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All Terrain Vehicle Service Manual

1. Ignition Switch ON Normal Ignition Switch OFF Normal k 0 2sec Drive Failure Detecting Switch OFF Belt Failure Total 100 hours of use Drive Belt Failure Mode Memory Clearing Procedure r lgnition SW OFF gt 1500 E 1 2 3 4 5 6 7 123 lt 9 Ssec 0 2sec gt E gt U UULU U U UUN lt A cycle repeat 71712345 gt e o0 5sec 0 2sec gt 1 oyolo repeat Ignition Switch OFF Memory Writing Failure Memory Writing Time Limit one hundred thousand Memory Reading Failure 4WD 2WD 4WD Actuator Failure Engine Brake Actuator Fail ure Both 2WD 4WD Actuator and Engine Brake Actuator Failure 11 Property of www SmallEngineDiscount com Not for Resale 16 50 ELECTRICAL SYSTEM LED Indicator Check 1 No Problem Check 2 No Problem Check 3 e Check the drive belt see Drive Belt Deflection Inspection and Drive Belt Inspection in Periodic Maintenance chapter x If it is flashed by abnormal belt replace the belt and torque converter cover e After completing the inspections do the drive belt failure mode memory clearing procedure see Drive Belt Failure Mode Memory Clearing Procedure Check 4 e Check the drive belt see Drive Belt Deflection
2. e Roll up the boot A toward the engine e Insert the drive shaft in the rear propeller shaft joint A e Tighten Torque Lower Engine Mounting Bracket Bolts 25 N m 2 5 kgf m 18 ft Ib Lower Engine Mounting Bolts and Nuts 42 N m 4 3 kgf m 31 ft lb Upper Engine Mounting Bracket Bolt and Nut 42 N m 4 3 kgf m 31 ft lb Upper Engine Mounting Bolt and Nut 25 N m 2 5 kgf m 18 ft Ib Property of www SmallEngineDiscount com Not for Resale Property of www SmallEngineDiscount com Not for Resale CRANKSHAFT TRANSMISSION 9 1 Crankshaft Transmission Table of Contents EXploded MW aaa 9 2 ST O 9 6 SP OS 9 7 Grankcase Disassembly rassir i etnea aa e a aaae a aaa igus e aa raaa aaeeea 9 7 Grankcase AssembliVecacos ams ao E e rora E ENER EESE IM 9 7 Crankshaft Balancer Shaft and Connection ROd ococccccnnccnocicoccconanoncnoncnonnnnnnn conc cnn ran rca n cnn 9 10 Crankshaft Balancer Shaft RemOVal ooonicincnnicnninnnnnccncnecnacnnnc cnn narrar 9 10 Crankshaft Balancer Shaft Installation ccceeececeeeeeeeeeeeeeneeseeeseeeeeaeeeaeeeaeeseeeeeaeseaeesaeeseaeseaeecaeeseeeseaeeeaeesieeeeeeeeaeeas 9 10 Crankshaft DiSaSS MDly ecccscceeseeceneeeeeeeeeeseeeeeaeeeaeecsaesaeeeaeeeaeesaeseaeeeaeecaaesaaesaeesseeseaeseaeesieesaeseaeseaesteeeseaeeeaees 9 10 CrankshattAssemblV circo iaa tidad 9 11 Connecting Rod Big End SeiZure iniciada 9 12 Connecting Rod Big En
3. 11 49 Pinion Gear Unit Disassembly ee 11 51 Pinion Gear Unit ASsembly cceeeeeeee 11 51 Bevel Gear Inspection 0 0 0 cceeeeeeeeeeeeeeeeeneees 11 52 Bearing and Oil Se al eeeeeceeeeeeeteeteteteeeeeeeaes 11 53 Ball or Needle Bearing Inspection 11 53 Oil Seal Inspection eee eee eeeeeeeteeteeteteeeaees 11 54 Property of www SmallEngineDiscount com Not for Resale 11 2 FINAL DRIVE Exploded View Property of www SmallEngineDiscount com Not for Resale FINAL DRIVE 11 3 Exploded View z 9 Fastener Remarks e Output Driven Bevel Gear Housing Bolts Output Drive Bevel Gear Housing Bolts 3 Bearing Holder 4 Bevel Gear Holder Nut 157 16 116 L 5 Bearing Holder 118 12 87 L 6 Output Shaft Holder Nut 157 16 116 L 7 Rotor Mounting Bolts 12 1 2 104 in lb 8 Output Drive Bevel Gear Cover Bolts 8 8 0 9 78 in lb 9 Forward Reverse Detecting Sensor Mounting Bolts 15 15 11 G Apply grease for oil seal and O ring L Apply a non permanent locking agent M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil Property of www SmallEngineDiscount com Not for Resale 11 4 FINAL DRIVE Exploded View Property of www SmallEngineDiscount com Not for Resale FINAL DRIVE 11 5 Exploded View Torque No Fastener N m kgm ft lb Remarks Variable Front Differential Co
4. ceceeeeeeeeeee 16 36 Starter Circuit Relay Inspection 16 36 Starter Motor Clutch Removal 16 37 Starter Motor Clutch Installation 16 38 Starter Motor Clutch Inspection 16 38 Torque Limiter Inspecti0N ooonncinniconnnn on 16 38 Lighting SYStOM ecceeeeeeeeeeeeeeeeeeeeetseeeeeeeneetaes 16 39 Headlight Beam Vertical Adjustment 16 39 Headlight Bulb Replacement 16 39 Headlight Body Removal 16 40 Headlight Body Installation 16 40 Taillight Bulb Replacement 16 40 Oil Cooler Fan System 16 43 Oil Cooler Fan Circuit Inspection 16 43 Oil Cooler Fan Motor Inspection 16 43 Speedometer Optional Part for U S model 16 44 Speedometer REMOVAI ecceeceeeeeeeeeeteee 16 44 Speedometer Inspection cesses 16 44 EED Indicato eerie cido cedsanediecdsesackdaees sccceeeses 16 47 Drive Belt Failure Mode Memory Clearing Proce OU e aati E E E E TNE LED Indicator RemMoVal oooconocccnncccnonccononcnnnnnss LED Indicator Installation 2 0 LED Indicator Inspection cesses Actuator Control SyStem c eeceeeceeseeseeeeeeeneees 2WD 4WD Actuator Removal 2WD 4WD Actuator Installation Engine Brake Actuator Removal Engine Brake Actuator Installation Actuator Control System Outline
5. e Check the belt A for abnormal wear B O Measure the width C of the belt at abnormal wear point x If any measurements exceed 0 5 mm 0 02 in replace the belt O When using the belt of large abnormal wear the drive belt failure detection switch could be activated HS05003B51 Property of www SmallEngineDiscount com Not for Resale PERIODIC MAINTENANCE 2 15 Periodic Maintenance Procedures e Check the belt for cracks breaks or peeling x If necessary replace the belt with a new one Belt A Crack B Broken C Peeling D NOTE O Whenever the belt is replaced inspect the drive and the driven pulleys HS05002BS1 Drive Belt Deflection Inspection NOTE O If the drive belt failure detection system is activated by abnormal belt the drive belt failure detection switch is damaged Make sure to replace the torque converter cover e Remove the torque converter cover see Torque Converter Cover Removal in Converter System chapter e Put the transmission in neutral and rotate the driven pulley by hand to make sure the belt is shifted all the way to the top of the driven pulley e Measure the belt deflection A as shown O Place a straightedge B on top of the belt between the drive pulley C and the driven pulley D O Use a ruler to push the belt away from the straightedge Push hard but with no more force than 59 N 6 kgf 13 Ib Belt Deflecti
6. Headlight R BK R BK Left R Y R Y 12V30 30W BK Y BK Y Regulator Rectifier Accessory R R x Connector ue Eas ARSS Power Outlet EUR Reverse Light RUN g 12V10W R Y OR R BK BR m Y R BR gt BR 4 HI 1 1 1 y 1 f Xl except US and CA models Left Handlebar Switches Le0FF_ _OFFe i L X2 except US model 1 Light Dimmer Switch tenias 2 Engine Stop Switch er US U S A Model 3 Starter Button O O 4 CA Canada Model Reverse Power Assist Switch GB United Kingdom Model Override EUR Europe Model Left Handlebar Switch Connections Light Dimmer Switch Engine Stop Switch Starter Button Reverse Power Assist Switch Color R Y R R BK BR Color BR Y R Color Y R BK Color BR Y W W2L7508BW5 C Property of www SmallEngineDiscount com Not for Resale ELECTRICAL SYSTEM 16 73 Wiring Diagram Indicator Lights 1 Reverse 12V3W 2 Neutral 12V3W 3 0il Pressure 0il Temperature 12V1 7W Carburetor Heater 12V23W are gt Air Temperature Sensor Brake Light Switches 1 Front Brake Light Switch 2 Parking Brake Light Switch 3 Rear Brake Light Switch Actuator Controller O Ex gt gt ao o sas Slo a a W R R x aoe BK BL BK Engine a ao o 0 Brake BL R Y Actuator BL Y BL 2 Z 25353 Frame 5 a Ground wy R i BK Terminal BK R 2WD 4WD 9 9 Actuato
7. KEIHIN CVK34 155 70 6 N2LQ 35 150 1 1 2 turns out 90 1300 50 r min rpm 0 5 1 mm 0 02 0 04 in above bottom edge of carburetor body 17 0 2 mm 0 67 0 08 in 155 92063 1332 or 158 92063 1344 155 92063 1332 145 92063 1017 135 92063 1014 125 92063 1069 Service Limit Air Cleaner Air cleaner element oil High quality foam air filter oil Refer to pg 5 23 for high altitude setting in Converter System chapter Special Tools Fuel Level Gauge 57001 1017 Carburetor Drain Plug Wrench Hex 3 57001 1269 Pilot Screw Adjuster A 57001 1239 Property of www SmallEngineDiscount com Not for Resale FUEL SYSTEM 3 7 Throttle Lever and Cable Throttle Lever Free Play Inspection e Refer to Throttle Lever Free Play Inspection in Periodic Maintenance chapter Throttle Lever Free Play Adjustment e Refer to Throttle Lever Free Play Adjustment in Periodic Maintenance chapter Throttle Case Removal Disassembly e Remove the throttle case screws A and pull the case open e Slide the cable adjuster dust cover out of place e Remove the rubber cover A e Pull the cable tip A out of the throttle lever catch with the throttle lever opened e Loosen the locknut B and unscrew the adjuster C e Disassemble the throttle case as follows Remove the throttle lever screw D lockwasher and flat washer and lift the throttle lever E and return spri
8. Air Cleaner Housing Removal e Remove Seat see Frame chapter Air Cleaner Element see Air Cleaner Element Removal Housing Mounting Bolts A e Remove Snokel Duct A Air Ducts B e Remove Breather Hose A Property of www SmallEngineDiscount com Not for Resale FUEL SYSTEM 3 21 Air Cleaner e Through the housing A under the bracket B e Turn the housing counterclockwise at right angle A and take it as shown Air Cleaner Housing Installation e Align A the notch in the duct with the ridge on the air cleaner housing e Tighten Torque Air Cleaner Housing Mounting Bolts 6 9 N m 0 7 kgf m 61 in Ib Air Cleaner Duct Rear Clamp Screw 4 N m 0 41 kgf m 36 in Ib Air Cleaner Intake Duct Clamp Screws 1 4 N m 0 14 kgf m 12 in Ib Snorkel Duct Removal e Remove Seat see Frame chapter Fuel Tank Cover see Frame chapter Clamp A Screws B Snorkel Duct C Property of www SmallEngineDiscount com Not for Resale 3 22 FUEL SYSTEM Fuel Tank Fuel Tank Removal e Turn the fuel tap to the OFF position e Remove Screw A Fuel Tap Knob B AWARNING Gasoline is extremely flammable and can be explosive 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 Remo
9. e Check that the T mark A on the alternator rotor aligns with the slot B in the alternator cover O Be sure to position the crankshaft at TDC of the end of the compression stroke x If the T mark is not aligned hold the camshaft chain taut and turn the crankshaft with a wrench on the alternator rotor bolt e Confirm the notching line A of the weight holder B aligns with the pointer C on the cylinder head Property of www SmallEngineDiscount com Not for Resale ENGINE TOP END 4 11 Camshaft Sprocket e Fit the camshaft sprocket under the chain and install the sprocket on the weights so that the mark A aligns with the pointer B e Apply a non permanent locking agent to the camshaft sprocket bolts and tighten them while holding the crankshaft from turning with a wrench on the alternator rotor bolt Torque Camshaft Sprocket Bolts 14 N m 1 4 kgf m 10 ft Ib e Install the camshaft chain tensioner see Camshaft Chain Tensioner Installation e Before going any further check the cam timing O Turn the crankshaft counterclockwise with a wrench on the alternator rotor bolt until the mark on the sprocket realigns with the pointer on the head CAUTION If any resistance is felt when turning the crankshaft stop immediately or you may bend the valves The T mark on the alternator rotor should align with the slot x If the camshaft timing is not correct rem
10. Connector BK Y Terminal 10 O Install the needle adapters on the tester leads Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 e Turn ON the ignition switch e Spin a rear wheel measure the voltage Speed Sensor Output Voltage Standard repeat from 0 to 5 V x If the reading is not standard replace the speed sensor Check 5 2WD 4WD Shift Switch Inspection NOTE Be sure the battery is fully charged e Remove Seat see Frame chapter OHHH e Connect LL Y BROW Controller Connector A AAEN Hand Tester B range DC 25 V ou N aas Tester Connector G Terminal 7 Tester Connector BK Y Terminal 10 ans E O Install the needle adapters on the tester leads Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 e Turn ON the ignition switch e Push the switch to the 4WD position Controller Output Voltage at 2WD 4WD Shift Switch OFF 4WD Standard about 5 V If the reading is not standard check the 2WD 4WD shift switch or actuator controller unit e Push the switch to the 2WD position Controller Output Voltage at 2WD 4WD Shift Switch ON 2WD Standard OV If the reading is not standard check the 2WD 4WD shift switch or actuator controller unit Property of www SmallEngineDiscount com Not for Resale 16 60 ELECTRICAL SYSTEM Actuator Control System Check 6 Controller Unit Inspection NOTE O Be sure the bat
11. PERIODIC MAINTENANCE 2 3 Torque and Locking Agent The following tables list the tightening torque for the major fasteners and the parts requiring use of a non permanent locking agent or liquid gasket Letters used in the Remarks column mean L Apply a non permanent locking agent LB Apply a non permanet locking agent Three Bond TB2471 Blue MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 EO Apply engine oil M Apply molybdenum disulfide grease SS Apply silicone sealant Kawasaki Bond 56019 120 Lh Left hand Threads R Replacement Parts S Follow the specific tightening sequence St Stake the fasteners to prevent loosening Torque Fastener N m kgf m ft lb Remarks Fuel System Throttle Cable Locknut 1 3 0 13 11 in lo Air Cleaner Duct Front Clamp Screw 1 4 0 14 12 in lb Air Cleaner Duct Rear Clamp Screw 4 0 41 36 in lb Air Cleaner Housing Mounting Bolts 6 9 0 7 61 in lb Air Cleaner Intake Duct Clamp Screws 1 4 0 14 12 in lb Engine Top End Camshaft Chain Tensioner Mounting Bolts 8 8 0 9 78 in lb Camshaft Sprocket Bolts 14 1 4 10 L Camshaft Cover Bolts 8 8 0 9 78 in lb Bearing Retainer Bolts 12 1 2 104 in lb Camshaft Chain Guard Bolts 8 8 0 9 78 in lb Rear Camshaft Chain Guide Bolt 9 8 1 0 87 in lb Cylinder Head Bolts M11 first torque 25 2 5 18 MO S Cylinder Head Bolts M11 final torque 44 4 5 33 S Cylinder He
12. 4 Trailer Hitch Bracket Bolts M10 49 5 0 36 L 5 Trailer Hitch Bracket Bolts M8 24 2 4 17 L 6 Canada United Kingdom and Europe models L Apply a non permanent locking agent Property of www SmallEngineDiscount com Not for Resale 15 4 FRAME Exploded View Property of www SmallEngineDiscount com Not for Resale FRAME 15 5 Exploded View Property of www SmallEngineDiscount com Not for Resale 15 6 FRAME Exploded View Lag fh YA Property of www SmallEngineDiscount com Not for Resale FRAME 15 7 Exploded View Front Final Gear Case Bolts and Nuts ACI CI E IS Lower Engine Mounting Bracket Bolts Lower Engine Mounting Bolts and Nuts 42 4 3 31 Footboard Mounting Nuts L O a s L Apply a non permanent locking agent Property of www SmallEngineDiscount com Not for Resale 15 8 FRAME Specifications Special Tool Outside Circlip Pliers 57001 144 Property of www SmallEngineDiscount com Not for Resale FRAME 15 9 Seat Seat Removal e Remove the seat A by pulling the looped seat latch B and then pulling the seat up to the rear Seat Installation e Slip the front seat hook A into the brace B on the frame and put the stoppers C into the holes in the frame e Push down the rear part of the seat until the locks D with a click 10038003 P al i Property of www SmallEngineDiscount
13. Kawasaki All Terrain Vehicle Service Manual All rights reserved No parts of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Quality Assurance Department 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 such changes to products manufactured previously See your dealer for the latest information on product improvements incorporated after this publication All information contained in this publication is based on the latest product information available at the time of publication Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts O 2002 Kawasaki Heavy Industries Ltd Second Edition 1 Jun 20 2002 K Property of www SmallEngineDiscount com Not for Resale 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 Celcius direct current farad s degree s Fahrenhei
14. O Install the actuator lever measurement tool plate A and rods B on the torque converter cover C and tighten the two cover bolts Special Tool Actuator Lever Measurement Tool 57001 1499 O Set the rod ends on the resin tips D O Measure the recess length E between the plate and rods with Vernier calipers F or depth gauge Measurement Length E Standard 1 33 2 47 mm 0 052 0 097 in x If the measurement is 1 33 mm 0 052 in or less use the actuator lever assembly 13236 1385 of yellow paint x If the measurement is more than 2 47 mm 0 097 in use the actuator lever assembly 13236 1386 of green paint x If the length is not within the specified length after the actuator lever assembly is replaced replace the torque converter cover and install the actuator lever assembly 13236 1387 HSO4006BS2 C Actuator Lever Assemblies Part Number Paint Color A Length B 13236 1385 0 4 0 1 mm 0 016 0 004 in 13236 1387 1 0 0 1 mm 0 039 0 004 in 13236 1386 1 6 0 1 mm 0 063 0 004 in HSO4G03BS1 Property of www SmallEngineDiscount com Not for Resale 5 10 CONVERTER SYSTEM Drive Belt Drive Belt Removal e Remove the drive pulley A see Drive Pulley Removal NOTE O Before removing observe the direction the belt s printed informa tion B such as manufacturer s name and arrow marks is facing so that it may be reinstalled on the pull
15. Steering Centering Adjustment e Hold a straightedge A against the rear wheel rim on one side at axle height e With the handlebar straight ahead loosen the locknuts A B and turn the tie rod adjusting sleeve C until the front wheel on that side is parallel to the straightedge NOTE The locknut A near the flattened area D on the tie rod has left hand threads Turn the wrench clockwise for loosening CAUTION Adjust the tie rod so that the visible thread length A is even A O on both ends of the tie rod or the threads could be damaged HJO4G00BS1 Property of www SmallEngineDiscount com Not for Resale 10 6 WHEELS TIRES Wheel Alignment e Repeat the straightedge procedure on the other side of the vehicle Now the front wheels are parallel to each other and to the center line of the vehicle Front Wheel A Vehicle Center Line B Parallel each other C Straightedges D Rear Wheels E e Go on to the Toe in Inspection procedure Toe in Inspection e Apply a heavy coat of chalk or a paint line near the center of the front tires e Using a needle nose scriber make a thin mark near the center of the chalk coating while turning the wheel e With the front wheels on the ground set the handlebar straight ahead e At the level of the axle height measure the distance between the scribed or painted lines for both front and rear of the front tire
16. e Remove Oil Cooler Oil Cooler Removal Oil Cooler Fan Switch A HG11001BS1 G Oil Temperature Warning Light Switch B Oil Cooler Fan Switch Oil Temperature Warning Light Switch Installation e Apply grease to the O rings of the oil cooler fan switch and oil temperature warning light switch e Tighten the oil cooler fan switch and oil temperature warning light switch Torque Oil Cooler Fan Switch 16 N m 1 6 kgf m 12 ft lb Oil Temperature Warning Light Switch 16 N m 1 6 kgf m 12 ft Ib Oil Cooler Fan Switch Oil Temperature Warning Light Switch Inspection e Refer to Electrical System chapter Oil Cooler Inspection e Refer to Oil Cooler Ceaning and Inspection in Periodic Maintenance chapter Property of www SmallEngineDiscount com Not for Resale ENGINE REMOVAL INSTALLATION 8 1 Engine Removal Installation Table of Contents Exploded VIEW zsebes iritas niad a aaa e a idad 8 2 Engine Removal Installation wiiioinnicin cc ii iia oietik aii stave 8 4 Engine Removal iii A eed et esia 8 4 Engine Install ON mii li sti 8 5 Property of www SmallEngineDiscount com Not for Resale 8 2 ENGINE REMOVAL INSTALLATION Exploded View Property of www SmallEngineDiscount com Not for Resale ENGINE REMOVAL INSTALLATION 8 3 Exploded View No Fastener Nm kgtm ftib Upper Engine Mounting Bolt and Nut 25 e te Lower Engine Mounting Bracket Bolts 2 2s ef 4 Low
17. s dye to seating surface This makes seating surface distinct and 32 and 50 grinding operation easier O When the valve guide is replaced be sure to grind with 45 cutter for centering and good contact 6E15012151 x If the outside diameter A of the seating surface is too large make the 32 grind described below x If the outside diameter of the seating surface is within the specified range measure the seat width as described below e Grind the seat at a 32 angle B until the seat O D is within the specified range O To make the 32 grind fit a 32 cutter into the holder and slide it into the valve guide O Turn the holder one turn at a time while pressing down very lightly Check the seat after each turn A 6E15012251 CAUTION The 32 cutter removes material very quickly Check the seat outside diameter frequently to prevent overgrinding O After making the 32 grind return to the seat O D measurement step above e To measure the seat width use a vernier caliper to measure the width of the 45 angle portion of the seat at several places around the seat 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 If the seat width is too wide make the 50 A grind described below x If the seat width is within the specified range lap the valve to the seat
18. 2 i Orange t Vcc Forward Reverse Yellow Detecting Sensor Dm 4 A Vout Hand Switch Vacant Selectable 2WD 4WD are Selectable 2WD 4WD Terminal Shift Switch OFF 4WD ON 2WD controller Note The circled figures indicate the pin layout of the controller HP23015B S Property of www SmallEngineDiscount com Not for Resale 16 56 ELECTRICAL SYSTEM Actuator Control System Actuator Control System Troubleshooting When the actuator fails the controller enters failure mode and the 4WD indicator light LED A is flash HP23B015 P Failure Indication Pattern and Failure Part No Failure Indication Pattern 4WD Indicator Light Failure Part 1 Selectable 2WD 4WD actuator ON OFF Engine brake actuator ON OFF Both the selectable 2WD 4WD actua tor and the engine brake actuator Malfunction Mode Malfunction Mode Probable Faulty Part Location Check Number 2WD 4WD actuator 1 The 2WD 4WD actuator does not Controller power supply operate correctly Speed sensor 2WD 4WD shift switch Controller Engine brake actuator The engine brake actuator does Controller power supply not operate correctly Speed sensor F R detecting sensor Controller The 4WD indicator light does not switch 2WD 4WD shift switch Controller LED indicator light 0 0 dada Y AP Y NO 0 A Y Property of ww
19. 5 Carburetor Vent Tube retor 6 View from Upside 13 Snaps 7 from Cylinder Head Property of www SmallEngineDiscount com Not for Resale APPENDIX 17 13 Cable Wire and Hose Routing Cross Section B B VIEW A N A A P j N I A V y SS EDS y 5 S HB09012BW4 6 Right Headlight Lead 7 Left Headlight Lead Band 8 Rotate head of band forward to prevent interfer Main Harness 3 4 5 ence with rear fender Battery Cable Battery Cable Property of www SmallEngineDiscount com Not for Resale 17 14 APPENDIX Cable Wire and Hose Routing l ME S HBO9013BW4 1 White Mark 7 Igniter 2 Band 8 Regulator Rectifier 3 Carburetor Heater Leads 9 Rear Brake Cable 4 Clamp on Torque Converter Cover 10 Brake Pedal Light Switch 5 Frame Ground Lead 11 Speed Sensor Connector 6 2WD 4WD Actuator Breather Tube Property of www SmallEngineDiscount com Not for Resale APPENDIX 17 15 Cable Wire and Hose Routing 1 Band 2 Rear Final Gear Case Breather Tube 3 Brake Cable Rear 4 Brake Cable Parking 5 Torque Converter Cover Intake Duct 6 Circlip Property of www SmallEngineDiscount com Not for Resale 17 16 APPENDIX Cable Wire and Hose Routing HBO9015BW4 1 Band 8 Main Fuse 30 A 2 Carburetor 9
20. 57001 1476 ST5714548T SEO ST571476ST C Pulley Holder Attachment 57001 1472 Spacer amp Holder 57001 1477 gt ST5714728ST C oy ST5714778T C S Drive amp Driven Pulley Holder 57001 1473 Socket Wrench Hex 50 57001 1478 ST571473ST C if y ST571478ST C Property of www SmallEngineDiscount com Not for Resale 1 12 GENERAL INFORMATION Special Tools and Sealant Output Shaft Holder amp Spacer 57001 1479 ST571479ST C Socket Wrench Hex 41 57001 1484 Pinion Gear Holder 57001 1480 Y ST571484ST C ST571480ST C Pinion Gear Holder 57001 1485 Nut Holding Bolts 57001 1481 ST571485ST C sT571481ST C Oil Seal Driver 57001 1487 Socket Wench 57001 1482 S T571487ST C gt Y ST571482ST C Gear Holder amp Socket Wrench Hex 24 57001 1489 Spring Holder Set 57001 1483 ST571489ST C ST571483ST C Hexagon Wench Hex 41 57001 1491 Property of www SmallEngineDiscount com Not for Resale ST571491ST C GENERAL INFORMATION 1 13 Special Tools and Sealant Drive Pulley Measurement Tool 57001 1498 Valve Seat Cutter 50 44 57001 1516 SF ST571498ST ST571516ST Actuator Lever Measurement Tool 57001 1499 Oil Seal Driver 57001 15
21. 8 0 31 4T 10 14 1 0 1 4 87 122 in lb 10 0 39 7T 39 44 4 0 4 5 29 33 10 0 39 4T 20 24 2 0 2 4 TA 17 5 0 20 4T 2 2 2 6 0 22 0 27 19 23 in lb Basic Torque for General Fasteners of Frame Parts Threads dia Torque mm in N m kgf m ft lb 5 0 20 3 4 4 9 0 35 0 5 30 43 in lb 6 0 24 5 9 7 8 0 6 0 8 52 69 in lb 8 0 31 14 19 1 4 1 9 10 0 13 5 10 0 39 25 34 2 6 3 5 19 0 25 12 0 47 44 61 4 5 6 2 33 45 14 0 55 73 98 74 10 0 54 72 Property of www SmallEngineDiscount com Not for Resale 2 8 PERIODIC MAINTENANCE Specifications Fuel System Throttle lever free play Air cleaner element oil Engine Top End Valve clearance Exhaust Inlet Standard 2 3 mm 0 08 0 12 in High quality foam air filter oil 0 15 0 20 mm 0 0059 0 0079 in 0 08 0 13 mm 0 0032 0 0051 in Converter System Actuator lever guide shoe wear Belt width Belt deflection A 6 mm 0 24 in 29 8 31 0 mm 1 17 1 22 in 29 4 mm 1 16 in 20 27 mm 0 79 1 06 in e Engine Lubrication System Engine oil Type Viscosity Capacity Wheels Tires Tire tread depth Front Rear Standard tire Front Rear API SF or SG API SH or SJ with JASO MA SAE10W40 1 50 L 1 59 US qt When filter is not removed 1 74 L 1 84 US qt When filter is removed 2 3 L 2 43 US qt When engine is completely dry 3 mm 0
22. Accessory Fuse 5 A 3 Oil Pressure Switch 10 Air Temperature Sensor 4 to Starter Motor 11 Front Side 5 Clamp 12 Apply grease Amoco rykon premium grease No 6 Forward Reverse Detecting Sensor 2 EP Green to terminals of neutral and reverse 7 Batter Terminal position switch Property of www SmallEngineDiscount com Not for Resale APPENDIX 17 17 Cable Wire and Hose Routing HBO9016BW4 1 Battery Vent Hose 10 Battery Cable 2 Band 11 Battery Cable 3 Clamp 12 Starter Circuit Relay Brake 4 Starter Motor 13 Starter Circuit Relay Neutral 5 Battery 14 Actuator Controller 6 Starter Relay 15 Main Fuse 30 A 7 Actuator Controller 16 Accessory Fuse 5 A 8 Inside 17 Starter Relay 9 Front Side Property of www SmallEngineDiscount com Not for Resale 17 18 APPENDIX Cable Wire and Hose Routing HBOSO17BW4 1 Variable Differential Control Cable 2 Throttle Cable 3 Front Brake Hose 4 Choke Cable 5 Rear Parking Brake Cable 6 Clamp Property of www SmallEngineDiscount com Not for Resale
23. B Dowel Pins C Front Final Gear Case Center Cover Bolts M6 D Front Final Gear Case Center Cover Bolts M8 E Front Final Gear Case Center Cover F e Remove Ring Gear Assembly A Shim s B IS Property of www SmallEngineDiscount com Not for Resale FINAL DRIVE 11 31 Front Final Gear Case e Hold the front final gear case right cover A in a vise and remove the bearing holder using the socket wrench B Special Tool Socket Wrench Hex 41 57001 1484 O If the holder seems too difficult to break free apply heat to softer the locking agent e Remove Pinion Gear Bearing Holder E HK110012 P a e Remove Pinion Gear Unit A Shim s HK110013 P Front Final Gear Case Assembly e Install Ball Bearing A Needle Bearing B O Press the ball bearing and needle bearing until they are bottomed e Install Circlip C Special Tool Inside Circlip Pliers 57001 143 e Install Oil Seal D O Install the oil seal until it is bottomed HK11011BS1 e Visually check the pinion gear and ring gear for scoring chipping or other damage x Replace the bevel gear as a set if either gear is damaged since they are lapped as a set in the factory to get the best tooth contact e Insert the pinion gear in the front final gear case right cover e Install Ring Gear Assembly e Apply grease to the O ring A on the front final gear case center cover P
24. HP23011BW4 1 2WD 4WD Shift Switch 2 Igniter 3 Drive Belt Failure Detecting Switch 4 Drive Belt Failure Detecting Switch Fuse 5A 5 Reverse Switch 6 LED Indicator Actuator Controller Engine Brake Actuator 2WD 4WD Actuator Speed Sensor Ignition Switch Battery Main Fuse 30A Property of www SmallEngineDiscount com Not for Resale 16 64 ELECTRICAL SYSTEM Drive Belt Failure Detection System If the drive belt failue detetion system is activated by abnormal belt the drive belt failure detection switch is damaged Make sure replace the torque converter cover see Converter System chapter Drive Belt Failure Detection System Inspection e Remove Fuel Tank Cover see Frame chapter e Check the drive belt failure detection system according to following chart Property of www SmallEngineDiscount com Not for Resale ELECTRICAL SYSTEM 16 65 Drive Belt Failure Detection System Confirm the 4WD shift position Disconnect the belt failure detection switch lead connector Put the shit lever in neutral position and tum ON the ignition switch Inspect Has the 2WD 4WD change over actuator stopped making Actuator Controller an operating sound Is the drive train shifted to 2WD mode 2WD 4WD Actuator automatically Igniter Inspect a Has the CHECK BELT Indicator LED started flashing LED Indicator Start the engine When the throttle is open can the engi
25. NOTE O This is not an exhaustive list giving every possi ble cause for each problem listed It is meant sim ply as a rough guide to assist the troubleshooting for some of the more common difficulties Engine Doesn t Start Starting Difficulty Starter motor not rotating Neutral switch trouble Starter motor trouble Battery voltage low Relays not contacting or operating Starter button not contacting Wiring open or shorted Ignition switch trouble Engine stop switch trouble Fuse blown Starter motor rotating but engine doesn t turn over Starter motor clutch trouble Recoil starter not operating Recoil starter spring broken Recoil starter pawl not engaging Engine won t turn over Valve seizure Rocker arm seizure Cylinder piston seizure Crankshaft seizure Connecting rod small end seizure Connecting rod big end seizure Transmission gear or bearing seizure Camshaft seizure Balancer bearing seizure No fuel flow Fuel tank air vent obstructed Fuel tap clogged Fuel line clogged Float valve clogged Engine flooded Fuel level too high Float valve worn or stuck open Starting technique faulty When flooded crank the engine with the throttle fully opened to allow more air to reach the engine Fuel air mixture incorrect Pilot screw and or idle adjusting screw maladjusted Pilot jet or air passage clogged Air cleaner clogged poorly sealed or missing Starter jet clogged No spark spark weak Spark plug dirty broken or maladjusted Spar
26. Recommended Tool Peak Voltage Adapter Type KEK 54 9 B Brand KOWA SEIKI O Connect the adapter between the G W lead terminal of the ignition coil C and the engien ground D O Install a new spark plug E into the spark plug cap and ground it to the engine WA TO To avoid extremely high voltage shocks do not touch the spark plugs or tester connections e Turn the ignition switch ON rotate the engine for 4 5 seconds with the transmission in neutral to measure the primary peak voltage e Repeat the measurements 5 times for one ignition coil HP10017BS1 Ignition Coil Primary Peak Voltage Standard 100 V or more x If the reading is less than the specified value check the following Ignition Coils see Ignition Coil Inspection Pickup Coil see Pickup Coil Inspection x If the ignition coils and pickup coil are normal see the Ignition System Troubleshooting chart on page 16 30 Pickup Coil Removal e Remove Alternator Cover see Alternator Cover Removal Pickup Coil Mounting Bolts A Plate B Pickup Coil C HPIOBD1F P Property of www SmallEngineDiscount com Not for Resale 16 28 ELECTRICAL SYSTEM Ignition System Pickup Coil Installation e Install Stator Coil Leads A Plate B Pickup Coil C e Tighten Torque Pickup Coil Mounting Bolts 5 9 N m 0 6 kgf m 52 in Ib e Fit the lead grommets into the notch on the alternator cover Grommet
27. Steering Stem Bottom End Nut B Collar C Steering Stem Bearing D HN04008B51 C Steering Stem Installation e Full grease up the seal grooves A in the steering stem bearing B e Install Collar e Tighten Torque Steering Stem Bottom End Nut 62 N m 6 3 kgf m 46 ft lb Property of www SmallEngineDiscount com Not for Resale 14 6 STEERING Steering e Bend both ends of the cotter pin A as shown Steering Stem Bottom End Nut B HN04001B51 e Apply a non permanent locking agent Steering Stem Bearing Joint Bolts A HN04009BS1 e Apply Amoco Rykon Premium Grease No 2 EP Green Inside of Grease Seals A Steering Stem B e Install Grease Seals Steering Clamps C and Collars D Plate E Lockwasher F and Steering Stem Clamp Bolts G e Tighten Torque Steering Stem Clamp Bolts 25 N m 2 5 kgf m 18 ft Ib Tie Rod End Nuts 42 N m 4 3 kgf m 31 ft Ib e Bend the lockwasher along the bolt head e Inspect the toe in see Wheels Tires chapter Steering Knuckle Removal e Remove Front Wheel and Hub see Wheel Tires chapter Brake Caliper see Brakes chapter Tie Rod End Nut and Tie Rod End A CAUTION Do not loosen the locknuts at the ends of the tie rod adjusting sleeve B or the toe in of the front wheels will be changed e Remove Front Shock Absorber Clamp Bolts C and Nuts Knuckle Joint Bolt D and Nut e R
28. Torque Front Guard Bolts B 20 N m 2 0 kgf m 14 ft Ib e Install Front Lower Guard C Front Lower Guard Bolts D HOOSO11BS2 C Property of www SmallEngineDiscount com Not for Resale 15 18 FRAME Guards Engine Bottom Guard Removal e Remove Bolts A Engine Bottom Guard HOGSG12BS1 Engine Bottom Guard Installation e Confirm Damper A e Install Engine Bottom Guard B Bolts Rear Bottom Guard Removal e Remove Bolts M6 A Bolts M8 B Rear Bottom Guard C HOOSGOSBS1 Rear Bottom Guard Installation e Confirm Dampers D e Install Rear Bottom Guards Bolts M8 Bolts M6 Property of www SmallEngineDiscount com Not for Resale FRAME 15 19 Flaps and Footboards Front Flap Removal e Remove Quick Rivets A Screws B Washers and Nuts Front Flap C and Flap Holder Plate Front Flap Installation e Install Front Flap A Flap Holder Plate B Screws L 22 mm 0 87 in C Washers and Nuts Quick Rivet D Screws L 16 mm 0 63 in E Rear Flap Removal e Remove Quick Rivets A Screws B Washers and Nuts Rear Flap C and Flap Holder Plate Rear Flap Installation e Install Rear Flap A Flap Holder Plate B Screws C Washers and Nuts Quick Rivet D Footboard Removal e Remove Screws A Washer and Nut A E HOOSGOIBS1 d
29. as shown x If the relay does not work as specified the relay is defective Replace the relay Testing Relay Hand Tester Range x 12 range Criteria When battery is connected gt 0 2 When battery is disconnected gt Q Starter Circuit Relay Inspection e Remove Seat see Frame chapter Starter Circuit Relay A Brake Switch Circuit Starter Circuit Relay B Neutral Switch Circuit O The starter circuit relays for the brake and neutral switch circuits are identical e Connect the hand tester A and a 12 V battery B to the starter circuit relay C as shown x If the relay does not work as specified the relay is defective Replace the relay Testing Relay Hand Tester Range x 1 2 Criteria When battery is connected gt 0 2 When battery is disconnected gt o Q Relay Coil Terminals 1 and 2 Relay Switch Terminals 3 and 4 Property of www SmallEngineDiscount com Not for Resale ELECTRICAL SYSTEM 16 37 Electric Starter System Electric Starter Circuit A O Yoo lr Si ma A F o a e i let T O i s A E ca g E m a pe ul x u 335 x om ao m mx mM Oens oo om m Mi x 5 i E HP11003BW3 1 Engine Stop Switch 6 Starter Circuit Relay Brake 10 Main Fuse 30A 2 Starter Button 7 Neutral Switch 11 Starter Relay 3 Front Brake Light Switch 8 Starter Circuit Relay Neutral 12 St
30. battery is charged while still installed battery electrolyte may spill and corrode the frame or other parts of the vehicle Do not use a high rate battery charger as is typically employed at automotive service stations unless the charger rate can be reduced to the level required Charging the battery at a rate higher than specified may ruin the battery Charging at a high rate causes excess heat which can warp the plates and cause internal shorting Higher than normal charging rates also cause the plates to shed active material Deposits will accumulate and can cause internal shorting If the temperature of the electrolyte rises above 45 C 113 F during charging reduce the charging rate to lower the temper ature and increase charging time proportionately e Turn the charger off or unplug it then disconnect it from the battery e Check battery condition x If the battery condition indicates that it is not fully charged additional charging time is necessary Property of www SmallEngineDiscount com Not for Resale ELECTRICAL SYSTEM 16 17 Battery Battery Charging Rate Time Table 12 V 14 Ah 1 270 Fully Charged Specific Gravity An Oo Tine at aes Shown Battery Troubleshooting Guide Good Battery Suspect Battery Plates Chocolate color white sulphated plates bro Replace gt gray ken or corroded Sediment none or small amount sediment up to plates causing Replace
31. e Install Headlight Cover see Headlight Cover Installation Front Carrier see Front Carrier Installation Rear Fender Removal e Remove Seat see Seat Removal Rear Carrier see Rear Carrier Removal Fuel Tank Cover see Fuel Tank Cover Removal Battery A see Electrical System chapter Electrical Equipments B with Grommet C Bolts D Screws E Property of www SmallEngineDiscount com Not for Resale FRAME 15 13 Fenders e Remove Rear Flap Lower Screws A both sides Collars Rear Fender Rear Fender Installation e Install Dampers A Collars B Grommet C Rear Carrier see Rear Carrier Installation HOG4G03BS1 Property of www SmallEngineDiscount com Not for Resale 15 14 FRAME Covers Headlight Cover Removal e Remove Front Carrier see Front Carrier Removal Collars A e Push up the stopper part B at the inside of the front guard and remove the headlight cover C e Remove Circlip A Special Tool Outside Circlip Pliers B 57001 144 e Remove Collar C Washer Damper Headlight Cover Installation e Install Damper A Collar B Washer C Circlip D Special Tool Outside Circlip Pliers 57001 144 e Put the headlight cover on the headlight e Push the stopper A lightly and fit it inside the front guard B e Install Rear Carrier see Rear Carrier Installation Front Inner Cover Removal e Rem
32. e Raise the input frequency of the oscillator to see the result of this inspection x If the value indicated by the trip meter does not increase replace the meter unit AN HP20026BS1 Property of www SmallEngineDiscount com Not for Resale 16 46 ELECTRICAL SYSTEM Speedometer Optional Part for U S model Speedometer Circuit E Doe ie BR W BR BK Y a ASE BK gt 5 BK BY BR W w Fw O WR KT W R BK Y HP20028BW3 C 1 Speedometer except US model 2 Speed Sensor 3 Ignition Switch 4 Main Fuse 30A 5 Battery Property of www SmallEngineDiscount com Not for Resale ELECTRICAL SYSTEM 16 47 LED Indicator Drive Belt Failure Mode Memory Clearing Procedure A flashing CHECK BELT warning LED Light Emitting Diode light means that the drive belt needs inspection The belt warning light will activate every 100 key on hours or sooner if the belt becomes damaged or fails NOTE O Follow the instruction on pages 2 14 to 2 16 of this Service Manual to complete the necessary inspections O After completing the inspections follow these instructions to clear the system memory and stop the flashing light e Turn off the ignition switch e Disconnect the belt switch at the 2 pin connector A above the torque converter cover e Disconnect both sets of 5 pin connectors B which are located above the torque converter co
33. e Turn B the bearing back and forth while checking for roughness or binding x If roughness or binding is found replace the bearing Tie Rod End and Steering Knuckle Joint Inspection e Inspect each spherical bearing A If roughness excessive play or seizure is found replace the tie rod end or steering knuckle joint e Inspect each grease seal B If damage wear or deterioration is found replace the tie rod end or steering knuckle joint HNOSB004 P Property of www SmallEngineDiscount com Not for Resale STEERING 14 11 Handlebar Handlebar Removal e Remove Throttle Case Front Brake Master Cylinder Left hand Switch Housing Rear Brake Lever Assembly Handlebar Cover Assembly Handlebar Holder Bolts A and Brackets B Handlebar Holders C Handlebar D Handlebar Installation e Install the handlebar lower holder A on the steering stem bracket B so that the projections C face rearward e Apply a non permanent locking agent to the holder nuts A and tighten them e Tighten Torque Handlebar Lower Holder Nuts 37 N m 3 8 kgf m 27 ft lb e Install the handlebar so that the angle of the handlebar is 0 5 degrees A as shown e Install the brackets A e Tighten the holder rear bolts B first and then the front bolts C Torque Handlebar Holder Bolts 27 N m 2 8 kgf m 20 ft lb O If the holder is correctly installed there will be no gap at the rear and an eve
34. in accordance with the Periodic Maintenance Chart or if the shaft is noisy during operation x If the joint boot is torn worn or deteriorated replace the joint boot and check the propeller shaft see Rear Propeller Shaft Inspection in Final Drive chapter Property of www SmallEngineDiscount com Not for Resale PERIODIC MAINTENANCE 2 21 Periodic Maintenance Procedures Brakes Front 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 Brake Hose and Connection Check e Inspect the brake hose and fittings for deterioration cracks and signs of leakage O The high pressure inside the brake line can cause fluid to leak A or the hose to burst if the line is not properly maintained Bend and twist the rubber hose while examining it x Replace the hose if any cracks B or bulges C are noticed e Tighten any loose fittings 6L10020151 Brake Hose Replacement e Pump the brake fluid out of the line as explained in the Brake Fluid Change e Remove the banjo bolts at both ends of the brake hose and pull the hose off the vehicle e Immediately wipe up any brake fluid that spills CAUTION Brake fluid quickly ruins painted surfaces any spilled
35. mark facing upward e Tighten Torque Valve Adjusting Cap Bolts 8 8 N m 0 9 kgf m 78 in Ib Valve Removal e Remove Cylinder Head see Cylinder Head Removal Camshaft see Camshaft Removal Rocker Arms and Shafts see Rocker Arm and Shaft Removal e Use the valve spring compressor assembly A and adapter B to press down the valve spring retainer Special Tools Valve Spring Compressor Assembly 57001 241 Valve Spring Compressor Adapter 428 2 57001 243 e Remove the split keepers e Loosen the valve spring compressor and take out the valve Property of www SmallEngineDiscount com Not for Resale 4 22 ENGINE TOP END Valves Guides Seats Springs Oil Seals Valve Installation e f a new valve is to be used check the valve to guide clearance x If there is too little clearance ream the valve guide x If there is too much clearance install a new valve guide e Check the valve seat see Valve Seat Inspection e After proper valve seating has been confirmed replace the valve stem oil seal A e Apply a thin coat of molybdenum disulfide grease to the valve stem B and install the valve into the guide e Put the spring seat C e Put the inner and outer springs D in place O Place the springs so that the closed coil end E of each spring faces down e Set the valve spring retainer F on the springs e Use the valve spring compressor to press down the retainer e Install the split keepers G a
36. post C on the movable sheave at all four arms Shoe Side Clearance Standard 0 15 0 30 mm 0 0059 0 0118 in If any of the measurements are greater than the maximum replace all shoes with standard shoes P No 49048 1080 see Drive Pulley Disassembly HSO6GO1BS1 e Turn the movable sheave clockwise e Measure the resulting clearance A between the shoe B and the post C on the movable sheave at two positions as shown D Arrow Mark If the clearance is not within the specified range adjust it according to following chart Clearance Measurement Present Shoes Part Number Thickness up to 0 15 mm 0 0059 in 49048 1078 7 2 mm 0 283 in 49048 1079 7 3 mm 0 287 in over 0 15 to 0 30 mm no change over 0 0059 to 0 0118 in 49048 1080 7 4 mm 0 291 in standard clearance 49048 1081 7 5 mm 0 295 in 49048 1082 7 6 mm 0 299 in 49048 1083 7 7 mm 0 303 in over 0 30 mm 0 0118 in 49048 1084 7 8 mm 0 307 in 49048 1085 7 9 mm 0 311 in 49048 1086 8 0 mm 0 315 in HS06002BS2 C e Check that the movable sheave A moves smoothly after the shoe side clearance adjustment O The movable sheave must move freely towards the fixed sheave B x If the movable sheave does not move smoothly readjust the shoe side clearance HS06003BS1 Property of www SmallEngineDiscount com Not for Resale CONVERTER SYSTEM 5 15 Drive
37. short Voltage above 12 V below 12 V Test charge Electrolyte Level above plates below top of plates Fill and test charge Specific Gravity above 1 200 in all cells no two below 1 100 or difference of Test charge cells more than 0 020 different more than 0 020 between two cells Battery Test Charging e f the battery is suspected of being defective sulfated or unable to take a charge consult the table e To test charge a battery perform the ordinary charging procedure and monitor the battery voltage and other signs as mentioned below Special Tool Hand Tester 57001 1394 x If the battery voltage suddenly jumps to over 13 V just after the start of charging the plates are probably sulfated A good battery will rise to 12 V immediately and then gradually go up to 12 5 or 13 V in about 30 min to an hour after the start of charging x If one cell produces no gas bubbles or has a very low specific gravity it is probably shorted x If there does not appear to be enough sediment in a cell to short the plates but that cell has a very low specific gravity after the battery is fully charged the trouble may be that there is not enough acid in that one cell In this case only sulfuric acid solution may be added to correct the specific gravity x If a fully charged battery not in loses its charge after 2 to 7 days or if the specific gravity drops markedly the battery is defective The self discharge rate of a good ba
38. so that the tip of the gauge is against the splined portion B of the pinion gear shaft e To measure the backlash move the pinion gear shaft back and forth C while holding the front axle steady The difference between the highest and the lowest gauge reading is the amount of backlash O Measure backlash at three locations equally spaced on the splines Front Final Bevel Gear Backlash Standard 0 10 0 20 mm 0 004 0 008 in at pinion gear spline x If the backlash is not within the limit replace the pinion gear shims To increase backlash increase the thickness of the shim s To decrease Soot P backlash decrease the thickness of the shim s O Change the thickness a little at a time e Recheck the backlash and readjust as necessary Tooth Contact Adjustment e Clean any dirt and oil off the bevel gear teeth e Apply checking compound to 4 or 5 teeth on the pinion gear NOTE O Apply checking compound to the teeth in a thin even coat with a fairly stiff paint brush If painted too thickly the exact tooth pattern may not appear O The checking compound must be smooth and firm with the consistency of tooth paste Special compounds are available from automotive supply stores for the purpose of checking differential gear tooth patterns and contact Use one of these for checking the bevel gears e Assemble the front final gear case see Front Final Gear Case Assembly It is not necessary to install the varia
39. 0 279 in 36 7 mm 1 445 in 40 0 mm 1 575 in 80 10 mm 3 154 in 79 80 mm 3 142 in 0 18 mm 0 0071 in 0 17 mm 0 0067 in 0 90 mm 0 035 in 0 90 mm 0 035 in 1 13 mm 0 0445 in 1 12 mm 0 0441 in 0 6 mm 0 0236 in 0 8 mm 0 0315 in 1 0 mm 0 0394 in Property of www SmallEngineDiscount com Not for Resale ENGINE TOP END 4 7 Specifications Special Tools Valve Guide Reamer 7 57001 162 Valve Guide Arbor 47 57001 163 Compression Gauge 57001 221 Valve Spring Compressor Assembly 57001 241 Valve Spring Compressor Adapter 628 2 57001 243 Piston Pin Puller Assembly 57001 910 Compression Gauge Adapter M12 x 1 25 57001 1018 Valve Seat Cutter 45 441 5 57001 1117 Valve Seat Cutter 32 438 5 57001 1122 Valve Seat Cutter Holder 7 57001 1126 Valve Seat Cutter Holder Bar 57001 1128 Piston Pin Puller Adapter 57001 1211 Filler Cap Driver 57001 1454 Valve Seat Cutter 32 644 57001 1515 Valve Seat Cutter 50 644 57001 1516 Property of www SmallEngineDiscount com Not for Resale 4 8 ENGINE TOP END 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 Retighten
40. 1 1057 in 37 985 38 085 mm 1 4955 1 4994 in 0 15 0 30 mm 0 0059 0 0118 in 60 mm 2 36 in 28 12 mm 1 107 in 38 12 mm 1 501 in Driven Pulley Sheave bushing inside diameter Spring free length Special Tools Circlip Pliers 57001 154 39 994 40 104 mm 1 5746 1 5789 in 75 1 mm 2 96 in Flywheel 8 Pulley Holder 57001 1343 Drive 8 Driven Pulley Holder 57001 1412 Drive Pulley Puller Bolt 57001 1429 Pulley Holder Attachement 57001 1472 Drive 8 Driven Pulley Holder 57001 1473 Drive Pulley Wrench 57001 1474 Spring Holder Set 57001 1483 Drive Pulley Measurement Tool 57001 1498 Actuator Lever Measurement Tool 57001 1499 Drive Pulley Holder 57001 1520 Property of www SmallEngineDiscount com Not for Resale 40 13 mm 1 580 in CONVERTER SYSTEM 5 7 Torque Converter AWARNING Excessive imbalance or operating rpm could cause torque converter pulley failure resulting in severe injury or death The pulleys of the belt drive torque converter are precision balanced components designed to operate within certain rpm limits Disassembly assembly and servicing procedures of the pulley assemblies must be followed closely Modifications to the engine or pulleys that increase rpm may cause failure CAUTION Do not turn the ignition switch OFF position from ON position while the torque converter cover is removed If it is done the learning control of Engine B
41. 12 in 4 mm 0 16 in AT 25 X 8 12 Dunlop KT121 Tubeless AT 25 x 10 12 Dunlop KT405C KT127A Tubeless Final Drive Front Final Gear Case Gear Case Oil Type Viscosity Oil level Capacity Rear Final Gear Case Gear Case Oil Type Oil level Capacity Brakes Front Brake Fluid Type Front Disc Brake Pad lining thickness Rear Brake Lever Pedal and Cables Rear brake lever free play Brake pedal free play API SF or SG API SH or SJ of JASO MA SAE 10W 40 Filler opening bottom 430 mL 0 45 US at MOBIL Fluid 424 or Kawa Chem Gear amp Wet Brake Oil CITGO TRANSGARD TRACTOR HYDRAULIC FLUID Filler opening bottom 900 mL 0 95 US qt DOT 3 or DOT 4 4 5 mm 0 18 in 1 2 mm 0 04 0 08 in 15 25 mm 0 6 1 0 in Electrical System Spark plug gap Rear brake light switch timing 0 8 0 9 mm 0 031 0 035 in On after 10 mm 0 4 in of pedal travel Property of www SmallEngineDiscount com Not for Resale PERIODIC MAINTENANCE 2 9 Specifications Special Tools Carburetor Drain Plug Wrench Hex 3 57001 1269 Belt Measuring Gauge 57001 1519 Flywheel 8 Pulley Holder 57001 1343 Pulley Holder Attachment 57001 1472 Oil Filter Wrench 57001 1249 Property of www SmallEngineDiscount com Not for Resale 2 10 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System Throttle Lever Free Play Inspection e Check that the throt
42. 2 mm 0 047 in 92180 1344 Backlash Adjustment e Clean any dirt and oil off the bevel gear teeth e Install the pinion gear assembly with the primary shim 1 0 mm 0 039 in thickness e Assemble the rear final gear case see Rear Final Gear Case Assembly O Install the ring gear with the primary shim 1 0 mm 0 039 in thickness O Check the backlash during tightening the cover bolts and stop tightening them immediately if the backlash disappears Then change the ring gear shim to a thinner one e Temporarily install the rear axle in the gear case and hold it with a vise so that the ring gear is lower than the pinion gear e Mount a dial gauge A so that the tip of the gauge is against the splined portion B of the pinion gear joint e To measure the backlash move the pinion gear shaft back and forth C while holding the rear axle steady The difference between the highest and the lowest gauge reading is the amount of backlash O Measure backlash at three locations equally spaced on the splines Rear Final Bevel Gear Backlash 0 07 0 14 mm 0 003 0 006 in at pinion gear spline If the backlash is not within the limit replace the ring gear shim s To increase backlash decrease the thickness of the shim s To decrease backlash increase the thickness of the shim s x Change the thickness a little at a time e Recheck the backlash and readjust as necessary Tooth Contact Adjustment e Clean any dirt
43. 25 V DC Battery Battery 14 15V e Turn off the ignition switch and disconnect the hand tester x If the regulator rectifier output voltage is between the values given in the table the charging system is working normally x If the output 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 lf the battery voltage does not increase as the engine speed increases then the regulator rectifier is defective or the alternator output is insufficient for the loads Check the alternator and regulator rectifier to determine which part is defective Alternator Inspection There are three types of alternator failures short open 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 perform the following proce dures Disconnect the alternator connector A O Connect a hand tester as shown in the table O Start the engine O Run it at the rpm given in the table O Note the voltage readings total 3 measurements Alternator Output Voltage Tester to Tester to 3 000rpm Tester Range 250 V AC One black lead dere rae 36 54 V I
44. 49 5 0 36 L G Apply grease for oil seal and O ring L Apply a non permanent locking agent M Apply molybdenum disulfide grease MF Apply MOBIL FLUID 424 or equivalent oil S Follow the specific tightening sequence Property of www SmallEngineDiscount com Not for Resale 11 8 FINAL DRIVE Specifications Standard Service Limit Output Bevel Gear Case Output bevel gear backlash 0 06 0 12 mm 0 0024 0 0047 in at output drive shaft spline Front Final Gear Case Gear case oil same engine oil Type API SF or SG API SH or SJ with JASO MA Viscosity SAE10W 40 Oil level Filler opening bottom Capacity 430 mL 0 45 US qt LSD clutch torque when variable differential control lever 15 20 N m 1 5 2 0 kg m 11 14 ft lb is released when variable differential control lever 157 N m 16 kg m 116 ft lb or more is pulled in Bevel gear backlash 0 10 0 20 mm 0 004 0 008 in at pinion gear spline Rear Axle Shaft Rear axle shaft runout TIR 1 mm 0 04 in or less TIR 2mm 0 08 in Rear Final Gear Case Gear case oil MOBIL Fluid 424 or Kawa Chem Gear amp Wet Brake Oil CITGO TRANSGARD TRACTOR HYDRAULIC FLUID Oil level Filler opening bottom a Capacity 900 mL 0 95 US qt Rear final bevel gear backlash 0 07 0 14 mm 0 003 0 006 in at pinion gear spline Special Tools Bearing Puller 57001 135 Inside Circlip Pliers 57001 143
45. A 8 8 N m 0 9 kgf m 78 in Ib e HK11002551 Oil Seal Installation e Press the oil seal A in the front final gear case left cover B to the dimension as shown C 4 6 5 6 mm 0 18 0 22 in HK11000BS1 Ring Gear Disassembly e Remove Ring Gear Assembly see Front Final Gear Case Disassembly Ring Gear Bolts A Ring Gear B e Remove Differential Gear Cover A Right Side Gear 16T B Pins C Spider Gear Shaft D Spider Gears 10T E Left Side Gear 16T F Left Differential Gear Case G HK11002851 Property of www SmallEngineDiscount com Not for Resale 11 36 FINAL DRIVE Front Final Gear Case Ring Gear Assembly e Press the bearing A on the left differential gear case B until it is bottomed e Apply engine oil C to the spider gears e Apply molybdenum disulfide grease D to the spline in the side gear 16T E e Install Left Side Gear 16T Spider Gears 10T F Spider Gear Shaft G and Pins H HK11002951 e Apply engine oil A to the spider gears e Apply molybdenum disulfide grease B to the spline in the side gear 16T C e Install Side Gear 16T Differential Gear Case Cover D Ring Gear E e Apply a non permanent locking agent Three Bond TB2471 Blue to the ring gear bolts F and tighten them Torque Ring Gear Bolts 57 N m 5 8 kgf m 42 ft Ib NOTE O Keep the ring gear assembly
46. A on the carburetor holder and air cleaner duct e Remove the choke cable lower end B Carburetor Installation e Adjust the pilot screw before installation e Align the carburetor holder notch A with the carburetor projection B e Align the air cleaner duct notches A with the carburetor projections B Torque Air Cleaner Duct Front Clamp Screws 1 4 N m 0 14 kgf m 12 in Ib e Route the carburetor vent tube according to Appendix chapter e Check fuel leakage from the carburetor AWARNING Fuel Spilled from the carburetor is hazardous x If the carburetor has been disassembled or if there is some other reason that the fuel level may be incorrect inspect the fuel level see Carburetor Fuel Level Inspection HCO6BO14 P Property of www SmallEngineDiscount com Not for Resale 3 14 FUEL SYSTEM Carburetor e Connect the carburetor heater lead A and ground lead B connec tors e Route the carburetor hoses according to Cable Wire and Hose Routing section in Appendix chapter e Adjust the idle speed see Idle Speed Adjustment e Check the throttle cable see Throttle Lever Free Play Inspection in Periodic Maintenance chapter Carburetor Disassembly e Remove the carburetor see Carburetor Removal e Disassemble the carburetor top end as follows O Remove the upper chamber cover screws and take off the cover A and spring B O Pull out the vacuum piston C with the dia
47. Case Oil Change e Warm up the oil by running the vehicle so that the oil will pick up any sediment and drain easily Then stop the vehicle e Park the vehicle so that it is level both side to side and front to rear e Place an oil pan beneath the rear final gear case and remove the drain plug A AAWARNING When draining or filling the final gear case be careful that no oil gets on the tire or rim because oil will deteriorate the tire Clean off any oil that inadvertently gets on them with a high flash point solvent e After the oil has completely drained out install the drain plug with a new aluminum gasket Torque Oil Drain Plug 20 N m 2 0 kg m 14 ft Ib e Fill the final gear case up to the bottom of filler opening with the oil specified below Rear Final Gear Case Oil Type MOBIL Fluid 424 or Kawa Chem Gear amp Wet Brake Oil CITGO TRANSGARD TRACTOR HYDRAULIC FLUID Capacity 900 mL 0 95 US qt e Be sure the O ring is in place Torque Oil Filler Cap B 29 N m 3 0 kg m 22 ft Ib Joint Boots Inspection e Visually inspect the front axle joint boots in accordance with the Periodic Maintenance Chart or if the axles are noisy during operation e Remove Guard A e Visually inspect the joint boots B x If the joint boot is torn worn deteriorated or leaks grease replace the front axle assembly Rear Propeller Shaft Joint Boot Inspection e Visually inspect the rear propeller shaft joint boot A
48. Crankshaft Balancer Shaft Installation e The left shaft A of the crankshaft is longer than the right shaft B e Apply engine oil to the both main journals and teeth of the sprocket e Insert the right crankshaft tapered end the shorter end into the right crankcase using a press HI05010B51 e Align the punch mark A on the balancer shaft gear with the punch marks B on the crankshaft gear as shown H104003BS1 Crankshaft Disassembly CAUTION Since assembly of the crankshaft demands exacting toler ances the disassembly and reassembly of the crankshaft should only be performed by experienced mechanics with the necessary tools and equipment The crankshaft left main bearing chain sprocket and left crankshaft are available separately as spare parts however it is recommended that the crankshaft assembly be replaced rather than attempting to replace the components e Press the crankpin out of the crank halves to separate the crank halves connecting rod spacers crankpin needle bearing and crankpin Property of www SmallEngineDiscount com Not for Resale CRANKSHAFT TRANSMISSION 9 11 Crankshaft Balancer Shaft and Connection Rod Crankshaft Assembly e Apply engine oil to the needle bearing e Press the crank halves onto the crankpin noting the crankpin direction until connecting rod side clearance is within specification see Connecting Rod Big End Side Clearance O M
49. Cylinder Head Removall ccccsceeeeeeteeeteees 4 17 Cylinder Head Installation 0 00 ee 4 18 Cylinder Head Assemblly 0 tee 4 19 Cylinder Head Cleaning 0 eee 4 19 Cylinder Head Warp cccesceesesteeeeeeeeneenees 4 20 Valves Guides Seats Springs Oil Seals 4 21 Valve Clearance Inspection ccceceeeeeeee 4 21 Valve Clearance Adjustment cceeeeee 4 21 Valve REMOVAI ccceecceceereeeseeneseeeeeseeeeeeenes 4 21 Valve Installation 4 22 Valve Visual Inspection 4 22 Valve Guide Removal cccscceeceeeeeseenersees 4 22 Valve Guide Installation cceeceeeeeeeeeeees 4 22 Valve to Guide Clearance Measurement 4 23 Valve Seat INSPeCtion cceeeeeeeeeeeeretereeees 4 23 Valve Seat Repair Valve Lapping 4 24 Cylinder and Piston cceeceeeceeeeseeeeeeeeeteeeeeeeeaees 4 28 Cylinder Removal ceccceeeseeeeeetseeeeneeeneerees 4 28 Cylinder Installation eceeeeeeeeeeeeeeeeeeeeeeeeeee 4 28 Cylinder Assembly eceeeeeeeeeereeereeeneeeeeeeaes 4 29 Piston REMOVAI cccesseeeeneeeeseeeeeneeeeneeereaees 4 29 Piston Installation ccceeseeeseeseneeeeneeeeeeees 4 30 Cylinder Piston Weal cccccceeceeeeteteeeneeeaes 4 31 Piston Cylinder Clearance 4 31 Piston Ring and Ring Groove Wear 4 31 Piston Ring Groove Width 4 32 Piston Ring Thickness 4 32 Piston
50. Gray 92104 1065 Three Bond 1215 Gray Property of www SmallEngineDiscount com Not for Resale CRANKSHAFT TRANSMISSION 9 7 Crankcase Crankcase Disassembly e Remove Engine see Engine Removal Installation chapter Drive and Driven Pulleys see Converter System chapter Starter Motor see Electrical System chapter Oil Filter Starter Clutch Gear see Electrical System chapter Oil Pump see Engine Lubrication System chapter Piston see Engine Top End chapter Camshaft Chain see Engine Top End chapter Shift Shaft Positioning Bolt A Washer Spring and Steel Ball Damper B e Remove Crankcase Bolts M6 A Crankcase Bolts M8 B e Wrap the teeth on the sprocket C by taping for protecting the bushing in the crankcase e Using the pry points D split the crankcase halves e Lift off the left crankcase half Crankcase Assembly CAUTION Right and left crankcase halves are machined at the factory in the assembled state so the crankcase halves must be replaced as a set NOTE Be certain that all parts are cleaned thoroughly before assembly O Blow through all oil passages with compressed air to clear any blockage in the crankcase halves and crankshaft HI04B009 P AWARNING Clean the engine parts in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Do not use gasoline or a low flash point so
51. HMO4B026 P e Tighten the nuts A and compress the spring to loosen the piston rod nut B O Pull the top joint C upward Property of www SmallEngineDiscount com Not for Resale 13 10 SUSPENSION Shock Absorbers e Holding the top joint A with a suitable bar B and loosen the piston rod nut with a wrench C e Remove Top Joint e Remove Nuts A and Upper Holder B Spring Guide C Spring D Rear Shock Absorber Spring Installation e Tighten the piston rod nut A fully by hand e Insert the damper assembly B into the center of the spacer and holder see Rear Shock Absorber Spring Removal Special Tools Holder amp Guide Arbor 57001 1476 Spacer amp Holder 57001 1477 e Install Adjusting Sleeve C Spring Seat D Stepped side facing upward e Install the spring A with the smaller end facing downward on the spring seat e Install the spring guide B with the smaller end facing downward HMO4BO31 P e Put the upper holder A 57001 1477 on upper ends of the spring guide B and arbors C so that the recess side faces downward e Tighten the nuts D and compress the spring Property of www SmallEngineDiscount com Not for Resale SUSPENSION 13 11 Shock Absorbers e Tighten the top joint A fully by hand e Tighten the piston rod nut B against the top joint Torque Piston Rod Nut 49 N m 5 0 kgf m 36 ft lb e Fit the top joint on the spr
52. High Altitude Setting Information Specifications Altitude m ft 0 500 0 1 700 500 1 400 1 700 4 700 Drive Pulley Ramp Weight P No 39152 1096 STD EC P No 39152 1096 STD EC Spring Spring Spacer P No 92145 1465 STD Pink P No 92145 1465 STD Pink Driven Pulley Main Jet P No 92063 1332 STD 155 or P No 92063 1344 158 P No 92063 1332 STD 155 1 400 2 300 4 700 7 700 P No 39152 1098 EC H1 P No 92145 1187 Gray P No 92026 1623 P No 92063 1017 145 2 300 3 300 P No 39152 1100 P No 92145 1187 P No 92026 1623 P No 92063 1014 7 700 10 700 EC H2 Gray X 2 pc 135 3 300 4 500 P No 39152 1100 P No 92145 1187 P No 92026 1623 P No 92063 1069 10 700 14 800 EC H2 Gray X 2 pc 125 Refer to the Drive Pulley and Drive Pulley sections in this chapter and Carburetor section in Fuel System chapter for the parts replacement Property of www SmallEngineDiscount com Not for Resale Property of www SmallEngineDiscount com Not for Resale RECOIL STARTER 6 1 Recoil Starter Table of Contents Exploded Vie W cerimonie aan ai 6 2 SA A A EE EA 6 4 Recoil Starter Removal diana aiii ida 6 4 Recoil Starter lnstalaio aii dae 6 4 Recoil Starter Inspection acocisacosonsrciloan aaa ds 6 4 Property of www SmallEngineDiscount com Not for Resale 6 2 RECOIL STARTER Exploded View HTO2001BW
53. Ib 1 4 L 60 mm 2 4 in 5 8 L 30 mm 1 2 in e Apply grease to the oil seal lip A e Press the oil seal B in the coupling C to the specified position as shown D 1 mm 0 04 in Special Tool Oil Seal Driver 618 57001 1505 HK11003BS1 e Apply molybdenum disulfide grease to the spline A in the shifter B and inner surface C of the coupling e Install the shifter and coupling on the pinion gear shaft D e Apply grease to the oil seal lip E e Press the oil seal F in the front final gear case so that the oil seal surface is flush G with the case end Special Tool Oil Seal Driver 648 57001 1506 HK11004BS1 e Hold the front final gear case with the gear holder amp socket wrench A in a vise Special Tool Gear Holder amp Socket Wrench Hex 24 57001 1489 Property of www SmallEngineDiscount com Not for Resale FINAL DRIVE 11 35 Front Final Gear Case e Install Washer A Front Final Gear Case Coupling Nut B e Tighten Torque Front Final Gear Case Coupling Nut 20 N m 2 0 kgf m 14 ft lb HK11005BS1 e Install the variable front differential control shaft lever A on the shift shaft B so that the punch mark C on the lever aligns with the punch mark D on the shaft as shown E 45 8 50 4 mm 1 803 1 984 in D e Tighten N Torque Variable Front Differential Control Shift Shaft Lever Bolt F
54. Inspection and Drive Belt Inspection in Periodic Maintenance chapter e After completing the inspections do the drive belt failure mode memory clearing procedure see Drive Belt Failure Mode Memory Clearing Procedure Check 5 This flashing is the indication pattern for the drive belt failure mode memory clearing procedure Check 6 e The LED indicator may be broken e Do the drive belt failure mode memory clearing procedure x If the same flashing appears replace the LED indicator Check 7 The writing memory in the LED indicator is a limit one hundred thousand times e Replace the LED indicator Check 8 e The LED indicator may be broken e Do the drive belt failure mode memory clearing procedure x If the same flashing appears replace the LED indicator Check 9 10 11 e See Actuator Control System Troubleshooting Property of www SmallEngineDiscount com Not for Resale ELECTRICAL SYSTEM 16 51 LED Indicator LED Indicator CHECK BELT LED 4WD LED Reset Connector Battery Ignition Switch Drive Belt Failure Detecting Switch Igniter Input from Drive Belt Failure Detecting Switch 10 Output to LED Indicator 11 Actuator Controller 12 2WD 4WD Shift Switch LED Indicator External Circuit P OANDARWDN HP26001BS3 G Property of www SmallEngineDiscount com Not for Resale 16 52 ELECTRICAL SYSTEM LED Indicator Led Indicato
55. Locknut 20 N m 2 0 kgf m 14 ft Ib e Apply molybdenum disulfide grease Outside of Tie Rod End Collar D e Apply grease to the oil seals and install them e Tighten Torque Tie Rod End Bolt E 9 8 N m 1 0 kgf m 87 in Ib HI1100005W1 e Align the mark A on the shaft end with the slit B of the shift shaft lever e Position the shift shaft lever end C on the boss center D of the crankcase e Install Bracket E Shift Lever Assembly Nut F e Tighten Torque Shift Lever Assembly Nut 20 N m 2 0 kgf m 14 ft lb Tie Rod End Nut G 20 N m 2 0 kgf m 14 ft Ib HI110001BW2 Property of www SmallEngineDiscount com Not for Resale CRANKSHAFT TRANSMISSION 9 17 Transmission e Install Guide A e Tighten Torque Shift Lever Assembly Bracket Bolts B 20 N m 2 0 kgf m 14 ft Ib e Set the lever assembly in the neutral position C while turning the tie rod D NOTE O Do not turn the shift shaft E when setting the lever assembly on neutral position O Turn the tie rod until the rod F of the shift lever assembly contact with the guide G and then the tie rod can be turned until 1 8 At that time the clearance H which can be made between the rod and the guide is 0 0 5 mm 0 0 02 in O This clearance is a setting range for the neutral position e Tighten Torque Tie Rod End Rear Locknut I 9 8 N m 1 0 kgf m 87 in Ib e Holding th
56. Mounting Bolts 9 8 N m 1 0 kgf m 87 in Ib HP23000BS1 Engine Brake Actuator Removal e Remove Actuator Lead Connector A Property of www SmallEngineDiscount com Not for Resale 16 54 ELECTRICAL SYSTEM Actuator Control System e Remove Actuator Mounting Bolts A Actuator B Engine Brake Actuator Installation e Apply grease to the O ring A and install it e Apply molybdenum disulfide grease to the pin B e Insert the pin into the collar C of the engine brake lever assembly D e Tighten Torque Engine Brake Actuator Mounting Bolts 8 8 N m 0 9 kgf m 78 in Ib O Wipe off any protruding grease HP23B005 P Actuator Control System Outline The actuator controller A has a microprocessor that detects vehicle speed state of the selectable 2WD 4WD shift switch ignition switch and the forward reverse movement of the vehicle in order to control the engine brake actuator and selectable 2WD 4WD actuator Property of www SmallEngineDiscount com Not for Resale ELECTRICAL SYSTEM 16 55 Actuator Control System Actuator Control System Wiring Diagram Black Orange Vcc i O 3 Yellow Vout 1 Ps 3 FO O Blue Ground Indicator GND Groun ae Engine Brake Actuator 12V Power 1 1 Speed LED Sensor Pulse Indi oe O ay Signal 1 Red SO e a Pulse Sena
57. OONDARWN Oil Pressure Temperature Warning Indicator Light Oil Temperature Switch Tail Brake Light Front Brake Light Switch Parking Brake Light Switch Rear Brake Light Switch Ignition Switch Main Fuse 30 A Battery Property of www SmallEngineDiscount com Not for Resale ELECTRICAL SYSTEM 16 43 Oil Cooler Fan System Oil Cooler Fan Circuit Inspection e Remove the left front side cover see Frame chapter e Disconnect the leads A from the oil cooler fan switch e Using an auxiliary wire connect the oil cooler 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 Oil Cooler Fan Motor Inspection e Remove the Front Fender see Frame chapter e Disconnect the connector A in the fan lead e Using two auxiliary wires supply battery B voltage to the fan motor x If the fan does not rotate the fan motor is defective and must be replaced Oil Cooler Fan Motor Leads Battery BK Battery Oil Cooler Fan Circuit Sa GB wo i Ae 5 7 W G BK Y gt L BK Y I xx E ba OL vo foo W R LE wr HP25000BW2 1 Oil Cooler Fan 4 Main Fuse 30A 2 Oil Cooler Fan Switch 5 Battery 3 Oil Cooler Fan Fuse 20A Property of www SmallEngineDiscount com Not for Resale 16 44 ELECTRICAL SYSTEM Speedometer Optional
58. Pulley Drive Pulley Assembly e Install the ramp weight A as shown e Tighten Torque Ramp Weight Nuts B 6 9 N m 0 7 kgf m 61 in Ib e Check that the ramp weights swing smoothly e Hold the fixed sheave A with the drive pulley holder B in a vise Special Tool Drive Pulley Holder 57001 1473 e Clean the threads of the fixed sheave and spider e Install Movable Sheave Spider A and Wear Guides B O Align the arrow C on the spider with the arrow D on the movable sheave O Insert the guides so that the rubber side small diameter faces inward e Put the drive pulley wrench A on the spider B and tighten the bolt C Special Tool Drive Pulley Wrench 57001 1474 e Turn the wrench counterclockwise for tightening Torque Spider 275 N m 28 kgf m 203 ft lb HS060004 P e Install the spacer e Put the spring A in the groove of the spider e Align the arrows B on the drive pulley cover and spider e Install Dowel Pins C Drive Pulley Cover e Tighten Torque Drive Pulley Cover Bolts 13 N m 1 3 kgf m 113 in Ib e Clean the surface of the sheaves with an oil less cleaning fluid Property of www SmallEngineDiscount com Not for Resale 5 16 CONVERTER SYSTEM Drive Pulley Drive Pulley Installation e Clean the following portions with an oil less cleaning fluid such as trichloroethylene or acetone Fixed Sheave Tapered Portion A Crankshaft Tapered Portion B AWAR
59. Switch A Engine Stop Switch B Starter Button C Reverse Power Assist Switch Override D Rear Brake Light Switch E Power Outlet Connector F 2WD 4WD Shift Switch G Front Brake Light Switch H Ignition Switch I Speedometer A except US model Neutral Indicator Light B Oil Pressure and Temperature Warning Indicator Light C Reverse Indicator Light D Drive Belt Check Indicator Light LED E AWD Indicator Light LED F Headlights A Fan Fuses 20A and Belt Switch Fuse 5A B Ground Wire Frame A Ignition Coil B Oil Cooler Fan C Spark Plug D 2WD 4WD Actuator E Drive Belt Failure Detection Switch A Carburetor Heater and Ground Terminals B Drive Belt Failure Mode Reset Connectors C Engine Brake Actuator D Rear Brake Light Switch E Speed Sensor F Property of www SmallEngineDiscount com Not for Resale 16 12 ELECTRICAL SYSTEM Parts Location Alternator A Starter Motor B Pickup Coil C Reverse Position Switch D Neutral Position Switch E Ground Wire Engine F Forward Reverse Detecting Sensor G Oil Pressure Warning Light Switch H Battery A Accessory Fuse 5A B Air Temperature Sensor C Starter Circuit Relay Neutral D Starter Relay E Starter Circuit Relay Brake F Actuator Controller G Main Fuse 30 A H Tail Brake Light A Igniter B Regulator Rectifier C Oil Tempe
60. System 2 17 Engine Oil ChanQl ooooncccocicnccconcnoncninnncnncnoncnnnos 2 17 Oil Filter Change oooocconnccnocicocccancconcnnnnncnnccanccnno 2 17 Oil Cooler Cleaning and Inspection 2 17 Oil Hose and Connection Check 2 18 Wheels Tires cscccescceceseeeeeeeeeseeneeseeneneneeeeesees 2 18 Tire INSPOCtION ceseeceeseeeeeseeeeseneeeeeeeneeeeere 2 18 Final DriVO ooo oia ata 2 19 Variable Differential Control Lever Position Inspec A cachecessdustencesssccaces 2 19 Variable Differential Control Lever Position Adjust A ae 2 19 Front Final Gear Case Oil Change 2 19 Rear Final Gear Case Oil Change 2 20 Joint Boots Inspection eeen 2 20 Rear Propeller Shaft Joint Boot Inspection 2 20 BAK GS ui dr rita ds 2 21 Front Brake Pad Wear Inspection 2 21 Brake Hose and Connection Check 2 21 Brake Hose Replacement sccceseeeeneeees 2 21 Brake Fluid Level Inspection n 2 21 Brake Fluid Change ccccceeceeseeseeeeeeeeeeeaes 2 22 Brake Master Cylinder Piston Assembly and Dust Seal Replacement ccccccessseeeeeeeeeseeeeees 2 22 Caliper Piston Seal and Dust Seal Replacement2 23 Rear Brake Plates Replacement 0 0 2 23 Rear Brake Lever Free Play Inspection 2 23 Brake Pedal Free Play Inspection 2 23 Rear Brake Lever and Pedal Free Play Adjust Steering
61. 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 inspection in the procedural step or sub step it follows 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 specified tightening torque oil grease or a locking agent during assembly Property of www SmallEngineDiscount com Not for Resale Property of www SmallEngineDiscount com Not for Resale GENERAL INFORMATION 1 1 General Information Table of Contents Before Servicing iia A eee Re es 1 2 Model Identification ccoo it EE A E 1 4 General SpecificatiOnS conciliar rn Eo as IA la lid 1 6 Special Tools and SSAA sas caus saad ii dde rea 1 8 Unit Gonversion Table itonasnaratancdia aro tota 1 14 Property of www SmallEngineDiscount com Not for Resale 1 2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a vehicle read the precautions given below To facilitate actual operations notes illustrations photographs cautions and detailed descriptions have been included in each chapter wherever necessary This section explains the items that require particular attention during the
62. a short Replace the starter motor NOTE Even if the foregoing checks show the armature to be good it may be defective in some manner not readily detectable with the hand tester If all other starter motor and starter motor circuit components check good but the starter motor still does not turn over or only turns over weakly replace the starter motor with a new one Starter Motor Brush Length e Measure the overall length A of each brush Starter Motor Brush Length Standard 10 mm 0 39 in Service Limit 3 5 mm 0 14 in If any is worn down to the service limit replace the brush plate assembly Brush Assembly Inspection e Using the x 1 Q range measure the resistance as shown A Terminal Bolt and Positive Brush B Brush Plate and Negative Brush x If there is not close to zero ohms the brush lead has an open Replace the brush plate assembly Brush Plate and Terminal Bolt Inspection e Using the highest range measure the resistance as follows A Terminal Bolt and Right Hand End Cover B Terminal Bolt and Brush Plate x l there is any reading the brush holder assembly has a short Replace the brush plate assembly Property of www SmallEngineDiscount com Not for Resale 16 36 ELECTRICAL SYSTEM Electric Starter System Starter Relay Inspection e Remove Seat see Frame chapter Starter Relay A e Connect the hand tester A and a 12 V battery B to the starter relay
63. about four rotations e Remove one nut holding bolt and look at through the hole x If the groove of the bevel gear holder nut is not seen loosen the other three bolts e Drive the gear shaft end using a copper mallet until the grooves of the bearing holder nut can be seen again e Retighten the nut holding bolts 4 securely into the groove of the bevel gear holder nut in the output drive bevel gear housing Special Tool Nut Holding Bolts 57001 1481 e Repeat the above procedure and remove the bevel gear from the housing e Remove the bearing holder A using the hexagon wrench B Special Tool Hexagon Wrench Hex 41 57001 1491 O If the holder seems too difficult to break free apply heat to softer the locking agent HK160007 P e Remove Outer Ball Bearing A Special Tool Oil Seal amp Bearing Remover B 57001 1058 e Remove Output Drive Bevel Gear Holder Nut Inner Ball Bearing A Special Tool Oil Seal amp Bearing Remover B 57001 1058 Property of www SmallEngineDiscount com Not for Resale 11 12 FINAL DRIVE Output Bevel Gears Output Drive Bevel Gear Assembly e Press the new inner ball bearing until it is bottomed Special Tool Bearing Driver Set A 57001 1129 e Apply a non permanent locking agent to the threads of the bearing holder A and tighten it so that the deep side B faces outward Torque Bearing Holder 118 N m 12 kgf m 87 ft lb e Press the output
64. ae cil sattiegyede restates 13 4 SNOCK A A e 13 5 Front Shock Absorber Removal viii ba 13 5 Front Shock Absorber InstallatiON oonnonnnncnnnnnnnninnnnnnconnconccncccncccn crac 13 5 Front Shock Absorber Inspection oia 13 5 Front Shock Absorber Spring REMOVAalI ccccesceeeceeeeeseeeeeneeeeeceeeeaeeeaeeeeeseaeeeaeesaeesaeseaeseaeesieeseaeseaeesieeseeeenaeenaees 13 6 Front Shock Absorber Spring Installation cccceceeeceeseeeeeeeeeeeeeeeseeeeeaeeeeeecaaeseaeeeaeeseeeseaeeeaeesaeeseeeenaeeeeeseeeeneeseatens 13 7 Rear Shock Absorber Preload AdjUStMent ccceeceseseeeseeeeeeeseeteaeeeaeeeseecaaeeeaeesaeesaeeseaeeeaeesseesaeseaeeeseeseaeseaeeeaeetaas 13 8 Rear Shock Absorber REMOVAI c ccecceeeceseeeeeeeeeneeceeeeeeecaeeeaeeeeeseeeeeaeeeaeesaeeseaeseaeecaeeseeseeeecaeesieeseeeeeaeesieeseeeseaten 13 8 Rear Shock Absorber Installation woth dea aoa eG eee An lee 13 8 Rear Shock Absorber Inspection ccccceseeseeeseeseeeeeneeeaeecsaeeaeeeaeeeseeseneseaeesseesaaessaeeeaeesaeeeneeseaeesaeesieeseaeeneeseeeenaees 13 9 Rear Shock Absorber Spring REMOVal c cceccececeeeeseeeeeneeeeeeeeeeseaeeeaeesaeesaeeeaeseaeeseeeeeaeeeaeeseeseaeseaeesieeseaeeeeeeneetaas 13 9 Rear Shock Absorber Spring Installation ccceecceeceeseeeseeeneeceeeeeaeeeeeeeeeeseaeeeaeesaeeseaeseeeeseeseeeeeaeeseesiaeeeaeesneetaee 13 10 Rear Shock Absorber Scrapping cccecceeeceseeeceeeeeneeeeeeseeeeeaeeeaeecaeeseaeseaeecaeeseaeseaees
65. any solvent 9 Gasket O Ring Replace a gasket or an O ring with a new part when disassembling Remove any foreign matter from the mating surface of the gasket or O ring to ensure a perfectly smooth surface to prevent oil or compression leaks 10 Liquid Gasket Locking Agent Clean and prepare surfaces where liquid gasket or non permanent locking agent will be used Apply them sparingly Excessive amount may block engine oil passages and cause serious damage 11 Press When using a press or driver to install a part such as a wheel bearing apply a small amount of oil to the area where the two parts come in contact to ensure a smooth fit 12 Ball Bearing and Needle Bearing Do not remove a ball bearing or a needle bearing unless it is absolutely necessary Replace any ball or needle bearings that were removed with new ones Install bearings with the manufacturer and size marks facing out applying pressure evenly with a suitable driver Apply force only to the end of the race that contacts the press fit portion and press it evenly over the base component 13 Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones as removal generally damages seals Oil or grease seals should be pressed into place using a suitable driver applying a force uniformly to the end of seal until the face of the seal is even with the end of the hole unless instructed otherwise When pressing in an oil or grease seal which has manufacturer
66. bracket e Install Washer and Headlight Beam Adjusting Screw e Connect Headlight Lead Connector HP12B023 P Taillight Bulb Replacement e Remove Taillight Lens Mounting Screws A Taillight Lens B e Push the bulb A in turn it counterclockwise and pull it out e Be sure the socket is clean e Insert the new bulb by aligning the pins A with the grooves B in the walls of the socket e Push the bulb in turn it clockwise and release it lt should lock in position Property of www SmallEngineDiscount com Not for Resale ELECTRICAL SYSTEM 16 41 Lighting System e Insert the projection A on taillight lens into the groove B in the taillight body N me HP126027 Property of www SmallEngineDiscount com Not for Resale 16 42 ELECTRICAL SYSTEM Lighting System Lighting System Circuit gt we a R BK BK Y R BK BK Y Y edi R BK BK Y BR W G R W BR BL R g R W E BK Y R BK BK Y BL R BL R BK Y R BK R BK o b R R Le R Y R Y BR BR BR R D gt LT R BK Y gt __ 8K Y BL gt __ BL BL LK DL BR BR gt 1_ BR BR Zo f SA HP12001BW4 Light Dimmer Switch Headlight Left Headlight Right Neutral Indicator Light Reverse Indicator Light Reverse Switch Neutral Switch Oil Pressure Switch
67. dirt and fuel deposits AWARNING Clean the tank in a well ventilated area and take care that there is no spark or flame anywhere near the working area this includes any appliance with a pilot light Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents to clean the tank A fire or explosion could result e Pour the solvent out the tank e Remove the fuel tap from the tank by taking out the bolts e Clean the fuel tap filter screens in a high flash point solvent e Pour high flash point solvent through the tap in both ON and RES positions e Dry the tank and tap with compressed air e Install the fuel tap in the tank see Fuel Tap Installation e Install the fuel tank see Fuel Tank Installation Fuel Tap Inspection e Check the fuel tap filter screens A for any breaks or deterioration x If the filter screens have any breaks or are deteriorated it may allow i dirt to reach the carburetor causing poor running Replace the fuel tap HCO8B009 P Property of www SmallEngineDiscount com Not for Resale 3 24 FUEL SYSTEM Fuel Tank x If the fuel tap leaks or allows fuel to flow when it is OFF replace the damaged gasket A or O rings B Fuel Level Gauge Removal e Remove the fuel tank cap AWARNING Gasoline is extremely flammable and can be explosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure t
68. 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 difficult to wash off completely and will eventually deteriorate the rubber used in the disc brake e Take care not to scratch the piston or the inner wall of the cylinder e Apply brake fluid to the removed parts and to the inner wall of the cylinder e Tighten Torque Brake Lever Pivot Bolt 5 9 N m 0 6 kgf m 52 in Ib Brake Lever Pivot Bolt Locknut 5 9 N m 0 6 kgf m 52 in Ib Master Cylinder Inspection Visual Inspection e Disassemble the master cylinder see Master Cylinder Disassembly e Check that there are no scratches rust or pitting on the inner wall of the master cylinder A and on the outside of the piston B x If the master cylinder or piston shows any damage replace them e Inspect the primary C and secondary D cups x If a cup is worn damaged softened rotted or swollen the piston assembly should be replaced to renew the cups x lf fluid leakage is noted at the brake lever the piston assembly should be replaced to renew the cups e Check the dust cover E for damage If it is damaged replace it e Check that the relief F and supply G ports are not plugged x If the relief port becomes plugged the br
69. drive bevel gear until it is bottomed e Apply a non permanent locking agent to the threads of the bevel gear holder nut A and tighten it so that the projection side B faces outward Special Tool Socket Wrench 57001 1482 C Torque Bevel Gear Holder Nut 157 N m 16 kgf m 116 ft Ib e Press the new outer ball bearing until it is bottomed Output Driven Bevel Gear Removal e Remove Swingarm see Suspension chapter and Front Propeller Shaft see Front Propeller Shaft Removal or Engine see Engine Removal Installation chapter Output Driven Bevel Gear Housing Bolts A Output Driven Bevel Gear Housing B HK168004 P Property of www SmallEngineDiscount com Not for Resale FINAL DRIVE 11 13 Output Bevel Gears e Tap lightly the front end A of the output driven bevel gear shaft using a plastic mallet O The output driven bevel gear shaft assembly comes off with the housing HK16B005 P Output Driven Bevel Gear Installation e Apply grease O ring A e Install the output driven bevel gear shaft assembly e Tighten Torque Output Driven Bevel Gear Housing Bolts 26 N m 2 7 kgf m 20 ft Ib HK160019 P Output Driven Bevel Gear Disassembly e Remove Output Driven Bevel Gear Housing Assembly see Output Driven Bevel Gear Removal e Hold the holder in a vise and set the housing assembly A on the holder Special Tools Damper Spring Compressor Set B 57001 1475 Holder amp Guide Arb
70. e Apply a non permanent locking agent to the pinion gear bearing holder A and tighten it Special Tool Socket Wrench Hex 50 57001 1478 Torque Pinion Gear Bearing Holder 137 N m 14 kgf m 101 ft lb e Inspect Ball Bearing A see Bearing and Oil Seal section Oil Seals B see Bearing and Oil Seal section If they are damaged replace the rear final gear case right cover C e Apply grease to the oil seal lips and O ring D e Install Rear Final Gear Case Right Cover A e Apply a non permanent locking agent to the cover bolts and tighten them Torque Rear Final Gear Case Right Cover Bolts M10 B 49 N m 5 0 kgf m 36 ft Ib Rear Final Gear Case Right Cover Bolts M8 C 24 N m 2 4 kgf m 17 ft Ib e Install Rear Final Gear Case Left Cover Rear Axle see Rear Axle Installation YK LAPOpESI Trailer Hitch Bracket see Frame chapter Property of www SmallEngineDiscount com Not for Resale 11 48 FINAL DRIVE Rear Final Gear Case Oil Seal Installation e Press the oil seals in the right and left covers to the specified positions as shown A Left Cover B Outside Oil Seal C 31 5 32 5 mm 1 24 1 28 in D Inside Oil Seal E 21 3 22 3 mm 0 84 0 88 in O Use the oil seal driver A for the outside oil seals of the right and left covers Special Tool Oil Seal Driver 57001 1487 HK148000 P Property of www SmallEngineDiscoun
71. e Apply a non permanent locking agent to the threads of the bearing holder C and tighten it Special Tool Socket Wrench Hex 50 57001 1478 Torque Bearing Holder 137 N m 14 kgf m 101 ft lb e Hold the housing assembly A with the output shaft holder B 8 spacer C in a vise Special Tool Output Shaft Holder amp Spacer 57001 1479 e Insert the output shaft D in the housing e Apply a non permanent locking agent to the threads of the output shaft holder nut E and tighten it so that the projection side F faces outward Special Tool Socket Wrench 57001 1482 Torque Output Shaft Holder Nut 157 N m 16 kgf m 116 ft lb e Apply grease to the oil seal and press it 7 a f HK160027 P e Hold the holder A in a vise and set the housing assembly B on the holder Special Tool Holder amp Guide Arbor 57001 1476 e Install Output Driven Bevel Gear C Cam Damper D Spring E Spring Holder F Circlip G e Install Guide Bars A Damper Spring Compressor Set B Special Tools Holder amp Guide Arbor 57001 1476 Damper Spring Compressor Set 57001 1475 e Tighten the nuts C and compress the damper spring e Install Circlip Special Tool Circlip Pliers 57001 154 HK160029 P Property of www SmallEngineDiscount com Not for Resale 11 16 FINAL DRIVE Output Bevel Gears Outp ut Bevel Gears Adjustment Output Bevel Gear Adjustment Procedure The backlash and tooth contact p
72. either ring is greater than the service limit replace all the rings Property of www SmallEngineDiscount com Not for Resale O HE14013BS1 ENGINE TOP END 4 33 Exhaust System This vehicle is equipped with a spark arrester approved for off road use by the U S Forest Service lt must be properly maintained to ensure its efficiency In accordance with the Periodic Maintenance Chart clean the spark arrester Spark Arrester Cleaning e Refer to Spark Arrester Cleaning in Periodic Maintenance chapter Muffler Removal e Loosen the muffler clamp bolt A until the clamp turns freely on the muffler e Remove the muffler mounting bolts B e Remove the muffler C from the rear of the frame Exhaust Pipe Removal e Remove Left Front Wheel see Wheels Tires chapter Front Left Inner Cover see Frame chapter Exhaust Pipe Cover see Frame chapter Muffler see Muffler Removal Exhaust Pipe Nuts A Exhaust Pipe B Gasket Exhaust Pipe and Muffler Installation e Replace the exhaust pipe holder gasket A and clamp gasket B with new ones e Install Exhaust Pipe C and Clamp D Muffler E and Dampers F and Collars G Plane Washers H and Spring Washers I e Tighten Torque Muffler Mounting Bolts J 26 N m 2 7 kgf m 20 ft Ib x If the cover was removed install it Qe HE15001BS1 Exhaust System Inspection e Before removing the exhaust system chec
73. fluid should be completely washed away immediately e Use a new flat washer for each side of the hose fittings e Install the new brake hose in its place see Appendix chapter and tighten the banjo bolts Torque Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft lb Brake Fluid Level Inspection e Position the reservoir horizontal and check that the fluid level in the reservoir is higher than the lower level line A x If the fluid level is lower than the lower level line check for fluid leakage of the brake line and add the fluid as follows Property of www SmallEngineDiscount com Not for Resale 2 22 PERIODIC MAINTENANCE Periodic Maintenance Procedures O Remove the reservoir cap and fill the reservoir to the upper level line A in the reservoir with the same type and brand of the fluid that is already in the reservoir And then install the reservoir cap dA WARNING Change the fluid in the brake line completely if the fluid must be refilled but the type and brand of the fluid that is already in the reservoir are unidentified e Tighten Torque Reservoir Cap Screws 1 5 N m 0 15 kgf m 13 in Ib Brake Fluid Change e Remove the front wheels see Wheels Tires chapter e Remove the reservoir cap and the rubber cap on the bleed valve e Attach a clear plastic hose to the bleed valve on the caliper and run the other end of the hose into a container e Fill the reservoir with
74. 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 satisfactorily Brake fluid quickly ruins painted surfaces any spilled fluid should be completely washed away immediately 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 Fluid Recommendation Use extra heavy duty brake fluid only from a container marked DOT3 or DOT4 Recommended Disc Brake Fluid Type DOT 3 or DOT 4 Property of www SmallEngineDiscount com Not for Resale 12 8 BRAKES Brake Fluid Brake Fluid Level Inspection e Refer to Brake Fluid Level Inspection in Periodic Maintenance chapter Brake Fluid Change e Refer to Brake Fluid Change in Periodic Maintenance chapter Brake Line Air Bleeding e Remove the front wheels see Wheels Tires chapter e Bleed the air whenever brake parts are replaced or reassembled e Remove the reservoir cap and fill the reservoir with new brake fluid e Slowly pump the brake lever several times until no air bubbles can be seen rising up through the fluid from the hose at the bottom of the reservoir This bleeds the air from the master cylinder and the brake line NOTE O Tap the brake hose lightly going from the caliper to the reservoir side and bleed the air o
75. gears as a set if either gear is damaged e Also inspect the differential gear shaft B gear case C and cover D where the differential gears rub x If they are scored discolored or otherwise damaged replace them as a set HK11003751 Property of www SmallEngineDiscount com Not for Resale 11 42 FINAL DRIVE Front Final Gear Case Correct Tooth Contact Pattern Bottom Toe Heel A Bottom Bottom Ca Bottom Top aN Heel Bottom Ring Gear No adjustment is required Heel Bottom a H Bottom rd Toe hz Pinion Gear Incorrect Tooth Contact Patterns Example 1 Decrease the thickness of the ring gear shim s by 0 1 mm 0 004 in to correct the pattern shown below Repeat in 0 1 mm 0 004 in steps if necessary Bottom Heel yo Top Bottom Toe Pinion Gear Toe Heel A Bottom io 308 Ring Gear Example 2 Increase the thickness of the ring gear shim s by 0 1 mm 0 004 in to correct the pattern shown below Repeat in 0 1 mm 0 004 in steps if necessary d Heel Top f Bottom Toe Pinion Gear Property of www SmallEngineDiscount com Not for Resale FINAL DRIVE 11 43 Rear Propeller Shaft Rear Propeller Shaft Removal e Drain the rear final gear case oil see Rear Final Gear Case Oil Change in Periodic Maintenance chapter e Remove Swingarm A see Suspen
76. guide arbor and a hammer to drive the guide into the head from the outside until the snap ring on the guide against the head e Allow the cylinder head to cool e Ream the valve guide with the valve guide reamer A even if the old guide is reused Special Tool Valve Guide Reamer 7 57001 162 Property of www SmallEngineDiscount com Not for Resale HE13BOOS P ENGINE TOP END 4 23 Valves Guides Seats Springs Oil Seals Valve to Guide Clearance Measurement If a small bore gauge is not available inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below e Insert a new valve A into the guide B and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface e Move C the stem back and forth to measure valve valve guide clearance e Repeat the measurement in a direction at a right angle to the first x If the reading exceeds the service limit replace the guide HE13005BS1 NOTE The reading is not actual valve valve guide clearance because the measuring point is above the guide Valve Valve Guide Clearance Wobble Method Standard Service Limit Exhaust 0 07 0 14 mm 0 30 mm 0 0028 0 0055 in 0 0118 in Inlet 0 05 0 13 mm 0 30 mm 0 0020 0 0051 in 0 0118 in Valve Seat Inspection e Remove the valve see Valve Removal e Check the valve seating
77. m 78 in Ib Property of www SmallEngineDiscount com Not for Resale CRANKSHAFT TRANSMISSION 9 21 Transmission Shift Fork Bending e Visually inspect the shift fork x l the fork is bent replace the shift rod with a new one A bent fork could cause difficulty in shifting or allow the transmission to jump out of gear when under power A 90 H110002251 Shift Fork Gear and Shifter Groove Wear e Measure the thickness of the shift fork ears A and measure the width B of the gear groove and shifter x l the thickness of a shift fork ear is less than the service limit the shift rod must be replaced Shift Fork Ear Thickness Standard 5 9 6 0 mm 0 2322 0 2362 in Service Limit 5 8 mm 0 228 in If the groove is worn over the service limit the shifter must be replaced Shifter Groove Width Standard 6 05 6 15 mm 0 2382 0 2421 in Service Limit 6 25 mm 0 2460 in Transmission and Shift Mechanism Inspection e Visually inspect Gears Dogs on Gear and Shifter x l they are damaged or worn excessively replace them Property of www SmallEngineDiscount com Not for Resale 9 22 CRANKSHAFT TRANSMISSION Transmission OOGO WOOO DEDIDA HI10000BW4 1 Driven Shaft 12 Drive Low Gear 20T 2 Spacer 17 3 x 30 x 2 0 13 Reverse Idle Shaft 3 Reverse Gear 12T 14 Reverse Driven Gear 16T 4 Spacer 21 2 x 29 x 1 6 15 Rever
78. on the rims so that each air valve is toward the outside of the vehicle NOTE O The direction of the tire rotation B is shown by an arrow on the tire sidewall e Install the tire on the rim using a suitable commercially available tire changer e Lubricate the tire beads again and center the tire on the rim Property of www SmallEngineDiscount com Not for Resale 10 10 WHEELS TIRES Tires e Support the wheel rim A on a suitable stand B to prevent the tire from slipping off e Inflate the tire until the tire beads seat on the rim Maximum Tire Air Pressure to seat beads when cold Front and Rear 250 kPa 2 5 kg cm 36 psi AWARNING Do not inflate the tire to more than the maximum tire air pressure Overinflation can explode the tire with possibility of injury and loss of life e Check to see that rim lines A on both sides of the tire are parallel with the rim flanges B x If the rim lines and the rim flanges are not parallel deflate the tire lubricate the sealing surfaces again and reinflate the tire e After the beads are properly seated check for air leaks O Apply a soap and water solution around the tire bead and check for bubbles e Deflate the tire to the specified pressure e Check the tire pressure using an air pressure gauge NOTE O Kawasaki provides the air pressure gauge P N 52005 1082 with the owner s tool kit Tire Air Pressure when cold Fr
79. pulley bolt has left hand threads Turn the wrench clockwise for loosening e Using the drive pulley holder A and drive pulley puller bolt B remove the drive pulley C from the crankshaft Special Tools Drive Pulley Puller Bolt 57001 1429 Drive Pulley Holder 57001 1520 HSO6B009 P Drive Pulley Disassembly e Hold the drive amp driven pulley holder A and guide 57001 1412 B in a vise so that the upper surface on the holder is 7 mm 0 28 in C above the vise Special Tools Drive Pulley Holder 57001 1473 Drive amp Driven Pulley Holder 57001 1412 HS06B002 P e Set the pulley onto the pulley holder e Remove Drive Pulley Cover Bolts A Drive Pulley Cover B HS060002 P e Remove Spring A Spacer HS060003 P Property of www SmallEngineDiscount com Not for Resale 5 12 CONVERTER SYSTEM Drive Pulley e Put the drive pulley wrench A on the spider B and tighten the bolt C Special Tool Drive Pulley Wrench 57001 1474 e Turn the wrench clockwise and remove the spider with the movable sheave NOTE O The spider has left hand threads Turn the wrench clockwise for loosening HS060004 P e Remove Spider A Shoes B Nuts C Ramp Weight Pin D Ramp Weight E Movable Sheave F Fixed Sheave G HS06000BS2 C Drive Pulley Inspection x l the sheave surfaces A appear damaged replace the sheaves HS060011 P x If the cover bu
80. see Wheels Tires chapter Rear Bottom Guard see Frame chapter Trailer Hitch Bracket see Frame chapter Rear Final Gear Case Left Cover e Tap A the right end of the rear axle B and pull it out from the left O The left axle bearing comes off with the axle Rear Axle Installation e Install the rear axle from the left side with the left bearing installed while aligning the splines e Apply grease O ring A Oil Seal Lips in Rear Final Gear Case Left Cover e Install Rear Final Gear Case Left Cover A Trailer Hitch Bracket B see Frame chapter Ball Bearing Wear CAUTION Do not remove the bearing A for inspection Removal may damage it e Check the ball bearing O Since the ball bearing is made to extremely close tolerances the wear must be judged by feel rather than measurement O Spin the bearing by hand to check its condition x If the bearing is noisy does not spin smoothly or has any rough spots HK13B005 P replace the rear axle shaft Rear Axle Runout Inspection e Visually inspect the axle for damage x If the axle is damaged or bent replace it e Set the rear axle in an alignment jig or on V blocks and place a dial gauge A against the middle point e Turn the axle slowly The difference between the highest and lowest dial gauge readings is the axle runout TIR x If the runout exceeds the service limit replace the axle Rear Axle Shaft Runout Standard TIR 1 mm 0 04 in
81. specified length after the drive pulley cover is replaced replace the drive pulley assembly HS06013BS2 C Drive Pulley Covers Part Number Paint Color A Length B 14041 1148 Red 24 0 mm 0 945 in 14041 1149 25 4 mm 1 000 in 14041 1150 None 24 7 mm 0 972 in HS06005BS1 Property of www SmallEngineDiscount com Not for Resale 5 18 CONVERTER SYSTEM Driven Pulley Driven Pulley Removal e Remove Torque Converter Cover see Torque Converter Cover Drive Pulley see Drive Pulley Removal Drive Belt see Drive Belt Removal e Using a flywheel amp pulley holder A and adapter B remove the driven pulley nut C and washers Nut has R H threads Special Tools Flywheel amp Pulley Holder 57001 1343 Pulley Holder Attachment 57001 1472 e Remove Driven Pulley Driven Pulley Disassembly e Hold the drive amp driven pulley holder A in a vise Special Tool Drive Pulley Holder 57001 1473 e Screw the guide bar B into the holder Special Tool Spring Holder Set 57001 1483 e Put the driven pulley C on the guide bar e Tighten nut D and compress the spring with the spring holder E Special Tool Spring Holder Set 57001 1483 e Remove circlip A with circlip pliers B Special Tool Circlip Pliers 57001 154 e Remove nut and spring holder C e Remove Spring Seats A Spring B Spring Spacer if used for high altit
82. surface A between the valve B and valve seat C O Coat the valve seat with machinist s dye O Push the valve into the guide O Rotate the valve against the seat with a lapping tool O Pull the valve out and check the seating pattern on the valve head It must be the correct width and even all the way around e Measure the outside diameter D of the seating pattern on the valve seat x If the outside diameter of the valve seating pattern is too large or too small repair the seat see Valve Seat Repair Valve Seating Surface Outside Diameter Exhaust 34 9 35 1 mm 1 374 1 382 in Inlet 39 9 40 1 mm 1 571 1 579 in NOTE The valve stem and guide must be in good condition or this check will not be valid x If the valve seating pattern is not correct repair the seat see Valve Seat Repair e Measure the seat width E of the portion where there is no build up GE15011782 carbon white portion of the valve seat with a vernier caliper x If the width is too wide too narrow or uneven repair the seat see Valve Seat Repair F Good G Too Wide H Too Narrow J Uneven Valve Seating Surface Width Exhaust 0 5 1 0 mm 0 02 0 04 in Inlet 0 5 1 0 mm 0 02 0 04 in Property of www SmallEngineDiscount com Not for Resale 4 24 ENGINE TOP END Valves Guides Seats Springs Oil Seals Valve Seat Repair Valve Lapping e Using the valve seat cutters A repair the valve
83. the battery at a rate higher than specified may ruin the battery Charging at a high rate causes excess heat which can warp the plates and cause internal shorting Higher than normal charging rates also cause the plates to shed active material Deposits will accumulate and can cause internal shorting If the temperature of the electrolyte rises above 45 C 113 F during charging reduce the charging rate to lower the temper ature and increase charging time proportionately e Turn the charger off then disconnect it from the battery e Check battery voltage Battery voltage should be 12 13 V Property of www SmallEngineDiscount com Not for Resale 16 16 ELECTRICAL SYSTEM Battery Ordinary Charging e Remove the battery see Battery Removal 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 con nect the battery to the charger before turning on the charger This procedure prevents sparks at the battery terminals which could ignite any battery gases e Connect a charger to the battery BEFORE plugging it in or turning it on e Set the charging rate and time according to the battery condition previously determined using the Battery Charging Rate Time Table e Check the electrolyte level after charging CAUTION Always remove the battery from the vehicle for charging If the
84. the crankcase until it is bottomed using a press e Apply engine oil to the needle bearings and install them e Install the following parts on the low gear A Needle Bearings B Spacer C P No 92026 1599 48 2 x 54 3 x 1 0 High Gear D e Install Idle Shaft A with Gear Assembly B Spacer C Spacer D P No 92026 1599 48 2 x 54 3 x 1 0 e Install the spacer E so that the stepped side F faces outward e Install Spacer A Toothed Washer B Circlip Special Tool Outside Circlip Pliers 57001 144 Property of www SmallEngineDiscount com Not for Resale 9 20 CRANKSHAFT TRANSMISSION Transmission e Apply engine oil Shift Rod and Shift Fork Ear A Needle Bearing e Install Shift Rod B with Shifter C Spacer D Needle Bearing E e Install Reverse Drive Gear A Spacer B Reverse Idle Shaft C e Apply molybdenum disulfide oil to the shift shaft A e Install Shift Shaft Spring Bolt B Spring C Guide D e Apply a non permanent locking agent Shift Shaft Spring Bolt e Tighten Torque Shift Shaft Spring Bolt 25 N m 2 5 kgf m 18 ft Ib e When a new bushing A and oil seal B are installed in the shift shaft cover C press and insert the new bushing and oil seal so that there surfaces are flush with the end of the each hole H110002151 e Install Shift Shaft Cover e Tighten Torque Shift Shaft Cover Bolts 8 8 N m 0 9 kgf
85. the same manner as specified in the Regulator Circuit Test 1st Step e Apply 12 V to the BR terminal e Check Y1 Y2 and Y3 terminals x If the test light turns on the regulator rectifier is defective If the test light does not turn on continue the test Regulator Circuit Test 3rd Step e Connect the test light and a 12 V battery in the same manner as specified in the Regulator Circuit Test 1st Step e Momentarily apply 24 V to the BR terminal by adding a 12 V battery e Check Y1 Y2 and Y3 terminals CAUTION Do not apply more than 24 V to the regulator rectifier Do not leave the 24 V applied for more than a few seconds or the unit will be damaged If the test light did not light when the 24 V was applied momentarily to the BR terminal the regulator rectifier is defective x If the regulator rectifier passes all of the tests described it may still be defective If the charging system still does not work properly after checking all of the components and the battery test the regulator rectifier by replacing it with a known good unit Property of www SmallEngineDiscount com Not for Resale 16 24 ELECTRICAL SYSTEM Charging System Charging System Circuit O lk j R HBK Y HBK Y FL A BK Y IA FBK BR BK x gt gt gt 5 so HPOSOOOBW3 C 1 Ignition Switch 3 Regulator Rectifie
86. 0 C 177 kPa 1 8 kg cm 25 6 psi 248 F Special Tools Oil Filter Wrench 57001 1249 Oil Pressure Gauge 10 kgf cm 57001 164 Oil Pressure Gauge Adapter 57001 1033 Sealant Kawasaki Bond Silicone Sealant 57001 120 Property of www SmallEngineDiscount com Not for Resale ENGINE LUBRICATION SYSTEM 7 5 Engine Oil Flow Chart HGO4001BW4 1 Oil Hose 7 Oil Filter 12 Oil Nozzle 2 Oil Pipe 8 Oil Pressure Switch 13 Rocker Shaft 3 Oil Screen 9 Drive Shaft 14 Camshaft 4 Oil Pump 10 Input Shaft 15 Engine Breather 5 Relief Valve 11 Crankshaft 16 Blow by Gas to Air Cleaner 6 Oil Cooler Property of www SmallEngineDiscount com Not for Resale 7 6 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter AWARNING Vehicle operation with insufficient deteriorated or contami nated engine oil will cause accelerated wear and may result in engine or transmission seizure accident and injury Oil Level Inspection e Park the vehicle so that it is level both side to side and front to rear e f the oil has just been changed start the engine and run it for several minutes to fill the oil filter CAUTION Allow the engine to idle for several minutes so that oil may reach all parts of the engine Racing a dry engine may cause severe damage e Stop the engine and wait several minutes for all the oil to drain back to the sump e Unscrew the oi
87. 0 mm Connecting Rod Bend Standard Under 0 05 100 mm 0 002 3 94 in Service Limit 0 2 100 mm 0 008 3 94 in e Measure the connecting rod twist With the crankshaft still in the alignment jig hold the connecting rod horizontally and measure the amount that the arbor varies from being parallel with the crankshaft over a 100 mm 3 94 in length of the arbor to determine the amount of connecting rod twist If connecting rod twist exceeds the service limit the connecting rod must be replaced 100 mm Connecting Rod Twist Standard Under 0 15 100 mm 0 006 3 94 in Service Limit 0 2 100 mm 0 008 3 94 in Property of www SmallEngineDiscount com Not for Resale CRANKSHAFT TRANSMISSION 9 15 Transmission Shift Lever Removal e Set the shift lever in the neutral position e Remove Air Cleaner Housing see Fuel System chapter Shift Shaft Lever Bolt A e Remove the shift shaft lever B from the shift shaft e Remove Nut A Shift Lever Assembly B e Remove Tie Rod End Bolt A Tie Rod B e Remove Oil Seals A Collar B Property of www SmallEngineDiscount com Not for Resale 9 16 CRANKSHAFT TRANSMISSION Transmission Shift Lever Installation e Twist the tie rod end A and tie rod locknut B to bottom of the screw and then turn back to dimension with 77 10 C as shown e Tighten the locknut against the tie rod end Torque Tie Rod End
88. 03B5S1 o Property of www SmallEngineDiscount com Not for Resale 4 20 ENGINE TOP END Cylinder Head Cylinder Head Warp e Clean the cylinder head see Cylinder Head Cleaning e Lay a straightedge across the lower surface of the cylinder head e Use a thickness gauge A to measure the space between the straightedge B and the head at several locations Cylinder Head Warp 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 Property of www SmallEngineDiscount com Not for Resale ENGINE TOP END 4 21 Valves Guides Seats Springs Oil Seals Valve Clearance Inspection e Refer to Valve Clearance Inspection in Periodic Maintenanc chapter Valve Clearance Adjustment e Loosen the locknut A and turn the adjusting screw B until the clearance is correct e Hold the adjusting screw from turning and tighten the locknut to the specified torque Torque Valve Adjusting Screw Locknuts 12 N m 1 2 kgf m 104 in Ib e Recheck the clearance x If the clearance is incorrect repeat the adjustment procedure x If the clearance is correct perform the adjustment procedure on the other valve e Apply grease to the O ring A e Install the valve adjusting cap so that the UP
89. 08BW4 1 2WD 4WD Actuator 5 Clamp 2 2WD 4WD Actuator Breather Tube 6 Do not interfere the actuator lead and tube with 3 2WD 4WD Actuator Lead tie rod etc Property of www SmallEngineDiscount com Not for Resale 17 10 APPENDIX Cable Wire and Hose Routing Dra YA i x Da V fi APN MPA o AE EN eles 7 N HB09009BW4 1 Oil Cooler 7 Fix oil pressure switch lead with clamp 2 Oil Pipe Joint Nut 8 Clamp 3 Oil Screen 9 Grommets 4 Oil Pressure Switch 10 Oil Cooler Mounting Bolt 5 Oil Hose Banjo Bolts 11 Damper 6 to Air Cleaner 12 Oil Hose Property of www SmallEngineDiscount com Not for Resale APPENDIX 17 11 Cable Wire and Hose Routing HBO9010BW4 1 Rear Final Gear Case Breather Tube 2 2WD 4WD Actuator Breather Tube 3 Front Final Gear Case Breather Tube 4 Band Property of www SmallEngineDiscount com Not for Resale 17 12 APPENDIX Cable Wire and Hose Routing 7 oA NN ATT A Mia EA le HBOSO1IBW4 1 Mark 8 Engine Breather Hose 2 Align the duct groove with the mark on the carbu 9 Starter Motor retor 10 Carburetor Drain Tube 3 Carburetor Holder 11 Run the carburetor drain tube between the 4 Align the carburetor holder groove with the mark crankcase and starter motor on the carburetor 12 Align the duct groove with the mark on the carbu
90. 17 ST571499ST ST571517ST Oil Seal Driver 618 57001 1505 Belt Measuring Gauge 57001 1519 sT5715058T C sT5715198T C Oil Seal Driver 648 57001 1506 Drive Pulley Holder 57001 1520 ST5715068T oN ST5715208T Valve Seat Cutter 32 444 57001 1515 Kawasaki Bond Silicone Sealant 56019 120 ST571515ST C Property of www SmallEngineDiscount com Not for Resale 1 14 GENERAL INFORMATION Unit Conversion Table Prefixes for Units Units of Length Prefix km x 0 6214 mile 1 000 000 m x 3 281 ft 1 000 mm x 0 03937 in 0 01 0 001 Units of Torque 0 000001 N m x 0 1020 kg m N m x 0 7376 ft lb Units of Mass N m x 8 851 in lb kg x 2 205 lb kg m x 9 807 N m g x 0 03527 2 oz kg m x 7 233 ft lb kg m x 86 80 in lb Units of Volume L x 0 2642 gal US Units of Pressure L x 0 2200 gal imp kPa x 0 01020 kg cm L x 1 057 qt US kPa x 0 1450 psi L x 0 8799 qt imp kPa x 0 7501 cmHg L x 2 113 pint US kg cm x 98 07 kPa L x 1 816 pint imp kg cm x 14 22 psi mL x 0 03381 oz US cm Hg x 1 333 kPa mL x 0 02816 E oz imp mL x 0 06102 cu in Units of Speed km h x 0 6214 mph Units of Force X i 9 1020 kg Units of Power X x eal lb kW x 1 360 PS kg x 9 807 N kw x 1 341 z HP kg x 2 205 lb PS x 0 7355 z kW PS x 0 9863 HP Units of Temperature ICE gpa E SOL aTa 5 9 oF oF 4 32 68 104 176 212 2
91. 1G Tires Standard tire Front AT 25 x 8 12 DUNLOP KT121 Tubeless Rear AT 25 x 10 12 DUNLOP KT405C KT127A Tubeless Tire air pressure when cold Front 35 kPa 0 35 kgf cm 5 0 psi Rear 35 kPa 0 35 kgf cm 5 0 psi Maximun tire air pressure 250 kPa 2 5 kgf cm 36 psi to seat beads when cold Tire tread depth 3 mm 0 12 in 4 mm 0 16 in Special Tool Jack 57001 1238 Property of www SmallEngineDiscount com Not for Resale WHEELS TIRES 10 5 Wheel Alignment Toe in is the amount that the front wheels are closer together in front than at the rear at the axle height When there is toe in the distance A Rear is the greater than B Front as shown The purpose of toe in is to prevent the front wheels from getting out of parallel at any time and to prevent any slipping or scuffing action between the tires and the ground If toe in is incorrect the front wheels will be dragged along the ground scuffing and wearing the tread knobs Caster and camber are build in and require no adjustment A Rear B Front Amount of Toe in Distance A and B are measured at axle height with the vehicle sitting on the ground or at 1G Steering Centering Inspection e Test ride the vehicle If the handlebar is straight when the vehicle is traveling in a straight line go on to the Toe in Inspection procedure x Otherwise go on to the Steering Centering Adjustment procedure
92. 48 284 40 20 O 20 40 60 E 80 100 120 140 160 180 200 220 240 260 280 300 320 40 20 0 20 40 6 i 8 400 120 140 160 17 8 4 4 26 7 48 9 71 1 93 3 116 138 E C Property of www SmallEngineDiscount com Not for Resale PERIODIC MAINTENANCE 2 1 Periodic Maintenance Table of Contents Periodic Maintenance Chalticinnccnnncccconocccnncananccanccnns 2 2 Torque and Locking AQeMt ooooocccononccinocccnoncncnancnonnnos 2 3 Specifications Vinci 2 8 Periodic Maintenance Procedures eee 2 10 Fuel SysteM cccccccocccoccconcnonnnonnnnnnn eicere 2 10 Throttle Lever Free Play Inspection 2 10 Throttle Lever Free Play Adjustment 2 10 Fuel System Cleanliness Inspection 2 11 Air Cleaner Element Cleaning and Inspection 2 11 Air Cleaner Draining cccescesseeeseeseesettees 2 12 Fuel Hose and Connection Check 2 12 Fuel Hose Replacement 2 12 Engine Top End isc ion iii 2 13 Valve Clearance INnSpectiON oonocinninnccnnccinnmm 2 13 Spark Arrester CleaninQ ooooonnccnnnnnninncnnncconns 2 13 Converter SySteM oocoincccicccnoccconanocnconccnnnnnancnancnnnos 2 14 Actuator Lever Engine Brake Control Lever As sembly Inspection 2 14 Drive Belt Inspecti0N ooooocccnnonccnnonccconancnnnnnon 2 14 Drive Belt Deflection Inspection 2 15 Drive Belt Deflection Adjustmen t 2 16 Engine Lubrication
93. 5 C Property of www SmallEngineDiscount com Not for Resale RECOIL STARTER 6 3 Exploded View Recoil Starter Mounting Bolts 59 o6 52 in lb L Apply a non permanent locking agent Property of www SmallEngineDiscount com Not for Resale 6 4 RECOIL STARTER Recoil Starter Recoil Starter Removal e Remove Recoil Starter Mounting Bolts A Recoil Starter B Recoil Starter Installation e Apply a non permanent locking agent Recoil Starter Mounting Bolts e Tighten Torque Recoil Starter Mounting Bolts 5 9 N m 0 6 kgf m 52 in Ib Recoil Starter Inspection e Check the starter rope for excessive wear or fraying Property of www SmallEngineDiscount com Not for Resale ENGINE LUBRICATION SYSTEM 7 1 Engine Lubrication System Table of Contents Exploded Vi Words dede 7 2 Speciticatlons triana ciedad iaa 7 4 Engine Oil Flow Chalma A tina es a irisada aaier iaa 7 5 Engine Oil and Oil Filter ccc ccc eeseeeseeceeeeeaeeeaeeeseeseaeeeaeeeaeecaaeseaesaeesaeeseaeeeaeesaeesaesaaeesseeseaesnaeeeaeesaeeseeeteaeesieesneeenaees 7 6 Oil Level Inspection iras circos irda lbaas 7 6 Engine DICOAMIE 20 eiii 7 6 Oil Fiter Chang esiis edson ninisi anaana e estaa a aA teta pila in ibi ia 7 6 Oil Screen Removal sii dae Ae ei Ani ep en E EENE Eie 7 6 OllScreen Clean tosco tdt E 7 7 Oil Pressure Measurement coccion o ct a ie ici 7 8 Oil Pressure EE 7 8 Oil Pressure Relief Valve cccceceese
94. 8 0 9 78 in lb 9 Neutral Position Switch 15 1 5 11 10 Reverse Position Switch 15 1 5 11 11 Actuator Controller 12 LED Indicator 13 Carburetor Heater 14 Air Temperature Sensor G Apply grease for oil seal and O ring L Apply a non permanent locking agent S Follow the specific tightening sequence M Apply molybdenum disulfide grease Property of www SmallEngineDiscount com Not for Resale 16 8 ELECTRICAL SYSTEM Exploded View HP02008BW5 C Property of www SmallEngineDiscount com Not for Resale ELECTRICAL SYSTEM 16 9 Exploded View No Fastener Remarks 1 Oil Cooler Fan Switch 2 Oil Temperature Warning Light Switch 3 Oil Pressure Switch 4 Regulator Rectifier Mounting Bolts 8 8 0 9 78 in lb 5 Oil Pressure Switch Terminal Bolt 1 5 0 15 13 in lb 6 Speedometer other than U S A model 7 Starter Circuit Relays 8 Horn other than U S A and Canada models SS Apply silicone sealant Kawasaki Bond 56019 120 OP Optional Parts for U S A and Canada models Property of www SmallEngineDiscount com Not for Resale 16 10 ELECTRICAL SYSTEM Specifications o ttem Standard Battery Capacity 12V 14 Ah Electrolyte level Between upper and lower levels Specific gravity of electrolyte 1 270 20 C 68 F Charging System Alternator type Three phase AC Charging voltage 14 15V Regulator rectifier output voltage Alternator outp
95. A Property of www SmallEngineDiscount com Not for Resale ELECTRICAL SYSTEM 16 67 Carburetor Heater System Air Temperature Sensor Inspection e Remove Seat see Frame chapter Air Temperature Sensor A e Connect the battery and hand tester to the sensor Red Connector A White Connector B 12 V Battery C Hand Tester D Special Tool Hand Tester 57001 1394 HP17001BS1 CAUTION Use the sensor within 30 80 C 22 176 F If it is used without the specified range the sensor will be damaged e Suspend the sensor A in a container of cold water of less than 8 C 46 4 F so that the temperature sensing part B is submerged as shown C Ice e Suspend an accurate thermometer D in the water e Measure the output voltage between W Y terminal and battery terminal tester range DC 25 V HP17002BS1 Air Temperature Sensor less than 8 C 46 4 F Output Voltate 8 16 V near battery voltage x If the voltage is less than DC 0 1 V replace the sensor e Warm up the sensor A more than 22 C 71 6 F with a hand e Measure the output voltage between W Y terminal and battery terminal tester range DC 2 5 V Air Temperature Sensor more than 22 C 71 6 F Output Voltate less than 0 1 V x If the voltage is 8 16 V replace the sensor HP17003BS1 Property of www SmallEngineDiscount com Not for Resale 16 68 ELE
96. A 17 N m 1 7 y kgf m 12 ft lb d HK11B016 P e Check the variable differential control lever position see Variable Differential Control Lever Position Inspection in Periodic Maintenance chapter Variable Differential Control Cable Lubrication Whenever the variable differential control cable is removed lubricate the cable as follows e Apply a small amount of multi purpose grease to the cable both ends e Lubricate the cable with a penetrating rust inhibitor through the pressure cable luber Variable Differential Control Cable Inspection e With the variable differential control cable disconnected at both ends the cable should move freely within the cable housing x If the cable does not move freely after lubricating if the cable is frayed or if the housing is kinked replace the cable j Front Final Gear Case Removal e Drain the gear case oil see Front Final Gear Case Oil Change e Remove Front Propeller Shaft see Front Propeller Shaft Removal Right and Left Front Axles see Front Axle Removal Steering Shaft see Steering chapter Left Suspension Arm see Suspension chapter 2WD 4WD Actuator see Electrical System chapter Breather Tube Brake Joint Bolt A e Remove Variable Front Differential Control Cable Lower End A Front Final Gear Case Bolts B and Nuts e Remove the front final gear case from the right side HT 1BD18 _P Property of www SmallEngineDisc
97. A anria AE 14 8 TiesRod End Installation a E seep este 14 8 Steering Maintenance omnonicnnnnncnoncnncnnccnccnc nr 14 9 SIA beac hk L125 aa aaa a re aE a E E E a A EE a EE E E aAA 14 9 Steering Stem Straightness ocoonnccncnnnicnnnnncnnnrncnrccr aaeei mediace sarea aa caiene dens raa saaa ir iane 14 9 Ti nnno anaana aiaa a aa a A G E a a ieaiai 14 9 Steering Stem Clamp Inspector 14 9 Steering Stem Bearing Inspection oonnccnnnciccnnnonnconncnnncnnncnn acc cn nro 14 9 Steering Knuckle Bearing INSP CtiON cecceeeeseeeeeeceeeeeeeeeeecaeeeaeeeaeecsaeseaeeeaeesaeeseaeeeaeeseeseaeeeaeeeaeesiaeseaeseneesees 14 10 Tie Rod End and Steering Knuckle Joint INSpectiON oooocncnninnninnnnnnonnncnnccnonannccnnncn cra r arcano 14 10 AAA PPP cues Mabic bk ebone payee sbescoewesciehewans E E E a E EO E EEEa 14 11 Handlebar Removal it 14 11 Handlebar Installation 14 11 Property of www SmallEngineDiscount com Not for Resale 14 2 STEERING Exploded View Property of www SmallEngineDiscount com Not for Resale STEERING 14 3 Exploded View z o Fastener Handlebar Holder Bolts Handlebar Lower Holder Nuts Tie Rod Adjusting Sleeve Locknuts Tie Rod End Nuts Steering Stem Clamp Bolts k oo Steering Stem Bearing Joint Bolts Steering Stem Bottom End Nut Front Shock Absorber Clamp Bolts and Nuts OINIDO a s Steering Knuckle Joint Nut Parking Brake Lever Screw 19 in lb
98. Actuator Control System Troubleshooting 16 56 Drive Belt Failure Detection System 16 64 Drive Belt Failure Detection System Inspection16 64 Carburetor Heater System eceeseeeeeeeeeeeeeeees 16 67 Air Temperature Sensor Inspection 16 67 Carburetor Heater Inspection 16 68 Switches c ccccocccononcconononononcnononoconnnnnonnncnnnnnnnnnnnnnannnnos 16 69 Brake Light Switch Adjustment c 16 69 Oil Cooler Fan Switch Inspection 16 69 Oil Temperature Warning Light Switch Inspec A Ae ei EE eel 16 69 Switch INSPeCtION cceeceeeeeeeeeeteeeeeeeeeneetaees 16 69 Drive Belt Failure Detection Switch 16 70 Property of www SmallEngineDiscount com Not for Resale 16 2 ELECTRICAL SYSTEM USCS ivi iii il 16 71 Wiring Diagram 00 eee eeeseeeeneeeeeeeeeneeeeenneereneees 16 72 Fuses Removals 16 71 Fuse INSPOCHION c seccceseceeseereteeceneseneeeeee 16 71 Property of www SmallEngineDiscount com Not for Resale ELECTRICAL SYSTEM 16 3 Precautions There are a number of important precautions that should be taken when servicing electrical systems Learn and observe all the rules below O Do not reverse the battery lead connections This will burn out the diodes in the electrical parts O Always check battery condition before condemning other parts of an electrical system A fully charged battery is required for conducting accurate electrical system test
99. Assembly Bracket Bolts 14 Tie Rod End Rear Locknut i 87 in lb Tie Rod End Front Locknut 87 in lb Grip Hold Nut 87 in lb Shift Shaft Spring Bolt 18 Shift Shaft Cover Bolts E 78 in lb Oil Line Plugs o 17 Wheels Tires Tie Rod Adjusting Sleeve Locknuts 27 Wheel Nuts 38 Front Axle Nuts Rear Axle Nuts Final Drive Output Bevel Gears Output Drive Bevel Gear Housing Bolts i 20 Rotor Mounting Bolts 104 in lb Output Drive Bevel Gear Cover Bolts i 78 in lb Forward Reverse Detecting Sensor Mounting Bolts 11 Bearing Holder 87 Bevel Gear Holder Nut 116 Output Drive Bevel Gear Housing Bolts 20 Bearing Holder 101 Output Shaft Holder Nut 116 Front Final Gear Case Oil Filler Cap 22 Oil Drain Plug 17 Variable Differential Control Cable Locknut 12 Front Final Gear Case Bolts and Nuts 31 Front Final Gear Case Center Cover Bolts M8 17 Front Final Gear Case Center Cover Bolts M6 87 in lb Pinion Gear Bearing Holder 101 Front Final Gear Case Left Cover Bolts M6 87 in lb Property of www SmallEngineDiscount com Not for Resale PERIODIC MAINTENANCE 2 5 Torque and Locking Agent Fastener Remarks Front Final Gear Case Coupling Nut 14 Variable Front Differential Control Shift Shaft Lever y 78 in lb Ring Gear Bolts 42 LB Pinion Gear Bearing Holder Nut 94 St Rear Axle Bearing Holder M Bearing Holder Screws 12 L Rear Final Gear Case Oil Filler Cap 22 Oil D
100. Axle 395 mm 15 55 in A HKXX0034S1 Left Front Axle 403 mm 15 87 in B HK10000B51 e Install the large board O Assemble it the same as the small band noting this setting Outside Diameter of Band 69 0 0 3 mm 2 717 0 012 in After tightening the outside large diameter Property of www SmallEngineDiscount com Not for Resale 11 26 FINAL DRIVE Front Axle e While the band is held at the diameter above tap down A the wings of the clamp Property of www SmallEngineDiscount com Not for Resale FINAL DRIVE 11 27 Front Final Gear Case Front Final Gear Case Oil Level Inspection e Park the vehicle so that it is level both side to side and front to rear e Remove the filler cap CAUTION Be careful not to allow any dirt or foreign materials to enter the gear case e Check the oil level The oil level should come to the bottom of the filler opening A x If it is insufficient first check the front final gear case for oil leakage remedy it if necessary and add oil through the filler opening Use the same type and brand of oil that is already in the final gear case e Be sure the O ring is in place and tighten the filler cap Torque Oil Filler Cap 29 N m 3 0 kgf m 22 ft Ib Front Final Gear Case Oil Change e Refer to Front Final Gear Case Oil Change in Periodic Maintenance chapter Variable Differential Control Lever Position Insp
101. B 57001 1363 Pinion Gear Holder C 57001 1480 Torque Pinion Gear Bearing Holder Nut 157 N m 16 kgf m 116 ft lb Property of www SmallEngineDiscount com Not for Resale 11 52 FINAL DRIVE Rear Final Gear Case Bevel Gear Inspection e Visually check the bevel gears A for scoring chipping or other damage x Replace the bevel gears as a set if either gear is damaged HK14001751 Property of www SmallEngineDiscount com Not for Resale FINAL DRIVE 11 53 Bearing and Oil Seal Ball or Needle Bearing Inspection Since the bearings are made to extremely close tolerances the clearance cannot normally be measured CAUTION Do not remove any bearings for inspection except the right rear axle bearing e Turn each bearing in the case or hub back and forth A while checking for plays roughness or binding x If bearing play roughness or binding is found replace the bearing 6114010151 C e Check the needle bearings A in the rear final gear case lt Q O The rollers in the 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 the bearing is damaged replace the rear final gear case Property of www SmallEngineDiscount com Not for Resale 11 54 FINAL DRIVE Bearing and Oil Seal Oil Seal Inspection e Inspect the oil seals A
102. B faces up e Install the top ring C so that the R mark D faces up HE14011BS1 e Install the piston pin A O Oil the piston pin lightly and slide it through the side of the piston without a snap ring O Hold the piston in position over the connecting rod with the arrow B pointing forward and slide the piston pin the rest of the way through the connecting rod and piston e Fit a new piston pin snap ring into the side of the piston so that the ring opening does not coincide with the slit of the piston pin hole Property of www SmallEngineDiscount com Not for Resale ENGINE TOP END 4 31 Cylinder and Piston Cylinder Piston Wear e Since there is a difference in cylinder wear in different direction take a side to side and a front to back measurement at each of the 3 locations total of 6 measurements shown in the figure x If any of the cylinder inside diameter measurements exceeds the service limit replace the cylinder 20 mm 0 79 in A 40 mm 1 57 in B 10 mm 0 39 in C Cylinder Inside Diameter Standard 80 000 80 012 mm 3 1496 3 1501 in oli and less than 0 01 mm 0 0004 in difference between any two measurements Service Limit 80 10 mm 3 154 in or more than 0 05 mm 0 0020 in difference between any two measurements e Measure the piston diameter A of each piston 5 mm 0 20 in B up from the bottom of the piston at a right an
103. Battery section in Electrical System chapter for Battery Inspection Spark Plug Cleaning Inspection e Clean the spark plug preferably in a sandblasting device and then clean off any abrasive particles The plug may also be cleaned using a wire brush or other suitable tool x If the spark plug electrodes are corroded or damaged or if the insulator is cracked replace the plug Use the standard spark plug or its equivalent Spark Plug Gap Inspection e Measure the gap A with a wire type thickness gauge x If the gap is incorrect carefully bend the side electrode B with a suitable tool to obtain the correct gap r EEK LL LSS WY SISI Spark Plug Gap Ky 0 8 0 9 mm 0 031 0 035 in WN v WY A Drive Belt Failure Detection System Inspection Refer to Drive Belt Failure Detection System section in Electrical System chapter Brake Light Switch Adjustment e Check the operation of the brake light switch by depressing the brake pedal A The brake light should go on after about 10 mm 0 4 in of pedal travel B Property of www SmallEngineDiscount com Not for Resale PERIODIC MAINTENANCE 2 25 Periodic Maintenance Procedures x If it does not adjust the brake light switch A up or down To change the switch position turn the adjusting nut B Brake Light Switch Timing Standard ON after 10 mm 0 4 in of pedal travel CAUTION To avoid damaging th
104. CTRICAL SYSTEM Carburetor Heater System Carburetor Heater Inspection e Disconnect Carburetor Heater Lead Connector A Ground Lead Connector B e Using the hand tester measure the resistance of the heater e Connect the tester between the heater terminal and the ground terminal x If the tester does not read as specified replace the heater Carburetor Heater Resistance 11 200 Carburetor Heater System Circuit HP17000BW3 C 1 Carburetor Heater 12V23W 4 Main Fuse 30A 2 Air Temperature Sensor 5 Alternator 3 Ignition Switch 6 Battery Property of www SmallEngineDiscount com Not for Resale ELECTRICAL SYSTEM 16 69 Switches Brake Light Switch Adjustment e Refer to Brake Light Switch Adjustment in Periodic Maintenance chapter Oil Cooler Fan Switch Inspection e Remove Oil Cooler Fan Switch see Engine Lubrication System chapter e Suspend the fan switch A in a container of oil so that the temperature sensing projection and threaded portion are submerged e Suspend an accurate thermometer B in the oil NOTE O The switch and thermometer must not touch the container sides or bottom e Place the container over a source of heat and gradually raise the temperature of the oil while stirring the oil gently e Using the hand tester measure the internal resistance of the switch across the terminals at the temperatures shown in the table x If the hand tester does not show
105. Camshaft Chain Guide Bolt E 9 8 N m 1 0 kgf m 87 in Ib Camshaft Chain Guide Wear e Visually inspect the rubber on the guides x If the rubber is damaged cut or is missing pieces replace the guide Property of www SmallEngineDiscount com Not for Resale ENGINE TOP END 4 17 Cylinder Head Cylinder Compression Measurement NOTE O Use the battery which is fully charged e Warm up the engine thoroughly and stop the engine e Remove the spark plug see Electrical System chapter e Attach the compression gauge A and adapter B firmly into the spark plug hole Special Tools Compression Gauge 57001 221 Compression Gauge Adapter M12 x 1 25 57001 1018 e Hold the throttle wide open and crank the engine with the electric starter or the recoil starter several times e When the gauge stops rising stop cranking and read the gauge Cylinder Compression Usable Range Electric Starter 810 1260 kPa 8 3 12 8 kgf cm 118 182 psi 0630 r min rpm The following table should be consulted if the obtainable compression reading is not within the usable range Problem Diagnosis Remedy Action Cylinder compression Carbon accumulation on piston cylinder head is higher than usable and in combustion chamber possibly due to range damaged valve stem oil seal and or damaged piston oil rings This may be indicated by white exhaust smoke Incorrect cylinder head gasket thickness Damag
106. Disc B Disc Installation e The disc must be installed with the marked side A facing toward the A steering knuckle e Apply a non permanent locking agent O O Disc Mounting Bolts e Tighten O O D O Torque Disc Mounting Bolts 37 N m 3 8 kgf m 27 ft lb O MIN TH 3MM O e After installing the discs check the disc runout Completely clean off any grease that has gotten on either side of the disc with a high flash point solvent Do not use one which will leave an oily residue HL090002S1 Disc Wear e Measure the thickness of each disc at the point A where it has worn the most x Replace the disc if it has worn past the service limit Disc Thickness Standard 3 3 3 7 mm 0 130 0 146 in Service Limit 3 mm 0 12 in HL090003S1 Disc Runout e Jack up the vehicle so that the wheels are off the ground e Remove the front wheels and turn the handlebar fully to one side e Set up a dial gauge against the disc A and measure the disc runout x If the runout exceeds the service limit replace the disc Disc Runout Standard TIR 0 2 mm 0 008 in or less Service Limit TIR 0 3 mm 0 012 in HLO9000451 Property of www SmallEngineDiscount com Not for Resale BRAKES 12 17 Brake Hoses Brake Hose Inspection e Refer to Brake Hose and Connection Check in Periodic Maintenance chapter Brake Hose Replacement e Referto Brake Hose Replacement in Per
107. Electric Starter System Starter Motor Removal e Remove Fuel Tank Cover see Fuel System chapter Starter Motor Cable A Starter Motor Mounting Bolts B Starter Motor C CAUTION Do not tap the end of the starter motor shaft or the motor may be damaged Starter Motor Installation e When installing the starter motor clean the starter motor lugs A and crankcase B where the starter motor is grounded x If the O ring A shows wear or damage or if it is hardened replace it with a new one e Apply a small amount of engine oil to the O ring e Install Starter Motor Starter Motor Cable e Tighten Torque Starter Motor Mounting Bolts 8 8 N m 0 9 kgf m 78 in Ib Starter Motor Terminal Nut 4 9 N m 0 5 kgf m 43 in Ib HP118025 P Starter Motor Disassembly e Remove Starter Motor Bolts A Left End Cover B Right End Cover C Yoke D HP118026 P e To remove the brush plate assembly A remove the terminal nut B ELECTRICAL SYSTEM 16 33 Electric Starter System e Hold the brush spring A with needle nose pliers and pull the brush B off the holder Starter Motor Assembly e Replace the O rings e Install the brush plate assembly to the right end cover so that the projection A on the brush plate fits into the groove on the right end cover e Install the O ring insulators B and washer C in that order on the terminal bolt e Tighten Torque Starter Motor Termina
108. Guides Seats Springs Oil Seals START Machinist s dye on seat 45 Grind Tool 45 Cutter Valve Seat Repair Purpose make seating area smooth and round Measure Seating Area O D Tool Vernier Caliper Purpose check seat O D against spec 45 Grind Tool 45 Cutter Purpose increase O D of seat area to spec Machinist s dye on seat 32 Grind Tool 32 Cutter Purpose reduce O D of seat area to spec Measure Seat Width Tool Vernier Caliper Purpose check seat width against spec 45 Grind Machinist s Tool 45 Cutter dye on seat Purpose increase width of seat area beyond spec to increase O D 50 Grind Tool 50 Cutter Purpose reduce seat width to specification Lap Valve Tools Valve Lapper Grinding Compound Purpose perfectly match valve FINISHED and seat area check valve head for damage HE13004BW5 S Property of www SmallEngineDiscount com Not for Resale 4 28 ENGINE TOP END Cylinder and Piston Cylinder Removal e Remove Cylinder Head see Cylinder Head Removal Front Chain Guide A e Lift off the cylinder B and remove the cylinder base gasket If necessary tap lightly around the base of the cylinder with a plastic mallet taking care not to damage the cylinder O Immediately stuff a clean cloth around the piston to prevent parts or dirt from falling into the crankcase Cylinder Installation NO
109. IL Fluid 424 or Kawa Chem Gear amp Wet Brake Oil CITGO TRANSGARD TRACTOR HYDRAULIC FLUID Capacit 900 mL 0 95 US qt Frame Type Double cradle tubular steel Caster rake angle 2 5 Camber 0 5 King pin angle 14 5 Trail 15 mm 0 59 in Tread Front 890 mm 35 04 in Rear 895 mm 35 24 in Front tire Type Tubeless Size AT25 x8 12 Rear tire Type Tubeless Size AT25 x 10 12 Suspen Front Type MacPherson strut sion Wheel travel 170 mm 6 69 in Rear Type Swingarm Wheel travel 180 mm 7 09 in Brake Front Disc x 2 Rear Enclosed wet multi plate Electrical Equipment Battery 12V 14 Ah Headlight Type Semi sealed beam Bulb 12 V 30 30 W x 2 Tail brake light Bulb 12V 5 18 W Alternator Type Three phase AC Rated output 25 A 14 V 8000 r min rpm Specifications are subject to change without notice and may not apply to every country US U S A Model Property of www SmallEngineDiscount com Not for Resale 1 8 GENERAL INFORMATION Special Tools and Sealant Bearing Puller 57001 135 Valve Guide Arbor 7 57001 163 Inside Circlip Pliers 57001 143 Oil Pressure Gauge 10 kg cm 57001 164 Drs Outside Circlip Pliers 57001 144 LA Valve Spring Compressor Assembly 57001 241 Valve Guide Reamer 7 57001 162 Valve Spring Compressor Adapter 28 2 57001 243 SS Property of www SmallEngineDiscount com Not fo
110. ION eee eee eteeeeeeteeeeeeeeaeeeseeteeeaeeeaeecseesseecsaeeeaeesaeeeaaeseaeeeaeecaeessaeseaeeeaeesiaeseaeeeaeesieesnaeseaeeeaeeseeeeeaeeeas 9 23 Property of www SmallEngineDiscount com Not for Resale 9 2 CRANKSHAFT TRANSMISSION Exploded View Property of www SmallEngineDiscount com Not for Resale CRANKSHAFT TRANSMISSION 9 3 Exploded View AO 1 Camshaft Chain Guard Bolts i 2 Oil Line Plugs 3 Engine Drain Plug Crankcase Bolts M8 20 Remarks os ene 14 S L 1 4 5 Crankcase Bolts M6 8 8 78 in lb L Apply a non permanent locking agent M Apply molybdenum disulfide grease O Apply engine oil LG Apply liquid gasket Three Bond 1215 Gray S Follow the specific tightening sequence Property of www SmallEngineDiscount com Not for Resale 9 4 CRANKSHAFT TRANSMISSION Exploded View Property of www SmallEngineDiscount com Not for Resale CRANKSHAFT TRANSMISSION 9 5 Exploded View EE CITI ft lb Remarks Tie Rod End Locknut 14 Shift Lever Assembly Nut 14 Tie Rod End Front Locknut 87 in lb Tie Rod End Rear Locknut 87 in lb Tie Rod End Nut 14 Shift Shaft Cover Bolts E 78 in lb Neutral Position Switch 11 Reverse Position Switch 11 Shift Shaft Pontony Bolt 18 G Apply grease for oil seal and O ring L Apply a non permanent locking agent M Apply
111. Inner Width A of Disc Assembly Disc Assembly 2 4 mm 0 0945 in 16 7 17 3 mm 0 6675 0 6811 in 1 8 mm 0 0709 in 17 31 17 9 mm 0 6815 0 7047 in 1 2 mm 0 0472 in 17 91 18 5 mm 0 7051 0 7283 in Measure the width of the disc assembly at three locations and calculate average for three points NOTE HK11002051 O Be careful not to damage the facing surface C on the outer plates x If the width is within the specified range install the inner disc and disc assembly lf the width is not within the specified range replace the disc assembly e Install Inner Disc A Disc Assembly B and Housing C e Apply engine oil to the needle bearing A e Install Needle Bearing Outer Disc B e Apply engine oil to the variable front differential control shaft A e Install the shaft and spring B in the front final gear case left cover C as shown HK110023 P Property of www SmallEngineDiscount com Not for Resale 11 34 FINAL DRIVE Front Final Gear Case e Turn the shaft counterclockwise and insert the tab A of the shift shaft into the groove B of the cam plate e Install Front Final Gear Case Left Cover C e Apply a non permanent locking agent to the cover bolts 1 4 and tighten them following the tightening sequence as shown Torque Front Final Gear Case Left Cover Bolts 1 8 9 8 N m 1 0 kgf m 87 in
112. JURY FROM THE FAN BLADES e Drain the engine oil see Engine Oil Change e Remove Front Fender see Frame chapter Oil Cooler Fan Switch Lead Connectors A Oil Temperature Warning Light Switch Lead Connectors B Oil Cooler Fan Motor Lead Connector e Loosen the oil pipe joint nuts C and remove the oil pipes from the oil cooler D e Remove Oil Cooler Mounting Bolts E and Nuts Oil Screen and Oil Cooler 1 J aa Oil Cooler Installation e Connect Oil Cooler Fan Switch Lead Connectors Oil Temperature Warning Light Switch Lead Connectors Oil Cooler Fan Motor Lead Connector e Install Oil Cooler A Screen B Fame C Damper D as shown Collar E e Tighten Torque Oil Cooler Mounting Bolts F 8 8 N m 0 9 kgf m 78 in Ib HGO7G02BS1 e Apply grease to the O rings in the oil pipe joint and insert them into the oil cooler e Tighten Torque Oil Pipe Joint Nuts 29 N m 3 0 kgf m 22 ft Ib Oil Cooler Disassembly e Remove Oil Cooler see Oil Cooler Removal Fan Assembly Mounting Bolts A Fan Assembly B Property of www SmallEngineDiscount com Not for Resale 7 14 ENGINE LUBRICATION SYSTEM Oil Cooler Oil Cooler Fan Switch Oil Temperature Warning Light Switch Removal CAUTION The oil cooler fan switch or the oil temperature warning light switch should never be allowed to fall on hard surface Such a shock to their parts can damage them
113. NE LUBRICATION SYSTEM 7 9 Oil Pressure Relief Valve Oil Pressure Relief Valve Removal e See Crankcase disassembly see Crankshaft Transmission chapter e Remove the oil pressure relief valve A Oil Pressure Relief Valve Installation e See crankcase assembly see Crankshaft Transmission chapter e Apply a non permanent locking agent to the threads of oil pressure relief valve and tighten it Torque Oil Pressure Relief Valve 15 N m 1 5 kgf m 11 ft Ib Oil Pressure Relief Valve Inspection e Remove the relief valve e Using a wooden stick push the inner valve to make sure that the valve A moves smoothly and that it returns to its original position by the force of the spring B NOTE O The relief valve cannot be disassembled and it must be inspected in the assembled state x If the valve movement is not smooth wash the relief valve with high flash point solvent and use compressed air to remove any foreign particles from it GG080301 S WARNING Clean the oil pressure relief valve in a well ventilated area and take care that there is no spark or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline to low flash point solvent x If the valve does not move smoothly even after washing it replace the relief valve The oil pressure relief valve is precision made with no allowance for replacement of individual parts Prope
114. NING These cleaning fluids are usually highly flammable and harm ful if breathed for prolonged periods Be sure to heed the fluid manufacturer s warnings HSO6011BS1 e Install the drive pulley and washers 3 A on the drive pulley bolt as shown 1 Bolt Head HS06014BS1 e Hold the drive pulley with the drive pulley holder A Special Tool Drive Pulley Holder 57001 1520 e Tighten Torque Drive Pulley Bolt B New left hand threads 93 N m 9 5 kgf m 69 ft lb e Adjust the installation length A of the drive pulley between the surface of the crankcase B and the collar C on the drive pulley as followings Drive Pulley Installation Length A Standard 149 85 150 95 mm 5 900 5 943 in Property of www SmallEngineDiscount com Not for Resale CONVERTER SYSTEM 5 17 Drive Pulley O Install the drive pulley measurement tool legs A and plate B on the crankcase C Special Tool Drive Pulley Measurement Tool 57001 1498 O Measure the length D between the plate and collar E with Vernier calipers F or a depth gauge Measurement Length D Standard 14 55 15 65 mm 0 573 0 616 in If the measurement is 14 55 mm 0 573 in or less use the drive pulley cover 14041 1148 of red paint x If the measurement is more than 15 65 mm 0 616 in use the drive pulley cover 14041 1149 of blue paint x If the length is not within the
115. Outside Circlip Pliers 57001 144 Circlip Pliers 57001 154 Oil Seal amp Bearing Remover 57001 1058 Bearing Driver Set 57001 1129 Socket Wrench 57001 1363 Damper Spring Compressor Set 57001 1475 Holder amp Guide Arbor 57001 1476 Socket Wrench Hex 50 57001 1478 Output Shaft Holder amp Spacer 57001 1479 Pinion Gear Holder 57001 1480 Nut Holding Bolts 57001 1481 Socket Wrench 57001 1482 Socket Wrench Hex 41 57001 1484 Pinion Gear Holder 57001 1485 Oil Seal Driver 57001 1487 Gear Holder amp Socket Wrench Hex 24 57001 1489 Hexagon Wrench Hex 41 57001 1491 Oil Seal Driver 618 57001 1505 Oil Seal Driver 648 57001 1506 Property of www SmallEngineDiscount com Not for Resale FINAL DRIVE 11 9 Output Bevel Gears Output Drive Bevel Gear Removal e Remove Left Side Cover see Frame chapter Forward Reverse Detecting Sensor Lead Connector A Output Drive Bevel Gear Cover Bolts B Output Drive Bevel Gear Cover C e Remove Circlip A Special Tool Outside Circlip Pliers 57001 144 e Remove Output Drive Idle Gear B e Remove Output Drive Bevel Gear Housing Bolts A Output Drive Bevel Gear Housing B TA Hk ieBog Output Drive Bevel Gear Installation e Install the output drive bevel gear housing e Tighten Torque Output Drive Bevel Gear Housing Bolts 26 N m 2 7 kgf m 20 ft lb e Install the rotor A so that the projections B face outward e Tighten f Torque Ro
116. Part for U S model Speedometer Removal e Remove Front Fender see Frame chapter Switch Housings Brake Master Cylinder Variable Differential Control Lever Screws A Washers and Collars e Remove Nuts A Bracket B Rubber Damper and Speedometer HP20B007 P Speedometer Inspection e Remove Speedometer see Speedometer Removal CAUTION Do not drop the meter unit 1 Battery Red 2 Battery Black 3 Speed Sensor Pulse Green Check 1 Pointer and LCD Check e Using auxiliary wires connect a 12 V battery to the meter terminals as follows e Connect the battery negative terminal to terminal 2 Black e Connect the battery positive terminal to terminal 1 Red O The pointer will be move counterclockwise past 0 and then back up to 0 O For the first second after power up the LCD display A will show the software revision i e 6801 r2 etc O For the next four seconds the accumulated hours will be shown O Finally the LCD display will change to the current odometer reading after a total of five seconds If this display function does not work replace the meter unit HP20025BS1 Property of www SmallEngineDiscount com Not for Resale ELECTRICAL SYSTEM 16 45 Speedometer Optional Part for U S model Check 2 MODE Button Operation Check e Connect the wires in the same manner as Check 1 e Pushin
117. Rear Brake Lever Pedal and Cables Rear brake pedal position 60 65 mm 2 36 2 56 in above footboad Rear brake lever free play 1 2 mm 0 04 0 08 in Rear brake pedal free play 15 25 mm 0 6 1 0 in Special Tool Inside Circlip Pullers 57001 143 Property of www SmallEngineDiscount com Not for Resale BRAKES 12 7 Brake Fluid AWARNING When working with the disc brake observe the precautions listed below 1 Never reuse old brake fluid 2 Do not use fluid from a container that has been left unsealed or that has been open for a long time 3 Do not mix two types and brands of fluid for use in the brake This lowers the brake fluid boiling point and could cause the brake to be ineffective It may also cause the rubber brake parts to 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 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 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
118. Resale CONVERTER SYSTEM 5 3 Exploded View Torque No Fastener Nm kgtm Remarks 1 Drive Pulley Bolt 69 R Lh 2 Driven Pulley Nut 3 Drive Pulley Cover Bolts 113 in lb 4 Ramp Weight Nuts 6 9 0 7 61 in lb 5 Spider 275 28 203 Lh 6 Spacer for High Altitude Setting G Apply grease for oil seal and O ring M Apply molybdenum disulfide grease Lh Left hand Threads R Replacement Parts Property of www SmallEngineDiscount com Not for Resale 5 4 CONVERTER SYSTEM Exploded View HS02003BN5 C Property of www SmallEngineDiscount com Not for Resale CONVERTER SYSTEM 5 5 Exploded View el Fastener Nm kgtm ftib Converter Cover Bolts ss 09 78 intb Engine Brake Actuator Mounting Bolts 88 09 78 in lb Coverter Air Duct Botts 8s 09 78imb S Follow the specific tightening sequence G Apply grease for oil seal and O ring M Apply molybdenum disulfide grease Property of www SmallEngineDiscount com Not for Resale 5 6 CONVERTER SYSTEM Specifications Item Torque Converter Actuator lever guide shoe wear Drive Belt Belt Deflection Belt Width Standard 20 27 mm 0 79 1 06 in 29 8 31 0 mm 1 17 1 22 in Service Limit 6 mm 0 24 in 29 4 mm 1 16 in Drive Pulley Cover bushing inside diameter Sheave bushing inside diameter Shoe side clearance Spring free length 27 985 28 085 mm 1 1018
119. Rim Inspection 10 7 Wheel Rim Replacement cesccccssceeeseeeeeseeeeeseeeeeeneeeeaeeeesaeeesseneesneneesaeeenenensseseaesseaeesaneessaneeseeeenenanenenenensneees 10 8 MMS bear 10 9 Mire Removal ae a a a lider 10 9 Tire Installation Lorca a an a 10 9 Tire Inspection as 10 10 Front HUD OPEP To O 10 11 Front Hub Removal icon e ie iii 10 11 Front Hub Installation sssini aeara Ea e aee Ea aE eaea EA Eaa a a EE a Eaa 10 11 Front Hub Disassembly AsSseMbly oooonccconccconnoccnonccnnncccnr acen arce 10 11 RearA UDua a ae 10 12 Rear Hub Removal oia it r e GRE a Opa a eiaa E r arnis 10 12 Rear Hub Installati n isisisi eaae a iiaae a Eaa a a anA iaaii 10 12 Rear Hub Disassembly ASSOMbIy e ccceseeeceeeceeseneeseeeeeeesneneseneeeseeeeceeeessaeeeseaeeessaeaesnaneesnasensseeesenaneneseeeeseenens 10 12 Property of www SmallEngineDiscount com Not for Resale 10 2 WHEELS TIRES Exploded View HJ02001BN5 C Property of www SmallEngineDiscount com Not for Resale WHEELS TIRES 10 3 Exploded View 1_ Wheel Nuts se 53 2 Front Axle Nuts 3 Tie Rod End Nuts 4 Tie Rod Adjusting Sleeve Locknuts 37 3 8 27 5 Rear Axle Nuts 265 27 195 W Apply water or soap and water solution R Replacement Parts Property of www SmallEngineDiscount com Not for Resale 10 4 WHEELS TIRES Specifications Wheel Alignment Toe in of front wheels 0 20 mm 0 0 79 in at
120. Ring End Gap Measurement 4 32 Exhaust Syste a ssccistesievdsen cra 4 33 Spark Arrester Cleaning 4 33 Muffler RemoVal oooocooccconocicnnoconnoncconancncnannnonn nos 4 33 Exhaust Pipe Removal 4 33 Exhaust Pipe and Muffler Installation 4 33 Exhaust System Inspection cceeeeeeeeees 4 33 Property of www SmallEngineDiscount com Not for Resale 4 2 ENGINE TOP END Exploded View Property of www SmallEngineDiscount com Not for Resale ENGINE TOP END 4 3 Exploded View Fastener Remarks ME AN ECT DET Cylinder Head Bolts M11 first torque 2 5 Cylinder Head Bolts M11 final torque Ps pe Js gt 3 Cylinder Head Bolts M6 12 1 2 104 in lb 4 Camshaft Cover Bolts 8 8 0 9 78 in lb 5 Engine Breather Plate Screws 4 4 0 45 39 in lb 6 Face the round end outward G Apply grease for oil seal and O ring MO Apply molybdenum disulfide oil S Follow the specific tightening sequence O Apply engine oil R Replacement Parts Property of www SmallEngineDiscount com Not for Resale 4 4 ENGINE TOP END Exploded View HE02004BN5 C Property of www SmallEngineDiscount com Not for Resale ENGINE TOP END 4 5 Exploded View Torque Fastener Nm kgfm ft lb Remarks a Rear Camshaft Chain Guide eon os 1o embe 4 Camshaft Chain Tensioner Mounting Bolts 8 8 0 9 78 in lb 5 Camshaft C
121. Steering INSPECtION cceeeeeeeeeeeeeteeeeeeeeeeees 2 24 Electrical System ceeceeceeseeeceeeeeteeeeeeeeeetaes 2 24 Battery INSpectiON ooonccionncninncconcccnnnorcnnnoncnnnos 2 24 Spark Plug Cleaning Inspection 2 24 Spark Plug Gap InspectiON ooocooicninninncccn c 2 24 Drive Belt Failure Detection System Inspection 2 24 Brake Light Switch Adjustment 2 24 General Lubrication 0 cceceeseeeeeeseeeeeeeeeeeees 2 26 Lubrication iia 2 26 Bolts and Nuts Tightening 2 27 Tightness Inspection 2 27 Property of www SmallEngineDiscount com Not for Resale 2 2 PERIODIC MAINTENANCE Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the vehicle in good running condition The initial maintenance is vitally important and must not be neglected First FREQUENCY Series Regular Service ar Ed Every 90 days or After 10 1700 km 1100 mi days days hrs or or 200 or 600 of use or when Every 100 km BELT indicator light year of km km 60 mi comes on 100 use 120 360 of use a hrs whichever mt OF 2 comes first OPERATION use use ENGINE Converter drive belt wear inspect O Converter drive belt deflection inspect O Drive belt failure detection system function inspect e NOTE Engine brake control lever inspect O Air cleaner service Throttle lever play inspect Valve clear
122. TE O If a new cylinder is installed be sure to check piston cylinder clearance see Piston Cylinder Clearance e Clean any remains of the old cylinder base gasket from the bottom of the cylinder and the top of the crankcase e Install Dowel Pins A New Cylinder Base Gasket B HETABOO Ip e The arrow A on the piston head must point toward the front of the engine e The piston ring openings must be positioned as shown The openings of the oil ring steel rails must be about 30 40 B of angle from the opening of the top ring Top Ring C Second Ring D Oil Ring Expander E Oil Ring Steel Rails F e Apply engine oil to the cylinder bore and piston rings e The rear camshaft chain guide also fit inside the tunnel errrer re e Fit the cylinder down over the piston and rings O Hold the rings into their groove with your fingers so that the cylinder does not catch on them e Push the cylinder down solidly against the crankcase Property of www SmallEngineDiscount com Not for Resale ENGINE TOP END 4 29 Cylinder and Piston Cylinder Assembly e Insert the rubber dampers A in the fin grooves B Front Side C Right Side D Rear Side E 22 mm 0 87 in F 21 mm 0 83 in G 31 mm 1 22 in VAART 5 O 27 Cg HE14010B53 G Piston Removal e Remove the cylinder see Cylinder Removal e Place a clean cloth under the piston remove the one of the pist
123. Variable Differential Control Lever Bolt 31 in lb Master Cylinder Clamp Bolts E 78 in lb 13 Speedometer other than U S A model 14 Cover U S A model L Apply a non permanent locking agent G Apply greae for oil seal and O ring AD Apply adhesive agent AG Apply grease Amoco rykon premium grease No 2 EP Green S Follow the specific tightening sequence Property of www SmallEngineDiscount com Not for Resale 14 4 STEERING Specifications Standard eRe oe aaa Rods Tie Rod Length 315 0 7 mm 12 4 0 03 in Special Tools Inside Circlip Pliers 57001 143 Bearing Driver Set 57001 1129 Property of www SmallEngineDiscount com Not for Resale STEERING 14 5 Steering Steering Stem Removal e Remove Fuel Tank see Fuel System chapter Front Wheels see Wheels Tires chapter Cotter Pins A Tie Rod End Nuts B and Tie Rod End Steering Stem Bearing Housing Bolts C right and left CAUTION Do not loosen the locknuts D at the ends of the tie rod adjusting sleeve or the toe in of the front wheels will be changed e Remove Handlebar Holder Mounting Nuts A Handlebar Assembly HNG4G07BS1 C e Flatten out the bended parts A of the lockwasher e Remove Steering Clamp Bolts B Lockwasher and Plate Steering Clamps C and Collars Grease Seals D upper and lower e Pull the steering stem out of the frame e Remove Cotter Pin A
124. a low flash point solvent to clean the foam element e Remove the air cleaner element e Clean the element in a bath of high flash point solvent using a soft bristle brush e Squeeze it dry in a clean towel A Do not wring the element or blow it dry the element can be damaged e Inspect the element for damage If it is torn punctured or hardened replace it NOTE O Replace the element after cleaning it five times or if it is damaged e After cleaning saturate the element with a high quality foam air filter oil squeeze out the excess oil then wrap it in a clean rag and squeeze it as dry as possible Be careful not to tear the element Property of www SmallEngineDiscount com Not for Resale 2 12 PERIODIC MAINTENANCE Periodic Maintenance Procedures Air Cleaner Draining A drain tube A is connected to the bottom of the air cleaner housing to drain water or oil accumulated in the housing e Visually check the drain tube if the water or oil accumulates in the tube If any water or oil accumulates in the tube drain it by taking off the tube After draining be sure to install the tube and clamp firmly Fuel Hose and Connection Check e Turn the fuel tap to the OFF position e Remove Fuel Tank Cover see Frame chapter Exhaust Cover see Frame chapter e Check the fuel hose A x If the fuel hose is frayed cranked or bulged replace the fuel hose e Check that the hose is securely conne
125. able ignition timing and helps maintain a thorough combustion process within the engine which contributes to a reduction of exhaust pollutants entering the atomosphere The Clean Air Act which is the Federal law covering motor vehicle pollution contains what is commonly referred to as the Act s tampering provisions Sec 203 a The following acts and the causing thereof are prohibited 3 A for any person to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to its sale and delivery to the ultimate purchaser or for any manufacturer or 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 knowingly 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 following its sale and delivery to the ultimate purchaser NOTE O The 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 devices or elements of desig
126. aced Repeat the shim change procedure as necessary NOTE O If the backlash is out of the standard range after changing the pinion gear shim s change the ring gear shim s to correct the backlash before checking the tooth contact pattern Pinion Gear Unit Disassembly e Remove Pinion Gear Unit A see Rear Final Gear Case Disassembly e Hold the pinion gear bearing holder nut B with the socket wrench C in a vise and loosen the pinion gear shaft using the pinion gear holder D Special Tools Socket Wrench 57001 1363 Pinion Gear Holder 57001 1480 e Remove the ball bearing E as necessary Special Tool Bearing Puller 57001 135 Pinion Gear Unit Assembly O The pinion gear and ring gear are lapped as a set in the factory to get the best tooth contact They must be replaced as a set e Visually inspect the bearing for abrasion color change or other damage x If there is any doubt as to the condition of a bearing replace the bearing e Be sure to check and adjust the bevel gear backlash and tooth contact when any of the backlash related parts are replaced see Front Final Bevel Gear Adjustment e Press the bearing A on the pinion gear until it is bottomed peiacaiasice e Install the pinion gear bearing holder nut B so that the projection C faces outward e Apply a non permanent locking agent to the pinion gear bearing holder nut A and tighten it Special Tools Socket Wrench
127. ad Bolts M6 12 1 2 104 in lb S Valve Adjusting Screw Locknuts 12 1 2 104 in lb Valve Adjusting Cap Bolts 8 8 0 9 78 in lb Muffler Mounting Bolts 26 2 7 20 Converter System Converter Cover Bolts 8 8 0 9 78 in lb S Driven Pulley Nut 93 9 5 69 Ramp Weight Nuts 6 9 0 7 61 in lb Spider 275 28 203 Lh Drive Pulley Cover Bolts 13 1 3 113 in lb Drive Pulley Bolt 93 9 5 69 R Lh Converter Air Duct Bolts 8 8 0 9 78 in lb Recoil Starter Recoil Starter Mounting Bolts 5 9 0 6 52 in lb L Engine Lubrication System Engine Drain Plug 20 2 0 14 Oil Filter 18 1 8 13 R Oil Pressure Switch 15 1 5 11 SS Oil Pressure Relief Valve 15 1 5 11 L Oil Pump Cover Bolt 20 2 0 14 Oil Pump Cover Screws 5 4 0 55 48 in lb Oil Pipe Bolts 8 8 0 9 78 in lb Property of www SmallEngineDiscount com Not for Resale 2 4 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Oil Pipe Joint Nuts Oil Cooler Mounting Bolts 3 78 in lb Oil Cooler Fan Switch E 12 Oil Temperature Warning Light Switch 12 Oil Filter Mounting Bolt 18 Oil Hose Banjo Bolts 22 Oil Pressure Switch Terminal Bolt 13 in lb Engine Removal Installation Engine Mounting Bracket Bolts 18 Engine Mounting Nuts 31 Engine Mounting Upper Bolt 18 Crankshaft Transmission Crankcase Bolts M8 14 Crankcase Bolts M6 78 in lb Shift Shaft Positioning Bolt 18 Tie Rod End Locknut E 14 Tie Rod End Bolt 87 in lb Shift Lever Assembly Nut 14 Tie Rod End Nut 14 Shift Lever
128. aeesaeseeeseaeeseeseeeseaeeseeseeeeeaeeeas 13 11 SUSPENSION AMS cir et ates 13 12 Suspension Arm RemoOVal occonccnncccnccnnnccnoncnoccnonncnc nono non RRA RR nena nana 13 12 Suspension Arm InstallatiON ooonnocnnnnnnnninnnnnconncnnnccnnccnnn cnn oran nro corran rre 13 12 Suspension Arm Disassembly ccccccceeeeeseeeeeeeeeeseeeceaeeeaeeeaeecseeseaeseaeesaeeseaesaeseaeesaeesneeseaeesseesaeeseaeenaeeeneeseaeeeas 13 12 Suspension Arm Assembly cococinccnnccnoninoncnnncnnncn nono rn 13 13 SIND Mist A a aA a eE Ea Ea 13 14 Swingarm Removal a seier aienea a racial EENE ENEAN 13 14 Swingarm InstallatiOn 0 coincida aaa at aa airada ceda 13 14 Swingalm DisassemblVurccicio torito e kataa eaaa eaaa eean N e ian aia 13 14 Swinda ASSembIV rrenan adn sprite atan 13 16 Swingarm Bearing Inspection a A eee 13 16 Swingarm Bearing LubricatiON onooninndinnnnnnnnnnnnnnonnccnnccnernncncn rca 13 16 Property of www SmallEngineDiscount com Not for Resale 13 2 SUSPENSION Exploded View HMO02001BW5 C Property of www SmallEngineDiscount com Not for Resale SUSPENSION 13 3 Exploded View Front Shock Absorber Mounting Nuts 74 75 Front Shock Absorber Clamp Bolts and Nuts 2 3 Steering Knuckle Joint Nut 4 Suspension Arm Pivot Bolts 88 9 0 65 5 Rear Shock Absorber Mounting Nuts 62 6 3 46 6 Piston Rod Nut 49 5 0 36 7 Swingarm Pivot Right Shaft 152 15 5 112 L 8 Swingarm Pivot Left S
129. ake pads will drag on the disc Blow the ports clean with compressed air e Check the piston return spring H for any damage x If the spring is damaged replace it Property of www SmallEngineDiscount com Not for Resale BRAKES 12 11 Calipers Caliper Removal e Remove the front wheel see Wheels Tires chapter e Loosen the banjo bolt A at the brake hose lower end and tighten it loosely e Unscrew the caliper mounting bolts B with a socket wrench and an extension bar e Detach the caliper C from the disc e Unscrew the banjo bolt and remove the brake hose D from the caliper CAUTION Immediately wash away any brake fluid that spills NOTE Ifthe 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 Disassembly Caliper Installation e Install the caliper and brake hose lower end O Replace the washers that are on each side of hose fitting with new ones e Tighten Torque Caliper Mounting Bolts 25 N m 2 5 kgf m 18 ft Ib Brake Hose Banjo Bolt 25 N m 2 5 kgf m 18 ft lb e Check the fluid level in the brake reservoir e Bleed the brake line see Brake Line Air Bleeding e Check the brake for good braking power no brake drag and no fluid leakage WA TO Do not attempt to drive the vehicle until a firm brake lever can be obtained by pumping the brake lever
130. ake pedal has the correct amount of play e Operate the pedal a few times to see that it returns to its rest position immediately upon release e Rotate the rear wheels to check for brake drag e Check braking effectiveness x If there is any doubt as to the conditions of the brake check the brake parts for wear or damage Property of www SmallEngineDiscount com Not for Resale 2 24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Steering Inspection e Turn the handlebar left and right and check the steering action x If the steering action is not smooth or if the steering binds or catches before the stop lubricate the steering stem bearing NOTE O The cables and wires will have some effect on the steering action which must be taken into account e Check the steering action again x If steering stem bearing lubrication does not remedy the problem inspect the steering stem for straighteness steering stem clamps and tie rod bearings If you feel looseness or if the steering rattles as it turns check the tightness of the steering bolts and nuts e Tighten loose bolts and nuts to the specified torque see Exploded View and check the steering action again x If the steering action does not change by tightening the bolts and nuts inspect the steering stem clamps steering stem bearings tie rod bearings and steering knuckle joints Electrical System Battery Inspection e Refer to
131. ake sure oil passages of the crank and crankpin are lined up during assembly e Check that the connecting rod radial clearance is within specification see Connecting Rod Big End Radial Clearance e Adjust crankshaft runout until runout is within specification see Crankshaft Alignment HI05008BW3 C 1 Crankpin 7 Right Crankshaft 2 Spacers 8 45 1 3 Crankpin Needle Bearing 9 Center of Crankpin 4 1 1 0 35 mm 0 043 0 014 in 10 57 25 30 From web end to crankpin end 11 Center of Sprocket Tooth 5 Balancer Gear 12 Punch Mark 6 Left Crankshaft Property of www SmallEngineDiscount com Not for Resale 9 12 CRANKSHAFT TRANSMISSION Crankshaft Balancer Shaft and Connection Rod Connecting Rod Big End Seizure e In the case of serious seizure with damage to the crank halves the crankshaft must be replaced x If the seizure was less severe disassemble the crankshaft and replace the crankpin needle bearing and connecting rod Connecting Rod Big End Radial Clearance e Set the crankshaft on V blocks and place a dial gauge A against the connecting rod big end e Push B the connecting rod first towards the gauge and then in the opposite direction The difference between the two gauge readings is the radial clearance If the radial clearance exceeds the service limit the crankshaft assembly must be replaced or disassembled and the crankpin needle bearing and connecting
132. al rotate the driven pulley to allow the belt to return to the top of the sheaves before measuring the belt deflection e Measure the belt deflection again and repeat the above procedures until it is within the standard range e Using the flywheel amp pulley holder and adapter tighten the driven pulley nut Special Tools Flywheel amp Pulley Holder 57001 1343 Pulley Holder Attachment 57001 1472 Torque Driven Pulley Nut 93 N m 9 5 kgf m 69 ft lb Property of www SmallEngineDiscount com Not for Resale PERIODIC MAINTENANCE 2 17 Periodic Maintenance Procedures Engine Lubrication System Engine Oil Change e Support the vehicle so that it is level side to side and front to back after warming up the engine e Remove the engine drain plug A to drain the oil O The oil in the filter can be drained by removing the filter see Oil Filter Change x Replace the drain plug gasket with a new one if it is damaged e Tighten Torque Engine Drain Plug 20 N m 2 0 kgf m 14 ft Ib e Pour in the specified type and amount of oil HGOSGO1BS1 C Engine Oil Type API SF or SG API SH or SJ with JASO MA Viscosity SAE 10W 40 Amount 1 50 L 1 59 US qt When filter is not removed 1 74 L 1 84 US qt When filter is removed 2 3 L 2 43 US qt When engine is completely dry 1 1 1 SAE 20W 50 SAE 20W 40 NOTE O Depending on the atmospheric temperature of your riding ar
133. ance inspect Fuel system cleanliness inspect Engine oil change Oil filter replace Spark plug clean and gap Spark arrester clean Oil cooler clean Oil hoses and connections inspect Fuel hoses and connections inspect Fuel hose replace 4 years CHASSIS Joint boots inspect O 0 Rear brake pedal and lever adjustment inspect O O Rear brake plates change every 10 000 km 6 000 mi Cables adjustment Bolts and nuts tighten Front brake pad wear inspect Brake light switch inspect Battery inspect Steering inspect Differential control lever play inspect Tire wear inspect Front and rear finial gear case oil change General lubrication e Front brake fluid level inspect O 0 Front brake fluid change Brake master cylinder piston assembly and dust seal 2 years replace Caliper piston seal and dust seal replace 2 years Brake hoses and connections inspect O Brake hose replace 4 years Service more frequently when operated in mud dust or other harsh riding conditions or when carrying heavy loads or pulling a trailer e Clean adjust lubricate torque or replace parts as necessary NOTE O When the drive belt failure detection system is activated inspect the drive belt Property of www SmallEngineDiscount com Not for Resale
134. and oil off the bevel gear teeth e Apply checking compound to 4 or 5 teeth of the pinion gear NOTE O Apply checking compound to the teeth in a thin even coat with a fairly stiff paint brush If painted too thickly the exact tooth pattern may not appear O The checking compound must be smooth and firm with the consistency of tooth paste O Special compounds are available at automotive supply stores for the purpose of checking differential gear tooth patterns and contact Property of www SmallEngineDiscount com Not for Resale FINAL DRIVE 11 51 Rear Final Gear Case e Assemble the rear final gear case see Rear Final Gear Case Assembly e Turn the pinion gear for one revolution in the drive and reverse coast direction while creating drag on the ring gear e Remove the ring gear and pinion gear unit to check the drive pattern and coast pattern of the bevel gear teeth O The tooth contact patterns of both drive and coast sides should be centrally located between the top and bottom of the tooth The drive pattern can be a little closer to the toe and the coast pattern can be a somewhat longer and closer to the toe xXlf the tooth contact pattern is incorrect replace the pinion gear shim s following the examples shown see Correct Tooth Contact Pattern in the Front Final Bevel Gear Adjustment section e Then erase the tooth contact patterns and check them again Also check the backlash every time the shim s are repl
135. arter Motor 4 Parking Brake Light Switch 9 Ignition Switch 13 Battery 5 Rear Brake Light Switch Starter Motor Clutch Removal e Remove the alternator rotor see Alternator Rotor Removal e Hold the rotor with the flywheel holder and take out the starter motor clutch bolts A Special Tool Flywheel Holder 57001 1313 HP118017 P Property of www SmallEngineDiscount com Not for Resale 16 38 ELECTRICAL SYSTEM Electric Starter System e Take out the one way clutch A Starter Motor Clutch Installation e Install the one way clutch so that the flange A fits on the recess B of the race e Apply engine oil One Way Clutch e Apply a non permanent locking agent Starter Motor Clutch Bolts e Tighten Torque Starter Motor Clutch Bolts 34 N m 3 5 kgf m 25 ft lb HP118019 P Starter Motor Clutch Inspection e Remove Alternator Rotor see Alternator Rotor Removal e Fit the starter clutch gear into the starter motor clutch x If the alternator rotor turns counterclockwise A freely from the starter clutch gear but not clockwise B the clutch is operating correctly lf the clutch does not operate correctly or if it makes noise disassemble it and examine each part visually Replace any worn or damaged parts NOTE O Examine the starter clutch gear A Replace it if it is worn or damaged P _HP1IBOZ1 P Torque Limiter Inspection e Remove Alterna
136. as described below e Grind the seat at a 50 angle until the seat width is within the specified range O To make the 50 grind fit 50 cutter into the holder and slide it into the valve guide O Turn the holder while pressing down lightly O After making the 50 grind return to the seat width measurement step above Correct Width B ceini Property of www SmallEngineDiscount com Not for Resale 4 26 ENGINE TOP END Valves Guides Seats Springs Oil Seals e Lap the valve to the seat once the seat width and O D are within the ranges specified above O Put a little coarse grinding compound on the face of the valve in a number of places around the valve head O Spin the valve against the seat until the grinding compound produces a smooth matched surface on both the seat and the valve O Repeat 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 it is it may have been refaced too much replace it e Be sure to remove all grinding compound before assembly e When the engine is assembled be sure to adjust the valve clearance see Valve Clearance Adjustment 6E15012051 Property of www SmallEngineDiscount com Not for Resale ENGINE TOP END 4 27 Valves
137. ase Bolt M8 3 e Tighten the left crankcase bolts M8 following the tightening se quence 1 7 Torque Crankcase Bolts M8 20 N m 2 0 kgf m 14 ft Ib 1 L 85 mm 3 35 in 2 5 6 7 L 75 mm 2 95 in 3 4 L 110 mm 4 33 in o Tighten HI104001BS1 Torque Crankcase Bolts M6 8 8 N m 0 9 kgf m 78 in Ib A L 40 mm 1 57 in B L 65 mm 2 56 in C L 85 mm 3 35 in Property of www SmallEngineDiscount com Not for Resale CRANKSHAFT TRANSMISSION 9 9 Crankcase e Press the oil seal A into the crankcase B with the oil seal driver C 3 mm 0 12 in Special Tool Oil Seal Driver D 57001 1517 H104002B51 e Apply grease to the steel ball A and spring B e Install Steel Ball Spring Washer C Shift Shaft Positioning Bolt D e Tighten Torque Shift Shaft Positioning Bolt 25 N m 2 5 kgf m 18 ft Ib H104001251 e Check Crankshaft driven shaft and output shaft turn freely x If any of the shaft do not turn freely split the crankcase to locate the problem Property of www SmallEngineDiscount com Not for Resale 9 10 CRANKSHAFT TRANSMISSION Crankshaft Balancer Shaft and Connection Rod Crankshaft Balancer Shaft Removal e Split the crankcase see Crankcase Disassembly e Remove Balancer Shaft A Transmission Shaft Assemblys e Remove the crankshaft B from the crankcase using a press
138. at more than 20 C 68 F for six hours after tightening the bolts HK11003051 LSD Clutch Torque Inspection x l the vehicle has the following symptoms check the LSD Limited Slip Differential clutch torque The handlebar is hard to turn The front final gear case overheats Abnormal noises come from the front final gear case when rounding a curve e Ensure 2WD mode e Support the vehicle so that the front wheels are off the ground e Remove One Front Wheel see Wheels Tires chapter Front Axle Nut Cotter Pin e Secure the other side front wheel from rotating e Measure the clutch torque using a torque wrench A Turn the wrench evenly O The clutch torque is the mean torque reading during about a quarter turn of the wrench LSD Clutch Torque When variable differential control lever is released Standard 15 20 N m 1 5 2 0 kg m 11 14 ft lb LSD Clutch Torque When variable differential control lever is pulled in Standard 157 N m 16 kg m 116 ft lb or more x If the clutch torque is out of the specified range check the width of the disc assembly see Front Final Gear Case Assembly NOTE O The correct type of oil must be installed Property of www SmallEngineDiscount com Not for Resale FINAL DRIVE 11 37 Front Final Gear Case Pinion Gear Unit Disassembly e Remove Pinion Gear Unit see Front Final Gear Case Disassembly e Pry open the staking of the pinion gear bearin
139. ating the axle shaft Property of www SmallEngineDiscount com Not for Resale 11 46 FINAL DRIVE Rear Final Gear Case e Tighten the rear final gear case bolts following the tightening se quence 1 10 Torque Rear Final Gear Case Bolts 42 N m 4 3 kgf m 31 ft lb Rear Final Gear Case Disassembly e Remove Rear Final Gear Case see Rear Final Gear Case Removal Rear Final Gear Case Right Cover Bolts A Rear Final Gear Case Right Cover B HK14004BS1 e Remove Shim s A Ring Gear B e Remove Pinion Gear Bearing Holder A Hold the rear final gear case A in a vise and remove the bearing holder using the socket wrench B Special Tool Socket Wrench Hex 50 57001 1478 O If the holder seems too difficult to break free apply heat to softer the locking agent Property of www SmallEngineDiscount com Not for Resale FINAL DRIVE 11 47 Rear Final Gear Case e Remove Pinion Gear Unit A Shim s Rear Final Gear Case Assembly e Visually check the pinion gear and ring gear for scoring chipping or other damage x Replace the bevel gear as a set if either gear is damaged since they are lapped as a set in the factory to get the best tooth contact e Install Shim s Pinion Gear Unit O Be sure to check and adjust the bevel gear backlash and tooth contact when any of the backlash related parts are replaced see Rear Final Bevel Gear Adjustment
140. atten out the bended parts of the lockwasher A e Loosen the pad mounting bolts B e Lift off the caliper by taking off the caliper mounting bolts with the hose left attached e Remove Pad Mounting Bolts Pads HLO8B000 P Brake Pad Installation e Push the caliper piston in by hand as far as it will go e Be sure that the anti rattle spring is in place e Install the pads O The inboard pad A next to the piston has a wear protecting shim B Be careful not mix it up with the outboard pad e Tighten Torque Pad Mounting Bolts 18 N m 1 8 kgf m 13 ft lb WARNING Do not attempt to drive the vehicle until a full brake lever is obtained by pumping the brake lever until the pads are against each disc The brake will not function on the first application if this is not done Brake Pad Wear Inspection e Refer to Front Brake Pad Wear Inspection in Periodic Maintenance chapter Property of www SmallEngineDiscount com Not for Resale 12 16 BRAKES Brake Discs Disc Cleaning Poor braking can be caused by oil on a disc Oil on a disc must be cleaned off with an oilless cleaning fluid such as trichloroethylene or acetone AAWARNING These cleaning fluids are usually highly flammable and harm ful if breathed for prolonged periods Be sure to heed the fluid manufacturer s warnings Disc Removal e Remove Front Hub see Wheels Tires chapter Brake Disc Mounting Bolts A Brake
141. attern of the bevel gears must be correct to prevent the gears from making noise and being damaged Adjust gear backlash When replacing any one of the backlash related parts be sure to rd Adjust tooth contact pattern check and adjust the backlash and tooth contact First adjust the Assemble the output bevel gear completely backlash and then tooth contact by replacing shims These two adjustments are of critical importance and must be carried out in the correct sequence using the procedures shown Output Bevel Gear Backlash related Parts 0 Y 1 FTI E HK160031W3 C 1 Ball Bearings 4 Bearing Housings 7 Driven Bevel Gear Shims 2 Drive Bevel Gear Shims 5 Output Driven Bevel Gear 3 Output Drive Bevel Gear 6 Output Driven Shaft Property of www SmallEngineDiscount com Not for Resale FINAL DRIVE 11 17 Output Bevel Gears Drive Bevel Gear Shims for Tooth Contact Adjustment Thickness Part Number 0 15 mm 0 006 in 92180 1311 0 2 mm 0 008 in 92180 1312 0 5 mm 0 020 in 92180 1313 0 8 mm 0 031 in 92180 1314 1 0 mm 0 039 in 92180 1351 1 2 mm 0 047 in 92180 1352 Driven Bevel Gear Shims for Backlash Adjustment Thickness Part Number 0 15 mm 0 006 in 92180 1307 0 2 mm 0 008 in 92180 1308 0 5 mm 0 020 in 92180 1309 0 8 mm 0 031 in 92180 1310 1 0 mm 0 039 in 92180 1349 1 2 mm 0 047 in 92180 1350 Bevel Gea
142. bber Cover Bolts A and Valve Adjusting Caps B e Remove Recoil Starter see Recoil Starter chapter Timing Inspection Plug e Position the crankshaft at TDC of the end of the compression stroke see Camshaft Sprocket Installation in Engine Top End chapter e Measure the clearance of each valve between the end of the valve stem and the adjusting screw on the rocker arm with a thickness gauge A x If the valve clearance is not correct adjust it see Engine Top End chapter Valve Clearance when cold Exhaust 0 15 0 20 mm 0 0059 0 0079 in Inlet 0 08 0 13 mm 0 0032 0 0051 in Spark Arrester Cleaning AWARNING To avoid burns wear gloves while cleaning the spark arrester Since the engine must be run during this procedure the muffler will become hot e Remove the drain plug A on the muffler e In an open area away from combustible materials start the engine with the transmission in neutral e Raise and lower engine speed while tapping on the muffler with a rubber mallet until carbon particles are purged from the muffler AWARNING Do not run the engine in a closed area Exhaust gases con tain carbon monoxide a colorless odorless poisonous gas Breathing exhaust gas leads to carbon monoxide poisoning asphyxiation and death e Stop the engine e Install the drain plug Property of www SmallEngineDiscount com Not for Resale 2 14 PERIODIC MAINTENANCE Periodic Maintenance Proc
143. ble front differential control unit e Turn the pinion gear shaft A for one revolution in the drive and reverse coast direction while creating a drag on the ring gear e Remove the ring gear and pinion gear unit to check the drive pattern and coast pattern of the bevel gear teeth HKTIB005 P Property of www SmallEngineDiscount com Not for Resale FINAL DRIVE 11 41 Front Final Gear Case O The tooth contact patterns of both drive and coast sides should be centrally located between the top and bottom of the tooth The drive pattern can be a little closer to the toe and the coast pattern can be a somewhat longer and closer to the toe x If the tooth contact pattern is incorrect replace the ring gear shim s following the examples shown e Then erase the tooth contact patterns and check them again Also check the backlash every time the shim s are replaced Repeat the shim change procedure as necessary NOTE O If the backlash is out of the standard range after changing the ring gear shim s change the pinion gear shim s to correct the backlash before checking the tooth contact pattern Bevel Gear Inspection e Visually check the bevel gears A for scoring chipping or other damage x Replace the bevel gears as a set if either gear is damaged HK110036 P Differential Gear Inspection e Visually check the differential gears A for scoring chipping or other damage x Replace the differential
144. ble of Contents O A 4 2 Specifications oooonnccncnnnncnnccnncnocnnnccnnnccrnrncnrnnanccnnnn 4 6 Camshaft Chain Tensi0Ner ooooconocccinocccinoccninnnnnnonnnnnos 4 8 Camshaft Chain Tensioner Removal 4 8 Camshaft Chain Tensioner Installation 4 8 Camshaft Sprocket cceccesceseceseeeeeeeeeeeeeeeeeerensees 4 10 Camshaft Sprocket Removal csesceeeee 4 10 Camshaft Sprocket Installation 4 10 Rocker Arms and Shafts cscccsscessseeessseeesees 4 12 Rocker Arm and Shaft Removal 4 12 Rocker Arm and Shaft Installation 4 12 Rocker Arm and Shaft Inspection 4 13 A 4 14 Camshaft REMOval cccccesseeeeseeesseeeeeees 4 14 Camshaft Installation ccccesseeeseeeeseeees 4 14 Cam Wear INSpection ecccecceeeeeeeeteteeeeeetees 4 14 Camshaft Bearing Inspection ceeeeee 4 15 KAGR Inspection 0 eceeeceeeeeeeeeeeeeeneeeneeeeeetaaes 4 15 Camshaft Chain and Guides ccccccsceseseeeees 4 16 Camshaft Chain Removeal cccceesseeeees 4 16 Camshaft Chain Installation 4 16 Camshaft Chain Guide Removal 4 16 Camshaft Chain Guide Installation 4 16 Camshaft Chain Guide Weat 00ce 4 16 Cylinder Head scrisorii eine 4 17 Cylinder Compression Measurement 4 17
145. broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Compression release cam K A C R sticks open Engine stalls when moving off Other Carburetor vacuum piston doesn t slide smoothly Engine oil viscosity too high Brake dragging Igniter trouble Front or rear final gear case oil viscosity too high Poor Running or No Power at High Speed Firing incorrect Spark plug dirty broken or maladjusted Spark plug cap or spark plug lead trouble Spark plug cap shorted or not in good contact Spark plug incorrect Pickup coil trouble Igniter trouble Ignition coil trouble Drive belt failure detection switch activated Property of www SmallEngineDiscount com Not for Resale APPENDIX 17 3 Troubleshooting Guide Fuel air mixture incorrect Main jet clogged or wrong size Jet needle or needle jet worn Main air jet clogged Bleed holes of air bleed pipe or needle jet clogged Fuel level too high or too low Air cleaner clogged poorly sealed or missing Starter plunger stuck open Water or foreign matter in fuel Carburetor holder loose Air cleaner duct loose Fuel tank air vent obstructed Fuel tap clogged Fuel line clogged Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Pis
146. com Not for Resale 15 10 FRAME Carriers Front Carrier Removal e Remove Carrier Bolts A Front Carrier B Collars C Headlight Cover D Front Carrier Installation e Install Collars A e Install Front Carrier A e Apply a non permanent locking agent Front Carrier Bolts L 65 mm 2 56 in B Front Carrier Bolts L 80 mm 3 15 in C HO07006B5S1 Rear Carrier Removal e Remove Rear Carrier Bolts A Rear Carrier B Rear Carrier Installation e Install Damper A Collar B Rear Carrier A Oe H007007B51 Property of www SmallEngineDiscount com Not for Resale FRAME 15 11 Carriers e Tighten Torque Rear Carrier Bolts A and Nuts B 25 N m 2 5 kgf m 18 ft lb Property of www SmallEngineDiscount com Not for Resale 15 12 FRAME Fenders Front Fender Removal e Remove Seat see Seat Removal Fuel Tank Cover see Fuel Tank Cover Removal Front Carrier see Front Carrier Removal Headlight Cover see Headlight Cover Removal Front Flap Lower Screws A both sides Ignition Switch Nut B e Remove Quick Rivets A Screws B and Collars both sides Front Fender Front Fender Installation e Install Damper A Clamp Nuts B Collars C HO04002B51 e Fit the projection A on the ignition switch into the recess in the front fender e Tighten the nut B securely
147. cted and clamps B are tightened x If the fuel hose has been sharply bent or kinked replace the fuel hose x If the clamps are loosened or damaged replace the clamps e When installing the fuel hose route the hose according to Cable Wire and Hose Routing section in Appendix chapter e When installing the fuel hose avoid sharp bending kinking flattening or twisting and route the fuel hose with a minimum of bending so that the fuel flow will not be obstructed Fuel Hose Replacement AWARNING Gasoline is extremely flammable and can be explosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Turn the fuel tap to the OFF position e Remove Fuel Tank Cover see Frame chapter Exhaust Cover see Frame chapter Clamps A Fuel Hose B e Fit the fuel hose A onto the pipe fully and install the clamps B beyond the raised rib C HUGSGOOBS1 Property of www SmallEngineDiscount com Not for Resale PERIODIC MAINTENANCE 2 13 Periodic Maintenance Procedures Engine Top End Valve Clearance Inspection NOTE O Check the valve clearance only when the engine is cold at room temperature e Remove Left Front Wheel see Wheels Tires chapter Left Front Inner Cover see Frame chapter Fuel Tank see Fuel System chapter Ru
148. ction e Refer to Spark Plug Gap Inspection in Periodic Maintenance chapter Property of www SmallEngineDiscount com Not for Resale 16 26 ELECTRICAL SYSTEM Ignition System Ignition Coil Removal e Remove Front Right Inner Cover see Frame chapter Spark Plug Cap A Primary Lead Connectors B Ignition Coil Mounting Bolt C Ignition Coil D Ignition Coil Installation e Connect the primary leads to the ignition coil terminals as shown G W Lead Mark A BK Y Lead Mark e Tighten Torque Ignition Coil Mounting Bolt 8 8 N m 0 9 kgf m 78 in Ib HP10016BS1 Ignition Coil Inspection e Remove the ignition coil e Measure the arcing distance with a coil tester A to check the condition of the ignition coil B e Connect the ignition coil with the spark plug cap left attached at the end of the spark plug lead to the tester in the manner prescribed by the manufacturer and measure the arcing distance Ignition Coil Arcing Distance 7 mm 0 28 in or more AWARNING To avoid extremely high voltage shocks do not touch the ignition coil body or leads x If the distance reading is less than the specified value the ignition coil or spark plug cap is defective e To determine which part is defective measure the arcing distance again with the spark plug cap removed from the ignition coil Remove the cap by turning it counterclockwise x If the arcing distance is as befor
149. d inspect the pickup coil Alternator Rotor Inspection e Check the timing projection A for damage such as chipping or grooving If the timing projection on the rotor is visibly damaged replace the alternator rotor Ignition Timing Test e Remove the ignition timing inspection plug e Attach a timing light A and a tachometer in the manner prescribed by the manufacturer Special Tool Timing Light 57001 1241 e Start the engine and aim the timing light at the timing mark on the alternator rotor e Run the engine at the speeds specified and note the alignment of the timing marks Ignition Timing Engine speed r min rpm Slot A aligned with 1 000 Advanced mark B on alternator rotor 5 000 Advanced mark C on alternator rotor x If the ignition timing is incorrect replace the igniter and the pickup coil NOTE IT O Do not mix up the timing marks with mark hk ae HP10013BS1 Property of www SmallEngineDiscount com Not for Resale 16 30 ELECTRICAL SYSTEM Ignition System Ignition System Troubleshooting Faulty ignition No spark Battery Inspection Charge or replace battery Good Ignition system wiring No good Repair or replace and connector inspection damaged part Good p No good Spark plug inspection Replace spark plug Good N d Plug cap inspection e Replace plug cap Good e ee E No good Voltage is less than Ignition coil primary peak vol
150. d Radial Clearance eeccecceeeceseceeeeeeeneeeneeeceeeeaeeeaeeseeeseneeeaeesaeeseaeeeaeeeaeeseeesneeseaeesieeeneeennees 9 12 Connecting Rod Big End Side Clearance ecccecceeeceeeceeeneeeeeeeeeeceaeeeaeeeeeseeeeaeeeaeeseeeeaeeeaeeseeseaeeeaeesieesiaeseaeteneenaes 9 12 CrakshattAliQ ie rites tati il at iia 9 13 Connecting Rod Bend TWiSt ooonocincnnncnnconccnncnnccnnennncnnnn cnn cnica 9 14 TOS Miri id 9 15 Shift Lever Removal cccccccsscceeseeeesseeeeseneeeeneeecseeeesaaeeseaeeeseneeeseaeescaeescaeeesaeeseeeeseeeeseaeeeceeeeeseaeeeseeesseeeesenseesees 9 15 Shift Lever Installation unica title EA EARS 9 16 Transmission Removals ssia ni rae EEE E E Ea E raea aaa a eE eae Eae E aa EER 9 18 Transmission Installations sireenin nsari no iaiiaeeeai eran Lied 9 19 Shift Fork Bending asaros ti eian E ad 9 21 Shift Fork Gear and Shifter Groove Weal ecceeccceseeeeeeeeeeeeeeeseeeeecaeseaeeeseeseaeceaeeeaeeseeseaeeeaeesaeeseaeseaeeeeeseeeeneeeeaees 9 21 Transmission and Shift Mechanism INSPe CtiOn ceceecceeeceeeeeeeeteeeeeeeeeaeecaeeeaeeeaeeseeeseaeseaeeseeseaeseaeeceeseeeeneeeenees 9 21 Ball Bearing Needle Bearing and Oil Seal cccccecccccescccesneceeeseeeeeeeeeeaeecsaneeseeeeeseaaeeseaaeecsaeeeseseeeseaeeesaneeeseeeessensessaes 9 23 Ball and Needle Bearing Replacement ococcococcconocccononccononcnnonononanoncnnon nn non cnn norris 9 23 Ball and Needle Bearing Weals s2 cti net a a 9 23 Oil Seal INSPECT
151. ding is not within the specified range replace the forward reverse detecting sensor B e Using the highest resistance measure the resistance between for ward reverse detecting sensor leads and chassis ground x If the tester reading is less than infinity so indicates a short replace the forward reverse detecting sensor Check 8 Indicator Light LCD Inspection NOTE Be sure the battery is fully charged e Remove Seat see Frame chapter e Connect Controller Connector A Hand Tester B range DC 25 V Tester Connector G W Terminal 8 Tester Connector BK Y Terminal 10 TET Tee O Install the needle adapters on the tester leads Special Tool Hand Tester 57001 1394 Needle Adapter Set 57001 1457 e Turn ON the ignition switch e Push the switch to the 4WD position and shift the vehicle to 4WD mode Controller Output Voltage to LED Indicator Standard about 5 V x If the reading is not standard check the 2WD 4WD shift switch x If the 2WD 4WD shift switch is normal replace the actuator controller unit x Even if the reading is standard when the 4WD light does not go on replace the LED indicator tf 14 2 mo ES Es Property of www SmallEngineDiscount com Not for Resale ELECTRICAL SYSTEM 16 63 Actuator Control System Actuator Control System Circuit W BK al BK Y W BK
152. e the trouble is with the ignition coil If the arcing distance is normal the trouble is with the spark plug cap If a coil tester is not available the coil can be checked for a broken or badly shorted winding with a hand tester Special Tool Hand Tester 57001 1394 NOTE O The hand tester cannot detect layer shorts and shorts resulting from insulation breakdown under high voltage Property of www SmallEngineDiscount com Not for Resale ELECTRICAL SYSTEM 16 27 Ignition System e Measure the primary winding resistance A as follows O Connect the tester between the coil terminals O Set the tester to the x 1 Q range e Measure the secondary winding resistance B as follows O Remove the plug cap by turning it counterclockwise O Connect the tester between the spark plug lead and terminal O Set the tester to the x 1 kQ range Ignition Coil Winding Resistance Primary windings 0 09 0 13 2 Secondary windings 3 8 5 8 kQ x If the hand tester does not read as specified replace the coil To install the plug cap turn it clockwise Ignition Coil Primary Peak Voltage Inspection NOTE Be sure the battery is fully charged e Remove the spark plug cap see Spark Plug Removal but do not remove the spark plug e Measure the primary peak voltage as follows O Connect a commercial peak voltage adapter A to the hand tester B 250 V DC range Special Tool Hand Tester 57001 1394
153. e Bevel Gear Assembly 11 12 Output Driven Bevel Gear Removal 11 12 Output Driven Bevel Gear Installation 11 13 Output Driven Bevel Gear Disassembly 11 13 Output Driven Bevel Gear Assembly 11 14 Output Bevel Gears Adjustment Bevel Gears Inspection eeeeeeeeeeeeeeeneees Cam Damper Inspection cceceeeeeeeetees Front Propeller Shaft c ccccccecsssessseeeseneeeens Front Propeller Shaft Removal Front Propeller Shaft Installation Front AXIE iii iaa Front Axle Removal c cccceeseseeeeeeeeeeees Front Axle Installati0D ooooonnocccnnnnnicccnnnnn Front Axle Joint Boot Inspection Front Axle Joint Boot Replacement Front Final Gear CaS sssrinin Front Final Gear Case Oil Level Inspection 11 27 Front Final Gear Case Oil Change 11 27 Variable Differential Control Lever Position Inspec Variable Differential Control Lever Removal 11 27 Variable Differential Control Lever Installation 11 27 Variable Differential Control Cable Installation 11 28 Variable Differential Control Cable Lubrication1 1 28 Variable Differential Control Cable Inspection 11 28 Front Final Gear Case Removal 11 28 Front Final Gear Case Installation 11 29 Front Final Gear Case Disassembly 11 29 Fron
154. e Check conductivity of the following pair of terminals Rectifier Circuit Inspection W R Y1 W R Y2 W R Y3 Tester connection BK Y1 BK Y2 BK Y3 The resistance should be low in one direction and more than ten Y 1 times as much in the other direction If any two leads are low or high in both directions the rectifier is defective and must be replaced NOTE O The actual meter reading varies with the meter and the individual rectifier Generally speaking the lower reading should be from zero to one half of the scale Y2 Y3 Regulator Circuit Check To test the regulator out of circuit use three 12 V batteries and a test light 12 V 3 6 W bulb in a socket with leads CAUTION The test light works as an indicator and also a current limiter to protect the regulator rectifier from excessive current Do not use an ammeter instead of a test light e Check to be sure the rectifier circuit is correct before continuing Property of www SmallEngineDiscount com Not for Resale ELECTRICAL SYSTEM 16 23 Charging System Regulator Circuit Test 1st Step e Connect the test light and the 12 V battery to the regulator rectifier as shown e Check Y1 Y2 and Y3 terminal respectively x If the test light turns on the regulator rectifier is defective If the test light does not turn on continue the test Regulator Circuit Test 2nd Step e Connect the test light and a 12 V battery in
155. e Remove Outer Race A e Remove Ball Bearing A Special Tool Oil Seal amp Bearing Remover B 57001 1058 e Remove Oil Seal A Property of www SmallEngineDiscount com Not for Resale 13 16 SUSPENSION Swingarm e Remove Collar A Oil Seal B Swingarm Assembly e Apply grease Inside A of Oil Seals e Apply MOBIL FLUID 424 or Equivalent Surface of Collar B e Install the following parts as shown Brake Lever Oil Seal C D 14 5 0 1 mm 0 571 0 004 mm Collar level with surface Propeller Shaft Oil Seal E F 25 0 1 mm 0 984 0 004 mm huc oo1251 Ball Bearing G level with surface e Apply Amoco Rykon Premium Grease No 2 EP Green Inside of Oil Seals A O rings B e Install the following parts as shown Tapered Roller Bearing C Oil Seal level with surface O ring Collar D Special Tool Bearing Driver Set 57001 1129 HMOGGOOBS1 Swingarm Bearing Inspection e Remove the rear final gear case see Final Drive chapter e Move the swingarm up and down to check for abnormal friction and push and pull it back and forth to check for bearing play If abnormal friction is felt the bearings are damaged Replace the oil seals and both left and right bearings e The play developed during use may indicate bearing damage In this case remove the swingarm and inspect the bearings Replace both left and right bearings i
156. e actuator controller unit e Support the vehicle on a stand or a jack so that the wheels are off the ground e Run the engine and shift to the 4WD position e Stop the engine and turn OFF the ignition switch e Connect Controller Connector A Hand Tester B range DC 25 V Tester Connector W Y Terminal 12 Tester Connector BK Y Terminal 10 O Install the needle adapters on the tester leads Special Tools Hand Tester 57001 1394 HP23007851 Needle Adapter Set 57001 1457 e Turn ON the ignition switch e Shift to the 2WD position e Measure the controller output voltage for the 2WD 4WD actuator until the actuator stops Controller Output Voltage to 2WD 4WD actuator Standard 5 12V x If the reading is not standard check the 2WD 4WD shift switch x If the 2WD 4WD shift switch is normal replace the actuator controller unit Property of www SmallEngineDiscount com Not for Resale 16 62 ELECTRICAL SYSTEM Actuator Control System Check 7 Forward Reverse Detecting Sensor Inspection e Remove Left Side Cover see Frame chapter e Disconnect forward reverse detecting sensor lead wire connector A e Measure the forward reverse detecting sensor resistance O Connect the hand tester between the BK lead and the W lead O Set the tester to the x kQ range Special Tool Hand Tester 57001 1394 Forward Reverse Detecting Sensor Resistance Standard 1 2 1 6 KQ If the rea
157. e electrical connections inside the switch be sure that the switch body does not turn during adjustment Property of www SmallEngineDiscount com Not for Resale 2 26 PERIODIC MAINTENANCE Periodic Maintenance Procedures General Lubrication Lubrication e Before lubricating each part clean off any rusty spots with rust remover and wipe off any grease oil dirt or grime e Lubricate the points listed below with indicated lubricant NOTE O Whenever the vehicle has been operated under wet or rainy conditions or especially after using a high pressure spray water perform the general lubrication Cables Lubricate with Cable Lubricant Brake Cables Throttle Cable Choke Cable e Lubricate the cables by seeping the oil between the cable and housing The cable may be lubricated by using a pressure cable luber with an aerosol cable lubricant 6C04011451 e With the cable disconnected at the both ends the cable should move freely A within the cable housing x If cable movement is not free after lubricating if the cable is frayed or if the cable housing is kinked replace the cable Points Lubricate with Grease Throttle Inner Cable ENds A Choke Cable Lower End Brake Cable Ends Slide Points Lubricate with Grease Brake Lever Brake Pedal Pivot Shaft Throttle Lever Shaft Property of www SmallEngineDiscount com Not for Resale PERIODIC MAINTENANCE 2 27 Per
158. e o HOO8BO10 P 3 x Property of www SmallEngineDiscount com Not for Resale 15 20 FRAME Flaps and Footboards e Remove Screws A e Remove Bolts A Footboard B Footboard Installation e Be sure the dampers A is in place e Confirm Footrest A Center Holes of Three Holes B both side Bolts C and Nuts D e Install Footboard Bolts Screws Washers and Nuts O Apply a non permanent locking agent to the footboard mounting nuts HO08003BS1 Property of www SmallEngineDiscount com Not for Resale FRAME 15 21 Trailer Hitch Bracket Trailer Hitch Bracket Removal e Drain Rear Final Gear case Oil see Rear Final Gear Case Oil Change section in Final Drive chapter e Remove Rear Bottom Guard see Rear Bottom Guard Removal Trailer Hitch Bracket Bolts M8 A e Remove Trailer Hitch Bracket Bolts A Trailer Hitch Bracket B Trailer Hitch Bracket Installation e Install Rear Final Gear Case Left Cover A see Rear Axle Installation section in Final Drive chapter Trailer Hitch Bracket B e Apply a non permanent locking agent to the trailer hitch bracket bolts e Tighten Torque Trailer Hitch Bracket Bolts M10 C 49 N m 5 0 kgf m 36 ft Ib Trailer Hitch Bracket Bolts M8 D 24 N m 2 4 kgf m 17 ft lb e Install Rear Bottom Guard see Rear Bottom Guard Installation e Fill the final gear case up to the bottom of filler opening with the s
159. e rear locknut and tighten the front locknut J Torque Tie Rod End Front Locknut 9 8 N m 1 0 kgf m 87 in Ib NOTE O The front locknut has left hand threads O Do not lean the tie rod rear end after tightening the front locknut Right K Wrong L e Check that the shift lever moves from right to left smoothly e Install Spring M Trim Seal N e Align the mark O of the grip P with the projection Q on the guide e Tighten Torque Grip Hold Nut R 9 8 N m 1 0 kgf m 87 in Ib HI10003BW2 Property of www SmallEngineDiscount com Not for Resale 9 18 CRANKSHAFT TRANSMISSION Transmission Transmission Removal e Sprit the crankcase see Crankcase Disassembly e Remove Shift Shaft Cover Bolts A Shift Shaft Cover B HI10B005 P e Remove Shift Shaft Spring Bolt A Shift Shaft B e Remove Reverse Idle Shaft A Spacer B Reverse Drive Gear C Needle Bearing and Spacer Shifter D Shift Rod E e Remove Circlip A Special Tool Outside Circlip Pliers 57001 144 e Remove Spacer A Idle Gear Assembly B Washers and Spacer C Low and High Gears D Property of www SmallEngineDiscount com Not for Resale CRANKSHAFT TRANSMISSION 9 19 Transmission e Remove Needle Bearings A e Remove the driven shaft B from the crankcase using a press Transmission Installation e Insert the driven shaft in
160. ea the a a ar ao aoti engine oil viscosity should be changed according to the chart da L J HGOSGO2BS1 C Oil Filter Change e Drain the engine oil e Remove the oil filter A with the oil filter wrench B Special Tool Oil Filter Wrench 57001 1249 4 lt lt T e Replace the filter with a new one e When installing the oil filter be careful of the following O Apply oil to the gasket A before installation O Tighten the filter with the oil filter wrench Special Tool Oil Filter Wrench 57001 1249 Torque Oil Filter 18 N m 1 8 kgf m 13 ft lb O Pour in the specified type and amount of oil Oil Cooler Cleaning and Inspection e Check the oil cooler A x If there are obstructions to air flow remove them x If the corrugated fins are deformed carefully straighten them with the blade of a thin screw driver al NON 1 iat a M l 1 if AAA i Wh a NAN NNN yh i i MI CAN NA t AAA AO AA AA co CAUTION Do not tear the cooler tubes while straightening the fins Y AA x If the air passage of the cooler core are blocked by unremovable obstructions or irreparably deformed fins replace the oil cooler Property of www SmallEngineDiscount com Not for Resale HGO7G01BS1 C 2 18 PERIODIC MAINTENANCE Periodic Maintenance Procedures CAUTION When cleaning the oil cooler with compressed air be ca
161. eck the screen carefully for any damage holes broken wires or gasket pulling off x If the screen is damaged replace it Property of www SmallEngineDiscount com Not for Resale 7 8 ENGINE LUBRICATION SYSTEM Oil Pressure Measurement Oil Pressure Measurement NOTE O Measure the oil pressure after the engine is warmed up e Remove the front left flap and oil pressure switch and attach the oil pressure gauge A and adapter B Special Tools Oil Pressure Gauge 10 kgf cm 57001 164 Oil Pressure Gauge Adapter 57001 1033 Oil Pressure Standard 177 kPa 1 8 kgf cm 25 6 psi E 4500 r min i rpm 120 C 248 F of oil temp A x If the oil pressure is much lower than the standard inspect the relief valve oil pump and or crankshaft bearing insert wear x If the oil pressure is much higher than the standard inspect the oil filter oil screen and other areas of the lubrication system for clogging e Stop the engine e Remove the oil pressure gauge and adapter WARNING Take care against burns form hot engine oil that will drain through the oil passage when the gauge adapter is removed e Apply silicone sealant to 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 Ib Oil Pressure Switch Terminal Bolt 1 5 N m 0 15 kgf m 13 in Ib Property of www SmallEngineDiscount com Not for Resale ENGI
162. ecting Switch Fuse 5A B A e a 3 a ZB C Oil Cooler oe my Fuse Inspection e Inspect the fuse element A If it is blown out replace the fuse Before replacing a blown fuse B always check the amperage in the affected circuit If the amperage is equal to or greater than the fuse rating check the wiring and related components for a short circuit CAUTION When replacing a fuse be sure the new fuse matches the specified fuse rating for that circuit Installation of a fuse with A a higher rating may cause damage to wiring and components Property of www SmallEngineDiscount com Not for Resale 16 72 ELECTRICAL SYSTEM Wiring Diagram LED Indicator G W G W BL Y BL Y BR BR BL W BL W 2WD 4WD kt Shift BK Y BK Y Switch Drive Belt Failure q Ignition Mode Reset Connector Ol Switch ale a a Qil Temperature Switch El BK Y B N le ol 021 BL R BL R varo AS Neutral Reverse Oil Cooler Fan BK ERES Switch Switch BL a Sa gt zo 2 a ol BK Y BK Y La Oil Cooler Fan Switch o 41 w e W G g 0il Cooler Fan Fuse 204 BL w __k lt BL W zo ze bai gt BL gt BL w 4 BR Horn ej ar m XI ep ay Drive Belt Failure Detecting MAAA BR LO BR Switch Fuse 5A a R Right BK Y BK Y 12V30 30W po ho if Speedometer Mo I X2 rit o gt XE
163. ection e Refer to Variable Differential Control Lever Position Inspection in Periodic Maintenance chapter Variable Differential Control Lever Position Adjustment e Refer to Variable Differential Control Lever Position Adjustment in Periodic Maintenance chapter Variable Differential Control Lever Removal e Remove Plate Bolt A Cable Stopper Plate B Variable Differential Control Lever Bolt C Washer and Collar Variable Differential Control Lever D Variable Differential Control Cable Upper End Variable Differential Control Lever Installation e Install Variable Differential Control Cable Upper End Variable Differential Control Lever A Variable Differential Control Lever Bolt B Washer C and Collar D Cable Stopper Plate E Plate Bolt F e Check the variable differential control lever position see Variable Differential Control Lever Position Inspection in Periodic Maintenance chapter HK11001BS1 C Property of www SmallEngineDiscount com Not for Resale 11 28 FINAL DRIVE Front Final Gear Case Variable Differential Control Cable Installation e Lubrication the variable differential control cable before installation e Route the cable correctly according to Appendix chapter AWARNING Operation with an improperly adjusted incorrectly routed or damaged cable could result in an unsafe operating condition e Tighten Torque Variable Differential Control Cable Locknut
164. ed or missing compression release cam spring Compression release weights do not move smoothly Cylinder compression Gas leakage around cylinder head is lower than usable Remove the carbon deposits and replace damaged parts if necessary Replace the gasket with a standard part Replace the spring Replace the compression release unit Replace damaged gasket and check cylinder head warp range Bad condition of valve seating Repair if necessary Incorrect valve clearance Adjust the valve clearance Incorrect piston cylinder clearance Replace the piston and or cylinder Piston seizure Inspect the cylinder and liner and replace repair the cylinder and or piston as necessary Bad condition of piston ring and or piston ring grooves Replace the piston and or the piston rings Compression release weights do not move smoothly Replace the compression release unit Cylinder Head Removal e Remove Fuel Tank Carburetor see Fuel System chapter Exhaust Pipe and Muffler see Exhaust Pipe and Muffler Removal Camshaft Sprocket see Camshaft Sprocket Removal Converter Air Intake Duct Weights A Oil Pipe Bolt B Oil Pipe End C Engine Mounting Bolt D Spark Plug Cap Property of www SmallEngineDiscount com Not for Resale 4 18 ENGINE TOP END Cylinder Head e Remove Rubber Cover Bolts A and Cylinder Head Bracket B e Remove Cylinder Head Bolts M6 A Cyli
165. edures Converter System Actuator Lever Engine Brake Control Lever Assembly Inspec O tion e Measure the width A of the guide B A If the guide contact area width is greater than the service limit replace SS the actuator lever assembly Actuator Lever Guide Shoe Wear SE Service Limit 6 mm 0 24 in HS04005BS1 Drive Belt Inspection Inspection of the drive belt is required at least every 90 days of vehicle use average 12 mile day not to exceed 1 100 mile More frequent inspection is necessary if the vehicle is subjected to hard usage WARNING Neglect abuse or failure to maintain the transmission can result in a severely worn or damaged drive belt locking up the transmission and wheels This can cause the operator to lose control and have an accident resulting in injury or death e Measure the width A of the belt at several locations with a suitable straightedge B as shown x If any measurements exceed the service limit replace the belt Belt Width EE Standard 29 8 31 0 mm 1 17 1 22 in Ge Service Limit 29 4 mm 1 16 in wo HSOSGO1BS1 NOTE O Use the belt measuring gauge A in order to make easy to inspect the drive belt width Special Tool Belt Measuring Gauge 57001 1519 e Fit the drive belt B into the belt measuring gauge If the upper surface C of the belt sank in the upper surface D of the gauge replace the belt HUGSGOOBS1
166. el gears worn or chipped Bevel gears maladjusted Worn LSD clutch friction plate Front final gear case Worn LSD clutch spring Front final gear case Damaged side gears or pinions Front final gear case Abnormal Frame Noise Shock absorber noise Shock absorber damaged Disc brake noise Pad installed incorrectly Pad surface glazed Disc warped Caliper trouble Rear brake noise Foreign matter in hub Brake not properly adjusted Other noise Bracket nut bolt etc not properly mounted or tightened Exhaust Smokes Excessively White smoke Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Cylinder head gasket damaged Engine oil level too high Black Smoke Air cleaner clogged Main jet too large or fallen off Starter plunger stuck open Fuel level too high Brown smoke Main jet too small Fuel level too low Air cleaner duct loose Air cleaner poorly sealed or missing Handling and or Stability Unsatisfactory Handlebar hard to turn Tire air pressure too low Steering stem bearing damaged Steering stem bearing lubrication inadequate Steering stem bent Damaged steering knuckle joint Damage tie rod end LSD clutch maladjusted front final gear case Noise when turning Damaged side gear or pinion front final gear case Worn LSD clutch friction plates Front final gear case Worn LSD clutch spring Front final gear case Handlebar shakes or excessively vibrates Tire worn Wheel ri
167. emove the steering knuckle E from the front axle and front shock absorber Property of www SmallEngineDiscount com Not for Resale STEERING 14 7 Steering Steering Knuckle Installation e Inspect the spherical bearing A x If roughness excessive play or seizure is found replace the knuckle joint B e Clean the shanks C of the knuckle joint e Check that the joint boot D is not torn worn deteriorated or is leaking grease e Tighten Torque Steering Knuckle Joint Nut 47 N m 4 8 kgf m 35 ft Ib Front Shock Absorber Clamp Nuts 47 N m 4 8 kgf m 35 ft lb HNO4003BS1 Tie Rod End Nut 42 N m 4 3 kgf m 31 ft lb Steering Knuckle Bearing Removal e Remove Steering Knuckle see Steering Knuckle Removal Circlip A Special Tool Inside Circlip Pliers B 57001 143 e Drive the bearing out using a suitable bearing driver from the bearing driver set Special Tool Bearing Driver Set 57001 1129 Steering Knuckle Bearing Installation e The marked side of the bearing faces outward e Press in the bearing until it is bottomed Special Tool Bearing Driver Set A 57001 1129 e Replace the circlip with a new one Special Tool Inside Circlip Pliers 57001 143 Tie Rod Removal e Remove Cotter Pins A and Tie Rod End Nuts Tie Rod B CAUTION When removing the tie rod be careful not to bend it Do not loosen the locknuts C at the end of the tie rod adju
168. er Engine Mounting Bolts and Nuts 4 3 31 Property of www SmallEngineDiscount com Not for Resale 8 4 ENGINE REMOVAL INSTALLATION Engine Removal Installation Engine Removal e Remove Engine Oil drain Front Fender see Frame chapter Muffler and Exhaust Pipe see Engine Top End chapter Carburetor see Fuel System chapter Left Footboard see Frame chapter Torque Converter Air Intake Duct Tie rod Shift Lever Engine Brake Actuator Lead Connector A Drive Belt Failure Detecting Switch Lead Connector B Spark Plug Cap C Front Propeller Shaft D Speed Sensor Connector E Torque Converter Air Duct F e Remove Alternator Lead Connector Pickup Coil Lead Connector Forward Reverse Detecting Sensor Lead Connector Reverse Position Switch Lead Connector A Neutral Position Switch Lead Connector B Engine Ground Lead C Oil Pressure Switch Lead D Oil Hoses E e Remove Engine Mounting Upper Bolt A Engine Mounting Front Bracket B e Remove Boot A Engine Mounting Bolts B Engine Mounting Rear Brackets C HHOSB004 P Property of www SmallEngineDiscount com Not for Resale ENGINE REMOVAL INSTALLATION 8 5 Engine Removal Installation e Put a tape to protect the frame e Move the engine forward to remove the drive shaft A from the rear propeller shaft joint B e Remove the engine from the left side Engine Installation e Be sure the damper A is in place
169. er s should move freely and return smoothly by spring x If the lever is heavy disassemble the throttle case clean and lubricate the throttle case e Examine the lever and case for cracks Replace the case assembly if it is cracked HCO40009 P Throttle Cable Lubrication Whenever the throttle cable is removed lubricate the cable as follows e Apply a small amount of multi purpose grease to the cable both ends e Lubricate the cable with a penetrating rust inhibitor through the pressure cable luber Throttle Cable Inspection e With the throttle cable disconnected at both ends the cable should move freely within the cable housing x If the cable does not move freely after lubricating if the cable is frayed or if the housing is kinked replace the cable Property of www SmallEngineDiscount com Not for Resale FUEL SYSTEM 3 9 Choke Lever and Cable Choke Lever and Cable Removal e Remove the fuel tank see Fuel Tank Removal e Remove the carburetor from the carburetor holder e Slide the dust cover A out of place e Unscrew the starter plunger cap B and pull out the starter plunger e Hold the starter plunger spring compressed and free the choke cable lower end A from the plunger B e Remove Choke Lever Mounting Screw A Plane Washer and Wave Washer Switch Case Mounting Screws B e Free the choke cable upper end A from the choke lever B e Pull of
170. ery Connector 6 terminal Black e Stop applying the power when the output shaft comes near the starting point C e Install the actuator see Engine Brake Actuator Installation x If the output shaft is in the operative angle range the engine brake malfunction could be caused by other parts HP23022BS1 Check 3 Controller Power Supply Inspection NOTE O Be sure the battery is fully charged e Remove Seat see Frame chapter e Connect Controller Connector A Hand Tester B range DC 25 V Tester Connector BR Terminal 9 Tester Connector BK Y Terminal 10 ipsas o O Install the needle adapters on the tester leads Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 e Turn ON the ignition switch Controller Power Supply Voltage Standard near Battery Voltage x If the reading is not battery voltage check the wiring harness 30 A fuse or ignition switch Property of www SmallEngineDiscount com Not for Resale ELECTRICAL SYSTEM 16 59 Actuator Control System Check 4 Speed Sensor Inspection NOTE O Be sure the battery is fully charged e Support the vehicle on a stand or a jack so that the wheels are off the ground e Remove Seat see Frame chapter e Connect Controller Connector A Hand Tester B range DC 25 V Tester Connector P Terminal 5 HP23003B51 Tester
171. eseeeseecseeceseeeseeeeeeseaeeeaeeeseessaeseaeesaeesseeseaeeeaeesseeseaeseaeeeaeeseeesaeseaeesseeeeeseaeesaeeseeeenaten 7 9 Oil Pressure Relief Valve Removal a ibid 7 9 Oil Pressure Relief Valve InstallatiOD oooonnooninninidn nnlnnnnninonnonncnnnccnncannccnnncr rra cnc 7 9 Oil Pressure Relief Valve INSpectiON o oocnnncinnnnnnnnnnnnnnconnccnocnnccnn nc rra cnn 7 9 iL PUM Deae pac cance ce acctesic vate acne staat Des a bu ata eke putea te cacao ace acon aac e seta eas eeeees cfau E EE 7 10 A A aauplests bide cldegshSvGA edartestenddtas adh stat loseebeghnu settable ayia lt ldnasagoetes 7 10 Oil Pump Installations cc id ee ee acc 7 10 A A ecpre err erererrererctrrrrcrstereerrntrcerre a trererercrcrersererecrerecer E E 7 11 Oil Pipe Removal ica aan nsa aa ia a aiana ioei aea ia a Mesnard aie aaa 7 11 QiliPipe installato Msie sea aae aeaa a e asar 7 11 Oil Hose REMOVAL r aa T a a a E a a A E a E a EA a a AE E di AEE eE 7 12 Oil Hose Installation ai dide aa a i a To cie se 7 12 GiEC OO ica att A EEST A A cere Tree ee 7 13 Oil Cooler Removal vicios ii pad 7 13 Ol Cooler Installation ar ideas 7 13 Oil Cooler DisaSsembly scooter creci illa do adelaida 7 13 Oil Cooler Fan Switch Oil Temperature Warning Light Switch RemoOVal oocoonconccnninnncnnnccnncononcnnnccrncnc arcano 7 14 Oil Cooler Fan Switch Oil Temperature Warning Light Switch InstallatiON ooonnoninnninnnnnnnnnnnnninonninnnnaonranccnrcaa 7 14 Oil Cooler Fan Switch Oil Temperature War
172. ess Parts Number 0 15 mm 0 006 in 92180 1331 0 2 mm 0 008 in 92180 1332 0 5 mm 0 020 in 92180 1329 0 7 mm 0 028 in 92180 1381 0 8 mm 0 031 in 92180 1330 0 9 mm 0 035 in 92180 1382 1 0 mm 0 039 in 92180 1339 1 1 mm 0 043 in 92180 1383 1 2 mm 0 047 in 92180 1340 3 Ring Gear Left Shims for Tooth Contact Adjustment Thickness Parts Number 0 15 mm 0 006 in 92180 1334 0 2 mm 0 008 in 92180 1336 0 5 mm 0 020 in 92180 1335 0 7 mm 0 028 in 92180 1387 0 8 mm 0 031 in 92180 1333 0 9 mm 0 035 in 92180 1388 1 0 mm 0 039 in 92180 1341 1 1 mm 0 043 in 92180 1389 1 2 mm 0 047 in 92180 1342 Property of www SmallEngineDiscount com Not for Resale 11 40 FINAL DRIVE Front Final Gear Case Backlash Adjustment e Check and adjust the gear backlash when any of the backlash related parts are replaced with new ones e Clean any dirt and oil off the bevel gear teeth e Assemble the front final gear case see Front Final Gear Case Assembly O It is not necessary to install the variable front differential control unit O Check the backlash during tightening of the front final gear case center cover bolts and stop tightening them immediately if the backlash disappears Then change the ring gear shim to a thicker one e Temporarily install the right front axle in the gear case and hold it in a vise so that the ring gear is lower than the pinion gear e Mount a dial gauge A
173. essececeeeeceeeeeaueueussnssecceceeeeceeseeeeuaaeaansseceececeseueeeeseaaaaageess 15 12 Rear Fender Installation cti 15 13 COVES RRA e cadet cet encased crete st eect calles ove a actausuece2asteacnetesceeteersta wieetectcancte eda test earanstdaskaa 15 14 Headlight Cover REMOValI c cceccesseeceseeeceeeeeeceeeeeaeeeaeesaeecaaeseaeeeaeesiaeeaeeeaeecaaesaaeseaeeeaessaeesaeeeaeesaeessaeseaeseeeeneeteas 15 14 Headlight Cover Installati n comriina te leia 15 14 Front inner Cover Removal acotada 15 14 Front Inner Cover InstallatiON ooooooononcncnnonananananannnnnnnononononononnnnano nro nonnnnnnonono ronca nnnnnn non rn nnnnnn nana rn rana nnnnann nono non 15 15 Fuel Tank Gover A 15 15 Fuel Tank Gover Installation Bes 2occcocccdcaneassecedebadeestanecslexescauadacaseacedes bzeenhuduagsdydeacacsuncbsuedJenateasiteeeedavesgaa 15 15 Left Side Cover Removaltiiiniodo ninas di 15 15 Exhaust Pipe Cover Removal cccccesceseeeseeeceeeeeeeeeeseeeeeaeeeaeecaeesaeeaeecaeeseeseeeeeaeeseeseeseaeeseeseeeseeeeeaeesinesseeeeas 15 15 A 15 17 Front Guard Removal ld 15 17 Front Lower Guard RemMoval cccccccccccnnnnanonononnncnononnnononononanananonononnnnnnnnnnnnnnnnnnnnnnnn nro nonnnnnnnn cnn nr rra nnnnn anno rnnnnnnnananans 15 17 Front Guards Instala iii 15 17 Engine Bottom Guard Removal c ccccceseceseceeeceeeeeeeeeeseeeeeaeeeaeesaeeceaeseaeesaeeseaeeeaeesaeesaeseaeseaeesaeeseaeseaeesieeseaeenaeeeaes 15 18 Engine Bott
174. eys to rotate in the same direction as originally installed e Lift the drive belt C off the driven pulley D Drive Belt Installation NOTE O Be sure the printed information faces the same direction so the belt rotates in the same direction as originally installed When installing a new belt install it so the printed information A can be read from beside the vehicle e Installation is basically the reverse of removal e Loop the belt over the driven pulley e Install the drive pulley see Drive Pulley Installation e Put the transmission in neutral and rotate the driven pulley to allow the belt to return to the top A of the sheaves before measuring belt deflection HSOBBDOA P Drive Belt Deflection Inspection e Refer to Drive Belt Deflection Inspection in Periodic Maintenance chapter Drive Belt Deflection Adjustment e Refer to Drive Belt Deflection Adjustment in Periodic Maintenance chapter Drive Belt Inspection e Refer to Drive Belt Inspection in Periodic Maintenance chapter Property of www SmallEngineDiscount com Not for Resale CONVERTER SYSTEM 5 11 Drive Pulley Drive Pulley Removal e Remove Torque Converter Cover see Torque Converter Cover Removal e Remove the three bolts of the drive pulley cover e Install and tighten the drive pulley holder A and the three bolts B as shown Special Tool Drive Pulley Holder 57001 1520 e Loosen the drive pulley bolt C NOTE O The drive
175. f either of the bearings is damaged Swingarm Bearing Lubrication e Remove the swingarm e Using a high flash point solvent wash the bearings clean of grease and dry them e Inspect the bearings and oil seals for abrasion color change or other damage e Apply grease to the outer races A and pack the tapered roller bearings B with the same grease e Apply Amoco Rykon Premium Grease No 2 EP green to the inside of the oil seals e Install the swingarm see Swingarm Installation Property of www SmallEngineDiscount com Not for Resale STEERING 14 1 Steering Table of Contents Exploded VIEW ssaka ehedatest idad 14 2 SPSCINCAIONS stots ano Ea an E a EE ES E SISE A EErEE ESES 14 4 O E E E TE E E E eee 14 5 Steering Stem Removal occonnccnninnicninnonncnnccnccnnc rra 14 5 Steering Stem Installation saina aaa ara aaa ra araa aaa Ea r aa aa a AAA A TAE AE A Aa Ea A EEA N aaeain 14 5 Steering Knuckle Removal ui ceedessced geadnanaereacapanehedeanece 14 6 Steering Knuckle InstallatiON ooonnoninnnnnndn nnonnnnnnconnnonnncnnnccnnrnncccnnc conan crac 14 7 Steering Knuckle Bearing Removal ocococincccnncnonccincnnccnconoconcnonnnonnnonnc cnn cnn rra 14 7 Steering Knuckle Bearing Installati0D oonoonnicnininnnncnnnnnnnonnnnnncnnncnncannccnnrcnnn circa 14 7 TIS ROd Removals reesen a dd a e A ta 14 7 Tie Rod Installati n sesira sses eean e a ETa oaae Eaa veal adi ii aaa 14 7 Tie Rod End Removals reessione
176. f the output voltage is within the values in the table the alternator is operating correctly and the regulator rectifier is damaged A much lower reading indicates that the alternator is defective Property of www SmallEngineDiscount com Not for Resale 16 22 ELECTRICAL SYSTEM Charging System e Check the stator coil resistance as follows O Stop the engine O Disconnect the alternator connector O Connect a hand tester as shown in the table O Note the readings total 3 measurement Stator Coil Resistance Connections Tester Range Reading Tester to Tester to Anoth x10 One black lead ae ia 0 33 0 49 Q x If there is more resistance than shown in the table or no reading infinity for any two leads the stator has an open and must be replaced Much less resistance means the stator is shorted and must be replaced e Using the highest resistance range of the hand tester measure the resistance between each of the black leads and chassis ground x Any reading less than infinity indicates a short necessitating stator replacement x If the stator coils have normal resistance but the voltage check shows the alternator to be defective then the rotor magnetism has probably weakened and the rotor must be replaced Special Tool Hand Tester 57001 1394 Regulator Rectifier Inspection e Remove Bolts A and Regulator Rectifier B Connectors C disconnect Rectifier Circuit Check
177. f the retaining clip A Property of www SmallEngineDiscount com Not for Resale 3 10 FUEL SYSTEM Choke Lever and Cable e Fit the cable end A in the grommet B and free the cable from the switch case e Pull the cable out of the vehicle Choke Lever and Cable Installation e Lubricate the choke cable before installation e Install the wave washer plain washer and screw in that order e Route the choke cable according to Appendix chapter WARNING Operation with an incorrectly routed or damaged cable could result in an unsafe riding condition Choke Cable Lubrication Whenever the choke cable is removed lubricate the cable as follows e Lubricate the cable with a penetrating rust inhibitor through the pressure cable luber Choke Cable Inspection e With the choke cable disconnected at both ends the cable should move freely in the cable housing x If the cable does not move freely after lubricating if the cable is frayed or if the housing is kinked replace the cable Property of www SmallEngineDiscount com Not for Resale FUEL SYSTEM 3 11 Carburetor Idle Speed Inspection e Start the engine and warm it up thoroughly e With the engine idling turn the handlebar to both sides to check for any changes in the idle speed x If handlebar movement changes the idle speed the throttle cable may be improperly adjusted incorrectly routed or damaged Be sure
178. ff at the reservoir e Attach a clear plastic hose to the bleed valve on the caliper and run the other end of the hose into a container e Bleed the brake line and the caliper as follows O Hold the brake lever applied A O Quickly open and close the valve B O Release the brake lever C e The fluid level must be checked several times during the bleeding operation and replenished as necessary NOTE O 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 O If the brake lever action still feels soft or spongy tap the brake hose from bottom to top and air will rise up to the top part of the hose Slowly pump the brake lever in the same manner as above e Tighten Torque Bleed Valves 5 9 N m 0 6 kgf m 52 in Ib e Install the front wheels see Wheels Tires chapter e Apply the brake lever forcefully for a few seconds and check for fluid leakage around the fittings Property of www SmallEngineDiscount com Not for Resale BRAKES 12 9 Master Cylinder Master Cylinder Removal e Remove Brake Hose Banjo Bolt A Master Cylinder Clamp Bolts B Master Cylinder C CAUTION Brake fluid quickly ruins painted surface any spilled fluid should be completely washed away immediately Master Cylinder Installation e The master cylinder clamp must be
179. fixed sheave and dry them with a clean cloth e Install Spacers A for Drive Belt Deflection Adjustment e Apply grease to the oil seal lips A e Apply molybdenum disulfide grease to the inner surface of the bushings B e When installing the new oil seal press and insert it so that the seal surface is flush with the end of each housing in the movable sheave HSO7G03BS1 Property of www SmallEngineDiscount com Not for Resale CONVERTER SYSTEM 5 21 Driven Pulley e Align the match marks on the sheaves made when disassembled and the opening A and hole B will be matched easily e Apply molybdenum disulfide grease to the seating surface A of the pins and insert them into the holes in the movable sheave e Draw the movable sheave onto the fixed sheave and apply molybde num disulfide grease of 1 g 0 035 oz to all openings A NOTE O Do not heap up the grease out of the openings HSO7BOT8 P e Check that the O rings A are in good condition x If any of the O rings are damaged replace them e Apply grease to the O rings e Hold the drive amp driven pulley holder in a vise Special Tool Drive Pulley Holder 57001 1473 e Screw the guide bar into the holder Special Tool Spring Holder Set 57001 1483 e Put the driven pulley A onto the guide bar e Put the thrust plate B so that the alloy side gray faces the movable sheave e Install Spring Spacer see Hi
180. for Resale BRAKES 12 3 Exploded View No Fastener ft lb Remarks Reservoir Cap Screws 13 in lb 2 Brake Lever Pivot Bot 59 oe 52mb a Brake Lever Pivot Bot Lont se os seme 4 Master Cylinder Clamp Bolts 8 8 0 9 78 in lb 5 Brake Switch Mounting Bolt 1 2 0 12 10 in lb 6 Brake Hose Banjo Bolts 25 2 5 18 7 Pad Mounting Bolts 18 1 8 13 8 Bleed Valves 5 9 0 6 52 in lb 9 Caliper Mounting Bolts 25 2 5 18 10 Caliper Holder Shaft 18 1 8 13 11 Disc Mounting Bolts 37 3 8 27 L B Apply brake fluid L Apply a non permanent locking agent Si Apply silicone grease Property of www SmallEngineDiscount com Not for Resale 12 4 BRAKES Exploded View Property of www SmallEngineDiscount com Not for Resale BRAKES 12 5 Exploded View AR Fastener MC atm fib Variable Differential Control Lever Bolt 31 in lb KA Gasket Screws ee e G Apply grease for oil seal and O ring L Apply a non permanent locking agent Gr Apply grease MF Apply MOBIL FLUID 424 or equivalent oil Property of www SmallEngineDiscount com Not for Resale 12 6 BRAKES Specifications Brake Fluid Type DOT 3 or DOT 4 Front Disc Brake Pad lining thickness 4 5 mm 0 18 in 1 mm 0 04 in Disc thickness 3 3 3 7 mm 0 130 0 146 in 3 mm 0 12 in Disc runout TIR 0 2 mm 0 008 in or less TIR 0 3 mm 0 012 in
181. g in a high flash point solvent dry it do not spin the bearing while it is dry and oil it with engine oil O Spin the bearing by hand to check its condition x If the bearing is noisy does not spin smoothly or has any rough stops replace it KACR Inspection The Kawasaki Automatic Compression Release KACR momentarily opens the exhaust valves on the compression stroke at very low speeds This allows some of the compression pressure to escape making it easy to turn over the engine during starting Due to the simplicity of the mechanism no periodic maintenance is needed There are only two symptoms of problems with the KACR mechanism A compression is not released during starting and compression is released during running HEOSGO4BS1 1 If compression is not released during starting the weights are not D returning to their rest position e Remove the camshaft see Camshaft Removal e Remove the KACR unit e Visually inspect the spring x If damaged deformed or missing replace the spring e Remove the spring and move the weights back and forth x If the weights do not move smoothly replace the KACR unit Also inspect the exhaust rocker arm for any damage and replace the rocker arm if necessary A Rest Position compression is released B Weights C Spring HEOSGOSBS1 2 If compression is released while the engine is running the weights are not swinging out e Remove the s
182. g holder nut with a small chisel e Hold the pinion gear unit A with the pinion gear holder B in a vise and remove the pinion gear bearing holder nut C Special Tool Pinion Gear Holder 57001 1485 e Remove the ball bearing only if required Special Tool Bearing Puller 57001 135 Pinion Gear Unit Assembly O The pinion gear and ring gear are lapped as a set in the factory to get the best tooth contact They must be replaced as a set e Visually inspect the bearing for abrasion color change or other damage x If there is any doubt as to the condition of a bearing replace the bearing e Be sure to check and adjust the bevel gear backlash and tooth contact when any of the backlash related parts are replaced see Front Final Bevel Gear Adjustment e Press the bearing on the pinion gear until it is bottomed e Install the pinion gear bearing holder nut A so that the projection B faces outward e Tighten Special Tool Pinion Gear Holder 57001 1485 Torque Pinion Gear Bearing Holder Nut 127 N m 13 kgf m 94 ft lb e Stake C the nut with a punch at three positions to secure it HK110032 P Front Final Bevel Gear Adjustment The backlash distance one gear will move back and forth without Front Final Bevel Gear moving the mate gear and tooth contact pattern of the bevel gears Adjustment Procedure must be correct to prevent the gears from making noise and being damaged Above two adju
183. g the mode switch A briefly will toggle the LCD display B from Odo to Trip or visa versa however pushing the switch more often than once per second will not toggle the display e The trip count includes tenths of a mile whereas the odo count does not e The trip mode may therefore be identified by the presence of a decimal point next to the tenths digit e To clear the trip count push and hold the switch for at least three seconds regardless of which mode the display is currently in and Roba resi a do not let go until you see the trip count reset to zero Check 3 Speedometer Check e Connect the wires in the same manner as Check 1 e The speed equivalent to the input frequency is indicated in the oscillator A if the square wave is input into terminal 3 Green e Raise the input frequency of the oscillator to see the result of this inspection x If the value indicated by the speedometer does not increase replace the meter unit Check 4 Odometer Check e Connect the wires in the same manner as Check 3 e Pushing the mode switch A cycles the odometer B e Raise the input frequency of the oscillator to see the result of this inspection x If the value indicated by the odometer does not increase replace the meter unit HP20026BS1 Check 5 Trip Meter Check e Connect the wires in the same manner as Check 3 e Pushing the mode switch A cycles the trip meter B
184. gh Altitude Setting Information Spring Seat C 18 5 mm 0 728 in Spring D Spring Seat E 9 3 mm 0 366 in Circlip F Property of www SmallEngineDiscount com Not for Resale 5 22 CONVERTER SYSTEM Driven Pulley e Tighten nut A and compress the spring with the spring holder B Special Tool Spring Holder Set 57001 1483 e Install circlip C with circlip pliers D Special Tool Circlip Pliers 57001 154 e Remove the driven pulley from the spring holder set e Clean the surface of the sheaves with an oil less cleaning fluid Driven Pulley Installation e Clean the transmission driven shaft A e Install Driven Pulley NOTE O When engaging the spline on the driven pulley with the spline B on the shaft do not damage the pulley s spline If any damage occurs remove it with a file e Clean the driven shaft and driven pulley ends to open the air vent passage Wipe off any extra grease O Wipe off any protruding grease A e Install the washers A on the shaft as shown A ee A HSO6014BS1 Bolt Head e Using a flywheel amp pulley holder A and adapters B tighten the driven pulley nut C Special Tools Flywheel amp Pulley Holder 57001 1343 Pulley Holder Attachment 57001 1472 Torque Driven Pulley Nut 93 N m 9 5 kgf m 69 ft lb Property of www SmallEngineDiscount com Not for Resale CONVERTER SYSTEM 5 23
185. gle to the direction of the piston pin Piston Diameter Standard 79 952 79 967 mm 3 1477 3 1483 in Service Limit 79 80 mm 3 142 in x If the piston diameter is less than the service limit replace it HE14004BS1 Piston Cylinder Clearance e Subtract the piston diameter from the cylinder inside diameter to get the piston cylinder clearance Piston Cylinder Clearance Standard 0 033 0 060 mm 0 0013 0 0024 in Piston Ring and Ring Groove Wear e Check for uneven groove wear by inspecting the ring seating x 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 measurements with a thickness gauge A to determine piston ring groove clearance Piston Ring Groove Clearance Standard Service Limit Top 0 04 0 08 mm 0 18 mm 0 0016 0 0032 in 0 0071 in Second 0 03 0 07 mm 0 17 mm geese 0 0012 0 0028 in 0 0067 in x If the piston ring groove clearance is greater than the service limit measure the ring thickness and groove width as follows to decide whether to replace the rings the piston or both Property of www SmallEngineDiscount com Not for Resale 4 32 ENGINE TOP END Cylinder and Piston Piston Ring Groove Width e Measure the piston ring groove width O Use a vernier caliper at several points around the piston Piston Ring Gr
186. h bearing in a high flash point solvent dry it do not spin the bearing while it is dry and oil it with engine oil O Spin A the bearing by hand to check its condition x If the bearing is noisy does not spin smoothly or has any rough spots replace it e Check the needle bearings O The 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 bearing replace it Oil Seal Inspection e Inspect the oil seals x Replace it if the lips are misshapen discolored indicating that the rubber has deteriorated hardened or otherwise damaged Property of www SmallEngineDiscount com Not for Resale Property of www SmallEngineDiscount com Not for Resale WHEELS TIRES 10 1 Wheels Tires Table of Contents EXploded Vi Wiiiaci oa plis 10 2 SA O 10 4 Wheel Allgh MENE cio imitacion iiO ida pi iii oie 10 5 Steering Centering INSpectiON oooonicnnnnnnnnoncnnncnrecnncnnccn cnn rnc cren 10 5 Steering Centering AdjuStMeNt ocoonncinnicnnncnnnncnncncnccnncc conc nnnnn conca 10 5 Toei Inspection a ehdda ee ee ee de ere ee es 10 6 Teim AJJUS MEN sisirin rn aaa a a a aa dancers peace paa a aaa aeiia 10 6 Wheels RIMS E E E AT 10 7 Wheel Removal siase a aiaa aaea retira 10 7 Wheel Installation ooonmsnsrna ii ib aiaiai 10 7 Wheel
187. haft 20 2 0 14 9 Swingarm Pivot Left Nut 152 15 5 112 G Apply grease for oil seal and O ring L Apply a non permanent locking agent AG Apply grease Amoco rykon premium grease No 2 EP Green MF Apply MOBIL FLUID 424 or equivalent oil Gr Apply grease Property of www SmallEngineDiscount com Not for Resale 13 4 SUSPENSION Specifications Shock Absorbers Usable Range Spring preload setting position Rear No 2 1 5 Special Tools Outside Circlip Pliers 57001 144 Oil Seal amp Bearing Remover 57001 1058 Steering Stem Nut Wrench 57001 1100 Bearing Driver Set 57001 1129 Jack 57001 1238 Holder amp Guide Arbor 57001 1476 Spacer 8 Holder 57001 1477 Property of www SmallEngineDiscount com Not for Resale SUSPENSION 13 5 Shock Absorbers Front Shock Absorber Removal e Remove Front Fender see Frame chapter Front Inner Cover see Frame chapter Cotter Pins A Front Shock Absorber Clamp Bolts and Nuts B Suspension Arm Pivot Bolts e Remove Circlip A Special Tool Outside Circlip Pliers 57001 144 e While supporting the vehicle with a jack loosen the nut B Special Tool Jack 57001 1238 e Remove the ball joint C of the shock absorber from the frame bracket D HMO4B0 105 Ps a e Remove Front Shock Absorber A Front Shock Absorber Installation e Insert the shock absorber into the knuckle and align its recess A and the lower bolt hole B in the kn
188. hain Guard Bolts 8 8 0 9 78 in lb 6 Valve Adjusting Screw Locknuts 12 1 2 104 in lb 7 Rocker Shaft Holder Bolts 8 8 0 9 78 in lb 8 Muffler Mounting Bolts 26 2 7 20 G Apply grease for oil seal and O ring L Apply a non permanent locking agent MO Apply molybdenum disulfide oil M Apply molybdenum disulfide grease O Apply engine oil R Replacement Parts Property of www SmallEngineDiscount com Not for Resale 4 6 ENGINE TOP END Specifications Rocker Arms and Shafts Rocker arm inside diameter Rocker shaft diameter Camshaft Cam height Exhaust Inlet Standard Service Limit 13 000 13 018 mm 0 5118 0 5125 in 12 973 12 984 mm 0 5107 0 5112 in 40 693 41 801 mm 1 6021 1 6063 in 40 837 40 945 mm 1 6078 1 6120 in 13 05 mm 0 514 in 12 95 mm 0 510 in 40 59 mm 1 598 in 40 74 mm 1 604 in Cylinder Head Cylinder compression Electric starter 630 r min rpm Cylinder head warp Usable Range 810 1260 kPa 8 3 12 8 kgf cm 118 182 psi Valves Valve clearance Exhaust Inlet Valve valve guide clearance wobble method Exhaust Inlet Valve seating surface width Exhaust Inlet Valve seating surface outside diameter Exhaust Inlet Valve seat cutting angle Valve head thickness Exhaust Inlet Valve stem bend Valve stem diameter Exhaust Inlet Valve guide inside diameter Exhaust Inlet Valve spring free length Inner Outer Cylinder Pi
189. he area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Remove the fuel tank cover see Fuel Tank Removal e Install the fuel tank cap immediately e Pry off the gauge cap A and discard the cap e Check the grooves B in the fuel tank boss If the grooves are damaged by removing the cap or can not hold the cap nails the fuel tank must be replaced e Pull out the fuel level gauge C Fuel Level Gauge Installation dA WARNING Gasoline is extremely flammable and can be explosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Install the fuel level gauge so that the 1 2 scale A faces the front B e Push the new gauge cap over the gauge so that the notch C aligns with the 1 2 scale e Check that the gauge cap nails fit securely in the grooves in the fuel tank boss Fuel Level Gauge Check e Remove the fuel level gauge from the fuel tank see Fuel Level Gauge Removal e Check that the float A moves up and down B smoothly without binding It should go down under its own weight x If the float does not move smoothly or has visual damage replace the gauge Property of www SmallEngineDiscount com Not for Resale ENGINE TOP END 4 1 Engine Top End Ta
190. hragm may be damaged Remove as many rubber or plastic parts from the carburetor as possible before cleaning the carburetor with a cleaning solution This will prevent damage or deterioration of the parts The carburetor body has plastic parts that cannot be removed Do not use a strong carburetor cleaning solution which could attack these parts instead use a mild high flash point clean ing solution safe for plastic parts Do not use wire or any other hard instrument to clean carbu retor parts especially jets as they may be damaged e Disassemble the carburetor see Carburetor Disassembly e Immerse all the metal parts in a carburetor cleaning solution e Rinse the parts in water e When the parts are clean dry them with compressed air e Blow the air and fuel passages with compressed air e Assemble the carburetor see Carburetor Assembly Property of www SmallEngineDiscount com Not for Resale FUEL SYSTEM 3 17 Carburetor Carburetor Inspection AWARNING Gasoline is extremely flammable and can be explosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Before disassembling the carburetor check the fuel level see Service Fuel Level Inspection x If the fuel level is incorrect inspect the rest of the carburetor before correcting it e Remove
191. ing guide e Remove Nuts A Upper Holder B HMO4B034 P Rear Shock Absorber Scrapping AWARNING Since the rear shock absorber contains nitrogen gas do not incinerate or disassemble the rear shock absorber Before a rear shock absorber is scrapped drill a hole at a point about 15 mm 0 59 in A up from the bottom of the cylinder to release the nitrogen gas completely Wear safety glasses when drilling the hole as the gas may blow out bits of drilled metal when the hole opens Property of www SmallEngineDiscount com Not for Resale 13 12 SUSPENSION Suspension Arms Suspension Arm Removal e Remove Front Wheel see Wheels Tires chapter Knuckle Joint Bolt A Knuckle Joint B from Knuckle Suspension Arm Pivot Bolts C Suspension Arm D Suspension Arm Installation e Tighten Torque Suspension Arm Pivot Bolts 88 N m 9 0 kgf m 65 ft Ib Steering Knuckle Joint Nuts 47 N m 4 8 kgf m 35 ft Ib Suspension Arm Disassembly e Remove Axle Guard Bolts A and Washers Axle Guard B Circlip C e Press out the knuckle joint D CAUTION Do not remove the knuckle joint grease seal It is packed with grease e Remove Rubber Bushings A Property of www SmallEngineDiscount com Not for Resale HMO05000351 HMOSGO3BS1 SUSPENSION 13 13 Suspension Arms Suspension Arm Assembly e Position the bushing
192. ing that the part has been installed in its proper location Then tighten them to the specified torque in the tightening sequence and method indicated If tightening sequence instructions are not given tighten them evenly in a cross pattern Conversely to remove a part first loosen all the bolts nuts or screws that are retaining the part a 1 4 turn before removing them 5 Torque When torque values are given in this Service Manual use them Either too little or too much torque may lead to serious damage Use a good quality reliable torque wrench 6 Force Common sense should dictate how much force is necessary in assembly and disassembly If a part seems especially difficult to remove or install stop and examine what may be causing the problem Whenever tapping is necessary tap lightly using a wooden or plastic faced mallet Use an impact driver for screws particularly for the removing screws held by non permanent locking agent in order to avoid damaging the screw heads 7 Edges Watch for sharp edges as they could cause injury through careless handling especially during major engine disassembly and assembly Use a clean piece of thick cloth when lifting the engine or turning it over 8 High Flash Point Solvent A high flash point solvent is recommended to reduce fire danger A commercial solvent commonly available in North America is standard solvent generic name Always follow manufacturer and container directions regarding the use of
193. ing 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 Tensioner 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 Fuel Tank Cover see Frame chapter Exhaust Pipe Cover see Frame chapter e Loosen the cap bolt A e Remove the mounting bolts B and take off the camshaft chain tensioner Camshaft Chain Tensioner Installation e Remove the cap bolt and O ring O While compressing A the push rod B turn it clockwise C with a suitable screwdriver D until the rod stops O While holding the rod in position with a holder plate install the tensioner on the cylinder block CAUTION Do not turn the rod counterclockwise at installation This could detach the rod and the tensioner cannot be reinstalled HE08001B51 NOTE O To make the procedure easy use a holder plate A to keep the rod from pushing out A replacement chain tensioner spare parts has a holder plate e The holder plate can be made of 0 8 mm 0 03 in thick aluminum plate as shown B 8 5 mm 0 33 in C 3 5 mm 0 14 in D 5 mm 0 20 in E 12 mm 0 47 in 6E10000BS1 Property of www SmallEngineDiscount com Not for Resale ENGINE TOP END 4 9 Camshaf
194. installed with the UP mark A upwards e Tighten the upper clamp bolt first and then the lower clamp bolt There will be a gap at the lower part of the clamp after tightening Torque Master Cylinder Clamp Bolts 8 8 N m 0 9 kgf m 78 in Ib e Use a new flat washer on each side of the brake hose fitting and tighten the banjo bolt Torque Brake Hose Banjo Bolt 25 N m 2 5 kgf m 18 ft Ib e Bleed the brake line after master cylinder installation see Brake Line Air Bleeding e Check the brake for good braking power no braking brag and no fluid leakage PEG IN Do not attempt to drive the vehicle until a firm brake lever can be obtained by pumping the brake lever until the pads are against each disc The brakes will not function on the first application of the lever if this is not done Master Cylinder Disassembly e Remove Master Cylinder see Master Cylinder Removal Brake Lever Pivot Nut A Brake Lever Pivot Bolt B Brake Lever C Dust Cover D Circlip E Piston F Spring G Special Tool Inside Circlip Pliers 57001 143 CAUTION Do not remove the secondary cup H from the piston since removal will damage it Property of www SmallEngineDiscount com Not for Resale 12 10 BRAKES Master Cylinder 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
195. iodic Maintenance Procedures Bolts and Nuts Tightening Tightness Inspection e Check the tightness of the bolts and nuts listed here in accordance with the Periodic Maintenance Chart Also check to see that each cotter pin is in place and in good condition x lf there are loose fasteners retorque them to the specified torque following the specified tightening sequence Refer to the appropriate chapter for torque specifications If torque specifications are not listed in the appropriate chapter see the Basic Torque Table see Torque and Locking Agent For each fastener first loosen it by 1 2 turn then tighten it x lf cotter pins are damaged replace them with new ones Bolts Nuts and Fasteners to be checked Wheels Front Axle Nuts and Cotter Pins Rear Axle Nuts and Cotter Pins Wheel Nuts Brakes Master Cylinder Clamp Bolts Brake Lever Pivot Bolt Brake Lever Pivot Nut Caliper Mounting Bolts Brake Pedal Cotter Pin Steering Suspension Handlebar Clamp Bolts Stem Clamp Allen Bolts Stem Bearing Housing Bolts Tie Rod End Nuts and Cotter Pins Tie Rod Adjusting Sleeve Locknuts Shock Absorber Mounting Bolts and Nuts Suspension Arm Pivot Bolts Steering Knuckle Pivots Nuts and Cotter Pins Engine Engine Mounting Bolts Engine Mounting Bracket Bolts Exhaust Pipe Holder Nuts Muffler Mounting Bolts Muffler Clamp Bolt Front Final Drive Gear Case Bracket Bolts Others Footrest Mounting Bolts Throttle Mounting Bo
196. iodic Maintenance chapter Property of www SmallEngineDiscount com Not for Resale 12 18 BRAKES Rear Brake Lever Pedal and Cables Brake Pedal Position Inspection e Check that the brake pedal A is in the correct position as shown B Footboard Pedal Position C Standard 60 65 mm 2 36 2 56 in above footboard x If it is incorrect adjust the brake pedal position Brake Pedal Position Adjustment e Loosen the locknut A and turn the adjusting bolt B until the brake pedal is correctly positioned e Tighten the locknut e Check the brake pedal free play see Brake Pedal Free Play Inspec tion Rear Brake Lever Free Play Inspection e Refer to Rear Brake Lever Free Play Inspection in Periodic Mainte nance chapter Brake Pedal Free Play Inspection e Refer to Brake Pedal Free Play Inspection in Periodic Maintenance chapter Rear Brake Lever and Pedal Free Play Adjustment e Refer to Rear Brake Lever and Pedal Free Play Adjustement in Periodic Maintenance chapter Brake Pedal Removal e Remove Right Footboard see Frame chapter e Loosen the locknut and the adjusting bolt A e Remove Brake Switch Spring B Cotter Pin Washer Pin and Brake Cable Joint C Cotter Pin and Washer D O ring and Brake Pedal E Spring Brake Pedal Installation O e Apply grease Brake Pedal Pivot A O ring B gt HL11000BS1 Property of www SmallEngineDiscount co
197. ion e Install the air valve cap Property of www SmallEngineDiscount com Not for Resale WHEELS TIRES 10 9 Tires Tire Removal e Remove the wheel e Unscrew the valve core to deflate the tire O Use a proper valve core tool A e Lubricate the tire beads and rim flanges on both sides of the wheel with a soap and water solution or water A This helps the tire beads slip off the rim flanges CAUTION Do not lubricate the tire beads and rim flanges with engine oil or petroleum distillates because they will deteriorate the tire e Remove the tire from the rim using a suitable commercially available tire changer NOTE O The tires cannot be removed with hand tools because they fit the rims tightly Tire Installation e Inspect the rim see Wheel Rim Inspection e Replace the air valve with a new one CAUTION Replace the air valve with whenever the tire is replaced Do not reuse the air valve e Check the tire for wear and damage see Tire Inspection in Periodic Maintenance chapter e Lubricate the tire beads and rim flanges with a soap and water solution or water dA WARNING Do not use the lubricant other than a water and soap solution or water to lubricate the tire beads and rim because it may cause tire separation e Check the tire rotation mark A on the tire and install the tire on the rim accordingly O The tires should be installed
198. ion system Starting system Ignition system Timing advance Ignition timing Air cooled 80 0 x 72 0 mm 3 15 x 2 83 in 362 mL 22 1 cu in 8 3 1 15 7 kW 21 4 PS 7000 r min rpm US 26 1 N m 2 66 kgf m 19 25 ft lb 4500 r min rpm Carburetor Keihin CVK34 Electric Starter amp Recoil Starter DC CDI Electronically advanced From 10 BTDC 1300 r min rpm to 30 BTDC 5 000 r min rpm Spark plug NGK DPR8EA 9 Valve timing Inlet Open 38 BTDC Close 58 ABDC Duration 276 Exhaust Open 68 BBDC Close 28 ATDC Duration 276 Lubrication system Forced lubrication wet sump Engine oil Type API SF or SG API SH or SJ with JASO MA Viscosity SAE 10W 40 Capacity 2 3 L 2 17 US qt Drive Train Primary reduction system Type Belt converter Reduction ratio 3 122 0 635 Property of www SmallEngineDiscount com Not for Resale GENERAL INFORMATION 1 7 General Specifications Items KVF360 A1 Transmission Type 2 speed plus reverse Gear ratios Forward High 3 548 30 26 x 29 18 x 21 11 Low 5 536 36 20 x 29 18 x 21 11 Reverse 4 613 16 12 x 18 16 x 29 18 x 21 11 Final drive system Type Shaft 2WD 4WD Reduction ratio 4 375 35 8 Overall drive ratio Forward High 48 474 9 859 Low 75 619 15 380 Reverse 63 016 12 817 Front final gear case oil Type API SF or SG API SH or SJ with JASO MA Viscosity SAE 10W 40 Capacity 0 43 L 0 45 US at Rear final gear case oil Type MOB
199. ired position with the wrench Special Tool Steering Stem Nut Wrench 57001 1100 Rear Shock Absorber Removal e Support the vehicle on a stand or a jack so that the rear wheels are off the ground Special Tool Jack 57001 1238 e While holding the rear wheels remove the lower and upper shock absorber mounting bolts A nuts and washers e Remove the rear shock absorber B Rear Shock Absorber Installation e Install Bushings A Washers B e Tighten Torque Rear Shock Absorber Mounting Nuts C 62 N m 6 3 kgf m 46 ft lb HM04001B51 Property of www SmallEngineDiscount com Not for Resale SUSPENSION 13 9 Shock Absorbers Rear Shock Absorber Inspection e Check the rubber bushings A in the upper and lower pivots x If bushings are worn cracked hardened or otherwise damaged replace them HMO4002BS2 C Rear Shock Absorber Spring Removal e Remove Rear Shock Absorber see Rear Shock Absorber Removal e Hold the holder A 57001 1476 and spacer B 57001 1477 in a vice as shown e Install the guide arbors C 57001 1476 on the holder e Insert the rear shock absorber D into the center of the spacer and holder Special Tools Holder amp Guide Arbor 57001 1476 Spacer amp Holder 57001 1477 e Put the upper holder A 57001 1477 on upper end of the spring guide B and arbors C so that the recess side faces downward
200. k 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 gasket it should be replaced If the muffler to exhaust pipe joint leaks tighten the clamp e Remove the exhaust pipe and muffler see Exhaust Pipe and Muffler Removal e Inspect the gasket for damage and signs of leakage 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 If the exhaust pipe or muffler is damaged or has holes it should be replaced for best performance and least noise Property of www SmallEngineDiscount com Not for Resale Property of www SmallEngineDiscount com Not for Resale CONVERTER SYSTEM 5 1 Converter System Table of Contents Exploded Vie Wisin A a 5 2 Specification dic de a dead aida oia 5 6 Torque Converter aii a a dd iia 5 7 Torque Converter Cover Removal siasii eeror niia n EE E AE a 5 7 Torque Converter Cover InstallatiOM ooooonnnnnnnninnnnnnonnonnccnononnnccnnccnn narran rara 5 7 Torque Converter Cover Disassembly siessetek nr 5 8 Actuator Lever Engine Brake Control Lever Assembly INSpecti0N ooocinncnnnnconnccnnnccccnnncnnonnnancnnncn nana nnncnnnncnnnnnns 5 8 Torque Converter Cover Assembly ceccececeeeeeceeeeeeeeeeeeeeeeteaeeeaeeseecsaeeeaeeeaeeseeeseaeeeaeeseeseaeeeaeeseeseaeseaeeeaeeseneeneeeeaees 5 8 Drive Belta recne a a rere terc
201. k plug cap or spark plug lead trouble Spark plug cap not in good contact Spark plug incorrect Pickup coil trouble Igniter trouble Ignition coil trouble Battery voltage low Ignition or engine stop switch shorted Wiring shorted or open Fuse blown Compression Low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Compression release cam K A C R sticks open Engine stalls when moving off Poor Running at Low Speed Spark weak Spark plug dirty broken or maladjusted Spark plug cap or spark plug lead trouble Spark plug cap shorted or not in good contact Spark plug incorrect Igniter trouble Pickup coil trouble Ignition coil trouble Battery voltage low Fuel air mixture incorrect Pilot screw and or idle adjusting screw maladjusted Pilot jet or air passage clogged Starter plunger stuck open Air cleaner clogged poorly sealed or missing Fuel level too high or too low Fuel tank air vent obstructed Carburetor holder loose Air cleaner duct loose Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak
202. ket see Camshaft Sprocket Removal Weights A e Loosen the cylinder head bolts B e Remove Bolts A and Bearing Retainer B e Pull the camshaft C straight out of the head O Screw the camshaft sprocket bolt in to the end of the camshaft and pull it with the camshaft Camshaft Installation e Blow the oil passage with compressed air e Apply molybdenum disulfide oil to the cam lobes A e Carefully push the camshaft into the cylinder head with the cam lobes down e Install Bearing Retainer e Tighten Torque Bearing Retainer Bolts 12 N m 1 2 kgf m 104 ft Ib e Align the notching line A of the weight holder B with the pointer C on the cylinder head e Tighten the loosened cylinder head bolts see Cylinder Head Instal lation Cam Wear Inspection e Measure the height of each cam lobe with a micrometer If the cam height is less than the service limit for either lobe replace the camshaft Cam Height Standard Service Limit Exhaust 40 693 41 801 mm 40 59 mm 1 6021 1 6063 in 1 598 in Inlet 40 837 40 945 mm 40 74 mm 1 6078 1 6120 in 1 604 in Property of www SmallEngineDiscount com Not for Resale ENGINE TOP END 4 15 Camshaft Camshaft Bearing Inspection e Check the ball bearing which is press fitted on the camshaft O Since the ball bearing is made to extremely close tolerances the wear must be judged by feel rather than measurement Clean the bearin
203. l 10 O Install the needle adapters on the tester leads Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 e Turn ON the ignition switch e Measure the controller output voltage for the 2WD 4WD shift switch y Y paonon 9 9 21 19 e 091 01 E HP23004BS1 Controller Output Voltage to 2WD 4WD shift switch Standard 510 25 V x If the reading is not standard replace the actuator controller unit Property of www SmallEngineDiscount com Not for Resale ELECTRICAL SYSTEM 16 61 Actuator Control System e Support the vehicle on a stand or a jack so that the wheels are off the ground e Connect Controller Connector A Hand Tester B range DC 25 V Tester Connector W R Terminal 15 Tester Connector BK Y Terminal 10 O Install the needle adapters on the tester leads Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 e Turn ON the ignition switch npeagoeeen e e Spin a rear wheel as forward rotation e After the wheels stop and one second elapses turn OFF the ignition switch e After two seconds elapses measure the controller output voltage for the engine brake actuator until the actuator stops Controller Output Voltage to engine brake actuator Standard 5 12V x If the reading is not standard check the forward reverse detecting sensor x If the forward reverse detecting sensor is normal replace th
204. l Gear Case see Final Drive chapter Gasket Screws A Gasket B Dowel Pins C e Remove Steel Plates A Friction Plates B Pins C and Springs e Remove Cam Plate A e Remove Steel Balls A e Remove Brake Cam Lever Bolt and Nut A Brake Camshaft B Brake Cam Lever C Property of www SmallEngineDiscount com Not for Resale BRAKES 12 21 Internal Wet Brake Internal Wet Brake Assembly e Apply A MOBIL FLUID 424 or equivalent oil to the brake camshaft and the inside of the collar e Insert the camshaft in the swingarm e Align the punch mark A on the brake cam lever with the punch mark B on the brake camshaft e Install Steel Balls Brake Cam Plate A O Fit the cam plate and brake camshaft B as shown e Install Steel Pressure Plate A and Pins B as shown e Install Friction Plates A Steel Plates B Springs C Steel Pressure Plate D HL15001051 Property of www SmallEngineDiscount com Not for Resale 12 22 BRAKES Internal Wet Brake e Install Dowel Pins A New Gasket B e Apply a non permanent locking agent to the gasket screws C and tighten them e Install Rear Final Gear Case see Final Drive chapter Property of www SmallEngineDiscount com Not for Resale SUSPENSION 13 1 Suspension Table of Contents EXploded VIG Wii a 13 2 MP CCIICALIOMS tasas road dpi lla
205. l Locknut D 6 9 N m 0 7 kgf m 61 in Ib e Install the washers A e Install the armature B between the brushes HP11B030 P e Install the yoke A onto the right end cover B aligning the marks C on the yoke and right end cover NO HP118031 P e Install the washers A 16 34 ELECTRICAL SYSTEM Electric Starter System e Install the plate A on the left end cover B HP118033 P e Align the mark A on the left end cover with the mark B on the yoke e Tighten Torque Starter Motor Bolts 3 4 N m 0 3 kgf m 30 in Ib HP118034 P Commutator Cleaning Inspection e Smooth the commutator surface A if necessary with fine emery cloth B and clean out the grooves e Measure the diameter A of the commutator x Replace the starter motor with a new one if the commutator diameter is less than the service limit Commutator Diameter Standard 28 mm 1 10 in Service Limit 27 mm 1 06 in Property of www SmallEngineDiscount com Not for Resale ELECTRICAL SYSTEM 16 35 Electric Starter System Armature Inspection e Using the x 1 Q range measure the resistance between any two commutator segments A x If there is a high resistance or no reading between any two segments a winding is open Replace the starter motor e Using the highest range measure the resistance between the segments and the shaft B x If there is any reading at all the armature has
206. l filler cap wipe its dipstick A dry and tighten it into the filler opening e Unscrew the oil filler cap and check the oil level The oil level should be between the upper H level line B and lower L level line C x If the level is too high suck the excess oil out the filler hole with a syringe or other suitable device x If the level is too low add oil through the filler hole Use the same type and make of oil that is already in the engine HGOSGOOBS1 Engine Oil Change e Refer to Engine Oil Change in Periodic Mantenance chapter Oil Filter Change e Refer to Oil Filter Change in Periodic Maintenance chapter Oil Screen Removal e Split the crankcase see Crankshaft Transmission chapter e Pull the oil screen A out of the crankcase Property of www SmallEngineDiscount com Not for Resale ENGINE LUBRICATION SYSTEM 7 7 Engine Oil and Oil Filter Oil Screen Cleaning e Clean the oil screen A thoroughly whenever it is removed for any reason e Clean the oil screen with a high flash point solvent and remove any particles stuck to it AWARNING 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 O While cleaning the screen check for any metal particles that might indicate internal engine damage e Ch
207. lts A out x If any hub bolt is damaged replace the hub B and bolts as a unit HJO7B003 P Property of www SmallEngineDiscount com Not for Resale 10 12 WHEELS TIRES Rear Hub Rear Hub Removal e Remove Cap A Cotter Pin B e Loosen the axle nut C e Remove Wheel see Wheel Removal Axle Nut A Rear Hub B Rear Hub Installation e Tighten Torque Rear Axle Nuts 265 N m 27 kgf m 195 ft Ib e Insert a new cotter pin A and bend it over the nut B NOTE O When inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle shaft tighten the nut clockwise up to next alignment It should be within 30 degree O Loosen once and tighten again when the slit goes past the nearest hole Rear Hub Disassembly Assembly e Do not press the hub bolts A out x If any hub bolt is damaged replace the hub B and bolts as a unit HJ08003BS1 Property of www SmallEngineDiscount com Not for Resale FINAL DRIVE 11 1 Final Drive Table of Contents Exploded VieW oiooriomsesmerimicomicer rre 11 2 SpecificatiONS oooooonccononcconncccnoocncnoncncnnrnnonannnonnnos 11 8 Output Bevel GealS oocconcicnnccnconncinnccconncnnccnncnnnnncnn ns 11 9 Output Drive Bevel Gear Removal 11 9 Output Drive Bevel Gear Installation 11 9 Output Drive Bevel Gear Disassembly 11 10 Output Driv
208. lts Carrier Mounting Bolts Property of www SmallEngineDiscount com Not for Resale Property of www SmallEngineDiscount com Not for Resale FUEL SYSTEM 3 1 Fuel System Table of Contents Exploded Vi Wero ges 3 2 SPecification ooonocnnnnnnicnncnnnonnacnnncnnnrnnrarnrnrnnnrcnnncn 3 6 Throttle Lever and CablO oocccnccnnnnniccnnccnncnncccnocncnnnns 3 7 Throttle Lever Free Play Inspection 3 7 Throttle Lever Free Play Adjustment 3 7 Throttle Case Removal Disassembly 3 7 Throttle Case Assembly Installation 3 7 Throttle Cable InstallatiOM oooonnoocnnnnninnnnnnnnnnn 3 8 Throttle Case Inspection ooonnccnccnnnnnnnonncccnnonnns 3 8 Throttle Cable Lubricati0N oomconicnnnnnnnnnion 3 8 Throttle Cable Inspection oooonccnnninnnnnncnnnnm 3 8 Choke Lever and Cable eccccceeeceeseeeeeeeeeeeneeeeaes 3 9 Choke Lever and Cable Removal 3 9 Choke Lever and Cable Installation 3 10 Choke Cable Lubrication ccceeeeeeeees 3 10 Choke Cable Inspection cccccceeeeeeeeeereee 3 10 GANDULCtO ls scces AEE E 3 11 Idle Speed InspectiON oooonocoiccnicccincnnacinnccnanann 3 11 Idle Speed Adjustment ccsceeseeeeeees 3 11 Pilot Screw Adjustment csseeeseeeeeeees 3 11 Service Fuel Level Inspection cceceeeee 3 11 Fuel Level Adjustment 3 12 Fuel Sy
209. lvent to clean parts A fire or explosion could result e Apply a small amount of engine oil to the transmission gears bearings and shift forks e Be sure the mating surfaces of the crankcase halves are clean and dry e Press and insert the new ball bearings until they are bottomed Special Tool Bearing Driver Set 57001 1129 A Ball Bearing B Ball Bearing sealed side towards crankcase e Press and insert the new needle bearing so that the bearing surface is flush with the end of the hole C Needle Bearing e Apply engine oil to the bearings e Install Oil Pressure Relief Valve D see Engine Lubrication System chapter HIO4B003 Py 9 8 CRANKSHAFT TRANSMISSION Crankcase e Press and insert the new ball bearings A until they are bottomed Special Tool Bearing Driver Set 57001 1129 e Press and insert the new needle bearing so that the bearing surface is flush with the end of the hole B Needle Bearing e Apply engine oil to the bearings e Be sure the following parts are in place in the right crankcase half Crankshaft and Balancer Shaft see Crankshaft Balancer Shaft Installation Transmission Shafts and Shift Rod A Spacers B Oil Screen C Dowel Pins D e Apply liquid gasket A to mating surface of the left crankcase half Sealant Three Bond 1215 Gray e Install Oil Pump see Engine Lubrication System chapter e Apply a non permanent locking agent Left Crankc
210. m Not for Resale BRAKES 12 19 Rear Brake Lever Pedal and Cables e Install Spring A Brake Pedal B e Apply grease O ring C e Install Brake Cable Joint and Pin D Brake Switch Spring E Washers F e Replace the cotter pins G with new ones e Adjust the brake pedal position see Brake Pedal Position Brake Cable Removal e Remove Right Rear Flap see Frame chapter e Unscrew the adjusters A at the rear ends of the cables and pull the cables out of the joints B and cable mounts C HL118009 P e Loosen the knurled locknut A at the rear brake lever and screw in the adjuster B e Line up the slots C in the brake lever knurled locknut and adjuster and then free the cable from the lever D e Remove the brake lever cable from the frame e Remove Circlip A Cotter Pin Washer and Pin B Brake Pedal Cable C Brake Cable Installation e Grease the brake cable front ends e Replace the cotter pin with a new one e Route the brake cables according to the Cable Wire and Hose Routing section in Appendix chapter e Adjust the brake pedal and rear brake lever Brake Cable Lubrication Whenever the brake cable is removed lubricate the cable as follows e Lubricate the cable with a penetrating rust inhibitor Property of www SmallEngineDiscount com Not for Resale 12 20 BRAKES Internal Wet Brake Internal Wet Brake Disassembly e Remove Rear Fina
211. m warped Rear axle runout excessive Wheel bearing worn Handlebar clamp loose Steering stem clamp bolt loose Handlebar pulls to one side Frame bent Wheel maladjustment Suspension arm bent or twisted Steering stem bent Front or rear tire air pressure unbalanced Front shock absorber unbalanced Shock absorption unsatisfactory Too hard Tire air pressure too high Shock absorber maladjusted Too soft Shock absorber oil leaking Shock absorber spring weak Tire air pressure too low Shock absorber maladjusted Property of www SmallEngineDiscount com Not for Resale APPENDIX 17 5 Troubleshooting Guide Brake Doesn t Hold Front brake Battery Discharged Air in the brake line Brake fluid leakage Brake fluid deteriorated Primary or secondary cup trouble Master cylinder scratched inside Pad overworn or worn unevenly Oil grease on pads and disc Disc worn or warped Brake overheated Rear Brake Brake not properly adjusted Plates worn Brake parts worn or damaged K EBC and Selectable 2WD 4WD System Malfunction Actuators failed Speed sensor short or open Forward Reverse detecting sensor short or open Actuator controller failed Controller 10A fuse blown Battery disconnected Battery faulty e g plates sulphated shorted through sedimentation electrolyte level too low Battery leads making poor contact Load excessive e g bulb of excessive wattage Ignition switch trouble Regulator rec
212. molybdenum disulfide grease O Apply engine oil MO Apply molybdenum disulfide oil Lh Left hand Threads Gr Apply grease LG Apply liquid gasket Three Bond 1215 Gray Property of www SmallEngineDiscount com Not for Resale 9 6 CRANKSHAFT TRANSMISSION Specifications Standard Service Limit Crankshaft Connecting Rods Connecting rod big end radial clearance 0 008 0 020 mm 0 0003 0 0008 in 0 07 mm 0 003 in Conencting rod big end side clearance 0 25 0 35 mm 0 0098 0 0138 in 0 6 mm 0 024 in Crankshaft runout Left TIR 0 03 mm 0 0012 in or less TIR 0 08 mm 0 0032 in Right TIR 0 04 mm 0 0016 in or less TIR 0 10 mm 0 0039 in Connecting rod bend under 0 05 100 mm 0 002 3 94 in 0 2 100 mm 0 008 3 94 in Connecting rod twist under 0 15 100 mm 0 006 3 94 in 0 2 100 mm 0 008 3 94 in Crankshaft main journal bearing 0 025 0 052 mm clearance 0 001 0 002 in Crankshaft main journal diameter 37 989 38 000 mm 37 97 mm 1 4949 in 1 4956 1 4961 in Crankcase main bearing bore diameter 38 025 38 041 mm 38 07 mm 1 4988 in 1 4970 1 4977 in Transmission Shift fork ear thickness 5 9 6 0 mm 0 2322 0 2362 in 5 8 mm 0 228 in Shifter grooove width 6 05 6 15 mm 0 2382 0 2421 in 6 25 mm 0 2460 in Special Tools Outside Circlip Pliers 57001 144 Bearing Driver Set 57001 1129 Oil Seal Driver 57001 1517 Sealant Kawasaki Bond Liquid Gasket
213. move the front end B from the front final gear case e Remove the front propeller shaft from the vehicle Front Propeller Shaft Installation e Wipe any old grease off the splines of the propeller shaft A and the coupling B e Inspect the splines of the propeller shaft and the coupling x If the splines are twisted or damaged in any way replace the parts as needed e Apply molybdenum disulfide grease to all splines e Replace the circlip C with a new one if it is removed e Wipe off any old grease on the splines of the shafts on the output bevel gear and front final gear case e Inspect the O rings on those shafts for damage x If any doubt exists replace the O rings with new ones e Apply molybdenum disulfide grease to the splines of the shafts on the output bevel gear and front final gear case e First install the rear end and then install the front end e Slip the two O ring clamps into the groove on the small rubber boot O ring D Boots E Spring F Spring Seat G Front H HKOSOOOBS2 C Property of www SmallEngineDiscount com Not for Resale FINAL DRIVE 11 21 Front Axle Front Axle Removal e Drain the front final gear case oil see Front Final Gear Case Oil Change in Periodic Maintenance chapter e Remove Front Wheel see Wheels Tires chapter Knuckle Joint Bolt A e Remove the knuckle joint B from the knuckle C e Pull the front axle A in a straight line out of the fro
214. ms and Shafts O Install the rocker shafts A so that the punch marks B facing to the GB camshaft e Tighten LA HA Torque Rocker Shaft Holder Bolts 8 8 N m 0 9 kgf m 78 in Ib Ca a Eh mm LEP er Se Rocker Arm and Shaft Inspection e Inspect the area A on the rocker arm where the cam rubs x If the rocker arm is scored discolored or otherwise damaged replace it Also inspect the camshaft lobes e Inspect the end of the valve clearance adjusting screw B where it contacts the valve stem x If the end of the adjusting screw is mushroomed or damaged in any way or if the screw will not turn smoothly replace it Also inspect the end of the valve stem e Measure the inside diameter C of the rocker arm with a dial bore gauge x lf the rocker arm inside diameter is larger than the service limit replace it Also check the rocker shaft diameter D Rocker Arm Inside Diameter Standard 13 000 13 018 mm 0 5118 0 5125 in Service Limit 13 05 mm 0 514 in e Measure the diameter of the rocker shaft where the rocker arm pivots on it with a micrometer x If the rocker shaft diameter is smaller than the service limit replace it Rocker Shaft Diameter Standard 12 973 12 984 mm 0 5107 0 5112 in Service Limit 12 95 mm 0 510 in Property of www SmallEngineDiscount com Not for Resale 4 14 ENGINE TOP END Camshaft Camshaft Removal e Remove Camshaft Sproc
215. n Property of www SmallEngineDiscount com Not for Resale FUEL SYSTEM 3 19 Air Cleaner Air Cleaner Element Removal e Remove Seat see Frame chapter Snaps A Air Cleaner Cover B e Pull the rear end A of the air cleaner element assembly B to the upper and rear and take it out of the air cleaner housing C e After removing the element stuff pieces of lint free clean cloth into the air cleaner duct to keep dirt out of the carburetor and engine AWARNING 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 engine wear and HCO7GO1BS1 possibly engine damage will occur e Remove Stopper A Element B Air Cleaner Element Installation e Apply grease Outside of Blue Urethane A Inside of Grommet B HCO7B012 P e Install the following parts on the metal net A Element B Stopper C Property of www SmallEngineDiscount com Not for Resale 3 20 FUEL SYSTEM Air Cleaner e Insert the blue urethane A into the air cleaner housing and push the stopper B until it is bottomed Air Cleaner Element Cleaning and Inspection e Refer to Air Cleaner Element Cleaing and Inspection in Periodic Maintenance chapter Air Cleaner Draining e Refer to Air Cleaner Draining in Periodic Maintenance chapter
216. n above the bottom edge of the carburetor body Fuel Level Adjustment e Remove the carburetor e Drain the carburetor e Remove the float see Carburetor Disassembly 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 0 2 mm 0 67 0 08 in Float Bowl Mating Surface A A Float Valve Needle Rod contacted but unloaded B Float C Float Height D la x If the fuel level cannot be adjusted by this method the float or the B Mi float valve is damaged e Assemble the carburetor install it on the vehicle and recheck the fuel C level Fuel System Cleanliness Inspection e Refer to Fuel System Cleanliness Inspection in Periodic Maintenance chapter Property of www SmallEngineDiscount com Not for Resale FUEL SYSTEM 3 13 Carburetor Carburetor Removal AWARNING Gasoline is extremely flammable and can be explosive 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 Fuel Tank see Fuel Tank Removal Screw A and Washer Throttle Cable Pulley Cover B Throttle Cable Lower End C Carburetor Heater Lead and Ground Lead Connectors e Loosen the clamp screws
217. n t take shortcuts e Remember to keep complete records of maintenance and repair with dates and any new parts installed How to Use This Manual In this manual the product is divided into its major sys tems 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 chap ter in turn has its own comprehensive Table of Contents For example if you want ignition coil information use the Quick Reference Guide to locate the Electrical System chapter Then use the Table of Contents on the first page of the chapter to find the Ignition Coil section Whenever you see these WARNING and CAUTION symbols heed their instructions Always follow safe operating and maintenance practices This warning symbol identifies special instruc tions or procedures which if not correctly fol lowed could result in personal injury or loss of life CAUTION This caution symbol identifies special instruc tions or procedures which if not strictly ob served could result in damage 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 information NOTE O This note symbol indicates points of particular in terest for more efficient and convenient operation e Indicates a procedural step or work to be done O Indicates
218. n gaps D at the front after tightening HNOGGO3BS1 C Property of www SmallEngineDiscount com Not for Resale 14 12 STEERING Handlebar e Install the left switch housing C on the handlebar B so that the opening angle is 40 A or less NOTE O Do not open the housing more than 40 the built in parts in the housing may be damaged e Install Left Switch Housing A Rear Brake Lever Assembly B C 3 mm 0 12 in HNO06005BS1 Property of www SmallEngineDiscount com Not for Resale FRAME 15 1 Frame Table of Contents EXPIOIEA Vi E E E ii 15 2 SpecitcalonS euclidiana oia E acid ciri n 15 8 R eR Pe PO ee 15 9 Seat REMOVAL A EAEE EE AEAEE A EAE O isaeacchaedesiessecd lacedbic oat E 15 9 Seat Installation aii daba 15 9 E A A E 15 10 Front CartierRemovalscs isis lidia 15 10 Front Carrier Installatio M ia ia 15 10 Rear GarrieriRemovalt utrisin ii iiiid 15 10 Rear Carrier Installation ooooonccccnnnnnanananananonononononononcnnnnnno nono nnnnnnnnnnnnnn cnn nnnnnn nn nro rn nn cnn nn nn nn nana n anno n o rana nnnnnnnnnnnnnn 15 10 REE NR 15 12 Front Fender R MOvVal ccccccccccceccccssssssseeeeececceeeceeeaneesensssessececeeceececeseaeaaenssssseeeececeseeeeseueanagsnsesseceeceeeeeeeteeeaaaaeaes 15 12 Front Fender Instala ii cas biota 15 12 Rear Fender REMOval cccccccccccssssssssssseseccceccccccenseeeeeeesss
219. n in order to perform maintenance 2 Tampering could include a Maladjustment of vehicle components such that the emission standards are exceeded b Use of replacement parts or accessories which adversely affect the performance or durability of the vehicle c Addition of components or accessories that result in the vehicle exceeding the standards 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 Property of www SmallEngineDiscount com Not for Resale PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM US MODEL only To minimize the noise emissions from this product Kawasaki has equipped it with effective intake and exhaust silencing systems They are designed to give optimum performance while maintaining a low noise level Please do not remove these systems or alter them in any which results in an increase in noise level Property of www SmallEngineDiscount com Not for Resale Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop However it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work A basic knowledge of mechanics the proper use of tools and w
220. ncnnn oo 12 15 Brake Pad Wear Inspection 12 15 Brake DISCS ooocooncoccccconococonccononcconcnnnnnccnnnnnnnncnnnannns 12 16 Disc Cl anih comia ida 12 16 Disc ReMoOValcooooocccccnnocccccconnonccnncnnnanccncnnnnnncnnos 12 16 Disc Installation oooonnoocccnnnnnicicnnonacoccccnnncncccnnn 12 16 DISC WEAN ease arnie elenini 12 16 Disc RUNQUtacoccccinnoccccnnnncccnnncnnnnncnnnnnnencnnnannnnnos 12 16 Brake POSES cuicos 12 17 Brake Hose Inspection 12 17 Brake Hose Replacement ceeeeeeeeees 12 17 Rear Brake Lever Pedal and Cables 12 18 Brake Pedal Position Inspection 12 18 Brake Pedal Position Adjustment 12 18 Rear Brake Lever Free Play Inspection 12 18 Brake Pedal Free Play Inspection 12 18 Rear Brake Lever and Pedal Free Play Adjust MEn scott arias adn Brake Pedal Removal oooocccconnoccccccccccccccnccnnnncos Brake Pedal Installation Brake Cable RemoVal ooooooincconnccnocicocicoccconccnn Brake Cable Installation Brake Cable LubricatiON ooooocncccnnnnncnncnnn 12 19 Internal Wet Brake oooooncocccccnnnccccccccnnonccncconnanccnnnns 12 20 Internal Wet Brake Disassembly 12 20 Internal Wet Brake Assembly 12 21 Property of www SmallEngineDiscount com Not for Resale 12 2 BRAKES Exploded View Ni ie W HL02004BW 5 C Property of www SmallEngineDiscount com Not
221. ncnnos 16 21 Regulator Rectifier Inspection 16 22 Ignition SYStOM ceeeeeceeeeeeeneeeneeeeeeteeeeeeeeneetees 16 25 Spark Plug REMOoval cceeceeeeeeeeeeeteees 16 25 Spark Plug Installati0M oooonnoonninnnninnnnno 16 25 Spark Plug Cleaning Inspection 16 25 Spark Plug Gap Inspection eee 16 25 Ignition Coil Removal ccceceeeeeeeeeeeeeneees 16 26 Ignition Coil Installati0N ooooonionnnnnnnninnnonnc 16 26 Ignition Coil Inspection 0 0 eeeeeeeeeeeeeeeeees 16 26 Ignition Coil Primary Peak Voltage Inspection 16 27 Pickup Coil Removal c ccecceeeeeeteeeeeeneees 16 27 Pickup Coil InstallatiON oonnoonnnnnnnnninnnnnnno 16 28 Pickup Coil Inspection cceeceeeeeeeeereeeees 16 28 Pickup Coil Peak Voltage Inspection 16 28 Alternator Rotor Inspection seee 16 29 Ignition Timing Test 16 29 Electric Starter SysteM ooooccococinccnoconocccoonnnnccnancninos 16 32 Starter Motor ReMoVal ccoonncinnccnnconnncccccccnccncs 16 32 Starter Motor InstallatiON oonnoonnnnnnnnnnnon 16 32 Starter Motor Disassembly cceceeeeee 16 32 Starter Motor ASSEMDIy ccceeeeeeeeeeetees 16 33 Commutator Cleaning Inspection 16 34 Armature Inspection s e 16 35 Starter Motor Brush Length 16 35 Brush Assembly Inspection 16 35 Brush Plate and Terminal Bolt Inspection 16 35 Starter Relay Inspection
222. ncorrect Oil cooler clogged Oil cooler fan switch trouble Fan motor broken Fan blade damaged Converter Operation Faulty Belt slipping Belt dirty worn or wetted Drive or driven pulley sheave dirty or worn Drive pulley spring broken or weak Converter engagement speed too low Drive pulley spring broken or weak Converter engagement speed too high Belt dirty or worn Drive or driven pulley sheave dirty or worn Drive pulley weight doesn t move smoothly Drive pulley movable sheave doesn t move smoothly Drive or driven pulley movable sheave bush worn Drive pulley weight or roller worn Shifting too quickly Drive pulley spring weak Driven pulley spring weak or incorrectly installed too loose Shifting too slowly Belt dirty or worn Drive or driven pulley sheave dirty or worn Drive pulley weight doesn t move smoothly Drive pulley movable sheave doesn t move smoothly Drive pulley spring incorrect installed too tight Driven pulley movable sheave doesn t move smoothly Gear Shifting Faulty Doesn t go into gear Shift arm bent or seized Gear stuck on the shaft Shift tie rod maladjusted Shift tie rod damaged Jumps out of gear Shifter groove worn Gear dogs worn Shift block worn Shift arm positioning bolt spring weak or broken Shift tie rod maladjusted Drive shaft output shaft and or gear splines worn Overshifts Shift arm positioning bolt spring weak or broken Shift tie rod maladjusted Property of www SmallEngineDiscount com Not f
223. nd Hose Routing section in Appendix chapter Electrolyte Level Inspection e The electrolyte level should be between the upper and lower level lines A x If the level of electrolyte in any cell is below the lower level line add only distilled water to the cell until the level is at the upper level line CAUTION Ordinary tap water is not a substitute for distilled water and will shorten the life of the battery Electrolyte Specific Gravity Inspection e Check battery condition by testing the specific gravity of the electrolyte in each cell with a hydrometer O Read the level of the electrolyte A on the floating scale x lf the specific gravity is below 1 200 the battery needs to be charged NOTE O The specific gravity of the electrolyte varies with changes in temperature so the specific gravity reading must be corrected for the temperature of the electrolyte O Celsius Add 0 007 points to reading for each 10 C above 20 C or subtract 0 007 points for each 10 C below 20 C O Fahrenheit Add 0 004 points to reading for each 10 F above 68 F or subtract 0 004 points for each 10 F below 68 F x If the specific gravity of any of the cells is more than 0 050 away from any other reading the battery will probably not accept a charge It is generally best to replace a battery in this condition If the specific gravity of all the cells is 1 270 or more the battery is fully charged Pr
224. nd slowly remove the spring compressor e Be sure the keepers stay in place holding the retainer down e Repeat the procedure for the other valve e Install the removed parts to the cylinder head e Install the cylinder head see Cylinder Head Installation e Adjust the valve clearance see Valve Clearance Inspection HE13007BS2 C Valve Visual Inspection e Inspect the valve head seating area A for erosion nicks and warpage x If the valve head seating area is warped replace the valve x If the valve head seating area is eroded or nicked it may be possible O to repair the valve on a valve refacing machine e Inspect the stem B for obvious wear discoloration and stem end C damage x If the stem is obviously worn or discolored replace the valve x If the stem end is damaged it may be possible to repair it on a valve refacing machine 0 Valve Guide Removal e Remove Valve see Valve Removal Valve Stem Oil Seal e Heat the area around the guide to 120 to 150 C 250 to 302 F and hammer lightly on the valve guide arbor A to remove the guide from the top of the head Special Tool Valve Guide Arbor 7 57001 163 Valve Guide Installation e Clean the valve guide hole in the cylinder head e Lightly oil the valve guide e Set the snap ring into the groove in the valve guide e Heat the cylinder head around the valve guide hole to 120 to 150 C 250 to 300 F e Use the valve
225. nder Head Bolts M11 B Cylinder Head HE12000BS1 Cylinder Head Installation e Install Dowel Pins A New Cylinder Head Gasket B e Be sure the camshaft chain guides are in place see Camshaft Chain Guide Installation e Apply molybdenum disulfide oil to the M11 bolt threads and both sides of the washers e Tighten the cylinder head bolts 1 7 following the tightening se quence as shown 1 4 L 220 mm 8 7 in 2 3 L 245 mm 9 6 in Torque First Cylinder Head Bolts M11 1 4 25 N m 2 5 kgf m 18 ft Ib Torque Final Cylinder Head Bolts M11 1 4 44 N m 4 5 kgf m 33 ft Ib Torque Cylinder Head Bolts M6 5 7 12 N m 1 2 kgf m 104 ft Ib HE12001BS1 Property of www SmallEngineDiscount com Not for Resale ENGINE TOP END 4 19 Cylinder Head Cylinder Head Assembly e Insert the rubber dampers A in the fin grooves B Left Side C Right Side D Rear Side E 73 mm 2 87 in F 57 mm 2 24 in G 15 mm 0 59 in e Fit the groove A in the carburetor holder B on the projection C of the cylinder head Cylinder Head Cleaning e Remove the cylinder head see Cylinder Head Removal e Scrape the carbon out of the combustion chamber and exhaust port with a suitable tool e Wash the head with a high flash point solvent DI YI DAI 2 L PASCU is i a 74 A lw HE12002B53 G HE120
226. ne gain speed without causing misfire No Turn OFF the ignition switch and do the drive belt failure mode memory clearing procedure And then turn ON the ignition switch Inspect Has the LED Indicator stopped flashing and retumed to Belt Failure Detection Switch normal mode Also is the 4WD indicator light off LED Indicator Yes Start the engine When the throttle is open can the engine gain speed in good order Yes Reverse Switch Drive Belt Failure Detection System is no problem If 2WD 4WD change over the actuator keeps making a sound try move the vehicle back and forth a little This will help the actuator disconnect the drive train Property of www SmallEngineDiscount com Not for Resale 16 66 ELECTRICAL SYSTEM Drive Belt Failure Detection System Drive Belt Failure Detection System Circuit 0 E i 4 Je He No E x gt lt Ne e La gt m a 30m Lom o os m m i x gt gt o N S Xx lt peers E Je x E a gt Oo m m o BK Y _KE BK Y a gt gt gt gt gt p gt e gt se C7 ADOS S gt o dai a ao oom m o a HP24008BW3 C 1 2WD 4WD Actuator 7 Actuator Controller 2 LED Indicator 8 Igniter 3 Drive Belt Failure Detecting Switch 9 Ignition Coil 4 Drive Belt Failure Detecting Switch Fuse 5A 10 Spark Plug 5 Ignition Switch 11 Battery 6 Main Fuse 30
227. ne oil see Engine Oil Change e Remove Front Inner Covers see Frame chapter Left Side Cover see Frame chapter e Loosen the oil pipe joint nuts A and remove the oil pipes from the oil cooler B e Remove Oil Hose Banjo Bolts C Oil Hoses D HG609001B52 C Oil Hose Installation e Apply grease to the O rings E on the oil pipe joint and insert them into the oil cooler e Rout the oil hoses according to Cable Wire and Hose Routing section in Appendix chapter e When installing the oil hose avoid sharp bending kinking flattening or twisting and route the oil hose with a minimum of bending so that the oil flow will not be obstructed e Tighten Torque Oil Pipe Joint Nuts 29 N m 3 0 kgf m 22 ft Ib e Install the rear ends of the oil hoses A on the crankcase as shown B 3 C 6 e Replace the washers on each side of the banjo bolt D with new ones e Tighten Torque Oil Hose Banjo Bolts 29 N m 3 0 kgf m 22 ft Ib ir LAN DON At EA HG09000BS1 Property of www SmallEngineDiscount com Not for Resale ENGINE LUBRICATION SYSTEM 7 13 Oil Cooler Oil Cooler Removal AWARNING The oil cooler fan is connected directly to the battery The oil cooler fan may start even if the ignition switch is off NEVER TOUCH THE OIL COOLER FAN UNTIL THE OIL COOLER FAN CONNECTOR IS DISCONNECTED TOUCHING THE FAN BE FORE THE CONNECTOR IS DISCONNECTED COULD CAUSE IN
228. new brake fluid e Change the brake fluid as follows O Open the bleed valve A O Apply the brake lever and hold it B O Close the bleed valve C O Release the brake lever D e Check the fluid level in the reservoir often replenishing it as neces sary NOTE O If the fluid in the reservoir runs completely out any time during fluid changing air will enter the line and the system must be bled NN e Repeat this operation until fresh brake fluid comes out into the plastic hose or the color of the fluid changes dA WARNING Do not mix two brands of fluid 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 reservoir are not known e Tighten Torque Bleed Valves 5 9 N m 0 6 kgf m 52 in Ib e Install the front wheels see Wheels Tires chapter e Apply the brake lever forcefully for a few seconds and check for fluid leakage around the fittings dA WARNING If the brake lever has a soft or spongy feeling when it is applied there might be air in the brake line or the brake may be defective Since it is dangerous to operate the vehicle under such conditions bleed the air from the brake line immediately Brake Master Cylinder Piston Assembly and Dust Seal Replace ment e Refer to Master Cylinder section in Brakes chapter for Brake Master Cylinder Cup and Dust Seal Replacement Prope
229. ng A in the collar B is in good condition e Apply grease to the O ring e Install the collar on the alternator cover HPOSGO3BS1 e Hold the drive pulley with the drive pulley holder A Special Tool Drive Pulley Holder 57001 1520 e Install the pulley A so that the holes of the pulley fit on the pins B of the collar e Tighten Torque Alternator Rotor Bolt C 127 N m 13 kgf m 94 ft lb e Add engine oil Alternator Rotor Removal e Remove Alternator Cover see Alternator Cover Removal Ball Bearing A Property of www SmallEngineDiscount com Not for Resale 16 20 ELECTRICAL SYSTEM Charging System e Thread the flywheel puller A onto the alternator rotor Special Tool Flywheel Puller 57001 1405 e Holding the flywheel puller turn the rotor puller until the alternator rotor is forced off the end of the crankshaft CAUTION If the rotor is difficult to remove turn the puller while tapping the end of the puller Do not strike the alternator rotor Striking the rotor can cause the magnets to lose magnetism Alternator Rotor Installation e Apply a thin coat of molybdenum disulfide grease to the crankshaft A e Install the starter clutch gear B HPOSGO2BS1 e Clean A the inside of the rotor and the end of the crankshaft e Fit the rotor onto the crankshaft so that woodruff key B fits in the groove C in the hub of the ro
230. ng from the case O Pull the throttle control lever F out of the case Throttle Case Assembly Installation e Lubricate the throttle case and cable before assembly installation e Be certain that the return spring is correctly installed on the throttle lever A Property of www SmallEngineDiscount com Not for Resale 3 8 FUEL SYSTEM Throttle Lever and Cable e Swing the throttle control lever so that the carburetor throttle valve is fully open Turn the throttle limiter screw A until it is spaced about 1 mm 0 04 in B away from the throttle lever stop C Tighten the locknut D NOTE O Refer to the Owner s Manual for the function of the throttle limiter and adjustment procedure of it AWARNING Operation with an improperly assembled throttle case could result in an unsafe riding condition e Check the throttle lever free play see Throttle Lever Free Play Inspection in Periodic Maintenance chapter Throttle Cable Installation e Lubricate the throttle cable before installation e Route the cable correctly according to Appendix chapter AAWARNING Operation with an improperly adjusted incorrectly routed or damaged cable could result in an unsafe riding condition e Check the throttle cable see Throttle Lever Free Play Inspection in Periodic Maintenance chapter Throttle Case Inspection y e With the throttle cable disconnected from the throttle lever the lev
231. ning Light Switch INSpectiON oonnccnccnnnnnnnnnncnnconnconnccnnrcnancnnncnrarnnno 7 14 OI GOGlER MSP SCHON sia ii Ena 7 14 Property of www SmallEngineDiscount com Not for Resale 7 2 ENGINE LUBRICATION SYSTEM Exploded View A x i PA O x IND SOT Sh Me 0 OH AN NS AA HG02001BW5 C Property of www SmallEngineDiscount com Not for Resale ENGINE LUBRICATION SYSTEM 7 3 Exploded View EE 4 5 6 7 8 9 Oil Temperature Warning Light Switch Oil Hose Banjo Bolts Oil Pipe Bolts 78 in lb Oil Filter 13 Oil Filter Mounting Bolt 18 Oil Pressure Relief Valve 11 10 Oil Pressure Switch 11 Oil Pump Cover Screws Oil Pump Cover Bolt 12 Oil Line Plugs Engine Drain Plug Oil Pressure Switch Terminal Bolt G Apply grease for oil seal and O ring L Apply a non permanent locking agent O Apply engine oil SS Apply silicone sealant Kawasaki Bond 56019 120 R Replacement Parts Property of www SmallEngineDiscount com Not for Resale 7 4 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil Type API SF or SG API SH or SJ with JASO MA Viscosity SAE 10W 40 Capacity 1 50 L 1 59 US at when filter is not removed 1 74 L 1 84 US at when filter is removed 2 3 L 2 43 US at when engine is completely dry Oil Pressure Measurement Oil Pressure 4500 r min rpm oil temp 12
232. ns 1 gear shim s by 0 1 mm 0 004 in to correct the pattern shown below Repeat in 0 1 mm 0 004 in steps if necessary Bortom Ad Heel Top To Bottom To e Drive Gear Bottom Toe Top Bottom e Heel Driven Gear HK16003552 C Property of www SmallEngineDiscount com Not for Resale FINAL DRIVE 11 19 Output Bevel Gears Example 2 Increase the thickness of the drive bevel gear shim s by 0 1 mm 0 004 in and or decrease the thickness of the driven bevel gear shim s by 0 1 mm 0 004 in to correct the pattern shown below Repeat in 0 1 mm 0 004 in steps if necessary Bevel Gears Inspection e Visually check the bevel gears A for scoring chipping or other damage x Replace the bevel gears as a set if either gear is damaged Cam Damper Inspection e Visually inspect Bevel Gear Cam A Cam Follower B Spring C Shaft D x Replace any part if it appears damaged Incorrect Tooth Contact Patterns 2 Bottom Top gt Toe 0 Drive Gear Bo Heel Heel me Toe oe Top Bottom Heel A Driven Gear HK16003652 C HK16003951 Property of www SmallEngineDiscount com Not for Resale 11 20 FINAL DRIVE Front Propeller Shaft Front Propeller Shaft Removal e Slip the O ring clamps off the grooves on the small rubber boots A and then pull the boot e Push the front propeller shaft A rearward and re
233. nt Dent Scratch Wear Color change Deterioration Seizure 20 Specifications Specification terms are defined as follows Standards show dimensions or performances which brand new parts or systems have Service Limits indicate the usable limits If the measurement shows excessive wear or deteriorated performance replace the damaged parts Property of www SmallEngineDiscount com Not for Resale 1 4 GENERAL INFORMATION Model Identification KVF360 A1 HBO3B004 P Property of www SmallEngineDiscount com Not for Resale GENERAL INFORMATION 1 5 Model Identification KVF360 A1 HB03B005 P Property of www SmallEngineDiscount com Not for Resale 1 6 GENERAL INFORMATION General Specifications Items Dimensions Overall length Overall width Overall height Wheelbase Ground clearance Rear final gear case Center of frame Seat height Dry mass Curb mass Front KVF360 A1 2065 mm 81 30 in 1205 mm 47 44 in 1175 mm 46 26 in 1250 mm 49 21 in 195 mm 7 68 in 250 mm 9 84 in 890 mm 35 04 in 274 kg 604 Ib US 272 5 kg 601 Ib 154 kg 340 Ib US 153 kg 337 Ib Rear 135 kg 298 Ib US 134 kg 295 Ib Fuel tank capacity 13 5 L 3 6 US gal Performance Minimum turning radius 3 1 m 10 17 ft Engine Type 4 stroke SOHC 1 cylinder Cooling system Bore and stroke Displacement Compression ratio Maximum horsepower Maximum torque Carburet
234. nt brush If painted too thickly the exact tooth pattern Bottom Toe Drive Gear Bottom may not appear Heel N O The checking compound must be smooth and firm with the consistency of tooth paste O Special compounds are available from automotive supply stores for A p Bottom the purpose of checking differential gear tooth patterns and contact Use this for checking the bevel gears e Turn the output driven shaft for 3 or 4 turns in the drive and reverse coast directions while creating a drag on the drive bevel gear shaft e Check the drive pattern and coast pattern of the bevel gear teeth The tooth contact patterns of both drive and coast sides should be centrally located between the top and bottom of the tooth and a little closer to the toe of the tooth If the tooth contact pattern is incorrect replace the shim s at the i Dri 6 drive bevel gear and shim s at the driven bevel gear following the riven ear unisoosas2 c examples shown Then erase the tooth contact patterns and check them again Also check the backlash every time the shims are replaced Repeat the shim change procedure as necessary NOTE O If the backlash is out of the standard range after changing shims correct the backlash before checking the tooth contact pattern Example 1 Decrease the thickness of the drive bevel gear shim s by Incorrect Tooth Contact 0 1 mm 0 004 in and or increase the thickness of the driven bevel Patter
235. nt final gear case Front Axle Installation e Wipe the old grease off the splines of the axle and the gear case oil seal e Visually inspect the splines of the axle x If they are badly worn or chipped replace the axle with a new one e Apply molybdenum disulfide grease to the axle splines e Apply grease to the gear case oil seal e Insert the left axle so that the teeth A fit in the grooves B e Tap A the end of the front axle lightly and install the front axle NOTE O The axle shaft must not come off easily HKTOBO05 P Front Axle Joint Boot Inspection e Refer to Joint Boots Inspection in Periodic Maintenance chapter Property of www SmallEngineDiscount com Not for Resale 11 22 FINAL DRIVE Front Axle Front Axle Joint Boot Replacement NOTE O Only the inboard joint can be disassembled so replacement of either the inboard or outboard joint boots always begins at the inboard end Inboard Joint Boot Removal e Remove the front axle see Front Axle Removal e Remove the boot bands A of inside joint boot O Scrap the removed boot bands Slide the joint boot towards the center B of the axle e Remove the retaining ring A e Separate to the axle shaft e Remove Circlip A Ball Bearing B Inside Joint Boot C Outboard Joint Boot Replacement NOTE O If inspections of the outboard joint and boot reveal no probels do not remove the outboard boot M
236. ntrol Shift Shaft Lever Bolt 8 8 78 in lb Di Front Final Gear Case Left Cover Bolts M6 9 8 87 in lb S L 4 Ring Gear Bolts 42 1 0 57 LB Front Final Gear Case Center Cover Bolts M6 9 8 87 in lb L S Oil Filler Cap 29 A 22 Front Final Gear Case Center Cover Bolts M8 24 17 L S Pinion Gear Bearing Holder Nut 94 St Pinion Gear Bearing Holder 101 L Front Final Gear Case Coupling Nut 20 14 10 Oil Drain Plug 24 17 2WD 4WD Actuator Mounting Bolts 9 8 87 in lb oINI DJAJA 1 Variable Differential Control Cable Locknut 1 2 7 f 12 5 2 z 1 Front Final Gear Case Bolts and Nuts 4 Apply grease for oil seal and O ring L Apply a non permanent locking agent M Apply molybdenum disulfide grease O Apply engine oil LB Apply a non permanent locking agent Three Bond TB2471 Blue S Follow the specific tightening sequence St Stake the fasteners to prevent loosening Property of www SmallEngineDiscount com Not for Resale 11 6 FINAL DRIVE Exploded View Property of www SmallEngineDiscount com Not for Resale FINAL DRIVE 11 7 Exploded View Oil Filler Cap Oil Drain Plug Pinion Gear Bearing Holder 4 Pinion Gear Bearing Holder Nut 157 16 116 L 5 Trailer Hitch Btacket Bolts M10 49 5 0 36 L 6 Rear Final Gear Case Bolts 42 4 3 31 S 7 Rear Final Gear Case Right Cover Bolts M8 24 2 4 17 L 8 Rear Final Gear Case Right Cover Bolts M10
237. oat in place with the tang hooked into the needle hanger B e Slip the float pivot pin through the pivot posts and the float as shown AWARNING If the float is improperly installed the specified fuel level cannot be maintained Fuel spilled from the carburetor is hazardous e Set the float height as specified HC06B025 P Property of www SmallEngineDiscount com Not for Resale 3 16 FUEL SYSTEM Carburetor e Insert the jet needle A into the hole in the center of the vacuum piston B and place the spring seat C over the needle HCO6004B51 e Slip the needle through the hole in the center of the vacuum piston and put the spring seat A on the top of the needle Turn the seat so that it does not block the hole B at the bottom of the vacuum piston e After installing the upper chamber cover check that the vacuum piston slides up and down smoothly without binding in the carburetor bore Carburetor Cleaning AWARNING Clean the carburetor in a well ventilated area and take care that there is no spark or flame anywhere near the working area this includes any appliance with a pilot light Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents to clean the carburetor A fire or explosion could result CAUTION Do not use compressed air on an assembled carburetor the float may be crushed by the pressure and the vacuum piston diap
238. om Guard Installati0O oonoonnnicinndinncnnnnnnonnconncannccnnrcnn carac r rra rr 15 18 Rear Bottom Guard RemoVal oooooooococccccccncncnnnnonanananancnonononnnonononononnnnnnnnnononnnnnnnnnncnnnnnnnnnnnn Aa aadete a ianiai ania 15 18 Rear Bottom Guard InstallatiON ooonnncnocccuucunocnananononanananananononnnnnnnononononnnnnnnno non nnnnnnnnnnnn nn nana n ana nro rn EEEE E nErenn enen 15 18 Flaps and FootboardS eirean e SL eR ee 15 19 Front Flap Removals ar eE Ie RA 15 19 Front Flap Installation tit a eae a R 15 19 Rear Flap Removals siteon diia 15 19 Rear Flap Instala r a r aE r eaaa EAA EE a EE A SEa EEE E EEA 15 19 Footboard REMOVAl ect diia ici 15 19 Footboard INStallation cssssssssecceccecceeceeeccaeeeesesssesecceeeeecceeseceauauesssessececeeeeceeeeeeeeaaeasnsssseseeceeeeeeeeeeeauanageasesseeess 15 20 Trailer Hitch Brack E A E 15 21 Trailer Hitch Bracket REMOValI ssscccccceeceececeeaseesessseseececeeeeececeeeeeaaaesssssseeceeeeeceeeseaeauansusesseceeceeseeseneetenaaeans 15 21 Trailer Hitch Bracket INStallation cccccccccecccecececcseessssseeceeeceeceeeeeeecaueasessssesecceeeeeeeeeesauaaaaeessesseceeeeeseeeeeeeeeaaagens 15 21 Property of www SmallEngineDiscount com Not for Resale 15 2 FRAME Exploded View Property of www SmallEngineDiscount com Not for Resale FRAME 15 3 Exploded View No Fastener Remarks 1 Front Carrier Bots oo
239. on Standard 20 27 mm 0 79 1 06 in If the belt deflection is not within the specified range first measure the drive belt width see Drive Belt Inspection Adjust the deflection by adding or removing spacers on the fixed sheave HsosoooRs1 e When adjusting the deflection less is better than more Less deflection will maintain better performance for more time as the belt width decreases by normal wear which causes the deflection to increase with usage Property of www SmallEngineDiscount com Not for Resale 2 16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Drive Belt Deflection Adjustment e Disassemble the driven pulley see Driven Pulley Disassembly in Converter System chapter x l the belt deflection is more than 27 mm 1 06 in remove the spacers to decrease it O The rule of thumb is 0 1 mm 0 004 in change in spacer thickness equals about 1 3 mm 0 051 in change in belt deflection x If the belt deflection is less than 20 mm 0 79 in add the spacers A to increase it O The rule of thumb is 0 1 mm 0 004 in change in spacer thickness equals about 1 6 mm 0 063 in change in belt deflection Spacers Part No Thickness 92026 1569 0 6 mm 0 024 in 92026 1617 0 8 mm 0 032 in 92026 1565 1 0 mm 0 039 in 92026 1570 1 4 mm 0 055 in e Assemble the driven pulley see Driven Pulley Assembly in Converter System chapter e With the transmission in neutr
240. on pin snap rings A CAUTION Do not reuse snap rings as removal weakens and deforms them They could fall out and score the cylinder wall ME148005 P e Push out the piston pin and remove the piston O If necessary use the piston pin puller assembly A Special Tools Piston Pin Puller Assembly 57001 910 Piston Pin Puller Adapter B 57001 1211 Property of www SmallEngineDiscount com Not for Resale 4 30 ENGINE TOP END Cylinder and Piston e Remove the top and second piston rings A O Spread the ring open with your thumbs O Push up on the opposite side with your fingers e Remove the oil ring upper and lower steel rails e Spread the rail open with your thumbs O Push up on the opposite side with your fingers e Remove the oil ring expander Piston Installation O NOTE O If a new piston is used check piston to cylinder clearance see Piston Cylinder Clearance and use new piston rings O The oil ring rails have no top or bottom e Install the oil ring expander A in the bottom piston ring groove so the ends B butt together e Install the oil ring steel rails one above the expander and one below it O Spread the rail with your thumbs but only enough to fit the rail over the piston O Release the rail into the bottom piston ring groove e Do not mix up the top ring and second ring e Install the second ring A so that the RN mark
241. ont 35 kPa 0 35 kg cm 5 0 psi Rear 35 kPa 0 35 kg cm 5 0 psi e Install the air valve cap e Install the wheel see Wheel Installation e Wipe off the soap and water solution on the tire and dry the tire before operation WARNING Do not operate the vehicle with the water and soap still around the tire beads They will cause tire separation and a hazardous condition may result Tire Inspection e Refer to Tire Inspection in Periodic Maintenance chapter Property of www SmallEngineDiscount com Not for Resale WHEELS TIRES 10 11 Front Hub Front Hub Removal e Remove Cap A Cotter Pin B e Loosen the axle nut C e Remove the wheel see Wheel Removal e Remove the caliper A by taking off the mounting bolts and let the caliper hang free e Remove the axle nut B and pull off the front hub C and brake disc e Separate the brake disc from the front hub Front Hub Installation e Install the brake disc see Brakes chapter e Tighten Torque Front Axle Nuts 196 N m 20 kgf m 145 ft Ib e Insert a new cotter pin A and bend it over the nut B NOTE O When inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle shaft tighten the nut clockwise up to next alignment O It should be within 30 degree O Loosen once and tighten again when the slit goes past the nearest hole Front Hub Disassembly Assembly e Do not press the hub bo
242. oove Width Top Second Standard 1 03 1 05 mm 0 0405 0 0413 in 1 02 1 04 mm 0 0402 0 0409 in Service Limit 1 13 mm 0 0445 in 1 12 mm 0 0441 in x If the width of any of the two grooves is wider than the service limit at any point replace the piston Piston Ring Thickness e Measure the piston ring thickness O Use a micrometer to measure at several points around the ring Piston Ring Thickness Top Second Standard 0 97 0 99 mm 0 0382 0 0390 in 0 97 0 99 mm 0 0382 0 0390 in Service Limit 0 90 mm 0 035 in 0 90 mm 0 035 in x If any of the measurements is less than the service limit on either of the rings replace all the rings NOTE O When using new rings in a used piston check for uneven groove wear The rings should fit perfect parallel to the groove sides If not replace the piston Piston Ring End Gap Measurement e Place the piston ring inside the cylinder using the piston to locate the ring squarely in place Set it close to the bottom of the cylinder where cylinder wear is low e Measure the gap A between the ends of the ring with a thickness gauge where cylinder wear is low Piston Ring End Gap Top Second Oil Standard 0 20 0 30 mm 0 0079 0 0118 in 0 30 0 45 mm 0 0118 0 0177 in 0 20 0 70 mm 0 0079 0 0276 in Service Limit 0 6 mm 0 0236 in 0 8 mm 0 0315 in 1 0 mm 0 0394 in x If the end gap of
243. operty of www SmallEngineDiscount com Not for Resale ELECTRICAL SYSTEM 16 15 Battery Initial Charging dA 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 pre vents sparks at the battery terminals which could ignite any battery gases e Fill each cell to the upper level line on the battery case with fresh electrolyte specific gravity 1 270 at a temperature of 30 C 86 F or less Let the battery stand for about 30 minutes before charging NOTE O If the electrolyte level drops add electrolyte to the upper level line before charging e Set the charging rate at 1 10 the battery capacity and charge it for 10 hours For example if the battery is rated at 14 Ah the charging rate would be 1 4 Ah CAUTION If the battery is not given a full initial charging it will discharge in a few weeks After that it can not be charged by supplemen tal charging Always remove the battery from the vehicle for charging If the battery is charged while still installed battery electrolyte may spill and corrode the frame or other parts of the vehicle Do not use a high rate battery charger as is typically employed at automotive service stations unless the charger rate can be reduced to the level required Charging
244. or C 57001 1476 e Tighten the nuts D and compress the damper spring E e Remove Circlip A Special Tool Circlip Pliers 57001 154 HK160021 P e Remove Circlip A Spring Holder B Spring C Cam Damper D Output Driven Bevel Gear E HK16003051 Property of www SmallEngineDiscount com Not for Resale 11 14 FINAL DRIVE Output Bevel Gears e Hold the housing assembly A with the output shaft holder B amp spacer C in a vise Special Tool Output Shaft Holder amp Spacer 57001 1479 e Remove Oil Seal D e Remove Output Shaft Holder Nut A Special Tool Socket Wrench B 57001 1482 HK160023 P e Hold the housing assembly A with the holder B in a vise Special Tool Holder amp Guide Arbor 57001 1476 e Remove Bearing Holder C Special Tool Socket Wrench D Hex 50 57001 1478 O If the holder seems too difficult to break free apply heat to softer the locking agent e Remove Ball Bearing Special Tool Oil Seal amp Bearing Remover 57001 1058 a HK160024 P Output Driven Bevel Gear Assembly e Press the new ball bearing until it is bottomed Special Tool Bearing Driver Set A 57001 1129 Property of www SmallEngineDiscount com Not for Resale FINAL DRIVE 11 15 Output Bevel Gears e Hold the housing assembly A with the holder B in a vise Special Tool Holder amp Guide Arbor 57001 1476
245. or Resale 17 4 APPENDIX Troubleshooting Guide Abnormal Engine Noise Knocking Igniter trouble Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Overheating Piston Slap Cylinder piston clearance excessive Cylinder piston worn Connecting rod bent Piston pin piston holes worn Valve noise Valve clearance incorrect Valve spring broken or weak Camshaft bearing worn Rocker arm worn Other noise Connecting rod small end clearance excessive Connecting rod big end clearance excessive Piston ring worn broken or stuck Piston seizure damage Cylinder head gasket leaking Exhaust pipe leaking at cylinder head connection Crankshaft runout excessive Engine mounts loose Crankshaft bearing worn Camshaft chain tensioner trouble Camshaft chain sprocket guides worn Balancer bearing worn Balancer gear worn or shipped Loose alternator rotor Abnormal Drive Train Noise Converter noise Belt worn Drive or driven pulley sheave worn Drive or driven pulley movable sheave bush worn Drive or driven pulley mount loose Driven pulley shoe worn Drive pulley weight or roller side washer worn Drive pulley weight or roller worn Wear guides worn Transmission noise Bearing worn Transmission gears worn or chipped Metal chips jammed in gear teeth Engine oil insufficient or too thin Front or rear final gear case noise Insufficient lubricant Incorrect oil Front final gear case Bevel gear bearings worn Bev
246. or less Service Limit TIR 2 mm 0 08 in HK13000551 6 Property of www SmallEngineDiscount com Not for Resale FINAL DRIVE 11 45 Rear Final Gear Case Rear Final Gear Case Oil Level Inspection e Park the vehicle so that it is level both side to side and front to rear e Remove the filler cap CAUTION Be careful not to allow any dirt or foreign materials to enter the gear case e Check the oil level The oil level should come to the bottom of the filler opening A HK148003 P a x lf it is insufficient first check the rear final gear case for oil leakage remedy it if necessary and add oil through the filler opening Use the same type and brand of oil that is already in the final gear case e Apply grease to the O ring e Be sure the O ring is in place Torque Oil Filler Cap 29 N m 3 0 kgf m 22 ft Ib Rear Final Gear Case Oil Change e Refer to Rear Final Gear Case Oil Change in Periodic Maintenance chapter Rear Final Gear Case Removal e Remove Rear Shock Absorber see Suspension chapter Rear Brake Cable Ends A Vent Hose B e Remove Rear Axle A see Rear Axle Removal Rear Final Gear Case Bolts B 10 Rear Final Gear Case C Rear Final Gear Case Installation e Install Rear Axle Shaft A Dowel Pins B New Gasket C see Brake System chapter Spring D e Insert the pinion gear shaft of the rear final gear case in the plate assembly O Align the splines by rot
247. orkshop procedures must be understood in order to carry out maintenance and repair satisfactorily Whenever the owner has insufficient experience or doubts his ability to do the work all adjustments maintenance and repair should be carried out only by qualified mechanics In order to perform the work efficiently and to avoid costly mistakes read the text thoroughly familiarize yourself with the procedures before starting work and then do the work carefully 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 adversely affect safe operation For the duration of the warranty period we rec ommend that all repairs and scheduled maintenance be performed in accordance with this service manual Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty To get the longest life out of your vehicle e Follow the Periodic Maintenance Chart in the Service Manual e Be alert for problems and non scheduled maintenance e Use proper tools and genuine Kawasaki Vehicle parts Special tools gauges and testers that are necessary when servicing Kawasaki vehicles are introduced by the Special Tool Catalog or Manual Genuine parts provided as spare parts are listed in the Parts Catalog e Follow the procedures in this manual carefully Do
248. ount com Not for Resale FINAL DRIVE 11 29 Front Final Gear Case Front Final Gear Case Installation e Install the gear case bolts from the vehicle left side Torque Front Final Gear Case Bolts and Nuts 42 N m 4 3 kgf m 31 ft Ib e Install the removed parts e Fill the front final gear case with the specified oil see Front Final Gear Case Oil Change in Periodic Maintenance chapter Front Final Gear Case Disassembly e Remove Front Final Gear Case see Front Final Gear Case Removal Variable Front Differential Control Shift Shaft Lever Bolt A and Nut B Variable Front Differential Control Shift Shaft Lever C 2WD 4WD Actuator see Electrical System chapter e Hold the front final gear case with the gear holder amp socket wrench A in a vise Special Tool Gear Holder amp Socket Wrench Hex 24 57001 1489 e Remove Front Final Gear Case Coupling Nut A Washer B Front Final Gear Case Coupling C Shifter D Oil Seals E e Remove Front Final Gear Case Left Cover Bolts A Front Final Gear Case Left Cover B Variable Front Differential Control Shift Shaft Spring Property of www SmallEngineDiscount com Not for Resale 11 30 FINAL DRIVE Front Final Gear Case e Remove Outer Disc A Needle Bearing HK110007 P e Remove Housing A and Differential Disc Assembly B Inner Disc Needle Bearing e Remove Cam Plate A e Remove Steel Balls A Gasket
249. ove Bracket Screws A and Bracket Screws B and Collar Front Inner Cover C HOOSBO16 Pi Property of www SmallEngineDiscount com Not for Resale FRAME 15 15 Covers Front Inner Cover Installation e Install Collar A Brackets B Fuel Tank Cover Removal e Remove Seat see Seat Removal Screws A Bolts B Grip C Fuel Tank Cap D Fuel Tank Cover E e Install the fuel tank cap at once Fuel Tank Cover Installation e Insert the tabs A of the cover into the recesses both sides Left Side Cover Removal e Remove Quick Rivets A Screws B Left Side Cover C Exhaust Pipe Cover Removal e Remove Seat see Seat Removal Fuel Tank Cover see Fuel Tank Cover Removal Left Side Cover see Left Side Cover Removal Quick Rivets A Front Left Flap B HOOSGO7BS1 osoo g Property of www SmallEngineDiscount com Not for Resale 15 16 FRAME Covers e Remove Screws A Exhaust Pipe Cover B Property of www SmallEngineDiscount com Not for Resale FRAME 15 17 Guards Front Guard Removal e Remove Front Carrier see Front Carrier Removal Headlight Cover see Headlight Cover Removal Headlight Lead Connector A e Remove Front Guard Bolts A Front Guard B Front Lower Guard Removal e Remove Front Lower Guard Bolts A Front Lower Guard B Front Guards Installation e Install Front Guard A e Tighten
250. ove on to Inboard Joint Boot Assembly e Remove the boot bands of outside joint boot O Scrap the removed boot bands A e The out side joint A cannot be disassembled e Inspect the joint bearing B x If the joint does not move smoothly due to wear or corrosion replace the front axle because the joint bearing is damaged e Inspect whether the axle shaft spline is damaged or not x If there is clear damage or wear on the spline replace the axle shaft e Clean the axle shaft by wiping off the used grease on it A CAUTION Do not clean the boot with the mineral oil or gasoline because they damage the boot Property of www SmallEngineDiscount com Not for Resale FINAL DRIVE 11 23 Front Axle e Wind the tape A on the inside splines of the axle shaft in order to protect the joint boot e Apply the special grease slightly on the inside of the boot small diameter and install the joint boot on the groove of the shaft CAUTION Only the special grease which is included with the boot kit can be applied to the boots e Apply the special grease B slightly on the part of band installation in order to make easy to install the band A e Install the small band first MN WAN A w e Squeese all of the special grease A about 70 grams into the outboard boot B and slide the boot onto the outside joint C e Open the edge A of the boo
251. ove the sprocket from the camshaft and install it again as detailed above e Apply grease to the O ring A and push the cover into place e Tighten Torque Camshaft Cover Bolts 8 8 N m 0 9 kgf m 78 in Ib e Install the timing inspection plug Special Tool Driver Filler Cap 57001 1454 HEO9BO010 P Property of www SmallEngineDiscount com Not for Resale 4 12 ENGINE TOP END Rocker Arms and Shafts Rocker Arm and Shaft Removal e Remove Recoil Starter see Recoil Starter chapter e Position the crankshaft at TDC of the end of the compression stroke see Camshaft Sprocket Installation Rear Side e Remove Fuel Tank see Fuel System chapter Rubber Cover Valve Adjusting Cap Bolts A Valve Adjusting Cap B Rocker Shaft Holder Bolts C Rocker Shaft D Washers e Push the rocker arm A in the rocker case and turn it in place e Remove the rocker arm A Front Side e Remove Right Front Inner Cover see Frame chapter Converter Air Intake Duct Cylinder Head Bolt A Valve Adjusting Cap B Rocker Shaft Holder Bolts C Rocker Shaft D Washers e Remove the rocker arm in the same manner as above HEJOB004 B d Rocker Arm and Shaft Installation e Apply molybdenum disulfide oil to the rocker shaft A e Install Rocker Arm B Washers C Rocker Shaft HE10004BS1 Property of www SmallEngineDiscount com Not for Resale ENGINE TOP END 4 13 Rocker Ar
252. pecified oil see Rear Final Gear Case Oil Change section in Final Drive chapter Property of www SmallEngineDiscount com Not for Resale Property of www SmallEngineDiscount com Not for Resale ELECTRICAL SYSTEM 16 1 Electrical System Table of Contents Pr cautions nilo Exploded Vie W oonoconnccnnnccocccconncncornccnnnnccnnnnnnrnnennns Specifications oooocccinccnonicoccconccoccnnnccnnrncnncnnnncnnnnnn Parts locations Electrical WiriNQ oooooooncccnnnnconocccnnonccnnnrnncnarnnnnn no Wiring INSpectiON oooonnccnnnccinnncnnnncncnananono noo Balloon aaa ias Battery ReMoOVal ooooconnccconnccccnocncnnonnnnancnonancnnnns Battery Installation Electrolyte Level Inspection eee 16 14 Electrolyte Specific Gravity Inspection 16 14 Initial CharginQ ooonconnccnonicnnccnccnnonnnanccanccrnnnnnos 16 15 Ordinary CharginQ ccocconconncnnccnncnnonncanccancnnns 16 16 Battery Test CharginQ ccoooncccncnncnnnccnnccccncnn 16 17 Charging SySteM oooncccnccnnccconiconcconccnnnnnnnccanccnnnnnns 16 18 Alternator Cover Removal 16 18 Alternator Cover Installation 16 18 Alternator Rotor Removal seses 16 19 Alternator Rotor Installation o 16 20 Alternator Stator RemoOVal oooocccnconnccncccccccnns 16 20 Alternator Stator InstallatiOM o n 16 21 Regulator Rectifier Output Voltage Inspection 16 21 Alternator Inspection oooocccioniconocccinacncnnnn
253. phragm CAUTION During carburetor disassembly be careful not to damage the diaphragm Never use a sharp edge to remove the diaphragm O Slide the jet needle D out of the vacuum piston from the bottom It will come out with a spring seat E e Unscrew the pilot screw A and remove it with its spring washer and O ring e Disassemble the carburetor bottom end as follows O Remove Screws B Float Bowl C O Slide out the float pivot pin A remove the float B and drop out the float valve needle with its hanger Property of www SmallEngineDiscount com Not for Resale FUEL SYSTEM 3 15 Carburetor O Remove Main Jet A Air Bleed Pipe B Starter Jet C Pilot Jet D Carburetor Heater E HC06B021 P O Push the needle jet A out from the inside of the carburetor with your finger Carburetor Assembly e Turn the carburetor body upside down and drop the needle jet A into place so that the smaller diameter end B of the jet goes in first e Carefully screw in the air bleed pipe C It will seat against the needle jet pushing the end of the jet into the carburetor bore CAUTION Do not force the air bleed pipe or overtighten it The needle jet or the carburetor body could be damaged requiring replace ment e Apply temperature conductive grease Carburetor Heater A H006B024 P e Drop the float valve needle A into the valve seat and hold the fl
254. placement O Remove any foreign objects from the tread After removal check for leaks with a soap and water solution e Measure the tread depth at the center of the tread with a depth gauge A Since the tire may wear unevenly take measurements at several places If any measurements are less than the service limit replace the tire Tire Tread Depth Service Limit Front 3 mm 0 12 in Rear 4 mm 0 16 in Standard Tire Front AT 25 x 8 12 DUNLOP KT121 Tubeless Rear AT 25 x 10 12 DUNLOP KT405C KT127A Tubeless Property of www SmallEngineDiscount com Not for Resale PERIODIC MAINTENANCE 2 19 Periodic Maintenance Procedures Final Drive Variable Differential Control Lever Position Inspection e Pull the variable differential control lever A towards the handlebar grip B with a spring scale until it reads 30 N 3 kgf 7 lb of force O The clearance C between the control lever and grip should be 20 mm 0 8 in x If the clearance is not within the specified range adjust the cable Differential Control Lever Position Standard 20 mm 0 8 in Variable Differential Control Lever Position Adjustment e Loosen the locknut A of the differential control cable e Turn the adjuster B until the cable has proper amount of play e Tighten the locknut securely Front Final Gear Case Oil Change e Warm up the oil by running the vehicle so that the oil will pick up any sediment and drain easil
255. pring and move the weights back and forth x If the weights do not move easily from the retracted position replace the KACR unit Also inspect the exhaust rocker arm for any damage and replace the rocker arm if necessary A Running Position compression is not released B Weights C Spring HEOSGOGBS1 C Property of www SmallEngineDiscount com Not for Resale 4 16 ENGINE TOP END Camshaft Chain and Guides Camshaft Chain Removal e Remove Camshaft Sprocket see Camshaft Sprocket Removal Starter Clutch Gear see Alternator Rotor Removal section in Electrical System chapter Bolts A and Camshaft Chain Guard B Camshaft Chain C Camshaft Chain Installation CAUTION Always pull the camshaft chain taut while turning the crankshaft when the camshaft chain is loose This avoids kinking the chain on the lower crankshaft sprocket A kinked chain could damage both the chain and the sprocket e Tighten Torque Camshaft Chain Guard Bolts 8 8 N m 0 9 kgf m 78 in Ib Camshaft Chain Guide Removal e Remove Cylinder Head see Cylinder Head Removal Starter Clutch Gear see Alternator Rotor Removal section in Electrical System chapter Front Camshaft Chain Guide A Bolt B and Rear Camshaft Chain Guide C Camshaft Chain Guide Installation e Slip the front camshaft chain guide A into the position B e Install Rear Camshaft Chain Guide C Collar D e Tighten Torque Rear
256. pring seat A and remove the spring seat stopper B e Remove Nuts and Upper Holder Spring Guide A Spring B HMO4B016 HMO4B017 P HMWO4B020 P Property of www SmallEngineDiscount com Not for Resale SUSPENSION 13 7 Shock Absorbers Front Shock Absorber Spring Installation e Set the front shock absorber A into the center of the spacer B and holder C see Front Shock Absorber Spring Removal Special Tools Holder amp Guide Arbor 57001 1476 Spacer 8 Holder 57001 1477 e Install Spring A Spring Guide B e Put the upper holder C 57001 1477 on upper end of the spring guide and arbors D so that the recess side faces downward e Tighten the nuts E and press the spring HMO4B022 P e Install the spring seat stopper A by the reverse of removal e Fit the spring seat stopper under the spring seat A e Remove Nuts B Upper Holder Property of www SmallEngineDiscount com Not for Resale 13 8 SUSPENSION Shock Absorbers Rear Shock Absorber Preload Adjustment The spring adjusting sleeve A on rear shock absorber has 5 positions so that the spring can be adjusted for different terrain and loading conditions If the spring action feels too soft or too stiff adjust it in accordance with the following table Spring Action Force 2 STD l Stronger e Turn the adjusting sleeve on rear shock absorber to the des
257. r BL Y BL Speed BR S I SKYY ensor ooo HA e e a E sL 13 aL Tail Brake a O O O E D E E O REE Bey 8 7 eee a ee ES E RLE R L H tt 8 E PT gt C 9D HA Mai F Accessory aro Tse Connector 30A 4 Forward Reverse Detecting Sensor e z i az gt gt gt ax r gt x gt Pas a ERAS 25 2 2 56335 mz e mm a aa 5a D i i a ax Z A g ES ak a o c 1 oo 1 a Igniter D xve x 18 1 1 8 O lenition Starter Starter Pickup Coil Circuit Circuit Relay Relay Neutral Brake BR 7 Se Oil Pressure Spark 25 osessary Starter Motor i Color Code Switch Plug Fuse 5A a oe BL Blue BR Brown Drive Belt Failure G Green Detecting Switch GY Gray LB Light Blue LG Light Green lenition Switch Connections Color BR GY J Orange OFF P Pink ON R Red W White 98052 7508B Y Yellow W2R7508BW5 C Property of www SmallEngineDiscount com Not for Resale Property of www SmallEngineDiscount com Not for Resale APPENDIX 17 1 Appendix Table of Contents Troubleshooting Guideen eena eanes asin eee ias 17 2 Cable Wire and Hose ROUtINQ cocccnccnnnnnnncnnncnnncnncnnononn cnn nr 17 6 Property of www SmallEngineDiscount com Not for Resale 17 2 APPENDIX Troubleshooting Guide
258. r 5 Main Fuse 30 A 2 Alternator 4 Battery 6 Load Property of www SmallEngineDiscount com Not for Resale ELECTRICAL SYSTEM 16 25 Ignition System dA WARNING The ignition system produces extremely high voltage Do not touch the spark plug ignition coil or spark plug lead while the engine is running or you could receive a severe electrical shock CAUTION Do not disconnect the battery leads or any other electrical connections when the ignition switch is on or while the engine is running This is to prevent igniter damage Do not install the battery backwards The negative side is grounded This is to prevent damage to the diodes and igniter Use the standard regulator rectifier or the igniter will be damaged Spark Plug Removal e Remove Spark Plug Cap A Spark Plug B HP10015BS1 Spark Plug Installation e Tighten Torque Spark Plugs 14 N m 1 4 kgf m 10 ft lb e Fit the spark plug cap securely e Pull up the spark plug cap lightly to make sure of the installation of the spark plug cap Spark Plug Cleaning Inspection e Clean the spark plug preferably in a sandblasting device and then clean off any abrasive particles The plug may also be cleaned using a wire brush or other suitable tool xXx If the spark plug electrodes are corroded or damaged or if the insulator is cracked replace the plug Use the standard spark plug or its equivalent Spark Plug Gap Inspe
259. r Backlash Adjustment The amount of backlash is influenced by driven bevel gear position more than by drive bevel gear position e Remove the output drive idle gear see Output Drive Bevel Gear Removal e Set up a dial gauge A against the output drive shaft spline groove to check gear backlash O To measure the backlash turn the shaft clockwise and counterclock wise slightly so as not to move the mate gear A rod can be inserted through the lower hole of the housing and into contact with driven gear This may help to hold it still The difference between the high est and lowest gauge reading is the amount of backlash x If the backlash is not within the limit replace the shim s at the driven bevel gear x Change the thickness a little at a time e Recheck the backlash and readjust as necessary Output Bevel Gear Backlash Standard 0 06 0 12 mm 0 0024 0 0047 in at output drive shaft spline Property of www SmallEngineDiscount com Not for Resale 11 18 FINAL DRIVE Output Bevel Gears Tooth Contact Adjustment Correct Tooth Contact Patterns O Tooth contact location is influenced by drive gear position more than No adjustment is required by driven gear position e Clean any dirt and oil off the bevel gear teeth Bottom e Apply checking compound to 4 or 5 teeth on the output driven bevel gear NOTE Heel Op Toe O Apply checking compound to the teeth in a thin even coat with a E k fairly stiff pai
260. r Circuit O ess xx PB WR _ lt R L_ wr R gt E mice o 0 Do BL R Y f X BL Y a Wy R BK R ak JE ES Y Y BL Y BL HP26000BW3 C LED Indicator 4WD Mode Indicator LED 4WD Drive Belt Failure Mode Reset Connector Igniter 2WD 4WD Shift Switch Acturator Controller Engine Brake Actuator PADAALPA Property of www SmallEngineDiscount com Not for Resale Drive Belt Failure Indicator LED CHECK BELT 2WD 4WD Actuator Battery Main Fuse 30A Ignition Switch Drive Belt Failure Detecting Switch Fuse 5A Drive Belt Failure Detecting Switch ELECTRICAL SYSTEM 16 53 Actuator Control System 2WD 4WD Actuator Removal e Remove Right Front Inner Cover see Frame chapter Actuator Lead Connector A e Remove Breather Hose A Actuator Mounting Bolts B Actuator C 2WD 4WD Actuator Installation e When installing the pin A install the collar B on the actuator and then press the pin e Visually inspect the collar x If the collar is damaged or worn excessively replace it e Apply grease to the O ring C e Insert the collar into the groove D of the shifter so that the long side E faces downward HP23B011 P e Apply a non permanent locking agent to the actuator mounting bolts and tighten them following the tightening sequence 1 3 Torque 2WD 4WD Actuator
261. r Resale GENERAL INFORMATION 1 9 Special Tools and Sealant Piston Pin Puller Assembly 57001 910 Steering Stem Nut Wrench 57001 1100 Fuel Level Gauge 57001 1017 Valve Seat Cutter 45 641 5 57001 1117 Sa Compression Gauge Adapter M12 x 1 25 57001 1018 Valve Seat Cutter 32 438 5 57001 1122 Oil Pressure Gauge Adapter PT 1 8 57001 1033 Valve Seat Cutter Holder Bar 57001 1128 Oil Seal amp Bearing Remover 57001 1058 Bearing Driver Set 57001 1129 Property of www SmallEngineDiscount com Not for Resale 1 10 GENERAL INFORMATION Special Tools and Sealant Piston Pin Puller Adapter 57001 1211 Carburetor Drain Plug Wrench Hex 3 57001 1269 e FE Jack 57001 1238 Flywheel amp Pulley Holder 57001 1343 Socket Wrench 57001 1363 Timing Light 57001 1241 Flywheel Puller Assembly 57001 1405 Property of www SmallEngineDiscount com Not for Resale GENERAL INFORMATION 1 11 Special Tools and Sealant Drive amp Driven Pulley Holder 57001 1412 Drive Pulley Wrench 57001 1474 ES E ST5714748T C Drive Pulley Puller Bolt 57001 1429 Damper Spring Compressor Set 57001 1475 a ST571475S8T C Filler Cap Driver 57001 1454 Holder amp Guide Arbor
262. r to tables in the Wiring Diagram x If the switch has an open or short repair or replace it with a new one Property of www SmallEngineDiscount com Not for Resale 16 70 ELECTRICAL SYSTEM Switches Neutral Switch Connection When transmission is in neutral oo When transmission is not in neutral MA a A Neutral Switch Reverse Switch Connections MY Y HP148006 P When transmission is in reverse lolo When transmission is not in reverse a a B Reverse Switch 2WD 4WD Shift Switch OOOO er Oil Pressure Switch Connections Engine lubrication system is in good condition Drive Belt Failure Detection Switch If the drive belt failure detection system is activated by abnormal belt the drive belt failure detection switch is damaged Make sure to replace the torque converter cover see Converter System chapter e Remove Torque Converter Cover see Torque Converter Removal section in Converter System BLIW When drive belt failure detection switch is in ON position Oo When drive belt failure detection switch is in OFF position A Drive Belt Failure Detection Switch Property of www SmallEngineDiscount com Not for Resale ELECTRICAL SYSTEM 16 71 Fuses Fuses Removal e Remove Seat see Frame chapter Fuse Cap A Fuse B e Remove Main Fuse 30A A Accessary Fuse 5A B e Remove Oil Cooler Fan Fuse 20A A Drive Belt Failure Det
263. rain Plug 14 Rear Final Gear Case Bolts 31 S Pinion Gear Bearing Holder 101 L Rear Final Gear Case Right Cover Bolts M10 E 36 L Rear Final Gear Case Right Cover Bolts M8 17 L Pinion Gear Bearing Holder Nut 116 L Brakes Reservoir Cap Screws E 13 in lb Bleed Valves 52 in lb Master Cylinder Clamp Bolts 78 in lb Brake Hose Banjo Bolts 18 Brake Lever Pivot Bolt 52 in lb Brake Lever Pivot Bolt Locknut i 52 in lb Caliper Mounting Bolts 18 Caliper Holder Shaft 13 Caliper Holder Shaft Allen Bolt 17 Pad Mounting Bolts E 13 Disc Mounting Bolts 27 L Suspension Front Shock Absorber Clamp Bolts and Nuts 35 Front Shock Absorber Mounting Nuts 54 Rear Shock Absorber Mounting Nuts E 46 Piston Rod Nut y 36 Suspension Arm Pivot Bolts E 65 Swingarm Pivot Right Shaft L Swingarm Pivot Left Shaft 14 Swingarm Pivot Left Nut Steering Steering Stem Bottom End Nut Steering Stem Clamp Bolts Tie Rod End Nuts Steering Knuckle Joint Nuts Front Shock Absorber Clamp Bolts and Nuts Tie Rod Adjusting Sleeve Locknuts Handlebar Lower Holder Nuts L Handlebar Holder Bolts S Frame Rear Carrier Bolts and Nuts Front Carrier Bolts L Front Guard Bolts Trailer Hitch Bracket Bolts M10 5 L Trailer Hitch Bracket Bolts M8 L Property of www SmallEngineDiscount com Not for Resale 2 6 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Footboard Mounting Nu
264. rake Control system works and the engine brake actuator works an error operation NOTE O If the drive belt failure detection system is activated by abnormal belt the drive belt failure detection switch is damaged Make sure to replace the torque converter cover Torque Converter Cover Removal e Turn the ignition switch OFF NOTE O If the drive failure detection switch lead connector is disconnected when the ignition switch is in the ON position the drive Belt Failure Detection System is activated in the drive belt failure mode For resetting the failure mode the drive belt failure mode clearing procedure must be done see LED Indicator section in Electrical System chapter e Disconnect Drive Belt Failure Detection Switch Lead Connector A Engine Brake Actuator Lead Connector B x If the disconnecting is difficult remove the fuel tank cover see Frame chapter e Remove Clamp A Air Duct B Torque Converter Cover Bolts C Torque Converter Cover D Torque Converter Cover Installation e Check the actuator lever assembly installation length see Torque Converter Cover Assembly e Fit the trim seal into the converter cover O Position point A as shown HSO4G07BS1 Property of www SmallEngineDiscount com Not for Resale 5 8 CONVERTER SYSTEM Torque Converter e Check Drive Belt Failure Detection Switch see Switch Inspection section Q in Electric Sys
265. rature Switch A Oil Cooler Fan Switch B HPO4G01BS1 Property of www SmallEngineDiscount com Not for Resale ELECTRICAL SYSTEM 16 13 Electrical Wiring Wiring Inspection e Visually inspect the wiring for signs of burning fraying etc If any wiring is defective replace the damaged wiring e Pull each connector A apart and inspect for corrosion dirt and damage x If the connector is corroded or dirty clean it carefully If it is damaged replace it e Check the wiring for continuity Use the wiring diagram to find the ends of the lead which is suspected of being a problem O Connect the hand tester between the ends of the leads Special Tool Hand Tester 57001 1394 O Set the tester to the x 1 Q range x If the tester does not read 0 the lead is defective Replace the lead or the wiring harness B if necessary Zs HP07000B51 Property of www SmallEngineDiscount com Not for Resale 16 14 ELECTRICAL SYSTEM Battery Battery Removal e Remove Seat see Frame chapter e Disconnect the battery negative cable A first and then the positive cable B e Remove Battery Holder Bolt C Battery Holder D e Take out the battery E Battery Installation e Connect the positive cable first and then the negative cable e Puta light coat of grease on the terminals to prevent corrosion e Route the battery vent hose according to the Cable Wire a
266. re storing Marks Stamped on the Cutter The marks stamped on the back of the cutter A represent the following Oribe Cutter angle B Dimas E EET Outer diameter of cutter C 6E15011851 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 turn it right or left Grind the seating surface only until it is smooth CAUTION Do not grind the seat too much Overgrinding will reduce valve clearance by sinking the valve into the head If the valve sinks too far into the head it will be impossible to adjust the clearance and the cylinder head must be replaced Property of www SmallEngineDiscount com Not for Resale ENGINE TOP END 4 25 Valves Guides Seats Springs Oil Seals Widened Width A of engagement by machining with 45 cutter Ground Volume B by 32 cutter 32 C Correct Width D Ground Volume E by 50 cutter 50 F 6E15011951 e Measure the outside diameter of the seating surface with a vernier caliper x If the outside diameter of the seating surface is too small repeat the 45 grind A until the diameter is within the specified range Original Seating Surface B NOTE O Remove all pittings of flaws from 45 ground surface O After grinding with 45 cutter apply thin coat of machinist
267. reen W White DG Dark green O Orange Y Yellow O Electrical Connectors Female Connectors A Male Connectors B Property of www SmallEngineDiscount com Not for Resale 16 4 ELECTRICAL SYSTEM Exploded View Property of www SmallEngineDiscount com Not for Resale ELECTRICAL SYSTEM 16 5 Exploded View a S 2 Starter Motor Terminal Mat CYC e sere io tena sing es f or Term 4 Starter Motor Bolts 30 in lb 5 Starter Motor Clutch Bolts 34 3 5 25 L 6 Starter Relay Terminal Nuts 4 9 0 5 43 in lb 7 Alternator Stator Bolts 14 1 4 10 8 Pickup Coil Mounting Bolts 5 9 0 6 52 in lb 9 Alternator Cover Bolts 8 8 0 9 78 in lb 10 Alternator Rotor Bolt 127 13 94 G Apply grease for oil seal and O ring L Apply a non permanent locking agent M Apply molybdenum disulfide grease O Apply engine oil R Replacement Parts Property of www SmallEngineDiscount com Not for Resale 16 6 ELECTRICAL SYSTEM Exploded View Property of www SmallEngineDiscount com Not for Resale ELECTRICAL SYSTEM 16 7 Exploded View Fastener Nm kgtm ftib a smo ooo a a o ioner uring pots f es os ore IA 4 Speed Sensor Mounting Bolt 78 in lb 5 Forward Reverse Detecting Sensor Mounting Bolts 15 15 11 6 2WD 4WD Actuator Mounting Bolts 9 8 1 0 87 in lb L S 7 Ignition Switch Nut 2 7 0 28 24 in lb 8 Engine Brake Actuator Mounting Bolts 8
268. reful of the following to avoid damage to the fins Keep the air nozzle A over 0 5 m 20 in B away from the oil cooler Blow air perpendicularly to the cooler core Never blow air at an angle against the fins but straight through them in the direction of natural air flow Never shake the air nozzle at a right angle against the fins be sure to move it at a level with the fins oK lt perpendicular gt Oil Hose and Connection Check e Remove Left Side Cover see Frame chapter Front Inner Covers see Frame chapter e Check the oil hoses A x If the oil hoses are frayed cracked or bulged replace the oil hose e Check that the hose is securely connected and banjo bolts B and oil pipe joint nuts C are tightened x If the oil hose has been sharply bent or kinked replace the oil hose Torque Oil Pipe Banjo Bolts 29 N m 3 0 kgf m 22 ft Ib Oil Pipe Joint Nuts 29 N m 3 0 kgf m 22 ft lb HUO9O00BS1 C e When installing the oil hose route the hose according to Cable Wire and Hose Routing section in Appendix chapter e When installing the oil hose avoid sharp bending kinking flattening or twisting and route the oil hose with a minimum of bending so that the oil flow will not be obstructed Wheels Tires Tire Inspection e Examine the tire for damage and wear x If the tire is cut or cracked replace it O Lumps or high spots on the tread or sidewalls indicate internal damage requiring tire re
269. removal and reinstallation or disassembly and reassembly of general parts Especially note the following 1 Dirt Before removal and disassembly clean the vehicle Any dirt entering the engine will shorten the life of the vehicle For the same reason before installing a new part clean off any dust or metal filings 2 Battery Ground Disconnect the ground wire from the battery before performing any disassembly operations on the vehicle This prevents the engine from accidentally turning over while work is being carried out sparks from being generated while disconnecting the wires from electrical parts as well as damage to the electrical parts themselves For reinstallation first connect the positive wire to the positive terminal of the battery 3 Installation Assembly Generally installation or assembly is the reverse of removal or disassembly However if installation or assembly sequence is given in this Service Manual follow it Note parts locations and cable wire and hose routing during removal or disassembly so they can be installed or assembled in the same way It is preferable to mark and record the locations and routing whenever possible 4 Tightening Sequence When installing bolts nuts or screws for which a tightening sequence is given in this Service Manual make sure to follow the sequence When installing a part with several bolts nuts or screws start them all in their holes and tighten them to a snug fit thus ensur
270. rer cree et rere E aa eR rere rere 5 10 Drive Belt Removals siririn enini raia aae a tte 5 10 Drive Belt Installation ico roads 5 10 Drive Belt Deflection INSPOCtiOn cesccceseeseeeeeeeeeeeeeeeneeeeneeeseeeesaeeeesseeessaeeessenaesnaneesneneesaeaenenaaeseseeeseseeenseneeesanes 5 10 Drive Belt Deflection AdjuStMeNt oooonocconnconnnccnnnccnonncnnnrccnnnnccn cer 5 10 Drive Belt Inspection ainia aida 5 10 Drive Pull ninia ia 5 11 Drive Pulley Removal caia a el eda eet eee 5 11 Drive Pulley Disassembly ici cintia te delicada dani aereo a 5 11 Drive Pulley INSPOCtOm ccc ici diras 5 12 Spider Shoe Side Clearance AdjUStMent cccecceeeeeeeeeeeneeeeeeeeeeceaeeeaeeeeeseeeeaeeeaeesaeeseaeseaeeseeseaeseaeeseessaeeeaeeeneenaes 5 14 Drive Pulley AsSemMblV coincida o ii aiia 5 15 Drive Pulley Installation iii a 5 16 Driven PUNY iia nidad cada 5 18 Driven Pulley Removal coccion ltd ibn ideal aaa ed Eea ENA 5 18 Driven Pulley Disassembly sissi otiradi aaaea lit 5 18 Driven Pulley INSPOCUOM is iii ia 5 19 Driven Pulley Assembly citada ee dias 5 20 Driven Pulley Installation ise aliada daa 5 22 High Altitude Setting Informati0N ooonncnninnnnicncnnncnnconncnnccon cnn rnnnn nc cnrc nn 5 23 SSPOCHICATOMS A ERTE T TA E EE O AT A aaa dida il 5 23 Property of www SmallEngineDiscount com Not for Resale 5 2 CONVERTER SYSTEM Exploded View HS02002BW5 C Property of www SmallEngineDiscount com Not for
271. rod big end examined or wear Connecting Rod Big End Radial Clearance Standard 0 008 0 020 mm 0 0003 0 0008 in Service Limit 0 07 mm 0 003 in Connecting Rod Big End Side Clearance i i e Set the crankshaft on V blocks e Measure the side clearance A of the connecting rod with a thickness gauge x If the big end side clearance exceeds the service limit the crankshaft assembly must be replaced or disassembled and the connecting rod and thrust washers visually inspected for wear Connecting Rod Big End Side Clearance Standard 0 25 0 35 mm 0 0098 0 0138 in Service Limit 0 6 mm 0 024 in Property of www SmallEngineDiscount com Not for Resale CRANKSHAFT TRANSMISSION 9 13 Crankshaft Balancer Shaft and Connection Rod Crankshaft Alignment e With the crankshaft on V blocks turn the crankshaft slowly and measure runout at each of the locations shown A 8 mm 0 315 in B 25 5 mm 1 004 in Crankshaft Runout Left Half C Standard TIR 0 03 mm 0 0012 in or less Service Limit TIR 0 08 mm 0 0032 in Right Half D H105009BS1 Standard TIR 0 04 mm 0 0016 in or less Service Limit TIR 0 10 mm 0 0039 in If runout at either location exceeds the service limit align the crankshaft so that runout is within the service limits e In the case of horizontal misalignment strike the projecting crankshaft half with a plastic soft lead or bras
272. roperty of www SmallEngineDiscount com Not for Resale 11 32 FINAL DRIVE Front Final Gear Case e Install Front Final Gear Case Center Cover A e Tighten the cover bolts following the tightening sequence as shown Torque Front Final Gear Case Center Cover Bolts M8 1 3 24 N m 2 4 kgf m 17 ft Ib Front Final Gear Case Center Cover Bolts M6 2 4 9 8 N m 1 0 kgf m 87 in Ib e Adjust the gear backlash and tooth contact pattern see Front Final Bevel Gear Adjustment e Apply a non permanent locking agent to the cover bolts and tighten them to the specified torque in the tightening sequence 1 4 e Apply a non permanent locking agent to the pinion gear bearing holder A and tighten it so that the deep recess B faces outward Special Tool Socket Wrench Hex 41 57001 1484 Torque Pinion Gear Bearing Holder 137 N m 14 kgf m 101 ft lb HK11007BS1 e Install Dowel Pins A New Gasket B Steel Balls C e Install Cam Lever A Needle Bearing B e Apply engine oil to the needle bearing e Check the wear of the disc assembly as follows O Measure the thickness of the inner disc A HK11006BS1 Property of www SmallEngineDiscount com Not for Resale FINAL DRIVE 11 33 Front Final Gear Case e Select the width A of the disc assembly B in accordance with the thickness of the inner disc refer to the below table Thickness of
273. rty of www SmallEngineDiscount com Not for Resale 7 10 ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump Removal e Remove Alternator Rotor and Starter Clutch Gear see Electrical System chapter Oil Pump Cover Screws A Oil Pump Cover Bolt B Oil Pump Cover C li HGOGBOO e Remove Inner Rotor A Outer Rotor B Oil Pump Installation e Apply engine oil Inner and Outer Rotors e Install Inner Rotor Outer Rotor Oil Pump Cover e Tighten Torque Oil Pump Cover Bolt 20 N m 2 0 kgf m 14 ft lb Oil Pump Cover Screws 5 4 N m 0 55 kgf m 48 in Ib Property of www SmallEngineDiscount com Not for Resale ENGINE LUBRICATION SYSTEM 7 11 Oil Pipe Oil Hose Oil Pipe Removal Engine Left Side Oil Pipe e Remove Engine Left Side Cover see Frame chapter Oil Pipe Bolts A Oil Pipe B Engine Inside Oil Pipe e Remove Cylinder Head see Engine Top End chapter Alternator Rotor and Starter Clutch Gear see Electrical System chapter Rear Camshaft Chain Guide A e Remove Oil Pipe Bolts A Oil Pipe B Oil Pipe Installation e Replace the O ring A with new ones if they are damaged e Apply grease to the O rings before installation e Tighten Torque Oil Pipe Bolts 8 8 N m 0 9 kgf m 78 in Ib HGO9B003 P Property of www SmallEngineDiscount com Not for Resale 7 12 ENGINE LUBRICATION SYSTEM Oil Pipe Oil Hose Oil Hose Removal e Drain the engi
274. rty of www SmallEngineDiscount com Not for Resale PERIODIC MAINTENANCE 2 23 Periodic Maintenance Procedures Caliper Piston Seal and Dust Seal Replacement e Refer to Calipers section in Brakes chapter for Caliper Piston Seal and Dust Seal Replacement Rear Brake Plates Replacement e Refer to Internal Wet Brake section in Brakes chapter for Rear Brake Plates Replacement Rear Brake Lever Free Play Inspection e Check the rear brake lever free play A O Pull the rear brake lever lightly until the brake is applied x If the play is incorrect adjust it Rear Brake Lever Free Play Standard 1 2 mm 0 04 0 08 in Brake Pedal Free Play Inspection e Check the brake pedal free play A O Depress the brake pedal lightly by hand until the brake is applied x If the free play is incorrect adjust it Brake Pedal Free Play Standard 15 25 mm 0 6 1 0 in Rear Brake Lever and Pedal Free Play Adjustment NOTE O Since the rear brake lever and pedal free play adjustments affect each other make them at the same time Rear Brake Lever e Loosen the knurled locknut A and turn the adjuster B at the rear brake lever in as far as it will go e Tighten the locknut e Turn the brake lever adjuster A at the rear end of the brake cable until the rear brake lever has the correct amount of play Brake Pedal e Turn the brake pedal adjuster B at the rear end of the brake cable until the br
275. s O The 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 O To prevent damaging electrical parts do not disconnect the battery leads or any other electrical connections when the ignition switch is on or while the engine is running O Because of the high current never keep the starter button depressed when the starter motor will not turn over or the current may burn out the starter motor windings O Only use an illumination bulb rated for the voltage or wattage specified in the wiring diagram or the handle cover could be warped by excessive heat radiated from the bulb O Take care not to short the leads that are directly connected to the battery positive terminal to chassis ground O Troubles may involve one or in some cases all items Never replace a defective part without determining what CAUSED the failure If the failure was caused by some other item or items they too must be repaired or replaced or the new replacement will soon fail again O Make sure all connectors in the circuit are clean and tight and examine wires for signs of burning fraying etc Defective wires and bad connections will affect electrical system operation O Measure coil and winding resistance when the part is cold at room temperature O Color Codes BK Black G Green P Pink BL Blue GY Gray PU Purple BR Brown LB Light blue R Red CH Chocolate LG Light g
276. s O Use a straightedge along the stem x If the steering stem is bent replace the steering stem Steering Lubrication e Lubricate the steering stem clamps O Remove the steering stem see Steering Stem Removal O Wipe all the old grease off the steering stem bearing sleeves and out of the grease seals O Apply Amoco Rykon Premium Grease No 2 EP Green to the steering stem A grease seals B and mating surface C of the clamp e Lubricate the steering stem bearing A O Remove the steering stem bearing O Pack the grease seal lips with grease HNOSGOOBS1 C Steering Stem Clamp Inspection e Inspect the steering stem clamps A x If roughness excessive play or seizure is found replace both clamps Steering Stem Bearing Inspection e Inspect the spherical bearing A x lf roughness excessive play or seizure is found replace the steering stem bearing e Inspect the upper and lower grease seals B x If damage wear or deterioration is found replace the steering stem bearing HNOSGO2BS1 Property of www SmallEngineDiscount com Not for Resale 14 10 STEERING Steering Maintenance Steering Knuckle Bearing Inspection CAUTION Do not remove any bearings for inspection e Remove the steering knuckle see Steering Knuckle Removal e Examine the bearing seal A for tears or leakage x If the seal is torn or is leaking replace the bearing
277. s e Subtract the measurement of the front from the measurement of the rear to get the toe in If the toe in is not in the specified range go on to the Toe in Adjustment procedure Toe in of Front Wheels Standard 0 20 mm 0 0 79 in at 1G Toe in Adjustment e Loosen the locknuts A B and turn the adjusting sleeves C the same number of turns on both sides to achieve the specified toe in NOTE O The locknut A near the flattened area D on the tie rod has left hand threads Turn the locknut clockwise for loosening O The toe in will be near the specified value if the tie rod length E is 315 0 7 mm 12 4 0 03 in on each tie rod CAUTION Adjust the tie rod length so that the visible thread length F is even on both ends of the tie rod Uneven thread length could cause tie rod damage O e Check the toe in e Tighten Torque Tie Rod Adjusting Sleeve Locknuts 37 N m 3 8 kgf m 27 ft lb e Test ride the vehicle HJO4004BS1 Property of www SmallEngineDiscount com Not for Resale WHEELS TIRES 10 7 Wheels Rims Wheel Removal e Loosen the wheel nuts A e Support the vehicle on a stand or a jack so that the wheels are off the ground Special Tool Jack 57001 1238 e Remove Wheel Nuts Wheel Wheel Installation e Check the tire rotation mark A on the tire and install the wheel accordingly NOTE O The direction of the tire rotation B i
278. s A for Alternator Leads Grommets B for Pickup Coil Leads Pickup Coil Inspection e Remove the seat see Frame chapter e Disconnect the pickup coil lead connector A e Measure the pickup coil resistance O Connect a hand tester between the BK W lead and the BL lead O Set the tester to the x 10 9 range Pickup Coil Resistance 110 140 Q x If the tester does not read as specified replace the pickup coil Pickup Coil Peak Voltage Inspection NOTE O Be sure the battery is fully charged e Remove the spark plug caps but do not remove the spark plugs e Disconnect Pickup Coil Wire Connector A e Set the hand tester B to the 10 V DC range e Connect the peak voltage adapter C to the hand tester and pickup Zs coil leads in the connector _ E Special Tool Hand Tester 57001 1394 e Y HP1OBOZO P Recommended Tool Peak Voltage Adapter Type KEK 54 9 B Brand KOWA SEIKI Connections Pickup Coil Connector Adapter Hand Tester Bule Red gt Black White Black gt e Turn the ignition switch on and rotate the engine for 4 5 seconds with the transmission gear in neutral to measure the pickup coil peak voltage Property of www SmallEngineDiscount com Not for Resale ELECTRICAL SYSTEM 16 29 Ignition System e Repeat the measurement 5 or more times Pickup Coil Peak Voltage Standard 3 6 V or more x If the peak voltage is lower than the standar
279. s A in the suspension arm B as shown B C 0 4 0 6 mm 0 016 0 024 in e Confirm that the knuckle joint is smooth motion after installed COOLS ARA ELLAOLIAL EA HMOSGO4BS1 C Property of www SmallEngineDiscount com Not for Resale 13 14 SUSPENSION Swingarm Swingarm Removal e Support the vehicle on a stand or a jack so that the rear wheels are off the ground Special Tool Jack 57001 1238 e Remove Rear Final Gear Case see Final Drive chapter Swingarm Pivot Left Nut A Swingarm Pivot Left Shaft B e Loosen Boot Clamp Screw A e Remove Boot Swingarm Pivot Right Shaft B Swingarm C Swingarm Installation e Apply molybdenum disulfide grease to the spline of the output shaft A e Fit the propeller shaft B on the output shaft e Apply a non permanent locking agent Swingarm Pivot Right Shaft A e Tighten Torque Swingarm Pivot Right Shaft 152 N m 15 5 kgf m 112 ft lb e Tighten Torque Swingarm Pivot Left Shaft B 20 N m 2 0 kgf m 14 ft Ib Swingarm Pivot Left Nut C 152 N m 15 5 kgf m 112 ft Ib e Fit the boot on the swingarm and tighten the clamp screw HMO6G004S1 Swingarm Disassembly y e Remove Collars A O ring B Property of www SmallEngineDiscount com Not for Resale SUSPENSION 13 15 Swingarm e Remove Oil Seal A e Remove Tapered Roller Bearing A
280. s furthermore necessary to rotate the engine in the direction of positive rotation as well 17 Replacement Parts When there is a replacement instruction replace these parts with new ones every time they are removed Replacement parts will be damaged or lose their original function once they are removed Therefore always replace these parts with new ones every time they are removed Although the previously mentioned gasket O ring ball bearing needle bearing grease seal oil seal circlip and cotter pin have not been so designated in their respective text they are replacement parts 18 Electrical Wires All the electrical wires are either one color or two color A two color wire is identified first by the primary color and then the stripe color For example a yellow wire with thin red stripes is referred to as a yellow red wire it would be a red yellow wire if the colors were reversed Unless instructed otherwise electrical wires must be connected to wires of the same color Two Color Electrical Wi re cross section Color Indicated on the Wire Color Indicated on the Wiring Diagram Red Wire Strands Yellow Red Y Ru Yellow Red 6B020801W1 19 Inspection When parts have been disassembled visually inspect these parts for the following conditions or other damage If there is any doubt as to the condition of them replace them with new ones Abrasion Crack Hardening Warp Be
281. s hammer as shown e Recheck the runout and repeat the process until the runout is within service limits O Vertical misalignment is corrected either by driving a wedge in between the crank halves or by squeezing the crank halves in a vise depending on the nature of the misalignment e In the case of both horizontal and vertical misalignment correct the horizontal misalignment first e Recheck big end side clearance after aligning crankshaft see Con necting Rod Big End Side Clearance NOTE O If crankshaft alignment cannot be corrected by the above method replace the crankpin or crank halves as required gt CAUTION Don t hammer the flywheel at the point A 5 a Property of www SmallEngineDiscount com Not for Resale 9 14 CRANKSHAFT TRANSMISSION Crankshaft Balancer Shaft and Connection Rod Connecting Rod Bend Twist e Measure the connecting rod bend O Set the crankshaft in an alignment jig or in V blocks on a surface plate O Select an arbor of the same diameter as the piston pin and at least 100 mm 3 94 in long and insert the arbor through the connecting rod small end O 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 If connecting rod bend exceeds the service limit the connecting rod must be replaced 10
282. s marks press it in with the marks facing out Property of www SmallEngineDiscount com Not for Resale GENERAL INFORMATION 1 3 Before Servicing 14 Circlip Retaining Ring and Cotter Pin When installing circlips and retaining rings take care to compress or expand them only enough to install them and no more Install the circlip with its chamfered side facing load side as well Replace any circlips retaining rings and cotter pins that were removed with new ones as removal weakens and deforms them If old ones are reused they could become detached while the vehicle is driven leading to a major problem 15 Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the sliding surfaces have an adequate lubricative film During assembly make sure to apply oil to any sliding surface or bearing that has been cleaned Old grease or dirty oil could have lost its lubricative quality and may contain foreign particles that act as abrasives therefore make sure to wipe it off and apply fresh grease or oil Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended 16 Direction of Engine Rotation To rotate the crankshaft manually make sure to do so in the direction of positive rotation Positive rotation is counterclockwise as viewed from the left side of the engine To carry out proper adjustment it i
283. s shown by an arrow on the tire sidewall e Position the wheel so that the air valve A is toward the outside of the vehicle e Tighten the wheel nuts in a criss cross pattern Torque Wheel Nuts 52 N m 5 3 kgf m 38 ft Ib Wheel Rim Inspection e Examine both sides of the rim for dents A If the rim is dented replace it x If the tire is removed inspect the air sealing surfaces A of the rim for scratches or nicks Smooth the sealing surfaces with fine emery cloth if necessary Property of www SmallEngineDiscount com Not for Resale 10 8 WHEELS TIRES Wheels Rims Wheel Rim Replacement e Remove the wheel see Wheel Removal e Disassemble the tire from the rim see Tire Removal O Remove the air valve and discard it CAUTION Replace the air valve whenever the tire is replaced Do not reuse the air valve Plastic Cap A Valve Core B Stem Seal C Valve Stem D Valve Seat E Valve Opened F e Install a new air valve in the new rim O Remove the valve cap lubricate the stem with a soap and water solution and pull the stem A through the rim from the inside out until it snaps into place CAUTION Do not use engine oil or petroleum distillates to lubricate the stem because they will deteriorate the rubber e Mount the tire on the new rim see Tire Installation e Install the wheel see Wheel Installat
284. se Driven Output Gear 16T 5 Shifter 16 Idle Shaft 6 Circlip 17 Spacer 20 3 x 33 x 2 0 7 Washer T 1 5 18 Driven Output Gear 18T 8 Spacer 28 2 x 34 5 x 1 6 19 Driven Hi Gear 30T 9 Spacer Hi and Low 20 Driven Low Gear 36T 10 Spacer 48 2 x 54 3 x 1 0 21 Needle Bearing 11 Drive Hi Gear 26T Property of www SmallEngineDiscount com Not for Resale CRANKSHAFT TRANSMISSION 9 23 Ball Bearing Needle Bearing and Oil Seal Ball and Needle Bearing Replacement CAUTION Do not remove the ball or needle bearings unless it is neces sary Removal may damage them e Using a press or puller remove the ball bearing and or needle bearing outer race NOTE O In the absence of the above mentioned tools satisfactory results may be obtained by heating the case to approximately 93 C 200 F max and tapping the bearing in or out CAUTION Do not heat the case with a torch This will warp the case Soak the case in oil and heat the oil e Using a press and the bearing driver set A install the new bearing or outer race until it stops at the bottom of its housing Special Tool Bearing Driver Set 57001 1129 Ball and Needle Bearing Wear CAUTION Do not remove the bearings for inspection Removal may damage them e Check the ball bearings O Since the ball bearings are made to extremely close tolerances the wear must be judged by feel rather than measurement Clean eac
285. seal A with a new one O Apply brake fluid to the fluid seal and install it into the cylinder by hand e Replace the dust seal B with a new one if it is damaged O Apply brake fluid to the dust seal and install it into the cylinder by hand e Install the anti rattle spring A in the caliper as shown e Apply brake fluid to the outside of the piston A and push it into the cylinder by hand Take care that neither the cylinder nor the piston skirt gets scratched e Replace the rubber boots B and plug C if they are damaged e Apply a thin coat of silicone grease to the caliper holder shafts D and holder holes E Silicone grease is a special high temperature water resistant grease HLOGGOOBS1 C e Install the caliper holder plate A Torque Caliper Holder Shaft 18 N m 1 8 kgf m 13 ft Ib e Install the bleed valve and rubber cap Torque Bleed Valve 5 9 N m 0 6 kgf m 52 in Ib e Install the pads see Brake Pad Installation HLOGGOSBS1 C Fluid Seal Damage The fluid seals A around the piston maintain the proper pad disc clearance If the seals are not satisfactory pad wear will increase and constant pad drag on the disc will raise brake and brake fluid temperature e Replace the fluid seals under any of the following conditions a fluid leakage around the pad b brakes overheat c there is a large difference in inner and outer pad wear d the seal is stuck to the pis
286. seat Special Tools Valve Seat Cutters Exhaust Valves Valve Seat Cutter 45 641 5 57001 1117 Valve Seat Cutter 32 638 5 57001 1122 Valve Seat Cutter 50 644 57001 1516 Inlet Valves Valve Seat Cutter 45 641 5 57001 1117 Valve Seat Cutter 32 644 57001 1515 Valve Seat Cutter 50 644 57001 1516 Holder amp Bar Valve Seat Cutter Holder 7 57001 1126 B Valve Seat Cutter Holder Bar 57001 1128 C If the manufacturer s instructions are not available use the following procedure Seat Cutter Operation Care 1 This valve seat cutter is developed to grind the valve seat 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 diamond 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 Do 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 O Prior to grinding apply engine oil to the cutter and during 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 befo
287. shing is damaged or worn replace the drive pulley cover Cover Bushing Inside Diameter A Standard 27 985 28 085 mm 1 1018 1 1057 in Service Limit 28 12 mm 1 107 in A r 7 HSO60012 P amp Property of www SmallEngineDiscount com Not for Resale CONVERTER SYSTEM 5 13 Drive Pulley x If the sheave bushing is damaged or worn replace it Sheave Bushing Inside Diameter A Standard 37 985 38 085 mm 1 4955 1 4994 in Service Limit 38 12 mm 1 501 in HSO60013 P x If the spider shoes A are damaged replace them e Check the spider shoe side clearance see Spider Shoe Side Clearance Inspection If the ramp weights A are damaged or worn replace them x If the pins B are damaged or worn replace them x If the rollers A are damaged or worn replace the spider B x If the washers C are damaged or worn replace the spider x If the spring is worn or damaged replace the spring Spring Free Length A Standard 60 mm 2 36 in Property of www SmallEngineDiscount com Not for Resale 5 14 CONVERTER SYSTEM Drive Pulley Spider Shoe Side Clearance Adjustment e Remove Drive Pulley see Torque Converter Removal Drive Pulley Cover and Spring see Drive Pulley Disassembly e Temporarily install Dowel Pins 2 Drive Pulley Cover Two Bolts at dowel pins e Turn the movable sheave clockwise e Measure the resulting clearance A between the shoe B and the
288. sion chapter Rear Propeller Shaft B Rear Propeller Shaft Installation e Wipe the old grease off the front and rear end splines A of the rear propeller shaft B and apply new molybdenum disulfide grease in those e Be sure to install the spring C on the pinion gear nut of the rear final gear case e Install the rear propeller shaft while aligning the splines HK12000251 Rear Propeller Shaft Joint Boot Inspection e Refer to Joint Boots Inspection in Periodic Maintenance chapter Rear Propeller Shaft Inspection e Remove the rear propeller shaft see Rear Propeller Shaft Removal e Check that the universal joint A works smoothly without rattling or sticking Ny x If it does rattle or stick the universal joint is damaged Replace the propeller shaft with a new one e Visually inspect the splines B on the propeller shaft x If they are badly worn chipped or loose replace the propeller shaft e Also inspect the splines on the rear end of the output shaft and the pinion gear joint in the final gear case x If splines are badly worn chipped or loose replace the output shaft and the pinion gear joint Property of www SmallEngineDiscount com Not for Resale 11 44 FINAL DRIVE Rear Axle Rear Axle Removal e Drain the rear final gear case oil see Rear Final Gear Case Oil Change in Periodic Maintenance chapter e Remove Rear Wheels see Wheels Tires chapter Rear Hub
289. stem Cleanliness Inspection 3 12 Carburetor Removal cccceeceeeceeseeeseeeeeerees 3 13 Carburetor InstallatiO0N oonnoonninnnndnnnnion 3 13 Carburetor DisasSeMmbly eccesceeeeeeeeeeeees 3 14 Carburetor ASSEMDIy eceeceeeeeeeeeeeeeeeeeeees 3 15 Carburetor CleaniOQ cocccnnccncinnccnoncniccncnccnnnnnnos 3 16 Carburetor INSPeCtiOn eeceeceeeteeteeeeteeeeees 3 17 Air CIGANGM iii ii 3 19 Air Cleaner Element Removal 0 cceee 3 19 Air Cleaner Element Installation 3 19 Air Cleaner Element Cleaning and Inspection 3 20 Air Cleaner Draining ccceccesceteeeeteeeseeees 3 20 Air Cleaner Housing Removal cc cceceee 3 20 Air Cleaner Housing Installation 3 21 Snorkel Duct REMOval cccccceeseessseeseees 3 21 Fuel Tank rre ene its 3 22 Fuel Tank RemMoVal oooococcnccccccnnocococcncconancconcnanns 3 22 Fuel Tank InstallatiON oooonooocicnnnnicicnnnnncccccnccn 3 22 Fuel Tap ReMoOVal coocoocccccccococcccccnnoncconccanancnnnnnns 3 23 Fuel Tap InstallatiON oooon oooccnnnnnnccnnnnnacccccnnnno 3 23 Fuel Tank and Fuel Tap Cleaning 3 23 Fuel Tap Inspection eee 3 23 Fuel Level Gauge Removal 3 24 Fuel Level Gauge Installation 3 24 Fuel Level Gauge Check 3 24 Property of www SmallEngineDiscount com Not for Resale 3 2 FUEL SYSTEM Exploded Vie
290. sting sleeve or the toe in of the front wheels will be changed Tie Rod Installation e The right and left tie rods are identical e Tighten Torque Tie Rod End Nuts 42 N m 4 3 kgf m 31 ft lb e Inspect the toe in see Wheels Tires chapter Property of www SmallEngineDiscount com Not for Resale 14 8 STEERING Steering Tie Rod End Removal e Remove the tie rod see Tie Rod Removal e Holding the tie rod flattened area A loosen the locknut B and unscrew the tie rod end C NOTE O The locknut near the flattened area D on the tie rod has left hand threads Turn the wrench clockwise as viewed from the joint end for loosening CAUTION Do not remove the grease seal It is packed with grease Tie Rod End Installation e Check that the seal lip A is on the shank B HNO4G05BS1 e Install the tie rod ends so that the tie rod has the correct length A and both visible thread lengths B are equal Tie Rod Length Standard 315 0 7 mm 12 4 0 03 in e Tighten Torque Tie Rod Adjusting Sleeve Locknuts 37 N m 3 8 kgf m 27 ft lb HNO4G06BS1 Property of www SmallEngineDiscount com Not for Resale STEERING 14 9 Steering Maintenance Steering Inspection e Refer to Steering Inspection in Periodic Maintenance chapter Steering Stem Straighiness e Remove the steering stem see Steering Stem Removal e Check the steering stem for straightnes
291. stments are of critical importance and must be carried out following the correct sequence and method e When any one of the backlash related parts are replaced check and adjust the bevel gear backlash and tooth contact by replacing shims O The amount of backlash is influenced by the ring gear position more than by the pinion gear position O Tooth contact location is influenced by the pinion gear position more than by the ring gear position Adjust gear backlash Adjust tooth contact pattern Assemble the final gear case completely Property of www SmallEngineDiscount com Not for Resale 11 38 FINAL DRIVE Front Final Gear Case Front Final Gear Case Backlash related Parts 1 Pinion Gear Shim s 4 Front Final Gear Case Center 6 Ball Bearings 2 Ring Gear Right Shim s Cover 7 Ring Gear 3 Ring Gear Left Shim s 5 Front Final Gear Case Right 8 Ring Gear Assembly Cover 9 Pinion Gear Property of www SmallEngineDiscount com Not for Resale FINAL DRIVE 11 39 Front Final Gear Case 1 Pinion Gear Shims for Backlash Adjustment 0 15 mm 0 006 in 92180 1325 0 2 mm 0 008 in 92180 1327 0 5 mm 0 020 in 92180 1326 0 7 mm 0 028 in 92180 1384 0 8 mm 0 031 in 92180 1328 0 9 mm 0 035 in 92180 1385 1 0 mm 0 039 in 92180 1337 1 1 mm 0 043 in 92180 1386 1 2 mm 0 047 in 92180 1338 2 Ring Gear Right Shims for Tooth Contact Adjustment Thickn
292. ston Cylinder inside diameter Piston diameter Piston cylinder clearance Piston ring groove clearance Top Second Piston ring thickness Top Second Piston ring groove width Top Second Piston ring end gap Top Second Oil 0 15 0 20 mm 0 0059 0 0079 in 0 08 0 13 mm 0 0032 0 0051 in 0 07 0 14 mm 0 0028 0 0055 in 0 05 0 13 mm 0 0020 0 0051 in 0 5 1 0 mm 0 02 0 04 in 0 5 1 0 mm 0 02 0 04 in 34 9 35 1 mm 1 374 1 382 in 39 9 40 1 mm 1 571 1 579 in 45 32 50 1 0 mm 0 04 in 1 0 mm 0 04 in under 0 01 mm 0 0004 in TIR 6 955 6 970 mm 0 2738 0 2744 in 6 965 6 980 mm 0 2742 0 2748 in 7 000 7 015 mm 0 2756 0 2762 in 7 000 7 015 mm 0 2756 0 2762 in 39 05 mm 1 537 in 42 47 mm 1 672 in 80 000 80 012 mm 3 1496 3 1501 in 79 952 79 967 mm 3 1477 3 1483 in 0 033 0 060 mm 0 0013 0 0024 in 0 04 0 08 mm 0 0016 0 0032 in 0 03 0 07 mm 0 0012 0 0028 in 0 97 0 99 mm 0 0382 0 0390 in 0 97 0 99 mm 0 0382 0 0390 in 1 03 1 05 mm 0 0405 0 0413 in 1 02 1 04 mm 0 0402 0 0409 in 0 20 0 30 mm 0 0079 0 0118 in 0 30 0 45 mm 0 0118 0 0177 in 0 20 0 70 mm 0 0079 0 0276 in 0 30 mm 0 0118 in 0 30 mm 0 0118 in 0 5 mm 0 020 in 0 7 mm 0 028 in 0 05 mm 0 002 in TIR 6 94 mm 0 2732 in 6 95 mm 0 2736 in 7 08 mm 0 279 in 7 08 mm
293. t foot feet gram s hour s liter s LIST OF ABBREVIATIONS pounds 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 Read OWNER S MANUAL before operating Property of www SmallEngineDiscount com Not for Resale EMISSION CONTROL INFORMATION To protect the environment in which we all live Kawasaki has incorporated crankcase emission 1 and exhaust emission 2 control systems in compliance with applicable regulations of the California Air Resources Board 1 Crankcase Emission Control System A sealed type crankcase emission control system is used to eliminate blow by gases The blow by gases are led to the breather chamber through the crankcase Then it is led to the air cleaner Oil is separated from the gases while passing through the inside of the breather chamber from the crankcase and then returned back to the bottom of crankcase 2 Exhaust Emission Control System The exhaust emission control system applied to this engine family is engine modifications that consist of a modified carburetor and an ignition system having optimum ignition timing characteristics The carburetor has been calibrated to provide lean air fuel mixture characteristics and optimum fuel economy with a suitable air cleaner and exhaust system A maintenance free ignition system provides the most favor
294. t Chain Tensioner e Install a new gasket e Install the tensioner body with the arrow A on it pointing downwards e Tighten the mounting bolts B Torque Camshaft Chain Tensioner Mounting Bolts 8 8 N m 0 9 kgf m 78 in Ib e Remove the holder plate C e Apply grease to the O ring and install it on the tensioner body e Tighten the cap bolt e Turn the crankshaft 2 turns counterclockwise to allow the tensioner to expand and recheck the camshaft chain timing Property of www SmallEngineDiscount com Not for Resale 4 10 ENGINE TOP END Camshaft Sprocket Camshaft Sprocket Removal e Remove Fuel Tank Cover see Frame chapter Exhaust Pipe Cover see Frame chapter Left Front Inner Cover see Frame chapter Recoil Starter see Recoil Starter chapter Bolts A and Camshaft Cover B HEO9B004 P e Turn the crankshaft counterclockwise with a wrench on the alternator rotor bolt until the mark A on the camshaft sprocket aligns with the pointer B on the cylinder head O Be sure to position the crankshaft at TDC of the end of the compression stroke e Remove the camshaft chain tensioner see Camshaft Chain Ten sioner Removal e Remove the camshaft sprocket bolts C Hold the crankshaft from turning with a wrench on the alternator rotor bolt e Remove the camshaft sprocket D Camshaft Sprocket Installation e Remove Timing Inspection Plug A Special Tool Driver Filler Cap B 57001 1454
295. t Final Gear Case Assembly 008 11 31 Oil Seal Installation ceeeeeeeeeeneeeeeeteeee 11 35 Ring Gear Disassembly 0 c eee 11 35 Ring Gear Assembly 0 ce eee 11 36 LSD Clutch Torque InspectiON oo on 11 36 Pinion Gear Unit Disassembly ee 11 37 Pinion Gear Unit Assembly ceeeeeeee 11 37 Front Final Bevel Gear Adjustment 11 37 Bevel Gear Inspection eceeeeeeeeeeeeeeeeteees 11 41 Differential Gear Inspection cee 11 41 Rear Propeller Shafft c ccccescesscseeeeteeeeeeeneees 11 43 Rear Propeller Shaft Removal 11 43 Rear Propeller Shaft Installation 11 43 Rear Propeller Shaft Joint Boot Inspection 11 43 Rear Propeller Shaft Inspection 11 43 A oarn Rear Axle Removal ooooccccccccccccncccccconcononono o Rear Axle Installation Ball Bearing Weal seeren Rear Axle Runout Inspection eee 11 44 Rear Final Gear Case oooccccccccoccccoccnnncnonnnanccnnccnnnos 11 45 Rear Final Gear Case Oil Level Inspection 11 45 Rear Final Gear Case Oil Change 11 45 Rear Final Gear Case Removal 11 45 Rear Final Gear Case Installation 11 45 Rear Final Gear Case Disassembly 11 46 Rear Final Gear Case Assembly 06 11 47 Oil Seal Installation ce eeeeeeeeeeeeeeeeteeee 11 48 Rear Final Bevel Gear Adjustmen t
296. t com Not for Resale FINAL DRIVE 11 49 Rear Final Gear Case Rear Final Bevel Gear Adjustment O The backlash and tooth contact pattern of the bevel gears must be correct to prevent the gears from making noise and being damaged e After replacing any of the backlash related parts be sure to check and adjust the backlash and tooth contact of the bevel gears First adjust backlash and then tooth contact by replacing shims O The amount of backlash is influenced by the ring gear position more than by the pinion gear position O Tooth contact locations is influenced by the pinion gear position more than by the ring gear position Rear Final Gear Case Backlash related Parts HK140015W3 C 1 Pinion Gear 5 Ring Gear 2 Pinion Gear Bearing Holder 6 Pinion Gear Shim s 3 Gear Case Right Cover 7 Ring Gear Shim s 4 Ball Bearings Property of www SmallEngineDiscount com Not for Resale 11 50 FINAL DRIVE Rear Final Gear Case 6 Pinion Gear Shims for Tooth Contact Adjustment Part Number 0 15 mm 0 006 in 92180 1320 0 2 mm 0 008 in 92180 1319 0 5 mm 0 020 in 92180 1321 0 8 mm 0 031 in 92180 1322 1 0 mm 0 039 in 92180 1345 1 2 mm 0 047 in 92180 1346 7 Ring Gear Shims for Backlash Adjustment 0 15 mm 0 006 in 92180 1318 0 2 mm 0 008 in 92180 1316 0 5 mm 0 020 in 92180 1317 0 8 mm 0 031 in 92180 1315 1 0 mm 0 039 in 92180 1343 1
297. t in order to equalize the air pressures Inboard Joint Boot Assembly e Slide the small band A onto the shaft and then slide the boot B into the groove C on the shaft Property of www SmallEngineDiscount com Not for Resale 11 24 FINAL DRIVE Front Axle O Tighten the band pulling the tip of band B with a plier and a driver while measuring the outside diameter of the band Outside Diameter of Band 26 1 0 3 mm 1 028 0 012 in After tightening the outside small diameter A Vernier Calipers O When the outside diameter of the band comes to the specified value bend the tip of band about 90 degrees O After bending the tip of band stake it with a chisel A so that it does not loosen O After staking it cut off the extra tip of the band and bend it securely e Install the ball bearing A and new circlip B e Squeese about half a tube 35 grams of the special grease A into the inboard joint boot e Squeese the remaining special grease A into the bearing cup B Property of www SmallEngineDiscount com Not for Resale FINAL DRIVE 11 25 Front Axle e Install the inside shaft and install the new retaining ring A e Compress the axle assembly to the specified length while relieving the air pressure inside the inboard boot A b gt 9 AZ e Hold the axle at this setting Da Standard Length of Assembling Right Front
298. tage inspection the specified value Good No good Ignition coil is defective Voltage is zero Inspect Replace ignition coil or almost zero 1 Lower resistance ina No good hand tester Use KAWASAKI Hand Tester 2 Pickup coil peak voltage Inspect Adapter connection is incorrect or adapter is defective Ignition switch and engine stop switch Pickup coil peak voltage Replace bad parts Igniter is defective Replace igniter Replace bad parts or inspect them with KAWASAKI Hand Tester HP10018BWS S Property of www SmallEngineDiscount com Not for Resale ELECTRICAL SYSTEM 16 31 Ignition System Ignition System Circuit O i P a Y 1 BK Y C a Le BK Y o VA BK Y G BK Y BR GY W G W Y R BL W Y W BK Y R W R W BK Y gt _ O W R _ kc W R Perz E pl BL Y or O O HP10012BW4 1 2WD 4WD Shift Switch 8 Main Fuse 30A 2 Actuator Controller 9 Ignition Coil 3 Engine Stop Switch 10 Spark Plug 4 Drive Belt Failure Detecting Switch 11 Pickup Coil 5 Drive Belt Failure Detecting Switch Fuse 12 LED Indicator 5A 13 Igniter 6 Reverse Power Assist Switch Override 14 Reverse Position Switch 7 Ignition Switch 15 Battery Property of www SmallEngineDiscount com Not for Resale 16 32 ELECTRICAL SYSTEM
299. tem Cleanliness Inspection AWARNING Gasoline is extremely flammable and can be explosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Turn the fuel tap to the OFF position e Remove the check valve A at the end of the carburetor overflow hose e Run the lower end of the carburetor overflow hose to a suitable container e Turn out the carburetor drain plug a few turns and drain the fuel system Special Tool Carburetor Drain Plug Wrench Hex 3 57001 1269 A 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 carburetor tank fuel hose Air Cleaner Element Cleaning and Inspection NOTE O In dusty areas the element should be cleaned more frequently than the recommended interval O After riding through rain or muddy terrains the element should be cleaned immediately O Also if there is a break in the element material or any other damage to the element replace the element with a new one AWARNING Clean the element in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Because of the danger of highly flammable liquids do not use gasoline or
300. tem chapter e Set the switch lever A to the ON mark side B NOTE O The failure detection system is activated when the switch is in the ON position This is the normal running mode Engine rpm is limited when the switch is in the OFF position e Tighten the No 3 bolt temporarily e Tighten the No 1 and No 2 bolts temporarily e Press the cover toward the arrow A and then tighten the cover bolts following the tightening sequence as shown Torque Converter Cover Bolts 8 8 N m 0 9 kgf m 78 in Ib B Clamp Torque Converter Cover Disassembly e Remove Torque Converter Cover see Torque Converter Cover Removal Engine Brake Actuator see Electrical System chapter Circlip A Spring B Actuator Lever Assembly C Actuator Lever Engine Brake Control Lever Assembly Inspec tion e Refer to Actuator Lever Engine Brake Control Lever Assembly Inspection in Periodic Maintenance chapter Torque Converter Cover Assembly e Install New Circlip Spring Actuator Lever Assembly Engine Brake Actuator see Electrical System chapter e Measure the installation length A of the actuator lever assembly between the cover end B and resin tips C on the actuator lever assembly as follows Actuator Lever Assembly Installation Length Standard 149 33 150 47 mm 5 879 5 924 in alice Property of www SmallEngineDiscount com Not for Resale CONVERTER SYSTEM 5 9 Torque Converter
301. tery is fully charged e Remove Seat see Frame chapter e Connect Controller Connector A Hand Tester B range DC 10 V Tester Connector O Terminal 2 Tester Connector BK Y Terminal 10 O Install the needle adapters on the tester leads Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 e Turn ON the ignition switch e Measure the controller output voltage for the actuators 3 4 12 HP23005BS1 Controller Output Voltage to Actuators Standard 4 8 0 2 V x If the reading is not standard replace the actuator controller unit e Disconnect the speed sensor lead connector e Connect Controller Connector A Hand Tester B range DC 10 V Tester Connector P Terminal 5 Tester Connector BK Y Terminal 10 O Install the needle adapters on the tester leads Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 e Turn ON the ignition switch e Measure the controller output voltage for the speed sensor HP23003BS1 Controller Output Voltage to speed sensor Standard 5 0 25 V If the reading is not standard replace the actuator controller unit e Disconnect the 2WD 4WD shift switch lead connector e Connect Controller Connector A Hand Tester B range DC 10 V Tester Connector G Terminal 7 Tester Connector BK Y Termina
302. the carburetor see Carburetor Removal e Turn the throttle cable pulley A to check that the throttle butterfly valve B moves smoothly and return back with the spring tension x If the throttle valve does not move smoothly replace the carburetor e Disassemble the carburetor see Carburetor Disassembly e Clean the carburetor see Carburetor Cleaning e Check the vacuum piston diaphragm A and the O rings B on the float bowl pilot screw and starter plunger cap If any of the diaphragm or O rings are not in good condition replace them e Check the plastic tip A of the float valve needle It should be smooth without any grooves scratches or tears x If the plastic tip is damaged B replace the float valve C e Push the rod D in the other end of the float valve needle and then release it x If it does not spring out replace the float valve e Check the tapered portion A of the pilot screw for wear or damage x If the pilot screw is worn or damaged on the tapered portion it will prevent the engine from idling smoothly Replace it Property of www SmallEngineDiscount com Not for Resale 3 18 FUEL SYSTEM Carburetor e Check that the vacuum piston moves smoothly in the carburetor body The surface of the piston must not be excessively worn If the vacuum piston does not move smoothly or if it is very loose in the carburetor body replace both the body and the vacuum pisto
303. the specified values replace the switch Oil Cooler Fan Switch Resistance ORising temperature From OFF to ON at 67 73 C 153 163 F C Falling temperature From ON to OFF at 57 63 C 135 145 F ON Less than 0 5 0 OFF More than 1 MQ HP14003BS2 Oil Temperature Warning Light Switch Inspection e Remove Oil Temperature Warning Light Switch see Engine Lubrication System chapter e Suspend the switch A in a container of oil so that the temperature sensing projection and threaded portion are submerged e Suspend an accurate thermometer B in the oil NOTE O The switch and thermometer must not touch the container sides or bottom e Place the container over a source of heat and gradually raise the temperature of the oil while stirring the oil gently e Using the hand tester measure the internal resistance of the switch across the terminals at the temperatures shown in the table x If the hand tester does not show the specified values replace the switch Oil Temperature Warning Light Switch Resistance ORising temperature From OFF to ON at 107 113 C 225 235 F Falling temperature From ON to OFF at 97 103 C 207 217 F ON Less than 0 5 2 HP14002BS2 OFF More than 1 MO Switch Inspection e Using the hand tester check to see that only the connections shown in the table have continuity about zero ohms O For the handlebar switches ignition switch refe
304. tifier trouble Alternator trouble Wiring faulty Battery Overcharged Regulator rectifier trouble Battery trouble Property of www SmallEngineDiscount com Not for Resale 17 6 APPENDIX Cable Wire and Hose Routing HBOSOOSBW4 1 Brake Cable 8 LED Indicator 2 Left Switch Housing 9 Neutral Indicator Light Lead LG BR 3 Choke Cable 10 Oil Pressure Temperature Warning Indicator Light 4 Clamp Lead W G BR 5 Brake Hose 11 Reverse Indicator Light Lead R W BR 6 Throttle Cable 12 Band 7 Fuel Tank Vent Hose Property of www SmallEngineDiscount com Not for Resale APPENDIX 17 7 Cable Wire and Hose Routing HBO9006BW4 1 Band 7 Seat Latch 2 Cover 8 Cover for U S A model Speedometer Leads 3 Drive Belt Failure Detecting Switch Fuse 5 A 9 Cover 4 Oil Cooler Fan Fuse 20 A 10 Fold the cover 5 Seat Bracket 11 Tie the cover with band 6 Grommet Property of www SmallEngineDiscount com Not for Resale 17 8 APPENDIX Cable Wire and Hose Routing HBOSOO7BW4 1 Rear Brake Lever 5 Cable Adjuster 2 Parking Brake Lock Lever 6 Handle Holder Clamp 3 Variable Differential Control Lever 7 Variable Differential Operating Lever 4 Variable Differential Control Cable Property of www SmallEngineDiscount com Not for Resale APPENDIX 17 9 Cable Wire and Hose Routing HB090
305. tle lever moves smoothly from full open to close and the throttle closes quickly and completely in all steering positions by the return spring x If the throttle lever does not return properly check the throttle cable routing lever free play and for possible cable damage Then lubricate the throttle cable e Run the engine at the idle speed and turn the handlebar all the way to the right and left to ensure that the idle speed does not change x If the idle speed increases check the throttle lever free play and the cable routing e Stop the engine and check the throttle lever free play A x If the free play is not within the specified range adjust the cable Throttle Lever Free Play Standard 2 3 mm 0 08 0 12 in Throttle Lever Free Play Adjustment e Slide the rubber cover off the adjuster at the throttle case e Loosen the locknut A and turn the throttle cable upper adjuster B until the cable has proper amount of play e Tighten the locknut and reinstall the rubber cover Torque Throttle Cable Locknut 13 N m 0 13 kgf m 11 in Ib x If the free play cannot be adjusted by using the upper cable adjuster remove the throttle cable pulley cover and then use the cable adjusting nuts A at the lower end of the throttle cable and make the necessary free play Property of www SmallEngineDiscount com Not for Resale PERIODIC MAINTENANCE 2 11 Periodic Maintenance Procedures Fuel Sys
306. to correct any of these conditions before riding AWARNING Operation with improperly adjusted incorrectly routed or damaged cables could result in an unsafe riding condition e Check idle speed with a suitable tachometer x If the idle speed is out of the specified range adjust it Idle Speed Standard 1 300 50 r min rpm Idle Speed Adjustment e Start the engine and warm it up thoroughly e Turn the idle adjusting screw A until the idle speed is correct O Open and close the throttle a few times to make sure that the idle speed is within the specified range Pilot Screw Adjustment e Adjust the pilot screw if necessary e Turn the carburetor pilot screw A all the way in until it seats lightly Special Tool Pilot Screw Adjuster A 57001 1239 B CAUTION Do not overtighten the pilot screw or the carburetor body will be damaged and require replacement e Back the pilot screw out the specified number of turns Carburetor Pilot Screw Setting Standard 1 1 2 turns out Service Fuel Level Inspection AWARNING Gasoline is extremely flammable and can be explosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Park the vehicle on a level surface e Remove the fuel tank cover e Remove the check valve A at the end of the carb
307. ton x If the fluid seal is replaced replace the dust seal as well Also replace all seals every other time the pads are changed HLOGGOIBS1 C Property of www SmallEngineDiscount com Not for Resale 12 14 BRAKES Calipers Dust Seal and Friction Boot Damage S e Check that the dust seals A and friction boots B are not cracked worn swollen or otherwise damaged x lf they show any damage replace them Q 30 SO J p Y ORNO o Piston and Cylinder Damage e Visually inspect the piston A and cylinder surfaces x Replace the caliper if the cylinder and piston are badly scored or rusty HLOGGO3BS1 Caliper Holder Shaft Wear Inspection The caliper body must slide smoothly on the caliper holder shafts A 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 friction boots are not damaged x lf the rubber friction boot is damaged replace the rubber friction boot If caliper holder shaft is damaged replace the caliper holder shaft and rubber friction boot as a unit HLOGOO4BS1 Property of www SmallEngineDiscount com Not for Resale BRAKES 12 15 Brake Pads Brake Pad Removal e Remove the front wheel see Wheels Tires chapter e Fl
308. ton rings bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Compression release cam K A C R sticks open Engine stalls when moving off Knocking Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Igniter trouble Miscellaneous Throttle valve won t fully open Carburetor vacuum piston doesn t slide smoothly Brake dragging Overheating Engine oil level too high Engine oil viscosity too high Balancer mechanism malfunctioning Front or rear final gear case oil viscosity too high Overheating Firing incorrect Spark plug dirty broken or maladjusted Spark plug incorrect Igniter trouble Fuel air mixture incorrect Main jet clogged Fuel level too low Carburetor holder loose Air cleaner poorly sealed or missing Air cleaner duct loose Air cleaner clogged Compression high Carbon built up in combustion chamber Compression release cam sticks close K A C R Engine load faulty Engine oil level too high Engine oil viscosity too high Drive train trouble Brake dragging Lubrication inadequate Engine oil level too low Engine oil poor quality or incorrect Front or rear final gear case overheating Insufficient oil Bevel gears maladjusted LSD clutches in front final gear case maladjustment Oil cooler i
309. tor e Install the alternator rotor A while turning the starter clutch gear B e Install the torque limiter C Alternator Stator Removal e Remove Alternator Cover see Alternator Cover Removal Pickup Coil A see Pickup Coil Removal Bolts B and Alternator Stator C Property of www SmallEngineDiscount com Not for Resale ELECTRICAL SYSTEM 16 21 Charging System Alternator Stator Installation e Tighten Torque Alternator Stator Bolts 14 N m 1 4 kgf m 10 in Ib e Install Pickup Coil see Pickup Coil Installation e Fit the lead grommets into the notch on the alternator cover Grommets A for Alternator Leads Grommets B for Pickup Coil Leads Regulator Rectifier Output Voltage Inspection e Remove the seat see Frame chapter e Check the battery condition see Battery section e Warm up the engine to obtain actual alternator operating conditions e Check that the ignition switch is turned off and connect a hand tester A to the battery terminals Special Tool Hand Tester 57001 1394 e Start the engine and note the voltage readings at various engine speeds with the headlight turned on and then off The readings should show nearly battery voltage when the engine speed is low and as the engine speed increases the readings should also increase Regulator Rectifier Output Voltage Connections Tester Range Reading Tester Tester t to O
310. tor Mounting Bolts C 12 N m 1 2 kgf m 104 in Ib e Install Output Drive Idle Gear New Circlip Special Tool Outside Circlip Pliers 57001 144 Property of www SmallEngineDiscount com Not for Resale 11 10 FINAL DRIVE Output Bevel Gears e Apply grease O rings A e Install Output Drive Bevel Gear Cover B e Tighten Torque Output Drive Bevel Gear Cover Bolts C 8 8 N m 0 9 kgf m 78 in Ib e Install Forward Reverse Detecting Sensor A e Tighten Torque Forward Reverse Detecting Sensor Mounting Bolt 15 N m 1 5 kgf m 11 ft Ib fiky6B003 P Output Drive Bevel Gear Disassembly e Remove Output Drive Bevel Gear Housing A see Output Drive Bevel Gear Removal e Look through the hole B in the housing e Turn the bevel gear C until the groove of the output drive bevel gear holder nut is seen HK160004 P e Tighten the nut holding bolts A 4 securely into the grooves B of the bevel gear holder nut C in the output drive bevel gear housing Special Tool Nut Holding Bolts 57001 1481 D Output Drive Bevel Gear Housing E Outer Ball Bearing F Inner Ball Bearing G Bearing Holder H Output Drive Bevel Gear HK16001652 C Property of www SmallEngineDiscount com Not for Resale FINAL DRIVE 11 11 Output Bevel Gears e Hold the output drive bevel gear housing A in a vise e Loosen the bevel gear B using an Allen wrench
311. tor Rotor see Electrical System chapter e Remove the torque limiter A and visually inspect it x If the limiter has wear discoloration or other damage replace it as a unit HP11B022 P Property of www SmallEngineDiscount com Not for Resale ELECTRICAL SYSTEM 16 39 Lighting System Headlight Beam Vertical Adjustment e Turn the adjusting screw A on each headlight rim in or out to adjust the headlight vertically NOTE O On high beam the brightest point should be slightly below horizon tal with the vehicle on its wheels and the rider seated Adjust both headlights to the same angle Headlight Bulb Replacement e Disconnect Headlight Lead Connector A e Turn the bulb holder B counterclockwise and remove it from headlight body e Insert the bigger projection A of the bulb holder into the bigger hole B in the headlight body e Turn the bulb holder until it is contact the projection A to the stopper B C Headlight Bulb Property of www SmallEngineDiscount com Not for Resale 16 40 ELECTRICAL SYSTEM Lighting System Headlight Body Removal e Remove Headlight Cover see Frame chapter Headlight Beam Adjusting Screw A and Washer e Pull the lower side of the headlight body forward and remove it HP128022 P Headlight Body Installation e Insert the tongues A on the headlight body into the grommets B in the
312. ts L Electrical System Alternator Cover Bolts 8 8 0 9 78 in lb Alternator Rotor Bolts 127 13 94 Alternator Stator Bolts 14 1 4 10 Spark Plug 14 1 4 10 Ignition Coil Mounting Bolt 8 8 0 9 78 in lb Pickup Coil Mounting Bolts 5 9 0 6 52 in lb Starter Motor Mounting Bolts 8 8 0 9 78 in lb Starter Motor Terminal Nut 4 9 0 5 43 in lb Starter Motor Terminal Locknut 6 9 0 7 61 in lb Starter Motor Bolts 3 4 0 3 30 in lb Starter Motor Clutch Bolts 34 3 5 25 L 2WD 4WD Actuator Mounting Bolts 9 8 1 0 87 in lb L S Engine Brake Actuator Mounting Bolts 8 8 0 9 78 in lb Reverse Position Switch 15 1 5 11 Neutral Switch 15 1 5 11 Starter Relay Terminal Nuts 4 9 0 5 43 in lb Igniter Mounting Bolts 2 3 0 23 20 in lb Ignition Switch Nut 2 7 0 28 24 in lb Oil Pressure Switch Terminal Bolt 1 5 0 15 13 in lb Regulator Rectifier Mounting Bolts 8 8 0 9 78 in lb Property of www SmallEngineDiscount com Not for Resale PERIODIC MAINTENANCE 2 7 Torque and Locking Agent The tables below relating tightening torque to thread diameter lists the basic torque for the bolts and nuts Use this table for only the bolts and nuts which do not require a specific torque value All of the values are for use with dry solvent cleaned threads Basic Torque for General Fasteners of Engine Parts Threads d a Mark of mm in bolt head 6 0 24 aT 6 0 24 4T 3 9 49 0 4 0 5 35 43 in lb 8 0 31 7T 18 22 1 8 2 2 13 16
313. ttery is only about 1 per day Sulfation here A Sediment here B Property of www SmallEngineDiscount com Not for Resale 16 18 ELECTRICAL SYSTEM Charging System Alternator Cover Removal e Disconnect Alternator Lead Conenctor A Pickup COil Lead Connector B e Remove Recoil Starter see Recoil Starter chapter Torque Converter Cover see Converter System chapter e Remove the three bolts of the drive pulley cover e Install and tighten the drive pulley holder A and the three bolt B as shown Special Tool Drive Pulley Holder 57001 1520 e Holding the drive pulley with the drive pulley holder loosen the alternator rotor bolt A e Remove the alternator rotor bolt and pulley e Place an oil pan under the engine left side e Remove Collar A Alternator Cover Bolts B Alternator Cover C Alternator Cover Installation e Be sure all of the old gasket has been removed from the alternator cover and the left crankcase sealing surfaces e Check that the dowel pins A are in place and fit a new gasket on the crankcase e Check that the bearing B is in place Property of www SmallEngineDiscount com Not for Resale ELECTRICAL SYSTEM 16 19 Charging System e Fit the grommets A into the notch in the cover e Apply grease the alternator cover oil seal e Tighten Torque Alternator Cover Bolts 8 8 N m 0 9 kgf m 78 in Ib e Check that the O ri
314. uckle e Tighten Torque Front Shock Absorber Clamp Bolts and Nuts 47 N m 4 8 kgf m 35 ft lb Hu04BO12 P e Insert the ball joint into the frame bracket e Tighten the nut Torque Front Shock Absorber Mounting Nut 74 N m 7 5 kgf m 54 ft Ib e Replace the circlip with a new one Special Tool Outside Circlip Pliers 57001 144 e Lower the vehicle and remove the jack Front Shock Absorber Inspection Since the front shock absorbers are sealed units which cannot be disassembled only external checks are necessary x If one unit is damaged replace both shock absorbers as a set If only one unit is replaced and the two are not balanced vehicle instability at high speed may result Property of www SmallEngineDiscount com Not for Resale 13 6 SUSPENSION Shock Absorbers Front Shock Absorber Spring Removal e Remove Front Shock Absorber see Front Shock Absorber Removal e Hold the holder A 57001 1476 and spacer B 57001 1477 in a vice as shown e Install the guide arbors C 57001 1476 on the holder e Insert the front shock absorber D into the center of the spacer and holder Special Tools Holder amp Guide Arbor 57001 1476 Spacer amp Holder 57001 1477 e Put the upper holder A 57001 1477 on upper end of the spring guide B and arbors so that the recess side C faces downward e Tighten the nuts A and press the spring until the spring seat stopper is free e Pull up the s
315. ude setting Thrust Plate C e Make match marks A and B on the sheaves so that it can be installed later in the same position Movable Shoe C Fixed Sheave D Property of www SmallEngineDiscount com Not for Resale CONVERTER SYSTEM 5 19 Driven Pulley e Wipe off the molybdenum disulfide grease e Remove the four pins A with a thin standard tip screwdriver B e Remove the movable sheave from the fixed sheave e Remove Spacer s A for Drive Belt Deflection Adjustment Driven Pulley Inspection x If the sheave surfaces A appear damaged replace the sheaves e Replace sheave with uneven wear on the belt contacting surfaces A Sheave Surface B Straight Edge Property of www SmallEngineDiscount com Not for Resale 5 20 CONVERTER SYSTEM Driven Pulley x If the guide bushings A are damaged or worn replace the movable sheave Sheave Bushing Inside Diameter Standard 39 994 40 104 mm 1 5746 1 5789 in Service Limit 40 13 mm 1 580 in e Inspect seals for damage x If seals are damaged replace the movable sheave x If the splines A are damaged or worn replace the fixed sheave x If the spring is damaged or worn replace the spring Spring Free Length A Standard 75 1 mm 2 96 in x If the spring coils are distorted replace the spring Driven Pulley Assembly e Clean off any grease or dirt on the movable and
316. until the pads are against each disc The brakes will not function on the first application of the lever if this is not done Caliper Disassembly e Remove Caliper see Caliper Removal Pads see Brake Pad Removal Anti rattle Spring e Using compressed air remove the piston O Cover the caliper opening with a clean heavy cloth A O Remove the piston by lightly applying compressed air B to where the brake line fits into the caliper dA WARNING To avoid serious injury never place your fingers or palm inside HLo6010151 C the caliper opening If you apply compressed air into the caliper the piston may crush your hand or fingers NOTE O If compressed air is not available do as follows with the brake hose connected to the caliper O Prepare a container for brake fluid O Remove the pads and spring see Brake Pad Removal O Pump the brake lever to remove the caliper piston Property of www SmallEngineDiscount com Not for Resale 12 12 BRAKES Calipers e Remove Plug A e Loosen Caliper Holder Shaft Allen Bolt A e Remove Washer A and Caliper Holder shaft B Caliper Holder C Boots D e Remove Dust Seal A Fluid Seal B e Remove Caliper Holder Shaft A Washer B Caliper Holder C HLO6BO06 P Property of www SmallEngineDiscount com Not for Resale BRAKES 12 13 Calipers Caliper Assembly e Replace the fluid
317. uretor overflow hose Property of www SmallEngineDiscount com Not for Resale 3 12 FUEL SYSTEM Carburetor e Connect the fuel level gauge to the open end of the carburetor overflow hose Special Tool Fuel Level Gauge 57001 1017 Fuel Level Gauge A Zero Line B Drain Plug C Carburetor Body Bottom Edge D Fuel Level E e Hold the gauge vertically against the side of the carburetor body so that the zero line is several millimeters higher than the bottom edge of the carburetor body e Turn the fuel tap to the ON position to feed fuel to the carburetor and gauge then turn out the carburetor drain plug a few turns Special Tool Carburetor Drain Plug Wrench Hex 3 57001 1269 e Wait until the fuel level in the gauge settles e Keeping the gauge vertical slowly lower the gauge until the Zero line is even with the bottom edge of the carburetor body NOTE O Do not lower the zero line below the bottom edge of the carburetor body If the gauge is lowered and then raised it 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 in the gauge and compare it to the specification e Tighten the drain plug and remove the fuel level gauge x If the fuel level is incorrect adjust it Fuel Level Standard 0 5 1 mm 0 02 0 04 i
318. ut voltage 36 54 V 3 000 r min rpm Stator coil resistance 0 33 0 49 Q Ignition System Spark plug Spark plug gap 0 8 0 9 mm 0 031 0 035 in Spark plug cap resistance 3 75 6 25 KQ Ignition coil 3 needle arcing distance 7 mm 0 28 in or more Primary winding resistance 0 09 0 13 2 Secondary winding resistance 3 8 5 8 KQ Primary peak voltage 100 V or more Pickup coil resistance 110 140 Q Pickup coil peak voltage 3 6 V or more Electric Starter System Starter motor Commutator diameter 28 mm 1 10 in 27 mm 1 06 in Brush length 10 mm 0 39 in 3 5 mm 0 14 in Switches Brake light switch timing ON after 10 mm 0 4 in of pedal travel Oil cooler fan switch resistance Rising temperature From OFF to ON at 67 73 C 153 163 F Falling temperature From ON to OFF at 57 63 C 135 145 F ON Less than 0 5 Q OFF More than 1 MQ Oil temperature warning light switch resistance Rising temperature From OFF to ON at 107 113 C ON 225 235 F Falling temperature From ON to OFF at 97 103 C 207 217 F ON Less than 0 5 2 OFF More than 1 MQ Special Tools Timing Light 57001 1241 Flywheel Holder 57001 1313 Hand Tester 57001 1394 Flywheel Puller 57001 1405 Needle Adapter Set 57001 1457 Drive Pulley Holder 57001 1520 Property of www SmallEngineDiscount com Not for Resale ELECTRICAL SYSTEM 16 11 Parts Location Light Dimmer
319. ve Seat see Frame chapter Fuel Tank Cover see Frame chapter Exhaust Pipe Cover see Frame chapter Fuel Hose A Fuel Tank Remove the fuel tank and fuel tap from the vehicle then be careful with the choke cable Fuel Tank Installation WA TO Gasoline is extremely flammable and can be explosive 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 Check the rubber dampers A e Check the grommets B x If the dampers are damaged or deteriorated replace them e Insert the projection A on the fuel tank into the damper grommet B e When installing the fuel tank be careful with the choke cable e Be sure the fuel hose is clamped to the fuel tap to prevent leakage AWARNING Fuel spilled from the fuel tap is hazardous Property of www SmallEngineDiscount com Not for Resale FUEL SYSTEM 3 23 Fuel Tank Fuel Tap Removal e Remove the fuel tank and drain it see Fuel Tank Removal e Remove Bolts A Fuel Tap B HC08B008 P Fuel Tap Installation e Be sure the O rings A are in good condition to prevent leakage HCOSGOIBS1 Fuel Tank and Fuel Tap Cleaning e Remove the fuel tank and drain it see Fuel Tank Removal e Pour some high flash point solvent into the fuel tank and shake the tank to remove
320. ver e Reconnect these 5 pin connectors to their opposite gray to black and black to gray e Turn on the ignition switch e Observe the belt warning light A O It should be flashing at a 0 4 second interval O Let it flash for at least seven seconds NOTE O More than seven seconds is OK O The 4WD LED light B will also flash only if 4WD is selected e While observing the belt warning light turn off the ignition switch Property of www SmallEngineDiscount com Not for Resale 16 48 ELECTRICAL SYSTEM LED Indicator e Disconnect the mismatched 5 pin connector sets and reconnect them normally Black to black gray to gray A e Connect the belt switch 2 pin connector B e Turn on the ignition switch e Confirm that no warning lights are flashing O The LED lights go on for one second LED Indicator Removal e Remove Front Fender see Frame chapter Handlebar Cover e Disconnect LED Indicator Lead Connector A e Remove Screws B and Collars LED Indicator C and Bracket LED Indicator Installation e Install Bracket A LED Indicator B Screws C and Collars D HP26002BS1 LED Indicator Inspection Flashing Pattern Inspection Property of www SmallEngineDiscount com Not for Resale ELECTRICAL SYSTEM 16 49 LED Indicator Indication Pattern Condition r lgnition SW ON y isee im ON r lgnition SW OFF gt 1sec gt 0 2sec
321. w Property of www SmallEngineDiscount com Not for Resale FUEL SYSTEM 3 3 Exploded View Throttle Cable Locknut Mim Choke lever Choke cable Throttle cable Throttle lever Jet needle Pilot jet Main jet Needle jet Pilot screw Priming pump OOONDAKRW PD i ak Apply engine oil Apply grease CA Canada model Do Property of www SmallEngineDiscount com Not for Resale 3 4 FUEL SYSTEM Exploded View Property of www SmallEngineDiscount com Not for Resale FUEL SYSTEM 3 5 Exploded View Torque Fastener Nm kgtm ft lb Remarks Air Cleaner Duct Front Clamp Screw 12 in lb Air Cleaner Duct Rear Clamp Screw 36 in lb Air Cleaner Housing Mounting Bolts 69 07 61 in lb Air Cleaner Intake Duct Clamp Screws 1 4 0 14 12 in lb S Gr Apply grease Property of www SmallEngineDiscount com Not for Resale 3 6 FUEL SYSTEM Specifications Item Throttle Case and Cable Throttle lever free play Carburetor Make Type Main jet Main air jet Needle jet Jet needle Pilot jet Pilot air jet Pilot screw Starter jet Idle speed Service fuel level Float height Optional parts Main jet Altitude 0 500 m 0 1700 ft 500 1400 m 1700 4700 ft 1400 2300 m 4700 7700 ft 2300 3300 m 7700 10700 ft 3300 4500 m 10700 14800 ft Standard 2 3 mm 0 08 0 12 in
322. w SmallEngineDiscount com Not for Resale ELECTRICAL SYSTEM 16 57 Actuator Control System Check 1 2WD 4WD Actuator Inspection e Remove Right Front Inner Cover see Frame chapter Actuator Lead Connector A e Measure the resistance between the following terminals in the actuator lead connector A Special Tool Hand Tester 57001 1394 Actuator Internal Resistance 4 Red 6 Black 3 150 1 Orange 3 Blue 3 5 6 5 kQ 2 Yellow 3 Blue 630 3 720 Q If any reading is not within the specified range replace the 2WD 4WD actuator x If the reading is within the specified range inspect the position of the actuator output shaft as following procedure HP23001BS1 e Remove 2WD 4WD Actuator see 2WD 4WD Actuator Removal e Check if the output shaft A position is within the inoperative angle range F as shown in the figure A Actuator Output Shaft B 2WD Point C 4WD Point D Operative Range Angle 109 5 deg E Angle 45 6 deg F Inoperative Range Angle 91 2 deg G Actuator Lead Connector x If the output shaft is in the inoperative range angle move the shaft in the operative range angle e Apply the 12 V battery voltage to the actuator Battery Connector 4 terminal Red Battery Connector 6 terminal Black e Stop applying the power when the output shaft comes near the 2WD point B e Install the actuator see 2WD 4WD Actuator Installation
323. x If the output shaft is in the operative range angle the malfunction of the 2WD 4WD actuator could be caused by other parts HP23021BS1 Check 2 Engine Brake Actuator Inspection e Remove Actuator Lead Connector A Property of www SmallEngineDiscount com Not for Resale 16 58 ELECTRICAL SYSTEM Actuator Control System e Measure the resistance between the following terminals in the actuator lead connector A Special Tool Hand Tester 57001 1394 Actuator Internal Resistance 4 Red 6 Black 3 150 1 Orange 3 Blue 3 5 6 5 kQ 2 Yellow 3 Blue 630 5 330 2 x If any reading is not within the specified range replace the engine brake actuator If the reading is within the specified range inspect the position of the actuator output shaft as following procedure HP23001BS1 e Remove Engine Brake Actuator see Engine Brake Actuator Removal e Check if the output shaft A position is within the inoperative angle range G as shown in the figure A Actuator Output Shaft B Angle 51 4 deg C Starting Point D Ending Point E Operative Range Angle 180 deg F Angle 7 deg G Inoperative Range Angle 91 2 deg H Actuator Lead Connector x If the output shaft is in the inoperative angle range move the shaft in the operative angle range e Apply the 12 V battery voltage to the actuator Battery Connector 4 terminal Red Batt
324. x Replace any if the lips are misshapen discolored indicating that the rubber has deteriorated hardened or been otherwise damaged Property of www SmallEngineDiscount com Not for Resale BRAKES 12 1 Brakes Table of Contents Exploded ViOW c cesccccsccssescetecceenseeetseecetaceeeeeneeess 12 2 Specifications 0 0 eeeeeeeeeeeeeeeteeeeeneeeeeetseeeeeeeneetaes 12 6 Brake Fluid coca 12 7 Brake Fluid Recommendation 12 7 Brake Fluid Level Inspection cere 12 8 Brake Fluid Change cccceeseeseeseeseteeeeeeeaes 12 8 Brake Line Air Bleeding 12 8 ECC 12 9 Master Cylinder Removal 12 9 Master Cylinder Installati0N o oo 12 9 Master Cylinder Disassemblly cceceee 12 9 Master Cylinder Assemblly cceeeeeee 12 10 Master Cylinder Inspection Visual Inspection 12 10 Calp GES cionales 12 11 Caliper REMOval eccececeeeeeeeeeeeeeeeeeeneeeees 12 11 Caliper Installation c cceeceeseeseeereeeeeeees 12 11 Caliper DisassemblY oocoocccincccocccnociconananccancnnns 12 11 Caliper AsSeMDlY cocoocccnccinconocnocininnonccnnnnnnnno 12 13 Fluid Seal DaMaQ6 cccocccocccncccnocononnnanccanccinnnonos 12 13 Dust Seal and Friction Boot Damage 12 14 Piston and Cylinder Damage 12 14 Caliper Holder Shaft Wear Inspection 12 14 Brake Pads ait aaa 12 15 Brake Pad Removal 12 15 Brake Pad InstallatiON ooo ooonncnnnnnnonnn
325. y Then stop the vehicle e Park the vehicle so that it is level both side to side and front to rear e Remove the front side cover see Frame chapter e Place an oil pan beneath the front final gear case and remove the drain plug A AWARNING When draining or filling the final gear case be careful that no oil gets on the tire or rim Clean off any oil that inadvertently gets on them with a high flash point solvent e After the oil has completely drained out install the drain plug with a new aluminum gasket and tighten it Torque Oil Drain Plug 24 N m 2 4 kg m 17 ft lb e Fill the gear case up to the bottom of filler opening with the oil specified below Front Final Gear Case Oil Type API SF or SG API SH or SJ with JASO MA Viscosity SAE 10W 40 Capacity 430 mL 0 45 US qt NOTE O Depending on the atmospheric temperature of your riding area the engine oil viscosity should be changed according to the chart e Be sure the O ring is in place and tighten the filler cap Torque Oil Filler Cap 29 N m 3 0 kg m 22 ft lb HK118007 P HK118013 P 1 1 1 SAE 20W 50 SAE 20W 40 SAE 10W 50 ee AE a 20 1 1 4 14 32 50 68 J 86 10 L 1 1 1 1 1 1 30 40 1 4 F HG05002BS1 C Property of www SmallEngineDiscount com Not for Resale 2 20 PERIODIC MAINTENANCE Periodic Maintenance Procedures Rear Final Gear

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