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Tighten the two clamp bolts alternately two times to en

1. ENGINE LUBRICATION SYSTEM 7 1 Engine Lubrication System Table of Contents ee 7 2 Lubrication System Chart nsa aa a eA ie eee 7 4 Tee 7 6 Special EEN 7 7 Engine Oiand Ol EE 7 8 Engine Oil Level Inspection EE 7 8 Engine Oil CA sd id 7 8 Oil IMIG nan aia ts 7 9 OSS CROSSE cessor AR CR at eta nD aes ele ecclesia AS RG Se a Da eas 7 10 Oil Screen Scavenge Removal ii 7 10 Oil Screen Scavenge Installation nano cnn nannennnnnnns 7 10 Oil Screen Feed Removal sarao til ile Es 7 11 Oil Screen Feed Installation tocino rial nia 7 11 Oil Screen RE e Ren ne io ricas 7 11 Oil Screen Feed Cleaning miii tada oca 7 12 Cl Pressure Relief Valve tacita oi ide toi 7 13 Oil Pressure Relief Valve Removal 7 13 Oil Pressure Relief Valve Installation 7 13 Oil Pressure Relief Valve Inspection 7 13 SUE NEE 7 14 Oil Pump Scavenge Hemoval EE 7 14 Oil Pump ne El ET e TEE 7 14 Oil PUMP FSSA REMOV EE 7 15 Oil Pump Feed Installation corrida ENEE EEN 7 15 Oil PRIA HIS SS CO ashes ait tt e a ea ina idee weds a 7 16 Oll EE 7 17 Oil Pressure Measurement cece eeeeecceeeeceeeeceeeeeceeeeceueecceeeeceeeecuaeeeceesecneeeseeeeseeeseneesneess 7 17 7 2 ENGINE LUBRICATION SYSTEM Exploded View ENGINE LUBRICATION SYSTEM 7 3 Exploded View Torque No Fastener Nm kgtm felb Remarks 1 Engine Oil Dra
2. PERIODIC MAINTENANCE 2 13 Periodic Maintenance Procedures A WARNING Operation with an improperly adjusted incorrectly routed or damaged cables could result in an unsafe riding Condition Follow the service manual to be make sure to correct any of these conditions Hot Starter Lever Free Play Inspection e Slide the clutch lever dust cover A back e Check the hot starter lever play B when pulling the start lever C lightly Hot Starter Lever Free Play Standard 0 5 1 0 mm 0 02 0 04 in x lf the free play is improper adjust the hot starter cable Slide the adjuster cover A back e Loosen the locknut B and turn the adjuster C to obtain the proper lever free play e Tighten the locknut securely e Check that the hot starter lever moves smoothly from full open to close and the lever closes quickly and completely in all steering positions by the return spring If the hot starter lever does not return properly check the hot starter cable routing free play and cable damage Then lubricate the hot starter cable Idle Speed Inspection NOTICE This motorcycle is designed for competition use only Therefore the radiator does not incorporate a cooling fan Prolonged idling of the engine with no airflow through the radiator can cause coolant loss and engine overheating resulting in possible en gine damage Any riding conditions that increase engine temperature will further
3. ST5710588T ST5712658T Steering Stem Nut Wrench Bearing Remover Head 415 x p17 57001 1100 57001 1267 ST5711008T ST571267ST Hook Wrench R37 5 R42 Fork Oil Seal Driver 48 57001 1101 57001 1509 ST5711018ST ST5715098T Bearing Driver Set Top Plug Wrench 49 mm 57001 1129 57001 1653 ST5711298T ST571653ST Jack 57001 1238 ST5712388ST 13 8 SUSPENSION Front Fork Air Pressure The standard air pressure in the front fork legs is atmo spheric pressure Air pressure in the fork legs increase with normal use so the fork action stiffens during opera tion Release air pressure form the fork legs prior to each race through the pressure relief screw located in each front fork cap e Place the jack under the frame so that the front wheel off the ground Special Tool Jack 57001 1238 e Remove the screws A at the top of the front fork top plugs to let the air pressure equalize NOTE ODo not use the sidestand when adjusting the air pres sure OAajust the air pressure when the front forks are cold e Replace the O ring with a new one e Install the screw Rebound Damping Adjustment e Place the jack under the frame so that the front wheel off the ground Special Tool Jack 57001 1238 e Clean the bottom of the fork tubes e Remove the caps on the bottom of the fork tubes e To adjust rebound damping turn the adj
4. KHL15 10 KAYABA 01 or equivalent 335 mL 11 3 US oz 189 mL 6 4 US oz Service Limit 323 mm 12 7 in 0 5 mm 0 020 in 1 mm 0 04 in 1 mm 0 04 in Adjustable range 300 380 mL 10 1 12 8 US oz Electrical System Spark Plug Gap 0 8 0 9 mm 0 03 0 04 in TIR Total Indicator Readings PERIODIC MAINTENANCE 2 11 Special Tools Inside Circlip Pliers Spark Plug Wrench Hex 16 57001 143 57001 1262 ST570143ST ST571262ST Steering Stem Nut Wrench Filler Cap Driver 57001 1100 57001 1454 e D ST5711008T ST5714548T Jack Top Plug Wrench 49 mm 57001 1238 57001 1653 ST5712388ST ST571653ST 2 12 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System Fuel Hose and Connection Inspection OThe fuel hoses are designed to be used throughout the motorcycle s life without any maintenance however if the motorcycle is not properly handled the inside the fuel line can cause fuel to leak A or the hose to burst e Check the fuel hose Replace the fuel hose if any fraying cracks B bulges C or ozonic cranks D are noticed e Check that the hose A is securely connected and clamps B are tightened correctly e When installing route the hose according to Cable Wire and Hose Routing section in the Appendix chapter e When installing the fuel hose avoid sharp bending kink i
5. 96 10 mm 3 783 in 95 82 mm 3 772 in 0 18 mm 0 0071 in 1 13 mm 0 0445 in 0 90 mm 0 035 in 0 6 mm 0 8 mm 18 96 mm 19 08 mm 0 02 in 0 03 in 0 7465 in 0 7512in oa 19 07 mm 0 7508 in TIR Total Indicator Readings 5 8 ENGINE TOP END Specifications Cam Height Camshaft Runout GE11012281 GE11077BS1 C Cam Height A Valve Stem Diameter Valve Stem Bend GE15049BS1 C 6E150112S1 C Valve Stem Diameter A Dial Gauge A 45 B Special Tools and Sealant ENGINE TOP END 5 9 Compression Gauge 20 kgf cm 57001 221 T5702218T Valve Spring Compressor Assembly 57001 241 ST5702418T Valve Guide Arbor 5 5 57001 1021 ST5710218T Valve Guide Reamer 5 5 57001 1079 OS Piston Ring Compressor Grip 57001 1095 ST5710798T ST5710958T Valve Seat Cutter 45 635 57001 1116 Valve Seat Cutter 32 35 57001 1121 ST5711168T ST5711218T Valve Seat Cutter 32 638 5 57001 1122 S15711228T Valve Seat Cutter Holder 5 5 57001 1125 SA Valve Seat Cutter Holder Bar 57001 1128 ST5711288T 8757112597 5 10 ENGINE TOP END Special Tools and Sealant Valve Seat Cutter 55 35 57001 1247 ST571247ST Spark Plug Wrench Hex 16 57001 1262
6. 000 Y DOF D a sch 16 4 ELECTRICAL SYSTEM Exploded View GPO2424BW5 C ELECTRICAL SYSTEM 16 5 Exploded View No Fastener Joruue Remarks N m kgf m ft Ib 1 Starter Motor Terminal Nut 5 9 0 60 52 in lb 2 Starter Motor Mounting Bolts 9 8 1 0 87 in lb 3 Crankshaft Sensor Bolts 7 0 0 71 62 in lb 4 Stator Bolts 4 0 0 41 35 in lb L 5 Flywheel Nut 98 10 72 6 Magneto Cover Bolts 9 8 1 0 87 in lb 7 Timing Inspection Cap Hand Tighten 8 Flywheel Nut Cap Hand Tighten 9 Torque Limiter Cover Bots 98 10 87mb St 30 inb n L 3 Starter Relay a Starter Motor 15 Magneto 16 Stator 17 Magneto Cover G Apply grease L Apply a non permanent locking agent M Apply molybdenum dislfide grease R Replacement Parts SS Apply silicone sealant 16 6 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 16 7 Exploded View T No Fastener Se Remarks N m kgf m ft lb 1 Head Light Bracket Screws 1 4 0 14 12 in lb 2 Gear Position Switch Screws 2 9 0 30 26 in lb L 3 Meter Unit 4 Headlight 5 Speed Sensor 6 Tail Light 7 Gear Position Switch 8 Australia Models HG Apply high temprerature grease L Apply a non permanent locking agent 16 8 ELECTRICAL SYSTEM Specifications Item Battery Type Model Capacity Magneto Crankshaft Sensor Resistance Magneto Output Vol
7. FUEL SYSTEM 3 17 Carburetor OAgjust the following items if necessary Throttle Cable see Throttle Grip Free Play Adjustment in the Periodic Maintenance chapter Idle Speed see Idle Speed Adjustment in the Periodic Maintenance chapter Fuel Inspection e Refer to the Fuel Inspection in the Periodic Maintenance chapter Carburetor Disassembly e Remove the carburetor and drain the fuel into a suitable container see Carburetor Removal e Remove all vent hoses A and fuel hose B e Unscrew the screw A e Pull out the fuel hose fitting B e Unscrew the carburetor cap bolts A e Remove the carburetor cap B e Unscrew the throttle valve link screw A e Pull out the throttle valve assembly B 3 18 FUEL SYSTEM Carburetor e Disassemble the throttle valve assembly jet needle holder A unscrew spring B retainer C jet needle with circlip D O ring with throttle valve plate E and throttle valve F e Remove the choke knob starter plunger assembly A from the carburetor e Remove the throttle pulley shaft A with the spring B steel washer C plastic washer D and throttle valve link E OTurn the throttle pulley shaft A clockwise while holding down the acceleration pump lever B and clear the idle stop screw C to the stopper D of the pulley e Turn in the pilot air screw A fully but not tightly and count the number of turns Australia and Europe models
8. Threads dia Torque mm kgf m ft lb 5 3 4 4 9 0 35 0 50 30 43 in lb 6 5 9 7 8 0 60 0 80 52 69 in lb 8 14 19 1 4 1 9 10 0 13 5 10 25 34 2 6 3 5 19 0 25 12 44 61 4 5 6 2 33 45 14 73 98 7 4 10 0 54 72 16 115 155 11 5 16 0 83 115 18 165 225 17 0 23 0 125 165 20 225 325 23 33 165 240 PERIODIC MAINTENANCE 2 9 Specifications Item Standard Service Limit Fuel System Throttle Grip Free Play 2 3 mm 0 08 0 12 in Hot Starter Lever Free Play 0 5 1 0 mm 0 02 0 04 in Air Cleaner Element Oil High quality foam air filter oil a5 Cooling System Coolant Type recommended Permanent type antifreeze Color Green Mixed Ratio Soft water 50 and coolant 50 Sas Freezing Point 35 C 31 F Total Amount 1 05 L 1 11 US qt Engine Top End Valve Clearance Exhaust 0 17 0 22 mm 0 0067 0 0087 in Inlet 0 10 0 15 mm 0 0039 0 0059 in Cylinder Head Warp 0 05 mm 0 002 in Cylinder Inside Diameter see 96 000 96 012 mm 3 7795 3 7800 in 96 10 mm 3 783 in text Piston Cylinder Clearance 0 020 0 042 mm 0 00079 0 0017 in Gegen Engine Right Side Clutch Lever Free Play 8 13 mm 0 3 0 5 in Friction Plate Thickness 2 92 3 08 mm 0 115 0 121 in 2 6 mm 0 10 in Friction Plate Warp 0 15 mm 0 0059 in or less 0 3 mm 0 01 in Steel Plate Warp 0 2 mm 0 008 in or less 0
9. 2 24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Piston Cylinder Clearance The piston to cylinder clearance is measured whenever a piston or cylinder is replaced with a new one The standard piston to cylinder clearance must be adhered to whenever the cylinder is replaced If only a piston is replaced the clearance may exceed the standard slightly But it must not be less than the minimum in order to avoid piston seizure The most accurate way to find the piston clearance is by making separate piston and cylinder diameter measure ments and then computing the difference between the two values Measure the piston diameter as just described and measure the cylinder diameter at the very bottom of the cylinder Piston Cylinder Clearance Standard 0 020 0 042 mm 0 00079 0 0017 in Piston Piston Ring and Piston Pin Replacement e Refer to the Cylinder and Piston Section in Engine Top End chapter Spark Arrester Cleaning This vehicle is equipped with a spark arrester It must be properly maintained to ensure its efficiency The spark arrester must be installed correctly and functioning properly to provide adequate fire pro tection A WARNING Hot exhaust system parts can cause serious burns The exhaust system becomes very hot soon after the engine is started To avoid burns be sure the exhaust system is cold before cleaning the spark arrester e Remove Muffler End Mounting Bolts A
10. e Assemble the valve guide driver A and valve guide driver attachment D B Special Tools Valve Guide Driver 4 5 57001 1564 Valve Guide Driver Attachment D 57001 1659 e When install the exhaust valve guide using the attached washer t 2 0 C e Using the valve guide driver press and insert the valve guide in until the valve guide driver surface D touches the head surface E Exhaust 11 1 11 3 mm 0 437 0 445 in F Inlet 13 1 13 3 mm 0 516 0 524 in GE15114BS1 C 5 28 ENGINE TOP END Valves e Ream the valve guide with valve guide reamer A even if the old guide is reused Special Tool Valve Guide Reamer 65 5 57001 1079 Valve Valve Guide Clearance Measurement Wobble Method Olf a small bore gauge is not available inspect the valve guide wear by measuring the valve valve guide clearance with the wobble method as indicated below e Insert a new valve A into the guide B and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface e Move the stem back and forth C to measure the valve wobble e Repeat the measurement in a direction at a 90 angle to the first measurement x If the reading exceeds the service limit replace the guide NOTE O The reading is greater than the actual valve valve guide clearance because the measurement is taken outside of the guide Valve Valve Guide Clearance Measurement Wobble
11. Battery Negative Cable Black Starter Relay Connector Red Starter Relay Black Cap Battery Positive Cable Red Starter Motor Cable White Tail Light Lead Clamps Fix the tail light lead by twisting the clamps Tail Light Lead Connector White Main Relay Main Relay Connector White Regulator Rectifier Regulator Rectifier Lead Connector Green Run the regulator rectifier lead to the inside of the front left side cover mounting bracket of the air cleaner housing Run the main harness and starter motor cable under the frame pipe Run the tail light lead to the most bottom of grooves on the U shaped bracket To Main Relay To Regulator Rectifier Bracket Bracket Clamps Tightened together with the bracket Clamp Fix only the main relay lead 23 Run the starter motor cable to inside of the main relay lead 25 Run the tail light lead to inside of the main relay lead Place the band at the hollow of the battery holder ei DO Cable Wire and Hose Routing 17 12 APPENDIX a e D e IT EZ e ELA UL SSE gS APPENDIX 17 13 Cable Wire and Hose Routing OONDAaARWND gt dl 8 D Ol Starter Motor Cable White Run the starter motor cable over the harness Tighten together the battery negative cable and starter mounting bolt Connect the starter motor cable to the starter m
12. Gear Position Switch Inspection NOTE OBe sure the transmission mechanism is good condition e Remove the left radiator shroud e Disconnect the gear position switch lead connector A e Set the hand tester A to the x1 kQ or x100 Q range and connect it to the terminals in the gear position switch lead connector B and ground C Internal Circuit D Green Red Lead E Black Lead Special Tool Hand Tester 57001 1394 Gear Position Switch Resistance Gear D Terminal Ground E Terminal Ground Position ist 3 00 3 32 kO Neutral 1 70 1 89 kQ 2nd 1 07 1 19 KQ 3rd 0 695 0 769 kQ 4th 0 430 0 476 kQ 5th 0 248 0 274 kQ xlf the tester reading is not as specified replace the gear position switch with a new one Ist N 2nd 3rd 4th 5th GP18459BS2 ELECTRICAL SYSTEM 16 53 Main Relay Main Relay Inspection e Remove the seat see Seat Removal in the Frame chap ter e Remove the main relay A e Check conductivity of the following numbered terminals by connecting the hand tester and one 12 V battery to the main relay as shown x lf the tester does not read as specified replace the main relay GP18354BS1 C Main Relay Inspection with the battery disconnected Tester Connection Tester Reading Q 3 5 eo 1 2 Not The actual reading varies with the hand tester used Main Relay Inspection with the batte
13. e Place a container under the coolant drain plug A and drain the coolant from the radiator and engine by remov ing the drain plug on the water pump cover Immediately wipe or wash out any coolant that spills on the frame or engine e Inspect the old coolant for visual evidence of corrosion and abnormal smell see Coolant Deterioration Inspection in the Periodic Maintenance chapter e Remove Bolts A Reserve Tank Cap B e Turn over the reserve tank and pour the coolant into the suitable container Coolant Filling NOTICE Use coolant containing corrosion inhibitors made specifically for aluminum engines and radiators in accordance with the instruction of the manufac ture s Soft or distilled water must be used with the antifreeze see below for antifreeze in the cooling system If hard water is used in the system it causes scale accumulation in the water passages and considerably reduces the efficiency of the cooling system Recommended Coolant Type Permanent type antifreeze soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators Color Green Mixed ratio Soft water 50 Coolant 50 Freezing point 35 C 31 F Total amount 1 05 L 1 11 US qt e Install the drain plug OReplace the gasket with a new one Torque Coolant Drain Plug 7 0 N m 0 70 kgf m 62 in Ib 4 10 COOLING SYSTEM Coolant e Fill the radiator up to the bo
14. _ Kawasaki KLX450R Motorcycle Service Manual Quick Reference Guide General Information Periodic Maintenance Fuel System Cooling System Engine Top End Engine Right Side Engine Lubrication System Engine Removal Installation Crankshaft Transmission Wheels Tires Final Drive Brakes Suspension Steering Electrical System mk sch ech sch h Lech sch NIO Bi Oo IN O0 0l NI I IO IG Aj ON em Appendix This quick reference guide will assist you in locating a desired topic or pro cedure send the pages back to match the black tab of the desired chapter num ber with the black tab on the edge at each table of contents page Refer to the sectional table of contents for the exact pages to locate the spe cific topic required Kawasaki KLX450R Motorcycle Service Manual All rights reserved No parts of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Quality Assurance Division Consumer Products amp Machinery Company Kawasaki Heavy Industries Ltd Japan No liability can be accepted for any inaccuracies or omissions in this publication although every possible care has been taken to make it as complete and accurate as possible The right is reserved to make changes at any time without pri
15. A Water Pump Shaft B COOLING SYSTEM 4 15 Water Pump e Insert a bar A into the water pump shaft hole from the outside of the right engine cover and remove the ball bearing B by tapping C evenly around the bearing in ner race e Remove the spacer D e Remove the ball bearing E and oil seal F from the right engine cover in the same way as ball bearing removal e Insert a bar A into the water pump shaft hole from the inside of the right engine cover and remove the oil seal B by tapping C evenly around the seal lips Oil Seal and Bearing Installation NOTICE If the oil seal or ball bearing is removed replace all of them with new ones at the same time e Be sure to replace the oil seals e Apply plenty of high temperature grease to the oil seal lips e Press in the new oil seal A using a bearing driver set from the outside of the right engine cover so that the seal bottom surface is flush with the end face B of the right engine cover e Press in the new oil seal C using a bearing driver set from the outside of the right engine cover so that the oil seal surface is flush D with the surface of the right engine cover Special Tool Bearing Driver Set 57001 1129 e Press the ball bearings A together with the spacer B into the hole until the face of the bearing is even C with the end of the hole Special Tool Bearing Driver Set 57001 1129 6D06060BS1 C G6D060
16. A and Nuts B Chain Guide Plate C Chain Guide D e Unscrew the rocker arm pivot nut A and pull out the rocker arm pivot bolt B NOTICE When pulling out the mounting bolts lift the swingarm slightly Forcing or tapping on a bolt could damage the bolt sleeve and bearing e Unscrew the nut A e Pull out the swingarm pivot shaft B and remove the swingarm C SUSPENSION 13 29 Swingarm e Unscrew the screws A e Separate the chain slipper B from the swingarm Swingarm Installation e Apply plenty of grease to the inside of the needle bear ings sleeves and oil seals e Tighten the following Torque Swingarm Pivot Shaft Nut 98 N m 10 kgf m 72 ft Ib Rocker Arm Pivot Nut 59 N m 6 0 kgf m 44 ft lb e Refer to the Wheels Tires Final Drive and Brakes chap ters for wheel installing Swingarm Bearing Removal e Remove Swingarm see Swingarm Removal Collars A Grease Seals B Sleeves C Needle Bearings D e Remove the needle bearings E using the oil seal amp bear ing remover Special Tool Oil Seal amp Bearing Remover 57001 1058 Swingarm Bearing Installation e Replace the needle bearings and grease seals with new ones e Apply plenty of grease to the sleeves grease seals C and needle bearings A B NOTE Olnstall the needle bearings so that the manufacturer s marks face out Olnstall the grease seals so that the deep groove side of the rip in ward
17. A of the holder into the projection B of the cylinder head 6E17013BS1 o 5 40 ENGINE TOP END Muffler A WARNING The muffler can become extremely hot during nor mal operation and cause severe burns Do not re move the muffler while it is hot Muffler Removal e Loosen the muffler clamp bolt A e Remove the exhaust pip holder nuts B e Remove the exhaust pipe C and muffler clamp e Remove Right Side Cover see Side Cover Removal in the Frame chapter e Remove the muffler mounting bolts A e Remove the muffler B from the back Muffler Installation e Replace the holder gasket A with a new one e Check the gasket B at the clamp and replace it if it is damaged Make sure that the gasket is placed securely outside the exhaust pipe e First tighten the exhaust pipe holder nuts and rear muffler mounting bolt temporary e Second pull the muffler backward and tighten the front muffler mounting bolt temporary Torque Front Muffler Mounting Bolt First 9 8 N m 1 0 kgf m 87 in Ib e Third tighten the rear muffler mounting bolt and exhaust pipe holder nuts in order to the specified torque Torque Rear Muffler Mounting Bolt 20 N m 2 0 kgf m 15 ft lb Exhaust Pipe Holder Nuts 20 N m 2 0 kgf m 15 ft lb e Fourth tighten the exhaust pipe clamp bolt securely e Lastly tighten the front muffler mounting bolt to the spec ified torque Torque Front Muffler Mounting Bolt Fi
18. AU 2 reference Service Fuel Level 6 5 1 mm 0 26 0 04 in below the bottom edge of the carb body Float Height 8 1 mm 0 3 0 04 in Air Cleaner Air Cleaner Element Oil High quality form air filter oil FUEL SYSTEM 3 7 Special Tool Fuel Level Gauge M18 x 1 0 57001 122 8757012297 3 8 FUEL SYSTEM Throttle Grip and Cable If the throttle grip has excessive free play due to cable stretch or misadjustment there will be a delay in throttle re sponse Also the throttle valve may not open fully at full throttle On the other hand if the throttle grip has no play the throttle will be hard to control and the idle speed will be erratic Check the throttle grip play periodically in accor dance with the Periodic Maintenance Chart and adjust the play if necessary The throttle cable routing is shown in Cable Wire and Hose Routing Section in the Appendix chapter Free Play Inspection e Refer to the Throttle Grip Free Play Inspection in the Pe riodic Maintenance chapter Free Play Adjustment e Refer to the Throttle Grip Free Play Adjustment in the Periodic Maintenance chapter Throttle Cable Replacement e Slide out the dust cover A and cable housing dust cover B e Unscrew the screws A e Separate the throttle cable housing B e Free the tips A from the grip B FUEL SYSTEM 3 9 Throttle Grip and Cable e Remove the exhaust pipe see Muffler Removal in
19. Always release nitrogen gas pressure be fore disassembling the rear shock absorber to pre vent explosive separation of parts e Adjust the gas reservoir damping adjusters A to the soft est position e Remove the air bleed bolt B and pump the rear shock to drain the oil out the rear shock body e Install the air bleed bolt PERIODIC MAINTENANCE 2 55 Periodic Maintenance Procedures e Using the suitable tool A and press push the reservoir cap B in 10 mm 0 39 in e Remove the circlip C from the gas reservoir e Pull the gas reservoir cap B out of the gas reservoir using the pliers A e Pry or tap A at the gaps B in the stop C with suitable tools to free the stop from the rear shock body D e Slide the stop up the top of the piston rod then lightly tap around the seal with a suitable rod and mallet and push the seal assembly 10 mm 0 39 in down e Remove the circlip A e Lightly move the piston rod back and forth and pull out the piston rod assembly e Pour the oil out of the rear shock body GMO5065BS1 e Visually inspect the piston A O ring B and oil seal assy C elt the piston O ring and oil seal assy are badly scored rusty or damaged replace them 2 56 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Using the grinder shave off the stopper portion A of the rod e Remove Nut B Washer C Piston D e Install
20. Axial TIR 1 0 mm 0 039 in or less Radial TIR 1 0 mm 0 039 in or less Service Limit Axial 2 mm 0 08 in Radial 2 mm 0 08 in Wheel Bearing Inspection e Raise the front rear wheel off the ground Special Tool Jack 57001 1238 e Spin the wheel lightly and check for roughness binding or noise lf roughness binding abnormal noise is found replace the hub bearing e Turn the handlebar until the handlebar doesn t move to either side e The wheel edge is moved to one direction gripping the edge of the wheel by both hands and the play of the wheel bearing is checked lf the play is found replace the bearing 2 32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Final Drive Drive Chain Slack Inspection e Raise the rear wheel off the ground rotate the rear wheel to find the place where the chain is tightest because it wears unevenly e Check the wheel alignment see Wheel Alignment Inspec tion in the Final Drive chapter and adjust it if necessary see Drive Chain Slack Adjustment NOTE OClean the drive chain if it is dirty and lubricate it if it appears dry e Rotate the rear wheel to find the position where the chain is tightest e Measure the space chain slack A between the chain and the swingarm at the rear of the chain slipper as shown If the drive chain slack exceeds the standard adjust it Chain Slack Standard 52 58 mm 2 0 2 3 in Drive Chain Slack Adj
21. C e Pry open the clamps A e Disconnect Magnet Lead Connector B Ignition Coil Lead Connector C e Remove Breather Hose D Spark Plug Cap Ignition Coil Ignition Coil Removal in the Electrical Sys tem chapter E Upper Engine Bracket Bolts F Upper Engine Mounting Bolts and Nuts G Upper Engine Brackets H e Remove Engine Guard A Middle Engine Bracket Bolts and Nuts B Middle Engine Mounting Bolt and Nut C Middle Engine Brackets Left and Right D Lower Engine Mounting Bolts and Nuts E ENGINE REMOVAL INSTALLATION 8 7 Engine Removal Installation e Remove the swingarm pivot shaft nut A to pull out the swingarm pivot shaft B OPull out the swingarm pivot shaft half way from right side to free the engine e Remove the engine from the vehicle to right side OClear the engine rear portion from the swingarm and then remove the engine 8 8 ENGINE REMOVAL INSTALLATION Engine Removal Installation Engine Installation e Install the engine OFirst insert the front portion of the engine and then install the rear portion e Install the swingarm pivot shaft all engine bracket and mounting bolts temporarily OSwingarm pivot shaft insert from the right side Olnsert the middle and lower engine mounting bolts from the left side e First tighten the pivot shaft nut next tighten the lower en gine mounting nut Torque Swingarm Pivot Shaft Nut 98 N m 10 kgf m 72 ft Ib Lower
22. For each fastener first loosen it by 1 2 turn then tighten it If cotter pins are damaged replace them with new ones Nut Bolt and Fastener to be checked Wheels Spoke Nipples Front Axle Nut Front Axle Clamp Bolt Rear Axle Nut Cotter Pin Rear Axle Nut Final Drive Chain Adjuster Locknut Rear Sprocket Nuts Brakes Front Master Cylinder Clamp Bolts Brake Lever Pivot Nut Front Caliper Mounting Bolts Brake Pedal Bolt Rear Brake Joint Cotter Pin Rear Master Cylinder Mounting Bolts Rear Caliper Mounting Bolts Suspension Front Fork Clamp Bolts Front Fender Bolts Rear Shock Absorber Mounting Bolts Nuts Swingarm Pivot Nut Steering Steering Stem Head Nut Handlebar Clamp Bolts Engine Throttle Cable Adjuster Locknuts Engine Mounting Bolts Nuts Shift Pedal Bolt Muffler Mounting Bolts Exhaust Pipe Holder Nuts Clutch Cable Adjuster Locknut Clutch Lever Pivot Nut Others Footpeg Cotter Pins Rear Frame Bolts FUEL SYSTEM 3 1 Fuel System Table of Contents Exploded dese In eege Eege see anges 3 2 EEN 3 6 PSC I Al Lee 3 7 Throttle Grip anid Ke EE 3 8 Free Play INspocl Oia 3 8 Free Play EST 3 8 Throttle ee Ee EE 3 8 Throttle Cable Lubrication eege acts 3 9 Throttle Cable Inspeccion ki 3 9 Hot Starter Cabl Removal 5 rs Eege EEA NEEN ne ENEE Eeer 3 10 Hot Starter Cable Installation CERS EEN EEN 3 10 Hot Starter Lever Free Play Inspection 3 10 Hot Starter Lever Free Play Adjustment AAA 3 11 Hot sta
23. Tie Rod see Tie Rod Removal Rocker Arm see Rocker Arm Removal Collars A Sleeves B Oil Seals C Grease Seals D e Remove the needle bearings E using the bearing re mover head and bearing remover shaft e Remove the needle bearing F using the oil seal amp bear ing remover Special Tools Bearing Remover Head 57001 1267 Bearing Remover Shaft 57001 1265 Oil Seal amp Bearing Remover 57001 1058 GMO7034BS2 SUSPENSION 13 33 Tie Rod Rocker Arm Tie Rod and Rocker Arm Bearing Installation e Replace the needle bearing grease seals and oil seals with new ones e Apply plenty of grease to the oil seal and needle bearings A NOTE Olnstall the grease seals so that the deep groove side of the rip out ward e Install the needle bearings A B and grease seals C position as shown Olnstall the needle bearings and grease seals position as shown OThe installation procedure is the same as the counter side 1 mm 0 04 in D Rear Shock Absorber G 4 5 mm 0 18 in E Tie rod H 4 25 mm 0 167 in F Rocker Arm I gt 5 g m E Lr AAA e d DC DI HE Je H GM07035BW2 Needle Bearing Inspection kif there is any doubt as to the condition of either needle bearing replace the bearing and sleeve as a set 13 34 SUSPENSION Uni Trak Maintenance Uni Trak Linkage Inspection e Refer to the Swingarm and Uni Trak Linkage
24. amount fork oil and discharge an excess of oil 2 52 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Completely wipe of the fork oil from the spring A spacer B and cylinder unit C e Insert above mentioned parts into the fork e Temporarily tighten the fork top plug A subtank using the top plug wrench Special Tool Top Plug Wrench 49 mm B 57001 1653 e Clamp the axle holder with a vise OProtect the axle holder with a rag when using a vise A WARNING Clamping the axle holder too tight can damage it which will affect riding stability Do not clamp the axle holder too tight e Compress the outer tube by hands and install the top plug wrench A between the axle holder bottom and locknut Special Tool Top Plug Wrench 49 mm 57001 1653 WARNING The fork spring applies pressure to the adjuster assembly and can eject the special tool with sub stantial force ifthe tool is not properly and securely placed Be sure the tool is fully in place as shown in the photo and keep fingers away to avoid getting them pinched between the tool adjuster assembly and axle holder e Insert the push rod A into the piston rod PERIODIC MAINTENANCE 2 53 Periodic Maintenance Procedures e Replace the O ring and gasket on the adjuster assembly with new ones and apply specified fork oil to the O ring e Turn the locknut A counterclockwise until it contacts wi
25. and damage If they are worn as illustrated or damaged replace the sprocket A Worn Tooth Engine Sprocket B Worn Tooth Rear Sprocket C Direction of Rotation NOTE Olf a sprocket requires replacement the chain is proba bly worn also When replacing a sprocket inspect the chain 6K04030351 6K05017BS1 PERIODIC MAINTENANCE 2 35 Periodic Maintenance Procedures Rear Sprocket Warp Inspection e Using the jack raise the rear wheel off the ground Special Tool Jack 57001 1238 e Set a dial gauge A against the rear sprocket B near the teeth as shown and rotate C the rear wheel to measure the sprocket runout warp The difference between the highest and lowest dial gauge readings is the amount of runout warp kif the runout exceeds the service limit replace the rear sprocket GS12024BS1 C Rear Sprocket Warp Standard 0 4 mm 0 016 in or less Service Limit 0 5 mm 0 02 in Brakes Brake Lever and Pedal Position Adjustment A WARNING An improperly adjusted brake could drag and cause the brake to overheat damaging the brake assem bly and possbily locking the rear wheel resulting in loss of control Always maintain the proper brake adjustment e Adjust the front brake lever A to suit you e Slide the brake lever dust cover B out of place e Loosen the adjuster locknut C and turn the adjuster D to either side e After adjustm
26. cident Visually inspect removed parts for corrosion discol oration or other damage Refer to the appropriate sections of this manual for service limits on individual parts Replace the parts if any damage has been found or if the part is be yond its service limit Replacement Parts Replacement Parts must be KAWASAKI genuine or H em recommended by KAWASAKI Gaskets O rings Oil seals e Grease seals circlips or cotter pins must be replaced with new ones whenever disassembled 68020108 S Assembly Order In most cases assembly order is the reverse of disassem e gt K A 7 Fi A Ba e Be bly however if assembly order is provided in this Service gie Manual follow the procedures given q on Sos d e NZ here DE 22 gt TR gt ERA es S pd 66020118 S 1 4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally when installing a part with several bolts nuts or screws start them all in their holes and tighten them to a snug fit Then tighten them according to the specified se quence to prevent case warpage or deformation which can lead to malfunction Conversely when loosening the bolts nuts or screws first loosen all of them by about a quar ter turn and them remove them If the specified tightening sequence is not indicated tighten the fasteners alternating diagonally Tightening Torque Incorrect torque applied to a bolt nut or screw may lead to serious da
27. damage the bolt sleeve and bearing e Remove the tie rod rear mounting bolt A e Remove the tie rod front mounting bolt B and then take out the tie rod C Tie Rod Installation e Apply plenty of grease to the inside of the oil seals e Apply plenty of 2 stroke oil to the threads of the tie rod front and rear mounting bolts e Tighten the tie rod front and rear mounting nuts Torque Tie Rod Mounting Nuts Front Rear 59 N m 6 0 kgf m 44 ft lb Rocker Arm Removal e Using the jack under the frame raise the rear wheel off the ground Special Tool Jack 57001 1238 When pulling out the mounting bolts lift the rear wheel slightly Forcing or tapping on bolt could damage the bolt sleeve and bearing e Remove the rear shock absorber lower mounting bolt A e Remove the tie rod rear mounting bolt B e Remove the rocker arm pivot bolt C e Remove the rocker arm D 13 32 SUSPENSION Tie Rod Rocker Arm Rocker Arm Installation e Apply plenty of grease to the inside of the rocker arm needle bearings oil seals and grease seals outside of the sleeve e Apply plenty of 2 stroke oil to the threads of the tie rod rear mounting bolts e Tighten Torque Rear Shock Absorber Mounting Nut Lower 34 N m 3 5 kgf m 25 ft lb Rocker Arm Pivot Nut 59 N m 6 0 kgf m 44 ft lb Tie Rod Mounting Nuts Rear 59 N m 6 0 kgf m 44 ft lb Tie Rod and Rocker Arm Bearing Removal e Remove
28. large make the 32 grind described below x lf the outside diameter of the seating surface is within the specified range measure the seat width as described be low e Grind the seat at a 32 angle B until the seat O D is within the specified range OTo make the 32 grind fit a 32 cutter into the holder and slide it into the valve guide OTurn the holder one turn at a time while pressing down very lightly Check the seat after each turn NOTICE The 32 cutter removes material very quickly Check the seat outside diameter frequently to pre vent overgrinding OAfter making the 32 grind return to the seat O D mea surement step above e To measure the seat width use a vernier caliper to mea sure the width of the 45 angle portion of the seat at sev eral places around the seat lf 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 If the seat width is too wide make the 55 A grind de scribed below x If the seat width is within the specified range lap the valve to the seat as described below e Grind the seat at a 55 angle until the seat width is within the specified range OTo make the 55 grind fit a 55 cutter into the holder and slide it into the valve guide OTurn the holder while pressing down lightly OAfter making the 55 grind return to the seat width mea surement step above C
29. or contaminated engine oil will cause accelerated wear and may result in engine seizure accident and injury Check the oil level before each use and change the oil and filter according to the periodic maintenance chart The engine oil level indicated in the right engine cover oil level gauge is very sensitive to the motorcycle s posi tion and engine rpm at time of shut down Because of the semi dry sump lubrication system with separate oil cham bers in the crank room and transmission room under cer tain conditions oil can accumulate in the crank room and give a false low reading at the oil level gauge which indi cates oil volume in the transmission room Engine Oil Level Inspection e Situate the motorcycle so that it is vertical e Check that the engine oil level is between the upper A and lower levels B in the gauge NOTE OSituate the motorcycle so that it is perpendicular to the ground Olf no oil appears in the gauge tip the motorcycle slightly to the right until oil is visible then return to an upright po sition If no oil appears even when tipped at an extreme angle remove both drain bolts to empty any oil that may be in the transmission and crankcase reinstall the drain bolts and refill with the specified amount of oil Olf the motorcycle has just been used wait several min utes for all the oil to drain down Olf the oil has just been changed start the engine and run it for several minutes at idle
30. the caliper holder shafts C and holder holes PBC is a special high temperature water resistance grease e Install the pads see Brake Pad Installation in the Brakes chapter e Install the caliper see Caliper Installation in the Brakes chapter e Wipe up any spilled brake fluid on the caliper with wet cloth 2 44 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose and Connection Check e Inspect the brake hose and fittings for deterioration cracks and signs of leakage OThe high pressure inside the brake line can cause fluid to leak A or the hose to burst if the line is not properly main tained Bend and twist the rubber hose while examining it x Replace the hose if any cracks B or bulges C are no ticed Tighten any loose fittings Brake Hose Replacement Brake fluid quickly ruins painted surfaces any spilled fluid should be completely washed away immediately e When removing the brake hose take care not to spill the brake fluid on the painted or plastic parts e When removing the brake hose temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum e Immediately wash away any brake fluid that spills e Remove each banjo bolts A and washers B e Replace the washers with new ones For Front Brake e Remove Bolts A Brake Hose Clamps B GL10010181 PERIODIC MAINTENANCE 2 45 Periodic Mainte
31. the numbers that repre sent the minutes flash B 6P17935BS1 o e In the Hour setting mode and the Minute setting mode set the time by pressing the TRIP A B button A to increase the number of Hours and Minutes SC e Then change to the Hour Minute setting mode and press a SIA the TRIP A B button to complete the time setting process HH u O 58888 888888 Y GP17936BS1 o LCD Segment Inspection e Remove Headlight Assy see Headlight Removal Installation Meter Unit see Meter Unit Removal Installation e Check that all the LCD segments the letters and numbers of the liquid crystal display illuminate for 3 seconds after connecting pins 4 and 8 of the meter connector A to the battery B then connecting pin 2 and battery terminal together Next check that all the LCD segments become unlit when pin 2 is disconnected lf there is any problem replace the meter unit lf there are no problems inspect the power wiring NOTE 6P17933BS1 C Oln case that the Liquid Crystal Display LCD malfunc tions e g display freezing wait for 30 seconds or more after disconnecting it from the battery The LCD will function normally after reconnected 16 48 ELECTRICAL SYSTEM Meter Gauge Meter Circuit Other than Australia Models De Yow gt 1 Speed Sensor 6 Battery 12 V 6 A 2 Meter Unit 7 IC Igniter
32. 00 2 525 92025 1984 3 3 00 92025 1890 Be sure to remeasure the clearance after selecting a shim The clearance can be out of the specified range because of the shim tolerance Olf there is no valve clearance use a shim that is a few sizes smaller and remeasure the valve clearance e When installing the shim face the marked side A toward the valve lifter B At this time apply engine oil to the shim or the valve lifter to keep the shim in place during camshaft installation Do not put shim stock under the shim This may cause the shim to pop out at high rpm causing ex tensive engine damage Do not grind the shim This may cause it to fracture causing extensive engine damage e Apply engine oil to the valve lifter surface and install the lifter e Install the camshaft see Camshaft Installation in the En gine Top End chapter e Recheck the valve clearance and readjust if necessary e Install the cylinder head cover see Engine Top End chap ter timing inspection cap and the crankshaft cap Special Tool Filler Cap Driver 57001 1454 PERIODIC MAINTENANCE 2 23 Periodic Maintenance Procedures Cylinder Head Warp Inspection e Remove the cylinder head see Cylinder Head Removal in the Engine Top End chapter e Lay a straightedge A across the lower surface of the head at several different points and measure warp by inserting a thickness gauge between the st
33. 3 mm 0 01 in Engine Lubrication System Engine oil Type API SG SH SJ SL or SM with JASO MA A MA1 or MA2 Viscosity SAE 10W 30 10W 40 or 10W 50 Capacity Oil Change When filter is not removed Oil Change When filter is 1 06 L 1 12 US at eg 1 08 L 1 14 US at E removed e engine is completely 4 4 1 4 US qt ENS Crankshaft Transmission Connecting Rod Big End Side 0 25 0 35 mm 0 0098 0 014 in 0 6 mm 0 02 in Clearance Wheels Tires Rim Runout Axial TIR 1 0 mm 0 039 in or less TIR 2 mm 0 08 in Radial TIR 1 0 mm 0 039 in or less TIR 2 mm 0 08 in Front and Rear Tires Air 100 kPa 1 0 kgf cm 14 psi Pressure 2 10 PERIODIC MAINTENANCE Specifications Item Standard Tire Front Size Make Type Rear Size Make Type Final Drive Drive Chain Slack Drive Chain 20 Link Length Rear Sprocket Warp Brakes Brake Lever Free Play Brake Fluid Type Front Rear Brake pad lining thickness Front Rear Suspension Fork Oil Oil Viscosity Oil Quantity Outer Outer Inner Tubes Inner Subtank Standard 80 100 21 51M AU EUR 80 100 21 M C 51P BRIDGESTONE D401 Tube AU EUR EDO3 Tube 110 100 18 64M AU EUR 120 90 18 M C 65P BRIDGESTONE M402 Tube AU EUR ED04 Tube 52 58 mm 2 0 2 3 in 317 5 318 2 mm 12 50 12 53 in 0 4 mm 0 016 in or less to suit rider DOT3 or DOT4 DOT4 3 8 mm 0 15 in 6 4 mm 0 25 in
34. 5 25 mm 0 207 in If the thickness of a shift fork ear is less than the service limit the shift fork must be replaced If the gear groove is worn exceeding the service limit the gear must be replaced Shift Fork Guide Pin Shift Drum Groove Wear e Measure the diameter of each shift fork guide pin A and measure the width B of each shift drum groove Shift Fork Guide Pin Diameter Standard 5 9 6 0 mm 0 232 0 236 in Service Limit 5 8 mm 0 228 in Shift Drum Groove Width Standard 6 05 6 20 mm 0 238 0 244 in Service Limit 6 3 mm 0 25 in If the guide pin on any shift fork is less than the service limit the fork must be replaced lf any shift drum groove is worn exceeding the service limit the drum must be replaced Gear Damage e Visually inspect the gear dogs A and gear dog holes B Replace any damaged gears or gears with excessively worn dogs or dog holes e Visually inspect the gear teeth C on the transmission gears Replace lightly damaged gear teeth with an oilstone The gear must be replaced if the teeth are badly damaged When gear is repaired or replaced the driving gear should also be inspected and repaired or replaced if necessary 6113236BS1 C 6113372BS1 C 6113238BS1 C 9 24 CRANKSHAFT TRANSMISSION Balancer Balancer Removal e Remove Right Engine Cover see Right Engine Cover Removal in the Engine Right Side chapter
35. 9 6 0 mm 0 232 0 236 in 6 05 6 20 mm 0 238 0 244 in 4 8 mm 0 19 in 5 25 mm 0 207 in 5 8 mm 0 228 in 6 3 mm 0 25 in CRANKSHAFT TRANSMISSION 9 5 Special Tools and Sealant Outside Circlip Pliers Crankcase Splitting Tool Assembly 57001 144 57001 1362 ST570144ST ST571362ST Bearing Driver Set Liquid Gasket TB1216 57001 1129 92104 1063 gt ST571129ST ST921063ST Crankshaft Jig 57001 1174 ST5711748T 9 6 CRANKSHAFT TRANSMISSION Crankcase Crankcase Disassembly e Remove the engine from the frame see Engine Removal in the Engine Removal Installation chapter e Set the engine on clean surface while parts are being re moved e Remove Magneto Cover see Magneto Cover Removal in the Electrical System chapter Cylinder Head Cover see Cylinder Head Cover Re moval in the Engine Top End chapter Cylinder Head see Cylinder Head Removal in the En gine Top End chapter Cylinder see Cylinder Removal in the Engine Top end chapter Piston see Piston Removal in the Engine Top End chap ter Right Engine Cover see Right Engine Cover Removal in the Engine Right Side chapter Clutch see Clutch Removal in the Engine Right Side chapter Primary Gear see Primary Gear Removal in the Engine Right Side chapter Balancer see Balancer Removal Oil Pumps see Oil Pump Scavenge Feed Removal in the Engine Lubrication System chapter Kick Shaft
36. Assembly see Kick Shaft Removal in the En gine Right Side chapter Kick Shaft Idle Gear see Idle Gear Removal in the En gine Right Side chapter External Shift Mechanism see External Shift Mecha nism Removal in the Engine Right Side chapter Flywheel see Flywheel Removal in the Electrical Sys tem chapter e Remove the output shaft sleeve A and the O ring B ODo not reuse the O ring e Remove Gear Position Switch Screws A Gear Position Switch B CRANKSHAFT TRANSMISSION 9 7 Crankcase e Remove Gear Position Switch Finger A Spring B e Remove Circlip A Balancer Drive Gear B Special Tool Outside Circlip Pliers 57001 144 e Remove Circlip A Special Tool Outside Circlip Pliers 57001 144 e Remove the crankcase bolts A e Pry the points A with a screwdriver to split the crankcase halves apart evenly There are two dowel pins on the crankcase mating surface Pull off the left crankcase half 9 8 CRANKSHAFT TRANSMISSION Crankcase OThe crankcase may also be split using the crankcase splitting tool assembly Olnstall the jig A between the crankshaft flywheels Special Tool Crankshaft Jig 57001 1174 OAttach the crankcase splitting tool A to the left crankcase Special Tool Crankcase Splitting Tool Assembly 57001 1362 OTighten the center bolt B of the crankcase splitting tool to split the crankcase halves ORemove the left crankcase half e Remove
37. C and pull out the wheel Take off the collars and caps D from each side of the front hub NOTICE Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so the disc does not touch the ground e Insert a wood wedge between the disc brake pads this prevents them from being moved out of their proper posi tion should the brake lever be squeezed accidentally Front Wheel Installation e Apply grease to the seals e Fit the projection A on the cap to the groove B on the collar e Install the caps and collars on the left and right side of the hub GJ04136BS1 WHEELS TIRES 10 7 Wheels Rims e Install the speedometer gear housing so that the projec tions A fit in the drive notches B e Fit the collar on the right side of the hub e Fit the speedometer gear housing stop A on the fork leg clamp flat face B e Insert the axle A from right side e Tighten the right B axle clamp bolts temporally e Tighten the axle nuts C e Tighten the left axle clamp bolts D Torque Front Axle 79 N m 8 0 kgf m 58 ft Ib Left Axle Clamp Bolts 20 N m 2 0 kgf m 15 ft Ib NOTE O Tighten the two clamp bolts alternately two times to en sure even tightening torque 6J04199BS1 C 10 8 WHEELS TIRES Wheels Rims e Remove the jack e Before tightening the right clamp bolts on the right fork leg pump the
38. Clamps Face the tabs to left side Air Cleaner Housing 10 Chain Guide Roller 12 13 14 15 16 Boot Install the boot as shown in the figure Vent Hoses Drain Hose Run the drain hose leftmost of the bracket View from A View from B Run the breather hose under the radiator fitting 17 18 APPENDIX Cable Wire and Hose Routing EN de aq gt lt GL KS Z GP TAN DS WA P S y e aa Zei 2 PS i Di a 3 WET Cs SSS Sei SA A d AIS 6B093120W5 C APPENDIX 17 19 Cable Wire and Hose Routing Reserve Tank Hose Hot Starter Cable Clutch Cable Clamp Clamps Run the reserve tank hose under the throttle cables and main harness Regulator Rectifier Lead Connector Green Starter Motor Cable White Main Harness Clamp Throttle Cables _ sch 17 20 APPENDIX Cable Wire and Hose Routing U S A California and Canada Models Q Bay APPENDIX 17 21 Cable Wire and Hose Routing JO O1 P D X nu ND Vacuum Switch Valve Hose Cylinder Head Cover Front of the engine White paint Insert the vacuum switch valve hose to the white painted portion of the pipe Clamps Face the tabs to the upper of the engine Clamp Face the tab to the upper of the engine Face the white painted portion to the upper of the engine
39. Coil Winding Resistance Primary windings 0 28 0 38 O at 20 C 68 F Secondary windings 7 65 10 35 kQ at 20 C 68 F lf the meter does not read as specified replace the coil lf the meter reads as specified the ignition coil windings are probably good However if the ignition system still does not perform as it should after all other components have been checked test replace the coil with one known to be good e Check the spark plug lead for visible damage If the spark plug lead is damaged replace the coil Spark Plug Cleaning and Inspection e Refer to the Spark Plug Cleaning and Inspection in the Periodic Maintenance chapter Y 6P10199BS1 GP10274BS1 C 16 28 ELECTRICAL SYSTEM Ignition System Spark Plug Gap Inspection e Refer to the Spark Plug Cleaning and Inspection in the Periodic Maintenance chapter Igniter Removal e Remove the right side cover see Side Cover Removal in the Frame chapter e Disconnect the main harness connector A e Pull out the igniter B Igniter Inspection When inspecting the IC Igniter observe the follow ing to avoid damage to the IC Igniter Do not disconnect the IC Igniter while the engine is running This may damage the IC Igniter Ignition Coil Primary Peak Voltage Check e Disconnect the spark plug cap from the spark plug but do not remove the spark plug e Connect the good spark plug A to the spark
40. Cylinder and Piston Installation 5 34 Camshaft Chain Tensioner Cylinder Wear 5 36 Installations 5 15 Piston Wear uses 5 36 AGAINST EE 5 17 Piston Cylinder Clearance 5 36 Camshaft Removal oocooo ccc 5 17 Piston Ring Ring Groove Camshaft Installation 5 18 Clearance 5 36 Camshaft Chain Removal 5 20 Piston Ring Groove Width 5 37 Camshaft Chain Installation 5 20 Piston Ring Thickness 5 37 Camshaft and Camshaft Cap Piston Ring End Gap A ments 5 21 Measurement AA 5 37 Camshaft Runout 5 21 Piston Piston Pin Connecting Cam Mett adidas 5 21 Rod Wear Inspection 5 38 Cylinder Head 5 22 Carburetor Holder 5 39 Cylinder Compression Carburetor Holder Installation 5 39 Measurement A 5 22 reese eege 5 40 Cylinder Head Removal 5 23 Muffler Hemoval 5 40 Cylinder Head Installation 5 24 Muffler Installation 000000aaaaae 5 40 Cylinder Head Cleaning 5 25 Spark Arrester Cleaning 5 40 Cylinder Head Wam 5 25 Exhaust System Inspection 5 41 VIE 5 26 5 2 ENGINE TOP END Exploded View ENGINE TOP END 5 3 Exploded View Torque we Fastener kaim PR Remarks 10 87imb 50 4 S MO 12 inb 12 106 inb 10 87mb Su C
41. ENGINE REMOVAL INSTALLATION 8 1 Engine Removal Installation Table of Contents Exploded VIEWS ns eanet eooo See ii tege enge deg 8 2 Sp cial e EEN 8 4 Engine Removal lnstallation EE 8 5 Engine Removal EEN 8 5 ene a Ee 8 8 8 2 ENGINE REMOVAL INSTALLATION Exploded View ENGINE REMOVAL INSTALLATION 8 3 Exploded View Torque No Fastener Nam kgf m itib Remarks 1 Upper Engine Mounting Bolts M10 49 5 0 36 2 Middle Engine Mounting Nut M10 49 5 0 36 3 Lower Engine Mounting Nut M10 49 5 0 36 4 Upper Engine Bracket Bolts M8 29 3 0 21 5 Middle Engine Bracket Nuts M8 Swingarm Pivot Shat nur e 0 7 7 KLX450A8F Model 8 4 ENGINE REMOVAL INSTALLATION Special Tool Jack 57001 1238 o e Di so Ei N ba e pis Di ENGINE REMOVAL INSTALLATION 8 5 Engine Removal Installation Engine Removal e Place the jack A under the frame to support the motor cycle Special Tool Jack 57001 1238 A WARNING When the swingarm pivot shaft is removed the swingarm and rear wheel assembly will become detached and allow the frame to fall to the floor creating the potential for injury Removing the engine requires the swingarm pivot to be removed so support the bottom of the frame with a jack or other appropriate stand e Squeeze the brake lever slowly and hold it with a band A A WARNING Motorcycle
42. Exchange the spring for an optional part Install the spring so that closed coil large diameter end A faces upward e Install the spring guide e Adjust the spring preload see Spring Preload Adjust ment e Install the rear shock absorber e Install the parts removed GMO5055BS1 Rear Shock Absorber Disassembly Oil Change e Refer to the Rear Shock Absorber Oil Change in the Pe riodic Maintenance chapter Rear Shock Absorber Assembly e Refer to the Rear Shock Absorber Oil Change in the Pe riodic Maintenance chapter Rear Shock Absorber Scrapping A WARNING When heated pressurized gas may explode and cause serious injury or death Since the rear shocks contains gas do not incinerate them Be fore discarding a rear shock remove the air valve to prevent the possibility of explosion e Remove the shock absorber see Rear Shock Absorber Removal e Remove the valve cap A and release the nitrogen gas completely from the gas reservoir e Remove the valve A WARNING Pressurized gas can cause injury Do not point the valve toward your face or body 13 28 SUSPENSION Swingarm Swingarm Removal e Place the jack A under the frame so that the rear wheel is off the ground Special Tool Jack 57001 1238 e Remove Rear Wheel see Rear Wheel Removal in the Wheels Tires chapter Clamps B Brake Pedal C see Brake Pedal Removal in the Brakes chapter Disc Protector D e Remove Bolts
43. Muffler End B PERIODIC MAINTENANCE 2 25 Periodic Maintenance Procedures e Remove Spark Arrester Mounting Bolts A Spark Arrester B e With a wire brush remove the carbon off the inside of the spark arrester A and muffler e Inspect the spark arrester lf the spark arrester is damaged replace it with a new one e Replace the gasket B to the new one e Install the spark arrester into the rear end of the muffler Torque Spark Arrester Mounting Bolts 10 N m 1 0 kgf m 89 in Ib e Install the muffler end Torque Muffler End Mounting Bolts 10 N m 1 0 kgf m 89 in Ib ESO P Engine Right Side A WARNING The engine and exhaust system get extremely hot during normal operation and can cause serious burns Never touch the engine or exhaust pipe during clutch adjustment Clutch Lever Free Play Check e Slide the clutch lever dust cover A and adjusting bolt cover B out of place e Check that the clutch cable upper end is fully seated in the adjusting bolt C e Check that the clutch lever D has 8 13 mm 0 3 0 5 in of play E lf it does not adjust the lever play 2 26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Lever Free Play Adjustment e Slide the clutch lever dust cover out of place e Turn the adjuster A so that the clutch lever will have 8 13 mm 0 3 0 5 in of play NOTE OBe sure that the outer cable end
44. N m 2 5 kgf m 18 ft lb e Check the brake pedal position e Install the joint pin washer and a new cotter pin OBend the ends A of the cotter pin GLO4020BS1 GLO4008BS1 BRAKES 12 9 Brake Fluid A WARNING When working with the disc brake observe the pre cautions listed below 1 2 3 Never reuse old brake fluid Do not use fluid from a container that has been left unsealed or that has been open for a long time Do not mix two types and brands of fluid for use in the brake This lowers the brake fluid boiling point and could cause the brake to be ineffective It may also cause the rubber brake parts to deteriorate Don t leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid Don t change the fluid in the rain or when a strong wind is blowing Except for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning of the brake parts Do not use any other fluid for cleaning these parts Gasoline engine oil or any other petroleum distillate will cause deterio ration of the rubber parts Oil spilled on any part will be difficult to wash off completely and will eventually deteriorate the rubber used in the disc brake When handling the disc pads or disc be careful that no disc brake fluid or any oil gets on them Clean off any fluid or oil that inadvertently gets on t
45. ODo not add any chemical additive to the oil Oils fulfilling the above requirements are fully formulated and provide adequate lubrication for both the engine and the clutch OThe oil viscosity may need to be changed to accommo date atmospheric conditions in your riding area e Check the oil level see Engine Oil Level Inspection in the Engine Lubrication System chapter Oil Filter Change e Drain Engine Oil see Engine Oil Change e Remove Oil Filter Cover Bolts A Oil Filter Cover B 2 28 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Remove the Oil Filter A e Install the spring A to the right engine cover e Apply grease to the grommet B e Be sure to install the filter with the grommet facing outside as shown Inside out installation stop oil flow causing engine seizure e Replace the oil filter cover O rings A with a new one e Replace the oil filter with new ones e Apply grease to the O rings e Install the oil filter cover Torque Oil Filter Cover Bolt 9 8 N m 1 0 kgf m 87 in Ib e Pour in the specified type and amount of oil see Engine Oil Change Breather Hose Inspection e Be certain that the breather hose are routed without being flattened or kinked and is connected correctly If it is not correct it e Inspect the breather hoses A for damage or sings of de terioration OThis hose should not be hard and brittle nor should be soft swollen x Replac
46. Oil Screen Feed A see Oil Screen Feed Removal in the Engine Lubrication System chapter Shift Rods B see Transmission Shaft Removal 2 Shift Forks C see Transmission Shaft Removal Shift Dram D see Transmission Shaft Removal Transmission E see Transmission Shaft Removal e Remove the crankshaft F from the right crankcase half see Crankshaft Removal Do not remove the bearings and the oil seals unless it is necessary Removal may damage them Crankcase Assembly Right and left crankcase halves are machined at the factory in the assembled state so if replaced they must be replaced as a set e Remove the old gasket from the mating surfaces of the crankcase halves and clean them off with a high flash point solvent e Using compressed air blow out the oil passages in the crankcase halves A WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the engine parts in a well ventilated area and take care that there is no spark or flame anywhere near the working areas Do not use gasoline or low flash point solvents to clean parts CRANKSHAFT TRANSMISSION 9 9 Crankcase e Support the crankcase bearing boss with a suitable re tainer A e Using a press and the bearing driver set C install a new bearing B until it bottoms out Special Tool Bearing Driver Set 57001 1129 NOTICE Support the cr
47. Procedures Swingarm and Uni Trak Linkage Inspection e Check the uni trak component parts for wear periodically or whenever excessive play is suspected e Using the jack under the frame raise the rear wheel off the ground Special Tool Jack 57001 1238 e Push and pull on the swingarm A up and down to check for wear xA small amount of play on the swingarm is normal and no corrective action is needed However if excessive play is felt remove the uni trak parts from the frame and check for wear Swingarm and Uni Track Linkage Pivot Lubricate e Refer to the Swingarm Bearing Installation and Rocker Arm Bearing Installation in Suspension chapter Steering Steering Inspection e Using the jack raise the front wheel off the ground Special Tool Jack 57001 1238 e With the front wheel pointing straight ahead alternately nudge each end of the handlebar The front wheel should swing fully left and right from the force of gravity until the fork hits the stop x lf the steering binds or catches before the stop check the routing of the cables hoses and harnesses x lf the steering feels tight adjust or lubricate the steering e Feel for steering looseness by pushing and pulling the forks lf you feel looseness adjust the steering Steering Adjustment e Using the jack raise the front wheel off the ground Special Tool Jack 57001 1238 2 60 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Re
48. Protection Agency and California Air Resources Board Addi tionally Kawasaki has incorporated an evaporative emission control system 3 in compliance with applicable regulations of the United States Environmental Protection Agency 1 Crankcase Emission Control System This system eliminates the release of crankcase vapors into the atmosphere Instead the vapors are routed through an oil separator to the intake side of the engine While the engine is operating the vapors are drawn into the combustion chamber where they are burned along with the fuel and air supplied by the fuel injection system 2 Exhaust Emission Control System This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this vehicle The fuel ignition and exhaust systems of this vehicle have been carefully de signed and constructed to ensure an efficient engine with low exhaust pollutant levels 3 Evaporative Emission Control System The evaporative emission control system for this vehicle consists of low permeation fuel hoses and a fuel tank The Clean Air Act which is the Federal law covering motor vehicle pollution contains what is commonly referred to as the Act s tampering provisions Sec 203 a The following acts and the causing thereof are prohibited 3 A for any person to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regul
49. Rectifier Inspection e Remove the left side cover see Side Cover Removal in the Frame chapter e Disconnect the connector A e Remove Nut B Regulator Rectifier C ELECTRICAL SYSTEM 16 23 Flywheel Magneto e With the Kawasaki hand tester measure the internal re sistance in both directions between the terminals E Special Tool Hand Tester 57001 1394 kif the reading is not the specified value replace the reg ulator rectifier Internal Resistance 20 C Unit kQ Tester Lead O E Terminal C L B E GPOSO18BSi LJ Tester Lead Connection NOTICE Use only Hand Tester 57001 1394 for this test An ohmmeter other than the Hand Tester may show different readings If a megger or a meter with a large capacity battery is used the regulator will be damaged Charging System Circuit Other than Australia Models 30 e gt gt o gt d 1 Frame Ground 2 Flywheel Magneto 3 Regulator Rectifier 4 Starter Relay 5 Main Fuse 20A 6 Battery 12V 6Ah Y G R BK BK Y W R Dawn el GP09210BW2 C 16 24 ELECTRICAL SYSTEM Starter Motor Clutch Starter Motor Clutch Removal Installation e Refer to the Flywheel Removal Installation Starter Motor Clutch Inspection e Remove Torque Limiter see Torque Limiter Removal Installation in the Crankshaft Transmission chapter Magneto Cover see Magneto C
50. Remove Side Covers see Side Cover Removal in the Frame chapter Seat see Seat Removal in the Frame chapter Muffler see Muffler Removal in the Engine Top End chapter Rear Fender see Rear Fender Removal in the Frame chapter Rear Frame Bolts A e Remove the hoses B from the air cleaner housing e Loosen the air cleaner duct clamp C e Remove the rear frame e Unscrew the bolts A e Remove the air cleaner housing B Air Cleaner Housing Installation e Installation is the reverse of the removal e Tighten Torque Rear Frame Mounting Bolts 34 N m 3 5 kgf m 25 ft lb Element Removal e Remove Screw A Front Left Side Cover B e Remove Wing Bolt A Element B e Stuff a clean lint free towel into the carburetor so no dirt is allowed to enter the carburetor e Wipe out the inside of the air cleaner housing with a clean damp towel Check inside of the inlet tract and carburetor for dirt If dirt is present clean the intake tract and car buretor thoroughly You may also need to replace the element and seal the housing and inlet tract FUEL SYSTEM 3 29 Air Cleaner Element Installation e When installing the element coat the lip of the element with a thick layer of all purpose grease A to assure a complete seal against the air cleaner element base Also coat the base where the lip of the element fits e Apply grease to all connections and screw holes in the air cleaner
51. ST5710768T Head Pipe Outer Race Driver 54 5 57001 1077 ST571077ST Steering Stem Nut Wrench 57001 1100 ST5711008T Head Pipe Outer Race Remover ID gt 37 mm 57001 1107 ST571107ST Jack 57001 1238 ST5712388ST Bearing Puller 57001 1575 ST5715758T STEERING 14 5 Steering Steering Inspection e Refer to the Steering Inspection in the Periodic Mainte nance chapter Steering Adjustment e Refer to the Steering Adjustment in the Periodic Mainte nance chapter Steering Stem Stem Bearing Removal e Remove Front Wheel see Front Wheel Removal in the Wheels Tires chapter Front Fender Bolts A Front Fender B e Remove Handlebar Pad A Headlight B see Headlight Removal Installation in the Electrical system chapter Speedometer C see Meter Unit Removal Installation in the Electrical System chapter Breather Hose D Pull out e Remove the bolt A to remove the brake hose C from the holder B e Remove Handlebar Clamp Bolts A Handlebar Clamps B Handlebar C see Handlebar Removal e Remove the front fork upper clamp bolts D e Remove the steering stem head nut E and washer e Remove the steering stem head F 14 6 STEERING Steering e Remove Front Fork Lower Clamp Bolts A Front Forks B e Pushing up on the stem base A and remove the steering stem nut B
52. Steering stem head nut loose Front rear axle runout excessive Handlebar pulls to one side Frame bent Rear wheel misalignment Swingarm bent or twisted Swingarm pivot shaft bent Steering maladjusted Steering stem bent Front fork bent Right and left front fork oil level uneven Suspension operation trouble Too hard Tire air pressure too high Front fork oil excessive Front fork oil viscosity too high Rear shock absorber adjustment too hard Front fork bent Front fork air pressure too high Too soft Front fork oil insufficient or leaking Front fork oil viscosity too low Rear shock absorber adjusted too soft Front fork rear shock absorber spring weak Rear shock absorber oil or gas leaking Tire air pressure too low Brake Doesn t Hold Air in brake system Pad disc worn Brake fluid leakage Contaminated pad Brake fluid deteriorated Brake master cylinder cups damaged Master cylinder scratched inside Disc warped Battery Trouble Battery discharged Charge insufficient Battery faulty too low terminal voltage Battery lead making poor contact Load excessive e g bulb of excessive wattage Magneto trouble Wiring faulty Regulator rectifier trouble Battery overcharged Magneto trouble Regulator rectifier trouble Battery faulty MODEL APPLICATION Year Model Beginning Frame No ane 1 mum ES CHR Aaea mo mur as O This digit in the frame number changes from one machine to another WE Kawasaki KAW
53. T5712628T Fork Oil Level Gauge 57001 1290 ST5712908T Compression Gauge Adapter M10 x 1 0 57001 1317 ST5713178T Piston Ring Compressor Belt 995 108 57001 1358 ST571358ST Filler Cap Driver 57001 1454 ST5714548T Valve Seat Cutter 45 440 57001 1496 ST571496ST Valve Seat Cutter 55 038 5 57001 1497 ST571497ST Valve Guide Driver 57001 1564 ST5715648T Piston Pin Puller 57001 1568 ST571568ST ENGINE TOP END 5 11 Special Tools and Sealant Valve Spring Compressor Adapter 24 Liquid Gasket TB1211F 57001 1586 92104 0004 gt ST571586ST ST9200048T Valve Guide Driver Attachment D 57001 1659 ST5716598T 5 12 ENGINE TOP END Clean Air System U S A California and Canada Models LAS me 7 et GE94068BW4 C 1 Air Cleaner 2 Carburetor 3 Vacuum Switch Valve 4 View from A 5 Inlet Air 6 Exhaust Gas 7 Secondary Air ENGINE TOP END 5 13 Clean Air System U S A California and Canada Models Vacuum Switch Valve Removal e Remove Fuel Tank see Fuel Tank Removal in the Fuel System chapter e Slide out the clamp A e Remove the hose B from the cylinder head pipe C Slide out the clamps A and take off the hoses B from the vacuum
54. a flush ing compound Avoid the use of a flushing compound which is harmful to the aluminum engine and radiator Carefully follow the instructions supplied by the manufacture of the cleaning product e Warm up the engine and run it at normal operating tem perature for about ten minutes e Stop the engine and drain the cooling system after the coolant cools down e Fill the system with fresh water e Warm up the engine and drain the system after the coolant cools down e Repeat the previous two steps once more e Fill the system with a permanent type coolant and bleed the air from the system see Air Bleeding 6D05013BS1 4 12 COOLING SYSTEM Coolant Reserve Tank Removal e Remove Seat see Seat Removal in the Frame chapter Left Side Cover see Left Side Cover Removal in the Frame chapter e Remove Bolts A Cap B e Drain the coolant to the suitable container e Remove Hose C COOLING SYSTEM 4 13 Water Pump Water Pump Cover Removal e Remove engine guard see Coolant Draining e Unscrew the drain plug A and drain the coolant see Coolant Draining e Loosen the clamp screw B and remove the water hose C from the water pump cover e Unscrew the cover bolts D e Using the pry points A remove the pump cover B Water Pump Cover Installation e Replace the pump cover gasket A with a new one e Check to see that the dowel pins B are in place in the
55. a short and the starter motor must be replaced Special Tool Hand Tester 57001 1394 NOTE OEven if the foregoing checks show the armature to be good if 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 GP110608S1 Brush Lead Inspection e Using the x 1 O hand tester range measure the continuity between the following Terminal Bolt and Positive Brush A Brush Plate and Negative Brush B lf there is not close to zero ohms the brush lead has an open Replace the terminal bolt assembly and the brush holder assembly Special Tool Hand Tester 57001 1394 SIB P ELECTRICAL SYSTEM 16 39 Electrical Starter System Terminal Bolt Inspection e Using the highest hand tester range measure the resis tance as shown Terminal Bolt and Brush Plate A Terminal Bolt and Negative Brush Holder B Terminal Bolt and End Cover C lf there is any reading the brush holder assembly and or terminal bolt assembly have a short Replace the brush holder assembly and the terminal bolt assembly Special Tool Hand Tester 57001 1394 CALS P FALSE Starter Relay Inspection e Remove the seat see Seat Removal in the Frame chap ter e Disconnect the connector A e Disconnect
56. and screw a fuel level gauge B into the plug hole Special Tools Fuel Level Gauge M18 x 1 0 57001 122 e Hold the gauge vertically against the side of the carbure tor body so that the zero line C is several millimeters higher than the bottom edge D of the carburetor body e Turn the fuel tap to the ON position to feed fuel to the carburetor e Wait until the fuel level in the gauge settles e Keeping the gauge vertical slowly lower the gauge until the Zero line is even with the bottom edge of the carbu retor body NOTE ODO not lower the zero line below the bottom edge of the carburetor body If the gauge is lowered and then raised again the fuel level measure 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 GCo6122BS2 FUEL SYSTEM 3 13 Carburetor e Read the fuel level in the gauge and compare it to the specification Service Fuel Level below the bottom edge of the carb body Standard 6 5 1 mm 0 26 0 04 in lf the fuel level is incorrect adjust it e Turn the fuel tap to the OFF position and remove the fuel level gauge e Install the drain plug on the bottom of the float bowl Service Fuel Level Adjustment A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Always stop the engine and do not smoke Make
57. and time conditions indicated on the battery NOTICE This battery is designed to sustain no unusual deterioration if refresh charged according to the method specified above However the battery s performance may be reduced no ticeably if charged under conditions other than given above Never remove the seal cap during refresh charge If by chance an excessive amount of gas is generated due to overcharging the relief valve releases the gas to keep the battery normal 3 When you do not use the motorcycle for months Give a refresh charge before you store the motorcycle and store it with the negative cable re moved However check the battery s state of charge at every 6 months to be sure it meets the minimum 12 4 V specification and charge it to 100 state of charge 4 Battery life If the battery will not start the engine even after several refresh charges the battery has ex ceeded its useful life Replace it Provided however the vehicle s starting system has no prob lem ELECTRICAL SYSTEM 16 15 Battery A DANGER Batteries produce an explosive gas mixture of hydrogen and oxygen that can cause seri ous injury and burns if ignited Keep the battery away from sparks and open flames during charging When using a battery charger connect the battery to the charger before turning on the charger This procedure prevents sparks at the battery terminals which could ignite any battery gases The electr
58. be done Olndicates a procedural sub step or how to do the work of the procedural step it follows It also precedes the text of a NOTE Indicates a conditional step or what action to take based on the results of the test or inspec tion in the procedural step or sub step it fol lows In most chapters an exploded view illustration of the system components follows the Table of Contents In these illustrations you will find the instructions indicating which parts require spec agent during assembly ified tightening torque oil grease or a locking GENERAL INFORMATION 1 1 General Information Table of Contents Before Servicing E Model Identifica REN EE CEET Wit CONVERSION Table geesde eege ici 1 2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera tion on a motorcycle read the precautions given below To facilitate actual operations notes illustra tions photographs cautions and detailed descriptions have been included in each chapter wherever necessary This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts Especially note the following Battery Ground Before completing any service on the motorcycle discon nect the battery cables from the battery to prevent the en gine from accidentally turning over Disconnect the ground c
59. carry out maintenance and repair satisfactorily When ever the owner has insufficient experience or doubts his ability to do the work all adjust ments maintenance and repair should be car ried out only by qualified mechanics In order to perform the work efficiently and to avoid costly mistakes read the text thor oughly familiarize yourself with the procedures before starting work and then do the work care fully in a clean area Whenever special tools or equipment are specified do not use makeshift tools or equipment Precision measurements can only be made if the proper instruments are used and the use of substitute tools may ad versely affect safe operation For the duration of the warranty period we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty To get the longest life out of your 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 Mo torcycle parts Special tools gauges and testers that are necessary when servicing Kawasaki motorcycles are introduced by the Service Manual Genuine parts provided as spare parts are listed in the Parts Catalog e Follow the procedures in this manual care fully Don t take shortcuts e Remember to k
60. clean cloth e Fit the woodruff key C securely in the slot in the crank shaft e Install the flywheel following procedures NOTE OConfirm the flywheel fit or not to the crankshaft before tightening it with specified torque Olnstall the flywheel and tighten it with 54 N m 5 5 kgf m 40 ft lb of torque ORemove the flywheel nut OCheck the tightening torque with rotor puller x lf the flywheel is not pulled out with 20 N m 2 kgf m 15 ft lb of drawing torque it is installed correctly xklf the flywheel is pulled out with under 20 N m 2 kgf m 15 ft lb of drawing torque clean off any oil dirt or flaw of the crankshaft and flywheel tapered portion and dry them with a clean cloth Then confirm that it is not pulled out with above torque e Holding the flywheel steady with the flywheel holder and tighten the flywheel nut Special Tool Flywheel Holder 57001 1313 Torque Flywheel Nut 98 N m 10 kgf m 72 ft lb e Install the magneto cover see Magneto Cover Installa tion 16 20 ELECTRICAL SYSTEM Flywheel Magneto Stator Removal e Remove Magneto Cover see Magneto Cover Removal Stator Bolts A Crankshaft Sensor Bolts B Wiring Holder C Wiring Grommet D e Remove the stator E and crankshaft sensor F as a set Stator Installation e Route the wires according to the Cable Wire and Hose Routing section in the Appendix chapter e Apply a non permanet locking agent to the stator bolt
61. first and tighten the bolt e Tighten Torque Ratchet Plate Mounting Screw 6 4 N m 0 65 kgf m 56 in Ib Ratchet Plate Mounting Bolt 9 8 N m 1 0 kgf m 87 in Ib e Apply grease to the collar C and install it e Before installing the shift shaft apply high temperature grease to the oil seal lips and shift shaft splines e Insert the shift shaft A e Replace the circlip B with a new one e Install Oil Pump Driven Gear C Circlip Clutch see Clutch Installation Right Engine Cover see Right Engine Cover Installa tion e Install the shift pedal so that the split portion A on the pedal and punch mark B on the shift align e Tighten External Shift Mechanism Inspection e Check the shift shaft A for bending or damage to the splines x lf the shaft is bent straighten or replace it If the splines are damaged replace the shift mechanism e Check the return spring B for cracks or distortion lf the spring is damaged in any way replace it e Check the shift lever C for distortion If the shift lever is damaged in any way replace the shift shaft ENGINE RIGHT SIDE 6 21 External Shift Mechanism e Check the ratchet assembly for damage xlf ratchet A pawls B pins C or springs D are dam aged in any way replace them e Check the gear set lever A and its spring B for cracks or distortion x If the lever or spring is damaged in any way replace them e Visuall
62. housing and intake tract e Take out the towel from the carburetor securely e Install the element so that its tab A faces leftside and fit the frame projections B to the holes of the holder C e Tighten the wing bolt D e Install the seat see Seat Installation in the Frame chap ter Element Cleaning and Inspection e Refer to the Air Cleaner Element Cleaning and Inspection in the Periodic Maintenance chapter 6C07046BS1 C 6C07045BS1 C 3 30 FUEL SYSTEM Fuel Tank Fuel Tank Removal A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Always stop the engine and 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 lever A to the OFF position e Slide out the clamp B and pull the fuel hose C off the fuel tap D e Remove the bolt E e Remove Seat see Seat Removal in the Frame chapter Bolts A e Remove the fuel tank mounting bolt B and unhook the band C e Pull out the fuel tank breather hose D from the steering stem e Remove the fuel tank E together with the radiator shrouds e Drain the fuel Fuel Tank Installation e Check the rubber dampers A on the frame xlf the dampers are damaged or deteriorated replace them e Be sure the fuel hose is clamped to the fuel tap to prevent leaks e Inser
63. in the Sus pension chapter NOTE OTighten the fork upper clamp bolts first next the stem head nut last the fork lower clamp bolt e Tighten Torque Steering Stem Head Nut 98 N m 10 kgf m 72 ft Ib Front Fork Clamp Bolts Upper 20 N m 2 0 kgf m 15 ft lb Front Fork Clamp Bolts Lower 20 N m 2 0 kgf m 15 ft lb NOTE O Tighten the two clamp bolts alternately two times to en sure even tightening torque e Install the parts removed see the appropriate chapter A WARNING If the handlebar does not turn to the steering stop it may cause an accident resulting in injury or death Be sure the cables harnesses and hoses are routed properly and do not interfere with handlebar move ment see Cable Wire and Hose Routing section in the Appendix chapter e Check and Adjust Steering Front Brake Clutch Cable Throttle Cable Stem Bearing Lubrication e Refer to the Stem Bearing Lubrication in the Periodic Maintenance chapter Stem Bearing Wear Damage e Using a high flash point solvent wash the upper and lower tapered rollers in the cages and wipe the upper and lower outer races which are press fitted into the frame head pipe clean off grease and dirt e Visually check the outer rase and the rollers x Replace the bearing assembly if it show damage Stem Warp e Whenever the steering stem is removed or if the steering cannot be adjusted for smooth action check the steering stem for straightnes
64. it moves out to take up camshaft chain slack Observe all the rules listed below When removing the tensioner do not take out the mounting bolts only halfway Retightening the mounting bolts from this position could damage the tensioner and the camshaft chain Once the bolts are loosened the tensioner must be removed and reset as described in Camshaft Chain Ten sioner Installation Do not turn over the crankshaft while the tensioner is removed This could upset the camshaft chain timing and damage the valves e Remove the starter motor see Starter Motor Removal in the Electrical System chapter e Loosen the cap bolt A e Remove the tensioner mounting bolts B and remove the chain tensioner body C Camshaft Chain Tensioner Installation e Remove the tensioner cap bolt and O ring e While compressing the push rod A turn it clockwise with a suitable screwdriver until the rod stopped Do not turn the rod counterclockwise at installation This could detach the rod and the tensioner cannot be reinstalled e While holding the rod in position with a suitable push rod holder plate A install the tensioner on the cylinder block GE10014BS1 C 5 16 ENGINE TOP END Camshaft Chain Tensioner e Replace the chain tensioner gasket with a new one e Tighten Torque Chain Tensioner Mounting Bolts A 9 8 N m 1 0 kgf m 87 in Ib e Take out the holder plate B e Install the O ring an
65. loose 17 26 APPENDIX Troubleshooting Guide Compression low Spark plug loose Cylinder head not sufficiently tightened Fuel tap clogged Fuel line clogged Compression low 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 de formed worn or carbon accumulation on the seating surface Decompression trouble Other Faulty IC igniter Engine oil level to high Engine oil viscosity too high Brake dragging Drive train trouble Engine overheating Clutch slipping Vacuum Switch Valve trouble equipped models 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 de formed worn carbon accumulation on the seating surface Decompression trouble Knocking Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect heat valve Faulty IC igniter Crankshaft Sensor trouble Other Throttle valve won t fully open Brake dragging Air cleaner clogged Poor Running or No Power at High Speed Water or forei
66. mating surfaces of the right engine cover e Install the water pump cover OReplace the drain plug gasket with a new one e Tighten Torque Water Pump Cover Bolts A 9 8 N m 1 0 kgf m 87 in Ib Coolant Drain Plug B 7 0 N m 0 70 kgf m 62 in Ib e Insert the water hose C into the water pump cover e Tighten Torque Radiator Hose Clamp Screws D 3 0 N m 0 30 kgf m 27 in Ib e Fill the cooling system see Coolant Filling e Bleed the air from the cooling system e Check the coolant level and add the coolant 4 14 COOLING SYSTEM Water Pump Impeller Removal e Drain Coolant see Coolant Draining e Remove Water Pump Cover see Water Pump Cover Removal Impeller Bolt A Impeller B Impeller Installation e Install Impeller A e Tighten Torque Water Pump Impeller Bolt B 9 8 N m 1 0 kgf m 87 in Ib e Install Water Pump Cover see Water Pump Cover Installation Water Pump Inspection e Visually check the impeller A lf the surface is corroded or if the blades B are dam aged replace the impeller e Check the drainage outlet passage A at the bottom of the right engine cover for coolant leaks lf the oil seal is damaged the coolant leaks through the seal and drains through the passage Replace the oil seals Oil Seal and Bearing Removal e Remove Impeller see Impeller Removal Right Engine Cover see Right Engine Cover Removal in the Engine Right Side chapter Circlip
67. may fall over unexpectedly resulting in an accident or injury Be sure to hold the front brake when removing the engine Be sure to hold the front brake when removing the engine or the motorcycle may fall over The engine or the motorcycle could be damaged e Drain Engine Oil see Engine Oil Change in the Periodic Main tenance chapter Coolant see Coolant Draining in the Cooling system chapter e Remove the mounting bolt A and remove the engine guard B e Remove Seat see Seat Removal in the Frame chapter Side Covers see Side Cover Removal in the Frame chapter Fuel Tank see Fuel Tank Removal in the Fuel System chapter 8 6 ENGINE REMOVAL INSTALLATION Engine Removal Installation e Remove Radiator see Radiator Removal in the Cooling System chapter Muffler see Muffler Removal in the Engine Top End chapter Air Cleaner Housing with Rear Frame see Air Cleaner Housing Removal in the Fuel System chapter Starter Motor see Stater Motor Removal in the Electrical System chapter Carburetor see Carburetor Removal in the Fuel System chapter Clutch Cable Lower End A Drive Chain see Drive Chain Removal in the Final Drive chapter Shift Pedal see External Shift Mechanism Removal in the Engine Right Side chapter Vacuum Switch Valve see Vacuum Switch Valve Re moval in the Engine Top End chapter equipped models e Remove Bolts A Rear Brake Pedal B Master Cylinder
68. nut e Install the engine sprocket cover Torque Engine Sprocket Cover Bolts 9 8 N m 1 0 kgf m 87 ft lb Rear Sprocket Removal e Remove the rear wheel see Rear wheel Removal in the Wheels Tires chapter NOTICE Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground e Unscrew the rear sprocket bolts A and remove the rear sprocket B 11 10 FINAL DRIVE Sprockets Rear Sprocket Installation e Install the rear sprocket A so that the marked side B faces out e Install the rear sprocket bolts and tighten the nuts Torque Rear Sprocket Nuts 34 N m 3 5 kgf m 25 ft lb Sprocket Wear Inspection e Refer to the Sprocket Wear Inspection in the Periodic Maintenance chapter Rear Sprocket Warp Inspection e Refer to the Rear Sprocket Warp Inspection in Periodic Maintenance chapter BRAKES 12 1 Brakes Table of Contents Exploded VIEW sareni EAR EE 12 2 Elle 12 6 Special EN 12 7 Brake Lever Brake EE 12 8 Brake Lever e E En EE 12 8 Brake Pedal Position Ad USTME serge iia 12 8 Brake Pedal Removal EE 12 8 Brake Pedal EE te BEE 12 8 El EE E 12 9 Fluid Level Dee EE 12 9 MUI Change E 12 9 Bleeding the Brake Im eieiei giereg Egger EAR ee 12 10 Cali eelere 12 12 Calipet Removal static tdo 12 12 Caliper lS tall SE 12 12 Caliper DISASSEMDIY sci esse sn dee NENN
69. oil to the con tact area Be sure to maintain proper alignment and use smooth movements when installing Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary Replace with new ones whenever removed Press bearings with the manufacturer and size marks facing out Press the bearing into place by putting pressure on the correct bearing race as shown Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage Oil Seal Grease Seal Do not remove pressed oil or grease seals unless removal is necessary Replace with new ones whenever removed Press new oil seals with manufacture and size marks facing out Make sure the seal is aligned properly when installing Apply specified grease to the lip of seal before installing the seal Circlips Cotter Pins Replace circlips or cotter pins that were removed with new ones Take care not to open the clip excessively when in stalling to prevent deformation 6B02046BS1 GB02026B S 1 6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation Lubri cation points are called out throughout this manual apply the specific oil or grease as specified Direction of Engine Rotation When rotating the crankshaft by hand the free play amount o
70. on the tang B of the float C e Fit the float valve into the valve seat e Insert the pin D 3 26 FUEL SYSTEM Carburetor e Install Leak Jet A e Replace the O ring with new one e Fit the O ring B onto the groove of the float chamber e Install Float Bowl e Tighten the screws with hose clamps A and cable holder B as shown e Replace the O rings with new ones e Fit the O rings A e Install Diaphragm B Spring C Acceleration Pump Cover Olnstall the diaphragm so that its mark facing D outward e Tighten the bolts e Install the choke knob starter plunger A e Replace the O rings A with the new ones e Install the fuel hose fitting B e Tighten the screws FUEL SYSTEM 3 27 Carburetor e Install all hoses A e Install the carburetor see Carburetor Installation elt turn the adjusting screw of the acceleration pump follow the procedures below OAdjust the acceleration pump timing OSelect an arbor A of the same diameter as the throttle valve height B and insert it under the throttle valve Throttle Valve Height 1 25 mm 0 0492 in OTurn in the adjusting screw A fully OCheck the push rod holder B play OTurn the adjusting screw counterclockwise gradually to adjust with the push rod holder moving forward or back ward till no free play is available Push Rod C 3 28 FUEL SYSTEM Air Cleaner Air Cleaner Housing Removal e
71. or rubber lubricant 10 4 WHEELS TIRES Specifications Item Wheels Rims Rim Runout Axial Radial Axle Runout 100 mm 3 94 in Rim Size Front Rear Standard TIR 1 0 mm 0 039 in or less TIR 1 0 mm 0 039 in or less 0 1 mm 0 004 in or less 21 x 1 60 18 x 2 15 Service Limit TIR 2 mm 0 08 in TIR 2 mm 0 08 in 0 2 mm 0 008 in Tires Air Pressure Front and Rear Tires Standard Tire Front Size Make Type Rear Size Make Type 100 kPa 1 0 kgf cm 14 psi 80 100 21 51M AU EUR 80 100 21 M C 51P BRIDGESTONE M401 Tube AU EUR EDO3 Tube 110 100 18 64M AU EUR 120 90 18 M C 65P BRIDGESTONE M402 Tube AU EUR ED04 Tube WHEELS TIRES 10 5 Special Tools Inside Circlip Pliers Bearing Driver Set 57001 143 57001 1129 ST5701438T ST5711298T Rim Protector Jack 57001 1063 57001 1238 ST5710638T ST5712388ST Bead Breaker Assembly 57001 1072 ST5710728T 10 6 WHEELS TIRES Wheels Rims Front Wheel Removal e Using the jack A under the frame and stabilize the mo torcycle Special Tool Jack 57001 1238 e Apply the rear brake to rear wheel does not turn e Unscrew the axle nut A e Loosen the left and right axle clamp bolts B e Place a commercially available jack under the engine to raise the front wheel off the ground e Remove the axle
72. push down and turn it further in the same direction and remove the cap e Check the coolant level The coolant level A should be at the bottom of the filler neck B lf the coolant level is low add coolant through the filler opening to the bottom of the filler neck Install the cap Recommended coolant Permanent type antifreeze soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators Water and coolant mixture ratio 1 1 soft water 50 Coolant 50 Total amount 1 05 L 1 11 US qt Coolant Deterioration Inspection e Visually inspect the coolant If whitish cotton like wafts are observed aluminum parts in the cooling system are corroded If the coolant is brown iron or steel parts are rusting In either case flush the cooling system If the coolant gives off an abnormal smell check for a cooling system leak It may be caused by exhaust gas leaking into the cooling system A B 6D04016BS1 6S06008BS1 PERIODIC MAINTENANCE 2 19 Periodic Maintenance Procedures Radiator Hoses and Connections Inspection OThe high pressure inside the radiator hoses and water hoses A can cause coolant to leak B or the hose to burst if the line is not properly maintained Visually inspect the hoses for signs of deterioration Squeeze the hoses A hose should not be hard and brittle nor should it be soft or swolle
73. reduce idling time before coolant loss occurs These conditions in clude high ambient temperature sandy or muddy terrain or other conditions causing high engine loads at low speeds Furthermore warming the engine up excessively before operation or leaving idling with the hot engine temperature after opera tion results in the engine overheating too 2 14 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Start the engine and warm it up thoroughly e With the engine idling turn the handlebar to both sides A If handlebar movement changes the idle speed the throt tle cable may be improperly adjusted or incorrectly routed or it may be damaged Be sure to correct any of these conditions before riding see Cable Wire and Hose Rout ing section in the Appendix chapter A WARNING Operation with an improperly adjusted incorrectly routed or damaged cables could result in an unsafe riding Condition Follow the service manual to be make sure to correct any of these conditions e Check the idle speed using the engine revolution tester A for high accuracy If the idle speed is out of specified range adjust it Idle Speed Standard 1 800 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 To increase idle speed B To decrease idle speed C e Open and close the throttle a few times to make sur
74. remove the rear flap B Reflector Installation e Install the reflector so that the projection A fits to the groove B of the bracket Sof S S G008020BS1 FRAME 15 11 Footpegs and Brackets Footpeg Removal e Remove Cotter Pin A Washer B Pin C Spring D Footpeg E Upper Bolt F Lower Bolt G Footpeg Bracket H Footpegs Installation e Apply a non permanent locking agent to the bracket lower bolts e Tighten the upper bracket bolt A Torque Upper Footpeg Bracket Bolts 54 N m 5 5 kgf m 40 ft lb 6014011BS1 C e Install Footpeg A Cotter Pin B e Bend the longer side C of the cotter pin as shown 6014012BS1 C ELECTRICAL SYSTEM 16 1 Electrical System Table of Contents Exploded View Specifications eet ugeeegEge eege Ee Special Tools and Sealant Wiring Diagram Other than Australia ee EE Late Electrical Wiring Wiring Inspection ee BallGly EE Battery Removal scen Battery Installation Precautions denger Interchange EE Charging Condition Inspection Refreshing Charme Flywheel Magneto Magneto Cover Removal Magneto Cover Installation Flywheel Hemoval Flywheel Installation Stator Removal cceeeeeeeees Stator Installation Flywheel Inspection Charging Voltage In
75. replaced 4 a 16 22 ELECTRICAL SYSTEM Flywheel Magneto Charging Voltage Inspection e Check the battery condition see Charging Condition In spection e Warm up the engine to obtain actual magneto operating conditions e Remove the seat see Seat Removal in the Frame chap ter e Connect the hand tester A as shown in the table Special Tool Hand Tester 57001 1394 Charging Voltage Tester Connections Reading Range Tester to Tester to Battery Battery Battery voltage to GE Terminal Terminal 14 4 0 5 V e Start the engine and note the voltage readings at various engine speeds The readings should show nearly battery voltage when the engine speeds is low and as the engine speed rises the readings should also rise But they must be kept under the specified voltage e Stop the engine and disconnect the hand tester If the charging voltage is kept between the values given in the table the charging system is considered to be working normally lf the charging voltage is much higher than the values specified in the table the regulator rectifier is defective or the regulator rectifier leads are loose or open If the charging voltage does not rise as the engine speed increases the regulator rectifier is defective or the mag neto output is insufficient for the loads Check the mag neto and regulator rectifier to determine which part is de fective Regulator
76. steel plates lf there are notches worn into the clutch hub splines A replace the clutch hub Replace the steel plates if their teeth are damaged as well GRO5032BS1 C GRO50105S1 SAA AS GRO5033BS1 C 6 18 ENGINE RIGHT SIDE Primary Gear Primary Gear Removal e Remove Right Engine Cover see Right Engine Cover Removal Clutch see Clutch Removal e Temporarily install the clutch housing A e Using the gear holder B secure the primary gear and loosen the primary gear nut Special Tool Gear Holder m2 0 57001 1557 e Remove the clutch housing e Remove the primary gear nut C washer primary gear D and oil pump drive gear OPrimary gear nut is left hand threads Primary Gear Installation e Insert the oil pump drive gear A and primary gear B to the crankshaft e Install the washer C as shown e Replace the primary gear nut A with a new one e Using the gear holder B secure the clutch gear and the bottom of the primary gear then tighten the primary gear nut OPrimary gear nut is left hand threads Torque Primary Gear Nut 98 N m 10 kgf m 72 ft lb Special Tool Gear Holder m2 0 57001 1557 e Install Clutch see Clutch Installation Right Engine Cover see Right Engine Cover Installa tion ENGINE RIGHT SIDE 6 19 External Shift Mechanism External Shift Mechanism Removal e Remove Shift Pedal
77. than the Incorrect seating surface of valve Repair seating surface if possible ES EE Valve clearance is too narrow Adjust the valve clearance Piston cylinder clearance is too wide Replace the piston and or cylinder Piston seizure Inspect the cylinder and piston repair or replace them if necessary Bad condition of piston ring and or Replace the piston and or the piston piston ring grooves rings Auto decompressor do not move Replace the auto decompressor smoothly Cylinder Head Removal e Remove Fuel Tank see Fuel Tank Removal in the Fuel System chapter Starter Motor see Starter Motor Removal in the Electri cal System chapter Camshaft Chain Tensioner see Camshaft Chain Ten sioner Removal Cylinder Head Cover see Cylinder Head Cover Re moval Camshaft see Camshaft Removal Exhaust Pipe see Muffler Removal Carburetor see Carburetor Removal in the Fuel System chapter Vacuum Switch Valve A see Vacuum Switch Valve Re moval equipped models Clamp Screw B Water Hose C e Remove Engine Bracket Bolts A Engine Bracket B e Remove the 6 mm cylinder head bolts C and loosen the cylinder bolt D OThis prevents the 6 mm bolts from becoming damaged 5 24 ENGINE TOP END Cylinder Head e Remove the vacuum switch valve hose A and vacuum hose B from the cylinder head equipped models e Remove the 10 mm cylinder head bolts following the tight ening sequence 1 4 as shown e Tap
78. the Engine Top End chapter e Unscrew the bolt A e Remove the throttle pulley cover B e Loosen the mounting bolts A e Remove the cables B from the carburetor e Free the tips C from the pulley e Pull out the cables from the frame e Lubricate the cable e Apply grease to the tips of the cables e Install the throttle cable lower ends A e Install the mounting bolts B to the holder as shown e Install the throttle pulley cover Torque Throttle Cable Mounting Bolts 6 9 N m 0 70 kgf m 61 in Ib Throttle Pulley Cover Bolt 3 4 N m 0 35 kgf m 30 in Ib 6004019BS1 C e Install the throttle cable in accordance with the Cable Wire and Hose Routing section in the Appendix chapter e After the installation adjust each cable properly A WARNING Operation with improperly adjusted incorrectly routed or damaged cables could result in an unsafe riding condition Follow the service manual to be make sure to correct any of these conditions Throttle Cable Lubrication e Whenever the throttle cable is removed or in accordance with the Periodic Maintenance Chart lubricate the these cables see Lubrication in the Periodic Maintenance chapter OApply a thin coating of grease to the cable upper or lower ends OUse acommercially available pressure cable lubricator to lubricate these cables Throttle Cable Inspection e Refer to the Cable Inspection in the Periodic Maintenance cha
79. the both side adjust to the same width A e Apply 2 stroke oil to the thread of the handlebar clamp bolts e Install the handlebar clamp so that center D of the han dlebar clamp C and handlebar bridge E align Torque Handlebar Clamp Bolts 25 N m 2 5 kgf m 18 ft Ib Front F e After tighten make sure space A B of the ahead and back are same width e Instal the clamps C GNO6034BS1 GNO6036BS1 C FRAME 15 1 Frame Table of Contents Exploded VieWiia EA adi 15 2 Be let 15 5 Frame IMSPOCHON ii Eege CES 15 5 Rear Frames Removal ccc gedeien dee Se Mater a teat an ea ah ls 15 5 Rear Frame Installaton nara noncnno narco nn nano nccnonaninnnaans 15 5 Engine Guard leed sad e 15 6 Le A E DE 15 7 e EE ne EE 15 7 Seat Instala EE 15 7 Sid ee EE 15 8 Right Side Cover AGMOV EE 15 8 Right Side Cover Installations 15 8 Left Side Cover Bemoval none nacononacinnns 15 8 Left Side Cover Installation nn nana cn nn nn nncnnnn conc nn nono nannnnnonananononacinnns 15 9 Fonden a dl te 15 10 Front Fender Removal cas 15 10 Rear Fender Removal eii a ai 15 10 Rear Flap Rene EE 15 10 Reflector Installation ooonnnncnnnnncnnnnnnacnconcninancncno nano ncncnnnrnconcnno nana nonannonarnnnn nano nacnonacinnanans 15 10 F0OIpe0S anid Bee 15 11 Foo pea e une EE 15 11 Footpegs Installation 15 11 15 2 FRAME Exploded View 60022578W5 C FRAME 15 3 E
80. the front chain guide in e Install the removed parts Cylinder Wear e Refer to the Cylinder Wear Inspection in the Periodic Maintenance chapter Piston Wear e Using a micrometer measure the outside diameter A of each piston 8 5 mm 0 33 in B up from the bottom of the piston at a right angle to the direction of the piston pin x If the pistons outside diameter is smaller than the service limit replace the piston Piston Diameter Standard 95 970 95 980 mm 3 7783 3 7787 in Service Limit 95 82 mm 3 772 in Piston Cylinder Clearance e Refer to the Piston Cylinder Clearance in the Periodic Maintenance chapter Piston Ring Ring Groove Clearance e Check for uneven groove wear by inspecting the ring seat ing 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 mea surements with a thickness gauge A to determine piston ring groove clearance Piston Ring Ring Groove Clearance Standard Top 0 04 0 08 mm 0 002 0 003 in Service Limit Top 0 18 mm 0 0071 in x lf the piston ring groove clearance is greater than the ser vice limit measure the ring thickness and groove width as follows to decide whether to replace the rings the piston or both GE16135BS1 GE16136BS1 ENGINE TOP END 5 37 Cylinder and Piston Piston Ring Groove Width e Measure
81. the new piston and tighten the locknut ODiscard a washer or two e Pour KYB K2 C SAE 5W or Bel Ray SE2 40 oil into the gas reservoir to 60 70 mm 2 63 2 76 in A from the gas reservoir upper end e Check that the bladder A on the gas reservoir cap is not partially collapsed If it is push down the valve core with a screwdriver e Check the bladder for sign of damage or crack If necessary replace it with a new one NOTICE Do not use a damaged or partially collapsed blad der because it may burst gently reducing rear shock performance e Apply grease to the lip B of the bladder and install the reservoir cap C e Push the bladder into the gas reservoir slowly until it just clears the circlip groove Wipe out any spilled oil Ensure that no air remains in the system e Check the circlip for weakening deformity and flaws If necessary replace it with a new one NOTICE If weakened deformed or flawed circlip is used the gas reservoir cap may not hold when injecting the nitrogen gas This would allow oil and internal parts to explode out of the reservoir SI P GM05010481 GMO5066BS1 PERIODIC MAINTENANCE 2 57 Periodic Maintenance Procedures e Mount the circlip A in the groove in the gas reservoir e Pull up the gas reservoir cap A against the circlip The end of the gas reservoir cap must align B with the end
82. the starter motor cable B and battery positive cable C from the starter relay D e Connect the hand tester A and 12 V battery B to the starter relay C as shown lf the relay does not work as specified the relay is defec tive Replace the relay Starter Relay Inspection Tester range x10 Standard When battery is connected gt 0 Q When battery is disconnected Q 6P11019BS1i Special Tool Hand Tester 57001 1394 16 40 ELECTRICAL SYSTEM Electrical Starter System Electric Starter Circuit Other than Australia Models BK Y BK W Y R BR IE ib fit W R Y R GP11122BW3 C 1 Frame Ground 4 Main Fuse 20 A 7 Engine Starter Button 2 Starter Motor 5 Battery 12 V 6 Ah 8 Engine Stop Switch 3 Starter Relay 6 IC Igniter 9 Starter Lockout Switch ELECTRICAL SYSTEM 16 41 Lighting System Headlight Aiming Inspection e Inspect the headlight beam for aiming lf the headlight beam points too low or high adjust the vertical beam Headlight Beam Vertical Adjustment e Turn the vertical adjuster A on the headlight with the screwdriver in or out to adjust the headlight vertically NOTE OON high beam the brightest points should be slightly below horizontal with the motorcycle on its wheels and the rider seated Adjust the headlight to the proper an gle according to local regulations Headlight Bulb Replacement e Remove Headlight
83. throttle cables and Leads between the meter bracket and upper mounting Meter Unit Connector Black Cap Headlight Connector Black Clamp Fix the leads by twisting the clamp Front side of the harness cable guide Inside of the harness cable guide Speed Sensor Lead Connector Gray ONDARON P N sch sch S sch AS sch eck St OOONDARWN O APPENDIX 17 5 Cable Wire and Hose Routing XA dl dd y O O1 P D ch 17 18 19 20 21 22 HN O U1 amp D Hot Starter Cable Main Harness Clamps Run the throttle cables over the main harness White Tape Throttle Cables Blue Tape Clamps Band Clutch Cable Run the clutch cable outside of the fuel hose Fuel Hose Clamp Face the tab to the underside Magneto Lead Transmission Position Sensor Lead If the magneto lead and transmission position sensor lead have the play do no play by pulling down them Run the hot starter cable and clutch cable over the radiator hose Right Side Ignition Coil Ground Lead View from A A Ground Lead Left Side 17 6 APPENDIX Cable Wire and Hose Routing A SAN Was Y 8 A SEA HS D APPENDIX 17 7 Cable Wire and Hose Routing Throttle Cables Clamp Harness Cable Guide Speed Sensor Lead Connector Gray Fix the connector on the bracket Clamp Put the sensor grommet into the clamp and
84. use any other fluid for cleaning these parts Gasoline engine oil or any other petroleum distillate will cause deterioration of the rubber parts Oil spilled on any part will be diffi cult to wash off completely and will eventually dete riorate the rubber used in the disc brake 7 When handing the disc pads or disc be careful that no disc brake fluid or any oil gets on them Clean off any fluid or oil that inadvertently gets on the pads or disc with a high flash point solvent Do not use one which will leave an oily residue Replace the pads with new ones if they cannot be cleaned satisfacto rily 8 Brake fluid quickly ruins painted surfaces any spilled fluid should be completely wiped up imme diately 9 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 Recommended Disc Brake Fluid Type Front DOT3 or DOT4 Rear DOT4 2 38 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTE OThe procedure to change the front brake fluid Chang ing the rear brake fluid is the same as for the front brake e Level the brake fluid reservoir e Remove the screws A reservoir cap B and diaphragm C e Remove the rubber cap A on the bleed valve B e Attach a clear plastic hose A to the bleed valve on the caliper and run the other end of the hose into a container B e Change the brake fluid as follows ORepeat this operation until fresh brak
85. weak or broken Shift fork guide pin worn Drive shaft output shaft and or gear splines worn Overshifts Gear set lever spring weak or broken Pawl guide plate worn Abnormal Engine Noise Knocking Faulty IC igniter Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect heat value Overheating Piston slap Cylinder piston clearance excessive Cylinder piston worn Connecting rod bent Piston pin piston pin hole worn Valve noise Valve clearance incorrect Valve spring broken or weak Camshaft bearing or cam face worn Valve lifter worn Other noise Connecting rod big end small end clear ance excessive Piston ring worn broken or stuck Piston seizure damage Cylinder head gasket leaking Exhaust pipe leaking at cylinder head con nection Crankshaft runout excessive Engine mounts loose Crankshaft bearing worn Camshaft chain tensioner trouble Camshaft chain sprocket chain guide worn Primary gear worn or damaged Decompressor spring broken Magneto flywheel loose Vacuum switch valve damaged equipped models Abnormal Drive Train Noise Clutch noise Clutch housing finger and friction plate tang worn Clutch housing gear worn Metal chips jammed in clutch housing gear teeth Transmission noise Bearings worn Transmission gears worn or chipped Metal chips jammed in gear teeth Engine oil insufficient low viscosity Kick ratchet gear not properly disengaging from kick gear Kick shaft idle gear
86. 0005 e Attach the compression gauge A and the adapter hose B firmly into the spark plug hole e With the throttle fully open turn the engine with the kick starter or the starter motor until the compression gauge stops rising the compression is the highest reading ob tainable Special Tools Compression Gauge 57001 221 Compression Gauge Adapter M10 x 1 0 57001 1317 Cylinder Compression Usable Range 450 750 kPa 4 59 7 65 kg cm 65 2 109 psi O 5 kicks kickstarter Usable Range 450 750 kPa 4 59 7 65 kg cm 65 2 109 psi 420 r min rpm Electric Starter e Install the spark plug Torque Spark Plug 13 N m 1 3 kgf m 115 in Ib e Pull the spark plug cap lightly to make sure the installation of the spark plug cap ENGINE TOP END 5 23 Cylinder Head Problem Diagnosis Remedy Action The cylinder Carbon accumulation on piston and in Remove the carbon deposits and replace compression is cylinder head combustion chamber is damaged parts if necessary higher than the suspected due to damaged valve stem usable range or piston oil rings Incorrect cylinder head gasket Replace the gasket with a standard one thickness Damaged auto decompressor spring or Replace the spring or auto decompressor do not move smoothly decompressor The cylinder Exhaust gas leakage around cylinder Replace the damaged gasket and check compression is head cylinder head warp lower
87. 105040781 CRANKSHAFT TRANSMISSION 9 19 Torque Limiter Torque Limiter Removal Installation e Remove Torque Limiter Cover Bolts A Torque Limiter Cover B Torque Limiter C NOTICE Do not disassemble the torque limiter The torque limiter will not function if this is done e Install the torque limiter cover so that the arrow mark A faces upward Torque Limiter Inspection e Remove the torque limiter and visually inspect it lf the limiter has wear discoloration or other damage replace it as a set Gear A Shaft B Spring C Pinion D Shim E 6110003BS1 C 9 20 CRANKSHAFT TRANSMISSION Transmission Transmission Shaft Removal e Disassemble the crankcase halves see Crankcase Dis assembly e Pull out the shift rods A allowing the shift fork guide pins to free from the shift drum B e Remove the shift forks C e Remove the shift drum e Pull out the drive shaft A and output shaft B together with their gears meshed Transmission Shaft Installation e Apply engine oil to the sliding portion of the transmission shafts gears and ball bearings e Install the drive shaft A and output shaft B in the right crankcase C with their gears meshed e Install the shift drum e Apply a small amount of engine oil to the shift fork fingers and fit each shift fork into the groove of the proper gear e The shift forks can be identified by their shape or mark In
88. 1121 Valve Seat Cutter 55 935 57001 1247 Inlet Valve Seat Cutter 45 p40 57001 1496 Valve Seat Cutter 32 638 5 57001 1122 Valve Seat Cutter 55 638 5 57001 1497 lf the tool manufacturer s instructions are not available operate in accordance with the following procedure 6E15011752 5 30 ENGINE TOP END Valves Seat Cutter Operation Care 1 This valve seat cutter is developed to grind the vale for repair Therefore the cutter must not be used for other purposes than seat repair 2 Do not drop or shock the valve seat cutter or the dia mond particles may fall off 3 Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface Also wash off ground particles sticking to the cutter with washing oil NOTE ODo not use a wire brush to remove the metal particles from the cutter It will take off the diamond particles 4 Setting the valve seat cutter holder in position operate the cutter in one hand Do not apply too much force to the diamond portion NOTE OPrior to grinding apply engine oil to the cutter and dur ing the operation wash off any ground particles sticking to the cutter with washing oil 5 After use wash it with washing oil and apply thin layer of engine oil before storing Marks Stamped on the Cutter The marks stamped on the back of the cutter A represent the following LEE Cutter Angle B FT DO titan tits Cutter Outer
89. 14 SUSPENSION Front Fork e Remove the dust seal A and the retaining ring B NOTICE Be careful not to scratch the inner tube e Grasp the outer tube and stroke A the inner tube several times The shock to fork seal separates the inner tube from the outer tube e Remove the following parts from the inner tube A Guide Bushes B Washer C Oil Seal D Retaining Ring E Dust Seal e Holding the top plug wrench A with a vise loosen the base assembly B on the subtank C Special Tool Top Plug Wrench 49 mm 57001 1653 e Remove the base valve assembly A from the subtank B NOTE OSlowly compress the piston rod until it stops so that the base valve assembly can be removed easily NOTICE Disassembling the base valve assembly can lead to trouble Do not disassemble the base valve assembly SUSPENSION 13 15 Front Fork e Drain the fork oil A from the cylinder unit B by pumping the piston rod several times Front Fork Assembly e When the fork tubes are not disassembled hold the fork inverted position for more than 20 minutes to allow the fork oil to fully drain 6M04251BS1 e Replace the following with new ones Dust Seal A Retaining Ring B Oil Seal C Guide Bushes D e Place an oil coated plastic bag E over the end of the inner tube to protect the oil seals OThe inner tube guide bush groove has a sharp edge F that can out the seali
90. 3 Drive chain inspect and adjust e 2 32 Drive chain lubricate e 2 34 Wheels tires inspect o 2 30 PERIODIC MAINTENANCE 2 3 Periodic Maintenance Chart FREQUENCY Traveled Distance km mi Every Every Every Every Every 100 500 1000 1500 2000 see 60 300 600 900 1200 Page or 2 5 or 7 5 or 15 or 30 or 60 OPERATION hr hr hr hr hr Rear sprocket inspect o 2 35 Front fork inspect and clean o 2 45 Cable inspect e e 2 62 C Fuel hose connections inspect t e 2 12 H Fuel system clean e e 2 17 E Steering play inspect t e e 2 59 s Steering stem bearing grease e 2 61 Swingarm and Uni Trak linkage pivots grease o 2 59 S Swingarm and Uni Trak linkage pivots inspect t e o e e 2 59 Nuts bolts fasteners inspect t e e 2 63 Rear shock absorber inspect e e 2 54 Chassis parts lubricate e e o o e t Replace add adjust clean or torque if necessary Periodic Replacement Parts FREQUENCY Traveled Distance km mi Every Every Every Every Every 100 500 1000 1500 2000 sae 60 300 600 900 1200 Page or 2 5 or 7 5 or 15 or 30 or 60 OPERATION hr hr hr hr hr Engine oil change Every 1000 km 600 mi 2 26 Piston and piston ring replace Every 1500 km 900 mi 2 24 Piston pin replace Every 1500 km 900 mi 2 24 Oil filter replace Every 1000 km 600 mi 2 27 Bra
91. 3 Frame Ground 8 Main Relay 4 Starter Relay 9 Engine Starter Button 5 Main Fuse 20 A 10 Starter Lockout Switch ELECTRICAL SYSTEM 16 49 Switches and Sensors Speed Sensor Removal e Disconnect the speed sensor connector A and remove the sensor lead from the clamp e Remove the bolts A and open the clamps B take off the sensor lead e Remove the front wheel with the speed sensor see Front Wheel Removal in the Wheels Tires chapter Speed Sensor Installation e Install the front wheel with the speed sensor see Front Wheel Installation in the Wheels Tires chapter e Install the sensor cable A into the clamps B and con nect the connector C Speed Sensor Inspection e Remove the speed sensor see Speed Sensor Removal e Connect the speed sensor connector A with the battery B 10 kQ resistor C and hand tester D as shown e Set the tester to the DC 25 V range Special Tool Hand Tester 57001 1394 GP18355BS1 C 16 50 ELECTRICAL SYSTEM Switches and Sensors e Turn A the rotor of the speed sensor OThen the tester indicator should flick B If the tester indicator does not flick replace the speed sensor GP18096B S Throttle Position Sensor Removal Installation e Refer to the Carburetor Disassembly Assembly in the Fuel System chapter Switch Inspection e Using the hand tester check to see that only the con nections shown in the table have continuity ab
92. 34 PERIODIC MAINTENANCE Periodic Maintenance Procedures A WARNING A chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock the rear wheel severely damaging the motorcycle and causing it to go out of control Inspect the chain for damage and proper adjustment before each ride If chain wear exceeds the service limit replace it with the standard chain It is an endless type and should not be cut for installation Standard Chain Make DAIDO Type D I D 520MXV Link 114 Links Drive Chain Lubrication OThe chain should be lubricated with a lubricant which will both prevent the exterior from rusting and also absorb shock and reduce friction in the interior of the chain lf the chain is especially dirty it should be washed in diesel oil or kerosene and afterward soaked in a heavy oil Shake the chain while it is in the oil so that oil will pen etrate to the inside of each roller e An effective good quality lubricant specially formulated for chains is best for regular chain lubrication e f a special lubricant is not available a heavy oil such as SAE90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication e Apply oil to the sides of the rollers so that oil will penetrate to the rollers and bushings e Wipe off any excess oil Oil applied area A Sprocket Wear Inspection e Visually inspect the front and rear sprocket teeth for wear
93. 4 17 Filler Neck Spec Mc entend deel LA RAS Re er 4 18 wie Ee TEE 4 18 Hose Installationz zsssss nine ne es Seege deel 4 18 4 2 COOLING SYSTEM Exploded View COOLING SYSTEM 4 3 Exploded View Torque No Fastener Nm kgm tib Remarks 1 Water Pump Cover Bolts 9 8 1 0 87 in lb 2 Coolant Drain Plug 7 0 0 70 62 in lb 3 Water Pump Impeller Bolt 9 8 1 0 87 in lb 4 Right Engine Cover Bolts 9 8 1 0 87 in lb 5 Radiator Hose Clamp Screws 3 0 0 30 27 in lb ON O Water Pump Cover Impeller Right Engine Cover Right Radiator 10 Radiator Cap 12 13 HG Left Radiator Reserve Tank Hose KLX450A9F AAF Model Apply high temperature grease Replacement Parts 4 4 COOLING SYSTEM Coolant Flow Chart COOLING SYSTEM 4 5 Coolant Flow Chart Radiator Cap Radiators Reserve Tank Hose Reserve Tank Reserve Tank Over Flow Hose Cylinder Head Jacket Cylinder Jacket Impeller Hot Coolant 10 Cold Coolant Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion When the engine starts the water pump turns and the coolant circulates The system is pressurized by the radiator cap to suppress boiling and the resultant air bubbles which can cause engine overheating As the engine warms up the coolant in the radiator and the water jacket expands The exc
94. 43 2 1 GM04445BS1 C Oil Change each fork leg e Refer to Front Fork Oil Change in the Periodic Mainte nance chapter Front Fork Removal e Unscrew the bolts A and remove the front brake hose clamps B e Remove Front Wheel see Front Wheel Removal in the Wheels Tires chapter Master Cylinder Camp Bolts A e Remove the caliper B from the fork leg to be removed and restthe caliper on some kind of stand so that it doesn t dangle e Remove Bolts C Fork Protector D 13 10 SUSPENSION Front Fork e Loosen the upper A and lower B fork clamp bolts e Remove the front fork OWith a twisting motion A work the fork leg B down and out Front Fork Installation e Install the fork so that the distance between the top end of the outer tube and the upper surface of the steering stem head is specified dimension A 8 mm 0 31 in e Route the cables and hose according to the Cable Wire and Hose Routing section in the Appendix chapter e Install the front wheel see Front Wheel Installation in the Wheels Tires chapter e Tighten the fork clamp bolts Torque Front Fork Clamp Bolts Upper 20 N m 2 0 kgf m 15 ft lb Front Fork Clamp Bolts Lower 20 N m 2 0 kgf m 15 ft lb NOTE O Tighten the two clamp bolts alternately two times to en sure even tightening torque e Tighten Torque Front Caliper Mounting Bolts 25 N m 2 5 kgf m 18 ft lb e Check the front brake oper
95. 61BS1 C G6D06062BS1 C 4 16 COOLING SYSTEM Radiator Radiator Removal e Drain the coolant see Coolant Draining e Remove Radiator Shrouds e Loosen Clamp Screws A Clamps B e Remove Radiator Hoses C Bolt D Left Radiator Screen E e Remove Bolts A Left Radiator B e Loosen Clamp Screws A e Remove Radiator Hoses B Bolt C Right Radiator Screen D e Remove Bolts A Right Radiator B COOLING SYSTEM 4 17 Radiator Radiator Installation e Fit the projections A of the screen in the holes B of the radiator Torque Radiator Hose Clamp Screws 3 0 N m 0 30 kgf m 27 in Ib e Route the radiator and breather hoses correctly see Cable Wire and Hose Routing section in the Appendix chapter e Fill the cooling system with a permanent type coolant Radiator Inspection e Check the radiator core lf there are obstructions to air flow remove them lf the corrugated fins are deformed carefully straighten them with the thin blade of a screwdriver A NOTICE SS SS SS WOH RSS NE SS RSS RAN SS S S S SAS RENN X SS SS SS S SS SS ESS ST NS Do not tear the radiator tubes while straightening the fins xklf the air passages of the radiator core are blocked more than 20 by unremovable obstructions or irreparably de formed fins replace the radiator with a new one NOTICE When clea
96. 7 Table 1 Magneto Output Voltage Tester Connections Reading Range Tester to Tester to 4 000 rpm 50 V AC Yellow Green lead Ground 29 V or more 50 V AC White lead Red lead 25 V or more 50 V AC Blue lead Ground 26 V or more x If the output voltage shows the value in the table the mag neto operates properly x If the output voltage shows a much lower reading than that given in the table indicates that the magneto is defective e To check the stator coil resistance as follows OStop the engine OConnect the hand tester as shown in the table 2 ONote the readings total 2 measurement Table 2 Stator Coil Resistance Tester Connections Reading Range Tester to Tester to x10 Yellow lead Ground 16 230 x10 White lead Red lead 20 50 Q x10 Blue lead Ground 13 200 x lf there is more resistance than shown in the table or no hand tester reading infinity the stator has an open lead and must be replaced Much less than this 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 leads and chas sis ground Any hand tester reading less than infinity indicates a short necessitating stator replacement If the stator coils have normal resistance but the voltage check showed the magneto to be defective then the fly wheel have probably weakened and the flywheel must be
97. 7 15 1 5 11 S 2 6 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Remarks N m Gear Set Lever Nut 8 8 Engine Oil Drain Plug M6 Sub 7 0 Engine Oil Drain Plug M10 Main 20 Shift Drum Cam Bolt 24 L Piston Oil Nozzle 4 0 Bearing Retaining Screws 15 L Balancer Weight Mounting Nut 52 Gear Position Switch Screws 2 9 L Wheels Tires Spoke Nipples 2 2 Front Axle Nut 79 Front Axle Clamp Bolts 20 AL Rear Axle Nut 110 Final Drive Rear Sprocket Nuts 34 3 5 25 Engine Sprocket Nut 127 13 0 93 7 Brakes Front Master Cylinder Clamp Bolts 8 8 78 in lb S Brake Hose Banjo Bolts 25 18 Brake Pad Bolt 17 13 Caliper Bleed Valve 7 8 69 in lb Caliper Mounting Bolts 25 18 Front Brake Disc Mounting Bolts 10 89 in lb L Brake Lever Pivot Bolt Locknut 5 9 52 in lb Brake Lever Pivot Bolt 5 9 52 in lb Si Brake Reservoir Cap Screws 1 5 13 in lb Front Brake Light Switch Screw 1 2 10 in lb Brake Hose Banjo Bolts 25 18 Rear Master Cylinder Mounting Bolts 10 89 in lb Rear Master Cylinder Push Rod Locknut 17 18 Caliper Bleed Valve 7 8 69 in lb Brake Pad Bolt 17 13 Rear Brake Pad Bolt Plug 2 4 21 in lb Caliper Holder Shaft 27 20 Si Brake Pedal Mounting Bolt 25 18 G L Rear Brake Disc Mounting Bolts 23 17 L Brake Reservoir Cap Bolts 1 5 13 in lb Suspension Base Valve Assembly 28 21 Front Fork Top Plug 30 22 Front Fork Clamp Bolts Upper 20 15 AL Front Fork Clamp Bolts Lower 20 15 AL Steering Stem Head Nut 98 72 PERIODIC MAIN
98. 80 kgf m 69 in Ib GLO9034BS2 BRAKES 12 11 Brake Fluid e Check the fluid level e After bleeding is done check the brake for good braking power no brake drag and no fluid leakage A WARNING After servicing it takes several applications of the brake lever or pedal before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the motorcycle until a firm brake lever or pedal is obtained by pumping the lever or pedal until the pads are against the disc 12 12 BRAKES Caliper Caliper Removal Front Brake e Loosen the banjo bolt A so as not to spill brake fluid e Remove the caliper mounting bolts B e Remove the banjo bolt and take off the brake hose from the caliper C e f the caliper is to be disassembled after removal and if compressed air is not available remove the piston using the following steps before disconnecting the brake hose from the caliper ORemove the pads OPump the brake lever to remove the piston Rear Brake e Unbolt the caliper guard bolts A and remove the caliper guard B e Unbolt the disc guard bolts C and remove the disc guard D e Loosen the banjo bolt A so as not to spill brake fluid e Loosen the brake pad bolt plug B and pad bolt C before the caliper removal if the caliper is to be disassembled NOTE Olf the caliper is t
99. 98T 4 8 COOLING SYSTEM Coolant Check the coolant level each day before riding the motor cycle and replenish coolant if the level is low Change the coolant in accordance with the Periodic Maintenance Chart see Periodic Maintenance chapter A WARNING Hot engine coolant can cause serious burns To avoid burns do not remove the radiator cap or try to inspect the coolant level or change the coolant when the engine is still hot Wait until it cools down Coolant Level Inspection e Refer to the Coolant Level Inspection in the Periodic Main tenance chapter Coolant Deterioration Inspection e Refer to the Coolant Deterioration Inspection in the Peri odic Maintenance chapter Coolant Draining e The coolant should be changed periodically to ensure long engine life A WARNING Coolant can be extremely hot and cause severe burns is toxic and very slippery Do not remove the radiator cap or attempt to change the coolant when the engine is hot allow it cool completely Immediately wipe any spilled coolant from tires frame engine or other painted parts Do not ingest coolant e Remove the radiator cap A NOTE ORemove the radiator cap in two steps First turn the cap counterclockwise to the first stop and wait there for a few seconds Then push down and turn it further in the same direction and remove the cap e Remove Bolt A Engine Guard B COOLING SYSTEM 4 9 Coolant
100. ASAKI HEAVY INDUSTRIES LTD Consumer Products amp Machinery Company Part No 99924 1385 03 Printed in Japan
101. Assy see Headlight Removal Installation Headlight Bulb Dust Cover A e Open the clamp B and free the headlight lead C e Remove Headlight Connector A e Remove Hook A Headlight Bulb B NOTICE When handling the quartz halogen bulb never touch the glass portion with bare hands Always use a clean cloth Oil contamination from hands or dirty rags can reduce bulb life or cause the bulb to explode NOTE OClean off any contamination that inadvertently gets on the bulb with alcohol or soap and water solution 16 42 ELECTRICAL SYSTEM Lighting System e Replace the headlight bulb e Fit the projections A of the bulb in the hollow B of the headlight e Install the hook C e Fit the dust cover A firmly so that the headlight lead B faces downward C as shown e After installation adjust the headlight aim see Headlight Aiming Inspection in the Periodic Maintenance chapter Headlight Removal installation e Remove the mounting bolts A e Disconnect the headlight connector A e Remove the headlight assy e Installation is the reverse of removal OFit the projections A of the steering stem into the grom mets B of the headlight assy ELECTRICAL SYSTEM 16 43 Lighting System Tail Light Removal e Remove the seat see Seat Removal in the Frame chap ter e Disconnect the tail light lead connector A e Unhook the tai
102. Bolt A Shift Pedal B e Remove Right Engine Cover see Right Engine Cover Removal Clutch Housing see Clutch Removal Circlip A Oil Pump Driven Gear B e Pull out the shift shaft C e Remove the bolt D and screw E take off the shift ratchet assembly F with ratchet plate G e Remove the bolt A and shift dram cam B e Remove the nut C and take off the gear set lever D External Shift Mechanism Installation e Install the gear set lever A OFit each end of the spring B or original positions ODo not forget to install the color and washer C e Tighten the gear set lever nut D Torque Gear Set Lever Nut 8 8 N m 0 90 kgf m 78 in Ib e Holding the gear set lever A with the driver B and install the shift dram cam C OApply a non permanent locking agent to the shift dram cam bolt OFit the groove D on the pin E e Align the roller of the gear set lever with the slot of the shift dram cam 6 20 ENGINE RIGHT SIDE External Shift Mechanism e Set up the shift ratchet assembly as shown in the figure Ratchet A Pawls B Pins C Springs D OAssembly the shift ratchet so that groove E of the pawl facing the crankcase side F e Then install the ratchet assembly A to the ratchet plate B as shown in the figure e Install the ratchet assembly to the shift drum cam e Apply a non permanent locking agent to the ratchet plate mounting screw e Tighten the screw
103. Brake Lever Pivot Bolt 5 9 0 60 52 in lb Si 9 Brake Reservoir Cap Screws 1 5 0 15 13 in lb 10 Front Brake Light Switch Screw 1 2 0 12 10 in lb Front Brake Reservoir Brake Lever Brake Lever Adjuster Locknut Brake Hose Clamps Front Caliper Brake Pad Piston Front Disc Australia Models KLX450A9F AAF Model Apply brake fluid Apply a non permanent locking agent Replacement Parts Tighten the fasteners following the specified sequence i Apply silicone grease 12 4 BRAKES Exploded View BRAKES 12 5 Exploded View Torque Re No Fastener N m kgf m ft Ib marks 1 Brake Hose Banjo Bolts 25 25 18 2 Rear Master Cylinder Mounting Bolts 10 1 0 89 in lb 3 Rear Master Cylinder Push Rod Locknut 17 1 7 13 4 Caliper Bleed Valve 7 8 0 80 69 in lb 5 Brake Pad Bolt 17 1 7 13 6 Rear Brake Pad Bolt Plug 2 4 0 24 21 in lb 7 Caliper Holder Shaft 27 2 8 20 Si 8 Brake Pedal Mounting Bolt 25 2 5 18 G L 9 Rear Brake Disc Mounting Bolts 23 2 3 17 L 10 Brake Reservoir Cap Bolts 15 0 15 13 in lb 11 Brake Hose 12 Rear Master Cylinder 13 Brake Pedal 14 Rear Caliper Cover 15 Rear Caliper 16 Piston 17 Brake Pads 18 Rear Disc BF Apply brake fluid Apply high temperature grease Apply a non permanent locking agent Replacement Parts i Apply Silicone grease 12 6 BRAKES Specifications Item Ser
104. C on the base valve assembly e With the piston rod held immorable in fully compressed position A gently install the base valve assembly B to the subtank e Screw in the base valve assembly in the subtank when the piston rod extends NOTE OWhen it is hard to screw in the base valve assembly pull down the piston rod a little PERIODIC MAINTENANCE 2 51 Periodic Maintenance Procedures e Holding the top plug wrench A with a vise Special Tool Top Plug Wrench 49 mm 57001 1653 e Holding the subtank B with the top plug wrench torque the base valve assembly C Torque Base Valve Assembly 28 N m 2 9 kgf m 21 ft Ib e Protect the piston rod end A with a rag B to prevent fork damage e Discharge the extra oil off the cylinder unit by pumping C the piston rod to full stroke Be careful not to bend or damage the piston rod when the piston rod is stroked Service carefully because oil flies out from the oil hole of the cylinder unit NOTE OSet the compression damper setting to the softest OCheck the piston rod sliding surface for damage OApply fork oil to the piston rod sliding surface e Drain the extra oil from the subtank oil hole A e With the cylinder unit in horizontal position move A the piston rod B by hand to inspect it if operating smoothly Olf the piston rod is not extend remove the base valve assembly and perform the air bleeding pour the specified
105. Clamp Face the tab to the upper of the engine View from A Clamp Install the clamp as shown in the figure Vacuum Hose Clamp Face the tab to the upper of the engine 17 22 APPENDIX Cable Wire and Hose Routing EE 2 1 W a E EA Si E APPENDIX 17 23 Cable Wire and Hose Routing I O O1 P D N Radiator Hose Clamps Install the clamp as shown in the figure Radiator Hose Clamps Install the clamp as shown in the figure Face the white painted portion to the right side of the engine Water hose Face the white painted portion to the right side of the engine View from the rear side of the engine To Water Pump Cover Water Hose Stoppers Radiator Hose 17 24 APPENDIX Cable Wire and Hose Routing E H E E A y AN d US RO 7 i gt xo EE G CH Une NE Se AN S Sigs VAG RS Wes ORSIN OAA Dw Ho p D CA wei A CA Vo X TE pa Ss NA Ai Wi A US Si fry 6B09329CW4 C 1 Clamp Install the clamp as shown in the figure 2 Fuel Hose 3 Carburetor 4 Clamp Install the clamp as shown in the figure 5 Clamp Run the vent hoses through the clamp on the backward of the crankcase 6 Vent Hoses Troubleshooting Guide APPENDIX 17 25 This is not an exhaustive list giving every
106. Cooling System Bore and Stroke Displacement Compression Ratio Carburetion System Starting System Ignition System Timing Advance Ignition Timing Spark Plug Valve Timing Inlet Open Close Duration Exhaust Open Close Duration Lubrication System Engine Oil Type Viscosity Capacity Drive Train Primary Reduction System Type Reduction Ratio Clutch Type 4 stroke single cylinder DOHC 4 valve Liquid cooled 96 0 x 62 1 mm 3 78 x 2 44 in 449 cm 27 4 cu in 12 0 1 Carburetor KEIHIN FCR MX40 Electric starter Primary kick Digital AC CDI BTDC 10 2 1 800 r min rpm NGK CPR8EB 9 BTDC 38 ABDC 66 284 BBDC 68 ATDC 36 284 Forced lubrication semi dry sump API SG SH SJ SL or SM with JASO MA MA1 or MA2 SAE 10W 30 10W 40 10W 50 1 3 L 1 4 US at Gear 2 727 60 22 Wet multi disc GENERAL INFORMATION 1 9 General Specifications Items KLX450A8F AAF Transmission Type 5 speed constant mesh return shift Gear ratios 1st 2 167 26 12 2nd 1 533 23 15 3rd 1 188 19 16 4th 0 950 19 20 5th 0 810 17 21 Final Drive System Type Chain drive Reduction Ratio Overall Drive Ratio Frame Type Steering Angle Caster rake angle Trail Front tire Size Make Type Rear tire Size Make Type Rim size Front Rear Front suspension Type Wheel travel Rear suspension Type Wheel travel Brake type Front and Rear Effective disc diameter Front e
107. Damping Adjuster Setting Standard 9 clicks B Softer Counterclockwise C Harder Clockwise D Number of turns counterclockwise usable range 22 or more Counterclockwise from the fully seated position NOTE OAdjustment of the rebound damping adjuster for the rear suspension will slightly affect the compression damping force Always make any damping adjustments in small steps and test their effects before using them in com petition 222120131211109 8 7 6 5 432 D D D Re GM05273BS1 C Compression Damping Adjustment There are two adjustments you can make to the rear shock absorber gas reservoir High Speed Compression Damping Adjuster A Low Speed Compression Damping Adjuster B 13 24 SUSPENSION Rear Suspension Uni Trak e Adjust the high speed compression damping turn the high speed compression damping adjuster with a 17 mm wrench If the damping feels too soft or too stiff adjust it in accor dance with the following table High Speed Compression Damping Standard 1 1 4 turns out B Softer counterclockwise C Harder clockwise D Number of turns counterclockwise usable range 2 or more A Counterclockwise from the fully seated position e Adjust the low speed compression damping turn the low speed compression damping adjuster with a flat head screwdriver If the damping feels too soft or too stiff adjust it in accor dance with the following table Low Spe
108. Diameter C Repair 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 Do not grind the seat too much Overgrinding will reduce valve clearance by sinking the valve into the head If the valve sinks too far into the head it will be impossible to adjust the clearance and the cylin der head must be replaced Widened Width A of engagement by machining with 45 cutter Ground Volume B by 32 cutter 32 C Correct Width D Ground Volume E by 55 cutter 55 F GE15011881 GE15011981 ENGINE TOP END 5 31 Valves e Measure the outside diameter of the seating surface with a vernier caliper If the outside diameter of the seating surface is too small repeat the 45 grind until the diameter is within the spec ified range Original Seating Surface B ORemove all pittings of flaws from 45 ground surface OAlter grinding with 45 cutter apply thin coat of machin ists dye to 45 A seating surface This makes seating surface distinct and 32 and 55 grinding operation eas ier OWhen the valve guide is replaced be sure to grind with 45 cutter for centering and good contact If the outside diameter A of the seating surface is too
109. EN 12 13 Eluid Seal Damages ss uen nn An nai 12 13 Dust Seal and Cover Damage sine 12 13 Psion Cy Wt AAG inicia 12 13 Caliper Holder Shaft Wear EE 12 13 Brake Pad Removal EE 12 14 Brake Pad Installation EE 12 14 Brake Pad Inspection nn EBEN 12 14 Ee ne EE 12 15 Front Master Cylinder Removal gue ENEE interet miennes 12 15 Front Master Cylinder installations sans nantes attentes etn 12 15 Rear Master Cylinder Removal ue coins dias 12 16 Rear Master Cylinder Installation 12 16 Front Master Cylinder Disassembly oooooccccconccccccconocccononancncnnnnnncnononnnncnnnnnnn nn nn nnnnncnnnnnnncnns 12 16 Rear Master Cylinder Disassembly cocida 12 16 Ee ale ge EE 12 16 Master Cylinder Inspection Visual Inspection 12 17 eC E 12 18 Brake Disc Removal doi ias 12 18 Brake Dise Installation cts e illes 12 18 Brake Disc Inspection iia deban na 12 18 o EE 12 19 Brake Hose Removal InstallatiOn 0ooconiia EENS REENEN EEN 12 19 Brake Hose INSP SCLiO Me cias oa ore tet at EE 12 19 12 2 BRAKES Exploded View BRAKES 12 3 Exploded View No Fastener ER Remarks N m kgf m ft Ib 1 Front Master Cylinder Clamp Bolts 8 8 0 90 78 in lb S 2 Brake Hose Banjo Bolts 25 2 5 18 3 Brake Pad Bolt 17 1 7 13 4 Caliper Bleed Valve 7 8 0 80 69 in lb 5 Caliper Mounting Bolts 25 2 5 18 6 Front Brake Disc Mounting Bolts 10 1 0 89 in lb L 7 Brake Lever Pivot Bolt Locknut 5 9 0 60 52 in lb 8
110. Engine Mounting Nut M10 49 N m 5 0 kgf m 36 ft lb e Tighten the following OTighten the M10 bolts and nut first Torque Upper Engine Mounting Bolts M10 49 N m 5 0 kgf m 36 ft lb Middle Engine Mounting Nut M10 49 N m 5 0 kgf m 36 ft lb Upper Engine Bracket Bolts M8 29 N m 3 0 kgf m 21 ft lb Middle Engine Bracket Nuts M8 29 N m 3 0 kgf m 21 ft lb Olnstall the shim to the inside of the right upper engine bracket KLX450A8F Model e Install the removed parts see Appropriate chapter e Run the cables hoses and leads according to the Cable Wire and Hose Routing section in the Appendix chapter e Fill Engine Oil see Engine Oil Change in the Periodic Main tenance chapter Coolant see Coolant Filling in the Cooling System chap ter e Adjust Throttle Cable see Throttle Grip Free Play Adjustment in the Periodic Maintenance chapter Clutch Cable see Clutch Lever Free Play Adjustment in the Periodic Maintenance chapter Drive Chain see Drive Chain Slack Adjustment in the Periodic Maintenance chapter e Adjust the idling see Idle Speed Adjustment in the Peri odic Maintenance chapter e Check the operation of the clutch lever e Check the brake effectiveness WARNING After servicing it takes several applications of the brake pedal before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride th
111. Fuel Tap and Filter Inspection Cooling System Coolant Level Inspechon Coolant Deterioration Inspection Radiator Hoses and Connections INSpection ee se Engine Top End 1 Vacuum Switch Valve Test Valve Clearance Inspection Valve Clearance Adjustment Cylinder Head Warp Inspection Cylinder Wear Inspection Piston Cylinder Clearance Piston Piston Ring and Piston Pin Heplacement e Spark Arrester Cleaning Engine Right Side aanneeeeeeeee Clutch Lever Free Play Check Clutch Lever Free Play Adjustment 3322 Friction and Steel Plates deele WEE Engine Lubrication Gvstem Engine Oil Change Oil Filter Change sseesseeeeseenen Breather Hose Inspection Crankshaft Transmission Crankshaft Inspection 00 0 Wheel Tires 2 17 2 17 2 17 2 18 2 18 2 19 2 19 2 19 2 20 2 21 2 23 2 23 2 24 2 24 2 24 2 25 2 25 2 26 2 26 2 26 2 26 2 27 2 28 2 29 2 29 2 29 Air Pressure Inspection Adjust Tires Inspection Spoke Tightness Inspection Rim Runout Inspection Wheel Bearing Inspection SIB Drive Chain Slack Inspection Drive Chain Slack Adjustment Drive Chain Wear Inspection Drive Chain Lubrication Sprocket Wear Inspection Rear Sprocket Warp Inspection Brake Lev
112. INTENANCE Periodic Maintenance Procedures Electrical System Spark Plug Cleaning and Inspection e Remove Seat see Seat Removal in the Frame chapter Fuel Tank see Fuel Tank Removal in the Fuel System chapter Spark Plug Cap e Clean the plug hole A using the compressed air B e Remove the spark plug A using the spark plug wrench B Special Tool Spark Plug Wrench 57001 1262 Owner s Tool Spark Plug Wrench 16 mm 92110 0005 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 high flash point solvent and a wire brush or other suitable tool l the spark plug electrodes are corroded or damaged or if the insulator is cracked replace the plug Use the standard spark plug e Measure the gap A with a wire type thickness gauge lf the gap is incorrect carefully bend the side electrode B with a suitable tool to obtain the correct gap Spark Plug Gap Standard 0 8 0 9 mm 0 03 0 04 in e Install the spark plug Torque Spark Plug 13 N m 1 3 kgf m 115 in Ib e Fit the plug cap securely OPull the spark plug cap A to make sure the installation of the spark plug cap Cable Inspection Lubrication e Before lubricating each part clean off any rusty spots with rust remover and wipe off any grease oil dirt or grime e Lubricate the points listed below with indicated lubricant NOTE OWhenever the vehi
113. Inspection e Check that the rear end A of the left chain adjuster aligns with the same swing arm mark B as the right chain ad juster A WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition Be sure the wheel is properly aligned Wheel Alignment Adjustment This procedure is the same as Drive Chain Slack Adjust ment see Drive Chain Slack Adjustment in the Periodic Maintenance chapter Drive Chain Wear Inspection e Refer to the Drive Chain Wear Inspection in the Periodic Maintenance chapter Drive Chain Lubrication e Refer to the Drive Chain Lubrication in the Periodic Main tenance chapter Drive Chain Removal e Using a suitable tool replace the drive chain Recommended Tool DID Chain Joint ZJ Make DAIDO KOGYO NOTICE Read the Tool Instruction Manual before replacing the chain e Remove Body A Pin Holder B Positioning Pin C U Holder D Plate Holder E Cutting and Riveting Pin F Part for Riveting G Part for Cutting H 11 6 FINAL DRIVE Drive Chain e Grind A the heads of the link pin to make it flat e Set the cutting and riveting pin C in the pin holder B as shown in the figure e Set the U holder and body align the positioning pin A with the A mark B e Turn the pin holder C clockwise until the cutting and riv eting pin touches the link pin e Be sure that the cutting
114. Inspection in the Periodic Maintenance chapter Tie Rod and Rocker Arm Sleeve Wear e Pull out the sleeves A of the tie rod and rocker arm e Measure the outside diameter of the sleeve lf the sleeve is worn past the service limit replace the sleeve Sleeve Outside Diameter Standard Tie rod 19 987 20 000 mm 0 7888 0 78740 in Rocker Arm Large 19 987 20 000 mm 0 78688 0 78740 in Small 15 995 16 000 mm 0 62972 0 62992 in Service Limit Tie rod 19 85 mm 0 781 in Rocker Arm Large 19 85 mm 0 781 in Small 15 85 mm 0 624 in Tie Rod and Rocker Arm Mounting Bolt Bend A bent bolt causes vibration poor handling and instabil ity e To measure the bolt runout remove the bolt place it in V blocks and set a dial gauge to the bolt at a point halfway between the blocks Turn A the bolt to measure the runout The amount of dial variation is the amount of runout If runout exceeds the service limit replace the bolt Bolt Runout Standard Under 0 1 mm 0 004 in Service Limit 0 2 mm 0 008 in GMO7036BS1 GMO7038BS1 STEERING 14 1 Steering Table of Contents Exploded E 14 2 Special EEN 14 4 ed EE 14 5 Steering Ree EE 14 5 Steering e TE 14 5 Steering Stem Stem Bearing Removal AAA 14 5 Steering Stem Stem Bearing Installation EEN 14 7 Stem Bearing EUDEBATIONE SSSR acs d aay atuacthicasa itech serene encase 14 8 stem Bearing Wear Dam
115. Magneto Cover see Magneto Cover Removal in the Electrical System chapter Flywheel see Flywheel Removal in the Electrical Sys tem chapter e Install the flywheel A temporary and hold it steady with the flywheel holder B loosen the balancer weight mount ing nut C Special Tool Flywheel Holder 57001 1313 e Remove Balancer Weight Mounting Nut Balancer Weight D Balancer Gear E e Pull out the balancer shaft from the right crankcase Balancer Installation e Insert the balancer shaft from the right crankcase e Install the balancer gear so that the stepped portion A on the balancer shaft and punch mark B on the balancer gear align e Align the punch mark A on the balancer drive gear and punch mark B on the balancer gear e Install the balancer weight so that the punch mark A on the balancer and punch mark B on the balancer gear e Install the flywheel temporary and hold it steady with the flywheel holder tighten the balancer weight mounting nut Torque Balancer Weight Mounting Nut 52 N m 5 3 kgf m 38 ft lb CRANKSHAFT TRANSMISSION 9 25 Bearings Oil Seals Bearing Replacement Do not remove the ball bearings unless it is neces sary Removal may damaged them e Remove the ball bearing and or needle bearing outer race using a press or puller NOTE O ln the absence of the above mentioned tools satisfac tory results may be obtained by heating the case to ap proximat
116. Method Standard Exhaust 0 09 0 16 mm 0 0035 0 0063 in Inlet 0 06 0 14 mm 0 0024 0 0055 in Service Limit Exhaust 0 36 mm 0 014 in Inlet 0 33 mm 0 013 in GE15010481 ENGINE TOP END 5 29 Valves Valve Seat Inspection e Remove the valve see Valve Removal e Check the valve seating surface A between the valve B and valve seat C e Measure the outside diameter D of the seating pattern on the valve seat x lf the outside diameter is too large or too small repair the seat see Valve Seat Repair Valve Seating Surface Outside Diameter Standard Exhaust 29 4 29 6 mm 1 16 1 17 in Inlet 34 4 34 6 mm 1 35 1 36 in e Check the seating surface width of the valve seat OMeasure the seat width E of the portion where there is no build up carbon white portion of the valve seat with a vernier caliper Good F Valve Seating Surface Width Standard Exhaust 0 8 1 2 mm 0 03 0 047 in Inlet 0 5 1 0 mm 0 02 0 039 in x lf the width is too wide G too narrow H or uneven J repair the seat see Valve Seat Repair Valve Seat Repair e For the instructions on how to use the valve seat cutter A follow the operation manual provided by the to man ufacturer Special Tools Valve Seat Cutter Holder 65 5 57001 1125 B Valve Seat Cutter Holder Bar 57001 1128 Exhaust Valve Seat Cutter 45 635 57001 1116 Valve Seat Cutter 32 935 57001
117. ORecord this number as the manufacture set number of turns out e Unscrew the pilot air screw Australia and Europe mod els NOTE ODo not remove the pilot air screw plug U S A Califor nia and Canada models FUEL SYSTEM 3 19 Carburetor e Unscrew the screws A e Remove the acceleration pump cover B from the carbu retor e Remove the spring A diaphragm B and the O rings C e Remove the following parts from the carburetor body A Idle Adjusting Screw B Screws C Clamps D Float Bowl E Leak Jet F O ring G Pin H Float I Main Jet J Needle Jet K Starter Jet L Pilot Jet M Pilot Air Jet e Pull out the push rod A of the acceleration pump 3 20 FUEL SYSTEM Carburetor e Remove E clip A Washer B e Pull out the acceleration pump lever assembly C as a set e Remove the throttle sensor mounting bolt A e Before removing the throttle sensor B mark C the car buretor body and sensor so that it can be installed later in the same position Carburetor Cleaning A WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the carburetor in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Do not use gasoline or a low flash point solvent to clean the carburetor e M
118. RAL LAW THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING 10 000 PER VIOLATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below e Replacement of the original exhaust system or muffler with a component not in compliance with Federal regulations e Removal of the muffler or any internal portion of the muffler e Removal of the air box or air box cover e Modifications to the muffler or air inlet system by cutting drilling or other means if such modi fications result in increased noise levels Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop However it contains enough detail and basic in formation to make it useful to the owner who de sires to perform his own basic maintenance and repair work A basic knowledge of mechanics the proper use of tools and workshop proce dures must be understood in order to
119. Seat Seat Removal e Remove the bolts A e Pull the seat B out from the back Seat Installation e Stick the pad on the inside of the seat e Fit the hooks A of the seat under the flange collar B and brackets C Olnstall the brackets A of the seat to inside B of side cover e Tighten the seat mounting bolts 15 8 FRAME Side Cover Right Side Cover Removal e Remove Bolts A Side Cover B Right Side Cover Installation e Stick the pad A on the inside of the right side cover B e Insert the inside rib C between rear fender and rear frame 6006007BS1 e Insert the tab A of the right side cover into the air cleaner housing B and install the bolts Left Side Cover Removal e Remove Air Cleaner Cover A Quick Fastener B e Remove Bolts A Washer B Left Side Cover C FRAME 15 9 Side Cover Left Side Cover Installation e Install Left Side Cover Washer Bolts Air Cleaner Cover A Quick Fastener 15 10 FRAME Fender Front Fender Removal e Unscrew the bolts A and remove the front fender B Rear Fender Removal e Remove Seat see Seat Removal Reserve Tank see Reserve Tank Removal in the Cool ing System chapter Regulator Rectifier see Regulator Rectifier Inspection in the Electrical System chapter e Unscrew the bolts A and remove the rear fender B Rear Flap Removal e Unscrew the screws A and
120. Service Limit 22 93 mm 0 9028 in lf the clearance still remains out of the service limit re place the cylinder head unit Camshaft Runout e Remove the camshaft see Camshaft Removal e Set the camshaft in a camshaft alignment jig or on V blocks e Measure the runout with a dial gauge at the specified place as shown kxif the runout exceeds the service limit replace the camshaft Camshaft Runout Standard TIR 0 02 mm 0 0008 in or less Service Limit TIR 0 1 mm 0 004 in Cam Wear e Remove the camshaft see Camshaft Removal e Measure the height A of each cam with a micrometer xklf the cams are worn down past the service limit replace the camshaft Cam Height Standard Exhaust 36 443 36 557 mm 1 4348 1 4392 in Inlet 37 143 37 257 mm 1 4623 1 4668 in Service Limit Exhaust 36 34 mm 1 431 in Inlet 37 04 mm 1 458 in 6E11077BS1i GE11012281 5 22 ENGINE TOP END Cylinder Head Cylinder Compression Measurement e Start the engine e Thoroughly warm up the engine so that the engine oil be tween the piston and cylinder wall will help seal compres sion as it does during normal running e Stop the engine e Remove Fuel Tank see Fuel Tank Removal in the Fuel System chapter e Remove the spark plug A with spark plug wrench B or owner s tool Special Tool Spark Plug Wrench Hex 16 57001 1262 Owner s Tool Spark Plug Wrench 92110
121. Special Tool Bearing Driver Set 57001 1129 e Install the needle bearings and grease seals position as shown OThe installation procedure is the same as the counter side Le Lea H Imm 6M06034BS1 13 30 SUSPENSION Swingarm Swingarm Bearing Sleeve Inspection NOTICE Do not remove the bearings for inspection Re moval may damage them e Inspect the needle bearings installed in the swingarm OThe rollers in a bearing normally wear very little and wear is difficult to measure Instead of measuring visually inspect the bearing for abrasion discoloration or other damage If the needle bearing and sleeve show any sings of ab normal wear discoloration or damage replace them as a set Drive Chain Guide Guide Roller Chain Slipper Wear e Visually inspect the drive chain guide A and replace it if excessively worn or damaged e Visually inspect the upper and lower chain guide rollers A and replace them if excessively worn or damaged e Visually inspect the chain slipper A on the swingarm B and replace it if worn or damaged SUSPENSION 13 31 Tie Rod Rocker Arm Tie Rod Removal e Using the jack under the frame raise the rear wheel off the ground Special Tool Jack 57001 1238 e Unscrew the nut A and remove the guide roller B NOTICE When pulling out the mounting bolts lift the rear wheel slightly Forcing or tapping on a bolt could
122. Standard Friction Plate 0 15 mm 0 0059 in or less 6F13010751 0 Steel Plate 0 2 mm 0 008 in or less Service Limit Friction Plate 0 3 mm 0 01 in Steel Plate 0 3 mm 0 01 in Engine Lubrication System Engine Oil Change e Warm up the engine thoroughly so that the oil will pick up any sediment and drain easily Then stop the engine PERIODIC MAINTENANCE 2 27 Periodic Maintenance Procedures e Remove the engine oil drain plugs on the bottom of the engine and let the oil drain completely Drain Plug Sub A Drain Plug Main B NOTE OHold the motorcycle upright so that the oil may drain completely e Replace the gaskets at the drain plugs with a new one e After the oil has completely drained out install the drain plugs with the gaskets and tighten them Torque Engine Oil Drain Plug M6 Sub 7 0 N m 0 71 kgf m 62 in Ib Engine Oil Drain Plug M10 Main 20 N m 2 0 kgf m 15 in Ib e Fill the engine with a good quality motor oil specified be low Recommended Engine l Type Castrol R4 Superbike SAE 5W 40 or SAE 10W 50 API SG SH SJ SL or SM with JASO MA MA1 or MA2 SAE 10W 30y Viscosity SAE 10W 30 10W 40 10W 50 Capacity 1 06 L 1 12 US qt when filter is not removed 20 10 0 10 20 30 40 C ee 4 14 32 50 65 86 104 1 08 L 1 14 US qt when filter is remove ee 1 3 L 1 4 US qt when engine is 6S09013BS1 completely dry NOTE
123. TENANCE 2 7 Torque and Locking Agent Fastener E Remarks N m kgf m ft Ib Locknut Adjuster Assembly 29 3 0 21 Adjuster Assembly 55 5 6 41 L Front Axle Clamp Bolts 20 2 0 15 AL Swingarm Pivot Shaft Nut 98 10 72 Rocker Arm Pivot Nut 59 6 0 44 Tie rod Mounting Nut Front Rear 59 6 0 44 Rear Shock Absorber Mounting Nut peep g 39 4 0 29 e Absorber Mounting Nut 34 35 25 Air Bleed Bolt 6 5 0 66 58 in lb Steering Handlebar Clamp Bolts 25 2 5 18 2T Steering Stem Head Nut 98 10 72 Steering Stem Nut 4 9 0 50 43 in lb T Front Fork Clamp Bolts Upper 20 2 0 15 AL Front Fork Clamp Bolts Lower 20 2 0 15 AL Frame Rear Frame Mounting Bolt 34 3 5 25 Upper Footpeg Bracket Bolts 54 5 5 40 L Electrical System Spark Plug 13 1 3 115 in lb Starter Motor Terminal Nut 5 9 0 60 52 in lb Starter Motor Mounting Bolts 9 8 1 0 87 in lb Crankshaft Sensor Bolts 7 0 0 71 62 in lb Stator Bolts 4 0 0 41 35 in lb L Flywheel Nut 98 10 72 Magneto Cover Bolts 9 8 1 0 87 in lb Timing Inspection Cap a Hand Tighten Flywheel Nut Cap Hand Tighten Torque Limiter Cover Bolts 9 8 1 0 87 in lb Starter Motor Terminal Locknut 6 9 0 70 61 in lb Starter Motor Through Bolts 3 4 0 35 30 in lb Breather Fitting 15 1 5 11 L Head Light Bracket Screws 1 4 0 14 12 in lb Gear Position Switch Screws 2 9 0 30 26 in lb L 2 8 PERIODIC MAINTENANCE Torque and Locking Agent Basic Torque for General Fasteners
124. Terminal Voltage V A Battery Charge Rate B yy 12 Refresh charge is required C es Good D 0 25 50 75 100 B GPO8071BS1 C 16 16 ELECTRICAL SYSTEM Battery Refreshing Charge e Remove the battery see Battery Removal e Do refresh charge by following method according to the battery terminal voltage A WARNING This battery is sealed type Charge with current and time as stated below Terminal Voltage 12 less than 12 4 V Standard Charge 0 6 A x 5 10 h see following chart Quick Charge 3Ax1h If possible do not quick charge If quick charge is done unavoidably do standard charge later on Terminal Voltage less than 12 V Charging Method 0 6 Ax 20 h NOTE Olncrease the charging voltage to a maximum voltage of 25 Vif the battery will not accept current initially Charge forno more than 5 minutes at the increased voltage then check if the battery is drawing current If the battery will accept current decrease the voltage and charge by the standard charging method described on the battery case If the battery will not accept current after 5 min utes replace the battery Battery A Battery Charger B Standard Value C Current starts to flow D e Determine the battery condition after refresh charge ODetermine the condition of the battery left for 30 minutes after completion of the charge by measuring the terminal voltage according to the table below C
125. Torque Fastener 4 Remarks kgf m ft Ib ER Primary Gear Nut 10 Lh R Clutch Cover Bolts 87 in lb Right Engine Cover Bolts 9 8 1 0 87 in lb Clutch Spring Bolts 0 90 78 in lb GC Clutch Hub Nut 10 R Primary Gear Push Rod Holder Release Lever Shaft Clutch Lever 10 Clutch Cable 11 Clutch Hub 12 Clutch Housing 13 Clutch Spring Plate 14 Friction Plates Width of the lining blocks are wide 15 Friction Plates Width of the lining blocks are narrow 16 Steel Plates CL Apply cable lubricant EO Apply engine oil G Apply grease HG Apply high temperature grease Lh Left hand Threads M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil R Replacement Parts JO 6 4 ENGINE RIGHT SIDE Exploded View Exploded View ENGINE RIGHT SIDE 6 5 we Fastener Ratchet Guide Bolt 2 Kick Pedal Bolt Ratchet Plate Mounting Bolt Ratchet Plate Mounting Screw Gear Set Lever Nut 6 Shift Drum Cam Bolt Kick Pedal Kickshaft Idle Gear Ratchet Gear Kick Gear Shift Pedal Ratchet Plate Ratchet Assembly Gear Set Lever Shift Drum Cam Shift Shaft Apply grease Apply a non permanent locking agent Apply molybdenum disulfide oil Replacement Parts Stake the fasteners Remarks 6 6 ENGINE RIGHT SIDE Specifications Item Clutch Lever Standard Clutch Lever Free Play Lever pointed 8 13 m
126. YSTEM Special Tools and Sealant Flywheel Puller M28 x 1 0 57001 1471 Ni Se ST5714718T Liquid Gasket TB1211F 92104 0004 gt ST9200048T ELECTRICAL SYSTEM 16 11 Models la Diagram Other than Australi iring W Cem enna BEDIEN al CI 34314 apo 10 09 uf UVIAZL 1040W 49311838 Asay eg ADM A N9 CI 19 14 al rel Ael oy UIeH 31411998 40zein8ey EI A JM8 48 84 9 A 1931431 IDODULOT I XIE ZOO J10su9S uO S0g 9 1104Y1 ya A 4 14 oyousey 199YM y AOSUdS MW ypeys que A A 4 9 Y a A 1a A A B D Y A D A 14 lt 33 35 uong 4911835 eulgug youlas uol3isogd 1899 yg 4 9 D anid 44edg gt 1109 90 1148 A M8 A AG o 1i 0 A H8 EE gt gt an Yo yIMs yor ims dois 1n0 907 su1suz 1874828 A a A A Ma xa Wasa Y hA A D H yg a H MGE SEAZL 14317 peoH yrun 142 W A A9 14 ga a ral O 40suas peads GPO5111845 C 16 12 ELECTRICAL SYSTEM Precautions There are numbers of important precautions that are musts when servicing electrical systems Learn and ob serve all the rules below OThe electrical parts should never be struck sharply as with a hammer or allowed to fall on a hard surface Such a shock to the pa
127. able first and then the positive When completed with the service first connect the positive cable to the positive terminal of the battery then the negative ca ble to the negative terminal Edges of Parts Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts Solvent Use a high flash point solvent when cleaning parts High flush point solvent should be used according to directions of the solvent manufacturer Cleaning vehicle before disassembly Clean the vehicle thoroughly before disassembly Dirt or other foreign materials entering into sealed areas during ve hicle disassembly can cause excessive wear and decrease performance of the vehicle y b A Aye E ODA 7 ee el ss eil Of e 0 a HN 7 AN DISASSEMBLY ASSEMBLY eau S 65020048 68020058 S GENERAL INFORMATION 1 3 Before Servicing Arrangement and Cleaning of Removed Parts Disassembled parts are easy to confuse Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly Storage of Removed Parts After all the parts including subassembly parts have been cleaned store the parts in a clean area Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re assembly Inspection Reuse of worn or damaged parts may lead to serious ac
128. ably the crankshaft is not centered tap the appropriate end of the crankshaft with a mallet A to reposition it G104289BS1 CRANKSHAFT TRANSMISSION 9 13 Crankcase e Install the gear set lever A ELA LAN OFit each end B of the spring or original positions ODo not forget to install the collar and washer C e Tighten the gear set lever nut D Torque Gear Set Lever Nut 8 8 N m 0 90 kgf m 78 in Ib e To install the shift drum cam A use the driver B to bring the gear set lever C to the bottom of the crankcase e Mate the shift drum pin D into the shift drum hole OFit the groove E of the shift drum cam on the shift drum pin e Apply non permanent locking agent to the shift drum cam bolt and tighten it Torque Shift Drum Cam Bolt 24 N m 2 4 kgf m 18 ft lb e Check to see that gears shift smoothly from 1st to 5th gear and 5th to 1st while spinning the output shaft e Set the shift drum in the neutral position e Replace the O ring A on the output shaft with new one and apply grease it e Install the O ring on the grinding faces of the output shaft while expanding the O ring by the hand e Apply grease to the inside of the output shaft collar B e Insert the collar with the oil groove ends C facing in e Install the balancer drive gear A so that the stepped portion B of the balancer drive gear and crankshaft are aligned e Replace the cir
129. aft must be replaced In case of less serious damage disassemble the crank shaft and replace the crankpin needle bearing and con necting rod Connecting Rod Bend e Remove the connecting rod e Select an arbor A of the same diameter as the connect ing rod big end and insert the arbor through the connect ing rod big end e Select an arbor of the same diameter as the piston pin and more than 105 mm long and insert the arbor B through the connecting rod small end e On a surface plate set the big end arbor on a V block C 6105040681 e With the connecting rod held vertically use a height gauge to measure the difference in the height of the arbor above the surface plate over a 100 mm length to determine the amount of connecting rod bend If connecting rod bend exceeds the service limit the con necting rod must be replaced Connecting Rod Bend Service Limit TIR 0 2 100 mm 0 08 3 94 in 9 18 CRANKSHAFT TRANSMISSION Crankshaft Connecting Rod Connecting Rod Twist e With the big end arbor A still on the V block C hold the connecting rod horizontally and measure the amount that the arbor B varies from being parallel with the surface plate over a 100 mm length of the arbor to determine the amount of connecting rod twist If connecting rod twist exceeds the service limit the con necting rod must be replaced Connecting Rod Twist Service Limit TIR 0 2 100 mm 0 08 3 94 in G
130. age EE 14 8 SUSI A EEIT E E E 14 8 ee EE 14 9 Handlebar GOV EE 14 9 Handlebar Installation ceccccecccececeecceeeeeeeeeececeeeeeeeaeeeaeeeaeeeaceeeceneeeeeeeeeeseeeneteneeenenennens 14 9 14 2 STEERING Exploded View STEERING 14 3 Exploded View No Fastener E Remarks N m kgf m ft lb 1 Handlebar Clamp Bolts 25 2 5 18 2T 2 Steering Stem Head Nut 98 10 72 3 Steering Stem Nut 4 9 0 50 43 in lb T 4 Front Fork Clamp Bolts Upper 20 2 0 15 AL 5 Front Fork Clamp Bolts Lower 20 2 0 15 AL 6 Handlebar Clamp 7 Handlebar 8 Handlebar Holder 9 Steering Stem Head Bracket Upper Tapered Roller Bearing Head Pipe Lower Tapered Roller Bearing Steering Stem Apply adhesive cement Tighten the two clamp bolts alternately two times to ensure even tightening torque Apply grease Apply 2 stroke oil First tighten the stem locknut with 39 N m 4 0 kgf m 29 ft lb of torque then loosen it and retighten it with 4 9 N m 0 50 kgf m 43 in lb of torque 14 4 STEERING Special Tools Bearing Puller 57001 135 ST5701358T Steering Stem Bearing Driver 57001 137 ST5701378T 57001 1074 ST5710748T Steering Stem Bearing Driver Adapter 634 5 Head Pipe Outer Race Press Shatt 57001 1075 ei ST5710758T Head Pipe Outer Race Driver 651 5 57001 1076
131. aged WHEELS TIRES 10 1 Wheels Tires Table of Contents ee RE 10 2 Specificato Siinai Nae ten E ears en as 10 4 Special TOO S cusco r Piles net otre sde 10 5 VR E E 10 6 FONE Wheel Removal oi ce ocak acetate alien il Ne une 10 6 Front Wheel Installation coins 10 6 Rear Wheel Jett scarce sais usa hucance eegene Seege geed 10 8 Rear Wheel Installation nets e 10 9 Wheels Inspection is 10 10 Spoke Tightness Inspection dos a odian erat 10 10 Rimi Runout Inspection 10 10 ARS NS PSC dd de e 10 10 A O 10 11 TES le EE 10 11 IT e EH 10 12 Air Pressure Inspection Adjustment nan rre 10 13 Hub MOS ips 10 14 lte Eine BEL EE 10 14 Hub Bearing Me EE e EE 10 14 Hub Bearing le Ce A D 10 14 Hub Bearing Lubrication tege deed ee EE 10 15 10 2 WHEELS TIRES Exploded View ey 3 a A a a ch Ka Cj pla AAD 5 x de dad O at Qs GJ02110845 C WHEELS TIRES 10 3 Exploded View No Fastener Torque Remarks N m kgf m ft lb 1 Spoke Nipples 2 2 0 22 19 in lb 2 Front Axle Nut 79 8 0 58 3 Front Axle Clamp Bolts 20 2 0 15 AL 4 Rear Axle Nut 110 11 2 81 1 5 Spokes 6 Front Tire 7 Rims 8 Front Axle 9 Rear Tire 10 Rear Axle AL Tighten the two clamp bolts alternately two times to ensure even tightening torque HG Apply high temperature grease WL Apply soap and water solution
132. agneto lead connector from the main harness NOTE OMeasure the voltage with each lead connected cor rectly The correct value may not be obtained if disconnected OMaintain the correct value of compression pressure for the cylinder Be sure to measure the voltage with the spark plug installed to the cylinder head OSet the hand tester to DC 2 5 V range OConnect the peak voltage adapter A to the tester and the terminals of the magneto lead connector B Special Tools Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Connection Adapter Positive Green White Lead C Adapter Negative White Yellow Lead D OCrank the engine by kicking the kick pedal and by pushing the starter button several times with the transmission gear in neutral to measure the peak voltage of the crankshaft sensor Crankshaft Sensor Peak Voltage Standard 1 1 V or above Kick starter 2 V or above Electric starter A WARNING Electrical equipment can cause serious electrical shock To avoid being shocked do not touch the metal portion of the probe when measuring voltage If the voltage is less than the specified check the crank shaft sensor see Crankshaft Sensor Inspection If the crankshaft sensor is good check the other parts see the flow chart in this section lf the all parts are good replace the igniter 6P10426BS1 C 16 32 ELECTRICAL SYSTEM Ignition System Ex
133. aintenance chapter Hot Starter Cable Inspection e Refer to the Cable Inspection in the Periodic Maintenance chapter 3 12 FUEL SYSTEM Carburetor Since the carburetor regulates and mixes the fuel and air going to the engine there are two general types of carbure tor trouble too rich a mixture too much fuel and too lean a mixture too little fuel Such trouble can be caused by dirt wear maladjustment or improper fuel level in the float chamber A dirty or damaged air cleaner can also alter the fuel to air ratio Idle Speed Inspection e Refer to the Idle Speed Inspection in the Periodic Main tenance chapter Idle Speed Adjustment e Refer to the Idle Speed Adjustment in the Periodic Main tenance chapter Service Fuel Level Inspection A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Always stop the engine and 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 fuel tank see Fuel Tank Removal e Remove the carburetor and hold it in true vertical position on a stand The fuel hose and carburetor cable do not have to be removed to inspect the fuel level A e Put the fuel tank on a bench and connect the fuel tap to the carburetor using a suitable hose e Remove the drain plug from the bottom of the float bowl
134. ake Pad Wear Inspection in the Periodic Maintenance chapter BRAKES 12 15 Master Cylinder NOTICE Brake fluid quickly ruins painted or plastic sur faces any spilled fluid should be completely wiped up immediately Front Master Cylinder Removal e Remove the banjo bolt A to disconnect the upper brake hose B from the master cylinder C e When removing the brake hose temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum e Unscrew the clamp bolts A and take off the master cylin der B as an assembly with the reservoir and brake lever Front Master Cylinder Installation e Install the master cylinder so that the reservoir cap A is horizontally e The master cylinder clamp must be installed with the ar row mark A upward OTighten the upper clamp bolt B first and then the lower clamp bolt C There will be a gap at the lower part of the clamp after tightening Torque Front Master Cylinder Clamp Bolts 8 8 N m 0 90 kgf m 78 in Ib e Replace the washers that are on each side of hose fitting with new ones e Tighten the brake hose banjo bolt Torque Brake Hose Banjo Bolt 25 N m 2 5 kgf m 18 ft lb e Bleed the brake line see Bleeding the Brake Line e Check the brake for good braking power no brake drag and no fluid leakage 12 16 BRAKES Master Cylinder Rear Master Cylinder Removal e Remove the cotter pin A e Pull off th
135. ake sure the fuel tap is in the OFF position e Remove the carburetor see Carburetor Removal e Drain the fuel in the carburetor e Disassemble the carburetor see Carburetor Disassem bly Do not use compressed air on an assembled carbu retor the float may be deformed by the pressure Remove as many rubber or plastic parts from the carburetor as possible before cleaning the carbu retor with a cleaning solution This will prevent damage or deterioration of the parts Do not use a strong carburetor cleaning solution which could at tack the plastic parts instead use a mild high flash point cleaning solution safe for plastic parts Do not use wire or any other hard instrument to clean carburetor parts especially jets as they may be damaged FUEL SYSTEM 3 21 Carburetor e Immerse all the metal parts in a carburetor cleaning solu tion e Rinse the parts in water e After the parts are cleaned dry them with compressed air e Blow through the air and fuel passages with compressed air A e Assemble the carburetor and install it on the motorcycle Carburetor Inspection A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Always stop the engine and do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Remove the carburetor see Carburetor Removal e Before disas
136. am Height Exhaust Inlet Camshaft Journal Camshaft Cap Clearance Camshaft Journal Diameter Camshaft Journal Inside Diameter Camshaft Runout Standard 36 443 36 557 mm 1 4348 1 4392 in 37 143 37 257 mm 1 4623 1 4668 in 0 020 0 061 mm 0 00079 0 0024 in 22 959 22 980 mm 0 90390 0 90472 in 23 000 23 020 mm 0 90551 0 90630 in TIR 0 02 mm 0 0008 in or less Service Limit 36 34 mm 1 431 in 37 04 mm 1 458 in 0 15 mm 0 0059 in 22 93 mm 0 9028 in 23 08 mm 0 9087 in TIR 0 1 mm 0 004 in Cylinder Head Cylinder Compression Kick Starter Electric Starter Cylinder Head Warp Usable range 450 750 kPa 4 59 7 65 kg cm 65 2 109 psi 5 kicks Usable range 450 750 kPa 4 59 7 65 kg cm 65 2 109 psi 420 r min rpm Valve Valve Clearance Exhaust Inlet Valve Stem Bend Valve Stem Diameter Exhaust Inlet Valve Guide Inside Diameter Exhaust Inlet Valve valve Guide Clearance wobble method Exhaust Inlet Valve Seat Cutting Angle Valve Seating Surface Outside Diameter Exhaust Inlet Valve Seating Surface Width Exhaust Inlet 0 20 0 25 mm 0 0079 0 0098 in 0 10 0 15 mm 0 0039 0 0059 in TIR 0 01 mm 0 0004 in or less 5 455 5 470 mm 0 2148 0 2154 in 5 465 5 480 mm 0 2152 0 2157 in 5 500 5 512 mm 0 2165 0 2170 in 5 500 5 512 mm 0 2165 0 2170 in 0 09 0 16
137. amshaft Sprocket Bots 12 12 omb L 7 Carburetor Holder Clamp Screws 2 0 0 20 18 in lb Plug 20 2 0 15 L o Rear Camshaft Chain Guide Bot 15 15 1 10 Oil Pump Scavenge Cover Bolts 9 8 1 0 87 in lb 11 Chain Tensioner Mounting Bolts 9 8 1 0 87 in lb 12 Chain Tensioner Cap Bolt 0 51 44 in lb 13 Water Hose Fitting Bolts 1 0 87 in lb 14 Oil Line Plug 0 31 27 in lb L 15 Decompressor Plug Plate Bolt 1 0 87 in lb 0 90 78 inb L 10 87imb 18 Closed coil end faces down 19 Circle Mark 20 Top Ring 21 Oil Ring 22 U S A California and Canada Models EO Apply engine oil G Apply grease L Apply a non permanent locking agent M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil R Replacement Parts S Follow the specific tightening sequence SS Apply silicon sealant 5 4 ENGINE TOP END Exploded View 6E02407BW5 C ENGINE TOP END 5 5 Exploded View Torque No Fastener kgm np Remarks 2 2 2 N m 1 Exhaust Pipe Cover Bolts 12 106 in lb 20 2 Rear Muffler Mounting Bolt 3 Front Muffler Mounting Bolt First 9 8 87 in lb Front Muffler Mounting Bolt Final 20 15 19 4 Exhaust Pipe Holder Nuts 20 15 1 2 HU 1 0 HU HU 1 0 1 0 20 5 Muffler End Mounting Bolts 10 89 in lb 6 Spark Arrester Mounting Bolts 10 89 in lb 7 KLX450A8F Model R Replacement Parts 5 6 ENGINE TOP END Specifications Item Camshafts C
138. and remove any particles stuck to them A WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the oil screens in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Do not use gasoline or a low flash point solvent to clean the oil screens 7 12 ENGINE LUBRICATION SYSTEM Oil Screen e Check the screen A carefully for any damage holes broken wires gasket pulling off If the screen is damaged replace it e Install the oil screen see Oil Screen Scavenge Installa tion GGO7000BS1 Oil Screen Feed Cleaning e Remove the oil screen see Oil Screen Feed Removal e Clean the oil screen with a high flash point solvent and remove the particles stuck e Blow away the particles by applying compressed air A from the inside to the outside from the clean side to the dirty side A WARNING Gasoline and low flash point solvents can be E flammable and or explosive and cause severe burns Clean the cylinder head in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Do not use gasoline or a low flash point solvent to clean the cylinder head NOTE OWhile cleaning the screens check for any metal parti cles that might ind
139. and riveting pin hits center of the link pin e Hold the body with a wrench A e Turn the pin holder clockwise B with another wrench and remove the link pin e Do the same procedure for removal of the other link pin Drive Chain Installation e Engage the new drive chain to the old drive chain and change the position of the chains by pulling the old chain e Remove the old drive chain from the new drive chain e Replace the link pin A link plate and grease seals B C with new ones e Apply grease to the link pin and grease seals e Install the grease seals on the link pin and insert it in the ends of the drive chain e Install the link plate so that the mark D faces out e Set the cutting and riveting pin B and plate holder C on the pin holder A as shown in the figure GKO4090BS1 FINAL DRIVE 11 7 Drive Chain e Set the U holder and body align the positioning pin A with the A mark B e Hold the body with a wrench C e Turn the pin holder clockwise D with another wrench and press in the link plate on the link pin e Remove the U holder and body e Set the cutting and riveting pin B in the pin holder A as shown in the figure e Set the U holder and body align the positioning pin A with the B mark B e Turn the pin holder C clockwise until the cutting and riv eting pin touches the link pin e Hold the body with a wre
140. ankcase bearing boss when the bear ing is pressed or the crankcase could be damaged crankcase half so that the sealed side B faces outside of the engine Special Tool Bearing Driver Set 57001 1129 e Press the new transmission shaft bearing A in the left 6104194BS1 C e Press the new drive shaft bearing A in the right crankcase B half so that the stepped side C faces inside of the engine Special Tool Bearing Driver Set 57001 1129 6104195BS1 C e Press the new crankshaft bearings A in the left and right crankcase half B so that the stepped side C faces in side of the engine Special Tool Bearing Driver Set 57001 1129 6104196BS1 C e Press the shift drum needle bearing A and shift shaft needle bearing B in the left crankcase half so that bear ing surface flush with the crankcase surface C Special Tool Bearing driver Set 57001 1129 6104197BS1 C 9 10 CRANKSHAFT TRANSMISSION Crankcase e First press the inside release shaft needle bearing A until its top comes 19 5 mm B from the surface using the bearing driver set e Next press the oil seal C until it reach to the inside nee dle bearing with the bearing driver set Special Tool Bearing driver Set 57001 1129 e Next press the outside release shaft needle bearing A until the surface of the bearing is even with the crankcase surface B Special Tool Bearing
141. ar Damage Inspection e Refer to the Friction and Steel Plates Inspection in the Periodic Maintenance chapter Friction and Steel Plate Warp Inspection e Refer to the Friction and Steel Plate Inspection in the Pe riodic Maintenance chapter Clutch Spring Free Length Inspection e Measure the free length A of the clutch springs x If any clutch spring is shorter than the service limit it must be replaced Clutch Spring Free Length Standard 49 2 mm 1 94 in Service Limit 46 7 mm 1 84 in GRO5034BS2 GFO6O303S1 ENGINE RIGHT SIDE 6 17 Clutch Clutch Housing Finger Damage e Visually inspect the clutch housing fingers A that come in contact with the friction plate tangs x lf they are damaged or if there are groove cuts in the areas that come in contact with the tangs replace the housing Replace the friction plates if their tangs are damaged as well Friction Plate Clutch Housing Clearance e Measure the clearance between the tangs A on the fric tion plate and the fingers B of the clutch housing x lf this clearance is excessive the clutch will be noisy If the clearance exceeds the service limit replace the fric tion plates Friction Plate Clutch Housing Clearance Standard 0 20 0 60 mm 0 0079 0 024 in Service Limit 0 8 mm 0 03 in Clutch Hub Spline Damage e Visually inspect the areas of the clutch hub splines that come in contact with the teeth of the
142. ar Inspection csm rial mee 11 10 Rear Sprocket Warp Inspection EE 11 10 11 2 FINAL DRIVE Exploded View q S O oS Le FINAL DRIVE 11 3 Exploded View Torque No Fastener Remarks N m kgf m ft lb 1 Rear Sprocket Nuts 34 3 5 25 2 Engine Sprocket Nut 127 13 0 93 7 3 Engine Sprocket Cover 4 Engine Sprocket 5 Output Shaft 6 Chain Slipper 7 Swingarm 8 Chain Guide 9 Locknut 10 Adjusting Bolt 11 Chain Adjuster 12 Drive Chain 13 Rear Sprocket 14 Upper Chain Guide Roller 15 Lower Chain Guide Roller G Apply grease L Apply a non permanent locking agent O Apply oil R Replacement Parts 11 4 FINAL DRIVE Specifications Item Drive Chain Chain Slack Chain 20 link Length Standard Chain Make Type Length Link Pin Outside Diameter Link Plate Outside Width Standard 52 58 mm 2 0 2 3 in 317 5 318 2 mm 12 50 12 53 in DAIDO D I D 520MXV 114 Links 5 5 5 8 mm 0 22 0 23 in 16 50 16 70 mm 0 650 0 657 in Service Limit 323 mm 12 7 in Sprocket Rear Sprocket Warp 0 4 mm 0 016 in or less 0 5 mm 0 020 in FINAL DRIVE 11 5 Drive Chain Drive Chain Slack Inspection e Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter Drive Chain Slack Adjustment e Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter Wheel Alignment
143. ash point solvents can be flammable and or explosive and cause severe burns Clean the oil screens in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Do not use gasoline or a low flash point solvent to clean the oil screens NOTE OWhile cleaning the screens check for any metal parti cles that might indicate internal engine damage e Check the screen A carefully for any damage holes broken wires gasket pulling off If the screen is damaged replace it GGO7000BS1 e Apply engine oil to the rubber portion A on the oil screen e Install the oil screen facing the carved line B to the out side e Install the oil pump scavenge cover see Oil Pump Scavenge Installation GGO7001BS1 ENGINE LUBRICATION SYSTEM 7 11 Oil Screen Oil Screen Feed Removal e Split the crankcase see Crankcase Disassembly in the Crankshaft Transmission chapter e Remove Bolts A Oil Screen B Oil Screen Feed Installation e Replace the O ring A with a new one e Apply grease to the O ring and install it e Install the oil screen A and tighten the bolts B Torque Oil Screen Feed Mounting Bolts 9 8 N m 1 0 kgf m 87 in Ib Oil Screen Scavenge Cleaning e Remove the oil screen see Oil Screen Scavenge Re moval e Clean the oil screen with a high flash point solvent
144. at the clutch lever is fully seated in the adjusting bolt at the clutch lever or it could slip into the place later creating enough cable play to prevent clutch disengagement e f it cannot be done loosen the lower locknut A at the lower of the clutch cable and turn the upper locknut B so that clutch lever has 8 13 mm 0 3 0 5 in of play e After the adjustment is made tighten the locknut and start the engine and check that the clutch does not slip and that it release properly Friction and Steel Plates Inspection e Remove the clutch plates see Clutch Removal in the En gine Right Side chapter e Visually inspect the friction and steel plates to see if they show any signs of seizure or uneven wear If any plates show signs of damage replace the friction plates and steel plates as a set e Measure the thickness of the friction plates A with vernier calipers x If they have worn past the service limit replace them with new ones GFO606028S1 Friction Plate Thickness Standard 2 92 3 08 mm 0 115 0 121 in Service Limit 2 6 mm 0 10 in e Place each friction plate or steel plate on a surface plate and measure the gap between the surface plate A and each friction plate or steel plate B with a thickness gauge C The gap is the amount of friction or steel plate warp If any plate is warped over the service limit replace it with a new one Friction and Steel Plates Warp
145. ation after installation SUSPENSION 13 11 Front Fork Front Fork Disassembly each fork leg e Loosen the front fork upper clamp bolts A e Loosen the fork top plug subtank A with the top plug wrench B Special Tool Top Plug Wrench 49 mm 57001 1653 B e Remove the front fork see Front Fork Removal NOTE OSet rebound and compression damping setting to the softest settings before disassembling to prevent the needle of adjusters from damaging Record the setting before turning the adjuster e Thoroughly clean the fork before disassembly NOTICE Be careful not scratch the inner tube and not to damage the dust seal Avoid scratching or damaging the inner tube or the dust seal Use a mild detergent and sponge out dirt with plenty of water e Using the top plug wrench A remove the fork top plug B subtank from the outer tube and slowly slide down the outer tube C Special Tool Top Plug Wrench 49 mm 57001 1653 13 12 SUSPENSION Front Fork e Place a drain pan under the front fork and drain fork oil A NOTE OPump the fork tube several times to discharge the fork oil e Raise the outer tube and temporarily install the fork top plug A subtank to the outer tube B with the top plug wrench C Special Tool Top Plug Wrench 49 mm 57001 1653 e Hold the axle holder A with a vise OProtect the axle holder with a rag when using a vise e Loosen the adj
146. ations under this title prior to its sale and delivery to the ultimate purchaser or for any manufacturer or dealer knowingly to remove or render inoperative any such device or element of design after such sale and delivery to the ultimate purchaser 3 B for any person engaged in the business of repairing servicing selling leasing or trading motor vehicles or motor vehicle engines or who operates a fleet of motor vehicles know ingly to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title follow ing its sale and delivery to the ultimate purchaser NOTE OThe phrase remove or render inoperative any device or element of design has been generally interpreted as follows 1 Tampering does not include the temporary removal or rendering inoperative of de vices or elements of design in order to perform maintenance 2 Tampering could include a Maladjustment of vehicle components such that the emission standards are ex ceeded b Use of replacement parts or accessories which adversely affect the performance or durability of the motorcycle c Addition of components or accessories that result in the vehicle exceeding the stan dards d Permanently removing disconnecting or rendering inoperative any component or element of design of the emission control systems WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDE
147. between ODO and CLOCK each time the ODO CLOCK button B is pushed If the display does not shift replace the meter unit e Check that the display A shifts between TRIP A and TRIP B each time the TRIP A B button B is pushed If the display does not shift replace the meter unit e Push the ODO CLOCK button A to display the clock e Keeping the TRIP A B button pushed turning ON the ODO CLOCK button B enables the hours and the min utes of the clock to be set C Verify that the time can be set here If the time cannot be set replace the meter unit Clock Setting e Press the ODO CLOCK button A to show the clock in the odometer display e Keep the ODO CLOCK button pressed and turn the TRIP A B button B ON to enable the display to assume the Hour Minute setting mode C in which the numbers flash thus enabling you to set the time on the clock OStarting with the Hour Minute setting mode each press ing of the ODO CLOCK button changes the setting modes as follows Hour Minute Setting Mode Hour Setting Mode Minute Setting Mode t GP17930BS1 GP17931BS1 GP17934BS1 ELECTRICAL SYSTEM 16 47 Meter Gauge Oln the Hour Minute setting mode the numbers that rep resent the hours and the minutes flash In the Hour set ting mode the numbers that represent the hours flash A And in the Minute setting mode
148. citer Coil Peak Voltage Check e Disconnect the magneto lead connector from the main harness e To check the peak voltage do the following procedures NOTE OMeasure the voltage with each lead connected cor rectly The correct value may not be obtained if disconnected OMaintain the correct value of compression pressure for the cylinder Be sure to measure the voltage with the spark plug installed to the cylinder head OSet the hand tester to DC 50 V range OConnect the peak voltage adapter A to the tester and the terminals of the magneto lead connector B Special Tools Hand Tester 5701 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Connection Adapter Positive White Lead C Adapter Negative Red Lead D OCrank the engine by kicking the kick pedal and by pushing the starter button several time with the transmission gear in neutral to measure the peak voltage of the exciter coil Exciter Coil Peak Voltage Standard 36 V or Above Kick starter 33 V or above Electric starter lf the voltage is less than the specified check the exciter coil see Flywheel Inspection x lf the exciter coil is good replace the igniter Throttle position sensor Inspection e Remove the fuel tank transiently see Fuel Tank in the Fuel System chapter e Disconnect the throttle position sensor lead connector A GP10427BS1 ELECTRICAL SYSTEM 16 33 Ignition System e Connect the throt
149. cle has been operated under wet or rainy conditions or especially after using a high pressure water spray perform the general lubri cation zuN Ee NY 22 N gt G 17051BS1 PERIODIC MAINTENANCE 2 63 Periodic Maintenance Procedures Points Lubricate with Grease Clutch Inner Cable Upper and Lower Ends A Hot Start Inner Cable Upper End Throttle Inner Cable Upper End Cables Lubricate with Rust Inhibitor Throttle Cables Clutch Cable Hot Starter Cable 6004011481 e With the cable disconnected at the both ends the cable should move freely A within the cable housing lf cable movement is not free after lubricating if the cable is frayed B or if the cable housing is kinked C replace the cable 6004020152 Nut Bolt and Fastener Tightness Inspection 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 NOTE OFor the engine fasteners check the tightness of them when the engine is cold at room temperature 2 64 PERIODIC MAINTENANCE Periodic Maintenance Procedures x If there are loose fasteners retorque them to the specified torque following the specified tightening sequence Refer to the Torque and Locking Agent section of the General Information chapter for torque specifications
150. clip with a new one and install it Special Tool Outside Circlip Pliers 57001 144 9 14 CRANKSHAFT TRANSMISSION Crankcase e Replace the circlip A with a new one and install it to the output shaft CRANKSHAFT TRANSMISSION 9 15 Crankshaft Connecting Rod Crankshaft Removal e Disassemble the crankcase see Crankcase Disassem bly e Using the hand pull out the crankshaft A from the right crankcase B Crankshaft Installation e Apply high temperature grease to the outer side of the crankshaft bearings and use the bearing driver set C to face the stepped side A to the engine inside and drive the bearing to the bottom of the crankcase B While driving the bearing in make sure to use a holder to support the boss area Special Tool Bearing Driver Set 57001 1129 e Install the crankshaft to the right crankcase Fi 9502088T O e Apply engine oil to the connecting rod big end bearing Crankshaft Disassembly Since assembly of the crankshaft demands exacting tol erances the disassembly and reassembly of the crankshaft can only be done by a shop having the necessary tools and equipment lf it should be necessary to disassemble the crankshaft use a press to remove the crankpin Crankshaft Assembly Since the assembly of the crankshaft demands exacting tolerances the disassembly and reassembly of the crank shaft can only be done by a shop having the necessary tools and equip
151. ct the inside of the carburetor body for these same faults lf it is badly scratched or worn replace the entire carbu retor e Check the jet needle for wear e For the throttle sensor inspection see the Electrical Sys tem chapter A worn jet needle should be replaced e Clean the fuel and air passages with a high flash point solvent and compressed air Carburetor Assembly e Clean the disassembly parts before assembling OClean the fuel and air passages with a high flash point solvent and compressed air A e Set up the acceleration pump lever assembly as shown Acceleration pump lever A Spring B Push Rod Holder C Adjusting Screw with Spring D OFit the spring end on the stopper E of the push rod holder 6006014351 C FUEL SYSTEM 3 23 Carburetor e Install the return spring A to the acceleration pump lever B e Install the acceleration pump lever assembly to the car buretor body OFit the end A of the return spring into the recess B on the carburetor body e Install Washer A E clip B e Apply thin coat silicone grease to the shaft e Fit the hook A of the return spring onto the stopper B of the throttle cable pulley e Insert the throttle cable pulley shaft A and install the steel washer B nylon washer C and valve link D 3 24 FUEL SYSTEM Carburetor OFit the end A of the return spring into the recess B of the carburetor body e T
152. d Wear Inspection e Remove the brake pad see Brake Pad Removal in Brakes chapter e Check the lining thickness and condition of the pads in each caliper lf either pad is damaged replace both pads in the caliper as a set xklf the lining thickness A of either pad is less than the service limit B replace both pads in the caliper as a set Lining Thickness Standard Front 3 8 mm 0 15 in Rear 6 4 mm 0 25 in Service Limit Front 1 mm 0 04 in Rear 1 mm 0 04 in Brake Master Cylinder Cup and Dust Seal Replacement e Remove the front master cylinder see Front Master Cylin der Removal in the Brakes chapter e Remove the reservoir cap and diaphragm and pour the brake fluid into a container e Unscrew the locknut and pivot bolt and remove the brake lever e Pull the dust cover A out of place and remove the circlip SE B Special Tool Inside Circlip Pliers 57001 143 e Remove the washer C e Pull out the piston D secondary cup E primary cup F and return spring G 2 40 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTICE Do not remove the secondary cup from the piston since removal will damage it e Remove the rear master cylinder see Rear Master Cylin der Removal in the Brakes chapter NOTE ODo not remove the push rod clevis for master cylinder disassembly since removal requires brake pedal posi tion adjustment e Remove the reservoir cap an
153. d diaphragm and pour the brake fluid into a container e Slide the dust cover A on the push rod B out of place and remove the circlip C Special Tool Inside Circlip Pliers 57001 143 e Pull out the push rod with the piston stop D e Take off the piston E secondary cup F primary cup G and return spring H NOTICE Do not remove the secondary cup from the piston since removal will damage it e Before assembly clean all parts including the master cylinder with brake fluid or alcohol Except for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning of the brake parts Do not use any other fluid for cleaning of these parts Gasoline engine oil or any other petroleum distillate will cause de terioration 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 Apply brake fluid to the removed parts and to the inner wall of the cylinder e Take care not to scratch the piston or the inner wall of the cylinder e Apply silicone grease ex PBC grease Brake Lever Pivot Bolt Brake Lever Pivot Contact Push Rod Contact Rear Dust Covers e Tighten Torque Brake Lever Pivot Bolt 5 9 N m 0 60 kgf m 52 in Ib Brake Lever Pivot Bolt Locknut 5 9 N m 0 60 kgf m 52 in Ib GLO7OS7BS2 C PERIODIC MAINTENANCE 2 41 Periodic Maintenance Proc
154. d tighten the cap bolt Torque Chain Tensioner Cap Bolt 5 0 N m 0 51 kgf m 44 in Ib e Install the starter motor see Starter Motor Installation in the Electrical System chapter ENGINE TOP END 5 17 Camshaft Camshaft Removal e Remove Cylinder Head Cover see Cylinder Head Cover Re moval Timing Inspection Cap A Crankshaft Shaft Cap B Special Tool Filler Cap Driver 57001 1454 e First bring the piston to the TDC of either the compres sion or exhaust stroke OPlace a wrench over the flywheel nut and turn it counter clockwise to align the TDC mark A with the center of the groove B of the inspection hole e Remove Camshaft Chain Tensioner see Camshaft Chain Ten sioner Removal Camshaft Cap Bolts 1 8 sequence numbers Camshaft Caps A together with the oil pipes B OPlug the oil passage and camshaft chain tunnel with a clean cloth for prevent the oil pipe from dropping into the crankcase OWhile keeping parallel remove the camshaft caps and oil pipes e Remove Positioning Rings A e Disengage the Camshafts B from camshaft chain C e Staff a clean cloth into the camshaft chain tunnel to keep any parts from dropping into the crankcase NOTICE The crankshaft may be turned while the camshafts are removed Always pull the chain taut while turning the crank shaft This avoids kinking the chain on the lower crankshaft sprocket A kinked chain could dam age both the chai
155. da 6 10 Right Engine Cover Installation ic 6 11 Release Shaft Removal cet osito io cia 6 11 Release Shaft Installation sis 6 12 MIM y A a ts oat ese Rance vst de causa Se el ea bate nao oes Saba bande aaa ee Ghat aes 6 13 MTEC SIN E 6 13 Gl tehilnstallation EE 6 13 Clutch Plate Assembly Free Play Inspection Adjustment oocccccnncccccccccancccnonanccnnnnnnancncnnns 6 16 Friction and Steel Plates Wear Damage Inspechon 6 16 Friction and Steel Plate Warp Inspechon cnn nccnnnnnnccns 6 16 Clutch Spring Free Length Inspection oia dic 6 16 Clutch Housing Finger Damage six cscs ace tee ii ae 6 17 Friction Plate Clutch Housing Clearance ss 6 17 Clutch Hub eet MR ne GE 6 17 gl ae 6 18 Primary Gear Smoove EE 6 18 cae eegen ees eege ege Veedel 6 18 External Shift Mecha EE 6 19 External Shift Mechanism Removal nne 6 19 External Shift Mechanism Installation socia at SCENE 6 19 External Shift Mechanism Inspection cnn cnn ncc cnn 6 20 ele ln TEE 6 22 Kick Pedal Assy Removal iia cid llciis 6 22 Kick Pedal Assy Installation caia ii 6 22 Kick Pedal Assy DIS ne EE 6 22 Kick Pedal Assy EE 6 22 Idle Gear AO EP dentate tac 6 22 idle Gear Installation RE 6 23 KICKS Hatt ne EE 6 23 ele CAE ee 6 23 Kick Shaft Assembly Disassembly ASSeMbly AAA 6 24 6 2 ENGINE RIGHT SIDE Exploded View 6R02032BW5 C ENGINE RIGHT SIDE 6 3 Exploded View
156. der clearance see Piston Cylinder Clearance and use new piston rings 6E16042BS1i e Apply engine oil to the inside wall of the small end of the connecting rod e Face the circle mark A on the top of the piston must point toward the front B of the engine GE16132BS1 C e Fit a new piston pin snap ring into the side of the piston so that the ring opening A does not coincide with the slit B of the piston pin hole OWhen installing the piston pin snap ring compress it only enough to install it and no more NOTICE Do not reuse snap rings as removal weakens and deforms them They could fall out and score the cylinder wall e Install Dowel Pins A New Cylinder Base Gasket B e The piston ring openings must be positioned as shown in the figure The openings of the oil ring steel rails must be A 20 of angle from the opening of the oil ring expander 4 D Circle Mark A a 4 EE aA Top Ring B Upper Oil Ring Steel Rails C Oil Ring Expander D 20 IN Lower Oil Ring Steel Rail E IN 20 GE16134BS1 C 5 36 ENGINE TOP END Cylinder and Piston e Apply engine oil to the cylinder bore e Determine the position of the piston ring ends e Install the cylinder while compressing the piston rings with your fingers or the special tool A Special Tools Piston Ring Compressor Grip 57001 1095 Piston Ring Compressor Belt 995 4108 57001 1358 e Drive
157. driver Set 57001 1129 e Replace the oil seals if removed e Press the oil seals A of the output shaft shift shaft and pull rod so that oil seal lip B face to the engine outside and oil seal surface flush with the left crankcase surface C e Apply high temperature grease to the oil seal lip Special Tool Bearing driver Set 57001 1129 e Apply a non permanent locking agent to the retaining screws e Tighten the bearing retaining screws A Torque Bearing Retaining Screws 15 N m 1 5 kgf m 11 ft lb Piston Oil Nozzle B 4 0 N m 0 41 kgf m 35 in Ib G104286BS1 G104287BS1 CRANKSHAFT TRANSMISSION 9 11 Crankcase e Apply engine oil to the transmission gears bearings shift forks shift drum and crankshaft bearing e Install the drive shaft A and output shaft B in the right crankcase C as a set e Install Shift Drum A see Transmission Shaft Installation Shift Rods B see Transmission Shaft Installation Shift Forks C see Transmission Shaft Installation e Install Crankshaft A Dowel Pins B e Replace the O ring A with a new one e Install the Oil Screen Feed Torque Oil Screen Feed Mounting Bolts 9 8 N m 1 0 kgf m 87 in Ib e With the connecting rod positioned at the bottom dead center install the crankshaft jig A Special Tool Crankshaft Jig 57001 1174 9 12 CRANKSHAFT TRANSMISSION Crankcase e Apply liqu
158. e Vacuum Switch Valve Closing Pressure open close Standard 48 59 kPa 360 440 mmHg High Vacuum A Secondary air cannot flow B Valve Clearance Inspection NOTE OValve clearance must be checked and adjusted when the engine is cold at room temperature e Remove Cylinder Head Cover see Cylinder Head Cover Re moval in the Engine Top End chapter Crankshaft Cap A Timing Inspection Cap B Special Tool Filler Cap Driver 57001 1454 e First bring the piston to the top dead center of its com pression stroke to inspect the valve clearance the posi tion at the end of the compression stroke when the cam lobe faces outside of the camshaft see Camshaft Instal lation in the Engine Top End chapter OPlace a wrench over the flywheel nut and turn it counter clockwise to align the TDC mark A with the center of the groove B of the inspection hole e Using a thickness gauge A measure the clearance be tween each cam lob and valve lifter for all four valves OFor the purpose of adjusting the valve clearances record the measured values Valve clearance between cam and valve lifter Standard Exhaust 0 20 0 25 mm 0 0079 0 0098 in Inlet 0 10 0 15 mm 0 0039 0 0059 in If the valve clearance is not within the specified range adjust it GE04071BS1 PERIODIC MAINTENANCE 2 21 Periodic Maintenance Procedures Valve Clearance Adjustment e Remove the camshaft ca
159. e Fastener Nm kgf m itib Remarks Fuel System Throttle Pulley Cover Bolt 3 4 0 35 30 in lb Throttle Cable Mounting Bolts 6 9 0 70 61 in lb Vacuum Switch Valve Bracket Bolts 9 8 1 0 87 in lb Fuel Tap Knob Screws 0 80 0 080 7 0 in lb Rear Frame Mounting Bolts 34 3 5 25 Cooling System Water Pump Cover Bolts 9 8 1 0 87 in lb Coolant Drain Plug 7 0 0 70 62 in lb Water Pump Impeller Bolt 9 8 1 0 87 ml Right Engine Cover Bolts 9 8 1 0 87 in lb Radiator Hose Clamp Screws 3 0 0 30 27 in lb Engine Top End Cylinder Head Cover Bolts 9 8 1 0 87 in lb Cylinder Head Bolts M10 59 6 0 44 S MO Cylinder Head Bolts M6 12 1 2 106 in lb S Cylinder Bolt 12 1 2 106 in lb Camshaft Cap Bolts 9 8 1 0 87 in lb S MO Camshaft Sprocket Bolts 12 1 2 106 in lb L Carburetor Holder Clamp Screws 2 0 0 20 18 in lb Plug 20 2 0 15 L Rear Camshaft Chain Guide Bolt 15 1 5 11 Oil Pump Scavenge Cover Bolts 9 8 1 0 87 in lb Chain Tensioner Mounting Bolts 9 8 1 0 87 ml Chain Tensioner Cap Bolt 5 0 0 51 44 in lb Water Hose Fitting Bolts 9 8 1 0 87 in lb Oil Line Plug 3 0 0 31 27 in lb L Decompressor Plug Plate Bolt 9 8 1 0 87 ml PERIODIC MAINTENANCE 2 5 Torque and Locking Agent Torque Fastener Nem kgf m ap Remarks Vacuum Hose Fitting 8 8 0 90 78 in lb L Cylinder Head Pipe Mounting Bolt 9 8 1 0 87 in lb Exhaust Pipe Cover Bolts 12 1 2 106 in lb Rear Muffler Mounting Bolt 20 2 0 15 Front Muffler Mounting Bolt First 9 8 1 0 87 in lb Fr
160. e crankshaft assembly Crankshaft Runout e Set the crankshaft in a flywheel alignment jig or on V blocks and place a dial gauge as shown and turn the crankshaft slowly The maximum difference in gauge reading is the crankshaft runout Crankshaft Runout Standard TIR 0 03 mm 0 001 in or less Service Limit TIR 0 08 mm 0 003 in If the runout at either point exceeds the service limit re place the crankshaft assembly with a new one or align the crankshaft so that the runout falls within the service limit 8 5 mm 0 33 in A e First correct the horizontal misalignment by striking the projecting crank half A with a plastic soft lead or brass hammer as shown e Recheck the runout with a dial gauge and repeat the process until the runout falls within the service limit 6105018BS1 G105134BS1 G105135BS1 G105136BS1 CRANKSHAFT TRANSMISSION 9 17 Crankshaft Connecting Rod e Next correct the vertical misalignment by either driving a wedge A in between the crank halves or by squeezing them in a vice depending on the nature of the misalign ment NOTICE Do not hammer the crank half at the point B x If flywheel misalignment cannot be corrected by the above method replace the crank pin or the crankshaft itself 6105004B52 Connecting Rod Big End Seizure In case of serious seizure with damaged flywheels the cranksh
161. e the element and seal the housing and inlet tract e Separate the element A from the frame B e Clean the element A in a bath of a high flash point sol vent using a soft bristle brush 6S05025BS1 2 16 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Squeeze it dry in a clean towel A Do not wring the ele ment or blow it dry the element can be damaged e Check all the parts of the element for visible damage lf any of the parts of the element are damaged replace them e After cleaning saturate the element with a high quality foam air filter oil squeeze out the excess then wrap it in a clean towel and squeeze it as dry as possible OBe careful not to tear the sponge filter e Assemble the element e Remove the towel from the carburetor e Apply grease to all connections and screw holes in the air cleaner housing and intake tract e Install the element onto its frame and coat the element lip and lip seat with a thick layer of all purpose grease to assure a complete seal e Install the air cleaner element so that its tab A faces left side and its projections B align with the holes C in the housing e Tighten the wing bolt D e Install the seat see Seat Installation in the Frame chap ter Fuel Inspection WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Always stop the engine and do not smoke Make sure the area is
162. e Fuel Sys tem chapter Starter Motor see Starter Motor Installation in the Elec trical System chapter Exhaust Pipe see Muffler Installation Fuel Tank see Fuel Tank Installation in the Fuel System chapter Cylinder Head Cleaning e Refer to the Cylinder Head Warp Inspection in the Peri odic Maintenance chapter Cylinder Head Warp e Refer to the Cylinder Head Warp Inspection in the Peri odic Maintenance chapter 5 26 ENGINE TOP END Valves Valve Clearance Inspection e Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter Valve Removal e Remove the cylinder head see Cylinder Head Removal Remove the valve lifter and the shim from the valve NOTE OUse the valve spring compressor assembly and the adapter to press down the valve spring retainer Special Tools Valve Spring Compressor Assembly 57001 241 A Valve Spring Compressor Adapter 24 57001 1586 B Valve Installation NOTICE Do not lap the valve to the valve seat using the grinding compound It will come off oxide film treated surface of the valve e Visually inspect the valve surface If the surface is damaged replace it e Replace the oil seal C with a new one e Apply a thin coat of molybdenum disulfide grease to the valve stem A before installing the valve e Check to make sure that the valve moves up and down smoothly e Check to make sure that the valve and the valve seat are making proper co
163. e Remove Exhaust Pipe see Muffler Removal in the Engine Top End chapter Right Engine Cover Bolt A Oil Filter Cover Bolt B Oil Filter Cover C e Install the O rings to the oil pressure cap Special Tool Oil Pressure Cap 57001 1656 e Install the oil pressure cap e Attach the oil pressure gauge adapter A and oil pressure gauge B Special Tools Oil Pressure Gauge Adapter M10 x 1 0 57001 1182 Oil Pressure Gauge 5 kgf cm 57001 125 e Start the engine and warm up the engine thoroughly e Run the engine at the specified speed and read the oil pressure gauge x lf the oil pressure is much lower than the standard check the feed oil pump x lf the reading is much higher than the standard check the oil filter first and oil passages for dirt or clogging Oil Pump Pressure oil temperature 90 C 4 000 rpm Standard 39 98 kPa 0 4 1 0 kgf cm 5 6 14 psi NOTE OWarm up the engine thoroughly before measuring the oil pressure e Stop the engine and remove the oil pressure cap oil pres sure gauge adapter and gauge A WARNING Hot oil can cause severe burns Beware of hot en gine oil that will drain through the oil passage when the gauge adapter is removed e Install the oil filter cover Torque Oil Filter Cover Bolt 9 8 N m 1 0 kgf m 87 in Ib Right Engine Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib e Install the exhaust pipe see Muffler Installation in the En gine Top End chapter
164. e Remove the fuel tank see Fuel Tank Removal e Disconnect the throttle sensor connector A GCO6O88BS1 C FUEL SYSTEM 3 15 Carburetor e Loosen the clamp screw A fully e Remove Engine Mounting Bracket Bolts B Right Engine Mounting Bracket C e Remove Seat see Seat Removal in the Frame chapter Side Covers see Side Cover Removal in the Frame chapter Muffler see Muffler Removal in the Engine Top End chapter Fuel Tank see Fuel Tank Removal Starter Motor see Starter Motor Removal in the Electri cal System chapter Battery see Battery Removal in the Electrical System chapter Igniter see Igniter Removal in the Electrical System chapter Tail Light Connector see Tail Light Removal in the Elec trical System chapter Rear Frame Bolts A e Pull out the rear frame B with the air cleaner housing from the carburetor e Unscrew the hot start plunger cap bolt A e Remove the hot start plunger e Unscrew the throttle pulley cover bolt A e Remove the throttle pulley cover B 3 16 FUEL SYSTEM Carburetor e Loosen the mounting bolts A e Pull out the end of the throttle cables B e Free the tips C e Remove the carburetor to the right side of the frame e Drain the fuel from the float bowl by removing the drain plug After draining install the drain plug securely e After removing the carburetor push a clean lint free towel into the carbureto
165. e Visually inspect the snap rings A still fitted in place lf the rings show weakness or deformation replace the rings Also if the pin hole groove shows excessive wear replace the piston e Measure the diameter of the piston pin B with a microm eter lf the piston pin diameter is less than the service limit at any point replace the piston pin e Using a cylinder gauge measure the diameter of both of piston pin holes C in the piston and the inside diameter of the connecting rod small end D x lf either piston pin hole diameter exceeds the service limit replace the piston lf the connecting rod small end inside diameter exceeds the service limit replace the connecting rod Piston Pin Diameter Standard 18 991 19 000 mm 0 74768 0 74803 in Service Limit 18 96 mm 0 7465 in Piston Pin Hole Diameter Standard 19 004 19 010 mm 0 74819 0 74842 in Service Limit 19 08 mm 0 7512 in Connecting Rod Small End Inside Diameter Standard 19 019 19 030 mm 0 74878 0 74921 in Service Limit 19 07 mm 0 7508 in GE16139BS2 ENGINE TOP END 5 39 Carburetor Holder Carburetor Holder Installation e Install the carburetor holder A with the marked B side facing toward the cylinder head outside Olnstall the holder clamp C with its screw head D facing left side 6E17012BS1 o Torque Carburetor Holder Clamp Screws 2 0 N m 0 20 kgf m 18 in Ib e Fit the recess
166. e brake pedal see Brake Pedal Removal in the Brakes chapter e Remove the clutch cover bolts A and right engine cover bolts B remove the clutch cover C Clutch Cover Installation e Replace the clutch cover gasket with a new one e Be sure to install the dowel pins e Apply a non permanent locking agent to the brake pedal bolt e Install the clutch cover A Torque Clutch Cover Bolts B 9 8 N m 1 0 kgf m 87 in Ib Right Engine Cover Bolts C 9 8 N m 1 0 kgf m 87 in Ib Brake Pedal Bolt 25 N m 2 5 kgf m 18 ft Ib Right Engine Cover Removal e Drain Engine Oil see Engine Oil Change in the Periodic Main tenance chapter Coolant see Coolant Draining in the Cooling System chapter e Remove Right Engine Guard A Kick Pedal B see Kick Pedal Removal Brake Pedal C see Brake Pedal Removal in the Brakes chapter Exhaust Pipe D see Muffler Removal in the Engine Top End chapter e Remove Water Hose A Right Engine Cover Bolts B Right Engine Cover C ENGINE RIGHT SIDE 6 11 Clutch Cover and Right Engine Cover Right Engine Cover Installation e Three dowel pins A are installed at the mating surface between the crankcase and the right engine cover e Apply grease to the O rings B and install them to the crankcase Olnstall the lower O ring so that the tapered side facing outside e Replace the engine cover gasket with a new one e Apply a high temperature grease t
167. e disc cover e Check the rear brake for good braking power and no brake drag A WARNING After servicing it takes several applications of the brake pedal before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the motorcycle until a firm brake pedal is obtained by pumping the pedal until the pads are against the disc 6K04061BS1 6J04034BS1 10 10 WHEELS TIRES Wheels Rims Wheels Inspection e Place the jack under the frame so that the front rear wheel is raised off the ground Special Tool Jack 57001 1238 e Spin the wheel lightly and check for roughness or binding x If the roughness or binding is found replace the hub bear ings e Visually inspect the front and rear axles for damage If the axle is damaged or bent replace it Spoke Tightness Inspection e Refer to the Spoke Tightness Inspection in the Periodic Maintenance chapter Rim Runout Inspection e Refer to the Rim Runout Inspection in the Periodic Main tenance chapter Axle Inspection e Visually inspect the front and rear axle for damages If the axle is damaged or bent replace it e Place the axle in V blocks that are 100 mm 3 937 in A apart and set a dial gauge on the axle at a point halfway between the blocks Turn the axle to measure the runout The difference between the highest and lowest d
168. e ee pe ae A 13 8 PAPE EE 13 8 Rebound Damping AdjUSIMGNt 3 c 8 c ie aia einai 13 8 Compression Damping Re Te 13 9 Oil Change each fork leg usina is 13 9 Front Fork RemMOV al senpre ns ann ga renean tes ayia dende coreana ANETO sde 13 9 Front Fork Installation EE 13 10 Front Fork Disassembly each fork leg re uen ve ani menti 13 11 Fronti Fork AssemDlIy eroen So ee nt atte ne teense Riga 13 15 Adjuster Assembly INSPECUO Mecca das 13 20 Base Valve Assembly Inspection ennt 13 20 Cylinder Unit aspecto sete nes cs nan re pias 13 21 Inner Tube Inspection EE EE 13 21 ET INSPEC EE 13 21 Dust Seal Oil Seal Inspection eege uechter Ee these 13 21 Spring Tenia tides deniers mudideeas nucettaee nee 13 22 Rear Suspension Ent E 13 23 Rear Shock ADSOFDE FT econ lenta adds 13 23 Rebound Damping AUSTIN EE 13 23 Compression Damping AdjustMENE ceooiocoio ideada 13 23 Spring OR Ta EE Spina e EE EE Rear Shock Absorber Removal Rear Shock Absorber Installation EE 13 26 Spring Replacement EE 13 26 Rear Shock Absorber Disassembly Oil Change 13 27 Rear Shock Absorber EE 13 27 Rear Shock Absorber Scrapping EE 13 27 le EE 13 28 Elle Een CIN OV Ee 13 28 Swingarm Installation odas 13 29 Swingarm Bearing Removal EE 13 29 Swingarm Bearing Installation EE 13 29 Swingarm Bearing Sleeve Inspection RE 13 30 Drive Chain Guide Guide Roller Chain Slipper VWear 13 30 Tie Rod Rocker AM iaa 13 31 Te Ee Rem
169. e even tightening torque L Apply a non permanent locking agent to the threads R Replacement Parts 13 4 SUSPENSION Exploded View 6M02199BW5 C SUSPENSION 13 5 Exploded View Torque No Fastener Remarks ft lb Swingarm Pivot Shaft Nut 72 Rocker Arm Pivot Nut 44 Tie rod Mounting Nut Front Rear A 44 29 Rear Shock Absorber Mounting Nut Lower 34 3 5 25 Air Bleed Bolt 6 5 0 66 58 in lb 5 6 7 Swingarm Pivot Shaft 8 Swingarm 9 Rocker Arm 10 Tie Rod 11 Rear Shock Absorber Cylinder 12 O ring 13 Bladder 14 Cap 15 Circlip 16 Valve Cap 17 Locknut 18 Adjusting Nut 19 Spring 20 Spring Guides 21 Circlip 22 Piston Rod Assembly 23 Piston 24 O ring 25 Oil Seal 26 Stopper 27 Rear Shock Absorber G Apply grease L Apply a non permanent locking agent R Replacement Parts 2T Apply 2 stroke oil 13 6 SUSPENSION Specifications Item Front Fork Air Pressure Rebound Damping Adjustment from the seated position adjuster turned fully clockwise Compression Damping Adjustment from the seated position adjuster turned fully clockwise Oil Viscosity Oil Quantity Outer Outer Inner Tubes Inner subtank Fork Spring Free Length Rear Suspension Uni Trak Rear Shock Absorber Rebound Damping Adjustment from the seated position adjuster turned fully clockwise Spring Preload Adjustment Ad
170. e fluid comes out from the plastic hose or the color of the fluid changes 1 Open the bleed valve A 2 Apply the brake and hold it B 3 Close the bleed valve C 4 Release the brake D OFill the reservoir with fresh specified brake fluid NOTE OThe fluid level must be checked often during the chang ing operation and replenished with fresh brake fluid If the fluid in the reservoir runs out any time during the changing operation the brakes will need to be bled since air will have entered the brake line GS13119BS1 6S13121BS2 PERIODIC MAINTENANCE 2 39 Periodic Maintenance Procedures e Remove the clear plastic hose e Tighten the bleed valves and install the rubber caps Torque Caliper Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib Brake Reservoir Cap Screws 1 5 N m 0 15 kgf m 13 in Ib e After changing the fluid check the brake for good braking power no brake drag and no fluid leakage lf necessary bleed the air from the lines see Bleeding the Brake Line in the Brakes chapter A WARNING Mixing brands and types of brake fluid can reduce the brake system s effectiveness and cause an ac cident resulting in injury or death Do not mix two brands of brake fluid Change the brake fluid in the brake line completely if the brake fluid must be re filled but the type and brand of the brake fluid that is already in the reservoir are unidentified Brake Pa
171. e it if any cracks or swelling is noticed PERIODIC MAINTENANCE 2 29 Periodic Maintenance Procedures Crankshaft Transmission Crankshaft Inspection Connecting Rod Big End Side Clearance e Remove the cylinder head see Cylinder Head Removal in the Engine Top End chapter e Remove the cylinder see Cylinder Removal in the Engine Top End chapter e Remove the piston see Piston Removal in the Engine Top End chapter e Measure the connecting rod big end side clearance at right side of big end using a thickness gauge A Connecting Rod Big End Side Clearance Standard 0 25 0 35 mm 0 0098 0 014 in Service Limit 0 6 mm 0 02 in kif the clearance exceeds the service limit replace the crankshaft assembly e Make sure that the crankshaft rotates smoothly after as sembling the engine Wheel Tires Air Pressure Inspection Adjustment e Using tire air pressure gauge A measure the tire pres sure when the tires are cold Adjust the tire air pressure to suit track conditions and rider preference but do not stray too far from the recom mended pressure When the track is wet muddy sandy 80 kPa 0 8 kgf om2 or slippery reduce the tire pressure e 11 psi to increase the tire tread surface on hb the ground When the track is pebbly or hard increase the tire pressure to prevent damage or punctures through the tires will skid more easily 6J050103S1 d 100 kPa 1 0 k
172. e joint pin B with washer NOTE OPull off the joint pin while pressing down the brake pedal e Unscrew the master cylinder mounting bolts C and re move the master cylinder D e Unscrew the brake hose banjo bolt E e When removing the brake hose temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum Rear Master Cylinder Installation e Replace the cotter pin with a new one e Replace the washers are on each side of hose fitting with new ones e Tighten the following Torque Brake Hose Banjo Bolt 25 N m 2 5 kgf m 18 ft Ib Rear Master Cylinder Mounting Bolts 10 N m 1 0 kgf m 89 in Ib e Bleed the brake line see Bleeding the Brake Line e Check the brake for good braking power no brake drag and no fluid leakage e Check the brake pedal position see Brake Lever and Pedal Position Adjustment in the Periodic Maintenance chapter Front Master Cylinder Disassembly e Refer to the Brake Master Cylinder Cup and Dust Seal Replacement in the Periodic Maintenance chapter Rear Master Cylinder Disassembly e Refer to the Brake Master Cylinder Cup and Dust Seal Replacement in the Periodic Maintenance chapter Master Cylinder Assembly e Refer to the Brake Master Cylinder Cup and Dust Seal Replacement in the Periodic Maintenance chapter GLO7068BS1 BRAKES 12 17 Master Cylinder Master Cylinder Inspection Visual Inspection e Disassemble the fron
173. e motorcycle until a firm brake pedal is obtained by pumping the pedal until the pads are against the disc CRANKSHAFT TRANSMISSION 9 1 Crankshaft Transmission Table of Contents ee RE 9 2 MDS C ICAO LIS EEN 9 4 special Tools and SSal EE 9 5 e 9 6 Crankcase Disassembly tele liv oia 9 6 Crankcase Assembly acicate 9 8 Crankshaft Connecting Rod 522 8er detec usd nn dor incl pide ds tenant 9 15 Grankshiatt REMOVAL ooo dois 9 15 Grankshatt Installation iba io 9 15 Eelere gege de eege Eeselen 9 15 Grankshatt ASS OI E 9 15 Crankshaft Inspection EE 9 16 Connecting Rod Bend EE 9 17 Connecting Rod IWS cities 9 18 Torque ln EE 9 19 Torque Limiter Removal InstallatiON cosico seins hante Torque Limiter Inspector Eli Elo A e PO PO EOI O Transmission Shaft R moOval sssiasss one didas Transmission Shaft Installation cuina raro rls contras Mein adan bolitas Transmission Shaft Disassembly cooooocccccnonocccconanccononancncnnnannncncnnnn cnn rca e ncnnnnnnn cnc nnnnn cnn nnnnns 9 20 Transmission Shaft E eege RE een nt eren 9 21 Shift Fork Bending EE 9 22 Shift Fork Gear Groove WE aletas tada 9 23 Shift Fork Guide Pin Shift Drum Groove Wear reenact eeeeeeeeeeeeeeeeeeeeteeeeeeeea 9 23 E Een LEE 9 23 Balancer Ao eene 9 24 Balancer ue E EEN 9 24 Balancer Instala seconds 9 24 Bearings Oll Seals ceiba 9 25 Bearing Replaco menta a esse ie See cates 9 25 Bearing Inspection iii 9 25 Ee rl 9 26 9 2 CRANKSHAFT TRANSMISSION Ex
174. e that the idle speed is within the specified range Readjust if necessary Air Cleaner Element Cleaning and Inspection NOTE Oln dusty areas the element should be cleaned more frequently than recommended interval OArfter riding through rain or on muddy roads the element should be cleaned immediately OSince repeated cleaning opens the pores of the ele ment replace it with a new one in accordance with the Periodic Maintenance Chart Also if there is a break in the element material or any other damage to the ele ment replace the element with a new one PERIODIC MAINTENANCE 2 15 Periodic Maintenance Procedures A WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the element in a well ventilated area and take care that there is no spark or flame any where near the working areas Do not use gasoline or low flash point solvents to clean the element e Remove Front Left Side Cover see Element Removal in the Fuel System chapter Air Cleaner Element see Element Removal in the Fuel System chapter e Stuff a clean lint free towel into the carburetor so no dirt is allowed to enter the carburetor e Wipe out the inside of the air cleaner housing with a clean damp towel NOTICE Check inside of the inlet tract and carburetor for dirt If dirt is present clean the intake tract and car buretor thoroughly You may also need to replac
175. e wheel so the disc does not touch the ground e Insert a wood wedge between the brake pads This pre vents them from being moved out of their proper position should the brake pedal be squeezed accidentally WHEELS TIRES 10 9 Wheels Rims Rear Wheel Installation e Install the groove A of the brake holder B onto the pro jection C of the swingarm e Install the rear wheel while holding the disc cover D e Fit the projection on the cap to the groove on the collar e Install the collars A on the left and right side of the hub OThe collars are identical e Engage the drive chain with the rear sprocket and install the rear wheel e Insert the axle from the left side of the wheel and install the axle nut e Check the drive chain slack see Drive Chain Slack In spection in the Periodic Maintenance chapter e Tighten the axle nut Torque Rear Axle Nut 110 N m 11 2 kg m 81 1 ft Ib e Install the new cotter pin A and spread its end NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle shaft tighten the nut clockwise A up to next alignment Olt should be within 30 degree OLoosen one and tighten again when the slot goes past the nearest hole A WARNING A loose axle nut can lead to an accident resulting in serious injury or death Tighten the axle nut to the proper torque and install a new cotter pin e Install th
176. ean for the radiator cap to function properly Hose Inspection e Refer to the Radiator Hoses and Connections Inspection in the Periodic Maintenance chapter Hose Installation e Install the hoses being careful to follow the performed bends see Cable Wire and Hose Routing section in the Appendix chapter Avoid sharp bending kinking flatten ing or twisting e Tighten the hose clamps securely Torque Radiator Hose Clamp Screws 3 0 N m 0 30 kgf m 27 in Ib 6D07001BS1 ENGINE TOP END 5 1 Engine Top End Table of Contents Exploded View 5 2 Valve Clearance Inspection 5 26 Sp cifications 5 6 Valve Removal 5 26 Special Tools and Sealant 5 9 Valve Installation 5 26 Clean Air System U S A California Valve Guide Removal 5 27 and Canada Models 5 12 Valve Guide Installation 5 27 Vacuum Switch Valve Removal 5 13 Valve Valve Guide Clearance Vacuum Switch Valve Installation 5 13 Measurement Wobble Method 5 28 Cylinder Head Cover 5 14 Valve Seat Inspection 00 0n Cylinder Head Cover Removal 5 14 Valve Seat Repair Cylinder Head Cover Installation 5 14 Cylinder and Piston ooooooccccconcccccccnnns 5 15 Camshaft Chain Tensioner Cylinder PHemouval Camshaft Chain Tensioner Piston Hemoval 5 34 FGMOV lucas sio 5 15
177. ectiveness and cause an ac cident resulting in injury or death Do not mix two brands of brake fluid Change the brake fluid in the brake line completely if the brake fluid must be re filled but the type and brand of the brake fluid that is already in the reservoir are unidentified 6S13044BS1 PERIODIC MAINTENANCE 2 37 Periodic Maintenance Procedures Brake Fluid Change In accordance with the Periodic Maintenance Chart change the brake fluid The brake fluid should also be changed if it becomes contaminated with dirt or water Furthermore the brake fluid should be changed to bleed the air quickly and completely whenever the brake line parts are removed A WARNING When working with the disc brake observe the pre cautions 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 4 Don t leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid 5 Don t change the fluid in the rain or when a strong wind is blowing 6 Except for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning brake parts Do not
178. ed Compression Damping Standard 11 clicks B Softer counterclockwise C Harder clockwise D Number of turns counterclockwise usable range 22 clicks or more A Counterclockwise from the fully seated position NOTE OAdjustment of the rebound damping adjuster for the rear suspension will slightly affect the compression damping force Always make any damping adjustments in small steps and test their effects before using them in com petition Spring Preload Adjustment e Remove Seat see Seat Removal in the Frame chapter Side Covers see Side Cover Removal in the Frame chapter Rear Frame see Rear Frame Removal in the Frame chapter Carburetor Holder Clamp Screw loosen Muffler see Muffler Removal in the Engine Top End chapter Rear Frame Mounting Bolts A Rear Frame B with Air Cleaner Housing e Using the jack under the frame raise the rear wheel off the ground Special Tool Jack 57001 1238 GMO5206BS1 2221 2013121110 9 o iS bt GMO5274BS1 SUSPENSION 13 25 Rear Suspension Uni Trak e Using the hook wrenches A loosen the locknut B on the rear shock absorber Special Tool Hook Wrench R37 5 R42 57001 1101 e Using the stem nut wrench A turn the adjusting nut B as required Turning the adjusting nut downward marks the spring action harder and upward softer Special Tool Steering Stem Nut Wrench 57001 1101 Spr
179. edures Caliper Piston Seal and Dust Seal Replacement e Loosen the brake pad pin A and banjo bolt B and tighten them loosely e Remove Front Caliper Mounting Bolts C Banjo Bolt Brake Hose E Front Caliper D see Front Caliper Removal in the Brakes chapter Brake Pads see Brake Pad Removal in the Brakes chapter e Separate the caliper holder A from the caliper B and remove the anti rattle spring e Using compressed air remove the pistons One way to remove the pistons is as follows OCover the caliper opening with a clean heavy cloth A ORemove the pistons by lightly applying compressed air B to the hose joint opening A WARNING The piston in the brake caliper can crush hands and fingers Never place your hand or fingers in front of the piston OPull out the piston A by hand e Remove the dust seals B and fluid seals C NOTE Olf compressed air is not available do as follows for both calipers coincidentally with the brake hose connected to the caliper OPrepare a container for brake fluid and perform the work above it ORemove the spring and pads see Brake Pad Removal in the Brakes chapter OPump the brake lever until the pistons come out of the cylinders and then disassembly the caliper 2 42 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Remove the rear caliper see Caliper Removal in the Brakes chapter e Remove the pads see Brake Pad Rem
180. eep complete records of main tenance and repair with dates and any new parts installed How to Use This Manual In this manual the product is divided into its major systems and these systems make up the manual s chapters The Quick Reference Guide shows you all of the product s system and assists in locating their chapters Each chapter in turn has its own comprehensive Ta ble of Contents For example if you want ignition coil informa tion use the Quick Reference Guide to locate the Electrical System chapter Then use the Table of Contents on the first page of the chap ter to find the Ignition Coil section Whenever you see symbols heed their in structions Always follow safe operating and maintenance practices A DANGER DANGER indicates a hazardous situa tion which if not avoided will result in death or serious injury A WARNING WARNING indicates a hazardous situa tion which if not avoided could result in death or serious injury A CAUTION CAUTION indicates a hazardous situa tion which if not avoided could result in minor or moderate injury NOTICE is used to address practices not related to personal injury This manual contains four more symbols which will help you distinguish different types of information NOTE OThis note symbol indicates points of par ticular interest for more efficient and con venient operation e Indicates a procedural step or work to
181. ely 93 200 F max and tapping the bearing in or out NOTICE Do not heat the case with a torch This will warp the case Soak the case in oil and heat the oil e Install the new bearing until its outer race stops at the bottom of the case using a press and the bearing driver set A Special Tool Bearing Driver Set 57001 1129 6114060581 Bearing Inspection NOTICE Do not remove the bearings for inspection Re moval may damage them e Inspect the ball bearings OSince the ball bearings are made to extremely close toler ances the wear must be judged by feel rather than mea surement Clean each bearing in a high flash point sol vent dry it do not spin the bearing while it is dry and oil it with engine oil to it OSpin A the bearing by hand to check its condition If the bearing is noisy does not spin smoothly or has any rough spots replace it 6113014981 9 26 CRANKSHAFT TRANSMISSION Bearings Oil Seals e Check the needle bearing OThe rollers in a needle bearing normally wear very little and wear is difficult to measure Instead of measuring inspect the bearing for abrasion color change or other damage x lf there is any doubt as to the condition of a needle bear ing replace it Oil Seal Inspection e Inspect the oil seal x Replace the oil seal if the lips are deformed discolored indicating that the rubber has deteriorated hardened or otherwise dam
182. ent tighten the locknut GLO4004BS1 NOTE OUsually it is not necessary to adjust the pedal position but always adjust it when the master cylinder is disas sembled or pedal position is incorrect e Measure the length indicated in the figure Length A Standard 68 5 1 mm 3 09 0 04 in lf it is not specified length the brake pedal may be de formed or incorrectly installed If it is not within the specified length adjust the push rod in the master cylinder as follows 2 36 PERIODIC MAINTENANCE Periodic Maintenance Procedures OLoosen the push rod locknut A OReplace the cotter pin with a new one ORemove Cotter Pin B Washer Joint Pin C OTurn the bracket D to obtain the specified length OTighten the locknut Torque Rear Master Cylinder Push Rod Locknut 17 N m 1 7 kgf m 13 ft lb Brake Fluid Level Inspection e Check the brake fluid level in the front or rear brake reser voir A NOTE OHold the reservoir horizontal when checking brake fluid level e The front or rear reservoir must be kept above the lower level line B Olf the fluid level in front or rear reservoir is lower than the lower level line fill the reservoir to the upper level line In side the reservoir is stopped end showing the upper level line C Torque Reservoir Cap Screws 1 5 N m 0 15 kgf m 13 in Ib A WARNING Mixing brands and types of brake fluid can reduce the brake system s eff
183. er and Pedal Position Adjustment Brake Fluid Level Inspection Brake Fluid Change ooooccccconcnccco Brake Pad Wear Inspection Brake Master Cylinder Cup and Dust Seal Replacement Caliper Piston Seal and Dust Seal Replacement Brake Hose and Connection Brake Hose Replacement SUSPENSION cintia eden Front Fork Inspection aeeeseee Front Fork Oil Change each fork EE Rear Shock Absorber Inspection Rear Shock Absorber Oil Change Swingarm and Uni Trak Linkage Ieper Sean Swingarm and Unt Track Linkage Pivot Lubricate ooooooomo Steerihg E EE Steering Inspection ooooonnoccccnnn Steering Adjustment Stem Bearing Lubrication A edd Te Frame Inspection Electrical System AAA Spark Plug Cleaning and Inspection teste mener Cable Inspection ssssnnssseeee eene Lubrication EE Nut Bolt and Fastener Tightness INSPOCON EE Tightness Inspection 0 00seeeee0 2 41 2 44 2 44 2 45 2 45 2 45 2 54 2 54 2 59 2 59 2 59 2 59 2 59 2 61 2 61 2 61 2 62 2 62 2 62 2 62 2 63 2 63 2 2 PERIODIC MAINTENANCE Periodic Maintenance Chart The maintenance must be done in accordance with this chart to keep the motorcycle in good running condition Periodic Inspection FREQUENCY Traveled Dis
184. er it has been removed GMO4169BS1 6M04168BS1 GM040119S1 6M040120S1 13 22 SUSPENSION Front Fork Spring Tension e Since a spring becomes shorter as it weakens check its free length A to determine its condition lf the spring of either fork leg is shorter than the service limit it must be replaced If the length of a replacement spring and that of the remaining spring vary greatly the remaining spring should also be replaced in order to keep the fork legs balanced from motorcycle stability Fork Spring Free Length Standard 460 mm 18 1 in Service Limit 451 mm 17 8 in 6M040116S1 SUSPENSION 13 23 Rear Suspension Uni Trak Rear Shock Absorber The rear suspension system of this motorcycle is New Uni trak It consists of a rear shock absorber swing arm tie rod and rocker arm To suit to various riding conditions the spring preload of the shock absorber can be adjusted or the spring can be replaced with an optional one Also the damping force can be adjusted easily so changing oil viscosity unnecessary Rebound Damping Adjustment e Turn the rebound damping adjuster A on the rear shock absorber lower end with the blade of a screwdriver until you feel a click If the damper setting feels too soft or too stiff adjust it in accordance with the following table Seated position adjuster turned fully clockwise A Rebound
185. ess coolant flows through the radiator cap and hose to the reserve tank to be stored there temporarily Conversely as the engine cools down the coolant in the radiator and the water jacket contracts and the stored coolant flows back to the radiator from the reserve tank The radiator cap has two valves One is a pressure valve which holds the pressure in the system when the engine is running When the pressure exceeds 112 3 141 7 kPa 1 145 1 445 kgf cm 16 28 20 55 psi the pressure valve opens and releases the pressure to the reserve tank As soon as pressure escapes the valve closes and keeps the pressure at 112 3 141 7 kPa 1 145 1 445 kgf cm 16 28 20 55 psi When the engine cools down another small valve vacuum valve in the cap opens As the coolant cools the coolant contracts to form a vacuum in the system The vacuum valve opens and allows the coolant from the reserve tank to enter the radiator 4 6 COOLING SYSTEM Specifications Item Coolant Type Color Mixed Ratio Freezing Point Total Amount Radiator Cap Relief Pressure Service Limit Permanent type antifreeze soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators Green Soft water 50 coolant 50 35 31 F 1 05 L 1 11 US at 112 3 141 7 kPa 1 145 1 445 kgf cm 16 28 20 55 psi COOLING SYSTEM 4 7 Special Tool Bearing Driver Set 57001 1129 ST57112
186. ethod e Remove the ignition coil e Connect the ignition coil with the spark plug cap left in stalled on the spark plug lead A to the tester B and measure the arcing distance A WARNING To avoid extremely high voltage shocks do not touch the coil body or lead If the distance reading is less than the specified value the ignition coil or spark plug cap is defective 3 Needle Arcing Distance Standard 7 mm 0 26 in or more e To determine which part is defective measure the arcing distance again with the spark plug cap removed from the ignition coil lead x lf the arcing distance is subnormal as before the trouble is with the ignition coil itself If the arcing distance is now normal the trouble is with the spark plug cap Measuring Coil Resistance If the arcing tester is not available the coil can be checked for a broken or badly shorted winding with an ohmmeter However an ohmmeter cannot detect layer shorts and shorts resulting from insulation breakdown under high voltage e Remove the ignition coil see Ignition Coil Removal e Measure the primary winding resistance A OConnect an ohmmeter between the coil terminals OSet the meter to the x 1 Q range and read the meter e Measure the secondary winding resistance B OPull the spark plug cap off the lead OConnect an ohmmeter between the spark plug lead and the ground lead terminal OSet the meter to the x 1 kQ range and read the meter Ignition
187. f rotating direction will affect the adjustment Ro tate the crankshaft to positive direction clockwise viewed from output side Electrical Leads A two color lead is identified first by the primary color and then the stripe color Unless instructed otherwise electrical leads must be connected to those of the same color Instrument Use a meter that has enough accuracy for an accurate measurement Read the manufacture s instructions thor oughly before using the meter Incorrect values may lead to improper adjustments n e E eh g Ze ed a ott ea Kb A d tary AN A lt 4 j l i A j N A 68020218 S 602078 6020272 GBO2062BS1 GENERAL INFORMATION 1 7 Model Identification KLX450A8F Left Side View KLX450A8F Right Side View 1 8 GENERAL INFORMATION General Specifications Items KLX450A8F AAF Dimensions Overall Length 2 180 mm 85 83 in AU EUR 2 175 mm 85 63 in Overall Width 820 mm 82 3 in Overall Height 1 255 mm 49 41 in AU EUR 1 250 mm 49 21 in Wheelbase 1 480 mm 58 27 in Road Clearance 320 mm 12 6 in AU EUR 315 mm 12 4 in Seat Height 940 mm 37 0 in AU EUR 935 mm 36 8 in Dry Mass KLX450A8F 115 kg 254 Ib Curb Mass KLX450A9F AAF 126 kg 278 lb Fuel Tank Capacity 8 L 2 1 US gal Performance Minimum Turning Radius Engine Type
188. ffect dia Rear effect dia Electrical Equipment Battery Headlight Type Bulb 3 846 50 13 8 492 Top gear Tubular semi double cradle 42 to either side 27 7 AU EUR 28 122 mm 4 80 in 80 100 21 51M AU EUR 80 100 21 M C 51P BRIDGESTONE M401 Tube type AU EUR EDO3 Tube type 110 100 18 64M AU EUR 120 90 18 M C 65P BRIDGESTONE M402 Tube type AU EUR ED04 Tube type 21 x 1 60 18 x 2 15 Telescopic fork up side down 305 mm 12 0 in Swingarm New Uni trak 315 mm 12 4 in Single disc 225 mm 8 86 in 215 mm 8 46 in 12 V6 Ah Semi sealed beam 12 V 35 W 35 W Hi Lo 1 10 GENERAL INFORMATION General Specifications tems KLXASOASE AAF Tail Light LED Magneto Rated Output 2 0 A 14 V Specifications subject to change without notice and may not apply to every country Unit Conversion Table GENERAL INFORMATION 1 11 Prefixes for Units Prefix Symbol Power mega M x 1 000 000 kilo k x 1000 centi c x 0 01 milli m x 0 001 micro H x 0 000001 Units of Mass kg x 2 205 lb g x 0 03527 oz Units of Volume L x 0 2642 gal US L x 0 2200 gal imp L x 1 057 qt US L x 0 8799 qt imp L x 2 113 pint US L x 1 816 pint imp mL x 0 03381 oz US mL x 0 02816 oz imp mL x 0 06102 cu in Units of Force N x 0 1020 kgf N x 0 2248 lo kgf x 9 807 N kgf x 2 205 lo Units of Tem
189. fork top plug A Special Tool Top Plug Wrench 49 mm B 57001 1653 e Remove Front Wheel see Front Wheel Removal in the Wheels Tires chapter Front Brake Caliper see Caliper Removal in the Brakes chapter Brake Hose Clamps see Brake Hose Replacement e Loosen the front fork lower clamp bolts A e Remove the front fork OWith a twisting motion work the fork leg B down and out NOTE OSet rebound and compression damping setting to the softest settings before disassembling to prevent the needle of adjusters from damaging Record the setting before turning the adjuster e Thoroughly clean the fork before disassembly Be careful not scratch the inner tube and not to damage the dust seal Avoid scratching or damaging the inner tube or the dust seal Use a mild detergent and sponge out dirt with plenty of water e Using the top plug wrench A remove the fork top plug B subtank from the outer tube and slowly slide down the outer tube C Special Tool Top Plug Wrench 49 mm 57001 1653 PERIODIC MAINTENANCE 2 47 Periodic Maintenance Procedures e Place a drain pan under the front fork and drain fork oil A NOTE OPump the fork tube several times to discharge the fork oil e Raise the outer tube and temporarily install the fork top plug A subtank to the outer tube B with the top plug wrench C Special Tool Top Plug Wrench 49 mm 57001 1653 e Hold the axle
190. forks up and down A 4 or 5 times to allow the right fork leg to find a neutral position on the front axle NOTE ODo not apply the front brake during this process to stop the motorcycle from rolling forward Put a block B in front of the wheel to stop it from moving e Tighten the right axle clamp bolts Torque Right Axle Clamp Bolts 20 N m 2 0 kgf m 15 ft Ib NOTE O Tighten the two clamp bolts alternately two times to en sure even tightening torque e Check the front brake for good braking power and no brake drag A WARNING After servicing it takes several applications of the brake pedal before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the motorcycle until a firm brake pedal is obtained by pumping the pedal until the pads are against the disc Rear Wheel Removal e Using the jack under the frame so that the rear wheel is raised off the ground Special Tool Jack 57001 1238 e Remove Cotter Pin A Axle Nut B e Pull out the axle C and remove the chain adjuster e Disengage the drive chain from the rear sprocket toward the left e Move the rear wheel back with the rear caliper installed e Take off the collar and cap from the each side of the rear hub NOTICE Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under th
191. front brake line is as follows Bleeding the rear brake line is the same as for the front brake e Remove the reservoir cap and check that there is plenty of fluid in the reservoir e With the reservoir cap off slowly pump the brake lever several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reser voir OBleed the air completely from the master cylinder by this operation e Install the reservoir cap e Attach a clear plastic hose to the bleed valve on the caliper and run the other end of the hose into a con tainer e Bleed the brake line and the caliper as follows ORepeat this operation until no more air can be seen com ing out into the plastic hose 1 Pump the brake lever until it becomes hard and apply the brake and hold it A 2 Quickly open and close the bleed valve while holding the brake applied B 3 Release the brake C NOTE O The fluid level must be checked often during the bleed ing operation and replenished with fresh brake fluid as necessary If the fluid in the reservoir runs almost out any time during bleeding operation the bleeding opera tion must be done over again from the beginning since air will have entered the line O Tap the brake hose lightly from the caliper to the reser voir for easier bleeding e Remove the clear plastic hose e Tighten the bleed valves and install the rubber caps Torque Caliper Bleed Valve 7 8 N m 0
192. gf cm 14 psi 2 30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Tires Inspection As the tire tread wears down the tire becomes more sus ceptible the puncture and failure e Remove any imbedded stones or other foreign particles from the tread e Visually inspect the tire for cracks and cuts replacing the tire in case of bad damage Swelling or high spots indi cate internal damage requiring tire replacement A WARNING Some replacement tires may adversely affect han dling and cause an accident resulting in serious in jury or death To ensure proper handling and sta bility use only the recommended standard tires for replacement inflated to the standard pressure NOTE OCheck and balance the wheel when a tire is replaced with a new one Standard Tire U S A California and Canada Models Front Size 80 100 21 51M Make BRIDGESTONE Type D401 Tube Rear Size 110 100 18 64M Make BRIDGESTONE Type M402 Tube Standard Tire Australia and Europe Models Front Size 80 100 21 M C 51P Make BRIDGESTONE Type EDO03 Tube Rear Size 120 90 18 M C 65P Make BRIDGESTONE Type ED04 Tube Spoke Tightness Inspection e Check that all the spokes are tightened evenly lf spoke tightness is uneven or loose tighten the spoke nipples evenly Torque Spoke Nipples 2 2 N m 0 22 kgf m 19 in Ib e Check the rim runout WARNING A missing spoke places an additional load o
193. gn matter in fuel Firing incorrect Clutch slipping Spark plug dirty broken or gap malad justed Spark plug cap or high tension wiring trou ble Spark plug cap shorted or not in good con tact Spark plug incorrect heat value Faulty IC igniter Crankshaft sensor trouble Flywheel damage Ignition coil trouble Wiring connector not in good contact Fuel air mixture incorrect Starter plunger stuck open Hot start stuck open Main jet clogged or wrong size Jet needle or needle jet worn Air jet clogged Fuel level in carburetor float bowl too high or too low Needle Jet or air passage clogged Air cleaner clogged poorly sealed or miss ing Air cleaner duct loose Water or foreign matter in fuel Carburetor holder loose Fuel tank cap air vent obstructed Overheating Engine oil level too high Engine oil viscosity too high Drive train trouble Crankshaft bearing worn or damage Vacuum Switch Valve trouble equipped models Engine Overheating Firing incorrect Spark plug dirty broken or maladjusted Spark plug incorrect Faulty IC igniter Fuel air mixture incorrect Main jet clogged or wrong size Fuel level in carburetor float bowl too low Carburetor holder loose Air cleaner clogged poorly sealed or miss ing Air cleaner duct loose Hot start stuck open Compression high Carbon built up in combustion chamber Engine load faulty Clutch slipping Engine oil level too high Engine oil viscos
194. h tension wiring trou ble Spark plug cap shorted or not in good con tact Spark plug incorrect heat value Faulty IC igniter Crankshaft sensor trouble Ignition coil trouble Engine stop switch shorted Neutral switch trouble Wiring shorted or open Flywheel damage 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 de formed worn or carbon accumulation on the seating surface Decompression trouble Poor Running at Low Speed Spark weak Battery voltage low Spark plug dirty broken or gap malad justed Spark plug cap or high tension wiring trou ble Spark plug cap shorted or not in good con tact Spark plug incorrect heat value Faulty IC igniter Crankshaft sensor trouble Flywheel damaged Ignition coil trouble Wiring connector not in good contact Fuel air mixture incorrect Pilot screw maladjusted Pilot jet or air passage clogged Needle Jet or air passage clogged Air cleaner clogged poorly sealed or miss ing Starter plunger stuck open Hot start stuck open Fuel level in carburetor float bowl too high or too low Fuel tank cap air vent obstructed Fuel tap clogged Carburetor holder loose Air cleaner duct
195. he pads or disc with a high flash point solvent Do not use one which will leave an oily residue Replace the pads with new ones if they cannot be cleaned satisfacto rily Brake fluid quickly ruins painted surfaces any spilled fluid should be completely wiped up imme diately If any of the brake line fittings or the bleed valve is opened at any time the AIR MUST BE BLED FROM THE BRAKE LINE Fluid Level Inspection e Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter Fluid Change e Refer to the Brake Fluid Change in the Periodic Mainte nance chapter 12 10 BRAKES Brake Fluid Bleeding the Brake Line The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action Air however is easily compressed When air enters the brake lines brake lever or pedal movement will be partially used in compressing the air This will make the lever or pedal feel spongy and there will be a loss in braking power A WARNING Air in the brake lines diminish braking performance and can cause an accident resulting in injury or death If the brake lever has a soft or spongy feel ing mushy when it is applied there might be air in the brake lines or the brake may be defective Do not operate the vehicle and service the brake sys tem immediately NOTE O The proceaure to bleed the
196. holder A with a vise OProtect the axle holder with a rag when using a vise e Remove the cap e Loosen the adjuster assembly B completely A WARNING Clamping the axle holder too tight can damage it which will affect riding stability Do not clamp the axle holder too tight e Compress the outer tube by hands and install the top plug wrench A between the axle holder bottom B and locknut C Special Tool Top Plug Wrench 49 mm 57001 1653 A WARNING The fork spring applies pressure to the adjuster as sembly and can eject the special tool with substan tial force if the tool is not properly and securely placed Be sure the tool is fully in place as shown in the photo and keep fingers away to avoid getting them pinched between the tool adjuster assembly and axle holder 2 48 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Hold the locknut A with a wrench B and remove the adjuster assembly C e Remove the push rod A e With the outer tube compressed by hands remove the top plug wrench A NOTICE Removing the locknut and pushing the piston rod thread into the cylinder unit will damage the oil seal Do not remove the locknut from the piston rod e Remove the fork leg from the vise e Loosen the fork top plug subtank A with the top plug wrench B Special Tool Top Plug Wrench 49 mm 57001 1653 e Remove Cylinder Unit A Spacer B Fork Spri
197. ht Engine Cover Right Engine Cover Removal in the Engine Right Side chapter Clutch Clutch Removal in the Engine Right Side chap ter Circlip A Oil Pump Driven Gear B Shaft C Oil Pump Idle Gear D e Remove Oil Pump Cover Bolts A Oil Pump Cover B e Remove Inner Rotor A Outer Rotor B Oil Pump Feed Installation e Install the dowel pins A to the crankcase e Apply engine oil to the each oil pump rotor and sliding surface of the oil pump shaft e Install Outer Rotor B Inner Rotor C e While turn the oil pump shaft install the oil pump so that the left and right oil pump shaft may mesh in the crankcase e Install the oil pump cover A e While pushing the oil pump cover tighten the oil pump cover bolts B Short Bolts C Torque Oil Pump Feed Cover Bolts 9 8 N m 1 0 kgf m 87 in lb 7 16 ENGINE LUBRICATION SYSTEM Oil Pump e Apply molybdenum disulfide grease to the oil pump idle gear shaft A e Install the oil pump idle gear B facing the stepped side C to the outside e Replace the circlip D with a new one e Install the oil pump driven gear E and circlip Oil Pump Inspection e Remove the oil pump e Visually inspect the oil pump body outer rotors and the inner rotors x lf the oil pump is any damaged or unevenly worn replace the rotors cover or body or the crankcase ENGINE LUBRICATION SYSTEM 7 17 Oil Pressure Oil Pressure Measurement
198. ial read ings is the amount of runout If the runout exceeds the service limit replace the axle Axle Runout 100 mm 3 94 in Standard 0 1 mm 0 004 in or less Service Limit 0 2 mm 0 008 in GJ04139BS1 WHEELS TIRES 10 11 Tires Tire Removal NOTICE Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so the disc does not touch the ground e Remove the wheel from the motorcycle see Wheels Re moval e To maintain front wheel balance mark A the valve stem position on the tire with chalk so that the tire can be rein stalled in the same position e Remove the valve cap B GJO5029BS1 e Take out the valve core A to let out the air e Remove the valve stem nut B y A G koe CY GJO5030BS1 e Loosen the bead protector nut A e Lubricate the tire beads and rim flanges on both sides with a soap and water solution or rubber lubricant This helps the tire beads slip off the rim flanges NOTICE Never lubricate with mineral oil engine oil or gaso line because they will cause deterioration of the tire e Break the beads away from both sides of the rim with the bead breaker A Special Tool Bead Breaker Assembly 57001 1072 6J05031BS1 10 12 WHEELS TIRES Tires e Step on the side of the tire opposite valve stem pry the tire off the rim w
199. icate internal engine damage e Check the screen carefully for any damage holes and broken wires If the screen is damaged replace the oil screen ENGINE LUBRICATION SYSTEM 7 13 Oil Pressure Relief Valve Oil Pressure Relief Valve Removal e Remove Right Engine cover see Right Engine Cover Removal in the Engine Right Side chapter Clutch see Clutch Removal in the Engine Right Side chapter e Remove the oil pressure relief valve A Oil Pressure Relief Valve Installation e Apply high 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 lb Oil Pressure Relief Valve Inspection e Remove the relief valve see Oil Pressure Relief Valve Removal 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 6608066281 c 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 A WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the cylinder head in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this includes an
200. ick spring B out of the hole in the crankcase e Turn the kickshaft counterclockwise C and pull out the kickstarter assembly D e Remove the bolt A take off the ratchet guide B Kickshaft Installation e Install the ratchet guide A Torque Ratchet Guide Bolt 8 8 N m 0 90 kgf m 78 in Ib e Apply molybdenum disulfide grease to the end of the kick shaft e Insert the kick shaft assembly B into the crankcase OSecurely engage the stopper portion C of the ratchet gear with the guide e Insert the spring end D into the hole E e Install Clutch Housing see Clutch Installation Right Engine Cover see Right Engine Cover Installa tion 6 24 ENGINE RIGHT SIDE Kickstarter Kick Shaft Assembly Disassembly Assembly e The kick shaft assembly consists of the following parts A Kick Gear B Circlip C Washer D Spring E Ratchet Gear F Kick Shaft G Kick Spring H Spring Guide e Check the kick shaft assembly parts for damage x Any damaged parts should be replaced with new ones e Apply molybdenum disulfide oil to the inside of the kick gear and ratchet gear e Apply grease to the inside of the spring guide e When assembling the ratchet gear A onto the kick shaft B align the punch mark C on the ratchet gear with the punch mark C on the kick shaft e Replace the circlips that were removed with new ones Special Tool Outside Circlip Pliers 57001 144 GROSO18BS1
201. id gasket to the mating surface A of the left crankshaft half Sealant Liquid Gasket TB1216 92104 1063 NOTE OMake the application finish within 30 minutes when the liquid gasket to the mating surface of the left crankcase half is applied OMoreover fit the case and tighten the case bolts just after finishing the application of the liquid gasket e Using a plastic mallet A press B the rear portion of the crankcase and tap the area around the crankshaft of the left crankcase While maintaining the mating surfaces of the right and left crankcase halves constantly parallel mate the crankcase halves evenly NOTE OConstantly check the alignment of the two crankcase halves and the position of the transmission shafts and shift drum The front and rear of the crankcase must be pushed together evenly e Remove the crankshaft jig C e Tighten the crankcase bolts starting with the periphery of the crankshaft then outward e Replace the copper washer B with a new one OTighten the crankcase bolt together with the clamp A Torque Crankcase Bolts M6 12 N m 1 2 kgf m 106 in Ib Crankcase Bolts M7 15 N m 1 5 kgf m 11 ft lb NOTE OAfter tightening the crankcase bolts wipe up the liquid gasket seeping out around the mating surface espe cially around the area e Make sure that the crankshaft driveshaft and the output shaft rotate smoothy in the neutral position lf the crankshaft will not turn prob
202. il is good check the other parts see the flow chart in this section lf the all parts are good replace the igniter 16 30 ELECTRICAL SYSTEM Ignition System Troubleshooting Faulty ignition Malfunctioned engine Battery Inspection Good Charge or replace battery Wiring and connect portion of the ignition No good Repair system inspection Good No good Spark plug inspection Good No good Spark plug cap inspection Good Ignition coil primary peak voltage inspection Good No good Voltage is No good Voltage is Voltage is specified none or almost less than the but faulty ignition specified value Inspect Inspection 1 Adapter connection is Speed of cranking engine is incorrect or adapter is slow Increase force of kicking directive engine Engine stop switch Lower resistance in the tester Defective ignition Crankshaft sensor peak Use KAWASAKI Hand Tester voltage Lacking of sampling Sampling Replace the Exciter coil peak voltage few times malfunctioned Throttle Sensor Inspection Crankshaft sensor peak voltage no good parts Throttle Sensor Inspection All good All good IC Igniter is defective No good Replace the malfunctioned parts or inspect in proper way GP10401B F ELECTRICAL SYSTEM 16 31 Ignition System Crankshaft Sensor Peak Voltage Check e To check the peak voltage do the following procedures ODisconnect the m
203. in Plug M10 Main 20 2 0 15 2 Engine Oil Drain Plug M6 Sub 7 0 0 71 62 in lb 3 Oil Pump Scavenge Cover Bolts 9 8 1 0 87 in lb 4 Oil Pump Feed Cover Bolts 9 8 1 0 87 in lb 5 Right Engine Cover Bolts 9 8 1 0 87 in lb 6 Piston Oil Nozzle 5 0 0 50 44 in lb Oil Filter Cover Bolt 98 1 0 87inlb 8 Oil Screen Feed Mounting Bolts 98 1 0 87 in lb ER Oil Pressure Relief Valve 15 1 5 11 HL Breather Fitting 15 1 5 11 L Oil Filler Cap Hand tighten 2 Oil Filter Cover e Inner Rotor feed 14 Outer Rotor feed 15 Oil Screen Feed 16 Oil Screen Scavenge 17 Oil Pump Idle Gear 18 Oil Pump Gear 19 Oil Level Gauge 20 Breather Hose 21 Drain Hose 22 Inner Rotor Scavenge 23 Outer Rotor Scavenge EO Apply engine oil G Apply grease HL Apply high locking agent L Apply a non permanent locking agent M Apply molybdenum disulfide grease R Replacement Parts 7 4 ENGINE LUBRICATION SYSTEM Lubrication System Chart Ah Y 7 d Loe E a S Ve E y d S AM 7 7 jj AZ UN l ENGINE LUBRICATION SYSTEM 7 5 Lubrication System Chart A III D GE LIN GGO4108BHW3 C Oil Screen feed Oil Pump feed Oil Pressure Relief Valve Right Engine Cover Oil Passage from Feed Oil Pump to Oil filter Oil Filter Right Engine Cover Oil Passage from Oil filter
204. ing the top plug wrench Special Tool Top Plug Wrench 49 mm 57001 1653 B e Clamp the axle holder with a vise OProtect the axle holder with a rag when using a vise A WARNING Clamping the axle holder too tight can damage it which will affect riding stability Do not clamp the axle holder too tight SUSPENSION 13 19 Front Fork e Compress the outer tube by hands and install the top plug wrench A between the axle holder bottom and locknut Special Tool Top Plug Wrench 49 mm 57001 1653 A WARNING The fork spring applies pressure to the adjuster as sembly and can eject the special tool with substan tial force if the tool is not properly and securely placed Be sure the tool is fully in place as shown in the photo and keep fingers away to avoid getting them pinched between the tool adjuster assembly and axle holder e Insert the push rod A into the piston rod e Replace the O ring and gasket on the adjuster assembly with new ones and apply specified fork oil to the O ring e Turn the locknut A counterclockwise until it contacts with the adjuster assembly B e With the locknut held immovable using a wrench tighten the adjuster assembly to the specified torque Torque Locknut Adjuster Assembly 28 N m 2 9 kgf m 21 ft lb e With the outer tube compressed by hands remove the top plug wrench e Apply a non permanent locking agent to the threads of adjuster assembly e Torque the adjus
205. ing Preload Adjustment Adjusting nut position at the lower surface A from the center of the mounting hole Standard 123 5 mm 4 86 in Adjustable Range 121 5 138 5 mm 4 783 5 453 in e Tighten the locknut securely e After adjusting move the spring up and down to make sure that the spring is seated e Install the parts removed e Tighten the rear frame mounting bolts Torque Rear Frame Mounting Bolts 34 N m 3 5 kgf m 25 ft lb Spring Tension e Since the spring becomes shorter as it weakens check its free length A to determine its condition lf the spring length is less than the service limit replace the spring with a new one Shock Absorber Spring Free Length Standard 260 mm 10 2 in Service Limit 255 mm 10 0 in GM040116S1 13 26 SUSPENSION Rear Suspension Uni Trak Rear Shock Absorber Removal e Remove Seat see Seat Removal in the Frame chapter Side Covers see Side Cover Removal in the Frame chapter Muffler see Muffler Removal in the Engine Top End chapter Rear Frame with Air Cleaner Housing e Using the jack under the frame raise the rear wheel off the ground Special Tool Jack 57001 1238 When pulling out the mounting bolts lift the rear wheel slightly Forcing or tapping on a bolt could damage the bolt sleeve and bearing e Remove the tie rod rear mounting bolt and nut and turn it downward e Remove the rear shock absorber lower mounting b
206. ire and rim 6J05010481 GD Die 2005 08 2 W ss049010 GJ05093BS1 WHEELS TIRES 10 13 Tires e Tighten the bead protector nut A and valve stem nut B and put on the valve cap C e Check and adjust the air pressure after installing Air Pressure Inspection Adjustment e Refer to the Air Pressure Inspection Adjustment in the Pe riodic Maintenance chapter 10 14 WHEELS TIRES Hub Bearings Hub Bearing Removal e Remove the wheel see Wheel Removal Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground e Remove the oil seals and circlips Special Tool Inside Circlip Pliers 57001 143 e Remove the hub bearing by tapping evenly around the bearing inner race as shown A Bar B Distance Collar C Hub Bearing Hub Bearing Installation e Before installing the wheel bearings blow any dirt or for eign particles out of the hub A with compressed air to prevent contamination of the bearings e Replace the bearings with new ones e Lubricate them and install them using the bearing driver set B so that the marked or shielded sides face out OPress in the bearings until they are bottomed Special Tool Bearing Driver Set 57001 1129 e Replace the circlips and oil seals with new ones e Press in the oil seals A so that the seal surface
207. is flush B with the end of the hole e Apply high temperature grease to the oil seal lips Special Tool Bearing Driver set 57001 1129 C Hub Bearing Inspection NOTE Olt is not necessary to remove any bearings for inspec tion If any bearings are removed they will need to be replaced with new ones e Spin A it by hand to check its condition lf it is noisy does not spin smoothly or has any rough spots it must be replaced e Examine the bearing seal B for tears or leakage lf the seal is torn or is leaking replace the bearing 6J06013BS1 6J06009BS1 6J06008BS1 6J06002BS1 WHEELS TIRES 10 15 Hub Bearings Hub Bearing Lubrication NOTE OSince the hub bearings are packed with grease and sealed lubrication is not required FINAL DRIVE 11 1 Final Drive Table of Contents Exploded MiS Wii it 11 2 o ee Eeer ege TR Net Les 11 4 Drive Chal add cc 11 5 EE el EL DEE 11 5 Drive Chain Slack Adjustment ss 11 5 Wheel Alignment Inspeccion 11 5 Wheel Alignment Adjustment nee 11 5 Drive Chain Wear Inspection ta tias 11 5 Drive Chain UDC ATON cos isa 11 5 Drive Chain Removal EE 11 5 A ET 11 9 Engine Sprocket REMOVAL cuisine 11 9 Engine Sprocket Installation EE 11 9 Rear Sprocket Re MOVal s unes ias cas 11 9 Rear Sprocket Installation cdi reia bla ici 11 10 Sprocket We
208. ith the tire iron A of the bead breaker protecting the rim with rim protectors B Special Tools Rim Protector 57001 1063 Bead Breaker Assembly 57001 1072 Take care not to inset the tire irons so deeply that the tube gets damaged e Remove the bead protector and tube when one side of the tire is pried off e Pry the tire off the rim Tire Installation NOTE O The Tires should be installed so that the ID serial NO A faces to left side e Inspect the rim and tire and replace them if necessary e Install the tube band and tube e Apply a soap and water solution or rubber lubricant to the rim flange and tire beads e Position the front tire on the rim so that the valve A is at the tire balance mark B the chalk mark made during removal or the white paint mark on a new tire see Re moval e Insert the valve stem into the rim and screw the nut on loosely e Fit the rim protectors and use tire irons to install the tire bead NOTE OTo prevent rim damage be sure to place the rim protec tors at any place the tire irons are applied e Pry one side of the tire back onto the rim Fit the bead protector into the tire e Pry the other side of the tire onto the rim starting at the side opposite the valve OTake care not to insert the tire irons so deeply that the tube is damaged e Install the other side of the tire bead onto the rim in the same manner e Check that the tube is not pinched between the t
209. ity too high Troubleshooting Guide APPENDIX 17 27 Brake dragging Drive train trouble Lubrication inadequate Engine oil level too low Engine oil poor quality or incorrect Coolant incorrect Coolant level too low Coolant deteriorated Cooling system component incorrect Radiator clogged Radiator cap trouble Water pump not rotating Water pump impeller damaged Clutch Operation Faulty Clutch slipping No clutch lever play Clutch cable maladjusted Clutch inner cable sticking Friction plate worn or warped Steel plate worn or warped Clutch spring broken or weak Clutch release function trouble Clutch hub or housing unevenly worn Clutch not disengaging properly Clutch lever play excessive Clutch spring compression uneven Engine oil deteriorated Engine oil viscosity too high Engine oil level too high Clutch housing seized Clutch release function trouble Clutch hub nut loose Clutch plate warped or rough Clutch hub spline damaged Gear Shifting Faulty Doesn t go into gear shift pedal doesn t return Clutch not disengaging Shift fork bent worn or seized Shift return spring pin loose Shift return spring weak or broken Shift shaft lever broken Pawl guide plate broken Shift pawl broken Shift pawl spring tension lose Gear seized Gear set lever operation trouble Shift drum broken Jumps out of gear Shift fork ear worn bent Gear groove worn Gear dogs and or dog holes worn Shift drum groove worn Gear set lever spring
210. iver 57001 1454 Camshaft Chain Removal e Remove Camshaft see Camshaft Removal Flywheel see Flywheel Removal in the Electrical Sys tem chapter Oil Pump Scavenge Cover Bolts A Lower Chain Guide B Front Chain Guide C e Remove the camshaft chain D from the crankshaft sprocket Camshaft Chain Installation e Hang the camshaft chain A to the crankshaft sprocket e Install Front Chain Guide B Lower Chain Guide C e Tighten Torque Oil Pump Scavenge Cover Bolts D 9 8 N m 1 0 kgf m 87 in Ib e Install Flywheel see Flywheel Installation in the Electrical Sys tem chapter Camshaft see Camshaft Installation ENGINE TOP END 5 21 Camshaft Camshaft and Camshaft Cap Wear e Measure each clearance between the camshaft journal and camshaft cap using plastigauge press gauge A e Install the camshaft caps see Camshaft Installation NOTE ODo not turn the camshaft when the plastigauge is be tween the journal and camshaft cap If any clearance exceeds the service limit measure the diameter of each camshaft journal with a micrometer Camshaft Journal Camshaft Cap Clearance Standard 0 020 0 061 mm 0 00079 0 0024 in Service Limit 0 15 mm 0 0059 in lf the camshaft journal diameter is less than the service limit replace the camshaft with a new one and measure the clearance again Camshaft Journal Diameter Standard 22 959 22 980 mm 0 90390 0 90472 in
211. justing nut position from the center of the mounting hole upper Rear Shock Spring Free Length Gas Reservoir High Speed Compression Damping Adjustment Low Compression Damping Adjustment from the seated position adjuster turned fully clockwise Gas Pressure Tie Rod Rocker Arm Sleeve Outside Diameter Tie rod Rocker Arm Large Small Rocker Arm Mounting Bolt Runout Standard Atmospheric pressure 9 clicks counterclockwise 11 clicks counterclockwise KHL15 10 KAYABA 01 or equivalent 335 mL 11 3 US oz 189 mL 6 4 US oz 460 mm 18 1 in 9 clicks counterclockwise 123 5 mm 4 86 in 260 mm 10 2 in 1 1 4 turn out 11 clicks counterclockwise 1 000 kPa 10 kgf cm 145 psi 19 987 20 000 mm 0 78688 0 78740 in 19 987 20 000 mm 0 78688 0 78740 in 15 995 16 000 mm 0 62972 0 62992 in under 0 1 mm 0 004 in Service Limit Adjustable Range 18 clicks Adjustable Range 22 clicks Adjustable Range 300 380 mL 10 1 12 8 US oz 451 mm 17 8 in Adjustable Range 22 clicks Adjustable Range 121 5 138 5 mm 4 783 5 453 in 255 mm 10 0 in Adjustable Range 0 2 turn out Adjustable Range 22 clicks 19 85 mm 0 781 in 19 85 mm 0 781 in 15 85 mm 0 624 in 0 2 mm 0 008 in SUSPENSION 13 7 Special Tools Oil Seal amp Bearing Remover Bearing Remover Shaft 69 57001 1058 57001 1265
212. ke fluid change Every 2 years 2 37 Brake master cylinder cup and dust seal replace Every 2 years 2 39 Brake caliper piston seal and dust seal replace Every 2 years 2 41 Brake hoses replace Every 4 years 2 44 Front fork oil change o e 2 45 Rear shock oil replace o 2 54 Fuel hose replace Every 4 years 2 12 2 4 PERIODIC MAINTENANCE Torque and Locking Agent Tighten all bolts and nuts to the proper torque using an accurate torque wrench If insufficiently tightened a bolt or nut may become damaged strip an internal thread or break and then fall out The following table lists the tightening toque for the major bolts and nuts and the parts requiring use of a non permanent locking agent or liquid gasket When checking the tightening toque of the bolts and nuts first loosen the bolt or nut by half a turn and then tighten to specified torque Letters used in the Remarks column mean AL Tighten the two clamp bolts alternately two times to ensure even tightening torque HL Apply high locking agent L Apply a non permanent locking agent to the threads Lh Left hand Threads MO Apply molybdenum disulfide oil S Tighten the fasteners following the specified sequence Si Apply Silicone grease R Replacement Parts 2T Apply 2 stroke oil T First tighten the stem locknut with 39 N m 4 0 kgf m 29 ft lb of torque then loosen it and retighten it with 4 9 N m 0 50 kgf m 43 in lb of torque Torqu
213. ket TB1211F 92104 0004 e Tighten Torque Magneto Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib e Run the gear position switch lead A and magneto lead according the Cable Wire and Hose Routing section in the Appendix chapter Clamps B e Connect the lead connector e Install the removed parts Flywheel Removal e Remove the magneto cover see Magneto Cover Re moval e Hold the flywheel steady with the flywheel holder A and remove the nut B Special Tool Flywheel Holder 57001 1313 e Remove the flywheel holder ELECTRICAL SYSTEM 16 19 Flywheel Magneto e Screw the rotor pullers A onto the flywheel e Remove the flywheel from the crankshaft by turning in the puller and tapping the head of the bolt lightly with a hammer while holding the puller body steady There is a woodruff key in the crankshaft tapered portion Special Tools Flywheel Rotor Puller 57001 1471 Rotor Puller M16 M18 M20 M22 x 1 5 57001 1216 NOTICE If the flywheel is difficult to remove turn the puller shaft using a wrench while tapping the head of the puller shaft with a hammer Do not attempt to strike the grab bar or the flywheel itself Striking the bar or the flywheel can cause the bar to bend or the magnets to lose their magnetism Flywheel Installation e Using a high flash point solvent clean off any oil or dirt that may be on the crankshaft taper A or in the hole B in the flywheel Dry them with a
214. ket count to the 1st pin Feed the exhaust camshaft thought the chain and align the 29th pin with the timing mark on the inlet camshaft sprocket 6E111528W2 1st Pin A Mark exhaust D 2nd Pin B Punch Mark inlet E 29th Pin C Upper Cylinder Head Surface F e Be sure to install the positioning rings A and dowel pins B e Plug the oil passage and camshaft chain tunnel with a clean cloth for prevent the any parts from dropping in the crankcase 5 20 ENGINE TOP END Camshaft e Apply grease to the rubber portions of the oil pipes e Assemble Camshaft Caps A Oil Pipes B e While keeping parallel install them e Uniformly tighten all bolts and after the camshaft has set tled uniformly tighten all the bolts OFollowing the sequence numbers on the camshaft caps Tighten the cap bolts 1 8 after applying molybdenum disulfide oil to the thread of them Torque Camshaft Cap Bolts 9 8 N m 1 0 kgf m 87 in Ib e Install the camshaft chain tensioner see Camshaft Chain Tensioner Installation then check the camshaft chain timing After this procedure if any resistance is felt while turning over the crankshaft stop immediately and check the camshaft chain timing Valves will be bent if the timing is not properly set e Install the cylinder head cover see Cylinder Head Cover Installation timing inspection cap and the balancer shaft cap Special Tool Filler Cap Dr
215. l light lead A from the clamps B e Unscrew the bolts C and remove the tail light D Tail Light Installation e Installation is the reverse of removal note the following ORoute the harness and leads correctly see Cable Wire and Hose Routing section in the Appendix chapter 16 44 ELECTRICAL SYSTEM Lighting System Headlight Tail Light Circuit Other than Australia Models GP12334BW3 C 1 Headlight 6 Main Fuse 20 A 2 Frame Ground 7 Battery 12 V 6 Ah 3 Flywheel Magneto 8 Tail Light 4 Regulator Rectifier 9 Main Relay 5 Starter Relay 10 IC Igniter ELECTRICAL SYSTEM 16 45 Meter Gauge Meter Unit Removal Installation R e Remove the headlight assy see Headlight Removal In stallation e Remove the mounting nuts A e Slide the boots B and disconnect the meter connector C e Installation is reverse of removal Meter Unit Disassembly Assembly e Remove Screws A Lower Meter Cover B e Remove Screws A Meter Assy B e Assembly is reverse of Disassembly Switch Inspection e Starting the engine causes all the LCD segments the let ters and numbers of the liquid crystal display A illumi nate for 3 seconds SS SSA xlf they do not illuminate check the LCD segments see LCD Segment Inspection 58888 SBEBB SY GP17929BS1 C 16 46 ELECTRICAL SYSTEM Meter Gauge e Check that the display A shifts
216. lightly up with a plastic mallet A to separate the cylin der head B from the cylinder e Remove the cylinder head gasket Cylinder Head Installation e Fit the projection A of the front camshaft chain guide B in the groove C of the cylinder Olnsert the guide end D into the recess E of the crankcase securely e Install Dowel Pins A New Cylinder Head Gasket B e Install the cylinder head OThe camshaft caps are machined with the cylinder head therefore if a new cylinder head is installed use the caps that are supplied with the new head e Apply molybdenum disulfide oil to the both sides A of the 10 mm cylinder head bolt washer and thread B of the 10 mm cylinder head bolts GE14072BS1 ENGINE TOP END 5 25 Cylinder Head e Tighten the 10 mm cylinder head bolts in the numbered sequence 1 4 Torque Cylinder Head Bolts M10 59 N m 6 0 kgf m 44 ft Ib e Tighten Torque Cylinder Bolt A 12 N m 1 2 kgf m 106 in Ib Cylinder Head Bolts M6 B 12 N m 1 2 kgf m 106 in Ib e Install Camshaft see Camshaft Installation Cylinder Head Cover see Cylinder Head Cover Instal lation Engine Bracket C see Engine Installation in the Engine Removal Installation chapter e Connect the Water hose and tighten the hose clamp screw e Install Vacuum Switch Valve see Vacuum Switch Valve Instal lation equipped models Carburetor see Carburetor Installation in th
217. lter and tap with compressed air e Install the filter in the fuel tank e Install the tap and fuel tank Fuel Tap and Filter Inspection e Remove the fuel filter from the fuel tank e Check the fuel filter screens A for any breaks or deteri oration x lf the fuel filter screen have any breaks or is deteriorated it may allow dirt to reach the carburetor causing poor run ning Replace the fuel filter e Remove the fuel tap e Check the fuel tap for fuel leaks e If the fuel tap leaks or allows fuel to flow when it is at OFF position replace the fuel tap Cooling System A WARNING Coolant can be extremely hot and cause severe burns is toxic and very slippery Do not remove the radiator cap or attempt to change the coolant when the engine is hot allow it cool completely Immediately wipe any spilled coolant from tires frame engine or other painted parts Do not ingest coolant 2 18 PERIODIC MAINTENANCE Periodic Maintenance Procedures Coolant Level Inspection NOTE OCheck the level when the engine is cold room or ambi ent temperature e Lean the motorcycle slightly to the left until the radiator cap is level to the ground so that the radiator cap is located uppermost in order to exhaust the air accumulated in the radiator e Remove the radiator cap A NOTE ORemove the radiator cap in two steps First turn the cap counterclockwise to the first stop and wait there for a few seconds Then
218. m 0 3 0 5 in end Clutch Friction Plate Thickness Friction Plate Warp Steel Plate Warp Clutch Spring Free Length Friction Plate Clutch Housing Clearance Clutch Plate Assembly Length 2 92 3 08 mm 0 115 0 121 in 0 15 mm 0 0059 in or less 0 2 mm 0 008 in or less 49 2 mm 1 94 in 0 20 0 60 mm 0 0079 0 024 in 34 9 35 5 mm 1 37 1 40 in Service Limit 2 6 mm 0 10 in 0 3 mm 0 01 in 0 3 mm 0 01 in 46 7 mm 1 84 in 0 8 mm 0 03 in ENGINE RIGHT SIDE 6 7 Special Tools Outside Circlip Pliers Gear Holder m2 0 57001 144 57001 1557 ST5701448T ST571557ST Clutch Holder 57001 1243 C ST5712438T 6 8 ENGINE RIGHT SIDE Clutch Lever and Cable Due to friction plate wear and clutch cable stretch over a long period of use the clutch must be adjusted in accor dance with the Periodic Maintenance Chart A WARNING The engine and exhaust system get extremely hot during normal operation and can cause serious burns Never touch the engine or exhaust pipe during clutch adjustment Clutch Lever Free Play Inspection e Refer to the Clutch Lever Free Play Check in the Periodic Maintenance chapter Clutch Lever Free Play Adjustment e Refer to the Clutch Lever Free Play Adjustment in the Periodic Maintenance chapter Clutch Lever Installation e Install the clutch lever A so that it incline 20 5 B more
219. mage Tighten fasteners to the specified torque using a good quality torque wrench Often the tightening sequence is followed twice initial tightening and final tightening with torque wrench Force Use common sense during disassembly and assembly excessive force can cause expensive or hard to repair dam age When necessary remove screws that have a non permanent locking agent applied using an impact driver Use a plastic faced mallet whenever tapping is necessary Gasket O ring Hardening shrinkage or damage of both gaskets and O rings after disassembly can reduce sealing per formance Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains Install new gaskets and replace used O rings when re assembling Liquid Gasket Non permanent Locking Agent For applications that require Liquid Gasket or a Non permanent Locking agent clean the surfaces so that no oil residue remains before applying liquid gasket or Non permanent locking agent Do not apply them ex cessively Excessive application can clog oil passages and cause serious damage Le f ole leg Por gt 4 AT LA AS ns H d Go vs d Gs 9 Af 66020128 68020138 68020148 68020158 6B02016B_ GENERAL INFORMATION 1 5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place apply small amount of
220. mbly in the subtank when the piston rod extends NOTE OWhen it is hard to screw in the base valve assembly pull down the piston rod a little e Holding the top plug wrench A with a vise e Holding the subtank B with the top plug wrench torque the base valve assembly C Special Tool Top Plug Wrench 49 mm 57001 1653 Torque Base Valve Assembly 28 N m 2 9 kgf m 21 ft Ib e Protect the piston rod end A with a rag B to prevent fork damage e Discharge the extra oil off the cylinder unit by pumping C the piston rod to full stroke Be careful not to bend or damage the piston rod when the piston rod is stroked Service carefully because oil flies out from the oil hole of the cylinder unit NOTE OSet the compression damper setting to the softest OCheck the piston rod sliding surface for damage OApply fork oil to the piston rod sliding surface 13 18 SUSPENSION Front Fork e Drain the extra oil from the subtank oil hole A e With the cylinder unit in horizontal position move A the piston rod B by hand to inspect it if operating smoothly Olf the piston rod is not extend remove the base valve assembly and perform the air bleeding pour the specified amount fork oil and discharge an excess of oil e Completely wipe of the fork oil from the spring A spacer B and cylinder unit C e Insert above mentioned parts into the fork e Temporarily tighten the fork top plug A subtank us
221. mbly with new ones Base Valve Assembly Inspection e Inspect the threads portion A bushing B and spring C of base valve assembly D for damage If they are damaged replace base valve assembly with new one e Replace the O rings E with new ones 6M04254BS1 SUSPENSION 13 21 Front Fork Cylinder Unit Inspection e Inspect the piston rod B of cylinder unit A for scratches or bending lf it has scratches or is bent replace cylinder unit with a new one Inner Tube Inspection e Visually inspect the inner tube A repair any damage e Nick or rust damage can sometimes be repaired by using a wet stone to remove sharp edges or raised areas which cause seal damage lf the damage is not repairable replace the inner tube Since damage to the inner tube damages the oil seal replace the oil seal whenever the inner tube is repaired or replaced e Temporarily assemble the inner A and outer tubes B and pump them back and forth manually to check for smooth operation NOTICE If the inner tube is badly bent or creased replace it Excessive bending followed by subsequent straightening can weaken the inner tube Guide Bush Inspection e Visually inspect the guide bushes A and replace them if necessary Dust Seal Oil Seal Inspection e Inspect the dust seal A for any signs of deterioration or damage Replace it if necessary e Replace the oil seal B with a new one whenev
222. ment e Carefully align the oil passage hole in the right flywheel A with the one in the crankpin B at rebuilding of the crankshaft as shown 6105144BS1 C e Reassemble the crankshaft according to the standard tol erances in Specifications OConnecting rod bend twist OConnecting rod big end radial clearance OCold fitting tolerance between crankpin and flywheels OSide clearance between the connecting rod big end and one of flywheels OCrankshaft runout 9 16 CRANKSHAFT TRANSMISSION Crankshaft Connecting Rod Crankshaft Inspection 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 two gauge readings is the radial clearance Connecting Rod Big End Radial Clearance Standard 0 002 mm 0 014 mm 0 00008 0 0006 in Service Limit 0 06 mm 0 002 in If the radial clearance exceeds the service limit crank shaft should be either replaced or disassembled and crankpin needle bearing and connecting rod big end should be examined for wear Connecting Rod Big End Side Clearance e Measure the connecting rod big end side clearance A Connecting Rod Big End Side Clearance Standard 0 25 0 35 mm 0 0098 0 014 in Service Limit 0 6 mm 0 02 in If the clearance exceeds the service limit replace th
223. minal Locknut 6 9 N m 0 70 kgf m 61 in Ib e Fit the tongue C on the brush plate into the end cover groove e Insert the armature A between the brushes Thin Washer B Thick Washer C e Align the marks A of the yoke B and end covers C Torque Starter Motor Through Bolts 3 4 N m 0 35 kgf m 30 in Ib Carbon Brush Inspection e Measure the length A of each brush lf any one is worn down to the service limit replace the carbon brush holder assembly B Carbon Brush Length Standard 10 mm 0 39 mm Service Limit 6 5 mm 0 26 in Pisses P 16 38 ELECTRICAL SYSTEM Electrical Starter System Commutator Inspection Cleaning e Smooth the commutator surface A if necessary with fine emery cloth B and clean out the grooves GP110610S1 e Measure the outer diameter A of the commutator B Replace the starter motor with a new one if the commu tator diameter is less than the service limit Commutator Diameter Standard 28 mm 1 10 in Service Limit 27 mm 1 06 in Armature Inspection e Using the x 1 Q hand tester range measure the resis tance between any two commutator segments A x lf there is a high resistance or no reading between any two segments a winding is open and the starter motor must be replaced e Using the x kQ hand tester range measure the resistance between the segments and the shaft B x lf there is any reading at all the armature has
224. mm 0 0035 0 0063 in 0 06 0 14 mm 0 0024 0 0055 in 45 32 60 29 4 29 6 mm 1 16 1 17 in 34 4 34 6 mm 1 35 1 36 in 0 8 1 2 mm 0 03 0 047 in 0 5 1 0 mm 0 02 0 039 in TIR 0 05 mm 0 002 in 5 44 mm 0 214 in 5 45 mm 0 215 in 5 58 mm 0 220 in 5 58 mm 0 220 in 0 36 mm 0 014 in 0 33 mm 0 013 in ENGINE TOP END 5 7 Specifications Item Valve Spring Free Length Exhaust Outer Inner Inlet Outer Inner Standard 36 2 mm 1 43 in 32 4 mm 1 28 in 39 3 mm 1 55 in 36 0 mm 1 42 in Service Limit 34 6 mm 1 36 in 30 9 mm 1 22 in 37 8 mm 1 49 in 34 5 mm 1 36 in Cylinder and Pistons Cylinder Inside Diameter Piston Diameter Piston Cylinder Clearance Piston Ring Ring Groove Clearance Top Piston Ring Groove Width Top Piston Ring Thickness Top Piston Ring End Gap Top Oil Piston Pin Diameter Piston Pin Hole Diameter Connecting Rod Small End Inside Diameter 96 000 96 012 mm 3 7795 3 7800 in 95 970 95 980 mm 3 7783 3 7787 in 0 020 0 042 mm 0 00079 0 0017 in 0 04 0 08 mm 0 002 0 003 in 1 03 1 05 mm 0 0406 0 0413 in 0 970 0 990 mm 0 0382 0 0390 in 0 25 0 35 mm 0 0098 0 014 in 0 15 0 50 mm 0 0059 0 020 in 18 991 19 000 mm 0 74768 0 74803 in 19 004 19 010 mm 0 74819 0 74842 in 19 019 19 030 mm 0 74878 0 74921 in
225. move Handlebar Pad A Headlight B see Headlight Removal Installation in the Electrical System chapter e Remove Handlebar Clamp Bolts A Handlebar Clamps B Handlebar C from holder e Loosen the front fork upper clamp bolts A and remove the steering stem head nut B and steering stem head C e Turn the steering stem nut A with the steering stem nut wrench B to obtain the proper adjustment x If the steering is too tight loosen the stem nut a fraction of a turn if the steering is too loose tighten the nut a fraction of a turn Special Tool Steering Stem Nut Wrench 57001 1100 NOTE O Turn the stem nut 1 8 turn at a time maximum e Install the steering stem head e Tighten the following Torque Steering Stem Head Nut 98 N m 10 kgf m 72 ft Ib Upper Front Fork Clamp Bolts 23 N m 2 3 kgf m 17 ft lb NOTE O Tighten the two clamp bolts alternately two times to en sure even tightening torque e Check the steering again If the steering is too tight or too loose repeat the adjust ment as mentioned above PERIODIC MAINTENANCE 2 61 Periodic Maintenance Procedures the protruded scales of the both side adjust to the same width A e Route the hose according to Cable Wire and Hose Rout ing section in the Appendix chapter e Apply 2 stroke oil to the threads of the handlebar clamp bolts e Install the handlebar clamp so that center D of the han dlebar cla
226. mps C and handlebar bridge E align Torque Handlebar Clamp Bolts 25 N m 2 5 kgf m 18 ft Ib Front F e Install the handlebar B on the handlebar holder so that n 6S15026BS1 C e After tighten make sure space A B of the ahead and back are same width e Install the handlebar pad and number plate Stem Bearing Lubrication e Remove the steering stem see Steering Stem Stem Bearing Removal in the Steering chapter e Using a high flash point solvent wash the upper and lower tapered rollers in the cages and wipe the upper and lower outer races which are press fitted into the frame head pipe clean off grease and dirt e Visually check the outer races and the rollers Replace the bearing assemblies if they show wear or damage e Pack the upper and lower tapered roller bearings A in the cages with grease and apply a light coat of grease to the upper and lower outer races e Install the steering stem and adjust the steering see Steering Adjustment 6S15024BS1i C Frame Frame Inspection e Clean the frame with steam cleaner e Visually inspect the frame and rear frame for cracks dents bending or warp lf there is any damage to the frame replace it WARNING A repaired frame may fail in use possibly causing an accident resulting in injury or death If the frame is bent dented cracked or warped replace it GS16003BSi C 2 62 PERIODIC MA
227. n Replace the hose if any fraying cracks C or bulges D are noticed e Check that the hoses are securely connected and clamps are tightened correctly Torque Radiator Hose Clamp Screws 3 0 N m 0 30 kgf m 27 in Ib Engine Top End Vacuum Switch Valve Test U S A California and Canada Models Using the vacuum gauge and a syringe inspect the vac uum switch operation as follows e Remove the vacuum switch valve see Vacuum Switch Valve Removal in the Engine Top End chapter e Connect a vacuum gauge A and syringe B or fork oil level gauge to the vacuum hoses as shown Air Flow C Special Tool Fork Oil Level Gauge 57001 1290 e Gradually raise the vacuum lower the pressure applied to the vacuum switch valve and check the valve opera tion When the vacuum is low the vacuum switch valve should permit air to flow When the vacuum raises to the level shown below the valve should stop air flow When the vacuum is high enough air cannot flow through the valve Spring A Diaphragm B Valve C Low Vacuum D Secondary Air Flow E Air Suction Valve F pp CSS e BO eh 2 6S06027BS1i C GE04069BS1 C GE04070BS1 C 2 20 PERIODIC MAINTENANCE Periodic Maintenance Procedures x If the vacuum switch valve does not operate as described replace it with a new one NOTE OTo check air flow through the vacuum switch valve just blow through the air cleaner hos
228. n stalling the clutch hub C 6 14 ENGINE RIGHT SIDE Clutch e Install the washer so that stamp mark A facing the out side e Tighten the clutch hub nut A with the clutch holder B Special Tool Clutch Holder 57001 1243 Torque Clutch Hub Nut 98 N m 10 kgf m 72 ft lb e Install the friction plates and steel plates starting with a friction plate A and alternating them Finishing with a friction plate Olnstall the friction plates so that the width of the lining blocks B at the plates of the both ends are wider than the other plates OApply engine oil to the new friction plates when it shall be installed NOTICE If dry steel plates and friction plates are installed apply engine oil to the surfaces of each plate to avoid clutch plate seizure e Apply molybdenum disulfide grease to the rubbing portion A of the push rod holder e Install the push rod B and push rod holder e Apply molybdenum disulfide grease to the needle bearing C and adjusting washer D and install them ENGINE RIGHT SIDE 6 15 Clutch e Tighten Torque Clutch Spring Bolts A 8 8 N m 0 90 kgf m 78 in Ib e Install the clutch cover see Clutch Cover Installation e Check the pull rod positions A OPulling B the pull rod C lightly upward by hand and measure the portion of the pull rod coming out Pull Rod Position Standard 9 2 14 4 mm 0 36 0 567 in xklf the rod position is n
229. n and that all circlips and the washers are properly in place e The output shaft gears can be identified by size the largest diameter gear is 1st gear and the smallest is 5th Be sure that all parts are put back in the correct sequence facing the proper direction and that all circlips and washers are properly in place 9 22 CRANKSHAFT TRANSMISSION emeng O Q Armaris Transmission WO 3 amp bb od GI13371BW3 C 1 Circlip 7 5th Gear 21 T 13 4th Gear 19 T 2 Toothed Washer 8 1st Gear 12 T 14 3rd Gear 19 T 3 2nd Gear 15 T 9 Drive Shaft 15 5th Gear 17 T 4 Bushing 10 Output Shaft 16 ist Gear 26 T 5 4th Gear 20 T 11 Collar 6 3rd Gear 16 T 12 2nd Gear 23 T e Check each gear spins or slides freely on the transmission shaft without binding after assembly Shift Fork Bending e Visually inspect the shift forks and replace any fork that is bent A bent fork may cause difficulty in shifting or allow A the transmission to jump out of gear when under power 90 A G113235BS1 CRANKSHAFT TRANSMISSION 9 23 Transmission Shift Fork Gear Groove Wear e Measure the thickness A of the shift fork ears and mea sure the width B of the gear grooves with which the fork engages Shift Fork Ear Thickness Standard 4 9 5 0 mm 0 193 0 197 in Service Limit 4 8 mm 0 19 in Gear Groove Width Standard 5 05 5 15 mm 0 199 0 203 in Service Limit
230. n the other spokes which will eventually cause other spokes to break creating the potential for an accident resulting in serious injury or death Immediately replace any broken spoke s 6J05002BS1 GS11041BS1 PERIODIC MAINTENANCE 2 31 Periodic Maintenance Procedures Rim Runout Inspection e Place the jack under the frame so that the front rear wheel off the ground Special Tool Jack 57001 1238 e Inspect the rim for small cracks dents bending or warp ing lf there is any damage to the rim it must be replaced e Set a dial gauge against the side of the rim and rotate the rim to measure the axial runout A The difference be tween the highest and lowest dial readings is the amount of runout e Set a dial gauge against the outer circumference of the rim and rotate the rim to measure radial runout B The difference between the highest and lowest dial readings is the amount of runout lf rim runout exceeds the service limit check the wheel bearings first Replace them if they are damaged If the problem is not due to the bearings correct the rim warp runout A certain amount of rim warp can be corrected by recentering the rim Loosen some spokes and tighten others within the standard torque to change the position of different parts of the rim If the rim is badly bent however it must be replaced 604061081 Rim Runout with tire installed Standard
231. n and the sprocket 5 18 ENGINE TOP END Camshaft e Remove Bolts A Auto Decompressor B with the sprocket e Remove Circlips A Camshaft Installation e Assemble the auto decompressor weights A and spring B to install it to the sprocket C e Replace the circlips D with new ones and install them e Apply a non permanent locking agent to camshaft sprocket bolts e Fit the recess E of the weight and projections F of the camshaft and install it Torque Camshaft Sprocket Bolts G 12 N m 1 2 kgf m 106 in Ib e Apply molybdenum disulfide oil to the ball bearing all cam and journal surfaces of the camshaft e f the camshaft is replaced with a new part apply a thin coat of molybdenum disulfide grease to the cam and jour nal surfaces e First bring the crankshaft to the TDC of either the com pression or exhaust stroke OPlace a wrench over the flywheel nut and turn it counter clockwise to align the TDC mark A with the center of the groove B of the inspection hole GE11232BS1 ENGINE TOP END 5 19 Camshaft e Engage the camshaft chain with the camshaft sprockets OPull the tension side exhaust side of the chain taut to install the chain OThe timing marks on the sprocket must be aligned with the cylinder head upper surface e Pull the chain taut and fit it onto the camshaft sprocket e Starting with the timing mark on the front of the exhaust sproc
232. nal 20 N m 2 0 kgf m 15 ft lb e Thoroughly warm up the engine wait until the engine cools down and then retighten the exhaust pipe holder nuts and the clamp bolt securely Spark Arrester Cleaning e Refer to the Spark Arrester Cleaning in the Periodic Main tenance chapter GE18079BS1 ENGINE TOP END 5 41 Muffler Exhaust System Inspection e The exhaust system in particular the silencer is designed to reduce exhaust noise and conduct the exhaust gases away from the rider while minimizing power loss If car bon has built up inside the silencer exhaust efficiency is reduced causing engine performance to drop kif the silencer is badly damaged dented cracked or rusted replace it Clean the spark arrester if the exhaust noise becomes too loud or engine performance drops ENGINE RIGHT SIDE 6 1 Engine Right Side Table of Contents Exploded VIEW deene Eege Genee eet eege Eege deg 6 2 EEN 6 6 Special TOONS E 6 7 Clut h Lever and Cable EEN 6 8 Clutch Lever Free Play Inspector 6 8 Clutch Lever Free Play Adjustment AAA 6 8 Gluteh Lever retten is 6 8 Clutch Cable Removal EE 6 8 Gluten Cable Installation nine An RSS Net on ns 6 9 Clutch Cable Inspection and Lubrication cece cece eeeeee cere teases teeters eeeeeneeeeeeeeaeereeea 6 9 Clutch Cover and Right Engine Cover mue EEN 6 10 Gluten Gover ne EE 6 10 Clutch Cover Installation socio das 6 10 Right Engine Cover Removal constata
233. nance Procedures For Rear Brake e Remove Master Cylinder A Hose Clamps B Caliper Cover C e When installing the hoses avoid sharp bending kinking flattening or twisting and route the hoses according to Cable Wire and Hose Routing section in the Appendix chapter e Tighten the banjo bolts on the hose fittings Torque Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft lb e Fill the brake line after installing the brake hose see Brake Fluid Changing Suspension Front Fork Inspection e Holding the brake lever pump the front fork back and forth manually to check for smooth operation e Visually inspect the front fork for oil leakage scoring or scratches on the outer surface of the inner tube A lf necessary repair any damage e Nick or rust damage can sometimes be repaired by using a wet stone to remove sharp edges or raised areas which cause seal damage If the damage is not repairable replace the inner tube Since damage to the inner tube damages the oil seal replace the oil seal whenever the inner tube is repaired or replaced elt the fork is not smooth confirm the cause If the inner tube is badly bent or creased replace it Excessive bending followed by subsequent straightening can weaken the inner tube Front Fork Oil Change each fork leg e Loosen the front fork upper clamp bolts A 2 46 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Loosen the
234. nch A and turn the pin holder clockwise B with another wrench until the cutting and riveting pin touches the link plate e Do the same procedure for removal of the other link pin 11 8 FINAL DRIVE Drive Chain e After riveting check the ends of the riveted pins for cracks e Measure the outside diameter A of the link pin and width B of the link plates Link Pin Outside Diameter Standard 5 5 5 8 mm 0 22 0 23 in Link Plate Outside Width Standard 16 50 16 70 mm 0 650 0 657 in x If the reading is not the specified length cut and rejoin the chain again e Check that the rollers move smoothly e Adjust the drive chain slack after installing the chain see Drive Chain Slack Adjustment in the Periodic Mainte nance chapter GKO4091BS1 FINAL DRIVE 11 9 Sprockets Engine Sprocket Removal e Remove Engine Sprocket Cover Bolts A Engine Sprocket Cover B Drive Chain Guide C e Remove Drive Chain B free of engine sprocket e Flatten the bended sprocket washer A e Remove the engine sprocket nut C and sprocket washer and pull off the engine sprocket D Engine Sprocket Installation e Install the engine sprocket so that the flatten side faces A inside e Replace the sprocket washer with a new one e Install the sprocket washer and sprocket nut Torque Engine Sprocket Nut 127 N m 13 0 kgf m 93 7 ft lb e Bend the one side of the sprocket washer on the
235. ng C Disassembling the cylinder unit can lead to trouble Do not disassemble the cylinder unit PERIODIC MAINTENANCE 2 49 Periodic Maintenance Procedures e Holding the top plug wrench A with a vise loosen the base valve assembly B on the subtank C Special Tool Top Plug Wrench 49 mm 57001 1653 e Remove the base valve assembly A from the subtank B NOTE OSlowly compress the piston rod until it stops so that the base valve assembly can be removed easily NOTICE Disassembling the base valve assembly can lead to SIT P trouble Do not disassemble the base valve assembly e Drain the fork oil A from the cylinder unit B by pumping the piston rod several times e Hold the front fork inverted position for more than 20 min utes to allow the fork oil to fully drain N GM04251BS1 e Clean the threads A of subtank and base valve assem bly 2 50 PERIODIC MAINTENANCE Periodic Maintenance Procedures e With the piston rod in fully compressed position pour the specified amount of fork oil A Recommended Oil KHL15 10 KAYABA01 or equivalent Recommended Quantity 189 ml 6 4 US oz NOTE OPlug the two oil holes on the subtank B with fingers e Pump A the piston rod B slowly several times to expel air e Replace the O rings A on the base valve assembly with new ones e Apply specified fork oil to the O rings A B and bushings
236. ng flattening or twisting and route the fuel hose with a minimum of bending so that the fuel flow will not be ob structed Replace the hose if it has been sharply bent or kinked Throttle Grip Free Play Inspection e Check throttle grip free play A by lightly turning the throt tle grip B back and forth x lf the free play is improper adjust the throttle cable Throttle Grip Free Play Standard 2 3 mm 0 08 0 12 in e Check that the throttle grip moves smoothly from full open to close and the throttle closes quickly and completely in all steering positions by the return spring If the throttle grip does not return properly check the throt tle cable routing grip free play and cable damage Then lubricate the throttle cable e Run the engine at the idle speed and turn the handlebar all the way to the right and left to ensure that the idle speed does not change If the idle speed increase check the throttle cable free play and the cable routing Throttle Grip Free Play Adjustment e Loosen the locknuts A B at the upper end of the throttle cable e Screw both throttle cable adjuster C D to give the throt tle grip plenty of play e Turn out the decelerator adjuster C until there is no play when the throttle grip is completely closed e Tighten the locknut A e Turn the accelerator cable adjuster D until 2 3 mm 0 08 0 12 in of throttle grip play is obtained e Tighten the locknut B
237. ng lip of the seals as they as are pushed down over the inner tube e Install in order these parts on the inner tube e When assembling the new outer tube guide bush A hold the washer against the new one and tap the washer with the fork oil seal driver B until it stops Special Tool Fork Oil Seal Driver 648 57001 1509 e After installing the washer install the oil seal by using the fork oil seal driver Special Tool Fork Oil Seal Driver 648 57001 1509 e Install the retaining ring to the outer tube e Push the dust seal into the outer tube and put the spring band on the dust seal 6M040420S1 13 16 SUSPENSION Front Fork e Clean the threads A of subtank and base valve assem bly e With the piston rod in fully compressed position pour the specified amount of fork oil A Recommended Oil KHL15 10 KAYABAO1 or equivalent Recommended Quantity 189 ml 6 4 US oz NOTE OPlug the two oil holes on the subtank B with fingers e Pump A the piston rod B slowly several times to expel air e Replace the O rings A on the base valve assembly with new ones e Apply specified fork oil to the O rings A B and bushings C on the base valve assembly O D n yt mi o O SUSPENSION 13 17 Front Fork e With the piston rod held immorable in fully compressed position A gently install the base valve assembly B to the subtank e Screw in the base valve asse
238. ning the radiator with steam cleaner be careful of the following to prevent radiator damage Keep the steam gun A away more than 0 5 m 1 64 ft B from the radiator core Hold the steam gun perpendicular to the core surface Run the steam gun following the core fin direction C Radiator Cap Inspection e Check the condition of the valve seals A and the top and bottom valve spring B of the radiator cap If any one of them shows visible damage replace the cap 6D07000BS1i 4 18 COOLING SYSTEM Radiator e Wet the top and bottom valve seals with water or coolant to prevent pressure leaks e Install the cap A on a cooling system pressure tester B e Watching the pressure gauge slowly pump the pressure tester to build up the pressure The gauge hand must remain within the relief pressure range in the table below at least 6 seconds Continue to pump the tester until the relief valve opens indicated by the gauge hand flicking downward The relief valve must open within the specified range Radiator Cap Relief Pressure Standard 112 3 141 7 kPa 1 145 1 445 kgf cm 16 28 20 55 psi x If the cap cannot hold the pressure or if the relief pressure is too high or too low replace the cap with a new one Filler Neck Inspection e Check the radiator filler neck for signs of damage e Check the condition of the top and bottom sealing seats A in the filler neck They must be smooth and cl
239. nob 12 Idle Adjusting Screw 13 Pilot Jet 14 Main Jet 15 Needle Jet 16 Starter Jet 17 Float 18 Leak Jet 19 Throttle Sensor 20 Hot Start Plunger 21 Acceleration Pump Diaphragm 22 Slow Air Jet CL Apply cable lubricant G Apply grease 2T Apply 2 stroke oil R Replacement Parts 3 4 FUEL SYSTEM Exploded View GCO2374BW5 C FUEL SYSTEM 3 5 Exploded View No Fastener Torque N m kgf m ft Ib Remarks Vacuum Switch Valve Bracket Bolts 9 8 1 0 87 in lb Fuel Tap Knob Screws 0 80 0 080 7 0 in lb Rear Frame Mounting Bolts 34 3 5 25 1 2 3 4 5 6 7 8 9 10 11 12 13 AD G O R Fuel Tank Cap Fuel Tank Fuel Tap Element Frame Holder Air Cleaner Duct Air Cleaner Housing Rear Frame U S A California and Canada Models Apply adhesive cement Apply grease High quality foam air filter oil Replacement Parts 3 6 FUEL SYSTEM Specifications Item Standard Throttle Grip and Cable Throttle Grip Free Play 2 3 mm 0 08 0 12 in Hot Starter Lever Free Play 0 5 1 0 mm 0 02 0 04 in Carburetor Make Type KEIHIN FCR MX40 Starter Jet 55 Leak Jet 50 Main Jet 145 Throttle Valve Cutaway 1 5 Jet Needle NLZU EUR AU NCVU Jet Needle Clip Position EUR AU 2th groove from the top Slow Jet 45 Slow Air Jet 100 Pilot Air Screw turns out 2 1 2 EUR
240. ntact e Install the inner valve spring D and outer valve spring E so that the closed coil end faces the spring seat B e Compress the valve springs to install the split keepers G in order to secure the spring retainer F in place Special Tools Valve Spring Compressor Assembly 57001 241 Valve Spring Compressor Adapter 24 57001 1586 e The shim H must be installed with its thickness indication facing up towards the retainer OApply high temperature grease to the shim or to the retainer to prevent the shim from falling off when the camshaft is being installed e Apply engine oil to the valve lifter I surface then install the lifter GE15113BS2 ENGINE TOP END 5 27 Valves Valve Guide Removal e Remove Valve see Valve Removal Oil Seal Spring Seat Heat the area around the valve guide up to 120 150 C 248 302 F Do not heat the cylinder head with a torch This will warp the cylinder head Soak the cylinder head and heat the oil e Hammer lightly on the valve guide arbor A to remove the guide Special Tool Valve Guide Arbor 65 5 57001 1021 GE15070681 Valve Guide Installation e Apply a thin coat of oil to the outer surface of the valve guide e Heat the area around the valve guide up to 120 150 C 248 302 F NOTICE Do not heat the cylinder head with a torch This will warp the cylinder head Soak the cylinder head and heat the oil
241. o be disassembled after removal and compressed air is not available disassemble the caliper before brake hose removal see Caliper Disassembly e Remove the rear wheel see Rear Wheel Removal in the Wheels Tires chapter e Unscrew the banjo bolt and remove the brake hose D from the caliper see Brake Hose Replacement in the Pe riodic Maintenance chapter NOTICE Immediately wipe up any brake fluid that is spilled Caliper Installation e Tighten the brake pad bolts if it was removed Torque Brake Pad Bolt 17 N m 1 7 kgf m 13 ft Ib Front Brake e Install the caliper and tighten the bolts Torque Caliper Mounting Bolts 25 N m 2 5 kgf m 18 ft Ib Rear Brake e Before install the caliper install the rear wheel see Rear Wheel Installation in the Wheels Tires chapter e Install the brake hose lower end OReplace the washers that are on each side of hose fitting with new ones Torque Brake Hose Banjo Bolt 25 N m 2 5 kgf m 18 ft Ib BRAKES 12 13 Caliper e Bleed the brake line see Bleeding the Brake Line e Check the brake for good braking power no brake drag and no fluid leakage A WARNING After servicing it takes several applications of the brake lever or pedal before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the motorcycle until a firm brake lever or pedal is obtained by
242. o the oil seal lip of the crankshaft of the right engine cover e Apply a grease to the kick shaft oil seal lips and kick shaft spline e When installing the cover doesn t go well the cover is installed according to the following procedures OFit the water pump shaft A and groove B of the balancer shaft while turning the water pump shaft e Tighten Torque Right Engine Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib e Insert the water hose A into the water pump cover B and tighten it with the clamp C e Install the kick pedal see Kick Pedal Assy Installation e Install the engine oil drain plugs surely see Engine Oil Change in the Periodic Maintenance chapter e Pour in the specified type and amount of oil see Engine Oil Change in the Periodic Maintenance chapter e Pour in the specified type and amount of coolant see Coolant Filling in the Cooling System chapter e Check the rear brake for good braking power and no brake drag Release Shaft Removal e Remove Clutch see Clutch Removal Magneto Cover see Magneto Cover Removal in the Electrical System chapter Magneto see Magneto Removal in the Electrical Sys tem chapter e Remove the clutch cable upper end see Clutch Cable Removal e Remove the tip A of the clutch cable see Clutch Cable Removal e Remove the tip B of the short cable C from the pull rod D 6 12 ENGINE RIGHT SIDE Clutch Cover and Right Engine Cover e Turn the
243. of the gas reservoir C A WARNING Pressurized nitrogen gas can explode out of the shock reservoir cap if the circlip is not properly in stalled allowing oil and internal parts to burst out of the reservoir with great force and cause serious in jury To avoid injury be sure to install a new circlip UREA in the proper position If the end of the gas reservoir cap and the end of the gas reservoir are not aligned the circlip is not correctly fitted in the groove in the gas reservoir or the circlip is deformed and should be replaced with a new one e Pour KYB K2 C SAE 5W or Bel Ray GEZ 40 oil into the rear shock body to 55 mm 1 77 in A from the lower end of the rear shock body B GMO5068BS2 C 2 58 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Insert the piston end A of the piston rod assembly into the rear shock body C slowly Do not insert the seal assembly B yet Pump the piston rod until all the air is forced out of the rear shock body e Push the seal assembly into the rear shock body until it just clears the circlip groove e Check the circlip x lf it is deformed or damaged replace it with a new one e Fit the circlip A into the groove in the rear shock body B If the circlip is not a certain fit in the groove in the rear shock body the piston rod assembly may come out of the shock absorber when injecting the nitro gen gas or riding
244. olt A and nut e Remove the rear shock absorber upper mounting bolt B nut and pull out the rear shock absorber C down and out Rear Shock Absorber Installation e Pack the rocker arm needle bearings with grease e Apply plenty of 2 stroke oil to the threads of the tie rod front mounting bolts e Tighten the following Torque Rear Shock Absorber Mounting Nut Upper 39 N m 4 0 kgf m 29 ft lb Rear Shock Absorber Mounting Nut Lower 34 N m 3 5 kgf m 25 ft lb Rear Frame Mounting Bolts 34 N m 3 5 kgf m 25 ft lb Tie Rod Mounting Nut Front 59 N m 6 0 kgf m 44 ft lb e Install the removal parts Spring Replacement In addition to the standard spring heavy and light springs are available If the standard spring is improper for your purpose select a proper one according to the rider s weight or course conditions e Remove the rear shock absorber see Rear Shock Ab sorber Removal e Clean the threaded portion on the upper of the rear shock absorber e Hold the lower of the rear shock absorber with a vise SUSPENSION 13 27 Rear Suspension Uni Trak e Using the hook wrenches C loosen the locknut B and turn the adjusting nut A all way up Special Tool Hook Wrench R37 5 R42 57001 1101 GM05195BS1 C e Remove the rear shock absorber from the vise e Slide down the rubber bumper A e Remove the spring guides B from the shock absorber and lift off the spring C e
245. olyte contains sulfuric acid Be careful not to have it touch your skin or eyes If touched wash it off with liberal amount of water and seek medial at tention for more severe burns Interchange A sealed battery can fully display its performance only when combined with a proper vehicle electric system Therefore replace a sealed battery only on a motorcycle which was originally equipped with a sealed battery Be careful if a sealed battery is installed on a motorcycle which had an ordinary battery as original equipment the sealed battery s life will be shortened Battery Date Inspection 0109 06 XxX e Remove the battery see Battery Removal e Check the manufactured date stamp A Day B Month C Year D MFG Code F NOTE ODo refresh charge with the battery that passes one month or more GPO8106BS1 C Charging Condition Inspection OBattery charging condition can be checked by measuring battery terminal voltage with a digital voltmeter A e Remove the seat see Seat Removal in the Frame chap ter e Disconnect the battery terminals Be sure to disconnect the negative cable first e Measure the battery terminal voltage NOTE OMeasure with a digital voltmeter which can be read one decimal place voltage GPO80108S1 l the reading is 12 4 V or more refresh charge is not required however if the read is below the 12 4 V refresh ES charge is required A iss
246. on Terminal Bolt Inspection Starter Relay Inspection Lighting Systemes Headlight Aiming Inspection Headlight Beam Vertical Adjustment Headlight Bulb Replacement Headlight Removal Installation Tail Light Hemoval ee Tail Light Installaton Meter Gauge reee Meter Unit Removal Installation Meter Unit Disassembly Assem Switch Inspection LCD Segment Inspection Switches and Sensors ee Speed Sensor Removal Speed Sensor Installation Speed Sensor Inspection Throttle Position Sensor Removal Installation Switch Inspection Gear Position Switch Removal Gear Position Switch Installation Gear Position Switch Inspection Main Relay o cucuta Main Relay Inspection 16 38 16 38 16 38 16 39 16 39 16 41 16 41 16 41 16 41 16 42 16 43 16 43 16 45 16 45 16 45 16 45 16 47 16 49 16 49 16 49 16 49 16 50 16 50 16 50 16 51 16 52 16 53 16 2 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 16 3 Exploded View Torque N m kgf m ft Ib Spark Plug 13 1 3 115 in lb Ignition Coil Spark Plug Cap Starter Button Engine Stop Switch Starter Lockout Switch Battery Main Relay Igniter Main Harness Regulator Rectifier No Fastener Remarks _
247. ones OApply grease to the lower tapered roller bearing A and drive it onto the stem using the steering stem bearing driver B and adapter C Special Tools Steering Stem Bearing Driver 57001 137 Steering Stem Bearing Driver Adapter 34 5 57001 1074 e Apply grease to the upper tapered roller bearing and in stall it in the head pipe e Install the stem through the head pipe and upper bearing install the stem cap and hand tighten the stem nut while pushing up on the stem base e Install the stem head and washer and tighten the stem head nut lightly e Settle the bearing in place as follows OTighten the stem nut to 39 N m 4 0 kgf m 29 ft lb of torque To tighten the steering stem nut to the specified torque hook the wrench A on the stem nut and pull the wrench at the hole by 22 2 kg force B in the direction shown Special Tool Steering Stem Nut Wrench 57001 1100 OCheck that there is no play and the steering stem turns smoothly without rattles If not the steering stem bearings may be damaged OAgain back out the stem nut a fraction of a turn until it turns lightly OTurn the stem nut lightly clockwise until it just becomes hard to turn Do not overtighten or the steering will be too tight Torque Steering Stem Nut 4 9 N m 0 50 kgf m 43 in Ib GNO504028S1 GNO4012BSi C GNO50605S1 14 8 STEERING Steering e Install the front fork see Front Fork Installation
248. ont Muffler Mounting Bolt Final 20 2 0 15 Exhaust Pipe Holder Nuts 20 2 0 15 Muffler End Mounting Bolts 10 1 0 89 in lb Spark Arrester Mounting Bolts 10 1 0 89 in lb Engine Right Side Primary Gear Nut 98 10 72 Lh R Clutch Cover Bolts 9 8 1 0 87 in lb Right Engine Cover Bolts 9 8 1 0 87 in lb Clutch Spring Bolts 8 8 0 90 78 in lb Clutch Hub Nut 98 10 72 R Ratchet Guide Bolt 8 8 0 90 78 in lb Kick Pedal Bolt 25 25 18 L Ratchet Plate Mounting Bolt 9 8 1 0 87 in lb S Ratchet Plate Mounting Screw 6 4 0 65 56 in lb L S Gear Set Lever Nut 8 8 0 90 78 mb Shift Drum Cam Bolt 24 2 4 18 L Engine Lubrication System Engine Oil Drain Plug M10 Main 20 2 0 15 Engine Oil Drain Plug M6 Sub 7 0 0 71 62 in lb Oil Pump Scavenge Cover Bolts 9 8 1 0 87 in lb Oil Pump Feed Cover Bolts 9 8 1 0 87 in lb Right Engine Cover Bolts 9 8 1 0 87 in lb Piston Oil Nozzle 5 0 0 50 44 in lb Oil Filter Cover Bolt 9 8 1 0 87 in lb Oil Screen Feed Mounting Bolts 9 8 1 0 87 in lb Oil Pressure Relief Valve 15 1 5 11 HL Breather Fitting 15 1 5 11 L Oil Filler Cap Es Hand tighten Engine Removal Installation Upper Engine Mounting Bolts M10 49 5 0 36 Middle Engine Mounting Nut M10 49 5 0 36 Lower Engine Mounting Nut M10 49 5 0 36 Upper Engine Bracket Bolts M8 29 3 0 21 Middle Engine Bracket Nuts M8 29 3 0 EA Swingarm Pivot Shaft Nut 98 10 72 Crankshaft Transmission Crankcase Bolts M6 12 1 2 106 in lb S Crankcase Bolts M
249. oot is not dam aged If the shafts or rubber friction boot are damaged replace the shafts rubber friction boot and the caliper holder 12 14 BRAKES Caliper Brake Pad Removal Front Brake Pad e Unscrew the pad bolt A e Take the piston side pad B e Push the caliper holder toward the piston and then re move another pad C from the caliper holder Rear Brake Pad e Remove Plug A e Unscrew the pad bolt A e Take the piston side pad B e Push the caliper hold toward the piston and then remove another pad C from the caliper holder Brake Pad Installation e Push the caliper pistons in by hand as far as they will go e Install the piston side pad first and then another pad OFit the pad end A into the groove B of the anti rattle spring securely e Tighten the brake pad bolt Torque Brake Pad Bolt 17 N m 1 7 kgf m 13 ft lb Rear Brake Pad Bolt Plug 2 4 N m 0 24 kgf m 21 in Ib e Check the brake for good braking power no brake drag and no fluid leakage A WARNING After servicing it takes several applications of the brake lever or pedal before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the motorcycle until a firm brake lever or pedal is obtained by pumping the lever or pedal until the pads are against the disc Brake Pad Inspection e Refer to the Br
250. or high accuracy Ignition Timing Engine speed r min rpm 1 000 Line mark on flywheel x If the ignition timing is incorrect check the crankshaft sen sor see Crankshaft Sensor Inspection If the crankshaft sensor are normal check the igniter see Igniter Inspection e Install the timing inspection cap Hole groove aligns with 16 26 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Removal e Refer to the Stator Removal Crankshaft Sensor Installation e Refer to the Stator Installation Safety Instructions A WARNING The ignition system produces extremely high volt age Do not touch the spark plug ignition coil or ig nition coil lead while the engine is running or you could receive a severe electrical shock Ignition Coil Removal e Remove Fuel Tank see Fuel Tank Removal in the Fuel System chapter Bolt A Left Radiator Screen B Left Radiator Mounting Bolts C e Push the left radiator backward D e Pry open the clamps A e Disconnect the ignition coil primary lead connector A e Pull the plug cap off the spark plug e Unscrew the mounting bolts B and remove the ignition coil C ELECTRICAL SYSTEM 16 27 Ignition System Ignition Coil Inspection Measuring Arcing Distance The most accurate test for determining the condition of the ignition coil is made by measuring arcing distance using the coil tester for the 3 needle m
251. or notice and without incurring an obligation to make such changes to products manufactured previously See your Motorcycle dealer for the latest information on product improvements incorporated after this publication All information contained in this publication is based on the latest product information available at the time of publication Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts 2007 Kawasaki Heavy Industries Ltd Third Edition 1 Jun 4 2009 K LIST OF ABBREVIATIONS A ampere s lo pound s ABDC after bottom dead center m meter s AC alternating current min minute s ATDC after top dead center N newton s BBDC before bottom dead center Pa pascal s BDC bottom dead center PS horsepower BTDC before top dead center psi pound s per square inch C degree s Celsius r revolution DC direct current rpm revolution s per minute F farad s TDC top dead center F degree s Fahrenheit TIR total indicator reading ft foot feet V volt s g gram s W watt s h hour s Q ohm s liter s COUNTRY AND AREA CODES AU Australia EUR Europe CA Canada US United States CAL California EMISSION CONTROL INFORMATION To protect the environment in which we all live Kawasaki has incorporated crankcase emis sion 1 and exhaust emission 2 control systems in compliance with applicable regulations of the United States Environmental
252. orrect Width B 6E150121S1i GE15012281 6E150123S1 5 32 ENGINE TOP END Valves e The seating area should be marked about in the middle of the valve face If the seat area is not in the right place on the valve check to be sure the valve is the correct part If it is it may have been refaced too much replace it e When the engine is assembled be sure to adjust the valve clearance see Valve Clearance Adjustment in the Peri odic Maintenance chapter ENGINE TOP END 5 33 Valves Valve Seat Repair Machinist s dye on seat 45 Grind Tool 45 Cutter Purpose make seating area smooth and round Measure Seating Area O D Tool Venire Caliper Purpose check seat O D against spec 45 Grind Machinist s dye on seat Tool 45 Cutter Purpose increase O D of seat area to spec 32 Grind Tool 32 Cutter Purpose reduce O D of seat area to spec Measure Seating Width Tool Venire Caliper Purpose check seat width against spec Results Tool 45 Cutter Machinist s dye on seat 55 Grind 45 Grind Purpose increase width of seat area beyond spec to increase O D Tool 55 Cutter Purpose reduce seat width to specification FINISHED GE15117B F 5 34 ENGINE TOP END Cylinder and Piston Cylinder Removal e Remove Cylinder Head see Cylinder Head Remo
253. ot within the standard select the correct thickness of adjusting washer s according to the tables shown Adjusting Washers Thickness Part Number 1 5 mm 92200 1548 1 0 mm 92200 0045 Pull Rod Position and Adjusting Washer Selection Installed Washer Position Length Less than More than 9 2 mm E 14 4mm Washers Thick ness Qty Thikness Qty Qty to fi NG o f 15 fi si EEES to 2 15 1 o ne e Remove the push rod holder assy as necessary and re install the clutch 6 16 ENGINE RIGHT SIDE Clutch Clutch Plate Assembly Free Play Inspection Ad justment e Assemble the following parts Clutch Hub A Friction Plates B Steel Plates C Friction Plates D Spring Plate E Spring F Bolts G OF riction Plates B have lining blocks that are wider than other plates These plates install both end of the all plates Torque Clutch Spring Bolts 8 8 N m 0 90 kgf m 78 in Ib e Measure the clutch plate assembly H Clutch Plate Assembly Length Standard 34 9 35 5 mm 1 37 1 40 in x lf clutch plate length is not within the standard select the correct length of adjusting plates according to the table shown Thickness Part Number 1 2 mm 0 047 in 13089 1010 1 6 mm 0 063 in 13089 1095 2 0 mm 0 079 in 13089 1005 ODo not use the steel plate of 1 2 mm 0 047 in and 2 0 mm 0 079 in thickness at the same time Friction and Steel Plates We
254. otor terminal bolt Meter Unit Connector Black Cap Headlight Connector Black Harness Cable Guide Starter Lockout Switch Connector Green Engine Stop Switch Connector White Starter Button Lead Connector Black Speed Sensor Lead Connector Gray Band Blue Tape Clamp Fix the starter motor cable and battery negative cable by the clamp near the carbu retor side Battery Negative Cable Run the battery negative cable over the harness 17 14 APPENDIX Cable Wire and Hose Routing 6B09762CW5 C APPENDIX 17 15 Cable Wire and Hose Routing Xd dl sss y ch YN OO PS D JO U1 amp D Brake Lever Front Brake Master Cylinder Front Brake Hose Clamp View from A A Clamps Front Brake Caliper Front Brake Disc Brake Pedal Rear Brake Master Cylinder Rear Brake Hose Clamps Rear Brake Caliper Rear Brake Caliper Guard Rear Brake Disc Rear Brake Disc Guard Cotter Pin 17 16 APPENDIX Cable Wire and Hose Routing APPENDIX 17 17 Cable Wire and Hose Routing akON ch JO Breather Hose Fuel Hoses Run the breather hose over the fuel hoses Clamp Stretch to the arrow mark without loosing the hose when mounting the fuel tank Keep the gap of the chain guide roller and hoses Breather Hose Face the painted portion to left side
255. out zero ohms Special Tool Hand Tester 57001 1394 If the switch has an open or short repair it or replace it with a new one Engine Stop Switch Connections Color BK Y BK W oF RUN O O Starter Button Color Y R BR Push O Release GP18352BN3 Starter Lockout Swith Color Y R Clutch Lever Pulled in Oz Released GP18353BN3 Gear Position Switch Removal e Remove Left Radiator Shroud Bolt A Left Radiator Screen B Left Radiator Mounting Bolts C e Push the left radiator backward D ELECTRICAL SYSTEM 16 51 Switches and Sensors e Pry open the clamps A e Disconnect the gear position switch connector e Remove Shift Pedal External Shift Mechanism Removal in the Engine Right Side chapter Screws A Gear Position Switch B e Remove O ring A Gear Position Switch Finger B Spring C Gear Position Switch Installation e Insert the spring into the hole in the shift drum e Insert the switch finger A so that the small diameter B is toward hole side e Apply grease to the O ring e Clean the contact points on the position sensor af e Apply a non parmanent locking agent to the gear position switch screws B S Tighten GP180103S1 Torque Gear Position Switch Screws 2 9 N m 0 30 kgf m 26 in Ib e Install the other removed parts 16 52 ELECTRICAL SYSTEM Switches and Sensors
256. oval in the Brakes chapter e Separate the caliper holder B from the caliper A e Using compressed air remove the piston OCover the caliper opening with a clean heavy cloth A ORemove the piston by lightly applying compressed air B to where the brake line fits into the caliper A WARNING The piston in the brake caliper can crush hands and fingers Never place your hand or fingers in front of the piston e Pull out the piston A by hand e Remove the dust seal B and fluid seal C e Clean the caliper parts except for the pads NOTICE For cleaning of the parts use only disc brake fluid isopropyl alcohol or ethyl alcohol e The bleed valve was removed install the bleed valve and rubber cap Torque Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib e Replace the fluid seal s A with new ones OApply brake fluid to the fluid seal s and install them into the cylinders by hand e Replace the dust seal s B with new ones OApply brake fluid to the dust seal s and install them into the cylinder by hand e Apply brake fluid to the outside of the pistons C and push them into each cylinder by hand PERIODIC MAINTENANCE 2 43 Periodic Maintenance Procedures e Install the anti rattle spring A in the caliper as shown e Replace the shaft rubber friction boot A and dust boot B if they are damaged e Apply a thin coat of PBC Poly Butyl Cuprysil grease to
257. oval raid do e 13 31 TSAO Min EE EE 13 31 Rocker Arm BS ne EE EE 13 31 Rocker Arm Installation cion tine 13 32 Tie Rod and Rocker Arm Bearing Removal 13 32 Tie Rod and Rocker Arm Bearing Installaton 13 33 Needle Bearing Inspeccion in lb a 13 33 Uni Trak Maintenance socials 13 34 Uni Trak Linkage Inspection sss bey sssrscedersqcad sastdaccnetesdeadhcgadel edensatensy deere lacas 13 34 Tie Rod and Rocker Arm Sleeve Wear ntet 13 34 Tie Rod and Rocker Arm Mounting Bolt Bend 13 34 13 2 SUSPENSION Exploded View 6M02198BW5 C SUSPENSION 13 3 Exploded View Torque No Fastener Nem Kate itib Remarks 1 Base Valve Assembly 28 2 9 21 2 Front Fork Top Plug 30 3 1 22 3 Front Fork Clamp Bolts Upper 20 2 0 15 AL 4 Front Fork Clamp Bolts Lower 20 2 0 15 AL 5 Steering Stem Head Nut 98 10 72 6 Locknut Adjuster Assembly 29 3 0 21 7 Adjuster Assembly 55 5 6 41 L 8 Front Axle Clamp Bolts 20 2 0 15 AL 9 Screw 10 O ring 11 Piston Rod 12 Rebound Damping Adjuster Rod 13 Subtank 14 Cylinder Unit 15 Outer Tube 16 Spacer 17 Fork Spring 18 Bushings 19 Washer 20 Oil Seal 21 Retaining Ring 22 Dust Seal 23 Inner Tube 24 O ring 25 Gasket 26 Steering Stem Head 27 Steering Stem AL Tighten the two clamp bolts alternately two times to ensur
258. over Removal e Turn the starter motor clutch gear A by hand The starter motor clutch gear should turn clockwise B freely but should not turn counterclockwise C x If the starter motor clutch does not operate as it should or if it makes noise go to the next step e Disassemble the starter motor clutch and visually inspect the clutch parts If there is any worn or damaged part replace it NOTE OExamine the starter motor clutch gear as well Replace it if it worn or damaged Starter Motor Clutch Disassembly e Remove Flywheel see Flywheel Removal Snap Ring A Circlip B Starter Motor Clutch C Special Tool Inside Circlip Pliers 57001 143 Starter Motor Clutch Assembly e When installing the circlip fit the projections A of the circlip into the slits B of the starter motor clutch Special Tool Inside Circlip Pliers 57001 143 ELECTRICAL SYSTEM 16 25 Ignition Timing Ignition Timing Inspection e Remove the timing inspection cap A Special Tool Filler Cap Driver 57001 1454 e Attach the timing light A to the ignition coil lead in the manner prescribed by the manufacturer Special Tool Timing Light 57001 1241 e Start the engine and aim the timing light at the ignition timing mark B on the flywheel e Run the engine at the speeds specified and note the align ment of the ignition timing marks OCheck the engine speed using the engine revolution tester A f
259. past the nearest hole 6J04034BS1 A WARNING A loose axle nut can lead to an accident resulting in serious injury or death Tighten the axle nut to the proper torque and install a new cotter pin e Check the rear brake NOTE Oln wet and muddy conditions mud sticks to the chain and sprockets resulting in an overly tight chain and the chain may break To prevent this adjust the chain to 58 68 mm 2 28 2 68 in of slack whenever necessary Drive Chain Wear Inspection e Rotate the rear wheel to inspect the drive chain for dam aged rollers and loose pins and links xlf there is any irregularity replace the drive chain x Lubricate the drive chain if it appears dry A Bushing B Roller C Pin D Pin Link E Roller Link F O ring e Stretch the chain taut by hanging a 98 N 10 kgf 20 Ib O weight A on the chain e Measure the length of 20 links B on the straight part C of E the chain from the pin center of the 1st pin to the pin center of the 21st pin Since the chain may wear unevenly take O measurements at several places Chain 20 link Length Standard 317 5 318 2 mm 12 50 12 53 in Service Limit 323 mm 12 7 in 6K040606S1 If any measurements exceed the service limit replace the chain Also replace the front and rear sprockets when the drive chain is replaced d es STi Ae 7 4 Ho e Y Y d f Na KI SSKY e le 2
260. perature 9 C 40 SAO gy op F 4 32 68 104 Units of Length km x 0 6214 mile m x 3 281 ft mm x 0 03937 in Units of Torque N m x 0 1020 kgf m N m x 0 7376 ft lb N m x 8 851 in lo kgf m x 9 807 N m kgf m x 7 233 ft lb kgf m x 86 80 in 1b Units of Pressure kPa x 0 01020 kgf cm kPa x 0 1450 psi kPa x 0 7501 cm Hg kgf cm x 98 07 kPa kgf cm x 14 22 psi cm Hg x 1 333 kPa Units of Speed km h x 0 6214 mph Units of Power kw x 1 360 P kw x 1834 HP PS x 0 7355 kW PS x 0 9863 HP 5 F 40 40 c F 176 212 248 284 40 20 10 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 40 20 0 20 40 C 17 8 4 4 26 7 48 9 80 100 120 440 160 C 71 1 93 3 116 138 PERIODIC MAINTENANCE 2 1 Periodic Maintenance Table of Contents Periodic Maintenance Chart Torque and Locking Agent Specifications sr Special TOONS sudar Z if Periodic Maintenance Procedures Fuel weenst ee eesti deeds Fuel Hose and Connection Inspection BEE Throttle Grip Free Play Inspection Throttle Grip Free Play Adjustment Hot Starter Lever Free Play ee A Idle Speed Inspection ss ssesnn Idle Speed Adiustment Air Cleaner Element Cleaning and Inspection A eege geed ege Fuel Inspechon Fuel Tank Filter and Tap Cleaning cece eeeeeeeeeeeeeeteeeeeeees
261. ploded View FR S AT NEO Ze Bn Ser 00 q SCH YE x Ox e JI re CRANKSHAFT TRANSMISSION 9 3 Exploded View Torque No Fastener SE EA 8 8 7 0 Pao 18 E ony Ryo P Engine Oil Drain Plug SC Man 20 20 15 Shift Drum Cam Bolt 24 2 4 18 Piston Oil Nozzle Bearing Retaining Screws Balancer Weight Mounting Nut 10 Gear Position Switch Screws 2 9 0 30 26 in lb L 11 Copper Washer EO Apply engine oil G Apply grease HG Apply high temperature grease L Apply a non permanent locking agent LG Apply liquid gasket R Replacement parts S Tighten the fasteners following the specified sequence o COIN 9 4 CRANKSHAFT TRANSMISSION Specifications Clearance Clearance Item Connecting Rods Connecting Rod Big End Radial Connecting Rod Big End Side Crankshaft Runout Connecting Rod Bend Connecting Rod Twist Standard 0 002 0 014 mm 0 00008 0 0006 in 0 25 0 35 mm 0 0098 0 014 in TIR 0 03 mm 0 001 in or less Service Limit 0 06 mm 0 002 in 0 6 mm 0 02 in TIR 0 08 mm 0 003 in TIR 0 2 mm 0 08 in 100 mm 3 94 in TIR 0 2 mm 0 08 in 100 mm 3 94 in Transmission TIR Total Indicator Readings Shift Fork Ear Thickness Gear Shift Fork Groove Width Shift Fork Guide Pin Diameter Shift Drum Groove Width 4 9 5 0 mm 0 193 0 197 in 5 05 5 15 mm 0 199 0 203 in 5
262. plug cap then touch the engine with it NOTE OMeasure the voltage with each lead connected cor rectly The correct value may not be obtained if disconnected OMaintain the correct value of compression pressure for the cylinder Be sure to measure the voltage with the spark plug install to the cylinder head e Connect the peak voltage adapter B between the termi nal of primary lead orange and ground connection of the unit with the lead of the ignition coil C connected OSet the tester to DC 250 V range Special Tools Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Needle Adapter Set 57001 1457 Connection Adapter Positive Ground Lead D Adapter Negative Orange Lead E IC Igniter F Needle Adapter G GP10425BS1 ELECTRICAL SYSTEM 16 29 Ignition System e Shift the gear to the neutral position e Crank the engine by kicking the kick pedal and by push ing the starter button several times to measure the peak voltage of the primary ignition coil Ignition Coil Primary Peak Voltage Standard 128 V or above Kick starter 110 V or above Electric starter A WARNING Electrical equipment can cause serious electrical shock To avoid being shocked do not touch the metal portion of the probe when measuring voltage xklf the voltage is less than the specified value check the ignition coil see Ignition Coil Inspection lf the ignition co
263. possible cause for each problem listed it is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties Engine Doesn t Start Starting Difficulty Starter motor not rotating Starter lockout switch trouble Starter motor trouble Battery voltage low Starter relay not contacting or operating Starter button not contacting Wiring open or shorted Engine stop switch trouble Fuse blown Starter motor rotating but engine doesn t turn over Starter clutch trouble Engine won t turn over Valve seizure Valve lifter seizure Cylinder piston seizure Crankshaft seizure Connecting rod small end big end seizure Transmission gear or bearing seizure Camshaft seizure Starter idle gear seizure Kick shaft return spring broken Kick ratchet gear not engaging No fuel flow No fuel in tank Fuel tank cap air vent obstructed Fuel tap clogged Fuel tap turned off Fuel line clogged Carburetor float valve clogged Engine flooded Fuel level in carburetor float bowl too high Float valve worn or jammed with foreign matter Starting technique faulty When flooded crank the engine with the hot start opened to allow more air to reach the engine Fuel air mixture incorrect Pilot screw and or idle adjusting screw mal adjusted Pilot jet or air passage clogged Air cleaner clogged poorly sealed or miss ing Starter jet clogged No spark spark weak Spark plug dirty broken or gap malad justed Spark plug cap or hig
264. ps A see Camshaft Removal in the Engine Top End chapter e Remove the camshafts B see Camshaft Removal in the Engine Top End chapter e Remove the valve lifters C of the applicable valve e Remove the shims D from the top of the spring retainer NOTE OMark and record the locations of the valve lifters and shims so that they can be reinstalled in their original positions e Clean the shim to remove any dust or oil e Measure the thickness of the removed shim A e Select a new shim thickness calculation as follows A B C D A Replace Shim Thickness B Measured Valve Clearance C Specified Valve Clearance D Present Shim Thickness Example 0 31 mm 0 10 0 15 mm 2 60 mm 2 81 2 76 mm OExchange the shims for the 2 775 or 2 800 size shim NOTICE Don t use the shims for another models This could cause wear of the valve stem end and valve stem damage 2 22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Adjustment shims Wee P No Mark Kl P No Mark 2 00 92025 1870 o 255 92025 1881 2 05 5 2 575 92025 1985 2 10 92025 1872 10 92025 1882 2 15 92025 1873 15 92180 1059 2 20 92025 1874 20 92025 1883 65 2 25 92025 1875 25 2 675 92180 1194 68 sie e 2 35 5 2 92025 1877 35 2 725 92180 1195 73 2 375 2 425 92025 1982 43 2 80 92025 1886 80 2 475 92025 1983 48 2 90 92025 1888 90 5
265. pter 3 10 FUEL SYSTEM Throttle Grip and Cable Hot Starter Cable Removal e Slide the clutch lever dust cover A back e Loosen the locknut B e Turn in the adjuster C fully e Remove the cable end D from the hot starter lever E e Remove Fuel Tank see Fuel Tank Removal e Unscrew the plunger cap bolt A and remove the cable end e Disassemble the cable end from the plunger A Spring B Plunger Cap Assy C e Remove Clamps A Open Hot Starter Cable B d GC04022B51 Hot Starter Cable Installation e Install the hot starter cable in accordance with the Cable Wire and Hose Routing section in the appendix chapter e After the installation adjust the cable properly A WARNING Operation with improperly adjusted incorrectly routed or damaged cables could result in an unsafe riding condition Follow the service manual to be make sure to correct any of these conditions Hot Starter Lever Free Play Inspection e Refer to the Hot Starter Lever Free Play Inspection in the Periodic Maintenance chapter FUEL SYSTEM 3 11 Throttle Grip and Cable Hot Starter Lever Free Play Adjustment e Refer to the Hot Starter Lever Free Play Inspection in the Periodic Maintenance chapter Hot Starter Cable Lubrication e Whenever the hot starter cable is removed or in accor dance with the Periodic Maintenance Chart lubricate the these cable see Lubrication in the Periodic M
266. pumping the lever or pedal until the pads are against the disc Caliper Disassembly e Refer to the Caliper Piston Seal and Dust Seal Replace ment in the Periodic Maintenance chapter Fluid Seal Damage The fluid seal around the piston maintains the proper pad disc clearance If this seal is not in good condition 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 condi tions a fluid leakage around the pad b brakes over heat c there is a large difference in left and right pad wear d the seal is stuck to the piston If the fluid seal is replaced replace the dust seal as well Also replace all seals every other time the pads are changed Dust Seal and Cover Damage e Check that the dust seals and covers are not cracked worn swollen or otherwise damaged lf they show any damage replace them Piston Cylinder Damage e Visually inspect the piston and cylinder surfaces x Replace the cylinder and piston if they are badly scored or rusty Caliper Holder Shaft Wear The caliper body must slide smoothly on the caliper holder shafts If the body does not slide smoothly one pad will wear more than the other pad wear will increase and con stant drag on the disc will raise disc and brake fluid temper ature e Check too see if the caliper holder shafts are not badly worn or stepped or the rubber friction b
267. r holder and the air cleaner duct to keep dirt or other foreign material from entering A WARNING If dirt or dust is allowed to pass through into the carburetor the throttle may become stuck possibly causing accident Replace the air cleaner element according to the maintenance chart If dirt gets through into the engine excessive en gine wear and possibly engine damage will occur Carburetor Installation e Install Throttle Cables see Throttle Cable Replacement Hot Start Plunger see Hot Starter Cable Installation e Tighten Torque Throttle Pulley Cover Bolt 3 4 N m 0 35 kgf m 30 in Ib Throttle Cable Mounting Bolts 6 9 N m 0 70 kgf m 61 in Ib e When installing the carburetor into the carburetor holder fit the projection A of the carburetor with the groove B on the holder OFit the claw A of the clamp onto the groove B of the inlet duct e Tighten the clamps securely e Route the air vent and overflow hoses properly see Cable Wire and Hose Routing Section in the Appendix chapter Always keep the hoses free of obstruction and make sure they do not get pinched by the chain or shock absorber e Connect the throttle sensor connector e After installing the carburetor do the following OTurn the fuel tap to the ON position and check for fuel leakage from the carburetor A WARNING Fuel spilled from the carburetor is hazardous GC06124BS1
268. r neck e Install the radiator cap e Check the cooling system for leaks A 6 6D04016BS1 COOLING SYSTEM 4 11 Coolant Cooling System Pressure Testing NOTICE During pressure testing do not exceed the pres sure for which the system is designed to work The maximum pressure is 141 7 kPa 1 445 kgf cm 20 55 psi e Remove the radiator cap and install a cooling system pressure tester A and adapter B on the radiator filler neck C NOTE OWet the adapter cap sealing surfaces with water or coolant to prevent pressure leaks e Build up pressure in the system carefully until the pres sure reaches 141 7 kPa 1 445 kgf cm 20 55 psi e Watch the gauge for at least 6 seconds If the pressure holds steady the cooling system is all right e Remove the pressure tester replenish the coolant and install the radiator cap lf the pressure drops and no external source is found check for internal leaks Check the cylinder head gasket for leaks Cooling System Flushing Over a period of time the cooling system accumulates rust scale and lime in the water jacket and radiator When this accumulation is suspected or observed flush the cool ing system If this accumulation is not removed it will clog up the water passages and considerably reduce the effi ciency of the cooling system e Drain the cooling system e Fill the cooling system with fresh water mixed with
269. raightedge and the head If warp exceeds the service limit repair the mating sur face Replace the cylinder head if the mating surface is e badly damaged CSO Lis Cylinder Head Warp Service Limit 0 05 mm 0 002 in e Remove the valves see Valve Removal in the Engine Top End chapter e Scrape the carbon out of the combustion chamber and exhaust port with a scraper A or a suitable tool e Clean the cylinder head using high flash point solvent e Blow out any particles which may obstruct the oil passage in the cylinder head using compressed air e Install the valves see Valve Installation in the Engine Top End chapter Cylinder Wear Inspection NOTE OMeasure the cylinder inside diameter when the cylinder is cold room or ambient temperature e Visually Inspect the inside of the cylinder for scratches and abnormal wear x lf the cylinder is damaged or badly worn replace it with a new one e Since there is a difference in cylinder wear in different di rections take a side to side and a front to back measure ment shown in the figure lf any of the cylinder inside diameter measurements ex ceeds the service limit the cylinder must be replaced with a new one since the PLATING cylinder cannot be bored or honed A 10 mm 0 39 in B 30 mm 1 2 in C 50 mm 2 0 in 6S07067BS1i C Cylinder Inside Diameter Standard 96 000 96 012 mm 3 7795 3 7800 in Service Limit 96 10 mm 3 783 in
270. release lever shaft A and remove the short ca ble B from the lever e Pull the lever and shaft assembly C out of the crankcase Release Shaft Installation e Apply grease to the oil seal lips e Apply engine oil to the bearing in the hole of the crankcase e Apply molybdenum disulfide grease to the part where the push rod comes in contact e Insert the release shaft straight into the hole of the crankcase NOTICE When inserting the release shaft be careful not to remove the spring of the oil seal e Install the removed parts ENGINE RIGHT SIDE 6 13 Clutch Clutch Removal e Drain the engine oil see Engine Oil Change in the Peri odic Maintenance chapter e Remove the clutch cover see Clutch Cover Removal e Remove Clutch Spring Bolts A Clutch Springs Clutch Spring Plate B e Remove Adjusting Washer A Needle Bearing B Push Rod Holder C Push Rod Friction Plates D Steel Plates E e Fix the clutch hub A with the clutch holder B Special Tool Clutch Holder 57001 1243 e Loosen the clutch hub nut C counterclockwise e Remove Washer Clutch Hub Toothed Washer A Clutch Housing B Clutch Installation e Check the clutch plate assembly free play see Clutch Plate Assembly Free Play Inspection Adjustment e Apply molybdenum disulfide oil to the inside of the clutch housing gear e Install the clutch housing A e Do not forget to install the toothed washer B before i
271. riteria Judgement 12 8 V or higher Good 12 0 lower than 12 8 V Charge insufficient Recharge lower than 12 0 V Unserviceable Replace Charge Time h 0 11 5 13 0 Battery Terminal Voltage v GPOBOT2BS1 C O sy RC ES E EE ET 12 0 12 5 Alla vB A AI lan 6P08022BS1 ELECTRICAL SYSTEM 16 17 Flywheel Magneto Magneto Cover Removal e Remove Left Radiator Shroud Bolt A Left Radiator Screen B Left Radiator Mounting Bolts C e Push the left radiator backward D e Pry open the clamps A e Drain the engine oil from the crank room oil sump see Engine Oil Change in the Periodic Maintenance chapter e Pull the stopper A to the this side to remove the magneto lead connector B e Disconnect the magneto lead connector from the main harness e Remove Torque Limiter A see Torque Limiter Removal Installa tion in the Crankshaft Transmission chapter Bolt B Left Engine Guard C Breather Hose D e Remove the shift pedal see External Shift Mechanism Removal in the Engine Right Side chapter e Remove Magneto Cover Mounting Bolts A Magneto Cover B 16 18 ELECTRICAL SYSTEM Flywheel Magneto Magneto Cover Installation e Replace the gasket A with a new one e Be sure to install the dowel pins B e Apply silicone sealant to the area A to the magneto lead grommet Sealant Liquid Gas
272. rque wrench whose length gives leverage of approximately 310 mm between the grip point to the center of the coupling square 6M04254BS1i 2 54 PERIODIC MAINTENANCE Periodic Maintenance Procedures Rear Shock Absorber Inspection e Bounce A the rear of the motorcycle up and down and check for smooth suspension stroke e Remove the rear frame See Rear Frame Removal in the Frame chapter e Check for a broken or collapsed spring e Check the shock for a bent shaft or oil leaks If the shock does not smoothly or damaged replace or repair defective parts Rear Shock Absorber Oil Change The oil should be changed in the rear shock absorber at least once per racing season The frequency for best per formance must be based upon riding conditions and rider ability e Remove the rear shock absorber from the frame see Rear Shock Absorber Removal in the Suspension chap ter e Remove the shock absorber spring see Spring Replace ment in the Suspension chapter e Pointthe valve A away from you slowly release nitrogen gas pressure by pushing down the valve core with a screw driver A WARNING The shock contains high pressure nitrogen gas that when suddenly released can eject oil and internal shock parts at high velocity causing serious injury To avoid injury do not point the reservoir valve to ward your face or body when releasing nitrogen gas pressure since an oil mist is often released with the nitrogen
273. rter Cable Eet e EE 3 11 Hot Starter Cable Inspection cda eterna 3 11 ASUS te gd att eae ccc cut ack hea a eee ceca cate acetoacetate OEE TETTE 3 12 Idle Speed Inspection EE EEN 3 12 LUIS Speed AdIESIME NE 2e RNA O 3 12 Service Fuel Level Inspection WEN 3 12 Service Fuel Level AUS ME SE es crete eege d e EE 3 13 Carburetor le EEN 3 14 Carb retor heel EE 3 16 TN EE 3 17 Carburetor DISASSEMBLY miosina die 3 17 Carbur tor Cleaning acs at ne te alii wee Seat 3 20 Carburetor Inspection dai 3 21 Carburetor ASSO MADLY EE 3 22 Lige 3 28 Air Cleaner Housing Remo EE 3 28 Air Cleaner Housing Installation 3 28 Element AG IMOVA EE 3 28 ElementinstallatiO a il erer 3 29 Element Cleaning and Inspection mari id iia pla cis 3 29 eh Eege eegen ee eg eg ee EEN 3 30 Fuel Tank Removal sic sens g DEE AER iaa 3 30 Fuel Tank Installati n casita ted placa 3 30 Fuel Filter Removal oia aii 3 30 ST Tt IMStallatiOn ca EE 3 30 Fuel Tank Filter and Tap Gleaning sss units 3 31 Fuel Tap and Filter Inspection fret mA nee ee ess 3 31 3 2 FUEL SYSTEM Exploded View FUEL SYSTEM 3 3 Exploded View No Fastener sande Remarks N m kgf m ft lb Throttle Pulley Cover Bolt 3 4 0 35 30 in lb Throttle Cable Mounting Bolts 6 9 0 70 61 in lb 7 2 3 Hot Starter Cable 4 Throttle Cables 5 Throttle Grip 6 Carburetor Cap 7 Throttle Valve Plate 8 Throttle Valve 9 Jet Needle 10 Throttle Pulley Shaft 11 Choke K
274. rts can damage them OTroubles may involve one or in some cases all items Never replace a defective part without determining what CAUSED the failure If the failure was caused by some other item or items they too must be repaired or replaced or the new replacement will soon fail again OMake sure all connectors in the circuit are clean and tight and examine wires for signs of burning fraying etc Poor wires and bad connections will affect electrical system op eration OMeasure coil and winding resistance when the part is cold at room temperature OElectrical Connectors A Connectors B Connectors Safety Instructions A WARNING The ignition system produces extremely high volt age Do not touch the spark plug ignition coil or ig nition coil lead while the engine is running or you could receive a severe electrical shock GP060101S1 6P0601028S1 ELECTRICAL SYSTEM 16 13 Electrical Wiring Wiring Inspection e Visually inspect the wiring for signs of burning fraying etc lf any wiring is poor replace the damaged wiring e Pull each connector A apart and inspect it for corrosion dirt and damage x lf the connector is corroded or dirty clean it carefully If it is damaged replace it e Check the wiring for continuity OUse the wiring diagram to find the ends of the lead which is suspected of being a problem OConnect an ohmmeter between the ends of the lead
275. ry connected Battery Connection Tester Connection Tester Reading MA 0 1 2 3 5 0 Apply positive lead gt Apply negative lead 16 54 ELECTRICAL SYSTEM Fuses Main Fuse 20 A Removal e Remove the seat see Seat Removal in the Frame chap ter e Disconnect the starter relay connector A e Remove the main fuse B from the starter relay Main Fuse 20 A Inspection e Remove the fuse see Main Fuse 20 A Removal and in spect the fuse element lf the fuse element is blown replace the fuse Housing A Fuse Element B Terminal C Blown Element D GP20000181 When replacing a fuse be sure the new fuse matches the specified fuse rating for that circuit Installation of a fuse with a higher rating may cause damage to wiring ad components APPENDIX 17 1 Appendix Table of Contents Cable Wire and Hose Routing eegene nn a don ann EA 17 2 lege lte BEE 17 25 17 2 APPENDIX Cable Wire and Hose Routing APPENDIX 17 3 Cable Wire and Hose Routing Starter Button Lead Throttle Cables Marked AAA cable is accelerator side Bands Brake Hose Engine Stop Switch Lead Starter Lockout Switch Lead Hot Starter Cable Clutch Cable Harness Cable Guide Starter Lockout Switch Connector Green Engine Stop Switch Connector White Starter Button Lead Connector Black Meter Unit Lead Run the
276. s OSet the meter to the x 1 Q range and lead the meter xlf the meter does not read 0 Q the lead is defective Re place the lead or the wiring harness if necessary GPO7030BS1 C 16 14 ELECTRICAL SYSTEM Battery Battery Removal e Remove the seat see Seat Removal in the Frame chap ter e Disconnect the negative cable A and then positive cable B Be sure to disconnect the negative cable first e Remove the battery holder bolts C and holder D e Remove the battery Battery Installation e Visually inspect the surface of the battery container If any signs of cracking or electrolyte leakage from the sides of the battery e Put the battery into the battery case e Install the battery holder and tighten the bolts e Connect the positive cable A to the terminal first and then the negative cable B to the terminal e Apply a light coat of grease on the terminals to prevent corrosion e Cover the terminal with the cap 088149 P Precautions 1 No need of topping up No topping up is necessary in this battery until it ends its life under normal use Forcibly prying off the seal cap to add water is very dangerous Never do that 2 Refreshing charge Give refresh charge for 5 to 10 hours with charge current shown in the specification see Re freshing Change When a fast charge is inevitably required do it following precisely the maximum charge current
277. s e Install the stator and tighten it Torque Stator Bolts 4 0 N m 0 41 kgf m 35 in Ib e Install the crankshaft sensor and wiring holder A ORun the magneto leads under the holder and sensor Torque Crankshaft Sensor Bolts 7 0 N m 0 71 kgf m 62 in Ib e Apply silicone sealant around the circumference of the wiring grommet Sealant Liquid Gasket TB1211F 92104 0004 e Set the stator wiring grommet B securely in the notch C e Install the magneto cover see Magneto Cover Installa tion Flywheel Inspection e There are three types of magneto problems short open wire burned out or loss in flywheel 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 flywheel which may be caused by dropping or hitting the flywheel by leaving it near an electromagnetic field or just by aging will result in low output e Check the magneto output voltage do the following pro cedures ORemove the left radiator shroud OPull the stopper A to the this side and remove the mag neto lead connector B ELECTRICAL SYSTEM 16 21 Flywheel Magneto OConnect the hand tester A to the connector B as shown in the table 1 using the needle adapter set C OStart the engine ORun it at the rpm given in the table 1 ONote the voltage readings total 2 measurements Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 145
278. s x lf the steering stem shaft is bent A replace the steering stem GNO4013BS1 STEERING 14 9 Handlebar Handlebar Removal e Remove Clutch Holder A Engine Stop Switch B Clamps C Left Handlebar Grip D e Remove Throttle Grip Assy A see Throttle Cable Replacement in the Fuel System chapter Master Cylinder B see Front Master Cylinder Removal in the Brakes chapter Clamps C Handlebar Pad D e Remove Handlebar Clamp Bolts A Handlebar Clamps B Handlebar C Handlebar Installation e Apply adhesive cement to the inside of the left handlebar grip e Install the left handlebar grip so that the projection A on the grip face to the upward e Install the clutch lever A so that it incline 20 5 B more than the horizontal line C and position it from the edge of the grip to 170 mm 6 69 in D GR110040 1 C 14 10 STEERING Handlebar e Apply grease to the throttle cable upper end and clutch cable upper end e Apply a 2 stroke oil to the throttle grip inner wall A e Install the throttle grip assy so that the grip A is in as far as it will go e Position the throttle grip assy so that the parting line B of the throttle case vertically and tighten the screws e Install the front master cylinder see Front Master Cylinder Installation in the Brakes chapter e Install the handlebar B on the handlebar holder so that the protruded scales of
279. sc Mounting bolts 10 N m 1 0 kgf m 89 in Ib Rear Brake Disc Mounting bolts 23 N m 2 3 kgf m 17 ft lb Brake Disc Inspection e Visually inspect the disc A If it is scratched or damaged replace the disc e Measure the thickness of each disc at the point B where it has worn the most Replace the disc if it has worn past the service limit Thickness Standard Front 2 85 3 15 mm 0 112 0 124 in Rear 3 85 4 15 mm 0 152 0 163 in Service Limit Front 2 5 mm 0 10 in Rear 3 5 mm 0 14 in e Place a jack under the motorcycle so that the front rear wheel is raised off the ground Special Tool Jack 57001 1238 e Set up a dial gauge against the disc A as illustrated OFor the front disc turn the handlebar fully to one side e Measure the disc runout while rotating the wheel slowly B K ihe runout exceeds the service limit replace the disc Runout Standard TIR 0 25 mm 0 0098 in or less Service Limit TIR 0 3 mm 0 01 in GL08024BS1 GLO8025BS1 BRAKES 12 19 Brake Hose Brake Hose Removal Installation e Refer to the Brake Hose Replacement in the Periodic Maintenance chapter Brake Hose Inspection e Refer to the Brake Hose and Connection Check in the Periodic Maintenance chapter SUSPENSION 13 1 Suspension Table of Contents e KE 13 2 Specification Sen stl hk EE 13 6 Ee OOS eeneg eieiei eege 13 7 Pront FER eegene EE cede ag on cea eee ea
280. sembling the carburetor check the fuel level see Service Fuel Level Inspection If the fuel level is incorrect inspect the rest of the carbu retor before correcting it e Turn the throttle pulley to check that the throttle valve A moves smoothly and returns by spring pressure x lf the throttle valve does not move smoothly Replace the throttle valve or pulley spring e Disassemble the carburetor see Carburetor Disassem bly e Clean the carburetor see Carburetor Cleaning e Check the tapered portion A of the pilot air screw B for wear or damage If the pilot air screw is worn or damaged on the tapered portion it will prevent the engine from idling smoothly Replace the carburetor 6C060144S1 C 3 22 FUEL SYSTEM Carburetor e Remove the float valve needle e Check the plastic tip A of the float valve needle B for wear x If the needle is worn as shown right C replace the valve needle e Push the rod D in the valve needle then release it lf the rod does not come out fully by spring tension re place the valve needle Push and release E e Remove the starter jet e Check the slow jet for any damage If the slow jet is damaged replace it with a new one e Remove the throttle valve and jet needle e Inspect the outside of the throttle valve and plate for scratches and abnormal wear If it is badly scratched or worn replace the throttle valve or plate e Inspe
281. spection Regulator Rectifier Inspection Starter Motor Clutch ooooccccccccccccccnnos Starter Motor Clutch Removal Installation Starter Motor Clutch Inspection Starter Motor Clutch Disassembly Starter Motor Clutch Assembly Ignition TIMING Ignition Timing Inspection Ignition System Crankshaft Sensor Removal Crankshaft Sensor Installation Safety Instructions Ignition Coil Removal Ignition Coil Inspection Spark Plug Cleaning and WES DQ CUON EE Spark Plug Gap Inspection Igniter Hemoval Igniter Inspection Throttle Position Sensor Resistance Inspection 16 11 16 12 16 13 16 13 16 14 16 14 16 14 16 14 16 15 16 15 16 16 16 17 16 17 16 18 16 18 16 19 16 20 16 20 16 20 16 22 16 22 16 24 16 24 16 24 16 24 16 24 16 25 16 25 16 26 16 26 16 26 16 26 16 26 16 27 16 27 16 28 16 28 16 28 16 33 Throttle Position Sensor Position Adjustment Crankshaft Sensor Inspection Electrical Starter System snneannn Starter Motor Removal Starter Motor Installation Starter Motor Disassembly Starter Motor Assembly Carbon Brush Inspection Commutator Inspection Cleaning Armature Inspection Brush Lead Inspecti
282. speed This fills the oil filter with oil ODo not run the engine at high engine speed Stop the engine then wait several minutes until the oil settles NOTICE Racing the engine before the oil reaches every part can cause engine seizure lf the oil level is too high remove the excess oil through the filler opening using a syringe or some other suitable device xlf the oil level is too low add the correct amount of oil through the oil filler opening Use the same type and make of oil that is already in the engine NOTE Off the engine oil type and make are unknown use any brand of the specified oil to top off the level rather than running the engine with the oil level low Then at your earliest convenience change the oil completely Engine Oil Change e Refer to the Engine Oil Change in the Periodic Mainte nance chapter ENGINE LUBRICATION SYSTEM 7 9 Engine Oil and Oil Filter Oil Filter Change e Refer to the Oil Filter Change in the Periodic Maintenance chapter 7 10 ENGINE LUBRICATION SYSTEM Oil Screen Oil Screen Scavenge Removal e Remove the oil pump scavenge cover see Oil Pump Scavenge Removal e Pull out the oil screen A from the crankcase Oil Screen Scavenge Installation e Clean the oil screens thoroughly whenever it is removed for any reason e Clean the oil screens with a high flash point solvent and remove any particles stuck to them A WARNING Gasoline and low fl
283. stall them noting the direction shown Olnstall each shift forks with its mark A facing the engine left side Marks 43 Drive shaft 47 Output shaft e Assembly the crankcase see Crankcase Assembly OFit each shift fork guide pin into the corresponding groove in the shift drum OApply a small amount of engine oil to the shift rods and slide them into the shift forks OAssembly the crankcase see Crankcase Assembly Transmission Shaft Disassembly e Remove the transmission shafts e Remove the circlips washers then gears Special Tool Outside Circlip Pliers 57001 144 e Do not reuse the removed circlips CRANKSHAFT TRANSMISSION 9 21 Transmission Transmission Shaft Assembly e Apply engine oil liberally to the transmission shaft gears and bearings e Replace any circlips that were removed with new ones OAlways install the circlips A so that the opening B is aligned with a spline groove C and install toothed wash ers To install a circlip without damage first fit the circlip onto the shaft expanding it just enough to install it and then use a suitable gear to push the circlip into place Special Tool Outside Circlip Pliers 57001 144 6113114BS1 e The drive shaft gears can be identified by size the small est diameter gear is 1st gear and the largest is 5th Be sure that all parts are put back in the correct sequence facing the proper directio
284. sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Remove the carburetor and drain the fuel into a suitable container e Remove the float bowl see Carburetor Disassembly e Drive out the pivot pin A and remove the float B with valve needle C 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 8 1 mm 0 3 0 04 in 3 14 FUEL SYSTEM Carburetor NOTE OFloat height A is the distance from the float bowl mat ing surface B of the carburetor body with the gasket removed to the top of the float C Measure the height with the carburetor upside down ODo not push the needle rod D in during the float height measurement e Assemble the carburetor and recheck the fuel level If the fuel level cannot be adjusted by this method the float or the float valve is damaged Carburetor Removal A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Always stop the engine and 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 lever A to the OFF position OSlide off the clamp B and pull the fuel hose C off the tap
285. switch valve e Remove the bolts C and take off the vacuum switch valve D Vacuum Switch Valve Installation e Installation is the reverse of removal 5 14 ENGINE TOP END Cylinder Head Cover Cylinder Head Cover Removal e Remove Fuel Tank see Fuel Tank Removal in the Fuel System chapter Spark Plug Cap e Remove the cylinder head cover bolts A and remove the cylinder head cover B Cylinder Head Cover Installation e Apply silicon sealant A to the cylinder head as shown Sealant Liquid Gasket TB1211F 92104 0004 e Replace the head cover gasket e Install the head cover gasket A on the cylinder head e Install the spark plug hole gasket B e Make sure that the upper chain guide A is bottomed Unless the upper chain guide is bottomed the camshaft chain could push the cylinder head cover upward leading to an oil leak e Install the head cover from the motorcycle left side e Install the head cover bolt washers A with the metal side upwards e Tighten the cover bolt B Torque Cylinder Head Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib e Install the spark plug cap OPull up the spark plug cap lightly to make sure of the in stallation of the spark plug cap ENGINE TOP END 5 15 Camshaft Chain Tensioner Camshaft Chain Tensioner Removal NOTICE This is a non return type camshaft chain tensioner The push rod does not return to its original position once
286. t and rear master cylinders e Check that there are no scratches rust or pitting on the inner wall of each master cylinder A and on the outside of each piston B If a master cylinder or piston shows any damage replace them e Inspect the primary C and secondary D cups If a cup is worn damaged softened rotted or swollen the piston assembly should be replace to renew the cups lf fluid leakage is noted at the brake lever the piston as sembly should be replaced to renew the cup e Check the dust covers E for damage lf they are damaged replace them e Check that the relief F and supply G ports are not plugged kif the small relief port becomes plugged the brake pads will drag on the disc Blow the ports clean with com pressed air e Check the piston return springs H for any damage l a spring is damaged replace it J Front Master Cylinder K Rear Master Cylinder wy ca 1 DAY GLO7021B S a Ces LA ilie Tg SCH Ca D GLO7022B 12 18 BRAKES Brake Disk Brake Disc Removal e Remove the wheel see Front Rear Wheel Removal in the Wheels Tires chapter e Unscrew the mounting bolts A and take off the disc B Brake Disc Installation e Install the disc on the wheel so that the marked side A faces out e Apply a non permanent locking agent to the threads of the brake disc bolts B e Tighten Torque Front Brake Di
287. t the fuel tank breather hose outlet end into the steer ing stem hole Fuel Filter Removal e Remove the fuel tank and drain it see Fuel Tank Re moval e Remove the mounting bolts A and take out the fuel filter B Fuel Filter Installation e Replace the O ring with a new one e Be sure to clamp the fuel hose to the tap and fuel filter to prevent leaks FUEL SYSTEM 3 31 Fuel Tank Fuel Tank Filter and Tap Cleaning e Refer to the Fuel Tank Filter and Tap Cleaning in the Periodic Maintenance chapter Fuel Tap and Filter Inspection e Refer to the Fuel Tap and Filter Inspection in the Periodic Maintenance chapter COOLING SYSTEM 4 1 Cooling System Table of Contents Exploded EE 4 2 Goolant Flow Chart EEN 4 4 Geer 4 6 Special EE ER COOL AI EE Coolant Level Inpec ide A de nee Coolant Deterioration Inspection COOIANE DIN id eS Coolant FUN MN sins kiss PW TBC A EE 4 10 Cooling System Pressure Testing cion coda EVA 4 11 Cooling System Ela EE 4 11 Reserve Tank Removal cionado taa 4 12 Water PUMP A q RAS ent nt nn 4 13 Water Pump Cover emgeet sind iodo 4 13 Water Pump Cover Installation ii adidas alot ia 4 13 Impeler EN EE 4 14 Impeller Installation a 4 14 Water Pump special yd 4 14 Oil Seal and Bearing REMO si ia 4 14 Oil Seal and Bearing Installation 4 15 Lt 10 Ez 110 RON COL Eed 4 16 Ren EE 4 16 Radiator Installation is 4 17 Seele ee EE 4 17 Radiator Cap Inspection hist diamant as
288. tage Stator Coil Resistance Ignition System Ignition Timing Ignition Coil 3 Needle Arcing Distance Primary Winding Resistance Secondary Winding Resistance Spark Plug Type Gap IC Igniter Standard Sealed Battery wet YTZ7S F 12 V6 Ah 190 290 Q at 20 C 68 F in the text in the text 10 2 BTDC 1 000 r min rpm 7 mm 0 26 in or more 0 28 0 38 Q at 20 C 68 F 7 65 10 35 KQ at 20 C 68 F NGK CPR8EB 9 0 8 0 9 mm 0 03 0 04 in in the text Service Limit Electric Starter System Starter Motor Brush Length Commutator Diameter Throttle position sensor Input Voltage Output Voltage when engine is idle speed 10 mm 0 39 in 28 mm 1 10 in around 5 V 0 58 0 78 V 6 5 mm 0 26 in 27 mm 1 06 in ELECTRICAL SYSTEM 16 9 Special Tools and Sealant Inside Circlip Pliers Hand Tester 57001 143 57001 1394 ST5701438T ST5713948T Rotor Puller M16 M18 M20 M22 x 1 5 Throttle position sensor Setting Adapter 1 57001 1216 57001 1400 T5712168T ST5714008T Timing Light Peak Voltage Adapter 57001 1241 57001 1415 T5712418T ST5714158T Spark Plug Wrench Hex 16 Filler Cap Driver 57001 1262 57001 1454 AA El ST571262ST ST571454ST Flywheel Holder Needle Adapter Set 57001 1313 57001 1457 ST5713138T ST571457ST C 16 10 ELECTRICAL S
289. tage is within the specified voltage and tighten the sensor bolt Crankshaft Sensor Inspection e Remove Magneto Lead Connector see Magneto Cover Re moval e Set the hand tester A to the x 100 Q range and connect it to the Green White B and White Yellow C Leads in the connector Special Tool Hand Tester 57001 1394 If there is more resistance than the specified value the coil has an open lead and must be replaced Much less than this resistance means the crankshaft sensor is shorted and must be replaced Crankshaft Sensor Resistance Standard 190 290 Q at 20 C 68 F e Using the highest resistance range of the tester measure the resistance between the crankshaft sensor leads and chassis ground Any tester reading less than infinity indicates a short necessities replacement of the crankshaft sensor assem bly GP10428BS1 ELECTRICAL SYSTEM 16 35 Ignition System Ignition System Circuit Other than Australia Models Ee W R Y R Om BK Y Tors 1 N BK GP10432BH3 C 1 Frame Ground 9 Starter Relay 2 Ignition Coil 10 Main Fuse 20 A 3 Spark Plug 11 Battery 12 V 6 Ah 4 Frame Ground 12 IC Igniter 5 Gear Position Switch 13 Engine Starter Button 6 Flywheel Magneto 14 Engine Stop Switch 7 Crankshaft Sensor 15 Starter Lockout Switch 8 Throttle Position Sensor 16 36 ELECTRICAL SYSTEM Electrical Starter S
290. tance km mi Every Every Every Every Every 100 500 1000 1500 2000 see 60 300 600 900 1200 Page or 2 5 or 7 5 or 15 or 30 or 60 OPERATION hr hr hr hr hr Spark plug clean gap t Every 500 km 300 mi 2 62 Spark plug inspect t e e e e 2 62 Clutch cable adjust Every 100 km 60 mi 2 26 O O O O O Clutch and friction plates inspect t After 2000 km 1200 mi every 2 26 1000 km 600 mi Throttle cable adjust Every 100 km 60 mi 2 12 O O O O O Air cleaner element clean t After 2000 km 1200 mi every 2 14 1000 km 600 mi E Carburetor inspect and adjust e e e e e 2 12 S Cylinder head cylinder inspect is SS E e 2 23 o N Valve clearance inspect t After 2000 km 1200 mi every 2 20 E 1000 km 600 mi Hot starter cable adjust Every 100 km 60 mi 2 13 Spark arrester clean Every 1500 km 900 mi 2 24 Vacuum switch valve inspect e e 2 19 Kick pedal and shift pedal clean e o o Engine sprocket inspect o 2 34 Coolant inspect t Se e 2 18 Radiator hoses and connections inspect t e o o o e 2 19 Crankshaft inspect e 2 29 Breather hose inspect E e 2 28 Brake adjustment inspect t e o o o e 2 35 Brake pad wear inspect t e 2 39 Brake fluid level inspect MM e 2 36 C Brake hoses connections inspect t e 2 44 S Spoke tightness and rim runout inspect t e 2 30 S Wheel bearing inspect t e 2 31 Frame inspect and clean e 2 61 s Drive chain wear inspect 2 3
291. ter assembly A Torque Adjuster Assembly 55 N m 5 6 kgf m 41 ft lb 13 20 SUSPENSION Front Fork e Loosen and remove the fork top plug subtank form the outer tube and slowly slide down the outer tube Special Tool Top Plug Wrench 49 mm 57001 1653 e Pour A the specified amount of fork oil into the outer tube Recommended Oil KHL15 10 KAYABAO1 or equivalent Recommended Quantity 335 mL 11 3 US oz e Raise the outer tube and temporarily tighten the fork top plug subtank Special Tool Top Plug Wrench 49 mm 57001 1653 e After installing the front fork torque the top plug A Special Tool Top Plug Wrench 49 mm 57001 1653 B The torque of fork top plug is specified to 30 N m 3 1 kgf m 22 ft lb however when you use the top plug wrench special tool A reduce the torque to 90 of the specified value 27 N m 2 8 kgf m 20 ft Ib due to the distance B between the center of the square hole where the torque wrench is fitted and that of the octagonal hole of the wrench This torque value 27 N m 2 8 kgf m 20 ft Ib is appli cable when you use a torque wrench whose length gives leverage of approximately 310 mm between the grip point to the center of the coupling square Adjuster Assembly Inspection e Inspect the adjuster assembly A and push rod B for damage If they are damaged replace them with new ones e Replace the gasket C and O ring D on the adjuster as se
292. th the adjuster assembly B e With the locknut held immovable using a wrench tighten the adjuster assembly to the specified torque Torque Locknut Adjuster Assembly 29 N m 3 0 kgf m 22 ft lb e With the outer tube compressed by hands remove the top plug wrench e Apply a non permanent locking agent to the threads of a adjuster assembly e Tighten the adjuster assembly A Torque Adjuster Assembly 55 N m 5 6 kgf m 41 ft lb e Loosen and remove the fork top plug subtank form the outer tube and slowly slide down the outer tube Special Tool Top Plug Wrench 49 mm 57001 1653 e Pour A the specified amount of fork oil into the outer tube Recommended Oil KHL15 10 KAYABA01 or equivalent Recommended Quantity 335 mL 11 3 US oz e Raise the outer tube and temporarily tighten the fork top plug subtank Special Tool Top Plug Wrench 49 mm A 57001 1653 e After installing the front fork torque the top plug B Special Tool Top Plug Wrench 49 mm 57001 1653 The torque of fork top plug is specified to 30 N m 3 1 kgf m 22 ft lb however when you use the top plug wrench special tool A reduce the torque to 90 of the spec ified value 27 N m 2 8 kgf m 20 ft Ib due to the dis tance B between the center of the square hole where the torque wrench is fitted and that of the octagonal hole of the wrench This torque value 27 N m 2 8 kgf m 20 ft Ib is appli cable when you use a to
293. than the horizontal line C and position it from the edge of the grip to 170 mm 6 69 in D Clutch Cable Removal e Loosen the adjusting nuts A fully at the lower end of the clutch cable e Slide the adjuster cover A and clutch lever dust cover B back e Screw the adjuster C at the clutch lever fully e Line up the slots D in the clutch lever and adjuster and then free the cable from the lever 118011 ENGINE RIGHT SIDE 6 9 Clutch Lever and Cable e Free the clutch inner cable tip A from the pull rod B Do not remove the clutch release shaft unless it is absolutely necessary If removed release shaft oil seal must be replaced with a new one e Pull the clutch cable out of the frame Clutch Cable Installation e Run the clutch cable correctly see Cable Wire and Hose Routing section in the Appendix chapter e Adjust the clutch cable see Clutch Lever Free Play Ad justment in the Periodic Maintenance chapter Clutch Cable Inspection and Lubrication e During a periodic inspection or when the cable has been removed inspect and lubricate the cable see Lubrication in the Periodic Maintenance chapter bh A la MN gt va y ll 7 GAP d ME p E CO 0 A o gt 6 10 ENGINE RIGHT SIDE Clutch Cover and Right Engine Cover Clutch Cover Removal e Drain the engine oil see Engine Oil Change in the Peri odic Maintenance chapter e Remove th
294. the groove width at several points around the piston with a vernier caliper Piston Ring Groove Width Standard Top 1 03 1 05 mm 0 0406 0 0413 in Service Limit Top 1 13 mm 0 0445 in lf any of the groove widths exceeds the service limit re place the piston Piston Ring Thickness e Measure the thickness at several points around ring with a micrometer Piston Ring Thickness Standard Top 0 970 0 990 mm 0 0382 0 0390 in Service Limit Top 0 90 mm 0 035 in If any of the measurements is less than the service limit on either of the rings replace the rings as a set NOTE OWhen using new rings in a used piston check for un even groove wear The rings should fit perfectly parallel to the groove sides If not replace the piston Piston Ring End Gap Measurement e Place the piston ring A inside the cylinder using the pis ton to locate the ring squarely in place Place the piston ring close to the bottom of the cylinder where cylinder wear is minimal e Measure the gap B between the ends of the ring using a thickness gauge lf the ring end gap exceeds the service limit replace the ring Piston Ring End Gap Standard Top 0 25 0 35 mm 0 0098 0 014 in Oil 0 15 0 50 mm 0 0059 0 020 in Service Limit Top 0 6 mm 0 02 in Oil 0 8 mm 0 03 in 6E16055BS1 5 38 ENGINE TOP END Cylinder and Piston Piston Piston Pin Connecting Rod Wear Inspection
295. the main harness e Set the hand tester to the x 100 Q range and connect it to the throttle position sensor lead connector Throttle Position Sensor Resistance Connections Blue Lead Black Lead Service Limit 4 6kQ lf the reading is out of the range replace the throttle po sition sensor x lf the reading is within the specified range check the other parts see the previous flow chart lf the all parts are good replace the igniter 6P10429BS1 C GP10430BS1 C 16 34 ELECTRICAL SYSTEM Ignition System Throttle Position Sensor Position Adjustment e Check the idle speed using the engine revolution tester for high accuracy and adjust the idle speed specified see Idle Speed Inspection in the Periodic Maintenance chap ter e Disconnect the throttle position sensor lead connector and connect the throttle position sensor setting adapter between throttle position sensor lead connector and main harness connector Special Tools Hand Tester 57001 1394 Throttle Position Sensor Setting Adapter 1 57001 1400 e Set the hand tester to the 2 5 V DC range Hand Tester Yellow White Lead Hand Tester Black Blue Lead e Temporary install the fuel tank e Start the engine e Check the sensor output voltage at the idle speed Throttle Position Sensor Output Voltage Standard 0 58 0 78 V when engine is idle speed e Adjust the position of the throttle position sensor so the vol
296. the motorcycle e Pull up the piston rod assembly C against the circlip e Force the stop D into the rear shock body by lightly tap ping around the edge of the stop with a mallet e Fully extend the piston rod assembly e Install the suitable oil cup A to the air bleed bolt hole and fill the specified oil into the cup e Purge the air from between the gas reservoir B and rear shock body C by slowly pumping the piston rod D in and out e Install the air bleed bolt securely Torque Air Bleed Bolt 6 5 N m 0 66 kgf m 58 in Ib e Fully extend the push rod assembly e Inject nitrogen gas to a pressure of 50 kPa 0 5 kgf cm 7 psi through the valve on the gas reservoir e Check the rear shock body and gas reservoir for oil and gas leaks x If there are no leaks inject the nitrogen gas up to the 980 kPa 10 kgf cm 142 psi pressure A WARNING High pressure gas is dangerous and can explode causing serious injury To avoid injury have a qual ified mechanic pressurize the shock reservoir with nitrogen gas only Do not use air or other gases since they may cause premature wear rust fire haz ard or substandard performance e Install the spring and spring guide e Adjust spring preload Reinstall the rear shock absorber e Install the parts removed woes GMO5067BS1 GMO5069BS1 6M05105BS1 PERIODIC MAINTENANCE 2 59 Periodic Maintenance
297. then fix it by crushing the clamp Speed Sensor Lead Run the harnesses to inside of the clamp Run the switch lead to inside of the throttle cables OMNAARWNH 17 8 APPENDIX Cable Wire and Hose Routing APPENDIX 17 9 Cable Wire and Hose Routing NENN NN NNN N AH HSH AH AB do od au ol O O1 BR D D OO J O O1 R ND D HN O U1 amp D Headlight Connector Black Speed Sensor Lead Connector Gray Meter Unit Connector Black Cap Starter Lockout Switch Connector Green Engine Stop Switch Connector White Starter Button Lead Connector Black Clamps White Tape Clamps Blue Tape Main Harness Clamps Run the harnesses under the frame pipe Igniter Connector Black Bands Starter Relay Connector Red Tail Light Lead Connector White Main Relay Connector White Regulator Rectifier Lead Connector Green 50 mm 2 0 in Throttle Position Sensor Lead Connector White Ground Lead Magneto Lead Connector Gray Ignition Coil Lead Connector Black Transmission Position Sensor Lead Connector White Clamp Fix only the main relay lead 17 10 APPENDIX Cable Wire and Hose Routing A Ze SS Y gt RY E CG dl A Ae SEO A APPENDIX 17 11 Cable Wire and Hose Routing X dl y 8 D 15 16 17 18 19 20 21 22 24
298. tle position sensor setting adapter A between throttle position sensor lead connector B and main harness connector C Special Tools Hand Tester 57001 1394 Throttle Position Sensor Setting Adapter 1 57001 1400 e Set the hand tester D to the DC 10 V range and connect it to the adapter leads Hand Tester Blue Lead Hand Tester Black Blue Lead e Temporary install the fuel tank e Start the engine e Check the sensor input voltage with the engine running Throttle Position Sensor Input Voltage Standard around 5 V xf it is not within the specified voltage replace the igniter lf it is within the specified voltage go to the next step e To check the output voltage do the following procedures OConnect the digital voltmeter A as follows Tester Yellow White Lead Tester Black Blue Lead OStart the engine OMeasure the throttle position sensor output voltage with the engine idling speed Throttle Position Sensor Output Voltage Standard 0 58 0 78 V when engine is idle speed kif it is not within the specified voltage range adjust the throttle sensor position see Throttle Position Sensor Po sition Adjustment If the throttle position sensor position is good inspect the other parts see the previous flow chart lf the all parts are good replace the igniter Throttle Position Sensor Resistance Inspection e Disconnect the throttle position sensor lead connector from
299. to Crankshaft Crankshaft Piston Oil Nozzle Left Crankcase Oil Passage from Oil filter to Transmission Oil Passage Cylinder Oil Passage from Crankcase Oil Passage to Cylinder Head Oil Passage Oil Pipes Oil Screen scavenge Oil Pump scavenge Balancer Weight Fitting Breather Hose To Air Cleaner Housing Drain Hose Crank Room Oil Transmission Room Oil Blowby Gas OO J O O1 BR CO D ch M bh sch sch sch bh 1 COD gt J O Om P D 7 6 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil Type API SG SH SJ SL or SM with JASO MA MAT or MA2 Viscosity SAE 10W 30 10W 40 or 10W 50 Capacity Oil Change when filter is not removed 1 06 L 1 12 US qt Oil Change when filter is removed 1 08 L 1 14 US qt when engine is completely dry 1 3 L 1 4 US at Oil Level after warm up or driving Upper level Oil Pressure Measurement oil temperature 90 C engine speed 4 000 rpm 139 98 kPa 0 4 1 0 kgf cm 5 6 14 psi ENGINE LUBRICATION SYSTEM 7 7 Special Tools Oil Pressure Gauge 5 kgf cm Oil Pressure Gauge Adapter M10 x 1 25 57001 125 57001 1182 ST5701258T 8757118297 Outside Circlip Pliers Oil Pressure Cap 57001 144 57001 1656 ST5701448T ST5716568T 7 8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter A WARNING Vehicle operation with insufficient deteriorated
300. ttom of the radiator filler neck B with coolant A and install the cap turning it clockwise about 1 4 turn OLean the motorcycle slightly to the right until the radiator filler neck is level to the ground so that the filler neck is lo cated uppermost in order to exhaust the air accumulated in the radiator NOTE OPour in the coolant slowly so that it can expel the air from the engine and radiator The radiator cap must be installed in two steps First turn the cap clockwise to the first stop Then push down on it and turn it the rest of the way e Check the cooling system for leaks e Fill the reserve tank up to the F full level line A with coolant and install the cap e Start the engine and warm it up thoroughly e Check the coolant level in the reserve tank several times while the engine is cooling down and replenish as nec essary x If the coolant level is lower than the L level line B add coolant to the F level line Do not add more coolant above the F level line Air Bleeding Before putting the motorcycle into operation any air trapped in the cooling system must be removed as follows e Startthe engine warm up the engine thoroughly and then stop the engine Wait until the engine cools down e Remove the radiator cap e Check the coolant level see Coolant Level Inspection in the Periodic Maintenance chapter If the coolant level is low add coolant up to the bottom of the fille
301. urn the pulley counterclockwise A while holding down the acceleration pump lever B and clear the stopper C of the pulley from the throttle stop screw head D e Install the push rod A into the push rod holder B e Assembly Throttle Valve A Jet Needle B Circlip C Retainer D Spring E Jet Needle Holder F O ring G Throttle Valve Plate H OAssemble the valve plate so that the hole side I down ward e Apply a non permanent locking agent to the link screw e Insert the throttle valve assembly Olnsert the link rollers A on the throttle link into the slits B of the throttle valve e Tighten the screw FUEL SYSTEM 3 25 Carburetor e Apply a grease to the O ring A e Fit the stopper B of the throttle sensor onto the projection C on the throttle cable pulley shaft Olnstall the throttle sensor so that the marks aligns and check it position see Throttle Sensor Inspection in the Electrical System chapter e Install O ring A Carburetor Cap B Bolts tighten e Install Starter Jet A Pilot Jet B Baffle Plate C Needle Jet D Main Jet E e Replace the O ring with new one Australia and Europe models e Install Australia and Europe models Pilot Air Screw A Spring B Washer C O ring D OTurn in the pilot air screw fully but not tightly and the back it out the counted number of turn see Carburetor Disassembly e Hanging the float valve A
302. uster A on the front fork cylinder valve with the blade of a screwdriver until you feel a click Adjust the rebound damping to suit your preference under special condition NOTE OThe left and right fork legs must have the same shock damping Seated positions adjuster turned fully clockwise A Rebound Damping Adjuster Setting Standard 9 clicks B Softer Counterclockwise C Harder Clockwise D Number of turns counterclockwise usable range 18 clicks or more Counterclockwise from the fully seated position e Put the caps into the bottom of the fork tubes 181716131211 10 9 8 7 6 5 4 3 2 1 d GM04521BS1 SUSPENSION 13 9 Front Fork Compression Damping Adjustment e Place the jack under the frame so that the front wheel off the ground Special Tool Jack 57001 1238 e To adjust compression damping turn the adjuster A on the front fork top plugs with the blade of a screwdriver until you feel a click Adjust the compression damping to suit you preference under special condition NOTE OThe left and right fork legs must have the same shock damping Seated positions adjuster turned fully clockwise A e E O Compression Damping Adjuster Setting Standard 11 clicks B Softer Counterclockwise C Harder Clockwise D Number of turns counterclockwise usable range 22 4 clicks or more Counterclockwise from the fully seated position 22 2120131211109 8 7 6 5
303. uster assembly B completely A WARNING Clamping the axle holder too tight can damage it which will affect riding stability Do not clamp the axle holder too tight e Compress the outer tube by hands and install the top plug wrench A between the axle holder bottom B and locknut C Special Tool Top Plug Wrench 49 mm 57001 1653 WARNING The fork spring applies pressure to the adjuster as sembly and can eject the special tool with substan tial force if the tool is not properly and securely placed Be sure the tool is fully in place as shown in the photo and keep fingers away to avoid getting them pinched between the tool adjuster assembly and axle holder SUSPENSION 13 13 Front Fork e Hold the locknut A with a wrench B and remove the adjuster assembly C e Remove the push rod A e With the outer tube compressed by hands remove the top plug wrench A Removing the locknut and pushing the piston rod thread into the cylinder unit will damage the oil seal Do not remove the locknut from the piston rod e Remove the fork leg from the vise e Loosen the fork top plug subtank A with the top plug wrench B Special Tool Top Plug Wrench 49 mm 57001 1653 B e Remove Cylinder Unit A Spacer B Fork Spring C NOTICE Disassembling the cylinder unit can lead to trouble Do not disassemble the cylinder unit 13
304. ustment e Loosen the left and right chain adjuster locknuts A e Remove the cotter pin B and loosen the axle nut C If the chain is too tight back out the left and right chain adjusting bolts D evenly and push the wheel forward until the chain is too loose If the chain is too loose turn both chain adjusting bolts evenly until the drive chain has the correct amount of slack To keep the chain and wheel properly aligned the notch on the left chain adjuster should align with the same swingarm mark E as the right chain adjuster notch F Check the wheel alignment A WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition Be sure the wheel is properly aligned e Tighten both chain adjuster locknuts securely e Tighten the axle nut Torque Rear Axle Nut 110 N m 11 2 kgf m 81 1 ft Ib e Rotate the wheel measure the chain slack again at the tightest position and readjust if necessary e Install a new cotter pin A through the axle nut and axle and spread its ends 6S12041BS2 65128113 P GKO4001BS1 C PERIODIC MAINTENANCE 2 33 Periodic Maintenance Procedures NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle shaft tighten the nut clockwise A up to next alignment Olt should be within 30 degree OLoosen one and tighten again when the slot goes
305. val Front Camshaft Chain Guide A Cylinder Bolt B e Tap lightly up with a plastic mallet to separate the cylinder from the crankcase e Remove the cylinder base gasket Piston Removal e Remove the cylinder see Cylinder Removal e Place a clean cloth under the piston and remove the pis ton pin snap ring A from one end of the piston pin Do not reuse snap rings as removal weakens and deforms them They could fall out and score the cylinder wall e Remove the piston pin using a piston pin puller Special Tool Piston Pin Puller Assembly 57001 1568 A e Remove the piston e Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring A to remove it e Remove the oil ring in the same procedure Cylinder and Piston Installation NOTE OThe oil ring rails have no top or bottom e Install the oil ring expander A in the bottom piston ring groove so the ends B butt together e Install the oil ring steel rails one above the expander and one below it OSpread the rail with your thumbs but only enough to fit the rail over the piston ORelease the rail into the bottom piston ring groove GE16131BS1 WAAARARAARAL lt 6E16044BS1 ENGINE TOP END 5 35 Cylinder and Piston e Install the top ring A so that the R mark B faces up NOTE Olf a new piston or cylinder is used check piston to cylin B
306. vice Limit Brake adjustment Lever Play Adjustable to suit rider Brake Fluid Recommended Disc Brake Fluid Type Front DOT3 or DOT4 Sie ee Rear DOT4 Brake Pads Lining thickness Front 3 8 mm 0 15 in 1 mm 0 04 in Rear 6 4 mm 0 25 in 1 mm 0 04 in Brake Disc Thickness Front 2 85 3 15 mm 0 112 0 124 in 2 5 mm 0 10 in Rear 3 85 4 15 mm 0 152 0 163 in 3 5 mm 0 14 in Runout TIR 0 25 mm 0 0098 in or less TIR 0 3 mm 0 01 in BRAKES 12 7 Special Tools Inside Circlip Pliers Jack 57001 143 57001 1238 ST5701438ST ST5712388ST 12 8 BRAKES Brake Lever Brake Pedal Brake Lever Adjustment e Refer to the Brake Lever and Pedal Position Adjustment in the Periodic Maintenance chapter Brake Pedal Position Adjustment e Refer to the Brake Lever and Pedal Position Adjustment in the Periodic Maintenance chapter Brake Pedal Removal e Remove Cotter Pin A Joint Pin B Washer C e Remove the mounting bolt D and take off the brake pedal E and return spring Brake Pedal Installation e Replace O rings with new one and apply high tempera ture grease to the O rings e Apply high temperature grease to the shaft portion and a non premanent locking agent to the thread of the brake pedal mounting bolt and install the pedal with return spring onto the frame Olnstall the return spring direction A as shown Torque Brake Pedal Mounting Bolt 25
307. well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light 6S05026BS1 6S05027BS1 GCO7045BS1 PERIODIC MAINTENANCE 2 17 Periodic Maintenance Procedures e Turn the fuel tap to the OFF position e Place a suitable container beneath the carburetor drain hose B e Loosen the drain plug A from the bottom of the float bowl and check for water or dirt in the fuel lf any water or dirt comes out clean the carburetor fuel filter fuel tap and fuel tank e Tighten the drain plug securely Fuel Tank Filter and Tap Cleaning A WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the tank in a well ventilated area and take care that there are no sparks or flame any where near the working area Do not use gasoline or low flash point solvents to clean the tank e Remove the fuel tank and drain it see Fuel Tank Removal in the Fuel System chapter e Pour some high flash point solvent into the fuel tank and shake the tank to remove dirt and fuel deposits e Pour the solvent out of the tank e Remove the fuel filter from the tank by taking out the bolts e Clean the fuel filter screens in a high flash point solvent After cleaning install the fuel filter e Pour high flash point solvent through the tap in all lever positions e Dry the tank fi
308. with the steering stem nut wrench C then remove the steering stem D and stem base Special Tool Steering Stem Nut Wrench 57001 1100 e Take off the upper stem bearing inner race tapered roller bearing A e Drive out the bearing outer races from the head pipe ORemove the outer races pressed into the head pipe using the head pipe outer race remover A and hammer the head pipe outer race remover to drive it out Special Tool Head Pipe Outer Race Remover ID gt 37 mm 57001 1107 NOTE Olf either steering stem bearing is damaged it is recom mended that both the upper and lower bearing includ ing outer races should be replaced with new ones e Remove the lower stem bearing inner rase tapered roller bearing A with its grease seal from the stem using bear ing puller Special Tools Bearing Puller 57001 1575 Bearing Puller 57001 135 GNO4002BS1 GNO70106S1 GNO4011BS1 STEERING 14 7 Steering Steering Stem Stem Bearing Installation e Replace the bearing outer race with new ones OApply grease to the outer races and drive them into the head pipe at the same time using the head pipe outer race press shaft A and the head pipe outer race drivers Special Tools Head Pipe Outer Race Press Shaft 57001 1075 Head Pipe Outer Race Driver 54 5 57001 1077 B Head Pipe Outer Race Driver 651 5 57001 1076 C e Replace the lower inner races with new
309. worn or chipped 17 28 APPENDIX Troubleshooting Guide Drive chain noise Drive chain maladjusted Drive chain worn Rear and or engine sprocket worn Drive chain lubrication insufficient Rear wheel misaligned Abnormal Frame Noise Front fork noise Oil insufficient or too thin Spring weak or broken Front fork air pressure high Rear shock absorber noise Shock absorber trouble Spring weak or broken Disc brake noise Pad surface glazed Disc warped Caliper trouble Pad installed incorrectly Master cylinder damaged Other noise Bracket nut bolt etc not properly mounted or tightened Abnormal Exhaust Color White smoke Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Engine oil level too high Black smoke Air cleaner element clogged Main jet too large or fallen off Starter plunger stuck open Fuel level in carburetor float bowl too high Brown smoke Main jet too small Fuel level in carburetor float bowl too low Air cleaner duct loose Air cleaner poorly sealed or missing Handling and or Stability Unsatisfactory Handlebar hard to turn Cable hose wire routing incorrect Steering stem nut too tight Steering stem bearing damaged Steering stem bearing lubrication inade quate Steering stem bent Tire air pressure too low Handlebar shakes or excessively vibrates Tire worn Swingarm pivot bearings worn Rim warped or not balanced Spokes loose Wheel bearing worn Handlebar holder bolt loose
310. xploded View i Rear Frame Mounting zt Ja 25 amp G Apply grease L Apply a non permanent locking agent R Replacement Parts 15 4 FRAME Exploded View 1 CA Model FRAME 15 5 Frame Frame Inspection e Refer to the Frame Inspection in the Periodic Mainte nance chapter Rear Frame Removal e Remove Seat see Seat Removal Right and Left Side Cover see Side Cover Removal Battery Cables A and Holder B see Battery Removal in the Electrical System chapter Starter Motor Cable C Starter Relay Connector D Starter Relay E Main Relay F Tail Light Lead Connector G Igniter H Reserve Tank see Reserve Tank Removal in the Cool ing System chapter Muffler see Muffler Removal in the Engine Top End chapter Rear Fender see Rear Fender Removal e Loosen the air cleaner duct clamp screw see Air Cleaner Housing Removal in the Fuel System chapter e Unscrew the rear frame mounting bolts A e Remove the rear frame B with air cleaner housing C e Remove Bolts A Air Cleaner Housing B Rear Frame Installation e Install the air cleaner housing e Tighten Torque Rear Frame Mounting Bolts 34 N m 3 5 kgf m 25 ft lb e Install the removal parts 15 6 FRAME Frame Engine Guard Installation e Install the engine guard as shown Engine Guards A Collar B Bolts C Engine Guard D Bolts E G009021BS2 FRAME 15 7
311. y appliance with a pilot light Do not use gasoline or a low flash point solvent to clean the cylinder head lf 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 7 14 ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump Scavenge Removal e Drain Engine Oil see Engine Oil Change in the Periodic Main tenance chapter Coolant see Coolant Draining in the Coolant System chapter e Remove Shift Pedal see External Shift Mechanism in the Engine Right Side chapter Flywheel see Flywheel Removal in the Electrical Sys tem chapter e Remove Oil Pump Cover Bolts A Lower Camshaft Chain Guide B Oil Pump Cover C e Remove Inner Rotor A Outer Rotor B Oil Pump Scavenge Installation e Install the dowel pins A to the crankcase e Apply engine oil to the each oil pump rotor and sliding surface of the oil pump shaft e Install Outer Rotor B Inner Rotor C OWhile turn the oil pump shaft install the oil pump so that the left and right oil pump shaft may mesh in the crankcase e Install Oil Pump Cover A Lower Camshaft Chain Guide B e While pushing the oil pump cover tighten the oil pump cover bolts C Torque Oil Pump Scavenge Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib ENGINE LUBRICATION SYSTEM 7 15 Oil Pump Oil Pump Feed Removal e Remove Rig
312. y inspect the shift drum cam A xlf it is badly worn or if it shows any damage replace it GRO7O21BS1 C 8 A GRO7O23BS1 C GRO7022BS1 C 6 22 ENGINE RIGHT SIDE Kickstarter Kick Pedal Assy Removal e Remove Mounting Bolt A Kick Pedal Assy B Kick Pedal Assy Installation e Install the kick pedal assy A at the angle shown 17 27 mm 0 67 1 1 in B e Apply a non permanent locking agent to the kick pedal bolt e Tighten Torque Kick Pedal Bolt 25 N m 2 5 kgf m 18 ft lb Kick Pedal Assy Disassembly e Remove the kick pedal assy e Remove Plug Screw A Spring B Steel Ball C Detente Screw D Oil Seal E GROSO17BS1 Kick Pedal Assy Assembly e Apply grease to the steel ball oil seal lip spring and the sliding portion of the lever e After tightening the screws stake it with a punch Idle Gear Removal e Remove Clutch Cover see Clutch Cover Removal Clutch Housing see Clutch Removal Circlip A Idle Gear B ENGINE RIGHT SIDE 6 23 Kickstarter Idle Gear Installation e Apply engine oil to the inside of the idle gear e Replace the circlip A with a new one e Install the idle gear B facing embossed letter C to the outside e Install the circlip Kickshaft Removal e Remove Right Engine Cover see Right Engine Cover Removal Clutch Housing see Clutch Removal e Pull the end A of the k
313. ystem Starter Motor Removal e Remove Exhaust Pipe see Muffler Removal in the Engine Top End chapter Starter Motor Terminal Nut A Starter Motor Mounting Bolts B e Pull out the starter motor to right side Starter Motor Installation NOTICE Do not tap the starter motor shaft or body Tapping the shaft or body could damage the motor e Clean the starter motor mounting surface A and the crankcase surface B mating surface with starter motor mounting e Replace the O ring A with a new one e Apply engine oil to the O ring Torque Starter Motor Mounting Bolts 9 8 N m 1 0 kgf m 87 in Ib Starter Motor Terminal Nut 5 9 N m 0 60 kgf m 52 in lb e Install the starter motor Pies P Starter Motor Disassembly e Remove the starter motor see Starter Motor Removal e Remove Starter Motor Assembly Bolts A Both End Covers B e Pull the armature out of the yoke eso Y e Remove the terminal locknut A and then remove the brush with the brush plate B from the end cover C BA FA a ies P ELECTRICAL SYSTEM 16 37 Electrical Starter System Starter Motor Assembly e Replace the O ring with a new one e Apply a thin coat of high temperature grease to the oil seal A and the needle bearing B e Fit the toothed washer C into the end cover Thin Washer D Thick Washer E wuts P e Install the brush plate A and tighten the terminal locknut B Torque Starter Motor Ter

Tighten the two clamp bolts alternately two times to en

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