter A Standard 27 000 27 021 mm 1 0630 1 0638 in Service Limit 27 03 mm 1
81. T TAMPER WITH NOISE CONTROL SYSTEM US MODEL only To minimize the noise emissions from this product Kawasaki has equipped it with effective intake and exhaust silencing systems They are designed to give optimum performance while maintaining a low noise level Please do not remove these systems or alter them in any which results in an increase in noise level Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop However it contains enough detail and basic in formation to make it useful to the owner who de sires to perform his own basic maintenance and repair work A basic knowledge of mechanics the proper use of tools and workshop proce dures must be understood in order to carry out maintenance and repair satisfactorily When ever the owner has insufficient experience or doubts his ability to do the work all adjust ments maintenance and repair should be car ried out only by qualified mechanics In order to perform the work efficiently and to avoid costly mistakes read the text thor oughly familiarize yourself with the procedures before starting work and then do the work care fully in a clean area Whenever special tools or equipment are specified do not use makeshift tools or equipment Precision measurements can only be made if the proper instruments are used and the use of substitute tools may ad versely affect safe operation For the duration of the warranty per
82. a well ventilated area and take care that there are no sparks or flame any where near the working area this includes any appliance with a pilot light Because of the danger of highly flammable liquids do not use gasoline or a low flash point solvent to clean the foam element e Remove the air cleaner element see Air Cleaner Element Removal e Clean the element in a bath of high flash point solvent using a soft bristle brush Periodic Maintenance Procedures PERIODIC MAINTENANCE 2 9 e Squeeze it dry in a clean towel A Do not wring the ele ment or blow it dry the element can be damaged e Inspect the element for damage x lf it is torn punctured or hardened replace it NOTE OReplace the element after cleaning it five times or if it is damaged e After cleaning saturate the element with a high quality foam air filter oil squeeze out the excess oil then wrap it in a clean rag and squeeze it as dry as possible Be careful not to tear the element Air Cleaner Draining Two drain tubes A are connected to the bottom of the air cleaner housing to drain water or oil accumulated in the housing e Squeeze open the two drain tubes to expel dust and or water accumulated inside Fuel Hose and Connection Check e Turn the fuel tap to the OFF position e Check the fuel hose A x If the fuel hose is frayed cranked or bulged replace the fuel hose e Check that the hose is securely connected and clamps are ti
83. ad must point toward the front of the engine e The piston ring openings must be positioned as shown The openings of the oil ring steel rails must be about 30 150 of angle from the opening of the top ring Top Ring A Second Ring B Oil Ring Expander C Top Oil Ring Steel Rail D Bottom Oil Ring Steel Rail E Arrow Mark F Front G e Apply molybdenum disulfide oil to the piston rings and smear some oil inside the cylinder bore e The rear camshaft chain guide also fit inside the tunnel e Fit the cylinder down over the piston and rings OHold the rings into their groove with your fingers so that the cylinder does not catch on them e Be sure the O ring A is in place at the bottom of the cylinder e Push the cylinder down solidly against the crankcase HE14006BS2 C 4 32 ENGINE TOP END Cylinder and Piston Piston Removal e Remove the cylinder see Cylinder Removal e Place a clean cloth under the piston remove the one of the piston pin snap rings CAUTION Do not reuse snap rings as removal weakens and deforms them They could fall out and score the cylinder wall e Push out the piston pin and remove the piston Olf necessary use the piston pin puller assembly A Special Tool Piston Pin Puller Assembly 57001 910 HE14007BS1 e Remove the top and second piston rings A OSpread the ring open with your thumbs OPush up on the opposite side with your fingers
84. aging Engine won t turn over Valve seizure Rocker arm seizure Cylinder piston seizure Crankshaft seizure Connecting rod small end seizure Connecting rod big end seizure Transmission gear or bearing seizure Camshaft seizure Balancer bearing seizure No fuel flow Fuel tank air vent obstructed Fuel tap clogged Fuel line clogged Float valve clogged Engine flooded Fuel level too high Float valve worn or stuck open Starting technique faulty When flooded crank the engine with the throttle fully opened to allow more air to reach the engine Fuel air mixture incorrect Pilot screw and or idle adjusting screw mal adjusted Pilot jet or air passage clogged Air cleaner clogged poorly sealed or miss ing Starter jet clogged No spark spark weak Spark plug dirty broken or maladjusted Spark plug cap or spark plug lead trouble Spark plug cap not in good contact Spark plug incorrect Crankshaft Sensor trouble Igniter trouble Ignition coil trouble Battery voltage low Ignition or engine stop switch shorted Wiring shorted or open Fuse blown Compression Low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Compressio
85. ankshaft Balancer Shaft and Connection Rod 9 11 Crankshaft Removal sienne 9 11 Crankshaft Balancer Shaft Installation 9 11 Crankshaft RE E 9 11 Crankshaft Assembly es esdceadeteidacennteeateeentneeslecdveleg des dea eae eat ie turned 9 11 Connecting Rod Big End EE 9 12 Connecting Rod Big End Radial Clearance ooooocooccccncccconononoonnccncccnnnannancnnnnnnnnnnnnnnnn nono 9 13 Connecting Rod Big End Side Clearance su 9 13 Cranksha t Alignment ss cennmenmenntennnendne ia retourne 9 14 Conmecting ROd Be nd Detna eg ged ESA te 9 15 Transmission EEN 9 16 External Shift Mechanism Removal rr rr rr rn 9 16 External Shift Mechanism Installation 9 16 External Shift Mechanism Inspection 9 17 Reverse Knob Free Play Adjustment non nn nncccrrnnnnncns 9 17 Reverse Shift Mechanism Removal renn eenn nnn 9 17 Reverse Shift Mechanism Installation 9 18 Transmission Removal ooooooocccoccocccoooconcnononononnnnnnnnnonnnonnnnnnonnno nono nnnnn nro nono nnnnnnnnnnnnnnnrnnnnnnnns 9 18 Transmission Installation A Aia 9 19 Transmission Shaft DisasseMblY viciado 9 19 Transmission Shaft Assorted alone 9 19 Shift Drum DISASSOMDIY 2 coccion A a eco 9 19 Shift Eu le EE 9 20 SALE OFK BENIN esse A ren en nn ns ne et en Sen tt er
86. any measurement is greater than the service limit re place the drum Alf the drum is worn unevenly or scored lightly turn the drum on a brake drum lather or replace it Do not turn the drum beyond the service limit Brake Shoe Lining Wear e Measure the lining thickness at several points as shown Brake Shoe Lining Thickness Front and Rear Standard 4 0 mm 0 16 in Service Limit 2 0 mm 0 08 in Alf any measurement is less than the service limit replace both shoes as a set Alf the lining thickness is greater than the service limit do the following before installing the shoes e File or sand down any high spots on the surface of the lining e Use a wire brush to remove any foreign particles from the lining e Wash off any oil or grease with an oilless solvent CAUTION Do not use a solvent which will leave an oily residue or the shoes will have to be replaced 12 14 BRAKES Brake Maintenance Brake Cam and Cam Hole Wear e Measure the brake cam diameter A Brake Cam Diameter Front Standard 14 957 14 984 mm 0 589 0 590 in Service Limit 14 88 mm 0 586 in Rear Standard 16 957 16 984 mm 0 668 0 669 in Service Limit 16 88 mm 0 665 in x If the brake cam wear is less than the service limit replace the brake cam e Measure the inside diameter B of the cam hole Cam Hole Inside Diameter Front Standard 15 00 15 06 mm 0 591 0 593 in Service Limit 15 15 m
87. ar Suspension Arm Pivot Bolts 34 N m 3 5 kgf m 25 ft lb e Install the center arm as shown A Front Side B Center Arm Right Side e Tighten Torque Rear Suspension Arm Pivot Bolts 34 N m 3 5 kgf m 25 ft lb Suspension Arm Assembly e When installing the rubber bushings into the arm lubri cate the outer surface of the bushings with a soap and water solution CAUTION Do not lubricate the rubber bushings with engine oil or petroleum distillates because they will deteri orate the rubbers lt CH x SO B HMO5005BS1 A lt HMO5006BS1 HMO5007BS1 SUSPENSION 13 7 Suspension Arms Suspension Arm Inspection e Move the suspension arm A up and down B to check for abnormal friction Alf abnormal is felt the rubber bushings may be damaged Remove the suspension arm to check for rubber bushing damage e Check the rubber bushings in the pivots x Replace any bushings that are worn cracked hardened or otherwise damaged Front Suspension Arm Lubrication e Fill inside of oil seals A with grease e Force molybdenum disulfide grease into the nipple B and wipe off any excess grease see Steering Knuckle Pivot Lubrication section in Steering chapter STEERING 14 1 Steering Table of Contents Exploded Views titane ar nr net hein 14 2 Tele oil Le LOTI A mces secnateadndsdcdatcecetcs saetacasnqeeanesaatsdeatsdestataniads 14 4
88. ary clutch housing e Install One Way Clutch C Inner Race D Clutch Hub Assembly E Primary Clutch Hub Nut F OApply molybdenum disulfide oil to the primary and sec ondary clutch hub nuts and tighten them Special Tool Gear Holder 57001 1015 Torque Primary Clutch Hub Nut 127 N m 13 kgf m 94 HRO6002BS1 ft lb e Tighten Torque Secondary Clutch Hub Nut 78 N m 8 0 kgf m 58 ft lb e Install Ball Bearing Pusher e Install External Shift Mechanism see Crankshaft Transmission chapter Ball Bearing A Pusher B Dowel Pins C New Gasket D Right Engine Cover e Tighten Torque Right Engine Cover Bolts 8 8 N m 0 9 kgf m 78 in Ib e After assembling the engine right side adjust the clutch see Clutch Adjustment 5 10 ENGINE RIGHT SIDE Clutches Clutch Adjustment e Refer to the Clutch Adjustment in the Periodic Mainte nance chapter Clutch Release Removal e Remove Right Engine Cover A Adjusting Screw B e Pull the clutch release lever C and spring D out of right engine cover Locknut E Holder F O ring G Clutch Release Wear e Visually inspect the O ring at the clutch adjusting screw x If O ring is damaged deteriorated compressed or hard ened replace it Primary Clutch Housing Wear e Measure the inside diameter A of the clutch housing where the shoes wear against it OUse calipers and measure at several points as shown x If any measuremen
89. ase charg ing time proportionately e Turn the charger off or unplug it then disconnect it from the battery e Check battery condition x lf the battery condition indicates that it is not fully charged additional charging time is necessary ELECTRICAL SYSTEM 16 15 Battery Battery Charging Rate Time Table 1 270 Fully Charged Specific Gravity 1 5 10 15 20 21 at 2A charge rate 1 3 5 7 9 10 5 at 3A charge rate 1 2 3 4 5 6 1 2 3 4 7 area Hours of Charging Time at Rates Shown Battery Troubleshooting Guide Good Battery Suspect Battery Plates Chocolate color white sulphated plates Replace gray broken or corroded Sediment none or small amount sediment up to plates Replace causing short Voltage above 12 6 V below 12 6 V Test charge Electrolyte peween Upper ana lower below lower level line Fill and test charge Level level lines above 1 240 in all cells no below 1 100 or difference Specific Gravity two cells more than 0 020 of more than 0 020 between Test charge different two cells Battery Test Charging x If the battery is suspected of being defective sulfated or unable to take a charge consult the table e To test charge a battery perform the ordinary charging procedure and monitor the battery voltage and other signs as mentioned below Special Tool Hand Tester 57001 1394 x If the battery voltage suddenly jumps to over 13 V ju
90. ating surface A of the final gear case Sealant Three Bond 1215 Gray e Insert Axles B Axle Shaft Pipes e Tighten Torque Axle Shaft Pipe Bolts 20 N m 2 0 kgf m 14 ft Ib Rear Axle FINAL DRIVE 11 21 e Install O ring A Collar B Olnstall the collar so that the stepped side C face outward Axle Shaft Pipe Disassembly e Remove Axle Shaft Pipes see Rear Axle Removal Left Side e Remove Oil Seal A e Remove Circlip A Special Tool Inside Circlip Pliers B 57001 143 e Remove Ball Bearing Special Tool Oil Seal 8 Bearing Remover A 57001 1058 Right Side e Remove Ball Bearing Special Tool Oil Seal amp Bearing Remover A 57001 1058 e Remove Oil Seal 11 22 FINAL DRIVE Rear Axle Axle Shaft Pipe Assembly Left Side e Press and insert the ball bearing until it is bottomed Special Tool Bearing Driver Set A 57001 1129 e Install Circlip A Special Tool Inside Circlip Pliers 57001 143 e Apply molybdenum disulfide grease to the oil seal lips e Install the oil seal B so that the seal surface is flush with the end of the pipe housing Special Tool Bearing Driver Set 57001 1129 Right Side e Apply molybdenum disulfide grease to the oil seal lips e Press and insert the oil seal A and ball bearing B until they are bottomed Special Tool Bearing Driver Set 57001 1129 HK13001BS1 Final Gear Case FINAL
91. ation System Oil Pipe Banjo Bolts 15 1 5 11 Oil Pump Screws 4 4 0 45 39 in lb Engine Drain Plug 29 3 0 22 Oil Filter Cover Bolts 8 8 0 9 78 in lb Relief Valve 15 1 5 11 L 2 4 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Nm kgfm ftIb Remarks Engine Removal Installation Engine Bracket Bolts and Nuts 26 2 7 20 Engine Mounting Nuts M10 39 4 0 29 Engine Mounting Nut M8 29 3 0 22 Crankshaft Transmission Engine Drain Plug 29 3 0 22 Crankcase Bolts 8 8 0 9 78 in lb Clutch Release Cam Pin 25 2 5 18 L Return Spring Pin 25 2 5 18 L Output Shaft Bearing Position Plate Screws 8 8 0 9 78 in lb L Relief Valve 15 1 5 11 L Bearing Stopper Screws 9 8 1 0 87 in lb Positioning Lever Bolt 8 8 0 9 78 in lb Neutral and Reverse Switch Screws L Shift Drum Pin Plate Bolt 12 1 2 104 in Ib Wheels Tires Wheel Nuts 34 3 5 25 S Front Axle Nuts 34 3 5 25 Tie rod End Nuts 41 4 2 30 Tie rod Adjusting Sleeve Locknuts 26 2 7 20 Rear Axle Nuts 147 15 108 Final Drive Output Bevel Gear Case Bolts M8 25 2 5 18 L 1 Output Bevel Gear Case Bolts M6 8 8 0 9 78 in lb Oil Seal Housing Nuts 25 2 5 18 Drive Gear Nut 118 12 87 MO Cam Damper Mounting Nut 78 8 0 58 MO Driven Gear Shaft Nut 147 15 108 L Bearing Retainer 108 11 80 L Pinion Gear Nut 69 7 0 51 St Propeller Shaft Housing Nuts 25 2 5 18 Final Gear Case Drain Bolt 20 2 0 14 Speedometer Plug 20 2 0 14 Final Gear Case Filler Cap 15 1 5 11 Rin
92. ator Circuit Test 3rd Step e Connect the test light and a 12 V battery in the same man ner as specified in the Regulator Circuit Test 1st Step e Momentarily apply 24 V to the BR voltage monitoring terminal by adding a 12 V battery e Check Y1 Y2 and Y3 terminals CAUTION Do not apply more than 24 V to the regulator recti fier and do not leave the 24 V applied for more than a few seconds or the unit will be damaged x If the test light did not light when the 24 V was applied momentarily to the BR voltage monitoring terminal the regulator rectifier is defective x If the regulator rectifier passes all of the tests described it may still be defective If the charging system still does not work properly after checking all of the components and the battery test the regulator rectifier by replacing it with a known good unit HP09012BS1 HP09013BS1 Charging System ELECTRICAL SYSTEM 16 25 Charging System Circuit Fr BK Y W R CC gt gt E A KLF250 A1 1 Ignition Switch 4 Battery B KLF250 A2 2 Alternator 5 Main Fuse 20 A 3 Regulator Rectifier 6 Load 16 26 ELECTRICAL SYSTEM Ignition System A WARNING The ignition system roduces extremely high volt age Do not touch the spark plug ignition coil or spark plug lead while the engine is running or you could receive a severe electrical sh
93. blem HI04006BS1 CRANKSHAFT TRANSMISSION 9 11 Crankshaft Balancer Shaft and Connection Rod Crankshaft Removal e Split the crankcase see Crankcase Disassembly e Remove Transmission e Push the crankshaft out of the left crankcase half with a press Crankshaft Balancer Shaft Installation e Position the right crankcase half so that the right hand main bearing housing is seated on a suitable press fixture e Press the crankshaft into the right hand main bearing housing Olnsert crankshaft jig A between the crankshaft halves opposite the crankpin to prevent crankshaft distortion during installation Special Tool Crankshaft Jig 57001 1174 Crankshaft Disassembly CAUTION Since assembly of the crankshaft demands exact ing tolerances the disassembly and reassembly of the crankshaft should only be performed by experienced mechanics with the necessary tools and equipment The crankshaft left main bearing chain sprocket and left crankshaft are available separately as spare parts however it is recommended that the crank shaft assembly be replaced rather than attempting to replace the components e Press the crankpin out of the crank halves to separate the crank halves connecting rod spacers crankpin needle bearing and crankpin Crankshaft Assembly e Apply engine oil to the needle bearing e Press the crank halves onto the crankpin noting the crankpin direction until co
94. bly Installation ooooooccccnnnnnnnnacoccccccncncccnnnnnanancccnccnnnnnnarnncccnnnnnns 12 8 Rear Brake Panel Removal DisaSSeMbly ooooooocccccc nccccconanoconoconcncnnnnanononcnnnnnnnnnnnnnncnnnnnnnnns 12 10 Rear Brake Panel Assembly installation cnc 12 11 Brake Dri ER 12 12 Brake MaimMenance ebe A den R nn bots 12 13 Brake Druin WE eegene 12 13 Brake Shoe RE lie e AE 12 13 Brake Cam and Cam Hole Wes ee 12 14 KR Brake Shoe Spring Inspection cocccccccccnccnnncnnncnnnnnnnnnnnnnonononnnnnnnnnnnnnnnnnnnnnnnnninnninnnninnnss 12 14 BraKe lUbrication less ns asd dos LR Ste TR Seen det 12 15 Brake Pedal and Cable EE 12 16 Brake Cable Removal isis Seene ET A ole el R E 12 16 Brake Gable Installation ita aii 12 16 Brake Cable Lubrication s rias a it Ltd 12 16 Brake Pedal Installation ccccccccecceecceeccueecueeceseceecccesseessceceseceeecoescceseuseeuseeeeeeeeesenenaees 12 16 12 2 BRAKES Exploded View HLO2006B 5 BRAKES 12 3 Exploded View Torque No Fastener R k Nm kgfm ftip Front Axle Nuts 34 3 5 Rear Axle Nuts 147 1 5 Front Brake Panel Bolts 25 2 5 Rear Brake Panel Bolts 29 3 0 9 3 0 22 Rear Brake Drum Drain Bolt 2 6 Bend both hooks after installing the spring AG Apply grease Amoco rykon premium grease No 2 EP Green G Apply grease for oil seal and O ring Gr Apply grease L Apply a
95. bsorbers as a set If only one unit is replaced and the two are not balanced vehicle instability at high speed may result e Check the rubber bushings A in the upper and lower pivots x lf bushings are worn cracked hardened or otherwise damaged replace them HM04003BS1 SUSPENSION 13 5 Suspension Arms Front Suspension Arm Removal e Remove Front Wheel see Wheels Tires chapter Front Brake Panel Assembly see Brakes chapter Steering Knuckle Joint see Steering chapter Lower Front Shock Absorber mounting Bolt A Suspension Arm Pivot Bolts B Front Suspension Arm C Front Suspension Arm Installation e Tighten Torque Front Suspension Arm Pivot Bolts 88 N m 9 0 kgf m 65 ft lb Rear Suspension Arm Removal e Remove Suspension Arm Pivot Bolts A Center Arms B Left Side e Remove Suspension Arm Pivot Bolts A Center Arm B Right Side e Remove Rear Wheels see Wheels Tires chapter Rear Flaps see Frame chapter Suspension Arm Pivot Bolts A Left Arm B 13 6 SUSPENSION Suspension Arms e Remove Suspension Arm Pivot Bolts A Right Arm B Rear Suspension Arm Installation e Install the left and right arms as shown A Front Side B Left Arm OThe right arm has a clamp e Tighten Torque Rear Suspension Arm Pivot Bolts 34 N m 3 5 kgf m 25 ft lb e Install the center arm as shown A Front Side B Center Arm Left Side e Tighten Torque Re
96. ce and without incurring an obligation to make such changes to products manufactured previously See your dealer for the latest information on product improvements incorporated after this publication All information contained in this publication is based on the latest product information available at the time of publication Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts 2002 Kawasaki Heavy Industries Ltd Forth Edition 1 Apr 1 2005 K LIST OF ABBREVIATIONS A ampere s Ib pounds s ABDC after bottom dead center m meter s AC alternating current min minute s ATDC after top dead center N newton s BBDC before bottom dead center Pa pascal s BDC bottom dead center PS horsepower BTDC before top dead center psi pound s per square inch C degree s Celcius r revolution DC direct current rpm revolution s per minute F farad s TDC top dead center F degree s Fahrenheit TIR total indicator reading ft foot feet V volt s g gram s W watt s h hour s Q ohm s L liter s Read OWNER S MANUAL before operating EMISSION CONTROL INFORMATION To protect the environment in which we all live Kawasaki has incorporated crankcase emission 1 and exhaust emission 2 control systems in compliance with applicable regulations of the California Air Resources Board 1 Crankcase Emission Control System A sealed ty
97. coil Guide F OApply grease to the pin and collar Olnstall the pawl A and recoil guide B as shown for proper starter operation e Install Friction Plate e Tighten Torque Recoil Starter Flange Nut 12 N m 1 2 kgf m 104 in 1b e Turn the reel A two turns clockwise to preload the spring HTO3002BS1 RECOIL STARTER 6 7 Recoil Starter e Clamp the rope with a locking pliers A e Install Handle OKnot the end of the rope tightly e Install Handle Cap Recoil Starter Cleaning e Disassemble the recoil starter e Immerse only the metal parts in a bath of high flash point solvent WARNING Clean the starter in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Do not use gasoline or a low flash point solvent to clean the starter A fire or explo sion could result CAUTION Do not clean any non metallic parts in the solvent as they may be damaged OUse compressed air to dry the cleaned components Recoil Starter Inspection e Clean the recoil starter e Examine the starter pawl for chips or excessive wear e Check the starter rope for excessive wear or fraying e Check the condition of the recoil spring and friction plate spring Olnspect the springs for breaks rust distortion or weak ened condition ENGINE LUBRICATION SYSTEM 7 1 Engine Lubrication S
98. d then release it x If it does not spring out replace it the stopper e Apply a non permanent locking agent to the neutral re verse switch screws A e Apply silicone sealant to the circumference of the switch lead grommet and fit the grommet into the notch Sealant Kawasaki Bond Silicone Sealant 56019 120 e Route the neutral reverse switch leads B as shown Transmission Removal e Split the crankcase see Crankcase Disassembly e Remove Shift Rods A Shift Forks B e Pull all the transmission shafts out together CRANKSHAFT TRANSMISSION 9 19 Transmission e Remove Shift Drum Positioning Lever A Shift Drum Bearing Stopper B Transmission Installation e Apply a small amount of engine oil to the transmission gears bearings and shaft journals e Set the transmission shafts together and fit them into the left crankcase half at the same time Olnstall the washers on the both ends of the reverse shaft A e Apply a small amount of engine oil to the shift fork fingers e Fit each shift fork into the groove of the proper gear so that the shift fork guide pin is in the proper groove on the shift drum e Install the shift rods through the shift forks OThe shift forks are identical Transmission Shaft Disassembly e Remove the transmission shafts see Transmission Re moval e Using the outside circlip pliers A remove the circlip and disassemble the transmission shafts complete
99. ded View ENGINE TOP END 4 5 Fastener Camshaft Sprocket Bolt Rear Camshaft Chain Guide Bolt 9 8 Camshaft Chain Tensioner Mounting Bolts 87 in lb 78 in lb Remarks MO Valve Adjusting Screw Locknuts 104 mb Rocker Shaft Retainer Screws Camshaft Chain Guard Screws 4 4 M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil R Replacement Parts 39 in lb 39 in lb 4 6 ENGINE TOP END Specifications Item Standard Service Limit Rocker Case Rocker Arm Inside Diameter 13 000 13 018 mm 13 05 mm 0 5118 0 5125 in 0 514 in Rocker Shaft Diameter 12 976 12 994 mm 12 95 mm 0 5109 0 5116 in 0 510 in Camshafts Cam Height Exhaust 39 720 39 828 mm 39 62 mm 1 5638 1 5680 in 1 560 in Inlet 40 395 40 503 mm 40 30 mm 1 5904 1 5946 in 1 587 in Cylinder Head Cylinder Compression with Recoil Starter 5 times with Electric Starter Cylinder Head Warp Valve Valve Clearance Exhaust Inlet Valve Head Thickness Exhaust Inlet Valve Stem Bend Valve Stem Diameter Exhaust Inlet Valve Guide Inside Diameter Exhaust Inlet usable range 750 1 180 kPa 7 7 12 kgf cm 110 171 psi 450 r min rpm 930 1 435 kPa 9 5 14 6 kgf cm 135 208 psi 600 r min rpm 0 18 0 23 mm 0 0071 0 0091 in 0 15 0 20 mm 0 0059 0 0079 in 1 0 mm 0 039 in 0 8 mm 0 031 in
100. der C OBe careful not to pinch the O rings when installing the insulator e Apply a non permanent locking agent to the carburetor holder bolts D and tighten them Torque Carburetor Holder Bolts 11 N m 1 1 kgf m 95 in Ib HE12005BS1 o 4 22 ENGINE TOP END Cylinder Head Cylinder Head Cleaning e Remove the cylinder head see Cylinder Head Removal e Remove the valves see Valve Removal e Wash the head with a high flash point solvent e Scrape the carbon out of the combustion chamber and exhaust port with a suitable tool e Install the valves see Valve Installation Cylinder Head Warp e Clean the cylinder head see Cylinder Head Cleaning e Lay a straightedge across the lower surface of the cylinder head at the positions shown e Use a thickness gauge A to measure the space between the straightedge B and the head Cylinder Head Warp Service Limit 0 05 mm 0 002 in x lf the cylinder head is warped more than the service limit replace it x If the cylinder head is warped less than the service limit repair the head by rubbing the lower surface on emery paper secured to a surface plate first No 200 then No 400 Valves Guides Seats Springs Oil Seals ENGINE TOP END 4 23 Valve Clearance Inspection e Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter Valve Clearance Adjustment e Loosen the locknut A and turn the adjusting screw B un
101. dges Watch for sharp edges as they could cause injury through careless handling especially during major engine disassembly and assembly Use a clean piece of thick cloth when lifting the engine or turning it over High Flash Point Solvent A high flash point solvent is recommended to reduce fire danger A commercial solvent com monly available in North America is standard solvent generic name Always follow manufacturer and container directions regarding the use of any solvent Gasket O ring Replace a gasket or an O ring with a new part when disassembling Remove any foreign matter from the mating surface of the gasket or O ring to ensure a perfectly smooth surface to prevent oil or compression leaks GENERAL INFORMATION 1 3 Before Servicing 10 Liquid Gasket Locking Agent Clean and prepare surfaces where liquid gasket or non permanent locking agent will be used Apply them sparingly Excessive amount may block engine oil passages and cause serious dam age 11 Press When using a press or driver to install a part such as a wheel bearing apply a small amount of oil to the area where the two parts come in contact to ensure a smooth fit 12 Ball Bearing and Needle Bearing Do not remove a ball bearing or a needle bearing unless it is absolutely necessary Replace any ball or needle bearings that were removed with new ones Install bearings with the manufacturer and size marks facing out applying pressure evenly with a suitable driv
102. ding the flywheel puller turn the rotor puller until the alternator rotor is forced off the end of the crankshaft CAUTION If the rotor is difficult to remove turn the puller while tapping the end of the puller Do not attempt to strike the alternator rotor itself Striking the rotor can cause the magnets to lose their magnetism Charging System ELECTRICAL SYSTEM 16 19 e Remove Woodruff Key Spacer A Starter Clutch Gear B Alternator Rotor Installation e Using a cleaning fluid clean off any oil or dirt on the fol lowing portions and dry them with a clean cloth A Crankshaft Tapered Portion B Alternator Rotor Tapered Portion e Apply a thin coat of molybdenum disulfide oil to the crank shaft C e Install the starter clutch gear A and spacer B e Again clean the crankshaft tapered portion C and dry there e Install the woodruff key e Install the alternator rotor A while turning B it counter clockwise e Apply molybdenum disulfide oil to the both ends of the torque limiter A e Apply molybdenum disulfide grease to the gear of the torque limiter and install it e Install Ball Bearing Alternator Cover see Alternator Cover Installation 16 20 ELECTRICAL SYSTEM Charging System Alternator Stator Removal e Remove Alternator Cover see Alternator Cover Removal Alternator Stator Lead Clamp Screw A and Plate B Alternator Stator Screws C and Alternat
103. drain easily Then stop the vehicle e Park the vehicle so that it is level both side to side and front to rear e Place an oil pan beneath the final gear case and remove the drain plug A CAUTION When draining or filling the final gear case be care ful that no oil gets on the tire or rim because oil will deteriorate the tire Clean off any oil that inadver tently gets on them with a high flash point solvent e After the oil has completely drained out install the drain plug with a new aluminum gasket Torque Final Gear Case Drain Plug 20 N m 2 0 kgf m 14 ft Ib e Unscrew the oil level inspection bolt e Pour the oil into the case until the oil comes out of the bolt hole Final Gear Case Oil Type API GL 5 Hypoid gear oil Viscosity SAE90 above 5 41 F SAE80 below 5 41 F Capacity 0 2 L 0 21 US qt NOTE O GL 5 indicates a quality and additive rating GL 6 rated hypoid gear oils can also be used e Be sure the O ring A is in place and tighten the filler cap B Torque Final Gear Case Filler Cap 15 N m 1 5 kgf m 11 ft lb Propeller Shaft Joint Boot Inspection e Visually inspect the rear propeller shaft joint boot A in accordance with the Periodic Maintenance Chart or if the shaft is noisy during operation x If the joint boot is torn worn or deteriorated replace the joint boot and check the propeller shaft see Propeller Shaft Inspection in Final Drive chapter
104. e carburetor as possible before cleaning the carbure tor with a cleaning solution This will prevent dam age or deterioration of the parts The carburetor body has plastic parts that cannot be removed DO NOT use a strong carburetor cleaning solution which could attack these parts instead use a mild high flash point cleaning solu tion safe for plastic parts e Disassemble the carburetor see Carburetor Disassem bly e Immerse all the metal parts in a carburetor cleaning solu tion e Rinse the parts in water e When the parts are clean dry them with compressed air e Blow the air and fuel passages with compressed air e Assemble the carburetor see Carburetor Assembly Carburetor Inspection Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Before removing the carburetor check the fuel level see Fuel Level Inspection x lf the fuel level is incorrect inspect the rest of the carbu retor before correcting it 3 16 FUEL SYSTEM Carburetor e Disassemble the carburetor see Carburetor Disassem bly e Clean the carburetor see Carburetor Cleaning e Check the carburetor holder starter plunger plunger cap idle adjusting screw pilot screw needle jet holder A and float valve seat B
105. e the regulator rectifier is defective or the regulator rectifier leads are loose or open x lf the battery voltage does not increase as the engine speed increases then the regulator rectifier is defective or the alternator output is insufficient for the loads Check the alternator and regulator rectifier to determine which part is defective 16 22 ELECTRICAL SYSTEM Charging System Alternator Inspection e There are three types of alternator failures short open or loss in rotor magnetism A short or open in one of the coil wies will result in either a low output or no output at all A loss in rotor magnetism which may be caused by dropping or hitting the alternator by leaving it near an electromagnetic field or just by aging will result in low output e To check the alternator output voltage perform the follow ing procedures ODisconnect the alternator connector A OConnect a hand tester as shown in the table OStart the engine ORun it at the rpm given in the table ONote the voltage readings total 3 measurements Alternator Output Gees Tester Connections Reading Range Tester Tester 4 000 r min to to rpm Another yellow 250 V AC One yellow lead lead 38 V or more x If the output voltage is within the values in the table the alternator is operating correctly and the regulator rectifier is damaged much lower reading indicates that the al ternator is defective e Check the
106. e A and B are measured at axle height with the vehicle sitting on the ground or at 1G Steering Centering Inspection e Test ride the vehicle x If the handlebar is straight when the vehicle is traveling in a straight line go on to the Toe in Inspection procedure Otherwise go on to the Steering Centering Adjustment procedure Steering Centering Adjustment e Hold a straightedge A against the rear wheel rim on one side at axle height e With the handlebar straight ahead loosen the locknuts A B and turn the tie rod adjusting sleeve C until the front wheel on that side is parallel to the straightedge NOTE OThe locknut A on the opposite side of the flattened area D on the tie rod has left hand threads Turn the wrench clockwise for loosening HJO4006B S Wheel Alignment WHEELS TIRES 10 7 CAUTION Adjust the tie rod so that the visible thread length A is even on both ends of the tie rod or the threads could be damaged e Repeat the straightedge procedure on the other side of the vehicle Now the front wheels are parallel to each other and to the center line of the vehicle Front Wheel A Vehicle Center Line B Parallel each other C Straightedges D Rear Wheels E e Go on to the Toe in Inspection procedure Toe in Inspection e Apply a heavy coat of chalk or a paint line near the center of the front tires e Using a needle nose scriber make a thin mark near
107. e Remove Secondary Clutch e Flatten out the bent tab A of the toothed washer ENGINE RIGHT SIDE 5 7 Engine Right Side e Using a suitable gear A hold the balancer drive gear B and balancer gear C OLoosen the balancer drive gear nut D with socket wrench Special Tool Socket Wrench 57001 1354 e Using a suitable gear A hold the balancer drive gear and balancer gear e Remove Balancer Gear Nut B Balancer Gear C Balancer Drive Gear Nut D Toothed Washer Balancer Drive Gear E e Remove Oil Pump see Engine Lubrication System chapter External Shift Mechanism see Crankshaft Transmission chapter Engine Right Side Assembly e Install Oil Pump see Engine Lubrication system chapter Woodruff Key A Oil Pump Gear B OFace the stepped side C of oil pump drive gear inward e Install Balancer Drive Gear A OFace the punch mark side B of balancer drive gear out ward e Install Toothed Washer C OFit the tab D of the toothed washer into the slot in the balancer drive gear e Apply molybdenum disulfide oil to the threads of the bal ancer drive gear nut e Face the chamfered side of the nut inward 5 8 ENGINE RIGHT SIDE Engine Right Side e Apply molybdenum disulfide oil to the threads of the bal ancer gear nut and balancer drive gear nut e Align the punch marks A on the balancer drive gear and the balancer gear B e Tighten Torque Bala
108. e carburetor body will be damaged and require replacement e Back the pilot screw out the specified number of turns Carburetor Pilot Screw Setting Standard 1 1 2 turns out KLF250 A1 2 1 2 turns out KLF250 A2 Fuel Level Inspection A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Park the vehicle on a level surface AONE H Carburetor FUEL SYSTEM 3 11 e Connect the fuel level gauge to the open end of the car buretor drain hose Special Tool Fuel Level Gauge 57001 1017 Fuel Level Gauge A Zero Line B Drain Plug C Carburetor Body Bottom Edge D Fuel Level E e Hold the gauge vertically against the side of the carburetor body so that the zero line is several millimeters higher than the bottom edge of the carburetor body e Turn the fuel tap to the ON position to feed fuel to the carburetor and gauge then turn out the carburetor drain plug a few turns e Wait until the fuel level in the gauge settles e Keeping the gauge vertical slowly lower the gauge until the zero line is even with the bottom edge of the carbu retor body NOTE ODo not lower the zero line below the bottom edge of the carburetor body If the gauge is lowered and then raised it agai
109. e shaft B x lf there is any reading at all the armature has a short Replace the starter motor NOTE OEven if the foregoing checks show the armature to be good it may be defective in some manner not readily detectable with the hand tester If all other starter motor and starter motor circuit components check good but the starter motor still does not turn over or only turns over weakly replace the starter motor with a new one Starter Motor Brush Length e Measure the overall length A of each brush Starter Motor Brush Length Standard 10 mm 0 39 in Service Limit 6 5 mm 0 26 in Alf any is worn down to the service limit replace the brush plate assembly Brush Assembly Inspection e Using the x 1 Q range of the hand tester measure the resistance as shown A Terminal Bolt and Positive Brush B Brush Plate and Negative Brush x If there is not close to 0 Q the brush lead has an open Replace the brush plate assembly GP110608S1 16 38 ELECTRICAL SYSTEM Electric Starter System Brush Plate and Terminal Bolt Inspection e Using the highest range of the hand tester measure the resistance as follows A Terminal Bolt and Right Hand End Cover B Terminal Bolt and Brush Plate x lf there is any reading the insulator may be failed Re place the washer insulator of the end cover Starter Relay Inspection e Remove Seat see Frame chapter Starter Relay A e Connect the
110. e with a syringe or other suitable device x If the level is too low add oil through the filler hole Use the same type and make of oil that is already in the engine NOTE Olf the engine oil type and make are unknown use any brand of the specified oil to top off the level in preference to running the engine with the oil level low Then at your earliest convenience change the oil completely Engine Oil Change e Refer to the Engine Oil Change in the Periodic Mainte nance chapter Oil Filter Change e Refer to the Oil Filter Change in the Periodic Maintenance chapter Bypass Valve Removal e Remove Oil Filter see Oil Filter Removal e Drive the retaining pin A out of the filter mounting pin B e Remove Spring Bypass Valve Piston ENGINE LUBRICATION SYSTEM 7 7 Engine Oil and Oil Filter Bypass Valve Installation e Drop the bypass valve piston closed end A first into the O i filter mounting pin B e Put the spring C into the mounting pin and compress it beyond the small hole OY e Drive the retaining pin D into the small hole to hold the e B spring oe A e Install the oil filter see Oil Filter Installation al HG05003BS1 Bypass Valve Cleaning and Inspection e Clean the bypass valve parts in a high flash point solvent WARNING Clean the parts in a well ventilated area and take care that there is no spark or flame anywhere near the working area Because of the dange
111. earing and connecting rod big end examined or wear EH Connecting Rod Big End Radial Clearance Standard 0 008 0 020 mm 0 0003 0 0008 in Service Limit 0 07 mm 0 003 in Connecting Rod Big End Side Clearance e Set the crankshaft on V blocks E RO e Measure the side clearance A of the connecting rod with a thickness gauge x If the big end side clearance exceeds the service limit the crankshaft assembly must be replaced or disassembled and the connecting rod visually inspected for wear Connecting Rod Big End Side Clearance Standard 0 4 0 5 mm 0 016 0 020 in Hiosoosas1 Service Limit 0 7 mm 0 028 in 9 14 CRANKSHAFT TRANSMISSION Crankshaft Balancer Shaft and Connection Rod Crankshaft Alignment e Check crankshaft alignment by measuring runout OWith the crankshaft in an alignment jig turn the crank shaft slowly and measure runout at each of the locations shown A 10 5 mm 0 413 in Crankshaft Runout Standard TIR 0 04 mm 0 0016 in or less Service Limit TIR 0 1 mm 0 0039 in x If runout at either location exceeds the service limit align the crankshaft so that runout is within the service limits e In the case of horizontal misalignment strike the project ing crankshaft half with a plastic soft lead or brass ham mer as shown e Recheck the runout and repeat the process until the runout is within service limits OVertical misalignment is corrected either by d
112. ease e Lubricate the steering stem bearing ODisassemble the steering stem bearing OWipe all the old grease off the steering stem and out of bearing grease seal OPack the grease seal grooves A between the lips with grease Steering Stem Clamp Inspection e Inspect the steering stem clamps A Alf roughness excessive play or seizure is found replace both clamps Steering Stem Bearing Inspection e Inspect the spherical bearing A Alf roughness excessive play or seizure is found replace the steering stem bearing assembly e Inspect the upper and lower grease seals B lf damage wear or deterioration is found replace the steering stem bearing assembly 14 10 STEERING Steering Maintenance Tie rod End Inspection e Inspect each spherical bearing A x If roughness excessive play or seizure is found replace the tie rod end e Inspect each grease seal B x If damage wear or deterioration is found replace the tie rod end Steering Knuckle Pivot Lubrication e Lubricate the knuckle pivot in the suspension arm through the grease nipple A with a grease gun according to Pe riodic Maintenance Chart in Appendix chapter Olt is normal for a small amount of grease to seep out around the grease seals B x If the knuckle pivot is disassembled lubricate the pivot as follows OWipe all the old grease off the knuckle bushing sleeve C and grease seals OGrease the knuckle bush
113. ease No 2 EP Green 15 6 FRAME Seat Seat Removal e Remove the seat by pulling the seat latch A and then pulling the seat up to the rear Seat Installation e Slip the seat hooks A under the brace B on the frame and put the stoppers C into the holes in the frame e Push down the rear part of the seat until the lock clicks Front and Rear Fenders FRAME 15 7 Front Fender Removal e Remove Front Carrier Bolts A Front Carrier B e Remove Front Cover Screws A Front Cover B e Remove Ignition Switch A Reverse Knob B Fuel Tank Cover Screws C Fuel Tank Cap D Fuel Tank Cover E e Install the fuel tank cap at once e Remove Front Flap Screws A Left and Right Sides e Remove Front Fender Bolts A and Collars 15 8 FRAME Front and Rear Fenders e Remove Front Fender Screws A Left and Right Sides Front Fender B Front Fender Installation e Fit the tabs A on the headlight cover in the slots of the rear fender e Fit the tabs A on the front fender in the slots of the rear fender e Fit the tabs A on the fuel tank cover in the slots of the front fender from rear to front e Fit the projection A on the reverse knob into the recess in the front fender e Tighten the nut securely FRAME 15 9 Front and Rear Fenders e Fit the projection A on the ignition switch into the recess in the front fender e Tighten Torque Ignition S
114. eat with machinist s dye e Fit a 45 cutter into the holder and slide it into the valve guide e Press down lightly on the handle and turn it right or left Grind the seating surface only until it is smooth CAUTION Do not grind the seat too much Overgrinding will reduce valve clearance by sinking the valve into the head If the valve sinks too far into the head it will be impossible to adjust the clearance and the cylin der head must be replaced GE15011881 4 28 ENGINE TOP END Valves Guides Seats Springs Oil Seals Widened Width A of engagement by machining with 45 cutter Ground Volume B by 32 cutter 32 C Correct Width D Ground Volume E by 60 cutter 60 F e Measure the outside diameter of the seating surface with a vernier caliper x If the outside diameter of the seating surface is too small repeat the 45 grind A until the diameter is within the specified range Original Seating Surface B NOTE ORemove all pittings of flaws from 45 ground surface OAfter grinding with 45 cutter apply thin coat of machin ist s dye to seating surface This makes seating surface distinct and 32 and 60 grinding operation easier OWhen the valve guide is replaced be sure to grind with 45 cutter for centering and good contact x lf the outside diameter A of the seating surface is too large make the 32 grind described below x If the outside diameter of t
115. eck the backlash and readjust as necessary Bevel Gear Backlash Front Standard 0 06 0 13 mm 0 0024 0 0051 in at driven gear shaft nut Tooth contact adjustment e Clean any dirt and oil off the bevel gear teeth e Apply checking compound to 4 or 5 teeth on the output driven bevel gear NOTE OApply checking compound to the teeth in a thin even coat with a fairly stiff paint brush If painted too thickly the exact tooth pattern may not appear OThe checking compound must be smooth and firm with the consistency of tooth paste OSpecial compounds are available from automotive sup ply stores for the purpose of checking differential gear tooth patterns and contact Use this for checking the bevel gears e Turn the front end of the output driven shaft for 3 or 4 turns in the drive and reverse coast directions while creating a drag on the drive bevel gear Special Tool Pinion Gear Holder m1 0 57001 1281 e Check the drive pattern and coast pattern of the bevel gear teeth The tooth contact patterns of both drive and coast sides should be centrally located between the top and bottom of the tooth and a little closer to the toe of the tooth x lf the tooth contact pattern is incorrect replace the shim s at the drive bevel gear and shim s at the driven bevel gear following the examples shown Then erase the tooth contact patterns and check them again Also check the backlash every time the shims are replaced R
116. eeenn 11 16 Pinion Gear Disassembly Propeller Shaina 11 17 Pinion Gear Assembly Propeller Shaft Removal 11 17 Bevel Gear Inspection Propeller Shaft Installation 11 18 Ball Bearing Inspection Propeller Shaft Inspection 11 18 Oil Seal Inspection 11 2 FINAL DRIVE Exploded View D Ve Go M Exploded View FINAL DRIVE 11 3 No Fastener Remarks L 1 2 Output Bevel Gear Case Bolts M6 8 8 78 in lb 3 Oil Seal Housing Nuts 25 2 5 18 4 Output Drive Gear Nut 118 12 87 MO 5 Cam Damper Mounting Nut 78 8 0 58 MO 6 Driven Gear Shaft Nut 147 15 108 L 7 Bearing Retainers 108 11 80 L 8 Pinion Gear Nut 69 7 0 51 St 9 Propeller Shaft Housing Nuts 25 2 5 18 G Apply grease for oil seal and O ring L Apply a non permanent locking agent M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil St Stake the fasteners to prevent loosening 11 4 FINAL DRIVE Exploded View OKA w HKO2009BW5 FINAL DRIVE 11 5 Exploded View Torque No Fastener SC kaim SO Remarks 2 Speedometer Plug 20 2 0 14 3 Final Gear Case Filler Cap 15 1 5 11 4 Ring Gear Cover Bolts 25 2 5 18 L 5 Axle Shaft Pipe Bolts 20 2 0 14 6 Oil Level Inspection Bolt 7 8 0 8 69 in lb 7 Australia and Europe Mod
117. efer to the appropriate chapter for torque specifications If torque specifications are not listed in the appropriate chapter see the Basic Torque Table see Torque and Locking Agent For each fastener first loosen it by 1 2 turn then tighten it x lf cotter pins are damaged replace them with new ones Bolts Nuts and Fasteners to be checked Wheels Front Axle Nuts and Cotter Pins Rear Axle Nuts and Cotter Pins Wheel Nuts Brakes Brake Lever Pivot Bolt Brake Lever Pivot Nut Brake Pedal Cotter Pin Steering Suspension Handlebar Holder Bolts Steering Stem Clamp Bolts Steering Stem Bearing Joint Bolts Tie Rod End Nuts and Cotter Pins Tie Rod Adjusting Sleeve Locknuts Shock Absorber Mounting Bolts and Nuts Suspension Arm Pivot Bolts Steering Knuckle Arm Pivot Nuts and Cotter Pins Engine Engine Mounting Bolts Engine Mounting Bracket Bolts Exhaust Pipe Holder Nuts Muffler Mounting Bolts Muffler Clamp Bolt Others Footpeg Mounting Bolts Throttle Case Screws Carrier Mounting Bolts FUEL SYSTEM 3 1 Fuel System Table of Contents Exploded View 3 2 Fuel Level Inspection 3 10 Specifications 3 4 Fuel Level Adjustment 3 11 Special Tools and Sealant 3 5 Fuel System Cleanliness Throttle Lever and Cable nnn 3 6 Inspection 3 12 Throttle Lever Free Play Carburetor Removal
118. el Toe Ring Gear GEN se Pinion Gear Toe Toe Bottom eZ Top cu Bottom Bottom Heel Incorrect Tooth Contact Patterns Example 1 Decrease the thickness of the pinion gear shim s by 0 05 mm 0 002 in to correct the pattern shown below Repeat in 0 05 mm 0 002 in steps if necessary Heel Toe Ring Gear Bottom D Den Heel Pinion Gear y _ E HA IS Bottom Toe SA Bottom o Heel Bottom Example 2 Increase the thickness of the pinion gear shim s by 0 05 mm 0 002 in to correct the pattern shown below Repeat in 0 05 mm 0 002 in steps if necessary Ring Gear Bottom Heel Top Pinion Gear The Bottom Toe N To Bottom p Bottom Heel HK14008B S FINAL DRIVE 11 29 Final Gear Case Pinion Gear Disassembly e Remove the final gear case see Final Gear Case Re moval e Pull the pinion gear assembly A off the final gear case The shim s comes off with the assembly e Pry open the staking B of the pinion gear nut with a small chisel HX 148018 P e Unscrew the pinion gear nut A using the bevel gear holder B to keep the pinion gear assembly as shown and remove the pinion gear nut flat washer and pinion gear joint Special Tool Bevel Gear Holder 57001 1618 e Pull out the pinion gear e Pry the oil seal off the housing e To remove the bearing unscrew the bearing retainer us ing the hexagon wrench A Special
119. el too high or too low Engine load faulty Air cleaner clogged poorly sealed or miss Clutch slipping ing Engine oil level too high Starter plunger stuck open Engine oil viscosity too high Water or foreign matter in fuel Brake dragging Carburetor holder loose Lubrication inadequate Air cleaner duct loose Engine oil level too low Final gear case oil viscosity too high Overheating Firing incorrect 17 14 APPENDIX Troubleshooting Guide Engine oil poor quality or incorrect Rear final gear case overheating Insufficient oil Bevel gears maladjusted Clutch Operation Faulty Clutch slipping Friction and or steel plates worn or warped Clutch housing or shoe linings overworn or worn unevenly Clutch spring broken or weak Clutch release maladjusted Clutch release mechanism trouble Clutch hub or housing unevenly worn Clutch not disengaging properly Friction and or steel plates warped or too rough Clutch spring tension uneven Clutch shoe spring broken or weak Engine oil deteriorated Engine oil viscosity too high Engine oil level too high Clutch housing frozen on crankshaft or drive shaft Clutch release mechanism trouble Gear Shifting Faulty Doesn t go into gear shift pedal doesn t return Clutch not disengaging Shift fork s bent or seized Gear s stuck on the shaft Shift return spring weak or broken Shift mechanism arm spring broken Shift return spring pin loose Shift drum positioning lever binding on pivot bolt Shift mechanis
120. els 8 U S A Canada and United Kingdom Models G Apply grease LG Apply liquid gasket Three Bond 1215 Gray L Apply a non permanent locking agent M Apply molybdenum disulfide grease 11 6 FINAL DRIVE Specifications Item Standard Bevel Gear Backlash Front 0 06 0 13 mm 0 024 0 0051 in at driven gear shaft nut Final 0 13 0 25 mm 0 0051 0 0098 in at ring gear tooth Final Gear Case Oil Type API GL 5 Hypoid gear oil Viscosity SAE90 above 5 C 41 F SAE80 below 5 C 41 F Capacity 0 2 L 0 21 US qt Special Tools and Sealant Inside Circlip Pliers 57001 143 ST5701438ST Gear Holder m1 75 57001 1015 ST571015ST Oil Seal amp Bearing Remover 57001 1058 ST5710588T Bearing Driver Set 57001 1129 ST5711298T Bevel Gear Holder 57001 1618 GID ST5716188ST FINAL DRIVE 11 7 Hexagon Wrench Hex 32 57001 1194 ST5711948T Jack 57001 1238 ST5712388ST Bearing Retainer Wrench Hex 40 57001 1256 ST5712568T Pinion Gear Holder m1 0 57001 1281 ST571281ST Socket Wrench 57001 1354 ST5713548T 11 8 FINAL DRIVE Output Bevel Gear Case Output Bevel Gear Case Removal e Drain the engine oil see Engine Lubrication System chapter e Remove Engine see Engine Removal Installation chapter Re
121. en Torque Ring Gear Cover Bolts 25 N m 2 5 kgf m 18 ft lb e Check the backlash during tightening the cover bolts and stop tightening them immediately if the backlash disap pears Then change the ring gear shim to a thinner one e Set up a dial gauge A against a ring gear tooth to check gear backlash e To measure the backlash move the ring gear back and forth B while holding the pinion gear steady with the bevel gear holder C Special Tool Bevel Gear Holder 57001 1618 D Rear Axle e The difference between the highest and the lowest gauge reading is the amount of backlash Bevel Gear Backlash Rear Standard 0 13 0 25 mm 0 0051 0 0098 in at ring gear tooth x If the backlash is not within the limit replace the ring gear shim s To increase backlash decrease the thickness of the shim s To decrease backlash increase the thick ness of the shim s Change the thickness a little at a time e Recheck the backlash and readjust as necessary Final Gear Case FINAL DRIVE 11 27 Tooth contact adjustment e Clean any dirt and oil off the bevel gear teeth e Apply checking compound to 4 or 5 teeth of the pinion gear NOTE OApply checking compound to the teeth in a thin even coat with a fairly stiff paint brush If painted too thickly the exact tooth pattern may not appear OThe checking compound must be smooth and firm with the consistency of tooth paste OSpecial compounds are avai
122. epeat the shim change procedure as necessary NOTE Olf the backlash is out of the standard range after chang ing shims correct the backlash before checking the tooth contact pattern Correct Tooth Contact Patterns No adjustment is required Bottom E Heel Top To Bottom Drive Gear Bottom Heel N Toe Bottom Driven Gear HK16003452 C Output Bevel Gear Case FINAL DRIVE 11 15 Example 1 Decrease the thickness of the drive gear shim s by 0 05 mm 0 002 in and or increase the thick ness of the driven bevel gear shim s by 0 05 mm 0 002 in to correct the pattern shown Repeat in 0 05 mm 0 002 in steps if necessary Example 2 Increase the thickness of the drive bevel gear shim s by 0 05 mm 0 002 in and or decrease the thick ness of the driven bevel gear shim s by 0 05 mm 0 002 in to correct the pattern shown Repeat in 0 05 mm 0 002 in steps if necessary Bevel Gear Inspection e Visually check the bevel gears A for scoring chipping or other damage x Replace the bevel gears as a set if either gear is dam aged Incorrect Tooth Contact Patterns 1 Bottom AR Heel Top To S Bottom SEN Toe Toe Top Bottom DR Drive Gear Heel Driven Gear HK16003552 Incorrect Tooth Contact Patterns 2 Bottom ABs Heel Top o an Drive Gear Heel Bottom Toe e Top Bottom Driven Gear HK160036S2 HK08
123. er Apply force only to the end of the race that contacts the press fit portion and press it evenly over the base component 13 0il Seal and Grease Seal Replace any oil or grease seals that were removed with new ones as removal generally dam ages seals Oil or grease seals should be pressed into place using a suitable driver applying a force uniformly to the end of seal until the face of the seal is even with the end of the hole unless instructed otherwise When pressing in an oil or grease seal which has manufacturer s marks press it in with the marks facing out 14 Circlip Retaining Ring and Cotter Pin When installing circlips and retaining rings take care to compress or expand them only enough to install them and no more Install the circlip with its chamfered side facing load side as well Replace any circlips retaining rings and cotter pins that were removed with new ones as re moval weakens and deforms them If old ones are reused they could become detached while the motorcycle is driven leading to a major problem 15 Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the sliding surfaces have an adequate lubricative film During assembly make sure to apply oil to any sliding surface or bearing that has been cleaned Old grease or dirty oil could have lost its lubricative quality and may contain foreign particles that act as abrasives therefore make sure to wipe it off and ap
124. er while pressing down lightly OAfter making the 60 grind return to the seat width mea surement step above Correct Width B e Lap the valve to the seat once the seat width and outside diameter are within the ranges specified above OPut a little coarse grinding compound on the face of the valve in a number of places around the valve head OSpin the valve against the seat until the grinding com pound produces a smooth matched surface on both the seat and the valve ORepeat the process with a fine grinding compound A Lapper B Valve Seat C Valve e The seating area should be marked about in the middle of the valve face If the seat area is not in the right place on the valve check to be sure the valve is the correct part If itis it may have been refaced too much replace it e Be sure to remove all grinding compound before assem bly e When the engine is assembled be sure to adjust the valve clearance see Valve Clearance Adjustment GE15012381 GE15012081 4 30 ENGINE TOP END Valves Guides Seats Springs Oil Seals Valve Seat Repair START Machinist s dye on seat 45 Grind Tool 45 Cutter Purpose make seating area smooth and round Measure Seating Area Outside Diameter Tool Venire Caliper Purpose check seat outside diameter against spec 45 Grind Machinists dye on seat Tool 45 Cutter Purpose increase
125. es braking effectiveness cam lever angle adjustment should not be neglected Reduced braking effec tiveness could lead to a crash 2 18 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Steering Inspection e Turn the handlebar left and right and check the steering action x If the steering action is not smooth or if the steering binds or catches before the stop lubricate the steering stem bearing NOTE OThe cables and wires will have some effect on the steer ing action which must be taken into account e Check the steering action again x If steering stem bearing lubrication does not remedy the problem inspect the steering stem for straightness steer ing stem clamps and tie rod bearings x If you feel looseness or if the steering rattles as it turns check the tightness of the steering bolts and nuts e Tighten loose bolts and nuts to the specified torque see Exploded View and check the steering action again x lf the steering action does not change by tightening the bolts and nuts inspect the steering stem clamps steer ing stem bearings tie rod bearings and steering knuckle joints Electrical System Battery Inspection e Refer to the Electlyte Level Inspection in the Electrical System chapter e Refer to the Electlyte Specific Gravity Inspection in the Electrical System chapter e Refer to the Ordinary Charging in the Electrical System chapter Spark Plug Cleaning Inspectio
126. evel gears First adjust backlash and then tooth con tact by replacing shims OThe amount of backlash is influenced by the ring gear position more than by the pinion gear position OTooth contact location is influenced by pinion gear posi tion more than by ring gear position Final Gear Case Backlash related Parts HK14006BH3 1 Pinion Gear Housing 4 Ring Gear Cover 7 Ball Bearings 2 Pinion Gear Shim s 5 Ring Gear Shim s 8 Ring Gear 3 Final Gear Case 6 Final Gear Shaft 9 Pinion Gear 11 26 FINAL DRIVE Final Gear Case 7 Pinion Gear Shims Thickness Part Number 0 10 mm 0 004 in 92025 1865 0 15 mm 0 006 in 92025 1866 0 50 mm 0 020 in 92025 1867 0 80 mm 0 031 in 92025 1868 1 0 mm 0 039 in primary 92025 1864 8 Ring Gear Shims Thickness Part Number 0 10 mm 0 004 in 92025 1850 0 15 mm 0 006 in 92025 1851 0 50 mm 0 020 in 92025 1856 0 80 mm 0 031 in 92025 1857 1 0 mm 0 039 in primary 92025 1849 Backlash Adjustment e Clean any dirt and oil off the bevel gear teeth e Install the pinion gear assembly with the primary shim 1 0 mm thickness e Tighten the propeller shaft housing mounting nuts without the propeller shaft housing Torque Propeller Shaft Housing Nuts 25 N m 2 5 kgf m 18 ft lb e Install the ring gear in the final gear case with the primary shim 1 0 mm thickness onto the ring gear e Install Ring Gear Case Cover e Tight
127. g A Ignition Coil B Crankshaft Sensor A Starter Motor B Regulator Rectifier C Alternator D Engine Ground Terminal E Neutral Reverse Switch F Battery A Main Fuse 20 A B Starter Relay C Starter Circuit Relay D Precautions ELECTRICAL SYSTEM 16 9 There are a number of important precautions that should be taken when servicing electrical systems Learn and ob serve all the rules below ODo not reverse the battery lead connections This will burn out the diodes in the electrical parts OAlways check battery condition before condemning other parts of an electrical system A fully charged battery is required for conducting accurate electrical system tests OThe electrical parts should never be struck sharply as with a hammer or allowed to fall on a hard surface Such a shock to the parts can damage them OTo prevent damaging electrical parts do not disconnect the battery leads or any other electrical connections when the ignition switch is on or while the engine is running OBecause of the high current never keep the starter button depressed when the starter motor will not turn over or the current may burn out the starter motor windings OOnly use an illumination bulb rated for the voltage or wattage specified in the wiring diagram or the handle cover could be warped by excessive heat radiated from the bulb OTake care not to short the leads that are directly con nected to the batter
128. g Gear Cover Bolts 25 2 5 18 L Axle Shaft Pipe Bolts 20 2 0 14 Oil Level Inspection Bolt 7 8 0 8 69 in lb Brakes Front Axle Nuts 34 3 5 25 Rear Axle Nuts 147 15 108 Front Brake Panel Bolts 25 2 5 18 L Rear Brake Panel Bolts 29 3 0 22 L Rear Brake Drum Drain Bolts 29 3 0 22 Torque and Locking Agent PERIODIC MAINTENANCE 2 5 Fastener Suspension Front Suspension Arm Pivot Bolts Rear Suspension Arm Pivot Bolts and Nuts Shock Absorber Mounting Bolts and Nuts Steering Knuckle Pivot Nuts Remarks 65 25 25 29 Steering Steering Stem Clamp Bolts Steering Stem Bottom End Nut Tie rod End Nuts Tie rod Adjusting Sleeve Locknuts Steering Knuckle Arm Pivot Nuts Handlebar Holder Bolts 20 22 30 20 29 14 Frame Rear Carrier Bolts 14 Electrical System Alternator Cover Bolts Spark Plug Starter Motor Clutch Bolts Ignition Switch Nut Alternator Rotor Bolt Starter Motor Mounting Bolts Starter Motor Terminal Nut Starter Motor Terminal Locknut Starter Motor Bolts 78 in lb 10 25 26 in lb 43 78 in lb 43 in lb 61 in lb 30 in lb The table below relating tightening torque to thread diameter lists the basic torque for the 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 Basic Torque for General Fasteners Threads dia mm N m kgf m ft lb 5 3 4 4 9 0
129. g point is above the guide Valve Valve Guide Clearance Wobble Method Standard Service Limit Exhaust 0 05 0 11 mm 0 27 mm 0 0020 0 0043 in 0 0106 in Inlet 0 02 0 08 mm 0 23 mm 0 0008 0 0032 in 0 0094 in HE13005BS1 4 26 ENGINE TOP END Valves Guides Seats Springs Oil Seals Valve Seat Inspection e Remove the valve see Valve Removal e Check the valve seat width A OMeasure the seat width of the portion where there is no build up carbon white portion of the valve seat with vernier calipers Valve Seat Surface Width Exhaust 0 5 1 0 mm 0 02 0 04 in Inlet 0 5 1 0 mm 0 02 0 04 in x lf the valve seat width is not within the specified range repair the valve seat e Measure the outside diameter B of the seating pattern on the valve seat Good C Too Wide D Too Narrow E Uneven F x If the outside diameter of the valve seating pattern is too large or too small repair the valve seat Valve Seat Surface Outside Diameter Exhaust 26 9 27 1 mm 1 059 1 067 in Inlet 30 9 31 1 mm 1 217 1 224 in Valve Seat Repair Valve Lapping e Using the valve seat cutters repair the valve seat Special Tools Valve Seat Cutter 45 630 57001 1187 Valve Seat Cutter 45 635 57001 1116 Valve Seat Cutter 32 635 57001 1121 Valve Seat Cutter 60 630 57001 1123 Valve Seat Cutter 60 441 57001 1124 Valve Seat Cutter Holder 65 5 57
130. ghtened x If the fuel hose has been sharply bent or kinked replace the fuel hose x lf the clamps are loosened or damaged replace the clamps e When installing the fuel hose avoid sharp bending kink ing flattening or twisting and route the fuel hose with a minimum of bending so that the fuel flow will not be ob structed Fuel Hose Replacement Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Turn the fuel tap to the OFF position e Remove Clamps Fuel Hose HGO7010381 2 10 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Fit the fuel hose A onto the pipe fully and install the clamps B beyond the raised rib C Engine Top End Valve Clearance Inspection NOTE OCheck the valve clearance only when the engine is cold at room temperature e Remove Front Fender see Frame chapter Bolts A and Valve Adjusting Caps B e Remove Recoil Starter see Recoil Starter chapter Timing Inspection Plug e Turn the crankshaft counterclockwise with a wrench on the alternator rotor bolt until the T mark A on the alter nator rotor aligns with the slot B as shown e Measure the clearance of each valve between the end of the valve stem and the adjusting screw on
131. h changes in temperature so the specific gravity reading must be corrected for the temperature of the electrolyte OCelsius Add 0 007 points to reading for each 10 C above 20 C or subtract 0 007 points for each 10 C be low 20 C OFahrenheit Add 0 004 points to reading for each 10 F above 68 F or subtract 0 004 points for each 10 F be low 68 F x If the specific gravity of any of the cells is more than 0 050 away from any other reading the battery will probably not accept a charge It is generally best to replace a battery in this condition x If the specific gravity of all the cells is 1 270 or more the battery is fully charged HPO8O101S1 GPO8000BS1 ELECTRICAL SYSTEM 16 13 Battery Initial Charging WARNING Keep the battery away from sparks and open flames during charging since the battery gives off an ex plosive gas mixture of hydrogen and oxygen When using a battery charger connect the battery to the charger before turning on the charger This procedure prevents sparks at the battery terminals which could ignite any battery gases e Fill each cell to the upper level line on the battery case with fresh electrolyte specific gravity 1 270 at a temperature of 30 C 86 F or less Let the battery stand for about 30 minutes before charging NOTE Olf the electrolyte level drops add electrolyte to the upper level line before charging Set the charging
132. hand tester A and 12 V battery B to the starter relay as shown x If the relay does not work as specified the relay is defec tive Replace the relay Testing Relay Hand Tester Range x 10 range Criteria When battery is connected gt 0 Q When battery is disconnected gt Q Starter Circuit Relay Inspection e Remove Seat see Frame chapter Starter Circuit Relay A Electric Starter System ELECTRICAL SYSTEM 16 39 e Connect the hand tester A and 12 V battery B to the starter circuit relay C as shown x lf the relay does not work as specified the relay is defec tive Replace the relay Testing Relay Hand Tester Range x 1 QO Criteria When battery is connected gt 0 Q When battery is disconnected gt e Q Relay Coil Terminals 1 and 2 Relay Switch Terminals 3 and 4 16 40 ELECTRICAL SYSTEM Electric Starter System Electric Starter Circuit K A KLF250 A1 B KLF250 A2 1 Starter Button 4 Starter Circuit Relay 7 Starter Motor 2 Engine Stop Switch 5 Starter Relay 8 Neutral Reverse Switch 3 Ignition Switch 6 Main Fuse 20 A 9 Battery ELECTRICAL SYSTEM 16 41 Starter Motor Clutch Starter Motor Clutch Removal e Remove the alternator rotor see Alternator Rotor Re moval e Gently pry the clutch rollers A out They will be followed by the spring caps B and springs C e Hold the rotor with the flywheel holder and remove t
133. he starter motor clutch bolts A Special Tool Flywheel Holder 57001 1313 e Take out the starter motor clutch B Starter Motor Clutch Installation e Apply a non permanent locking agent Starter Motor Clutch Bolts e Tighten Torque Starter Motor Clutch Bolts 34 N m 3 5 kgf m 25 ft Ib Starter Motor Clutch Inspection e Remove the starter motor see Starter Motor Removal e Turn the starter idle gear with your finger x lf the idle gear turns clockwise A freely but not counter clockwise the clutch is operating as it should lt the clutch does not operate as it should or if it makes noise disassemble it examine each part visually and re place any worn or damaged parts NOTE OExamine the starter clutch gear A as well Replace it if it is worn or damaged 16 42 ELECTRICAL SYSTEM Starter Chain and Sprockets Torque Limiter Inspection e Remove the torque limiter A and visually inspect it x lf the limiter has wear discoloration or other damage replace it as a unit ELECTRICAL SYSTEM 16 43 Lighting System Headlight Beam Vertical Adjustment e Turn the adjusting screws A on each headlight rim in or out to adjust the headlight vertically NOTE OOn high beam the brightest point should be slightly be low horizontal with the vehicle on its wheels and the rider seated Adjust both headlights to the same an gle Headlight Bulb Replacement e Slide back the dust cover
134. he locknut A e Turn the adjusting screw B clockwise until it becomes hard to turn e Turn the adjusting screw counterclockwise until it be comes hard to turn e Tighten the locknut without changing the adjusting screw position Torque Clutch Adjustment Locknut 11 N m 1 1 kgf m 95 in Ib e Install the adjusting screw cover 2 12 PERIODIC MAINTENANCE Periodic Maintenance Procedures Engine Lubrication System Engine Oil Change e Support the vehicle so that it is level side to side and front to back after warming up the engine e Remove the engine drain plug A to drain the oil OThe oil in the filter can be drained by removing the filter see Oil Filter Change Replace the drain plug gasket with a new one if it is dam aged e Tighten Torque Engine Drain Plug 29 N m 3 0 kgf m 22 ft Ib e Pour in the specified type and amount of oil Engine Oil Type API SF or SG API SH or SJ with JASO MA Viscosity SAE 10W 40 Amount 2 0 L 2 11 US qt When filter is not removed 2 1 L 2 22 US qt When filter is removed 2 75 L 2 91 US qt When engine is completely dry NOTE ODepending on the atmospheric temperature of your rid ing area the engine oil viscosity should be changed ac cording to the chart Oil Filter Change e Drain the engine oil e Remove Oil Filter Cover Bolts A Oil Filter Cover B e Replace the filter A with a new one e When installing the oil filter be careful of
135. he seating surface is within the specified range measure the seat width as described be low e Grind the seat at a 32 angle B until the seat outside diameter is within the specified range OTo make the 32 grind fit a 32 cutter into the holder and slide it into the valve guide OTurn the holder one turn at a time while pressing down very lightly Check the seat after each turn CAUTION The 32 cutter removes material very quickly Check the seat outside diameter frequently to pre vent overgrinding OAfter making the 32 grind return to the seat outside di ameter measurement step above e To measure the seat width use a vernier caliper to mea sure the width of the 45 angle portion of the seat at sev eral places around the seat x If the seat width is too narrow repeat the 45 grind until the seat is slightly too wide and then return to the seat outside diameter measurement step above GE15011981 GE15012181 GE15012281 ENGINE TOP END 4 29 Valves Guides Seats Springs Oil Seals Alf the seat width is too wide make the 60 A grind de scribed below x lf the seat width is within the specified range lap the valve to the seat as described below e Grind the seat at a 60 angle until the seat width is within the specified range OTo make the 60 grind fit 60 cutter into the holder and slide it into the valve guide OTurn the hold
136. heck its condition x If the bearing is noisy does not spin smoothly or has any rough stops replace it GE11012281 4 18 ENGINE TOP END Camshaft Chain and Guides Camshaft Chain Removal e Remove Camshaft Sprocket see Camshaft Sprocket Removal Alternator Rotor see Electrical System chapter Screws A and Camshaft Chain Guard B Camshaft Chain C Camshaft Chain Installation CAUTION Always pull the camshaft chain taut while turning the crankshaft when the camshaft chain is loose This avoids kinking the chain on the lower crank shaft sprocket A kinked chain could damage both the chain and the sprocket e Tighten Torque Camshaft Chain Guard Screws 4 4 N m 0 45 kgf m 39 in Ib e Install the camshaft sprocket see Camshaft Sprocket In stallation Camshaft Chain Guide Removal e Remove Cylinder Head see Cylinder Head Removal Camshaft Chain see Camshaft Chain Removal Front Camshaft Chain Guide A Bolt B Rear Camshaft Chain Guide C and Collar Camshaft Chain Guide Installation e Slip the front camshaft chain guide A into position B Be sure the hook C of the chain guide hangs on the cylinder catch e Tighten Torque Rear Camshaft Chain Guide Bolt 9 8 N m 1 0 kgf m 87 in Ib Camshaft Chain Guide Wear e Visually inspect the rubber on the guides x If the rubber is damaged cut or is missing pieces replace the guide Cylinder
137. igh in both directions the rectifier is defective and must be replaced NOTE OThe actual meter reading varies with the meter and the individual rectifier Generally speaking the lower read ing should be from zero to one half of the scale Tester connection Regulator Circuit Check To test the regulator out of circuit use three 12 V batteries and a test light 12 V 3 6 W bulb in a socket with leads CAUTION The test light works as an indicator and also a cur rent limiter to protect the regulator rectifier from ex cessive current Do not use an ammeter instead of a test light e Check to be sure the rectifier circuit is correct before con tinuing Regulator Circuit Test 1st Step e Connect the test light and a 12 V battery to the regula tor rectifier as shown e Check Y1 Y2 and Y3 terminal respectively x If the test light turns on the regulator rectifier is defective x If the test light does not turn on continue the test HPO9010BS1 HPOSO11BS1 16 24 ELECTRICAL SYSTEM Charging System Regulator Circuit Test 2nd Step e Connect the test light and a 12 V battery in the same man ner as specified in the Regulator Circuit Test 1st Step e Apply 12 V to the BR voltage monitoring terminal e Check Y1 Y2 and Y3 terminals x If the test light turns on the regulator rectifier is defective x lf the test light does not turn on continue the test Regul
138. ing A Cover B e Remove Clamp A Circlip B Special Tool Inside Circlip Pliers 57001 143 e Remove the propeller shaft from the propeller shaft hous ing C 11 18 FINAL DRIVE Propeller Shaft Propeller Shaft Installation e Wipe off old grease in the ends of propeller shaft A e Apply grease to the universal joint outer surface B e Apply molybdenum disulfide grease Splines at Front End A of Propeller Shaft Splines at Rear End B of Driven Gear Shaft e Fit the propeller shaft to the driven gear shaft e Apply molybdenum disulfide grease Splines at Rear End A of Propeller Shaft Splines at Front End of Pinion Gear Joint e Install Spring B Rear Final Gear Case and Rear Axle Assembly e Tighten Torque Propeller Shaft Housing Nuts 25 N m 2 5 kgf m 18 ft lb Propeller Shaft Inspection e Remove the propeller shaft see Propeller Shaft Re moval e Check that the universal joint A works smoothly without rattling or sticking x If it does not the universal joint is damaged Replace the propeller shaft with a new one e Visually inspect the universal joint grease cap B x If there are any signs of deterioration damage or loose ness replace the propeller shaft x If grease leakage is noted replace the propeller shaft e Inspect the center bearing C OSince the ball bearings are made to extremely close toler ances the wear must be judged by feel rather than mea surement OS
139. ing sleeve and grease seal lips HNO5010481 HNO50G4BS2 C STEERING 14 11 Handlebar Handlebar Removal e Remove Handlebar Cover A Throttle Case Front Brake Lever Left hand Switch Housing Rear Brake Lever e Remove Handlebar Holder Bolts A Handlebar Holders B Handlebar C Handlebar Installation e Tighten the holder front bolts A first and then the rear bolts B Torque Handlebar Holder Bolts 20 N m 2 0 kgf m 14 ft lb Olf the holder is correctly installed there will be even gaps C at the rear part of the holder after tightening FRAME 15 1 Frame Table of Contents EXploded Mi A RE R E A O eee Ent 15 2 SEE LEE 15 6 MEAL REMOVAL EE EETAS E EAT A EET dees ccapnectancasigansabadeatseneses tenes 15 6 seat Installation AA EE 15 6 Frontand R r Fend rs 22525228 EE e eer 15 7 Front Fender Removal viii dico 15 7 Front Fender Installation lia nt aan 2e 15 8 Rear Fender Removal ee its 15 9 Rear Fender Installation gd daa 15 10 SA O 15 11 Front Guard IREMOVAl uti EE Ee Eed 15 11 15 2 FRAME Exploded View FRAME 15 3 Exploded View AD Apply adhesive agent 15 4 FRAME Exploded View FRAME 15 5 Exploded View 1 Rear Carrier Bolts 20 20 14 2 Other than U S A and Canada Models 3 United Kingdom and Australia Models 4 Canada Model 5 Europe and United Kingdom Models AG Apply grease Amoco rykon premium gr
140. ints listed below with indicated lubricant NOTE OWhenever the vehicle has been operated under wet or rainy conditions or especially after using a high pressure spray water perform the general lubri cation Cables Lubricate with Cable Lubricant Brake Cables Throttle Cable Choke Cable e Lubricate the cables by seeping the oil between the ca ble and housing OThe cable may be lubricated by using a pressure cable luber with an aerosol cable lubricant 6004011481 2 20 PERIODIC MAINTENANCE Periodic Maintenance Procedures e With the cable disconnected at the both ends the cable should move freely A within the cable housing x If cable movement is not free after lubricating if the cable is frayed or if the cable housing is kinked replace the cable 6004040281 Points Lubricate with Grease Throttle Inner Cable Ends A Choke Cable Lower End Brake Cable Ends 6004040351 Slide Points Lubricate with Grease Brake Lever Brake Pedal Pivot Shaft Throttle Lever Shaft PERIODIC MAINTENANCE 2 21 Periodic Maintenance Procedures Bolts and Nuts Tightening Tightness Inspection e Check the tightness of the bolts and nuts listed here in accordance with the Periodic Maintenance Chart Also check to see that each cotter pin is in place and in good condition x lf there are loose fasteners retorque them to the speci fied torque following the specified tightening sequence R
141. iod we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty To get the longest life out of your vehicle e Follow the Periodic Maintenance Chart in the Service Manual eBe alert for problems and non scheduled maintenance e Use proper tools and genuine Kawasaki Vehi cle parts Special tools gauges and testers that are necessary when servicing Kawasaki vehicles are introduced by the Service Man ual Genuine parts provided as spare parts are listed in the Parts Catalog e Follow the procedures in this manual care fully Don t take shortcuts e Remember to keep complete records of main tenance and repair with dates and any new parts installed How to Use This Manual In this manual the product is divided into its major systems and these systems make up the manual s chapters The Quick Reference Guide shows you all of the product s system and assists in locating their chapters Each chapter in turn has its own comprehensive Ta ble of Contents For example if you want ignition coil informa tion use the Quick Reference Guide to locate the Electrical System chapter Then use the Table of Contents on the first page of the chap ter to find the Ignition Coil section Whenever you see these WARNING and CAUTION symbols heed their instructions Always f
142. is damaged replace the hub B and bolts as a unit FINAL DRIVE 11 1 Final Drive Table of Contents Exploded View 11 2 Propeller Shaft Joint and Pinion Specifications 11 6 Gear Joint Inspection 11 19 Special Tools and Sealant 11 7 Propeller Shaft Joint Boot Output Bevel Gear Case coocccccccncc 11 8 Inspechon nssnonseeeeeeeeeeeeeeeeeeeea 11 19 Output Bevel Gear Case Rear AXle 5 24 11 20 Removal cc ccceeeceeeeeeeeeteees 11 8 Rear Axle Removal 11 20 Output Bevel Gear Case Rear Axle Installation 11 20 Installations 11 8 Axle Shaft Pipe Disassembly 11 21 Output Bevel Gear Case Axle Shaft Pipe Assembly 11 22 Disassembly 11 8 Final Gear Case aaee 11 23 Output Bevel Gear Case Final Gear Case Oil Level Assembly 11 9 Inspection hs 11 23 Output Drive Gear Removal 11 11 Final Gear Case Oil Change 11 23 Output Drive Gear Installation 11 11 Final Gear Case Removal 11 23 Output Bevel Gear Adjustment 11 11 Final Gear Case Installation 11 23 Bevel Gear Inspection 11 15 Final Gear Case Disassembly 11 23 Cam Damper Inspection 11 16 Final Gear Case Assembly Ball Bearing Inspection 11 16 Final Bevel Gear Adjustment Oil Seal Inspection saseeee
143. k Voltage 12 V 14 Ah US 12 V 11 Ah Between upper and lower levels 1 270 20 C 68 F Three phase AC 14 15V 38 V or more 4 000 r min rpm 0 4 1 10 0 6 0 7 mm 0 024 0 028 in 3 75 6 25 KQ 7 mm 0 28 in or more 0 09 0 13 Q 3 8 5 8 KQ 100 V or more 100 150 Q 3 6 V or more Electric Starter System Starter Motor Commutator Diameter Brush Length 28 mm 1 10 in 10 mm 0 39 in 27 mm 1 06 in 6 5 mm 0 26 in Switches Brake Light Switch Timing ON after 10 mm 0 4 in of pedal travel Special Tools and Sealant Spark Plug Wrench Hex 18 57001 1024 ST5710248T Hook Wrench R37 5 R42 57001 1101 ST5711018ST Flywheel Puller M30 x 1 5 57001 1191 ST571191ST Rotor Puller M16 M18 M20 M22 x 1 5 57001 1216 T5712168T Timing Light 57001 1241 T5712418T ELECTRICAL SYSTEM 16 7 Flywheel Holder 57001 1313 wy ST571313ST Hand Tester 57001 1394 ST5713948T Peak Voltage Adapter 57001 1415 Je ST5714158T Kawasaki Bond Silicone Sealant 56019 120 ST5601208ST 16 8 ELECTRICAL SYSTEM Parts Location Light Dimmer Switch A Engine Stop Switch B Starter Button C Front Brake Light Switch D Neutral Reverse Indicator Lights E Rear Brake Light Switch F Ignition Switch G Igniter A Spark Plu
144. kgf m 58 ft Ib Special Tool Bevel Gear Holder 57001 1618 e Be sure to check and adjust the bevel gear backlash and tooth contact when any of the parts that influence these items are replaced see Output Bevel Gear Adjustment HKOSBOIO y HKOSOO5BS1 Output Bevel Gear Case FINAL DRIVE 11 11 Output Drive Gear Removal e Remove Engine Engine Removal Installation chapter Output Bevel Gear Case see Output Bevel Gear Case Removal Right Engine Cover see Engine Right Side chapter e Shift the transmission into any gear position e Using the gear holder hold the primary and secondary clutch gears to keep them from turning see Engine Right Side chapter Special Tool Gear Holder 57001 1015 e Remove Output Drive Gear Nut A Output Drive Gear B Shim s Output Drive Gear Installation e Install Shim see Output Bevel Gear Adjustment Output Drive Gear e Apply molybdenum disulfide oil to the threads and seating surface of the output drive gear e Tighten Torque Output Drive Gear Nut 118 N m 12 kgf m 87 ft lb Special Tool Gear Holder 57001 1015 Output Bevel Gear Adjustment In order to prevent one gear from moving away from the other gear under load the backlash and tooth contact pattern of the bevel gears must be correct to prevent the gears from making noise and being damaged When replacing any one of the backlash related parts be sure to check and adjust the backlash and tooth
145. l Starter Mounting Bolts 8 8 N m 0 9 kgf m 78 in lb Recoil Starter Disassembly e Remove the recoil starter e Pull the handle A out 100 200 mm 4 0 8 0 in Clamp the rope B in place with locking pliers e Remove the handle cap C e Pry the knot D out of the handle and untie it Pull the handle off the rope e Hold the reel E in one hand while removing the locking pliers with the other e Pull the rope in through the rope hole in the housing and hold it in the notch A in the reel NOTE ODo not let the rope wedge between the reel and the housing e Slowly allow recoil spring tension to unwind the reel e Remove Flange Nut A Friction Plate B A WARNING Be careful that the recoil spring does not fly loose and does not injure you It is under great pressure Turn the reel one quarter turn counterclockwise past the rest position where no tension can be felt Now slowly lift the friction plate straight up out of the housing Recoil Starter RECOIL STARTER 6 5 e Remove Pawl A Pin B Friction Plate Spring C Recoil Guide D Collar E e Remove the reel A noting the following WARNING Be careful that the recoil spring B does not fly loose and does not injure you It is still under great pressure Turn the reel one quarter turn counterclockwise past the rest position where no tension can be felt Now slowly lift the reel straight up out of the housing
146. lable at automotive supply stores for the purpose of checking differential gear tooth patterns and contact Use one of these for checking the bevel gears e Install Pinion Gear Assembly and Shim s e Tighten Torque Propeller Shaft Housing Nuts 25 N m 2 5 kgf m 18 ft lb e Install Ring Gear Assembly and Shim s Ring Gear Cover e Tighten Torque Ring Gear Cover Bolts 25 N m 2 5 kgf m 18 ft lb e Turn the pinion gear for one revolution in the drive and reverse coast direction while creating drag on the ring gear e Remove the ring gear and pinion gear assembly to check the drive pattern and coast pattern of the bevel gear teeth OThe tooth contact patterns of both drive and coast sides should be centrally located between the top and bottom of the tooth The drive pattern can be a little closer to the toe and the coast pattern can be a somewhat longer and closer to the toe x lf the tooth contact pattern is incorrect replace the pinion gear shim s following the examples shown e Then erase the tooth contact patterns and check them again Also check the backlash every time the shim s are replaced Repeat the shim change procedure as nec essary NOTE Olf the backlash is out of the standard range after changing the pinion gear shim s change the ring gear shim s to correct the backlash before checking the tooth contact pattern 11 28 FINAL DRIVE Final Gear Case Correct Tooth Contact Pattern He
147. le wire and hose routing during removal or disassembly so they can be installed or assem bled in the same way It is preferable to mark and record the locations and routing whenever possible Tightening Sequence When installing bolts nuts or screws for which a tightening sequence is given in this Service Manual make sure to follow the sequence When installing a part with several bolts nuts or screws start them all in their holes and tighten them to a snug fit thus ensuring that the part has been installed in its proper location Then tighten them to the specified torque in the tightening sequence and method indicated If tightening sequence instructions are not given tighten them evenly in a cross pattern Conversely to remove a pat first loosen all the bolts nuts or screws that are retaining the part a 1 4 turn before removing them Torque When torque values are given in this Service Manual use them Either too little or too much torque may lead to serious damage Use a good quality reliable torque wrench Force Common sense should dictate how much force is necessary in assembly and disassembly If a part seems especially difficult to remove or install stop and examine what may be causing the problem Whenever tapping is necessary tap lightly using a wooden or plastic faced mallet Use an impact driver for screws particularly for the removing screws held by non permanent locking agent in order to avoid damaging the screw heads E
148. le case and cable before assembly in stallation e Be certain that the return spring A is correctly installed on the throttle lever e Tighten Torque Throttle Lever Bolt 5 9 N m 0 6 kgf m 52 in Ib e Swing the throttle lever so that the carburetor throttle valve is fully open Turn the throttle limiter screw A until it is spaced about 1 mm 0 04 in B away from the throttle lever stop C Tighten the locknut D NOTE ORefer to the Owner s Manual for the function of the throt tle limiter and adjustment procedure of it Operation with an improperly assembled throttle case could result in an unsafe riding condition e Check the throttle lever free play see Throttle Lever Free Play Inspection Throttle Cable Installation e Lubricate the throttle cable before installation e Route the cable correctly according to Appendix chapter A WARNING Operation with an improperly adjusted incorrectly routed or damaged cable could result in an unsafe riding condition e Check the throttle cable see Throttle Lever Free Play In spection Throttle Case Inspection and Lubrication e With the throttle cable disconnected from the throttle lever the lever should move freely and return smoothly by spring Alf the lever is heavy disassemble the throttle case clean and lubricate the throttle case e Examine the lever and case for cracks Replace the case assembly if it is cracked HC040106S
149. ler knowingly to remove or render inoperative any such device or element of design after such sale and delivery to the ultimate purchaser 3 B for any person engaged in the business of repairing servicing selling leasing or trading motor vehicles or motor vehicle engines or who operates a fleet of motor vehicles know ingly to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title follow ing its sale and delivery to the ultimate purchaser NOTE OThe phrase remove or render inoperative any device or element of design has been generally interpreted as follows 1 Tampering does not include the temporary removal or rendering inoperative of de vices or elements of design in order to perform maintenance 2 Tampering could include a Maladjustment of vehicle components such that the emission standards are ex ceeded b Use of replacement parts or accessories which adversely affect the performance or durability of the motorcycle c Addition of components or accessories that result in the vehicle exceeding the stan dards d Permanently removing disconnecting or rendering inoperative any component or element of design of the emission control systems WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING 10 000 PER VIOLATION PLEASE DO NO
150. ll out the main fuse B from the starter relay Fuse Inspection e Inspect the fuse element x lf it is blown out replace the fuse Before replacing a blown fuse always check the amperage in the affected circuit If the amperage is equal to or greater than the fuse rating check the wiring and related components for a short circuit Housing A Fuse Element B Terminals C Blown Element D GP20010181 CAUTION When replacing a fuse be sure the new fuse matches the specified fuse rating for that circuit Installation of a fuse with a higher rating may cause damage to wiring and components 16 48 ELECTRICAL SYSTEM Wiring Diagram U S A and Canada Models uss19 y1eq 9q 93e 090y9 CH PLAZL 9pow epeueg apog 40109 1030 1911878 ZX HLZ 8 AZI 14317 exergy lel gt OD a e ng kam Ka B E 44317 O Ke ko IAs E 19 1e41 sjeujwsaj Jossaooy uong EDD 8S1849H E4IN8N M UC KIA A 9151 ya 14 1a 14 ug 14 y uni om LV 0624371Y ES yoja 34311 94848 IER 4911818 suolIzosuuog YO IMS yorlmg dog aus Bug YOTIAS 1eqge pueH 34e uoring iin yoring 191835 gang demwig eurzuz 434817 Kaes PER U 1 1 1 L 1 l 103244972 y dosuas ECH DEER a 4 97 yg V a9 ao T N EUREN punoag awed Ka hed O ayedg 1 09747y 97 uo de gt M Y IA 8 1
151. locking agent to the threads MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 S Tighten the fasteners following the specified sequence St Stake the fasteners to prevent loosening Torque Fastener kgfm Pe Remarks Fuel Sytem Carburetor Holder Bolts 1 1 95 in lb Throttle Lever Bolt E 0 6 52 in lb Engine Top End Cylinder Head Bolts M10 first torque 13 1 3 113 inlb L 1 MO S Cylinder Head Bolts M10 final torque 34 3 5 25 S Cylinder Head Bolts M6 first torque 5 9 0 6 52 in lb MO S Cylinder Head Bolts M6 final torque 9 8 1 0 87 in lb S Valve Adjusting Cap Bolts 8 8 0 9 78 in lb Retaining Bolt 4 4 0 45 39 in lb Compression Releasing Lever Bolt 8 8 0 9 78 in lb Camshaft Sprocket Bolt 34 3 5 25 MO Rear Camshaft Chain Guide Bolt 9 8 1 0 87 in lb Camshaft Chain Tensioner Mounting Bolts 8 8 0 9 78 in lb Valve Adjusting Screw Locknuts 12 1 2 104 in lb Rocker Shaft Retainer Screws 44 0 45 39 in lb Camshaft Chain Guard Screws 4 4 0 45 39 in lb Engine Right Side Right Engine Cover Bolts 8 8 0 9 78 in lb Clutch Spring Bolts 12 1 2 104 in lb Primary Clutch Hub Nut 127 13 94 MO Secondary Clutch Hub Nut 78 8 0 58 MO Balancer Drive Gear Nut 83 8 5 61 MO Balancer Gear Nut 118 12 87 MO Clutch Adjusting Screw Locknut 11 1 1 95 in lb Recoil Starter Recoil Starter Mounting Bolts 8 8 0 9 78 in lb Recoil Starter Flange Nut 12 1 2 104 in lb Engine Lubric
152. ly Special Tool Outside Circlip Pliers 57001 144 Transmission Shaft Assembly e Replace any circlips that were removed with new ones NOTE OTo install a circlip without damage first fit the circlip onto the shaft and then expand it just enough to install Hence use a suitable gear to push the circlip into place e Install the circlips A so that the opening B is aligned with a spline groove C Shift Drum Disassembly e Remove Shift Drum see Transmission Removal Pin Plate Bolt A Pin Plate B Pins C Operating Plate D Pin E Ball Bearing F Shift Drum G 6113011381 HI10004BS1 9 20 CRANKSHAFT TRANSMISSION Transmission Shift Drum Assembly e Tighten Torque Shift Drum Pin Plate Bolt 12 N m 1 2 kgf m 104 in 1b Shift Fork Bending e Visually inspect the shift forks and replace any fork that is bent A bent fork could cause difficulty in shifting or allow the transmission to jump out of gear when under power A 90 Shift Fork Wear e Measure the thickness A of the shift fork ears and di ameter B of the shift fork guide pin x lf the thickness and or diameter of a shift fork is less than the service limit replace the shift fork Shift Fork Ear Thickness Standard 4 9 5 0 mm 0 193 0 197 in Service Limit 4 8 mm 0 189 in Shift Fork Guide Pin Diameter Standard 5 9 6 0 mm 0 232 0 236 in Service Limit 5 8 mm 0 228 in Shift Dr
153. m 0 596 in Rear Standard 0 669 0 672 in 17 00 17 07 mm Service Limit 17 15 mm 0 675 in x If the cam hole wear is more than the service limit replace the brake panel Brake Shoe Spring Inspection e Visually inspect the brake shoe springs for breaks or dis tortion x lf the springs are damaged in any way replace them BRAKES 12 15 Brake Maintenance Brake Lubrication Whenever the brake is disassembled and in accordance with the Periodic Maintenance Chart perform the following e Clean all old grease out of the brake parts with a cloth NOTE ODo not get any grease on the brake shoe linings and wipe off any excess grease so that it does not get on the linings or drum after brake assembly e Apply high temperature grease A to the following Brake Shoe Anchor Pin Spring Ends Cam Surfaces Brake Cam Groove Brake Pedal Pivot Front and Parking Brake Lever Pivot HL13001BS1 e Fill box with grease Amoco rykon premium grease No 2 EP Green A after cables are installed E HANH 12 16 BRAKES Brake Pedal and Cables Brake Cable Removal e Unscrew the adjusters A at the rear ends of the cables and pull the cables out of the joints B and cable mounts C e Loosen the knurled locknut A at the rear brake lever and screw in the adjuster B e Line up the slots C in the brake lever knurled locknut and adjuster and then free the cable from the lever D e
154. m arm broken Shift drum damaged Jumps out of gear Shift fork s worn Gear groove s worn Gear dogs dog recesses and or dog holes worn Shift drum groove s worn Shift drum positioning lever spring weak or broken Shift fork guide pin s worn Shift mechanism arm spring weak or broken Drive shaft output shaft and or gear splines worn Overshifts Shift drum positioning lever spring weak or broken Shift mechanism arm spring weak or broken Abnormal Engine Noise Knocking Igniter trouble 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 Rocker arm worn Other noise Connecting rod small end clearance exces sive Connecting rod big end clearance exces sive Piston ring worn broken or stuck Piston seizure damage Cylinder head gasket leaking Exhaust pipe leaking at cylinder head con nection Crankshaft runout excessive Engine mounts loose Crankshaft bearing worn Camshaft chain tensioner trouble Camshaft chain sprocket guides worn Balancer bearing worn Balancer gear worn or shipped Loose alternator rotor Abnormal Drive Train Noise Clutch noise Clutch housing and or hub damaged Transmission noise Bearing worn Transmission gears worn or chipped Troubleshooti
155. n 37 2 mm 1 46 in 0 02 0 11 mm 0 0008 0 0043 in 27 000 27 021 mm 1 0630 1 0638 in 26 959 26 980 mm 1 0614 1 0622 in 25 000 25 021 mm 0 9842 0 9851 in 24 970 24 985 mm 0 9831 0 9837 in 116 5 mm 4 587 in 0 5mm 0 02 in 2 6 mm 0 10 in 0 3 mm 0 012 in 0 3 mm 0 012 in 35 7 mm 1 41 in 0 14 mm 0 0055 in 27 03 mm 1 0642 in 26 94 mm 1 0606 in 25 03 mm 0 9854 in 24 95 mm 0 9823 in Special Tools and Sealant Gear Holder m1 75 57001 1015 ST5710158T ENGINE RIGHT SIDE 5 5 Socket Wrench 57001 1354 2 ST5713548T 5 6 ENGINE RIGHT SIDE Engine Right Side Engine Right Side Disassembly e Drain the engine oil see Engine Lubrication System chapter e Remove Footpeg Brake Pedal Oil Filter see Engine Lubrication System chapter Right Engine Cover Bolts A Right Engine Cover B e Using the gear holder A hold the primary gear and sec ondary gear Special Tool Gear Holder 57001 1015 e Remove Primary Clutch Hub Nut B e Remove Ball Bearing A and Pusher B e Using the gear holder C hold the primary gear and sec ondary gear Special Tool Gear Holder 57001 1015 e Remove Secondary Clutch Hub Nut D e Turn the secondary clutch A until the dent B on the sec ondary clutch housing comes against the primary gear and pull out the primary clutch housing C with the hub
156. n e Clean the spark plug preferably in a sandblasting device and then clean off any abrasive particles The plug may also be cleaned using a wire brush or other suitable tool x lf the spark plug electrodes are corroded or damaged or if the insulator is cracked replace the plug Use the standard spark plug or its equivalent Spark Plug Gap Inspection e Measure the gap A with a wire type thickness gauge x lf the gap is incorrect carefully bend the side electrode B with a suitable tool to obtain the correct gap Spark Plug Gap 0 6 0 7 mm 0 024 0 028 in DEER Y AURA DOA SE SC TN Qn PERIODIC MAINTENANCE 2 19 Periodic Maintenance Procedures Brake Light Switch Adjustment e Check the operation of the brake light switch by depress ing the brake pedal A The brake light should go on after about 10 mm 0 4 in of pedal travel B x If it does not adjust the brake light switch A up or down To change the switch position turn the adjusting nut B Brake Light Switch Timing Standard ON after 10 mm 0 4 in of pedal travel CAUTION To avoid damaging the electrical connections in side the switch be sure that the switch body does not turn during adjustment General Lubrication Lubrication e Before lubricating each part clean off any rusty spots with rust remover and wipe off any grease oil dirt or grime e Lubricate the po
157. n the fuel level measured shows some what higher than the actual fuel level If the gauge is lowered too far dump the fuel out of it into a suitable container and start the procedure over again e Read the fuel level in the gauge and compare it to the specification e Tighten the drain plug and remove the fuel level gauge Alf the fuel level is incorrect adjust it see Fuel Level Ad justment Fuel Level Below the bottom edge of the caburetor body Standard 5 1 mm 0 20 0 04 in KLF250 A1 5 8 1 mm 0 22 0 04 in KLF250 A2 Fuel Level Adjustment e Remove the carburetor e Drain the carburetor e Remove the float bowl by taking out the screws e Bend the tang A on the float arm very slightly to change the float height Increasing the float height lowers the fuel level and decreasing the float height raises the fuel level Float Height Standard 22 6 2 mm 0 89 0 04 in HCOGOQ9BS2 C HCO6010BS1 3 12 FUEL SYSTEM Carburetor Float Bowl Mating Surface A Float Valve Needle Rod contacted but unloaded B Float C Float Height D x lf the fuel level cannot be adjusted by this method the float or the float valve is damaged e Assemble the carburetor install it on the vehicle and recheck the fuel level Fuel System Cleanliness Inspection e Refer to the Fuel System Cleanliness Inspection in the Periodic Maintenance chapter Carburetor Removal A WARNING
158. n release mechanism trouble Poor Running at Low Speed Spark weak Spark plug dirty broken or maladjusted Spark plug cap or spark plug lead trouble Spark plug cap shorted or not in good con tact Spark plug incorrect Igniter trouble Crankshaft Sensor trouble Ignition coil trouble Battery voltage low APPENDIX 17 13 Troubleshooting Guide Fuel air mixture incorrect Fuel tank air vent obstructed Pilot screw and or idle adjusting screw mal adjusted Pilot jet or air passage clogged Starter plunger stuck open Air cleaner clogged poorly sealed or miss ing Fuel level too high or too low Fuel tank air vent obstructed Carburetor holder loose Air cleaner duct loose Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Compression release mechanism trouble Other Carburetor throttle valve doesn t slide smoothly Engine oil viscosity too high Brake dragging Igniter trouble Final gear case oil level too high Final gear case oil viscosity too high Fuel tap clogged Fuel line clogged Compression low Spark plug loose Cylinder head not sufficiently tightened down No val
159. n the camshaft and out from under the chain Camshaft Sprocket Installation e Remove Timing Inspection Plug A Special Tool Filler Cap Driver B 57001 1454 e Check to see that the T mark A on the alternator rotor aligns with the slot B x If the T mark is not aligned hold the camshaft chain taut and turn the crankshaft with a wrench on the alternator rotor bolt Camshaft Sprocket ENGINE TOP END 4 13 e Fit the sprocket under the chain and slip it over the shoul der on the camshaft so that the tab on the sprocket fits the hole in the end of the camshaft and the punch mark A on the sprocket aligns with the pointer B on the cylinder head e Apply molybdenum disulfide oil to the threads of the camshaft sprocket bolt e Tighten the camshaft sprocket bolt while holding the crankshaft from turning with a wrench on the alternator rotor bolt Torque Camshaft Sprocket Bolt 34 N m 3 5 kgf m 25 ft lb e Install the camshaft chain tensioner see Camshaft Chain Tensioner Installation e Before going any further check the cam timing OTurn the crankshaft counterclockwise with a wrench on the alternator rotor bolt until the punch mark on the sprocket realigns with the pointer on the head CAUTION If any resistance is felt when turning the crankshaft stop immediately or you may bend the valves OThe T mark on the alternator rotor should align with the slot Alf the camshaft
160. nal Gear Case e Unscrew the ring gear cover bolts A and pull off the cover B The shim s comes off with the cover Pry Points C e Take the ring gear assembly A out of the case Final Gear Case Assembly CAUTION Be careful not to scratch the sealing surfaces A of the final gear case and case cover during the bear ing removal and installation A scratched sealing surface may allow oil to leak e Check Oil Seal see Oil Seal Inspection Ball Bearings see Bearing Inspection e Visually check the bevel gears for scoring chipping or other damage Replace the bevel gears as a set if either gear is damaged since they are lapped as a set in the factory to get the best tooth contact OBe sure to check and adjust the bevel gear backlash and tooth contact when any of the backlash related parts are replaced see Final Bevel Gear Adjustment e Install Ring Gear Assembly e Apply a non permanent locking agent to the ring gear cover bolts and tighten them Torque Ring Gear Cover Bolts 25 N m 2 5 kgf m 18 ft lb e Install Shim s see Final Bevel Gear Adjustment Pinion Gear Assembly FINAL DRIVE 11 25 Final Gear Case Final Bevel Gear Adjustment OThe backlash and tooth contact pattern of the bevel gears must be correct to prevent the gears from making noise and being damaged e After replacing any of the backlash related parts be sure to check and adjust the backlash and tooth contact of the b
161. ncer Gear Nut 118 N m 12 kgf m 87 ft lb e Tighten Torque Balancer Drive Gear Nut 83 N m 8 5 kgf m 61 ft Ib Special Tool Socket Wrench 57001 1354 e Bend a tab C of the toothed washer into the slot in the nut e Apply molybdenum disulfide oil to the drive shaft and crankshaft e Install Thinner Spacer A 20 2 x 36 x 2 Collar B and Clutch Housing C OApply engine oil to the outer surface of collar e Install Thicker Spacer D 20 2 x 35 x 4 e Install Clutch Operating Plate A Friction Plate B Steel Plate C Clutch Hub D Spring E Spring Holder F Clutch Spring Bolts G e Tighten Torque Clutch Spring Bolts 12 N m 1 2 kgf m 104 in Ib CAUTION If new dry steel plates and friction plates are in stalled apply engine oil to the surfaces of the each plate to avoid clutch plate seizure e There should be a gap A between the clutch wheel and housing e Apply molybdenum disulfide oil to the secondary clutch hub nut and tighten it lightly HROGOOOBS1 HRO6001BS1 ENGINE RIGHT SIDE 5 9 Engine Right Side e Fit the projection A on the cage into the groove B on the housing first and then install the one way clutch C completely e Install Spacer A 28 1 x 34 x 1 0 Primary Clutch Housing B OTurn the secondary clutch until the dent on the secondary clutch housing comes against the crankshaft and install the prim
162. nd dowel pin B on the crankcase e Tighten Torque Oil Pump Screws 4 4 N m 0 45 kgf m 39 in Ib A L 30 mm 1 18 in B L 20 mm 0 79 in 7 10 ENGINE LUBRICATION SYSTEM Oil Pipe Oil Pipe Removal e Remove Oil Pipe Banjo Bolt A and Washers e Remove Oil Pipe Banjo Bolts A and Washers Starter Motor Mounting Bolt B Oil Pipes C Oil Pipe Installation e Tighten Torque Oil Pipe Banjo Bolts 15 N m 1 5 kgf m 11 ft lb Starter Motor Mounting Bolt 8 8 N m 0 9 kgf m 78 in lb ENGINE REMOVAL INSTALLATION 8 1 Engine Removal Installation Table of Contents Exploded EE 8 2 Engine Removal lnstallation EE 8 4 Engine ROMO ua ii A id AA A A N e dt 8 4 Enga e EE 8 5 8 2 ENGINE REMOVAL INSTALLATION Exploded View ENGINE REMOVAL INSTALLATION 8 3 Exploded View No Fastener Remarks N m 39 29 1 2 Engine Mounting Nuts M10 3 Engine Mounting Nut M8 8 4 ENGINE REMOVAL INSTALLATION Engine Removal Installation Engine Removal e Remove Engine Oil drain Fuel Tank see Fuel System chapter Rear Fender and Front Fender see Frame chapter Muffler and Exhaust Pipe see Engine Top End chapter Carburetor see Fuel System chapter Reverse Lever and Cable see Crankshaft Transmission chapter Spark Plug Cap Alternator Lead Connector A Crankshaft Sensor Lead Connector B Neutral Reverse Switch Lead Connectors C e Remove Ground
163. ndition of the ignition coil B e Connect the ignition coil with the spark plug cap left at tached at the end of the spark plug lead to the tester in the manner prescribed by the manufacturer and measure the arcing distance Ignition Coil Arcing Distance 7 mm 0 28 in or more A WARNING To avoid extremely high voltage shocks do not touch the ignition coil body or leads x If the distance reading is less than the specified value the ignition coil or spark plug cap is defective e To determine which part is defective measure the arcing distance again with the spark plug cap removed from the ignition coil lead ORemove the cap by turning it counterclockwise x lf the arcing distance is subnormal as before the trouble is with the ignition coil itself If the arcing distance is now normal the trouble is with the spark plug cap x If the coil tester is not available the coil can be checked for a broken or badly shorted winding with the hand tester Special Tool Hand Tester 57001 1394 NOTE OThe hand tester cannot detect layer shorts and shorts resulting from insulation breakdown under high voltage HP10008BS2 C 16 28 ELECTRICAL SYSTEM Ignition System e Measure the primary winding resistance A as follows OConnect the tester between the coil terminals OSet the tester to the x 1 Q range and read the tester e Measure the secondary winding resistance B as follow
164. ng Guide Metal chips jammed in gear teeth Engine oil insufficient or too thin Drive train noise Insufficient lubricant Bevel gear bearings worn Bevel gears worn or chipped Bevel gears maladjusted Propeller shaft bearing worn Front bevel gear cam damper damage Abnormal Frame Noise Shock absorber noise Shock absorber damaged Brake noise Brake linings overworn or worn unevenly Drum worn unevenly or scored Brake spring weak or broken Foreign matter in hub Brake not properly adjusted Other noise Bracket nut bolt etc mounted or tightened Exhaust Smokes Excessively White smoke Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Cylinder head gasket damaged Engine oil level to high Black Smoke Air cleaner clogged Main jet too large or fallen off Starter plunger stuck open Fuel level too high Brown smoke Main jet too small Fuel level too low Air cleaner duct loose Air cleaner poorly sealed or missing Handling and or Stability Unsatisfactory Handlebar hard to turn Tire air pressure too low Steering stem bearing damaged Steering stem bearing lubrication inade quate Steering stem bent not properly APPENDIX 17 15 Damage tie rod end Handlebar shakes or excessively vibrates Tire worn Wheel rim warped Rear axle runout excessive Wheel bearing worn Handlebar clamp loose Steering stem clamp bolt loose Handlebar pulls to one side Frame bent Wheel maladjustment Suspension arm be
165. ning condition The initial maintenance is vitally important and must not be neglected General lubrication FREQUENCY Greg Regular Service After 10 Every 10 Every 30 Every 90 hrs or days or days or days or Every OPERATION 100 km 200 km 600 km 1 700 km year of 60 mi 120 mi 360 mi 1 100 mi use of use of use of use of use ENGINE Air cleaner service e e Throttle lever play inspect o Valve clearance inspect e Fuel system cleanliness inspect NE e Engine oil change e Oil filter replace e Clutch adjustment Spark plug clean and gap e Spark arrester clean me E a Fuel hoses and connections inspect e CHASSIS Joint boots inspect Rear brake pedal and lever adjustment inspect Cables adjustment Bolts and nuts tighten Brake wear inspect Brake light switch inspect Battery inspect Steering inspect e Tire wear inspect Final gear case oil change EAS A Service more frequently when operated in mud dust or other harsh riding conditions e Clean adjust lubricate torque or replace parts as necessary PERIODIC MAINTENANCE 2 3 Torque and Locking Agent The following tables list the tightening torque for the major fasteners and the parts requiring use of a non permanent locking agent or liquid gasket Letters used in the Remarks column mean L Apply a non permanent
166. nnecting rod side clearance is within specification see Connecting Rod Big End Side Clearance OMake sure oil passages of the crank and crankpin are lined up during assembly e Check that the connecting rod radial clearance is within specification see Connecting Rod Big End Radial Clear ance e Adjust crankshaft runout until runout is within specification see Crankshaft Runout 9 12 CRANKSHAFT TRANSMISSION Crankshaft Balancer Shaft and Connection Rod View A A H105011B 3 Crankpin Needle Bearing Ball Bearing Camshaft Chain Sprocket Nozzle Center of Crankpin 6 47 30 Connecting Rod Big End Seizure e In the case of serious seizure with damage to the crank halves the crankshaft must be replaced x lf the seizure was less severe disassemble the crank shaft and replace the crankpin needle bearing and con necting rod see Crankshaft Disassembly NOOR ND A CRANKSHAFT TRANSMISSION 9 13 Crankshaft Balancer Shaft and Connection Rod Connecting Rod Big End Radial Clearance e Set the crankshaft on V blocks and place a dial gauge A against the connecting rod big end e Push B the connecting rod first towards the gauge and then in the opposite direction The difference between the two gauge readings is the radial clearance x If the radial clearance exceeds the service limit the crank shaft assembly must be replaced or disassembled and the crankpin needle b
167. non permanent locking agent 12 4 BRAKES Specifications Item Standard Service Limit Brake Adjustment Front Brake Lever Free play Rear Parking Brake Lever Free Play Brake Pedal Free Play Brake Drum and Panel Brake Drum Inside Diameter Front Rear Brake Shoe Lining Thickness Brake Cam Diameter Front Rear Brake Cam Hole Diameter Front Rear Brake Cam Lever Angle 1 2 mm 0 04 0 08 in 2 3 mm 0 08 0 12 in 25 35 mm 1 0 1 4 in 140 000 140 160 mm 5 512 5 518 in 160 000 160 160 mm 6 299 6 305 in 4 0 mm 0 16 in 14 957 14 984 mm 0 589 0 590 in 16 957 16 984 mm 0 668 0 669 in 15 00 15 06 mm 0 591 0 593 in 17 00 17 07 mm 0 669 0 672 in 80 90 140 75 mm 5 541 in 160 65 mm 6 325 in 2 0 mm 0 08 in 14 88 mm 0 586 in 16 88 mm 0 665 in 15 15 mm 0 596 in 17 15 mm 0 675 in Brake Adjustment BRAKES 12 5 Front Brake Adjustment e Refer to the Front Brake Adjustment in the Periodic Main tenance chapter Brake Pedal Position Inspection e Measure from the top center of the brake pedal A in its rest position to the upper surface of the right footpeg B The brake pedal should be level C with the upper surface of the right footpeg Brake Pedal Position 0 mm 0 in Brake Pedal Position Adjustment e To adjust the pedal position loosen the locknut A turn the adjusting
168. nspection Crankshaft Sensor see Crankshaft Sensor Inspection If the ignition coil and crankshaft sensor are normal see the Ignition System Troubleshooting chart on page 16 34 HP10009BS1 HP10017BS1 Ignition System ELECTRICAL SYSTEM 16 29 Crankshaft Sensor Removal e Remove Alternator Cover see Alternator Cover Removal Lead Connector A e Remove Crankshaft Sensor Screws A Crankshaft Sensor B and Spacer Crankshaft Sensor Inspection e Disconnect the Crankshaft Sensor lead connector A e Measure the Crankshaft Sensor resistance OConnect the hand tester between the BK lead and the BL lead Special Tool Hand Tester 57001 1394 OSet the tester to the x 10 Q range and read the tester Crankshaft Sensor Resistance 100 150 Q x If the tester does not read as specified replace the Crank shaft Sensor 16 30 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Peak Voltage Inspection NOTE OBe sure the battery is fully charged e Remove the spark plug cap but do not remove the spark plug e Disconnect Crankshaft Sensor Wire Connector A e Set the hand tester B to the 10 V DC range e Connect the peak voltage adapter C to the hand tester and crankshaft sensor leads in the connector Special Tool Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Connections Crankshaft Sensor Connector Adapter Hand
169. nstall the following parts to the brake panel B O ring C Brake Cam e Install O ring A Indicator B BRAKES 12 9 Brake Drum and Panel e Fit the brake cam lever A so that the marks align B e Install Cam Lever Bolt and Nut Brake Shoes e Install Brake Panel Assembly e Apply a non permanent locking agent to the brake panel bolts and tighten them Torque Front Brake Panel Bolts 25 N m 2 5 kgf m 18 ft lb e Install Collar A Ball Bearings B Oil Seal C Collar D e Apply grease Amoco rykon premium grease No 2 EP Green to the seal lips in the drum and install the brake drum e Tighten Torque Front Axle Nuts 34 N m 3 5 kgf m 25 ft lb HL14001BS1 e Insert a new cotter pin A NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle shaft tighten the nut clockwise B up to next alignment Olt should be within 30 degree OLoosen once and tighten again when the slot goes past the nearest hole HJO7007BS1 e Bend the cotter pin A over the nut B HJO7008BS1 12 10 BRAKES Brake Drum and Panel Rear Brake Panel Removal Disassembly WARNING Brake linings contain asbestos fiber Inhalation of asbestos may cause serious scarring of the lungs and may promote other internal injury and illness including cancer Observe the following precau tions when handling brake linings
170. nt or twisted Steering stem bent Front or rear tire air pressure unbalanced Front shock absorber unbalanced Shock absorption unsatisfactory Too hard Tire air pressure too high Shock absorber maladjusted Too soft Shock absorber oil leaking Shock absorber spring weak Tire air pressure too low Shock absorber maladjusted Brake Doesn t Hold Brake not properly adjusted Linings overworn or worn unevenly Drum worn unevenly or scored Cam camshaft shaft hole worn Oil grease on lining and drum Dirt water between lining and drum Overheated Battery Discharged Battery faulty e g plates sulphated shorted through sedimentation elec trolyte level too low Battery leads making poor contact Load excessive e g bulb of excessive wattage Ignition switch trouble Regulator rectifier trouble Alternator trouble Wiring faulty Battery Overcharged Regulator rectifier trouble Battery trouble MODEL APPLICATION Year Model Beginning Frame No 2003 KLF250A1 JKALF250AAB600001 nn nmn BE nn nmn E nn wm BEST O This digit in the frame number changes from one machine to another WE Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Consumer Products amp Machinery Company Part No 99924 1284 04 Printed in Japan
171. ock CAUTION Do not disconnect the battery leads or any other electrical connections when the ignition switch is on or while the engine is running This is to prevent igniter damage Do not install the battery backwards The negative side is grounded This is to prevent damage to the diodes and igniter Use the standard regulator rec tifier or the igniter will be damaged Spark Plug Removal Installation e Remove the spark plug cap A e Remove or install the spark plug using the spark plug wrench from the vehicle right side Special Tool Spark Plug Wrench Hex 18 57001 1024 Torque Spark Plug 14 N m 1 4 kgf m 10 ft lb e Fit the plug cap securely e Pull up the spark plug cap lightly to make sure of the in stallation of the spark plug cap Spark Plug Cleaning Inspection e Refer to the Spark Plug Cleaning Inspection in the Peri odic maintenance chapter Spark Plug Gap Inspection e Refer to the Spark Plug Gap Insepction in the Periodic Maintenance chapter Ignition Coil Removal e Remove Spark Plug Cap A Bolt B Primary Lead Connectors C Ignition Coil D Ignition System ELECTRICAL SYSTEM 16 27 Ignition Coil Installation e Connect the primary winding leads to the ignition coil ter minals as shown G W Lead Mark A BK Y Lead Mark Ignition Coil Inspection e Remove the ignition coil e Measure the arcing distance with a coil tester A to check the co
172. ollow safe operating and maintenance practices A WARNING This warning symbol identifies special instructions or procedures which if not correctly followed could result in per sonal injury or loss of life CAUTION This caution symbol identifies special instructions or procedures which if not strictly observed could result in dam age to or destruction of equipment This manual contains four more symbols in addition to WARNING and CAUTION which will help you distinguish different types of informa tion NOTE OThis note symbol indicates points of par ticular interest for more efficient and con venient operation e Indicates a procedural step or work to be done Olndicates a procedural sub step or how to do the work of the procedural step it follows It also precedes the text of a NOTE x Indicates a conditional step or what action to take based on the results of the test or inspec tion in the procedural step or sub step it fol lows In most chapters an exploded view illustration of the system components follows the Table of Contents In these illustrations you will find the instructions indicating which parts require spec ified tightening torque oil grease or a locking agent during assembly GENERAL INFORMATION 1 1 General Information Table of Contents Belore SEMVICING EE TEE 1 2 Model Identification 1 5 ELE EE Re e e Le ET 1 6 Unit Conversion Table sien name dirait 1
173. olution Fastener N m Torque kgf m 26 2 7 147 15 ftlb Remarks 10 4 WHEELS TIRES Specifications Item Standard Service Limit Wheels Rims Rim Size Front Rear 9 x 6 0 10 x 8 5 Wheel Alignment Toe in of Front Wheels Tires Standard Tire Front Rear Tire Air Pressure when cold Front Rear Maximum Tire Air Pressure to seat beads when cold Tire Tread Depth Front Rear 15 35 mm 0 59 1 38 in at 1G AT21x8 9 DUNLOP KT856 Tubeless AT22x10 10 DUNLOP KT857 Tubeless 21 kPa 0 21 kgf cm 3 0 psi 21 kPa 0 21 kgf cm 3 0 psi 250 kPa 2 5 kgf cm 36 psi 4 mm 0 16 in 4 mm 0 16 in WHEELS TIRES 10 5 Special Tool and Sealant Jack 57001 1238 o e a E Ei N ba e gt Di 10 6 WHEELS TIRES Wheel Alignment Toe in is the amount that the front wheels are closer to gether in front than at the rear at the axle height When there is toe in the distance A Rear is the greater than B Front as shown The purpose of toe in is to prevent the front wheels from getting out of parallel at any time and to prevent any slip ping or scuffing action between the tires and the ground If toe in is incorrect the front wheels will be dragged along the ground scuffing and wearing the tread knobs Caster and camber are build in and require no adjust ment A Rear B Front Amount of Toe in Distanc
174. on External Shift Mechanism Inspection e Examine the shift mechanism for any damage e Check the shift mechanism shaft A springs B and shift mechanism arm C Alf the shaft is bent straighten or replace it If the spline D is damaged replace the shaft Alf the springs are damaged in any way replace them x lf the shift mechanism arm is damaged in any way re place the lever e Check the cam area A and ball assembly B x lf the cam area is damaged or if the ball assembly is worn visibly replace the damaged part Reverse Knob Free Play Adjustment e Check the reverse knob free play A when the transmis sion is in neutral Reverse Knob Free Play Standard 2 3 mm 0 08 0 12 in B Reverse Knob x lf the free play incorrect loosen the locknuts A and turn them until the reverse knob has the proper amount of play Reverse Shift Mechanism Removal e Drain the engine oil see Engine Lubrication System chapter e Remove Reverse Lever Bolt A Reverse Lever B e Remove the engine see Engine Removal Installation chapter 9 18 CRANKSHAFT TRANSMISSION Transmission e Remove Front Bevel Gear Case see Final Drive chapter Screws A Neutral Reverse Switch B e Remove Shift Drum Stopper A Dowel Pin B Shift Drum Stop Lever C Reverse Shift Mechanism Installation e Be sure the dowel pin A and contact pin B are in place OPush the contact pin in the shift drum stopper C an
175. on 13 6 SUSPENSION GE ege iii A A A Eta dant ey 13 6 Suspension Arm INSPECTION ccccccececeeccaeceaeeececeececeeeeeeecaeceaeceaeccaeseaeceeeecaeeeeeeeaeenaeesas 13 7 Front Suspension Arm Lubrication ss 13 7 13 2 SUSPENSION Exploded View SUSPENSION 13 3 Exploded View Torque No Fast Remarks S da Nm kgfm felb Front Suspension Arm Pivot Bolts 88 2 Rear Suspension Arm Pivot Bolts and Nuts 34 3 5 25 3 Shock Absorber Mounting Bolts and Nuts 34 3 5 25 4 Steering Knuckle Pivot Nuts 39 4 0 29 G Apply grease for oil seal and O ring 13 4 SUSPENSION Shock Absorbers Shock Absorber Removal e Remove n Front Wheels see Wheels Tires chapter Shock Absorber Mounting Bolts A and Nuts Front Shock Absorber B br H LL d RN e Remove Rear Wheels see Wheels Tires chapter Shock Absorber Mounting Bolts A and Nuts Rear Shock Absorber B Rear Shock Absorber Installation e Install Front Shock Absorber Rear Shock Absorber Shock Absorber Mounting Bolts and Nuts Olnstall the shock absorber so that the closed coil end of the spring faces upward e Tighten Torque Shock Absorber Mounting Bolts and Nuts 34 N m 3 5 kgf m 25 ft lb Rear Shock Absorber Inspection Since the shock absorbers are sealed units which cannot be disassembled only external checks are necessary x If one unit is damaged replace both shock a
176. oosen the locknut B and unscrews the tie rod end C NOTE OThe locknut on the opposite end of the tie rod from the flattened area has left hand threads Turn the wrench clockwise for loosening CAUTION Do not remove the grease seal It is packed with grease HNO4012BS1 HNO4010281 14 8 STEERING Steering Tie rod End Installation e Inspect the tie rod end see Tie rod End Inspection e Install the tie rod ends so that the tie rod has the correct length A and the both visible thread length B make equal Tie rod Length Standard 288 mm 11 3 in e Tighten Torque Tie rod Adjusting Sleeve Locknuts 26 N m 2 7 kgf m 20 ft lb HJ04003B S Steering Maintenance STEERING 14 9 Steering Inspection e Refer to the Steering Inspection in the Periodic Mainte nance chapter Steering Stem Warp e Remove the steering stem see Steering Stem Removal e Check the steering stem for straightness OUse a straightedge along the stem x If the steering stem is bent replace the steering stem Steering Lubrication e Lubricate the steering stem clamps ORemove the steering stem see Steering Stem Removal OWipe all the old grease off the steering stem and clamps and out of the grease seals OApply Amoco Rykon Premium Grease No 2 EP Green to the steering stem A grease seal lips and mating sur face B of the clamp and pack the grooves C in the clamp with gr
177. or Stator D Alternator Stator Installation e Clean the contact surfaces A on the alternator stator core and the left engine cover e Apply silicone sealant to the circumference of the stator coil lead grommet and fit the grommet into the notch of the cover securely Sealant Kawasaki Bond Silicone Sealant 56019 120 Charging System ELECTRICAL SYSTEM 16 21 Regulator Rectifier Output Voltage Inspection e Remove the seat see Frame chapter e Check the battery condition see Battery section e Warm up the engine to obtain actual alternator operating conditions e Check that the ignition switch is turned off and connect a hand tester to the battery terminals Special Tool Hand Tester 57001 1394 Regulator Rectifier Output Voltage Tester Connections Reading Range Tester Tester 4 000 r min to to rpm 25 V DC Battery Battery 14 15 V e Start the engine and note the voltage readings at various engine speeds with the headlight turned on and then off OThe readings should show nearly battery voltage when the engine speed is low and as the engine speed in creases the readings should also increase e Turn off the ignition switch and disconnect the hand tester x If the regulator rectifier output voltage is between the val ues given in the table the charging system is working nor mally x If the output voltage is much higher than the values spec ified in the tabl
178. outside diameter of seat area to spec 32 Grind Tool 32 Cutter Purpose reduce outside diameter of seat area to spec Measure Seating Width Tool Venire Caliper Purpose check seat width against spec Results Too narrow 45 Grind Tool 45 Cutter Purpose increase width of seat area beyond spec to increase outside diameter C Machinists dye on seat 60 Grind Tool 60 Cutter Purpose reduce seat width to spec Lap Valve Tools Valve lapper grinding FINISHED compound Purpose perfectly match valve and seat are check valve head for damage GE15020B F Cylinder and Piston ENGINE TOP END 4 31 Cylinder Removal e Remove Cylinder Head see Cylinder Head Removal Front Chain Guide A e Lift off the cylinder B and remove the cylinder base gas ket If necessary tap lightly around the base of the cylin der with a plastic mallet taking care not to damage the cylinder Olmmediately stuff a clean cloth around the piston to pre vent parts or dirt from falling into the crankcase Cylinder Installation NOTE Olf a new cylinder is installed be sure to check pis ton cylinder clearance see Piston Cylinder Clearance e Clean any remains of the old cylinder base gasket from the bottom of the cylinder and the top of the crankcase e Install Dowel Pins A New Cylinder Base Gasket B e The arrow on the piston he
179. parallel to groove surfaces If not replace the piston and all the piston rings e With the piston rings in their grooves make several mea surements with a thickness gauge A to determine piston ring groove clearance Piston Ring Groove Clearance Standard Service Limit Top 0 02 0 06 mm 0 16 mm 0 0008 0 0024 in 0 0063 in Second 0 02 0 06 mm 0 16 mm 0 0008 0 0024 in 0 0063 in x If the piston ring groove clearance is greater than the ser vice limit measure the ring thickness and groove width as follows to decide whether to replace the rings the piston or both Piston Ring Groove Width e Measure the piston ring groove width OUse a vernier caliper at several points around the piston Piston Ring Groove Width Standard Service Limit Top 0 81 0 83 mm 0 91 mm 0 0319 0 0327 in 0 0358 in Second 1 21 1 23 mm 1 31 mm 0 0476 0 0484 in 0 0516 in Oil 2 51 2 53 mm 2 61 mm 0 0988 0 0996 in 0 1028 in x If the width of any of the two grooves is wider than the service limit at any point replace the piston GE1602088S1 ENGINE TOP END 4 35 Cylinder and Piston Piston Ring Thickness e Measure the piston ring thickness OUse a micrometer to measure at several points around the ring Piston Ring Thickness Standard Service Limit Top 0 77 0 79 mm 0 70 mm 0 0303 0 0311 in 0 028 in Second 1 17 1 19 mm 1 10 mm 0 0461 0 0469 in 0 043 in
180. pe crankcase emission control system is used to eliminate blow by gases The blow by gases are led to the breather chamber through the crankcase Then it is led to the air cleaner Oil is separated from the gases while passing through the inside of the breather chamber from the crankcase and then returned back to the bottom of crankcase 2 Exhaust Emission Control System The exhaust emission control system applied to this engine family is engine modifications that consist of a modified carburetor and an ignition system having optimum ignition timing character istics The carburetor has been calibrated to provide lean air fuel mixture characteristics and optimum fuel economy with a suitable air cleaner and exhaust system A maintenance free ignition system provides the most favorable ignition timing and helps main tain a thorough combustion process within the engine which contributes to a reduction of exhaust pollutants entering the atomosphere The Clean Air Act which is the Federal law covering motor vehicle pollution contains what is commonly referred to as the Act s tampering provisions Sec 203 a The following acts and the causing thereof are prohibited 3 A for any person to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to its sale and delivery to the ultimate purchaser or for any manufacturer or dea
181. pin the bearing by hand to check its condition x If the bearing is noisy does not spin smoothly or has any rough spots replace the propeller shaft Propeller Shaft FINAL DRIVE 11 19 Propeller Shaft Joint and Pinion Gear Joint Inspection e Visually inspect the splines of both the propeller shaft slid ing joint A and the pinion gear joint B Alf they are badly worn or chipped replace the part with a new one Propeller Shaft Joint Boot Inspection e Refer to the Propeller Shaft Joint Boot Inspection in the Periodic Maintenance chapter 11 20 FINAL DRIVE Rear Axle Rear Axle Removal e Drain the rear final gear case oil see Final Gear Case Oil Change e Remove Rear Wheels see Wheels Tires chapter Rear Hub Brake Drum and Brake Panel see Brakes chapter Center Arm see Suspension chapter e Support the final gear case on a stand or jack e Remove Rear Suspension Arms see Suspension chapter Rear Shock Absorber Lower Bolts Collar A O ring B e Remove Left Axle Shaft Pipe Bolts A Left Axle Shaft Pipe B and Left Rear Axle C e Cut away the sealant between the axle shaft pipe and final gear case e Remove Right Axle Shaft Pipe Bolts A Right Axle Shaft Pipe B and Right Rear Axle C e Cut away the sealant between the axle shaft pipe and final gear case Rear Axle Installation e Apply molybdenum disulfide grease to the oil seal lips in the axle shaft pipes OApply liquid gasket to the m
182. ply fresh grease or oil Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended 16 Direction of Engine Rotation To rotate the crankshaft manually make sure to do so in the direction of positive rotation Pos itive rotation is counterclockwise as viewed from the left side of the engine To carry out proper adjustment it is furthermore necessary to rotate the engine in the direction of positive rotation as well 17 Replacement Parts When there is a replacement instruction replace these parts with new ones every time they are removed Replacement parts will be damaged or lose their original function once they are removed There fore always replace these parts with new ones every time they are removed Although the pre viously mentioned gasket O ring ball bearing needle bearing grease seal oil seal circlip and cotter pin have not been so designated in their respective text they are replacement parts 18 Electrical Wires All the electrical wires are either one color or two color A two color wire is identified first by the primary color and then the stripe color For example a yellow wire with thin red stripes is referred to as a yellow red wire it would be a red yellow wire if the colors were reversed Unless in structed otherwise electrical wires must be connected to wires of the same color 1 4 GENERAL INFORMATION
183. r Removal e Loosen the muffler clamp bolt A until the clamp turns freely on the muffler e Take out the muffler mounting bolts B e Remove the muffler C from the rear of the frame Exhaust Pipe Removal e Remove Muffler see Muffler Removal Exhaust Pipe Holder Nuts A both sides e Take off the exhaust pipe B work them out of the frame and remove the exhaust pipe assembly e Remove the exhaust pipe gaskets from the cylinder head Exhaust System ENGINE TOP END 4 37 Exhaust Pipe Installation e Replace the new exhaust pipe gasket A and stick it into the exhaust port in the cylinder head e Slip the exhaust pipe holder B over the exhaust pipe e Attach the exhaust pipe loosely to the cylinder head OTape the split collars C in place OPosition the exhaust pipe in the exhaust port OSlide the holder into place on the studs OThread on the nuts D but do not tighten them yet e Fit the gasket E into the muffler so that the chamfered side of the gasket faces to the front e Put the muffler clamp F over the muffler OFace the head of the clamp bolt downward and outward e Slip the muffler into place from the rear of the frame so that it fits over the exhaust pipe e Hold the muffler and install the mounting bolts G but do not tighten them yet e Tighten the exhaust pipe holder nuts evenly and securely e Tighten the muffler mounting bolts securely e Tighten the muffler clamp bolt securely
184. r change or other damage Alf there is any doubt as to the condition of a needle bear ing replace it Oil Seal Inspection e Inspect the oil seals Replace it if the lips are misshapen discolored indicating that the rubber has deteriorated hardened or otherwise damaged 6114060581 6114010181 WHEELS TIRES 10 1 Wheels Tires Table of Contents EXploded ET 10 2 Specifications EE 10 4 Special Tool and Sealant ss 10 5 Wheel Alignment sirieni tie nn en nette EKE 10 6 steering Centering Inspection semaine mar maintenue 10 6 Steering Centering Adjustment er 10 6 Toen Inspection EE 10 7 Be Cl RE TEE 10 8 WV GIS FRIIS EE 10 9 Wheel REMOVAL ito dio test es nt 10 9 Rear aU ese a Or mr RV RE YP oI E PNY eS PP 10 13 Rear eft Aub REMOVAl oie sheik EENS O ae 10 13 Rear Left Hub Installation oooocccncccncccncnnncnnncnonononcnoncnononnncnnncnnnconcnnnrnn cnn ncnnnrnnncnnncnnn 10 13 Rear Left Hub Disassembly Assembly ss 10 13 10 2 WHEELS TIRES Exploded View Exploded View WHEELS TIRES 10 3 No Wheel Nuts 34 3 5 Front Axle Nuts 34 3 5 Tie rod End Nuts 41 4 2 Tie rod Adjusting Sleeve Locknuts Rear Axle Nuts R Replacement Parts S Follow the specific tightening sequence W Apply water or soap and water s
185. r of highly flammable liquids do not use gasoline or low flash point solvents e Visually inspect the bypass valve parts x If the spring is bent or distorted replace it If the piston is worn replace all of the bypass valve parts Oil Screen Removal e Remove the right engine cover see Engine Right Side Disassembly section in Engine Right Side chapter e Pull the oil screen A out of the crankcase Oil Screen Installation e Clean the oil screen A thoroughly whenever it is removed for any reason e Clean the oil screen with a high flash point solvent and remove any particles stuck to it WARNING Clean the screen in a well ventilated area and take care that there is no spark or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents NOTE OWhile cleaning the screen check for any metal particles that might indicate internal engine damage e Check the screen carefully for any damage holes broken wires gasket pulling off Alf the screen is damaged replace it 7 8 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Oil Pressure Relief Valve Removal e See Crankcase Disassembly see Crankshaft Transmis sion Chapter e Remove the oil pressure relief valve A Oil Pressure Relief Valve Installation e See Crankcase Assembly See Crankshaft Transmission Chapter OApply a non permanent locking agent to the
186. rate at 1 10 the battery capacity and charge it for 10 hours For example if the battery is rated at 14 Ah 11 Ah U S model the charging rate would be 1 4 Ah 1 1 Ah U S model CAUTION If the battery is not given a full initial charging it will discharge in a few weeks After that it can not be charged by supplemental charging Always remove the battery from the vehicle for charging If the battery is charged while still in stalled battery electrolyte may spill and corrode the frame or other parts of the vehicle Do not use a high rate battery charger as is typi cally employed at automotive service stations un less the charger rate can be reduced to the level re quired Charging the battery at a rate higher than specified may ruin the battery Charging at a high rate causes excess heat which can warp the plates and cause internal shorting Higher than normal charging rates also cause the plates to shed active material Deposits will accumulate and can cause internal shorting If the temperature of the electrolyte rises above 45 C 113 F during charging reduce the charging rate to lower the temperature and increase charging time proportionately e Turn the charger off then disconnect it from the battery e Check Electrolyte Level see Electrolyte Level Inspection Battery Voltage OBattery voltage should be 12 6 V or more 16 14 ELECTRICAL SYSTEM Battery Ordinary Charging e Remove the battery see Ba
187. rburetor Loosen the locknut B and turn the throttle cable lower adjuster C to obtain the specified free play Tighten the locknut and reinstall the rubber cover 2 8 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System Cleanliness Inspection A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Turn the fuel tap to the OFF position e Run the lower end of the carburetor drain hose to a suit able container e Turn out the carburetor drain plug a few turns and drain the fuel system e Check to see if water or dirt comes out e Tighten the drain plug If any water or dirt appears during the above inspection clean the fuel system carburetor tank fuel hose Air Cleaner Element Cleaning and Inspection NOTE Oln dusty areas the element should be cleaned more frequently than the recommended interval OAfter riding through rain or muddy terrains the element should be cleaned immediately OSince repeated cleaning opens the pores of the ele ment replace it with a new one in accordance with the Periodic Maintenance Chart OAlso if there is a break in the element material or any other damage to the element replace the element with a new one Clean the element in
188. ressure e Check the tire pressure using an air pressure gauge NOTE OKawasaki provides the air pressure gauge P N 52005 1082 as the owner s tool Tire Air Pressure when cold Front 21 kPa 0 21 kgf cm 3 0 psi Rear 21 kPa 0 21 kgf cm 3 0 psi e Install the wheel see Wheel Installation e Wipe off the soap and water solution on the tire and dry the tire before operation Do not operate the vehicle with the water and soap still around the tire beads They will cause tire sep aration and a hazardous condition may result Tire Inspection e Refer to the Tire Inspection in the Periodic Maintenance chapter HJO5008B S HJO5009B S WHEELS TIRES 10 13 Rear Hub Rear Left Hub Removal e Remove Cap A Cotter Pin B e Loosen the axle nut C e Remove Wheel see Wheel Removal Axle Nut Washer Rear Left Hub D Rear Left Hub Installation e Tighten Torque Rear Axle Nuts 147 N m 15 kgf m 108 ft lb e Insert a new cotter pin A NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle shaft tighten the nut clockwise B up to next alignment Olt should be within 30 degree RENTE OLoosen once and tighten again when the slot goes past the nearest hole e Bend the cotter pin A over the nut B HJO7008BS1 Rear Left Hub Disassembly Assembly e Do not press the hub bolts A out Alf any hub bolt
189. riving a wedge in between the crank halves or by squeezing the crank halves in a vise depending on the nature of the misalignment e In the case of both horizontal and vertical misalignment correct the horizontal misalignment first e Recheck big end side clearance after aligning crankshaft see Connecting Rod Big End Side Clearance NOTE Olf crankshaft alignment cannot be corrected by the above method replace the crankpin or crank halves as required CAUTION Don t hammer the flywheel at the point A HI05012BS1 6105007BS1 6105008BS2 C CRANKSHAFT TRANSMISSION 9 15 Crankshaft Balancer Shaft and Connection Rod Connecting Rod Bend Twist e Measure the connecting rod bend OSet the crankshaft in an alignment jig or in V blocks on a surface plate OSelect an arbor of the same diameter as the piston pin and at least 100 mm 3 94 in long and insert the arbor through the connecting rod small end 100mm OWith the connecting rod held vertically use a height gauge to measure the difference in the height of the arbor above the surface plate over a 100 mm 3 94 in HORS length to determine the amount of connecting rod bend Alf connecting rod bend exceeds the service limit the con necting rod must be replaced Connecting Rod Bend Standard Under 0 05 100 mm 0 002 3 94 in Service Limit 0 2 100 mm 0 008 3 94 in e Measure the connecting rod twist
190. rn parts could cause the brake to lock or fail BRAKES 12 7 Brake Drum and Panel Front Brake Panel Removal Disassembly WARNING Brake linings contain asbestos fiber Inhalation of asbestos may cause serious scarring of the lungs and may promote other internal injury and illness including cancer Observe the following precau tions when handling brake linings 1 Never blow brake lining dust with compressed air 2 If any component are to be cleaned wash them with detergent then immediately discard the clean ing solution and wash your hands 3 Do not grind any brake lining material unless a ventilation hood is available and properly used e Loosen the axle nut e Remove Wheel see Wheels Tires chapter Axle Nut Brake Drum A Brake Adjuster B at the brake cam lever C e Remove Brake Panel Bolts A Brake Panel B e Remove Brake Shoes A 12 8 BRAKES Brake Drum and Panel e Remove Cam Lever Bolt A Cam Lever B NOTE OBefore removing the brake cam lever mark C the po sition of the cam lever so that it can be installed later in the same position e Pull the brake cam out from the inside e Remove Collar A Grease Seal B e Drive out the bearings Bearings A Collar B Metal Rod C Front Brake Panel Assembly Installation Improper installation will cause ineffective braking which could lead to a crash e Apply grease to the brake cam A e I
191. s ORemove the plug cap by turning it counterclockwise OConnect the tester between the spark plug lead and terminal OSet the tester to the x 1 KQ range and read the tester Ignition Coil Winding Resistance Primary windings 0 09 0 13 Q Secondary windings 3 8 5 8 kQ x If the hand tester does not read as specified replace the coil OTo install the plug cap turn it clockwise Ignition Coil Primary Peak Voltage Inspection NOTE OBe sure the battery is fully charged e Remove the spark plug cap see Spark Plug Removal but do not remove the spark plug e Measure the primary peak voltage as follows OConnect a commercial peak voltage adapter A to the hand tester B 250 V DC range Special Tool Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B OConnect the adapter between the G W lead terminal of the ignition coil C and the engine ground D Olnstall a new spark plug E into the spark plug cap and ground it to the engine To avoid extremely high voltage shocks do not touch the spark plugs or tester connections e Turn the ignition switch ON rotate the engine for 4 5 seconds with the transmission in neutral to measure the primary peak voltage e Repeat the measurements 5 times for one ignition coil Ignition Coil Primary Peak Voltage Standard 100 V or more x lf the reading is less than the specified value check the following Ignition Coil see Ignition Coil I
192. s ren ege 3 10 Fuel Level Gauge Removal 3 21 Idle Speed Adjustment 3 10 Fuel Level Gauge Installation 3 22 Idle Speed Adjustment 3 10 Fuel Level Gauge Check 3 22 Carburetor Pilot Screw Adjustment 3 10 3 2 FUEL SYSTEM Exploded View FUEL SYSTEM 3 3 Exploded View va sm e 3 hrote Lever Bot 59 os nb 3 Choke Lever 4 Choke Cable 5 Throttle Cable 6 7 8 Throttle Lever Jet Needle Pilot Jet 9 Main Jet 10 Needle Jet 11 Pilot Screw 12 Tighten the clamp screws from rear then front Gr Apply grease L Apply a non permanent locking agent 3 4 FUEL SYSTEM Specifications Item SE Service Limit KLF250 A1 KLF250 A2 Throttle Case and Cable Throttle Lever Free Play 2 3 mm 0 08 0 12 in Carburetor Make Type Main Jet Main Air Jet Needle Jet Jet Needle Pilot Jet Pilot Air Jet Pilot Screw Starter Jet Idle Speed Service Fuel Level Float Height Optional Parts Main Jet Altitude 0 500 m 0 1 600 ft 500 1 500 m 1 600 4 900 ft 1 500 2 500 m 4 900 8 200 ft 2 500 3 500 m 8 200 11 500 ft 3 500 4 500 m 11 500 14 800 ft Air Cleaner Air cleaner element oil MIKUNI VM24SS 115 61 0 O 6M 5GN64 1 30 61 3 1 1 2 turns out 120 1 8 O 2M 5GN74 1 22 5 1 0 2 1 2 turns out 45 1 300 1 40
193. sassembly 16 35 Starter Motor Assembly 16 35 Commutator Cleaning Inspection 16 36 Armature Inspection 16 37 Starter Motor Brush Lengfth 16 37 Brush Assembly Inspection 16 37 Brush Plate and Terminal Bolt Inspection 16 38 Starter Relay Inspection 16 38 Starter Circuit Relay Inspection 16 38 Starter Motor Clutch ooooooccccccccccccnnn 16 41 Starter Motor Clutch Removal 16 41 Starter Motor Clutch Installation 16 41 Starter Motor Clutch Inspection 16 41 Starter Chain and Sprockets 16 42 Torque Limiter Inspection 16 42 Lighting System 16 43 Headlight Beam Vertical Adjustment coancinnnccnnnncnninnin senos 16 43 Headlight Bulb Replacement 16 43 Taillight Bulb Replacement 16 44 Neutral and Reverse Indicator Light Bulb Replacement ener Brake Light Switch Adjustment 16 46 Switch Inspection 16 46 A Ze 16 47 20 A Main Fuse Removal 16 47 Fuse Inspection 16 47 Wiring Diagram U S A and Canada Models ss es nn cua iets 16 48 Wiring Diagram Europe Model 16 49 Wiring Diagram Australia Model 16 50 16 2 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 16 3 Exploded View Torque No Fastener Nem kaim SO Remarks
194. st Pipe and Muffler see Exhaust Pipe and Muffler Removal Camshaft Sprocket see Camshaft Sprocket Removal Oil Pipes A e Pull the spark plug cap B off the spark plug e Remove Engine Mounting Bolt A Bolts B and Engine Bracket C ENGINE TOP END 4 21 Cylinder Head e Loosen the cylinder head M6 bolts A and M10 bolts B completely and remove all the bolts e Remove the cylinder head Cylinder Head Installation e Blow out the oil passage with compressed air e Install a new cylinder head gasket A e Be sure the dowel pins B are in place e Be sure the front camshaft chain guide C is in place see Camshaft Chain Guide Installation e Apply molybdenum disulfide oil M to the flange and threads of all cylinder head bolts e Apply a non permanent locking agent L to the right front 4 cylinder head bolt 4 ES e Tighten the cylinder head bolts in a criss cross pattern as TT shown in two steps Cylinder Head Bolt Torque First Torquing M10 Bolts 1 4 13 N m 1 3 kgf m 113 in Ib M6 Bolts 5 6 5 9 N m 0 6 kgf m 52 in Ib Final Torquing M10 Bolts 1 4 34 N m 3 5 kgf m 25 ft lb M6 Bolts 5 6 9 8 N m 1 0 kgf m 87 in Ib e Tighten Torque Engine Bracket Bolts 26 N m 2 7 kgf m 20 ft lb Engine Mounting Nut M8 29 N m 3 0 kgf m 22 ft Ib HE12004BS2 C Cylinder Head Assembly e Apply grease to the O rings A e Install Insulator B Carburetor Hol
195. st af ter the start of charging the plates are probably sulfated A good battery will rise to 12 V immediately and then grad ually go up to 12 5 or 13 V in about 30 min to an hour after the start of charging 16 16 ELECTRICAL SYSTEM Battery If one cell produces no gas bubbles or has a very low specific gravity it is probably shorted x lf there does not appear to be enough sediment in a cell to short the plates but that cell has a very low specific gravity after the battery is fully charged the trouble may be that there is not enough acid in that one cell In this case only sulfuric acid solution may be added to correct the specific gravity x lf a fully charged battery not in loses its charge after 2 to 7 days or if the specific gravity drops markedly the battery is defective The self discharge rate of a good battery is only about 1 per day Sulfation here A Sediment here B 6P08004BS1 ELECTRICAL SYSTEM 16 17 Charging System Alternator Cover Removal e Remove Recoil Starter see Recoil Starter chapter Footpeg Shift Pedal e Holding the recoil starter pulley A steady with the hook wrench B loosen the alternator rotor bolt C Special Tool Hook Wrench 57001 1101 e Remove the alternator rotor bolt pulley and key The pulley may be pulled out easily e Remove Reverse Cable Rear End A e Disconnect Alternator Lead Connector A e Place an oil pan beneath the engine left
196. t is greater than the service limit re place the clutch housing Primary Clutch Housing Inside Diameter Standard 116 0 116 2 mm 4 567 4 575 in Service Limit 116 5 mm 4 587 in Primary Clutch Shoe Lining Wear e Visually inspect the primary clutch shoe lining A x If any of the linings are damaged replace the shoes e Measure the shoe groove depth B OUse a depth gauge and measure at several points as shown x If any measurement is less than the service limit replace all shoes as a set Primary Clutch Shoe Groove Depth Standard 1 0 1 3 mm 0 04 0 05 in Service Limit 0 5 mm 0 02 in M SE Se BS E HROSOQOBS2 C ENGINE RIGHT SIDE 5 11 Clutches One way Clutch Inspection e Turn the primary clutch housing A by hand The primary clutch housing should turn counterclockwise B freely but should not turn clockwise e Visually inspect the clutch parts inner race A one way clutch B and outer race C at the primary clutch hous ing Alf there is any worn or damaged part replace it Friction Plate Wear Alf any friction plate thickness is less than the service limit replace the friction plates as a set A Friction Plate Friction Plate Thickness Standard 2 9 3 1 mm 0 11 0 12 in Service Limit 2 6 mm 0 10 in GFO60602S1 Friction and Steel Plate Warp Alf any plate is warped over the service limit replace the plates as a set
197. tallation e Install the following parts on the holder A Metal Net B Element C Stopper D Screw E and Washer OAfter cleaning the element grease to the both sides F on the element 2 8 0 4 g 0 01 0 014 oz on one side e Grease the element inlet A as shown HGO7010181 3 18 FUEL SYSTEM Air Cleaner Air Cleaner Element Cleaning and Inspection e Refer to the Air Cleaner Element Cleaning and Inspection in the Periodic Maintenance chapter Air Cleaner Draining e Refer to the Air Cleaner Draining in the Periodic Mainte nance chapter Air Cleaner Housing Removal e Remove Seat see Frame chapter Housing Mounting Bolts A e Loosen the clamp screw B e Remove Engine Breather Hose A e Remove Regulator Mounting Bracket Bolt A Air Cleaner Housing B Fuel Tank FUEL SYSTEM 3 19 Fuel Tank Removal A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Remove Front Fender see Frame chapter e Turn the fuel tap to the OFF position e Remove Fuel Hose A e Remove Bolts A Fuel Tank B Fuel Tank Installation A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition s
198. the following OThe large end of mounting pin B goes in first Bypass Valve C 50 SAE 20W 50 gt SAE 20W 40 SAE 10W SAE 10W SAE 40 10W 30 50 20 68 40 C 104 F HU09002BS1 Periodic Maintenance Procedures PERIODIC MAINTENANCE 2 13 OApply grease to the O ring A in the cover e Tighten Torque Oil Filter Cover Bolts 8 8 N m 0 9 kgf m 78 in Ib OPour in the specified type and amount of oil Wheels Tires Tire Inspection e Examine the tire for damage and wear x lf the tire is cut or cracked replace it H605B006 P OLumps or high spots on the tread or sidewalls indicate internal damage requiring tire replacement ORemove any foreign objects from the tread After re moval check for leaks with a soap and water solution e Measure the tread depth at the center of the tread with a depth gauge Since the tire may wear unevenly take measurements at several places lf any measurements are less than the service limit re place the tire Tire Tread Depth Service Limit Front 4 mm 0 16 in Rear 4 mm 0 16 in Standard Tire Front AT 21 x 8 9 DUNLOP KT856 Tubeless Rear AT 22 x 10 10 DUNLOP KT857 Tubeless 2 14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Final Drive Final Gear Case Oil Change e Warm up the oil by running the vehicle so that the oil will pick up any sediment and
199. threads of oil pressure relief valve and tighten it Torque Oil Pressure Relief Valve 15 N m 1 5 kgf m 11 ft lb Oil Pressure Relief Valve Inspection e Check to see if the steel ball B inside the valve A slides smoothly when pushing it in with a wooden or other soft rod and see if it comes back to its seat by spring C pressure NOTE Olnspect the valve in its assembled state Disassembly and assembly may change the valve performance If any rough spot is found during above inspection wash the valve clean with a high flash point solvent and blow out any foreign particles that may be in the valve with compressed air A WARNING Clean the oil pressure relief valve in a well ventilated area and take care that there is no spark or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline to low flash point solvent x If cleaning does not solve the problem replace the oil pressure relief valve as an assembly The oil pressure relief valve is precision made with no allowance for re placement of individual parts 6608010151 ENGINE LUBRICATION SYSTEM 7 9 Oil Pump Oil Pump Removal e Remove Oil Pump Balancer Drive Gear see Engine Right Side Disassembly section in Engine Right Side chapter Oil Pump Screws A Oil Pump Assembly B Oil Pump Installation e Fill the pump with engine oil A e Be sure to install the O rings A a
200. through the rim from the inside out until it snaps into place CAUTION Do not use engine oil or petroleum distillates to lu bricate the stem because they will deteriorate the rubber e Mount the tire on the new rim see Tire Installation e Install the wheel see Wheel Installation e Install the air valve cap GJ05030781 HJO5005B S Tires WHEELS TIRES 10 11 Tire Removal e Remove the wheel e Unscrew the valve core to deflate the tire OUse a proper valve core tool A e Lubricate the tire beads and rim flanges on both sides of the wheel with a soap and water solution or water A This helps the tire beads slip off the rim flanges CAUTION Do not lubricate the tire beads and rim flanges with engine oil or petroleum distillates because they will deteriorate the tire e Remove the tire from the rim using a suitable commer cially available tire changer NOTE OThe tires cannot be removed with hand tools because they fit the rims tightly Tire Installation e Inspect the rim see Wheel Rim Inspection e Replace the air valve with a new one CAUTION Replace the air valve with whenever the tire is re placed Do not reuse the air valve e Check the tire for wear and damage see Tire Inspection e Lubricate the tire beads and rim flanges with a soap and water solution or water Do not use the lubricant other than a water and soap solution or
201. til the clearance is correct e Hold the adjusting screw from turning and tighten the lock nut to the specified torque Torque Valve Adjusting Screw Locknuts 12 N m 1 2 kgf m 104 in lb e Recheck the clearance x If the clearance is incorrect repeat the adjustment proce dure x If the clearance is correct perform the adjustment proce dure on the other valve e Be sure that the valve adjusting cap O ring A are in place e The valve adjusting caps are marked UP B on the top end e Tighten Torque Valve Adjusting Cap Bolts 8 8 N m 0 9 kgf m 78 in Ib Valve Removal e Remove Cylinder Head see Cylinder Head Removal Camshaft see Camshaft Removal Rocker Arms and Shafts see Rocker Arm and Shaft Re moval e Use the valve spring compressor assembly A and adapter to press down the valve spring retainer Special Tools Valve Spring Compressor Assembly 57001 241 Valve Spring Compressor Adapter 25 57001 1019 e Remove the split keepers e Loosen the valve spring compressor and take out the fol lowing parts Valve Spring Retainer Outer Spring Inner Spring Outer Spring Seat e Push out the valve e Repeat the procedure for the other valve 4 24 ENGINE TOP END Valves Guides Seats Springs Oil Seals Valve Installation elf a new valve is to be used check the valve to guide clearance x If there is too little clearance ream the valve guide x If there is too much clearance
202. timing is not correct remove the sprocket from the camshaft and install it again as detailed above e Smear a little engine oil on the camshaft cover O ring A and push the cover into place e Putin the camshaft cover bolts and tighten them securely e Install the timing inspection plug 4 14 ENGINE TOP END Rocker Arms and Shafts Compression Releasing Lever Removal e Remove Retaining Bolt A and Washer Compression Releasing Lever Bolt B Compression Releasing Lever C Return Spring and Washer Compression Releasing Shaft Compression Releasing Lever Installation e Replace the oil seal A if it is damaged e Apply grease to the oil seal lip e Install Compression Releasing Shaft A Retaining Bolt B and Washer e Tighten Torque Retaining Bolt 4 4 N m 0 45 kgf m 39 in Ib e Install Washer C Return Spring D Compression Releasing Lever E Compression Releasing Lever Bolt F e Tighten Torque Compression Releasing Lever Bolt 8 8 N m 0 9 kgf m 78 in Ib OHook the return spring ends A as shown HE10006BS1 Rocker Arms and Shafts ENGINE TOP END 4 15 Rocker Arm and Shaft Removal e Remove Camshaft Sprocket see Camshaft Sprocket Removal Screws A and Rocker Shaft Retainer B e Remove Compression Releasing Lever see Compression Re leasing Lever Removal Valve Adjusting Caps e Screw the camshaft sprocket bolt A into the rocker shaft and pull out the shaft
203. tion nette 2 14 Inspection 2 7 Brake ire ennemies 2 15 Throttle Lever Free Play Front Brake Adjustment 2 15 AdIUSIMEN Last ea deacons 2 7 Rear Parking Brake Lever Free Fuel System Cleanliness Play Inspection 2 16 Inspection 2 8 Brake Pedal Free Play Inspection 2 16 Air Cleaner Element Cleaning and Rear Parking Brake Lever and INSpectiOn vendus 2 8 Pedal Free Play Adjustment 2 17 Air Cleaner Draining 2 9 A BN 2 18 Fuel Hose and Connection Steering Inspection seeeeesea 2 18 EE 2 9 Electrical System eeeeeeeeeeees 2 18 Fuel Hose Replacement 2 9 Battery Inspection 2 18 Engine Top End nsee 2 10 Spark Plug Cleaning Inspection 2 18 Valve Clearance Inspection 2 10 Spark Plug Gap Inspection 2 18 Spark Arrester Cleaning 2 10 Brake Light Switch Adjustment 2 19 Clutches ossi eiiie riknir tsa 2 11 General Lubrication 2 19 Clutch Adjustment 2 11 KEIER A 2 19 Engine Lubrication System 2 12 Bolts and Nuts Tightening 2 21 Engine Oil Change 2 12 Tightness Inspection 2 21 Oil Filter Change c06 2 12 2 2 PERIODIC MAINTENANCE Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the vehicle in good run
204. tment e Clean any dirt and oil off the bevel gear teeth e Install the output drive gear with the primary shim see the shim tables e Apply molybdenum disulfide oil to the seating surface and threads of the output drive gear nut and tighten it Torque Output Drive Gear Nut 118 N m 12 kgf m 87 ft lb e Install the driven gear with the primary shim see the shim tables e Temporarily install the output bevel gear case on the crankcase and tighten the case bolts OBe sure to install the case gasket ODo not install the following part Oil Seal Holder Torque Output Bevel Gear Case Bolts M8 25 N m 2 5 kgf m 18 ft lb Output Bevel Gear Case Bolts M6 8 8 N m 0 9 kgf m 78 in lb e Check the backlash during the tightening of the case bolts and stop tightening them immediately if the backlash dis appears Then change the shim to a thinner one 11 14 FINAL DRIVE Output Bevel Gear Case e Set up a dial gauge A against the driven gear shaft nut B to check gear backlash e To measure the backlash turn the shaft clockwise and counterclockwise C slightly while holding the output drive gear steady The difference between the highest and lowest gauge reading is the amount of backlash OTo hold the output drive gear steady hold the shift drum at the full turned position x If the backlash is not within the limit replace the shim s at the drive and or driven gear Change the thickness a little at a time e Rech
205. to lock the push rod e Pull out the wire to release the spring C e Be sure the O ring D is in place in the tensioner body e Install Tensioner Body and Clamp e Tighten Torque Camshaft Chain Tensioner Mounting Bolts 8 8 N m 0 9 kgf m 78 in lb e Loosen the lock bolt and then tighten it With the bolt loos ened the spring inside takes up any slack automatically Camshaft Chain Tensioner Wear e Visually inspect the push rod A spring B ball and re tainer assembly C tensioner body D and O ring E e Slide the push rod in and out of the tensioner body without the spring or ball and retainer assembly x If the parts show any damage or if the push rod does not slide smoothly in the tensioner body replace the camshaft chain tensioner GE10001BS1 HEO90101S1 4 12 ENGINE TOP END Camshaft Sprocket Camshaft Sprocket Removal e Remove Fuel Tank see Fuel System chapter Front Fender see Frame chapter Recoil Starter see Recoil Starter chapter Bolts A and Camshaft Cover B e Turn the crankshaft with a wrench on the alternator rotor bolt until the punch mark A on the camshaft sprocket aligns with the pointer B on the cylinder head e Remove the camshaft chain tensioner see Camshaft Chain Tensioner Removal e Remove the camshaft sprocket bolt C OHold the crankshaft from turning with a wrench on the alternator rotor bolt e Slide the sprocket off the shoulder o
206. ttery Removal A WARNING Keep the battery away from sparks and open flames during charging since the battery gives off an ex plosive gas mixture of hydrogen and oxygen When using a battery charger connect the battery to the charger before turning on the charger This proce dure prevents sparks at the battery terminals which could ignite any battery gases e Connect a charger to the battery BEFORE plugging it in or turning it on e Set the charging rate and time according to the battery condition previously determined using the Battery Charg ing Rate Time Table e Check the electrolyte level after charging CAUTION Always remove the battery from the vehicle for charging If the battery is charged while still in stalled battery electrolyte may spill and corrode the frame or other parts of the vehicle Do not use a high rate battery charger as is typi cally employed at automotive service stations un less the charger rate can be reduced to the level re quired Charging the battery at a rate higher than specified may ruin the battery Charging at a high rate causes excess heat which can warp the plates and cause internal shorting Higher than normal charging rates also cause the plates to shed active material Deposits will accumulate and can cause internal shorting If the temperature of the electrolyte rises above 45 C 113 F during charging reduce the charging rate to lower the temperature and incre
207. um Inspection e Measure the shift drum grooves A If any shift drum groove is worn over the service limit A d replace the drum E AA A Shift Drum Groove Width PE A lil le H Standard 6 05 6 20 mm 0 238 0 244 in r Service Limit 6 3 mm 0 248 in Transmission Gear Inspection e Measure the shift drum grooves A in the transmission gear If a shift fork groove in the gear is worn over the service limit replace the gear Gear Shift Fork Groove Width Standard 5 05 5 15 mm 0 199 0 203 in Service Limit 5 3 mm 0 209 in CRANKSHAFT TRANSMISSION 9 21 Transmission e Visually inspect Gear Dogs A Gear Dog Holes B Replace any gears that have damaged or excessively worn dogs or dog holes HI10005BS1 9 22 CRANKSHAFT TRANSMISSION Transmission Ve G 4 6 6 6 4 E 2 BEER EE OT ETES e TL E 9 A7 CH Ge 27mm 6 HI10006B 4 1 Reverse Shaft 10 Shift Rod 19 Reverse Gear 33T 2 Washer 11 Shift Fork 20 Washer 3 Top Gear 28T 12 Shift Drum 21 Top Gear 22T 4 Washer 13 Bevel Gear 22 3rd Gear 27T 5 Circlip 14 Circlip 23 2nd Gear 33T 6 3rd 2nd Gear 23T 19T 15 Low Gear 38T 24 4th Gear 24T 7 4th Gear 26T 16 Needle Bearing 25 Circlip 8 Low Gear 13T 17 Output Shaft 9 Input Shaft 18 Shim CRANKSHAFT TRANSMISSION 9 23 Ball Bearing Needle
208. ve clearance Cylinder piston worn Piston rings bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Compression release mechanism trouble Knocking Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Igniter trouble Miscellaneous Throttle valve won t fully open Carburetor throttle valve doesn t slide smoothly Brake dragging Clutch slipping Overheating Engine oil level too high Engine oil viscosity too high Balancer mechanism malfunctioning Final gear case oil level too high Poor Running or No Power at High Speed Firing incorrect Spark plug dirty broken or maladjusted Spark plug cap or spark plug lead trouble Spark plug dirty broken or maladjusted Spark plug cap shorted or not in good con Spark plug incorrect tact Igniter trouble Spark plug incorrect Fuel air mixture incorrect Crankshaft Sensor trouble Main jet clogged Igniter trouble Fuel level too low Ignition coil trouble Carburetor holder loose Fuel air mixture incorrect Air cleaner poorly sealed or missing Main jet clogged or wrong size Air cleaner duct loose Jet needle or needle jet worn Air cleaner clogged Main air jet clogged Compression high Needle jet clogged Carbon built up in combustion chamber Fuel lev
209. verse Lever A Output Bevel Gear Case Bolts M6 B Output Bevel Gear Case Bolts M8 C Output Bevel Gear Case D Output Bevel Gear Case Installation e Replace the gasket with a new one e Apply a non permanent locking agent to the output bevel gear case bolt A e Tighten Torque Output Bevel Gear Case Bolts M8 25 N m 2 5 kgf m 18 ft lb Output Bevel Gear Case Bolts M6 8 8 N m 0 9 kgf m 78 in Ib Output Bevel Gear Case Disassembly e Remove Output Bevel Gear Case see Output Bevel Gear Case Removal Oil Seal Holder Nuts A Oil Seal Holder B e Remove Bearing Housing A and Cam Damper Assembly B Shim s C e Using the bevel gear holder A remove the cam damper mounting nut B slowly while holding the driven gear by a person OCarefully unscrew the nut to prevent the nut from shooting out as the spring pressure is released Special Tool Bevel Gear Holder 57001 1618 e Remove Washer Driven Gear C Spring D Output Bevel Gear Case FINAL DRIVE 11 9 e Turn the driven gear shaft upside down e Bend back the toothed washer tab A B Driven Gear Shaft Nut e Loosen the driven gear shaft nut with the socket wrench A Special Tools Socket Wrench 57001 1354 Bevel Gear Holder B 57001 1618 e Remove Driven Gear Shaft Nut Washer Toothed Washer Collar e Hold the bearing housing A with a vise and unscrew the bearing retainer B using the bearing retainer wrench C
210. witch Nut 2 9 N m 0 3 kgf m 26 in Ib e Install Front Cover Front Carrier Rear Fender Removal e Remove Taillight Lead Connectors A e Remove Rear Carrier Bolts A Rear Flap Bracket Bolts B e Remove Seat A see Seat Removal Rear Carrier Bolts B Rear Carrier C 15 10 FRAME Front and Rear Fenders e Remove Bolts A and Battery Holder B Battery see Electrical System chapter Electrical Equipment Plate C e Remove Front Fender Bolts A Rear Fender Bolts B Dampers Rear Fender C Rear Fender Installation e Fit the tabs A of the front fender in the slot e Install Battery Electrical Equipment Plate e Connect Taillight Lead Connectors e Tighten Torque Rear Carrier Bolts A 20 N m 2 0 kgf m 14 ft lb HOO4004BS1 Guard FRAME 15 11 Front Guard Removal e Remove Front Carrier see Front Fender Removal Front Guard Bolts A Front Guard B Rear Guard Removal e Remove Rear Carrier see Rear Fender Removal Bolts A Rear Guard B ELECTRICAL SYSTEM 16 1 Electrical System Table of Contents Exploded View Specifications Special Tools and Sealant Parts Location PreCautions cccceeceeeceeeeeeeeeeeeeeeeees Electrical Wiring Wiring Inspection A r Battery Removal
211. witch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Check the rubber dampers A on the frame top tubes as shown Alf the dampers are damaged or deteriorated replace them e Be sure the fuel hose is clamped to the fuel tap to prevent leakage WARNING Fuel spilled from the fuel tap is hazardous 3 20 FUEL SYSTEM Fuel Tank Fuel Tap Removal e Remove the fuel tank and drain it see Fuel Tank Re moval e Remove Bolts A Fuel Tap B Fuel Tap Installation e Be sure the O rings A are in good condition to prevent leakage HCO8002BS1 Fuel Tank and Fuel Tap Cleaning e Remove the fuel tank and drain it see Fuel Tank Re moval e Pour some high flash point solvent into the fuel tank and shake the tank to remove dirt and fuel deposits Clean the tank in a well ventilated area and take care that there is no spark or flame anywhere near the working area this includes any appliance with a pilot light Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents to clean the tank A fire or explosion could result e Pour the solvent out the tank e Remove the fuel filter from the tank by taking out the bolts e Clean the fuel filter screens in a high flash point solvent e Pour high flash point solvent through the tap in both ON and R
212. with it e Pull out the rocker shafts B and remove the rocker arms Rocker Arm and Shaft Installation e Before installation of the rocker arms and shafts turn the camshaft so that the cam lobes A point to the down e Apply molybdenum disulfide oil to the rocker shaft e Install each rocker shaft with the shaft notch A to the inside e Install the rocker shaft retainer B with the chamfered side C to the front side e Tighten Torque Rocker Shaft Retainer Screws 4 4 N m 0 45 kgf m 39 in Ib e After installation be sure to check and adjust the valve clearance HE10010381 4 16 ENGINE TOP END Rocker Arms and Shafts Rocker Arm and Shaft Inspection e Inspect the area A on the rocker arm where the cam rubs x If the rocker arm is scored discolored or otherwise dam aged replace it Also inspect the camshaft lobes e Inspect the end of the valve clearance adjusting screw B where it contacts the valve stem x If the end of the adjusting screw is mushroomed or dam aged in any way or if the screw will not turn smoothly replace it Also inspect the end of the valve stem e Measure the inside diameter C of the rocker arm with a dial bore gauge x If the rocker arm inside diameter is larger than the service limit replace it Also check the rocker shaft diameter D Rocker Arm Inside Diameter Standard 13 000 13 018 mm 0 5118 0 5125 in Service Limit 13 05 mm 0 514 in
213. y positive terminal to chassis ground OTroubles may involve one or in some cases all items Never replace a defective part without determining what CAUSED the failure If the failure was caused by some other item or items they too must be repaired or replaced or the new replacement will soon fail again OMake sure all connectors in the circuit are clean and tight and examine wires for signs of burning fraying etc De fective wires and bad connections will affect electrical sys tem operation OMeasure coil and winding resistance when the part is cold at room temperature OColor Codes BK Black G Green P Pink BL Blue GY Gray PU Purple BR Brown LB Light blue R Red CH Chocolate LG Lightgreen W White DG Dark green O Orange Y Yellow OElectrical Connectors Female Connectors A GPO60101S1 16 10 ELECTRICAL SYSTEM Precautions Male Connectors B GP06010281 Electrical Wiring ELECTRICAL SYSTEM 16 11 Wiring Inspection e Visually inspect the wiring for signs of burning fraying etc Alf any wiring is defective replace the damaged wiring e Pull each connector A apart and inspect for corrosion dirt and damage x If the connector is corroded or dirty clean it carefully If it is damaged replace it e Check the wiring for continuity OUse the wiring diagram to find the ends of the lead which is suspected of being a problem OConnect the hand tester between the ends of the
214. ystem Table of Contents Exploded EE 7 2 A NEE 7 4 Engine ON e Chart sense A AA ea deal Sead Aiba 7 5 Engine Oil And Oil Piel EE 7 6 Oil Level Inspection taa nie UR te CEET Oil Se CEET EEEE E eiia aaa Bypass Valve Removal ea ten E Bypass Valve Installation assessment dendeneemetessiten times Bypass Valve Cleaning and Inspection su 7 7 Oil Scree Re MOA e a Get e ari a a dize 7 7 Oil Screen Installation min aai engin EE 7 7 Oil Pressure Relief Valve 7 8 Oil Pressure Relief Valve Removal ss 7 8 Oil Pressure Relief Valve Installation oooononncccnnccnnncnnncnnnnnnnonnnnnonnnnnnnnnnnnnennnnnnnnnos 7 8 Oil Pressure Relief Valve Inspection 7 8 A RER E E RE tent tete ten dune laseun E A E these es autel Su that ne De E 7 9 Qil PUMP Remo adicta ca 7 9 Ol Pump Installation taa dadas 7 9 EUR 7 10 Oil PIPES ue EE 7 10 Oil Pipe Installationi ssssnsceienermeenmerenneimenenererennetennennee mens N E aani a a aa tien 7 10 7 2 ENGINE LUBRICATION SYSTEM Exploded View HG02002BN5 ENGINE LUBRICATION SYSTEM 7 3 Exploded View T No Fastener a ha Remarks kgf m ft Ib Oil Pipe Banjo Bolts 2 1 5 Oil Pump Screws 39 in lb Engine Drain Plug 22 Oil Filter Cover Bolts 5 78 in 1b Oil Pressure Relief Valve 11 L G Apply grease for oil seal and O ring L Apply a non permanent locking agent al 7 4 ENGINE

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