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Do not lower the - Manuale de reparatie si tutoriale / Service

1. Fastener Nan kim it Remarks Camshaft Cap Bolts 106 in lb Camshaft Cap Bolts 106 in lb 3 Cylinder Head Bolt M6 106 in lb 4 Cylinder Head Bolts M8 18 5 Water Passage Plugs 15 6 Carburetor Holder Clamp Screws a 18 in lb 7 Water Drain Bolt 52 in lb 8 Muffler Body Rear Cover Bolts 9 8 1 0 87 in lb L 9 Muffler Body Mounting Bolt 30 3 1 22 10 Muffler Body Clamp Bolt 17 1 7 13 11 Muffler Cover Bolts 9 8 1 0 87 in lb 12 Muffler Cover Clamp Screw 6 9 0 70 61 in lb 13 Exhaust Pipe Mounting Bolt 9 8 1 0 87 in lb 14 Exhaust Pipe Holder Nuts 12 1 2 104 in 1b EO Apply engine oil L Apply a non permanent locking agent M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disufide grease in a weight ratio 10 1 S Follow the specific tightening sequence SS Apply silicon sealant 5 6 ENGINE TOP END Exhaust System Exhaust System MANIFOLD Honeycomb Type Catalyst P No 39178 0076 Mark KHI M 121 SILENCER Honeycomb Type Catalyst P No 18091 0385 Mark KAW5340250 EPA Noise Emission Control Information Non Catalyst P No 18091 0536 Mark KHI K 535 SPECIFICATION US US CALIF CANADA INDONESIA MALAYSIA AUSTRALIA PHILIPPINE MODEL EX250J8F EX250J8FL EX250J8F EX250J8F EX250J8F EX250J8F EX250J8F GE24251B F H Honeycomb Type Catalyst
2. sise 15 9 Upper Cover Installation ccccceccceccceccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeneeeseeeeseeeeeeeneees 15 9 Side COVE Fis ree A falc tin AN ene ee cee O RO Tee he Re NE 15 10 ele Ee el ne UE 15 10 Side Cover Installation oooonnnnncnnnnninccnnnccananccnnnccnnnnanoncncn nano narco nn nn cnn anna nana nana nana nano 15 10 Fender tata a it e adn a a an nr ne 15 11 Front Fender Removal dias 15 11 RearF nder ReMOVa iii tata 15 11 Rear Fender sta i 15 12 15 2 FRAME Exploded View 6002316845 C FRAME 15 3 Exploded View Torque Fast Vtt R k astener Geen kgfm ftlb emarks Sidestand Nut 44 4 5 32 Front Footpeg Bracket Mounting Bolts 25 2 5 18 Rear Footpeg Bracket Mounting Bolts 25 2 5 18 Sidestand Switch Bolt 8 8 0 90 78 in Ib L G Apply grease L Apply a non permanent locking agent 15 4 FRAME Exploded View FRAME 15 5 Exploded View Va beta 1 Windshield Mounting Screws 0 043 37inb 15 6 FRAME Seat Front Seat Removal e Remove the side covers see Side Cover Removal e Remove the front seat bolts A e Slide the front seat backwards B and remove the front seat C Front Seat Installation e Slip A the hooks into the hollows and put B the projec tions on the frame Rear Seat Removal e Insert the ignition switch key into the seat lock A e Turning the key
3. e Install the new inserts in the connecting rod and check insert crankpin clearance with the plastigage Crankshaft Side Clearance Inspection e Inserta thickness gauge A between the crankcase main bearing and the crank web at the No 2 journal B to determine clearance lf the clearance exceeds the service limit replace the crankcase halves as a set NOTE OThe upper and lower crankcase halves are machined at the factory in the assembled state so the crankcase halves must be replaced as a set Crankshaft Side Clearance Standard 0 05 0 20 mm 0 002 0 008 in Service Limit 0 40 mm 0 016 in 6105060181 6105041781 6105019BS1 CRANKSHAFT TRANSMISSION 9 19 Crankshaft and Connecting Rods Crankshaft Runout Inspection e Measure the crankshaft runout x If the measurement exceeds the service limit replace the crankshaft Crankshaft Runout Service Limit TIR 0 05 mm 0 002 in Crankshaft Main Bearing Insert Journal Wear Inspection e Using a plastigage press gauge measure the bearing insert journal B clearance A NOTE OTighten the crankcase bolts to the specified torque see Crankcase Assembly ODo not turn the crankshaft during clearance measure ment OJournal clearance less than 0 025 mm 0 001 in can not be measured by plastigage however using genuine parts maintains the minimum standard clearance Crankshaft Main Bearing
4. VISE Wb Q N NY 5 Q NS L G104311BS2 CRANKSHAFT TRANSMISSION 9 13 Crankcase e Apply molybdenum disulfide oil solution to flange A and the threads B of the M8 bolts which is tightening order is 1 8 only see the next figure OFollowing the sequence numbers on the lower crankcase half tighten the 8 mm bolts A first to about one half of the specified torque and finally to the specified torque in the same sequence OReplace the copper washer C with a new one OTighten the 6 mm bolts B on the lower crankcase half to the specified torque Torque Crankcase Bolts 98 L 90 First 10 N m 1 0 kgf m 89 in Ib Final 24 N m 2 4 kgf m 18 ft lb Crankcase Bolts 8 L 73 First 10 N m 1 0 kgf m 89 in Ib Final 19 N m 1 9 kgf m 14 ft lb OReplace the copper washer B with a new one OTighten the 6 mm bolts A on the upper crankcase half to the specified torque Torque Crankcase Bolts 46 12 N m 1 2 kgf m 104 in Ib e After tightening all crankcase bolts check the following items ODrive shaft and output shaft turn freely OWhile spinning the output shaft shift the transmission smoothly from 1st to 6th gear and back OUnless the output shaft is turning the transmission cannot be shifted to 2nd gear or other higher gear positions Crankcase Exchange x If the crankcase is damaged replace it with a new one e Remove the crankcase pa
5. 68020148 GENERAL INFORMATION 1 5 Before Servicing Press For items such as bearings or oil seals that must be WK pressed into place apply small amount of oil to the con oie tact area Be sure to maintain proper alignment and use et SC smooth movements when installing IX Dr 68020178 Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is GR m absolutely necessary Replace with new ones whenever removed Press bearings with the manufacturer and size NA ES M marks facing out Press the bearing into place by putting ES RSs pressure on the correct bearing race as shown a E BR g A Pressing the incorrect race can cause pressure between fe el Li the inner and outer race and result in bearing damage E TITI 6020188 Oil Seal Grease Seal Do not remove pressed oil or grease seals unless removal A is necessary Replace with new ones whenever removed d Press new oil seals with manufacture and size marks facing NA out Make sure the seal is aligned properly when installing 8 SJ y wi St 6802018 Apply specified grease to the lip of seal before installing the seal Grease 6B02046BS1 Circlips Cotter Pins Replace the circlips or cotter pins that were removed with new ones Take care not to open the clip excessively when installing to prevent deformation GB02026B S 1 6 GENERAL INFORMATION Before Servicing
6. Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation Lubri E AH ec ECH cation points are called out throughout this manual apply A Y gt the specific oil or grease as specified A lt A T K P j Y 6020218 Direction of Engine Rotation a When rotating the crankshaft by hand the free play h amount of rotating direction will affect the adjustment Ro C Ce tate the crankshaft to positive direction clockwise viewed e from output side J By 68020728 Electrical Wires A two color wire is identified first by the primary color and then the stripe color Unless instructed otherwise electrical Y R wires must be connected to those of the same color AA oar 68020738 Instrument Use a meter that has enough accuracy for an accurate measurement Read the manufacture s instructions thor oughly before using the meter Incorrect values may lead to improper adjustments GBO2062BS1 GENERAL INFORMATION 1 7 Model Identification EX250J8F Left Side View United States and Canada 00850 P EX250J8F Right Side View United States and Canada G80383331 P Frame Number Engine Number 1 8 GENERAL INFORMATION General Specifications Items EX250J8F Dimensions Overall Length 2 085 mm 82 1 in Overall Width 715 mm 28 1 in Overall Height 1 110 mm 43 7 in Wheelbase 1 4
7. e Fill the reserve tank up to the full level line with coolant and install the cap CAUTION Soft or distilled water must be used with the an tifreeze see below for antifreeze in the cooling sys tem If hard water is used in the system it causes scales accumulation in the water passages and consider ably reduces the efficiency of the cooling system Water and Coolant Mixture Ratio Recommended Soft Water 50 Coolant 50 Freezing Point 35 C 31 F Capacity 1 5 L 1 59 US qt NOTE OChoose a suitable mixture ratio by referring to the coolant manufacturer s directions 2 46 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Bleed the air from the cooling system as follows OStart the engine with the radiator cap removed and run it until no more air bubbles A can be seen in the coolant OTap the radiator hoses to force any air bubbles caught inside OStop the engine and add coolant up to the radiator filler neck e Install the radiator cap e Start the engine warm it up thoroughly until the radiator fan turns on and then stop the engine e Check the coolant level in the reserve tank after the en gine cools down If the coolant level is lower than the low level line add coolant to the full level line CAUTION Do not add more coolant above the full level line Radiator Hose and O ring Replacement e Drain the coolant see Coolant Change e Remove Thermostat
8. 6106014BS1 CRANKSHAFT TRANSMISSION 9 23 Balancer x If either journal has worn past the service limit replace the balancer shaft with a new one x If the measured journal diameter is not less than the ser vice limit but does not coincide with the original diameter markings A on the balancer shaft write new marks on it Balancer Shaft Journal Diameter Marks None 25 984 25 994 1 0230 1 0234 in O 25 995 26 000 mm 1 0234 1 0236 in e Put the lower crankcase half on the upper crankcase half without bearing inserts and tighten the case bolts to the specified torque and sequence see Crankcase Assem bly e Measure the main bearing inside diameter and mark the upper crankcase half in accordance with the inside diam eter NOTE OThe mark A already on the upper crankcase half should almost coincide with the measurement Crankcase Bearing Inside Diameter Marks O 29 000 29 008 mm 1 1417 1 1420 in None 29 009 29 016 mm 1 1421 1 1424 in e Select the proper bearing insert A in accordance with the combination of the crankcase and balancer shaft coding e Install the new insert in the crankcase and check in sert journal clearance with plastigage Size Color B Crankcase Balancer Bearing Inside Shaft Journal Diameter Mark Diameter Mark Bearing Insert Size Color Part Number 92028 1424 92028 1422 Brown Blue 92028 142
9. CAUTION If dirt gets through into the engine excessive en gine wear and possibly engine damage will occur Air Cleaner Housing Installation e Install the air cleaner housing clamps A as shown Approx 18 B GCO7048BS1 Air Cleaner Housing Disassembly e Remove Air Cleaner Housing see Air Cleaner Housing Removal Air Cleaner Element see Air Element Removal in the Periodic Maintenance chapter Screw A Right Cover B Flame Arrester Air Cleaner Housing Assembly e Install the flame arrester A e Be sure the O ring B is in position FUEL SYSTEM 3 25 Air Cleaner e Apply a bonding agent to the slash portion A of the air cleaner housing Oil Draining e Remove the drain cap A at the lower end of the air cleaner housing and drain water or oil accumulates in the air cleaner housing e Be sure to install the cap firmly or the air is drawn in through it Be sure to install the cap in the air cleaner housing after draining Oil on tires make them slippery and can cause an accident and injury 3 26 FUEL SYSTEM Fuel Tank Fuel Tank Removal A WARNING Gasoline is extremely flammable and can be explo sive under certain conditions Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch OFF Be prepared for fuel spillage any
10. 10 18 WHEELS TIRES Speedometer Gear Housing Speedometer Gear Housing Disassembly e Pull the speedometer gear housing A off the front wheel e Pull out the grease seal C using a hook e Pull out the speedometer gear B e f the speedometer cable housing F or speedometer pin ion E needs to be removed work in accordance with fol lowing procedures Pin D e First drill the housing A through the spring pin B using a 1 0 1 5 mm drill bit C e Drill the housing from the under side to the pin end B using 3 0 3 5 mm drill bit A e Using a 3 mm 0 12 in rod A tap out the pin B and then pull out the speedometer cable bushing speedome ter pinion and washers NOTE Olt is recommended that the assembly be replaced rather than attempting to repair the components Speedometer Gear Housing Assembly e When assembling the speedometer gear housing be careful of the following items OAfter inserting a new pin stake the housing hole to secure the pin in place OReplace the grease seal with a new one Apply a little grease to the seal Install it using a press or a suitable driver so that the face of the seal is level with the surface of the housing ORegrease the speedometer gear Olnstall the speedometer gear housing so that it fits in the speedometer gear drive notches ESS SR NN SS GJ07010181 6y070102851 6y07010351 WHEELS TIRES
11. Alternator Pink Purple Red W White IGNITION SWITCH CONNECTIONS RIGHT SWITCH HOUSING CONNECTIONS Ignition Battery Ignition Tail LE Battery Tail3 Color BR GY BL W BK 0 6 Front Brake Light SwitchEngine Stop Switch Starter Button Color BK BK Color R Y R Color BK RIBK R Pe eee e PA Brake Lever OFF Free Pulled In a O RUN a O Push a O 98052 0320D W2RO320DW5 C 16 12 ELECTRICAL SYSTEM Wiring Diagram Indonesia Water Temper Switch Water Temperetre Warning Light 12V 3 AN Meter Light 12V 3 AN Meter Light 12V 3 4W Meter Light 12V 3 AN Fuel Gauge Speedmeter Tachometer High Beam Indicator Light 12V 3 AN Turn Signal Indicator Light 12V 3 4 Neutral Indicator Light 12V 8 4 Oil Pressure Warning Light 12V 3 4W Front Right Turn Signal Light 12V 10W City Light 12V 54 Headlight HI 12V 55W Headlight Lo 12V 55 Front Left Turn Signal Light 12V 10W Fuel Level Right Switch Housing Sensor 1 Headlight Switch SE Ae 2 Front Brake Light BATTERY JQa H Switch lenit i on teat SC 3 Engine Stop Switch Switch R 4 Starter Button W BK mas Jl W G gt 53 Radiator F CS an BK BK Y 12V 2 6A lt gt 33 Radiator E BL W ni Fan Switch org W BL etre A all ES w e 6 E R BL R BL LG BK LG BK E BR BR BK L D E WEE EE PEE ME RE G G BK BK LG LG RRG RER El E EE EEN ee
12. FREQUENCY Whichever ODOMETER READING x 1 000 km x 1 000 mile CHANGE REPLACE ITEM Air cleaner element Fuel hose Rubber parts of master cylinder and caliper Spark plug Service more frequently when operating in severe conditions dusty wet muddy high speed or frequent starting stopping For higher odometer readings repeat at the frequency interval established here 2 6 PERIODIC MAINTENANCE Torque and Locking Agent Use a torque wrench to tighten bolts and nuts to their specified torque values If too little torque is applied the bolts and nuts could loosen and fall out If too much torque is applied the threads could be sheared off To tighten a bolt or a nut or to check their torque loosen the bolt or nut one half turn before tight ening it to the specified torque Letters used in the Remarks column mean EO Apply engine oil G Apply grease L Apply a non permanent locking agent to the threads M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil solution R Replacement Parts S Tighten the fasteners following the specified sequence Si Apply silicone grease SS Apply silicone sealant Fastener Torque Remarks N m kgf m ft lb Fuel System Fuel Tap Mounting Bolts 2 5 0 25 22 in lb Fuel Gauge Mounting Bolts 6 9 0 7 61 in lb Air Cleaner Housing Cap Bolts 2 5 0 25 22 in lb Air Cleaner Housing Screws 1 15 0 12 10 in lb
13. NOTE OWheel alignment can be also checked using the straightedge or string method A WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition Drive Chain Wear Inspection e Remove Chain Cover see Swingarm Removal in the Suspension chapter e Rotate the rear wheel to inspect the drive chain for dam aged rollers and loose pins and links x lf there is any irregularity replace the drive chain x Lubricate the drive chain if it appears dry e Stretch the chain taut by hanging a 98 N 10 kg 20 Ib weight A on the chain e Measure the length of 20 links B on the straight part C of the chain from the pin center of the 1st pin to the pin center of the 21st pin Since the chain may wear unevenly take measurements at several places If any measurements exceed the service limit replace the chain Also replace the front and rear sprockets when the drive chain is replaced Drive Chain 20 link Length Standard 317 5 318 1 mm 12 50 12 52 in Service Limit 323 mm 12 72 in A WARNING If the drive chain wear exceeds the service limit re place the chain or an unsafe riding condition may result A chain that breaks or jumps off the sprock ets could snag on the engine sprocket or lock the rear wheel severely damaging the motorcycle and causing it to go out of control For safely use only the standard chain It is an end less type and should not be
14. e Raise the rear wheel off the ground with the stand e Free the drive chain from the rear sprocket and remove the rear wheel CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground Rear Wheel Installation e Apply a high temperature grease to the grease seal lips and coupling wheel sliding portions 10 8 WHEELS TIRES Wheels Rims e Fit the swingarm stop A into the caliper holder stops B e Install Alignment Indicators Axle Chain Adjusting Nuts and Locknuts Axle Nut and Washer Axle Nut Cotter Pin Torque Rear Axle Nut 98 N m 10 0 kgf m 72 ft lb NOTE Olnsert the axle from the right side of the wheel and tighten the axle nut e Install a new cotter pin NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle tighten the nut clockwise B up to next alignment Olt should be within 30 degree OLoosen once and tighten again when the slot goes past the nearest hole e Bend the cotter pin A over the nut e Adjust the drive chain slack see Drive Chain Slack Ad justment in the Periodic Maintenance chapter e Check the rear brake see Brake Operation Inspection in the Periodic Maintenance chapter Do not attempt to drive the motorcycle until a full brake pedal is obtained by pumping the brake pedal until the
15. 38 5 mm 1 52 in 2 92 3 08 mm 0 115 0 121 in 0 15 mm 0 0059 in or less Gear Marking E A O1 oloo w Clutch Housing Color F White Red Red None None Yellow Yellow 36 8 mm 1 45 in 2 6 mm 0 10 in 0 3 mm 0 012 in Clutch Housing Gear Selection when Replacing Clutch Housing Gear Part Number 13095 0095 13095 0096 13095 0096 13095 0097 13095 0097 13095 0098 13095 0098 CLUTCH 6 5 Special Tool and Sealant Clutch Holder Kawasaki Bond Silicone Sealant 57001 1243 56019 120 T5712438T ST5601208ST 6 6 CLUTCH Clutch Lever and Cable Clutch Lever Free Play Inspection e Refer to Clutch Operation Inspection in the Periodic Main tenance chapter see Clutch Operation Inspection in the Periodic Maintenance chapter Clutch Lever Free Play Adjustment e Refer to Clutch Operation Inspection in the Periodic Main tenance chapter see Clutch Operation Inspection in the Periodic Maintenance chapter Clutch Cable Removal e Remove Right Lower Fairing see Lower Fairing Removal in the Frame chapter e Loosen the knurled locknut A at the clutch lever and screw in the adjuster B e Line up the slots C in the clutch lever locknut and ad juster and then free the cable from the lever e Remove the lower cable adjuster of clutch cable from the cable holder A loosening the cable adjuster lock nuts B e Free the clutch inner cable
16. Idle Speed Adjustment e Start the engine and warm it up thoroughly e Turn the 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 Readjust if necessary PERIODIC MAINTENANCE 2 19 Periodic Maintenance Procedures Fuel Hose Inspection fuel leak damage installation condition OThe fuel hose is designed to be used throughout the mo torcycle s life without any maintenance However if the motorcycle is not properly handled the high pressure in side the fuel line can cause fuel to leak A or the hose to burst Remove the fuel tank see Fuel Tank Removal in the Fuel System chapter and check the fuel hose Replace the fuel hose if any fraying cracks B bulges C or ozone cracks D are noticed e Check that the hose A are securely connected and clamps B are tightened correctly e Check that the hoses are routed according to Cable Wire and Hose Routing section in the Appendix chapter Replace the hose if it has been sharply bent or kinked Evaporative Emission Control System California Model Evaporative Emission Control System Inspection W e Inspect the canister as follows r ORemove Left Lower Fairing see Lower Fairing Removal in the Frame chapter ORemove the canister A and disconnect the hoses from the canister OVisually inspect the canister for cracks or other da
17. 14 2 STEERING Exploded View GN92123845 C STEERING 14 3 Exploded View Torque Item N m kgf m ft Ib Steering Stem Nut 4 9 0 5 43 in lb 2 5 T Remarks Handlebar Holder Mounting Bolts 3 Steering Stem Head Bo A Front Fork Clamp Bolts Upper 2 i 5 Front Fork Clamp Bolts Lower AD Apply adhesive agent G Apply grease L Apply a non permanent locking agent 14 4 STEERING Special Tools Steering Stem Bearing Driver 57001 137 Head Pipe Outer Race Press Shaft 57001 1075 ST5701378T Bearing Puller 57001 158 ST5701588T Bearing Puller Adapter 57001 317 ST570317ST Oil Seal 8 Bearing Remover 57001 1058 ST571058ST Steering Stem Bearing Driver Adapter 34 5 57001 1074 ST5710748T ST5710758T Head Pipe Outer Race Driver 51 5 57001 1076 Q ST5710768T Steering Stem Nut Wrench 57001 1100 ST5711008T Head Pipe Outer Race Driver 47 57001 1447 g ST5714478T Steering STEERING 14 5 Steering Inspection e Refer to Steering Play Inspection in the Periodic Mainte nance chapter see Steering Play Inspection in the Peri odic Maintenance chapter Steering Adjustment e Refer to Steering Play Adjustment in the Periodic Mainte nance chapter see Steering Play Inspection in the Peri odic Maintenance chap
18. 218 psi 470 r min rpm 0 15 0 24 mm 0 0059 0 0094 in 0 22 0 29 mm 0 0087 0 0114 in 0 50 mm 0 0197 in 0 80 mm 0 0315 in 4 475 4 490 mm 0 1762 0 1768 in 4 455 4 470 mm 0 1754 0 1760 in 4 500 4 512 mm 0 1772 0 1776 in 0 03 0 09 mm 0 0012 0 035 in 0 08 0 15 mm 0 0031 0 0059 in 21 9 22 1 mm 0 8622 0 8701 in 19 3 19 5 mm 0 7598 0 7677 in 0 5 1 0 mm 0 0197 0 0394 in 39 5 mm 1 555 in 39 5 mm 1 555 in 32 45 67 5 0 3 mm 0 012 in 0 5 mm 0 020 in 0 05 mm 0 002 in TIR 4 46 mm 0 176 in 4 44 mm 0 175 in 4 58 mm 0 180 in 0 27 mm 0 011 in 0 33 mm 0 013 in 38 0 mm 1 15 in 38 0 mm 1 31 in 5 8 ENGINE TOP END Specifications Item Standard Service Limit Cylinder Piston Cylinder Inside Diameter 62 000 62 012 mm 2 4409 2 4414 in 62 10 mm 2 44 in Piston Diameter 61 942 61 957 mm 2 4387 2 4392 in 61 80 mm 2 43 in Piston Cylinder Clearance 0 043 0 070 mm 0 0017 0 0028 in Oversize Pistons and Rings 0 5 mm 0 020 in SE Piston Ring Groove Clearance Top 0 03 0 07 mm 0 0012 0 0028 in 0 17 mm 0 0067 in Second 0 02 0 06 mm 0 0008 0 0024 in 0 16 mm 0 0063 in Piston Ring Groove Width Top 0 82 0 84 mm 0 0323 0 0331 in 0 92 mm 0 0362 in Second 0 81 0 83 mm 0 0319 0 0327 in 0 91 mm 0 0358 in Oil 1 51 1 53 mm 0 0594 0 060
19. 56019 120 ST5601208T Kawasaki Bond Liquid Gasket Black 92104 1064 ST921003ST 9 10 CRANKSHAFT TRANSMISSION Crankcase Crankcase Splitting e Remove the engine see Engine Removal in the Engine Removal Installation chapter e Set the engine on a clean surface or preferably mount it on an engine stand to hold the engine steady while parts are being removed e Remove the water pipe and hose cylinder rearward NOTE Olf the engine is to be mounted on an engine stand the upper crankcase half bolts A shown must be removed before mounting the engine Washer B 6104096BS1 e Remove Alternator Cover see Alternator Cover Removal in the Electrical System chapter Water Pump Hose and Pipe see Water Pump Removal in the Cooling System chapter Starter Motor Clutch Gear Oil Pipe and Banjo Bolt Starter Motor see Starter Motor Removal in the Electri cal System chapter Oil Pump see Oil Pump Removal in the Engine Lubri cation System chapter Cylinder Head Cover see Cylinder Head Cover Re moval in the Engine Top End chapter Alternator Rotor see Alternator Rotor Removal in the Electrical System chapter One Way Clutch Gear Oil Hose Banjo Bolt Camshafts Chain Tensioner see Camshafts Chain Ten sioner Removal in the Engine Top End chapter Clutch Cover see Clutch Cover Removal in the Clutch chapter Camshafts see Camshaft Removal in the Engine Top End chapter Cylinder Head see
20. Front Left x 2 Turn Signal Switch z 6 6 Turn Signal Light Gilet 3 Dimmer Switch 12V 10 4 Starter Lockout Switch LEFT SWITCH HOUSING CONNECTIONS Horn Button Turn Signal Switch Dimmer Switch Starter Lockout Switch Color GE soter GY Color wa BL YR BK Color BK BK R Push LG Clutch Lever Released OFF Pa Released Pulled In W2LO320DW5 C ELECTRICAL SYSTEM 16 11 Wiring Diagram United States Canada and Australia Startre Headlight EE Circuit Circuit 00000 el Relay Relay Diode A Diode B ie i lt G BK G BK Y G LG G W Y G BK R Y BL Y Fuse Box Fuse Box 1 Turn Signal Relay Fuse 104 2 Horn Fuse 10A 3 lenition Fuse 10A 4 Taillight Fuse i A 5 Headlight Fuse 104 6 Fun Fuse 10A Rear Brake Light Switch BR BL TE R BL BL R UE Rear Right Turn Signal Light Do E 124104 BL R BL H Tail Brake nee Wd Light 12V 21 5W License Plate R BL BK Y adi Light 12V5Ww Rear Left Turn G a e g BK Y BK Y Signal Light L 12V10Ww Y BK W BK Y BK Y 2 A Frame Ground sek ek r Y K BK Y Y R L Starter Relay Peg Main Fuse 30A e A qe Crankshaft Sensor A Qil Battery Neutral Pressure Sen Starter 12V6Ah Switch Motor le a J S Regulator Rectifier BK Y BR U LB Light Blue 0 Orange P Pu
21. Left Switch Housing Connectors Front Turn Signal Light Connector Neutral Switch Connector Sidestand Switch Connector Bands Starter Relay Fuse Box Turn Signal Relay Clamp Choke Cable 17 20 APPENDIX Cable Wire and Hose Routing E Ne A F p Ze Cable Wire and Hose Routing APPENDIX 17 21 J O O1 ND A License Plate Light Connector Tail Brake Light Connector IC Igniter Connector Rear Right Turn Signal Light Connector Rear Left Turn Signal Light Connector Brake Light Switch Connector Starter Relay Connector Headlight Circuit Relay Diode Diode Battery Cable Alternator Connector Crankshaft Sensor Connector Front Turn Signal Light Connector Fuel Level Sensor Connector Ignition Switch Connector Frame Ground Terminal Radiator Fan Switch Connector Ignition Coil Connector Right Switch Housing Connector Radiator Fan Connector Bands 17 22 APPENDIX Cable Wire and Hose Routing APPENDIX 17 23 Cable Wire and Hose Routing OMNOAOARWN Thermostat Radiator Cap Install the hose so that its white mark side faces the radiator Radiator Clamp Screw 45 Cylinder Head 45 55 Align the white mark on the hose with the projection mark on the fitting Install the hose so that its end cover the white mark on the pipe Cylinder
22. Problem Diagnosis Remedy Action Cylinder Carbon accumulation on piston and in Remove the carbon deposits compression is combustion chamber possibly due to and replace damaged parts if higher than usable damaged valve stem oil seal and or necessary range damaged piston oil rings This may be indicated by white exhaust smoke Incorrect cylinder head gasket thickness Replace the gasket with a standard part Cylinder Gas leakage around cylinder head compression is Replace damaged gasket and check cylinder head warp lower than usable Bad condition of valve seating Repair if necessary range 9 Incorrect valve clearance Adjust the valve clearance Incorrect piston cylinder clearance Replace the piston and or cylinder Piston seizure Bad condition of piston ring and or piston ring grooves Inspect the cylinder and replace repair the cylinder and or piston as necessary Replace the piston and or the piston rings 5 22 ENGINE TOP END Cylinder Head Cylinder Head Removal e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove Lower Fairing see Lower Fairing Removal in the Frame chapter Fuel Tank see Fuel Tank Removal in the Fuel System chapter Radiator see Radiator Radiator Fan Removal in the Cooling System chapter Muffler see Muffler Removal Camshaft Chain Tensioner see Camshaft Chain Ten sioner Removal Left and Right Engine Bracke
23. e Remove the swingarm pivot nut A and shaft remove the swingarm B Swingarm Installation e Installation is the reverse of removal OApply grease to the lip of oil seals OBe sure to install the oil seal and collar to swingarm e Tighten the swingarm pivot nut Torque Swingarm Pivot Nut 98 N m 10 0 kgf m 72 ft lb e Install the removed parts Swingarm SUSPENSION 13 15 Swingarm Bearing Removal e Remove Swingarm see Swingarm Removal Grease Seal A Sleeve B Special Tool Inside Circlip Pliers 57001 143 e Remove the needle bearing Special Tool Oil Seal amp Bearing Remover 57001 1058 A Swingarm Bearing Installation e Apply plenty of grease to the needle bearings e Install the needle bearings so that the manufacturer s marks faces out Special Tool Bearing Driver Set 57001 1129 A Swingarm Bearing Sleeve Inspection CAUTION Do not remove the bearings for inspection Re moval many damage them e The rollers in a needle bearing A normally wear very lit tle and wear is difficult to measure Instead of measuring inspect the bearing in the swingarm for abrasion color change or other damage x If there is any doubt as to the condition of any of the nee dle bearings or sleeve replace the sleeve and needle bearings as a set 6M06060351 6M060604S1 13 16 SUSPENSION Swingarm Swingarm Lubrication e Lubricate the swingarm need
24. 0 004 in Crankpin Diameter 29 984 30 000 29 97 mm 1 1805 1 1811 in 1 18 in Marking None 29 984 29 994 mm 1 1805 1 1809 in O 29 995 30 000 1 1809 1 1811 in Connecting Rod Big End Bore Diameter 33 000 33 016 mm 1 2992 1 2998 in Marking None 33 000 33 008 mm 1 2992 1 2995 in O 33 009 33 016 mm 1 2996 1 2998 in Connecting Rod Big End Bearing Insert Thickness Brown 1 480 1 485 mm 0 0583 0 0585 in Black 1 485 1 490 mm 0 0585 0 0587 in Blue 1 489 1 494 mm 0 0586 0 0588 in Crankshaft Runout EE 0 05 mm 0 0020 in TIR Crankshaft Main Bearing Insert Journal 0 014 0 038 mm 0 08 mm Clearance 0 0006 0 0015 in 0 0031 in Crankshaft Main Journal Diameter 27 984 28 000 mm 27 96 mm 1 1017 1 1024 in 1 101 in Marking None Crankcase Main Bearing Bore Diameter Marking O 27 984 27 992 mm 1 1017 1 1020 in 27 993 28 000 1 1021 1 1024 in 31 000 31 016 mm 1 2205 1 2211 in 31 000 31 008 mm 1 2205 1 2208 in CRANKSHAFT TRANSMISSION 9 7 Specifications Item Standard Service Limit None 31 009 31 016 mm pe 1 2208 1 2211 in Crankshaft Main Bearing Insert Thickness Black 1 495 1 499 mm 0 0589 0 0590 in Blue 1 499 1 503 mm 0 0590 0 0592 in Yellow 1 503 1 507 mm 0 0592 0 0593 in Crankshaft Side Clearance 0 05 0 20 mm
25. Bearing Driver Set 57001 1129 ST5711298T Fork Outer Tube Weight 57001 1218 T5712188T Front Fork Oil Seal Driver 57001 1219 E O ST5712388T Fork Oil Level Gauge 57001 1290 ST5712908T ST571219ST Jack 57001 1238 13 6 SUSPENSION Special Tools Jack Attachment 57001 1608 LS J ST571608ST SUSPENSION 13 7 Front Fork Front Fork Removal NOTE ORemove the handlebar holder and remove the fork top plug A beforehand if the fork leg is to be disassembled e To remove the top plug remove the snap ring B pushing down the top plug with the screwdriver e Remove Front Brake Caliper see Front Caliper Removal in the Brakes chapter Front Wheel see Front Wheel Removal in the Wheels Tires chapter Front Fender see Front Fender Removal in the Frame chapter Lower Fairings see Lower Fairing Removal in the Frame chapter e Remove the clamps and free the brake hose from the fork leg e Loosen the front fork upper A and lower B clamp bolts e With a twisting motion remove the fork leg down and out Front Fork Installation each fork leg e Insert the fork leg until the inner tube top hit the handlebar holder lightly that is the distance between the inner tube top A and the steering stem head surface B is approx imate 12 mm 0 47 in C 6M04201BS1 Torque Front Fork Clamp Bolts Upper 21 N m 2 1 kgf m 1
26. Coolant Draining e Refer to Coolant Change in the Periodic Maintenance chapter see Coolant Change in the Periodic Mainte nance chapter Coolant Filling e Refer to Coolant Change in the Periodic Maintenance chapter see Coolant Change in the Periodic Mainte nance chapter Pressure Testing e Remove Right Lower Fairing see Lower Fairing Removal in the Frame chapter e Remove the radiator cap and install a cooling system pressure tester A on the filler neck NOTE OWet the cap sealing surfaces with water or coolant to prevent pressure leaks e Build up pressure in the system carefully until the pres sure reaches 123 kPa 1 25 kgf cm 18 psi CAUTION During pressure testing do not exceed the pres sure for which the system is designed The maxi mum pressure is 123 kPa 1 25 kgf cm 18 psi e Watch the gauge for at least 6 seconds x If the pressure holds steady the system is all right If the pressure drops and no external source is found check for internal leaks Droplets in the engine oil indicate internal leakage Check the cylinder head gasket and the water pump e Remove the pressure tester replenish the coolant and install the radiator cap GD05011181 Coolant COOLING SYSTEM 4 9 Cooling System Flushing Over a period of time the cooling system accumulates rust scale and lime in the water jacket and radiator When this accumulation is suspected or observed
27. Coupling Bearing Lubrication e Pack the bearing with high temperature grease Turn the bearing around by hand a few times to make sure the grease is distributed uniformly inside the bearing 6yJ060101S1 6114010181 11 14 FINAL DRIVE Sprocket Coupling Coupling Damper Inspection e Remove the rear wheel coupling and inspect the rubber dampers A e Replace the damper if it appears damaged or deterio rated Grease Seal Inspection and Lubrication If the grease seals are examined without removing the seals themselves look for discoloration indicating the rub ber has deteriorated hardening damage to the internal ribbing or other damage If the seal or internal ribbing has hardened the clearance between the seal and the axle sleeve will not be take up which will allow dirt and moisture to enter and reach the bearing If in doubt as to its condition and whenever the seal is removed for greasing the bearing the seal should be replace The seals are generally dam aged upon removal Sprocket Wear Inspection e Visually inspect the engine and rear sprocket teeth for wear and damage x If the teeth are worn as illustrated replace the sprocket and inspect the drive chain wear see Drive Chain Wear Inspection in the Periodic Maintenance chapter A Worn Tooth Engine Sprocket B Worn Tooth Rear Sprocket C Direction of Rotation NOTE Olf a sprocket requires replacement the chain is pro
28. Do not scrape off the deposits with a scraper as this could damage the rubber requiring replacement of the suction valve assembly GE04082BS1 B 048117 P Clean Air System ENGINE TOP END 5 13 Clean Air System Hose Inspection e Be certain that all the hoses are routed without being flat tened or kinked and are connected correctly to the air cleaner housing carburetor assembly and cylinder head cover see Cable Wire and Hose Routing section in the Appendix chapter x lf they are not correct them Replace them if they are damaged 5 14 ENGINE TOP END Cylinder Head Cover Cylinder Head Cover Removal g e Drain the Coolant see Coolant Change in the Periodic Maintenance chapter e Remove Spark Plug Caps Radiator A see Radiator and Radiator Fan Removal in the Cooling System chapter e Disconnect the primary lead B and ground lead C con nectors of the 2 right ignition coil D e Remove the right engine bracket mounting bolts E and remove the engine bracket with the right ignition coil e Disconnect the air suction valve hose e Remove the cylinder head cover bolts A e Remove the cylinder head cover B Cylinder Head Cover Installation e Scrape off the old silicone sealant A on the cylinder head mating surface and apply silicone sealant A on the mat ing surface e Be sure the water pipe B is in place e Be sure the damper A on the water pipe is in
29. F Left Side E J Right Side F A 2 a 8 GJ04074BS1 e Be sure to install the balance weight OCheck that the blade A and clip B are fully seated on the rim C and that the clip is hooked over the rib D Left Side E Right Side F 6J04089BS1 10 12 WHEELS TIRES Tires Air Pressure Inspection Adjustment e Refer to Air Pressure Inspection in the Periodic Mainte nance chapter see Air Pressure Inspection in the Peri odic Maintenance chapter Tire Inspection e Refer to Wheels Tires Damage Inspection in the Periodic Maintenance chapter see Wheels Tires Damage Inspec tion in the Periodic Maintenance chapter Tire Removal e Remove Wheel see Wheel Removal Disc Valve Core let out the air e To maintain wheel balance mark the air valve position on the tire with chalk so that the tire can be reinstalled in the same position Chalk Mark or Yellow Mark A Air Valve B Align C e Lubricate the tire beads and rim flanges on both sides with a soap and water solution or rubber lubricant This helps the tire beads slip off the rim flanges CAUTION Never lubricate with engine oil or petroleum distil lates because they will deteriorate the tire e Brake the beads away from both sides of the rim with the bead breaker A Special Tool Bead Breaker Assembly 57001 1072 e Step on the side of the tire opposite the valve stem and start prying the tire off the rim nea
30. Fan System Circuit Inspection e Disconnect the leads A from the radiator fan switch e Using an auxiliary wire B connect the radiator fan switch leads x If the fan rotates inspect the fan switch x If the fan does not rotate inspect the following Leads and Connectors Main Fuse and Fan Fuse Fan Motor Fan Motor Inspection e Remove the right lower fairing see Frame chapter e Disconnect the 2 pin connector A in the fan motor leads e Using two auxiliary wires supply battery B power to the fan motor x lf the fan does not rotate the fan motor is defective and must be replaced Lead Connections Battery BL Lead Battery BK Lead Radiator Fan Circuit O te BL BL W BK Y t gt L BK Y GP150648 2 C 1 Radiator Fan 4 Fan Fuse 10 A 2 Radiator Fan Switch 5 Main Fuse 30 A 3 Fuse Box 6 Battery 16 56 ELECTRICAL SYSTEM Meters Gauge and Indicator Unit Meter Unit Removal e Remove Upper Cover A see Upper Cover Removal in the Frame chapter e Unscrew the bolts A and remove the meter unit B from the upper cover CAUTION Place the meter unit so that the face is up If a meter unit is left upside down or sideways for any length of time it will malfunction Meter Unit Disassembly e Remove Meter Unit see Meter Unit Removal Reset Knob Screws A Meter Cover B ies P e Remove the speedometer A tachometer B and fuel gauge C by remov
31. Rear Master Cylinder Disassembly NOTE ODo not remove the push rod clevis for master cylinder disassembly since removal requires brake position ad justment e Remove the rear master cylinder see Rear Master Cylin der Removal in the Brakes chapter e Remove the circlip Special Tool Inside Circlip Pliers 57001 143 e Pull out the push rod with the piston stop e Take off the piston A secondary cup B primary cup C and return spring D e Remove the circlip F and pull out the brake hose con nector G and O ring H Special Tool Inside Circlip Pliers 57001 143 CAUTION Do not remove the secondary cup from the piston since removal will damage it Master Cylinder Assembly e Before assembly clean all parts including the master cylinder with brake fluid or alcohol CAUTION Except for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning brake parts Do not use any other fluid for cleaning these parts Gasoline engine oil or any other petroleum distillate will cause deterioration of the rubber parts Oil spilled on any part will be diffi cult to wash off completely and will eventually de teriorate the rubber used in the disc brake iia GS13228BS1 GS13229BS2 PERIODIC MAINTENANCE 2 51 Periodic Maintenance Procedures e Apply brake fluid to the removed parts and to the inner wall of the cylind
32. _ Kawasaki Ninja 250R Motorcycle 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 Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal Installation Crankshaft Transmission Wheels Tires Final Drive Brakes Suspension Steering Electrical System a ala la sch NIO BIO IN e o Ol ol Ion B IIN Appendix Kawasaki Ninja 250R Motorcycle Service Manual All rights reserved No parts of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Quality Assurance 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 notice and without incurring an obligation to make su
33. e Using the highest resistance range of the hand tester measure the resistance between each of the black leads and chassis ground Any hand tester reading less than infinity indicates a short necessitating stator replacement x If the stator coils have normal resistance but the voltage check showed the alternator to be defective then the rotor magnets have probably weakened and the rotor must be replaced Special Tool Hand Tester 57001 1394 Regulator Rectifier Inspection e Remove Right Lower Fairing see Lower Fairing Removal in the Frame chapter Bolts A Regulator Rectifier B Connector C Disconnect Charging System ELECTRICAL SYSTEM 16 29 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 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 high in both directions the rectifier is defective and the regulator rectifier must be replaced NOTE OThe actual meter reading varies with the meter used and the individual rectifier but generally speaking the lower reading should be from zero to one half 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 a
34. 6104097BS1 9 12 CRANKSHAFT TRANSMISSION Crankcase OWhen the oil pressure switch is installed apply the sili cone sealant to the threads of the switch Special Tool Kawasaki Bond Silicone Sealant 56019 120 CAUTION Make sure the crankcase set pins are properly aligned to avoid damage to the crankcases upon installation Don t use usual set pins because the set pins of this model are different from usual pins They are hollow and also used to pass oil If you use usual pins by mistake the engine always seized OCheck that the knock pins 2 are in place OApply a little engine oil to the transmission gears ball bear ings shift drum and crankshaft main bearing inserts e Apply liquid gasket to the mating surface of the lower crankcase half Special Tool Kawasaki Bond Liquid Gasket Black 92104 1064 A OAfter assembling the crankcase halves wipe off excess liquid gasket on the inside portion B CAUTION If liquid gasket adheres to any areas not indicated the engine oil passage may be obstructed causing engine seizure OCheck to see that the shift drum is in the neutral position that is the projection at operating plate is seen from neu tral switch hole at the upper crankcase half OWhen fitting the lower crankcase half on the upper crankcase half each shift fork must fit in its gear groove OLoosely tighten all lower crankcase half bolts to a snug fit
35. A in a container of coolant so that the temperature sensing projection and threaded portion are submerged e Suspend an accurate thermometer B in the coolant so that the sensitive portions C are located in almost the same depth NOTE OThe switch and thermometer must not touch the con tainer side or bottom e Place the container over a source of heat and gradu ally raise the temperature of the coolant while stirring the coolant gently e Using the hand tester measure the internal resistance of the sensor across the terminal and the body at the tem peratures shown in the table Special Tool Hand Tester 57001 1394 GP18020382 C 16 62 ELECTRICAL SYSTEM Switches and Sensor x If the hand tester does not show the specified values re place the switch Water Temperature Switch Connections Rising temperature From OFF to ON at 112 118 C 226 232 F Falling temperature From ON to OFF at 108 C 226 F temperature less than ON temperature ON Less than 0 5 Q OFF More than 1 MQ Fuel Level Sensor Inspection e Remove the fuel tank see Fuel Tank Removal in the Fuel System chapter e Remove the fuel level sensor from the fuel tank e Check that the float moves up and down smoothly without binding It should go down under its own weight x If the float does not move smoothly replace the sensor A Float in Full Position B Float in Empty Position C Float Arm Stoppers e Using a hand tester
36. Install the hose so that its white mark side faces the pipe 17 24 APPENDIX Cable Wire and Hose Routing gel Cais APPENDIX 17 25 Cable Wire and Hose Routing Run the reserver tank vent hose into the guide 2 places Reserver Tank Vent Hose Bracket Run the clutch cable and over flow hose into the hole of the reserver tank Clutch Cable Radiator Overflow Hose Radiator Cap Coolant Reserver Tank Clamp Hose Curve Side Run the only reserver tank vent hose into the bracket guide J O O1 ND _ 17 26 APPENDIX Cable Wire and Hose Routing UC S Nu gt A E SA Le A SA S yA C DAL A 6B09709CW5 C APPENDIX 17 27 Cable Wire and Hose Routing Air Suction Valve Cover Vaccum Switch Valve Carburetor Install the vaccum switch valve hose so that its white mark faces the air cleaner box Air Cleaner Box Install the vaccum valve switch fitting so that its white mark side faces the air suction valve hose This side is closed Air Suction Valve Hose 0 JO O1 P Gabi A 17 28 APPENDIX Cable Wire and Hose Routing 4 Se C i A gt Pa LI m ES MAS U n D lt e ES OS 6B097100W5 APPENDIX 17 29 Cable Wire and Hose Routing 1 Air Cl
37. Manifold Mark Position A Honeycomb Type Catalyst Position D of Manifold GE24253BN2 C Silencer Mark Position B Honeycomb Type Catalyst Position C of Silencer 6E24252BN2 C Specifications ENGINE TOP END 5 7 Clean Air System Vacuum Switch Valve Closing Pressure Standard Open Close 41 3 49 3 kPa 310 370 mmHg Service Limit Camshafts Camshaft Chain Rocker Arms Cam Height Exhaust Inlet Camshaft Journal Camshaft Cap Clearance Camshaft Journal Diameter Camshaft Bearing Inside Diameter Camshaft Runout 32 843 32 957 mm 1 2930 1 2975 in 33 843 33 957 mm 1 3324 1 3369 in 0 028 0 071 mm 0 0011 0 0071 in 23 950 23 972 mm 0 9429 0 9438 in 24 000 24 021 mm 0 9449 0 9457 in TIR 0 02 mm 0 0008 in or less 32 74 mm 1 289 in 33 74 mm 1 328 in 0 16 mm 0 0063 in 23 92 mm 0 942 in 24 08 mm 0 948 in TIR 0 1 mm 0 004 in Cylinder Head Cylinder Compression Cylinder Head Warp Valves Valve Clearance Inlet Exhaust Valve Head Thickness Inlet Exhaust Valve Stem Bend Valve Stem Diameter Inlet Exhaust Valve Guide Inside Diameter Valve valve Guide Clearance Wobble Method Inlet Exhaust Valve Seating Surface Outside Diameter Inlet Exhaust Width Valve Spring Free Length Inlet Exhaust Valve Seat Cutting Angle Usable Range 980 1 500 kPa 10 0 15 3 kgf cm 142
38. Periodic Maintenance Procedures Bolts Nuts and Fasteners Tightness Inspection e Check the tightness of the bolts and nuts listed here Also check to see that each cotter pin is in place and in good condition NOTE OFor the engine fasteners check the tightness of them when the engine is cold at room temperature x lf there are loose fasteners retighten them to the spec ified torque following the specified tightening sequence Refer to the appropriate chapter for torque specifications If torque specifications are not in the appropriate chapter see the Standard Torque Table For each fastener first loosen it by 1 2 turn then tighten it x If cotter pins are damaged replace them with new ones Bolt Nut and Fastener to be checked Engine Clutch Lever Pivot Nut Engine Mounting Bolts and Nuts Exhaust Pipe Manifold Holder Nuts Muffler Body Mounting Bolts Wheels Front Axle Rear Axle Nut Rear Axle Nut Cotter Pin Brakes Brake Lever Pivot Nut Brake Pedal Bolt Brake Rod Joint Cotter Pin Caliper Mounting Bolts Front Master Cylinder Clamp Bolts Rear Master Cylinder Mounting Bolts Suspension Front Fork Clamp Bolts Rear Shock Absorber Bolt and Nut Swingarm Pivot Shaft Nut Steering Steering Stem Head Bolt Handlebar Holder Bolts Others Footpeg Stay Bolts Front Fender Bolts Sidestand Bolt 2 44 PERIODIC MAINTENANCE Periodic Maintenance Procedures Replacement Parts Air Cleaner Element Replacement e R
39. Sidestand Switch Leads 5 Clamp 6 Sidestand Switch 17 14 APPENDIX Cable Wire and Hose Routing Cable Wire and Hose Routing APPENDIX 17 15 OMNOAONARWND Rear Left Turn Signal Light Connector Rear Right Turn Signal Light Connector IC Igniter Fuse Box Headlight Circuit Relay Starter Circuit Relay Diodes Starter Relay Fuel Level Sensor Connector Clamp Alternator Connector Crankshaft Connector Clamp Battery Cable Starter Relay Starter Motor Cable Battery Cable Rear Brake Switch Clamp Rear Brake Switch Connector 17 16 APPENDIX Cable Wire and Hose Routing GBOSTOMC E Cable Wire and Hose Routing APPENDIX 17 17 e eee Rear Left Turn Signal Light Connector Rear Right Turn Signal Light Connector Brake Tail Light Connector License Plate Light Connector Clamps Clamp Rear Left Turn Signal Light Connector Rear Right Turn Signal Light Connector License Plate Light Connector Turn Signal Relay Bracket 17 18 APPENDIX Cable Wire and Hose Routing Cable Wire and Hose Routing APPENDIX 17 19 JO O1 amp N Headlight High Connector Headlight Low Connector Bands Horn Connector Meter Connector Diode Connector Regulator Rectifier Connector Ignition Coil Connector Radiator Fan Switch Connector Oil Pressure Switch Connector
40. and wheel properly aligned the notch E on the left wheel alignment indicator F should align with the same swingarm mark or position G that the right indicator notch aligns with A WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition e Tighten both chain adjuster locknuts securely e Tighten the axle nut Torque Rear Axle Nut 98 N m 10 0 kgf m 72 ft lb e Turn the wheel measure the chain slack again at the tight est position and readjust if necessary 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 tighten the nut clockwise B up to next alignment Olt should be within 30 OLoosen once and tighten again when the slot goes past the nearest hole e Bend the cotter pin A over the nut B A WARNING If the rear axle nut is not securely tightened or the cotter pin is not installed an unsafe riding condi tion may result HJ07007BS1 HJO7008BS1 PERIODIC MAINTENANCE 2 31 Periodic Maintenance Procedures Wheel Alignment Inspection e Check that the notch A on the right wheel alignment indi cator B aligns with the same swingarm mark or position C that the left alignment indicator notch aligns with x If they do not adjust the chain slack and align the wheel alignment see Drive Chain Slack Adjustment
41. angle B until the seat O D 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 O D mea surement 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 O D measurement step above x lf the seat width is too wide make the 67 5 A grind described below x If the seat width is within the specified range lap the valve to the seat as described below e Grind the seat at a 67 5 angle until the seat width is within the specified range OTo make the 67 5 grind fit a 67 5 cutter into the holder and slide it into the valve guide OTurn the holder while pressing down lightly OAfter making the 67 5 grind return to the seat width mea surement step above Correct Width B GE15012181 A GE15012281 GE15012381 5 30 ENGINE TOP END Valves e Lap the valve to the seat once the
42. flush the cool ing system If this accumulation is not removed it will clog up the water passage and considerable reduce the effi ciency of the cooling system e Drain the cooling system see Coolant Change in the Pe riodic Maintenance chapter e Fill the cooling system with fresh water mixed with a flush ing compound CAUTION Do not use a flushing compound which is harmful to the aluminum engine and radiator Carefully follow the instructions supplied by the manufacturer of the cleaning product e Warm up the engine and run it at normal operating tem perature for about ten minutes e Stop the engine and drain the cooling system e Fill the system with fresh water e Warm up the engine and drain the system e Repeat the previous two steps once more e Fill the system with a permanent type coolant and bleed the air from the system see Coolant Change in the Peri odic Maintenance chapter 4 10 COOLING SYSTEM Water Pump Pump Cover Removal e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove Left Lower Fairing see Lower Fairing Removal in the Frame chapter Coolant Pipes A B Engine Sprocket Cover C see Engine Sprocket Re moval in the Final chapter e Remove the water pump mounting bolts A and water pump cover B Pump Cover Installation e Fit the O ring A into the groove of the pump cover B e Install the removed parts Torque Water Hose Clamp Screws 1
43. life 90 worn So it is false economy and unsafe to use the tires until they are bald e Measure the tread depth at the center of the tread with a depth gauge A Since the tire may wear unevenly take measurement at several places x If any measurement is less than the service limit replace the tire see Tire Removal Installation in the Wheels Tires chapter GJO5007BS1 2 28 PERIODIC MAINTENANCE Periodic Maintenance Procedures Tread Depth Standard Front BRIDGESTONE 4 6 mm 0 181 in DUNLOP 4 5 mm 0 177 in Rear BRIDGESTONE 7 0 mm 0 276 in DUNLOP 7 4 mm 0 291 in Service Limit Front 1 mm 0 04 in Rear 2 mm 0 08 in Up to 130 km h 80 mph 3 mm 0 12 in Over 130 km h 80 mph A WARNING To ensure safe handling and stability use only the recommended standard tires for replacement in flated to the standard pressure NOTE OMost countries may have their own regulations a mini mum tire tread depth be sure to follow them OCheck and balance the wheel when a tire is replaced with a new one Wheel Bearing Damage Inspection e Raise the front wheel off the ground with jack see Front Wheel Removal in the Wheels Tires chapter e Turn the handlebar all the way to the right or left e Inspect the roughness of the front wheel bearing by push ing and pulling A the wheel e Spin B the front wheel lightly and check for smoothly turn roughness binding or nois
44. 0 5 1 mm 0 02 0 04 in above the mating surface of carburetor float bowl 17 2 mm 0 67 0 08 in Air Cleaner Element Type Polyurethane foam FUEL SYSTEM 3 9 Special Tools Fuel Level Gauge Pilot Screw Adjuster A 57001 1017 57001 1239 ST571017ST ST571239ST 3 10 FUEL SYSTEM Throttle Grip and Cables Free Play Inspection e Refer to Throttle Control System Inspection in the Peri odic Maintenance chapter see Throttle Control System Inspection in the Periodic Maintenance chapter Free Play Adjustment e Refer to Throttle Control System Inspection in the Peri odic Maintenance chapter see Throttle Control System Inspection in the Periodic Maintenance chapter Throttle Cable Removal e Split the right handlebar switch housing A removing the screws B and remove the throttle cable upper ends from the throttle grip e Remove Front Seat see Front Seat Removal in the Frame chap ter Side Cover see Side Cover Removal in the Frame chap ter Right Lower Fairing see Lower Fairing Removal in the Frame chapter e Loosen the locknuts A and remove the lower end of the accelerator cable B from the pulley e Loosen the locknuts C and remove the lower end of the decelerator cable D from the pulley e Pull out the throttle cables upward Throttle Cable Installation e Install the throttle cables in accordance with the Cable Wire and Hose Routing in the Appendix chapter e Insta
45. 10 19 Speedometer Gear Housing Speedometer Gear Housing Lubrication e Clean and grease A the speedometer gear housing B GJO7003BS1 FINAL DRIVE 11 1 Final Drive Table of Contents Exploded E 11 2 eelere de EE 11 4 Special TOO EE 11 5 Drive COIN at A eae eee aia a kas 11 6 Drive Chain Slack Inspection ssssssssrrnrrrttrrrttrtrrtttttttttttttttttttttEEEEEEAEEEEEEEAEEEEEEEEE EEEE EEEn 11 6 Drive Chain Slack Adjusiment sssgus ses nanas mea ne a lost 11 6 Wheel Alignment Inspection Adjustment AA 11 6 Drive Chain Wear Inspection Drive Chain Lubrcatton ss Drive Chain Removal A dado Drive Chain Installation nnnnnennnnannnnnnentrntntnnnttntrnnttnnttnnntnnntnntttnntnnntnnnEnnAnnn Ennn nnna nnen nenna Drive Chaim EE Drive Chain Replacement ooocccccnccnnccnnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnninnnininiss Sprocket COUPLING KEE Engine Sprocket ne E Engine Sprocket Installation Rear Sprocket REMOVAL iia Eed a re ni ner tee Rear Sprocket Installation Coupling gl Ee EE Coupling Bearing Rermomal uerge LEES EEN receded eked deed ete ee ee Coupling Bearing Installation Coupling Bearing Inspection Coupling Bearing FObrtGetept 8 ndeegge dene han A ata ets 11 13 Coupling Damper Inspechon eent 11 14 Grease Seal Inspection and Lubrication coccccccnnnccnnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnncnnnnss 11 14 Sprocket Wear Inspechon see 11 14 Rear Sp
46. 1020 kgf m N m x 0 7376 ft lb Units of Mass N m x 8 851 in Ib kg x 2 205 Ib kgf m x 9 807 N m g x 0 03527 OZ kgf m x 7 233 ft lb kgf m x 86 80 in lb Units of Volume L 0 2642 gal US Units of Pressure L x 0 2200 gal imp kPa x 0 01020 kgf cm L x 1 057 S qt US kPa x 0 1450 psi L 0 8799 qt imp kPa x 0 7501 cm Hg L x 2 113 pint US kgf cm x 98 07 kPa L S 1 816 pint imp kgf cm x 14 22 psi mL x 0 03381 oz US cm Hg x 1 333 kPa mL x 0 02816 oz imp mL x 0 06102 cu in Units of Speed km h x 0 6214 mph Units of Force N x 0 1020 kg N x 0 2248 Ib Units of Power kg x 9 807 S N Ku x 1 360 PS kg x 2 205 Ib kW x 1 341 HP PS x 0 7355 kw PS x 0 9863 HP Units of Temperature so OO ee sips EE 5 9 oF oF 4 32 68 104 176 212 248 284 40 20 0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 40 20 o 2 40 i 60 i 80 400 120 440 160 17 8 4 4 26 7 48 9 71 1 93 3 116 138 PERIODIC MAINTENANCE 2 1 Periodic Maintenance Table of Contents Periodic Maintenance Chart 2 3 Torque and Locking Ee ari ney deems untae St AA A nd estan A a aa Ai epoha 2 6 Specifications EE 2 11 Special TOO EE 2 13 Periodic Maintenance Procedures 2 14 A In 2 14 Air Cleaner Element Cleaning usnsaaiis diese 2 14 Air Cleaner Element Installation 2 15 Throttle Control System Inspection 2 15
47. 5 N m 0 15 kgf m 13 in Ib Water Pump Removal e Remove Pump Cover see Pump Cover Removal e Remove the water pump mounting bolts A and remove the water pump B Water Pump Installation e Check the O ring A visually whether or not there is a damage on it e Grease the O ring e Install the water pump aligning the slit B of water pump shaft with the oil pump shaft COOLING SYSTEM 4 11 Water Pump Pump Impeller Inspection e Visually check the impeller A x lf the surface is corroded or if the blades are damaged replace the water pump unit 4 12 COOLING SYSTEM Radiator Radiator Fan Radiator and Radiator Fan Removal WARNING The radiator fan is connected directly to the bat tery The radiator fan may start even if the ignition switch is off NEVER TOUCH THE RADIATOR FAN UNTIL THE RADIATOR FAN CONNECTOR IS DIS CONNECTED TOUCHING THE FAN BEFORE THE CONNECTOR IS DISCONNECTED COULD CAUSE INJURY FROM THE FAN BLADES e Remove the lower fairings see Lower Fairing Removal in the Frame chapter e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Disconnect the fan motor lead connector A before re moval of the radiator or radiator fan e Disconnect the fan switch lead connector A Fan Switch B e Loosen the hose clamp C and pull off the water hose D e Loosen the hose clamp A and pull off the water hose B e Remo
48. 6 0 44 Rear Shock Absorber Mounting Nuts 59 6 0 44 Swingarm Pivot Nut 98 10 0 72 Steering Steering Stem Nut 4 9 0 5 43 mb Handlebar Holder Mounting Bolts 25 2 5 18 Steering Stem Head Bolt 44 4 5 32 Front Fork Clamp Bolts Upper 20 2 0 15 Front Fork Clamp Bolts Lower 30 3 1 22 Frame Sidestand Nut 44 4 5 32 Front Footpeg Bracket Mounting Bolts 25 2 5 18 Rear Footpeg Bracket Mounting Bolts 25 2 5 18 Sidestand Switch Bolt 8 8 0 90 78 in lb L Windshield Mounting Screws 0 42 0 043 3 7 in lb Electrical System Tail Brake Light Mounting Bolts 5 9 0 6 52 in lb Plugs on Alternator Cover Hand Tighten Alternator Cover Bolts 9 8 1 0 87 in lb Alternator Rotor Bolt 68 6 7 0 51 Alternator Stator Bolts 12 1 2 104 mb Regulator Rectifier Bolts 9 8 1 0 87 in lb Starter Motor Clutch Bolts 34 3 3 5 25 L Crankshaft Sensor Screws 3 0 0 30 27 in lb Ignition Coil Bolts see text Spark Plugs 13 1 3 115 in lb Starter Motor Terminal Locknut 9 8 1 0 87 in lb Starter Motor Assembly Bolts 3 5 0 36 31 in lb Starter Motor Mounting Bolts 9 8 1 0 87 in lb Starter Relay Terminal Nut 5 0 0 5 44 in lb Oil Pressure Switch 15 1 5 11 SS Neutral Switch 15 1 5 11 2 10 PERIODIC MAINTENANCE Torque and Locking Agent 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 sol
49. 6 0 kgf m 44 ft lb e Install the rear wheel see Rear Wheel Installation in the Wheels Tires chapter Coupling Installation e Grease the following and install the coupling Coupling Grease Seal A Coupling Internal Surface A Ball Bearing A Coupling Bearing Removal e Remove Coupling Grease Seal Bearing A GKO5098BS1 GKO501068S1 Sprocket Coupling FINAL DRIVE 11 13 e Remove the bearing A by tapping from the wheel side Special Tool Bearing Driver Set 57001 1129 B Coupling Bearing Installation e Replace the bearing with a new one e Press in the bearing A until it is bottomed Special Tool Bearing Driver Set 57001 1129 B e Pack the bearing with high temperature grease e Replace the grease seal with a new one e Press in the grease seal so that the seal surface is flush with the end of the hole OApply high temperature grease to the grease seal lips Special Tool Bearing Driver Set 57001 1129 Coupling Bearing Inspection Since the coupling bearing is made to extremely close tolerances the clearance can not normally be measured NOTE Olt is not necessary to remove the coupling bearing for inspection If the bearing is removed it will need to be replaced with a new one e Turn the bearing in the coupling back and forth A while checking for plays roughness or binding x If the bearing play roughness or binding is found replace the bearing
50. A Special Tool Pilot Screw Adjuster 57001 1239 OTurn in the pilot screw fully but not tightly and then back it out the specified turns To set the screw to its original position Pilot Screw Setting L 2 1 2 R 1 3 4 NOTE OThe standard number of turns the pilot screw must be backed out varies by carburetor The values given in the specifications should be used only when the number of the original back out turns is unavailable Carburetors FUEL SYSTEM 3 13 Service 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 Situate the motorcycle so that it is perpendicular to the ground e Remove Front Seat see Front Seat Removal in the Frame chap ter Fuel Tank see Fuel Tank Removal e Prepare an auxiliary fuel tank and connect the fuel hose to the carburetor e Prepare a fuel hose e Connect the fuel level gauge A to the carburetor float bowl with the fuel hose Special Tool Fuel Level Gauge 57001 1017 e Hold the gauge vertically against the side of the carburetor body so that the middle line B is several millimeters higher than the mating surface C of the carburetor float bowl e Feed fuel to the carburetor then turn the carburetor drain plug
51. A replace the clutch hub Replace the steel plates if their teeth are damaged as well GFO6169BS1 GFO6171BS1 ENGINE LUBRICATION SYSTEM 7 1 Engine Lubrication System Table of Contents E leie Ee WEE 7 2 Specifications EE 7 4 Special Tools and Sealant nesesario eine line entre Ad 7 5 Engine Oil Flow Chart EE 7 6 Engine Oil eich Ou Fier An ananas tata ee anne en cent Lens 7 7 Oil Level Inspection see 1 7 Engine Oil Change sois Ten iaa Dado ocn 7 7 Oil Filter Replacement Si ieeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeenee 7 7 Bypass Valve Disassembly aiii den mass tant Eege ege Devt le 7 8 Bypass Valve Assembly n etant de AU deeg Eed 7 8 Bypass Valve Cleaning and Inspection 7 8 Oil Screen Cleaning and Inspection 7 9 Oil Pressure Relief Valve sise 7 10 Oil Pressure Relief Valve Hemoval ss 7 10 Oil Pressure Relief Valve Installation ssnssnnsnnnnnnneneneneeerersrrerrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrent 7 10 Oil Pressure Relief Valve Inspection 7 10 Ol PUNA dale 7 11 Oil Pump Removal incas ricardo roca haandregeacitedanoudenpamevesncatovaetuugetan 7 11 Oil Pump Installation see 7 11 Oil Pump Dis assembly EE 7 11 A A E TA TT 7 11 Oil PUMP INSPECT ON EE 7 11 Oil Pressure Measurement oooccccccccccconnnocnnnnnnnnnnnnnnnnnnn nn nn n ner nn RR RR RR RRRRRRnRnnnnnnnnnnnnnnnineninis 7 12 Oil Pressure Measurement sie 7 12 Oil Pressure SWITCN s ccccoccseccsseczieccccacctaneccdadaceadocazena
52. Air Cleaner Housing Mounting Bolts 9 8 1 0 87 in lb Air Cleaner Housing Clamp Screws 2 0 0 2 18 in lb Separate Bracket Bolt 9 8 1 0 87 in lb Cooling System Water Temperature Switch 7 5 0 76 66 in lb SS Thermostat Cover Bolts 9 8 1 0 87 in lb Thermostat Housing Mounting Bolts 9 8 1 0 87 in lb Radiator Fan Switch 23 5 2 4 17 Radiator Bolts 9 8 1 0 87 in lb Radiator Cap Bracket Bolt 9 8 1 0 87 in lb Water Pipe Bolts 9 8 1 0 87 in lb Water Hose Clamp Screws 1 5 0 15 13 in lb Drain Bolt 9 8 1 0 87 in lb Water Pump Cover Bolts 9 8 1 0 87 in lb Water Pump Bolts 9 8 1 0 87 in lb Reserve Tank Cap Hand Tighten Reserve Tank Bolts 9 8 1 0 87 in lb Reserve Tank Bracket Bolt 9 8 1 0 87 in lb Engine Top End Cylinder Head Cover Bolts 9 8 1 0 87 in lb Camshaft Sprocket Bolts 15 1 5 11 L Chain Tensioner Cap Bolt 5 0 0 5 44 in lb Air Suction Cover Bolts 9 8 1 0 87 in lb Vacuum Switch Valve Bracket Bolts 9 8 1 0 87 in lb Rear Camshaft Chain Guide Bolt Lower 17 1 7 13 PERIODIC MAINTENANCE 2 7 Torque and Locking Agent Fastener Chain Tensioner Mounting Bolts 9 8 1 0 87 in lb Camshaft Cap Bolts 12 1 2 106 in Ib S Camshaft Cap Bolts 12 1 2 106 in Ib S Cylinder Head Bolt M6 12 1 2 106 in Ib MO S Cylinder Head Bolts M8 24 5 2 5 18 MO S Water Passage Plugs 20 2 0 15 L Carburetor Holder Clamp Screws 2 0 0 2 18 in lb Water Drain Bolt 5 9 0 6 52 in lb Muffler Body Rear Cover Bolts 9 8 1 0 87 in lb L Muffler Body Mounting Bolt 30 3 1 22 M
53. Blue Mark Red Mark Hose Blue Hose Red Separator Hose White Hose Green Hose Blue Canister APPENDIX 17 37 Cable Wire and Hose Routing 0 JO O1 P GO A Filter Body Clamps Cooling Hose Water Pipe Carburetor Coolant Valve Assmbly Damper Run the cooling hose inside of the water pipe 17 38 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 Starter lockout switch or neutral switch trou ble Starter motor trouble Battery voltage low Starter relays not contacting or operating Starter button not contacting Wiring open or shorted Ignition switch trouble Engine stop switch trouble Main fuse blown Starter motor rotating but engine doesn t turn over Starter motor clutch trouble Engine won t turn over Valve seizure Valve lifter seizure Cylinder piston seizure Crankshaft seizure Connecting rod small end seizure Connecting rod big end seizure Transmission gear or bearing seizure Camshaft seizure Starter idle gear seizure No fuel flow No fuel in fuel tank Fuel tap vacuum hose clogged Fuel tank air vent obstructed Fuel tap clogged Fuel line clogged Float valve clogged Engine flooded Fuel level in carburetor fl
54. Bracket Bois and Nuts 64 65 a 2 Engine Mounting Nuts a 65 4 8 4 ENGINE REMOVAL INSTALLATION Engine Removal Installation Engine Removal e Drain the engine oil see Engine Oil Change in the Peri odic Maintenance chapter e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove Front Seat see Front Seat Removal in the Frame chap ter Side Covers see Side Cover Removal in the Frame chapter Lower Fairings see Lower Fairing Removal in the Frame chapter Upper Fairings see Upper Fairing Removal in the Frame chapter Fuel Tank see Fuel Tank Removal in the Fuel System chapter Throttle Cable see Throttle Cable Removal in the Fuel System chapter Choke Cable see Choke Cable Removal in the Fuel System chapter Clutch Cable Lower End see Clutch Cable Removal in the Clutch chapter Muffler see Muffler Removal in the Engine Top End chapter Engine Sprocket see Drive Chain Removal in the Final Drive chapter e Remove Left Side Coolant Pipe A Oil Pressure Switch Lead Connector B Neutral Switch Terminal C Breather Hose D at Air Cleaner Housing Carburetor Holder Clamp Loosen E Spark Plug Caps F ENGINE REMOVAL INSTALLATION 8 5 Engine Removal Installation e Remove or disconnect Cooling Hose A at Cylinder Head Starter Motor Cable B Engine Ground Terminal C Alternator Lead Connector D Crankshaft Sensor Lead Connector E Air Suction
55. Circuit Q BK BK O BK Y BK Y S BR BR BK o BK Y KI BK Y GP17995BW2 C Tachometer Fuse Box Ignition Fuse 10 A Ignition Switch Main Fuse 30 A Battery IC Igniter zl OO O1 N A 16 58 ELECTRICAL SYSTEM Meters Gauge and Indicator Unit Water Temperature Warning System Inspection The water temperature warning light goes on when the ignition switch is turned on and goes off soon after the en gine starts running oil pressure switch off to ensure that its circuit functions properly The warning light also goes on whenever the coolant temperature rises to 110 120 C 230 248 F when the motorcycles is in operation If it stays on stop the engine and check the coolant level in the reserve tank after the engine cools down e Inspect the water temperature warning light and the sys tem wiring see Wiring Inspection e Turn on the ignition switch e Disconnect the water temperature switch lead A and oil pressure switch lead then ground them together to the frame or engine using auxiliary lead x lf the warning light is lit inspect the water temperature switch see Specifications and the oil pressure switch B Replace any switch if damaged x If the warning light is not lit check the warning light bulb Water Temperature Warning System Circuit A i Se eat BR BK BL R BL R 1 6 lies ve lau BK Y GP17996BW2 Ignition Switch F
56. Cylinder Head Removal in the En gine Top End chapter Cylinder see Cylinder Removal in the Engine Top End chapter Pistons see Piston Removal in the Engine Top End chapter CRANKSHAFT TRANSMISSION 9 11 Crankcase e Remove the clutch only if the transmission drive shaft as sembly is to be removed e Remove the oil pressure bolt A with the oil pressure switch B and oil hose C e Remove the neutral switch D e Remove the upper crankcase half bolt 1 3 were re moved just after engine removal e Turn the engine upside down e Remove the oil filter mounting bolt oil filter and large O ring e Remove the oil screen cover A and screen B e Remove the 6 mm A and 8 mm B lower crankcase half bolt ply the point C shown to split the two crankcase halves apart and lift off the lower crankcase half Washer D Crankcase Assembly NOTE OThe upper lower crankcase halves are machined at the factory as an assembly so the crankcase halves must be replaced as a set e Assembly is the reverse of splitting Be careful of the following items OWith a high flash point solvent clean off the mating sur face of the crankcase halves and wipe dry OWhen installing the output and drive shafts the crankcase set pins A must go into the holes in the needle bearing outer races and the set rings B must fit into the grooves in the ball bearings G104314BS1 TL
57. Disc Warp Inspection e Jack up the motorcycle so that the wheel is off the ground see Front Rear Removal in the Wheels Tires chapter OFor front disc inspection turn the handlebar fully to one side e Set up a dial gauge against the disc A as shown and measure the disc runout while turning B the wheel by hand x If the runout exceeds the service limit replace the disc Disc Runout Service Limit 0 3 mm 0 01 in TIR GLOSO10BS1 1080902 12 18 BRAKES Brake Fluid Brake Fluid Level Inspection e Refer to Brake Fluid Level Inspection in the Periodic Main tenance chapter see Brake Fluid Level Inspection in the Periodic Maintenance chapter Brake Fluid Change e Refer to Brake Fluid Change in the Periodic Maintenance chapter see Brake Fluid Change in the Periodic Mainte nance chapter Brake Line Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action Air however is easily compressed When air enters the brake lines brake lever or pedal movement will be partially used in compressing the air This will make the lever or pedal feel spongy and there will be a loss in braking power A WARNING Be sure to bleed the air from the brake line when ever brake lever or pedal action feels soft or spongy after the brake fluid is changed or when ever a brake line f
58. Do not attempt to drive the motorcycle until a full brake lever is obtained by pumping the brake lever and the pads are against the disc The brake will not function on the first application of the lever if this is not done 078274 P 12 14 BRAKES Master Cylinder Rear Master Cylinder Removal e Remove the cotter pin A and then pull the joint pin B out of the push rod clevis C and brake pedal NOTE OPull off the joint pin while pressing down the brake pedal e Slide the brake hose clamp A out of place see Brake Hose and Pipe Replacement in the Periodic Maintenance chapter e Disconnect the brake hoses B from the brake hose con nector of the master cylinder C and temporarily secure the end of the brake hose so some high place to keep fluid loss to a minimum and immediately wipe up any brake fluid that spills e Remove the master cylinder mounting bolts D and take the master cylinder off the footpeg bracket e Remove the banjo bolt E to disconnect the brake hose from the master cylinder and temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum There are flat washers on each side of the hose fitting CAUTION Immediately wash away any brake fluid that spills Rear Master Cylinder Installation e Tighten the banjo bolt with a specified torque after in stalling a new flat washer on each side of the brake hose fitting Be sure that the metal pipe is proper
59. Gauge KEK 55 5 57001 1369 2 18 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Start the engine and let it idle to measure the carburetor intake vacuum x If the intake vacuum difference between the two cylinders exceeds the limit adjust the synchronization Engine Vacuum Synchronization Less than 2 7 kPa 2 cmHg difference between both cylinders e Turn the adjusting screw A to synchronize the carbure tor x lf the carburetor synchronization cannot be obtained by using the adjusting screw check for dirt or blockage and then check the pilot screw settings e Check the Carburetor Synchronization again NOTE ODo not turn the pilot screws carelessly during carburetor synchronization You may cause poor running at low engine speed Idle Speed Inspection e Start the engine and warm it up thoroughly e With the engine idling turn the handlebar to both sides A xlf handlebar movement changes the idle speed the throttle cables may be improperly adjusted or incorrectly routed or damaged Be sure to correct any of these conditions before riding see Throttle Control System Inspection or Cable Wire and Hose Routing section in the Appendix chapter A WARNING Operation with improperly adjusted incorrectly routed or damaged cables could result in an unsafe riding condition e Check idle speed x lf the idle speed is out of the specified range adjust it Idle Speed Standard 1 300 50 r min rpm
60. Housing A see Water Pump Removal in the Cooling System chapter Water Pump Cover B see Water Pump Removal in the Cooling System chapter Hoses C Pipe D O rings E e Apply grease to the new O rings and install them e Install the new hoses and tighten the clamps securely e Fill the coolant see Coolant Change e Check the cooling system for leaks GDO050109S1 GSO6046BS3 C PERIODIC MAINTENANCE 2 47 Periodic Maintenance Procedures Engine Oil Change A WARNING To avoid a serious burn never touch the exhaust pipe during oil change e Warm up the engine sufficiently with the motorcycle standing on its side stand and stop the engine e Place an oil pan under the engine and remove the drain bolt A to drain the oil e Replace the drain bolt gaskets with new ones if they are damaged OThe oil in the oil filter can be drained by removing the filter e After draining the oil tighten the drain bolts Torque Oil Drain Bolts 19 6 N m 2 0 kgf m 14 5 ft Ib Oil Filter Mounting Bolt 19 6 N m 2 0 kgf m 14 5 ft Ib e Pour in the specified type and amount of oil Recommended Engine Oil Type API SE SF or SG API SH SJ or SL with JASO MA Viscosity SAE 10W 40 Capacity 1 3 L 1 4 US qt When filter is not removed 1 6 L 1 7 US qt When filter is removed NOTE OAlthough 10W 40 engine oil is the recommended oil for most conditions the oil viscosity may need to be cha
61. Insert Journal Clearance Standard 0 014 0 038 mm 0 0006 0 0015 in Service Limit 0 08 mm 0 0031 in x If the clearance is within the standard no bearing replace ment is required x If the clearance is between 0 038 mm 0 0015 in and the service limit 0 08 mm 0 0031 in replace the bearing in serts with inserts A painted blue B Check insert journal clearance with the plastigage The clearance may exceed the standard slightly but it must not be less than the min imum in order to avoid bearing seizure x lf the clearance exceeds the service limit measure the diameter of the crankshaft main journal Crankshaft Main Journal Diameter Standard 27 984 28 000 mm 1 1017 1 1024 in Service Limit 27 96 mm 1 101 in x If any journal has worn past the service limit replace the crankshaft with a new one x If the measured journal diameters are not less than the service limit but do not coincide with the original diameter markings on the crankshaft make new marks on it Crankshaft Main Journal Diameter Marks None 27 984 27 992 mm 1 1017 1 1020 in 1 27 993 28 000 mm 1 1021 1 1024 in O Crankshaft Main Journal Diameter Marks 1 mark or no mark 6105052BS1 6105041751 6105053BS1 C 9 20 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods e Measure the main bearing bore diameter and mark the upper crankcase half in accordance with the bore
62. TIR 0 03 mm 0 0012 in or less TIR 0 2 mm 0 008 in Wheel Balance 10 g 0 35 oz or less Balance Weights 10 g 0 35 oz 20 g 0 71 oz 30 g 1 06 oz Rim Size Front 17 x 2 75 Rear 17 x 3 50 Tires Air Pressure when Cold Front Up to 170 kg 375 Ib load 200 kPa EE 2 00 kgf cm 28 psi Rear Up to 170 kg 375 Ib load 225 kPa 2 25 kgf cm 32 psi Tread Depth Front BRIDGESTONE 4 6 mm 0 181 in 1 mm 0 04 in DUNLOP 4 5 mm 0 177 in Rear BRIDGESTONE 7 0 mm 0 276 in Up to 130 km h 80 mph 2 mm 0 08 in DUNLOP 7 4 mm 0 291 in Over 130 km h 80 mph 3 mm 0 12 in Standard Tires Make Type Size Front BRIDGESTONE BATTLAX BT45F 110 70 17 M C 54 H DUNLOP GT 501FG T L Rear BRIDGESTONE BATTLAX BT45R 130 70 17 M C 62 H DUNLOP GT501 T L A WARNING Use the same manufacturer s tires on both front and rear wheels WHEELS TIRES 10 5 Special Tools Inside Circlip Pliers Bearing Driver Set 57001 143 57001 1129 ST5701438T ST5711298T Rim Protector Bearing Remover Shaft 9 57001 1063 57001 1265 ST571063ST ST5712658T Bead Breaker Assembly Bearing Remover Head 415 x 17 57001 1072 57001 1267 T5710728T ST571267ST 10 6 WHEELS TIRES Wheels Rims Front Wheel Removal e Remove Speedometer Cable Lower End A Axle Nut Cotter Pin B Axle Loosen C Front Caliper Moun
63. Tools Fork Cylinder Holder Handle 57001 183 D Fork Cylinder Holder Adapter 57001 1057 E e Take the cylinder unit out of the inner tube e Remove the following from the top of the outer tube Dust Seal A Retaining Ring B e Use the fork outer tube weight A to separate the inner tube from the outer tube Holding the inner tube by hand in a vertical position pull down the outer tube several times to pull out the inner tube Special Tool Fork Outer Tuber Weight 57001 1218 e Take out the cylinder base from the outer tube bottom e Remove the inner guide bushing from the inner tube 6M040404S1 GM04515BS1 GM04062281 13 10 SUSPENSION Front Fork Front Fork Assembly e Check the top plug O ring and snap ring and replace them with new ones if necessary e Replace the following parts with new ones Inner Guide Bushing A Retaining Ring B Oil Seal C Outer Guide Bushing D Bottom Allen Bolt Gasket E e Put the cylinder unit A with the spring into the inner tube B protruding from the inner tube and install the cylinder base C onto the bottom end of the cylinder unit Olnstall the cylinder base with the tapered end D facing upward e Install the inner tube cylinder unit and cylinder base as a set into the outer tube e Install the new guide bushing A with a use one B on it by tapping the use one with the fork oil seal driver C OTh
64. Vacuum Switch Valve Unit Test 5 11 Valve Guide Removal 5 25 Air Suction Valve Removal 5 12 Valve Guide Installation 5 25 Air Suction Valve Installation 5 12 Valve to Guide Clearance Air Suction Valve Inspection 5 12 Measurement Wobble Clean Air System Hose Method E 5 26 Inspection 5 13 Valve Seat Inspection 5 27 Cylinder Head Cover 5 14 Valve Seat Repair 5 27 Cylinder Head Cover Removal 5 14 Cylinder PRISONS 5 32 Cylinder Head Cover Installation 5 14 Cylinder Removal 5 32 Camshaft Chain Tensioner 5 15 Cylinder Installaton 5 32 Camshaft Chain Tensioner Piston Hemoval 5 33 Removal reit ait 5 15 Piston Installaton 5 33 Camshaft Chain Tensioner Cylinder Wear Inspection 5 34 Installation 5 15 Piston Wear Inspection 5 34 Camshaft Camshaft Chain 5 17 Piston Ring Piston Ring Groove Camshaft Removal 5 17 Wear Insepction 5 35 Camshaft Installation 5 17 Piston Ring Groove Width Camshaft and Sprocket INSpeEction geess kascht derr geng 5 35 A 5 19 Piston Ring Thickness Inspection 5 35 Camshaft and Camshaft Cap Piston Ring End Gap Inspection 5 36 Wear Inspection 5 19 Boring Honing n e 5 36 Camshaft Ru
65. a container for brake fluid and perform the work above it ORemove the spring and pads see Brake Pad Removal OPump the brake lever or pedal until the pistons come out of the cylinders and then disassemble the caliper 2 52 PERIODIC MAINTENANCE Periodic Maintenance Procedures Caliper Assembly e Clean the caliper parts except for the pads CAUTION For cleaning of the parts use only disc brake fluid ispopropyl alcohol or ethyl alcohol e Install the bleed valve and rubber cap Torque Bleed Valve 5 5 N m 0 55 kgf m 49 in Ib e Replace the fluid seals A and dust seals B with new one e Apply brake fluid to the fluid seals and dust seals and install them into the cylinder by hand e Apply brake fluid A to the outside of the pistons and push them into each cylinder by hand without scratching the cylinder and piston skirt e Apply silicone grease B to the caliper holder shaft and holder holes and install the caliper holder C rubber boot D and dust cover E e Install the anti rattle spring F and pads in the caliper see Pad Installation in the Brakes chapter Spark Plug Replacement e Remove Spark Plugs see Spark Plug Removal in the Electrical System chapter e Remove the spark plugs using the 16 mm plug wrench A Owner s Tool Spark Plug Wrench 16 mm 92110 0044 e Insert the spark plug vertically into the plug hole with the spark plug installed in the plug wrench A Owner s
66. and ignition fuse Diodes Inspection e Remove the left lower fairing see Lower Fairing in the Frame chapter e Disconnect the diode A e Remove the front seat see Front Seat Removal in the Frame chapter e Disconnect the diode assemblies A e Zero the hand tester and connect it to each diode terminal to check the resistance in both directions x The resistance should be low in one direction and more than ten times as much in the other direction If any diode shows low or high in both directions the diode is defective and the diode assembly must be replaced GP108701 P lt ELECTRICAL SYSTEM 16 39 Ignition System NOTE Anode OThe actual meter reading varies with the meter used and the individual diode but generally speaking the lower reading should be from zero to one half the scale d O Cathode GP100308 S 16 40 ELECTRICAL SYSTEM Ignition System Ignition System Circuit ane l l LT l 9 Y9 l 9 A M 9 91 S 9 4 xa 9 xa 9 A 4 18 ADR 44 3 SEH D DE gt CAS YE gt 8 88 Lp ve bey E Bip OPE SIIE kT GP10472BW4 C 2 Engine Stop Switch 3 Ignition Coils 4 Spark Plugs 5 Diode A 7 Ignition Fuse 10 A 8 Battery 9 Main Fuse 30 A 1 Ignition Switch 10 Pickup Coil 6 Fuse Box 14 Starter Lockout Switch 11 Neutral Switch 12 IC Igni
67. before tighten it with the specified torque Olnstall the rotor bolt and tighten it with 55 N m 5 6 kgf m 41 ft lb of torque ORemove the rotor bolt OCheck the tightening torque with flywheel puller x If the rotor is not pulled out with 20 N m 2 0 kgf m 14 5 ft lb of drawing torque it is installed correctly x If the rotor is pulled out with 20 N m 2 0 kgf m 14 5 ft lb of drawing torque clean off any oil dirt or flaw of the crank shaft and rotor tapered portion and dry them with a clean cloth Then confirm that it is not pulled out with above torque e Tighten the alternator rotor bolt with holding the alternator rotor steady with the flywheel holder Special Tool Flywheel Holder 57001 1313 Torque Alternator Rotor Bolt 68 6 N m 7 0 kgf m 51 ft lb e Apply a thin coat of molybdenum disulfide grease to the shaft A and install it and starter idle gear B e Install the alternator cover see Alternator Cover Installa tion Alternator Inspection There are three types of alternator failures short open wire burned out or loss in rotor magnetism A short or open in one of the coil wires 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 do the following procedures OTurn off the ign
68. between the highest and lowest dial readings is the amount of runout x If the axle runout exceeds the service limit replace the axle Axle Runout 100 mm 3 94 in Standard TIR 0 10 mm 0 0394 in or less Service Limit TIR 0 2 mm 0 008 in GJ04130BS1 6J04018BS1 10 10 WHEELS TIRES Wheels Rims Balance Inspection e Remove the wheel e Support the wheel so that it can be spun freely e Spin the wheel lightly and mark A the wheel at the top when the wheel stops ORepeat this procedure several times If the wheel stops of its own accord in various positions it is well balanced x If the wheel always stops in one position adjust the wheel balance Balance Adjustment elt the wheel always stops in one position provisionally attach a balance weight A on the rim at the marking using adhesive tape e Rotate the wheel 1 4 turn B and see whether or not the wheel stops in this position If it does the correct balance weight is being used x If the wheel rotates and the weight goes up replace the weight with the next heavier size If the wheel rotates and the weight goes down replace the weight with the next lighter size Repeat these steps until the wheel remains at rest after being rotated 1 4 turn e Rotate the wheel another 1 4 turn and then another 1 4 turn to see if the wheel is correctly balanced e Repeat the entire procedure as many times as necessary to achieve correct
69. check the wiring and related components for a short circuit 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 ad components and installation of a fuse with a lower rating may cause the fuse to be blown quickly GP20000181 APPENDIX 17 1 Appendix Table of Contents Cable Wire and Hose Routing EE 17 2 Troubleshooting QUA astas a a a a a id a Aaaa Eaa Eana ts 17 38 17 2 APPENDIX Cable Wire and Hose Routing 6809970 G Cable Wire and Hose Routing APPENDIX 17 3 JO O1 amp ND Right Switch Housing Leads Ignition Switch Leads Left Switch Housing Leads Choke Cable Guide Guide Guide Speedometer Cable Throttle Cable Accelerator Throttle Cable Decelerator Brake Hose Throttle Cables Guide Guide Left Switch Housing Leads Right Switch Housing Leads 17 4 APPENDIX Cable Wire and Hose Routing APPENDIX 17 5 Cable Wire and Hose Routing JO O1 amp ND Choke Cable Clutch Cable Left Switch Housing Leads Meter Leads Connectors Band Guide Band Headlight Leads Connectors Guide Speedometer Cable Guide Starter Locknut Switch Lead 17 6 APPENDIX Cable Wire and Hose Routing no WE k Cable Wire a
70. diame ter A Crankcase Main Bearing Bore Diameter Marks O mark or no mark NOTE OTighten the crankcase bolts to the specified torque see Crankcase Assembly OThe mark already on the upper crankcase half should almost coincide with the measurement Crankcase Main Bearing Bore Diameter Marks O 31 000 31 008 mm 1 2205 1 2208 in None 31 009 31 016 mm 1 2208 1 2211 in e Select the proper bearing insert A in accordance with the combination of the crankcase and crankshaft coding Size Color B Crankcase Main Bearing Bore Crankshaft Main Journal Diameter Bearing Insert 6105054BS1 6105041751 Diameter Marking Marking Size Color Part Number Journal Nos 92028 1487 1 3 92028 1490 2 None 29028 1486 1 3 O 92028 1489 2 92028 1582 1 3 None None Yellow 92028 1586 2 The bearing insert for No 2 journal have an oil groove e Install the new inserts in the crankcase halves and check insert journal clearance with the plastigage CRANKSHAFT TRANSMISSION 9 21 Starter Motor Clutch Starter Motor Clutch Removal Installation e Refer to Alternator Rotor Removal and Installation in the Electrical System chapter see Alternator Rotor Removal and Installation in the Electrical System chapter Starter Motor Clutch Inspection e Remove Alternator Cover see Alternator Cover Removal in the Electrical System chapter Starter Idle Gear e Turn the starte
71. e Remove Rear Footpeg Bracket Bolts Rear Footpeg Bracket e Remove the screws A both sides e Disconnect the electrical connectors from the main har ness and remove the fender bolts rear A 15 12 FRAME Fenders e Remove the battery see Battery Removal in the Electrical System chapter e Take out the fuse box A and IC igniter B e Remove Battery Case Screws C Rear Fender Bolts Front D e Remove the rear fender Rear Fender Installation e Route the following therough the hole A on the rear fender License Plate Light Leads Rear Right and Left Turn Signal Light Leads e Install the damper to the cover so that its flatten side A faces downwards e Be sure that the damper A is in position ELECTRICAL SYSTEM 16 1 Electrical System Table of Contents E olle 1o Ee WEE 16 4 Wiring Diagram United States Canada and Australia 16 10 Wiring Diagram Indonesia sisas aii Specification deidad Special Loge ANG Sealants serrera Ai Parts Location iaa PESCANDO Electrical Wiring ces dsd Wiring INS pectin es mans a nan fon Pen ee ds a ne an NT i E la Ae EE Battery le EE Battery ACI ON tii PDA AN ne Po ee ebe See Te RARE AO Int rchange rene a akara auanei nette ANEA EAk e Mens eine re dered Charging Condition le Det EE Refreshing Ee CEET Charging System E EE Alternator Cover Removal EEEE EEEE Alternator Cover Ins
72. iaie EE EEA AA E EEEE EE EEE aE 16 63 Ee VE IR 16 63 FUSE Instala iii ege eer A A A a 16 63 Se Dee Le E 16 63 ELECTRICAL SYSTEM 16 3 Dummy Page 16 4 ELECTRICAL SYSTEM Exploded View 6P024018W5 C ELECTRICAL SYSTEM 16 5 Exploded View Tail Brake Light Mounting Bolts 59 06 52 imlb 16 6 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 16 7 Exploded View _ Fastener Plugs on Alternator Cover EURE Hand Tighten N Alternator Cover Bolts 9 8 1 0 87 in lb Alternator Rotor Bolt 68 6 7 0 EE 5 Regulator Rectifier Bolts 87 in lb 6 Starter Motor Clutch Bolts SS 25 L 7 Crankshaft Sensor Screws 3 0 0 30 27 in lb 8 Ignition Coil Bolts see text 9 Spark Plugs 13 1 3 115 in lb 10 Starter Motor Terminal Locknut 9 8 1 0 87 in lb 11 Starter Motor Assembly Bolts 3 5 0 36 31 in lb 12 Starter Motor Mounting Bolts 9 8 1 0 87 in lb 13 Starter Relay Terminal Nut 5 0 0 5 44 in lb 14 IC Igniter G Apply grease L Apply a non permanent locking agent M Apply molybdenum disulfide grease SS Apply silicone grease 16 8 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 16 9 Exploded View LT Jon Pressure Switch e ps ns 2 Neutral Switch Rear Brake Light Switch Side Stand Switch Radiator Fan Switch Water Temperature Switch Ignition Switch Turn Signal Relay Fus
73. in the Electrical System chapter PERIODIC MAINTENANCE 2 39 Periodic Maintenance Procedures e Set the dimmer switch to high beam position e The low beam A and high beam B headlights should go on e The high beam indicator light C should go on x If the high beam headlight and or high beam indicator light does not go on inspect or replace the following item Headlight High Beam Bulb see Headlight Bulb Replace ment in the Electrical System chapter Dimmer Switch see Switch Inspection in the Electrical System chapter e Turn off the engine stop switch e The low beam and high beam headlights should stay go ing on x If the headlights and high beam indicator light does go off inspect or replace the following item Headlight Relay see Relay Circuit Inspection in the Electrical System chapter e Turn off the ignition switch e The headlights and high beam indicator light should go off Headlight Aiming Inspection e Inspect the headlight beam for aiming x lf the headlight beam points to one side rather than straight ahead adjust the horizontal beam Headlight Beam Horizontal Adjustment e Turn the horizontal adjuster A on the headlight with the screwdriver in or out until the beam points straight ahead x lf the headlight beam points too low or high adjust the vertical beam Headlight Beam Vertical Adjustment e Turn the vertical adjuster A on the headlight with the screwdriver in or out to adjust the h
74. llene vice hrs et annee ale al cela Wein veined dena aden 2 30 Wheel Alignment Inspection en 2 31 Drive Chain Wear Inspection ooocccccnnccnnncnnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnninnnnnnninnnnss 2 31 Chain Guide Inspection sise 2 32 Brake SM unica 2 32 Brake Fluid Leak Brake Hose and Pipe Inspection 2 32 Brake Hose and Pipe Damage and Installation Condition Inspechon 2 32 Brake Operation Inspection ss 2 32 Brake Fluid Level Inspechon EEEn Ennn EnEn 2 33 Brake Pad Wear Inspection ss 2 33 Brake Light Switch Operation Inspection ssssessrerrrernrtrnttrtttnrttnrttnnntnnttnn ttnn nenn n ennnen 2 34 SUSPENSIONS hassen AA EE eet dee eran 2 34 Front Forks Rear Shock Absorber Operation Inspection 2 34 Front Fork Oil Leak Inspection 2 35 Rear Shock Absorber Oil Leak Inspection 2 35 2 2 PERIODIC MAINT ENANCE Rocker Arm Operation Inspection Tie Rod Operation Inspection Swingarm ee EE Steering System Steering Play Inspection Steering Play Adjustment Steering Stem Bearing Lubrication 4 44 Electrical System Lights and Switches Operation Inspection Headlight Aiming Inspecti ON ENEE Sidestand Switch Operation Inspection Engine Stop Switch Operation Inspection DUR ge Ase
75. needle D 6006015652 C Carburetors FUEL SYSTEM 3 15 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 17 2 mm 0 67 0 08 in NOTE ODo not push the needle rod A in during the float height measurement B e Assemble the carburetor and recheck the fuel level x If the fuel level cannot be adjusted by this method the float or the float valve C is damaged 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 Remove Right Lower Fairing see Lower Fairing Removal in the Frame chapter e Connect a suitable hose A to the fitting at the bottom of each carburetor float bowl e Run the lower end of the carburetor drain hose into a suit able container e Turn out each drain plug B a few turns and drain the float bowls with a hexagon wrench C e Check to see if water or dirt comes out e Tighten the drain plug x If any water or dirt appears during the above inspection clean the fuel system see Carburetor Cleaning and Fuel Tank Cleaning 6006016451 C GC06016
76. on the lower crankshaft sprocket A kinked chain could dam age both the chain and the sprocket Camshaft Installation e Apply molybdenum disulfide oil solution to the cam and journal surfaces NOTE OBe sure to operate from the engine left side e Position the crankshaft at 2 piston TDC see Camshaft Removal CAUTION The crankshaft may be turned while the camshafts are removed Always pull the chain taut while turning the crank shaft This avoids kinking the chain on the lower crankshaft sprocket A kinked chain could dam age both the chain and the sprocket 5 18 ENGINE TOP END Camshaft Camshaft Chain e Engage the camshaft chain A with the camshaft sprock ets OPull the tension side exhaust side of the chain taut to install the chain on the sprockets OTiming marks B align with the cylinder head upper sur face Exhaust Camshaft Sprocket C Inlet Camshaft Sprocket D OCount the camshaft chain link pins as shown to verify that the sprocket are positioned correctly e Place the six dowel pins on the marks A e Install the camshaft caps as shown noting the EX B and IN C marks CAUTION The camshaft caps are machined with the cylinder head So if a cap is installed in a wrong location the camshaft may seize because of improper oil clearance in the bearings e Put the plates on the bearing caps OThe exhaust side plates A is longer the inlet side plate
77. or swollen the piston assembly should be replaced to renew the cups x If fluid leakage is noted at the brake lever the piston as sembly should be replaced to renew the cups Front Master Cylinder J e Check the dust covers E for damage x If they are damaged replace them e Check the piston return springs F for any damage x If the springs are damaged replace them e Check that relief port G and supply port H are not plugged xlf the relief port becomes plugged the brake pads will drag on the disc Blow the ports clean with compressed air Rear Master Cylinder K GS13050BS2 Brake Disc BRAKES 12 17 Brake Disc Removal e Remove the wheel see Front Rear Wheel Removal in the Wheels Tires chapter e Unscrew the mounting bolts and take off the disc Brake Disc Installation e Install the brake disc on the wheel so that the marked side B faces out e Apply a non permanent locking agent to the threads of the brake disc mounting bolts A e Tighten Torque Brake Disc Mounting Bolts 27 N m 2 8 kgf m 20 ft lb Brake Disc Wear Inspection e Measure the thickness of each disc A at the point where it has worn the most x If the disc has worn past the service limit replace it Measuring Area B Disc Thickness Standard Front 4 3 4 6 mm 0 17 0 18 in Rear 4 8 5 1 mm 0 19 0 20 in Service Limit Front 4 0 mm 0 16 in Rear 4 5 mm 0 18 in Brake
78. out a few turns e Wait until the fuel level in the gauge settles GC06015582 C 3 14 FUEL SYSTEM Carburetors e Keeping the gauge vertical align the middle line with the mating surface NOTE ODo not lower the middle line below the mating surface of the carburetor float bowl If the gauge is lowered and then raised again the fuel level measured shows somewhat 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 E in the gauge and compare to the specification e Screw in the carburetor drain plug D e Stop feeding and remove the fuel level gauge x lf the fuel level is incorrect adjust it see Service Fuel Level Adjustment Service Fuel Level above the mating surface of carburetor float bowl Standard 0 5 mm 1 mm 0 02 0 04 in Service Fuel Level Adjustment 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 the carburetor and drain the fuel into a suitable container e Remove the fittings with water hose e Remove the float bowl e Slide out the pivot pin A with a suitable tool B and remove the float C and float valve
79. pads are against the disc The brake will not function on the first application of the pedal if this is not done 6J04071BS1 GJ04072BS1 Wheels Rims WHEELS TIRES 10 9 Wheel Inspection e Raise the front rear wheel off the ground e Spin the wheel lightly and check for roughness or binding x If the roughness or binding is found replace the hub bear ings e Inspect the wheel for small cracks dents bending or warp x If there is any damage to the wheel replace the wheel e Measure the rim runout radial B and axial A with a dial gauge x If the rim runout exceeds the service limit check the hub bearings x lf the problem is not due to the bearings replace the wheel Rim Runout with tire installed Standard Axial TIR 0 5 mm 0 02 in or less Radial TIR 0 8 mm 0 03 in or less Service Limit Axial TIR 1 0 mm 0 04 in Radial TIR 1 0 mm 0 04 in Never attempt to repair a damaged wheel If there is any damage besides wheel bearings the wheel must be replaced to insure safe operational condi tion Axle Inspection e Remove the front and rear axles e Visually inspect the front and rear axle for damages x lf the axle is damaged or bent replace it e Place the axle in V blocks that are 100 mm 3 94 in A apart and set a dial gauge B on the axle at a point halfway between the blocks Turn C the axle to mea sure the runout The difference
80. plug is dirtied or the carbon is accumulated replace the spark plug e Measure the gap D with a wire type thickness gauge x If the gap is incorrect replace the spark plug 0 7 0 8 mm 0 03 0 04 in e Use the standard spark plug or its equivalent CR8E or U24ESR N Spark Plug Gap Spark Plug JE SS ANNEE WN y SSSR AZ Kk hikes NN IS GS17009BS1 16 38 ELECTRICAL SYSTEM Ignition System IC Igniter Inspection CAUTION When inspecting the IC igniter A observe the fol lowing to avoid damage to the IC igniter Do not disconnect the IC igniter connector B with the ignition switch on This may damage the IC igniter Do not disconnect the battery leads while the en gine is running This may damage the IC igniter IC Igniter Operation Inspection e Remove the seat cover see Rear Fender Removal in the Frame chapter e Disconnect the IC Igniter connector e Set the hand tester A to the x 25 V DC range and con nect it to the connector B come from harness side as follows Tester terminal C BR BK lead Tester terminal D BK Y lead Special Tool Hand Tester 57001 1394 Needle Adapter Set 57001 1457 e Turn the ignition switch on and read the voltage IC Igniter Operation Voltage Battery Voltage x If the tester reading is not specified one check the battery voltage ignition switch
81. position e Install the new cylinder head cover gasket and install the cylinder head cover with the specified torque Torque Cylinder Head Cover Bolts 9 8 N m 1 0 kgf m 87 in 1b e Install the removed parts GE09072BS1 ENGINE TOP END 5 15 Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non return type camshaft chain tensioner The push rod does not return to its original position once it moves out to take up camshaft chain slack Observe all the rules listed below When removing the tensioner do not take out the mounting bolts only halfway Retightening the mounting bolts from this position could damage the tensioner and the camshaft chain Once the bolts are loosened the tensioner must be removed and reset as described in Camshaft Chain Ten sioner Installation Do not turn over the crankshaft while the tensioner is removed This could upset the camshaft chain timing and damage the valves e Remove the right lower fairing see Lower Fairing Re moval in the Frame chapter e Loosen the cap bolt A e Remove the tensioner mounting bolts B and remove the chain tensioner body C Camshaft Chain Tensioner Installation e Remove the tensioner cap bolt and O ring e While compressing the push rod A turn it clockwise with a suitable screwdriver until the rod stopped CAUTION Do not turn the rod counterclockwise at installation This cou
82. pound or hammer When properly installed the strip of the caps will be level with the top of the battery CAUTION Once the strip of the caps A is installed onto the battery never remove the caps nor add water or electrolyte to the battery 6P090009S1 NOTE OTo ensure maximum battery life and customer satisfac tion it is recommended the battery be load tested at three times ts amp hour rating for 15 seconds Re check voltage and if less than 12 8 volts repeat the charging cycle and load test If still below 12 8 volts the battery is defective Precautions 1 No need of topping up No topping up is necessary in this battery until it ends its life under normal use Forcibly prying off the seal cap to add water is very dangerous Never do that 2 Refreshing charge ELECTRICAL SYSTEM 16 23 Battery If an engine will not start a horn sounds weak or lamps are dim it indicates the battery has been discharged Give refresh charge for 5 to 10 hours with charge current shown in the specification see this chapter When a fast charge is inevitably required do it following precisely the maximum charge current and time conditions indicated on the battery CAUTION This battery is designed to sustain no unusual deterioration if refresh charged according to the method specified above However the battery s performance may be reduced no ticeably if charged under conditions other than given abov
83. seat width and O D 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 x 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 Engine Top End in the Periodic Mainte nance chapter GE15012081 ENGINE TOP END 5 31 Valves Valve Seat Repair Machinist s dye on seat 45 Grind Tool 45 Cutter Purpose make seating area smooth and round Measure Seating Area O D Tool Vernier Caliper Purpose check seat O D against spec Too small Machinist s dye on seat 45 Grind Tool 45 Cutter Purpose increase O D of seat area to spec 32 Grind Tool 32 Cutter Purpose D Measure Seating Width p eae seat area to spec Tool Vernier Caliper Purpose check seat width against spec ox 45 Grind ES dye on sea Tool 45 Cutter P
84. shaft for any damage x If the shift shaft A is bent straighten or replace it x If the splines B are damaged replace the shaft x If the return spring C or pawl spring D is broken or dis torted replace them xlf the shift mechanism arm E or over shift limiter F is distorted replace the shift shaft e Check the return spring pin is not loose x If it is loose unscrew it and apply a non permanent lock ing agent to the threads and tighten it Torque External Shift Mechanism Return Spring Pin 19 6 N m 2 0 kgf m 14 5 ft lb e Visually inspect the shift drum pins A pin holder B and pin plate C x If they are badly worn or if they show any damage replace them Transmission Removal e Split the crankcase see Crankcase Splitting e Remove the drive shaft A and output shaft B GET P 9 26 CRANKSHAFT TRANSMISSION Transmission Transmission Installation e With a high flash point solvent clean off the outer cir cumferences of the transmission ball bearings and needle bearing housings and wipe dry e Check to see that the set rings A and set pins B are in place in the transmission bearing housings clean with compressed air e Install the drive shaft and output shaft into the upper crankcase half e Apply engine oil to the sliding surfaces of the gears and bearings OThe bearing set pins and rings must match properly with the holes or grooves in the bearing outer races Whe
85. that the RN mark D faces up OApply molybdenum disulfide oil solution to the piston rings Cylinder Wear Inspection e Since there is a difference in cylinder wear in different di rections take a side to side and a front to back measure ment at each of the two locations total of four measure ments shown in the figure lf any of the cylinder inside diameter measurements ex ceeds the service limit replace the cylinder A 10 mm B 60 mm Cylinder Inside Diameter Standard 62 000 62 012 mm 2 4409 2 4414 in Service Limit 62 10 mm 2 44 in Piston Wear Inspection e Measure the outside diameter A of each piston 5 mm B up from the bottom of the piston at a right angle to the direction of the piston pin x If the measurement is under service limit replace the pis ton Piston Diameter Standard 61 942 61 957 mm 2 4387 2 4392 in Service Limit 61 80 mm 2 43 in GE160130S1 GE16061BS1 GE16036BS1 C 6E16037BS1 Cylinder Pistons ENGINE TOP END 5 35 Piston Ring Piston Ring Groove Wear Insepction e Check for uneven groove wear by inspecting the ring seat ing The rings should fit perfectly 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 Pi
86. the caliper if the cylinder and piston are badly scores or rusty Fluid Seal B Dust Seal C Front Caliper D Rear Caliper E Dust Boot F Caliper Holder Shaft Wear The caliper body must slide smoothly on the caliper holder shafts G If the body does not slide smoothly one pad will wear more than the other pad wear will increase and constant drag on the disc will raise brake and brake fluid temperature e Check to see that the caliper holder shafts are not badly worn or stepped and that the rubber boots H are not damaged x If the rubber boot is damaged replace the rubber boot To replace the rubber boot remove the pads and the caliper bracket x If the caliper holder shaft is damage replace the caliper bracket GLO5204BS1 GLO5205BS1 12 12 BRAKES Brake Pads Brake Pad Removal e Loosen the holder shaft A e Remove the caliper see Front Rear Caliper Removal e Draw out the holder shaft e Remove the pads B Brake Pad Installation e Push the caliper pistons by hand as far as they will go e Install the pad on the piston side first then install the other pad e Install the anti rattle spring A in its correct position A WARNING Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal and the pads are against the disc The brake will not function on the first appli cation of the lever or pedal if th
87. the standard check the oil passages for clogging Oil Pressure Standard 98 147 kPa 1 0 1 5 kgf cm 14 21 psi 4 000 r min rpm oil temperature 90 C 194 F e Stop the engine e Remove the oil pressure gauge and adapter A WARNING Take care against burns form hot engine oil that will drain through the oil passage when the gauge adapter is removed ENGINE LUBRICATION SYSTEM 7 13 Oil Pressure Switch Oil Pressure Switch Removal e Remove Lower Fairing see Lower Fairing Removal in the Frame chapter Switch Cover A Switch Terminal B Oil Pressure Switch C Oil Pressure Switch Installation e Apply silicone sealant to the threads of the oil pressure switch and tighten it Sealant Kawasaki Bond Silicone Sealant 56019 120 Torque Oil Pressure Switch 15 N m 1 5 kgf m 11 ft lb e Tighten the oil pressure switch terminal bolt Torque Oil Pressure Switch Terminal Bolt 1 5 N m 0 15 kgf m 13 in lb Olnstall the oil pressure switch lead A as shown Front B 45 C e Apply grease to the terminal GG13011BS1 ENGINE REMOVAL INSTALLATION 8 1 Engine Removal Installation Table of Contents E olle 1o Ee BE 8 2 Engine RemovallInstallati n ti et o EOS 8 4 Gate ane EE 8 4 Engine Installation EE 8 6 8 2 ENGINE REMOVAL INSTALLATION Exploded View ENGINE REMOVAL INSTALLATION 8 3 Exploded View nof Tomm LT Engine Mounting
88. tip from the clutch release lever Clutch Cable Lubrication e Refer to Chassis Parts Lubrication in the Periodic Mainte nance chapter see Chassis Parts Lubrication in the Pe riodic Maintenance chapter Clutch Lever Removal e Remove the upper end of clutch cable e Remove the left switch housing A e Remove the clutch lever mounting bolt B and nut and remove the clutch lever CLUTCH 6 7 Clutch Cover Clutch Cover Removal e Drain the engine oil see Engine Oil Change in the Peri odic Maintenance chapter e Remove Right Lower Fairing see Lower Fairing Removal in the Frame chapter Clutch Cable see Clutch Cable Removal Oil Filler Plug e Remove the clutch cover mounting bolts A and the clutch cable guide e Turn the clutch release lever couterclockwise fully to re lease the clutch release shaft Clutch Cover Installation Note e Scrape the old gasket from the surface of clutch cover and crankcase and apply silicone sealant on the mating surface A of the crankcases e Install the new clutch cover gasket Special Tool Kawasaki Bond Silicone Sealant 92104 0004 e Turn the clutch release lever A counterclockwise fully B and install the clutch cover Clutch Release Shaft Removal e Remove Clutch Cable see Clutch Cable Removal Clutch Cover see Clutch Cover Removal e Pull out the clutch release shaft from the clutch cover NOTE ODo not damage the oil seal when it sh
89. using a wet stone to remove sharp edges or raised areas which cause seal damage x lf the damage is not repairable replace the inner tube Since damage to the inner tube damages the oil seal replace the oil seal whenever the inner tube is repaired or replace CAUTION If the inner tube is badly bent or creased replace it Excessive bending followed by subsequent straightening can weaken the inner tube e Temporarily assemble the inner tube and outer tube B and pump them back and forth manually to check for smooth operation x If it does not operate smoothly replace both the inner tube and the outer tube A WARNING A straightened inner or outer fork tube may fail in use possibly causing an accident Replace a badly bent or damaged inner or outer tube and inspect the other tube carefully before reusing it Fork Spring Inspection e Measure the free length B of the fork spring A x lf the spring of either fork leg is shorter than the service limit it must be replaced If the length of the replacement spring and that of the remaining spring vary greatly the remaining spring should also be replaced in order to keep the fork legs balanced for motorcycle stability Fork Spring Free Length Standard 420 5 mm 16 6 in Service Limit 412 mm 16 2 in Oil Seal Dust Seal Inspection e Inspect the oil seal A and dust seal B for any signs of deterioration or damage Replace it if necessary
90. 0 40 mm 0 002 0 008 in 0 016 in Balancer Balancer Shaft Bearing Insert Journal 0 020 0 044 mm 0 08 mm Clearance 0 0008 0 0017 in 0 0031 in Balancer Shaft Journal Diameter 25 984 26 000 25 96 mm 1 0230 1 0236 in 1 022 in Marking None 25 984 25 994 mm 1 0230 1 0234 in O 25 995 26 000 mm 1 0234 1 0236 in Crankcase Balancer Shaft Bore Diameter 29 000 29 016 mm 1 1417 1 1424 in Marking O 29 000 29 008 mm secs eee 1 1417 1 1420 in None 29 009 29 016 mm reed 1 1421 1 1424 in Balancer Shaft Bearing Insert Thickness Brown 1 495 1 499 mm 0 0589 0 0590 in Black 1 499 1 503 mm 0 0590 0 0592 in Blue 1 503 1 507 mm 0 0592 0 0593 in Transmission Gear Backlash 0 0 17 mm 0 25 mm 0 0 0067 in 0 010 in Gear Shift Fork Groove Width 5 05 5 15 mm 5 3 mm 0 1988 0 2028 in 0 209 in Shift Fork Ear Thickness 4 9 5 0 mm 4 8 mm 0 1929 0 1969 in 0 189 in Shift Fork Guide Pin Diameter 5 9 6 0 mm 5 8 mm 0 2323 0 2362 in 0 228 in Shift Drum Groove Width 6 05 6 20 mm 6 3 mm 0 2382 0 2441 in 0 248 in Journal clearance less than 0 025 mm 0 0010 in can not be measured by plastigage however using genuine parts maintains the minimum standard clearance 9 8 CRANKSHAFT TRANSMISSION Specifications Connecting Rod Big End Bearing Insert Selection Con r
91. 00 mm 55 1 in Road Clearance 130 mm 5 1 in Seat Height 775 mm 30 5 in Dry Mass 152 kg 335 Ib Curb Mass Front 82 kg 181 Ib Rear 87 kg 192 Ib Fuel Tank Capacity 18 0 L 4 8 US gal Performance Minimum Turning Radius 2 7 m 8 9 ft Engine Type 4 stroke DOHC 2 cylinder Cooling System Bore And Stroke Displacement Compression Ratio Maximum Horsepower Maximum Torque Carburetion System Starting System Ignition System Timing Advance Ignition Timing Spark Plug Cylinder Numbering Method Firing Order Valve Timing Inlet Open Close Duration Exhaust Open Close Duration Liquid cooled 62 0x 41 2 mm 2 5 x 1 6 in 249 cm 15 2 cu in 11 6 23 4 kW 31 8 PS 11 000 r min rpm 22 0 N m 2 24 kg m 16 2 ft lb 9 500 r min rpm Carburetor Keihin CVK 30x 2 Electric starter Battery and coil transistorized Electronically advanced From 10 BTDC 1 300 r min rpm 35 BTDC 4 000 r min rpm NGK CR8E or ND U24ESR N Left to Right 1 2 1 2 36 BTDC 56 ABDC 272 61 BBDC 31 ATDC 272 GENERAL INFORMATION 1 9 General Specifications eme EX250J8F Lubrication System Engine Oil Grade Viscosity Capacity Drive Train Primary Reduction System Forced ubrication wet sump API SE SF or SG API SH SJ or SL with JASO MA SAE10W 40 1 7 L 1 80 US qt Type Gear Reduction Tatio 3 087 71 23 Clutch Type Wet multi disc Transmission Type 6 speed consta
92. 11 Caliper Holder Shaft Wear EI Brake Pad Rem alii Seuasadesauchesbeh sedi dendbastendecenaccnnaica st Brake Pad Installation mem tan eadquudeancdenntauchennderhtactin Brake Pad Wear Inspection ss Master Cydia Ae Front Master Cylinder RemoVal c oirlo ita ee Front Master Cylinder Installation Rear Master Cylinder Removal se Rear Master Cylinder Installation Rear Brake Reservoir Removal ccecceee eee ee eee eeeeeeeeeeeeeeeeeeeeeeeeeeeeeeneeeneeeeeeeneeeneeeeeeeees Rear Brake Reservoir Installation Front Master Cylinder Disassembly ssun sata tuent amende denis 12 15 Rear Master Cylinder Disassembly ss 12 15 Master Cylinder Assembly aarne Zeg Eed ee Ee 12 15 Master Cylinder Inspection fs rnninieunne 12 16 Brake DiS Cuca EEN 12 17 Brake Disc Removal sie 12 17 Brake Disc Installation alii ria ent lente eee ELE 12 17 Brake Disc Wear Inspection 12 17 Brake Disc Warp Inspection 12 17 Brake e EE EE 12 18 Brake Fluid Level Inspechon Ennan Ennn nenn Ennn 12 18 Brake d DEE 12 18 Brake Line Blesding siiis di 12 18 Brake OSO iio tn vias AA E E deer 12 21 Brake Hose HRemovalllnstallaton nnna reenn eenn 12 21 Brake Hose Inspection his dede eh colado 12 21 12 2 BRAKES Exploded View Si SH 6L02332BW5 C BRAKES 12 3 Exploded View EM ue ese perme 3 Froni Mester Gyinder amp Baws es 09 Teme 5 4 5 B Apply b
93. 2 in 1 61 mm 0 0634 in Piston Ring Thickness Top Second 0 77 0 79 mm 0 0303 0 0311 in 0 7 mm 0 028 in Piston Ring End Gap Top 0 15 0 30 mm 0 0059 0 0118 in 0 6 mm 0 024 in Second 0 40 0 55 mm 0 0157 0 0217 in 0 9 mm 0 035 in Oil 0 20 0 80 mm 0 0079 0 0315 in 1 1 mm 0 043 in Special Tools Compression Gauge 20 kgf cm 57001 221 Valve Spring Compressor Assembly 57001 241 T5702218T ST5702418T Piston Pin Puller Assembly 57001 910 ST5709108ST Valve Seat Cutter 45 24 5 57001 1113 Valve Seat Cutter 32 625 57001 1118 ST571113ST ST5711188ST ENGINE TOP END 5 9 Valve Seat Cutter Holder Bar 57001 1128 ST5711288ST Valve Seat Cutter 32 622 57001 1206 D T5712068T Valve Seat Cutter 67 5 622 57001 1207 LO ST571207ST Valve Spring Compressor Adapter 16 57001 1305 8757130597 Compression Gauge Adapter M10 x 1 0 57001 1317 ST5713178T 5 10 ENGINE TOP END Special Tools Valve Seat Cutter Holder 4 5 57001 1330 Valve Guide Arbor 4 5 57001 1331 ST5713308T ST5713318T Valve Guide Reamer 4 5 57001 1333 ST571333ST Piston Base 92 3 57001 1336 LE 8757133697 Valve Guide Driver 57001 1564 ST5715648T Wa
94. 3 6106009BS1 6106008BS1 6105041781 9 24 CRANKSHAFT TRANSMISSION Transmission External Shift Mechanism Removal e Drain the engine oil see Engine Oil Change in the Peri odic Maintenance chapter e Remove the shift lever link bolt A and pull the lever link off the shift shaft end e Remove the clutch see Clutch Removal in the Clutch chapter e Move the shift mechanism arm A and over shift limiter B out of their positions on the end of the shift drum C and pull out the shift shaft D with the arm pawl spring E and return spring F External Shift Mechanism Installation e Check that the return spring A and pawl spring B are properly fitted on the mechanism install the external shift mechanism and place the shift mechanism arm C and over shift limiter D on the shift drum pins e Add the engine oil see Lubrication System in the Periodic Maintenance chapter e Be sure the sealing lip of the rubber boot A fits into the groove of the ball joint after installing the shift lever link OCorrectly Boot Fitting Position A Olncorrectly Boot Position B A 61138572 i CRANKSHAFT TRANSMISSION 9 25 Transmission e Align the mark A on the shift shaft with the mark B on the shift lever link e Position the shift lever C as shown Approx 15 D External Shift Mechanism Inspection e Examine the shift
95. 5 C Exploded View FUEL SYSTEM 3 5 No Fastener pore Remarks N m kgf m ft Ib 1 Fuel Tap Mounting Bolts 2 5 0 25 22 in lb 2 Fuel Gauge Mounting Bolts 6 9 0 7 61 in lb 3 Air Cleaner Housing Cap Bolts 2 5 0 25 22 in lb 4 Air Cleaner Housing Screws 1 15 0 12 10 in lb 5 Air Cleaner Housing Mounting Bolts 9 8 1 0 87 in lb 6 Air Cleaner Housing Clamp Screws 2 0 0 2 18 in lb 7 Vacuum Switch Valve AO Apply motor oil SE SF or SG class SAE 10W 30 3 6 FUEL SYSTEM Exploded View GCO2352BW5 FUEL SYSTEM 3 7 Exploded View N Fast Torgus Remarks S ees Nm kgfm ftlb 1 Separate Bracket Bolt 9 8 1 0 87 in lb 2 Canister 3 Separator 4 Green Hose 5 Blue Hose 6 White Hose 7 Red Hose 3 8 FUEL SYSTEM Specifications Item Standard Throttle Grip and Cable Throttle Grip Free Play Choke Cable Free Play 2 3 mm 0 08 0 12 in 2 3 mm 0 08 0 12 in Carburetor Make Type Main Jet Optional Main Jet Main Air Jet Jet Needle Needle Jet Pilot Jet Pilot Air Jet Starter Jet Pilot Screw turns out Throttle Valve Idle Speed Carburetor Synchronization Vacuum Service Fuel Level Float Height Keihin CVK30 98 92 95 100 102 100 FL NOVU HR N9VW 6 38 100 48 L 2 1 2 R 1 3 4 11 00 1 300 50 r min rpm Less than 2 7 kPa 2 cmHg difference between two carburetors
96. 5 ft lb Front Fork Clamp Bolts Lower 30 N m 3 1 kgf m 22 ft lb e Route the brake hoses and clamp it to the right fork leg e Install Handlebar Holder Front Brake Caliper see Caliper Installation in the Brakes chapter Front Wheel see Front Wheel Installation in the Wheels Tires chapter Front Fender Lower Fairings see Lower Fairing Removal in the Frame chapter Torque Handlebar Holder Mounting Bolts 25 N m 2 5 kgf m 18 ft lb 13 8 SUSPENSION Front Fork Front Fork Oil Change e Remove the front fork see Front Fork Removal e Remove Snap Ring A see Front Fork Removal Top Plug B with O ring C Collar D Fork Spring Seat E Fork Spring F e Compress A the fork B upside down to draw out the oil into the suitable container C e Pour in the specified amount of oil Fork Oil Viscosity KAYABA SS 8 or equivalent Amount Per Side When changing oil 310 mL 10 5 US oz After disassembly 360 2 5 mL 12 2 0 08 US oz and completely dry NOTE OMove the outer tube up and down a few times to remove the air that is trapped in the fork oil in order to stabilize the oil level e Hold the outer tube vertically in a vise and compress the fork completely e Wait until the oil level stabilizes e Use the fork oil level gauge A to measure the distance between the top of the inner tube to the oil level Special Tool Fork Oil Level Gauge 57001 1290 OSet the oil level gauge stop
97. 7S1 C 3 16 FUEL SYSTEM Carburetors Carburetor 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 Seat see Front Seat Removal in the Frame chap ter Fuel Tank see Fuel Tank Removal Lower Fairings see Lower Fairing Removal in the Frame chapter Battery see Battery Removal in the Electrical System chapter Battery Damper Battery Case Screws A Battery Case B e Remove the air cleaner housing mounting bolts A e Loosen the carburetor holder clamps B off the air cleaner ducts e Pull the air cleaner housing rearward e Remove the throttle cable and choke cable see Throttle Cable and Choke Cable Removal e Remove Bolts C Bracket D Carburetor E e Stuff the pieces of lint free clean cloths into the carbure tor holder and the air cleaner duct to keep dirt out of the engine and air cleaner 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 Carburetors FUEL SYSTEM 3 17 Carburetor Installation e Route the cables harness
98. 8 0 032 in 10 mm 0 39 in 28 mm 1 10 in ON after about 10 mm 0 39 in pedal travel From OFF to ON 95 101 C 196 203 F From ON to OFF within 3 8 C 37 46 F of ON temperature ON less than 0 5 Q OFF More than 1 MQ From OFF to ON 112 118 C 226 232 F From ON to OFF 108 C 226 F temperature less than ON ON Less than 0 5 Q OFF More than 1 MQ 5 mm 0 20 in 27 mm 1 06 in ELECTRICAL SYSTEM 16 15 Special Tools and Sealant Flywheel Holder Peak Voltage Adapter 57001 1313 57001 1415 wy ST571313ST ST5714158T Hand Tester Needle Adapter Set 57001 1394 57001 1457 ST5713948T ST571457ST C Flywheel Puller Assembly M38 x 1 5 M35 x 1 5 Kawasaki Bond Silicone Sealant 57001 1405 56019 120 ST5714058ST ST5601208ST 16 16 ELECTRICAL SYSTEM Parts Location a CAN 4 _ ER 2 000 C I O O1 B N Diode Horn Radiator Fan Switch 1 Ignition Coil Oil Pressure Switch Alternator Crankshaft Sensor Neutral Switch Sidestand Switch AA Y Main Fuse 30 A Fuse Box IC Igniter Starter Circuit Relay Headlight Circuit Relay Diodes Battery Starter Relay Starter Motor 1 Spark Plug Regulator rectifier Front Brake Light Switch Starter Lockout Switch 2 Spark Plug Radiato
99. 92180 1180 98 3 00 92180 1034 00 3 025 92180 1181 03 3 05 92180 1036 05 3 075 92180 1182 08 92180 1038 10 3 125 92180 1183 13 92180 1040 15 92180 1184 18 3 20 92180 1042 20 92180 1044 25 3 30 92180 1046 30 92180 1048 35 3 40 92180 1050 40 3 45 92180 1052 45 3 50 92180 1054 50 2 26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Clutch Operation Inspection e Pull the clutch lever just enough to take up the free play A e Measure the gap between the lever and the lever holder x If the gap is too wide the clutch may not release fully If the gap is too narrow the clutch may not engage fully In either case adjust it Clutch Lever Free Play Standard 2 3 mm 0 08 0 12 in A WARNING To avoid a serious burn never touch the engine or exhaust pipe during clutch adjustment e Turn the adjuster B so that 5 6 mm 0 20 0 24 in A of threads are visible e Remove the right lower fairing see Lower Fairing Re moval in the Frame chapter Slide the dust cover A from the clutch cable lower end out of place e Loosen both adjusting nuts B at the clutch cover as far as they will go e Pull the clutch outer cable C tight and tighten the adjust ing nuts against the bracket D e Slip the rubber dust cover back onto place e Turn the adjuster at the clutch lever until the free play is correct A WARNING Be sure that the outer cable end at the clutch lever is fully sea
100. Choke Operation Inspection sise 2 17 Engine Vacuum Synchronization Inspection 2 17 Idle Speed Inpec WEE 2 18 Idle Speed AG EE 2 18 Fuel Hose Inspection fuel leak damage installation condition 2 19 Evaporative Emission Control System California Model 2 19 Evaporative Emission Control System Inspection 2 19 CODING EE 2 20 Coolant Level Inspechon see 2 20 Radiator Hose Damage and Installation Condition Inspection 2 21 Coolant Filter Cleaning Australia Model 2 21 FUE SUCHOM oy SUS bi A PR AE Melanesian ead Rene eee 2 21 Air Suction System Damage JInspechon nn nncnnnnnnn 2 21 Engine Top End ee acess eae ere a de Pe des an ee ey Go tn E Su ne Nul 2 22 Valve Clearance Inspection EEEn 2 22 Valve Clearance Eu E 2 23 CITC EE EE 2 26 Clutch Operation Inspechon 2 26 te TER 2 27 Air Pressure Inspechon cnn nrnnnrnn rn rnn rre rre 2 27 Wheel Tire Damage Inspection eegenen geb Eed 2 27 Tire Tread Wear Abnormal Wear Inspechon 2 27 Wheel Bearing Damage Inspection EE 2 28 DYIVG ARE LES E RARE RS CE AT A EE EE 2 29 Drive Chain Lubrication Condition Inspection sssssssessrerrrtrnrtrrttnntnnrnennntnn renaren nrnna 2 29 Drive Chain Slack Inspection ssssseerrrerrtrrtttttttrtttttttntttttttrtttEtEEEEEEEEEEEEEEAEEEEE EEEE EEEE EEEE 2 29 Drive Chain Slack G
101. ERING 14 7 Steering Stem Stem Bearing Installation e Replace the bearing outer race with new ones e Apply grease to the outer races and drive them into the head pipe at the same time Special Tools Head Pipe Outer Race Press Shaft 57001 1075 A Head Pipe Outer Race Driver 57001 1076 B Head Pipe Outer Race Driver 57001 1447 C e Replace the bearing inner race with new one e Install the washer D and grease seal E on the steering stem and drive the ball bearing inner race A applied grease onto the stem Special Tools Steering Stem Bearing Driver 57001 137 B Steering Stem Bearing Driver Adapter 57001 1074 C e Apply grease to the lower ball bearings 20 and stem inner race and install them onto the steering stem e Apply grease to the upper ball bearing 19 A and outer race B and install the ball bearings onto the outer race e Insert the steering stem A carefully through the head pipe so that the steel balls on the steering stem does not fall e Install the stem cap B and steering stem nut C and tighten it by hand e Install the stem head D with the handlebars e Tighten the stem head bolt E lightly GNO05040281 14 8 STEERING Steering Stem e Settle the bearings in place as follows OTighten the steering stem nut with 15 N m 1 5 kgf m 11 ft lb of torque first and loosen it a fraction of a turn until it turns lightly To tighten the stem nut
102. Hose F e Support the engine with a suitable stand A e Remove the regulator rectifier A and the engine mount ing bracket bolts and nuts e Remove Engine Mounting Bolts and Nuts A Engine Assembly B 8 6 ENGINE REMOVAL INSTALLATION Engine Removal Installation Engine Installation e Engine installation is the reverse of removal and note the following point Olnsert the lower engine mounting bolt A first while sup porting the engine Then insert the upper engine mount ing bolt B and tighten the nut loosely OBefore tightening the mounting bolts install the engine brackets When inserting the front engine mounting bolt use the suitable stand under the engine to lift it Torque Engine Mounting Bracket Bolts Nuts 64 N m 6 5 kgf m 47 ft lb Engine Mounting Nuts 64 N m 6 5 kgf m 47 ft lb ORoute the wiring harness correctly see Cable Wire and Hose Routing in the Appendix chapter OAdjust the following items after engine installation Throttle cable see Throttle Control System Inspection in the Periodic Maintenance chapter Choke Cable see Choke Cable Free Play Inspection in the Fuel System chapter Clutch Cable see Clutch Operation Inspection in the Pe riodic Maintenance chapter Drive Chain Slack see Drive Chain Slack Inspection in the Periodic Maintenance chapter Carburetor Idling see Idle Speed Inspection in the Peri odic Maintenance chapter e Fill the engine oil see Engine Oil Ch
103. ICAL SYSTEM 16 47 Electrical Starter Circuit m Y G LG BK R noe Lew ue fel BR BK BR 6P111328W4 OMNOAONARWND Ignition Switch Engine Stop Switch Starter Button Diode A Diode B Starter Circuit Relay Fuse Box Ignition Fuse 10 A Battery Main Fuse 30 A Starter Motor Neutral Switch Sidestand Switch Starter Lockout Switch 16 48 ELECTRICAL SYSTEM Lighting System Headlight Beam Horizontal Adjustment e Refer to Headlight Aiming Inspection in the Periodic Main tenance chapter see Headlight Aiming Inspection in the Periodic Maintenance chapter Headlight Beam Vertical Adjustment e Refer to Headlight Aiming Inspection in the Periodic Main tenance chapter see Headlight Aiming Inspection in the Periodic Maintenance chapter Headlight Bulb Replacement e Remove Upper Fairing see Upper Fairing Removal in the Frame chapter Headlight Connector Headlight Bulb Dust Cover Clip A Disconnect Headlight Bulb B CAUTION When handling the quartz halogen bulb never touch the glass portion with bare hands Always use a clean cloth Oil contamination from hands or dirty rags can reduce bulb life or cause the bulb to explode NOTE OClean off any contamination that inadvertently gets on the bulb with alcohol or soap and water solution e Fit the dust cover A firmly onto the bulb B as shown Dust Cover A Top Mark B Bul
104. ING 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 E OWhile cleaning the screen check for any metal particles that might indicate internal engine damage e Check the screen carefully for any damage holes and broken wires x If the screen is damaged replace the oil screen assembly GGO5026BS1 C 7 10 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Oil Pressure Relief Valve Removal e Remove the clutch cover see Clutch Cover Removal in the Clutch chapter e Unscrew the oil pressure relief valve A from the crankcase Oil Pressure Relief Valve Installation e Apply a non permanent locking agent to the threads of the relief valve and tighten it with the specified torque Torque Oil Pressure Relief Valve 15 N m 1 5 kgf m 11 ft lb CAUTION Do not over apply a non permanent locking agent to the threads This may block the oil passage Oil Pressure Relief Valve Inspection e Check to see if the valve A slides smoothly when push ing it in with a wooden or other soft rod and see if it comes back to its seat by spring B pressure NOTE Olnspect the valve in its assembled state Disassembly and assembly may change the valve performance If any rough spots are found during above inspection wash the valve
105. Liquid fuel is caught by a vapor separator and returned to the fuel tank 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 dealer 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 ina 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 Maladjustmen
106. Mechanism Return Spring Pin 19 6 2 0 14 5 L Shift Drum Positioning Bolt 24 5 2 5 18 Shift Lever Link Bolt 12 1 2 104 in lb Front Tie Rod Locknut Left Hand Threads 7 0 0 7 62 in lb Rear Tie Rod Locknut Right Hand Threads 7 0 0 7 62 in lb Shift Pedal Mounting Bolt 25 2 5 18 Wheels Tires Front Axle Nut 88 9 0 65 Rear Axle Nut 98 10 0 72 Final Drive Engine Sprocket Cover Bolts 9 8 1 0 87 in lb Engine Sprocket Nut 127 13 94 MO Rear Sprocket Nuts 59 6 0 44 Rear Sprocket Studs L Brakes Brake Lever Pivot Bolt Locknut 5 9 0 6 52 mb Bleed Valve 5 5 0 55 49 in lb Front Master Cylinder Clamp Bolts 8 8 0 9 78 in lb S Brake Disc Mounting Bolts 27 2 8 20 L Brake Hose Banjo Bolts 25 2 5 18 Front Caliper Mounting Bolts 25 2 5 18 Front Brake Light Switch Screw 1 0 0 1 9 in lb Brake Lever Pivot Bolt 1 0 0 1 9 in lb Front Reservoir Cap Screws 1 5 0 15 13 in lb Reservoir Mounting Bolt 6 9 0 7 61 in lb Bleed Valve 5 5 0 55 49 in lb Brake Pedal Pivot Bolt 8 8 0 9 78 in lb L Push Rod Locknut 18 1 8 13 Brake Disc Mounting Bolts 27 2 8 20 E Brake Hose Banjo Bolts 25 2 5 18 Rear Master Cylinder Mounting Bolts 25 2 5 18 Rear Caliper Mounting Bolts 25 2 5 18 Suspension Front Fork Clamp Bolts Upper 21 2 1 15 Front Fork Top Plugs 23 2 3 16 5 Front Fork Clamp Bolts Lower 30 3 1 22 Front Fork Bottom Allen Bolts 20 2 0 15 L PERIODIC MAINTENANCE 2 9 Torque and Locking Agent Fastener Rocker Arm Pivot Nut 59 6 0 44 Tie Rod Nuts 59
107. NCE 2 17 Periodic Maintenance Procedures Choke Operation Inspection e Remove Front Seat see Front Seat Removal in the Frame chap ter Fuel Tank see Fuel Tank Removal Side Covers see Side Cover Removal in the Frame chapter Lower Fairings see Lower Fairing Removal in the Frame chapter Fuel Tank see Fuel Tank Removal e Push the choke lever A back all the way to its released position e Check choke cable free play B ODetermine the amount of choke cable play at the choke lever x lf the free play is incorrect adjust the choke cable Choke Cable Free Play Standard 2 3 mm 0 08 0 12 in e Push the choke lever back all the way to its released po sition e Pull the choke lever until the starter plunger lever A at the carburetor touches the starter plunger B the amount of choke lever travel is the amount of choke cable play e Loosen the locknut A and turn the adjuster B until the cable has the proper amount of free play e Tighten the locknut securely Engine Vacuum Synchronization Inspection e Situate the motorcycle using the center stand so that it is perpendicular to the ground e Remove the fuel tank and connect the sub fuel tank to supply the fuel e Remove the right lower fairing e Warm up the engine e Check the idle speed and adjust if necessary e Pull the vacuum hoses off and attach vacuum gauge A to the vacuum hose fittings on the carburetors Special Tool Vacuum
108. PRI without engine running replace the damaged gasket B or O rings C Fuel Tank and Cap Inspection e Open the tank cap e Visually inspect the gaskets A on the tank cap for any damage x Replace the gaskets if they are damaged e Remove the drain pipes and check to see if the pipes in the tank do not clogged up Check the tank cap breather also x If they are clogged remove the tank and drain it and then blow the breather free with compressed air CAUTION Do not apply compressed air to the air vent holes B in the tank cap This could cause damage and clogging of the labyrinth in the cap GC09088BS1 COOLING SYSTEM 4 1 Cooling System Table of Contents EXploded WEE 4 2 Specifications EE 4 4 TE iii iia 4 5 Coolant Flow Chain o 4 6 A NON 4 8 Coolant Deterioration Inspechon 4 8 Coolant Level Inspechon see 4 8 Coolant Draining ER 4 8 Goolant FUMING EE 4 8 Press re Testing EE 4 8 Cooling System FIUSMING EE 4 9 WV ALC FAR UNM 0 TEE 4 10 Pump Cover Removal isc isc eines are e a A ai aaa di 4 10 Pump Cover Installation 4 10 Water Pump Removal ss sssssssssssisesssesssessseseseeseeesseesseesseseiesee 4 10 Water Pump Installation en manne int 4 10 Pump Impeller Inspection see 4 11 Radiator Radiator Fan tested iba 4 12 Radiator and Radiator Fan Removal ccecccecceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeeeeess 4 12 Radiator Inspection assis Ces eee ns se teste
109. Pawl spring broken Shift mechanism arm broken Shift pawl broken Jumps out of gear Shift fork ear worn Gear groove worn Gear dogs and or dog holes worn Shift drum groove worn Neutral positioning pin spring weak or bro ken Shift fork guide pin worn Drive shaft output shaft and or gear splines worn Overshifts Neutral positioning lever spring weak or broken Pawl spring broken Abnormal Engine Noise Knocking IC 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 pin hole worn Valve noise Valve clearance incorrect Valve spring broken or weak Camshaft bearing 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 Piston ring groove worn Piston ring groove clearance excessive 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 guide worn Alternator rotor loose Primary gear worn or broken Abnormal Drive Train Noise Clutch noise Weak or damaged damper Clutch housing friction plate clearance ex cessive Clutch housing gear worn Transmission noise Bearings worn Transmission g
110. Primary Lead Terminal C Adapter black lead Ignition Coil Ground Terminal IC Igniter D Battery E Ignition Coil F Special Tool Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B A WARNING To avoid extremely high voltage shock do not touch the spark plug or tester connection e Turn the ignition switch and engine stop switch on e Pushing the starter button turn the engine 4 5 seconds with the transmission in neutral to measure the ignition coil primary peak voltage e Repeat the measurement 5 or more times Ignition Coil Primary Peak Voltage Standard 223 V or more x lf the reading is less than the specified value check the following Ignition Coil see Ignition Coil Inspection Crankshaft Sensor see Crankshaft Sensor Inspection IC Igniter see IC Igniter Inspection Spark Plug Removal e Refer to Spark Plug Replacement in the Periodic Mainte nance chapter see Spark Plug Replacement in the Peri odic Maintenance chapter Spark Plug Installation e Refer to Spark Plug Replacement in the Periodic Mainte nance chapter see Spark Plug Replacement in the Peri odic Maintenance chapter Spark Plug Condition Inspection e Remove the spark plugs see Spark Plug Replacement e Visually inspect the spark plugs lf the spark plug center electrode A and or side elec trode B are corroded or damaged or if the insulator C is cracked replace the plug x If the spark
111. Rocker Arm Sleeve Inspection ss 13 17 13 2 SUSPENSION Exploded View WHO O Seng we 32 CY SUSPENSION 13 3 Exploded View D o f e e Ve kom mlb 2 4 5 Rocker Arm Pivot ut s 60 4 Terons a 60 amp 7 Rear Shock Absorber Mounting Nuts se 60 4 Swingarm Pront a 10 L Apply a non permanent locking agent M Apply molybdenum disulfide grease R Replacement Parts 13 4 SUSPENSION Specifications Item Standard Service Limit Front Fork Fork oil Viscosity Amount Per Side Fork oil level Fork spring free length KAYABA SS 8 or equivalent 310 mL 10 5 US oz when changing oil 360 2 5 mL 12 2 0 08 US oz after disassembly and completely dry 108 2 mm 4 3 0 08 in Fully compressed without spring 420 5 mm 16 6 in 412 mm 16 2 in Rear Suspension Rear shock absorber spring preload adjustment Rear shock absorber gas pressure non adjustable 1st position 980 kPa 10 kgf cm 142 psi 1 5 Usable range Special Tools Inside Circlip Pliers 57001 143 ST5701438T Fork Cylinder Holder Handle 57001 183 ST5701838T Fork Cylinder Holder Adapter 57001 1057 w ST571057ST Oil Seal amp Bearing Remover 57001 1058 ST5710588T Steering Stem Nut Wrench 57001 1100 ST5711008T SUSPENSION 13 5
112. SW 1 6M04206BS1 6M04041351 6M04042BS1 13 12 SUSPENSION Rear Shock Absorber Spring Preload Adjustment e Remove the bolts A chain cover B and left foot guard C to turn the wrench e Using the steering stem nut wrench A turn the adjusting nut to adjust the spring preload Special Tool Steering Stem Nut Wrench 57001 1100 e The spring preload can be left soft for average riding But it should be adjusted harder for high speed riding or riding with a passenger If the spring action feels too soft or too stiff adjust it in accordance with the following table Spring Preload Adjustment Position porcs Setting Load Road Speed 1 Weak Soft Light Good Low l t 1 t 1 l l l l l 5 Strong Hard Heavy Bad High e The standard adjuster setting for an average build rider of 68 kg 150 Ib with no passenger and no accessories is 1 step Rear Shock Absorber Removal e Remove the lower fairings see Lower Fairing in the Frame chapter e Raise the rear wheel off the ground with jack Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Squeeze the brake lever slowly and hold it with the band A WARNING Be sure to hold the front brake when removing the shock absorber or the motorcycle may tall over It could cause an accident and injury SUSPENSION 13 13 Rear Shock Absorber e Remove Tie rod L
113. Special Tool Steering Stem Nut Wrench 57001 1100 NOTE OTurn the stem nut 1 8 turn at a time maximum e Tighten Torque Steering Stem Head Bolt 44 N m 4 5 kgf m 32 ft Ib Front Fork Clamp Bolts lower 30 N m 3 1 kgf m 22 ft lb e Check the steering again x If the steering is still too tight or too loose repeat the ad justment PERIODIC MAINTENANCE 2 37 Periodic Maintenance Procedures Steering Stem Bearing Lubrication e Remove the steering stem see Stem Stem Bearing Re moval in the Steering chapter e Using a high flash point solvent wash the upper and lower ball bearings and wipe the upper and lower outer races which are press fitted into the frame head pipe clean off grease and dirt e Visually check the outer races and the ball bearings Replace them if they show wear or damage e Apply a light coat of grease to the upper and lower A ball SE bearings and outer races e Install the steering stem see Stem Stem Bearing Instal lation in the Steering chapter e Adjust the steering see Steering Play Adjustment Electrical System Lights and Switches Operation Inspection First Step e Turn on the ignition switch e The following lights should go on according to below table Taillight A goes on License Plate Light B goes on Meter Panel Lights C goes on Neutral Indicator Light D goes on Oil Pressure Warning Indicator Light E goes on Water Temperatur
114. System ds leak brake hose and pipe year SES BAESCH WS EST Brake hose and pipe damage inspect year ojo o jo o o o 2 32 SEET and pipe installation condition year O ae PRIS ete ie effectiveness play no year Se all ogee tl re E Brake fluid level inspect 6 months e e e e o o 2 33 Brake pad wear inspect lIelielelelels 2 33 Brake light switch operation inspect ele o e o o 2 34 Suspensions Front forks rear shock absorber operation damping and smooth stroke inspect j s i Naf Front forks rear shock absorber oil leak inspect year e e e 2 35 Rocker arm operation inspect e e e 2 35 Tie rods operation inspect e e e 2 35 Swingarm pivot lubricate e 2 36 Steering System Steering play inspect year e e e e 2 36 Steering stem bearings lubricate 2 years e 2 37 Electrical System Lights and switches operation inspect year 2 37 Headlight aiming inspect year 2 39 Sidestand switch operation inspect year le fe 2 40 Engine stop switch operation inspect year e e e 2 41 Others Chassis parts lubricate year e e e 2 42 Bolts and nuts tightness inspect e e e e 2 43 Service more frequently when operating in severe conditions dusty wet muddy high speed or frequent starting stopping For higher odometer readings repeat at the frequency interval established here PERIODIC MAINTENANCE 2 5 Periodic Maintenance Chart Periodic Replacement Parts
115. TEM 3 23 Air Cleaner Element Removal e Refer to Air Cleaner Cleaning in the Periodic Maintenance chapter see Air Cleaner Cleaning in the Periodic Mainte nance chapter Air Cleaner Element Installation e Refer to Air Cleaner Cleaning in the Periodic Maintenance chapter see Air Cleaner Cleaning in the Periodic Mainte nance chapter Air Cleaner Housing Removal e Remove Front Seat see Front Seat Removal in the Frame chap ter Rear Seat see Rear Seat Removal in the Frame chap ter Fuel Tank see Fuel Tank Removal Rear Fender see Rear Fender Removal in the Frame chapter e Pull out the rear axle and place the rear wheel A on the ground e Take out the bolts A and remove the fuel tank bracket B e Pull out the starter relay C e Remove the rear brake reservoir bolt A and disconnect the clamp B and free the rear brake reservoir and main harness from the frame e Remove the air cleaner cap C e Remove Carburetor Holder Clamps A Loosen Air Cleaner Housing Mounting Bolts B Air Suction Valve Hose C e Remove the air cleaner housing D pulling out the duct portion E from the grommet 3 24 FUEL SYSTEM Air Cleaner e Cover the carburetors intakes with a clean lint free towel to keep dirt or other foreign material from entering A WARNING If dirt or dust is allowed to pass through into the car buretors the butterfly valves may become stuck possibly causing an accident
116. Tool Spark Plug Wrench 16 mm 92110 0044 e Tighten Torque Spark Plugs 13 N m 1 3 kgf m 115 in Ib e Install Spark Plugs see Spark Plug Installation in the Electrical System chapter 6L05040281 FUEL SYSTEM 3 1 Fuel System Table of Contents EXPO WEE 3 2 Specifications EE 3 8 Special TO Sui en due eegene Meats 3 9 Throttle Grip and Cables cccccssccacaceccicnsccsnccceceucedaceseavessendenehdeapsdceacdunasuedshavesngavenehsetenanenseuciss 3 10 Free Play InSp CtOn ste srl de es ar entr detre AAE stats 3 10 Free Play AUS Me iii ieennrnanmtntess 3 10 Throttle Cable Removal esse 3 10 Throttle Cable Installation ses 3 10 Throttle Cable Lubrication ss 3 10 CHOKE ADI EE 3 11 Free Play inspection BND 3 11 Pree iPlay AUSTEN EE 3 11 Choke Cable Removals aux io a enter er 3 11 Choke Cable Installation ses 3 11 Choke Cable Lubrication and Inspection 3 11 IR ele 3 12 Idle Speed Inspection ss 3 12 Idle Speed E EE 3 12 Engine Vacuum Synchronization Inspection 3 12 Engine Vacuum Synchronization Adjustment 0 22 eee cece cece terete eeeaaeeeeeeeeeeteeneeneeeeeeeees 3 12 POS CHEW EE E EE 3 12 Service Fuel Level Inspection 3 13 Service Fuel Level Adjustment sienne 3 14 Fuel System Cleanliness Inspection mens 3 15 Carburetor Removal rtt rtt tttrrttErEt EEE EEE rEEteEEeent 3 16 Carburetor installation nissin a e a a nen eee s 3 17 Carburetor S
117. aa aena 16 45 Starter Relay Inspection ads 16 45 Starter Circuit Relay Inspection d ses mien hrs sentant der e 16 46 Lighting SM dd 16 48 Headlight Beam Horizontal Adjustment AAA 16 48 Headlight Beam Vertical Adjustment ns 16 48 Headlight Bulb Replacement cut 16 48 Tail Brake Light Bulb Replacement ooooccocoonononccccconnnononarcccocncnnncnnnnnnnnnne rines 16 49 Front Turn Signal Light Bulb Replacement A 16 49 Rear Turn Signal Light Bulb Replacement 16 50 Turn Signal Relay Inspection see 16 51 Headlight Circuit Relay Inspection ss 16 51 Radiator Fan YM riada 16 55 Fan System Circuit EE 16 55 Fan Motor Inspection non nn 16 55 Meters Gauge and Indicator Unit 16 56 Meter Unit Removal sise 16 56 Meter Unit Disassembly esata tar Reda a hand NS A AS 16 56 Meter Unit Installation ss 16 56 Indicator Light Replace Me EE 16 57 Tachometer Inspection 16 57 Water Temperature Warning System Inspechon 16 58 Switches AN SENSO ici tdi Ai aaa 16 59 Brake Light Timing INSpection EE 16 59 Brake Light Timing Adjustment au cat id iii ot tek Bhan col 16 59 Switch Een EE 16 59 Radiator Fan Switch Inspection ses 16 61 Water Temperature Switch Inspection oocccccccccnonnnonnncnnnnnnnnnnnononnnnnnnnnnnnnnnnnnnnnnninnnss 16 61 Fuel Level Sensor Inspection 16 62 NIT 16 63 30 A Main Fuse Remova eiii i
118. ace the sprocket washer and axle cotter pin e Install the engine sprocket onto the shaft the protruding side A of it faces in e Apply molybdenum disulfide oil solution to the threads of the output shaft and the seating surface of the engine sprocket nut e After torquing the engine sprocket nut bend the one side of the washer over the nut NOTE OTighten the nut while applying the rear brake Torque Engine Sprocket Nut 127 N m 13 kgf m 94 ft Ib e Adjust the drive chain slack after installing the sprocket see Drive Chain Slack Adjustment in the Periodic Main tenance chapter e Install the new axle cotter pin and bend the end of it surely e Install the engine sprocket cover e Install the shift lever onto the shift shaft aligning the mark which is marked before removing 11 12 FINAL DRIVE Sprocket Coupling Rear Sprocket Removal e Remove the rear wheel see Rear Wheel removal in the Wheel Tires chapter CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground e Pull out the coupling collar from the left and coupling sleeve from the right e Remove the rear sprocket nuts A e Remove the rear sprocket B Rear Sprocket Installation e Install the sprocket with the tooth number marking A out ward e Install the rear sprocket nuts Torque Rear Sprocket Nuts 59 N m
119. age No Good Battery Voltage No Good Replace e Measurement Peak Voltage Faulty Parts e Ignition Coil Connector Crankshaft Sensor Inspection No Good Good Inspect e Peak Vol A r Crankshaft Sensor Peak Voltage No Good ey Ole Reeve No Good Replace e Crankshaft Sensor Measurement Faulty Parts Connector e Battery Voltage IC Igniter Inspection Inspect e Battery Voltage IC Igniter Operation e Ignition Switch e Ignition Fuse No Good Replace IC Igniter Starter Button Operation No Good Inspect Side Stand Switch Operation e Side Stand Switch O Starter Lockout Switch No Good EN Replace Faulty Parts 0 Gear Position Sensor Operation O Starter Circuit Relay GP10139B F Ignition System ELECTRICAL SYSTEM 16 33 A WARNING The ignition system produces extremely high volt age Do not touch the spark plugs ignition coil or high tension lead while the engine is running or you could receive a severe electrical shock CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch is on or while the engine is running This is to prevent IC igniter damage Do not install the battery backwards The negative side is grounded This is to prevent damage to the diodes and IC igniter Crankshaft Sensor Removal e Remove Front Seat see Front Seat Removal in the Frame chap ter Left Lower Fairing see Lower Fairing Re
120. al It is generally under stood that higher running durability is obtained by perma nent internal repairs than by temporary external ones Also permanent internal repairs have the advantage of permitting a thorough examination for secondary damage not visible from external inspection of the tire For these reasons Kawasaki does not recommend temporary exter nal repair Only appropriate permanent internal repairs are recommended Repair methods may vary slightly from make to make Follow the repair methods indicated by the manufacturer of the repair tools and materials so that safe results can be obtained 6J05004BS1 10 16 WHEELS TIRES Hub Bearing Hub Bearing Removal e Remove the wheel and take out the following Collars Speedometer Gear Drive out of front hub Coupling out of rear hub Grease Seals Circlips A Special Tool Inside Circlip Pliers 57001 143 B e Use the bearing remover to remove the hub bearing A CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground Special Tools Bearing Remover Shaft 99 57001 1265 B Bearing Remover Head 415 x 17 57001 1267 C Hub Bearing Installation e Before installing the wheel bearings blow any dirt or for eign particles out of the hub with compressed air to pre vent contamination of the bearings e Replace the
121. all be inserted into the clutch cover hole Clutch Release Shaft Installation e Apply engine oil to the oil seal A and needle bearing B e Insert the clutch release shaft into the clutch cover hole e Install Clutch Cover see Clutch Cover Installation Clutch Cable see Clutch Cable Installation CAUTION When inserting the release shaft be careful not to remove the spring of the oil seal PE 6 8 CLUTCH Clutch Clutch Removal e Remove Clutch Cable see Clutch Cable Removal Clutch Cover see Clutch Cover Removal e Remove the clutch spring mounting bolts A springs clutch operating plate B with the clutch push rod C e Remove the clutch steel plates and friction plates e Remove the clutch hub nut using the special tool A e Remove the washer clutch housing needle bearing bushing and the thrust spacer Special Tool Clutch Holder 57001 1243 Clutch Installation e Install the thrust spacer A so that the chamfer side of it faces to inside of the engine e Install the spacer bushing A and needle bearing B Olnstall the snap ring C on the bushing so that it faces to inside of the engine e Install the clutch housing clutch hub washer and the clutch hub nut e Tighten the clutch hub nut with the specified torque Special Tool Clutch Holder 57001 1243 Torque Clutch Hub Nut 132 N m 13 5 kgf m 97 4 ft lb Clutch CLUTCH 6 9 e f the clutch housing is
122. an agence Chassis Parts Lubrication Bolts Nuts and Fasteners Tightness Inspechon reenen Replacement Parts Air Cleaner Element Repl Fuel Hose Replacement Coolant Change le E EE Radiator Hose and O ring Replacements os rss ENKEN EA recae Engine Oil Change Oil Filter Replacement Brake Hose and Pipe Replacement oocooccccccnccccccccncccnccnnccnncnnnonnnnnnnnnnnonnnnnnnnnnnnnnnnnnnnnnnnnn Brake Fluid Change Master Cylinder Rubber Parts Replacement 0 ceceeeeeeeeeeeeeeeeeeennaeeeeeeeeeeeeneneeeeeeeeees Caliper Rubber Parts Replacement ss Spark Plug Replacement 2 35 2 35 2 36 2 36 2 36 2 36 2 37 2 37 2 37 2 39 2 40 2 41 2 42 2 42 2 43 2 44 2 44 2 44 2 44 2 46 2 47 2 47 2 48 2 48 2 50 2 51 2 52 PERIODIC MAINTENANCE 2 3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition The initial maintenance is vitally important and must not be neglected Periodic Inspection FREQUENCY Whichever ODOMETER READING comes yy x 1 000 km first x 1 000 mile See y 116 12 18 24 30 36 Page INSPECTION Every 0 6 4 7 5 12 15 20 24 Fuel System Air cleaner element clean e e e 2 14 Throttle control system play smooth year a R e 2 15 return no drag inspect Choke operation inspect year e e e e 2 17 Engi
123. and chassis ground x Any tester reading less than infinity indicates a short necessitating replacement of the crankshaft sensor as sembly Crankshaft Sensor Peak Voltage Inspection e Disconnect the crankshaft sensor connector A e Set the hand tester B to the x 25 V DC range and con nect it the peak voltage adapter C as shown in the dia gram e Using two auxiliary wires connect the black lead of the adapter to black lead D and red lead to yellow lead E in the crankshaft sensor connector A e Turn the ignition switch and engine stop switch on e Grasp the clutch lever and pushing the starter button turn the engine 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 2 V or more Special Tool Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Ignition Coil Removal e Remove Front Seat see Front Seat Removal in the Frame chap ter Fuel Tank see Fuel Tank Removal in the Fuel System chapter Right or Left Lower Fairing see Lower Fairing Removal in the Frame chapter e Disconnect the primary winding leads A from the ignition coil e Pull out the spark plug cap from the spark plug e Remove the mounting bolts B and take out the ignition coil C Ignition System ELECTRICAL SYSTEM 16 35 Ignition Coil Installation e In
124. and hoses correctly see Ca ble Wire and Hose Routing section in the Appendix chap ter e Tighten the clamps for the carburetor holders and slide back the spring bands for the air cleaner housing securely e Check fuel leakage from the carburetor A WARNING Fuel spilled from the carburetor is hazardous e Adjust the following items if necessary Idle Speed see Idle Speed Adjustment in the Periodic Maintenance chapter Carburetor Synchronization see Carburetor Synchro nization Adjustment in the Periodic Maintenance chap ter Throttle Cable see Throttle Control System Inspection in the Periodic Maintenance chapter Choke Cable Carburetor Separation e Remove the carburetor see Carburetor Removal e Pull out the air cut valve hoses A B C of the air cut valve e Remove the choke plunger lever D spring E and car buretor mounting plates F G e Gently separately the carburetors each other Carburetor Joining e When installing the carburetor check to see that the O rings A are in place GC06163BS1 3 18 FUEL SYSTEM Carburetors e Install the fitting A and spring B as shown e Install the connecting plates A B and spring C as shown e The center lines of the carburetor bores must be parallel both horizontally and vertically If they are not loosen the mounting screws and align the carburetors on a flat surface Retighten the mounting screws e After installi
125. ange in the Periodic Maintenance chapter e Fill the coolant see Coolant Change in the Periodic Main tenance chapter CRANKSHAFT TRANSMISSION 9 1 Crankshaft Transmission Table of Contents Exploded View 9 2 Starter Motor Clutch Assembly 9 21 Specifications oooconcoccnnnncnnno 9 6 Balance iii sd 9 22 Special Tools and Sealants 9 9 Balancer Removal 9 22 Crankcase 9 10 Balancer Installation 9 22 Crankcase Splitting 9 10 Balancer Shaft Bearing Crankcase Assembly 9 11 Insert Journal Wear Inspection 9 22 Crankcase Exchange 9 13 Transmission 9 24 Crankshaft and Connecting Rods 9 14 External Shift Mechanism Crankshaft Removal 9 14 Removal aanneeoeeeeeeeeeeeeereeeee 9 24 Crankshaft Installation 9 14 External Shift Mechanism Connecting Rod Removal 9 15 Installation 288 2 nude 9 24 Connecting Rod Installation 9 15 External Shift Mechanism Crankshaft Connecting Rod Inspection 9 25 A nine tes 9 16 Transmission Removal 9 25 Connecting Rod Bend Inspection 9 16 Transmission Installation 9 26 Comnecting Rod Twist Inspection 9 16 Transmission Shaft Disassembly 9 26 Connecting Rod Big End Side Transmission Sha
126. ap Nuts 27 5 2 8 20 MO 7 Shift Drum Bearing Holder Bolt 12 1 2 104 in lb L L Apply a non permanent locking agent LG Apply liquid gasket Kawasaki Bond 92104 1064 M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts S Follow the specified tightening sequence W Washer 9 4 CRANKSHAFT TRANSMISSION Exploded View CRANKSHAFT TRANSMISSION 9 5 Exploded View No Fastener ft lb Remarks EE ofan 2 Neutral Switch 1 5 11 3 External Shift Mechanism Return Spring Pin ce 2 0 14 5 L 4 Shift Drum Positioning Bolt 24 5 2 5 18 5 Shift Lever Link Bolt 12 1 2 104 in Ib 6 Front Tie Rod Locknut Left Hand Threads 7 0 0 7 62 in lb 7 Rear Tie Rod Locknut Right Hand Threads 7 0 0 7 62 in lb 8 Shift Pedal Mounting Bolt 25 2 5 18 EO Apply engine oil G Apply grease L Apply a non permanent locking agent R Replacement Parts 9 6 CRANKSHAFT TRANSMISSION Specifications Item Standard Service Limit Crankshaft Connecting Rods Connecting Rod Bend SE 0 2 100 mm 0 008 3 94 in Connecting Rod Twist EE 0 2 100 mm 0 008 3 94 in Connecting Rod Big End Side Clearance 0 13 0 38 mm 0 50 mm 0 005 0 015 in 0 020 in Connecting Rod Big End Bearing 0 031 0 059 mm 0 10 mm Insert Crankpin Clearance 0 0012 0 0023 in
127. as pressure escapes the valve closes and keeps the pressure at 93 123 kPa 0 95 1 25 kgf cm 14 18 psi When the engine cools down another small valve vacuum valve in the cap opens As the coolant cools the coolant contracts to form a vacuum in the system The vacuum valve opens and allows the coolant from the reserve tank to enter the radiator COOLING SYSTEM 4 7 Coolant Flow Chart Reserve Tank Overflow Hose Radiator Cap E gt Hot Coolant Reserve Tank Hose Thermostat Housing Ny Br BAS ISA N WK gt o Ste Ce X a Fig Bw AG N IA IN s Water Pump ya D D T La gt oO o ane o bal en Cy inder CS Cold Coolant 6004008 E 4 8 COOLING SYSTEM Coolant Coolant Deterioration Inspection e Remove the right lower fairing see Lower Fairing Re moval in the Frame chapter e Visually inspect the coolant in the reserve tank If whitish cotton like wafts are observed aluminum parts in the cooling system are corroded If the coolant is brown iron or steel parts are rusting In either case flush the cooling system x lf the coolant gives off an abnormal smell check for a cooling system leak It may be caused by exhaust gas leaking into the cooling system Coolant Level Inspection e Refer to Coolant Level Inspection in the Periodic Mainte nance chapter see Coolant Level Inspection in the Peri odic Maintenance chapter
128. ay Switch Terminals 3 and 4 GP120703S2 ELECTRICAL SYSTEM 16 53 Lighting System Headlight Tail Light Circuit R BK BK Y i Y be 2 Za gt 22 gt gt Zo a BL Y BK Y BL Y R BK gl R Y BL Y R BK mu ee H Oi GP12374BW3 C Ignition Switch Diodes B Headlight Relay Fuse Box Tail Light Fuse 10 A Headlight Fuse 10 A Tail Brake Light License Plate Light Alternator 10 Battery 11 Main Fuse 30 A 12 Dimmer Switch 13 Headlight Low Beam 14 Headlight High Beam JO O1 amp N 16 54 ELECTRICAL SYSTEM Lighting System Turn Signal Light Circuit ll o oT 6 sie GY BK Y BK Y TT BK Y BK Y GP12375BW3 C 1 Ignition Switch 2 Turn Signal Relay 3 Fuse Box 4 Turn Signal Relay Fuse 10 A 5 Rear Right Turn Signal Light 6 Rear Left Turn Signal Light 7 Battery 8 Main Fuse 30 A 9 Turn Signal Switch 10 Front Left Turn Signal Light 11 Front Right Turn Signal Light 12 Turn Signal Indicator Light ELECTRICAL SYSTEM 16 55 Radiator Fan System A WARNING The radiator fan is connected directly to the bat tery The fan may start even if the ignition switch is off NEVER TOUCH THE RADIATOR FAN UNTIL THE RADIATOR FAN CONNECTOR IS DISCONNECTED TOUCHING THE FAN BEFORE THE CONNECTOR IS DISCONNECTED COULD CAUSE INJURY FROM THE FAN BLADES
129. b C Good D Bad E e Connect the headlight connector e Adjust the headlight beam see Headlight Aiming Inspec tion in the Periodic Maintenance chapter GP12020781 ELECTRICAL SYSTEM 16 49 Lighting System Tail Brake Light Bulb Replacement e Remove the rear seat see Rear Seat Removal in the Frame chapter e Unscrew the socket A counterclockwise B e Push A the bulb B in the socket turn it counterclock wise C and pull it out e Push the bulb in and turn it clockwise e Screw in the socket A aligning the tabs B with the re cesses C Front Turn Signal Light Bulb Replacement e Remove the lens mounting screw A and remove lens 16 50 ELECTRICAL SYSTEM Lighting System e Push A the bulb B in and turn C it counterclockwise and then remove it e Insert the new bulb A by aligning the projections B with the grooves C in the socket e Push the bulb and turn it clockwise and then replace it It should lock in lock position e Insert the socket by aligning the projection with the notch in the wall and turn the socket clockwise Pies P Rear Turn Signal Light Bulb Replacement e Remove the lens mounting screw A and remove the lens e Push A the bulb B in and turn C it counterclockwise and then remove it e Insert the new bulb A by aligning the projections B with the grooves C in the wall of the socket e Push the bulb in and turn it
130. ba bly worn also When replacing a sprocket inspect the chain Rear Sprocket Warp Inspection e Raise the rear wheel off the ground using the jack so that it will turn freely e Set a dial gauge A against the rear sprocket B near the teeth as shown and rotate C the rear wheel to measure the sprocket runout warp The difference between the highest and lowest dial gauge readings is the amount of runout warp x If the runout exceeds the service limit replace the rear sprocket Rear Sprocket Warp Standard TIR 0 4 mm 0 016 in or less Service Limit TIR 0 5 mm 0 02 in GKO5017BS1 6K05000BS1 BRAKES 12 1 Brakes Table of Contents Exploded E 12 2 eelere de EE 12 6 Special TO EE 12 7 Brake Lever Brake P dales ones ote Mariette lidera 12 8 Brake Pedal Position Inspection occcccccnncccnnccnccnnnnnnnnnnnonnnnnnnononononononnnnnnnnnnnnninnnnnnnnos 12 8 Brake Pedal Position Adjustment sfas son dde diodes 12 8 E let 12 9 Front Caliper Removal 222 iciisterescvhhsclevrsl tardive guished EES 12 9 Rear Caliper Hemoval sise 12 9 CaliperInstallatiON ila actus fol ent id died 12 9 Caliper EE 12 10 E ren EE 12 10 Caliper Fluid Seal Damage EEN 12 10 Rear Caliper Dust Boot and Friction Boot Damage ocoooccccccccccccccncnocononcnccccnananan cnn ccnnnnnnnns 12 10 Caliper Piston and Cylinder Damage INSPeCtiON occccccnncnononaccnccinonananancnnnnnnnnnnnnnnnnnnnnnnos 12
131. bearings with new ones NOTE Olnstall the bearings so that the marked side faces out e Install the bearings by using the bearing driver set which does not contact the bearing inner race e Press in each bearings A until they are bottomed Special Tool Bearing Driver Set 57001 1129 B e Replace the circlips with new ones Special Tool Inside Circlip Pliers 57001 143 e Replace the grease seals with new ones e Press in the grease seals A so that the seal surface is flush B with the end of the hole OApply high temperature grease to the grease seal lips Special Tool Bearing Driver Set 57001 1129 C 6J06060651 605000451 605000551 Hub Bearing WHEELS TIRES 10 17 Hub Bearing Inspection Since the hub bearings are made to extremely close tol erances the clearance can not normally be measured NOTE ODo not remove any bearings for inspection If any bear ings are removed they will need to be replaced with new ones e Turn each bearing in the hub back and forth A while checking for plays roughness or binding x lf bearing play roughness or binding is found replace the bearing e Examine the bearing seal B for tears or leakage x If the seal is torn or is leaking replace the bearing Hub Bearing Lubrication NOTE OSince the hub bearings are packed with grease and sealed lubrication is not required 6J06002BS1
132. breakdown under high voltage e Measure the primary winding resistance A as follows OConnect the hand tester between the coil terminal and primary winding terminal GP10518BS1 6P10108BS1 6P10109BS1 16 36 ELECTRICAL SYSTEM Ignition System e Measure the secondary winding resistance B as follows ORemove the plug cap by turning it counterclockwise OConnect the tester between the high tension lead and the ignition coil terminal x If the tester does not read as specified replace the coil Ignition Coil Resistance Standard Primary windings 2 1 3 2 Q x 1 Q Secondary windings 10 16 kQ x 1 kQ Special Tool Hand Tester 57001 1394 e Visually inspect the secondary winding lead x If it is damaged replace the ignition coil Ignition Coil Primary Peak Voltage NOTE OBe sure the battery is fully charged e Remove Front Seat see Front Seat Removal in the Frame chap ter Fuel Tank see Fuel Tank Removal in the Fuel System chapter Right or Left Lower Fairing see Lower Fairing in the Frame chapter e Remove the spark plug cap e Measure the ignition coil primary peak voltage as follows e Install the new spark plug G into the spark plug cap and ground it onto the engine e Connect the peak voltage adapter A into the hand tester B and set it to the x 250 V DC range Ignition System ELECTRICAL SYSTEM 16 37 Adapter red lead Ignition Coil
133. cated electrolyte container for correct electrolyte volume e Place the battery on a level surface e Check to see that the sealing sheet has no peeling tears or holes in it e Remove the sealing sheet NOTE OThe battery is vacuum sealed If the sealing sheet has leaked air into the battery it may require a longer initial charge e Remove the electrolyte container from the vinyl bag e Detach the strip of caps A from the container and set aside these will be used later to seal the battery NOTE ODo not pierce or otherwise open the sealed cells B of the electrolyte container Do not attempt to separate individual cells e Place the electrolyte container upside down with the six sealed cells into the filler ports of the battery Hold the container level push down to break the seals of all six cells You will see air bubbles rising into each cell as the ports fill NOTE ODo not tilt the electrolyte container e Check the electrolyte flow x If no air bubbles A are coming up from the filler ports or if the container cells have not emptied completely tap the container B a few times e Keep the container in place for 20 minutes or more Don t remove the container from the battery until it s empty the battery requires all the electrolyte from the container for proper operation CAUTION Removal of the container before it is completely empty can shorten the service life of the battery Do not remove t
134. ch changes to products manufactured previously See your Motorcycle 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 2007 Kawasaki Heavy Industries Ltd First Edition 1 Nov 15 2007 M LIST OF ABBREVIATIONS ABDC AC ATDC BBDC BDC BTDC C DC F ft ampere s after bottom dead center alternating current after top dead center before bottom dead center bottom dead center before top dead center degree s Celsius direct current farad s degree s Fahrenheit foot feet gram s hour s liter s Ib m min N Pa PS psi rpm TDC TIR V W Q pound s meter s minute s newton s pascal s horsepower pound s per square inch revolution revolution s per minute top dead center total indicator reading volt s watt s ohm s AT AU CA CAL CH DE FR COUNTRY AND AREA CODES Austria Australia Canada California Switzerland Germany France WVTA United Kingdom Malaysia United States Indonesia Philippines Whole Vehicle Type Approval EMISSION CONTROL INFORMATION To protect the environment in which we all live Kawasaki has incorpora
135. 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 or low flash point solvent 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 GG080601S1 ENGINE LUBRICATION SYSTEM 7 11 Oil Pump Oil Pump Removal e Remove the clutch cover see Clutch Cover Removal in the Clutch chapter e Remove the clutch see Clutch Removal in the Clutch chapter e Remove the circlip and oil pump gear e Remove the oil pump mounting Allen bolts A e Pull the oil pump B off the crankcase Oil Pump Installation e Fill the oil pump with engine oil for initial lubrication e When installing the oil pump A note the position of the water pump shaft slot C and turn the oil pump shaft so that the projection B fits into the slot e Apply a non permanent locking agent to the threads of the oil pump mounting Allen bolts and tighten them securely Torque Oil Pump Mounting Bolts 9 8 N m 1 0 kgf m 87 in Ib Oil Pump Disassembly e Remove the circlip A with circlip plire on th
136. clearance between the camshaft journal and the camshaft cap using the plastigauge press gauge A e Tighten Torque Camshaft Cap Bolts 12 N m 1 2 kgf m 106 in Ib NOTE ODo not turn the camshaft when the plastigauge is be tween the journal and camshaft cap Camshaft Journal Camshaft Cap Clearance Standard 0 028 0 071 mm 0 0011 0 0071 in Service Limit 0 16 mm 0 0063 in x If any clearance exceeds the service limit measure the diameter of each camshaft journal with a micrometer Camshaft Journal Diameter Standard 23 950 23 972 mm 0 9429 0 9438 in Service Limit 23 92 mm 0 942 in x If the camshaft journal diameter is less than the service limit replace the camshaft with a new one and measure the clearance again x If the clearance still remains out of the service limit re place the cylinder head unit GE11270BS1 IN GE11271BS1 5 20 ENGINE TOP END Camshaft Camshaft Chain Camshaft Runout Inspection e Remove the camshaft e Set the camshaft in a camshaft alignment jig or on V blocks e Measure the runout with a dial gauge at the specified place as shown x If the runout exceeds the service limit replace the shaft Camshaft Runout Standard TIR 0 02 mm 0 0008 in Service Limit TIR 0 1 mm 0 004 in Cam Wear Inspection e Remove the camshaft see Camshaft Removal e Measure the height A of each cam with a micrometer x If the cams are w
137. clockwise raise the front of the seat up B and pull the seat frontwards Rear Seat Installation e Slip A the rear seat hook into the hollow cubic bracket on the frame e Push down the front part of the seat until the lock clicks algining B the pin with the hole FRAME 15 7 Fairings Lower Fairing Removal e Remove the side covers see Side Cover Removal e Remove the rivets A e Remove the lower fairing mounting screws B and mount ing Allen bolts C e Disconnect the front turn signal light connectors A and remove the lower fairings B e Remove the radiator fairing screws A and the rivets B and remove the radiator fairing C Lower Fairing Installation e Fit the front portions A of radiator fairing into the lower portions B of upper fairing 15 8 FRAME Fairings e Route the front turn signal light lead A on the fooks B e Install the lower fairing OFit the front portion of the lower fairing in the rear portion of the upper fairing Olnstall the tabs B on the lower fairing into the rescesses C on the upper cover Upper Fairing Removal e Remove Lower Fairings see Lower Fairing Removal Radiator Fairing see Lower Fairing Removal e Remove the windshield mounting screws A and take out the windshield B e Remove the upper fairing bolts A and pull the upper fair ing B forwards e Disconnect the headlight connectors A and remove the upper
138. clockwise and then install it It should lock in position e Install the lens and tighten the lens mounting screw Be careful not to overtighten the lens mounting screw ELECTRICAL SYSTEM 16 51 Lighting System Turn Signal Relay Inspection e Remove Seat Cover see Rear Fender Removal in the Frame chapter Turn Signal Relay Connector A Turn Signal Relay B e Connect one 12 V battery and turn signal lights as indi cated in the figure and count how many times the lights flash for one minute Turn Signal Relay A Turn Signal Lights B 12 V Battery C x If the lights do not flash as specified replace the turn sig nal relay Testing Turn Signal Relay GP12040281 Load The Number of Flashing times c m Turn Signal Lights Wattage M 1 21 or 23 Light stays on 2 42 or 46 75 95 Cycle s per minute Correspond to one light burned out Headlight Circuit Relay Inspection e Remove the front seat see Front Seat Removal in the Frame chapter e Remove the headlight circuit relay A 16 52 ELECTRICAL SYSTEM Lighting System e Connect the hand tester A and 12 V battery B to the starter circuit relay C as shown x If the relay does not work as specified the relay is defec tive Replace the relay Testing Relay Tester Range x 1 Q Criteria When battery is connected 0 Q When battery is disconnected Q Relay Coil Terminal 1 and 2 Rel
139. cord the clearance and adjust it Valve Clearance Adjustment e To change the valve clearance remove the camshaft chain tensioner camshafts and valve lifters Replace the shim with one of a different thickness NOTE OMark and record the locations of the valve lifters and shims so that they can be reinstalled in their original positions LLL GSO7073BS1 2 24 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Clean the shim to remove any dust or oil e Measure the thickness of the removed shim A e Select a new shim thickness calculation as follows atb c d a Present Shim Thickness b Measured Valve Clearance c Specified Valve Clearance Mean Value 0 255 mm Exhaust 0 195 mm Inlet d Replace Shim Thickness Example Inlet 2 90 0 45 0 195 3 155 mm OExchange the shim for the 3 175 size shim CAUTION Don t use the shims for another models This could cause wear of the valve stem end and valve stem damage PERIODIC MAINTENANCE 2 25 Periodic Maintenance Procedures Adjustment Shims Thickness Part Number Mark 92180 1014 50 2 55 92180 1016 55 92180 1018 60 2 65 92180 1020 65 SZ 92180 1174 68 2 70 92180 1022 70 EH 2 725 92180 1175 73 2 75 92180 1024 75 2 775 92180 1176 78 92180 1026 80 2 825 92180 1177 83 92180 1028 85 92180 1178 88 2 90 92180 1030 90 92180 1179 93 2 95 92180 1032 95
140. crankcase and wipe each bearing insert and jour nal A surface clean of oil OCut strips of plastigage press gauge B to bearing insert width and place a strip on each journal parallel to the balancer shaft so that the plastigage will be compressed between the journal and the bearing insert Olnstall the lower crankcase half and tighten the case bolts to the specified torque Torque Crankcase Bolts 98 27 N m 2 8 kgf m 20 ft lb Crankcase Bolts 6 12 N m 1 2 kgf m 104 in Ib NOTE ODo not turn the balancer shaft during clearance mea surement ORemove the lower crankcase half and measure the plas tigage width to determine the bearing insert journal clear ance Balancer Shaft Bearing Insert Journal Clearance Standard 0 020 0 044 mm 0 0008 0 0017 in Service Limit 0 08 mm 0 0031 in x If the clearance is within the standard no bearing replace ment is required x lf the clearance is between 0 044 mm 0 0017 in and the service limit 0 08 mm 0 0031 in replace the bear ing inserts with inserts painted blue Check insert journal clearance with plastigage The clearance may exceed the standard slightly but it must not be less than the minimum in order to avoid bearing seizure x If the clearance exceeds the service limit measure the diameter of the balancer shaft journal Balancer Shaft Journal Diameter Standard 25 984 26 000 1 0230 1 0236 in Service Limit 25 96 mm 1 022 in
141. ctusceiadvesancacasdasedacaaeshccsaseatagent ed tee s et est 7 13 Oil Pressure Switch Removal siens 7 13 Oil Pressure Switch Installation o ooccocccocccnccnnccnncnnncnnncnnncnnnconcconcnonnronnrnnncnnncnnncnnss 7 13 7 2 ENGINE LUBRICATION SYSTEM Exploded View Oy d sr DI EX DNA O Y IRE SEX SC 6 SCH Se C ENGINE LUBRICATION SYSTEM 7 3 Exploded View Nm kgfm ftlb 1 Biereg fes eo fs Po 2 Oil Pressure Relief Valve 3 Crankcase Oil Passage Plug e e 11 4 Oil Passage Plugs for Oil Pump 20 2 0 15 L 5 Oil Pipe Banjo Bolts 12 1 2 104 in lb 6 Oil Drain Bolt 19 6 2 0 14 5 7 OU Pressure Switch 15 1 5 11 SS 8 Oil Pressure Switch Terminal Bolt 1 5 0 15 13 in lb 9 OU Filter Mounting Bolts 19 6 2 0 14 5 10 Oil Breather Mounting Bolts 9 8 1 0 87 in lb L 11 Oil Pump Mounting Bolts 9 8 1 0 87 in lb L 12 Oil Screen Cover Bolts 9 8 1 0 87 in lb 13 Plug 19 6 2 0 14 5 14 Breather Bolt 9 8 1 0 87 in lb EO Apply engine oil G Apply grease L Apply a non permanent locking agent R Replacement Parts SS Apply silicone sealant Kawasaki Bond 56019 120 7 4 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil Grade API SE SF or SG API SH SJ or SL with JASO MA Viscosity SAE 10W 40 Capacity 1 3 L 1 37 US gt when filter is not removed 1 6 L 1 69 US gt when filter is removed 1 7 L 1 80 US gt when e
142. cut for installation GKO40606S1 Standard Chain Make ENUMA Type EK520SR O2 Link 106 links 2 32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Chain Guide Inspection e Remove Swingarm see Swingarm Removal in the Suspension chapter e Visually inspect the chain guide A Replace the chain guide if it shows any signs of abnormal wear or damage Brake System Brake Fluid Leak Brake Hose and Pipe Inspection e Apply the brake lever or pedal and inspect the brake fluid leak from the brake hoses A fittings B and pipes C x If the brake fluid leaked from any position inspect or re place the problem part Brake Hose and Pipe Damage and Installation Condition Inspection e Inspect the brake hoses fittings and pipes for deteriora tion cracks and signs of leakage OThe high pressure inside the brake line can cause fluid to leak A or the hose to burst if the line is not properly main tained Bend and twist the rubber hose while examining it x Replace the hose and pipe if any crack B bulge C or leakage is noticed Tighten any brake hose banjo bolts and brake pipe joint nuts Torque Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft lb e Inspect the brake hose routing x If any brake hose routing is incorrect route the brake hose according to Cable Wire and Hose Routing section in the Appendix chapter Brake Operation Inspection e Inspect the operation
143. d and insert the arbor through the connect ing rod big end e Select an arbor of the same diameter as the piston pin and at least 100 mm 3 94 in long and insert the arbor B through the connecting rod small end e On a surface plate set the big end arbor on V block C e With 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 length to determine the amount of connecting rod bend x If the connecting rod bend exceeds the service limit the connecting rod must be replaced Connecting Rod Bend Service Limit TIR 0 2 100 mm 0 008 3 94 in Connecting Rod Twist Inspection e With the big end arbor A still on V block C hold the connecting rod horizontally and measure the amount that the arbor B varies from being paralleled with the surface plate over a 100 mm 3 94 in length of the arbor to de termine the amount of connecting rod twist x If the connecting rod twist exceeds the service limit the connecting rod must be replaced Connecting Rod Twist Service Limit TIR 0 2 100 mm 0 008 3 94 in 100mm 6105040681 6105040781 CRANKSHAFT TRANSMISSION 9 17 Crankshaft and Connecting Rods Connecting Rod Big End Side Clearance Inspection e Measure the connecting rod big end side clearance A Olnsert a thickness gauge B between the big end and the crank web to determ
144. d harness correctly see Cable Wire and Hose Routing in the Appendix chapter A WARNING Do not impede the handlebar turning by routing the cables harnesses and hoses improperly e Check and adjust the following Front Brake Clutch Throttle Cable Rear View Mirrors Headlight Aim GNO50605S1 STEERING 14 9 Steering Stem Stem Bearing Lubrication e Refer to Steering Stem Bearing Lubrication in the Periodic Maintenance chapter see Steering Stem Bearing Lubri cation in the Periodic Maintenance chapter Grease Seal Deterioration Damage Inspection e Inspect the grease seal for any sign of deterioration or damage Replace the grease seal if necessary Steering Stem Warp Inspection e Whenever the steering stem is removed or if the steering can not be adjusted for smooth action check the steering stem for straightness x If the steering stem A is bent replace the steering stem GNO5021BS1 14 10 STEERING Handlebars Right Handlebar Holder Removal e Remove Right Switch Housing A Front Master Cylinder Clamp Bolts B Handlebar Holder Mounting Bolts C Right Handlebar D Right Handlebar Holder Installation e Install Right Handlebar Holder Right Switch Housing e Install the front master cylinder so that the punch mark A of the handlebar is aligned with the mating surface B of the master cylinder clamp to level the reservoir NOTE OWhen the master cylind
145. deteriorate Don t leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid Don t change the fluid in the rain or when a strong wind is blowing Except for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning of the brake parts Do not use any other fluid for cleaning these parts Gasoline engine oil or any other petroleum distillate will cause deterio ration of the rubber parts Oil spilled on any part will be difficult to wash off completely and will eventually deteriorate the rubber used in the disc brake When handling the disc pads or disc be careful that no disc brake fluid or any oil gets on them Clean off any fluid or oil that inadvertently gets on the pads or disc with a high flash point solvent Do not use one which will leave an oily residue Replace the pads with new ones if they cannot be cleaned satisfacto rily Brake fluid quickly ruins painted surfaces any spilled fluid should be completely wiped up imme diately If any of the brake line fittings or the bleed valve is opened at any time the AIR MUST BE BLED FROM THE BRAKE LINE Brake Hose BRAKES 12 21 Brake Hose Removal Installation e Refer to the Brake Hose and Pipe Replacement in the Periodic Maintenance chapter see Brake Hose and Pipe Replacement in the Periodic Maintenance chapter Brake Hose Inspection e Refer to Brake Ho
146. e If roughness binding or noise is found remove the front wheel and inspect the wheel bearing see Front Wheel Removal Hub Bearing Inspection in the Wheels Tires chapter e Raise the rear wheel off the ground with stand see Rear Wheel Removal in the Wheels Tires chapter e Inspect the roughness of the rear wheel bearing by push ing and pulling A the wheel e Spin B the rear wheel lightly and check for smoothly turn roughness binding or noise If roughness binding or noise is found remove the rear wheel and inspect the wheel bearing see Rear Wheel Re moval Hub Bearing Inspection in the Wheels Tires chap ter and coupling see Coupling Bearing Inspection in the Final Drive chapter 65118127 P PERIODIC MAINTENANCE 2 29 Periodic Maintenance Procedures Drive Train Drive Chain Lubrication Condition Inspection elt a special lubricant is not available a heavy oil such as SAE 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication elt the chain appears especially dirty clean it before lubri cation CAUTION The O rings between the side plates seal in the lu bricant between the pin and the bushing To avoid damaging the O rings and resultant loss of lubri cant observe the following rules Use only kerosene or diesel oil for cleaning an O ring drive chain Any other cleaning solution such as gasoline or trichloroethylene will cause deteri
147. e Never remove the seal cap during refresh charge If by chance an excessive amount of gas is generated due to overcharging the relief valve releases the gas to keep the battery normal 3 When you do not use the motorcycle for months Give a refresh charge before you store the motorcycle and store it with the negative cable re moved Give a refresh charge once a month during storage 4 Battery life If the battery will not start the engine even after several refresh charges the battery has ex ceeded its useful life Replace it Provided however the vehicle s starting system has no prob lem A WARNING Keep the battery away from sparks and open flames during charging since the battery gives off an explosive 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 No fire should be drawn near the battery or no terminals should have the tightening loos ened The electrolyte contains sulfuric acid Be careful not to have it touch your skin or eyes If touched wash it off with liberal amount of water Get medial attention if severe Interchange A sealed battery can fully display its performance only when combined with a proper vehicle electric system Therefore replace a sealed battery only on a motorcycle which was originally equipped with a s
148. e following Torque Fuel Tap Mounting Bolts 2 5 N m 0 25 kgf m 22 in Ib e Be sure to clamp the fuel hose to the tap to prevent leaks e Be sure the fuel level sensor leads A are routed as shown GC09087BS1 o Fuel Tank and Tap Cleaning A WARNING Clean the tank in a well ventilated area and take care that there are no sparks or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents to clean the tank e Remove the fuel tank and drain it e Pour some high flash point solvent into the fuel tank and shake the tank to remove dirt and fuel deposits e Pour high flash point solvent e Pour the solvent out of the tank e Remove the fuel tap from the tank by taking out the bolts e Clean the fuel tap in a high flash point solvent e Pour high flash point solvent through the tap in ON and PRI positions e Dry the tank and tap with compressed air e Install the tap in the tank e Install the fuel tank see Fuel Tank Installation 3 28 FUEL SYSTEM Fuel Tank Fuel Tap Inspection e Remove the fuel tap see Fuel Tap Removal e Check the fuel tap filter screen A for any breaks or dete rioration xlf the fuel tap screens have any breaks or are deterio rated they 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 at ON or
149. e removed Do not use a strong carburetor cleaning solution which could attack these parts instead use a mild high flash point cleaning solution safe for plastic parts Do not use wire or any other hard instrument to clean carburetor parts especially jets as they may be damaged 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 through the air and fuel passages with compressed air e Assemble the carburetor see Carburetor Assembly Carburetor 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 Remove the carburetors see Carburetor Removal e Before disassembling the carburetors check the fuel level see Fuel Level Inspection x If the fuel level is incorrect inspect the rest of the carbu retor before correcting it e Slide the choke plunger lever A right to the left to check that the choke plungers move smoothly x If the choke plungers do not work properly replace the carburetors e Turn the throttle cable pulley to check that the throttle but terfly valves B move smoothly and return by spring te
150. e Box Headlight Circuit Relay Starter Circuit Relay Apply grease Apply a non permanent locking agent SS Apply silicone grease XA elo EE CEET 16 10 ELECTRICAL SYSTEM Wiring Diagram United States Canada and Australia Fuel Level 3 7 x s Right Switch Housing Toser 1 Front Brake Light CON JOFF PARK E renion ka BR omit en aa BATTERY Qa LU A i lgnition Es SC Sgr 2 Engine Stop Switch Switch R R 3 Starter Button BATTERY W BK W BK Ignition rara Os 0 6 K Di cY goile oral es o Turn Radiator tr Signal Relay Fan BK AE 12V 2 6A Il i Radiator ER BL SCT Fan Switch all BL Water Temperetre Switch Water Temperetre Warning Light 12V 3 AN Meter Light 12V 3 4 Meter Light 12V 3 4 Meter Light 12V 3 4W Fuel Gauge i Speedmeter ox 6 OT R BL BR BK Tachometer BK Y BL R G BK LG Light 12V 3 4W ay a Neutral Indicator Light 12V 3 AN E Oil Pressure Warning Light 12V 3 44 High Beam Indicator Light 12V 3 4W Turn Signal Indicator Sen gt eee e E z gt l ee x 905 a NN Front Right SS az ox Turn Signal Light Sy 12V 10W gt x copi a IC Igniter Headlight R BK Hi BK Y 12V 55W e el sx D D 1 Letz Mier ont o Headlight EN o ae BK Y Left Switch ON OFF 12V 55W Housing Sidestand Switch Horn Left Switch Housing 12V 2 5A 1 Horn Button
151. e Caliper Rubber Parts Replacement in the Periodic Maintenance chap ter Rear Caliper Removal e Loosen the banjo bolt A at the brake hose lower end and tighten it loosely e Unscrew the caliper mounting bolts B and detach the caliper C from the disc e Unscrew the banjo bolt and remove the brake hose D from the caliper see Brake Hose Removal Installation CAUTION Immediately wash away any brake fluid that spills NOTE Olf the caliper is to be disassembled after removal and if compressed air is not available disassemble the caliper before the brake hose is removed see Caliper Rubber Parts Replacement in the Periodic Maintenance chap ter Caliper Installation e Install the caliper and brake hose lower end OReplace the washers on each side of hose fitting with new ones e Tighten Torque Front Caliper Mounting Bolts 25 N m 2 5 kgf m 18 ft lb Rear Caliper Mounting Bolts 25 N m 2 5 kgf m 18 ft lb Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft Ib 12 10 BRAKES Calipers e Check the fluid level in the brake reservoirs e Bleed the brake line see Brake Line Bleeding e Check the brake for good braking power no brake drag and no fluid leakage A WARNING Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal and the pads are against the disc The brakes will not function on the first appli cation of the leve
152. e Fit the toothed washer C into the end cover 27118245 P Pie P ELECTRICAL SYSTEM 16 43 Electric Starter System e Install the brush terminal bolt washers with the brush plate A and tighten the terminal locknut B Torque Starter Motor Terminal Locknut 9 8 N m 1 0 kgf m 87 in lb e Fit the tongue C on the brush plate into the end cover groove 211828 P e Install the steel washer A and resin washer B into the starter shaft and insert the armature C between the brushes 2118245 P e Align the end cover A with the mark C of the yoke B Torque Starter Motor Assembly Bolts 3 5 N m 0 36 kgf m 31 in Ib Carbon Brush Inspection e Measure the length C of each brush A x If any is worn down to the service limit replace the carbon brush holder assembly B Carbon Brush Length Standard 10 mm 0 39 in Service Limit 5 mm 0 20 in Commutator Inspection Cleaning e Smooth the commutator surface A if necessary with fine emery cloth B and clean out the grooves GP110610S1 16 44 ELECTRICAL SYSTEM Electric Starter System e Measure the outer diameter A of the commutator B x 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 hand tester range
153. e Fuse Inspection in the Electrical System chapter Ignition Fuse 10 A see Fuse Inspection in the Electrical System chapter Ignition Switch see Switch Inspection in the Electrical System chapter Sidestand Switch see Switch Inspection in the Electrical System chapter Engine Stop Switch see Switch Inspection in the Elec trical System chapter Starter Button see Switch Inspection in the Electrical System chapter Neutral Switch see Switch Inspection in the Electrical System chapter Starter Relay see Starter Relay Inspection in the Elec trical System chapter Starter Circuit Relay see Relay Circuit Inspection in the Electrical System chapter Harness see Wiring Inspection in the Electrical System chapter x lf the all parts are good condition replace the IC Igniter Engine Stop Switch Operation Inspection First Step e Turn on the ignition switch e Set the neutral position e Turn the engine stop switch to stop position A e Push the starter button e The engine does not start x If the engine starts inspect or replace the following item Engine Stop Switch see Switch Inspection in the Elec trical System chapter Second Step e Turn on the ignition switch e Set the neutral position e Turn the engine stop switch to run position A e Push the starter button and run the engine e Turn the engine stop switch to stop position e Immediately the engine should be stop x If the engine does not stop inspect or rep
154. e Warning Indicator Light F x If the light does not go on inspect or replace the following item Battery see Charging Condition Inspection in the Elec trical System chapter Applicable Bulb see Wiring Diagram in the Electrical System chapter Meter Unit for Meter Lights see Meter Unit Inspection in the Electrical System chapter Meter Unit for Neutral Indicator Light see Meter Unit Inspection in the Electrical System chapter Meter Unit for Oil Pressure Warning Indicator Light see Meter Unit Inspection in the Electrical System chapter Meter Unit for Water Temperature Warning Indicator Light see Meter Unit Inspection in the Electrical System chapter Main Fuse 30 A and Taillight Fuse 10 A see Fuse In spection in the Electrical System chapter Ignition Switch see Switch Inspection in the Electrical System chapter Neutral Switch see Switch Inspection in the Electrical System chapter Harness see Wiring Inspection in the Electrical System chapter goes on e Turn off the ignition switch e The all lights should go off x lf the light does not go off replace the ignition switch 2 38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Second Step e Turn on the turn signal switch A left or right position e The left or right turn signal lights B front and rear ac cording to the switch position should flash e The turn signal indicator light C in the meter unit should flash If the each light doe
155. e ee eee Senf st Zeie gt EE 3 ES gt gt ee za Seer lt s e zoe Da ee G 0 GY BK Y BK Y gt gt gt xe PRET D EE ae a R R IC Igniter BK Y BK Y Z os R BK aK Y TL DL DIN Log 2 Flore on KE Left Switch Be i on DU ee Housing EE Sidestand BL Y Switch BK Y Left Switch Housing 1 Horn Button 2 Turn Signal Switch 3 Dimmer Switch 4 Starter Lockout Switch HORN e 12V2 5A aA DE LEFT SWITCH HOUSING CONNECTIONS Horn Button Turn Signal Switch Dimmer Switch Starter Lockout Switch Color BK WBK Y Color o 6Y Color R YBL YR BK Color BK BK R Push a O R a O LO a O Clutch Lever Released DEF Push Released a D LL comm n hud W2L0410BW5 C ELECTRICAL SYSTEM 16 13 Wiring Diagram Indonesia Fuse Box 1 Turn Signal Relay Fuse 10A 2 Horn Fuse 10A Starter let hen Fuse 10A Ci Fuse Box 4 Taillight Fuse 104 Ignition X ek ae 777 5 Headlight Fuse 104 Rel S Coils elay 100000 e 6 Fun Fuse 10A i Rear Brake J Light Switch Diode Diode Turn Signal Sa Relay Zo ase E 222 e 552 ez as s55 ac amp Eat SS eases za o amp E ail BL R BK Y eK R eles BK Y BK Y A D RR RN E o Ce d Si BK Y 12 Rear Right Turn Signal Light 12V10K it le Tail Brake Light 12V 21 5W License Plate Light 12V5W G BK Y BK Y S Q z Sula Es 5 S gt
156. e oil pump shaft end Special Tool Outside Circlip Pliers 57001 144 e Take off the gear B from the shaft C e Loosen the screws D before removing the oil pump mounting bolts E e Remove the oil pump see Oil Pump Removal e Unscrew the oil pump cover screws D and take off the cover F e Pull the oil pump shaft A washer B pins C inner rotor D and outer rotor E from the pump body F Oil Pump Assembly e Oil pump assembly is the reverse of disassembly e After completing the oil pump assembly check that the rotor shaft and rotor turn smoothly Oil Pump Inspection e Disassemble the oil pump see Oil Pump Disassembly e Visually inspect the oil pump body inner and outer rotors and covers x lf there is any damage or uneven wear replace the oil pump as an assembly GSi P 7 12 ENGINE LUBRICATION SYSTEM Oil Pressure Measurement Oil Pressure Measurement e Remove the lower fairing see Lower Fairing Removal in the Frame chapter e Remove the oil plug and attach the adapter B and gauge A to the plug hole Special Tools Oil Pressure Gauge 10 kgf cm 57001 164 Oil Pressure Gauge Adapter M18 x 1 5 57001 1278 e Start the engine and warm up the engine e Run the engine at the specified speed and read the oil pressure gauge x If the oil pressure is much lower than the standard check the oil pump and oil pump relief valve x If the reading is much higher than
157. e split D of the bushing should face toward the side of the vehicle Special Tool Front Fork Oil Seal Driver 57001 1219 e Apply molybdenum disulfide grease to the oil seal lips and install the washer and the oil seal A into the outer tube Special Tool Front Fork Oil Seal Driver 57001 1219 B e Install the retaining ring on the outer tube e Install a new bottom Allen bolt gasket e Apply a non permanent locking agent to the threads of the bottom Allen bolt and screw the Allen bolt into the bottom of the outer tube e Hold the outer tube in a vise A hold the cylinder unit B with the special tools then tighten the Allen bolt C OApply a non permanent locking agent to the front fork bot tom Allen bolt Special Tools Fork Cylinder Holder Handle 57001 183 D Fork Cylinder Holder Adapter 57001 1057 E Torque Front Fork Bottom Allen Bolt 20 N m 2 0 kgf m 15 ft lb GM04010281 GM04031281 GM04041281 GM040138S1 Front Fork SUSPENSION 13 11 e Fill with the specified type of oil and install the parts re moved see Fork Oil change e Install the dust seals Fork Oil KAYABA SS 8 or equivalent Capacity per 360 2 5 mL 12 2 0 08 US oz after one unit fork disassembly and completely dry Inner Tube Outer Tube Inspection e Visually inspect the inner tube A and repair any damage e Nick or rust damage can sometimes be repaired by
158. e spring retainer Special Tools Valve Spring Compressor Assembly 57001 241 A Valve Spring Compressor Adapter 16 57001 1305 B Valve Installation e Replace the oil seal with a new one e Apply engine oil to the lip of oil seal e Apply a thin coat of molybdenum disulfide grease to the valve stem before valve installation e Install the spring so that the closed coil end faces down wards A Valve Stem E Retainer B Spring Seat F Split Keepers C Spring G Closed Coil End D Oil Seal Valve Guide Removal e Remove Valve see Valve Removal Oil Seal Spring Seat e Heat the area around the valve guide to 120 150 C 248 302 F and hammer lightly on the valve guide arbor A to remove the guide from the top of the head CAUTION Do not heat the cylinder head with a torch This will warp the cylinder head Soak the cylinder head in oil and heat the oil Special Tool Valve Guide Arbor 4 5 57001 1331 Valve Guide Installation e Apply a thin coat of oil to the outer surface of the valve guide e Heat the area around the valve guide up to 120 150 C 248 302 F CAUTION Do not heat the cylinder head with a torch This will warp the cylinder head Soak the cylinder head and heat the oil GE150303 GE15171BS1 GE150305 S 5 26 ENGINE TOP END Valves e Using the valve guide driver A and washer B press and insert the valve
159. e that the position of muffler cover clamp screw A is as shown approx 15 B GE18098BS1 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 system see Muffler Removal e Inspect the gasket for damage and signs of leakage x If the gasket is damaged or has been leaking replace it e Check the exhaust pipe and muffler for dents cracks rust and holes x lf the exhaust pipe or muffler is damaged or holes it should be replaced for best performance and least noise CLUTCH 6 1 Clutch Table of Contents Exploded WEE EE 6 2 Specifications ER 6 4 Special Tool and Gealant ss 6 5 Clutch Eever and Ree 6 6 Clutch Lever Free Play INSpectiOn sssssssssssesst discs duscccebecaphactagetiuagaited canvas aseheae sh 6 6 Clutch Lever Free Play Adjustment sis 6 6 Clutch Cable Removal s ivedsdvessscauterddaceteaeetenccued a a a a a a a Aa a 6 6 Clutch Cable Lubrtcaton 6 6 Clutch Lever Removal lora ciedad 6 6 Cl GU E 6 7 Clutch Cover Removal t teg ZEN later eo tada R A tara ete ondes 6 7 Clutch Cover Installation Note sseesseeeeseneseeeseesrrrererrrrrrrrrrrrrrrrrrtrrrtrrrttrrttertrrrtrrtrrertren 6 7 Clutch Release Sha
160. eadlight vertically 2 40 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTE OON high beam the brightest points should be slightly below horizontal with the motorcycle on its wheels and the rider seated Adjust the headlight to the proper an gle according to local regulations OFor US model the proper angle is 0 4 degrees below horizontal This is 50 mm 2 in drop at 7 6 m 25 ft measured from the center of the headlight with the motorcycle on its wheels and the rider seated 50 mm 2 in A Center of Brightest Spot B 7 6 m 25 ft C Low Beam D Height of Headlight Center E High Beam F Sidestand Switch Operation Inspection e Inspect the sidestand switch A operation accordance to below table Sidestand Switch Operation y Gear Clutch Engine Engine sidestand Position Lever Start Run Up Neutral Released Starts nang running Up Neutral Pulled in Starts ES running Up In Gear Released Poean Stops start Continue Up In Gear Pulled in Starts running running Down Neutral Pulled in running Down In Gear Released start Down In Gear Pulledin Poesnt Stops a start p GS17057BS1 GS17058BS1 PERIODIC MAINTENANCE 2 41 Periodic Maintenance Procedures x If the sidestand switch operation does not work inspect or replace the following item Battery see Charging Condition Inspection in the Elec trical System chapter Main Fuse 30 A se
161. ealed battery Be careful if a sealed battery is installed on a motorcycle which had an ordinary battery as original equipment the sealed battery s life will be shortened Charging Condition Inspection OBattery charging condition can be checked by measuring battery terminal voltage with a digital voltmeter A e Remove Front Seat see Front Seat Removal in the Frame chap ter Battery Cover e Disconnect the battery terminals d CAUTION GPO80108S1 Be sure to disconnect the negative cable first e Measure the battery terminal voltage NOTE OMeasure with a digital voltmeter which can be read one decimal place voltage 16 24 ELECTRICAL SYSTEM Battery x If the reading is 12 8 V or more no refresh charge is re quired however if the read is below the specified refresh charge is required Battery Terminal Voltage Standard 12 8 V or more Refreshing Charge e Remove the battery A see Battery Removal e Do refresh charge by following method according to the battery terminal voltage A WARNING This battery is a sealed type Never remove sealing cap B even at charging Never add water Charge with current and time as stated below Terminal Voltage 11 5 less than 12 8 V Standard Charge 0 7 A x 5 10 h see following chart Quick Charge 4Ax1h CAUTION If possible do not quick charge If quick charge is done unavoidably do standard charge later on Te
162. eaner Box 2 Battery 3 Run the carburetor vent hose between the air cleaner box and battery 4 Fuel Hose 5 Run the fuel hose inside of the frame 17 30 APPENDIX Cable Wire and Hose Routing O BO 6B09711CW5 C APPENDIX 17 31 Cable Wire and Hose Routing J O O1 ND Front Master Cylinder Front Brake Hse Bracket Clamp Front Brake Caliper Rear Brake Resevvoir Rear Brake Caliper Clamp Rear Master Cylinder 17 32 APPENDIX Cable Wire and Hose Routing California Model NEA 6 T ZA Tee O g y Es ade S 1 5 ES Ce D Q C7 d di YY aA TES IN M O D A au CARTES SUR ES LAR 6B097120W5 APPENDIX 17 33 Cable Wire and Hose Routing OMNOAOARWN Install the clamps as shown noting their clip direction Vaccum Switch Valve Fitting To Air Cleaner Box To Carburetor Regulator Rectifier Bracket Canister Align the hole on the separator with the white mark on the hose Align the hole on the separator with the hose direction Run the hoses through the guide of the bracket To Air Suction Volve Cover 17 34 APPENDIX Cable Wire and Hose Routing California Model 6B097130W5 APPENDIX 17 35 Cable Wire and Hose Routing _ OO JO O1 P ND A Fuel Tank
163. eaner clogged poorly sealed or miss ing Air cleaner duct poorly sealed Water or foreign matter in fuel Fuel to carburetor insufficient Fuel tank air vent obstructed Carburetor holder loose Fuel tap clogged Fuel line clogged 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 APPENDIX 17 39 Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Knocking Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect IC igniter trouble Miscellaneous Throttle valve won t fully open Vacuum piston doesn t slide smoothly Brake dragging Clutch slipping Overheating Engine oil level too high Engine oil viscosity too high Drive train trouble Overheating Firing incorrect Spark plug dirty broken or maladjusted Spark plug incorrect IC Igniter trouble Fuel air mixture incorrect Main jet clogged or wrong size Fuel level in carburetor float bowl too low Carburetor holder loose Air cleaner poorly sealed or missing Air cleaner duct poorly sealed Air cleaner clogged Compression high Carbon built up in combustion chamber Engine load faulty Clutch slipping Engine oil level too high Engine oil viscosity too high Drive train t
164. ears worn or chipped Metal chips jammed in gear teeth Engine oil insufficient Drive line noise Drive chain adjusted improperly Drive chain worn Rear and or engine sprocket worn Chain lubrication insufficient Rear wheel misaligned Abnormal Frame Noise Front fork noise Oil insufficient or too thin Troubleshooting Guide Spring weak or broken Rear shock absorber noise Shock absorber damaged Disc brake noise Pad installed incorrectly Pad surface glazed Disc warped Caliper trouble Other noise Bracket nut bolt etc mounted or tightened not properly Oil Pressure Warning Light Goes On Engine oil pump damaged Engine oil screen clogged Engine oil level too low Engine oil viscosity too low Camshaft bearing worn Crankshaft bearings worn Oil pressure switch damaged Wiring faulty Relief valve stuck open O ring at the oil passage in the crankcase damaged Engine oil filter clogged Exhaust Smokes Excessively White smoke Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Engine oil level too high Black smoke Air cleaner clogged Main jet too large or fallen off Choke plunger stuck open Fuel level in carburetor float bowl too high Brown smoke Main jet too small Fuel level in carburetor float bowl too low Air cleaner duct loose Air cleaner poorly sealed or missing Handling and or Stability Unsatisfactory Handlebar hard to turn Cable routing incorrect Hose routing incorrect Wirin
165. eeeeeeeeeeeeeeeeeeeeseeeeeeeeeeeeeeseeeseeeseeeeseeeseeess 10 6 Rear Wheel Removal ioue anra ea raa ae A AAA 10 7 Rear Wheel Installation 10 7 Wheel Inspection iii a ee meta A 10 9 AXle Inspection EE 10 9 Balance Inspection c3d ves aneen e a ae ae ea EEA AE EARE 10 10 Balance Adjustment ss REENEN SEN ECEN EENEG EELER 10 10 Balance Weight Removal a eeh eae e elton 10 10 Balance Weight e EE Te EE 10 10 HIER 10 12 Air Pressure Inspection Adjustment nn ncccnnnnnn 10 12 Tire Inspection TS Te EE EE Tire Installation APIFOUR Dalle AR dest ah Aalst E tidad PIU IB Le DE PUB Bearing ne EE 10 16 Hub Bearing Instala EE 10 16 Hub Bearing Wa e EE 10 17 H b Bearg Upri aO ha ell Guy Guten gece Vata edith edad de ben tee ed EE 10 17 Speedometer Gear Hol Mii oi di nuntuna Kndasdeeereteenas 10 18 Speedometer Gear Housing Disassembhy 10 18 Speedometer Gear Housing Assembly 10 18 Speedometer Gear Housing Lubrcaton 10 19 10 2 WHEELS TIRES Exploded View Y A lt S ak ANN WHEELS TIRES 10 3 Exploded View LE Front AU lale 2 Rear Ave Nut 6 00 E G Apply grease R Replacement Parts 10 4 WHEELS TIRES Specifications Item Standard Service Limit Wheels Rims Rim Runout Axial TIR 0 5 mm 0 02 in or less TIR 1 0 mm 0 04 in Radial TIR 0 8 mm 0 03 in or less TIR 1 0 mm 0 04 in Axle Runout 100 mm 3 94 in
166. efer to the Air Cleaner Element Cleaning see Air Cleaner Element Cleaning Fuel Hose Replacement e Refer to Fuel Hose Inspection see Fuel Hose Inspection Coolant Change A WARNING To avoid burns do not remove the radiator cap or try to change the coolant when the engine is still hot Wait until it cools down Coolant on tires will make them slippery and can cause an accident and injury Immediately wipe up or wash away any coolant that spills on the frame engine or other painted parts Since coolant is harmful to the human body do not use for drinking e Remove Lower Fairings see Lower Fairing Removal in the Frame chapter Radiator Cap A e Place a container under the drain bolts A at the bottom of the water pump cover and cylinder e Drain the coolant from the radiator and engine by remov ing the drain bolts Torque Drain Bolt 9 8 N m 1 0 kgf m 87 in Ib PERIODIC MAINTENANCE 2 45 Periodic Maintenance Procedures e Remove Hoses A Mounting Bolts B and Reserve Tank C e Remove the cap D and pour the coolant of the reserve tank into the container e Install Hoses Reserve Tank e Tighten the drain bolt with the specified torque Torque Drain Bolt 9 8 N m 1 0 kgf m 87 in Ib e Fill the radiator up to the radiator filler neck A with coolant and install the radiator cap NOTE OPour in the coolant slowly so that it can expel the air from the engine and radiator
167. emoval e When holding the shift drum with a vise remove the shift drum pin plate bolt Shift Drum Assembly e Be sure to install the dowel pin F e The shift drum pins C are identical e Apply a non permanent locking agent to the threads of the shift drum pin plate bolt A and tighten it Torque Shift Drum Pin Plate Bolt 9 0 N m 0 9 kgf m 80 in Ib Shift Drum Pin Plate B Shift Drum Bearing Holder D er1s106BS1 Shift Drum Bearing E Shift Drum G Operating Plate Pin H Operating Plate I Circlip J 9 30 CRANKSHAFT TRANSMISSION Transmission Gear Backlash Inspection e Split the crankcase leaving the transmission in place e Set a dial gauge against the teeth on one gear and move the gear back and forth A while holding the other gear steady B The difference between the highest and the lowest gauge readings is the amount of backlash x Replace both gears if the amount of backlash exceeds the service limit Gear Backlash Standard 0 0 17 mm 0 0 0067 in Service Limit 0 25 mm 0 010 in Shift Fork Bending Inspection 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 90 A Shift Fork Gear Groove Wear Inspection e Measure the thickness of the shift fork ears A and mea sure the width B of the gear grooves x If the thickness of a shift fo
168. er e Take care not to scratch the piston or the inner wall of the cylinder e Apply silicone grease ex PBC grease Brake Lever Pivot Bolt Brake Lever Pivot Contact Push Rod Contact Rear Dust Cover e Tighten Torque Brake Lever Pivot Bolt 1 0 N m 0 10 kgf m 9 in Ib Brake Lever Pivot Bolt Locknut 5 9 N m 0 60 kgf m 52 in lb Caliper Rubber Parts Replacement Caliper Disassembly e Remove a front Caliper see Front Caliper Removal in the Brakes chapter e Remove the pads and anti rattle spring see Pad Removal in the Brakes chapter x If compressed air is available the piston may be removed using compressed air as follows e Insert the wooden board of 5 mm 0 2 in thick inside the caliper opening or cover the caliper opening with a clean heavy cloth A e Lightly apply compressed air B to the hose joint opening until the pistons hit the wooden board or heavy cloth A WARNING To avoid serious injury never place your fingers or palm in front of the piston If you apply compressed air into the caliper the piston may crush your hand or fingers e Pull out the pistons by hand e Immediately wipe up any brake fluid that spills It may ruin painted or plated surfaces e Remove the dust seals and fluid seals e Remove the bleed valve and rubber cap NOTE Olf compressed air is not available do as follows for both calipers coincidentally with the brake hose connected to the caliper OPrepare
169. er clamp shall be installed be sure to install it so that the arrow mark A on it direct upward OTighten the upper clamp bolt B first and then the lower clamp bolt C with a specified torque so that there will be a gap at the lower part of the clamp Torque Front Master Cylinder Clamp Bolts 8 8 N m 0 9 kgf m 78 in Ib Right Handlebar Holder Mounting Bolts 25 N m 2 5 kgf m 18 ft lb Left Handlebar Holder Removal e Remove Left Switch Housing A Clutch Lever Holder Clamp Bolt B Handlebar Holder Mounting Bolts C Left Handlebar D Handlebars STEERING 14 11 Left Handlebar Holder Installation Note e Install the clutch lever holder so that the punch mark A of the handlebar is aligned with the mating surface B of the clutch lever holders clamps e Tighten the following with the specified torque Torque Clutch Lever Holder Clamp Bolts 8 8 N m 0 9 kgf m 78 in lb Left Handlebar Holder Mounting Bolts 25 N m 2 5 kgf m 18 ft lb FRAME 15 1 Frame Table of Contents EXploded WA 15 2 OC EE 15 6 Front seat Removal livia cicero thier E A ee A ate eats vei ETA 15 6 Front seatenstal lation mt E EE EE 15 6 Rear Seat REMOVAL sssi52 sn n slice a EE ta cites Eeer Aere 15 6 ele El EE e EE EEN 15 6 elle E 15 7 Lower Fainn Remo atrial te lealtad 15 7 Lower Farina Instala avatar EELER 15 7 Upper Fairing Removal see 15 8 Upper Fairing Installation 15 9 Upper Cover Removal
170. ersize piston original diameter minus 0 15 mm 0 006 in If the exact figure for the re bored diameter is unknown it can be roughly determined by measuring the diameter at the base of the cylinder ONever separate the liner from the cylinder because the top surface of cylinder and liner is machined at the factory as an assembly 6E16034BS1 ENGINE TOP END 5 37 Carburetor Holder Carburetor Holder Installation e Install the carburetor holders A so that the HEAD marks B faces forward cylinder head side and CARB mark C faces backward carburetor side e Install the holder clamps as shown being careful of the screw D position and the screw head direction A WARNING Install the clamp screws horizontally Otherwise the screws could come in contact with the vacuum ad justing screws resulting in an unsafe riding condi tion ES P 5 38 ENGINE TOP END Muffler Muffler Removal e Remove Lower Fairings see Lower Fairing Removal in the Frame chapter e Remove Muffler Cover Bolts A Muffler Cover Clamp Bolt B Muffler Cover C e Loosen the muffler clamp bolt A until the clamp turns freely on the mufflers e Remove the muffler mounting bolt B and nuts at the rear footpeg bracket and take off the left and right mufflers e Remove the exhaust pipe holder nuts A and slide the holders B C off its cylinder head studs e Remove the split keepers e Pull the
171. eser voir for more complete bleeding OFront Brake First bleeding the right caliper then repeat the above steps for the left caliper e Remove the clear plastic hose e Install the diaphragm and reservoir cap e Tighten Torque Front Brake Reservoir Cap Screws 1 5 N m 0 15 kgf m 13 in lb e Follow the procedure below to install the rear brake fluid reservoir cap correctly OFirst tighten the rear brake fluid reservoir cap B clock wise C by hand until slight resistance is felt indicating that the cap is seated on the reservoir body then tighten the cap an additional 1 6 turn D while holding the brake fluid reservoir body A e Tighten the bleed valve and install the rubber cap Torque Bleed Valve 5 5 N m 0 55 kgf m 49 in Ib e Check the fluid level see Brake Fluid Level Inspection in the Periodic Maintenance chapter e After bleeding is done check the brake for good braking power no brake drag and no fluid leakage GLO9052BS2 12 20 BRAKES Brake Fluid WARNING When working with the disc brake observe the pre cautions listed below J 2 3 Never reuse old brake fluid Do not use fluid from a container that has been left unsealed or that has been open for a long time Do not mix two types and brands of fluid for use in the brake This lowers the brake fluid boiling point and could cause the brake to be ineffective It may also cause the rubber brake parts to
172. exhaust pipe toward the front and remove it e Remove the gaskets and the exhaust pipe holders from the exhaust pipe CAUTION Be careful not to touch the radiator fins during work The fins are easily deformed Muffler Installation e Smear a little grease on a new exhaust pipe gasket and stick it into the exhaust port in the cylinder head e Slip the exhaust pipe holder over the exhaust pipe e Attach the exhaust pipe loosely to the cylinder head OPosition the exhaust pipe in the exhaust port OSlide the holders into the studs holding the split keeper in place OScrew in the nuts loosely on the studs so that the holders does not fall down e Slip the muffler into place from the rear of the frame so that it fits over the exhaust pipe e Install the gasket A so that its chamfer side B faces manifold side Manifold Side C Muffler Side D e Hold the muffler up and install the mounting bolts not to tighten them securely e Tighten the exhaust pipe holder nuts evenly and securely e Tighten the muffler mounting bolts securely GE18099BS1 ENGINE TOP END 5 39 Muffler e Tighten the muffler clamp bolt A securely waving the di rection of the clamp bolts 74 84 B OBe sure that the distance between the clamp bolt end and the swingarm C is more than 15 mm D GE18097BS1 e Insert the claw A into the cover clamp B and tighten the clamp screw securely OBe sur
173. fairing B FRAME 15 9 Fairings e Remove Bolts A Headlight Unit B Upper Fairing Installation e When installing the windshield align the windshield bot tom end A with the projection B on the upper fairing Upper Cover Removal e Remove the upper fairing see Upper Fairing Removal e Disconnect Speedometer Cable Lower End A Meter Lead Connectors B e Remove the upper cover A e Remove the meter from the upper cover see Meter Re moval in the Electrical System chapter Upper Cover Installation e Route the cable and leads correctly see Cable Wire and Harness Routing in the Appendix chapter 15 10 FRAME Side Cover Side Cover Removal gt e e Remove the side cover bolt A e Pull the side cover outwards to clear the stoppers B e Slide the side cover forwards C and remove the side cover D Side Cover Installation e Slip A the hook into the brace and put B the stoppers into the grommets e Tighten the side cover bolt securely Fenders FRAME 15 11 Front Fender Removal e Remove the front fender mounting bolts A both sides and pull out the front fender B forward Rear Fender Removal e Remove Rear Seat see Rear Seat Removal Front Seat see Front Seat Removal e Remove the seat cover screws A and pull the seat cov ers B to clear the stoppers C e Remove the projection A from the hole B and slide C the cover D frontwards
174. fective Re place the lead or the wiring harness B if necessary GPO6003BS1 16 20 ELECTRICAL SYSTEM Battery Battery Removal e Pull the diodes A and headlight circuit relay B out of the cover e Unscrew the screw C and remove the cover D clearing the projections E e Disconnect the negative cable A and then the positive cable B CAUTION Be sure to the disconnect the negative cable first e Remove the battery e To remove the battery case B remove the screws A Battery Installation e Be sure the battery damper A is in position e Connect the positive cable first then the negative cable to the battery Battery Activation Electrolyte Filling e Make sure that the model name A of the electrolyte con tainer matches the model name B of the battery These names must be the same Battery Model Name for EX250J8F YTX7A BS CAUTION Be sure to use the electrolyte container with the same model name as the battery since the elec trolyte volume and specific gravity vary with the battery type This is to prevent overfilling of the electrolyte shorting the battery life and deteriora tion of the battery performance GP10517BS1 GP08020481 Battery ELECTRICAL SYSTEM 16 21 CAUTION Do not remove the aluminum sealing sheet A from the filler ports B until just prior to use Be sure to use the dedi
175. fer to the selection section in the specifications Olf the crankshaft is replaced with a new one refer to the Connecting Rod Big End Bearing Crankshaft Main Bearing Insert Selection in the Selection Section CAUTION If the crankshaft bearing inserts or crankcase halves are replaced with new ones select the bear ing inserts and check clearance with a plastigage press gauge before assembling engine to be sure the correct bearing inserts are installed Part Number 13031 0111 13031 0111 13031 0112 13031 0112 13031 0113 13031 0113 13031 0114 CRANKSHAFT TRANSMISSION 9 15 Crankshaft and Connecting Rods e Align the timing mark C on the balancer drive gear A with the timing mark C on the balancer gear B e Apply molybdenum disulfide oil solution to the crankshaft main bearing inserts e Install the crankshaft Connecting Rod Removal e Split the crankcase see Crankcase Splitting e Remove the connecting rod big end cap nuts e Remove the crankshaft NOTE OMark and record the locations of the connecting rods and their big end caps so that they can be reassembled in their original positions e Remove the connecting rods from the crankshaft CAUTION Discard the connecting rod bolts To prevent dam age to the crankpin surfaces do not allow the con necting rod bolts to bump against the crankpins Connecting Rod Installation CAUTION To minimize vibration the connecting rods sho
176. ft Assembly 9 27 Clearance Inspection 9 17 Shift Drum and Fork Removal 9 28 Connecting Rod Big End Shift Drum and Fork Installation 9 28 Bearing Insert Crankpin Wear Shift Drum Disassembly 9 29 q EE 9 17 Shift Drum Assembly oc 9 29 Crankshaft Side Clearance Gear Backlash Inspection 9 30 Inspection 9 18 Shift Fork Bending Inspection 9 30 Crankshaft Runout Inspection 9 19 Shift Fork Gear Groove Wear Crankshaft Main Bearing nS pectoris rat s 9 30 Insert Journal Wear Inspection 9 19 Shift Fork Guide Pin Drum Starter Motor Clutch 9 21 Groove Wear Inspection 9 30 Starter Motor Clutch Gear Dog and Gear Dog Hole Removal Installation 9 21 Damage Inspection 9 31 Starter Motor Clutch Inspection 9 21 Ball and Needle Bearing Wear Starter Motor Clutch Disassembly 9 21 IS POON nn 9 31 9 2 CRANKSHAFT TRANSMISSION Exploded View ot z AL ON ow E y AA Ex 2 o E y NS se AX gd SR f LE Eee CRANKSHAFT TRANSMISSION 9 3 Exploded View No Fastener ft lb Remarks 2 Crankcase Bolts Ap 1 2 104 mb 3 Crankcase Bolts 8 L 90 24 2 4 18 MO S 4 Crankcase Bolts 48 L 73 19 1 9 14 MO S 5 Starter Motor Clutch Bolts 34 3 3 5 25 L 6 Connecting Rod Big End C
177. ft Removal ss 6 7 Clutch Release Shaft Installation n nnsneennneenneeneeenerereeerrrrrrrrrrrrrterterrttrrtrrrtrrrrerrreertrent 6 7 GUC DEER 6 8 Clutch RREMOVAl EE 6 8 Clutch Installationer cc ata ee 6 8 Clutch Plate Wear and Damage Inspection o ooooooococcccc ccnoncnnoconnccncncnnnnnnannnonnnnnnnnnannnnnnnnno 6 10 Clutch Plate Warp Inspechon ss 6 10 Clutch Spring Free Length Inspection EE 6 10 Clutch Housing Finger Damage Inspection ccc ecceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeenaaeees 6 11 Clutch Hub Spline Damage Inspection cocccccncccnnncnnncnnnnnnnnnnnnnnnonnnnnnnnnnnnnnnnnnnnnnnnnnnnnss 6 11 6 2 CLUTCH Exploded View 6F021308W5 C CLUTCH 6 3 Exploded View No Fastener e Remarks 2 Clutch Spring Bolts 8 8 0 9 78 in lb 3 Clutch Hub Nut 132 13 5 97 4 4 Oil Filler Plug Hand Tighten 5 Clutch Cover Bolts 9 8 1 0 87 in lb 6 Starter Lockout Switch 7 Clutch Lever Pivot Nut CL Apply cable lubricant EO Apply engine oil G Apply grease M Apply molybdenum disulfide grease R Replacement Parts Si Apply silicone grease W Apply water 6 4 CLUTCH Specifications Item Standard Service Limit Clutch Clutch Lever Play Clutch Spring Free Play Friction Plate Thickness Friction and Steel Plate Warp Crankshaft Primary Gear Marking C Va 1D A White White Red Red None None Yellow 2 3 mm 0 08 0 12 in
178. g Sleeve Inspection in the Suspen sion chapter 2 36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Swingarm Pivot Lubrication e Remove the swingarm bearing see Swingarm Bearing Removal in the Suspension chapter e Supply grease to the needle bearings and grease seals in accordance with the Periodic Maintenance chart Steering System Steering Play Inspection e Raise the front wheel off the ground with jack see Front Wheel Removal in the Wheels Tires chapter e With the front wheel pointing straight ahead alternately tap each end of the handlebar The front wheel should swing fully left and right from the force of gravity until the fork hits the stop x If the wheel binds or catches before the stop the steering is too tight e Feel for steering looseness by pushing and pulling the forks x If you feel looseness the steering is too loose NOTE OThe cables and wiring will have some effect on the mo tion of the fork which must be taken into account OBe sure the wires and cables are properly routed OThe bearings must be in good condition and properly lubricated in order for any test to be valid Steering Play Adjustment e Loosen Front Fork Clamp Bolts lower both sides Stem Head Bolt A e Adjust the steering x If the steering is too loose tighten the steering stem nut a fraction of a turn using the special tool B x If the steering is too tight loosen the stem nut a fraction of a turn
179. g routing incorrect Steering stem locknut too tight Steering stem bearing damaged Steering stem bearing lubrication inade quate Steering stem bent Tire air pressure too low APPENDIX 17 41 Handlebar shakes or excessively vibrates Tire worn Swingarm pivot bearings worn Rim warped or not balanced Wheel bearing worn Handlebar clamp bolts loose Steering stem head nut loose Front rear axle runout too large Handlebar pulls to one side Frame bent Wheel misalignment Swingarm bent or twisted Steering maladjusted Front fork bent Right and left front fork oil level uneven Shock absorption unsatisfactory Too hard Front fork oil excessive Front fork oil viscosity too high Rear shock absorber adjustment too hard Tire air pressure too high Front fork bent Too soft Front fork oil insufficient and or leaking Front fork oil viscosity too low Front fork rear shock absorber spring weak Rear shock absorber oil leaking Rear shock absorber adjustment too soft Tire air pressure too low Brake Doesn t Hold Air in the brake line Pad or disc worn Brake fluid leakage Disc warped Contaminated pad Brake fluid deteriorated Primary or secondary cup damaged Master cylinder scratched inside Battery Trouble Battery discharged Battery faulty e g plates sulphated shorted through sedimentation elec trolyte insufficient Battery cables making poor contact Load excessive e g bulb of excessive wattage Ig
180. guide in until the washer surface C touches the head surface D 15 3 15 5 mm E Special Tools Valve Guide Driver 64 5 57001 1564 Washer 57001 1720 e Wait until the cylinder head cools down and then ream the valve guide with the valve guide reamer A even if the old guide is reused OTurn the reamer in a clockwise direction until the reamer turns freely in the guide Never turn the reamer counter clockwise or it will be dulled OOnce the guides are reamed they must be cleaned thor oughly Special Tool Valve Guide Reamer 4 5 57001 1333 Valve to Guide Clearance Measurement Wobble Method 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 the stem back and forth C 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 measuring point is above the guide Valve Valve Guide Clearance Wobble Method Standard Inlet 0 03 0 09 mm 0 0012 0 0035 in Exhaust 0 08 0 15 mm 0 0031 0 0059 in Service Limit Inlet 0 27 mm 0 011 in Exhaus
181. 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 Battery Ground Before completing any service on the motorcycle discon Je nect the battery cables from the battery to prevent the en Y_ KA gine from accidentally turning over Disconnect the ground Ba Re _ AD cable first and then the positive When completed Wa f c Se e with the service first connect the positive cable to the e d P E positive terminal of the battery then the negative ca AA ble to the negative terminal DISASSEMBLY ASSEMBLY 6020248 S Edges of Parts Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts 6020048 Solvent Use a high flush point solvent when cleaning parts High flush point solvent should be used according to directions of the solvent manufacturer 68020058 Cleaning vehicle before disassembly Clean the vehicle thoroughly before disassembly Dirt or H other foreign materials entering into sealed areas during ve hicle disassembly can cause excessive wear and decrease performance of the vehicle GENERAL INFORMATION 1 3 Before Servicing Arrangement and Cleaning of Removed Parts Disassembled parts are easy to confuse Arrange the parts according to t
182. have worn past the service limit replace them with new ones Friction Plate Thickness Standard 2 92 3 08 mm 0 115 0 121 in Service Limit 2 6 mm 0 10 in Clutch Plate Warp Inspection e Place each friction plate or steel plate on a surface plate and measure the gap between the surface plate A and each friction plate or steel plate B with a thickness gauge C The gap is the amount of friction or steel plate warp x If any plate is warped over the service limit replace it with a new one Friction and Steel Plate Warp Service Limit 0 3 mm 0 012 in Clutch Spring Free Length Inspection e Measure the free length of the clutch springs A If any spring is shorter than the service limit it must be replaced Clutch Spring Free Length Standard 38 5 mm 1 52 in Service Limit 36 8 mm 1 45 in GFO606028S1 GFO60603S1 Clutch CLUTCH 6 11 Clutch Housing Finger Damage Inspection e Visually inspect the clutch housing fingers A that come in contact with the friction plate tangs x If they are damaged or if there are groove cuts in the areas that come in contact with the tangs replace the housing Replace the friction plates if their tangs are damaged as well Clutch Hub Spline Damage Inspection e Visually inspect the areas of the clutch hub splines that come in contact with the teeth of the steel plates x If there are notches worn into the clutch hub splines
183. he electrolyte container until it is com pletely empty and 20 minutes have elapsed 6P08003BS1 6P090006S1 E IQ D IT 6P090007S1 6P090008S1 16 22 ELECTRICAL SYSTEM Battery e Gently remove the container from the battery e Let the battery sit for 30 minutes prior to charging to allow the electrolyte to permeate into the plates for optimum performance NOTE OCharging the battery immediately after filling can Shorten service life Let the battery sit for at least 60 minutes after filling Initial Charge e Place the strip A of caps loosely over the filler ports e Newly activated sealed batteries require an initial charge Standard Charge 0 7 A x 5 10 hours x lf using a recommended battery charger follow the charger s instructions for newly activated sealed battery Kawasaki recommended chargers Optimate III GPOSO19BS1 Yuasa 1 5 Amp Automatic Charger Battery Mate 150 9 If the above chargers are not available use equivalent one NOTE OCharging rates will vary depending on how long the battery has been stored temperature and the type of charger used Let battery sit 30 minutes after initial charge then check voltage using a voltmeter If it is not at least 12 8 volts repeat charging cycle e After charging is completed press down firmly with both hands to seat the strip of caps A into the battery don t
184. he order the parts were disassembled and clean the parts in order prior to assembly Storage of Removed Parts After all the parts including subassembly parts have been cleaned store the parts in a clean area Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re assembly 68020088 S Inspection Reuse of worn or damaged parts may lead to serious ac cident Visually inspect removed parts for corrosion discol DN 8 oration or other damage Refer to the appropriate sections N of this manual for service limits on individual parts Replace Ki the parts if any damage has been found or if the part is be ZE yond its service limit a 02008 Replacement Parts Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI Gaskets O rings oil seals grease seals circlips or cotter pins must be replaced with new ones whenever disassembled 65020108 Assembly Order In most cases assembly order is the reverse of disassem e E bly however if assembly order is provided in this Service Ce See Manual follow the procedures given Y Pa 6 D gt i ee Ga WS 68020118 S 1 4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally when installing a part with several bolts nuts or screws start them all in their holes and tighten them to a snug fit Then tighten them according to the specified se quence to prevent case war
185. htly Forcing or tapping on a bolt could damage the bolt and sleeve Rocker Arm Installation e Apply grease to all the O ring bushing sleeve grease seal e Tighten Torque Rocker Arm Pivot Nut 59 N m 6 0 kgf m 44 ft lb Tie rod Nut 59 N m 6 0 kgf m 44 ft lb Rear Shock Absorber Mounting Nut 59 N m 6 0 kgf m 44 ft lb Tie rod Rocker Arm Bushing Inspection e The busings wear so little that the wear is difficult to mea sure Instead inspect the bushings for abrasion color change or other damage x If there is any doubt as to the condition of either bushings replace the busing with new one Tie rod Rocker Arm Sleeve Inspection x lf there is visible damage replace the sleeve with new one STEERING 14 1 Steering Table of Contents Elei e WEE 14 2 Special Tools sri me e e a e a ae a e a E A e aa 14 4 ln Le DEE 14 5 Steering INSPECUOM EE 14 5 te Ne E nn 14 5 Steering EE 14 6 Steering Stem Stem Bearing Removal ss 14 6 Steering Stem Stem Bearing Installation 14 7 Stemi Bearing LUDMGAUOM EE 14 9 Grease Seal Deterioration Damage Inspection occccccccnnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnos 14 9 Steering Stem Warp Inspection ss 14 9 ee WEE 14 10 Right Handlebar Holder Removal ss 14 10 Right Handlebar Holder Installation vs 14 10 Left Handlebar Holder Removal s issus 14 10 Left Handlebar Holder Installation Note 14 11
186. ib 98 10 87imb TT _ HandTighten 98 10 87m 98 10 87imb 15 Radiator Fan 16 Reserve Tank 17 Thermostat 18 Radiator 19 Water Pump G Apply grease R Replacement Part SS Apply silicone sealant to the threads 4 4 COOLING SYSTEM Specifications Item Standard Coolant Type Permanent type of antifreeze soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators Mixed Ratio Soft water 50 coolant 50 Freezing Point 35 C 31 F Total Capacity 1 5 L 1 59 US qt Radiator Radiator Cap Relief Pressure 93 123 kPa 0 95 1 25 kgf cm 14 18 psi Thermostat Valve Opening Temperature 63 5 66 5 C 146 152 F Valve Full Opening Lift More than 6 mm 0 24 in 80 C 176 F COOLING SYSTEM 4 5 Sealant Kawasaki Bond Silicone Sealant 56019 120 ST560120ST 4 6 COOLING SYSTEM Coolant Flow Chart Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion When the engine starts the water pump turns and the coolant circulates The thermostat is a wax pellet type which opens or closes with coolant temperature changes The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level When coolant temperature is below 63 5 66 5 C 146 152 F the thermostat closes so that the coolant flow is restricted through the air bleeder hole cau
187. ibly causing an accident CAUTION If dirt gets through into the engine excessive en gine wear and possibly engine damage will occur PERIODIC MAINTENANCE 2 15 Periodic Maintenance Procedures A WARNING Clean the element in a well ventilated area and make sure that there are no sparks or flame any where near the working area Because of the danger of highly flammable liquids do not use gasoline or a low flash point solvent to clean the element e Clean the element A in a bath of high flash point solvent and then dry it with compressed air or by shaking it e After cleaning saturate a clean lint free towel with SE SF or SG class SAE 30 oil and apply the oil to the element by tapping the element outside with the towel e Visually check the element for tears or breaks elt the element has any tears or breaks replace the ele ment Air Cleaner Element Installation e Install the removed parts in reverse of removal e Torque the air cleaner cap bolts Torque Air Cleaner Cap Bolts 2 5 N m 0 25 kgf m 22 in Ib Throttle Control System Inspection e Check that the throttle grip moves smoothly from full open to close A and the throttle closes quickly and completely by the return spring in all steering positions x If the throttle grip doesn t return properly check the throt tle cable routing grip free play and cable damage Then lubricate the throttle cable e Check the throt
188. icle 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 Mo torcycle parts Special tools gauges and testers that are necessary when servicing Kawasaki motorcycles are introduced by the Service Manual 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 Table 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 follow safe operating and maintenance practices 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 iden
189. ier may be damaged Do not apply 24 V more than a few seconds If 24 V is applied for more than a few seconds the regula tor rectifier may be damaged x lf the test light did not light when the 24 V was applied momentarily to the voltage monitoring terminal the regu lator rectifier is defective Replace it x lf 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 Torque Regulator Rectifier Bolts 9 8 N m 1 0 kgf m 87 in 1b Charging Voltage Inspection e Check the battery condition see Charging Condition In spect e Warm up the engine to obtain actual alternator operating conditions e Remove the front seat see Front Seat Removal in the Frame chapter e Check that the ignition switch is turned off and connect the hand tester A as shown in the table Special Tool Hand Tester 57001 1394 e Start the engine and note the voltage readings at vari ous engine speeds with the headlight turned on and then turned off To turn off the headlight disconnect the head light connector in the upper fairing The readings should show nearly battery voltage when the engine speed is low and as the engine speed rises the readings should also rise But they must be kept under the specified voltage Charging V
190. ill the radiator with coolant Thermostat Housing Removal e Drain the Coolant see Coolant Change in the Periodic Maintenance chapter e Remove Front Seat see Front Seat Removal in the Frame chap ter Fuel Tank see Fuel Tank Removal in the Fuel System chapter e Disconnect the water temperature switch lead connector A e Loosen the water hose clamps B and slide the hoses C D back and forth from the thermostat housing E and cover F Water Temperature Switch G e Remove the thermostat housing mounting bolts H and pull the housing out of the frame e Remove the thermostat cover and pull out the thermostat if necessary Thermostat Housing Installation Note e Be sure to install the ground lead on the thermostat hous ing mounting bolt 4 16 COOLING SYSTEM Thermostat Thermostat Inspection e Remove the thermostat and visually inspect the thermo stat valve A at room temperature x If the valve is open replace the thermostat with a new one e To check valve opening temperature suspend the ther mostat A in a container of water and raise the tempera ture of the water OThe thermostat must be completely submerged and must not touch the container sides or bottom Suspend an ac curate thermometer B in the water so that the heat sen sitive portions C are located in almost the same depth It must not touch the container either x If the measurement is out of the specified range replace
191. in B as shown e Screw the pin holder until it touches the link pin e Be sure that the cutting pin hits center of the link pin e Screw the handlebar A into the body e Turn the pin holder with the wrench B clockwise to ex tract the link pin GKO4016BS1 GKO4018BS1 GKO4019BS1 Drive Chain FINAL DRIVE 11 9 e Replace the link pin link plate and grease seals e Apply grease to the link pins A and grease the seals B C e Engage the drive chain on the engine and rear sprockets e Insert the link pins in the drive chain ends e Install the grease seals C e Install the link plate D so that the mark faces out e Push the link plate by hand or plier to fix it e Be sure to set the grease seals correctly e Set the plate holder A A and plate holder B B on the body e Fit the plate holder A to the link plate e Turn the pin holder by hand until the plate holder B touches the other link plate e Turn the pin holder by a wrench clockwise until two pins of link come into groove of the plate holder A e Take off the plate holder e Set the plate holder B A and the cutting and rivetting pin B as shown GKO4020BS1 GKO4021BS1 6K04023BS1 6K04024BS1 11 10 FINAL DRIVE Drive Chain e Turn the pin holder until the rivetting pin touches the link pin e Turn the wrench clockwise until the tip of rivetti
192. ine Oil Change in the Periodic Main tenance chapter Coolant see Coolant Change in the Periodic Mainte nance chapter e Remove Left Lower Fairing see Lower Fairing Removal in the Frame chapter Shift Lever Link Engine Sprocket Cover Coolant Pipes A B e Remove Alternator Cover Bolts C Alternator Cover D Alternator Cover Installation e Apply silicone sealant to the alternator lead grommet and crankcase halves mating surface A on the front and rear side of the cover mount Sealant Kawasaki Bond Silicone Sealant 56019 120 e Check that the knock pins B are in place on the crankcase e Install a new gasket and the alternator cover Torque Water Hose Clamp Screws 1 5 N m 0 15 kgf m 13 in lb Stater Coil Removal e Remove Alternator Cover see Alternator Cover Removal Crankshaft Sensor Screws A and Clamps Alternator Lead Grommet B Stator Coil Bolts C e Remove the stator coil D from the alternator cover 16 26 ELECTRICAL SYSTEM Charging System Stator Coil Installation e Install the alternator leads A and crankshaft sensor leads B into the alternator cover as figure Stator Coil C Crankshaft Sensor Coil D Rubber Damper E Clamp F Grommet G Silicone Sealant Applied Areas H OFit the alternator leads and crankshaft sensor leads into the grommet OApply silicone sealant to the grommet and fit it into the notch in the alternator cover Special Tool Kawasaki Bo
193. ine clearance Connecting Rod Big End Side Clearance Standard 0 13 0 38 mm 0 005 0 015 in Service Limit 0 5 mm 0 020 in x If the clearance exceeds the service limit replace the con necting rod with new one and then check the clearance again If the clearance is too large after connecting rod replacement the crankshaft also must be replaced Connecting Rod Big End Bearing Insert Crankpin Wear Inspection e Measure the bearing insert crankpin clearance B with plastigage A e Tighten the big end nuts to the specified torque see Con necting Rod Installation NOTE ODo not move the connecting rod and crankshaft during clearance measurement aw 0105189881 Connecting Rod Big End Bearing Insert Crankpin Clearance Standard 0 031 0 059 mm 0 0012 0 0023 in Service Limit 0 10 mm 0 004 in x If the clearance is within the standard no bearing replace ment is required x lf the clearance is between 0 059 mm 0 0023 in and the service limit 0 10 mm 0 004 in replace the bear ing inserts A with inserts painted black B Check the insert crankpin clearance with the plastigage The clear ance may exceed the standard slightly but it must not be less than the minimum in order to avoid bearing seizure x lf the clearance exceeds the service limit measure the diameter of the crankpins 6105041781 Crankpin Diameter Standard 29 984 30 000 mm 1 1805 1 1811 in Se
194. ing kink ing flatting or twisting and route the hoses according to Cable Wire and Hose Routing section in the Appendix chapter e Fill the brake line after installing the brake hose see Brake Fluid Change Brake Fluid Change NOTE OThe procedure to change the front brake fluid is as fol lows Changing the rear brake fluid is the same as for the front brake OO ee pb gt 6 woe 6605018BS1 PERIODIC MAINTENANCE 2 49 Periodic Maintenance Procedures e Level the brake fluid reservoir e Remove the reservoir cap and diaphragm e Remove the rubber cap from the bleed valve A on the caliper e Attach a clear plastic hose B to the bleed valve and run the other end of the hose into a container e Fill the reservoir with fresh specified brake fluid e Change the brake fluid ORepeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes 1 Open the bleed valve A 2 Apply the brake and hold it B 3 Close the bleed valve C 4 Release the brake D NOTE OThe fluid level must be checked often during the chang ing operation and replenished with fresh brake fluid If the fluid in the reservoir runs out any time during the changing operation the brakes will need to be bled since air will have entered the brake line OFront Brake Repeat the above steps for the other caliper e Remove the clear plastic h
195. ing is not necessary but place the oil pan un der the oil filter because oil drain a little at the oil filter removal e Drive the retaining pin A out of the filter mounting bolt B e Drop out the spring C and the bypass valve steel ball D Bypass Valve Assembly e Drop the bypass valve steel ball into the filter mounting bolt e Put the spring into the mounting bolt and compress it be yond the small hole e Drive the retaining pin into the small hole to hold the spring e Install the oil filter see Oil Filter Replacement in the Pe riodic Maintenance chapter Bypass Valve Cleaning and Inspection e Remove the oil filter see Oil Filter Replacement in the Periodic Maintenance chapter e Disassemble the bypass valve see Bypass Valve Disas sembly e Clean the bypass valve parts in a high flash point solvent A 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 danger of highly flammable liquids do not use gasoline or low flash point solvent e Visually inspect the bypass valve parts x If there is any damaged part replace it OO lt noe 6605019BS1 ENGINE LUBRICATION SYSTEM 7 9 Engine Oil and Oil Filter Oil Screen Cleaning and Inspection e Remove the oil screen cover A e Clean the oil pump screen B with high flash point solvent and remove any particles stuck to it A WARN
196. ing screws D CAUTION Do not remove a meter pointer unless the meter is to be replace The pointers cannot be reinstalled The pointer mounting is different from replacement meters aia P Meter Unit Installation e Check to see that the rubber damper A are installed on the meter mounting bracket B e The installation is a reverse of the meter unit removal ELECTRICAL SYSTEM 16 57 Meters Gauge and Indicator Unit Indicator Light Replacement e Remove the meter unit see Meter Unit Removal e To remove the wedge base type bulbs pull out the bulb sockets A and pull the bulbs B off the sockets CAUTION Do not use bulbs rated for greater wattage than the specified wattage as the meter or gauge panel could become warped by excessive heat radiated from the bulbs ma P Tachometer Inspection e Check the tachometer circuit wiring lf all wiring and components other than the tachometer unit check out good the unit is suspect Check the unit as shown e Remove the following Upper Fairing see Upper Fairing Removal in the Frame chapter e Disconnect the BK lead e Reinstall the BK terminal screw e Turn the engine stop switch to RUN position e Turn the ignition switch ON e Open or connect the BK lead A to the BK terminal screw B Then the pointer should flick e Turn the ignition switch OFF x If the pointer does not flick replace the tachometer unit Tachometer
197. inlet system by cutting drilling or other means if such modifications result in increased noise levels 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 period 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 veh
198. instructions are not available use the following procedure GE15011782 C GE150709S1 5 28 ENGINE TOP END Valves Seat Cutter Operation Cares 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 NOTE ODo not use a wire brush to remove the metal particles 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 of the cutter A represent the following O nanas Cutter angle B ST O EE Outer diameter of cutter C Operating Procedures e Clean the seat area carefully e Coat the seat 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 t
199. is is not done Brake Pad Wear Inspection e Refer to Brake Pad Wear Inspection in the Periodic Main tenance chapter see Brake Pad Wear Inspection in the Periodic Maintenance chapter Master Cylinder BRAKES 12 13 Front Master Cylinder Removal e Slide the dust cover A and remove the banjo bolt B to disconnect the upper brake hose from the master cylinder C There are flat washers on each side of the hose fitting e Remove the front master cylinder clamp bolts D and take off the master cylinder CAUTION Immediately wash away any brake fluid that spills Front Master Cylinder Installation e Install the front master cylinder so that the punch mark A of the handlebar is aligned with the mating surface B of the master cylinder clamp to level the reservoir e Install the master cylinder clamp A pointing with the ar row mark B upward e Tighten the upper clamp bolt C first and then the lower clamp bolt D with a specified torque There will be a gap E at the lower part of the clamp after tightening e Tighten the banjo bolt with a specified torque after in stalling a new flat washer on each side of the brake hose fitting Torque Front Master Cylinder Clamp Bolts 8 8 N m 0 9 kgf m 78 in lb Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft Ib e Bleed the brake line see Brakes Line Bleeding e Check the brake for good braking power no brake drag and no brake fluid leakage WARNING
200. ition switch ORemove the right side cover see Side Cover Removal in the Frame chapter GPO9228BS1 16 28 ELECTRICAL SYSTEM Charging System ODisconnect the alternator lead connector A OConnect the hand tester B as shown in the table 1 OStart the engine and run it 4 000 rpm 5 minutes ORun it at the rpm given in the table 1 ONote the voltage readings total 3 measurements Table 1 Alternator Output Voltage Tester Connections Reading Range Tester to Tester to 4 000 rpm 250 V AC One Yellow lead Another Yellow lead about 40 V x lf the output voltage shows the value in the table the al ternator operates properly x If the output voltage shows a much higher than the value in the table the regulator rectifier is damaged A much lower reading than that given in the table indicates that the alternator is defective e Check the stator coil resistance as follows OStop the engine OConnect the hand tester as shown in the table 2 ONote the readings total 3 measurement Table 2 Stator Coil Resistance Tester Connections Reading Range Tester to Tester to One Yellow lead Another Yellow lead 0 05 0 6 Q x If there is more resistance than shown in the table or no hand tester reading infinity for any two leads the stator has an open lead and must be replaced Much less than this resistance means the stator is shorted and must be replaced
201. itting has been loosened for any reason NOTE OThe procedure to bleed the front brake line is as follows Bleeding the rear brake line is the same as for the front brake e Remove the reservoir cap A and diaphragm e Fill the reservoir with fresh brake fluid to the upper level line in the reservoir e Slowly pump the brake lever several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reservoir OBleed the air completely from the master cylinder by this operation e Remove the rubber cap from the bleed valve A on the caliper e Attach a clear plastic hose B to the bleed valve and run the other end of the hose into a container GLO9021BS1 Brake Fluid BRAKES 12 19 e Bleed the brake line and the caliper ORepeat this operation until no more air can be seen com ing out into the plastic hose 1 Pump the brake lever until it becomes hard and apply the brake and hold it A 2 Quickly open and close B the bleed valve while hold ing the brake applied 3 Release the brake C NOTE OThe fluid level must be checked often during the bleed ing operation and replenished with fresh brake fluid as necessary If the fluid in the reservoir runs completely out any time during bleeding the bleeding operation must be done over again from the beginning since air will have entered the line OTap the brake hose lightly from the caliper to the r
202. justed cable could result in an unsafe riding con dition Choke Cable Lubrication and Inspection e Whenever the cable is removed or in accordance with the Periodic Maintenance Chart lubricate the choke cable see General Lubrication in the Appendix chapter OApply a thin coating of grease to the cable lower end OUse a commercially available pressure cable lubricator to lubricate the cable OWith the cable disconnected at both ends the cable should move freely in the cable housing 6004011481 3 12 FUEL SYSTEM Carburetors Idle Speed Inspection e Refer to Idle Speed Inspection in the Periodic Mainte nance chapter see Idle Speed Inspection in the Periodic Maintenance chapter Idle Speed Adjustment e Refer to Idle Speed Adjustment in the Periodic Mainte nance chapter see Idle Speed Adjustment in the Periodic Maintenance chapter Engine Vacuum Synchronization Inspection e Refer to Engine Vacuum Synchronization Inspection in the Periodic Maintenance chapter see Engine Vacuum Synchronization Inspection in the Periodic Maintenance chapter Engine Vacuum Synchronization Adjustment e Refer to Engine Vacuum Synchronization Inspection in the Periodic Maintenance chapter see Engine Vacuum Synchronization Inspection in the Periodic Maintenance chapter Pilot Screw Adjustment x If the engine idle is still not stable adjust the pilot screw to obtain the proper idle speed using the pilot screw adjuster
203. lace the follow ing item Engine Stop Switch see Switch Inspection in the Elec trical System chapter x If the engine stop switch is good condition replace the IC Igniter 2 42 PERIODIC MAINTENANCE Periodic Maintenance Procedures Others Chassis Parts 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 points listed below with indicated lubricant NOTE OWhenever the vehicle has been operated under wet or rainy conditions or especially after using a high pressure water spray perform the general lubri cation Pivots Lubricate with Grease Brake Lever Brake Pedal Clutch Lever Rear Brake Joint Pin Sidestand Points Lubricate with Grease Clutch Inner Cable Upper and Lower Ends A Throttle Inner Cable Upper and Lower Ends Cables Lubricate with Rust Inhibitor Clutch Cable Throttle Cables e Lubricate the cables by seeping the oil between the cable and housing OThe cable may be lubricated by using a commercially available pressure cable lubricator with an aerosol cable lubricant e With the cable disconnected at both ends the inner cable should move freely A within the cable housing If cable movement is not free after lubricating if the cable is frayed B or if the cable housing is kinked C replace the cable 6004040351 6004011481 6004020281 PERIODIC MAINTENANCE 2 43
204. ld detach the rod and the tensioner cannot be reinstalled While holding the rod in position with a suitable push rod holder plate A install the tensioner on the cylinder block GE10014BS1 5 16 ENGINE TOP END Camshaft Chain Tensioner e Replace the chain tensioner gasket with a new one e Tighten Torque Chain Tensioner Mounting Bolts A 9 8 N m 1 0 kgf m 87 in Ib e Take out the holder plate B e Install the O ring and tighten the cap bolt Torque Chain Tensioner Cap Bolt 5 0 N m 0 5 kgf m 44 in 1b Camshaft Camshaft Chain ENGINE TOP END 5 17 Camshaft Removal e Remove the cylinder head cover see Cylinder Head Cover Removal e Remove the inspection plugs on the alternator cover e Position the crankshaft at 2 piston TDC OUsing a wrench on the crankshaft rotation bolts turn the crankshaft clockwise until the 2T mark A on the alterna tor rotor is aligned with the projection B in the inspection window on the alternator cover e Remove Camshaft Chain Tensioner see Camshaft Chain Ten sioner Removal Camshaft Cap Bolts A Plates Camshaft Top Chain Guide B Camshaft Caps C Camshafts D e Stuff a clean cloth into the camshaft chain tunnel to keep any parts from dropping into the crankcase CAUTION The crankshaft may be turned while the camshafts are removed Always pull the chain taut while turning the crank shaft This avoids kinking the chain
205. le bearings A according to the Periodic Maintenance Chart They are normal for a small amount of grease to seep out around the grease seals Olf the swingarm pivots is disassembled wipe all the old grease off the bearings sleeves and grease seals then grease them Chain Guide Inspection e Refer to the Chain Guide Wear Inspection in the Periodic Maintenance chapter see Chain Guide Wear Inspection in the Periodic Maintenance chapter SUSPENSION 13 17 Tie Rod Rocker Arm Tie rods Removal e Remove the lower fairings see Lower Fairing Removal in the Frame chapter e Raise the rear wheel off the ground with jack Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Remove the tie rod lower bolt A and nut e Remove the tie rod upper bolt B and nut and take off the tie rod C e Remove the other tie rod Tie Rod Installation e Install the tie rod upper bolt first and then the lower bolt Torque Tie rod Nuts 59 N m 6 0 kgf m 44 ft Ib Rocker Arm Removal e Remove the lower fairings see Lower Fairing Removal in the Frame chapter e Raise the rear wheel off the ground with jack Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Remove Rear Shock Absorber Lower Nut and Bolt A Tie rod Lower Nut and Bolt B Rocker Arm Pivot Shaft C Rocker Arm D OSupport the rear wheel to remove the bolts CAUTION When pulling out the bolts lift the rear wheel slig
206. leeding e Follow the procedure below to install the rear brake fluid reservoir cap correctly OFirst tighten the rear brake fluid reservoir cap B clock wise C by hand until the resistance is felt fully then tighten the cap an additional 1 6 turn D while holding the brake fluid reservoir A body Front Master Cylinder Disassembly e Refer to Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter see Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter Rear Master Cylinder Disassembly e Refer to Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter see Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter Master Cylinder Assembly e Refer to Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter see Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter 12 16 BRAKES Master Cylinder Master Cylinder Inspection e Remove the master cylinders see Front Rear Master O Cylinder Removal e Disassemble the front and rear master cylinders e Check that there are no scratches rust or pitting on the inner wall A of each master cylinder and on the outside SE of each piston B she If a master cylinder or piston shows any damage replace them e Inspect the primary cup C and secondary cup D e If a cup is worn damaged softened rotted
207. ll the accelerator cable first and then decelerator ca ble e After installation adjust each cable properly see Throttle Cable Inspection in the Periodic Maintenance chapter A WARNING Operation with incorrectly routed or improperly ad justed cables could result in an unsafe riding con dition Throttle Cable Lubrication e Refer to Chassis Parts Lubrication Perform in the Peri odic Maintenance chapter see Chassis Parts Lubrication Perform in the Periodic Maintenance chapter FUEL SYSTEM 3 11 Choke Cable Free Play Inspection e Refer to Choke Operation Inspection in the Periodic Main tenance chapter see Choke Operation in the Periodic Maintenance chapter Free Play Adjustment e Refer to Choke Operation Inspection in the Periodic Main tenance chapter see Choke Operation in the Periodic Maintenance chapter Choke Cable Removal e Split the left handlebar switch housing A and remove the choke cable B upper end from the choke lever C e Remove Front Seat see Front Seat Removal in the Frame chap ter Fuel Tank see Fuel Tank Removal e Remove the choke cable end from the cable bracket of carburetor e Pull out the choke cable upward Choke Cable Installation e Install the choke cable in accordance with the Cable Wire and Hose Routing section in Appendix chapter e After installation adjust the cable properly A WARNING Operation with an incorrectly routed or improperly ad
208. ller Cap Driver 57001 1454 e Check the valve clearance when the pistons are at TDC OThe pistons are numbered beginning with the engine left side e Using a wrench on the crankshaft rotation bolt turn the crankshaft clockwise until the 2 T A mark on the timing rotor is aligned with the projection B in the inspection window on the alternator cover OMeasure the valve clearance of the valves for which the cam A are turned away from each other GSO7189BS1 PERIODIC MAINTENANCE 2 23 Periodic Maintenance Procedures e Using the thickness gauge A measure the valve clear ance between cam and valve lifter Valve Clearance Standard Exhaust 0 22 0 29 mm 0 0087 0 0114 in Inlet 0 15 0 24 mm 0 0059 0 0094 in 65076214 P OEach piston has two inlet and two exhaust valves Mea sure these two inlet or exhaust valves at the same crank shaft position Valve Clearance Measuring Position 1 Piston TDC at End of Compression Stroke Inlet valve clearances of 1 piston and Exhaust valve clearances of 1 piston NOTE OCheck the valve clearance using this method only Checking the clearance at any other cam position may result in improper valve clearance Valve Clearance Measuring Position 2 Piston TDC at End of Compression Stroke Inlet valve clearances of 2 piston and Exhaust valve clearances of 2 piston x If the valve clearance is not with in the specified range first re
209. ly fitted into the U shaped notch in the master cylinder Torque Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft lb e Tighten the rear master cylinder mounting bolts with a specified torque Torque Rear Master Cylinder Mounting Bolts 25 N m 2 5 kgf m 18 ft lb e Connect the brake hose to the master cylinder and re place the brake hose clamp in place Master Cylinder BRAKES 12 15 e Connect the push rod clevis to the brake pedal with the joint pin e Install the cotter pin and bend the end of it securely e Bleed the brake line see Brake Line Bleeding e Check the brake for good braking power no brake drag and no brake fluid leakage A WARNING Do not attempt to drive the motorcycle until a full brake pedal is obtained by pumping the brake pedal and the pads are against the disc The brake will not function on the first application of the pedal if this is not done e Check the brake pedal position see Brake Pedal Position Inspection e Check the rear brake light switch see Rear Brake Light Switch Operation Inspection in the Periodic Maintenance chapter Rear Brake Reservoir Removal e Remove Reservoir mounting Bolt A Brake Hose Clamp Slide B Reservoir C CAUTION Immediately wash away any brake fluid that spills Rear Brake Reservoir Installation e Install the clamp for the brake hose end e Fill the reservoir with fresh brake fluid and bleed the brake line see Brake Line B
210. mage x If the canister has any cracks or bad damage replace it with a new one NOTE OThe canister is designed to work well through the motor cycle s life without any maintenance if it is used under normal conditions 2 20 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Check the liquid vapor separator as follows ORemove Left Lower Fairing see Lower Fairing Removal in the Frame chapter ODisconnect the hoses from the separator and remove the separator B from the motorcycle left side OVisually inspect the separator for cracks and other dam age x If the separator has any cracks or damage replace it with a new one OTo prevent the gasoline from flowing into or out of the canister hold the separator perpendicular to the ground e Check the hoses of the evaporative emission control sys tem as follows OCheck that the hoses are securely connected and clips are in position OReplace any kinked deteriorated or damaged hoses ORoute the hoses according to Cable Wire and Hose Routing section in the Appendix chapter OWhen installing the hoses avoid sharp bending kinking flattening or twisting and route the hoses with a minimum of bending so that the emission flow will not be obstructed Cooling System Coolant Level Inspection NOTE OCheck the level when the engine is cold room or ambi ent temperature e Check the coolant level in the reserve tank A with the motorcycle held perpendicular D
211. measure the resis tance between any two commutator segments A x If there is a high resistance or no reading between any two segments a winding is open and the starter motor must be replaced e Using the highest hand tester range measure the resis tance between the segments and the shaft B GP110608S1 Starter System ELECTRICAL SYSTEM 16 45 x If there is any reading at all the armature has a short and the starter motor must be replaced Special Tool Hand Tester 57001 1394 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 Brush Lead Inspection e Using the x 1 Q hand tester range measure the continuity between the following Terminal Bolt and Positive Brush A Brush Plate and Negative Brush B x lf there is not close to zero ohms the brush lead has an open Replace the terminal bolt assembly and or the brush holder assembly Special Tool Hand Tester 57001 1394 Terminal Bolt Inspection e Using the highest hand tester range measure the resis tance as shown Terminal Bolt and Brush Plate A Terminal Bolt and Negative Brush Holder B Terminal Bolt and Yoke C x If there is any reading the b
212. measure the resistance across the terminals in the fuel level sensor lead connector A x If the tester reading are not as specified or do not change smoothly according as the float moves up and down re place the sensor Fuel Level Sensor Resistance Standard Full position 4 100Q Empty position 90 100 Q Special Tool Hand Tester 57001 1394 GC18437BS1 ELECTRICAL SYSTEM 16 63 Fuses 30 A Main Fuse Removal e Remove the front seat see Front Seat Removal in the Frame chapter e Unlock the hook to clear the lids of the main fuse cover A e Pull up the main fuse cover with the starter relay connec tor Fuse Removal e Remove the front seat see Front Seat Removal in the Frame chapter e Unlock the hook to lift up the lid from the fuse case e Pull the fuses A straight up from the fuse case with the nose plier Fuse Installation x If a fuse fails during operation inspect the electrical sys tem to determine the cause and then replace it with a new fuse of proper amperage e Install the junction box fuses on the original position as specified on the lid Fuse Inspection e Remove the fuse and inspect the fuse element x If the fuse element is blown replace the fuse Housing A Fuse Element B Terminal C Blown Element D NOTE OBefore replacing a blown fuse always check the am perage in the affected circuit If the amperage is equal to or greater than the fuse rating
213. motorcycle so that it is perpendicular to the ground Olf the motorcycle has just been used wait several min utes for all the oil to drain down 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 Olf the engine oil type and make are unknown use any brand of the specified oil to top up the level in preference to running the engine with the oil level low Then at your earliest convenience change the oil completely CAUTION Racing the engine before the oil reaches every part can cause engine seizure If the engine oil gets extremely low or if the oil pump or oil passages clog up or otherwise do not function properly the oil pressure warning light will light If this light stays on when the engine is running above idle speed stop the engine immediately and find the cause Engine Oil Change e Refer to Engine Oil Change in the Periodic Maintenance chapter see Engine Oil Change in the Periodic Mainte nance chapter Oil Filter Replacement e Refer to Oil Filter Replacement in the Periodic Mainte nance chapter see Oil Filter Replacement in the Periodic Maintenance chapter 7 8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter Bypass Valve Disassembly e Remove the oil filter see Oil Filter Replacement in the Periodic Maintenance chapter NOTE OOil drain
214. moval in the Frame chapter Alternator Cover see Alternator Cover Removal e Disconnect the crankshaft sensor connector A e Remove the crankshaft sensor screws A and clamp B and then remove the crankshaft sensor C Crankshaft Sensor Installation e Apply silicone sealant to the grommet and fit it into the notch in the alternator cover e Install the clamp and crankshaft sensor to the alternator cover e Clamp the harness of crankshaft sensor leads as shown e Apply silicone sealant to the mating surface A of the crankcase e Install the alternator cover see Alternator Cover Installa tion Special Tool Kawasaki Bond Silicone Sealant 56019 120 16 34 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Inspection e Remove the right side cover see Side Cover Removal in the Frame chapter e Disconnect the crankshaft sensor connector A from near the right side of the carburetor e Set the hand tester B to the x 100 Q range and connect the lead C to the black lead and lead D to the yellow lead in the connector Special Tool Hand Tester 57001 1394 x If there is more resistance than the specified value the coil has an open lead and must be replaced Much less than this resistance means the coil is shorted and must be replaced Crankshaft Sensor Resistance 100 150 Q e Using the highest resistance range of the tester measure the resistance between the crankshaft sensor leads
215. n sion x If the throttle valves do not move smoothly replace the carburetors 3 22 FUEL SYSTEM Carburetors e Disassemble the carburetors see Carburetor Disassem bly e Clean the carburetors see Carburetor Cleaning e Check that the O rings on the float bowl and pilot screw and the diaphragm on the vacuum piston are in good con dition x If any of the O rings or diaphragms are not in good con dition replace them e Check the O ring and diaphragm of coasting enricher sys tem x If any of the O ring or diaphragm 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 If 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 If the rod does not spring out replace the 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 e Check that the vacuum piston A moves smoothly in the carburetor body The surface of the piston must not be excessively worn x lf the vacuum piston does not move smoothly or if it is very loose in carburetor body replace the carburetor 6006014351 C 6c06014481 C 6co6017281 C Air Cleaner FUEL SYS
216. n they are properly matched there is no clearance between the crankcase A and the bearing outer races B e Assemble the crankcase Transmission Shaft Disassembly e Remove the transmission shafts see Transmission Shaft Removal eRemove the circlips disassemble the transmission shafts Special Tool Outside Circlip Pliers 57001 144 e The 5th gear A on the output shaft has three steel balls assembled into it for the positive neutral finder mecha nism Remove the 5th gear OSet the output shaft in a vertical position holding the 3rd gear C OSpin the 5th gear quickly B and pull it off upward e Remove the ball bearing A from each shafts Special Tools Bearing Puller 57001 135 B Bearing Puller Adapter 57001 317 C e Discard the bearing ae hes ace ENTE 2 ALA Ile Sr ANO E See AS 61130302 S CEN A Y 6113040681 CRANKSHAFT TRANSMISSION 9 27 Transmission Transmission Shaft Assembly e Install the ball bearing on the drive shaft with the groove toward the clutch side e Install the gear bushing A on the shafts with their oil holes B aligned 6113040851 e The drive shaft gears can be recognized by size the gear with the smallest diameter is 1st gear and the largest one is 6th gear Be sure that all parts are put back in the cor rect sequence and all circlips and washers are properly in place e The
217. nd Silicone Sealant 56019 120 e Install the crankshaft sensor e Clamp the harness of the crankshaft sensor leads e Tighten the stator bolts with the specified torque Torque Alternator Stator Bolts 12 N m 1 2 kgf m 104 in 1b Alternator Rotor Removal e Remove the alternator cover see Alternator Cover Re moval e Hold the alternator rotor A steady with the flywheel holder B and remove the rotor bolt C Special Tool Flywheel Holder 57001 1313 e Remove the rotor A using the flywheel puller assembly B Special Tool Flywheel Puller Assembly M38 x 1 5 M35 x 1 5 57001 1405 CAUTION Do not attempt to strike the alternator rotor itself Striking the rotor can cause the magnets to lose their magnetism 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 Crankshaft Tapered Portion A Alternator Rotor Tapered Portion B e Apply a thin coat of molybdenum disulfide grease to the crankshaft C GPOSO66BS1 Charging System ELECTRICAL SYSTEM 16 27 e Install the starter gear A and washer B e Again clean the crankshaft tapered portion and dry there e Install the alternator rotor A while turning it counterclock wise to make easy to align the key B and key groove C of the rotor NOTE OConfirm the alternator rotor fit or not to the crankshaft
218. nd Hose Routing APPENDIX 17 7 J O O1 ND A Throttle Cables Guide Radiator Fan Leads Connectors Clamp Right Switch Housing Leads Water Temperature Switch 2 Ignition Coil Clutch Cable Front Right Turn Signal Light Connector 2 Ignition Coil Water Temperature Switch Main Harness Guide Front Left Turn Signal Light Connector Bracket Bracket Ignition Switch Leads Connector 17 8 APPENDIX Cable Wire and Hose Routing GB09700C G Cable Wire and Hose Routing APPENDIX 17 9 J O O1 ND A Left Switch Housing Leads Clutch Cable Clamp Left Switching Housing Leads Connector Guide Front Left Turn Signal Light Connector Guide 1 Ignition Coil Oil Pressure Switch Connector Radiator Fan Switch Radiator Rectifier Guide Choke Cable Horn Guide Guide Coolant Reserver Tank Breather Hose Guide Fuel Tank Tank Breather Hose Fuel Tank Tank Breather Hose Guide Guide 17 10 APPENDIX Cable Wire and Hose Routing APPENDIX 17 11 Cable Wire and Hose Routing 1 Alternator Leads 2 Crankshaft Sensor Leads 3 Brackets 4 Engine Ground Lead 5 Clutch Cable 6 Guide 17 12 APPENDIX Cable Wire and Hose Routing APPENDIX 17 13 Cable Wire and Hose Routing 1 Neutral Switch Connector 2 Clamp 3 Sidestand Switch Connector 4
219. nd 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 normal before con tinuing e Do the 1st step regulator circuit test OConnect the test light and the 12 V battery to the regula tor rectifier as shown OCheck the Y1 Y2 and Y3 terminal respectively x If the test light turns on the regulator rectifier is defective Replace it x If the test light does not turn on continue the test e Do the 2nd step regulator circuit test OConnect the test light and the 12 V battery in the same manner as specified in the Regulator Circuit Test 1st Step OApply 12 V to the voltage BR terminal OCheck the Y1 Y2 and Y3 terminal respectively x If the test light turns on the regulator rectifier is defective Replace it x If the test light does not turn on continue the test R W BK Y Y1 Y2 Y3 GPO9221BS1 6P100004S1 GP100005S1 16 30 ELECTRICAL SYSTEM Charging System e Do the 3rd step regulator circuit test OConnect the test light and the 12 V battery in the same manner as specified in the Regulator Circuit Test 1st Step OMomentarily apply 24 V to the voltage BR terminal by adding a 12 V battery OCheck the Y1 Y2 and Y3 terminals respectively CAUTION Do not apply more than 24 V If more than 24 V is ap plied the regulator rectif
220. ne vacuum synchronization inspect Idle speed inspect Fuel leak fuel hose and pipe inspect Fuel hose and pipe damage inspect Fuel hose and pipe installation condition inspect Evaporative Emission Control System CAL Evaporative emission control system function inspect Cooling System Coolant level inspect Coolant leak radiator hose and pipe inspect Radiator hose damage inspect Radiator hose installation condition inspect Coolant filter clean Air Suction System Air suction system damage inspect Engine Top End Valve clearance inspect Clutch Clutch operation play disengagement engagement inspect Wheels and Tires Tire air pressure inspect Wheel tire damage inspect Tire tread wear abnormal wear inspect Wheel bearing damage inspect Drive tra Drive chain lubrication condition inspect Every 600 km 400 mile 2 29 2 4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY Whichever ODOMETER READING comes gt x 1 000 km first x 1 000 mile See 1 6 12 18 24 30 36 Page INSPECTION Every 0 6 4 7 5 12 15 20 24 Drive chain slack inspect Every 1 000 km 600 mile 2 29 Drive chain wear inspect e o e 2 31 Drive chain guide wear inspect e e 2 32 Brake
221. ng pin con tact with the link pin e Rivet it e Repeat the same procedure for the other link pin e After staking check the staked area of the link pin for cracks e Measure the outside diameter A of the link pin and link plates width B Link Pin Outside Diameter Standard 5 3 5 7 mm 0 21 0 22 in Link Plates Outside Width Standard 17 35 17 50 mm 0 68 0 69 in x If the reading exceeds the specified length cut and rejoin the chain again e Check Movement of the Rollers e Adjust the drive chain slack after installing the chain see Drive Chain Slack Inspection in the Periodic Maintenance chapter GKO4026BS1 Gk04028BS1 FINAL DRIVE 11 11 Sprocket Coupling Engine Sprocket Removal e Remove Shift Lever Link Bolt A Shift Shaft B Engine Sprocket Cover Bolts C e Remove the engine sprocket cover D e Flatten out the bended washer A e Remove the engine sprocket nut B and washer NOTE OWhen loosening the engine sprocket nut hold the rear brake on e Raise the rear wheel off the ground e Remove the axle cotter pin and loosen the rear axle nut e Loosen the both chain adjuster locknut to loosen the drive chain e Remove the drive chain from the rear sprocket toward the right e Pull the engine sprocket A with drive chain B off the output shaft C e Disengage the drive chain from the engine sprocket Engine Sprocket Installation e Repl
222. ng the choke mechanism check to see that the choke plunger lever slides right to left smoothly with out abnormal friction CAUTION Fuel mixture trouble could result if the choke plunger does not seat properly in its rest position after the choke lever is returned e Visually synchronize the throttle butterfly valves OCheck to see that all throttle valves open and close smoothly without binding when turning the pulley OVisually check the clearance A between the throttle valve and the carburetor bore in each carburetor x lf there is a difference between two carburetors turn the balance adjusting screw B to obtain the same clearance e Install the carburetors see Carburetor Installation e Adjust the synchronization see Carburetor Synchroniza tion Adjustment in the Periodic Maintenance Chapter Carburetors FUEL SYSTEM 3 19 Carburetor Disassembly e Remove the carburetors see Carburetor 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 For the Canada model remove the pilot screw plug as follows punch a hole in the plug and pry there with an awl or other suitable tool e Turn in the pilot screw and count the number of turns until it seats fully but
223. ng what CAUSED the failure If the failure was caused by some other item or items they 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 leads for signs of burning fraying etc Poor leads and bad connections will affect electrical system 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 Light green W White DG Dark green O Orange Y Yellow OElectrical Connectors Connectors A GPO60101S1 16 18 ELECTRICAL SYSTEM Precautions Connectors B GP06010281 Electrical Wiring ELECTRICAL SYSTEM 16 19 Wiring Inspection e Visually inspect the wiring for signs of burning fraying etc x If any wiring is in poor replace the damaged wiring e Pull each connector A apart and inspect it 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 leads Special Tool Hand Tester 57001 1394 OSet the tester to the x 1 Q range and read the meter x If the tester does not read 0 Q the lead is de
224. nged to accommodate atmospheric conditions in your riding area 0 0 SAE 10W 30 I I I 20 10 0 10 20 30 40 L 1 1 1 4 14 32 50 68 86 104 F AAA AA AAA E GSO9010BS1 Oil Filter Replacement e Drain the engine oil see Engine Oil change e Remove the oil filter mounting bolt A 2 48 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Replace the oil filter with a new one e Apply engine oil to the O rings A before installation after inspecting its damage e Install the oil filter mounting bolt B with a specified torque Torque Oil Filter Mounting Bolt 19 6 N m 2 0 kgf m 14 5 ft Ib e Pour in the specified type and amount of oil see Engine Oil Change Brake Hose and Pipe Replacement CAUTION Brake fluid quickly ruins painted plastic surfaces any spilled fluid should be completely washed away immediately e Remove the banjo bolts e When removing the brake hose take care not to spill the brake fluid on the painted or plastic parts e When removing the brake hoses A temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum e Immediately wash away any brake fluid that spills e There are washers on each side of the brake hose fitting Replace them with new ones when installing e Tighten Torque Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft Ib e When installing the hoses A avoid sharp bend
225. ngine is completely dry Oil Pressure Measurement Oil Pressure 4 000 r min rpm Oil 98 147 kPa 1 0 1 5 kgf cm 14 21 psi Temperature 90 C 194 F Special Tools and Sealant Outside Circlip Pliers 57001 144 ST5701448T Oil Pressure Gauge 10 kgf cm 57001 164 ST5701648T ENGINE LUBRICATION SYSTEM 7 5 Oil Pressure Gauge Adapter M18 x 1 5 57001 1278 8757127897 Kawasaki Bond Silicone Sealant 56019 120 ST560120ST 7 6 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart Intake Camshaft Oil Crankshaft Puressure Switch l Drive Shaft N Bal Shaft gt oi Flow pre Oil Pump Relief date e Oil Pipe Oil Screen 66041588 G ENGINE LUBRICATION SYSTEM 7 7 Engine Oil and Oil Filter A WARNING Motorcycle operation with insufficient deteri orated or contaminated engine oil will cause accelerated wear and may result in engine or trans mission seizure accident and injury Oil Level Inspection e Check that the engine oil level is between the upper A and lower B levels in the gauge x If the oil level is too high remove the excess oil using a syringe or some other suitable device x lf the oil level is too low add the correct amount of oil through the oil filler opening Use the same type and make of oil that is already in the engine NOTE GG050108S1 C OSituate the
226. nition switch trouble Alternator trouble Wiring faulty Regulator rectifier trouble Battery overcharged Regulator rectifier trouble Battery faulty MODEL APPLICATION Year Model Beginning Frame No 2008 EX250J8F JKAEXMJ108DA00001 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 1391 01 Printed in Japan
227. not tightly and then remove the screw This is to set the screw to its original position when as sembling CAUTION During carburetor disassembly be careful not to damage the diaphragm Never use a sharp edge to remove the diaphragm e Remove Spring A Spring Seat B Jet Needle C Vacuum Piston D Needle Jet E Needle Jet Holder F and Main Jet G Pilot Screw H Carburetor Assembly e Turn in the pilot screw A fully but not tightly and then back it out the same number of turns counted during dis assembly e Install the pilot screw plug as follows install a new plug B in the pilot screw hole of the carburetor body and apply a small amount of a bonding agent C to the circumference of the plug to fix the plug CAUTION Do not apply too much bonding agent to the plug or the pilot screw itself may be fixed GCO6080BS2 C GC06147BS1 3 20 FUEL SYSTEM Carburetors e To install the needle jet A turn the carburetor body up side down and drop the needle jet into place so that the smaller diameter end B of the jet goes in first e Carefully screw in the needle jet holder A It will seat against the needle jet pushing the end of the jet into the carburetor bore Main Jet B CAUTION Do not apply force to the jet or overtighten it as this could damage the jet or the carburetor body requiring replacement e Install the float bowl e Sli
228. nout Inspection 5 20 Carburetor Holder 5 37 Cam Wear Inspection 5 20 Carburetor Holder Installation 5 37 Camshaft Chain Guide Wear A A nes 5 38 Inspection 5 20 Muffler Removal 5 38 Cylinder Head 5 21 Muffler Installation 5 38 Cylinder Compression Exhaust System Inspection 5 39 Measurement 5 21 5 2 ENGINE TOP END Exploded View 6E02386BW5 C ENGINE TOP END 5 3 Exploded View Torque Fastener f Koetz SC Remarks Cylinder Head Cover Bolts 1 0 2 Camshaft Sprocket Bolts 15 1 5 11 L 3 Chain Tensioner Cap Bolt 5 0 0 5 44 in lb 4 Air Suction Cover Bolts 9 8 1 0 87 in lb 5 Vacuum Switch Valve Bracket Bolts 9 8 1 0 87 in lb 6 Rear Camshaft Chain Guide Bolt Lower 17 1 7 13 7 Chain Tensioner Mounting Bolts 9 8 1 0 87 in lb EO Apply engine oil L Apply a non permanent locking agent M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disufide grease in a weight ratio 10 1 R Replacement Parts SS Apply silicon sealant Kawasaki Bond 92104 0004 5 4 ENGINE TOP END Exploded View LP lol Ka Es C x J dr SET SC E 0000 SY Nt OL nA EAI AO lol Y e d Uer ENGINE TOP END 5 5 Exploded View
229. nt mesh return shift Gear Ratios 1st 2 600 39 15 2nd 1 789 34 19 3rd 1 409 31 22 4th 1 160 29 25 5th 1 000 27 27 6th 0 893 25 28 Final Drive System Type Chain drive Reduction Ratio Overall Drive Ratio 3 214 45 14 AU 3 071 43 14 8 859 Top gear AU 8 466 Top gear Frame Type Tubular diamond Caster Rake Angle 26 Trail 82 mm 3 2 in Front Wheel Tire Type Tubeless Tire Size 100 70 17M C 54H Rim Size 17 x 2 75 Rear Wheel Tire Type Tubeless Tire Size 130 70 17M C 62H Rim Size 17 x 3 50 Front suspension Type Telescopic fork Wheel Travel 120 mm 4 7 in Rear Suspension Type Swingarm uni trak Wheel Travel 130 mm 5 1 in 1 10 GENERAL INFORMATION General Specifications Items EX250J8F Brake Type Front Single disc Rear Single disc Electrical Equipment Battery 12 V6 Ah Headlight Type Semi sealed beam Bulb High 12 V 55 W 55 W quartz halogen Low 12 V 55 W quartz halogen Tail brake Light 12 V 5 21 W Alternator Type Three phase AC Rated Output 19 A 5 000 r min rpm 14 V Specifications are subject to change without notice and may not apply to every country AU Australia Model GENERAL INFORMATION 1 11 Unit Conversion Table Prefixes for Units Units of Length Prefix Power km x 0 6214 mile mega x 1 000 000 m x 3 281 ft kilo x 1 000 mm x 0 03937 in centi x 0 01 milli x 0 001 micro x 0 000001 Units of Torque N m x 0
230. nt to prevent pressure leaks e Watching the pressure gauge pump the pressure tester to build up the pressure until the relief valve opens the gauge hand flicks downward Stop pumping and measure leak time at once The relief valve must open within the specified range in the table below and the gauge hand must remain within the same range at least 6 seconds Radiator Cap Relief Pressure Standard 93 123 kPa 0 95 1 25 kgf cm 14 18 psi x If the cap cannot hold the specified pressure or if it holds too much pressure replace it with a new one 6D070104S1 6D07001BS1 4 14 COOLING SYSTEM Radiator Radiator Fan Radiator Filler Neck Inspection e Check the radiator filler neck for signs of damage e Check the condition of the top and bottom sealing seats A in the filler neck They must be smooth and clean for the radiator cap to function properly Thermostat COOLING SYSTEM 4 15 Thermostat Removal e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove Front Seat see Front Seat Removal in the Frame chap ter Fuel Tank see Fuel Tank Removal in the Fuel System chapter Thermostat Cover Bolts A e Move the thermostat cover A outwards and remove the thermostat B Thermostat Installation e Install the removed part in reverse of removal e Fit the thermostat A in the housing so that the air bleeder hole B faces as shown e F
231. o ration and swelling of the O ring Immediately blow the chain dry with compressed air after cleaning Complete cleaning and drying the chain within 10 minutes e Apply oil to the sides of the rollers so that oil will penetrate to the rollers and bushings Apply the oil to the O rings so that the O rings will be coated with oil e Wipe off any excess oil Oil Applied Areas A O rings B GKO040607S1 Drive Chain Slack Inspection NOTE OCheck the slack with the motorcycle setting on its side stand OClean the chain if it is dirty and lubricate it if it appears dry e Check the wheel alignment see Wheel Alignment Inspec tion e Rotate the rear wheel to find the position where the chain is tightest e Measure the vertical movement chain slack A midway between the sprockets x If the chain slack exceeds the standard adjust it Chain Slack Standard 20 30 mm 0 8 1 2 in G 12021BS1 2 30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Drive Chain Slack Adjustment e Remove the cotter pin A and loosen the axle nut B e Loosen the both chain adjuster locknuts C x lf the chain is too loose turn in the left and right chain adjuster nuts D evenly x lf the chain is too tight turn out the left and right chain adjuster nuts evenly and kick the wheel forward e Turn both chain adjuster nuts evenly until the drive chain has the correct amount of slack To keep the chain
232. o locate the ring squarely in place Set it close to the bottom of the cylinder where cylinder wear is low e Measure the gap B between the ends of the ring with a thickness gauge Piston Ring End Gap Standard Top 0 15 0 30 mm 0 0059 0 0118 in Second 0 40 0 55 mm 0 0157 0 0217 in Oil 0 20 0 80 mm 0 0079 0 0315 in Service Limit Top 0 6 mm 0 024 in Second 0 9 mm 0 035 in Oil 1 1 mm 0 043 in x lf the end gap of either ring is greater than the service limit replace all the rings Boring Honing When boring and honing a cylinder note the following OThere is one size of oversize piston available Oversize piston require oversize rings Oversize Piston and Ring 0 5mm Oversize OBefore boring a cylinder first measure the exact diameter of the oversize piston and then according to the standard clearance in the Service Specification Section determine the rebore diameter However if the amount of boring necessary would make the inside diameter greater than 0 5 mm oversize the cylinder block must be replaced OCylinder inside diameter must not vary more than 0 01 mm 0 0004 in at any point OBe wary of measurements taken immediately after boring since the heat affects cylinder diameter Oln the case of a rebored cylinder and oversize piston the service limit for the cylinder is the diameter that the cylin der was bored to plus 0 1 mm 0 004 in and the service limit for the piston is the ov
233. o not use the sidestand x If the coolant level is lower than the L level line B re move the right center fairing see Center Fairing Removal in the Frame chapter and unscrew the reserve tank cap and add coolant to the F level line C L low P full CAUTION For refilling add the specified mixture of coolant and soft water Adding water alone dilutes the coolant and degrades its anticorrosion properties The diluted coolant can attack the aluminum en gine parts In an emergency soft water alone can be added But the diluted coolant must be returned to the correct mixture ratio within a few days If coolant must be added often or the reservoir tank has run completely dry there is probably leakage in the cooling system Check the system for leaks Coolant ruins painted surfaces Immediately wash away any coolant that spills on the frame engine wheels or other painted parts PERIODIC MAINTENANCE 2 21 Periodic Maintenance Procedures Radiator Hose Damage and Installation Condition Inspection OThe high pressure inside the radiator hose and pipe can cause coolant to leak A or the hose to burst if the line is not properly maintained e Visually inspect the hoses for signs of deterioration Squeeze the hoses A hose should not be hard and brittle nor should it be soft or swollen x Replace the hose if any fraying cracks B or bulges C are noticed e Check that the hose
234. oat bowl 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 No spark spark weak Battery voltage low Spark plug dirty broken or maladjusted Spark plug cap or high tension wiring trou ble Spark plug cap not in good contact Spark plug incorrect IC igniter trouble Neutral starter lockout or sidestand switch trouble Crankshaft sensor trouble Ignition coil trouble Ignition or engine stop switch shorted Wiring shorted or open Main 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 Fuel air mixture incorrect Pilot screw or idle adjusting screw malad justed Pilot jet or air bleed hole clogged Air cleaner clogged poorly sealed element missing Starter jet clogged Poor Running at Low Speed Spark weak Battery voltage low Spark plug dirty broken or maladjusted Spark plug cap or high tension wiring trou ble Spark plug cap shorted or not in good con tact Spark plug incorrect IC igniter trouble Crankshaft sensor trouble Ignition coil tro
235. od Big End Bore Crankpin Diameter Bearing Insert Diameter Marking Marking Size Color Parts Number O O Black 92028 1493 None None O None Blue 92028 1492 None O Brown 92028 1494 Crankshaft Main Bearing Insert Selection Crankcase Main Crankpin Main Bearing Insert Bearing Bore Journal Diameter Diameter Marking Marking Size Color Parts Number Journal Nos 2 E s 4 Black 92028 1487 1 3 92028 1490 2 92028 1582 1 3 N N Yell l ne Ss Ge 92028 1586 2 O None Blue 92028 1486 1 3 None 1 92028 1489 2 The bearing inserts for No 2 journal have an oil groove Balancer Shaft Bea ring Insert Selection Balancer Shaft Crankcase Balancer Bearing Insert Journal Diameter Shaft Bore Diameter e Marking Marking Size Color Parts Number O O Brown 92028 1424 O None Black 92028 1423 None O None None Blue 92028 1422 Crankshaft Selection when Replacing Crankshaft Clutch Housing Crankshaft Gear Marking E Color F o Te Color D Part Number A EAU B Red A White 13031 0111 B 13031 0172 S 13081 0112 C None C None 13031 0113 D Yellow C None 13031 0113 D Yellow D Yellow 13031 0114 Special Tools and Sealants Bearing Puller 57001 135 Outside Circlip Pliers 57001 144 ST5701358T ST5701448T Bearing Puller Adapter 57001 317 ST570317ST CRANKSHAFT TRANSMISSION 9 9 Kawasaki Bond Silicone Sealant
236. of the front and rear brake by run ning the vehicle on the dry road If the brake operation is insufficiency inspect the brake system When inspecting by running the vehicle note a surrounding traffic situation enough in the place of safety GL10020181 PERIODIC MAINTENANCE 2 33 Periodic Maintenance Procedures Brake Fluid Level Inspection e Check that the brake fluid level in the front brake reservoir A is above the lower level line B NOTE OHold the reservoir horizontal by turning the handlebar when checking brake fluid level x If the fluid level is lower than the lower level line fill the reservoir to the upper level line C in the reservoir e Check that the brake fluid level in the rear brake reservoir A is above the lower level line B x If the fluid level is lower than the lower level line fill the reservoir to the upper level line C A WARNING Change the brake fluid in the brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that is already in the reser voir are unidentified After changing the fluid use only the same type and brand of fluid thereafter Recommended Disc Brake Fluid Grade DOT4 e Follow the procedure below to install the rear brake fluid reservoir cap correctly OFirst tighten the rear brake fluid reservoir cap B clock wise C by hand until slight resistance is felt indicating that the ca
237. oltage Tester Range Reading Tester to Tester to 25 V DC Battery Battery 14 15 V GP100006S1 ELECTRICAL SYSTEM 16 31 Charging System e Turn off the ignition switch to stop the engine and discon nect the hand tester x If the charging voltage is kept between the values given in the table the charging system is considered to be working normally x lf the charging voltage is much higher than the values specified in the table the regulator rectifier is defective or the regulator rectifier leads are loose or open x If the charging voltage does not rise 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 Charging System Circuit yt eet CECR W IN BK YT _HBK gt gt GP090302W2 C 1 Ignition Switch 2 Alternator 3 Regulator Rectifier 4 Battery 5 Main Fuse 30 A 6 Load 16 32 ELECTRICAL SYSTEM Ignition System Ignition System Troubleshooting Faulty Ignition Malfunctioned engine Ignition System Wiring Connector and Battery Voltage Inspection No Good Repair Replace or Charge SES No Good Spark Plug Inspection Good No Good Ignition Coil Inspection Good Inspect Charge or Ignition Coil Primary Peak Volt
238. on gt E Frame Ze Ground Se Color Code x 2 WER BK Black BL Blue Regulator BR Brown a A ES 7 Crankshaft Sensor oil 7 Pressure Neutral Switch Switch Starter Motor Battery 12V6Ah Rectifier Alternator G Green o Orange P Pink PU Purple R Red W White RIGHT SWITCH HOUSING CONNECTIONS IGNITION SWITCH CONNECTIONS Front Brake E Switch Engine Stop Switch Starter Button Headlight Switch 98052 0410B L I RO410BW5 16 14 ELECTRICAL SYSTEM Specifications Item Standard Service Limit Battery Type Model Name Capacity Voltage Sealed battery YTX7A BS 12 V 6 Ah 12 8 V or more Charging System Alternator Output Voltage Alternator Stator Coil Resistance 40 V or more 4 000 r min rpm 0 05 0 6 Q Ignition System Crankshaft Sensor Air Gap Crankshaft Sensor Resistance Ignition Coil 3 Needle Arcing Distance Primary Winding Resistance Secondary Winding Resistance Spark Plug Gap Electrical Stater System Starter Motor Carbon Brush Length Commutator Diameter Switches and Sensors Rear Brake Light Switch Radiator Fan Switch connections Rising Temperature Falling Temperature Water Temperature Switch Connections Rising Temperature Falling Temperature 0 7 mm 0 028 in 100 150 Q 7 mm 0 28 in or more 21 250 10 16 kQ 0 7 0 8 mm 0 02
239. ork B and the output shaft shift forks C e Pull out the shift drum A about half of it and remove the circlip B and the operating plate C e Pull out the shift drum fully from the upper crankcase Shift Drum and Fork Installation e Set the transmission gear in the neutral position e Insert the shift drum into the upper crankcase half and install the operating plate pin A operating plate B and circlip C NOTE OWhen installing the operating plate the projection D faces toward the outside CRANKSHAFT TRANSMISSION 9 29 Transmission e Apply a little engine oil to the shift rods and shift fork fin gers e Insert the shift rods D running them through the shift forks fitting each shift fork guide pin into the shift drum grooves OPosition the one with shortest ear A on the drive shaft and place the guide pin in the center groove in the shift drum B OThe two forks C on the output shaft are identical e Install the shift drum bearing holder plate A OApply a non permanent locking agent to the threads of the shift drum bearing holder bolts B and tighten them with the specified torque Torque Shift Drum Bearing Holder Bolts 12 N m 1 2 kgf m 104 in 1b e Install the neutral positioning bolt with the specified torque to the upper crankcase Torque Shift Drum Positioning Bolt 24 5 N m 2 5 kgf m 18 ft lb Shift Drum Disassembly e Remove the shift drum see Shift Drum R
240. orn down past the service limit replace the camshaft Cam Height Standard Exhaust 32 843 32 957 mm 1 2930 1 2975 in Inlet 33 843 33 957 mm 1 3324 1 3369 in Service Limit Exhaust 32 74 mm 1 289 in Inlet 33 74 mm 1 328 in Camshaft Chain Guide Wear Inspection e Visually inspect the rubber A on the guide elt the rubber is damaged or cut replace the guides 6E11063BS1 GE11012281 GE11275BS1 ENGINE TOP END 5 21 Cylinder Head Cylinder Compression Measurement NOTE OUse the battery which is fully charged e Warm up the engine thoroughly e Stop the engine e Remove Front Seat see Front Seat Removal in the Frame chap ter Fuel Tank see Fuel Tank Removal in the Fuel System chapter Spark Plug see Spark Plug Replacement in the Periodic Maintenance chapter e Attach the compression gauge A and adapter B firmly into the spark plug hole e Using the starter motor turn the engine over with the throt tle fully open until the compression gauge stops rising the compression is the highest reading obtainable Special Tool Compression Gauge 57001 221 Compression Gauge Adapter M10 x 1 0 57001 1317 Cylinder Compression Usable Range 961 1 471 kPa 9 8 15 0 kgf cm 139 213 psi 470r min rpm e Repeat the measurement for the other cylinder e Install the spark plugs Torque Spark Plug 13 N m 1 3 kgf m 115 in Ib
241. ose e Install the diaphragm and reservoir cap e Tighten Torque Front Brake Reservoir Cap Screws 1 5 N m 0 15 kgf m 13 in Ib e Follow the procedure below to install the rear brake fluid reservoir cap correctly OFirst tighten the rear brake fluid reservoir cap B clock wise C by hand until slight resistance is felt indicating that the cap is seated on the reservoir body then tighten the cap an additional 1 6 turn D while holding the brake fluid reservoir body A e Tighten the bleed valve and install the rubber cap Torque Bleed Valve 5 5 N m 0 55 kgf m 49 in Ib e After changing the fluid check the brake for good braking power no brake drag and no fluid leakage x If necessary bleed the air from the lines GLO9030BS2 2 50 PERIODIC MAINTENANCE Periodic Maintenance Procedures Master Cylinder Rubber Parts Replacement Front Master Cylinder Disassembly e Remove the front master cylinder see Front Master Cylin der Removal in the Brakes chapter e Remove the reservoir cap and diaphragm and pour the brake fluid into a container e Unscrew the locknut and pivot bolt and remove the brake lever e Pull the dust cover out of place and remove the circlip Special Tool Inside Circlip Pliers 57001 143 e Pull out the piston A secondary cup B primary cup C and return spring D CAUTION Do not remove the secondary cup from the piston since removal will damage it
242. output shaft gears can be recognized by size the gear with the largest diameter is 1st gear and the small est one is 6th gear Be sure that all parts are put back in the correct sequence and all circlips and washers are properly in place e Fit the steel balls into the 5th gear holes in the output shaft as shown View A A see CRANKSHAFT TRANSMISSION 9 30 A Gear 5th B Shaft C Steel Balls CAUTION Do not apply grease to the steel balls to hold them in place This will cause the positive neutral finder mechanism to malfunction OCheck the ball locking effect that the 5th gear does not come out of the output shaft when moving it up and down by hand e Replace any circlip that were removed with new ones e Install the circlips A so that opening B is aligned with a spline groove C e Check that each gear spins or slides freely on the trans mission shafts without binding after assembly 6113042381 9 28 CRANKSHAFT TRANSMISSION Transmission Shift Drum and Fork Removal e Split the crankcase see Crankcase Splitting e Remove the neutral positioning bolt A and take off the washer B spring C and pin D from the upper crankcase half E e Remove the shift drum bearing holder bolts A and take the holder plate D out of the shift drum B and shift rod C e Pull the shift rods A off the right side of the upper crankcase half and take off the drive shaft shift f
243. ower and Bolt A Rear Shock Absorber Nuts and Bolts B Rear Shock Absorber Installation e Install the rear shock absorber e Tighten the tie rod lower bolt and nut Torque Rear Shock Absorber Mounting Nuts 59 N m 6 0 kgf m 44 ft lb Tie rod Nut Lower 59 N m 6 0 kgf m 44 ft lb e Adjust the rear shock absorber spring preload in response to riding condition see Spring Preload Adjustment Rear Shock Absorber Scrapping A WARNING Since the rear shock absorber contains nitrogen gas do not incinerate the rear shock absorber with out first releasing the gas or it may explode Before a rear shock absorber is scrapped drill a hole at the point A shown to release the nitrogen gas completely Wear safety glasses when drilling the hole as the gas may below out bits of drilled Lee metal when the hole opens e Drill the cylinder A of the shock absorber using about 2 mm 0 08 in drill bit 13 14 SUSPENSION Swingarm Swingarm Removal e Remove the lower fairings see Lower Fairing Removal in the Frame chapter e Remove the bolts A and the chain cover B e Raise the rear wheel off the ground with jack Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Remove Rear Wheel see Rear Wheel Removal in the Wheels Tire chapter Rear Shock Absorber A see Rear Shock Absorber Re moval Tie rod B see Tie rod Removal e Remove Brake Hose Clamp Bolt A Bracket B with Brake Hose
244. p is seated on the reservoir body then tighten the cap an additional 1 6 turn D while holding the brake fluid reservoir body A Brake Pad Wear Inspection e Check the lining thickness A of the pads in each caliper x If the lining thickness of either pad is less than the service limit B replace both pads in the caliper as a set Pad Lining Thickness Standard 4 5 mm 0 18 in Service Limit 1 mm 0 04 in Ge yo GS13024B S 6S13224BS1 2 34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Light Switch Operation Inspection e Turn on the ignition switch e The brake light A should go on when the brake lever is applied or after the brake pedal is depressed about 10 mm 0 39 in x lf it does not adjust the brake light switch e Disconnect the connector A e Turn the brake light switch to adjust the switch e Connect the connector x If it does not go on inspect or replace the following items Battery see Charging Condition Inspection in the Elec trical System chapter Brake Light see Tail Brake Light Removal in the Electri cal System chapter Main Fuse 30 A and Taillight Fuse 10 A see Fuse In spection in the Electrical System chapter Front Brake Light Switch A see Switch Inspection in the Electrical System chapter Rear Brake Light Switch see Switch Inspection in the Electrical System chapter Harness see Wiring Inspection in the Electrical System chapte
245. p the jet needle B through the hole in the center of the vacuum piston and put the spring seat C on the top of the needle Turn the seat so that it does not block the hole at the bottom of the vacuum piston A Spring D e Install the carburetor top cover e Turn in the pilot screw fully but not tightly and then back it out the same number of turns counted during disassem bly e When removing the air cut valve assembly unscrew the mounting screws B and remove the cover C spring D O ring E and diaphragm F e Install Left Carburetor A Air Cut Valve Body G Air Cut Valve Mounting Plate H 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 6C06081BS1 6C06082BS1 Carburetors FUEL SYSTEM 3 21 CAUTION Do not use compressed air on an assembled carbu retor or the floats may be crushed by the pressure and the vacuum piston diaphragm may be dam aged Remove as many rubber or plastic parts from the carburetor as possible before cleaning the carburetor with a cleaning solution This will pre vent damage to or deterioration of the parts The carburetor body has plastic parts that cannot b
246. page or deformation which can lead to malfunction Conversely when loosening the bolts nuts or screws first loosen all of them by about a quar ter turn and then remove them If the specified tightening sequence is not indicated tighten the fasteners alternating diagonally Tightening Torque Incorrect torque applied to a bolt nut or screw may lead to serious damage Tighten fasteners to the specified torque using a good quality torque wrench Force Use common sense during disassembly and assembly excessive force can cause expensive or hard to repair dam age When necessary remove screws that have a non permanent locking agent applied using an impact driver Use a plastic faced mallet whenever tapping is necessary Gasket O ring Hardening shrinkage or damage of both gaskets and O rings after disassembly can reduce sealing performance Remove the old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material re mains Install the new gaskets and replace the used O rings when re assembling Liquid Gasket Non permanent Locking Agent For applications that require Liquid Gasket or a Non permanent Locking Agent clean the surfaces so that no oil residue remains before applying liquid gasket or non permanent locking agent Do not apply them exces sively Excessive application can clog oil passages and cause serious damage 02018 65020138 6020148 LX f D 6020158
247. paration TT 3 17 Carburetor JOINING ME 3 17 Carburetor Disassembly rinra nena EE 3 19 Carburetor Assembly EE 3 19 Carburetor le e Be 3 20 Carburetor Inspection see 3 21 ARCO Mt Ee A ner Rien 3 23 Air Cleaner Element Hemoval cnn nar r rre rrrrr 3 23 Air Cleaner Element Installaton nenn nnnn nenn rnnntnnntnnntnnnttnnttnntnnnnnnnnnnn nnan nn anneanne 3 23 Air Cleaner Housing Removal see 3 23 Air Cleaner Housing Installation E 3 24 Air Cleaner Housing Disassembly rn nene nen nccce nera 3 24 Air Cleaner Housing Assembly econ ride 3 24 Oil Draining EE 3 25 AN A 3 26 Fuel Tank Removal sustratos 3 26 Fuel Tank Installation nsei eener aree e a a a E arer aer ET EE 3 26 IERT NEE le EE 3 27 Fuel Tap Installation id 3 27 Fuel T nk and Tap Cleaning E 3 27 Fuel Tap Inspection 3 28 Fuel Tank and Cap Inspection cccecceee cece cece e eee eeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeneeeteeeeeeeeeeees 3 28 3 2 FUEL SYSTEM Exploded View Exploded View OONOARWNDN Throttle Cable accelerator Throttle Cable decelerator Choke Cable Idle Adjusting Screw Air Cut Valve Jet Needle Vacuum Valve Float Valve Needle Jet Needle Jet Holder Main Jet Pilot Jet Pilot Air Screw Float Plug Apply cable lubricant Apply grease FUEL SYSTEM 3 3 3 4 FUEL SYSTEM Exploded View 60023518W
248. per B so that the distance C from the bottom of the stopper to the lower end of the pipe is the standard oil level distance OA correct measurement can not be obtained unless the level gauge pipe is placed in the center of the inner tube Oil Level fully compressed without spring Standard 108 2 mm 4 3 0 08 in OPlace the stopper of the level gauge at the top D of the inner tube E and pull the handle slowly to draw out the excess oil from fork into the gauge thus attaining the stan dard level Olf not oil is drawn out there is not enough oil in the fork Pour in some more oil and measure again GMO4515BS1 GM04297BS1 GM04303BS2 C Front Fork SUSPENSION 13 9 e Repeat the same procedure for adjusting the other fork e Install the fork spring A fork spring seat B and collar C e Inspect the top plug O ring and snap ring and replace them with new ones e Install the front fork see Front Fork Installation Front Fork Disassembly e Remove the front fork see Front Fork Removal e Remove Snap Ring A see Front Fork Removal Top Plug B with O ring C Collar D Fork Spring Seat E Fork Spring F e Hold the front fork leg horizontally in a vise A e Stop the cylinder unit B from turning by using the special tools e Unscrew the front fork bottom Allen bolt C and then take out the bolt and gasket out of the bottom of the outer tube Special
249. r Suspensions Front Forks Rear Shock Absorber Operation Inspection e Pump the forks down and up A 4 or 5 times and inspect the smooth stroke x If the forks do not smoothly or noise is found inspect the fork oil level or fork clamps see Front Fork Oil Change in the Suspension chapter 05136636 PERIODIC MAINTENANCE 2 35 Periodic Maintenance Procedures e Pump the seat down and up A 4 or 5 times and inspect the smooth stroke x If the shock absorber does not smoothly stroke or noise is found inspect the oil leak see Rear Shock Absorber Oil Leak Inspection Front Fork Oil Leak Inspection e Visually inspect the front forks A for oil leakage Replace or repair any defective parts if necessary Rear Shock Absorber Oil Leak Inspection e Visually inspect the shock absorber A for oil leakage x If the oil leakage is found on it replace the shock absorber with a new one Rocker Arm Operation Inspection e Pump the seat down and up 4 or 5 times and inspect the smooth stroke x If the rocker arm A does not smoothly stroke or noise is found inspect the fasteners and bushings see Rocker Arm Tie Rod Bushing Sleeve Inspection in the Suspen sion chapter Tie Rod Operation Inspection e Pump the seat down and up 4 or 5 times and inspect the smooth stroke x If the tie rod A do not smoothly stroke or noise is found inspect the fasteners and tie rod bushings see Rocker Arm Tie Rod Bushin
250. r ENEE en let eege ger des 4 13 e EE 4 13 Radiator Cap Inspection ss 4 13 Radiator Filler Neck Inspection rn 4 14 A er a EN A a a E E 4 15 Thermostat HRemoval eee eeeeeeaeeeeeeeeaeeeaeeeeseaeeeeeedeesseesseeseeeeseeeeeeees 4 15 Thermostat Installation ss nent restes A RAR nn ei 4 15 Thermostat Housing Removal er sine men Anti ds nee dada 4 15 Thermostat Housing Installation Note 4 15 Thermostat Inspection nina nie mire 4 16 Hoses and PIpeS EE 4 17 Hose Installation WEE 4 17 Hose Inspection EE 4 17 Radiator Fan Switch Water Temperature Switch 4 18 Radiator Fan Switch Water Temperature Switch Removal nnnnssnnnn0nnnnnnnnnsnenneneneneo 4 18 Radiator Fan Switch Water Temperature Switch Installation 4 18 Radiator Fan Switch Water Temperature Switch Inspection 4 18 4 2 COOLING SYSTEM Exploded View Q 3 A D COOLING SYSTEM 4 3 Exploded View No Fastener Tome Remarks N m kgf m ft Ib 1 Water Temperature Switch 7 5 0 76 66 in lb Ss 2 Thermostat Cover Bolts 9 8 1 0 87 in lb 3 Thermostat Housing Mounting Bolts 9 8 1 0 87 in lb 4 Radiator Fan Switch 23 5 2 4 17 5 Radiator Bolts 9 8 1 0 87 in lb 6 Radiator Cap Bracket Bolt 9 8 1 0 87 in lb 7 Water Pipe Bolts 9 8 1 0 87 in lb Water Hose Clamp Screws 1 5 0 15 13 in Ib 98 10 87in
251. r Fan 1 Ignition Coil Engine Ground Terminal Rear Brake Light Switch Precautions ELECTRICAL SYSTEM 16 17 There are a number of important precautions that are musts 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 a must 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 damage to 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 large amount of current never keep the starter button pushed when the starter motor will not turn over or the current may burn out the starter motor wind ings ODo not use a meter illumination bulb rated for other than voltage or wattage specified in the wiring diagram as the meter or gauge panel could be warped by excessive heat radiated from the bulb OTake care not to short the leads that are directly con nected to the battery positive terminal to the chassis ground OTroubles may involve one or in some cases all items Never replace a defective part without determini
252. r Head Warp Inspection e Lay astraightedge across the lower surface of the cylinder head at several positions e Use a thickness gauge A to measure the space between the straightedge B and the head Cylinder Head Warp Standard Service Limit 0 05 mm 0 002 in x If 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 5 24 ENGINE TOP END Cylinder Head Cylinder Head Cleaning e Remove Cylinder Head see Cylinder Head Removal Valves see Valve Removal e Scrape A the carbon out of the combustion chamber and exhaust port with a suitable tool e Wash the cylinder head with a high flash point solvent e Using compressed air blow out any particles which may obstruct the oil passage A in the cylinder head e Install the valve see Valve Installation e Install the cylinder head see Cylinder Head Installation Valves ENGINE TOP END 5 25 Valve Clearance Inspection e Refer to Valve Clearance Inspection in the Periodic Main tenance chapter Valve Clearance Adjustment e Refer to Valve Clearance Adjustment in the Periodic Maintenance chapter Valve Removal e Remove the cylinder head see Cylinder Head Removal e Use the valve spring compressor assembly and the adapter to press down the valv
253. r motor clutch gear A by hand The starter motor clutch gear should turn clockwise B freely but should not turn counterclockwise C x If the starter motor clutch does not operate as it should or if it makes noise go to the next step e Disassemble the starter motor clutch and visually inspect the clutch parts x If there is any worn or damaged part replace it NOTE OExamine the starter motor clutch gear as well Replace it if is worn or damage Starter Motor Clutch Disassembly e Remove Alternator Rotor see Alternator Rotor Removal in the Electrical System chapter Starter Motor Clutch Bolts A and Starter Motor Clutch B Alternator Rotor C Starter Motor Clutch Assembly e Apply a non permanent locking agent to the threads of the starter motor clutch bolts and tighten them Torque Starter Motor Clutch Bolts 34 3 N m 3 5 kgf m 25 ft lb Spa P 9 22 CRANKSHAFT TRANSMISSION Balancer Balancer Removal e Split the crankcase see Crankcase Splitting e Pull the balancer shaft with the balancer gear out of the crankcase Balancer Installation e Balancer installation is the reverse of removal e Apply oil to the inside of the balancer shaft bearing insert e Align the timing mark C on the balancer gear B with the timing mark C on the balancer drive gear A of the crankshaft Balancer Shaft Bearing Insert Journal Wear Inspection e Measure the bearing insert journal clearance OSplit the
254. r or pedal if this is not done Caliper Disassembly e Refer to Caliper Rubber Parts Replacement in the Peri odic Maintenance chapter see Caliper Rubber Parts Re placement in the Periodic Maintenance chapter Caliper Assembly e Refer to Caliper Rubber Parts Replacement in the Peri odic Maintenance chapter see Caliper Rubber Parts Re placement in the Periodic Maintenance chapter Caliper Fluid Seal Damage The fluid seal piston seal A is placed around the pis ton to maintain clearance between the pad and the disc If the seal is in a poor condition it could lead the pad to wear excessively or the brake to drag which may cause the tem perature of the discs or the brake fluid to increase e Replace the fluid seal if it exhibits any of the conditions listed below OBrake fluid leakage around the pad OBrakes overheat OConsiderable difference in inner and outer pad wear OSeal and piston are stuck together x If the fluid seal is replaced replace the dust seal B as well Also replace all seals every other time the pads are changed Rear Caliper Dust Boot and Friction Boot Damage e Check that the dust boot A and friction boot B are not cracked worn swollen or otherwise damaged x If they show any damage replace it GLO5202BS1 GLO5203BS1 BRAKES 12 11 Calipers Caliper Piston and Cylinder Damage Inspection e Visually inspect the piston A and cylinder surfaces Replace
255. r the air valve with tire irons Special Tools Rim Protector 57001 1063 A Tire lrons of the Bead Breaker Assembly 57001 1072 B 6J05006BS1 6J05017BS1 6J05018BS1 Tires WHEELS TIRES 10 13 NOTE OFor easier removal always position the tire bead oppo site the valve stem in the rim well and pry the tire bead a little at a time CAUTION Be careful not to scratch the inner liner and air seal ing surfaces of the rim and tire with the tire irons A scratched inner liner B or sealing surface A may allow air to leak e After removing the bead on one side remove the other bead from the same side e Remove the rim from the tire Tire Installation A WARNING Use the same manufacture s on both front and rear wheels e Inspect the rim and tire and replace them if necessary e Clean the sealing surfaces of the rim and tire and smooth the sealing surfaces of the rim with a fine emery cloth if necessary e Remove the air valve and discard it CAUTION Replace the air valve whenever the tire is replaced Do not reuse the air valve e Install a new valve in the rim ORemove the valve cap lubricate the stem seal A with a soap and water solution or rubber lubricant and pull the valve stem 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 becau
256. rake fluid L Apply a non permanent locking agent R Replacement parts S Follow the specific tightening sequence Si Apply silicone grease 12 4 BRAKES Exploded View GLO2333BW5 C Exploded View BRAKES 12 5 Reservoir Mounting Bolt Ke es CS Push Rod Locknut Brake Disc Mounting Bolts 7 Brake Hose Banjo Bolts 25 Torque kgfm ft lb Remarks Cos rein 1 gt Rear Master Cylinder Mounting Bolts 25 Rear Caliper Mounting Bolts 25 B Apply brake fluid G Apply grease L Apply a non permanent locking agent R Replacement parts Si Apply silicone grease 8 2 2 5 2 5 2 5 12 6 BRAKES Specifications Item Standard Service Limit Brake Pedal Pedal Free Play Non adjustable SE Pedal Position About 40 mm 1 6 in below footpeg top Brake Discs Thickness Front 4 3 4 6 mm 0 17 0 18 in 4 0 mm 0 16 in Rear 4 8 5 1 mm 0 19 0 20 in 4 5 mm 0 18 in Runout TIR 0 15 mm 0 006 in or less TIR 0 3 mm 0 01 in BRAKES 12 7 Special Tool Inside Circlip Pliers 57001 143 ST5701438ST 12 8 BRAKES Brake Lever Brake Pedal Brake Pedal Position Inspection e Check that the brake pedal A is in the correct position B Footpeg Pedal Position Standard About 40 mm 1 6 in C below top of footpeg x If it is incorrect adjust the brake pedal position Brake Pedal Position Adjustment NOTE OUsuall
257. replaced with a new one select the proper clutch housing in accordance with the combination of the clutch housing gear and crankshaft primary gear markings with colors Crankshaft Primary Gear A Clutch Housing Gear B e Be sure to confirm the marking and color on the clutch housing gear Primary Gear Marking C Color D GF06172BS2 Color F Part Number White White 13095 0095 White 13095 0096 13095 0097 13095 0097 NOTE Olf the selection mark and color are missing or not selec tion refer to the selection section in the specifications of the Crankshaft Transmission chapter e Install the friction plate first and clutch steel plate and afterward install them alternately OThe outer end A and inner end B friction plate blocks are wider than the others Wider C Narrower D 13095 0098 13095 0098 6 10 CLUTCH Clutch e Install the clutch operating plate A with the clutch push rod B e Install the springs and tighten the clutch spring bolts with specified torque Torque Clutch Spring Bolts 8 8 N m 0 9 kgf m 78 in Ib e Install the clutch cover see Clutch Cover Installation Clutch Plate Wear and Damage Inspection e Visually inspect the friction and steel plates for signs of seizure overheating discoloration or uneven wear e Measure the thickness of each friction plate A at several points x If any plates show signs of damage or if they
258. rk ear is less than the service limit the shift fork must be replaced Shift Fork Ear Thickness Standard 4 9 5 0 mm 0 1929 0 1969 in Service Limit 4 8 mm 0 189 in x If the gear groove is worn over the service limit the gear must be replaced Gear Groove Width Standard 5 05 5 15 mm 0 1988 0 2028 in Service Limit 5 3 mm 0 209 in Shift Fork Guide Pin Drum Groove Wear Inspection e Measure the diameter of each shift fork guide pin A and measure the width B of each shift drum groove x If the guide pin on any shift fork is less than the service limit the fork must be replaced Shift Fork Guide Pin Diameter Standard 5 9 6 0 mm 0 2323 0 2362 in Service Limit 5 8 mm 0 228 in If any shift drum groove is worn over the service limit the drum must be replaced Shift Drum Groove Width Standard 6 05 6 20 mm 0 2382 0 2441 in Service Limit 6 3 mm 0 248 in 6113107 D 6113014581 6113011581 6113010481 CRANKSHAFT TRANSMISSION 9 31 Transmission Gear Dog and Gear Dog Hole Damage Inspection e Visually inspect the gear dogs A and gear dog holes B x Replace any damaged gears or gears with excessively worn dogs or dog holes Ball and Needle Bearing Wear Inspection e Check the following ball bearings right hand drive shaft left hand output shaft and right hand shift drum OSince the ball bearings are made to e
259. rminal Voltage less than 11 5 V Charging Method 0 7 A x 20h NOTE Olncrease the charging voltage to a maximum voltage of 25 V ifthe battery will not accept current initially Charge for no more than 5 minutes at the increased voltage then check if the battery is drawing current If the battery will accept current decrease the voltage and charge by the standard charging method described on the battery case If the battery will not accept current after 5 min utes replace the battery Battery A Battery Charger B Standard Value C Current starts to flow D e Determine the battery condition after refresh charge ODetermine the condition of the battery left for 30 minutes after completion of the charge by measuring the terminal voltage according to the table below Criteria Judgement 12 8 V or higher Good 12 0 lower than 12 8 V Charge insufficient Recharge lower than 12 0 V Unserviceable Replace lt wade ee eee 1 4 1 1 1 1 J T 1 1 1 U Terminal Voltage 5 0 25 50 75 100 Refreshing charge Battery Charge is required Note Good cposozoss1 po900i1281 Charge Time h 11 6 11 8 12 0 12 2 12 4 12 6 12 8 13 0 Battery Terminal Voltage V GPO8023BS1 GP08008BS1 ELECTRICAL SYSTEM 16 25 Charging System Alternator Cover Removal e Drain Engine Oil see Eng
260. rocket Warp Inspection 11 14 11 2 FINAL DRIVE Exploded View Exploded View FINAL DRIVE 11 3 No N m Engine Sprocket Cover Bolts 9 8 87 in lb 127 13 94 MO Fastener Engine Sprocket Nut Torque q Remarks weit fib Rear Sprocket Nuts G il Rear Sprocket Studs 5 Chain Adjusting Nuts and Locknuts G Apply grease L Apply a non permanent locking agent MO Apply molybdenum disulfide oil solution mixture of engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts 11 4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain Make Enuma EE Type EK520SR O2 EE Link 106 Links Sprockets Rear Sprocket Warp TIR 0 4 mm 0 016 in or less TIR 0 5 mm 0 02 in FINAL DRIVE 11 5 Special Tool Bearing Driver Set 57001 1129 ST5711298T 11 6 FINAL DRIVE Drive Chain Drive Chain Slack Inspection e Refer to Drive Chain Slack Inspection in the Periodic Maintenance chapter see Drive Chain Slack Inspection in the Periodic Maintenance chapter Drive Chain Slack Adjustment e Refer to Drive Chain Slack Inspection in the Periodic Maintenance chapter see Drive Chain Slack Inspection in the Periodic Maintenance chapter Wheel Alignment Inspection Adjustment e Refer to Wheel Alignment Inspection in the Periodic Main tenance chapter see Wheel Alignment Inspection in
261. rouble Brake dragging Lubrication inadequate Engine oil level too low Engine oil poor quality or incorrect Coolant incorrect Coolant level too low Coolant deteriorated Cooling system component incorrect Radiator fin damaged Thermostat trouble Radiator cap trouble Radiator fan switch trouble Fan relay trouble Fan motor broken Fan blade damaged Water pump not turning Water pump impeller damaged 17 40 APPENDIX Troubleshooting Guide Over Cooling Cooling system component incorrect Radiator fan switch trouble Thermostat trouble Gauge incorrect Water temperature gauge broken Water temperature sensor broken Clutch Operation Faulty Clutch slipping Friction plate worn or warped Steel plate worn or warped Clutch inner cable trouble No clutch lever play Clutch spring broken or weak Clutch release mechanism trouble Clutch hub or housing unevenly worn Clutch not disengaging properly Clutch plate warped or too rough Clutch spring compression uneven Engine oil deteriorated Engine oil viscosity too high Engine oil level too high Clutch housing frozen on drive shaft Clutch release mechanism trouble Clutch hub spline damaged Clutch friction plate installed wrong Clutch lever play excessive Clutch hub nut loose Gear Shifting Faulty Doesn t go into gear shift pedal doesn t return Clutch not disengaging Shift fork bent or seized Gear stuck on the shaft Shift return spring weak or broken Shift return spring pin loose
262. rts from the damaged case and install it to the new case Pay attention to the following items OWhen installing the oil passage plug must be inserted as shown 1 Lower Crankcase Half 2 Oil Passage Pipe 3 Press 4 Small Hall Up 5 Slit Horizontal OFit the oil passage O ring on the breather body Replace the O ring with new ones if deteriorated or damage The flat side of the O ring must face down OApply a non permanent locking agent to the threads of the breather bolts and tighten them G104218BS1 6104098BS1 6104099BS1 6104100BS1 9 14 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods Crankshaft Removal e Split the crankcase see Crankcase Splitting e Take the crankshaft out of the upper crankcase Crankshaft Installation elt the crankshaft is replaced with a new one select the proper crankshaft in accordance with the combination of the crankshaft primary gear and clutch housing gear markings with colors Crankshaft Primary Gear A Clutch Housing Gear B e Be sure to confirm the marking and color on the crank shaft primary gear GF06172BS2 Crankshaft Selection when Replacing Crankshaft Clutch Housing Crankshaft A Primary Gear Gear Marking E Color F Marking C Color D A B B C None C None D Yellow C None D Yellow D Yellow NOTE Olf the selection mark and color are missing or not selec tion re
263. rush holder assembly and or terminal bolt assembly have a short Replace the brush holder assembly and the terminal bolt assembly Special Tool Hand Tester 57001 1394 Starter Relay Inspection e Remove the fuel tank see Fuel Tank Removal in the Fuel System chapter e Remove Fuel Tank Bracket Bolts A Fuel Tank Bracket B 16 46 ELECTRICAL SYSTEM Starter System e Disconnect the cables A and remove the starter relay C with the main fuse B e Remove the main fuse from the starter relay e Connect the hand tester A and 12 V battery B to the starter relay C as shown x If the relay does not work as specified the relay is defec tive Replace the relay Relay Function Test Tester Range x 1 Q range Standard When battery is connected 0 Q When battery is disconnected Q Special Tool Hand Tester 57001 1394 Starter Circuit Relay Inspection e Remove the front seat see Front Seat Removal in the Frame chapter e Remove the starter circuit relay A e Connect the hand tester A and 12 V battery B to the starter circuit relay C as shown x If the relay does not work as specified the relay is defec tive Replace the relay Testing Relay Tester Range x10 Criteria When battery is connected 0 Q When battery is disconnected Q Relay Coil Terminal 1 and 2 Relay Switch Terminals 3 and 4 ieee P GP120703S2 Starter System ELECTR
264. rvice Limit 29 97 mm 1 18 in x If any crankpin has worn past the service limit replace the crankshaft with a new one x If the measured crankpin diameters are not less than the service limit but do not coincide with the original diameter markings on the crankshaft make new marks on it Crankpin Diameter Marks None 29 984 29 994 mm 1 1805 1 1809 in O 29 995 30 000 mm 1 1809 1 1811 in o Crankpin Diameter Marks O mark or no mark 6105051BS1 9 18 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods e Measure the connecting rod big end bore diameter and mark each connecting rod big end in accordance with the bore diameter e Tighten the big end nuts to the specified torque see Con necting Rod Installation NOTE OThe mark already on the big end should almost coincide with the measurement because of little wear Connecting Rod Big End Bore Diameter Marks None 33 000 33 008 mm 1 2992 1 2995 in O 33 009 33 016 mm 1 2996 1 2998 in Big End Cap A Connecting Rod B Weight Mark Alphabet C Diameter Mark Around Weight Mark D O or no mark e Select the proper bearing insert A in accordance with the combination of the connecting rod and crankshaft coding Size Color B Con rod Bid Crankpin Bearing Insert End Bore Diameter Diameter Marking Size Color Part Number None Brown 92028 1494 None Black 92028 1493 O O O None Blue 92028 1492
265. s B e First tighten down the chain guide A and bearing caps B evenly to seat the camshafts in place then tighten all bolts following the specified tightening sequence Torque Camshaft Cap Bolts 12 N m 1 2 kgf m 106 in Ib Plates EX C Plates IN D e Install the camshaft chain tensioner see Camshaft Chain Tensioner Installation e Check the chain timing e Finally inject A engine oil into 8 places on the cylinder head as shown St Wae SAN ESO Hri VAR e NEO E en nf 0 GE11267BS1 GE11268BS1 GE11274BS1 GE11269BS1 GE11276BS1 ENGINE TOP END 5 19 Camshaft Camshaft Chain Camshaft and Sprocket Assembly e Install the cam sprockets as shown in figure Exhaust Cam Sprocket A Inlet Cam Sprocket B e Apply a non permanent locking agent to the camshaft sprocket bolts and tighten them Torque Camshaft Sprocket Bolts 15 N m 1 5 kgf m 11 ft lb x If a new camshaft is to be used apply a thin coat of a molybdenum disulfide grease to the cam surfaces NOTE OThe exhaust camshaft has a groove A and the inlet camshaft has no groove Be careful not to mix up these shafts Camshaft and Camshaft Cap Wear Inspection e Remove Camshaft Top Guide Camshaft Caps e Cut the strips of plastigauge to journal parallel to the camshaft installed in the correct position e Measure each
266. s are securely connected and clamps are tightened correctly Torque Radiator Hose Clamp Screws 1 5 N m 0 15 kgf m 13 in lb Coolant Filter Cleaning Australia Model e Remove the fuel tank see Fuel Tank Removal in the Fuel System chapter e Drain the coolant see Coolant Change e Remove the filter A from the water hoses B of carbure tor system e Blow off dirt and sediment on the filter with compressed air Filter Body C Water Pipe D Coolant Valve Assy E Water Pump F Carburetor G Damper H Air Suction System Air Suction System Damage Inspection e Pull the vacuum switch valve hose A out of the air cleaner 6S06005BS1 65070210 P 2 22 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Start the engine and run it at idle speed e Plug A the vacuum switch valve hose end with your fin ger and feel vacuum pulsing in the hose x If there is no vacuum pulsation check the hose line for leak If there is no leak check the vacuum switch valve or air suction valve see Engine Top End chapter Engine Top End Valve Clearance Inspection NOTE OValve clearance must be checked and adjusted when the engine is cold room temperature e Remove Cylinder Head Cover see Cylinder Head Cover Re moval in the Engine Top End chapter Left Lower Fairing see Lower Fairing Removal in the Frame chapter e Unscrew the two plugs A B on the alternator cover Special Tool Fi
267. s not flash inspect or replace the following item Turn Signal Light Bulb see Turn Signal Light Bulb Re placement in the Electrical System chapter Meter Unit for Turn Signal Light Indicator Light see Me ter Unit Inspection in the Electrical System chapter Turn Signal Relay Fuse 10 A see Fuse Inspection in the Electrical System chapter Turn Signal Switch see Switch Inspection in the Electri cal System chapter Turn Signal Relay see Turn Signal Relay Inspection in the Electrical System chapter Harness see Wiring Inspection in the Electrical System chapter e Push the turn signal switch e The turn signal lights and indicator light should go off x If the light does not go off inspect or replace the following item Turn Signal Switch see Switch Inspection in the Electri cal System chapter Turn Signal Relay see Turn Signal Relay Inspection in the Electrical System chapter Third Step e Set the dimmer switch A to low beam position e Start the engine e The low beam headlight should go on x If the low beam headlight does not go on inspect or re place the following item Headlight Low Beam Bulb see Headlight Bulb Replace ment in the Electrical System chapter Headlight Fuse 10 A see Fuse Inspection in the Electri cal System chapter Dimmer Switch see Switch Inspection in the Electrical System chapter Headlight Relay see Relay Circuit Inspection in the Electrical System chapter Harness see Wiring Inspection
268. se Damage and Installation Condition Inspection in the Periodic Maintenance chapter see Brake Hose Damage and Installation Condition Inspec tion in the Periodic Maintenance chapter SUSPENSION 13 1 Suspension Table of Contents Exploded WE 13 2 ee de TEE 13 4 Special TOS ii aia 13 5 A RN 13 7 Front ForK ne RE 13 7 Front Fork Installation each Tork leg ga es an rennes 13 7 Front Er cl ni tes nn ne te ETT 13 8 Front Fork Disassembly se td anna A At ak 13 9 Front FOTKCASSOMDIV E 13 10 Inner Tube Outer Tube Inspection oooooicicniciniccnnccnccconoconcnononnnnnnncnnnnnnncnnn cnn nr nnnnnnnrrnnnnnnnn 13 11 FOr Spring INSPECHON xiii A A AA 13 11 Oil Seal Dust Seal Inspection sis 13 11 Rear Shock ADSOMDE E ssl ee ANERER Bee 13 12 Spring Preload Adjustment coco oa 13 12 Rear Shock Absorber Removal ss 13 12 Rear Shock Absorber Installation nen ennenen 13 13 Rear Shock Absorber Scrapping occocccncccncccociconicononnnonnncnnn cnn nr rn rr rr rre 13 13 O 13 14 SWINGAMTD ue EE 13 14 Swingarm Installato EE 13 14 Swingarm Bearing REMOVAl iii dant A eau 13 15 Swingarm Bearing Re EE e E 13 15 Swingarm Bearing Sleeve Inspection su 13 15 Swingarm LUbricat N EE Chain Guide Inspection Mo APP Tie rods Removal see eienenn A EENS EEN ENEE NEEN Fie Rod Installations A A a ee is A NA Rocker Arm Installation Tie rod Rocker Arm Bushing Inspection ss 13 17 Tie rod
269. se they will deteriorate the rubber OThe air valve is shown in the figure A Valve Cap B Valve Core C Stem Seal D Valve Stem E Valve Seat F Valve Opened GJ05026BS1 GJ05030781 10 14 WHEELS TIRES Tires e Apply a soap and water solution or rubber lubricant to the rim flange and tire beads e Check the tire rotation mark on the front and rear tires and install them on the rim accordingly Tire Rotation Mark A Rotating Direction B e Position the tire on the rim so that the air valve A is at the tire balance mark B the chalk mark made during removal or the yellow paint mark on a new tire e By hand slide as much as possible of the lower side of the tire bead over the rim flange starting at the side opposite the valve e Fit the rim protectors and tire irons to install the remaining part of the tire bead which cannot be installed by hand For easy tire installation position the parts of the bead which is already over the rim flange in the rim well NOTE OTo prevent rim damage be sure to place the rim protec tors at any place the tire irons are applied e Install the other side of the tire bead onto the rim in the same manner e Lubricate the tire beads and rim flanges with a soap and water solution or rubber lubricant to help seat the tire beads in the sealing surfaces of the rim while inflating the tire e Center the rim in the tire beads and inflate
270. sher 57001 1720 8757172097 Clean Air System ENGINE TOP END 5 11 Vacuum Switch Valve Removal e Remove Fuel Tank see Fuel Tank Removal in the Fuel System Chapter Vacuum Switch Valve Hose Ends A Vacuum Switch Valve B Vacuum Switch Valve Installation e Install the vacuum switch valve so that the vacuum hose fitting A faces downwards see Cable Wire and Hose Routing in the Appendix chapter NOTE OThis hose fitting B side is plugged Vacuum Switch Valve Operation Test e Refer to Air Suction System Damage Inspection in the Periodic Maintenance chapter see Air Suction System Damage Inspection in the Periodic Maintenance chapter Vacuum Switch Valve Unit Test e Remove the fuel tank see Fuel Tank Removal in the Fuel System chapter ODo not remove the vacuum switch valve e Connect a vacuum gauge A and syringe B or the fork oil level gauge to the vacuum hose as shown Special Tool Fork Oil Level Gauge 57001 1290 Air Flow C e Gradually raise the vacuum lower the pressure applied to the vacuum switch valve and check the valve opera tion When the vacuum is low the vacuum switch valve should permit air to flow When the vacuum is raised to valve closing pressure the valve should stop air flow Spring A Diaphragm B Valve C Low Vacuum D Secondary Air Flow E GE04081BS1 5 12 ENGINE TOP END Clean Air System x If the vacuum swi
271. sing the engine to warm up more quickly When coolant temperature is more than 63 5 66 5 C 146 152 F the thermostat opens and the coolant flows When the coolant temperature goes up beyond 96 100 C 205 212 F the radiator fan switch conducts to operate the radiator fan The radiator fan draws air through the radiator core when there is not sufficient air flow such as at low speeds This increases up the cooling action of the radiator When the temperature is below 91 C 196 F the fan switch opens and the radiator fan stops In this way this system controls the engine temperature within narrow limits where the engine op erates most efficiently even if the engine load varies The system is pressurized by the radiator cap to suppress boiling and the resultant air bubbles which can cause engine overheating As the engine warms up the coolant in the radiator and the water jacket expands The excess coolant flows through the radiator cap and hose to the reserve tank to be stored there temporarily Conversely as the engine cools down the coolant in the radiator and the water jacket contracts and the stored coolant flows back to the radiator from the reserve tank The radiator cap has two valves One is a pressure valve which holds the pressure in the system when the engine is running When the pressure exceeds 93 123 kPa 0 95 1 25 kgf cm 14 18 psi the pressure valve opens and releases the pressure to the reserve tank As soon
272. spilled fuel must be completely wiped up immediately e Remove the side covers see Side Covers Removal in the Frame chapter e Turn the fuel tap position to the ON A position e Remove Front Seat see Front Seat Removal in the Frame chap ter Lower Fairings see Lower Fairing Removal in the Frame chapter Fuel Tank Mounting Bolts A Fuel Hose B Vacuum Hose C Fuel Level Sensor Connector D Fuel Tank e Drain the fuel tank if necessary OArrange a suitable container under the fuel tap OTurn the fuel tap position to the PRI position to drain the fuel into the container Fuel Tank Installation e Read the above WARNING mentioned in Fuel Tank Re moval e Route the hose correctly e Be sure the hoses are clamped securely to prevent fuel leaks e Be sure the rubber dampers A are in position If any dampers is damaged or deteriorated replace it FUEL SYSTEM 3 27 Fuel Tank Fuel Tap 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 the fuel tank see Fuel Tank Removal e Drain the fuel into a suitable container e Remove the bolts A and take out the fuel tap B Fuel Tap Installation e Fuel tap installation is the reverse of removal Note th
273. stall the ignition coil as shown both sides Ignition Coil Right Side A Bolt B Washer C Nut D Washer E 0 3 mm 0 12 in F Ignition Coil Inspection e Remove the ignition coil see ignition Coil Removal e Measure the arcing distance with the suitable commer cially available coil tester B to check the condition of the ignition coil A 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 A WARNING To avoid extremely high voltage shocks do not touch the coil body or leads x If the distance reading is less than the specified value the ignition coil or spark plug cap is defective Ignition Coil Arcing Distance Standard 7 mm 0 28 in or more e To determine which part is defective measure the arcing distance again with the spark plug cap removed from the ignition coil Remove the cap by turning it counterclock wise 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 lf the coil tester is not available the coil C can be checked for a broken or badly shorted winding with the hand tester special tool Special Tool Hand Tester 57001 1394 NOTE OThe hand tester cannot detect layer shorts and shorts resulting from insulation
274. ston e Remove the piston pins Special Tool Piston Pin Puller Assembly 57001 910 A e Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring A to remove it e Remove the 3 piece oil ring with your thumbs in the same manner Piston Installation NOTE Olf a new piston is used use a new piston ring e Install the piston with its marking hollow facing forward e Fit a new piston pin snap ring into the side of the piston so that the ring opening A does nat coincide with the slit B of the piston pin hole OWhen installing the piston pin snap ring compress it only enough to install it and no more CAUTION Do not reuse snap rings as removal weakens and deforms them They could fall out and score the cylinder wall GE16158BS1 GE16159BS1 6E16041BS1 5 34 ENGINE TOP END Cylinder Pistons 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 NOTE OThe oil ring rails have no top or bottom e Do not mix up the top and second ring e Install the top ring A so that the R mark B faces up e Install the second ring C so
275. ston Ring Groove Clearance Standard Top 0 03 0 07 mm 0 0012 0 0028 in Second 0 02 0 06 mm 0 0008 0 0024 in Service Limit Top 0 17 mm 0 0067 in Second 0 16 mm 0 0063 in Piston Ring Groove Width Inspection e Measure the piston ring groove width OUse a vernier caliper at several points around the piston Piston Ring Groove Width Standard Top 0 82 0 84 mm 0 0323 0 0331 in Second 0 81 0 83 mm 0 0319 0 0327 Oil 1 51 1 53 mm 0 0594 0 0602 in Service Limit Top 0 92 mm 0 0362 in Second 0 91 mm 0 0358 in Oil 1 61 mm 0 0634 in x If the width of any two grooves is wider than the service limit at any point replace the piston Piston Ring Thickness Inspection e Measure the piston ring thickness OUse the micrometer to measure at several points around the ring Piston Ring Thickness Standard Top 0 77 0 79 mm 0 0303 0 0311 in Second 0 77 0 79 mm 0 0303 0 0311 in Service Limit Top 0 70 mm 0 028 in Second 0 70 mm 0 028 in x If 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 perfectly parallel to the groove sides If not replace the piston GE16163BS1 5 36 ENGINE TOP END Cylinder Pistons Piston Ring End Gap Inspection e Place the piston ring A inside the cylinder using the pis ton t
276. t OE i SS BR BR o BR BR BK 2 p BK Y BK Y LG BK L6 BK GP17997BW3 C Ignition Switch Fuel Gauge Fuse Box 10 A Ignition Fuse Fuel Level Sensor Battery 30 A Main Fuse Starter Relay 0 JO O1 P Gabi A ELECTRICAL SYSTEM 16 61 Switches and Sensor Radiator Fan Switch Inspection e Remove the fan switch e Suspend the switch A in a container of coolant so that the temperature sensing projection and threaded portion are submerged e Suspend an accurate thermometer B in the coolant so that the sensitive portions C are located in almost the same depth NOTE OThe switch and thermometer must not touch the con tainer sides or bottom e Place the container over a source of heat and gradu ally raise the temperature of the coolant while stirring the coolant gently e Using the hand tester measure the internal resistance of the switch across the terminals at the temperatures shown in the table Special Tool Hand Tester 57001 1394 x If the hand tester does not show the specified values re aP18020252 place the switch Fan Switch Resistance ORising temperature From OFF to ON at 95 101 C 196 203 F OFalling temperature From ON to OFF within 3 8 C 37 46 F of ON temperature ON Less than 0 5 Q OFF More than 1 MQ Water Temperature Switch Inspection e Remove the water temperature switch e Suspend the switch
277. t 0 33 mm 0 013 in H If We ps GE15170BS1 GE150306 S GE15010481 Valves ENGINE TOP END 5 27 Valve Seat Inspection e Remove the valve see Valve Removal e Check the valve seating surface A between the valve B and valve seat C OMeasure the outside diameter D of the seating pattern on the valve seat x If the outside diameter is too large or too small repair the seat see Seat Repair Valve Seating Surface Outside Diameter Standard Inlet 21 9 22 1 mm 0 8622 0 8701 in Exhaust 19 3 19 5 mm 0 7598 0 7677 in OMeasure the seat width E of the portion where there is no build up carbon white portion of the valve seat with a vernier caliper Good F x If the width is too wide G too narrow H or uneven J repair the seat see Valve Seat Repair Valve Seating Surface Width Standard Inlet Exhaust 0 5 1 0 mm 0 0197 0 0394 in Valve Seat Repair e Repair the valve seat with the valve seat cutters A Special Tools Valve Seat Cutter Holder 44 5 57001 1330 B Valve Seat Cutter Holder Bar 57001 1128 C For Inlet Valve Seat Valve Seat Cutter 45 624 5 57001 1113 Valve Seat Cutter 32 625 57001 1118 Valve Seat Cutter 67 5 622 57001 1207 For Exhaust Valve Seat Valve Seat Cutter 45 624 5 57001 1113 Valve Seat Cutter 32 p22 57001 1206 Valve Seat Cutter 67 5 622 57001 1207 If the manufacturer s
278. t 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 TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below e Replacement of the original exhaust system or muffler with a component not in compliance with Federal regulations e Removal of the muffler s or any internal portion of the muffler s e Removal of the air box or air box cover e Modifications to the muffler s or air
279. t with Ignition Coils e Remove Cylinder Head Cover Camshafts Rear Camshafts Chain Guide Bolt Lower A and Chain Guide B Front Camshaft Chain Guide C e Pull out the water pipe e Remove the 6 mm cylinder head bolt A first then remove the 8 mm cylinder head bolts e Remove the oil hose banjo bolt B e Before removing the cylinder head hold the carburetor to the air cleaner ducts securely Cylinder Head Installation NOTE OThe camshaft cap is machined with the cylinder head so if a new cylinder head is installed use the cap that is supplied with the new head e Install the pin and new cylinder head gasket e Apply molybdenum disulfide oil to the both sides A of the 8 mm cylinder head bolt washers GE14117BS1 Cylinder Head ENGINE TOP END 5 23 e Tighten the 8 mm cylinder head bolts 1 7 following the tightening sequence Torque Cylinder Head Bolts 24 5 N m 2 5 kgf m 18 ft lb e Tighten the 6 mm cylinder head bolt 8 following the tight ening sequence Torque Cylinder Head Bolts 12 N m 1 2 kgf m 106 in Ib e After cylinder head installation install the front camshaft chain guide A e Tighten the rear camshaft chain guide bolt lower B to the specified torque e Tighten the oil hose banjo bolt to the specified torque Torque Camshaft Chain Guide Bolt lower 17 N m 1 7 kgf m 13 ft lb Oil Hose Banjo Bolt 19 6 N m 2 0 kgf m 14 5 ft Ib Cylinde
280. tallations non cnn A A E aR Stater Coil REMOVA AEE AE A E AEA E Stator Coil Installation e aio Alternator Rotor Removal see Alternator Rotor Installation s sena a a a Alternator Inspection Regulator Rectifier Inspection rene EP Re het Daca Gaal na she atenlex Charging Voltage Spec WEE TE ignition SM EE Crankshaft Sensor HRemoval see Crankshaft Sensor Installation nnnneneenneeeneeeseeeeeeerrerrrerrrrrrtrrrtrrttrrttrrttrrttertrrtererteer ent Crankshaft Sensor Inspection Crankshaft Sensor Peak Voltage Inspection Ignition Coil E E Ignition Col MSTA AMON ss nee nent lobe Din ad Er dE ie cit ts Ne Ignition COMMIS DOCU ON fascist tente Po Mme Heed eae gi nl d un nn em a iads Ignition Coil Primary Peak Voltage decsasecsssecheccztdeceetscshiccseseeteasetiacedensedeabe Spark Nu EE Spark Plug Install PM AER ege ao Spark Plug Condition Inspection ss a WEE IC Igniter Operation Inspection ooooooniinncccnnccnccnnccnncnnncnnnccnnnnnnnnnnnnnnonnnnnnnnnnn rr rn rr nnrrnnnnnnns Diodes Ieper ere ii ida Electric Starter sie Mic EE Seele Starter Motot R mOValii sentier eccwoestonagutbcanemeer einen eran e aa a A a EEA Starter Motor Installaton see Starter Motor Disassem Bly EE Starter Motor Assembly EE Carbon Brush Inspection sise Commutator Inspection Cleaning ss eu ET e e EE 16 2 ELECTRICAL SYSTEM Starter SY DEE 16 45 Brush e H ee EE 16 45 Terminal Bolt Inspechon a a Eea
281. tch valve does not operate as described replace it with a new one NOTE OTo check air flow through the vacuum switch valve just blow through the vacuum switch hose C Vacuum Switch Valve Closing Pressure Open Close Standard 41 3 49 3 kPa 310 370 mmHg High Vacuum A Secondary air cannot flow B Air Suction Valve Removal e Remove Fuel Tank see Fuel Tank Removal in the Fuel System chapter Vacuum Switch Valve see Vacuum Switch Valve Re moval e Unscrew the bolts A and remove the air suction valve covers B Air Suction Valve Installation e Install the air suction valve A so that its reed opening side B faces backwards Torque Air Suction Valve Cover Bolts 9 8 N m 1 0 kgf m 87 in lb Air Suction Valve Inspection e Remove the air suction valve see Air Suction Valve Re moval e Visually inspect the reeds for cracks folds warps heat damage or other damage x If there is any doubt as to the condition of the reeds A replace the air suction valve as an assembly e Check the reed contact areas B of the valve holder for grooves scratches any signs of separation from the holder or heat damage e If there is any doubt as to the condition of the reed contact areas replace the air suction valve as an assembly e If any carbon or other foreign particles have accumulated between the reed and the reed contact area wash the valve assembly clean with a high flash point solvent CAUTION
282. ted crankcase emis sion 1 and exhaust emission 2 control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board Addi tionally Kawasaki has incorporated an evaporative emission control system 3 in compliance with applicable regulations of the California Air Resources Board on vehicles sold in California only 1 Crankcase Emission Control System This system eliminates the release of crankcase vapors into the atmosphere Instead the vapors are routed through an oil separator to the inlet side of the engine While the engine is operating the vapors are drawn into combustion chamber where they are burned along with the fuel and air supplied by the fuel injection system 2 Exhaust Emission Control System This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this motorcycle The fuel ignition and exhaust systems of this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels The exhaust system of this model motorcycle manufactured primarily for sale in California in cludes a catalytic converter system 3 Evaporative Emission Control System Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere In stead fuel vapors are routed into the running engine to be burned or stored in a canister when the engine is stopped
283. ted in the adjuster at the clutch lever or it could slip into place later creating enough cable play to prevent clutch disengagement e After the adjustment start the engine and check that the clutch does not slip and that it releases properly PERIODIC MAINTENANCE 2 27 Periodic Maintenance Procedures Wheels Tires Air Pressure Inspection e Remove the air valve cap e Measure the tire air pressure with an air pressure gauge A when the tires are cold that is when the motorcycle has not been ridden more than a mile during the past 3 hours e Install the air valve cap Adjust the tire air pressure according to the specifications if necessary Air Pressure when Cold Front Up to 170 kg 375 Ib 200 kPa 2 00 kgf cm 28 psi Rear Up to 170 kg 375 Ib 225 kPa 2 25 kgf cm 32 psi Wheel Tire Damage Inspection e Remove any imbedded stones A or other foreign parti cles B from tread e Visually inspect the tire for cracks and cuts and replace the tire if necessary Swelling or high spots indicate inter nal damage requiring tire replacement e Visually inspect the wheel for cracks cuts and dents dam age If any damage is found replace the wheel if necessary Tire Tread Wear Abnormal Wear Inspection As the tire tread wears down the tire becomes more sus ceptible to puncture and failure An accepted estimate is that 90 of all tire failures occur during the last 10 of tread
284. tem chapter Water Temperature Switch Lead Connector A Water Temperature Switch B Radiator Fan Switch Water Temperature Switch Installation e Apply silicone sealant to the threads of the water temper ature switch Sealant Kawasaki Bond Silicone Sealant 56019 120 e Tighten the fan switch and water temperature sensor Torque Radiator Fan Switch 23 5 N m 2 4 kgf m 17 ft lb Water Temperature Switch 7 5 N m 0 76 kgf m 66 in Ib e Fill the coolant and bleed the air from cooling system see Coolant Change in the Periodic Maintenance chapter Radiator Fan Switch Water Temperature Switch Inspection e Refer to Water Temperature Switch Inspection in the Elec trical System chapter see Water Temperature Switch In spection in the Electrical System chapter ENGINE TOP END 5 1 Engine Top End Table of Contents Exploded View 5 2 Cylinder Head Removal 5 22 Exhaust System 5 6 Cylinder Head Installation 5 22 Specifications 5 7 Cylinder Head Warp Inspection 5 23 Sp cial TOONS 2 inner 5 9 Cylinder Head Cleaning 5 24 Clean Air Gvstem 5 11 NEE sich ds nie ne Eee 5 25 Vacuum Switch Valve Removal 5 11 Valve Clearance Inspection 5 25 Vacuum Switch Valve Installation 5 11 Valve Clearance Adjustment 5 25 Vacuum Switch Valve Operation Valve Removal 5 25 KEEN 5 11 Valve Installation 5 25
285. ter 14 6 STEERING Steering Stem Steering Stem Stem Bearing Removal e Remove Front Seat see Front Seat Removal in the Frame chap ter Lower Fairings see Lower Fairing Removal in the Frame chapter Fuel Tank see Fuel Tank Removal in the Fuel System chapter Steering Stem Head Bolt Steering Stem Head with Handlebars Front Wheel see Fuel Wheel Removal in the Wheels Tires chapter Front Fender see Front Fender Removal in the Frame chapter Front Fork see Front Fork Removal in the Suspension chapter e Pushing up the stem base by the hand and remove the steering stem nut A stem cap B and then remove the steering stem C Special Tool Steering Stem Nut Wrench 57001 1100 D NOTE OBe aware of removing the steering stem so that the stem bearing steel balls are not lost e Remove the upper ball bearing inner race e Remove the upper and lower outer races using the outer race remover A Special Tool Oil Seal amp Bearing Remover 57001 1058 NOTE Olf either stem bearing is damaged it is recommended that both the upper and lower bearings including the outer races should be replaced with new ones e Remove the lower bearing inner race A with its grease seal which is pressed onto the steering stem using the bearing puller B and adapter C Special Tools Bearing puller 57001 158 Bearing Puller Adapter 57001 317 GNO7O15BS1 GNO7030281 Steering Stem STE
286. ter 13 Sidestand Switch ELECTRICAL SYSTEM 16 41 Electric Starter System Starter Motor Removal e Remove the lower fairings see Lower Fairing Removal in the Frame chapter e Disconnect the starter motor lead A from the starter mo tor C e Remove the starter mounting bolts B and pull out D the starter motor toward the left side AR Se PB P Starter Motor Installation e Clean the starter motor lugs A and crank case surface B where the starter motor is grounded 16 42 ELECTRICAL SYSTEM Electric Starter System e Apply a small amount of engine oil to the O ring A e Put the starter motor on the crankcase e Press the part of the starter motor end cover and push the starter motor into the crankcase hole e Tighten the starter motor mounting bolts e Connect the starter motor lead to the starter motor termi nal e Install Starter Idle Gear Alternator Cover Engine Sprocket Cover Shift Lever Water Pipes Starter Motor Disassembly e Remove the starter motor see Starter Motor Removal e Remove the bolts A and take out both end covers B e Take the armature off from the pinion gear side of the yoke e Remove the terminal locknut A and washers and then remove the brush and terminal bolt B with the brush plate C from the yoke Starter Motor Assembly e Replace the O rings with a new ones e Apply a thin coat of high temperature grease to the oil seal A and needle bearing B
287. the Periodic Maintenance chapter Drive Chain Wear Inspection e Refer to Drive Chain Wear Inspection in the Periodic Maintenance chapter see Drive Chain Wear Inspection in the Periodic Maintenance chapter Drive Chain Lubrication e Refer to Drive Chain Lubrication Condition in the Periodic Maintenance chapter see Drive Chain Lubrication Con dition in the Periodic Maintenance chapter Drive Chain Removal e Remove Engine Sprocket Cover Drive Chain Cover Rear Shock Absorber see Rear Shock Absorber Re moval in the Suspension chapter Swingarm Pivot Shaft see Swingarm Removal in the Suspension chapter e Flatten out the bended washer A e Remove the engine sprocket nut B and washer NOTE OWhen loosening the engine sprocket nut hold the rear brake on Drive Chain FINAL DRIVE 11 7 e Raise the rear wheel off the ground e Remove the axle cotter pin and loosen the rear axle nut e Loosen the both chain adjuster locknut to loosen the drive chain e Remove the drive chain from the rear sprocket toward the right e Pull the engine sprocket A with drive chain B off the output shaft C e Disengage the drive chain from the engine sprocket NOTE OThe swingarm may be moved with the rear wheel left installed on it Drive Chain Installation e Replace the sprocket washer and axle cotter pin e Install the engine sprocket onto the shaft the protruding side A of it faces in e Apply molybdenum dis
288. the thermostat with a new one Thermostat Valve Opening Temperature 63 5 66 5 C 146 152 F GD09020282 C Hoses and Pipes COOLING SYSTEM 4 17 Hose Installation e Install the hoses and pipes being careful to follow bend ing direction Avoid sharp bending kinking flattening or twisting e Install the clamp A as near as possible to the hose end to clear the raised rib of the fitting This will prevent the hoses from working loose OThe clamp screws should be positioned correctly to pre vent the clamps from contacting anything Torque Water Hose Clamp Screws 1 5 N m 0 15 kgf m 13 in 1b Hose Inspection e Refer to Radiator Hose and Connection Inspection in the Periodic Maintenance chapter see Radiator Hose and Connection Inspection in the Periodic Maintenance chap ter ZZA RSS SD GD10010181 4 18 COOLING SYSTEM Radiator Fan Switch Water Temperature Switch Radiator Fan Switch Water Temperature Switch Removal CAUTION The fan switch or the water temperature switch should never be allowed to fall on a hard surface Such a shock to their parts can damage them e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove Radiator Fan Switch Lead Connector A Radiator Fan Switch B Front Seat see Front Seat Removal in the Frame chap ter Fuel Tank see Fuel Tank Removal in the Fuel Sys
289. the tire with compressed air until the tire beads seat in the sealing surfaces A WARNING Be sure to install the valve core whenever inflating the tire and do not inflate the tire to more than 400 kPa 4 0 kgf cm 57 psi Overinflation can explode the tire with possibility of injury and loss of life GJO5005BS1 Tires WHEELS TIRES 10 15 e Check to see that the rim lines A on both sides of the tire sidewalls are parallel with the rim flanges x If the rim flanges and tire sidewall rim lines are not parallel remove the valve core e Lubricate the rim flanges and tire beads e Install the valve core and inflate the tire again e After the tire beads seat in the rim flanges check for air leakage Olnflate the tire slightly above standard inflation OUse a soap and water solution or submerge the tire and check for bubbles that would indicate leakage e Adjust the air pressure to the specified pressure see Wheels Tires in the Periodic Maintenance chapter e Install the brake disc s so that the marked side faces out see Brake Disc Installation in the Brakes chapter e Adjust the wheel balance see Balance Adjustment Tire Repair Currently two types of repair for tubeless tires have come into wide use One type is called a temporary external re pair which can be carried out without removing the tire from the rim and the other type is called permanent internal repair which requires tire remov
290. tifies 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 See Le Le WEE EE Model Identifica ME General Specifications Unit Conversion Table 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
291. ting Bolts D e Using a jack raise the front wheel off the ground e Pull the axle and remove the front wheel CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground Front Wheel Installation e Apply a high temperature grease to the grease seal lips e Install the speedometer gear housing to the front wheel e Install the front wheel so that the speedometer gear hous ing stop A fit into the fork leg stops B e Install the speedometer cable so that the drive notch B of it fits into the projection A of the speedometer gear in the housing e Tighten the front axle nut with the specified torque Torque Front Axle Nut 88 N m 9 0 kgf m 65 ft lb WHEELS TIRES 10 7 Wheels Rims e Check the front brake effectiveness see Brake Operation Inspection in the Periodic Maintenance chapter A WARNING Do not attempt to drive the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc The brake will not function on the first application of the lever if this is not done Rear Wheel Removal e Remove Axle Nut Cotter Pin A Axle Nut B and Washer C Chain Locknuts Loosen D and Adjusting Nuts E Axle F Alignment Indicators G e Remove Rear Caliper Mounting Bolts A Rear Caliper B
292. tle grip free play A x If the free play is incorrect adjust the throttle cable Throttle Grip Free Play Standard 2 3 mm 0 08 0 12 in 2 16 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Loosen the locknut A and screw accelerator cable ad juster B in completely so as to give the throttle grip plenty of play e Turn the accelerator cable adjuster until 2 3 mm 0 08 0 12 in of throttle grip play is obtained e Tighten the locknut x If the throttle cables can not be adjusted by using the ca ble adjuster at the upper end of the throttle cable use the cable adjusters at the lower ends of the throttle cables e Remove Side Cover see Side Cover Removal in the Frame chap ter Right Lower Fairing see Lower Fairing Removal in the Frame chapter e To make service easy unscrew the reserver tank bolts and remove the reserver tank with hoses e Turn out both upper nuts A and turn in both lower nuts B as far as they will go so as to give the throttle grip plenty of play e With the throttle grip completely closed turn out the lower nut and turn in the upper nut of the decelerator cable C until the inner cable just becomes tight e Turn out the lower nut and turn in the upper nut of the accelerator cable D until the correct free play is obtained e Check that the throttle linkage lever A stops against the idle adjusting screw B with the throttle grip closed PERIODIC MAINTENA
293. to the specified torque hook the wrench on the stem nut and pull the wrench at the hole by 84 N 8 3 kg B force in the direc tion shown 1 OTighten the steering stem nut with specified torque using a special tool A OCheck that there is no play and the steering stem turns smoothly without rattles If not the steering stem bearing may be damaged OAgain back out the stem nut a fraction of turn until it turns lightly e Turn the stem nut lightly clockwise until it just becomes hard to turn Do not overtighten or the steering will be too tight Special Tool Steering Stem Nut Wrench 57001 1100 A Torque Steering Stem Nut 4 9 N m 0 5 kgf m 43 in Ib e Adjust the steering see Steering Play Inspection in the Periodic Maintenance chapter e Install the front fork see Front Fork Installation Suspen sion chapter NOTE OTighten the fork upper clamp bolts first next the stem head bolt last the fork lower clamp bolts Torque Steering Stem Head Bolt 44 N m 4 5 kgf m 32 ft Ib Front Fork Clamp Bolts Upper 20 N m 2 0 kgf m 14 5 ft Ib Front Fork Clamp Bolts Lower 30 N m 3 1 kgf m 22 ft lb e Install Front Fender Front Wheel see Front Wheel Installation in the Wheel Tires chapter Fuel Tank see Fuel Tank Installation in the Fuel System chapter Lower Fairings see Lower Fairing Installation in the Frame chapter Front Seat see Front Seat Installation in the Frame chapter e Route the cables an
294. uble Fuel air mixture incorrect Pilot screw maladjusted Pilot jet or air passage clogged Air bleed pipe bleed holes clogged Pilot passage clogged Air cleaner clogged poorly sealed or ele ment missing Choke plunger stuck open Fuel level in carburetor float bowl 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 Troubleshooting Guide No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head warped Cylinder head gasket damaged Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Other IC igniter trouble Carburetor not synchronizing Vacuum piston doesn t slide smoothly Engine oil viscosity too high Drive train trouble Brake dragging Poor Running or No Power at High Speed Firing incorrect Spark plug dirty broken or maladjusted Spark plug cap shorted or not in good con tact Spark plug incorrect IC igniter trouble Crankshaft sensor trouble Ignition coil trouble Fuel air mixture incorrect Choke plunger stuck open Main jet clogged or wrong size Jet needle or needle jet worn Air jet clogged Fuel level in carburetor float bowl too high or too low Bleed holes of needle jet holder or needle jet clogged Air cl
295. uffler Body Clamp Bolt 17 1 7 13 Muffler Cover Bolts 9 8 1 0 87 in lb Muffler Cover Clamp Screw 6 9 0 70 61 in lb Exhaust Pipe Mounting Bolt 9 8 1 0 87 in lb Exhaust Pipe Holder Nuts 12 1 2 104 mb Clutch Clutch Lever Holder Clamp Bolts 78 in lb Clutch Spring Bolts S 78 in lb Clutch Hub Nut 97 4 Oil Filler Plug Hand Tighten Clutch Cover Bolts 87 in lb Engine Lubrication System Oil Hose Banjo Bolts E 14 5 Oil Pressure Relief Valve 11 Crankcase Oil Passage Plug 11 Oil Passage Plugs for Oil Pump 15 Oil Pipe Banjo Bolts 104 mb Oil Drain Bolt 14 5 Oil Pressure Switch 11 Oil Pressure Switch Terminal Bolt 13 in lb Oil Filter Mounting Bolts 14 5 Oil Breather Mounting Bolts d 87 in lb Oil Pump Mounting Bolts 87 in lb Oil Screen Cover Bolts 87 in lb Plug E 14 5 Breather Bolt 87 in lb Engine Removal Installation Engine Mounting Bracket Bolts and Nuts 47 Engine Mounting Nuts 47 Crankshaft Transmission Oil Breather Mounting Bolts 87 in lb Crankcase Bolts d 104 mb Crankcase Bolts 8 L 90 A 18 2 8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Nm kgfm SC Remarks Crankcase Bolts 8 L 73 19 1 9 14 MO S Starter Motor Clutch Bolts 34 3 3 5 25 L Connecting Rod Big End Cap Nuts 27 5 2 8 20 MO Shift Drum Bearing Holder Bolt 12 1 2 104 in lb L Shift Drum Pin Plate Bolt 9 0 0 9 80 in lb L Neutral Switch 15 1 5 11 External Shift
296. uld have the same weight mark Big End Cap A Connecting Rod B Weight Mark Alphabet C Diameter Mark Around Weight Mark D O or no 6105060151 mark CAUTION If the connecting rods big end bearing inserts or crankshaft are replaced with new ones select the bearing insert and check clearance with a plasti gage press gauge before assembling engine to be sure the correct bearing inserts are installed CAUTION The connecting rod bolts are designed to stretch when tightened Never reuse them e Replace the connecting rod big end bolts and nuts with new ones 9 16 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods e Apply molybdenum disulfide oil solution to the inner sur face of upper and lower bearing inserts A e Apply molybdenum disulfide oil solution to the threads B and seating surface C of the connecting rod nuts Torque Connecting Rod Big End Cap Nuts 27 5 N m 2 8 kgf m 20 ft lb Crankshaft Connecting Rod Cleaning e After removing the connecting rods from the crankshaft clean them with a high flash point solvent e Blow the crankshaft oil passages with compressed air to remove any foreign particles or residue that may have accumulated in the passages Connecting Rod Bend Inspection e Remove the connecting rod big end bearing inserts and reinstall the connecting rod big end cap e Select an arbor A of the same diameter as the connect ing rod big en
297. ulfide oil solution to the threads of the output shaft and the seating surface of the engine sprocket nut e After torquing the engine sprocket nut bend the one side of the washer over the nut NOTE OTighten the nut while applying the rear brake Torque Engine Sprocket Nut 127 N m 13 kgf m 94 ft Ib e Adjust the drive chain slack after installing the sprocket see Drive Chain Slack Adjustment in the Periodic Main tenance chapter e Install Swingarm see Swingarm Installation in the Suspension chapter Rear Shock Absorber see Rear Shock Absorber Instal lation in the Suspension chapter Drive Chain Cover Engine Sprocket Cover Torque Rear Shock Absorber Mounting Nuts 59 N m 6 0 kgf m 44 ft lb Swingarm Pivot Nut 98 N m 10 kgf m 72 ft Ib e Adjust the drive chain slack after installing the chain see Drive Chain Slack Inspection in the Periodic Maintenance chapter 11 8 FINAL DRIVE Drive Chain Drive Chain Replacement CAUTION For safety if the drive chain shall be replaced re place it using a recommended tool Recommended Tool Type EK JOINT Tool 50 Brand ENUMA CHAIN Body A Handlebar B Cutting and Riveting Pin C For Cutting D For Riveting E Plate Holder A F Plate Holder B G Gauge H e Remove Chain Cover see Drive Chain Removal Engine Sprocket Cover see Engine Sprocket Removal e Grind A the pin head to make it flat e Set the cutting and rivetting p
298. urn 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 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 67 5 cutter 67 5 F GE15011881 GE15011981 Valves ENGINE TOP END 5 29 e Measure the outside diameter O D of the seating sur face 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 67 5 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 of the seating surface is too large make the 32 grind described below e f the outside diameter A of the seating surface is within the specified range measure the seat width as described below e Grind the seat at a 32
299. urpose increase width of seat area beyond spec to gt increase O D 67 5 Grind Tool 67 5 Cutter Purpose reduce seat width to spec Lap Valve Tool Valve Lapper Grinding Compound Purpose perfectly match valve FINISHED and seat area check valve head for damage GE15057B F 5 32 ENGINE TOP END Cylinder Pistons Cylinder Removal e Remove Cylinder Head see Cylinder Head Removal e Loosen the clamps A and take off the water hose B and pipe C e Remove the cylinder D Cylinder Installation NOTE Olf a new cylinder is used use a new piston ring e Install the pins A and new cylinder gasket B e Apply molybdenum disulfide oil solution to the cylinder bore piston rings and pistons e The piston ring openings must be positioned as shown in the figure The openings of the oil ring steel rails must be about 30 40 of angle from the opening of the top ring A Top Ring B Second Ring C Oil Ring Steel Rail Lower D Oil Ring Steel Rail Upper E Oil Ring Expander F Arrow Mark G 30 40 e Slip the piston base A as shown to hold piston level and install the cylinder Special Tool Piston Base 42 3 57001 1336 im P ENGINE TOP END 5 33 Cylinder Pistons Piston Removal e Remove the cylinder see Cylinder Removal e Place a clean cloth under the pistons and remove the pis ton pin snap ring A from the outside of each pi
300. use Box Ignition Fuse 10 A Starter Relay Main Fuse 30 A Water Temperature Warning Light Oil Pressure Waning Light Diode Water Temperature Switch Oil Pressure Switch Battery zl O O1 P Gah A ch Switches and Sensor ELECTRICAL SYSTEM 16 59 Brake Light Timing Inspection e Refer to Brake Light Switch Operation Inspection in the Periodic Maintenance chapter Brake Light Timing Adjustment e Refer to Brake Light Switch Operation Inspection in the Periodic Maintenance chapter Switch Inspection e Using a hand tester check to see that only the con nections shown in the table have continuity about zero ohms OFor the handlebar switches and the ignition switch refer to the tables in the Wiring Diagram x If the switch has an open or short repair it or replace it with a new one Special Tool Hand Tester 57001 1394 Rear Brake Light Switch Connections Color BR BL When brake pedal is pushed down OO When brake pedal is released Side Stand Switch Connections Color G BK When side stand is down Neutral Switch Connections Color SW Terminal Ground When transmission is in neutral O o When transmission is not in neutral Oil Pressure Switch Connections Color BK Ground When engine is running Engine lubrication system is in good condition 16 60 ELECTRICAL SYSTEM Switches and Sensor Fuel Gauge Circui
301. ve the radiator bolts C and take the radiator D off the frame e Separate the filler and water hose from the radiator e Separate the radiator fan A from the radiator Radiator Fan Screws B CAUTION Do not touch the radiator core This could damage the radiator fins resulting in loss of cooling effi ciency Radiator Radiator Fan COOLING SYSTEM 4 13 Radiator Inspection e Check the radiator core x If there are obstructions to air flow remove them xlf the corrugated fins A are deformed carefully straighten them x If the air passages of the radiator core are blocked more than 20 by unremovable obstructions or irreparably de formed fins replace the radiator with a new one Radiator Cleaning CAUTION When cleaning the radiator with steam cleaner be careful of the following to prevent radiator damage Keep the steam gun A away more than 0 5 m 1 6 ft B from the radiator core Hold the steam gun perpendicular to the core sur face Run the steam gun following the core fin direction Radiator Cap Inspection e Remove the right lower fairing see Lower Fairing Re moval in the Frame chapter e Check the condition of the top and bottom valve seals A and valve spring B x If any one of them shows visible damage replace the cap with a new one e Install the cap A on a cooling system pressure tester B NOTE OWet the cap sealing surfaces with water or coola
302. vent cleaned threads Basic Torque for General Fasteners Threads Torque dia mm N m kgf m ft lb 5 3 4 4 9 0 35 0 50 30 43 in lb 6 5 9 7 8 0 60 0 80 52 69 in Ib 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 Specifications PERIODIC MAINTENANCE 2 11 Item Standard Service Limit Fuel System Throttle Grip Free Play Idle Speed Carburetor Synchroniza tion Vacuum Air Cleaner Element 2 3 mm 0 08 0 12 in 1 300 50 r min rpm Less than 2 7 kpa 2 cmHg difference between two carburetors Polyurethane foam Cooling System Coolant Type Recommended Color Mixed Ratio Freezing Point Capacity Engine Top End Valve Clearance Inlet Exhaust Clutch Clutch Lever Free Play Engine Lubrication System Engine Oil Grade Viscosity Capacity Level Wheels Tires Tread Depth Front BRIDGESTONE DUNLOP Rear BRIDGESTONE DUNLOP Air pressure when Cold Front Rear Final Drive Drive Chain Slack Permanent type antifreeze Green Soft water 50 coolant 50 35 C 31 F 1 5 L 1 59 US at 0 15 0 24 mm 0 0059 0 0094 in 0 22 0 29 mm 0 0087 0 0114 in 2 3 mm 0 08 0 12 in API SE SF or SG API SH SJ or SL with JASO MA SAE 10W 40 1 3 L 1 4 US qt
303. wheel balance e Permanently install the balance weight Balance Weight Removal e Insert a regular tip screwdrivers A B between the rib C and weight D as shown e Pry the balance weight with two screwdrivers and remove the balance weight e Discard the used balance weight CAUTION Do not tap the screwdrivers The rim could be dam aged Balance Weight Installation e Check if the weight portion has any play on the blade A and clip B x If it does discard it If the balance weight has any play on the rib of the rim the blade and or clip have been stretched Re place the loose balance weight Do not reuse used balance weight Unbalanced wheels can create an unsafe riding condition 604041381 604041481 G6J04088BS1 WHEELS TIRES 10 11 Wheels Rims Balance Weight Part Number Weight 41075 0007 10 g 0 35 oz 41075 0008 20 g 0 71 oz 41075 0009 30 g 1 06 oz NOTE OBalance weights are available from Kawasaki dealers in 10 20 and 30 gram 0 35 oz 0 71 oz and 1 06 oz sizes An imbalance of less than 10 grams 0 35 oz will not usually affect running stability ODo not use four or more balance weight more than 90 gram If the wheel requires an excess balance weight disassemble the wheel to find the cause e Slip the balance weight A on to the rib B by pushing or lightly hammering C the clip D E lt
304. when filter is not removed 1 6 L 1 7 US qt when filter is removed Between upper and lower level lines Wait 2 3 minutes after idling or running 4 6 mm 0 181 in 4 5 mm 0 177 in 1 mm 0 04 in 7 0 mm 0 276 in 7 4 mm 0 291 in 2 mm 0 08 in up to 130 km h 80 mph 3 mm 0 12 in over 130 km h 80 mph Up to 170 kg 375 Ib load 200 kPa 2 0 kgf cm 28 psi Up to 170 kg 375 Ib load 225 kPa 2 25 kgf cm 32 psi 20 30 mm 0 8 1 2 in 2 12 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Brakes Brake Fluid Grade DOT4 gea Ee 4 5 mm 0 18 in 1 mm 0 04 in Brake Light Timing Wee Front Pulled ON Rear ON after 10 mm 0 39 in of pedal travel Electrical System Type CR8E U24ESR N PERIODIC MAINTENANCE 2 13 Special Tools Steering Stem Nut Wrench Filler Cap Driver 57001 1100 57001 1454 ST5711008T ST5714548T Vacuum Gauge KEK 55 5 57001 1369 ST5713698T 2 14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System Air Cleaner Element Cleaning e Remove Right Side Cover see Side Cover Removal in the Frame chapter Air Cleaner Cap Bolts A Air Cleaner Cap B e Pull out the air cleaner element A e Separate the plastic holders A WARNING If dirt or dust is allowed to pass through into the car buretors the butterfly valves may become stuck poss
305. xtremely 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 following needle bearing left hand drive shaft and right hand output shaft OThe rollers in a needle bearing normally wear very little and wear is difficult to measure Instead of measuring inspect the bearing for abrasion color change or other damage x If there is any doubt as to the condition of a needle bear ing replace it 6113010581 6114010181 9 32 CRANKSHAFT TRANSMISSION Transmission Bil OPO Kai te NOGOEOASOSS OOVUOO WY 0 YVYOVOOOOMOOOOOO 49 1st Gear 2nd Gear 3rd Gear 4th Gear 5th Gear 6th Top Gear Circlip Circlip Toothed Washer 10 12 13 15 16 17 18 Washer Thrust Washer Needle Bearing Ball Bearing Collar Bearing Outer Race Steel Ball Drive Shaft Output Shaft G113409BW4 C WHEELS TIRES 10 1 Wheels Tires Table of Contents Exploded WEE EE 10 2 Specifications EEN 10 4 MSPCCIAl TOONS EE 10 5 LISTES E EE 10 6 Front Wheel Removal se 10 6 Front Wheel Installation 2 cc cceccceeccecccecceeeeeeeeee
306. y it is not necessary to adjust the pedal position but always adjust it when push rod locknut has been loosened e Loosen the locknut A and up or down the clevis B by turning the adjuster C to adjust the brake pedal position e Tighten the locknut with specified torque Torque Push Rod Locknut 18 N m 1 8 kgf m 13 ft Ib NOTE Olf the pedal position cannot be adjusted by turning the clevis A the brake pedal may be deformed or incor rectly installed Olf the brake rod B protrusion is 3 5 5 5 mm 0 14 0 22 in C below the nut the pedal position will be with in the standard range about 40 mm 1 6 in e Check the brake pedal position and readjust it if neces sary Calipers BRAKES 12 9 Front Caliper Removal e Loosen the banjo bolt A at the brake hose lower end and tighten it loosely e Unscrew the caliper mounting bolts B and detach the caliper C from the disc CAUTION Do not loosen the caliper assembly bolts Take out only the caliper mounting bolts for caliper removal Loosening the caliper assembly bolts will cause brake fluid leakage e Unscrew the banjo bolt and remove the brake hose from the caliper see Brake Hose Removal Installation CAUTION Immediately wash away any brake fluid that spills NOTE Olf the caliper is to be disassembled after removal and if compressed air is not available disassemble the caliper before the brake hose is removed se

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